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Free excavator undercarriage inspection checklist

Free excavator undercarriage inspection checklist covering track shoes, bushings, sprockets and idlers per OEM measurement specs.

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Updated 26 Oct 2026

Excavator Undercarriage Inspection Checklist

Competent-person inspection | Per OEM measurement standards

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0 of 31 checks

Track shoes & chain

1Track shoe height measured against OEM new and minimum
2Track chain pitch elongation across measured links
3Link rail height measured on both sides
4Grouser bar height measured against OEM new
5Percentage wear calculated for each metric

Bushing wear & turn thresholds

6Outer bushing diameter measured at each position
750 percent first-turn threshold applied
8100 percent retirement threshold applied
9Bushing turn or replacement decision recorded
10Master link condition and bolt torque verified

Sprockets & idlers

11Drive sprocket tooth profile inspected against template
12Sprocket pocket wear recorded
13Front idler tread wear measured
14Rear idler tread wear measured
15Idler flange and bearing seal condition

Carrier & track rollers

16Each carrier roller tread wear measured by position
17Each track roller tread wear measured by position
18Top roller wear recorded separately
19Bottom roller wear recorded separately
20Single-flange and double-flange positions noted
21Bearing seal condition on each roller

Recoil & track tension

22Recoil spring grease pressure or stroke measured
23Dust seal condition recorded
24Tensioner adjustment verified
25Track frame and motor mount weld visual
26Final drive oil sample submitted

Wear report & rebuild forecast

27Full eight-metric undercarriage measurement report compiled
28Percent life remaining calculated per component
29Projected rebuild date entered against carrier
30Work orders raised for bushing turns or replacements
31Next undercarriage measurement date set in MapTrack

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Jarrod Milford

Jarrod Milford

Co-Founder & Commercial Director

Updated 26 October 2026
Also see:GPS Trackers for Excavators →Compliance and inspections →Best inspection software →MapTrack vs SafetyCulture →

Short answer

An excavator undercarriage inspection checklist records a competent person's wear measurements of the track group, from shoes, chain pitch, link height and bushings to sprockets, idlers, rollers, grousers and the recoil spring, against OEM wear limits. Operators check visually each shift; full measurement intervals come from the manufacturer or site practice. Model WHS reg 213 requires competent-person inspection following manufacturer recommendations.

Checked against Model WHS Regulations as at 5 December 2025 (cited within as the Work Health and Safety Regulations 2011) on by the MapTrack templates team. How we check templates

Key takeaways

  • The MapTrack excavator undercarriage inspection checklist contains 31 checks across 6 sections. Sections covered: Track shoes & chain, Bushing wear & turn thresholds, Sprockets & idlers, Carrier & track rollers, Recoil & track tension, Wear report & rebuild forecast.
  • OEM undercarriage measurement standards give the new, turn and minimum dimensions; record each reading against the figure for that track group.
  • When to turn bushings comes from the OEM wear limits for that track group, not a universal percentage or a legal rule.
  • Trend top and bottom roller wear separately so the staged rebuild follows each component's own wear limit.
  • Six-monthly and 12-monthly full measurement cycles are common practice; high-cycle mining fleets often measure more often.
  • Reg 213 requires the inspector to be competent; record their name and the measuring tools used.

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Used by construction, mining and field service teams

Saunders InternationalMineral ResourcesSupagasHacer GroupMetro TunnelUltrabuilt

What is an excavator undercarriage inspection checklist?

An excavator undercarriage inspection checklist is the structured wear and condition assessment used by a competent person to decide where each undercarriage component sits on the OEM wear curve and whether the track group stays in service, gets turned, or is retired and replaced. It applies to crawler excavators from 5 tonne mini-excavators up to 600 tonne mining hydraulic shovels and covers the full track group including track chain, track shoes, track bushings, sprockets, idlers, carrier rollers, track rollers, recoil spring and grouser bars. Unlike an excavator pre-start that runs across the whole carrier, or a 250 hour service that focuses on lubricants and filters, this checklist concentrates on the eight measurement points that drive the undercarriage cost-per-hour calculation. The scope covers track shoe height measurement against the OEM minimum, track chain pitch elongation, link height wear, bushing turn life (first turn at 50 percent and full retirement at 100 percent), sprocket tooth wear profile, idler tread wear, carrier roller and track roller wear (with the top and bottom roller positions trended separately), grouser bar height, master link condition and recoil spring condition.

