Track Tensioner Issues on Hitachi EX220LC-3 – Troubleshooting and Solutions

[MikePhua]

Introduction
The Hitachi EX220LC-3 is a well-regarded excavator, but like any heavy machinery, it may experience issues over time. One common problem that operators face is track tensioner issues, which can affect the machine's performance and lifespan. This guide explores the causes of track tensioner problems and provides solutions for troubleshooting and maintenance.
Symptoms of Track Tensioner Problems
When there are issues with the track tensioner, you may notice the following symptoms:

1. Loose Tracks: The most obvious sign is loose tracks, which can cause uneven wear and instability while operating the machine.
   
2. Excessive Track Tightness: Tracks that are too tight can lead to increased wear on both the tracks and the machine’s components.
   
3. Uneven Track Wear: If the tracks are not properly tensioned, you may observe uneven wear patterns, which can affect the overall performance of the excavator.
   
4. Track Squealing or Noise: A squealing noise may indicate that the track tension is not properly adjusted, putting unnecessary strain on the machinery.
   

Common Causes of Track Tensioner Issues
Several factors can contribute to track tensioner problems on the Hitachi EX220LC-3:

1. Hydraulic Problems: The track tensioner is often operated hydraulically, and issues with the hydraulic system, such as low fluid levels or leaks, can affect the tensioning mechanism.
   
2. Worn or Damaged Tensioner: Over time, the track tensioner itself can become worn or damaged. This could be due to regular wear and tear or excessive load.
   
3. Dirt or Debris: Accumulation of dirt or debris in the track tensioner mechanism can cause improper functioning, leading to issues with track tension.
   
4. Incorrect Maintenance: Improper maintenance, such as incorrect track adjustments or failure to check the tension regularly, can lead to tensioner problems.
   

Troubleshooting and Solutions

1. Inspect the Hydraulic System: Start by checking the hydraulic system. Ensure the fluid levels are adequate, and look for any signs of leaks that may be affecting the track tensioner. If there are any hydraulic issues, they should be repaired to ensure proper track tension adjustment.
   
2. Check the Track Tensioner: Inspect the track tensioner for signs of wear or damage. If the tensioner is worn out or damaged, it may need to be replaced or repaired.
   
3. Clean the Tensioner Mechanism: If dirt or debris is causing the tensioner to malfunction, clean the mechanism thoroughly. Make sure there is no buildup obstructing the tensioning system.
   
4. Adjust the Track Tension: Once the tensioner is in good working order, adjust the track tension according to the manufacturer’s specifications. Ensure the tracks are neither too tight nor too loose.
   
5. Regular Maintenance: To avoid future issues, regularly check the track tension and perform routine maintenance on the tensioner. This will help extend the lifespan of both the tracks and the machinery.
   

Conclusion
Track tensioner problems on the Hitachi EX220LC-3 can lead to inefficient operation and increased wear on the excavator. By identifying the symptoms and causes of track tensioner issues, you can take the necessary steps to troubleshoot and fix the problem. Regular maintenance and proper adjustments are key to keeping your machine in optimal condition and preventing future issues.