Turning Track Bushings: A Guide for Maintenance and DIY Repairs

[MikePhua]

Turning track bushings are essential components in the undercarriage of tracked machinery such as excavators, bulldozers, and other heavy equipment. These bushings facilitate smooth movement by reducing friction between the track links and other moving parts of the undercarriage. Over time, wear and tear can cause these bushings to lose their efficiency, resulting in uneven wear on the track system and reduced performance.
In some cases, machine operators or maintenance teams may opt to turn or rotate these bushings themselves to extend their service life and avoid the high costs of replacement. In this article, we’ll explore the process of turning track bushings, why it’s necessary, how it can be done safely, and the benefits of doing this maintenance task on your own.
Why Turn Track Bushings?
The purpose of track bushings is to act as a cushion and reduce the wear and tear that occurs when the metal track links rub against other components in the undercarriage. Over time, the contact surfaces of these bushings wear down, leading to less efficiency in the movement of the tracks and potentially causing further damage to other undercarriage components.
By rotating or turning the bushings, operators can redistribute wear and maximize their lifespan, delaying the need for costly replacements. Typically, bushings in tracked machines are designed to rotate as part of their normal function, but if they become too worn in one spot, they may no longer rotate effectively, which is when turning them becomes necessary.
The Process of Turning Track Bushings
Turning the track bushings involves adjusting the position of the bushings so that they wear evenly across the surface. This requires disassembling part of the undercarriage, rotating the bushings, and then reassembling the equipment. The process may sound complex, but with the right tools and careful attention to detail, many operators can perform this task themselves. Here's a step-by-step breakdown:

1. Safety First
   Before beginning any maintenance work on heavy machinery, it's crucial to ensure safety. Always wear the appropriate safety gear such as gloves, safety glasses, and steel-toed boots. Ensure that the equipment is on stable ground, and if working on a large machine, use a jack or other lifting devices to safely raise the track.
   
2. Remove the Track
   To gain access to the track bushings, you’ll need to remove the track from the undercarriage. This process will vary depending on the machine model, but typically it involves loosening the track tension, removing the track adjuster, and using a track pin press to disengage the track.
   
3. Inspect the Bushings
   Once the track is removed, thoroughly inspect the bushings for signs of excessive wear, damage, or corrosion. If a bushing is overly worn or damaged, it might be best to replace it entirely rather than attempting to turn it. On the other hand, if the wear is moderate and the bushing is still in good overall condition, turning it can help redistribute the wear evenly.
   
4. Turn the Bushings
   To rotate the bushings, you will need to reposition them in a way that changes the contact point between the bushing and the track link. This is usually done by flipping or rotating the bushing to a less worn area. In some machines, the bushings can be turned manually by removing a retaining clip or bolt, while in others, a hydraulic press may be required. Ensure that the bushing is rotated evenly and securely to avoid damage during reassembly.
   
5. Reassemble the Track
   After turning the bushings, carefully reassemble the track on the undercarriage. Tension the track to the correct specification and reattach all components securely. It's essential to ensure that everything is properly aligned before testing the machine to avoid any issues during operation.
   
6. Test and Inspect
   After completing the bushing rotation, it’s important to test the machine. Operate the equipment at a low speed to check for any unusual vibrations or noises, which may indicate improper installation or alignment. After running the machine for a short period, inspect the bushings once more to ensure they are wearing evenly and there are no signs of damage or misalignment.
   

Benefits of Turning Track Bushings

1. Cost Savings
   The most significant benefit of turning track bushings is the cost savings. Replacing undercarriage components can be expensive, with the cost of a new set of bushings adding up quickly. Turning the bushings extends their lifespan, potentially saving thousands of dollars in replacement costs.
   
2. Prolongs Track Life
   By rotating the bushings, you help ensure that the entire undercarriage system wears evenly. This not only extends the life of the bushings themselves but also the tracks, rollers, sprockets, and other components. In turn, this improves the overall performance and reliability of the machine.
   
3. Improved Performance
   When bushings are worn unevenly, the machine’s performance can suffer. Rotating the bushings restores balance and functionality to the undercarriage, leading to smoother operation, better track movement, and reduced strain on the engine.
   
4. Flexibility for Future Repairs
   Turning the bushings when they are still serviceable buys time until a more convenient time to perform full replacement or rebuilds of the undercarriage. This is particularly useful for operators who want to avoid major downtime or additional maintenance during busy project periods.
   

When to Replace Track Bushings
Although turning track bushings can significantly extend their life, there are times when replacement is necessary. Some signs that replacement is required include:

• Excessive Wear: If the bushings are excessively worn down and turning them doesn’t restore the surface, it's best to replace them.
  
• Cracks or Damage: Visible cracks, chips, or other physical damage to the bushings are signs that they need to be replaced.
  
• Excessive Noise or Vibration: If turning the bushings does not resolve issues with excessive noise or vibration during operation, further inspection or part replacement may be necessary.
  

Best Practices for Preventing Premature Wear
While turning track bushings is a great way to extend their life, proper maintenance and care are essential to preventing premature wear in the first place. Consider the following best practices:

1. Regular Inspections: Inspect the undercarriage components regularly to check for early signs of wear or damage. This proactive approach helps catch issues before they escalate.
   
2. Proper Track Tensioning: Ensure that tracks are properly tensioned. Both over-tightening and under-tightening the tracks can accelerate bushing wear.
   
3. Avoid Overloading: Operating the machine beyond its rated capacity can put excessive strain on the undercarriage components, including the bushings. Always operate within the recommended weight limits.
   
4. Track Cleaning: Regularly clean the tracks and undercarriage to remove debris and dirt that can cause friction and wear on the bushings.
   
5. Use the Right Lubricants: Ensure that the undercarriage components are properly lubricated to minimize friction and wear. Always use the manufacturer’s recommended lubricants and follow the maintenance schedule.
   

Conclusion
Turning track bushings is a valuable maintenance task that can save significant costs while extending the life of your tracked machinery. While it requires some effort and attention to detail, many operators can perform this task with the right tools and a bit of mechanical knowledge. By regularly inspecting and maintaining your undercarriage system, you can ensure smoother operation, reduce wear, and improve the overall performance of your heavy equipment. However, if you find that your bushings are beyond repair, don’t hesitate to invest in new components to keep your equipment running efficiently and reliably.