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Industrial Utility Vehicle & Mobile Equipment

E-Report
—May 2005—
 In this Issue:

New Vehicles & Mobile Equipment

Motive Power

Components

 

 

 Sponsored Announcement - Click here to have your company's message featured.
 

Innovative Motion Control Systems - Today and Tomorrow
The evolution of Electric Vehicles is driven by end-user requirements such as performance, ergonomics, safety and cost of ownership. Development of new technologies is of course vital. However, capacity in areas such as system application engineering, supply chain management and after sales support is required by large multinational OEMs. Efficient vehicle design, assembly, and procurement can be achieved by purchasing seamlessly integrated systems. Also, integrated motion control technologies enable OEM engineers to focus their efforts on developing specific functionalities and the overall feel of his vehicle.
This session will include a Lift Truck OEM case study illustrating the importance of innovation capabilities by discussing historic developments as well as future needs.
~Bill King, Danaher Motion

Sound Interesting? Then come see this and more at IUV Technology 2005!
IUV Technology 2005 will be held September 7-8, 2005 in Denver, CO and will focus on the latest advancements in the design, engineering and manufacturing of lift trucks, industrial & utility vehicles, mobile equipment and special-purpose off-highway vehicles and equipment.

 

 New Vehicles
 

Kawasaki's Mule 3010 Incorporates First Transformable Cargo Bed into a Four-Passenger, 4x4 Design
Kawasaki has introduced its new Mule 3010 Trans4x4, the industry's first four-passenger 4x4 off-road utility vehicle that can be transformed by the operator into a two-passenger vehicle with an extended cargo bed. Based on the 3000 series, the 3010 offers a four-passenger cab that can easily accommodates four adults. However, after a few quick adjustments that can be made in just a minute, the operator can fold down the rear bench seat and extend the cargo bed farther forward to increase payload capacity.
To compensate for the added cargo area Kawasaki made the 3010 Trans4x4's wheelbase 11.6-inches longer than that of the regular 3010. One of the benefits of this added size is that engineers were able to increase the fuel capacity nearly 20 percent from 5.3 gallons to 6.4 gallons. With this extra wheelbase, combined with a heavy duty DeDion/leaf spring rear suspension system the 3010 Trans4x4 has a cargo capacity of 400 lbs. in four-passenger guise and 800 lbs. capacity with the bed extended forward. Additionally, with an optional towing hitch the new Trans can tow up to 1,200 lbs., giving the utility vehicle a total load capacity of 1,330 lbs. Other suspension features include a MacPherson strut long travel front suspension that helps provide a smooth ride, even when the cargo box is empty.
"Design considerations for the Trans 4x4 included making a four passenger, versatile, 4x4 vehicle with the ability to comfortably move people in an off-road environment," said Hal Saito, assistant to president, and director of research and development at Kawasaki Motors Mfg.
Other considerations mentioned by Saito include, a high driver comfort level, a convertible rear sear and cargo bed configuration that can be convert quickly and easily without tools, a removable rear screen, designing the vehicle to hold four passengers with the shortest possible wheel base and a strong and rigid cab frame without disturbing the rear seating area.
"So of the main modifications made to the Mule 3010 included a stretched frame of 300 mm, an added rear folding type seat, the new bad frame and a two size, convertible carrier," said Saito.
To power the Mule 3010 trans4x4 Kawasaki utilized a 617cc, liquid-cooled V-twin engine. The four-stroke, overhead valve twin has a 76 mm bore and a 68 mm stroke and is fed by a Mikuni BW28-16 carburetor. Coupled with the 3010's engine is Kawasaki's continuously variable transmission (CVT).
The CVT has been designed to handle the Trans' higher passenger and cargo capacity, features a high/low range for forward and reverse. The operator can also select either two or four-wheel drive operation, with power being transferred to a shaft-driven, dual mode differential and limited-slip front differential that can be locked for added pulling power.
Additional features for the 3010 Trans4x4 include retractable rear seat belts, padded rear-passenger grab handles and dashboard and front under hood storage. Operator instruments include a parking brake warning light, coolant temperature warning light, horn, a 12 V DC outlet, two 5/21-watt taillight/brake lights and two 30 W sealed beam headlights. The Mule 3010 Trans4x4 is available in hunter green and Aztec red color schemes for $9,599 or in RealTree HardWoods Green HD camouflage for $9,999.

