Big Cat on the Prowl in Paris

Caterpillar has launched its 56 tonne 836K landfill compactor, the latest update to the 836 series which has been a staple for landfill operators for almost 20 years. The first of the new model to arrive in Europe has recently entered service on a landfill site just outside of Paris. by Ben Messenger France continues to top the tables when it comes to tourism. Last year it was the only country in the world to receive more than 80 million tourists – significantly more than the U.S. and Spain in second and third place, respectively. Capital city Paris can largely be attributed for attracting visitors from around the world. From the Eiffel Tower, to the Louvre, Champs-Elysees and Arc de Triomphe, France's capital city's skyline is full to the brim of historic sites to tempt even the least explorative traveller over. Yet today I'm in the city to see technology which could be seen as equally impressive: the European debut of a new landfill compactor. The first dedicated landfill compactors began to appear back in the 1960s. Over the next decades the format took off, changing the way in which landfill sites handle waste, and increasing the density to which it is compacted. Among the milestones in the development of the breed was the release in early 1970s of Caterpillar's 816 and 826 series of compactors. Following a number of revisions to those two product lines, in 1993 the company launched its 836 series – the largest landfill compactor in its range. Fast forward twenty years and 2013 saw the arrival of the 836K, a 56 tonne, 419 kW (562 hp) behemoth of machine. Having become a staple piece of kit for landfill operators around the world, the latest incarnation of the compactor made its European debut this summer on the EMTA Guitrancourt site just outside of Paris. Operated by SARP Industries, a subsidiary of Veolia, the site is used to dispose of industrial and hazardous waste and bottom ash from waste incineration facilities. The facility has recently been granted an increase in the maximum amount of waste it can accept each year. The site is now licensed to accept some 150,000 tonnes per year of Class 1 hazardous waste and 220,000 tonnes per year of Class 2. The company is also looking for a further increase to its Class 1 permit to 220,000 tonnes. On a recent visit to the site, Arnaud Pisarek landfill manager at the site, told WMW that the increased permitted capacity, combined with the recent closure of another nearby landfill, means that the facility will handle significantly more waste than was previously the case - hence the arrival of the 836K. Rental The newly arrived 836K being put to work on the EMTA site has not actually been purchased by the landfill operator. Instead it has been leased from full service plant equipment rental specialist, : Terre-Net, Group POISSON. Vincent Moulinot, fleet manager at Poisson explains that the company currently has around 400 machines on its books in France – 80% of which are operating in the waste recycling industry. A further 100 machines are based in Australia, where the company offers additional services. One of the advantages for operators of opting for a machine from the Gretz-Armainvilliers based rental firm is that takes care of all maintenance and servicing – it can even supply the operator if needed. The company has its own specialist maintenance engineers operating out of three main facilities in France that enables it to perform everything from routine maintenance to complete machine rebuilds. “It is the only customer that we know that is doing its own rebuilds, except for Cat dealers,” Michel Jenny, corporate account manager for Caterpillar's Industrial & Waste Group explains. According to Moulinot, Poisson chose the new K series 836 based on its previous experience of Cat machines proving to be reliable, as well as their good relationship with the dealer. He says the latest machine is a good evolution of the previous generation, with significant improvements to operator comfort combined with excellent compaction capabilities. Joy ride Discussing the merits of the new arrival, Pisarek reinforces the importance of a comfortable working environment for the operators, who spend seven to eight hours per day in the cab. The 836K features a newly designed operator's station with improved ingress/egress for the convenience of the operator, as well as a rear view camera to enhance overall visibility as standard. It also sports a new instrument pod, which features membrane switch panels with LED activation indicators. The switches themselves are labelled with ISO symbols for quick function identification. Vibrations in the cab have been reduced with the use of isolation mounts and seat air suspension. It is also pressurised with filtered air and automatic temperature control adds to the overall comfort of the cabin. The STIC™ steering controller uses a single lever for steering and transmission control, allowing the operator to sit comfortably back in the seat, significantly lessening fatigue. It offers a simple side-to-side motion that turns the machine right