24 minute read
SHAW’S WIRE ROPES IRON TEST
by nzlogger
Story & Photos: John Ellegard
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EST 1909EST 1909EST 1909 THE SUPPLIER TO NEW ZEALAND HEAVY INDUSTRY THE SUPPLIER TO NEW ZEALAND HEAVY INDUSTRY THE SUPPLIER TO NEW ZEALAND HEAVY INDUSTRY
Gisborne-based BBL Logging is among the first in New Zealand to put the Next Generation Cat 538 LL to work.
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A good 11m reach means fewer movements on the skid with the Next Generation Cat 538.
IT SEEMS LIKE ONLY YESTERDAY THAT
we were testing the all-new Cat 538 tracked forestry machine after it had just been introduced and yet, just four years later we’re in the bush eyeing up its successor – the Next Gen 538.
Back in 2017 we got to grips with one of the first early generation 538’s to go to work in New Zealand with Goodman Logging in the Kinleith Forest, performing loading duties on the skid and also shovelling out in the cut-over. Even though it wasn’t designed for that letter role it still proved to be a major step forward over its predecessor, the longserving 320 DFM.
This time we’re with BBL (Big Bark Logging), south of Gisborne to check out what has changed in the Next Generation Cat 538 and how much difference it’s made to everyday operations.
There are two versions of the 538, the low cab General Forestry model and the high cab Log Loader, which is the version that appeals to a large number of Kiwi logging contractors because the extra viewing height enhances safety when performing skid duties, although buyers can also get the LL model with a low riser.
That’s the version BBL’s Tony ‘Irish’ Shanahan has put to work in one of his two crews, currently operating in the Kopua Forest, situated on the northern flanks of the imposing Wharerata range.
Caterpillar has a strong following among logging contractors in New Zealand, but ‘Irish’ is a pragmatic fellow and has spread his purchasing favours across numerous brands over the years, tending towards whatever machine suits the allotted task. His purchase of the Next Gen 538 LL follows a similar path.
“I had an old guarded-up Komatsu working in that role before, but with the cost of converting excavators these days it made sense to go for a purpose-built forestry loader, plus it’s just about impossible to get into a build shop now,” says ‘Irish’. “And the price of the Cat was pretty good.”
His 538 arrived almost ready to go into the forest, apart from getting the local TerraCat team to add some extra railings behind the cab to make it safer when people are up on top of the bodywork, as well as fitting the Ensign 1730 grapple.
With long lines forming for any sort of new equipment, ‘Irish’ was fortunate to be
close to the front of the queue for the new Cat, being one of the first to take delivery of a Next Gen 538 in New Zealand in August. Having clocked up a couple of hundred hours already, the BBL crew has had time to assess the merits of the Next Generation updates and ‘Irish’ is very complementary: “It’s going really well and the operator is very happy with it – he’s driven 538’s before but this being the new version, he’s very impressed with it.” And yet, looking at the new Cat, it doesn’t really appear much different to the Goodman machine we tested four years ago. So what’s changed? Externally, the most obvious change is the redesigned forestry cab, which stands out through the larger flush-mounted glass screens (the front being extra-thick polycarbonate so no heavy guarding bars now) and smaller cab pillars that allow in much more daylight and increase allround vision – about 50% greater overall visibility than the previous 538, according to Caterpillar. The cab is also 25% larger than before, providing much more elbow room and BANNER 4BANNER 1BANNER 1 additional fore and aft space. That’s good,
SERIOUS POWER FOR BIG TIME LOGGERS
ALWAYS SWING A BIG STICK
Improved track speed helps the Next Gen Cat 538 get around the skid quicker, making it more productive.
because the previous model did feel a wee bit tight inside – especially for larger operators – and this 538’s regular man on the controls, Zak Parker, says he definitely noticed the difference when first getting into his new machine.
“The old one was very cramped and door was too small, but this one is way roomier and the front screen doesn’t come right up against your knees,” he says.
