Analysis of main parts of loader and solutions to common faults
Posted: Apr 27th, '25, 03:00
1. Analysis of the main parts of the loader
Understanding the key parts of the loader is the basis for mastering the "loader repair and maintenance skills". The following are the most core parts of the loader:
1. Engine system
As the "heart" of the whole machine, "the performance of the loader engine directly determines the operating efficiency". The engine not only needs to provide stable high torque output, but also has good fuel economy and durability. Common brands such as Cummins and Weichai Power are particularly outstanding in "loader engine selection under heavy load conditions".
Common faults and responses:
Fault phenomenon: insufficient engine power or difficulty in starting.
Solution: Check whether the fuel supply system is unobstructed, whether the air filter is blocked, and replace the oil and filter element in time to maintain the "optimal working state of the loader engine".
2. Hydraulic system
The hydraulic system is responsible for driving the boom, bucket and steering mechanism, and is the key to achieving "efficient hydraulic operation performance of the loader". Hydraulic pumps, hydraulic valves, cylinders and pipelines constitute the core components of this system.
Common faults and solutions:
Fault phenomenon: The boom cannot be lifted and the movement is slow.
Solution: Check the hydraulic oil level and quality, eliminate oil leakage problems, and pay attention to whether the hydraulic pump is worn.
3. Gearbox (transmission system)
"Loader gearbox failure rate analysis" shows that the stability of the transmission system directly affects the adaptability of the equipment under complex working conditions. In particular, the combination of planetary gearbox and torque converter is widely used in medium and large loaders.
Common faults and solutions:
Fault phenomenon: large gear shift impact or failure to shift normally.
Solution: Check the gearbox oil level and contamination, and replace it if necessary; at the same time, check the electronic control system and sensor fault code.
4. Axle and tire system
The axle undertakes the important task of transmitting power and supporting the weight of the whole machine. According to different use environments, users need to reasonably configure the "loader drive axle type selection", for example, the use of wet brake axle can improve the safety of mining operations.
Tires affect the traction, stability and passability of the loader. "Recommendation of wear-resistant tires for loaders" usually selects heavy-duty tires with high wear resistance and puncture resistance to adapt to complex terrain.
Common faults and responses:
Fault phenomenon: abnormal tire wear or puncture, abnormal noise from the axle.
Solution: Maintain correct tire pressure, check the axle lubricant regularly, and avoid overloading.
5. Structural parts (frame and boom)
"Optimization of the structural strength of the loader frame boom" is the basis for ensuring the durability of the whole machine. High-strength steel, optimized force design and advanced welding technology are all important factors in extending the service life of the equipment.
Common faults and responses:
Fault phenomenon: cracking of the boom and deformation of the frame.
Solution: Avoid overloading, regularly check key welds and connection parts, and repair small cracks in time.
2. Common fault response and prevention measures
In order to reduce the occurrence rate of faults and improve the continuity of operations, in addition to daily inspections, a scientific "loader fault prevention and maintenance plan" should be mastered:
1. Formulate standardized maintenance cycles
Develop a detailed maintenance plan based on the manufacturer's manual, covering core links such as "regular maintenance of loader hydraulic system", "engine three filter replacement cycle", and "regular inspection of transmission oil".
2. Implement status monitoring and fault warning
By installing the "loader remote monitoring system", real-time data such as engine speed, oil temperature, and oil pressure can be collected. Once an abnormality is found, an early warning can be issued, greatly improving the reliability of the equipment.
3. Operator skill training
Correct operating habits are an important guarantee for extending the life of the loader. The training content should include "correct starting and stopping operation methods for the loader", "reasonable use of the bucket to avoid impact", etc., to avoid damage caused by misoperation.
4. Use high-quality spare parts and consumables
Choosing "recommended loader original accessories" produced by regular manufacturers, such as engine filters, hydraulic oil, tires, etc., can significantly reduce the early failure rate of the equipment.
Understanding the key parts of the loader is the basis for mastering the "loader repair and maintenance skills". The following are the most core parts of the loader:
1. Engine system
As the "heart" of the whole machine, "the performance of the loader engine directly determines the operating efficiency". The engine not only needs to provide stable high torque output, but also has good fuel economy and durability. Common brands such as Cummins and Weichai Power are particularly outstanding in "loader engine selection under heavy load conditions".
Common faults and responses:
Fault phenomenon: insufficient engine power or difficulty in starting.
Solution: Check whether the fuel supply system is unobstructed, whether the air filter is blocked, and replace the oil and filter element in time to maintain the "optimal working state of the loader engine".
2. Hydraulic system
The hydraulic system is responsible for driving the boom, bucket and steering mechanism, and is the key to achieving "efficient hydraulic operation performance of the loader". Hydraulic pumps, hydraulic valves, cylinders and pipelines constitute the core components of this system.
Common faults and solutions:
Fault phenomenon: The boom cannot be lifted and the movement is slow.
Solution: Check the hydraulic oil level and quality, eliminate oil leakage problems, and pay attention to whether the hydraulic pump is worn.
3. Gearbox (transmission system)
"Loader gearbox failure rate analysis" shows that the stability of the transmission system directly affects the adaptability of the equipment under complex working conditions. In particular, the combination of planetary gearbox and torque converter is widely used in medium and large loaders.
Common faults and solutions:
Fault phenomenon: large gear shift impact or failure to shift normally.
Solution: Check the gearbox oil level and contamination, and replace it if necessary; at the same time, check the electronic control system and sensor fault code.
4. Axle and tire system
The axle undertakes the important task of transmitting power and supporting the weight of the whole machine. According to different use environments, users need to reasonably configure the "loader drive axle type selection", for example, the use of wet brake axle can improve the safety of mining operations.
Tires affect the traction, stability and passability of the loader. "Recommendation of wear-resistant tires for loaders" usually selects heavy-duty tires with high wear resistance and puncture resistance to adapt to complex terrain.
Common faults and responses:
Fault phenomenon: abnormal tire wear or puncture, abnormal noise from the axle.
Solution: Maintain correct tire pressure, check the axle lubricant regularly, and avoid overloading.
5. Structural parts (frame and boom)
"Optimization of the structural strength of the loader frame boom" is the basis for ensuring the durability of the whole machine. High-strength steel, optimized force design and advanced welding technology are all important factors in extending the service life of the equipment.
Common faults and responses:
Fault phenomenon: cracking of the boom and deformation of the frame.
Solution: Avoid overloading, regularly check key welds and connection parts, and repair small cracks in time.
2. Common fault response and prevention measures
In order to reduce the occurrence rate of faults and improve the continuity of operations, in addition to daily inspections, a scientific "loader fault prevention and maintenance plan" should be mastered:
1. Formulate standardized maintenance cycles
Develop a detailed maintenance plan based on the manufacturer's manual, covering core links such as "regular maintenance of loader hydraulic system", "engine three filter replacement cycle", and "regular inspection of transmission oil".
2. Implement status monitoring and fault warning
By installing the "loader remote monitoring system", real-time data such as engine speed, oil temperature, and oil pressure can be collected. Once an abnormality is found, an early warning can be issued, greatly improving the reliability of the equipment.
3. Operator skill training
Correct operating habits are an important guarantee for extending the life of the loader. The training content should include "correct starting and stopping operation methods for the loader", "reasonable use of the bucket to avoid impact", etc., to avoid damage caused by misoperation.
4. Use high-quality spare parts and consumables
Choosing "recommended loader original accessories" produced by regular manufacturers, such as engine filters, hydraulic oil, tires, etc., can significantly reduce the early failure rate of the equipment.