 

Kubota Releases its First-Ever Utility Vehicle
After 30 years of development in the under 100 horsepower tractor market, Kubota Tractor Corp. (KTC) has introduced its first utility vehicle, the RTV900. The RTV 900 is available in four configurations, general purpose, worksite, turf and recreational, and combines Kubota's diesel engine technology with a unique drivetrain system.
Comprised of a hydraulic pump, hydraulic motor an assist motor, the vehicles drive train generates power and speed for a variety of conditions by controlling the release of oil flowing through a closed circuit. This system is connected to a Kubota D902-E-UV, three cylinder, four cycle diesel engine. The OHV power plant is rated at 21.6 hp at 3,200 rpm and carries 54.8 cubic inches of displacement, giving all four models a maximum travel speed of 25 mph.
The RTV900 is the only vehicle in its class to host Kubota's three range variable hydrostatic transmission (VHT). The transmission boasts a braking feature that never allows the unit to enter a free-wheel status when traveling downhill. The three-range shifting provides low (0 to 10 mph), mid (0 to 18 mph) and high (0 to 25 mph) operational speeds adding diversity when climbing hills and hauling or towing a load.
To stop the vehicle the RTV900 features front and rear wet-type disc brakes provide a reliable braking force. For added stability and operation in challenging terrain the unit has a long wheelbase of 77.4-inches, a MacPherson type strut front suspension and semi-independent rear suspension axle, including a leaf spring and shock.

 

New FW Landover Utility Work Vehicle From Flannegan Western
It's not a Hummer and it's not a Jeep, it's a new utility vehicle from Flannegan Western named the FW Landover. Available in three models, the MVP 32, MVP 45 and MVP 65, the Landover is an aggressively styled vehicle designed for use in rugged conditions.
First introduced as a prototype at the MEGA Utility Equipment Expo, the MVP 32 comes standard with 72-inch by 60-inch structural steel stake bed with hydraulic lift cylinders and a cab protector, a 8-inch steel frame and a front-end quick attach system. The vehicles steal frame, combined with the use or Dana axles, provide a base for the unit that can carry a 2,000 pound load capacity.
To provide enough power to handle 2,000 pounds of materials the MVP 32 features a 32 hp, Twin Vanguard gas engine and a variable speed hydrostatic drive. The air-cooled big block engine is manufactured DBS, a Briggs and Stratton Commercial Power joint venture with Daihatsu, and is rated for commercial duty. The 895 cc displacement of the v-twin provides 31 horsepower at 3,600 rpm and features OHV technology, cast iron sleeves, five-inch centrifugal multi-stage industrial air cleaner and a full pressure oil lubrication system with spin-on filter.
The Landover's variable speed hydrostatic drive provides high torque, simplified shifting and an added speed control to help regulate the vehicle.
"Hydrostatic transmissions provide several advantages to mechanical transmissions," said Greg Fender, Application Engineer, Bondiolo & Pavesi, Inc. "The closed-loop piston pump has its own variable displacement control, which is a lever operated servo control. This control is easy to shift because the servo control use internal charge pressure to shift the servo piston. The driver simply shifts a joystick, or foot pedal, connected to the pump control by the cable."
"The vehicle can go from full speed reverse to full speed forward without pausing to shift gears, added Fender. "The hydrostatic transmission allows the engine to run at optimum speed for peak output torque at all times. The vehicle speed is controlled by the pump control, so the engine speed can be constant at all times."

 

SoloRider Single-Rider Golf Cart Upgraded for 2005
SoloRider has made several upgrades to its single-rider golf cart for 2005, including improved battery life and better steering. The single-rider unit features a unique design to help golfers with mobility impairments play the game of golf. Users of the cart can either address the ball while leaning against the seat for balance and stability, address the ball while sitting or address the ball from the seat with a chest belt.
To increase battery life SoloRider added 50 more amps, from 130 to 150, to the units three 12 V, deep cycle batteries. This allows the cart to be used on as many as 45 holes, depending on course conditions, instead of the old models 36 hole maximum. SoloRider has also reprogrammed the internal controller in the unit to help slow it's acceleration. This slower ramp-up speed allows for less tire slippage, making for a more secure cart.
Another engineering change to the cart includes a new steering mechanism design that reduces torque, making the vehicle 40 percent easier to handle. SoloRider made this change to make it more comfortable and easier for golfers who have suffered a stroke, and have use of only hand, to play. Other changes to the controls include a lengthening tiller steering column to bring the steering wheel closer to the golfer and a modification to the cart's patented stand-up, electric seat to make it more comfortable and easier for golfers to play their shots while seated.

