What are the reasons for the malfunction of excavator track roller?
1. Wear and tear issues
Normal friction and wear
Reason analysis: During the operation of the excavator, the supporting wheels always come into contact with the tracks and bear the weight of the machine. With the frequent movement and operation of excavators, friction between the track roller and tracks is inevitable. Long term friction can lead to gradual wear of components such as the wheel body surface, shaft, and seals of the supporting wheel. For example, when excavating hard foundations or working on rough and uneven roads for a long time, the friction force borne by the supporting wheels will significantly increase, accelerating the wear process.
Impact: Worn supporting wheels can lead to poor fit between the tracks and supporting wheels, making the tracks prone to looseness, deviation, and other issues. Meanwhile, excessive wear of the wheel body may also affect the walking stability of the excavator, increase energy loss, and reduce work efficiency.
Foreign objects entering causing wear and tear
Reason analysis: The working environment of excavators is usually harsh, and foreign objects such as dust, sand, and metal fragments on the construction site can easily enter between the track roller and tracks. These foreign objects will intensify friction, causing scratches and wear on the surface of the supporting wheel. For example, in the construction site of demolishing old buildings, broken bricks, concrete blocks, etc. may be embedded between the tracks and track roller.
Impact: This type of wear not only damages the appearance of the supporting wheel, but may also cause pits or scratches on the surface of the wheel body, further affecting the service life of the supporting wheel. Moreover, foreign objects may damage the sealing structure of the supporting wheel, causing lubricating oil leakage and exacerbating the wear of internal components.
2. Sealing failure
Seal aging
Reason analysis: The seals of the supporting wheels are usually made of rubber material, and over time and under the influence of the usage environment, the rubber seals will gradually age. High temperature, chemical substances (such as oil stains, acidic and alkaline substances, etc.), and prolonged mechanical stress can accelerate the aging process of seals. For example, excavators operating in high-temperature open-pit mines may experience premature aging of seals due to prolonged exposure to high temperatures.
Impact: After the aging of the seal, its sealing performance decreases, which can lead to leakage of lubricating oil inside the supporting wheel. The loss of lubricating oil can cause the internal parts of the supporting wheel (such as shafts and bearings) to lose lubrication, increase friction, and lead to increased wear of the parts, which may even result in jamming.
Seal damaged
Cause analysis: In addition to aging, seals may also be damaged due to external impact, excessive compression, or improper installation. For example, when an excavator crosses large obstacles, the supporting wheels may experience severe vibrations, causing the seals to be squeezed or torn. In addition, improper operation during the installation of seals can also make them prone to damage during use.
Impact: After the seal is damaged, impurities such as dust and moisture from the outside can easily enter the interior of the supporting wheel, contaminate the lubricating oil, and accelerate the corrosion and wear rate of internal parts, affecting the normal use of the supporting wheel.
3. Internal parts damaged
Bearing damage
Reason analysis: Bearings are key components of supporting wheels, which bear the weight of the machine and various forces during operation. The main reasons for bearing damage include long-term overload, poor lubrication, and improper assembly. If excavators often work under overweight loads, the pressure on the bearings will exceed their design limits, causing fatigue wear, deformation, and even rupture of the ball bearings or raceways. In addition, as mentioned earlier, seal failure leading to lubricant leakage can cause bearings to lack lubrication, increase friction and wear.
Impact: After the bearing is damaged, the supporting wheel will produce abnormal noise during rotation, and the rotation will not be smooth. In severe cases, it may cause the supporting wheel to get stuck, making it impossible for the excavator to move normally.
Damage to the shaft
Cause analysis: Shaft damage is usually caused by long-term bending stress, torsional stress, or wear. During the operation of the excavator, the supporting wheels may experience uneven force, causing the shaft to bend. Meanwhile, friction between the shaft, bearings, and wheel body may also cause wear on the shaft surface. If there are defects in the material of the shaft or improper heat treatment, it will also make it more susceptible to damage during use.
