Step by Step Guide: How to Turn Your Existing Excavator into a Falcon Winch Assist

Section One: The Build Process

Introduction

Investing in entirely new equipment can be a significant financial barrier for many logging operations. However, the Falcon Winch Assist offers a cost-effective solution by allowing you to repurpose your existing base machines. This approach not only maximises and maintains the value and longevity of your current assets but also spreads the cost of the investment over a longer period. With the value-for-money of the current second-hand base machine market, this method has become a favoured choice for many logging contractors and below is how we can help you make it happen.

Step One - Reach Out & Consultation

Begin by reaching out to discuss your operational needs and ensure that a Falcon Winch Assist is the right solution for you. We work closely with you to understand your specific requirements and challenges.

Step Two - Machine Evaluation

The second step is to determine if your current machine is suitable for conversion into a Falcon Winch Assist. We work closely with you, the contractor to assess the machine's condition and compatibility through a detailed checklist.

This checklist includes evaluating the structural integrity, hydraulic systems, and overall performance and specifications of the machine.

Consultation and Advice: If the evaluation reveals that the machine is not suitable for conversion, the contractor has two options. You can either identify a suitable second-hand machine on your own, or we can provide support and advice on suitable options available in the market. Our team is equipped with practical logging experience to help you find a machine that meets the necessary criteria and offers practicality and value for your investment.

Step Three – Quotation

Customised Quote Preparation: After determining the suitability of your machine and understanding your specific needs, we prepare a customised quotation. This quotation includes a detailed breakdown of all costs associated with the conversion process.

Itemised Costs: The quotation will cover the cost of the Falcon Winch Assist system, any additional components required, installation fees, and potential modifications needed for your machine. We ensure transparency by itemising each ‘additional extras (more on this below) costs so you know exactly what you're paying for.

Comprehensive Support: Along with the quotation, we provide a detailed timeline for the conversion process, ensuring you know what to expect at each stage. Our team is available to answer any questions and provide support throughout the entire process, from initial consultation to final deployment.

Step Four - Fixed Price Contract & Payment

Once you’re happy with the quotation, we provide a contract which includes the pricing & build schedule, scope of works and terms of conditions. We also discuss your financing options

Flexible Options: Through our finance partners, we can offer a variety of payment options to help manage the financial aspect of the investment. Whether you prefer a one-time payment or a structured payment plan, we work with you to find the best solution.

Step Five - Building the Winch Assist

Winch Construction: Once the contract documents are signed, we move on to building the winch. This phase involves fabricating and assembling the Falcon Winch Assist system according to the customised design specifications.

Timeframe: The construction process generally takes between 10-12 weeks. The exact duration depends on several factors, including the complexity of the winch system, the condition of the base machine, and any additional customisations or optional extras requested by the contractor. We’ll consult with you for the final date to ensure it suits your operations schedule.

Customisation and Extras: During this period, any additional features or modifications specified by the contractor are also incorporated. This could include upgrades, extra kits for additional tethered machines, reinforced protection safety, or other specialised components tailored to meet specific operational or regulatory needs.

Quality Assurance: Throughout the build process, our team conducts ongoing quality checks to ensure that every component meets our high standards of performance and reliability. This commitment to quality ensures that the Falcon Winch Assist system will operate smoothly and efficiently once installed on your machine. You will be able to follow the progress of your build on a weekly basis through receiving our weekly progress reports which are sent to you. This open line of communication helps address any questions or adjustments needed during the construction phase.

Step Six - Build Complete & Pre-Delivery Check

Build Completion: Upon completing the construction of the Falcon Winch Assist system, our team performs a thorough inspection to ensure all components are correctly assembled and meet the highest quality standards.

Pre-Delivery Check: Once the build is complete, we conduct a comprehensive pre-delivery check to ensure everything is functioning as expected.

This includes:

• Initial Testing: Testing the winch system to confirm its operational efficiency and performance.
• Calibration: Calibrating the winch system to match the specific requirements of your logging operations, ensuring optimal functionality.
• Safety Inspections: Performing rigorous safety checks to ensure the machine meets all safety standards and regulations.

Step Seven: Delivery & Commissioning

Delivery: After the pre-delivery check and operator training, we arrange for the transportation of your newly converted Falcon Winch Assist machine to your site. Our logistics team ensures that the machine is delivered on schedule however if you have a preferred transport partner, we can cater this also.

Commissioning Day: Commissioning is a crucial step to ensure your Falcon Winch Assist machine is ready for operational use. Here’s what a typical commissioning day entails:

• • Machine Induction: A DC Equipment authorised technician or representative conducts a comprehensive induction with the tethered machine operator.
  • Safety Features: Verification of safety features such as drum over speed protection, emergency stops, safety warning alarms, emergency exits, and fire suppression systems.
  • Safety Protocols: Ensuring the operator understands safe anchoring procedures, stability considerations, work zones, and safe winching angles.

• • Pre-Start Checks: Detailed instruction on performing pre-start checks to ensure the machine is ready for operation.
  • Startup and Shutdown Procedures: Guidance on the proper startup and shutdown procedures to maintain machine health and safety.
  • Controls and Gauges: Familiarisation with the machine’s controls and gauges for efficient operation.
  • Maintenance: Instruction on essential maintenance tasks, such as grease points and regular inspections.

• • Compliance: Ensuring all machine certifications are in place and the operator understands their responsibilities relating to machine warranty and adherence to rules and regulations.

• • Hands-On Training: The operator runs the machine while the representative observes, providing real-time feedback and addressing any issues.
  • Hazard Awareness: Discussion of all potential hazards and controls to ensure the operator can manage the machine safely.
  • Re-Inspection: After initial operation, the machine is re-inspected to confirm everything is functioning correctly.

