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Wheel Loader__
Basics___________________________

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Wheel Loader
Definition

A wheel loader is a construction machine to move, transport

and load material in short to middle distances.

Wheel Loaders from Komatsu

Komatsu offers a range from 5t – 262t, which is the widest range any manufacturer can offer.

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Komatsu Wheel Loader - Line-up

Product Range & Applications
Multiple purpose machine
WA70M-8 - „motorised wheel barrow“ at small construction sides
Compact WA80M-8 - Earthmoving
WA100M-8 - Community services/ industrial applications

Industrial application machine

WA200-8 - Community services/ industrial applications
Small WA270-8 - Earthmoving
WA320-8 - Production machine, small material quantities (sand & gravel)
WA380-8 Production machine
Mid
WA470-8 - Production machine (easy loosening material)
WA475-10 - Production machine, heavy duty application (recycling crusher feeding)
WA480-8
WA500-8
Production/ „quarry face“ machine
Large WA600-8
- Production machine, severe applications (quarry face, heavy duty material
WA800-8
loosening)
WA900-8
WA1200-6
Wheel loader = Allround-Talent
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Komatsu Wheel Loader – Key Technologies

Type Application Models Driveline Concept Axles Linkage
Standard Option Standard Option

WA70M-8
WA80M-8
Simple HST Parallel Z
Compact WL Multiple Purpose WA100M-8

WA200-8
WA270-8
Advanced HST TPD --- Parallel Z
Small WL Industrial WA320-8

WA380-8
WA470-8
Torque Converter STD LSD Z-Bar
Mid WL Production WA480-8
WA475-10 Hydraulic Mechanical Transmission

WA500-8
WA600-8
Torque Converter STD LSD Z-Bar
Large WL Extraction WA800-8
WA900-8
WA1200-6

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Wheel Loader
Main Structure
Loader Linkage Cabin After-treatment system Engine

Radiator

Bucket
Counter Weight

Wheels&Tires

Front Axle Articulation Area Transmission Rear Axle

Different configurations are possible based on machine & application.

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Transmission Principles
Torque Converter Transmission Hydraulic Mechanical Transmission (HMT)

Hydrostatic Transmission (HST)

Latest transmission technology

Highly competitive transmission:

• Lowest fuel consumption
• Best efficiency

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Overview of competition transmission technology

Compact Size

Hydrostatic

Hydrostatic
Hydrostatic
Hydrostatic
WA70M8

WA100M-8

11 t
Small Size

Torque Converter
WA200-8

WA320-8

16 t

Torque Converter

Torque Converter
Mid Size

HMT
WA380-8

HMT

HMT
-

WA500-8

35 t

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Axles
Torque Prototional Differental (TPD) Standard Differential (STD) Limited Slip Differential (LSD)
WA200-320 WA380-500 as standard WA200 – 500 as option
15% locking value 0% locking value Up to 45% self locking
Hard Ground Ice Hard Ground Ice Hard Ground Ice

+ 7,5% - 7,5% 0% 0% +22,5% -22,5%

Wheel Wheel „Following the line of least Wheel Wheel

Wheel resistance“
Wheel
rotates spins stops spins rotates spins

Features
Features • Automatic self lock function
• Suitable for all industrial applications • Giving enhanced traction
• Suitable to work on hard ground with • Suitable for earthmoving application
good traction Suitable to work on soft or slippery
• No tire wear ground (sand)

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Loader Linkage - Kinematics

+ Positive
1. High breakout forces  Extraction/ Earthmoving
2. High dumping speed  Dedicated for loading & feeding
Z-Kinematic 3. Simple in design  Very durable
- Negative
4. No parallel movement  Not suitable for use with pallet fork
5. Low tilting torque  Limited suitability for heavy industrial
attachements

+ Positive
1. High breakout forces  Extraction/ Earth Moving
2. Parallel movement  Suitable for use of fork
3. High tilting torque  Suitable for heavy industrial
TP-Kinematic attachements
- Negative
4. Slower dumping speed  Lack of productivity
5. Complex design  Less durable
6. Heavy  Less payload

+Positive
1. Parallel Movement  Suitable for use of fork
2. High tilting torque  Suitable for heavy industrial attachements
- Negative
P-Kinematic 3. Low breakout force  Limited suitability for Extraction & Earthmoving
4. Slow dumping speed  Less suitable for loading & feeding
5. Complex design  Less durable
6. Heavy  Less available payload

