THE IMPACT OF CLIMATE AND WEATHER ON HEAVY EQUIPMENT AND MAINTENANCE

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How Weather Conditions Affect Heavy Equipment Maintenance

Climate and weather can significantly impact maintenance needs and overall performance of heavy equipment. Understanding these effects is crucial to ensuring your machine’s safety, efficiency and longevity. 

Different climates and their varying environmental conditions could require specialized maintenance strategies. Extreme temperatures, humidity and precipitation often affect the machinery's performance and longevity.

Maintaining equipment under extreme conditions involves regular cleaning, protective coverings and climate control measures to mitigate these environmental impacts.

Heavy Equipment Maintenance in Cold Climates

Freezing temperatures can significantly affect heavy machinery, affecting engine startup, fuel and hydraulic systems. Here's an overview of these impacts and some strategies for mitigation:

Engine Startup: Cold temperatures make it more challenging to start engines because engine oils become thicker and the cold temps reduce battery efficiency. Cold starts increase mechanical stress on engines, leading to premature wear. Using block heaters can pre-warm engines, making cold-weather startups more manageable. Engines can start to have difficulty at around freezing (32°F) but more pronounced problems start to occur at below 20°F.

Fuel Systems: Diesel fuel can gel at low temperatures, typically around 15°F, causing engine performance issues and potential failures. This issue occurs when paraffin waxes in the fuel crystallize and clog the filters.

Anti-gel additives can prevent fuel gelling. Regularly draining water separators and keeping fuel tanks full also minimizes condensation buildup. Additionally, replacing your machine’s fuel filter regularly, especially in anticipation of cold weather, can mitigate these problems.

Hydraulic Systems: Cold temperatures increase the viscosity of hydraulic fluids, most noticeably starting at around 20°F, which can lead to reduced system performance, cavitation and component wear. Elastomeric components like O-rings and seals often become brittle and prone to cracking in cold conditions.

Using hydraulic fluids with appropriate viscosity and warming-up systems before operation can prevent these issues. Replacing O-rings and other seals when they become brittle can prevent further issues down the road.

Key Parts to Inspect in Cold Weather

Knowing how to prepare for a freeze is crucial for heavy equipment. Inspecting the essential parts of your heavy equipment helps to maintain performance and prevent excessive damage. Here are some of the components you should pay attention to in cold weather:

• Make sure batteries are fully charged and in good condition. Batteries can lose 20-30% of their cranking power at 32°F and can lose up to 60% of their power at 0°F.
• Regularly inspect block heaters and starting devices to ensure they function correctly.
• Check for signs of fuel gelling and use winter-grade diesel fuel and anti-gel additives when the temperature drops below 20°F.
• Check that the coolant mix is appropriate for cold temperatures, typically a 50/50 or more concentrated mix of antifreeze and water. Properly mixed coolant typically protects against freezing down to -34°F, but a 60/40 (60% coolant 40% water) mix can offer protection down to -62°F.
• Low-viscosity hydraulic fluids suitable for cold weather help to maintain system efficiency. Regularly check fluid levels as they can contract in freezing temperatures, particularly at 20°F and below.
• Inspect for visible damage and hydraulic leaks from cylinders and hoses during cold temperatures.
• Clean or replace air filters more frequently in dusty or cold conditions. Fresh snow or sleet can be pulled into the air intake, causing moisture to freeze inside the filter and block airflow. Winter job sites are still dusty, particularly when snow starts to melt and dirt, sand or even fine road salt gets stirred up.
• Protect electrical components from moisture to prevent malfunctions.

Regular inspections and maintenance of these components will help ensure heavy equipment operates efficiently and safely in cold weather conditions.

Heavy Equipment Maintenance in HOT Climates

Like cold conditions, extreme heat can have a devastating impact on your equipment's performance and longevity. Here are some notable effects of hot weather and strategies for mitigation:

Problematic Ambient Temperature Breakpoints:

Engine and Hydraulic Systems: High temperatures can cause overheating in engines and hydraulic systems, resulting in breakdowns and reduced efficiency. Most heavy-duty diesel engines are designed to operate between 180°F and 220°F, with critical problems occurring as early as 230°F. Hydraulic systems typically have a safe operating zone between 100°F and 140°F, with problems occurring as early as 180°F. Heat can degrade hydraulic and engine oils, reducing their effectiveness and increasing wear on related components such as seals.

Material Expansion and Deformation: Metal components expand in extreme heat, typically above 300°F where a 10 ft. Boom Arm can expand as much as 0.24 inches, causing mechanical issues. Prolonged exposure to direct sunlight can weaken or deform plastic parts, compromising a component’s integrity.

