Turning Excavators: Techniques, Challenges, and Best Practices

[MikePhua]

Excavators are one of the most versatile and widely used pieces of equipment in the construction, mining, and infrastructure sectors. Their ability to dig, lift, carry, and demolish makes them essential for various tasks, but one skill that operators must master is turning the excavator efficiently and safely. Turning an excavator might seem straightforward, but there are specific techniques, challenges, and considerations that come into play, especially when operating in confined spaces or on uneven terrain.
Understanding Excavator Design and Function
Before diving into turning techniques, it's important to understand the basic design and functionality of an excavator. Excavators are equipped with a large arm, bucket, and a rotating platform mounted on a set of tracks or wheels. The design of the machine allows the upper structure (house) to rotate 360 degrees, which is a key feature when it comes to maneuvering and turning.

1. Tracks and Stability: Most excavators use tracks instead of wheels, providing better stability and mobility on uneven ground, such as dirt, mud, or sand. Tracks distribute the machine's weight over a larger surface area, preventing it from sinking into soft ground.
   
2. Hydraulic System: The excavator’s movement is driven by a sophisticated hydraulic system that powers the arm, bucket, and tracks. Hydraulic cylinders in the tracks help the machine turn and rotate efficiently.
   
3. Rotation of the House: The upper structure, or "house," of the excavator can rotate independently from the undercarriage, providing exceptional maneuverability. This is a key element that allows operators to pivot and turn the machine with precision.
   

Techniques for Turning Excavators
While the basic act of turning an excavator involves rotating the house while the tracks continue to move, several techniques can help operators turn the machine more effectively, depending on the situation.

1. Pivot Turns (Full Rotation): Pivoting is when the excavator’s house rotates 180 or 360 degrees, turning the entire machine around its center. This technique is especially useful in open spaces where the operator has sufficient room to rotate. The key to performing a pivot turn smoothly is controlling the hydraulic system and ensuring the machine's weight is distributed evenly. This helps avoid any strain on the machine and reduces wear on the tracks.
   
2. Counter Rotation (Track Steering): In tighter spaces, operators can perform a counter-rotation, which involves using the tracks to steer the machine. By moving the tracks in opposite directions, the excavator can turn in place. This is particularly useful when working in confined areas such as narrow streets, construction sites, or when maneuvering around obstacles. Proper use of counter-rotation allows the operator to turn the excavator with minimal movement and maximum precision.
   
3. Slow and Steady Turns: When operating in constrained or delicate environments, it’s crucial to make slow, controlled turns. Rapid or jerky movements can cause the machine to lose balance, damage the undercarriage, or even cause tipping. By slowly adjusting the speed of the tracks and rotating the house gently, operators can maintain control and prevent accidents.
   
4. U-Turns: In situations where a complete turnaround is necessary, a U-turn can be performed by pivoting the excavator while simultaneously adjusting the tracks in a coordinated motion. This technique allows the operator to reverse the direction of the machine without needing to reposition it. U-turns are commonly used when maneuvering through narrow lanes or around tight corners.
   

Challenges in Turning Excavators
Turning an excavator, especially in difficult conditions, presents several challenges. Understanding these challenges is crucial for operators to avoid costly mistakes or damage to the equipment.

1. Limited Space: One of the biggest challenges when turning an excavator is working within a limited space. Construction sites, urban environments, or busy work areas often have restricted room for turning. In these situations, counter-rotation or slow, precise pivoting is essential. Operators must be aware of their surroundings, including the location of obstacles and other equipment, to avoid collisions.
   
2. Uneven Terrain: Operating an excavator on uneven terrain makes turning more difficult. The machine’s tracks may slip or become stuck, especially if the ground is too soft or muddy. To mitigate this, operators should adjust the speed of the turn and avoid overloading the machine. In some cases, operators may need to use additional support, such as a stabilizer, to prevent tipping during the turn.
   
3. Speed Control: Turning an excavator too quickly can lead to stability issues. The force generated by fast turning can cause the machine to tip, especially if the load is unbalanced or the ground is uneven. Slowing down while turning helps maintain the machine's stability, but operators should also be mindful of the job’s efficiency. Striking the right balance between speed and control is crucial.
   
4. Track Wear: Over time, frequent turning, especially sharp turns or counter-rotations, can lead to track wear. The friction created by constant turning on tough surfaces can result in track damage or misalignment. Regular maintenance, such as track inspections and lubrication, helps to extend the lifespan of the tracks and keep the machine operating smoothly.
   
5. Tipping Risk: When turning on slopes or uneven ground, the risk of tipping increases. Excavators have a high center of gravity, and improper turns can cause the machine to become unstable. Operators must always be cautious when turning on inclines and should avoid turning with a heavy load or when operating on soft ground that may not provide adequate support.
   

Best Practices for Safe Turning
To ensure safe and efficient operation, operators should follow these best practices when turning an excavator:

1. Pre-Turn Inspection: Before making a turn, operators should conduct a quick inspection to ensure that the area is clear of obstacles, including other equipment, workers, and debris. It’s essential to check the ground condition to avoid instability during the turn.
   
2. Maintain Steady Speed: Operators should always aim to maintain a steady speed when turning the excavator. Rapid movements can lead to instability, while slow, controlled movements ensure greater safety.
   
3. Use the Right Technique: Depending on the available space and the nature of the terrain, operators should choose the appropriate turning technique. For tight spaces, counter-rotation is recommended, while pivot turns are ideal for open areas.
   
4. Stay Within the Machine’s Limits: Operators should never attempt to turn an excavator when the ground conditions or machine load exceed the recommended limits. Always refer to the manufacturer’s guidelines for safe operating procedures.
   
5. Regular Maintenance: Regularly inspecting and maintaining the excavator's hydraulic system, tracks, and undercarriage ensures that the machine operates smoothly and can turn effectively. Maintenance should include checking for leaks, lubrication, and wear on the tracks, particularly after heavy turning.
   

Conclusion
Turning an excavator is more than just a simple task; it requires a combination of technique, awareness, and understanding of the machine’s capabilities. Whether in open spaces or tight quarters, mastering the art of turning an excavator is essential for ensuring safe and efficient operations. By following best practices, overcoming the challenges, and using the appropriate turning techniques, operators can maximize their machine's performance while minimizing risks and wear. Regular maintenance and safety precautions further enhance the machine’s longevity and ensure its reliability in demanding work environments.