How to check and tune track tension

If you operate a tracked machine, whether it be excavators or loaders on steel or rubber tracks, then it is imperative that you maintain your undercarriage properly as 50 per cent of operating costs lie in the undercarriage.

In addition to cleaning your tracks frequently, operators should also always check that the track tension is just right to get the most out of their machine. Just like how you would check the tyre pressure of your car to ensure it performs at its best on the road.

Too tight a track tension and machine components such as rollers and idlers will wear faster. Power and productivity will consequently suffer. In addition, there is a risk of tearing the tracks if they're tuned too tight.

If the tracks are too loose, the machines might suffer track loss during turns or while traveling on uneven ground, putting operators and site personnel in harm’s way.

As a general rule, soft, muddy conditions will warrant slacker tracks. Rocky and harder ground, on the other hand, requires tighter tracks.

Always consult the machine operating manual for recommended tension levels and directions.

Machine application also affects wear and tension, hence requiring specific adjustments. For example, non-packing (sand, gravel) tensions in packing (clay, mud) situations will cause the tracks to tighten.

Cleanliness can also affect the track tension.

Compact Track Loaders

A simple recoil grease tensioner allows for easy track tension modifications. Machine operating manuals usually contain specific tension levels and instructions for use.

Once adjusted, new tracks shouldn't need constant correction. They only need monthly checks or as operating conditions or applications change. Remember, running tensions outside of recommended specifications speeds up component wear.

Compact track loaders with too loose a track risk "ratcheting", where the track drive embeds jump over the sprocket teeth, damaging both components. If the tracks are too tight, you risk premature undercarriage wear.

Multi Terrain Loaders

Rubber tracks are a critical component in a multi terrain loader's undercarriage. Having proper tension on the tracks will ensure optimum performance and longer service intervals.

Slack between the drive sprocket and front roller wheel is normal. Also, allow a break-in period for new and replacement tracks to allow for the embedded cord length to settle. How much time depends on application, machine model, and operating techniques.

The process of checking track tension is:

1.      Apply a specific amount of weight to the track midpoint - causing it to bend.

2.      Measure the deflection amount with weight applied.

3.      Reference your operation and maintenance manual to check that it is within the specified range.

Multi terrain loaders use a unique turnbuckle arrangement to adjust track tension. Lubricate it with good, penetrating oil spray on the threads and nut weekly. This will prevent rusting and seizing, and make for easy adjustments when needed.

Like compact track loaders, loose tracks will cause "ratcheting", and tight tracks will speed up wear.

Tracked dozers, tractors and hydraulic excavators (with steel or rubber tracks)

Tight tracks on larger tracked machines will increase bushing and sprocket wear, triggered as the bushing rotates and/or slides in the sprocket. Steel link, track rollers and idler are also affected to a lesser extent.

Loose tracks are a big concern as it leads to de-tracking which will cause component failure or breakage; as well as compromised site safety. The result is unplanned, unwanted downtime; costing time and money.

At least once a month, check the track tension via a track adjuster located behind the front idler. Pumping or draining grease through the adjuster valve alters tension. Remember: tiny adjustments in track sag have a massive impact.

In fact, one inch (2.54cm) to half an inch (1.27cm) of sag change increases tension by around 3,000 pounds (1,360kg)!

Inspect the adjuster valve to ensure it works as part of your equipment service procedure. If it shows any sign of leakage - book it in for repair. Leakage usually leads to loss in tension, and to bigger issues down the road.

Always check your operation and maintenance manual for proper track tensions and procedures.

If you need professional help, contact your dealer.

Hastings Deering specialises in Cat heavy equipment and offers a free Custom Track Service as part of an overall machine inspection. As part of the service, the company will analyse the wear and tear of your machine's track and undercarriage and will offer free advice for any repair work required.