In a mine, a haul truck that stops moving stops earning, and the cost of that stoppage is far larger than the repair itself. Reliability comes from a program that connects inspections, preventive maintenance, condition monitoring, tire management and haul road upkeep into one disciplined routine. This guide lays out a practical mobile equipment reliability program for mining fleets, and shows where Oxmaint maintenance management software keeps the records, schedules and work orders in one place.
Fleet Types and Use Cases: Mining
Mining Fleet Maintenance: A Mobile Equipment Reliability Program Built Around Availability
Haul trucks, loaders, dozers, graders and support vehicles each fail differently. A reliability program gives every machine class its own inspection, service and monitoring rhythm, and records the outcome.
The reliability pyramid
Reliability engineering and failure elimination
Condition monitoring and oil analysis
Preventive maintenance by hours
Operator and shift inspections
Accurate asset register and clean data
Why Mining Fleets Need a Different Maintenance Approach
Cost of failure
Haul trucks are among the most expensive assets a mine owns, and a single unplanned stop idles loaders, crushers and the trucks queued behind it. Trade sources quote lost-production costs from thousands to tens of thousands of dollars per hour, which varies widely by site, so calculate your own figure.
Operating environment
Dust, heat, grade, shock loading and 24-hour duty wear components faster than normal highway fleets and make planned downtime windows scarce.
Tire dependency
Industry sources describe large mining tires as costing tens of thousands of dollars each, and tire programs often rank among the largest single operating costs on a haul fleet.
Safety regulation
Mine safety regulators require examination of mobile equipment and correction of safety defects, so inspection records are part of compliance, not just good practice.
Machine Classes and Their Dominant Failure Areas
| Machine class | Major systems to protect | Typical failure drivers | Monitoring focus |
|---|---|---|---|
| Rigid haul trucks | Engine, drivetrain, suspension, brakes, tires, frame | Overload, heat, poor road surface, contamination | Oil sampling, tire pressure and temperature, payload, brake condition |
| Wheel loaders and excavators | Hydraulics, undercarriage or tires, buckets, swing and travel systems | Impact, dust, hydraulic contamination | Hydraulic oil cleanliness, wear parts, cylinder leaks |
| Dozers | Undercarriage, final drives, blades, cooling | Abrasion, ripping loads, overheating | Undercarriage measurements, coolant and oil trends |
| Motor graders | Circle drive, blade controls, tires, hydraulics | Neglected seals, worn cutting edges, cutting edge damage | Circle and blade inspection, hydraulic leaks |
| Water trucks and light vehicles | Pumps, brakes, steering, tires, lights | Mud, corrosion, high utilization | Pre-start checks, brake and steering findings |
Put Every Machine on a Reliability Schedule
See how hours-based preventive maintenance, shift inspections and work orders come together for a mixed mining fleet in Oxmaint.
The Five Layers of a Mobile Equipment Reliability Program
Layer 1
Clean asset data
Every machine has a unique ID, model, serial, component list and accurate hour meter. Without this, no schedule or cost report can be trusted.
Layer 2
Inspections every shift
Operators and supervisors complete pre-start and shift-end checks. Defects feed directly into work orders and are tracked to closure.
Layer 3
Preventive maintenance
Service tiers triggered by engine hours follow OEM guidance, adjusted by your own failure and sample history.
Layer 4
Condition-based work
Oil analysis, vibration, thermography and sensor data raise work orders when readings move, instead of waiting for a fixed interval.
Layer 5
Failure elimination
Repeat failures receive root-cause review, and findings change the PM, the part, the procedure or the operating practice.
Service Tiers by Engine Hours
OEM manuals define the actual intervals for each model, and extended-interval programs depend on oil sampling. Use the structure below as a template, then fill in the numbers from your own machine documentation.
PM-A
Frequent service
Fluid levels, filter checks, greasing, leak walk-around, tire pressure and wear documentation, oil sample collection.
PM-B
Intermediate service
Includes PM-A tasks, filter replacement, cooling system checks, brake and steering inspection, electrical connections and hose condition.
PM-C
Major service
Includes lower tiers, wheel-end and final drive checks, suspension and structural inspection, and component condition assessment.
PM-D
Component and overhaul planning
Schedules component change-outs and rebuilds based on hours, sample trends and measured wear, with parts and labor planned in advance.
Tire Management: The Heat Budget Problem
Heat is a main reason large mining tires are lost early. Tonne-kilometre-per-hour ratings describe how much work a tire can do before heat builds, so payload, speed, haul distance and ambient conditions all matter.
