Even experienced wheel loader operators can benefit from these tips to extend the life and performance of the wheel loader
Even the most skilled operator can shorten the life of the wheel loader and reduce its productivity by misusing certain functions or by operating the machine in a way that accelerates the wear of parts. When a new user falls into the control, the risk will increase dramatically.
Operator training is essential, and this is even more important when a new machine is put into use. Operators who jump onto the new machine for the first time may not even realize they are using it incorrectly. If they do not understand its features, functions, and technology, they are likely to run the loader in the same way as any other machine. However, as technology changes so quickly, unknowing operations can cause many problems, leading to damage or wear.
The operating manual is another valuable resource. In addition to basic training for operators, the research manual is one of the best ways for operators to get started quickly and increase productivity-both can bring considerable returns for the company to complete more work.
The most common areas of wear on loaders are front pins, buckets, bucket wear plates and teeth; lack of general maintenance can accelerate this wear. For example, lack of grease will accelerate the wear of the front pins. Therefore, be sure to follow the grease and other daily maintenance guidelines in the operation manual.
Monitor the bucket and rotate or replace the front wear plate before starting to tear the bucket itself. If the wear plate is bitten to the point where it starts to wear on the bucket prematurely, the cost will be high.
Matching the bucket to the application and material will reduce the force required to drive into the pile. This in turn can reduce the wear of the front pins, bucket, bucket wear plates and teeth. The choice of bucket also affects the wear on the front of the machine. Choose the bucket that suits the application and material. The bucket should have easy access to the material to reduce undue stress on the pins and bushings attached to the loader.
Avoid running the engine at full rpm and hitting the pile hard, as this will put pressure on the bucket and cause the bushings and pins on the front of the machine to wear. In addition, it burns more fuel than needed for the process.
All loader brakes (except hydrostatic machinery) work by friction and generate heat. Excessive use of the brake can lead to overheating and premature wear, which may cause the brake to fail before it fails. Common reasons include:
In order to prolong the brake life, the train driver should slow down as soon as possible before braking, and allow the weight and load of the machine to close the loader.
Wear of gearboxes and gearbox clutches can be a problem, depending on how the machine operates. Improper gear shifting will cause increased wear on the transmission and clutch.
High-speed shifting is the most common culprit. In other words, the operator uses the gearbox and torque converter to change direction: the operator reverses the loader, “pushes” it into forward gear and hits the throttle, and vice versa. If they are loading the truck all day, don’t touch the brakes. , All the increased force goes into the gearbox and torque converter, causing these components to overheat.
Although this approach can reduce cycle time, it can also lead to premature failure of very expensive components. Fortunately, among other functions, manufacturers are choosing whether to reduce the burden on the driver through automatic transmission to reduce excessive wear.
Preheating the loader before use can not only ensure that the hydraulic system is working properly, but it can also minimize the risk of excessive wear on components due to lack of proper lubrication.
The loader operator may skip preheating during start-up, but this may be difficult on the engine and hydraulic system. Cold oil also cannot lubricate well, so reaching operating temperature before operation will extend component life.
When starting the loader, follow the manufacturer’s instructions for preheating. Other systems (such as hydraulic systems and axles) will warm up while the machine is working, so operators should expect that the machine will not be able to perform at full performance before reaching temperature.
At the end of the day, shutting down is equally important. The average speed of the turbocharger on a large diesel engine can reach 40,000 to 50,000 rpm. If you don’t let the machine idle and cool for at least two to three minutes, the turbine will still spin after 30 minutes without oil entering the bearing, which will generate heat and cause a lot of internal wear. Let the machine cool down before shutting it down, which means that the turbine will not spin for a long time after shutting down.
Manufacturers are working to reduce such risks by increasing timer shutdowns. If provided as an option, it is a cheap price compared to the high cost of replacing the turbocharger.
Inexperienced operators can easily spin the tires, which is one of the worst things for a wheel loader. The machine cannot use the differential lock to lock the front axle, so all the power will go to the two front tires instead of just one, which will reduce spin. The result is premature tire wear.
Improper inflation pressure is another common cause of excessive wear on expensive loader tires. For radial tires, low air pressure generates heat, because the rubber flexes under its full weight. If there is no recommended tire pressure to keep the sidewalls rigid, the tire will overheat severely, degrading the rubber compound and shortening the life of the tire.
In some cases, tire rotation is a malfunction of the tire, not an operator’s malfunction. One of the reasons is the wrong type of wheel loader tires in the app. Ensure that the tread pattern meets the application requirements. For example, a high-traction tire with a more open tread pattern will wear faster on the pavement surface. Therefore, if the loader mainly runs on concrete or asphalt, L4 or L5 will reduce wear. If the loader will mainly work in the soil, choosing a more aggressive traction pattern is a better choice.