Telescopic loaders load all the interesting stuff here
For some time now, there has been a battle for supremacy in the telehandler sector. The rapid growth in popularity of these machines both in the UK and Ireland and throughout the world has attracted the interest of almost every special equipment manufacturer. The numbers alone (currently, the number of telehandlers in the world is, according to rough estimates, about 56 thousand units - and it continues to grow) has lured several well-known manufacturers into this market, wanting to get at least a small part of it. Today we will tell you about the latest developments in this rapidly growing and highly competitive sector.
Vanishing trend
Let's start with questions. Why has demand for telehandlers soared? And why did they take over the "original" niche of the backhoe loader, so popular in the UK and Ireland?
The general answer is that today's approach to materials delivery has changed: by some estimates, more than 80% of materials are delivered to their destination in the form of freight packages. This is why the telehandler becomes an indispensable machine on any construction site. So, what exactly are the latest developments and types of machines that we will see in this area in the near future?
We should immediately make a reservation: North American manufacturers should not be discounted, since they firmly understood one thing - in order for a car to be bought in Europe, it must be made specifically for the Old World. For example, Pettibone has been producing telehandlers in America for many years. And he plans to sell “unusual wheel loaders” in Europe, because he understands that no one in Europe will buy “traditional American loaders.” JLG has several lines for the American market (for example, Lull, Sky Trak and Gradall).
But the company also produces a number of cars for Europe, which began with the acquisition of Atlas. Its successful and growing alliance with Caterpillar also focused on a new line of Cat machines designed specifically for the European market. Unfortunately, we won't be able to see these loaders until next year.
But it is already clear that the trend in recent years towards a constant increase in working height has begun to decline at 30 meters - apparently, this height will not increase further. At the same time, more and more compact machines are appearing on the market. And the main priority for all manufacturers now is safety - regardless of size (for telehandlers, safety is synonymous with all-round visibility).
JCB telehandlers (UK)
In most markets, the most popular brands in the telehandler segment are JCB and Manitou. They are fighting among themselves and for global leadership in the industry. JCB recently released a preview of the JCB 515-40 telehandler, described as a "miniscopic" telehandler: 4m lift height, 2000kg rated capacity, 1500kg maximum lift capacity. The model is intended for use in situations that require low lifting heights and a small supporting area, such as restoration work in buildings. According to JCB, the key features of the "miniscopic" concept are: small dimensions (the machines are narrower and lower than conventional forklifts), hydrostatic all-wheel drive transmission with rear steering wheels and versatile application capabilities (as a forklift or 0.5 cubic meter loader). .
However, the company has decided not to show this machine yet, and instead presented two 535 HiViz low-boom telescopic lifts. These machines have improved rear visibility - by three quarters - thanks to the lowering of the boom support joint by 235 mm. In addition, the overall size of the boom section has been reduced by 13%, the rear overhang has been reduced by 90 mm and the turning radius has been reduced by 300 mm. To top it all off, the car has a side-mounted 63kW JCB Dieselmax engine, as well as new instruments and dashboard. A model with a 74 kW Tier III engine will be available later this year. In addition, JCB confidently described itself as the world leader in the telehandler market, with a 22 percent share.
Loaders Manitou (France)
Manitou, which calls itself the world leader in all-terrain forklifts, has built more than 236,000 of them - and is clearly the leader in the entire sector. In addition, Manitou - without wanting to trumpet it like its British competitor - is already quietly calling itself the leading manufacturer of telehandlers (26 percent share of this market). Among Manitou's latest machines are the rotating telescopic MRT "Privilege" (18 to 25 m), which have undergone a complete redesign, as a result of which they are equipped with Mercedes Euro III engines, providing an additional 13% of power.
As for the operator's workplace, the machines have a new, state-of-the-art cab design - more spacious, with improved visibility of the attachments through the curved windshield. Among the latest events in the company, we note the launch into mass production of the MRT 3050 model (lifting height 30 m, maximum load capacity 5 tons), first presented last year at the Intermat exhibition. The five-section telescopic boom with a pentagonal cross-section has increased rigidity, especially in a horizontal position. Options are available with a winch and lifting platform, as well as working platforms (working height up to 40 m).
Haulotte (France)
A newcomer to this sector, Haulotte has created a line of two machines from scratch: the Top Lift HTL 4014 and HTL 4017. Both loaders have a maximum lifting capacity of 4 tons and a lifting height of 14.1 and 17.2 m, respectively. One of the main features of these lifts is more than double the stability. In addition, the security system is distinguished by the presence of several visual and audio indicators, as well as locking mechanisms. Finally, these models use a single, multi-functional control unit that allows you to perform both simple and complex movements with high precision using only one hand.
According to the head of Haulotte, Alexander Sobo, the goal of creating the HTL 4014 and HTL 4017 was not just to achieve maximum lifting height, the machines performing their functions in any conditions, under the control of any operators, who, in turn, can always commit violations in operation. Sobo also noted that this year it will be possible to build no more than 1,000 such machines. Given that it needs to produce about 3,000 telehandlers per year to be economically viable.
However, in fierce competition with many established manufacturers, Haulotte optimistically plans to achieve a market share of around 10% over time, which equates to approximately 5,000-6,000 machines per year. The company views the telehandler market as an important stepping stone towards diversification, and the interpenetration of the lifting equipment and telehandler rental markets is to its advantage. However, when this time will come is not clear. After all, the effort it took to enter this market has already had a negative impact on new products, and further development of car lifts is likely to be delayed due to problems with compliance with road laws and new engine requirements.
Telescopic boom loaders Faresin (Italy)
But Faresin, freed from the partnership agreement with Haulotte, is expanding its range at a rapid pace. Among the new models are the compact "6.25" (1.9 m high and 1.8 m wide, lifting height 6 m, load capacity - 2.5 t), as well as the first full-turn models "15.45" and "18.45" (height lift - 15 and 18 m respectively, load capacity - 4.5 tons, ability to rotate 360°).
