Wheel Loader - Higher on Results . . .

Wheel Loader comes with substantial value as an exclusive loading equipment machinery both from loading and long lifecycle perspective. Not to mention the other assorted advantages it can offer. Partha Pratim Basistha finds the details.

Wheel Loader is an absolute loading equipment that delivers enormous utilities to its owner at the job site. This is primarily owing to the wide range of loading functions it can undertake for variegated loading applications based on the user industry requirements. Added to the loading usefulness, the machine comes with long lifecycle and low operating costs.

" Being entirely loading equipment, wheel loaders are structured to undertake various loading applications be it for the construction industry for loading aggregates, mining for moving overburden or aggregates, or for the port stevedoring industry to remove and load iron ore or other bulk cargo. However, the bigger utility of the machine comes through its rapid mobility, hauling and high loading and unloading output," says, Mr. Sunil Sapru, Director, Sales & Marketing, Liugong India Pvt. Ltd. The higher loading and unloading output is generally based on the different bucket sizes wheel loaders across different brands offer, usually comprising a range of 0.78 cubic metre-6 cubic metre or even more based on custom requirement.

Mr. Sapru says, "to undertake high output and different loading applications, Liugong offers wheel loaders with advanced technical features, notably with the machines fitted with Cummins Engines. Added to this, the machines are fitted with Liugong / ZF transmission and axles, Premco hydraulics etc." He informs, "our loaders have higher horse power which meets operation in adverse conditions and high altitudes. The machines have 20% higher productivity as compared to available range." Liugong wheel loaders are equipped with ROPS / FOPS cabin, safety struts, audio visual alarm, adjustable steering wheel, electronic surveillance system etc. To provide higher cycle times, the machines are equipped with centralized automatic lubricating system, automatic bucket return to dig, automatic boom height kick control etc." Liugong offers range of wheel loaders product variants from 1.5 to 10 tons with bucket capacity ranging from 0.78-6 cubic metre. The company has a population of over 850 loaders of different range working in India.


Being entirely a loading equipment and possessing high bucket capacity range, wheel loaders are able to provide higher output. This also enables the machines greatly to cut down lead times while undertaking loading - hauling - unloading - applications at various points at the job site. Wheel loaders are also able to curtail on lead times owing to their mobility advantage and further owing to undertake functions in rough terrain conditions.

This is agreed by Mr.Wice Li, Executive Director, Changlin Engineering Services India Pvt Ltd. He says, "given the structural features of wheel loaders and its large bucket sizes, the equipment are absolutely fit to undertake high capacity loading and unloading above the excavation point." Mr. Li points out, "the machines are highly productive from loading point of view owing to its higher loading height capabilities and less fuel consumption per ton lifting." High loading height becomes applicable for loading stone aggregates, iron ore cargo in high sided wagons with high axle load and also for high sided dump trucks.

Mr. Li says to provide higher productivity, Changlin wheel loaders are equipped with advanced technical features. He says further, "Changlin wheel loaders have been proved at site in lower fuel consumption and less operation cost along with high stability and stable output. This comes from long experience in wheel loader industry and national class research and development ability carried during the span of last thirty years in China." Changlin offers wheel loaders in India, all imported from China with a capacity range from 3 tons to 6 tons bearing bucket capacities ranging from 1.5 cubic metre to 6.0 cubic metre.

The mobility advantage of wheel loaders is admitted by Mr. Abhijeet Pai, President, Puzzolana Machinery Fabricators. He says, "on contrary being positioned in place to deliver its output, wheel loader is a mobile machinery. This allows it to undertake continous loading and unloading functions allowing the machine to work at higher cycle times." Mr. Pai informed, Puzzolana would be launching its wheel loaders at Excon 2009. The compsany would launch its W5T 5 tons wheel loader having 3 cubic metre bucket capacity and PW3T 3 ton wheel loader being a bucket capacity of 1.7 cubic metre. Puzzolana wheel loaders are equipped with Cummins engine. The machines have simple hydraulics gear pumps for less maintenance, power assisted gear shifts for less cycle times, engine with turbo pre cleaner, enabling to function in high dust and humid conditions.

While mobility and enlarged bucket provide wheel loader high production output and add on high cycle times. The structural built up of wheel loaders is an added advantage. The articulated structure of the machine provides it with higher maneuverability in turning as compared to other wheeled and crawler excavation equipment with rigid chassis compelling it to work in confined areas.

The facts are endorsed by Mr. K Sunil Kumar, Executive President, Construction Equipment Division, Greaves Cotton Ltd. He says, "the machines have high productivity and economy in bulk loading applications. Besides, the machines are flexible, have a better dump clearance and dump reach from loading point of view." Greaves Cotton has recently launched its wheel loader CG932. The machine comes with a rated load carrying capacity of 3 ton with a 1.8 cubic meter bucket. Mr. Kumar informs, "the machines would be targeted for mining, quarrying, port stevedoring segments and also for other construction industry applications."