Rear-entry cab coming
Like the Goodman loader we tested in 2017, this one also has the ladder up to a side entry door sitting on top of a 1.22 metre riser, which tilts forward for transporting. It’s easier to get in and out, due to the wider and taller door and extra space in front of the operator’s seat. Caterpillar has also painted the hand grabs black instead of yellow to make them easier to locate. But where’s the rear-entry? Wayne Baker, Manager Forestry Industry for TerraCat, says the rear-entry cab option is a late arrival and probably won’t be seen here until the New Year.
Personally, I prefer the rear cab entry from a safety point of view because there’s less potential for the operator to fall. Especially given that this Next Gen model is slightly higher than the previous one.
The reason? Well, the eagle-eyed might have spotted the bigger high & wide track base, which has improved ground clearance by 15%, now 758mm against the old machine’s 660mm. That means the Next Gen machine is better placed to clear stumps and lumps on the skid and even out at the cut-over if it needs to go and help with shovelling.
The track base is longer than before, too. It’s been stretched out from 4,555mm to 4,665mm to provide a steadier platform
Above left: The upgraded electro-hydraulic system lifts productivity while reducing fuel consumption. Above right: Softer feel to the controls makes for more precise handling. Right: Increasing the track length, doubling the size of the fuel tank and moving it to the back of the machine results in greater stability for the Next Gen Cat 538.
when reaching out to grab heavy loads. Particularly useful for offloading a 5-axle trailer from the back of a log truck.
Touching on the new cab again, you may have noticed from the photos that Caterpillar has redesigned the body layout next to the boom so that even with this left-side-entry design there are still steps placed next to the boom that lead up to the top of the machine, in readiness for the rear-entry option. The other thing to note is that the bodywork on top of the engine is now completely flat, with no protruding cover – you lift up a trapdoor that sits flush with the rest of the bonnet to access the engine.
The fuel tank has moved to the back of the machine and has more-than doubled in size to 990 litres so that it can now act as the counterweight when fully topped up, allowing for the steel counterweight to be reduced by almost half. The DEF tank is also repositioned under the first step by the boom.
But if these were all the changes being made, Caterpillar wouldn’t have gone to the bother of calling it a Next Generation model. Our experience of other Next Generation Cats – namely the 325 and 336 – has taught us to expect a lot of hidden upgrades in the electronic and hydraulic systems.
You see, when Caterpillar launched the first 538 four years ago it hadn’t yet completed the development of the Next Generation systems that feature in the latest models. The first 538 was good, but not as good as it could have been. A bit cramped in the cab. Not quite as responsive. Not quite as efficient. And not as fast.
Has the Next Generation solved those issues? Have they ever!
We’ve already noted how the cab has been given a dramatic makeover and we’ll get into more detail shortly. But it’s those hidden BANNER 3BANNER 1BANNER 1 upgrades that really make this an all-new model.
One of the most significant changes to the Next Gen 538 is the move to a new electric-over-hydraulic control system, which provides about 10% more swing torque, says Caterpillar. That may not sound like much, but in practice it works really well, as it builds on the improved hydraulics that were developed for the earlier generation 538. Those previous changes included a larger main hydraulic pump to allow the engine to effectively operate at lower revs, along with a new back-to-back main hydraulic control valve design that reduces oil flow restrictions to boost response. Combine those changes with snappier electro-initiated controls in the Next Gen machine and the feeling is way better according to Zak.
Smoother and more precise
He says it feels faster, smoother and more precise in the way the controls work “not too touchy, like some other machines”. Changes to the smart mode programme automatically match the engine and hydraulic power to suit the working conditions, which reduce fuel consumption by a further 5%.
‘Irish’ likes the sound of that, saying, “5% would make a huge difference over the course of a year, especially with the price of diesel these days”, though he did admit he hasn’t actually checked on the PRODUCT LINK™ system yet to see what it’s doing. TerraCat expects fuel burn around 14.5- to 15-litres per hour, depending on which mode they are using. Our guest Iron Tester, Tapu Dixon, who also runs an older 538 says he averages in the high teens, which is not unexpected with the bigger wood harvested on the East Coast, so anything less would be a bonus. Zak says he only needs to fill the tank once a week, although it was suggested he should do it more often to retain the weight in the tail.
