On construction sites, in mining, construction, agriculture, and forestry, construction vehicles are often used in these environments. Wheel dump trucks, tracked tippers, and tracked turners often undertake critical tasks such as loading, transporting, unloading, and turning materials. These vehicles operate in harsh environments, experience large fluctuations in loads, and have complex structures. Improper maintenance can easily lead to breakdowns and shorten their lifespan. Therefore, to extend the lifespan of these construction vehicles, regular maintenance is essential to minimize breakdowns. This article systematically summarizes and outlines key maintenance points for these two types of unloading/turning equipment from multiple perspectives for reference by equipment managers, maintenance technicians, and field operators.
Wheeled dump trucks are the most common type of dump truck. Maintenance involves multiple subsystems, including the vehicle structure, powertrain, transmission, hydraulic unloading system, chassis and tires, body structure and corrosion protection, and dust and water protection. The following sections provide detailed descriptions of each subsystem.
1.1 Engine and Fuel System
Regularly Change the Engine Oil and Filter
As the engine's core power source, a poor lubrication system can increase wear, cause localized heating, and damage components. The engine oil and oil filter should be changed according to the manufacturer's recommended intervals (e.g., every 5,000 km or shorter depending on operating conditions).
Cleaning the Fuel Filter and Injector
Especially in dusty operating conditions or with poor fuel quality, the fuel filter should be regularly inspected and replaced. The fuel injectors and fuel system should also be cleaned of carbon deposits and the spray quality should be checked.
Intake/Exhaust System Maintenance
Regularly inspect the air filter, turbocharger (if installed), and exhaust pipes to prevent dust blockage, carbon deposits, or exhaust misalignment.
Cooling System Inspection
Regularly change the coolant (seasonally or based on operating hours), clean the waterways and radiator, and remove scale and corrosion. This is especially critical during the transition between summer and winter.
1.2 Transmission and Gearbox
Lubricant and Oil Seal Inspection
Transmission system components, such as the transmission, differential, and drive shaft, should have their gear oil, seals, and oil seals replaced according to the manufacturer's schedule to prevent sludge accumulation and seal failure.
Lubrication System and Filter Element
Replace the transmission filter element and clean any deposits inside the transmission to maintain clear lubricant passages and prevent shifting jerks and wear.
Inspect the drive shaft coupling and universal joints.
Lubricate the universal joints and inspect the couplings for looseness or cracks. Tighten or repair them promptly.
1.3 Hydraulic Unloading System (Lifting System)
The most typical "unloading" process for wheel dump trucks involves lifting the truck bed. Failure in this system can easily lead to a rollover or unloading failure. Key maintenance tasks include:
Hydraulic Oil Replacement and Filter Maintenance
Select appropriate hydraulic oil and replace it regularly. Also, replace/clean the return filter, pilot filter, and suction filter. Avoid hydraulic oil contamination or degradation.
Inspect the Oil Pump, Valves, and Hydraulic Cylinder
Before and after each operation (or periodically), inspect the hydraulic pump for abnormal noise, excessive oil temperature, valves for sticking or leakage, and the hydraulic cylinder piston rod for scratches and seals for oil leakage.
Unloading Operation Control Specifications
Unloading operations must be performed while the vehicle is stationary, in neutral, and braked.
Do not raise the vehicle while it is in motion.
After unloading, disengage the power take-off (PTO) before driving. Otherwise, prolonged no-load operation of the hydraulic pump can lead to overheating and damage to the oil seal or pump body.
When unloading, avoid sudden lifting or rapid lowering to minimize impact damage to the structure and seals.
Structural Inspection
Carriage hinges, supports, pins, hinge plates, etc. should be regularly inspected for cracks, looseness, or wear, and repaired or reinforced promptly.
1.4 Chassis, Suspension, Axles, and Tires
Tire and Pressure Management
Proper tire pressure and proper load distribution prevent uneven tire wear and blowouts. Tires should be regularly inspected for wear, cracks, bulges, and other abnormalities.
