The Knowledge of 1-10t Balance-weight Type Forklift Truck with Engine HELI CHINA 2012.01 安徽叉车集团有限责任公司 ANHUI FORKLIFT TRUCK GROUP CO.,LTD

The Knowledge of 1-10t Balance-

weight

Type Forklift Truck with Engine

HELI CHINA

2012.01

安徽叉车集团有限责任公司 ANHUI FORKLIFT TRUCK GROUP

CO.,LTD

The Types of Forklift

1 、 According to power types, forklift can be divided into two major categories of internal combustion engine forklifts and electric forklifts.

2 、 According to structure types and the methods of stability,

forklift can be divided into balance-weight type trucks, reach type trucks, straddle type trucks and sideway type trucks.

3 、 According to transmission types, forklift can be divided into Mechanical transmission type trucks and Hydraulic transmission type trucks.


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The Brief Introduce of HELI 1~10t Forklift


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Counter Weight

Overhead Guard

Rear Lamp

Rearview Mirror

Head LampMas

t

Fork

Lift Cylinder

Lift Bracket and backrest

Tilt Cylinder

Drive Axle and Wheel

Steering System

Meters

Bonnet

Steering Axle and Wheel

Seat

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ASPECT

1 to 3.5 ton gasoline/diesel/LPG(Liquefied petroleum gas)/gasoline or LPG

forklift trucks with clutch/torque converter have 3 series: α, H and G in HELI.

5 to 7 ton gasoline/diesel/LPG(Liquefied petroleum gas)/gasoline or LPG

forklift trucks with torque converter have 2 series: X and H in HELI.

8 to 10 ton diesel forklift trucks with torque converter have 1 series: H in

HELI.

The tonnage distribution in HELI is 1t 、 1.5t 、 1.8t 、

2t 、 2.5t 、 3t 、 3.5t 、

4t 、 4.5t 、 5t 、 6t 、 7t 、 8t 、 10t 。

For example, CPCD50-CU3 ( CP: balance-weight forklift truck; C: diesel;

D:torque converter CU: Cummins engine made in USA 3: NO.3 type)


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The Brief Introduce of HELI 1~10t Forklift

THE CONTRAST OF HELI TRUCKS WITH OTHERS

1 、 HELI design and manufacture drive system ourselves. Our machine devices keep ahead in the international. The key components of transmission which has lower failure rate are the best in the international. The quality of HELI transmission is NO.1 in CHINA.2 、 Brake system apply a type of hydraulic dynamic braking system, and hydraulic spring storage (5-10t) that termination pressure ≥10MPa, oil volume ≥100ml. You may only consume a little strength for pressing the pedal. The reliability of system is very well, and it has higher efficiency.3 、 The mast which may fix many types of attachments has double internal hose pulley assembly, and do not need to apply hose reel device. This design can reduce your costs, increase the beauty of truck and the sheave space.4 、 All hydraulic lines of mast have some explosion relief valves for safety while lifting goods.5 、 The link between exhaust system and frame are bellows, can cut down more vibration and noise.


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6 、 The junctions of steering axle and frame have been redesigned for

reducing vibration. The truck’s vibration reduce 30%.

7 、 Muffler expand and interference the airflow which going in engine,

inhibit the inlet pulse, and reduce the inlet noise.

8 、 All types of hose connector and transition connector in pipeline

apply cone sealing form which effect is very well. Do not need ring,

and will have not any oil leakage in a long time.

9 、 The key seals all come from Japan or German.

10 、 Steering trapezoid design apply optimization program. it’s error angle ＜

1°,and can reduce more abrasion of tires.

11 、 16 automatic tests can detect torque, speed of engine, oil

temperature, oil pressure, and so on. More 10 parameters can be

show, memory, count, analysis and output in

real time.


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12 、 About differential , a pair of spiral bevel gear impacting noise should be

checked one by one, especially noise inspection which can ensure the

prevention of howl.

