Professional Documents
Culture Documents
Front Loader Operation Techniques
Front Loader Operation Techniques
Front Loader Operation Techniques
follow us on
FRONT LOADER OPERATION TECHNIQUES
SECURITY IN THE ROOM cefomn
Industrial Mining Training Center
Security
In case of emergency in the room
Leave the path clear to the exit doors.
Evacuate calmly to the designated emergency meeting points,
until waiting for the order to restart work tasks.
cefomn
Industrial Mining Training Center
PRESENTATION
Ppesem(2c7ém fe mS(rUc(tO?
cefomn
Industrial Mining Training Center
GENERAL RULES.
LUNCH 1 HOUR
1st INTERMISSION 10:15
15MIN
2nd INTERMISSION 15:15
15MIN
CELL
PHONES
OFF YES
cefomn
Industrial Mining Training Center
GOALS
SPECIFIC OBJECTIVES.
WORK AGENDA
100% ASSISTANCE
FRONT LOADER
The Front Loaders have the technical name Articulated Mechanical Shovels and
have been specially built for loading and lifting materials in the fields of open shortcut
mining, in construction, to fix roads, etc.
The Front Loader was manufactured in 1939 in the USA and consisted of a rigid
structure similar to a tractor but with a bucket in the front, mechanically operated by
cables, which was initially called PILOTHER.
There are many Brands and dimensions of Front Loaders such as:
Caterpillar Komatsu Volvo Case OYK Michigan Letourneu Shantui Clark
Liebherr JCB Merko Fiat Allis Kawasaki New Holland Kobelco
cefom
CLASSIFICATION OF THE
FRONT LOADERS
h
Recommended Distances
economically
Distance/Slope
0-500 ft./150 m
Loading and 0-10% slope
Hauling
da Wheel Loader More than 300 ft/150 m
Application Requirements
Excavation
- Tractive force
- Breakout Force
- Levante force
Burden
- Maneuverability
- Hydraulic/Speed Ratio
- Cycle time
- Load control
- Visibility
cefomn
Industrial Mining Training Center
Application Requirements
Tilt Linkage
Tilt Cylinder
Arms of
I raised
Scope
1
Full Dump
@Max. lift
Clear Height of
Download
Counterwei
ghts Joint
Ladle
cefomn
Industrial Mining Training Center
WHEEL LOADER
The components shown are:
1. Engine
2. Torque converter
3. Input Drive Shaft
4. Input Transfer Gear Box
5. Transmission
6. Output Transfer Gear Box
7. Front Drive Axle
8. Rear Drive Axle
9. Front and Rear Differential
10. Final Drives j
cefomn
Industrial Mining Training Center
SECURITY.
A.
M
cfomn
Industrial Mining Training Center
SECURITY.
SECURITY.
cfomn
SECURITY. Industrial Mining Training Center
A tire explosion is much more violent than a tire blowout. The explosion can
propel the tire, rim and axle components out of the machine. Stay out of the way.
Both the force of the explosion and the ejected components can cause property
damage, serious injury, or death.
cfomn
SECURITY. Industrial Mining Training Center
• ROPS Cab
• Seat belt
• Backup alarm
cfomn
• Horn
SECURITY.
• Mirrors
• Lights
• Communication radio
• Fire extinguishers
• The current cutoff
cfomn
SECURITY. Industrial Mining Training Center
Personal security
Machine safety
around the machine
Security features
Work area
Traffic patterns
Conditions
climatic
cfomn
Industrial Mining Training Center
SECURITY.
Always be alert!
cfomn
Industrial Mining Training Center
SECURITY.
Buckle up
of security:
On all teams, ALWAYS!
• Adjust for your comfort
• Adjust the seat to reach all controls and pedals.
• Readjustment during the work day.
• Support your back.
• Adjust the suspension.
cfomn
SECURITY. Industrial Mining Training Center
SECURITY.
Helme
t Safety glasses
Security
vest
thick gloves
Security shoes
cfomn
Industrial Mining Training Center
SECURITY.
Avoid clothing that could be a problem:
Ties
Loose clothing
Scarves
Rings
Wristwatches
Bracelets
cfomn
SECURITY. Industrial Mining Training Center
In the cabin:
Communication radio
Water
In the team:
Fire extinguisher
Fire suppression systems
First aid kit
At the job site:
washing stations
Emergency numbers
On-site offices
First aid stations
cfomn
Industrial Mining Training Center
SECURITY.
