Transcript Marketing

I.C. Products
Features and Benefits
I.C. Products
Clark Simpson
I.C. Product Manager
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Product Introduction Meeting 2005
I.C. Products
CLARK Uprights
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CLARK Upright Features
• High-strength, low-alloy steel.
– Excellent fatigue life.
– Good weldability.
– High yield strength
• Nested I-channel (not flat-faced)
• Silent staging.
• Cylinders internally “vented”.
• Large view window.
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CLARK Upright Features
• Drop rail design for easy roller replacement.
• Low-glare black paint.
• Carriage and rail section stops.
• Canted rollers design.
• Over-sized rollers
– Available through parts to account for wear.
• Velocity fuse.
• Flow control.
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Why Does CLARK Use I-Channel?
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Why Does CLARK Use I-Channel? Shear
Center Location
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Nested I-Channel
• Better arrangement of cylinders,
chains and hosing to maximize
view window width.
• Interlocking rails will not
separate if roller fails.
• Can use wider sections without
penalty. Stiffer upright design
makes for less deflection and
twisting.
• Better connection of tie-bars to
rail sections.
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Nested I-Channel
• Allows use of “external” side
thrust rollers
– Prevents inner rail from
spreading rails with side loads.
– Less carriage twisting from side
loads.
– Prevents carriage rollers from
riding at edge of flange.
• Increased stiffness
– Better resistance to twisting
– Less deflection due to loads
• Longer fatigue life, less wear
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Silent Staging-Raising
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Cushioning on primary and secondary cylinders when
raising, just prior to full extension.
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Oil is trapped and forced to bleed out slowly.
– No “clanging” during lifting.
– Avoid product damage.
– Longer component life.
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Silent Staging-Raising
Air
OIL
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Silent Staging-Lowering
• Cushioning on secondary cylinder when lowering, just
prior to full retraction.
• Oil is trapped and forced to bleed out slowly, providing
“cushioning” effect.
– No “clanging” during lowering.
– Avoid product damage.
– Longer component life.
• Not needed on primary cylinder since forks hit the ground.
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Silent Staging-Secondary Cylinder- Lowering
Trapped Oil
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Internally “Vented” Cylinders
• Seals designed to seep from
high pressure to low pressure.
– Keeps fluid on top for cushioning.
– Caution: Could run dry if wrong seal
used.
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If excessive oil leaks past piston and
is trapped on top side of piston, it
will bleed back to pressure side via
one-way valve.
– External return to tank not
needed.
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Sealed Canted Rollers
• Roller face in full contact with
rail flange.
– Increased contact area,
reduces flange stress and
bending.
• Radius of roller fits neatly in
radius of rail.
– Reduces side-to-side free
play.
– Eliminates need for slides or
side thrust rollers.
– Reduces “rattle”.
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Shimable Rollers
• Can install shims behind roller
to adjust clearance.
– Removes free play if wear
occurs.
Oversized Rollers
• Can install oversized rollers to
account for flange face wear.
– Retains tight fit.
– Extends life of rail sections.
Shim
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“Negative Drop” rails
• Allow rail rollers to be serviced without removing
upright from truck or dismantling upright.
• Lift cylinders are disconnected and rails lowered to
expose rollers for replacement or shimming.
– Minimizes time required to service upright.
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Large View Window
• Nesting allows space for
cylinders, hoses and
chain.
• Maintains excellent view
window even with 4-hose
internal.
• Hoses and chains are
over the top of the
primary cylinder for max
vision window.
• Lift chains share load,
side-loading no problem
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CLARK Carriages
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Carriage Features
• Six load rollers.
• External and/or internal sidethrust rollers.
• Heavy-duty fork bar sections.
• HSLA steel fork-bars and roller
brackets.
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Six Load Rollers
• Outermost rollers take load when in
carrying position.
• Maximum spacing lowers load when load
is highest:
– Bouncing while traveling.
– Ground level pick-up.
• Innermost rollers take load when upright
extended past free-lift.
– Not as much bouncing when upright is
extended.
• Allows for competitive lowered heights.
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Six Load Rollers
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Side-Thrust Rollers
• Carriages have internal
side- thrust rollers,
external or both.
• More effective control of
carriage under off-set
loading conditions.
• Mounted on eccentric
shaft that adjusts and
locks into place.
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Heavy-Duty Fork Bars and
Load Roller Brackets
• Made from HSLA steel.
• Massive section size.
– Better impact strength.
– Holds up better in demanding
operations.