 

  Motive Power
  Kohler Debuts Courage Single Cylinder Engine Line
Kohler has debuted its Courage model to its line of single cylinder engines. The line is available in six models with horsepower figures up to 20 hp. The vertical shaft motor is designed for use in the turf market and features technologies including a patented dual cam design and a cross-flow cylinder head.
The courage line's six models include the SV470, SV480, SV530, SV540, SV590 and SV600. The SV470 and SV480 are both 477 cc engines but the 470 model has an output of 15 hp and 36.6 Nm of peak torque at 2,200 rpm, while the 480 puts out 16 hp and 37.8 Nm of peak torque at 2,200rpm. The larger SV530 motor has a displacement of 535 cc and puts out 17 hp and 42.71 Nm of torque at 2,200 rpm. The 540 series also carries a displacement of 535 cc and a peak torque rating of 42.71 Nm, but has 18 hp. The final two models in the line are the 19 hp SV590, which produces 48.8 Nm of peak torque at 2,200 rpm and the SV600, which is the lines most powerful model with a 20 hp rating and producing 50 Nm of torque.
All models in the Courage line feature full-pressure lubrication, a tri-phase air induction system and a ported-power intake. This intake helps create an air/fuel mixture that tumbles in the cylinder head for higher combustion efficiency. The three-phase air induction system is mated to an air filter that is 39 percent larger than other models and its unique design provides users with a long-lasting air-cleaner that also makes the engine quieter while running. An additional feature is an inverted crankcase that eliminates the oil leaks and provides simple, no mess removal of the automotive-type full flow oil filter.
The Courage line, which exceeds current EPA and CARB emission standards, also features an OHV design, electronic ignition, cast-iron cylinder liner and a patent pending reciprocating balance system. The new balance system decreases in-line and side-to-side unbalanced forces to minimize vibration.

 

GNB Industrial Power Launches Tubular-HP Lift Truck Battery
GNB Industrial Power, a division of Exide Technologies has expanded its line of industrial lift truck batteries with the new Tubular-HP product range. The line of batteries consists of 100 Ah and 140 Ah plate sizes, with the 100 Ah being the same height as a typical 85 Ah flooded flat-plate product and the 140 Ah Tubular-HP product being the same height as a typical 125 Ah flooded flat-plate product.
"This means that a customer can achieve more power, using tubular technology, in the same size compartment that was previously occupied by a flooded flat-plate battery," said Keith Schmid, vice president and General Manager for GNB Industrial Power.
GNB has also extended the applicability of its Liberatorl low-maintenance flooded Tubular line. The battery was introduced in the North American market in 2004, but the unit was initially limited to the use of a GNB SCR200 charger with a I-W-P profile in order to achieve a minimum watering cycle of 90 days. Exide has recently established that SCR chargers with an I-E-I profile and ferroresonant chargers also can be used, but watering cycles are limited to 45 days for SCR chargers and approximately 10 to 15 days when ferroresonant chargers are used.

 

Robin Subaru Adds EX27 OHC Nine hp Engine to EX Series
Robin Subaru has introduced a 9 hp OHC engine based on Subaru's WRX World Rally Championship boxer engine named the EX27. The newest member to its EX Series, the EX27 is targeted to power general construction equipment and features an aluminum alloy block with a cast iron cylinder liner.
Robin Subaru's EX line ranges from 4.5 to 9 hp, are air-cooled and come standard with an electric ignition, automatic timing adjustment, dual ball bearing supported crankshaft, automatic decompression system and splash type lubrication. Other features for the entire EX line include lower operating temperature and easy interchangeability with existing slant-cylinder engines.
Specifically, the one cylinder, four-cycle EX27 carries a displacement of 265 cc, a maximum of 9 hp at 4,000 rpm and 13.74 foot pounds of torque at 2,500. The engine measures 351 by 420 by 410 mm, weighs 46 lbs. and carries a 1.59-gallon fuel capacity.
Part of Subaru's rally car engine technology used in the entire EX series include a pent-roof combustion chamber for added motor efficiency. Also incorporated is a new, optimized intake and exhaust system, which intensifies air intake and fuel-air mixing, reduces dead volume and eliminates flow losses. The result is said to improve engine breathing and volumetric efficiency which, in turn, increases horsepower density per cc of displacement and reduces both exhaust emissions and fuel consumption.
Further advancements for the line include 30 to 40 percent recoil pulling forces required to start the engine and a reduction of noise by 2 dBa. The series was also designed with a new ignition system the provides a hotter spark at a lower speed, allowing it to turn over easier.