SERIOUS POWER BIG TIME LOGGERS
Above left: Slew has increased by 10% in the Next Generation Cat 538. Above right: The first Next Gen Cat 538 log loaders arriving in New Zealand have side entry, but rear-entry cabs are on the way. Right: The taller cab and increased glass gives the operator better vision, important for tasks such as loading bin wood trucks.
The Next Gen 538 still offers a choice of three power modes to select from, based on the workload to be undertaken (high, standard and eco modes). These can be called up on the new console pad as before, but Zak says he has left it in the standard setting that the
TerraCat techie dialled in for him on delivery and hasn’t felt the need to change it yet.
Another area that has improved is the travel speed, which we reckoned was only adequate in our previous 538 test. Updates to the drive system have resulted in a 12% increase in travel speed, enabling the Next Generation 538 to cover more ground faster and get more done in a day. Zak says the walking speed is a bit quicker – “the old one was pretty slow” – and although it’s only a small improvement, at the end of the day it all adds up and he can achieve more each shift.
The Tier 4 Final Cat 7.1 engine remains largely as before, with
Caterpillar adding that it is also designed to run on bio-diesel mixes up to B20. With the New Zealand government looking to use biodiesel as part of its climate change strategy in future, it’s good to know the Next Gen 538 won’t be handicapped if such a move is mandated across all industries.
Tier 4 Final technology has been around long enough for users to feel comfortable with it and ‘Irish’ had no problems taking it BANNER 5BANNER 1BANNER 1 on with this purchase – it is the way of the future, after all. While these engines do run hotter than their Tier 2 or Tier 3 counterparts, Caterpillar has increased cooling in Tier 4 Final-powered machines to compensate and temperatures stay well within the normal range, even on hot East Coast days, according to Zak.
The Next Gen 538 can operate across a wide climatic range, from a cold-start capability of -32˚C right up to temperatures reaching 48˚C, so shouldn’t be troubled by our weather. It also operates effectively at altitudes reaching 3,000 metres without derating and to our knowledge, there are no forests grown at that level anywhere in New Zealand, so no worries on that count either.
Mind you, it can get cold on top of the Wharerata range in extreme winters and, in addition to the uprated A/C system that keeps the cab toasty in winter and cool in summer, the seat also comes with built-in heating and cooling – we eventually find the switch on the left side of the backrest, under the seat cover.
The seat itself is very comfy and the visibility from the cab is superb, even to the rear, thanks to the new flat-topped bonnet (and a window in the floor to see the tracks). For extra vision, Zak has the advantage of two cameras that display in the top segment of the display screen. One of them shows what’s immediately behind, while the other is placed on the right-hand side of the body, ostensibly to get over the blind spot created by the boom. But Zak says the camera still doesn’t overcome that blind spot and the lens needs to
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be pointed more forward. Shame it doesn’t have the 360˚ camera views of what is all around the machine that we experienced in other Next Generation Cat models.
That big expanse of glass does come with one drawback – heat build-up from the sun, as there are no blinds fitted to any of the windows and Zak says it can be an issue later in the day when the sun is lower in the sky.
The larger 254mm (10-inch) highresolution touchscreen monitor is placed out of the way on the right pillar, with easyto-navigate menus. Above this display is another screen that tells Zak when log and bin wood trucks are scheduled to arrive.
Tapu describes the cab and controls in greater detail in his Iron Test column on page 26 but I have to say the overall impression is of a much nicer working environment.
Back on the ground, Zak opens up all the doors and points to the new lower position of the dipstick that can now be reached from the ground, along with all the other daily checks.
Service costs are expected to be lower, too. Improved filters and replacement intervals result in 50 fewer filters being consumed over 12,000 hours. For instance, fuel filters feature a synchronised 1,000hour change interval, which doubles the service life of the previous model. A new hydraulic oil return filter improves filtration and delivers a 3,000-hour service life, which is 50% longer than previous designs.
Moving to the new electro-hydraulic control system also eliminates the need for a pilot filter and pilot oil altogether.
Lower maintenance costs
Compared to the previous model, Caterpillar says the Next Generation 538 lowers maintenance costs by up to 15% over the course of 12,000 hours of operation.
