The Most Commonly Replaced Excavator Parts and How to Improve the Lifespan of Excavator Components

Excavators are required on many jobsites, playing crucial roles like digging, grading and lifting. Like most heavy equipment, they can wear significantly due to constant operation under harsh conditions.  This article explores the key components that require routine replacement. Understanding each part's typical lifespan allows for better maintenance planning and budget allocation—and helps you maximize the performance of your machine.

Hydraulic System Parts

The hydraulic system in an excavator uses fluid power to perform tasks like lifting, digging and rotating. It converts mechanical energy into hydraulic energy using components like pumps, valves, cylinders and motors to create force and movement.

The Typical Lifespan of Hydraulic System Components

• Hydraulic Pumps: 5,000 to 10,000 hours.
• Hydraulic Hoses: 1,000 to 2,000 hours.
• Hydraulic Cylinders: Up to 10,000 hours.
• Seals: 2,000 to 5,000 hours.
• Hydraulic Filters: 500 to 1,000 hours.

Signs and Symptoms of Wear

• Hydraulic Pumps: Reduced efficiency, strange noises, overheating or fluid leaks.
• Hydraulic Hoses: Cracks, bulges or fluid leaks.
• Hydraulic Cylinders: Slow or erratic movement, leaking seals or visible damage.
• Seals: Contaminated hydraulic fluids, incorrect installation or extreme temperature changes.
• Filters: Increased fluid contamination and blockage or damage to the hydraulic filter.

Maintenance Tips to Prevent Premature Wear

• Inspect all hydraulic components for signs of wear, damage or leaks.
• Use high-quality, manufacturer-recommended hydraulic fluids and adhere to a strict schedule for fluid changes and filter replacements.
• Keep the hydraulic system clean to prevent contamination from dirt and debris, which can cause internal damage.
• Ensure all moving parts are lubricated to reduce friction and wear.
• Avoiding extreme temperatures can prevent fluid breakdown and component stress.

Common Factors Affecting Hydraulic System Wear

Hydraulic system wear in heavy equipment is often caused by a combination of factors. Contaminated fluid introduces dirt and particles that can damage internal components, emphasizing the need for clean fluid and properly maintained filters. Improper fluid levels contribute to overheating and increased strain on the system, while harsh operating conditions, such as extreme heat or cold, place additional stress on hydraulic components. Overloading or improper operation can further accelerate wear and lead to premature failure of parts. Neglecting scheduled inspections and servicing allows small issues to escalate, significantly reducing the lifespan of hydraulic components.

Undercarriage Parts

The undercarriage is the excavator's foundation, distributing the machine's weight and allowing efficient movement. It comprises several components, including track shoes, rollers, idlers, sprockets and track chains. Each of these undercarriage components contribute to an excavator’s overall mobility and strength.

Lifespan of Undercarriage Components

• Track Shoes: 2,000 to 3,000 hours.
• Rollers: 3,000 to 5,000 hours.
• Idlers: 4,000 to 6,000 hours.
• Sprockets: 3,000 to 4,000 hours.
• Track Chains: 3,000 to 5,000 hours.

Signs and Symptoms of Wear

• Track Shoes: Look for thinning, cracks or loss of traction.
• Rollers: Excessive noise, vibration or oil leaks are common indicators.
• Idlers: Watch for unusual noises, misaligned tracks or surface damage.
• Sprockets: Inspect for worn or broken teeth, chain skipping or uneven wear.
• Track Chains: Signs include link elongation, pin and bushing wear or track sag.

Maintenance Tips to Prevent Premature Wear

• Routinely check all undercarriage components for signs of wear, ensuring timely maintenance and replacement.
• Maintain correct track tension to prevent excessive wear on the chains, sprockets and other components.
• Clean the undercarriage regularly to remove dirt and debris, which can cause abrasion and increased wear.
• Adequate lubrication reduces friction and wear, extending component life.
• Limit sharp turns and unnecessary pivoting on hard surfaces to prevent undue stress.

Common Factors Affecting Undercarriage Wear in Excavators

Undercarriage wear in heavy equipment is influenced by several factors. Operating on rough, rocky or abrasive terrains accelerates the wear on critical components, while overloading can add unnecessary strain. Prolonged exposure to extreme weather conditions can also hasten the deterioration of undercarriage parts. Additionally, neglecting timely servicing, inspections and adjustments allows wear to progress unchecked, reducing the lifespan and efficiency of the undercarriage system.

Engine Parts

The engine is the heart of an excavator, providing the power needed for all its operations. Here's a detailed overview of crucial engine parts, including their functions, lifespans, signs of wear, maintenance tips and factors affecting their longevity:

Lifespan of Engine Components

• Engine Oil Filters: 250 to 500 hours.
• Fuel Injectors: 1,500 to 4,000 hours.
• Pistons: Typically exceeding 10,000 hours.
• Cooling Fans: 2,000 to 5,000 hours.

