Common Mistakes to Avoid When Using an Excavator Long Arm

Below are the most common mistakes to avoid — each with its real-world risks and practical solutions.

Using a Standard Bucket Instead of a Long Arm Bucket

Why It’s a Problem

A standard excavator bucket is designed for short booms and normal digging depth. When used with a long arm, the bucket becomes too heavy and unbalanced, increasing stress on the hydraulic system and reducing digging efficiency.

The Consequences

Excessive load on boom and stick cylinders

Premature wear on pins and bushings

Reduced machine stability, especially during full extension

The Right Solution

Always use a lightweight long arm bucket designed for extended reach applications. It reduces the total working weight and ensures smoother operation, particularly for dredging and deep trenching.

No Counterweight Installed

Why It’s a Problem

A longer boom shifts the excavator’s center of gravity forward. Without the right counterweight, the excavator can easily lose balance, especially when lifting material at maximum reach.

The Consequences

Risk of tipping forward

Damage to swing bearing and undercarriage

Reduced safety for the operator

The Right Solution

Install a custom counterweight based on your excavator model and arm length. For example, a CAT D6R bulldozer used for land leveling also relies on proper balance — the same principle applies here. A professional counterweight setup ensures stability and safer operation.

Incorrect Hydraulic Pressure Settings

Why It’s a Problem

Hydraulic pressure directly affects the performance of the long reach arm. If it’s set too high, it can overstress the cylinders and seals; too low, and the arm loses digging power.

The Consequences

Hydraulic oil leakage and seal failure

Overheating in long-term operation

Reduced working efficiency

The Right Solution

Always check the hydraulic system pressure after installing the long arm. Follow the manufacturer’s recommended settings or consult your equipment supplier. Using a pressure gauge regularly can prevent costly repairs.

Overloading at Maximum Reach

Why It’s a Problem

The further the arm extends, the lower its lifting capacity becomes. Many operators push the machine beyond safe limits, leading to structural damage.

The Consequences

Bending or cracking of the boom and stick

Stress on hydraulic cylinders and weld joints

Potential overturning in unstable ground conditions

The Right Solution

Never exceed the load chart limit of your excavator long arm. If you need to lift heavier materials, use a shorter reach or stronger model. Overloading once might not show immediate damage, but repeated abuse shortens your arm’s life significantly.

Ignoring Welding Cracks and Structural Damage

Why It’s a Problem

Long reach arms experience extreme stress, especially at the joints and welds. Small cracks may seem harmless at first, but they grow quickly under heavy load and vibration.

The Consequences

Structural failure during operation

Safety hazards for operators and nearby workers

Costly downtime for repair or replacement

The Right Solution

Perform regular visual inspections before and after each project. Check welding seams, pin holes, and cylinder mounts. If cracks are found, stop using the machine immediately and repair using certified welding standards.

Using the Wrong Cylinder Stroke

Why It’s a Problem

Each hydraulic cylinder is designed with a specific stroke length. Using the wrong one changes the working geometry of the arm, reducing efficiency and causing misalignment.

The Consequences

Cylinder bottoming out during operation

Damage to mounting brackets

Reduced digging range and precision

The Right Solution

When customizing or replacing cylinders, always confirm the stroke and bore size match your long reach design. Working with professional suppliers like Dewanda ensures every excavator attachment and part fits your machine’s specifications.

Final Advice for Safe and Efficient Long Arm Operation

Operating a long reach excavator requires more than just skill — it demands attention to detail and proper equipment setup. Avoiding the above mistakes will extend your long arm’s service life, improve efficiency, and ensure safe working conditions.

If you’re planning to upgrade your excavator with a long arm, high-quality attachments, or related excavator parts, Dewanda provides complete customization and support for all major brands.

For technical assistance, pricing, or detailed specifications — contact us.