NORTHERN TECHNICAL COLLEGE

AUTOMOTIVE DEPARTMENT

MODULAR TRAINING PROGRAMS

WORKSHOP PRACTICAL:

TRACK CHAIN REMOVAL AND ASSEMBLY

PROCEDURE

CAUTION

Mixing new and old track rollers on the same side can overload the new ones as
they sit lower than the worn ones, therefore taking a lot of extra weight. The effect
would be dangerous.

TRACK ROLLERS & IDLERS

If not replacing all new bottom rollers, it is recommended to fit all the better half on one side
and all new ones on the other side. This keeps even pressure on each roller without overloading
individual ones

When replacing new rollers and idlers, do not travel long distances without stopping the
machine frequently as they could overheat and seize. Stop every 4-5 minutes and go the
opposite direction a little to help circulate the oil. This is standard precaution for the first 100
hours.

An effective way to check for wear in the undercarriage components is by measuring the
components. With the full weight of the machine on the track chain, keeping a good lug height
on your Grouser shoes will ensure proper traction and help reduce track slippage. A spinning
track under load will increase the wear rate of your undercarriage system. Grouser relug bars
can be used to build up your worn shoe lugs and maximise traction

Preparation

Steam clean the general work area.

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TRACK CHAIN REMOVAL AND ASSEMBLY

REMOVAL

1. Drive the tractor forward on level ground until the master link pin (identified by a roll
pin) is in front of the front idler.
2. Jack up rear of the tractor on side to be removed.
3. Loosen the track chain tension.
4. Remove the roll pin from the master link pin and using a heavy track pin-driver and
sledge, drive out the master link pin. See Fig. 1

Fig. 1 removing a master pin

Note: A track pin drive is made from a length of steel rod slightly smaller in diameter
than the track pin. Another rod or pipe is welded to this to form a tee and serve as a
handle, see Fig. 1.
Note: A pin that does not move immediately should have a heavy bar used to back up
the assembly.
5. Jack the tractor up until the rollers are clear of the chain. Place the tractor in reverse.
Holding steering clutch back to brake position on the chain not being removed, slowly
ease the clutch out, feeding the chain off of the sprocket as shown in Fig. 2 and Fig.3.
Drag the track out from under the track frame.

Fig.2 Removing track chain assembly

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 Fig 3. Removing track chain

6. Remove sprocket.

INSPECTION

1. Inspect the track chain, pin, and bush for wear

ASSEMBLY

1. Slide track chain under the track frame. The pin end (without the bushing) should be in
the same position as that shown in Fig. 4.

Fig 4. Installing track chain

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 Note: If the track chain is installed reversed from the position shown, severe wear on
the sprocket teeth and track link bushings will result
2. Locate the tractor on the track until the sprocket is slightly ahead of the rear end of the
track chain.
3. Place a bar through the master pin hole. See Fig 4. Pull the track chain up around the
sprocket and forward over the track idler or idlers, and the front idler as the tractor is
driven forward.
4. Position a block (8 to 10 inches high) under the grouser of the shoe on the second from
last link of the tractor. This will hold the track chain against the front idler.
5. Apply just enough power in the forward speed by slipping the clutch to take the slack
out of the bottom part of the track chain. Install the master pin into place (see Fig 5.),
and secure it with a roll pin. Be sure that the roll pin hole in the master pin has not
collapsed due to difficult removal. Resize if necessary to turn the master pin to the rear
sprocket, by moving the tractor forward, to install roll pin.

Fig 5. Installing master pin.

NOTE: The wide end of the link is the pin end and the narrow end of the link is the
bushing end. The link must be installed as shown in Fig 5. Reversing the links will
accelerate bushing wear.

6. Adjust track chain tension

NOTE: Continuous shearing of the roll pin lock at the master pin is a result of too loose
a fit of the master pin in the links.

LOWER TRACK ROLLER

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The tread wear of the roller is most important and is measured on the roller diameter.
The most suitable tool is a large outside calliper.

