GL and GLL Presentation 2013 - Isidro Albites

Giving a Generation 2 Presentation
2013 Longview Factory Sales Conference

2013 Loader Sales Meeting
Michael Fleet
Joy Global, Joy, P&H, LeTourneau, Klenz, LINCS II and related

logos are trademarks of Joy Global Inc. or one of its affiliates.
2013 Joy Global Inc. or one of its affiliates. All rights reserved.
CURSO CARGADOR FRONTAL L-2350
Relator: Isidro Albites
2
14-16 May 2013 Giving A Gen 2 Presentation
CONTENIDO CURSO
Objetivos
Seguridad
Filosofia de Diseo
Sistema 24VDC
Sistema LINCS
Software de Apoyo
Sistema Propulsion
Sistema Aire Comprimido
Sistema KLENZ
Sistema Hidraulico

3 14-16 May 2013 Giving A Gen 2 Presentation
Seguridad es NO
tener Accidentes!

Un Accidente es un evento
NO DESEADO que puede causar
dao a la persona o propiedad.
Trabaje de manera segura
SIEMPRE!

SEGURIDAD
6
Existen al menos seis (6) diferentes fuentes de
energia en el Cargador L-1850:
1.
2.
3.
4.
5.
6.
Electrica: Corriente DC de Bajo Voltaje - Hasta 27

Volts
Electrica: Corriente DC de Alto Voltaje Hasta 650
Volts
Electrica: Corriente AC de Alto Voltaje - Hasta 700
Volts
Mecanica: Rotacion de Eje Cardan, Correa
Alternador, etc.
Neumatica: Aire Comprimido
Hidraulica: Aceite a Presion

JGI 50-Series Loader Locations
L-950
L-1150
L-1350
L-1850
L-2350
25 Units
16 Units
56 Units
145 Units
38 Units

-CONFIDENTIAL-
Wheel Loader Competition

Hydraulic & Wheel Loader Product Positioning by Payload Class
Komatsu
PC2000
PC3000
PC4000
PC5500
PC8000
EX1900
EX2500
EX3600
EX5500
6018 FS
6030 FS
6040 FS
6050 FS
6060 FS
R9250
R9350
R995
R996
Hitachi
EX5600
EX8000
Caterpillar
6090 FS
Liebherr
R9800
LeTourneau
L950
L1150
L1350
L1850
L2350
Caterpillar
992K
993K
994H
Komatsu
WA800-3WA900-3
WA1200
Cu. M
10 m
15 m
20 m
25 m
30 m
35 m
40 m
45 m
50 m
Metric ton
US ton
18 t
20 st
27 t
30 st
36 t
40 st
45 t
50 st
49 t
55 st
63 t
70 st
72 t
80 st
81 t
90 st
90 t
100 st

-CONFIDENTIAL-
Truck Match

-CONFIDENTIAL-
Generation 2 Product Line

L-2350
L-1850
L-1350
L-1150
L-950
Engine
Payload
Standard
High Lift
Super
High Lift
1715 KW
(2300HP)
16V4000
QSK60 16V
72,574 Kg
(160,000 lb)
68,039 Kg
(150,000 lb)
54,431 Kg
(120,000 lb)
Engine
Payload
Standard
High Lift
1491 KW
(2000HP)
16V4000
QSK60 16V
54,431 Kg
(120,000 lb)
49,895 Kg
(110,000 lb)
Engine
1193 KW
(1600HP)
12V4000
QSK50 16V
Payload
Standard
High Lift
Std. Bkt.
40.52m3
(53yd3)
Truck Match
290 - 362 t
(320 - 400 T)
Std. Bkt.
30.58m3
(40yd3)
Truck Match
218 - 327 t
(240 - 360 T)

