In extreme cold weather, construction machinery faces numerous challenges, including difficulty starting, sluggish lubrication, sluggish hydraulic operation, material embrittlement, fuel wax formation, and reduced battery performance. Even minor issues can lead to equipment failure, damage, or unplanned downtime. For operators, maintenance managers, and procurement personnel, understanding these cold-weather problems and implementing targeted solutions is crucial for ensuring smooth winter operations, extending equipment lifespan, and controlling operating costs.
This article addresses these issues from four perspectives: "Starting Problems," "Operation and Maintenance," "Adaptation to the Construction Environment," and "Organizational and Procurement Strategies." It provides specific recommendations and operational procedures based on common scenarios for construction equipment such as excavators, loaders, bulldozers, and road rollers.
Starting construction equipment in extreme cold is the most challenging aspect. The main difficulties include:
1.1 Reduced Battery Power and Insufficient Starting Current
The chemical reaction rate of a battery slows dramatically with decreasing temperature. Even at -30°C, the available starting current can drop significantly.
Insufficient starting current results in weak crankshaft rotation, prolonged starting time, and even failure to start.
Solutions:
Use a battery with a high cold cranking amps (CCA) rating and good low-temperature performance, or use multiple batteries in series or parallel to increase starting power.
During downtime, remove the battery and store it in a warm environment or use a battery blanket/heater to maintain its temperature.
Use a smart charger (constant voltage or constant current) to maintain battery voltage and capacity during non-operating periods.
Preheat the battery with a battery heater or other warming device before starting.
1.2 High Viscosity of Lubricating and Hydraulic Oils
At low temperatures, the viscosity of lubricating and hydraulic oils increases significantly, making it difficult for mechanical parts to move.
Poor lubrication leads to increased friction and accelerated wear during startup. Solutions:
Use low-viscosity or fully synthetic "winter-grade" lubricating oil and hydraulic fluid (e.g., multi-grade oil suitable for extreme cold or "Arctic-grade" oil).
Preheat the engine oil before starting or during initial operation using a heater (such as a crankcase heater or oil heater) to increase oil temperature and reduce viscosity.
Install or activate a crankcase heater or thermal shield (to block cold air and reduce heat dissipation) to maintain oil temperature.
1.3 Fuel Gelation or Waxing (Especially for Diesel Engines)
At extremely low temperatures, wax components in diesel fuel may precipitate and solidify, causing filter clogging or fuel line blockage.
Water freezing in the fuel system can also impede fuel flow.
Solutions:
Use low-pour-point (cold-flow) diesel fuel or add anti-wax and flow improver additives.
Keep the fuel tank full before ending work each day to minimize condensation and water accumulation.
Use a dual-stage fuel filter and a heated fuel filter or fuel pre-heater in extreme cold conditions.
Regularly drain water from the fuel filter and check the water separator for potential water accumulation and freezing.
1.4 Insufficient Radiator, Coolant, and Antifreeze Pressure
If the antifreeze concentration in the cooling system is insufficient or the quality is substandard, the freezing point of the coolant may not meet requirements at low temperatures.
Air in the cooling system or leaks can also cause poor circulation during startup.
Solutions:
Ensure the antifreeze/coolant system is suitable for temperatures below -40°C (e.g., 50:50 premixed, long-life type).
Check coolant, hydraulic fluid, and engine oil levels before starting to ensure they are within the recommended range, preventing air intake or damage due to low levels.
Install an electric heater, assembly heater, or heating pipes in the cooling system to preheat it before starting.
1.5 Insufficient Preheating and Idle Warm-up
Running under load immediately after a cold start can cause high stress and wear on the engine, hydraulic system, and transmission. Operating the machine without allowing the various systems to reach their normal operating temperature can easily cause premature damage.
Solutions:
After starting, allow the engine to idle at low speed and under no load for a certain period (usually 5-10 minutes, or as per the equipment manual) to allow the engine oil and hydraulic oil temperatures to rise to an appropriate range.
During idling, slowly cycle the various hydraulic circuits (lifting, swinging, steering, etc.) to gradually warm the hydraulic oil and lubricate the components.
If the machine model allows, use cold-start assist devices (such as a hot air starter, pre-heater, or crankcase heater).
The table below summarizes six steps for starting construction equipment in extremely cold environments; operators are advised to review it.
|
step
|
Key points of operation
|
Technical Parameters
|
|
1. Preheating |
Turn on the engine glow plug for 3 minutes or more and heat the oil pan to above -15°C |
Heating power≥500W |
|
2. Oil inspection |
Confirm that the engine oil is SAE 0W-30 grade and the freezing point of the antifreeze is≤-45℃ |
Engine oil pour point≤-55℃ |
|
3. Power supply guarantee |
Connect an external power source or activate the emergency starter |
Starting current≥800A |
|
4. Slow start |
The first ignition should not exceed 5 seconds, and try again after 30 seconds. |
Speed≥150rpm |
|
5. Idle warm-up |
Keep idling at 800rpm for 15 minutes, and then load when the water temperature reaches 40℃ |
Hydraulic oil temperature≥10℃ |
|
6. System self-test |
Scan dial alarm codes, focusing on monitoring ABS and DPF |
Fault code clearing rate 100% |
After successfully starting the construction equipment, maintaining its operating status and mitigating the risk of wear and failure caused by low temperatures is the core challenge of year-round winter operation.
