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November 2003 SAE OHE 21

This month’s editorial focus is on construction vehicle technology.

by David Alexander

In the pursuit to build reliability into its rough terrain(RT) mobile hydraulic cranes, Grove Worldwidecollaborated with HED Inc. for a controlled areanetwork (CAN) solution to manage operations andinformation while maximizing performance. Amongother goals, Grove was seeking to incorporate “smart”engine technology, decrease the number of slip ringsbetween the superstructure and the carrier, andeliminate some wiring and traditional control relays.

“We wanted to purchase a standard controller,rugged enough to handle the off-road environ-ment our cranes operate in on a daily basis,” saidSid Shreiner, Lead Electrical and Control Engineerfor Grove.

The RT9130E is the largest RT-style crane Groveproduces. The equipment has 160 ft (49 m) ofmain boom, and another 119 ft (36 m) of latticeextension, giving the crane an overall tip height of279 ft (85 m). The 130-ton (118-t) crane ispowered by a Cummins QSC 8.3-L, 300-hp (224-kW) engine that delivers 1000 ft•lb (1356 N•m) at1300 rpm. The outrigger system comprises fourhydraulic-telescoping single-stage double-boxbeams with inverted jacks and integral holdingvalves. The outrigger boxes are removable for easeof transportation, as is the hydraulically installedand removed counterweight with a mass of 40,000lb (18,150 kg).

HED provided two microprocessor modules fromtheir CANLink multiplexed family of controls; theCL-404 mounted in the chassis/carrier and the CL-403 in the superstructure/ turret.

The CL-403 has 41 inputs to process commandsfrom the operator’s cab. The 21 outputs sendinformation to the dashboard standard digitalgauges and operate cab comfort features. In thechassis, the CL-404 has 40 outputs that control thetransmission, outriggers, steer valves, and thelighting package. The module has a total of 13inputs to monitor a variety of functions, largelyhandling registered SAE J-1939 messages from theCummins electronic control unit (ECU), conveyinginformation from the diesel such as engine diagnos-tics, oil temperature, engine pressure, and rpm. Themodule translates these messages and sends theinformation to the dashboard indicators. The drive-by-wire technology on this engine enables reducedemissions and greater operator control.

The two modules have a peer-to-peer interrela-tionship, in which information is shared via atwisted pair of wires. Along with managing signals,the programs contained on the modules provide

controls to protect components and equipment onthe crane. The modules also maximize the benefitsof the ECU for the engine, commanding themachine to operate within set parameters.

The slip rings lie in the path between the twomodules. These modules significantly reduce the wiresdedicated to operating or monitoring each componenton the crane. As a result, the RT-9130E has just 10 sliprings vs. more than 75 needed for a traditional system,making the operation more reliable, and easier tomanufacture and service.

To increase service efficiency, HED provides itsdiagnostic tool software, which Grove makes availableto service reps and dealers. A laptop connects to a porton the modules. Using the software, technicians canquickly pinpoint if a light going out is in fact the lightbulb, or a break in a wire leading to or from themodule. Diagnosis that used to take an hour or morecan happen in minutes.

As part of an upgrade to new Cummins QSC-series engines, Groveincorporated CAN technology into its RT-series cranes to providegreater control and maximize performance. The 130-ton (118-t)capacity RT9130E crane is the largest in the series, and offers amaximum tip height of 279 ft (85 m).

Grove and HED team builds reliability

These solid-state CANLinkmodules from HED havereplaced a number ofcomponents used onprevious Grove RT-seriescranes, providing greaterreliability and morepowerful servicediagnostics.

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22 SAE OHE November 2003

The diagnostic tool works by finding modules on the systemand displaying their status on the monitor screen. If a modulestate is in the “OK” mode, the user can click on the module toopen a module viewer. This viewer displays all the information

about the module’s inputs and outputs. Several viewers can beopened at a time to see if modules are working together. Usingthe debug mode, the tool can manipulate the inputs andoutputs of the CANLink modules during run time.

Compact Vermeer breaks groundVermeer Manufacturing Co. has added the CX218 and theCX219z to its recently introduced line of compact excavators.With a mass of 3750 lb (1700 kg) and measuring 3.3 ft (1 m)wide, the CX218 features 8.9 ft (2.7 m) of reach, a diggingdepth of 7.8 ft (2.4 m), bucket breakout force of 3310 lb(14,720 N), and a Kubota D1005-E diesel engine that puts out18 hp (13.4 kW) at 2500 rpm. The maximum digging height is11.4 ft (3.5 m) with a dumping height of 7.9 ft (2.4 m). Theability to swing the boom independently of the upper structureadds expanded versatility, allowing the excavator to work insmall confines and against physical barriers. The boom can swing55° left and 80° right.

