Appendix A2- Technical Specifications

Technical specification for 32,000 kg load/1200 mm load center Fork Lift Truck

(FLT)

1. Intended use

1.1. The FLTs will be used for port and warehouses operations in Israel

Railways (ISR) facilities, in Israel. The FLTs will be used for quayside

operations and inside storage warehouses.

The FLT will operate in hard operation conditions and dusty environment.

Temperature inside the warehouses can reach the 45 c/degrees.

1.2. The FLT systems, engine, transmission, torque converter, drive

axle, planetary gear, must be capable to withstand the severe

working conditions existing in the sites.

1.3. All systems shall be capable to withstand the changing of traveling

direction without bringing the FLT to a full stop.

1.4. The FLT shall be provided with the following attachment :

►forks (see para. 2.4)

►integral side shifter/fork positioner (see para. 11).

►a full preparation for connecting and operating of steel coil

attachement.

FLT and attachments to be provided for quick connect / disconnect

hydralic and mechanical.

1.5. FLT stability and safety shall be according to FEM or ASME b56.1

standard.

2. Performance characteristics

2.1. Capacity (basic, no attachments)

►FLT 32T -not less than 32,000 kg.

►max. Deration due to side shift/fork positioner

not more than 5%

2.2. Load center 1200 mm.

2.3. Lifting height and mast construction:

standard duplex mast, free view construction with two (2) lift

cylinders mounted on the side of the mast. Carriage to be designed

for maximum visibility

►lift height (T.O.F) about 4,000 mm

►overall lowered height

not more than 4,300 mm.

2.4. Forks

2.4.1. Standard (pin type)

►fork length min. 2,400 mm

►fork thickness bout 110 mm.

►fork width bout 300 mm.

forks should be suitable for general cargo handling and 20'

containers with ISO fork pockets

2.5. Tilt angle

maximum manufacturer standard, according to lift height.

2.6. Overall dimensions

FLT has to operate in narrow aisles, therefore minimum length and

turning radius are most important.

2.7. Speeds

►top travel with load over 23.0 km / hr

►top travel without load over 23.0 km / hr

►lift with load over 0.20 m / sec

►lift without load over 0.20 m / sec.

►lowering with load over 0.45 m / sec.

►lowering without load over 0.45 m / sec.

3. Power plant

3.1. Engine : diesel. To be according to updated polution / emission rules

cummins, perkins or mercedes - preferred ,with power of at least

170 KW(227 hp) .

3.2. Transmission

power shift with torque converter (heavy duty)

( see para. 1.2 & 1.3 ) hydrostatic drive system is not accepted.

Synthetic oil shall be offered as an option.

3.3. Engine cooling

rated for work in the tropical zone, (see para. 1.1 for ambient

temperatures), water cooled engine equipped with a coolant

recovery bottle. The radiator shall be provided with a screen to

eliminate radiator clogging when working in application involving

fibrous materials. The radiator shall be easily accessible for screen

checking & cleaning.

3.4. Engine air inlet

engine air inlet will be provided with a heavy duty double stage

Donaldson type or equivalent cyclonic pre cleaner and multi tube

dry paper filter element with an air restriction indicator. Intake to be

high as possible. Above ground level.

3.5. Exhaust

exhaust pipe mounted in upswept position.

3.6. Engine oil filter

full flow heavy duty replaceable element type.

3.7. Transmission oil system

the transmission oil system shall have a separate oil cooler and a full

flow heavy duty oil filter with a replaceable element and differential

pressure indicator . There will not be any connection between the

transmission oil system and the hydraulic system.

3.8. Advantage will be given to manufacturer that will suggest an

efficient, environment friendly and economic "drive plant"

4. Travel

4.1. Tires:.

Tire size to be according to manufacturer standard for heavy duty

work. Same size to front and rear wheels is preferred.

Tires manufactured by Bridgestone/Toyo /Yokohama/Michelin

/Goodyear/Continental or Simex will be offered

4.2. Steer axle and steering cylinder

steering cylinder shall be of the double acting double ended single

cylinder and a fixed length rod type, heavy duty and well protected.

(pivoting steer axle with dual steer cylinders is not acceptable).

4.3. Steering system

fully hydrostatic - the system shall permit dead engine steering.