Suspension System Inspection
Springs, buffers, lifting lugs, and saddle bolts should be regularly inspected for tightness, corrosion, and breakage.
Axles and Differentials
Regularly check differential oil temperature, lubricant condition, bearing and housing seals, and replace gear oil and seals promptly.
Chassis Corrosion Protection and Sealing
The chassis and frame should be coated with an anti-corrosion coating or protective layer. Check for coating damage and corrosion spots and repair them promptly. Regularly clean the chassis of mud, sand, and corrosive materials.
1.5 Vehicle Structure, Joints, and Corrosion and Rust Prevention
Structural Weld and Load-bearing Component Inspection
Regularly inspect the vehicle body, frame, load beams, reinforcement plates, brackets, and bolted joints for cracks, loose bolts, and deformation.
Hinge Pin and Bushing Lubrication and Replacement
Lubricate car body hinges, hanger pins, and other areas with grease. Check bushings for wear and replace if necessary.
Corrosion and Rust Prevention
Especially when operating in humid, saline, or chemically exposed environments, strengthen anti-corrosion coatings, zinc spraying, oxidation treatment, or partial repainting to prevent rust and corrosion on metal parts.
1.6 Electrical and Control System
Electrical Wiring and Connector Inspection
Apply waterproof and dustproof treatment. Inspect wiring harness insulation and connectors for looseness, corrosion, and damage.
Control Devices, Sensors, and Instruments
Check sensors, switches, instruments, and alarm systems for proper function. Clear fault codes promptly and ensure connections are secure.
Battery Maintenance
Check battery voltage, electrolyte level, and terminals for looseness and oxidation. Charge and discharge regularly and keep the battery clean.
1.7 Daily Inspection and Operating Specifications
Daily Inspection Checklist
Includes engine oil level, coolant level, fuel level, hydraulic oil level, pump and pipeline leaks, tire pressure, carriage hinge points, pins, hydraulic pump temperature and sound levels, control switch and instrument indicators, and bolt tightness.
Shortening the Maintenance Cycle Based on Operating Conditions
Maintenance intervals (such as lubrication, filter replacement, and structural inspection) should be appropriately shortened under conditions of high dust, high loads, high temperatures, and corrosion.
Maintenance Records and Trend Analysis
Record each maintenance and troubleshooting operation (including time, labor hours, components, wear, oil condition, and test data). Trend analysis can be used to proactively prevent potential failures.
Operating Environment and Operation Training
Train operators to follow standard operating procedures and avoid illegal operations such as overloading, forced lifting, forced lowering, and dumping while in motion. The operating environment should also be kept as clean as possible, with improved drainage and dust control facilities.
Crawler dumpers, also known as crawler dumpers, crawler transporters, and rail-mounted stacking equipment, incorporate both a crawler travel mechanism and a stacking/turning mechanism. Maintenance focuses on the crawler chassis module and the stacking/turning mechanism. These are discussed below.
2.1 Crawler Travel System Maintenance
The crawler travel system is a unique feature of the truck. Improper maintenance can easily lead to problems such as track detachment, breakage, loosening, and track biting.
2.1.1 Tracks (Rubber, Steel, or Hybrid)
Track Tension Adjustment
Maintain appropriate pre-tension; avoid excessive looseness or tightness. Excessive looseness can easily lead to derailment, while excessive tightness can accelerate wear.
Removing Foreign Objects and Mud
During operation, promptly clean mud, sand, stones, grass, and entangled objects from inside and outside the tracks to prevent them from getting stuck or deforming.
Preventing Lubricant/Chemical Contamination
Prevent grease, oil, or chemical solvents from coming into contact with the tracks, especially rubber tracks.
Proper Operation for Crossing Obstacles
When crossing high ground, ravines, or hard objects, slow down and drive head-on to avoid slipping, twisting, or straining. Exercise caution when using the tracks on hard surfaces or concrete to minimize wear.
