Yesterday, 12:50 PM
The Hitachi EX 120-3 is a widely used crawler excavator known for its reliability and robust performance across various construction and excavation tasks. Like all heavy equipment, maintaining the undercarriage in optimal condition is crucial for smooth operations and longevity. One key aspect of undercarriage maintenance is ensuring proper track tension.
Incorrect track tension can cause premature wear on the tracks, rollers, and other components, leading to costly repairs and decreased machine performance. In this guide, we will cover how to measure track tension on the Hitachi EX 120-3, why it’s essential to maintain proper tension, and the consequences of improper tension.
Understanding Track Tension in the Hitachi EX 120-3
The track tension on an excavator like the Hitachi EX 120-3 is vital for the proper operation of the undercarriage. The tension controls how tightly the tracks are fitted around the rollers, which, in turn, affects the performance of the excavator, especially in rough terrain.
Track tension is primarily controlled by hydraulic cylinders that adjust the tension in the track chain. The right amount of tension ensures that the track remains tight enough for efficient power transfer, but not so tight that it puts excessive strain on the rollers and sprockets.
Key factors that influence track tension:
Maintaining the correct track tension is essential for several reasons:
Measuring and adjusting track tension on the Hitachi EX 120-3 is a straightforward process if you follow these steps carefully:
1. Lift the Machine
Before measuring the track tension, lift the machine using the boom so that the tracks are not under load. This is critical to ensure an accurate reading. The machine should be placed on a flat surface with enough clearance for you to measure the track tension properly.
2. Locate the Track Tension Gauge
The Hitachi EX 120-3 is equipped with a track tension gauge, typically located on the side of the track frame. This gauge is used to measure the track’s sag and is an essential tool for making adjustments.
You will usually find the gauge near the front or rear of the undercarriage, along the track frame. It will have a scale that indicates the amount of slack in the track.
3. Check the Track Sag
Track sag refers to the amount of deflection or “sag” that occurs in the track chain when it’s not under load. To measure track sag:
If the track tension is not within the recommended range, it can be adjusted through the hydraulic tensioning system. The Hitachi EX 120-3 uses a hydraulic cylinder that adjusts the track tension by adding or releasing pressure. Here’s how you can adjust the tension:
After adjusting the tension, recheck the track sag using the track gauge. Make sure that the measurement is within the recommended range. If the track is still too tight or too loose, repeat the adjustment process until the correct tension is achieved.
6. Test the Machine
Once you have measured and adjusted the track tension, lower the machine back to the ground and take it for a short test run. Observe the machine’s performance, including its movement and the sound of the tracks. If the machine feels sluggish or the tracks are making unusual noises, further adjustments may be needed.
Consequences of Incorrect Track Tension
Maintaining the correct track tension is not just about ensuring smooth operation; improper tension can cause serious damage to the undercarriage components. Here’s what can happen if the tension is off:
1. Excessive Track Wear
Improper tension leads to inefficient power transfer from the engine to the tracks, causing the machine to work harder and consume more fuel.
3. Hydraulic Stress
A track that is too tight puts excess strain on the hydraulic system, potentially causing hydraulic pump failure or reduced performance over time.
4. Operational Issues
If the track tension is not correctly adjusted, you may experience issues with the machine’s stability, traction, and overall maneuverability, which could lead to unsafe working conditions.
Real-World Example: Managing Track Tension in Construction
A construction company working on a large excavation project noticed that their Hitachi EX 120-3 was consuming more fuel than expected and the tracks seemed to be wearing faster than usual. After a routine inspection, they discovered that the track tension was too tight, causing unnecessary strain on the machine. After adjusting the tension to the recommended range, the machine’s fuel efficiency improved, and the wear on the undercarriage components was significantly reduced. This example shows the importance of regular maintenance and proper tension adjustments.
Conclusion: Maintaining Optimal Track Tension for Longevity
Track tension is a crucial factor in ensuring the longevity and optimal performance of your Hitachi EX 120-3. Regularly measuring and adjusting the track tension not only improves machine performance but also helps prevent costly repairs and downtime. By following the steps outlined in this guide, operators can ensure that the tracks remain in optimal condition and continue to deliver the reliability and power expected from the Hitachi EX 120-3.
Remember, proper maintenance and timely adjustments are key to maximizing the life of your excavator’s undercarriage and reducing long-term costs.
Incorrect track tension can cause premature wear on the tracks, rollers, and other components, leading to costly repairs and decreased machine performance. In this guide, we will cover how to measure track tension on the Hitachi EX 120-3, why it’s essential to maintain proper tension, and the consequences of improper tension.
Understanding Track Tension in the Hitachi EX 120-3
The track tension on an excavator like the Hitachi EX 120-3 is vital for the proper operation of the undercarriage. The tension controls how tightly the tracks are fitted around the rollers, which, in turn, affects the performance of the excavator, especially in rough terrain.
Track tension is primarily controlled by hydraulic cylinders that adjust the tension in the track chain. The right amount of tension ensures that the track remains tight enough for efficient power transfer, but not so tight that it puts excessive strain on the rollers and sprockets.
