standard technical specification for deisel …standard technical specification for deisel engine /...

STANDARD

TECHNICAL SPECIFICATION

FOR

DEISEL ENGINE / BATTERY OPERATED FORKLIFT TRUCK

SPECIFICATION NO: PE-TS-STD-563-A-004

BHARAT HEAVY ELECTRICALS LTD POWER SECTOR PROJECT ENGINEERIING MANAGEMENT

NEW DELHI INDIA

Title STANDARD TECHNICAL SPECIFICATION FOR

FORK LIFT TRUCK

Specification no.: PE-TS-STD-563-A-004

Rev. 00 Date: May 2011 Sheet 1 of 1

INDEX

S.N. VOLUME SECTION DESCRIPTION PAGES 1.0 Volume II B Section-A Scope of Enquiry 1 2.0 Volume II B Section-B Project Information (Project Specific) 3.0 Volume II B Section-C Scope of work 4 4.0 Volume II B Section-C Annexure-V, Painting specification

4

5.0 Volume II B Section-C Annexure-VI, Distribution of engineering documents.

1

6.0 Volume II B Section-D Technical specification for FORK LIFT 3 7.0 Volume II B Section-D Data sheet –A: FORK LIFT 3 8.0 Volume III Schedule of deviation 1

9.0 Volume III Schedule of weights and dimensions 1

10.0 Volume III Schedule of performance guarantees 1

VOLUME - IIB

SECTION – A

TITLE SPECIFICATION NO. PE-TS-STD-563-A-004

STANDARD TECHNICAL SPECIFICATION VOLUME II - B

FORK LIFT TRUCK SECTION -A

REV 0 DATE May 2011 SHEET OF 1 1

PE

M-6

666-

0

1.0.0. SCOPE OF ENQUIRY

This specification covers the design, manufacturing, inspection and testing at manufacture’s

works, properly packed and forwarding to site of Forklift as specified below.

A. UP to 10 T capacity, Engine / Battery driven Forklift truck and necessary

accessories.

(Capacity, Quantity & Driving force for Forklift shall be project specific)

It is not the intent to specify completely herein all the details of design and construction of

equipments. However, all the equipments shall conform in all respect to high standard of

engendering, design, workmanship and be capable of performing in continuous commercial operation

up to the vendors / subcontractor’s guarantees in a manner acceptable to the purchaser / engineer

who will interpret the meaning of drawing and specifications and shall be entitled to reject any work or

material which in his judgement is not in full accordance herewith.

The general terms and conditions, instructions to bidder and other attachments referred to elsewhere

are made a part of the tender specification. The equipment materials and works covered by this

specification is subject to all the attachments referred in the specification. The bidder shall be

responsible of and governed by all the requirements stipulated herein.

The bidder shall submit the standard quality plan to enable the purchaser to understand the extent of

inspection and testing requirements to execute this job. The successful bidder has to follow the

agreed quality plan.

VOLUME - IIB

SECTION – C

SCOPE OF WORK



FORK LIFT TRUCK SECTION -C

REV 0 DATE May 2011

Page 1 of 4

PE

M-6

666-

0

1.0.0. SCOPE OF WORK

1.1.0. SUPPLIES

1.1.1. Equipment and services to be furnished by the bidder for the Fork Lift Truck with

accessories as per the details given in data sheet A. Any equipment / accessories not

specified in the specification but required to make the Fork Lift Truck unit complete

and efficient shall also be under the bidder's scope of work.

A. Up to 10 T capacity, Engine / Battery driven Forklift truck and necessary

accessories.

(Capacity, Quantity and Driving Force for the Fork Lift Truck shall be

project specific)

1.1.2. Maintenance Tools and Tackles

A complete unused new set of special purpose tools, tackles and accessories along

with detailed instructions and maintenance manual shall be supplied. Each tool and

wrench shall be stamped so as to be identified easy for its use. The tools shall be

supplied in steel toolbox and with a copy of instruction manual. The items supplied

shall be of the best quality and specially protected against rusting in tropical climate.

.

