7 Steps to Maximize Heavy Equipment Longevity

For any of you who use heavy equipment every day — construction, mining, logging operations and so on — we know maximizing the life of your machines is not only a practical goal but also a key strategy to control your costs and improve overall equipment efficiency. The longer your machines are operational, the lower your cost-per-hour investment, and the higher the value they provide.

With the right steps, it’s possible to get more hours out of the equipment you currently own and still have those machines perform adequately, efficiently and safely. Many of these steps you may already take — but just in case, here are seven ways to up your machine hours.

1. Use high-quality fuel. Diesel quality is a fundamental factor in machine longevity, especially in extreme environments. Northern operations often contend with frigid temperatures where traditional fuels gel up. These regions typically require a special diesel blend to maintain flow and performance in extreme cold. Beyond temperature considerations, clean, high-quality diesel helps avoid build-up that can lead to long-term wear in the engine, filters and injectors.

2. Invest in premium lubricants and oils. Quality oils like Volvo Lubricants are specially formulated to protect engine parts against breakdown, reduce friction and increase flow efficiency. Volvo oils in particular meet strict industry standards and include additives to help prevent degradation. By investing in premium engine and hydraulic oils, you not only protect engine components but may also extend the time between oil changes, keeping your equipment running longer with less downtime.

3. Use OEM filters for extended life. Filters play a critical role in maintaining the health of your equipment — so if you’re using high-quality oils, it makes sense to do the same with your filters. Volvo filters, for example, are designed to last up to 1,000 hours, providing a longer service life than many aftermarket options. OEM oil filters, air filters and so on also meet strict quality standards, reducing the chance of contaminants reaching engine components. Skimping on filters may save costs initially, but in the long run, the savings are often lost in additional repairs and machines running inefficiently.

4. Stick to a machine maintenance schedule. One of the simplest yet most effective ways to increase the life of your equipment is to adhere to regular heavy equipment maintenance schedules. Routine inspections and timely replacement of worn components prevent minor issues from turning into major, costly repairs.

5. Match machines to applications. Using a machine that’s too large or too small for the job can lead to premature wear. Diesel engines perform best when working under optimal loads. If a machine is oversized, it may spend too much time idling, which wastes fuel and increases engine wear. Limiting idle time not only saves fuel but also helps avoid “washing” your engine cylinders (when fuel isn’t burned properly, it can wash oil from the cylinders and create more wear). Educating your operators on the importance of minimizing idle time is a proactive way to extend machine life.

On the other hand, an undersized machine might be overstressed. A balance is ideal — aim for a machine that can work effectively for about seven hours of an eight-hour shift.

6. Perform preventative maintenance and fluid sampling. Heavy equipment preventative maintenance — such as a fluid analysis — can help identify issues before they become costly failures. For example, noticing an increase in metal content in axle oil might lead to a simple bearing replacement versus replacing the entire axle. Proactively scheduling downtime to address small issues prevents unexpected, more costly repairs and increases overall machine longevity.

7. Invest in heavy equipment operator training. From what I’ve seen, most operators out there are pretty good at what they do. But we’re all human — anyone can inadvertently get into a bad habit that costs the company money. Proper machine training ensures your operators use their equipment efficiently, which directly impacts machine life. Systems like Volvo’s MATRIS provide data (the same data used in CareTrack and ActiveCare^® Direct) on fuel consumption, idle times, engine RPMs and more to help you monitor machine use and operator habits. It’s worth repeating that educating your operators to avoid excessive RPMs and idle times is crucial for long-term performance.

While some of these strategies may seem obvious to many of you, it’s important to check in to see that each one has been implemented or at least considered. Working closely with your maintenance team to ensure these practices are in place can pay off in extended machine life, reduced downtime and lower operating costs. These steps can be a bigger investment up front, but the payoff in the end is usually well worth it.

By Tony D’Angelica