Earthmovers November 2022 by Sundial Magazines

NUMBER ONE FOR ALL THE LATEST PLANT & MACHINERY NEWS

EARTHMOVERS EXCLUSIVE!

NOVEMBER 2022

GROWING POPULARITY OF COMPACT RADIUS EXCAVATORS 24t Hyundai under the spotlight SHOW PREVIEW BAUMA

MARKET REVIEW

TOWED & MOTOR SCRAPER REVIVAL

Latest Volvo hauler

PLUS

HYDRADIG JCB DUO WORKING IN WASTE HANDLING

New Bobcat driven

£4.40

115-tonne Cat dozer

● Eurocomach forestry mini ● Liebherr wheeled excavators EM1122 Cover_v6.indd 1

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SMALL EXCAVATORS. BIG RESULTS.

IN STOCK AND READY TO WORK FOR YOU. Visit www.finning.com/smallexcavators to find the best fit for your business.

© 2022 Caterpillar. All Rights Reserved. CAT, CATERPILLAR, LET’S DO THE WORK, their respective logos, “Caterpillar Corporate Yellow”, the “Power Edge” and Cat “Modern Hex” trade dress as well as corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permission.

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WELCOME November 2022 Issue 223 PHOTO CREDIT: NICK DREW

Editor Graham Black Editor@EarthmoversMagazine.co.uk

News Editor Kyle Molyneux Sub Editor Paul Carter Advertisement Sales Tom Pickford +44 (0) 20 8639 4416 Jacob Hayes +44 (0) 20 8639 4416 Sales & Marketing Manager Richard Cosgrove Administrator Martin Attis Publishing Director Paul Cosgrove

EARTHMOVERS is published by Sundial Magazines Ltd, Sundial House, 17 Wickham Road, Beckenham, Kent BR3 5JS. +44 (0) 20 8639 4400 www.EarthmoversMagazine.co.uk Info@EarthmoversMagazine.co.uk Subscriptions Earthmovers subscriptions Trinity House, Sculpins Lane, Essex, CM7 4AY, England. +44 (0) 1371 853 632 earthmovers@escosubs.co.uk Newstrade If you have any difficulty obtaining Earthmovers from your newsagent please contact Seymour Distribution, 5 East Poultry Avenue, London EC1A 9PT. +44 (0) 20 7429 4000 Repro Design & Printing Solutions Ltd, First Floor, Unit 45C, Joseph Wilson Industrial Estate, Whitstable, Kent CT5 3PS. Printing Precision Colour Printing, Haldane, Halesfield 1, Telford, Shropshire TF7 4QQ. Copyright Sundial Magazines Ltd 2022. All rights reserved. Reproduction in whole or in part is forbidden except with the written permission of the publishers. ISSN 1743-0372 Sundial Magazines Ltd. Registered in England No 4134490. Conditions for advertising All advertisements are accepted subject to the publisher’s standard conditions of insertion. For a copy of Advertising Terms & Conditions, please write to Paul Cosgrove at Sundial Magazines Ltd, Sundial House, 17 Wickham Road, Beckenham, Kent BR3 5JS. Australian subs sales agent Greg McNiece, Rally Badges, PO Box 9, Tatura, Victoria 3616, Australia. +61 (0) 3 5824 1734

NUMBER ONE FOR ALL THE LATEST PLANT & MACHINERY NEWS

EARTHMOVERS EXCLUSIVE!

NOVEMBER 2022

GROWING POPULARITY OF COMPACT RADIUS EXCAVATORS 24t Hyundai under the spotlight SHOW PREVIEW BAUMA

PLUS

MARKET REVIEW

HYDRADIG JCB DUO WORKING IN WASTE HANDLING

TOWED & MOTOR SCRAPER REVIVAL

Latest Volvo hauler

New Bobcat driven

£4.40 £

115-tonne Cat dozer

O Eurocomach forestry mini O Liebherr wheeled excavators EM1122 Cover_v6.indd 1

23/09/2022 15:01

The wait is finally over fter an enforced delay, the global construction and mining machinery industry is heading back to Munich for the extravaganza that is the Bauma Show. In addition to the sheer entertainment value of such a visit, there is serious business to be conducted by visitors. Not prearranged PR stunts announcing large orders, but the wider plant community taking the opportunity to learn more about emerging technologies such as using hydrogen as a fuel. A more immediate business concern of visitors should be to look at batterypowered compact equipment with an open mind: products that are still mocked by many in the industry in the same way that tilt-rotators and GPS machine guidance systems were treated for many years – and look how they are turning out. Without doubt battery-powered mini-excavators, compact telehandlers and site dumpers are going to play an increasingly important role in the UK plant scene. The real advantage that early adopters gain is not individual transaction values with hire customers, but being a big step ahead in the steep learning curve of how to manage the kit of the future.

www.twitter.com/ EarthmoversMag

The next issue of EARTHMOVERS magazine is available on 4 November

Yours till next month Graham Black, Editor NOVEMBER 2022

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CONTENTS UPFRONT

FEATURES

47 RUNNING REPORT CAT D11T

FIRST IMPRESSIONS HYUNDAI HX235ALCR One compact radius 24-tonner replaces two conventional tailswing excavators.

13 NEWS

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

21 NEW PRODUCT VOLVO R100 Next-gen 95-tonne capacity hauler on long-term test with Banks Group.

27 FIRST DRIVE BOBCAT T86 Report from the cab of the maker’s most powerful tracked skid-steer.

33 SITE VISIT EUROCOMACH 28ZT

SEE PAGE 90

53 SITE VISIT EDINBURGH TRAMS A pair of Liebherr A910 Compact wheeled excavators at work in Edinburgh.

57 MARKET REVIEW SCRAPERS Towed and motor scrapers together with a review of prominent UK fleets.

63 FLEET FOCUS MEANEY PLANT Recent additions to the fleet of Kildarebased Meaney Plant and Civil.

69 RECYCLING NEWTOWN WASTE A pair of JCB Hydradigs work within a busy, compact recycling facility.

73 MARKET REVIEW CONSTRUCTION DOZERS Construction-sized dozers with operating

Recent investment in a fleet of JCB 3CX Sitemaster backhoe loaders.

CRIPTION ANNUAL SUBS SAVE UP D TAKE OUT AN AN E SU IS AN S – DON’T MIS TO THE BARGAIN! TO £8.20 IN

ripper duties at Croxden Quarry.

The Editor previews the upcoming construction and mining machinery show.

43 FLEET FOCUS H&C PLANT HIRE

November 2022

SUBSCRIB! E & SAVE

Stokey Plant’s 115-tonne dozer on

Forestry contractor Dan Hurle and his new mini-excavator at work.

39 SHOW PREVIEW BAUMA 2022

ISSUE NUMBER 223

weights below 35 tonnes.

EARTHMOVERS NOVEMBER 2022

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57 18

73 TAIL END

79 FACTORY VISIT KOMATSU UK Taking a closer look at their new retro-fit machine guidance system.

85 CLASSIC PLANT TOWER EXCAVATORS A detailed review of these forgotten members of the excavator family.

91 INTERVIEW AID ALLIANCE Ardent Hire CEO Jeremy Fish speaks for the UK’s Plant & Hire Aid Alliance.

94 PLANTMOBILIA 3D PRINTING EARTHMOVERS reviews a range of 3D-printed diorama accessories and vehicle loads.

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

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

NOVEMBER 2022

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CHANGING GROUNDWORKS FOR GOOD

GAME CHANGER! WATCH THE VIDEO AND FIND OUT MORE AT SITESTAK.CO.UK

FIRST IMPRESSIONS // HYUNDAI HX235ALCR

TWO INTO ONE DOES GO

Nick Drew visits a compact radius 24-tonne excavator on a housing site, which will be undertaking the work of conventional counterbalance 21- and 13-tonners “WE NEEDED SOMETHING THAT WAS A LOT MORE PRODUCTIVE, BUT THAT WAS NOT REALLY MASSIVELY BIGGER IN ITS FOOTPRINT” Inset above and below: This compact radius 24-tonner has just 150mm of rear overhang, and a track footprint of 4446mm long x 3090mm wide.

or decades, the go-to machines for undertaking groundworks for housing developments have been 20- and 12-tonne conventional counterbalance excavators, both of which have gained at least an extra tonne in weight over the years. Typically, the larger excavator is used to strip the site, perform bulk earthworks and for heavy lift duties. The smaller machine is used for working on and around the house bases. Savvy contractors are now opting for a one-size-fits-all approach, employing a single excavator that can perform the vast majority of groundworks required on a typical site: a 25-tonne class reduced swing radius machine. It can be deployed at the

start of the job, but is equally at home working close in to the building plots as the development proceeds. Confidence in the abilities of compact upper-structure excavators has been bolstered by the recent success of 15-tonne class reduced radius and zero-tailswing machines within this sector, largely used to cope with increasingly tight sites. One developer who has embraced this approach is Stonevale Homes, based at Gillingham in North Dorset. Stonevale was founded three years ago when Andrew Popplestone of Geometric Civils teamed up with Gary Adlem of Charlestone Homes. To form this new venture, they combined their many years of experience in the

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There is a lot packed into the small upperstructure, but routine service points seem easy to access.

groundworks and architectural sectors. This firm typically works within a 45-mile radius of its HQ, focusing on bespoke smaller developments of prestigious, luxury properties. Previously Andrew had undertaken all the groundworks and civils for Charlestone Homes. The pair joined forces to undertake slightly larger developments. We met the team shortly after starting their biggest project to date, in the glorious rural Wiltshire village of Maiden Bradley, the site of a former timber yard. Some of the existing buildings will be converted into a pair of semi-detached properties, and eight new detached homes are being built across the rest of the site.

LARGER EXCAVATOR Stonevale Homes runs its own fleet of machinery, including a 10-tonne capacity NC site dumper, a Takeuchi TB260 mini and a JCB telehandler. Until March of this year they also had a 15-tonne compact radius Hyundai R145CR-9A, which had served them well over the years, but was too small to effectively tackle this project. It was

therefore traded-in with dealer Molson against a new 24-tonne Hyundai HX235ALCR model, which was delivered in March this year. Andrew said, “Obviously we were familiar with the compact radius machines and, being that this site was so big, we needed something that was a lot more productive, but that was not really massively bigger in its

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FIRST IMPRESSIONS // HYUNDAI HX235ALCR HYUNDAI HX235ALCR

Above and left: The cab offers a comfortable seat, good visibility, simple controls and even a bit of storage space behind the seat.

“ITS SPEED, POWER AND PERFORMANCE HAVE SURPRISED US. WE FIND IT HAS THE POWER COMPARABLE TO A MUCH LARGER MACHINE”

Left: The excavator has proved to be an exceptionally stableplatform, even at full stretch over the side. Right: The compact upper-structure will really come into its own when building work commences on this site.

footprint. We did our research and tried out some other makes for a comparison with the Kobelco and Volvo equivalent models, but we found the Hyundai to be a lot more familiar to us. “This one is on another level, so smooth and responsive. As I have always said, you can drive a fast machine slowly, but you can’t drive a slow machine quickly. We are more than happy with how it’s performed so far. Its speed, power and performance have also surprised us, and we find it has the power comparable to a much larger machine. It certainly packs a punch! “We also find the Hyundai represents great value for money: it was cheaper to buy than all the others we looked at by a considerable margin, which was also a key factor in the decision, especially when we

This compact radius 24-tonner is powered by a Stage 5 ultra-low emissions six-cylinder Cummins engine, rated in this application at a very healthy 195hp (145kW) and delivering a whopping 881Nm of torque. It drives a hydraulic system that features Hyundai’s electronic pump flow control (EPFC) system, which allows the operator to fine tune the machine to the task in hand. Hyundai’s new A series also features an improved cab, including a redesign of the door handle area to provide a bit more nearside visibility and an extended anti-slip step. In addition, the offside window is now larger, offering an improved view especially down to the tracks. The focal point inside the cab is the 8in touch-screen monitor, which is simple to use and offers all the information an operator could possibly need. The new integrated audio system includes USB and MP3 compatibility and Bluetooth hands-free phone handling. The cab in general seems a nice place to spend a shift, unusual for a compact radius excavator. There is actually some space behind the seat for a small lunch bag or cool box. Taking a walk round the excavator, the cooling pack, expansion bottle, screen wash bottle and air filter are behind the nearside rear panel. The offside rear panel opens to reveal the hydraulic pump and access to the fluid filters, all of which are accessible from ground level. The massive panel on the front offside opens to allow access to the main hydraulic valve block, the 48-litre AdBlue tank and the electric refuelling pump.

are delivering projects to a strict budget. “In addition, in terms of site safety, the Advanced Around View Monitoring (AAVM) camera system that is fitted is just fantastic. Especially in the way it picks up on people getting too close to the machine in the working zone, warning the operator both visibly and audibly. Safety features like that are just so crucial on jobs nowadays.” The new Hyundai’s regular operator is Emlyn Hodges, who said, “Cab comfort is very good, with a nice seat that has plenty of adjustment. All-round visibility is also excellent and general driveability is very good. I also find the settings in the menu are really easy to navigate around, a lot more operator friendly than some of the others. “It’s also incredibly stable. It doesn’t seem to matter where you are in the working arc, it remains well and truly planted at all times. We do have quite a large bulking NOVEMBER 2022

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FIRST IMPRESSIONS // HYUNDAI HX235ALCR bucket on her, but with its wide and long, heavy-duty undercarriage nothing seems to faze it. Andrew added, “Where this machine will come into its own is when we are working around scaffolding in between buildings as they are being built, where you could be tight for room. It’s brilliant that this machine only has 150mm of overhang on the back end, which makes it a lot safer and offers peace of mind to the operator. It is, without a doubt, going to be a game changer for us.”

Talking about game changers, although Andrew has no immediate plans to invest in a tilt-rotator for this machine, clearly he is a fan of the working method, particularly as housing sites are becoming more congested.

CONCLUSION This compact radius 24-tonner has got off to a good start, but as Andrew said, it will really come into its own as this site develops and it has to work between the new structures. In addition to the performance and controllability of the working equipment, the stability of this reduced radius 24-tonner has impressed both operator and owner. Its compact upper-structure sits on a long undercarriage with an overall length of 4446mm and a track width of 3090mm. A somewhat inconveniently wide load to transport, but this excavator will probably be the first on site and one of the last to leave. This latest generation A series of Hyundai’s HX excavator range features

“IT DOESN’T SEEM TO MATTER WHERE YOU ARE IN THE WORKING ARC, IT REMAINS WELL AND TRULY PLANTED AT ALL TIMES” a new upper-structure frame, the design of which is intended to significantly improve the machine’s lifting capacity. These excavators also come with a state-of-the-art hydraulic system that now includes a lifting mode. Making the best use of the excavator’s excellent stability, this working mode will improve lifting precision and capability by changing the way the flow from the hydraulic pump is managed, while working at lower engine speeds, but providing the operator with a power boost function. The new compact radius Hyundai HX235ALCR seems to be a cracking piece of kit, on which the positivity of the owner and operator left a big impression on me. I look forward to a return visit to see how the excavator is performing in a wider range of duties.

Left and below: Andrew Popplestone and operator Emlyn Hodges are extremely positive about the new Hyundai, which genuinely seems like a cracking bit of kit.

EARTHMOVERS NOVEMBER 2022

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Earthmoving PR 726 G8

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NEWS

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

UK TRADING RESULTS n the second quarter of 2022, imports and exports of construction and earthmoving equipment recorded increases over Q1 levels, both in terms of value and tonnage. In value terms, overall trade was at the highest quarterly level since monitoring began in 2013. These record levels can be partly attributed to the higher prices for equipment due to increases in the price of steel and components. However, the level of trade measured on a tonnage basis has also been relatively high in recent quarters.

Exports of equipment in Q2 were £984m, while we imported £696m-worth off kit, both figures representing a 10% increase over Q1. The UK remained a net exporter of construction equipment in the first half of 2022, when exports of £1879m were 41% higher than imports at £1330m. However, this was a much smaller overall margin than in 2021, when exports were 64% higher than the level of imports. The USA remained the top destination for UK exports in the first half of 2022, increasing its share of total exports to 27%. Exports to the Irish Republic remained strong in Q2 and

maintained its position in second place in the destination country rankings. Similar to previous years, Japan remained the leading source for UK imports in the first half of the year on a tonnage shipped basis, while Germany remains the leading source on a value basis. Between them, these two countries accounted for just under 30% of total imports. Imports from France continued to grow in the first half of the year compared with 2021 levels; as a result this has moved France up to fourth place in the country ranking, compared with 10th place last year.

LEADERS OF THE FUTURE KUBOTA SHELLPLANT MILESTONE Kubota dealer Shellplant has surpassed the 5000 sales mark for mini-excavators, racked up over the past 25 years. Based in Northamptonshire, the firm celebrated its 1000th sale as recently as 2011, a good indication of the increased demand for Kubota minis over the last decade. To mark the achievement, Shellplant has donated £5000 to the local Riding for Disabled Group, based in Mears Ashby.

CB has created more than 150 new jobs for apprentices and graduates with an £8m investment in its industry-leading early careers programme. The new recruits were among 2000 applicants for roles in manufacturing, engineering and business and started their jobs in mid-September. From left to right, new JCB apprentices Libby Hodge, Lexi Anderson and Freya Barkas.

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NEWS

NEW TAKEUCHI TRIO AT BAUMA he recently introduced Takeuchi TB335R 3.7-tonne miniexcavator will be joined by two more new compact excavators tors at the Bauma Show, the TB350R mini and the 10-tonne TB395W 95W wheeled machine. The brand new five-tonne TB350R mini-excavator is essentially a bigger version of the reduced radius TH335R design. It is powered by a 43.4hp 4hp (32.4kW) engine, offers a boom swing of 71degrees left/55degrees right and has a maximum digging depth of 3575mm. The 10-tonne TB395W compact wheeled excavator has a 113.9hp (85kW) engine driving a powerful hydraulic system. It provides slewing speed of 10rpm, a maximum bucket breakout force of 58.9kN, a maximum arm digging force of 39.7kN and a traction force of 57.8kN. Its working equipment provides a maximum digging depth of just over 4m.

