SHAW’S WIRE ROPES IRON TEST
The newest member of the Cat 500-series swing machine range has taken a while to reach the market, but the wait has been well worth it. The first Cat 538 LL loader is now working for Goodman Logging in Kinleith Forest and the new model impressed our Iron Test team.
GETTING YOUR FIVE-PLUS HELPING OF FRUIT AND VEGGIES every day is, we’re told, good for your bodily health. And a good dose of this new five-plus green machine from Caterpillar would equally benefit the health of your business, not to mention the environment, on account of its cleaner Tier 4f engine.
The 538 LL is the latest extension to the new 500-Series forestry swing machine range from Caterpillar and it’s been a long-time coming.
The big 568 was the first to be announced, but that was way back in 2013. It was an all-new model, replacing the 330DFM in the Cat lineup. It stood in isolation as the other Cat 300-Series forestry models soldiered on in the marketplace for another four years, and some continue to do so, while the roll-out of their replacements extends a little further.
But the wait for the other models will be worth it, if they are anywhere near as good as the 538 machines that have now started to land on our shores.
The first to arrive here went to Goodman Logging, operating in Kinleith Forest, which readers might recall seeing in our coverage of THE Expo show at Mystery Creek earlier in the year, where it starred on the Gough Cat stand.
NZ Logger climbed all over it at THE Expo and, suitably impressed, the Iron Test team has been champing at the bit ever since. But we were forced to wait a little longer as the machine went back into the engineering shop to have some additional guarding work around the body.
Additional guarding? Don’t these forestry machines arrive ready to go straight to work in the forest? Well, yes they do, but you loggers are a cautious lot and you’re not keen on seeing signs of contact between wayward wood and pristine bodywork. With good reason, too. When we turned up to see Paul and Nick Goodman and their newest acquisition, the front panel underneath the screen showed signs of coming off second best from one of those unfortunate contacts.
It can happen to any machine. And often does. When you are working with reasonably big wood, especially shovelling out at the cut-over, it’s all part of the game.
This machine wasn’t actually purchased to do shovelling, but it is pressed into that role occasionally when stems build up and there’s not much to keep it occupied on the skid.
The dent is mildly annoying to Paul, who likes his fleet to look good for as long as possible, to the extent that all the equipment is washed at least once a month, which also helps identify any small leaks that need to be attended to before they become major issues.
On this job, Paul and Nick have been operating a greater percentage of older machines than in the past, after purchasing a contract and some equipment – which came with operators – 18 months ago from Allan Sinton. They are always prepared for something to happen to older machines, but the time has come to update and put those worries behind them.
The new 538 LL loader is the first move in the replacement programme and has recently been followed by another new Cat, a 336 processor sporting a SATCO head, which replaced an old 330.
Paul didn’t have much experience with Cats before the Sinton deal, but he’s been impressed enough with both the machines and the support to stick with Caterpillar.
The Goodmans have owned other makes and still do, but Paul
says: “A lot of it came down to back-up, Goughs is hard to beat in that respect.”
The 538 LL is a direct replacement for the 320 DFM in the Caterpillar forestry range, but the machine that it took over from in the Goodman fleet was a 24,000-hour Cat 324 standard excavator base with low factory cab, fitted up with a grapple for loading duties. So, the changeover has proven to be a significant difference to what Paul and Nick had before.
For a start, it’s much taller because it sports a 1.2 metre riser and purpose-built cab that towers over a machine like the 324 – from the ground to the top of the cab the 538 LL measures 4,578mm, against 2980mm for an ordinary 324. Even without the riser, the general forestry version of the new 538 lords it over the 324, at 3,901mm to the top of the cab.
“We went for the cab on the riser because it works on the skid most of the time and you see more from up there,” says Paul, adding that they are also looking at getting another 538 to replace one of the machines that mostly does shovelling, so it won’t require the riser.
For contractors running a 320 DFM, the differences are not nearly so dramatic, and in some respects the new model is a little more compact.
For instance, the 538 LL with riser is actually 79mm lower to the top of the cab than the 320 DFM.
A slight reduction in the length of the boom and arm has reduced the new Cat’s overall shipping length, which is now down to 13,485mm, against the 320 DFM’s 13,630mm. But the 538’s cab is a shade longer, so when it’s tilted forward for transporting there is an extra 142mm of height to take into account.
