ASIAN STAR PROJECT SALES HANDBOOK
Hitachi Construction Machinery Co., Ltd. www.hitachi-c-m.com HO-EN008
09.03 (KA/KA,GT2) Printed in Japan
ASIAN STAR PROJECT SALES HANDBOOK
- Contents 1. Steel Industry
3
2. Scrap Industry
9
3. Magnet Machine
21
4. Material Handling Machine
37
5. High mount Cab
53
6. Base Machine for Mobile Shear
65
7. Mobile Shear (Maker:GENESIS)
73
8. Electric Material Handling Machines
91
9. Recycling Equipments
101
10. Mining & Quarry Equipment
131
11. Forestry Machines
155
12. Brochures List
161
1
2
1. Steel Industry
3
1-1. Basic Steel Production Methods Blast Furnace Blast Furnace
Electric Arc Furnace
BOS Furnace
Production
Volume
Variety
Large Facility
High efficiency
Raw
Iron ore䊶Coal䊶
Material
Limestone + scrap
Scrap
Heat
Pure oxygen
Electric Arc
Slag
Slag
Process
source Byproduct
ZX
ZR
ZW
HITACHI
Product
4
ZW
ZX
1-2. Blast Furnace Stock yard
Maintenance
Port handling
Variety of HITACHI products working in steel works
Recycling
5
1-3. Electric Arc Furnace Recycling
Maintenance
Port handling
Variety of HITACHI products working in steel works
6
Stock yard
1-4. Supply of Raw Materials for Electric Arc Furnace
Manufacture
Products
Scrap Dealer
Domestic market
Steel Manufacture Port handling
Export Scrap
Import Scrap
7
8
2. Scrap Industry
9
2-1. Dividing and Sizing
Demolish
Retirement
Gus Cutting
Pressing
Shearing
Shredding
All materials will be Treated
Steel Manufacturer
Steel materials using in construction
10
2-2. Outline of Scrap Yard Shredder
Scrap Loader
Shearing
Scrap Yard
Magnet
Mobile Shear
11
Grapple
2-3. Scrap Grade (1) Classifi cation
Variety
Steel Scrap
Heavy*
Grade
Specification ( m/ m ) Thickness
Press
Shredder
Width㬍 Height㬍 Length
Unit Weight (kg)
Densit y (t/ m3 )
Cu %
HS
>6
<500 㬍 <700
<600
<=0.15
H1
>6
<500 㬍 <1200
<1000
<=0.20
H2
3䌾6
<500 㬍 <1200
<1000
H3
1䌾3
<500 㬍 <1200
<1000
H4
<1
<500 㬍 <1200
<1000
A
W+H+L<1800,with the max dimension <800
B
W+H+L<1800,with the max dimension <800
CS**
600<=W+H+L<1800,with the max dimension <800
>=0.6
C*
600<=W+H+L<1800,with the max dimension <800
>=0.6
AS
>=1.0
<=0.15
B C Steel Sheet Clipping
A ( Bundle of Steel Sheet)
W+H+L<1800, with the max dimension <800
B ( Bundle of Steel Sheet)
W+H+L<1800, with the max dimension <800
A ( Busheling , Steel Sheet Clipping etc ) B ( Busheling , Steel Sheet Clipping etc ) Turning
A B
Pig Iron Scrap
Cast Iron Iron Boring
Press
W+H+L<1800, with the max dimension < 800
A
Length of one dimension < 1200
<1000
B
Length of one dimension < 1200
<1000
A B
* Not contaminated with plastic dust etc. ** CS & C are such items as not only pressed for each piece but formed as a solid cube unbreakable in handling EXCEPTIONS A. Hazardous or Hermetically Sealed Items ( Gun shells, bullets, high-pressurized containers, pipes with closed ends, shock-absorbers, door controllers, Jacks, etc.) B. Steel Alloy Scraps, Non-Ferrous Metals or those containing or contaminated with them (tin, cupper, zinc, lead, nickel, chromium, Aluminum, manganese, etc ) C. Foreign materials or those containing or contaminated with them (enameled wares, welding rods, glass, plugs, textiles, vinyl or other plastics, concrete, tar, scale, rubber, woodchip, oil/ grease, etc. ) D. Items difficult to handle in loading/ unloading( those ball-shaped and/or entangled steel bars or wires, those disturbing magnetic operations) E. Those rusted and/or corroded heavily. F. Those containing radioactive elements. G. Containers not allowing to identify the contents therein specifically
12
2-3. Scrap Grade (2) Classification
Variety
Grade
Remarks (Examples)
Steel Scrap
Heavy*
HS
Steel plate, Wide Flange Beam, Angle, Channel, Hot rolled Bars, Rail, Punching, Small Clipping, Scrap of Heavy Machinery ( other than Concrete Reinforcing Bars, sheet piles ) etc.
H1
Rail, Punching, Small Clipping, Wheels, Nuts & Bolts, Pipes
H2
Steel plate, Angel, Channel, Scrap of Heavy Machinery etc.
H3
Light Gavage, Steel Sheet, Steel Band, Auto Wheel, Spring Plate etc.
H4
Steel Sheet, Wire, Wire rope, Steel Furniture, Door Shutter, Bicycle etc.
Press
Shredder
Steel Sheet Clipping
Turning
A
Auto Body, Fender, Galvanized Sheet
B
Galvanized Sheet, Pressed Turing of mild steel, Electric Household Appliance, motorcycles, Bicycles etc.
CS**
Cans for food/drink, Cans in general( expect for paint, chemicals or oil )
C*
Mixed cans of various types, including 18-liter cans
AS
Auto Body, Fender, Clipping etc. especially not contaminated with non-ferrous dusts.
A
Auto Body, Fender, Steel Furniture etc.
B
Galvanized Sheet, Electric Household Appliance, Motorcycles, Bicycles etc.
C
Tin Plated Sheet, Mixed cans etc.
A ( Bundle of Steel Sheet)
Hot or Cold Sheet with no rust
B ( Bundle of Steel Sheet)
Hot or Cold Sheet with some rust, incl. Coated Sheet without harm for steel making
A ( Busheling , Steel Sheet Clipping etc )
Hot or Cold Sheet with no rust
B ( Busheling , Steel Sheet Clipping etc )
Hot or Cold Sheet with some rust, incl. Coated Sheet without harm for steel making
A
Turing of mild steel with no rust, in fine forms
B
Turning of mild steel with some rust, in various forms
Press Pig Iron Scrap
Cast Iron
Iron Boring
“Press” grade added for new market
A
Machinery parts, Clean Auto Blocks etc.
B
Charging box cast, unstripped auto blocs
A
Iron boring of mild casting
B
Iron boring of mild casting with some rust
13
2-4. Scrap Processing Facility
Pressing
Shearing
Shreding
Reduce volume
Sizing
Dividing &Sizing
(Factory bindle/Can/Car)
(H beam/Pipe/Ship/etc)
(Ferrous/Aluminum/Co pper/etc)
Our products
Our products
14
Our products
2-5. Scrap Handling Machine Equipment Front 1 Standard 2 High boss 3 Straight 4 Long
Cabin 1 Standard cabin 2 Fixed high cabin 3 Linkage high cabin
Engine 1 Diesel 2 Electric
Attachment Undercarriage 1 Grouser * 2 Flat 3 Rubber pad 4 Wheel 5 Stationary ( high post)
ZX330-3
15
1 Fork grapple 2 Magnet 3 Orange grapple 4 Shear
2-6. How to Select Attachment ferrous
Non ferrous
mixture
Scrap handling Popular handling attachment
Popular machine size 20ton-30ton
Excavator Simple
function
function
+ attachment
Volume
Process
Fork Grapple
Light weight scrap handling
function Usefully and Separate
Over size On site
Magnet Orange Grapple Easy to loading and unloading from lorry. Easy to picking up from ground.
16
Shear
2-7. Characteristic Structure of Front Hanging
Value 1.Wide working radius 2.Reduce front damage
Weakness 1.Separating operation 2.pushing operation
Tilt Type
Value 1.Separating operation 2.pushing operation
Weakness 1.Front damage
High boss
Value 1.High working radius/low cost
Weakness 1.Shallow working radius
17
2-8. Characteristic Structure of High Cab Fixed
Value
1.0 m 1.5 m 2.0 m
1.Low initial cost 2.High stability 3.Low maintenance cost
Weakness 1.Transportation with reduction high cab unit 2.unadjustment height
Value
Linkage
1.Higher eye point level 2.easy transportation 3.adjustment height
Weakness 1.High initial cost 2.less stability 3.Need Maintenance for Rink unit
18
2-9. Characteristic Structure of Undercarriage Value
Crawler
1.Reasonable initial cost 2.Off road travel ability
1 Grouser * 2 Flat 3 Rubber pad
Weakness 1.Slow traveling speed 2.Damage for Concrete Yard 3.High undercarriage Operation cost
Value
Wheel
1.Large size yard 2.High traveling Speed 3.Low undercarriage maintenance cost
Weakness 1.High initial cost 2.low off road travel ability
Stationary
Value 1.low operation cost 2.Saving space 3.wide operation reach
Weakness 1.Fixed operation 2.high initial cost
19
2-10. Characteristic Structure of Power Source
Diesel Engine
Value 1.Low initial cost 2.Generale machine 3.Location free
Weakness 1.High operation cost 2.High CO2 discharge 3.Dirty exhaust guss
Value
Electric Motor
1.Low operation cost 2.Clean operation 3.Low noise
Weakness 1.High initial cost 2.limited location
20
3. Magnet Machine
21
3-1. What’s a Magnet Machine
It is a machine that absorbs, loads the iron scrap with the electromagnet.
