Material Handlers

You could say that cranes—or excavators or material handlers, as they’re variously called—are the “weightlifters” of the scrap industry, the equipment that can literally move mountains and do the heavy lifting required in a scrap operation.
   While lifting capacity is a top consideration in selecting a crane/excavator/material handler, other important factors include durability (to survive harsh scrap plant conditions), dependability (to take a licking and keep delivering), and efficiency (to meet the productivity demands of the volume-focused scrap industry). Manufacturers are also responding to the industry’s needs by producing material handlers that offer easy maintenance, electronic diagnostics and controls, and quick attachment changes. 
   Some of the biggest changes in design, though, are inside the cab where ergonomics has become the buzzword. Design engineers, realizing that a comfortable operator is less prone to injury, less fatigued, and—hence—more productive, have combined functionality with comfort. The latest cabs can be hydraulically elevated and sport extensive glass to give the operator maximum visibility and enhance safety. Inside, cabs are more ergonomically designed—featuring, for instance, luxuriously cushioned and adjustable seats—and appointed with “automotive-type” amenities, such as air conditioning/heating, beverage holders, radio/cassettes, and more.
   High-end handlers feature computer-monitored operations that maintain production efficiency under changing conditions. Also available are models with onboard diagnostics that take the worry out of maintenance, notifying the operator about engine or hydraulic problems, scheduled maintenance, and much more, using an LCD screen mounted in the cab.
   Equally notable, while tracked or crawler-type handlers continue to be the most popular, several vendors offer wheeled versions that put less wear-and-tear on paved surfaces and provide another option for scrap operators.

Product Showcase
If 2001 is your year to expand, replace, or upgrade your fleet of material handlers, you should have no problem finding a model that fits your needs. Here’s a review of crane/excavator/material handler manufacturers serving the scrap niche:
   • Atlas ERS Inc.: Atlas ERS’s Industrial Series of material handlers encompasses four models—the 1504, 1604, 1704, and 1804—which can come with tires or tracks or as pedestal-mounted units.
Working weights range from about 31,000 to 80,000 pounds, with reaches from 30 to 59 feet. The new Model 5005 being introduced this year has a working weight of 100,000 pounds and a reach of 70 feet.
   With their advanced technical design, Atlas ERS’s hydraulic machines are ideal for handling scrap metal effectively and profitably, the company says. Their main features include rapid working movements, generous reach and working height, and tremendous lifting capacity. The AWE 4 hydraulic system means that several working movements can be performed simultaneously on an output demand basis, regardless of the load value. This makes working movements smooth and powerful.
   The machines’ frame structure, heavy-duty running gear, and four broad support pads ensure stability throughout their slewing range. Every Atlas ERS scrap handler is available with several boom/jib combinations, with special steep-angle positions for maximum working height.
   The 1804 tracked units are available with mechanically or hydraulically extendable track frames. The main advantages are their impressive stability and the robust nature of the crawler-track undercarriage, which is highly resistant to damage.
All Atlas ERS running gear systems have ample ground clearance, with the travel motors, hoses, and lines all located in a protected position within the frame and track profile. The AWE 4 system, planetary gear drivetrain, and two travel speeds make for outstanding climbing ability.
   For more information, contact Atlas ERS at 716/675-2040, or visit www.ersindustries.com.
   • Case Corp.: To meet the performance needs of scrap processors, Case offers the 9050B Material Rehandler, a high-productivity crane with a custom boom and guarding package designed specifically for the rigors of scrap handling.
   The 240-hp 9050B MR is outfitted with a Pierce material-handling boom and auxiliary hydraulic package that works with a Pierce orange-peel grapple. Operators can also use the 20-kW Crane System generator with a 57-inch magnet.
   In the 9050B MR, scrap handlers get features like a complete guarding package and manual-tilt cab riser coupled with an exceptional level of power and control, the company says.
   Among the control choices are four work modes—high, standard, light, and fine—which let the operator choose the hydraulic output setting that best matches hydraulic horsepower to the job.
   Selectable attachment cushion control automatically activates to smoothly stop the boom or arm at any point through the cylinder stroke. During normal operation, hydrostatic braking stops the turntable, but the operator can select “controlled free swing” to override the brake and provide a smoother stop, reducing oscillation of the magnet.
