Your excavator is the workhorse of many operations, and because of that, its undercarriage takes the brunt of that work. That’s because it constantly supports the total weight of the machine and is always in contact with rough, abrasive surfaces. As a result, an excavator’s undercarriage will undergo significant wear and tear.
Keeping an eye on this will keep your machine up and running, something that’s crucial if you want your project to remain on schedule. By understanding what causes premature wear, you can extend the life of your equipment and keep your sites running smoothly. Here are eight common excavator undercarriage wear issues to watch out for.
1. Improper Track Tension
Track tension is a bit like the Goldilocks principle: it needs to be just right. If your tracks are too tight, you are essentially increasing the load on the undercarriage components. This excessive tension creates unnecessary friction, generating heat and accelerating wear on bushings, sprockets, and idlers. It also robs your machine of power, making it work harder than it needs to.
On the flip side, tracks that are too loose can be just as damaging. Loose tracks have a tendency to “slap” as the machine moves, which can cause them to derail or come off the idler. This not only stops your work dead in its tracks but can also damage the track links and shoes. The key is to check your tension regularly and adjust it according to the manufacturer’s manual, especially when site conditions change (like moving from soft mud to hard rock).
2. Misalignment of Tracks
Just like the tires on your truck, your excavator tracks need to be properly aligned. Misalignment usually happens when internal components like track rollers, idlers, or sprockets are worn out or not adjusted correctly. When the tracks aren’t aligned, they don’t move in a straight line. This forces the track links to rub against the sides of the track rollers and the idler flanges.
Over time, you’ll start to see uneven wear patterns on the track shoes and links. If you notice that one side of your track is wearing down much faster than the other, or if you hear grinding noises during operation, you’ll need to check your alignment. Catching this early can save you from having to replace expensive track chains prematurely.
3. Debris Buildup
It’s the nature of the job for excavators to get dirty, but leaving that dirt on the machine is a recipe for disaster. Mud, rocks, gravel, and demolition debris can easily get packed into the undercarriage frame. When this material hardens, it acts like sandpaper or a grinding wheel against the moving parts.
Debris packed around the rollers prevents them from turning properly. When rollers seize up, the track chain drags over them instead of rolling, causing flat spots on the rollers and excessive wear on the track links. In cold climates, mud can freeze solid overnight, locking up components completely. Making it a daily habit to shovel out or pressure wash the undercarriage at the end of a shift is one of the simplest, most effective ways to prevent wear.
4. Operating on Harsh or Abrasive Terrain
Even if the debris doesn’t build up, it can still do damage to your excavator’s undercarriage. For example, abrasive materials like crushed rock, sand, or demolition concrete naturally wear down steel faster than working on soft soil or grass. These sharp, gritty materials grind away at the track shoes and cut into the rubber seals on lubricated tracks.
While you can’t always choose your job site, you can choose how you manage it. That’s why, if possible, you should try to minimize the distance the machine travels over abrasive surfaces. When the job is done, inspect the tracks for any sharp rocks wedged in the links that could continue to cause damage even after you’ve moved to softer ground.
5. High-Speed Operation
Excavators are designed for power, not speed. Traveling at high speeds across a job site generates significant heat within the undercarriage components. This heat causes the internal oil in pins and bushings to thin out, reducing its ability to lubricate and protect metal surfaces.
High-speed travel also increases the shock loads transferred through the machine when you hit bumps or obstacles. This impact stress accelerates wear on rollers, idlers, and track shoes. If you need to move the machine a long distance, it is often better (and cheaper in the long run) to transport it on a trailer rather than driving it there. If you must drive, keep the speed down to reduce friction and heat buildup.
6. Frequent Sharp Turns
Turning an excavator isn’t like steering a car. Pivot turns (or spot turns) put a tremendous amount of side-load stress on the tracks. When you spin the machine around in a tight circle, you are dragging the track shoes sideways through the ground. This digs into the terrain and puts immense pressure on the track links, rollers, and sprockets.
This side-loading can lead to “de-tracking,” where the track is forced off the rollers. It also causes rapid wear on the sides of the track components. Whenever possible, try to make wider, more gradual turns. If you must make a sharp turn, try to do it gradually while moving forward or backward, rather than spinning in place. This reduces the strain on the undercarriage significantly.
7. Excessive or Uneven Load Distribution
How you load and position your excavator affects the undercarriage more than you might think. Frequently working over the side of the tracks (rather than over the front or rear idlers) shifts the machine’s weight and the load’s weight onto a smaller area of the undercarriage. This concentrates the stress on just a few rollers and track links, leading to uneven wear.
Similarly, consistently carrying loads that are too heavy for the machine can cause the track pads to bend or crack. It also compresses the rollers and idlers beyond their design limits. Always try to work with the drive sprockets to the rear of the machine and the idlers to the front. This configuration is designed to handle the digging forces most effectively.
8. Lack of Regular Maintenance
The biggest enemy of any excavator, which causes common undercarriage wear issues, is neglect. Skipping regular inspections means you miss the small problems—a loose bolt, a leaking seal, a slightly loose track—that can cause excessive damage to these machines.
While it might seem tedious, regular maintenance doesn’t have to be complicated. It can be as simple as a daily walk-around to check for loose hardware, oil leaks, and abnormal wear patterns. Check the track tension weekly. Keep the undercarriage clean. Replacing a 50-cent bolt today is a lot easier than replacing a $5,000 track assembly next month.
How We Can Help
While Pro Construction Parts can’t stop the general wear and tear of your components, we can help you out by providing a variety of construction equipment parts. We have a vast selection to choose from, and the best part is that our components are built to last. That means they should be able to withstand more wear and tear than your previous parts.
