Track rollers can be measured with either a depth gauge, a caliper or an ultrasonic tool. All methods are shown in the videos below.
- Ultrasonic Tool
- Depth Gauge
- Caliper
Potential Observations
What to look for
Below are some of the issues you should be looking for when inspecting track rollers. This list does not cover all possible issues, but is a starting point that covers most genral issues.
Uneven Tread Wear (Inner/Outer)
| Examples | Causes | Effects | Recommendations |
|---|---|---|---|
 |
• Deflection of track roller frame • Sidesloping • Abrasion • High loading • Equalizer end &/or pivot shaft bearing |
• Differential tread wear | • At CTS inspection, measure inner & outer treads • Swap rollers side to side at service • Check & service equalizer & pivot bearings at service as needed |
Tread Cusp Wear
| Examples | Causes | Effects | Recommendations |
|---|---|---|---|
 |
• Common to elevated machines • Link running in same position in roller tread • Gap between adjacent links creates cusp Abrasion |
• Difficult for accurate measurement of roller wear | • Measure on both sides of cusp to accurately measure wear • Continue running |
High Roller Side Flange Wear Details
| Examples | Causes | Effects | Recommendations |
|---|---|---|---|
 |
• Elevated sprocket • Sidesloping • Wide shoes • Equalizer end &/or pivot shaft bearing wear |
• Limited rebuildability • Possible flange breakage — Loss of guiding • Possible accelerated wear on guide guard wear strips |
• Directional changes on sideslope • Use narrower shoes • Rebuild/Replace roller • Swap rollers side to side • Service equalizer end &/or pivot shaft bearings as needed |
Roller Tread Wear (Front to Rear) Details
| Examples | Causes | Effects | Recommendations |
|---|---|---|---|
 |
• Increased abrasive flow at track frame ends • Unbalanced machine |
• Premature roller wear • Improper idler rise height • Can affect fine dozing |
• Install guarding package • Proper machine balance • Manage by swapping end rollers to center — Single to single — Double to double |
Roller Flange Breakage Details
| Examples | Causes | Effects | Recommendations |
|---|---|---|---|
  |
• 200% link/roller system wear life exceeded • Wide shoes • Sidesloping • Uneven terrain • High side heat treat — Brittle under high loads |
• Roller flange diameter hitting link pin boss • Loss of chunks &/or partial/complete flange • Reduced primary guiding |
• Trim flange &/or replace roller • Can be highly cosmetic • Level operation: — Up to 90° of missing flange, leave on & manage — Greater than 90° of missing flange, replace roller • Sideslope operation: — Up to 45° of flange missing, leave on & manage — Greater than 45° of flange missing, replace roller • Remove & replace end rollers w/ broken flanges |
Roller Retainer Wear Details
| Examples | Causes | Effects | Recommendations |
|---|---|---|---|
 |
• Contact w/ abrasive &/or impact material resulting in: — Outer wear around bolt heads — Inner wear around seal cavity • Chain de-tracking resulting in links running on top of retainer |
• Potential loss of sealability • Premature bolt loosening • Difficulty in bolt removal at service |
• Replace retainers at service • Improve primary guiding: — Tall double flange rollers • Improve secondary guiding: — New/Replace end guide guard wear strips — Additional short center guards — Possible full-length roller guards |