A Comprehensive Guide to Heavy Equipment Maintenance Best Practices

Businesses, municipalities, and other public institutions invest significantly in heavy equipment. Tough conditions and challenging environmental factors can erode critical components, making heavy equipment less effective. They can also degrade assets, forcing costly repairs. 

It’s critical that employees protect these assets by performing routine and preventive maintenance practices. These help preserve machines’ lives, making them more efficient and reducing costs. 

Let’s explore some industry best practices to ensure your heavy equipment functions as intended for a long time. 

What types of heavy equipment need maintenance?

Heavy equipment is typically classified as machinery that can complete intensive work. Things like earthmoving, forestry, paving, inventory movement, and other types of work all need heavy equipment. 

Because of the nature of the work they complete, these machines need significant upkeep. Following industry best practices can extend the life of your heavy equipment for years. 

Here are some types of heavy equipment that need to be maintained. 

Dump trucks 

Dump trucks are a very common piece of heavy equipment. They are present on most construction sites and transport various materials like dirt, gravel, and waste. 

Pavers

A paver is an essential piece of heavy equipment for laying asphalt and concrete. Many organizations use them to create surfaces on bridges, roads, and parking lots. 

Backhoes 

A backhoe is another common piece of heavy machinery. It is used to excavate and dig ground. It’s made up of a digging bucket on an arm.

Boom lifts

Boom lifts, also known as cherry pickers, are essential for work above ground level. Regular maintenance of boom lifts is crucial to ensure safe operation at height. This includes inspecting hydraulic systems, checking for leaks, examining structural integrity, and examining safety mechanisms. 

Compactors

Compactors compress materials such as soil, gravel, or trash. Proper maintenance of compactors requires checking hydraulic systems, inspecting plates for wear, and ensuring proper alignment.

Multi-terrain loaders 

Multi-terrain loaders are versatile machines designed to operate on various surfaces, from soft soil to uneven terrain. Maintenance tasks for multi-terrain loaders include inspecting tracks, checking hydraulic systems, lubricating pivot points, and cleaning air filters.

Dozers

Dozers are powerful earthmoving machines used for tasks such as grading, excavation, and pushing materials. Routine maintenance of dozers involves checking blade edges for wear, inspecting the undercarriage, and ensuring hydraulic systems function.

Excavators

Excavators are versatile machines in various construction, mining, and landscaping projects. Maintenance of excavators includes inspecting bucket teeth and cutting edges, checking hydraulic fluid levels, and greasing pivot points.

Snow plows

Snow plows are essential equipment for clearing roads, parking lots, and other surfaces during winter weather conditions. Snow plow maintenance involves inspecting blades for damage and checking hydraulic systems.

Tow motors

Tow motors, also known as forklifts or lift trucks, are used for lifting and transporting heavy loads in warehouses, distribution centers, and manufacturing facilities. Tow motor maintenance includes checking brakes, inspecting tires, lubricating moving parts, and testing safety features such as horns and lights.

Utility vehicles 

Utility vehicles are used for various tasks, including transportation, maintenance, and recreational activities. Utility vehicle maintenance involves checking fluid levels, inspecting tires, lubricating chassis components, and testing electrical systems.

Skid steers

Skid steers are versatile machines commonly used in construction, landscaping, and agriculture for tasks such as digging, loading, and grading. Skid steers require inspecting hydraulic systems, checking attachment connections, and greasing pivot points.

Benefits of heavy equipment maintenance

There are many reasons to complete a comprehensive heavy equipment maintenance program. Regularly scheduled maintenance can extend machine lifespan, improve safety, increase efficiency, reduce costs, and enhance productivity. Here is how maintenance can improve each. 

Extend heavy equipment lifespan

Worksite machines are a significant investment, so it’s critical to make them last as long as possible. Most are built to last for years, but without proper care, they may not live up to their potential. By identifying and addressing potential issues early, maintenance procedures help mitigate major breakdowns and costly repairs, prolonging the machine’s lifespan. 

Improve safety 

Well-maintained machinery operates more reliably and reduces accident risk caused by equipment failure or malfunction. Additionally, maintenance tasks help identify and fix potential job site hazards before they impact assets or the workplace.

Increase efficiency 

Maintaining equipment helps it operate more efficiently, delivering optimal performance with less fuel consumption and downtime. Lubricating, calibrating, and cleaning help equipment function efficiently, maximizing productivity and minimizing operational costs.

Cut costs 

Preventive maintenance reduces breakdowns and the need for repairs. It also increases performance, lowering fuel consumption. Additionally, it prolongs equipment’s operational life, slashing replacement costs.