Motive power
Power transmission Generator
Power supply box
Electromagnet Absorption & Release
Iron scrap
22
3-2. Structure of Magnet Bracket
Insulation
Check the wear on the magnet bottom plate. Repair or replace the inner and outer poles according to the wear limits shown in the table below. Magnet
Wear limit
LECHX11F6
10 䌭䌭
LECHX13F6
15 䌭䌭
LECHX15F6
15 䌭䌭
Yoke
(portion H)
Coil
㪟 Iron core Inner pole ring 䃨1 stainless steel welding
䃨䋱 Outer pole ring Coil support (non-magnetic, stainless steel)
䃂 Use the magnet within the adsorption time ratio and the continuous adsorption time. For the magnet of 60% ED, the adsorption time to attract scraps is 60% or less in one cycle, and the continuous attraction time is 6 minutes or less. 䃂 In case the appearance of the magnet is excessively deformed or the wear on the bottom surface becomes remarkable, repair the magnet or replace the bottom plate.
23
3-3. Engine: Magnet Machine One Engine Type Generator is work with Excavator’s engine 䊶 Reasonable Price 䊶 Easy Maintenance Good 䊶 Better Rear Visibility
Excavator’s Engine
䊶 Much Fuel Consumption =>High idling drive for engine 䊶 Heavy Engine Load
No Good
Two Engine Type Generator is work with Engine - Generator unit Engine – Generator unit
䊶 Less Engine Load Good
Excavator’s Engine
䊶 High Price 䊶 Poor Rear Visibility 䊶 More Maintenance Required No Good (for Two engines)
24
3-4. Power Transmission Hydraulic Pump & Motor Drive (HITACHI Genuine Magnet) Generator Engine
HYD.Motor
HYD. Pump 䊶The Layout position is free.
Good䊶Better weight balance 䊶Better performance by using hyd system (Good heat balance). 䊶Good stability (better than transmission).
V-Belt Drive (Local Magnet) V-Belt
Engine
䊶Cheap in Price (but cheap in quality)
Generator
Good 䊶Layout Space is Limited. 䊶Frequent change of V-belt is necessary. 䊶Life time of bearing is short.
No Good
䊶Weight balance is bad 25
3-5. Advantage of Control System Production is Different between HITACHI and Local made. Local magnet Slow response
Fixed Current Control Magnetism Curve
200V Slow release
Slow Absorption
Absorption 䋧 Releasing time: Approx.6 sec
current
Releasing point
Absorption point
HITACHI magnet Over excite Current Control! Quick response!! Quick release
Absorption 䋧 Releasing time: Approx.1 sec
Quick Absorption
current
Releasing point
Reverse Excitation
26
3-6. HITACHI Magnet Machine Engine Power Transmission Generator Power Supply Box
㸢 1 Engine type 㸢 Hydraulic Pump & Motor Drive 㸢 3-phase A.C Generator 㸢 Over excitement & Reverse excitation control type
Boom slow return val䌶e Magnet
Electric Cable
Base machine Heavy Counterweight Grip Switch (adsorption) Instrument Box (Control Switch Box)
Power Supply Box Bracket, Cover for Power supply box & Generator
Grip Switch (release) 3-phase AC power generator
Parts for Generator drive
27
3-7. ZAXIS-3 Model Magnet Machine Control Panel
Magnet
(Power Supply Box)
Control switch box
Additional hydraulic pump
Magnet switch
Generator
Large sized air filter
Hydraulic motor
28
3-8. Characteristics Cable layout is between the upper side of the arm and the magnet.
Reduction of broken cable accidents.
Engine Controls Engine speed when a magnet is used. When the magnet main switch turns on, the engine speed switches to its rated speed.
Improvement of operability.
Auto Idle Control When magnet is not adsorbing and the machine is not operating any other operation, the engine speed decreases to a specified speed. Improvement of fuel consumption. By comparison with ZX-1, about 15% less. However fuel consumption vary by working conditions.
ZX200LC䌾ZX330LC Magnet Comparison Scrap Absorption MODEL
Gravity
MAGNET 0.7
1.3
ZX200LC/ZX240LC
1 370 mm
515-605 kg
815-920 kg
ZX330LC
1 570 mm
630-760 kg
990-1 130 kg
29
3-9. ZX200LC-3 Specification Working Range
Unit : mm Model
ZX200LC-3
A Max. working reach
8 680
B Max. working height
7 930
C Magnet height (arm rolled-in)
3 370
Magnet outside diameter
1 370
B
C
A 30
3-10. ZX240LC-3 Specification Unit : mm
Working Range
Model
ZX240LC-3
A Max. working reach
8 960
B Max. working height
8 050
C Magnet height (arm rolled-in)
3 640
Magnet outside diameter
1 370
B
C
A 31
3-11. ZX330LC-3 Specification Unit : mm
Working Range Model
ZX330LC-3
A Max. working reach
9 730
B Max. working height
8 220
C Magnet height (arm rolled-in)
3 600
Magnet outside diameter
1 570
B
C
A 32
3-12. Vs. Local Magnet : Warranty
Standard Machine
KOMASTU
Local Modification
KOBELCO
USER
Machine Trouble
NO WARRANTY
䊶Unstable Counterweight
䊶Engine Overheat
HCM Magnet Machine with WARRANTY *Selling Points
33
3-13. Vs. Local Magnet : Productivity
Volume of Magnet absorption Absorption volume Outside Diameter
Duty ratio
Weight
Pig Iron / Crop Ends
HS1 Scrap Steel / Iron Chips
HITACHI Magnet
1 570 mm
60%ED
3 120 kg
1 900 / 1 710 kg
1 250 / 1 120 kg
Local magnet
1 500 mm
60%ED
3 000 kg
1 990 / 1 570 kg
1 150 / 940 kg
HS1 scrap steel 㹢 9-19 % More absorption 9 % More absorption Pig iron 㹢 3600sec㬍1 .185t HITACHI =185 magnet 23sec(cycle t/hr time)
䋾
㶎10% bigger volume against ZX-1 model. due to bigger diameter. 㶎Shorter turning radius (130mm) by 5%.
Local magnet
㶎Add. 5 sec for local magnet.
Loading volume
38% up!! 34
3600sec㬍1. 045t =134t 23+5sec(cyc /hr le time)
3-14. Vs. Local Magnet : Selling Point
HITACHI genuine magnet Machine
Include Heavier Counterweight
Good Stability 㶎C/W : counter weight
Base machine Magnet size
ARM
Heavy C/W (STD + ? Ton)
ZX200LCZX200LC-3
1 370
2.9m STD
1.5
ZX240LCZX240LC-3
1 370
2.96m STD
1.7
ZX330LCZX330LC-3
1 570
3.2m STD
2.2
Local Magnet Machine Bad Stability Cut out counterweight
Not Include Heavier Counterweight Unbalanced *Many trouble cases 35
36
4. Material Handling Machine
37
4-1. Suggestion of Elimination DOUBLE HANDLING WORKS.
No Good 13 750 mm
8 000 mm
Double!! Maintenance Fuel Labor Fee
5 750 mm
Change!! HITACHI Material Handling Machine WORKS.(EX.ZX240LC-3)
Good
OneOne-Half!! Maintenance Fuel
13 710 mm
Labor Fee
38
Can work with One machine
4-2. Equipment
Arm Cyl. 䋺 Installed both sides.
