Track Tossing in Crawlers and Excavators Requires Root Cause Analysis

[MikePhua]

The Problem of Track Tossing in Heavy Equipment
Track tossing—when a crawler or excavator throws its track off the undercarriage—is a frustrating and costly issue that plagues operators across industries. Whether it happens during slope work, tight turns, or under heavy load, the result is the same: downtime, labor-intensive recovery, and potential damage to the track components. While some machines are more prone to this than others, the root causes are often mechanical, environmental, or operational.
Manufacturers like Caterpillar, Komatsu, and John Deere have spent decades refining undercarriage systems, yet even modern machines can toss tracks if conditions align poorly. Understanding the mechanics behind track retention and the variables that influence it is essential for prevention and repair.
Terminology Notes

• Track Frame: The structural assembly that supports the rollers, idlers, and sprockets.
  
• Carrier Roller: A roller mounted on top of the track frame that helps guide the track and reduce sag.
  
• Track Tensioner: A hydraulic or spring-loaded mechanism that maintains proper track tightness.
  
• Sprocket Engagement: The interaction between the drive sprocket and track links, critical for propulsion and alignment.
  

Common Causes of Track Tossing
Track tossing rarely results from a single failure. Instead, it’s often a combination of wear, misalignment, and terrain. Key contributors include:

• Improper Track Tension
  • Loose tracks sag and can slip off during turns or uneven travel
    
  • Solution: Adjust tension per manufacturer spec, typically allowing 1–2 inches of sag between rollers
    
• Worn or Missing Carrier Rollers
  • Without proper guidance, the track can drift off the frame
    
  • Solution: Replace worn rollers and inspect mounting brackets
    
• Bent Track Frames or Idlers
  • Impact damage can misalign the track path
    
  • Solution: Measure frame straightness and replace bent components
    
• Excessive Side Loading
  • Working on slopes or turning sharply under load increases lateral stress
    
  • Solution: Reduce turn radius under load and avoid sidehill travel when possible
    
• Debris Accumulation
  

• Mud, rocks, or roots packed into the undercarriage can lift the track
  
• Solution: Clean undercarriage daily and install guards if needed
  

A contractor in Alberta reported frequent track tosses on a mid-size dozer during winter logging. After inspection, he found the carrier rollers were missing entirely—removed during a previous repair and never replaced. Once reinstalled and tension adjusted, the issue disappeared.
Equipment Design and Track Retention Systems
Some machines are more prone to tossing due to design. Older crawlers with rigid frames and minimal roller support are especially vulnerable. Modern excavators often include:

• Extended track frames for better stability
  
• Dual carrier rollers for improved guidance
  
• Hydraulic tensioners with grease reservoirs
  
• Bolt-on guards and track guides
  

Manufacturers like Komatsu and Hitachi have introduced segmented track guides that reduce lateral drift. A technician in Texas retrofitted his excavator with aftermarket guides and reduced track toss incidents by 80% over six months.
Recovery Techniques and Field Repairs
When a track is tossed, recovery depends on terrain and equipment availability. Common methods include:

• Using a boom or blade to lift the machine and reposition the track
  
• Winching the track into place with a come-along or chain hoist
  
• Removing track pads to reduce resistance during reinstallation
  
• Releasing tension via grease valve or spring assembly
  

A forestry crew in British Columbia developed a recovery protocol using a skidder and snatch block to realign tossed tracks in under 30 minutes. They trained all operators and reduced downtime across their fleet.
Preventive Maintenance and Operator Training
To prevent track tossing:

• Inspect track tension weekly and after heavy use
  
• Replace worn rollers, sprockets, and idlers promptly
  
• Clean undercarriage daily in muddy or rocky environments
  
• Avoid sharp turns under load and minimize sidehill travel
  
• Train operators to recognize early signs of misalignment
  

A fleet manager in Georgia created a track health checklist including tension measurements, roller wear logs, and operator feedback. This improved uptime and reduced repair costs across his crawler fleet.
Operator Anecdotes and Field Wisdom
A retired operator in Montana recalled working on steep shale slopes with an old cable dozer. The machine tossed tracks weekly until he installed homemade track guides using angle iron and U-bolts. The fix held for two seasons and became standard on his crew’s machines.
In Maine, a contractor used a compact excavator for trenching in wet clay. After tossing a track twice in one week, he added a second carrier roller and switched to a wider pad design. The machine ran for 1,200 hours without another incident.
Recommendations for Buyers and Technicians
To improve reliability and serviceability:

• Choose machines with extended track frames and dual carrier rollers
  
• Retrofit older machines with aftermarket guides and guards
  
• Maintain a log of tension adjustments and component replacements
  
• Train operators on terrain awareness and recovery procedures
  
• Coordinate with OEM support for updated service bulletins and retrofit kits
  

A project manager in Connecticut developed a track retention protocol including terrain mapping, operator rotation, and undercarriage inspections. This reduced toss incidents and improved safety across multiple job sites.
Conclusion
Track tossing is a preventable problem rooted in mechanical wear, terrain challenges, and operational habits. With proper maintenance, thoughtful upgrades, and skilled operators, machines can run smoothly even in the toughest conditions. In crawler equipment, alignment is everything—and keeping the track on means keeping the job moving.