FIRST CABBED 3.5T DUMPER taffordshire-based plant hire firm Double M has taken delivery of the first Mecalac 3.5MDX site dumper in the UK, sold by dealer SM Plant. The state-of-theart, 3.5-tonne cabbed unit is already being used by customers across the region.

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FIRST BOBCAT

MAXCONTROL IN UK JH Fencing, based in Holmfirth in West Yorkshire, has purchased the first Bobcat MaxControl remote control system in the UK, from Bedale-based dealer Grays Machinery. The MaxControl system consists of a hardware kit and a smart phone app, providing the operator with an easy way to control the machine from a better vantage point. JH Fencing is using this system to remotely control its Bobcat steer loader, which was supplied by Grays at the end of last year, configured with a specialist fence post hammer attachment. The firm’s owner, Jack Hampshire, said that the system is taking two to three hours off a 10-hour working day.

NOVEMBER 2022

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Easy on wallets. Tough on everything else.

Visit Doosan at bauma on stand FM.711/1

Unbeatable total cost of ownership If low fuel consumption, powerful Stage V engines, auto idle, auto shut-down and enhanced durability and reliability weren’t enough, Doosan’s latest 7 Series Wheel Loaders also come equipped as standard with 3 year warranties and our revolutionary DoosanCONNECT machine lifecycle and performance management solution, ensuring Doosan customers are always up and running. With Doosan, there is no need to choose between brains or brawn, we already offer you both. Find out more: www.eu.doosanequipment.com

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21.07.2022 08:30:58

NEWS

SCOTTISH PLANT

APPRENTICES

he Scottish Plant Owners Association (SPOA) is calling on plant owners to consider taking on an apprentice. Funding is in place for plant owners to access an apprenticeship grant of up to £14,500, as well as a further £500 for those employers with a wage bill lower than £400,000. Financially, these incentives mean that there has never been a better time to start an apprentice, which will help to secure the future of the industry. Employers interested in starting a mechanic or operator apprentice can reach the dedicated plant apprenticeship contact at the Construction Industry Training Board, John Bond. The SPOA is also happy to support employers interested in starting an apprentice, but struggling to find a suitable candidate, by working with them to generate interest in the local area. Employers are encouraged to contact the association at info@SPOA.org.uk.

WARWICK WARD EXPANSION arthmoving and recycling dealer Warwick Ward has expanded its operations with the opening of a new training centre in Barnsley, less than five miles away from the company’s HQ. The new site will house the company’s bespoke training academy to develop future employees, seen as a key to maintain business growth.

SANY FITS CESAR

CALL TO NEW PM uneeta Johal, CEO of the Construction Equipment Association (CEA), has called on new UK Prime Minister Liz Truss to tackle soaring energy costs and protect the long-term health of the construction industry. Suneeta said, “Companies are fearing their energy costs could go up by as much as 300%, which is simply not sustainable. We need immediate action from Government to introduce a business energy price cap and reduce the VAT on business energy bills. Rising energy costs have been compounded by the steep price increases in fuel, and while this has stabilised at source, it’s not being passed on to the consumer. The construction industry is also bearing

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the brunt two-fold with the end of the red-diesel rebate. “The Government has committed to achieving net zero by 2050. It has also stated that its target is to decarbonise the power system by 2035. It has been estimated that around £40bn per year would be required on average to be invested in new low-carbon and digital infrastructure over the next 10 years. “There is a significant gap between the Government’s objectives and the practical policy that is needed to provide confidence and positive, clear signals to potential investors. Introducing a long-term capital allowance regime will drive investment in greener technologies and clean technology, which will in turn reduce energy consumption.”

Sany UK is the latest distributor to fit the CESAR and its emissions compliance verification system as standard to all its machinery. The CESAR system uses a range of state-ofthe-art technology to give each piece of equipment a unique fingerprint, which aids the identification and recovery of stolen equipment, as marked machines are twice as likely to be recovered as unmarked ones.

HUSQVARNA FOR MOLSON he four-strong DXR range of Husqvarna remote-control demolition robots is now sold and supported from the Molson Group. Such machines have a key role to play in further improving the safety of the demolition sector, carrying out risky work that would otherwise be undertaken by humans using hand-held power tools. A wide range of attachment is available, including breakers, hammers, crushers and steel shears.

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In a league of your own Whether it’s on the job site or at home, you go the extra mile and think outside the box. By teaming up with the right equipment, even the toughest customers will meet you with open arms. NOTICE: ALWAYS FOLLOW WARNINGS AND INSTRUCTIONS PROVIDED BY THE MANUFACTURER. FOR MORE DETAILS VISIT WWW.BOBCAT.COM

NEWS // HYUNDAI DUCK

NEW HYUNDAI DUCK yundai has added a new compact radius machine to its wheeled excavator range, the 17-tonne HW150ACR model. It is powered by a 173hp (129kW) Cummins B4.5 engine driving a Bosch Rexroth load sensing hydraulic system and a fully hydrostatic, four-wheel drive powertrain. Hyundai promises excellent controllability in simultaneous multiple function operations from this modern driveline and hydraulic system. The driveline includes an automatic digging brake, which locks the front axle oscillation and the service brake, allowing the operator to start work as soon as the machine stops. The upper-structure frame on this A series design has been repositioned, which contributes to a shorter slew radius, increased lifting capacity and improved stability. It also accommodates the latest design of Hyundai cab, which looks a decent place to spend a shift. A variety of undercarriage configurations are available, including fully interchangeable stabilisers and a dozer blade. The parallel-frame blade features an increased range, delivering additional

stability while digging or lifting and boosting productivity in site clearance. The additional reach also provides space around the wheels for maintenance. The working equipment has also been changed; the dipper arm cylinder has been reversed to provide increased protection of the ram. The boom and arm cylinders have safety valves fitted as standard. Two boom configurations are available: either a mono-boom or the far more versatile two-piece variant. The new Hyundai HW150ACR has an operating weight between 16.9 and 17.2 tonnes and a tailswing radius of 1800mm.

It provides a maximum digging depth of 5130mm, a maximum digging reach of 8370mm, bucket breakout force of 102.9kN and arm digging force of 66.4kN.

Top left: This A series machine features Hyundai’s latest wheeled excavator cab. Above and below: The new 17-tonne Hyundai wheeled excavator is available with either a monoor a two-piece boom.

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THE EXPERT EXCAVATION

WHAT MAKES A REAL EXPERT? Is it intelligence, skill or just the way they make even the toughest job look easy? The LiuGong excavation team has the answer. Breaking, lifting, digging or loading, the LiuGong machines have the job site credibility to get the job done right. The team covers every application and delivers the intelligent control, digging force, comfort and fuel economy you need. With 50,000 machines already in action, and over 1/2 billion productive hours worked, LiuGong has the expertise you can trust.

TOUGH MACHINES

1.8-95 TONNES

DESIGNED, TESTED AND SUPPORTED RIGHT HERE, IN EUROPE

See us online or talk to us today to ﬁnd out more.

02392 123 392 info@liugong.co.uk www.liugong.co.uk

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A LONG WAY

TOGETHER

EARTHMAX SR 41 No matter how challenging your needs, EARTHMAX SR 41 is your best ally when it comes to operations that require extraordinary traction. Thanks to its All Steel radial structure and the special block pattern, EARTHMAX SR 41 provides excellent resistance against punctures and an extended service life. In addition to long working hours without downtime, the tyre ensures extraordinary comfort. EARTHMAX SR 41 is BKT’s response to withstand the toughest operating conditions in haulage, loading and dozing applications.

IMPORTER FOR THE UK

Tel: +44 0151 728 4171 bkt_enquiries@kirkbytyres.co.uk www.kirkbytyres.co.uk

NEW PRODUCT // VOLVO R100

EXCLUSIVE REPORT

NEXT GEN 100-TON HAULER

David Wylie reports on the next-generation Volvo 95-tonne capacity R100 rigid hauler, which is currently undertaking long-term testing by the Banks Group hen Volvo bought the historic Motherwell-based Euclid/Terex off-road dump truck business in 2014, one of its priorities was to integrate the rigid mining truck range into its own global product offering. The smaller models in the range were to be updated, but the real challenge was to design a replacement for Motherwell’s flagship product, the Terex TR100.

FLAGSHIP VOLVO TRUCK Competing in the large global market for 100-short-ton capacity rigid haulers, the bull-nose TR100 was launched back in 1998, a direct descendant of a smaller 33-11 series model introduced in the early 1970s. Under the leadership of technology director David Maslin, a muchstrengthened Motherwell R&D team pulled off a remarkable achievement. They designed, sourced

components, built and tested the Volvo R100E rigid haul truck in less than four years. Launched in 2018, the R100E was a complete departure from the TR100, the radically modern design featuring a tapered chassis and a V-profile skip, together with an extremely well-protected cab. The original R100E was powered by a Stage 2 emissions-compliant engine,

aimed at less regulated export markets such as Indonesia, where the big Volvo hauler has subsequently proved particularly popular. Examples have also been supplied to customers in the Nordic region, particularly Norway, but European and American customers are generally demanding machines with the latest Stage 5 powerpacks.

“THE REAL CHALLENGE WAS TO DESIGN A REPLACEMENT FOR MOTHERWELL’S FLAGSHIP PRODUCT, THE TEREX TR100”

Right and inset: The 95-tonne capacity Volvo R100 rigid haul truck is powered by a 30.5-litre V12 Cummins engine rated at 1065hp.

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Above, inset and above right: While hauling overburden at the Bantycock Quarry this 95-tonne capacity Volvo R100 has an average fuel consumption of just 39 litres per hour.

The latest version of Volvo’s 100-shortton capacity truck, which features a Stage 5 Cummins V12 engine rated at 1065hp, is simply known as the R100 model. Pre-production development examples were placed with customers operating in arduous sites, including the Arctic Circle, South Africa and the Scottish coal fields. As surface coal mining in Ayrshire comes to an end, the R&D team looked for another development partner in the UK, which they found in County Durham-based Banks. Robbie Bentham, plant director of the Banks Group, said, “We have a wellestablished history of supporting and investing in the local supply chain wherever possible and are delighted to be able to support the Motherwell factory. I’m also delighted to report that feedback on the Volvo R100 has been very positive, as it appears to be extremely reliable and the operators are impressed with the ride quality.” Far left: The modern tapered frame design has 10 degrees of slope. The truck is fitted with a new rear axle and a front axle with MacPherson strut suspension. Left: The start of shift routine is quick and easy to perform: the engine oil level is accessible from ground level, while most checks are performed in the cab via the smart monitor.

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NEW PRODUCT // VOLVO R100 VOLVO R100 WALK-ROUND

R100 FEEDBACK

in the colder and wet seasons, as these conditions are likely to produce sticky This R100 model, used to test and develop overburden material. new components, was first used by Banks “We have found the truck to be extremely Mining on the restoration works of the well balanced when tipping its 95-tonne massive Shotton surface mine, then payload at the tip site and has very good transferred to Banks Infrastructure’s new traction and rim-pull performance as it contract at Bantycock Quarry, which pulls away from the spotting area fully featured in the previous issue of loaded, which all Earthmovers. Banks adds up to good has been using this “THE R100E WAS A cycle times.” hauler for over a If Neil was being year; it now has 2100 COMPLETE DEPARTURE FROM picky, his only hours on the clock THE TR100, THE RADICALLY criticism is the need and covered 11,000km. MODERN DESIGN FEATURING for a slightly higher reverse speed to get Neil Cook, Banks’ A TAPERED CHASSIS AND A the truck spotted site manager at the under the excavator Bantycock gypsum V-PROFILE SKIP” a few seconds quarry, said, “We run quicker. a busy operation This development unit is fitted with and site safety is paramount, so I’m pleased a transmission offering a single reverse to see the Volvo R100 comes equipped as speed, a two-speed option is already standard with a 360-degree camera system available on production machines, as is displayed on a large LCD screen. an optional final drive unit aimed at those “This development truck has a host of faced with long, high-speed hauls. optional extras fitted, such as the LED At the controls of the R100 was lighting package, an extra-tall spill guard experienced operator John Barrett, who on the skip’s canopy to minimise spillage, said, “Overall this R100 is a good truck as well as a fire suppression system and and is right up there with the best of them. effective auto-lube to help keep It has a very good air-con system and maintenance downtime to the minimum. a well-appointed cab. The short, sloping The optional heated body will also be a big engine hood, 360-degree cameras and the benefit to this operation, as we are keen to lighting package offer good visibility avoid any carry-back issues when operating

This R100 is powered by the latest version of the digitally-controlled Cummins ST30 engine, a 30.5-litre V12 rated in this application at 1065hp. It drives a smart Allison H8610 full- automatic transmission, which includes a transmission retarder as standard, offering Eco and Performance working modes along with an optional load-sensing gear selection sub-system. The new rear axle retains the same differential unit as the TR100, one of the very few carryovers from the predecessor, which proved itself over the decades. The axle features new fixing points for the A-frame, stabiliser bar and rear suspension units, which are inverted like mining shovel boom rams to keep dirt from harming the outer seals. The MacPherson strut front suspension design features variable rate nitrogen/oil suspension struts and robust-looking cast lower A-frame wishbones. The well-proven front disc and rear oil-cooled multi-disc enclosed brakes integrate with the transmission retarder to offer good braking performance and lower running costs. The R100 sports the latest industry-standard wheels and fixing stud arrangement. The modern tapered chassis design has 10 degrees of slope and has undergone accelerated fatigue testing equivalent to over 60,000 hours. The V-shape body floor of the skip is designed to provide good stability and material retention on the climb out of the mining cut. The body is made from Hardox 400 steel, with a standard floor thickness of 19mm and 6mm to 19mm liners available from the factory. Hoist rams are positioned externally, for improved stability and tipping performance, and are fully raised in just 11 seconds and lowered in 13sec. To improve long-term service life, the hydraulic oil and fuel tanks are not bolted to the frame, but are on two large rubber top mountings and a lower one to absorb vibrations. An option for the 1290-litre fuel tank is a ground-level fast fill point. The R100 has a large walk-through cab, complete with a seat for a trainer. It is one of the few designs in this size class to have a clearly visible roll-over protection frame built into the cab structure. In the event of a roll-over, traditional designs rely on the front of the skip to provide some protection to the cab. Volvo’s approach makes the R100 an ideal candidate for conversion to an extreme heavy-duty water or fuel bowser, while still maintaining full ROPS protection for the operator.

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“THE AVERAGE FUEL CONSUMPTION OF THE NEW VOLVO IS A TRULY IMPRESSIVE 39LPH, AND IT’S CARRYING A FEW TONNES MORE ON EVERY CYCLE”

Above and top right: The cab features its own ROPS structure, making the R100 ideal for conversion to a water bowser, while still protecting the operator in the event of a roll-over.

when operating such a big truck. It is a much better experience and more comfortable ride than the older TR100 model.”

CONCLUSION Jim Moffat, Volvo’s engineering development manager at Motherwell, said, “We are delighted to have the support of Banks Group, as they are an ideal partner to help us develop the R100. They are a highly experienced and professional mineral extraction company, whose skilled people provide good feedback.” One of Jim’s previous roles was the UK dealer service support manager for the Terex TR range. Comparing the two designs he stated, “We know from years of 24

experience supporting the TR100 in the Scottish coal fields that customers of the all-new R100 are enjoying lower total cost of ownership, ease of maintenance and improved uptime with high availability rates. “The whole design ethos of the new R100 is all about safety, productivity, low cost of ownership and ease of use for the operator. This includes minimising the amount of time taken to do daily checks, as most of this is covered using the diagnostic screen in the cab, along with a quick walk-round from ground level to check sight glasses on the rear axle oil level and the engine oil dipstick.” This R100 is running with prototype components, but has remained totally reliable, requiring nothing more than planned visits from factory staff to carry out 500-hour services. One of the components not yet tested on this

particular model is a new traction control aid. Although the hardware and software are available, the standard R100 driveline has proved to offer plenty of traction in wet conditions. As Banks operates a 10-strong fleet of its own 91-tonne capacity Komatsu HD785-7 haulers on the Bantycock Quarry project, the new 95-tonne Volvo R100 is standing up extremely well to direct on-site comparisons. Although the official R&D programme for this component test truck is not focused on its fuel consumption, obviously Banks has been keeping a very close eye on its performance. As a benchmark, their well-proven fleet of Komatsu haulers had a collective average fuel consumption of 56 litres per hour while working at the Shotton surface mine, which had steep ramps out of the mining void. On the less demanding Bantycock Quarry job this has improved to around

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NEW PRODUCT // VOLVO R100

Right: Operator John Barrett praises the well-appointed cab and the good levels of visibility for such a big truck.

48lph, a very respectable figure indeed. However, the average fuel consumption of the new Volvo on the same job is a truly impressive 39lph, and it’s carrying a few tonnes more on every cycle. The Scottish-built Volvo R100 is the largest rigid hauler currently made in Europe, a combination of Volvo’s engineering flair with a focus on offering the lowest cost of ownership. NOVEMBER 2022

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FIRST DRIVE // BOBCAT T86

HIGH-POWER SKID-STEERS

Nick Drew spends time in the cab of the new T86 tracked skid-steer, the most powerful compact loader ever built by Bobcat he forthcoming Bauma Show will be the official European launch pad for the long-awaited replacement of Bobcat’s largest skid-steer loaders, the wheeled S770 and S850 and the tracked T770 and T870 models. They are now superseded by the R series S86 and T86 skid-steers, which have been available to North American customers for some time.

Left and below: With a 105hp (78kW) engine, the new five-tonne T86 and its S86 wheeled equivalent, are the most powerful skid-steers that Bobcat has ever produced.

