It has been said that eating breakfast is the most important meal of the day. Incorporating it into your morning routine refuels your body, jump-starts your day and lays the foundation for long-term health benefits. The morning routine you perform with your full-size excavator is equally important to the health of your machine. What you do during the first 15 to 30 minutes of each day pays big dividends in terms of increasing productivity, maintaining residual value and lowering operating costs.
Key areas for preventive maintenance fall into three main categories: engines, hydraulics and undercarriage systems. A detailed timeline of scheduled maintenance for each area can be found in your owner’s manual. As Bill Metzger, product sales instructor at Doosan Infracore, notes: “A lot of money goes into research, development and engineering to determine at what intervals filters are to be changed, what items are to be greased and at what hour interval. Planned maintenance is always less expensive than reactive maintenance.” For a broader look, explore our equipment maintenance management strategies for construction sites.
Engine Maintenance in the Daily Excavator Check
Maintenance has become increasingly important with the move to Tier III and Tier IV engines. These newer engines are more susceptible to damage caused by contamination. A filtration system for today’s high-pressure fuel and sensitive pumping systems goes down to as low as 2 microns, compared to no limit for earlier models. Contractors need to stick with manufacturer recommendations to get the best life out of the engine, fuel and hydraulic systems.
Fluid Checks and Filter Changes
Make sure the oil and fuel are kept clean by changing filters and fluids as recommended. Between changes, check fluid levels daily and top off as needed. Many manufacturers have incorporated features to make fluid checks quick and simple. Adrian Hall, market development manager at JCB, Inc., explains: “We have done a lot to make daily checks simple so contractors can easily perform maintenance tasks. They are all available from ground level. Our oil checks are part of the startup sequence.”
Oil Sampling Programs
Oil sampling is crucial to keep today’s engines functioning at peak levels. According to Metzger: “The greatest asset to any contractor is to get their excavators on an oil-sampling program. When implemented correctly, the analysis you receive from the lab will let you know ahead of time if something needs to be addressed. It also allows any potential problem to be addressed before the situation is catastrophic, and keeps repair costs to a minimum.” Maintaining good records, including oil sample reports, also adds value at trade-in or resale time.
Warm-Up Procedures and Cooling System Care
As part of daily engine maintenance, leave sufficient time to properly warm up the machine, especially in colder climates. Drawing high RPMs or power out of a cold engine can cause significant damage. Many modern excavators feature auto warm-up systems that run a cycle of up to 20 minutes to warm both the hydraulics and engine prior to operation. In high ambient temperatures, ensure the engine does not run too hot. Running repeatedly in overheat mode can damage or distort expensive engine and hydraulic components.
The best way to keep coolers clean is to blow them out with an air hose. Using water runs the risk of dirt turning into a solid when it dries. If you work in a very dusty environment, coolers should be blown out every day. For general applications, clean them at least once a week.
| Maintenance Task | Daily | Weekly | Per Service Interval |
|---|---|---|---|
| Engine oil level check | Yes | – | – |
| Coolant level check | Yes | – | – |
| Fuel filter inspection | – | Yes | As specified |
| Oil sampling | – | – | Per manual |
| Cooler cleaning (dusty site) | Yes | – | – |
| Cooler cleaning (normal site) | – | Yes | – |
| Fuel/water separator drain | Yes | – | – |
| Air filter inspection | – | Yes | – |
Hydraulic System Inspections for Peak Performance
If an engine is the heart of the machine, then the hydraulic system is its circulatory system. Though hydraulic fluid does not need to be changed as often as engine oil, fluid levels must be checked frequently. When dealing with servo lines feeding into the joysticks, any form of contamination can cause the machine to not work efficiently. Clean oil equates to reliable hydraulics. Some manufacturers now fit ultra-fine in-line kidney filter systems that eliminate debris greater than 1 micron and extend hydraulic oil changes to 5,000 hours.
Understanding Service Intervals
Many hydraulic oils have service intervals of roughly 2,000 hours. However, the application makes a significant difference:
- Standard excavation: Hydraulic fluid changes at 2,000 hours or per manufacturer specification.