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Fuel Systems
EPA 2004--EPA 2007
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EPA 2004 Spark Ignited Engines
• Low Emissions of unburned Hydrocarbons, Oxides of
Nitrogen and Carbon Monoxide
• Must meet requirements both new and throughout 3500
hours of use, cannot degrade out of specification
• System must be tamper-proof so that mechanics
cannot readjust and destroy fuel settings
Emission Levels--Grams per Horsepower-Hour
Exhaust
Certified Results
Emission Requirement Mit 4G-64 Mit 4G-63 GM 4.3
HC + Nox
3.0
2.1
2.1
0.6
CO
37.0
0.4
0.4
0.7
CO %
0.010
0.010
0.010
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The Basics
• Computer controlled fuel
mixture using oxygen sensor
• Three-way catalyst further
removes contaminants
• Patterned after automotive
systems
• Similar to conventional LP
systems with Trim Valve added
• Drive by wire
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EPA 2007--Large Spark Ignited Engines (LSI)
• Similar to 2004 levels of HC + Nox, Co during steady
state running.
• Must meet requirements during “transient” conditions,
(acceleration, deceleration, sudden load applied).
• System must be tamper-proof so that mechanics
cannot readjust and destroy fuel settings
• Technology not much different from 2004 to 2007
– Venturi systems (Impco, Woodward, Aisan) will shorten
response times to get back to “stoich”
• Major development is in testing to certify.
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System Strengths
• Simplicity
– Only one additional fuel system component, Trim Valve; all
remaining fuel parts are conventional
– Trim valve meters air, not fuel
– Service with fault codes and manual-expensive tools not
required
• Proven ECM
– Over 100,000 in use
– Manufactured by Motorola; quality, consistency excellent
• Self-Correcting
– “Adaptive Learn” allows adjusting for wear, fuel deposits
– Adapts to specific application-truck configuration, altitude,
operation
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Fabricated Axle Beam
• High strength ASTM A-572 steel
– good weldability, high impact
strength
• Extra thick top plate
– prevents deflection and
misalignment of kingpin bearing
for long life
• Deep “I-Beam” style design
– prevents bending under extreme
conditions
• Fully machined
– results in accurate bearing
alignment, steering geometry,
long life
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Knuckle
• Alloy steel forging
AISI 4140 forging heat treated for
superior fatigue life and impact
Steer Linkage
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Sealed, greaseable, spherical bearings
Double shear link pins
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Kingpin and Bearings
•Tapered Roller bearings
–Resist impact loads without fracture,
high capacity, long life
•Precision bearing adjustment
–Castellated nut allows precise bearing
adjustment, no bearing play
•“Captured” kingpin design
–Prevents deflection of top and bottom
plates, prevents uneven bearing loading
•Double metal seal
–Excludes dirt, fibers, retains grease
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Design Goals
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Enhance model family ergonomics
Improved cushion model footprint
Design a truck reflecting “Built To Last”
Improve performance
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Cushion Models
•C15C
3000 lb @ 24” L.C.
•C18C
3500 lb @ 24” L.C.
•C20sC 4000 lb @ 24” L.C.
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Pneumatic Models
•C15
3000 lb @ 24” L.C.
•C18
3500 lb @ 24” L.C.
•C20s 4000 lb @ 24” L.C.