13 、 Torque converter has been designed and manufactured on the basis of

Japanese technology, and now has been improved for HELI trucks, make the

efficiency increase 2% to 3%.

14 、 G series forklift trucks have apply a type of muffler , can eliminate many

types of noise such as LF, IF, HF, and can reduce noise outside the truck or

outside driver ’ s ear.

15 、 The mast of G series forklift fix a type of buffer device, can reduce some

vibration and pound.

16 、 The human design of G reduce the pressure of pedal, relieve our arm’s

fatigue, improve driver’s vision. More safety and more cozy. No apply asbestos.

17 、 The safety of G is very well. It have all types of protection facilities ,

especially operating sensing system.


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18 、 For G, its main oil pump displacement is low, but lifting speed

is high, Hydraulic oil temperatue is low, fuel temperature is low, traction and climbing ability all are high.19 、 G forklift trucks’ emission are lower than others, correspond

the last standard of EC in Europe and EPA in USA.

20 、 G may apply a tape type cab, which can ensure truck’s safety.

21 、 G fix a type of intelligent parking brake system, can ensure

truck’s stillness at any circumstance.22 、 The design of low-energy can reduce some loss of energy and

torque.


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POWER SYSTEM

1 、 Engine structure

2 、 Engine’s feature for forklift

a ） Low speed

b ） High torque

c ） Normal operation in the case of idle, while can run at forward

gears

d ） The attachment of engine can be redesigned for forklift reality

3 、 Engine’s forklift （ China ）4 、 Engine’s forklift （ International ）


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POWER SYSTEM

4-1 、 Japan ISUZU 6BG1 （ for 5-10t ） Emission: China I

Rated Power/Speed （ kW/rpm ）： 82/2000

Rated Torque/Speed （ Nm/rpm ）： 415/1500

Engine Displacement （ L ）： 6.494

Engine Cylinder ： 6

Naturally aspirated


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POWER SYSTEM

4-2 、 Japan MITSUBISHI S6S-T （ for 5-7t ） Emission: EPA tier 3 and EU

stage 3A

Rated Power/Speed （ kW/rpm ）： 63.9/2300




High-pressure Common-rail Shock mounting system

Silencer (Resistance/ Dissipative) Operator presence

sensing system

Cost-effective


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POWER SYSTEM

4-3 、 USA Cummins QSB4.5-C110 （ for 5-10t ） Emission: EPA tier 3 and

EU stage 3A





Electronic control High-pressure Common-rail Air to air intercooler

Shock mounting system Muffler(Resistance/ Dissipative) ECM

control

Operator presence sensing system Linear electron accelerator system Exhaust type radiator Low fuel consumption

Automatic fault diagnosis and alarm Maintenance monitoring

Altitude correction


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POWER SYSTEM

4-4 、 UK Perkins 1104D-44TA （ for 5-10t ） Emission: EPA tier 3 and

EU stage 3A





Air to air intercooler

High-pressure Common-rail Shock mounting system

Muffler (Resistance/ Dissipative) Operator presence

sensing system

Cost-effective

4-5 、 Engine for forklift (for 1 to 3.5t)


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EnginePower

kW / rpmTorque

Nm / rpmDisplacement (L)

EmissionFor

ISUZU C240PKJ-30 34.5/2500 139.2/1800 2.369 EU stage 3A 1~3.5t

ISUZU C240PKJ-32 34.5/2500 139.2/1800 2.369 EU stage 3A 1~3.5t

ISUZU 4JG2PE-01 44.9/2450186/1600 ～

18003.059 EU stage 3A 2~3.5t

Yanmar 4TNE92 33 /2450 136~150 /1600 2.66 EU stage 3B 1~3.5t

Yanmar 4TNE98 44.3/2300 3.317 EU stage 3A 2~3.5t

Kubota V2403(IDI 2400RPM)

35.4/2400 155.4/1500 2.434 EU stage 3A 1~2.5t

Kubota V2403(IDI 2600RPM)

