Track Tensioner Leaking: Troubleshooting and Solutions

[MikePhua]

Track tensioners are crucial components in maintaining the proper tension on a machine’s track, whether it’s a bulldozer, excavator, or skid steer. A properly functioning track tensioner ensures that the track remains in good condition, preventing unnecessary wear and tear. However, if the tensioner starts leaking, it can lead to loss of pressure and cause premature damage to the track system. This article explores common causes of track tensioner leaks and provides troubleshooting tips and solutions.
Understanding the Function of a Track Tensioner
Track tensioners are responsible for keeping the correct amount of tension in the track. They adjust the track’s tension based on the machine’s movement, making sure the track does not become too loose or too tight. These tensioners are hydraulic-powered and often incorporate grease or oil to maintain pressure.
When a tensioner starts leaking, it can result in several problems. The most obvious is that the track will become too loose, which leads to an inefficient operation and increased wear on the track system. It may also cause premature failure of the track links and rollers.
Common Causes of Track Tensioner Leaks

1. Seal Failure
   One of the most common causes of a leaking track tensioner is seal failure. The seals, typically made of rubber or polyurethane, are designed to keep the hydraulic fluid or grease inside the tensioner. Over time, the seals can degrade due to wear, exposure to extreme temperatures, and contamination from dirt or debris. When the seals fail, hydraulic fluid or grease escapes, resulting in a loss of tension.
   
2. Damaged Hydraulic Hoses
   Hydraulic hoses connect the tensioner to the hydraulic system of the machine. Over time, these hoses can become brittle, cracked, or damaged, leading to leaks. This can be particularly problematic if the damage occurs near the tensioner itself, as it can cause a substantial loss of pressure and make it difficult to maintain proper tension.
   
3. Contamination
   Contaminants such as dirt, sand, or debris can make their way into the tensioner’s hydraulic system, causing damage to the seals, bearings, or other components. When contaminants enter the system, they can cause excessive wear and even result in complete failure of the tensioner, leading to a leak.
   
4. Improper Maintenance
   Track tensioners require regular maintenance to ensure their longevity. If the tensioner is not properly lubricated or maintained, it can lead to the development of leaks. Regular inspections of the seals, hoses, and fluid levels are essential for avoiding issues related to leaking tensioners.
   

Troubleshooting Track Tensioner Leaks

1. Check for Leaking Fluid
   If you notice that your track is becoming loose, the first thing to do is inspect the tensioner for visible leaks. Look for oil or grease leaking from the tensioner or surrounding area. You may also notice a drop in fluid levels in the hydraulic reservoir or see the track becoming loose while operating.
   
2. Examine the Seals
   Once you've identified the location of the leak, inspect the seals on the tensioner. Look for signs of cracking, dryness, or wear. If the seals are damaged, they will need to be replaced. Replacing the seals is typically an easy task but requires you to disassemble the tensioner.
   
3. Inspect Hydraulic Hoses
   Check the hydraulic hoses connected to the tensioner. Look for any cracks, bulges, or signs of wear. If any hoses are damaged, they will need to be replaced. Make sure to use hoses rated for the appropriate pressure to prevent further leaks.
   
4. Check for Contamination
   If there is visible debris or dirt around the tensioner, contamination could be the issue. Carefully clean the area around the tensioner, ensuring no contaminants enter the system when you disassemble it. If contamination has already occurred, you may need to flush the hydraulic system and replace the seals or other components that have been damaged.
   
5. Inspect Tensioner Fluid Levels
   Ensure that the hydraulic fluid or grease in the tensioner is at the correct level. A low fluid level could indicate that the tensioner has been leaking for a while. If necessary, refill the fluid and monitor the tensioner to see if the leak persists.
   

Solutions for Fixing Track Tensioner Leaks

1. Replace Damaged Seals
   If the seals are worn out or damaged, the solution is to replace them. Be sure to use the correct type of seal specified by the manufacturer. When installing new seals, ensure they are lubricated properly to prevent further damage.
   
2. Replace Damaged Hydraulic Hoses
   If the hoses are damaged, replace them immediately. Use high-quality hydraulic hoses rated for the appropriate pressure and temperature. Ensure the hoses are routed properly to avoid damage from rubbing or pinching.
   
3. Flush the Hydraulic System
   If contamination is the cause of the leak, flush the hydraulic system thoroughly to remove dirt and debris. After flushing, inspect the tensioner and replace any parts that have been damaged by contamination, including seals, bearings, or internal components.
   
4. Regular Maintenance
   Prevent future leaks by performing regular maintenance on the tensioner. This includes inspecting seals, checking fluid levels, cleaning the tensioner, and ensuring the hydraulic system is free from contaminants. Regularly replacing the hydraulic fluid or grease as recommended by the manufacturer will also extend the life of the tensioner.
   

Conclusion
A leaking track tensioner can cause significant issues with track performance, leading to costly repairs and reduced machine efficiency. By understanding the common causes of leaks, such as seal failure, damaged hoses, contamination, or improper maintenance, you can take steps to prevent and resolve these issues. Regular inspections, timely maintenance, and replacement of worn components are key to keeping your track tensioner in optimal working condition and ensuring the longevity of your machine’s track system.