Three causes of accidents are…
• Equipment
• Climate
• human element
Carry out operations without prior training Operate equipment without authorization
cfomn
SECURITY.
cfomn
Industrial Mining Training Center
SECURITY.
Not using safety elements or not knowing how to use them
cfomn
Industrial Mining Training Center
SECURITY.
Overloading Equipment
cfomn
Industrial Mining Training Center
SECURITY.
Overconfidence
cfomn
SECURITY. Industrial Mining Training Center
SECURITY.
Being unaware of unsafe risks during work
cfomn
Industrial Mining Training Center
SECURITY.
For all machines:
• You must use the stairs
and the steps provided
– Keep clean and in safe conditions
of use
• You must use three points of
contact with steps
and handrails
• Always look towards the machine
• Do not use controls like
railing
DO NOT JUMP!
cfomn
TEAM SYMBOLS
Industrial Mining Training Center
900@
Transmission or power train oil
temperature
Temperature of
engine coolant
Brake
temperature
cfomn
SYMBOLOG Industrial Mining Training Center
Another very important element today is safety, in addition to taking care of our
equipment, we must take care of something much more important, which is our life and
health, this is not worth millions of dollars, since it is priceless.
cefomn
Industrial Mining Training Center
This will improve the performance of the equipment and its operator,
reducing downtime, maintaining the designated useful life of the
equipment, which is reflected in the productivity of the mine.
cefomn
Industrial Mining Training Center
The power train is counted from the engine to the final drives, whereas the
power train is only taken into account from the converter to the final drives.
POWER TRAIN
Torque converter
Engin
transfer case e
Cardan
Differentia Transmissio
l n
Final controls
POWER TRAIN
transfer case
Carda
Differenti n
al
Transmissi
on Torque converter
Final controls
O_OIN
ENGIN
E
The engine is the part of a machine capable of transforming some type
of energy (electric, fossil fuels, etc.) into mechanical energy capable of
performing work: supplying power to the rest of the systems.
ENGIN
E
It is very important to check that the engine oil level is between the
minimum and maximum marks.
Nowadays, most equipment has a dipstick or sight glass with the option of
measuring the oil level with a cold and hot engine.
ENGIN
E
For the operation of the engine, the operation of the following systems is
essential:
• System of refrigeration
• System of lubrication
• Electric system
COOLING SYSTEM
The main function of the cooling system is to maintain the correct engine temperature
by removing excessive heat generated by combustion and friction. Approximately 33%
of the thermal energy developed during combustion is converted into usable power,
7% is radiated directly from the engine surfaces, and 30% is exhausted through the
exhaust.
The remaining 30% is dissipated by the cooling system.
COOLING SYSTEM
Coolant circulates through passages in the engine called coolant or water jackets.
Coolant absorbs heat from hot engine surfaces and carries it to the radiator, where it is
transferred to the atmosphere.
The cooling system also helps maintain the correct temperature of the engine,
transmission and hydraulic system through the use of oil coolers.
COOLING SYSTEM
Thermostat Box
Possible causes
The function of the lubrication system is to prevent wear of the engine parts, creating
a layer of lubricant between the parts, which are always rubbing. The lubricant is
usually collected (and stored) in the lower crankcase (piece that closes the engine
from below)
LUBRICATION SYSTEM
Solenoid
Engine Oil Renewal
Sweep
System
Pump
Bypass
Valv
Cooler e
Engine Oil
Bomb
Oil Engine
FUEL SYSTEM
The fuel system of a diesel engine is tasked with delivering the correct amount of
clean fuel in a timely manner to the engine's combustion chamber.
It is responsible for supplying the fuel necessary for the operation of the engine,
being able to differentiate two fundamental sections:
FUEL SYSTEM
AIR INTAKE AND EXHAUST SYSTEM
Its function is to supply large quantities of clean air to the engine. It works on the
principle of supercharging. In the case of Diesel engines; Overcharging is not a
cause of problems but on the contrary, it is beneficial for optimal engine
performance.
AIR INTAKE AND EXHAUST SYSTEM
AIR INTAKE AND EXHAUST SYSTEM
AIR INTAKE AND EXHAUST SYSTEM
Atmospheri
c air inlet Exhaust Gas
Outlet
Lubrication
Oil Outlet
Exhaust gas inlet
TURBO
COMPRESSOR
To care for the turbo compressor, it is very important to wait 3 to 5 minutes at idle
before turning off the equipment.
