The difference between proactive equipment replacement and reactive emergency responses can determine whether mining equipment servicing happens during planned windows or forces unexpected production shutdowns. Mining operations that master the art of recognising early warning signs consistently outperform those that wait for equipment to fail, maintaining higher productivity rates and significantly better safety records.
HDDSol’s expert diesel fitters and technicians have compiled the top 10 signs that indicate your mining equipment needs replacing. We’re passionate about helping you achieve success beneath the surface. If you recognise any of these signs, contact our team immediately and see how we can help.
Warning Signs You Need Immediate Mining Equipment Servicing
Below are the most common signs your machinery is facing imminent problems. Remember, the faster you act, the better your chance of preventing further damage to your assets or creating a mining safety issue (the risk of accidents).
1. Decrease in the Performance of Machinery
One of the most obvious signs you need maintenance of mining equipment is when heavy-duty equipment doesn’t perform as well. You may have months or years of exceptional performance, but suddenly it may begin to struggle to operate at peak standards and may start to malfunction.
While this can impact the success of projects, it’s also important to remember that it poses a health and safety risk. It’s your duty of care as an employer to provide safe working conditions for workers, so you should move quickly to address signs of faulty machinery. Otherwise, there may be an on-site injury due to defective equipment.
2. Strange Noises and Vibrations
Another significant telltale sign that there’s a problem is the noises a machine makes. Your asset may begin making odd noises, such as:
- Grinding
- Kniocking
- Squealing
- Rattling
These are all signs that all is not well. It may mean parts are misaligned, loose, or worn down. Workers need to be trained to recognise these sounds, as continuing to use equipment making these noises may be dangerous.
3. Signs of Smoke or Leaking Fluids
If your machinery begins creating excessive amounts of smoke, it’s safe to assume there’s a problem. The same goes if it’s leaking fluids. The former may suggest an overheating problem, with thick black smoke, a particular health hazard to workers.
Leaking fluids suggest a coolant, oil, or hydraulic issue that can, in time, lead to a total breakdown of your machinery.
4. Visible Wear and Tear
Wear and tear suggest you need to consider mining equipment servicing. Equipment that’s been used many times can start to show cracks, rust, damaged tyres, and worn tracks. These are all signs of defects that require attention. Continuing to use machinery that has wear and tear can lead to further, greater damage to the asset. It may also create health and safety issues for your workforce.
5. Warning Alarms and Lights
Many modern pieces of mining equipment feature warning lights and alarms. Obviously, these go off for a reason and can indicate low oil pressure, overheating, or a system malfunction.
Your workers must be trained to understand how to deal with these warning lights. They mustn’t be ignored, and the sooner the issue is reported, the sooner the problem can be repaired. In some instances, it can indicate a wider problem with the mining equipment, and you may need to have it serviced.
6. Difficulty Starting
If it’s taking a long time to start an asset, then that’s a clear sign there’s a technical issue. Further to this, if the machine stalls, then it’s a further indication of a problem, such as:
- Ignition system faults
- Battery issues
- Fuel system failures
- Wear and tear
7. Increased Power Consumption
If an asset begins using more fuel, it can be a sign of a clogged filter, engine problems, or transmission wear. Left unserviced, this may lead to the total failure of expensive assets.
8. Jerky Machinery Movements
A clear indication of hydraulic system issues is with jerky movements. Workers may also experience unresponsive controls or slow hydraulic lift points. As this function is critical to mining, it’s vital to repair technical issues as soon as possible.
9. Electrical Failure
Dimming lights, flickering dashboards, and failing sensors suggest an electrical failure has occurred. This will affect vehicle performance, but can also present a fire safety hazard.
10. Reduced Braking Efficiency
Due to the tough, often steep, conditions in Australian mines, prolonged use can lead to less efficient brakes. Alongside being a serious health and safety concern, reduced braking performance will impact project productivity.
Choose HDD Solutions for Expert Mining Equipment Maintenance in Australia
HDD Solutions is a specialist in asset repair services. Regular and reliable support ensures your equipment operates at its best, minimises downtime, and keeps your business compliant with Australian laws. We go above and beyond with our services so you can keep your operation running smoothly. Enquire now for an industry-leading quote: 08 9302 1532.
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Maintenance of Underground Mining Equipment FAQs
How Often Should Underground Mining Equipment be Serviced?
Regular maintenance is key. You should carry out daily inspections on all assets. But for servicing, you may want to schedule a monthly, quarterly, or annual checkup.
What’s the Average Lifespan of Different Types of Mining Equipment?
Most mining equipment offers around 25,000 hours (around three years) in performance. However, the long-term use of your assets will depend on how well you maintain the machine and how frequently it’s used. The more maintenance time you schedule for it, the stronger the chance it’ll last longer.
Is it More Cost-Effective to Repair or Replace Mining Equipment?
Refurbishing or repairing is often more cost-effective than outright replacement. One of your assets may simply need several new parts, then operate at full performance again. However, if an asset is simply outdated and outlived its effective service life, it’d be more cost-effective to buy a new machine.
What are the Legal Requirements for Equipment Servicing in Australian Mines?
Equipment servicing is regulated under national and state Work Health and Safety (WHS) laws. All businesses must ensure that machinery is fit for purpose, maintained in a safe working order, and serviced by trained personnel to match Australian Standards (such as AS/NZS 1200 for pressure equipment). Mine operators must implement a documented Safety Management System (SMS) with safe work procedures, risk assessments, permit-to-work and lockout–tagout systems, regular inspections, and detailed maintenance records. As a business, you must also ensure an effective condition monitoring system for all assets.