We’d like to have had a bit more time to poke around the inner workings of this machine, but there’s a bin wood truck on the way, followed by a flotilla of log trucks. This is a busy site. While BBL is primarily a road-lining operation, it does harvest a lot of wood and there are tight deadlines to meet.
“Doing 300-to-350 tonnes a day on average,” says ‘Irish’. “We’re probably overproducing a little at the moment, just because we’re a little ahead of the roading due to all the restrictions that are now in place.
“We’re doing a lot of end hauling. Being extra careful about cleaning up around creeks and that. A lot of built-up edges on the roads to direct the water flow to the culverts and flumes and make sure they are kept clean. A lot more compaction is required, too. More emphasis on that now and more recording of everything that we do, with photos as well as writing it all down – much more since the floods and court cases.
“We do something called Survey 123, which is a spreadsheet so we can record everything step by step. We do that on a daily basis, all done on a tablet that we submit on the cloud.”
When we previously visited BBL, it was just a single crew but has now expanded to two crews and a total of 28 people – they would like more staff, as there are three machines parked up with no one to drive them.
But even with those limitations, ‘Irish’ says that having the two crews is “the perfect combination, really does the job and allows us to keep ahead.”
Just as well. After only a week creating roads and new skid sites in this part of the forest, they’ll be out of here the next day. So the pressure is on to clear the remaining wood and move.
That’s why you need fast and reliable equipment, like the Next Gen Cat 538. It’s the sole fleeting and loading machine on the skid, fed by a Cat 336F with a Woodsman processor sitting on a ledge just above.
Zak is back in the driver’s seat to demonstrate the pace of the machine with the arrival of the bin wood truck. He uses the Ensign 1730 grapple to grab big fistfuls of waste and soon has the truck loaded up and on its way.
No time to rest. The next log truck is just minutes away and Zak finishes laying out the heavier logs on the ground in readiness for loading into the bottom of the truck and trailer bunks. Just 5.9s going out on this load.
The truck arrives and Zak lifts the 5-axle trailer off with ease and plonks it down next to the ready-made log piles. We detect a small hint of rocking on the tracks, which is down to the fuel tank nearing empty, even though the machine itself weighs in at 31 tonnes. The heavy logs go on first – some weighing two-and-a-half-to-three tonnes – and the thinner ones further up. A good way to keep the trucks stable on the twisty Gisborne region roads.
After the log truck, the diesel fuel truck arrives to top up the 538 and restore balance. The fill needs to be quick, as there is another log truck waiting to come up to the skid.
Refuelling done, it’s Tapu’s turn at the controls and he goes through the same
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Left: The new cab is 25% larger than in the previous Cat 538. Right: The bigger display screen has plenty of room for the two camera views to be shown at the top and leaves space for other information below. Below: No problem lifting and holding onto these four logs in the Ensign 1730 grapple tongs.
procedure – laying out heaver logs on the ground to make up the base layer in the bunks. Then lifts off the trailer, this time without the rocking, thanks to almost 1,000 litres of diesel keeping the rear of the track firmly planted on the ground.
As Tapu starts filling the bunks, I ask Zak if there is anything in particular he likes about his new steed and he says: “I pretty much like everything about it, very happy. Especially the bigger cab.
“The electro-hydraulics feel very good, it’s fast around the skid and quick to load. Great on the skid work, although it doesn’t have the slew power to drag some of those big heavy stems around. But I don’t do much shovelling anyway, so that’s not a problem for me.”
Before we know it, Tapu has completed loading the truck and he’s now laying out heavy logs on the ground for the next truck. The 538 is kicking up a fair bit of dust as Tapu walks across the skid, which causes the hydraulically driven, auto reversing cooling fan to work over-time to keep the radiator fins clean.
As the morning progresses the trucks come and go, and the wood pile shrinks. The Next Gen 358 has no trouble keeping up and ‘Irish’ is confident it will continue to perform like that for years to come. NZL
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THERE’S NOTHING LIKE A NEWLY
released model to give you machine envy and that’s what I’m suffering from after testing BBL Logging’s Next Generation version of my own Cat 538.