Piping guard plate
Clamping pipe : Fixes with two bolts. (Prevent loosing bolts)
Cab : 䊶Standard Cab 䊶HighHigh-Mount Cab (Option) 䊶Fixed Type Type 䊶Linkage Type
Counterweight : heavier type (reinforced main frame)
End of piping point with stop valve
Front light : Boom x 1 Arm x 2
39
4-3. Working Range (Arm Point)
Comparison
Material Handling Machine
Excavator (STD front)
40
4-4. ZX200LC-3 Specification Working Range & Dimension Unit : mm Model Operating weight A Max. arm point reach
ZX200LC-3 23 000(kg) 11 000
B Max. arm point height
12 280
C Min. swing radius
3 190
D Max. arm point depth
5 680
E Max. arm point depth reach
6 150
F Overall length
9 520
G Length from swing center to front end H Overall height of boom
6 770 3 270
41
ZX200LC-3 ENGINE Model
Isuzu AI-4HK1X
Type
4-cycle watercooled, intercooled
Rated power
122kW(164HP)
Maximum torque
At 2 000min-1(rpm) 655N䍃m(67kgf䍃m) At 1 500min-1(rpm)
4-5. ZX240LC-3 Specification Working Range & Dimension Unit : mm Model
ZX240LC-3
ZX240LC-3 ENGINE
26 100(kg)
Model
Isuzu AI-4HK1X
A Max. arm point reach
12 500
Type
B Max. arm point height
13 710
4-cycle watercooled, intercooled
C Min. swing radius
3 770
Rated power
132kW(177HP)
D Max. arm point depth
6 700
E Max. arm point depth reach
6 680
F Overall length
10 400
G Length from swing center to front end
7 400
H Overall height of boom
3 400
Operating weight
42
Maximum torque
At 2 000min-1(rpm) 673N䍃m(69kgf䍃m) At 1 500min-1(rpm)
4-6. ZX330LC-3 Specification Working Range & Dimension Unit : mm Model
ZX330LC-3
ZX330LC-3 ENGINE
35 600(kg)
Model
Isuzu AI-6HK1X
A Max. arm point reach
14 200
Type
B Max. arm point height
15 660
4-cycle water-cooled, intercooled
C Min. swing radius
3 850
202kW(271HP)
D Max. arm point depth
6 150
Rated power
E Max. arm point depth reach
8 420
F Overall length
12 340
G Length from swing center to front end
8 800
H Overall height of boom
2 690
Operating weight
43
At 1 900min-1(rpm)
Maximum 1 080N䍃m(110kgf䍃m) torque At 1 500min-1(rpm)
4-7. ZX450LC-3 Specification Working Range & Dimension Model Operating weight Max. arm point reach Max. arm point height Min. swing radius Max. arm point depth Max. arm point depth reach Overall length Length from swing center to front end Overall height of boom
Unit :mm ZX450LC-3 50 700(kg) 16 200 17 500 5 300 7 210 9 370 13 420 9 900 3 370
44
ZX450LC-3 ENGINE Model
Isuzu AH6WG1XYSA-01
Type
4-cycle water-cooled, direct injection
Rated power
260kW(349HP) At 1 800min-1(rpm)
Maximum 1 580N䍃m(161kgf䍃m) torque At 1 500min-1(rpm)
4-8. Outline of Lifting Capacity Lifting capacity 㻢 Total weight of attachment and material ZX200LCZX200LC-3
ZX240LCZX240LC-3
ZX330LCZX330LC-3
ZX450LCZX450LC-3
Max. Load radius
m
11.0
12.5
14.2
16.2
Lifting capacity (at Max. reach)
ton
2.3
2.1
3.2
4.1
Load radius When selecting the attachments, refer to Lifting Capacities in Specification. Take care to the weight of the attachment and select the attachment.
Lifting capacity Prevent the front from contacting the attachment. When the front is raised, it is possible that the attachment may come in contact with the arm. Operate the machine carefully when the front is raised.
45
4-9. ZAXIS-3 Specifications 䊶LIFTING CAPACITY( Unit :1000kg) & Load radius ( Rating over-front) EX) Load point height 2m
Lifting capacity
MAX Working range 14200mm
㪉㪇 㪈㪏
MAX Working range 16200mm
㪈㪍 㪈㪋 㪈㪉
㪱㪯㪉㪇㪇 㪱㪯㪉㪋㪇 㪱㪯㪊㪊㪇 㪱㪯㪋㪌㪇
㪈㪇 㪏 㪍 㪋
MAX Working range 11000mm
㪉
MAX Working range 12500mm
㪇 㪊㫄
㪋㫄
㪌㫄
㪍㫄
㪎㫄
㪏㫄
㪐㫄 㪈㪇㫄 㪈㪈㫄 㪈㪉㫄 㪈㪊㫄 㪈㪋㫄 㪈㪌
㪈㪍 Loading radius
ZX200LC䌾ZX450LC Main Spec Comparison MODEL
Arm
Boom length Undercarriage Operating
length
length
weight
Engine rated power
ZX200LC-3
4950mm
6500mm
4470mm
23000kg
122kW (2000min-1)
ZX240LC-3
6000mm
7000mm
4640mm
26100kg
132kW(2000min-1)
ZX330LC-3
6200mm
8500mm
4940mm
35600kg
202kW(1900min-1)
ZX450LC-3
7300mm
9500mm
5470mm
50700kg
260kW(1900min-1)
46
4-10. ZX200LC-3 Lifting Capacity
47
4-11. ZX240LC-3 Lifting Capacity
48
4-12. ZX330LC-3 Lifting Capacity
49
ZX450LC-3
4-13. ZX450LC-3 Lifting Capacity
50
4-14. Comparison Data Weight Class Manufacturer
Model
20t䌾23䌴
23䌴䌾30䌴
HITACHI
LIEBHERR
HITACHI
LIEBHERR
CAT
KOMATSU
ZX200LC-3
R904C
ZX240LC3
R924B
320C MH
PC210LC- PC220LC7 8
23.0t
22.2t
26.1t
27t
25.5t
25.0t
Track
LC
HD-SL
LC
HD-SL
LC
LC
LC
Boom
6.5m
6.6m
7.0m
6.8m
6.5m
6.8m
7.2m
Arm
4.95m
5.0m
6.0m
6.0m
5.8m
4.0m
5.0m
Max. Reach
11.0m
11.5m
12.5m
12.7m
12.4m
12.45m
11.5m
Max. Height
12.28m
12.8m
13.7m
13.8m
13.7m
13.6m
11.8m
2.7t (11m)
2.9t (10.5m)
3.4t (12m)
3.3t (12m)
3.2t (12.4m)
2.9t (12.45m)
-t(-m)
Weight
Lifting capacity
Weight Class Manufacturer Model Weight
30t䌾40t
27.4t
40t䌾50t
HITACHI
LIEBHERR
CAT
ZX330LC-3
R934C(3A)
330C MH
KOMATSU
HITACHI
PC330LC-7 ZX450LC-3
LIEBHERR R944C
35.6t
35.7t
38.4t
38.4t
50.7t
Track
LC
HD-SL
HDHW
LC
LC
EW
Boom
8.5m
7.6m
9.1m
10.5m
9.5m
9.5m
Arm
6.2m
6.0m
6.0m
6.8m
7.3m
7.3m
Max. Reach
14.2m
13.5m
14.1m
16.1m
16.2m
16.5m
Max. Height
15.6m
15.1m
14.4m
16.2m
17.5m
18.3m
Lifting capacity
4.6t (14m)
4.1t (13.4m)
4.35t (14.1m)
-t(-m)
4.0t (16m)
3.7t (16.5m)
HITACHI material handling machines are comparable to competitor’s machines.
51
46.1t
52
5. High mount Cab 䊶Fixed Cab 䊶Linkage Cab
53
5-1. Fixed Type High Cab Normal cabin is BAD VISIBILITY. No Good
Operator cannot see loads from truck. Difficult Difficultto toOperate Operate --Low Productivity Low Productivity
HIGH cabin is GOOD VISIBILITY. Good
Wider WiderWorking WorkingRange Range&&Better BetterVisibility Visibility for High Productivity for High Productivity
54
5-1-1. Operator’s Eye Point of Fixed Cab Example: ZX330LC-3 with 2.0m Fixed High-mount cabin
Advantages of Fixed high-mount cabin 䃂 Higher visibility allows Operators to see truck loading position. 䃂 Lower capital 䋧 maintenance cost
Eye point of Fixed cab
Eye point of Std cab
4 730
Truck Height
55
5-1-2. Kind of Extention Stand
Options of fixed high-mount cabin
1.0 m
1.5 m
2.0 m
Better Visibility = Better Operation !!
Side ladder type
Sidewalk stair type
56
5-1-3. Dimensions Dimensions
ZX210LC-3 Extension stand
1.0 m
1.5 m
2.0 m
ZX240LC-3 1.0 m
1.5 m
2.0 m
ZX330LC-3 1.0 m
1.5 m
2.0 m
A Overall height of cab
3 990 4 490 4 990 4 010 4 510 5 010 4 160 4 660 5 160
B Operator's view
3 530 4 030 4 530 3 600 4 100 4 600 3 730 4 230 4 730
C Floor height
2 330 2 830 3 330 2 360 2 860 3 360 2 520 3 020 3 520
D Operator's view between swing center E Step height
480
370
370
530
420
420
640
530
530
2 090 2 590 2 570 2 160 2 660 2 660 2 290 2 790 2 790
57
5-2. Linkage Type High Cab Better Visibility = More Safety & Efficient Operation
Cab Height
Operator’s Eye
About 35sec
㶎Picture : ZX200-3 Magnet machine
58
5-2-1. Feature Linkage cab has two cylinders. Lock pin
Holding valve on lift cylinder is equipped
Enhancement of safety device Emergency lowering switch is located both inside and outside the cab.
Push
59
5-2-2. Operator’s Eye Point of Linkage Cab Example ZX330LC-3 Advantages of 1 Link cabin 䃂 Higher visibility allows Operators to see the truck loading position. 䃂 Cab height can be adjustable according to working conditions. 䃂 Easier transportation.
Eye point of Linkage cab
Truck Height
5 180
Eye point of Std cab
60
5-2-3. Dimensions Dimensions
Unit: mm ZX200LC-3
ZX240LC-3
ZX330LC-3
A Overall height of cab
2 950 to 5 450 3 010 to 5 510 3 160 to 5 660
B Operator's view
2 500 to 5 000 2 570 to 5 070 2 700 to 5 180
C Floor height
1 300 to 3 800 1 360 to 3 860 1 490 to 3 990
D Operator's view between swing center
1 270 to 1 330 1 320 to 1 380 1 430 to 1 490
61
5-2-4. Selling Point (1) Customer (Malaysia): Purchased 1 Linkage Cab Before purchasing ZX240LC-3 1 link high cabin Model : EX 220 40 ft / 16 wheels truck takes metal scrap. One day :
2
U
2 ½ hrs loading 30 tons
truck loading only.
D SE
E
A XC
V
OR T A
62
R FO
A LO
NG I D
5-2-5. Selling Point (2)
Model
:
Less than 1 One day
NE
W
EX
:
ZX240LC-3 1 link high cabin
hr to load 30 tons scrap metal. 4 - 5 truck loading.
