May-Jun e 2010
Industr ialLiftandH oist.com
Smooth Operators Pneumatic tire forklifts rule on paved roads and surfaces
Making the Case for Automated Overhead Material-Handling Systems
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INDUSTRIAL LIFT AND HOIST • PO BOX 1052 • FORT DODGE IA 50501-1052 • 800-231-8953
American Made
American Owned
American Quality
Website: www.chicagohardware.com Email: info@chicagohardware.com DROP FORGED PRODUCTS Turnbuckles Shackles Wire Rope Clips (also malleable) Machinery Eye Bolts Eye Bolts regular & shoulder Eye Nuts Rod Ends: blank & machined Ring Bolts Hooks Swivels Pad Eyes Yoke Ends WIRE PRODUCTS “S” Hooks Turned Eye Bolts (threaded) lag, mach. or welded U-Bolts (galv. & zinc) rd., sq. & long tangent Threaded Rod
SPECIAL PRODUCTS Manufactured to Specifications OTHER PRODUCTS Alloy Steel Hoist Rings Wire Rope Thimbles Bevel Washers Clevis Pins Coupling Nuts Plated Steel Shapes Brass - rounds, flats & angles STAINLESS & METRIC (check availability) Eye Bolts & Eye Nuts U-Bolts “S” Hooks Wire Rope Clips Blank Rod Ends Threaded Rods
HEADQUARTERS: Franklin Park, Illinois (847) 455-6609 WAREHOUSE LOCATIONS: Chino, CA (909) 591-1099 Monroe, GA (770) 266-5600 Houston, TX (713) 664-7722
Contents 16
M a y - J u n e 2 010
26
13
23
34
On the Cover: Houston-based Fiberspar LinePipe LLC took delivery of the 110,000pound capacity Hoist Liftruck P1100 in April 2009 to handle large reels of its spoolable LinePipe products. The lift truck was designed with 32 feet of lift and a unique attachment to carry reels up to 22 feet in diameter.
F E A T U RES 16 Product Focus
23 Trends & Technology
COL U MNS 6 Commentary
Forklifts Pave the Way By Katie Parrish
Making the Case to Automate By Dan Beilfuss
By Katie Parrish Real Work After the Travel Season
Whether moving items in a yard or port, transporting items in a metal fabrication facility, or lifting boats at a dry stack marina, pneumatic tire lift trucks can be employed in a variety of capacities in the industrial marketplace.
22 Plant Profile Putting the Squeeze on In-House Trash
Pack-A-Drum, a Florida-based manufacturer of manual compaction systems, discovered that pairing its units with the manually operated Genie Load Lifter improved the compactor’s functionality and addressed a number of other industry-wide challenges.
Upcoming Articles Overhead Cranes Order Pickers Rigging Trucks
4 | Industrial Lift and Hoist
Technological advancements in control products and engineering have enabled the industry to install new automated material-handling systems or convert outdated manually controlled overhead cranes, hoists, and monorail systems into modern production tools.
26 Equipment Spotlight Options in the Air By Katie Parrish
Although many facilities have adopted the use of personnel lifting devices over the last two decades, there is still room for discussion—particularly when it comes to selecting the right aerial lift for the job.
31 Business Issues A New Cab-Down Classic By Tracy Bennett
8 Best Practices By Kurt Minten Alternative Lifting with Single-Beam Gantry Cranes
D EP A RTMENTS 9
Headlines
13 Products 34 Equipment in Action 34 Ad Index
Heavy industrial users of rough-terrain cranes who rely on these compact units to get into tight areas now have options for replacing aging cranes in their fleets.
industrialliftandhoist.com • May-June 2010
Magnetek has a proven track record working with industries such as steel, aerospace, automotive, aluminum, paper, logging, ship loading, power generation, locomotive yards, the grain industry and more. We’re dedicated to providing turnkey solutions, innovative system design, state-of-the-art manufacturing, and technical engineering and application support that is second to none! Contact us today to find out how Magnetek Material Handling can be your one-stop source for overhead material handling power control and delivery solutions.
800.288.8178 US 800.792.7253 Canada sales@magnetek.com www.magnetekmh.com
Commentary
Real Work After the Travel Season By Katie Parrish, Editor-in-Chief
Like many of you, my spring was chock full of travel, providing many opportunities to meet new readers, review new products, and discuss the industrial lifting market with professionals from across the globe. Although at press time, I have not completed my travel rounds— Industrial Lift and Hoist’s own Industrial Crane & Hoist Conference in Houston, Texas, is still two weeks away—the information I’ve gathered over the last few months indicates that the industrial lifting equipment industry is kicking back into gear. While there appears to be dissenting views from economists on when the recession was over (or even if it is over), manufacturers have expressed that things are looking up. At NA2010 in Cleveland, Ohio, a hoist manufacturer told me that its sales have steadily increased since January, and an overhead bridge crane installer reported that business started bouncing back last fall. Looking around the biennial trade show, it was obvious that attendees and vendors were more optimistic. The number
usually gauge how successful a trade show is simply by entering a booth. If company delegates are too busy to talk and I have to return later, I often come back with the question, “How is the show going?” Many will respond with positive comments and discuss a recent sale or project where their machines are being used. When I hear comments like that, it makes my job feel much more worthwhile because I depend on these types of leads in order to bring you interesting and current information. The Manufacturers Alliance/MAPI Survey on the Business March 2010 backs up claims that the industry is turning around. It reported the March 2010 composite index rose to 78 percent from 57 percent from December 2009. This is the highest level since June 2004 and points to increased confidence in the manufacturing section, said Donald Norman, MAPI economist and survey coordinator. At the close of the travel season and back at our desks, the real work begins by following up on leads and building new relationships. My first year in trade publishing, a fellow editor gave me some good advice: Look at ...manufacturers have every business card you gathered at an expressed that things event and try to remember the person’s are looking up. face who you collected the card from. Difficult, right? But if you train your brain to remember the person, then it of professionals that stopped by Industrial Lift is easier to think back to the conversation and and Hoist’s booth also appeared to be enthusi- follow up on the lead. These leads will provide astic about the economy turning around, and us with real work for the rest of the year. It was nice meeting many of you at various many attendees I spoke to were interested in buying equipment, learning about new prod- trade shows and events, and I hope to learn ucts, and discovering new business opportuni- more about your businesses later this month at ties. This is a dramatic change from 2009 trade ICHC. As always, please send me an email at shows where attendance was down, and those kparrish@maxcapmedia.com or call with any questions or comments. I look forward to hearthat turned out were just there to kick tires. As a journalist walking any event, I can ing from you.
6 | Industrial Lift and Hoist
May-june 2010 Volume 3, Issue 3 EDITORIAL & DESIGN PRESIDENT AND PUBLISHER Guy Ramsey 602-368-8552 gramsey@maxcapmedia.com vice president of operations Barbara Benton 800-231-8953, ext. 114 bbenton@maxcapmedia.com EDITORIAL DIRECTOR Tracy Bennett 816-536-7903 tbennett@maxcapmedia.com Editor-in-Chief Katie Parrish 480-241-5625 kparrish@maxcapmedia.com Staff Writer Lucy Perry 816-214-5032 lperry@maxcapmedia.com ART DIRECTOR Jeffery Hanson design@maxcapmedia.com
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800-231-8953 515-574-2312 (direct) • FAX 515-574-2361 Advertising Rates, Deadlines, and Mechanical Requirements furnished upon request. Director of Business Development Mark Bridger 480-231-9672 mbridger@maxcapmedia.com ACCOUNT REPRESENTATIVE Cindy Boge 515-574-2312, ext. 284 cboge@maxcapmedia.com ACCOUNT REPRESENTATIVE Floyd Geopfert 515-574-2312, ext. 278 fgeopfert@maxcapmedia.com ACCOUNT REPRESENTATIVE Kip Krady 480-329-5773 kkrady@maxcapmedia.com SALES & MARKETING ASSISTANT Franci Motz 602-368-8552 fmatz@maxcapmedia.com MARKETING ASSISTANT Becky Grazier 515-574-2312 bgrazier@maxcapmedia.com
Maximum Capacity Media LLC Publisher of Industrial Lift and Hoist, Crane Hot Line, and Lift and Access magazines, and Lifting 360 eNewsletter 1003 Central Ave., P.O. Box 1052 Fort Dodge, IA 50501 515-574-2312 • Fax: 515-574-2361 Industrial Lift and Hoist is published six times per year in January-February, March-April, May-June, JulyAugust, September-October, and November-December by Maximum Capacity Media LLC, 1003 Central Ave., Fort Dodge, IA 50501, Phone 515-574-2312, Fax 515-574-2361. Entire contents copyright 2010 by Maximum Capacity Media LLC. All rights reserved. Opinions expressed by writers of Industrial Lift and Hoist are not necessarily held by the publisher. Subscription: Industrial Lift and Hoist is mailed free to users of lifting equipment in the United States and Canada. POSTMASTER: Please send address changes to Maximum Capacity Media, 1003 Central Ave., Fort Dodge, IA 50501.
