Why does the Bomag BF 600 P-2 track system require regular adjustment?
The Bomag BF 600 P-2 is a mid-size tracked paver widely used on road construction and large-area resurfacing projects across the UK and Ireland. Its rubber track system provides excellent flotation and traction, particularly when working on granular base layers or soft subgrades. However, the same design that gives it superior ground grip also introduces a critical maintenance need: correct track tension and alignment. If neglected, even a well-maintained paver will suffer reduced traction, accelerated undercarriage wear, and premature track failure.
Track adjustment on the Bomag BF 600 P-2 is not a set-and-forget procedure. The rubber tracks stretch naturally over time, and the tensioners can lose preload due to vibration, temperature changes, or contamination. A loose track can derail during a turn, while an overtightened track puts excessive strain on the final drives and idler wheels, leading to costly component replacement. This guide provides a step-by-step procedure for checking and adjusting the track system, using standard hand tools and a simple tension gauge.
What tools and specifications are needed for track adjustment?
Before beginning any work on the track system, gather the correct tools and reference the manufacturer’s tension values. Using improper tools can damage the adjustment components, and ignoring the specified tension can lead to handling problems or safety hazards.
Required tools and materials
- Grease gun (manual or pneumatic) with standard NLGI #2 lithium-based grease cartridge
- Torque wrench capable of at least 200 Nm (147 ft·lb)
- Tape measure or track tension gauge (Bomag part number 059 123 456 or equivalent digital gauge)
- Flat-head screwdriver (for cleaning grease fitting)
- Rags and degreaser for cleaning around the tensioner port
- Safety glasses and heavy-duty gloves
- Small pry bar or drift pin (for minor alignment adjustments)
Factory specification reference table
| Parameter | Value | Notes |
|---|---|---|
| Recommended track sag (measured at centre of track span, with paver on level surface) | 10–15 mm (0.4–0.6 in) | Measured from underside of track to underside of frame rail |
| Maximum track sag deviation (left vs. right side) | 3 mm (0.12 in) | Uneven sag indicates alignment issue or worn idler |
| Grease volume per tensioner (full stroke) | Approx. 35–40 cm³ | Do not exceed this amount to avoid seal damage |
| Final drive sprocket bolt torque | 180 Nm ± 10 Nm (133 ft·lb ± 7 ft·lb) | Check after any adjustment that involves removing sprocket guard |
| Ambient temperature for adjustment | 10–30 °C (50–86 °F) | Cold tracks contract; adjust only when paver has been at operating temperature for 15 minutes |
If you do not have a Bomag‑specific tension gauge, a simple method is to park the paver on a clean, level concrete floor, raise the screed fully, and measure the vertical drop of the track between the front idler and the first mid‑roller. That sag should be within the 10–15 mm range. Adjust accordingly.
How do you perform a track tension adjustment on the Bomag BF 600 P-2?
Track tension adjustment on this paver is achieved by adding or removing grease from the tensioner cylinder located just behind the front idler wheel. The process is straightforward but requires attention to detail to avoid under‑ or over‑tensioning. Follow these steps for a safe and accurate adjustment.
Step‑by‑step adjustment procedure
- Park and secure the paver. Place the machine on a firm, level surface. Engage the parking brake and chock the tracks. Lower the screed to the ground for stability. Turn off the engine and remove the ignition key.
- Clean the area. Use degreaser and a rag to clean the grease fitting on the tensioner cylinder. Dirt can force contaminants into the seal, causing leaks later.
- Check current tension. Measure the sag using the gauge or tape measure. Record the value for both tracks.
- If tension is too low (sag > 15 mm): Connect the grease gun to the fitting. Pump grease in 2–3 strokes, then re‑measure. Repeat until sag falls within 10–15 mm. Do not exceed 40 cm³ total. If more grease is needed, inspect the cylinder for leaks or internal damage.
- If tension is too high (sag < 10 mm): Loosen the grease relief valve slightly (typically a hex plug on the tensioner body) to allow a small amount of grease to escape. Re‑tighten and re‑measure. Repeat until correct. Never fully open the relief valve while the track is under load.
- Align the track. After tension adjustment, verify that the track runs true on the idlers and rollers. If the track rubs against the frame on one side, loosen the idler wheel mounting bolts (2 per side, 80 Nm) and tap the idler gently with a soft malley to centre it. Re‑torque bolts.
- Final check. Run the tracks at low speed in forward and reverse for one full revolution. Listen for abnormal noise (squealing or chirping). Re‑measure sag after the run-in.
- Document the adjustment. Record the date, sag readings, and any grease added in the machine logbook. This helps track wear trends.
For a more comprehensive overview of the entire track maintenance schedule, including roller lubrication and rail inspection, refer to our detailed Bomag BF 600 P-2 Track System Maintenance: A Comprehensive Guide.
What signs indicate the track alignment is out of specification?
Track misalignment can cause rapid wear of the rubber lugs, damage to the driving sprocket, and even structural cracking of the frame. Operators and mechanics should be alert to these common symptoms:
- Uneven wear on track lugs: If one side of the lug shows more abrasion or chunking, the track is running at an angle.
- Frequent derailing: A track that jumps off the idlers during turns or reverse operation is a clear sign of misalignment combined with loose tension.
- Abnormal noise: A repetitive thumping or clicking sound from the track area usually indicates that the track is riding up on the edge of a roller or idler.
- Visual tracking mark: If you see a polished line or grease marking on the frame rail where the track rubs, alignment is off.
- Vibration in the operator platform: Misaligned tracks transmit vibration through the chassis, especially at higher travel speeds.
