Nobody expects an undercarriage to last forever. It works in dirt, rock, mud and snow every day the machine is on the job.

But there is a difference between normal wear and replacing track chains, rollers or sprockets sooner than you should.

Heavy equipment undercarriage wear isn’t only determined by machine hours. Track tension, operating habits, ground conditions and basic maintenance can all affect how quickly components wear. A small issue left alone can also start wearing out other parts of the undercarriage.

Here are some of the most common causes of premature wear.

Incorrect Track Tension

Track tension is one of the first things to check when undercarriage wear doesn’t look right.

Tracks that are too tight place additional load on the pins, bushings, rollers, idlers and other components. They can also increase the amount of power required to move the machine.

Tracks that are too loose can move around excessively, strike other components or potentially come off the machine. A loose track can also ride poorly against the sprocket and speed up wear.

There isn’t one track-tension measurement that works for every machine. Check the manufacturer’s specifications and measure the track under the recommended conditions. Eyeballing it usually isn’t good enough.

Packed Mud, Dirt and Debris

Mud isn’t doing your undercarriage any favors.

Material packed between the tracks and undercarriage frame can reduce clearance and place additional tension on the system. Dirt, sand and small rocks can also act like an abrasive as the machine travels.

This becomes an even bigger concern during Saskatchewan’s freeze-and-thaw season. Mud left in the undercarriage at the end of the shift can freeze solid overnight, leaving the operator with more than just a cleanup job the next morning.

Clean out packed material regularly and pay attention to anything caught around the rollers, idlers or sprockets. You don’t need to stop every few minutes, but cleaning the undercarriage at the end of the shift can prevent material from building up over time.

Too Much High-Speed Travel

Tracked equipment is built to travel, but unnecessary high-speed travel creates additional friction and heat throughout the undercarriage.

Long travel distances across a jobsite, especially when they are repeated every day, can add up quickly. Frequent reverse travel can also increase wear on undercarriage components.

When possible, plan the work to reduce non-productive travel. If a machine needs to be moved a considerable distance, transporting it may be easier on the undercarriage than tracking it the entire way.

Sharp Turns and Counter-Rotation

Sharp turns and counter-rotating might get the machine pointed in the right direction faster, but they also place additional side load on the undercarriage.

Repeated sharp turns can increase wear on track shoes, links, roller flanges and other components. Always turning in the same direction can also cause one side of the undercarriage to wear faster than the other.

Operators should use wider, more gradual turns when the job allows and alternate turning directions where practical. The same applies when working across slopes. Operating in the same direction all day can lead to uneven wear between the uphill and downhill sides.

Track Spinning

When the tracks are spinning, the machine isn’t producing much useful work, but the undercarriage is still wearing.

Track spin grinds the shoes and other components against the ground, especially in sand, gravel and other abrasive material. It can also be a sign that the machine, track shoes or operating technique aren’t well matched to the conditions.

Instead of continuing to spin, reposition the machine, reduce the load or adjust the approach.

Worn Components That Are Left Too Long

The undercarriage works as a complete system. When one component becomes badly worn, it can start affecting the parts around it.

A seized roller can change how the track chain carries the machine’s weight. A worn sprocket can accelerate bushing wear. Loose or damaged track shoes can place extra stress on the links and hardware.

Replacing the most obvious worn part may not solve the full problem. It is worth checking both sides of the undercarriage and looking at how the components are wearing together.

Ground and Jobsite Conditions

Some jobs are simply harder on an undercarriage than others.

Sand and gravel are highly abrasive. Large rocks and demolition material can create impact damage. Sticky clay and mud can pack tightly around components. Working on slopes can cause uneven side wear.

You may not be able to change the ground conditions, but you can adjust your maintenance routine. Machines working in severe conditions should be cleaned and inspected more often than equipment working on firm, level ground.

What Should You Look for During an Undercarriage Inspection?

A quick walkaround can catch problems before they become a larger repair. Watch for:

• Loose or missing track hardware
• Bent, cracked or damaged track shoes
• Excessive or uneven track sag
• Leaking rollers or idlers
• Rollers that aren’t turning properly
• Uneven wear from one side of the machine to the other
• Sprocket teeth that appear sharp, hooked or heavily worn
• Unusual noises while travelling
• A track that pulls, wanders or frequently needs adjustment

It also helps to record wear measurements over time. One inspection gives you a snapshot. Regular measurements show how quickly the components are actually wearing and make it easier to plan repairs around your schedule.

A Few Minutes Now Can Prevent a Larger Bill Later

Undercarriage wear can’t be eliminated, but premature wear can often be reduced.

Keep the tracks clean, maintain the correct tension, limit unnecessary travel and pay attention to how the machine is being operated. Most importantly, don’t ignore a worn component and assume the rest of the undercarriage is fine.

If you need replacement rollers, idlers, track pads, links, sprockets or hardware, EMSCO’s Heavy Equipment Parts team can help source options for a wide range of makes and models.

Not sure how serious the wear is? Contact our Heavy Equipment Service team to discuss your machine and the components you’re concerned about. Having the make, model, serial number and a few clear photos ready can help us get you pointed in the right direction.