3,000-Mile Road Trip Secures JCB a Spot in The Guinness Book of World Records
The new JCB 3CX Backhoe prepares to take off on its trip across America from Tybee Island, GA.
JCB’s 3CX Backhoe Loader has earned a world record by completing a 26-day, 3,185-mile road trip across America. The epic “Backhoe Across America” fundraising trek beat the existing record for “The Longest Journey in an Excavator” by 600 miles and has secured the company a place in The Guinness Book of World Records.
With JCB veteran Neil Smith at the controls and support from a Backhoe Across America crew, the newly updated JCB 3CX set off from Tybee Island, Georgia on March 26, carrying a bucket of East Coast sand.
After spending 119.5 hours in the cab at speeds averaging 27mph, Smith drove the machine onto the beach at the Santa Monica, California pier on April 20 and dropped off the Tybee Island sand. “It’s been an amazing journey,” Smith said. “The JCB backhoe performed brilliantly, and it has been an incredible way to see the country.”
The JCB backhoe that completed the epic journey features a striking new design that exudes ruggedness and strength. The 3CX model now includes a re-styled counterweight and new vertical grille design offering an even more aggressive feel. The sharper lines on the excavator and loader profiles contribute to the robust look, while the sloping hood retains excellent forward visibility.
In addition to the new styling on the machine, the new 3CX comes with an EcoRoad feature that resulted in 30% fuel savings throughout the Backhoe Across America journey. To further increase fuel efficiency, the new generation backhoes feature an EcoDig system resulting in an average of 15% fuel savings while working in ground-engaging applications.
Along the way, the crew made “pit stops” at JCB dealerships in eight cities to help raise awareness and funds for the American Red Cross Haiti Relief and Development Fund. The fundraising pit stops were the only stops Smith and his crew had to make. The JCB backhoe stood up to the ultimate test of endurance, durability and reliability with no unscheduled service checks.
“I am proud of the team for completing the rigorous journey and for earning a world record,” said JCB Inc. Chairman and Chief Executive John Patterson. “It has been wonderful to see the support we have received not only from this community, but from our dealers and their communities across the country.”
Follow the 3CX journey, watch the daily video logs and see what Neil and his crew encountered on the road by visiting www.JCBforHaiti.
New generation tire in 33-, 35- and 49-inch sizes for mining, construction, quarry sites
The new MICHELIN X-TRACTION tire from Michelin Earthmover Tires will be available July 1 for the North American market. The E4 tire is designed for earthmover transport equipment operating in rocky terrain. Beyond the initial 27.00R49 size now being introduced to North America, additional sizes of the X-TRACTION tire will be available: 24.00R35 (September 2010); 21.00R33 and 18.00R33 (2011).
The MICHELIN X-TRACTION tire was originally available in 2004 outside North America for large mining trucks, and, as of July 1, 2010, will be available in North America for 100-ton mining and infrastructure trucks using the 49-inch E4 size. With the addition of the 33- and 35-inch sizes, Michelin is bringing to the North American market a new generation of the tire specially designed for smaller rigid dump trucks that operate on public works sites, such as construction and infrastructure sites. The tire will also be seen in quarries, where rigid frame trucks are more often used.
“We’re constantly monitoring the North American market’s tire needs in order to provide the industry with the best possible tire performance for the application,” said Roger Lucas, vice president of sales and marketing, Michelin Earthmover Tires. “Expanding the X-TRACTION tire offering into North America and with additional sizes is a prime example of this commitment. The X-TRACTION tire will provide outstanding performance for rigid frame trucks in a wide variety of applications.”
Rigid frame dump trucks face application challenges that require significant tread life and traction levels, as well as sidewall and tread area damage resistance. To help cope with the demands rigid frame trucks face, Michelin has integrated two new technologies into the new generation of X-TRACTION tires. The first feature is the new Cooling System shoulder design and the second is the C2 Technology casing architecture. Together, these innovations reduce heat build-up, thereby enabling trucks to operate continuously at higher speeds.