   With the scrap boom, the Case unit has an operating weight of 91,662 pounds and a maximum reach of 48 feet. At 45 feet of reach at 5 feet above ground level, the 9050B MR has 8,540 pounds of lift over the side and 11,650 pounds over the ends.
   For more information, contact Case at 262/636-5879, or visit www.casecorp.com.
   • Caterpillar Inc.: Caterpillar makes a wide variety of cranes designed exclusively for the scrap industry, with its current lineup including six tracked models (M318, M320, 325B, 330B, 345B, and 375) and four wheeled models. 
   It’s a common misconception that Caterpillar manufactures equipment mainly for the largest operations. In reality, its product line includes models suitable for scrap businesses of any size.
   Operating weights range from 48,350 pounds for the M318 to 203,000 pounds for the M375 track models, with front lift capacities from 11,000 to 47,000 pounds (using a 20-foot height and 20-foot reach for comparison). The 325B offers a maximum horizontal reach of nearly 44 feet from swing center and a maximum vertical pin height of more than 50 feet, while the 345B offers a maximum reach of 54 feet and a maximum height of 53 feet.
   Tracked models feature an extra-wide track gauge that creates over-the-side stability for handling heavier loads with enhanced productivity.
C   aterpillar’s wheeled models, with six wheels mounted on five nonsteering axles, steer like tracked machines. The three wheels per side are mechanically linked, allowing the operator to distribute power to all wheels or any single wheel depending on ground conditions.
   All models are constructed with an extra high and wide car body to allow maximum use of hydraulic lift capacity over both front and side.
   The hydraulics in Cat machines are designed specifically to meet the requirements of the attachments. Magnets are operated by a hydraulically driven generator set, and the electronic magnet controller and generator are linked to totally eliminate traditional contactor maintenance.
   Cat cabs are built on a 6-foot 5-inch riser to give the operator maximum visibility for loading or unloading processing equipment, trucks, and railcars. A cab-mounted magnet system monitor/control provides the operator with system information via a set of indicator lights for magnet on, generator hot, voltage fault, ground fault, and over 75 percent duty cycle. In addition, a rotary selector switch allows the operator to optimize magnet performance for different grades of scrap.
   For more information, contact Cat at 309/675-8995, or visit www.cat.com.
• Daewoo Heavy Industries America Corp.: Daewoo introduced the Solar-V excavator series in 1999, including the S290LC-V specifically for the scrap industry.
T   he unit is powered by a Daewoo turbodiesel engine that delivers 194 hp at 1,900 rpm. With an operating weight of 62,400 pounds, the S290LC-V showcases other advanced features designed to boost performance. These features include a full-time engine-hydraulic interface system that controls engine output, hydraulic pressure, and oil volume.
The S290LC-V also offers a new swing motor with increased torque that can deliver faster work cycles and a new control valve design that allows precise boom and arm cylinder movement. A power-boost feature increases the unit’s performance in demanding work situations.
   All Solar-V excavators also sport Daewoo’s Command Cab operator compartment, which has increased insulation, improve climate control, expanded visibility, easy-to-read controls, and more.
   For more information, contact Daewoo at 770/831-2200, or visit www.dhiac.com.
   • John Deere Construction Equipment Co. Deere’s excavators cover the spectrum of machine weights, engine power, and reach used in the scrap industry—from the 35,500-pound, 105-hp 160LC with maximum reach of 21 feet 1 inch to the 73,000-pound, 235-hp 370 model that can reach 39 feet 9 inches and lift 33,600 pounds over the front.
   All are available with couplers, buckets, thumbs, grapples, guarding/protection packages, and other related attachments available through Deere’s extensive dealer network.
   All models also come with Deer’e Powerwize hydraulic management system, designed to ensure smooth multifunction operations. The system works with two variable-displacement axial piston pumps that maintain a constant balance between pressure and flow. Two power modes—standard and economy—regulate engine rpm. There are also four work modes that prioritize hydraulic flow independent of the power modes, enabling the operator to select the proper machine performance for all jobs, Deere says.
   For the operator, Deere excavators provide a wide, spacious, comfortable, and quiet cab, the firm says. In addition to a fully adjustable seat and hand control levers, the cab offers excellent visibility, windows with reinforced glass, reduced noise and vibration through six silicone-filled cab mounts, and air conditioning.
