文本说明讲稿the knowledge of1-10t balanceweight type forklift truck with enginev

1、The Knowledge of 1-10t Balance-weight Type Forklift Truck with Engine HELI CHINA2012.01安徽叉车集团有限责任公司 ANHUI FORKLIFT TRUCK GROUP CO.,LTDThe Types of Forklift1、According to power types, forklift can be divided into two major categories of internal combustion engine forklifts and electric forklifts.2、Ac

2、cording 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 transmi

3、ssion type trucks.安徽叉车集团有限责任公司 ANHUI FORKLIFT TRUCK GROUP CO.,LTD2The Brief Introduce of HELI 110t Forklift 安徽叉车集团有限责任公司 ANHUI FORKLIFT TRUCK GROUP CO.,LTDCounter WeightOverhead GuardRear LampRearview MirrorHead LampMastForkLift CylinderLift Bracket and backrestTilt CylinderDrive Axle and WheelSteer

4、ing SystemMetersBonnetSteering Axle and WheelSeat3ASPECT 1 to 3.5 ton gasoline/diesel/LPG(Liquefied petroleum gas)/gasoline or LPG forklift trucks with clutch/torque converter have 3 series: , H and G in HELI. 5 to 7 ton gasoline/diesel/LPG(Liquefied petroleum gas)/gasoline or LPG forklift trucks wi

5、th 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:

6、 diesel; D:torque converter CU: Cummins engine made in USA 3: NO.3 type)安徽叉车集团有限责任公司 ANHUI FORKLIFT TRUCK GROUP CO.,LTD4The Brief Introduce of HELI 110t ForkliftTHE CONTRAST OF HELI TRUCKS WITH OTHERS 1、HELI design and manufacture drive system ourselves. Our machine devices keep ahead in the interna

7、tional. 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 volu

8、me 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

9、 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.安徽叉车集团有限责任公司 ANHUI FORKLIFT TRUCK GROUP CO.,LTD

10、56、The junctions of steering axle and frame have been redesigned for reducing vibration. The trucks 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

11、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. its error angle1,and can reduce more abrasion of tires.11、16 automatic

12、 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. 安徽叉车集团有限责任公司 ANHUI FORKLIFT TRUCK GROUP CO.,LTD6THE CONTRAST OF HELI TRUCKS WITH OTHERS 12、About differential , a pair of spiral bevel

13、 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

14、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 redu

15、ce the pressure of pedal, relieve our arms fatigue, improve drivers 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.安徽叉车集团有限责任公司 ANHUI FORKLIFT TRUCK GROUP CO.,LTD7THE CONTRAST OF H

16、ELI TRUCKS WITH OTHERS 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 an

17、d EPA in USA. 20、 G may apply a tape type cab, which can ensure trucks safety.21、G fix a type of intelligent parking brake system, can ensure trucks stillness at any circumstance.22、The design of low-energy can reduce some loss of energy and torque. 安徽叉车集团有限责任公司 ANHUI FORKLIFT TRUCK GROUP CO.,LTD8TH

18、E CONTRAST OF HELI TRUCKS WITH OTHERS POWER SYSTEM1、Engine structure2、Engines 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 reality3、Engines forklift （China）4、Engines for

19、klift （International）安徽叉车集团有限责任公司 ANHUI FORKLIFT TRUCK GROUP CO.,LTD9POWER SYSTEM4-1、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安徽叉车集团有限责任公司 ANHUI FORKLIFT TRUCK

20、 GROUP CO.,LTD10POWER SYSTEM4-2、Japan MITSUBISHI S6S-T（for 5-7t） Emission: EPA tier 3 and EU stage 3A Rated Power/Speed （kW/rpm）：63.9/2300 Rated Torque/Speed （Nm/rpm）：285/1700 Engine Displacement （L）：4.996 Engine Cylinder ：6 High-pressure Common-rail Shock mounting system Silencer (Resistance/ Dissi

21、pative) Operator presence sensing system Cost-effective安徽叉车集团有限责任公司 ANHUI FORKLIFT TRUCK GROUP CO.,LTD11POWER SYSTEM4-3、USA Cummins QSB4.5-C110（for 5-10t） Emission: EPA tier 3 and EU stage 3A Rated Power/Speed （kW/rpm）：82/2200 Rated Torque/Speed （Nm/rpm）：488/1500 Engine Displacement （L）：4.5 Engine C

22、ylinder ：4 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 Mainten

23、ance monitoring Altitude correction安徽叉车集团有限责任公司 ANHUI FORKLIFT TRUCK GROUP CO.,LTD12POWER SYSTEM4-4、UK Perkins 1104D-44TA（for 5-10t ） Emission: EPA tier 3 and EU stage 3A Rated Power/Speed （kW/rpm）：83/2200 Rated Torque/Speed （Nm/rpm）：418/1400 Engine Displacement （L）：4.4 Engine Cylinder ：4 Air to air

