“COVER PAGE”

PROJECT TITLE

A PROJECT REPORT

Submitted to

SUNRISE UNIVERSITY

in partial fulfilment for the award of the diploma of

POLYTECHNIC

In

MECHANICAL ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

SUNRISE UNIVERSITY
ALWAR
RAJASTHAN, INDIA

MAY 2014

“Annexure1”
PROJECT TITLE
<Font Size 16><1.5 line spacing>

1
 A PROJECT REPORT
<Font Size 14><Italic>

Submitted to
SUNRISE UNIVERSITY
<Font Size 14><Bold

in partial fulfilment for the award of the diploma of

<Font Size 14><1.5 line spacing><Italic>

POLYTECHNIC
<Font Size 16><Bold
IN MECHANICAL
ENGINEERING
<Font Size 14><Bold

DEPARTMENT OF MECHANICAL ENGINEERING

<Font Size 12><Bold
SUNRISE UNIVERSITY
<Font Size 16><Bold
ALWAR RAJASTHAN,
INDIA
<Font Size 12><Bold
MAY 2014
<Font S ize 14><Bold

2
 CERTIFICATE

This is to certify that the project report entitled “TITLE OF PROJECT WORK ”

submitted by NAME OF GROUP to the SunRise University Alwar,Rajasthan in partial

fulfilment for the award of Diploma of Polytechnic in Mechanical Engineering is a confide

record of the project work carried out by him under my supervision during the year 2015-

2016.

Submitted to: Submitted by:

Name of incharge Name of student(Roll)

Designation

Name (Project Guide)

Designation

SUNRISE UNIVERSITY
Bagad Rajput, ALWAR-301030(Raj.)
INDIA

3
 ACKNOWLEDGEMENT

I take this opportunity to express my profound gratitude and deep to my mentor Mr.

Vinayak Hemadri for his exemplary guidance, monitoring and constant encouragement

throughout the course of this thesis. The blessing, help and guidance given by him time to

time shall carry me a long way on the journey of life in which I am about to embark. I also

take this opportunity to express a deep sense of gratitude to the mentor for his cordial

support, valuable information and guidance, which helped me in completing this task through

various stages.

Lastly, I thank almighty, my parents, and friends for their constant encouragement

without which this assignment would not be completed.

4
 ABSTRACT

A fluid power system is defined as a means of power transmission in which a

relatively incompressible fluid is used as the power transmitting media

The primary purpose of fluid power system is the transfer of energy from one

location to another and this energy into useful work. By this hydraulic jack is used to lift the

fork. In industries this kind of fork lift can be used in order to decrease the human effort. This

type of fork lift need less maintenance and logs days of operational quality.

5
 TABLE OF CONTENTS

CHAPTER NO TITLE PAGE NO

ABSTRACT 5

LIST OF FIGURES 6

LIST OF TABLES 8

1. INTRODUCTION

1.1 PRINCIPLES OF HYDRAULIC JACK 10

1.2 PASCAL’S LAW 10

1.3 ADVANTAGES 11

1.4 DISADVANTAGES 12

CHAPTER 2

2.1 BLOCK DIAGRAM 13

2.2 FORKLIFT 15

2.3 WHY USE FORKLIFT? 16

2.4 COMPONENTS 17

2.5 HYDRAULIC CYLINDER 17

2.6 HYDRAULIC FLUID 18

2.7 ARM 19

2.8 HYDRAULIC FLUID 21

2.9 BRAKE FLUID 22

2.10 TYPES OF LUBRICANTS 25

6
CHAPTER 3

3.1 WHY PREFER HYDRAULCS OVER PNEUMATICS 27

3.2 WORKING PRINCIPLE 28

3.3 MAINTENANCE AND STORAGE 29

3.3.1 LUBRICATING 30

3.4 MAINTAINING OIL LEVEL 32

3.4.1 IMPORTANT NOTE 33

3.4.2 ADDING OIL 34

3.4.3 REPLACING OIL 34

3.4.4 CLEANING 34

3.4.5 STORAGE 35
3.4.6 REPAIRING JACK 35

CHAPTER 4

4.1 PROPOSED MODEL - HYDRAULIC FORK

WITH JACK OF LIFITING CAPACITY 2 TONNES 36
4.2 PROPOSED MODEL - HYDRAULIC FORK

CRANK ROD FOR LIFITING AND PRESSURE PRODUCER 37

4.3 HARDWARE USED IN PROJECT 37

4.4 TOOLS USED IN PROJECT 38

CHAPTER 5

5.1 CONCLUSION 39

REFERENCES 40

7
 LIST OF FIGURES

FIGURE.NO NAME PAGE.NO

1.1 Pascal’s Demonstration Setup 10

2.1 Hydraulic Fork Lift 12

2.4 Working Of Hydraulic Fork Lift 13

2.8 Sketch Of Reservoir 15

3.3.2 Sketch Of Ram cylinder 17

3.4.2 Working Of Hydraulic force with oil 20

4.1 Proposed Model - Hydraulic Fork with Jack Of Lifting

Capacity 2 Tonnes 19

4.2 Proposed Model - Hydraulic Fork Crank Rod For Limiting

And Pressure Producer 20

8
 CHAPTER 1

1.1 INTRODUCTION

There are mainly two types of fluid power systems:

 Hydraulic Power System( employing liquids)

 Pneumatic Power System(employing air)

1.2 Pascal’s law

Pascal’s law states that the pressure applied anywhere to a confined liquid is transmitted

equally to every portion of the surface of the containing vessel. When a force is applied to the

liquid by a piston, the liquid transmits this force equally to all surfaces of the container.

Fig 1.1: Pascal’s demonstration setup

9
1.3 ADVANTAGES

 The process uses low- cost energy source

 Large machines frames are not required on the process

 No extra skill is required for operating this system

 Easier maintenance

 Less loss in power transmission

1.4 DISADVANTAGES

 Machining work is very complicated

 Very sturdy base needed

 Hydraulics components cost is high

The forklift one man was driving in 1996 was not fitted with a seatbelt forklift

attachment. When the forklift began to tip over due to a faulty rear axle and a fault in the

steering mechanism, the driver instinctively attempted to jump out of the cab to safety.

Instead, he was pinned beneath the forklift’s overhead guard and died. This tragic accident

highlights the vital importance of safety attachments on forklifts. In this case, several things

could have prevented the accident.

Had the older model forklift been retro-fitted with a seatbelt forklift attachment, the man

would not have been able to attempt to jump out of the cab. He would have been held

securely within the protective confines of the steel structure that supported the overhead

guard. He would have probably been injured anyway, but he most likely would not have died.

10
 A forklift mechanical attachment like a seatbelt or a replacement part like an axle or

portion of a steering mechanism is not an expensive purchase. The lesson from this example

(and there have been many other similar accidents since) is that forklift safety is important.

Every day, a brief inspection should be carried out. Tire pressure, for instance, is

extremely important, because low pressure in a tire or tires can allow the forklift to tilt

beyond its design capabilities and tip over. Are there cracks, deformations or other signs of

weakness in the forks, masts, overhead guard or seat backrest? If so, find the proper forklift

attachment and replace the defective part.

The lights, horn and any other warning devices should be checked daily, as well. If the

forklift is not fitted with a reverse beeper, this is one forklift attachment that should seriously

be considered. Accidents happen frequently when forklifts are travelling in reverse, when the

operator has poor visibility.

These are just a few of the safety precautions that every forklift operator should take.

Thorough training and a complete understanding of forklift operation and safety, combined

with safety forklift attachments can and do save lives. Hydraulic jack works on the principle

of ―Pascal‘s law‖. When the handle is operated, the plunger reciprocates then the oil from

the reservoir is sucked into the plunger cylinder during upward stroke of the plunger through

the suction valve. The oil in the plunger cylinder is delivered into the ram cylinder during the

downward stroke of the plunger through the delivery valve. This pressurized oil lifts the load

up, which is placed on top plate of the ram. After the work is completed the pressure in the

ram cylinder is released by unscrewing the lowering screw thus the pressure releases and the

11
ram is lowered, then the oil is rushed into the reservoir. It consists of plunger cylinder on one

side and ram cylinder on the other side. These two cylinders are mounted on base which is

made of mild steel. Plunger cylinder consists of plunger which is used to build up the

pressure by operating the handle. Plunger cylinder consists of two non-return valves i.e. one

for suction and other for delivery.

Ram cylinder consists of ram which lifts the load. The ram cylinder connected to

delivery valve of plunger cylinder. It is also consists of lowering screw this is nothing but a

hand operated valve used for releasing the pressure in the ram cylinder for get down the load.

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 where there is a lot of switch back in a short distance assuming loading

work to a truck. shows the frequency distribution of engine speed and torque at the high load

course 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.

In cooperation with Power Train Development Centre and Hydraulic Equipment Technical

Centre, we have realized commercialization of forklifts installed with electronically

controlled HST and CLSS hydraulic system for the first time as Komatsu. We will continue

to make efforts to expand the model line-up 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.

12
 CHAPTER 2

2.1 BLOCK DIAGRAM

Fig 2.1.1: Hydraulic fork lift

For more than 150 years since the birth of the modern elevator, lifts have formed an

important part of our life. While lifts are widely used for transporting men to higher floors,

and in multi-storeyed buildings all over the world, there is also a completely different use for

lifts, as far as work and industries are concerned.

