After sugarcane harvesting, sugarcane loaders should not be simply shut down. Proper maintenance not only extends machine life and reduces downtime, but also prepares the machine for the next harvest and lowers operating costs. Especially in large-scale sugarcane loading operations in mining, industry, or agriculture, where equipment loads are high and operating environments are harsh, the post-harvest "rest" and "repair" phase is crucial. This article analyzes the systematic maintenance procedures for sugarcane loaders after harvesting from a professional perspective, applicable to post-harvest maintenance of equipment in mining and agricultural environments.
1.1 Safe Shutdown and Cleanup
After the harvesting cycle, the loader should first be parked in a flat, stable, and well-ventilated location. The engine should be turned off, and the power supply/hydraulic system should be disconnected and locked. Operation should only resume after the engine oil and hydraulic oil temperatures have dropped to safe levels.
Meanwhile, clean up any residue at the work site: sugarcane stalks, leaves, soil, gravel, and other attachments easily adhere to the equipment surface and internal structure and should be removed promptly. Long-term adhesion of these impurities can cause corrosion, wear, or jamming of the hydraulic system and bucket/grab components. It is recommended to thoroughly clean the machine body, hydraulic cylinders, conveyor chains, and other parts using a high-pressure water gun, paying particular attention to cleaning the gaps between the rotary joints and the grabbing device to ensure the 360-degree rotating mechanism is not interfered with by foreign objects. After cleaning, the equipment must be completely dried to prevent moisture residue from causing rust.
During the cleaning process, use appropriate tools (high-pressure water gun, air blower, brush, etc.), but before disassembly or maintenance, avoid direct water ingress into sensitive areas such as electrical connectors, hydraulic pump inlets, and filters.
1.2 Operating Data and Status Records
Before maintenance operations, it is recommended to record key data at the end of the current operating season: cumulative operating hours, fuel consumption, hydraulic oil temperature, oil pressure, filter replacement time, and whether major components (such as grab bucket, telescopic boom, hydraulic cylinders, slide rails/guide rails, tires/tracks) show obvious wear, cracks, or deformation.
These records will provide a basis for the preventive maintenance plan for the next season and are an important part of machinery management. Literature indicates that establishing a comprehensive equipment maintenance management process can significantly improve equipment availability.
2.1 Hydraulic System Maintenance
The hydraulic system is the "heart" of the sugarcane loader—key movements such as the grab bucket/boom/telescopic boom rely on hydraulics, making it the core power source of the loader. The hydraulic oil quality and level should be checked carefully. Maintenance recommendations include:
Check the hydraulic oil level and quality (whether it is mixed with water, blackened, has an unusual odor, or contains bubbles). If the oil is found to be blackened, emulsified, or contains suspended matter, it should be replaced immediately.
If the hydraulic fluid becomes emulsified, cloudy, or contains metal shavings, it must be replaced immediately with a qualified hydraulic oil. Simultaneously, carefully inspect the oil pipes for aging cracks and leaks at joints. Perform a sealing test on the travel and swing motors, and replace any failed seals promptly.
Replace the hydraulic filter/return filter element. If the equipment follows the manual's recommended cycle, this should be completed before the end of the quarter. Referring to the instructions for a certain brand of sugarcane loader, "Replacing the hydraulic filter and promptly applying a breather" is a warranty condition.
Inspect all hydraulic hoses, joints, and cylinders for leaks, cracks, wear, and looseness, especially the grab bucket, rotating mechanism, telescopic boom, and high-mounted operating mechanism. Any leaks or looseness will lead to performance degradation or safety risks.
Hydraulic cylinder piston rods and seals should be kept clean, free of deposits or scratches, and moving parts should be coated with the manufacturer's recommended grease or oil film.
Before prolonged periods of inactivity (such as during the post-season maintenance period), it is recommended to release the pressure in the hydraulic system to a low level and pull moving parts to the neutral position to reduce seal deformation or fatigue caused by prolonged static operation.
2.2 Engine and Transmission System Inspection
Although the focus of a sugarcane loader is on loading operations, its engine and transmission systems are equally crucial to its lifespan:
Check the engine oil: The engine oil and oil filter should be changed immediately at the end of the harvest season (if not already changed). The presence of water, metal powder, or blackening in the oil indicates system fatigue.
Check the engine cooling system: Ensure the coolant concentration is correct, the antifreeze level is sufficient, the radiator fins are not clogged, and the fan belt and tensioner are not loose or damaged.
Check the gearbox/transmission oil and filter (if applicable), and inspect the drive shaft, universal joints, and couplings for looseness, cracks, or abnormal vibration. Literature indicates that the transmission system is often a source of failure during towing operations or heavy-duty loading.
For a three-wheeled loader with a wheelbase of 1790mm and a track width of 3062mm, the stability of the transmission system directly affects the overall machine performance. The gearbox lubricating oil condition should be checked, the gearbox breather cleaned, and the driveshaft joints lubricated. The tires on the running gear should be checked for wear, and tire pressure maintained within the standard range.
If the equipment is equipped with a telescopic/rotating boom, check the condition of the internal slide rails, rollers, chain (or timing belt), and hydraulic motor/reducer of the telescopic mechanism. Before long-term storage, it is recommended to perform a no-load test run to observe for any abnormal noises or vibrations.
2.3 Cleaning and Lubrication Maintenance
Thoroughly clean the entire machine (high-pressure water gun → air blower → brush), focusing on removing dirt from the engine compartment, hydraulic components, telescopic boom joints, grab mechanism, tracks/tires, and undercarriage. Common agricultural/industrial environments contain acidic residues, gravel, and plant debris; if these remain for a long time, they can cause corrosion or premature wear.
