Earthmovers March 2024

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Editor Graham Black

Editor@EarthmoversMagazine.co.uk

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The next issue of EARTHMOVERS magazine is available on 3 May

Full steam ahead

It has been a busy start to the year, with a wave of new batterypowered compact kit launched on to the market and fullsized electric excavators also being trialled in the UK. Talking of emerging technologies, an autonomous articulated dump truck is currently working in the China clay pits of the south-west, and National Highways is looking at intelligent compaction systems.

Such next generation tools of the trade are going to transform the productivity of the industry. They will also lay a foundation to attract the next generation of employees, who will not necessarily be spending their days driving a dump truck or a roller. Instead, they will be driving a computer screen in the offi ce, working alongside colleagues from the fi rm’s survey, plant maintenance and management units, on a fully connected site.

In addition to such strategic changes in the industry, there is much that is being done with current off-the-shelf technology to improve site productivity and safety, in particular the widespread adoption of GPS systems and more sophisticated hitches, such as tilt-rotators.

Yours till next month

Graham Black, Editor

CONTENTS

County Wexford-based operator’s latest mount, a Komatsu PC170-11.

A round-up of the latest news from the earthmoving and associated machinery industry.

When it comes to compact construction equipment the future looks electric.

Young operator’s latest Kubota midi includes an Engcon tilt-rotator.

Finnish firm introduces thirdgeneration

20-tonne wheeled excavator that is a factory-built road-rail machine.

We report on a wave of new JCB compact construction equipment.

Brassington Moor Quarry’s latest generation 70-tonne class excavator.

Birmingham’s Operator Skills Hub is a dedicated plant training facility.

Burnside Plant’s new pair of Volvo compact radius excavators at work.

Recycled aggregates are being used on London’s gas and water mains repairs.

Graham Black introduces our review of factory-built long-reach excavators.

JCB’s mighty 4CX backhoe is the perfect tool carrier to erect utility poles.

Two time-critical Cawarden demo projects on the university campus.

TAIL END

78 PLANT HISTORY

CAT

ADT ORIGINS

Insight into the history of Caterpillar’s range articulated dump trucks.

84

EXTREME MACHINES

P&H 757

Europe’s largest dragline is now at work on a coal site in North Dakota.

91 INTERVIEW STEELWRIST

In conversation with Stefan Stockhaus, the company’s president and CEO.

92 NEXT MONTH

Here’s a taster of just some of the exciting features planned for the next issue.

96 PLANTMOBILIA O&K CUSTOM BUILDS

EARTHMOVERS reviews unique scale models of O&K mining excavators that once worked in the UK.

98 PICTURE POST

Got any interesting or unusual pictures of earthmoving men or machinery? WIN £20 for our ‘Pic of the Month’.

MIDDLEWEIGHT

CHAMPION

Eoghan Daly reports on the experiences of County Wexford-based Phelim Kelly with his latest mount, a Komatsu PC170-11 excavator

Some 18 months ago, Ballycarney, County Wexford-based owneroperator Phelim Kelly found himself with an aging but reliable excavator, but made the decision to upgrade to the latest generation of machine. He ended up with a Komatsu, the first he had operated during a lifetime in plant. However, at around 18 tonnes, it continued Phelim’s belief in the advantages of operating a cross-over machine between standard 14- and 21-tonners.

BACKGROUND

Phelim’s 45-plus-year involvement with plant started at the age of 17, operating kit in his father’s plant hire business. He then began running his own Hymac hydraulic excavator, initially with a 580C followed by

Inset and right: County Wexfordbased owneroperator Phelim Kelly continues to run a single excavator, his current mount being a Komatsu PC170-11.

a 580D, before moving to the more technically advanced 141 model.

He recalls; “Everyone was saying Cat excavators like the 215 were the best in their class at the time. Based on this, I changed from Hymac to Caterpillar, first with a 215 and then on to a 215C and finally a 215D. They were well-built machines, but with the Perkins engine they used were a bit underpowered for their size, which made them a bit of a let-down, but they still managed to get through a lot of work.

“Back when I was running Cats, I would usually replace them every five years, but when the recession hit, I was running a Case CX160B. I held on to it longer than normal and in the end it had worked over 20,000 hours. It had a bit of wear in the usual places, but was still a great machine and had never let me down, which was why another Case machine seemed the best option.

“The new Case E series was just coming on stream but they weren’t in a position even to give a quote and were uncertain of the delivery timeframe. I wasn’t prepared to wait, which led me to look at other options, including the Komatsu PC170-11 from McHale Plant Sales, which then had a six-month delivery time.

“THEREISNOPOINTTYINGBIGMONEY UPINEXTRAPLANTANDNOTGETTING FULLUSEFROMTHEM”

“THEKOMATSUDEFINITELY ISAHIGH-CLASSMACHINE TOOPERATEANDIWOULD HAVENOTHINGNEGATIVE TOSAYABOUTTHECAB”

“An excavator in this size class is ideal for an operation like mine. It provides a machine that is still not overly big for working in confined places and is easier to transport between sites. It has much greater digging power than a 14-tonne class machine and can get through bulk digging like a 21-tonne excavator, without being under any pressure and remains economical to run. I have been working with machines of this size class now since the Cat 215s and view it as being a working model that has proven itself over many years.”

CONFIGURATION

As the Komatsu PC170’s undercarriage is just shy of 4m long and its track gauge 1990mm, with 700mm-wide track shoes the 18-tonner has a firm stance, while exerting less ground pressure and occupying a smaller footprint than a 21-tonner. Komatsu certainly has not scrimped on the undercarriage, as each track frame features two top rollers, seven bottom rollers and a central track guide, in addition to

Above and below: This PC170-11 is configured with a heavier counterweight and a long dipper stick. It sits on a 4m-long undercarriage shod with 700mm track pads.

the normal idler end track guides.

One result of its beefy-looking undercarriage is that the PC170-11 is a relatively tall machine, the clearance under its counterweight being just 30mm short of the larger PC210-11 model. In view of this, and wanting to use the longest 2.9m dipper stick available, Phelim ticked the option box for a heavier counterweight. At 3250kg, it is half a tonne more than the standard component, but results in better stability when making full use of the working equipment. He chose a Geith quick-hitch, a brand he has used since his time with a Cat 215D.

SITE VISIT

Phelim undertakes excavation and groundworks for one-off houses, but his bread-and-butter work comes from a loyal customer base within the local farming community, for whom he undertakes farm building construction, land reclamation and drainage projects.

We met him on the Ballyhamilton Farms estate near Enniscorthy, working on an extension to a grain store, which required an extensive reduced level dig. Once topsoil had been stripped, the site was to be excavated in two levels. The first metre or so was subsoil, of which Phelim obtained a heaped bucket on every cycle. The tip area was just a short distance away, the excavator keeping the drivers of two tractor and dump trailer combinations busy.

Below the subsoil was a layer of rock, which was not a particularly high density at first. However, as Phelim got deeper, he had to use a ripper attachment on the excavator to fracture the material.

He continued, “I have always heard good things about Komatsu excavators when it comes to digging power and this one definitely has not been a disappointment where breakout force is concerned. It also has great speed and is very well balanced and smooth on the levers.

“At first, I thought fuel consumption was a bit high, but over time it became clear that it wasn’t, based on the amount of work it is able to get through. Obviously on lighter work it is very efficient and in tough going it will burn more diesel, but it is a great machine and really has that extra bite when you need it in hard digging.”

The British-built PC170-11 is powered by an ultra-low emissions four-cylinder Komatsu engine rated at 90kW. It is a torque rich powerpack that is mapped to work lower down its rev range, for better fuel economy. Undertaking intensive excavation work at the time of our visit, the PC170-11 was consuming 12.2 litres per hour, which is reasonable considering the progress it was achieving.

Phelim continued, “The Komatsu definitely is a high-class machine to operate and I would have nothing negative to say about the cab design or layout. The machine has just passed the 1400 hours service recently, in just under a year’s operation, which has been completely without problems, so everything remains positive.”

CONCLUSION

Over the decades, Phelim has resisted the temptation to expand his business. He is content being an owner-operator, delivering quality over quantity. He owes much to the loyalty of his client base, with whom he maintains a continuity of work.

He concluded, “There is no point tying big money up in extra plant and not getting full use from them. I have never regretted not expanding machine numbers over the years and believe the single machine owner-operator approach is one that has always worked for me, so why change it?

“I am always working within a 20-mile radius of Ballycarney, which brings constant work my way. Now with a new machine, which has been very reliable so far, I have no reason to regret making the change to my first ever Komatsu excavator.”

Right and below left: The British-built Komatsu is a well-equipped machine, which has proved to be totally reliable over its first year of work.

A LONG WAY TOGETHER

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NEWS WORLD’S FIRST ELECTRIC SIXTONNE DUMPER

ecalac has introduced its all-new eMDX batterypowered site dumper, the first electric hauler to offer a capacity of six tonnes. Equipped with a 75kWh pack, Mecalac claims it will provide at least eight hours of operating time from a single charge and, with its raid recharger, can be ready for another day’s work after being plugged in for four hours.

THIRD GENERATION STEELWRISTS

s we go to press, Steelwrist has launched its third generation of tilt and rotate hitch technology, which includes the new XTR20 tilt-rotator and XR series of rotating couplers, together with redesignated tilting hitches, the XT range. Further details in the next issue.

A round-up of news stories in the plant and machinery construction industry ant

JCB-LEICA MACHINE GUIDANCE DEAL

As we go to print it has been announced that JCB and Leica will offer factory-fitted Leica 2D and 3D-ready semi-automated excavator control systems. This will initially be offered on their 22-tonne class X Series excavator for UK customers, before being rolled out across the range and to other regions.

Moredetailsinthenextissue,whichincludesthelaunchofthe370X excavator.

NEW BOBCAT ROTO-HANDLERS

obcat has launched a new range of rotary telehandlers, covering lifting heights from 18m to 39m and providing lifting capacities from five to eight tonnes. Those models with lifting heights up to 26m are powered by Deutz engines, the larger models by Volvo powerpacks. A key feature of the new range is their pressurised ROPS & FOPS protected panoramic cab, which offers great visibility, clearly inspired by cabs used on cranes.

Market note: With more than 4500 examples sold in 2023, the total global market for rotary telehandlers continues to grow, but a whopping 85% of these sales are made to European customers. The only other notable market is the USA, which takes 10% of total production.

KRAMER DASH 8 LOADERS

Kramer has launched the Dash 8 series of compact wheel loaders, the 8085, 8095, 8105, 8115, 8085T and 8095T models, providing bucket tipping loads from 3650kg to 4250kg. The standard build for the range includes a 55kW/75hp Deutz engine, but the 8105, 8115 and 8095T models can be specified with a 74.4kW/100hp powerpack.

NEW HOME FOR LIEBHERR

ELECTRIC WHEEL LOADERS

fter roughly 10 months of construction, Liebherr has commissioned a new assembly hall, within its giant factory at Bischofshofen, for the manufacture of battery-electric compact wheel loaders. Over €2.2m has been invested in the 1000sq.m facility, which has been designed and laid out with the help of virtual reality technology.

The firm’s first electric loader, the L507E model, has started to roll off the line, which has a production capacity of 500 battery-electric wheel loaders a year.

CATS CROSS WATER

Located at Glensanda on the shore of Loch Linnhe in south-west Scotland, Aggregate Industries operates the largest granite quarry in Europe. Caterpillar distributor Finning supplies the site with machinery and support services, which can be a challenge at times. For example, the phased delivery of their latest batch of 18 machines, which includes a dozen Cat 777 haul trucks and large 992 wheel loaders, together with a D9 dozer and a model 16 motor grader. Organised by Finning Glasgow, the transport arrangements include having to navigate narrow and twisting Highland roads, before being loaded on to a barge for the last part of the journey.

SCOTTISH OPERATOR

CHALLENGE

Hosted by Morris Leslie, the final of the Scottish Plant Operator Challenge will take place during the Working Vintage Plant Weekend on 27 July, at Errol Airfield in Perthshire.

The Scottish Plant Operators Association’s Callum Mackintosh said, “Last year was the inaugural Scottish Plant Operator Challenge and I was proud to be part of it. Once again, colleagues across the plant industry have stepped up to make this event happen. I’m delighted to join Morris Leslie and James Currie on the organising team.

“We are on a mission to present an even grander spectacle in 2024. Our vision is to create a platform that not only celebrates the prowess of skilled operators, but also serves as a dynamic stage to unveil the latest innovations and equipment that define the forefront of the plant industry. It all starts at ScotPlant, so if you think you’ve got what it takes then come along and give it a go!”

The overall winner will receive a cheque for £5000, together with exclusive rewards from the event sponsors.

EXCAVATOR EXPERTS

SUBSIDISED MACHINE DEALS AVAILABLE NOW

TAKEUCHI offer an extensive range of proven high performance excavators with more than 20 models from 1 to 15-tonnes.

Always the operator’s favourite, you can trust a Takeuchi to excel in every weight class.

IMITATIONS DON’T COME CLOSE CONTACT

Reliable and dependable, we set the standard for excavating excellence.

Designed and manufactured in Japan, TAKEUCHI deliver precision engineered excavators that outperform year on year.

SELF-POWERED SCALPER SCREEN

Stuart Partners has invested in a Sandvik QE342e dual-fuel scalper from dealer Retec for their recycling operation in Exeter. It features a heavy-duty, high-speed 4.7m x 1.45m screen, and the machine is powered either by its internal diesel engine or from an external electrical supply. The company has been granted planning permission to build a new

gasification plant on site, which will incinerate waste to produce electricity. The plan is to power the Sandvik and the site’s main wash plant from this renewable source. In the meantime, the scalper screen, powered by an external generator, is being used to separate out larger fractions of the waste stream, the remainder being the main feed to the wash plant.

NEW UNDERGROUND LOADER

omatsu has introduced a new WX11 load-haul-dump underground mining wheeled machine. With a heavy-duty driveline and redesigned working equipment to provide high breakout forces, it has been specifically designed for hard rock applications.

MAGNI ROTATING TELEHANDLER

agni’s new RTH 8.39 rotating telescopic handler further extends their range of eighttonne capacity machines, alongside the 8.27, 8.35 and 8.46 models. The new machine is a redesigned 6.39 model, but offering larger capacity.

M

UK DEALER NEWS

The Molson Group has been awarded the distribution rights of XCMG excavators and wheeled loaders in Scotland, through Molson Young Plant Sales.

Sany has announced a change of dealer in the north-west of England, with the appointment of TDL Equipment.

Ausa has signed an agreement with Warwick Ward to distribute its site dumpers, rough terrain forklifts and compact telehandlers throughout the north-east of England and Yorkshire, together with the south-east region.

Boss Plant Sales has been appointed by Thwaites as the new distributor for London and Oxfordshire.

Sunward has appointed two further dealers to its UK network. Based at Insch in Aberdeenshire, Crowmec will also cover the Highlands and Islands, in addition to Perthshire and Morayshire. Based at Binfield in Berkshire, Golf and Turf Equipment will also cover customers in London and in parts of Surrey and Oxfordshire.

Kubota dealer PV Dobson has opened a new branch in Washington, Tyne and Wear, where the site includes workshop and parts storage spaces, together with considerable yard space.

IS GOING PREMIUM

CASE’s response to the growing premium business market is an additional step forward in terms of global performance. The new Wheel Loader 651G comes with cutting-edge enhancements, as new reinforced frame, axles, and new direct-mount rehandling buckets.

Contact your CASE dealer NOW

The Cornwood china-clay quarry in Devon, operated by Sibelco, is piloting the introduction of autonomous articulated dump trucks (ADTs). This follows long-term trials of the system by manufacturer Bell and technology specialist Xtonomy, to create an autonomous B40E ADT.

The hardware includes radar sensors, high-precision GPS, multi-channel communication systems, together with lots of on-board processing power. The result is a resilient navigation system that dynamically plans the ADT’s route, and

predictively controls the vehicle around the entire quarry site.

Autonomous quarry dump trucks have the potential to significantly reduce accidents and near misses during the haul cycle. They can work long stints without interruptions and with no drop-off in performance, all while achieving a consistently accurate tip. This allows the quarry to introduce more effective working patterns, tailored to improve productivity.

AUTONOMOUS ADT IN DEVON

aggregates sector must embrace technology as a way of continually delivering improvements.

Dr Christian Riedel, the CEO of Xtonomy, said, “Supporting the quarrying sector through the appliance of automation platforms is a key commitment for our business. Expectations and needs are changing, as the industry looks to transition to a future where improved efficiency, better safety and targeted environmental considerations are key priorities.”

The haul is undertaken, time and time again, in the same fuel- and time-efficient manner, which also results in reduced and extended component life.

FEEDBACK

Ben Uphill, operations director for Sibelco’s Kingsteignton cluster of quarries, said, “We envisage many benefits from having access to this sector-first autonomous ADT solution.

The minerals &

South African-based Bell chose UK dealer Chepstow Plant International to pilot the development and introduction of this technology, who in turn brought their client Sibelco into the equation.

Chepstow’s MD, John Corcoran, said, “We are delighted to be involved in this exciting and UK-first collaboration. One that is focused on a next generation adventure, to ensure UK quarries continue to maximise operational efficiencies and remain competitive. It is important that stakeholders come together in this way to drive advancements and support the industry’s future prospects. We are sure that this pilot project will both deliver progress, as well as further challenges, both of which will provide the pathway towards the ultimate goal.”

We hope to bring you further details of this innovative development in a future issue.

Above, inset and below: An autonomous Bell B40E articulated dump truck is being piloted at Sibelco’s Cornwood china-clay quarry.

SPECIAL NEWS REPORT

LIVE TRIAL OF INTELLIGENT COMPACTION

National

Highways is trialling a high-tech compaction management system on the A303 road project in the south-west of England

Anew compaction technology has been trialled by National Highways on the A303 road upgrade scheme between Sparkford and Ilchester. Caterpillar’s new intelligent compaction system is a key development in its own right, but also represents a big step towards autonomous rollers.

