The Backbone of Earthmoving Machines: Steel Excavator Tracks

RALPH COPE
Oct 3, 2023
16 min read

When it comes to heavy construction equipment, excavators are among the most versatile and indispensable machines. These mammoth marvels of engineering rely heavily on their steel tracks, which play a pivotal role in connecting them to the earth and providing stability and mobility. In this blog, we will delve into the individual components that make up steel tracks, the parts responsible for turning them, and the most common mistakes operators make that can lead to excessive wear and tear.

The Anatomy of Steel Excavator Tracks

Links: The foundation of any steel track system is its links. These are the metal segments that interlock to form a continuous loop around the undercarriage of the excavator. Links are typically made from high-quality steel to withstand the immense pressure and weight exerted on them during operation. They come in various shapes and sizes, depending on the specific requirements of the machine.
Grousers: Grousers are the protruding, tooth-like ridges that run along the surface of the steel tracks. They serve two essential purposes. First, they provide traction by biting into the ground, which is crucial for the excavator's stability and movement. Second, they distribute the weight of the machine over a larger surface area, reducing the risk of damaging the ground beneath.
Bolts and Pins: The links are connected to one another through bolts and pins. These components ensure that the track remains a continuous loop and does not disassemble during operation. Properly tightened bolts and pins are essential for the structural integrity of the track.

Turning the Tracks: Hydraulic System

Sprockets are the toothed wheels that engage with the grousers on the tracks, providing the rotational force necessary for movement. They are located at the rear of the undercarriage and are typically powered by the excavator's hydraulic system. Sprockets are subject to significant wear due to the constant friction with the track's grousers, so regular inspection and maintenance are crucial.

The sprockets of an excavator are typically turned by a hydraulic motor connected to the excavator's hydraulic system. Here's how it works:

Hydraulic System: Excavators are equipped with a hydraulic system that powers various components of the machine, including the boom, arm, bucket, and tracks. This hydraulic system is driven by a hydraulic pump, which pressurizes hydraulic fluid (usually hydraulic oil) and sends it to different hydraulic motors and cylinders throughout the excavator.
Hydraulic Motor: At the heart of the undercarriage, near the sprocket, there is a hydraulic motor specifically designed for turning the sprockets. This motor receives pressurized hydraulic fluid from the hydraulic pump.
Power Transmission: The hydraulic motor takes the hydraulic energy and converts it into mechanical rotational energy. This mechanical energy is used to turn the sprocket.
Sprocket Engagement: The sprocket is designed with teeth or gears that engage with the grousers on the steel tracks. As the hydraulic motor turns, it drives the sprocket, and the engagement with the grousers causes the tracks to move, propelling the excavator forward or backward.

The operator controls the speed and direction of the tracks by manipulating the hydraulic controls in the excavator's cabin. By adjusting the flow of hydraulic fluid to the hydraulic motor responsible for the sprocket, the operator can control the speed and direction of the excavator's movement.

It's important to note that the hydraulic system in an excavator is a critical component, and proper maintenance and care are essential to ensure the hydraulic motor and other hydraulic components, including hoses and pumps, function reliably. Regular inspections and maintenance of the hydraulic system help extend the life of the excavator and its undercarriage components, including the sprockets. Idlers are non-powered wheels positioned at the front of the undercarriage. They guide the track and help maintain its tension. Properly tensioned tracks are essential for reducing wear and ensuring optimal performance. Idlers also need periodic inspection to ensure they are not worn or misaligned.

Changing Direction

A tracked excavator can change its direction of movement thanks to the mechanical design of its undercarriage, which allows for controlled and versatile mobility. The key mechanics involved in changing the direction of a tracked excavator include:

Tracks: Tracked excavators have two sets of tracks, one on each side. These tracks consist of a series of interconnected links made of high-strength steel. The tracks are the primary components responsible for propelling the machine and enabling it to change direction.
Drive Sprockets: At the rear of the excavator's undercarriage, you'll find drive sprockets on both sides, one for each track. These sprockets have teeth or gears that engage with the links on the tracks. The drive sprockets are connected to a hydraulic motor or a mechanical drive system.
Hydraulic Motors (or Mechanical Transmission): In most modern tracked excavators, hydraulic motors are used to control the rotation of the drive sprockets. These hydraulic motors receive pressurized hydraulic fluid from the excavator's hydraulic system. By varying the flow and pressure of hydraulic fluid to the motors, operators can control the speed and direction of the tracks.
Idlers and Tensioners: At the front of the undercarriage, you'll find idlers and tensioners. Idlers are non-powered wheels that guide the upper part of the track and help maintain its tension. Tensioners are mechanisms that adjust the tension in the tracks. Properly tensioned tracks are essential for smooth and efficient operation.

Here's how the mechanics work together to change the direction of a tracked excavator:

To move forward, hydraulic fluid is sent to the hydraulic motors that drive the sprockets on both sides in a forward direction. This causes both tracks to rotate in the forward direction, propelling the excavator forward.
To move backward, hydraulic fluid is directed to the hydraulic motors in the reverse direction, causing the tracks to rotate backward.
To turn left, the hydraulic fluid is adjusted to drive the left track faster than the right track. This results in the excavator pivoting or turning to the left.
To turn right, the hydraulic fluid is adjusted to drive the right track faster than the left track, causing the excavator to turn to the right.

The ability to independently control the speed and direction of each track allows the excavator to perform intricate maneuvers and precisely navigate the work site. The operator's inputs, whether through joysticks or pedals, manipulate the hydraulic system to control the speed and direction of the tracks, providing the operator with full control over the excavator's movement.

Common Operator Mistakes Leading to Excessive Track Wear

Improper Tension: One of the most common mistakes operators make is failing to maintain proper track tension. Loose tracks can easily slip off, causing damage to the undercarriage and tracks themselves. Conversely, overly tight tracks can accelerate wear on the sprockets and idlers.
Inadequate Lubrication: Steel tracks require regular lubrication to minimize friction and heat buildup. Operators who neglect this maintenance task may find themselves dealing with prematurely worn tracks and sprockets.
Ignoring Ground Conditions: Operating an excavator in conditions it wasn't designed for, such as extremely rocky or abrasive terrains, can quickly wear out the grousers and damage the links. It's essential for operators to assess ground conditions and adjust their approach accordingly.
Sharp Turns and High-Speed Operation: Abrupt turns and high-speed operation can put undue stress on the tracks, leading to accelerated wear. Smooth and controlled operation is key to preserving the life of steel tracks.

Perfecting Tension: A Guide to Properly Adjusting Tracks on a Steel Tracked Excavator

Steel tracked excavators are powerful machines that rely on their tracks for stability and mobility. One crucial maintenance task that operators and technicians should regularly perform is track tension adjustment. Correctly tensioned tracks ensure optimal performance, reduce wear and tear, and enhance safety on the job site. In this blog, we'll walk you through the steps to properly tension the tracks on a steel tracked excavator.

Step 1: Safety First

Before you start, prioritize safety. Ensure the excavator is parked on a level surface and that the engine is turned off. Here's a list of safety gear and tools you'll need:

Safety glasses
Gloves
Appropriate wrenches or tools for the specific excavator model
Measuring tape or a tension gauge (for reference)
Operator's manual (for specific instructions)

Step 2: Identify Tensioning Points

Different excavators may have varying track tensioning systems, so consult the operator's manual for your specific machine to locate the tensioning points. Common tensioning systems include grease or hydraulic cylinders and adjusting nuts. Most excavators have tensioning points near the idler and front of the undercarriage.

Step 3: Measure Initial Tension

Start by measuring the initial track tension. Use a measuring tape or a tension gauge to determine the current tension. This measurement will serve as a reference point for the adjustment.

Step 4: Loosen the Track

Use the appropriate tool to loosen the track. This may involve loosening adjusting nuts, releasing hydraulic pressure, or adjusting grease cylinder settings. The goal is to provide enough slack in the track for the tension adjustment.