   For more information, contact Deere at 309/765-1848, or visit www.deere.com.
   • Fuchs Loaders: Fuchs Loaders, a division of Schaeff of North America Inc., serves the scrap industry with six rubber-tired scrap loaders and two crawler models.
   The firm’s smallest model, the rubber-tired MHL 320, weighs 41,900 pounds, while its biggest rubber-tired machine—the MHL 380—weighs 136,685 pounds. The two crawler models, the RHL 340 and RHL 350, are midsized with operating weights of 70,550 pounds and 90,388 pounds, respectively.
   Lifting capacities for the rubber-tired models range from 19,200 pounds at 15 feet for the MHL 320 to 48,500 pounds for the MHL 380. On the crawler side, the RHL 340 has a lifting capacity of 30,200 pounds at 15 feet, while the RHL 350 can lift up to 34,170 pounds.
   Despite the large size and weight of some of its machines, Fuchs keeps the dimensions of its handlers compact and their center of gravity low to make them more flexible and reduce nonproductive maneuvering time.
   Fuchs loaders also have outstanding stability during operation, a function of the low center of gravity and the high strength-to-weight ratios in their steel components, the company says. All components and structures are designed around 90-percent duty cycle work for maximum service life.
   Also, Fuchs designers believe in simple elegance throughout their machines. Hydraulic and electrical systems are functional yet simple to maximize reliability and minimize service time. All models offer walk-up service access, which significantly reduces maintenance time. The Fuchs quick-attach system is another time-saving feature, allowing a magnet and grapple to be interchanged in about 10 minutes.
   According to Fuchs, it was first to develop and patent the elevating cab, which comes standard on all of its scrap handlers. The cab design makes long moves less arduous, enhances maneuvering in tight areas, and improves efficiency of loading operations, according to the firm.
   For more information, contact Fuchs at 214/357-8300, or visit www.fuchsusa.com.
• Kobelco America Inc.: Kobelco offers two models of excavators for the scrap industry—the SK330MH and the SK290MH.
The SK330MH has an operating weight of 89,559 pounds and is equipped with a 238-hp Mitsubishi engine. At its maximum reach of 50 feet, the unit can lift 8,110 pounds over the front and 7,750 pounds over the side.
   The smaller SK290MH weighs 79,652 pounds and comes with a 185-hp Mitsubishi engine. At its maximum reach of 46 feet, the excavator has a front lift capacity of 8,470 pounds and a side lift capacity of 6,570 pounds.
   Both models feature an extra-wide undercarriage and heavier counterweight to provide a firm stance and stable work platform.
   Unique to Kobelco’s machines is the NeuralNet Command System—onboard software that assists the operator by automatically adjusting the machine’s response to varying job conditions. Instead of the operator having to select from five to 10 different operating modes, the computer electronically maintains consistent engine rpm under varying load conditions to maximize production efficiency.
   To improve reliability and performance under tough conditions, Kobelco builds these machines with lifetime-lubricated idlers, lower rollers, and carrier rollers in the crawler system. To minimize maintenance, flexible seals on the track links keep dirt out and lubrication in, and centralized lubrication points are located throughout the rest of the machines.
   According to Kobelco, its excavators feature the industry’s largest cabs, recently redesigned to expand interior space 18 percent for maximum operator comfort and ergonomics. The 6-foot cab riser is designed to give the operator excellent 360o visibility. The onboard computer displays up to 68 different service items and up to 100 system fault codes, trouble location, and hours of each event, all accessible from the cab’s control console.
   For more information, contact Kobelco at 706/629-5672, or visit www.kobelcoamerica.com.
• Komatsu America International Co.: Komatsu’s new 306-hp PC450LCD-6 excavator is designed for use in material handling operations.
   The powerful 118,915-pound excavator uses a new Komatsu-designed super-long front boom. With an 82-foot maximum work height and more than 40 feet of horizontal reach, the excavator can work in various applications and offer a safer work environment for the operator.
   The PC450LCD-6 has an excellent working height but can also stand well away from the working point, improving the operator’s visibility of the attachment.
Easy pin removal of the mid-boom section allows working down to ground level, eliminating the need to have two different machines on site. 
Inside the cab, the PC450LCD-6 offers a fatigue-reducing environment that includes easy-to-use lever controls, controlled climate for operator comfort in weather extremes, and adjustable restrictors. The cab has been specially modified to give a full view of the attachment. To keep the view clear even in dusty environments, the full-length cab roof window has an integrated wiper and wash system.