Undercarriage typically represents 50 percent of total excavator maintenance cost, which is why every OEM (CAT, Komatsu, Hitachi, Volvo, Kobelco, Liebherr) publishes its own undercarriage measurement standard, and ISO 6165 (Earth-moving terminology) gives the common machine vocabulary. The WHS Regulations 2011 Chapter 5 make track group condition part of the PCBU plant maintenance duty, because a track derailment or sudden bushing failure on a slope can cause death or serious injury. The full undercarriage measurement report is the document that drives the rebuild decision, the budget approval and the hire-fleet residual value calculation, and the record needs to be defensible at trade-in, finance audit and SafeWork inspection. A digital record in MapTrack ties each measurement to the carrier serial, the undercarriage serial, the install date and the running hour count so cost-per-hour trends and rebuild forecasting stay accurate across a fleet.

Learn more about compliance and inspections in MapTrack.

Watching undercarriage wear on your excavators? See civil plant and equipment tracking for each machine's inspections and hours on its own record.

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Benefits of using this excavator undercarriage inspection checklist

  • Cost-per-hour visibility: Each measurement feeds the OEM undercarriage cost-per-hour calculation so rebuild timing is data-driven, not based on engine hours alone
  • Undercarriage measurement record: The checklist compiles the full eight-metric undercarriage measurement report with percent life remaining for each component, ready for warranty and rebuild claims
  • Bushing turn life tracking: The 50 percent first-turn and 100 percent retirement thresholds are captured in measurement, so the bushing turn decision is timed correctly to halve undercarriage cost
  • Track derailment prevention: Recoil spring condition, master link condition and chain pitch elongation are inspected together, intercepting the failure modes that cause derailment on slopes
  • Roller position trending: Top and bottom track roller wear is recorded separately, exposing the loading-direction wear pattern that misalignment, slope work or undercarriage skewing creates
  • Sprocket and idler matching: Sprocket tooth profile and idler tread wear are inspected as a system, ensuring matched replacement so a new chain is not run on worn sprockets
  • Lifecycle records: Every undercarriage measurement, bushing turn, component replacement and final retirement sits against the carrier for the full life of the asset

Benefits of digitising forms in MapTrack

When you digitise excavator undercarriage inspection checklists in MapTrack, you get:

  • Field users can easily scan a QR code to complete a form on mobile. Unlimited users.
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  • File every completed form against the asset, location or person it covers.
  • Download any completed form as a PDF, with failed answers listed at the top.
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  • Build conditional logic (show or hide questions based on answers).
  • Take pictures or attach photos. Not possible with a paper-based form.
  • Electronic signatures.
  • Edit forms later without reprinting.
  • Set who can view, fill in or edit forms with user roles.
  • Upload a paper form (PDF, Word, Excel or a photo) and MapTrack's AI builds a digital version for you to check.
  • Email safety managers when a hazard report is submitted, with an automation you set up.
  • Keep every hazard and incident report against the site it came from, with photos.
  • Turn a hazard report into a corrective-action work order with its own review step.