“THE LONG-AWAITED REPLACEMENT OF BOBCAT’S LARGEST SKIDSTEER LOADERS, THE R SERIES S86 AND T86”

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DRIVELINE Bobcat describes the new S86/T86 models as the most powerful skid-steers they have ever produced. Powered by the well-proven in-house D34 engine, in ultra-low emissions Stage 5 guise this powerpack produces 105hp (78kW) at 2600rpm. That’s 5% more than the outgoing T870 model, lifting the top of both Bobcat’s wheeled and tracked skid-steer ranges to new heights. The new S86/T86 models are available as standard flow (87lit/min) variants, intended for those working

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Right, left and below: To match the increase in power, the working equipment has been completely redesigned. It now includes lighter but stronger cast-steel lift arm sections.

in load and carry applications and the like. However, the main reason for wanting more power and torque is that top-of-therange skid-steers are increasingly being asked to power heavier-duty hydraulic attachments. The cream of the crop are those machines specified with Bobcat’s new electronic displacement control (EDC) hydraulic pump. The EDC pump provides a high-flow option of 138lit/min at 24MPa, or a new super flow option, which takes hydraulic performance up to 150lit/min at 28MPa. A new five-coupler connection block is mounted on the nearside loader arm, which allows for the use of larger diameter quick coupler connectors and hoses than preceding models, to facilitate improved oil flow to power-hungry attachments. These new R series skid-steers are brimming with new or improved technologies, including a horsepower management system. Similar to those used in modern hydraulic excavators, this electronic control system automatically manages the engine and the high-flow hydraulic system to efficiently deliver sufficient power to suit the task in hand. For those who prefer to work without such operator aides, it can 28

simply be switched off by the touch of a button in the cab. A speed management system is also available, which allows the operator to set and adjust the travel speed independent of engine speed. This is particularly useful when using attachments such as road planers, which require a high hydraulic flow, but a slow and constant travel speed.

RUNNING GEAR While wheeled skid-steer loaders have their place in certain applications, tracked models offer so much more in terms of mobility and stability, together with a far more comfortable working environment for the operator. Earlier this year I had the opportunity to put the new five-tonne tracked T86 model through its paces at Bobcat’s Dobris campus in the Czech Republic. This example was fitted with Bobcat’s five-link torsion suspension undercarriage, an option that takes ride comfort to a whole new level. Designed to absorb shocks and vibration, the torsion suspension system features a new triple-flange rear idler, helping to damp ground vibrations. Five lower rollers

further improve the ride quality and help to avoid losing a track during awkward manoeuvres round obstacles or while negotiating steep batters. As if that is not enough, there is an optional ride control system that damps the movement of the loader arms during carry operations, similar to the systems available for large wheel loaders and backhoe loaders. In addition to maintaining the stability of the load, either in a bucket or on pallet forks, it further improves the ride quality.

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FIRST DRIVE // BOBCAT T86 BOBCAT T86 WALK-ROUND

Above and right: Configured with Bobcat’s new electronic displacement control hydraulic pump, the T86 offers auxiliary flow rates of up to 150lit/min.

IN THE CAB Climbing into the cab, which is never the easiest thing to do on the vast majority of skid-steer loaders, then closing the one-piece front screen, I surveyed my surroundings. It was a hot sunny day in the Czech Republic, so I was delighted to discover air-conditioning controls, located in the upper right of the cab. Just forward of the air-con controls, in the top right corner of the cab, is the machine’s main control monitor, a touch-screen that can be used to access a raft of menus, including those allowing adjustment of the auxiliary hydraulic circuits. Operators can also pair their mobile phones to the system

“THE INCREASED GRUNT FROM THIS SKID-STEER WAS A DELIGHT; THE WAY IT WAS EFFORTLESSLY DELIVERED TRULY IMPRESSIVE” Left and below: With Bobcat’s five-link torsion suspension system, a ride control system and a suspended seat, this tracked skid-steer provides an extremely comfortable ride.

The front-end working equipment on this new generation of Bobcat skid-steer has been redesigned to offer better all-round performance to match the more powerful driveline. There are now lighter but stronger cast-steel lift arm sections, totally different from those fitted on the previous T870 model. In fact, the whole geometry has been changed to enable the machine to lift more, carry more and reach further. This is noticeable from the operator’s seat, from increased lifting capacity right through the working arc of the machine. In familiar Bobcat style, the durable large rear door opens out to reveal the engine bay. The engine is mounted in-line with direct drive, which, according to Bobcat, improves the cooling capacity of the engine and hydraulic components. The engine bay is also home to the diesel and AdBlue tanks, fluid filters, air filter and coolant expansion bottle, in addition to the battery isolation switch. The over-sized cooling fan is mounted above the engine with the coolant radiator above it, drawing hot air out of the engine bay in the process. A reversible cooling fan option is available – a worthwhile addition to the specification in my opinion. It’s all a bit tightly packed within the engine bay, but the service items fall easily to hand. For more in-depth maintenance, the entire cab can easily be raised and tilted to allow access other key components.

via Bluetooth for on-the-move hands-free communication. I especially like the location of this monitor; high up and well shaded, it does not appear to be affected by any glare and is also used to display the output from the rear-facing camera. The standard fit is a 5in screen, while a full colour 7in monitor is available as a factory option. I quickly found my ideal operating position by altering the fully adjustable air suspension seat, which turned out to be extremely comfortable. Visibility can often be an issue in skid-steers, but the view from the seat in the T86 was pretty good, especially to the sides thanks to plenty of glass and minimal steel guarding. The main bank of switches is located on the right-hand pillar, including stop and start buttons, auto idle, handbrake and NOVEMBER 2022

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speed of 8.7kph, which was adequate for what I was going to be doing. The second speed propels the machine up to 16.7kph. The cycle on the demonstration area was to dig out a mixture of clay and stone from the bottom of a pile, then carry the material to the top of the heap for tipping, before returning to the dig. The 1956mm-wide bucket had no teeth, just a standard cutting edge, but I was amazed at how well it performed in the dig. Admittedly this material has been moved IN THE DIG around over and over again, but even so, it Plugging in my seat belt and lowering the was quite a dense combination. Toothless safety bar, I turned the ignition key and bucket or not, the T86 put down plenty of pressed the start button. The machine can grunt while going about its business, the be run using the foot throttle, but I like to first indication of the set the throttle dial available from when operating “TO BE PERFECTLY HONEST, power the new driveline. skid-steers. With the I ENJOYED EVERY SINGLE With a heaped dial cranked right up, bucket load on board, a tug on the rightMINUTE OF MY TIME I headed for the steep hand joystick raised OPERATING THE T86” ramp up to the top of the bucket; pushing the pile. The 105hp, the left joystick five-tonne tracked skid-steer loader proved forward the machine started to move. to be a beast of a machine, powering up the Nice and steady to start with, but as slope, but with hardly any strain on the I applied more forward pressure to the engine. joystick the machine’s speed picked up. Within the confines of the busy Below and below right: Everything falls nicely to hand demonstration area, I remained in the first within the confines of this well-appointed, sealed and travel mode, which gave me a maximum pressurised air-conditioned cab.

work lights. Below that is the rotary throttle/speed selector dial, and the remote menu toggle dial located underneath that. Another bank of switches on the left-hand pillar includes the controls for the front screen wiper/wash, ride control, reversible fan, auto bucket levelling and the Bob-Tach quick-hitch system. In default mode the multi-function joysticks are set to the ISO control pattern, with the left lever controlling direction of travel and steering. This joystick has a number of auxiliary controls, including selection of crawler/first/second travel speed modes. The right-hand joystick controls the loader arms and the attachment dump/curl functions, again containing a number of auxiliary controls, including one to select the bucket float function.

Above and right: The T86 powered up inclines without any fuss and remained stable on faster downhill return runs to the digging point.

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FIRST DRIVE // BOBCAT T86

exceptional, with none of the bouncing about that usually occurs from a wheeled machine.

CONCLUSION

Tipping the load and then counterrotating on the spot, I set off back down the heap at speed, keeping the bucket low for maximum stability. The ride was

I spent a good hour repeating this load and carry cycle in the T86. The joystick controls were very responsive, positive and, with all their auxiliary controls, extremely operatorfriendly. They had the feel of joysticks found on modern excavators. The torsion suspension system on the undercarriage and the suspension seat were doing their job very well indeed, as it really was a comfortable ride. I also got the feeling

you could work this tracked loader at some insane angles and it would still remain planted to the ground. The increased grunt available from this top-of-the-range skid-steer was a delight, and the way it effortlessly delivered was truly impressive. Clearly the T86 has the potential to achieve extremely high production rates. To be perfectly honest, I enjoyed every single minute of my time operating the T86. This is Bobcat’s most powerful skid-steer loader and is also their best, which sets a new benchmark for this sector of the market. NOVEMBER 2022

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SITE VISIT // EUROCOMACH 28ZT This 2.7-tonne Eurocomach 28ZT works with hydraulicallypowered forestry attachments, often simultaneously with tracking the machine.

ITALIAN FORESTRY FLAIR Nick Drew visits forestry contractor Dan Hurle and his new mini-excavator at work on a Duchy of Cornwall job within the Penclenick Estate

he Cornish-based forestry contracting firm of John Hurle and Sons was formed in 2004 (see panel overleaf). The business is very much a family affair, with father John (74 years young) still involved in tendering and other admin jobs. He still likes to get out though to fell the odd tree now and again, just to keep his hand in. The business is run by younger son Dan, whose sister Gemma undertakes the office work, while older brother Mat helps out when needed. The core team out on site is Dan together with Viv, who has been with the firm for many years, and Edd undertakes the climbing work, all assisted by apprentice Olly.

forestry/landscaping contracting work, For the first decade or so, the new business undertook a lot of railway deideally within 1.5 hours from their vegetation projects, the furthest afield being Cornish base. at Porthmadog in North Wales, together Most notably it has included moving a lot with lengthy spells of of iconic trees for the overnight flail strip of Cornwall and THE BOBCAT WAS ACE AND Duchy clearance works in the Truro City Council. Welsh Valleys. Dan and his close-knit I WOULD HAPPILY HAVE As anyone who has team have occasionally ANOTHER ONE, BUT THE worked on rail projects ventured further afield will tell you, although for certain jobs, NEW EUROCOMACH IS A the money is good, it including junction BIT BETTER IN ALL AREAS” improvement works can be a very stressful and tiring occupation, on the M20 at Ashford, never mind all the travelling involved. tree maintenance on a stretch of the With this in mind, over recent years the M25 and some work for the MOD on business has refocused on more traditional Salisbury Plain. NOVEMBER 2022

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Above left, left, and above: The new owner reports that the Eurocomach’s hydraulics are smooth and powerful, and the surprisingly large cab, once you get in it, is a quiet working environment.

“I’VE BEEN IMPRESSED BY ITS ABILITY TO RUN THE FLAIL AND TRACK AT THE SAME TIME, WHICH HAS LED TO A LOT OF ADDITIONAL WORK” MINI-EXCAVATORS The firm has been using excavators since 2006, but didn’t actually own its own machine until 2015, when they purchased a Bobcat E26 mini. This has recently been upgraded to a Eurocomach 28ZT, from the same Italian stable as the new range of Case mini-excavators. The forestry contractor’s first experience of using mini-excavators came about when they started to pick up a lot of rhododendron clearance work, due to the 34

outbreak of phytophthora in Cornwall. Initially with the help of their craneequipped forestry tractors, the team cut then burnt the material, but this was a slow process, particularly across more difficult terrain. Dan recalls, “On really steep ground we were having to do it all by hand, which is time consuming and hard work. We therefore contacted owner-operator Graham Sandercock to come and help us on a job in the Pentewan Valley, to see if we could speed the whole process up.

“At the time Graham was running a little Kubota KX71 mini-excavator and we were totally amazed at what he could do with it. We basically left him to it, grubbing out everything and eliminating the need to respray any regrowth, making the whole procedure much more cost effective. In addition, he moved all the material to a location where we could pick it up with a forwarder. Graham showed us just what was possible with an excavator utilising flails and timber grab attachments, and he

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SITE VISIT // EUROCOMACH 28ZT undertook all our excavator works over the next few years.” As Graham’s other workload grew, Dan started to hire in a mini-excavator in the form of a JCB 8026 from local business Acland Plant, and undertook the work themselves. In 2015, after much research, they bought their first mini, a Bobcat E26. The purchase decision was based on its reach, power and comfort, while Dan particularly liked the rocker switches on the joysticks to operate the grab and rotation hydraulic services. At the very end of last year, with the potential of a few big jobs coming their way, Dan started looking for a replacement for their six-year-old Bobcat. Having been very happy with their existing E26, the obvious upgrade would be to Bobcat’s new zerotailswing E27Z model, but unfortunately the quoted delivery time was October this year. Dan then turned to Graham Sandercock, now running the Mecalac dealership Specialist Plant South West, for advice. He suggested a closer look at the Italian-built Eurocomach range, which led Dan to having a chat with Davide Cerca, the MD of dealer Robustrack. The zero-tailswing, 2.7-tonne Eurocomach 28ZT model was quickly identified as best meeting their needs. Dan continued, “With Graham helping me to spec it up to meet our requirements, Davide suggested we could have a build slot for February this year, which led to me putting in the order. Unfortunately, due to world events it was a bit delayed, but I must say Davide and Robustrack were great to deal with and kept us updated on progress. It eventually arrived in mid-June, supplied with a full set of buckets and an Agriforest GMR 1100SP rotating timber grab. Graham also supplied us with a Femac T90 flail mower.”

Above and below: Eurocomach’s in-house undercarriage is matched to a unique upper-structure, which provides great service access to the main driveline components.

SITE VISIT We encountered the new 28ZT mini on a Duchy of Cornwall job within the Penclenick Estate, where the team were conducting works due to ash dieback disease. The project involved removing the affected trees along the boundary of a school sports pitch for safety reasons. The opportunity was also taken to thin the wood and remove a lot of the squirreldamaged understory, the plants beneath the forest canopy, but above the forest floor. The arisings were chipped on site, leaving the ground clear for replanting this coming winter. This 2.7-tonne, zero-tailswing example from the stylish Eurocomach range features a striking black livery. It initially caused a few concerns among clients with regard to its visibility within a stand of trees. Hence the hastily-added red and yellow stickers, and in due course Dan planned a full chevron wrap across its back end.

The mini is powered by an ultra-low emissions three-cylinder Kubota engine rated at 24.7hp (18.2 kW), a modern powerpack used by a number of compact equipment manufacturers. It drives a unique load sensing hydraulic system, which combined with a flow sharing distributor, allows for multiple movements to be carried out at the same time. Maximum reach at ground level with the long dipper arm is 4720mm, while a slew speed of 10 rpm certainly gave the impression of a lively piece of kit, as Dan demonstrated to full effect. He said, “So far it has proved to be superb, a lot better than I was expecting. The Bobcat was ace and I would happily have another one, but the new Eurocomach is a bit better in all areas. For starters, it’s a bit heavier, so it provides a more stable platform for shearing and timber handling, which enables us to run a slightly bigger

DAN HURLE BACKGROUND Dan said, “My dad has been involved in forestry contracting since the 1960s. He was one of the first in his cutting gang to start using chainsaws. In those days it was an early Husqvarna model, which he paid for on a weekly basis. “From an early age, especially during school holidays, my brother and I used to go to work with him and ride in the machines. I can vividly remember being driven up Dartmoor to a place called Dendles Wood in a Mini-Brunnet 678 forwarder. It was one of the first purpose-built machines in the area and I was amazed by where it would go. “It was this exposure that led to my keen interest and love of the great outdoors, and the catalyst for me following the ‘old man’ into the woods. When I was old enough, I used to go hand weeding young trees during the summer holidays. Eventually I gained my chainsaw and climbing tickets and worked on a firm called Fountains for a few years, alongside my brother and father. “In 2000 dad took the plunge and set up on his own. I was attending Sparsholt College in Winchester, where I did an HND in forestry management, while still helping dad out during weekends and holidays. In 2004 we set up John Hurle and Sons and went on from there.”

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SITE VISIT // EUROCOMACH 28ZT Below: This 2.7-tonne mini is punching well above its weight, including handling a decent-sized hydraulic attachments at reach.

grab with ease. I’ve also been impressed at the rear. The design of the Eurocomach by its ability to run the flail and track at the 28ZT uses this space for a 46-litre fuel tank, same time, which is thanks to the additional a 30-litre hydraulic oil tank, together with pump that is fitted on these machines. the cooling pack located on the offside This has led to a lot of additional work corner. on the new St Austell link road project. The upside of this layout is that the “The hydraulics are really smooth and compact Kubota engine and main hydraulic powerful for the size of the machine and the pump are side-mounted on the offside of reach is incredible. The cab is very quiet and the mini, concealed by a large gullwing well insulated, and with the side-mounted door. It opens to reveal absolutely fantastic engine there does access to the engine and seem to be a lot its service points, far “WITH PLENTY OF LEGROOM, all more room in the superior to the norm on cab area. With such I FIND IT EASY TO TRACK plenty of legroom, a mini-excavator. Access WITH THE PEDALS, I find it really easy to the slew motor and to track with the other major hydraulic SOMETHING I REALLY pedals, which components is gained STRUGGLED WITH IN is something I have by tilting the cab. really struggled The cab is typically OTHER SMALL MACHINES” with in other Italian in design: well smaller machines. laid out and stylish. My only real dislikes are that I find door is a I found the seat especially comfortable. The bit narrow for entry and exit, and it is a bit only downside for me was that there was no of a step up, but that’s more about me being air-conditioning, which is an optional extra. overweight and having dodgy knees. This does not detract from a 2.7-tonne Overall, I have to say it’s proving to be a mini that clearly punches well above its fantastic piece of kit.” weight. Not just in terms of handling decent-sized hydraulic attachments at reach, but its ability to simultaneously flail and WALK-ROUND track, which has already won its new owner On such a zero-tailswing mini-excavator it additional business. would be expected to find the engine bay 36

VERMEER DRUM CHIPPER On the day of our visit Dan was also busy feeding his classic Vermeer BC1000XL drum chipper. He describes this machine as a bit of a beast, which features a 14 x 17in feed opening and is powered by a pre-emissions Cummins 3.3 litre engine producing a healthy 90hp. Dan said, “We like it because it’s very easy to set up and maintain. With only four bolts on each blade and no depth gauges to adjust, it’s simply just a great machine. We bought it because we needed a bigger chipper to go with the digger, which was mobile and easy to get from site to site. In the past, when we were railway contracting, we had smaller tracked chippers and worked with larger PTO-driven units. As we began using diggers more, we were finding a need for a larger capacity chipper. “The Vermeer has worked brilliantly; when funds allow we will upgrade, but I’m not sure what to go for. Emissions-strangled engines really aren’t that great in this application and the bigger machines are good but too heavy to move around. Ultimately, I would like a Schliesing 550zx mobile unit on a turntable, as they just scrape in under 3.5 tonnes and with the turntable would be better for highway works.”