Step 5: Adjust the Tension

To achieve the correct track tension, follow these general guidelines:

Too Tight: Over-tensioned tracks can lead to premature wear and damage to the undercarriage components. Loosen the tension until you can press down on the track with your foot or hand and deflect it slightly (typically around 1 inch or 25 mm).
Too Loose: Under-tensioned tracks can cause instability and affect the machine's performance. Tighten the tension until there is minimal sag in the track but avoid excessive tension that can strain the components.

Remember that specific tensioning requirements can vary depending on the excavator's make and model, so consult the operator's manual or manufacturer guidelines for precise tensioning specifications.

Step 6: Recheck and Adjust

After adjusting the tension, recheck it using your measuring tape or tension gauge. Ensure it matches the manufacturer's recommended tension specifications. Make any necessary adjustments to achieve the correct tension.

Step 7: Secure the Tension

Once you have achieved the correct track tension, secure it in place by tightening adjusting nuts, locking mechanisms, or re-pressurizing hydraulic cylinders, depending on your excavator's system.

Step 8: Final Inspection

Conduct a final visual inspection to ensure that all components are secure, and there are no loose bolts or damaged parts. Lubricate the undercarriage components if necessary.

Step 9: Test Run

Before resuming work, take the excavator for a short test run to ensure that the track tension adjustment has improved stability and mobility.

Properly tensioned tracks are essential for the performance and longevity of steel tracked excavators. Regularly checking and adjusting track tension is a vital maintenance task that ensures safety and efficiency on the job site. By following these steps and referring to your excavator's manual for specific guidelines, you can keep your machine in top-notch condition, minimize wear and tear, and complete projects with confidence.

Ten Biggest Mistakes in the Maintenance of Steel Excavator Tracks Maintaining the steel tracks on excavators is crucial to ensure the longevity and optimal performance of these heavy machines. However, several common mistakes are often made when it comes to track maintenance. Recognizing these mistakes and taking steps to avoid them can save time and money in the long run. Here are some of the biggest mistakes people make:

Neglecting Regular Inspections: One of the most significant mistakes is neglecting routine inspections of the tracks. Regularly checking for wear and tear, loose bolts, damaged links, or signs of misalignment is essential. Ignoring these issues can lead to more extensive and costly repairs down the line.
Incorrect Track Tension: Maintaining the proper track tension is crucial for track longevity and machine performance. Over-tightening or under-tightening the tracks can lead to premature wear, damage to sprockets and idlers, and increased fuel consumption. Operators should follow the manufacturer's recommendations for track tension or consult the operator's manual.
Inadequate Lubrication: Steel tracks require proper lubrication to reduce friction and heat buildup. Some operators forget to lubricate the undercarriage components, such as idlers, sprockets, and track links, leading to accelerated wear and potential breakdowns.
Ignoring Ground Conditions: Operating an excavator on unsuitable ground conditions can be detrimental to the tracks. Rough or abrasive terrains can cause excessive wear on the grousers and damage to the links. It's crucial to assess ground conditions and adjust the machine's operation accordingly.
Skipping Track Cleaning: Failing to clean the tracks after working in muddy or abrasive environments can lead to the accumulation of debris and dirt. This buildup can accelerate wear on the track components and increase maintenance costs.
Noisy Operation: Unusual noises, such as squeaking or grinding, should not be ignored. These noises can be indicators of problems with the tracks or undercarriage components. Addressing such issues promptly can prevent more extensive damage.
Using Damaged or Worn Tracks: Continuing to use tracks that have visible damage, significant wear, or missing grousers can lead to further deterioration and damage to the undercarriage and other components. Damaged tracks should be replaced promptly.
Inadequate Training: Operators who are not adequately trained in excavator operation and maintenance may inadvertently cause excessive wear and damage to the tracks due to improper techniques or habits. Providing proper training and education is crucial.
Ignoring Manufacturer Guidelines: Each excavator model may have unique maintenance requirements and guidelines provided by the manufacturer. Ignoring these recommendations and relying on one-size-fits-all approaches can lead to suboptimal maintenance practices.
Procrastination: Delaying necessary maintenance and repairs can escalate the extent of damage and increase repair costs. Regularly scheduled maintenance and addressing issues promptly can save money in the long run.

