Skip to content

Maintenance is Key for Heavy Machine Engines

Heat, cold, rain, humidity, mud etc leading the machine to go through heavy wear and tear and also affect the machine’s performance. Depending on the working conditions and operators, different problems may arise in the machine. Here are some obvious and rather interesting reasons why maintenance is key for heavy machine engines.

Safety: Heavy machines are cost intensive assets that take a rather long period of time to recover the original investment and record profits. Keeping this in mind safety of the machine, people operating the machine and of those working around the machine becomes imperative. Preventive and regular maintenance is a must to ensure safe working of the machine. It saves cost on having to deal with broken/ damaged parts and human injuries that can possibly be involved due to lack of maintenance.

Keep an eye: Most damage to heavy machines comes from being used by unskilled operators. Keeping a track of usage data one can figure out as to when the machine is being used by inadequately skilled operators. These days machines come with GPS trackers and inbuilt data collection softwares that record and monitor all data about the machine for analysis in the future. Preventive maintenance helps catch problems in the bud with regular data analysis.

Regular parts check: Checking parts of the machines on a regular basis helps keep an eye on the wear and tear of the parts and remedy the situation as required. Regular check ups help replace damaged parts before they cause bigger problems and can be repaired in case it is a better suited option. Most major costs and damage to the machine comes from not catching damaged parts in time before major damage is caused to other parts of the machine.

Cost saving: Regular maintenance is a must since it helps save costs by trouble shooting when the costs involved are much lesser in the beginning of the problem. While most machines require an insurance, it can become void if the machine is not adequately maintained. Not being able to claim insurance in case of accidents occurring due to an unmaintained machine is a big hole in the pocket adding to the costs.

Store safe: Heavy machines are exposed to different working conditions and have enough of their working parts exposed to the damage from environmental factors. Such exposure can lead to contamination of the lubricants, there by causing sizeable problems and damage if not caught in time. Cleaning the machines after using them and storing them in a enclosed storage space can help prevent down time, damage and huge repair/ replacement costs.

Given the rather sub par conditions of use, operations and storage that these heavy machines are subjected to, maintenance is quite literally the golden key to making the most of these amazing heavy machine engines.

How to Replace a Hydraulic Hose

Most heavy equipment and farm equipments use hydraulics to create and exert the required power for executing heavy duty jobs like digging, breaking, paving, lifting of heavy material etc. The hydraulic system usually consists of hydraulic cylinders, pumps and valve spools in various combinations. This arrangement is usually connected and interconnected with a number of steel tubes and steel reinforced rubber hoses. Given the natures of work of the machines and the high pressure that this arrangement is subjected to, the hydraulic oil is bound to leak at some point of time or the other. Leaking hydraulic oil is an indication that the hose or hoses need to be replaced.

Steps to replace a hydraulic hose

1. Locate the leak: Before one goes about replacing a hose, one has to be sure about the exact hose that is leaking and its location before starting with the rather messy procedure. Follow the oil leak back to its source using a cardboard, paper or a leak detection kit, never any of you body parts.

2. Make note when dissembling: The hydraulics are a complex assembly with various small and big components. Keeping this fact in mind its best to make note and mark the components in the order that they are removed. Failing to do so may cause difficulties when reassembling the set up.

3. Check for live load: Before getting to work ensure that the hose in question does not have a live load. The attachments need to be placed down and the hoses decompressed before opening them up. Opening hoses under pressure will cause the oil to gush out and spilling all over.

4. Gear up and clean up: Gear up with all the required set of tools that may be required to get the job done at the earliest possible. Remove any components that are not required or can cause difficulty when replacing the hose.

5. Removing the hose: It is a delicate job and must be done with caution. As required, loosen the parts and unfasten the hose on both ends before pulling to remove it. Ensure that no parts are damaged when extracting the hose in question. The fitting that remain attached should be coved appropriately to keep debris from entering the system.

6. Replace with original parts: Use an original replacement from the OEM so that the hoses are proper fits and compatible. Using low quality products can significantly damage your machine.

7. Clean up: The new hose and the existing assembly both need to be clean of any debris which can possibly damage the system. All oil and dirt on the outside of the components should be cleaned properly.

8. Reassembling: Carefully reassemble the components in their proper place and tighten the fittings all the while making sure that everything is properly aligned and is a snug fit. Do not remove any parts or add extras.

