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Loaders
Overview
Basic Concept.
A loader is a type of construction equipment (engineering vehicle) machinery that is primarily used to "load" material into another type of machinery (dump truck, conveyor belt, rail-car, etc.).Loaders are used mainly for uploading materials into trucks, laying pipe, clearing rubble, and digging. A loader is not the most efficient machine for digging as it cannot dig very deep below the level of its wheels, like a backhoe can. Their deep bucket can usually store about 3-6 cubic meters of earth. The front loader's bucket capacity is much bigger than a bucket capacity of a backhoe loader. Loaders are not classified as earthmoving machinery, as their primary purpose is other than earthmoving.
Unlike most bulldozers, most loaders are wheeled and not tracked, although track loaders are common. They are successful where sharp edged materials in construction debris would damage rubber wheels, or where the ground is soft and muddy. Wheels provide better mobility and speed and do not damage paved roads as much as tracks but provide less traction.
Unlike standard tractors fitted with a front bucket, many large loaders do not use automotive steering mechanisms. Instead, they steer by a hydraulically actuated pivot point set exactly between the front and rear axles. This is referred to as "articulated steering" and allows the front axle to be solid, allowing it to carry greater weight. Articulated steering provides better maneuverability for a given wheelbase. Since the front wheels and attachment rotate on the same axis, the operator is able to "steer" his load in an arc after positioning the machine, which can be useful
the loader assembly may be a removable attachment or permanently mounted. Often the bucket can be replaced with other devices or tools--for example, many can mount forks to lift heavy pallets or shipping containers, and a hydraulically-opening "clamshell" bucket allows a loader to act as a light dozer or scraper.
In construction areas loaders are also used to transport building materials - such as bricks, pipe, metal bars, and digging tools - over short distances. Loaders are also used for snow removal, using their bucket or a snow basket, but usually using a snowplow attachment. They clear snow from streets, highways and parking lots. They sometimes load snow into dump trucks for transport.
Front loaders gained popularity during the last two decades, especially in urban engineering projects and small earthmoving works. Many engineering vehicle manufacturers offer a wide range of loaders, the most notable are those of John Deere, Caterpillar, Case, Volvo, Komatsu and Liebherr.
Applications
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1. loading materials；2. earthmoving；3. forestry engineering；4. snow removing；5. underground work；6. loading and unloading；7. pipe laying；8. maintain pavement；9. land clearing；10. garden work；11. rolling compaction；12. tunnel construction
Types
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1. mini type loader；2.small type wheel loader；3.medium type wheel loader；4.large type wheel loader；5. track-type loader；6. skid steer loader；7. underground mining loader；8. multi terrain loader；9. wheel backhoe loader；10. side dumping loader
Components and Features
Components
Basic Components
1. bucket；2. front axle；3.instrumentation console；4. cab and operating system；5.engine and transmission system；6. engine hood；7. counterweight；8. rear axle；9.rear frame；10. electrical system；11. front frame；12. mudguard；13. boom；14. rocker arm cylinder；15. connecting rod；16. rocker arm；17. boom cylinder；18. frame
Hydro mechanical Transmission System
1.engine；2. torque converter；3. power shifting transmission box；4. front axle；5. Caliper disc brake；6. wheel；7. parking brake； 8. rear axle；9. gear shift pump；10. steering pump；11. operational pump；12. wheel redactor
Transmission System Arrangement
1. engine；2. torque converter；3. power shift transmission box；4. rear frame；5. front frame；6. front axle；7. transmission shaft；8. rear axle
Torque Converter
1. flywheel；2、4、7、11、17、19. bearing；3. torque converter rotation housing；5. elastic plate；6. first turbine； 8. second turbine；9. stator；10. pump impeller；12. gear；13. stator shaft；14. second turbine shaft；15. first turbine shaft；16. spacer ring；18. one-way clutch gear；20. one-way clutch roller
Performance Characteristic
1. engine；2. piston pump；3. low speed piston motor；4.high peed piston motor；5. transfer case
Hastate Power Train System
1. Neutral-start parking brake lever；2. Track motors；3. Hastate pumps hoses；4. Hydraulic oil cooler；5. Service brakes；6. hoses；7. Wet, multi-disc parking brakes；8. Double reduction planetary final drives；9. hydraulic filters
Operator Station of Track Loader
1. Neutral-start parking brake lever；2. Track motors；3. Hastate pumps hoses；4. Hydraulic oil cooler；5. Service brakes；6. hoses； 7. Wet, multi-disc parking brakes；8. Double reduction planetary final drives；9. hydraulic filters
Standard Equipment Specifications
1. Engine：Type：Water-cooled, 4-stroke cycle；Aspiration：Turbocharged：Number of cylinders；Bore x stroke ；Piston displacement：Governor： Mechanical, all-speed control：Horsepower rating @ 2400 rpm (SAE J1349) /2400 rpm（SAE： J1349）；Gross horsepower；Net horsepower；Meets EPA emissions regulations EPA；Fuel system：Direct injection：Lubrication system：Method：Gear pump, force-lubrication：Filter：Full-flow：；Air cleaner：Dry-type with double elements and dust evacuator, plus dust indicator：
2. Transmission：Torque converter：3-element, single-stage, single-phase：Transmission.：Full power shift, countershaft, automatic.
