How to Spot Early Signs of Undercarriage Wear

By Sammuel MacMullin | Proven Mining Solutions Inc.

Tracked equipment is the workhorse of mining, construction, and pipeline projects. Whether it’s pushing dirt with a D8 or laying pipe with a sideboom, the undercarriage is what keeps the machine moving. And because it’s constantly in contact with the ground, it’s also the part that takes the most abuse.

Undercarriage costs make up as much as half of your machine’s lifetime maintenance bill. Spotting early signs of wear isn’t just good practice — it’s the difference between a scheduled service and an unexpected breakdown that brings your whole job site to a halt.

⚙️ Why Undercarriage Care Matters

It’s a big investment. Pins, bushings, rollers, and tracks aren’t cheap. Protecting them adds years of service life.

Small issues turn into big ones. What starts as a little uneven wear can chew through idlers, sprockets, and even frames if ignored.

Downtime is costly. If your dozer or excavator is down, production slows or stops. Preventative maintenance keeps uptime high.

🔎 Key Signs of Wear to Watch For

1. Track Tension

Too tight? Accelerated wear on pins, bushings, and idlers. Too loose? You risk throwing a track. Proper adjustment is one of the cheapest ways to extend component life.

2. Uneven Wear Patterns

If one side of the machine shows different wear than the other, or track shoes look mismatched, alignment may be off. Misalignment eats rollers and idlers quickly.

3. Worn or “Shark Finning” Sprockets

Look for sprocket teeth that are sharp or hooked. This “shark finning” happens when chain links wear and ride higher on the sprocket instead of sitting in the throat. It causes premature wear on both sprockets and the chain — and if ignored, it’ll also start damaging new chains when they’re installed.

4. Cracked or Loose Track Shoes

Shoes take direct impact from terrain. Cracks, missing bolts, or bent shoes weaken the chain and stress the entire undercarriage.

5. Idlers & Rollers

Listen for squeals or grinding. Lift the machine and check if rollers free-spin. Dry rollers and leaking seals are silent killers that shorten component life.

📏 The Value of Regular Measurement & Inspections

Undercarriage wear isn’t random — it follows measurable patterns. Recording bushing wear, link height, and roller diameter tells you exactly how much life is left.

Why it matters:

Plan, don’t react. Measurements help you schedule maintenance around production, not after a failure.

Maximize availability. Less unplanned downtime means more hours in operation.

Save money long-term. Replacing components at the right time avoids chain reactions of damage.

At Proven Mining, we provide undercarriage inspection services to help clients track wear rates. This turns maintenance into a proactive tool rather than a reaction to failure.

❌ Common Mistakes

Running tracks too tight. One of the fastest ways to burn through pins and bushings.

Ignoring sprocket wear. Shark finning accelerates chain wear and ruins new components.

Skipping daily walkarounds. Loose shoes, cracked links, or leaking seals are often obvious on inspection.

Never cleaning out. Letting mud and rock pack into the undercarriage is like running with sandpaper.

Stretching components too far. Waiting until parts “completely fail” often causes collateral damage that costs more.

🧹 Cleaning: The Forgotten Task

Packed mud, frozen ice, and compacted gravel act like grinding compound. Leaving it in place accelerates wear dramatically. A quick wash-down or clean-out at the end of shift is one of the most effective, low-cost maintenance practices available.

🧠 Pro Tips from the Field

Check tension daily. It only takes a minute, and it saves thousands.

Inspect sprockets with a critical eye. Shark finning is one of the clearest signs your chain is overdue for service.

Keep it clean. Clean machines live longer — simple as that.

🔧 Proven Mining Has You Covered

From on-site inspections and measurement tracking to full undercarriage rebuilds, Proven Mining Solutions helps extend the life of your machines and keep them moving.

📞 587-723-8777

🌐 provenmining.ca