Key factors that influence track tension:
- Hydraulic adjustments: The tension is adjusted through hydraulic pressure in the track adjuster, which can be controlled manually or automatically depending on the model.
- Track wear: Over time, the track links, rollers, and other undercarriage components wear down, which can lead to changes in tension.
- Machine usage: Regular operation on uneven surfaces, or under heavy load, can alter track tension, especially if the machine is consistently used in rough conditions.
Maintaining the correct track tension is essential for several reasons:
- Maximized Performance: Proper track tension ensures that the machine’s power is efficiently transferred to the tracks, giving the excavator better traction, stability, and overall performance.
- Reduced Wear and Tear: Tracks that are too tight can cause premature wear on the track rollers, sprockets, and the track itself. On the other hand, tracks that are too loose can cause excessive slippage and unnecessary stress on the components.
- Extended Lifespan of Components: With correct tension, there’s less strain on the undercarriage components, leading to a longer lifespan for your machine and lower maintenance costs.
- Improved Fuel Efficiency: Properly tensioned tracks can improve the overall efficiency of the machine, which can result in better fuel consumption.
Measuring and adjusting track tension on the Hitachi EX 120-3 is a straightforward process if you follow these steps carefully:
1. Lift the Machine
Before measuring the track tension, lift the machine using the boom so that the tracks are not under load. This is critical to ensure an accurate reading. The machine should be placed on a flat surface with enough clearance for you to measure the track tension properly.
2. Locate the Track Tension Gauge
The Hitachi EX 120-3 is equipped with a track tension gauge, typically located on the side of the track frame. This gauge is used to measure the track’s sag and is an essential tool for making adjustments.
You will usually find the gauge near the front or rear of the undercarriage, along the track frame. It will have a scale that indicates the amount of slack in the track.
3. Check the Track Sag
Track sag refers to the amount of deflection or “sag” that occurs in the track chain when it’s not under load. To measure track sag:
- Use a measuring tape or a track tension gauge.
- Measure the vertical distance between the center of the lower track roller and the track.
- For the Hitachi EX 120-3, the optimal track sag is usually around 1 to 1.5 inches, but always refer to the operator’s manual for the exact specification.
If the track tension is not within the recommended range, it can be adjusted through the hydraulic tensioning system. The Hitachi EX 120-3 uses a hydraulic cylinder that adjusts the track tension by adding or releasing pressure. Here’s how you can adjust the tension:
- Release Pressure (if the track is too tight): To reduce tension, the hydraulic system will release pressure from the tension cylinder. This can be done by loosening a valve or using a dedicated adjustment mechanism.
- Increase Pressure (if the track is too loose): To tighten the track, add pressure to the hydraulic system by activating the adjustment mechanism. This will cause the tension cylinder to push the track tighter around the rollers.
After adjusting the tension, recheck the track sag using the track gauge. Make sure that the measurement is within the recommended range. If the track is still too tight or too loose, repeat the adjustment process until the correct tension is achieved.
6. Test the Machine
Once you have measured and adjusted the track tension, lower the machine back to the ground and take it for a short test run. Observe the machine’s performance, including its movement and the sound of the tracks. If the machine feels sluggish or the tracks are making unusual noises, further adjustments may be needed.
Consequences of Incorrect Track Tension
Maintaining the correct track tension is not just about ensuring smooth operation; improper tension can cause serious damage to the undercarriage components. Here’s what can happen if the tension is off:
1. Excessive Track Wear
- Too Loose: If the track is too loose, the track links may not properly engage with the sprockets. This can lead to excessive wear on the track and the sprocket teeth, leading to frequent replacements.
- Too Tight: If the track is too tight, the rollers and sprockets will wear out much faster due to increased friction. The tight track will also cause more strain on the machine’s hydraulic system and engine, potentially leading to premature failure of these components.
Improper tension leads to inefficient power transfer from the engine to the tracks, causing the machine to work harder and consume more fuel.
3. Hydraulic Stress
A track that is too tight puts excess strain on the hydraulic system, potentially causing hydraulic pump failure or reduced performance over time.
4. Operational Issues
If the track tension is not correctly adjusted, you may experience issues with the machine’s stability, traction, and overall maneuverability, which could lead to unsafe working conditions.
Real-World Example: Managing Track Tension in Construction
A construction company working on a large excavation project noticed that their Hitachi EX 120-3 was consuming more fuel than expected and the tracks seemed to be wearing faster than usual. After a routine inspection, they discovered that the track tension was too tight, causing unnecessary strain on the machine. After adjusting the tension to the recommended range, the machine’s fuel efficiency improved, and the wear on the undercarriage components was significantly reduced. This example shows the importance of regular maintenance and proper tension adjustments.
Conclusion: Maintaining Optimal Track Tension for Longevity
Track tension is a crucial factor in ensuring the longevity and optimal performance of your Hitachi EX 120-3. Regularly measuring and adjusting the track tension not only improves machine performance but also helps prevent costly repairs and downtime. By following the steps outlined in this guide, operators can ensure that the tracks remain in optimal condition and continue to deliver the reliability and power expected from the Hitachi EX 120-3.
Remember, proper maintenance and timely adjustments are key to maximizing the life of your excavator’s undercarriage and reducing long-term costs.
