Improvement on 1-10T IC Forklift

Report
Always Specialized, Steady, Responsible
Partner
HELI 1-10T IC Forklift-2013
Anhui Heli Co.Ltd..
HELI 1-10T IC Forklift-2013
Content
1、General info for 1-10T IC Forklift
2、New product for 1-10T IC Forklift
3、Improvement on 1-10T IC Forklift
General info for IC Forklift
1-3.5T
New H series to replace old
H2000 series to cover
medium-low requirement
customers
New G series(GII) to meet
high requirement customers
1-10T IC
TRUCK
4-5t
(500mm LC)
New H series to replace the
old H2000 series
H2000 series 5-10t
5-10t
(600 LC)
G series 5-10t
1-3.5T IC forklift
Series
H2000 series
(including
cushion tire)
First
generation G
series
New H series
(Available
from June,
2013)
Second
Generation
G series
(Available
from Aug.
2013)
Photo
Optional engines
Diesel engine:Isuzu C240PKJ/4JG2、Chinese HJ493、
Kubota V2403/3600
Gasoline engine(inc. LPG):Nissan K15/K21/K25, GM3.0
Diesel engine:Isuzu C240PKJ/4JG2、Chinese HJ493、
Kubota V2403/3600
Gasoline engine(inc. LPG):Nissan K15/K21/K25, GM3.0
Diesel engine:Isuzu C240PKJ/4JG2、Chinese engineHJ493
Gasoline engine(inc. LPG):Nissan K15/K21/K25
Diesel engine:Isuzu C240PKJ/4JG2、Chinese HJ493、
Kubota V2403/3600
Gasoline engine(inc. LPG):Nissan K15/K21/K25, GM3.0
5-10T IC Forklift
Series
H2000 series
Photo
Optional engines
Diesel engine:Chinese engine CA6110、Isuzu 6BG1、
Mitsubishi S6S-T(for 5-7t)、Cummins QSB4.5、Perkins
1104D-44TA
Gasoline(inc. LPG):GM4.3(for 5-7t)
Special
model for
Operating in
container
Diesel engine:Chinese engine CA4110(6t)、Chinese engine
CA6110(8t、10t)、Perkins engine1104D-44TA(6t、8t、
10t)
G series
(Available
from Aug..
2013)
Diesel engine:Chinese engine CA6110、Isuzu engine 6BG1、
Mitsubishi engine S6S-T(for 5-7t)、Cummins QSB4.5、
Perkins1104D-44TA
Gasoline engine(inc. LPG):GM4.3(for 5-7t)
New Model-1
H2000 series 5-7T with GM4.3 gasoline engine(inc. LPG)
Performance comparison for 5-7t with
TB42 and GM4.3 engine
Electronically
controlled
GM4.3
engine,
with
Ite
m
Testing subject
unit
TB42
GM4.3
1
Max. lifting speed
(without /with load)
mm/s
251/228
355/312
2
Max. driving speed
(without/with load)
km/h
24.9/19.6
30.7/23.1
HC
ppm
284
34
CO
%
3.64
0.21
HC
ppm
156
2
CO
%
1.61
0.19
advanced
technology and easy maintenance.
Lower exhaust, lower noise, low fuel consumption.
Idle
speed
Dual LPG bottles with automatic switchover between bottles
Load sensing technology for hydraulic system with high working
3
exhaust
efficiency.
electric-hydraulic direction switch with easy operation to relieve
the operator.
Full
speed
New Model-2
H2000 series 10T with Perkins 1204E
1.Engine emission complying with EU Stage IIIB and
EPA Tier 4i regulation.
2. With DPF+DOC exhaust treating measure, the PM
value is reduced by 90%, NOx value is reduced by 60%.
3. With Rexroth hydraulic actuating device, API
Aluminum radiator , Multi-wing fan, the radiating effect
is increased by 10%, the noise is reduced by 3Db, and
the fuel consumption is reduced by 5%
4. Standard rear-window glass to prevent the hot-air
directly to driver.