9. Final check: Before concluding the job, check the fluid levels and do a final check for any leaks and trapped air bubbles. If required make the necessary changes in case a problem is noticed.

Backhoe Loader Inspection Checklist

So, here is an inspection checklist that you can follow to purchase the right BHL (used or new) for your construction site…

Backhoe loader inspection checklist

1. A no-start engine or an engine that starts with difficulty – Take your time and have the sellers explain all the controls in detail. Make sure that you try every speed and movement. If it’s really cold, then expect some smoke. If there is excess smoke emission, then it is an indicator of poor maintenance or some default within the machine. If this is the case, then don’t prefer buying that BHL.

2. Leaking fluids under the machine – Make sure that you thoroughly check along the backhoe loader and the cylinders. Also, check all the hoses or arms. As the machinery wares off, oils and lubricant begin to leak from the arms, hoses, cylinders and engine as well. This may impact the speed of the machine and you will have to call for repairs more than often, resulting in unnecessary delays. So, one should look at the equipment carefully before buying it.

3. Coolant in the oil or oil in the coolant – This is a sign of an engine that will cause nothing but wasted time for you. So, examine the equipment thoroughly.

4. Welds on the backhoe, loader arms or buckets – Machinery constantly gets beaten up until it breaks and then it’s welded. A weld is never as strong as the original steel, plus the hard abuse may cause other trouble that you wont be able to notice at first glance. So, check the machine thoroughly.

5. Strange noise or incorrect behaviour of the brakes – Test the working of the brakes as sometimes the original ones are replaced by cheap quality ones. This may result in incorrect behaviour or strange noises, thus hampering the work at jobsite. So, you need to start the machine and check the noise level. If the engine makes strange noise, then it means that the machine may not give good results.

6. Poor hydraulics: The hydraulic excavator system is responsible for the efficient operation of many moving parts of BHL. If the hydraulic system of the machine is strong, then it will work for long and demand less maintenance. So, observe the machine carefully and check all the hydraulic components such as movement of the arms and swings, working of the joysticks, boom, arm and bucket functions. Difficulty in steering, high fluid temperature and fall in pressure are some hydraulics related issues which can be spotted and sorted well-in-advance.

In a nutshell

Apart from the above mentioned inspection list, one also needs to look at the overall structure and exteriors of the equipment. For example, you need to check the loader bucket and its components thoroughly, inspect the backhoe boom, stick and bucket, pay attention to the tyres and underneath and finally check the cab and other general operation of the BHL. Also, taking a close look at the stabilizers for any signs of leaks, damage, cracks or dents is necessary. Majorly, it is the maintenance of the equipment which defines its future usability and effectiveness. So, select the equipment with caution.

How to Safely Maintain Your Backhoe Loader?

Hence, it is very important to maintain your BHL so as to get the most from your investment and see the machine utilised to its maximum capacity.

Here are six tips that can make maintaining your equipment simpler and easier…

How to safely maintain your backhoe loader?

1. Follow a maintenance schedule: In order to keep a tap on the maintenance requirement of the equipment, you need to create and follow a maintenance schedule which would have notations on how often each part of the machinery should be inspected for problems, repairs and general maintenance. You need to be consistent with the maintenance schedule and inspect the equipment thoroughly.

2. Ensure proper cleaning of BHL: This is necessary to ensure that the dirt and debris do not damage the delicate parts of the BHL and result in costly repairs. For this, after you are done with the day’s work, clean the parts that made the most contact with the soil and debris. Also, ensure that the engine oil and hydraulic fluid system stays clean. The mantra is the cleaner you keep your BHL, the better it will perform.

3. Always keep the BHL properly greased and lubricated: Proper greasing of all moving parts of the equipment is also absolutely necessary in order to save them from failing to work and creating excess friction leading to severe wear and tear of the machinery, frequent breakdowns and shorter life span. If you hear noise coming from the system pins, bushings, bearing joints etc., you need to grease those parts. There can be several joints that require daily or weekly greasing schedule, so you need to take care of that. Further, too little as well as too much lubrication can be harmful for the machine. So, you need to lubricate the equipment wisely with the recommended grade of grease.

