Excavator tracks eventually wear out from normal use, abrasive ground conditions, heavy workloads, and insufficient undercarriage maintenance. When tracks become excessively worn, damaged, or difficult to keep properly tensioned, replacement may be necessary.

Replacing excavator tracks is a job that requires careful preparation, appropriate tools, and the correct procedure for your specific machine. The process also differs depending on whether you're working with rubber tracks on a mini excavator or steel tracks on a larger excavator.

This guide explains how excavator track replacement generally works, what to inspect before installation, how track tension affects undercarriage life, and when professional service may be the better option.

Important: Excavator track systems vary by make and model. Always follow your machine manufacturer's Operation and Maintenance Manual or service instructions for the correct lifting, track-removal, installation, and tension-adjustment procedures.

When Should You Replace Excavator Tracks?

Excavator tracks don't have one universal replacement interval. Their service life depends on the machine, application, ground conditions, operating technique, maintenance, and undercarriage condition.

Inspect your tracks regularly for signs such as:

1. Excessive tread or grouser wear

2. Deep cuts or cracks in rubber tracks

3. Damaged or missing track components

4. Loose or poorly fitting tracks

5. Repeated track derailment

6. Damaged sprocket teeth

7. Worn rollers or idlers

8. Track tension that cannot be maintained

9. Unusual movement or noise during operation

Regular undercarriage inspections can help identify problems before they result in downtime or additional component damage. Caterpillar recommends checking track condition, debris buildup, sprockets, rollers, idlers, and track sag as part of routine maintenance.

A key warning sign: improper track tension

Tracks that are too tight can accelerate wear and place additional stress on undercarriage components. Tracks that are too loose can increase the risk of derailment or improper engagement with the sprocket.

Rubber vs. Steel Excavator Tracks

Before replacing a track, identify which type your excavator uses. Rubber tracks and steel tracks have different construction, service procedures, and inspection requirements.

For rubber-track mini excavators, replacement may involve releasing tension, removing the track from the idler and sprocket, installing the new track, and restoring the specified tension. Caterpillar's current mini-excavator procedure follows this general process.

Steel-track systems can involve substantially heavier components and more specialized procedures. Don't assume the rubber-track process applies to a steel track chain.

Tools and Equipment You May Need

The exact tools depend on your excavator and track system.

Depending on the machine, replacement may require:

1. Replacement track or track chain

2. Suitable lifting equipment

3. Heavy-duty jack or approved lifting device

4. Proper cribbing or machine supports

5. Pry bars

6. Grease gun

7. Hand tools

8. Track-specific tools

9. Track press or pin press for applicable steel-track systems

10. PPE

Don't improvise lifting or support equipment. Excavator tracks and undercarriage components are heavy and can move unexpectedly during removal and installation.

For some compact excavators, the manufacturer may specify relatively simple tools for rubber-track replacement. Larger steel-track machines may require specialized service equipment.

Step 1: Prepare and Secure the Excavator

Before working on the track, prepare the machine and work area.

1. Park the excavator on firm, level ground.

2. Lower the attachment according to the manufacturer's procedure.

3. Shut down the engine.

4. Follow the machine's recommended shutdown and isolation procedures.

5. Raise and support the track using approved equipment and the manufacturer's procedure.

6. Use suitable cribbing or supports where required.

7. Wear appropriate personal protective equipment.

8. Keep other people away from the work area and potential pinch points.

Caterpillar's current rubber-track replacement guidance similarly calls for firm, level ground, engine shutdown, appropriate PPE, and suitable lifting or support equipment before beginning the job.

Do not begin removing a track until you are certain the excavator is stable and properly supported.

Step 2: Release Track Tension

Most excavator track systems use an adjuster to maintain proper track tension.

On many machines, tension is adjusted using grease through a track-adjuster system. However, the exact procedure varies by model.

For applicable rubber-track systems, the general process may involve:

1. Accessing the track-adjustment system.

2. Carefully releasing tension according to the manufacturer's instructions.

3. Allowing sufficient slack for track removal.

4. Supporting the track before attempting to move it.

Caterpillar's current mini-excavator procedure, for example, instructs technicians to release tension through the grease fitting before removing the rubber track.

Never assume a universal procedure for releasing track tension. Follow the service instructions for your excavator.

Step 3: Remove the Old Track

Once the track has been properly detensioned and supported, remove it from the undercarriage.

For many rubber-track excavators, the track is worked off the sprocket and idler using appropriate tools such as a pry bar and lifting/support equipment.

The general sequence is:

1. Confirm the track is fully detensioned.

2. Support the track.

3. Disengage it from the sprocket.

4. Work the track away from the idler.

5. Carefully remove the old track.

Avoid placing hands or feet between the track and undercarriage components.

A track is heavy, even on a compact excavator, and can shift suddenly once it comes free.

For steel track systems, removal may involve track pins, master links, bolts, or other components depending on the machine design. Do not apply a generic steel-track removal procedure to every excavator.

Step 4: Inspect the Undercarriage

A new track won't solve every undercarriage problem.

