Front End Loaders

Mansoor Azam Qureshi

NUST
Islamabad
 2

Loaders
• Loaders are used extensively in
construction operations to handle
and transport material, to load haul
units, to excavate, and to charge
aggregate bins at both asphalt and
concrete plants.
• The loader is a versatile piece of
equipment designed to excavate at
or above wheel or track level.
• The hydraulic-activated lifting
system exerts maximum breakout
force with an upward motion of the
bucket.
• Large rubber tires on wheel models
provide good traction and low
ground-bearing pressure.
• A wheel loader can attain high
speeds, which permits it to travel
from one job site to another under
its own power.
 3

Loader Types
• Classified on the basis of running gear, there are two
types of loaders:
▫ Crawler-tractor-mounted type
▫ Wheel-tractor-mounted type
• They may be further grouped by the capacities of
their buckets or the weights that the buckets can lift.
• Wheel loaders may be steered by the rear wheels, or
they may be articulated.
• To increase stability during load lifting, the tracks of
crawler loaders are usually longer and wider than
those found on comparable-size tractors.
 4

Specification for Loaders

 5

Bucket Capacities and Tipping Loads

 6

Specification for Tracked Loaders

 7

Production Rates
• The two critical factors to be considered in choosing a loader are
▫ Type of material and
▫ Volume of material to be handled.
• Wheel loaders are excellent machines for soft to medium-hard
material.
• However, wheel loader production rates decrease rapidly when
used in medium to hard material.
• Another factor to consider is the height that the material must be
lifted. When loading trucks, the loader must be able to reach
over the side of the truck's cargo container.
• A wheel loader attains its highest production rate when working
on a flat smooth surface with sufficient space to maneuver.
 8

Factors Affecting Production

• Fixed cycle time required
to load the bucket, Fixed Cycle Times
maneuver with four
reversals of direction, and
dump the load
• Time required to travel
from the loading to the
dumping position
• Time required to return to
the loading position
• Volume of material hauled
each cycle
 9

Affect of Haul Distance

 10

Operating Loads
• Under SAE standards the maximum operating load
of a wheel loader should not exceed 50% of the static
tipping load with the loader in full turn position .
• For track-type loaders, the operating load should
not exceed 35% of the static tipping load.
• Tipping load values may be increased when required
by ballasting tires, by using counterweights, or by
adding attachments to the rear of the machine.
• Thus, the machine weight as well as its lifting power
determine the size of bucket that may be safely used
with the machine.
 11

Wheel Loaders
• The large rubber tires used on wheel loaders give them excellent job
and between-the-job mobility with maximum highway speeds over
25 mp/h (40 km/h).
• Their ground pressure is relatively low and may be varied by
changing tire size and inflation pressure .
• However, the vulnerability of its tires to cutting makes it poorly
suited to loading sharp shot rock, especially under wet floor
conditions, unless its tires are protected in some way (protective
mesh chains, for example).
• Many modem wheel loaders are articulated. An articulated wheel
loader has a frame which is hinged between the front and rear
axles, thus providing more maneuverability and a shorter turning
radius than a rigid frame .
• Rigid frame wheel loaders usually steer from the rear axle.
Hydraulic steering and control systems are commonly used
 12

Track Loaders
• Track loaders operate in the same basic way that wheel
loaders operate. However, their low ground pressure
enables them to operate in areas that would be
unsuitable for wheel loaders.
• Their greater tractive ability makes them suitable for the
toughest digging conditions while their steel track resists
the cutting action of sharp rock.
• They can travel on side slopes up to 35% while wheel
loaders are limited to about 15%.
• Their climbing ability enables them to climb 60% grades
compared to 30% grades for wheel loaders.
• Because of their lower travel speed, however, their
mobility is much less than that of wheel loaders .
• Their production will similarly be lower than that of a
wheel loader if the haul distance is appreciable.
 13

