What Fleet Managers Need to Know About Track Carrier Maintenance

Mud, brush, rock, water, steep terrain and harsh weather are all factors that contribute to track vehicle breakdowns.

That is, unless your team maintains those vehicles properly.

“Overheating, hydraulic component failures and premature wear – these are the most common issues we see when proper maintenance isn’t performed,” said Gerry Carriere, director of customer service for Panther crawler carriers at Prinoth (www.prinoth-crawlercarriers.com). “It’s not just about following a schedule. These machines operate in rough conditions, so daily inspections and preventive care are essential.”

In a recent conversation with UFP, Carriere outlined six maintenance areas that fleet professionals should prioritize to maximize uptime and extend the service life of their track carriers.

1. Cooling System
Radiators are a hotspot for debris accumulation, especially in dusty or muddy conditions.

“There’s a lot of dirt and debris that can fly into those radiators,” Carriere said. “Clogged radiators lead to overheating, which can cascade into engine and hydraulic failures. Prinoth’s reversible fans help, but manual cleaning is still essential. It takes an hour to clean them out properly.”

Coolant maintenance follows manufacturer guidelines, typically requiring a flush every one to two years. However, Carriere recommended using test tools to check coolant quality, as utility fleet applications may not accumulate enough hours to warrant frequent coolant replacements.

2. Undercarriage and Track System
The undercarriage – including tracks and sprockets – takes the brunt of the punishment in off-road environments. While Prinoth’s self-cleaning undercarriage design reduces buildup and wear, Carriere said operators must still conduct daily visual checks.

“Tracks on our vehicles clean themselves out quite well. But in some areas, like clay, debris can stick, so regular cleaning is critical,” he explained.

In particular, sprockets can become expensive problems if neglected. “If you let them wear down too much, they become almost like knives into your tracks, which can prematurely damage them.”

Sprocket replacement is not based solely on hours. Instead, technicians should rely on measurement tools or visual inspections. According to Carriere, “We provide wear gauges and go/no-go tools so technicians can determine if sprockets need to be changed.”

3. Hydraulic System Maintenance
The key maintenance activities for the hydraulic system focus on fluid quality and line integrity.

“The main thing for that is oil changes and inspection of the hydraulic lines,” Carriere said. Because these machines operate in rough terrain, hydraulic lines can shift and potentially contact sharp edges or wear points.

Carriere recommended comprehensive hydraulic system inspections every 500 hours, with additional spot checks at the 250-hour mark if conditions warrant extra attention.

4. Engine
Engine maintenance largely follows OEM recommendations, but Carriere suggested that harsh operating conditions may require more frequent service intervals than standard guidelines indicate. “We go with what is recommended by the engine manufacturer, and if we feel that it’s not enough, we’ll decrease the time cycles between maintenance.”

Standard engine maintenance includes oil changes, fuel filter changes and visual inspections. Telematics systems can provide additional insights into engine performance and alert operators to developing issues before they become major problems.

5. Drive System
Track carriers use hydrostatic drive systems instead of conventional mechanical transmissions. This distinction is important because it changes how fleets must approach maintenance.

“The hydrostatic is what drives the vehicle, makes it move,” Carriere said. “It’s really a closed-loop system where the pump sends oil back and forth to the motors, creating pressure to turn the tracks.”

Unlike open hydraulic systems, which draw oil from a tank and return it after each cycle, hydrostatic systems continuously circulate the same oil between the pump and motor. That means oil quality and filter changes are critical, especially during the first 150 hours of operation when break-in debris can cause premature wear.

The drive system also includes planetary gears, which transfer power from the hydraulic motors to the tracks. Here, oil levels must be precise. “If you put too much oil, they will overheat. If you put too little, they overheat and go through premature wear as well,” Carriere explained.

6. Electrical Systems and Controls
Electrical systems and controls require regular checks to ensure functionality. Inside the cab, operators should verify that all functions are working properly and check the drive display for any fault codes. Outside the cab, technicians should inspect wiring harnesses for loose connectors or rubbing.

The Bottom Line
Track carriers are built for the most demanding conditions. But even the most rugged machine depends on consistent care to deliver reliable performance.

“The secret to success is basic maintenance and cleaning,” Carriere said. “If you stay on top of that, you’ll avoid most failures and keep your carriers running strong.”

For fleet managers, that means instilling a culture of daily inspections, adhering to service intervals, investing in training and leveraging telematics. The payoff? Extended service life, reduced downtime and greater return on investment from these machines.

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Pre-Operation Inspection Checklist
What should track carrier operators look for during their pre-operation inspections? Gerry Carriere, director of customer service for Panther crawler carriers at Prinoth, recommended following a checklist along these lines.

1. Fluid level checks (before engine start). Check:

• Engine oil level.
• Coolant level.
• Hydraulic fluid level.
• Hydrostatic transmission fluid level.
• Fuel level (ensure adequate fuel for planned operations).

2. Undercarriage inspection. Look for:

• Track condition and proper alignment.
• Sprocket wear condition (using visual inspection or measurement tools).
• Debris accumulation, especially clay-type materials that stick.
• Any loose or damaged components.

3. Hydraulic lines. Check for:

• Signs of wear from rubbing or contact with sharp edges.
• Fluid leaks at connections and along line runs.
• Proper securing and routing.

4. Electrical systems. Inspect:

• Wiring harnesses for damage or loose connections.
• Connectors to ensure they’re tight and clean.
• For any signs of rubbing or chafing.

5. Cooling system. Verify:

• Radiator fans are clean and free of debris.
• No visible coolant leaks exist.
• Fan operation (if hydraulically driven, check pressure/speed).

6. General condition. Look for:

• Oil leaks from any component.
• Loose bolts or fasteners.
• Any unusual wear or damage.
• Proper greasing at the few grease points that exist.