Inputs that raise tire heat
- Overloading or uneven loading
- Long, fast, uninterrupted hauls
- Low inflation pressure
- High ambient temperature
- Rough or poorly drained roads
Controls maintenance can own
- Scheduled pressure checks by position
- Tire inspection findings linked to work orders
- Position and rotation records for each tire
- Removal reason coding for failure analysis
- Coordination with road crews on problem sections
Tire records worth keeping
- Tire serial number, size, type and install date by machine and position
- Pressure and temperature readings over time
- Cuts, impacts and separation findings with photos
- Hours achieved at removal and the reason for removal
Haul Road Condition Is a Maintenance Input
Road surface, grade, berm height and drainage directly affect tire damage, suspension loading, fuel burn and cycle times. Treat road work as part of the reliability program and track grader availability like any other critical asset.
Grader missed or down
Rough or wet road surface
Impact and cut damage
Early tire and suspension failures
- Schedule grading passes per road segment and record completion on work orders
- Inspect berms, drainage and edge conditions on a defined routine
- Log road defects found by operators so crews can target them
- Compare tire damage trends against road work to prove the connection
Condition Monitoring That Triggers Work Orders
| Technique | What it detects | Work order trigger |
|---|---|---|
| Oil analysis | Wear metals, contamination, fuel dilution, coolant ingress | Results outside set limits or a rising trend |
| Vibration measurement | Bearing and gearbox wear, imbalance, misalignment | Alarm level crossed on rotating components |
| Thermography | Hot connections, overheating bearings and brakes | Temperature rise above baseline |
| Telematics and onboard data | Fault codes, payload, pressures, temperature events | Critical fault or repeated warnings |
| Wear measurement | Undercarriage, cutting edges, liners, brake linings | Measurement below replacement limit |
Planned Versus Reactive Maintenance on Site
Reactive pattern
- Failures found during the shift, parts ordered in a hurry
- Emergency labor, overtime and expedited freight
- Secondary damage to adjacent components
- Records written after the fact, if at all
Planned pattern
- Defects found early and scheduled into shutdown windows
- Parts, tools and labor staged before the machine arrives
- Failure limited to the original component
- Complete records created at the point of work
Shift Inspection Checklist for Mobile Equipment
- Walk-around for leaks, cracks, loose parts and damage
- Engine oil, coolant, hydraulic and transmission fluid levels
- Brakes, steering, retarder and parking brake function
- Tires, wheel nuts, rims and pressure condition
- Lights, horn, backup alarm, cameras and proximity systems
- Fire suppression system condition and seal integrity
- Seat belt, cab glass, mirrors and access ladders or handrails
- Any defect rated unsafe stops the machine until corrected
Contamination Control and Lubrication Discipline
Dust and dirty fluid shorten the life of engines, hydraulics and final drives faster than almost any other factor. Contamination control should be scheduled work with measurable results, not a good intention.
| Control point | Task | Evidence to record |
|---|---|---|
| Air intake | Inspect pre-cleaners, filters, ducting and seals | Restriction indicator reading and filter change date |
| Hydraulic system | Filter new oil before use, check breathers and return filters | Cleanliness test result and filter change record |
| Greasing points | Follow route-based lubrication with correct grease type | Completed route, missed points and grease usage |
| Fluid storage and transfer | Use sealed containers and dedicated dispensing equipment | Inspection of storage points and dispensing equipment |
| Cooling system | Clean cores, check fans, belts and hoses | Temperature trend and cleaning completion |
Using Operator Feedback as an Early Warning System
Operators feel changes in braking, steering, vibration and noise long before an alarm sounds. A fast, simple reporting path turns that experience into planned work.
What operators can report
- Unusual vibration, noise or smell
- Slow response from brakes or steering
- Warning lights that clear and return
- Temperature or pressure readings outside normal
What the system should do
- Create a defect record linked to the machine
- Notify the planner or supervisor
- Rate the defect for safety and production impact
- Tell the operator when the issue is closed
- Closing the loop with the operator builds trust, and trusted reporting produces better early warnings
- Photo and voice notes help technicians understand the symptom before they reach the machine
Repair, Rebuild or Replace: Using Cost History
Major components and whole machines eventually reach a point where repair costs and downtime outweigh the benefit of keeping them. Accurate history makes that decision a calculation rather than an argument.
1
Collect lifetime cost
Total parts, labor, outside services and downtime hours for the machine or component.
