Safety and maintenance of excavation loaders

The backhoe loader (referred to as "excavator-loader" for short) is an engineering machinery equipment that integrates excavation and loading functions, and is widely used in mines, infrastructure, municipal engineering and other scenarios. Due to its complex working environment and heavy load, safety maintenance is directly related to the equipment's service life, operating efficiency and the safety of operators. The following is a detailed explanation from four aspects: safety maintenance principles, key maintenance contents, common problem handling and precautions:

I. Core Principles of Safety Maintenance

• "Prevention first": Through regular inspection, lubrication and adjustment, potential faults are found in advance to avoid safety accidents caused by component wear or failure (such as hydraulic system leakage, structural part fracture).
• "Operation in accordance with regulations": Strictly follow the maintenance cycle and procedures in the equipment manual. It is prohibited to arbitrarily shorten the inspection time or replace non-original accessories (such as bolts, filters).
• "Man-machine collaboration": Operators need to participate in daily inspections, maintenance personnel must have professional qualifications (such as hydraulic system maintenance certification), and both parties need to properly hand over information (such as recording abnormal equipment noise and vibration).

II. Safety Maintenance Contents of Key Systems

1. Structural Parts (Frame, Boom, Bucket)

• Daily inspection:
• Check whether there are cracks at the welding joints (focus on the connection between the boom and the frame, and near the bucket pin shaft). If cracks are found, stop the machine immediately and have professionals evaluate whether repair welding or replacement is needed.
• Check the wear of pins and bushings: If the gap is too large (exceeding the value specified in the manual, such as 5mm), replace them in time to avoid structural part fracture due to uneven stress.
• Regular maintenance:
• Derust and paint the structural parts every six months (using special anti-corrosion paint for engineering machinery) to prevent rust from weakening the structural strength.
• Check the wear of bucket teeth. If the wear exceeds 1/3 of the original size, replace them in time to avoid equipment overload due to reduced excavation efficiency.

2. Hydraulic System (Pump, Valve, Oil Cylinder, Pipeline)

• Daily inspection:
• Observe the hydraulic oil level (replenish when it is lower than 1/4 of the oil tank scale line), and check whether the oil is emulsified or deteriorated (normally light yellow with no impurities). If abnormal, replace it immediately and clean the oil tank.
• Check whether there is leakage at pipeline joints and oil cylinder seals: If oil seepage is found, tighten the joints or replace the seals (such as O-rings). It is prohibited to work in a leaking state (to prevent oil splashing from causing fire or slipping).
• Regular maintenance:
• Replace the hydraulic oil filter every 500 hours (must use original filters to avoid impurities entering the system), and completely replace the hydraulic oil every 2000 hours (according to the model specified in the manual, such as No. 46 anti-wear hydraulic oil).
• Check the operation sound of the hydraulic pump and motor: If there is abnormal noise (such as a "buzzing" sound accompanied by vibration), it may be due to internal wear or insufficient oil. Stop the machine for maintenance.

3. Power System (Engine, Gearbox)

• Engine maintenance:
• Daily check the engine oil level and coolant level to ensure no leakage; replace the engine oil and filter every 200 hours (select oil according to the engine model, such as CF-4 grade diesel engine oil).
• Clean the air filter (every 50 hours): If the working environment is dusty, shorten the cleaning cycle to avoid reduced engine power and overheating due to insufficient air intake.
• Check the belt tightness: Press the middle of the belt with a finger, the deflection should be 10-15mm. Too loose will easily cause slipping (resulting in insufficient power generation), and too tight will easily break.
• Gearbox maintenance:
• Check the gearbox oil level every 1000 hours, and replace the gear oil every 3000 hours (according to the model in the manual, such as 85W-90 heavy-duty gear oil).
• If there is jamming or abnormal noise during gear shifting, it may be due to clutch wear or oil deterioration. Timely maintenance is required to avoid gearbox damage caused by forced gear shifting.

4. Braking and Travel System (Tire / Track, Brake)

• Tire-type backhoe loader:
• Check the tire pressure (according to the manual, such as 8-10bar), and the tread pattern depth should not be less than 3mm. Avoid high-speed driving on gravel roads (to prevent tire blowout).
• Check the brake pedal stroke: When the pedal is pressed until the brake takes effect, the stroke should be 1/2-2/3 of the total stroke. If it is too short, adjust the brake clearance; if it is too long, check whether the brake fluid is sufficient.
• Track-type backhoe loader:
• Check the track tension: Lift the track, the sag should be 20-30mm (measured with a ruler). Too loose will easily cause derailment, and too tight will aggravate the wear of the track link.
• Clean the soil and stones between the track links (after daily operation) to prevent them from hardening and jamming the track, resulting in increased travel resistance.

5. Electrical System (Battery, Lights, Instruments)

• Check whether the battery terminals are oxidized (if there is white powder, rinse with hot water and apply vaseline), and ensure sufficient power (the voltage should not be lower than 12V when starting).
• Verify the light function: Headlights, turn signals, and warning lights must be complete and effective to avoid collisions during operation at night or in complex environments.
• The instrument display must be normal: If a fault code appears (such as engine overheating, low hydraulic oil pressure), check the cause according to the manual, and it is prohibited to work with faults.

III. Common Safety Hazards and Handling Methods

IV. Precautions for Safety Maintenance

• Preparation before operation:
• Before maintenance, park the equipment on a flat and solid ground, pull the handbrake, turn off the engine and pull out the key.
• If maintenance is performed at a high place (such as checking the boom), safety belts must be used, no one is allowed below, and warning signs should be set up.
• Tools and accessories:
• Use special tools (such as torque wrenches) to avoid bolt slipping or component damage due to improper tools.
• Replacement accessories must be original or certified products (such as hydraulic hoses must meet high-pressure standards), and the use of inferior substitutes is prohibited.
• Records and training:
• Establish a maintenance ledger, record each inspection, replaced parts and time, to facilitate traceability and formulate the next plan.
• Operators need to receive maintenance training, master basic inspection skills (such as identifying oil leakage and abnormal noise), and report problems in a timely manner.