Excavator

Moving The Earth: The Workbook of Excavation Sixth Edition

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The definitive guide to earthmoving and machines--fully updated</h4>
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"The most comprehensive source of basic excavation information available." -- Construction Methods & Equipment</div>
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"The down-in-the-dirt standard work for the excavation industry." -- Military Engineer</div>
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Completely revised throughout for the latest methods, equipment, and regulations, Moving the Earth,Sixth Edition is the industry-standard source of practical expertise for the excavation and construction industries. This all-inclusive workbook covers every aspect of site preparation and management, and details every machine and vehicle needed to perform each task.</div>
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The Sixth Edition includes new information on international developments in earthwork construction, updated OSHA excavation safety standards, and both SI and U.S. customary units. Detailed and comprehensive, this practical, on-the-job guide is as indispensable as your hard hat.</div>
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I ordered the latest edition of this book for my husband, who had spent hours studying the previous one. Whether you're operating a dozer or an excavator, or even a Bobcat; transplanting trees, landscaping, making stock ponds or building roads... this is a valuable reference.</div>
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Moving The Earth: The Workbook of Excavation Sixth Edition

The definitive guide to earthmoving and machines--fully updated "The most comprehensive source of basic excavation information ava...

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Battery - Clean /recycle/Battery Hold-Down - Tighten

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Clean the battery surface with a clean cloth. Keep the terminals clean and keep the
terminals coated
with petroleum jelly.
Install the post cover
after you coat the terminal post with petroleum jelly.<o:p></o:p></div>
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Always recycle a battery. Never discard a battery.<o:p></o:p></div>
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Always return used batteries to one of the following locations:<o:p></o:p></div>
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•   A battery supplier<o:p></o:p></div>
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•   An authorized battery collection facility<o:p></o:p></div>
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•   Recycling facility<o:p></o:p></div>
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Tighten the hold-downs for the battery in order to prevent the batteries from moving during machine operation.<o:p></o:p></div>
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Battery or Battery Cable - Inspect/Replace</div>
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Personal injury can result from battery fumes or explosion. Batteries give off flammable fumes that can ex- plode. Electrolyte is an acid and can cause per- sonal injury if it contacts the skin or eyes. Prevent sparks near the batteries. Sparks could cause vapors to explode. Do not allow jumper ca- ble ends to contact each other or the engine. Im- proper jumper cable connections can cause an ex- plosion. </div>
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Always wear protective glasses when working with batteries.</div>
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1.    
Turn the engine start switch key to the OFF position. Turn all of the switches to the OFF position.<o:p></o:p></div>
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2.    
Turn the battery disconnect switch to the OFF position. Remove the key.<o:p></o:p></div>
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3.    
Disconnect the negative battery cable at the battery.</div>
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4.     Disconnect the positive battery cable at the battery.<o:p></o:p></div>
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5.    
Disconnect the battery cables at the battery disconnect switch. The battery disconnect switch is connected to the machine frame.<o:p></o:p></div>
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6.     Make necessary repairs or replace the battery.<o:p></o:p></div>
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7.     Connect the battery cable at the battery disconnect switch.<o:p></o:p></div>
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8.     Connect the positive battery cable of the battery.<o:p></o:p></div>
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9.     Connect the negative battery cable of the battery.<o:p></o:p></div>
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10. 
Install the key and turn the battery disconnect switch to the ON position.<o:p></o:p></div>
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Battery - Clean /recycle/Battery Hold-Down - Tighten

C l e a n t h e ba t te ry s u r fa c e w it h a c l e a n cl oth . K ee p the t e r m i na l s c l e a n a n d k e e p th e ...

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Air Conditioner/Cab Heater Filter (Recirculation) - Inspect/Replace Caterpillar

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An air recirculation filter element plugged with dust will result in decreased performance and service life to the<o:p></o:p></div>
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air conditioner or cab heater.<o:p></o:p></div>
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The air conditioner filter is located on the lower left side of the cab behind the seat.</div>
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1. Slide the operator seat forward.</div>
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2. Slide the filter element upward.</div>
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3. Tap the air filter in order to remove the dirt. Do not use compressed air to clean the filter.</div>
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4. After you clean the filter element, inspect the filter element. If the filter element is damaged or badly contaminated, use a new filter element. Make sure that the filter element is dry.</div>
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5. Install the filter element.</div>
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Air Conditioner/Cab Heater Filter (Recirculation) - Inspect/Replace Caterpillar

NOTICE A n a i r r e ci r c u l at i o n f i l t e r e l e me n t pl u gg e d w i t h du s t w i l l r e s u l t i n d e c r e...

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Introduction of PC200-8 Hybrid Hydraulic Excavators

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A goal has been set to make a contribution to society in challenging global warming, especially to reduce 
  the emissions of CO2, by developing a hybrid system that drives the swing device of a hydraulic excavator by 
electric drive, to significantly reduce fuel consumption.   Reductions in emissions of greenhouse gases are not 
making satisfactory progress and regulation of the construction industry is also expected to become stricter in 
the future. Under such circumstance, provisioning of products that promise lower fuel consumption to the 
customers will win customer satisfaction, leading to activation of the market. 
This introduction of product explains the outline of the sales of Komatsu’s PC200 hybrid hydraulic excavator series starting this spring aimed at an accomplishment of this goal. 
 