40,823 Kg
(90,000 lb)
38,102 Kg
(84,000 lb)
Engine
Payload
Standard
High Lift
Std. Bkt.
22.94m3
(30yd3)
Truck Match
181 - 236 t
(200 - 260 T)
-CONFIDENTIAL-
Std. Bkt.
899 KW
(1205HP)
16V2000
QSK38 12V
Engine
34,473 Kg
(76,000 lb)
31,751 Kg
(70,000 lb)
Payload
Standard
19.11m3
(25yd3)
Truck Match
109 - 181 t
(120 - 200 T)
High Lift
Std. Bkt.
783 KW
(1050HP)
16V2000
QST30 12V
24,494 Kg
(54,000 lb)
21,773 Kg
(48,000 lb)
13.76m3
(18yd3)
Truck Match
68 - 136 t
(75 - 150 T)
Generation 2 Production Estimates

-CONFIDENTIAL-
FILOSOFIA DE DISEO
12

Longevity
Robust Design
Historically Achieving
60,000+ hrs. of Operation
for More than 4 Decades
Modular Componentry
Common Systems Across
Wheel Loader Line

-CONFIDENTIAL-
Commonality
LINCS II Control System

Low Voltage Cabinet
SR Generators
SR Motors
Cab
Drive Modules
Hydraulic Components
Pumps
Valves
Braking Grids

-CONFIDENTIAL-
DIAGRAMA DE FLUJO SEALES
15

56
ESTANQUE HIDRAULICO
Monitoreo:
Nivel
Temperatura
Presion de Aire
Basket
10
1420 l

16
113
ESTANQUE HIDRAULICO
Valvula de Alivio (14 psi)
Valvula Venteo Automatico
Estanque de Expansion
Valvula Venteo Manual
Cabezales Filtros
Fill Cap
17
114
BOMBAS HIDRAULICAS
Compresor
Bomba #7 (Levante/balde)
Caja P.T.O.
Eje Motriz
Bomba #8 (Direccion)
Bomba #9
(Ventilador/
Soplador)
Bomba #6 (Levante/Balde)
Bastidor Delantero
Bomba #5 (Recirculacion)
Enfriamiento auxiliar
Bomba #4 (Levante)
Bomba #3 (Caja P.T.O.)
Bomba #2 (Accesorios)

Bomba #1 (Levante/Balde)
18
118
Hydraulic Pumps and Controls

Product Line Commonality
Pumps
Variable Displacement Pressure Compensated Piston Pumps
Double Shaft Seal w/Weep Hole
High Temperature Viton Seals
Main Valves and Control Valves
Located in Front Frame

Electro-Hydraulic
No Hydraulics in Cab
Low Pressure Pilot Controlled

-CONFIDENTIAL-
CAJA P.T.O. (POWER TAKE OFF)

20
Reduccion 1:1
Autolubricada
Aceite Filtrado y
Enfriado
CAJA PTO CAPACIDAD 27 LTS Monitoreo Presion
y Temperatura
Enfriador Auxiliar

115
VALVULAS CONTROL LEVANTE Y

BALDE (VALVULAS HUSCOS)
Valvula HUSCO #1 (Spool Doble)
Control Levante y Balde
Valvula HUSCO #3 (Spool Unico)

Levante Solamente
Valvula HUSCO #2 (Spool Doble)

Control Levante y Balde
Las 3 Valvulas son Electrocontroladas

21
127
VALVULA HUSCO
Admision
Alivio Principal
3800 psi
Alivio Principal
3800 psi
Volteo
2000 psi
Recogida
3800 psi
Admision
hacia SOL 4
(800 psi)
Levante
3800 psi
Bajada
2000 psi
Retorno
Retorno
hacia SOL 4
(800 psi)
3800
4000
3800
3800

128
MOTOR VENTILADOR
Motor de Pistones controlado por
Temperatura de Aceite;
Refrigerante; Frenado Dinamico
Sensor RPM

166
Generation 2 Energy Recovery

Stage 4: Excess Energy Transfers to Grids
2000 RPM

-CONFIDENTIAL-
Typical Ball Life and Failure Mode

Expected life to fatigue failure
Life of frame
Frame life typically greater than 80,000 hours (10-15 years) in practice
Typical yearly sales of balls

