The 10 Expert Steps for Replacing Rubber Tracks on Mini Excavators

Maintaining your heavy machinery’s undercarriage isn’t about keep-it-pretty aesthetics—it’s about keeping your job site moving and your crew safe. Did you know that a worn-out track can lead to slippage, inefficient fuel consumption, and potential damage to internal components?

Whether you're running a heavy-duty Kobelco excavator or a versatile mini digger, knowing how to swap out your rubber tracks is a must-have skill. Here is how to get it done in 10 simple, manageable steps to get your machine back in the dirt

Why Track Maintenance Matters for Your Fleet

The undercarriage typically accounts for a significant portion of a machine's lifetime maintenance costs. Rubber tracks provide the necessary traction for mini excavators to traverse soft terrain without damaging finished surfaces.

When these tracks become worn, the risk of "de-tracking" increases, which can cause significant delays on-site. By following Al Marwan’s expert advice, you can extend the life of your equipment and ensure your Kobelco excavator maintains its industry-leading performance.

Preparation: Tools and Safety First

Before you begin the physical labor, you must prepare your workspace. Ensure the machine is parked on a level, solid surface to prevent any tilting or sliding during the lifting process.

Safety is the cornerstone of every Al Marwan operation—whether you are the operator sitting in the cab or the technician working on the ground. Everyone involved in the replacement process must wear high-visibility vests, steel-toed boots, and heavy-duty gloves. Having a second person on site is critical: the technician relies on the operator for precise machine controls, while the operator needs a dedicated spotter to assist with heavy lifting and guide the track safely into place.

Essential Tool Checklist:

• Large Flat-Head Screwdriver or Pry Bar: To help maneuver the track edges.
• Wrench or Socket Set: To access the grease valve and inspection plates.
• Grease Gun: Loaded with high-quality lithium grease.
• Wooden Blocking or Jack Stands:  For secondary support once the machine is raised.
• Pressure Washer:  To clean the undercarriage before starting.

Step 1: Deep Clean the Undercarriage

The first step is often the most overlooked: cleaning. Mud, rocks, and debris can hide the grease tensioner and make it difficult to see wear patterns on the rollers.

Use a high-pressure washer to clear out the "track frame." This ensures that when you loosen bolts or valves, you aren't grinding grit into the threads. A clean machine is much safer and easier to work on.

Learn more about undercarriage maintenance in our previous blog.

Step 2: Lift the Excavator Safely

You need to get the side you are working on completely off the ground. For mini excavators, you can use the machine’s own hydraulic power.

Lower the dozer blade and use the boom to push the bucket into the ground, lifting the tracks. Once the machine is elevated, slide heavy-duty wooden blocks under the frame for safety. Never rely solely on hydraulics while working underneath the machine.

Step 3: Remove the Access Cover

Locate the small steel plate on the side of the track frame. This is the inspection hatch that protects the grease valve.

Undo the bolts using your socket wrench and set the cover aside. Inside, you will see a grease nipple or a large nut; this is the gateway to your track's tensioning system.

Step 4: Release the Track Tension

To remove the old track, you must collapse the idler wheel. This is done by loosening the grease valve (usually one full turn is enough).

As the grease escapes, the tension on the track will vanish. If the grease doesn't flow out immediately, you may need to gently push the front idler back toward the center of the machine using a pry bar.

Step 5: Pull the Track Off the Idler

With the tension released, start at the front of the machine. Use a metal bar to pry the track over the lip of the front idler wheel.

It is often helpful to have an operator slowly rotate the tracks in reverse while you guide the track outward. Be extremely careful to keep hands away from pinch points during this rotation.

Step 6: Disengage the Sprocket

Once the front is free, move to the rear. The drive sprocket has teeth that lock into the track’s metal lugs.

Slide the track off the sprocket carefully. If the track is old and stiff, you may need to use a forklift or a second piece of Al Marwan equipment to help pull the heavy rubber away from the frame.