These models are state-of-the-art, featuring Canbus load and stability management, electronic integrated active safety system EISAS for load monitoring, and a 94kW Iveco Tier III engine mounted centrally on the chassis for improved serviceability.
Liebherr (Germany)
The new range of Liebherr telehandlers is already well known in the German-speaking world. The series of four models includes machines with lifting heights from 10 to 13 m and maximum lifting capacities from 3,500 to 4,500 kg. Initially it consisted of TL4 35/10, TL4 35/13, TL4 42/13 and an industrial type machine TL4 45/10.
The oval boom of this loader looks quite unusual - it shows the company's experience in developing crane booms: with a relatively small size and a low location of the support hinge, they have good rear visibility. Several of these machines have already entered the British Liebherr rental fleet.
JLG (USA)
The forklift alliance between Caterpillar and JLG is growing successfully - perhaps much more successfully than Cat could have expected. Production began last fall, and all dealers are satisfied with the quality of equipment produced at the Belgian JLG plant. However, the new generation of machines from these two companies will not be seen until next year, but Caterpillar customers and dealers are looking forward to them. The heads of the JLG-Cat alliance, Mike Rafii (JLG) and Klaus Ukens (Cat), unanimously claim that in the first year the main task was the integration of the two companies. And after production of Cat machines under the JLG brand began last October, you can try designing new models. And Oshkosh, the new owner of JLG, calls this alliance “very attractive” and “we are happy to support any of JLG’s initiatives.”
Meanwhile, JLG has released a new upgraded PS series of nine machines for the European market. These models come standard with a full power shift transmission for increased traction. The load-sensing variable displacement pump is now integrated with a new compensation valve. According to the manufacturer, this provides more responsive and balanced proportional control - due to reduced hydraulic cycle times - as well as more efficient use of power with an overall increase in productivity and fuel economy. In addition, the power shift transmission has a switchable clutch release function built into it using the brake pedal. Finally, the interlocking system between the stabilizer and chassis has been improved, which has reduced the installation time into the required position during loading operations.
Telescopic machines Genie (USA)
Genie has expanded its European lineup with another machine – the GTH-6025R Giro. This full rotation model has a lift height of 24.8m and a maximum front reach of 20.85m with a lifting capacity of 6000kg. The all-wheel drive vehicle is controlled by two electric proportional handles (four-in-one type) with a button that allows you to change the transmission on the fly.
The extensive use of electronics is evident in the presence of a maintenance indicator and a black box that records “operating parameters and deviations.” The GPS module, which is installed if necessary, also allows you to determine the location of the machine. Power comes from a side-mounted (for easy access) 165 hp Cummins four-cylinder engine with turbo cooler.
Merlo (Italy)
Merlo has a reputation for using the most advanced technology in the development of telehandlers, so simply releasing a new product is a big deal. With a lift height of 8.6 m and a lifting capacity of 5,500 kg, the Panoramic P 55.9 CS features a new body design and a lower pivot point for increased rear visibility. The latest hydropneumatic cab suspension provides even greater operator comfort. There are other innovations as well.
These include Merlo axles with epicycloid gearboxes and a Tier III 140 HP four-cylinder engine, which is said to produce less noise. Merlo is of the opinion that customers would prefer an increase in lifting capacity over a higher lift height. As part of this philosophy, the Roto line of compact loaders has been released, which includes improved versions of the K and KS models (maximum load capacity 5000 kg). The lifting height does not exceed 16 meters. The new models have a rotation limit of 415°, while the overall width is reduced by 50 mm and the length by 130 mm.
Others
The seductive growth of the telehandler market has attracted lesser-known manufacturers to also try to take this “springboard”. For example, the Spanish company MZ Imer has already released models with both a stationary body and full-rotary ones. And recently they also introduced a nice-looking MZ-2706-Lift machine.
Built at the Zaragoza plant, this loader has a maximum lift height of 6 m and a maximum lifting capacity of 2,700 kg (at a height of 3.5 m with the boom fully extended, the maximum lifting capacity is 800 kg). Measuring just 2 x 1,845 m, it is powered by a Yanmar engine and has a top speed of 25 km/h. According to official data, the car has very good reviews and will go on sale at the end of this year.
Portuguese company Galmax has released a slightly smaller loader, the compact 6516 Giraffe, which will go on sale later this year. The total height of the machine is less than two meters, the width is only 1.53 m, the maximum lifting height is 5.2 m, but the maximum load capacity is only 1.6 tons.
Chinese manufacturer Sunward is also “looking to the West” and hopes to find dealers there. The company's first telescopic handler, the 13.65-metre SWTH 3514, is capable of lifting up to 3,500 kg, is equipped with a two-speed transmission and reaches speeds of up to 35 km/h when driving on the road, can tow loads weighing up to 6 tons and overcome 60% slopes with full load. Company representatives noted that all pumps, motors and valves are supplied by the Rexroth Bosch group of companies.
Latest Bobcat Telehandler The compact T2250 offers the features and benefits of a skid steer, an articulated wheel loader and a telehandler all in one, the company says. With an overall height of just 1.97 m and a width of 1.8 m, the T2250 has the same dimensions as the largest Bobcat skid steer loader models. And at the same time, according to the company, it has performance comparable to an articulated wheel loader of the same size.
With the UK side-steer loader market traditionally static and the telehandler market still growing, Bobcat is keen to expand its niche in the latter. The rapidly growing Italian manufacturer Dieci continues to add models to its already large line-up. The company's production recently moved to a new plant, which allowed it to almost double its production volume - to almost 2,400 units per year.