3. Axles and Final Drives：Drive system：Four-wheel drive；Front：Fixed, semi-floating： Rear：Center-pin support, semi-floating,24° total oscillation；Reduction gear：Spiral bevel gear；Differential gear：Torque proportioning；Final reduction gear：Planetary gear, single reduction
4. Brakes：Service brakes: Hydraulically-actuated, wet disc brakes actuate
on four wheels；Parking brake: Wet, multi-disc brake on transmission output shaft.
5. Steering System：Type：Articulated type, full-hydraulic power steering；Steering angle：40° each direction；Minimum turning radius at the center of outside tire.
6. Boom and Bucket：
Z-bar loader linkage is designed for maximum rigidity and offers powerful breakout.
Rap-out loader linkage design enables shock dumping for removing sticky materials.
Sealed loader linkage pins with dust seals extend greasing intervals.
The bucket is made of high-tensile strength steel.
7. Bucket Controls：
The use of a PPC hydraulic control valve offers lighter operating effort for the work equipment control levers.
The reduction in the lever force and travel makes it easy to operate in the work envy- raiment.
Control positions：Boom：Raise, hold, lower, and float；Bucket ：Roll back, hold, and dump.
8. Hydraulic System：Capacity (discharge flow) engine-rated rpm：Loader pump；Steering pump；Pilot pump(Gear-type pumps)；Relief valve setting；Control valve：2-spool open center type；Hydraulic cylinders：Double-acting, piston；Hydraulic cycle time (rated load in bucket)：Raise，Dump，Lower (empty)，Total cycle time.
Dimensions
Wheel Loader
1. Height to top of ROPS；2. Height to top of exhaust pipe；3. Height to top of hood；4. Ground Clearance；5. B-Pin height at max. height；6. Center line of rear axle to edge of
counterweight；7. Wheelbase；8. B-Pin height at carry position；9. Center line of rear axle to hitch；10. Rack back at maximum lift；11. Dump angle at maximum lift；12. Rack back at carry position；13. Rack back at ground ；14. Height to center line of axle；15. Bucket reach；16. Dump clearance at 45° full height°
Track-Type Loader
1. Overall machine width with bucket；2. Overall machine width without bucket；3.Machine height to top of cab；4.Length to front of track；5.Overall machine length；6.Digging Depth；7.Maximum rollback at carry position；8.Reach at full lift height；9.S.A.E. specified dump angle ；10.Maximum rollback, fully raised；11.Dump clearance at full height and 45° discharge ；12.Height to bucket hinge pin；13.Overall machine height, bucket fully raised。
Bucket Features
1. Edge steel with extra hardened and toughened wear plates of up to 500 Brunel gives the bucket longer operating life.
2. Bucket shell and side plates of up to 400 Brunel to withstand abrasive wear. Reinforced
mounting points where the attachment is installed give less wear.
3. Bucket cutting edges of abrasive-resistant steel of up to 500 Brunel. Replaceable bolt-on wears plates on bucket floor, 500 Brunel.
4. Bolt-on edge savers and segments protect the cutting edge from unnecessary wear.
5. Volvo Tooth System with bolt-on or weld-on adapters of up to 515 Brunel gives excellent penetration and less bucket wear.
Skid-steer Loader Features
1. The round-back bucket design is stronger with no angled corners. This configuration makes it easier to fill and dump — improving productivity.
2. The ROPS/FOPS structure protects and shields the operator.
3. A total of four exterior lights help to illuminate any job site day or night.
4. A safety system locks lift, tilt and drive systems when the operator leaves the seat, raises the seat bar, or turns off the ignition switch. The brakes are wet-type multiple discs that require no maintenance.