Signs and Symptoms of Wear

• Engine Oil Filters: Reduced performance, increased engine noise, frequent oil changes.
• Fuel Injectors: Reduced fuel efficiency, engine misfires, rough idling, exhaust smoke.
• Pistons: Loss of compression, increased oil consumption, hearing piston slap.
• Cooling Fans: Engine overheating, unusual noise and reduced cooling efficiency are symptoms of a faulty engine fan.

Maintenance Tips to Prevent Premature Wear

• Conduct frequent inspections to detect and promptly address early signs of wear.
• Adhere to the manufacturer's maintenance schedule for oil changes, filter replacements and general servicing.
• Use high-quality replacement parts and fluids to ensure optimal performance and longevity.
• Avoid operating in extreme temperatures beyond the engine's ratings to prevent stress and wear.

Engine wear in heavy equipment is influenced by several key factors. Harsh operating conditions, such as extreme temperatures, dusty or dirty environments and high altitudes, can put added strain on engine components. Load variability also plays a significant role, as consistently operating at maximum capacity or under fluctuating loads places additional stress on the engine. Neglecting regular maintenance schedules exacerbates these issues, increasing the likelihood of premature engine wear and unexpected breakdowns.

Electrical System Components

The excavator's electrical system powers and controls various functions vital for efficient operation. Because of the important role they play in an excavator’s operation, it’s crucial that electrical components stay up to date.

Lifespan of Electrical Parts

• Batteries: 3 to 5 years, but highly dependent on use.
• Sensors: Designed for long-term use.
• Wiring Harnesses: Designed to last the equipment's life.
• Control Panels: Designed to last the equipment's life.

Signs and Symptoms of Wear

• Batteries: Difficulty starting and frequent recharging.
• Sensors: Erratic readings, warning lights, system malfunctions.
• Wiring Harnesses: Power failure, visible damage, burning smell.
• Control Panels: Non-responsive controls, error messages, cracks or damage

Maintenance Tips to Prevent Premature Wear

• Routine Inspections: Regular checks can help identify early signs of wear or damage.
• Environmental Protection: Shield components from dust, moisture and severe temperature changes.
• Quality Components: Use high-quality, compatible parts for repairs and replacements to ensure longevity and reliability.

The electrical system in heavy equipment can be impacted by various factors. Exposure to rain or extreme temperatures can compromise electrical components, while continuous vibration during machine operation can loosen connections or damage wiring. Neglecting regular inspections and cleaning allows dirt and debris to accumulate, potentially leading to malfunctions. Power surges or overloading circuits may cause components to fail or sustain permanent damage. Incorrectly installed components can disrupt the system's functionality and, over time, natural wear and fatigue can degrade the materials and integrity of electrical components, increasing the likelihood of failure.

Excavator Attachments

Excavator attachments, including buckets, teeth and quick-couplers, can increase the functionality of an excavator.

Lifespan of Attachments

• Buckets: 7,500 to 10,000 hours.
• Teeth: Variable based on terrain, generally several hundred hours.
• Quick Couplers: Several thousand hours with proper care.

Signs and Symptoms of Wear

• Buckets: Cracks, bends and missing teeth.
• Teeth: Worn teeth points, ineffective digging.
• Quick Couplers: Unreliable locking, hydraulic issues, visible wear

Maintenance Tips to Prevent Premature Wear

• Ensure all moving parts are well-lubricated.
• Schedule regular checks for damage or signs of wear.
• Use attachments for their intended purpose and within load capacity.
• Protect attachments from harsh weather when not in use to prevent rust and deterioration.

Common Factors Affecting Excavator Attachments

The performance and durability of attachments in heavy equipment can be influenced by several factors. Operating on abrasive or rocky surfaces increases wear and tear, while prolonged exposure to moisture can cause rust and corrosion. Overloading attachments beyond their designed capacity places undue stress on the components, potentially leading to damage. A lack of regular inspections can allow minor issues to escalate into significant problems, while insufficient lubrication causes excessive friction and accelerates wear on moving parts. Inexperienced operators may inadvertently apply unnecessary force, further straining attachments. Additionally, using low-quality attachments often results in premature failure and reduced operational efficiency.

Proper Attachment Storage

To properly store a heavy equipment attachment and protect it from wear and rust, start by cleaning it thoroughly to remove dirt, grease and debris that can trap moisture and accelerate corrosion. Apply a rust inhibitor or protective oil to any exposed metal surfaces, especially if the attachment will be stored for an extended period. Store it in a dry, covered area, such as a shed or warehouse, to shield it from rain, snow and direct sunlight, which can cause premature deterioration. If indoor storage isn't possible, use a heavy-duty tarp to cover the attachment, ensuring proper ventilation to prevent condensation buildup. Position the attachment on stable, level ground or wooden blocks to keep it elevated and avoid prolonged contact with damp surfaces. Regularly inspect the attachment for signs of rust or damage and reapply protective coatings as needed to maintain its condition.