   Visibility when working at ground level is maintained by using angled cross members on the front guard. An electronic angle sensor is installed onto the first boom, which gives the operator an audible alarm if a potentially unstable operating position is approached. This alarm, which can be switched off during conventional operations, backs up the angle gauge that the operator can see through the cab window.
   For more information, contact Komatsu at 847/970-5815, or visit www.komatsuamerica.com.
   • LBX Co. L.L.C.: LBX produces the Link-Belt Quantum material handling equipment, purpose-built for scrap operations.
   The Quantum line includes the 3900, 4300, and 6000 Scrapmaster models that take a magnet or grapple on a two- or three-piece arm, and the 4300 and 6000 Material Handlers that take a clamshell
attachment on a two-piece arm.
   Working weight for the 3900 (equipped with a three-piece attachment and 48-inch field magnet) is 69,918 pounds.
   For the 4300 similarly equipped with a 57-inch magnet, working weight is 93,850 pounds, while the 6000 with a 60-inch magnet tops out at 124,280 pounds for the track model and 140,110 pounds for the rubber-tired model equipped with a 66-inch magnet.
   Lifting capacity for the 3900 equipped with a 42-foot three-piece arm is 22,800 pounds for an end load and 16,500 pounds for a side load (20-foot radius load at 20-foot grapple height). The 4300 has a lifting capacity of 36,200 pounds for an end load and 27,900 pounds for a side load under the same conditions.
   The 6000 Scrapmaster track model and the 6000 Material Handler have a 40,000-pound lifting capacity for end or side loads under these conditions, and the 6000 rubber-tired model equipped with the three-piece attachment in outriggers maxes out at 38,300 pounds for end or side loads.
   A sealed track as well as lubricated rollers and idlers are standard on all models, with the 6000 Scrapmaster also available with large-diameter wide rubber tires for longer life in tough environments.
   Elevated, manual-tilt cabs are available on all models in 4-, 6-, and 8-foot heights, while hydraulically tilting cabs are an option (except on the 3900).
   All models incorporate an undercarriage designed specifically for the scrap industry. The extra-wide, X-style, heavy-duty car body and high-capacity turntable bearing provide superior lift capacities and long service life, the company says.
   Link-Belt cabs are designed to maximize operator comfort and ergonomics. Notably, cabs are attached to the frame on six fluid mountings that minimize vibration in rough environments. Water temperature, hydraulic oil temperature, and fuel level are constantly displayed in a bar graph for the operator’s information, and a service monitor that displays up to 19 messages keeps the operator in touch with critical machine functions.
   For more information, contact LBX/Link-Belt at 859/245-3900, or visit www.lbxco.com.
   • Liebherr Construction Equipment Co.: Liebherr offers 20 models of material handlers—from the E934 electric pedestal mount with 52-foot reach to the rugged
   R 954 HDW with 55-foot reach to the versatile A924—enabling end users to select the most efficient machine to meet their requirements. Weights range from 42,000 to 260,000 pounds, with reach capabilities from 37 to 80 feet.
   Among their attributes, Liebherr machines offer rugged construction and stability. Extra-wide industrial undercarriages or extra-heavy-duty machines can be ordered to handle extreme job applications. Units are built at the factory as scrap handlers, from the ground up.
   In addition to coming with either wheeled or crawler undercarriages, Liebherr handlers are available with a wide range of boom shapes, stick lengths, and accompanying tools such as magnets, grapples, and lift hooks. The straight industrial material handling boom and sticks are Liebherr products and are built with each machine at the factory. Platforms and drives for magnet generators as well as grapple circuits and controls are also built into the machines.
   Liebherr’s operator cabs are well-appointed, with most models offering air conditioning as a standard feature. Seat and joystick consoles are independently adjustable for best positioning by the operator. The cabs also provide excellent visibility and come with extra sound insulation to maximize operator comfort.
   A new dashboard provides service interval reminders, total operating hours, daily operating hours, push-button throttles, and warning indicator lights. Other standard features include a menu-driven query of operating conditions via an LCD display, automatic monitoring, display, warning, and saving machine malfunction data.
