What percentage of excavator maintenance cost is the undercarriage?

Expert Answer

The excavator undercarriage often represents about 40% to 50% of total machine maintenance cost, and in harsh working conditions it can be even more. In simple terms, it is usually one of the biggest ongoing cost drivers on a tracked excavator.

That percentage is not fixed, because wear depends heavily on ground conditions, operating style, and maintenance discipline. Abrasive rock, demolition, mud, sand, and frequent turns can accelerate wear on track chains, track shoes, rollers, idlers, sprockets/segments, rubber tracks, and track bolts and nuts. A machine that is properly cleaned, adjusted, and inspected will generally spend less over time than one that runs with poor track tension or packed material in the undercarriage.

Useful signs that undercarriage costs are rising include uneven wear, frequent track derailment, noisy rollers or idlers, excessive chain stretch, cracked or loose shoes, and reduced traction or travel performance. If wear is becoming visible on multiple components at once, the undercarriage may be approaching a major repair cycle rather than just a routine service interval.

To manage cost, focus on a few practical checks: keep track tension within the machine maker’s recommended range, remove mud and debris regularly, rotate or flip components when appropriate, and measure wear before it becomes severe. It is also important to compare repair cost versus replacement cost once multiple parts are nearing end of life, because replacing only one worn item while leaving badly worn mates in place can shorten the life of the new part.

VANROCK Track Solutions supplies undercarriage parts for 350+ machinery brands through an appointed dealer network, with pricing quoted on request. If you mention an OEM brand, note that VANROCK is an independent manufacturer and is not affiliated with the OEM.

Answered by VANROCK specialists · Published 7/20/2026