Track Storage and Spare Parts
When out of service for an extended period, clean the tracks, keep them dry, and store them overhead to prevent compression and deformation.
2.1.2 Track Components, Support Rollers, Roller Rollers, Guide Rollers, and Drive Mechanism
Lubrication and Bearing Inspection
The track pins, bushings, roller bearings, and sliding surfaces should be cleaned and lubricated regularly. The bearings should be inspected to prevent grease depletion or water infiltration.
Wheel-by-Wheel Wear Inspection
Roller rollers, support rollers, and guide rollers are susceptible to wear. Their diameters and rim wear should be measured regularly, and any abnormalities should be replaced promptly.
Drive Gear/Drive Wheel Inspection
Inspect the drive gear for wear, cracks, and engagement. Check the gear oil, seals, and drive shaft components.
Track Droop Measurement
To determine tightness, use a wooden wedge method or a ruler to measure droop and adjust the tensioning device.
2.2 Turning/Tilting Components and Hydraulic Mechanisms
Tracked dumpers typically have turning, mixing, pushing, and turning mechanisms, and are often driven by hydraulic or electro-hydraulic hybrids. Key maintenance points for this area include:
Hydraulic System
Maintenance points for the hydraulic system of a wheel dump truck are similar: regular hydraulic oil replacement, filter cleaning, pump and valve inspection, pipe seal testing, exhaust, and temperature monitoring.
Tilting Mechanism Inspection
Inspect the tilting frame, support mechanism, connecting pins, sliding guides, guide devices, and chains (if any) for wear, deformation, or looseness, and add lubricant.
Structural Component Maintenance
The turning bucket, brush arm, agitator arm, flip plate, and plate chain mechanism should be inspected for cracks, deformation, weld condition, and bolt connection conditions, and repaired or replaced promptly.
Electrical and Control System
Inspect the motor, control cabinet, wiring, sensors, switches, and waterproof and dustproof properties to ensure control system reliability.
Anti-Corrosion/Rust Treatment
Especially for dump trucks used in organic fertilizer, chemical, humid, and high-temperature areas, corrosion is severe and should be enhanced with anti-corrosion coatings, painting, or surface treatments.
2.3 Operation Monitoring and Fault Warning
Vibration/Temperature Monitoring
Install temperature or vibration monitoring devices on key components (bearings, drive sprockets, hydraulic pumps, gearboxes, etc.) to promptly detect abnormalities.
Regular Inspection and Measurement
Use precision tools to regularly measure key dimensions, clearances, deformation, wear, looseness, etc.
Maintenance Log and Lifecycle Analysis
Record each repair, part replacement, cause of failure, operating time, and environmental conditions to facilitate reliability analysis and predictive maintenance strategies.
Although wheel dump trucks and tracked dump trucks differ significantly in their travel and unloading mechanisms, they share many commonalities in maintenance and management. The following summarizes some common principles and management methods to facilitate unified management and improve equipment reliability.
