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648 June 2011
Wheel loader Bucket capcity 4,8 m3 Operating weight 26,6 ton Net power 245 kW
BY CLAUDIO MARINI
WALKAROUNDMACCHINE di
VOLVO
L180G
Power kW
800 280 260
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Rpm 2000 2200
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Torque daNm
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n I DESIRE TO BUY IT
Today, the best machine in its category...who spend more, spend less! 11 17
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VOLVO L180G
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n THE PLUS BY COSTRUZIONI 1
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Innovative, highlyperforming Engine Tier4 Interim (12,8 l) With high torque and power, at the lower RPM on the market External EGR, cooled, with electronic control. Injection with Unit pump at 250 MPa Volvo Optishift engine and transmission with standard Lockup low stressed Reduction gears in wheel
hubs Oil bath parking brake into the gearbox The best hydraulic system on the market 9 Three Full Load Sensing pumps, with delivery cutoff at low and high pressure, combined with a new Closed-center control valve 20 electroproportional (no hot oil in the cab), pressure compensated (Flow sharing), to convey higher push to the wheels,
to reduce consumptions and to allow boom and return to dig end stroke setting from the cab Smart and sturdy structure 11 Parallel to the ground equipment lifting and lowering, plus an exclusive “one or two-way flot” 12 Long wheel base Wide axle oscillation (15 °) and more ground clearance 13 (61 cm) Back (not side) air suction flow to reduce radiators
WALKAROUNDMACCHINE di PECULIARITIES 2
Variable geometry turbocharger with water-cooled shaft, protected by overspeed
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Excellent torque (202,4 daNm) at the lowest rpm on the market (1.000 rpm)
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Exhaust gases after-treatment, with DPF and fuel post injection (without problems due to Urea)
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braking system, in order to minimize stress to the gearbox and not to move the foot from the accelator
Torque converter with low stall conversion ratio (1,86:1) for minimium stress on gearbox, differential and axle shafts Torque converter with “free stator” to reduce fuel consumptions (in addition to the standard Lock up) and to increase load&carry speed
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Exclusive steering system, proportional to the effort, by engaging one or both cylinders
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Energy recovery during booms lowering
Optishift system with RBB: reverse gear with automatic
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Axles oil temperature sensors as standard
No competitors for the most powerful and efficient
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clogging 4,8 m3 sturdy bucket which, with teeth and cutting edge made in Brinnel HB 500 steel, weights 2,94 ton 18 New steering cylinders “high” location New side air filter intake allowing excellent rear visibility 14 Sparing and ergonomic driving Smart accelerator allowing proportional to fuel consumption actuating effort
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4-level new transmission cut-off. High power air-conditioning and defrosting system Low noise level 70/108 dBA Rear video-camera as standard Long windshield wiper, 80 cm, allowing better visibility in case of rain Easy maintenance environmental-friendly and safety New integral hood profile, electrically-lifted, also in case of open rear hatch
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Satellite Care Track as standard. Advanced diagnostic system Bleeds strictly filtered and protected by dropping to the ground Remote drain pipes with ecologic valves Grouped maintenance points New batteries location in the articulation area
VOLVO L180G
n ADVANCED TIER 4 INTERIM ENGINE TECHNOLOGY (WITH NO UREA POST-INJECTION)
n Variabile geometry turbocharger to increase power at low rpm
An electronically-controlled electro-mechanical actuator moves the “collar� which reduces the gases outlet section. Their speed is this way boosted, also at low rpm, thus also increasing, as a consequence, the turbocharger speed, which increases the specific power Collar which reduces the gases outlet section thus increasing their speed also at low rpm. The engine electronic control activates the collars also in case of high feeding pressure peaks, in order to avoid impeller overspeed and to make combustion process uniform The two impellers connecting shaft is not simply lubricated, but also cooled by means of a water circulating system (reliability). Besides, a warning message to wait some seconds before switching the engine off appears on the dashboard. This to allow the gradual turbocharger cooling (thus avoiding seizings)
WALKAROUNDMACCHINE di n Unit-pump injectors at 250 MPa (+ 60% compared to Common rail system) increase the nebulization, improve combustion, reduce harmful emissions and fuel consumption -+
The injector electronic control for timing and fuel injection rating Injection system
Pump
Injector Low pressure pump
