PLANNED INDICATORS

Planned — as opposed to unplanned — maintenance is relatively easy to execute. Planned maintenance relies on four things:

1. Staying up to date with Cat S·O·S℠ Services (scheduled oil sampling) and regular inspections. This ensures insights into the internal condition of your components.

2. Following the service intervals Caterpillar recommends, as written in the machine’s Operation and Maintenance Manual (OMM).

3. Keeping good records of the service history for tracking and predictability.

4. Performing daily inspections to look for additional signs of trouble.

PROBLEM INDICATORS

For a technician, regular service, daily observations and intuition are some of the best tools in the maintenance toolbox. By the time the operation is affected, a failure may have already occurred. Always listen to operator feedback, but remember that trained technicians doing regular planned maintenance typically detect problems that may escape the untrained eye.

Look out for changes in fuel use, including excessive fuel consumption or leakage. If anything seems off in the machine performance — including unusual noises, hesitation or vibration — stop the machine and complete a safety check. And if you notice reduced hydraulic or engine power, overheating, or debris in filters, take the time to investigate if there are any repair needs.

By detecting emerging problems early, you can significantly reduce the cost of repairs and disruptions to the production schedule. When one component fails, it often leads to contamination or damage to another component. One blown hydraulic cylinder seal, for example, can contaminate the entire hydraulic system. And waiting to repair an engine after failure costs on average 190% more than repairing it before failure.

KEEP THE WORK GOING

When you are on top of your equipment maintenance needs, your machines will likely only be out of production for a few hours or days. This minimizes impact on production schedules and gives the production team time to decide how to compensate for the temporary absence of a machine.

After you’ve found and identified problems, it’s time to decide how best to reduce downtime and optimize your spending on repairs. Consider the following:

1. Do you repair before failure or run the machine until something fails?

2. Do you repair it yourself or let your dealer handle it?

3. Should you choose new, remanufactured or exchange components?

4. Would a Cat Customer Value Agreement (CVA) or Maintenance and Repair Contract (MARC) make the most financial sense for your operation?

MULTIPLE REPAIR OPTIONS

Fortunately, your Cat dealer offers a range of parts and programs for repairing the issues you may find. These include Cat certified components with wide parts availability, customizable options and tiered pricing. On-site repairs can help you minimize downtime. Cat technicians have the expertise to make sure the repair work is done well and that you’re back to work as soon as possible. And when it comes to problem repair indicators, you’ve got options depending on the possible causes for malfunction.

• Unusual noises can be caused by worn gears or bearings, dirt entry or low fluid level. Determine the repair options by checking S·O·S Services for wear trends or completing a technical analysis inspection.