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Dimensional Comparisons-Cushion
C15C
CMC 15
Toyota
Mitsubishi
Head room
39.5
37.5
37.8
Knee room
29.5
27.0
29.5
Knee room, sides
34
31
30.0
Foot room, center
13.5
12.5
17.0
Foot room, sides
18.0
12.5
18.0
Seat Back to Steer Wheel
17/23
13/19
15/20
OAW
37.0
40.0
37.0
38.2
Length
80.2
80.53
82.3
82.0
Height over guard
81.1
79.1
80.1
81.1
Load Center Distance
14.9
14.63
15.7
15.3
Drawbar Pull
3913
3530
3750
4245
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Dimensional Comparisons-Pneumatic
C15
CMP 15
Toyota
Mitsubishi
Head room
40.25
37.5
40.1
Knee room
31.0
27.0
Knee room, sides
37.5
29.0
Foot room, center
16.0
12.5
17.0
19.0
Foot room, sides
21.0
12.5
18.0
13.0
Seat Back to Steer Wheel
17/23
13/19
15/20
15/21
OAW
42.1
43.7
42.2
42.0
Length
86.4
85.5
88.4
89.0
Height over guard
83.5
81.0
81.9
83.0
Load Center Distance
15.5
15.0
15.8
15.7
Drawbar Pull
3908
2980
3950
4125
31.0
33.0
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Styling Comparison
C15C
C25C
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Model Commonality
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Mitsu. 4G63 2.0L same base engine as CMC/CMP15/20S
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EPA compliant fuel system common with GEN2
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TA12 transmission w/ gearing improvements common with
CMC15/20S, CMP15/20S, GCX/GPX12/17E
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Base upright common with TMG including hosing kits, carriages,
LBR's
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Instrument panel with all improvements, common with GEN2
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Tilt steering column / wheel common with GEN2
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Hood latch system similar to CMC / CMP – No Cables
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Operator Compartment
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80 dba - weighted average at
operator’s ear - various
engine speeds and periods
of time per ASME test
requirements
Designed for 95 percentile
person - additional
headroom, seat travel
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Operator Compartment Comparison
C15C
CMC 15
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Operator Compartment Comparison
Mitsubishi
Toyota
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Operator Compartment
• Welded Integral Structure
– Structural rigidity
– Optimum Visibility
– Forward/upward
• Modular design
– Simple removal
(4 bolts/wiring/plumbing)
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Operator Compartment
• Welded, integral construction
– Long lasting, more strength
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•Cell mounted on rubber
isolators
-Reduced vibration
-Less fatigue
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Operator Compartment
•Pneumatic same as Gen 2
–Open steps both sides
–Cowl-mounted levers
•Cushion similar
–Vertical dimensions
identical
–Right side step only
–4.5 in narrower
–Cowl, rear guardleg more
vertical
–18 in foot space vs 21
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Operator Compartment
• Low Step
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15.2 in height on cushion
Easy on, easy off
Non-slip tread
Excellent traction
• Large step
• 5 in. deep, even fits boots
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Operator Compartment
•Low Step
-16 in. pneumatic
-Easy on, easy off - either
side
•Non-slip treads
-Excellent traction
•Large steps
-5 in. deep, even fits boots
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Operator Compartment
• Floor plate - no tools required for
removal
– Uncluttered foot area
– Two-piece hinged construction always lays flat
• Floormat - thick, molded
– Reduces vibration
– Reduces noise
– Cushioned & comfortable
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Operator Compartment
• Brake pedals - 2-pedal system
- Proven most effective in lift truck
operation
• Left inching brake - slow forward
travel - maximum lift speeds
– Unmatched productivity
• Right brake - dedicated
– Prevents “roll-back”
• Operator has pedal choice
– Operator has full control
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Operator Compartment
Park Brake
• Foot Operated
– Uses strong leg muscles
– Easy operation
• Fingertip release
– Low effort
• Electric transmission interrupt
– Prevents driving against park
brake
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Operator Compartment
• Electrical fuse panel
mounted on front cowl
– Easy access
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Operator Compartment
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Easy to operate Hood Latch
No Cables
•
Simple Adjustment
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Operator Compartment
• Soft touch control valve levers
– Ergonomically correct
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– Easy to use, less fatigue
Single aux valve standard
– Adding attachments is made
easier
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Operator Compartment
• Directional control electrically
operated
– No adjustments necessary
• Fingertip operation
– Short travel
– Low effort
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Operator Compartment
• 2 front headlights on the OHG
are standard
– With the order of one rear
accessory light the complete
harness is included- optional
additional lights can easily be
connected
– Mounted inside the profile of
the overhead guard
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Instrument Panel Features
•
Full LED/digital display
– No mechanical parts to replace
•
3 pieces; top/bottom housing,
circuit board
– Rugged design
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Common with GEN2
Hi-impact resistant polymer
Sealed with gasket – Truck can be steam cleaned
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Circuit board is coated with
moisture resistant film
Heat and extreme cold protected
Ultra Violet protected– Sunlight does not affect surface
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Instrument Panel
Design features
-No maintenance instrument panel
-Eliminate relays and switches for
lights
-No bulbs to burn out
-Horn will sound if the park brake
not set when key is turned off
-Powertrain protection
-Liquid Crystal Display (LCD) hour
meter
-Maintenance interval indicator
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Instrument Panel
•Maintenance interval programmable to customer
requirements
-Can be set to 50 hour increments
-Time remaining until scheduled service indicated on
LED display upon each start
-Maintenance indicator illuminates when scheduled
maintenance is due
•Operator and Maintenance personnel have clear
indication of truck service status
•Facilitates tracking of fleet maintenance
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Instrument Panel
Features
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Negligible current draw with Key
Off (.010 amp). Typical automotive
practice is .007to .012 amps.