CG932 wheel loaders are equipped with Cummins Engine and according to Mr. Kumar the USPs of the machine are Low Owning and operating cost due to lower maintenance and high fuel efficiency, High productivity due to Low working device cycle time and faster operations. Greaves Cotton, a relatively new entrant in wheel loader market in the country is quite optimist on the application potential of the equipment.

According to Mr. Kumar, "The low owning and operating cost combined with the superior technical and ergonomical features of our wheel loaders supported by pan India Greaves Service and Spare parts Dealer network (Greaves has 42 Dealer points all over India apart from their own office network) will create value for our customers." CG932 wheel loaders augments product ranges of Greaves Construction Equipment Division apart from the existing range of concrete and compaction equipment.

Structural built up of wheel loaders provides the equipment with higher lifecycle. According to wheel loader manufacturers, average life span of wheel loaders is eight to ten years or 30,000 hours. However, enhanced life span of the machine would depend upon operator's efficiency, product upkeep, periodic maintenance, and proper usage of genuine spare parts.

Higher lifecycle of wheel loaders is attributed owing to structural built up and exclusively owing to the front end loading and unloading application it undertakes. Based on the entirely front end applications undertaken by wheel loaders and less number of movable components in the equipment, there is less number of components loss in the machinery comprising, pipes, hoses, ramps, pins etc. All which goes on to, provide the equipment with a longer lifecycle. However, longer lifecycle of the equipment depends on the advanced features of the wheel loaders.

Longer lifecycle of wheel loaders in terms of less maintenance and high productivity in term of output and mobility is approved by Volvo. As per an official statement of the company, wheel loaders can undertake pure loading functions at the job site supported by its design. The strength of a wheel loader, aided by its structural built up, precisely owing to less number of movable components and rugged features, provides it with the ability to quickly change directions. The best wheel loaders will always have automatic transmissions, quick change from forward to reverse direction, no clutch and high power engines." As per Volvo, "in any surface loading application, a Volvo wheel loader will offer lower total cost per ton loaded, provided the quantity is large enough."

According to Volvo, advanced features of its wheel loaders make it high on productivity at low cost per ton. Volvo wheel loaders are equipped with features comprising, fuel efficient Volvo V-ACT diesel engine with High Torque at lower rpm. The engine is matched to the Volvo Fully Automatic Power Shift transmission for smooth shifting of the gears.

Other features include, load sensing variable displacement axial piston pump for maximum loader performance. Load sensing optimizes engine power utilization and fuel efficiency. Volvo's wheel loaders are fitted with its own patented torque parallel linkage. This, according to the company, provides the wheel loaders with benefits involving, increased breakout torque from forward tilt to full roll back unlike the "Z" bar which loses torque at the same point. Further, with TP linkage Break out force loss is significantly lower than the "Z" Bar in its entire working range. Besides, this the linkage leads to better roll back and load retention – additional 10% as compared to Z bar linkage. Volvo wheel loaders are equipped with MATRIS (Machine Tracking Information System) to measure machine performance parameters.

Value in loading through its wheel loaders is claimed to be offered by Volvo through wide range of buckets provided by it. Bucket variant cab be selected based on the density of the material to be handled. According to Volvo, "there are more than 150 different options that a customer can choose from and optimize his specific application."

As per Volvo, its buckets are of high quality wear resistant buckets, all made from high tensile strength steel, with upto 500 Brinell hardness to ensure longer life and reduced operating costs. It offers, quick change mechanisms for its bucket variants for the customer concerned, requiring to load and unload different materials.

Volvo wheel loaders are imported in India from Sweden. The Swedish equipment manufacturing major, provides wheel loader with bucket capacity variants ranging from 4.2–8.2 cubic metre capacity.

Equipment value is claimed to be offered by Telcon through its wheel loaders owing to its advanced technical features, which according to Telcon provides enhanced equipment availability at the job site. Telcon has its own indigenously developed TWL 3036 wheel loaders. TWL 3036 wheel loader has a bucket capacity of 2.0 cubic metre for standard items like sand, 1.8 cubic metre for heavy duty, 3.0 and1.5 cubic meter for coal and iron ore and 2.5 cubic metre medium density coal respectively with dump height ranging from 2709mm-2568mm. Telcon also provides bigger size wheel loaders bearing model number ZW220. The machine has an operating weight of 17,800 kg having a bucket capacity of 2.7 cubic metres–4.5 cubic metres. While the engine output of the machine is 164 Kw. ZW 220 is imported from Hitachi, Japan.