Impact: After the shaft is damaged, the rotation accuracy of the support wheel will be affected, resulting in uneven operation of the track. Moreover, damage to the shaft may further affect the normal operation of other components and increase maintenance costs.
How to determine if the excavator support wheel needs to be replaced?
1. Observe the appearance of wear and tear
Wheel wear: Check the surface of the supporting wheel. If the wheel is severely worn, with obvious pits, scratches, and a depth exceeding a certain limit (such as over 3.5mm), replacement needs to be considered. These dents and scratches can affect the fit between the track and the support wheel, causing the track to run unevenly. In addition, when the diameter wear of the wheel body reaches 5% or 10% of the original diameter, replacement should also be considered. Because reducing the diameter of the wheel body will cause changes in the tension of the track, increasing the risk of wear and detachment of the track.
Edge wear: The wear of the supporting wheel edge is also critical. If the edge wear is uneven and severe serrated wear occurs, it will cause the track to easily deviate during operation. Under normal circumstances, the edge should be kept relatively flat. When the edge wear exceeds a certain range (such as 30% or 50% of the original edge thickness), it may affect the guiding effect of the supporting wheel and track, and needs to be replaced.
2. Check the sealing condition
Lubricating oil leakage: Check for signs of lubricating oil leakage around the supporting wheel. If obvious oil stains are found on the surface of the supporting wheel, it indicates that the seal may have been damaged and lubricating oil is leaking. Sealing failure can cause external impurities to enter the interior of the supporting wheel, contaminate the lubricating oil, and accelerate the wear of internal components. When it is found that the lubricating oil leakage is severe and cannot be solved after simple repairs (such as replacing seals), it is necessary to replace the supporting wheel.
Aging or damage of seals: Carefully inspect the seals themselves. If there is aging, hardening, cracking, or deformation of the seals, even if there is no obvious lubricant leakage temporarily, it may indicate that the sealing performance is about to decline. Aging seals will lose their elasticity and cannot effectively prevent impurities from entering and lubricating oil from flowing out. Generally speaking, after a certain period of use (usually 12 years depending on the working environment and frequency of use), it is necessary to check the condition of the seal. If the above problems are found, replacement of the supporting wheel should be considered.
3. Listen to the sound of operation
Abnormal noise: During the normal operation of the excavator, listen to the sound of the supporting wheels running. If you hear a piercing metal friction sound, buzzing sound, or other irregular abnormal noise from the supporting wheel, it may be a signal of damage to internal components such as bearings and shafts. For example, when a bearing is damaged, it usually emits a continuous "buzzing" or "creaking" sound, which is caused by the wear and deformation of the bearing ball or raceway, resulting in poor operation. When this abnormal sound occurs, it is necessary to further check the condition of the internal parts. If the internal parts are severely damaged, replacing the supporting wheels is a good choice.
4. Check the flexibility of operation
Increased rotational resistance: Manually rotate the supporting wheel to feel its flexibility in rotation. If the resistance of the roller increases significantly when it rotates, and it feels "stuck", it may be caused by wear and damage of internal parts or insufficient lubricating oil. A normal supporting wheel should be able to rotate relatively easily. The supporting wheel can be compared with a normal supporting wheel for rotation. If a significant difference in rotational resistance is found, it needs to be repaired or replaced.
Stuck phenomenon: If the supporting wheel is completely stuck, that is, unable to rotate, it indicates that the internal parts (such as bearings stuck, shafts and other components stuck, etc.) have been severely damaged. In this case, the supporting wheels must be replaced immediately, otherwise it will cause more serious damage to the tracks and excavator's walking system.
What is the general service life of excavator track roller?