Mounted in a Cat roller by dealer Finning, the system is being trialled on a machine being used by contractor Galliford Try. It is intended to speed up and improve the quality of road construction, together with other environmental, cost and safety benefits. Using 3D mapping and a sophisticated sensor system, the system ensures that the right level of compaction is achieved first time and spots any uneven areas that could cause settlement issues.

National Highways’ Claire Hamar said, “We are constantly exploring new ways to design, build and maintain our roads and are committed to making connected and autonomous plant the norm in construction.

“A huge positive that we discovered in the Intelligent Compaction trial was the improved efficiency and environmental benefits, as work did not need to be repeated so, thanks to the reduced fuel use, we had reduced carbon. Not only is the work completed more quickly, saving resources and taxpayers’ money but, most importantly, it improves safety and reduces risk.”

The compactor unit is fitted with Cat’s machine drive power and compaction meter. They allow the operator to set the target depth and compaction level, and to pre-set the drive functions so the roller is automated and operates within the required parameters. This ensures the task is completed safely and eliminates the need for a ground worker to be on site during the compaction process.

Finning’s Jonathan Davies said, “Technology increases performance and operational efficiency, with reduced fuel consumption. Cat soil compactors have two types of sensor that measure the ground stiffness as well as an accelerometer base system, which is common in the industry. This is complemented by a rolling resistance system that works

particularly well in cohesive and clay-like material, which is common across the UK.

“Without the use of such technology, the only way to be sure of the compaction level across a site is through random testing, which can cause delays on site and safety issues.”

Galliford Try’s Jon de Souza said, “We were delighted to be able to demonstrate our commitment to innovation through the collaborative delivery of this research trial. We believe that connected and autonomous plant has the potential to transform construction over the coming years, improving safety and productivity while reducing carbon emissions.

“We look forward to continuing our work with National Highways to trial this technology across our infrastructure delivery.”

Left, above and inset: Using 3D mapping and sophisticated sensors, the right level of compaction is achieved first time around, without the need for frequent manual checks.

As Nick Drew reports from Coventry, when it comes to compact construction equipment the future looks electric

INNOVATIVE MERLO

An eye-catching machine on the Merlo stand was the Cingo M12.3-EVO Handler 400, a pedestrian-controlled tracked telescopic handler. It offers a maximum lift capacity of 400kg and a maximum lift height of 3.4m, all in a machine with an overall width of 1000mm.

Attracting a healthy 2000 of the UK hire industry’s top decision makers, the 17th Executive Hire Show took place at the Coventry Arena in mid-February. The focus of attention was on a new generation of battery-powered mini-excavators, site dumpers, tracked spider cranes, telehandlers and the like, together with electrical energy production, storage and distribution systems. This reflects what is going to become a £multi-million market for the UK plant hire sector, as clients and main contractors increasingly demand working methods with lower environmental impact.

Event director Chris Moore said, “I would

like to extend a special thank you to our sponsors, The Hire Exchange and the Hire Association Europe (HAE), for their invaluable support. Their contributions played a crucial role in the success of this year’s networking event, helping to bring the hire community together. We’re grateful for their partnership and look forward to continuing to work together to advance the hire industry.

“This year’s Executive Hire Show was fantastic, with an unprecedented amount of deals done. The atmosphere was electric, and it was evident that our focus on innovation and sustainability resonated with both exhibitors and visitors.”

AN ELECTRIC ATMOSPHERE REVOTRUCK RAMP-UP

Also gracing the Merlo stand was the electric EWorker 25.5-90 telescopic handler. Its traditional lead-acid battery pack is capable of delivering a range of up to eight hours. This compact rearwheel-steer machine offers a maximum load capacity of 2.5 tonnes, a maximum forward reach of 2.6m and a maximum lift height of 4.8m.

Located just up the road from the Coventry exhibition centre, the Mecalac factory is ramping up to start production of the unique Revotruck, which features a cab that can rotate through 225 degrees. It offers superb visibility when hauling, the key to further improving site safety, while also allowing the operator to face the swivelling skip during discharge. The Revotruck will be available as six- or nine-tonne capacity models, both powered by a 55kW (74hp) Perkins engine driving a hydrostatic transmission.

JCB PRODUCT LAUNCH

The day before the show opened, exhibitor JCB launched a raft of new products, details of which are elsewhere in this issue.

XCMG ELECTRIC SCISSOR LIFT

xhibitor Genesis Equipment Sales is the sole UK distributor of XCMG access equipment. On show was a XG1012AC battery-powered model, which has a rated load capacity of 450kg, suitable for carrying two people to a maximum working height of 10m.

ELECTRIC TRACKED SPIDER CRANE

Looking like it had just come out of an edition of Thunderbirds, this tracked variant of the Unic spider crane was on display on the GGR Group stand. Providing far more mobility away from a hard and level surface that its more familiar wheeled counterpart, this tracked version can still fit through a standard double doorway. It provides a maximum lift capacity of 2.9 tonnes, a maximum lift height of 8.8m and a maximum working radius of 8.41m. Power comes from a 48v DC battery, which can be recharged from a 110v or 240v supply.

NEW GREENEY-GREY MINI

ans of red and grey Takeuchi compact excavators were probably a little confused when they stopped by their stand, as the star attraction was sporting a new two-tone grey livery. The two-tonne TB20e model is the first of a new generation of zeroemissions, battery-powered mini-excavators, which will be in the same paint scheme. As so many small battery-powered minis have been introduced over the last few years, it is easy to forget that, with their tethered model, Takeuchi was at the forefront of the development of electric-powered machines. This possibly gave them a valuable insight

into electric-powered hydraulic systems, machine hydraulics being Takeuchi’s speciality.

Adding a state-of-the-art battery system to the equation, the TB20e offers a working time of eight hours from a single charge when working at 65% load. Another distinguishing feature of Takeuchis are quirky design elements that are extremely practical. Not content with offering the option of a fast charger, which is capable of fully charging the TB20e in two hours, it is designed so that it can be carried on the mini’s dozer blade, accompanying the machine as it moves from job to job.

COMPACT ASPHALT PAVER

irtgen exhibited the Hamm HD12eVV battery powered tandem drum vibratory roller, which offers a working width of 1.2m and weighs 2755kg. However, the star of their stand was the UK debut of the Vogele Mini 500 compact mini asphalt paver, a battery version of which is due for launch later this year. The transportfriendly, one-tonne Mini 500 offers working widths from 0.80m to 1.80m.

BOBCAT PORTABLE POWER

Taking pride of place on the Bobcat stand was the latest version of their E10E battery powered mini, one of the first electric-powered compact excavators available. However, in many ways, the highlight of their stand was the PA7.4 generator-compressor, which represents the first sight of a new range of Bobcat branded portable power products.

The simple and robust-looking PA7.4 can be configured to a customer’s needs, e.g. with an 8.5kVA generator to power the latest generation of fusion welding equipment, as used in the utilities sector of the market. It can also be used to power lights and hand tools, together with providing compressed air at 4cu.m/min (140cfm) at 7bar.

RIDE-ON ELECTRIC HAULER

Staffordshire based Tufftruk showcased their range of Truxta pedestrian-controlled site dumpers, including the new battery powered EB800 BENDie model, which offers a 800kg payload.

ALTERNATIVE BATTERY TECHNOLOGY

Sany presented several new products for the UK market, including the all-new SY26C and SY35C miniexcavators.

They also showcased their SY19E electric mini, which is powered by a lithium iron phosphate battery pack. When it comes to the use of battery-powered construction equipment, Sany’s Chinese home market is a few years ahead of the rest of the world. For example, we are beginning to see the first 20-plus-tonne electric excavators in Europe, many of which are already proven products in China.

China is also the global hub for the development and production of automotive battery packs, which is a rapidly maturing industry. Lithium iron phosphate (LiFePO4) technology provides several key advantages over the more common lithium ion battery packs. It does not require the use of the rare mineral cobalt, which brings a string of advantages. But what marks out LiFePO4 batteries are their durability and a lower cost to manufacture. They provide the user with a more stable battery pack over a longer lifetime, less prone to environmental conditions and are less picky about what and how they are being recharged.

The Lithium iron phosphate battery pack in the Sany SY19E is designed to provide a lifespan of up to 3500 full charge cycles, equating to at least a decade of typical work. Featuring a single automotive standard charging socket, the machine can be fully recharged from a 240v domestic outlet in nine hours, or by spending 2.5 hours on a 360v industrial supply, with just 90 minutes needed on a DC fast charger.

n addition to their Solar Pod, AJC Power Solutions showcased their Battery Pod, which can store electrical energy from multiple sources and automatically channel it to where it is needed when demand is high. The five-model range provides storage capacities from 30kW to 250kW.

UPGRADE TO THE ULTIMATE.

KX085-5: THE 8-TONNE STANDARD

The ultimate in operator comfort, efficiency, and high productivity.

Talk to your Kubota dealer today to find out more.

The Kubota KX085-5 is equipped with a host of built-in operational and safety technologies as standard, including engine auto-stop, intuitive control systems, an integrated rear-view camera and much more. Add a new ultra-quiet, spacious cab, and it all adds up to our most productive 8 tonne mini excavator ever.

OWNER-OPERATOR // JACK DICKSON

VERSATILITY IS THE KEY

Paul Argent reports on a young owner-operator with a high-spec Kubota midiexcavator, which includes an Engcon tilt-rotator

Last year Jack Dickson (22) became the proud owner of the first Kubota KX085-5 compact excavator in the UK configured with a two-piece boom and Engcon tilt-rotator. Jack hails from the Lake District where his family run a caravan and holiday park. He has spent countless hours helping with the maintenance and redevelopment of the site, but his dream is to build up the work for external clients.

He started out with a Kubota KX080-4A midi, which now has 3600 almost trouble-free hours on its clock. When the

new Dash 5 model was announced, he immediately inquired as to its price and availability with his local dealer, PV Dobson at Kendal, who Jack and his family have been doing business with for years.

Jack said, “I had heard some very encouraging reviews about the increase in performance and productivity from the Dash 5. While the older machine was still doing fine, I just wanted an upgrade with a two-piece boom to increase my versatility.”

Part of the thinking was that a higher-spec machine would help

“THETILT-ROTATORISABIGFINANCIAL INVESTMENT,BUTIENVISAGETHATITWILLPAY FORITSELFINJUST12MONTHS”

Above and inset: Already running a Kubota KX080-4A midi, Jack Dickson upgraded to a KX085-5 complete with a two-piece boom and Engcon tilt-rotator.

to obtain more work, but, as things turned out, there was an influx of jobs, as Jack explains, “We agreed a deal with Dobson for a trade-in on the older machine, but with additional contracts being secured, we decided to keep the Dash 4A for a while longer.”

TILT-ROTATOR

While the new Dash 5 Kubota comes with improved hydraulics, increased cab comfort and a variety of other improvements, Jack was particularly attracted to the option of a two-piece boom, as he also wanted to fit a tilt-rotator. The combination of these two features has given him a bigger boost in productivity than he ever imagined. He said, “I already

Below: Having cut his teeth on the family’s Lake District holiday park, we met Jack Dickson and his new

midi-excavator on a long-term inner-city job.

although I do have a few more extras I want to add when I have the time.”

had a standard tilting ditcher on my old machine, which just opened up a raft of possibilities. I thought that the tilt-rotator would take that a step further when in fact it’s given us a huge leap instead.”

While the choice of base machine was almost a given, Jack took the time to look at all the tilt-rotators available before making his decision, adding, “They all have their pros and cons, but it was the recommendation of Jack Hull by Dobsons that swung it for me. Jack specified the Engcon EC209 for us and fitted it all prior to delivery from the dealer. The machine was ready to go to work when it landed,

At the time of our visit, Jack was waiting for his breaker and grab to be converted to work with the Engcon EC-Oil headstocks, which are fitted to the top and bottom of the tilt-rotator. In addition, he was expecting the imminent delivery of a brush attachment.

SITE VISIT

While much of Jack’s work centres round the Lake District, one of the first major projects for the new Kubota was in the centre of Bradford, where he is working on a long-term project from ERH Contracting. ERH is undertaking the installation of district heating pipes through the city centre. They will be used to distribute hot water to heat public and civic buildings, eventually fed by a waste-to-energy plant currently under construction. The twin steel pipes are insulated and coated in impact- and wear-resistant plastic before being buried almost 2.5m below

Left, above and above right: The Kubota midi, configured with a triple articulated boom and equipped with a tilt-rotator, proved to be ideal for this pipeline project in central Bradford.

Kubota

OWNER-OPERATOR // JACK DICKSON

Bradford’s busy streets and pavements. Its compact dimensions and the incredible working envelope provided by a tilt-rotator on three-piece working equipment make the Kubota midi the ideal machine to undertake this work.

“THETILT-ROTATORISA GREATADDITION,ITNOT ONLYMAKESOURLIVES ONTHEGROUNDEASIER, BUTALSOSAFER”

Jack commented, “With the two-piece boom fully extended I can easily reach the bottom of the cut, but also having the ability to curl it in tight means we don’t need a full road closure in which to operate. I can also sit outside of the line of the cut and still dig a flat-bottomed trench thanks to the Engcon.”

We met Jack and his high-spec Kubota in Bradford as he was excavating around an

existing 600mm water main. Under the watchful eye of his banksman, Jack was able to carefully remove the material from round the HDPE pipe. As the trench stays open for a few days to allow the pipe crew to do their thing, Jack was cleaning the sides of the excavation to allow him and his banksman to install lightweight piles, to ensure the excavation stayed safe.

Careful and considered movement of the bucket saw Jack clean the sides of the trench and, having the ability to rotate the bucket any way he wanted, there was very little work left for the banksman Richard to undertake with a shovel. Richard said, “The tilt-rotator is a great

KUBOTA KX085-5

With its triple articulated boom (TAB) and the full-spec Engcon tilt-rotator, this KX085-5 now tips the scales at a shade over the nine-tonne mark. It is powered by an in-house engine rated at 66hp that features a diesel particulate filter (DPF) with a service interval of up to 6000 hours.

The noise level in the Dash 5 cab has been reduced to 72dB, which also now features a new full colour 7in LCD control screen. With an easy and intuitive jog dial, Jack is able to navigate through the control system’s various functions with ease, including the ability to adjust auxiliary hydraulic flow rates. He can also use the control system to programme the LED lights to remain on for a short while after the engine has stopped, allowing him to leave the machine with the benefit of illumination. Another nice touch that Jack has discovered is the new blade float function, which allows easier and quicker grading of material.

addition to the machine, it not only makes our lives on the ground easier, but also safer. We don’t have to be using a pick or a shovel to dig round services, as Jack just spins the bucket round and does it so much quicker and easier.”

Jack concluded, “I have a range of buckets to use with the machine, but the Scandi-style Engcon bucket is ideal for this project. It’s the perfect size for the trench, lightweight and will dig through the harder material with ease.

The tilt-rotator is a big financial investment to make, but what we are able to do with it and the added productivity gains, I envisage that it will pay for itself in just 12 months.”

Below left and below right: Compared to the Dash 4A model, the KX080-5 brings a host of upgrades, especially to the cab interior and, more importantly, to its hydraulic performance.

PRODUCT LAUNCH // AVANT

“UPTOHALFTHE COMPACTLOADERS WESELLCOULDBE ELECTRICINAS LITTLEASFIVE YEARS’TIME”

THIRD-GENERATION ELECTRIC KIT

As Nick Drew reports, the family-run Finnish manufacturer Avant has introduced its third-generation battery-powered compact loaders

Back in 1997, Finnish compact wheel loader manufacturer

Avant developed the MultiTec, its first battery-powered machine. It was pioneering R&D work, but the technologies available at the time, particularly the batteries, were not up to the job and the project was cancelled.

Fast forward to 2017 and with the availability of modern AC electrical components Avant launched its e5 and e6 electric models, of which over 700 examples have been sold to date. They were the first compact loaders in the world to use lithiumion batteries. Broadly speaking, the industry is now using similar technology to roll out a wide range of compact electric equipment.

DIVERSIFICATION

Compact construction equipment producers will increasingly be procuring batteries, competing on the global market with much higher volume on-road vehicle manufacturers. Just like a diesel engine, the battery pack is the single most expensive component in any item of compact construction equipment. Securing a supply of such components is critical, but with a continued dramatic increase in global demand, the cost of battery packs remains frighteningly high.

Since Avant was established in 1991, it has manufactured 90,000 compact wheel loaders. On average, 33 machines roll off the assembly line every day, 90% of which

are exported. Jani Käkelä, son of company founder Risto Käkelä, claimed, “According to our predictions, up to half the compact loaders we sell could be electric in as little as five years’ time.”

Against this background, in 2022 it was decided to establish Avant Power, to develop and manufacture battery packs for compact construction equipment. The cost savings associated with local, in-house production will be reflected in the price of electric Avant products, giving them a competitive edge. It also gave Avant the opportunity to develop battery packs specifically suited to such a rugged application, complete with a superior heating and cooling system better suited

Left and above: Avant has launched two compact electric loaders featuring the firm’s in-house produced, high-tech battery packs.

“OURBATTERY

TECHNOLOGYWILL BRINGMANY BENEFITSANDWE WILLBEABLETO RESPONDTO STRONGGROWTH INTHEFUTURE”

to working on snow clearance duties during the harsh Scandinavian winters.

The new Avant Power operation was established in a purpose-built, state-of-theart facility next to the main factory at Ylöjärvi. The new firm’s chief operating officer, Mikko Piepponen, explained, “We have invested heavily in product development and we also have partners with world-class expertise. The exceptional solutions in our battery technology will bring many benefits to our customers and we will be able to respond to strong international growth in the future.”

POWER PACK FEATURES

Production of lithium-ion battery packs at Ylöjärvi began in January this year, and operations are currently being ramped up to produce a projected 700-plus units next year. Two 44v lithium-ion battery packs are available, rated at 13kWh and 27kWh.