Positive starter lockout-engine
must be stopped for 2 seconds
before starter will crank
Failsafe hour meter-cannot lose
hours due to faults
Key switch turns off electrical
system
Programmable headlight and work
light function
Key switch controlled accessory
fuse block
If key switch is left on with engine
off, lights shut off after 5 minutes
Reverse polarity protection
Voltage spike protection
Short circuit protection-shorted
circuit displayed as fault code
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Instrument Panel
• Major Component
– Covered by 2 year / 4000 hour
Standard Owner Protection
Warranty
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Shutdown functions - protects investment
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Low oil pressure
High engine coolant temperature
High transmission oil temperature
Fuel system malfunction
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Powertrain
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TA-12 Transaxle
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Electric Solenoid controlled
forward-reverse shifting
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“Modulated” clutch
engagement gradually
increases clutch pressure
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Smooth, jerk-free direction
changes
“No drive” park brake
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Eliminates mechanical linkage
that requires adjustment and
high effort
Applying park brake puts
transmission in neutral
Hydraulic inching control
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Allows smooth, positive
transmission engagement at
high engine speeds and low
travel speeds
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TA-12 Transaxle
• TA-18 Charge Pump
• TA-18 Cooler Bypass Circuit
– Speeds convertor filling on
start-up
– Prevents “Morning
Sickness”
• Cast-Shoe, Perrot-Style
drum and shoe brakes
– Long life
– Low noise
• Single-stage master cylinder
• Higher gear ratio for
pneumatic models
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Engine
• 2.0 liter dynamic internally
balanced, overhead cam Mitsubishi
engine
– Proven reliability on current trucks
– Simple design and fewer parts
• EPA compliant low emission fuel
system
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Improved acceleration
Improved fuel economy
Increased speed on long runs
Minimal CO, HC, NOx emissions
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Engine
Air intake System
• High air intake
- Provides clean and cooler air for
engine, also location reduces
noise level
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Engine Air Intake System
• High efficiency 2 stage air intake
system
– Long engine life
• Air restriction indicator is
standard equipment
– Visual warning when air filter
needs service
• Optional safety element and precleaner
– Additional protection for engine in
dirty environments
– Operator’s cell is pre-punched for
field installed pre-cleaner
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Engine Cooling System
• 3 row, 8 fin per inch, 313 sq. in.
open core with plate/fin design
and 9 plate water to oil cooler
– Reduced plugging, better
tolerance for pushing loads, high
cycle operations
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Engine Cooling System
• Venturi type shroud and 7
blade plastic fan
– High air volume, low noise
cooling system
• Radiator hand guard
standard equipment
– Protection from accidental
injury in radiator
• Radiator fan centered
–
More efficient air flow
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• Over 900 parts common with existing models
– For example, hosing, upright components and
sideshifter common with TMG
– Pneumatic operator compartment, steering
components, pedals, floorboard, hood
– Transaxle gearing, brakes, axle components
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Optional Equipment
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Convenience console
Cloth & suspension seats
Mirrors
Swing-down LP bracket
Seat activated engine shutdown
protection
Mounting holes provided for options
standard on cell
Speed Control
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Optional Full Suspension Seat
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Full 60 mm travel
Constant ride height
Wide weight range--designed for
operators from 90 to 350 lb.
“Dial in” weight adjustment--put the
pointer on your weight.
Easy adjustment--no springs are
compressed
Easy cushion replacement--two
screws and no dismantling
suspension parts.
