How to Replace Mini Excavator Rubber Tracks Safely: Step by Step Guide

Replacing rubber tracks on a mini excavator is not difficult when the machine is prepared correctly, but it can become unsafe if the operator rushes the job. In 2026, the biggest on site issue is still downtime. A track comes off or splits, the machine blocks access, and the crew tries to change it quickly. That is when fingers, hands and feet are exposed to heavy moving parts.

This guide is written for owners and operators who need a clear process. Always treat it as general guidance. The machine manual comes first, and any workplace task must follow site rules and the current WHS process. 

If you need the correct replacement track before starting the job, check Tradefaire’s mini excavator rubber tracks range or ask for help with size and model fitment.

Before you start

Do not begin with the machine sitting in mud, on a slope or near traffic. Pick a firm, level area where you have room to work around both sides. Lower the attachment to the ground, isolate the machine as required by your workplace procedure and keep other workers away from the track area.

You will usually need:

1. Correct replacement rubber track

2. Machine manual

3. Grease gun or release tools for the track adjuster

4. Socket set and basic hand tools

5. Long pry bar or suitable bar

6. Wood blocks or rated support equipment

7. Gloves and eye protection

8. Another trained person when the track is heavy or access is poor

Step 1: Check the new track before removing the old one

Confirm the width, pitch and number of links. Also check direction if the tread pattern has one. Many delays happen because the old track is removed before the new track is confirmed. Once the machine is disabled, a wrong size track becomes a real cost.

If the numbers are missing from the old track, measure it before removal. The Tradefaire rubber tracks page is a useful starting point for matching mini excavator, CTL, MTL and agricultural tracks.

Step 2: Lift and support the machine correctly

Use the boom and blade only as the machine manual allows. Many operators lift one side slightly to free the track. Do not put any part of the body under the machine unless it is safely supported. A hydraulic system can move without warning if the machine is not controlled correctly.

Keep the track just clear enough to work. Too much height can make the machine unstable. If the ground is soft, move to a better area before starting.

Step 3: Release track tension

Most mini excavators use a grease tensioner. Remove the access cover, then release grease pressure slowly through the adjustment valve as stated in the manual. Grease can be under high pressure, so keep your face and hands clear of the valve path.

The track should loosen once the idler moves back. If it does not move, do not force the track with extra leverage. Hardened grease, seized parts or packed debris may be stopping movement. Clean and inspect before continuing.

Step 4: Remove the old track

Start working the track off the front idler or sprocket, depending on the machine design. Use a pry bar with care and rotate the track slowly if needed. Keep hands away from pinch points. Do not use engine power unless the method is allowed, controlled and supervised. Many injuries happen when the track suddenly walks off the frame.

Once the track is clear, move it away from the work area. Old tracks are heavy and awkward. Dragging them across finished surfaces may cause damage, so plan the removal path.

Step 5: Inspect the undercarriage

This step saves money. A new track fitted over worn sprockets or seized rollers can wear early. Check:

1. Sprocket tooth shape and sharpness

2. Roller movement and flat spots

3. Idler wear and cracks

4. Mud, stones and wire trapped in the frame

5. Oil leaks near final drives and rollers

6. Damage to guards and covers

If parts are badly worn, repair them before fitting the new track. Otherwise the new rubber may fail before its time.

Step 6: Fit the new track

Place the new track in the correct direction. Start by positioning it over the sprocket, then guide it around the rollers and front idler. Keep the track aligned with the centre of the roller path. Work slowly, and avoid twisting the track sidewall.

A second person can help keep the track square while it is guided on. Keep communication clear. One person should control any machine movement.

Step 7: Set the correct tension

Add grease to the adjuster until the track reaches the manual’s sag specification. Do not guess. A track that looks tight may be too tight once the machine works under load. A track that looks relaxed may still be correct for that machine.

Step 8: Test slowly before returning to work

Lower the machine, travel forward and reverse slowly, and make gentle turns. Stop and recheck alignment and tension. New tracks can settle after the first short movement. Recheck again after the first few hours of work, mainly if the machine is working in mud or rock.

When to call for help

Call a competent technician if the adjuster will not move, the track is very heavy, the site is unsafe, or undercarriage damage is found. It is cheaper to pause than to damage a new track or injure a worker.

Tradefaire also has a simple rubber track replacement guide for mini excavator and CTL fitment. For the correct track size or replacement support, contact the Tradefaire contact team.