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Hydraulic Schematic Animation Hydraulic Schematic Animation

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Learning objective Learning objective
Learning Objectives:
At the completion of this lesson, the student will be able to:
Given a truck, operate all truck functions using correct
safety procedures.
Identify and explain the function of each hydraulic
component.
Given schematics and training materials, describe the
hydraulic system and trace the functional circuits on the
truck.
Using schematics and training materials, find and test all
hydraulic test points on the truck.
Troubleshoot electrical and hydraulic problems in a logical
manner
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MIT MIT Forklift Trucks dealer network. Forklift Trucks dealer network.
Copyright Copyright by MCFS. All rights reserved. Reproduction of this material in by MCFS. All rights reserved. Reproduction of this material in any form is Prohibited without written permission of MCFS. any form is Prohibited without written permission of MCFS.
Learning Objectives:
At the completion of this lesson, the student will be able to:
Given a truck, operate all truck functions using correct safety procedures.
Identify and explain the function of each hydraulic component.
Given schematics and training materials, describe the hydraulic
system and trace the functional circuits on the truck.
Using schematics and training materials, find and test all hydraulic
test points on the truck.
Troubleshoot electrical and hydraulic problems in a logical manner.
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System Layout for MC type System Layout for MC type
Block Diagram showing all hydraulic components and controls.
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Hydraulic component locations Hydraulic component locations
Pressure
Switch
Priority
Valve
This valve is located under the LH step.
Because this model is a so called 2-motor system , the traction system is
one and the hydraulic system is the other one.
The hydraulic system only has one motor and one pump. In the pump has no
priority valve. Therefore, an external priority valve is used togive steering
priority over mast operation for safety reasons.
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Identifying Hydraulic Components Identifying Hydraulic Components
Hydraulic
Tank
Gear
Pump
Control
Valve
Flow
Regulator
Valve
Down
Safety
Valve
Lift
Cylinders
Tilt
Cylinder
Component view from the operator seat
1.Hydraulic tank
2.Gear pump
3.Control valve
4.Flow regulator valve
5.Down safety valve
6.Lift cylinder
7.Tilt cylinder
8.First lift cylinder (3-stage and 2-stage full-free panorama mast system)
When the lifts lever or Tilt lever is operated, the micro-switches located in
the spool of the control valve send signals to the logic card inthe main
controller. Based on received signals, the logic card drives thepump motor
and operates the oil pump.
The oil flows from the oil pump to the hydraulic system is the same way as
in the engine powered models.
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Identifying Identifying Hyd Hyd. Control Valve Components . Control Valve Components
Lift Valve
Ass
Tilt Valve
Ass
Att. Valve
Ass
End Cover
Pump Port
From Steering
Control valve
To Tank
Main Relief
Valve
Unload
Solenoid Valve
Lift Lock
Solenoid Valve
Lift Micro-
Switches 1, 2
Tilt Micro-
Switches
Att. Micro-
Switches
1. Lift valve assembly 9. Unload solenoid valve
2. Tilt valve assembly 10. Lift lock solenoid valve
3. Attachment valve assembly 11. Tie bolt
4. End cover 12. Nut
5. Pump port 13. Lift switch 1, 2 (Micro-switch)
6. From steering control valve 14. Tilt switch (Micro-switch)
7. To tank 15. Att. switch (Micro-switch)
8. Main relief valve
The lift valve assembly contains the main relief valve, lift lock solenoid
valve and unload solenoid valve. The tilt valve spool contains the tilt
lock valve.
The micro-switch located on top of the control valve turn ON and OFF
according to the spool movement and send lift and tilt signals to the
logic card.
The lift valve is equipped with two micro-switch for two-step lift speed
selection.
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Flow Regulator Valve Flow Regulator Valve
The flow regulator valve is located between each lift cylinder and
control valve.
It limits the flow of oil forced out of the cylinder to keep a constant
safe lowering speed regardless of load when the loaded forks are
lowered.
The flow regulator valve is located between each lift cylinder and control
valve.
It limits the flow of oil forced out of the cylinder to keep a constant safe
lowering speed regardless of load when the loaded forks are lowered.
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Down Safety Valve Down Safety Valve
The down safety valve is located at
the bottom left of second lift
cylinder.
This safety valve regulates the flow
of oil to prevent the fork from
moving down too quickly in the
following situations:
Hose burnt
Maladjusted of regulator valve
A fault of another component.
The down safety valve is located at the bottom left of second lift cylinder.
This safety valve regulates the flow of oil to prevent the fork from moving
down too quickly in the following situations:
If the piping between the lift cylinder and flow regulator valveis
broken, or
If the flow of return oil from the lift cylinder because excessive
due to a maladjusted regulator valve or
a fault of another component.