Note: - Forklift shall be supplied with one set of tool and tackles with O&M manual in

the toolbox separately.

1.1.3. Recommended Spares

A complete unused and new set of Recommended Spares for two (2) years

successful operation of the equipments shall be supplied. Each part shall be stamped

so as to be identified easy for its use. The items supplied shall be of the best quality

and specially protected against rusting in tropical climate.

1.3.0. Inspection and Testing

1.3.1. Inspection and testing at Manufacturer’s works

A. Shop inspection and tests will be carried out at manufacturer’s works.




REV 0 DATE May 2011

Page 2 of 4

PE

M-6

666-

0

Bidder shall submit detailed quality plan, indicating various test to be carried out at

works at various stages along with final performance test procedure along with

guaranteed parameters for customer approval during contract stage.

1.4.0. SURFACE PREPARATION, PAINTING & COLOUR SCHEME

1.4.1. Surface preparation & painting of the equipment shall be carried out as per the Special

Painting Schedule given by BHEL as a part of this technical specification.

1.5.0. Drawing / design document for submission.

A. For Approval

a) G.A. drawing of forklift, showing all dimensions, materials of construction, lifts

and other parameters.

b) Detailed Technical data sheet of all components / equipments.

c) Quality Plan.

j) Test certificates and reports on various shop tests.

k) O& M Manuals

2.0.0. Number of drawing and documents for submission

The number of prints / copies required for various drawing and documents are listed in

Annexure –VI, section-C, volume II-B of this specification.

3.0.0. Deviations

If the proposal submitted has got any deviation from the technical stipulations in the

tender document, bidder shall tabulate the same in the appropriate “Schedule of

Deviations” furnishing full particular of such deviations. Deviations are to be furnished

with mention to specific clause Number. Notes / comments etc. is not acceptable. If

there are no deviations from the tender document, bidder shall indicate so. Reasons /

explanations for such deviations shall be furnished

4.0.0. Performance Guarantee

Forklift along with its drives, controls and other accessories shall be guaranteed for

the rated capacity against the rated speed of motions and for the service conditions

specified




REV 0 DATE May 2011

Page 3 of 4

PE

M-6

666-

0

The bidder shall have the full responsibility for the safe and efficient operation of the

crane with associated accessories as a single unit. If the shop/site performance tests

indicate the failure of any of the components to achieve the guaranteed performance,

the deficiency shall be made good at bidder’s cost.

5.0.0. Makes of Sub - Vendor items.

Bidder shall submit the ‘List of Makes of Bought-out items’ for review / approval

6.0.0. Drawing & Documents attached with Tender

7.1.0. Data sheet A

7.0.0 INFORMATION TO BE FURNISHED BY TENDERER ALONG WITH OFFER

Bidder shall submit following separate drawings / documents for forklift.

7.1.1 List of tools & tackles to be deployed at site for erection & commissioning of forklift

truck

7.1.2 Data sheet A duly filled up.

7.1.3 Duly stamped and signed copy of Quality Plan.

7.1.4 List of recommended Spare parts for two (2) years successful operation of the

equipments.

7.1.5 List of commissioning spares

7.1.6 Other reference drawing / documents / literature etc.

7.1.7 List of complete scope of supply / services

7.1.8 Deviation sheet

8.0 Commissioning Spares

Bidder to provide along with its offer separate list of commissioning spares with its

quantity required for forklift.

9.0.0 Each and every item (including) to be shipped shall have material identification tag for

easy identification and tractability at site. An exhaustive part / component list including

material identification tag numbers / details shall be furnished by vendor before

shipment of any equipment.

10.0.0 Painting of the equipment shall be as per BHEL approved painting procedures.




REV 0 DATE May 2011

Page 4 of 4

PE

M-6

666-

0

11.0 Scope of Documentation (as per Vol I, Section-VI of Technical specification): The supplier shall submit a number of twelve (12) copies of each final documentations

and catalogs related to the whole system and components. These documents shall be

complete in all respects in hard and soft copies.