4.4. Drive axle

extra heavy duty with planetary final dual drive.

Special care should be given to drive axle configuration, to

withstand the working condition described in para. 1.

4.5. Brakes

self-energizing and self adjusting, hydraulic brakes.

Brake lining should be of asbestos-free material.

Wet brake system preferred.

5. Hydraulic system

5.1. All hydraulic components to be of heavy duty type, and to be made

of highest quality steel. All cylinder rods to be chrome plated.

5.2. All hydraulic hoses - fix and flexible, to be well protected against

operation damage. Flexible hoses to be as short as possible and

easily replaceable.

5.3. Hydraulic system to be designed in such a way that use of pipes and

hoses will be reduced to a minimum.

5.4. A filter with restriction indicator shall be provided. Tank strainers to

protect the hydraulic pumps shall be provided in the pressure line.

5.5. Multi stage control valve shall be provided to control basic FLT

systems.

5.6. A load protector control valve shall be provided.

5.7. Hydraulic oil to be according to ATF type a suffix a specification.

6. Fuel system

double stage fuel filter:

► first stage - sediment bowl.

► Second stage - replaceable cartridge.

Fuel tank capacity to be sufficient for at least 16 operating hours.

7. Electrical system

► 24 volt system.

► heavy duty alternator.

► battery capacity(amp/hr) to be max. available, low maintenance /

maintenance free type.

►All electric components to be heavy duty type and rated for 24 volt

operation.

► Fuses and relays will be mounded in central electrical box.

8. Driver cab, controls and instruments

8.1. The following controls shall be provided :

8.1.1. Brake pedal, and separate inching pedal.

8.1.2. Power shift selector.

8.1.3. Hydraulic system motion controls by handle, (Joystick not

acceptable) mounted on the right side of the steering wheel

► raise / lower control.

► tilt control.

► side shift / fork positioner controls.

8.1.4. Two rear view mirrors- one on each side.

8.1.5. Audio alarm for reverse movement.

8.2. Instruments

hour meter, engine coolant temp., fuel gauge, ammeter, engine oil

pressure gauge, transmission oil pressure gauge, transmission oil

temperature gauge.

8.3. central lubrication system

fully automatic central lubrication system shall be provided. The

system shall lubricate all the main surface contact areas (axels,mask

sliding bars ,etc.) .recommended grease type shall not contain

graphite.

8.4. Warning lights

low engine oil pressure, low transmission oil pressure, high

transmission oil temperature, alternator, clogged air cleaner, break

fluid level and water in fuel. (Including warning signal).

8.5. Engine protection system

an engine automatic shutoff protection system or "crawl home"

system shall be provided (the "Crawl Home" System should lower

the engine RPM and the power).The system will monitor at least the

following functions:

► low engine oil pressure.

► high transmission oil temperature.

► high coolant temperature.

► low coolant level

8.6. Overhead guard shall be provided. The Overhead guard shall be

according to ASME B56.1 standard or equivalent.

8.7. Tropical zone air condition. The air condition unit is to be installed

inside the cab.

The temperature in the cab should reach to 22 °C at ambient

temperature described in para.1. All components to be H.D. suited

for automotive equipment.

8.8. The Cab shall be provided with sound and heat insulation. Extra

insulation should be provided also between cab and engine.

Heater/demister and fresh air ventilator, with high ventilation

efficiency will be installed.

The cab shall be mounted on rubber elements to ensure low level of

vibration in operator's compartment.

Great care shall be given to the operator’s visibility (front, rear and

sides). The cab, front and rear windows shall be large to assure

unobstructed front & back visibility of the operator.

8.9. A full suspension full adjustable with double sided ajustment

mechanizm, vinil covered seat shall be provided (bostrom seat

preferred).

8.10. Window blinds for all windows.

8.11. Sound level

sound level at operators ears shall not exceed 80 db(a) the

manufacturer shall attach to his proposal data regarding the noise

level of the offered equipment, tested according to din 45635 t36.

The results of the tests shall be entered onto the appropriate form

attached to din 45635 t36 bbl1 noise level tested according to s.a.e.

J88 or bita rp20 standard is acceptable.

8.12. Lights

Lights (traveling lights to be operated automatically at engine

starting)

● Four mast mounted floodlights:

● Tail, stop, reversing lights and turn signals.