4. Regularly check the tyres of BHL: Another step for safely maintaining your BHL is making sure that each tyre has the right pressure as this can help in lessening tyre wear, improve stability and reduce the fatigue of the operator. Also, you need to check for any cuts and replace the tyres when needed.

5. Pay proper attention to wear and tear: You also need to watch out for signs of wear and tear as they can cause machinery to malfunction or result in costly repairs or component replacements before your regular inspection. Particularly, check all the components that make contact with the ground for wear and tear. These may include bucket pins and bolts, swing pins and backhoe hoses. Some common signs of wear and tear are vibration, heat, belt shape and leaks. Fix these wear and tear issues as soon as possible.

6. Give proper training to the operators of BHL: Last but not the least, one of the important ways to protect the equipment is to make sure that operators have all the required skills to operate the BHL. Without proper training, operators can damage the machinery or even injure themselves or others.

The above mentioned few tips for maintenance of BHL may seem like a lot of work but it is sure that these extra efforts will pay off well in future as well-maintained equipment can deliver more uptime and efficiency.

How to Repair Backhoe Hydraulic Cylinder?

Occasionally, these hydraulic cylinders need to be repaired because of leaking seals around the piston rod. Every time, rushing to the repair shop may cost a lot of money and long waiting hours.

To solve this problem, we help you rebuild and repair the backhoe hydraulic cylinders without taking any professional help. Even if you are not experienced in this field, below mentioned tips and tricks can guide you through the steps needed to repair the backhoe hydraulic cylinder.

How to repair backhoe hydraulic cylinder?

1. Remove the yoke from the stabilising jack stand and take it out by pulling the retaining pins. Keep it on the ground and place a board or some non-metal object beneath the cylinder to keep it steady and away from any dirt getting on to the parts.

2. Remove the gland in the hydraulic cylinder by loosening the hydraulic lines to allow release of the fluid pressure and prevent a vacuum which can make removal of the piston more difficult.

3. Unscrew the gland and remove the piston rod from the cylinder.

4. Use a sturdy surface to attach the piston rod and yoke in order to unscrew the retaining bolt from the piston rod. Use original yoke connection if possible.

5. In order to keep the retaining bolt from vibrating loose, a thread locking substance should be used.

6. Heating of the end of the retaining bolt may be necessary, before you can get it to break free from the threads.

7. After the removal of the retaining bolt, the piston and gland could be separated from the piston rod easily.

8. These pieces should then be placed on a clean surface at a comfortable working height and seals from the hydraulic cylinder rebuild kit should be checked to ensure that they are of correct size and dimensions.

9. For reassembling the piston to the rod using a thread locking adhesive when replacing the piston rod bolt, reverse the whole process. Oil all the parts well and if needed, use a piece of wood on the rod when tapping the piston back into the cylinder.

10. Screw the glands back into the cylinder. Replace the hydraulic lines and test for leaks around the new seal.

General tips

  • Safety is an important factor while repairing the backhoe hydraulic cylinder. Hence, be careful and do not be in a hurry to do any task. Take time to study the backhoe hydraulic cylinder that needs to be repaired.
  • Remember not to scratch the piston rod or any the parts of the assembly because it may lead to new seals wearing out quickly.
  • By extending the hydraulic cylinder to its full length before removing the gland will save you the trouble of having to pull the piston rod very far to remove it.
  • Keep the hydraulic cylinders straight through some support while removing the piston rod.
  • Try to keep the piston rod from falling into the dirt or against other metal objects when it pulls out of the cylinder.
  • Protect all the parts as otherwise you might have to spend a huge amount on procuring new parts.

How to inspect a backhoe loader

So, here are some inspection tips that you can follow to purchase the right BHL (used or new) for your construction site…

How to inspect a backhoe loader?

1. Check loader bucket and its components thoroughly- Inspect the loader bucket carefully and pay close attention to the leading edges, thickness of the bucket side panels, the condition of bucket bottom and bucket teeth.

2. Check the backhoe boom, stick and bucket: Looking at the overall condition of the backhoe bucket is also necessary. You need to inspect the backhoe boom and stick for any cracks or bends. You also need to ensure that the overall dig depth of the backhoe is the maximum as per your requirement.

3. Check the hydraulic system and engine: The hydraulic system is responsible for the efficient operation of many moving parts of BHL. So check all the hydraulic components such as arms and swings, working of the joysticks etc., carefully. Difficulty in steering, high fluid temperature, fall in pressure and chattering signs are some hydraulics related issues. A powerful diesel engine at the heart and amazing hydraulics are a must for the BHL.

