No matter how diligent you are with maintenance, equipment breakdowns do happen. But minor issues don’t need to sideline your machinery. Here are some common problems operators face and tips to troubleshoot them efficiently.
Hard Starting or Stalling Engine
– Check fuel filter/tank for water or contamination and change as needed.
– Inspect battery connections and voltage. Replace the battery if weak.
– Test ignition components like spark plugs, coil, and wires for wear or gap clearance.
– Listen for injector pump issues on types of diesel or listen for fuel pumps on gasoline engines.
– Check engine oil level and condition. Change if dirty.
Loss of Hydraulic Power
– Inspect hydraulic fluid reservoirs. Top up levels if low.
– Check hydraulic lines and fittings for leaks. Tighten or replace worn parts.
– Test the hydraulic pump for normal output pressure. Rebuild or replace if worn.
– Check control valves aren’t stuck or leaking internally. Repair or replace.
– Bleed air from lines if any parts were disconnected.
Electrical Diagnostics
– Check all fuses and breakers. Replace blown items.
– Inspect wiring harnesses for cuts, abrasions, and loose connections. Repair as needed.
– Test key voltage components like the alternator, starter, and voltage regulators.
– Check battery charging voltage. Service alternator if not charging fully.
– Test switches and solenoids with a multimeter. Replace faulty components.
Brake or Steering Issues
– Inspect brake pads and shoes for wear. Replace worn parts.
– Check brake fluid level and bleed system if air has entered the lines.
– Test hydraulic brake pumps and valves. Repair or replace malfunctioning items.
– Inspect the Pullman arm, tie rods, and stabilizer links for looseness or wear. Tighten.
– Check the power steering fluid level and condition. Fill or flush old fluid.
Transmission Problems
– Check transmission fluid level and condition. Change fluid regularly per manual.
– Inspect drive belts for cracks or looseness. Replace worn belts.
– Listen for abnormal noises that could indicate worn gears or bearings inside.
– Consult the manual if error codes are present. May need ECM reprogramming.
Hydraulic Leak Diagnosis
– Inspect all hydraulic fittings, hoses, and cylinders for exterior leaks. Tighten or replace.
– Use a piece of cardboard to find a leak source on hoses or a light rag on fittings.
– Check O-rings and seals inside cylinders for wear rings. Replace seals.
– Test hydraulic components individually to isolate faulty sections needing repair.
Handling issues early prevents unnecessary breakdowns on job sites. With some basic tools and know-how, you can get most equipment running smoothly again in no time. Don’t hesitate to consult service manuals or professionals if stumped.