SECTION 6 HYDRAULIC SYSTEM

Group 1 Structure and Function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-1 Group 2 Operational Checks and Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-19 Group 3 Disassembly and Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-23

SECTION 6 HYDRAULIC SYSTEM

GROUP 1 STRUCTURE AND FUNCTION
1. HYDRAULIC CIRCUIT (Non OPSS and non boosted brake)

20L7HS01

1 2 3 4 5

Gear pump with priority valve Main control valve Steering unit Steering cylinder Lift cylinder

6 7 8 9 10

Tilt cylinder Suction strainer Return filter Down safety valve Hydraulic tank

6-1

SECTION 6 HYDRAULIC SYSTEM

GROUP 1 STRUCTURE AND FUNCTION
1. HYDRAULIC CIRCUIT (Non OPSS and non boosted brake)

4 5
L R

3 9
1A LIFT TILT P
22.0MPa

2B

2A

3B 3A

4B 4A

2
16.5MPa

AUX1

AUX2

LS

P T G

LS CF

EF

9.0MPa

T/M

10
20L7HS01

1 2 3 4 5

Gear pump with priority valve Main control valve Steering unit Steering cylinder Lift cylinder

6 7 8 9 10

Tilt cylinder Suction strainer Return filter Down safety valve Hydraulic tank

6-1

HYDRAULIC CIRCUIT (OPSS and boosted brake)

7 6 11
L R

1A LIFT

2B

2A TILT

3B 3A AUX1

4B 4A AUX2

3
16.5MPa

22.0MPa

P P T EF SF G

2
T LS T

BF

T/M

TO BRAKE

10

12
20L7HS02

1 2 3 4 5 6

Hydraulic gear pump Dual flow divider Main control valve Brake valve Steering unit Steering cylinder

7 8 9 10 11 12

Lift cylinder Tilt cylinder Suction strainer Return filter Down safety valve Hydraulic tank

6-2

1) WHEN THE LIFT CONTROL LEVER IS IN THE LIFT POSITION

1A LIFT

2B

2A

3B 3A

4B 4A

2
16.5MPa

TILT

AUX1

AUX2

22.0MPa

Steering system
T G

LS

CF

EF

9.0MPa

T/M

Return line

10
20L7HS03

When the lift control lever is pulled back, the spool on the first block moves to lift position. The oil from hydraulic gear pump(1) flows into main control valve(2) and then goes to the large chamber of lift cylinder(5) by pushing the load check valve of the spool. The oil from the small chamber of lift cylinder(5) returns to hydraulic oil tank(10) at the same time. When this happens, the fork goes up.

6-3

2) WHEN THE LIFT CONTROL LEVER IS IN THE LOWER POSITION

1A LIFT

2B

2A

3B 3A

4B 4A

2
16.5MPa

TILT

AUX1

AUX2

22.0MPa

Steering system
T G

LS

CF

EF

9.0MPa

T/M

Return line

10
20L7HS04

When the lift control lever is pushed forward, the spool on the first block moves to lower position. The work port(1A) and the small and the large chamber of lift cylinder are connected to the return passage, so the fork will be lowered due to its own weight.

6-4

3) WHEN THE TILT CONTROL LEVER IS IN THE FORWARD POSITION

1A

2B

2A

3B 3A

4B 4A

2
16.5MPa

LIFT

TILT

AUX1

AUX2

22.0MPa

Steering system
T G

LS

CF

EF

9.0MPa

T/M

Return line

10
20L7HS05

When the tilt control lever is pushed forward, the spool on the second block is moved to tilt forward position. The oil from hydraulic gear pump(1) flows into main control valve(2) and then goes to the large chamber of tilt cylinder(6) by pushing the load check valve of the spool. The oil at the small chamber of tilt cylinder(6) returns to hydraulic tank(10) at the same time. When this happens, the mast tilt forward.

6-5

4) WHEN THE TILT CONTROL LEVER IS IN THE BACKWARD POSITION

1A

2B

2A

3B 3A

4B 4A

2
16.5MPa

LIFT

TILT

AUX1

AUX2

22.0MPa

Steering system
T G

LS

CF

EF

9.0MPa

T/M

Return line

10
20L7HS06

When the tilt control lever is pulled back, the spool on the second block is moved to tilt backward position. The oil from hydraulic gear pump(1) flows into main control valve(2) and then goes to the small chamber of tilt cylinder(6) by pushing the load check valve of the spool. The oil at the large chamber of tilt cylinder(6) returns to hydraulic tank(10) at the same time. When this happens, the mast tilts backward.