or left with minimal movement required from the operator. Precise positioning for loading in tight areas is taken care of with 43° each way of steering articulation. Changing gear is light work too, requiring only the flick of a finger, while a heated seat and radio are also options that can be fitted to the cab, as well as Bluetooth, MPS, or satellite. Also adding to the improved comfort both inside and outside of the cab is the reduced noise emissions. According to Cat, interior sound levels are a quiet 73 dB(A) and optional sound-suppression package is also available. “The comfort of the operator is important to productivity. If the operator is happy in the machine he will do a better job,” says Pisarek. Another driver aid for the new K series landfill compactors is an optional CCS900 GPS guiding system that indicates through a graphic interface which points on the landfill face need additional compaction. Frugal, clean and fast Another benefit cited by Moulinot is the 836K's turn of speed. While the machine's top speed of 12.3 kph (7.6 mph) in its second direct drive reverse gear (top speed in its second direct drive forward gear is marginally less) may not be a winning statistic in a game of Top Trumps, it's pretty rapid for a 56 tonne landfill compactor. “The first time that the operator rode in the machine they asked to go slower, but I said “I am in first gear”. Now they are used to that speed, and they are very impressed,” says Jenny. Helping the K series achieve this level of performance is a new 419 kW C18 ACERT engine that meets U.S. EPA Tier 4-Final and EU Stage IV emissions regulations and develops some 3085 Nm (2275 lb-ft) of torque. To achieve this it uses Selective Catalytic Reduction (SCR) to control NOx emissions and the Cat Clean Emissions Module – a diesel particulate filter (DPF), diesel oxidation catalyst, and Cat Regeneration System - to control particulate emissions. The 836K sees the addition of three new wheel tips. A Paddle Tip offers high performance and rmore traction, while the Plus Tip has a traditional design for increased side slope stability. Both can be seen here. The Combination Tip merges both. DPF regeneration is automatic and does not interrupt the machine's work cycle. For added efficiency, an auto-reversing, hydraulically driven fan adjusts its speed to match cooling requirements, reducing horsepower draw and conserving fuel. Jenny explains that the entire engine bay is also sealed and pressurised to minimise dust intrusion. The power is sent to the wheels through Cat's Planetary Powershift Transmission, which is said to deliver smooth shifting and efficiency through integrated electronic controls that use Advanced Productivity Electronic Control Strategy (APECS). It also features a torque converter with lock-up Clutch which eliminates torque converter losses while lowering system heat and improving travel speed. Caterpillar's Impeller Clutch Torque Converter works with a throttle-lock feature to allow modulation of rimpull in order to slow the machine without reducing engine speed. This capability allows full hydraulic power for blade and steering functions at all ground speeds, while providing performance claimed to be comparable to that of a hydrostatic drive. But it's not just out and out performance that has been the target of Cat's developments. The 836K provides a number of fuel-saving features that reduce its CO2 footprint. Auto Idle Kickdown reduces engine speed when the machine is inactive for a set time interval, and Idle Shutdown stops the engine after a safe idling interval. Furthermore, fully integrated electronic engine controls are said to work in concert with the entire machine to improve fuel economy, as does improved hydraulic efficiency which is achieved with new flow sharing variable displacement load sensing piston pumps. This means that hydraulic flow is now 'on demand' rather than continuous - thus improving fuel efficiency. Reinventing the wheel The 836K is available with a choice of three new wheel and tip configurations to meet a particular application. Jenny explains that the new Paddle Tip offers high performance and reduced fuel consumption with more traction and less weight. The Plus Tip has a traditional design for increased side slope stability and the Combination Tip merges both paddle and plus tips to give high performance with side slope stability. Striker bars in front of and behind the rear wheels, and behind the front wheels, help keep wheels free of debris and assist in maintaining the required compaction. In cohesive material or severe packing conditions, optional cleaner fingers are available to assist wheel-tip cleaning. Further to this, to protect key components and systems from damage the 836K features specialised guards, including hydraulically actuated engine and power-train shields, front-frame guards to prevent waste building up inside the frame and to protect hydraulic lines, and axle-seal guarding to stop material from binding around the axles Maintenance While the move to EPA Tier 4-Final and EU Stage IV compliance has led to much lower