How Compacts Became a Big Deal in North America

Sometimes when size matters,
less is more.

North American earthmoving contractors began buying hydraulic excavators in great quantities in the last half of the 1980s, often using them in combination with articulated haulers to replace — and dramatically out-produce, in many applications — traditional machines like scrapers, crawler loaders, and even wheel loaders.

But even as North America quickly became the world’s leading market for production-sized excavators of 40,000 pounds or greater, the region’s fleet managers showed little interest in the small excavator classes.

The so-called mini excavator — for our purposes, machines up to 12,000 pounds in operating weight — dominated the European and Asian construction markets in the 1980s, but in the U.S. and Canada they were almost unknown. Major excavator manufacturers from Europe and Asia took turns trying and failing to launch minis in North America during that time, but the region’s equipment fleets were focused on a different kind of compact machine — the skid-steer loader.

Minis arrive

What launched the popularity of the mini excavator in North America was the combination of two events.

First, Bobcat, then the pre-eminent skid-steer loader manufacturer in North America and the world, redefined its corporate goals in the mid-1980s, positioning itself to be a marketer of all types of compact machinery. The first order of business was the decision to make and market mini-excavators. The second was to quit calling them minis and start calling them compacts.

Initially, Bobcat’s target was the huge North American market for backhoe loaders. The company’s marketing proposition was that, for about the same money, a fleet could have two machines, a skid-steer loader and a compact excavator, that could work simultaneously and thus out-produce the popular backhoe loader.

Canales Dirt Works used a Bobcat 337 compact excavator as a primary earth mover on a road widening and utility installation project in Waco, Texas.

Canales completed the Waco project with two compact machines— the second is a Bobcat T300 compact track loader. The 48-horsepower excavator functioned as the primary digging machine while the track loader performed rough grading work and loaded the excavated material on a dump truck.

While backhoe loader sales have remained very strong in North America in the intervening years, the logic of Bobcat’s proposition became as clear to backhoe loader manufacturers as it did to equipment fleets, and in the early 1990s, most of the major backhoe loader players covered their bets with skid-steer/compact-excavator offerings. While the new domestic-branded compact-excavator offerings were remarkably similar to the machines that the market had ignored earlier, the companies marketing them now were much more intimate with the North American market and much more aggressive than the Japanese and European firms had been.

At the same time, North America was becoming a huge market for rental equipment, and like the easy-to-operate skid-steer loader, the compact-excavator was the perfect machine for rental fleets and rental users. Rental fleets large and small bought thousands of them, giving equipment users a risk-free means of testing their usefulness.

The rest, as they say, is history. Thousands of construction fleets discovered the category through short-term rentals, then found more and more ways to use them. They have become a staple of the North American construction scene as rentals and as owned machines.

Applications and benefits

Compact excavators bring a lot of advantages to road and bridge jobsites. They are, first and foremost, powerful little machines, using cutting edge hydraulics and electronics to achieve high productivity and precise controls in a compact, space-saving unit powered by a fuel-stingy, small-horsepower diesel engine.

In road-related applications, compacts are used for pavement removal, ditching and drainage, and even grading base. They can also be used in road widening projects such as the one shown in the accompanying photos. Municipalities equip them with saws and hammers as well as buckets and use them for street repairs and water and sewer repairs.

Due to their compact dimensions, compacts are becoming popular for a variety of roadside applications, too. Of special interest in the latter applications are the models with short or no tail swing, which can turn within, or almost within, the width of their tracks.

While track-mounted compact excavators can’t be driven down the road from one job to another, they bring their own mobility virtues to the job site. First and foremost, the vast majority of compacts can be towed behind a pickup truck from task to task, dramatically reducing hauling costs. On the site, most have rubber tracks that allow them to move about on paved surfaces, base, and even grass without causing damage.

Recent trends

The most notable improvements in compact excavators over the past half decade or so have been in controls and in the operator environment.

The improvement in the controls has been dramatic. Today’s compacts swing smoothly and stop gently, even when operated by an amateur — an important consideration because they are frequently operated by inexperienced people.

Equally important are their creature comforts. At a time when North American fleets are finding it difficult to attract and retain construction workers, compacts offer employers a way to automate their workforce and also pamper them. They are quiet and getting quieter. They are available with luxurious cabs that have climate control systems to keep the operator warm in cold weather and cool in hot weather. They have luxurious seats with multiple adjustments for individual comfort, as well as sound proofing, excellent visibility, and plenty of space for the operator.

Compact Excavator All-Stars
The latest offerings from leading marketers of compact excavators.

Volvo Construction Equipment
First wheeled compact excavator

Volvo Construction Equipment has extended its line of conventional and short-swing-radius compact excavators with the introduction of its first ever wheel-mounted compact, the 11,500-pound EW55B. The new offering puts the upper structure of Volvo’s proven EC55B compact excavator on a hydrostatic four-wheel-drive undercarriage capable of speeds up to 18.6 miles per hour.

The new chassis features a front axle with power-assisted steering and a center oscillating pivot to enhance the machine’s safety and stability when moving over rough terrain. To maintain stability when digging, two oscillation lock cylinders keep the front axle fixed.