The CX219z has a mass of 3970 lb (1800 kg) and is 3.3 ft (1m) wide. It has the ability to dig to a depth of 8.3 ft (1.5 m), 12.4ft (3.8 m) of reach, and the bucket breakout force is 3300 lb(14,680 N). The power is drawn from the Kubota D 722-E dieselengine that supplies 14.3 hp (10.6 kW) at 2500 rpm. Themaximum digging height of the CX219z is 11.4 ft (3.5 m) and ithas a dumping height of 7.8 ft (2.4 m). The machine has the

The Vermeer CX218 features a Kubota diesel engine, independent-swing boom, and extendable tracks.

ability to swing up to 50° to the left and 85° to the right. Unlikethe other six compact excavators in the Vermeer lineup, theCX219z has a zero tail-swing feature, which means that there isno overhang, enabling the excavator to fit into and maneuverthrough smaller spaces.

The CX218 and CX219z both feature variable-width tracksthat can adjust from 40 to 51 in (1015 to1300 mm) for conve-nient transport and increased stability. Auxiliary hydraulics forattachment add-ons, SAE/ISO controls, and working lights arestandard equipment. The compact excavators also feature top-mounted boom cylinders and complete bi-directional auxiliaryhydraulics. Short-lever hydraulic pilot joystick controls delivercomfort and operational responsiveness, with a choice betweenbackhoe- and excavator-style controls available with the flip of alever. The excavators come equipped with a standard canopy,and a heated cab is optional.

The CX219z is thefirst Vermeer

compactexcavator to offerzero tail swing for

productivity inconfined spaces.

Caterpillar paves the wayThe latest asphalt paver from Caterpillar, Inc. is the AP-655C,featuring dual operator stations, Mobil-trac undercarriage,and a hydrostatic drive system that eliminates mechanicallinkages. With an operating mass of 18,500 kg (40,800 lb)contained within an 8 ft (2.4 m) width, it is possible to movethe machine from job to job in a single day without the needfor extra-width transport.

Power comes from the Cat 3056E ATAAC (air-to-air after-cooling), turbocharged, six-cylinder, 5.98-L diesel engine thatmeets both EPA and CARB emissions engine regulations. At2200 rpm the engine is rated at 130 kW (174 hp).

The engine compartment is lined with noise-suppressioninsulation to reduce sound levels. The maximum operatorsound pressure level measured is 85 dBA. The spectator sound

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pressure level for the standard machine measured at adistance of 15 m (50 ft), 85% maximum fan speed, and 2250rpm is 72 dB(A). These sound levels are further reduced inactual operation by the electronically controlled on-demandvariable-speed cooling fan.

The hydrostatic drive system eliminates chains and othermechanical linkages between the diesel engine and final drivecomponents. The closed-loop system incorporates pave,travel, and maneuver modes. A speed-control system main-tains preset paving speeds throughout a job. A propulsioncontroller provides accurate control of both the steering andpropulsion systems, assuring straight-line tracking. The drive

system consists of dual-path hydro-static pumps and two fixed-displace-ment motors, one pump and onemotor for each side of the machine.The pumps are controlled by theoperator and are infinitely variablewith electronic displacementcontrols. The motors drive two-speedplanetary gearboxes to provide twopropel ranges: paving 2 to 75 m/min(7 to 246 ft/min), and travel 0 to13.6 km/h (0 to 8.5 mph).

The high-speed Mobil-tracundercarriage consists of a durable,high-strength rubber belt with athick outer cover that includes fiveinternal layers of flexible steel cable.The track is 3025 mm (119 in) longand 405 mm (16 in) wide. Drivetraction is provided by a hydraulictensioning cylinder that maintainsfriction between the belt and thedrive wheels. The fully bogiedundercarriage with even weightdistribution over the entire length ofthe belt provides a smooth ride andhigh tractive efficiency. The paverframe is fabricated from heavy gaugesteel and tubing to optimize spaceand is designed for maximumloading conditions.