The 538 LL also runs wider track gear than the 320 DFM, which delivers an additional 203mm to increase stability. Plus, the rear counterweight has grown in size, for similar stability reasons, which has pushed out the tail swing radius from 2,774mm to 2,789mm. Ground clearance has increased by 10mm to 660mm.
Those are just minor detailed changes. The main bulk of the differences are actually housed inside the new 538.
In comes a brand new Tier 4f Cat C7.1 ACERT engine in place of the Tier 3 Cat C6.4 ACERT unit in the old 320 DFM, which has lifted peak power output to 122kW (164hp) at 1,800rpm and raised torque to
742Nm, peaking at 1,400rpm.
This is the third new Cat forestry machine in New Zealand to move to greener Tier 4f technology. The 568 was the first and a couple of years ago the Cat 555D skidder also adopted Tier 4f.
Contractors who have been running these machines report no issues and say they soon get used to adding the Diesel Exhaust Fluid (AdBlue) every two fuel fills. The Tier 4f technology employs Selective Catalytic Reduction (SCR), Diesel Oxidation Catalyst (DOC) and Ammonia Oxidation Catalyst (AMOX) systems to remove nitrogen oxide gasses from the exhaust while a service-free Diesel Particulate Filter (DPF) removes soot and other particulates.
And yes, it does generate more heat than older Tier 3 and Tier 2 engines that don’t have the SCR technology, but Caterpillar compensates by increasing the cooling capacity in the 538 by 12% using an improved side-by-side cooling system. The fin spacing has increased 25% to improve airflow and cooling capability and an auto reversing fan is now standard, not optional as in the 320DFM.
Caterpillar also employs something called a nitrogen oxide (NOx) reduction system that captures a small quantity of exhaust gas and routes it back into the combustion chamber to help further reduce engine temperature, as well as cutting nitrogen oxide emissions.
Seems to work, say Paul, Nick and regular operator Jack ‘Jacko’ Ngatamaraki, because they’ve all noticed the operating temperatures running lower than what they’ve been used to seeing.
Fuel consumption appears to be better than their old 324, too. The new machine has a 410-litre fuel tank, carried over from the 320 DFM, which they refuel daily to avoid condensation forming in the tank.
One of the reasons for the improved fuel economy is that the larger main hydraulic pump now fitted to the 538 allows the engine to effectively operate at lower revs.
Also, the component layout and back-to-back main hydraulic control valve reduces oil flow restrictions, which further improves fuel economy without any performance penalty. In fact, everyone who has got behind the controls of the new machine rates its hydraulic performance very highly. They reckon it does more work for less operating expense, which is what everyone is after these days.
We’ll focus more on the performance in a minute, but let’s just have a look at some of the other changes in the 538 LL, compared to the 320 DFM.
If you are a 320 DFM owner, one of the biggest things you’ll notice visually is that the engine compartment and body behind the cab/riser is bigger than before. It used to be level with the third step on the riser, but now it stretches up to be in line with the bottom of the cab.
The additional space under the bonnet is obviously to allow for the new engine, along with the upgraded cooling system and other components. It also provides more room around all these items to make it easier for service technicians to work on.
There’s plenty of storage places inside the riser and in a box on the outside of the boom, where the Goodmans have extended the guarding. The box next to the boom is very handy for placing the AdBlue container, as it sits right next to the filler point, which is situated in a flap under the step up to the engine compartment.
This handy step provides good access up to a cat-walk to get to the cover over the engine and transmission. It also provides safe access for those who tick the box for the all-new optional rear entry cab, rather than climbing up steps on the riser and then hanging off the grab handle with one hand to open the side door. Paul and Nick’s machine arrived before that option was available. Gough Cat says the rear-entry cab becomes available for the 538 from the end of this year.
The cab itself is a nice working environment, with the slightly taller roof drawing even more light through those big glass windows. First impressions are that the cab seems a little narrow, but that’s an illusion created by the height – it’s the same width as before. It’s a bit longer, however, with most of that space providing additional storage behind the seat. With the thick polycarbonate glass on the front and side screens, there’s just the minimal number of bars required for operator protection. Stan Barlow goes into further detail on the cab and controls in his Iron Test column on page 36.