The new tire features a tread that is up to 13 percent deeper, which extends tire life by up to 15 percent. Thicker under tread rubber improves resistance to cuts and impacts. The new MICHELIN X-TRACTION tire also reduces tire costs because it is easier to retread, owing to the robust tread that helps to protect the casing. The X-TRACTION tire’s casing design helps to reduce fuel consumption by up to 5 percent, saving nearly $4,000 a year in fuel. The fuel saved consequently lowers carbon emissions by an estimated 14.5 tons per year.*
On November 5, 2009, Komatsu America Corp. (KAC) introduced its newest “Green Machine,” the Hybrid PC200LC-8 excavator, into the North American market. This introduction took place at the company’s Cartersville, GA training center. Dave Grzelak, chairman and CEO of KAC, took great pride in introducing the newest addition to the Komatsu line of excavators. Before getting into the company’s history of “greening” its products, Grezlak introduced the Matt Santini, Mayor of Cartersville.
David W. Grzelak, Chairman and Chief Executive Office, Komatsu America Corp.
Grzelak gave attendees an overview of the company’s involvement with hybrid technology and its efforts to make its products more environmentally friendly. Two years ago Komatsu introduced the Sigmadozer blade for the D155 and D275 dozers that increases productivity while fuel efficiency by more than 10%; it also introduced large capacity wheel loaders with larger torque convertors that improved fuel efficiency more than 10%. Komatsu also produces notably efficient thermoelectric modules that can waste heat into electricity and high performance wire saws use to precision cut the silicon wafers that are used to make solar cells. The company also produces diesel electric off highway haul trucks that have haulage capacities of 300 tons.
In 2007 Komatsu introduced a hybrid forklift that uses a similar regenerative electrical energy system via capacitors. There are more than 400 of these currently operating in Japan. These forklifts achieve a 20% reduction in energy use compared to the standard electric powered models.
Grzelak pointed out that the CO2 reducing actions of a Hybrid PC200LC-8 operating 2,000 hrs per year emits 25 tons less than the conventional PC200LC-8. This is equivalent to 591 x 5,000 gallon tanker trucks.
Matt Santini, Mayor of Cartersville GA
Substantial “green” impact
Komatsu’s goal is to meet increasing global environmental concerns through the development of innovative equipment designed to reduce environmental impact, including CO2 reduction. By developing a successful hybrid excavator in the largest construction machine segment (20-22 ton), Komatsu’s green technology will have a substantial impact on saving fuel and reducing green house emissions.
“Komatsu’s decision to apply its engineering excellence to the largest construction machine segment, clearly signals our commitment to developing environment-friendly equipment”, Grzelak says. “Since the company’s inception, Komatsu has been setting the global standard for technology and engineering excellence and today that tradition continues with the introduction of the Hybrid PC200LC-8 excavator.”
Cutting-edge technology
Powered by the Komatsu Hybrid System, the Hybrid PC200LC-8 uses a newly developed electric swing motor, power generator motor, capacitor and diesel engine. Komatsu developed its revolutionary hybrid system to work on the principle of swing energy regeneration and energy storage using the Komatsu Ultra Capacitor system. Komatsu’s Ultra Capacitors provide fast energy storage and instantaneous power transmission.
The kinetic energy generated during the swing-braking phase is converted to electricity, which is sent through an inverter and then captured by the Ultra Capacitor. This captured energy is then discharged very quickly for upper structure rotation and to assist the engine as commanded by the hybrid controller when accelerating under workload conditions.
In tests comparing the standard PC200LC-8 hydraulic excavator to the Hybrid PC200LC-8, the hybrid model reduced fuel consumption by approximately 25-40%, depending on the application.
During the demonstration session of the program, skilled operators, one running the new hybrid machine and the other running a standard version of the same machine went head to head to illustrate the fuel savings potential. The standard machine was operating at a fuel consumption rate of 4.1 gallons per hour compared to the hybrid’s consumption rate of 3.2 gallons per hour. This is around a 47% fuel savings. Both machines were equipped with furl monitoring gauges.
The hybrid is on the left and the standard on the right.