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SHOW PREVIEW // BAUMA 2022 Graham Black previews some of the likely trends at the forthcoming giant Bauma machinery show in Germany

ALL EYES ON

auma, the Earth’s leading trade show for mining and construction machinery, takes place at the massive showground at Munich, Germany, from 24 to 30 October. The event was last held in 2019, when around 3600 exhibitors attracted almost 630,000 visitors from over 200 countries. A lot has happened since those carefree days, including the pandemic followed by the current energy crisis. Following the global climate conference in Glasgow last year, there has also been a significant shift in attitudes towards environmental issues. Within the machinery industry, this has had a dramatic impact on the world’s largest surface mining companies, who have demanded that manufacturers

MUNICH

accelerate the development of zeroemissions, ultra-class mining kit. At the other end of the scale, manufacturers of compact equipment are offering a rapidly increasing range of battery-powered machines, with an enthusiasm for the technology that is not yet matched by the majority of their customer base. The Bauma 2022 show takes place over 410,000sq.m of outdoor space and within 200,000sq.m of exhibition halls, but with fewer exhibitors than 2019, including a few of the big boys. As the global supply chain has not yet fully recovered from the impact of the pandemic, never mind the multitude of other issues caused by the war in Ukraine, this is an understandable decision. Particularly, as many machinery and

component manufacturers have full order books, there is a reluctance to spend money on a grand presence at Bauma, when the cash will be better invested in recruiting and training more staff. A few noticeable absences from the exhibitors list will not deter general visitors to the show, which will still be the world’s largest assembly of construction and mining machinery. And, let’s face it, there is a lot of enthusiasm for the opportunity once again to attend a major industry gathering. Suppliers of Bavarian beer and suspicious-looking sausages are poised to conduct a huge logistics exercise. As usual with such a major exhibition, manufacturers have issued teasers of a few new machines that will be launched at the show, but inevitably the really big news NOVEMBER 2022

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DOOSAN 4X4 ADT The new Doosan 40-tonne class, two-axle DA45-7 articulated dump truck has been developed at their factory at Elnesvågen, near Molde in Norway, the former Moxy facility. The front of the machine is the same as Doosan’s conventional 6x6 ADT models, and the rear section features a twin-wheel axle and a dump body, reminiscent of a rigid-chassis mining hauler. Indeed, the DA45-7 has been developed to offer an alternative to a small rigid dump truck, which is able to tackle slightly worse ground conditions, but being less than 4m wide and with articulating steering, is far more manoeuvrable. Doosan says that with its shorter turning radius and the design of the skip, this is suited to carrying flat and heavy rocks, provide particular advantages in the mining and tunnelling industries in southern Africa, the UK and Australia.

will be held back until the start of the event. This preview includes some of the pre-show product announcements, but focuses on the trends within the industry, so that new product reveals made during the show can be put into context.

DRIVELINE DEVELOPMENTS The headline news items concerning zero-emissions mini-excavators and massive mining monsters will have little relevance to the majority in the construction industry, those working with excavators, articulated dump trucks (ADT), dozers and wheel loaders. Part of the reason for this is that there is not yet a clear pathway as to how such machines will be powered in the future. It is unlikely that battery-electric systems developed for compact-equipment can 40

be up-scaled in a practical package, and hydrogen fuel cell-powered ultra-class mining machines are still in the development stage. In any case, there is still plenty of life left in the current designs, which will be with us for at least the next couple of generations. These are now powered by ultra-low emissions Stage 5 engines that, coupled with developments in drivelines and control systems, are incredibly fuel efficient. However, with the possible exception of tracked excavators, there is plenty of scope to further develop construction machinery drivelines. There are two game-changing driveline technologies that are currently available: Caterpillar’s diesel-electric D6XE dozer and, as championed by Liebherr, continuously variable transmissions (CVT) in wheel loaders. Both have proved to be

more fuel-efficient and more productive than their conventional counterparts. Expect more manufacturers to go down these routes, particularly with CVT boxes. Such driveline developments are not limited to components, as some manufacturers are taking a fresh look at the whole question of chassis configurations. For example, Bauma 2022 will see the launch of Doosan’s 40-tonne class 4x4 articulated dump truck (see panel).

FUELS OF THE FUTURE The internal combustion engine is by no means dead: diesel versions will be with us for many decades, but increasingly fuelled by modern diesel substitute fuels, such as hydro-treated vegetable oil (HVO). There is also scope to run fairly conventional engines on a variety of common gases,

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SHOW PREVIEW // BAUMA 2022

BATTERY COMPACTS Battery-powered compact equipment has been available for some time. Wacker Neuson’s WL20e compact wheel loader has been in series production since 2015. The third-generation model will be introduced at Bauma, powered by a choice of lithium-ion battery packs to provide customers with a range of running and charging times to suit the application. Expect to see a flurry of battery-powered mini-excavators being introduced at the show, as the full-line manufacturers rush to catch up with the compact equipment specialists. One manufacturer that has made great strides over a relatively short time is Hitachi, which is introducing the 5.3-tonne battery-powered X55U-6EB short-swing mini at the show.

LIEBHERR HYDROGEN which may well appeal to machinery users in niche sectors of the market, but is unlikely to gain traction in the mass market. What is increasingly looking promising is internal combustion engines fuelled by hydrogen gas, which produce zero harmful emissions. Looking outside the industry, the concept of hydrogen-fuelled internal combustion engines has recently been bolstered by Toyota, the world’s largest car maker, which recently showcased its new GR Yaris model. Using hydrogen in what is a familiarlooking engine has massive practical advantages for the construction industry. One of them is that they are no more complex to maintain than an LPG-powered road vehicle. The practicality of such a powerpack is dependant on ramping up the manufacture and distribution of green

hydrogen, which is produced in an environmentally-friendly way. The big news is that Bauma 2022 will host the world premiere of the Liebherr R9H2, a 50t tracked excavator that is powered by an in-house hydrogen combustion engine (see panel). This is a major milestone for the industry, indicating that production versions of such machines may be only a few years away. One result of the massive amount of R&D currently being undertaken by manufacturers of large mining machinery will be the widespread use of hydrogen fuel cells. These are fuelled by hydrogen gas and, through a chemical reaction with oxygen, produce electricity. Again, this technology is not that far away, as Hyundai will preview a hydrogen fuel cell-powered wheeled excavator during the show.

The French-built 50t class Liebherr R9H2 crawler excavator is powered by a hydrogen combustion engine, an H966 powerpack from Liebherr’s Bulle factory in Switzerland. This prototype will be used as a test bed for Liebherr’s first generation of hydrogenpowered engines, which are based on an intake manifold injection technology, also known as PFI. Work is also underway to develop a direct injection cylinder head, which would enable a higher power density than the established intake manifold injection design. Based on the current generation of conventional Liebherr excavators, the R9H2 offers the same overall performance, but with zero harmful emissions. Henrik Weitze, project manager at Liebherr France, stated, “The tests carried out in Colmar were extremely convincing. This technology promises many advantages for us in the future, especially in the most challenging applications.”

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FLEET FOCUS // H&C PLANT HIRE

BACKHOES ON THE ROAD

H&C Plant Hire has taken delivery of 20 new JCB 3CX Pro backhoe loaders, the majority of which are already committed to long-term clients.

Paul Argent reports on a new fleet of high-spec backhoe loaders available for hire across the UK

hree years ago we reported on the latest investment made by Lee Barlow and his team at H&C Plant Hire in a fleet of JCB 3CX Sitemaster backhoe loaders. Once common on UK sites, backhoe loaders offer the highest levels of versatility: as wheeled machines they are ideal for working on paved surfaces and travelling to and from site under their own power. As the latest generation of backhoes offer much better roading performance, coupled with the machine’s inherent versatility, there are early signs that backhoe loaders may be coming back into fashion. We recently met Lee at the firm’s yard at Levenshulme in Greater Manchester, where they had just taken delivery of 20 examples of the latest 3CX Pro models. Supplied by local dealer Gunn, it represents a significant order from a UK customer. H&C Plant Hire has expanded from its base in the north west to become a specialist national hirer of JCB 3CX backhoe loaders, under the banner SiteMASTERS Nationwide Hire, as Lee explained, “We are hoping to help generate interest in this one machine/Swiss army knife product. Having 20 new machines allows us the opportunity to offer both short- and long-term flexible hire nationwide.

“DESPITE THE PANDEMIC, MOST OF OUR MACHINES HAVE REMAINED OUT ON HIRE THROUGHOUT THEIR STINT ON THE FLEET” NOVEMBER 2022

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Left, right and below: A hydraulic quick-hitch on the backhoe allows rapid change of attachments to remove the failed surface and kerbs, then grading the sub-base.

job a day, just from the quicker on-road times.” A trio of the new 3CX Pro models have been specified with servo controls, which bring a host of operator assistance features, including auto SPECIFICATION PAYS In addition to this long-term work with local 2WD, auto seat select, auto stabilisers and auto authorities, H&C also has several backhoes available for spot hire and contract work, as level. Lee added, “We took the three servo models as a trial; Lee continued: “We have a varied customer they are performing just as we base across the UK, from large civils to expected, and excavator operators like the waste companies and smaller developers. change. The remainder of the machines We also have a lot of repeat work to come with traditional sticks, but are able to undertake test holes on development sites, for which we have taken our latest machines switch from JCB’s X pattern controls to ISO at the flick of a switch.” with the 50kph transmissions.” JCB’s CommandPlus cab has been The 3CX Pro versions come with an updated, including a revised layout for ultra-low emissions 81kW JCB engine many of the controls, which feature a new coupled to their new EcoRoad auto-shift 7in display. In addition transmission. Lee has the usual machine chosen to configure “WE WORKED OUT THAT to status and audio/ these all-wheel drive THE ECOROAD phone controls, it even machines with larger plays how-to videos, front tyres than the SPECIFICATION WILL handy for those norm, to further SAVE US TIME AND FUEL without much time in improve their roading cab of a modern abilities, at the expense MOVING BETWEEN JOBS” the backhoe loader. of a slightly wider The Pro spec also turning circle. includes air conditioning as standard, He said, “We looked at all the something the previous models didn’t transmission options and worked out that have, as Lee said, “Many of the operators the EcoRoad specification will save us time will have every window open during the and fuel moving between jobs. Our clients hot weather. But dust ingress or working will see these savings, especially as many of them return the machines to their allocated in foul smelling environments call for something a little more than that. depots at night. It will also be a benefit for The operators all have the premium us when we undertake trial hole works. We air-suspended and heated seat too.” estimate that we could undertake an extra “We try and keep the fleet fresh, operating a three-year replacement programme. Despite the pandemic, most of our machines have remained out on hire throughout their stint on the fleet. There can’t be many companies out there that can say this. “We are in the lucky position that we supply both backhoe loaders and other smaller bits of kit to many of the local authorities around the north west, which means we have a regular hire for the majority of the backhoe loader fleet.”

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FLEET FOCUS // H&C PLANT HIRE

The three Servo models also feature a quick coupler on the front loader, allowing for a quick swap from a standard 4-in-1 attachment to a side-tipping bucket. All models feature a hydraulic-powered sliding kingpost at the rear, while the backhoe is equipped with additional pipework for hammers and compactors, together with a hydraulic quick coupler.

SITE VISIT We called in to see two of the new machines working on similar contracts for Stockport Council, in the hands of two extremely experienced operators. Working under the direction of the council’s street works teams, the ongoing project is to upgrade

kerbing and pavements along many miles of crowded residential streets. The working method is to advance along a road by dealing with a 20m to 30m stretch at a time. The 3CX is first used to lift either the failed pavement, before removing the kerbs. These arisings are loaded into an adjacent tipper truck, after which the sub-base is graded back. The stretch is then re-kerbed before a base layer of tarmac is laid. Once the road is ready, a surfacing gang puts down the finishing layer. The investment in 20 new high-spec backhoe loaders shows optimism in the current marketplace. Lee says that the majority of the fleet is already committed

to long-term contracts; those that are used as spot-hire machines are being booked out well in advance. He concluded by saying, “We could have easily taken the lower cost specification machines, but we felt that the higher spec not only helps our operators out, but also increases the resale value when we come to trade them in. We are also very pleased with our push towards the nationwide supply as siteMASTERS, as a good number of the new machines are being taken on long-term contracts by some high-profile clients.” Below left, centre and below: The front wheels of the new fleet are equipped with larger than standard tyres and a 4-in-1 front bucket; servo-equipped models also get a front hydraulic quick-hitch.

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RUNNING REPORT // CAT D11T

ULTRA-CLASS DOZING David Wylie visits Stokey Plant’s 115-tonne Cat D11T dozer at work on their longterm contract at Croxden Quarry

hropshire-based Stokey Plant was founded in 1967 by Leonard Stokes and featured a fleet of large Cat dozers such as D9G and D10Ns. Today, Stokey has a wide range of plant available for long- or short-term hire and has been involved in many of the UK’s major bulk earthmoving projects. They have included road construction and quarrying/mining applications across Britain. Their best-known contract over recent decades started in 2001: the provision of an ultra-class dozer and operator to Tarmac’s Croxden Quarry near Stoke-on-Trent. To service this high production role, in what can be extremely tough conditions, Stokey bought the first 100-tonne class Cat D11R dozer in the UK. A running report of this impressive machine featured in an early issue of Earthmovers.

BACKGROUND The principal task for this dozer is to rip the well-cemented sandstone conglomerate rock found on site, then form stockpiles

“INVESTING AROUND £1.5 MILLION IN ADOZER IS A BIG DECISION FOR A FAMILY FIRM TO MAKE”

Above and inset: The 115-tonne dozer is configured with an over-sized ripper and a 27.2cu.m capacity semi-U blade, together with Stokey’s own design of own ripper shank protective shroud.

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successfully run a number of their smaller of the material. This is then pushed dozers. However, at the end of the day both towards a receiving hopper, which feeds Stokey and, perhaps more importantly, a conveyor belt taking it to the aggregate their client, felt more production plant. comfortable with Having undergone three major overhauls “THE CAB IS WARM, QUIET another big Cat. The performance, running during its 17-year AND COMFORTABLE, ONE costs and dealer back-up working life at by Finning for Croxden, the Cat OF MY FAVOURITE PARTS provided the D11R were wellD11R clocked up IS THE HEATED SEAT FOR proven. In such a over 28,000 hours, heavy-duty application it and a replacement THE COLD WINTER is sometimes necessary machine was ordered MORNINGS” to replace ripper tips for delivery in 2018. half a dozen times Sarah Jones took during a single shift. over the role as MD of Stokey Plant from A flagship Cat D11T dozer was duly her late father in 2007. The management ordered from Finning, complete with a team did consider the alternative to a Cat 27.2cu.m semi-U blade and an over-sized D11, a Komatsu D475A, and indeed they 48

ripper. In theory, the new 115-tonne D11T could extract up to a million tonnes of material a year from this site. With production rates currently between 600,000 and 650,000 tonnes, this application is well within the ultra-dozer’s capabilities. Sarah said, “Investing around £1.5m in a dozer is a big decision for a family firm to make, but in consultation with our longstanding customer, we feel we made the right decision. The D11T is a more productive and fuel-efficient machine than our old D11R, which provided outstanding service.” A critical part of the equation is dozer operator Pete Boustouller, who spent a decade in the previous D11R. Sarah explained that Pete has extensive knowledge of the quarry’s geology and uses the dozer in

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RUNNING REPORT // CAT D11T

Left, above, above right and right: Extremely experienced dozer operator Pete Boustouller praises the D11T’s productivity, reliability, cab comfort and visibility, together with the ease and safety of the fold-down access steps.

the most productive manner possible to deal with the varying hardness of rock layers encountered. As was apparent during my visit, they range from a sand and gravel deposit on the higher benches to extremely challenging material on the deeper layers, all of which are highly abrasive. Sarah provided an interesting comparison of the D11T’s productivity on this site. When it is due for a 500-hour service, Pete will spend most of his time ripping a large area of the quarry. During its couple of days in the workshop, a D9T dozer is deployed just to push the ripped material to the stockpile. Adding a D10 to the equation, even with both large dozers working together, they cannot match the ripping and pushing performance of the mighty D11T.