To ensure the proper maintenance of steel tracks on excavators, it's essential to follow manufacturer guidelines, conduct routine inspections, invest in operator training, and address any issues promptly. By avoiding these common mistakes, operators and owners can maximize the lifespan and efficiency of their excavators' undercarriage components.

Steel vs. Rubber Tracks on Excavators: Making the Right Choice

Excavators are essential heavy machinery in various industries, and the choice of tracks can significantly impact their performance in different work conditions. When it comes to selecting tracks for an excavator, two primary options are steel tracks and rubber tracks. In this blog, we'll explore the differences between steel and rubber tracks, highlighting their respective pros and cons and helping you determine the best fit for various work and environmental conditions.

Steel Tracks: Durability and Stability

Pros:

Durability: Steel tracks are incredibly durable and resistant to wear and tear. They are designed to withstand rugged and abrasive terrains, making them an excellent choice for heavy-duty tasks.
Longevity: Steel tracks typically have a longer lifespan than rubber tracks. They are less prone to damage from sharp objects and can endure high-impact operations.
Stability: Steel tracks provide exceptional stability and traction, especially in muddy or uneven terrains. This makes them ideal for digging in challenging conditions.
Less Maintenance: Steel tracks generally require less maintenance than rubber tracks. They are easier to clean and less susceptible to damage from debris.

Cons:

Ground Impact: The steel tracks can be harsher on the ground surface, potentially causing more damage when operating on delicate or finished surfaces like asphalt or concrete.
Weight: Steel tracks are heavier than rubber tracks, which can lead to increased ground pressure. This might limit their use in certain conditions where weight is a concern.
Noise and Vibration: Steel tracks can produce more noise and vibrations, which may not be suitable for noise-sensitive work environments or residential areas.

Rubber Tracks: Versatility and Reduced Ground Impact

Pros:

Reduced Ground Impact: Rubber tracks are gentler on the ground surface, making them suitable for use on sensitive or finished surfaces like lawns, pavements, or asphalt. They minimize the risk of surface damage.
Lower Ground Pressure: Rubber tracks distribute the machine's weight over a larger area, resulting in lower ground pressure. This is beneficial for soft or muddy terrain where reducing ground disturbance is essential.
Comfort: Operators often find rubber tracks to provide a smoother and more comfortable ride due to reduced noise and vibration levels.
Versatility: Rubber tracks are versatile and can be used in a wide range of applications and environments. They offer good traction and are suitable for both construction and agricultural tasks.

Cons:

Durability: Rubber tracks are less durable than steel tracks and are more susceptible to damage from sharp objects and rough terrain. They may need more frequent replacement.
Limited Weight Capacity: Rubber tracks typically have a lower weight capacity compared to steel tracks, which can be a limitation for heavy excavation work.
Maintenance: Rubber tracks require more frequent maintenance, such as cleaning and tension adjustment. Over time, they can become loose and need retensioning.

Choosing the Right Track for Your Needs

The choice between steel and rubber tracks ultimately depends on your specific work requirements and environmental conditions. Here are some guidelines:

Steel Tracks: Opt for steel tracks when durability, longevity, and maximum traction are essential. They are ideal for heavy excavation work in rugged terrains where ground impact and surface damage are not concerns.
Rubber Tracks: Choose rubber tracks when you need versatility and reduced ground impact. They are suitable for sensitive surfaces, muddy terrains, and when minimizing noise and vibration is crucial.
Hybrid Tracks: Some excavators offer hybrid track options that combine the benefits of both steel and rubber tracks. These tracks may have steel cores with rubber pads, providing a balance between durability and reduced ground impact.

In conclusion, the choice between steel and rubber tracks should be based on your specific work conditions and priorities. By understanding the pros and cons of each track type, you can make an informed decision that maximizes the efficiency and effectiveness of your excavator in various applications.

Maximizing the Lifespan of Your Excavator Tracks: Tips and Tricks

Excavators are vital assets in construction, mining, and various other industries, and their tracks play a pivotal role in their performance and mobility. Extending the life of your excavator tracks is not only cost-effective but also crucial for uninterrupted productivity. In this blog, we'll explore several practical tips and tricks to help you get the most out of your excavator tracks.