Electrical and Cooling Systems: High temperatures can cause electrical components to malfunction, especially when exposed to direct sunlight. Cooling systems work harder in the heat, increasing the risk of failure if they’re not properly maintained. Wiring insulation softens and melts at above 195°F; connectors and plugs can loosen or arc at 185°F; ECUs may experience thermal shutdown or logic errors at 185°F; sensors can give incorrect readings as early as 185°F; alternators and voltage regulators can have reduced output at 212°F; relays and fuses may trip or degrade early at 185°F; and lithium batteries can see rapid degradation, or even thermal shutdown, at 140°F.

Strategies for Mitigating Heat-Related Issues

Regular Maintenance: Regularly inspect and maintain the cooling system to prevent overheating, monitor the hydraulic and engine oils for degradation and change them if needed.

Operational Practices: If possible, limit operations during peak sunlight hours to reduce exposure to extreme heat. Use shade structures or covers to protect equipment from direct sunlight when you aren’t using it. Ideally, you want to target 41°F to 86°F for the ambient operating temperature of your heavy equipment. That’s the temperature range at which all of your systems perform at peak reliability with minimal stress.

Key Parts to Inspect in Hot Weather

Inspecting key components of heavy equipment in hot weather is crucial to prevent overheating, maintain performance and ensure safety. Here are some components to concentrate on:

• Ensure your machine’s radiator and coolers are clean and free of debris.
• Check that your coolant is at the recommended level to prevent overheating.
• Check all coolant hoses for signs of wear, damage or leaks.
• Monitor oil levels and their condition since heat can degrade oil quality.
• Check hydraulic fluid levels and condition, as high temperatures can affect viscosity and performance.
• Regularly check tire pressure, as heat can cause pressure increases, leading to over-inflation and potential blowouts.
• Inspect your tires for wear and damage because hot conditions can accelerate tire degradation.
• Make sure your A/C system functions correctly to maintain operator comfort and reduce strain on the system.
• Check belts and hoses for signs of wear, fraying or damage, as heat can cause them to degrade more quickly.
• Use thicker grease to offset the reduced adhesive properties in hot conditions.
• Inspect attachments like buckets and hydraulic breakers for wear and ensure they have sufficient grease.

By implementing these strategies, you can protect your equipment and personnel from the adverse effects of extreme heat.

Wear and Tear of Parts Due to Harsh Weather Conditions

Other weather conditions can affect the performance and longevity of construction equipment. Here is a look at these effects and some strategies for mitigation:

Heavy Dust

Dust particles can act as abrasives, accelerating the wear on moving parts like bearings and gears. Dust accumulation can impede airflow, causing machinery to overheat. It can infiltrate electrical components, causing short circuits and other malfunctions.

High Humidity

High humidity accelerates corrosion on metal parts, mainly if moisture condenses on surfaces. Condensation can lead to coating failures by causing rust or blistering on metal surfaces.

Extreme Rain

Rainy conditions can compromise electrical systems and damage other components, leading to malfunctions or failures. Surface corrosion can begin after just 6 to 12 hours of continuous rainfall in high humidity with no drying period.

Extreme Wind

High winds can affect equipment stability, especially during transport or operation, posing safety risks. It can also cause lightweight materials to blow away and damage equipment or temporary structures.

Strategies For Mitigating Weather-Related Challenges

To mitigate weather-related challenges on the job site, it's important to establish regular cleaning schedules to remove dust and debris that can interfere with equipment performance. Frequent inspections should also be conducted to identify potential issues early and address them before they escalate. Protective covers can help shield sensitive components from dust and moisture, while sealed enclosures offer additional protection against environmental contaminants. Finally, utilizing weather forecasts allows teams to plan operations around favorable conditions, reducing the risk of delays or equipment damage caused by harsh weather.

Final Thoughts

Keeping detailed maintenance records and adopting a seasonal maintenance schedule can prevent weather-related damage to heavy equipment. Regular inspections and timely repairs help mitigate the impact of extreme temperatures, humidity and precipitation. This proactive approach can help your equipment remain in optimal condition, reducing downtime and extending its lifespan.

When your equipment is faced with the harmful effects of extreme weather, let the EquipmentShare™ Shop help. Our vast selection of OEM and aftermarket parts has you covered for any preventive or reactive maintenance needs you have. Can’t find exactly what you’re looking for? Reach out to our dedicated parts experts and get personalized assistance.

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