The correct measurement is to take the least diameter of either tread on the roller
which will be the one with the highest wear. Because of the difficulty in measuring the
rollers on the machine, it is usually sufficient to measure the front (nearest idler) and
back (nearest sprocket) roller as the greatest wear occurs at these two points due to the
rocking action of the machine

EXCESSIVE SIDE FLANGE WEAR

Besides operational conditions, this wear can be caused by misalignment of excessive

If the rollers have not reached their wear limit, then adjust the chain tension and rotate
some of the rollers

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It should be noted that double flange rollers have a longer life and the correct sequence
of double and single flange rollers is important

If longer life is required due to the operating conditions, then more double flange rollers
can be fitted.

TOP FLANGE DEFORMATION

This is caused by contact of the link pin boss or due to the chain sliding over the flanges
because of exceptional snaking of the chain. If the chain is not completely worn out,
adjust the chain tension, realign the rollers and reposition track guide rails

TOP CARRIER ROLLER

The normal wear condition can be measured as for the bottom rollers. Other wear
patterns are analysed below

EXCESSIVE FLANGE SIDEWEAR

 This can be caused by hillside operation, using special offset grousers, and
incorrect alignment or track tension

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  To increase the roller life, align carrier rollers with idler and sprocket and rotate
top rollers if more than one are fitted to the machine

FLAT SPOTS AND IRREGULAR WEAR

This is usually caused by material packing under the top carrier roller and restricting its
rotation. Rollers should be cleaned and all material removed regularly

IDLER

Radial tread wear is the most important factor. The easiest method of measuring tread
wear is to measure the depth of the tread from the centre of the idler.

It must be noted that the centre rim has not been changed from the original diameter
by abnormal wear or obvious after inspection

EXCESSIVE FLANGE SIDEWEAR

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  The main causes of this wear is abrasive soil conditions, hillside operation or
excessive turning
 Other factors influencing side wear can be incorrect roller alignment or chain
tension
 To reduce side wear to a minimum, make sure the correct chain tension is used
and the idler is correctly aligned in the track frame

TOP FLANGE WEAR

Usually caused by material packing under the

TREAD CRACKING AND SPALDING

This can be caused by high impact loads due to heavy working conditions or by
excessive wear of the idler

The condition of the chain can also contribute to the effect

Unfortunately, the factors which lead to the breakdown of the idler cannot be controlled
and therefore the only remedy will be not to exceed the wear limits of the idler or any of
the undercarriage components

SPROCKETS AND SEGMENTS

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Sprocket wear measurement is one of the most difficult to take. Under normal
conditions of work, the wear occurs in such a way that no trace of the original toothing
remains as a valid reference to base measuring the wear on

Consequently, it is not possible to get the exact data and for any evaluation, it is always
necessary to refer to an unused sprocket of the same type

As a general rule, the sprocket has to be replaced or rerimmed when the wear line
reaches the limits as outlined in the figure above

Due to the fact that the wear is never even, the point where there is major wear must
be considered.

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UNDERCARRIAGE MEASUREMENT

The wear analysis can be completed on site, providing real-time data that will help you
make informed decisions

Chain stretch (measure 4 sections of links

R/H ________________________________ L/H ______________________________

Shoe Lug Height (A) R/H: ____________________ L/H: _________________

Shoe thickness (B) R/H: ____________________ L/H: __________________

Shoe width ____________________________________________

Number of shoes ___________________________________________

Rail Height R/H _________________________ L/H ___________________

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Front Idler flange (A) R/H:_____________________ L/H: _____________________

Rear Idler flange (B) R/H: _____________________ L/H: _____________________

(High track dozers)

Top Toller Diameter R/H: 1) ____________ 2). ____________3). _____________

Top Roller Diameter L/H: 1). ____________ 2). ____________ 3). _____________

(Measure from sprocket end)

List Roller Brand(s) (if possible)

Track roller diameter R/H (Measure from sprocket)

1). 2), 3). 4). 5).

6). 7). 8). 9). 10).

Track Roller Diameter L/H (Measure from sprocket)

1). 2), 3). 4). 5).

6). 7). 8). 9). 10).

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 Outside diameter

Outside Bushing Diameter:

R/H: _____________________________ L/H:

Width of Sprocket Tip:

R/H: _____________________________ L/H: ___________________________

Number of Holes: ___________________________________

Number of Teeth: ___________________________________

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