2.1 Preheating and Proper Operation
During the initial stages of operation, operate the machine slowly and under light load, avoiding high-load operations to allow sufficient time for the systems to warm up.
Hydraulic system movements should be smooth and gradual; avoid sudden, large movements to prevent hydraulic shock in cold oil conditions.
If possible, increase the load gradually (for example, perform simple or small movements first, then proceed to heavy-duty operations).
Avoid frequent starting and stopping. If the work breaks are short, keeping the machine idling or running at low speed is safer than repeatedly cold-starting.
2.2 Remove Ice and Snow, Maintain Ventilation and Prevent Blockages
After each shift or at the end of each day, promptly remove ice, snow, and dust from the machine's exterior, air intakes, oil lines, filters, radiators, and exhaust outlets to prevent blockages or increased airflow resistance.
Check regularly for moisture or snow on hydraulic, oil, and filter components, as these can freeze or clog in low temperatures.
For tracked or chassis-type equipment, ice or frozen mud can cause increased wear or even jamming; these should be cleaned promptly. 2.3 Lubrication and Lubrication Point Maintenance
Use lubricants suitable for low-temperature environments (low-temperature grease, synthetic grease), ensuring that the lubricant maintains fluidity and lubrication performance under extremely cold conditions.
Regularly apply grease to critical lubrication points such as hinges, bearings, pins, ball joints, and steering linkages.
Lubrication should be performed when the equipment is still warm or preheated to avoid condensation preventing the grease from reaching the lubrication points.
2.4 Hydraulic System and Seal Protection
The viscosity of the hydraulic oil should be selected according to the manufacturer's recommendations for low-temperature environments.
Check the materials of seals, O-rings, and hoses to ensure they are suitable for low temperatures, and inspect for signs of aging, microcracks, or hardening. Rubber components are more prone to cracking or losing elasticity at low temperatures.
Avoid prolonged idling of the hydraulic system to reduce the risk of airlocks, uneven oil temperature, and oil line freezing.
Consider installing electric heating or insulation for critical valves or pipelines to maintain hydraulic oil temperature.
2.5 Cooling System and Temperature Control
Ensure the cooling system is in good condition: no leaks, no airlocks, proper coolant concentration, and reliable temperature control switches.
Depending on the operating environment and machine type, install localized heating devices or insulation on the cooling circuit, oil lines, or critical components.
For radiators, oil coolers, air conditioners, and heaters, regularly check that defrosting, dust removal, and de-icing functions are working correctly.
2.6 Monitoring and Inspection
Increase the frequency of daily inspections, especially before starting work in the morning, at midday, and in the evening, checking temperature, oil pressure, oil temperature, fuel status, hydraulic response, and instrument alarms.
If the equipment has a remote monitoring/sensor system, monitor temperature curves, oil pressure fluctuations, and abnormal lubrication alarms for timely alerts and troubleshooting.
Maintain records of low-temperature operation for critical components (e.g., engine, hydraulic pump, valves, seals) to accumulate operational data. 2.7 Emergency Response and Protection Measures
If any abnormalities are detected, such as startup issues, alarms, abnormal oil pressure, leaks, or jamming, operation should be immediately stopped and troubleshooting performed.
In extreme cold or rapidly changing weather conditions, shorten the work cycle or schedule rest and warm-up periods to avoid operating the equipment under load during the coldest periods.
During nighttime or extended downtime, use methods such as localized heating, insulation covers, or machine coverings to keep the entire machine or critical components warm and prevent freezing.
Besides equipment maintenance, construction environment and operational safety are particularly important in extreme cold conditions.
3.1 Road/Site Management
When operating on frozen ground or ice, test the foundation strength and bearing capacity in advance to prevent equipment sinking or skidding.
Apply salt, sand, or lay non-slip mats on work paths, slopes, platforms, and turns to improve traction.
Clear snow and ice from the site promptly to prevent equipment from getting stuck or losing control.
3.2 Operational Rhythm and Work Condition Coordination
Winter days are shorter; therefore, schedule work processes scientifically, prioritizing critical tasks and avoiding tasks unsuitable for the coldest periods.
If necessary, set up a heated workshop, pre-heating area, or heated shelter so operators can warm up the cab, controls, and pedals before entering the machine.
Operators should wear warm, non-slip, and safe work clothes to maintain hand dexterity and prevent frostbite.
3.3 Visibility, Safety, and Monitoring
Fog, snow, frost, and condensation can impair visibility; ensure clear vision, clean mirrors, and adequate lighting during operation.