The capacity of the two factories allows the production of up to 5,000 cars per year, which means good prospects for the future. Recently released models include the compact Apollo 25-6 with an upgraded 85 hp turbocharged engine and the powerful full-rotary Pegasus 70-11 (11 m/7000 kg). The vehicles are equipped with a new cab, seat, instrument panel and redesigned switchgear. The slightly smaller full-rotating Pegasus 60.16 is capable of lifting up to 6,000 kg and has a working height of up to 16 m. It was released last fall and has much in common with the 70-11.
Another new line of telehandlers Dieci - Atlante(lifting height from 6 to 11 m). These vehicles have a power shift transmission (four forward and three rear). According to the company, this is in response to customer requests. Models such as 30-6, 30-9, 33-11 and Zeus 38-10 with higher lifting capacities are available.
An indispensable assistant in any department of agricultural production, the telescopic loader is confidently winning the sympathy of agricultural producers, displacing front-end loaders that are traditionally common in this sector of work. Power, maneuverability, compactness and versatility make these machines in demand all year round and every day. How to correctly select, maintain and extend the service life of this “jack of all trades”?
The popularity of telescopic loaders in the agricultural sector is very high: despite the crisis, the demand for them has been steadily increasing since the early 2000s. Moreover, even on the secondary market, interest in “telescopes” is extremely high. If in Europe farmers usually replace three- to five-year-old machines (with 5 thousand operating hours) with new ones, then in Russia, even on the used equipment market, it is difficult to find telescopic loaders with 10-15 thousand operating hours, since there is an uninterrupted supply of spare parts They are used in agricultural enterprises until they are completely worn out.
Minus comfort
When choosing a telescopic loader, first of all you need to pay attention to its technical characteristics and compare them with the tasks that this machine has to solve.
Most often, buyers want to get a universal machine that can be used in both the livestock and crop production sectors (load grain, store straw, load a feed dispenser, etc.). At the same time, the use of universal loaders in agricultural work is not limited to, notes Maxim Grigoriev, deputy director of the technical department of the Agroprom-MDT company (sales of universal telescopic loaders Faresin and MERLO, Italy). Soon, the telescopic loader will begin to be used in construction or reconstruction of premises, cleaning roads, loading heavy construction materials, etc. Of course, multifunctionality helps to quickly recoup the cost of the machine and make maximum use of the available capacity on the farm, says the specialist. However, in order to achieve positive results, even at the selection stage, it is necessary to think through the package and not skimp on the necessary functions.
No matter how trite, the main mistake when choosing a telescopic loader, according to the observations of the technical director of the SMART-M company (the official representative of the MERLO concern in Russia) Maxim Doroshenko, is focusing on the price of the machine. “The buyer looks at the cheapest “bare” configurations, without comparing the capabilities of such a loader with his plans for it, and as a result, having saved 2-3 thousand euros, he receives equipment that is uncomfortable for the operator, difficult to operate, or does not at all correspond to the nature of the work being performed,” - states Doroshenko.
According to his observations, the first on the list of “reduced prices” are windshield wipers (rear and roof). In this case, when the operator works in dirty, dusty conditions (loading grain into a warehouse, straw in the field, etc.), he, not seeing the load either on the boom above or behind, is forced to act blindly.
Also, according to Doroshenko, they save on additional lighting. However, the loader can only operate in good visibility, and this is sometimes difficult to achieve both in the field and in a dusty warehouse, not to mention the fact that during feed harvesting you have to work around the clock. In such a situation, the light from standard headlights is not always enough.
It is unacceptable, in the opinion of Maxim Doroshenko, to abandon the air conditioning system (and this, alas, is a fairly common practice). Buying a telescopic loader without air conditioning for field work, where such a machine is used almost constantly, is tantamount to killing the operator, an expert warns.
Don't skimp on hydraulic capabilities
The main component of a hydraulic system is the hydraulic pump. The speed of operations and the operating capabilities of the loader depend on its performance. Telescopic loaders are equipped with gear type or axial piston type pumps. Rarely, a pair of pumps located behind each other can be used.
As Maxim Doroshenko explains, a gear pump is cheaper, but its service life is 3-4 times less than an axial plunger pump. A machine with a gear pump performs work operations more slowly, which reduces productivity and also makes it impossible to use attachments that require high hydraulic flow: brushes, snow throwers, straw spreaders, etc.
At the same time, oil flow is important, which directly affects the performance of the machines: the stronger the flow, the faster the main operations in the operation of the loader can be performed - lifting, extending the boom, turning the bucket and operating the implement (for example, closing the gripper), says the business manager for agricultural JCB equipment in Russia and the CIS Semyon Kostin.
In the same context, Maxim Grigoriev draws attention to the fact that for fast operation of attachments in motion, the hydraulic pump capacity must be at least 150 l/min.
For work such as silo excavation (with a milling cutter or silage-cutting gripper), the pump capacity should be at least 140 l/min, adds Semyon Kostin. For other jobs, this high productivity allows for high speed combined operations.
The type of hydraulic distributor is equally important. Especially in jobs where several hydraulic functions are involved at the same time. For example, in the loading cycle of grain or feed: the load is lifted, the boom extends, and the hydraulics of the silage cutting grip work. As Semyon Kostin explains, the manufacturer often supplies so-called “construction” hydraulic valves in simpler configurations, in which only one hydraulic function can be used. In this case, each operation will be performed sequentially. Such loaders are more useful for working with pallet forks).
When multi-purpose loading of the “telescope” in the agricultural sector (loading straw, preparing rations, pruning trees, etc.), a monofunctional hydraulic distributor will slow down the work process and make production cycles extended and discrete, Kostin warns.
Manitou regional agricultural manager Pavel Konkov points out that for some work (for example, where attachments with hydraulic motors are installed - a silage bucket with a cutter or a brush) are used - an additional hydraulic line will be needed - the option of free drainage into the hydraulic tank.
When using a telehandler with a tree trimmer, a constant mandatory free-flow oil return is required, explains the company's telehandler specialist as an example CLAAS Leonid Yakovlev. Also, during such work, it is convenient to use the hydraulic circulation function on the boom (so as not to constantly press the function button, but simply activate it “and forget”), the specialist adds.