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Component
Identification
Hydraulic System Animation Hydraulic System Animation
Component Identification
Left click mouse
Hydraulic tank and filters
Left click mouse
Pump motor and hydraulic pump
Left click mouse
Steering Priority Valve
Left click mouse
Steer Orbitrol Unit
Left click mouse
Steer Cylinder
Left click mouse
Steering Pressure Sensing Switch
Left click mouse
Main Hydraulic Control Valve
Left click mouse
Tilt Cylinders
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Component
Identification
Hydraulic System Animation Hydraulic System Animation
Component Identification
Left click mouse
Mast Lift Cylinders and Down Safety Valve
Left click mouse
Flow Regulator Valve
Left click mouse
Overload Valves (auxiliary relief cartridges)
Standard with truck
Qty 2, P/N 91273-04700 18.1 MPa 2625 PSI
Option
Qty 2, P/N 05461-23050 4.9 MPa 710 PSI
Qty 2, P/N 05461-23070 6.9 MPa 1,001 PSI
Qty 2, P/N 05461-23080 7.8 MPa 1,031 PSI
Qty 2, P/N 05461-23100 9.8 MPa 1,421 PSI
Qty 2, P/N 05461-23120 11.8 MPa 1,711 PSI
Qty 2, P/N 05461-23140 13.7 MPa 1,987 PSI
Qty 2, P/N 05461-23160 15.7 MPa 2,277 PSI
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Component
Identification
Hydraulic System Animation Hydraulic System Animation
Component Identification
Left click mouse
Mast Lift Cylinders and Down Safety Valve
Left click mouse
Flow Regulator Valve
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Hydraulic System Animation Hydraulic System Animation
Pump Running (No Operator Request)
Suction
Pressure
Return
Hydraulic System Animation Hydraulic System Animation
Pump Running (No Operator Request)
Left click mouse
Pump Motor is started and oil is drawn from the hydraulic tank. Pressurized oil
is sent to the steering orbitrol but it is at rest and oil flow is stopped. Pilot oil
now shifts the steering priority valve envelopes letting oil go the hydraulic
valve.
Left click mouse
Oil flows then to the open centered valve, all spools and back to tank.
Left click mouse
Note: See circle. The next lines identified are connected to return to tank.
Left click mouse
All low pressure lines connected to tank are identified.
Steering Theory will be addressed in Steering Section (Tab 6) in student
work book.
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(Lift Request)
Suction
Pressure
Return
(Unloader Solenoid Disabled)
Hydraulic System Animation Hydraulic System Animation
Operator Requests Lift (Unloader Solenoid Disabled)
Left click mouse
Operator pulls lift lever back and shifts the envelopes in the lift spool.
Left click mouse
Lift switch 1 closes and if the pump motor is turned on. At thismoment oil is
being pumped to the lift spool. Then to the lift cylinders.
Left click mouse
Seat switch is open. Unloader Solenoid is not enabled and N/O normally open.
This allows the poppet to be pushed open and allows oil to return to tank and no
active hydraulic functions.
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Hydraulic System Animation Hydraulic System Animation
(Lift Request)
Suction
Pressure
Return
(Unloader Solenoid Enabled)
Hydraulic System Animation Hydraulic System Animation
Operator Requests Lift
Left click mouse
Operator is in the seat and seat switch is closed the Unloader Solenoid is
enabled and closed. No oil can return to the hydraulic tank through it.
Left click mouse
Operator pulls lift lever back and shifts the envelopes in the lift spool.
Left click mouse
Lift switch 1 closes and the Pump motor is turned on or if direction switch is
closed pump motor speed is increased to lift speed 1. At this moment oil is
being pumped to the lift spool. Then to the lift cylinders.
Note: Pulling the lift lever back further closes lift switch 2 and increases
the oil flow to the lift cylinders by increasing pump motor speed.
Results are increased lift speed.
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(Lower Request)
Suction
Pressure
Return
(Lift Lock Solenoid Enabled)
Hydraulic System Animation Hydraulic System Animation
Operator Requests Lower
Left click mouse
Operator pushes lift lever forward and shifts the envelopes in the lift spool.
Seat switch is open. Mast Interlock Solenoid is not enabled and N/C normally
closed. This stops the poppet from being pushed open and does not allow oil to
return to tank and the mast will lower.
Seat switch is closed the solenoid is open. This allows the poppet to be pushed
open and allows oil to return to tank and the mast will lower.
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(Tilt Forward Request)
Suction
Pressure
Return
(Unloader Solenoid Enabled)
Hydraulic System Animation Hydraulic System Animation
Operator Requests Tilt Forward
Left click mouse
Operator is in the seat and seat switch is closed the operator pushes tilt lever
forward and shifts the envelopes in the tilt spool.
Left click mouse
Tilt switch closes and the Pump motor is turned on or if direction switch is
closed pump motor speed is increased to tilt speed. At this moment oil is being
pumped to the tilt spool. Then to the piston side of the tilt cylinders. Then back
to the AnticavitationValve in the tilt spool.
