Wheel loaders—a.k.a. bucket loaders or front-end loaders—are versatile tools on a job site. While often thought of in conjunction with mining applications, large-capacity wheel loaders are also commonly used for road building, job site preparation, and digging and moving materials. These heavy-duty workhorses are durable, tough, and highly mobile, traveling at high rates of speed, facilitating quick loading of materials into awaiting trucks.
Right-sizing a machine to an application is important, claims Andrew Dargatz, product marketing manager, CASE Construction Equipment, especially since wheel loaders are often used in production/cycle applications that impact upstream and downstream operations, based on how efficiently they load materials. Too large of a machine will end up sitting idle for long periods, and too small of a machine won’t be able to keep up with production.
Manufacturers of the Original
Volvo Construction Equipment built the first wheel loader in 1954 and has been continuously developing the machine ever since. Updates were made to the 150–180 size class about a year ago, notes Eric Yeomans, product manager, wheel loaders. One of those updates involves the hydraulic system, which features load sensing to regenerate the oil when you drop the boom or bucket. “It turns off the hydraulic pumps to save power and fuel, which makes work faster.”
A more recent update is a new app available on the L110–L260 models. Operator Coaching features two parts: one, a guided interactive system between the operator and the switch panels, tells the functions of the switches and advises on ways to improve productivity. This gives the operator a chance to correct issues in the field immediately. The other gives the operator advice to improve. It monitors utilization, such as brakes, throttle, and lock-up torque converter for better fuel efficiency.
“Activity is only between the operator and the machine—not the back office,” points out Yeomans. The operator is not “spied on,” he says, which helps with buy-in. He reports that operator feedback has been positive. “They’re glad to improve, and they set goals.” Volvo customers are also pleased, due to “huge savings” resulting from reduced idle time and maintenance. “The operators don’t sit idling anymore.” With an industry struggling to attract operators, operator coaching assists in attracting and creating better operators.
About the Operator
Because operators are typically in the cab for 8–12 hours a day, it’s important to ensure operator comfort to be able to increase daily production. With that in mind, the new John Deere L-Series wheel loader cab is roomier than previous models, not only for the operator, John Chesterman—product marketing manager, production class four-wheel drive loaders, John Deere Construction & Forestry—interjects, but also for storage of items such as a lunch box.
To further maximize operator comfort, John Deere’s premium L-Series cab includes a heated and fan-cooled seat with multiple adjustments and automatic temperature control. “Features like boom height kick out, return-to-carry, and return-to-dig push-button settings, and our new smooth operating, electric-over-hydraulic controls that include two multifunction buttons, help operators get the most out of their loader, day in and day out,” lists Chesterman.
The premium cab on Deere’s 744L, 824L, and 844L includes remote-powered and heated exterior mirrors, allowing operators to make mirror adjustments from inside the cab. A rearview camera system provides a view of the activity behind the machine and can also include radar object detection.
Deere’s L-Series wheel loaders come with a seat belt minder system that reports to JDLink. An optional indicator light is also available to make external bystanders aware when the seat belt is latched. “LED work lights are ideal for customers who work underground or in low light conditions,” observes Chesterman.
JDLink does more than just monitor seat belt usage. A factory-installed auto-lube system with integrated diagnostics and JDLink reporting ensures the machine is greased, even when it’s cold or rainy—conditions in which operators may be less inclined to grease the machine by hand. This system contributes to reduced downtime and keeps the machine running, both critical aspects of operation.
Another feature that promotes uptime is the hydraulic reversing fan and John Deere’s exclusive Quad-Cool cooling system that provides easy cooling system cleanout. To enhance visibility, the 744L, 824L, and 844L have a new front window washing platform with an anchor point tested to 5,000 pounds.
Comfortable Cabs
Today’s operators require more comfort, contends Jason Boerger, marketing manager, Bobcat Company. The all-new Bobcat R-Series loaders, which he calls “a revolution in both form and function,” deliver an “unmatched cab experience that keeps productivity high.”
Designed to tackle the toughest challenges, these next-generation loaders include several machine and feature changes focused on quality, reliability, and durability, such as all-around visibility, comfortable controls like the MaxControl Remote Operation with Selectable Joystick Controls for remote-control operation using an app on a smartphone, and a roomy environment.
The cab design is a one-piece, sealed, and pressurized design for a new level of operator comfort, Boerger continues. “The roomier design offers a sealed and pressurized environment that repels dust and dirt in the cab, isolates the operator from engine and hydraulic noise, and enhances the efficiency of optional heating and air conditioning.”
Visibility has been enhanced. “Operators can easily see to the sides of the machine and can maneuver more confidently with the new clear-side enclosure,” says Boerger, adding that the new, mesh-free windows also allow for an optimal view.