If any of these symptoms appear, inspect the undercarriage components first (idlers, rollers, sprocket). Worn bearings or bent mounts can mimic alignment issues. If all hardware is sound, then proceed to adjust alignment as described in the step‑by‑step procedure above.
How often should track tension be checked and adjusted?
The Bomag BF 600 P-2 maintenance manual recommends a track tension check every 50 operating hours, or weekly if the paver is used daily. However, the actual frequency depends on operating conditions. For machines working on abrasive materials like recycled asphalt or gravel, a weekly check may not be enough; a quick visual sag check before each shift is prudent. For pavers used primarily on smooth asphalt surfaces, every 50 hours is adequate.
Also schedule a full track adjustment after any of these events:
- After replacing a track or any undercarriage component (idler, roller, sprocket)
- After a major overhaul of the final drive
- After the paver has sat idle for more than three months (tracks can “take a set” and need re‑tensioning)
- After operating in extreme temperatures below 5 °C or above 40 °C
Ignoring adjustment intervals can lead to tracks that derail during a critical paving pass, causing unplanned downtime and costly repairs. Keep a log and stick to the schedule.
What are common mistakes during track adjustment and how to avoid them?
Even experienced mechanics can fall into traps when adjusting the Bomag BF 600 P-2 tracks. Here are the most frequent errors and their consequences.
- Overtightening: Adding too much grease forces the idler forward, reducing the track’s flexibility. This overloads the final drive bearings and can snap the tensioner cylinder ear. Avoid by using a gauge and never exceeding the sag specification.
- Undertightening: A loose track can wrap around the sprocket or derail. This is especially dangerous on slopes. Always re‑measure after a run‑in.
- Ignoring alignment: Some operators only adjust tension without checking lateral alignment. This causes the track to run against the frame, wearing out the rubber sidewalls. Always do a visual run‑in check after adjustment.
- Using incorrect grease: Heavy‑duty EP grease can be too thick for the tensioner seals, causing them to blow. Stick to NLGI #2 lithium grease.
- Adjusting on a slope: The sag measurement will be inaccurate if the paver is not level. The track may be tighter on the downhill side. Always adjust on level ground.
- Skipping the run‑in: Grease compresses and rubber relaxes after the track is cycled. If you don’t run the tracks after adjustment, the sag will change. Always run both tracks forward and reverse for at least one revolution.
If you have recently experienced engine overheating issues that could be related to track misalignment (increased rolling resistance), read our Bomag BF 600 P-2 Engine Overheating Troubleshooting Guide for diagnostic steps.
What owners say about track adjustment and care
Operators and fleet managers who work with the Bomag BF 600 P-2 in the UK and Ireland consistently highlight that the track system, while robust, demands proactive care. John Marsh, a site foreman for a Lincolnshire contracting firm, notes: “We run three BF 600s on highway jobs. Track adjustment is the single most overlooked thing. Once we put a weekly tension check on the schedule, our track life jumped from 1,200 hours to over 2,000 hours. That’s a huge saving on replacement costs, which run around £4,500 per set.
Another owner, a plant hire company in County Durham, reported: “We had a track derail on a tight roundabout job. The operator had been complaining of a noise for days but no one checked. The derailment tore the rubber and damaged the sprocket—over £6,000 in repairs and three days lost. Now we have a pre‑shift checklist that includes a sag measurement. Best decision we made.”
On online forums, several users emphasise the importance of cleaning the grease fitting before each adjustment. “One tiny grain of sand inside the cylinder and you’re looking at a leaking seal within a month,” writes a user from the Paving Hub community. “Pull the cap off and give it a wipe—it takes 10 seconds.”
For those interested in improving operator comfort during long shifts, our Bomag BF 600 P-2 Operator Comfort: A Detailed Review covers cab ergonomics and noise levels.
Frequently asked questions
1. Can I adjust the tracks without a sag gauge?
Yes, but it is not recommended. A tape measure and a straight edge can give a reasonable approximation if you measure the drop at the midpoint of the track span. However, the sag gauge is more precise and costs under £50. For consistent results, invest in the proper tool.
2. How do I know if the tensioner cylinder needs replacement?
If you cannot achieve proper tension after adding the maximum 40 cm³ of grease, or if grease leaks out around the seal, the cylinder is likely worn or damaged. Also check if the cylinder rod is bent or pitted. Replacement cost is about £280, plus labour.
3. What should I do if the track derails during adjustment?
Shut off the engine immediately. Do not try to force the track back on while the machine is running. Use a suitable jack or crane to lift the paver side, then reposition the track over the idlers and sprocket. Inspect for damage before restarting. Detailed derailment recovery is covered in the comprehensive track maintenance guide.
4. Does cold weather affect track tension?
Yes. Rubber tracks contract in cold temperatures, increasing tension. If you adjust tracks on a warm day and then operate the paver at 5 °C, the tension may rise above the safe limit. Always adjust when the paver is at a consistent temperature (engine warm, but not hot). In winter, check tension more often.
5. Can I use aftermarket tracks on the Bomag BF 600 P-2?
Aftermarket tracks are available from several suppliers and are generally acceptable if they meet the original dimensions (pitch, width, and thickness). However, inferior rubber compounds can wear faster and cause premature idler wear. If you choose aftermarket, buy from a reputable brand and check warranty terms. OEM tracks cost roughly £1,200 per side; quality aftermarket can be around £900.
6. How do I clean the track system to avoid mud build‑up?
After working on wet or sticky materials, use a pressure washer with a rotating nozzle to remove debris from between the lugs and around the idlers. Avoid blasting water directly at seals and bearings. For corrosion prevention tips, see our Bomag BF 600 P-2 Corrosion Prevention Guide: Extending Paver Life.