Comprehensive Guide to Identifying and Solving Machinery Maintenance Issues
Is your equipment’s latest issue a result of typical wear, or is it a sign of a more complex problem? Understanding how to resolve maintenance issues can help you extend the lifespan of your heavy machinery and protect yourself from on-the-job accidents. Equipment Trader has more here on the most common issues you should know how to recognize and address.
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1. Machinery Corrosion
While metal corrosion may seem like a slow-moving problem you can put off, it is one of the most common causes of shortened equipment life spans. Environmental factors like heightened humidity can accelerate this issue, causing pitting, rust, or cracks. If you notice surfaces developing small holes or rust spots, act quickly.
Use Corrosion Control Measures
You must have corrosion control measures in place. They can reduce corrosion-related expenses by 35% and significantly extend your equipment’s lifespan. If you have the budget for humidity sensors, get them—they can tell you how high your rust risk is.
2. Faulty Electrical
Anything from a loose connection to damaged wiring insulation can create sparks, generate excessive heat, or cause electrical fires. The signs of electrical system trouble are subtle—your display may flicker, your machine may run hotter than usual, or the metal may shock you. More often than not, you will have to rely on diagnostic trouble codes for clarification.
Use Temperature Sensors
Electrical systems are complex and dangerous, so you should generally hire a professional. Proactive maintenance can keep it from getting to that point. Follow the manufacturer’s manual for depleting and charging. Also, consider installing temperature sensors to detect overheating.
3. Excessive Wear
Over time, blades dull, tires wear, controls stick and engines slow—that’s a natural part of operating heavy machinery daily. However, you could unknowingly contribute to this problem by overusing or misusing your machines. You can differentiate excessive and natural wear by comparing your records to component life span expectations.
Periodically Inspect Machinery
Inspections are critical for identifying and fixing excessive wear. A good general rule is to inspect equipment before and after a job. Replace worn parts as soon as possible to prevent them from degrading other components.
4. Improper Lubrication
How often do you lubricate your machinery? Precision is key. While under-lubrication causes friction and erosion, too much lubricant can generate excessive heat or create leaks. Either way, your seals, bearings, and gears will take on damage. You can tell if you’ve over or under-lubricated if you see leaks or hear unusually loud grinding noises.
Follow the Manufacturer’s Manual
The best advice anyone can give you on proper lubrication is to follow the equipment manufacturer’s instructions since the specifics vary from model to model. Remember to double-check the application area to identify any cracks or holes.
5. Contaminated Hydraulics
Gaps allow debris, dust, crop residues, and dirt to enter the hydraulic system, affecting viscosity and rapidly degrading quality. A sudden loss of control is a common consequence. When operating a vehicle the size of a small shed, the last thing you want is to lose steering. Common signs of contamination include leaks, unusual noises, or abnormally high fluid temperatures.
Conduct Fluid Inspections
Periodic fluid inspections are crucial. They evaluate the chemical composition of hydraulic fluid to identify any contaminants present. You should also regularly check and replace filters. These minor tasks can keep your machinery from developing leaks or malfunctioning.
6. Worn Tires
Whether you’re plowing a field or driving back and forth on a worksite, your machine’s tires are supposed to handle tough jobs. However, you shouldn’t mistake durability for invulnerability. Hard debris can create tears or punctures. Rough terrain can cause irregular wear. Fortunately, these issues are plainly visible.
Routinely Inspect Tires
Check your tires frequently. You should measure tread thickness and air pressure at least once per month and after driving over debris-ridden sites.
7. Debris Accumulation
More often than not, your work is messy. Unfortunately, debris can build up in gaps and openings, clogging fluids or jamming rotating parts. Muddy terrain can cause dirt to accumulate and harden on the tire’s sidewalls. Alternatively, mud can get stuck in a chain’s teeth, preventing it from moving or affecting performance.
Clean Your Machine
Cleanliness is a crucial—and often overlooked—aspect of maintenance. Clean machines are less likely to malfunction or break down. Proactively preventing debris buildup mitigates other issues like corrosion and hydraulic contamination.
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Is Your Maintenance Strategy Reactive or Proactive?
A reactive maintenance strategy is not ideal. You will always be one step behind if you’re constantly fixing problems as they arise. Leveraging sensors, documentation and telematics systems to proactively monitor equipment health can help you catch potential problems before they evolve, saving you time and money while extending your machinery’s lifespan. And if you’re on the market for your next unit, you’ll find a nationwide inventory of new and pre-owned heavy machinery on Equipment Trader.
Evelyn Long
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