The heavy machinery used in your company is a valuable investment that requires proper care and maintenance to ensure its optimal performance. Fluid management plays a very significant role in keeping the machinery running smoothly and efficiently. By implementing the following suggestions, you can increase the lifespan of your equipment, reduce maintenance costs, and maintain site productivity.
I. Understanding the Essential Fluids
To ensure the proper functioning of heavy machinery powered by diesel, it is important to manage the following fluids.
Diesel fuel
Diesel fuel powers and maintains the operation of your machinery.
Diesel exhaust fluid (DEF)
DEF helps diesel engines produce fewer emissions, reducing air pollution.
Engine and transmission oil
Lubricates the moving components in heavy equipment engines, minimizing power loss and friction.
Hydraulic fluid
Transmits power, acts as a lubricant and sealer, cools down machinery, and cleans out pollutants.
Coolant
Protects the equipment from rust, corrosion, freezing, and cavitation.
II. Utilizing Instruction Manuals and Safety Precautions
Read and utilize instruction manuals
Always refer to the instruction manuals provided with your heavy machinery. Keep them nearby so that operators can access them whenever they need a refresher on fluid control. The manuals contain valuable information about maintenance requirements, suggested fluid intervals, and manufacturer-recommended fluids.
Familiarize with safety precautions
Encourage equipment operators to read the safety precautions in the manuals and become familiar with the instructional decals placed on the machine. Manufacturers often include service interval information on stickers for convenient reference.
III. Proper Handling of Fluids
To maintain the integrity of the fluids used in heavy machinery, it is really important to handle and store them properly.
Ensure cleanliness
Prevent water, dust, and debris from entering fluid tanks, as they can alter the chemical composition and cause issues with pumps, filters, or injectors. Establish a designated fluid containment zone and maintain high cleanliness standards.
Implement best practices
Use dispensing filters
Install filters on tanks as required by fluid manufacturers to filter certain liquids before they enter storage tanks.
Store fluids properly
Keep fluid containers in dry, well-ventilated areas with secure closures. Reseal containers after each use and store them upright to prevent leaks.
Follow fluid labels
Adhere to safety instructions and handling precautions mentioned on the fluid labels. Wear protective gear while handling fluids to protect your skin and keep the components clean.
DEF storage
Take special care to prevent dust and soil contamination in DEF storage, as it can harm the selective catalytic reduction system. Fill the DEF tank directly from the container or use a clean intermediary container exclusively for DEF.
IV. Optimal Fluid Delivery
Selecting an effective fluid delivery method is crucial for maintaining machinery health and preventing downtime.
Collaborate with a fluid distributor
Consider partnering with a fluid distributor that offers clean mobile fluid services. These distributors bring the required fluids directly to your operation site, ensuring cleanliness and contaminant-free delivery to protect machine components.
Implement proactive maintenance
Establish a preventative maintenance program carried out by trained maintenance experts. Proactive maintenance helps identify and address small equipment issues before they escalate, ensuring optimal machinery performance and longevity.
V. Fluid Analysis for Maintenance Optimization
Fluid analysis can provide valuable insights into the condition of your machinery.
Implement fluid analysis programs
Equipment manufacturers may offer fluid analysis programs that check fuel, oil, and coolant samples for contaminants. Analyzing the results helps assess the overall viability of the fluids and predicts when maintenance might be required based on component wear.
Identify metal particles
Fluid analysis kits can detect small metal particles released into the operating fluids as equipment components deteriorate. By determining the types and concentrations of metals present in the fluids through fluid analysis, you can estimate the remaining lifespan of each component and plan maintenance accordingly.
VI. Regular Inspection and Maintenance
To ensure continuous fluid management and optimal performance, incorporate the following practices into your maintenance schedule.
Diesel fuel examination and cleaning
Hire a seasoned diesel fuel examination and cleaning service to inspect your fluid storage tanks every six months or as needed. The inspection should identify the presence of water, debris, dirt, or other impurities. If significant concentrations of pollutants are found, the tanks should be emptied and thoroughly cleaned to start afresh with a new, clean tank.
Maintain a preventative maintenance journal
Keep a detailed preventative maintenance journal to track supply tanks and record essential information. This log should include details such as filter changes, service history, and particle counts. Maintaining a comprehensive record helps monitor fluid conditions and facilitates timely maintenance interventions.
Effectively managing fluids in heavy machinery is so important for ensuring the longevity, performance, and efficiency of your equipment. Simply by following the suggestions that are outlined above, including utilizing instruction manuals, proper handling of fluids, selecting an optimal fluid delivery method, implementing fluid analysis, and conducting regular inspections and maintenance, you can extend the lifespan of your heavy machinery, reduce maintenance costs, and maintain operational productivity. Prioritize fluid management as an integral part of your heavy equipment maintenance routine to reap the benefits of improved performance and prolonged equipment life.