At such places, lifts are increasingly required to raise heavy loads in the form of

machinery, and equipment at different levels. Due to the heavy weight to be lifted, the

standard roped elevator design is not very efficient for the purpose.

The forklift one man was driving in 1996 was not fitted with a seatbelt forklift

attachment. When the forklift began to tip over due to a faulty rear axle and a fault in the

steering mechanism, the driver instinctively attempted to jump out of the cab to safety.

Instead, he was pinned beneath the forklift’s overhead guard and died. This tragic accident

13
highlights the vital importance of safety attachments on forklifts. In this case, several things

could have prevented the accident.

Had the older model forklift been retro-fitted with a seatbelt forklift attachment, the man

would not have been able to attempt to jump out of the cab. He would have been held

securely within the protective confines of the steel structure that supported the overhead

guard. He would have probably been injured anyway, but he most likely would not have died.

A forklift mechanical attachment like a seatbelt or a replacement part like an axle or

portion of a steering mechanism is not an expensive purchase. The lesson from this example

(and there have been many other similar accidents since) is that forklift safety is important.

A hydraulic lift typically uses hydraulic cylinders to either raise or lower platforms for work,

or other lifting devices. Hydraulic lifts are ideally used for support, as well as lift and move

heavy to very heavy, and large objects; at the same time providing a safe environment that is

ergonomically useful. While hydraulic lifts are mainly used for loading, and positioning work

objects, at times this can also used for transporting personnel, if required. The kind of

hydraulic lift to be used in a particular situation will depend upon the style of the platform,

and its mounting style, as well as the material that it uses. Commonly used types of hydraulic

lifts are table lifts, dock lifts, forklifts, pallet lifts etc.

2.2 FORKLIFT

A forklift truck (also called a lift truck, a fork truck, a forklift, or a tow-motor) is a

powered industrial truck used to lift and transport materials

14
 Forklift attachments are used to increase the number of functions performed by a

forklift. Forklifts are basically designed to lift rectangular loads and carry them from one

place to another. With the help of attachments, it can perform a number of varied tasks.

A forklift consists of a fork shaped lifting mechanism that is powered using a

hydraulic system. All the attachments are designed to fit in the forks or projecting platform of

the forklift. Some attachments are also connected to the hydraulic system of the forklift. A

range of attachments like waste handling, sweeping machines, drum handling equipment,

snow ploughs, salt spreaders and others are in use today.

These attachments make the forklifts more versatile, and save considerable costs for a

company or warehouse that uses it. Safety attachments like fork fenders can be used to warn

people of moving forklifts. Companies also design customized attachments based on the

exclusive needs of the customer.

The forklift one man was driving in 1996 was not fitted with a seatbelt forklift

attachment. When the forklift began to tip over due to a faulty rear axle and a fault in the

steering mechanism, the driver instinctively attempted to jump out of the cab to safety.

Instead, he was pinned beneath the forklift’s overhead guard and died. This tragic accident

highlights the vital importance of safety attachments on forklifts. In this case, several things

could have prevented the accident.

Had the older model forklift been retro-fitted with a seatbelt forklift attachment, the man

would not have been able to attempt to jump out of the cab. He would have been held

securely within the protective confines of the steel structure that supported the overhead

guard. He would have probably been injured anyway, but he most likely would not have died.

15
 A forklift mechanical attachment like a seatbelt or a replacement part like an axle or

portion of a steering mechanism is not an expensive purchase. The lesson from this example

(and there have been many other similar accidents since) is that forklift safety is important.

New attachments are constantly being designed so that forklifts can enter new work areas and

improve cost effectiveness. However, some of these attachments create handling problems, as

they are heavy and do not have lifting handles. Attaching and removing these can take a lot of

time and effort. Apart from these, other attachments certainly add value to a forklifts

performance. The kind of hydraulic lift to be used in a particular situation will depend upon

the style of the platform, and its mounting style, as well as the material that it uses.

Commonly used types of hydraulic lifts are table lifts, dock lifts, forklifts, pallet lifts etc.

2.3 WHY USE FORKLIFT?

 To reduce the human effort

 To make the work easy and simple

 To reduce the time taken

2.4 COMPONENTS

 HYDRAULIC CYLINDER

 PUMP

 STRUCTURE

 ARM

16
  WHEELS

 HYDRAULIC FLUID

Fig 2.4 Working Of Hydraulic Fork Lift

2.5 HYDRAULIC CYLINDER

 They convert the pressure energy of fluid into mechanical output to perform useful

work

 The fluid power is converted into straight line reciprocating motion 2.6 ARM

 It is made by joining pieces of steel and made into a frame

 The arm is used to load the objects on it

17
2.6 HYDRAULIC FLUID

 Hydraulic fluids, also called hydraulic liquids, are the medium by which power is