A closed-loop hydrostatic systemprovides dynamic braking. Thespring-applied/hydraulically releasedbrakes are located within the trackfinal drives. The parking brake is

actuated through a switch located on each operator station.The parking brake is also activated when the engine is in theoff position and when the main disconnect switch is in theoff position.

”Electric-over-hydraulic” dual-path differential steeringassures precise machine control, and is independent of thepropel speed. Steering modes are selected by the Pave/Travel/Maneuver switch. The machine’s steering range is automati-cally adjusted for each of the three modes. When in the paveor travel mode, the steering range is electrically reduced toprovide smooth steering movements. Minimum turningradius, measured at the inside track when in pave mode, is

The AP-655C paver from Caterpillar hasdual operator stations that can bemoved into four different positions.

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approximately 305 mm (12 in). When in maneuver mode, thesteering is at full range, allowing the paver to pivot-turn bycounter-rotating the tracks.

The AP-655C has a 24-V electrical system using two 12-Vbatteries and a 70-A alternator. The wiring is color coded andnumber impregnated for easy servicing, and is protected byvinyl-coated nylon braiding for greater durability. All circuits tie toa main junction box with circuit breakers that can be reset.

Dual operator stations are provided with suspension seats.Both stations swing out for improved visibility. The centerconsole instrumentation includes analog gauges supplementedby an information display that alerts the operator to items of

concern. All of the analog gaugesexcept paving speed are monitored byan alarm system that will alert theoperator to a potential problem.

A ventilation system helps removeasphalt fumes from the area, consist-ing of inlet vents in the auger chamber,a hydraulically driven exhaust fan, andan exhaust stack to vent fumes awayfrom the operator and screed areas.

Large doors and panels give accessto all service areas. Transverse enginemounting provides ground-level accessto hydraulic pumps and the engine-cooling system, and lubrication fittingsare clustered for quick service.Propulsion and material controllersprovide machine diagnostics for rapidtrouble-shooting of the hydraulic andelectrical systems.

The Caterpillar3056E six-cylinder dieselengine isturbochargedwith air-to-airaftercoolingand iselectronicallycontrolled forimprovedperformanceand loweremissions.

The Caterpillar Mobil-tracundercarriage is designedto give even weightdistribution, smooth ride,and high traction.

Hamm smoothesthe pathHamm Compaction Division’soscillatory compaction technology hasbeen introduced to the North Ameri-can construction market. The designa-tion HD O90V signifies a hybridroller—based on the Hamm HD 90platform—in which the front has aconventional vibratory drum, and therear incorporates the oscillatorytechnology. The Hamm Division ofWirtgen America Inc. is the onlymanufacturer to offer such a system.

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Vibratory compactors now accountfor the majority of all compactionequipment sold worldwide. Firstdeveloped in the late 1950s, traditionalvibratory compactors use an eccentricdrive within the drum. Rotated athigh speed, this causes the drum tovibrate, generating centrifugal forcesfrom the drum to be passed downinto the ground.

The oscillatory system is different. Inthe oscillation drum, two masses turningin the same direction cause a movementaround the drum axle. The movementchanges its direction of effect duringone turn so that it generates anoscillating or rocking movement of thedrum. This causes horizontal forces to betransmitted from the drum into thepavement.Unlike traditional vibratorycompactors that achieve compaction by“bouncing” the drum on the ground,Hamm’s oscillatory system ensures that

the roller drums maintain constantcontact with the ground for faster, moreeffective compaction. The companyclaims the result is better compaction infewer passes, less vibration-related wearand tear on operators and surroundings,significantly longer machine life, and theadded ability to compact at lowertemperatures.

Achieving the optimal designeddensity level in hot mix asphalt requiresprecise control in the target densityrange (typically 95 to 96%). On manyoccasions, conventional eccentric/vibratory machines will “break-over” or“over-compact” in this critical targetarea, during which control over thecompaction process may be nearlyimpossible to achieve with the use ofconventional vibrating machines in theintermediate and finish position.

In recent North American compara-tive tests (performed by Hamm) of anoscillation compactor against a vibratorycompactor with a conventional circular(multidirectional) exciter system, theHamm oscillatory machine achieved therequired relative density in fewer passesthan the other machines. Furthermore,while additional passes of the Hammoscillatory machine produced additionalcompaction density, the other machinesactually produced a decline in compac-tion density from the third pass on.