The specs
The Hybrid PC200LC-8 is powered by the turbocharged and air-to-air after-cooled Komatsu SAA4D107E-1 which provides138HP. With an operating weight of 43,643 to 47,260 pounds, the Hybrid PC200LC-8 has a bucket capacity of 0.66 – 1.57 yd3. The Hybrid PC200LC- has the same working forces and performance levels of the conventional PC200LC-8.
The innovative cab design assures operator comfort because the viscous cab damper mounts reduce vibration. A 7” LCD monitor provides easy-to-read gauges and onboard diagnostics as well as displaying the rear-view monitoring system for viewing the work area to rear of the machine.
KOMTRAX on board
The Hybrid PC200LC-8 is also equipped with the latest KOMTRAX technology which sends machine operating information to a secure website utilizing wireless technology. Data such as operating hours, fuel consumption, machine location and machine utilization are relayed to the web application for analysis. The KOMTRAX fleet monitoring system increases machine availability, reduces the risk of machine theft and provides a wealth of other information to drive business efficiency.
The Hybrid PC200LC-8 excavator was introduced to the Japanese market in June 2008, and has been successful in reducing fuel consumption. In addition, Komatsu introduced the Hybrid to the Chinese market in August this year.
Armando Najera explains the inverter, convertor and control assembly on the hybrid.
Komatsu Hybrid Technology
Komatsu Harmony is fundamental in matching the diesel/electric Hybrid system to the hydraulic requirements to provide high productivity with low fuel consumption. The Hybrid controller synchronizes the conventional engine and hydraulic pumps with electric assist to provide a unique operational experience. The more the operator uses the Hybrid technology by swinging and regenerating energy, the greater is the fuel consumption benefit
Hybrid Excavator Energy Flow
The hybrid system drives the upper structure with an electric motor. The electric motor is also used to regenerate energy as the upper structure slows down. Fuel consumption is improved by the ability to use the regenerated energy to assist during high power demands allowing the engine to run at an optimum speed for high efficiency.
Ultra Capacitor for Energy Storage
In construction equipment, the energy demand is high and occurs in a short amount of time. Combined with a high frequency of demand, the electrical energy requirements to operate construction equipment cannot be met with current battery technology.
The “Komatsu Hybrid System” uses an “Ultra Capacitor” to instantaneously store and give off electrical energy efficiently. This capacitor charges and discharges at a much faster rate than the slower chemical reactions that take place in batteries. The instantaneous charging and dis- charging characteristics of a capacitor match the high-energy demand and frequent cycles needed by an excavator.
Swing Motor/Generator
The Hybrid PC200LC-8 uses an electric swing motor that rotates the upper structure and recovers energy during swing braking. A special housing, which circulates cooling water and lubricating oil, further enhances durability.
Inverter (Converter) and Ultra Capacitor
The inverter receives AC energy and converts it to DC energy from two sources:
1. Recovered energy from the swing motor/generator
2. Charging power from the engine’s generator/motor
The converted DC energy from these two sources is quickly stored in the Ultra Capacitor. The stored DC energy is then quickly released and converted to AC to power the swing motor and to assist the engine RPM. A special housing allows cooling water to circulate further enhancing durability.
Generator/Motor
The generator motor is built-in between the engine and hydraulic pump for effective power transmission to the hydraulic pumps. The generator can charge the capacitor during periods when no work equipment or travel operations are used. The generator motor also receives power from the capacitor for engine assist, as commanded by the Hybrid controller.
Energy Management
The machine monitor panel includes a “Hybrid Operation Monitor” screen to display energy flow as the machine operates. The monitor screen can be changed to display status of capacitor charging and discharging and engine assist by the generator/motor as energy flow. The Hybrid controller manages energy flow making it seamless for the operator.
The work equipment is operated hydraulically by energy generated by the engine as in the conventional equipment (red arrows). Swing is driven by electrical energy from the capacitor and generator (yellow arrows).
Energy generated during swing deceleration is regenerated and is stored in the capacitor (green arrows). Some of the regenerated energy assists the engine through the generator/motor and assists work equipment operation.
This article will be appearing in the December issues of all ACP magazines.
