Excavator & Bulldozer Sprockets: Features and Advantages
Manufactured from premium high-strength alloy steel, our sprockets undergo rigorous through-hardening or induction hardening processes. This advanced heat treatment significantly enhances wear resistance, effectively extending the service life of the entire undercarriage assembly and minimizing costly equipment downtime.
The tooth profile is precisely optimized to ensure seamless engagement with track links, resulting in smooth and efficient power transfer. This engineering maximizes machine traction and travel stability while preventing premature abrasion on track chains and track shoes. Featuring standardized bolt patterns for broad equipment compatibility, these sprockets facilitate rapid replacement and streamline inventory management. Delivering a lower total cost of ownership, they are the superior choice for long-term aftermarket procurement.
What is a Bulldozer/Excavator Sprocket?
The sprocket is a specialized toothed wheel that serves as the driving force behind the crawler undercarriage system. Engineered to precisely match the pitch of the track chain for accurate engagement, it is typically mounted on the final drive hub. This component converts engine power into the tractive force required to propel the machine, enabling essential travel operations such as moving forward or reversing.
Primary Functions
The sprocket acts as the critical interface for power transmission, effectively transferring torque from the drive shaft to the track chain to initiate movement. Its design ensures positive engagement with the track links, maintaining machine stability and high operational efficiency even under heavy loads or on challenging terrain. By preventing slippage and ensuring continuous power delivery, the sprocket is vital for the overall reliability and mobility of the heavy equipment.
Sprockets Specifications & Applications
| Specification Type | Core Parameter Range | Compatible Models | Applicable Scenarios |
|---|---|---|---|
| Small (Mini) Sprocket | Pitch: 90-120mm Teeth Count: 10-14 Outer Diameter: 280-380mm | Excavator: 6-15 Tons Bulldozer: 8-12 Tons | Municipal engineering (pipe trenching, green belt maintenance), orchard operations, indoor demolition, and other light-duty conditions. Designed for the flexible operation needs of small crawler equipment. |
| Medium Sprocket | Pitch: 135-190mm Teeth Count: 14-18 Outer Diameter: 400-580mm | Excavator: 15-35 Tons Bulldozer: 12-22 Tons | General construction (foundation pit excavation, earthwork backfilling), road construction, mine stripping, and other medium-duty conditions. Balances operational efficiency with stability. |
| Large (Heavy-duty) Sprocket | Pitch: 200-250mm Teeth Count: 16-22 Outer Diameter: 600-850mm | Excavator: 35-70 Tons Bulldozer: 22-45 Tons | Open-pit mining, large-scale infrastructure (hydropower stations, port construction), heavy material handling, and other heavy-duty conditions. Built to withstand high-intensity friction and torque. |
Sprocket Specifications for PC200 and Volvo Excavators
| Compatible Models | Core Specs (Link/Sprocket) | Part Number | Supplementary Features |
|---|---|---|---|
| Komatsu PC200-3 | Pitch: 190mm Link Count: 45 Track Pin Dia: 38mm Bolt Hole Dia: 20mm | 20Y-32-01015 20Y-32-01014 | Fits machine S/N 20001 and up. Made of high-strength alloy steel. |
| Komatsu PC200-5 | Pitch: 190mm Link Count: 45 Long Pitch Offset: 160mm Short Pitch Offset: 124mm | 20Y-32-01015 20Y-32-01014 | Fits S/N 45001 and up (including 5S, 5X, 5Z sub-versions). |
| Komatsu PC200-6/7 | Pitch: 190mm Corresponding Sprocket Model: 20Y-27-11581 / 11582 | 20Y-27-11581 20Y-27-11582 | Compatible with PC200LC-6/7 (Long Carriage) versions. Quenched tooth surface. |
| Komatsu PC200-8 | Universal spec with PC200-6/7 Pitch: 190mm | 20Y-27-D3080 | Fits PC160-8, PC220-8 series. Enhanced wear resistance. |
| Volvo EC140 / EC150 / EC160 / EC180 / EC210 | Teeth: 21 Bolt Holes: 22 Surface Hardness: 56°-62° HRC Material: 50MnB Steel | SA1181-00050 VOE14520151 | Fits EC210LC, EC160BLC and variants. Induction hardened teeth. |
| Volvo EC230 / H10BLC | Pitch: 190mm Bushing OD: 59mm Pin OD: 38mm | CTHE15690850 | Fits 2" Type versions. Link External Guide Width: 170.6mm |
| Volvo EC210B LC | Pitch: 190mm Bolt Hole Dia: 20.5mm Link Total Width: 218.6mm | CTHE1569B849 | Track Chain Weight: 569.5kg. Track assembly designed for heavy-duty operations. |
