4 Most Common Heavy Equipment Issues

May 17, 2023

Did you know that each year, companies in the United States spend upwards of $100 billion on maintenance and repairs for facilities and critical equipment? Many factors warrant the need for heavy machine servicing. This guide will explore some prevalent mining and construction equipment issues along with key maintenance tips.

Common Heavy Machinery Problems and How to Address Them

Why do machines wear out and break down? Here are the common heavy equipment problems and ways to prevent them.

1. Hydraulics

Substances like water, dirt, metal and dust proliferate during manufacturing and construction processes. They can invade the hydraulic system and cause various issues.

Water and particulate matter can enter the system in different ways. They can accumulate within the system during operation, such as through wear and tear on the seals or metal edges. Debris from the surrounding environment can also enter through leaks and openings.

If the system is not properly flushed out, these lingering particles can cause functional problems or premature failure. Even small quantities of contaminants can gradually degrade fluids. Fluid degradation can decrease viscosity, reduce load-bearing capacity and ultimately wear out internal components when left unaddressed.

A professional fluid inspection can determine the source of hydraulic system contamination. Maintenance is also a must to keep these contaminants at bay. Replace dirty, clogged or damaged hydraulic filters, and regularly oil and lubricate your machine to prevent hydraulic pump issues.

2. Electrical Failure

Electrical failure is one of the most common heavy machinery issues. Numerous factors can cause electrical failure in heavy equipment, such as:

Loose power connections: A loose electrical connection can cause arcing, where a current jumps from one connection to another. This can create sparks, cause electrocution or even lead to an electrical fire.
Contaminants: Dust, moisture and humidity are common culprits of electrical malfunction.
Insulation issues: Improper or defective insulation can cause electrical problems. Current leakage and increased resistance can damage insulation. These leaks can overload the electrical system, potentially overheating and damaging the electronic components. This can degrade equipment performance and increase the risk of a fire.
Power overload: Electrical circuit overloading occurs when excess electricity travels through one part of the circuit. It can also occur when something in the circuit hinders electricity flow. Power overload can lead to a range of issues, such as a blown fuse, tripped breaker or electrical fire.

An electrical failure can wreak havoc on both your equipment and facility, causing significant downtime and putting on-site workers at risk. The Occupational Safety and Health Administration (OSHA) has electrical safety guidelines to protect equipment operators from shocks, fires and explosions.

Extensive safety training, risk assessments, voltage regulators and proper cord insulation are all crucial measures. Regular equipment maintenance can also minimize dust and debris buildup that often causes electrical issues.

3. Undercarriage Issues

A well-maintained undercarriage is essential to maintain stability, performance and longevity. But it is frequently exposed to demanding operating conditions, making it a common source of damage and failure. For instance, mining sites and other corrosive environments can deteriorate undercarriage components, reducing performance and life span.

Aside from natural stress and wear, here are some other reasons for undercarriage issues:

Leakage: Oil or hydraulic fluid leaks can occur in bearings, seals and gaskets. Leakage can disrupt performance and damage other components if left unresolved.
Damaged tracks: Impacts from uneven terrain, rocks and other debris can tear and puncture track rubber. Track damage can reduce equipment stability and traction.
Misalignment: Misaligned undercarriage parts can result from uneven loading, improper tensioning and other variables. They can lead to premature failure.
Insufficient lubrication: Inconsistent lubrication can increase friction and wear, potentially damaging the undercarriage. Proper oiling is vital for smooth undercarriage operation.
Overloading: Overloading the machine can strain undercarriage components. Be sure to follow the manufacturer-recommended load limits to help prevent this issue.

Maintenance tasks and thorough inspections — including alignment checks, tensioning, cleaning and part replacements — can sustain undercarriage performance and mitigate the need for costly repairs.

Additionally, harsh operating conditions like steep grading and rocky soil can fray undercarriage components. Try to limit these conditions as much as possible or factor them into a preventive maintenance schedule.

4. Metal Corrosion

Properly maintain your equipment to prevent corrosion.

Corrosion and rust are common causes of equipment malfunction, especially for job sites in humid environments or those near standing water. Lubricant oxidation can produce organic acids in metals like zinc and iron, causing them to corrode. Corrosion can damage seals and other metal components over time.

Proper maintenance can help prevent corrosion-related fatigue and breakdowns. Scheduled inspections can help identify metal corrosion in equipment early on. That way, you can replace these components well before they cause more substantial issues. You can also use rust and corrosion inhibitors to minimize contact between metal equipment surfaces and corrosive substances, like water, salt and oxygen.

Signs Your Equipment Needs a Repair or New Part

Here are some signs to bring your heavy equipment in for servicing:

Vibrations: Vibration during equipment operation can signify a loose part, gear misalignment or system imbalance.
Strange noises: If you notice hissing, screeching, wheezing or grinding sounds, bring your machine in for servicing as soon as possible. Odd sounds can point to various issues, such as leaks, hydraulic system malfunctions and misaligned valves or pumps.
Dashboard warning lights: If the dashboard lights activate, mechanical or hydraulic issues could be at play. Dashboard lights can alert you of low oil pressure, abnormal hydraulic oil temperatures or electronic control errors. As a precautionary measure, shut off the machine if a warning light comes on during operation.
High fuel consumption: If you need to refuel your equipment more frequently than usual, the engine could be malfunctioning. Excessive fuel consumption can also indicate low tire pressure or a clogged air filter.
Engine stalls: A variety of factors — such as a dying battery, lack of airflow or dirty fuel injector — can cause engine stalling or startup difficulties. Stalling could be a result of improper airflow, low fuel, electrical complications or a hydraulic system issue. It can also be a response to a sudden engine load increase.

Contact Stewart-Amos Equipment Co. for Repairs, Parts and New Equipment

Contact us for repairs, parts and new equipment today.

Now that you can identify some of the most common problems with heavy machinery, it is important to know who to call for your repair and maintenance requirements.

We offer a wide selection of replacement parts and tools at Stewart-Amos Equipment Co. in Pennsylvania. Our experienced technicians provide high-quality maintenance and repair services, helping improve your equipment performance and longevity. Contact us today or call us at 800-482-2302 for your equipment repair and replacement needs. We look forward to assisting you!

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