Excavator Track Roller Replacement

Core steps: Safe jacking → Track pressure relief & separation → Old roller removal → Mounting surface cleaning → New roller installation and diagonal torque tightening → Grease filling → Track adjustment → Trial operation

1. Preparations (Safety Priority)

Parking and shutdown

Park the machine on flat and solid ground. Turn off the engine, remove the key, cut off power, and engage the parking brake to lock traveling system.

Tools required

Heavy-duty jack (20-50 tons), wooden blocks, steel platesSocket wrench, impact wrench, torque wrench, crowbar, copper rod, puller (spare)Cleaner, grease, thread locker, lubricant, cleaning cloth

Jack up the machine

Place steel plates under the track frame main beam on the replacement side. Jack vertically to fully suspend the track and unload the roller. Secure the other track firmly to keep the machine stable.

Track pressure relief (critical)

Locate the grease nipple or pressure relief plug of tension cylinder, loosen it 1/4 to 1/2 turn slowly for pressure release. Do not fully unscrew to avoid high-pressure grease ejection. Pry up track plates after slackening to separate the roller completely.

2. Remove the Old Track Roller

Clear mud and gravel around the roller to expose fixing bolts.Loosen bolts diagonally with impact or socket wrench. Reserve 2 to 3 bolts to prevent sudden falling.Spray rust remover on seized bolts and wait 10-20 minutes before loosening. Do not force twisting to avoid thread damage.

Unscrew the remaining bolts alternately and slowly. Support the roller with a crowbar to prevent falling injuries.Tap the roller side gently with a copper rod or use a puller for stuck rollers. Never strike seals and bearing positions or hit hard with sledgehammer.

3. Install the New Track Roller

Thoroughly clean the mounting surface and bolt holes with cleaner, removing oil stains, metal scraps and burrs to prevent uneven stress and oil leakage.

Verify model specifications including shaft diameter, bolt pitch and width to ensure compatibility. Align mounting holes with crowbar assistance. Insert 1-2 guide bolts if positioning difficulty occurs.

Apply a thin layer of grease or thread locker on bolt threads for anti-loosening, anti-rust and accurate torque control.Tighten bolts evenly diagonally in 2 to 3 rounds, then fasten to standard torque specified in manual. Common torque: 80-120N·m for mini excavators, 150-250N·m for large excavators.

Inject special lubricant into roller cavity via grease fitting until fresh grease slightly overflows from seal edge to exhaust air and full lubrication.

4. Reset and Commissioning

Tighten the pressure relief plug and inject grease to adjust track tension. Standard sag of upper track middle part: 20-40mm. Excess slack causes derailment while over tension accelerates wear.

Lower the machine and start the engine. Run the suspended track at low speed for 3-5 minutes. Check abnormal noise, smooth rotation and oil leakage at seals.Drive slowly for 5-10 meters, recheck bolt torque, roller temperature and track tension to confirm normal condition.

5. Common Mistakes & Taboos

Dismantle without jacking: Track tension may break bolts and eject rollers

Improper torque or tightening sequence: Causes eccentric wear, oil leakage and loose bolts

Impact seals and bearings: Damages sealing structure leading to premature leakage

Insufficient grease filling: Results in rapid bearing abrasion and shortened service life

Global Service Network for Prompt Customer Response

With a worldwide service network, we respond to customer demands efficiently.

Backed by the FAJX brand, Qiansheng Heavy Industry has established 7 centers globally for service, research and marketing. We swiftly address client requirements concerning excavator track rollers, bucket pins, bulldozer ring gears and other parts. Customized and precise solutions are delivered to global partners, covering product selection and after-sales support to guarantee satisfactory user experience throughout all procedures.

Fifteen years of dedicated craftsmanship has made Quanzhou Qiansheng Heavy Industry Co., Ltd. a reliable professional supplier of undercarriage parts for excavators and bulldozers, serving both domestic markets and global exports. Going forward, we will keep focusing on technological innovation, supplying superior undercarriage components and professional services for construction machinery users worldwide.

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