Loaders (also known as excavators) are widely used in earthmoving operations for roads, railways, construction, mining, and other projects. They are primarily used for loading loose materials such as soil, sand, gravel, and coal, and can also perform light excavation work. By changing attachments, they can also perform functions such as earthmoving, lifting, and loading/unloading logs. Due to the widespread use of loaders, it is essential to understand their various operating techniques and safety precautions before use.
Before starting any operation, several fundamental principles must be kept in mind:
Before operating the loader, thoroughly inspect it, including oil levels (engine oil, hydraulic oil, coolant, fuel), tires, brakes, hydraulic hose connections, bucket attachments, switches, and warning lights, to ensure the machine is safe to operate.
Operators must be qualified and trained, with a clear understanding of the machine's control logic, hydraulic system, steering, and stability characteristics.
Always avoid abrupt movements: Whether starting, steering, lifting, shifting gears, accelerating, or braking, always operate smoothly, steadily, and gradually.
Always maintain awareness of surroundings and personnel safety, especially in narrow work areas, near steep slopes, or around material piles.
Never lift heavy loads at high positions on uneven or sloping ground; an off-center load can easily cause the machine to tip over.
During travel, do not raise the bucket or carry a load at high speed unless absolutely necessary. A US university safety manual emphasizes: "During travel, keep the working parts and load as low as possible."
The following sections outline some operating techniques and precautions for four stages of operation:
1.1 Starting and Warming Up
Before starting, ensure the transmission is in neutral and the parking brake is engaged. Turn the key (or press the start button) to "ON" to activate the instruments and pre-start the oil system. Check the engine oil, coolant, and hydraulic oil levels to ensure there are no leaks. After starting, let the engine run at idle for a few minutes (depending on ambient temperature and machine specifications) to allow the lubricating oil and cooling system to circulate fully, preventing damage to components from high-load operation when cold. Run at idle for 3-5 minutes, observing the oil temperature and pressure readings on the instrument panel to ensure they are normal.
After starting, gently move the control levers (lift, bucket tilt) to release any trapped air in the system. Many operation manuals recommend performing short movements of the operating mechanisms in all directions after starting to purge air.
Simultaneously, monitor the instruments to ensure that oil pressure, water temperature, and hydraulic pressure are within normal ranges.
1.2 Preparation for Movement
Confirm that there are no obstacles or people nearby; maintain good communication with any assisting personnel.
Close or retract any unnecessary protruding tools or attachments; ensure the machine's width matches the path of travel.
Release the parking brake, and gently engage the travel control pedal or system to allow the machine to respond smoothly. Start slowly to allow the operator to adjust to the direction and inertia.
1.3 Smooth Starting Techniques
When starting, gradually increase the throttle; avoid sudden acceleration that could cause wheel spin or damage to the transmission.
After starting, maintain a low gear and low engine speed, gradually adapting to the ground conditions and machine response.
On soft or loose ground, control the engine speed to prevent tire slippage; if necessary, gently lift the bucket to reduce pressure on the front wheels to improve traction (avoid lifting too high, which could shift the center of gravity forward).
If encountering resistance during starting (such as loose soil or gravel), lightly press down on the bucket to increase traction, then move slowly forward.
The loading stage is a critical part of loader operation, requiring both efficiency and safety.
2.1 Positioning and Entering the Pile
Before loading, select a level and stable surface as the work area; avoid loose, wet, or sloping ground. For higher or deeper material piles, first observe factors such as the material's hardness, internal voids, and surface shape. A shallow, exploratory cut can be made to assess the material.
When approaching the pile, try to maintain a suitable angle between the bucket and the pile (the cutting angle) – the bucket edge should be slightly angled relative to the pile surface to facilitate easier penetration.
If the pile is high, gently push away a layer of material first to allow the bucket to easily dig in before starting the main loading operation.
2.2 Cutting and Loading Techniques
Lowering the bucket: Slowly and steadily lower the bucket edge towards the pile (or the ground in front of the pile). Control the cutting depth; don't dig too deeply at once to prevent jamming or excessive impact.
When cutting, use power and forward momentum (from driving, or apply slight additional pressure) to assist the bucket in penetrating the material.
As the bucket digs in, gradually lift the bucket and slightly tilt it back (curl) to keep the material pressed against the bucket backplate, rather than abruptly lifting an empty bucket.
Maintain even loading; avoid overloading one side, which can cause the center of gravity to shift. If possible, load in layers or fill the edges first, then the center.
After loading, "seal" the bucket by slightly lifting it and tilting it back to prevent material from spilling out.
Never turn or change direction abruptly while fully loaded; this can easily cause tipping or material spillage.
2.3 Leaving the Pile and Smooth Transition
Before leaving the pile, lower the bucket to the most appropriate height, slightly above ground level, but not too high.
Maintain a slight backward tilt of the bucket to prevent material from sliding forward.
Slowly decelerate when leaving the pile; avoid sudden braking. If necessary, decelerate first, then brake, allowing gravity and inertia to smoothly complete the transition.
The driving stage, especially when loaded, tests the loader's stability, operator's control of visibility, and suspension performance.
3.1 Safe Driving Principles When Carrying a Load
When carrying a load, maintain a low and steady speed. Avoid sudden acceleration, deceleration, and sharp turns.
Keep the bucket at the lowest safe height, usually slightly above ground level, to maintain clear visibility and a stable center of gravity. Some safety regulations, such as those in the US, recommend "keeping the load and working parts as low as possible while driving."
If the ground is uneven or bumpy, slow down and proceed cautiously when carrying a load, and avoid deep potholes or soft ground.