|
Dimensions |
Common points |
Description/Reference |
|
Develop maintenance plans/cycles |
Corrected based on manufacturer recommendations + on-site conditions (dust, humidity, load) |
In harsh environments, maintenance cycles should be shortened |
|
Operator training and specifications |
Strictly require operating procedures and avoid illegal operations |
For example, it is forbidden to drive with the vehicle lifted, to unload suddenly, to overload, etc. |
|
Checklist/Standardization |
Establish daily inspection, weekly inspection, monthly inspection, quarterly inspection and annual inspection checklists |
Each inspection shall be carried out in a unified format, with unified items, and one by one |
|
Lubrication and oil management |
Uniformly select suitable lubricating oil, hydraulic oil, gear oil, etc. |
Strictly control oil quality, regularly sample and test, replace filter elements, and clean sediment |
|
Fault warning/condition monitoring |
Temperature, pressure, vibration, oil temperature, and sound monitoring |
Early detection of abnormalities and early treatment |
|
Parts Inventory and Replacement Strategy |
Appropriate spare parts for key parts (seals, filter elements, pins, bushings, lubricating parts, etc.) |
Reduce downtime due to parts shortage |
|
Maintenance records and statistical analysis |
Establish maintenance logs, failure analysis reports, and life statistics |
Analyze common failure trends and optimize maintenance plans |
|
Environmental and Protection Management |
Control dust, moisture, and corrosive substances in the working environment |
Strengthen equipment protection, covering, cleaning, coating protection, etc. |
|
Safety measures and work protection |
Provide safety support, power off and lock when performing maintenance, lifting and turning operations. |
Prevent accidental injuries and equipment damage |
The following lists some common faults and their prevention strategies, which complement the maintenance methods mentioned above.
4.1 Hydraulic Pump or Oil Seal Damage/Leakage
Causes: Excessive oil temperature, deteriorating oil quality, internal and external load impact, aging seals;
Prevention: Strictly control oil temperature, change oil promptly, avoid overloading and shock, and perform regular leak checks.
4.2 Carriage Hinges Cracked/Hinge Wear
Causes: High impact loads, uneven forces, insufficient lubrication;
Prevention: Enhance structural design or reinforcement, perform regular inspections, provide lubrication, and strictly prohibit illegal operation.
4.3 Track Derailment/Breakage/Damage (Applicable to crawler equipment)
Causes: Improper tensioning, foreign objects trapped, sharp turns, improper operation when crossing obstacles;
Prevention: Regularly adjust tensioning, promptly remove debris, and control operating speed and route.
4.4 Abnormal Noise or Stuttering in the Transmission or Gearbox
Causes: Insufficient lubrication, sludge contamination, gear wear, bearing failure;
Prevention: Regularly change the oil filter, clean the interior, monitor temperature and vibration, and promptly replace worn parts.
4.5 Electrical System Failure/Control Malfunction
Causes: Damaged wiring harness, loose connectors, short circuit, sensor failure;
Prevention: Strengthen sealing, waterproof and dustproof treatment, regularly check wiring harness insulation, and replace spare parts.
Because wheeled dump trucks and tracked dump trucks are used in harsh construction environments for a long time, necessary maintenance is more important than repair. In the automotive industry, there's a common saying that maintenance replaces repair, which is a key method for extending vehicle life. Preventing failures through daily inspections, regular maintenance, and standardized operation is more cost-effective and safer than post-repair overhauls.
Maintenance intervals should be tailored to the operating environment: In dusty, humid, or chemically corrosive environments, inspection and replacement intervals should be shortened. Proper operation of construction vehicles is key to extending their lifespan. Operators should be trained to strictly adhere to safe operating procedures to prevent major failures or accidents caused by human error.
Data Management and Trend Analysis: Utilize maintenance records, test data, and failure frequency statistics to continuously optimize maintenance strategies and equipment reliability.
Spare Parts Strategy: Appropriate spare parts are available for critical wear parts (seals, filters, bearings, pins, lubricants, etc.) to reduce significant losses caused by downtime awaiting replacement parts.
Emphasis on structural corrosion protection and cleaning: Mud, chemicals, and moisture accelerate metal corrosion and lubrication failure. Regular cleaning, protection, and repainting are essential.
Proactive Monitoring and Early Warning: Temperature, vibration, and pressure monitoring systems can provide warnings before a failure occurs, enabling proactive maintenance intervention.
Through the above maintenance information for wheeled dump trucks and tracked dump trucks, you should have a clearer understanding of how to minimize failures during the operation of these types of construction vehicles. If you have any questions about the maintenance of construction vehicles such as wheel dump trucks and crawler dump trucks, or want to purchase wheel dump trucks, crawler dump trucks and related accessories, please contact us.