1. Regular Inspection and Maintenance

Routine inspection is the cornerstone of track longevity. Develop a habit of inspecting your tracks and undercarriage components before and after each workday. Look for signs of wear, damage, loose bolts, and any abnormalities. Regular maintenance tasks include:

Cleaning: Remove dirt, debris, and mud from the tracks after each use. Accumulated debris can accelerate wear.
Tension Adjustment: Maintain the correct track tension as per the manufacturer's guidelines. Over-tightened or under-tightened tracks can lead to premature wear.
Lubrication: Grease the undercarriage components, including idlers and sprockets, according to the manufacturer's recommendations. Proper lubrication reduces friction and heat buildup.
Inspect for Damage: Check for damaged or missing grousers, broken links, or any signs of wear on the track itself. Promptly address any issues you find.

2. Match Tracks to the Terrain

Consider the terrain in which you operate your excavator. If you frequently work on soft or sensitive ground, rubber tracks may be a better choice as they minimize ground impact. For rugged terrains, steel tracks provide enhanced durability and traction. Selecting the right type of tracks for your specific applications can significantly extend their lifespan.

3. Control Operator Habits

The skill and habits of the operator can also affect track longevity. Encourage operators to:

Avoid abrupt movements and harsh turns that can strain the tracks.
Limit high-speed operation, as excessive speed can cause unnecessary wear.
Plan routes to minimize unnecessary pivoting, which can lead to uneven wear on the tracks.
Operate within the machine's weight and load capacity limits to prevent overloading.

4. Use Track Pads and Guards

Track pads and guards are add-on components that can protect your tracks in certain conditions. Track pads can reduce wear when operating on abrasive surfaces, and guards can shield the tracks from debris. Consider using these accessories when applicable.

5. Choose High-Quality Tracks

When it comes to replacement tracks, invest in high-quality, genuine parts from reputable manufacturers. While they may cost more initially, they tend to offer better durability and performance, ultimately saving you money in the long run.

6. Monitor and Record Track Life

Keep a record of the track's usage and monitor their wear patterns. By tracking the lifespan of your tracks, you can identify trends and patterns that may indicate the need for specific adjustments or maintenance practices.

7. Avoid Overloading

Operating your excavator within its recommended weight and load capacity limits is essential for preserving the tracks. Overloading can lead to excessive wear and damage to both the tracks and the machine's undercarriage.

8. Temperature Considerations

In extreme weather conditions, such as very high or low temperatures, tracks can be affected. Extreme heat can cause tracks to soften, while extreme cold can make them brittle. Take extra precautions and follow manufacturer recommendations for operation and maintenance in extreme temperatures.

Extending the life of your excavator tracks is a combination of proper maintenance, smart operating practices, and selecting the right tracks for the job. By following these tips and tricks, you can maximize the lifespan of your tracks, reduce downtime, and ensure that your excavator continues to perform efficiently for years to come. Remember that proactive maintenance and attention to detail can go a long way in preserving the integrity of your excavator's undercarriage.

Ten Indications that It May be Time to Change the Steel Tracks on Your Excavator Here are ten indications that it may be time to replace the steel tracks on your excavator:

Excessive Wear: If the tracks show significant signs of wear, including worn-down treads, thinning, or irregular wear patterns, it's a clear sign that replacement is due.
Cracks or Breaks: Any cracks, fractures, or breaks in the steel tracks are safety hazards and should be addressed promptly.
Uneven Tension: Uneven tension in the tracks, where one side is noticeably tighter or looser than the other, can indicate issues with track integrity.
Track Links Separation: If track links start separating from each other or become loose, it can result in reduced stability and performance.
Excessive Track Sag: When the tracks sag excessively between the idler and drive sprocket, it may indicate stretched or damaged tracks.
Reduced Traction: A noticeable decrease in traction, resulting in slipping or difficulty in maintaining grip on different terrains, suggests worn-out tracks.
Increased Noise: Unusual or increased noise during operation, such as clanking or grinding sounds, can be a sign of track issues.
Increased Fuel Consumption: Damaged or worn tracks can lead to increased resistance and, subsequently, higher fuel consumption.
Reduced Speed and Efficiency: If the excavator's speed and overall performance have decreased significantly, it could be due to deteriorating tracks.
Frequent Repairs: Continuous repair and maintenance of the tracks can be an indicator that the tracks have reached the end of their service life and need replacement.

