Allelys Repowers AK912 Crane With Stage V Deutz Engine

30 Second Takeaway

Allelys has completed a major modernisation of its 1,200 tonne Gottwald AK912 heavy lift crane, installing a Deutz TCD 7.8 Stage V engine to improve fuel efficiency, reduce emissions and extend the operational life of the machine. The three month programme also included a new control and instrumentation display with remote monitoring capabilities. Following commissioning, the upgraded crane returned to work by lifting two 186 tonne transformers from a river barge onto two 14 axle flat top trailers.

Three Month Modernisation for the AK912

Allelys has completed a three month engine and control system upgrade for its Gottwald AK912 crane at the company’s workshops in the United Kingdom. The project centred on replacing the crane’s existing engine with a Deutz TCD 7.8 Stage V power unit. The installation brings the crane into line with current European Stage V emissions requirements for non-road mobile machinery.

Allelys said the replacement engine provides:

• Improved fuel efficiency

• Lower exhaust emissions

• Quieter operation

• Updated engine technology

• Continued availability of the crane

• A longer operational life for the asset

The work allows Allelys to retain the lifting capability of the AK912 while modernising the systems used to power and monitor it.

Deutz TCD 7.8 Brings Stage V Compliance

The Deutz TCD 7.8 is a six cylinder, water cooled diesel engine designed for industrial and construction equipment. The engine has a displacement of approximately 7.8 litres and incorporates turbocharging with charge air cooling. Depending on the selected configuration, the TCD 7.8 family provides outputs between approximately 160 and 260 kW.

Deutz lists maximum torque of up to 1,400 Nm at 1,450 rpm, although the precise performance available in the AK912 depends on the specification selected for the installation.

For European Stage V compliance, the engine can be equipped with an exhaust aftertreatment system incorporating:

• A diesel oxidation catalyst

• A diesel particulate filter

• Selective catalytic reduction

These systems control pollutants including particulate matter and nitrogen oxides before the exhaust gases leave the crane. The TCD 7.8 is also approved for operation with hydrotreated vegetable oil, subject to the applicable engine specification and Deutz operating requirements.

What Stage V Means for the Crane

European Stage V emissions regulations apply to engines used in non-road mobile machinery, including construction equipment. The requirements establish limits for pollutants including nitrogen oxides, hydrocarbons, carbon monoxide, particulate mass and particle numbers.

Bringing the AK912 to Stage V specification allows Allelys to operate the crane with a more modern emissions system while retaining a specialist machine with substantial lifting capacity. This can be particularly relevant for work at ports, power facilities, industrial sites and infrastructure projects where environmental performance forms part of the project requirements.

The upgrade does not increase the crane’s rated lifting capacity. Its purpose is to preserve the AK912’s existing heavy lifting capability while improving the efficiency and emissions performance of its power system.

New Control and Instrumentation Display

Alongside the engine replacement, Allelys installed a new control and instrumentation display. The display gives the operating team improved access to information relating to crane and engine performance. It also incorporates remote monitoring capabilities, allowing authorised personnel to review operating data without relying solely on physical checks at the machine.

Remote access to performance information can support:

• Technical assessment

• Maintenance planning

• Fault investigation

• Engine performance monitoring

• Operating record review

• Workshop and site support

The control system was integrated with the new Deutz engine and the crane’s existing systems during the workshop programme. The modernisation provides updated monitoring functions without removing the established operating characteristics of the AK912.

Upgrade Completed With Deutz UK

The work was completed at Allelys’ own workshops with technical support from Deutz UK.

Integrating a modern engine into an existing heavy lift crane requires more than exchanging one power unit for another. The replacement must be connected to the crane’s fuel, cooling, exhaust, electrical, control and monitoring systems.

The project therefore required coordination between Allelys’ engineering team and Deutz UK to confirm that the engine and its supporting systems operated correctly within the AK912. The installation programme covered the engine replacement, control integration, instrumentation work, commissioning and functional testing.

David Allely, chairman of Allelys, said: 

“Upgrading the AK912 enables us to retain the capability of the crane while improving its efficiency, emissions performance and operational monitoring."

“It was a complex upgrade, carefully planned and completed in-house to ensure that the crane can continue supporting major projects across the UK.”

Commissioning and Testing

Following installation, the upgraded AK912 underwent commissioning and testing before returning to project work. This stage allowed the teams to check the performance of the new engine, control display and monitoring functions under operating conditions.

The process would also confirm communication between the engine management system and the crane’s controls, together with the operation of supporting systems such as cooling, exhaust treatment and instrumentation. Once testing had been completed, the AK912 was released directly to its first project following the upgrade.

First Project Involved Two 186 Tonne Transformers

The crane’s first operational assignment following the modernisation involved discharging two transformers from a river barge. Each transformer weighed 186 tonnes. The AK912 lifted the units from the barge before lowering them onto two 14 axle flat top trailers for the next stage of their journey.

The operation provided the first live-project test of the crane’s upgraded engine, instrumentation and control systems. Handling the transformers required coordination between the crane team, rigging personnel, barge operators and transport crews. The trailers had to be positioned accurately beneath the suspended loads before each transformer could be lowered onto its transport supports. Once landed, the transformers could be secured to the trailers for onward transport to the project site.

Barge to Trailer Transfer

Transferring a heavy component between a floating barge and a road transport system requires careful lift planning. Barge movement, water level, crane radius, rigging geometry and trailer position must all be considered before the lifting operation begins.