2
Review failure trend
Check whether failures are increasing in frequency or moving from small parts to major systems.
3
Compare options
Weigh rebuild cost, replacement cost, expected life and production risk during the work.
4
Schedule the outcome
Book the rebuild window, order parts and plan labor in the same system that holds the history.
Contractor and Rental Equipment
Many sites run contractor or rental machines alongside their own. Those machines still need to meet site safety and maintenance expectations, and the records should be visible to your planners.
- Register every contractor machine as an asset with owner, serial and entry date
- Require the same pre-start inspection form used on site equipment
- Track defects and corrective actions, and who is responsible for each
- Keep service records and inspection certificates attached to the asset
- Review performance before contract renewals using real downtime and defect data
Compliance Records for Mobile Equipment
Requirements differ by country, state and mine type. In the United States, surface metal and nonmetal mines have rules such as 30 CFR 56.14100 on examining equipment and correcting safety defects, and coal mines have their own provisions. Confirm what applies to your site.
| Record | Purpose | Maintenance system role |
|---|---|---|
| Equipment examination | Shows that checks were done before use | Digital inspection with date, operator and result |
| Safety defect correction | Shows hazards were fixed or the equipment was withdrawn | Defect-to-work-order link with closure date |
| Brake and steering tests | Shows safety-critical functions were verified | Scheduled test tasks and results |
| Fire suppression servicing | Shows protection systems are ready | Recurring inspection and service tasks |
Safety-Critical Systems That Deserve Their Own Schedule
Some systems protect people first and production second. Give them dedicated, frequent tasks with named owners and documented results.
- Service and parking brakes, retarders and brake cooling, with test results recorded
- Steering components, accumulators and emergency steering function
- Fire detection and suppression systems, including nozzles, cylinders and seals
- Proximity detection, cameras, lights and alarms that support collision avoidance
- Structural inspection of frames, hitches, ladders and ROPS or FOPS structures
- Seat belts and operator restraint systems
Reliability KPIs for the Mine Site
Physical availability
Share of calendar time the machine is mechanically able to work
Mean time between failures
Average operating hours between breakdowns by machine class
Mean time to repair
Average time to restore a machine, split by diagnosis, parts wait and labor
PM compliance
Preventive tasks completed on time compared with tasks due
Planned work ratio
Planned labor hours as a share of all maintenance labor hours
Tire cost per hour
Tire spend divided by operating hours, with premature removals highlighted
Parts, Inventory and Shutdown Planning
- Classify spares by criticality so slow-moving but essential items are always stocked
- Link standard jobs to parts kits so planners can stage stock before a machine arrives
- Track component serial numbers so rebuilds and warranties are traceable
- Use work order history to forecast major component demand
- Plan shutdown windows around hours-based services, not only calendar dates
Weekly Reliability Review Agenda
- Review machines that lost the most availability and the reason codes behind it
- Check overdue PMs and inspections, and agree who clears them and when
- Examine oil sample alerts and condition monitoring warnings that are still open
- Discuss tire removals and any damage linked to road conditions
- Confirm parts and shutdown readiness for the next planned window
- Assign actions with owners and dates, and verify last week's actions were closed
Implementation Path
- Audit the asset list, hour meters and existing service history
- Rank machines by production criticality and safety exposure
- Load OEM PM tiers and build hours-based schedules for each model
- Replace paper pre-start and shift inspections with mobile forms
- Add oil sampling and tire records as scheduled tasks
- Review failures monthly and update schedules from what the data shows
Frequently Asked Questions
How should PM intervals be set for haul trucks?
Start with the OEM schedule, then adjust using oil sample results and failure history. Hours, not calendar days, should usually drive the trigger.
Is tire management part of maintenance?
Yes. Pressure checks, inspections and removal records belong in the same system as services. Sign up to see how tire tasks are scheduled.
Can one system handle trucks, loaders and graders?
Yes, using separate asset classes, checklists and PM tiers for each machine type, with shared reporting for availability and cost.
What if mobile coverage is limited underground or in pits?
Choose a mobile workflow that lets technicians capture data on the device and sync when a connection returns. Confirm this during a demo.
Where do we start?
Begin with your most critical machine class and one inspection form. You can book a demo to plan the first phase.
Build a Reliability Program Your Whole Fleet Can Follow
Bring inspections, services, tires, work orders and failure history together so your mobile equipment spends more shifts working and fewer waiting for repairs.