● 2 floodlights - cab mounted.

● Rotating amber light - cab mounted.

● Reverse warning alarm, with flashing red lights.

9. Paint

standard manufacturer scheme.

10. Special attachments and accessories

10.1. Side shift / fork positioner

an integral side shift and fork positioner system shall be provided

with the FLT. The side shift and positioning cylinder shall be

mounted in a protected location, to protect them against operation

damage. Carriage to be of the quick connection type. Manufacturer

to provide a drawing showing the type of quick connection

proposed, with its proposal.

10.2. A scanner including integrated software shall be provided for each

forklift. The scanner shall be capable to connect to the forklift main

controller via a designated socket and derive essential date

(maintenance info, fault finding,diagnictic etc.) of the engine,

transmission and other main systems.

10.3. TV REAR VIEWER (CLOSED CIRCUIT TV) – Option (to be

priced separately)

The system should give the operator a clear view of the rear

traveling side. Camera shall be installed on the rear side of the FLTs

and a monitor in the operator cab. The monitor should display the

view in the rear direction of traveling.

The system shall be COMMAX CCM - 7RV or equivalent.

The COMMAX CCM - 7RV system shall include:

► CRT 5.5” black & white

► Resolution more than 800 line

► Power source 11 - 30 VDC

► Mirror function : change left (right) to right (left) of object

► Suitable for mobile use (vibration).

10.4. Steel coil pin (ram) -Option (to be priced separately)

The FLT will be provided with a steel coil handling pin.

● Pin capacity according to FLT capacity.

● Pin length - 1,800 mm.

● Load center about - 900 mm.

The pin will be provided with quick mounting / dismounting provisions suited to the

quick connection carriage of the FLT.

11. Quality control

11.1. The manufacturer shall be responsible for inspection methods,

maintaining surveillance and controls for all testing and special

processes, checking manufacturing methods, materials and bought-

in items, for compliance with applicable specifications,

manufacturing reports of inspections and tests to be provided to the

purchaser.

Test and inspection reports shall be furnished for:

(a) engine

(b) transmission

(c) hydraulic pumps and cylinders

(d) steel used in load bearing structural frame members

(e) brakes

(f) welders' certifications

(g) safety devices

11.2. The contractors' quality control system should follow ISO 9000/2

guidelines.

The manufacturer shall submit a certificate issued by an independent

organization showing that he and his major sub-contractors meet iso

9000 requirements.

12. Final adjustment and testing

the manufacturer shall submit to the purchaser for approval the full testing

program, including the content of test(including dynamic and static test) ,

methods of conducting control and measuring & Required characteristics

and result data.

Final test shall be conducted at the manufacturer plant and test report to be

submitted to the purchaser.

13. Safety arrangements

13.1. General assembly and detail design of the FLT shall conform the

safety regulations and codes.

13.2. All nuts, connecting the moving and rotating parts (couplings,

drums, sheaves, etc.) Shall be of the self-locking type to prevent

their loosening due to vibration.

13.3. All exposed rotating parts shall be provided with rigid safety guards.

13.4. Unavoidable hazardous points shall be marked with a special

warning paint (yellow and black stripes).

14. Operator maintenance

easy access shall be provided to enable the performance of all daily

maintenance checkout and liquids replenishment tasks without the necessity

to tilt the driver cab or to dismantle obstructing components or to use

special tool/equipment.

15. Recommend spare parts list

Manufacturer shall submit a quoted (including prices) recommended spare

parts list. The common spare parts list should be cover all spare parts

consumption for 3 years operation, based on 2000 working hours per unit

per year.

16. Technical manuals.

The following technical manuals in English shall be provided in 5 copies

with the FLT's and one copy is to be provided with the proposal). In

addition, one copy on magnetic media (pc disc or cd-rom) shall be

provided.

16.1. Operation manual in English and Hebrew.

16.2. Safety instruction in Hebrew

16.3. Maintenance manual in English.

16.4. Repair and overhaul manual.

16.5. Parts catalogue.

16.6. Engine operation and maintenance manual.

16.7. Engine overhaul manual.

16.8. Engine parts catalogue.

16.9. Transmission operation and maintenance manual.

16.10. Transmission overhaul manual.

16.11. Transmission parts catalogue.

16.12. Maintenance/repair manuals and parts catalogue for other repairable

components if were not included in the FLT manual.

