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Loaders
一、 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 snowbasket, 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.
二、Bucket Features
1. Edge steel with extra hardened and toughened wear plates of up to 500 Brinell gives the bucket longer operating life.
2.Bucket shell and side plates of up to 400 Brinell 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 Brinell. Replaceable bolt-on wear plates on bucket floor,500 Brinell.
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 Brinell gives excellent penetration and less bucket wear.
三． 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.
四 New Technology of Wheel Loader
1 Introduction
Komatsu-integrated design offers the best value, reliability, and versatility. Hydraulics, powertrain, 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.
2.High Productivity and Low Fuel Consumption
1Two 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.
2Automatic 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 rimpull when digging.
（2） Lifting Operations
The switch pump assists the loader pump to provide increased lifting speed and power when lifting and loading.
五、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.
裝載機
一、基本概念.
裝載機是一種主要用于向另一種機械（自卸車、輸送皮帶、鐵路運輸車輛等）“裝載”物料的建設機械（工程車輛）設備。裝載機主要用于向卡車裝載物料，以及鋪設管道、清理碎石和挖土等工作。作為挖土作業(yè)裝載機不是最有效的機械，與挖掘機不同，裝載機不適用于輪胎支承面以下較深處的挖掘作業(yè)。裝載機的深底鏟斗一般可裝載3～6立方米的土壤。鏟斗前置裝載機的斗容量遠大于挖掘裝載機的斗容量。裝載機不屬于鏟土運輸機械，因其主要用途并非土方運輸。
盡管履帶式裝載機是普遍的，但與大多數(shù)推土機不同，大多數(shù)裝載機是輪式的而并非履帶式。履帶式裝載機適用于棱角銳利的建筑材料會破壞橡膠輪胎的場合，或者在松軟泥濘道路上的作業(yè)。輪式裝載機具有良好的機動性和較高的工作速度，并且不像履帶那樣破壞鋪裝路面，但其所能提供的牽引力較小。
與安裝前置鏟斗的標準拖拉機不同，許多大型裝載機不使用汽車轉向機構。取而代之，它們通過液壓驅動的安裝于前、后橋之間的轉向鉸接裝置轉向。這種轉向稱為“鉸接轉向”，它可使前橋固定，并使其承受更大的重量。對于一定的軸距鉸接轉向提供了較好的機動性。由于前輪與工作裝置繞同一車軸旋轉，駕駛員在使機械定位后可使鏟斗沿弧線“轉向”，這一點是實用的。
裝載機的工作裝置可以是更換式的或者是固定安裝。鏟斗常常可用其它裝置或工具更換，例如，許多裝載機可以安裝叉車工裝提升重型貨物或者裝運集裝箱，裝備液壓開啟式“蛤殼”型鏟斗可以使裝載機像推土機或鏟運機一樣作業(yè)。
在各種建筑工地上裝載機也經常用來近距離轉運建筑材料，例如磚塊、管材、鋼筋、各種挖掘工具等。借助鏟斗或除雪鏟，裝載機也用于除雪作業(yè)，但通常使用除雪裝置。它們用來清除街道、公路和停車場上的積雪。有時用裝載機將積雪裝載到自卸車上進行運輸。
近20年來，特別是在城市建設工程和小型土方運輸工程中，裝載機獲得了普遍的應用。許多工程車輛制造商可生產多種類型的裝載機，其中最知名的有約翰迪爾、卡特彼勒、凱斯、沃爾沃、小松和利勃海爾等品牌。
