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Rugged machines for loading quarry materials

First publishedin Aggregates Business Europe & International
March April 2015
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Komatsu PC490LC-11 hydraulic excavator
Loading duties for Komatsu Europe International's new PC490LC-11 hydraulic excavator
The processing of aggregates and rock material starts at the drilling and blasting or breaking stage, but such material has to be moved quickly to the processing plant, writes Patrick Smith.

Excavators are usually the equipment of choice to load material from the quarry face onto haul trucks to be taken to crushing and screening facilities, and are also used to carry the breakers and to remove loose material from a quarry face.

Wheeled loaders are also widely used to load haul trucks and can be used to load material directly into a crusher or move it around the quarry, while at some quarries conveyors are in operation to move material around.

Like all quarry equipment, hydraulic excavators, wheeled loaders or conveyors are built to withstand severe quarry conditions, with manufacturers constantly updating and improving models.

In Israel, three large, heavy-duty Hitachi excavators bought by local contractor AD Edan Hadash Earthmoving Contractors help to supply rocks to extend breakwaters as part of the construction project for two new container terminals at the ports of Haifa and Ashdod.

The Hitachi ZX470LCH-5s and a ZX520LCH-5 join an existing fleet of construction machinery at a 170hectare site near Elifelet village, overlooking the Sea of Galilee.

The excavators are used to select and extract the stones from a depth of no more than 3m, after which each area is replenished to its former state. The materials, D rock (1-3tonnes) and C rock (3-6tonnes) are then determined by checking the weight, size and quality, before being transported to stockpiles for the ports.

The site opened in 2013 and the initial order for 200,000tonnes of rock was completed within eight months, but the AD Edan Hadash team is now geared up to supply a capacity of 300,000tonnes/year, with a total quantity of between 7-8 million tonnes to be delivered.
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Hitachi ZX470LCH-5 and ZX520LCH-5 excavators
At work in Israel are the Hitachi ZX470LCH-5 and ZX520LCH-5 excavators
“We are very comfortable with the fact that CMD and Hitachi monitor the machines using Global e-Service. The whole service package gives me the peace of mind to concentrate on other important activities within the business,” says Dan Cohen, company owner.

Some 4,000km to the northeast is County Fife, Scotland, which is home to the Skene Group’s Lomond Quarry, Leslie. Recent company acquisitions include a Volvo Construction Equipment 48tonne EC480DSeries excavator and a new generation L220H-Series wheeled loader (the first H-Series loader sold in the UK), equipped with a 5.6m³ rehandling bucket, and several options, including XMineD2 tyres, auto lube and a boom suspension system.

The loader is rehandling and stocking at Skene’s Soutra Mains Quarry, near Pathhead, County Midlothian, 18km south of Scotland’s capital city, Edinburgh. To gain access to the raw material the overburden is removed by the company’s fleet of excavators, wheeled loaders and haulers. This material is used to landscape the quarry or stored for later site restoration purposes.

The EC480D excavator at the Lomond Quarry has been specified with a 7m boom and 3.25m dipper arm, both heavy-duty variants, and it also has added belly plates and a cab-protecting falling object guard. A refurbished rock bucket owned by Skene is fitted to the excavator, which is feeding blasted dolerite rock into a mobile primary crusher followed by processing through a secondary crusher and screening to produce different stone sizes.

Caterpillar says its new M-Series small wheeled loaders, 926M (operating weight, 13,360kg), 930M (14,264kg) and 938M (16,348kg), build on the success of its K-Series predecessor models, 924K, 930K and 938K, with engineering refinements that include new engines meeting Stage IV emissions standards and new options and features that “further enhance value, operator comfort, and safety.”
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Caterpillar’s 938M wheeled loader
Caterpillar's 938M wheeled loader, one of the models in its new M-Series
Innovative features introduced with the K-Series carry over to the new M-Series family. With the M-Series introduction, the nomenclature for the smallest model in the family changes from 924 to 926, reflecting the increased capabilities of the new model, compared with those of the 924H and 924Hz. All three new models have increased engine power and higher tip loads for improved performance.

A new Cat C7.1 ACERT engine powers the loaders, and Caterpillar says it has a clean emissions module designed to require no operator intervention and causing no disruption of work cycles. The module uses a fit-for-life diesel particulate filter (DPF) and a selective catalytic reduction (SCR) system, which requires only the addition of diesel exhaust fluid. Regeneration of the DPF occurs passively at a low temperature. Cat Product Link, which is said to help lower owning and operating costs, and which offers daily operations support and information for business decisions, is standard.