Sprocket Pricing and Cost Factors
| Equipment Type | Compatible Model | Price Range (USD) |
|---|---|---|
| Excavator | Komatsu PC75, PC150 | 20 - 60 |
| Excavator | Komatsu PC200 | 32.68 - 60 |
| Excavator | Komatsu PC800 | 270 - 300 |
| Excavator | Volvo EC55, EC210, EC240 | 20 - 50 |
| Excavator | Hyundai R210, R220 | 32 - 47 |
| Excavator | Hyundai R290 | 95 - 99 |
| Excavator | Hitachi ZX200, ZX210, ZX240 | 45 - 58 |
| Bulldozer | Shantui SD16, SD22 | 800 - 1800 |
| Bulldozer | Shantui SD32 | 1200 - 1300 |
| Bulldozer | Caterpillar D6D | 60 - 98 |
| Bulldozer | Caterpillar D50, D51, D61 | 298 - 398 |
How to Address Bulldozer & Excavator Sprocket Wear
Step-by-Step Sprocket Replacement Guide
1. Relieve Track Tension
Locate the relief valve on the Track Adjuster. Slowly turn the valve counter-clockwise to release grease pressure. Use a pry bar to manually retract the Idler, creating sufficient slack in the Track Group to allow clearance for sprocket removal.
2. Clean and Pre-treat Mounting Surfaces
Thoroughly clean the final drive hub and the Sprocket mounting interface. Remove all old grease, oil, and rust to ensure a secure fit. Inspect the drive shaft key (if equipped) for damage or wear. Apply a light coating of clean engine oil to the new sprocket's seal ring and the mounting bolts to facilitate assembly and improve sealing.
3. Precision Sprocket Installation
Align the new Sprocket with the drive shaft keyway and press it firmly into position. Hand-tighten two opposing bolts to temporarily secure the component, then install the remaining bolts. Using a socket wrench, tighten all bolts in a cross-pattern to the manufacturer's specified torque settings.
- Note: Do not exceed torque specifications to prevent bolt shear.
- Tip: Apply a thread-locking compound to the bolts after initial seating to prevent loosening during heavy operation.
4. Reset Tension and Final Inspection
Adjust the Track Adjuster to restore the correct track tension specifications. Operate the machine at low speed to verify that the Sprocket engages the Track Chain smoothly without binding or abnormal noise. Once validated, reinstall the sprocket guards and lubricate all relevant components to complete the installation.
How to Replace Sprocket Segments
1. Removal of Worn Segments
Using a socket wrench, loosen the securing bolts on each segment in a cross/star pattern (typically 4–8 bolts per segment). If corrosion is present, apply penetrating fluid or apply controlled heat to the bolts to prevent shearing during removal. Remove the sprocket guard, then use a pry bar to separate the old segments from the mounting hub/keyway. Use lifting gear to safely remove heavy segments. Once removed, inspect the axis key and seal ring for damage and thoroughly clean the mounting area of oil, rust, and debris.
2. Comprehensive Undercarriage Inspection
While the segments are removed, inspect adjacent Undercarriage components, including the Track Chain (Links), Track Rollers, and Idlers. If wear on these components exceeds OEM specifications, they must be replaced to prevent premature abrasion on the new segments. Additionally, verify that the drive shaft is free of deformation to ensure stable future operation.
3. Installation of New Segments
Clean the drive shaft surface and keyway to remove all contaminants. Apply a light coat of grease to the new seal ring. Align the new segments with the keyway and press them firmly into position. Hand-tighten the bolts to secure the placement. Using a calibrated torque wrench, tighten all bolts in a cross pattern to the torque specifications found in the service manual.
- Tip: Apply thread-locking compound to the bolts before final tightening to ensure uniform gap spacing and prevent loosening under vibration.
4. Final Adjustment and Operational Testing
Reset the Track Group tension to the appropriate level. Operate the machine at low speed to verify smooth sprocket engagement; listen for abnormal noises or signs of misalignment. Reinstall the sprocket guard and lubricate all relevant points.
- Maintenance Note: Check bolt tightness daily during the break-in period. If the main sprocket hub shows severe structural wear, a complete assembly replacement is recommended rather than just replacing segments. If you lack specialized tooling or experience, consult a certified technician to prevent Track Link failure or derailment.
