Pit & Quarry • April 2024 • EXCAVATING & LOADING

Construction equipment must handle tasks like drilling, blasting and moving material on these sites. Equipment is subjected to extra stress due to high temperatures, dust and uneven terrain.

Inadequate maintenance in this environment can accelerate wear and result in unplanned downtime, necessitating repairs and compromising safety for operators and others in the quarry. Given the demanding nature of these tasks, it’s essential to mitigate potential hazards through proactive maintenance practices.

Here are a few key summer maintenance considerations for crawler excavators operating at quarries.

The cooling system is essential for regulating an excavator’s engine temperature and preventing critical components from being damaged by excessive heat.

“Radiators should be inspected for damage, corrosion or debris buildup that could obstruct airflow and cooling efficiency,” says Jacob Sherman, product and dealer marketing manager at Develon. “Coolant levels should also be monitored regularly and topped off as needed with the appropriate coolant mixture recommended by the excavator manufacturer. The coolant should be at the correct concentration to provide adequate heat protection, especially in regions where temperatures can fluctuate.”

Inspect an excavator’s hoses for signs of wear or damage to prevent coolant leaks that can lead to overheating or engine damage. Any worn or damaged hoses should be replaced.

Cooling fans and fan belts should also be checked regularly to ensure optimal performance.

“Over time, fan belts can become worn or loose, affecting the efficiency of the cooling fan,” Sherman says. “Replacing worn fan belts and adjusting belt tension as necessary can help prevent cooling system failures and ensure consistent airflow.”

Monitor engine temperature gauges and be aware of signs of overheating, such as steam or coolant leaks. In the event of such indicators, shut down the excavator and allow it to cool down before addressing the issue.

As a general rule, it’s advisable to wait at least 30 minutes to an hour to allow an engine to cool down sufficiently.

Dust is a common occurrence at quarries, posing a risk of buildup that can impair the performance of excavators and their internal components and systems.

“Clean the excavator’s air filtration system regularly to help prevent dust buildup and maintain optimal airflow to the engine and other critical components,” Sherman says. “Be sure to inspect air filters, air intake systems and engine compartments to prevent clogging. If these systems become clogged, it can lead to reduced engine performance, overheating, increased fuel consumption, potential damage and safety risks.”

Dust accumulation can adversely affect bearings, joints and other moving components, resulting in increased friction, heat and accelerated wear. To prevent the accumulation of dust particles, it’s important to lubricate moving parts regularly.

“Applying appropriate lubricants and greases according to the manufacturer’s specifications can help minimize friction, guard against corrosion and prolong the service life of critical components,” Sherman says. “Adhering to recommended lubrication schedules is essential and, when necessary, utilizing high-temperature grease can further extend the lifespan of components.”

The excavator’s undercarriage is subjected to heavy loads, abrasive materials and uneven terrain in quarry operations. To optimize performance and minimize premature wear, it’s essential to regularly check track tension and adjust it to the manufacturer’s specifications.

It’s also crucial to inspect the rollers, idlers, sprockets and track shoes. Any indication of wear, damage or misalignment should be promptly addressed to prevent further damage.

“Maintaining a clean undercarriage, free from debris, is vital to safeguarding track components from abrasive materials and minimizing wear,” Sherman says. “Regularly clearing mud, rocks and other debris from the undercarriage and track links helps prevent buildup and reduces the risk of damage to rollers, idlers and sprockets. Damage to these critical components can result in reduced machine performance, increased wear, risk of failure of the undercarriage system, costly repairs and safety hazards.”

The hydraulic system is responsible for digging, lifting and moving heavy loads. Regular inspection of hydraulic hoses, seals and connections is necessary to detect leaks, prevent system contamination and maintain optimal hydraulic fluid levels and pressure.

“Inspecting hydraulic fluid levels and periodically analyzing fluids to monitor contamination levels can help prevent equipment damage and maintain the hydraulic system,” Sherman says. “Also, proper hydraulic fluid temperature is essential, especially in hot summer conditions. Overheating of hydraulic fluid can lead to reduced viscosity, decreased lubrication and accelerated wear.”

Electrical components power lighting, instrumentation, controls and auxiliary systems. Elevated temperatures can expedite the wear of these parts, including wiring insulation, connectors and electrical insulation.

“Inspect electrical connections, terminals and wiring regularly for any indications of wear, corrosion or damage,” Sherman says. “This proactive approach helps prevent electrical malfunctions and potential safety hazards.”

The heat can also affect battery performance, causing the battery to lose capacity more quickly than it would at lower temperatures. Inspect the battery terminals for corrosion, and check battery fluid levels to maintain battery life and prevent starting problems or electrical system failures. If there is corrosion, disconnect the battery and clean the terminals with a brush or a mixture of baking soda and water.

Excavator operators working in quarries during the summer months must adhere to safety regulations to ensure a safe and secure working environment.

“Check safety features such as rollover protection structures, falling object protective structures and seat belts to make sure they are in good condition and functioning properly,” Sherman says. “By inspecting these components and adhering to safety regulations, we can maintain a safe working environment for everyone.”

It’s also a good idea to inspect air-suspension seats and cooled seats, which help enhance operator comfort during quarry work.

Properly trained operators are essential to maximize equipment performance, ensure safety and minimize downtime.

“All quarry excavator operators should be trained on summer-specific maintenance procedures, as well as how to recognize signs of equipment stress or malfunction,” Sherman says. “Training should include basic excavator operation, including machine controls, functions and operating procedures specific to quarry applications.

“In addition, they should be aware of safe work practices and communication protocols with other personnel and equipment operators,” he adds. “Operators should be familiar with safety features like rearview cameras and around-view monitor camera systems if the machine is equipped with these technologies.”

By prioritizing maintenance, operators can work with confidence in the summer months, maximizing their productivity and profitability at quarries.

Allison Grettenberg is PR and content strategy specialist at Two Rivers Marketing.