Lubricate all lubrication points according to the manufacturer's manual: hinges, pins, rollers, slide rails, foot pedals, grab bucket connectors, electrical connector covers, etc. Apply lubricant sparingly, avoiding excessive lubrication to prevent dust accumulation and a "gritty" finish. The literature specifically mentions that insufficient lubrication accelerates wear, while excessive lubrication may damage seals and introduce impurities.
Inspect the tracks or tires (depending on the model): Check for bulges, cracks, and proper tire pressure; check for loose tracks, worn connecting pins, and uneven guide wheels. Adjust or replace as necessary.
Apply anti-corrosion treatment to the exterior: For outdoor operations and long periods of inactivity, it is recommended to apply rust inhibitor or protective oil film to critical exposed metal parts.
2.4 Electrical and Control System Inspection
Check battery status: Is the battery fully charged? Are the connections secure? Are the plates corroded? Is the coolant (if maintainable) adequate? The operation manual reminds users not to generate sparks near the battery or clean the terminals during use.
Inspect all electrical connectors and wiring harnesses for wear, damage, or loosening; check lighting, indicator lights, monitoring systems, and sensors (such as hydraulic pressure sensors and temperature sensors) for proper functioning.
If the equipment is equipped with an automated control or remote control system, the electrical control box should be protected against moisture and dust, and a software/hardware self-test should be performed as needed (e.g., diagnose fault codes and check logs).
2.5 Grab/Loading Mechanism and Telescopic Boom Maintenance
The grab, boom, and telescopic boom are the "frontline weapons" of the sugarcane loader, and their maintenance is particularly critical. Check the grab grippers for severe wear, loose connecting pins, and broken or deformed gripping teeth.
The telescopic boom slide rails should be kept clean, adequately lubricated, and free of dust and sand. The telescopic chain (if applicable) should be tensioned periodically and its wear checked.
The boom swing mechanism and rotating platform (if applicable) should be inspected for cracks, corrosion, and wear in the gearbox, hydraulic cylinders, and turntable connections; adjust or replace the support bearings if necessary.
Loading operations subject to heavy loads, and prolonged operation may lead to structural deformation. It is recommended to conduct a structural inspection before the end-of-season shutdown: observe the boom for cracks, welds for fatigue cracks, and bolts at connections for looseness. Timely repairs can prevent major malfunctions during the next season's operation.
The working devices of the sugarcane grabber include the grabbing mechanism and the loading/unloading system. Special attention should be paid to checking the wear of the grabbing teeth; replacement is recommended for teeth worn more than 30% of their original size. Check the elongation and damage of the lifting chain or wire rope. Perform a stroke test on the lifting hydraulic cylinder with an unloading height of 3000mm to rule out the possibility of internal leakage.
4.1 End-of-Season Inspection and Spare Parts Replacement
For parts with a replacement cycle recommended by the manufacturer based on cumulative operating hours (such as hydraulic pumps, motors, slide rail rollers, and grab bucket pins), replacement should be scheduled in advance. Literature indicates that a good preventative maintenance plan can effectively control operating costs and improve equipment availability.
A comprehensive "health check" of the machine is recommended, including vibration analysis, sound detection, temperature anomaly recording, and structural inspection (cracks/fatigue). Any identified problems should be documented in a repair order, and repairs or replacements should be arranged.
If the loader is to be stored for an extended period (e.g., several months of inactivity outside of harvest season), it is recommended to perform static protection measures on the hydraulic, fuel, cooling, and lubrication systems. For example, add anti-corrosion oil, place the grab bucket in a neutral position, cover the machine or store it in a shed, disconnect the battery negative terminal to prevent self-discharge, keep the battery charged, and perform regular maintenance to prevent sulfation.
4.2 Storage Environment and Protective Measures
The storage location should be dry, well-ventilated, rainproof, dustproof, and away from pesticides, corrosive gases, and other environmental hazards. If parked outdoors, the machine should be covered with a dust cover/rain cover, and the condition of the cover should be checked regularly.
It is recommended to raise the machine, slightly reduce tire pressure, or add wooden blocks to reduce the risk of tire deformation or track loosening due to prolonged load.
During the storage period, start the engine and activate the hydraulic system (unloaded) every few weeks to prevent seal adhesion, oil line blockage, and rust.
Simultaneously, it is recommended to regularly check the machine's condition during storage: such as battery voltage, tire pressure/track tension, presence of corrosion or insect damage, and integrity of the lubrication film.
4.3 Maintenance Records and Spare Parts Management
Establish a complete maintenance record, documenting the time of each maintenance, replaced parts, and problems found. Maintain an adequate stock of wear parts, such as hydraulic oil filters and seals, to ensure timely maintenance.
Before the next sugarcane harvest season, a comprehensive pre-inspection is strongly recommended, including a review of the above systems. Key items include: oil parameters (oil color, temperature, pressure), tightness of mechanical connections, absence of hydraulic system leaks, track/tire condition, smooth operation of the grab/telescopic boom, and the integrity of electronic systems and safety devices. Ensure machines are "ready" rather than "started in emergencies" to reduce the risk of malfunctions and improve operational efficiency.
As a key piece of equipment in the sugarcane harvesting chain, the stability of sugarcane loaders directly affects loading efficiency, transportation connections, and subsequent processing. Proper and systematic post-harvest maintenance not only extends equipment lifespan but also provides reliable assurance for the next season's operations. In summary, from cleaning, recording, system checks, lubrication, structural repairs, shutdown protection, to pre-inspection and startup, every step is crucial. Agricultural and mining operations are characterized by variable environments, heavy loads, and high maintenance difficulty; only by adopting a strategy of "prevention first, maintenance second" can equipment operate efficiently and reliably during the intense harvesting season.