12.0 Optional items

Bidder shall quote following optional item applicable to each forklift. Oxy catalytic converter / purifier Spark arrestor Fork Extension Towing coupler Load back seat

ANNEXUE – V

PAINTING SPECIFICATION

TITLE STANDARD TECHNICAL SPECIFICATION

FOR FORKLIFT TRUCK

SPECIFICATION NO. PE-TS-STD-563-A-004 VOLUME III SECTION-E REV. 00 DATE: May 2011 Page 1 of 4

ANNEXURE- V

PAINTING PROCEDURE / SCHEME

S.No

ITEM DESCRIPTI

ON

SURFACE PREP.

PAINTING SCHEME REMARKES

PRIMER No. of Coats

MINDFT

µ

INTERMEDIA

TE

No. of Coats

MIN DFT

µ

FINISH No. of Coats

MINDFT

µ

TOTALDFT

a Piping / Structures / Vessels etc. (Temp. up to 90 Deg. C)

Degreasing and

Mechanical Cleaning with wire brushing / hand Tool

(SA1 / ST2 / ST3 as

applicable)

Red Oxide Zinc

Chromate as per IS: 2074

(alkyd mediu

m)

2 25-35 per coat

- - -

Synthetic

Enamel

(alkyd Medium) as

per IS : 2932

3

20 -25 per coat

110-145

b Electrical / Control Panels

Seven Tank Process

zinc phosphate (alkyd medium)

2

25 - 35 per coat

-

- -

Synthetic Enamel (alkyd med.) as per IS: 2932

3

20 - 25 per coat

110-145

c. Various type of

Degreasing and surface

zinc phosp

2 25-35 per

- - -

Synthetic

3 20 - 25

110-145


FOR FORKLIFT TRUCK


equipment, valves etc.

(Temp. upto 90 Deg. C)

preparation to SA 2 1/2

hate (alkyd medium)

coat Enamel (alkyd Medium) as per IS : 2932

per coat


FOR FORKLIFT TRUCK


ANNEXURE- B PAINTING PROCEDURE / SCHEME (FOR COASTAL AREA)

S.No

ITEM DESCRIPTI

ON

SURFACE PREP.

PAINTING SCHEME REMARKS

PRIMER No. of Coats

MINDFT

µ

INTERMEDIA

TE

No. of Coats

MIN DFT

µ

FINISH No. of Coats

MINDFT

µ

TOTALDFT

a Piping / Structures / Vessels etc. (Temp. up to 90 Deg. C) Degreasing

and surface preparation to SA 2 1/2

Epoxy based polyamide cured

(2) pack HB zinc

phosphate

primer

1 50-75 per coat

Epoxy based MIO

pigmented polyamide cured paint

1

50 per coat

Polyamide cured epoxy finish coatin

g

2

Min. 35 per coat

170-195

b Panels Seven Tank Process

Epoxy based polyamide cured (2) pack zinc phosphate

1 35 per coat

Epoxy based TIO2 pigmented polyamide cured paint (shop)

1 40

Aliphatic Acrylic (2) pack polyurethane finish paint

2 30 per coat

135


FOR FORKLIFT TRUCK


primer %VS=58 min.

c. Various type of

equipment, valves etc.

(Temp. upto 90 Deg. C)

Degreasing and surface preparation to SA 2 1/2

Epoxy based polyamide cured (2) pack HB zinc phosphate primer

1 50-75 per coat

Epoxy based MIO pigmented polyamide cured paint

1 50 per coat

Aliphatic Acrylic (2) pack glossy polyurethane paint

2

Min. 30 per coat

160-185

1.0 NOTE : - if the bidder is not following BHEL Painting specification, bidder is bound to give the standard painting specification followed by him in the same format, in which BHEL has given it’s painting specification.