SITE VISIT With 5500 hours on its clock over the past four years, the big D11T has settled well into the role. At the time of our visit Pete was working one of the upper areas of the quarry in a layer of sand and gravel, which the 115-tonne dozer was dealing with like a hot knife through butter. Once ripped, the huge 27.2cu.m semi-universal blade is used to push the material towards the stockpiling area. On this bench, the client’s wheel loaders then either load the material into their Cat 730 articulated dump trucks, or perform a load and carry operation to the nearest conveyor hopper. The D11T was specified with an over-sized 12-tonne ripper, usually found on carry dozer configurations, which adds an extra four tonnes over the standard ripper to the

back of the machine and helps to provide extra traction. Stokey has designed its own ripper shank protective shroud, which is much longer than the standard Cat item, in order to protect the integrity of the singleshank ripper’s face. The blade’s draft arms have also been up-armoured with strips of Hardox steel, and Cat’s ‘chocolate bar’ wear protection parts are fitted to the dozer blade’s side shrouds. Pete reports that this wear package is working very well indeed. As for the ripper tips, they can last for nearly two days in the softer layers of material, but on the lower, harder material, the D11T has got through seven of these penetration wear parts in a single shift. However, swapping the ripper tip takes less than five minutes, thanks to its simple pin retainer design. The D11T is on its second set of replacement NOVEMBER 2022

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track chains, and the opportunity has also been taken to change track pads as required. Its sprockets, idlers and bottom rollers were changed at 4000 hours. Undercarriage parts and the labour to fit them is one of the most expensive elements when running any dozer, let alone one weighing 115 tonnes working in such an abrasive material, as Sarah explained, “We enjoy longstanding business relationships with many of our customers; in the quarrying sector we are always striving to help our customers produce the lowest cost per tonne. With that in mind, we are in regular discussions with Finning and Caterpillar to maximise the life of the undercarriage parts, and we are working in collaboration to improve this area going forward.” The Cat D11T has been supplied by Finning with a five-year/8000-hour warranty package and a service contract. Sarah explained that it is very much a collaborative approach between Stokey’s in-house resources and Finning’s mechanics to carryout regular 500-hour services,

undercarriage overhauls and any running repairs. Despite the D11T being a more complex machine than the old D11R, it has proved exceptionally reliable, and Stokey’s mechanics report that the big dozer is easy to maintain thanks to great service access. It has a diesel fast-fill coupling point located at ground level on the ripper linkage cylinder for fast, safe and spill-free refuelling. It also has an auto-lube system, and daily checks of fluid levels are undertaken from the cab through the control monitor. The D11T was brought up to the latest UK quarry spec when Finning fitted a Spillard 360-degree camera system, rear hi-vis chevron markers and blue flashing strobe light and alarm to automatically indicate that reverse

Left and below: The over-sized ripper provides a working depth of just over 1.6m; in this extremely abrasive material the tips have to be changed a few times during a shift.

CAT D11T BRIEF SPEC

Undercarriage maintenance is a huge cost factor in running a 100-tonne class ultra-dozer; this example is fitted with Cat’s extreme service set-up and 710mmwide track pads.

“HAVING TRIED A VARIETY OF MACHINES OVER THE YEARS TO EXTRACT THIS HARD MATERIAL, A CAT D11 HAS PROVED TO BE THE BEST MACHINE FOR THIS JOB” 50

Operating weight

115 tonnes (104t in standard trim)

Engine

Cat C32, US Tier 4 Final emissions

Power

913hp gross/850hp net

Transmission

Planetary Powershift

Speeds

3F 2.4-7.3mph/3R 2.9-8.7mph

Torque converter

75% single-stage/25% direct drive

Blade

Semi-universal 27.2cu.m capacity

Ripper

12,461kg carry dozer version

Ripper depth

1612mm max with 4 positions

Tracks

Extreme service, 710mm-wide pads

Fuel tank

1609 litres

gear has been selected. Despite the significant cost, Sarah is pleased with the performance and reliability of the optional set of Cat fold-down steps. They have tried similar components on other machines, from third-party manufacturers, that proved to be problematic. She also appreciates the D11T’s standard catwalk, which wraps round the side and rear of the cab, so much so that Finning was asked to retro fit this design to a recently rebuilt Cat D9T.

EARTHMOVERS NOVEMBER 2022

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RUNNING REPORT // CAT D11T

OPERATOR FEEDBACK Pete Boustouller’s first dozer was a little Track Marshall, pulling a sheepsfoot compaction roller on motorway projects. He then progressed to a Cat D8, then a Cat D9G before the D11s, and has been working for Stokey Plant for 28 years. He said, “The D11T is a highly effective ripper and productive dozer in this arduous sand and gravel hard rock quarry application. The machine hasn’t really missed a beat since it was commissioned four years ago, since when the service, undercarriage overhauls and any repairs are carried out by Finning UK or our own team of skilled plant mechanics. “From an operator’s point of view, the fold-down access steps make climbing on and off the machine so much easier and safer and have proved to be very reliable, as it’s a Cat factory-fitted part The forward and rear view from the cab is also good and the additional 360-degree camera system works well. The cab is warm, quiet and comfortable, one of my favourite parts is the heated seat for the cold winter mornings at the start of shift at 6am.”

Pete also feels that Caterpillar’s elevated sprocket design makes for a more comfortable ride, as the final drive is not in contact with the ground. This also allows for a floating rear idler to oscillate with the contours of the ground and to track effortlessly over exposed large pieces of rock. One of Pete’s simple but effective little modifications is a rag tied on to the front camera mounting. The output from the radiator fan constantly blows this rag, keeping the camera lens clean, The draft arms have in what is a hard-to-reach area of been up-armoured with strips of Hardox the machine. steel, and Cat’s The client reports that they are ‘chocolate bar’ wear protection parts are happy with the performance of the fitted to the blade’s D11T and its highly experienced side shrouds. operator. Having tried a variety of machines over the years to extract this hard material, despite the costly ground engaging parts, a Cat D11 has proved to be the best machine for this job. As the fuel consumption of this D11T is between 700 and 800 litres over a 10-hour shift, they are pleased with the lower fuel burn and emissions compared to the previous D11R model. NOVEMBER 2022

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EARTHMOVERS

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SITE VISIT // EDINBURGH TRAMS Paul Argent reviews a pair of Liebherr A910 Compact wheeled excavators at work in the heart of Edinburgh

A DUO OF DUCKS est Lothian-based McMillan Plant runs a large and varied fleet of equipment. The core of its business has been general hire, alongside a specialist fleet of railspecific plant. Recent years have seen the family business also offering a full package of contracting services. Last year they decided to invest in a pair of compact wheeled excavators to target work on the extension of the Edinburgh tram network. This is one of the largest publicly-funded projects currently underway in Scotland. The project involves installing 4.7km of new track, from St Andrew Square on the east of the city centre to Newhaven on the North Sea coast, through the existing street layout of Edinburgh suburbs. The larger package of works includes improving the layout of local roads and junctions along the route, together with upgrading services and traffic signals.

Shaun, son of company founder Scott McMillan, said, “We wanted a machine that would be small enough to work in some of the tighter spots on the site, but also to give us the flexibility and productivity that a machine with a larger footprint. The A910 Compact fitted the bill for us and dealing with the team at Liebherr Bathgate was a very smooth and painless process.” Since being delivered last year, both machines have worked constantly on the tram project, undertaking a variety of works for the main contractor, with subcontractors or as part of

“WE HAVE BEEN VERY PLEASED WITH THE MACHINES SO FAR. THEY ARE WELL BUILT AND HAVE BEEN VERY RELIABLE” Above and below: For the past year a pair of Liebherr A910 Compact ducks have been at work on the Edinburgh tram extension project.

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“A MACHINE SMALL ENOUGH TO WORK IN TIGHT SPOTS, BUT ALSO TO GIVE THE PRODUCTIVITY OF A MACHINE WITH A LARGER FOOTPRINT”

Above, far right and below: A standard A910 Compact provides a maximum dig depth of 4m and a ground level reach of 8m. Its slewing boom allows a parallel dig within the width of the chassis.

EARTHMOVERS NOVEMBER 2022

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SITE VISIT // EDINBURGH TRAMS LIEBHERR A910 COMPACT

McMillan’s own groundworks teams. Their ability to relocate quickly to any part of the site has strengthened the demand for these versatile 12-tonne rubber ducks across the project. The modern Deutz engine is very quiet, even when working hard, but what has also impressed Shaun is its ability to stay away from diesel bowsers.

GPS & TILT-ROTATOR Liebherr package the A910 Compact model, the baby in its wheeled excavator range, to an extremely high specification as standard, including a TAB. McMillan’s operator of the second Liebherr, Matthew Hamilton, seems well pleased with the comfort and well laid-out workspace within the cab. Shaun has taken his machine a little further. It includes additional warning beacons, enhanced reflective livery and concealed strip lighting under the removable rear panel on the counterweight. The inside of the cab has been pimped with an upgraded sound system, carpeting and the seat recovered in McMillan tartan.

Shaun’s machine also features a Steelwrist X12 tilt-rotator, complete with integrated gripper, of which he said, “We run several tilt-rotators on the rail machines. And while they are an expensive addition to any machine, once you have used them, you don’t want a machine without one. You become so much more versatile and capable with one, especially with the gripper unit attached.” With an eye to the future, this wheeled excavator has also been fitted with a Moba GPS machine guidance system. It was not being used on the current project, but Shaun has used it on weekend work to great effect, saying, “It’s a great system, easy to use and makes undertaking jobs singlehandedly, a lot easier.”

The A910 Compact wheeled excavator has an operating weight from 12.1 to 13.1 tonnes, depending on specification. Unusually for Liebherr, the options list for its baby duck is not long. A single working equipment configuration is available, a TAB set-up, consisting of a 4m two-piece boom and 1.85m dipper stick. This provides the excavator with a maximum dig depth of 4m and a maximum ground level reach of an impressive 8m. The slewing kingpostmounted boom allows the operator to parallel dig within the width of the chassis. The only real difference between A910 models leaving the factory is their undercarriage configuration. This can be specified with a rear blade, front and rear blades or with a front blade and rear independent stabilisers. Shaun has opted for the single dozer blade option on both machines, as he says they are a very wellbalanced excavator. A 3.6 litre, four-cylinder Deutz engine rated at 116hp is mounted down the offside of the excavator, along with the machine’s cooling pack. The hydraulic compartment is located on the nearside of the upper-structure.

The tram project is due for completion in spring 2023, and McMillan may put one or both machines in their hire fleet, as there seems to be plenty of demand for them, as Shaun concluded, “We have a lot of work lined up. I just need to make sure that I stay with my A910 as long as I can!” Below: Shaun McMillan is pleased with the two Liebherrs, in particular their low fuel consumption and reliability.

SITE VISIT We came across both machines working together to finish and tidy up an area round a section of the newly-constructed tramway, to enable surfacing works to start. Equipped with a set of pallet forks on the quick-hitch, Matthew’s machine was located on one side of the tracks, moving bundles of ducting and pallets of fittings out of the way. The nimble little TAB-boomed Liebherr duck was quickly clearing the area, demonstrating the versatility of such an excavator. Meanwhile, on the other side of the track, Shaun was using the tilt-rotator to full effect to grade stone to the desired level, which would be compacted before the surfacing team arrived on site. Shaun said, “We have been very pleased with the machines so far. They are well built and have been very reliable. When we have needed anything from Liebherr they have been very responsive.” NOVEMBER 2022

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EARTHMOVERS

21/09/2022 09:39

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MARKET REVIEW // SCRAPERS Left and below: Scrapers, either motorised or towed, are considered to be the most cost-effective way to lift, haul and spread large volumes of soil.

ECONOMIC MUCK-SHIFTING

Peter Anderson looks at the mainstream towed and motor scrapers available in the UK, together with a review of prominent UK fleets otorised and towed scrapers are considered to be the most cost-effective way to move and place material, requiring fewer machines, and therefore operators, on site. They also consume less fuel per cubic metre shifted than excavators and articulated dump trucks (ADTs). The origins of the scraper date back to the early 1800s when a horse was used to haul an agricultural implement resembling a large shovel. By the 1930s and 1940s earthmoving had become increasingly mechanised,

as tracked tractors and pull scrapers became a common and effective way of excavating and transporting large amounts of earth. Towed scrapers were superseded by motorised self-propelled scrapers, which were used in large numbers to construct the UK motorway network in the 60s and 70s. As large-scale muck-shifts became fewer over the next few decades, their use in the UK shrank dramatically. However, since the turn of the century, some earthmoving contractors have returned to towed scrapers. Using an agricultural tractor

as the prime mover, the combination is less costly than buying motor scrapers. Single-engine motor scrapers and towed scrapers usually require the services of a dozer to help push them through the ground being removed. The common alternative is to temporarily link two twin-engine motor scrapers, each assisting the other in the loading part of the cycle. With high global fuel costs and a continuing shortage of staff, we expect more contractors to take a fresh look at the many advantages of using scrapers in bulk muck-shifting work. NOVEMBER 2022

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COLLINS EARTHWORKS To undertake the bulk muck-shifting phase of the ongoing Northampton Gateway project, Collins Earthworks invested in a raft of additional Cat machines, including four 637K push-pull motor scrapers. They have 38cu.m bowls and are powered by a 425kW engine for the tractor and 216kW for the scraper, providing a top speed of 55.8kph. In operation, the push-pull system combines the power of the four engines in a pair of scrapers on to one cutting edge to provide quick self-loading. Enabling works on the Northampton Gateway project began in October 2020. To date Collins has moved around 3.5 million cubic metres of muck, all of which has been remediated and used elsewhere on site. The bulk muck-shifting phase of the project is due to be completed around the end of 2023. The push-pull scrapers have proved to be a more cost-effective working method than excavators and ADTs.

Controlled from the cab, Collins’ Cat 637Ks can be temporarily linked together in the cut, but can also be used individually on this site with the help of a push dozer.

MOTOR SCRAPERS The latest models in Caterpillar’s range of motor scrapers are the new single-engine 651 and the flagship twin-engine 657. The new 651 re-enters the market with an upgraded powertrain, controls, hydraulics and structures. It is powered by a Stage 5 Cat C18 engine rated at 469kW, linked to Left: For those wanting the highest production rates with the lowest operating costs, the solution is a pair of twin-engine scrapers, which assist each other during loading.

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MARKET REVIEW // SCRAPERS

WILLIAMS PLANT HIRE

Top and above: Ashland produces a wide range of towed scrapers aimed at less intensive work with relatively modest prime movers. They are a staple in the scraper fleet of Ruthin-based Williams Plant Hire.

an eight-speed transmission, allowing a top speed of 56kph. Offering a heaped capacity of 33.6cu.m and a rated payload of 46.4 tonnes, the new model shares the same bowl design and many other components with the 657 model, including the same large and modern cab. The 651’s new high-pressure steering system is said to require significantly less effort. Other improvements include electro-hydraulic management of the bowl, controlled by a short-throw T handle. The Stage 5 emissions-compliant 657 model replaces the 657G, Cat claiming a 7% improvement in fuel efficiency. The tractor unit is powered by a 435kW Cat C18 engine, with a 333kW Cat C15 on the scraper. The rated payload is the same 46.4 tonnes as the 651, however, with two engines it is less reliant on a push dozer. The usual working method is to operate with a pair of 657 models in a push-pull arrangement in the cut. The 657 features an advanced electronic control system that allows the machine to better use engine power and torque. The transmission has an electronic clutch pressure control, designed to improve shift quality and fuel efficiency. A 21% larger cab interior than its predecessor provides good visibility to the bail, cutting edge and the bowl. The air suspension seat rotates 30 degrees, while the new advanced ride management system

adjusts damping to match ground conditions, all resulting in improved operator comfort. There is an integrated payload weighing system, and Cat’s telematics system provides real-time payload, machine location, fuel usage and idle time information, in addition to any diagnostic fault codes.

A variety of Ashland towed scrapers are run by Ruthin-based Williams Plant Hire, as MD David Williams explained, “Towed scrapers were widely used in the 60s, 70s and 80s for earthwork jobs, but with the fall in earthmoving demand their use diminished. The situation has changed in recent years as towed scrapers are making a comeback. I started using Ashland direct-mount scrapers a few years ago. We are now working with them behind our Komatsu D65PX dozers on short hauls and our Challengers and Valtra tractors as prime movers on long hauls. “Ashland scrapers are the most efficient earthmoving machines and the most fuel efficient. One tractor and scraper will move more earth than an articulated hauler or dozer, with fewer machines, fewer operators and using less fuel per cubic metre moved. As an example, one Challenger tractor towing a 21cu.m capacity scraper will move on average 1000 cubes in an eleven-hour day and only consume 450 litres of fuel, which equates to 81p per cubic metre.”

There is also the option of an integrated GPS machine guidance system.

ASHLAND TOWED SCRAPERS Sold and supported in the UK by Devonbased Red Bull Equipment, towed ejector and dump scrapers are produced by Canadianbased Ashland Industries. Ashland merged

Caterpillar’s latest motor scrapers are the single-engine 651 and the twin-engine 657 models, both with a rated capacity of 46.4 tonnes.

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MARKET REVIEW // SCRAPERS

VAS EARTHMOVING Based at Ickburgh in Norfolk, VAS Earthmoving has operated a fleet of Cat Challenger tractors and scraper boxes probably longer than any other firm in the UK. Company founder Les Garner, a no-nonsense muck shifter with an eye for innovation, acquired his first pair of Challengers to provide a faster and cheaper alternative to using a Cat D8 dozer as a prime mover for short-haul work. Long-term advocates of Cat machines, VAS has since increased its Challenger fleet to five units, paired up with K-Tec 1228 scraper boxes. For longer hauls and bulk cut ‘n’ fill jobs, VAS operates a fleet of four GPS-equipped Cat 631 motor scrapers, together with a D9 push dozer. Its most recent investment in this part of the fleet is a pair of 627 twin-engine push-pull motor scrapers, to undertake intermediate hauls and self-loading work.

with K-Tec in 2020 (see below), and the combined product offering of the two companies now covers towed scrapers with capacities from 16 to 48 cubic metres. Ashland offers six ejector models from the 16.4cu.m capacity 215TS2 up to the 3413E at 26.1cu.m. Both dump scrapers – 2012CS and 2014CS – have a 15.3cu.m capacity, and cutting widths of 4.2m and 4.8m respectively. The dump scrapers are intended for use in loose, sandy soil or for land levelling, while the ejector models are designed for highproduction muck-shifting work.

K-TEC TOWED SCRAPERS Volvo distributor SMT sells and supports the K-Tec range of towed ejector scrapers in the UK and Ireland. With over two decades of experience, Canadian-based K-Tec manufactures a wide range of scrapers with heaped capacities from 21.4 to 48.1cu.m. They include conventional direct-mount 60

K-Tec offers pull scrapers specifically designed for use with a 6x6 ADT chassis/ cab as prime mover, as operated by contractor Sirius in the UK.

models, those intended for use in tandem pairs with a total capacity of up to 56.5cu.m, together with models designed for use with an ADT chassis/cab unit as the prime mover. Introduced at the 2008 ConExpo show, K-Tec revolutionised the towed scraper market by launching the first-ever model specifically designed to be matched to an articulated hauler prime mover, obviously with its skip removed. No permanent alterations are made to the ADT, which can be returned to hauling duties if required. The ADT’s six-wheel drive, together with K-Tec’s automatic cushion ride system, provide for a smooth ride for the operator, plus the ability to travel faster over haul roads than agricultural tractor prime movers. It also allows contractors to use their existing machines as prime movers for towed scrapers, offering familiar operating and service routines.

