Fortens are forté
August 1st 2005 Five years and 32,000 testing hours in the making, Hyster’s new IC counterbalance family is now rolling out. Initially launching the 2.5 to 3.5 tonne models, the company aims to offer models from 1.5 to 2.5 tonnes by the year end
Nacco Materials Handling Group strategic product director, Lee Tracey, says the company feels “very strongly that we have developed a market leading truck”. Granted every manufacturer hails its latest offering as the zenith of product design. But Hyster, with five patents in the works, seems to have a genuine claim: Tracey says his confidence stems from the fact that the range has been comprehensively designed from the ground up, with all parties – assembly staff, distributors, and customers – involved in the decision making process at an early stage, with their feedback honing and shaping the final product. Over 500 respondents and 241 companies were consulted during the truck’s development, along with 60 channels of test data from 40 different customer sites.
The range is broken down into three main packages: Fortens; Fortens Advance and Fortens Advance +. Each package offers a choice of engines, transmissions, hydraulics and cooling systems so trucks can be tailored to individual needs and applications. All core elements, such as hydraulics, cooling, electronic control and transmissions, have been re-engineered for maximum efficiency. Furthermore, says Tracey, the modular component throughout the truck family means “value flows all he way through the chain”, with numerous configurations to suit any given application and simplified maintenance.
Team effort Despite decades of experience in the forklift market, Tracey says it's the biggest project he's ever worked on – a statement backedup by the $130m Hyster claims was spent honing the Fortens family. Customer and dealer needs drove development: “They want reliability and durability above all else,” says Tracey. Accordingly design and production disciplines were combined early on in the project, simplifying the manufacturing process, thereby reducing room for error and ensuring dependability.
Specifically, a range design strategy was implemented to reduce the number of unique parts in the production line, while a 'Poke-Yoke' system ensures assembly can only be done the correct way – guaranteeing uniform assembly practices.
This approach also enabled the company to design the truck with easy access maintenance in mind.
Technology From a technological aspect Tracey states there were three key development objectives: Cooling, electrics and hydraulics, and powertrain – which the company says are responsible for 70% of forklift downtime. Tracey believes Hyster now has the best cooling in the industry, while stamping out “niggly problems” has improved reliability in terms of hydraulics and electrics.
The Vehicle System Manager (VSM) software also adds something new to the range: trucks can be modified using software and minimal hardware – meaning customisation is less expensive. The Pacesetter VSM is the ‘brain’ of the truck, monitoring, controlling and protecting key truck elements including the powertrain and all electrical systems. It also enables service engineers to diagnose and fix problems by plugging laptops into it via the dashboard.
The more advanced models feature advanced DuraMatch transmission with an adjustable auto deceleration system (ADS) which can be programmed to slow the truck when the accelerator pedal is released – which Hyster claims increases break life by 60%. Controlled roll back on gradients further contributes to truck control and decreased operator fatigue. According to the company, the DuraMatch’s power reversal feature means even the most aggressive direction changes are smooth, increasing tyre life by up to 50%.
In terms of operator ergonomics, Hyster says its E-hydraulic control configuration, available as a mini-lever or joystick, built into the seat armrest and adjustable to operator’s requirements, makes for comfortable operation. Twenty per cent more foot space than previous models makes shifts less fatiguing for drivers: Evaluated by the Ergonomic Centre of North Carolina, 15 independent truck drivers were tested over a typical shift patterns on Hyster Fortens and four competitor trucks. According to Hyster, the results showed its trucks reduce operator fatigue and increase productivity.
Additionally, it has made enhancements to curtain and step design, making it easier for operators to hop on and off trucks.
All of these features, claims Hyster, mean lowest cost of ownership is assured. Which makes sense, because as Lee Tracey says: “The lower the total cost, the more profitable our customers are. Which in turn makes us more profitable.” More articles from Hyster Europe: | 