The principal stages of the transformer operation included:

• Positioning the AK912 beside the unloading area

• Preparing and inspecting the lifting arrangement

• Connecting the crane to each transformer

• Taking the load from its barge supports

• Lifting the transformer clear of the vessel

• Slewing it towards the transport area

• Aligning it with the trailer

• Lowering it onto the transport supports

• Disconnecting the rigging

• Securing the transformer for onward movement

The use of 14 axle flat top trailers allowed the transformer weight to be distributed across a large number of axle lines.

The trailer arrangement would have been selected according to the transformer weight, support positions, permitted axle loads and conditions along the transport route.

The Gottwald AK912

The Gottwald AK912 is a specialist heavy lift crane with a maximum rated capacity of approximately 1,200 tonnes. Allelys acquired the crane in 2023 and completed a substantial refurbishment before bringing it back to the United Kingdom.

The crane can be configured with a main boom of up to approximately 113 metres, allowing it to support projects involving heavy industrial components, transformers, generators, vessels and infrastructure structures. Unlike a conventional modern All Terrain crane, the AK912 is a large pedestal type lifting system prepared and configured for individual heavy lift projects.

This type of crane is suited to planned operations where high lifting capacity is required and sufficient time is available for transport, assembly and dismantling.

Its applications include:

• Transformer installation and removal

• Generator handling

• Port and marine lifting

• Power station projects

• Industrial construction

• Infrastructure works

• Heavy vessel handling

• Project cargo transfers

On an earlier project at the Port of Sutton Bridge, Allelys configured the AK912 with a 41 metre main boom to discharge two generators weighing approximately 365.9 tonnes each and two transformers weighing approximately 164 tonnes each. The components were lifted from a vessel and transferred onto a 12 axle, four file self propelled modular transporter arrangement.

Extending the Life of a Specialist Crane

Repowering an existing crane can preserve lifting capacity that would otherwise require replacement by another large and specialised machine. The structure, boom system, lifting machinery and mechanical components of a heavy crane can remain suitable for service even when its original engine and control technology have become less efficient or more difficult to support.

A modernisation programme can therefore focus investment on the systems most affected by technological change. For the AK912, the Stage V repower provides a modern engine and emissions system while retaining the crane’s existing structural and lifting capability.

The updated control display also improves access to operational information, creating a clearer interface between the machine, its operators and Allelys’ technical teams.

Continued safe operation remains dependent on scheduled inspection, maintenance, testing and compliance with the crane manufacturer’s requirements and applicable lifting regulations.

About Allelys

Allelys is a UK heavy transport, lifting and installation specialist headquartered in Studley, Warwickshire. The company provides engineering, planning, project management and operational delivery for the movement and installation of heavy and abnormal loads.

Its services cover:

• Heavy lift engineering

• Crane operations

• Heavy and abnormal transport

• Self propelled modular transporter operations

• Jacking and skidding

• Transformer movement

• Port and marine operations

• Route planning and surveys

• Installation and assembly

• Project management

• Permits and stakeholder coordination

Allelys works across the power generation, electricity transmission, civil engineering, manufacturing, rail, nuclear, renewable energy and infrastructure sectors. Its equipment fleet includes heavy lift cranes, specialist trailers, modular transport systems, self propelled modular transporters and equipment for jacking, skidding and positioning large components.

Company website: www.allelys.co.uk

About Deutz

Deutz AG is a German manufacturer of drive systems for construction, industrial, agricultural, material handling and power generation applications. Founded in 1864, the company is headquartered in Cologne and is one of the world’s longest established manufacturers of internal combustion engines.

Its product portfolio includes diesel, gas, hydrogen, electric and hybrid power systems, together with service, parts and remanufacturing operations. The company’s industrial engine range covers compact and medium duty power units for mobile and stationary machinery.

Deutz UK provides engines, parts, technical assistance and service support for customers in the United Kingdom and Ireland.

Company website: www.deutz.com

UK website: www.deutzuk.com

Frequently Asked Questions

What work was completed on the Allelys AK912?

Allelys replaced the crane’s previous engine with a Deutz TCD 7.8 Stage V diesel engine. It also installed a new control and instrumentation display with remote monitoring capabilities.

How long did the upgrade take?

The modernisation programme was completed over approximately three months.

Where was the work carried out?

The upgrade was completed at Allelys’ own workshops with support from Deutz UK.

What is the capacity of the AK912?

The Gottwald AK912 has a maximum rated lifting capacity of approximately 1,200 tonnes, depending on its configuration and operating radius.

How long is the crane’s boom?

The AK912 can be configured with a main boom of up to approximately 113 metres.

What engine was installed?

The crane received a Deutz TCD 7.8 six cylinder engine meeting European Stage V emissions requirements.

How powerful is the Deutz TCD 7.8?

The TCD 7.8 engine family covers outputs from approximately 160 to 260 kW, depending on configuration. Allelys has not published the precise output selected for the AK912.

Does the upgrade increase the crane’s lifting capacity?

No. The work retains the crane’s existing lifting capability while improving its fuel efficiency, emissions performance and operational monitoring.

What was the crane’s first job after the upgrade?

The AK912 discharged two 186 tonne transformers from a river barge and lowered them onto two 14 axle flat top trailers.

Why was remote monitoring added?

Remote monitoring provides improved access to operating and performance data, supporting technical assessment, maintenance planning and fault investigation.