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Tuning and maintenance of the Volvo L90G loader

Keeping your Volvo L90G Loader in optimal condition is essential to ensure its performance and durability. Below are the key points you should check regularly to keep your machine in excellent condition.

What elements should we take into account?

We will list all those points to check to have your Volvo L90G loader in perfect working order.

Hydraulics and Transmission

We will check the hydraulic system, making sure the oil is circulating properly.
We’ll inspect the differential locking system, which is crucial to maximizing traction.
We will ensure that the Automatic Gear Shift System (FAPS) works smoothly.
We will check the brake wear indicators.

Engine

We will carry out an exhaustive check of the turbo diesel engine, such as checking for possible leaks in the injection system.
We will check the fuel pump, tubes and hoses (are they free of leaks?), electrical connections of the injectors, cooled exhaust gas recirculation sensor and the particulate filter.
We will check the aftercooler line (clamps, hoses, etc.) so that no leaks are observed. A leak can cause a drastic loss of power.
As long as we have the necessary instruments, we will check the diesel particulate filters (DPF) and their correct operation.

Air conditioning and fuel efficiency

We will ensure the correct operation of the air conditioning system and monitor the warning indicators.
We will use the different work modes that the loader offers us to save fuel consumption.

Air Filter and Hydraulic Steering

We will inspect the air filter, both the pre-filter and the main filter, located on the top of the machine to ensure clean air flow.

We will verify the hydraulic steering system, we will check that it is free of leaks and that its operation is correct (for example that it does not shake during its activity).

Structure and Accessories

The axle supports are maintenance-free and designed for long life. Even so, it should be noted that the pivot shaft lubrication system works correctly.
We will ensure that the hydraulic cooling fan is properly controlled electronically and rotates only when necessary.

To facilitate maintenance tasks, the hood has a new design that opens electrically with a wide opening range.

Transmission and Brakes

We will review the single lever gearbox, the valves and the automatic gear change from 1 to 4.
We will check the brakes, including wear indicators and nitrogen accumulators.
We also ensure that the Contronic system activates automatic declutching when braking. It is important to check, always with the machine stopped, the braking system by applying the brakes for a minimum of 30 seconds).

Cabin and Safety

We will inspect the cabin, including monitors, heater and defroster, as well as the air vents on all windows.
We will check the seat suspension and seat belt.
The machine must be equipped with an emergency exit hammer to break the window if necessary.

Lifting and Hydraulics Cylinders

The lift cylinders, hydraulic pump, valves and hydraulic control levers must be visibly free of leaks.
We will verify the operation of the bucket positioner and the adjustable position indicator.

General Maintenance

We will check the levels of fuel, engine coolant, hydraulic oil, gearbox oil, engine oil and axle oil.
We will carry out regular maintenance, such as draining and filling the engine oil.
We will check the brake lines and system connections.

Exhaust System and Electrical System

We will check the exhaust system, especially possible sensor failures and possible intake air preheating failures.
We will check the electrical system, which includes:
- Alternator, battery disconnect switch, batteries, hour meter, horn, instrument panel, gearbox temperature, coolant temperature and instrument lighting.

Lighting System and Outdoor Equipment

We will check the lighting, which includes headlights, brake lights, taillights, turn signals, and halogen work lights (2 front and 2 rear).

This model of loader comes equipped with an important safety element, such as the rear camera, which we will periodically review to verify its correct operation.

We will check the condition of the fenders, the cabin fixings and the engine and gearbox sinemblocks. All protections must be in place.Maintaining a routine of regular inspection and maintenance of these points is essential to ensure optimal performance and prolong the life of your Volvo L90G. Follow Volvo’s recommended maintenance schedule and perform regular inspections to keep your machine in excellent condition.Do not hesitate to contact us for all the necessary spare parts for your machine atinfo@taopparts.com

What boosts our machines? A glimpse into a key element: The transmission

When we think of heavy machinery, we imagine an imposing power capable of moving earth, gravel, and stone with ease. But behind this vision, there is much more: achieving a longer lifespan with lower maintenance costs. In recent years, heavy machinery has evolved significantly to meet these demands. In this blog, we will explore the heart of these machines, the transmission. With a focus on wheel loaders, we will break down their key components, the fluids that keep them running, and their types.

Emphasizing Their Importance

Transmissions are the backbone of machines, allowing for the efficient transfer of engine power to the wheels or tracks. In a wheel loader, the transmission plays an essential role in adjusting speed and torque (the rotational force a motor can generate to perform work) according to operational needs.

And in the case of a wheel loader… What aspects do we highlight?