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Steve McAllister

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What to include in an excavator undercarriage inspection checklist

This excavator undercarriage inspection checklist covers 12 key areas:

  • Carrier and undercarriage identification: excavator make, model, serial number, undercarriage serial, install date and operating hours since install or last rebuild
  • Track shoe height measurement: at multiple points along each side, recorded against the OEM new height and minimum discard height, percentage wear calculated
  • Track chain pitch elongation: measurement across a fixed number of links (typically 4 or 8) and compared against the new chain pitch, percentage elongation calculated
  • Link height wear: measurement on the chain link rail surface against the OEM minimum, percentage wear calculated for both sides of the machine
  • Bushing turn life: outer bushing diameter measurement, percentage wear calculated, 50 percent first-turn threshold and 100 percent retirement threshold applied to drive the turn versus replace decision
  • Sprocket tooth wear: tooth profile inspection on both drive sprockets, sprocket pocket wear, sprocket bolt torque check and matched-pair planning against chain wear
  • Idler wear: front and rear idler tread wear measurement, idler flange condition, idler bearing seal condition and idler alignment to the chain
  • Carrier roller wear: each carrier roller tread wear measurement and bearing seal condition, recorded against position number on each side
  • Track roller wear: each track roller tread wear measurement at flange and tread positions, top and bottom roller wear recorded separately, single-flange and double-flange positions noted
  • Grouser bar height: grouser bar height measurement against the OEM new height, percentage wear and pad replacement requirement noted
  • Master link condition: master link visual inspection for cracking, pin retention and bolt torque, secondary lock pin position confirmed
  • Recoil spring condition: recoil spring grease pressure or stroke measurement against OEM specification, dust seal condition and tensioner adjustment recorded

How to use this excavator undercarriage inspection checklist

  1. 1. Plan the inspection and clean the undercarriage: book the carrier out of operation for 4 to 6 hours, position on level concrete or a wash bay, lock out the ignition and key in pocket, high-pressure wash the full undercarriage of mud and packed material so the rollers, chain and sprockets are clean for measurement
  2. 2. Pull undercarriage records and identify components: pull the carrier service log, undercarriage serial, install date and operating hours since install or last rebuild, gather the OEM undercarriage measurement standard, ultrasonic depth gauge, calipers, chain pitch gauge and sprocket profile template
  3. 3. Jack and rotate the track for chain pitch measurement: jack the machine according to OEM procedure with the track rotated to expose the measurement positions, measure chain pitch across the OEM-specified number of links, repeat on multiple positions and trend against previous reading
  4. 4. Measure shoes, link height and grouser bars: walk each side of the machine measuring track shoe height, link rail height and grouser bar height at multiple positions, calculate percentage wear against OEM new and minimum dimensions and record against position
  5. 5. Measure bushing outer diameter and apply turn rule: measure outer bushing diameter at each position, calculate percentage wear, apply the 50 percent first-turn threshold and the 100 percent retirement threshold, mark the next bushing turn date in the rebuild plan
  6. 6. Inspect sprockets, idlers and rollers: inspect sprocket tooth profile against the OEM template, measure tread wear on front and rear idlers, walk each carrier and track roller position recording tread and flange wear, note top and bottom roller wear separately
  7. 7. Inspect master link and recoil spring: visual inspection of master link for cracking and bolt torque, measurement of recoil spring grease pressure or stroke against OEM specification, dust seal and tensioner condition recorded
  8. 8. Generate the undercarriage measurement report: compile all eight measurement metrics into the full undercarriage measurement report, calculate percent life remaining for each component, project the rebuild or retirement date against engine hour trend
  9. 9. Close the record: stamp the inspection sheet, attach the full undercarriage measurement report and photos against the carrier in MapTrack, raise work orders for any bushing turn or component replacement, schedule the next undercarriage measurement date

In MapTrack, you can digitise safety inspections and compliance forms. Each submission is stored as a timestamped PDF against the asset record.

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How often should you complete this inspection checklist?

