Hitachi 200 Track Tension: Importance, Adjustment, and Maintenance

[MikePhua]

When it comes to maintaining excavators like the Hitachi 200, one of the most important yet often overlooked aspects is the track tension. Proper track tension is crucial for ensuring the smooth operation of the machine, prolonging its lifespan, and preventing costly repairs. If the tension is too tight or too loose, it can cause issues with both performance and wear. This article explores the importance of proper track tension on the Hitachi 200 excavator, how to adjust it, common problems related to track tension, and tips for maintenance.
Why Track Tension Matters
Tracks are one of the most essential components of a crawler excavator, providing both mobility and stability. The track system on the Hitachi 200 works through a series of components, including the track rollers, sprockets, and track links. The proper tension ensures that these parts work in harmony to keep the machine moving efficiently.
There are a few key reasons why track tension is so important for the performance and longevity of the excavator:

1. Prevents Excessive Wear: Tracks that are too loose or too tight can result in uneven wear of the track pads, rollers, and sprockets. A properly tensioned track ensures that weight is distributed evenly, reducing unnecessary wear on these parts.
   
2. Improves Mobility: If the tracks are too loose, they might slip off or fail to grip the surface properly, leading to poor traction, especially on uneven terrain. On the other hand, if the tracks are too tight, they can cause undue strain on the drive motor and hydraulic system, impairing mobility and potentially causing mechanical failure.
   
3. Enhances Performance: Correct track tension improves the overall operational efficiency of the excavator. Properly tensioned tracks allow for smoother movement, less wear on the drive components, and a more responsive machine.
   

How to Adjust Track Tension on the Hitachi 200
The process of adjusting track tension involves monitoring the track sag and using the track adjuster to set the correct level of tension. Here's a step-by-step guide on how to adjust the track tension on the Hitachi 200:

1. Inspect the Tracks: Before adjusting the tension, ensure that the tracks are clean and free from any debris. Inspect the track pads, rollers, and sprockets for any visible signs of wear or damage. If any parts are severely worn or damaged, it’s a good idea to replace them before adjusting the tension.
   
2. Check the Track Sag: Track sag is the amount of deflection or "give" that the track has when pressure is applied. Typically, you want the track sag to fall within a specific range, which can be found in the operator’s manual for your Hitachi 200. Track sag is usually measured by lifting the track off the ground slightly and seeing how far it sags.
   
3. Locate the Tensioning Mechanism: The track tensioning mechanism on the Hitachi 200 is typically found at the rear of the track assembly. You will see an adjusting bolt that can either be tightened or loosened to increase or decrease the tension. Use a grease gun or hydraulic pump to adjust the tension according to the recommended specs in the operator’s manual.
   
4. Adjust the Tension: If the tracks are too loose, use the grease gun to pump grease into the track adjuster, which will extend the adjuster and tighten the tracks. Conversely, if the tracks are too tight, release some grease from the adjuster to reduce the tension.
   
5. Verify the Adjustment: Once you've made the adjustment, check the track sag again and verify that it’s within the recommended range. You may need to make minor adjustments if the track is still not within the correct range.
   
6. Test the Tracks: After adjusting the tension, it’s important to test the machine on the ground. Drive the Hitachi 200 around for a short period and check for any unusual sounds or vibrations. If everything seems smooth, your track tension adjustment is complete.
   

Common Issues Related to Track Tension
If your Hitachi 200 is having problems with its tracks, it’s important to determine whether track tension is the cause. Below are some of the common symptoms and problems related to improper track tension:

1. Excessive Track Wear: If the tracks are too tight, they can lead to excessive wear on the track pads and rollers. You may also notice that the sprockets are wearing down more quickly than usual.
   
2. Track Slippage: If the tracks are too loose, you may experience track slippage, particularly when turning or when operating on uneven terrain. This can cause the machine to lose traction and make it difficult to move or operate.
   
3. Uneven Track Tension: If only one track is loose or tight, the machine may pull to one side or cause uneven wear. In these cases, it’s essential to check both tracks and ensure they are adjusted equally.
   
4. Unusual Noises: A track that’s too tight or too loose can produce grinding, squealing, or knocking noises. These sounds may be coming from the track rollers, sprockets, or idlers, indicating that there’s undue strain on the components.
   

Real-World Example: Track Tension Troubleshooting in the Field
A contractor working in Florida encountered an issue with their Hitachi 200 where one of the tracks would constantly slip off when driving over rough terrain. The operator noticed that the machine’s performance was significantly reduced, and the track on the left side had a lot of excess slack.
After inspecting the track, it was clear that the track tension had become uneven, likely due to a problem with the track adjuster. The contractor adjusted the tension by adding grease to the adjustment mechanism, bringing the track sag back into the optimal range. This resolved the issue, and the machine was back to operating at full capacity. This real-world example highlights the importance of regularly checking and adjusting track tension, especially when the machine is used for rough and varied work environments.
Preventive Maintenance Tips for Track Tension
Maintaining proper track tension is essential for prolonging the life of your Hitachi 200 and preventing costly repairs. Here are some key tips for maintaining the proper tension:

1. Regular Inspection: Check the track tension every 250-500 hours of operation, or as recommended by the manufacturer. Regularly inspect the tracks for wear, dirt buildup, and uneven tension.
   
2. Monitor Track Wear: Keep an eye on the condition of the track pads, rollers, and sprockets. Worn-out components should be replaced immediately to prevent further damage to the track system.
   
3. Keep the Track Adjuster Lubricated: Regularly grease the track adjuster to ensure it operates smoothly. If the adjuster becomes clogged with dirt or debris, it can cause improper tension adjustments.
   
4. Avoid Excessive Operation in Harsh Conditions: While the Hitachi 200 is built for durability, excessive operation in extreme conditions like steep slopes or rocky terrain can put additional strain on the tracks. Try to operate the machine on even ground whenever possible.
   

Conclusion: The Importance of Proper Track Tension
Proper track tension is essential to keeping your Hitachi 200 operating efficiently and extending its lifespan. By regularly adjusting the tension and monitoring the condition of the tracks, you can avoid costly repairs, improve mobility, and ensure the longevity of your machine. If you're experiencing issues with the tracks, a simple check and adjustment can often solve the problem and restore full functionality.
Regular maintenance, attention to detail, and understanding how track tension affects overall performance will ensure that your Hitachi 200 stays in top working condition, no matter the job site or terrain.