165 E06
165 E06
165 E06
Hiroyuki Yamamoto
Yasuo Harada
Hideyuki Hiraiwa
The 4-ton class engine powered forklift truck, FH series FH40/45/50-1, have been developed and introduced
into the market as Komatsus first forklift truck installed electronic controlled HST (Hydrostatic Transmission)
and variable pump CLSS (closed-center load sensing system). New technologies and outline of the improvement
for fuel efficiency in the new models are introduced.
Key Words: Forklift, HST, Hydrostatic Transmission, CLSS, Closed Center Load Sensing System, Low Fuel
Consumption, Environment, Safety, ICT
1. Introduction
In recent years, needs for low fuel consumption and
reduction in environmental loads have rapidly increased in
industrial vehicles and construction machinery due to growing
global environmental awareness and a rise in crude oil prices.
The response to the above has become an important element
in the development and manufacturing of forklifts.
Introduced below is the outline of a new hydrostatic
transmission forklift model FH Series (Fig. 1, Table 1)
which has adopted electronically-controlled HST (Hydrostatic
Transmission) in place of T/C (Torque Converter) + T/M
(Transmission) used for travel drive system of conventional
forklifts, has realized low fuel consumption and reduction in
Fig. 1
Table 1
Major Specifications
Item
Unit
Maximum load
Load center
Maximum travel speed
Performance and dimensions
Wheelbase
Tread Front/Rear
Machine mass
Manufacturer
Model name
Engine
No. of cylinders / Total displacement
Rated output
Fuel tank capacity
Information
ICT
kg
mm
km/h
mm
mm
kg
-/cc
kW/rpm
L
-
Developed
model
FH50-1
5000
600
23. 5
2000
1225/1120
7380
Komatsu
SAA4D95LE
4/3260
50.8/2150
105
KOMTRAX
Current
model
FD50AT-10
5000
600
25
2000
1150/1120
7295
Komatsu
SAA4D95LE
4/3260
59.7/2400
98
-
ecot3
engine
Electronically
controlled HST
Variable pump
CLSS
Fig. 2
3. Main Components
Our unique hydraulic system electronically-controlled
HST, which has been well proven in wheel loaders and
bulldozers, has been installed in the travel drive system while
variable pump and CLSS adopted for excavators has been
installed in the load handling system.
2012 VOL. 58 NO.165
4.2
HST hydraulic
pump
HST hydraulic
motor
4. Outline of System
4.1
Accelerator
pedal
Operating
lever
Pressure
sensor
Differential
Operating
valve
Engine
Fig. 5
Operating
lever
Variable pump
Operating
valve
Gear pump
Pump
Swash plate
Tire
Clutch
Fig. 4
Engine
Motor
Torque converter
Accelerator
pedal
Controller
Transmission
Tire
Inching
pedal
HST forklift
Differential
Commonrail
electronicallycontrolled engine
5.1
Usage of forklift
5.2
Conventional forklift
HST forklift
Torque [Nm]
(4)
Load
(5)
No load
(3)
Equivalent fuel
consumption diagram [L/h]
Fig. 7
HST
T/C
2-speed
transmission
Speed [km/h]
Fig. 6
Travel efficiency
Loss in neutral
Pump pressure
Flow rate
Reduction loss
Fig. 9
Fixed pump
Fixed pump
Variable pump
Pump pressure
Test
course
Reduction loss
Fixed pump
Reduction loss
Fig. 8
Variable pump
Conventional forklift
Variable pump
Reduction effect of
oil pressure loss
Lever input
HST forklift
Course A
Course B
High load
Low load
Conventional forklift
6. Result
Fig. 9 shows the fuel consumption reduction effect at
in-house measurement courses.
The fuel reduction effect was obtained in any course. In
particular, the effect of no less than 29% was obtained at a
high load course (Course A) where there is a lot of switch
back in a short distance assuming loading work to a truck.
Fig. 11 shows the frequency distribution of engine speed
and torque at the high load course (Course A). This shows that
as a circle is larger, the frequency is higher. It can be seen that
large circles move to the small fuel consumption side as
compared with those for the conventional forklift. In
particular, HST forklift used the range where there was little
change in engine speed during acceleration and fuel
consumption was small for a long time. Therefore, the result
as intended was obtained.
HST forklift
Medium load
user
Conventional forklift
HST forklift
Engine torque
6.1
Course C
Equivalent fuel
consumption diagram [L/h]
Type of business in which HST forklift is effective for decreasing fuel consumption (Fig. 12)
Handling business of recycled resources (wastepaper)
Bale clamp
Handling business of recycled resources (general)
Hinged fork
Handling business of concrete secondary product
Hinged fork
Hinged bucket
Fig. 12
6.2
6.3
Safety
6.4
7. Conclusion
In cooperation with Power Train Development Center and
Hydraulic Equipment Technical Center, we have realized
commercialization of forklifts installed with electronicallycontrolled HST and CLSS hydraulic system for the first time
as Komatsu.
We will continue to make efforts to expand the model
lineup installed with HST and CLSS in the future and at the
same time to aim at further technological leaps to develop
these models to be more attractive to customers.
Hiroyuki Yamamoto
Entered Komatsu Ltd. in 1981.
Yasuo Harada
Hideyuki Hiraiwa
Entered Komatsu Ltd. in 1992.
Currently assigned to Technical Center,
Utility Equipment Division