OEM undercarriage measurement standards set the inspection cadence, and regulation 213 of the WHS Regulations 2011 requires the inspection to be carried out by a competent person, following any recommendations of the manufacturer. The operator runs a visual pre-start undercarriage walk each shift, looking for cracked shoes, leaking final drives, missing pad bolts and obvious chain damage. A monthly inspection by a trained technician covers a visual walk of the full track group under stationary conditions. A 6-monthly competent-person inspection completes the full eight-metric undercarriage measurement report with shoe, chain pitch, link height, bushing, sprocket, idler, roller and grouser bar measurements. A 12-monthly major undercarriage measurement sits inside the carrier annual major service and is the formal record used for rebuild planning. Mining carriers on high-cycle production duty often pull the measurement cadence forward to 3-monthly, because the cost-per-hour calculation depends on accurate measurement of the wear curve. Any track derailment, sudden bushing failure, severe slope work or recoil spring discharge triggers an out-of-cycle inspection before the machine returns to service.

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Frequently asked questions

The OEM undercarriage measurement standards govern the inspection, and ISO 6165 (Earth-moving terminology) gives the OEM terminology baseline. Each OEM (CAT, Komatsu, Hitachi, Volvo, Kobelco, Liebherr) publishes its own undercarriage measurement standard, with the specific new, minimum and turn dimensions for that track group. The WHS Regulations 2011 Chapter 5 make undercarriage condition part of the PCBU plant maintenance duty, because a track derailment or sudden bushing failure on a slope can cause death or serious injury.

OEM undercarriage measurement standards specify that track bushings are turned (rotated 180 degrees on the chain) once outer bushing diameter wear reaches 50 percent of the original wear allowance. The turn effectively doubles bushing life by exposing the unworn face to the sprocket pocket. Bushings are retired and replaced once outer diameter wear reaches 100 percent of the original allowance, at which point the chain is rebuilt at a workshop. Running bushings past 100 percent damages the sprocket teeth and increases the cost-per-hour of the full undercarriage. The OEM measurement standard prints the specific dimensions for the chain on each carrier.

The full undercarriage measurement report covers eight metrics: track shoe height, track chain pitch elongation, link rail height, outer bushing diameter, sprocket tooth profile, front and rear idler tread wear, carrier roller and track roller tread wear (with top and bottom roller positions trended separately) and grouser bar height. Each metric is recorded at multiple positions along each side and converted to a percentage wear figure against the OEM new and minimum dimensions. The report then projects component life remaining and the rebuild or retirement date against engine hour trend. CAT, Komatsu, Hitachi and Volvo all publish their own measurement standard with the specific dimensions for each track group.

A visual pre-start walk by the operator at every shift, a monthly visual inspection by a trained technician, a 6-monthly competent-person inspection with the full eight-metric measurement report, and a 12-monthly major undercarriage measurement inside the annual major service. Mining carriers on high-cycle production duty often pull the measurement cadence forward to 3-monthly because the cost-per-hour calculation depends on accurate measurement of the wear curve. Any track derailment, sudden bushing failure or severe slope work triggers an out-of-cycle measurement before the machine returns to service.

Excavator undercarriages are designed to be rebuilt in stages, not replaced in one event. Bushing turns at 50 percent extend chain life. Sprocket, idler, carrier roller and track roller replacement happens as each component reaches its individual wear limit. A full chain replacement is triggered by 100 percent bushing wear or 100 percent link rail wear, whichever comes first. The full track group is only retired and scrapped when the carrier itself reaches end of life or when accumulated rebuild cost exceeds the cost of a complete new track group. The OEM measurement standard drives the staged rebuild plan.

Yes. This excavator undercarriage inspection checklist is completely free to download and use, and it downloads as a ready-to-print PDF. No MapTrack account is required. It suits competent persons completing the full eight-metric undercarriage measurement report against the OEM standards. If you later want to move off paper and spreadsheets, MapTrack turns this into a live digital record: shoe, chain pitch, bushing and roller measurements stored against each undercarriage serial so cost-per-hour trends and rebuild forecasting stay accurate, photos against each finding, and automated reminders for the 6-monthly and annual measurements with a complete timestamped audit trail. Start free at maptrack.com/free-trial or book a demo.

Applicable regulatory standards

This template is a starting point. Check the current requirements that apply to your equipment, work and location. The template alone does not establish compliance.