V CA
A
OR F R TO
63
G N I AD O L
64
6. Base Machine for Mobile Shear
65
6-1. Equipment
Item 㽲 Long crawler 㽳 Cab front guard (Lower & Upper) 㽴 Weight-added counterweight 㽵 Reinforced boom 㽶 Piping for Large flow volume exclusive use 㽷 2-Speed selector (auxiliary flow combining) 㽸 GENESIS shear
㽵Reinforced boom 㽳Cab front guard 㽴Weight-added counterweight
㽶Piping for large flow Volume Exclusive use
㽷2-Speed selector
㽸GENESIS shear
㽲Long crawler
66
6-2. Recommended Base Machine List
Base Machine (Boom mounted)
ZX250LCK-3
ZX350LCK-3
ZX470LCH-3
Counter weight (t)
Shear Model
shear weight (t)
Jaw opening (mm)
Jaw depth (mm)
Shear force (t)
GXP400R
5.4
711
737
980
GXP500
5.8
813
813
1 305
GXP500R
6.2
813
813
1 305
GXP700
6.3
889
889
1 460
GXP700R
7.7
889
889
1 460
GXP1000
7.2
965
965
1 750
6.5
8.2
9.2+2.5
㶎at throat 34.3(MPa)
*R=Rotation
67
6-3. ZAXIS-3 Demolition Version : K-Series
Lunched Model 䊶ZX210K(LC)-3 䊶ZX250K(LC)-3 䊶ZX350K(LC)-3
Standard Equipment (Difference with standard machine) Example ZX350K-3
K-cab (CRES㸈 with overhead window & guard)
Attachment basic piping Damage prevention plate Reinforced link B
Front screen of fuel cooler and air condenser
Twin wiper
Kreinforced bucket
8200kg Counterweight Reinforced lower flange
Reinforced idler bracket Front glass lower guard
600mm reinforced triple grouser shoe
Track undercover 6.0mm thickness undercover
68
6-4. K-Cab Specification Twin wiper switch
Overhead window
Head guard (ISO level 1)
Roof wiper , washer switch
Roof wiper
Twin wiper Wipe area 69
6-5. K-series Standard Equipment Front screen of fuel cooler 6.0mm Thickness undercover
Air condenser
Track center frame lower flange thickness increase
Class STD
200
240
330
14 mm 14 mm 22 mm
K-Series 19 mm 19 mm 28 mm
9.0 mm Thickness track undercover 70
6-6. ZAXIS-3 Heavy Duty Version : H Series ZX470(LC)H-3 Standard Equipment
Full track guard Protect track links and lower rollers from damage and deformation.
H/R Cab
*Heavy/Rock
H/R cab utilizes Reinforced front window and FOPS at roof for protection against falling objects. Front glass window, made of straight-laminated, is fixed to shut out dirt and debris
䊶 Reinforced boom and arm 䊶 4.5 mm thickness undercover 䊶 600 mm triple grouser shoes
71
72
7. Mobile Shear
Maker : GENESIS
73
7-1. Out Line of XP (GXP) Series
74
7-1-1. XP Series Performance Guide
75
7-2. Machanical Pulverizer (GMP)
76
7-3. Linkage Shear (GLS)
77
7-4. Rebar Shear (GRS)
78
7-5. Concrete Cracker (GCC)
79
7-6. Severe-Duty Grapple (GSD)
80
7-7. Image of Hydraulic Flow
81
7-8. Hydraulic Flows and Pressures
82
7-9. Genesis Shear Capability (1) Base Machine䋺ZX450-1 Genesis Shear䋺GPX700R Cuttable Object: Construction debris at demolition site
Approx: 10mm
Approx: 9mm
Blade position is the Key for efficient cutting
83
7-10. Genesis Shear Capability (2)
84
7-11. Genesis Shear Capability (3)
85
7-12. Genesis Shear Capability (4)
86
7-13. Genesis Shear Capability (5)
87
7-14. Comparison : Side Guard for Boss G䋺GENESIS VS L䋺Labounty
G
More Reinforcement. Easy to replace for Pin. Little trouble reported.
L
Looks reinforced, but Difficult to Remove it, after using long time. Much trouble reported.
88
7-15. Comparison : Blade Edge G䋺GENESIS VS L䋺Labounty
G
Not Invertible usage, But, More reinforcement, Can be used for Long time
L
Invertible usage, But, Less reinforcement, Can’t be used for Long time
89
90
8. Electric Material Handling Machines
㶎Japanese electricity charge & diesel fuel charge in 2008. Figures are different for your country & situation.
91
8-1. Market Needs Crude oil (dollar/barrel)
Change of Material Costs osts
Coal䊶LNG (yen/ton)
uranium (dollar/pound)
sts Co l a ri at e M l Al
Coal (yen/ton)
LNG (yen/ton)
䋣 ng䋣 i s a c re n I idly Ra p
Crude oil (dollar/barrel)
uranium (dollar/pound)
Total TotalMachine MachineRunning RunningCost Cost
Lease
Labor Fee
Fuel Cost Maintenance
Maximum: Approx 70% of Total cost Instead of Fuel (Diesel), Another Power Source Required ==> Electricity
92
8-2. Introduce Swing Approx360㫦 Approx360㫦
Grabbed Position
Power Supply Switch Board
Scrap Slot
Fixed Type 䋨No Need to Travel䋣䋩 Travel䋣䋩
Way Wayof ofPower PowerSupply Supply Fixed high post : 360㫦Swing
Collector Ring Switchboard
93
8-3. Feature
Ĭ Cheap Cheap in in Cost Cost Ĭ
Good
Lessthan thanEngine EngineType Type䋩 䋨䋨20-35% 20-35% Less 䋩 1L=150Yen **Diesel Diesel 1L=150Yen
ĭ Better Better for for Environment Environment ĭ
Emissionmaterial material=> =>CO2, CO2,Nox Nox, etc䋩 䋨䋨No No Emission , etc 䋩
Į Lower Lower Noise Noise Į
Lessthan thanEngine EngineType Type䋩 䋨䋨4-6dB 4-6dB Less 䋩
㽲 㽲A A Little Little Slower Slower Operation Operation No Good
䋨Approx 䋨Approx15-20% 15-20%Less) Less)=>Full =>FullMode Mode
㽳 㽳 Travel Travel Area Area Limited Limited *Some *SomeCustomers Customersdon’t don’trequire requiretravel travelfunction function
94
8-4. Cost Performance Ex.) -3 Case ZX200 Ex.)ZX200ZX200-3 Casein inJapan Japan %QORCTKUQP 4WPPKPI%QUV 㪎㪇㪇㪇㪇㪇㪇 㪍㪇㪇㪇㪇㪇㪇 㪌㪇㪇㪇㪇㪇㪇 㪋㪇㪇㪇㪇㪇㪇 㪊㪇㪇㪇㪇㪇㪇 㪉㪇㪇㪇㪇㪇㪇 㪈㪇㪇㪇㪇㪇㪇 㪇
㪍㪎㪌㪍㪇㪇㪇
-5 485 920Yen /Year 㪈㪉㪎㪇㪇㪏㪇
䉣䊮䉳䊮ᑼ Engine Type
䋨M¥䋩
Terms of Cost Comparison 䊶Normal Operation 䊶8hours/ day 䊶25days/month
㔚േ㚟േᑼ Electric Type
Engine Running Cost
䋪Engine Maintenance(4times/year) 240 000Yen Include in Engine Running Cost
14 12 10
Electric Running Cost
8 6
Modification Cost For Electricity 䋨8 000k¥ 000k¥䋩 Electric Driving Modification Recover within 1 year and half Initial Cost (Approx):
4 2
1
2
3
4
5 䋨Year䋩
95
8-5. Sales Record: in Japan
UnitsᲢyearᲣ
Unit䋨Year䋩 㪈㪇 㪏 㪍 㪋 㪉 㪇 㪈 2002
㪉 2003
㪊 2004
㪋 2005
㪌 2006
㪍 2007
Total 35 units!!
Category Breakdown Scrap Rental Steel Industrial waste Others
Approx 50% of Demand Scarp & Steel Category
11units 9units 6units 5units 4units
96
8-6. Job Site Study : ZX200-3 ZX200-3 ZX200-3 Fork Fork 200V-55KW Mechanical Fork Fixed Cabin
䊶Scrap Handling (Guillotine Operation ) *Prior owned machine - Komatsu( Engine type) 䊶Currently, new inquiry - interchange from Komatsu 78U 䊶Customer satisfy with cheaper running cost
䊶Protection: for Original Source Cable (Customer need to purchase Original cable䋩 䊶Swing 220㫦(Base machine)
Wall blackened by Engine
Cost Comparison
Hitachi
-482 000/M (versus Engine)
Prior Machine Fuel Cost䋺8h/d 㬍 25days = 570 000¥/m (110¥/L) Electricity Cost䋺8h/d 㬍 25days = 88 000¥/m
97
8-7. Job Site Study : High Post Type ȷAC400V 60Hv ȷ160kW ȷGrapple (Hanging type) ȷ7m High Post
ZX450-3 ZX450-3 High High Post Post
ZX330 ZX330 High High Post Post
ȷAC400V ȷ177KW/1 900min-1 ȷFork (Rotation type) ȷTotal Weight Ჴ31.0t
98
8-8. Check Point with Customer
㽲 Power Supply Voltage Should be (400/440V)
㽳 Operation Area䋨Fix or Travel䋩 Power supply Cable 㸣 Travel area is Limited *Need to Check - Installation Location Travel Area & Operation Area
㽴 Fetch Position: Electric Cable Original power supply -Customer need to set up Fetch position (Cabinet panel) -Need to Decide with Customer
99
100
9. Recycling Equipments
101
9-1. Product line
Soil recycler Crusher
Screen
Shredder
Wood grinder
5 main recycling equipment product lines.