24、 intercooler High-pressure Common-rail Shock mounting system Muffler (Resistance/ Dissipative) Operator presence sensing system Cost-effective4-5、Engine for forklift (for 1 to 3.5t)安徽叉车集团有限责任公司 ANHUI FORKLIFT TRUCK GROUP CO.,LTD13EnginePowerkW / rpmTorqueNm / rpmDisplacement (L)EmissionForISUZU C240

25、PKJ-3034.5/2500139.2/18002.369EU stage 3A13.5tISUZU C240PKJ-3234.5/2500139.2/18002.369EU stage 3A13.5tISUZU 4JG2PE-0144.9/2450186/160018003.059EU stage 3A23.5tYanmar 4TNE9233 /2450136150 /16002.66EU stage 3B13.5tYanmar 4TNE9844.3/23003.317EU stage 3A23.5tKubota V2403(IDI 2400RPM)35.4/2400155.4/15002

26、.434EU stage 3A12.5tKubota V2403(IDI 2600RPM)36.5/2600160/17002.434EU stage 3A23.5tKubota V360046.9/24003.620EU stage 3A23.5tNISSAN K1523.6/2400103/16001.46811.8tNISSAN K2131.2/2250143.7/16002.06513.5tNISSAN K2537.6/2400176.5/16002.48813.5tGM3.046/2800191.6/16002.967EPA tier 223.5tJMC HJ49339/250016

27、0/18002.771China 213.5tJMCHJ493G36.8/2500165/18002.771EU stage 3A13.5t14安徽叉车集团有限责任公司 ANHUI FORKLIFT TRUCK GROUP CO.,LTDPOWER SYSTEM15安徽叉车集团有限责任公司 ANHUI FORKLIFT TRUCK GROUP CO.,LTDPOWER SYSTEM16安徽叉车集团有限责任公司 ANHUI FORKLIFT TRUCK GROUP CO.,LTDPOWER SYSTEMPOWER SYSTEM5、Components5-1、 Air cleaner system

28、 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安徽叉车集团有限责任公司 ANHUI FORKLIFT TRUCK GROUP CO.,LTD17POWER SYSTEM5-2、Exhaust system Components：front exhaust t

29、ube, 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, c

30、ooling system, air cleaner system, and driver would be fixed away the exhaust tube which is very heat. 5）Do not touch water. 安徽叉车集团有限责任公司 ANHUI FORKLIFT TRUCK GROUP CO.,LTD18POWER SYSTEM Muffler 1）Resistance muffler: for LF and IF (intermediate frequency) 2）Dissipative silencer：for IF and HF 3） R/ D

31、 multiple silencer ：for LF, IF, and HF 安徽叉车集团有限责任公司 ANHUI FORKLIFT TRUCK GROUP CO.,LTD19POWER SYSTEM5-3 Cooling system 安徽叉车集团有限责任公司 ANHUI FORKLIFT TRUCK GROUP CO.,LTD1-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-Tan

32、k20POWER SYSTEM5-4 The experiment NO.1 Intake resistance Exhaust resistance 安徽叉车集团有限责任公司 ANHUI FORKLIFT TRUCK GROUP CO.,LTD21POWER SYSTEM5-4 The experiment NO.2 Fuel resistance Heat balance 安徽叉车集团有限责任公司 ANHUI FORKLIFT TRUCK GROUP CO.,LTD22POWER SYSTEM5-4 The experiment NO.3 Noise Insertion Loss Soun

33、d intensity analysis 安徽叉车集团有限责任公司 ANHUI FORKLIFT TRUCK GROUP CO.,LTD23DRIVE SYSTEMGeneral Description The components ： Transmission, Torque converter, Charging pump, Hydraulic clutch, Control valve, Inching valve, and Hydraulic circuit安徽叉车集团有限责任公司 ANHUI FORKLIFT TRUCK GROUP CO.,LTD24DRIVE SYSTEMThe

34、structure of transmission 安徽叉车集团有限责任公司 ANHUI FORKLIFT TRUCK GROUP CO.,LTD25DRIVE SYSTEMTorque convertor Function： The torque converter can be used to ensure efficient and smooth work of Transmission system. 安徽叉车集团有限责任公司 ANHUI FORKLIFT TRUCK GROUP CO.,LTD26DRIVE SYSTEM3、 Torque Converter Generally, t

35、he 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.安徽叉车集团有限责任公司 ANHUI FORKLIFT TRUCK GROUP CO.,LTD 1-Crank 2-Shell 3-Turbine 4-Impeller 5-Stator 6-Sleeve7-Output Axle27DRIVE SYSTEMTorque Converter 安徽叉车

