How to Correctly Replace an Excavator Track

Procedure:

1.  Position the Excavator: Drive the excavator so that the track you want to replace is slightly raised off the ground (e.g., position the opposite track on a sturdy block). Ensure the track is accessible and the master link (or section you plan to split) is accessible, often near the sprocket or idler.

2.  Clean the Master Link Area: Wire brush around the master link pins and bushings to remove dirt and debris. Identify the master link (it usually has markings like "M" or different shaped link plates).

3.  Relieve Track Tension: Locate the track tensioner grease fitting (usually near the front idler wheel). Place a container to catch grease. Slowly and carefully loosen the grease fitting (zerk) slightly to release grease pressure. Do NOT remove it completely yet. Allow grease to seep out slowly until the track becomes noticeably slack. Once slack, you can fully remove the grease fitting. Caution: High-pressure grease can cause serious injury.

4.  Access the Master Link:Rotate the track (by hand or carefully nudging the engine starter if possible and safe per manual) to position the master link at the top of the sprocket or in the most accessible position for removal (often 10 o'clock or 2 o'clock on the sprocket).

5.  Remove the Master Link:

   For Press-Fit Master Links: Use the track press tool. Position it correctly on the master link pins. Apply pressure to drive the pins out of the link plates and bushings. Once pins are driven out sufficiently, remove the outer master link plate. You may need to drive the pins the rest of the way through with a sledgehammer and drift pin. Remove the inner master link plate.

  For Bolted Master Links: Remove the retaining bolts and nuts from the master link plates. Remove the outer plate, then the inner plate. The pins may stay in the bushings or come out with the plates.

6.  Separate the Track: With the master link removed, the track is now split. Carefully push the two ends of the track chain apart using pry bars.

7.  Remove the Old Track: Use the lifting device with slings attached securely to the old track chain. Lift slightly to take the weight. Maneuver the excavator (slowly reverse or forward) away from the track, or carefully drag/pull the track out from under the machine using the lifting device. Lower the old track safely to the ground.

8. Prepare & Position the New Track: Inspect the new track for damage. Ensure it matches the specifications (pitch, width, number of links). Attach lifting slings securely. Use the lifting device to position the new track in front of the undercarriage, aligned with the sprocket, idler, rollers, and carrier rollers. The master link ends should be accessible where you plan to connect them.

9.  Connect the New Track: Carefully drive the excavator forward (or reverse) so the sprocket engages the new track. Maneuver until the two ends of the new track chain are close together near the top of the sprocket (similar position to step 4). Align the holes precisely.

10. Install the New Master Link:

     For Press-Fit Master Links: Position the inner master link plate on the track ends. Insert the master link pins (often pre-attached to the plate) through the link bushings. Position the outer master link plate. Use the track press tool to press the pins fully through the outer plate until they are seated correctly and the snap rings (if used) can be installed in their grooves. Ensure the press tool is applying force correctly to avoid damaging the pins/plates.

    For Bolted Master Links: Position the inner and outer plates. Insert the bolts (often shouldered bolts) through the plates and bushings. Install the nuts. Torque the bolts to the manufacturer's specification** using the correct procedure (e.g., criss-cross pattern, multiple stages).

11. Adjust Track Tension: Clean the grease fitting and tensioner housing. Reinstall the grease fitting (zerk). Using a grease gun, pump grease slowly into the tensioner cylinder while monitoring track sag. Refer to the operator's manual for the correct sag measurement (usually a specified distance between the top of the carrier roller and the bottom of the track chain link when measured midway between the idler and sprocket). Do not over-tighten. Over-tensioning damages components. Stop pumping when the correct sag is achieved. Wipe away excess grease.

12. Final Checks & Test:

     Visually inspect the entire track installation, especially the master link.

     Ensure all tools and blocks are removed from the work area.

    Start the engine (away from people) and slowly operate the travel controls to rotate the new track several full revolutions while observing it. Listen for unusual noises.

     Check the track tension sag measurement again after a few revolutions and adjust if necessary.

     Perform a slow, short test drive forward and backward on level ground, checking for smooth operation and alignment.