20-30 balls out of 2400 on machines

-CONFIDENTIAL-
Structures
Caterpillar
994H
P&H Brand
LeTourneau-Series
L-1350
Komatsu
WA1200-6

-CONFIDENTIAL-
Structural-Buckets
Proven Rugged Design
Standard Plate Lip
Multiple Lip Configurations &
GET Options Available
All GET Hardware Matched
to Application and Breakout
Force

-CONFIDENTIAL-
TABLA TIEMPOS CICLOS

HIDRAULICOS
Levante
Bajada en Potencia
12-14 Segundos
9-11 Segundos
Bajada en
Flotacion
6-8 Segundos
Recogida
3-5 Segundos
Volteo
3-5 Segundos
Direccion (Tope a
Tope)

6 Segundos
28
150
Stability
Electric Drive Low Center of Gravity
Superior Stability
Rear Axle 11 Total Oscillation

-CONFIDENTIAL-
Competitive Drive-Power Units

Operates at Varying RPM
Poor Efficiency
High Engine Load Cycle; Short
Engine Life
Hydraulics Responsiveness
varies with RPM
Difficult Accessibility
Much Larger Power Units:
994H: CAT 3516
WA1200: Cummins QSK60

-CONFIDENTIAL-
Ease of Operation
Dual Joystick Controls
Steering
Bucket and Hoist Functions
Right Pedal
Speed Control and Dynamic Brake
Left Pedal
Dynamic Brake and Service Brake
Central Dash Display with Touchscreen Interface
Automated Slip Control
Less Operator Fatigue
Improved Efficiency

-CONFIDENTIAL-
Ease of Operation
Clear Field of Vision
Switch Panel in Ceiling Pod
Pre-wired for 12V and 24V

-CONFIDENTIAL-
33
COMPRESOR
DE AIRE
Compresor Bendix 596

100
ENFRIAMIENTO COMPRESOR DE
AIRE
34
Enfriamiento
Lubricacion
Retorno a PTO

101
TANQUES DE AIRE COMPRIMIDO

Governador
Solenoide 15
Tanque de aire
Tanque del Klenz

103
SECADOR DE AIRE
36
LINEA DESDE
GOBERNADOR
FILTRO
CALEFACTOR
VALVULA DESCARGA
MANOMETRO

102
ACTUALIZACION SISTEMA DE AIRE

37
Brake Pedal
Front Park Brake Solenoid
Fro nt Park Brake Pressure Transduc e r
Front Park Brakes (L&R)
Sense Line
Left Servic e Brake

System A ir Pressure Transduc e r
Fro nt Servic e Bra ke Pre ssure Tra nsduc er
135~115
Purge C MD
O ut
Distribution
GOV
Dryer
Suministro
aire desde
flujo
From C ooling Air Flow
to
Front Fra me
enfriamiento
ducto
delantero
Heated DLU Purge

Va lve a nd Stainless Steel Spring
Front Brakes
Right Servic e Brake

Rear Park Brake Solenoid
Rear Pa rk Brake Pressure Transduc er
Drain valves
Rear Brakes
Rear Park Brakes (L&R)
COMP
596
Left Servic e Brake

Minimum 15 Length
Rear Se rvic e Brake Pressure Transduc e r
Drain valves
Right Servic e Brake

SO L 37
SO L 30
90PSI
REG
.060
A ir Ho rn
C ab C lea n O ut
KLENZ A ir Pre ssure Transduc er
Transductor
de presin
del sistema
Klenz
SO L 15
REG
Hyd Ta nk A ir Dump
KLENZ
Secador con valvula

de nuevo tipo que
permite drenar el
secador y aliviar el
compresor
Hydra ulic Ta nk
A estanque hidrulico
6PSI
.125
SO L 40
KLENZ Box
105
SISTEMA ENGRASE AUTOMATICO

SENSOR PRESION ENGRASE (CICLO= 2500 PSI)
VALVULA CONTROL DE FLUJO
BOMBA ENGRASE
VALVULA VENTEO
SOL 7
ESTANQUE GRASA
MOTOR
HIDRAULICO