FORKLIFT TRUCK SECTION -C

REV 0 DATE May 2011 SHEET OF 1 1

PE

M-6

666-

0

ANNEXURE-VI

DRAWING AND DOCUMENTS FOR SUBMISSION

S.N. Drawings and documents Number of prints / copies

1.0 DRAWING FOR APPROVAL

1.1 For approval 4

1.2 For customer approval 10

1.3 For final distribution 12

2.0 DRAWING FOR REFERENCE

2.1 For reference 4


3.0 CERTIFICATE, REPORTS ETC. 6

4.0 AS BUILD DRAWINGS ( IF REQUIRED ) 15

5.0 O&M MANUAL

5.1 Draft for approval 2


6.0 QUALITY PLAN 6

VOLUME - II B

SECTION-D

SPECIFICATION NO. PE-TS-STD-563-A-004

STANDARD TECHNICAL SPECIFICATION FOR VOLUME II - B

FORKLIFT TRUCKS SECTION -D

REV 00 DATE May 2011

Page 1 of 3

PE

M-6

666-

0

1.0. SCOPE

This specification covers the design, material, manufacture, assembly, inspection and testing at manu-

facturer works for Forklifts.

2.0. CODES AND STANDARDS

The equipment to be supplied under this specification shall conform to the following codes and

standards (latest revisions) unless otherwise specified hereinafter.

a) Load Rating as per Is:6765/72

b) Engine conforming to IS:10000(1-12) and IS: 10002-1981 or BS:5514-1982 or BSAU 141A-1971

c) Acceptance criteria as per IS:10517 -1983

d) Stability testing as per IS: 4357 / 74

e) Fork lift trick fork: IS: 6876 –1972

f) Defence JSS 3930-08-1999

g) Mounting dimensions for attachments to the extent applicable to IS: 7525-1974

3.0 DESIGN REQUIREMENTS

3.1 Chassis

Chassis shall have twin box envelope design with integral tanks. Components shall be protected from

damage. Fuel and hydraulic oil tanks shall be incorporated with inset tow bar.

3.2 Counterweight

Counter weight shall be low profile, vertical sides and rear face complete with inset tow bar.

3.3 Engine

Engine shall be suitable water cooled diesel engine of adequate horsepower with alternator with 12V

charging battery.

3.4 Transmission and Axle

Compact transaxle with single speed forward and reverse torque converter power shift transmission,

Optimum grade ability for rapid acceleration to working speed

3.5 Inching

Full power inching shall be controlled. Slow forward speed with full power to hydraulics for fast lift

speeds and easy precision maneuvering and stacking combined inch/brake pedal.

3.6 Brakes

Service

Hydraulically operated drum brakes (self adjusting) on transaxle for light, responsive braking.

Asbestos-free brake linings.

Parking

Ratchet type hand brake, mechanically linked to drum brakes.





Page 2 of 3

PE

M-6

666-

0

3.7 Steer Axle

Steer axle shall be large steel beam mounted on high energy absorbing bearings to protect the single

double-ended steer cylinder. This connects through steel links with sealed spherical bearings to the

stub axles. Stub end hubs shall have taper roller bearings. The steering geometry shall give a small

turning radius.

3.8 Hydraulics

Pump

Heavy duty gear pump, shaft driven from transmission power take off. Incorporates flow divider for

priority oil supply to steering.

Control Valve

Fine metering control valves are operated by hand levers having a long sweep for smooth accurate

control and feathering of all functions, integral pressure relief valve prevents system overload.

Cylinders

All hydraulic cylinders shall have suitable piston bearings and heavy duty wiper seals. Fine-honed

bores and hard chromium plated piston rods for long life and trouble-free operation.

3.9 Mast

Masts shall be constructed from specially designed, medium tensile rolled steel nesting sections with

lateral cross ties, positioned to ensure correct strength. Mast shall be mounted on large diameter pins

that are secured to the transaxle hook mountings for reliable operation and ease of removal. The mast

sections and two high-mounted tilt cylinders shall combine to resist mast “racking”. Lift cylinders shall

be positioned behind the mast uprights to maximize visibility.

3.10 Carriage and forks

Carriage and forks shall be narrow profile plate type built to ISO standards to allow maximum visibility

of fork tips and load, easy adjustment of fork spread.