Rational protector
Semyon Kostin also recommends paying attention to the choice of tire type and tread pattern, which should be selected based on the types of surfaces on which the loader will be used and the duration of the expected hauls.
When choosing tires, there should be reasonable savings, says Pavel Konkov. Of course, you can use diagonal tires, they will be cheaper, but they will have worse cross-country ability and a shorter service life. As a standard, agricultural loaders usually come with radial tires with a herringbone tread, which are designed for off-road use and provide better cross-country ability, have an increased service life and give a softer ride to the loader compared to diagonal tires, which are often installed on construction loaders. type. And if a loader is purchased for work only on hard surfaces (transfer of mineral fertilizers at railway units, grain conveyors, etc.), you need to order radial tires with an “industrial” tread.
A telescopic loader used in agricultural production usually works both on hard surfaces and in off-road conditions, Semyon Kostin is convinced. In this regard, the specialist recommends that farmers choose radial tires (with herringbone tread) for telescopic loaders. On poor surfaces, softer elastic tires of a radial design significantly increase the loader's maneuverability, and on broken and uneven roads they increase the speed of its movement, while harder “industrial” tires of a diagonal design, on the contrary, complicate movement and cause discomfort to the operator, explains Kostin.
However, soft rubber “Christmas trees” have a drawback - an increased tendency to abrasion, reminds Pavel Konkov. On average, a set of tires, if they are used not only in off-road conditions, but also on asphalt and concrete surfaces, and at the same time undergo medium-range and frequent runs, “live” for 1-2 seasons. As for width, from the point of view of reducing pressure on the soil, tires should be “the wider, the better,” Konkov has no doubt.
For example, for a vehicle with a carrying capacity of 3-4 tons, the optimal wheel diameter is at least 24 inches, clarifies Semyon Kostin. With such tires, a machine with a given load capacity will be able to work not only on a hard surface, but also in the field at the height of sowing, in a compost storage facility on a very loose surface, etc.
In addition, Maxim Grigoriev, taking into account the versatile use of telescopic loaders, advises taking machines with high ground clearance - at least 35 cm. In particularly difficult operating conditions, a set of pneumatic wheels with disks of size R24 can be installed as an option, the ground clearance in this case will increase to 42 cm , the specialist points out.
Maxim Doroshenko advises thinking about options such as “crab run” and “track to track” if the loader will “work” in narrow spaces. Such options are indispensable if, for example, you need to clean out a narrow passage in a barn: the crab motion allows the loader to cope with work on both sides of the building without having to turn around.
Calculate height
According to Leonid Yakovlev, some manufacturers' telescopic loaders do not have a front reach. In this case, the working lift height will be less than the maximum, and this must be taken into account when planning work and choosing a machine.
As Semyon Kostin explains, the arrow must be taken with a reserve. For example, with a silo trench height of only 3 meters, a seven-meter boom will be useful for removing snow, ballast, and covering material, that is, carrying out preparatory work for excavating silage without the use of additional equipment. If the loader is involved in crop production, then the starting point will be the height of the side of the grain truck - that is, a maximum of 4 m, and here a model with a lifting height of 5-6 meters is quite suitable.
At the same time, Leonid Yakovlev reminds that loaders with a long reach (8-10 m) are less maneuverable and compact, and the enterprise should take into account in advance the maximum height of openings and rooms into which this loader must enter.
During long hauls
Also, when correlating your tasks with the characteristics of the loader, you should proceed from the frequency of movement of the machine and the duration of the hauls. Semyon Kostin points out that the ability to disable all-wheel drive on a loader significantly affects fuel consumption and tire wear. As a rule, loaders with hydrostatic transmission do not have this option, while some “torque converter” models allow you to disable all-wheel drive.
If the movement of the machine is limited to one working platform, “hydrostats” are quite suitable - they are more compact and have a minimum of components. However, for long hauls it is worth choosing “torque converter” models.
In addition, if you know in advance that the “telescope” will have to regularly overcome long hauls, then you should choose cars that can drive at the maximum speed for this class - 40 km/h. Otherwise, according to Pavel Konkov, they will not have time to complete the entire volume of work assigned to them, not to mention the fact that they will become a source of difficulties on public roads.
In addition, Semyon Kostin notes, for telescopic loaders for agricultural purposes, an effective cooling system (which is useful for working in very dusty hangars and in hot weather when loading grain) and a differential lock to improve traction characteristics are important.
Some manufacturers (for example, Claas), adapting their cars to Russian realities, they install additional filters for Russian diesel fuel in the standard specification. However, many manufacturers offer such equipment as an option, and they strongly recommend installing additional filters as a safety net against low-quality diesel fuel.
Also, when choosing a machine for work in dusty conditions (loading straw bales into the field, working in warehouses, etc.), it is recommended to pay attention to whether it is equipped with a reverse cooling fan, warns Leonid Yakovlev. Otherwise, the radiator grille will become clogged, which can lead to engine overheating.
Weigh as required
Semyon Kostin calls a grain bucket and pallet forks a standard set of attachments for agricultural “telescopes.”
Experts recommend selecting attachments in accordance with the maximum load capacity of the loader. According to Pavel Konkov, it is important to choose the optimal grain bucket, and not to chase a large volume. The heavy weight of a maximum volume bucket will slow down the hydraulics, and its considerable dimensions will reduce visibility. In practice, it often turns out that when loading grain with 2.5 thousand and 2 thousand liter buckets on identical loader models, a smaller bucket is not inferior in performance to its “bigger brother,” Pavel Konkov gives an example. The reason is that a smaller bucket is smaller in size, which is more comfortable for the operator, and also weighs less, and hydraulic movements are faster.
