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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ASPECT
Mast
The Brief Introduce of HELI 1~10t Forklift
Head
Lamp
Rearview
Mirror
Rear
Lamp
Overhead
Guard
Counter
Weight
Lift
Cylinder
Meters
Seat
Fork
Lift
Bracket
and
backrest
Tilt
Cylinder
Drive
Axle and
Wheel
Steerin
g
System
Bonnet
Steering
Axle and
Wheel
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The Brief Introduce of HELI 1~10t Forklift
1 to 3.5 ton gasoline/diesel/LPG( L i q u e f i e d p e t r o l e u m
g a s )/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( L i q u e f i e d p e t r o l e u m
g a s )/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 。
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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
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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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THE CONTRAST OF HELI TRUCKS WITH OTHERS
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,
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memory, count, analysis and output in
real time.
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ANHUI FORKLIFT TRUCK GROUP CO.,LTD
THE CONTRAST OF HELI TRUCKS WITH OTHERS
12、About differential , a pair of spiral bevel gear impacting noise
should be checked one by one, especially noise inspection
ensure the prevention of
which can
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
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THE CONTRAST OF HELI 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 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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4-1、Japan ISUZU 6BG1（for 5-10t）
POWER SYSTEM
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
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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
Rated Torque/Speed （Nm/rpm）：285/1700
Engine Displacement （L）：4.996
Engine Cylinder ：6
High-pressure Common-rail
Silencer (Resistance/ Dissipative)
Shock mounting system
Operator presence
sensing system
Cost-effective
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POWER SYSTEM
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4-3、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 Cylinder ：4
Electronic control
High-pressure Common-rail
Air to air
intercooler
Shock mounting system
Muffler(Resistance/ Dissipative)
ECM
control
Operator presence sensing system
Exhaust type radiator
Automatic fault diagnosis and alarm
Altitude correction
Linear electron accelerator system
Low fuel consumption
Maintenance monitoring
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POWER SYSTEM
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4-4、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 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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POWER SYSTEM
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For
Engine
Power
kW / rpm
Torque
Nm / rpm
Displacem
ent (L)
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
44.9/2450
186/1600～1800
3.059
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
Emission
EU stage 3A
1~3.5t
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POWER SYSTEM
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ANHUI FORKLIFT TRUCK GROUP CO.,LTD
POWER SYSTEM
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ANHUI FORKLIFT TRUCK GROUP CO.,LTD
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 SYSTEM
5-2、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
1-Radiator 2-Air hood 3-Fan 4-Lower hose 5-Water pump 6Thermostat 7-Radiator cover 8-Upper hose 9-Transmission shaft
9-Pipeline10-Tank
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POWER SYSTEM
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5-4
The experiment NO.1
Intake resistance
Exhaust resistance
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POWER SYSTEM
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5-4
The experiment NO.2
Fuel resistance
Heat balance
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POWER SYSTEM
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5-4
The experiment NO.3
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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The
DRIVE SYSTEM
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
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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.
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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ANHUI FORKLIFT TRUCK GROUP CO.,LTD
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 SYSTEM
Control 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 SYSTEM
Hydraulic circulation system
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DRIVE AXLE
1、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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ANHUI FORKLIFT TRUCK GROUP CO.,LTD
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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STEERING SYSTEM AND STEERING AXLE
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STEERING SYSTEM AND STEERING AXLE
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.
1-Body 2-Tie rod 3-Steering
cylinder
4-Knuckle 5-wheel
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ANHUI FORKLIFT TRUCK GROUP CO.,LTD
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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BRAKE SYSTEM
2、Sketch map of hydraulic brake
1-Pedal 2-Master cylinder
3-Hose
4-Wheel brake
5-Operating
cylinder
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
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the cylinder is pressurized and opens the check valve, flowing
through the brake pipeline to the operating cylinder.
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2-1、Master cylinder
BRAKE SYSTEM
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
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.
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BRAKE SYSTEM
2-2、Wheel brake（3t）
Parking brake
1.Operating cylinder 2.Return spring 3.Friction piece 4.Spring
5.Parking push rod
6.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
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cable
16.Parking pull rod 17.plate 18.Pin
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BRAKE SYSTEM
2-2、Wheel brake（3t）
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 selfadjuster.
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BRAKE SYSTEM
2-3、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 selfadjusters.
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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
P —to Hydraulic pump (master cylinder) N —to Steering
unit
Br—to Operating cylinder
T —to Tank
PA—to
Energy storage
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BRAKE SYSTEM
5、The sketch map of hydraulic type powered brake(5-10t)
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BRAKE SYSTEM
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6、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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6、Parking
叉车组成系统——制动系统
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 cylinder
11. 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 cylinder
11. Strainer
For 5~10t
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Hydraulic System
2、Main pump
The main pump is a gear pump. It is driven
Directly by the PTO device of the engine. The
oil of oil tank flow to the control valve through
the 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.
1-Antrum for taking out
oil
2-Antrum for
discharging oil 53
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Hydraulic System
3、Control valve
The control valve (2 spool type) consists of
four valve housings, two spools, one relief valve
and flow divider. The four valve housings are
assembled together with three stud bolts and nuts.
The tilt spool valve consists a tilt lock valve.
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Hydraulic System
4、 Valve control and Oil tank
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ANHUI FORKLIFT TRUCK GROUP CO.,LTD
Hydraulic System
4、Valve control and Oil tank
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THANKS
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