The prominent feature of TWL 3036 consist of its heavy duty structure. The axles and transmissions of the machine are imported from ZF, Germany, according to Telcon, that allows the equipment to provide trouble free operation. While Z-bar linkage provides the equipment with high break out force and lower cycle times. The hydraulic system of the equipment consists of 2 spool, 3 position Husco control valve with built in relief valves mounted below operator's platform for improved operating comfort and spontaneous response. While the ZW 220 comes with electronically controlled CRDI Isuzu engine, possess unique total torque control for reduced loading cost, smoother simultaneous operations with advanced hydraulic circuit and extended hydraulic oil replacement intervals (up from 2000 to 4000 hours).


Not to be left behind, Caterpillar offers wide range of wheel loaders with different loading capacities. According to Caterpillar, wheel loaders and integrated tool carriers for different loading applications offered by it is most extensive. There are more than twenty different models of wheel loaders provided by Caterpillar. The smallest wheel loader is 904 B with a 52 horse power engine having 0.6 cubic metre bucket capacity for general application. While the biggest in its class is 994F with an engine of 1463 hp, posing a bucket capacity of 36 cubic metre.

Caterpillar's wheel loaders are classified into four segments. This consists of Cat, compact, small, medium and large capacity wheel loaders. The compact wheel loaders has bucket capacity range from 6 cu‎m-1.4 cu‎m. Prominent technical features of Cat's wheel loaders includes, strong breakout forces, fast cycle times and aggressive performance packaged in one compact machine. Better reach, proper visibility and low effort joystick control for easy material placement.

The small capacity Cat wheel loaders comes with a bucket capacity of 1.8 cu‎m - 2.3 cu‎m, is equipped with strong Z-bar linkage design for better breakout force for superior bucket loading and load retention. Load-sensing hydraulics to deliver precise control with low effort operation. Ride Control option for more comfortable ride and greater material retention over rough terrain etc.

Caterpillar H-Series, medium wheel loaders bearing bucket capacities from-2.3 cu‎m-3.0 cu‎m comes with load-sensing hydraulic system with simultaneous lift and tilt capabilities offering better control with less effort. Repeatable fine modulation for superior bucket control with less spillage. Ergonomically, designed cab offers best-in-class work environment. According to Caterpillar, equipped with advanced features, the H series machines can move more material, at less cost, over more hours than any other machine and has got a good resale value.

While, the Caterpillar, large size 300+ product line wheel loaders bearing a bucket capacity within a range of 6.3 cu‎m-36 cu‎m, meant for mining and quarrying applications, has features consisting of, enhanced structure design for high reliability, durability, multiple rebuilds and high-hour component life. Ergonomically designed cabs with low effort controls and better visibility to the truck bed or hopper. Caterpillar, claims to have engineered its wheel loaders to provide safety, durability, reliability, ease of serviceability and maximum performance for minimal downtime and optimized production.

Cat's wide range of wheel loaders with different capacities and attachments involving, brooms, material handling arms, buckets and forks can be deployed for various applications. According to the company, this can consist of irrigation site works, highways, roads and dam construction, tunnel projects, airports and industrial projects sites etc. The machines can also undertake waste landfill, scrap handling, bulk cargo handling at ports, forestry, block handling, slag handling at steel mills among others comprising application at mining sites to clear overburden etc. As per Cat, the company has well placed customer support network to enable the machines deliver optimum productivity.

Wheel loaders with advanced features and longer lifecycle is also claimed to be offered by Dozco through its imported Kawasaki wheel loaders from Japan. Dozco is the exclusive distributor of Kawasaki brand of wheel loaders in India. According to Mr. N.G Bangur, Director, Dozco India Pvt. Ltd, "the Kawasaki wheel loaders have notable features essentially, comprising the new Cummins tier-3 engines, as it enables to increase the greater peak torque from 9 to 14% and it gives our loaders better rimpull for noticeably improved performance. This results in a significant multiplication of power. Operators will be able to pull hills better, dig better, doze better, and do a lot of things better because of this extra torque. The new Cummins engines have extended oil change intervals from 250 to 500 hours, when the recommended grade of oil is used." He adds, "the Kawasaki wheel loader comes with a newly designed countershaft transmission. It offers smooth shifting and outstanding reliability. One unique transmission feature is the Auto brake, which is similar to what can be found on our larger machines. This protects the transmission from over speeding or improper directional shifting. It places the transmission in neutral and applies 50% brake pressure to reduce vehicle speed until the shift selection can be made safely. No other competitor has this patented feature. The other features are dual Z-bar linkage in this size class. It delivers high breakout force to handle tough digging and provides outstanding visibility to speed cycles and increase safety. The lift arms are made of heavy alloy steel for durability and long life."

