Can I retrofit a long boom to my existing excavator ?

Excavators are versatile construction machines, but their capabilities often depend on attachment compatibility. A common question among operators and fleet managers is: Can I retrofit an Excavator long boom to my existing excavator? The short answer is yes, but the process requires meticulous planning, technical expertise, and a thorough understanding of the equipment’s limitations.

Assessing Retrofit Feasibility for a Long Boom Excavator

Retrofitting an Excavator long boom is feasible for most modern excavators, provided the machine’s structural integrity, hydraulic capacity, and weight distribution align with the new attachment’s demands. Long boom excavators—commonly used in dredging, demolition, or deep excavation—extend the machine’s working range but impose additional stress on its components. Before proceeding, it is crucial to evaluate three critical factors:

1. Models and Years

After 2010, most excavator models adopt modular design principles, which facilitate easier adaptation to the configuration of long arm excavators. These modern machines are typically designed with retrofitting in mind, making the process more straightforward. However, older equipment, particularly those manufactured before 2010, may require significant structural strengthening or hydraulic upgrades to accommodate the additional stress and demands of a long boom. For example, older models might need reinforcement of key structural components to prevent deformation or failure under the increased load.

2. Hydraulic System Capacity

Excavator long arm boom operations demand higher flow rates and pressure levels compared to standard booms. It is essential to verify that the main pump, control valves, and hydraulic lines can withstand these increased demands. Insufficient hydraulic capacity can lead to reduced performance, slower cycle times, or even damage to the hydraulic system. Upgrading the hydraulic system may involve installing higher-capacity pumps, larger-diameter hoses, or more efficient control valves to ensure smooth and reliable operation of the long boom.

3. Stability and Counterweight

The addition of a long boom significantly alters the excavator’s center of gravity, which can affect its stability and resistance to tipping over. The counterweight must be recalculated and adjusted accordingly to maintain balance, especially when working on slopes or in challenging terrain. Additionally, the chassis and undercarriage may need reinforcement to enhance their resistance to overturning. Failure to address these stability issues can lead to unsafe operating conditions and potential accidents.

Case Studies: Excavator Long Boom Retrofits

CAT 312 Excavator long boom Retrofit

For a river dredging project, Dewanda successfully retrofitted a CAT 312 with a 14-meter Excavator long boom. This modification extended the machine’s working radius from 9 meters to 14 meters, significantly enhancing its reach and efficiency. By upgrading the hydraulic flow to 240 L/min, the daily dredging volume increased by 63%. The Long boom excavator operated seamlessly in Siberia’s permafrost (-25°C) for three months, thanks to the use of low-temperature hydraulic oil and heated pipelines. This retrofit not only improved the machine’s performance but also demonstrated its reliability in extreme cold conditions.

Komatsu PC300-7 Excavator long boom (2005 model)

In another retrofit project, Dewanda addressed the challenges of an 18-year-old Komatsu PC300-7. To support a 12-meter Excavator long boom, segmented reinforcement was implemented to strengthen the machine’s structure. The retrofitted Long boom excavator achieved 2,000 hours of fault-free operation in a mining environment, proving that even older machines can be effectively upgraded to meet modern demands with the right technical expertise and reinforcement.

Key Considerations for Retrofitting an Excavator Long Boom

1. Structural Reinforcement for Long Boom Excavators

Standard booms are not designed to withstand the torsional forces generated by an Excavator long boom. Retrofitting requires the use of high-tensile steel booms and sticks to ensure structural integrity. Dewanda’s Long boom excavator solutions utilize laser-cut, precision-welded components to maximize strength and durability. For example, during a high-rise demolition project involving a Hitachi ZX330, finite element analysis (FEA) revealed stress concentrations of 345 MPa on the original boom. By reinforcing the hinge points with Q690D steel, the Excavator long boom was able to operate safely at an 18-meter radius, demonstrating the importance of structural reinforcement in retrofitting projects.

2. Hydraulic Modifications for Long Boom Excavators

Extended Excavator long boom arms necessitate hydraulic upgrades to ensure optimal performance. For instance, when retrofitting a Kobelco SK350LC with a 16-meter Long boom excavator, the original pump’s insufficient flow (280 L/min) was resolved by adding a parallel gear pump and expanding the hydraulic tank to 450L. This modification achieved a stable flow of 340 L/min while maintaining stick speed at 0.35 m/s. In an Alaska pipeline maintenance project, this model was further enhanced with a hydraulic oil preheating system, reducing cold-start time from 45 minutes to 8 minutes at -30°C. In extremely cold environments, such as Yakutsk (-50°C), fully enclosed hydraulic insulation was used to ensure reliable operation of the Excavator long boom, maintaining oil temperatures between 15–65°C.

3. Stability Enhancements for Long Boom Excavators

Extended arms increase the hydraulic cylinder stroke length, which can potentially overload pumps and valves. Solutions to enhance stability include upgrading high-pressure hoses and installing larger-diameter cylinders. For example, a Hitachi ZX350 was equipped with a dual-mode counterweight system, allowing the Long boom excavator to safely excavate 18-meter slopes. In another extreme case, a CAT 336 Excavator long boom was retrofitted with snow anchors and an auto-lock system for ice drilling in 12-level winds in Antarctica. These enhancements highlight the importance of stability considerations in retrofitting projects, especially in challenging environments.

Why Retrofit an Excavator Long Boom Instead of Buying a New Long Boom Excavator?

Purchasing a new Long boom excavator can be prohibitively expensive, often exceeding $200,000. In contrast, retrofitting an existing machine typically costs between $20,000 and $50,000, offering a significantly more cost-effective solution. A cost-benefit analysis reveals substantial savings: for example, retrofitting a CAT 320D for $42,000 saved $98,000 compared to buying a used Long boom excavator. In another case, Norwegian firms saved $530,000 by retrofitting two Liebherr R914s with Excavator long boom kits for -45°C operations. Retrofitting not only reduces costs but also extends the life of existing equipment, providing a sustainable and economically viable alternative.

Choosing the Right Supplier for Your Long Boom Excavator Retrofit

When selecting a supplier for your Excavator long boom retrofit, it is essential to consider the following factors:

Technical Expertise

Choose a supplier with extensive technical expertise and a comprehensive database of retrofit parameters. Dewanda, for example, maintains a database of over 3,200 parameters for Excavator long boom retrofits across 58 models. This expertise ensures that the retrofit process is tailored to the specific needs of your machine, minimizing risks and maximizing performance.

Extreme Environment Solutions

If your retrofit project involves operating in extreme environments, such as extremely cold temperatures or high altitudes, specialized materials and coatings are critical. Dewanda has successfully completed projects in a wide range of challenging conditions, from permafrost in Siberia to ice drilling in Antarctica. Their experience in these environments ensures that your Long boom excavator will perform reliably, even in the most demanding conditions.

Choose Dewanda’s excavator long boom

From CAT 312 dredging to Hitachi ZX350 mining, Dewanda’s Excavator long boom retrofits have mastered challenges ranging from permafrost to Antarctic conditions. Whether upgrading older machines or tackling extreme environments, Long boom excavator retrofits offer cost-effective, high-performance solutions.

With over 800 successful Excavator long boom projects and 56 patented technologies, Dewanda ensures that your Long boom excavator meets even the most unique demands.

For more information, contact us at //www.dewandaparts.com/.