A turbo without oil is capable of causing the turbo to break down. At such high
revolutions, oil-free friction wears materials instantly.
TURBO
COMPRESSOR
To care for the turbo compressor, it is very important to wait 3 to 5 minutes at idle
before turning off the equipment.
A turbo without oil is capable of causing the turbo to break down. At such high
revolutions, oil-free friction wears materials instantly.
EXHAUST SMOKE PROBLEM INDICATORS
Excessive black smoke at full load (hot, unburned fuel)
Possible causes
• Dirty primary or secondary air filter
• Operating in too high a gear
• Excess fuel
• Overload
EXHAUST SMOKE PROBLEM INDICATORS
Blue smoke (oil consumption)
Possible causes
Worn turbocharger gaskets
• Worn rings/shirts
• Worn valve guides
• Hours on the engine
EXHAUST SMOKE PROBLEM INDICATORS
White smoke (steam: water in combustion chamber)
Possible causes
• Cracked cylinder head or liners
• Cylinder head gasket leaks
TORQUE CONVERTER
> >Converter
TORQUE CONVERTER FUNCTION
The main function of the Torque Converter is to multiply the engine torque,
that is, the power supplied from the engine flywheel is administered to the
converter, where the rotation speed is reduced to increase the torque.
In general, the main components in a torque converter are:
MAIN COMPONENTS TORQUE CONVERTER
1. Impeller or driving member
The Impeller is the driving section of the Converter.
It is attached to the flywheel by means of splines and rotates at the same RPM
as the engine.
The Impeller has vanes that direct the oil to the Turbine, propelling it.
Lack of power
Possible causes
The different types of Torque Converter that can be found in machinery are:
OPERATING PRINCIPLE
Machines have one or more transfer gearboxes that connect multiple power units, change the
direction and speed of power flow, or change the axis of power flow.
Another reason for the existence of transfer gearboxes is that they can drive auxiliary pumps,
The figure shows two applications of transfer gear boxes, both for a track tractor and a front
loader. In the latter case there are two gear boxes both for the power input to the
Transmission (input transfer gearbox) and for the output, post Transmission, (output transfer
gearbox), responsible for supplying power to both differentials (Front and Rear).
They allow a reduction in speed and increase in torque, which generates more force to
move the machine.
It is used when the transmission is not in direct line with the machine's motor and
converter.
INPUT TRANSFER GEARBOX OF A FRONT LOADER
The figure shows the input transfer gearbox of a Front Loader, used to transmit power from
the converter to the transmission. Because the transmission is not in line with the output shaft
of the Torque Converter, it is necessary to use a set of gears, (Input and Output), to be able to
supply power to the rest of the components of the power train.
TRANSMISSION OUTPUT TRANSFER GEARBOX
□ OUTPUT
The figure shows the output transfer gearbox for a front loader which is used since the
machine axles are not in direct line with the transmission.
It is also necessary to reduce the speed of the power flow and increase torque to the front and
rear axles.
TRANSMISSIONS
The transmission is responsible for controlling the direction and speed of the equipment.
That is, the power coming from the converter is transformed into useful power.
The first machines were equipped with mechanical transmission systems. That is, the
engine's power was transmitted through a mechanical clutch and a series of gears, which
were controlled by levers and cables. Over the years the transmission and power control
evolved until reaching recent designs in the development of the Servo transmission, existing
in two types:
The power supplied to the Servo Transmission is “managed” to be able to control both the
speed and direction of the equipment by stopping a certain component, the set of planetary
gears.
The stopping of this particular component of the planetary gear set is achieved by supplying
hydraulic oil to a set of Clutches.
Controlling the supply of hydraulic oil to the appropriate clutches allows obtaining “useful
power” from the transmission. This “useful power” is supplied to the rest of the power train
components, thus obtaining the direction and speed desired by the operator.
Possible causes
• Worn plates and discs
• Out of adjustment linkage
• Low fluid level
• Clogged linkage
• Incorrect pressure settings
• Using incorrect oil
INDICATORS OF TRANSMISSION PROBLEMS
Abnormal noises
Possible causes
• Worn gears/bearings
• Dirt at the entrance
• Aeration/cavitation
• Low fluid levels
INDICATORS OF TRANSMISSION PROBLEMS
Vibrations
Possible causes
• Bent or damaged drive axle
• Gear failure
• Damaged bearings
HYDROSTATIC TRANSMISSION
DIFFERENTIAL
CASE .
