Your excavator’s tracks do more than just move the machine – they carry the full weight, transfer the engine’s power to the ground, and determine how efficiently your equipment performs day after day. Whether you’re operating a mini excavator on rubber tracks or a full-size machine running on steel ones, track condition directly affects productivity, stability, and fuel efficiency.
Ignoring worn or damaged tracks might not seem critical at first, but the longer you wait, the higher the risk of hydraulic system failure, oil leaks, or even severe damage to other undercarriage components. A neglected track can quickly turn a simple maintenance task into major repairs and costly downtime.
Replacing excavator tracks isn’t just about keeping the machine moving – it’s also the perfect time to look deeper into the systems that keep your excavator performing at its best. The final drives (or travel motors) deserve particular attention. These components play a critical role in transferring hydraulic power into motion, and even small issues with hydraulic pressure or damaged seals can lead to further damage and expensive replacements later on.
In this guide, we’ll cover everything you need to know about excavator track replacement. From recognising when it’s time to replace your tracks, through practical steps for fitting a replacement rubber track, to why inspecting the final drives at the same time can save you time, money, and frustration in the long run.
Every operator eventually faces the same question: “Is it time to replace the tracks?” Knowing the signs early can prevent further damage and keep your machine running at optimal performance. Here’s what to look for.
Start with a visual inspection. For rubber tracks, check for cracked or missing tread blocks, exposed steel cords, or torn lugs. For steel tracks, look for worn or bent shoes, loose bolts, and excessive rust. If the old track shows uneven wear – for example, more on one side than the other side – it’s often a clear indication of an alignment issue or hydraulic imbalance within the final drive or speed control system.
A track that’s too tight increases friction, wear, and fuel consumption, while one that’s too loose can derail easily. If you find yourself frequently re-tensioning your tracks, the tensioning system may have a grease leak or a worn adjuster. Correct track tension is vital for smooth operation and preventing further wear on the undercarriage parts.
Performance changes are often the first sign of trouble. If the excavator begins tracking slow on one side, struggles to push in high-speed mode, or loses power during travel, it could point to a problem in the hydraulic system. Such as internal leaks, low hydraulic pressure, or a failing travel motor. These symptoms can sometimes be mistaken for track issues when, in reality, they’re linked to the final drives or hydraulic pumps.
Inspect around the gearbox cover, case drain line, and final drives for oil leaks or signs of damaged seals. A small leak can quickly lead to hydraulic oil contamination, bearing wear, and ultimately, hydraulic failures. Listen for grinding or clicking sounds when the tracks move – these often indicate that bearings or sprocket teeth are wearing unevenly.
Regularly check the undercarriage, rollers, and sprockets, and make these inspections part of your regular maintenance routine. Proactive care may seem time-consuming, but it’s far cheaper than facing major repairs after a system failure. Replacing a rubber track at the right moment prevents further damage to your hydraulic system and ensures your excavator remains reliable, responsive, and ready for work.
A successful excavator track replacement starts long before the first bolt is loosened. Preparation ensures the job runs smoothly and safely, saving time and avoiding unnecessary frustration or damage.
Before doing anything, secure the machine. Park the excavator on firm, level ground, engage the parking brake, and switch off the engine. Make sure the hydraulic system is fully depressurised – even a small amount of trapped hydraulic pressure can cause sudden movement or oil leaks. Always follow the manufacturer’s safety instructions when working near hydraulic components.
Having the correct equipment at hand will make all the difference. You’ll need:
If your excavator runs on rubber tracks, double-check the track width and pitch before ordering a new one. A mismatch can lead to poor alignment, more pressure on the sprocket, and premature wear.
Replacing tracks is the perfect moment to give your undercarriage and hydraulic system a full check-up. Look for:
Identifying and fixing small problems now helps you avoid costly downtime later. Even if your machine is running fine, regular inspections during maintenance tasks like this are key to proactive care and optimal performance.
Replacing tracks might look complicated, but with the right process, it’s straightforward and safe. Here’s a practical, step-by-step guide that works for most modern excavators – whether you’re changing rubber tracks on a mini excavator or steel tracks on a larger model.