Like the majority of automotive power packs, these are constructed from individual 21700 lithium-ion cells, in this case the nickel-manganese-cobalt variety (see panel), which look like a larger version of an AA battery. They are assembled into 360-cell modules, comprising two modules in the smaller capacity battery pack and four in the more powerful version. In automotive applications, the common

way to regulate the temperature of such battery packs is to sandwich cooling/ heating plates between the layers of individual cells, but Avant’s design is radically different. With the 360-cell modules fastened inside the green battery pack, the housing is filled a non-conductive coolant, which Avant calls OptiTemp. With this immersion thermal management technology, there is far greater control

available to the system’s digital brain to heat or cool the battery modules as required, including during recharging. In addition to the latest generation of multi-level protection sub-systems for the battery pack, this advanced thermal management system helps to extend both the battery’s range and lifespan. The battery packs come as self-contained units with a cluster of electrical connections.

Above and right: Both machines offer a lift capacity of 900kg and 30lit/min auxiliary hydraulics. The e513 is fitted with a 13kWh battery pack, while the e527 gets 27kWh of stored energy.

NEW PRODUCTS

The first compact loaders to feature Avant’s OptiTemp batteries are its new e513 and e527 models, which offer a significant increase in operating time over its original e5 and e6 machines. Equipped with the larger 27kWh battery pack, the e527 offers an operating time of six hours, double that of its predecessor, or it can travel on the road for 21km on a single charge, a 60% improvement in range.

The e513 is basically the same machine, but equipped with the smaller 13kWh battery pack, for which a single charge provides a range of 3hrs or 11.4km. This variant is aimed at less intensive applications, such as livestock, equine, greenhouse or DIY applications. Both machines offer a lift capacity of 900kg, an auxiliary hydraulic system capable of delivering oil flow of 30lit/min and, with the telescopic boom, a maximum lift height of 2820mm.

Both loaders have an on-board 3kW charger, which will take under three hours to fully recharge the smaller battery pack, while the e527 will spend over 5.5 hours hooked up to a domestic electrical supply. For professional use, a 400v/16a external charger is available, which slashes recharge times to 1hr 10min and 2hr 20min, respectively. Only available for the larger battery pack in the e527 model, a 400v/32a fast charger is also offered, which cuts its full recharge time to just over an hour.

PRODUCT LAUNCH // AVANT

FIRST IMPRESSIONS

With plenty of snow piled up from clearing the factory’s car park, there was a selection of new Avant loaders available to try out. I opted to spend time in an e527 model fitted with a toothed loading bucket, an attachment configuration not usually seen on small compact loaders.

These new electric loaders look like Avant’s diesel-powered 500 and 600 models, with the rear half of the chassis containing the engine or battery pack. Access to the seat is straightforward, a step up while grabbing the canopy frame and swing into position. This example was configured with a rear screen surround, which offered some protection from the elements, while the option of a fully heated cab will be offered in due course. I was delighted to discover that the PVC-covered seat in this canopy/ rear screen version was heated.

What I like about these machines, whether diesel- or electric-powered, is that they are simple to operate. Forward or reverse drive is selected by two pedals down on the right-hand side. A hand throttle is located just behind the joystick controlling the loader arm and attachment. Eight rocker switches, also on the operator’s right, control the machine’s lights, parking and master lock and boom float. One of these switches controls the machine’s working mode, which offers fast and slow settings, in addition to the default eco mode.

EDITOR’S COMMENTS BATTERY TECHNOLOGY

Lithium-ion type batteries have been with us for a long time, but the components used in smart phones and laptops are not suitable for upscaling for use in an electric vehicle. This is partly due to the weight, size and cost of the resulting battery pack, but also due to limitations of such battery technology’s operational and recharging performance, together with their projected lifespan. What changed all this was the development of different Lithium-ion chemistries, particularly the composition of the battery’s cathode, the metal that gathers and transmits the energy within the battery. The top three types of modern cathode are nickelmanganese-cobalt (NMC), nickel-cobaltaluminium (NCA) and lithium-iron-phosphate (LFP). Compared with a decade ago, these types of batteries are cheaper to produce, lighter and have a higher power density.

Avant uses NMC battery cells, an American technology that features a cathode with a high nickel content and offers an extremely high energy density, you can pack a lot of power into a kilo of NMC batteries. This is currently the most successful of the three alternatives that comes at a premium price, but it is also a battery technology that requires a relatively high degree of digital supervision, particularly its temperature. A similar product is NCA batteries, which is the Japanese technology used in Panasonic cells, their biggest customer being Tesla’s USA operation.

The new kid on the block is the LFP, often called LiFePO4, battery, produced and widely used in China. They may not have the energy density and other performance metrics of rival technologies, but they have two things going for them. The cathodes are made from common elements, mainly iron and phosphor, so they are cheaper to produce than their rivals. In addition, it is an incredibly stable battery chemistry, requiring relatively little in the way of digital supervision.

A module of 360 battery cells is assembled. Two of these modules are used in the 13kWh pack, while the 27kWh battery gets four modules containing a total of 1440 cells.

“THEYHAVETHE

HYDRAULICOUTPUT, TRACTIONANDWORKING ENVELOPETOUNDERTAKE AMULTITUDEOFTASKS”

FACTORY TOUR

Avant has invested €10m in its highly automated compact loader factory, with a recent large extension to increase production equipped with robot welding, cutting and bending machines. One example is the German-built Trumpf TruBend 5130 bending machine, which subjects a laser-cut piece of steel to a series of highly accurate bends, to produce a finished component.

Although some manual welding is still undertaken, increasingly this is being undertaken by robot welding machines. There are eight robotic welding stations for the major frame components alone. The completed loader frames are then sent through the site’s semi-automatic powder coating paint facility, before heading to the assembly line.

As we toured the factory, autonomous forklifts were scanning barcodes on the components, then moving them to where they were required. It’s absolutely incredible to see these units trundling around the floor space, occasionally stopping when they encountered the odd rogue trade journalist blocking their path.

An updated multi-functional display monitor is fitted to these new models, offering feedback on battery status, temperature and the loader’s power consumption, in addition to the usual machine functions, including setting the output of the auxiliary hydraulics.

FIRST DRIVE

Based on previous experience of Avant machines, I selected the hare position on the throttle, but with the machine set to eco mode, which would provide more than enough speed and power for my liking. I initially took it for a spin around the car park, to refamiliarise myself with how these quirky little machines react.

With the cab mounted on the front half of the articulated chassis, it can feel a little bit strange at first, but you soon get used to it, together with the advantages of the fixed view along the centrally mounted single loading arm. Even in its eco setting, I found the machine to be extremely lively and fast. I probably should have reduced the throttle input, but by this time the banks of snow beckoned.

Two electric motors are fitted, one for drive function and the other for the

working equipment and steering. Such electric motors instantaneously produce their maximum torque, providing a thrust of momentum as I ploughed into a heap of frozen snow, prompting an initial spell of wheel-spin.

I then decided to put the bucket teeth to good use, to break up the snow by using them in a downward action, which enabled me to grab a full bucket load.

The machine features a telescopic boom that extends outwards by 600mm. It is operated by a small lever, which is my only criticism of the otherwise straightforward controls. Taking your hand off the loader control joystick to operate this lever makes it a bit of a disjointed operation. I would like to see the boom extension controlled by a roller thumb control on the joystick. With an overall width of 1130mm and a length of 2610mm the machine is well balanced when working, and a travel speed of 10kph makes it no slouch. The inside turning radius is less than a metre, and the outside radius 2050mm, so it’s a highly manoeuvrable piece of kit. As with all electric machines, it is super quiet in operation, with just a few squeals to be heard while in use.

Inset above and above right: Components are delivered to the relevant part of the assembly operation by autonomous fork-lift trucks, which scan the part’s barcode.

Right: The manufacturing side of the factory is highly automated, including cutting, bending and welding metal to form structural components.

Left, below and below right: The Avants are simple to operate and with this articulated machine being just 1130mm wide and 2610mm long, it is extremely manoeuvrable and surprisingly quick.

PRODUCT LAUNCH // AVANT

CONCLUSION

Operating the e527 compact wheel loader/tool carrier in the snow was lots of fun, but don’t be fooled, they are not toys. They are incredibly quick and nimble machines, which have the hydraulic output, traction and working envelope to undertake a multitude of tasks, thanks to the 200-odd attachments available from Avant.

These latest electric versions take the concept to a new level, with an immediate surge of torque available from the power pack.

Located in the Pirkanmaa region to the west of Tampere, Avant’s compact equipment factory at Ylöjärvi is truly state of the art. The facility features a host of automated and robotic processes, undertaken in an unusually clean environment.

After an extensive period of R&D, Avant Power’s new operation is up and running, producing battery packs for the assembly line next door. Looking to the future, there will be a huge demand for such advanced batteries, which could offer a plug-‘n’-play solution to many applications.

OPERATOR FEEDBACK // HYDREMA MX20G

“DESIGNEDFORHEAVY LIFTINGTASKS,ITHASA REARSWINGRADIUSOF JUST1839MM,THE SHORTESTIN

COMPACT DUCK RUNNING ON RAILS

Eoghan Daly reports from Finland on a compact radius, 20-tonne wheeled excavator that is a factory-built road-rail machine

ail contractors working on the UK and Irish networks seem to favour a small number of manufacturers to satisfy their needs for road-rail excavators. Their Finnish counterparts adopt a different approach, using a far wider selection of base machines and factoryproduced road-railers. They all require additional engineering to operate on Finland’s 1524mm-wide gauge rail network, not the common 1435mm gauge used in most of Europe.

RWe visited Riihimaki railway station in southern Finland to see a Hydrema MX20G Rail excavator run by contractor Verkkoviikarit Oy. Our aim was not only to receive feedback on the capabilities of this

factory-built road-railer in this application, but also to take a closer look at the underlying short-tailswing 20-tonne wheeled excavator, which is a rarity on these shores.

BACKGROUND

In 2022, Danish manufacturer Hydrema revamped its dealer structure in Finland with phenomenal results. Sales of construction equipment have taken off and Hydrema products have also made a positive impression on the rail sector.

Verkkoviikarit is a major construction company in Finland, whose rail division runs a considerable fleet of specialised equipment, including several Hydrema road-rail excavators. In addition to rail

decommissioning, maintenance and construction projects, the scope of their activities includes dedicated electrical works and installing automation systems.

When not working on rail projects, the road-rail excavators and their highly experienced operators are kept busy on a variety of other tasks, which will inevitably include snow-clearing duties during the winter months. To get the most from this investment in people and machines, in true Nordic fashion the base machines are to an extremely high specification.

With 11 tracks and six platforms, Riihimaki is an important rail hub both for passenger and freight trains. The station, which has evolved considerably from its humble

Left and inset: The triple articulated working equipment on this Hydrema MX20G Rail excavator provides a reach of 8.8m, to which must be added the reach of the tilt-rotator.

“THELIFTINGPOWERANDSTABILITYAREINADIFFERENT CLASS,IDON’TTHINKTHEREISANYTHINGTOMATCHIT”

origins way back in 1862, is run with Scandinavian efficiency. The same is expected from their chosen contractors, to carry out their assigned duties in a safe and efficient manner, without unplanned disruption to the busy train timetable.

FIRST IMPRESSIONS

This Hydrema MX20G Rail excavator was the latest addition to the Verkkoviikarit road-rail fleet. At the time of our visit it was six months old and had clocked up 900 hours. It has remained trouble-free over this time, apart from a fault with the auto-greaser mechanism, which had been retrofitted by a third party.

Weighing in at 20,500kg, the MX20G is the largest dedicated road-rail excavator produced by Hydrema. Despite being designed for heavy lifting tasks, it has a rear swing radius of just 1839mm, the shortest in its class. It is powered by an ultra-low emissions four-cylinder Cummins engine rated at 129kW, but provides its maximum torque of 780Nm at just 1500rpm. It drives a ZF two-speed hydrostatic transmission, which in turn drives ZF axles.

The hydraulic system serving the upper carriage produces a combined oil flow of over 400 litres per minute. This is able to power heavy-duty rail attachments while simultaneously allowing smooth and precise slewing and movements of the working equipment, while an independent circuit powers travel movements. This version

features a hydraulic steering lock-up system, activated while the machine is running on the rail line.

As you would expect in this application, there are a variety of auxiliary hydraulic lines plumbed along the triple articulated boom (TAB), which provides a reach of 8.8m.

At the end of the dipper is a directly mounted Engcon tilt-rotator with an integrated gripper, which feeds attachment position data to the excavator’s 3D GPS machine guidance system.

OPERATOR FEEDBACK

The operator of the MX20G was Jari Huotari, who has spent a couple of decades working on rail projects. He said, “The first rail machine I operated was an Akerman and more recently a Doosan and then a Volvo 160. The Doosan had a much greater tailswing than the Hydrema, while the Volvo

needed an extra tonne of ballast on top of the standard counterweight.

“The Hydrema is the best machine I have used on rail work so far, as it is very compact and extremely stable, allowing me to make full and safe use of its lifting capacity. Hydraulic performance is also in a different league to other machines. This is very important for a rail machine, since we often use many different attachments that require high oil flow and put big demand on the system.

“There is plenty of engine power with this machine and it remains very economical. The previous Volvo I operated was much thirstier on fuel compared to this Hydrema. It is really economical in digging, but on road travel it does use slightly more.

“The MX20G Rail may be very much on top of any application it is expected to work in, but it is also very much an operator’s

Below: The MX20G Rail remains a versatile wheeled excavator, but is factory-built with heavy-duty rail wheels and other kit to allow it to operate on the local rail network.

machine. In the time I have been using it, I have found it a pleasure to operate from every point of view.”

This factory-built road-railer features 650mm-diameter steel rail wheels with individual disc brakes in each of the rail wheel hubs. The design of the rail gear units allows the machine to work in both low and high rail modes. In high mode, there is 100mm of clearance from the rail line.

The rear rail apparatus incorporates a coupling for a rail trailer, together with a frame to mount an extra-wide bucket. Jari commented, “The bucket linkage on the rail gear is a big benefit, as it allows me to carry tools and other things to the work area down the line. This bucket also has S hitch brackets, which allow it to be used on the boom. This kind of versatility is important in any work, but especially on rail work.”

IN THE CAB

Despite the 20-tonner’s extremely compact slew radius, the cab dimensions are generous, particularly legroom from the well-appointed seat. While a comprehensive control console extends down the offside of the cab, the main operator interface is the 10in all-singing, all-dancing control monitor, which also displays the output from a multi-camera system. The standard build includes Hydrema’s telematics system, providing remote data monitoring of the machine’s health and current workload.

Jari said, “I really like the Hydrema’s big cab, as there is really good space inside. Everything is nicely positioned and the seat gives a very high level of comfort. It is possible to make many different adjustments, so the joysticks sit exactly at the right position to suit what works best for every operator.

“The joysticks are very sensitive, some may say they are too loose, but over a 12-hour shift this is much better, making the machine a pleasure to operate. Having travel and steering on the joystick is also a big advantage and certainly something that should be on every machine.

OPERATOR FEEDBACK // HYDREMA MX20G

“Overall visibility is very good. The only one thing that is difficult is the view to the right side when the boom is in the outward position, but that is to be expected and is unavoidable. It is compensated for by the 360-degree camera system view that gives a very clear real time image on the screen of everything that is going on around the machine, making it really very safe.”

Above, left and below: Operator Jari Huotari highly rates the new Hydrema road-railer, praising its lifting power and stability, together with its large cab.

OPERATOR FEEDBACK // HYDREMA MX20G

LIFTING & TRACTION

For working on the local rail network, this excavator is fitted with the latest Prolec safe load indicator and slew/height limitation system, which is said to be easy to use and delivers fast set-up times.

Even though the system keeps a watchful eye on lifting operations, the machine’s capabilities are extremely impressive, as Jari remarked, “Lifting power and stability are in a different class, I don’t think there is

Below: The rail sector uses some weird and wonderful attachments, some are unwieldy like this one, some power hungry, and some a mixture of both.

Below inset and below left: Access to the powerpack is via a large electrically powered offside gullwing panel, and all key components are reachable from ground level.

anything to match it. Taking a full bucket over the side to the next railroad you see so much stability. When lifting rail track, it is so powerful out to full reach it really is a first class performer. The machine works the same, whether it is three tonnes on the end of the boom or nothing.

“What we appreciate in rail work is the traction a rail machine can deliver, as everything is pulled by the wheels. In winter I use a 4.5-metre plough on snow clearance and the machine just powers on with it.

“The whole machine lighting package is excellent as the location of the boom lights make a real difference to night-time working. When I am cutting the bushes below embankment level, the three lights positioned round the stick are ideally placed to light up the work without shadows. Even though this may seem like something obvious, many other machines do not get

their light placement correct.”

Putting aside the performance of the underlying machine and its rail bogies, perhaps this is the most impressive aspect of the Hydrema: how they have got the little details right, to make the operator’s life easier.

Expander® lightens the workload of pin maintenance - in the field or at the workshop. Regardless of pivot position, wear pattern or available equipment, Expander System can be installed in the field with general tooling. Cut repair hours, simplify installation & removal and upgrade to the longer lasting pin system.

See how it works and use our pin finder: www.nord-lock.com/expander-upgrade

IGEARING UP FOR THE FUTURE

Nick Drew reports on a wave of new JCB compact construction equipment

t is shaping up to be a busy year for JCB. As this issue goes to the printers they are hosting a second major product launch of the year. It follows the introduction of a raft of new compact construction equipment early in February, in time for the Executive Hire Show.

As previewed in the previous issue, the headline news is dual drive backhoe loaders, more about this later. However, this key development should not overshadow the other machines introduced to the extensive JCB range, particularly new 2.5-tonne class mini-excavators.

NEW 2.5-TONNERS

A 2.5-tonne class mini-excavator – the largest that can be towed within a 3.5t gross weight limit – is the workhorse of many a crew, both in conventional counterbalance and, increasingly, in zero-tailswing configurations.

JCB’s 8026CTS model has been a popular machine in the weight class over the years, particularly within the UK plant hire sector. However, it was showing its age, as was its stubby sibling, the 8025ZTS, which have now been replaced by the new 26C-1 and 25Z-1 models. The conventional 26C-1 tips the scales at 2675kg, while the zero-tailswing 25Z-1 model weighs 2550kg. Both have an overall width of 1500mm and feature no fewer than nine integrated trailer tie-down points.