CROWN SET
The Crown assembly is shown in the Figure and consists of the drive or input pinion
and the crown.
DIFFERENTIAL AND
AXLES
The drive pinion rotates the crown; the crown, due to its diameter, rotates at a lower
speed than the drive pinion.
The drive pinion is supported by conical bearings located in the pinion housing.
The ring gear is bolted to the differential case and rotates it for power transmission.
DIFFERENTIAL PLAY
The Differential Kit delivers balanced power to the final drives to transfer it to the
wheels.
The components are:
· differential case
· gears satellites
· gears sides
· Cross-piece
SATELLITE GEARS
Differential Case, Crosshead
Hs
The Satellite Gears are mounted on the crosshead shaft and transmit power from
the differential case to the lateral gears and from these to the lateral axles or
Pallieres. Satellite
The Satellite Gears remain stationary as long as the machine moves in a straight s
line. Side gears
The Satellite Gears rotate on the crosshead axis and travel through the Side Gears
when a turn occurs or when the wheels slip. When the machine makes a turn,
Satellite Gears rotate around the Side Gears so that the wheels can rotate at
different speeds.
CROSS-PIECE
The crosshead is driven by the differential case and serves as a mount for the
differential sprockets.
AXLE GROUP
The axle group is made up of the axle box, the semi-shafts or bearings and the
bearings.
The axle shafts transmit power to the final drives
The box and bearings are what support the weight of the machine
DIFFERENTIAL
It is very important to maintain correct oil levels in the differential and final drives.
Overfilling the differential and final drives will cause overheating and foaming of the
oil in long haul and high speed applications. Overheating and foaming of the oil can
reduce the life of the components.
INDICATORS OF PROBLEMS IN THE DIFFERENTIAL
Abnormal noises
(when moving in a straight line)
Possible causes
• Worn gears/bearings
• Need to adjust the pinion and crown
• Dirt at the entrance
• Low fluid level
INDICATORS OF PROBLEMS IN THE DIFFERENTIAL
Possible causes
• Worn differential case assembly
• Worn blade gears
INDICATORS OF PROBLEMS IN THE DIFFERENTIAL
Vibrations
Possible causes
• Gear failure
• Blade gear failure
• Differential fault
• Damaged bearings
• Bent or damaged drive axle
BRAKE GROUP-
TRUCK APP
They are splined to the wheels and rotate at the speed of the tires. Wheel speed
service brakes are applied and disengaged by hydraulic pressure.
Wheel parking brakes are hydraulically released and spring applied
· Discs plates
· Service and Parking Piston
· Springs and pins
BRAKING SYSTEM
> The brake group is a set of discs and friction plates, the wear of
these components is automatically compensated by hydraulic
pressure
• Service brake
• manual retarder Service Piston
• Automatic delay
• Parking break
• Emergency break Parking Piston
• Traction control.
PLANETARY GROUP-FINAL CONTROL
The planetary group provides the ultimate speed reduction and increased torque at the
wheel.
It can be single or double reduction
It consists of:
Crown Planetary holder
planetary gears Solar Gear
PLANETARY GROUP-FINAL
CONTROL
Another application of the planetary group with double speed reduction, that is, two sets of
planetary gears form the final drive.
In the first reduction the Sun gear is the driving member and the driven member is the
Planetary Porta which is connected to the Sun gear of the second reduction, which becomes
the driving member for the second reduction and the driven member is the Porta Planetary, the
one bolted to the rear wheel.
In both cases, the speed has been reduced but the torque to the wheels has increased.