Stepping back to take in the view of the new machine, the extra width in the track frame gives the 538 LL a nice, solid stance, and both
Nick and ‘Jacko’ say it does deliver good stability when they take the machine out to the cut-over to help with shovelling.
While the purpose-built forestry boom and arm are designed more with loading on the skid in mind, the reach is still OK for shovelling, they reckon.
The requirement to do the odd bit of shovelling was one reason why the Goodmans added the additional guarding around the body.
“We strengthened up around the wipers and front lights and then all this (boom-side) corner has been built right up so it’s a lot stronger and then guarded it right around the back and put a deflector on the back,” points out Nick.
“We did this bit because you tend to pull trees around this side, especially when you’re shovelling, even though it’s more of a skid machine, at least it’s more protected when it does go out to the cutover on the odd occasion.”
Over the Christmas break they are looking to insert an extra piece of steel on the inside of the dented front panel to protect it against future knocks.
‘Jacko’ is determined to make sure that’s the only knock it will get while he’s at the controls.
He’s been operating machines for a while and came across to Goodman Logging as part of the Sinton deal, where he had spent the last 15 years.
“I’ve been working on machines for ten years, mostly on loaders,” says ‘Jacko’, although today he is at the controls of the harvester so he can get his ticket and provide the Goodmans with another operator option.
‘Jacko’ drove the 324 before the 538 LL arrived and he is enjoying his first brand new machine, adding: “Can’t complain, it’s real nice to drive.”
His first impression was that the purpose-built cab felt a bit small when he climbed in to make himself comfy, but he’s got used to it.
“I’m quite a big guy, so when I hopped in I did notice that the 324’s standard cab felt a bit bigger, but it’s fine now – all that glass makes it feel like there’s more space,” he adds.
“What do I like about it? Everything pretty much. It’s very quiet – all I can hear is music.
“The controls are excellent, smooth and good feel – just the thumb control for opening and closing the grapple is wrong way round for me.
“Power-wise it’s way better. The old machine had a straight boom and arm. This forestry boom and arm is awesome, lots of power in the lift. Loading side of things for trucks, it’s bang-on. That’s what it does best. You can look on top of the truck and get your crowing good. It picks up the big trailers easy-as.”
But even with the extra cab height ‘Jacko’ says he still has to position the 538 LL to make sure he’s out of the blind spot caused by the boom when he lifts trailers off the back of log trucks.
“Took me a week to get used to the physics of the machine, to learn how much to bring in and how far out you go,” he adds, noting that the bigger 5-axle trailers are heavier and need to be lifted with caution. To assist the operator, the 538 LL does have a heavy lift mode
that increases lift capacity to handle larger payloads with improved control. The larger counterweight helps, too, now providing 5,821 tonnes on the end of the tail. All up, the 538 LL is another 1.38 tonnes heavier than the 320DFM, now tipping the scales at 31,480kg without the Duxson grapple and extra guarding, and just over 33,000kg on the skid.
‘Jacko’ has the choice of three power modes to call on for loading and shovelling duties (high, standard and eco modes), which he can dial up on the console switch pad, but generally leaves it in the standard setting when he’s on the skid. This helps with fuel consumption. It’s only when he has to deal with some really big stems when shovelling that the high mode might be required.
Another fuel-saving trick that comes with the 538 LL is the one-touch-idle control, which sees the machine revert automatically to a lower idle speed when there is a pause or lull in operations – the interval of time before the engine idles down being set by the operator. When the joysticks are used again, the engine automatically resumes normal operating rpm.
But it’s the way the engine works with the hydraulics that has impressed ‘Jacko’ the most with this new machine.
The hydraulic horsepower has increased around 10% over the 320DFM, which itself was always considered good in that respect. In the 538 LL, the pumps have been upsized to allow the engine to run at a lower rpm and yet still work perfectly well with big loads.
The Caterpillar team has also designed the main pumps, control valves, and hydraulic oil tank to be located close together to allow for shorter tubes and lines between components, which reduces friction and pressure drops
(and this compact design means there is less hydraulic oil required for the whole system than in the 320DFM). That onepiece, cast-block, back-to-back control valve design mentioned earlier in the article is also effective in minimising power losses and increasing efficiency through carefully designed ports and passageways. I like the way that any auxiliary valve attachments can be simply mounted on
top of the main valve, too. Easy as.
