Against the backdrop of rising fuel costs, reducing loader fuel consumption is not only an effective way to save costs for construction machinery companies and equipment operators, but also reflects their responsibility for green construction and sustainable development. This article will systematically explore how to improve loader fuel efficiency through scientific operation, focusing on operating techniques, equipment technology, and maintenance management.
Correct operating habits are the foundation of loader energy conservation, and any advanced energy-saving techniques are based on standardized operation.
1.1 Standard Operating Posture and Habits
Maintain a stable sitting posture: The driver should maintain a comfortable and stable posture in the driver's seat, sitting upright. This allows for a better sense of the loader's balance. During operation, the body should avoid swaying, as this may affect operational accuracy.
Proper hand and foot placement: The feet should be naturally placed near the accelerator and brake pedals. The grip on the joystick should be relaxed but maintain precise control. When operating a loader, the foot should be separated from the brake pedal and placed flat on the cab floor. Never place the foot on the brake pedal.
1.2 Familiarize Yourself with the Joystick Functions
Lift and Bucket Swing Joysticks: The lift lever controls the bucket's raising and lowering, while the bucket swing lever controls the bucket's tilting angle. These two levers must be operated in coordination during operation.
Steering Techniques: Before turning, hold the steering wheel with one hand and turn on the turn signal with the other. As needed, use both hands to adjust the steering direction. Turn off the turn signal immediately after turning.
1.3 Key Operating Procedures
No passengers are allowed anywhere on the machine except inside the cab.
When unloading material into a vehicle, the bucket must be raised to a height that does not contact the vehicle's bed panel. Never pass the bucket over the top of the vehicle's cab.
When descending a slope, use automatic deceleration and do not press the clutch pedal to prevent power loss and a rollaway accident.
Using high gear is strictly prohibited.
2.1 Optimizing Loading Posture and Path Planning
Place the truck at a 45° angle to the pile to minimize loader movement, shorten cycle times, and reduce fuel consumption.
Face the pile directly to ensure even force on the bucket, ensuring a full load and minimizing rework and fuel waste.
2.2 Using Low Gear for Smooth Operation
It is recommended to operate smoothly in first gear to avoid the high speed and fuel consumption associated with higher gears. When the loader bucket inserts into the pile and removes material, insertion resistance is high. Therefore, it is best to select first gear during loading, allowing for loading with relatively light throttle. Light throttle reduces diesel engine speed, which not only reduces fuel consumption but also reduces flow in the working device hydraulic system, resulting in less overflow losses.
2.3 Preventing Tire Slip and Unnecessary Spinning
Tire slipping wastes fuel and accelerates tire wear and should be avoided.
Use spin/slip control to reduce idling and improve grip efficiency.
When shoveling material from the ground, excessive downward pressure from the bucket can cause the front wheels to lift, and accelerating at this point will only waste diesel. If slippage occurs, slightly lift the bucket and then slowly increase the throttle to load.
2.4 Utilize a More Efficient Loading Path
It is recommended to utilize a "Y-shaped operating cycle" to coordinate the positions of the truck, pile, and loader for greater efficiency.
When turning, it is not necessary to turn completely straight; maintaining a 5° angle will speed up switching, saving time and fuel.
2.5 Reduce Idle Time and Encourage Active Shutdowns
Extended idling wastes fuel. It is recommended to utilize automatic shutdown or engine shutoff during standby operations.
Idling for five minutes after starting the engine and before shutting down is necessary, but prolonged idling only wastes fuel. The engine should be shut off when waiting for a job or resting to conserve fuel.
Reducing idling time is one of the simplest ways to reduce fuel costs for wheel loaders! Idling can consume nearly a gallon of fuel per hour.
2.6 Controlling Bucket Lift Height
During a fully loaded lift, the higher the bucket, the more diesel consumed. Therefore, it is best to control the fully loaded lift height of the loader based on the truck's tailgate to avoid unnecessary diesel waste.
2.7 Using the V-Shaped Loading Method
Position the forklift facing the pile, driving at a 45° angle to the truck. Lift the bucket slightly while loading. This creates pressure on the front wheels, increasing friction and providing stronger driving force. After the bucket is full, the forklift returns to its starting position and then moves forward to the truck.
3.1 Activating Eco Mode and Lock-Up Torque Converter
Eco Mode maintains maximum traction in first gear, accelerating loading while reducing fuel consumption.
The lock-up torque converter reduces energy loss and improves fuel efficiency.
3.2 Automatic Idle Control and Shutdown
Automatically reducing idle speed or shutting down the vehicle when unattended for extended periods can significantly reduce fuel consumption.
3.3 Intelligent Throttle Feedback and Energy-Saving Pedal Design
For example, the "Eco-Pedal" on Volvo loaders generates a mechanical reaction force when the accelerator is over-depressed, promoting economical operation.
3.4 On-site Intelligent Technology and Load Control
On-board weighing systems monitor load capacity in real time to prevent overloading and unnecessary fuel consumption.
Remote sensing and dispatch systems analyze idling time and driving paths to further optimize operating behavior.
3.5 Automated Control Functions Support Operational Efficiency
Functions such as "Backshovel" and "Backfill" automatically return to a preset loading position, reducing operation range and time. Intelligent drive systems (such as Volvo's "Smart Control") coordinate power and hydraulic output, shortening operating cycles and saving fuel.
4.1 Regular Maintenance and Inspection
This includes replacing air, fuel, and oil filters, and lubricating pins and joints to maintain hydraulic system and power transmission efficiency.
Regularly check the hydraulic oil quality and level, and replace deteriorated hydraulic oil promptly. Hydraulic system leaks can lead to energy loss and affect overall machine efficiency.
Change the engine oil and filter according to the manufacturer's recommendations to keep the engine in optimal operating condition. A dirty filter restricts air flow and reduces combustion efficiency.
Regularly check the transmission oil level and quality, and promptly replace worn transmission components. Transmission system efficiency directly affects the overall machine's power transmission efficiency.
4.2 Tire Maintenance and Pressure Management
Low tire pressure increases rolling resistance. It is recommended to regularly check and inflate tires according to manufacturer recommendations. Ensure correct tire pressure and that the steering wheel and tires are properly adjusted. Incorrect tire pressure increases rolling resistance and increases fuel consumption.
4.3 Reduce No-Load Patrols
Optimizing operating procedures and reducing the distance and frequency of loader idle travel can significantly save fuel.
This includes site layout planning, task coordination, and performing auxiliary tasks during waiting periods.
4.4 Operator Training to Raise Awareness
Professional training not only improves operational efficiency but also helps drivers realize the importance of energy-saving behaviors and actively practice fuel-saving methods.
4.5 Continuous Optimization through Data Monitoring
It is recommended to record fuel usage data under different circumstances for analysis and continuous optimization of operating methods.
Utilize remote monitoring and dispatching systems to improve task execution efficiency and resource utilization.
Energy conservation does not rely solely on advanced equipment technology; it requires an integrated integration of operating skills, intelligent assistance, and maintenance management. By optimizing loading angles and paths, anti-skid control, intelligent fuel-saving features, and coordinated maintenance and training, loaders can achieve significant fuel savings, improve production efficiency, and control operating costs.
By combining standardized operation, scientific techniques, and regular maintenance, loader operators can significantly reduce equipment fuel consumption, improve operational efficiency, and create greater economic benefits for the company. With the development of electrification and intelligent technologies, the energy-saving potential of loaders will continue to increase. Operators should continue to learn new technologies to adapt to industry developments.
If you have any questions about the energy-saving operation of the loader, or want to customize a loader, please contact us. We undertake customized services based on drawings.