VALVULA DE ALIVIO ( 350 PSI)
170
VALVULAS CONTROL DIRECCION

Main Relief 4000psi
Valvula Piloto DANFOSS PVG 32
Valvula Amplificadora DANFOSS
Steering Flow Amplifier

39
151
SISTEMA KLENZ
40
14 Filtros Primarios:
Filtraje Aire Admision Soplador
Filtraje Aire Admision Motor Diesel
4 Filtros Secundarios:
Filtraje Aire Admision Motor Diesel
Filtraje Aire Admision Unidad Aire
Acondicionado Cabina
Unidad contiene un Deflector de Lluvia
0.3

109
KLENZ System

-CONFIDENTIAL-
DIAGRAMA VALVULA DIAFRAGMA

42
Vlvula diafragma
KLENZ Pulse Valve Circuit

Solenoide de
disparo
Pulse Solenoid
Solenoid energized in 40ms intervals by LINCS

base on time set in calibrations.
HT > 60 sec
LT > 240 sec
*Pulsing can be turned off by placing the purge
cycle switch in the off position
Diaphragm Valve
KLENZ Supply
Manifold
KLENZ Tank Transducer
.125
Solenoid energized by un-switched

24v supplied by remote module
when LINCS is booted. When
de-energized the pressure in the
manifold will be vented to atmosphere.
KLENZ Supply
Tank
.60
REG
KLENZ Supply
Solenoid
System Pressure
from Distribution
Tank
90PSI
A tanque hidrulico
To Hydraulic Tank Supply Circuit

111
CILINDROS DE FRENO
FRENOS RECAMBIO RAPIDO
ACTUADOR
FRENO ESTACIONAMIENTO
VALVULA ACTUADORES
FRENOS SERVICIO
VALVULA ACTUADOR
FRENO PARQUEO
1 CILINDRO FRENO POR MOTOR

SOLENOIDE
FRENO ESTACIONAMIENTO
(SOL 34)
107
MANDO FINAL (DRIVER) MODELO 57

Reduccion Total 99:1

Capacidad Aceite 95 l
Sello MFS
Filtrado Aceite Automatico
Aceite MobilGear SHC 460
96
P&H Brand LeTourneau-Series SR Electric Drive

Modular Design
25-30,000 Hr. Major Component Life
HMI
VCU
G-100
51B & 45
Power
Modules
B-40A
-CONFIDENTIAL-
MOTOR
TRACCION MODELO J-2 (DC)
46
500 HP
0-650 VDC
0-1050 A (Armadura)
0-50 A (Campo)
0-2300 RPM
16 Carbones
Monitoreo de Temperatura
por Termistores (X2)
Enfriado con Aire

88
Generation 2 Technology

-CONFIDENTIAL-
SR Drive System (Propel)

-CONFIDENTIAL-
SR Drive System (Braking)

-CONFIDENTIAL-
SR Power Flow
Energy Moves In and Out of the DC Bus (Bank of Capacitors)
To/From Generator
To/From Motors
To Grids
Controlled by IGBTs

-CONFIDENTIAL-
Modular SR Drive Panel

Same for SR Motor or Generator
Common for All Loader Models
L-950/1150:
L-1350:
L-1850/2350:
6 Panels
7 Panels
12 Panels
Scalable - Panels can Run In

Parallel
45.4 kgs. (100 lbs.) Approx. 400 HP
700V Bus
Self-Contained
Water Cooled Cold Plate
Technology

-CONFIDENTIAL-
SR Motors & Generators

-CONFIDENTIAL-
SR Technology Motor Function

Stator has Coils
Magnetic Force Pulls Pole
on Rotor
Vary Torque with Current
and Timing
Requires Fast Switches
and Computer Control
Propel or Braking
Depending on Timing

-CONFIDENTIAL-
SR Technology Generating (Braking) Function

Field in Coil Attempts to
Stop the Pole as it Passes
This Creates Energy and
the SR Component is
Generating Power Either
as Generator or Motor
Braking