Key Words: Hydraulic excavator, Swing device, Electrically driven, Hybrid, Fuel consumption reduction, 
Capacitor 
 
 
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2.  Low Fuel-consumption Technology of<o:p></o:p></div>
 
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Hydraulic Excavator<o:p></o:p></div>
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The
energy flow in typical work of a hydraulic
excavator is illustrated in Fig. 1.   
According to this flow, 13.3% of energy is
extracted as effective work and the rest is generally dis- carded as heat loss.   During
this process, the engine output is entirely converted into hydraulic energy in the hydraulic
excavator and is distributed to each actuator. 
 Energy conver- sion  losses  are  generated  between  the
 engine  and  pump. Losses due 
to  pressure loss  and  other losses are  generated
when  pressurized oil  is  distributed.    Furthermore, potential and kinetic energy of the work equipment and upper structure is converted into a meter out loss of the hydraulic system and is calculated as a loss. 
 Compared with this, the hybrid system
drives the upper structure by an electric motor, reduces energy conversion
and transmission losses and regenerates
kinetic energy of the upper structure. 
 A dramatic reduction in fuel
consumption
reduction can be seen by optimally matching the depression effect of engine output thus obtained on an engine fuel consumption map.</div>
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3.  Overview of Hybrid Hydraulic Excavator<o:p></o:p></div>
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(1) Full view of hydraulic excavator<o:p></o:p></div>
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A full view of Komatsu PC200-S Hybrid Hydraulic Excava- tor is shown in Fig. 2.   The only difference
in appearance compared with the base machine is the sticker, as the additional components required
by the hybrid system are housed inside the existing space.</div>
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(2) Hybrid system<o:p></o:p></div>
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The hybrid hydraulic excavator consists of a swing electric motor, dynamo motor, inverter, capacitor and other compo- nents.  
 Energy that  is  generated during deceleration
of  the swing electric motor when turning of the machine
body decelerates is recovered as electric energy and stored in a con- denser called a “capacitor.”   This energy is reused through the inverter during
turning and is also used as assist energy during
engine  acceleration  in  excavation
 work.    As  a  result,  the engine revolution
speed can be kept low also during idling to
reduce fuel consumption. 
 One characteristic of the “Komatsu Hybrid System” is the use of a “capacitor” to instantaneously store and discharge electric
energy efficiently.</div>
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(3)
Hybrid components</div>
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(a)
Dynamo motor</div>
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 The dynamo
motor is built in between
the engine and hydraulic pump, to dramatically enhance
the transmission effi- ciency
to the hydraulic pump.   Electricity is efficiently gener- ated while the engine is idle and supplements
storage of electricity in the capacitor.<o:p></o:p></div>
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<div class="WordSection1">

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(b) Swing motor</div>
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An
electric motor that recovers
energy during swing decel-
eration was developed.   The efficiency of the electric motor during
acceleration is higher compared with the hydraulic motor, demonstrating smooth turning performance. 
 Circula- tion of lubricating oil and cooling water for the electric motor
is facilitated by a special
case, which was developed for the
hybrid hydraulic
excavator.   A
special decelerator was also developed to meet high-speed operation, which is characteristic of the electric
motor.<o:p></o:p></div>
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(c)
Inverter and capacitor<o:p></o:p></div>
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An inverter that integrates a booster, as well as a
capacitor, is compactly installed on the vehicle.   The reliability of each
component is assured by installing a special water cooling device. 
 A capacitor that can charge and discharge by migra-
tion of electrons and ions is installed as a condenser.   Charg-
ing and discharging in
a short time is therefore possible
compared   with   batteries   that   require 
 chemical   reaction,
enabling  frequent
 engine
 speed  variations  of  construction<o:p></o:p></div>
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machinery.<o:p></o:p></div>
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Theoretically,
the inverter and capacitor
are free of heat
generation and deterioration,
enabling long life and mainte- nance-free care.<o:p></o:p></div>
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(d)
Capacitor<o:p></o:p></div>
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A capacitor was installed
as a device to store the electricity
of  energy  regenerated
 by
 turning.  
 Automobiles  with  ad- vanced hybrid technology require a large amount of electric
energy during starting acceleration
and then run at a relatively
stable engine speed.   Therefore, batteries are installed in
automobiles as electricity storage equipment.   Compared
with automobiles, frequent
engine speed variations in a short time are caused with construction machinery by such as digging
work, etc. and a capacitor
was
installed to follow and assist in this frequent engine speed changes.<o:p></o:p></div>
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The
batteries installed in automobiles
involve a chemical
reaction and much time is required
for charging and discharg- ing. 
 An adequate assist therefore cannot
be obtained, while the capacitor efficiently recovers and stores regenerative power and instantaneously discharges electricity.<o:p></o:p></div>
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(4)
IT technology<o:p></o:p></div>
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The
hybrid machine is installed
with a “hybrid operation
monitor” to assist ecological operation.<o:p></o:p></div>
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(a)
Energy-saving navigation system<o:p></o:p></div>
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Fuel consumption during the most-recent five minutes is dis-
played by a bar graph in the center of the monitor
screen installed in the operator seat, to assist and encourage
eco opera- tion  by  the  operator.    The  screen
 can
 be
 changed  to  also
display fuel consumption data of the most recent one hour, 12
hours, one week and one month.<o:p></o:p></div>
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(b)
Energy monitor<o:p></o:p></div>
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The monitor screen can be changed to
display status of capacitor charging and discharging and
engine assist by the dynamo motor as an energy flow.<o:p></o:p></div>
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The components of the system and flow of energy among these
components are displayed on the screen in the following
color codes.<o:p></o:p></div>
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· Hydraulic
drive energy<o:p></o:p></div>
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· Electric drive
energy<o:p></o:p></div>
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· Regenerative energy<o:p></o:p></div>
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1)
During work equipment operation + Start of swing<o:p></o:p></div>
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The work equipment is operated hydraulically
by energy generated by  the  engine  as  in  the  conventional equipment. (Red
arrows)<o:p></o:p></div>
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Swing is driven by electric
energy from the capacitor and generator.   (Yellow arrows)<o:p></o:p></div>
 2)
During work equipment operation + Swing deceleration

