New Track Chains Feel Stiff Is That Normal

[MikePhua]

Track Chain Design and Initial Stiffness
When installing new track groups—especially SALT (Sealed and Lubricated Track) chains—on a dozer like the Caterpillar D7F, it's common to observe stiffness in the links and a lack of sag across the top of the track. This is not a defect but a result of how new chains are manufactured and assembled. SALT chains are press-fit and sealed with internal lubrication, which makes the pin and bushing joints tight until they wear in through use.
The stiffness is most noticeable during the first few hours of operation. The track links may appear rigid, and the machine may feel smoother due to reduced vibration from worn components. This is expected behavior and part of the break-in process.
What Is SALT and Why It Matters
SALT chains are designed to extend undercarriage life by sealing lubricant inside each joint. This reduces internal wear and prevents contamination from dirt and moisture. Key features include:

• Press-fit pins and bushings
  
• Internal grease or oil sealed with elastomer rings
  
• Reduced maintenance compared to dry chains
  
• Longer service intervals
  

However, the tight fit means the chain will resist flexing until the seals settle and the internal components wear slightly. This is why new SALT chains often feel “board stiff” initially.
Installation Challenges and Shop Practices
In many dealerships and repair shops, technicians use heavy hammers—sometimes 16 pounds or more—to flatten new chains before bolting on pads. This is especially true for SALT chains, which can be difficult to align due to their rigidity. The process involves:

• Laying out the chain on a flat surface
  
• Using impact force to settle the links
  
• Bolting pads with torque specs between 250–300 ft-lbs
  

This practice helps ensure proper pad alignment and reduces the risk of bolt loosening during early operation.
Break-In Period and Operator Observations
After installation, operators should run the machine under light load for several hours. During this time:

• Monitor for hot pins or uneven wear
  
• Check for abnormal noise or vibration
  
• Observe track sag and adjust tension if necessary
  

In one case, a contractor ran a D7F with new V-Trak SALT chains for several hundred yards at walking speed. The tracks remained quiet, and all pins showed uniform stiffness. No overheating or binding was observed, confirming that the system was functioning normally.
When to Be Concerned
While initial stiffness is expected, certain signs may indicate a problem:

• One side loosens significantly faster than the other
  
• Pins show discoloration or heat marks
  
• Track links bind or skip during rotation
  
• Audible popping or grinding noises
  

These symptoms could point to improper installation, seal failure, or misalignment. In such cases, a teardown and inspection may be necessary.
Maintenance Tips for New Track Groups

• Recheck track tension after 10–20 hours of use
  
• Inspect pad bolts for torque loss
  
• Grease idlers and rollers regularly
  
• Avoid high-speed travel during break-in
  
• Keep the undercarriage clean to prevent abrasive wear
  

Conclusion
New track groups—especially SALT chains—are designed to be tight and stiff at first. This is a sign of quality manufacturing, not a defect. With proper installation and a controlled break-in period, the stiffness will ease, and the track will settle into optimal performance. Operators should monitor but not worry unless clear signs of failure emerge. In the world of heavy equipment, stiffness today often means reliability tomorrow.