A multi-function joystick is attached to the operator’s seat to control the scraper, plus a separate screen to allow the operator to manage the ejector mode to match specific soil types and to allow an even spread of material. Below: Norfolk-based VAS Earthmoving operates a substantial fleet of towed and motor scrapers. Recent additions to its fleet are two Cat 627 twin-engine push-pull models.

EARTHMOVERS NOVEMBER 2022

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FLEET FOCUS // MEANEY PLANT

REPLACE & EXPAND Eoghan Daly reviews some of the recent additions to the substantial fleet of County Kildare-based Meaney Plant and Civil orking on a wide range of earthmoving, groundworks and civil engineering projects, Meaney Plant and Civil continues to grow its substantial mixed fleet of plant. The firm takes an open-minded approach to purchases, as machines are evaluated for their suitability and versatility, together with the after-sales support provided by the dealer. However, as far as tracked excavators are concerned, Volvo machinery is generally preferred, and the latest generation of Yanmar compact excavators has also found favour. Recent purchase decisions have been influenced by machine availability, which has led to the first Hyundai to join the fleet, a wheeled excavator complete with an SMP tilt-rotator.

Meaney Plant and Civil was founded 19 years ago by Kevin Meaney. From a family with a long plant background, Kevin initially worked as an operator in the UK, on the M62 upgrade project. Back in Ireland, he changed tack and became a power line technician, working in the Wicklow area with ESB International. However, the lure of the plant sector proved strong, and he became plant and sales manager with MW Hire in Scotland and Ireland. Over the years that Kevin has run his own firm, he has demonstrated the ability to recognise other business opportunities and pursue them through to fruition. This has resulted in the firm undertaking a variety of earthmoving works, supported by a comprehensive fleet of plant and a team

of experienced operators. Kevin also established KMPS as a separate business, which offers machine testing and certification services. While KMPS has become an important business activity, the mainstay of the operation is civils, groundworks and plant hire.

“I HAVE BEEN VERY SURPRISED WITH WHAT VOLVOS HAVE TO OFFER, AS THEY ARE VERY MUCH AN OPERATOR’S MACHINE”

Left and above: Meaney Plant and Civil runs a comprehensive mixed fleet of plant, but clearly favours Volvo machinery when it comes to mainstream tracked excavators.

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“SMP IS A TIDY HITCH AND DOESN’T GET IN THE WAY WHEN TRENCHING AND STILL HAS THE STRENGTH TO WORK WITH LARGER BUCKETS” VOLVO EC200E Meaney runs Case, Hitachi and LiuGong tracked excavators, but this part of the fleet is dominated by Volvo machines, mainly thanks to the impressive service achieved by the longer-serving models. They include an EC240C with 11,000 hours on its clock, still returning excellent levels of performance and reliability. In addition to new Volvo excavators, the firm also buys low-hours machines in good condition, such as their EC250E.

One of the firm’s star buys has been an EC200E excavator, purchased new some 18 months ago. It has been incredibly reliable, delivered good fuel economy and surprisingly high levels of performance. A rare model in Ireland, it is a true 21-tonner aimed at plant hire and groundworks applications. It is largely over-shadowed by the popular, more powerful EC220E. As the Meaney team has discovered, the EC200E may only have 115kW at its disposal, but it is more than capable of economically

undertaking the common tasks on the firm’s groundworks and civils projects. Operator Brendan Doyle said, “I have always been a big fan of Hitachi excavators and came to operating the Volvos with a certain level of apprehension. I have been very surprised with what Volvos have to offer, as they are very much an operator’s machine; they have lots of power and are very smooth on the levers and have a comfortable cab. “I am very impressed by how well the Volvo machines are laid out. It’s not just from the

The Volvo EC200E, the EC220E’s cheaper sibling, has proved to be a surprisingly good performer, able to undertake a wide range of duties.

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FLEET FOCUS // MEANEY PLANT

The Hyundai HW140 and SMP tilt-rotator is a well-matched combination, providing a stable and flexible digging package.

point of view of operating them; routine checks and maintenance are made really easy, as everything is within easy reach. Even small touches, like bringing the grease points down lower on the dipper arm in a single location, makes the maintenance routine on the machine so much easier and faster to complete. “I mainly operate an EC250E, but have also used the EC200E, which I would rate very highly. Having come from the 250, it is in no way a backward step, as the 200 has serious digging power for its size and still doesn’t come under pressure.” This was demonstrated on the EC200E’s current site, a large residential development for Lagan Homes at Straffan in County Kildare, where Meaney Plant and Civil is undertaking the full range of groundworks operations. Brendan continued, “Using the EC200E on bulk excavation with the larger digging buckets shows how it is at ease with harder work, which doesn’t result in any kind of major increase in fuel consumption, as it is very economical in all situations. We recently excavated for large attenuation tanks on this site with the 200. It worked really well in both excavation and loading out material both to trucks and dumpers.”

HYUNDAI DUCK Thanks to a run of contract wins for large projects, Meaney Plant and Civil had an urgent requirement for a high-spec wheeled excavator, which would host the firm’s first tilt-rotator. They had never run Hyundai machinery before, but dealer Whelan Plant Sales could supply an appropriate machine without delay, one of the last available HW140 models before the introduction of the current HW140A. Kevin Meaney said, “I knew a few other plant users who have had Hyundai machines over the longer term and always spoke very highly of them and the service from Whelan. Machine availability was also a big factor, as they had the machine we wanted when we wanted it. We had

This EC240C has clocked up over 11,000 hours and is still returning excellent levels of performance and reliability on front line duties.

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FLEET FOCUS // MEANEY PLANT “THIS LATEST GENERATION YANMAR IS IN A DIFFERENT LEAGUE, IT’S LIKE A TOTALLY DIFFERENT MACHINE”

Above and top right: The latest generation of Yanmar mini-excavators has made a particularly good start on the fleet; the six-tonner features a decent-sized cab. Right: Kevin Meaney has built up a considerable business using a fleet of quality plant and experienced operators.

secured some large-scale groundworks projects on large residential development sites, so the need for a new wheeled excavator was never greater.” Whelan offered Kevin – who had no previous experience of tilt-rotators – an appealing single package, as they are also dealers for SMP tilt-rotators. Supplied with a top hitch to allow the use of a hydraulic breaker, it has worked out very well. Not just the tilt-rotator itself, but how well it is matched to the Hyundai wheeled excavator. David McConnell was selected from the firm’s pool of operators to take charge of the new Hyundai, as he used tilt-rotators while working in Australia. He said, “Some tiltrotators are very demanding on the machine, since they are awkward and heavy, which reduces the lifting power, but the SMP is just right for the Hyundai duck. SMP is a tidy hitch and doesn’t get in the way when trenching with a narrow bucket and still has the strength to work with larger buckets on other work. The machine stays very stable when both slewing to the side or when lifting.”

YANMAR MINIS Meaney Plant and Civil runs a varied selection of compact excavators. One of their more recent purchases through dealer Oliver Laheen Plant Sales was a 2.4-tonne Yanmar Vio 23-6 zero-tailswing mini. It is the 66

first of the recently restyled red-liveried machines to join the fleet. Complete with an expandable width undercarriage, this model features the Japanese-based manufacturer’s new hydraulic system. Kevin said, “This latest generation Yanmar is in a different league to the previous generation of the same size class, which we also have on the fleet. It’s just like a totally different machine and has such digging power and oil flow to the tracks, which makes it perform so much better. Availability was also a big factor, plus excellent service from Oliver Laheen as always.” The team’s early experiences with the new zero-tailswing mini have been extremely positive, so much so that another red Yanmar has now joined the fleet, a six-tonne SV60-6B. One of the first examples of this model to be put to work in Ireland, this conventional counterbalance mini is a high specification machine, with performance to match. In addition to an air-conditioned cab and a rear-view camera, the SV60-6B comes with Yanmar’s SAR telematics system. The working equipment features check valves on the main hydraulic cylinders, which also benefit from protective guards. This

example is plumbed with hammer and rotation lines, together with a fully automatic Geith hydraulic hitch. The new SV60-6B has been entrusted to operator Paul Kennedy, who said, “I am very impressed with the new six-tonne Yanmar. Not only is it fast and powerful to use, it is also nicely balanced. It has the advantage of being able to turn down the hydraulic pressures quickly and easily, which is a big plus when breaking near something sensitive like concrete block walls. Even though you still get the performance from the breaker, it just cuts down on vibration. “For a six-tonne excavator, the space inside the cab is just unbelievable. It is one of the few in this size class built from the point of view of an operator spending eight to ten hours using the machine. The view is also excellent and as the recent heatwave showed, the air-conditioning system works really well. It really is an impressive little machine from every angle and I couldn’t fault it in any way.” Meaney Plant and Civil continues with a high level of investment in its considerable fleet. Kevin sees this as essential to achieve consistent levels of performance to deliver on demanding project completion schedules.

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Due to the recent success with sales, Liugong Machinery are looking to ﬁll the following vacancies:

QUALIFIED MOBILE PLANT ENGINEERS To service and repair LiuGong range of equipment. Competitive pay plus company vehicle. Permanent full time positions. Liugong Direct UK are looking for experienced, qualiﬁed mobile plant engineers to service and repair their LiuGong rage of equipment. Working across the UK directly for the manufacturer’s. Product training will be provided. Be computer literate, a good communicator and willing to work overtime. Package includes company vehicle, highly competitive rate of pay pension scheme, 25 day’s holiday.

WORKSHOP FITTERS Based at our Uxbridge Branch, working across the range of Liugong products. Permanent full time positions. Liugong Direct UK are looking for experienced workshop ﬁtters, based in Uxbridge, working across the range of Liugong products. Product training will be provided. Package includes competitive salary, pension scheme, 25 day’s holiday.

Contact 0203 897 0970 Email info@liugong.co.uk www.liugong.co.uk NOVEMBER 2022

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23/09/2022 17:39

RECYCLING // NEWTOWN WASTE

HYDRADIG HANDLERS David Wylie visits a pair of JCB Hydradigs in action within a busy but compact waste recycling facility Inset above and below: The two JCB Hydradigs are used for a wide range of duties around the site, including the tricky task of separating springs from mattresses.

“NOTHING COULD TOUCH THE HYDRADIG FOR POWER, COMFORT, PERFORMANCE AND OUTSTANDING VISIBILITY”

NOVEMBER 2022

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“THE CAB IS VERY COMFORTABLE AND THE CLIMATE CONTROL WORKS WELL TO PROVIDE GOOD DUST SUPPRESSION, THE CONTROLS ARE SMOOTH AND PRECISE”

JCB 560-80 WASTEMASTER Having arrived on site, Newtown’s new 560-80 Wastemaster Loadall keeps the yard tidy with a JCB SC240 hydraulic sweeper attachment on its quick-hitch. The operator then quickly switches to a 5cu.m bucket to move material around the yard and carry out stockpiling within the segregated cells. It was also being used to feed various trommels and screeners, and is capable of loading the largest of trucks. Offering a maximum lifting capacity of six tonnes and equipped with a 5cu.m bucket, the JCB 560-80 telehandler has the right combination of productivity, manoeuvrability, durability, comfort, safety and low cost of ownership for this application. The machine’s new hydraulic regeneration system offers faster cycle times and greater efficiency than its predecessor. All the JCB machines on site are under a service agreement and regular servicing is carried out at 500-hour intervals, as Michael Smith explained, “Scott JCB’s service back-up is absolutely second to none. If we do encounter an issue, it’s never really an issue, as nine times out of 10 the service engineer is on site within an hour. You can’t ask for better service than that.”

Right: In addition to being versatile, agile and powerful machines, the Hydradigs’ air-conditioned cabs come in for praise, particularly their all-round visibility.

otherwell-based Newtown Waste Solutions covers the central belt of Scotland and aims to recycle 95% of its incoming waste streams from domestic, commercial and industrial customers. The firm runs a fleet of HGV skip wagons, ranging from 7.5-tonne mini-skips to 32-tonne roll-on/off lorries, in addition to 44t bulk trailers. A far cry from when Martin McLindon and William Neilson established the business in 2006 with just one truck and a few skips. At the time, plans were being drawn up to regenerate the site of the former Ravenscraig steelworks into a new town; hence the company name.

SITE BACKGROUND Since 2012, Newtown’s site at Motherwell has also acted as a waste transfer station for North Lanarkshire Council. At the time of our visit another load of plastics and metal from the authority’s local collections had arrived on site, to be tipped into the large three-bay shed. Later in the day, such material is loaded into Newtown’s large walking floor bulk trailer, for onward transport to a centralised recycling facility at Levenseat.

Newtown has a licence to process 100,000 tonnes of waste a year on this site, which covers just two acres. It is a relatively small area in which to handle, process and load such a high volume of materials. Following a functional and safety review of the operation, it was decided that a JCB Hydradig zero-tailswing, wheeled excavator was required. The purchase decision was influenced by the exceptional levels of all-round visibility available to the operator, critical on such a tight and busy site. Operations director Michael Smith said, “During our operational review it became apparent it was too labour intensive, with too many smaller machines and groundworkers. We were quickly sold on the idea of a Hydradig for processing metal, wood and other segregated waste products, and have found it to be a highly efficient

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RECYCLING // NEWTOWN WASTE have found to be powerful and robust attachments. These grabs were being put to good use close to the hand picking station, where the majority of the recyclable waste for processing is tipped, sorting through the pile to segregate all the larger items, such as wood and metal. Both machines have a dozer blade, which Newtown’s operators put to good use to help extract springs from mattresses, which are difficult to recycle efficiently. The operators use the blade to clamp one end of the mattress, then use the selector grab to carefully de-sleeve the covering material from the metal springs. The zero-tailswing design allows the machines to work closely to the large concrete ‘Lego’ block walls, which form bays used to segregate material. The operator of the latest model, now with 800 hours on its clock, said, “The Hydradig is a great machine to drive as it’s very versatile, agile and very powerful, and the view from the cab is exceptional. The cab is also very comfortable and the climate control works well to provide good dust suppression, and the controls are smooth and precise. Also, as everything is at ground level, including the air filter, daily checks are so easy to do.”

Both Hydradigs are equipped with a Pladdet PRG2-200-EX selector grab, which is used to full advantage with the zero-tailswing machines’ long reach.

CONCLUSION

tool with a selector grab. The drivers love operating it and, since it performed so well, we invested in another Hydradig from Scot JCB. We also trialled competitor machines and operator feedback was that nothing could touch the Hydradig for power, comfort, performance and outstanding visibility, which are so key in our operation for safety reasons.”

SITE VISIT

various screening plants on site. The two Hydradig 110Ws have been specified for the waste recycling sector with puncture-proof solid tyres, a cab screen guard and a robust shield to cover the tipping link hydraulic ram cylinder-rod. They are configured with Pladdet PRG2-200EX selector grabs, which the team

It is an unusual application for JCB Hydradig 110W wheeled excavators, but they seem to be coping exceptionally well with this materials handling role. Not just in terms of the performance of the working equipment, but the low-profile, zero-tailswing upperstructure, which provides exceptional levels of visibility to the operator, which is a safety-critical consideration on such a site. Michael concluded, “We never profess to be the cheapest, as we pride ourselves on great customer service. The ethos of the company is we’re here to recycle. That means, regardless of the commodity price, we will spend the time and effort to pick and segregate all the waste to achieve our 95% recycling target.”

Newtown Waste Solutions is a long-term JCB customer, and another recent purchase was a 560-80 telescopic handler in Wastemaster configuration (see panel). The site hosts a variety of material separation, recovery and processing machines, together with a 10-person hand picking station. This station is fed by the output of a large trommel, which is normally loaded by the site’s Liebherr LH22 materials handler. When it is engaged on other tasks, one of the Hydradigs takes over these loading duties, providing sufficient reach and productivity to keep the trommel’s hopper well fed. They are also used to service the

The JCB 560-80 Wastemaster Loadall works with a hydraulic sweeper attachment and an oversized 5cu.m bucket.

NOVEMBER 2022

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NOVEMBER 2022

23/09/2022 17:19

MARKET REVIEW // CONSTRUCTION DOZERS

BULLDOZERS: 100 YEARS YOUNG Peter Anderson reviews construction-sized dozers, those with operating weights below 35-tonnes Above and inset: A variety of small and mid-size dozers are available to the construction sector, including Polish-built Dresstas and Komatsus with fullyintegrated machine control.

ulldozers have been part of the muck-shifting scene since the concept was developed in the 1920s. Over the past 100 years they have matured into a frontline earthmoving machine, ideal in applications such as heavy overburden stripping or fine site grading. Dozer productivity has risen sharply over recent years, initially with the use of 2D laser guidance systems, then GPS 3D machine guidance, followed by the current offering of 3D machine control systems that automatically adjusts the blade on the move.

The recent transition to ultra-low emissions Stage 5 engines has also resulted in improved fuel economy across the board, with an interesting choice of drivelines available. Liebherr has long championed hydrostatic drive over traditional powershift transmissions, and Caterpillar is now in its second generation of mid-sized diesel-electric driven dozer.

DRESSTA For those looking for a more straightforward dozer, which is reflected in its purchase price, Polish manufacturer Dressta offers six models with operating NOVEMBER 2022

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Komatsu offers six models with operating weights from 9.1 to 29.4 tonnes and blade capacities from 1.91 to 7.2cu.m.

shank ripper is the usual fit, but multishank versions can also be supplied. Dressta says that its latest design provides easy, safe and fast access to maintenance points, which reduces downtime. Lifetime lubricated rollers, heavy-duty chains and idlers for extended track life also help to minimise long-term maintenance costs. The TD-15M is grade-control ready, and Dressta also offers factory-fitted machine guidance/control systems.

