Hyundai supplies 16-ton large stacker truck to LWS in Hannover, "King of the Kabeltrommel" (“King of the cable drums”)

16-ton large hyundai stacker 160f-9l truck at LWS in Hannover,
The company LWS, Logistics Warehousing Systems GmbH, located in Hannover with 60 staff, on the site of two cable manufacturers has, since 2005 been responsible for the dispatch logistics of the cable drums that are up to 50 tons. LWS came from the works logistics of the cable makers Nexans and RFS that still have holdings today. Director York Pokornowski runs the logistics business that currently has a fleet of around 15 Hyundai frontloaders with load capacities from 1.3 to 16 tons.
 

"We are responsible for the loading and dispatch from the end of production", says Pokornowski. In addition there are special orders such as assembling special lengths, available for drums up to 15 tons and diameters up to 4.5 metres. Hyundai Material-Handling importer Nikolic, of Garbsen, has been taking care of the fork lift trucks for 17 years. For this, Nikolic Gabelstaplerservice GmbH has a workshop on the LWS premises.

The cable drums are becoming larger and heavier - director Pokornowski saw that a large stacker truck had to be acquired. "It was fine that Hyundai now has a 16-tonner with 1,200 mm load c-of-g (centre of gravity) point. This machine, fitted with forks of 3,500 mm length from Vetter, is used for the transport of the large drums." Thanks to the stage IV engine, the stacker can operate in the buildings without exceeding the limits.

Kabellogistik is a specialized business, since the very expensive cable types for telecommunications and for high powers must be handled carefully; empty cable drums are preferred and trucks must be loaded with great precision. At present the largest cable drums are 5,000 mm diameter and are up to 3,000 mm long. Significantly larger cable drums of up to 6,000 mm length, that can only be handled with cranes, are already around. 

 

Full-service Leasing

The new large stacker is currently hired in the Full Service for 60 months. Hyundai has even enabled painting the new flagship in the RAL colour 5015. The many special equipments of the south-Korean stacker include solid rubber tyres of dimension 12.00-20. "The rather unusual tyres in this class", says Pokorowski, "are necessary because in the past the service life of pneumatic tyres has been significantly reduced by many sharp-edged objects, kerbstones, ramps and edges. Therefore for all equipment we choose only solid-rubber tyres from a German maker". Pascal Volkering is the customer services manager of Nikolic and with his team he looks after the large fleet of stackers at LWS and in addition both of the multiple-manufacturer fleets of the cable makers on the factory site.

 

Stacker technology in detail

The 160D-9L can load 16 t with 1,200 mm load c-of-g. The machine is powered by a Cummins QSB6.7 engine of 122 kW power, which features optimized fuel consumption. The pollutant limit values of the exhaust norm Stage IV are implemented with a diesel oxidation catalyst (DOC) and selective catalytic reduction (SCR) by the addition of AdBlue. The combination of DOC and SCR reduces maintenance-related downtime and makes almost no demands on routine maintenance.

High-tech systems

The combination of fully automatic ZF transmission and Kessler front-axle ensures perfect maneuvering and gear-changing behaviour of the 160D-9L. The machine has a load-sensing fully proportional hydraulics system. Variable-displacement pumps from Bosch-Rexroth drive the working hydraulics (lifting/ lowering, mast tilt and further functions) and contribute to the reduced fuel consumption. The standard hydraulic cooling fan (reversible), that is controlled according to temperature, also supports the fuel saving. Depending on the application this corresponds to an energy saving of 5% to 10%. The reverse function of the fan is time-controlled - the switching intervals can be programmed using the central screen.

The new-design rubber-cushioned cabin gives the driver a comfortable place to work, with its excellent all-round view, plenty of room and the standard fully automatic air conditioning. The well positioned pedals are easily accessible. An adjustable steering column and an ergonomic sprung seat with manual weight adjustment enable the driver to work without fatiguing. A speed limiter is standard in these machines and easy to program through the central display in the driver's field of view. It supports the smooth and safe operation of the vehicle. 

The driver selects from the various modes of working: in the STD mode the fuel consumption is lower when the machine is doing the easier jobs, while for heavy loads and work on gradients the POWER mode is available. A load display monitors the pressure in the lifting cylinder for calculating the weight on the forks. The load is shown in the central display and when there is an overload the driver hears a warning signal and the load weight flashes red in the monitor. 

The available Triplex masts (up to 7,034 mm lift height) give the driver a clear view thanks to the optimized layout of the lift cylinder and standard mast damping. The panorama mirror and the standard reversing camera, the image from which is displayed on the central screen, further expand the view to the rear. A separate monitor is optionally available, to which four cameras can be connected. Installing this option replaces the standard reversing camera. The enlarged central display (LCD colour display, 4.3") keeps the driver well informed and also gives general operating data, but also displays safety warnings. To prevent the machine from being used by unauthorized people and to protect the stacker against theft, there is, as standard, a lock on engine start-up that can be cancelled only with an access code. Further anti-theft measures include a lockable fuel tank cap.

In the 160D-9L the electric handbrake is connected to the OPSS (operator presence sensing system). When stationary, if the driver leaves his place, the handbrake is automatically applied, preventing the machine from rolling away.

 

Rapid and easy maintenance

The 160D-9L has, as standard, the benefit of an electro-hydraulically tiltable cabin that provides ideal access to all the main components and enables easy and rapid maintenance (500 h maintenance interval) of all components of the drive train. With the large engine hoods, the engine compartment is easily accessible so that daily routine maintenance can be done quickly and efficiently.

 

The expanded digital LCD color monitor in the 160D-9L also gives information about safety warnings, fault messages (engine, transmission and air conditioning) and pending maintenance work. The display can be set to show 13 different languages. All machine settings can be managed using the LCD display. This also has tools for fault finding to reduce the downtime and no laptop is required for diagnosis and carrying out repair work. The instrument panel is, with all functions centrally located, easy to observe and user-friendly.