Repair techniques for damaged crawler excavator tracks

However, due to its complex and harsh working environment, the crawler, as a key component that directly contacts the ground and bears huge pressure, friction, and impact, is very easy to be damaged. Once there is a problem with the crawler, it will not only affect the normal operation of the excavator, reduce work efficiency, but also lead to a significant increase in maintenance costs. Therefore, mastering the repair skills of crawler excavator crawler damage is of great significance to ensure the smooth progress of the project. Next, we will explore in depth various common types of crawler damage and corresponding repair methods.

Common crawler damage types and causes analysis

Track shoe wear

In the long-term operation process, the crawler shoe frequently rubs against the ground, especially when working under rough road conditions such as sand, gravel, and rocks, the wear rate will be significantly accelerated. Wear forms are mainly divided into uniform wear and local wear. Uniform wear is usually the inevitable result of long-term normal operation, while local wear is often caused by uneven force on the crawler during operation. For example, when the excavator turns, the friction force on the outer track shoe is much greater than that on the inner side, which can easily cause the local wear of the outer track shoe to intensify. If the track shoe wears too quickly, it will not only shorten the service life of the track, but also affect the driving stability and operation accuracy of the excavator, thereby reducing the overall work efficiency.

Track shoe fracture

Track shoe fracture is mostly caused by excessive impact force or fatigue damage. When the excavator digs hard objects, such as large rocks or frozen soil, the track may be instantly subjected to huge external force impact. This impact force exceeds the bearing limit of the track shoe and will cause fracture. In addition, long-term operation under high-intensity conditions will gradually produce fatigue cracks inside the track shoe. Over time, these cracks continue to expand and eventually cause the track shoe to fracture. Track shoe fracture will prevent the excavator from driving and operating normally, seriously affecting the progress of the project, and if it is not repaired in time, it may cause further damage to other components and increase maintenance costs.

Track pin damage

The function of the track pin is to connect the track plate so that they form a complete and flexible track system. The main reasons for pin damage include wear and deformation. During the operation of the track, there is continuous friction between the pin and the connection hole of the track plate. Over time, the pin will gradually become thinner due to wear. When the excavator encounters abnormal impact, such as falling from a height or colliding with an obstacle, the pin may deform, thus affecting the normal operation of the track. Once the track pin is damaged, the integrity and transmission performance of the track will be seriously affected. The excavator may experience dangerous situations such as loosening and falling off during driving and operation, so it must be repaired or replaced in time.

Detailed explanation of track damage repair techniques

Track plate wear repair

For track plates with less wear, surfacing is a more common and effective repair method. First, the surface of the worn track plate should be thoroughly cleaned to remove impurities such as oil, rust, and soil to create good conditions for subsequent welding work. Next, according to the material and wear condition of the track plate, select the appropriate welding rod and accurately adjust the welding current and voltage. During the surfacing process, the welding sequence should be strictly controlled, and the appropriate welding technique should be used to ensure that the weld is flat and uniform, so that the surfacing layer is firmly attached to the track plate. After the surfacing is completed, the surfacing layer is finely trimmed with a grinding tool to restore its size and shape to a suitable state to meet the normal use requirements of the track. However, if the track plate is severely worn and its performance cannot be effectively restored by surfacing, then it is necessary to consider replacing a new track plate. When replacing, be sure to choose a product that is exactly the same model and specification as the original track plate, and strictly follow the installation process to ensure that the new track plate is firmly installed and accurately positioned, thereby ensuring the normal operation of the track.

Repair of track plate fracture

When the track plate is broken, if the degree of fracture is light and the material of the track plate is suitable for welding repair, it can be treated by welding. First, clean the fracture and its surrounding area, remove impurities, oxides, etc., and expose the metallic luster. Then, according to the material and thickness of the track plate, select the appropriate welding material and welding process. During the welding process, in order to reduce welding stress and prevent further crack expansion, segmented welding, symmetrical welding and other methods can be used, and the welding temperature and welding speed can be controlled. After welding is completed, the weld is polished to make its surface smooth and smooth. At the same time, the weld is tested for flaw detection to ensure that the welding quality meets the requirements. If the track plate is severely broken, or the performance still cannot meet the use requirements after multiple welding repairs, then a new track plate must be replaced. During the replacement process, pay attention to the installation direction and connection method of the track plate to ensure that the new track plate can perfectly match the original track system and work normally.

Track pin damage repair

If the track pin is only slightly worn, it can be repaired by grinding and re-heat treatment. First remove the pin from the track plate, use sandpaper or a grinder to carefully grind the worn part, remove the wear layer on the surface, and restore it to smoothness. Then, the pin is subjected to appropriate heat treatment, such as quenching, tempering, etc., to improve its hardness and wear resistance. After the treatment is completed, reinstall the pin back to the track plate and ensure that it is firmly installed and the pin can rotate flexibly in the connection hole. If the track pin is severely worn or deformed and cannot be repaired by the above method, a new pin must be replaced. When replacing the pin, choose a product with the same specifications as the original pin, and use appropriate tools for removal and installation to avoid damage to the track plate during operation. After installing the new pin, the track should be properly adjusted and tensioned to ensure that the track runs smoothly without jamming or loosening.

Overall adjustment and maintenance of the track

After repairing the damaged parts of the track, the track as a whole needs to be adjusted and maintained to ensure that it can run stably for a long time. First, check whether the tension of the track is appropriate. If the track is too tight, it will increase the wear of various components, reduce the mechanical transmission efficiency, and may also cause the track plate to break; if the track is too loose, it is easy for the track to fall off, affecting the driving stability of the excavator. Generally, the tension of the crawler can be changed by adjusting the crawler tensioning device. The adjustment methods of the tensioning devices of different models of excavators may be different. You can refer to the instruction manual of the excavator for operation. In addition, the crawler should be cleaned and lubricated regularly to remove impurities such as dirt, sand and gravel on the crawler to reduce wear; at the same time, apply an appropriate amount of lubricating oil to various rotating parts of the crawler, such as pins, sleeves, etc., to reduce friction resistance and extend the service life of the crawler. In addition, in daily use, pay attention to the operation of the crawler. If the crawler is found to have abnormal deviation, vibration or abnormal sound, it should be stopped in time for inspection, find out the cause and deal with it to avoid further deterioration of the problem.

In short, mastering the repair skills of crawler excavator crawler damage is crucial to ensure the normal operation of the excavator and improve work efficiency. In actual operation, according to the specific type and degree of crawler damage, choose the appropriate repair method, and pay attention to the daily maintenance and maintenance of the crawler to extend the service life of the crawler, reduce maintenance costs, and ensure the smooth progress of the project.

Choose DIG-DOG for high-quality, customizable brush cutters for skid steers with fast delivery. Contact us today to discover how our superior products can enhance your land management tasks!