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Loader Linkage - Forces

L Lifting force Break-out force

Lift force (L) Break-Out Force (B)

Force that acts in the center of the bucket up-wards. Force that acts at the tip of the bucket.
Related on lift cylinder power. Related on bucket cylinder power.
Longer bucket  longer leverage  less lifting force Longer bucket  longer leverage  less break-out
force

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Tipping Load
MLoad MMachine
The tipping load defines the stability of a machine standing still.
The Static Tipping Load (STL) defines the load in the bucket CPOGMachine
were the machine‘s rear tires just start to lift off the ground. CPOGLoad

Why is tipping load so important? STL

• Easier bucket filling as the rear wheels keep contact with ground for longer.
• Better stability during operation
• Higher productivity as the operator feels more safe

Conditions:
Bucket full tilted, boom horizontal (full reach)
FTSTL
There are two types of static tipping load
Lever
1) Straight: Machine is in straight position (higher value than full turned)
2) Full Turned: Machine is fully articulated  most critical, used to calculate payload

By legislation the maximum payload MUST NOT exceed 50% of the Full Turn Static Tipping Load (FTSTL)!

Payload (kg) = FTSTL (kg)

Maximum Payload
2
according to SAE and ISO = 50% Max. Payload = FTSTL/ 2
according to Komatsu- Rule = 47,5% Max. Payload = FTSTL/ 2.1 (gives additional operation comfort)

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Tipping Load
Articulation influence
Load

LLoad
MLoad

Front Axle

L1 MMachine
L3 L2
M1 < M2 < M3
40°
37°
Straight

40°
37°
0°
The values in the Komatsu W/L brochures always refer to 40° articulation angle.
Make sure that always this value is base for discussion!

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Payload calculation
Attachment influence
Net-Payload = Bucket volume x Material density
8.2t = 4.5m³ x 1.8t/m³
Gross-Payload = Net-Payload + Bucket weight
10,4t = 8,2t + 2,2t

The Gross-Payload needs to be considered when a local bucket is added, because an eventually higher
bucket weight needs to be considered for the stability and performance of the machine.
Attention: This calculation method will not consider changes in the centre of gravity of the bucket

QC STD Bucket QC LMB Bucket

QC STD Bucket DPO STD Bucket

L3
L1 L2
L2 L3

M2 > M1 M3 > M2
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Payload calculation
With tipping load with 50%
Tipping 50% of
Material Rated Tire Difference 50% vs.
Bucket size Bucket weight Add C/W load, FTSTL
Model density payload (Pattern Komatsu recommendation
(m³) (kg) (Type) articulated Calculation
(kg(m³) (kg) type) (kg)
(kg) Method (kg)
4,5 1.800 2.250 8.100 L3 STD 17.355 8.678 578
1.
4,9 1.600 2.365 7.840 L3 STD 17.120 8.560 720
WA475-10
4,9 1.600 2.365 7.840 L3 Heavy 2. 18.335 9.168 1.328
4,9 1.600 2.365 7.840 L5 3. Heavy 19.030 9.515 1.675

Conclusion:
Further factors which are not considered when using this type of calculation: The 50% payload calculation method does
• The bucket filling behaviour is getting worse not reflect all circumstances for a bucket
• The fuel consumption is getting higher capacity calculation.
• The risk of machine damages is increasing (Linkage, Axle, T/M etc.) When the customer is requesting other or
• The centre of gravity from the bucket changes when the bucket is having a especially bigger bucket, some studies from
higher volume the bucket manufacturer is required to make
• Others a proper recommendation.

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Buckets
Definition
• The bucket is one of the most important parts of a wheel loader.
• It is the only part which is in direct contact to the load.
• The bucket design has a high impact on machines efficiency.
• Depending on application, various bucket types & shapes are available.
Light material bucket Standard bucket Rock bucket

Bucket Capacity

Maximum Payload (kg)

Bucket capacity (m³) =
Material Density (kg/m³) x Bucket Fill Factor

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Bucket Capacity Definition

Bucket Capacity Rating by SAE Standard

2 2

1 1 HEAPED

STRUCK

Struck capacity
- Volume contained in a bucket after a load is leveled by drawing a straight edge resting on the cutting edge
and the back of the bucket
Heaped capacity (Komatsu brochure)
- Struck capacity plus that additional material that would heap on the struck load at a 2:1 angle of repose
with the struck line parallel to the ground

The values in the Komatsu W/L brochures always refer to the heaped capacity according to SAE Standard.
Make sure that always this value is base for discussion!