3.11 Electrical system

A 12 V battery with heavy duty alternator and starter motor shall be provided. The wiring shall be in

conduits and number coded.

3.12 Controls

The following controls shall be provided.

Foot pedals – accelerator and inching / brake.

Electrically operated forward/reverse direction control.

Hydraulic control levers and key switch for neutral start

3.13 Driver seat

Driver’s seat shall be adjustable cushioned type.





Page 3 of 3

PE

M-6

666-

0

3.14 Tyres

All tyre shall be pneumatic or solid, as indicated in data sheet-A.


DATA SHEET A/B VOLUME II - B

Fork Lift Truck SECTION -D

STANDARD TECHNICAL SPECIFICATION REV. 00

Page 1 of 3

PE

M-6

666-

0

A. Technical data sheet for Diesel engine / Battery operated Fork Lift Truck S.N. Description Specific requirement Bidders data 1.0 Number of Fork lift Project specific

2.0 Type of service Out door

3.0 Design Ambient temperature

500 C

4.0 Rated capacity at load center of 600mm / 500 mm

Project specific

5.0 Overall dimensions (mm), Mast type

5.1 Standard mast height lowered

Project specific

5.2 Standard mast height Raised

Project specific

5.3 Max. Fork Height ( lift ) Project specific

5.4 Free lift

5.5 Height load guard

5.6 Overall Truck length (mm)

Project specific

5.7 Fork dimensions Project specific

5.8 Wheel base

5.9 Drive axle to fork face

5.10 Truck width overall (mm)

6.0 Ground clearance (mm)

7.0 Out side turn radius (mm)

8.0 Speed when fully loaded

8.1 Max speed forward / Reverse (Km/hr)

Project specific

8.2 Hoisting speed – lade / unladen

8.3 Lowering speed – lade / unladen





Page 2 of 3

PE

M-6

666-

0

9.0 Mass of truck (Kgs.)

10.0 Mast tilt

10.1 Forward 6 deg. (min.)

10.2 Backward 10 deg. (min.)

11.0 Max. gradient at full rated load (%)

15-30%

12.0 Type of brakes

12.1 Service Hydraulic-Pneumatic

12.2 Parking Mechanical

13.0 Tyre

13.1 Type Solid / Pneumatic

13.2 Size (Front)

13.3 Size (Rear)

14.0 Prime Mover

14.1 Type

14.2 Model number

14.3 Max. Power (Kw / hp)

14.4 Engine 4 stoke, water cooled

14.5 Electricals

15.0 Accessories

15.1 Head and tail light

15.2 Spot light

15.3 Light reflectors

15.4 Electric horn





Page 3 of 3

PE

M-6

666-

0

15.5 Spare tyre One

15.6 Tool kit Set

15.7 Rear view mirror

16.0 Control panel with all instruments

All necessary equipments mounted on the truck

TITLE SCHEDULE OF DEVIATION

FORK LIFT TRUCK

SPECIFICATION NO.: PE-TS-STD-563-A-004 VOLUME III PART A SHEET OF

PARICULARS OF BIDDER / AUTHORISED REPRESENTATIVE

NAME

DESIGNATION

SIGN DATE

COMPANY SEAL

tTT ( ) From technical specifications (Vol II B)

We the undersigned hereby certify that the above-mentioned information’s are the ONLY deviations.

TITLE

SCHEDULE OF WEIGHTS AND DIMENSIONS



NAME

DESIGNATION

SIGN DATE

COMPANY SEAL

tTT The bidder shall state below the weights and dimensions of various packages for shipment covering the complete scope.

Description of package(s) Dimensions in (meter) Weight (in tones)

TITLE

SCHEDULE OF PERFORMANCE GUARNTEES

FORK LIFT TRUCK



NAME

DESIGNATION

SIGN DATE

COMPANY SEAL

tTT

S.N. ITEM UNIT OF MEASUREMENT

GURANTEED VALUE

We the undersigned hereby undertake to meet the performance guarantees as listed in the table above on the conditions as elsewhere specified. Any variation of the specified conditions during official test will be taken in to account by the customer.