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industrialliftandhoist.com • May-June 2010
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w w w . i r w i n c a r. c o m
Best Practices
Alternative Lifting with Single-Beam Gantry Cranes
to repair equipment and replace a damaged load. In fact, with the gantry crane’s wireless remote control, the operator can stay at a distance from the load and control the machine while visually inspecting its outside parameters. Bottom beam-mounted winches provide visibility and safety for the operators as well. By mounting the winches low, an operator can see the winding of the cable and perform any necessary maintenance without having to climb a ladder or rent an aerial work platform. By Kurt Minten The single-beam gantry crane’s compact size and maneuverability allows you to maximize Kurt Minten is director of industrial sales for Shuttlelift, Sturgeon Bay, Wis. He has more than 25 years of experience with lifting solutions for a wide your use of space both inside and outside your variety of manufacturing industries, including marine, prefabricated concrete, facility by using a single-beam gantry crane as an steel mills, modular buildings, wind power generation, and aerospace. alternative to a permanent overhead bridge crane. Instead of spending significant resources on your building’s foundation and structure to accommodate the overhead crane—and then investing in separate lifting solutions for your outdoor spacAvailable single-beam gantry cranes can In the current economy, plant managers es—you can use a single-beam gantry crane both manage loads from 30 to 100 tons, allowing for need to look at a broad range of criteria when indoors and out. All you need to do is make sure single-point picks, such as nacelle hubs, jail cells, selecting a machine for on-site material handling. the doors are large enough and provide adequate and septic tanks. To do the same with a heavyVersatility, efficiency, safety, and long-term value headroom and width. duty, dual-beam gantry like Shuttlelift’s ISL ganall directly impact the bottom line of your busitry, for example, you ness, which means you’re going to want to pursue comprehensive lifting solutions that address your would need a spreader A single-beam gantry’s size and frame to bring the unit specific needs. maneuverability allows you to to a single-pick point. One particular type of machine provides an maximize your facility’s space. The single-beam ganedge over other lifting equipment available in try, on the other hand, today’s market, offering improved material handling and operational efficiency while reducing is ideally suited for this As a side benefit, this solution reduces the asrequired manpower and operator risk. This solu- sort of task. sessed value of your facility, which saves tax money. These principles apply to tandem and singletion is the single-beam, rubber-tire gantry crane. Also, if you decide to relocate, you can disassemble point pick applications. With manufactured As far as material handling is concerned, look the gantry crane and move it to your new location. components being built to longer lengths, it no further than fundamental physics. When you Then there is the maintenance factor. Mainhas become increasingly common to transport use a single-beam gantry crane to lift a load, you’re taining a single-beam, rubber-tire gantry crane these items by tandem lifting. If you’re using the putting that weight directly under the frame of is as easy as keeping the wire ropes lubricated single-beam gantry crane in a tandem pick, as the crane. This mechanical advantage eliminates and the oil and filters regularly changed. This with wind-tower components or bridge beams, the potential stability issues you may experience provides a cost savings because machines that you’ll receive the same benefits. This versatile liftwhile using a rough-terrain crane, crawler crane, require more maintenance also will require more ing device can be used in conjunction with a conreach stacker, or forklift, and it allows you to lift significantly more of a load than you could with ventional rubber-tire crane that may already be on expensive downtime. In today’s marketplace, everyone is looking for site, regardless of brand. another type of machine. a cost-effective way to get both single- and tanThe fact that the load hangs directly beneath Plus, with an articulated pivot trunnion, the dem-picking capabilities. But the most successful the gantry crane structure means that machine crane’s frame will flex with uneven terrain; you companies will employ lifting solutions, not just stability is not an issue as it can be with boom won’t need to worry about structural damage or capabilities—and single-beam, rubber-tire gantry cranes and forklifts. There are no load charts to the safety of the load. And planetary drives mean cranes provide the versatility, efficiency, reliability misinterpret. If the single-beam gantry is rated at the crane will move smoothly when accelerating and measure of safety that will allow you to im50 tons, that is what it can lift. Stability accidents or decelerating, which gives the operator precise prove your operations and grow your business. can be serious for the operator, and it can be costly control of the load.
8 | Industrial Lift and Hoist
industrialliftandhoist.com • May-June 2010
Konecranes Aligns with Kito Corp.
Konecranes and Japanese hoist, crane and material-handling equipment company Kito Corp., owner of Harrington Hoists, announced that they have entered into a strategic alliance. The strategic alliance is based on the understanding that the resources of the two groups will complement each other and will contribute to each company’s further growth in the global market. The benefits of the alliance include cross-distribution of complementary products, wider regional coverage, license manufacturing, and possibly procurement. Under the alliance agreement, the parties have agreed to negotiate definitive distribution and license agreements by the end of June. Konecranes and Kito plan to continue pursuing their own growth strategies and retain their independence. Konecranes has agreed to purchase 22 percent, or 29,750 shares, of the share capital in Kito from private equity firm The Carlyle Group for approximately $35.5 million. The Carlyle Group will participate in a share buyback in Kito for an additional 10 percent of the Kito share capital. After the share purchase by Konecranes and the Kito share buyback, Konecranes will have approximately 24.4 percent of the voting rights in Kito. Detailing the agreement, Konecranes will sell Kito manual products while Kito will sell wire rope hoists manufactured by Konecranes. Additionally, the companies will jointly examine the possibilities to cooperate in distribution and license manufacturing of other produces, as well as in procurement. Konecranes and Kito also said they intend to transfer the hoist distribution business of Konecranes’ Japanese joint venture MHS Konecranes Co. Ltd to Kito to create a strong player in the Japanese hoist market.
Tips: Skyjack Adds Technical Service Portal to Website
Skyjack, Guelph, Ontario, has added a customerfriendly technical service portal to its website. Tech Talk will feature informative detailed overviews on various topics related to equipment operation, scheduled or recommended maintenance, troubleshooting, and other technical product information. As an extension of Skyjack’s service and support, Tech Talk will provide updated and current information on a regular basis. Skyjack’s product specialists and maintenance specialists will offer useful and detailed information to its customers. “We are very proactive about our level of technical support we provide to our customers,” said Chuck Berls, director of customer support. “Any information we are able to expand on and provide as a value add to our customers is definitely a philosophy we wish to remain diligent about moving forward.”
May-June 2010 • industrialliftandhoist.com
Headlines Promotions
Bradley Benner, vice president-general manager for Alps Wire Rope Corp., Glendale Heights, Ill., has been named by Newt Gingrich to the advisory board of the Jobs and Prosperity Task Force. The task force, comprised of successful and accomplished American business leaders and entrepreneurs, will focus on Jobs Here, Jobs Now, Jobs First. Toyota Material Handling North America (TMHNA) has been restructured, and key management positions have been appointed to strengthen the Raymond and Toyota brands. Kazue Sasaki is chairman of TMHNA and will continue to serve as president of Toyota Industrial Equipment Manufacturing and Toyota Industries North America. James Malvaso is the president and CEO of TMHNA and has resigned as the president and CEO of Raymond. Brett Wood will continue to serve as president for Toyota Material Handing USA. Michael Field is now president of the Raymond Operations division, and Charles Pascarelli is president of the Raymond Sales division.
Mark Fanelli
Systems Material Handling, Olathe, Kan., has named Mark Fanelli as regional manager of business development for the company’s Western region, which includes Washington, Idaho, Montana, Wyoming, Utah, Nevada, California, and Oregon. According to the company, Fanelli will be responsible for customer business development needs, as well as outside sales.
Dealer Awards Cat Lift Trucks, Houston, Texas, has announced the winners of its 2010 “Quest for Excellence” Dealer of the Year award. Recipients of this award are recognized based on 2009 sales performance, customer relationships and operational knowledge of Cat lift trucks. They include Adobe Equipment Houston LLC, Associated Supply Company, Daily Equipment Co., Equipment Depot Ohio, FMH Material Handling Solutions, Gregory Poole Equipment Co., Hewitt Equipment Ltd., Importadora Industrial Agricola SA (Ecuador), Independent Lift Truck of Alaska, Industrias Juan F. Secco SA (Argentina), Kelly Tractor Co., Miami Industrial Trucks, Thompson Lift Truck Co., Wiese Planning & Engineering, Inc. (East) and (Central), Wisconsin Lift Truck Corp., and Wyoming Machinery Co. Combilift, Greensboro, N.C., has awarded nine dealers with the Combilift Dealer of Excellence Award for 2009. These dealers were awarded for their superior performance in overall sales, investment in Combilift promotion, and new product development. They include Alta Lift Truck Services, Arnold Machinery, Combilift Depot Texas, Equipment Depot Pennsylvania, Industrial Parts and Service, Louisiana Lift & Equipment, Pape’ Material Handling, Riekes Equipment, and Springer Equipment. Additionally, Industrial Parts and Service was recognized as Combilift’s top-selling North American dealer in 2009. Mitsubishi Forklift Trucks, Houston, Texas, announced the winners of the 2010 “Quest For Excellence” Dealer of the Year award. Recipients of this award are recognized based on 2009 sales performance, customer relationships and operational knowledge of Mitsubishi forklift trucks. Dealers receiving this award have exceeded expectations in both new machine and parts sales. This year’s recipients are Autolevadores J. Ramírez SA (Uruguay), Herc-U-Lift, Lift Truck Parts and Service, and Wholesale Equipment of Fresno.
Hyster’s Top Dealers
Hyster Co., Greenville, N.C., recently honored its topperforming dealers with its Dealer of Distinction award. To become a Dealer of Distinction, companies must reach elevated goals in customer satisfaction, dealer performance, general management, truck sales, shortterm rental, training, aftermarket sales, and parts and service operations. Recipients of the award include Arnold Machinery Co.—Utah, Deep South Equipment Co., Equipco Division Phillips Corp.; MH Equipment Co.—Illinois and Iowa divisions; Papé Material Handling—Portland, Eugene, Central Washington, and Spokane Divisions; and Sellers Equipment.
Industrial Lift and Hoist | 9
Headlines Demag Receives First HMI Certification for Electric Chain Hoists Demag Cranes & Components, Cleveland, Ohio, is the first manufacturer to receive the Hoist Manufacturer Institute (HMI) certification for its DC line of electric chain hoists. HMI is a trade association affiliated with the Material Handling Industry of America (MHIA), and the HMI certification requires a stringent and thorough evaluation by an independent third-party professional engineer of the product’s technical design and specifications. Product design and test data was reviewed and certified to ensure Demag’s DC chain hoists conform to North American standards, which include the performance standards for electric chain hoists ASME HST 1-1999 reaffirmed (2004); safety standards for overhead hoists ANSI B30.16; and National Fire Protection NFPA 70 Article 610. Also required for certification were the availability of product safety, installation, operation, maintenance, and spare parts manuals; the availability of product training and technical support; life-cycle spare parts availability; and qualified service and repair capabilities. Demag’s HMI certification indicates that the company’s DC electric chain hoists meet or exceed every applicable requirement in the identified standards. Its purpose is to instill confidence in the product bearing that mark and in the licensee providing that product.