Semyon Kostin for excavation, construction and planning work, instead of the grain bucket included in the standard set of attachments, advises using a ground bucket (purchased separately). Its shape makes it easier to fill, and its dimensions increase visibility, says the specialist. And if for a machine with a lifting capacity of 3 tons the recommended size of a grain bucket is 2.5 m³, then for a dirt bucket for the same machine 1.2 m³ is enough. Moreover, even with such a small soil bucket, the productivity of loading heavy construction materials will be higher.
By the way, if it is assumed that the change of mounted implements will be frequent, then it makes sense to think about a hydraulic lock, advises Leonid Yakovlev. Then the guns can be changed without leaving the cockpit.
Configuration Errors: Do No Harm
Telehandler settings are simple and straightforward. The only thing that, according to Pavel Konkov, needs calibration is the safety system (rollover protection). Its adjustment is carried out during the period regulated by the instructions, and it should be done by a specialist. An improperly calibrated system can reduce the actual lifting capacity of the machine and increase the risk of rollover. Therefore, such adjustments are usually carried out together with the dealer, and no problems arise.
Semyon Kostin advises regularly checking boom clearances and spacers for wear, as well as monitoring tire pressure, as this not only affects their service life, but also prevents excessive rocking of the machine while lifting loads.
The main thing that Maxim Grigoriev asks to avoid is interference with the electronic system of the car. Eliminating computer errors on your own, as a rule, causes a lot of problems, which have to be fixed by service specialists, he states. Therefore, it is better to carry out any adjustments to the electronic system with a dealer.
Maxim Doroshenko agrees with him, who believes that about 80% of equipment breakdowns occur due to interference in the electronic systems of the machine by unqualified personnel. As a rule, they install additional equipment on their own that they saved on when purchasing, for example, more powerful headlights, a radio, air conditioning, fans and other “collective farm tuning,” lists a specialist from the SMART-M company.
According to his observations, connections occur with violations, leading to the failure of high-tech, expensive systems. For example, this often happens when installing additional lighting or when an additional GPS tracking module is unqualifiedly inserted into the standard electronic system.
Not omnipotent
A telescopic loader is a load-lifting machine, so first of all you should avoid moving with the boom extended, since any load on the extended boom adds extra torque and the machine becomes less stable, warns Leonid Yakovlev. You should also not drive with the boom raised, because a shift in the center of gravity contributes to loss of balance during maneuvers. Another mistake is ignoring overload sensor signals. All of these factors can cause the machine to tip over, resulting in inevitable damage to the boom.
Semyon Kostin reminds us that during long hauls it is better to disable all-wheel drive (if the car has this capability). Otherwise, the lack of a center differential will result in excessive tire wear, not to mention a significant increase in fuel consumption.
Also, according to the observations of Semyon Kostin, one of the common mistakes in controlling the “telescope” is the incorrect technique of filling the bucket. As a JCB specialist explains, an inexperienced operator first deepens the bucket as far as possible in a horizontal plane, and then tries to tip it over using hydraulics.
This is the most difficult task for a loader, because at this moment it lifts not only the volume of the bucket itself, but also the entire layer of material located on top, whereas with the correct technique for filling the bucket it must be simultaneously tipped over itself, raising the boom and not turning off the gear, explains Kostin.
Another common mistake he calls is stretching the loading cycle due to incomplete use of the properties of hydraulic functions. Very often, when loading a machine, an inexperienced operator first lifts the boom with the load up, then extends it, and only then overturns the bucket, says Kostin. But it is optimal to raise the load to the minimum height to overcome the side of the body, while simultaneously extending the boom and tipping the bucket. In this case, loading will be much faster.
In addition, in an effort to increase the load capacity, farmers often overload the machine, and “for stability” they artificially make the rear part heavier (most often they fill the loader wheels with water). The load capacity, of course, will increase by 50-100 kg, but this will negatively affect the reliability of the equipment, in particular the boom spacers and the calibration of the rollover sensor, warns Leonid Yakovlev. He points out that the main means of assessing the capabilities of a machine is the load diagram. It is by consulting it that the operator must choose tactics for working with the cargo.
Often, farmers try to use “telescopes” to move something heavy from its place, applying a dynamic load (pulling it, pushing it aside with a jerk, etc.). Such impacts are detrimental to technology, Maxim Doroshenko has no doubt. Often in such cases, booms break and hoses break.
Semyon Kostin also talks about how pressure in an additional hydraulic line is sometimes relieved using a “barbaric method”: the operator begins to knock on the couplings with a handy tool in order to relieve pressure, deforming and damaging them. Whereas there is a sequence of actions to relieve pressure, and for this you do not need to leave the cabin.
Studying in the off-season
Considering that telescopic loaders are one of the most heavily loaded machines in the enterprise’s agricultural fleet, which often operate in three shifts during the season, Maxim Grigoriev reminds us of the need for regular and strict maintenance in accordance with the regulations.
According to the observations of Maxim Grigoriev, during the post-warranty period, farmers skimp on the quality of engine oil, and sometimes even forget to change it. For such an expensive machine as a telehandler, such negligence is disastrous, he warns.
According to Pavel Konkov, constant joint work of dealers and agricultural producers will help to minimize such acute situations - regular training in the correct process of operating equipment, carried out in the off-season (winter period).
Often, after the service engineer has conducted training and shown which buttons are involved in the main processes, the machine operator does not look at the operating instructions, continues Konkov. If representatives of equipment manufacturing companies make it a rule to hold seminars on the equipment they sell, where they will talk about the capabilities of the already purchased machine and its proper operation, there will be much fewer errors and complaints about the equipment.
At the same time, he suggests that buyers (agricultural producers) demand that dealers conduct such seminars in the off-season.
Maxim Doroshenko focuses on the fact that machines used in the agricultural sector need high-quality diesel fuel. And he notes that refueling of equipment is often done in the field in an inappropriate way. It is also necessary to carry out timely maintenance using lubricants and filters of proper quality, preferably by an authorized dealer.