KOMATSU

weights from nine to 25 tonnes. A decade ago, the business was purchased by the Chinese manufacturer LiuGong, which has since reintroduced updated Dressta products to the western European market. The latest model to join the range is the 20-tonne class TD-15M, powered by a Stage 5 Cummins engine rated at 142kW. It drives through a combination of a three-speed powershift transmission and two-speed steering drive. Dressta says that its innovative steering drive maximises productivity by delivering all of the engine’s power to both tracks. This allows the machine to push a full load through turns 74

with near perfect load retention. This new M series dozer benefits from a much better cab than its predecessors, claimed to be some 30% larger, with 15% more glass and larger doors. The modern ergonomic-looking controls include an LCD touch-screen, which also includes a fault diagnosis system. Weighing between 20.6 and 21.5 tonnes depending on its configuration, the TD-15M has a standard blade capacity of 1.84cu.m. There are a variety of alternative blades available, including semi-U, straight, angled and a six-way blade with a folding option. A single-

Six models with operating weights from 9.1 to 29.4 tonnes and blade capacities from 1.91 to 7.2cu.m. Power ratings range from the 67.7kW D37-23 model, up to the 199kW D85-18. All are available in either long-track (EX) or low ground pressure (PX) undercarriage configurations. Komatsu says that its design of the track chain bushings lowers overall undercarriage maintenance costs by as much as 40%, by controlling wear between pins and bushings, and on bushing exteriors and sprocket teeth. The cream of the crop are the ‘intelligent’ versions of these dozers, which feature a fully integrated 3D GPS machine control system. This is not merely an additional batch of components fitted on a standard machine on the assembly line, but embedded within the dozers’ hydraulic and physical systems. The system senses the load on the blade and controls it to

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MARKET REVIEW // CONSTRUCTION DOZERS minimise track slip, allowing automatic operation from heavy dozing to fine grading. Komatsu says its ‘i’ models show a significant productivity increase compared with machines working with conventional automated grade-control systems.

CATERPILLAR

Right and below: Caterpillar has reorganised its range of small and mid-sized dozers, with six all-new, ultra-low emissions models with operating weights below 35 tonnes.

Over the last three years, Caterpillar has reorganised its range of small and mid-sized dozers, which now includes fewer than half a dozen all-new, ultra-low emissions models with operating weights below 35 tonnes. Launched in March 2020, the new D2 and D3 models weigh in at 8.4t and 9.2t and are powered by a Cat C3.6 engine rated at

NEW DOOSAN DOZER Doosan is entering the North America dozer market with its new USA-built DD100 model. With an operating weight of 11.5 tonnes and powered by a 90.9kW engine, the dozer has a maximum travel speed of 9kph. A second model, the 13-tonne DD130 is due for launch to American customers next year. There are no plans to introduce these dozers to the European market.

Left: The current trend of sharply-sloping front bonnets on dozers has a dramatic impact on visibility, as illustrated by a new Cat D4 against the old D6K.

68.8kW and 77.6kW respectively, offering up to a claimed 10% improvement in fuel economy over their predecessors. Cat says that this next generation of stylish small dozers is designed to optimise speed, transportability, manoeuvrability, versatility and finish grade accuracy. Replacing the old D6K2 model, last year Cat unveiled the new D4 dozer, which weighs 13.2t in standard configuration, or 14.0t with a low ground pressure undercarriage. With a 97kW engine, Cat says this dozer offers the power, precision and balance for smooth grading performance. The new D5 dozer, the smallest Cat high-drive model, has replaced the D6N. It is powered by a 127kW engine, with operating weighs between 17 and 19 tonnes depending on configuration. According to Cat, this model offers a broad choice of easy-to-use technology features to help users get the most from the machine. A fully automatic transmission provides seamless acceleration. Cat says that the D5 is nimble and responsive, with the power for dozing and the finesse for grading. The standard new generation D6 dozer is configured with Cat’s fully automatic, four-speed powershift transmission, driven by a Cat 9.3B engine rated at 161kW. NOVEMBER 2022

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MARKET REVIEW // CONSTRUCTION DOZERS Left below: Liebherr offers four new Generation 8 dozers with operating weights below 35 tonnes, from the PR716 at 13.3t up to the PR746 at 25.9t.

AUTONOMOUS DOZERS The D6XE version features Cat’s latest generation of diesel-electric dozer driveline systems, which provide higher levels of performance and lower fuel costs. A D6 has an operating weight of between 21.7 and 24.1 tonnes with standard 610mm-wide track shoes. Both D6 powertrains are said to offer unprecedented ease of operation. The operator simply sets the ground speed and the machine continuously adjusts for maximum power and efficiency based on load. With the XE electric drive version, there are no gears to shift, while the fully automatic conventional box optimises the transmission without the operator having to change gears. The new 30-tonne Cat D7 is powered by a 197kW engine mated to the four-speed auto transmission. The conventional D7 takes the place of the diesel-electric D7E in the range, but offers more power and a 10% increase in blade capacity, in addition to a high-drive undercarriage.

LIEBHERR Hydrostatically-driven dozers have been an integral part of the Liebherr range over the past 40 years. There are four models in the new Generation 8 range with operating weighs below 35 tonnes, from the PR716 at 13.3t up to the PR746 at 25.9t, all powered 76

by Liebherr’s latest EVO engines with power outputs from 97kW to 190kW. A variety of rippers are offered, together with straight, semi-U or six-way blades with capacities from 2.92 to 6cu.m. These models feature a new climatecontrolled cab, which is isolated from the rest of the machine for significantly reduced vibration levels and further improvement to noise emissions. The cab features a 23cm display, through which the operator can adjust and save the driving and steering response to suit their personal preference and the job at hand. The main functions can still be controlled by means of haptic buttons and keys. The control system includes Liebherr’s active sensor control (ASC) system as standard, which stabilises all blade axes. The ‘free grade’ operator assist setting uses this to provide active blade stabilisation during fine grading. The ‘definition grade’ setting is used for automatic blade positioning when working in 2D, while ‘3D grade’ is the optional full GPS machine control system. The dozers also come with Liebherr’s LiDAT fleet management telematics system as standard, including the machine’s position, operating data, fuel consumption and service interval information.

We have previously reported on a variety of remote-controlled and semi-autonomous ultra-class Cat dozers working in large surface mines, much of their development taking place in Australia. Due to the incredibly high cost of transporting and accommodating operators in isolated mining camps with challenging climatic conditions, there are a variety of reasons why this sector of the industry is moving towards fully autonomous dozers. Fleets of autonomous haul trucks have already proved themselves. One of the next steps along the road to fully autonomous dozers is to do away with the cab and its manual controls altogether, which greatly simplifies the machine. This was demonstrated by Liebherr at the 2019 Bauma show with a concept of a cab-less dozer, although this is intended for remote control, not to work autonomously. In a glimpse into the future, Chinese manufacturer Shantui has recently unveiled a prototype of a fully autonomous dozer, the DH17C2U model. Shantui worked with researchers from the Huazhong University at the National Digital Construction Technology Innovation Center in Wuhan. Autonomous operation is made possible via a highpowered computing system, a precision positioning system and 5G communication. On-site testing of the machine continues, and Shantui says it will bring the machine to market once the technology matures.

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FACTORY VISIT // KOMATSU UK // TAIL END Below and inset: Komatsu’s factory at Birtley in Tyne and Wear has been producing mid-range excavators for over 35 years, ranging from the PC170 to the PC700.

“WE HAVE INCREASED PRODUCTION BY AROUND 30%; TO SUPPORT THIS, WE HAVE TAKEN ON 150 NEW STAFF, INCLUDING APPRENTICES”

SMART ASSEMBLY & SMART M CONSTRUCTION Peter Haddock visits the Komatsu excavator factory at Birtley in Tyne and Wear and takes a closer look at their new retro-fit machine guidance system

id- to large-sized Komatsu construction excavators have been built at Birtley in the northeast of England for the past 35 years, making a valuable contribution to UK exports. The current production range includes a dozen tracked models, from the PC170 to the PC700. Earthmovers has frequently reported from this factory over the years, as it reached various milestones in the development of its human and technical resources. These include researching, developing and NOVEMBER 2022

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The undercarriage is fabricated on site, where supervisors physically mark it with their individual punch, to certify that it meets Komatsu’s quality standards.

heights of up to 32m and features Komatsu’s manufacturing long- and high-reach K100 quick-change boom system. Metalworking equipment, then launching bashing techniques have also changed a range of demolition rigs, together with considerably over this time, as robotic the introduction of their intelligent welders play an increasingly important excavators, which feature fully-integrated role in such an operation nowadays. GPS machine control systems. It was at the factory’s specialist boom Apart from seeing how the factory fabrication area where our tour started with processes have developed since our last guide John Lawson, who visit, a key part of this said, “When it comes to visit was to find out more “WE EVEN HAVE A the fabrication of the about Komatsu’s new SPECIAL ROBOT TO booms, 85% of the retrofit machine is carried out guidance system, PERFORM THE TASK OF welding by our robots, designed more about which later. and built by Komatsu BUILDING OUR HIGHcolleagues for these FACTORY VISIT REACH BOOMS ON specific tasks. We even When you arrive in have a special robot to Birtley, the Komatsu site A SEPARATE LINE” perform the task of is unmissable, stretching building our high-reach to 200,000 square booms on a separate line.” metres, of which 50,000sq.m is covered The next stop on the tour was the space. Decades ago undercarriage fabrication area, which it was a Caterpillar factory, but started life combines manual welding techniques with as part of the Birtley Iron Works, which more Komatsu-designed robots. It’s also opened in 1827. where individuals on the line literally put A lot has changed during 200 years their stamp on the machine. Each stage of of metal-bashing on this site, from the fabrication is quality checked, and the production of pig iron, to building persons responsible for this process each Komatsu’s impressive PC490HRD highhas their own stamp. reach demolition rig, which offers pin 80

John continued, “Stamping the undercarriage is part of our Komatsu engineering quality standard, as each track frame is checked and the final stamp added by the section supervisor before moving on to the paint shop. “The paint shop process is extremely important and it’s where I spent over 26 years of my career. Before any welded components go into painting, each weld is checked again. Components are then loaded on to a system that has a total of nine cranes. They first go through two phosphate pre-treatments; this helps the adhesion process when we come to apply the paint. The components’ journey then continues into the drying oven, before being checked to ensure the surface is nice and smooth. It is then manually painted, before finally being dried in a double oven.” Once the painted components have been inspected, they are ready to move on to the

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FACTORY VISIT // KOMATSU UK // TAIL END assembly line. The 156m-long line was commissioned after Komatsu took ownership of the site in 1985, producing its first excavator in 1987. This assembly line has literally helped the business move forward and is currently run at a speed of 215mm per minute. This gives the assembly operatives at each station 29 minutes to perform their tasks, resulting in 15 machines a day coming off the end of the line. Once fully assembled, each excavator goes into an inspection area, which is used to check the hydraulics and performance of the machine. John continued, “By pressurising the machine, we ensure there are no oil leaks and that the components are working properly. Once these tests are completed, we move on to a 200-point mechanical inspection check. After this is complete, a special blue sticker is placed on the machine, signed by the inspection department. Komatsu UK’s MD, Paul Blanchard, concluded, “Over the last 12 to 18 months we have increased production by around 30% to meet industry demands for our

The majority of the structural welding is carried out by bespoke Komatsu designed and built robots as other connected digital systems track the material to the tipping area.

Each station on the 156m-long assembly line has just under a half an hour to complete its part of the build; there are currently 15 excavators a day coming down the line.

products. To support this, we have taken on 150 new staff, including apprentices and graduates. For me, it’s all about building a sustainable, highly skilled local workforce and using our existing experts, some of which have been with us for 35 years, to train those joining us. Our training is all about supporting each team member coming into the business. “For example, new recruits for the assembly side will come in and do two weeks, or as much time as they need in the training room, and will then move on to our buddy-up system on the shop floor. This is a further four-week programme that ultimately leads to a role in the assembly line.” NOVEMBER 2022

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SMART CONSTRUCTION any modern excavator, to bring a mixed fleet into the Smart Construction fold. Komatsu Europe is rolling out its Smart Like all similar systems on the market, Construction portfolio of hardware and it requires sensors to be mounted on the software, which will offer an integrated boom, stick and bucket link. They are used set of digital tools for all phases of in conjunction with a pair of global a construction project, from bidding and navigation satellite system (GNSS) planning to construction and reporting. antennas, to determine the exact As part of this strategic move, a number position of the bucket’s of new products are “THE DATA FEED cutting edge. available to improve site If this happens to be connectivity and data DOESN’T ACTUALLY fitted to a recent processing. Examples HAVE THE VALUE, THE Komatsu excavator, the include rapidly turning system can also be linked drone data into a 3D VALUE COMES FROM to its payload sensor, terrain map on site, to remotely monitoring the THE INFORMATION YOU enabling tracking of not only where the material entire fleet of machines, CAN GLEAN FROM IT” came from, but how in addition to the much it weighed. project’s overall A valuable input into managing the progress, through an app on a tablet. muck-shifting effort, particularly when A key requirement on fully-connected combined with data from the haulers as construction sites is that all the prime to where it was tipped. movers must be digitally linked, those Unlike other machine guidance running Komatsu machines into the ever-expanding Smart Construction system. systems, this Komatsu product does not A recent development is the availability of a require any additional wiring in the cab, Komatsu 3D GPS machine guidance system, nor does it require an expensive bespoke control screen. The system’s main which can be cost-effectively, retro-fitted to 82

controller, hidden inside the machine, communicates to any Android tablet by wifi, allowing a wide and economical choice of in-cab screens. Komatsu Europe’s Richard Clement said, “By offering an entry-level machine guidance solution, rather than full machine control, we are able to connect machines for a lower price point. This solution has a dual purpose of providing guidance to the operator, to help the efficiency on the job site, while also sending a data feed from this machine directly into our Smart Construction ecosystem. In turn, this will join data from other machines in the fleet, allowing us to see progress on site through an as-built data model. “The data collected by Komatsu’s Smart Construction solution is also comparative, so you can work out where extra training or support is needed from one operator to the next, to boost productivity and efficiency. It’s all part of building a digital project focused ecosystem that allows you to manage, measure and monitor a site. “I think it’s important to understand that the data feed doesn’t actually have the

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FACTORY VISIT // KOMATSU UK // TAIL END Left, below and inset below: On modern connected sites, machine guidance systems help the operator dig in the right place, as other digital systems track its journey to the tipping area.

Left, and above: Komatsu has introduced a machine guidance system that can be fitted to any make of excavator that uses any Android tablet as its in-cab control screen.

value. The value comes from the information you can glean from it. And it’s not just about managing a fleet of machines. You have to take a holistic look at the overall project. For example, the terrain data from drone flights can be very useful, as can other surveys of the site. And bringing together this information can be very impactful. This is because no singular feed from, say, one machine, can answer questions around how to make improvements without complementary data from other sources.” Komatsu’s new machine guidance systems are currently available for tracked excavators with either a mono-boom or a two-piece boom, with or without a tilting bucket. A similar kit for wheeled excavators is due for launch soon. Richard concluded, “We already know what technologies are round the corner, like semi and full autonomous machines, but Smart Construction is about the here and now. And being able to simulate

BUCKET CONNECTIVITY Komatsu has also developed the Smart Construction Pilot, allowing different buckets to set up within the excavator’s payload weighing system, which can be digitally shared with another excavator using the same bucket. The geometrical data of the bucket can also be shared with machine guidance systems. Komatsu Europe’s Richard Clement said, “We have recognised there are varying different software packages used within construction and earthworks design. With this in mind, we have built a translator into the Pilot application, so you can transmit whatever file format you like, and it’ll convert it into the format that’s necessary for the machine to use.”

a project using our tools before a machine gets on to the site is a perfect example of forward planning that makes an immediate impact.” NOVEMBER 2022

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23/09/2022 17:47

CLASSIC PLANT // TOWER EXCAVATORS // TAIL END ifferent types of excavating machines often team together to accomplish long-term overburden stripping and mineral extraction at large quarrying and surface mining operations. They include walking and crawler draglines, rope and hydraulic face shovels, large hydraulic backhoes, together with bucket wheel and bucket chain excavators. All have a role to play, depending on the site’s geology, production requirements, excavation depth and haulage distance. A lesser-known and now almost forgotten part of this mix was the tower excavator. Sometimes referred to as a slackline cableway excavator, it was a close cousin to the dragline. It consisted of a head tower containing the working mechanism, called the draw works, positioned at one side of the excavation, and a tail tower positioned at the opposite side. A dragline bucket was suspended from a trolley running on a tracking cable between the two towers. The arrangement was similar in appearance to a forestry skyline cableway system. The dragline bucket dumped automatically when a pulley block, travelling ahead of the trolley, came into contact with a cable clamp positioned on the tracking cable. Further pulling caused the rear of the bucket to be raised, usually depositing its contents into a hopper feeding a conveyor belt. Some installations operated with a higher capacity scraper bucket, which was a crescent-shaped, bottomless dragline bucket. This simply dragged the material into the hopper and was often referred to as a drag scraper. In sand and gravel operations, the head tower was usually in a fixed position close to the processing plant; in other applications the head tower was mounted either on rails or tracks. The tail

EXCAVATING FROM ABOVE Keith Haddock takes a look at tower excavators, a forgotten member of the excavator family Above and right: An extremely rare Bucyrus-Erie product: a walking tail tower, part of a tower excavator system delivered the US Army Engineers for river dredging work in 1932.

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Left: The tail tower of the TX300 runs on eight tracks and carries draw works and ballast box; the operator controls the machine’s travel and also a winding drum to take up slack on the tracking cable.

tower could also be mounted on rails or tracks, and Bucyrus-Erie also offered a walking tail tower in the 1930s (see below). A crawler tractor, or even a large crawler excavator, could also function as a tail tower, when equipped with suitable framework, a counterweight and a pulley system. On some installations, movement of the tail tower could be controlled remotely by the operator on the head tower. When the head tower was located in a fixed position, the tail tower gradually moved round it, forming a circular pit as the excavation proceeded. When both head and tail towers were mobile, a rectangular pit was excavated. Given that spans of up to 1000ft have been installed, vast quantities of material could be extracted without significant movement of head or tail towers.