102
9-2. Position of Recycle Equipment *For customer, recycle equipment is a facility for making money. And money becomes an origin when the customer buy the next machine. So, recycle equipment is also important for customer site. Recycle equipments
Products
Material
Money
䋽
䋽
䋫
*And the most important thing to sell or select the machine is to know what the material is and what the customer wants to make.
103
9-3. Track Mounted Crusher
Crusher
ZR950JC Quarry Mining
Civil engineering (Dam)
High versatility
Recycle
Landfill or Illegal dumping
Demolition
104
Steel Slaggy
9-3-1. Feature : ZR950JC More detail, please see product information.
High Highperformance performance Jaw Jawcrusher crusher featuring featuringoverload overload protection protectionsystem. system.
Engine Enginecomplies complieswith with Tier 3 gas Tier 3 gasemission emission regulation regulation
e-Service e-Serviceisisavailable available Easy operation : 7 inch Easy operation : 7 inchwide widedisplay display
Over load protection cylinder Dimension
Applicable Applicablematerial material Stone, Stone,Concrete Concrete
105
Length
With
Height
Weight
(mm)
(mm)
(mm)
(kg)
12 400
2 900
3 200
29 800
9-3-2. Job Site Study : ZR950JC (1) Application reference at demolition site in Japan
Remove steal by Magnet machine
Rough crushing by breaker
Feed material into crusher
Rough crushing with multi-purpose boom
Crushing by ZR950JC Recycle as road foundation material
Screen by VR408 (vibration screen)
Discharge material
Feed back over size material Feed material into crusher
Crushing
Screening
Zaxis
ZR950JC
VR408
Product(0-40mm)
For more information, please see application bulletin
106
9-3-3. Job Site Study : ZR950JC (2) Application reference at quarry site in Australia
Material
:Concrete debris
Target size
:0-40mm
Loading machine
:ZX270䋨HCA Demo fleet)
Crusher followed by :N/A
Material
:Basalt
Target size
:0-40mm
Loading machine
:ZX270 (HCA demo fleet)
Crusher followed by :HITACHI VR408
107
9-3-4. Competitors of Crushure
Hitachi ZR950JC
Sandvik EXTEC
Hartl
C-10+
PC1055J
TEREX-PEGSON
Metso
M-Trak
LT95
KOMATSU BR380JG
ZR950JC and Competitors
More detail, please see product information.
108
9-4. Track Mounted Screen
Screen
VR516FS Quarry
Mining
Civil engineering
High versatility
Recycle
Demolition
Steel Slaggy
Landfill or Illegal dumping
VR408 109
9-4-1. Feature : VR516FS More detail, please see product information.
Finger Fingerscreen screenisis superior superiorto toscreen screen sticky material sticky materialthan than mesh meshscreen screen
Engine Enginecomplies complieswith with Tier 3 gas Tier 3 gasemission emission regulation regulation
Selectable Selectable screening screening mode mode㹢 㹢It’s It’s possible possibleto to select 2or select 2or33 way way separation. separation.
e-Service e-Serviceisisavailable available
Hydraulically Hydraulicallyadjustable adjustable screen screenbox boxangle angle 8㫦䊶10 㫦䊶12㫦䊶14 㫦䊶14㫦䊶16 㫦䊶16㫦 㫦 8㫦䊶10㫦䊶12
Dimension
Applicable Applicablematerial material Concrete debris, Top soil, Concrete debris, Top soil,Demolition Demolitiondebris debris Industrial Industrialwaste, waste,Contaminated Contaminatedsoil soiletc. etc.
110
Length
With
Height
Weight
(mm)
(mm)
(mm)
(kg)
16 030
7 370
5 030
27 500
9-4-2. Feature : VR408 More detail, please see product information.
Dimension Length
With
Height
Weight
(mm)
(mm)
(mm)
(kg)
9 250
5 800
3 500
9 000
Adjustable Adjustable screen screenbox box
Both Bothways ways rotation rotation
High discharge height
Superior transportability
Applicable Applicablematerial material Crushed Crushedconcrete, concrete,aggregate, aggregate, soil soilincluding includingpiece pieceofofwood,etc wood,etc
Equip Equipsingle singledeck deckvibration vibrationscreen screenand and 22discharge dischargeconveyor conveyorwith withcompact compactbody body Realize Realizesuperior superiorutility utility
111
9-4-3. Job Site Study : VR408 *Shearing dust screening Shearing Dust
Screening!
10%
90%
40mm over
Fines: under 40mm
Dumping / Recycling
Resalable / Reusable In this Case,
About 10% of Shearing dust was valuable material such as metals, steels. So, using Hitachi VR408, 10% of such valuable material was screened completely, and disposal cost was reduced.
112
9-4-4. Job Site Study : VR516FS/VR408 More information, please see application bulletin
Application reference Reference 1 : for mixed waste
VR516FS
:material
ZR900TS
Reference 2: for debris with topsoil
SR2000G
VR516FS
Reference 3: for soil improving
SR2000G
VR408
Reference 4: for Aggregate crushing
ZR950JC
VR408
113
ZR950JC
9-4-5. Competitor’s Crusher Product map of Mobile Screen 䋱䋰䌴䌯䌮
䋱䋵䌴䌯䌮
䂓1 or 2way 䃂3ways (Finger type) 䂥3ways
䋲䋰䌴䌯䌮
䋲䋵䌴䌯䌮
䋳䋵䌴䌯䌮
䋴䋰䌴䌯䌮
㪭㪩㪌㪈㪍㪝㪪
䂓
HITACHI
䋳䋰䌴䌯䌮
㪭㪩㪋㪇㪏 䌆䌉䌎䌌䌁䌙 䇼䌔䌅䌒䌅䌘䇽
䂥
㪪㫌㫇㪼㫉㫋㫉㪸㪺㪍㪌㪊 㪧㫆㫎㪼㫉㪫㫉㪸㪺㫂㪍㪇㪇
PowerScreen 䇼TEREX䇽
䂥 䂓㪚㪿㫀㪼㪽㫋㪸㫀㫅㪋㪇㪇
㪌㪐㪌㪟㫐㪻㫉㪸㫋㫉㪸㫂
䂥䂓
㪍㪍㪊
䂥
㪍㪏㪊
㪧㫆㫎㪼㫉㪫㫉㪸㪺㫂㪏㪇㪇 㪚㪿㫀㪼㪽㫋㪸㫀㫅㪈㪋㪇㪇
䃂䂥
䂓
㪪㪄㪊
㪩㫆㪹㫆㫋㫉㪸㪺
䂥
䌅䌘䌔䌅䌃䇼SANDVIC䇽
㪎㪐㪏
䂥
䂥
㪮㪸㫉㫉㫀㫆㫉㪈㪋㪇㪇 㪪㪄㪋 㪪㪄㪌
䂥 䂥
㪝㫀㫅㫋㪼㪺㪌㪋㪉
䌆䌉䌎䌔䌅䌃 䇼SANDVIC䇽
䂥䂥
㪪㪫㪈㪎㪈
䌎䌯䌲䌤䌢䌥䌲䌧 䇼MetsoMinerals䇽
䂥䂥 㪪㪫㪊㪋㪏
䃂 䃂
䂥
㪮㪸㫉㫉㫀㪼㫉㪈㪏㪇㪇 㪜㪄㪎
䂥
㪝㫀㫅㫋㪼㪺㪍㪋㪇
䂥
㪝㫀㫋㪼㪺㪌㪎㪇 㪪㪫㪊㪌㪉 㪪㪫㪊㪌㪏 㪪㪫㪋㪌㪏
䂥䂥 䂥 䂥 㪪㪫㪍㪉㪇
VR408 COMPETITORS
VR516FS COMPETITORS
Competitors
䃂3ways(Finger)
䂓1or2way
䂥3ways
SANDVIK-EXTEC S-5
HITACHI VR408
HITACHI VR516FS TEREX-FINLAY 694SUPERTRAK
TEREXPOWERSCREEN POWERTRAK 600
TEREX-FINLAY 883
114
䂥
㪩㪼㪺㫃㪸㫀㫄㪼㫉㪏㪏㪊 㪚㪿㫀㪼㪽㫋㪸㫀㫅㪉㪈㪇㪇
㪍㪐㪋
9-5. Track Mounted Wood Grinder
Wood grinder
ZR260HC Deforestation
Forestry Wood path
Recycle Agriculture
Landfill / Illegal dumping Waste management
115
9-5-1. Feature : ZR260HC More detail, please see product information.
Dimension Length
With
Height
Weight
(mm)
(mm)
(mm)
(kg)
11 200
2 980
3 200
24 000
High Highgrinding grinding performance performance
Easy Easymaterial material feeding feeding The Thehorizontal horizontal feeding feedinghopper hopper excels excelsat at processing processingof of long longmaterials. materials.