Highly loaded hinge joints of the frame and boom require special attention. It is especially important to use the correct lubricant for their maintenance. Experience shows that customers experience problems with broken bushings and hinge pins when using a lubricant that does not meet the operating requirements of the machine, says Semyon Kostin. Thus, Russian farmers love the cheap Litol-24, which is suitable for lubricating bearings and cardan joints that experience a completely different level of load. And for highly loaded connections, a specialized lubricant is needed that retains its properties even under these conditions.
Take care of your oils
Head of Technical Support Department " Shell» in Russia, Andrey Kudimov, notes that one of the most demanding components for lubricants of this type of equipment are the guides of telescopic booms. This is due to the fact that the design of such a unit has undergone a number of improvements in recent years. The introduction of more modern technologies and the use of composite materials is one of the priority areas. Accordingly, a different approach is needed in the use of lubricants.
“In practice, the operator may experience reduced guide boom life, high noise levels when extending, or jerking rather than smooth extension. In such cases, we can conclude that the node is under too high loads, is incorrectly designed or damaged. And the problem most often lies in the fact that to lubricate this area, products are used that do not fully meet the requirements (for lack of others or due to inattention),” explains Kudimov.
Often, the requirements for lubricants for guides specify only the consistency of the product. However, choosing a grease only based on consistency, even within the same class, will be a mistake, warns Kudimov. The fact is that the spread in the performance properties of products can be too wide. Therefore, when we talk about the efficient operation of the boom, the selection of lubricant should begin with determining the material for the guides, says the specialist.
For example, if the friction pair of the boom is metal-to-metal, it is recommended to use greases containing solid fillers. Most often it is graphite or molybdenum disulfide. Typically, such products are dark gray or almost black in color.
However, such classical lubricants are not applicable for a more promising material for the manufacture of guide booms - polymer (metal-polymer friction pair), Kudimov points out. In a metal-polymer friction pair, solid particles can act as an abrasive, and their presence in the lubricant is undesirable. Therefore, to provide the required level of anti-wear properties while maintaining smooth gliding, it is necessary to use higher viscosity base oils and advanced thickener technologies, he advises.
Thus, the usually recommended viscosity of the base oil in a lubricant is 150-220 centistokes (cSt), but in the absence of solid fillers it is increased more than twice (by the way, such lubricants are lighter in appearance). According to the specialist, one of the most promising types of grease for this unit is a lubricant made using a polyurea thickener. Initially, such lubricants were used in motorsports. This technology allows for a lower friction coefficient compared to classical solutions. In telescopic booms, the use of such lubricants ensures smoother sliding of the boom. Whereas using a lubricant with solid fillers for the metal-polymer pair can lead to wear on the boom guides, warns Kudimov.
In addition to lubricants for telescopic booms, Andrey Kudimov also advises, when servicing, to pay attention to the operating temperature range of use of mineral oils (transmission, hydraulic, motor), that is, to see how they coincide with the actual operating conditions of the machine.
Text: S. Kostin, business manager for JCB agricultural machinery in Russia and the CIS
Telescopic loaders are becoming increasingly popular auxiliary machines in Russian agriculture. Such universal equipment can be used in crop and livestock farming for various types of work, making these units indispensable assistants at agricultural enterprises.
The Russian market offers a fairly wide range of telescopic loaders from many manufacturers. Models differ in their technical characteristics, dimensions and other parameters that determine the possibility of their use for certain agricultural work. In this regard, practical advice on purchasing this agricultural machinery will be useful.
HEIGHT FACTOR
When choosing a telescopic loader, you first need to determine the main type of work for which it is purchased. The most important parameter of the unit—the maximum lifting or unloading height—depends on this factor. For example, if an agricultural enterprise plans to use such a machine for loading grain into trailers, then the determining indicator when choosing and purchasing equipment will be the level of the side of the truck, which usually does not exceed 3.8 m. In this case, for normal operation, a loader with a lifting height equal to six meters. Higher rates of this characteristic make it possible to expand the range of applications of the unit and the types of work it performs on the farm, and also provide greater versatility. However, it should be borne in mind that with an increase in lifting height, the dimensions of the equipment itself usually change, and, accordingly, its maneuverability is lost. Not every machine that performs feed loading work on a dairy farm can function inside a barn without difficulty due to its size. Often in such cases, instead of purchasing a loader with higher technical characteristics, it is better to use various types of replaceable attachments - buckets with increased dump height, boom extensions, and the like.
RELATIONSHIP OF COMPONENTS
Another important factor when purchasing a forklift is performance and the time it takes to complete the required amount of work. In this case, you need to pay attention to the carrying capacity of the machine. This parameter determines the maximum capacity of attachments, such as a bucket, whose size, in turn, affects the unloading height.
The optimal bucket is selected depending on the type of material being handled. For bulk grain, the angle of complete tilting of this working body is important, which affects its filling capacity and prevents excessive losses when moving material. When working with sticky and inert loads, for example, manure, soil, defecation and others, it is necessary to ensure an increased unloading angle so as not to complicate the process of emptying the bucket and shorten the loading cycle. Since filling of this equipment is carried out mainly by pushing it into the mass of material, it is necessary to pay attention to the traction force created by the unit. It depends not only on engine power and transmission type, but also on the type and size of tires. For example, radial tires with a herringbone tread will significantly increase traction on loose ground and prevent excessive wheel spin, while an industrial pattern can significantly increase the life of a set of tires when working constantly on hard surfaces.