CLASSIC BUCYRUS-ERIE Beginning in 1915, Bucyrus-Erie built some 33 tower excavators. Originally designed for constructing levees along the lower Mississippi River, these machines later found use in mineral extraction or stripping overburden in stone quarries. Bucyrus-Erie’s busiest period for supplying tower excavators was from 1929 to 1932, when they designed and installed 16 systems across North America. Known as the TX series, the largest was the TX-310 model that carried a 10-cubic-yard bucket over a span of 750ft. Weighing 324 tons in operation including ballast, the head tower was electrically powered and housed two winding drums for the bucket, for inhaul and backhaul, and a third drum to adjust the height of the tracking cable. Incoming Below: The largest of Bucyrus-Erie’s tower excavators, the TX-310, carried a 10-cubic-yard bucket over a span of 750ft. This one, installed in 1930, was owned by Sternberg Dredging Company of Illinois. Below right: Double rail tracks are needed to support the head tower of this Bucyrus-Erie TX300 owned by Clark Brothers Construction of Clinton, Iowa, shown working in 1930.

AC power drove a motor-generator set providing DC power to three 187hp motors, two for the bucket and one for the tracking cable. The head tower of the TX-310 was 130ft high and the operator’s cab positioned 90ft above ground, providing a good view of the working area as well as the tail tower. It was mounted on four crawler assemblies, each supporting two crawler tracks with 36inc shoes. The two crawler assemblies on one side of the machine were mounted on a pivoting beam, so that all four assemblies could share the load when travelling over uneven ground. Locally operated jaw clutches on each assembly allowed the tracks on one side to be driven independently of the other to provide steering of the machine. In situations where the machine had to be moved and electric power was unavailable, the designers saw fit to provide an auxiliary 80hp petrol engine as standard equipment. The tail tower of the TX-310 was of similar construction to the head tower except that all power requirements were provided by an 80hp petrol engine and controlled by a second operator. Weighing 145 tons, like the head tower it was mounted on four crawler assemblies, each fitted with a pair of 36in-wide crawler tracks. The engine not only provided propulsion for the tail tower, but also powered a take-up or storage drum for the tracking cable, often necessary during independent movement of either the head or tail towers. The track cable sheave on the tail tower could be positioned either at 30ft or 50ft above ground depending on the work in hand. As the Bucyrus-Monighan walking system worked so successfully in the company’s range of draglines, it was only natural that the same propulsion system would be applied to a tower excavator tail tower.

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CLASSIC PLANT // TOWER EXCAVATORS // TAIL END Left: Weighing 324 tons including ballast, the head tower of the TX-310 was electrically powered. The operator’s cab was positioned some 90ft above ground on the 130ft-high head tower. Below: The Bessemer Limestone & Cement Company operated this Bucyrus-Erie TX300 tower excavator at its operation near Lowellville, Ohio.

Looking like a walking dragline without its boom, the walking tail tower supported the usual tower structure and sheave arrangements above the house and revolved on a circular base just like its dragline cousins. Its obvious advantage was that it required no expensive rail set-up or high-maintenance crawler tracks, and its low ground pressure enabled its

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This Sauerman highline excavating system in a sand and gravel operation featured two tail towers supporting the cable, a pulley system allowed the operator in the head tower to move the tail pulley to form a triangular-shaped pit.

MODERN SAUERMAN

Above: This Sauerman drag scraper uses a crescentshaped bucket to simply drag the material, usually into a hopper.

operation on relatively soft ground. One of these was supplied to a US Army Corps of Engineers job at Slough Landing, Kentucky in 1932. Although these tower excavators performed well in the specific application they were individually designed for, most were then moved on to different assignments. Recognising that the market for new tower excavators was restricted, Bucyrus-Erie discontinued them as a standard product. The last tower excavators produced by the firm were delivered in 1937, two systems to strip overburden for Oliver Iron Mining in Minnesota. 88

Inset right: The two tail towers that worked with the BucyrusErie tower excavators installed by Oliver Iron Mining in Minnesota 1937.

The most prominent American manufacturer of tower excavators was Sauerman Brothers. Established in 1909 and many were also exported. with a factory at Bellwoood near By the 1980s, Sauerman offered Chicago, the company introduced its tower excavators with dragline first slackline cableway system in 1911. buckets up to five cubic yards capacity and At the time, the design of excavators spans to 500ft. When operating as a drag and off-road haulers was still in its scraper, buckets up to 15 cubic yards infancy. Work was carried out mostly capacity were used. using manpower, supplemented by Sauerman also offered to convert any horses and mules. In these standard dragline to a head tower. Using circumstances, the slackline cableway the dragline’s standard boom, a steel system rapidly gained acceptance with framework extended forward some 20ft or contractors and aggregate producers. so from the boom foot. The outer end was The system’s ability to excavate and attached to a moveable carrier, rail or roller haul material in dry or wet conditions, without needing transportation vehicles, was a distinct advantage. Known by Sauerman as Highline Excavating Systems, these tower excavators were primarily long-range machines. They gained their best advantage when working to considerable depths and conveying at least 200ft to an elevated dumping point. The bucket arrangement on a tower Over the decades, excavator showing the cable clamp dozens of Sauerman positioned on the tracking cable to dump the bucket in the desired systems in different position. configurations were installed across America,

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CLASSIC PLANT // TOWER EXCAVATORS // TAIL END

UK TOWER EXCAVATORS Above and below: The Henderson system rail-mounted head tower with a two-cubic yard bucket, together with the view from the operator’s cab showing the extent of excavation.

mounted, which supported the tower. The top of the tower was pinned to the dragline’s boom point forming a rigid triangle between boom, tower and supporting frame. The dragline’s normal winding drums provided the necessary pull and winding capacity for the tracking cable and dragline bucket. In the early 1990s, Sauerman Brothers had become part of AmClyde Engineered Products, which was formed when the famous crane builder Clyde Ironworks of Minnesota purchased the marine energy

division of American Hoist & Derrick Co. At this time Sauerman offered a range of machine types including standard highline excavating systems, yarder/tower arrangements for the logging industry and a conversion kit for Manitowoc crawler cranes, offering cableways up to 600ft spans with 10-cubic-yard buckets.

CONCLUSION Although many systems are still in operation today, since the turn of the new Millennium the global market for new

A prominent manufacturer of tower excavators in the UK was John M. Henderson of Aberdeen. Established in 1866, Henderson designed and built many types of materials handling and lifting machinery, which can still be found all over the world. Still in business today, Henderson specialises in producing coke oven machinery. Its tower excavators ranged from 0.5 to 3.5 cubic yards capacity, with spans up to 875ft. Each machine was tailor made for a particular application and powered by steam, electric motors, or by petrol/diesel engines. Henderson tower excavators and drag scrapers were frequently used within UK sand and gravel pits, but also on large civil engineering projects. John Mowlem operated three tower excavators on the Chingford Reservoir contract near Tottenham in the 1940s. Two carried 3.5-yard buckets over a span of 875ft, and another carried a two-yard bucket with a 600ft span. Mowlem also employed a two-yard tower excavator with a 600ft span on the Staines Reservoir. All were electrically driven and worked in stiff London clay. Other UK users included Sir Lindsay Parkinson, Richard Costain, Ribble Sand & Gravel and Hall & Company.

tower excavator systems has rapidly diminished. As an excavation system, the tower excavator had a number of key advantages, the foremost of which is that it could operate over a large area without assistance from any other machine. It didn’t even matter if this area was unstable or swampy ground, or even under water. Even better, only one operator was required to perform all operations, simply controlling the digging and tracking cables and, in some cases, movement of the tail tower. NOVEMBER 2022

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INTERVIEW // AID ALLIANCE // TAIL END

HELPING THOSE IN NEED IN UKRAINE

Peter Haddock talks with Jeremy Fish, the CEO of Ardent Hire, in his role as spokesperson for the UK’s Plant & Hire Aid Alliance stablished in August, the Plant & Hire Aid Alliance brings together a number of the UK’s plant and plant hire firms, to maximise the impact of their charity work on behalf of the Ukrainian people. To find out more, I met Jeremy Fish, the Alliance’s spokesperson and CEO of founder member Ardent Hire Solutions. He said, “In March this year, I was involved in a convoy to deliver aid to Ukraine. It was a rapidly pulled-together team, who collected food and other items like clothing, delivering it to Eastern Europe for distribution to refugees. “Like many others, including those in the plant and hire sector, we raced to act and managed to work our way through the challenges of fundraising, transportation, documentation, paperwork mistakes and exhaustion. Our aid was well received, but there was much more to do. We also learnt about the need for specific items like mattresses and suitcases for those fleeing the country. We launched a specific appeal for these items, which was delivered earlier this year.”

COLLABORATION Jeremy continued, “But the key, as with any other major project, was to work together to create an organisation that could pool resources, experience and scale up. This led to the formation of the Plant & Hire Aid Alliance in August, which has brought together like-minded companies in the plant and plant hire industry. Together, we have been able to join up our efforts to provide aid as a group and raise public awareness about the hardships that have been inflicted on millions of Ukrainian families. “Our first combined aid convoy, in partnership with Rotary International, takes place in October, when a convoy of vehicles will travel from the UK to a warehouse in Kosice, East Slovakia. Here, the supplies we are able to gather will be despatched all over Ukraine by local volunteers. It’s a tried and tested route that has made an impact on the lives of thousands of Ukrainians. “As the winter months are now fast approaching, I appeal to other industry players to join and support the alliance,

so we can work together to make an even bigger difference moving forward.” Since its formation, the alliance has grown to 31 members, and more are pledging support and donating key supplies. They include long-lasting food and baby food, hygiene items, medicines, bandages, blankets, duvets and sleeping bags, together with winter clothing. For further information, please visit www.aid-alliance.com

“AS THE WINTER MONTHS ARE NOW FAST APPROACHING, I APPEAL TO OTHER INDUSTRY PLAYERS TO JOIN AND SUPPORT THE ALLIANCE”

NOVEMBER 2022 EARTHMOVERS

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HIGH-TECH DIORAMA ASSETS

Steven Downes reviews a range of 3D-printed diorama accessories and vehicle loads

cale models are typically made using a metal die-cast process, which is both time consuming and expensive, and requires a reasonable production run to cover the investment in tooling. Over the last few years, we have seen the rapid growth in 3D printing technologies, which have now made it possible to create models in small numbers, produced in a range of colours and with different finishes. This technology is now beginning to impact construction equipment scale replica collectors, with a range of professionally 3D-prined 1:50-scale fuel tanks, waste skips and container buildings from Mountain Scale Manufacturing (MSM). This scale model producer is based in Liechtenstein, between Switzerland and Austria, and produce a growing range of 3D-printed models and accessories, which make great diorama pieces or loads for vehicles.

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PLANTMOBILIA // 3D PRINTING // TAIL END

xtruding lifting brackets allow them to be fitted to 1:50-scale skip trucks from the likes of Tekno and Conrad. MSM offers 10 different skip types, including generalpurpose, pallet, container and flat-trough designs.

leven fuel tanks are available, ranging from 550 to 20,000 litres. Each is printed in a yellow material, and decals are used for the warning and safety markings. The tanks can be ordered in kit form, allowing them to be painted in any desired colours and consist of the main tank, filler cover and decals.

pair of IBC water tanks are available, which feature an outer grey frame with a panel for warning labels, a white inner tank that can be removed from the frame, allowing it to be painted to simulate a full tank of fluid. The tanks have recesses to allow them to be used in conjunction with forklift trucks.

comprehensive range of 20ft container buildings is available, some with windows and doors, some open-sided and some with a hook-lift frame. They are modular in nature, allowing site office complex to be built. The surfaces of the buildings have good definition of the panels and inset windows that have clear glazing. The doors have handles in a different colour, while the floor and roof sections are printed in a dark grey, which contrasts with the yellow sides and frame. Each building has shipping container holes in the corners, allowing them to be joined together with plastic feet and metal bars that are available separately. They also allow a container to be suspended from a crane.

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EARTHMOVERS

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EARTHMOVERS

SITE VISIT JOHN DEERE 672GP Argyle-based A&L McCrae is running the first John Deere motor grader sold in the UK, in fact it’s the first JD construction machine sold here in the last 50 years!

RUNNING REPORT DOOSAN DX420-7

FLEET FOCUS EARTHLINE LIEBHERRS

Limehillock Quarries have been running their first Doosan excavator for just over a year, both in their own quarry and on contract crushing jobs.

This Swindon-based firm operates eight sites across the region, offering recycled and primary aggregates along with inert tipping facilities.

PLUS MARKET REVIEW ELECTRIC COMPACTS The latest battery-powered compact equipment reviewed, as a host of new products are launched at the massive Bauma trade show in Germany.

OPERATOR COMPETITION CAT CHALLENGE We report from Malaga in Spain on the European Finals of the Caterpillar Operator Challenge, which makes a welcome return this year.

CLASSIC PLANT NORTHUMBRIA DRAGLINES Keith Haddock reviews the history of opencast coal mining in Northumbria, focusing on the huge fleets of large draglines working there and at the Radar North sites.

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For the latest releases visit www.diecastconstruction.co.uk

NEW KOBELCO SK210lc from Conrad

BAUER BG 28 Drilling Rig from Conrad

CASE CX 800 Demolition from CONRAD

NEW KOMATSU PC8000-11 Diesel from BYMO

KLEEMAN MR 130 Impact Crusher from CONRAD

NEW LIEBHERR PR 776 DOZER from WSI

CONRAD MODELS 1:50 Scale ATLAS 350 MH ........................................................... £122.00 BAUER BG 28 Drilling Rig ........................................... £252.00 KOBELCO SK210lc ...................................................... £102.00 CASE CX 800 Demolition ............................................ £184.00 KLEEMAN MR130 Z EVO 2 Impact Crusher .................. £252.00 BYMO 1:50 Scale KOMATSU PC8000-11 Diesel white .................................. £ 426.00 KOMATSU PC8000-11 Diesel Yellow .................................. £418.00 FIRST GEAR 1:50 Scale NEW JCB 512-83R 1:34 SCALE ........................................... £65.00 KOMATSU D71PX Dozer ..................................................... £85.00 KOMATSU D475A Dozer .....................................................£132.00

WSI 1:50 Scale VOLVO EC220D Excavator .................................................... £88.00 VOLVO DD105 Compactor .................................................... £79.00 LIEBHERR PR 776 Dozer ......................................................£174.00 CCM 1:48 SCALE CAT 6030 Face Shovel ...................................................... £700.00 CAT 6030 Backhoe .......................................................... £700.00 DIECAST MASTERS 1:50 Scale CAT 6060 Face Shovel 1:87 Scale .......................................£136.00 CAT 6060 Back Hoe 1:87 Scale..........................................£136.00 CAT 794 AC Mining Truck ...................................................£245.00 CAT 320F L Weathered Excavator .......................................£108.00

DIECAST CONSTRUCTION

Email: diecastconstructionco@gmail.com We accept most major credit and debit cards. ALL PRICES INCLUDE POST AND PACKAGING FOR THE UK AND NORTHERN IRELAND

PO Box 318, Cirencester, Gloucestershire GL7 9HN Tel: 01285 642432 (afternoons/evenings)

NEW PERKINS ENGINES & PARTS

PLANT AND MACHINERY INSURANCE G From single machines to large fleet G Liability – Road Traffic Act Cover Fire & Theft

Call now for an immediate and competitive quote

200+ new engines in stock

Monthly payment scheme available

Next day nationwide delivery service

01978 758226

Telephone/Fax: www.johnpeers.com Email: john@johnpeers.com Includes FREE year's subscription to Earthmovers to all new insurance policies arranged

Ask for Ryan on 07843 314695 Email: engines@pvdobson.com View engines on www.pvdobson.com

Photo Journalist Wanted Passionate about machinery? Sundial magazines, the publishers of Farm Machinery Journal, Forestry Machinery, Classic Tractor and Earthmovers are seeking the services of a photo-journalist, based in the north east of England, for no-going freelance assignments to construction, demolition, waste processing and quarrying sites. The ideal candidate will have strong photography skills, a passion for any form of off-road machinery and the ability to effectively interact on site with machine operators and their senior management. Although this opportunity is primarily aimed at practicing technical communicators, consideration will also be given to those with other relevant experience, particularly from within the plant and machinery community. Your contributions would be on a freelance basis.

To register your interest send an e-mail – telling us a little bit about yourself and some examples to Paul Cosgrove, Publishing Director at paul@sundialmagazines.co.uk

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TAIL END // PICTURE POST

PICTURE POST

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

arthmovers 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.

KEEP ON TRUCKING

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OF THE

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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.

That’s a fair load over such ground conditions, even for such a heavy-duty truck, delivering one of the smaller components for a mining excavator in West Africa. A reminder of both that winter is approaching and of the time that Volvo made one of the best backhoe loaders in the world. When motor scrapers ruled the earth, mighty machines like this Scottish-built monster were common, particularly constructing UK motorways.

This classic fleet was, appropriately, helping to move rubble for an archaeological dig in the Roman city of Jerash in northern Jordan.

Looking at the latest reducedradius wheeled excavators, machinery designers have come a long way in a relatively short time.

EARTHMOVERS

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The clearing rake for processing tree cuttings and root material ial on the forest floor. • Made of high-strength Hardox® steel. Low maintenance and wear, highly rugged and d durable. • Available in three different sizes. Mountable to all conventional carrier vehicles. • Large amount of material can be grabbed and handled. Maximum capacity thanks to curved shape off the root rake. • Gripper fingers adapt individually to the material material. • optional: Fine rake Easy attachment to Woodcracker ® G. Used for thorough and extensive floor cleaning after processing.

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24.- 30.10 / München

WESTTECH FN. 1115/9

T learn more about the efficient Woodcracker ® forest machines Ħ www.westtech.at