Filling and Maintaining Track Rollers on Tracked Equipment

[MikePhua]

Track rollers play a crucial role in the undercarriage of tracked machinery like bulldozers, excavators, and track loaders. Maintaining the lubrication of track rollers is essential to prevent wear and leaks, thus prolonging equipment life and minimizing downtime.
Filling Track Rollers With Grease

• Track rollers typically require heavy-duty grease, often a Grade 00 (double zero) consistency, which is thick enough to resist leakage and protect components under heavy loads.
  
• When filling a track roller, you add grease until it begins to escape from the fill hole, ensuring the cavity is properly filled without excessive pressure.
  
• Exact grease quantity varies by manufacturer and model; consult the equipment's operation and maintenance manual for precise volumes and procedures.
  
• Filling can often be performed with the roller on the machine, but positioning the machine tilted (such as with a backhoe attachment) might facilitate better grease penetration.
  
• Proper filling helps seal minor leaks by maintaining internal pressure and lubrication but does not replace the need to service or replace damaged rollers.
  

Common Track Roller Issues

• Leaks are a sign of seal wear or damage and can result in lubricant loss and accelerated roller failure.
  
• Aftermarket track rollers may have different fill plug locations compared to OEM parts; understanding this is important for proper maintenance.
  
• Sitting idle for long periods can dry out seals or grease, causing minor leaks that might be temporarily remedied by grease addition.
  
• Consistent maintenance, including duplication of grease points and frequent grease application, helps extend roller and track life.
  

Maintenance Best Practices

• Inspect track rollers regularly for leaks, wear, or damages.
  
• Remove debris (mud, clay, stones) from rollers and track components frequently to prevent buildup that leads to uneven wear.
  
• Keep track tension within manufacturer specifications; improper tension leads to excessive roller and track wear.
  
• Schedule periodic roller replacement based on operator manual or when performance declines significantly.
  
• Track rollers are integral to the undercarriage system and should be treated with care during maintenance and inspection.
  

Terminology

• Track Roller: Rolling wheels supporting and guiding the track chain in tracked vehicles.
  
• Grade 00 Grease: Heavy consistency grease suitable for lubricating heavy-duty machinery components exposed to pressure and contamination.
  
• Fill Hole: Access point on the roller for grease or lubricant addition.
  
• Seals: Components preventing leakage of lubricants from within rollers.
  
• Undercarriage: Assembly comprising tracks, sprockets, rollers, idlers, and related components.
  

Small Story
A technician working on a Caterpillar D3B noticed a slight grease leak on an aftermarket track roller. Before condemning the roller as faulty, he carefully filled the roller cavity with Grade 00 grease until it slightly overflowed from the fill hole, then allowed the machine to tilt using a backhoe to facilitate grease distribution. This temporary fix helped maintain operation until a scheduled roller replacement could be performed, illustrating practical field maintenance techniques.
Summary List

• Use Grade 00 grease to fill track rollers until grease escapes the fill hole.
  
• Filling can be done on machine, tilting helps grease spread inside roller.
  
• Seal leaks may be softened by proper lubrication but require monitoring.
  
• Remove debris regularly to avoid accelerated wear.
  
• Correct track tension preserves roller and track life.
  
• Consult OEM manuals for grease amounts and fill procedures.
  

Proper lubrication and inspection of track rollers significantly enhance the durability and performance of tracked equipment, reducing costly downtime and repairs through proactive maintenance strategies.