How to Install and Maintain an Excavator Undercarriage: A Step-by-Step Guide

How to Install and Maintain an Excavator Undercarriage: A Step-by-Step Guide

The undercarriage is the backbone of your excavator. It supports the machine’s weight, ensures smooth movement, and absorbs stress during operation. Proper installation and maintenance are critical for safety, performance, and longevity. Follow this simple guide to install, repair, and maintain your excavator’s undercarriage.

1. Safety First

• Wear protective gear: Gloves, steel-toe boots, and safety glasses.

• Park safely: Work on flat, stable ground. Engage the parking brake and lower the bucket to the ground.

• Release hydraulic pressure: Turn off the engine and relieve hydraulic pressure by moving controls before disassembling components.

2. Tools & Materials

• Hydraulic jack or lifting equipment

• Torque wrench and socket set

• Grease gun and lithium-based grease

• Replacement parts (tracks, rollers, sprockets, etc.)

• Cleaning brushes and degreaser

3. Undercarriage Installation Steps

A. Remove Old Components

1. Loosen tracks: Use a breaker bar to remove track tension by releasing grease from the tension valve.

2. Disconnect tracks: Remove track pins or master links to separate the track chain.

3. Remove rollers/sprockets: Unbolt and carefully lift out worn rollers, idlers, or sprockets.

B. Install New Components

1. Clean the frame: Scrub away dirt and debris from the undercarriage frame.

2. Install sprockets/rollers: Secure new components with bolts, tightening them to the manufacturer’s torque specifications.

3. Reattach tracks:

   • Align the track chain with the sprocket and rollers.

   • Reconnect the master link or track pins.

   • Adjust track tension by pumping grease into the tension cylinder until the track sags 20–30 mm (check the manual for exact specs).

C. Final Checks

• Lubricate all pins and bushings with grease.

• Test the excavator at low speed to ensure smooth movement.

4. Routine Maintenance Tips

1. Daily Inspections

   • Check for cracks, loose bolts, or abnormal wear on tracks and rollers.

   • Look for oil leaks around final drives.

2. Clean After Use

   • Remove mud and rocks stuck in the track links to prevent corrosion and premature wear.

3. Lubricate Regularly

   • Grease track pins and rollers every 50 hours of operation.

4. Track Tension Adjustment

   • Over-tensioned tracks strain components; under-tensioned tracks cause slippage. Adjust as needed.

5. Common Problems & Fixes

A. Track Misalignment

• Cause: Worn sprockets or improper tension.

• Fix: Replace damaged sprockets and readjust tension.

B. Excessive Track Wear

• Cause: Working on abrasive surfaces (e.g., rocky terrain).

• Fix: Rotate tracks periodically to distribute wear evenly.

C. Noisy Rollers

• Cause: Lack of lubrication or damaged bearings.

• Fix: Grease rollers or replace them if grinding persists.

D. Hydraulic Leaks

• Cause: Damaged seals in the final drive.

• Fix: Replace seals immediately to avoid component failure.

6. When to Call a Professional

• Severe structural damage (e.g., cracked frames).

• Complex hydraulic system repairs.

• Persistent issues after basic troubleshooting.

7. Final Notes

• Always refer to your excavator’s manual for model-specific details.

• Keep records of maintenance and part replacements.

• Invest in high-quality parts to reduce downtime.

By following these steps, you’ll extend the life of your excavator’s undercarriage and avoid costly breakdowns. Stay safe and keep your machine running smoothly!