Excellent Donaldson air filter
5. With new treating measures on hydraulic oil filtering
and cooling, improve the working-condition of the
hydraulic oil and reduce the failure rate of the hydraulic
components.
New Model-3
New H series-1-3.5T IC forklift-1
1-3.5t
CPCD10
CPQD10
CPCD15
CPQD15
CPCD18
CPQD18
CPCD20
CPQD20
CPCD25
CPQD25
CPCD30
CPQD30
CPCD35
CPQD35
Rated capacity (kg)
1000
1500
1750
2000
2500
3000
3500
Load center(mm)
500
Length (mm )
2941
3165
3213
3430
3650
3770
3840
width(mm )
1070
1070
1070
1150
1150
1225
1285
height(mm )
2070
2070
2070
2140
2140
2170
2170
Min. turning
radius (mm)
1977
2052
2093
2170
2240
2400
2420
New Model-3
New H series-1-3.5T IC forklift-2
Air
intake
silencer
Hanged
brake
Adopting new CAE design technology
and implement of forward design,
optimize the structure & layout to
strengthen the chassis, overhead guard
and dashboard, also to avoid resonated
vibration.
Mounting the air intake silencer on the
air inlet inside the overhead guard to
lower down the driver’s ear noise.
Driver’s cab was hanged onto the
chassis with supported shock pad, also
the hanged brake pedal would relieve
the vibration to driver.
front./rear 4
shock pad
New Model-4
New H series-1-3.5T IC forklift-3
Optimize the engine hood design to enlarge the driver foot space;
Reduce the height of dashboard, and put the display on the right,
to widen the diver’s forward vision.
Heighten the overhead guard by 100mm to enlarge the space.
Use the small-diameter steering wheel to relieve the driver’s
fatigue.
With
electric-hydraulic
direction
switch
to
ensure
the
comfortable operation
Smaller steering
wheeler
Dashboard
New Model-4
New H series-1-3.5T IC forklift-4
Adopting the casting steering axle to improve the
waterproof and dustproof of the steering knuckle to prolong
the working life and increase the quality reliability.
Adopting the new adjusting device for steering wheel to
assure the convenience, easy and reliability.
By adding more baffle plates to prevent the hot-air reflow,
optimize the hot-air transfer channel on the counterweight,
use the aluminium radiator to improve the heat radiating,
prolong the engine working life.
Using the new engine hook lock for convenient operation.
Adopting the fixed displacement pump load sensing
steering system to reduce the hydraulic oil temperature,
increase the lifting speed
The difference between old H2000 and New H series
System
Air intake system
Exhaust system
Cooling system
chassis
Overhead guard
H2000 series
few machines with air
intake silencer
New H series
Built-in air intake silencer
Advantage of new H series
Reduce the air intake noise, easy maintenance
Distance the muffler and
The muffler is close to the
Reduce the heat radiation, improve the heat balance, reduce
radiator, impedance compound
radiator
the noise
muffler
Copper radiator
Plate-wing aluminium radiator
Oil tank interior wall is
Oil tank interior wall is made
made from two plates, the from one complete plate, the
oiling port is on the
oiling port is welded on the oil
overhead guard
tank
no shock pad between
Monolithic overhead guard
chassis and overhead
with shock pad to the chassis
guard
Engine hood
Directly fitted on the
chassis, the accelerating
pedal was fitted onto the
transmission
Hydraulic system
Optional load sensing
steering system
Steering axle
Welded axle
Casting axle
Engine hood lock
Cable
Integrated lock
Steering system
Unilateral lock device
Bilateral lock mechanism
Increase the heating transfer, prevent the hot-air reflow,
improve the heat balance
Increase the chassis strength, to reduce the vibration, simplify
the fuel system
Effectively reduce the vibration to overhead guard from
chassis
fitted onto the overhead guard, the shock pad between overhead guard and chassis effectively
dashboard is covered fully,
prevent the vibration transfer from chassis to engine hood,
hanged pedal
very little noise leakage from footplate and dashboard
Standard load sensing steering Reduce the hydraulic oil temperature, increase the lifting
system
speed
Increase the axle reliability, reduce the maintenance cost
Easy operation
More reliable, more flexible。
New Model-5
New second generation G(GII) series 2-3.5t-1
2-3.5t
CPCD20/CPQD20
CPCD25/CPQD25
CPCD30/CPQD30
CPCD35/CPQD35
Rated capacity (kg)
2000
2500
3000
3500
Load center(mm)
500
Length (mm )
3430
3650
3770
3840
width(mm )
1150
1150
1225
1285
height(mm )
2140
2140
2170
2170
Min. Turning radius (mm)
2170
2240
2400
2420
New Model-5
New second generation G(GII) series 2-3.5t-2
Adopting flexible transmission and V-type support to engine,
greatly reduce the vibration, the hyd pump is fitted onto the
transmission PTO port for easy maintenance.