FINAL DRIVE PROBLEM INDICATORS
Leaks
Possible causes
Possible causes
Compartment: cleaning
PREOPERATIONAL
INSPECTION Lights Mirror
Out-of-cab platform Mirror
inspections include:
• Mirrors and lights: Door
damage Windshield
wipers
• Fire Extinguisher/Fire condition
Suppressor - Charging
• Windshield
wiper/washer: wear,
fluid
• Intake air screens
• Wiper washer
Steps and
• Pipes and hoses handrails
• Railings and handrails
Windshield Wipers: Condition
Windshield Washer Fluid
Reservoir
PREOPERATIONAL
INSPECTION
In-cab inspections include:
• ROPS: any signs of damage
• Seat: adjustment for proper brake
pedal reach, height, operator weight
• Seat belt: damage, wear, fit, age
• Horn, backup alarm, lights:
operational
• Total cabin interior: cleaning
•—__•• •• • •_
cfomn
— _ — _ _ _ _ Industrial Mining Training Center
OPERATIONAL PERFORMANCE.
Production:
The range of application of chargers is applicable to a wide variety of industries. One
method expresses the loader's production as a function of the load moved in a given
time.
Work efficiency:
It is one of the most complex elements in production estimation, as it depends on
factors such as operator skill, minor repairs and adjustments, personnel delays, and
delays due to the work plan.
A good estimate of work efficiency is approximately 0.70 to 0.85, but actual
operating conditions must be taken into account to determine the most appropriate
value.
cfomn
Industrial Mining Training Center
EQUIPMENT APPLICATIONS.
• Loading and transportation of materials.
cefomn
OPERATION TECHNIQUES. Industrial Mining Training Center
• Bucket filling factor with well-fragmented rock: 90% to 110% most efficient coordination of
the number of passes: 4 to 6 passes.
• Favorable conditions for front loaders: level, dry and firm floors.
• Unfavorable conditions for front loaders: terrain in poor condition, wet, soft, irregular
loading areas (narrow), very tight or poorly blasted material.
OPERATION TECHNIQUES.
The total filling of the bucket must be carried out from the base of the pile, to the
horizontal projection of the operator's view of the loading pile.
OPERATION TECHNIQUES.
Because ?
Because it is in this section where we get the most benefit from the power that the
machine gives us.
By exceeding this height when moving the machine backwards and reversing to face
the truck, at this point we will already have the maximum lifting height, this increases
the risk of overturning when facing the truck.
OPERATION TECHNIQUES.
The bucket fill factor must be between 90% to 110% and between
5 to 7 passes to complete the load on the equipment.
Recommendations when loading trucks are the following:
Deposit the load in the first passes as centered as possible and without touching the bed
rails, do not push the load with the bucket as this will cause damage to the truck and an
erroneous reading of the weightometer.
OPERATION TECHNIQUES.
Before loading keep in mind:
Since the two frames are aligned, it will allow me to make the most of the power that
the machine gives me for the operation.
Keeping the loader articulated when loading the bucket on the forehead will cause the
machine to grind due to the force it exerts, and this grinding will damage the tires.
We will also have significant damage to the central, upper and lower pins.
There will be a percentage of power that will be lost when loading the bucket, impairing
the use of the equipment.
OPERATION TECHNIQUES.
How do we avoid it?
Keeping the front and rear frame aligned when loading the bucket on the loading front.
When do we do it?
Always.
OPERATION TECHNIQUES.
• When depositing the first pass, this must be done with finer material and gradually,
since dropping the load suddenly on the truck will cause damage to its structure,
incorrect load reading and the operator may suffer injuries. drop the load suddenly.
• The operator controls the impact of the load on the box.
• Place the material, instead of throwing the material in the truck bed.
• Do not push the material in the last passes as this will cause damage to the
structure of the truck, and incorrect reading of the weight meters.
OPERATION TECHNIQUES.
By positioning the trucks at 45° with respect to the loading front, we optimize
performance, bucket filling and minimize transfer. This way we also avoid material
hits on the sides of the truck, by not being perpendicular to the equipment.
Because ?
• This is how we obtain optimal filling of the bucket, taking advantage of 100%
OPERATION TECHNIQUES.
of the power that the machine gives us.
• When filling the bucket diagonally to the front, premature wear will occur on
its chocks and side protectors, we are talking about the first ones that face
the loading pile.
• Damage will also occur due to excess load in the steering cylinders and
hydraulic system, we are talking about the steering cylinder that absorbs the
force of the equipment to load the bucket against the pile.
• We also run the risk of damaging some of the shims (teeth) when filling the
bucket, due to the force generated by the equipment only on some and not
on the entire set.
OPERATION TECHNIQUES.
When do we do it?
Always.
OPERATION TECHNIQUES.