The oscillatory action can be used inlower temperature ranges without thefear of cracking the mat, unlike themore violent action generated by atraditional vibratory compactor. Whenusing a circular or directed exciter systemin an asphalt compaction application,over-compaction can result in the grainfragmentation of the stone, which doesnot happen with oscillatory compaction,according to Hamm.

The reduction in transmitted vibrationalso helps reduce wear on the machineand improves the working environmentfor the operator. Machine noise levels,both externally and at the operator’sstation, are significantly reduced, as arethe vibration levels felt within theoperator’s working area.

Oscillatory compaction provides themachine operator with more controlover the type and degreeof compaction. For even greaterflexibility, the oscillation systemcan be combined with a conventionalvibration system in a singlemachine. The operator can selectthe frequency and amplitude bestsuited for compacting the material.

Hamm’s oscillatory compaction systemkeeps the drums in constant contact withthe surface for faster, more effectivecompaction with no bouncing or ridges.

The HD O90V from Hamm features aconventional vibratory drum at the frontand an oscillatory drum at the rear, whilethe HD 90 is an all-vibratory model.

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Long reach digging from KomatsuWorking in congested or confined areas canbe a challenge, which is addressed by thePC138USLC-2 from Komatsu. Based on thePC120LC-6, the new machine aims to provideall the functionality of its standard-sizedcounterpart, with the benefit of almostno overhang.

The PC138USLC-2 gets its power from theturbocharged Komatsu S4D102E-1 four-cylinder, water-cooled engine. Output is 64kW (86 hp) at 2200 rpm, and the enginemeets emissions regulations, including CARBand EPA. An aluminum oil cooler helpsmaintain heat balance without increasing thefan speed, which contributes to reducednoise levels.

Raising the boom on the PC138USLC-2 toa wider angle enhances overall workingperformance. Job sites that require a longupper reach, such as demolition and slopecutting, also benefit from the increaseddigging and dumping ranges. The excavatorhas a bucket digging force of 78,000 N(17,530 lb) and an arm crowd force of 54,500 N (12,240 lb),facilitating the digging of hard rock-bed.

The PC138USLC-2 employs a new convex shape, largesize cab that was designed to provide a comfortableoperating environment. The multi-position, pressure-

The Komatsu PC138USLC-2 near-zero tail swing allows operation in confined worksettings that are inaccessible to standard machines.

proportional control levers allow the operator to work incomfort while maintaining precise control. A double-slidemechanism allows the seat and controllers to move togetheror independently, allowing the operator to adjust formaximum productivity and comfort. The rear window slides

open for extra ventilation.Komatsu’s low noise design uses

a partition between the cab and theengine compartment to reduce noiselevels to 72 dB(A) at the operator’sear. The cab rests on viscousdamping mounts to reduce vibrationand noise transmission.

The sliding convex door provideseasy entrance in confined areas andreduces the danger of beingdamaged on roadways because thedoor does not protrude when open.The door opens along the exteriorcurve of the cab rather than swing-ing out on hinges.

The new excavator featuresKomatsu’s advanced diagnosticsystem that identifies maintenanceitems and reduces diagnostic time.And Komatsu designed thePC138USLC-2 to have easy serviceaccess. With the left and right sideservice doors it is possible to accessthe major maintenance points fromground level. The fuel drain valve,engine oil filter, swing machinery oilfiller, and PTO oil filler are remotemounted. The new hybrid element inthe hydraulic circuit filter extends theelement replacement interval to 500h and the hydraulic oil replacementinterval to 5000 h.

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Simplified control for Dressta wheel loadersThe updated range of wheel loaders fromDressta—the 510E, 515E, and 520E—featureseveral performance enhancements, and arestyled tilt-open engine enclosure that givesimproved access for servicing. Included on allmodels is a single lever equipment controljoystick, giving the operator fingertip control ofthe bucket and boom.

The electric-controlled transmission has alsobeen improved by replacing the two levers onearlier models with a single lever mounted on the

left of the steering column. Movingthe lever forward or backward fromneutral engages forward or reversegear, and rotating the lever selectstransmission range 1, 2, or 3. Abutton controls the downshiftfunction.

Hystrostatic steering is anothernew feature that provides smoother,more responsive maneuvering withthe articulated frame. Maximumarticulation angle is 40° right or left.Four-wheel drive is standard, with afixed front axle and the rear axle ableto oscillate by 24° for the 510E and515E, and by 30° for the 520E.