Every excavator has a grease fitting near the track adjuster. Carefully release the grease until the track slackens. You can do this by slowly loosening the fitting or valve until grease begins to escape – don’t rush it.
If you release too much, you’ll let air into the system, which can cause hydraulic failures or pressure imbalance later. Once the track is loose enough to move freely, stop releasing pressure.
Lift the side of the machine slightly using the boom and bucket – just enough to take the weight off the track. Then, rotate the track forward until it rolls off the sprocket. On smaller excavators, this can be done by hand; on larger machines, you may need a helper or a lifting device.
Take care not to damage rollers, idlers, or sprocket teeth during removal. If you notice cracks or chipped edges, plan to replace these parts soon.
With the old track off, it’s the perfect moment to check everything underneath:
If you find oil seeping around the gearbox cover, it may mean the hydraulic motor inside the final drive is starting to fail. Replacing a damaged seal now prevents further damage and keeps the hydraulic system running efficiently.
Position the new track under the undercarriage and align it with the sprocket and idler. Use the boom and arm to carefully guide the track around the sprocket. Make sure it sits evenly on the rollers before tightening.
Once in position, add grease slowly to the tensioning system until the track tightens. You’re aiming for a firm but not over-tight fit. Too much tension increases friction and wears down bearings and seals; too little can cause the track to derail. Check the manufacturer’s recommended track slack – usually around 10–20 mm of sag.
Start the engine, and run the machine at low speed. Move forward and backward a few times to confirm smooth operation and even movement on both sides.
Listen for unusual noises, feel for vibration, and ensure the machine tracks straight at full speed. If one side moves slower than the other, it could signal internal leaks or a pressure issue in the final drive or hydraulic pump.
Once everything runs smoothly, wipe away any excess grease and check for oil leaks one final time. Congratulations – your new track is fitted, and your excavator is ready to get back to work.
When changing excavator tracks, most operators focus entirely on the undercarriage – but final drives (also known as travel motors) deserve just as much attention. They do the heavy lifting when it comes to movement, converting hydraulic pressure into torque and driving power to the tracks. Without healthy final drives, even a brand-new set of tracks won’t perform properly.
Each final drive plays a critical role in ensuring your excavator moves smoothly and efficiently. It regulates speed, power, and direction, allowing you to work precisely whether you’re grading, digging, or travelling at full speed across a site. A worn or damaged final drive can cause the machine to drag on one side, move slower than usual, or lose torque entirely.
The travel motor and gearbox inside each final drive rely on clean hydraulic oil, proper hydraulic pressure, and intact hydraulic seals. If any of these fail, you’ll notice oil leaks, loss of speed control, or even hydraulic system failure. Small warning signs – like a bit of oil under the gearbox cover or unusual vibration – can quickly escalate into severe damage if ignored.
Replacing tracks is the ideal moment to inspect your final drives thoroughly:
If you discover oil contamination or metal particles in the drained oil, it’s a clear indication that the internal hydraulic motor or gears may be failing. Replacing the drive before it fails completely prevents costly downtime and major repairs later.
At this point, it’s worth mentioning why quality matters. Track Motor supplies a full range of final drives/travel motors for modern excavators, designed for durability and optimal performance in demanding conditions.
Each unit is built to OEM specifications and rigorously tested to ensure smooth operation, consistent power delivery, and resistance to internal leaks and damaged seals.
By choosing a replacement final drive from Track Motor, you’re restoring performance and protecting your investment in the rest of the hydraulic system. The right components reduce friction, maintain pressure, and keep your excavator performing as it should – efficiently, reliably, and at full strength.
“A few years back, I was replacing the rubber tracks on a compact excavator we used daily for trenching jobs. Everything went smoothly – or so I thought. Two weeks later, the machine started dragging slightly on one side. I assumed the new track tension needed a tweak, but when I checked, it was perfect. The problem was deeper.
When I finally opened up the final drive, I found the hydraulic motor leaking internally and the hydraulic oil contaminated with metal dust. The damaged seals had failed silently. The result? One side of the machine was losing power because of a drop in hydraulic pressure. Replacing the final drive solved the issue, but it taught me a lesson I’ll never forget:
Whenever you replace tracks, always inspect your final drives. It’s the best moment to catch small issues before they lead to costly repairs or hydraulic failures. I never skip that step anymore.”