-CONFIDENTIAL-
SR Technology
Phase B
Phase A
Phase C
-CONFIDENTIAL-
LINCS II Control and Monitoring System

-CONFIDENTIAL-
LINCS II Maintenance and Accessibility
Central Connection Cabinet

Maintenance Friendly
Self-Contained Modular Design
Din Rail Connectors
Automotive Type ATC Fuses with Blown
Fuse Indicator Lights

-CONFIDENTIAL-
HMI Functionality
Gauge Cluster
Channel Charting
Event Viewing
Channel Forcing
Calibrations
Additional Channel and Event
Log Storage Capacity
Software Upload
Download Logs

-CONFIDENTIAL-
LINCS II User Interface

-CONFIDENTIAL-

During Transition to Braking
Motors become Generators
Braking Energy Transfers from Motors to
Generator
Generator becomes Motor that can Assist
Engine
1800 RPM

-CONFIDENTIAL-

Stage 1: Supply Losses
Satisfy Hydraulic Losses
Satisfy Engine Losses
Shut Off Fuel Supply
0% Engine Load
1800 RPM

-CONFIDENTIAL-

Stage 2: Supply Working Hydraulics
Energy for Lifting Load
0% Engine Load
1800 RPM

-CONFIDENTIAL-

Stage 3: Energy Storage
Driveline Speed Increases
Mass of Drive Train Acts as a Flywheel
0% Engine Load
1800 RPM
2000
RPM

-CONFIDENTIAL-

Stage 4: Excess Energy Transfers to Grids
2000 RPM

-CONFIDENTIAL-

-CONFIDENTIAL-
Fuel Consumption
L-2350
L-1850
L-1350
L-1150
L-950
Gal/Hour
Liters/Hour
Competition
Competition
42.3
160
(130.0)
(493)
36.6
139
(95.0)
(360)
28.7
109
(63)
(238)
22.3
84
(48)
(178)
19.5
74
(30.1)
(114)
Annual
Advantage
8 Year
Advantage
$1,534,750
$12,278,000
$1,022,000
$8,176,000
$686,000
$5,488,000
$514,000
$4,112,000
$185,500
$1,484,000
(Red Mechanical wheel loader Blue= Hydraulic Excavator)

Advantage Based on Fuel at $4.00 per Gallon and 5000 hrs./year
Fuel Consumption Based on LeTourneau at 39% Load Factor, Other Wheel Loaders at 60% Load
Factor and Hydraulic Excavator at 70% Load Factor

-CONFIDENTIAL-
Fuel Consumption
Actual Field Data of L-2350-2210

-CONFIDENTIAL-
Engine
MTU-Detroit Diesel
Cummins
Tier 1 and Tier 2
Operates at a Constant RPM
Fuel Efficient
Reduced Load Cycle
Hydraulics 100% on Demand
Conservatively Rated
Extended Engine Life

-CONFIDENTIAL-
Gear Train
Longview Designed and Manufactured

AGMA Class 10 Gearing
Carburized and Ground Gearing
Long 25,000 + Hour Life between Rebuilds
Synthetic Oil for Extended Change Intervals

-CONFIDENTIAL-
Safety Feature Walk Around
E-Stops
Safety Labels
Rear Ladder Access
Visibility
LED Lighting
Anti-skid Surfaces
Separation of High/Low Voltage
Cabinets
Wrap-around Cab Walkway
Handrails in all Maintenance
Areas
Ground Level Accessibility of
Battery Box
Optional Fire Suppression
Optional Rear View Camera

-CONFIDENTIAL-
Generation 2 Lighting
100% LED Lighting
Work/Operating Lights:
Ten Forward & Two Rear
Three Different Light Patterns

for Maximum Visibility:
Wide
Flood
Trapezoid
Front Frame
Ladders
Engine Bay
Tail Lights
Cab Interior lights
Efficient & Reliable