First impressions of the new minis are that they appear dynamic and stylish machines, in keeping with the overall design of JCB’s larger compact excavators. Like their larger counterparts, they feature pressed steel bodywork that can withstand the odd knock, ideally suited to the hire sector.

Inset and below: In time for the Executive Hire Show in Coventry, JCB launched a variety of compact construction equipment, including 2.5t minis and another electric site dumper.

As is the engine, an ultra-low emissions 18.4kW (24.7hp) Kohler, which does not use AdBlue and does not have a diesel particulate filter. Daily checks and routine servicing look easy enough, as filters and check points are readily accessible in the engine compartment.

“INTHEDIG,THEZEROTAILSWINGMININEVER

The lift-up bonnet extends almost the entire length of the offside and opens to reveal the battery, battery isolation switch and radiator cap, together with the hydraulic tank and its filter. Nicely positioned at the front is the diesel tank filler cap, providing excellent access for those who top up using 25-litre drums.

JCB’s high-tech working equipment bushes help to push out greasing intervals

to the 500-hour mark, again ideal for plant hire. The new minis feature improved boom and arm geometry over their predecessors. They also come with a high-flow double-acting auxiliary hydraulic circuit as standard, delivering 48 litres/min for powering attachments such as flail mowers and planers.

I wanted to spend time on the new zero-tailswing 25Z-1, which offers a maximum dig depth of 2824mm. In addition to a supplementary counterweight, the example available on the demo plot was fitted with the shorter 1100mm dipper arm, but a 1300mm option is available, which is likely to be the most popular configuration for the UK market.

Below: The 2550kg zero-tailswing JCB 25Z-1 mini-excavator is joined by the conventional tailswing 26C-1, which tips the scales at 2675kg.

IN THE CAB

The 26C-1 and 25Z-1 share the same cab structure, for which a canopy variant is also available. The canopy saves a little weight over the full cab, important when getting close to a 3.5t towing limit. In addition, utility contractors often prefer this configuration, as they are constantly getting off and on the machine during the course of their work.

The roll-over and tip-over protected cab is spacious enough and offers plenty of legroom, however, as is often the case with smaller minis, there is no space behind the seat for storing a lunch bag. A cab heater is the standard fitment, with a full air-conditioning package on the factory options list.

All-round visibility is excellent and it’s good to see that flat glass is fitted, which is a lot less expensive to replace when damaged. I especially liked the 66/34 split front screen. This horizontal windscreen split configuration has been used on and off

PRODUCT LAUNCH // JCB

throughout the industry for decades, but I still feel it’s a great feature. It is easy to use, the larger panel being moved up in the roof out of harm’s way, while also offering uninterrupted forward visibility into a trench.

The cab interior has a touch of JCB’s X-Series to it, but a lot simpler and more user-friendly. Most of the control buttons and function switches are located on the offside console, easy to use and selfexplanatory in design. There are a couple of cubbyholes and that all-important cup holder. Five adjustable air vents are located around the cab, four to the front and one to the rear. Those who like a bit of fresh air will be delighted with the double opening offside sliding window arrangement.

A rotary jog dial control, almost a staple requirement in a modern excavator these days, is provided, and can be used to access and navigate the monitor screen. Displays include service hours, oil flows for various attachments, oil temperatures and adjusting a multitude of settings.

IN THE DIG

Left and right: The cab of the

is spacious enough and offers plenty of legroom, but lacks any storage behind the seat.

I put the 25Z-1 to work on a pile of extremely wet stone in JCB’s quarry demonstration area. Cranking up the jog dial, which also doubles up as the throttle control, to the maximum power setting and the engine just purred away nicely. I set about digging into the pile, which was an effortless operation for this compact powerhouse.

Saving the best for last, a key feature of the 26C-1 and 25Z-1 models is a new type of variable displacement, load-sensing, electro proportional controlled hydraulic pump. This is said to allow every bit of engine power to be used by the hydraulic system. In the dig, the zero-tailswing mini never faltered once, with no noticeable dragging down of the engine power. The machine was nice and smooth to operate and had plenty of poke about it.

The new JCB 26C-1 and 25Z-1 mini-excavators tick a lot of boxes: for starters they are modern machines with decent cabs, which are robust and easy to maintain. What sets them apart is the new hydraulic pump technology, matched to revised working equipment that, from my short time in the seat, results in an impressive mini-digger.

THREE-TONNE ELECTRIC DUMPER

JCB continues to expand its range of battery-powered compact equipment with the all-new 3TE swivel skip, three-tonne class site dumper. It is powered by four lithium-ion batteries totalling 20kWh that, depending on usage, can provide enough power for a full day’s work. The battery pack drives a 22.3kW electric motor that connects to a drop box providing full-time four-wheel-drive. The hydraulics are powered by a 16.1kW electric motor driving a hydraulic pump, which delivers the power for the steering and raising and lowering the skip. The new site dumper can be recharged in eight hours from a 110v or 230v supply, or in just two hours connected to JCB’s optional universal fast charger.

25Z-1

Below and right: The new 2.5-tonne class minis are powered by an engine rated at 18.4kW (24.7hp), which does not use AdBlue nor require a DPF.

“ASIDE-ENTRYCABTAKESAWAY

DUAL-DRIVE BACKHOES

There can be no more iconic machine than JCB’s backhoe loader. This year the Staffordshire-based manufacturer is celebrating 70 years of producing them. The 3C model in particular has a special place in my affections, as my late father was a passionate operator of them his entire life. Always innovating, JCB has revealed a number of significant upgrades to the machines to simplify the operating experience, together with increased levels of comfort and functionality.

One of the most exciting developments is the all-new Dual-Drive function that will be available as standard on all 3CX Pro and 4CX Pro machines with servo controls. Put simply, this feature enables the operator to drive and operate the machine whether they are facing forward or to the rear. This ability has been present on large articulated Huddig and Lannen Scandinavian backhoe

loaders for many years, but it is the first time that this functionality is available on a conventional backhoe. Anyone who has spent time on a backhoe loader knows that it can be a time-consuming exercise. There is the constant need to move the machine, requiring you to raise the jack legs, spin round to face the front and lift the loader arms before moving forward, then having to repeat the exercise in reverse, which can all be a bit of a faff. But with the Dual Drive, the whole operation is speeded up and makes the machine more userfriendly for the operator and ultimately saves a lot of time on site.

REARWARDS DRIVING

I climbed on board a 4CX Pro Dual-Drive model to experience it for myself. Since I was a boy, operators started with the seat facing to the front, only spinning round to the rear to undertake backhoe work, so being invited to take the seat facing to the rear felt strange. With the flick of a switch on the left-hand dashboard I was in control of the travel functions. On the underside of the right-hand joystick, I found a forward and

moved off. It initially felt quite strange and I quickly learned that only light movements on the steering rocker are required. It is an extremely responsive steering system, but the longer I spent on it the more natural it felt. It is like the way a wheeled excavator reacts when you are driving with the steering wheels to the rear. It takes a bit of mind training to start with, but very quickly becomes second nature. A 7in monitor is nicely positioned to the operator’s left, providing a wide-angle view to the front of the machine.

The hydraulics are so well tuned I quickly learnt that I could travel and work the backhoe at the same time. That is an

Above, right and below: JCB’s Dual-Drive system allows the machine to be driven on site from the rear operating position, significantly improving the productivity of a backhoe loader.

PRODUCT LAUNCH // JCB

incredibly useful feature for undertaking work such as placing concrete for kerb layers and other similar situations. It’s a bit of a cliché, but I feel this could be a game changer for the backhoe loader. It not only increases the versatility and ability of what has always been a versatile machine, but takes it to another level.

WORKING EQUIPMENT

The new range of JCB backhoe loaders features improvements to the front-end working equipment, including a Return to Grade function on all machines fitted with servo controls, which enables the operator to set up the 6-in-1 front bucket for grading work.

With the uptake of laser levelling systems on sites up and down the country, JCB has come up with a 2D laser receiver mount, which is fitted to the front loader arms. The pole can be adjusted to suit a wide range of receivers, and on this occasion was fitted with a Leica system.

The option of having an integrated quickhitch with forks on the front arms has also been updated. As we all know, using bucket mounted flip-over forks can be a painful experience, especially when trying to use them at ground level, where visibility is virtually impossible. You are effectively relying on guesswork to enter the forks into a pallet.

With the new quick-hitch option, you can drop off the bucket and use the machine for dedicated fork work. Capable of a load capacity of 2000kg, the fork carrier has been widened by 220mm to improve stability when carrying wider loads. The forks now sit outside of the carrier frame, making it easier to reach them and stow them after use.

JCB now offers the option of twin front cameras, including a camera mounted within the quick-hitch frame, providing superb visibility of the forks and the load to be moved, which is much needed when working at ground level. A second camera mounted in the roof provides a view of the quick-hitch bar, and both cameras display their output on a 7in screen.

NEW TANDEM ROLLERS

JCB has introduced two new tandem vibratory rollers, the CT380-130 and the CT430-140, completing a five-model range of sub-five-tonne machines.

The 3.8-tonne class, 130cm drum width CT380-130 model is powered by a 36.5kW (49.6hp) Kohler engine. Its typical operating weight of 4.1 tonnes generates a linear load of 15.8kg/cm. With a centrifugal force of 41-59kN, the machine has a vibrating frequency of 50-60Hz and an amplitude of 0.50mm. The drums can be offset to either side by up to 80mm and the roller is capable of 30% gradeability when vibration is operating, or 40% when not compacting. The larger CT430-140 weighs 4.5 tonnes and offers a linear load of 16.4kg/cm. With the same frequency as its smaller stablemate, the heavier machine delivers a centrifugal force of 44-63kN.

The rollers feature a hydrostatic doubledrum drive system to both drive the drum and drum vibration systems, while the operator can select single or double drum vibration. They also feature an automatic vibration control system, which helps to prevent over-compaction at the end of a layer.

Above: The cab of the latest JCB backhoe loaders is a more pleasant and productive space to spend a shift, thanks to a host technology upgrades.

Below: In addition to a Return to Grade function for the 6-in-1 front bucket on servo-equipped machines, there is now a factory option of a 2D machine guidance system.

PRODUCT LAUNCH // JCB

Below and right: JCB’s skid-steers feature a single arm and a side-entry door, so the operator does not have to clamber over the attachment to get in and out.

REASSESSING SKID-STEERS

It was back in 1993 when JCB first revealed its revolutionary design for skid-steer loaders, which featured a single loader arm and a side-entry cab. No more climbing over whatever was attached to the front loader arms to get into and out of the cab. The design has now been upgraded with the new 270 wheeled and 270T tracked models, offering rated capacities of 1.25 tonnes, while load over height is 2.9m and 2.88m, respectively.

“ASIDE-ENTRYCABTAKES AWAYALLTHEHASSLEOF OPERATINGASKID-STEER LOADER”

system offering Bluetooth connectivity. In addition to a good rear camera, natural visibility has been improved by a rework of the door’s B-post and a wider roof window, together with some repositioning of buttons and instruments. The seat rail runners allow the seat to be moved a lot closer to the front screen, allowing an even better view of the attachment.

CONCLUSION

The new models are powered by an ultra-low emissions JCB DieselMax 430 engine rated at 55kW (74hp). This engine is 24% smaller and 30% lighter than its larger 4.4-litre predecessor, but produces 10% more maximum torque at just 1500rpm. A new control system allows the operator to set maximum forward and reverse speeds in 1kph increments. One of three acceleration rate settings can be selected for the hydrostatic transmission, and there are four power settings to choose from.

The cab has been updated with a new bank of soft-touch buttons, now located vertically on the right-hand pillar. A new 7in colour touch-screen provides the usual access to a myriad of machine setting and status data. There is even a sound

A side-entry cab takes away all the hassle of operating a skid-steer loader, which should be enough to warrant another look at these machines. However, the smart money is on taking the versatility

to a whole new level, as JCB’s single arm, Teleskid 3TS-8W model features a telescoping boom, providing increased lift height and forward reach. It offers a maximum lift capacity of 1.45 tonnes and can raise the load to a maximum height of 4m. The load remains level thanks to its in-built vertical lift path. JCB’s Smooth Ride boom suspension system is part of the standard build.

Similar to their Dual-Drive backhoe, JCB’s telescopic-boom side cab entry, wheeled skid-steer loader is such a leap forward that it certainly does deserve further consideration.

Above: The Teleskid 3TS-8W model features a telescoping boom that can raise the load to a maximum height of 4m, offering a maximum lift capacity of 1.45 tonnes.

ANOTHER HIRE NOT JUST

Paul Argent reports from Brassington Moor Quarry on the latest generation of 70-tonne class Liebherr excavator

A70-tonne class 972 excavator is the latest addition to the Liebherr Rental fleet, which includes material handling machinery in addition to excavators up to 80 tonnes.

Sales manager Gareth Blythin said, “We are not a traditional plant hire company offering just standard kit. We offer our clients a fleet of bespoke, high specification machinery aimed at particular material handling applications. All of our machines on the earthmoving side come fully compliant to meet current quarrying regulations.”

Below and inset: A 72-tonne Liebherr 972 excavator is on a three-year lease contract from Liebherr Rental at Longcliffe’s Brassington Moor Quarry in Derbyshire.

Launched in 2022 to replace the 966 model, the example on the Liebherr Rental fleet is spending three years at the Brassington Moor Quarry in the heart of Derbyshire’s Peak District, extracting and loading high quality calcium carbonate materials.

SITE BACKGROUND

This site is run by family-owned Longcliffe Quarries, which has been working the Derbyshire limestone deposits for almost 100 years. The 60-acre Brassington Moor Quarry produces some of the finest and most sought-after calcium

“WE HAVE BEEN VERY PLEASEDATTHEWAY LIEBHERRRENTALHAS APPROACHEDTHEDEAL”

carbonate powders and aggregates in the UK. Constant reinvestment and innovation in production processes over the decades has resulted in Longcliffe being the premier name in the UK limestone industry.

The quarry’s calcium carbonate products are used in a variety of industry sectors, from animal feeds to glass manufacture. They are also used in the production of sealants and adhesives, not forgetting being a key input into the manufacture of plasterboard.

Brassington Moor currently produces one million tonnes of material a year that, in the context of Peak District quarrying, is not a huge volume. However, in this sector of the limestone market, quality counts for everything. Like many modern UK quarrying concerns, Longcliffe uses a combination of its own equipment and leased machinery to provide a cost-effective means of extracting and loading the material.

“LIKETHESMOOTHNESS OFTHECONTROLSOVER THE966,THEYARE RESPONSIVEAND ACCURATEANDTAKE LITTLEEFFORT”

Quarry manager Jon Murgatroyd said, “To obtain the highest quality products we need to blend the material in specific quantities, and this means extracting from three separate seams around the site. Traditionally this has been done with a single large excavator and a wheeled loader. We recently changed our approach to extraction and replaced the wheeled loader with a second large excavator, and this has proved beneficial in terms of our production capabilities.

“As we were happy with how the implemented changes were working, we decided to look at renewing the second excavator in 2023 and spoke with several suppliers about a three-year lease deal for a 70t class machine. Following discussions with Gareth Blythin at Liebherr Rental we decided their 972 would give us the ideal combination of production and fuel economy.”

972 WALK-ROUND

While much of the Longcliffe fleet carries their blue and white corporate colour scheme, the new arrival has been supplied in Liebherr mining white. Sitting on a heavy-duty undercarriage with 600mm-wide track pads, this example features additional base-plate protection along with three-piece chain guides. Additional protection has also been fitted over the final drive units to prevent damage from larger rocks.

Incidentally, this quarry excavator is expected to clock up a higher than average time spent tracking, as it often has to move to another part of the site during a shift to extract a different grade of limestone. This is to ensure that the correct chemical balance of materials is available at the on-site processing plant.

While many 70-tonners use a somewhat complicated step

Above: The Brassington Moor Quarry produces one million tonnes a year of an exceptionally high-quality calcium carbonate, used in a variety of industries.

LIEBHERR 972 KEY FEATURES

The 972 is powered by a 16-litre Liebherr V8 engine developing 449hp at 1800rpm. However, it features Liebherr’s power efficiency engine management control, which delivers peak torque at a far more leisurely engine speed of just 1100rpm. Not only does this reduce noise, it also significantly improves fuel economy over the older 966 model, while delivering excellent digging performance.

All of the major components are easily accessible through large side panels in the upper-structure or through the engine hood up on top. To aid safe access, a non-slip and galvanised walkway is fitted to both sides of the upper-structure, while a similarly finished boxing ring surrounds the top of the machine.

The cab has been fitted with a top FOPS guard and the front screen gains a tiltable guard. A premium LED lighting package has been fitted to cab and boom. The service area also gets a full set of LED lights, while the operator benefits from a timed external illumination package at the end of a dark winter shift.

system for cab access, this Liebherr has been fitted with a simple folding step system made in Norway by Olav Wendelbo. It also features the optional Wiggins fast fill and drain connection system for fuel and engine oil, allowing the machine to be

refilled and serviced quicker, from a safer position at ground level.

For this application, the 972 has been configured with a 7m boom and a 2.6m dipper stick to provide the best combination of breakout force and reach. It is equipped with a 5.0cu.m capacity, heavy-duty Liebherr bucket, and its half-delta cutting edge carries five Z90CR teeth. Cylinder protection to both the boom and stick cylinders has been added, as well as additional protection to the base

of the stick. The entire excavator is lubricated by a centralised greasing system. Unlike mass-market construction excavators available for hire, this latest generation of Liebherr machines draw much of their inspiration from their larger mining kit. For example, there is a bucket fill assist function that offers automatic bucket filling for increased productivity over the entire shift. There is also Liebherr’s Modetronic system, which provides the operator with the

Top, above, below, below left and inset: This 972 is configured with a 7m boom and a 2.6m stick and is equipped with a heavy-duty 5cu.m capacity bucket featuring a half-delta cutting edge.

“HELIEBHERR972IS DELIVERINGINANUMBEROF COMPANYPRIORITYAREAS INCLUDINGSAFETYAND SUSTAINABILITY”

opportunity to customise the operating modes, to better match the work cycle in each type of application it is being used for.

