5 Profit-Draining Operator Errors and How to Spot Them

1. Hot turbo shutdowns

It’s recommended that operators let their machine idle for two to three minutes prior to shutting down to protect the turbocharger. While many newer machines (Volvos included) now feature auto-shutdown programming that manages this cool-down period automatically, those machines are still burning fuel and racking up hours while they wait to turn off. If an operator on an older unit repeatedly shuts down without properly idling, it can lead to turbocharger damage or failure — typically a $1,000 to $5,000 repair. Using your telematics dashboard, you can identify which machines are experiencing these shutdowns and distinguish between a necessary cool-down and a machine left running due to habit. This gives you the opportunity to train operators to avoid both costly repairs and unnecessary fuel burn.

2. High-speed shifts on wheel loaders

Operators should always bring the machine to a complete stop before shifting from reverse to forward (or vice versa). Shifting at high speeds over a long period of time can lead to eventual driveline failure. ActiveCare Direct flags instances of high-speed shifts on individual machines, giving you an opportunity to train operators before this bad habit leads to a potential transmission replacement costing upwards of $100,000.

3. Misuse of excavator work modes

Many operators tend to run in the highest work mode because they assume it gives them the highest productivity. Often, however, they could be achieving the same level of productivity in a lower work mode and burning up to 50 percent less fuel.

On previous generations of Volvo excavators, this meant shifting out of Heavy (H) mode. On our newest models, we’ve simplified this further with a 10-setting jog wheel — where modes 9 and 10 provide maximum flow, but modes 5 through 8 are often the sweet spot for standard digging and grading.

ActiveCare Direct is designed to automatically flag any excavator that runs in its highest power settings more than 80 percent of the time. By coaching operators to find the right balance between power and flow, you could save upwards of $10,000 per year, per excavator in fuel costs (assuming 1,500-hour-per-year usage).

4. Cycles with overloaded haulers

Overloading haul trucks has a number of downsides that can outweigh the increased amount of material moved, from dragline fatigue, damage to the haul road and shortening of tire life (which can be one of the most expensive replacement parts on a truck) to increased fuel consumption. Your ActiveCare Direct dashboard lets you know how many cycles your fleet has run with overloaded haulers — you can also see a breakout by machine to know which operators might need some additional training.

5. Excavator travel time

Excessive excavator travel time can cost you a lot of money, as it’s the number one cause of undercarriage wear. It puts a lot of stress on the tracks, sprockets and idlers, and these repairs can represent more than half of your machine maintenance costs. This wear can also lead to reduced resale values or extra charges at the end of your lease. Too much travel time could also indicate a problem with your site’s setup. ActiveCare Direct monitors excavator travel time across the entire fleet and by individual machine. It can help you determine if you need a higher number of smaller excavators to manage the workload or if your excavating/loading locations and/or haul routes aren’t configured efficiently.

Learn more about ActiveCare Direct and see how these online dashboards can help you easily spot and correct machine misuses to lower your costs.

By Jim Bretz