10 | Industrial Lift and Hoist
Design Challenges Overcome by Han-Tek Han-Tek, Victor, N.Y., recently installed an automated finishing system for a transportation sector manufacturing facility in Mexico. Each of the two finishing systems consisted of one overhead crane that services up to 18 different tanks. The runway is approximately 250 feet long and 15 feet wide. Parts are loaded into baskets at one end of the system and automatically transferred from tank to tank based on the guidelines for that given part. Parts can range in length from a couple inches up to 10 feet. The custom-designed finishing application is able to carry baskets weighing up to 4,000 pounds. According to Todd VandeSande, vice president of Han-Tek, the project faced some design challenges due to the building location and process tanks that surrounded the system. “The structure of the crane needed to fit into a condensed area, and because it was an earthquake region, the structure needed to be within Seismic D Standards,” he said. The application also handled hazardous materials, so the system was designed for automated application to ensure no one would be injured by materials in the tanks. In order to make the project more cost effective, Han-Tek implemented the concept of lean manufacturing throughout its duration.”By reducing the amount of manpower, there was less waste and less human error,” said VandeSande. “As the application has the ability to handle multiple recipes, it results in much quicker manufacturing. Additionally, a pull vs. push production approach was implemented to ensure that no parts are processed until needed. This guarantees a shorter wait time because the parts are positioned so that they are processed and moved to the next stage of production as soon as they are received. This means there is virtually no wasted movement.
industrialliftandhoist.com • May-June 2010
First Haulotte 19-Foot Scissor Rolls Off U.S. Production Line Haulotte Group has announced it has manufactured its first 19-foot Optimum 1930 E scissor lift in the United States in its Archbold, Ohio, facility. During the manufacturing process, the U.S. manufacturing and design team was able to improve the Optimum 1930 E for the U.S. market by gaining over 2.3 inches to the overall platform area. This maximizes the interior dimensions of the basket to increase functionality within the frame footprint. The Optimum 1930 E offers a maximum platform height of 18'11". With a stowed height of only 6'7", the compact machine is able to be passed through a standard doorway. It is ideally suited for working in congested areas and its lightweight design allows it to be easily transported by van or trailer.
Associated Material Handling
Manufacturers Report Improvement According to the Manufacturers Alliance/ MAPI Survey on the Business Outlook March 2010, optimism is emerging in the manufacturing sector as the March 2010 composite index rose to 78 percent from 57 percent reported in the December 2009 report, representing the highest level since the June 2004 survey registered 80 percent, and marks the second straight quarter it has reached 50 percent or above. By comparison, the March 2009 index registered an historic low 21 percent. “The sharp increase in the composite index, along with significant improvement in individual indexes, point to increased confidence that the manufacturing sector will continue to recover from the rapid decline that took hold in the fourth quarter of 2008 and continued through the first half of 2009,� said Donald A. Norman, Ph.D., MAPI economist and survey coordinator. Although many individual indexes are based on year-over-year comparisons and the composite index measures the direction of change rather than the absolute strength of activity in manufacturing, he notes the extent of the increases points to further expansion. While a variety of individual indexes are included in the survey, the business outlook index is a weighted sum of U.S. shipments, backlogs, inventories, and profit margin indexes. All 12 individual indexes showed improvement, including eight by double digits.
May-June 2010 • industrialliftandhoist.com
Industrial Lift and Hoist | 11
Headlines
Aisle-Master Forklift Production Moves to Combilift Facility
5 HR 20 HR Min. @ Min.@ CCA Rate Rate 75 Amps 25 Amps @ 00F
99
130
Length
13”
49
Width
225
Height
620
6-3/4” 9-3/4”
5 HR 20 HR Min. @ Min.@ Min.@ Rate Rate 75 Amps 56 Amps 25 Amps
122 155
Length
77
Width
110
Height
292
13-1/8” 7-1/6” 11-3/8”
5 HR Rate
181
20 HR Rate
232
Length
Min. @ 75 Amps
122
Width
Min.@ 25 Amps
474
Height
10-1/4” 7-1/8” 11-1/4”
5 HR Rate
322
20 HR Rate
420
Length
Min. @ 75 Amps
250
Width
Min.@ 25 Amps
940
Height
11-7/8” 7-1/8” 16-3/4”
5 HR Rate
226
20 HR Rate
260
Length
11.61”(295mm)
Min. @ Min.@ 75 Amps 56 Amps
149
Width
228
7.09”(180mm)
Min.@ 25 Amps
572
Aisle-Master Ltd., manufacturer of AC electric and LP gas-powered articulated forklifts with capacities up to 5,500 pounds and lift heights up to 41 feet, has moved it production to Combilift’s facility in Monaghan, Ireland. Having outgrown its original base in Clontibret, Ireland, the production line and R&D facilities available in Monaghan will enable the company to pursue its policy of continual product enhancement and add further models to the range. Martin McVicar, managing director for Combilift, now heads up Aisle-Master. “Just as Combilift addressed expansion by establishing its new premises in 2006, Aisle-Master’s move to Monaghan is the next logical step to enable increased production of this very distinct and successful brand,” he said. “Our engineering expertise and ability to invest substantial resources into research and development will ensure that Aisle-Master continues to enjoy its reputation as the quality articulated forklift in the marketplace, not only in the United Kingdom, Australia, United States, Middle East, and Ireland but throughout the world.” Combilift and Aisle-Master have a combined output of more than 2,000 units a year, creating an annual turnover of $123.6 million.
Hyster Introduces New In-House Certification Programs
Hyster Co., Greenville, N.C., has undertaken a new sales training effort aimed at further improving its lift truck dealer network, and has introduced a new on-line and classroom training program aimed at Hyster dealer technicians. The CERTRAX effort is designed to boost the ability of Hyster dealer sales staff to provide consultative customer support through online and classroom training on lift truck operations, financial acquisition options, and practical applications of materials handling equipment. Additionally, Hyster has launched the CERTECH online and classroom training program. Aimed at dealer technicians, Certech will further enhance the customer service abilities of the Hyster lift truck dealer network. The Certech technical training certification program helps assure Hyster customers that they can rely on a high level of ability and knowledge from all Hyster dealer service technicians, according to the company. “Hyster Co. has provided technical training to its dealers for many years, but we’re constantly improving everything we do and training is no exception,” said Patrick Duhaime, director of Hyster brand management, NACCO Materials Handling Group, Inc. “Our company has been working on this new curriculum for nearly two years to provide our dealer network with an industry-leading product diagnostics and repair education.”
Height
11.73”(298mm)
Correction
On page 13 of the MarchApril issue, the caption under the Harrington Hoist image was labeled incorrectly. It should have read “Harrington Hoists and Kito Corp. celebrate 20 years.” Industrial Lift and Hoist apologizes for the error.
12 | Industrial Lift and Hoist
industrialliftandhoist.com • May-June 2010
Combilift’s Latest Offerings In April, Combilift hosted an event at its Monaghan, Ireland, facility to introduce the 50,000-pound capacity C50,000 lift truck and a line of straddle carriers—a new product offering for the company. The C50,000 features many of the same features as the standard Combilift multi-directional forklifts except on a much larger scale. The challenge for engineering the unit was keeping it at a reasonable platform height. The size of three single wheels required for a machine of this weight would have resulted in an unworkable platform height, the company said, but by using double wheels, the platform height is only 45 inches. Hydraulic fork positioners also have been incorporated as a standard feature to allow operators to easily shift the forks and four-wheel hydrostatic drive. Powering the unit is a 170-hp John Deere 6068 HF engine, which is a departure from Combilift’s standard Kubota engine, which did not have a model large enough for the C50,000. Key specifications for the C50,000 include a 162.25-inch maximum lift height, which reaches 236.25 inches when the mast is raised. Integrated side-shift is +/-6 inches. The unit features 10 percent gradeability, 12 mph drive speed, and 181-inch outside turning radius. The unit measures 193 inches long and 196.75 inches wide. Without working lights, the C50,000 is 126 inches tall. Overall unladen weight is 77,000 pounds. Combilift also introduced the straddle carrier, which was developed as a cost-effective and flexible container-handling solution for distribution, shipping, and hauling companies. According to Combilift, it is a more economical option than using conventional container-handling forklifts, reach stackers, or mobile cranes to move containers and oversized loads onsite. The standard Combilift Straddle Carrier is a threewheel patented design model—a four-wheel option is also available—that ensures maximum stability of all three wheels. The straddle carrier design incorporates many of the same features as the Combilift four-way machines, including the hydrostatic drive and hydraulic steering, which will enable dealer networks to support the product. The design of the three-wheel model enables it to be disassembled and shipped in just one 40-foot container, reducing freight costs. Diesel powered with an LP gas engine option, the straddle carrier features a 38.5-ton capacity. The unit is suitable to lift all standard ISO containers, and the overall dimensions can be customized to handle non-ISO containers. It also can be configured to stack containers two high. Combilift’s straddle carrier features two-wheel hydrostatic drive, synchronized hydraulic steer, and front and rear independent side-shift.
combilift.com
Productivity
Products
Tools
• Jergens Introduces FSS Hoist Rings
Jergens, Cleveland, Ohio, has introduced a line of full-strength stainless (FSS) hoist rings, which are domestically manufactured from 17-4 PH stainless steel. These forged, center-pull hoist rings provide the same working load limit as Jergens’s alloy steel products with the added benefit of increased corrosion resistance in harsh environments, according to the company. Available in both inch and metric sizes, FSS hoist rings have unique design features that make them ideal for OEM and industrial use. The forged, “large eye-style” lifting bale includes a crossbar design that eliminates the possibility of spreading in misapplications. Additionally, a permanently secured lifting bolt makes these hoist rings tamper-proof. The hoist rings can be equipped with Lift ID, Jergens’s automated inspection and compliance system. These embedded RFID tags provide an efficient way to identify and track equipment in the field, improving the efficiency of lifting hardware inspections and simplifying workplace safety programs.
jergensinc.com
• MSE-Forks Unveils RollerForks for Pallet-Free Transport
Dutch attachment manufacturer MSE-Forks introduces RollerForks, which help companies go green through palletless shipping. Designed to replace standard lift truck forks, RollerForks feature floating roller cartridges, which have two layers of rollers that are built into each fork. When the forks are set down onto the floor, the upper rollers elevate above the fork surface. When the truck moves, the rollers spin in opposite directions, allowing them to easily creep under the load. When lifted, all rollers drop below the fork surface and the blades become virtually the same as any standard fork tines. According to the manufacturer, the devices, which are distributed in the United States by Reachable Solutions, Chesapeake, Va., do not require a dedicated forklift. They also have little, if any, affect on truck capacity; they do not hinder visibility; they offer versatility because they can be used like traditional forks; and they are easy to maintain. Because the RollerForks do not use hydraulics, risk of contaminating food products with oil is non-existent. They can be used as regular forks for pallet handling, as well as for handling slip-sheeted goods, bagged goods, FIBCs, cartons, gaylords, tires, and more.