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Bucket Fill Factor

Definition
Volume Required /
• Determines percentage of rated capacity in various materials Cycle
• Required bucket size to handle required volume per cycle is calculated Bucket size =
by using bucket fill factor Fill Factor

85% 90% 100~105% 105~110% 120%

Example:
Volume required per cycle = 4m³ Required bucket = 4m³/ 1,05 = 3,8m³
Fill Factor (Sand) = 105% Result: with a 3,8m³ bucket you can load 4m³ sand at a 105% fill factor.

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Bucket Fill Factor

Fill factors by material
Fill factors on wheel loaders are
Loose Material Fill factor affected by
Clay 110 – 120% • material type
Earth 100 – 115% • bucket penetration
Sand 100 – 110% • breakout force
Gravel 85 – 110% • tilt- back angle
Rock 60 – 100% • bucket profile and
• ground engaging tools
Blasted Rock
Well blasted 85 – 100%
Average 75 – 90%
Poor 60 – 75%

The values above refer to the heaped capacity as mentioned

in the W/L brochures

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Tires
Profile Selection

Traktion
Protection
Heat-Resistance Cut-Resistance

Note: When selecting L4 or L5 tires

• The weight of the machine and the fuel consumption increases. L5
• The suspension comfort decreases due to stiffer tire design.
L3
• The life time expectation is longer due to higher profile depth.

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Wheel Loader - Application

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Wheel Loader Applications

Earthmoving Production Recycling Harbour Stone Handling

Landscaping Aggregate Agrar Waste Steel Mill

Quarry Utility Timber Tunnel

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Wheel Loader Selection

Right size for the job??

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Wheel Loader Selection

Select the right machine for the right application 5 criteria determination

1) Existing machine at jobsite ???

• Might be the wrong size! Recalculate by productivity!
• Competition will offer smaller machine size if possible

2) Overloading height
• Machine size
• Standard or high-lift boom
• High dump bucket

3) Material to load
• required attachment type
• material density
• possible fill factor

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Wheel Loader Selection

Select the right machine for the right application

4) Required productivity
• Material volume or tonnage per day or hour
• Truck match: avoid „3 and ½” cycles to load a truck

5) Ground conditions
• Required axles (slippage)
• Tires: Cutting resistance & traction

Slippary, soft ground: Good traction, hard ground: Hard ground, high cutting risk:
L2 tires, LSD axles L3 tires, TPD axles L5 tires, STD axles
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Loading Method
1.V-Shape Loading 2.Cross-Loading

45-60°

3.Load & Carry

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Determination of W/L Capacity – V-Shape Loading

Average Production

Example:
310 m³ / hour required, 3
0,55 min per cycle possible (= 33 sec)
Start at (1) with cycle time, go to (2) to
next field with production equal or 1
higher than requested. Go up to (3) for 2
required volume per cycle = 3 m³

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Determination of W/L Capacity – Load & Carry

3
Average Production

1
2

3.Load & Carry

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Determination of Wheel Loader - Bucket Size

Based on the required bucket volume, material-density and fill factor, the loader can be determined.

Example:
Load and Carry, Hauling distance 100m, productivity target 150m³/h, material: Sand (1.650 kg/m³, 90% fill factor)

1) Determine required bucket volume based on productivity target

 Use tables  example: Load and Carry 100m hauling distance and 164 m³/ hour
 3,5 m³ loading volume required

2) Calculate minimum full-turn static tipping load based on required volume, material density and safety factor.
Choose machine based on FTSTL.

