Track Removal Process for Heavy Equipment

[MikePhua]

Track removal is a critical maintenance procedure for heavy equipment, particularly for tracked machines such as excavators, bulldozers, and skid steers. The process, while straightforward, requires a good understanding of the equipment’s design and tools. Whether you’re replacing worn tracks, performing routine maintenance, or inspecting components for damage, track removal is an essential skill for heavy equipment operators and mechanics.
In this article, we will break down the step-by-step process for removing tracks from tracked machinery, explain the necessary tools, and provide tips for a safe and efficient removal. We will also explore the importance of this maintenance task, including the various components that should be checked while removing tracks.
Understanding Tracked Equipment
Tracked equipment, including excavators, dozers, and other construction machinery, relies on continuous metal tracks for movement. These tracks consist of a chain of metal links that wrap around drive sprockets and idler wheels. The continuous tracks provide better traction on soft or uneven surfaces compared to wheeled equipment, which is why they are commonly used in construction, forestry, and mining.
The tracks are made up of several components, including the track links, rollers, sprockets, idlers, and the track tensioning system. Over time, wear and tear, harsh working conditions, and improper track tensioning can lead to track damage, such as cracks, broken links, or worn-out tread patterns. In such cases, removing and replacing the tracks is necessary to maintain the machine’s performance.
Tools and Equipment Required
Before starting the track removal process, you will need to ensure you have the appropriate tools and equipment. Here is a list of commonly used tools:

• Track jack: This tool is used to lift the track off the ground for easier removal.
  
• Wrenches: To remove bolts that secure the track tensioners and track bolts.
  
• Track pin remover: A specialized tool used to remove the track pins that hold the track links together.
  
• Hydraulic jack or lifting device: For larger machines, a hydraulic jack or lifting device might be necessary to lift the track and machine off the ground.
  
• Lubricants: Some parts, such as the pins and bushings, may require lubrication to ease their removal.
  
• Measuring tape or gauge: Used to measure track tension before and after removal.
  

Having the proper equipment is essential for ensuring the process is efficient and reduces the risk of damage to the machine or the track components.
Step-by-Step Guide to Removing Tracks
Here’s a general guide to removing tracks from a piece of tracked heavy equipment:
Step 1: Prepare the Equipment

1. Position the Machine: Place the equipment on stable, level ground. Ideally, you should perform the track removal on a solid surface, such as concrete, to prevent any shifting or instability.
   
2. Lift the Track: Use the track jack to lift the track off the ground. This will relieve tension from the track and allow for easier removal. If a track jack isn’t available, a hydraulic lift or block can be used to lift the equipment slightly.
   

Step 2: Loosen the Track Tension

1. Release Track Tension: Locate the track tensioning mechanism. On most machines, this consists of a grease-filled cylinder or a manual screw adjustment. Using the appropriate tool (wrench or grease gun), loosen the tension by releasing the pressure.
   
2. Check the Tension: Verify that the track is loose and no longer under tension. This will prevent the track from becoming stuck during removal and make it easier to disconnect the track from the machine.
   

Step 3: Remove the Track Pins

1. Locate Track Pins: Track pins are the components that hold the links together. Depending on your machine, the pins may be held in place by a retaining bolt or clip.
   
2. Remove Retaining Pins or Bolts: If there are retaining bolts or clips, remove them using the appropriate wrenches or socket set. Be sure to keep these parts for reinstallation.
   
3. Remove the Track Pin: Use a track pin remover or a hammer and drift to push the pins out. For large machines, a hydraulic press may be needed to apply enough force to remove stubborn pins. Keep in mind that track pins are often large and can be difficult to move.
   

Step 4: Disconnect the Track from the Sprocket

1. Locate the Sprocket: The sprocket is the large wheel that drives the track. It’s typically located at the rear of the machine. On some machines, the sprocket is mounted on a shaft, while others may use a bolt-on design.
   
2. Remove the Sprocket Bolts: Depending on your machine, you may need to remove bolts that secure the sprocket. Once removed, the sprocket can be detached from the track. If the sprocket is stuck, you may need to tap it gently with a mallet or apply some lubricant to loosen it.
   

Step 5: Remove the Track

1. Lift the Track: Once the track is no longer tensioned and the pins are removed, carefully slide the track off the machine. This may require some assistance, especially if the tracks are heavy. A second person or a crane may be needed for larger machines.
   
2. Inspect the Track and Components: Before moving the track away, inspect the track links, sprockets, rollers, and idlers for signs of damage or wear. This is a good time to check if any parts need replacement.
   

Important Considerations During Track Removal

• Track Alignment: Ensure the tracks are aligned correctly during reinstallation. Misalignment can cause excessive wear and even damage the sprockets.
  
• Track Maintenance: While the tracks are removed, it’s a great opportunity to inspect the undercarriage for damage. Check for worn-out rollers, damaged sprockets, and seals.
  
• Proper Disposal: If the tracks are too worn to be reused, dispose of them properly. Many manufacturers offer recycling programs for old tracks and other undercarriage components.
  

Tips for Efficient Track Removal

1. Regular Inspections: Make track removal easier by regularly inspecting the tracks for wear. Keeping the track tensioned correctly can reduce the likelihood of sudden damage, making removal a less frequent task.
   
2. Use Proper Lubrication: When removing track pins, lubricating them beforehand can make the process smoother and reduce the risk of damaging the pins or track components.
   
3. Consider Professional Help: For heavy-duty machinery or if you’re unsure of the process, consider seeking professional help. Track removal on large equipment can be challenging, and incorrect removal can damage the equipment.
   
4. Safety: Always ensure that the equipment is securely positioned and that all personnel are aware of the potential hazards involved in the track removal process. Use personal protective equipment (PPE) such as gloves, steel-toed boots, and safety goggles.
   

Conclusion
Track removal is an essential maintenance task that requires both technical know-how and the right equipment. With a bit of preparation, the right tools, and careful attention to detail, you can efficiently remove tracks from tracked equipment for inspection, repair, or replacement. Regular maintenance and proper track care will extend the life of your equipment and keep it running smoothly.