Casting steering axle:greatly improve the waterproof and dustproof, reduce the
maintenance cost, prolong the working life the axle
New Model-5
New second generation G(GII) series 2-3.5t-3
Adopting sunken mast, move the tilt cylinder
down to increase the arm of force, reduce the
tension and pressure, decrease the failure rate of
the hydraulic system.
The inclining-angle of front footplate was
changed into 15°from 25°, enlarge the foot
space, relieve the leg fatigue
New second generation G(GII) series 2-3.5t-4
Redesign the display and dashboard, dashboard is
covered by metal material, safe and reliable, elegant
appearance.
The display is put on the right side, steering oil-pipe and display
harness is laid out separately to ensure the safety of electric
system.
New adjusting mechanism for steering wheel to
increase the locking arm of force, free maintenance, move
the turning pivot to increase the leg space, move the
steering orbital down to reduce the ear noise
New second generation G(GII) series 2-3.5t-5
Hanged
pedal
prevent
accelerating
mechanism
the
to
vibration
transfer to driver’s leg from
chassis
Adopting the plate-wing aluminium radiator and two blowhole on
counterweight , reduce the heat, avoid the engine and transmission
problem because of overheating.
Compared with old tube type radiator, the heat balance temperature is
reduced by 3.4 degree.
New second generation G(GII) series 2-3.5t-6
Adopting toothed parking brake, implement different parking
force on ramp and flat ground to increase the parking reliability.
New engine hood lock, easy, convenient. operation
Fully cover the under-side of dashboard to reduce noise to driver
New second generation G(GII) series 2-3.5t-7
Compared with old G series, the
new GII with flexible transmission
had been improved a lot particularly
on the vibration.
Red line is for old G series,blue
and green line is for new G2。
New second generation G(GII) series 2-3.5t-8
System
G1
G2
Advantage of G2 compared with G1
Transmission
Rigid transmission
Flexible
transmission
1 、 greatly reduce the vibration and noise, improve the
comfortability.
.2、Hydraulic pump is fitted onto the transmission, easy
maintenance, more reliable.
Steering axle
Welding axle
Casting axle
Increase the reliability, reduce the maintenance cost
Lifting mast
Non-sunken mast
Sunken mast
Reduce the failure of lifting system
Inclining Angle
of front plate
25°
15°
Display
On the steering
column
On the right side
Display and
dashboard
enlarge the foot space, improve the comfortability
Separate layout of oil pipe and electric system to ensure the
safety
Dashboard is covered
The downside of the
by plastic material, no
dashboard is fully Avoid the noise transfer to driver, elegant dashboard
covered on the down
covered
side
Parking brake
On the left side
On the right side
More ergonomic
Hood lock
Cable
Lock device on
hood
More reliable and convenient
Hydraulic system
Fixed displacement
bypass hydraulic
system
1、increase the lifting speed with load by 7%, 11% without
Load sensing
load, increase the efficiency
hydraulic (steering )
2、reduce the fuel consumption by 6% in the same working
system
condition
New G series 5-10t model-1
5-10t
CPCD50
CPCD60
CPCD70
CPCD80
Rated capacity (kg)
5000
6000
7000
8000
Load center(mm)
600
length (mm )
4710
4785
4830
5160
width(mm )
2045
2045
2045
2165
height(mm )
2450
2450
2450
2560
Min. turning radius(mm)
3240
3300
3370
3700
New G series 5-10t model-2
Streamlined appearance
Shock pad
Driver’s Cab is hanged onto the
chassis
through
the
shock
pad,
improve the vibration.