   Mobility and travel speed are two advantages of Liebherr material handlers, which can also work in tight spaces,
according to the company.
   All Liebherr material handlers provide clear access to components that require periodic servicing. The units also include sealed attachment pivots, centralized lube points, and extended service intervals, all of which reduce maintenance costs.
   For more information, contact Liebherr at 757/245-5251.
   • Ohio Industries Inc.: Ohio Industries manufactures a variety of material handling equipment, including Ohio and American diesel electric locomotive cranes with lifting capacities from 25 to 250 tons.
   The company’s most popular models for duty-cycle operation include the American models 5030-DE (30/40 tons), 840-DEH (40/60 tons), 850-DEH (50/115 tons), and 855-DEH (55/115 tons) as well as the Ohio models DE-300 (30/40 tons), DE-400 (40/50 tons), and DE-600 (55/80 tons).
   Ohio Industries also offers the Model 480 material handler, an all-hydraulic articulated boom crane available on a newly engineered matched rail car body with hydraulic travel and braking. It’s also available as a crawler or on a hydrostatic rubber-tired wagon.
   For users preferring the upper works of another OEM’s manufacture, Ohio engineers and builds new heavy-duty rail carriers incorporating hydraulic travel and braking, optional hydraulic stabilizers, and decouplers. Ohio can provide a complete turnkey crane by mounting of the upper works at its factory. This service includes receipt of the upper in time for mounting on a newly manufactured lower, mounting of the front and any required catwalk/ladder combinations, installation of magnet or grapple control systems, installation of hydraulic circuitry and operator’s cab controls, testing, and disassembly of the machine for shipment.
   For more information, contact Ohio Industries at 419/562-6010, or visit www.ohioindustries.com.
   • Sennebogen L.L.C.: Among its material handlers for the scrap industry, Sennebogen offers the 88,000-pound 835M. This unit is powered by a 226-hp, water-cooled Deutz diesel engine, has a lifting capacity of up to 44,092 pounds, and top travel speeds of 12.8 mph on the road and 3.5 mph off the road.
   The 835M is available with a wide range of loading booms and grab sticks, which can give it a maximum working radius up to 61 feet 8 inches. Its load-sensing hydraulic system with variable displacement piston pumps contributes to better precision and accuracy, while a separate swing pump provides individual swing operation.
   The heavy-duty wheeled undercarriage is equipped with special wide axles and is welded in a rigid, torsion-free box-type
design with four-point outriggers.
   Optional all-wheel steering makes the 835M maneuverable in tight spaces. Also, the optional hydraulic cab, which rises to 18 feet 10 inches, gives the operator an unobstructed view of the work area. Sound insulation in the cab ensures a pleasant work environment for the operator.
   The 835M’s safety features include check valves on the lifting and stick cylinders and the Sennebogen Diagnostic System, which constantly monitors all essential machine and engine functions.
   For more information, contact Sennebogen at 877/309-0099, or visit www.sennebogen.de.
   • Volvo Construction Equipment North America Inc.: Volvo manufactures both crawler and wheeled excavators suitable for a variety of scrap applications.
   The company’s eight EC Series crawler excavators have operating weights from about 29,000 to 101,000 pounds and lifting capacities along the undercarriage from 7,190 to 29,570 pounds. These units also offer maximum reach from 27 feet 4 inches to 39 feet 8 inches.
   Volvo’s three EW Series wheeled excavators—EW140, EW160, and EW170—weigh up to 33,510, 36,160, and 39,900 pounds, respectively. The EW140 has a maximum reach of 26 feet 3 inches and lifting capacity along the undercarriage of 9,700 pounds, while the EW160 reaches longer at 28 feet 3 inches and has a higher lifting capacity of 11,243 pounds. The EW170, meanwhile, can reach 30 feet 1 inch and can lift 9,610 pounds.
   Volvo uses Cummins and Volvo engines in its excavators, with power ranging from 99 to 296 hp. Also, all units include an Automatic Sensing Work Mode hydraulic system that delivers high productivity, precise maneuvering, and fuel economy.
   The operator’s cab, which sits on hydraulic dampening mounts to reduce shock and vibration, features all-around visibility, sound-absorbing insulation, an integrated heating and air-conditioning system, and an ergonomic seat with eight adjustments.
   For more information, contact Volvo at 828/650-0200, or visit www.construction.volvo.se. •