Tips to Effectively Use Heavy Equipment

If you operate or maintain heavy equipment, you know the challenges of meeting deadlines, managing complex machinery and keeping your crew safe. You need your equipment to work efficiently and safely so you can minimize downtime. From construction sites to mines and every industry in between, the demands on you and your machinery are high. Using machinery correctly improves its performance, extends its life span, reduces the risk of accidents and keeps you within your budget.

This post provides tips on how to effectively use heavy equipment.

Importance of Proper Equipment Usage

Here’s why proper equipment usage matters:

• Improves productivity: Using the right machine for the job impacts efficiency and safety. Matching equipment to the task improves productivity and reduces the likelihood of accidents or damage caused by using the wrong machinery.
• Prioritizes safety: Deadlines and getting the job done quickly can feel like the top priority. However, rushing projects usually leads to mistakes, resulting in equipment damage or injuries. For example, an operator might skip a preshift inspection to save time, only to discover that the equipment is faulty mid-task. Prioritizing safety over speed prevents setbacks and provides long-term productivity.
• Extends machinery life span: Every piece of equipment has specific capabilities and limitations. Awareness of these details allows you to use the machinery to its full potential without pushing it beyond safe limits. Pushing the machine can cause mechanical failure or create hazardous situations for operators and nearby workers.

Training

Operators must undergo training to use heavy equipment. Without proper training, employees may unknowingly misuse equipment or not recognize hazardous situations. Proper training helps reduce employers’ liability and promotes a safer workplace.

Machinery and jobsites differ, so employers should develop comprehensive training materials tailored to their equipment and projects. This helps employees develop expertise that directly benefits their daily work. Ideally, programs should combine classroom instruction and hands-on practice.

A good training program should include:

• Equipment basics: Ensure your team is familiar with the controls, components and functions.
• Hazard recognition: Understand how to identify risks like unstable terrain, overhead obstructions or load imbalances.
• Operating techniques: Your team should know efficient and safe methods for tasks.
• Emergency procedures: Everyone should know what to do in case of equipment failures or other emergencies.
• Maintenance fundamentals: These are the procedures involved in daily checks.

Over time, operators may forget certain procedures, or someone may observe them using equipment unsafely, so refresher courses may be needed. Additionally, technology and regulations evolve. Keeping up with these changes is critical for secure and practical operations.

Refresher training helps employees:

• Reinforce core skills and safety protocols.
• Stay updated on new equipment features or software.
• Adapt to changes in industry regulations.

Maintenance Practices

Here’s what maintenance entails and how to implement it.

1. Follow Manufacturer Recommendations

Manufacturers design equipment with specific guidelines for optimal performance and longevity. These include maintenance schedules, part replacement intervals and operating procedures. Ignoring these recommendations may lead to premature wear. Keep manuals accessible, follow the prescribed schedules, and use only approved parts and supplies. Train your team on these requirements to keep everyone on the same page.

2. Conduct Equipment Specific Inspections

Each machine has unique components that require inspection. Tailored checks catch potential problems before they become major issues. Develop a checklist for each type of equipment and have employees perform daily pre- and post-use inspections.

3. Keep Accurate Maintenance Records

Records help you track what’s been done, when it was done and when the next service is due. They are also invaluable for warranty claims or equipment resale. Accurate records provide accountability, improve scheduling, and prevent redundant or missed upkeep. Use digital maintenance tracking tools or software to simplify recording service dates, parts replaced and costs.

4. Adhere to Warranty Requirements

Most heavy equipment has warranties covering repairs or part replacements under certain conditions. However, failing to follow the manufacturer’s maintenance guidelines can void these warranties. Maintaining compliance with warranty terms saves money and streamlines support when needed. Familiarize yourself with warranty terms and conditions and integrate them into your upkeep plan.

5. Keep a Parts Supply and Inventory Available

Waiting for parts to arrive can extend downtime and disrupt project deadlines. Maintaining an inventory of commonly needed parts can save time. Partner with reliable suppliers and stock up on essential parts based on your needs.