Custom Manufacturing Process for Excavator and Bulldozer Sprockets
1. Requirement Submission
Clients must provide precise equipment specifications, including the specific make and model of the excavator or bulldozer (e.g., CAT D7R, Hitachi EX-30). Essential sprocket parameters—such as dimensions, tooth count, bore diameter, and keyway type—are required. Additionally, defining the operational environment (e.g., soil hardness, impact load intensity) ensures the engineering matches the application's demands.
2. Material Selection & Process Engineering
Based on the submitted requirements, we select premium materials (such as 50MnB alloy steel) and determine the optimal production method—either forging or casting. We support full OEM customization, including custom designs, color specifications, and specialized surface hardening (achieving HRC 52–58) to maximize durability in specific terrain conditions.
3. Design Verification & Prototyping
We generate 3D CAD drawings for client review to ensure design accuracy. Once the design is approved, a precise quotation is issued. A prototype is then manufactured to physically verify fitment with the undercarriage assembly, ensuring seamless integration before full-scale production.
4. Precision Manufacturing
Strictly adhering to industry standards, production proceeds through material cutting, forging or casting, and precise tooth profiling. Subsequent heat treatment processes—specifically quenching and tempering—are applied to significantly enhance the sprocket's hardness and wear resistance, guaranteeing superior core performance.
5. Surface Finishing & Quality Assurance
Finished sprockets undergo sandblasting, polishing, or coating to ensure robust corrosion resistance. We conduct comprehensive quality inspections, including dimensional accuracy checks, hardness testing, and metallurgical analysis, to ensure every unit meets rigorous industry standards.
6. Assembly & Packaging
Final assembly involves fitting seals and applying OEM-customized labeling. All products are backed by a 6 to 24-month warranty. Prior to mass production, we perform additional load testing and alignment verification to ensure stability. Heavy-duty packaging is utilized to prevent damage during transit.
7. Delivery & After-Sales Support
Shipment is arranged only after the product passes a final comprehensive inspection. We fully support manufacturing based on client-provided drawings or samples. Post-delivery, we assist with installation testing and provide professional maintenance guidance. The typical production cycle ranges from 2 to 8 weeks depending on complexity. For guaranteed compatibility and quality, we recommend partnering with manufacturers possessing over 20 years of industry experience.
After-Sales Service & Support Protocols
- 24-Hour Response Guarantee: Should you encounter technical challenges or quality concerns during operation, our support team is available immediately. We pledge a response within 24 hours to provide expert technical assistance.
- Diagnostic Support: Upon receiving a report, we initiate remote troubleshooting to identify the root cause. Depending on the diagnosis, we coordinate on-site engineering support or provide detailed repair solutions to resolve issues rapidly.
- Parts Availability: We maintain a robust inventory of critical replacement parts to ensure immediate availability. This supply chain efficiency is designed to minimize costly equipment downtime.
- Warranty & Liability: Defective products are repaired or replaced at no cost, strictly adhering to contract terms. We take full responsibility for all maintenance and service claims covered under the warranty period to safeguard your investment.
- Proactive Maintenance: Our support team conducts regular follow-ups to monitor equipment status and provide maintenance recommendations. This proactive approach helps extend component service life and maximize operational efficiency.
Why Partner With Us
Factory-Direct Manufacturing & Expertise
Partnering with us for your heavy equipment components ensures access to professional, reliable, and cost-effective solutions. As a dedicated manufacturer with a specialized facility for excavator and bulldozer undercarriage parts, we bring years of R&D and production expertise to the table. Specializing in high-performance sprockets, we implement rigorous quality control protocols to ensure every component delivers superior durability and operational excellence.
Extensive Compatibility & Custom Engineering
Our inventory supports a vast range of mainstream equipment models, providing comprehensive coverage for diverse construction requirements. Beyond standard replacements, we offer advanced customization capabilities. We engineer components tailored to your specific operational environment and performance standards, ensuring precise fitment and optimized function.
Lifecycle Support & Global Logistics
We stand behind our products with a comprehensive after-sales ecosystem. Our rapid-response technical support team is dedicated to maximizing your equipment's uptime and efficiency. Furthermore, our extensive experience in international export streamlines the procurement process, ensuring a seamless and reliable purchasing experience for global clients.
Your Trusted Industry Partner
Choosing us means securing a partnership built on quality assurance and professional integrity. We are committed to powering the success of your projects with components you can trust.