Dirty and uneven floors have negative consequences for the loader's tires since we
can break or cause irreparable damage to them. After each loading cycle, clean the
floor only when necessary.
OPERATION TECHNIQUES.
When finishing the bench, be careful with loose material, do not exceed the extraction
limits, since we can cause structural damage to the bench and in the future a new failure
may be generated, keep floors in good condition and if necessary after loading The truck
cleans the front of the cargo.
OPERATION TECHNIQUES.
Incorrect loading
Correct charging
The load must be on the box lift cylinders. Do not deposit a large amount of material on
the cabin cover, to avoid material falling on the equipment and causing structural
damage to it. Keep the discharge in the central part (See indicator in the right image),
distribute the load correctly.
OPERATION TECHNIQUES.
Because ?
Approaching the truck in a controlled manner, without hitting it, this is in first gear and
at reduced speed.
When do we do it?
Always.
OPERATION TECHNIQUES.
Parallel digging pattern in narrow place:
Advantages.
When loading in narrow fronts, position the truck in the most appropriate way so that
material does not fall on it, sometimes it is necessary to wedge the bench as it moves to
ensure that no spillage is generated that could damage the transport equipment. The
first loads should be with the truck parallel to the bank or berm, digging behind it to be
able to widen the extraction front, as it advances it will widen. Always attack the foot of
the bank towards the edge, to have a view of potential spills on the extraction equipment.
Once the front is extended, the trucks can be positioned at a greater angle.
cfomn
Industrial Mining Training Center
BAD HABITS.
This action causes great damage to
the equipment, since it exerts
excessive and unnecessary effort,
causing premature wear on shims
and components. If this becomes
habitual, cracks will appear in the
bucket in the short term.
The steering, the central joint of the
loader are also overloaded, tire
slippage occurs, damage to
mechanical components such as
ring gear, differential, final drives, pivot axle of the rear differential.
Do not perform this action, request support equipment, if it is not enough, request an
evaluation, to analyze the most efficient and effective solution.
BAD HABITS.
By performing this operation we excessively damaged the front tires and central joint. It
is best to maintain a level floor or find a suitable position for filling the bucket. When
climbing with the loader, violent skidding of the front tires and deep cuts occur (if not
equipped with chains).
It also increases the probability of stepping on a rock that could tip the charger over.
BAD HABITS.
Because ?
We damage the power train due to excess temperatures
We damage the upper and lower center pins.
We damaged the pivot axle due to the irregularity of the terrain.
We damage tires due to temperature when skidding and being prone to cuts from
abrasive material.
When do we do it?
Always.
BAD HABITS.
The optimal height to work is up to the lower tilting pin of the bucket (8.5 to 10 meters).
Depending on the equipment configuration.
BAD HABITS.
How can we avoid this situation?
When carrying out this operation, you notice the damage caused to the access stairs to
the equipment. You can see the unevenness that exists on the floor, the extra stress
exerted on the central joint, steering cylinders, damage to the tires, and the possibility of
breaking the fuel tank due to rocks on the floor.
BAD HABITS.
If the truck exchange is very long, do not wait with the loaded bucket for it to reach your
front, as this will cause premature damage to the lifting system. We must wait until the
truck is pre-accumulated to begin the lift. Or we could wait with the loaded bucket resting
on our forehead, we could also clean, stockpile and remove the material, to optimize
loading times.
F _________ ______________________________ Industrial Mining Training Center
cfomn
BAD OPERATIONAL PRACTICES.
of
When trying to remove large rocks with the bucket, you will seriously damage the pins and
pantograph. When a rock appears, it is best to clear it and deposit it somewhere so that its
size is reduced. Never load on extraction trucks, since during transport they can move to
one side, causing structural damage to the truck and possible injuries to the operator.
BAD HABITS.
Because ?
When carrying out this type of maneuver with front loaders, significant damage occurs
to the shims, between shims, turning cylinders and pins.
When do we do it?
Always.
BAD HABITS.
Damage caused by poor operating practices,
excessive effort. To clear balls or load material that
is too tight on the loading face, tractor support must
be requested on the blasting site to facilitate the
extraction of material.
BAD HABITS.
Never operate the charger at low revolutions.
Because ?
• When working at low revolutions, we will not obtain the maximum power that
the machine has to do the work.
Front loaders should always be operated at high revolutions, between 1800 to 1850
rpm.
When do we do it?