二、鏟斗特點
1.鏟斗棱邊為超硬耐磨鋼板，布氏硬度達到500，具有較長的使用壽命。
2.鏟斗殼體與側板的布氏硬度達400,以抵抗磨料磨損。經強化處理的附件安裝鉸點減少了磨損。
3.鏟斗切削刀刃為抗磨料磨損鋼材，布氏硬度達500。鏟斗底板上安裝有耐磨襯板，由螺栓緊固可更換，布氏硬度為500。
4.螺栓緊固的邊緣節(jié)省塊和分段防止了切削刃的不必要磨損。
5.沃爾沃斗齒系統(tǒng)配備有螺栓緊固型或焊接型連接器，布氏硬度達515，具有最佳的插入深度和較小的磨損。
三、輪式裝載機特點
1. 圓弧底鏟斗設計更加堅固，沒有死角。這種結構使鏟斗更加容易裝載和傾卸物料，從而提高了生產率。
2. 防傾翻/防落物駕駛室結構保護了駕駛員的安全。
3.四個外部照明燈設置可在白天或夜晚照亮施工現(xiàn)場。
4.當駕駛員離開座椅、提起座椅橫桿或者關閉啟動開關時，安全系統(tǒng)將鎖定提升、傾翻和驅動系統(tǒng)。
5. 使用重型標準輪胎，適應滑移轉向的耐久性要求。
6. 全焊接整體車架由0.375英寸工具鋼建造，堅固耐用，滿足長期生產能力要求。重要樞軸均采用階梯襯套，以便增加強度和減小應力。
7. 較寬的軸距保證了平穩(wěn)行駛，重載作業(yè)更加穩(wěn)定。
8.液壓管路設置于裝載機動臂內部受到保護。
9. 野馬牌裝載機的特點是具有自找平垂直提升特性。
10. 先進的液壓系統(tǒng)可提供較長的工作時間，并配置了玻璃液面計，以便于檢查液壓油面高度。
11. 下落式臺階設置便于發(fā)動機和保養(yǎng)點的檢查。
四、輪式裝載機新技術
1. 簡介
小松集成設計可獲得最大的價值、最高的可靠性與多功能性。液壓系統(tǒng)、傳動裝置、機架等主要部件均由小松制造。機械部件通過設計使其共同協(xié)調工作，以獲得更大的生產能力、更高的可靠性和更多的功能。小松的高生產率、技術創(chuàng)新與環(huán)境友好型機械產品為21世紀而制造。
2.高生產率于低消耗率
1雙模式發(fā)動機功率選擇系統(tǒng)
本輪式裝載機設置了兩個可選發(fā)動機工作模式——正常與動力工作模式。駕駛員可以調節(jié)機器發(fā)動機特性，使其與工況要求相匹配。這一調節(jié)系統(tǒng)用右控制臺上的旋鈕進行控制。
（1） 正常工作模式：在大多數(shù)負載條件下提供最大的燃油效率。
（2） 動力工作模式：在堅硬土壤挖掘條件下或在爬坡行駛時提供最大的動力輸出。
2四工作模式自動變速箱
這一由駕駛員控制的系統(tǒng)允許其進行人力換擋或三級（低、中、高）自動換擋模式選擇。駕駛員能夠使作業(yè)要求與最佳性能相匹配。這一系統(tǒng)由控制臺上右邊的旋鈕進行控制。
（1）人力換擋模式：變速箱齒輪速度固定并通過變速桿進行選擇。
（2）自動低檔模式：抵擋模式保證發(fā)動機低速工況下的平穩(wěn)換擋，適用于普通鏟裝作業(yè)，具有較低的燃油消耗。
（3）自動中檔模式：提供發(fā)動機中速范圍換擋操作，適用于更加主動的作業(yè)工況。
（4）自動高檔模式：提供發(fā)動機高速工況下的換擋操作，可產生最大的鏟掘力與快速的作業(yè)循環(huán)。這一模式適用于爬坡、鏟裝與轉運的循環(huán)作業(yè)。
3.雙速液壓系統(tǒng)
小松自動雙速液壓系統(tǒng)通過使液壓需求與工況相匹配提高了作業(yè)效率和生產率。
（1） 鏟裝作業(yè)
鏟裝作業(yè)時，用來驅動轉換泵的發(fā)動機功率輸入變速箱以增加鏟掘力。
（2） 提升作業(yè)
提升裝載作業(yè)時，轉換泵輔助裝載機主泵以增加提升速度和功率。
五、提高可靠性
1. 主要部件
該輪式裝載機上小松制造了發(fā)動機、變矩器、液壓裝置和電器元件。小松裝載機制造采用了嚴格質量控制下的集成生產系統(tǒng)。
2.扁平面對面O型圈密封
對所有液壓軟管連接采用扁平面對面O型圈進行安全密封，以防液壓油泄露。
3. 液壓缸緩沖密封圈
緩沖密封圈安裝在全液壓油缸的頭部以降低推桿密封載荷，可延長液壓缸壽命30%并使總可靠性最大。
4. 濕式多片制動器與全液壓制動系統(tǒng)
行車與停車濕式盤式制動器完全密封并無需調節(jié)，從而減少了污染、磨損和維護。在制動系統(tǒng)中采用兩個獨立液壓回路，作為當某一液壓回路發(fā)生故障時的貯備，從而增加了系統(tǒng)的可靠性。當制動壓力降低時，報警燈閃爍，報警器間歇鳴叫。如果制動壓力持續(xù)降低，停車制動器將自動啟動，形成雙安全系統(tǒng)。
5. 大剛度車架
前、后車架及裝載機鉸接機構具有較大的剛度，以抵抗重復扭轉與彎曲載荷對裝載機機身和鉸接機構的作用。上、下中心樞軸軸承均采用圓錐滾子軸承以提高壽命。
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