Part of the package was the services of a Liebherr trainer, to run through the machine’s features on site before it was put to work. Site supervisor Ray White said, “Having Andy Roberts come out and spend a day running through the new machine was very handy. We are all experienced operators here, but as machines get more and more sophisticated, having that knowledge passed over makes a big difference.”

SITE VISIT

At the time of our visit, the new Liebherr’s regular operator Kevin Beacham was undertaking his core duty. Sitting on a small bench, he was pulling material down from the face into a rock trap, before loading over the side of rigid trucks. The quarry runs a small fleet of 70t capacity rigids, together with a solitary 40t articulated dump truck. The 72-tonne Liebherr excavator would usually be considered to be on the small

side to be an effective match to the haulers, taking 10 passes to load the 70-tonne capacity trucks. However, this application is not all about volume. Instead of being focused on getting as much material away from the face as possible, Kevin selects the right material to go on each load. Any oversize material is set aside for secondary breaking, as is any poorer quality material.

Kevin said, “It’s a very nice comfortable cab. It’s very quiet, the seat and seating position are excellent. One thing I do like is the smoothness of the controls over the older 966, which are responsive and accurate and take very little effort to use. All in all, the machine is a big step up from the older machine. It’s smoother, quieter and a lot better balanced too.”

Quarry manager Jon Murgatroyd commented,

“We have been very pleased at the way Liebherr Rental has approached the deal, not only for the new machine but also in supplying it when we needed it.”

Looking at the bigger picture, the Longcliffe Group’s MD, Paul Boustead, concluded, “As well as proving to be operationally excellent, the Liebherr 972 is delivering in a number of other company priority areas including safety and sustainability.”

Above and inset below: The 972 is powered by a 16-litre Liebherr V8 engine developing 449hp at 1800rpm, although maximum torque kicks at a fuel-efficient 1100rpm.

YOU ONLY NEED ONE

Toughness is the reason why we’ve already sold over 500,000 wheel loaders world-wide and when it comes to toughness, our H-Series is as tough as it gets. The H-Series has genuine heavyweight credibility delivering the power, control, comfort and durability required to make light work of the heaviest jobs. Whatever your reason, discover the H-Series for yourself. See us

BOOT CAMP BASICS

pened in 2021, the Operator Skills Hub at Coleshill near Birmingham is a dedicated plant training facility, built as a joint venture between Flannery Plant Hire and main contractor Balfour Beatty. More recently the centre, with its classrooms, simulators and dig area, has been awarded Government funding to operate a skills boot camp in plant operations.

This boot camp is aimed at two groups: existing operators using the facility to upskill, for example to use GPS 3D machine guidance systems; and giving potential new entrants to the industry a free first step up the ladder.

Earthmovers correspondent Peter Haddock despatched son Lucas, together with his friend Carta Davies, both aged 16, during the schools’ half term holiday to find out more.

Lucas said, “I have been waiting for this moment for a long time. Ever since I was young, I have been interested in diggers. I have worked with my dad at events and

shows, getting in the seat a couple of times. But I really wanted to be able to operate them properly. When I turned 16 in December, I looked at training opportunities and got in touch with Flannery, as the centre is close to where I live.”

WORK EXPERIENCE

Lucas continued, “During the training week, I woke up at 6am to pick up one of my close friends, Carta Davis, and then we headed to the Operator Skills Hub for 8am, ready for the training that was about to commence. On my first day, all the staff were very welcoming at the facility, which was very pleasing, as my nerves were really up there.

“After the initial meeting and tour, it was time for Carta and me to go and do our induction. This was about getting to know all of the site rules and procedures. They included where full PPE was required, any assembly points, all welfare areas, the names of all first aiders and what the procedure was in case of an emergency or fire.

inset: Already a social media star, we welcome Lucas Haddock as an Earthmovers correspondent, reporting on his first plant operator training experience.

“THISEXPERIENCEHASREALLYOPENEDMY EYES,SHOWINGTHEMANYOPPORTUNITIESIN THEPLANTOPERATINGSIDEOFCONSTRUCTION”

“Once the induction was over, we began basic training, where we learned many different things. These included red zones, which involve being safe around any operating machine. I learnt to make sure when passing any machines that the operator knew of my approach and how to safely approach in the first place.

“For example, if you are approaching an excavator you need to do so from the front driver’s side so they can see you. And only move towards the machine when they have grounded the bucket and given the double thumbs up. Once that signal has been given you are safe to move around the machine or approach the operator.”

MACHINE TIME

Now allocated to an exotic piece of machinery, Lucas continued, “The next thing we began to learn about was the machines themselves and in our case it was a Yanmar tracked dumper.

“Before you get into the machine you need to do all of the pre-start checks. Carta and I needed to conduct them each morning before we used the machine, checking off every aspect and making sure that the machine was in correct working order. Firstly, you must make sure there is no damage around the machine, especially that no teeth on the tracks were broken or missing.

“You then check for any oil leaks and

whether the machine has enough oil.

We were also shown how to check the air filter to make sure there is no debris inside and what areas you need to be greasing regularly on the machine. The greasing part generally is only conducted once a week.

“Once we finished the pre-start checks, Carta and I went on to the starting checks, which were conducted once we fired up the machine. They included checking if the horn was working, which was one of my favourite checks. We then lifted the skip up all the way and back down to make sure we didn’t get stuck with material in a none-working skip. We then checked it moved side to side and

that the tracks moved correctly, by going forwards, backwards and side to side.

“Once these checks were completed, we then went on to operate the machine to practise for the practical test that we would be given at the end of the week.”

LEARNING OUTCOMES

Regarding qualifications gained, Lucas continued, “In addition to the practical machine training, during my time at the Operator Skills Hub I gained several certificates. They included my CITB Health, Safety and Environment card, an essential qualification as it enables me to go on site.

Above and far right: In addition to a focus on site safety, the week-long Boot camp course provided the opportunity to be taught how to operate a tracked dumper.

idling time and focusing on the amount of revs your machine is using. From an employer’s point of view, this can also put you a step ahead of everyone else when it comes to being hired.”

CONCLUSION

“The test consisted of 50 questions that we had to get 90% on. After a lot of revision, Carta and I both managed to pass this test. Without passing, we wouldn’t have been able to get our ticket on the tracked dumper. This is because without proving that you first understand health and safety, you are unable to take the machine test.

“We also became Eco Operators after passing the CITB and CPCS practical test achievement in the A57D rigid chassis (tracked) dump truck. This is a new qualification that teaches you about how to use your machine to reduce your impact on the environment. Things like managing

However, the boot camp is not just about paper qualifications, as it exposes potential long-term employees to the culture and opportunities within the industry, as Lucas concluded, “I think that Flannery and Balfour Beatty are doing a brilliant job at getting young adults into the industry.  They are inspiring many people of different backgrounds, some of whom have had a difficult start to life, to join the plant world, which is great.

“I am glad I went to the Operator Skills Hub for my first ticket, as the team were very inviting and really showed me how the construction plant world really works. It gave Carta and me a big insight into the entire industry that we have both really enjoyed.

“This experience has really opened my eyes, showing the many different opportunities that you can have in the plant operating side of construction. And for those we met on the course wanting to find a job, Flannery offers the opportunity for an interview at the end of the course.”

CARTA DAVIS FEEDBACK

Carta Davis said, “Attending a plant operating course was a new experience that I was looking forward to, as I was thinking about getting into this kind of industry. The first thing that struck me about the course was the staff’s passion and dedication, and how supportive and considerate they are. They were not just instructors, but mentors who were genuinely invested in helping us succeed.

“Throughout the course, I found myself immersed in a dynamic learning environment, where theory seamlessly blended with hands-on practice. Whether that was answering questions on paper or questions about the machine, the staff patiently answered our questions and encouraged our exploration, providing constructive and positive feedback each step of the way. They not only taught us technical skills but also how important working together was because of the dangers on the work site.

“Furthermore, the staff went above and beyond to ensure Lucas and I felt valued and supported. All the staff were approachable, encouraging and willing to offer guidance whenever needed, and when it came to test day, all I felt was positivity and motivation. Their dedication to our learning journey was truly inspiring and played a significant role in the experience.

“By the end of the course, I not only gained valuable knowledge and skills in operating plant, but also meaningful connections with the staff. It was an absolutely brilliant experience and a great laugh, which has made me want to try more advanced courses in the future.”

Left and above: The Operator Skills Hub at Coleshill is a dedicated plant training facility, built as a joint venture between Balfour Beatty and Flannery Plant Hire.

EXCAVATOR PILING RIGS

CONTINUE TO IMPRESS

David Wylie visits Burnside Plant to see a pair of their Volvo compact radius excavators at work, together with a Movax sheet piling attachment

Based at East Kilbride, Burnside Plant Hire was founded by Ian Orr in 2011 to undertake general construction work. A few years later, one of his clients asked if they could install some piles over a weekend. They were so pleased with the result that Burnside was asked to undertake their next half-dozen or so piling jobs. Since then, Ian has grown the business into a proudly Scottish and well-respected piling installation company, which works throughout the UK on tubular and sheet piles, driven piles and mini-piles. The firm also has the capability to undertake associated engineering, design and groundwork elements of such projects.

“FORANEXCAVATORTHAT WEIGHSOVER40TONNESWHEN FULLYRIGGED,IT’SAN AMAZINGLYCOMPACTMACHINE”

Inset and below: Burnside has added a third Volvo ECR355E to its piling fleet, together with a smaller ECR235E. Both are compact radius designs configured with triple articulated booms (TAB).

“THECOMBINATIONIS CAPABLEOF ACCOMPLISHINGTHE ENTIREPILINGPROCESS WITHOUTTHENEEDFOR MANUALHANDLING”

FLEET FOCUS

Their fleet includes top-of-the-line drilling rigs and associated equipment, but recent investments have been in excavators equipped with piling attachments, an increasingly popular option for UK piling contractors. Burnside’s chosen excavators are large compact radius Volvos configured with a triple articulated boom (TAB) and equipped with Movax piling attachments.

Back in 2017 the firm ran a standard counterbalance EC220E and based on this experience have stuck with Volvo ever since. In particular, 38-tonne, compact radius, TAB-configured ECR355E models, which feature twin-pumps providing high hydraulic flow. Their first example was purchased in 2021, followed a year later by their second machine. More recently a third ECR355E has joined the fleet

Below and right: With its piling attachment this excavator weighs 40 tonnes, but occupies little in the way of real estate, while offering a huge envelope from its working equipment.

together with a 25-tonne ECR235E model, both equipped with Movax SG-60V side-grip vibratory pile driver attachments.

Ian Orr said, “We needed a big 40-tonne class machine with zero tailswing and a TAB for the toughest of piling applications on challenging sites with restricted room to manoeuvre.

The ECR355EL fits the bill perfectly and the sales and service support from Ross Logan at Volvo SMT GB has been first class.

We like to buy the very best equipment in the marketplace and that’s why we invested in two new Volvo machines with Movax piling equipment. Any bespoke tools or buckets we order from Derek Macaloney at Euro-Fab, such as the swan-neck attachment to provide extra reach for our clamshell bucket, used on deep cofferdam work up to 10 metres in depth.”

Left: The piling business uses a variety of specialist attachments on its excavators, including this swan-neck extender on a clamshell bucket for cofferdam work.

YARD EXPANSION

Burnside recently introduced a pile rental service, for which some 2000-tonnes of steel piles are available on a short- or long-term basis, which is already proving to be a great success. As pile installation services continued to expand, it was time to make more room in their yard at East Kilbride. We met the team as they were piling and then removing a 32m-long x 6m-wide slope on one of the site’s boundaries, which will create enough space to store around 500 tonnes of steel piles.

This task was being undertaken by their new ECR235E and ECR355E excavators, using

piles that were sound, but no longer suitable for hire. Ian explained, “These old 600mmwide, 6m-long GU21 clutch sheet piles are ideal for this job. I wouldn’t hire them out as some have slight end damage, but they will provide a long-lasting retaining wall.

The smaller excavator was initially fitted with Euro-Fab forks, moving piles, materials and tools up on to the elevated bank, where the Movax-equipped ECR355E was sitting.

A Cat-scan survey was also being undertaken, from the edge of the yard’s concrete slab towards the slope, to establish if there were any forgotten electric cables or other services buried beneath. Once the

MOVAX PILING ATTACHMENTS

The excavator-mounted Movax side-grip piling head range is suitable for excavators ranging from large midis to 50-tonners. The modular nature of the design allows them to be configured to handle, pitch, drive and extract different type of piles, ranging from sheet piles, trench sheets and H-beams, to tubular steel piles and timber piles.

The Movax piling head range is a high frequency type of side-grip pile driver, based on two different vibrating technologies. The Standard and Lite models feature fixed, eccentric vibratory movement, while a resonance-free start/stop vibratory system is available for applications in sensitive areas, where disturbances to the surrounding area is minimised.

With this vibratory pile driver attachment on a suitable excavator, the combination is capable of accomplishing the entire piling process without the need for manual handling or any other machinery assistance, an ideal combination for sites with limited space, headroom or access.

The attachment and the piling process are controlled with the help of Movax’s mControl+ system, which includes managing the host excavator’s auxiliary hydraulics and a data logging and reporting function.

piling work was complete, the ECR235E would be used to remove the embankment.

The ECR355E lifted the first 6m-long steel sheet pile into position using the sidegripping Movax SG-60V vibratory driver. The plan was to install a few test piles first, to

Left and above: The excavator-mounted Movax side-grip vibrating head can handle, pitch, drive and extract piles, and is capable of accomplishing the entire piling process without manual handling.

Right: The first test piles revealed an underground obstruction, so the piling head was soon swapped for an auger head, which drilled along the line of work to establish what lay beneath.

“YOUCANWORKIN REALLYTIGHT SPACESANDMAKE ITANALMOST STRAIGHTBOOM MACHINE,FORTHE EXTRA2.5MOF HEIGHT”

establish the ground conditions. Many years ago, there was a building and retaining wall along this boundary, but no one was exactly sure where it had been, or what was left of it in the ground.

With a laser light set up to establish the line of work, the first pile was driven into the hard ground with relative ease. However, the second pile soon hit an underground obstacle. Clearly more investigation was required. Using the double-latching quick-hitch and hydraulic quick coupling lines, the Movax piling head on the big Volvo was soon replaced by an auger head.

The first 3m-long auger flight was fitted with replaceable hardened bits, capable of drilling through solid concrete, which was encountered within the first couple of metres. Adding a second 3m flight, they augured down to 6m. This was repeated a handful of times, which established that a slab of concrete was at a depth of 1.5m to 2m along the piling line, sitting on top of hardcore. The smaller ECR235E was fitted with a narrow trenching bucket to quickly remove this obstruction.

Once the retaining wall was complete, using 66 sheet piles, a new fence will be erected and the ground levelled off, before being temporarily filled with 6F2 stone. This project is part of a series of hard landscaping improvements to the site in preparation for major works planned for next year. They will include additional storage sheds and a new workshop, as well as having the entire yard area resurfaced with concrete.

OPERATOR FEEDBACK

With over 30 years of experience, Ally Raitt operates the smaller 175hp Volvo. He said, “I feel this ECR235E is a wonderful machine,

very versatile, smooth to operate and extremely well balanced for a short swing radius excavator. For our line of work, its compact size can go into some areas that a conventional machine of a similar weight and power simply couldn’t manage. The TAB arm makes the machine even more versatile, particularly when working with the Movax piling head. You can work in really tight spaces and make it an almost straight boom machine for the extra 2.5m of height, to manoeuvre either the steel sheet piles or the auger drill attachment.

“My machine also has the bolt-on rubber pads fitted on its 800mm triple grouser track pads, which are ideal for travelling on a carriageway, as we do a lot of work for utility companies. They have a surprising amount of grip when climbing in soft ground conditions, such as this steep mucky embankment. The ECR235E also has a lot of digging power and a very quiet and comfortable cab space.”

Of the larger 243hp Volvo excavator, operator Calum MacPherson said, “The TAB

is fantastic for our line of work, as it makes the ECR355E extremely versatile when piling. The ability to move the boom geometry as the sheet piles are entering the ground makes the job so much easier. The 4.46m-long undercarriage and 700mm triple grouser track pads make this ECR355E amazingly stable, as we can swing our heavy six-tonne impact hammer head over the side.

“As long as you’re working reasonably close in, it is totally planted for a big compact radius machine. The 5.76m arm and 2.9m stick of the TAB working equipment also means I can work with three 3m auger flights to give a total of 9m of working drilling depth. The powerful engine and twin pumps produce plenty of hydraulic flow to feed the Movax piling head or the hydraulic auger drill motor.

“For an excavator that weighs over 40 tonnes when fully rigged, it’s an amazingly compact machine for piling and digging. When attached to the six-tonne forks it can move large amounts of materials in some very tight spaces.”

Above, inset and below:

The Volvo ECR235E has been fitted with rubber track pads for work for utility companies, and its triple articulated boom, fitted with forks, makes light work of moving the piles around.

“WEHANDLEOVER150TONNESADAY,WHICH WEHAVEHISTORICALLYBEENTIPPINGAT AVARIETYOFRECYCLINGCENTRES”

LONDON STREETS PROCESSING

As Paul Argent reports, some repairs on London’s gas and water mains are now being reinstated with recycled aggregates produced by Terex Evoquip machinery

In the past, when working on a section of gas or water mains, contractors dug down to the offending section of pipe, replaced or repaired it and then backfilled the trench with the excavated material. It was a relatively quick and self-contained working method, but one that often had to use inferior material to backfill the workings, which could result in the repair subsiding over time.

For many years now, contractors have been obliged to reinstate any open trenches with suitable fill material, compact it to prescribed levels, before finishing off the cut with a suitable wearing course, significantly extending the lifespan of the repair. In turn,

this has resulted in the need to truck the arisings off-site, then bring in suitably certified aggregates as part of the reinstatement operation.

More recently, contractors serving this sector are moving away from expensive virgin aggregates towards using high-quality recycled materials. The latest trend is for contractors to bring the aggregate recycling process in-house, to have better control over costs, quality and availability of suitable materials.

