High Hours on Heavy Equipment: Risks and Maintenance Considerations

[MikePhua]

In the world of heavy equipment, machines that accumulate high operating hours are common, especially in industries like construction, mining, and agriculture. While these machines can still perform effectively even with substantial use, high hours come with their own set of challenges. This article explores the implications of high hours on heavy equipment, including the risks involved, how to assess equipment condition, and the importance of preventive maintenance.
Understanding Equipment Hours
In the context of heavy equipment, "hours" refer to the total time a machine has been operational, typically measured using an onboard hour meter. These hours are a key indicator of the equipment’s usage and are used to estimate the remaining useful life, determine when maintenance is due, and assess resale value.
Heavy equipment such as excavators, bulldozers, and skid steers generally have a long lifespan if maintained properly. However, as the operating hours accumulate, the equipment experiences wear and tear that can impact its performance and reliability.
Impact of High Hours on Equipment
As machines rack up high hours, several components experience increased wear, and performance can begin to degrade. Here are some of the effects:

1. Increased Wear on Critical Components
   Engines, transmissions, hydraulic systems, and other critical components of heavy equipment endure a considerable amount of stress over time. As hours increase, components such as the engine, seals, bearings, and hydraulics are more likely to need repair or replacement. The performance of the equipment may decline due to these worn parts.
   
2. Higher Maintenance Costs
   With high hours, maintenance needs tend to escalate. Routine services like oil changes and filter replacements will become more frequent, and there will likely be a need for more extensive repairs such as replacing pumps, valves, or even entire drive motors. As these repairs add up, the overall operating costs increase.
   
3. Decreased Resale Value
   Equipment with high hours tends to lose its resale value. Potential buyers often perceive machines with higher hours as less reliable, even if they are in good condition. High-hour machines might be sold at a significantly lower price than those with fewer hours, even if they have been properly maintained.
   
4. Increased Risk of Unplanned Downtime
   The risk of unexpected breakdowns rises as equipment racks up more hours. A machine that has been working for thousands of hours without significant repairs is more likely to encounter issues that could result in costly unplanned downtime. This can be especially detrimental in industries where time is of the essence.
   

Evaluating High-Hour Equipment
When purchasing or inspecting equipment with high hours, it’s essential to assess its condition thoroughly. Here are key factors to consider:

1. Maintenance History
   A detailed maintenance history is crucial when assessing high-hour equipment. Machines that have been regularly serviced with the proper parts and fluids are more likely to remain reliable, even after thousands of hours of use. Make sure that routine services, such as oil changes, filter replacements, and inspections, have been documented.
   
2. Visual Inspection
   Inspecting the machine visually can provide valuable clues about its condition. Check for excessive wear on parts like the undercarriage, tracks, bucket, and hydraulics. Listen for unusual noises during operation, and pay attention to any leaks or signs of stress on key components.
   
3. Engine and Hydraulic System Check
   The engine and hydraulic system are critical to the overall performance of the machine. Have a qualified mechanic perform a diagnostic check on the engine, hydraulic pumps, cylinders, and valves. Monitoring the engine oil, coolant levels, and hydraulic fluid can reveal underlying issues that might not be immediately apparent.
   
4. Inspection of Major Components
   Assess the state of components such as the transmission, drive motors, and final drives. These parts are expensive to repair and replace. It is important to check their condition, and ask if any major parts have been replaced or repaired recently.
   

Maintenance Tips for High-Hour Equipment
Maintaining high-hour equipment involves proactive efforts to prolong its useful life. Here are key maintenance tips:

1. Stick to a Strict Maintenance Schedule
   Preventive maintenance is crucial for high-hour machines. Follow the manufacturer’s recommended maintenance schedule to the letter. Regular oil changes, fluid checks, filter replacements, and inspection of key components like the cooling system and exhaust system can significantly extend the machine’s life.
   
2. Use Quality Fluids and Parts
   Always use high-quality oils, filters, and hydraulic fluids recommended by the manufacturer. Subpar products can lead to premature wear and decreased performance. Using original parts ensures compatibility and optimal performance.
   
3. Monitor System Performance
   Utilize diagnostic tools to monitor the performance of major systems, including the engine, hydraulics, and electrical systems. Modern equipment often comes with onboard diagnostic capabilities that can provide real-time data on performance and flag issues before they lead to major failures.
   
4. Address Minor Issues Promptly
   Don’t ignore minor issues such as small leaks or strange noises. Often, these can be early indicators of more significant problems. Addressing them promptly prevents them from developing into expensive repairs down the line.
   
5. Perform In-Depth Inspections Regularly
   For equipment with high hours, consider scheduling more frequent in-depth inspections. This could include the checking of major components like the transmission, hydraulic systems, and engine internals. Regular inspections can identify worn parts that need replacement before they cause a breakdown.
   
6. Proper Storage and Operation
   Proper storage and careful operation are key to reducing wear. Avoid overloading the machine, ensure it operates within its specified limits, and always store it in a clean, dry environment when not in use. This minimizes the chance of environmental damage or corrosion.
   

When Is It Time to Replace High-Hour Equipment?
Despite the best maintenance efforts, high-hour equipment will eventually reach a point where it is no longer cost-effective to keep it running. Some indicators that it might be time for a replacement include:

1. Costly Repairs Outweighing Value
   If the cost of repairing critical components is higher than the market value of the equipment, it might be time to consider a replacement. A decision to continue repairing the machine could lead to diminishing returns.
   
2. Frequent Downtime
   If unplanned downtime becomes frequent and the machine is constantly out of service for repairs, it may be time to replace it. Continuous downtime can significantly impact productivity and profitability.
   
3. Declining Performance
   As machines age, their performance can degrade, especially when it comes to fuel efficiency, speed, and load capacity. If the equipment is no longer able to meet the demands of the job, it might be better to invest in newer machinery.
   

Conclusion
High-hour equipment isn’t necessarily a dealbreaker, but it does require more attention and care. Proper evaluation and consistent maintenance can help ensure that even high-hour machines continue to perform effectively. By sticking to a regular maintenance schedule, addressing issues promptly, and knowing when to retire equipment, operators and fleet managers can maximize the lifespan of their heavy machinery and avoid the pitfalls that come with excessive wear.