How to verify operating hours in used machinery?

Are you trying to figure out the true operating hours of used heavy machinery? Smart move! Hour meters aren’t always accurate, they can be reset or manipulated, which might end up costing you more in repairs or even in the purchase price. So, how do you go beyond the meter and get a real, data-backed picture of how much work a machine has actually done?

At makana.com, we specialize in detailed equipment inspections, using manufacturer records, diagnostic tools, and hands-on assessments to verify operating hours. But first, let’s answer this important question. 

Why operating hours matter more than machinery age?

A 10-year-old Caterpillar 320 excavator with 5,000 hours may be in far better condition than a 5-year-old unit with 15,000 hours. That’s because operating hours reflect how much wear and tear the machine has experienced, directly impacting the condition of its engine, hydraulics, and undercarriage.

• Engines & Transmissions: Most heavy equipment engines and transmissions last 10,000 to 20,000 hours with proper maintenance. A machine that has exceeded this range without major overhauls is a high-risk purchase.

• Hydraulic Systems: Hydraulic pumps and cylinders typically need major servicing after 8,000 to 12,000 hours. Machines with significantly lower reported hours but clear hydraulic wear could indicate false readings.

• Resale Value: Buyers and sellers set prices based on hours. A 5,000-hour machine could be worth 20-40% more than a similar model with 12,000 hours.

How to verify equipment operating hours?

1. Check manufacturer records and telematics data

Leading manufacturers store equipment operating history in centralized databases, accessible via authorized dealers. If the machine has been serviced at a dealership, its real operating hours should be on record.

Take, for instance, a Komatsu PC200-8 excavator listed with 6,500 hours. Before making a purchase, you request the Komtrax report, which shows that the machine actually had 11,200 hours during its last dealership service. This discrepancy suggests the hour meter was likely reset or replaced, a major red flag that calls for further inspection.

How to get this data?

• Caterpillar (CAT): Request a Product Status Report (PSR) via a CAT dealer.

• Komatsu: Komtrax system stores machine usage details.

• Volvo-CE: MATRIS reports provide machine history, including operational hours, fuel consumption, and even operator behavior.

2. Use onboard diagnostics to read actual hours

Even if a meter has been tampered with, the ECU (Electronic Control Unit) of modern construction machines keeps a separate, internal record of operating hours. Accessing this requires diagnostic software or an OEM scan tool.

Consider the case of a Caterpillar 950M wheel loader with an hour meter showing 7,800 hours. When connected to a CAT ET scanner, however, the engine ECU reveals 12,300 hours, revealing clear evidence of meter tampering.

This illustrates why it’s important to check the internal records stored in the ECU, especially when the hour meter appears suspicious.

To ensure accurate diagnostics for CAT equipment, use a CAT ET scanner to extract data from the engine and transmission ECUs. For Komatsu machines, dealers can access Komtrax records through an Equipment Management System (EMS) report, providing reliable information for equipment verification.

3. Look for hour meter replacement signs

Sometimes, meters aren’t tampered with, they’re just replaced. A new hour meter isn’t necessarily dishonest, but it should be documented in service records. If there’s no record, it’s a red flag.

What are key indicators of replaced hour meter?

When assessing a forklift or any heavy equipment, it's important to watch out for key indicators that the hour meter might have been replaced. One key indicator is if you see a newer hour meter on an older machine, this suggests it has been swapped.

Additionally, look for signs of screw tampering such as scratches or fresh paint around the meter area, which indicate it might have been removed. 

Another clear sign is inconsistent wear. For example, a machine with only 4,000 hours on the meter but showing worn-out joystick grips, torn seat covers, or faded labels likely has a much higher actual usage. These inconsistencies can help you determine if the hour meter's reading truly reflects the equipment's usage history.

This article discusses the issue of hour meter tampering on agricultural equipment.

4. Inspect undercarriage, hydraulics & wear points

A machine’s physical condition can tell a different story than its hour meter. Focus on components that naturally degrade with usage.

Key inspection points:

• Undercarriage (for track machines): At 5,000-6,000 hours, track chains, rollers, and sprockets should show moderate wear. Heavy wear with low-hour readings suggests a false reading.

• Hydraulics: A 5,000-hour excavator should not have significant hydraulic leaks, weak cylinders, or sluggish operations.

• Bucket & Pins: Look for excessive pin play and worn-out bushings, these should match the reported hours.

For instance, a Kobelco SK350LC excavator with 4,200 hours appears to be in better shape than expected. However, after closer inspection, worn-out track links, hydraulic drift, and a leaking swing motor are evident, all signs that suggest the machine has likely been used for over 10,000 hours.

This further reinforces the importance of inspecting physical components in addition to the hour meter reading.

How makana.com ensures accurate equipment inspections?

At makana.com, we don’t just rely on information provided by the seller, or conduct quick outdoor inspections. Instead, we follow a thorough process to ensure complete transparency. Here's how we guarantee accurate inspections and working-hour verification:

1. Inspections are conducted in a controlled environment

We ensure each machine is inspected under optimal conditions for a clear and accurate hour meter reading.

2. Comprehensive equipment inspections

At Makana, our inspection experts, with over 10 years of experience, conduct a thorough inspection of each machine based on 75+ checkpoints. This includes the hour meter, engine performance, hydraulic systems, and overall wear.

We document every detail with high-resolution images, detailed reports, and operational videos, all handled by the Makana team without relying on any external parties.

3. Multiple methods to verify working hours of heavy machines

To ensure accuracy, we cross-check operating hours using multiple verification methods:

• Physical inspection of the hour meter: High-resolution images are captured, allowing buyers to see the exact reading.

• Cross-referencing with service records: When available, maintenance history is reviewed to match logged hours with past services.

• Operational testing: The machine is run under load to verify the hour meter and performance, with operational videos available on our website.

4. Remote buyers can verify working hours via video and virtual tours

Makana.com offers multiple ways to inspect machines remotely:

• Operational video: Every machine listing includes a detailed operational video showing the engine running under load, the hour meter reading in action, and key functionality tests such as hydraulic performance and movement. This provides buyers with a clear view of the equipment’s condition before purchase.

• Interactive 360° equipment tours: For select machines, we offer immersive 360° virtual tours. Buyers can explore the equipment from every angle, zoom in on key areas. The hour meter can also be viewed up close in high detail, ensuring complete transparency.

Take a look at our full inspection process, where we evaluate over 75 points using advanced testing methods to ensure accuracy and reliability.

Final Takeaway

Verifying operating hours isn’t just about protecting your investment, it’s about making informed, data-driven decisions. If a seller can’t provide telematics reports, ECU readings, or clear physical evidence, proceed with caution.

At makana.com, we believe in radical transparency. our inspection process ensures you know exactly what you’re getting, no surprises, no guesswork.

Looking for verified, inspected used construction equipment? Visit makana.com today.