Essential Components of a Loader’s Transmission

Torque Converter

The torque converter is the first piece in a wheel loader‘s transmission. It functions as a hydraulic coupling that allows for the smooth and gradual transmission of power generated by the engine to the transmission. Its design enables jerk-free starts and efficient energy transfer. In situations of heavy loading, the torque converter acts as a torque multiplier, providing greater force to overcome obstacles and challenging terrains.

Gearbox (Powershift)

The gearbox, or powershift transmission, enables control of speeds and gear changes in the wheel loader. The distinctive feature of a powershift transmission is its ability to shift gears seamlessly, ensuring a smooth transition without power loss. It also allows the operator to adapt the machine, such as a wheel loader, to different load and terrain conditions, optimizing efficiency and performance in various tasks.

Axles and Driveshafts

Axles and driveshafts serve as crucial foundations in wheel loaders, playing an essential role in transferring the power generated by the engine to the wheels. Axles, designed to withstand loads and torsion, are responsible for maintaining precise wheel alignment and ensuring reliable traction on diverse terrains. Driveshafts, on the other hand, act as vital intermediaries by seamlessly transmitting motion from the gearbox to the axles.

The synergy between these components is fundamental for the optimal performance of the wheel loader, especially in construction, mining, and earthmoving environments.

Keeping them in optimal condition is a priority to ensure the reliability and efficiency of the machine throughout its lifecycle.

Fluids and Lubrication

In the past, powershift transmissions used to rely on engine oil, which was not an optimal choice due to differences in composition and performance required by transmissions. Compared to specialized oils, engine oils could lead to wear and friction issues in components such as clutches and brakes. Changes in fluid technologies and design have given rise to advanced oils that enhance performance and durability.

These modern lubricants fulfill several vital functions, including ensuring friction stability, anti-wear protection, and material compatibility. They also provide control over sludge, protection against rust and corrosion, and thermal stability.

You can choose between single-grade or multigrade oils, depending on the climate and requirements. As the industry evolves, oils will continue to adapt to new engines and emission requirements, remaining essential in maximizing the efficiency and longevity of heavy machinery.

Typology

In the realm of wheel loaders and most heavy machinery, we encounter a variety of transmission types, each designed to meet specific needs and situations:

Powershift: Renowned for its seamless gear shifts, allowing the machine to maintain its momentum and efficiency while changing speeds. Extremely useful in situations of constant load or on uneven terrains. The smooth transition between gears optimizes operation in various conditions, providing greater traction and reducing clutch wear. In construction and mining environments where power and durability are essential, they have proven to be an effective choice.

Hydrostatic: Hydrostatic transmissions employ hydraulic fluids to transmit engine power to the wheels or tracks. This technology offers precise control and smooth maneuverability, making it particularly valuable for operations requiring precise movements and maneuvers in tight spaces. The ability to vary speed and direction smoothly and continuously makes hydrostatic transmissions ideal for accurately loading and unloading materials in congested work areas.

Automatic: Automatic transmissions, known for their comfort and ease of use in passenger vehicles, have also been adapted for heavy machinery, including wheel loaders. These transmissions automatically shift gears based on load conditions and machine speed, allowing operators to focus on other critical tasks. Efficiency and the smoothness of gear transitions are standout features of this transmission type, resulting in a more comfortable and productive operation.

Recycling and Sustainability

The recycling of used transmission components plays an essential role in reducing environmental impact and promoting sustainability in the industry. Firstly, recycling helps minimize the accumulation of electronic and metallic waste, reducing pressure on landfills and preventing soil and water pollution. By salvaging and reusing parts from decommissioned transmissions, the need to extract and process new raw materials is decreased, contributing to the conservation of natural resources.

Additionally, it can have a positive impact on the economy by fostering job creation in the recycling and refurbishment industry. Workshops and specialized companies in parts recovery can repair and refurbish used components, extending their lifespan and offering them at a more affordable cost compared to entirely new parts. This benefits both heavy machinery operators and fleet owners by reducing maintenance and replacement costs.

Lastly, it contributes to a circular economy mindset in the industry, where products and materials are reused and recycled instead of being discarded after their initial lifespan. This not only reduces the industry’s environmental footprint but also promotes greater awareness of the importance of resource conservation and environmental responsibility in a critical sector for construction and infrastructure.

WA500-3

In TAOP PARTS, we can provide the necessary spare parts for your machine, including transmissions and their components. Feel free to contact us for inquiries and assistance.

www.TaopParts.com

info@taopparts.com

Ready for summer! And your machine… Is it truly prepared for the heat?