Regular inspection and maintenance of the tracks are essential to ensure safe and efficient excavator operation. If you notice any of these signs, it's advisable to consult with a qualified technician or equipment specialist to assess the condition of the tracks and determine if replacement is necessary to avoid costly downtime and potential safety risks.

Changing Excavator Tracks Using the Bucket: A Step-by-Step Guide

Changing the steel tracks on your excavator is a crucial maintenance task that ensures your machine continues to perform optimally. While there are various methods to replace tracks, using the excavator's bucket to lift the undercarriage is an efficient and straightforward approach. In this blog, we'll walk you through the step-by-step process of changing excavator tracks using the bucket safely and effectively.

Important Note: This method is only suitable for certain types of excavators and requires careful execution to avoid accidents. Always prioritize safety and consult your equipment's manual for manufacturer-specific guidelines.

Tools and Equipment Needed:

Before you begin, gather the following tools and equipment:

Replacement steel tracks
Lifting straps or chains
Heavy-duty jack stands
A reliable lifting device (e.g., a crane or forklift)
Safety gear: hard hat, gloves, safety glasses, and steel-toed boots
Blocking materials (e.g., wooden blocks or cribbing)

Step 1: Prepare the Excavator

Park on a Level Surface: Choose a flat, stable surface for the track replacement to ensure the excavator remains balanced during the process.
Turn Off the Engine: Ensure the excavator is turned off, and the ignition key is removed for safety.
Secure the Bucket: Lower the bucket flat on the ground, engaging the bucket teeth firmly into the ground. This adds stability and prevents accidental movement.

Step 2: Elevate the Undercarriage

Attach Lifting Straps/Chains: Securely attach lifting straps or chains to the lifting points on the undercarriage. These points are typically designated by the manufacturer in the operator's manual. Ensure the straps/chains are rated for the weight of the excavator.
Position the Lifting Device: Use a crane or forklift (properly rated for the machine's weight) to lift the undercarriage. The lifting device should be positioned safely and securely before lifting.
Lift the Excavator: Slowly and carefully lift the undercarriage off the ground using the lifting device. Raise it to a height that provides enough clearance for the old tracks to be removed and new ones installed. Ensure the excavator remains level during the lift.

Step 3: Remove the Old Tracks

Secure with Jack Stands: Once the undercarriage is lifted to a suitable height, place heavy-duty jack stands or blocking materials beneath it. These additional supports provide an extra layer of safety, preventing the excavator from falling in case of mechanical failure.
Remove the Old Tracks: With the undercarriage safely supported, proceed to remove the old tracks. Depending on your excavator's design, you may need to disassemble some components to access the tracks. Follow the manufacturer's instructions for track removal.

Step 4: Install the New Tracks

Install the New Tracks: Carefully guide the new steel tracks into place, making sure they align correctly with the undercarriage components. Follow the manufacturer's guidelines for track installation.

Step 5: Lower the Excavator

Remove the Jack Stands/Blocking: Once the new tracks are securely in place, remove the jack stands or blocking materials from beneath the undercarriage.
Lower the Excavator: Gradually lower the undercarriage using the lifting device, ensuring a smooth and controlled descent.

Step 6: Test and Final Adjustments

Test the Tracks: Start the excavator's engine and conduct a test run to ensure the new tracks function correctly and are properly tensioned. Adjust the track tension if necessary.

Changing the steel tracks on your excavator using the bucket and lifting equipment is a task that requires precision and safety precautions. Always prioritize safety, follow manufacturer guidelines, and consult your operator's manual for specific instructions related to your excavator model. By following this step-by-step guide and adhering to best practices, you can successfully replace your excavator's tracks and maintain the machine's optimal performance.

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