Driver’s cab is fully sealed from
engine compartment to prevent the
engine noise transfer.
Adopting the impedance compound
muffler to reduce the exhaust noise
Fully sealed
cover
New G series 5-10t model-3
Electric harness is laid out over the oil pipe, the exhaust pipe and all type of oil way are
separately laid out on the left/right side to ensure the safety
Increase the wheelbase for 5-7T by 50mm for better stability.
Use the fully covered dashboard for safety.
New G series 5-10t model-4
Enlarge the blowhole, use the high-performanced aluminium
radiator to increase the heat radiating.
New engine hood lock, easy and convenient.
Use the fixed displacement pump load sensing steering
system to reduce the hydraulic oil temperature, to increase the
lifting speed.
New G series 5-10t model-5
Implement of forward design, optimize the operating
mechanism and layout, relieve the driver fatigue,
improve the comfortability.
Use wider mast to have better visibility.
Toothed parking brake to have different parking force
on ramp and flat ground, improve the parking reliability.
Use the integrated electric box, easy maintenance.
Quality improvement-1
Performance improved muffler
for G series
90.00
怠速工况时空管和L型消声器排气尾管频谱
85
80
90.00
空管
W型消声器
75
65
Pa
dB(A)
60
55
50
dB
45
Pa
[0.00-8192.00 Hz]
70
40
35
30
25
20.00
20.00
22.39 32
40
50
63
80 100 125 160 200 250 315 400 500 630 800 1000 1250 1600 2000 2500 3150 4000 7079.46 A L
Octave 1/3
Hz
By the analysis and testing, the new muffler have the 30dB noise
reduction effect.
Quality improvement-2
Improvement of the piston rod
of steering cylinder
all the piston rod are treated with mid/high frequency quenching, to make the
piston rod surface hardness≥HRC67,to avoid the quality problem because of less
hardness
Quality improvement-3
Improvement on the brake
Trim the vertical degree of brake shoes, to ensure the gap under the below part of
brake shoes, change the touching surface between brake shoes and pin into fillet to get
the automatic adjustment. The improved brakes shoes is in over 95% surface touched
to improve the brake efficiency
Quality improvement-4
Improvement on the control
box
欣大943-1C12DS继电器
RC吸收保
护回路
By using the new relay to improve the quality of control box.
Quality improvement-6
Improvement of the
cleanness on hydraulic
system for 5-10t
for each 5-10t forklift in assembly, the hydraulic
system needed to be cleaned by KLEENOLL
filtering equipment. The cleanness would reach
NAS11 class after 20min circulating filtering.
Quality improvement-7
By changing of the matching gap between guide-shaft
Reduce the noise from
transmission for 5-10t
support, changing the elastic-plates thickness, increase
the manufacturing precision of the hydraulic pump gear,
greatly reduce the noise from transmission.
120
变矩器西侧-前进二档
原始状态测试
更换导轮轴-0.055
更换导轮轴-0.035
更换1mm厚弹性板
118
116
114
112
110
108
106
102
100
98
96
94
92
90
88
86
85
750 800
900
1000
1100
1200
1300
1400
1500
1600
1700
1800
1900
2000
2100
2200
2350
rpm
120
变矩器东侧-前进二档
原始状态测试
更换导轮轴-0.055
更换导轮轴-0.035
更换1mm厚弹性板
118
116
114
112
110
108
106
104
Pa
dB(A)
Pa
dB(A)
104
102
100
98
96
94
92
90
88
86
85
750 800
900
1000
1100
1200
1300
1400
1500
1600
rpm
1700
1800
1900
2000
2100
2200
2350
Quality improvement-8
New wide view triplex mast for 5-10t
Quality improvement-9
New cabin
New cabin for new H series 2-3.5t
model
New cabin for G series 5-10t
model
Thank You All!
Always Specialized, Steady, Responsible Partner
Anhui Heli Co.,Ltd.

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