36、集团有限责任公司 ANHUI FORKLIFT TRUCK GROUP CO.,LTD28DRIVE SYSTEMCharging 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 o

37、il pump supply oil in lower half of the transmission for every area of the transmission. 安徽叉车集团有限责任公司 ANHUI FORKLIFT TRUCK GROUP CO.,LTD29DRIVE SYSTEMHydraulic Clutch 安徽叉车集团有限责任公司 ANHUI FORKLIFT TRUCK GROUP CO.,LTD30DRIVE SYSTEMHydraulic Clutch It consists of friction piece, spacer, check valve ball

38、, piston assembly, spring, gear, clutch shuck , and so on. The power from the torque converter is transmitted to the transmission in安徽叉车集团有限责任公司 ANHUI FORKLIFT TRUCK GROUP CO.,LTD31DRIVE SYSTEMControl valve and inching valve The control valve provided on the upper part of transmission case. The chan

39、ge 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

40、 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. 安徽叉车集团有限责任公司 ANHUI FORKLIFT TRUCK GROUP CO.,LTD32DRIVE SYSTEMHydraulic circulation system 安徽叉车集团有限责任公司 ANHUI

41、FORKLIFT TRUCK GROUP CO.,LTD33DRIVE 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

42、reduction. 安徽叉车集团有限责任公司 ANHUI FORKLIFT TRUCK GROUP CO.,LTD34DRIVE AXLE2、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 t

43、he torque transmitted to the hubs, In the inside of the hub are oil seals to prevent water and dust from entering and oil leakage. 安徽叉车集团有限责任公司 ANHUI FORKLIFT TRUCK GROUP CO.,LTD35STEERING SYSTEM AND STEERING AXLE1、Characteristics The functions of forklift trucks are loading, unloading, and transpor

44、ting 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 wh

45、eels 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 turn

46、ing 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)

47、安徽叉车集团有限责任公司 ANHUI FORKLIFT TRUCK GROUP CO.,LTD36 安徽叉车集团有限责任公司 ANHUI FORKLIFT TRUCK GROUP CO.,LTD37STEERING SYSTEM AND STEERING AXLE3、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 axl

48、e body. The axis is been fixed in the frame of truck, also may swing a little. 安徽叉车集团有限责任公司 ANHUI FORKLIFT TRUCK GROUP CO.,LTD1-Body 2-Tie rod 3-Steering cylinder 4-Knuckle 5-wheel38STEERING SYSTEM AND STEERING AXLEBRAKE SYSTEM1、General description The brake system can make the forklift truck run sl

49、owly or parked, also control trucks 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 br

50、ake 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). 安徽叉车集团有限责任公司 ANHUI FORKLIFT TRUCK

51、 GROUP CO.,LTD39 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 pr

52、imary 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 cylinder2、Sketch map of hydraulic brake40BRAKE SYSTEM安徽叉车集团有限责任公司 AN

53、HUI FORKLIFT TRUCK GROUP CO.,LTD 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 actu

54、ated through the push rod by operation of the brake pedal. 2-1、Master cylinder41BRAKE SYSTEM安徽叉车集团有限责任公司 ANHUI FORKLIFT TRUCK GROUP CO.,LTD1-Link rod 2-Push rod3-Dust cover4-Sanp ring5-Secondary cup6-Piston7-Primary cup8-Spring9-Check valve1.Operating cylinder 2.Return spring 3.Friction piece 4.Spri

55、ng 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.PinParking brake2-2、Wheel brake（3t）42BRAKE SYSTEM安徽叉车集团有限责任公司 ANHUI FORKLIFT TRUCK GROUP

56、 CO.,LTD2-2、Wheel brake（3t）43BRAKE SYSTEM安徽叉车集团有限责任公司 ANHUI FORKLIFT TRUCK GROUP CO.,LTD 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 b

57、rake 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 c

58、learance 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-adjuster44BRAKE SYSTE

59、M安徽叉车集团有限责任公司 ANHUI FORKLIFT TRUCK GROUP CO.,LTDBRAKE SYSTEM3、Hydraulic type powered brake (for 5-10t) Its power comes from hydraulic pump.The oil entered brake valve comes from hydraulic pump, and its flux confirmed by pushing pedal, then transfer into the operating cylinder. 安徽叉车集团有限责任公司 ANHUI FOR

60、KLIFT TRUCK GROUP CO.,LTD45BRAKE SYSTEM4、Brake valve安徽叉车集团有限责任公司 ANHUI FORKLIFT TRUCK GROUP CO.,LTDP to Hydraulic pump (master cylinder) N to Steering unitBrto Operating cylinder T to Tank PAto Energy storage46BRAKE SYSTEM5、The sketch map of hydraulic type powered brake(5-10t)安徽叉车集团有限责任公司 ANHUI FORK