Heavy Machinery Prototyping

21m Reach Boom & Counterweight Design

A specialized heavy-duty engineering modification for the Komatsu PC800 Excavator, featuring a custom 21-meter long reach boom, optimized hydraulics, and a high-density counterweight system for maximum stability during high-reach operations.

21m Custom Extended Reach

FEA Structural Validation

PC800 Komatsu Upgraded

The Impact

Expanding Construction Capabilities

100%

Safety Compliant

21m

High-Reach Capability

Custom

Counterweight System

Optimized

Hydraulic Performance

Company Revenue	Estimated Additional Revenue

The Challenge

The client required a highly specialized 21-meter long reach boom for a Komatsu PC800 excavator to drastically enhance its construction capabilities. The primary engineering challenge was ensuring absolute structural integrity and calculating critical deflection limits with very limited reference data. Furthermore, we needed to optimize the hydraulic performance for the extended reach and design a completely custom counterweight system to maintain machine stability and a safe center of gravity during extreme high-reach operations.

The Solution

Advanced Engineering & Modification

Reinforced Structural Frame

Engineered a heavily reinforced excavator frame and boom structure designed to safely withstand the massive increased operational stress of a 21-meter reach.

Custom Counterweight System

Developed a specialized counterweight system utilizing high-density materials to dramatically improve stability while maintaining a low center of gravity.

Hydraulic Optimization & FEA

Upgraded the hydraulic systems with larger cylinders to support the extended boom, validated through rigorous Finite Element Analysis (FEA) to ensure compliance with strict safety standards.

Outcome

The project resulted in a fully functional, stable, and highly capable extended-reach excavator. By delivering complete assembly designs, General Assembly (GA) drawings, and precise STEP CAD files, the client successfully manufactured the modifications. The upgraded Komatsu PC800 is now perfectly engineered to handle complex, high-reach construction tasks efficiently and safely.

Technical Breakdown

Validating High-Reach Stability

Executing this massive modification required deep expertise in structural dynamics and heavy equipment kinematics. We focused heavily on balancing the physical weight distribution with the augmented hydraulic power to prevent tipping and ensure the boom's deflection remained within safe engineering limits.

Conducted comprehensive Finite Element Analysis (FEA) to validate the structural integrity of the 21m boom under peak load conditions.
Calculated precise deflection limits and stress concentrations despite the absence of standard reference data.
Engineered a high-density, low-CG counterweight solution specifically tailored for the Komatsu PC800 chassis.
Delivered fully manufacturing-ready STEP CAD files, detailed sub-assembly drawings, and GA documentation for seamless fabrication.