1. The impact of work environment factors on service life
Lifespan under harsh working conditions
In some extremely harsh working environments, such as mining and building demolition, the service life of excavator track roller will be significantly shortened. For example, in mining environments, a large amount of hard materials such as ore and rock fragments can cause frequent impact and wear on the supporting wheels. These hard particles are easily embedded between the track and the supporting wheel, accelerating the wear of the wheel surface. In this case, the supporting wheel may only be used for 1000 to 2000 hours.
At the same time, there is a large amount of ore dust in the mine, which can easily enter the sealing parts of the supporting wheels, causing wear of the seals and contamination of the lubricating oil. Moreover, excavators often carry heavy loads during mining operations, which increases the burden on the internal components of the supporting wheels (such as bearings and shafts) and further reduces their service life.
Life under normal working conditions
In relatively ordinary working environments, such as general earthwork excavation, road construction, etc., the wear and impact on the supporting wheels are relatively small. If the construction site is relatively flat, the soil is soft, and the excavator can be regularly maintained, the service life of the supporting wheels can reach 4000 to 6000 hours. In this working condition, although dust and small particles may also enter, the degree of damage to the supporting wheels is relatively low.
2. The impact of equipment quality and component materials on service life
The advantages of high-quality equipment
High quality excavator track roller have advanced component materials and manufacturing processes. For example, the wheel body is made of high-strength alloy steel, which has high hardness and toughness, and can better resist wear and impact. High quality bearings have high precision, strong load-bearing capacity, and use high-quality lubricating grease, which can effectively reduce friction and wear. For such high-quality supporting wheels, under normal working conditions, their service life can reach 6000, 8000 hours, or even longer.
Limitations of low-quality equipment
On the contrary, some low-quality supporting wheels are prone to deformation and wear due to poor component materials, such as insufficient strength of the wheel body material; Poor quality of seals, prone to aging and damage; The bearing has low precision, poor quality, and limited load-bearing capacity. These factors result in a shorter service life for low-quality supporting wheels under the same operating conditions, possibly only 2000 to 3000 hours.
3. The impact of maintenance on service life
Good maintenance measures extend lifespan
Regular maintenance is the key to extending the service life of the supporting wheel. For example, regularly cleaning the debris between the support wheel and the track can reduce the wear of the wheel body caused by foreign objects. Timely replacement of worn seals can prevent lubricant leakage and impurities from entering, ensuring good lubrication of internal components. If the manufacturer's recommendation can be followed to conduct a comprehensive inspection and maintenance of the support wheel every 500 to 1000 hours of operation, including cleaning, lubrication, inspection of seals and internal parts, the service life of the support wheel can be significantly extended, reaching about 6000 to 8000 hours under normal working conditions.
Lack of maintenance leads to shortened lifespan
On the contrary, if the maintenance of the supporting wheels is neglected, their service life will be greatly reduced. For example, if the supporting wheel is not cleaned for a long time, foreign objects may accumulate, which will accelerate the damage of the wheel body and seals. Failure to replace aging seals in a timely manner can cause lubricant leakage, leading to increased wear of internal components. In this case, even under normal working conditions, the service life of the supporting wheel may be shortened to 2000 to 3000 hours.
What are the methods to extend the service life of excavator track roller?
1. Keep the working environment clean
Timely cleaning of debris at the construction site: Prior to excavator operation, the construction site should be cleaned to remove as much debris as possible that may enter between the track roller and tracks, such as stones, metal fragments, wooden blocks, etc. During the homework process, if any debris is found piled up near the tracks, it should be cleaned up in a timely manner. For example, at construction demolition sites, there are often broken bricks, concrete blocks, and other debris that can easily get embedded between the tracks and track roller, accelerating the wear of the track roller. Regular cleaning can effectively reduce this wear and extend the service life of the supporting wheels.
Prevent the accumulation of dust and soil: Dust and soil are common substances in the working environment of excavators. Excessive dust can enter the sealing area of the supporting wheel, affecting the sealing effect and causing lubricant leakage and internal component wear. Therefore, after working in a dusty environment, it is necessary to clean the excavator in a timely manner, especially the area around the track roller. At the same time, in humid environments, soil is prone to adhere to the supporting wheels, increasing their rotational resistance and requiring timely cleaning. Keeping the supporting wheels clean can create good working conditions for them.
