Top 5 Most Common Heavy Equipment Issues

1. Hydraulic System Failures

Hydraulic systems are essential in many heavy machines, powering everything from booms and blades to steering and braking. When the hydraulic system fails, the machine is effectively paralyzed.

Common Causes:

• Contaminated fluid: Dirt, water, or metal shavings can wreak havoc on seals and valves.
• Hose or seal failure: Even a small crack in a hose can result in massive pressure loss.
• Overheating: Excessive temperatures degrade fluid and damage components.

Symptoms:

• Sluggish or unresponsive hydraulic actions
• Unusual whining or hissing sounds
• Visible fluid leaks

Prevention:

Implement a strict preventive maintenance schedule. Regularly inspect and replace filters, check fluid levels, and perform hydraulic oil analysis. Ensure your operators understand the signs of pressure loss and overheating.

2. Electrical System Malfunctions

Modern heavy equipment is packed with electronic components — from sensors and switches to full-blown ECM (Engine Control Module) tuning systems. When these fail, diagnosing the root cause can be a challenge.

Common Causes:

• Battery failure due to vibration or improper mounting
• Faulty alternators or starters
• Wiring damage from rodents or physical abrasion

Symptoms:

• Unpredictable startup behavior
• Warning lights or false fault codes
• Loss of function in critical systems (lights, instruments, actuators)

Prevention:

Secure all wiring with proper routing and insulation. Invest in mobile diagnostics tools for quicker pinpointing of electronic issues. Battery terminals should be corrosion-free, and alternator output should be routinely tested.

3. Undercarriage and Track Wear

In tracked equipment like excavators, dozers, and compact track loaders, the undercarriage typically accounts for 50% of the machine’s lifetime maintenance cost.

Common Causes:

• Poor operator habits (e.g., sharp turns on hard ground)
• Improper tensioning of tracks
• Debris build-up around rollers and idlers

Symptoms:

• Uneven wear patterns on tracks or pads
• Noisy operation when moving
• Reduced traction or tracking issues

Prevention:

After each shift, inspect the undercarriage for damage or wear. Clean off mud and debris to reduce abrasion. Make tension adjustments per the manufacturer’s specifications and avoid unnecessary pivot turns on high-friction surfaces.

4. Cooling System Problems

Cooling systems are essential to prevent overheating of the engine and hydraulic systems. A failure here can bring operations to a screeching halt and cause catastrophic damage to vital components.

Common Causes:

• Blocked or dirty radiators
• Faulty fan clutches
• Leaking coolant hoses or damaged water pumps

Symptoms:

• High engine temperatures
• Coolant leaks or puddles under the machine
• Overheating alarms or automatic engine shutdowns

Prevention:

Flush the coolant system as recommended and always use the correct coolant mix for the application. Check for cracked hoses, deteriorated belts, and clogged radiators. Ensure the thermostat and fan clutch operate correctly under load conditions.

5. Brake System Degradation

Brake systems in heavy equipment — especially those utilizing air brake systems — are vital for operator safety. Brake failure isn’t just a repair bill — it’s a serious hazard.

Common Causes:

• Moisture or contaminants in the air system
• Worn-out brake shoes or cracked drums
• Malfunctioning slack adjusters or service chambers

Symptoms:

• Spongy or slow braking response
• Hissing air leaks near wheels
• Increased stopping distance

Prevention:

Drain air tanks daily to remove moisture buildup. Conduct full brake inspections during regular service intervals, including measuring drum wear and testing spring brakes. Don’t overlook the importance of properly adjusted slack adjusters.

Keep Your Equipment in Top Shape

Heavy equipment is designed to take a beating, but without proper attention and proactive care, even the most robust machines will suffer breakdowns. By recognizing the signs of common heavy equipment problems — hydraulic failures, electrical issues, undercarriage wear, cooling malfunctions, and brake degradation — operators and fleet managers can keep downtime to a minimum.

If you require heavy equipment preventive maintenance in Somerville, NJ, reach out to our team at Altus Equipment Company today.