The fuel pump, directly located on the injector head, eliminates high pressure pipes (typical of Common rail systems) and any eventual seal problems, allowing even to double the injection pressures without risks
n 4 valves per cylinder improve the torque at low rpm and the combustion process (less consumption) n The over head camshaft facilitates maintenance operations to regain the “valve play” No additional plays due to intermediate pushrods
n The “replaceable” sleeves eliminate costs for engine re-bore It is only necessary to remove and replace them with new ones , without need to re-bore the old sleeves (also changing pistons)
The engine “breathes” better at low RPM and “pushes” more, since greater air quantity enters in less time, fuel burning is better performed
VOLVO L180G
n Compliance with antipollution regulations with external, cooled, electronically-controlled EGR system (exhaust gas ricirculation) + DPF EGR functioning The exhaust gas recirculation, inert at this point, reduces the peak combustion temperature and limits the nitrogen oxyde emission (NOx harmful gas) which is proportional to it. Advantages of the electronic control The EGR electronic control allows to recirculate the gas only in cycles with oxigen excess and does not penalize the minimum rpm (stable); besides, it avoids the discharge valves double lifting wear of the “continuous “EGR” The advantage of recirculating cooled gas The cooling allows less gas volume to be recirculated thus avoiding cycles in oxygen shortage conditions
EGR gas/water radiator
The gas recirculation, electronically controlled, is actuated by an electric small motor, which, by opening a diaphragm, meeter the recirculation from gas discharge to pure air inlet collectors
Meter (Venturi) of the recirculated gas volume
10 Costruzioni June 2011
WALKAROUNDMACCHINE di n Self-regenerating DPF (Diesel Particulate Filter) with fuel post-injection
D
E DPF Ceramic filter
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Advantages compared to Urea SCR system:
Thermal insulation
550째-650째 - no tank kept at 4째/25째 - no contamination with iron traces - no storage additional costs - no additional refueling
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Electronically-controlled unit to atomize water/diesel oil mixture High-flow low pressure compressor for the air necessary to the regeneration process Low-flow high pressure compressor for the atomizing air Injector and spark plugs for air/diesel oil mixture lighting Duct which takes to the DPF the greater air volume requested for filter regeneration Air dryer Tanks for regeneration air
Energy saving: an electric clutch disengage the compressor, in order to save energy when air compressed is not needed B
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Energy saving: a valve short-circuits the air between inlet and compressor outlet, in order to save energy when air compressed is not needed
Torque daNm
280 Power kW
VOLVO L180G
n THE RESULT OF THIS ENGINE TECHNOLOGY: OUTSTANDING TORQUE (AND POWER) AT THE LOWEST RPM ON THE MARKET n Higher production per fuel liter +9% ton/liter (LOAD&CARRY ON LEVEL GROUND) 2200
260
2000
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1800
220 200
Torque L180G Power L180G Torque L180F Power L180F
1600
Torque 2024 daNm, +27%
180 1400
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Max torque rpm at 1050 g/min, -40%
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140 120
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800
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Piston linear speed 7,1 mps only (engine durability and reliability)
2000
Rpm
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n Power 254 kW +4,7% (high performance) B
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n Displacement 12,8 l +5,5% (low exploitation and power reserve)
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nHIGH-CLASS ENGINE DETAILS
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Centrifugal filter on the cylinder head vent with oil recovery in the oil sump, to reduce engine oil consumption and to avoid dropping to the ground
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3,5 cm Polyvee belts automatic tensioning (no maintenance) (higher traction and durability compared to V-belts)
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Deep sump to guarantee lubrication suction, suitable for earth moving (not road trucks) machines, operating on steep slopes
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Cylinder head bolts with spring and sump elastic gasket to reduce noises and vibrations
Engine control unit elastic mounted to avoid vibrations, detached from the engine block and cooled by fuel circulation system to avoid overheating
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Cooling capacity only partially exploited by the big-size coolant radiator and by the fan which, on average, turns at 50% of its maximum speed
1,21 m H
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F 0,86 m H Rear-sucked (not from the sides) air flow and expelled laterally and upwards to have an efficient laminar air access flow on the radiators (non whirling typical o blowing fans) to reduce clogging of radiators, which only partially receive the dust caused by tyres.