The hydraulic system also answers to the input from the operator in a way that delivers excellent controllability. This is mainly due to the Negative Flow Control (NFC) system and how the main control valve works. The valve opens slowly with small movements of the joystick and opens rapidly when movement is faster, yet without any jerkiness.
Both ‘Jacko’ and Iron tester Stan commented on this feature as one of the very
likeable attributes of the new 538 LL.
They also like the amount of slew power on tap. Cat forestry machines have always been good in that respect and the 538 LL has stepped up a notch, delivering 18% more swing torque from the available 80kNm. Swing speed hasn’t changed much, it’s just how well it slews with a heavy load in the grapple that has improved – especially noticeable when shovelling.
Even though he’s only had a couple of months behind the controls of the 538 LL, ‘Jacko’ is really enjoying the experience, adding: “Once I got used to it I knew its capabilities, even out shovelling. Sure it hasn’t got a huge reach, but it lifts well and I can make it work.
“It took me a while to work out the AdBlue, that’s very new for me. Now I understand the machine and how to work it and filling it up when it tells me on the screen. Pretty good on gas, mind you the 324 wasn’t bad either, but this one is pretty efficient.”
When Stan and I turned up, the 538 LL was displaying all its loadout prowess by filling the bunks of a big off-highway double in doublequick time.
Unfortunately, that was going to be the only truck the Cat would be loading today, because the Goodman crew has been performing above expectations, surpassing their 340-tonne target. Their local Hancock supervisor has dropped by to advise them to ease off for the moment.
“Shows what we can do with a good crew and the right equipment in a nice forest,” says Paul.
“We were just a bit further down the road before this, in a real shitty block with 1,200 stems per acre planted in the old NZ Forest Products days to be used as pulp for the mill. That was a real test for us and the machines. The trees in this block are 27 or 28 years old, well looked after, with some big ones on the edges, but generally even and good form.”
Nick chips in: “This is a bit of a treat from that last block.”
In spite of getting ahead of their target, Paul says the forest manager has been impressed with what the Goodman crew has done and once this deal with Sinton is completed they are looking to pick up a contract with Hancock Forest directly. It will make a nice change after years of trying to make a living in production thinning and then woodlots, allowing Paul to step back further and for Nick to take over the business completely. They could do a lot worse than put their faith in the new Cat equipment they’ve recently taken on.
While there are no more trucks to load, there’s still plenty to do before the crew knocks off early for the day and Stan is given the job of stacking and tidying up the skid, then doing a spot of shovelling to complete his part of the Iron Test.
He’s operated all of the 300-series forestry machines in the past and requires little introduction to the new 538 LL.
He spends the next hour sorting the sawn logs into their graded stacks, loading up the grapple with various numbers to test the capabilities. Speaking of grapples, this Duxson GX 171 from Hamiltonbased Donaldson Mechanical is the first of this new mid-range model we’ve experienced during a test.
It’s an impressive piece of kit, with brilliant grabbing power, as Stan describes over the next page. The 171 tips the scales at a shade under 1,300kg and has a maximum opening of 1,700mm. Like the others in the Duxson range it has 360-degree rotation.
‘Jacko’ has been equally impressed with the Duxson and says it reacts with lightning speed, which makes it easier to pick up obstinate logs.
Right now, Stan is making it work hard for its living as he fills the stacks. Once this job is completed he heads out to the cutover to join a pair of older machines, a Doosan and a Hitachi, shovelling stems back towards the skid, trying out both rabbit and turtle modes (the top speed is now 4.3km/h, compared to 5.3km/h in the 320DFM).
Ideally, this is a job that should be done by a skidder, but the Goodmans are holding off on that purchase until they know where
they will be going next.
So the three swing machines form a line to pass the trees between each other, and the 538LL doesn’t let the side down, even though it’s smaller than the loaders on either side. That’s no mean feat, because a couple of the stems must weigh at least four or five tonnes. No sign of tipping with those giants in the jaws.
It might not be ideal for shovelling, but the Goodman’s new Cat 538 LL shows that it is versatile enough to handle any grapple-oriented job for their crew.
High five’s all-round, I’d say.