CONVENIENCE AND PERFORMANCE
Important technical characteristics of a telehandler are maximum hydraulic performance and pump type. These parameters determine the length of the loading cycle and can have a significant impact on fuel consumption per ton of material handled. If the machine is operating with an active attachment, the maximum hydraulic flow to the auxiliary hydraulic extension line will affect the productivity of the operation. For example, a silage cutter, which is powered by two or three powerful hydraulic cylinders, will be able to function faster and more efficiently. Equally important when choosing a loader are the type of transmission and the ease of its control, that is, switching the direction of movement and gears, since these parameters can seriously affect the overall productivity of the work performed. In particular, a hydrostatic transmission has an advantage over a hydromechanical one in terms of precision control, but significantly limits the capabilities of the loader when moving between work sites and when towing trailers. At the same time, the second type of transmission is usually much cheaper to operate and maintain.
Of course, there are other, more specific features of forklifts that will also help not only provide increased productivity, but also reduce operating costs. These include the presence of a quick-release device for attachments, boom shock absorption, automated lubrication and wheel alignment systems, a reversible cooling fan, four-wheel drive shutoff and much more.
Telehandlers are more versatile than conventional ones. This is why they are very common. They are used in many areas, from construction to the agricultural sector. In Russia, models from about ten leading companies from around the world are in demand. These are mainly European brands.
Manufacturing companies
In Russia, telescopic loaders from the following companies are in greatest demand:
- Gehl;
- Manitou B.F.;
- MustangManufacturingCo;
- Sky Trak.
These brands are leaders in the supply of such equipment to our country. The loaders produced by these companies are in demand everywhere.
MustangManufacturingCo is owned by Gehl. This is an American company that produces telescopic loaders of various lifting capacities. It is Gehl that owns the famous DL model, which has the function of quickly attaching mounted implements. Thanks to it, you can even install a platform for lifting workers on the boom. Therefore, the model has found its application not only in construction, but also in various installation and high-rise works.
Gehl also has a Caterpillar model that differs from all other types of forklifts in that it is equipped with a joystick that makes many of the system's functions automatic.
A distinctive feature of Gehl equipment is that when purchasing a telescopic loader, the client can independently choose the length of the boom.
JCB
JCB is a British company. Unlike its competitors, the company is not limited to two or three models of loaders. Today there are 12 models in the brand’s line, and new ones may appear soon. One of the JCB models is known for having a boom length of about 17 meters.
Operating JCB tools is very easy. This can be done with one turn of the lever. The developers specifically created systems that could make it possible to quickly replace working tools. Attachments on loaders can be changed very simply and easily on the job.
The advantage of JCB equipment is its stability. The company has provided for various unpleasant incidents that may arise during operation.
Manitou B.F.
Manitou BF is a French company that is famous for its forklifts. However, it also produces telescopic equipment, but only under the Maniscopic brand. The models of the French brand can be identified by their low rise, which provides them with maximum stability. The Gradall G6-42P loader has a unique steering system that is not found almost anywhere today.
The low landing (profile) of the loader with a low machine height and ground clearance of 460 mm makes this equipment very noticeable. It should be taken into account that the unit has a steering gear.
Sky Trak
Sky Trak manufactures Terex telehandlers. The company has a number of patents, one of which is a unique rear axle stabilization system. The use of this system increases the stability of the equipment even under high loads.
Other companies
In Russia there are telescopic loaders from other companies. For example, here you can even find models from the Belarusian company Amkodor-Udarnik. Brands that produce not only telescopic but also simple loaders also supply their products to the country. Thus, among loading equipment you can find quite popular installations from Bobcat, Sennebogen and Merlo.
Bobcat is an American company that supplies mini-special equipment to world markets. The brand produces and sells excavators, loaders, mini-loaders and other equipment for construction and agriculture. Bobcat products also include telescopic loaders. These are neat little units that are very compact and feature quick-change attachments. They are in great demand during construction, especially when it comes to small structures.
Merlo is known for its agricultural loader models, of which there are only two:
- Multifarmer;
- Turbofarmer.
Turbofarmer has a large lifting capacity and boom length. This model has eight modifications. Multifarmer is a less heavy-duty model with only four modifications.
Sennebogen produces tracked vehicles. On Russian markets you can find cranes of this brand, truck cranes, material handlers and other installations. Sennebogen lifting technology is known for its reliability and functionality. It is very durable because every part of any installation undergoes preliminary factory testing.
With so many brands and models, consumers can get confused. How to choose a reliable telehandler? It is known that a correctly selected unit can completely pay for itself within a couple of years. And it has a long service life without repair.
Telescopic loaders vary in lifting capacity and boom length. In addition, each of them comes with attachments.
When choosing, you need to pay attention to a number of details. First of all, you need to decide in what conditions the device will be used and what load-carrying characteristics it needs. The arrow is selected in the same way. In addition, you need to pay attention to the cabin. It should be comfortable and convenient. No details should interfere with the view.
The efficiency of the loader is also very important.
The buyer needs to look at both present costs (the cost of the forklift itself) and costs during operation and possible repairs.
For example, you need to find out what the fuel consumption of a forklift is. All leading brands today supply reliable equipment, but you need to choose it for specific needs.
Agriculture in Russia, as in other developed countries of the world, is the main market for the sale and operation of telescopic loaders. It is here that more than half of all telescopic loaders imported into Russia are used. They gained their popularity due to their versatility. Each telescopic loader model can be equipped with a variety of different attachments to perform different tasks facing builders, logisticians, farmers and mining workers. In agriculture, telescopic loaders play the role of the main loader, with the help of which almost all loading and unloading operations and delivery of cargo within farms are carried out in livestock farming. To fulfill all these purposes, the telescopic loader is equipped with manure buckets to clean the barn or pigsty, then reload, remove and store the manure. To work with silage, a telescopic loader is equipped with a cutting bucket for picking up silage from storage areas and further transporting and unloading it to storage areas. Agricultural forks have a hydraulically driven gripper and are designed for loading and unloading hay and silage. To work with hay bales, various side grips are provided with which the telescopic loader performs loading and unloading operations. The main application of a telescopic loader is the handling of grain and seeds - there is no equal to it in terms of efficiency, which is achieved through speed, efficiency and maneuverability. The telescopic loader is equipped with buckets with a volume of 2 to 4 cubic meters, which allows you to load a grain truck with a trailer in a matter of minutes, assisted by a high-performance hydraulic system powered by a diesel engine. Depending on the required volume of the bucket, the lifting capacity of the telescopic loader is selected; a 2-cube bucket is installed on a 2.5 or 3-ton model, and a 4-cube bucket is installed on a 6-ton telescopic loader. When choosing a bucket, consider not only the weight of the load itself, but also do not forget the weight of the bucket itself, the weight of which starts from 400 kg and can reach a weight of more than one and a half tons. There are many examples when, due to a discrepancy between the dimensions of the bucket and the load capacity, customers complain about the model itself, without seeing or admitting their mistakes.