16.13. In addition a list of all spare parts to be provided in xl format.

16.14. List of recommended spare parts to be provided in xl format.

Note: the manufacturer can combine one or more manuals into one volume.

17. Training.

The manufacturer shall provide operation and maintenance personal

training in Israel. Training will include:

17.1. Operators’ training.

17.2. Mechanical and electrical technicians training in performing routine

maintenance, fault monitoring, trouble shooting, using necessary diagnostic

scaners,

17.3. The manufacturer will enclose to his proposal a detailed training program.

17.4. The training for every field: mechanical, electrical and operation should be

handled up to three sessions for each field if necessary. Every session shall

last at least 2 day. The instructor should be a qualified technician.

18. General instructions.

The listed capacities, dimensions and ratings are only indicative. The

manufacturer shall propose his standard equipment to be as near as possible

to the listed capacities, dimensions and ratings.

The manufacturer shall submit with his proposal detailed specifications for

the FLT.

The manufacturer shall provide with his proposal a list of all standard

equipment that is not included in the proposal price.

19. Data to be submitted with the proposal.

19.1. FLT technical specification.

19.2. FLT general arrangement drawing showing at least the following

dimensions:

19.2.1. Overall width

19.2.2. Overall length chassis

19.2.3. Wheel base

19.2.4. Total length incl. Forks

19.2.5. Turning radius

19.3. Certificate of sound level according to the specification.

19.4. Completely filled out data sheet (b1).

19.5. Completely filled out summarized mandatory list (b2).

19.6. The manufacturer shall return a copy of this specification and note

at the end of each paragraph if the offered equipment complies or not with

this specification

19.7. Final test report and quality check list sample.

19.8. Other manufacturers options as: (to be offered and priced separately)

19.8.1. Different load center,

19.8.2. Any "Recovery" procedure needed due to engine pollution / emission rules.

19.8.3. central lubrication system,

20. Handing over.

It is the responsibility of the manufacturer to deliver the equipment to israel ready

for operation.

The manufacturer will perform at least the following tasks upon the arrival of the

equipment in Israel.

20.1. Checking and repairing of voyage damages

20.2. Remove all voyage protection materials.

20.3. Assembly and installation as necessary

20.4. Complete equipment checkup

20.5. Handing over of the equipment to ISR in a fully serviceable and operational

status.

21. Service facilities and spare parts.

21.1. The manufacturer should have authorized workshop approved by ministrery

of transportation in Israel for repairs and maintenance of forklift trucks, and

/ or agreement with such workshop.

21.2. Relevant documents (certificates from m.o.t and / or agreement) should be

submitted.

21.3. Regular service and repair will be performed by ISR.

21.4. The manufacturer will be obliged to supply spare parts in shortest time.

22. Supplying of Special tools and spare parts

22.1. One set of special tools for maintenance and overhaul including software

and monitoring appliance is to be supplied with the FLTs

22.2. Spare parts for periodical maintenance for 24 month and 4,000 working hours

shall be provided for every FLT (not including liquids)

23. Warranty

23.1. The equipment will be supplied free from any defects in material or

workmanship warranty period, under normal use and/or service, will be for

24 months or 4,000 working hours whichever occurs first.

23.2. The warranty will include (on top of the standard warranty) but not limited to

the following aspects:

23.2.1. Cost of parts and labor, including:

► cost of parts shipment or technicians transportation to the sites.

► cost of equipment shipment to and from the manufacturer’s workshop (if

necessary).

23.2.2. Systems such as engines, transmissions, batteries, tires, etc., which are

not manufactured by the manufacturer.

23.2.3. Response time by the local service station / representative, for calls

under warranty, of not more than 3 (three) working days.

23.3. Urgent repairs - may be done by ISR staff, without derogating from the

manufacturer’s obligations under the warranty.

The manufacturer will reimburse ISR for the spare parts used and the cost of

labor invested by ISR for the urgent repairs.

23.4. Any fuel additive or supplement or other material that is needed in order to

operate the FLT according to pollution / emotion rules (Tier IV) during

warranty period will be supplied by the manufacturer.

24.

Manufacturer- date- .