How to Tell If Your Excavator Part Can Be Repaired or Needs Replacing

Whether you're knee-deep in a construction site or managing a fleet of machines from behind a desk, there’s one headache every excavator owner dreads: part failure. You know the scenario—you hear a weird grinding noise, feel a loss of power, or notice your excavator just isn’t working like it used to. You pop the hood (so to speak), look at the component in question, and then you’re faced with the million-rand question: Can this part be repaired, or does it need to be replaced?

Let’s break it down. Because knowing the difference can save you thousands—and a whole lot of downtime.

Why It Matters

Excavators are built to last, but they're also built to work hard. That means wear and tear is inevitable. The real money lies not just in fixing your machine—but in knowing how to fix it smartly. Replace a part too soon, and you’re throwing money away. Wait too long, and you might turn a simple repair into a catastrophic failure.

So how do you know when to repair vs replace?

Let’s dig in.

1. Understand the Part’s Role

First, assess what the part does. Is it structural? Hydraulic? Electronic? Each category comes with its own rules of thumb.

• Hydraulic parts (like pumps, cylinders, hoses): These often give warning signs like slow response, loss of power, or fluid leaks. Some are worth repairing—others not.

• Wear parts (like bucket teeth, pins, bushings): Designed to wear out. Regularly replacing these is part of doing business.

• Powertrain components (like final drives, swing motors, transmissions): Expensive to replace. Often worth repairing—if caught early.

• Electronic components (like sensors, control modules): These are usually either working or they’re not. If they fail, replacement is often the only option.

• Structural parts (like booms, arms, frames): Can sometimes be welded or reinforced, but if the integrity is compromised, it’s game over.

  
  

If a part’s failure compromises safety or performance—and repairs don’t bring it back to full strength—replacement is the better option.

2. Look for the Obvious Signs

Let’s run through a few clear red flags that signal when to replace versus repair.

Signs a Part Might Be Repairable:

• Minor surface wear (e.g., scoring, scratches)

• Small cracks in non-load-bearing areas

• Slow leaks from hoses or fittings

• Slight loss of hydraulic pressure

• Worn but not broken seals or bearings

• Parts still within tolerance when measured

• Damage that is localized and not structural

Signs It’s Time to Replace:

• Deep cracks in high-stress areas

• Severe pitting or corrosion

• Repeated failure after previous repairs

• Unusual or grinding noises

• Overheating, burning smells, or smoke

• Broken gears, bent shafts, or shattered components

• Electronic failure with no error code or diagnostic solution

A general rule: if the cost of repairing approaches 50% or more of the replacement cost, it’s usually smarter to replace.

3. Consider the Age and Usage History

Think about how long the part’s been in service and how hard it’s worked. Is it original from the factory? Or has it already been through two or three patch jobs?

Let’s say you’re looking at a final drive that’s been rebuilt twice in the last five years. Sure, you could throw in new seals and hope for the best—but do you really want to risk it failing again in the middle of a big job?

On the flip side, if a hydraulic pump has a minor leak and it’s only 18 months old, a seal kit and pressure test might be all it needs.

📌 Pro tip: Always ask for service history when buying used parts or machines. It tells you whether you're buying a ticking time bomb or a well-maintained gem.

4. Do the Math – Repair vs Replacement Costs

Here’s where you channel your inner accountant.

Let’s compare:

Criteria	Repair	Replacement
Upfront cost	Lower	Higher
Downtime	Depends on repair time	Can be shorter with new part in stock
Long-term reliability	Varies	Higher (especially with OEM or quality used part)
Warranty	Limited	Often comes with guarantee
Labor costs	Add up with repeat repairs	One-and-done labor
Machine value impact	Neutral to negative	Can improve resale value

A basic formula to consider:If Repair Cost + Likelihood of Re-failure > 60% of Replacement Cost, choose Replacement.

5. Think About Downtime and Risk

Every hour your excavator sits idle is lost revenue. So even if a repair looks cheaper on paper, ask yourself:

• How long will the repair take?

• Do I have access to a skilled tech who can do it right the first time?

• What’s the risk of failure after the repair?

• Is this machine essential for an upcoming job?

For mission-critical machines, the smarter move is often to replace and move on.

Example:If your final drive goes down the day before a big job, waiting three days for a repair isn’t an option. You find a quality used part, swap it out in 12 hours, and keep your crew moving.

6. Evaluate the Availability of Parts

Some excavator models—especially older or less common ones—have parts that are hard to find or no longer made.

If the replacement part is rare or on backorder, a repair might be the only viable path—even if it’s not ideal.

Alternatively, if you find a quality used OEM part from a reputable supplier (hint: like Vikfin, if you're in South Africa), it might be better than paying a premium for a repair that may not last.

7. Inspect the Part Properly

Before making any call, get the part properly diagnosed. That means pressure tests, visual inspections, and measurements.

For example:

• Hydraulic cylinders should be pressure tested, rod inspected for scoring, and seals checked.

• Final drives should be opened and checked for metal contamination, gear damage, and bearing wear.

• Swing motors can be bench-tested for flow and power.

• Electronic parts should be scanned with diagnostic tools, not just guessed at.

⚠️ Guessing costs money. Testing saves it.

8. Don’t Ignore Your Gut (or Your Operator’s Gut)

If your machine operator says, “Something feels off,” don’t ignore it.

Operators know their machines. That weird whine or sluggishness might not be showing up on a sensor—but it’s still a warning.

Sometimes the decision to repair or replace isn’t based on hard science—it’s based on experience. Trust the guy (or girl) who spends 10 hours a day in the cab.

9. Know Your Supplier

Here’s the thing: not all parts are created equal, and neither are all suppliers.

A dodgy aftermarket part might look shiny and cheap—but it could cost you big time down the line. Meanwhile, a trusted used OEM part from a solid supplier can outlast even some new components.

When sourcing parts, look for suppliers who:

• Offer tested used parts

• Provide warranties

• Have inventory on hand

• Know the ins and outs of your specific excavator model

• Offer repair services too, so you can compare both options

Again, if you’re in South Africa, Vikfin is a go-to for high-quality used excavator parts. Just sayin’.

10. Make It a Habit – Regular Inspections

Want to avoid this entire dilemma in the first place? Inspect your machines regularly.

A scheduled maintenance routine catches issues before they become emergencies. It also gives you a trendline on how parts wear, so you’re not caught off guard.

• Check hoses for soft spots or bulges

• Listen for odd noises during startup or operation

• Monitor fluid levels and color

• Track machine performance—fuel consumption, speed, digging force

• Use diagnostic tools for error codes or sensor anomalies

Catch problems early, and you get to choose when to fix them—not the other way around.

Final Thoughts: When in Doubt, Ask the Pros

At the end of the day, the decision to repair or replace an excavator part isn’t always clear-cut. That’s why working with experienced professionals matters.

A seasoned mechanic or parts expert can save you thousands by steering you in the right direction.

And if you’re ever unsure, reach out to your parts supplier with photos, serial numbers, and a description of the issue. They’ve seen it all and can often tell you in minutes whether you’re dealing with a patch-up job or a bin-it-and-replace situation.

TL;DR – Quick Decision Checklist

Still not sure? Run through this:

✅ Does the part have minor, localized damage? → Consider Repair✅ Is the part critical, severely damaged, or repeatedly failing? → Replace✅ Is the repair cost more than 50-60% of a replacement? → Replace✅ Will downtime from a repair hurt your business? → Replace✅ Can you get a tested used part faster and cheaper than a long repair? → Replace✅ Is the machine still underutilized and part under warranty? → Repair

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