Power comes from a 52-horsepower diesel engine and Volvo’s proprietary hydraulic system which prioritizes the boom and dipper for fast, smooth cycle times and also acts as the boom anti-drift device. Pilot-operated servo controls provide easy, precise movements, and a one-touch boost feature increases the machine’s digging and lifting forces only when needed.

Standard features include a quiet operator station, with an air-conditioned, sound-insulated cab, rubber mountings on the chassis, and an exhaust silencer.

Volvo designed the EW55B for applications that require high mobility and the ability to operate and turn in confined spaces. Specific vocations the company is targeting include road and street agencies and contractors, and quarries and landfills that need speedy, mobile utility machines.

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Kubota Tractor
Zero-tail-swing models debut

Kubota has added three new zero-tail-swing excavators to its compact line. The 1.5-ton U15, 2.5-ton U25, and 4.5-ton U45 are designed to work in tight spaces and to provide advanced operator comfort, control, and visibility. To enhance durability, front hydraulic hoses on the new machines are routed through the arm and long-lasting pin bushings are used at all pivot points along the swing bracket, boom, arm, and bucket. The boom cylinder on the U15 is located above the boom to protect it from damage. The hydraulics systems on all three models can accommodate attachments like breakers and augers, and feature easy-to-reach auxiliary hydraulic connections that incorporate short hoses that are less susceptible to damage.

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Case Construction Equipment
More power, faster cycle times

In converting four of its CX compact excavators to Tier 2 engines, Case has increased their horsepower by 19%, hydraulic flow by 15%, and hydraulic horsepower by 14%. The net result is improved performance and faster cycle times. The machines are also easier to maintain and service thanks to the addition of swing-out access panels and ground-line fluid fills.

Cabs now have wider front glass for better sight lines and increased door width for ease of entry.

All four models feature zero tail swing and hydraulically controlled backfill blades for machine stability and light dozing work. Case says the newly designed backfill blade rolls material in front of the blade for more efficient backfilling, and it has increased lifting range to improve trailer loading.

The Case CX27B, CX31B, CX36B, and CX50B range from 5,666 to 10,383 pounds and deliver from 21 to 40.8 net horsepower. Bucket-digging forces range up to 7,936 pounds and maximum digging depths range from 9 feet, 2 inches to 11 feet, 9 inches.

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New Holland
Zero tail swing versatility

New Holland’s five-model line of compact excavators features a zero-tail-swing design, auxiliary hydraulics as standard equipment, and a sophisticated hydraulics system that delivers more breakout force and power. Hallmarks of the hydraulic sys-tem also include independent flow to the dozer blade so it can be adjusted while pushing without loss of power, and an independent swing-circuit pump that allows simultaneous operation of the boom, arm, bucket and swing.

The New Holland line ranges from the 3,240-pound, 11.9-horsepower E15 to the 10,275-pound, 40.8 horsepower E50. The E15 features telescoping tracks that can be narrowed to 35 inches to fit through a 36-inch gate, then expanded to 47 inches for full operating stability.

New Holland has recently increased the size of its compact excavator cabs to add operator comfort, and swing-out panels have been added for easier maintenance. New Holland recommends its compacts for demolition, earthmoving, and material handling applications, among others.

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JCB
Midi model for highway maintenance

JCB calls its new 8080 ZTS (zero tail swing) a midi excavator because it was designed to give the operator the performance of a larger machine without losing the advantages of a compact. The company designed the 11,250-pound machine for highway maintenance and general excavating. It has a 57.6-horsepower diesel engine, a maximum digging depth of 13 feet, 10 inches, and a two-speed auto shift-down power system. The machine produces 11,240 pounds-foot bucket breakout force.

JCB’s Advanced Management System gives operators a choice of standard, light, or heavy digging modes to maximize fuel efficiency.

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Caterpillar
More power and lifting capacity

Cat has recently expanded the power and capabilities of its two smallest excavators, the 3,800-pound 301.6C and 310.8C. The duo get 18-horsepower engines — a 4% increase — and more hydraulic flow and pressure, resulting in 22% more bucket digging force and more than 10% more stick digging force, plus increased lift capacities.

Four more compact models are expected to get C-series upgrades this year, including higher horsepower ratings, substantial increases in digging forces, and faster cycle times. These CR (compact radius) models range in size from the 7,300-pound 303C CR to the 11,400-pound 305C CR.

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Bobcat
Unique drive system delivers more power

Bobcat claims its 430 and 435 ZHS compact excavators have unmatched travel speed thanks to a unique drive system, while their “zero house swing” design is even more compact than most zero tail swing designs.

The 43-horsepower, 8,000-pound 430 ZHS and the 49-horsepower, 10,500-pound 435 ZHS both employ an all-hydrostatic drive system that works like the drive system on a skid-steer loader, splitting the power infinitely between the right and left tracks. Bobcat says this results in more torque, precise maneuvering, and smooth acceleration. Unlike conventional hydraulic drive systems, the FastTrack system uses separate piston pumps and high-torque drive motors for each track, resulting in better torque control for dozing, smoother turns under load, and more gradual turns on asphalt and concrete surfaces, according to Bobcat.