mse-forks.com
• Winkle Combines Grapple and Magnet
Winkle Industries, Alliance, Ohio, has added a product to its line of lifting magnets that will allow operators to combine a grapple and magnet on the fly. The company offers a permanent tower that is placed directly on top of the magnet, which can either be welded or pinned on to Winkle’s DSG, ELSA, LSA, DSA and EDSA magnets, as well as most other makes and models of scrap magnets. The grapple-magnet combination has traditionally been used for applications that require handling punchings, turnings, and shred, as well as other less-dense similar materials. These types of scrap generally fall through the grapple tines so the magnet is used to hold them in place. This combination is also often used to sweep up metal from the ground when the scrap pile is too shallow for the grapple to effectively lift scrap without picking up dirt and other debris. Standard scrap-handling magnets come with a three-legged magnet chain and are not designed to be bolted to the head plate inside the grapple. Some operators utilize a magnet grapple combination for this type of application. However, this configuration does have some limitations. “The tines need to be fully opened to use the magnet portion of the grapple for sweeping or sorting and in this position,” said Mark Volansky, Winkle’s director of sales. “Working like this in tight quarters is not practical.” This new product came as a result of Winkle’s customers wanting to increase their overall productivity and magnet utilization. “With the tines closed around the tower,” Volansky said, “the tower suspends the magnet below the grapple, allowing the operator clear view of the magnet for placement and ease of operation.” Now the tower can be grasped by the grapple tines while the operator is in the cab, instead of stopping to chain the magnet on to the grapple attachment or completely switching attachments. This means the operator has only to attach the electrical line for the generator. If a worker on the ground is available to do this, the operator does not even need to exit the cab, increasing on-the-job productivity.
winkleindustries.com
May-June 2010 • industrialliftandhoist.com
Industrial Lift and Hoist | 13
Products MSA Evotech Harness Improves Comfort The Evotech full-body harness from MSA, Pittsburgh, Pa., was designed to improve user comfort, ease of use, durability, and user safety, according to the manufacturer. The harness is RFID enabled, offering the Field ID Safety Network with Field ID access to provide a reliable, online inspection and safety compliance (ISCM) management system. The Evotech harness features reflective piping integrated into the webbing to increase visibility in low-light environments. It is available with a Suspension Trauma Safety Step that is designed to prevent suspension trauma, and a Medical ID kit, which provides medical information to potential rescuers/emergency personnel in the event of medical emergencies. The harness meets OSHA, ANSI Z359.1/ ANSI A10.32, and CSA standards.
msanet.com
Crane Rope Conditions Evaluated with Konecranes RopeQ Konecranes, Springfield, Ohio, has developed RopeQ, a system that evaluates the working condition of wire ropes using non-destructive testing (NDT) methods. RopeQ is a diagnostic tool that uses electromagnetic technology to assess the inner and outer wires and strands of a wire rope. This testing method achieves reliable, accurate, and repetitive inspection results that ensure safe use and may improve total lifecycle cost, according to the company. RopeQ is designed to improve the total lifecycle costs of equipment by optimizing wire rope change intervals in process duty and critical equipment. Throughout the working life of a wire rope, the strands and core are subjected to tension, bending, and abrasion, which can compromise strength and safety. The diagnostic tool fastens to wire rope assemblies and records a series of interior images along the entire length of the wire rope. The diagnostic survey produces data that pinpoints all areas and degrees of degradation. The precise results help to determine whether continued use is safe or whether the rope needs to be changed. According to Konecranes, RopeQ produces verifiable condition assessments that can be compared against discard criteria. The tool is designed to detect flaws that are not visible to the naked eye to improve the overall safety of the lifting equipment.
konecranes.com
AEM Develops OSHA-Approved RT Forklift Decal
Portable Smart-Rig Mini-Cranes Feature Eco-Friendly Design
Association of Equipment Manufacturers (AEM) has developed a safety decal for roughterrain forklifts, which has been approved by the U.S. Occupational Safety and Health Administration. The “Employer-Certified Operators ONLY” decal signifies that the machine should be operated only by personnel who have received employer certification of training and evaluation according to relevant OSHA standards. Equipment manufacturers working through AEM’s Rough Terrain Forklift Council developed the decal. A PDF version of the decal artwork, which companies can use to make their own customized labels, is available at no charge from the AEM Store on the association’s website.
Designed for multi-purpose applications, the Smart-Rig Crane, Newport Beach, Calif., is a mini-crane small enough to roll through a standard doorway and fit inside an elevator when stowed. The unit is battery operated and mobile. Utilizing a hydraulic jack with a two-piece telescopic boom, the unit can lift up to 2,400 pounds to a height of 20 feet. The machine also uses a counterweight water tank system that can be filled and drained easily. Smart-Rig Cranes have been used in HVAC, pipe, military, utility, schools, steel, fabrication, sewage plant, oil refinery, grain factory, farm, water park, building, port, cruise ship, cement masonry, and rental yard applications. They can work in hard to reach areas and prevent injuries caused by bending and twisting, according to the company.
aem.org
smartrigcranes.com
Toyota Launches 8-Series AC Electric Lift Trucks
Toyota Material Handling, U.S.A., Irvine, Calif, has unveiled a new line of 8-Series four-wheel AC electric lift trucks, available in 4,000 to 6,500 pound load capacities—including a new 5,500 pound model. Using AC power, the system contains no motor brushes, springs, commutator, or wearable parts to service and replace, resulting in fewer and less expensive maintenance and operating costs. The lift truck’s AC-powered drive and hydraulic systems boost travel and lift speeds. Also, by controlling the hydrostatic power steering through the AC hydraulic motor system, there is one less motor to service and maintain. The 8-Series offers Toyota’s System of Active Stability (SAS), which helps reduce the risk of tipover accidents that occur as a result of lateral and longitudinal tipovers. When SAS detects instability, its advanced sensors simultaneously signal and engage the appropriate controller. The active control rear stabilizer system and the active mast function controller system work in conjunction to add truck stability. A momentary hold and controlled descent feature is standard and maximizes lift truck control by regulating rolling speed when the accelerator pedal is released on a grade. It also allows the lift truck to be started on an inclined surface without rolling backward. Also, a Shock Sensor option enables end users to monitor lift truck damage or fleet abuse. In the cab, ergonomics have been improved and leg room has been expanded. A full suspension vinyl seat is standard, and the 8-Series features joystick hydraulic controls with Ergo-Shift and a three-way adjustable armrest. Operator visibility also has been increased through the use of angled tie-bars on the overhead guard and load backrest extension and lowered free-lift cylinders on the three- and four-stage masts.
toyotaforklift.com
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industrialliftandhoist.com • May-June 2010
Omme Lift Unveils 3700 RBDJ Compact Lift Omme Lift USA, Syossett, N.Y., has launched the 3700 RBDJ compact telescopic aerial lift. Mounted on a crawler chassis, the aerial lift features 121'5" platform height, a moveable jib, and 180° basket turn. For outdoor operation, the 3700 RBDJ uses a Kubota diesel engine. When working indoors, the electronic motors are powered by eight high-capacity 400 Ah batteries. No extension cables linked to mains are needed when traveling indoors. The new Omme Lift 3700 RBDJ is designed to traverse soft, muddy, or hilly terrain, but the crawler chassis also disperses the machine’s weight widely when traveling on delicate surfaces like pavements, lawns, marble, or other similar flooring. Although the machine is generally used in connection with applications where high and extensive reach is required, it is also used where low weight is a necessity. The 3700 RBDJ’s compact dimensions allow the unit to access tight areas. The height is 6’6”, and the length is 25'6". With the detachable 550-pound capacity basket removed, the length is reduced even further to 23'9". The 4'11" width can be retracted hydraulically to only 3'7". In order to overcome obstacles during transit, the jib and main boom can be raised to allow more than 8'2" free clearance under the basket.
trackedlifts.com
Raymond iWarehouse Optimizes Lift Truck Fleets The Raymond Corp., Greene, N.Y., offers the iWarehouse system, which allows fleet managers to collect and analyze real-time lift truck data from the operating systems of Raymond lift trucks • Effortless Free Warehouse managers can access this information via aChaining custom Web portal to generate reports on lift truck and operator productivity; diagnose potential lift truck issues remotely; reduce the risk of impacts; and optimize lift truck capital•andSingle maintenance costs.One-Handed Operation Step, The Raymond iWarehouse system connects to the lift truck vehicle manager with the iPort single connector. Data from lift trucks equipped with iWarehouse is not gathered from contactors and sensors, but • Low Handle Effort comes from the vehicle manager for improved accuracy and data quality. A variety of modules allow users to collect information to meet their needs. Some of the models include iControl, which configures specific operator profiles based on skill to limit lift speed acceleration and verifies operator licenses are • level Easy Grip EndandStop for Hook Attachment current; iImpact, which notifies warehouse and service managers or impacts or other significant events while the truck is in motion; and iTrack, which generates reports on lift truck fleet data by truck, facility, • 360° rotating handle region, and company. At NA2010, the iBattery module was introduced to help maintain lift truck battery fleets. iBattery Compact and Lightweight can detect numerous pieces•of battery fleet information, including battery weight to meet lift truck specifications and state-of-charge and voltage to aid in the prevention of overdischarging of the • Lifetime Warranty battery. The battery data can help operators ensure they are using the right battery and the battery is maintained properly. The data also can help ensure compliance with warranty requirements by providing detailed reports on the interval of charges, temperature, watering and equalization to validate battery maintenance.
raymondcorp.com
Ph: 800-888-0985
I
www.cmindustrial.com
Whether your needs call for a complete lifting system to address a unique application or you are looking for a standard, in-stock hoist, Columbus McKinnon has the brands and products to meet your requirements. Durable powered and manual hoists in a wide range of capacities and styles. Upgrades for spark-resistant, low-headroom, clean room, offshore, and other special environments. THE CHOICE IS YOURS.
For complete information, call: (800) 888-0985 or visit www.cmworks.com
May-June 2010 • industrialliftandhoist.com
Industrial Lift and Hoist | 15
Product Focus
Forklifts Pave theWay By Katie Parrish
Fleet managers cash in on the features and benefits of pneumatic tire machines
Mitsubishi designed the line of mid-size internal combustion, pneumatic tire forklifts for heavy-duty applications, such as lifting lumber, cement, and pipe.
Whether they
are moving items in a yard, working in a port or metal fabrication facility, or lifting boats at a dry stack marina, pneumatic tire lift trucks can be employed in a variety of capacities in the industrial marketplace. Since last fall, manufacturers have focused on introducing new pneumatic tire forklifts, and the size and capabilities of these units are impressive. From 3,000-pound capacity electric units to 12,000 midsize machines to massive 115,000-pound capacity forklifts, these new products are moving and lifting loads on jobs in every corner of North America. Read more on the latest introductions in pneumatic tire forklift technology.
16 | Industrial Lift and Hoist
industrialliftandhoist.com • May-June 2010
The forklift truck’s zero turning radius steer axle and dual AC drive motors combine to provide extraordinary maneuverability.