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“Hinged� DPF “ allowing easy side tilting, which assures the access to the beneath engine parts The DPF is thermoinsulated and made in
rustproof steel
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3 oil filters and two diesel big filters on one side
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Hydrostatic thermocontrolled fan (to reduce noise level and fuel consumption, as well as to facilitate to quickly reach the optimal temperature)
VOLVO L180G
n HOW TO SLIGHTLY STRESS THE TRANSMISSION (RELIABILITY), MAKING IT EFFICIENT (LESS CONSUMPTION AND FAST CYCLES)
n Converter stall conversion ratio exceptionally low 1,856:1 (-13%) Torque converter functioning: as the name itself, it increases the torque, reducing the output driveshaft speed. The lower the output torque, the less the stress to the downstream components. On the Volvo L180G the stall conversion ratio is exceptionally low, if compared to the previous model as well as to all competitors’ ones. This noticeably reduces the stress on gearbox, differential and axle shaft. Since the final torque increase (and speed reduction) is by Volvo obtained at final drives level, located after the axle shafts (in the wheel hubs), stress on these parts is reduced too. In other words, competitors increase the torque before, whereas Volvo does it at the end in order that all power transmission is less stressed 1
Engine-driven impeller
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Turbine impeller
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Grooved shaft connecting the turbine to the transmission
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Stator
Oil circulation 2
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4 5 Oil circulation 6
3 Impeller
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Connection between Lock up clutches and turbine impeller 3
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Lock up clutches 4 2
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n Converter LOCK UP AS STANDARD
n Converter “free” stator
Lock up functioning. When digging into the bank, the pump impeller, connected to the engine by a shaft, runs at high speeds, while the turbine, connected to the tyres through the gearbox, stands almost still. Both impellers are immersed in oil, therefore the “pump” impeller pushes oil on the “turbine” trying to make it run at its same speed. When the machine moves at high speed, instead, the running speed of the two impellers is almost the same. At this point, the Lock up clutch, which makes the two impellers shafts rotate together as if they were a unique block, is engaged, to avoid rpm loss between engine and transmission. In this phase, the converter cools off and the machine consumes less fuel
“Free” stator functioning. A traditional stator (fixed) takes the oil coming from the turbine and conveys it to the pump, addressing it at best in function of fins inclination and engine speed. When machine speed increases, before Lock up engagement, there is a phase characterized by great energy waste (oil heating in the converter), during which the conventional stator is “fixed” between the impellers, which instead runs fast. In this phase, Volvo stator free itself and and rotates together with the impellers reducing loading losses, oil overheating and fuel consumptions
WALKAROUNDMACHINE by
n Power not dispersed in the converter allows to run faster, also uphill
n Less stress on axle shafts n Better oil cooling
n End final drives in wheel hubs (not in the axle-center) Pressure to lower the accelerator (potentiometer) increases (mechanical system) over 1.700 rpm, advising the operator that consumption is exceeding
n The smart accelerator avoids useless consumption Axle shaft
n OPTISHIFT with RBB (automatic braking system when reversing direction) RBB (Reverse By Bracking) function. Activating the direction reverse lever on the steering wheel, brakes are automatically applied, avoiding clutches in the gearbox to slip (durability) or the movement of operator’s foot away from the accelerator June 2011 Costruzioni 15
VOLVO L180G
n 3 FULL LOAD SENSING PUMPS COMBINED WITH A PRECISE CLOSEDCENTRE CONTROL VALVE, FOR HIGHER “DRAWBAR PULL�
n The not-hydraulically wasted power is used for the rimpull against the bank or for the cycle speed
The flow cut of the 3 pumps with manipulators in neutrum and at the highest pressure in the circuit (it avoids flow leakage through pressure relief valves) allows power saving equal, in the stall moment, to the total installed power
Volvo piping which can bear 420 MPa
Fluid load waste are proportional to flows, not to pressures, therefore reducing the former ones and increasing the latter ones, efficiency increase being power generated the same
n Higher efficiency in the hydraulic power use with better performances: pressure increase, flow decrease and bucket cylinder diameter reduction
n Hydraulic regeneration during booms lowering
n No steering no consumption
The oil exiting from the lifting cylinders bottom plate is recirculated on rod side, without involving the pump, thus saving energy
