Replacing track rollers seems like a straightforward job — but trust me, there are plenty of ways to mess it up. Many machine operators and even some maintenance staff make simple mistakes that lead to early wear, misalignment, or even full undercarriage damage.
In this guide, we’ll cover the most common mistakes and how to avoid them, so your excavator, loader, or bulldozer keeps running smoothly.
One of the most frequent mistakes is picking a roller that doesn’t match your machine. Track rollers vary by:
Brand and model (Komatsu, Caterpillar, Hitachi, SDLG, Liugong, etc.)
Load capacity and size
Single flange vs double flange
Using the wrong roller may fit physically but fail under heavy loads. It can cause uneven wear and reduce the lifespan of your track system. Always double-check model numbers and specifications before ordering.
Some people go for cheap rollers to save money. Big mistake! Low-quality rollers often:
Crack under heavy load
Leak oil from poor seals
Wear unevenly due to substandard heat treatment
Investing in forged steel rollers from a trusted China manufacturer or supplier ensures better durability and performance. Cheap rollers might save money upfront but cost more in repairs later — you know how it goes.
Even a high-quality roller can fail if installed incorrectly. Common installation errors include:
Not cleaning the mounting surface – dirt or rust can prevent proper seating
Incorrect bolt torque – too loose causes misalignment; too tight can damage the roller
Skipping lubrication – insufficient grease leads to friction and overheating
Pro tip: always follow the manufacturer’s guidelines carefully. A little extra attention during installation goes a long way.
After replacement, misalignment is surprisingly common. Track rollers must line up perfectly with the chain and other rollers. Misalignment leads to:
Uneven wear on rollers and track links
Increased vibration
Potential chain derailment
Always rotate the track by hand after installation and visually inspect alignment before full operation.
Some operators install new rollers and then forget about them for months. Big mistake! Even new rollers need:
Regular inspections for leaks or cracks
Lubrication at recommended intervals
Check bolts and flanges for any loosening
Skipping these checks can cause new rollers to fail prematurely.
Replacing track rollers may seem simple, but common mistakes like choosing the wrong type, ignoring quality, improper installation, misalignment, and skipping maintenance can cost you big time.
To ensure your excavator, loader, or bulldozer performs reliably, always choose high-quality rollers from reputable China manufacturers and suppliers, follow installation guidelines, and keep up with regular maintenance.