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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  dynamo
motor and assists work equipment operation.<o:p></o:p></div>
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</div>
 (5)
Effect of low fuel consumption

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Compared with the conventional
machine “PC200-8,” the hybrid version saves
about 25% of fuel on average*. 
 In a
user test, a fuel consumption reduction of 41% maximum was regis- tered
at a work site at which the frequency of swing operations was  high.    This  is  because  this  system  regenerates 
swing energy so that the effects of fuel consumption reduction vary depending on the load during turning,
on the swing angle and on the frequency of swing operations.   In work in which the swing
angle is large, a reduction
effect in excess of a nominal value
of 25% can be obtained.<o:p></o:p></div>
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* The market average is a trial calculation based on an in-house standard for average
usage of construction machinery.<o:p></o:p></div>
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(6)
Trial calculation of CO2 reduction effect<o:p></o:p></div>
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One-hour operation of a hybrid machine produces 10kg less
of CO2  compared with a conventional
machine.   Assuming
that all Komatsu hydraulic excavators operating in Japan are replaced by hybrid machines, about 370,000 tons less CO2 will be produced each year as a trial calculation, equal to about 153</div>
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Tokyo Dome baseball stad</div>
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4.  Summary<o:p></o:p></div>
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The conventional hydraulic excavator system converts the engine output entirely
into hydraulic energy and drives each actuator.   Compared with this, in the hybrid system, the upper
structure is driven by an electric
motor, reducing energy
conversion and transmission losses and regenerating the
kinetic energy of the upper structure.   The depression effect of engine output thus obtained is combined with engine
fuel consumption matching, resulting in dramatic fuel consumption
reduction effect.   At the same time, the following
technologies were
established.<o:p></o:p></div>
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(1) Motor powering technology of swing device<o:p></o:p></div>
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The upper structure is driven by an electric motor replacing the hydraulic motor in the conventional hydraulic excavators. Motor control technology in machine operability, especially combined operations with other work equipment was estab-
lished.<o:p></o:p></div>
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(2) Technology that regenerates swing kinetic
energy<o:p></o:p></div>
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The voltage control technology
of the storage battery was established for energy regeneration
during deceleration of the swing
electric motor.<o:p></o:p></div>
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(3) Total
 energy  management
 technology
 for
 the
 engine,
hydraulic pressure and electricity.<o:p></o:p></div>
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Power distribution individually for the engine, hydraulic
pump and dynamo motor was decided
and total control tech- nology to achieve optimum fuel consumption
operation was established.<o:p></o:p></div>
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(4) Hybrid component development technology<o:p></o:p></div>
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A motor, inverter
and capacitor were developed
as compo- nents to deal with large loads of construction machinery.
(Capacitor cells were purchased)<o:p></o:p></div>
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5.  Conclusion<o:p></o:p></div>
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The history of hybrid construction machinery has
just started. However, hybrid
construction machinery
is expected to be sold by the manufacturers of
construction machinery as part of the
measures against global warming and resource depletion,
occupying a certain market share.   The key point for spread- ing of hybrid construction
machinery is cost reduction. Expectations are placed on the support of central and local governments as in a bidding
system based on comprehensive evaluation of machines.<o:p></o:p></div>
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Technically, energy
 saving
 techniques
 by
 hybrid  systems
will be extremely effective for construction
machinery, which has a wide variety of applications.   Efforts
on the further development
of hybrid construction machinery
will be continued.<o:p></o:p></div>
 
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Introduction of PC200-8 Hybrid Hydraulic Excavators

A goal has been set to make a contribution to society in challenging global warming, especially to reduce the emissions of CO2, by devel...

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