Left click mouse
Next slide
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(Tilt Forward Request)
(Anti Cavitation Valve Enabled)
Hydraulic System Animation Hydraulic System Animation
Tilt Anti Cavitation Valve in Tilt Spool
Left click mouse
When tilt forward is requested by the operator the tilt lever ispushed forward.
The oil flows through the top envelop tilt spool port.
The pressurized oil comes back into the spool from the ram side of the tilt
cylinders. Since the oil is blocked pressure is applied to a pilot port in the spool.
Left click mouse
Pressurized hydraulic oil is forced against the Anti CavitationValve in the tilt
spool. Because the valve is not open, pressure is applied to thebottom of the
moveable anti cavitationspool and against the spring tension. This opens the
port to let pressurized oil from the rod side of the tilt cylinders return to tank.
Left click mouse
The rod side oil flow is controlled returning to tank as the restriction will vary
as the pressure to the piston side of the tilt cylinders changes.
This prevents the tilt cylinders from moving faster than the quantity of oil
supplied to the piston end. If this valve is stuck open, the cylinders will acquire
an air pocket between the piston and cylinder tube from lack of oil. If this
occurs the mast will free fall backwards after tilting back past mast vertical.
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(Tilt Forward Request)
Suction
Pressure
Return
(Unloader Solenoid Enabled)
Hydraulic System Animation Hydraulic System Animation
Operator Requests Tilt Forward
Left click mouse
As the position of the spool and the position of the anticavitationgives the
operator the ability to control tilt speed.
Oil from the ram side of the tilt cylinders returns to tank.
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(Tilt Back Request)
Suction
Pressure
Return
(Unloader Solenoid Enabled)
(Tilt Backward Request)
(Unloader Solenoid Enabled)
Hydraulic System Animation Hydraulic System Animation
Operator Requests Tilt Backward
Left click mouse
Operator is in the seat and seat switch is closed the operator pushes tilt lever
forward and shifts the envelopes in the tilt spool.
Left click mouse
Tilt switch closes and the Pump motor is turned on or if direction switch is
closed pump motor speed is increased to tilt speed. At this moment oil is being
pumped to the tilt spool. Then to the rod side of the tilt cylinders. The oil on the
piston side of the tilt cylinder is now returned to tank.
Note: The anticavitationvalve is not needed for this function. The amount
of oil available at the piston side is much more than the rod side. No
possible vacuum bubbles are created during this function do to
hydraulic port size..
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(Tilt Back Request)
Suction
Pressure
Return
(Unloader Solenoid Enabled)
(1
st
Aux Request)
(Unloader Solenoid Enabled)
Hydraulic System Animation Hydraulic System Animation
Operator Requests 1
st
Aux Function
Left click mouse
Operator is in the seat and seat switch is closed the operator pulls aux lever back
and shifts the envelopes in the 1
st
aux spool.
Left click mouse
1
st
aux switch closes and the pump motor is turned on or if direction switch is
closed pump motor speed is increased to 1
st
aux speed. At this moment oil is
being pumped to the 1
st
aux spool. Then to the attachment cylinders. The oil on
the other side of the attachment cylinder is now returned to tank.
Note: This works for the lever pushed forward and the same for the 2
nd
aux
function.
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Hydraulic System Animation Hydraulic System Animation
Hydraulic Control Valve Oil Flow Capabilities
Oil flow is controlled by availability from the Hydraulic Pump and
the smallest restriction between the valve and the mechanism to
be operated.
Most likely on a Forklift this restriction will be located in the
fittings or hose size used to operate a hydraulic device.
The following maximum efficient oil flows are as follows:
1/ 4 # 4 hose at 2000 PSI at 20 ft per second = 5.0 GPM
3/ 8 # 6 hose at 2000 PSI at 20 ft per second = 10.0 GPM
1/ 2 # 8 hose at 2000 PSI at 20 ft per second = 15.0 GPM
Hydraulic Control Valve Oil Flow Capabilities
Oil flow is controlled by availability from the hydraulic pump and the smallest
restriction between the valve and the mechanism to be operated.
Most likely on a forklift this restriction will be located in the fittings or hose
size used to operate a hydraulic device.
The following maximum oil flows are as follows:
1/4 #4 hose at 2000 PSI at 20 ft per second =5.0 GPM
3/8 #6 hose at 2000 PSI at 20 ft per second =10.0 GPM
1/2 #8 hose at 2000 PSI at 20 ft per second =15.0 GPM
Attachments that are sometimes used require the following oil supply GPM.
Paper Roll Clamp Arm pressure: Max. 2300 PSI at 10 GPM
Paper Roll Clamp Rotator pressure: Max 2300 PSI at 15 GPM
Side Shifter Pressure: Max 2100 PSI at 5 GPM
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Any Questions? Any Questions?