5 Common Construction Equipment Repairs

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Equipment maintenance is essential to running a construction site. The global market for these construction vehicles and diesel parts is expected to be worth $237.66 by 2030. Mechanical issues and equipment failures can lead to expensive delays when the financial stakes couldn’t be higher. These vehicles contain an inordinate amount of power and are capable of hauling, lifting, demolishing and bulldozing thousands of pounds of raw materials.

They’re also the leading cause of accidents and injuries. According to the Occupational Safety and Health Administration, vehicles and equipment in the work zone are involved in over half of the worker fatalities in the construction industry. Learn about some of the most common construction equipment repairs and how to schedule them on your time.

Common Construction Equipment Issues

Dead Battery

The battery that powers the electrical components will gradually eventually lose efficiency and power. It activates the glow plugs, which heat air and fuel to trigger combustion. Cold weather forces the battery to work harder, leading to longer start times and reduced performance. Excess moisture can damage the terminals, causing corrosion.

Solution:

Check the battery for damage and test the voltage regularly. Replace aging units to avoid getting stuck with a dead battery.

Leaking EGR Cooler

Diesel engines use exhaust gas recirculation (EGR) coolers to recycle exhaust gas through the engine, reducing hazardous emissions. The cooler lowers the temperature of incoming exhaust gas before it enters the engine. Heavy hauling can overwhelm the system, leading to cracks and leaks. If the exhaust gas is too hot, it will burn the fuel before it can be converted into mechanical power.

Solution:

Check for blue smoke leaking from the exhaust, which means the EGR is leaking coolant. Monitor fuel efficiency to see if the engine burns more fuel than usual. If you suspect damage, inspect the cooling mechanism for cracks. Replace the EGR cooler on aging equipment to reduce fuel consumption.

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Clogged Injection Pump

Poor-quality fuel spreads debris through the fuel system. The fuel injector pump supplies fuel to the injectors, which pressurize the fuel to ensure it burns entirely and efficiently inside the combustion chamber. Dirt and dust can sneak into fuel containers sitting around the construction site. Exposing fuel to extreme temperature changes can lead to water separation inside the tank or storage container, exposing these passageways to oxidation. Metal shavings and other contaminants can choke the injector pump and injectors, cutting power to the engine. Efficiency will lag until these parts clog entirely.

Solution:

Monitor fuel efficiency, acceleration and pressure to assess the condition of the fuel system. Remove the injectors and replace them if they look rusted. If they continue to clog or pressure remains low, replace the injection pump and injectors to improve the flow.

Broken Belt or Chain

Belts on compressors, alternators and pumps can easily fray after many hours of use. The material can also lose tension, throwing off the gear timing or position of materials. Chains and gears also rust when exposed to moisture.

Solution:

Inspect these components at the start and end of every shift. Cover exposed gears and chains from elements when not in use. Replace belts with worn or frayed edges to avoid losing materials.

Flat or Worn Tires

Construction tires have thick tread patterns to gain traction in the dirt, mud and snow. Riding over obstacles can wear down the grooves, making it harder for the driver to control the vehicle. Worn and under- or over-inflated tires can easily get stuck after a storm, forcing another vehicle to tow it out. Sharp objects like screws and bolts can also penetrate the rubber, causing a flat.

Solution:

Replace aging tires as the tread wears down. Check air pressure at the start and end of each day and optimize your psi levels for the terrain. Keep driveways clear of debris and encourage drivers to watch out for obstacles. Rotate tires to balance out tread wear and tear.

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Minimize Disruptions with Preventative Maintenance

Preparing for your parts to fail will help minimize equipment downtime. Construction vehicle lifespans vary widely based on the terrain, application, maintenance and load weight. Each component also has a set shelf-life. Keep commonly replaced diesel parts on hand to replace aging parts before they break down. Swap them out at or before the recommended service interval to maximize fuel efficiency and performance.

Your employees should visually inspect and test every piece of equipment at the start of each shift to ensure it’s safe to operate. Schedule routine service inspections regularly throughout, before and after every job. Create an itemized list of the required service intervals, including regular fluid and filter changes. Older vehicles need more frequent oil and filter changes because they contain more debris.

Planning for maintenance will help you and your crew do the job quickly and safely. Everyone should watch out for strange sounds, smells, smoke and other performance issues that can make these vehicles unsafe to operate. Make time for regular inspections onsite to save time in the long run.