WALKAROUNDMACHINE by n Less steering wheel rotations,engaging one or two cylinders according to the effort The hydraulic tank located behind the cab and “high” above the pumps (not in the articulation) avoids cavitation (reliability)
The steering circuit is fitted with a double Load sensing system: the priority pump, which supplies oil to the equipment when not used by the steering system, and the steering cyilinder actuation system, both driven “only” under load (otherwise only one cylinder is activated). This system facilitates steering precision and absence of shocks “G” Series “F” Series Flow
New Orbitrol steering pump driven by the steering wheel through the steering column
Steering wheel rotation
Priority Pump P2 steering/equipment: 31 MPa (previously 24 MPa, +29%) Pump P3 fan/utilities: 202 l/min (previously 190 l/min) 25 MPa (previously 21 MPa, +19%) 77 l/min (ex 83 l/min) Pump P1 tool: 29 MPa (previously 26 MPa, +11,5%) 217 l/min (previously 247 l/min)
Volvo transmission
Volvo axle shafts
Volvo engine
n “Entirily” BUILT BY VOLVO Quality guarantee and outstanding components coupling
VOLVO L180G
n SMART ARCHITECTURE AND STURDY STRUCTURES FOR LEADING PERFORMANCES n “Parallel-to-the-ground” tool lifting and lowering (optimal for pallet and forks)
n Excellent breakout force 22670 daN, +10% (with bucket 4,8 m3 )
n Excellent bucket pin height 4,47 m
(4,96 m with extended boom)
n Outstanding bucket weight with teeth and cutting edge (4,8 m3) 2,94 ton Sturdiness and wear resistance Hard HD500 Brinnel for cutting edge and corners (durability)
WALKAROUNDMACHINE by
Automatic-engaged boom suspension over 5 kmph as standard
Axial-hinged rear axle shaft (with no intermediate New better protected cradle) to keep the machine centre of gravity low rear lights
The new “side” location of the air filter suction eliminates the “mushroom” on the hood allowing better rear visibility
n “Long” wheel base 3,55 m for excellent stability
Elastic steering endstroke
L1 80 F
VOLVO L180G
n New steering cylinders position (“high”) and articulation structural supports
n Cylinders inserted in the rear module to increase stability
8 mm plate to protect fuel tank
15°, 61 cm
n 15° ( 61 cm) axle oscillation for optimal stability
New batteries position, protected and easy to access in the articulation Spring-applied and hydraulicallyreleased parking brake, protected and in oil bath inside the gearbox (no maintenance required)
New more powerful batteries 170 Ah (previously 140 Ah)
Each tool pin “straddle�-mounted (supported at both ends) for higher reliability
55 cm Gaskets to prevent debris from entering all booms pins
n High ground clearance 55 cm (thanks to final drives in wheel hubs)
L180G Clear warning messages (not through codes)
Adjustable and telescopic steering wheel
Greasing nipples on hinges
Waterproof-membrane push button panel 16 kW heating, AC 7,5 kW, with 9 m3/min flow, through 13 adjustable gates
Front differential lock at 100%
n COMFORT AND NOISELESS DRIVING n The most powerful air conditioning system
WALKAROUNDMACHINE by
Suspended together with the seat controls No oil (hot) inside the cab thanks to the electro-proportional controls and easy cab detachment for extraordinary maintenance
Self-winding safety belt
All seat adjustments (heated as standard)
VOLVO L180G
Two roof lamps with automatic switching at door opening
Radio
Two hagers
Noiseless
n Electro-proportional controls and exclusive one-ways floating booms, with convenient pre-selections Thermal-insulated plastic roof, with drains to avoid dropping on glass windows
Automatic shifting gear selection for better performances or fuel saving
DPF regeneration Automatic Downshifting to 1a gear level
Rear video camera as standard
Rear video camera monitor
Pre-selection from driving seat of absorbed endstrokes booms lifting/lowering and bucket roll-back on the ground Well-inclined stairs Traditional and “oneway� (exclusive) floating booms
Booms suspension engagement 12 Volt socket for mobile phone recharging
Curved, antiglare windshield with long wiper blade (80 cm) for optimal visibility in case of rains
Easy to clean external cab air filter
80 cm
Angle sensors on bucket and booms
Documents compartment with key
VOLVO L180G
n EASY AND SAFE MAINTENANCE
“Book” Hinged radiators for easy cleaning
Easy side panels disassembly
Practical hatches spring holding devices (inside hinges)
PS oil pressure check points
n Hood lifting without fear of damaging the open rear hatch
n Easy diagnostics also from the satellite Care Track devices as standard
Wide no-slip surfaces
Batteries disconnect key and button for hood electric lifting
VOLVO L180G
nQUALITY DETAILS for reliability, second-hand value and safety
n Grouped and easy to access filters
Axles oil temperature sensor
Impurities sensor in the water/fuel separator (warning light on dashboard)
Brakes wear check
n Excellent care in the electric layouts of hydraulic circuits, in their protection and sturdy support Teflon hood endstrokes
n Easy to access, remote and environmental-friendly fluids drains
Emergency steering pump
Dust-proof fender
n Filtered breathers to reduce oil consumption and to avoid dropping to the ground