Life in the landfill is hard on equipment. The constant pushing of garbage and dirt puts a heavy strain on the hydraulics and drive train of large bulldozers. Compactors take a constant beating to prepare the trash to be covered.
Carlos Pineda is the resident mechanic contracted by Peterson Tractor Co. to maintain equipment at Waste Management’s Fremont, Calif., facility.
It’s a dirty, harsh work environment that’s tough on equipment. And it’s a job that cannot afford any downtime: If the trash isn’t covered by the end of the workday – a legal requirement – no one goes home until it is.
The same can be said about heavy equipment service mechanic Carlos Pineda. The resident mechanic contracted by Caterpillar dealer Peterson Tractor Co. of San Leandro, Calif., Pineda spends every day servicing and repairing these machines at Waste Management’s landfill in nearby Fremont. The tools he uses – air compressors, generators and a hydraulic crane – are typically run from a truck’s Power Take-Off (PTO), which puts wear and tear on its diesel engine and drive train. The PTO requires the truck to constantly idle, a factor that puts a significantly higher number of hours on the truck’s engine compared to just driving it to and from the work site.
Recognizing the need for a better solution to power equipment on a mechanic’s trucks, Miller Electric Mfg. Co. introduced EnPak Mechanic Series, a completely self-contained air compressor, hydraulic pump and generator that runs off its own 27-horsepower diesel engine. This eliminates the need for a PTO on a mechanic’s truck and allows these tools to work without running the truck’s engine. Pineda reports that EnPak has made his truck more fuel efficient, reduced his truck’s engine hours and improved the operating environment around his truck.
A Mobile Workshop
For a heavy equipment mechanic like Pineda, his workshop is completely mobile. The typical mechanic’s truck carries all the other tools required to do the job: impact wrenches, grinders, lights, a computer for diagnostics, etc. Each truck travels to and from the job site daily and then idles all day as the mechanic powers this equipment off the truck’s PTO. With the introduction of EnPak, Pineda has completely changed the way he uses his truck.
Pineda’s service truck is equipped with the EnPak Mechanic Series, a completely self-contained air compressor, hydraulic pump and generator that runs off its own 27-horsepower diesel engine.
“What I like the most about EnPak is that my truck doesn’t run now as I work,” he said. “There’s no wear and tear on my truck. I don’t put a bunch of hours on it just by idling and burning fuel for no reason, polluting the air. EnPak puts out a minimum amount of exhaust, a minimum amount of noise, and it powers all of my components as if the truck was running.”
The primary tool of any heavy equipment mechanic is an air compressor used to run impact wrenches and the carbon arc gouging capabilities of the welder. Pineda claims that EnPak gives him more consistent air compressor performance than the old compressor he ran off the truck’s PTO.
“I like the fact that the air compressor gives me on-demand air,” Pineda explained. “I can run my big heavy guns and not have to wait for the air to build back. With the old system, I could undo one or two fasteners at a time and then would have to wait for the compressor to build air back up. If there are 30 bolts and I have to wait a minute to take each bolt off, that’s a half-hour wasted. EnPak produces such a volume of air that I can run my gun without stopping. It’s very productive.”
EnPak’s rotary screw air compressor is rated at 40 cfm at 100 psi and is constantly able to produce up to 175 psi without stopping. Pineda reports that he can effectively use EnPak’s air compressor and hydraulic pump simultaneously without any lag in power. The variable displacement hydraulic pump (Eaton) is rated at 3,000 psi at 8.5 gpm with a maximum flow of 20 gpm.
“EnPak lets me use both air and hydraulics at the same time without slowing down,” Pineda said. “Sometimes I need to use my crane to support a piece when I’ll be using my impact gun to remove fasteners, and that all comes into play when you are disassembling a large machine.”
Another key tool for any mechanic is a generator. On many mechanic’s trucks, this is accomplished with a welding generator or a stand-alone generator. EnPak eliminates the need for either of these by producing 6,000 watts of power that can run welders and other power tools. It also offers 2,400 watts of pure sine wave EnVerter power (available at all engine speeds) to power items such as work lights, battery chargers and laptops used to check service codes and monitor the operating conditions of a machine.