Skid Steer Loaders

• A small wheel loader having rigid
axles is called a skid-steer loader .
These machines steer by braking the
wheels on one side while applying
power to the wheels on the other
side.
• A number of different attachments
are available for these machines
including backhoes, blades,
compaction rollers, rotary brooms ,
hydraulic hammers, saws, cold
planers, cement mixers, and
trenchers.
• Due to their small size, versatility,
and productivity these machines
have become increasing popular in
recent years.
 14

Example

• A 4-cy wheel loader will be used to load trucks from a quarry

stockpile of processed aggregate having a maximum size of 1 .25 in.
The haul distance will be negligible. The aggregate has a loose unit
weight of 3,100 Ib/cy. Estimate the loader production in tons based
on a 50-min hour efficiency factor. Use a conservative fill factor.

• Size of bucket, 4 cy
• Bucket fill factor for aggregate over 1 in., 85-90%; use 85%
conservative estimate
• Check tipping:
• Load weight: 4 cy x 0.85 = 3.4 Icy
• 3.4 Icy x 3,100 Ib/lcy (loose unit weight of material) = 10,540 Ib
 15

Example
• From Table 4lcy machine static tipping load at full turn is 25,0001b
• Therefore, operating load (50% static tipping at full turn) is
• 0.5 x 25,000 Ib = 12,500 Ib
• 10,540 Ib actual load < 12,500 Ib operating load; therefore okay
• Typical fixed cycle time (Table 9.10) 4-cy wheel loader, 30 to 33 sec;
use 30 sec.
• Efficiency factor, 50-min hour
• Class of material, aggregate 3,100 Ib per Icy
• Probable production= [3600x4x0.85/30] x [50/60] lcy/hr
= 340 lcy/hr
= 340 x 3100/2000
= 527 ton/hr
 16

EXAMPLE
• A 4-cy wheel loader will be used to charge the aggregate bins of an
asphalt plant that is located at the quarry. The one-way haul distance
from the 1.25 in. aggregate stockpile to the cold bins of the plant is 220
ft. The asphalt plant uses 105 tons per hour of 1.25-in. aggregate. Can
the loader meet this requirement.
• Size of bucket, 4 cy
• Bucket fill factor for aggregate over 1 in., 85-90%; use 85%
conservative estimate
• Check tipping:
Load weight: 4 cy x 0.85 = 3.4 Icy
3.4 Icy x 3,100 Ib/lcy (loose unit weight of material) = 10,540 Ib
From Table 4cy machine static tipping load at full turn is
25,0001b
Therefore, operating load (50% static tipping at full turn) is
0.5 x 25,000 Ib = 12,500 Ib
10,540 Ib actual load < 12,500 Ib operating load; therefore okay
 17

EXAMPLE
• Typical fixed cycle time 4-cy wheel loader, 30 to 33 sec; use 30 sec.
Travel speeds forward
First, 4.3 mph; second. 7.7 mph; third, 13.3 mph
Travel speeds reverse
First, 4.9 mph; second, 8.6 mph; third, 14.9 mph
• Travel loaded: 220 ft, because of short distance and time required
to accelerate and brake, use 80% maximum first gear maximum
speed.
4.3 mph X 80% X 88 fpm/mph
----------------------------------------= 5.0 ft/sec
60 /sec min
• Return empty: 220 ft; because of short distance and time required
to accelerate and brake, use 80% of second gear maximum speed
[7.7 mph X 80% X 88 fpm/mph] =9.0 ft/sec
60 sec/min
 18

EXAMPLE
• Cycle time
▫ Fixed time 30 sec 4-cy wheel loader
▫ Travel with load 44 sec 220 ft, 80% first gear
▫ Return travel 24 sec 220 ft, 80% second gear
▫ Cycle time 98 sec
• Production =
[3600x4x0.85/98] x 50/60 x 3100/2000
= 161 ton/hr
• 161 tons/hr > 105 tons/hr requirement
The loader will meet the requirement.