The power system of the loader is its core part, which is mainly composed of the engine, transmission system, hydraulic system, electrical system, etc., and directly affects the working efficiency and reliability of the equipment.
Repair and maintenance of common faults in loader power system is the key to ensuring efficient operation of the equipment.
1. Common faults and repair methods/Défauts courants et méthodes de réparation
1) Difficulty starting the engine/cannot start/Difficulté à démarrer le moteur/impossible à démarrer
Possible causes:Causes possibles :
The battery is low or the wiring is corroded
Fuel system is clogged (filter, oil line) or fuel quality is poor
Fuel injector failure
Starter motor/generator failure
Intake system blocked (dirty air filter)
Repair measures:Mesures de réparation :
Check battery voltage and clean electrodes; replace battery if necessary.
Replace the fuel filter, drain the water in the fuel tank, and use qualified diesel.
Test the starter motor and check the relays and fuses.
Clean or replace the air filter and check the air intake line.
Cleaning the fuel injectors
2) Insufficient engine power/Puissance moteur insuffisante
Possible causes:/Causes possibles :
Turbocharger failure (oil leakage, air leakage, blade damage)
Fuel injection system problems (injector nozzle clogged, high pressure pump insufficient pressure)
Air filter clogged, poor fuel quality
Insufficient cylinder pressure (piston ring wear, poor valve seal)
Repair measures:/Mesures de réparation :
Check the supercharger pipe for leaks, clean or replace the supercharger.
Clean or replace the fuel injector and check the high-pressure pump pressure.
Replace the air filter and use standard diesel
Measure cylinder pressure and overhaul engine if necessary.
3) Water temperature is too high (overheated)/La température de l’eau est trop élevée (surchauffée)
Possible causes:/Causes possibles :
Insufficient or deteriorated coolant
Radiator clogged (dust, catkins, etc.)
Water pump failure or thermostat stuck
Repair measures:/Mesures de réparation :
Refill or replace coolant (add antifreeze in proportion).
Back flush the radiator fins with high pressure air/water.
Check the tightness of the water pump belt and test the opening and closing function of the thermostat.
Replace the thermostat
4) Hydraulic system is slow/weak/Le système hydraulique est lent/faible
Possible causes:/Causes possibles :
Hydraulic oil is insufficient or contaminated (emulsification, impurities)
Hydraulic pump wear or pressure valve adjustment failure
Internal leakage in the oil cylinder or valve group, aging of the sealing ring, and wear of the piston
Repair measures:/Mesures de réparation :
Check the oil level, replace the hydraulic oil and filter element (recommended replacement every 2000 hours). Clean the valve group.
Test pump pressure and adjust or replace relief valve.
Check the sealing of the oil cylinder, replace the seal or the oil cylinder assembly, and repair the leakage point.
5) Transmission abnormality (gear shift shock, slippage)/Anomalie de transmission (choc de changement de vitesse, patinage)
Possible causes:/Causes possibles :
Transmission oil is dirty, too low or deteriorated
Clutch plate wear or valve body blockage
Torque converter oil temperature is high, transmission oil is insufficient
Bearing damage, gear wear
Repair measures:/Mesures de réparation :
Check oil quality, change transmission fluid and filter.
Disassemble and inspect the clutch assembly and clean the valve body oil circuit.
Check the radiator and add transmission oil
Disassemble and inspect bearings and gears, and replace damaged parts
6) Electrical system failure and maintenance/Panne et maintenance du système électrique
Possible causes:/Causes possibles :
The battery is dead, the starter relay is faulty
The fuse is blown and the line is short-circuited
Sensor damage, ECU failure
Repair measures:/Mesures de réparation :
Charge or replace the battery, check the relay
Replace the fuse and check the circuit
Replace the sensor and test the ECU
2. Daily maintenance points/Points d’entretien quotidien
1) Regularly replace oil and filter element/Remplacez régulièrement l’huile et l’élément filtrant
Engine oil/filter: Replace every 500 hours or six months (shorten the cycle in severe working conditions).
Hydraulic oil/hydraulic filter: Replace every 1000-2000 hours and take samples regularly to check contamination.
Fuel filter: Replace every 250 hours to prevent moisture and impurities from entering the high-pressure pump. Clean the fuel tank regularly, check the fuel injectors, turbochargers
Regularly replace the torque converter oil and clean the oil circuit
2) Cooling system maintenance/Entretien du système de refroidissement
Check the coolant level daily and clean the radiator surface debris regularly. Check the oil cylinder seal regularly and clean the radiator.
Replace antifreeze every 2 years to avoid corrosion and scaling.
3) Air intake system maintenance/Entretien du système d’admission d’air
The air filter should be cleaned (purged) every 250 hours and replaced every 500 hours (double the frequency in dusty environments).
4) Electrical system inspection/Inspection du système électrique
Regularly tighten the battery wiring, clean the wiring harness connectors to prevent oxidation, check the line insulation, and regularly check the battery electrolyte.
5) Precautions for long-term discontinuation/Précautions en cas d’arrêt prolongé
Drain the fuel tank or add preservative and start the engine and run it for 15 minutes every month.
3. Preventive recommendations/Recommandations préventives
Operating habits: Avoid long-term overload operation, and preheat the engine at idle speed for 3-5 minutes after starting the engine from cold.
Oil selection: Use engine oil, hydraulic oil and diesel with the grade specified by the manufacturer.
Fault records: Establish maintenance files and track high-frequency fault points (such as the vulnerability of a certain model of loader turbocharger).
Summarize:
Preventive maintenance is more important than post-failure repairs, and regular replacement of oil and filter elements is key.
Operating habits affect the life of the power system. Avoid long-term overload operation.
Through system maintenance and timely repairs, the life of the loader power system can be significantly extended and downtime losses can be reduced. For complex faults (such as problems with the electronic common rail system), it is recommended to contact professional technicians for diagnosis.
L’entretien préventif est plus important que les réparations après panne, et le remplacement régulier de l’huile et des éléments filtrants est essentiel.
Les habitudes d’exploitation influencent la durée de vie du système électrique. Évitez les surcharges prolongées.
Grâce à une maintenance et des réparations rapides, la durée de vie du système d’alimentation du chargeur peut être considérablement prolongée et les pertes dues aux temps d’arrêt peuvent être réduites. Pour les pannes complexes (comme celles liées au système électronique Common Rail), il est recommandé de faire appel à des techniciens professionnels pour un diagnostic.
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Post time: Jun-07-2025