Incorrect Crawler Crane Track Tension is a leading cause of undercarriage failure. Industry data shows improper tensioning can increase wear on track rollers, idlers, and drive sprockets by up to 50%. Beyond component damage, it also raises fuel consumption and generates damaging heat buildup.
For most crawler cranes, optimal tension sits around 800 pounds. However, over-tensioned tracks can reach 5,600 pounds, placing extreme stress on components and requiring more engine power.
Why Crawler Crane Track Tension Matters
Track tension is measured using track sag-the vertical gap between the track rollers and the track links.
Loose tracks risk derailment, especially during turning or on slopes. This can destroy the undercarriage frame, rollers, idlers, sprockets, and the tracks themselves.
Over-tightened tracks increase the load on every undercarriage component, accelerating wear throughout the system.
How to Measure Crawler Crane Track Tension Correctly
Follow this standard procedure for steel crawler tracks:
Park on level, solid ground.
Raise the tracks using the boom, bucket, or outriggers until the tracks are fully off the ground.
Clean the undercarriage thoroughly-debris will distort your readings.
Rotate the tracks two full turns backward, then two full turns forward.
Measure sag at the midpoint of the track frame, from the frame's bottom to the back face of the track shoe.
How to Tighten the Crawler Crane Track Tension
When the track is too loose (which can lead to derailment or the accumulation of debris), proceed as follows:
Park the machine on level, firm ground.
Remove the access cover protecting the grease valve on the track tensioning cylinder.
Connect a grease gun to the grease valve (nipple).
Inject grease slowly and intermittently, frequently checking the track sag to avoid over-tightening by injecting too much at once.
Once the specified track sag is achieved, reinstall the access cover.
Repeat the same procedure for the track on the opposite side.
How to Loosen the Crawler Crane Track Tension
When the track is too tight (which increases component load, accelerates wear, and increases fuel consumption), proceed as follows:
Locate the grease valve (pressure relief valve) on the track tensioning cylinder.
Using a socket wrench, slowly turn the valve counter-clockwise by 1 to 1.5 turns (do not unscrew it completely).
Allow the grease to discharge from the relief port; the track will gradually loosen.
If the grease does not discharge smoothly:
Lift the track off the ground.
Slowly rotate the track to release internal pressure.
Once the track sag reaches the specified value, tighten the valve by turning it clockwise.
Environmental Factors That Affect Tension
Temperature changes have a major impact. Tracks adjusted perfectly on a cool morning may become too slack as temperatures rise and tracks heat up.
Surface conditions matter. Tracks tensioned correctly inside a workshop may become too tight in muddy job site conditions.
Debris buildup from excessive track slack can lodge between crawler crane rollers and tracks, causing severe component damage.