  • Model Work Health and Safety Regulations

    Edition: Model WHS Regulations as at 5 December 2025 (cited within as the Work Health and Safety Regulations 2011)

    Inspection by a competent person following the manufacturer's recommendations, such as the OEM measurement standard.

    • reg 213: Plant must be maintained, inspected and, if necessary, tested by a competent person, following manufacturer or competent person recommendations; annual inspection applies only if neither is practicable.
    • Chapter 5: Plant and structures: general duties for plant, duties for registered plant, and registration of plant designs and items of plant.

    Safe Work Australia (drafted by the Parliamentary Counsel's Committee)

  • Model Code of Practice: Managing risks of plant in the workplace

    Edition: November 2024 version (reviewed May 2018; amended 2021, 2023 and 2024)

    Guidance on how and when a competent person should inspect plant.

    • Section 3.5: Inspecting plant: how and when plant should be inspected by a competent person, reflecting reg 213.

    Safe Work Australia

  • Earth-moving machinery - Basic types - Identification and vocabulary

    Edition: ISO 6165:2022 (Edition 7)

    Current 2022 edition is titled Identification and vocabulary; the page quotes the withdrawn 2012 title.

    International Organization for Standardization (ISO)Sold by the publisher

  • Earth-moving machinery - Safety, Part 5: Requirements for hydraulic excavators (ISO 20474-5:2017, MOD)

    Edition: AS 20474.5:2025

    Design and construction safety requirements for hydraulic excavators.

    Standards AustraliaSold by the publisher

Each source was read at its publisher and the page checked on 26 October 2026. The publisher's current text is the authority.

Check the current source

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  <p style="font-size:12px;font-weight:700;letter-spacing:0.05em;text-transform:uppercase;color:#071D49;margin:0;">Free template</p>
  <p style="font-size:18px;font-weight:700;color:#071D49;margin:6px 0 0;">Excavator Undercarriage Inspection Checklist</p>
  <ul style="margin:12px 0 0;padding-left:18px;color:#374151;font-size:14px;line-height:1.6;">
    <li style="margin:4px 0;">Carrier and undercarriage identification: excavator make, model, serial number, undercarriage serial, install date and operating hours since install or last rebuild</li>
    <li style="margin:4px 0;">Track shoe height measurement: at multiple points along each side, recorded against the OEM new height and minimum discard height, percentage wear calculated</li>
    <li style="margin:4px 0;">Track chain pitch elongation: measurement across a fixed number of links (typically 4 or 8) and compared against the new chain pitch, percentage elongation calculated</li>
    <li style="margin:4px 0;">Link height wear: measurement on the chain link rail surface against the OEM minimum, percentage wear calculated for both sides of the machine</li>
    <li style="margin:4px 0;">Bushing turn life: outer bushing diameter measurement, percentage wear calculated, 50 percent first-turn threshold and 100 percent retirement threshold applied to drive the turn versus replace decision</li>
    <li style="margin:4px 0;">Sprocket tooth wear: tooth profile inspection on both drive sprockets, sprocket pocket wear, sprocket bolt torque check and matched-pair planning against chain wear</li>
  </ul>
  <p style="font-size:13px;color:#6B7280;margin:14px 0 0;padding-top:12px;border-top:1px solid #E5E7EB;">Free <a href="https://www.maptrack.com/templates/excavator-undercarriage-inspection-checklist" style="color:#071D49;font-weight:600;text-decoration:none;">Excavator Undercarriage Inspection Checklist</a> by MapTrack</p>
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The MapTrack excavator undercarriage inspection checklist contains 31 checks across 6 sections.

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MapTrack. (2026). Excavator Undercarriage Inspection Checklist [Checklist template]. Retrieved from https://www.maptrack.com/templates/excavator-undercarriage-inspection-checklist

Free to reuse with credit under a Creative Commons Attribution 4.0 licence. If you’d rather link straight to it, the page is https://www.maptrack.com/templates/excavator-undercarriage-inspection-checklist.

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