transferred in hydraulic machinery

 Common hydraulic fluids are based on mineral oil or water

 The primary function of a hydraulic fluid is to convey power

 In use, however, there are other important functions of hydraulic fluid such as

protection of the hydraulic machine components

2.7 ARM

 It is made by joining pieces of steel and made into a frame

 The arm is used to load the objects on it

2.8 HYDRAULIC FLUID

• Hydraulic fluids, also called hydraulic liquids, are the medium by which power is

transferred in hydraulic machinery

• Common hydraulic fluids are based on mineral oil or water

• The primary function of a hydraulic fluid is to convey power

• In use, however, there are other important functions of hydraulic fluid such as

protection of the hydraulic machine components

18
 Fig 2.8 Sketch Of Reservoir

2.9 BRAKE FLUID

Brake fluid is a subtype of hydraulic fluid with high boiling point, both when new

(specified by the equilibrium boiling point) and after absorption of water vapour (specified by

wet boiling point). Under the heat of braking, both free water and water vapour in a braking

system can boil into a compressible vapour, resulting in brake failure. Glycol-ether based

fluids are hygroscopic, and absorbed moisture will greatly reduce the boiling point over time.

Mineral oil and silicone based fluids are not hygroscopic. Because industrial hydraulic

systems operate at hundreds to thousands of PSI and temperatures reaching hundreds of

degrees Celsius, severe injuries and death can result from component failures and care must

always be taken when performing maintenance on hydraulic systems. The forklift one man

was driving in 1996 was not fitted with a seatbelt forklift attachment. When the forklift began

to tip over due to a faulty rear axle and a fault in the steering mechanism, the driver

19
instinctively attempted to jump out of the cab to safety. Instead, he was pinned beneath the

forklift’s overhead guard and died. This tragic accident highlights the vital importance of

safety attachments on forklifts. In this case, several things could have prevented the accident.

Had the older model forklift been retro-fitted with a seatbelt forklift attachment, the man

would not have been able to attempt to jump out of the cab. He would have been held

securely within the protective confines of the steel structure that supported the overhead

guard. He would have probably been injured anyway, but he most likely would not have died.

A forklift mechanical attachment like a seatbelt or a replacement part like an axle or

portion of a steering mechanism is not an expensive purchase. The lesson from this example

(and there have been many other similar accidents since) is that forklift safety is important.

Forklifts and pallet lifts are used to lift the load from the base or pallets. Forklift

trucks are a common sight at docks, as well as warehouses, and storage places. These

trucks are mobile forklifts that are used to lift and transport goods at short distances. Fork

lifts, and pallet lifts are used for loading, unloading, as well as storage and working

purposes. Tilt table are hollow bins with four sides, and (usually) open at the top. These

cannot only raise or lower the work piece, but can also tilt it an angle to place it in an

ergonomically optimal position to be worked upon.

The main reason for the widespread use of the hydraulic lifts is the benefits it provides by

creating ergonomically safe working conditions. This helps to greatly reduce, or even

eliminate the large amount of injuries caused to workers due to repetitive stress.

Such injuries frequently occur when the job is much more physically demanding as

compared to the physical limitations of the workers. Hydraulic lifts help to place the work

20
material at positions that is not awkward to the workers, in an easy, and safe manner. The

worker may not only benefit from the better posture for work, but the lifts can also help in

placing the objects in such a manner that the worker would require the minimum force, and

labor to get the job done. Due to creation of such work friendly environment, it not only

results in reduced injuries, but also better productivity on the part of the workers.

By using hydraulic lifts, this can be successfully achieved in a variety of conditions that

are otherwise very demanding or dangerous. Hydraulic lifts can also be used to move

materials horizontally, as well as vertically. Many hydraulic lifts come with wheel, and are

thus mobile in nature, and thus can be used in various situations (the best example being the

forklift truck). For sustained use in a repetitive work environment, hydraulic lifts can be

permanently fixed, and be made a part of the process line. In a manufacturing workshop,

smaller hydraulic lifts are commonly used for holding and moving various products.

2.10 Types of Lubricants

The requirements that lubricants need to satisfy generally consist of the following.

(1) High oil film strength

(2) Low friction

(3) High wear resistance

(4) High thermal stability

(5) Non-corrosive

(6) Highly anti-corrosive

(7) Minimal dust/water content

(8) Consistency of grease must not be altered to a significant extent even after it is

repeatedly stirred.

21
 Forklift trucks are a very important equipment that are needed on a daily basis. They

are necessary because they speed up the production process by loading and offloading the

raw material and finished product to and from the warehouse or factory. These equipments

are highly useful as they have a huge loading capacity that ranges from one to five tons. To

lift very heavy loads, those with a capacity of up to 50 tons are used. People can buy the

various forklift parts online.