BACKGROUND

Terrafirma Pipelines is one of the leading contractors undertaking repair and replacement of gas and water mains throughout London and the surrounding

areas. Their reinstatement crews work within easy reach of the firm’s HQ at Beckton and now use tested and certified recycled aggregates, produced in-house at their modest-sized yard.

The firm’s reinstatement manager James Durkin said, “We handle over 150 tonnes a day of material taken from our projects, which we have historically been tipping at a variety of recycling centres. From there, we have picked up recycled material to return it to our jobs and complete reinstatement works. We were getting bigger and bigger bills for this and decided to look at the possibility of other options to reduce our, and our clients’, costs.”

Terrafirma’s management team looked at

Above: The Bison crusher features platforms to allow operatives to safely pick out any plastic or wood that may make it through the screening process.

several alternatives, before deciding to invest in their own recycling machinery. The firm’s head office in East London is typical of many yards in the area, offering limited space for expansion, which was not suitable for full-size crushers and screeners. Looking across the market, Terrafirma approached dealer Molson, a company they had already had dealings with, regarding the compact equipment available from Northern Ireland-based Terex Evoquip.

James continued, “Once we had made our initial enquiry with them, Molson were very quick to come back to us with details of suitable equipment. Following a demonstration, we placed an order for a tracked Colt 600 inclined scalper and a Bison 160 Hybrid crusher mounted on a hook-lift frame.”

With planning consent for recycling material at the yard granted, the two machines were soon delivered, as James continued, “The size of the equipment was an important factor for us on our compact site. Equally important was the productivity available from the machines. This was something that really impressed us with the Evoquip equipment, the capacity of both machines offers us the ability to increase production when we really get going with the venture.”

RAMPING UP

The 600 is the smallest in the four-model Colt range of inclined scalper screeners from Evoquip. It has a theoretical output of 280 tonnes per hour. With a 2.34m x 1.37m double-deck screen, the Colt 600 is more than capable of handling the mixed material excavated from the service trenches across London. James said, “We try and remove as much of the clay we find in the material before we screen it, as it sticks the aggregates together and spoils our testing process.”

The Bison crusher is a diesel-electric model, resulting in extremely good fuel consumption. A side benefit of this is that it requires very little attention, the contents of its diesel tank lasting almost a full week of work. James continued, “The Bison 160 is a great bit of kit too with its 100tph output and 700mm x 500mm jaw. It handles the incoming material from the Colt quickly and easily. With its in-built platforms, we can have an operative safely picking out any plastic or wood that may make it through the screening process.”

The ability to produce a variety of certified materials suitable for bedding pipework and backfilling the trenches has now given Terrafirma a massive cost saving, as James remarked, “Our reinstatement trucks can now leave the yard in the morning with a load of recycled material, tip, reload with excavated material and tip that back in the yard to start again.

“At the moment, we will only use this facility for works within a certain radius of the yard. But, as the machines can be transported and easily set up, we have the opportunity to use them at remote locations should the need arise.”

James and his team were hugely impressed by the way that Molson assisted with this business diversification project. James concluded, “Molson answered our questions quickly and fully and put our minds at rest at all times. Having a demonstration allowed us to see first-hand the capabilities of the machine in the materials we had, which was invaluable in us making our final purchasing decision. Overall, they are a great company to deal with and have a brilliant, reliable and productive range available in the Evoquip kit.”

Above, inset above and right: The diesel-electric Bison crusher is mounted on a hook-lift for easy mobility should the need occur, with a projected output of 100 tonnes per hour.

Above and right: With a 2.34m x 1.37m double-deck screen, on paper the Colt 600 has an output of 280tph, providing plenty of spare capacity as this new venture ramps up.

MAXIMUM OUTREACH

Peter Anderson reviews the current offering of factorybuilt long-reach excavators, with an introduction by Graham Black

There was a time, not that long ago, when designing and fitting long-reach working equipment was commonly undertaken by third party engineering firms, converting a standard excavator to meet a particular application.

To be fair, a few European manufacturers offered special adaptations of their excavators, but this was the exception rather than the norm. This route also tended to be more expensive than opting for a local company to engineer and fabricate

long-reach working equipment.

Of course, there is far more to such a conversion than providing a longer boom and dipper, as the load must be appropriately counterbalanced, together with working equipment and its load creating a higher demand on the machine’s hydraulic system. All of which puts greater stress on the machine’s undercarriage, slew ring mechanism and other structural components.

Times change and today most excavator manufacturers offer a factory-built range of long-reach excavators, typically providing a working range of up to 18m on a 30-tonne class machine. However, much larger long-reach excavators are also available from selected manufacturers.

This change has largely been driven by customer demand on two fronts. If something broke, the users would have to deal with two entities, one for the base

machine, another for the working equipment, each side blaming the other for a serious failure. One point of contact for all maintenance and warranty purposes was needed.

This change in attitude was initially evident in the quarry sector, where long-reach excavators are commonly used as production machines to extract sand and gravel from lagoons. A more active approach to site safety has largely driven the use of factory-built long-reach excavators in the construction/civil engineering sectors, where clients and main contractors want assurances that all the kit used on site is certified as being fit for purpose.

Like their standard counterparts, long-reach excavators are increasingly being fitted with 3D GPS systems, handy for grading the bank of a motorway cut, performing deep drainage work or extracting gravel.

KOBELCO DUO

Wobelco currently offers two long-reach excavators, the 25-tonne SK210 and the 28-tonne SK260, powered by a 127kW Yanmar and a 155kW Hino engine, respectively.

Equipped with 9.9m boom and 7.90m arm, the SK210 has a maximum digging reach of 18.18m and a maximum digging depth of 14.11m. The SK260 is fitted with a 10.35m boom and an 8.25m arm, providing a reach of 18.53m and a 14.73m dig depth.

FOUR FROM KOMATSU

Afour-model line-up of factorybuilt long-reach excavators is available from Komatsu, comprising the short radius PC138US-11, together with the counterbalance PC210-11, PC240-11 and PC360LC models. All are powered by in-house engines rated between 72.6kW and 202kW. The working equipment for these long-reach excavators consists of booms from 6.49m to 12.4m and dipper arms between 4.93m and 10.7m. They provide maximum dig depths from 9.19m to 17.49m and dump heights spanning 9.56m to 13.8m.

EXTENSIVE LONG LIEBHERR RANGE

When it comes to offering long-reach excavators, Liebherr, the traditional market leader in providing custom-spec excavators, takes a different approach to the rest. Its Multi User long-reach attachment configuration can be specified on all seven of its core tracked excavators, from the 24-tonne R922 right up to the R976, which has an operating weight approaching 100 tonnes.

The long-reach R922 is powered by an in-house engine rated at 120kW. It is usually configured with an 8.9m boom and 6.3 arm, providing a dig depth of 11.77m, a dumping height of 11.11m and reach at ground level of 15.5m.

The massive, long-reach R976 features a 400kW Liebherr engine. Configured with a 12m boom and 9.50m arm, it is capable of digging down to 18.5m, offers a dump height of 15.56m and a reach at ground level of 23.25m.

LONG REACH MODELS FROM HITACHI

itachi offers four long-reach excavators, the ZX130, ZX250, ZX300 and ZX350, which have operating weights from 15 to 40 tonnes. The smaller models are powered by a 74kW Toyota engine, the others use an Isuzu

powerpack rated from 140kW to 210kW. Monobloc boom lengths range from 7.7m to 12.3m and arm lengths between 5.3m and 9.45m, providing maximum digging depths from 10.16m to 16.43m and load over heights from 9.88m to 16.36m.

MARKET REVIEW // LONG-REACH EXCAVATORS

LONG TO DIGGING BOOM SWAP

olvo offers an innovative modular boom concept, allowing the excavator’s working equipment to be swapped between a standard digging configuration and long-reach boom and dipper. This facility is available on the EC220ELR, EC250ELR and EC300ELR models, with operating weights in long-reach mode of between 26 and 37 tonnes, and powered by in-house engines rated from 129kW to 189kW. Two long-reach booms are available – 8.85m and 10.2m – matched with 6.25m, 7.85m or 7.9m dipper arms. When fitted with the longest working equipment, the EC300ELR model has a dig depth of 14.75m, a load over height 12.6m and a maximum digging reach of 18.59m.

VLONG-REACH HYUNDAIS

yundai offers two factory-built long-reach excavators, the 25-tonne HX220ALR and the 33-tonne HX300ALR, powered by Cummins engines rated at 129kW and 194kW, respectively. The 25-tonner is configured with an 8.2m monoboom and a 6.3m dipper arm, delivering a maximum digging depth of 11.76m and a reach of up to 15.22m. The larger model has a 10.2m boom with a 7.85m dipper, taking maximum digging depth to 14.74m, with a reach of 18.53m.

HDISTANT DEVELONS

There are four long-reach excavators in the Develon range, the DX225-7SLR and DX300-7 SLR, together with two versions of the DX530-7SLR, with operating weights from 25 to 52 tonnes. The two smaller models are powered by six-cylinder engines, rated at 129kW and 202kW, respectively. The DX530-7 versions get a 294kW Scania DC13 powerpack. The working equipment for this range consists of boom lengths from 8.5m to 11m, with arms spanning 6m to 8m, offering dig depths from 11.66m to 15.13m and digging heights from 12.8m to 14.4m.

HUGE HIDROMEK

itachi offers four long-reach excavators, the ZX130, ZX250, ZX300 and ZX350, which have operating weights from 15 to 40 tonnes. The smaller models are powered by a 74kW Toyota engine, the others use an Isuzu powerpack rated from 140kW to 210kW.

Monobloc boom lengths range from 7.7m to 12.3m and arm lengths between 5.3m and 9.45m, providing maximum digging depths from 10.16m to 16.43m and load over heights from 9.88m to 16.36m.

LONG AND SUPER-LONG

H CCATS

aterpillar produces the long-reach 340LRE and 352LRE models, together with four so-called super long-reach excavators, the 320SLR, 323SLR, 326SLR and 330SLR.

Intended for lighter-duty, long-distance applications, such as dealing with ditches, slopes and waterways, the four smaller super long-reach models have operating weights from 24 to 31 tonnes, and are powered by a Cat C7.1 engine with outputs from 122kW to 205kW. Maximum digging depths extend from 11.4m to 14.61m, while maximum reach at ground level is between 15.7m and 18.29m.

The two long-reach excavators weight 44 and 58 tonnes, respectively, and are powered by a Cat C9.3B engine delivering outputs of 234kW and 317kW and featuring a heavy-duty, high and wide undercarriage. Equipped with an 11.5m boom and an 8.5m arm, the 352LRE, which is equipped with a variable width track frame for easier transport, is capable of digging to a depth of 13m and has a maximum reach at ground level of 19.64m.

More than just a machine.

WE HAVE INVESTED IN OUR BUSINESS TO SUPPORT YOURS.

From partnering with only the best manufacturers to 16 strategically positioned service centres that hold all the parts you need, and a network of over 90 fully equipped field service engineers, you can count on us to keep your operation going wherever you are in the UK.

GOING THE EXTRA MILE

As Nick Drew reports, JCB’s mighty 4CX backhoe loader makes the perfect tool carrier to erect utility poles

The sleepy rural setting of Boyton, near Launceston in Cornwall, is probably the last place imaginable to find a plant hire business that deals with Tier 1 contractors and clients across the length and breadth of Britain.

Currently enjoying a period of rapid growth, EJ Fry Transport and Plant Hire is perhaps best known for running an extensive fleet of trucks, in addition to their specialist utility pole erection 4x4 trucks and backhoes. However, they are increasingly hiring out a growing range of specialist kit to the utilities sector, including tracked access platforms, as well as serving the general plant hire market.

RECENT EXPANSION

The business was established by John Fry in 1999, who started out with a single lorry and went on to gradually expand the utilities-focused business to include a large fleet of plant and transport vehicles.

As John’s 60th birthday loomed on the horizon, and his wife Celia single-handedly ran the office, the idea of scaling down the workload was contemplated. Then, a few years ago, the family decided that son Josh, who trained as an electrician after leaving school, should join the business.

“ITSEEMEDPOINTLESS FORMETOCOMEBACK ANDFORTHEBUSINESS TOSTAYTHESAME,IWAS NATURALLYAMBITIOUS TODRIVEON”

Below and inset:

Utility contractor

EJ Fry has added a limited edition JCB 4CX backhoe to its extensive fleet of pole erection machines.

Josh said, “It seemed a bit pointless for me to come back and for the business to stay the same, I was naturally ambitious to drive on. After all, there is a lot of work out there in this sector at the moment, so it’s a good opportunity to take advantage of it. In the last four years the business has expanded rapidly. Last year alone we took delivery of 80 new vehicles/machines to meet demand. We expect the same number, if not more this coming year, which brings us up to around 200 items on the fleet.

“We are very lucky with our customer base, being mainly Tier 1 contractors and distribution network operators (DNOs) like National Grid and Scottish & Southern. We are having to turn down work at the moment, but we want to remain in control and be able to give the best service we can, including back-up, which we have always prided ourselves in.

“If the utility firms require a particular piece of equipment, we will have a go at it, cherry pickers, tracked gators anything. I would say by the end of this year we will be pushing towards 300 vehicles, we are very busy, with a lot of plans for the next two to three years.”

“ITSATNICELYWITHUS CELEBRATING20YEARS OFBUYINGJCBSANDOUR 25THANNIVERSARYOF BEINGINBUSINESS.”

LATEST FLEET ADDITION

The machinery fleet is dominated by two machine types: Wacker Neuson midi-excavators and JCB backhoes.

The 6.5-tonne ET65 midi is a particularly popular machine that the firm always takes with triple articulated booms, which are better suited to the work undertaken by their utility customers.

They tend to run one or two JCB 3CX models with a standard front bucket for general hire work, but the rest of their fleet of 3CX and particularly 4CX models are fitted with rotary pole grabs. There is a stack of new 6-in-1 buckets in the corner of the yard, which are taken off the new machines on arrival –when it comes time to trade the machine, an unused attachment is put back on.

The most recent addition to the fleet was a special 4CX Platinum Pro 70th Anniversary model, one of a production run of just 70 to celebrate the number of years JCB has been producing such backhoe loaders.

Josh continued, “We had a requirement from one of our customers who needed a 4CX. We ordered two, one of which has gone up to the job in Scotland, and this one you see in the yard, which is now heading to a job in Berkshire.

“We didn’t initially order a 70th Anniversary model. We placed the order for 4CX Pro variants, then Paul Butcher, our local sales representative from Holt JCB, asked us if we would be interested in taking the special edition. We thought, well why not, as it kind of sat nicely with us celebrating 20 years of buying JCBs and

our 25th anniversary of being in business, it all tied in very well.

“Dad’s been dealing with Holt JCB now for the past 20 years, and it’s been relatively good, the odd niggle here and there, but we always got it resolved. We have been dealing with Paul Butcher for several years and we find him to be pretty good, very helpful and he knows the products. We know we can ask Paul for something and he just comes back to us with a solution, so we are very happy with our relationship.”

WALK-AROUND

Featuring platinum-coloured wheels and decals, externally, the 70th Anniversary model stands out from the crowd. Even more so with Fry’s example, which has been fitted with an Autoguide pole grab and pole frame, painted to match. Josh commented, “The majority of this batch of 70 machines will be out there with a bucket on the front, so ours is going to be unique.”

“In layman’s terms, the grab enables you to pick up a pole from the ground and rotate it 180 degrees to stand upright and, of course, to transport the pole safely across the site using the support frame at the rear.

“There are a few manufacturers of pole grabs out there, but we have always stuck with Autoguide, mainly because it’s British made and good quality. Their product is rated and tested to remove old poles, a lot of other grabs are not rated for pulling them back out of the ground, which, as you can imagine, puts a lot of strain on the equipment.”

FRY TRANSPORT FLEET

The firm runs an articulated low-loader, a stunning 750hp Volvo FH16 complete with a Dutch-built Brohuis trailer. This flagship of their transport fleet is piloted by Josh’s uncle, Arthur Fry, who typically spends the whole week out of the yard, relocating in-house and customer machines across the country.

The 4x4 truck fleet is dominated by MAN products, but recently some Volvo FMX models have been added. A couple of eight-wheelers are also on the fleet, used for local general haulage work. They also have several beaver tail lorries, which are mainly used by the driver/operator, with a Wacker Neuson midi-excavator, on pole installation jobs.

In total the company runs around 70 trucks of various makes, models and configurations, and another 30 units are due this year, which are currently in various stages of build, some having cranes fitted.

Above, below, inset and right: Fitted with Autoguide pole-handling attachments, the rotating grab is also rated and tested to remove old poles, an extremely tough job.

“WEWANTTOCONTINUEBUILDINGONTHEFIRM FOUNDATION,TOCONTINUETOOFFERTHEVERY BESTSERVICETOOURCLIENTS”

Inside the cab the machine has a special feel to it, not just the 70th Anniversery logos adorning the interior, but because the seat has been upgraded to a truly luxurious perch. There are seat-mounted servo controls, the backhoe features a Powerslide offset boom and bi-directional auxiliary hydraulics. Under the bonnet there is an ultra-low emissions 4.8-lire JCB engine rated at 81kW producing maximum torque of 516Nm. It drives a six-speed autoshift, torqueLock transmission providing a maximum road speed of 40kph.

This backhoe is going to work for Scottish & Southern Electricity on pole standing and replacement work. Josh commented that the operator who will be taking on the machine is a keen JCB fan, who he expects to be very happy with his new mount.

FAMILY BUSINESS

Before starting to earn its keep, the special JCB backhoe loader will be stopping off at a local junior school for the entertainment and education of the pupils, including Josh’s son. He said, “I have four children, I’m not sure if any of them will want to join the business, but only time will tell. However, my youngest son Odin, who is only six, is Mr Machines, he just loves the diggers. We like to retain that family business feel, it’s very important to us. Mum Celia is also a director, and she deals with all

the paperwork and accounts single handedly, which is incredible.

