Industrial trucks: Trends and advances

Fleet Equipment, Oct 2002 by Deierlein, Bob

Equipment Technology

In many cases, JIT operations have reduced the size of shipments but increased their frequency. The result has been an increased use of industrial trucks in terminals as well as on shippers' docks.

Powered industrial trucks-- mobile, power-propelled trucks used to pull, push, carry lift, stack or tier materials-are commonly known as lift trucks, pallet trucks, rider trucks and forklifts.

In recent years there have been many technological advances in distribution/delivery vehicles, but advances in industrial trucks of all kinds have been keeping pace.

Trends

One of the most talked about changes is the introduction of AC drive-powered industrial trucks. The advantages of AC power over DC include: higher speeds and acceleration, use less energy, a 15 to 20 percent longer operating time per charge and there are no wear parts to service. AC power has lower operating costs because AC-powered units are maintenance-free and do not require directional contactors or motor brushes. The DC energy from the battery travels through a controller and an inverter and AC power comes out the controller. The initial cost is about the same for either design.

On the other hand, Crown says its FC-4000 has a DC motor and says, "Many of the motor and controller makers are not at all convinced that AC drives are the best solution in every case." It also feels that the AC's acceleration advantage lasts only a few seconds, and their top speed does not match Crown's DC machines.

Internal combustion (IC) trucks currently outperform electrics due to faster acceleration and higher speeds. On the other hand, ICs are noisier, have emissions concerns inside a warehouse and generally cost more to operate. This also makes them a marketing target for AC motor driven trucks.

Raymond introduced the first AC reach truck last October, the Accelerated Cycle Reach-Fork Truck using drive and lift motors.

Another trend is a move to narrow aisle lift trucks when truck terminals and warehouses are reconfigured due to the increasing cost of warehouse space. Other advances include ergonomic features to protect the operator while trying to drive the truck safely.

Finally, industrial trucks are also under mandates to reduce emissions. For example, California has mandated that manufacturers deliver into California commerce, certified compliant clean air engines under the following schedule: 25 percent of all LPG- and gasoline-powered forklifts sold in 2001 had to be certified, then 50 percent this year, 75 percent sold in 2003 and 100 percent sold in 2004 will need to be certified. The federal EPA is expected to require clean engines be utilized nationwide beginning in 2004.

In January 2001, Nissan Forklift announced it had become the first to achieve compliance certification in California with its H20-II and H25 4-- cylinder industrial engines.

New models

The key for a fleet manager is to spec a lift truck that meets all his operation's particular operating needs. General considerations are weight capacity and how high and how often a load is lifted. Users should review the features offered on new and updated trucks to see if they might be beneficial.

The newest lift truck series from the Hyster Company, billed as "The Newest Old Reliable," is the H45-65 X M. There are five different internal combustion models. All feature Hyster's own ComforCab which provides easy entry and exit, tilt cylinders and out of sight hydraulic linkage and 30 percent more leg room than conventional lift trucks. When seated, drivers do not have to extend arms and legs to reach for pedals, levers or the steering wheel. Straight ahead, backlit analog gauges and an LCD hour meter inform at a glance. When the key is turned, a built-in monitor automatically checks systems for service needs.

The new tilt steering column has a latch contoured for fingertip access to adjust the column to one of four comfortable positions. Power steering response is smooth and takes only 3.7 turns to go lock-to-lock.

"Soft touch" hydraulic levers mold to an operator's hand and are located seat-side. Finally, with its VISTA mast, wide-spaced mast channels and a grid-style overhead guard provide an extensive view.

There are two standard engine choices, single overhead cam, 4cylinder, 2.0 and 2.2 liter Mazda gasoline engines. These machines can also be optionally fitted with an LPG fuel system. Other engine options include a GM 3.0 gas/LPG and a Perkins 2.6 liter diesel.

Servicing is easy. A gas spring assisted hood tilts forward a full 63 degrees, so a periodic maintenance check can be completed in less than 10 minutes. For a quick lube job, there are only eight grease fittings. Mast load rollers are lubed for life and can be re-shimmed without having to remove the mast. Sensors continually monitor system operating conditions, such as brake fluid and coolant level, transmission oil temperature, engine oil pressure and air cleaner restriction.

Komatsu Forklift, USA markets a full line of electric and IC forklifts. It says its BX model offers better visibility, reduced vibration and noise and easier gauge readability than competitive models. The model is available with either diesel and gas/LPG engines. The company says daily maintenance is easy with the gas cylinder-assisted, lift-up engine compartment cover and lift out floorboard.