Why Track Tension Matters — And How Incorrect Tension Damages Your Excavator

If you want to destroy an undercarriage faster than a bulldozer on a wet hillside, run your excavator with the wrong track tension.

It’s one of the most overlooked forms of excavator maintenance, yet incorrect track tension is responsible for thousands of hours of unnecessary wear — and millions of rands in avoidable undercarriage repairs every year.

Most operators don’t check track tension.Most site managers don’t enforce it.Most contractors only notice a problem when the machine derails or the sprockets start looking like shark teeth.

This guide explains why track tension matters, how incorrect tension damages your excavator, how to check it properly, and how to get the tension right every time.

1. What Track Tension Actually Does

Track tension is the force that keeps your excavator’s steel tracks properly fitted around the undercarriage components:

• sprocket

• idler

• track rollers

• carrier rollers

• track chain

Correct tension ensures:

• smooth travel

• efficient power transfer

• minimal wear

• reduced fuel consumption

• longer undercarriage life

Your excavator was engineered with precise tolerances. Too loose or too tight, and the entire undercarriage suffers.

2. The Two Types of Incorrect Track Tension

2.1. Tracks Too Loose

Loose tracks hang, sag, and slap against the undercarriage.

Common symptoms:

• frequent de-tracking

• clunking noises when traveling

• chain slapping under the sprocket

• excessive sag between rollers

Loose tracks cause:

A. De-tracking

This is the big one.Loose tracks derail easily during turning, reversing, or working on uneven surfaces.

B. Impact damage to rollers and idlers

Every time a loose chain slaps the rollers, it applies shock loads.

C. Accelerated wear on bushings and sprockets

Loose tracks ride unevenly over the sprocket teeth, wearing them down.

2.2. Tracks Too Tight

Over-tensioning is just as bad — sometimes worse.

When tension is too tight, the hydraulic motor has to work much harder to move the tracks.

Tight tracks cause:

A. Excessive wear on bushings, pins, and idlers

You’re basically stretching the undercarriage every time the machine moves.

B. Overloading the final drives

This is a BIG one.Tight tracks dramatically increase load on the final drives, reducing their life.

C. Higher fuel consumption

More friction = more effort = more diesel burned.

D. Overheating during travel

Final drives and rollers get hot because they’re fighting unnecessary resistance.

3. How Incorrect Track Tension Damages Major Components

Let’s break down the damage in detail.

3.1. Sprockets

Loose tracks cause the chain to ride up on the sprocket teeth → “hooking” or “shark fin” wear.Tight tracks grind the sprocket down faster due to constant pressure.

3.2. Track Bushings & Pins

Incorrect tension accelerates wear on bushing surfaces.Worn bushings = stretched chain = impossible-to-correct tension.

3.3. Rollers (Top & Bottom)

Loose tracks slap rollers.Tight tracks overload bearings.

3.4. Idlers & Adjusters

Over-tightening pushes the idler further forward, stressing the adjuster and piston.

3.5. Final Drives

The final drive is one of the most expensive parts on an excavator.Incorrect tension directly reduces its lifespan by increasing load and heat.

4. What Causes Incorrect Track Tension?

4.1. Mud and material buildup

Clay, mud, and rocks packed inside the undercarriage effectively tighten the tracks.

4.2. Wear in the track chain

As chain stretch increases, tension becomes harder to control.

4.3. Poor maintenance

Operators rarely check tension unless instructed.

4.4. Incorrect tensioning method

Using the grease cylinder incorrectly is a common mistake.

4.5. Temperature changes

Tracks can feel tighter in cold weather and looser in hot weather.

4.6. Different soil conditions

Sand, clay, and rock all affect how tracks behave.

5. How to Check Track Tension Correctly

Even though every OEM has slightly different specs, the general method is the same:

Step 1: Park on level ground

Lift the track slightly off the ground using the boom and bucket.

Step 2: Let the track sag naturally

This removes any pressure that might affect measurement.

Step 3: Measure the sag

Typical measurement:

20–30mm per meter of track frame length(Always check your excavator’s manual for exact specs.)

You measure the distance between:

• the bottom of the track frame

• the top of the chain, midway between the rollers

Step 4: Adjust using the tension grease cylinder

To tighten:

Pump grease into the adjuster.

To loosen:

Release grease through the bleed valve (slowly!).Never stand in front of the idler while releasing grease — it can move suddenly.

6. When to Check Track Tension

Undercarriage experts recommend checking:

• Daily on high-wear sites (quarries, demolition, rocky terrain)

• Weekly on normal construction sites

• Every time track work feels unusual

• After traveling long distances

• After working in thick mud or clay

• After undercarriage repairs

Track tension is NOT a “set once and forget” item.

7. How Correct Track Tension Saves You Money

Proper tensioning leads to:

A. Longer undercarriage life

Tracks, sprockets, rollers, and idlers last significantly longer.

B. Lower fuel consumption

Reduced resistance = less diesel burned.

C. More efficient travel

Smooth travel = less stress on final drives.

D. Fewer breakdowns

Derailing is dangerous, expensive, and avoidable.

E. Lower maintenance costs

Incorrect tension accelerates everything that can go wrong.

8. What Happens If Track Tension Is Ignored

If you ignore track tension long enough, you’ll eventually face:

• worn sprockets

• stretched track chain

• seized rollers

• cracked idlers

• blown final drives

• excavator derailing

• complete undercarriage rebuild

A full undercarriage rebuild can cost:

R200,000 – R600,000+

A tension check takes 5 minutes.

9. How Vikfin Helps You Fix Track-Related Damage

If incorrect tension has already damaged your undercarriage, Vikfin can supply:

• OEM track adjusters

• OEM idlers

• OEM rollers

• OEM sprockets

• OEM final drives

• OEM track chains

All tested, all certified, and all significantly more affordable than buying new.

Keep your tracks right — and your excavator running right.

Final Thoughts

Track tension might seem minor, but it affects every major part of your excavator’s undercarriage and final drives.

A machine with correct tension will:

• travel smoother

• dig more efficiently

• consume less fuel

• experience less wear

• cost you less over its lifetime

Track tension is small maintenance with massive impact.

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