Reduce the safety factor and increase redundancy for slopes, platforms, lifting operations, and working at heights.
Operate more smoothly, avoiding sudden braking, sharp turns, and jerky movements to prevent skidding or hydraulic shock.
3.4 Safety Training and Emergency Plans
Provide operators with pre-emptive safety training for cold weather operations, including appropriate clothing, anti-freeze measures, non-slip precautions, emergency procedures for cold weather shutdowns, irrigation, and de-icing. Develop a winter emergency response plan, and equip with necessary cold-weather emergency tools (such as heaters, anti-freeze agents, portable heaters, spare filters, lubricants, emergency batteries, etc.).
Strengthen communication and personnel monitoring systems between work teams to prevent health risks to operators in extreme cold environments (such as frostbite and hypothermia).
For managers and procurement personnel, mere operation and maintenance are insufficient; they should also ensure appropriate preparation in terms of equipment selection, spare parts configuration, and policy formulation.
4.1 Equipment Selection and Technical Evaluation
During the procurement stage, prioritize equipment models with "cold-region standards" or "cold-start packages" (such as crankshaft heaters, engine insulation, pre-heating systems, and cold-start auxiliary devices).
Review the cold-start performance indicators provided by the equipment manufacturer (e.g., guaranteed start-up time at -30°C, oil heating speed, starting current requirements) and corresponding modification kits.
Clearly specify "cold-region suitability" and "cold-start/operation guarantee" clauses in the tender or contract to ensure the supplier meets the extreme environment requirements.
4.2 Spare Parts and Consumables Support
Maintain a stock of lubricants, hydraulic oil, gear oil, low-temperature grease, antifreeze, fuel additives, filters, and seals suitable for low temperatures.
Store an adequate quantity of critical spare parts such as batteries, starter motors, fuel filters, oil pumps, valves, hoses, and heating elements to address increased failure rates in cold weather.
Purchase low-temperature versions or suitable spare parts to avoid performance degradation of general-purpose parts in extreme cold.
Calculate the lifespan of wear parts under low-temperature conditions, considering potential lifespan reduction.
4.3 Operating Procedures and Evaluation Mechanism
Develop detailed winter operating procedures, including pre-shift checks, cold-start preparations, warm-up time, inspection frequency, shutdown protection, and fault recording and analysis procedures.
Implement a low-temperature operation training and certification program for operators and maintenance personnel, assessing their winter driving, starting, and maintenance skills. Implement a comprehensive equipment health monitoring system (including temperature sensors, oil temperature sensors, vibration monitoring, and fault alarm systems) to provide early warning and management for low-temperature anomalies.
In performance and cost evaluation, establish incentive and penalty mechanisms for downtime and repair costs caused by low-temperature failures, thus encouraging all parties to take low-temperature protection seriously.
4.4 Budget and Cost Control
Allocate funds in the procurement budget for low-temperature adaptation measures (e.g., heaters, insulation covers, preheating system upgrades, premium low-temperature lubricants, etc.).
Analyze the failure rate, repair costs, and downtime costs under low-temperature conditions and incorporate them into the total cost of ownership (TCO) assessment.
During extremely cold seasons, consider providing backup equipment or implementing a rotation system to ensure uninterrupted operation of critical processes.
For long-term projects, consider investing in centralized insulation facilities, indoor repair workshops, and preheating parking areas to reduce losses caused by temperature fluctuations.
The following summarizes some key considerations for engineering vehicle procurement decisions, for reference by procurement personnel:
|
Configuration level |
Basic |
Professional |
flagship model |
|
Preheating system |
Intake air preheating |
Oil circuit + water circuit dual preheating |
Intelligent temperature control and full vehicle preheating |
|
Battery Solutions |
Ordinary lead acid |
AGM battery |
Lithium battery + supercapacitor |
|
Tire configuration |
Ordinary anti-slip pattern |
Self-heating snow tires |
Air pressure adjustable tracks |
|
Cost Difference |
+0% |
+35% |
+80% |
|
Applicable Scenarios |
Intermittent work |
8 hours of continuous operation |
24-hour polar operations |
In the harsh winter environment, the starting, operation, and maintenance of construction machinery face significant challenges. Only by comprehensively addressing aspects such as preheating, lubrication control, environmental adaptation, inspection and monitoring, system support, and spare parts strategy can we ensure stable and reliable equipment operation, reduce downtime, and extend equipment lifespan.
For operators, standardized low-temperature starting and maintenance procedures are the "operating manual" for safe operation.
For maintenance managers, meticulous inspections, rapid response, and temperature monitoring are key to preventing problems.
For procurement and management, support and assurance are needed in terms of equipment selection, spare parts supply, system design, and cost control.
If you have any questions about starting and operating construction vehicles in extremely cold winter conditions, please contact us. We also offer customized engineering vehicle solutions.
