Telehandler forklift is a kind of multi-functional material handling equipment. The performance of its hydraulic system directly determines the accuracy and efficiency of core actions such as lifting, stretching, tilting and steering. However, there are huge differences in different operating conditions, and the standard factory configuration cannot cover all these special needs. The customization of hydraulic systems has become the focus of equipment procurement.
As the source factory of telescopic boom forklifts, EPDAS supports telehandler hydraulic system customization, but it needs to be implemented within the framework of the original factory project, combined with the requirements of working conditions, safety standards and compliance standards, and is not an unlimited modification.
The hydraulic system of the telescopic boom forklift is a closed-loop system composed of power components, executive components, control components, auxiliary components and working media. All components work together to ensure the accurate, stable and efficient operation of the equipment.
Power components
As the “power source” of the hydraulic system, the core of the power component is the hydraulic pump, which is mainly responsible for converting the mechanical energy of the engine into hydraulic energy, providing stable pressure and flow for the whole system, and ensuring that the output pressure can match the basic operation needs of the equipment.
Executive components
The actuator is the “action execution end” of the telehandler hydraulic system, which mainly includes lifting cylinders, telescopic cylinders, variable amplitude cylinders and brake cylinders. It is responsible for converting hydraulic energy into mechanical energy, driving the lifting, telescopic, variable amplitude, and realizing the parking and emergency braking of the equipment.
Control elements
The control element is the “brain” of the hydraulic system, including multi-way valves, proportional valves, overflow valves, reversing valves, etc., which are responsible for regulating the pressure, flow and flow direction of hydraulic oil to achieve precise control of the operation of the equipment.
Auxiliary components
Auxiliary components include hydraulic oil tank, hydraulic oil pipe, filter, seal, cooler, etc., which are very important for the stability and service life of the hydraulic system, and do not directly participate in power transmission and action control.
Hydraulic oil
Hydraulic oil is the “blood” of the hydraulic system. Its viscosity, wear resistance and oxidation resistance directly affect the operating efficiency and component life of the system. Use wear-resistant hydraulic oil that meets the GB/T 3141 standard to ensure that it can maintain stable performance under different working conditions.
As the core power transmission system of the telescopic boom forklift, the performance of the hydraulic system directly determines the lifting ability, action speed, control accuracy, braking safety and compatibility of the equipment. The stability and service life of the hydraulic system directly affect the operation and maintenance cost of the equipment. Through customized optimization of system design and selection of high-quality components, the stability of the hydraulic system can be improved, the occurrence of failures can be reduced, and operation and maintenance costs can be reduced.
At present, domestic mainstream telescopic forklift manufacturers take customization as a standard service, not a high-end value-added service. Modular customized solutions can be provided according to customer needs, taking into account cost and efficiency. Judging from the demand of the industry, the demand for customization is mainly concentrated in mining, construction, agriculture, emergency rescue and other fields, and mostly involves the optimization of core functions such as safety braking and auxiliary interfaces.
Mining users face strict underground safety regulations. Agricultural users need to drag and hang all kinds of hydraulic accessories, and construction sites may require multiple accessories to have the ability to change quickly. In rescue operations, it may be necessary to use winches, slings and other accessories to carry relief supplies, and need to customize and expand hydraulic auxiliary loops, etc.; through targeted optimization of telehandler hydraulic systems The parameters and configuration can make the telescopic forklift better adapt to the differentiated operation needs of different industries, improve operation efficiency and reduce safety risks.
The tail-end auxiliary hydraulic and electrical interface is the core component of the telescopic boom forklift connection accessory, and its configuration directly determines whether the equipment can adapt to different types of accessories. Users’ customized demand for tail interfaces mainly focuses on hydraulic hook integration and 7-hole power interface configuration.
Hydraulic hooks usually refer to the hydraulic quick coupling installed at the back of the frame, which is used to transmit the hydraulic power of the host to the executive components on the trailer, such as the lifting cylinder, hydraulic leg or motor of the dump trailer. From a technical point of view, on the current mainstream telescopic boom forklift platform, the rear hydraulic hook cannot be directly modified. Users can consider alternatives. They can choose mechanical hooks that can be connected quickly; it can not only meet the needs of convenience, but also reduce the cost of telehandler hydraulic customization.
Unlike the hydraulic hook, the configuration of the rear power interface is much simpler. Power sockets used for trailer lights (turn signals, brake lights, taillights) and auxiliary electrical equipment can be realized through standard electrical accessories. The 7-hole power interface configuration is another common customized demand, which has high feasibility and no additional cost. The core requirement is to ensure the standardized adaptation of the power interface and matches the power supply needs of the belonging equipment.