“I use the generator mostly for running big hydraulic rams or when I need a lot of psi to run a track press,” Pineda said. “It runs the pumps without stopping or slowing down. I use it for my droplights, my drills. I’ve also used it to run a welder.”
Easier to Work, Easier to Operate
Another key benefit of EnPak is a substantially improved operator environment. Mechanics work almost entirely off the back of their trucks. The loud noise of a running truck combined with the noise of running tools and the truck’s exhaust creates a nasty mix of distractions for the mechanic. Tests have shown that EnPak reduces jobsite sound levels by as much as 10 dB, and a vertical exhaust forces fumes up and away from the work environment (in addition to eliminating the truck’s exhaust).
Pineda operates the hydraulic crane on his truck in the Waste Management shop.
“If you’re working around high decibels, it puts a stress level on you that should be avoided,” said Jack Ravazza, general service manager, Peterson Tractor. “I think reduced noise can have a big effect on the performance of a technician. The better environment, the more productivity he is going to have.”
EnPak’s integrated control design also makes life easier on Pineda by providing all of the controls he needs right at the back of the truck.
“The EnPak remote panel lets me start all the functions from the back of the truck without having to go and climb into my cab, turn the PTO on, then climb back out and start working. I can just go right to the back panel, start the component and I’m ready to work.”
The remote panel also monitors, operates and provides diagnostics for engine and air compressor functions such as fuel usage and engine rpm. And Pineda didn’t have to learn any new controls as the integrated design allows him to use the crane remote he is already familiar with.
“Within five minutes I was running EnPak and all my tools like nothing had changed,” he recalled.
EnPak is completely integrated into the fuel and electrical systems of Pineda’s truck. Now he only has one tank to fill up in the morning compared to the two tanks he used to fill up every day (truck and engine-driven welding generator). Because it runs with the truck turned off, it lowers fuel use by as much as 30 percent and can reduce truck engine hours by as much as 60 percent. It also features Miller’s EnPower technology, which adjusts engine speed to match compressor and hydraulic load requirements, so that Pineda’s truck only burns as much fuel as necessary for the job.
“I can honestly say that I hardly see any fuel use,” said Pineda. “I can start out with a quarter-tank of fuel in the truck, run EnPak for two or three hours, and the needle on the fuel gauge hasn’t moved. It’s very fuel-efficient. And with the truck shut off, there’s not any hours being put on the engine or the transmission. That extends the life of the component two or three times longer than if you had to run them all the time.”
Ravazza – whose job it is to make sure Peterson Tractor’s customers’ needs are being met both through tooling and manpower – sees an obvious value to the reduced wear on the truck and the savings it provides equipment service departments.
“Our truck idling time to run tools is close to 50 percent,” he said. “Eliminate that and you’ll have substantial savings on truck engine life and fuel. And it will help us meet the ever-tightening emissions regulations on idling trucks put in place by California.”
Note: This article appeared in the September 2009 Issue of California Builder & Engineer, an ACP magazine.
Grzelak, chairman and CEO of KAC, took great pride in introducing the newest addition to the Komatsu line of excavators. Before getting into the company’s history of “greening” its products, Grezlak introduced the Matt Santini, Mayor of Cartersville.
Ultra Capacitor for Energy Storage
The “Komatsu Hybrid System” uses an “Ultra Capacitor” to instantaneously store and give off electrical energy efficiently. This capacitor charges and discharges at a much faster rate than the slower chemical reactions that take place in batteries. The instantaneous charging and dis- charging characteristics of a capacitor match the high-energy demand and frequent cycles needed by an excavator.
Swing Motor/Generator
Inverter (Converter) and Ultra Capacitor
Generator/Motor
Energy Management
This article will be appearing in the December issues of all ACP magazines.
EnPak’s rotary screw air compressor is rated at 40 cfm at 100 psi and is constantly able to produce up to 175 psi without stopping. Pineda reports that he can effectively use EnPak’s air compressor and hydraulic pump simultaneously without any lag in power. The variable displacement hydraulic pump (Eaton) is rated at 3,000 psi at 8.5 gpm with a maximum flow of 20 gpm.