emissions, Moulinot explains that it also brings with it some additional routine maintenance. For example, the SCR system consists of a catalyst that reacts with a urea based Diesel Exhaust Fluid (DEF) to significantly reduce NOx emissions. The fluid is a blended solution of 32.5% high purity urea and 67.5% deionised water. During operation the 836K consumes a small amount of DEF, approximately 2 to 3% of diesel fuel consumption by volume, from a tank which must be refilled. The diesel particulate filter is another new addition to the maintenance regime. However, while the K series has some additional systems to service, Caterpillar has put a lot of thought into minimising the maintenance required and making it convenient and safe to operate as possible. To ensure safe maintenance access, the 836K's routine service points are easily reached from ground level or from a single-level upper platform. The swing-out radiator facilitates cleaning, grease points are centralised and belly guards are hinged for easy handling. Sight gauges for coolant, transmission, and hydraulic-oil levels eliminate system contamination, an electronic air-inlet-restriction indicator eliminates visual filter inspections, and the electronics bay is located in the cab, safe from the working environment. For added safety, the 836K provides ground-level access to emergency shut-down, battery-disconnect, and stairway light switches. The 836K also uses Cat HYDO™ hydraulic oil, which is claimed to allow extended drain intervals (up to six times longer than conventional oils) and be significantly more biodegradable. Coming to a landfill site near you Cat's 836 series has been a staple for the landfill industry for over twenty years. Able to cope with the rigours of shifting large volumes of waste around some of the biggest landfill sites, while providing high density compaction, the model has proved popular around the world. It may be a distant thought for those considering upgrading to the 836K, but another feature that should resonate with the waste and recycling industry is that it's built for multiple lives, with components that allow rebuilding through Caterpillar's Reman and Certified Rebuild programs. While it may be many years into the future, for Poisson that's an undertaking it will handle for itself, and another reason that the machine it's leasing to EMTA Guitrancourt site is the first of three that it will be taking delivery of this year. If it proves as popular as its forebears, don't be surprised to find a big Cat prowling a landfill near you. Ben Messenger is managing editor of WMW Further to the European debut of the 836K, in the past few weeks Caterpillar has launched its latest generation of 826 Landfill Compactor, the K Series, featuring two ACERT™ engine options, meeting U.S. EPA Tier 4 Final/EU Stage IV emission standards or U.S. EPA Tier 3/EU Stage IIIA equivalent emission standards. As with its big brother, the introduction of the K Series model sees improved operator comfort and safety, ease of operation, durability, reliability, low-cost operation, and productivity for the 826. Weighing in at around 41 tonnes, the 826K has 405 net horsepower (302 kW) available for its drive train, which uses a 2F/2R planetary power-shift transmission, lock-up torque converter, and heavy-duty planetary axles that can accommodate three new wheel-and- tip configurations. To cut fuel consumption, Cat said that the 826K features an Eco Mode, which, when selected by the operator, limits engine speed and allows the machine to function in an auto-shift mode when maximum torque is not required. In common with the 836K, the Caterpillar's mid-sized landfill compactor has been designed with maintenance in mind. Swing-out doors on both sides of the engine compartment provide easy access to daily service checks, and ecology drains simplify service and help prevent spills. A swing-out stairway facilitates access to the engine. In addition, swing-out coolers for fuel and hydraulic fluid are said to simplify cleaning, and a ground-level power service centre has an electrical-disconnect, emergency-engine-shutdown, and stairway-light switches. To further improve serviceability, Cat's Vital Information System (VIMS™ 3G) is integrated into CAT Landfill compactor's design. It keeps operators informed about machine operating conditions via a graphic display that features touch-screen interface. Also expanding machine-monitoring capabilitiesis Cat Product Link™ system, which provides event and diagnostic codes as well as data such as operating hours, fuel level, and idle time. This information is transmitted to a secure web-based application, VisionLink®, which provides tools for conveying information to machine owners and dealers, including working time versus idle time and mapping functions. Machine Specifications Engine Cat C15 ACERT Net power 405 hp (302 kW) Operating weight .90,207 lb. (40 917 kg) Hydraulic flow, max 30.9 gpm (117 L/min.) Main relief pressure 3,495 psi (24 100 kPa) Fuel capacity 206.6 gal. (782 L) Operator sound level, std. 73 dB(A) Operator sound level, supp. 72 dB(A)