6. Schedule Regular Inspections and Preventive Maintenance

Preventive maintenance is proactive rather than reactive. Instead of waiting for problems to occur, regular inspections and servicing help identify and address issues early. Create an upkeep calendar and stick to it to prioritize consistency over convenience.

7. Invest in Continuous Training

Operators are the first line of defense in maintaining heavy equipment. Their daily interactions with machinery give them better insights into possible issues. Train workers to identify and report problems. Knowledgeable and empowered employees might also help you reduce costs and downtime because they may prevent minor concerns from worsening. Incorporate basic upkeep training into operator education and encourage open communication about equipment performance.

8. Invest in Smart Tools and Fleet Maintenance Software

Technology can streamline maintenance practices and improve efficiency. Fleet maintenance software tracks equipment usage, schedules inspections and alerts you to upcoming service needs. Similarly, smart diagnostic tools can pinpoint issues more accurately than traditional methods. Leveraging technology saves time, reduces errors and allows you to perform upkeep on schedule. Evaluate your needs and invest in software or tools that complement your operations.

9. Monitor Maintenance Costs

Monitoring upkeep expenses helps you identify trends and make informed decisions. If a particular machine often requires repairs, it may be time to consider replacement or reevaluate its usage. Tracking costs ensures your upkeep program is cost-effective and aligns with your budget. Use maintenance records and software to analyze costs and adjust strategies as needed.

Safety Guidelines

Below are some best practices for using heavy equipment to create a secure jobsite.

Before Operation

Before you start the engine, take the time to inspect the machine and surroundings. Here are some steps to achieve this process:

• Perform an inspection: Check for signs of wear or damage, such as leaks, frayed wires or low fluid levels. Pay attention to tires or tracks, brakes and the hydraulic system to verify that all controls, gauges and safety features function correctly.
• Review the jobsite: Look for potential hazards or nearby workers. Check the area and pathways to ensure they are clear of debris and obstructions.
• Wear proper personal protective equipment (PPE): This includes helmets, gloves, boots, safety glasses, vests and hearing protection. Each piece of equipment may have specific PPE requirements based on operation and environment.

During Operation

Once the machine is running, staying alert and following best practices is essential. Below are recommendations to keep yourself and others safe:

• Maintain a clear line of sight: Verify that your visibility is unobstructed. Use mirrors or spotters to monitor blind spots.
• Follow load and speed limits: Avoid exceeding the equipment’s load capacity or recommended speed. Adhering to limits ensures the machine’s stability and prevents damage and injuries.
• Use seatbelts: Always wear a seatbelt while driving heavy equipment.
• Communicate clearly with your team: Use hand signals or other communication tools to coordinate with coworkers. Everyone on the jobsite should be aware of the machine’s movements.
• Be cautious on slopes or uneven terrain: Drive equipment slowly and carefully when working on slopes. Always move up and down inclines rather than sideways to reduce the risk of tipping.

After Operation

Proper shutdown procedures can extend the longevity of your equipment and keep you safe. Here’s what to do at the end of a shift:

• Lower attachments and shut down properly: Before exiting, lower all attachments on level ground, turn off the engine and engage the parking brake.
• Use three points of contact: Always maintain three points of contact — two hands and one foot or two feet and one hand — when climbing in or out of the cab. This method reduces the risk of slips, trips and falls. Never jump off the equipment.
• Inspect and clean the machine: Remove dirt, debris or buildup from the machine, and check for any signs of wear or damage. Report any concerns immediately to the maintenance team.

Troubleshooting

Here’s how to undertake troubleshooting and prevent future issues.

1. Check if There’s an Issue

Before jumping into repairs, confirm that there is an actual problem with the equipment. You can do this by:

• Listening to operators: Gather details from those who use the equipment daily. Ask about unusual noises, performance changes or any abnormalities they may have noticed.
• Reviewing machine indicators: Check gauges, warning lights or digital displays for abnormal readings.

