Avoiding Track-Related Issues on Heavy Equipment

[MikePhua]

Track-based heavy equipment, such as track loaders, excavators, and dozers, are essential for construction, mining, and other heavy-duty applications. However, these machines often face one common issue: throwing tracks. This problem can significantly disrupt work, leading to costly downtime and potential damage to other components. Understanding why tracks can be thrown and how to prevent this from happening is critical for equipment longevity and smooth operation.
In this article, we will discuss the causes of track issues, particularly track throwing, and provide insights into the best practices for maintaining tracks and other undercarriage components on track-based equipment.
What Causes Tracks to Be Thrown?
A track on heavy equipment is an essential part of the undercarriage, allowing the machine to move over rough and uneven terrain. When a track is thrown, it comes off the undercarriage, which can result in significant downtime and expensive repairs. Common causes of track throwing include:

1. Improper Tension
   • Cause: One of the most common causes of thrown tracks is improper track tension. If the track is too loose, it can slip off the sprocket, leading to the track being thrown. Conversely, if the track is too tight, it can cause undue stress on the machine’s components, leading to premature wear and even failure.
     
   • Solution: Regularly check and adjust track tension according to the manufacturer’s specifications. Proper tension ensures the track remains securely on the sprocket and helps maintain the longevity of the undercarriage.
     
2. Worn or Damaged Sprockets
   • Cause: The sprockets engage with the track’s teeth, and if they are worn or damaged, they can cause the track to slip off. Sprockets can become worn due to normal wear and tear, improper tension, or even the use of incorrect tracks.
     
   • Solution: Inspect sprockets regularly for wear and damage. Replace worn sprockets as needed, and ensure that the correct track size and type are being used for the machine.
     
3. Undercarriage Misalignment
   • Cause: Misalignment in the undercarriage, such as a misaligned track frame or components, can cause the track to slip off. This can happen due to improper installation, damage to the frame, or prolonged wear.
     
   • Solution: Perform regular checks for alignment issues. If misalignment is found, realign the undercarriage or replace the damaged components. Proper installation and alignment from the beginning can prevent long-term issues.
     
4. Damaged or Worn Rollers and Idlers
   • Cause: Rollers and idlers are critical for maintaining the movement and tension of the track. If these components are worn or damaged, they may not properly guide the track, causing it to slip off.
     
   • Solution: Regularly inspect rollers and idlers for wear. If any rollers or idlers are worn down or damaged, replace them immediately to prevent further damage to the track system.
     
5. Operating on Rough Terrain
   • Cause: Operating on extremely rough or uneven terrain can put excessive stress on the track system. Objects such as large rocks, mud, or debris can catch the track and cause it to become dislodged.
     
   • Solution: While it’s not always possible to avoid rough terrain, operators should be mindful of obstacles that can disrupt the track. Whenever possible, try to clear obstacles before driving over them. Use the equipment’s full potential to navigate through rough terrain more efficiently, avoiding sharp turns or sudden movements that may exacerbate the issue.
     

Additional Don’ts and Best Practices for Track Equipment
Aside from the common causes of track throwing, there are several other key considerations and best practices for maintaining track-based heavy equipment:

1. Don’t Ignore the Undercarriage
   • Importance: The undercarriage is the backbone of track equipment, and ignoring it can lead to a host of problems, including thrown tracks. The condition of components like rollers, idlers, sprockets, and track links should always be monitored and maintained.
     
   • Solution: Schedule regular undercarriage inspections, especially when using the equipment in harsh conditions. Early detection of wear can prevent larger issues and extend the life of the machine.
     
2. Don’t Use Excessive Speed
   • Cause: Traveling at high speeds on rough terrain can create excessive strain on the track and undercarriage, leading to wear, misalignment, or track issues.
     
   • Solution: Operators should avoid excessive speed, particularly when operating on uneven ground or navigating tight spaces. Slower, controlled movements reduce strain on the machine and prevent premature wear.
     
3. Don’t Overload the Machine
   • Cause: Overloading the machine or attempting to lift more weight than the machine is designed to handle can put excessive strain on the undercarriage. This can cause the tracks to loosen, leading to a potential track throw.
     
   • Solution: Always adhere to the machine's maximum operating load capacity. The manufacturer's guidelines are set for a reason, and overloading can lead to severe damage.
     
4. Don’t Forget About Track Lubrication
   • Cause: Track lubrication is an often overlooked aspect of machine maintenance. Lack of lubrication can lead to increased friction between track components, causing excessive wear and tear.
     
   • Solution: Ensure that tracks are properly lubricated to prevent premature wear. Regularly check the track pins and other moving components to ensure smooth operation. In extreme conditions, consider more frequent lubrication.
     
5. Don’t Skip Proper Track Maintenance
   • Cause: Neglecting track maintenance, such as cleaning and checking for debris buildup, can lead to track slippage and other issues.
     
   • Solution: After working in conditions where dirt, mud, or debris have built up, take the time to clean the tracks and undercarriage thoroughly. This will prevent blockages and ensure that components like rollers and idlers function properly.
     

How to Repair and Reinstall a Thrown Track
If you do find yourself dealing with a thrown track, the process of reinstalling it can vary depending on the type of equipment, but generally involves the following steps:

1. Clear the Area Around the Equipment
   • Ensure the area around the equipment is clear of debris and obstacles. You’ll need space to safely work on the machine and reinstall the track.
     
2. Lift the Equipment
   • Use a hydraulic jack or a lifting device to raise the equipment off the ground. This will relieve pressure on the tracks and allow you to reposition the track properly.
     
3. Inspect the Track and Sprockets
   • Before reinstalling the track, inspect both the track and sprockets for damage. Ensure there are no broken teeth or excessively worn components that could lead to further issues. Replace any damaged parts.
     
4. Reinstall the Track
   • Carefully guide the track back onto the sprockets, ensuring that it is seated properly. This may require slight adjustments to the track tension using the track adjusters.
     
5. Adjust Track Tension
   • Once the track is back on, adjust the track tension to the manufacturer’s recommended settings. Ensure that the track is neither too tight nor too loose.
     
6. Test the Equipment
   • Once everything is in place, slowly test the equipment. Drive the machine a short distance to ensure the track is running smoothly and the equipment is operating properly.
     

Conclusion
Preventing track throwing on heavy equipment like the JCB 1550B, Caterpillar bulldozers, or any other tracked machinery is essential for maintaining operational efficiency and reducing downtime. Regular inspections, proper tensioning, and attention to the undercarriage will extend the life of the tracks and other critical components. Moreover, avoiding common mistakes such as overloading, excessive speed, and neglecting maintenance will help operators keep the machine running smoothly. With the right care, track equipment can provide years of reliable service, even in the harshest conditions.