36.5/2600 160/1700 2.434 EU stage 3A 2~3.5t

Kubota V3600 46.9/2400 3.620 EU stage 3A 2~3.5t

NISSAN K15 23.6/2400 103/1600 1.468 1~1.8t

NISSAN K21 31.2/2250 143.7/1600 2.065 1~3.5t

NISSAN K25 37.6/2400 176.5/1600 2.488 1~3.5t

GM3.0 46/2800 191.6/1600 2.967 EPA tier 2 2~3.5t

JMC HJ493 39/2500 160/1800 2.771 China 2 1~3.5t

JMCHJ493G 36.8/2500 165/1800 2.771 EU stage 3A 1~3.5t

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POWER SYSTEM

5 、 Components

5-1 、 Air cleaner system Components ： Air entrance, Air cleaner and pipelines

Pipelines ： low air resistance, low air temperature

Air cleaner ： high efficiency, long life, low air resistance NOTE ： NO water washing, keep clean


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POWER SYSTEM5-2 、 Exhaust system Components ： front exhaust tube, muffler, rear exhaust tube Mandates ： 1 ） muffler ； 2 ） exhaust pressure ； 3 ） The exhaust tube and turbocharger do not been pressed for weight, inertia, relative motion between different components, size diversification from thermal expansion. 4 ） Some components including electronic elements, fuel tube, cooling system, air cleaner system, and driver would be fixed away the exhaust tube which is very heat. 5 ） Do not touch water.


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POWER SYSTEM

Muffler

1 ） Resistance muffler: for LF and IF (intermediate

frequency)

2 ） Dissipative silencer ： for IF and HF

3 ） R/ D multiple silencer ： for LF, IF, and HF


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POWER SYSTEM

5-3 Cooling system


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1-Radiator 2-Air hood 3-Fan 4-Lower hose 5-Water pump 6-Thermostat 7-Radiator cover 8-Upper hose 9-Transmission

shaft 9-Pipeline10-Tank20

POWER SYSTEM

5-4 The experiment NO.1

Intake resistance Exhaust resistance


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POWER SYSTEM


Fuel resistance Heat balance


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POWER SYSTEM


Noise Insertion Loss Sound intensity analysis


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DRIVE SYSTEM

General Description The components ： Transmission, Torque converter, Charging pump, Hydraulic clutch, Control valve, Inching valve, and Hydraulic circuit


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DRIVE SYSTEM

The structure of transmission


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DRIVE SYSTEM

Torque convertor

Function ： The torque converter can be used to ensure efficient and smooth work of Transmission system.


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DRIVE SYSTEM

3 、 Torque Converter Generally, the torque converter

consists of pump wheel fitted to the

input shaft, turbine wheel fitted to

the output shaft, and stator wheel

fixed to the housing.


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1-Crank 2-Shell 3-Turbine 4-Impeller 5-Stator 6-Sleeve7-Output Axle

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DRIVE SYSTEM

Torque Converter


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DRIVE SYSTEM

Charging pump The construct of charging pump consists of driving gear, inner gear( driven gear), shuck and cover, mounted on the upper end of the tor-con housing. driving gear is driven by pump wheel, idle gear and oil pump driven gear , the oil pump supply oil in lower half of the transmission for every area of the transmission.


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DRIVE SYSTEM

Hydraulic Clutch


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DRIVE SYSTEM

Hydraulic Clutch It consists of friction piece, spacer, check valve ball, piston assembly, spring, gear, clutch shuck , and so on. The power from the torque converter is transmitted to the transmission in


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DRIVE SYSTEMControl valve and inching valve The control valve provided on the upper part of transmission case. The change spool and inching spool are incorporated in the valve body.The clutch relief valve is designated to adjust the hydraulic pressure of the hydraulic pressure of the transmission clutch.The convertor relief valve server to adjust the hydraulic pressure of fluid which fills the converter. The inching spool is connected to the link of brake pedal. When the brake pedal is depressed,the spool is forced in, so that hydraulic pressure of clutch is lowered temporarily to disengage the clutch.