Rated load = required loading volume x material density = 3,5 m³ x 1.650kg/ m³ = 5.775 kg

Min. full turn tipping load = rated load x 2,1 = 5.775 kg x 2,1 = 12.128 kg

3) Calculate required bucket size based on required volume and filling factor

Required volume
Min bucket capacity = = 3,5m³ / (Fill-Factor 0,9) = 3,88 m³
Bucket Fill Factor

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Wheel Loader – Options

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Cabin – Console RH
Control Lever
2-Lever 3-Lever Multifunction-Lever Multifunction-Lever 4V
3th Circuit 3th Circuit 4th Circuit 3th Circuit

Machine WA200-500 Machine WA200-500 Machine WA200-500 Machine WA200-380

Sales Code B70 Sales Code B73 Sales Code B72 Sales Code Q475

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Cabin - Steering
Steering system options Steering wheel K-SLS AJSS
Standard Option Option
Machine WA200-500 WA270-500 WA475-10

Price sensitive customer

●
More than 1x operator with different
preferences ●
Operator/ customer is Caterpillar minded
●
Operator/ customer is Volvo minded
●
Operator/ customer is Liebherr minded
● ●
Travelspeed more than 25kp/h with
Joystick-Steering ●
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Cabin - Seat

Standard Seat 2P Standard Seat 3P High Comfort Seat 4P High Comfort Seat 4P

Machine WA200-500 Machine WA200-500 Machine WA200-500 Machine WA200-500

Sales Code K29 Sales Code K33 Sales Code K38 Sales Code K48

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Electronically Controlled Suspension System (E.C.S.S.)

Effect of ECSS to restrict vibration

(+)

acceleration
ECS

Vibration
S

0
OFF

(-)
Time (sec)

(+)

acceleration
ECS

Vibration
S

0
ON

(-)
Time (sec)
Without E.C.S.S. With E.C.S.S.

E.C.S.S. improves the productivity during Load & Carry

• Reduces loss of material

• Increases driving comfort
• Increases productivity
• Reduces impact loads to the machine
• Increases lifetime of the bolts and sockets
• Works automatically
• Standard feature on WA200-500

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Loader Linkage – Boom Length

Standard Boom High-Lift Boom Super-High-Lift Boom**

**WA380-8 only

Advantages: Disadvantages:
 Maximizes dumping height (~ +450mm) - Lower tipping load
 Material can be handled as with std. boom - Smaller buckets
comprimization - More space required
 available WA200-8 to WA600-8 - additional counter wheight needed
(except: WA480)

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Buckets
Design Features
Flat Bottom Direct Pin-on Bolt-on cutting edge Spill Guard

Round Bottom Quick Coupler Teeth Colour

For more details & information see the Komatsu Bucket Sales Guide

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Bucket Application Comparison

Leveling Friction Road Maintenance Digging performance

Flat Bottom

Easy More Easy Lifting is needed

Round Bottom

Difficult Less With teeth no w/o lifting

maintenance

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Aggregate Handler

Highest Productivity through the line-up

Increased bucket capacity - Increased payload / rehandling with ease - perfect match for truck loading

WA320-8 WA475-10 WA480-8 WA500-8

HE-bucket 2,7-3,2m³ HE-bucket 5,0-5,5m³ HE-bucket 5,0-5,5m³ HE-bucket 6,6-7,2m³

4.900kg payload (+500kg) 8.300kg payload (+600kg) 8.800kg payload (+1.000kg) 12.500kg payload (+2.000kg)
Available beginning 2024

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Aggregate Handler
Pass # / cumulative load
Truck Payload Machine spec. #1 #2 #3 #4 #5

18t WA320-8 4,4t 8,8t 13,2t 17,6t

24,5t WA320-8 AGG 4,9t 9,8t 14,7t 19,6t 24,5t

WA475-10 7.8t 15.6t 23.4t 25.0t

25t
WA475-10 AGG 8.3t 16.6t 25.0t

WA475-10 7.8t 15.6t 23.4t 31.2t 32.5t

32.5t
WA475-10 AGG 8.3t 16.6t 24.9t 32.5t

WA480-8 7.8t 15.6t 23.4t 31,2t

26.5t
WA480-8 AGG 8.8t 17.6t 26.5t
WA500-8 10,5t 21t 32t
25t
WA500-8 AGG 12,5t 25t

WA500-8 10,5t 21t 32t 37,5t

37t
WA500-8 AGG 12,5t 25t 37,5t

Check for best matching machine/truck combination

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Where to find detailed information's

Sales material

Komatsu Sales Tool Brochures CPQ (Price list) Komatsu SABA

App

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