Excavator Design Upgrade | Ekarthaan 

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

Visual Showcase

FEA Data & CAD Assembly

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.

Analysis

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.
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Ireland
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Jon H.
Ireland
Ireland

This is the second job that this guy does a job for me, and even finished the job earlier. Highly recommend him, very talendet and creative.

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Stuardo Josue R.
Germany
Germany

Didn't deliver at all, I was asked to hire someone else for the project as he didn't wanted to do the project.

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Ludwik P.
United Kingdom
United Kingdom

Fantastic guy! Ask lots of questions in order to make sure that everything is up to my expectations. Delivered several different versions of the project for me to choose even if I asked for only one. Will definitely hire him again.

Source:Verified Client - Personal Client

Paulette E.
New Zealand
New Zealand

dedicated work ethics, passionate about what he does, with attention to detail, a definate asset to any project he chooses to accept

Source:Verified Client - Freelancer.com

Chris N.
United States
United States

This guy has got to be the best Freelancer I have ever used. He was so patient with me and the communication was Great! The video work he did for me was the Best! I will be using him a lot more! Thank you so much! This experience was really good!

Source:Verified Client - Upwork.com

Roger H.
United Arab Emirates
United Arab Emirates

Excellent work from itssid4545 ...and exactly what I wanted. Good communicator and knows what he's doing with Adobe After Effects.

Source:Verified Client - LinkedIn.com

Arash M.
United Arab Emirates
United Arab Emirates

Excellent work, exactly what i wanted, will work with again.

Source:Verified Client - Upwork.com

Ike T.
United States
United States

Great job. Love the video.

Source:Verified Client - LinkedIn.com

Maria W.
Australia
Australia

Sid was such a gentleman and delivered my project with speed, efficiency and creativity. I would recommend him 5 times over! Great work!

Source:Verified Client - Upwork.com

Arash M.
United Arab Emirates
United Arab Emirates

Excellent work. Will use again

Source:Verified Client - LinkedIn.com

Bernard A.
Ireland
Ireland

gr8 . thumbs up

Source:Verified Client - Upwork.com

Scott M.
United Kingdom
United Kingdom

Perfect job!

Source:Verified Client - Upwork.com

Jazr I.
Canada
Canada

Great Freelancer: professional, courteous, efficient!

Source:Verified Client - Personal Client

Peter Z.
Australia
Australia

Thank you. You did well.

Source:Verified Client - LinkedIn.com

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United States
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