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DRIVE SYSTEMHydraulic circulation system


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DRIVE AXLE1 、 Drive axle The drive axle(5 to 10 ton) that consists of a main reduction, differential, hub reduction and brakes as shown in fig is bolted to the front side of the frame. The masts are installed on the axle housing. The drive axle(1 to 3.5 tone) have no hub reduction.


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DRIVE AXLE

2 、 Working theory The power is transmitted to the halfshafts through the differential and drives the front wheels through the hubs.Each hub is fixed on the housing with two tapered roll bearings, so that the half-shafts bear only the torque transmitted to the hubs, In the inside of the hub are oil seals to prevent water and dust from entering and oil leakage.


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STEERING SYSTEM AND STEERING AXLE

1 、 Characteristics The functions of forklift trucks are loading, unloading, and transporting in a finite distance. Because the smaller working ground and frequent turning, the trucks need high-powered steering system which is flexible and agile very much.2 、 Components of steering system The steering system of forklift truck is a set of machines that can be control by driver, make the wheels turn left or right. The system include:1 ） control device: (including handle shaft, turning shaft, steering column, locking device of handle shaft)transferring and magnifying the torque of handle shaft from driver, and change turning to swing of steering rod units.2 ） steering rod units: make turning angle of the inner wheel is different from the outers, accord with steering disciplinarian.3 ） supporting device ： (including knuckle, king pin, and steering axle)support rear wheels and limit steering of wheels circling king pins.4 ） Hydraulic pipeline(only for hydraulic type powered steering system)


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3 、 Steering axle

The horizontal steering cylinder is of double-action piston type. The

supporting positions which are axis and bush locate middle, front, and rear of

axle body. The axis is been fixed in the frame of truck, also may swing a little.


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1-Body 2-Tie rod 3-Steering cylinder

4-Knuckle 5-wheel38


BRAKE SYSTEM

1 、 General description

The brake system can make the forklift truck run slowly or

parked, also control truck’s speed when declivity or parking on the

ramp. The brake system must have the best safety, can ensure the

security of truck and driver. The system consists of brake control

and parking system. The brake control and parking system all have

been controlled by wheel brake for 1-3.5t. In 5-10t trucks, brake

control is fixed in drive wheel, while parking brake is fixed with a

axle in transmission.

The types of brake system are hydraulic brake(for 1-3.5t), brake

commixing baric and hydraulic, hydraulic type powered brake(for

5-10t).


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When the pedal moves, it push the rod to course the piston moves and the pressure of the oil circuit increased. As the brake pedal is pressed, the push rod pushes the piston forwards. The brake fluid in the cylinder flows back to the reserve tank through the return port until the primary cup blocks up the return port, the brake fluid in the cylinder is pressurized and opens the check valve, flowing through the brake pipeline to the operating cylinder.

1-Pedal 2-Master cylinder 3-Hose 4-Wheel brake 5-Operating

cylinder

2 、 Sketch map of hydraulic brake

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BRAKE SYSTEM安徽叉车集团有限责任公司 ANHUI FORKLIFT TRUCK GROUP

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The master cylinder contains valve seat, check valve, return spring, primary cup, piston and secondary cup, which are all kept in place with a stop washer and a stop wire. The exterior of the cylinder is protected from dust by means of a stop wire. The piston is actuated through the push rod by operation of the brake pedal.

