The track system is the "legs" of a crawler crusher, and its stability is crucial. If you encounter a track system failure, you need to calmly analyze and systematically address it. Below is a detailed breakdown of the fault, along with diagnostic steps and troubleshooting methods.
Core principle: Safety first!
Before beginning any inspection or repair, always:
1. Completely stop the machine: Park the machine on flat, solid ground.
2. Shut down the engine and disconnect the power: Turn off the engine, remove the key, and turn off the main power switch.
3. Post warning signs: Post warning signs around the machine to prevent accidental startup.
4. Secure support: If you need to work under the machine, use specialized support blocks or brackets to secure the machine. Never rely solely on hydraulics or jacks.
Common Fault 1: Track Deviation or Derailment
This is the most common fault.
Diagnosis and Troubleshooting Steps:
1. Check track tension:
◦ Symptom: Excessive track tension is the primary cause of derailment. To check, measure the distance between the bottom of the track and the top of the rollers, midway between the two tracks. This value should comply with the standards specified in the equipment manufacturer's manual (usually within a few tens of millimeters).
◦ Action:
▪ Over-loose: Use a high-pressure grease gun to inject grease into the tensioning nozzle until the desired tension is achieved. Be careful not to over-tighten, as this will cause increased wear.
▪ Over-tightened: Slowly loosen the drain valve on the tensioning cylinder (usually requiring a special tool) to release some grease until the desired tension is achieved. Exercise caution when operating to prevent injury from high-pressure grease spraying out.
2. Check for wear:
◦ Areas to inspect: Inspect the track rollers, carrier rollers, guide wheels (idlers), and drive wheels for wear. If the flanges (ribs) of these wheels are severely worn, they will not effectively restrain the track shoe, potentially leading to derailment.
◦ Action: Replace severely worn wheels. It is recommended to replace them in pairs to ensure balance on both sides.
3. Check structural alignment:
◦ Areas to inspect: Check that all wheels are aligned. If the frame is deformed or the bracket of a wheel is damaged, the track track will not track correctly. ◦ Treatment: This is structural damage and requires correction or replacement by a professional repair technician.
4. Inspect the track shoes:
◦ Inspection Area: Check the track pins and bushings for excessive wear, which could result in uneven track pitch extension. Inspect the track shoes for cracks.
◦ Treatment: Replace any excessively worn track links or the entire track.
How to Install (Reinstall) a Detached Track:
This is a physically demanding task requiring experience and skill.
1. Use a jack and sleepers to lift one side of the machine so that the derailed track is suspended.
2. Clear the track track of dirt and debris.
3. Use a tool such as a crowbar to slowly "reset" the track to its correct position relative to the drive wheels, guide wheels, and rollers.
4. Start the machine (ensuring personal safety) and operate the machine at a very slow speed, using the force of the drive wheels to "engage" the track. Assistance and observation are required during this process.
5. After resetting, recheck and adjust the tension.
Common Fault 2: Weakness, Noise, or Inability to Move
Diagnosis and Troubleshooting Steps:
1. Initial Diagnosis: Is the fault unilaterally or simultaneously on both sides?
◦ Bilaterally: The problem is likely in a common component, such as the main hydraulic pump, central controller, or insufficient engine power.
◦ Unilateral: The problem is likely in an independent system on that side, such as the travel motor, reducer, control valve, or piping.
2. Check the hydraulic system:
◦ Check the hydraulic oil: Is the oil level too low? Is the oil deteriorating (blackened, foamy)? Is the oil temperature too high?
◦ Check the filter: Is the hydraulic return oil filter clogged? Is the indicator alarming?
◦ Listen for unusual noises: Listen for unusual noises in the travel motor or pump during travel operation. A harsh noise may indicate internal damage to the pump or motor (such as wear on the plunger or valve plate).
◦ Check for leaks: Check the hydraulic lines and fittings for obvious leaks. 3. Check the mechanical transmission:
◦ Check the travel motor and reducer: If the hydraulic pressure is normal but the tracks do not rotate, the problem may be inside the reducer (such as damaged gears or bearings) or the travel motor itself.
◦ Symptom: A "clicking" sound during travel may indicate damage to the gears in the reducer or drive wheel.
Common Fault 3: Abnormal Track Shoe Wear
Diagnosis and Treatment:
1. Avoid long-distance travel on hard surfaces: Traveling on asphalt or concrete roads can severely wear the track shoes. Use a flatbed truck for transport.
2. Check track tension: Tracks that are too tight or too loose can worsen wear.
3. Check site conditions: Avoid turning or stopping on sharp rocks for extended periods.
Summary: Troubleshooting Flowchart
| Fault Symptom | Possible Cause | Action |
| Track Deviation/Derailment | 1. Improper Track Tension (Too Loose) 2. Worn Track Rollers/Guide Rollers, etc. 3. Structural Misalignment 4. Worn Track Chain |
1. Adjust Tension to Standard 2. Replace Worn Wheels 3. Have the Frame Professionally Aligned 4. Replace Track Chain |
| Weak Travel/Unilateral Immobilization | 1. Low Hydraulic Oil Level/Poor Oil Quality 2. Internal Leakage in the Hydraulic Pump/Motor 3. Damaged Reducer 4. Clogged Filter |
1. Add Oil or Replace Hydraulic Oil 2. Repair or Replace the Pump/Motor 3. Repair or Replace the Reducer 4. Replace the Filter |
| Unusual Noise During Travel | 1. Cavitation or Erosion in the Hydraulic Pump/Motor 2. Damaged Reducer Gears/Bearings 3. Foreign Object in Track |
1. Check the oil line and remove air. 2. Repair the reducer. 3. Remove foreign objects. |
| Rapid Track Shoe Wear | 1. Running on hard surfaces. 2. Improper tension. 3. Severe working conditions. |
1. Avoid unnecessary running and use a trailer. 2. Adjust the tension. 3. Regularly inspect and replace. |
Top Tips
• Read the manual carefully: Your equipment's operating manual is your best friend, providing detailed maintenance standards and fault code descriptions.
• Daily Maintenance: Daily inspections of track tension and appearance, and monthly inspections of track rollers and other components for wear, can prevent 90% of track failures.
• Professional Support: For complex hydraulic or structural issues that you are unable to repair yourself, contact the equipment manufacturer or a professional service engineer immediately to prevent minor issues from turning into major losses.
Through systematic diagnosis and effective maintenance, you can significantly reduce the failure rate of the track system, ensuring equipment uptime and productivity.
Baichy Heavy Industry – Your Trusted Partner for Seamless Equipment Operation
To ensure optimal performance of your equipment, Baichy Heavy Industry offers:
- Professional on-site installation guidance
- Comprehensive operator training
- 24/7 technical support & maintenance services
Our complete after-sales service system guarantees long-term, stable operation of your machinery with minimal downtime.
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