When driving on a slope, if ascending, climb slowly when carrying a heavy load; if descending, control the speed and avoid coasting in neutral. Use engine braking by selecting a lower gear as needed.
When turning, slow down in advance and take the widest possible arc. Never turn at high speed with a full load.
When encountering a large turning radius or obstacles, you can slightly "oversteer" or "stage the turn" (first move the front of the vehicle slightly forward, then adjust the steering for the rear wheels). However, this technique requires advanced skills and is not recommended for inexperienced drivers.
3.2 Traversing Complex Terrain or Narrow Spaces
In narrow construction areas or intersections, maintain a constant speed and avoid approaching edges or ditches.
If there are blind spots, assign a spotter or observer to ensure no personnel or obstacles enter the turning radius.
When backing up, turning, or making a U-turn, do so with an empty or partially loaded vehicle to minimize risk.
If the ground is muddy or slippery, reduce the load and slow down to avoid tire slippage.
3.3 Energy Efficiency and Control When Driving Empty
When driving empty, you can slightly increase speed, but still avoid prolonged high-speed driving to prevent damage to components.
When driving empty, control acceleration and braking smoothly to avoid impact on the engine, transmission, and axle.
If an emergency stop is necessary, ease off the accelerator and gradually apply the brakes instead of slamming on them.
The unloading stage involves accurately and safely releasing the load, demonstrating the operator's skill and precision.
4.1 Preparation Before Unloading
Upon arriving at the unloading point, park the machine on a level, firm surface to prevent damage or collapse of the ground due to the weight of the material falling from a high position.
After parking, apply the brakes to stop the machine, then engage the parking brake.
Ensure that there are no people, obstacles, or structures in the unloading area, and that the material will fall within a safe area.
Slowly raise the bucket to the unloading height. Avoid abruptly dumping the material from a very high position; operate within a controlled height range.
4.2 Unloading Techniques
Unload the material from directly above the center of the unloading opening or chute to minimize impact.
Tilt the bucket smoothly and slowly. If the unloading point is far away, first raise the bucket, then extend it forward before tilting.
Avoid dumping the material all at once; unload in stages or slowly to reduce impact on the structure, bucket edges, and hinges.
If there are guardrails or other structures at the unloading platform or vehicle, be careful not to scrape or hit the bucket.
4.3 Post-Unloading Procedures
After unloading, tilt the bucket back to a safe position, then lower it to its lowest position or ground level.
After confirming that the unloading area is clear of obstacles and people, release the parking brake and slowly back away from the unloading area.
During the departure, be aware that any remaining material in the bucket may affect stability; operate cautiously.
Once completely clear, return the bucket to its standard transport position for the next cycle.
5.1 Handling Skidding and Side Slipping
If the tires skid, slow down and ease off the accelerator. If this doesn't work, slightly lift the bucket to increase traction on the front wheels. If equipped with a differential lock, engage it as needed (but follow the manufacturer's instructions).
When side-slipping, gently adjust the steering and slow down gradually; avoid sudden steering movements.
5.2 Spatial Positioning Techniques
During unloading, maintain a 30° angle between the machine and the transport vehicle to ensure the unloading height matches the side wall of the vehicle.
For high-level material bins, use the "two-stage lifting method": first lift to 2/3 height, then fine-tune the position for final unloading.
5.3 Safety Redundancy Design
The unloading path must not cross the top of the cab; maintain a lateral safety distance of at least 1.2 meters.
After completing the operation, lower the bucket to the ground and let the engine idle for 2 minutes before shutting it down.
5.4 Efficiency Optimization in Multiple Cycle Operations
During loading, plan the entry and exit routes in advance to minimize travel distance, turns, and intersections.
When the material pile surface is relatively flat, use the "partial scoop + finishing" method (roughly scoop first, then refine the edges and level the surface) to reduce idle time and increase loading efficiency.
For frequent loading and unloading cycles, try leaving some space in the load (i.e., not loading to capacity) to speed up the cycle and reduce vibration.
For long-distance transport or frequent heavy-load driving, select appropriate speed and gear based on terrain, load, and incline to avoid frequent gear changes or high engine speeds.
5.5 Maintenance and Service Recommendations
After each shift, clean the inside of the bucket, hinges, hydraulic hoses, and radiator to prevent mud and sand buildup, which can cause wear or overheating.
Regularly lubricate hinges, bearings, and pins to maintain smooth operation.
Monitor hydraulic oil temperature, filter clogging, and oil quality; replace oil and filters promptly to ensure system performance.
For high-intensity working environments, regularly inspect the main frame, axle housing, tires, and structural components for fatigue cracks.
Keep an operation log, noting any abnormal vibrations, noises, or temperature rises for timely troubleshooting.
The loader operation process seems simple—lift, load, transport, unload—but each step involves many details, precise control, and safety considerations. A truly skilled operator isn't defined by fast reflexes or quick movements; rather, they maintain a smooth, efficient, and appropriate operating rhythm under all terrain and material conditions.
In practical applications, operators should adjust their techniques based on the specific machine manual, the construction environment, and the material properties. With the advancement of automation and intelligent technologies, auxiliary systems (such as load sensing, path planning, and automatic control) can further enhance efficiency and safety. However, regardless of technological advancements, fundamental skills—including starting procedures, loading techniques, driving principles, and unloading procedures—remain essential and must be thoroughly mastered by every operator.
If you need assistance in developing operating guidelines for specific work environments (such as mines, tunnels, material storage areas, or areas with restricted access for lubrication equipment), or if you require customized loaders and loader attachments, please feel free to contact us.