My sister does a little bit of work covering the damage side of things.

“We want to continue building on the firm foundation we have here, to continue to offer the very best service to our clients, for the benefit of the whole family.”

Above, right and below: The mainstays of Fry’s excavator fleet are 6.5-tonne Wacker Neuson midi-excavators fitted with TAB booms. Their hire fleet includes several tracked access platforms.

DEVELOPMENT READY SOCIALLY AWARE DEMOLITION

Paul Argent looks back at two demolition projects carried out by Cawarden within the campus of Loughborough University

Across the industry there is a growing trend towards clients awarding development-ready contracts, as opposed to separate tenders for site clearance, then the main muck-shifting effort, followed by groundworks.

Like many leading UK demolition contractors, Derby-based Cawarden has diversified over the past few years from traditional demolition operations to offering turnkey packages for developers and builders.

Contracts director Samuel Crookes said, “We are responding to a growing list of clients who now want their sites demolished, land remediated and any groundworks completed before they arrive on site.

“While we were experienced in delivering remediation contracts, the drainage, paving and construction aspects are something we have developed significantly over the past few years. This has been achieved by recruiting experienced staff throughout the business, with the knowledge available to allow us to hit the ground running when it comes to delivering these sometimes complex packages.”

SITE VISIT

Cawarden has worked at Loughborough University on several occasions in the recent past, mainly as a sub-contractor. In the summer of 2023 they were back on site, as main contractor for two time-critical projects.

The demolition of the Sir Arnold Hall Building was a relatively straightforward task for the team, after which Cawarden undertook a reduced level dig, then installed drainage and hard landscaping. At the time of our visit they were completing part of the paving works, leaving just a small amount of top-soiling to undertake.

“ACROSSTHEINDUSTRY THEREISAGROWING TRENDTOWARDSCLIENTS AWARDINGDEVELOPMENTREADYCONTRACTS”

Above and inset: After demolishing the Sir Arnold Hall Building, Cawarden undertook a reduced level dig of the site, then installed drainage and hard landscaping.

SITE VISIT // LOUGHBOROUGH UNIVERSITY

“WITHUSZONINGAREASOFF,ITENSURESTHE SAFETYOFOURSTAFFANDANYONEELSE COMINGTOOURSITES”

So far so good, but such blue-chip clients are also increasingly demanding higher standards of environmental, social and corporate governance (ESG). On this contract, one result of this was Cawarden joining a pilot plasterboard recycling initiative run by the university in conjunction with British Gypsum and recycling specialists ENVA.

During the internal strip-out phase of the demolition works, much focus was placed on recovering the plasterboard, which was despatched to ENVA for treatment. ENVA uses a novel purification method, which produces a much higher quality gypsum than traditional recycling methods. British Gypsum will be manufacturing a range of circular plasterboard products, which will contain 35% recycled gypsum from ENVA.

was constructed in the 1960s. Years later, it was clad in a lightweight steel frame to support cosmetic panels. Unfortunately, the building hasn’t weathered the intervening years well and it was time to remove it from Loughborough’s skyline.

The first job was for a specialist subcontractor to deal with all the asbestos within the structure, where both licensed and non-licensed material had been identified in the survey. As each floor was cleared of asbestos, the Cawarden teams set about the laborious task of soft stripping each room, removing as much material as possible.

In turn, they will be used in the new structure that will replace the Sir Arnold Hall Building on this site, which will undergo assessment and performance testing as part of the university’s case study.

STRUCTURE STRIP

As work on the site of the former Sir Arnold Hall Building was nearing completion, the second project on site, a former chemistry block, is more of a traditional demolition job. The seven-storey concrete framed building

While many demolition contractors will simply segregate the materials and then dispose of them, Cawarden has taken a different route and is one of the latest companies to sign up to the Globechain ESG initiative. Globechain connects those with a waste stream with non-profit, small businesses and individuals to redistribute unneeded items.

Cawarden’s marketing manager Emma Attwood said, “Projects similar to this allow us to offer items to others that we would usually end up recycling. Not only does it cut down on material having to be handled numerous times, but it also provides an outlet for items that some people may find too expensive to buy or have trouble in locating. The system

generates data to allow us to manage and track any items we place on the marketplace, reduce costs and increase transparency.”

DEMO WORKS

Once the seven-storey building was stripped, project manager Mick Whitehead and his team were able to start the structural demolition. Access to and around the former chemistry block was extremely tight, as Mick explained, “We did have an access point with a pinch point of just over three meters between a hedge and an access ramp to another building, so getting our Komatsu PC490 in was going to be tight. We covered the access road in timbers and brought the tracks in on the machine, this allowed us to get the machine in. Just!”

The first task for operator Colin Williams at the controls on the 28m high-reach Komatsu was to remove external steel framework, which held glass-fibre flues from each of the chemistry labs. The removal of the flues gave Colin a little more room in which to start removing the outer cladding from the building, which would provide him with access to the concrete framed structure.

Cawarden has adopted a fully zoned approach to its demolition projects with limited access for any personnel within the Red Zone, where the high-reach excavator is in action. Commenting on this, Samuel Crookes concluded, “We take the safety of our team members extremely seriously. It adds more work for the team setting up and running the sites, but with us zoning areas off, it ensures the safety of our staff and anyone else coming to our sites.”

Above and inset below: External flues were first removed from the former chemistry block, then the cladding, before work could start on the sevenstorey concrete structure.

DURHAM’S DAZZLING DUMPERS

David Wylie delves into the history of Caterpillar’s range articulated dump trucks, which originated from the stable of the legendary off-road vehicle designer David J. Brown CBE

Above and below: The DJB series of articulated dump trucks included several 4x4 versions, and the 6x6 range was headed by the mighty 55t capacity D550 model.

PLANT HISTORY // CAT ADT ORIGINS

As with many innovations in muck-shifting machinery, the concept of an off-road articulated dump truck (ADT) can be traced back to the American engineering genius RG LeTourneau, who introduced the Tournatrailer model back in 1938.

In more recent times, the ADT concept was reinvented in the mid-1960s by various Swedish manufacturers, headed by the combined efforts of Bolinder-Munktell, Livab and Volvo. This followed a decade of Scandinavians using tractors hooked up to a dump trailer with a driven axle. Much like the development of motor scrapers, the tractor’s front steering axle was then dispensed with, replaced by hydraulic cylinders acting upon the articulation point. This gave birth to the 4x4 articulated dump truck, which evolved through 6x4 machines to those featuring 6x6 drivelines.

Joining LeTourneau and Volvo in the ADT hall of fame is the legendary British off-road machinery designer

J. Brown. From the late 1970s, his DJB range was a worldwide success story. They were held in such high regard that Caterpillar bought the product line and continues to this day to produce ADTs from the same factory at Peterlee in County Durham.

“IN1972DAVIDJ.BROWN

DAVID J. BROWN

Early in his career, David J. Brown worked as a logging contractor in Africa. This experience left him unsatisfied with the tractor and trailer combinations then available, and the durability and mobility of off-road machinery in general.

Back in the UK, he began to develop his own 4x4 tractor, which was patented in 1958. It was the start of a lifelong focus on designing a variety of all-wheel drive machinery. An early indication of his talent was designing the Chaseside model on behalf of Northrop, one of the first high-horsepower, four-wheel drive tractors available on the commercial market.

In 1965 he became the managing director of Muir-Hill, overseeing the introduction of a new range of 4WD tractors and loading shovels. He then introduced a range of heavy-duty dump trailers to go behind Muir-Hill’s 4x4 tractors. This was the acorn that grew into today’s range of Caterpillar articulated dump trucks.

In 1972, David J. Brown, in association with Ogden’s of Otley, a major muckshifting firm in northern England at the time, formed DJB Engineering at Peterlee. Their aim was to design and manufacture a range of off-road articulated dump trucks using well-proven powertrain components. Drawing upon his time in Africa, Cat engines and transmissions were the obvious choice for such an arduous application, which was the start of a lifelong association between David J. Brown and Caterpillar.

Initially working out of a small factory unit at Peterlee, within a year a prototype of the six-wheel D250 model was being tested at the nearby Cornforth Quarry. It was

Below: DJB articulated dump trucks were the first to offer front suspension in the standard build.

David

David J. Brown cut his teeth designing high-horsepower, all-wheel drive tractors and during his time as MD of Muir-Hill he matched them with dump trailers.

“IN1985AREMARKABLE DEALWASANNOUNCED, WHICHSAWCATBUYTHE DESIGNRIGHTSTOTHE ADTRANGE”

powered by a 235hp Cat 3306T engine driving a Cat transmission and provided a rated payload of 27.5 tons. In 1974, a second prototype was completed, in time for display at the Public Works Show in London. Business partner Ogden bought these two prototypes and put them to work in their fleet. As an aside, we believe that these units were spotted many years later, working in South Africa.

After its debut at the 1974 Public Works Show, the fledgling business was inundated with orders, prompting the purchase of the former Lancer Boss lift truck factory at Peterlee. Ogden bought the first five production machines off the new line and by the end of 1975 the factory was producing 10 trucks a month. This building remains the main assembly line for Cat ADTs, albeit substantially expanded and upgraded over the decades. A detailed report on the current factory will feature in a future issue.

DJB PETERLEE

1976 saw DJB’s first export order, two D250 units for a customer in the Netherlands, together with the introduction of the larger 33-ton capacity D300 model, which was also to be made available as a low-profile version

Below: The Cat 700 Series of Peterlee-built 6x6 ADTs was launched in 1999, upgraded to the low-emissions B Series in 2011, complete with a revised transmission and traction control systems.

Above and below: The DJB C Series was introduced in 1984, featuring a Cat six-speed transmission. The Cat D Series, made by Artix Peterlee, followed in 1990, featuring a full-time 6x6 powertrain.

PLANT

for underground mining applications.

The factory also produced the first prototype of David J. Brown’s design of a 55t capacity articulated truck, which would eventually become DJB’s flagship D550 model. Such large capacity ADTs never really found their niche in the market, it is only relatively recently that their advantages have been recognised, as Bell and Volvo now produce 50t class articulated haulers.

In just four years, DJB had developed its first model, relocated to a large factory and had begun to expand its range, but there were even more exciting times ahead. In 1977 the business received a major boost, following a 100-machine order from an Indonesian nickel mine.

The dump trucks didn’t simply use Cat components, but they were fully warranted by Caterpillar for use in the DJB range, and the global Cat dealer network was available to service their powertrains. This arrangement also provided Cat dealers in North America with access to a range of ADTs, which prompted the establishment of a DJB sales, parts and service organisation in the State of Maryland. By the

end of 1978 almost a third of the production from the Peterlee factory was being shipped to North America, and DJB was the only European dump truck manufacturer to export its products to the USA.

By this time, the Peterlee factory employed over 600 people and had benefited from a multi-million pound investment in machine tooling to allow the site to produce up to 500 articulated trucks a year. The range was expanded to include five new models, the four-wheel D25 and the six-wheel D275, D330, D350 and D550, all of which featured front suspension, another industry first for David J. Brown.

In 1979 the DJB factory at Peterlee manufactured its 1000th machine and was

AWD BEDFORD TRUCKS

In 1987, after the initial sale of the Artix ADT design rights to Caterpillar, David J. Brown bought what was left of the Bedford Truck Division of General Motors. The Dunstable factory had been closed the previous year, when GM decided that Bedford would withdraw from the commercial truck market. This followed a controversial decision to replace the British Army’s huge fleet of 4x4 Bedford general service trucks with new Leyland/DAF models, a blow from which the firm never really recovered.

The business was renamed AWD Trucks. In addition to producing 4x4 and 6x6 models, branded as AWD Bedford for the military market, the firm also supplied sister operation Multidrive with truck/tractor units for their PTO-driven trailer combinations. This is covered in more detail overleaf, but included the urgent supply of a couple of dozen 8x6 fuel and water tankers for the British Army for the 1991 Gulf War. However, despite continuing success in the military sector, against the background of an extremely challenging civilian marketplace, the AWD business could not be saved and went into receivership in 1992. The firm’s designs and other assets were bought by Marshalls of Cambridge, which continued limited production of the AWD range until 1998.

one of the largest manufacturers of articulated dump trucks in the world, of which over 90% was exported. They were worthy recipients of a Queen’s Award to Industry for export achievement, followed by the Queen’s Award for Enterprise (Technology) and then by a Queen’s Award for Trade (Export).

CHANGING TIMES

Having started out just a decade earlier, establishing such a globally successful business was a remarkable achievement for David J. Brown. In 1982 there was

Above and below right: In 1992 the E Series machines were launched, remaining true to the original design by David J. Brown.

Below, right and inset below: Caterpillar broadened its range with ejector-bodied variants and with a range-topping 45t capacity model, going through a C2 Series update in 2016, before the current generation of machines was introduced.

another hefty investment in the factory, together with the establishment of a hydraulic cylinder assembly shop at Peterlee, both designed to support an aggressive product development strategy.

Primarily due to feedback from their growing customer and dealer base in the US market, in 1982 the B Series of ADTs was introduced, including a new D35 model powered by a 225hp Cat 3306 engine, joining their D22 and D44 4x4 counterparts. The following year the iconic six-wheel D400 model was introduced. A further upgrade of the range occurred in 1984, with the C Series featuring a new Cat six-speed transmission.

In addition to a global success story, DJB articulated dump trucks were becoming an important product line for many Cat dealers around the world. Looking to the future, David J. Brown rearranged his business interests, as DJB Engineering came under the Artix Group of machinery manufacturers, which included newlyestablished Multidrive (see panel overleaf). In 1985 a remarkable deal was announced

between Caterpillar and Artix, which saw Cat buying the design rights to the ADT range, while Artix Peterlee continued to manufacture the products on their behalf. In a slow transition to Cat branding, it was not until 1989 that the last DJB-badged truck, a D44 model, left the factory. That same year Artix Peterlee was awarded yet another Queen’s Award for Export Achievement.

With Cat-branded products now being officially distributed through their global dealer network, in 1990 the factory received another major investment, which included an improved paint facility and robot welding installations. At the same time the

new D Series was introduced, all of which featured a full-time 6x6 powertrain. In 1992 the E Series of machines were launched, of which the D400E model was powered by a 400hp Cat 3406 engine mated to a Cat auto-shift transmission, torque converter with integral retarder, limited-slip differentials and final drives.

CAT 700 SERIES

By 1996 Caterpillar had purchased the Peterlee factory and acquired all remaining rights associated with the ADT product line, but retained David J. Brown as a design consultant. Three years later, the Cat 700 Series of 6x6 ADTs was introduced, which

Below: Multidrive’s futuristic military truck and trailer prototype featured several variations of its trailer drive and steering system.

The all-wheel drive Multidrive articulated dump truck featured an ejector body, originally designed for a specialist military application.

“THEPOWEREDTRAILER

ARRANGEMENTWAS DEVELOPEDINASERIESOF FUTURISTICPROTOTYPE TRUCKS”

also heralded a change to the factory’s working practice. Up until then, individual machines were assembled in separate stalls within the factory, then driven to the spray shop for painting. Caterpillar introduced a flowing assembly process. They also commissioned a new paint plant to allow fully painted components to be delivered to the assembly line, which would improve the overall durability of the machines.

An ejector-bodied ADT was launched, which was able to spread the material on the move, discharge under overhead obstructions and avoid the risky practice of raising the skip on the unsure ground of a tip area. In 2011 the B Series Cat 700 range was launched, which featured a revised transmission and traction control systems. It included the new 735B model, together with the 740B and its 740B ejector variant, all available with Stage 3B emissions-compliant engines.

Subsequent incarnations of the range would focus on two key areas: meeting increasingly stringent emissions controls and improving operator comfort and productivity. In 2016, a cab assembly shop is commissioned at Peterlee, followed by a range-topping 745B model.

Shortly afterwards, the C2 range of machines was launched, which included three smaller models, the 725C2 together with the 730C2 and its ejector variant. These came as standard with an automatic traction control system and a new design of dump body, built using Brinell HB450 wear resistant steel and featuring a diverging flow shape to promote clean tipping and minimise any carry-back.

The current generation of Cat ADTs, from the 725 to the 745 models, feature a new cab and a more fuel-efficient engine. Automatic

PLANT

EDITOR’S COMMENTS MULTIDRIVE: WHAT MIGHT HAVE BEEN

In 1996 David J. Brown sold the remaining Artix operation to Caterpillar, including the Peterlee ADT factory, but excluding the Multidrive operation. The following year, Multidrive moved into a purpose-built facility at Thirsk. A core Multidrive product was a 4x4 load-carrying agricultural tractor. However, it was R&D work on military trucks that was the focus of Mr Brown’s attention, which also led to the ejector-bodied Multidrive ADT.

Car design genius Colin Chapman had the motto, ‘Simplify, then add lightness’, David J. Brown focused on minimising what he termed ‘parasitic weight’, evident in the design of the ejector-bodied Multidrive ADT. His view was that a conventional dump body needs to be strengthened to withstand the side forces of the load being pushed out by an ejector plate, while the ejector mechanism itself also added to its weight, all of which would require more fuel to move every tonne of material at a decent speed.

The Multidrive design for an ejector body consists of a high-tech rubber belt on the floor of the skip, connected to a hydraulic powered roller at the rear that carries the load out, as opposed to pushing it out. Early examples were mounted on Multidrive’s driven trailer, pulled by some of the last AWD trucks, principally aimed at addressing a potential requirement from RAF airfield damage repair teams.

With Bedford/AWD products now out of the equation, the next couple of batches of Multidrive 8x6 fuel and water tankers for the British Army used Foden trucks. Foden, a shadow of its former self, was then owned by the American company Paccar, which in the

retarding control manages braking through a combination of engine, brake, gear selection and service brake application. The hill assist feature facilitates efficient stopping and starting on gradients, while the waiting brake system, quickly engaged by a push-button on the control lever, temporarily applies the service brake during pauses in the work cycle.

