Wheel loaders used in mines, large-scale earthworks, quarries, and port terminals often operate under ultra-long continuous working conditions, sometimes running 16–24 hours a day for weeks without sufficient rest. Such high-intensity use leads to extreme fatigue of engines, hydraulic systems, transmissions, and structural parts, accelerating wear, overheating, oil deterioration, and seal failures. This guide provides targeted maintenance strategies to protect loaders under ultra-long continuous operation, reduce failures, extend service life, and ensure stable output.
Engine maintenance is the top priority under long-term continuous operation. The engine is under high load for a long time, with high temperature, high fuel consumption, and fast oil deterioration. The oil change interval must be shortened appropriately-from the standard 250 hours to 150–200 hours. Use high-grade, high-temperature-resistant, anti-wear engine oil to maintain lubrication under prolonged high temperatures. The fuel system must be checked daily: drain water from the water separator, ensure clean diesel, and prevent injector blockage. The air filter must be inspected and cleaned frequently; in dusty environments, it should be cleaned every 2–3 days to avoid insufficient air intake and power loss.
The cooling system must be in optimal condition to prevent overheating. Long-term high load causes continuous high heat generation. The radiator, intercooler, and hydraulic oil cooler must be kept clean and unobstructed. Before entering long-term operation, thoroughly clean the radiator fins to remove dust, cotton wool, and debris. Check the fan belt tension, thermostat effectiveness, and coolant level and quality. Use long-life antifreeze with high boiling point to avoid boiling. In hot seasons, enhance cooling system maintenance to prevent shutdowns due to overheating.
The hydraulic system is prone to overheating and oil deterioration under continuous operation. High-frequency lifting, loading, and steering cause the hydraulic oil temperature to rise easily, reducing oil viscosity, accelerating seal aging, and increasing internal leakage. Use anti-wear, anti-oxidation hydraulic oil with good high-temperature stability. Check the oil temperature in real time; if it continuously exceeds 90°C, suspend operation for cooling. The hydraulic oil filter element should be replaced in advance to avoid clogging. Regularly check for oil leakage in pipelines, cylinders, and joints; aging seals must be replaced promptly.
The transmission and drive axle endure heavy continuous loads. The transmission oil and gear oil deteriorate faster under high temperature and heavy load. Shorten the oil change cycle and use special transmission oil with strong shear stability. Check for abnormal noise, vibration, or weak walking; these may indicate clutch wear or insufficient oil pressure. The drive axle oil should also be inspected regularly to prevent bearing damage and gear wear.
Undercarriage and working device wear must be closely monitored. Long-term digging and loading cause severe wear on bucket teeth, cutting edges, hinge pins, and bushings. Check bucket teeth daily and replace severely worn ones to avoid damaging the tooth base. Lubricate each hinge point every shift-high-frequency operation consumes grease quickly, and insufficient lubrication causes severe wear. Check the tightness of key bolts such as the bucket, boom, and frame; continuous vibration may cause loosening.
Operator behavior directly affects equipment life under long hours. Avoid violent operation, sudden acceleration, long-term idling, and overloading. Use smooth operation to reduce impact load on the engine and structural parts. Arrange reasonable rotation for operators to avoid fatigue driving, which may lead to improper operation and increased failure risk.
Battery and electrical system maintenance cannot be ignored. Long-term operation keeps the battery in a charging and discharging state. Check the generator output voltage to ensure normal charging. Clean the terminals to prevent poor contact. For electric loaders, monitor battery temperature and SOC in real time to avoid overcharging or over-discharging, which damage battery life.
Daily and periodic inspections must be stricter and more frequent. Under ultra-long continuous operation, hidden dangers develop faster. Conduct a comprehensive pre-shift inspection: oil levels, temperature, pressure, sound, leakage, and appearance. Weekly inspections should focus on wear of key moving parts. Monthly comprehensive maintenance includes replacing filters, adjusting clearances, and torquing bolts.
Reasonable shutdown rest is necessary even in urgent projects. Although the loader can run continuously, proper periodic shutdowns-such as 15–20 minutes every 8–10 hours-allow the engine, hydraulic system, and brakes to cool properly, slowing down thermal fatigue and material aging. This greatly extends overall service life.
In summary, maintenance under ultra-long continuous operation focuses on shortened oil change cycles, enhanced cooling, frequent lubrication, strict leakage control, and standardized operation. Scientific maintenance can ensure the loader maintains high efficiency and reliability even under extreme working conditions, significantly reducing downtime and extending service life.