The new R-Series loaders come equipped with an advanced in-cab display with a choice of camera-ready displays: a standard 5-inch display or optional full-color 7-inch display, which features a wide touchscreen to change settings, match performance to the job, and continuously monitor the machine’s maintenance needs. It comes with a USB power port and active noise canceling during phone calls.
Bobcat’s new 5-Link Torsion Suspension Undercarriage dramatically reduces stress and vibration from the undercarriage, making the ride more comfortable. And when it’s time for maintenance or repairs, the entire R-series cab lifts out of the way to provide improved service access—with hardware on the cab exterior for easy removal.
Visibility
In response to labor statistics that reveal a shrinking workforce in the construction industry, Komatsu America is offering safe, efficient, comfortable, and easy-to-use wheel loaders.
“The WA475-10 features a completely redesigned cab that has more glass for increased operator visibility,” reports Adam Braun, product marketing manager. The operator switches ergonomically placed on the front pillar of the cab help reduce operator fatigue because operators no longer have to search their right console for needed switch functions. The right console also adjusts in five different directions to provide the operator with precise comfort.
Similarly, JCB 427, 437, and 457 wheel loaders provide enhanced visibility by way of floor-to-roof glass, sloped rear hood, and a four-pillar design for a panoramic view with minimal obstructions, according to Rupert Bradley, product manager for wheel loaders, JCB North America.
The control panel layout in JCB’s CommandPlus cab is as clear as the view. Designed for effortless operation with two main control clusters along the A-pillar, access to switches is provided without obstructing visibility or requiring the operator to reach.
The CommandPlus cab allows the operator to adjust the speed at which the machine engages the JCB Smoothride System for smoother traveling and better load retention. Forward and Reverse are engaged by a rocker switch on the joystick, which allows the operator to keep one hand on the joystick and the other on the steering wheel.
Heavy-Duty Improvements
Case has made multiple improvements to the operator environment in their G Series wheel loaders. The cab features advanced electro-hydraulic controls, ergonomic design, and updated operator interfaces. A solid-state controller has been incorporated to provide software control over electrical power distribution and basic vehicle functions. Dargatz says this design eliminates fuses and relays and significantly lowers the amount of wiring throughout the machine. “A membrane keypad has replaced a series of rocker switches for common machine functions, and an updated steering console mimics the driver controls—lights, wipers, turn signals, etc.—found in most cars [and] trucks.”
An 8-inch LCD monitor provides information on loader functions, activities, and operating parameters such as fuel levels, temperatures and pressure readings, trip information, and vital machine service information like upcoming maintenance reminders and machine diagnostics.
The largest wheel loader in the G Series line is the 1121G, which features a 347 horsepower engine and is capable of providing more than 56,000 pounds of breakout force. Built for high-capacity production environments where truck loading, material carrying, and stockpiling is required, it comes with automatic bucket control features like return-to-dig, return-to-travel, and height control that simplify operation while approaching trucks and hoppers and transitioning back to travel, shortening the cycle in high-production applications.
Dargatz says that working in MAX operating mode “achieves fast and aggressive operation for the most demanding of applications,” while Optional Ride Control improves material retention in long haul applications, minimizing spilling and related cleanup.
CASE incorporates variable displacement pumps into their wheel loaders to produce only as much flow as needed, which increases the efficiency of the machine and eliminates excess heat. “We also design our equipment with multiple pumps,” says Dargatz. Utilizing multiple pumps and separating the steering from the work circuit allows them to match the pumps to the pressures that are needed, which reduces throttling losses.
Performance
Operator comfort contributes to machine performance, but other features can make a significant impact on productivity. Bobcat’s new loaders feature an inline engine design and a durable direct-drive system that contribute to improved performance. Together, they deliver the durability and characteristics necessary to accommodate new levels of performance required on today’s job sites.
With equipment running longer and completing bigger, more difficult jobs, better cooling is essential. Boerger says the R-series cooling system has been completely redesigned for optimal operation and maximum uptime. The fan size is increased by approximately 50%, which achieves more cooling at a slower rotation while using less power. It also reduces noise in the cab and around the machine.
“R-series loaders not only look tougher; they are tougher,” states Boerger. Bobcat lift arms are composed of cast steel for increased material strength and rigidity. Cast steel allows more material where it’s needed, which provides greater strength while enabling a slimmer profile arm that also enhances visibility. The cast-steel lift arm sections are lighter and stronger. “The lift arms, combined with the optimized lift arm linkage, ensure operators can handle more challenging jobs with greater confidence and ease.”
A new cast-steel Bob-Tach attachment mounting system provides a stronger connection point with more metal where it’s needed.
Productivity
The ability to lift more and carry more defines the true measure of productivity. According to Yeomans, the two most important parts of a loader are the bucket and the tires. Volvo has a special attachment department that designs and custom-builds buckets. He estimates they produce 400 a year.
But there are other measures of productivity, such as a SIM card that captures accuracy in weighing, or the Torque Parallel linkage, which produces high breakout torque and superior parallel movement throughout the entire lifting range.
