Written By: Corey Foy

In any industry that uses heavy equipment, minimizing equipment downtime is crucial for project success and profitability. Choosing the right fleet maintenance strategy can make all the difference. Let's dive deeper into preventative and conditional maintenance, exploring their pros and cons, scheduling factors, and monitoring conditions. To keep this blog post cohesive we will examine this issue from a construction perspective, however, these findings will apply to most of the industries we service.

Preventative Maintenance (PM): Proactive Care, Predictable Schedules

PM is a proactive approach that involves scheduled inspections, servicing, and component replacements based on time intervals or equipment usage. It is a form of routine maintenance, that while being more labor intensive can potentially lead to big savings in unexpected repairs.

Pros of PM:

  • Risk Mitigation: Regular checks catch wear and tear early, preventing catastrophic failures that can derail projects.
  • Increased Equipment Reliability: Consistent maintenance ensures optimal performance and reduces the risk of unexpected downtime.
  • Extended Equipment Lifespan: Proper lubrication and timely replacements of worn parts can significantly extend the life of your machinery.
  • Predictable Scheduling: Easier to plan maintenance around project timelines, minimizing disruptions.

Cons of PM:

  • Potential for Unnecessary Maintenance: Some components might be replaced before they're truly worn out, leading to unnecessary expenses.
  • Higher Upfront Costs: Regular servicing requires an initial financial investment, but can save money in the long run.

Scheduling Preventative Maintenance:

Developing a proper schedule takes time, and some trial and error. Furthermore, it is important to consider when your equipment will be in periods of high usage. Schedules are typically based on:

  • Manufacturer Recommendations: Equipment manuals often provide guidelines for service intervals based on operating hours or mileage.
  • Operating Environment: Harsh conditions (e.g., extreme temperatures, dust, heavy loads) may require more frequent maintenance.
  • Equipment Criticality: Essential equipment may need more frequent checks than less critical assets.
  • Historical Data: Analyzing past failures and wear patterns can help refine your schedule.

Conditional Maintenance (CM): Data-Driven Decisions, Targeted Repairs

CM is a form of maintenance scheduling that relies on monitoring equipment performance and using data to determine when service is needed. This approach aims to optimize maintenance by addressing issues only when they arise or just before they arise. This method requires constant inspection and condition monitoring however it maximizes the life of components and lubricants.

Pros of Conditional Maintenance:

  • Optimized Maintenance Schedules: By focusing on actual equipment condition, you can avoid over-maintaining or under-maintaining your fleet.
  • Cost Savings: Reduces labor and parts costs by eliminating unnecessary maintenance tasks.
  • Improved Resource Allocation: Focus maintenance efforts where they are truly needed, maximizing efficiency.

Cons of Conditional Maintenance:

  • Requires Monitoring Equipment: Can involve upfront investment in sensors, software, and training.
  • Risk of Unexpected Failures: If monitoring isn't comprehensive or data isn't interpreted correctly, problems can still arise.

Monitoring Conditions for Conditional Maintenance:

CM relies on monitoring various parameters:

  • Oil Analysis: Can reveal wear trends, contamination levels, and lubricant condition, indicating when you need to service the equipment.
  • Vibration Analysis: Helps identify bearing wear or misalignment before they lead to failure.
  • Temperature Monitoring: Detects abnormal temperature spikes that could signal lubrication issues or component failure.
  • Performance Data: Monitors output, energy consumption, and cycle times for deviations from normal operating parameters.

PM vs CM in Practice: Excavator Maintenance

In this scenario, we will examine two ways of maintaining a Caterpillar 320 excavator used for digging trenches and foundation. The excavator uses 49 North 5W-40 Advanced Heavy Duty Synthetic CK-4 Engine Oil, XPG-15 Grease, and 49 North Synthetic Multi-grade HD Drive Train Fluid. Additionally, its track tension requires periodic monitoring.

Preventative Maintenance (PM)

Scheduled Tasks:

  • Oil and filter changes every 250 operating hours.
  • Greasing of moving parts every 50 operating hours.
  • Track tension checks and adjustments every 100 operating hours.
  • Hydraulic fluid analysis every 500 operating hours

Benefits:

  • Reduced risk of hydraulic pump failure: Regular oil changes and fluid analysis prevent contamination and ensure optimal performance, minimizing the risk of costly pump breakdowns.
  • Increased track life: Consistent track tension checks and adjustments prevent premature wear and extend the life of the undercarriage.
  • Improved fuel efficiency: Well-lubricated moving parts reduce friction, leading to better fuel economy.

Conditional Maintenance (CM)

Monitoring Conditions:

  • Vibration analysis: Sensors on the excavator's boom and arm monitor for abnormal vibrations, which could indicate bearing wear or loose components.
  • Temperature monitoring: Sensors track hydraulic fluid temperature to detect overheating, a potential sign of pump issues or low fluid levels.
  • Oil analysis: Periodic sampling of the hydraulic fluid reveals contamination levels, wear particle counts, and changes in fluid properties, indicating when maintenance is needed.

Benefits:

  • Early detection of hydraulic leaks: Vibration analysis can often detect subtle leaks before they become major problems, preventing damage and downtime.
  • Optimized oil change intervals: Oil analysis determines the actual condition of the hydraulic fluid, allowing for oil changes only when necessary, saving costs and reducing waste.
  • Reduced risk of overheating: Temperature monitoring provides early warnings of potential overheating issues, preventing damage to the hydraulic system and ensuring continuous operation.

Our Conclusion

A thorough examination of both methods reveals distinct costs and benefits for each. However, our approach prioritizes risk mitigation and cost-effectiveness. Therefore, we generally recommend a preventative maintenance schedule, but we understand that each organization has unique needs that may require a customized approach. In this example, our confidence in the PM schedule is possible because we are using high quality products. Otherwise, active testing and monitoring would be crucial to ensure your equipment's health.

49 North Lubricants: Your Partner in Equipment Maintenance

At 49 North Lubricants, we can help you develop a comprehensive maintenance strategy that balances preventative and conditional approaches, tailored to your specific equipment and operating conditions. One of the biggest issues our customers face is eliminating downtime, and a good maintenance strategy is your best defence. Furthermore, to explore the potential cost of downtime check out our blog on the topic here.

Finally, for more information, do not hesitate to reach out to our technical specialist, Corey Foy at info@49northlubricants.com. Alternatively, feel free to browse our online store here.