get operator technices loader

8/13/2019 GET Operator Technices Loader

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Ground Engaging ToolsGround Engaging ToolsLoader Operator Technique

PEXT9050


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Ground Engaging ToolsGround Engaging Tools

Wear

Loader Operator Technique

Correct Position Incorrect PositionPEXT9050

Left: Correct position

Right: Incorrect position.

- Change of direction accelerates wear.


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Wear

Material Flow Material Flow


PEXT9050

Left: Correct

Right: Incorrect - When the machine is operated incorrectly like this, what also happens?

- Because youre pushing a much bigger footprint through the material, it takes a lot more

fuel and increases wear and tear on the: -- Engine -- Machine -- Bucket

Also, it doesnt clean up the pit floor... leading to:

- Tire wear or splits.- Rolling stress on the machine and operator.

- Slower cycle time leading to reduced productivity.

What happens if the base edge is nose down?

- Wear is transferred to the top of the tip pocket, top of the base edge and internal bucket floors.

- If its a spade edge, the tires become highly exposed to damage from rocks.

What causes the misalignment of the bucket?

- The bucket leveler is not set correctly.

- The bucket leveler is not checked frequently, i.e. maintained..

- Operator override of the bucket leveler.

Over time weve found some operators dont understand the purpose of the bucket leveler. In these cases, the operator setsthe heel of the bucket on the ground to enter the pile. This is because he can see it and believes it to be in the correct

position.

The correct position is to set the base edge parallel to the floor with the tips nearly touching the floor. In this position, the

heel of the bucket will be off the ground.

Heres an example of where excessive pocket wear on tips can lead us to a poor operating technique which will result in

significant unnecessary cost to a customers operation.


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Loader Operator TechniqueIf the machine is operated with the heel down

Penetration is reduced

Cycle times increase

More fuel is required

If the machine is operated with the nose down

Tire wear can be increased due to exposure to rocks left on the

pit floor

Changing the operational envelope

Changes the wear pattern

Load forces on the machine

Can cause additional unnecessary wear protection to be added

PEXT9050

( Run through the above )


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Maintain bucket positioner in

proper alignment

Base edge parallel to floor

Cat buckets are designed for the

material to slide over a flat floor

Operation outside the design

envelope changes the wear

pattern of the bucket and GET

and affect loading Align positioner correctly

PEXT9050

Many time the bucket angle it set incorrectly .

Buckets are designed to have the base edge parallel to the floor. This allows

the material to slide over the edge and floor with the least amount of

resistance to load the bucket. This also minimizes wear.

Any changes to this will result in wear occurring somewhere else . where

it is not protected. More fuel will be required, there will be more stress on the

machine, loading will not be as efficient, and the tires could be unnecessarily

exposed to wear.

Therefore, it is important to have this set up correctly at all times.


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VIMS Keypad

View bucket kick out via VIMS

Keypad

585 Tilt Linkage parameter

Should read 65%

PEXT9050

Use the VIMS key pad to view the bucket angle. If the bucket has been set up

correctly for operation with the base edge parallel to the ground the individual

will read 65.


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PEXT9050

Here we have a couple of good examples of worn out tips; clear evidence of the

machine being operated with the heel down. Worn GET is a library of stored

information that is often the only real evidence you have on how the machine was

operated. Worn GET should be used as an integral part of operator training and

management to help keep the machine at its optimum performance level.

What SOS is to power train, worn GET analysis (boneyard) is to implement

operator technique. Steel has memory and in this situation the wear pattern shows

you how it moved through the ground. From this you can determine the position of

the implement and how the machine was run. A valuable tool to help people

improve their performance through a simple application of cause and effect

information is stored in the worn out GET


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PEXT9050

Overnight the machine was left standing and the base edge rusted in the moist

nighttime air. Why did it only rust along the edge?

Because this was the only area that was wearing . Because only this part of

the edge had been in contact with the ground.

Why? Because it was operated with the nose down.There will also be other evidence supporting this, but the rust is a quick indication

of what to look for.


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PEXT9050

The wear on the front of the end bit, and the front of bolt heads, compared with very

little wear at the back is clear evidence of the bucket being angled too far forward.

In the correct position, with the base edge level to the ground, the wear would be

even with most wear at the leading edge.


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Wear profile shows the angle of operation

Nose angled downwards before edge was rotated

Cutting edge is being operated outside the design envelope

Will reduce cutting edge, base edge and inside bucket floor life


PEXT9050

In this photo all the wear is on the back of the edge. The cutting edge has been

rotated.

Comparing the angle of wear to that of the base edge you can see how far forward

the bucket was positioned taking it right out of its design envelope.

The wear rate on the edge is increased when operated in this position as well.Instead of presenting the larger flat surface on the bottom of the cutting edge to the

ground, only the front portion is in contact. This will concentrate heat and material

flow to the top and bottom of the bevel causing it to wear much faster than it would

if operated correctly


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PEXT9050

Here is an example of nose down wear. This time it is on a segment bucket

using abrasion tips and half arrow segments.

The scalloping is normal in many operations. Its important to keep an eye

on the replaceable iron wear. When replaceable iron becomes minimal iron it

should be replaced or relocated.


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LHSLHS

RHSRHS


Enter the pile with the

bucket square to the face

More contact on

one side

Equals more

wear

Stresses bucket,

linkage and

hinge pin

Adapters wear on

one side and weld is

washed out

PEXT9050

ALL LOADERS ARE DESIGNED TO ENTER THE PILE SQUARE TO

THE FACE. Turning into the pile or loading on one side, places great stresses

on the machine and is twisting the bucket and articulation joint. Additionally,

loading efficiency is decreased. There is nothing to gain by side loading .

However, it will substantially increase the cost per ton.

GET wear analysis (boneyard) is a great management tool to help prevent this

from occurring.

The GET will wear more on the side of initial contact. In the top photo we can

see the wear on the LHS of the tip, adapter and adapter weld. Instead of the

material flowing over the top from the front, the material is coming in from the

side. The change in flow direction to get around these components results in the

side wear. On the RHS which is now the trailing edge you can see the wear rate

is very low by comparison. This side is being shadowed by the LHS.


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Never operate a bare

bucket

Minimize ground contact.

Make the tips do the work


PEXT9050

Never operate a bare bucket. It is a structural component of the bucket, protect it.

A worn base edge will cause the bucket to crack and fail resulting in expensive

downtime and repairs, and will reduce the buckets load capacity and be more difficult

to load.

Minimize ground contact. Contact = Wear = CostIf the contact is not productive, dont do it.


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Minimize ground contact.Make the tips do the work


PEXT9050

Heel plates are to protect the bucket hinges from wear that occurs when the bucket is

not loaded correctly.

Correct loading requires the lift arms to be raised, then the bucket to be curled. This

raises the bucket out of the wear material to reduce contact and wear while curling. If

curling commences while the bucket is still in the pile the result will be unnecessary

wear. Make the quick-to-change components wear, not the more difficult to replace

and more costly components.

A clean floor is very important for tire life .. Unnecessary cleaning is just as

costly as no cleaning. There is a balance

get operator technices loader

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