OptiShift technology increases fuel saving as much as 15–20% by eliminating power loss in the engine and transmission while simultaneously reducing stress in the drivetrain. And Volvo’s patented reverse by braking function allows operators to transition from Forward to Reverse without stopping and without removing their foot from the accelerator.
Designed because of telematics data that indicates operators are not braking from Forward to Reverse—which affects component life—the system allows the computer to control downshifting and engage the transmission, Yeomans explains. “It’s quick and smooth and it eliminates damage.”
Uptime equals productivity. Downtime can kill the entire project, Yeomans assesses. Cabs on the 150–260 models tilt 30–70 degrees to make maintenance easier, as does a remote engine drain at ground level and placement of all filters on one side of the machine for easy access.
Maintenance
Because JCB wheel loaders don’t need a diesel particulate filter, there is less downtime for maintenance and no need for productivity-sapping regeneration. When engine maintenance is required, JCB’s single-piece hood lifts fully without the need to open multiple doors, Bradley explains.
Inside the engine bay, the engine air cleaning system prolongs filter life by removing larger particles before reaching the filter, which increases filter life. A reversing fan blows debris off the cooling packs and also swings out for access to both sides.
By delivering maximum torque at low engine speeds, JCB wheel loaders minimize fuel consumption. Their variable-speed cooling fan is regulated to work only as hard as conditions demand. To save time, daily checks are completed during startup, so work can begin sooner.
Limited-slip and Auto Diff-lock axles read ground conditions and automatically deliver increased torque to the tires to improve pushing performance and reduce tire wear.
New Technology
Komatsu has made significant innovations to machine systems for improved safety, increased productivity, better efficiency, operator information, and convenience. Their newest model in a new family of wheel loaders is the WA475-10, which introduces the Komatsu Hydraulic Mechanical Transmission. Braun says this transmission combines the efficiency of the hydrostatic transmission and the productivity and speed of the torque converter transmission. “The new KHMT allows the WA475-10 to have 30% greater fuel efficiency and consumes 19% less fuel while increasing production up to 14% compared to the WA470-8.”
It also features an innovative change to work equipment function. The work equipment is electronically controlled and independent of engine RPM input from the accelerator pedal. Work equipment movement speed is controlled by how far the operator strokes the work equipment levers.
Hydraulics
Modern hydraulic systems have become more intelligent. Today’s load-sensing hydraulics improve productivity. CASE has incorporated electro-hydraulic systems into their wheel loaders for improved functionality. Operators can activate and adjust automated machine functions like height control, return-to-dig, and return-to-travel, or select different power modes or other machine functions from the comfort of the cab.
“Hydraulic systems have also become easier to maintain, as our electro-hydraulic systems can self-diagnose failures or malfunctions,” states Dargatz. The system can show the operator which component has an issue and locate it easily. “We’ve made it easier for the operator to understand what’s happening inside the machine.”
Bobcat’s R-Series loaders also come equipped with optional high-flow hydraulics. This system provides additional hydraulic power to boost production of attachments like the Bobcat flail cutter, trencher, planer, and stump grinder, says Boerger, adding that machines with this option have two flow ranges so attachments that require lower flow can still be used by selecting standard flow mode.
Now and Later
The WA475-10 has many standard features that others sell as options, Braun continues. One, Komtrax, is standard on all products and provides the customer with remote equipment and monitoring system—features to help lower owning and operating costs. “The customer can use Komtrax to see fuel consumption information, along with machine health and operational data such as fuel consumption, utilization, and idle time.”
L-Series Deere Production Class loaders come standard with five-speed PowerShift transmission and automatic lock-up torque convertor, Chesterman says. A 4th-function field kit can be installed on the 744L and 824L. L-Series PC machines come factory with either a steering wheel or a joystick. Either option can be added in the field to have both, as long as the secondary steering option is not selected. “Most all of our factory options can be installed as dealer field kits if the unit is ordered without them.”
Monitoring
Machine management with Bobcat Machine IQ and the Bobcat Owner Portal uses wireless communication technology, allowing machines to be monitored from anywhere. Providing critical information decreases downtime and reduces costs.
Volvo offers Active Care Direct: customized reports on each machine. Yeomans says there’s “so much very complicated data,” that it can distract the operator. This system provides only the information they want and need, with critical alarms that go to the dealer and the customer.
All G Series wheel loaders are covered by CASE ProCare, which includes a three-year Advanced CASE SiteWatch telematics subscription, a three-year/3,000-hour full-machine factory warranty, and a three-year/3,000-hour planned maintenance contract.
Similarly, JCB wheel loaders include a five-year JCB LiveLink (telematics) subscription. The system allows remote access to information about the machine’s status, including utilization, fuel usage, hours tracking, location, geofencing, and service intervals.
