Maintenance objective

The more specific objectives of maintenance management are as follows:

 to optimize the reliability of equipment and infrastructure;
 to ensure that equipment and infrastructure are always in good condition;
 to carry out prompt emergency repair of equipment and infrastructure so as to secure the best
possible availability for production;
 to enhance, through modifications, extensions, or new low-cost items, the productivity of existing
equipment or production capacity;
 to ensure the operation of equipment for production and for the distribution of energy and fluids;
 to improve operational safety;
 to train personnel in specific maintenance skills;
 to advise on the acquisition, installation and operation of machinery;
 to contribute to finished product quality;
 to ensure environmental protection.

Forms of maintenance
 Maintenance has three major forms:
a) design-out maintenance;
b) preventive maintenance, which includes systematic (periodic) maintenance and
condition-based maintenance;
c) corrective maintenance.
These are illustrated in figure 21.5.

Figure 21.5: The forms of maintenance

 Maintenance can also be divided into planned and unplanned maintenance (or scheduled and
unscheduled). The following chart highlights the relation to the previous chart.
 Figure 21.6: Planned and unplanned forms of maintenance

Below is a brief explanation of the terms used in the two charts.

Maintenance- Maintenance is the function whose objective is to ensure the fullest

availability of production equipment, utilities and related facilities at
optimal cost and under satisfactory conditions of quality, safety and
protection of the environment.
1. Design-out This is also known as plant improvement maintenance, and its object is
maintenance- to improve the operation, reliability or capacity of the equipment in
place. This sort of work usually involves studies, construction,
installation, start-up and tuning.
2. Preventive The principle of preventive maintenance is anticipation. It is put into
maintenance- practice in two forms: systematic (periodic) maintenance and condition-
based maintenance.
2a. Systematic(periodic) This consists of servicing equipment at regular intervals, either
maintenance- according to a time schedule or on the basis of predetermined units of
use (hours of operation or distance travelled). The aim is to detect
failure or premature wear and to correct this before a breakdown occurs.
The servicing schedule is usually based on manufacturers’ forecasts,
revised and adjusted according to experience of previous servicing; this
information is recorded in the machine file. This type of maintenance is
also called periodic maintenance.
2b. Condition-based This type of maintenance, also called predictive or auscultative
maintenance- maintenance, is a breakdown-prevention technique which requires no
dismantling, as it is based on inspection by auscultation of the
equipment involved. It requires continuous observation of an item of
equipment in order to detect possible faults or to monitor its condition.

3. Corrective Also called breakdown maintenance, palliative or curative maintenance.

maintenance- This form of maintenance consists of:
 troubleshooting on machines whose poor condition results in
stoppage, or in operation under intolerable conditions;
 repairs.
Planned maintenance- Maintenance which is known to be necessary sufficiently in advance for
 normal planning and preparation procedures to be followed.
Unplanned maintenance- This is maintenance which is not carried out regularly as the need for it
is not predictable; it is sometimes called unscheduled maintenance.

The seven forms of maintenance distinguished above are the main types currently used in practice.
 Periodic maintenance of wheel loader

Maintaining your wheel loader is simple if you follow a wheel loader inspection checklist. It should
cover all service points, including:
1. Safety equipment & operator cab 7. Steering system
2. Engine 8. Fluids & lubrication
3. Tier 4 CEGR 9. Hydraulics
4. Tier 4 SCR 10. Electrical system
5. Cooling system 11. Powertrain
6. Brake system 12. Miscellaneous additional maintenance
When it comes to wheel loaders, preventative maintenance follows the 50-hour rule.
Every week, a light in your head — and possibly your dashboard — should illuminate,
reminding you that measures must be taken as soon as possible to keep your wheel loader
running smoothly. In addition to PM tasks every 50 hours, wheel loader owners must
schedule further inspections every 100 hours, every 500 hours and every 1,500 hours. Of
course, there is also a daily schedule of preventative maintenance, consisting of checking
and refilling fluids and giving the machine a good cleaning after the day’s work.

50 HOURS (WEEKLY)

The first 50-hour check will likely take place following the first week of the machine’s use.
These tasks are recommended every 50 hours or every week. Much of the maintenance
required at 50 hours is similar to your daily work. You need to check the engine and
hydraulic oil and brake fluid, refilling if it’s low. Another daily task you’ll need to do more
thoroughly every 50 hours is cleaning the dust valve on the air filter housing.

New maintenance jobs that must be completed every 50 hours include checking the engine
and hydraulic oil coolers. You’re looking for contamination. The V-belt needs your attention
at 50 hours as well. In addition to its overall condition, you need to check the tension,
tightening if necessary. You must also drain the water from the fuel/water separator and
clean the filter insert on the fuel pump. It may require replacement.