These machines help in timely delivering of the products to the clients. If this

machinery is not working properly you immediately need to buy forklift truck parts. If you

don’t have the budget to buy new ones, you can buy used forklift parts that are maintained in

good condition and have the capacity to work in an efficient way. There are several

companies that sell forklift parts online, but you need to choose one that satisfy your

requirements. You need to research online and narrow down your search to a few selected

companies which provide quality forklift spare parts. You can also check their testimonials

and be assured of the quality of the products and services they provide.

Background check for the company you have chosen and know the services they

provide along with the products. You should ask them beforehand whether they get the part

fixed themselves or not. Also, see whether they provide warranty for the replacement parts as

you’ll not want unnecessary expenses to be made on replacing them. You can get the

assistance of technicians who can suggest the right forklift part for your truck and thus save

time and energy.

So, whether you want a mast, load back rest, overhead Guard, cab, counter weight, tilt

cylinders, side shifter, wheels, rotator, mast rollers, pole attachments, man basket, starters etc,

you can order them online. With all the information gathered of a reputed company providing

22
forklift parts you can order for the needed forklift truck parts easily online. You can get them

at Low price side shifters and therefore you can reduce your the cost of the production

process.

The forklift one man was driving in 1996 was not fitted with a seatbelt forklift

attachment. When the forklift began to tip over due to a faulty rear axle and a fault in the

steering mechanism, the driver instinctively attempted to jump out of the cab to safety.

Instead, he was pinned beneath the forklift’s overhead guard and died. This tragic accident

highlights the vital importance of safety attachments on forklifts. In this case, several things

could have prevented the accident.

Had the older model forklift been retro-fitted with a seatbelt forklift attachment, the man

would not have been able to attempt to jump out of the cab. He would have been held

securely within the protective confines of the steel structure that supported the overhead

guard. He would have probably been injured anyway, but he most likely would not have died.

A forklift mechanical attachment like a seatbelt or a replacement part like an axle or

portion of a steering mechanism is not an expensive purchase. The lesson from this example

(and there have been many other similar accidents since) is that forklift safety is important.

23
 CHAPTER 3

3.1 WHY PREFER HYDRAULCS OVER PNEUMATICS?

 The force required to accelerate oil is many times greater than that required to

accelerate an equal volume of air

 Liquids also exhibit greater viscosity than gases. This results in larger frictional

pressure

 Due to compressibility of air, it is impossible to obtain a precise control of actuator

velocities in pneumatic systems

Table 3.1.1 Materilas used in this setup

24
1) Reduction in fuel consumption Reduction in power transmission loss thanks to the

electronically-controlled HST Realization of low fuel consumption in high load work by

controlling engine output in accordance with cargo weight Reduction in oil pressure loss

during simultaneous operation of load handling system and travel drive system thanks to

CLSS + variable pump

(2) Improvement in operability and workability Travel operation has become easier than that

of T/C forklifts due to the adoption of electronically-controlled HST. Improvement in

workability during stopping, hill starting and switch-back operation

(3) Improvement in safety Travel speed limiting function as standard equipment

The clutch is attached to the output shaft of the transmission and when the inching pedal is

depressed, power is shut off. If you want to travel forward slowly while operating the load

handling system fast (simultaneous operation of load handling and travel), depress the

accelerator pedal to increase engine speed and adjust clutch slip with the inching pedal to

control the travel speed.

The engine rotates the pump to produce oil pressure, which is converted again to turning

force with the motor. A flow rate of hydraulic oil is continuously increased or decreased by

changing the angle of the swash plate connected to the pistons to change the piston stroke.

This swash plate angle control realizes the stepless speed control from forward travel, stop to

reversing. When the swash plate is moved to the neutral position, the piston stroke stops,

producing the same effect as the application of the brake. When the inching pedal is

depressed, the HST pump swash plate moves to the neutral position and the machine stops.

During simultaneous operation of load handling and travel, depress the accelerator pedal to

increase engine speed, change a HST pump capacity control signal from the controller with

the inching pedal and adjust the swash plate angle (oil quantity) to control the travel speed. A

25
variable pump is used also for the hydraulic system of load handling system and supplies

only a necessary quantity of oil with a signal from the operating valve.

Forklifts are often operated in a limited place, and acceleration and stop (with change in

travel direction, forward and backward), and simultaneous operation of load handling and

travel are frequently performed. This type of usage is more remarkable in a worksite with

higher load and higher rate of operation. As such condition also makes the fuel consumption

larger, users have a keen interest in fuel consumption reduction. In consideration of such

worksites where fuel consumption reduction has a large merit to customers, the following

fuel consumption reduction technologies have been incorporated.

