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A well-kept excavator is less likely to break down. It saves time and money while drastically extending the lifespan of the excavator. Since excavators are subjected to harsh conditions while operating like digging the earth or loading materials into trucks in harsh sun, rain and on difficult terrains, proper routine maintenance is critical to keeping them in good working order.
Preventive Maintenance Plan
Most people use a preventive maintenance plan to minimize downtime and streamline the entire process. It’s an extremely cost-effective method that helps machine owners to anticipate change, and wear and tear. Avoiding breakdowns also helps prevent permanent damage to the excavator and lengthen its lifespan.
Well Trained Employees
In order for a preventive maintenance plan to work correctly, a lot of care and attention has to be put towards the machines in your fleet. Train your employees to operate the excavators effectively. Your operators, mechanics, and other staff will need to be knowledgeable enough about the excavator and know inside out about it. Knowledgeable machinery operators are more productive and cause less wear on machinery than untrained workers. Properly trained operators will be more respectful of their equipment and more likely to look after it before, during and after operation duties. They should be observant enough to notice the warning signs of an issue that might occur. That’s going to save money in repairs and replacement.
Preparing a Maintenance Tasks Checklist
Prepare a checklist and stick to it because having a plan for what checks need to be done and when will provide the most effective maintenance plan. It aids in remembering the tasks and ticking them off as servicing is complete. Documenting your machinery servicing lets you plan for future tasks. This includes being reminded to order replacement parts, fluids and filters, as well as scheduling maintenance that needs outsourcing to a dealer where shop-time is required or a dealer site visit is requested.
Here are the Main Tasks to be Done During a Preventive Maintenance Routine.
1) Start with the Inspection of the Safety Equipment and Operator’s cab.
A. Make sure the ID tag, safety decals, and operators manual are present.
B. Check if the seat belts, safety lever switch, and travel movement alarm system are working perfectly.
C. Look for wear and tear in the ROPS and the cab mounts.
D. Check if all the lights are working. Any burned-out bulbs should be replaced.
E. Ensure the wipers, horns and all other instruments are working.
F. Check the operation and function of the site-watch equipment.
G. Check the operation and function of machine control components.
2) Inspecting the Engine Compartment
A. The belt age, fraying, slackness, and discoloration should be on the list.
B. Exhaust systems tell a lot about engine performance. Abnormal and unusual sounds are one problem indicator but so is smoke. Ensure both are normal.
C. Check the fuel delivery systems. Ensure there are checkmark spots for fuel pumps, lines, and storage tanks. The cap should be in place on a fuel tank, and the tank itself should be inspected to ensure there are no dents in the metal that could weaken the tank and lead to leaks.
D. Diesel engines rely on injectors for fuel delivery. Plugged or dysfunctional injectors impact power and the economy. Injector cleaning or replacement belongs on the maintenance checklist.
E. Every filter on the equipment must have its own check-off that says if it was cleaned or replaced. That includes oil, fuel, air, and hydraulic filters. It could also be cabin filters. Checklist remarks can include whether filters were cleaned or replaced.
F. Analysis of the engine oil and hydraulic oil is mandatory during every maintenance check. Make sure there are no oil leaks.
3) Tier 4 CEGR
A. Exhaust connections like clamps and hangers should have their own checklist boxes.
B. Check the DPD chamber for cracks or damages.
4) Cooling System
A. Radiator and transmission coolants tell a lot about the excavator’s state. Aside from adequate levels and normal colors, coolants should have periodic analysis to check for internal problems that can’t be detected by the eye.
B. Check for coolant leaks, fan assembly, damage to the caps, clamps, and hoses, and check the functioning of the water pump.
5) Lubrication
Greasing and lubricating is a must on a checklist. The list should also identify critical moving areas like joints and sleeves and ensure proper lubrication at all greasing points.
6) Hydraulics
A. Inspect hydraulic lines for any signs of leaks that could cause equipment failure.
B. The oil that is carried through the hydraulic lines needs to be inspected, too. Look at the oil levels, and check the hoses, cylinders, and fittings for any leaks.
C. Do a hydraulic fluid particle count analysis and check the cycle times and overall operation of the hydraulics.
7) Electrical Connections
Electrical component checkpoints go beyond battery conditions. Checklists should include voltage and amperage testing, cable examination, and fuse conditions.
8) Undercarriage
A. Inspect the undercarriage for signs of rust or damage. Look for loose bolts on track and tighten if necessary.
B. Look for bent shoes on tracks. The shoes support each other and one bent shoe can lead to additional bent shoes.
C. Replace bent or damaged guards and guides on the bottom of track.
D. Inspect sprocket and drive at rear of track for oil leaks and to make sure all bolts are present and tight.
E. Clean out debris from around the track and adjust track tension if necessary to avoid excess wear. Make sure cotter pins in the master link are present.
9) Miscellaneous
A. Make sure teeth are present on the bucket and they are in good condition.
B. Grease all pins and bushings daily
C. Record tire wear, tread depth, and pressure. Balance is another item on the list.
D. Treads, cleats, and idlers should have their box as well as general wear condition.
E. Windshield should be inspected every time a checklist comes out. Chips can easily develop into sight-impairing cracks. Also, look for a mirror and light glass conditions.
YantraLive believes in the importance of routine and preventive maintenance services. We aim to provide the right diagnosis and get the right part at the right price with the right quality at the right time to machine owners. Our Vision is to improve livelihoods in construction through hassle-free equipment ownership and reduced machine downtime. We supply parts and Level 2 services for a large range of heavy equipment globally and pan India.