• • Operator Understanding: The operator demonstrates a general understanding of the induction and operational protocols. We also encourage anyone in your crew who may be interacting with the winch assist in the future to attend the commissioning so there is at least one person with the operational knowledge for future reference.
  • Documentation: Completion of the machine induction form, signed by both the DC Equipment technician/instructor and your operator, confirming that all steps have been completed and understood.

Ongoing Support: After commissioning, we continue to offer support and are available to address any questions or concerns that may arise, ensuring a smooth transition into using your Falcon Winch Assist machine in daily operations.

Step Eight - Post-Delivery Check-In and Servicing

Regular Check-Ins: After the machine has been delivered and commissioned, we maintain regular check-ins to ensure everything is running smoothly. Our support team reaches out periodically to discuss the machine’s performance and address any issues or concerns.

Scheduled Servicing: To keep your Falcon Winch Assist machine in optimal condition, we offer scheduled servicing. This includes:

• Routine Maintenance: Regularly scheduled maintenance tasks such as lubrication, hydraulic system checks, and inspection of critical components.
• Performance Monitoring: Monitoring the machine’s performance to detect and address potential issues before they become major problems.
• Safety Inspections: Conducting safety inspections to ensure all safety features remain functional and up to standard.

Technical Support: Our team of experts is available to provide technical support whenever needed. Whether it’s troubleshooting a problem, providing operational advice, or offering guidance on best practices, we are here to help.

Parts Replacement: If any parts need replacing, we provide genuine Falcon parts to ensure compatibility and maintain the high performance and reliability of your winch assist system.

Operator Feedback: We value feedback from operators and incorporate it into our support strategy. By understanding the practical challenges faced in the field, we can continually improve our service and support offerings.

Documentation and Records: We keep detailed records of all maintenance and servicing activities, which helps in maintaining the machine’s warranty and ensures a comprehensive service history.

Section Two: Benefits of a Falcon Winch Assist

We break down the benefits of Falcon Winch Assist into three key areas:

• Benefits of a Repurposed Falcon Winch Assist vs. New Equipment

• Benefits of a Repurposed Falcon Winch Assist vs. Other Winch Solutions

• Benefits of a Repurposed Falcon Winch Assist vs. Not Having a Winch Solution in your operation

Benefits of a Repurposed Falcon Winch Assist vs. New Equipment

Cost Efficiency: Repurposing is more budget-friendly compared to the high initial expense of new equipment.

Asset Utilisation:

• Extended Machine Life: Enhances the functionality of existing machines, maximising their lifespan.
• Depreciation Benefits: Minimises the financial hit from rapid depreciation seen with new equipment.

Quicker Integration:

• Faster Deployment: Conversion is often quicker than waiting for new equipment delivery and setup.
• Minimal Disruption: Uses existing machinery, reducing operational downtime compared to integrating new systems. All your communications and systems can remain in the machine.

Benefits of a Repurposed Falcon Winch Assist vs. Other Winch Solutions

• Custom Fit for your operation in mind:
  • Tailored Design: Specifically designed to work with your existing machinery, ensuring a perfect fit and optimal performance.
  • Customisation: Allows for bespoke modifications to suit your specific operational needs these include:
    • Grousers
    • Hand rails
    • Quick hitch
    • Rotating grapple
    • High and wide undercarriage modification
    • ROPS/FOPS/OPS (protection safety to local regulation)
    • Bucket cylinder guards
    • Guarding packages
    • Extra felling kits

• Cost Advantage & competitive pricing: Often more cost-effective than other new winch systems.

• Proven Reliability: Benefits from Falcon’s proven track record in winch technology, offering reliable performance and durability.

Benefits of a Repurposed Falcon Winch Assist vs. Not Having a Winch Solution in your operation

1. Enhanced Productivity:
   • Improved Efficiency: Significantly boosts operational efficiency and productivity by providing winch-assisted capabilities.
   • Increased Logging Capacity: Allows for more effective handling of logs and terrain, improving overall logging output.
2. Operational Flexibility:
   • Versatile Use: Expands the range of tasks your machine can perform, adapting to various logging challenges and environments.
   • Adaptability: Provides a solution that evolves with your operational needs, unlike fixed or manual methods.
3. Safety and Control:
   • Enhanced Safety: Offers better control and safety features compared to manual or non-winch assisted operations, reducing the risk of accidents.
   • Operational Precision: Facilitates precise winching operations, improving the safety and effectiveness of logging tasks.

Conclusion:

Transforming your existing excavator into a Falcon Winch Assist is a strategic move that delivers both financial and operational benefits. By opting for this conversion, you not only avoid the significant upfront cost of purchasing new equipment but also extend the life and utility of your current assets. This approach allows you to leverage the value of your existing machine, making a long-term investment more manageable and cost-effective.

The conversion process, outlined in detailed steps, ensures a smooth transition from evaluation to commissioning. Our comprehensive consultation, precise machine assessment, and customised quotation provide a clear understanding of the costs and timelines involved. Building the Falcon Winch Assist system with high standards of quality and incorporating any requested customisations guarantees that you receive a solution tailored to your specific needs.

Once the build is complete, our rigorous post-delivery checks and commissioning process ensure that the machine operates efficiently and safely. Ongoing support, including regular servicing and technical assistance, helps maintain optimal performance and addresses any issues promptly.

In essence, converting your excavator into a Falcon Winch Assist is a practical solution that enhances your logging operations while managing costs effectively. It represents a valuable investment in both productivity and cost-efficiency for your logging business.