crusher for payloader

Crusher for Payloader: Integrating Crushing Solutions with Wheel Loaders

The integration of a crusher with a payloader, commonly a wheel loader, represents a significant innovation in on-site material processing. This setup transforms a standard loading machine into a mobile, dual-purpose unit capable of loading, hauling, and crushing materials directly at the source. It is primarily employed in applications like demolition, construction site clearance, quarry operations, and road work to reduce transportation costs, minimize material handling steps, and improve overall operational efficiency. By attaching a crusher bucket or a jaw crusher module directly to the loader's arms, operators can process concrete, asphalt, rock, and natural stone into reusable aggregate on the spot.

Key Configurations and Their Comparison

There are two primary methods for equipping a payloader with crushing capabilities: the Crusher Bucket and the Dedicated Jaw Crusher Module. Each offers distinct advantages depending on the scale and requirements of the project.

Feature	Crusher Bucket	Dedicated Jaw Crusher Module
Integration	Directly replaces the standard bucket on the loader's arms.	A more permanent frame-mounted attachment or semi-fixed unit, often requiring specific mounting kits.
Mobility & Flexibility	High. Easy to attach/detach; allows quick switching between loading and crushing functions.	Moderate to Low. Typically a more dedicated setup; switching back to standard loading is less frequent.
Output & Production Rate	Lower to Medium. Ideal for smaller volumes and intermittent crushing (e.g., 10-50 m³/h depending on model/material).	Medium to High. Designed for higher, more consistent production over longer periods.
Best Suited For	Demolition sites, small-scale recycling, trench backfill preparation, processing natural stone in quarries for selective material sizing.	Larger-scale demolition projects, fixed or semi-fixed recycling yards attached to a quarry or landfill site where the loader primarily feeds/crushes.
Cost Implication	Generally lower initial investment; utilizes existing carrier machine.	Higher initial investment but often better cost-per-ton efficiency for continuous operation.

A critical operational note is that not all wheel loaders are suitable for crusher attachments. The machine must have adequate hydraulic flow (measured in liters per minute), pressure (bar), and structural strength at the attachment points. Manufacturers like MB Crusher (for crusher buckets) and GIPO (for modular crushers) provide specific compatibility charts matching their attachments to loader models from Caterpillar, Volvo, Komatsu, and others.

Real-World Application Case Study: Demolition Recycling in Germany

A prominent demolition contractor in North Rhine-Westphalia was tasked with clearing a 20,000 m² industrial site containing old factory buildings with reinforced concrete structures. The traditional method involved using excavators with hydraulic breakers to demolish the structure, loaders to move debris, and then transporting all waste to an off-site stationary crushing plant—a process involving high transport costs and tipping fees.

The contractor deployed two large wheel loaders (a Volvo L350H and a Caterpillar 986K) equipped with MB America's BF135.8 crusher buckets. The process was streamlined:

1. Demolition: High-reach excavators performed initial top-down demolition.
2. On-Site Crushing: The equipped wheel loaders picked up the concrete debris and processed it directly in the crusher bucket.
3. Material Reuse: The output material was separated into 0-30mm fine aggregate for site road sub-base and 30-70mm coarse aggregate for backfill.

This direct integration eliminated approximately 500 truck journeys to an external crushing facility. The project achieved over 90% material recycling on-site, reduced overall project time by an estimated 30%, and turned waste disposal costs into savings by creating valuable in-situ construction material.

Frequently Asked Questions (FAQ)

1. Can any wheel loader operate a crusher bucket?
   No. The loader must meet minimum requirements for weight counterbalance, hydraulic flow rate (typically above 150 l/min for smaller buckets and over 300 l/min for larger ones), and pressure stability provided by auxiliary hydraulic circuits or specific kits supplied by both the loader dealer and attachment manufacturer.

2. What are the main maintenance concerns when using a crusher on a payloader?
   Key maintenance focuses on wear parts specific to crushing (jaws/manganese teeth) which require periodic inspection/replacement based on processed tonnage; intensified filtration of hydraulic oil due to increased system stress; frequent checking of hose lines for abrasion; monitoring of attachment pivot pins/bushings; ensuring proper greasing schedules per manufacturer specifications.

3.How does crushed material quality from these attachments compare to stationary plants?
For most base-layer applications like sub-base or backfill—the primary use case—the quality is excellent when using modern jaw-type attachments which produce well-graded aggregate with controlled sizing via adjustable output grids.Crushing buckets may produce slightly more elongated particles compared to cone-type stationary plants but remain within specifications set by bodies like ASTM or local road authorities.

4.Is operator training different when using such an attachment?
Yes.Significant additional training is required beyond standard loading operations.Training covers safe operation during crushing cycles including managing flyout risks from feed materials;proper feeding techniques avoiding oversized uncrushable objects that cause jams;understanding optimal engine RPM settings maintaining consistent hydraulic power rather than relying solely upon pedal inputs used during typical loading cycles

5.What determines whether I should choose this solution over hiring mobile tracked crushers?
This integrated solution excels where space is limited,mobility needs are high,and tasks alternate between moving/loading materials intermittently throughout day.If your project involves continuous high-volume production exceeding ~100 tons/hour requiring precise final product specification then dedicated track-mounted units become more efficient despite higher mobilization costs