Choosing and Maintaining Excavator Chains: A Comprehensive Guide

[MikePhua]

Excavators are heavy-duty machines that are designed to handle tough tasks such as digging, lifting, and demolition. A key component that ensures their functionality and durability is the track system, particularly the chains. The chains, also known as track chains or track assemblies, play a vital role in supporting the weight of the excavator and ensuring smooth movement over various terrains. Whether you’re looking to replace worn-out chains or considering upgrading your excavator's track system, understanding the types of chains available and how to maintain them can significantly extend the lifespan of your equipment.
In this article, we will dive into the details of excavator chains, including the different types available, the factors to consider when purchasing new chains, and how to maintain them for optimal performance.
Understanding Excavator Chains and Their Function
The chains on an excavator are a crucial part of the track system. Unlike conventional wheels, the tracks distribute the weight of the machine over a larger surface area, providing better traction and stability. Excavators use track chains, which are made up of multiple interconnected links that wrap around the track rollers and sprockets.
The primary functions of excavator chains include:

1. Support and Mobility: Excavator chains support the weight of the entire machine, ensuring that it moves smoothly and efficiently. The tracks also help prevent the machine from sinking into soft ground.
   
2. Traction: The chains provide traction on a variety of surfaces, from soft mud to rocky terrain, enabling the excavator to operate in diverse environments.
   
3. Durability: Excavator chains are designed to withstand the harsh conditions of construction, mining, and demolition work, where they may come into contact with abrasive materials and excessive heat.
   

Excavator chains are typically paired with track shoes or pads, which are the metal components that make contact with the ground. Together, these components form the track system that allows the excavator to move efficiently.
Types of Excavator Chains
Excavator chains come in different types depending on the specific needs of the machine and the environment in which it will be used. The two most common types of excavator chains are sealed and non-sealed chains, but there are other variations based on design, material, and application.

1. Sealed and Lubricated Chains (SALT): These chains have seals between each link, and they are lubricated with grease. The seals prevent dirt and debris from entering the chain, helping to maintain proper lubrication and protect the chain from wear. Sealed chains are typically used in applications that involve high loads, long operational hours, and harsh environments, as they offer greater durability and require less maintenance.
   
2. Non-Sealed Chains: Non-sealed chains do not have seals between the links, making them less protected from contaminants like dirt and debris. While they tend to be more affordable, they require more frequent maintenance, including regular cleaning and lubrication. Non-sealed chains are usually used in less demanding environments where the machine operates in cleaner conditions.
   
3. Heavy-Duty Chains: These chains are designed for machines that operate in tough conditions such as mining, quarrying, or demolition. They are constructed with larger, stronger links and more durable materials to withstand the added strain of working in abrasive or rocky environments.
   
4. Rubber Tracks: Although not technically a "chain" system, rubber tracks are an alternative used in mini excavators or for applications requiring reduced ground damage. These tracks combine rubber with steel reinforcements and provide excellent traction, while also offering a more comfortable ride for the operator.
   
5. Steel Tracks: These are the traditional chains used in heavy equipment like full-sized excavators. Steel tracks are known for their durability and strength, making them ideal for tough environments. They are less flexible than rubber tracks but offer superior performance in rough terrain.
   

Factors to Consider When Purchasing New Excavator Chains
Choosing the right chains for your excavator is critical to ensuring optimal performance and longevity. When purchasing new chains, consider the following factors:

1. Machine Model and Size: Excavator chains must be compatible with the specific make and model of your machine. The size and weight of the excavator will dictate the type and size of chains required. Be sure to verify the specifications of your machine before purchasing new chains.
   
2. Operating Conditions: The environment in which the excavator will be working greatly affects the choice of chains. For example, if the machine will be working in soft, muddy environments, sealed chains or heavy-duty rubber tracks may be the best option. For rocky or abrasive environments, steel chains are typically recommended.
   
3. Durability and Maintenance: Sealed chains, while more expensive, are highly durable and require less maintenance over time. If your excavator is used heavily or in harsh conditions, investing in sealed chains could save on long-term repair and replacement costs.
   
4. Cost: While non-sealed chains are generally less expensive, they may require more maintenance and have a shorter lifespan. Sealed chains, while pricier upfront, offer better long-term value due to their durability and reduced need for maintenance.
   
5. Track Design: Some chains are designed with specific track shoes, which can have different designs depending on the surface the machine operates on. Consider whether your excavator needs wider track shoes for soft terrain or narrower shoes for more stable ground.
   

Installation and Replacement of Excavator Chains
Installing new chains on an excavator requires a fair amount of mechanical knowledge and expertise. If you are unfamiliar with the process, it may be best to hire a professional to handle the replacement. However, if you choose to tackle the job yourself, follow these general steps:

1. Lift the Excavator: Use a hydraulic jack or an overhead crane to lift the excavator off the ground, ensuring it is securely supported. The machine should be stable before attempting any work on the tracks.
   
2. Remove the Old Tracks: Use appropriate tools, such as track tensioners and pin extractors, to remove the old track chains. Be cautious when removing the tracks to avoid damaging any surrounding components.
   
3. Install the New Chains: Position the new chains around the track rollers and sprockets. Ensure that the chains are properly aligned with the track frame and securely in place.
   
4. Adjust Tension: Once the new chains are installed, adjust the track tension according to the manufacturer’s specifications. This is crucial for ensuring proper chain movement and preventing premature wear.
   
5. Test the Excavator: After installing the new chains, perform a test run to ensure that the machine moves smoothly and that the chains are properly functioning. Check for any unusual noise, vibration, or misalignment.
   

Maintaining Excavator Chains for Longevity
Proper maintenance is essential to ensuring the longevity of your excavator chains. Here are some key maintenance tips to keep your chains in top condition:

1. Regular Lubrication: For non-sealed chains, frequent lubrication is necessary to prevent wear. Be sure to use the recommended grease and apply it consistently to reduce friction and protect the chains from contaminants.
   
2. Inspect for Wear: Regularly inspect the chains for signs of wear, such as excessive stretching, cracks, or broken links. Early detection of wear can prevent further damage and costly repairs.
   
3. Clean the Tracks: Clean the tracks regularly to remove dirt, debris, and other contaminants that can cause friction and premature wear. Use high-pressure washers or track cleaning systems to keep the tracks clear.
   
4. Track Tension: Maintain proper track tension to prevent the chains from becoming too tight or too loose. Both conditions can lead to increased wear and potential failure of the track system.
   
5. Monitor for Leaks: Check for any leaks in the hydraulic system, especially in sealed chain systems. Leaks can reduce the pressure needed for proper operation and lead to damage over time.
   

Conclusion: Selecting the Right Chains for Your Excavator
Excavator chains are an essential part of your machine's overall performance and longevity. By understanding the different types of chains, the factors that affect your choice, and the importance of regular maintenance, you can ensure that your excavator operates at peak efficiency. Whether you opt for sealed or non-sealed chains, regular inspections and timely replacements will keep your track system running smoothly, minimizing downtime and costly repairs.
Investing in quality chains and maintaining them properly will not only extend the life of your excavator but also improve the productivity and safety of your operations.