4. Check the brakes of the BHL- Test the working of the brakes as sometimes the original ones are replaced by cheap quality ones. This may result in incorrect behaviour or strange noises, thus hampering the work at jobsite. So, you need to start the machine and check the noise level. If the engine makes strange noise, then it means that the machine may not give good results.

5. Check for leaking fluids under the machine- Make sure that you check along the backhoe loader and the cylinders. Also, check all the hoses or arms. As the machinery wears off, oils and lubricant begin to leak from the arms, hoses, cylinders and engine as well. This may impact the speed of the machine.

6. Check the tyres and underneath: Inspect the axle seals carefully to see if there are any signs of leaks. Get under the BHL and take a look at the driveshaft to find out if any damage is caused by rocks or bumpy terrain. If excessive noise comes from the drive shafts, when the machine is in operation, it means that there is some issue.

7. Check the cab and other general operations of BHL: Get into the cab and evaluate the overall condition of the seat, joysticks and foot pedals. Further, start up the machine and carry out general operating tasks, set the stabilizers on the ground, lift tires off the ground and swing the boom from left to right and move the loader arm up and down for checking any loose pins or bushings. Also, take a close look at the stabilizers for any signs of leaks, damage, cracks or dents.

Apart from the above mentioned points, one also needs to look at the overall structure and exteriors of the equipment. So, inspect the BHL thoroughly and select the equipment with caution.

How to Replace Backhoe Bucket Teeth

Out of all the three, backhoe is the main component of the Backhoe Loader (BHL) and is used to dig up hard and compact material, usually earth or to lift heavy loads. This backhoe again constitutes three segments i.e., boom, stick and bucket. The backhoe can dig all sorts of holes but is especially suited for digging ditches.

In this task of digging ditches, penetrating and breaking of compacted dirt and rock, the bucket teeth provide an edge to the backhoe bucket. They are fitted into the corresponding slots on the bucket and are held firm with the pins.

Why backhoe bucket teeth need to be replaced often?

Given the heavy tasks they perform, the bucket teeth are subjected to high wear and tear. Thus, they are designed in such a manner that they can be easily and inexpensively replaced. In many cases, there are tooth bars instead of individual teeth in the bucket. In these types of equipment, the entire tooth bar has to be removed for replacing the teeth.

Things needed to replace backhoe bucket teeth

  • New bucket teeth
  • Keeper pins
  • Wire bristle brush
  • Sledge hammer
  • Keeper-pin punch

Steps to replace the backhoe bucket teeth

1. Set up the equipment

• Keeping the teeth parallel to the ground, position the bucket using jack stand or wooden blocking for support. Any potential pinching or crushing accidents can be averted through this simple step.

2. Remove the worn out teeth

  • Use a wire bristle brush to remove the excess dirt from the tooth shank and mounting bolt.
  • Using the sledge hammer and the keeper-pin punch to tap out the tooth keeper pin.
  • Now the worn out tooth can be removed from the tooth shank. If it does not come out easily, tap it with the sledge hammer.
  • If any more dirt in the tooth shank, remove it using the wire bristle brush.
  • Inspect the tooth shank carefully to find out the signs of excess wear or damage such as cracks, if any. The tooth shank should be replaced if it is needed.

3. Place the new teeth

  • The new tooth should be slided onto the tooth shank until the pinholes align.
  • Using the sledge hammer and the keeper-pin punch, tap the keeper-pin in place.
  • By giving a few gentle taps with the sledge hammer, ensure that the new tooth is mounted securely. If the new tooth does not move from its place, it means that it is installed correctly.

General tips

  • Protective equipment like safety glasses and safety-toed boots should be used while replacing the backhoe bucket teeth.
  • Remember to set the parking brakes and turn off the loader without fail.
  • Always, keep the ignition key with you till the bucket teeth are replaced so as to prevent anyone from accidentally starting the machine while the work is going on.
  • Be very careful while removing the tooth to prevent it from falling onto your legs and feet.

In this way, you can successfully replace backhoe bucket teeth on your own without calling for any professional help.

How To Repair Backhoe Tires

Even best quality tires can wear out or puncture after a while and cost a lot of time and money to fix. So, what is needed is some technical knowledge, so that you can repair the backhoe tire on your own and get going.