On many zero tail swing designs, Bobcat says, the front corners of the house extend beyond the track footprint when slewing the machine. To avoid potential damage from that, the company eliminated this overhang in the 430 and 435 with its zero house swing design.

The two ZHS models accept 14 different Bobcat attachments.

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John Deere
More drawbar pull

John Deere introduced the D-series versions of its 30-horsepower, 7,600-pound 35D and 40-horsepower, 10,400-pound 50D compact excavators last year, touting increased productivity, improved cab and controls, and lower operating costs. Productivity boosts came from up to 35% more drawbar pull and faster operating speeds.

The new cabs are larger and have repositioned control levers for better visibility. Operating costs are lower thanks to auto-idle, which reduces rpms when the engine is not working, and due to extended maintenance intervals. Both models offer zero tail swing and independent swing boom systems.

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Bobcat
New attachment system

Bobcat introduced the new hydraulic X-Change Mounting System for its compact excavators late last year, saying it eliminates the need for operators to manually position or align attachment pins during hook-up. The optional mounting system features hydraulically activated attachment retention pins that retract to remove the attachment and extend to hook-up the attachment. By making attachment changes faster and easier, Bobcat says operators will save time and be more likely to use the right-size bucket or attachment choice for each task.

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Terex
Euro compact has rear engine

Terex introduced its German-made HR3.7 zero tail swing excavator last year claiming it was designed to turn 360 degrees within the width of its tracks. The 8,150-pound machine is powered by a 32.5 horsepower engine. It has a maximum digging depth of 11 feet and a reach of 18 feet, 8 inches. Its engine is mounted in the rear to act as a counterweight; side panels provide maintenance access to the engine. Earlier this year, Terex rolled out the HR16E, a 10,320-pound economy unit with fewer standard features than other models in the compact line. The model was designed for the rental market and economy buyers who want the same basic performance as the other machines but don’t need the “bells and whistles.”

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Kobelco
Changeable control pattern

Kobelco says its four-model family of compact excavators are ideally suited for smaller-scale excavation needs. They feature a combination of zero tail swing and center boom swing for the maneuverability to dig anywhere around the excavator and deposit material precisely with minimal repositioning, according to the company. All four models have an operating pattern control changer that allows the operator to select the control pattern he or she is most comfortable with. Also standard are auxiliary hydraulics and an independent boom swing mechanism that allows simultaneous operation of the boom, arm, or bucket without any effect on the swing operation. Kobelco’s models range from the 5,500-pound 27SR-3 to the 10,400-pound 50SR-3.

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IHI
12-model lineup of compacts

Compact excavator specialist IHI offers compact excavators in 12 sizes. At one end of the spectrum is the diminutive 9NX2, a 2,060-pound machine powered by a 10 horsepower engine.

At the other end of the line is the 18,100-pound 80NX-3, powered by a 56-horsepower engine and capable of digging 14-feet deep.

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Mustang
Four new compacts

Mustang has replaced three models in its compact excavator line and added another. The 10,600-pound 5003ZT is a zero tail swing design that replaces the former 5002. The 12,500-pound 6003 and 17,500-pound 8003 feature short tail swing designs and replace the former 6002 and 8002. All three have new cabs, and side-mounted engine compartments to go with their short-swing tail designs.

The company has also added the 16,200-pound 7503ZT to the lineup. The zero-tail-swing model has a 69-horsepower engine and, like its three stablemates, is said to have the largest cab in the field.

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McLaren Industries
Combining rubber and steel tracks

McLaren Industries refers to its Hybrid Series compact excavator tracks as “steel-enforced rubber tracks.” They consist of removable rubber pads bolted to a steel track base.

McLaren claims the Hybrid Series tracks are virtually unbreakable and last twice as long as regular rubber tracks. The tracks can be used as a direct replacement for existing rubber tracks on many models without changing sprockets, rollers, or idlers, according to McLaren.

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Ingersoll Rand
Power in a compact package

Ingersoll Rand has two entries in the compact excavator market, the 7.5-metric ton ZX-75 and the 12.5-metric ton ZX 125. The 72-horsepower ZX-75 weighs 16,500 pounds and has a maximum digging depth of 13 feet, 11 inches. The 94-horsepower ZX-125 weighs 27,500 pounds and has a digging depth of 15 feet, 4 inches. Both feature a zero tail swing design, auxiliary hydraulics, and dozer blades as standard equipment. Operators can choose between ISO and SAE control patterns with the push of a button, and the cabs feature air pressurization and climate control.

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Flannegan Western
Three tools in one

Flannegan Western designed its FW Orbiter as a rotating loader that can function as an excavator, a loader or a grader. The Orbiter’s house swings 360 degrees atop a wheeled chassis. In addition to zero tail swing, the machine has both front and rear-end quick-attach capabilities, allowing for multiple tool use. The main boom accommodates a backhoe, loader, lift platform, forklift, or grader attachment. Most skid-steer-loader attachments will operate on either end of the machine. Options include diesel, gasoline, or propane burning engines and two-wheel or four-wheel drive.

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Reprinted from Better Roads Magazine
April 2006