Reduction in heating loss and slip loss by HST In simultaneous operation of load handling

and travel of a T/C forklift, clutch slip loss and heating loss are produced because speed

control is performed by controlling the clutch slip with the inching pedal. On the other hand,

on a HST forklift, the travel speed is controlled by changing the pump swash plate angle to

reduce the oil flow rate instead of slipping the clutch. Therefore, heating loss and slip loss are

not produced, resulting in fuel consumption reduction.

High efficiency in low travel speed zone In a torque converter (3 elements, 1 stage, dual

phase type) used generally for forklifts, efficiency in the high travel speed zone is high due to

a free wheel, but efficiency is worse than that of HST in the low travel speed zone due to

large churning loss. Therefore, on a HST forklift, control is performed to suppress the rev-up

of engine while improving the acceleration performance, reducing fuel consumption during

acceleration without changing travelling performance.

26
3.2 WORKING PRINCIPLE

 The hydraulic cylinder consists of a hollow tube sealed at one end with a movable,

lubricated piston fitting into the other

 The hydraulic fluid is present inside the cylinder which acts as the force medium for

this operation

It enters the bottom of the cylinder through a special "one way" valve that allows fluid to

enter without leaking back out.

Fig 3.2 Sketch Of Ram Cylinder

3.3 MAINTENANCE AND STORAGE

3.3.1 Lubricating

All moving parts on jack should be lubricated every month with a general purpose

grease to maintain efficient operation. Apply grease to joints on lift arm hinges, push rods;

27
handle base, rear caster wheels, front roller, etc. Lifting arm pivot point #37 needs to be well

lubricated or jack may make creaking sounds under heavy loads.

When using an LM system, it is necessary to provide effective lubrication. Without

lubrication, the rolling elements or the raceway may be worn faster and the service life may

be shortened.

A lubricant has effects such as the following.

(1) Minimizes friction in moving elements to prevent seizure and reduce wear.

(2) Forms an oil film on the raceway to decrease stress acting on the surface and

extend rolling fatigue life.

(3) Covers the metal surface to prevent rust formation.

To fully bring out an LM system’s functions, it is necessary to provide lubrication according

to the conditions.

It is necessary to study the mounting positions of the grease nipple and piping joint

according to the installation direction.

If the mounting orientation of the LM Guide is other than horizontal installation, the lubricant

may not reach the raceway completely. Be sure to let know the installation direction and the

exact position in each LM block where the grease nipple or the piping joint should be

attached.

• the amount of oil to be supplied varies with stroke length. For a long stroke, increase

the lubrication frequency or the amount of oil so that an oil film reaches the stroke

end of the raceway.

• In environments where a liquid coolant is spattered, the lubricant will be mixed with

the coolant, and this can result in the lubricant being emulsified or washed away,

causing significantly degraded lubrication performance. In such settings, apply a

lubricant with high viscosity kinematic viscosity: approx. 68 cst) and high

28
 emulsification-resistant, and adjust the lubrication frequency or the amount of the

feed lubricant. For machine tools and similar devices that are subject to heavy loads

and require high rigidity and operate at high speed, it is advisable to apply oil

lubrication.

• Make sure that lubrication oil normally discharge

Hydraulic Pressure

• Pressure transducer is mounted in lift truck hydraulic circuit

• Pressure transducer not exposed to shocks and vibration

• Pressure transducer not affected by the environmental conditions

• Hydraulic pressure transducer weighing system does not have moving parts

• Hydraulic pressure transducer weighing system does not have cable installed along

the vehicle mast

• Hydraulic pressure transducer weighing system will not reduce lifting capacity of the

vehicle

• Hydraulic pressure transducer weighing system will not reduce the visibility to the

forks

• Hydraulic pressure transducer weighing system can be installed and operated on

vehicles regardless of the lifting capacity

• Hydraulic pressure transducer weighing system is robust and can operate in hazardous

environments

• Hydraulic pressure transducer weighing system can be easily moved from vehicle to

vehicle

• Hydraulic pressure transducer weighing system can be used in combination with any

kind of accessories and attachment

29
Load Cell Weighing Systems

• Load cells are sensitive elements

• Load cells assemblies must be protected from environmental influences

• Any forklift collision or "bumping" into the external elements within the operational

facility will disturb the scale accuracy

• In many cases any "bumping" will create weighing errors and is some cases damaging

the scale

• Carriage or forks mounted load cells systems are situated exactly where the lift truck

is most sensible and receives most of the bumps and vibrations

• The vehicle "bumps" is the reason why load cell based weighing systems suffers

break downs, constant maintenance, frequent technical service due to the need for re-

calibration of the system and in many cases replacement of the load cells

• The carriage plate load cell weighing systems will reduce the lifting capacity of the

vehicle from 20 to 25%

• The carriage plate load cell weighing systems will reduce the visibility to the forks

and the load being handled

• The load cell weighing systems can not be moved from vehicle to vehicle

• Installation must be done by qualified staff

• Load cell based weighing systems requires frequent maintenance

• Initial cost for the system purchase is high

30
3.4 Maintaining Oil Level

3.4.1 Important Note:

When adding or replacing oil, always use SAE 10 Hydraulic Jack Oil. Avoid mixing

types of oil. DO NOT use Brake Fluid, Alcohol, Glycerine, Detergent, Motor Oil or Dirty

Oil, Improper fluid can cause serious internal damage to Jack.

