Underground Loader Rebuild for a Gold Mine: Maximizing Performance in Harsh Conditions

When it comes to gold mining operations, few machines work harder or endure more abuse than the underground loader. Designed for low-clearance environments, high dust exposure, and constant cycling of heavy loads, these machines are vital to production. But when one fails—especially deep in the drift—a full replacement isn’t always feasible. That’s when a well-planned, field-tested underground loader rebuild becomes the smartest solution.

This case study explores how Industrial & Mining Services (IMS) was called to perform a full mechanical and structural rebuild of an underground loader used in a mid-sized gold mine in Northern Georgia. The project involved teardown, part remanufacturing, frame crack repair, hydraulic reseal, and full component testing—all completed underground to reduce downtime.

Client Overview

The client operates a mid-level gold mining facility processing 600 tons of ore per day. Their primary Sandvik LH514 underground loader had begun to fail after 16 months of continuous use. IMS was called to restore it to working condition without surface hoisting.

Loader Specs

• Make/Model: Sandvik LH514
• Bucket Capacity: 7.0 m³
• Operating Weight: ~28,000 kg
• Engine: 300+ HP Diesel Tier III
• Components: Articulation joint, boom arms, hydraulic system, ROPS frame

Initial Assessment Underground

IMS deployed a 3-person underground crew with mobile tooling. Key inspections included:

• Hydraulic flow and cylinder leak testing
• Engine compression and filter inspection
• Ultrasonic crack detection
• Pin and bushing wear measurement

Rebuild Plan and Goals

To avoid costly surface transport, IMS planned a full underground rebuild. Primary goals included:

• Restoring full hydraulic pressure and control
• Repairing frame cracks and welds
• Replacing bushings and repacking cylinders
• Conducting reassembly and testing in-place

Phase 1: Disassembly & Frame Repairs

Components removed included the bucket, boom pins, pump, and articulation joint. Weld repairs featured:

• Beveling and stop-drilling of cracks
• Low-hydrogen SMAW structural welds
• Reinforcement gusset fabrication and welding
• Ultrasonic testing for crack elimination

Phase 2: Mechanical Overhaul

IMS serviced the following components underground:

• Hydraulic cylinders (repacked and polished)
• Transmission and final drives (fluid tested and resealed)
• Brake calipers and lines (adjusted and flushed)
• Cooling system (radiator flushed and tested)

Phase 3: Reassembly and Testing

• Reinstallation of boom and steering components
• Hydraulic bleeding and system priming
• Heavy-duty bucket bushings installed
• 2-hour live load test underground

Timeline

Phase	Days	Task
Phase 1	2	Disassembly and structural welds
Phase 2	3	Mechanical overhaul
Phase 3	1	Reassembly and function testing

Results

• Eliminated need for surface hoisting ($15,000+ saved)
• Returned to service in under 1 week
• Full hydraulic function and frame integrity restored
• No downtime for 5 months following rebuild

Safety Measures

• Gas monitoring and confined space prep
• Lockout/tagout and fire suppression procedures
• MSHA-certified welders and safety briefings
• Ventilation curtain and PPE management

Why IMS?

Industrial & Mining Services offers:

• Certified underground welders and mechanics
• Portable diagnostic and repair tools
• Sandvik, CAT, and Atlas Copco expertise
• Fast turnaround with deep experience in mine logistics

Relevant Search Keywords

• underground loader rebuild
• LHD repair in gold mine
• sandvik lh514 frame crack
• mine loader rebuild underground
• underground equipment hydraulic repair

Client Testimonial

“IMS rebuilt our LH514 underground in just days—no delays, no excuses. Their field crew knew what to do the moment they arrived and delivered a flawless rebuild.”
— Mine Foreman, Northern GA Gold Operation

Need Underground Loader Repairs?

If you operate a loader deep underground and need structural welding, hydraulic rebuilds, or full system restoration, contact IMS. We serve gold, copper, aggregate, and precious metal sites across Georgia and the Southeast with underground equipment repair solutions built to last.