However, the user needs to confirm the following two points. The first is whether the definition of the plug pin is compatible with the trailer (for example: 1 pin is left steering, 2 pin is the reversing light, 3 pin is the ground wire, 4 pin is right steering, 5 pin is brake light, 6 pin is taillight, 7 pin is auxiliary power supply/12V or 24V); the second point is the maximum carrying capacity Whether the force meets the electrical load of the trailer (usually up to 10~15A per channel, and the total power of the auxiliary power supply does not exceed 150W).
For scenarios that require the simultaneous use of multiple subordinates (such as grabs + winches, aerial work platforms + slings), a single auxiliary hydraulic circuit cannot meet the needs. It is necessary to customize and expand the multi-loop hydraulic system to realize the simultaneous operation of multiple subordinates and improve operation efficiency. The expansion of multi-circuit hydraulic system mainly includes the design of double auxiliary circuits and three auxiliary circuits. Its core is to build an independent hydraulic circuit by adding hydraulic pumps, multiple valves, pipelines and other components.
The customization of multi-loop hydraulic system has been widely used in construction, mining and other scenarios. For example, the telescopic boom forklift on the construction site is connected to the grab and the high-altitude work platform through the double auxiliary loop, which can realize material grabbing and high-altitude operation at the same time, greatly improving the operation efficiency. In the mining scenario, it is connected through three auxiliary loops. Grabs, winches and crushing hammers can realize the integrated operation of ore grabbing, dragging and crushing, and adapt to the complex mining operation needs.
The core advantage of the SAHR braking system is that it has a fault safety protection function. Its working principle is: when working normally, the hydraulic oil applies pressure, compresses the spring, and releases the brake; when the hydraulic system fails (such as leakage, power outage), the spring automatically resets, applies braking force, realizes parking and emergency braking, and prevents the equipment Slipping, load falling, effectively avoid hydraulic drift and other common problems, and improve operation safety.
The two directions to choose from at present are shown in the following table.
| Contrast dimension | Domestic SAHR system | Italy COMER SAHR System |
| Additional cost (RMB) | +26,000 yuan | +35,000 yuan |
| Brand source | Domestic axle and brake manufacturers (such as suppliers in the supporting system of Xugong and Zhonglian Heavy Technology) | Italy COMER Industries (world-renowned transmission system brand) |
| Technical principle | Wet multi-piece SAHR brake, suitable for 3~7 tons telescopic boom forklift drive axle | Wet multi-chip SAHR brake, which meets EU and international mining standards |
| Regulatory certification | Pass the relevant domestic type test to meet the mandatory safety standards of mining (such as ISO 3450, MSHA equivalent requirements) | Passed the European Union and international mining certification (ISO 3450, MSHA, CE, etc.) |
| Supply cycle | Customization adds an additional 7~10 working days | Customization adds an additional 10~15 working days |
| After-sales spare parts | Domestic spare parts are easy to get, and the supply network covers major mining areas. | The global mining market has good universality of spare parts, but some domestic regions may need to transfer goods. |
| Reliability level | It meets the requirements of conventional mining operations and is cost-effective. | Higher reliability, suitable for harsh working conditions and export projects
|
| Applicable scene | Budget-sensitive, long-term operation of equipment in domestic mining areas, local domestic accessories support | Export projects, high reliability requirements, existing COMER supporting experience, EU or Australian mining area
|
Tips
If the equipment is operated in domestic mining areas for a long time and the budget is limited, the domestic SAHR system is more cost-effective.
If the equipment will be exported to Australia, Canada, Europe and other strictly regulated regions, or the user explicitly requires international brands, choose the Italian COMER system.
Dana Spicer axles are currently unable to adapt to some models of SAHR braking systems, and the original engineering team needs to evaluate the suitability in advance.
As a high-risk operation scene, the mining scene has extremely high requirements for the performance, compliance and maintenance support ability of the braking system. It is necessary to make a comprehensive comparison between domestic and imported SAHR braking systems, and choose a suitable solution in combination with the needs and budget of working conditions.
In terms of functional performance, the advantages of imported COMER SAHR braking system are more obvious. Its braking response speed is faster (≤0.3 seconds) and the braking torque is greater (≥2000N·m), which can better adapt to the needs of mining heavy loads and slope operations, and effectively prevent equipment from slipping; multi-piece wet braking design, stable braking, noiseless, excellent wear resistance, longer service life (usually for national 1.5-2 times the production system); automatic gap compensation function and fault diagnosis function can reduce the maintenance frequency, find faults in time, and reduce operation and maintenance costs.