Mine’s just 18 months old but it feels way older after spending time in the new model. What a difference. Heaps of room and heaps of vision in the bigger cab. Huge door and no bars in front of you, like on mine.
My knees almost touch the front screen in my machine, so I like how it has been pushed out a lot and there’s also the glass screen in the floor to see the tracks – I used it quite a bit when I was walking around the skid. More space behind the seat, I could even fit my vacuum cleaner in there, which I can’t do in mine.
Much easier to get into the cab with the larger door, though it would be nice to have a rear-entry cab to put your boots in the back. Safer too.
Much better vision all round and it goes right up to the roof, which means you’ll need blinds for hot Gizzy days. The rear-facing camera gets over the blind spot behind the machine, but I agree with regular driver, Zak that the side camera needs to be pointed more to the front so you can see what’s on the other side of the boom.
Another difference from mine is that you start the 538’s engine with a push button. Each operator can programme their own machine settings and function preferences, though I just left them all as Zak has them. I’m not one to keep changing the settings.
The A/C is much quieter than on my machine and I do like the fixed microphones on stalks positioned on either side of the cab. All you do is hit the mic button on the controls to speak; your hands don’t leave the sticks.
The seat is nice but it still doesn’t raise up enough. You can’t adjust the handles to bring them to a more comfortable height, so you’d need the seat to do that and it would be good if there was more adjustment.
The controls feel very light and it would take you a while to get used to it if you came
Iron Tester, Tapu Dixon.
1: Access to daily checks inside the left door is much improved and the DEF tank is now situated under the first step on the right. 2:The redesigned layout features steps behind the boom and protection plate up to the top of the body, in readiness for a rear-entry cab. 3: The Tier 4 Final Cat 7.1 engine now sits under a flush bonnet. 4: Regular operator, Zak Parker, is very impressed with the extra space and vision in the new cab.
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SPEC IFICATION S SPECIFICATIONS – NEXT GEN CATERPILLAR 538 LL LOADER
ENGINE
6-cylinder, 7.01-litre, Caterpillar 7.1, ACERT, Tier 4f Bore / stroke 105mm x 135mm
Net power 128.5kW (172hp) @1,800rpm
Max torque Max travel speed 742Nm @1,400rpm 4.9km/h
HYDRAULICS
Main pumps Max flow Swing speed Swing torque
BOOM / ARM
Model Reach Two variable displacement axial piston pumps 2 x 234L/min 11.0rpm 98,000Nm
Caterpillar forestry model 11.0m
GRAPPLE
Model Rotation Max clamp opening Capacity Weight Ensign 1730 Continuous 1,700mm 0.47m2 1,180kg REFILL CAPACITIES (LITRES)
Fuel tank Engine coolant
Engine oil tank Hydraulic system (incl tank) DEF tank
DIMENSIONS (MM)
Shipping length Shipping height (cab tilted) Shipping width Ground clearance Track length Track shoe width Tail swing radius Operating weight 990 17.5
25 262 41
boom/stick out) 13,690 3,400 3,490 758 4,665 700 3,135 31,460kg (minus grapple and extra rails)
from an older machine. You can adjust the feel through the computer, but I didn’t need to. It’s very smooth and responsive.
It has the standard Cat control pattern – stick and slew on the left with boom up and down on the right, RT buttons on both sides, but the grapple rotator is on the right, instead of the left, where it is on my machine. The locker switch is on the right, too.
I’ve got a Duxson grapple on my machine and it’s been a while since I’ve operated an Ensign, but this one is a lot faster than I remember and it holds onto the logs nicely.
The machine is very smooth and effortless. Really good lift and slew. Before the fuel truck arrived it did feel a bit rocky, but once the tank was filled it was very steady, so it pays to keep more diesel on board. I didn’t walk it far, but it felt fine to me, maybe a bit pacier than mine.
I see Cat has fitted more lights to the front roof – I have four LEDs whereas this has six, which would light up the skid better on dark mornings.
I’m not trading my 538 in just yet, but the Next Gen model would be on my shopping list if I was. NZL