Easy Easymaintenance maintenance Replace Replacescreen screen easily easily
Auto Autofeeder feeder The Theauto autofeeder feeder can adjust can adjustthe the amount amountof of feeding feeding e-Service is available e-Service is available materials. materials.
Applicable Applicablematerial material C&D C&Dwaste, waste,green greenwaste, waste, cut cutwood, wood,bamboo, bamboo,etc. etc.
116
9-5-2. Job Site Study : ZR260HC More information, please see application bulletin
At forestry site
At deforestation site
Material
Material
:Bamboo
:Log/Stump
Production :Primary grinding
Production :Primary grinding
Loading by :EX60-1 with grapple
Loading by :ZX120 with Grapple
At recycle site
At recycle site
Material
:Log/C&D waste etc
Material
:Green waste
Production :Chip for fuel/compost
Production :Compost
Loading by :ZX225USR
Loading by :CAT+ Grapple
with grapple 117
9-5-3. Competitors of Wood Grinder (*Include upper size/class)
HITACHI ZR260HC
Vermeer HG365E
WILLIBALD MZA2400
MORBARK 950TUB
Precision Husky PROGRIND1000
KOMATSU BR200T-2
118
9-6. Track Mounted Shredder
ZR900TS *Suitable for disposal of plastics, tires, vinyl, thin metal, and so on. *Not suitable for solid materials such as metals, slag, rocks etc.
High versatility
Recycle (General ) Landfill or Illegal dumping Incinerator Auto salvage
Disposal station Metal scrap (Thin material)
Waste management
119
9-6-1. Applicable Materials Rubber
Tire
Pallet
Conveyor belt
Wooden/ Fiber
Rubber hose
Pallet
Tatami mat
Urethan
Bumper
C&D waste
Waste textile
ZR900TS
Electric base
Refrigerator
ZR900TS is the machine that shred these kind of materials. Bowling ball
Hard waste
Vinyl
Container Soft waste
Plastic
pipe
Thin metal
Hard waste
Waste
120
Sheet
9-6-2. Feature : ZR900TS Specification
More detail, please see product information.
Length (mm)
With (mm)
Height (mm)
Weight (kg)
9 510
3 610
3 930
18 900
Feature *Realize minimized cost. -one-man operation by remote control can minimize labor cost. -ZR900TS is all-in-one design. There is no need to prepare additional control equipment. -self clean up function can minimize machine downtime. -maximum discharge height in 20t class can reduce the time of carry-out material and use less fuel. *Realize reducing maintenance cost. -adopting mono-cutter can reduce maintenance cost. (Cutters are reproduced about 3 times*.) *Realize more efficiency shredding. -adopting two axis shaft realize cutting sharpness. -variable cutter and the spacer makes various size of cutting. -easy layout change realize flexible placement.
121
9-6-3. Job Site Study : ZR900TS Example of Tire shredding
About 1min/piece
Estimated Capacity & Distribution -Condition – *Material weight :About 8Kg/Tire *Number of tires: ᾄ tires/Automobile *Shredded automobile per day: 84 1.Estimated capacity =8Kgᶣ5tiresᶣ84auto/dayᾌ3.36t/day
Fines
ᾄὫ over
2.Distribution *70%(2.36t) 70%(2.36t) was fine (under 50mm)= 50mm)= Resalable *30%(1t) 30%(1t) was over (over 50mm) =Waste
70ή
30ή
In this case, HITACHI ZR900TS could reduce 70% of disposal cost and made 70% of valuable / resalable materials.
122
9-6-4. Competitor’s Shredders Competitor 1:Fixed type *Fixed type of shredder is made by many companies. and sometimes, ZR900TS is preprocessor for Fixed type. Competitor 2:Tack mounted & Stationary type (*Include upper size/class)
HITACHI ZR900TS
KOMATSU BR300S
CAT MC220-S
HAMMEL VB650
Doppstadt DW2060
KOMPTECH TERMINATOR
Forus BZ171
123
9-7. Track Mounted Soil Recycler Soil Recycler
SR2000G Order recieved from Australian customer Disaster-relief
Erosion control
High versatility
Recycle Road construction
Dredging Contaminated treatment
124
9-7-1. Feature : SR2000G More detail, please see product information.
Dimension Length
With
Height
Weight
(mm)
(mm)
(mm)
(kg)
12 500
2 990
4 500
19 600
Note
-Structure-Structure-
-Flow-
Additive Additive hopper hopper Swing Swing Gate Gate
㽳Additive Additive Additivefeeder feeder
㽲Feeding material
Discharge Discharge conveyor conveyor
㽵Improved/ Hopper Hopper Feeder Feeder
Mixing Mixing chamber chamber
㽴Mixing
Treatmented Soil
*Apply to higher moisturized material by Horizontal and wide feed hopper *Realize stable material feeding without bridging by Swing Gate *Continuous and direct measurement of feed material by Level roller *Apply to various additive by Screw feeder *Feed additive precisely by Precise additive feed control *Realize higher mixing performance by Two shafts paddle mixer
125
9-7-2. Job Site Study (1) More information, please see application bulletin
At disaster-relief site
At erosion control site
Aim to :Banking reinforcement
Aim to :Prevent mud flow
Material :Levee soil
Material : Soil with volcanic ash l
Additive :Cement
Additive :Cement
At Highway construction site
At VOC’s contaminated site
Aim to : Recycle for road base
Aim to : Remediation
Material :Turned Soil
Material : Contaminated soil
Additive :Cement
Additive : Unknown
126
9-7-3. Job Site Study (2) Application reference Reference1:Dredged soil improvement
Digging by Dredging ship
Feed dredged soil
Prescreening
Improve
Products
Separate stone
to VR408
from soil
by Soil recycler
(Improved soil)
Reference2:Soil Recycle Pre screening by VR408 Digging by backhoe
Separate fine(0-20mm) from over(20-100mm)
Improve by soil recycler
Products(0-20mm)
Material
Backhoe
VR408
Soil recycler
127
Recycle products
9-7-4. Competitor’s Soil Recycler
HITACHI SR2000G
KOMATSU BZ210-1
3,500
128
9-7-5. Appendix : Estimated Productivity Note 䊶This information just shows estimated capacity. HCM doesn't warrant any information on this sheet. Estimated capacity depends much on feeding material, condition and so on.
129
130
10. Mining & Quarry Equipment
131
10-1. Process of Mine Development 㽲Examination Select of mountain
Close investigation
㽴Product Introduced Crusher/Screen Machines/Plants Conveyer/Mining
Examination of land surface Examination by literature
machines
Elastic wave exploration
Introduced each furnishing
Boring exploration
䍼
Digging of raw stone
license application
Blasting face/ road / stock yard / balancing reservoir / detritus tank
Blasting work Formation of Bench
㽳Development Processing production Wood grinding clearing
Introduced machines
Land cleaning
Custody control
Backhoe & Dump & Bulldozer
Product by product custody
Acceptance of order & Shipment
Creation of Stock yard
㽵Treatment Finish of digging treatment
Plant trees
Application of vacant lot
䋼Four components of Development of mine䋾 㽲䋮Rock ( Blasted rocks ) 㽳䋮Water (balancing reservoir / detritus tank ) 㽴䋮Burden ( Stock yard ( capacity ) 䋩 㽵䋮Equipment ( Machines & Plants 䋩
132
10-2. Product’s Line Up Aggregate
For road
Material for concrete
Ballast
Broken stone
For paving material
䌁䋮Aggregate is classified into four products. Aggregate products
㽲For road 㽳Material for concrete 㽴Ballast 㽵Broken stone
For road
For surface & Groundsill
For Base course For upper or lower material For sub grade material
Material for concrete
Coarse aggregate
Fine aggregate For railroad stone
Other
Ballast
Broken stone
For lower stone
Products are classified into size and/or grain by purpose and/or uses. 133
Dust & others
10-3. Specification Table of General Rock Various rare metals are included in many kinds of rocks. Loading capacity estimation is based on the chart below. Refer to the chart below for silica level
Average density
name
silica
soil (overburden)
ؚᆢޥ sedimentary rock
ޥ٭ metamorphic rock
້ޥ igneous rock
Bankίt/m3ὸ
low
Looseίt/m3ὸ
1.6
ჿޥ
sandstone
high
2.5
1.5
ᄒჿޥ
graywacke
high
2.7
1.6
ቬெޥ
slate
low
2.6
1.6
᠗ዯϹ໋ޥ
schalstein
high
2.8
1.7
ჽ໋ჽ
limestone
low
2.6
1.6
ἓἵὊἚ
chert
high
2.6
1.6
ჽ໗
coal
low
1.9
1.1
༾ޥ
gneiss
high
2.7
1.6
ᚌޥ
amphibolite
medium
3.0
1.8
ྸٻჽ
marble
low
3.0
1.8
ޥޛܤ
andesite
medium
2.6
1.5
നޥ
basalt
medium
3.0
1.8
ọỮޥ
porphyrite
medium
2.8
1.7
᠗ዯޥ
diabase
medium
3.0
1.8
ᑶ߈ޥ
granite
high
2.7
1.6
ዯޥ
diorite
medium
2.9
1.7
૮ἾỶޥ
gabbro
medium
3.0
1.8
ᖦኚޥ
serpentinite
low
3.0
1.8
134
10-4. Development of Mine in Japan (1) Bench-cut
Stock yard
floor
(mountain top cutting)
bench
Related with TOP6 companies
vertical shaft
䃨
1.Initial investment is huge. mainly, construction costs of vertical shaft & hauling tunnel. 2.Production cost is relatively stable, because carrying distance will not be so extended in future.