Hyster’s Pneumatic Tire Electric Lift Truck The J45-70XN is the newest line of lift trucks from Hyster Co., Danville, Ill. This forklift truck series offers an innovative component design and “Drop Battery Box,” which allows for the use of pneumatic tires on an electric truck. The feature provides a “zero emissions” alternative for 4,500- to 7,000-pound capacity indoor
and outdoor applications. The pneumatic tires are designed to help reduce vibration in order to provide a smooth, comfortable ride—even over less than ideal surfaces. With the specially configured drop battery box, the battery sits low in the frame for a lower seating position. This feature is devel-
oped to offer easier entry and exit from the truck. The lift truck’s stamped steel hood is built for durability and protection. Hyster’s newly designed operator module provides a comfortable and productive compartment that features a 20 percent increase in floor space and a relocated “heads-up” multifunction display for enhanced visibility and pallet control. AC technology delivers quick and smooth changes in travel direction, and it offers precise speed control during acceleration, which significantly increases productivity. The forklift truck’s zero turning radius steer axle and dual AC drive motors combine to provide extraordinary maneuverability. A Hyster-designed thermal management system maximizes performance during continuous operation, while preventing damage to components due to heat. hyster.com
• Effortless Free Chaining • Single Step, One-Handed Operation • Low Handle Effort • Easy Grip End Stop for Hook Attachment • 360° rotating handle • Compact and Lightweight • Lifetime Warranty
Ph: 800-888-0985
May-June 2010 • industrialliftandhoist.com
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www.cmindustrial.com
Industrial Lift and Hoist | 17
Product Focus
Hoist’s Heavy Lifters The Hoist Neptune from Hoist Liftruck Mfg., Bedford Park, Ill., allows operators at dry stack marinas to easily and comfortably remove boats from the water, move them, stack them, and replace in the water. The Neptune allows the operator to use one vehicle to reach as far down as 23 feet below the dock and securely grab and lift the boat with its adjustable spreading arms. Without transferring machines or setting the boat down, the operator is able to move the boat anywhere. An additional advantage is the machine enables the operator to place the ship up to 75 feet on a rack. The new Neptune design will accommodate wheelbases from 190 to 275 inches, as well as multiple cab placement configurations. Additionally, the Hoist marina liftruck includes a modular design, which has been adopted on redesigns of all Hoist pneumatics up to and including 115,000-pound capacity units. The modular design provides easier service and replacement parts, as well as allowing all vehicles to be containerized for shipping. In 2009, Hoist Liftruck redesigned its PSeries pneumatic forklift line, which features a modular chassis, similar to the ECH Series empty container handlers, and provides efficient serviceability. Bolt-on assemblies, such as fuel and hydraulic tanks, can be easily removed and replaced if damaged. “The modular design not only saves our customers on shipping costs but also [offers] more capacity and wheelbase options,” said Marty Flaska, president of Hoist Liftruck. He noted that with this redesign, Hoist Liftruck is able to offer models with more than 20-ton capacities on shorter wheelbases to meet the needs of customers who need highcapacity lift trucks in tight working environments.
20 | Industrial Lift and Hoist
The redesign also featured overhead tilt cylinders throughout the P-Series 10- to 50-ton capacity range. Additional features include a Cummins Tier 3 diesel engine, Dana automatic transmission, AxleTech planetary drive axle, outboard wet disc brakes, wide-view two-stage mast, electronic fingertip controls, true inching control, easy access service points and RemoteTech vehicle management system. hoistlift.com
The 8,000- to 12,000-pound capacity FG40N – FG55N LP Gas and 8,000- to 12,000-pound capacity FD40N – FD55N diesel forklifts are designed with heavy-handling features, which allow for the forklift’s use in outdoor environments and rough surface conditions. The machines come with two-speed forward and one-speed reverse transmission standard, and EPA-compliant envirO2 engines to ensure performance across a wide range of applications. They are equipped with a spacious, state-of-the art design operator compartment, and Mitsubishi’s Engine Protection System (EPS), which helps prevent overheating by automatically reducing RPMs if engine coolant temperatures get too hot. A variety of options is available, including ground speed limit, operator comfort enhancements, air intake pre-cleaner, wide load backrests and sideshifters, panel cab, and an orange seat belt. With capacities ranging from 3,000 to 7,000 pounds, the IC pneumatic tire forklifts Models FG15N – FG35N / FD20N – FD35N feature maneuverability and lift and lowering speeds, and the Integrated Presence System (IPS) is designed to help manage risk by temporarily disengaging the drive and hydraulic functions if
Mitsubishi’s Mid-Size IC Forklift Truck Line Mitsubishi Forklift Trucks, Houston, Texas, has introduced a new line of mid-size internal combustion, pneumatic tire forklifts. Offered in five capacities ranging from 8,000 to 12,000 pounds, the trucks are designed for heavy-duty applications, such as lumber, cement, and pipe. Several new product enhancements will also be offered to customers as part of the existing Class 4 and 5 product lines.
operators leave the normal operating position. The machine’s new LCD/LED display panel features operator passcode protection and key indicators for fluid and fuel levels, travel direction and more. The forklift also has customized options available, including a swing-down LP tank, full-suspension seat, foot directional control, fuel saver mode, and debris-resistance protection. mit-lift.com
industrialliftandhoist.com • May-June 2010
Toyota’s Expanded Lift Truck Lineup Toyota Material Handling, U.S.A., Inc., Irvine, Calif., has expanded its line of large IC pneumatic lift trucks to include machines with 33,000-, 40,000-, 44,000- and 51,000-pound capacities at a 36-inch load center. Designed for ports, construction, lumber yards, metal fabricators, and concrete and masonry yards, the units feature 6.7-liter J-Series Hino diesel engines and Toyota’s exclusive two-speed transmission. Toyota’s catalytic muffler system coupled with an exclusive closed-loop fuel system design adjusts and optimizes the air-fuel mixture ratio, resulting in a low emission lift truck that produces 70 percent less smog forming emissions than current federal EPA standards. Toyota’s two-speed transmission provides optimal performance comparable to industry standard three-speed transmissions, with the added benefit of a smoother operation due to fewer shift changes. According to Toyota, the two-speed, twostator transmission requires less maintenance than a comparable three-speed transmission. In addition, it is designed to handle more torque and
May-June 2010 • industrialliftandhoist.com
contains fewer parts to service. Toyota’s large IC pneumatic lift trucks offer fully oiled lift cylinders, which are durable in harsh environments and help prevent cylinders from rusting. Wet disc brakes are standard and operate under the most severe work conditions. Toyota’s wet disc brakes also help ensure minimum downtime and maximize operating performance by reducing maintenance costs and improving vehicle safety. For operators, Toyota’s large IC pneumatic lift trucks include the exclusive synchronized steering option, which enhances operator comfort by automatically correcting misalignment between the angle of the steering wheel and turn angle of the steer tires. This system maintains a consistent steering wheel position for improved hand placement during operation. A deluxe steel cab is standard and includes an air conditioner and heater/defroster. The deluxe cab features a special mounting system that absorbs and reduces noise and vibrations in the operating compartment to reduce operator fatigue. The front and rear windows feature a pillar less
design, allowing a wider, unobstructed field of view to make handling loads easier. For operator ease, the electronic parking brake can be engaged or disengaged at the push of a button. For an added layer of safety, an alarm will sound if the operator attempts to operate the lift truck with the parking brake engaged. And an integrated monitoring center continually checks the lift truck and notifies the operator if there are any issues with the unit’s systems. To provide exceptional control with low operator effort, Toyota provides hydraulic pilot-type control levers to reduce the vibrations experienced by operators. toyotaforklift.com
Industrial Lift and Hoist | 21
Plant Profile motors or electrical components. Individual bags of waste are placed into the Pack-a-Drum unit by a worker, who then turns a large wheel, which lowers a metal plate. This removes excess air from the trash and flattens the bag. The process is then repeated as many as five times until the separate, bulky bags of trash become a densely packed, clear bag. The front of the unit swings open, and the bag is removed and ready for disposal in the dumpster.
The Need for a Genie
Putting the Squeeze on
In-House Trash Pack-a-Drum partners with Genie Load Lifter
It’s
commonly accepted in business that when a piece of equipment is paired with a complementary unit, the end result is even greater. Pack-a-Drum Inc., a Florida-based manufacturer of manual compaction systems used in restaurants, retail pharmacies, and other settings, discovered that pairing its Pack-a-Drum compactor units with a manually operated Genie Load Lifter has not only improved the compactor’s functionality, but it also has addressed a number of other industry-wide challenges.
Reigning in costs Pack-a-Drum was developed by the Wagner family, which owned and operated five fast food restaurants on Florida’s Space Coast. “While running those shops, we started to see costs for trash pickup and removal rise at an unbelievable pace,” said Mark Wagner, Pack-a-Drum’s vice president of marketing and sales. “Waste pickup rates vary greatly from area to area—our area happened to be very high with no ability to ‘shop around’ for competitive haulers.” To reduce costs, the Wagners need to reduce the volume of trash, but electromechanical/hydraulic compactors exerted 7,000 to 10,000 pounds of force. “While that may be fine for an industrial application, it was overkill for us in the restaurant business, “ Wagner said. “For one, we were limited
22 | Industrial Lift and Hoist
by how dense our trash could be. Waste haulers want material in their containers to be less than 250 pounds per cubic yard—trash compacted by hydraulic units would easily exceed that. In addition, placing bags of restaurant trash under that kind of force would simply burst any bag, causing liquids—and more—to spill out.” This resulted in the development of manually operated Pack-a-Drum compactor, which reduces trash volumes up to 60 percent. The concept behind the product is to minimize the volume of trash headed to the dumpster (within limits), which reduces the number of times the dumpster has to be picked up. Wagner noted the advantages of the manual unit are that the cost is a fraction of hydraulic units, there is no need for electricity, and there are no
While increasing the density of bagged trash is great from a cost-savings perspective, food waste is a heavy by-product of a restaurant’s operation. The issue was presented to Wagner while visiting a customer in South Carolina, who was told by some employees that they liked the compactor, but it was a struggle for them to lift the Pack-aDrum bag to the height of the dumpster. “That got us thinking about pairing up our unit with a lift of some kind,” Wagner said. “We looked at a number of different companies, designs and models, and decided that the Genie Load Lifter, also manually operated via a winch, met all of our criteria for functionality, material, and cost.” The cost loomed large, Wagner said, because they needed the total package they brought to customers to be cost-effective. Like Pack-aDrum itself, they wanted the pair of units to have a good return on investment. Purchased together, the two units cost about $5,000. “We can virtually guarantee a 20 percent ROI and, in most cases, get anywhere from 70 percent to as high as 250 percent,” Wagner said, noting this applied to customers who had significant reductions in their hauling bills. After filling a Pack-a-Drum bag to capacity, workers can slide the bag onto the Load Lifter’s platform (in the down position), secure it with a bungee cord, wheel it out to the dumpster, use the manual winch to raise the bag weighing up to 200 pounds to the height of the dumpster opening, and push in the bag. While the Load Lifter boasts ease of operation, Wagner said its durability also won them over. “Both Pack-a-Drum and the Load Lifter are all-aluminum construction, so they stand up to almost anything and are good as new after only a pressure washing,” he said. The Load Lifter unit also was customized to meet Wagner’s particular needs, including an added brake and the winch has been redesigned. “This has really been a successful pairing of two technologies, and we are excited for what lies ahead as more and more customers become aware of the advantages both products provide,” he added.
industrialliftandhoist.com • May-June 2010
Trends &Technology An automated bridge crane application developed by Magnetek’s Engineered Systems Group resulted in more efficient, cost-effective, and safer operating conditions for a boat storage facility in Fort Lauderdale, Fla.