The other features of the Kawasaki wheel loaders consist of full box - section rear chassis, not a channel or light - duty plate frame to provide equipment durability. Besides, according to Dozco, the Kawasaki wheel loaders wheel base is long for a smoother ride. However, this provides the equipment with a turning circle radius, tightest in the class. Furthermore, the machines claim to have high cycle times owing to its in cab boom kick out, with dual settings feature.

Mr. Bangur points out, "with the given advanced features, the machines are easy to operate and to maintain. Innovative high-tech features on all Kawasaki wheel loaders allow the operator to adapt to the environment and the application right from the cab. Features like the Adjustable Declutch, In-Cab Boom Kickout with dual settings, Downshift button, ELS, and the Power Mode engine switch allow the operator to make adjustments from the comfort of the cab to increase productivity and efficiency."

Further, according to Mr. Bangur, "disdaining the approach of many competitors who use a lot of plastic, Kawasaki continues to use metal in critical areas. Redesigned buckets provide easy loading and excellent load retention. Bolt-on heel plates extend bucket life. Massive center pins and bearings, as well as a heavy box frame rear chassis, are extraordinarily durable for a very long life. Outboard-mounted, sealed wet disc brakes are designed for long life and easy access. All which makes the machine easy to maintain. Spin-on filters, grouped grease fittings, three-piece tire rims, and sealed universal joints all provide easy field maintenance. We've extended the grease intervals on the universal joints to 12,000 hours. Engine oil intervals have been extended to 500 hours, when the recommended oil is used." On less maintenance of Kawasaki wheel loaders Mr. Bangur informs, "One machine has already crossed 7000 kms in Bothra Shipping Corporation where customer has done only daily maintenance and parts consumption is almost nil."

Dozco makes Kawasaki wheel loaders available in India bearing payload from 5300 - 18050 Kgs with bucket sizes ranging from 2.8–6.8 cubic metres.

Wheel loaders with advanced technical features for higher cycle times are also claimed to be offered by JCB.

The construction equipment major offers three wheel loader model variants. According to Mr. Amit Gossain, Vice President, Marketing, JCB India Limited "our wheel loaders scores much on productivity and fuel efficiency. Additionally the machine has its edge on longer lifecycle." The three model variants of JCB wheel loaders comprise its 430z wheel loader bearing a three ton payload with 1.7 cubic metre bucket capacity, 432 ZX having a 3.6 ton payload with 2.1 cubic metre bucket capacity and 456 ZX imported variant with ton pay load having a 3.0 cubic metre bucket capacity.

According to JCB, the features of the equipment comprise higher flow hydraulics for faster cycle times leading to higher productivity, heavy duty Graziano axles for longer operating life. The other features include, priority steer hydraulic systems with priority valves, durable design with Z-bar geometry, traction control using torque proportioning differentials for smooth drive into the pile resulting in good bucket filling etc.

Value on Loading Applications

Being a loading equipment in its entirety, wheel loaders can deliver its utility through undertaking range of loading applications for various materials. Notably, the equipment can undertake certain niche applications as well, like dozing. According to Mr. Pankaj Kumar, Vice President, Equipment Sales, Dozco India Private Limited, "the wide range of loading applications is possible for wheel loaders owing to its different bucket variants many of which consists hazardous loading and unloading jobs, which only a wheel loader can undertake." Wheel loader comes with bucket variants consisting, coal bucket, general purpose bucket, iron ore bucket, rock bucket, side dump bucket (both for mining and construction applications essentially for tunnel projects, wagon dumping yard or stations, and with areas having space paucity), log fork, log grabs etc. The buckets can be selected depending on the density of the material.

Prerequisites

Wheel loaders are unique machines in their domain to undertake range of loading functions. However, to make the machines deliver optimum results and have a longer life cycle. There are certain essentialities, which the concerned user needs to undertake. Foremost among this is selection of right machine. As per type of material to be handled and nature of work site and operation area the contractor should select the proper machine with proper attachment and bucket. Further, the user should have well trained operator.

Additionally, there has to be a skilled mechanic in place having experience and ability to fast troubleshoot the machine. This will arrest longer down time in case of breakdown. With skilled mechanic in place, for longer lifecycle, the equipment has to be provided with genuine spare parts. In line, for optimum utilization of the machinery sufficient availability of material to be handled and proper availability of transporting equipment has to be in place at the job site is required for maximum utilization of Machine. At par with proper availability of transportation equipment the wheel loaders working at the job site have to be properly integrated with supporting equipment. All this would lead to appropriate utilization of the equipment and thereby ensure honest return on investment for the equipment owner.