Bench-cut (mountain side cutting)
There is crusher and/or feeder at bottom of the shaft
carrying distance is extended in future
Expanding area
Finished wall (rehabilitation)
bench
Stock yard
1.Initial investment is small. 2.Production cost will be increased in future because carrying distance will be extended in process. Need to check Periodical review of carrying volume is required, especially combination of machines
floor Down road carrying Plant 1st,2nd,3rd,
135
10-4. Development of Mine in Japan (2) Bench-cut (down the hall) 1.Initial investment is huge. (boring examination, digging up an overburden)
2.Production cost will be increased in future 0by increasing carrying distance in process. Need to check Periodical review. 3.In comparison with other methods, fuel cost 0is at a disadvantage by uphill carrying of load
Russia diamond mine
Chili copper mine
Indonesia coal mine (KPC) 136
10-5. Marketing : Production of Aggregate Mt
Quarry & 1 200 gravel
Quarry Sand & gravel (sea/river)
Limestone Cement
For steel
Sand & gravel (land/mountain)
Quarry
Others
For chemical Others
1 000
800
Total Products
䃨
600
400
Main Target
200
䃨
0 71 73 75 77 79 81 83 85 87 89 91 93 95 97 99 01 03 05
year
137
10-6. Marketing : Produce of Scale (1) …†․‗ …†
‗ ‧
‥
‧…†‥‗
2008 Limestone mines quarry sites 1.369
‥
†•‗ ‧•
…‥
More than 1 000kt / year
100⊡500kt / year
Less than 100kt / year
500⊡1 000kt / year
t/hr
Kt/year
m3
MODEL
᳸100
172
1.0
ZX240H
200
343
1.4᳸1.5
ZX350H
600
1 030
5.0
EX1200
800
1 373
5.6᳸12.0
EX1200BE EX1900
1 000
1 716
12.0
EX1900
1 500
2 574
15.0
EX2500
2 000
3 432
22.0᳸29.0
EX3600 EX5500
2 500
4 290
29.0
EX5500
Supposed loading machine è6.5hr/day 22days/month 12months/year èBucket Efficiency 90Ჟ èLoading Efficiency 65Ჟ
138
10-6. Marketing : Produce of Scale (2) ZX450 over Excavator sale records (units)
100 NOT FOUND
5
4
80
14
14 4 2
7
3
CAT JAPAN
14
4
60
4
11 15
OTHERS
2
4 4 1
KOMATSU
4
19
11
HITACHI
3
13 30
11
35
40 36
35
8
31 31
29
1
27
40 26 32 44
20 28
31
29
32
29
32
36 30
23 13
0 '03/F '03/S '04/F '04/S '05/F '05/S '06/F '06/S '07/F '07/S '08/F
139
10-7. Strategy Making in Japan Application range of our products
Main Market
EXCAVATOR
WL≋IN PLANT≌
CRUSHER
t/hr
Kt/ year
100
172
ZX240H
3.2
ZW220
ZR950JC
200
343
ZX350H ZX400
3.2
ZW220
ZR950JC
300
515
ZX470H ZX520LCH
3.2⊡ 3.5
ZW220 ZW250
ZR950JC LT105
400
686
ZX670H ZX870H
4.0⊡ 5.0
ZW310 LX300
LT125
500
858
ZX870H ZX870BEH
6.0
LX450
LT125 LT140
600
1 030
EX1200
LT140
800
1 373
EX1200BE EX1900
LT160
1 000
1 716
EX1900
LT160
m3
MODEL
MODEL
Developed Quarry-model Developed quarry-model Selecting customers & Selecting customers & Demo Demo
MODEL
Demo at customer’s site. Attending to the Hi-OSS demo site
Selection of Ⅴmain promotion ModelⅥ 140
10-8. Production Process & Machines in Japan (1) ℲRough Crushing & Digging up (with breaker)
ZX850H
EX800H
• After blasting operation need to crush rocks by hydraulic breaker. • Above crushing operation is quite heavily-loaded, HD spec is most suitable.
ℳDigging up (after blasting)
Back break of blasting ZX520H
Back break of blasting ZX870H
pit
by bulldozer by backhoe
The edge of blasting pit EX800H
The bottom of blasting face EX1200
• On dangerous job site, Excavator is more suitable than Bulldozer considered with safety issue.
141
10-8. Production Process & Machines in Japan (2) ℴ Shovel & Dump
Overburden ZX450H
Overburden EX1200
Blasted rock EX850H
Blasted rock ZW310
In SH&DP Work, blasted rocks are Loaded & Carried to Dump truck by big excavator & big WL.
ℵ Load & Carry L&C ZW310
In L & C work, WL directly carries rocks or gravel to hopper.
142
10-8. Production Process & Machines in Japan (3) ℶCrushing & Screening (Mobile Crusher & MCP ~Mobile Crushing Plant~) ZR950JC&VR408(screen) Producing Recycle Crusher-run
ZX450&Crusher Primary crusher Dump-less system
• After first crushing next two steps crushing operation done. • After that above, by Screen the rocks separated by each size.
143
10-9. Information of ZAXIS R-Model ZX520LCH (Back break of blasting) 2006/11 delivery 1 800hr
ZX870LCH (Rough Crushing) 2007/3 delivery 800hr
144
10-10. Wheel Loader Information (ZW series) ZW220~ZW330
Comfort-designed suspension seat
All round visibility panoramic cab Adjustable steering column 䌈䌎 Bushings
䌔䌔 system
transmission
Hydraulically operated cooling fan with HeatSensing system
䊶ZW’ Selling point Three works modes TT (Total Torque-control) system
Three work modes are selectable according to job needs and operator’s preference .In each Work mode, TT system controls the total torque of the engine and pump for well matched Penetration force and implement speed according to job needs. The three work modes can be Optimally selected to suit materials to be handled for higher production. P mode : Heavy-duty excavation N mode: Loading
L mode : Light-duty operation
Three driving modes 䋨L/N/H/M䋩 The three driving modes can be selected according to job needs and operator’s preference. Automatic shift Driving modes Shift timing Recommend site transmission L
䋲㹤䋴
N
䋲㹤䋴
H
䋱㹤䋴
M (manual mode)
nothing
Early
Long distance and/or flat terrain
Slow
Core working is digging䊶Sloping road
Voluntarily
All
Selectable Clutch Cutoff timing Clutch cutoff timing can be selected from three position to suit various job condition, including Rapid operation on level ground , and surefooted operation on gradient.
145
10-11. Loading Method of Wheel Loader (ZW series) Material
Material
Type-䌉 Loading method䋨Cross Loading method䋩
Type-V Loading method
Weld edge
Bucket Specification
Bolt-on Cutting edge (BOC) Bolt-on cutting edge isn’t compatible with bolt on teeth. (Weld edge is different.)
BOC
Teeth can’t be attached to BOC bucket.
Bolt-on Teeth (BOT)
Weld edge
146
10-12. Feature of Wheel Loader (ZW series) Extinguisher
With or Without of Gumball machine
BOC or Tooth Selectable for custom
EX.)
9mm
9mm 25mm
䊶Main work of WL by ZW310 class is loading to dump truck and feeding into hoppers by bucket. 䊶In case of carrying products, the bucket is not necessary to be reinforced. But in case of loading to dump truck& throwing into hoppers, it needs to be reinforced. 䊶Side, inner and bottom plates, and side edges are usually reinforced depending on customers request.
147
10-13. Tire Bias tire Tire size
Tire for WL
pattern
L3/L4/L5
Radial tire
Section
Ply Diameter of rim ( inch)
Height of tire
Bias tire
Diameter of rim
Outside Diameter of tire
Width of Tire ( inch)
Radial tire
Diameter of rim ( inch) Width of Tire ( inch)
Bridgestone Bias tire’s pattern Usually Europe and America use radial tire.
Michelin radial tire’s pattern 䌘䌌䌄䌄䋲 䋨䌌䋵䋩 㶎Michelin treat only radial tire. 䌘䌈䌁 䋨䌌䋳䋩
Contact pressure Deflection Decay durability Cost
Feature
Radial
Bias
Low
High
Side wall is only bow, Tread face isn’t bow㹢Contact area is stabilized to load.
Side wall and Tread face are bow.㹢 Contact area is fickleness.
䋲
䋱
䋱䋮䋵䌾䋲
䋱
Radial tire has several strong steel belts, carcass. Steel belt be for tread face’s stability and guard. Carcass is steel code of one ply that it is arranged radial pattern.
Bias tire is configured to nylon codes that it is piled up carcass.
148
10-14. Matching of Dump & Excavator Information (1) Carrying methods of minerals are as followings.
㽲 Dump-Truck method 㽳 Dump-less method In Japan, Dump method is usually went on to Shovel-Dump method that it combines Hydraulic Excavator and Dump.
Advantages of Dump-Truck method 1.High general versatility. Applicable to various sites 2.Damage would be smaller when trouble happens 3.Managable by adjusting no. of units for distance and/or amount of production change 4.High ability to handle various objects 5.Easier operation, less tiredness for operator 6.Easier maintenance 7.Lower cost for long distance carry comparing with Bulldozer method & L & C method.