– Adam Brooks, Construction Equipment Service Expert,
This kind of experience is common in the field. Machines often give early hints – a change in speed, a slow response in high-speed mode, or extra noise from the gearbox – that something isn’t right. But if you’re already doing a track replacement, you’re halfway there. That’s the perfect time to spot issues in your travel motors, hydraulic system, or case drain line.
Listening to your machine and following a proactive maintenance routine doesn’t just prevent breakdowns – it extends the life of every component, from the hydraulic pump to the undercarriage parts.
Replacing tracks or final drives shouldn’t be treated as a one-off fix – it’s part of a larger cycle of care that keeps your excavator running efficiently for years. Regular maintenance is the difference between smooth daily operation and unexpected, costly downtime.
Make it a habit to regularly check all undercarriage parts – not just when something goes wrong. Inspect tracks, rollers, sprockets, and idler wheels for wear, and keep the entire undercarriage clean from debris and hardened mud. Excess build-up causes friction, wears down bearings, and can reduce track tension accuracy.
A quick daily check after each shift can catch potential problems before they escalate. It’s simple, proactive care that pays off in the long run.
Your hydraulic system powers almost every function of the excavator, including the travel motors. Contaminated hydraulic oil is one of the most common causes of hydraulic failures and internal leaks.
Here’s what to do:
Small lapses in cleanliness can cause major failures down the line. Clean oil, clean air, and intact seals mean longer-lasting components, consistent pressure, and better operational efficiency.
Not all replacement parts are created equal. Using low-quality tracks or aftermarket drives can seem cheaper upfront, but they often lead to further damage and more frequent breakdowns.
Track Motor focuses on delivering quality, precision-engineered final drives that meet OEM standards. Each part is built to handle real-world workloads, ensuring optimal performance and reducing the risk of costly repairs.
A machine is only as reliable as its weakest component. Keeping everything in sync – from rubber tracks to the hydraulic motor – is the key to consistent, productive work and avoiding time-consuming repairs.
Replace them when you notice visible wear such as cracked pads, missing lugs, or uneven tread. Other signs include frequent re-tensioning, loss of traction, or the excavator tracking unevenly on one side. Waiting too long can damage the sprocket and final drives.
Release the grease fitting to loosen the track tension, remove the old track, position the new track, then slowly reapply grease to tighten. Always check for oil leaks, damaged seals, and worn undercarriage parts before finishing.
Steel tracks can often be recycled for scrap metal. Rubber tracks should be disposed of through a licensed recycling facility to prevent environmental harm.
Minor cuts or gouges can be patched temporarily, but if the steel cords are exposed or the damage affects track integrity, you’ll need a replacement rubber track. A repaired track won’t last long under load or high-speed conditions.
It’s usually a final drive or hydraulic system issue – possibly internal leaks, low hydraulic pressure, or bearing wear. Also check the speed control system, as uneven pressure between sides can cause one track to move slower than the other.
A common issue caused by a grease leak or a failing tensioning cylinder. Inspect the adjuster for cracks and the idler for wear. If grease escapes too easily, the system can’t hold track tension properly.
Most excavators should have around 10–20 mm of sag between the bottom rollers and the track. Too tight increases friction and wear; too loose risks derailing. Always refer to your manufacturer’s manual for precise measurements.
Watch for oil leaks, unusual noises, or loss of power on one side. If the machine fails to reach high-speed mode or produces heat around the gearbox cover, it could signal internal damage or hydraulic failure.
Replacing your excavator tracks is more than routine maintenance – it’s a crucial step in keeping your machine efficient, powerful, and reliable. Paying attention to the hydraulic system, inspecting the final drives, and performing regular maintenance all contribute to avoiding costly downtime and ensuring smooth operation.
Whether you’re fitting a new track or tackling a final drive replacement, using high-quality components makes the difference between a temporary fix and long-term reliability.
Track Motor is committed to keeping your excavator performing at its best. With a complete range of final drives designed for modern excavators, we help operators achieve consistent power, dependable speed, and trouble-free operation – every day.
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