Buyers who only track fuel costs underestimate true hourly operating cost by 40-60%. A complete framework includes fuel, parts, scheduled service, labour, depreciation, financing, and overhead.
Cost framework for a 25-tonne mid-class machine
| Cost element | USD per hour | % of total |
|---|---|---|
| Fuel (20 L/h × $1.20) | $24 | 30% |
| Scheduled service (oils, filters) | $5 | 6% |
| Wearing parts (teeth, pins, undercarriage) | $12 | 15% |
| Operator labour | $8 | 10% |
| Depreciation (8-year, 12,000h) | $15 | 19% |
| Financing interest | $5 | 6% |
| Repairs & unscheduled maintenance | $8 | 10% |
| Overhead, insurance | $3 | 4% |
| Total | $80 | 100% |
An $80/hour operating cost is typical for African 25-tonne mid-class operation. Mining-class operations run $250-450/hour. Caribbean mid-class operations typically $90-110/hour (higher labour, lower fuel intensity).