How to repair a backhoe tire

Here are some tips on how to repair a backhoe tire

  • Handle with care: Ensure that the backhoe is on a stable ground with some support so as to avoid any chances of slipping while fixing the tire. Since, the pry bars are heavy and can slip, you need to handle them carefully.
  • Backhoe stabilizers should be put to use: In order to raise the flat tire off the ground, backhoe stabilizer should be used. Through stabilizer, the backhoe can be lifted off the tire.
  • Using Pneumatic wrench: It can be used to remove the lug nuts and bolts, so that the entire wheel from the loader can be removed.
  • Removing inner and outer rim bead: A tire hammer or backhoe bucket can be used to get the inner as well as outer rim bead off the tire. Next, you can use a tire iron to pry the tire bead off the rim, however, ensure that you don’t pinch the valve.
  • Removing the tube: For doing this task, you will need to take the valve stem and the stem locknut out of the tube. After this, place the tube carefully on top of the tire and look for any damage.
  • Need for valve stem replacement: Inflate the tube for the leak and replace the valve stem so as to re-inflate the tube. You can even spray soapy water on the tube to find small punctures.
  • Deflating the tube: Repair the damage in the tube by placing the patch, deflate it again and place it on a flat work surface. Buffing tool can be used to score the rubber around the hole, so that the patch sticks better.
  • Putting the tube back in the tire: Before putting the tube back in the tire, check the tire for sharp things like nail etc., and if any, remove them. Thereafter, put the tube back on the rim. Make sure the valve stem is aligned with the hole in the rim and secured with the nut. Then, use your tire iron to pry the tire back onto the rim, like the way you did when you took the tire off the rim.
  • Valve replacement stage: Put valve stem core back in and re-inflate the tire. Once the tire is fully inflated, put it back on the backhoe like you put a wheel on the car.

So, this way, get going again!

5 Tips to Maintain Earth Moving Equipment

Here are some tips on maintaining earth moving equipment shared by the earth moving equipment manufacturers in India:

Tip 1: Always keep earth moving machinery lubricated

All moving parts of a machine will eventually fail if they aren’t lubricated properly. In fact, without proper lubrication, parts will create excess friction and this can cause severe wear and tear of the machinery. As a result of this deterioration, the lifespan of the moving parts of the machinery can be drastically shortened. In order to avoid this slow destruction, earth moving equipment should be properly maintained and all moving parts should be well lubricated. Too little as well as too much lubrication can be harmful for the machine. So, you need to lubricate the machine wisely.

Tip 2: Clean the equipment well

Another great tip for properly maintaining earth moving equipment is to make sure it stays as clean as possible. Dirt and debris can damage one or more of the delicate parts of the machinery and result in costly repairs. Earth moving machinery parts are fitted with special seals and filters designed to keep dirt and grime out of sensitive areas. Hence, broken seals must be repaired immediately, breathers must be kept clean and all filters should be inspected regularly and changed when they become dirty or clogged. One of the best ways to protect the machinery from dirt and the elements is to keep it housed in a building.

Tip 3: Maintain earth moving equipment regularly

Inspecting and repairing the equipment every now and then isn’t enough. You need to create and follow a maintenance schedule. You should include notations on how often each part of the machinery should be inspected for problems, repairs and general maintenance. You need to be consistent with the maintenance and inspect the equipment thoroughly. You can make a checklist of everything and follow it religiously. By maintaining earth moving machinery frequently, you can extend its life and increase its performance.

Tip 4: Pay attention to wear and tear

During normal operations, you may see signs that point to wear and tear. Be aware of these signs because they may signal problems that can cause machinery to malfunction more often or result in costly repairs or component replacements before your regular inspection. Some common signs of wear and tear are vibration, heat and belt shape. Fix the issues as soon as they are found so they don’t cause worse problems later.

Tip 5: Keep employees trained well

One of the most important ways to protect the equipment is to make sure employees are skilled at operating it. Without proper operator training, employees can damage the machinery or even injure themselves or others.

In a nutshell

While the earth moving equipment manufacturers in India have done their bit by producing superior equipment, now it is your turn to take care of that equipment. Follow the tips mentioned above to help increase the lifespan of your equipment and prevent dangerous injuries.