Although the performance of the domestic SAHR braking system is slightly inferior to that of the imported system, it can meet the basic compliance requirements of the mining scene. The brake response time, brake torque and other parameters meet the industry standards and have strong adaptability. It can be adapted to most medium and low-end models, which is more cost-effective.
In terms of compliance, both schemes meet the relevant requirements of GB/T 38055.1, mining safety regulations and other relevant requirements, and can pass the mining safety certification to ensure that the equipment can be put into mining operations. The imported COMER SAHR braking system also meets the European Union CE certification and North American ANSI standards. If the equipment needs to be exported, it is more advantageous to choose this scheme. The domestic SAHR braking system mainly meets the domestic industry standards and is suitable for domestic mining scenarios.
If the user has sufficient budget, high requirements for braking performance, and the equipment is used in high-end mining scenarios or needs to be exported, it is recommended to choose the imported COMER SAHR braking system; if the user has a limited budget, the equipment is used in ordinary mining scenarios, and pays attention to cost-effectiveness and maintenance convenience, it is recommended to choose domestic SAHR braking. System.
Lifting/falling speed is a key parameter affecting operation efficiency. Different operation scenarios have different requirements for speed: high-altitude operation and precision material handling scenarios need to be slow and stable to avoid material shaking or personnel safety risks; ordinary material handling scenarios need to be faster to improve operation efficiency. Through customized adjustment of the parameters of the hydraulic system, accurate matching of the lifting/fall speed can be achieved, while optimizing the smoothness of the action and reducing the impact.
The optimization of motion smoothness is mainly achieved by optimizing the load-sensitive control logic and adjusting the damping parameters of the hydraulic circuit. The load-sensitive system can automatically adjust the hydraulic oil flow and pressure according to the operating load to avoid flow waste, while reducing the action impact and improving smoothness.
For example, the telescopic boom forklift on the construction site needs to lift the boom slowly and smoothly when installing the high-altitude glass curtain wall. By adjusting the parameters of the proportional valve, the lifting speed is adjusted from 0.5m/s to 0.2m/s, and the load-sensitive control logic is optimized to ensure that the action is impact-free and avoid glass damage; When carrying ordinary rebar, adjust the lifting speed to 0.6m/s to improve the operation efficiency.
Hydraulic hoses are consumable parts and need to be replaced many times throughout the whole life cycle of the equipment. The number of hydraulic hoses contained in a telescopic boom forklift is about 70~80, covering all circuits such as moving arm, telescopic arm, tilt cylinder, steering cylinder, pilot control, braking system, etc. The specifications of these hoses (inner diameters ranging from 6mm to 25mm), lengths (from 300mm to 5000mm), working pressure (from 100 bar to 350 bar), and joint types (imper, metric, flange, etc.) are different.
No manufacturer can predict which hose the user will damage in future operation. It may be the main oil pipe of the large cavity of the arm cylinder, or it may be a thin hose of the pilot handle. Giving away a few random hoses can’t solve the actual problem, but instead causes waste. Therefore, not giving spare hoses is a common practice in the industry, not a specific manufacturer’s restriction.
The localized procurement of hydraulic hoses is the key to reducing the procurement cost of spare parts and shortening the procurement cycle. Users can choose the appropriate localized procurement channel according to the supply chain situation in their location.
Purchase by single root
The user provides a specific pipeline location description (such as “right steering cylinder inlet pipe”, “arm lifting cylinder large cavity pipeline”, “pilot pump outlet to multi-way valve P-mouth pipeline”), or provide the part number on the original car hose (usually printed with labels). The manufacturer confirms the hose specifications, length and joints according to the technical atlas, and quotes and ships separately. This method is the most accurate, but it requires users to identify faulty pipelines in advance.
Whole vehicle pipeline kit
For users in extremely remote areas (such as African mines and island construction sites), all 70~80 hoses can be purchased at one time as a complete set of spare parts. The cost of the kit is about 15,000 to 30,000 yuan (depending on the hose grade and joint type). Although the initial investment is high, it can ensure that any hose can be replaced immediately when it fails to avoid downtime losses.
Produced by the local hydraulic store
This is the fastest and lowest cost way. After removing the old hose, the user takes it to the local professional hydraulic parts store. The store can press a new hose on the spot according to the length, inner diameter and joint model of the old pipe. Generally, it can be completed within 30 minutes.
The customization capacity of the telehandler hydraulic system is not unlimited, but under the premise of clarifying the technical boundaries and cost data, users can still obtain solutions to meet the requirements of special working conditions. EPDAS has a professional engineering team and full-process technical support, providing one-stop customized solutions, contacting us for support to ensure the successful implementation of the project.
