Gilley Crane’s first lift with the Terex® Explorer 5800 crane is at the Jack Daniel Distillery

The Jack Daniel’s name stands for dedication to craftsmanship and quality. When ordering a Jack Daniel’s Tennessee Whiskey, you know you are getting a high quality product.

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The same is true for Gilley Crane Rigging and Lifting of Manchester, Tenn. The company stands for quality service by trained craftsmen, safe lifting practices and the high quality crane and rigging services with the most modern crane equipment on the market.

The two recently came together when Gilley Crane was tasked with lifting two boilers weighing more than 100,000 lb (45,360 kg) each at the Jack Daniel’s Distillery in Lynchburg. The challenging lifts required each boiler to be lifted twice at a 28-ft (8.5-m) radius in a confined space. "At one end of the lift, we had to work around a fenced-in lot nearby other equipment, while at the other end we had to work around rebar sticking up around the boiler base," explains Gilley Crane Owner, Robert Gilley.

Working in the confined area, Gilley Crane’s crew needed a compact crane with excellent maneuverability. Having only a two-day window to complete the project, the company needed a crane that offered fast roading, quick setup and efficient operation.

Gilley Crane selected a new crane from its fleet for the lift, one in which the brand name and team behind it stands for quality and service. It was the company’s new Terex® Explorer 5800 all terrain crane, purchased from its Terex Crane distributor in Cleveland, Tenn., Renegar-Driggers Machinery Co, Inc. "I have bought a lot of equipment in my life, and I can’t be any happier with the level of service and support provided by Terex and Renegar-Driggers,” says Robert Gilley.

The Right Fit

The Terex Explorer 5800 all terrain crane is designed to quickly travel the streets and highways of many market around the world. It can be configured so that its five-axle chassis meets stringent axle loads of less than 20,000 lb (9000 kg) per axle. The crane also features a compact, 43.3-ft (13.2-m) carrier length and 4-ft (1.2-m) front overhang. Its narrow 9.8-ft (3.0-m) width enables the 245 US-ton (220-t) capacity class crane to transport without restriction.

Gilley Crane’s four-man crew quickly roaded the Explorer 5800 crane plus full counterweight the 30 mi (48.3 km) from its Manchester yard to Lynchburg. It required just four additional transports to move the crane’s 154,800 lb (70,2 kg) of counterweights to the project site.

The Explorer 5800 all terrain crane transports with its standard 229.7-ft (70-m) telescopic main boom installed, which provided quick on-site setup and offered more than enough length for the boiler lifts. To improve on-site equipment setup, this Terex all terrain crane self-rigged its counterweight panels. "In total, it took us about 1.5 hours for crane setup before we were ready to work,” says Gilley Crane’s Project Manager, Scott Peterson.

The unique Explorer 5800 crane boasts another exclusive feature that boosts efficiency over the road and at the jobsite: the Terex single-engine concept to power both chassis and crane operation. "The engine offers intelligent power management that selects the best performance for all load cycles," explains Terex Cranes’ Regional Business Manager, Steve Ake. "With only one engine, we reduce crane weight, daily maintenance time and long-term operating costs."

Powered by a 12.7-liter, 550-hp (405-kW) Tier 4F (Euromot Stage IV) engine, the crane has the power to quickly make it to the jobsite at speeds reaching 53 mph (85 km/hr). Once on-site, engine speed and power is reduced to 1600 RPM and 275 hp (205 kW) respectively, providing ample capacity for proper crane operation, while reducing fuel consumption when compared to two-engine cranes. "The fuel efficiency and savings are unreal," says Peterson. Robert Gilley adds, "The one-engine concept works really well for us and provides plenty of power for both roading the crane and powering the lifting operations."

In total, the project required eight lifts to move and place the two boilers and bases. The 20-foot-tall by 25-foot-long (6.1-m by 7.6-m) boilers and 10,000-lb (4,5-kg) bases were first placed onto trailers and moved approximately 200 yd (187.9 m) to their final location. Working with 55.4 feet (16.7 m) of main boom at a 28-ft (8.5-m) radius, the Explorer 5800 crane delivered more than enough capacity to lift and position the boilers and bases.

"The space we had to work with left very little room to maneuver the crane, but the steering on the Explorer 5800 is more advanced than what we’ve seen from any other crane on the market," says Gilley. The Explorer 5800 crane offers six steering modes, including off-wall and crab, to deliver a turn radius of 37.3 ft (11.4 m), improving on-site maneuverability. “The speed with which it crab steers is very efficient,” adds Peterson. “It’s mind-boggling at how quickly and easily it steers and transitions between the different steering selections.”

All crane operations, from steering to boom settings, on the Explorer 5800 crane are managed by the IC-1 computer system. "The IC-1 system,” says Ake, “features touchscreen operation and intuitive controls to make it easy on the crane operator. Plus it stores all the load charts for quick access and confident operation." Gilley adds, "Our operators can quickly pick up crane operation because of the IC-1 controls.”

Within two days, Gilley Crane’s crews transported the Terex Explorer 5800 crane to the Jack Daniels’ Distillery, rigged it for the project, performed the picks and transported it back to the Manchester yard. "This crane is totally out-of-the-box," mentions Peterson. "Our operators are extremely pleased with its performance, and everyone who has seen it work is impressed with its capabilities."

About the Terex® Explorer 5800 all terrain crane

The 5-axle, 220 tonne (245 US ton) capacity class Explorer 5800 all terrain crane is designed for worldwide operation. Dimensions, variable axle load configurations, axle pair space, overhang, boom off solution, dolly operation: all variables have been taken into account for worldwide roadability.

The crane is designed so that the 70.2 t (77.4 US t) counterweight can be automatically rigged and no additional part is wider than 2.5 m (8.2 ft).

A major feature of the Explorer 5800 crane is the single engine concept. Powered by a Scania 405kw/550hp engine complying with Euromot IV/Tier 4F directives, the crane employs the latest engine management system to enhance performance for both road travel and lifting. Fuel efficiency is provided using stop/start technology for the upper cabin and engine remapping depending on what type of operation is being performed, lifting or travelling.

The latest Terex IC-1 touch screen control system, along with radio remote control, makes rigging and on-site operation safe and efficient. The control system provides the operator with accurate load moment measurements and wind speeds and simplifies the way the crane operates when handling even the most demanding of lifts. Designed to operate globally, the system includes 14 pre-programmed languages.

Also new is the 2.85 m (9.35 ft) walk-through carrier cabin with air conditioning, which is ergonomically designed to enhance the operator’s day-to-day experience.