Excavator Filters

Filters are essential in maintaining the efficiency and longevity of an excavator's engine and hydraulic systems.

Lifespan of Filters

• Air Filters: 500 to 1,000 hours.
• Fuel Filters: 500 to 1,000 hours.
• Hydraulic Filters: 1,000 to 2,000 hours.
• Oil Filters: 250 to 500 hours, typically with every oil change.
• DEF Filters: 1,000 to 2,000 hours.

Signs and Symptoms of Wear

• Air Filters: Increased fuel consumption and black exhaust smoke are symptoms of an air filter that needs replacing.
• Fuel Filters: Poor engine performance, difficulty starting and rough idling are signs of a faulty fuel filter.
• Hydraulic Filters: Reduced hydraulic performance, unusual noises and overheating are signs that a hydraulic filter may need to be replaced.
• Oil Filters: Dirty or sludgy oil, reduced engine performance and increased engine wear can indicate a clogged or failing oil filter.
• DEF Filters: Engine derating, warning lights on the dashboard and poor emissions performance may signal a clogged or failing DEF filter.

Maintenance Tips to Prevent Premature Wear

• Regular inspection: Check filters for signs of clogging, wear or damage.
• Use quality filters: Using OEM filters can ensure compatibility with your machine, but high-quality aftermarket parts from a trusted supplier are a great alternative.
• Clean surrounding areas: Keep areas around filters clean.
• Use quality fluids and fuels: Use clean, high-quality hydraulic fluids and fuels to reduce the load on filters.

Several factors can affect the performance and longevity of filters in heavy equipment. Operating in muddy, wet or dusty conditions exposes filters to higher levels of contaminants, while using poor-quality or contaminated fuels and hydraulic fluids can accelerate clogging and wear. Continuous, heavy-duty operation places additional strain on filters, especially when inconsistent or delayed maintenance allows debris to accumulate. Installing filters that are not suited for specific systems can compromise their efficiency and effectiveness. Leaks in fuel or hydraulic systems can introduce contaminants, and improper storage practices that expose filters to moisture or dirt can further degrade their performance before they are even installed.

Cooling System Parts

An excavator's cooling system helps maintain proper engine temperature and ensure optimal performance. 

Lifespan of the Cooling System

• Radiators: 5,000 to 10,000 hours.
• Fans: 2,000 to 5,000 hours.
• Thermostats: 5,000 to 7,000 hours.
• Pumps: Generally about 5,000 hours.

Signs and Symptoms of Wear

• Radiators: Overheating, coolant leaks, clogged fins.
• Fans: Unusual noises, reduced airflow, overheating.
• Thermostats: Irregular temperature gauge readings, coolant leaks, overheating.
• Pumps: Noisy operation, coolant leaks, poor coolant circulation.

Maintenance Tips to Prevent Premature Wear

• Routine Inspections: Consistently check all components for signs of wear or damage.
• Quality Coolant: To achieve optimal performance and avoid corrosion, use the manufacturer’s recommended coolant.
• Clean Environment: Maintain a clean work area to prevent dirt and debris from clogging radiator fins and fans.
• Frequent Service: Follow your machine's service schedule for coolant replacement to avoid buildup and maintain system efficiency.

Heavy equipment cooling systems can be influenced by several factors. Accumulated dust, dirt and debris can hinder airflow and reduce efficiency, while using substandard or contaminated coolant may lead to improper heat regulation. Over time, components such as hoses, pumps and seals naturally wear down, making them more prone to leaks. Regular inspection, cleaning and timely replacement of parts are essential to avoid these issues. Additionally, impacts or excessive vibrations can damage sensitive components, and a faulty thermostat can disrupt temperature control. Obstructions in the airflow path can further compromise the system’s ability to maintain optimal operating temperatures.

Final Thoughts on Replacement Excavator Parts

Conducting regular maintenance on excavators helps ensure they can operate efficiently and effectively under demanding conditions. Consistent upkeep helps identify and address issues before they lead to significant breakdowns, reducing the risk of downtime and costly repairs. 

An excavator’s maintenance routine often involves replacing vital parts, such as filters, attachments and essential cooling system components. By prioritizing maintenance, you can enhance your equipment’s safety and reliability, ultimately getting a better return on your investment. 

If your excavator is in need of replacement parts, check out the EquipmentShare Shop. Our collection of OEM and aftermarket excavator parts has you covered. With components for a variety of makes and models, you can find exactly what your machine needs. Don’t see the specific part you’re looking for? Reach out to our dedicated parts experts and get personalized assistance.