-CONFIDENTIAL-
Ergonomic Operators Cab

-CONFIDENTIAL-
Structural-Ball & Socket

Spherical Bearing Surface Absorbs
Loads from All Directions
Replaceable Hardened Bronze Liners
Shims for Clearance
Automatic Lubrication
Simple Maintenance and Long Life

-CONFIDENTIAL-
Electrical Braking and Engine/Hydraulic System Cooling
L&M Mesabi Heat Exchanger

Split-flow, Side-by-Side
Dedicated Oil-cooler w/Circulation Pump
Independent Thermostatically Controlled Fan
Swing Away Guard & Braking Grids
Auxiliary Oil
Cooler
(Optional)
Hydraulic Oil
Cooler
Engine Radiator
*Mesabi is a trademark of L&M Radiator, Inc.

-CONFIDENTIAL-
P&H Brand LeTourneau Electric Drive

vs. Mechanical Drive
Lower Operating Cost
Lower Fuel Consumption Extended Engine Life and Lower
Emissions
Favorable HP/Weight Ratio
Longer Tire Life
Operator Friendly
Increased Stability; Low Center-of Gravity
No Primary Brake Wear/Maintenance
No Transmission, Torque Converter, Transfer Cases, Differentials,
Wet Disc Brakes, and Associated Cooling Systems (60% Less
Moving Parts)

-CONFIDENTIAL-

-CONFIDENTIAL-

GL and GLL Presentation 2013 - Isidro Albites

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Giving a Generation 2 Presentation

2013 Longview Factory Sales Conference

Joy Global, Joy, P&H, LeTourneau, Klenz, LINCS II and related

CURSO CARGADOR FRONTAL L-2350

Relator: Isidro Albites

2013 Longview Factory Sales Conference

2013 Longview Factory Sales Conference

2013 Longview Factory Sales Conference

Electrica: Corriente DC de Bajo Voltaje - Hasta 27

2013 Longview Factory Sales Conference

JGI 50-Series Loader Locations

2013 Longview Factory Sales Conference

Wheel Loader Competition

2013 Longview Factory Sales Conference

2013 Longview Factory Sales Conference

Generation 2 Product Line

2013 Longview Factory Sales Conference

Generation 2 Production Estimates

2013 Longview Factory Sales Conference

2013 Longview Factory Sales Conference

2013 Longview Factory Sales Conference

LINCS II Control System

2013 Longview Factory Sales Conference

DIAGRAMA DE FLUJO SEALES

2013 Longview Factory Sales Conference

2013 Longview Factory Sales Conference

2013 Longview Factory Sales Conference

Hydraulic Pumps and Controls

Main Valves and Control Valves

Located in Front Frame

2013 Longview Factory Sales Conference

CAJA P.T.O. (POWER TAKE OFF)

2013 Longview Factory Sales Conference

VALVULAS CONTROL LEVANTE Y

Valvula HUSCO #3 (Spool Unico)

Valvula HUSCO #2 (Spool Doble)

Las 3 Valvulas son Electrocontroladas

2013 Longview Factory Sales Conference

2013 Longview Factory Sales Conference

2013 Longview Factory Sales Conference

Generation 2 Energy Recovery

2013 Longview Factory Sales Conference

Typical Ball Life and Failure Mode

Typical yearly sales of balls

2013 Longview Factory Sales Conference

2013 Longview Factory Sales Conference

2013 Longview Factory Sales Conference

TABLA TIEMPOS CICLOS

2013 Longview Factory Sales Conference

2013 Longview Factory Sales Conference

Competitive Drive-Power Units

2013 Longview Factory Sales Conference

2013 Longview Factory Sales Conference

2013 Longview Factory Sales Conference

2013 Longview Factory Sales Conference

2013 Longview Factory Sales Conference

TANQUES DE AIRE COMPRIMIDO

2013 Longview Factory Sales Conference

2013 Longview Factory Sales Conference

ACTUALIZACION SISTEMA DE AIRE

Front Park Brake Solenoid

Fro nt Park Brake Pressure Transduc e r

Front Park Brakes (L&R)