2-1 、 Master cylinder

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1-Link rod

2-Push rod

3-Dust cover

4-Sanp ring

5-Secondary cup

6-Piston

7-Primary cup

8-Spring

9-Check valve

1.Operating cylinder 2.Return spring 3.Friction piece 4.Spring 5.Parking push rod6.Brake shoe 7.Spring pull wire 8.Spring pull rod 9.Spring seat 10.Spring 11. Spring 12.Ratchet pawl 13.Clearance self-adjuster 14.Return spring 15.Brake cable16.Parking pull rod 17.plate 18.Pin

Parking brake

2-2 、 Wheel brake （ 3t ）

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2-2 、 Wheel brake （ 3t ）

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The wheel brake is the internal expansion hydraulic type consists of brake shoes, springs, operating cylinders and adjuster, and backing plates. Two wheel brakes are provided on each end of the front axle. The brake shoe, one end of it being connected to the anchor pin and the other to the adjuster, is stressed on the backing plate by the spring and spring pull rod. The primary shoe is provided with the parking pull rod while the secondary shoe with the adjusting lever of the clearance self-adjuster.

The clearance self-adjuster keeps suitable clearance between the friction piece and drum by itself. The construction is shown in fig. This adjuster, however, actuates only when the truck in reverse travel is braked. There are two different clearance self-adjusters.

2-3 、 Clearance self-adjuster

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BRAKE SYSTEM

3 、 Hydraulic type powered brake (for 5-10t)

Its power comes from hydraulic pump.

The oil entered brake valve comes from

hydraulic pump, and it’ s flux confirmed by

pushing pedal, then transfer into the

operating cylinder.


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BRAKE SYSTEM

4 、 Brake valve


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P —to Hydraulic pump (master cylinder) N —to Steering unitBr—to Operating cylinder T —to Tank PA—to Energy storage

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BRAKE SYSTEM5 、 The sketch map of hydraulic type powered brake(5-

10t)


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BRAKE SYSTEM6 、 Parking level and brake

The parking brake is of mechanical, internal

expansion type and built in the wheel brake for

1-3.5t or in a axle in transmission for 5-10t.

For 1-3.5t, it shares the brake shoes and

brake drum with the foot pedal. As the parking

brake level is pulled, the parking pull rod is

actuated through the brake cables. The parking

pull rod pushes, in turn, the parking push rod

to the right with the aid of the pin as a fulcrum,

forcing the secondary shoe against the brake

drum.


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叉车组成系统——制动系统6 、 Parking brake


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Hydraulic System

1 、 General Description

Hydraulic system is a type of transmission device which can transfer energy by oil. The oil entering into work cylinders make goods up or down.

Components:

Driving device ： main pump Execute device ： cylinders or hydraulic motor Control device: control valve, dividing valve, safety valve, and so on Accessories: oil tank, oil tubes, nipples, elbows, oil cleaners


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Hydraulic System

1 、 General description 1.Oil tank 2.Strainer 3.Gear pump 4.Control valve 5.Steering unit 6.Steering cylinder 7.Flow regulator 8.Check valve 9.Lift cylinder 10.Tilt cylinder11. Strainer

For 1~3.5t


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Hydraulic System

1 、 General description 1.Oil tank 2.Strainer 3.Gear pump 4.Control valve 5.Steering unit 6.Steering cylinder 7.Flow regulator 8.Check valve 9.Lift cylinder 10.Tilt cylinder11. Strainer

For 5~10t


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Hydraulic System

2 、 Main pump The main pump is a gear pump. It is drivenDirectly by the PTO device of the engine. The oil of oil tank flow to the control valve throughthe main pump. The main pump consists mainly of a pump body, a pair of gears, lining plates and snap rings.This pump uses pressure-balance type bearings and a special lubrication method so as to minimum the clearance of the gear face.


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1-Antrum for taking out oil

2-Antrum for discharging oil 53

Hydraulic System3 、 Control valve The control valve (2 spool type) consists of four valve housings, two spools, one relief valveand flow divider. The four valve housings areassembled together with three stud bolts and nuts.The tilt spool valve consists a tilt lock valve.


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Hydraulic System4 、 Valve control and Oil tank


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Hydraulic System4 、 Valve control and Oil tank


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THANKS


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Documents

The Knowledge of 1-10t Balance-weight Type Forklift Truck with Engine HELI CHINA 2012.01 安徽叉车集团有限责任公司 ANHUI FORKLIFT TRUCK GROUP CO.,LTD