Lubrication is your next 50-hour task. You’ll want to lubricate the bearings located in the following
areas: driveshaft, steering cylinder, articulation joint, lift arm linkages, tilt rod, tilt lever, lift
cylinder, tilt cylinder, quick-hitch and all hinges, joints and fittings (e.g. door arrester).
Every 50 hours of operation, it’s recommended that wheel loader users check the function of
the service and park brakes, steering system, lights and electrical system and the tires for
damage, air pressure and tread depth. Additionally, all connections need to be examined for
leaks. Make sure you check each of the following components: air intake line; engine
lubrication points; fuel lines; and the cooling, steering, hydraulic and brake systems.

100 HOURS

After 100 hours of operation, a compact wheel loader should receive its first formal
inspection. The oil and filter components will receive particular attention during this once-
over. You must change out each of the following components: engine oil and oil filter, fuel
filter and the hydraulic oil filter insert. Inspection of several areas must take place at 100
hours. Brake pads must be checked and replaced if needed on both the service and park
brake systems. The axle oil should be checked for contamination in all locations. Wheel
loader operators must also check the screw connections throughout the machine for
tightness. Some areas that you will need to pay close attention to include the engine bearing,
steering and hydraulic systems, loader unit (pin locking), axle mounting, counterweight,
driveshaft and the cab. The electrical system should also be examined. You’ll want to check
the electric and ground connections, as well as chafing on the wiring harness and battery
terminals. Just don’t forget that all of your 50-hour PM jobs must also be completed at this
time too.
500 HOURS

At 500 hours, wheel loaders will receive their second inspection. First-time PM tasks during
this assessment include replacing the air filter insert, changing the axle oil, both at wheel
end and center of axle, for the front and rear axles, draining the condensation water in the
hydraulic oil tank (if using biodegradable oil), checking the battery for a good charge and
checking the engine timing via the valve tip clearance. These assignments must be repeated
every 500 hours. And of course (don’t forget again!), your 50-hour PM jobs must be a part
of your 500-hour inspection.

1,500 HOURS

Remembering what tasks take place during every 1,500-hours inspection is simple —
everything. That’s right. Every task mentioned in this article must be completed at the
1,500-hour assessment. All oil and filter changes must be completed. All inspection work
must take place. All lubrication service must be done. All components must be tightened,
and, of course, all 50-hour, weekly assignments must be carried out. There are a few
additional tasks that must be completed for the first time during this inspection and every
1,500 hours thereafter. They include changing the hydraulic oil and the breather filter in the
hydraulic oil tank and cleaning the dust filter on the heating system.

WINTER IS COMING

Wheel loaders are great machines for year-round use. So when the seasons change, do some
of the maintenance procedures. In extreme cold weather situations, it is important to check
the antifreeze and washer fluid more often than on the printed schedule to be sure that it is
full and not frozen. Also during cold conditions, the use of an engine preheater system can
be helpful for top quality performance. The preheating system warms the engine fluids and
hydraulic tanks before starting to ensure proper and smooth flow through the machine.
Adjustments also need to be made for the fluids in extreme operation conditions. For
example, in cold weather, thinner grade oil may be required to properly lubricate engine and
hydraulic systems. In extremely hot weather, conditions call for thicker oil. Lastly,
temperature changes can be harmful to the batteries, which should be checked periodically.

Anytime wheel loaders are used for applications of de-icing salts in cold climates or for
hauling or spreading fertilizer, the loader is subject to a highly corrosive atmosphere. Under
these conditions, preventing rust should be a top priority. Salt and fertilizer can eat away at
metal parts of the wheel loader causing premature corrosion. Rubber components like hoses
and tires will experience a more rapid pace of deterioration. Application of an aggressive
media protection, like a spray-on corrosion inhibitor, should be applied to all main metal
components that are susceptible to rust. Also, one of the best and easiest ways to protect
your asset is to wash the wheel loader every day when used in these applications.
 Types of fuel

 Chemical
o Solid fuel
o Liquid fuels
o Gaseous fuels
o Biofuels- biomass.
o Fossil fuels- Fossil fuels are hydrocarbons, primarily coal and petroleum (liquid
petroleum or natural gas)
o Energy
 Nuclear

General types of chemical fuels

Primary (natural) Secondary (artificial)

wood, coal, peat, dung,

Solid fuels coke, charcoal
etc.

Liquid
petroleum diesel, gasoline, kerosene, LPG, coal tar, naphtha, ethanol
fuels

Gaseous hydrogen, propane, methane, coal gas, water gas, blast

natural gas
fuels furnace gas, coke oven gas, CNG