Heavy equipment such as bulldozers and cranes is necessary for construction, metallurgy and others. Nonetheless, like all mechanical systems, these strong machines have a tendency of suffering from breakdowns which causes losses due to down time, repairs and even fatalities. It is also important to know the reasons for failure of the apparatus and identify measures on how equipment failures can be minimized. In this article, we discuss the common failures of heavy equipment and how to avoid them.

Failure of Hydraulic Systems

Failure Causes: The moving parts such as the boom, blade and track are powered by the hydraulic systems which are the heart of different types of heavy equipment. Overpressurization, maintenance problems, leaks, and fluid contamination are the most common factors that lead to hydraulic system failure.

Prevention Tips:

Regular Fluid Checks: Periodically check the hydraulic fluid to supervise the extent of its contamination. Whenever there is a need to replace the fluid, lets do so but first make sure that the fluid is uncontaminated and more so the quality high filters are used.

Leak Detection: Check hoses, seals and fittings for any leaks. Any small leak should be corrected promptly to avoid loss of pressure and the consequent risk of damaging the system.

Avoid Overloading: Maintain the load limits of the machine since excessive loading can lead to overpressurization of the hydraulic system and consequently lead to the failure of the component.

Electric(os) System Problems

Failure Causes: Reasons for electrical system failure usually include oxidation, construction failure, bad assembly, and overloading. This kind of faulty operation may result to being compromised unit operations such as sensors and lights or control systems.

Prevention Tips:

Always Ensure Electrical Systems are Clean and Dry: Confirm that all electrical parts are well protected from moisture or debris so that they do not corrode.

General Checking of the Systems: Check all the wiring and possibly connections for any signs of wear and tear. Any loose connections should be retightened while any stripped cables should be cut for new ones.

Routine Maintenance of Batteries: Battery mounts should be managed and battery terminals should be checked for dirt accumulation. Noticed weak batteries should be written off since they suppress starting and other machine-powered electrical components.

Engine Overheating

Failure Causes: This situation leads to overheating which is rather common in heavy plants and if neglected may cause catastrophic damage to the engine. Reasons may range from coolant with coolant leaks, radiator blockage to faulty cooling fans.

Prevention Tips:

Coolant Variations: The different levels of coolant are regularly monitored and checks for leaks are performed within the system. Bronzed coolant should be renewed or refreshed strictly in accordance with the advice given by the Manufacturer.

Cooling Tower Cleaning: Maintain the radiator as well as the unclogged cooling tower. Airborne fertilizers, dust, or unwanted items may pile up and obstruct air flow and hence lower cooling efficiency.

Fuel Level: Make sure to keep a vigil on temperature gauges at all times. If the machine operating has a tendency to overheat, that should be stopped and investigated.

Unusual Wear and Undercarriage View

Failure Causes: The tracks and the undercarriage systems are crucial for the movement of heavy machine parts particularly excavators as well as bulldozers. Track and undercarriage problems can be avoided are excessive rashness, incorrect tension, and cleaning until all dirt is gone.

Prevention tips:

Regular Cleaning: The lower parts of the machine are vulnerable to wear and tear due to the gathering of mud, stones, and other debris. Therefore, a good habit of cleaning out the undercarriage on a regular basis should be encouraged.

Correct Track Tension: One of the regular eye attention is the clearance of the tracks. Slacker tracks might fall off the track and overly bound tracks might cause excessive wear to components.

Inspect for Wear: Though it is impossible to prevent wear from regular usage, bearings, rollers, idlers and sprockets require constant general checks and abnormal wear out of these components should warrant a replacement.

Transmission Failures

Failure Causes: Transmission issues and defects are also attributed to bad management of operations, low lubrication, as well as contaminants present in the fluid of the transmission system itself. Such failures will yield poor efficiency of the machines and at times complete breakdown.

Prevention Tips:

Fluid Maintenance: The transmission fluids should also be examined on a regular basis and replenished when the use of the machine exceeds a certain amount of fluid. The problems the outage presents are limited and internal degradation as a result of fluid poisoning is bound to cut down the useful workings of the transmission.

Proper Operation: Educate machinery operators on the proper use of the machine, specifically when to change or shift gears. If not done carefully, excess pressure may damage the transmission.

Routine Inspections: Check for strange sounds or leaks or what would seem like a lack in performance that could mean shorter transmission trouble. It’s much easier to fix things on a small problem than on a big one.

Issues with The Fuel System

Failure Causes: In most cases, the fuel system will break down because of dirt in the fuel, dirt in the filters or because of low grade fuel. These problems will cause a decrease in the engine performance, engine stalling, and engine breakdowns leading to expensive repairs.

Prevention Tips:

Use Clean Fuel: Always make it a point to purchase good quality fuel from a well known and authorized dealer in order to avoid such instances.

Replace Filters Regularly: Install fuel filters and change them as per the manufacturer’s recommendation; take them out and replace them to avoid clogging and maintain the gadgets in the appropriate state.

Drain Water Separators: The use of diesel engines gradually leads to wetting the fuel systems. The reason for this is usually water within the fuel system. Therefore, such intervals should be regularly maintained to avoid damaging the fuel injectors.

Failures of the Brake System

Failure Causes: Deficiencies in the brake system can be potentially dangerous especially if working with heavy machines over uneven or sloping grounds. Reasons consist of the brake pads that are worn out, melted brake fluids from the brake system, and air that may be present in the brake tubing.

Prevention Tips:

Brake Inspections: It is essential to perform periodical check-ups of almost all parts of the brake system for their wear; disc and pad changes can be helpful.

Fluid Checks: Verify the brake fluid levels and that there are no system leaks. Insufficient levels of fluid may lead to braking system failure.

Air Removal: Include bleeding off air from the brake lines to enhance the performance of the system and maintain the correct braking strength.

Conclusion

Breakdown of heavy equipment entails cost of downtimes and may potentially compromise safety requirements. Yet, it is possible to eliminate most of these breakdowns if preventive measures in regular maintenance and thorough inspections are undertaken. Safety is also guaranteed when you handle hydraulic system issues, electrical system failure, engine overheating, and track wear using a proactive approach for machine durability and efficiency.