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Gen 2 Features and Benefits
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Operator Compartment
• Optional factory installed cab
• One piece door
– Folds back for easy access to
seat deck
• No side pillar
– Better visibility to the side
• Heater mounted on right-side
door
– No obstructions on floor or
front cowl
• Front and rear wiper with
washer
• AM-FM Radio
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Akebono Brake System
• Automotive style drum and hub
easily removable drum
– Ensures quick Serviceability
• Basic brake used by Toyota,
Nissan, Mitsubishi, Hyster and
Yale. Clark lining has improved
friction and wear characteristics
– Proven in many other lift
trucks
• New heavier backing plate,
reinforced shoe anchor, larger
shoe tables
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Transaxle Controls
• Electric Solenoid controlled
forward-reverse shifting
– Eliminates mechanical linkage that
requires adjustment and high effort
• “Modulated” clutch engagement
gradually increases clutch
pressure
– Smooth, jerk-free direction
changes
• “No drive” park brake
– Applying park brake puts
transmission in neutral
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Transaxle Seep Control
• Viton Seal Kit 934671 for Charge
Pump
– Applications with hard usage, high
temperatures, long hours
– Seals both pump gearing and
suction/supply connection
• Close fit Dipstick Tube Kit 1813270
– Machined case insert
– Tighter tolerance on fit
– Viton O-ring with back-up ring
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CGC 40/70 Features and Benefits
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Engine
• GM 4.3 liter (262 CID)
– Industry standard
• Cast iron head & block
– Proven durability
• Hydraulic lifters
– No maintenance
– Quiet running
• Hardened valve seats &
faces
– Long valve life on LP
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Engine
• Single balance shaft
– Reduces secondary
engine vibration,
improves operator
comfort
• Low speed, high torque
industrial engine
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Brake System
• Direct power assist system
• Steering pump provides
hydraulic power
• Full flow brake valve
meters hydraulic oil to
brakes
• No reservoir required- oil
provided by hydraulic
system
• Brakes can be bled by
simply opening bleeder
with engine running
• Later versions have
reduced “kickback”
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Service Brake
• Higher temperature “Cosid”
lining material
– Longer life in high cycle
applications
• Larger lining area on axle end
side of disc
– Longer life, less chance of
damage to axle housing
• High temperature “Viton”
piston seals
– Reduced leakage, longer life in
high cycle applications
• Plated steel pistons
– Closer seal tolerances
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Service Brake
• Inspection port added
– Allows easy access to
view lining and rotor to
allow inexpensive lining
change without damage to
brake pistons, discs
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Parking Brake
• Separate drum-type
parking brake
– Not affected by service
brakes
• Applies to transmission
shaft
– Multiples holding power
• Quick change lining
– Drum can be removed and
lining changed without
removing any other
components
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Steer Axle
• Double shear pins and linkage
– No tapered tie rod ends
– Sealed spherical bearings
• Interchangeable with old style
axle
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CMP 450 Features and Benefits
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Transaxle
• Pressure lubricated tapered
roller bearings throughout
the transmission
– Long life, good heat
dissipation
• Helical gearing
– Low noise, high torque
capacity
• Smooth inching, same
inching components from
TA-12,18
• Improved oil flow, clutch
spring retainer, bearing
adjustment
Helical Gears
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Transaxle
• Special Reman program
– New turbine shaft with
larger drilling, increased
oil flow
– Reworked Lube relief for
more oil flow
– Improved clutch spring
retainer
– Precision bearing
adjustment
– Flow and pressure tested
Helical Gears
• Order 930234REM
National Service Managers New
Product Introduction Meeting 2005
I.C. Products
CMP 20,25,30 Features
National Service Managers New
Product Introduction Meeting 2005
I.C. Products
Simple Design-Durable
Components
• Rugged curved beam
overhead guard
• Reliable Engines
– Mitsubishi 4G-64 EPA 2004
compliant LPG
– Yanmar 4TNV94 diesel
• Automatic engine shutdown
from low oil pressure or high
coolant temperature on LPG
engines.
• Long-Life Powertrain, steer
axle
National Service Managers New
Product Introduction Meeting 2005
I.C. Products
Simple Design-Durable
Components
• Proven TA-18 Transmission
• Electric shift control
• Long Lasting, “Perrot” style
brakes-same as CGC20/30
• Two-stage master cylinder
National Service Managers New
Product Introduction Meeting 2005
I.C. Products
CMP 50,60,70,75S Features
National Service Managers New
Product Introduction Meeting 2005
I.C. Products
Simple Design-Durable
Components
•
•
Proven T-12000 Dana/Spicer
Transmission, 3 speed
Electronic Gear Selector
– Prevents Fwd-Rev shifts
until speed is less that 1
mph
– Prevents overspeed
downshifts
– Starts in 2nd gear
– Twist grip for up and
downshifts
– Self diagnosing
National Service Managers New
Product Introduction Meeting 2005
I.C. Products
Simple Design-Durable
Components
• Pressure-compensated
hydraulic valve
– Hood mounted levers
mounted directly on valve
– Improve feathering
– Reduced lever effort
– Integral counterbalance in
tilt spool
– Minimal lift and tilt drift
– Reduced horsepower loss
– Simultaneous spool
function
National Service Managers New
Product Introduction Meeting 2005
I.C. Products
National Service Managers New
Product Introduction Meeting 2005