Reduce downtime

Unplanned equipment downtime can disrupt project timelines, leading to delays and increased costs. Regular maintenance helps identify potential issues early, allowing for proactive repairs and minimizing the risk of unexpected breakdowns. 

Heighten workforce efficiency

Well-maintained equipment contributes to a smoother and more efficient work environment, enabling employees to perform their tasks effectively. Reduced downtime means less idle time for workers and increased productivity. Additionally, operators are more satisfied when relying on machinery that operates safely and consistently.

Checklists for the maintenance of heavy equipment

To unlock the benefits of heavy equipment maintenance, employees must perform regular checks. These range from daily to yearly inspections to ensure machinery is in good working order. There is no shortage of things to remember when performing maintenance. Here are a few checklists to help you remember what to check on.  

Daily inspections

Pre-start checklist

• Inspect for any visible damages, leaks, or loose parts
• Check fluid levels (oil, coolant, hydraulic fluid, etc.)
• Ensure proper tire inflation and condition
• Verify that lights, signals, and safety features work

Warm-up inspection 

• Allow the equipment to warm up before operation
• Listen for unusual sounds or vibrations during startup
• Monitor gauges

Operation checklist

• Continuously monitor equipment performance during operation
• Pay attention to any unusual noises, vibrations, or warning indicators
• Keep track of fuel consumption and operating temperatures

End-of-day check

• Refill fuel levels as needed
• Idle the engine for a few minutes to allow it to cool down
• Inspect the equipment for any signs of wear or damage incurred during the day

Weekly heavy equipment maintenance checklist

Cab and component check-in

• Clean and inspect cab interior for cleanliness and functionality
• Check controls, switches, and instrumentation for proper operation
• Inspect key components such as brakes, steering, and suspension for any signs of wear or damage

Assess performance

• Review equipment usage and performance over the past week
• Identify any recurring issues or abnormalities
• Plan for adjustments or repairs based on observed trends

Monthly heavy equipment maintenance checklist 

Oil and filter changes 

• Schedule regular oil changes 
• Replace oil filters and perform a visual inspection of the engine for leaks or damage
• Inspect and replace air filters
• Check and replace fuel filters 
• Inspect air intake systems for obstructions or damage

Coolant check

• Check coolant levels 
• Inspect hoses, connections, and radiator for leaks or damage

Annual heavy equipment maintenance checklist 

Inspect hydraulics, transmission, and radiators 

• Conduct a thorough inspection of hydraulic systems for leaks, worn hoses, or damaged seals
• Check hydraulic fluid levels and top up or replace as needed
• Inspect transmission fluid levels and condition
• Test transmission operation through all gears to ensure smooth shifting and functionality
• Clean debris and dirt from radiators and cooling fins
• Inspect for any signs of corrosion or damage to radiator components

How maintenance management software helps 

There are countless tasks to manage in an operation that uses heavy equipment. Planning and scheduling heavy machine maintenance is critical for keeping technicians organized. 

Technology advancements have significantly impacted maintenance planning and scheduling. Solutions provide organizations with powerful tools to streamline processes and improve efficiency. Computerized maintenance management systems (CMMS) offer a centralized platform for managing tasks, tracking asset performance, and generating data-driven insights. Some of the ways they can help an organization with heavy equipment maintenance include:

Creating heavy equipment maintenance checklists 

In a CMMS, users can create equipment-specific checklists for employees to perform. These allow businesses to tailor their maintenance routines to their needs. Checklists are an essential part of any heavy maintenance management process.  

Managing inventory, consumables, and needed tools

To perform heavy equipment maintenance, businesses need to know what they have on hand. Often, heavy machinery requires fuel, spare parts, and special tools to complete tasks. With a comprehensive CMMS, businesses can track these critical components to ensure their employees have what they need. 

Improving processes, traceability, and accountability

Organizations lose up to $1.3 million a year due to maintenance inefficiency, according to a report by Formstack and Mantis Research. This includes heavy equipment maintenance. With a CMMS solution, organizations improve processes and traceability. Managers know exactly what’s been serviced and when. 

Centralizing communication

A good CMMS allows organizations to create a centralized communication hub. Employees can discuss heavy maintenance tasks with one another, eliminating the need for disparate systems. 

Leading organizations leverage FMX to help with heavy equipment maintenance

FMX offers a comprehensive asset management solution that simplifies the maintenance planning process and helps organizations achieve peak performance. FMX’s powerful tools and features streamline maintenance activities, improve asset management, and allow you to make data-driven decisions that lead to better outcomes.