4 Most Common Heavy Equipment Issues and How to Prevent Them

Machinery maintenance topics are of much importance to a Plant & Machinery valuer as well as owners /users for evaluating machine health.

(Originally inspired by insights from Stewart-Amos Equipment Co.)

Heavy equipment plays a vital role in construction, mining, and other industrial operations — but even the most durable machinery requires consistent care to remain reliable. Understanding common problems and their warning signs can help you prevent costly repairs, downtime, and safety hazards.

Below are four of the most common heavy equipment issues and practical ways to prevent them.

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1. Hydraulic System Problems

Hydraulic systems are the backbone of heavy machinery, powering lifts, arms, and other moving parts. However, these systems are particularly vulnerable to contamination.

Common Causes:

• Contaminants such as water, dirt, metal shavings, or dust can infiltrate hydraulic fluid during manufacturing or operation.

• If the system isn’t properly flushed, these particles degrade hydraulic fluid over time, reducing viscosity and load-bearing capacity.

• This degradation can cause overheating, poor performance, or even total system failure.

Prevention Tips:

• Replace dirty or clogged hydraulic filters regularly.

• Keep the system well-oiled and properly lubricated.

• Conduct periodic fluid testing to check for contamination.

• Use only clean, high-quality hydraulic oil recommended by your manufacturer.

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2. Electrical Failures

Electrical systems in heavy machinery are complex and sensitive. Failures can lead to performance issues, safety risks, and even fires.

Common Causes:

• Loose power connections can cause sparks or electrocution.

• Dust, moisture, and humidity often lead to short circuits or corrosion.

• Damaged insulation can trigger current leakage and system overloads.

• Power overloads occur when too much electricity flows through one part of a circuit, causing blown fuses, tripped breakers, or overheating.

Prevention Tips:

• Perform regular electrical inspections.

• Clean electrical components and housings to reduce dust buildup.

• Ensure all cables and connectors are properly insulated and secured.

• Train operators to recognize early signs of electrical stress or overheating.

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3. Undercarriage Issues

A machine’s undercarriage supports its weight and ensures stability — but it also bears the brunt of harsh terrain, heavy loads, and environmental stress.

Common Causes:

• Oil or hydraulic leaks from seals, bearings, or gaskets.

• Track damage caused by rocks, uneven terrain, or debris.

• Misalignment due to uneven loading or improper track tension.

• Insufficient lubrication increasing friction and wear.

• Overloading, which places unnecessary strain on undercarriage components.

Prevention Tips:

• Schedule regular undercarriage inspections for alignment, tension, and lubrication.

• Clean mud, rocks, and debris from the undercarriage after use.

• Avoid exceeding manufacturer-recommended load limits.

• Adjust preventive maintenance schedules based on site conditions such as rocky or steep terrain.

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4. Metal Corrosion

Corrosion and rust are silent destroyers, particularly in humid or wet environments. Over time, oxidation and chemical reactions can weaken metals, damage seals, and cause costly breakdowns.

Common Causes:

• Humidity and standing water promote rust formation.

• Lubricant oxidation produces organic acids that corrode metals like iron and zinc.

Prevention Tips:

• Store equipment in a dry, covered area when not in use.

• Apply anti-corrosion coatings or paints.

• Schedule regular inspections to catch rust early.

• Keep metal surfaces clean and well-lubricated.

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Signs Your Equipment May Need Repair or Replacement

Recognizing early warning signs can save you from unexpected breakdowns:

• Vibrations: Could signal loose parts, misalignment, or imbalance.

• Strange noises: Hissing, screeching, or grinding may point to hydraulic leaks or mechanical issues.

• Dashboard warning lights: Indicate low oil pressure, high hydraulic temperatures, or electronic control errors.

• High fuel consumption: May suggest an engine issue, clogged filters, or underinflated tires.

• Engine stalling: Could result from a weak battery, airflow issues, or hydraulic malfunctions.

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Final Thoughts

Preventive maintenance is always cheaper and safer than emergency repairs. By keeping up with regular inspections, fluid checks, and cleaning routines, you can dramatically extend the lifespan of your heavy equipment and ensure it performs reliably on every job.

If your machinery shows any of the warning signs listed above, don’t wait — schedule professional servicing before small issues turn into major failures.