3.4.2 Adding Oil:

With head cap fully lowered & jack on level ground, remove Air Vent Valve. Oil

level should be visible at the air vent valve hole approx 12 mm below valve hole, do not

overfill. If low, add oil as needed then close air vent valve.

Fig 3.4.2 Working Of Hydraulic force with oil

3.4.3 Replacing Oil:

For better performance & longevity, replace oil supply once a year. To drain oil, open

Air Vent Valve and loosen the release Valve by turning handle counter clockwise. BE VERY

31
CAREFUL not to permit dirt or foreign matter to get into the system. Invert jack over

suitable container and allow oil to drain. Close release valve by turning handle clockwise, fill

with SAE 10 Hydraulic Jack Oil close Air Vent Valve wipe away any spilt fluid. Test jack

before lifting a load.

3.4.4 Cleaning

Jack should be wiped clean with soft cloth only. Do not use gasoline, kerosene, or

other such solvents or any abrasive cleanser as cleaning agents and solvents will cause

deterioration of the hydraulic seals.

3.4.5 Storage

Before storage, twist handle 1-1/2 turns counter clockwise to release pressure in

hydraulic cylinder. Leave handle in this position. Store jack on a level surface, in a clean

environment preferably indoors, in a dry area to protect jack from moisture.

3.4.6 Repairing Jack

There are no user serviceable parts except as outlined above. Only trained, licensed

and certified repair personnel should attempt any repairs or replacing of parts. Any

modifications to this jack, except those performed by the manufacturer, or their designee, will

void all warranties both written and implied

Hydraulic jack works on the principle of ―Pascal‘s law‖. When the handle is

operated, the plunger reciprocates then the oil from the reservoir is sucked into the plunger

cylinder during upward stroke of the plunger through the suction valve. The oil in the plunger

32
cylinder is delivered into the ram cylinder during the downward stroke of the plunger through

the delivery valve. This pressurized oil lifts the load up, which is placed on top plate of the

ram. After the work is completed the pressure in the ram cylinder is released by unscrewing

the lowering screw thus the pressure releases and the ram is lowered, then the oil is rushed

into the reservoir. It consists of plunger cylinder on one side and ram cylinder on the other

side. These two cylinders are mounted on base which is made of mild steel. Plunger cylinder

consists of plunger which is used to build up the pressure by operating the handle. Plunger

cylinder consists of two non-return valves i.e. one for suction and other for delivery. Ram

cylinder consists of ram which lifts the load. The ram cylinder connected to delivery valve of

plunger cylinder. It is also consists of lowering screw this is nothing but a hand operated

valve used for releasing the pressure in the ram cylinder for get down the load.

This pressurized oil lifts the load up, which is placed on top plate of the ram. After the

work is completed the pressure in the ram cylinder is released by unscrewing the lowering

screw thus the pressure releases and the ram is lowered, then the oil is rushed into the

reservoir. It consists of plunger cylinder on one side and ram cylinder on the other side. These

two cylinders are mounted on base which is made of mild steel. Plunger cylinder consists of

plunger which is used to build up the pressure by operating the handle. Plunger cylinder

consists of two non-return valves i.e. one for suction and other for delivery.

33
 Because forklift is a slow moving vehicles, the same risk it poses, such as a car or

truck. However, due to the nature of its work, the other, equally dangerous. Each security

forklift accessories serve a purpose, so they should not be taken lightly

It wasn’t until the 1990s that seatbelts became mandatory on forklifts. Unfortunately,

the forklift one man was driving in 1996 was not fitted with a seatbelt forklift attachment.

When the forklift began to tip over due to a faulty rear axle and a fault in the steering

mechanism, the driver instinctively attempted to jump out of the cab to safety. Instead, he

was pinned beneath the forklift’s overhead guard and died. This tragic accident highlights the

vital importance of safety attachments on forklifts. In this case, several things could have

prevented the accident.

Had the older model forklift been retro-fitted with a seatbelt forklift attachment, the

man would not have been able to attempt to jump out of the cab. He would have been held

securely within the protective confines of the steel structure that supported the overhead

guard. He would have probably been injured anyway, but he most likely would not have died.