Carrying distance and Cost ( Polar example) High Wheel loader
Bulldozer
Dump
Cost L & C method ( Load & Carry ) Bulldozer method
Low
㧝㧜㧜
㧡㧜
Carrying distance㧔㨙㧕 149
Shovel & Dump method
10-14. Matching of Dump & Excavator Information (2) Dimensions of Excavator, Size of Dump and Matching numbers of Unit should be considered. 䋨䋱䋩 Matching numbers of Loading machine & Dumping machine 㽲Dumping clearance of Loading machine & Bessel’s Height of Dump 㽳Dumping reach & Bessel’s Length of Dump 㽴Bucket width & Bessel width A :Rear-end swing radius B : Dumping height C : Dumping reach D : MAX. digging reach E : Bucket width F : Bessel length G : Inner Bessel width H : Bessel height (Standard Specification)
Excavator (Bucket capacity㧦ISOޔunit㧦mm) Bucket A B C D Model code capacity ZX380HH 1.5 m3 3 320 2 680 3 650 11 020 ZX470H-3 1.9 3 645 2 990 3 410 12 060 ZX520LCH-3 1.9 3 645 3 070 3 410 12 000 ZX650H 2.9 3 850 3 240 4 310 13 280 ZX670LCH-3 ZX650H(BE) 3.3 3 850 3 200 4 520 11 800 ZX670LCH-3(BE) ZX870LCH-3 3.5 4 600 4 000 4 590 14 100 ZX870LCH-3(BE) 4.3 4 600 3 770 4 620 12 340 EX1200-5C 5.0 4 850 3 220 7 000 15 340 EX1900-5 12.0 6 010 4 050 6 430 15 250 EX2500-5 15.0 6 290 4 250 7 580 17 050 EX3600-5 22.0 6 780 4 990 7 470 18 190
150
E 1 470 1 500 1 500 1 680 1 700 1 890 2 110 2 100 3 050 3 180 3 790
10-14. Matching of Dump & Excavator Information (3) 䋨㪬㫇㫇㪼㫉㩷㪺㪸㫊㪼䋺㫃㫆㪸㪻㫀㫅㪾㩷㫅㫌㫄㪹㪼㫉㩷㫆㪽㩷㫋㫀㫄㪼㫊䇮㪣㫆㫎㪼㫉㩷㪺㪸㫊㪼䋺㪣㫆㪸㪻㫀㫅㪾㩷㫋㫀㫄㪼㩷㩿㫊㪼㪺㪀䋩
(Standard Specification) Bucket capacity (m3)
Cycle tine (sec)
11t (7m3)
20t (14m3)
32t (24m3)
ZX450H
1.9
22
ZX650H
2.8
24
3䌾4 82 2䌾3 60
7䌾8 162 5䌾6 120
12䌾13 278 8䌾9 206
ZX650BE
3.3
24
2䌾5 2
4䌾5 102
ZX850H
3.4
25
2䌾3 52
ZX850BE
4.3
25
1䌾2 40
EX1200-5
5.0
26
EX1900-5
12.0
28
EX2500-5
15.0
EX3600-5 EX5500-5
Model code
46t (34m3)
55t (40m3)
64t (42m3)
90t (60m3)
136t (78m3)
7䌾8 174
10䌾11 248
12䌾13 290
4䌾5 102
7䌾8 176
10䌾11 250
11䌾12 294
3䌾4 82
5䌾6 140
7䌾8 198
9䌾10 232
2䌾3 72
4䌾5 124
6䌾7 176
7䌾8 192
8䌾9 218
2䌾3 56
2䌾3 80
3䌾4 94
3䌾4 98
5㨪6 140
6䌾7 182
29
2䌾3 66
2䌾3 78
2䌾3 82
3䌾4 116
5䌾6 150
22.0
30
1䌾2 50
1䌾2 58
2䌾3 62
2䌾3 88
3䌾4 114
29.0
32
1䌾2 44
1䌾2 46
2䌾3 66
2䌾3 86
Appropriate units of Dump per 1 lording machine is calculated by the following formula.
䌎䋽
Cm1 Cm2
䌎
䋺Required units 䋨unit䋩
䌃䌭䋱䋺Necessary time at 1 cycle of Dump ( second ) 䌃䌭䋲䋺Necessary time at loading to Dump ( second )
151
10-15. Mobile System in Mine VR516FS(Finger screen)
ZR260HC(Wood grinder)
Screening out usable material from stockpile of wastes in the stockyard
Woods & stubs are recycled by wood grinder. (used as recycle fuel or compost.)
SR2000G(Soil recycler) Improving overburden for recycle. (used as bank of road construction.)
152
10-16. Hearing seat to customer Format of acquisition of information Customer㵭s name
䂾䂾 mining company
Business place/Job site
䂾䂾 business place
Booklet/URL
Booklet䋺 Y
Rock quality
Coal 䊶ironstone䊶limestone㵹
Amount of production
Monthly output 䋷0000䌴/month Annual output 84000䌴/year
Condition of blast
6.0hr/day 22day/month 12month/year 1 584hr/year
Update term of Operation license
Development of forest land by September,2009 Rock extraction April,2010䋨per 5 years䋩
Method of quarrying
Bench cut
Method of carrying
SH&DP one way 800m L&C one way 60m
N
URL䋺 Y
N
Open shoot
SH ZX470R
PC450
ZX210H
WL WA400 ZW310 966G Ownership machines DP HD2052 10tDP5 others 1st䋺Joe crusher䋨䊶䊶䊶X䊶䊶䊶inch䋩 Plant/Equipment
etc.
2nd䋺Cone crusher
丵 丵 丵 丵 丵 丵
丵 丵 丵 丵 丵 丵 丵
3rd䋺
153
154
11. Forestry Machines
155
11-1. Dimensions : ZX130L Dimensions/Working Range Diagram Operating weight Bucket capacity (PCSA heaped) Traction force Gradeability Ground pressure Rated power
13 700 kg 0.5 m
3
130 kN 35°(70%) 41 kPa -1 P moed : 63/1950 kW/min -1 HP moed : 66/2150 kW/min
156
11-2. Equipment (1) ZX130L Forestry EQUIPMENT Tropical cover
High performance filter
Air cleaner double filters
Upperstructure reinforced under cover(4.5mm)
Std cab
Arm with damage prevention plate (Upper,Lower,Side)
Reinforced under carriage
Reinforced under carriage Reinforced under cover
Reinforced step
Two roller guard
Distance between tumbles L䋺2990mm STD䋺2880mm
157
Traction force 15%UP L䋺䋱䋳䋰kN STD䋺102kN
11-3. Equipment (2)
(Std:440mm)
(Std:890mm)
Min.ground clearance
Component comparison
Track link assembly Travel motor Upper rollers Lower rollers Idler assembly Spring track assembly Other Hydraulic circuit It is the same as std model䋨ZX120䋩.
Electric circuit It is the same as std model䋨ZX120䋩.
158
ZX110M ZX110M ZX200 ZX200 ZX200 ZX110M
11-4. Attachments (1) 㽲 Processor Device for Branch cutting off Transfer device for Hanging wood
Measure device
Grapple
Chain saw
Attachment for specializing in lopping branches off and cross cutting(cut same size). Composed of grapple(handling wood), blade cutter(lopping branches), feed controlling device, and chainsaw(cross cutting). Human operation(lopping branches): 10minutes Processor operation(lopping branches & cross cutting): 2minutes Shotens operation time and reduces manpower
159
11-5. Attachments (2) 㽳 Feller Buncher
Attachment for felling trees for easy collection. Lighter attachment weight than processor & harvester. Can be fitted to Long front machine. 㽴 Harvester Cut off device for Branch Transfer device for Hanging wood
Measure device Grapple
Chain saw
Attachment for felling trees, cutting branches off, cross cutting, Different point(from Processor): Equipped with Tilt system(for easy cutting down trees)
160
12. Brochures List For Metal Recycling Machines Brochure Scrap Metal Recycling Brochure
KA-EN077
Material Handling Machines Brochure
KA-EN078
Recycling Equipments Brochure ZR260HC
KA-EN044
ZR125HC
KA-EN043
VR516FS
KA-EN061P
VR408
KA-EN082
ZR950JC SR2000G
KA-EN020 KA-EN074
For Mining Machines Brochure ZX400LCH-3
KS-EN044
ZX450-3 Series (450-3/450LC-3/470H-3/470LCH-3)
KS-EN060
ZX450-3 F Type Series
KS-EN073
ZX500LC-3 Series (500LC-3/520LCH-3)
KS-EN030
ZX500-3 F Type Series
KS-EN074
ZX650LC-3 Series (650LC-3/670LCH-3)
KS-EN031
ZX650LC-3 F Type Series
KS-EN075
ZX850-3 Series (850-3/850LC-3/870H-3/870LCH-3)
KS-EN059
ZX850-3 F Type Series
KS-EN076
ZX-R Series (400R-3/470R-3/520R-3/670R-3/870R-3)
KS-EN047
ZX-R F Type Series
KS-EN077
EX1200-6 EX1900-6 EX2500-6 EX3600-6 EX5500-6 EX8000-6
Brochure
KS-EN109
Spec.
KS-EN112
Brochure
KS-EN058
Spec.
KS-EN052Q
Brochure
KS-EN057P
Spec.
KS-EN051Q
Brochure
KS-EN056P
Spec.
KS-EN105
Brochure
KS-EN122
Spec.
KS-EN104
Brochure Spec.
KS-EN125 KS-EN103
This information is the present in February, 2009.
161