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  Components
  Mobile Filtering System Extends Hydraulic Component Life
John Deere has introduced its new Super Caddy, a fluid filtering system that is designed to keep machines running smoothly and extend component life by eliminating fluid contamination. The system features a B7 1000 filter with a new, patented design. The filter pleat distributes the load to make use of space more efficiently, which enables it to distribute pressure evenly and hold more dirt. The flow is from the inside out, and the core is in the tower, making disposal easy. The mobile unit can also be transported to the machine on-site for thorough cleaning.
The top mistake technicians make is mixing lubricants as fluid additives are specifically designed for each type of application. For example, an engine requires detergency and anti-wear additives, but the hydraulic system needs antifoam and viscosity stability. Anti-wear additives are formulated differently for different applications, and they trigger protective mechanisms at different temperatures.
"That's why mixing is a bad idea, the main reactions are rust, changes in viscosity, oil film strength debilitation, oxidation, foaming and copper generation," said Amy Asselin, service marketing specialist, John Deere Construction and Forestry Company. "Super Caddy keeps fluids completely separate as it filters and cleans by carrying separate filters for each fluid type on-board."
On-board sensors provide information about particle count and percentage of water saturation as the technician filters the oil. A variable speed drive allows the technician to change the flow of the pump depending on fluid viscosity or temperature. In fact, the system is so sensitive that it actually can tell the technician if the oil is too cold to give an accurate reading, which keeps the system from giving a false signal when oil is still below 80°F.

 

Maintenance Free Torque Sensors
The Force/Torque Division of PCB Piezotronics, Inc. has introduced a line of rotary transformer torque sensors that utilize utilize non-contact, rotary transformers for sending excitation voltage to, and receiving measurement signals from, the rotating strain gage sensor. The maintenance-free transformer is designed to eliminate the need for replacing worn brushes, as is necessary with conventional slip-ring type rotating torque sensors. The units are well suited for use in torque studies on pumps, electric motors, engine dynamometers, transmissions and gearboxes.
Named the series 4200, the rotary transformer torque sensors offer capacities from 100 to 100,000 in-lb (11 to 11.3k N-m) and full-scale and maximum speeds to 10,000 RPM. These shaft-end, temperature-compensated units feature 2 mV/V output sensitivity and an integral shunt calibration network, and are available with an optional foot-mounted housing.

 

New Cartridge Watering Solution for Forklift Batteries
Now treated tap water can be easily available for forklift batteries with Flow-Rite Controls Ltd.'s new Niagara De-Ionizer Cartridge. This ion-exchange unit electro-statically removes dissolved impurities, providing water comparable to more expensive distilled water for longer vehicle battery life.
Hard water creates a hard time for batteries. Metals and salts can affect cell voltage, cause the battery to self discharge and lead to mossing and dendrite growth though the separators. These additives are dissolved solids that cannot be conventionally filtered out of the water. This de-ionizing technology, which in normally considered rather expensive, allows regular tap water to be passed through the cartridge to make it suitable for battery consumption while still being low in cost.
When the units de-ionizing cartridge becomes exhausted users can simply replace it for a new one and continue filling. Additional convenience features include an optional direct fill capability, easily installed cartridges and a continuos light that indicates that status of the current cartridge unit.
Depending on tap water quality, the Niagara cartridge can provide an average of 600 gallons of purified water at a cost of pennies per gallon, ranging from more capacity to less based on the water going into it. With a 36 V battery typically needing over a gallon of water every week, one Niagara cartridge can handle most fleet sizes.

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