Making the Case to Automate
Innovative automation trends can optimize performance and safety Technological advancements in
control products and engineering have enabled the industry to install new automated materialhandling systems or convert outdated manually controlled overhead cranes, hoists, and monorail systems into modern production tools with an extended life cycle. Automated material-handling systems offer a wide range of benefits, including space savings, lower building costs, improved productivity, more efficient material flow, accurate positioning, fewer personnel required, safer operations, reductions in inventory, increased reliability, reduced operating costs, and better return on investment. In addition to improving production and reducing costs, the trend in automation also focuses on broader issues, such as increasing quality and flexibility in the manufacturing process.
May-June 2010 • industrialliftandhoist.com
Hand-held transmitters like the TelePilot allow crane operators to wirelessly obtain data feedback.
By Dan Beilfuss Dan Beilfuss is the business development manager for Magnetek Engineered Systems Group, Menomonee Falls, Wis.
Highly developed solid-state logic and computer-regulated control systems define what automation is today. Flexibility and networking capabilities of programmable logic controllers (PLC) and computers allow easy integration of related systems. They can be linked to production management computer systems, thereby providing better inventory control, improved process control, and feedback of important management data on the operation. Overhead cranes are routinely interfaced with automatic guided vehicles, conveyors, stacker cranes, and monorails for increased efficiency. The ability to integrate standard components such as variable frequency drives (VFD) with their builtin innovative electronic control functions has revolutionized the industry and driven down the cost of automated systems. VFDs provide speed control and can aid in accurate positioning.
With serial communication, VFDs provide reliable digital linkage among various crane system peripherals, including Modbus, Modbus Plus, Profibus, and Ethernet. Radio frequency as a communications tool adds another dimension that simplifies wiring and adds flexibility to the system. Technology exists to perform remote diagnostics and provide direct feedback to the operator, maintenance department, or crane service provider. In addition, using sophisticated wireless transmitters/ transceivers, the crane operator can obtain data feedback such as load weights, order-picking information, processing instruction, and more.
Industrial Lift and Hoist | 23
Trends &Technology The automation solution While many operations would benefit from employing automated cranes regulated by programmable controllers or other computers, not every application requires this degree of sophistication. A number of operations can be enhanced by utilizing small scale automation solutions that can easily and cost effectively be added to the VFD crane control system. Applications such as auto-dispatch, distance detection and collision avoidance, skew control, and zone control may use simple relay logic and limit switches or involve standalone accessory packages. These concepts, whether part of a complete automation system or as standalone systems, should be considered as part of any overhead material-handling system and can offer immediate, tangible improvements in productivity, safety, and/or performance and deliver a rapid return on investment. Auto-dispatch systems are often used on cranes and monorails traveling over long distances or in hazardous environments. They increase productivity by decreasing travel times and providing accurate and automatic positioning. Due to the automatic speed control and positioning, cranes with auto-dispatch systems are more reliable and efficient than human-operated cranes or monorails. Distance detection and collision avoidance systems prevent crane-to-crane or crane-toobject collisions. This means reduced maintenance costs, increased operator safety, and reduced product damage. These systems use either infrared sensors or low-cost lasers and have their own standalone control packages that can be easily integrated with existing crane controls. Skewing the crane can cause excessive wheel wear and stress, especially to the wheel flanges. It also can produce horizontal forces at right angles to the rail, which can result in unusual stresses to the crane runway beams and building structure. Not only does crane skew inhibit the smooth operation of a bridge crane, but it also makes it more difficult to spot loads accurately in both manually operated and automated applications. In the past, crane builders limited skew by using taper tread drive wheels, extra-wide wheel bases, side guide rollers, or a combination thereof with varying degrees of success. However, crane skew can be significantly reduced electronically by using a combination of low-slip motors and individual motor drives on each end truck controlled by separate variable frequency crane controls. For example, when an external controller is used, if the east end of the crane bridge is detected to 24 | Industrial Lift and Hoist
With the automated boat storage facility, an overhead crane travels down an aisle between rack structures.
be traveling ahead of the west end, the east-end motor will be driven slower to allow the west end to catch up. Zone control, anti-collision path protection, and boundary protection systems restrict the operating areas of a crane due to obstructions, hazardous environments, or other cranes. They can employ a variety of equipment, such as limit switches, infrared sensors, lasers, and other positioning devices. A PLC is commonly used for these systems.
Innovation in automation Magnetek’s Engineered Systems Group recently developed an innovative automated bridge crane application that resulted in more efficient, cost-effective and safer operating conditions for a dry stack boat storage facility in Fort Lauder-
dale, Fla. With the increasing scarcity and cost of waterfront property for marinas, the boat storage industry is searching for a solution that can maximize storage space and provide a safe and secure marina for boat owners. The boating industry is growing, while dock space is diminishing. Supply isn’t keeping up with demand. Waterfront developers are eliminating boat slips from projects, and hurricanes and tropical storms have destroyed many others. Environmental regulatory land use restrictions also have cut supply even further. Magnetek has been providing automated bridge crane systems for applications as varied as foundries, offshore oilrigs, lumberyards, aerospace and manufacturing. Now the automated technology that employs hoists to move large loads along beams and rails has been applied to boat
industrialliftandhoist.com • May-June 2010
storage. The system uses computer-controlled, precision lifting for the storage of boats, utilizing a customizable, secure boat cradle instead of a forklift. Using this technology, the marina owner can expand his dry dock capacity to new heights. The automated boat storage facility contains an overhead crane that travels down an aisle between rack structures. It can manually or automatically lift one boat at a time from the water, transport it through a wash station, and then to a selected storage location. The crane also moves boats from their berths to the water. Boats are stored in racks perpendicular to the aisle inside an enclosed building, which is positioned partly over the water where there is a single pier location for boat pickup and drop-off. When applied to a marina application, bridge cranes allow marina owners to expand their dry dock facilities vertically, which allows for more boat storage on a much smaller footprint. By allowing marina owners to expand up—not out— precious waterfront property can be maximized in terms of usage and revenue for marina owners. In addition to increasing revenue, the vertical
storage system is cleaner and quieter. By using this automated system, forklifts traditionally used to remove boats from the water and stack them can be eliminated. These forklifts also may lose lifting capacity after a certain height and are unable to lift the heaviest boats. However, an automated bridge crane system for marina applications does not have these limitations. An added benefit for marina and boat owners is the system is gentler on boat hulls; it virtually eliminates the hull and gel-coat damage typically associated with forklifts. In addition, the crane system doesn’t emit soot and grease, and it is quieter than traditional forklift boatstacking operations. Equipment used on the Fort Lauderdale boat storage facility included Magnetek’s IMPULSE VG+ Series 2 vector drive, IMPULSE G+ Series 2 adjustable frequency drives, TelePilot hand-held radio transmitter, runway and trolley festoon, programmable logic controller, humanmachine interface, design engineering, PLC/ HMI programming, panel fabrication, and onsite startup services.
Choosing an automation partner The decision to incorporate automation into overhead cranes and hoists in manufacturing and other applications is often intimidating. Consideration must be given to increased capital expenditures, lead times on equipment acquisition, “debugging” and setup periods, and operator training. When choosing a supplier, designer, or integrator of an automated material-handling system, the importance of partnering with an experienced designer of material-handling control systems cannot be over-emphasized. Choose a supplier with real material-handling experience that can provide turn-key service, from project evaluation, project management, installation services, and field start-up, to operator training and system support. Request customer testimonials and evaluate their installation and system experience in detail. An automation system should provide users with a wide variety of options to increase productivity, improve reliability and safety, enhance performance, and prolong equipment life, while affording many opportunities to increase profits and obtain a significant return on investment.
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May-June 2010 • industrialliftandhoist.com 1 5285-2281_ExcellenceAd_HPH_D5g.indd
Industrial Lift and Hoist 3/25/10 8:54 AM | 25
Equipment Spotlight
Custom Equipment Hy-Brid HB1030
Options in the Air By Katie Parrish
Electric aerials provide solutions for all personnel lifting needs
Lifting workers to perform job duties at heights has never been easier and more widely accepted than it is right now. Although many facilities have adopted the use of personnel lifting devices over the last two decades, there is still some room for discussion—particularly when it comes to selecting the right equipment for the job. Traditional personnel lifting methods in industrial facilities, such as manufacturing plants and distribution centers, include stock pickers and electric narrow-aisle scissor lifts.According to one manufacturer, customers have driven the demand for electric aerial lifts, and use of these machines has increased since the mid-1990s. “Once you have it, you can’t work without it,” he said. “Customers generated a need.” Although manufacturers note that electric machines have caught on more rapidly in Europe, North American adoption continues to grow.
26 | Industrial Lift and Hoist
industrialliftandhoist.com • May-June 2010
Speaking with several aerial work platform manufacturers at the 2009 Equipment Showcase, hosted by sister publication Lift and Access, editors of Industrial Lift and Hoist found that evolving safety awareness is the real trend behind aerial lift usage growth. Instead of climbing ladders, erecting scaffold towers, or elevating workers through dangerous and unsafe methods, site owners and fleet managers have decided to look for safer ways to lift personnel and make a conscious shift to build a stronger safety culture. Through adopting safer work strategies, fleet procurement professionals are challenged to find the right machine to meet their jobsite needs. This may mean strictly going up and down with a scissor or vertical lift, being able to reach upand-over obstacles to complete the task with a compact spider-type lift or electric boom lift, or using a machine that can work inside the facility and out in the yard with an electric roughterrain scissor lift. Whether it is to perform facility maintenance, make repairs on overhead cranes, change light bulbs, or manage stock and inventory, there is an aerial lift designed for the needs of every facility.
