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
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1

A PROJECT REPORT
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Submitted to
SUNRISE UNIVERSITY
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in partial fulfilment for the award of the diploma of

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POLYTECHNIC
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IN MECHANICAL
ENGINEERING
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DEPARTMENT OF MECHANICAL ENGINEERING

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SUNRISE UNIVERSITY
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ALWAR RAJASTHAN,
INDIA
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MAY 2014
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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 20152016.

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.

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.

TABLE OF CONTENTS

CHAPTER NO

TITLE

PAGE NO

ABSTRACT

LIST OF FIGURES

LIST OF TABLES

1. INTRODUCTION
1.1 PRINCIPLES OF HYDRAULIC JACK

10

1.2 PASCALS 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

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

LIST OF FIGURES

FIGURE.NO

NAME

PAGE.NO

1.1

Pascals 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

4.2

19

Proposed Model - Hydraulic Fork Crank Rod For Limiting

And Pressure Producer

20

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 Pascals law
Pascals 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: Pascals demonstration setup

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 forklifts 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 Pascals 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 forklifts 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 forklifts 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
forklifts 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
dont 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
youll 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 forklifts 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 systems 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 recalibration 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

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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
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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 Pascals 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

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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.

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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 wasnt 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 forklifts 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.

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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 Pascals 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.
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CHAPTER 4
FABRICATION OF HYDRAULIC FORK LIFT

4.1 PROPOSED MODEL - HYDRAULIC FORK WITH JACK OF

LIFITING CAPACITY 2 TONNES

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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
Hardwares 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/-

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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

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