Exclusive to Cat machines, there is also an auto-hoist facility, which places the transmission in neutral, applies the parking break and hoists the body. This system also lowers the bed with a controlled descent. The stability assist function helps prevent machine roll-overs by giving the operator audible and visual alerts when moving and inhibits the body being raised if the machine is at an unsafe angle. There is even an optional payload weighting system available. Naturally, the machines are fully digitally

late 1990s also acquired the DAF and Leyland truck businesses. Together with fellow American companies Steward & Stevenson and Oshkosh, Paccar was a direct competitor to the small Multidrive operation for the major contracts coming up from the British Army.

Clearly Multidrive required a heavy-duty 4x4 truck tractor, not only for the future military contracts such as 8x8 fuel and water tankers, but more urgently to develop their ejector body into a commercially available articulated dump truck. The result was a high-speed, high-mobility tractor unit for the ADT that featured a fully warranted Caterpillar driveline.

The trailer drive system was also updated, with power to the trailer’s tandem bogie via the truck’s rear through-drive axle. The steering action of the tractor transmitted to the bogie through the drive shaft support, which pivots the bogie, maintaining a constant velocity driveline and enables the trailer to closely track the tractor. The new powered trailer arrangement of this ADT was developed further in a series of futuristic high manoeuvrability prototype trucks for the British Army.

Unfortunately, this story does not have a happy ending, as Multidrive did not win any of the Army’s major truck contracts. Tragically, David J. Brown died in a car accident on his estate near Thirsk in January 2004. 20 years later, he is remembered for kick-starting Caterpillar’s range of articulated dump trucks. If things had panned out differently, he would also have been remembered as the saviour of the British truck industry.

connected and interface with Cat’s product link production management and detect suite of systems.

CONCLUSION

By the late 1970s DJB Peterlee was one of the world’s largest manufacturers of articulated dump trucks and celebrated the production of the 1000th machine in 1979. Fast forward to 2007, when the factory produced its 30,000th dump truck, this tally quickly rose to 50,000 machines by 2018.

Caterpillar’s Brent Losey said, “The articulated truck has been a key member of Caterpillar’s core product line since it was developed in Peterlee, which has always been its proud home. I thank the entire team for their focus and dedication to continually improve the design, manufacture and support of these great trucks for our customers.”

THIRD LIFE OF ACE OF SPADES

Keith Haddock traces the history of what was the largest dragline operating in Europe from its original location in Northumberland to its present home in America

Billed as the largest dragline in Europe, the P&H 757 model named the ‘Ace of Spades’ was commissioned in 1992 at the huge Stobswood surface coal mine near Morpeth in Northumberland. This iconic earthmover worked at Stobswood until coaling operations ceased in 2003, when the 4400-ton giant was eventually dismantled and shipped to its new owner in Mississippi.

Unfortunately, the job it was bought for abruptly stopped, fortunately another buyer was found and the P&H 757 is expected to put in another couple of decades of work on a site in North Dakota.

NORTHUMBERLAND COAL

Built by the Harnischfeger Corporation (P&H) in the USA, the Ace of Spades was initially owned by British Coal Opencast, then by RJB Mining. It featured a 65-yard bucket on a 310ft boom and was run by opencast contractors Crouch Mining. It was essentially an upgraded version of the Page 757 model, the firm having been acquired by Harnischfeger a few years previously.

Stobswood was one of the largest opencast coal contracts ever awarded in the UK, involving the removal of over 325 million cubic yards of overburden to recover 15m tons of coal. To put this in context, this is roughly

equivalent to the material extracted to build the Panama Canal. The site occupied 1600 acres and encompassed 28 coal seams to a maximum depth of 620ft.

The P&H 757 dragline was electrically powered with a trailing cable supplying AC current at 7200 volts to two motorgenerator sets, each rated at 3000hp. They provided DC power to four hoist motors, four drag motors, four swing motors and two walk motors.

Twin hoist ropes and twin drag ropes manoeuvred the bucket; the specifications show a maximum digging depth of 180ft and a dumping height of 113ft. Walking shoes measuring 5ft 6in long x 11ft 6in wide provided a step of just over 7ft long. The circular tub or base measured 75ft in diameter.

Production of coal from Stobswood ceased in 2003, followed by a two-year, world-class site restoration project.

Below: The 65-yard capacity P&H dragline named the Ace of Spades, seen here during its last month of operation at Stobswood site in 2003.

EXTREME MACHINES // P&H 757 // TAIL

Above and inset: Launched with a blaze of glory in 1992, the P&H 757 is currently on its third life, working in North Dakota.

The P&H 757 was extensively modernised by its second owner, Liberty Fuels, who renamed it Liberty.

Photo: Michael Davis.

Below: With boom lowered, the big P&H dragline is parked at Stobswood site awaiting a buyer.

Photo: Jason Fisher.

Below, left and far left: The P&H 757, now renamed Legacy, has begun work at BNI Coal’s Center Mine in North Dakota.

Below: The 4400-ton dragline being assembled, for the third time, at the Center Mine, North Dakota

EXTREME MACHINES // P&H 757

MISSISSIPPI COALING

After finishing work at Stobswood in 2003, the P&H 757 was parked for a few years before being sold to Liberty Fuels, a division of North American Coal Corporation. It was disassembled and shipped back over the pond to work at a new surface mine in Mississippi. Before it was erected on this site, the giant machine benefited from several major upgrades, including replacing the old DC electrical system and its motors with modern AC electrics.

The cab was also refurbished and now featured two joysticks to control all digging motions, replacing the separate hoist and drag levers, along with the two slew pedals. Now named ‘Liberty’, the upgraded P&H 757 dragline was fully assembled at its new location in 2013.

This 4440-ton giant was purchased to uncover coal for the adjacent Mississippi Power’s new Kemper County power station, which was going to be a state-of-the-art gas to carbon-capture facility. However, major issues with the carbon capture process, along with serious cost over-runs, doomed the station before it even went into full production.

The dragline did commence work some time in 2015, but in 2017 the coal gasification section of the station was shut down, resulting in the dragline being idled and offered for resale again. The gas portion of the generating station is still operating.

NORTH DAKOTA COAL

Fortunately, a buyer for the P&H 757 was found. BNI Coal wanted it for their operation at the Center Mine in North Dakota, details of which were reported in the March 2020 issue of Earthmovers.

Large draglines work in separate pits across this vast site. The first was a Page 736, which was commissioned in 1970 when the mine opened. Now 54 years later, this

well-maintained dragline, named ‘Big Sandy’, is still in operation. Big Sandy swings a 23-yard bucket on a 190ft-long boom and is able to handle 60ft of overburden.

As the mine expanded, a second dragline was added in 1977, in the form of a 3200-ton Page 757 model named ‘Big Jake’, which was equipped with a 70-yard bucket on a 300ft boom. The site’s largest dragline is a Bucyrus 8200 commissioned in 2004, which is also named ‘Liberty’. This machine carries a 78-yard bucket on a 360ft boom, and has an operating weight of approximately 5200 tons.

well. After only 40-odd years of work, it was time to find a replacement. Although carrying the same model name, the P&H 757 was a superior machine, which had been vastly improved with a modern electric-drive system.

“THEFORMERACEOFSPADES, NOWRENAMED‘LEGACY’, ISEXPECTEDTOCONTINUE UNCOVERINGCOALFORAT LEASTTWOMOREDECADES.”

Compared to its smaller Big Sandy brother, which is still going strong, the Page 757 named Big Jake did not fare as

To save considerable transport costs, a cunning plan was hatched. The circular tub under the old Page 757 was in reasonably good condition, so the replacement P&H model would be moved without its old tub. After some misalignment problems were solved, the former Ace of Spades, now renamed ‘Legacy’ is reported to be working well and expected to continue uncovering North Dakota coal for at least two more decades.

Above: For the next couple of decades, the much-upgraded cab of the 1992-built P&H 757 will greet operators. Photo: Michael Davis.

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Machinery Journalists Wanted

Sundial Magazines, the publishers of Farm Machinery Journal, Forestry Machinery and Earthmovers is looking for Machinery Journalists to support the development of its Off-Highway Machinery portfolio.

Please contact our Publishing Director if you are seriously interested in writing articles for us. It would be ideal if you have a background in machinery journalism with a working knowledge of the agricultural and/or construction industries but this is not a prerequisite. If you have a flair for writing and an interest in photography, we would be delighted to hear from you. Your contribution to the magazines would be on a freelance basis.

To register your interest send a letter or e-mail telling us a little bit about yourself and your ideas to Paul Cosgrove, Publishing Director, Sundial Magazines Ltd, Sundial House, 17 Wickham Road, Beckenham BR3 5JS or paul@sundialmagazines.co.uk or call +44 (0)20 8639 4401

STANDARDISATION, SIMPLIFICATION & COMMUNICATION

Peter Haddock talks with Stefan Stockhaus, the president of Steelwrist

Simplification, standardisation and improved communication will help the uptake of productivity-increasing attachments across the world, according to Steerlwrist’s president and CEO, Stefan Stockhaus, who said, “This relates to product design, installation, support and speaking the right language.

“This is why we are supporting and encouraging other manufacturers to adopt the global Open-S industry standard for automatic quick couplers for excavators. If we all adopt Open-S, I believe the whole industry will benefit. Operators and contractors can combine quick couplers, tilt-rotators and work tools from a range of different manufacturers. This also opens up the potential for greater sharing of attachments and the benefits this will bring.

“But for me, the challenge we all face is simplifying the products we sell. Our Scandinavian customers have tilt-rotators and an array of attachments, and it is rare that they don’t use machine control to support them. For years now, the installation process for such systems has been very involved. Not just with the wiring of our control systems and joysticks, but also with the placement of a tilt sensor in our tilt-rotators when the machine control solution is added.

“With the launch of the first of our third-generation tilt-rotator range, the XTR20, we have taken these issues and either designed them out or simplified them. We no longer require manual greasing due to an OptiLube onboard lubrication system. We have dramatically simplified the control system installation and added the ability to remote dial in so that operators can communicate with our expert team.

“Most importantly, there is now no need to fit an additional tilt sensor as we have a new sensing set-up for both tilt and rotate. So, if you need to be able to use our products across different machines and machine control solutions, it’s now very simple.

“As new markets open up we need to recognise the importance of simplifying

products and overcoming the language barriers, particularly when it comes to installing and maintaining products and supporting end-users. For example, we have created an InstallMate application that uses artificial intelligence to ensure all languages are covered with simple graphical installation steps. Using the same process, we have also launched a new global parts portal to ensure the right parts can be identified and ordered quickly.

EDITOR’S COMMENTS OPEN-S HITCH STANDARD

With a large variety of pin sizes and spacings, for the majority of UK and Irish users, swapping standard buckets between different brands of similar-sized excavators can be problematic. A situation that is unheard of in Scandinavia, which has long since adopted the S-type symmetrical quick coupler standard.

Many would say it is a superior technical solution to other European quick-hitch designs. These folk do have a point, as the S-type hitch was designed to better transfer forces from sideways movements, which is of key importance to a region where tilt-rotators are fitted to most machines.

But things have moved on a pace in recent years, with automatic hitches now coupling auxiliary hydraulic lines and other services, such as central greasing pipework and electrical connections, available from a far wider range of manufacturers. This has led to an incompatibility of attachments, as there is no one industry standard. Open-S is an open standard for fully automatic quick couplers for excavators, building upon the foundation established by S-type hitches.

NEXT MONTH

EARTHMOVERS IN

EXTREME MACHINES

FFOS Y FRAN

As part of the restoration works of a site that was at the heart of the South Wales coal mining community, a 110-tonne Cat D11T dozer has been deployed, working alongside a 250-tonne class mining excavator loading 100t capacity dump trucks.

RUNNING REPORT CAT 289D SKID-STEER

County Tipperary-based owner-operator Gary Ryan is using a high-spec tracked skid-steer loader, configured with a grading box attachment and controlled by a Trimble machine guidance system.

NEW PRODUCT LAUNCHES & DEMOS

JCB, Steelwrist and Kubota are showcasing their latest products, which include new excavators and the next generation of control systems.

FIRST IMPRESSIONS LIEBHERR LR636

Swindon-based Hills Waste Solutions has recently taken delivery of a new waste spec Liebherr tracked loader for use on a landfill site.

SITE VISIT VOLVO ECR145E

We report from Elgin in the north-east of Scotland on Gordon Skene’s new short-radius Volvo ECR145E excavator, which is working alongside their versatile EWR130E wheeled machine.

MARKET GUIDE HYDRAULIC HAMMERS

We review the current widespread offering of large hydraulic-powered, excavator-mounted breakers/hammers.

SITE SERVICES

ARTIFACTS WANTED

(by collector)

Stone Ginger Beers, Stouts, Jugs, Pot Lids. All Early Glass & Stoneware, Enamel Signs, Chemist Bottles, Cream Pots. Old Pub & Tobacco, Memorabilia. Poison bottles and location of tips to dig. Top Prices Paid. Please phone Paul anytime 07816 960442

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New And Used Spare Parts Available

Final Drives, Hydraulic Pumps, Swing Drives Engine overhaul Kits, Bucket pins & Bushings. MACHINES

BREAKING FOR SPARE PARTS

Samsung, Volvo, Komatsu, Case/Poclain Caterpillar, Daewoo, Hitachi, Liebherr, JCB UNITED PARTS LTD

Station Farm, Station Road, Kirton Lindsey, Gainsborough, Lincs, DN21 4BD, UK

Tel UK 01652 648931 : Fax 01652 640769 : Mobile 07966 484425 Email sales@unitedparts.co.uk : Web www.unitedparts.co.uk Suppliers of Quality Used and Reconditioned Spare Parts

SOMETHING SPECIAL

David Wylie reviews unique scale models of O&K mining excavators that once worked in the UK

Having carefully ground off the simple half-round pipework cast into the top of the original boom, Andrew set about piping up the highly detailed valve block with 1.2mm brass rod. He also updated the face shovel with a wear package to the bucket visor and the back wall.

The cab was built from scratch to a very high standard: fine details include a horn fitted below the front catwalk. Also, the original cast roof was ground down to remove the not-so-fine detailed lights, which were replaced by highly detailed crystal lights. Overall, the fit and finish of all the additional components, together with the immaculate paintwork and razor-sharp homemade decals, is simply outstanding.

Father and son team Andrew and Alfie Thompson have created a highly detailed replica of the first O&K RH120-C ever sold, a face shovel commissioned for R J Budge in 1983, using an old Conrad base model. Both are O&K enthusiasts, and Andrew has customised many such models over the years. As Alfie was working on a 3D printing project at school, he made the incredibly detailed track motors, complete with lifting eyes.

PLANTMOBILIA // O&K CUSTOM BUILDS

Something always lacking on the basic Conrad model in years gone by is detailed track motors and gearboxes. Hamish sorted this and also removed the plastic track pads and added his own metal tracks to finish off the undercarriage to a high standard. The backhoe bucket has a nice level of detail on the wear package, complete with heel-blocks and the bucket teeth painted in ESCO green.

The five hydraulic, boom, stick and bucket cylinders have been made with incredible detail, leaving the cylinder cap head bolts clearly visible. Other details added to the base model include a grease barrel, a toolbox and a highly detailed, boom-mounted hydraulic control valve block, together with its associated pipework connected to the cylinders. The O&K logos and Miller Mining livery are super-sharp and the famous blue colour scheme looks great.

Idecided to upgrade an AutoRussa model into a more detailed replica of the first RH200 to be built, originally commissioned for RJ Budge in 1989, but in its latter livery of RJB mining. The fold-down steps came from a donor model, modified by cutting the side handrails and fitted in a new upright element. An adapted KPS catwalk kit was used across the upper deck.

One of the biggest challenges was to make the hydraulic valve blocks, then shape 2.5m of 1.2mm brass rod to replicate the hydraulic hoses, all of which I am particularly proud of. I even cut up some Lego blocks to fabricate some parts, such as the mounting plate to place the service crane in the correct position. The bucket was also treated to some backwall detailing, side shrouds and heel blocks, again finished off with a coat of real ESCO green paint.

Ex-O&K Falkirk depot manager Hamish Ross once led the team that built up virtually every RH120-C and RH200 mining excavator in the UK. An early global adopter of RH120-C backhoes was Miller Mining, whose first example was given the fleet number MM708 (pictured). However, Hamish has particularly fond memories of fleet number MM731, the 25th machine off the line, which worked at the Thornyhill opencast coal site in Scotland.

Conrad made a few 1:50-scale versions of RH120-C face shovels, but never a backhoe. With years of experience of the actual machines, Hamish set about converting one to a highly detailed replica of MM731. The base model was completely stripped down then Hamish fabricated a backhoe boom, stick, tipping link and highly detailed bucket from scratch, using metal and resin compounds. He also used some parts from the KPS Models upgrade kit, including the four exhausts, signifying that this particular RH120-C was powered by a quad-turbo Cummins powerpack.

PICTURE POST

Spotted an interesting earthmover? Send us the details and you could win £20!

Earthmovers turn up in every corner of the world. It doesn’t matter whether they are stuck, submerged, or just plain interesting - we want to see them all. As an extra incentive (other than the obvious thrill of seeing your pictures in print), we’re offering £20 for each month’s star picture.

Tell us as much as you can about the machine in the picture, and don’t forget to enclose your name and address, and an SAE if you would like us to return your picture(s).

E-mail high-resolution images to editor@ EarthmoversMagazine.co.uk or send your prints to:Picture Post, EARTHMOVERS, Sundial Magazines Limited, Sundial House, 17 Wickham Road, Beckenham, Kent BR3 5JS.

READY TO ROLL

The

time and

It was a bit ambitious of the operator to attempt to drive over a trench, even with a lightly loaded site dumper.

It was obviously time to give this JCB a welldeserved clean, but trying to keep the expensive attachment out of the water.

Thanks to the fitment of an anti-tip-over system in telehandlers, we are seeing far fewer of these incidents these days.

A remarkable photograph provided by Gary Steen from Australia, on a project that would move 25 million cubic metres of earth.

driver slewed the cab just in

was unhurt, but the Hitachi excavator took a couple of days to remove from the bog.

SERVICE & REPAIR

Our mobile and workshop-based engineers and coded welders are equipped to carry out repairs and the knowledge and back-up to be able to solve most problems that your equipment may throw at you.

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