2. Find the Root Cause

Once you’ve confirmed a problem, the next step is to identify and resolve the underlying issue. Follow these steps:

• Start with simple checks: Rule out common causes, such as low fuel, dirty filters or improper fluid levels.
• Inspect components: Examine areas of the machine related to the symptoms. For example, if there is a hydraulic issue, check for leaks, worn seals or damaged hoses.
• Use diagnostic tools: Leverage diagnostic systems or external tools to analyze error codes, monitor system performance and test components.

3. Correct the Underlying Issue

After determining the cause, take appropriate corrective actions to resolve the issue, such as repairing or replacing parts or adjusting settings. The troubleshooter should use the equipment’s manual or troubleshooting guide to perform repairs correctly. Use high-quality replacement parts and follow proper installation procedures.

4. Verify the Problem Is Resolved

After making repairs or adjustments, test the equipment to confirm the problem is corrected. Operate the machine under normal conditions and monitor for any lingering issues or warning signs. Have the person who reported the issue verify the machine is functioning as expected.

5. Prevent Future Issues

Once you’ve fixed the problem, focus on preventing similar issues from arising. Prevention requires a combination of regular maintenance, operator training and the use of advanced tools. Document the issue, its root cause and the corrective actions taken. This documentation helps identify patterns and improve future troubleshooting measures. Educate operators on proper equipment use and early warning signs of probable issues. Additionally, perform regular inspections and servicing to catch slight problems before they escalate.

Tips for Operating Different Machines

Here are some tips for operating heavy machinery commonly used across industries.

Excavators

Here’s how to properly use excavators:

• Swing speed: Stabilize the machine and use smooth and controlled movements to help maintain balance. Excessive speed can destabilize the machine or cause undue stress on components.
• Dig efficiently: Position the machine close to the digging site to minimize reach.

Backhoe Loaders

Below are some recommendations to safely use backhoe loaders:

• Evenly distribute the load: Keep the load balanced in the bucket to prevent tipping or spilling.
• Stabilize the machine: Use the backhoe loader’s stabilizers, especially when working on uneven terrain.
• Perform smooth lifts: Raise and lower the bucket gradually.

Bulldozers

Here’s how to make the most of your bulldozer:

• Monitor blade angles: Adjust the blade angles according to the task.
• Avoid overworking the blade: Don’t overload the blade with too much material at once. Work in layers if necessary.
• Use low gear for heavy loads: Lower gears provide better traction and control when pushing large amounts of material.

Compactors and Rollers

Follow these tips to use compactors and rollers:

• Match the machine to the material: Use the correct roller type based on the compacted material.
• Maintain a steady pace: Drive at consistent speeds to avoid uneven compaction.
• Avoid sharp turns: Make gradual turns to prevent surface damage and maintain machine stability.

Skid Steer Loaders

Some best practices for using skid steer loaders include:

• Selecting the right attachments: Use attachments suited to the task.
• Being mindful of weight distribution: Avoid overloading the bucket to maintain balance and control.
• Carrying loads close to the ground: Handle loads close to the ground but high enough to remove debris.

Cold Planers

Here are some tips for driving a cold planer:

• Maintain cutting depth: Set the drum to the correct depth to avoid over-milling.
• Inspect your attachments: Make sure your attachments are free of debris. Additionally, check for wear and replace components when needed.

Browse Heavy Equipment From Blanchard Machinery Company

Blanchard Machinery Company can help you maximize heavy equipment efficiency, jobsite safety and productivity. With over 30 years of industry experience, we have the expertise and resources to help you tackle various heavy machinery and material handling projects. We understand that every project is unique, so we offer an extensive range of equipment from reputable brands designed to handle the toughest challenges.

We’re also here to support you with our comprehensive parts and service solutions to minimize downtime. Our skilled and dedicated sales representatives are always ready to keep your machine in peak condition. Browse our full lineup of machinery today.