Heatwaves pose significant challenges, not only for people but also for machinery operating in construction sites, quarries, mines, and, in general, outdoor workplaces.

High temperatures can have a detrimental impact on the performance, lifespan, and integrity of all heavy machinery, including excavators, wheel loaders, rigid and articulated dump trucks, and bulldozers. Let’s examine the risks that heatwaves present and discuss essential tips on how to properly protect and maintain this equipment in challenging weather conditions.

Understanding the Risks

Extreme heat can trigger a series of issues in machinery, affecting their operation and leading to costly breakdowns. Let’s examine some of these risks:

Engine Overheating

High temperatures can strain the cooling system. Excessive heat can push the engine to operate at dangerous temperatures, potentially resulting in severe damage.

Accelerated Wear and Tear

Extreme heat accelerates the wear of mechanical parts, electrical components, and seals, which in turn can reduce the overall equipment lifespan.

Decreased Performance

Machines may become less efficient in extreme heat, impacting productivity and increasing operational costs.

Preventive Maintenance and Cleaning

Comprehensive preventive maintenance before and during heatwaves is essential to keep the machinery in optimal condition. Here are some key measures:

Cooling System Inspection

Always ensure that radiators, coolers and ventilation systems are clean and free from obstructions. It’s crucial that fans work properly to ensure adequate cooling.

Fluid Control

Maintain the proper levels of coolant and lubricants in the tanks according to the manufacturer’s specifications. High-quality fluids are essential to protect the machinery from high temperatures and friction.

Air Conditioning System (AC)

We must ensure that the air conditioning system is functioning properly to provide the operator with a more comfortable and safe environment, which can also help maintain focus and reduce fatigue. To achieve this, we will check the refrigerant level, clean filters, inspect hoses and connections, and remember to perform periodic system tests before shifts where the machine will be exposed to high temperatures.

Constant Temperature Monitoring

Implementing temperature monitoring systems can be vital to detect overheating issues in a timely manner and take preventive measures. Infrared thermometers and temperature sensors can provide real-time readings to identify potential hotspots.

Adjustment or Replacement of Components

An essential aspect of maintenance is regular inspection of the machine’s key components for signs of wear. We must replace and adjust worn-out parts to prevent unexpected breakdowns that may occur during work in extreme conditions, such as the high temperatures that some work sites can experience during the summer months.

Smart Scheduling

Planning heavy machinery operations based on weather forecasts can significantly reduce stress on the machine. Avoiding operation during the hottest hours of the day and performing the most intensive tasks in the early morning or late afternoon, when temperatures are lower, is beneficial.

Protection and Shelter

When the machines are not in use, it is advisable to keep them in shaded areas or under covers to protect them from direct sunlight. This can help reduce exposure to high temperatures and prevent damage to sensitive components, such as the electrical system, which can be vulnerable to overheating, leading to significant wear on the insulation materials of the wiring.

Operator Training

While we’ve primarily focused on machines, we cannot overlook the role of the operator. Training the operator on how to recognize signs of overheating and how to take corrective actions is essential. Operators should be attentive to warning signs and know when to stop the machine to prevent further damage.

Heat-Sensitive Components

Some components most sensitive to high temperatures in the summer are those subject to constant friction, involved in cooling processes, or containing materials that can degrade in extreme heat. For example:

Belts

Transmission belts, like alternator belts and fan belts, are susceptible to hardening, cracking, or breaking due to excessive heat. If they’re worn out, they can result in system failures and energy loss.

Hoses or Tubes

Since they transport coolant, oils, and hydraulic fluids, hoses and tubes can become more susceptible to leaks and ruptures when exposed to high temperatures. If they are weak or damaged, they can cause a loss of essential fluids necessary for proper functioning.

Radiators

Radiators and coolers are vital for the cooling system. If they become obstructed or damaged due to the accumulation of dirt, dust, or other contaminants, they can lead to engine overheating.

Thermostats

Thermostats regulate the engine temperature by controlling the flow of coolant. If they fail due to extreme heat, they can cause overheating or inadequate cooling of the engine.

Seals and Gaskets

High temperatures can cause seals and gaskets to degrade, leading to leaks and contamination of critical fluids.

Oils and Lubricants

If of low quality, their viscosity can be affected under extreme heat, which impacts their ability to properly lubricate and protect moving parts.

Electrical Components

Some electrical components, such as relays, switches, cables, and connections, may experience overheating due to high temperatures, which could result in malfunction or failure.