5. Heavy-duty tires are standard — matching the durability of the skid-steer.
6. The rugged all-welded unitized frame is constructed of .375-inch gauge steel for years of productivity. Step bushings are placed in all key pivot areas to increase strength and reduce stress.
7. A wider wheelbase provides for a smooth ride and more balance for stability with heavier loads. A 9-inch ground clearance allows easy maneuverability through mud and other terrain.
8. Hydraulic lines are protected within the loader arm.
9. Mustang features a self-leveling vertical lift.
10. The advanced hydraulic system affords longer service intervals and comes with a sight glass for quick and easy fluid level inspections.
11. A drop-down step makes it convenient to check engine and maintenance points.
Working Attachments
Bucket Type
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1.Spade nose rock bucket；2. straight edge rock bucket with teeth；3. General purpose bucket with teeth；4. General purpose bucket with bolt-on-edges；5. Light material bucket with bolt-on edges；6. Log/Sorting grapples
Working Attachments of Skid-steer Loader
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1. Cold Planer；2. Pallet Fork；3. Hydraulic Breakers；4. Angle Brooms；5. General Purpose Pick-Up Broom；6. Brush Grapple Bucket；7. Forked Scrap Grapple Bucket；8. Power Rake；9. Heavy Duty Scrap Grapple Bucket；10. Rock Bucket；11. Stump Grinder；12. Snow Blower；13. Snow Blade；14. Vibratory Roller
New Technology of Wheel Loader
Introduction
Komatsu-integrated design offers the best value, reliability, and versatility. Hydraulics, power train, frame, and all other major components are engineered by Komatsu. You get a machine whose components are designed to work together for higher production, greater reliability, and more versatility. Komatsu’s highly productive, innovative technology, environmentally friendly machines built for the 21st century.
High Productivity and Low Fuel Consumption
1. Two Mode Engine Power Select System
This wheel loader offers two selectable engine operating modes — Normal and Power. The operator can adjust the machine’s engine performance to match the condition requirements. This system is controlled with a dial on the right side control panel.
（1） Normal Mode: provides maximum fuel efficiency for most general loading conditions.
（2）Power Mode: provides maximum power output for hard digging conditions or hill climb operations.
2. Automatic Transmission with Four Mode Select System
This operator controlled system allows the selection of manual shifting or three levels of automatic shifting modes (low, medium, and high). The operator can match the machine’s operating requirements with optimum performance efficiency. This system is controlled with a dial on the right side of the control panel.
（1）Manual: The transmission is fixed to the gear speed and selected with the gear shift lever.
（2）Auto Low: Low mode provides smooth gear shifting at low engine speeds suitable for general excavating and loading while offering reduced fuel consumption.
（3）Auto Medium: Medium mode provides gear shifting at mid-range engine speeds required for more aggressive conditions.
（4）Auto High: High mode provides maximum rim pull and fast cycle times by shifting the transmission at high engine speeds. This mode is suitable for hill-climb and load and carry operations.
3. Dual-Speed Hydraulic System
Komatsu’s automatic dual-speed hydraulic system increases operational efficiency and productivity by matching the hydraulic demands to the work conditions.
（1） Digging Operations
Engine power used to operate the switch pump is transferred to the transmission to provide increased rim pull when digging.
（2） Lifting Operations
The switch pump assists the loader pump to provide increased lifting speed and power when
lifting and loading.
Increased Reliability
1. Komatsu Components
Komatsu manufactures the engine, torque converter, transmission, hydraulic units, and electrical parts on this wheel loader. Komatsu loaders are manufactured with an integrated production system under a strict quality control system.
2. Flat Face-to-Face O-Ring Seals
Flat face-to-face O-ring seals are used to securely seal all hydraulic hose connections and prevent oil leakage.
3. Cylinder Buffer Rings
Buffer rings are installed to the head-side of the all-hydraulic cylinders to lower the load on
the rod seals, prolong cylinder life by 30% and maximize overall reliability.
4. Wet multi-disc brakes and fully hydraulic braking system
The wet disc service and parking brakes are fully sealed and adjustment-free to reduce contamination, wear and maintenance. Added reliability is designed into the braking system by the use of two independent hydraulic circuits providing hydraulic backup should one of the circuits fail. If the brake oil pressure drops, a warning lamp flashes and an alarm sounds intermittently. If the brake pressure continues to drop, the parking brake is automatically applied providing a double safety system.
5. High-Rigidity Frames
The front and rear frames along with the loader linkage have high rigidity to withstand repeated twisting and bending loads to the loader body and linkage. Both the upper and lower center pivot bearings use tapered roller bearings for increased durability.
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