Top 10 Common Construction Equipment Issues and How to Diagnose Them
Operating heavy machinery requires precision, but even the most robust equipment can face mechanical issues. Here’s a quick guide to diagnosing 10 common problems and their solutions to keep your machines running smoothly.
1. Oil in the Coolant
Possible Causes:
• Cracked oil cooler core.
• Failed water pump seal or clogged drain hole.
• Blown cylinder head gasket.
2. Coolant in the Engine Oil
Check These Areas:
• Damaged oil cooler core.
• Blown cylinder head gasket.
• Cracks in the cylinder head or engine block.
3. Low Oil Pressure
Troubleshooting Steps:
• Check oil level (low oil can cause pressure drops).
• Inspect for diesel or coolant contamination.
• Look for clogged oil filters or leaking suction pipes.
• Test oil pressure relief valve (stuck open or broken spring).
• Assess oil pump wear or excessive bearing clearance.
4. Overheating Engine
Common Culprits:
• Low coolant level.
• Faulty thermostat.
• Loose drive belts reducing fan speed.
• Malfunctioning water pump.
• Engine overload.
• Clogged radiator (internal or external).
5. Generator Not Charging
Inspect These Components:
• Dead battery.
• Faulty charging or ground circuit.
• Worn commutator brushes.
• Failed voltage regulator or rectifier diodes.
• Damaged rotor or field coil.
6. Hydraulic System Vibrations or Noise
Likely Issues:
• Air in the hydraulic pump.
• Worn swashplate or piston shoes in the pump.
7. Uneven Track Movement
Check for:
• Incorrect track tension.
• Internal leaks in travel motors or damaged final drives.
• Low hydraulic pump flow due to internal leaks.
• Faulty pilot control valves or main circuits.
• Damaged seals in the swing bearing causing oil crossover.
8. Slow Travel Speed
Investigate:
• Malfunctioning pilot control valve or main circuit.
• Issues with the pilot pump or hydraulic pump.
• Oil crossover due to failed swing bearing seals.
9. Weak Climbing/Digging Power
Key Checks:
• Low pressure in main or pilot circuits (faulty relief valves).
• Malfunctioning overload relief, counterbalance, or shock valves.
• Internal leaks in hydraulic pumps, pilot pumps, or holding valves.
10. Electrical Circuit Failure
Quick Fixes:
• Blown fuse.
• Damaged components or wiring in the circuit.
Pro Tip:
Regular maintenance—including fluid checks, filter replacements, and system inspections—can prevent most of these issues. For complex problems, consult your equipment’s service manual or a qualified technician. Keep your machinery running strong with proactive care!