Step 7: Inspect the Internal Components

Do not put a new track on a broken machine. Now that the frame is bare, inspect the following:

Bottom Rollers: Ensure they spin freely and aren't leaking oil.

Sprocket Teeth: If the teeth look like "sharks' fins" (pointed), they will damage your new track.

Top Carrier Roller: Check for flat spots.

At Al Marwan, we stock a full range of parts for Kobelco excavators to ensure your undercarriage is in top shape before the new rubber goes on.

Step 8: Mount the New Rubber Track

Position the new track next to the machine. Slide it over the drive sprocket first, ensuring the internal lugs are perfectly aligned with the sprocket teeth.

Then, lift the track onto the front idler. This is the most physically demanding part of the job. Using a long pry bar can provide the leverage needed to "pop" the track over the idler's edge.

Step 9: Re-Tension the Track

Once the track is seated on all rollers, it is time to tighten it. Close the grease valve and use your grease gun to pump grease back into the cylinder.

This will push the idler forward, taking up the slack. Refer to your operator’s manual for the specific sag measurement. Generally, for mini excavators, you want about 1 to 2 inches of sag between the middle roller and the track.

Step 10: The Final Test Run

Lower the machine back to the ground. Drive the excavator forward and backward for about 30 meters, performing a few gentle turns.

Re-check the tension. New tracks often "settle" after the first few minutes of movement. If the sag has increased, add a few more pumps of grease to reach the perfect tension.

Watch this video for more information 

Maintenance Tips from Al Marwan

To ensure your mini excavators stay productive, follow these professional maintenance tips:

By investing time in proper installation, you protect your investment. Al Marwan Heavy Machinery is proud to support the region's construction industry with top-tier equipment and expert repair services. 

Al Marwan Machinery

Leading heavy machinery provider in the GCC since 1978. Recognized as the GCC Rental Company of the Year for three consecutive years (2023, 2024, 2025), Al Marwan is the trusted one-stop shop for construction projects across the UAE, Saudi Arabia, and Oman. As an authorized dealer for brands like Kobelco, Powerscreen, Dynapac, Sinoboom, Socma, and CIFA, we offer a comprehensive suite of services covering the entire machinery lifecycle:

• ​​New Heavy Equipment: As an authorized dealer, Al Marwan offers access to the latest models of excavators, crawler cranes, crushers, concrete pumps, and more. All new machinery comes backed by manufacturer warranties.
• Heavy Equipment Rental Fleet: Access one of the largest construction equipment rental fleets in the Middle East, featuring 3,500+ machines and certified operators. This allows clients to scale operations efficiently, minimizing capital expenditure.
• Used Heavy Equipment: We offer a curated selection of used equipment from global leaders like Caterpillar, Volvo, Komatsu, and Hitachi. Each piece undergoes rigorous inspection and maintenance to guarantee optimal performance and reliability.
• Expert Support & Maintenance: Al Marwan provides comprehensive after-sales support and maintenance services to ensure the long-term performance and reliability of your investments.

Frequently Asked Questions (FAQ)

Q: How often should I replace tracks on my Kobelco excavator?

A: Most rubber tracks last between 1,200 and 1,600 operating hours. However, this depends heavily on the terrain. Sharp rocks and debris will shorten this lifespan significantly.

Q: Can I replace just one track at a time?

A: While possible, Al Marwan recommends replacing them in pairs. Uneven tracks can cause the machine to "pull" to one side and may cause uneven wear on the drive motors.

Q: What is the correct tension for mini excavator tracks?

A: Every machine is different, but a common rule of thumb is a 10- 15 mm gap between the track and the center roller when the machine is lifted. Always check your specific manual.

Q: Do you sell replacement tracks for all mini excavators?

A: Yes, Al Marwan offers a wide variety of high-quality rubber tracks and undercarriage parts for multiple brands, including specialized components for Kobelco excavators.