Before installing the replacement, inspect:

1. Sprocket teeth

2. Front idler

3. Rollers

4. Track adjuster

5. Track chain or track guides

6. Pins and bushings on applicable steel systems

7. Track shoes or grousers

8. Guards

9. Hardware

10. Debris buildup

Look for cracks, abnormal wear, damaged hardware, leaks, or components that appear significantly worn.

This is an important opportunity to identify related problems before putting a new track into service.

Caterpillar recommends regular inspection of sprockets, rollers, idlers, track hardware, pins, joints, and other undercarriage components because wear in one component can affect the rest of the system.

Step 5: Install the New Track

Before installing the replacement, confirm that the new track is the correct size and specification for your excavator.

For a rubber track, the general process may include:

1. Positioning the replacement track around the undercarriage.

2. Engaging the track correctly with the sprocket.

3. Positioning the track around the idler.

4. Using approved tools to seat the track.

5. Confirming that the track is properly aligned.

6. Restoring track tension according to the manufacturer's specification.

Caterpillar's current rubber-track installation procedure specifically emphasizes correct engagement of the track links with the drive sprocket teeth before tensioning the track.

For steel tracks, installation can involve connecting track-chain components and using specialized presses or tools. Follow the manufacturer's service procedure for the specific excavator.

Step 6: Set the Correct Track Tension

Proper tension is one of the most important parts of excavator track replacement.

How tight should excavator tracks be?

There is no universal excavator track-tension measurement. The correct specification depends on the machine and track system.

The general process is to:

1. Position the excavator as specified by the manufacturer.

2. Measure track sag at the specified location.

3. Compare the measurement with the machine's service specification.

4. Add grease if the track requires tightening.

5. Release pressure according to the manufacturer's procedure if it is too tight.

6. Measure again.

For its mini excavator rubber tracks, Caterpillar instructs users to measure sag at the center roller and compare the result with the machine's Operation and Maintenance Manual.

Do not use a track-tension number from another excavator model.

Incorrect tension can shorten track and undercarriage life.

Step 7: Perform a Final Inspection

Before returning the excavator to normal work, inspect the installation.

Check that:

1. The track is properly seated.

2. The track is correctly aligned.

3. Sprocket engagement is correct.

4. Track tension meets the manufacturer's specification.

5. No tools or supports remain in the work area.

6. There are no obvious leaks or damaged components.

7. The undercarriage is free of excessive debris.

If the manufacturer specifies a particular post-installation procedure, follow it before returning the machine to service.

How to Extend Excavator Track Life

Replacing tracks is only part of the equation. Proper operation and maintenance can help maximize the life of the new track.

Keep the undercarriage clean

Packed dirt, mud, rocks, and other debris can interfere with undercarriage components and accelerate wear. Regular cleaning and inspection are recommended.

Check track tension regularly

Don't wait until a track comes off to check its tension.

Too much tension can accelerate wear, while insufficient tension can increase the chance of derailment.

Match operating technique to the job

Aggressive operation, abrasive ground conditions, and demanding applications can accelerate track and undercarriage wear.

Inspect the entire undercarriage

Replacing a track while ignoring a badly worn sprocket, idler, or roller can reduce the value of the new component.

Can You Replace Excavator Tracks Yourself?

For some smaller excavators with rubber tracks, an experienced owner or operator may be able to perform replacement using the proper tools and manufacturer instructions.

However, track replacement involves heavy components, pinch points, lifting hazards, and potentially pressurized track-adjustment systems.

Professional service may be the better choice when:

1. The excavator is large.

2. The machine uses steel track chains.

3. Specialized tools are required.

4. Undercarriage components also need replacement.

5. You don't have suitable lifting/support equipment.

6. You're uncertain about the manufacturer's procedure.

When in doubt, consult a qualified heavy-equipment technician.

Frequently Asked Questions

How do you replace excavator tracks?

The general process involves securing the excavator, releasing track tension, removing the old track, inspecting the undercarriage, installing the replacement, restoring the manufacturer's specified tension, and completing a final inspection. The exact procedure varies by machine.

How often should excavator tracks be replaced?

There is no universal replacement interval. Track life depends on operating conditions, ground conditions, machine use, maintenance, track type, and undercarriage wear. Regular inspections are more useful than relying on a fixed replacement schedule.

How do you know when excavator tracks need replacing?

Look for excessive tread or grouser wear, cracks, damaged components, repeated derailment, inability to maintain proper tension, and other signs of undercarriage wear.

How tight should excavator tracks be?

Track tension should meet the manufacturer's specification for your particular excavator. Tracks that are too tight can accelerate wear, while tracks that are too loose can increase the risk of derailment.

Can you change excavator tracks yourself?

Some experienced owners can replace rubber tracks on smaller excavators with the correct tools and instructions. Larger excavators and steel-track systems may require specialized equipment and professional service.

Keep Your Excavator Moving

Replacing worn tracks can restore machine performance, but track replacement should be treated as part of overall undercarriage maintenance - not an isolated repair.

Before installing a new track, inspect the sprocket, idlers, rollers, adjuster, and other components. After installation, verify alignment and track tension according to the manufacturer's specifications.

And if your excavator is experiencing repeated track or undercarriage problems, it may be worth evaluating whether continued repairs make sense compared with replacing the machine.

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