Solving Track Popping Noise on the Takeuchi TB135

[MikePhua]

The Takeuchi TB135 and Its Undercarriage Design
The Takeuchi TB135 compact excavator was introduced in the early 2000s as part of Takeuchi’s push into the North American market. Known for its reliability, smooth hydraulics, and tight tail swing, the TB135 became a popular choice for contractors working in urban environments and residential excavation. With an operating weight of around 7,000 lbs and a 27.4 hp Yanmar diesel engine, the machine balances power and maneuverability. Takeuchi, founded in Japan in 1963, pioneered the compact track loader and continues to be a leader in undercarriage innovation.
The TB135 uses a rubber track system with steel-reinforced cores and molded drive lugs that engage with the sprocket teeth. The undercarriage includes track rollers, idlers, sprockets, and a grease-tensioned recoil system. When properly aligned and tensioned, the track should run quietly and smoothly. However, a loud popping noise—especially during turns—can indicate a mismatch between track pitch and sprocket geometry.
Identifying the Source of the Popping Sound
After replacing worn tracks, rollers, and sprockets with aftermarket components, one operator noticed a loud popping sound when turning left. The noise originated from the track lugs engaging the sprocket teeth, suggesting misalignment or improper pitch matching. Despite correct tension and smooth straight-line travel, the popping persisted.
Common causes of track popping include:

• Incorrect pitch between track and sprocket
  
• Misaligned rollers or idlers
  
• Excessive tension or slack
  
• Deformed track lugs or worn sprocket teeth
  
• Uneven wear on one side of the undercarriage
  

Terminology:

• Pitch: The center-to-center distance between adjacent drive lugs on the track
  
• Sprocket: A toothed wheel that engages with the track lugs to propel the machine
  
• Idler: A wheel that guides the track and maintains tension
  
• Recoil system: A spring and grease-filled mechanism that adjusts track tension automatically
  

Measuring Track Pitch and Sprocket Compatibility
To confirm pitch compatibility, measure the distance between two adjacent track lugs (pin-to-pin) and compare it to the spacing of the sprocket teeth. For the TB135, the standard track size is 350x52.5x86, meaning:

• 350 mm track width
  
• 52.5 mm pitch
  
• 86 links per track
  

If the sprocket was designed for a different pitch—such as 50 mm or 55 mm—the lugs will not seat properly, causing popping or skipping. Even a 1–2 mm mismatch can lead to noise and accelerated wear.
Recommendations:

• Use calipers to measure pitch precisely
  
• Confirm sprocket part number matches OEM spec for 52.5 mm pitch
  
• Avoid mixing aftermarket tracks with OEM sprockets unless verified compatible
  
• Inspect track moldings for manufacturing defects or uneven lug spacing
  

In one documented case, a contractor installed aftermarket tracks labeled 350x52.5x86, but the actual pitch measured closer to 53 mm. The sprocket, designed for 52.5 mm, caused the lugs to bind and pop during turns.
Roller and Idler Influence on Track Alignment
Rollers and idlers play a critical role in guiding the track and centering it on the sprocket. If rollers are misaligned or worn unevenly, the track may drift laterally, causing the lugs to engage the sprocket at an angle. This misalignment amplifies popping sounds, especially during directional changes.
Inspection steps:

• Check roller spacing and alignment with a straightedge
  
• Verify idler position and recoil spring tension
  
• Look for signs of side wear on track lugs or roller flanges
  
• Ensure all rollers rotate freely and are properly greased
  

Replacing rollers without correcting alignment may not resolve the issue. In some cases, aftermarket rollers have slightly different flange profiles, which can affect centering.
Grease Tensioner and Track Slack
The TB135 uses a grease-filled tensioner to maintain proper track tension. If the tensioner is underfilled or leaking, the track may sag and cause improper lug engagement. Conversely, over-tensioning can stress the track and sprocket, leading to popping and premature wear.
Best practices:

• Check grease level and refill as needed
  
• Measure track sag at midpoint—typically 10–20 mm is acceptable
  
• Avoid over-pumping grease, which can damage seals
  
• Inspect recoil spring for corrosion or fatigue
  

A technician in Ohio reported that after adjusting the tensioner and confirming proper sag, the popping noise decreased but did not disappear—suggesting pitch mismatch remained the root cause.
Factory vs. Aftermarket Track Quality
While aftermarket tracks offer cost savings, they may vary in pitch accuracy, rubber compound, and lug geometry. Factory tracks are molded to tighter tolerances and tested for compatibility with OEM sprockets. Some aftermarket suppliers mold pitch dimensions into the rubber, but these markings may not reflect actual measurements.
Recommendations:

• Purchase tracks from reputable suppliers with documented pitch specs
  
• Request dimensional drawings or test reports before installation
  
• Consider factory tracks if persistent noise or wear occurs
  
• Avoid mixing brands across undercarriage components
  

In one restoration project, switching from aftermarket to factory tracks eliminated the popping noise entirely, confirming that pitch precision matters more than visual fit.
Conclusion
A loud popping sound from the tracks of a Takeuchi TB135 is often caused by pitch mismatch between the track lugs and sprocket teeth. Even with new rollers and proper tension, incompatible components can lead to misalignment and noise. By measuring pitch, inspecting alignment, and verifying part compatibility, operators can restore smooth operation and extend undercarriage life. In compact excavators, silence isn’t just golden—it’s a sign that everything is running true.