The second most important area of application is construction, where telescopic loaders perform most of the work of lifting, moving, transporting cargo, as well as lifting people in order to carry out high-altitude installation work. Models intended for construction, having changed the working body, can simultaneously be a forklift or bucket loader, a self-propelled crane and a high-altitude lift for lifting personnel for installation work.
Telescopic loader
This is a universal 4 in 1 construction machine. Laying road slabs with its help is one of the many tasks where a telescopic loader has no equal, unloading slabs from a truck, transporting them to the unloading point and laying them, all this will make a telescopic loader faster than other material handling machines construction machines. Lifting bulk cargo onto the floors of a high-rise building - no problem, a loader equipped with a construction bucket will take the cargo in a matter of minutes, bring it to the unloading site and can unload it even on the 14th floor of a high-rise building! Territory leveling is also not a problem for a telescopic loader, by installing a 4x1 bucket, you can easily carry out leveling, because the telescopic loader is equipped with a transverse frame leveling device, and the operator can always keep the leveling bucket leveled to the horizon. By installing one of several crane booms with hooks on a telescopic loader, you get a full-fledged self-propelled crane that can not only move loads, but also transport them around the construction site. Some models of telehandlers are capable of lifting a load weighing 2 tons to a height of over 40 meters. Depending on the customer's needs, manufacturers offer a choice of crane booms, jibs, hooks and winches. They all differ in their purpose, providing the customer with the choice of the optimal model of attachments. But that’s not all, a telescopic loader can perform the functions of a self-propelled lifting platform; for this, the manufacturer offers a wide range of lifting baskets for personnel with a lifting capacity of up to 1000 kg and width. Using a wide platform, you can quickly and safely install 6-meter wall panels for prefabricated warehouse and industrial buildings and structures. Recently, lifting platforms with a crane installation have become in demand, which makes it possible to deliver both cargo and personnel to a height to the installation site in one lifting cycle, saving time, resources, and in total, this saves construction companies money. To install double-glazed windows at heights within 40 meters, you will need only one telescopic loader, equipped with a lifting platform with a crane boom and a vacuum glass gripper. Having secured the double-glazed window using a gripper, it will quickly deliver workers to the installation site in one lift - this will take the minimum possible time. Control is available to the operator not only from the cab, but also using a radio remote control, which is available for many modern models, and the remote control can be used from a radius of up to 100 meters or while standing on a lifting platform. In general, there is always the opportunity to choose the most convenient place to operate a telehandler; for example, the operator can be on the 10th floor of the building and lift the load to this floor from the ground. On a telescopic loader, control transfer from the cabin to the control panel is available, when one operator, while in the cabin, grabs the load from the ground and then transfers control to another operator located on one of the upper floors of multi-story buildings under construction. This arrangement provides better safety because the loading and unloading processes are under the control of operators in close proximity. Lifting platforms with telescopic extensions can increase the working height of the forklift up to 12 meters, and the tallest telehandler has a working height of over 50 meters! Articulated lifting platform arms provide better reach for hard-to-reach areas. In addition, the telescopic boom allows you to increase the horizontal deflection of the basket from the chassis and, depending on the model, the lifting basket can deviate up to 30 meters from the turning center.
In logistics, telescopic handlers provide loading and unloading processes for various materials. These machines have an undeniable advantage compared to others - it is a horizontal reach, thanks to which it is possible to unload cargo behind an obstacle, for example, behind a ditch. Or another example is to unload the snow by throwing it over the fence using a bucket. A telehandler is used to unload shipping containers because the horizontal reach of 12.5 meters is almost equal to the length of the largest 40-foot container. Telescopic loaders can also load containers themselves, including loaded 40-foot containers weighing up to 35 tons; for this they are equipped with a spreader - a special gripper for containers with hydraulic locks. We especially note utility work, which can be easily and quickly completed with a telescopic loader on your balance. By equipping the latter with a road brush, you can keep your area clean. In winter, when roads need to be cleared, install a snow plow or use a snow bucket. Loading snow into dump trucks is not a problem; the lifting height is sufficient even for the smallest model, with a lifting capacity of 2.5 tons.
In the mining industry, telehandlers are service vehicles for servicing mining excavators, dump trucks and other mining equipment. Telescopic loaders are equipped with a grip for mounting dump truck wheels, the load capacity of the grip is up to 16 tons, the grip diameter of wheels up to 63 inches is more than 4 meters. Using the grip, a telescopic loader can move the wheel in three directions and rotate it without restrictions. Also available are grips for changing hydraulic cylinders of mining excavators and grips for RMK wheeled dump trucks.
Do not forget that a telescopic loader is a full-fledged all-terrain vehicle and all of the above work is performed not only on ideal asphalt concrete, but also on rough terrain. Most telehandlers are equipped with a transmission with two drive axles with limited-slip differentials to improve all-terrain capabilities, but it is worth mentioning that not all, some manufacturers, continue to save money by installing non-locking axles. This can be understood by the make and model of the bridge itself, the most common brands being DANA SPICER and CARRARO are the most common in the world, with spare parts readily available and inexpensive in Russia.