May-June 2010 • industrialliftandhoist.com
lift is raised and lowered. The unit is designed to Some U.S. manufacturers note they have capture virtually any leak that may occur, making received input from the industry to fill the it safe for applications such as food processing. One unique feature of the Hy-Brid HB1030 gap in traditional-style machine product lines. Richfield, Wis.-based Custom Equipment was is its steering system, which incorporates a pair building mausoleum lifts in the 1980s and saw of dual caster wheels that counter-rotate when where the lightweight, high-capacity scissor lift turning. According to Custom, the weight of the concept may be appropriate in other industries. machine goes down between the two wheels and The company introduced the Hy-Brid self-pro- will not buckle carpet or scuff floors. The nonpelled scissor-style lift in 2004. The 10-foot Maintenance is minimal, and batteries platform height unit are accessible through a slide-out tray. weighs only 1,275 pounds but offers 750 pounds of lift capacity. Designed for any slab, firm-level surface, the Hy- marking wheels are a urethane composition. Maintenance is minimal, and batteries are Brid HB1030 has a rolling load weight of about accessible through a slide-out tray. The HB1030 300 pounds per wheel. The name “Hy-Brid” refers to the scissor lift’s uses two 12-volt batteries instead of four six-volt electric drive, electric steer, and hydraulic lift batteries because of the machine’s efficient elecsystem. Because the machine features regenera- tric drive system. Since the pump motor for the tive braking drive motors and electric steer, the hydraulic lift system takes more amperage than company says there is no potential for a hydraulic the drive motor, the machine won’t lift if power leak when driving. The only time the Monarch- runs low. However, it will allow the unit to be supplied hydraulic pump is operating is when the driven to an outlet for charging.
Traditional strategies
Industrial Lift and Hoist | 27
Equipment Spotlight Genie GR-20 Runabout
The unit can be driven at maximum elevation, and when equipped with the optional slideout deck, operators have a 55-inch workspace. Standard non-marking tires keep floors clear of marks. Although the Runabout Series looks quite different than its scissor lift counterparts, in fit and finish, the GR-20 Runabout is as rugged as a 19-foot electric scissor lift. Additionally, its capabilities offer industrial users a machine designed specifically for their jobsite needs.
Up-and-over abilities Beyond safety, the need for accessing tight, hard-to-reach areas is a key element for the acceptance of aerial lifts. Electric boom lifts and compact spider-type aerial lift users embracing these machine types have found that the up-andover capabilities on these units help access those once unattainable areas. Pair this feature with low ground pressure provided by many track-mounted
ward is controlled via a dolly-style handle at the back of the machine (note the unit cannot be driven while the boom is elevated). The FS95 features four six-volt 200Ah gel batteries with a typical run time between 1 to 1.5 hours. The onboard Honda generator can charge the batteries during operation. For interior projects, the machine can be plugged into a standard outlet for recharging. The 110V chargeable battery system does not require the machine to be completely charged before operation. A Hatz diesel motor is optional. More compact and quieter than ever, electric boom lifts often offer easy maintenance options, common components with other products in the line, and enough drive speed, torque, and gradeability to handle any on-slab jobsite. Snorkel International, Elwood, Kan., introduced the AB46JE electric boom lift in spring 2008, and its compact, narrow design features a 5'8" width, 6'6" stowed height, and a 23-inch Reachmaster Falcon FS95
Although the Genie Runabout Series vertical lifts from Terex AWP, Redmond, Wash., offer similar capabilities to Genie’s 15- and 19-foot narrow aisle scissor lifts, the genesis of this product line was determined by different factors. A number of contractors, big box retailers, and industrial end users required a lift with room for only one person. Additionally, a machine with a shorter wheelbase was necessary to maneuver in certain applications—particularly on sites where the machine was moving around obstructions. There also was a need for a machine that was lightweight and could be moved in elevators. Order picking in retail environments, including setting up displays or changing drop lighting, also requires a shorter wheelbase and lighter floor loading. Four models make up the Runabout Series and feature platform heights ranging between 12 to 20 feet and overall weights ranging from 1,525 to 2,500 pounds. The Genie GR-20 Runabout vertical lift has a 24-volt hydraulically powered chassis that is run by hydraulic wheel motors with SAHR brakes and near-zero inside turning radius. All drive functions are similar to the Genie 19-foot GS-1930 narrow scissor lift and share the same electric motor, pump, control system, and multidisc brakes. The GR-20 has slightly smaller wheel motors than the 19-foot scissor. The operating system also is the same as the Genie electric scissor lifts, and the lower ECM and control box can be swapped with a 19-foot scissor.
28 | Industrial Lift and Hoist
compact aerial lifts, and sites with floor weight restrictions, narrow aisles, and hard-to-reach applications assuredly can benefit from these machines. Reachmaster has a long history of building compact spider-type lifts, having produced its first machine in Denmark in 1964. Kingwood, Texas-based Reachmaster US’s Falcon FS95 is the smallest machine in the Falcon product line. The FS95 can be fitted with solid, non-marking tires; pneumatic tires; dual tires; or tracks. Weighing only 8,800 pounds, this unit can fit through a single doorway, elevate to 95 feet, and reach out up to 46 feet. Because the machine is lightweight, the Falcon FS95 relies on outriggers for stability. The outriggers can be adjusted in three different positions to work around various obstacles and elevations. For example, one outrigger can be set up 3 feet down in a hole while another is located five steps above ground level. Driving the FS95 forward and back-
Snorkel AB46JE
industrialliftandhoist.com • May-June 2010
inside turning radius (9'10" outside turning radius), making it easy to work in tight jobsites and facilities. With 30 percent gradeability, the machine can easily climb up steep grades. Maximum drive speed on the AB46JE is 3.2 mph, and Honeywell limit switches default the unit to a 0.3 drive speed when the boom is elevated. The boom lift features a maximum platform height of 46'3", 24'11" working outreach, and 25'2" up-and-over clearance, yet the unit weighs about 14,310 pounds. The jib boom is 5 feet long and has a jib arc of 140°. The platform also rotates 180°. The turret turns 360° non-continuously. Powering the AB46JE are eight six-volt 350Ah batteries. The motor controller offers quiet and smooth drive operation. The AB46JE features a pair of efficient 48-volt DC electric direct drive motors and spring-applied hydraulically released brakes. The 40-amp, 110V Signet battery charger monitors the amperage flow into the batteries to ensure that they are charged to the appropriate levels. For emergency power, the AB46JE uses an isolated 12-volt motor and pump for battery-powered down. The unit has enough reserve capacity—12 volts from the pack—to get you down, so no hand pump is necessary.
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Industrial Lift and Hoist | 29
Equipment Spotlight Another electric boom lift manufacturer making strides is Haulotte Group, Archbold, Ohio, which offers the HA 43 JE (see photo on page 29). The unit features a compact size and whisper-quiet operation. The machine measures 4'11" wide and has a 6'7" stowed height, making it easy for the unit to travel through double doorways. It also has a short 12'2" outside turning radius, which allows it to operate in congested areas. The platform height is 42'8" with a horizontal reach of 27’11” and up-and-over clearance of 21'8". To keep the basket within the width of the machine, the HA 43 JE incorporates a 3'11" wide basket. The control system on this unit is a CANbus system, which is designed so the operator can select between driving and steering the unit or operating the boom individually. Battery packs are located on either side of the HA 43 JE. Looking at the size of these battery packs, it is apparent there is a lot of weight in the packs and the unit’s overall weight of 16,000 pounds supports this observation. A backup battery is also included and is isolated from the main service batteries. Haulotte noted that the eight six-volt 446 Ah batteries should provide 12 hours of operation per charge when working in normal applications. Non-marking solid tires are standard.
Noise- and fume-free sites Although an electric rough-terrain aerial work platform may sound a bit like an oxymoron, the market is gravitating toward machines that not only reduce noise pollution and emissions but also improve fuel costs. Battery-powered electric scissors seemingly fulfill that need, and manufacturers like Skyjack and MEC offer non-marking tire options so these units can work inside finished structures and interior atriums, as well as in the yard. An additional benefit is the DC-powered RT scissor lifts affect on the environment. Paul Kreutzwiser, senior product marketing manager for Skyjack, Guelph, Ontario, said the company has offered electric RT scissors for a number of years—the SJ 8831E was introduced in 1995— and the initial market demand was for roughterrain units that reduced noise, emissions, and improved air quality while working indoors. “The reasons driving the demand have shifted from concern over indoor air quality from a health and safety point of view to an expanded overall environment point of view at both the micro and macro levels,” Kreutzwiser noted in 2008. He
30 | Industrial Lift and Hoist
Skyjack SJ 8831E
getting through a full eight-hour day once the batteries are fully charged. Stated drive speed on the machine is about 3 mph, and it provides 30 percent gradeability. Tilt is 2.5° side-to-side and 4.5° fore-and-aft. Driving while elevated more than 10 feet will decrease the drive speed, but the direct electric drive offers maximum torque at any speed. Pneumatic, foam-filled, non-marking, and floatation tires are available. Several years ago MEC Aerial Work Platforms made a decision to develop a wide series of electric battery-powered rough-terrain scissor lifts. The company now has five electric RT models, including the 37-foot platform height 3772ES scissor lift. It uses eight 6-volt, 375 amphour batteries, which provide up to 10 hours of standard use per day. Optional 425 amp-hour batteries offer 12 hours of use each day. To protect the electrical system from low voltage operation, the machine is equipped with a fail-safe system. The 3772ES has three modes of drive: high speed, midrange, and Quad-Trax low MEC 3772ES range. In low range, the Quad-Trax allows all four wheels to work completely independently of each other. In a muddy or slippery application, the machine only needs one wheel to provide traction. Gradeability is 40 percent, and the advertised top speed is 3 mph. Lift cycle time is about 35 seconds to get to 37 feet high. There is no question that aerial lifts make the jobsite safer and more productive. With the broad range of offerings available, fleet managers should have no problem with finding the right machine for their facilities.
indicated that as concerns for the environment become more prominent, Skyjack is receiving more inquiries from LEED buildings and equipment owners searching for the most environmentally friendly machines available. The Skyjack SJ 8831E is an axle-based, electric-drive scissor lift and uses the same axles, scissor stack, and platform as the engine-powered version of this model. Naturally, the key difference is the 48-volt direct electric drive, and the eight 6-volt batteries located on the slide-out tray that would normally house the engine. Fourwheel and two-wheel drive options are available. Steel lockable cabinets located on the side of the scissor lift house the hydraulic tank and two 48-volt chargers. While only one charger is required, the SJ 8831E’s charge time is cut in half when both are used together. The company notes a dead machine can be brought to full charge in about five hours. If only one charger or outlet is available, charge time is about 10 to 12 hours. Skyjack says the scissor lift has no problem
industrialliftandhoist.com • May-June 2010
Business Issues
A New Cab-Down Classic The CD4420 is rated at 20 tons.
