Replacing Undercarriage Components While Changing Tracks

[MikePhua]

Replacing the undercarriage components of heavy machinery, such as track loaders and excavators, is a critical maintenance task that ensures optimal performance and longevity. When changing tracks, it's an opportune moment to inspect and replace other undercarriage parts that may have worn out over time. This guide provides a detailed overview of the process, including necessary tools, safety precautions, and step-by-step instructions.
Understanding the Undercarriage Components
The undercarriage of a tracked machine comprises several key components:

• Tracks: The continuous bands that provide traction and support the machine's weight.
  
• Rollers: Cylindrical components that support the track and allow it to rotate smoothly.
  
• Idlers: Guide the track and maintain its tension.
  
• Sprockets: Engage with the track to propel the machine forward.
  
• Track Adjusters: Mechanisms that maintain proper track tension.
  
• Track Shoes: The individual metal plates that make contact with the ground.
  

Each of these components plays a vital role in the machine's operation, and their condition directly impacts performance and safety.
Tools and Equipment Needed
Before beginning the replacement process, ensure you have the following tools and equipment:

• Impact Wrench: For removing and installing bolts.
  
• Torque Wrench: To tighten bolts to the manufacturer's specifications.
  
• Hydraulic Jack or Lifting Equipment: To lift the machine safely.
  
• Track Pin Press or Hydraulic Puller: For removing and installing track pins.
  
• Safety Gear: Including gloves, safety glasses, and steel-toed boots.
  
• Replacement Parts: New tracks, rollers, idlers, sprockets, and other necessary components.
  

Step-by-Step Replacement Process

1. Preparation and Safety Measures
   • Park the machine on a stable, level surface.
     
   • Engage the parking brake and ensure the machine is powered off.
     
   • Wear appropriate safety gear throughout the process.
     
2. Lifting the Machine
   • Use a hydraulic jack or lifting equipment to raise the machine off the ground.
     
   • Secure the machine with jack stands to prevent accidental lowering.
     
3. Removing the Old Tracks
   • Loosen and remove the bolts securing the track adjusters.
     
   • Use a track pin press or hydraulic puller to remove the track pins.
     
   • Carefully remove the old tracks from the machine.
     
4. Inspecting Undercarriage Components
   • Examine rollers, idlers, sprockets, and other components for signs of wear or damage.
     
   • Replace any parts that are worn beyond acceptable limits.
     
5. Installing New Components
   • Install new rollers, idlers, and sprockets, ensuring they are properly aligned.
     
   • Apply anti-seize lubricant to bolts to prevent corrosion.
     
   • Tighten bolts to the manufacturer's specified torque settings.
     
6. Installing New Tracks
   • Position the new tracks onto the machine.
     
   • Use a track pin press or hydraulic puller to install the track pins.
     
   • Ensure the tracks are properly aligned and tensioned.
     
7. Final Checks
   • Lower the machine to the ground.
     
   • Check track tension and adjust as necessary.
     
   • Test the machine to ensure all components are functioning correctly.
     

Maintenance Tips for Prolonging Undercarriage Life

• Regular Inspections: Periodically check undercarriage components for signs of wear or damage.
  
• Proper Lubrication: Ensure all moving parts are adequately lubricated to reduce friction and wear.
  
• Avoid Overloading: Do not exceed the machine's rated capacity to prevent excessive strain on undercarriage components.
  
• Cleanliness: Keep the undercarriage clean to prevent debris buildup, which can cause premature wear.
  
• Track Tension: Maintain proper track tension to ensure optimal performance and longevity.
  

Conclusion
Replacing undercarriage components while changing tracks is an essential maintenance task that ensures the continued performance and safety of heavy machinery. By following the steps outlined in this guide and adhering to maintenance best practices, operators can extend the lifespan of their equipment and reduce the likelihood of costly repairs. Always consult the manufacturer's manual for specific instructions and torque specifications related to your machine model.