- Demolition with breaker attachment: Change hydraulic fluid at around 1,000 hours. Hammering causes shock damage to the oil, breaking it down twice as fast.
- Extreme temperature climates: May require more frequent hydraulic oil changes to maintain proper viscosity for the conditions.
In climates where temperatures drop well below zero, normal oil becomes too thick. A low-viscosity oil ensures flow at lower temperatures. If the oil is too thick, the machine takes longer to warm up, may be slower to operate, and risks cavitation in the hydraulic system which can damage the main pump.
Hose and Component Checks
Pay attention to hoses during your morning walk-around. Be aware of the burst pressure of any hoses you replace. Your best bet is to buy OEM components to ensure a proper fit. Integrating telematics into your construction equipment fleet management can help track maintenance intervals and alert you to developing issues before they become failures.
Undercarriage Preservation Through Routine Checks
The undercarriage of a full-size excavator accounts for about 20 percent of the total cost of a new unit. Maintenance and replacement costs over the unit’s life account for about 60 percent of total costs. Therefore, it is essential to preserve the undercarriage for as long as possible. The downtime to replace undercarriage components is usually long, and many contractors cannot afford extended machine downtime. Adopting preventive maintenance strategies for construction equipment is key to managing these costs.
Track Tension and Bolt Torque
Checking bolt torque, track tension and alignment are key areas. Bolt torque is most important during the first 100 hours of operation and every time you change track pads or shoes. Track pads are most vulnerable in hard rock applications. Once the pad is gone, so is protection for the chain surface. If left too long, damage occurs to the track chain surface where the pad mounts.
Check track tension to ensure tracks are not too tight or too loose. If too tight, components wear out prematurely. If too loose, the track chain may slide out of the guide. Typically, you want a sag of about 1 to 2 inches, varying by site conditions:
- Rocky conditions: Tighter track tension to prevent side-to-side movement.
- Soft or swampy conditions: Looser track tension to reduce ground pressure.
- Standard earth: Follow manufacturer sag specifications for general applications.
Roller, Idler, and Sprocket Alignment
The rollers, idlers, springs, chains and sprockets should work as one entity. If the front wheel is misaligned, the chain will not follow in a straight line, resulting in uneven component wear. The heavier the machine, the greater the risk of misalignments. Have your dealer check alignment when the machine is serviced. Steel working against steel means guides will wear over time and may need replacement. Pay extra attention when working in rock or demolition applications.
Cleaning and Severe Application Care
Cleaning the tracks extends undercarriage life. If tracks are not cleaned regularly, material builds up and can prevent rollers from turning, especially carrier rollers. Use a shovel to remove mud and dirt buildup. Pay special attention to the top, which is more susceptible to buildup. Clean tracks at the end of every shift and before traveling long distances. In abrasive environments such as wet sandy conditions, an enhanced maintenance program with reduced lead time between checks is necessary. For more on heavy machinery care, read about heavy construction equipment selection and maintenance best practices.
Building a Sustainable Morning PM Program
Implementing a consistent morning preventive maintenance routine for your excavator delivers measurable returns across the life of the machine. By focusing on engine health, hydraulic system integrity, and undercarriage preservation, operators can reduce unplanned downtime, lower repair costs, and maintain strong resale value.
A successful morning PM program includes the following steps:
- Walk-around inspection: Check for visible leaks, loose bolts, damaged hoses, and worn track components.
- Fluid level verification: Confirm engine oil, coolant, hydraulic fluid, and fuel levels.
- Cooler and filter check: Inspect coolers for debris and check air filter restriction indicators.
- Warm-up cycle: Allow the machine to run through its warm-up sequence before heavy work.
- Track inspection: Verify track tension and look for damaged pads or leaking rollers.
- Record keeping: Log all checks and note abnormalities for follow-up during scheduled maintenance.
Many manufacturers have incorporated reminder systems into machine CPUs for oil changes, filter changes, and other service tasks. These integrated systems, combined with a disciplined morning walk-around, ensure small issues are caught before they become expensive problems. Planned maintenance is always less expensive than reactive maintenance.