A forklift mechanical attachment like a seatbelt or a replacement part like an axle or

portion of a steering mechanism is not an expensive purchase. The lesson from this example

(and there have been many other similar accidents since) is that forklift safety is important.

Every day, a brief inspection should be carried out. Tire pressure, for instance, is

extremely important, because low pressure in a tire or tires can allow the forklift to tilt

beyond its design capabilities and tip over. Are there cracks, deformations or other signs of

weakness in the forks, masts, overhead guard or seat backrest? If so, find the proper forklift

attachment and replace the defective part.

34
 The lights, horn and any other warning devices should be checked daily, as well. If

the forklift is not fitted with a reverse beeper, this is one forklift attachment that should

seriously be considered. Accidents happen frequently when forklifts are travelling in reverse,

when the operator has poor visibility.

These are just a few of the safety precautions that every forklift operator should take.

Thorough training and a complete understanding of forklift operation and safety, combined

with safety forklift attachments can and do save lives. Hydraulic jack works on the principle

of ―Pascal‘s law‖. When the handle is operated, the plunger reciprocates then the oil from

the reservoir is sucked into the plunger cylinder during upward stroke of the plunger through

the suction valve. The oil in the plunger cylinder is delivered into the ram cylinder during the

downward stroke of the plunger through the delivery valve. This pressurized oil lifts the load

up, which is placed on top plate of the ram. After the work is completed the pressure in the

ram cylinder is released by unscrewing the lowering screw thus the pressure releases and the

ram is lowered, then the oil is rushed into the reservoir. It consists of plunger cylinder on one

side and ram cylinder on the other side. These two cylinders are mounted on base which is

made of mild steel. Plunger cylinder consists of plunger which is used to build up the

pressure by operating the handle. Plunger cylinder consists of two non-return valves i.e. one

for suction and other for delivery. Ram cylinder consists of ram which lifts the load. The ram

cylinder connected to delivery valve of plunger cylinder. It is also consists of lowering screw

this is nothing but a hand operated valve used for releasing the pressure in the ram cylinder

for get down the load.

35
 CHAPTER 4

FABRICATION OF HYDRAULIC FORK LIFT

4.1 PROPOSED MODEL - HYDRAULIC FORK WITH JACK OF

LIFITING CAPACITY 2 TONNES

36
4.2 PROPOSED MODEL - HYDRAULIC FORK CRANK ROD FOR

LIFITING AND PRESSURE PRODUCER

37
4.3 HARDWARE USED IN PROJECT:
 Fabricated Scissor Jack

• Mounting Plate

• Threaded Screw

• Base Plate

• Bearing

• Coupling

• Movable Joints

• Steel Plates For Supporting

• Welding Electrodes

 Motor

 Hardware’s To Fit

 Power Supply

 Switch

 Castor Wheel

 Nut and bold

 Angle

4.4 TOOLS USED IN PROJECT:

 Welding Machine

 Screw driver

 Spanner

 Soldering Rod

 Soldering flux

38
4.4 ESTIMATION OF THE PROJECT:

HARDWARE WORKS ESTIMATION COST

FORK LIFT SET UP 500

CRANK ROD (CUTTING &SURFACING) 1500

BASE PLATE(CUTTING &GRINDING) 250

STEEL CASTOR WHEEL 500

NUTS AND BOLTS 250

HYDRAULIC OREING(LATHE) 1750

HYDRAULIC OIL RINGS(LATHE) 320

HYDRAULIC ASSEMBLING (RIVETING) 400

HYDRAULIC OIL 530

TOTAL 6000/-

39
 CHAPTER 5

CONCLUSION

 Thus we are able to reduce the effort and time taken by manual operation using

forklift

 Also there is less vibration when compared to other mechanisms and therefore even

fragile materials can be easily handled

 Hydraulic lifts require special care and regular maintenance to make sure it works in

the desired manner. Improperly maintained lifts can cause serious injury. As with any

hydraulic system, care should always be taken when operating hydraulic lifts. Even

when the whole system is shut down, the oil can still be under pressure, which can be

very dangerous if not handles properly. Leaks of hydraulic fluid are especially

dangerous, as it is at very high pressure, and has the capability of puncturing human

skin.

 Care should be taken to allow only those people that are properly trained in the use of
hydraulic lifts, and positioning vehicles are operating the equipment. The required

hydraulic pressure should always be maintained, and should never be allowed to cross the

recommended levels. The lift area should be kept clean of dirt, oil, tools, grit, etc. Also, it

is never a good idea to overload a hydraulic lift.

40
 REFERENCES

 http://www.engineersedge.com

 http://www.efunda.com

 http://www.steeltubeinstitute.org

 http://www.emjmetals.com

 http://www.usstubular.com

BOOKS REFERRED:

 1. Machine design by RS KHURMI

 2. Work shop technology by RK JAIN

41