Fans

While designed to assist in the cooling system, fans can also be affected by high temperatures. If fans do not operate properly or if they become obstructed, the cooling system may not be as efficient, increasing the risk of overheating.

In conclusion

Proper protection and maintenance of earthmoving and mining machinery during heatwaves are essential to ensure the safety, efficiency, and longevity of the equipment.

By understanding the risks and implementing preventive measures such as regular maintenance, temperature monitoring, and smart planning, we can minimize the negative impact of extreme heat. Let’s remember that these investments in care and prevention not only safeguard our assets but also protect the workers operating these machines, ensuring a safer and more productive work environment in any climatic conditions.

You can reach us at:

info@taopparts.com

www.TaopPart.com

A Glimpse into the Heart of Our Machines: Hydraulic Pumps

The hydraulic system is a vital component in earthmoving and mining machines, as it utilizes special fluids, usually hydraulic oil, that are under pressure.

This pressure, generated by the fluid, is essential to transmit the required power and enable the efficient operation of various components in the machines. In this way, it enables the control of actions and other crucial movements in the equipment’s operation.

Components of the hydraulic system

Hydraulic pump: Converts mechanical energy into hydraulic energy, generating hydraulic flow that drives the operation of the components.

Hydraulic valves: Control direction, pressure, and flow, enabling precise movement of actuators.

Hydraulic cylinders: Transform hydraulic fluid energy into linear motion, driving lifting, pushing, and pulling actions. Among the top sellers at TAOP PARTS are:

Lift cylinder: Allows the movement of the boom and generates the force needed for lifting loads.

Steering cylinder: Enables control and change of the machine’s direction.

Boom cylinder: Provides lifting and tilting motion in heavy machinery, such as excavators, for excavation and loading tasks.

Bucket cylinder: Facilitates the movement of the bucket or other attachments.

Hydraulic motors: They are responsible for converting hydraulic oil into circular motion, enabling the operation of elements such as wheels and tracks. In this way, the hydraulic system drives essential movements for the machine’s mobility and operation.

Hydraulic filters: Maintain fluid cleanliness, protecting the system components from potential damage caused by particles and contaminants.

Accumulators: Store hydraulic energy and release it when a temporary increase in pressure or flow is needed.

At TAOP PARTS, we offer all the hydraulic system spare parts, as well as a large stock of its main component, the hydraulic pump.

The hydraulic pump in Komatsu and Volvo machinery

What is it?

The hydraulic pump is a device that converts mechanical energy into hydraulic energy, generating the necessary fluid flow that drives the operation of the hydraulic system.

Types

Gear pumps

They are simple and economical, suitable for low-pressure and low-flow applications.

Axial piston pumps

Composed of multiple pistons or plungers (usually six or eight), they can handle pressures of around 380 bar. They offer higher efficiency and pressure capacity, making them ideal for demanding applications.

There are 2 types:

Variable displacement: With the same speed, the hydraulic fluid flow can vary.
Fixed displacement: Depending on the speed, the flow varies. Higher speed results in higher flow, and vice versa.

Vane pumps

Commonly used for fuel and/or oil transfer. They do not generate high pressure but provide a good flow rate.

Gear pumps

Composed of two gears, they have a constant flow rate. The flow rate increases with higher revolutions. They operate at a pressure of approximately 250kg.

How does a hydraulic pump work?

Typically, the hydraulic pump takes in fluid at low pressure and sends it out at high pressure, creating a continuous flow that activates the entire hydraulic system of the machine, including cylinders, main valves, hydraulic distributors, etc.

It has an inlet or suction port and a main pressure outlet (PP).

On the other hand, variable displacement piston pumps work differently, as they act by internal signal to vary the flow.

Our most popular pump models

Here are the models that our best-selling pumps fit:

Komatsu

708-1S-00230 for wheel loaders like WA470-5, WA480-5, and WA380-5.

708-1S-00940 for wheel loaders like WA470-6, WA430-6 and WA380-6.

Volvo

15068597 for wheel loaders like L220D, L220E, L180E and L150E.

11709023 for wheel loaders like L220D, L150E and L180E.

In summary, the hydraulic system is a crucial component in earthmoving and mining machinery, with hydraulic pumps playing a vital role in its operation by generating the necessary hydraulic flow.

At TAOP PARTS, we understand the importance of supplying high-quality components for hydraulic systems. We offer a wide range of parts and spare parts for Komatsu and Volvo hydraulic systems. We work to ensure our customers’ machines perform at their best while promoting environmental protection and circular economy by giving our spare parts a second life.

Feel free to contact us!

TAOP PARTS

info@taopparts.com