By Tracy Bennett
Heavy industrial users of RT cranes now have options for replacing aging fleets Nuclear power plants, refineries,
and other heavy industrial facilities have long relied on a special kind of rough-terrain crane to get into tight places for maintenance and material handling. Cab-down RTs are compact and feature a stationary operator’s cab at the front of the machine for improved visibility in confined spaces. Dating back to the 1960s, this workhorse was fast becoming a dying breed. Until recently, new cab-down RTs were no longer being manufactured, leaving plant managers and maintenance crews with few options for replacement. “I’ve toured a refinery where there were 60 older cab-downs working on the site,” said Paul Marxen, sales manager for Badger Equipment Co., Winona, Minn. “The facility was two miles long and had a chemical plant on one end. The cab-downs were used to pick and carry pipes, filters, and pumps and to haul them to the shop for repair.” To meet this need, Badger Equipment Co., Winona, Minn., introduced an all-new cabdown rough-terrain crane last year. Deliveries have already begun on the 30-ton CD4430 and 20-ton CD4420 for work in refineries, petrochemical applications, and on the railroad. Mike Daniels, president of Contractors Crane Co., Houston, Texas, is one customer excited about the new cranes. He explained that many petrochemical plants have age restrictions on equipment, and he believes there are more than 1,000 old cab-down cranes, like the Galion FA 150, that will need to be replaced over the next decade.
May-June 2010 • industrialliftandhoist.com
High-visibility features A notable feature of the new Badger cranes is full electric-over-hydraulic controls, which the company positions as the wave of the future. Twin electronic joysticks command all boom and winch functions. In the creep mode the 30-ton unit can pick and carry 25,000 pounds. Badger chose to go with the electric-over-hydraulic control configuration for ease of service and because of the simplified hydraulic system, explains Marxen. The system “gives the operators control over the ‘feel’ of the machine,” he says adding that the configuration aids in trouble-shooting or selfdiagnostic issues and reduces heat input in and around the operator’s compartment. When asked if he sees a trend in crane design toward the electric joystick configuration, Marxen remarked that most crane manufacturers have already adopted this technology. “The 30-ton cab-down style rough-terrain crane is targeted to niche markets such as railroads, refineries, bridge contractors, and heavy industrial users,” said Marxen. “A unique feature for railroad equipment managers is the ability to have high-rail gear integrated at the factory, which simplifies their buying process and reduces lead-time to get the crane into the field. It’s a product that we are confident will be met with great enthusiasm by our customers and will find solid demand in the marketplace.” With a 97-foot maximum tip height with jib, the new Badger cranes, feature a six-sided boom in two configurations, a three-section 77-foot synchronized, or a two-section 55-foot synchronized.
Both are equipped with self-lubricating boom slider pads. They also feature a two-speed planetary grooved drum hoist designed with a negative draft flange and a hoist drum rotation indicator. Under the hood, the cranes have a Tier 3 Cummins QSB 4.5 diesel engine that is 160 hp at 2500 rpm. The four-cylinder turbocharged water-cooled engine is standard, but an optional six-cylinder QSB 6.7 is available. Badger also has designed in electronic sensors and controls to reduce service issues and provide easy maintenance. The cranes’ two-door high visibility cab features a multi-position seat, in-dash display, main wiper and upper wiper, as well as electronic joystick controls. The crane is equipped with continuous 360° rotation and standard all-wheel drive/ steer, and crab steering. Each model also comes with Badger’s electronically-controlled powershift with six forward speeds and six reverse. They are also designed with cantilever-style outriggers. Operational features include a radio antitwo-block system, and an automotive-style electrical system. Options include a load moment indicator with digital display, CANbus system interface, and overload shutdown. The optional Hi-Rail gear system will be fully integrated for easy adaptation in rail applications.
Other applications In addition to the heavy industrial applications already mentioned, Marxen adds that the company has delivered quotes to a phosphate mine and shipbuilders. “One shipbuilder is looking to
Industrial Lift and Hoist | 31
Business Issues Dating back to the 1960s, this workhorse was fast becoming a dying breed. fund four new cranes with the American Reinvestment Act and another to upgrade to our 30ton machine from an older 15-ton model for use on the dock,” he said. A natural gas contractor is considering one for unloading trucks and hauling parts to the site. But it’s the refineries and railroads that have the most to gain from these new cab-downs, having depended on this style of crane for so many years. “There are contractors working in refineries that own very large fleets of these cranes—upwards of 125 cranes in just the cabdown style,” said Marxen. “They can use one crane for every 10 pipefitters and welders. One refinery refurb project is expecting to employ 4,000 workers this year.” Railroads will most likely use the high-railequipped cranes for threading rail on a track to be
Amtrak uses a high rail-mounted CD4430 Badger along tracks in Maryland.
Badger was acquired by Manitex International nailed down. Marxen explains that larger railroads will often supply up to 20 work gangs with two or Inc., Bridgeview, Ill., in 2009. The cranes will be more cranes each. “Options such as hydraulic hoses distributed through existing Badger and Manitex with hose reels allow the gang to operate hydraulic dealers. According to Scott Rolston, Manitex vice tools right on site, magnets and generator sets can president of sales and marketing, “We intend to be used to pick up scrap metal, recovery winches develop a full product line in the near future decan be operated at the front, and extra steel plating signed to support the requirements of our customon the front bumper allows the crane to be used for ers in this niche.” 338wide_mag_refinery.pdf 1 9/30/2009 1:01:07 PM badgerequipment.com pushing rail,” he said.
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industrialliftandhoist.com • May-June 2010
Options for Upkeep What about all those older cab-down cranes still working in the field? After years of repairing the hoisting brake system of Galion/Dresser hydraulic cranes, career mechanic Reynold LeBlanc made a commitment to find a better solution than the complicated and expensive temporary fixes suggested by the factory. The result of shear determination by the owner of RJ Enterprise, LLC, Denham Springs, La., is a permanent fix in the Wrap Band Safety Brake. In LeBlanc’s opinion, the Galion/Dresser 15-ton cranes cannot be beat for overall performance and maneuverability for jobs in their load range, and therefore, will continue to be in demand. He notes the only persistent problem is the hoist brake slippage. “I’ve made my living with Galion/Dresser cranes,”
An older Galion cab-down crane is used to lift pipe. When the Wrap Band Safety Brake is installed, downtime for repairs and replacements of the factory brake system is no longer necessary.
adds LeBlanc. “Galion/Dresser hoist brakes do not hold 110 percent of the rated load capacity as required by OSHA and ANSI, and in my experience, they never have —even when the machines tested, were relatively new and [had] less than 500 hours logged,” says LeBlanc. “When the cranes’ hoist brake is not holding, it causes the load block to dangerously slip or creep down. This can result in injuries to personnel working with loads on the cranes.” LeBlanc began his career in hydraulic cranes, at the then-
largest Galion hydraulic crane distributor in the United States, and later owned his own rental fleet of Galions. There were a little more than 12,000 Galion/ Dresser cranes made with this winch system from 1967 to 2004, he says. Though the cranes are no longer being manufactured, he estimates that probably at least 6,000 remain in use, as they continue to be popular machines. It takes about 45 minutes to install the Wrap Band Safety Brake onto the crane, says LeBlanc, “and any crane mechanic can perform the installation by following the simple step-by-step installation manual.” No removal or disassembly of the factory brake is necessary. The Wrap Band Brake is installed over the existing brake drum, and the actuator link is attached to the Galion brake lever by
drilling a 5/16-inch hole in the lever. Once in place, the Safety Brake acts as an auxiliary system to assist the Galion/Dresser winch brake to hold the load. “The Safety Brake works with the factory brake in all functions including anti-two-block mode,” says LeBlanc, and will not interfere with the Galion’s crossline relief system. In the event of a hydraulic system failure, the load will not slip with the Safety Brake engaged. And should the brake band liner wear down over time, the Safety Brake will automatically adjust itself to compensate for wear of the liner. rjenterprisellc@yahoo.com
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Industrial Lift and Hoist | 33
Equipment In Action
Deadline Set in Stone Cosmos Granite &
Marble relies on North American Industries to quickly install four bridge cranes and runways North American Industries, Woburn, Mass., was recently chosen by Cosmos Granite & Marble to design and install four bridge cranes and runways. Cosmos, headquartered in Raleigh, N.C., is an importer and wholesale supplier of premium quality natural stone for commercial and residential building projects. Through five distribution facilities across the United States in North Carolina, Illinois, Georgia, and Washington, the company imports and distributes marble and granite slabs and tiles. Maintaining a short lead time was one of the key criteria for Cosmos when selecting North American Industries to supply the overhead crane systems. As part of a rapid move to a new warehouse facility, Cosmos required that its cranes and 750 feet of runway be designed, manufactured, and installed in less than eight weeks. North American Industries’s lean operating environment has allowed it to deliver and install more than 175,000 pounds of steel columns, runway beams, and cranes within Cosmos’s tight lead-time requirements.
Four 48-foot span, 5-ton single-girder bridge cranes were installed at the stone supplier’s Raleigh warehouse.
To date, each of the four 48-foot span, 5-ton single-girder bridge cranes has been installed in the Raleigh warehouse. They allow easy access to all the granite and marble slabs and tiles. Each crane is set on its own 188-foot runway with an independent traveling pendant, which allows the operator to stand
separated from the load and move anywhere along the bridge, thereby improving his or her safety. North American Industries also specified an electrified transfer cart for Cosmos, enabling it to transfer loads among cranes quickly and efficiently. “North American Industries has been a pleasure to work with,” said Vamsi Nallapati, president of Cosmos Granite & Marble. “The staff on hand has been great and is very knowledgeable in the crane industry. We had a very tight deadline to keep, and NAI was able to keep meet this time constraint with ease.”
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Columbus McKinnon
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Del Hydraullics
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HGR Industrial Surplus (866) 447-7117
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34 | Industrial Lift and Hoist
industrialliftandhoist.com • May-June 2010
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