Always.
cefomn
PROGRAMMING OF MARCHES. ;
Industrial Mining Training
Because ?
It is in this gear, in which the equipment works at full load, the cooling and lubrication
systems are maintained at an optimal work level, according to the speed generated by
the equipment in this gear.
In addition, the hydraulic system carries out the work cycle according to the floor
speed, achieving dynamic and efficient operation.
If we load in second gear we will lose a significant percentage of the traction force and
the filling factor will be poor. We will reduce the useful life of all systems by increasing
their temperatures.
PROGRAMMING OF MARCHES.
Remember: Second and third gear are only for transfers. The use of these depends on
different factors such as:
• Distance.
• Road configuration (incline, slope.).
• Tire condition.
• Equipment status.
NOTE: Always disconnect the lock clutch actuation button when making
transfers. Failure to do this could result in high transmission and torque
converter temperatures, which will cause premature damage to these
components.
PROGRAMMING OF MARCHES.
Transfers: When making transfers, schedule the appropriate route for this, taking into
account the factors mentioned above.
Additionally, disconnect the automatic acceleration, to have better control of the
equipment, since if this is not done, when going down a slope the equipment could
exceed the travel speed, producing at the same time an overspeed of the engine,
producing an operational event. This being recorded in the equipment monitoring
system
Pin Restore.
up.
CARE AND EFFICIENT USE
cfomn
Industrial Mining Training Center
OF THE GET.
GET : Ground Engaging Tools = Cutting Tools.
Tips : There are tips of many sizes and configurations. Long tips provide greater
penetration for operations where penetration is more important than tip breakage. The
short tips are for high-impact work, such as loading dynamited rock. The most resistant
are the abrasion-resistant tips, which are used to load sand and gravel. Penetrating bits
are efficient for loading dense, highly compacted materials, such as clay. The one-piece
tooth (Unitooth) is the combination of a tip and adapter in a single piece and is used for
light or medium effort work.
CARE AND EFFICIENT USE
OF THE GET.
Wear ratio:
The area of a bucket where the flow of material is concentrated is the corners, for this
reason it is normal to find that the tips of the loaders in the corners are 25% to 35%
more worn than the central ones. For this reason, customers are recommended to
change the position of the tips when the end tips reach half of their useful life. Those
from the center to the corners and vice versa. At this time it is advisable to change their
position to prolong their useful life.
Tips worn on the bottom or cracked in the socket should be replaced immediately.
CARE AND EFFICIENT USE
OF THE GET.
Frequent tip breakage:
An important opportunity to improve the life of the tips is to verify that the customer
maintains the tips by rotating them, which extends the useful life by up to 80%, this
implies a completely relevant reduction in costs.
The moment to perform the rotation is obtained by knowing the duration of the tips that
have not been rotated. Normally the time to rotate the tips is equivalent to 70%
(approximately) of the hours they lasted without rotation.
CARE AND EFFICIENT USE
OF THE GET.
For example:
If some tips were removed after 300 hrs, without rotating them. Calculate the
performance of the tips, the value you will obtain will be approximately 45% to 50%
of available wear material.
The time to rotate the tips should be at 210 hours.
CARE AND EFFICIENT USE
OF THE GET.
Adapters:
On welded adapters, check for cracks; Check bolted adapters for looseness
or missing hardware. Check for adapters that have very worn bottom plates.
(If the tips have come off, also see if the nose of the adapter is worn.) On
bolt-on adapters, look at the heads of the bolts (especially the back bolt). If
the head begins to be square, the adapter must be changed. Check for
missing or broken retainers by tapping the end of each pin. If the pin moves
easily, it is highly likely that the tip will be lost when replacing the retainer.
CARE AND EFFICIENT USE
OF THE GET.
A poor bucket tilt adjustment results in a poor and unlevel floor. Which contributes
excessively to the generation of damage to the tires.
TIRE CARE.
NOTE: Do not water the loading face directly, since water acts as a lubricant and
contributes to the penetration of rocks into the cuts.
TIRE CARE.
Remember to always keep the floors clean, this could considerably damage the
tires or chains, the safety of the operator and the machine.
1.
TIRE CARE.
Wear and tear.
Among the operating errors that can be observed is the following list:
e application in your work may vary by altering the methods and techniques described.
END OF THE COURSE. cfomn
Industrial Mining Training Center
QUESTIONS?