Other major manufacturers have also unveiled new models including Doosan which has introduced a number of Stage IV-compliant excavators. The flagship DX530LC-5 (51.6tonnes), DX490LC-5 (49.7tonnes) and DX420LC-5 (operating weight from 42.6tonnes) are the company’s largest Stage IV-compliant crawler excavators, “providing significantly improved performance compared to the previous LC-3 Stage IIIB models.” On the DX530LC-5, lifting capacity over the side is increased by 12%, while on the DX420LC-5 and DX490LC-5, the average increase is 5%. The operating weights of the DX420LC-5 and DX490LC-5 have increased by 700kg and 500kg, respectively, while that of the new DX530LC-5 remains the same.

“The new excavators offer the strength and productivity needed for heavy-duty work such as large-scale earthmoving, moving rock, pulling down buildings, secondary breaking, loading haulers and pipeline projects found on quarrying and mining, highway, aggregate, demolition, utility and general construction projects,” says Doosan.

The excavators are powered by Scania engines that meet Stage IV emissions regulations without the need of a DPF, through the use of cooled exhaust gas recirculation (EGR) and SCR after-treatment technologies.
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Doosan’s DX530LC-5 excavator
Doosan's Stage IV-compliant flagship DX530LC-5 excavator
Doosan’s new 30tonne DX300LC-5 Stage IV-compliant crawler excavator has its operating weight increased by 900kg, and this says the company, results in increases in lifting capacities of 1% over the front and 5% over the side, while the company’s new 36tonne DX340LC-5 and 40tonne DX380LC-5 Stage IV-compliant crawler excavators have also seen operating weights increased by 1,300kg and 1,000kg respectively.

Komatsu Europe International’s PC210LCi-10 hydraulic excavator, branded “the world’s first intelligent machine control excavator,” features including stroke sensing hydraulic cylinders for the boom, arm and bucket, the exclusive machine control system means PC210LCi-10 operators are said to no longer need to worry about digging too deep or damaging a target surface.

“This latest Komatsu technology is a revolution in how hydraulic excavators will be used in the coming years” says Mal McCoy, product manager for hydraulic excavators and intelligent machine control products.

“The ability of the PC210LCi-10 to achieve and maintain grade with minimum effort from the operator is awesome.”

With an operating weight of 22.62-23.48tonnes, depending on configuration, the excavator is fitted with Komatsu’s KOMTRAX technology that sends data such as operating hours, fuel consumption, location, cautions and maintenance alerts to the web application for analysis. It is also said to increase machine availability; reduce the risk of machine theft; allow for remote diagnosis by the distributor, and provides a wealth of other information to “drive business efficiency and productivity.”

Komatsu Europe International says its new PC490LC-11 hydraulic excavator, with operating weights between 46,470kg-48,860kg, sees an EU Stage IV Komatsu engine with a net 270kW at 1,900rpm offering up to 11% improved fuel efficiency along with an upgraded cab design and enhanced safety and serviceability.
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Volvo CE new generation L220H-Series wheeled loader
Skene Group's Volvo CE new generation L220H-Series wheeled loader, the first H-Series loader sold in the UK
The new PC240LC-11 has operating weights between 24,700kg-26,200kg, and its EU Stage IV Komatsu engine has a net 141kW at 2,000rpm; up to 6% improved fuel efficiency; an upgraded cab design; and enhanced serviceability.

Kobelco Construction Machinery Europe’s latest specialist excavator to Europe, the Generation 10 Series, replaces the “successful” Generation 9, and is the first Kobelco model to comply with Stage 4 of the exhaust emissions regulations.

For Generation 10 (20tonnes- 35tonnes), Kobelco says fuel efficiency improvements have been realised through regenerative technology.

“Generation 10, for example SK210LC-10, with Stage 4 engine configuration delivers greater performance and efficiency in its working environment when compared to the previous Generation 9 equivalent,” says Kobelco.

“In H-mode (heavy work), work volume increases by 6.7% for the same level of fuel consumption. In S (normal work) and Eco modes fuel consumption is reduced by an impressive 6.1%,” says Peter Stuijt, KCME product marketing manager.

JCB develops remote-controlled excavator

JCB has developed a remotely-operated excavator for Birmingham, UK-based demolition specialists Coleman & Company, which has bought the bespoke 21tonne machine.

Combining a JCB JS190 upper structure with a JS220LC undercarriage and rubber track pads, the result is a machine that can deploy a 4tonne multi-processor attachment without exceeding a gross weight of 25tonnes.

Development of the “ground-breaking machine” required close cooperation between Coleman Engineering Services; dealer Gunn JCB and JCB Heavy Products in Uttoxeter, County Staffordshire, England. The new excavator is working on the redevelopment of Birmingham New Street railway station, removing the existing reinforced concrete floors to create a void beneath the new atrium roof.

The current phase sees the removal of 6,000tonnes of mass reinforced concrete during 2014-2015, with some beams weighing as much as 80-90tonnes.

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