2. Operate the excavator correctly
Avoid overload operation: The track roller of excavators are designed based on a certain load capacity. During the operation, it is necessary to strictly follow the rated load of the excavator to avoid overloading the supporting wheels for a long time. For example, when excavating hard rocks or handling overweight materials, if the design load of the excavator is exceeded, the pressure borne by the supporting wheels will be too high, resulting in excessive wear of internal parts (such as bearings and shafts), and may even cause deformation of the wheel body. Accurately estimating the weight of each excavation or transportation and distributing the load reasonably can reduce the burden on the supporting wheels and extend their service life.
Smooth operation to avoid impact: During the walking and operation of the excavator, it is important to maintain a smooth movement as much as possible. Avoid sudden acceleration, sudden braking, sudden turning and other violent operations, as these actions can cause the supporting wheels to experience a huge instantaneous impact force. For example, when an excavator makes a quick turn, one side of the support wheel will bear a large lateral force, which can easily cause damage to the wheel body and internal parts. Operators should operate the excavator slowly and steadily, so that the track roller can evenly bear the load and reduce damage caused by impact.
3. Strengthen maintenance and upkeep
Regular inspection and replacement of lubricating oil: The lubricating oil inside the supporting wheel is crucial for reducing friction and wear between parts. Regularly check the oil level and quality of the lubricating oil. Depending on the working intensity and environment of the excavator, it is generally checked every 500 to 1000 hours of operation. If insufficient lubricating oil is found, it should be added in a timely manner; If the lubricating oil is contaminated or deteriorated, such as mixed with dust, water, or metal particles, it should be replaced in a timely manner. At the same time, high-quality lubricating oil that meets the equipment requirements should be used to ensure good lubrication effect.
Check and maintain seals: Seals are key components that prevent external impurities from entering the interior of the supporting wheel and lubricating oil leakage. Regularly check the condition of the seals, usually every 1000 to 2000 working hours. If aging, hardening, cracking, or deformation of the seal is found, it should be replaced in a timely manner. When installing new seals, make sure they are installed correctly to avoid damaging the seals due to improper installation. In addition, an appropriate amount of lubricating grease can be applied around the seal to improve its sealing performance.
Check and tighten connecting components: Regularly inspect the connecting components between the support wheel, track, and excavator body, such as bolts, nuts, etc. These connecting components may become loose due to vibration during the operation of the excavator, causing displacement or shaking of the track roller and increasing wear. Generally, the fastening of connecting components should be checked every 500 to 800 working hours. If there is any looseness, it should be tightened in a timely manner. At the same time, attention should be paid to checking whether the connecting components are damaged, such as whether the threads of the bolts are worn, whether the nuts are deformed, etc. If there is any damage, it should be replaced in a timely manner.
4. Choose high-quality track roller and accessories
Choose high-quality branded products: When purchasing or replacing track roller, try to choose well-known brands with reliable quality. High quality brand supporting wheels usually use high-quality materials and advanced manufacturing processes, with high wear resistance of the wheel body, precision and reliability of internal parts. For example, some high-end brands' supporting wheels use special alloy steel materials for the wheel body, which can achieve a good balance between hardness and toughness after fine heat treatment, effectively resisting wear and impact.
Ensure the quality of accessories: In addition to the supporting wheel itself, the quality of its accessories (such as bearings, seals, etc.) is also important. The use of high-quality accessories can ensure the overall performance of the supporting wheel. When replacing accessories, choose products that match the model of the supporting wheel and meet the equipment requirements. For example, high-quality bearings can withstand greater loads and have good wear resistance and sealing properties; High quality seals can effectively prevent impurities from entering and lubricating oil leakage, thereby extending the service life of the supporting wheel.