The 510E has an operating mass of7800 kg (17,200 lb) and is poweredby a Komatsu S4D102E-1 four-cylinder, turbocharged diesel enginethat delivers 77 kW (103 hp) netflywheel power at 2500 rpm, andtorque of 397 N•m (293 lb•ft) at1500 rpm. Bucket capacity is 0.96 to1.53 m3 (1.25 to 2.0 yd3).

The 515E has an operating massof 8790 kg (19,400 lb) and ispowered by the Komatsu S6D102E-1 six-cylinder, turbocharged dieselengine that delivers 90 kW (120 hp)at 2500 rpm, and 499 N•m

The 515E wheel loader from Dressta now has a single lever joystickfor control of the bucket and boom.

The largest of the updated wheel loaders from Dressta is the 520E,which has a bucket capacity of up to 2.3 m3 (3 yd3).

(368 lb•ft) at 1600 rpm. Bucket capacity is 1.34 to 1.91 m3

(1.75 to 2.5 yd3).The largest of the new machines, the 520E, has an operat-

ing mass of 10,400 kg (23,000 lb) and is powered by anuprated Komatsu S6D102E-1 six-cylinder, turbocharged dieselengine that produces 106 kW (142 hp) at 2500 rpm, and 561N•m (414 lb•ft) at 1600 rpm. Bucket capacity is 1.53 to 2.29m3 (2.0 to 3.0 yd3).

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Dumb robot from Halo is smart

The Halo H-30automated

concrete-handling

robot canmanage loads

of 30,000 lb(13,600 kg)

with a singleoperator.

Douglas Jatcko, President of Halo, Inc., has a different view ofthe future of robots than many others in the robotics industry.“Rather than spending resources trying to make robots dothings that humans do, why not focus on creating robots toperform actions well beyond the realm of human capabilities?”he said. “Many of the tasks performed by the latest robots arecool but irrelevant.”

Halo has developed equipment capable of handling loads of30,000 lb (13,600 kg) or more. The current model of themultitasking robot is specialized for the precast concrete industry,and handles tooling, manufacturing, stocking, and deliveryloading. The machine provides automated high-volume produc-tion of concrete vessels and building products such as electricalequipment vaults, storm water inlets, and tunnel sections.

The mechanized drive unit can be programmed totransport and arrange inner and outer forms to prepare for

Upgraded Yanmar excavatorThe ViO75 mini-excavator from Yanmar Diesel America Corp.includes a standard hydraulic quick-coupler system thataccommodates most manufacturers’ buckets. To enable the useof additional hydraulic attachments, the PTO is piped to theend of the arm. Left and right boom swing allows diggingstraight trenches against walls, and a large dozing blade addsstability. The cab, boom bracket, and tail all swing within thetrack width for operation in tight spaces, for a true zero tail-

The Yanmar ViO75 mini-excavator features a hydraulicquick-coupler system and truezero tail swing.

The Yanmar 4TNE98diesel engine that

powers the ViO75 has“Clean & Silent” engine

technology.

concrete filling. After curing, the drive unit can lift eachform containing the finished product, and rotate it so theproduct is properly positioned. Finally the robot will trans-port and release the product at the stockpile or it can beinstructed to load a delivery vehicle.

swing. The boom features a recessed work light to preventunwanted damage.

Power for the ViO75 comes from a Yanmar 4TNE98 four-cylinder, direct-injection diesel engine that is rated at 55 hp (41kW) at 1900 rpm. The engine features Yanmar’s “Clean &Silent” technology, which registers 66 dB(A) at 23 ft (7 m) and isEPA emissions-certified compliant. At 1900 rpm, the hydraulicPTO produces 34 gal/min (129 L/min) at 3000 psi (20,600 kPa).The three-pump hydraulic system—two of which are variabledisplacement pumps—maintains straight and accurate travelspeed even when other hydraulic functions are being operated.

The cab features cup holders, pedal guard covers, and anewly designed instrument panel. A forward-angled overheadroof window provides extra visibility for safer overhead bucketmanipulation. The operator platform is 30% larger than theViO70 it replaces.

With steel tracks the Yanmar ViO75 has a mass of 17,640 lb(8000 kg), and with rubber tracks it is 17,530 lb (7950 kg).Maximum digging depth is 175 in (4445 mm).

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