6-6

2. HYDRAULIC GEAR PUMP

1) STRUCTURE (Booster brake)

15 16

5 12

10 11

13 14

8
20D7HS14

1 2 3 4 5 6

Housing Body Rear cover Bushing O-ring Pin

7 8 9 10 11

Drive gear Idle gear Side plate O-ring Back up ring

12 13 14 15 16

Side plate Oil seal Snap ring Bolt Washer

6-7

STRUCTURE (Non booster brake)

SERIAL NO :

PART NO :

HYUNDAI

HEAVY INDUSTRIES CO.,LTD.

15 16

29,30 3 B 23 22 21 20 19 B 17 18 6 8 4 12 5 2 7 9 10 11 1 13 14

24 25

28

27

26

SECTION B - B"

20L7HS07

1 2 3 4 5 6 7 8 9 10

Housing Body Priority valve body Bushing O-ring Pin Drive gear Idle gear Side plate O-ring

11 12 13 14 15 16 17 18 19 20

Back up ring Side plate Oil seal Snap ring Bolt Washer Plug O-ring Orifice plug Spool

21 22 23 24 25 26 27 28 29 30

Spring Plug O-ring Adjust screw O-ring Bolt plug Poppet Relief spring Plug O-ring

6-8

3. MAIN CONTROL VALVE

1) STRUCTURE (4- Spool)
3 4 6
G F

2
F I

27 25
E G F F I

7 12 16 15 28 17 30 29 13 14 8 9 10

26
SECTION H - H

18

SECTION T - T

31

SECTION E - E

11

32 19 22 23
T H

15
H

24
T

15 19

22 23

20

VIEW I - I

21

8
VIEW G - G VIEW F - F

Port name Inlet port Outlet port

Size 1-1/16-12UNF-2B 1-1/16-12UNF-2B

20D7HS07

1 2 3 4 5 6 7 8 9 10 11

Lift block assy Tilt block assy Aux1 block assy Aux2 block assy T cover Gauge plug assy Long bolt Hydrostat plug O-ring Hydrostat spring Hydrostat sleeve

12 13 14 15 16 17 18 19 20 21

Relief piston Nut Relief plug O-ring Relief spring Pilot poppet Plug O-ring O-ring O-ring

22 23 24 25 26 27 28 29 30 32

O-ring O-ring, retainer Plug Steel ball Load sensor spring Load sensor spring O-ring System relief seat Secondary relief seat Solenoid valve assy

6-9

2) INLET SECTION OPERATION (1) Structure and description

(Relief valve piston) 12 16 28 17 30 Relief valve piston

T

13 14 9 8 10

29

11

20D7HS08

8 9 10 11 12 13

Hydrostat plug O-ring Hydrostat spring Hydrostat sleeve Relief piston Nut

14 16 17 28 29 30

Relief plug Relief spring Pilot poppet O-ring System relief seat Secondary relief seat

6-10

(2) Operation

Secondary relief valve To neutral passage

P

16.5MPa

To aux block To neutral passage

System relief valve

T

22.0MPa T

P 1 To load check valve

20L7HS15

Oil flows from P(pump) port to reservoir(T) by pushing hydrostat spool(1). Before the center bypass line closed, hydrostat spool is keep opening, so pump port(P) and tank port(T) are always connected in operation to minimize heat generation.

6-11

3) LIFT SECTION OPERATION (1) Lift position

1A

Load check valve

20D7HS09

When the lift control lever is pulled back, the spool moves to the right and the neutral passage is closed. The oil supplied from the pump pushes up the load check valve and flow into lift cylinder port(1A). The pump pressure reaches proportionally the load of cylinder and fine control finished by shut off of the neutral passage. The return oil from cylinder flows into the tank.

6-12

(2) Lower position

1A

Load check valve

20D7HS10

When the lift control lever is pushed forward, the spool moves to the left and the neutral passage is closed. The spool moves to the lift lower position, opening up the neutral passage to tank and (1A) T. In lift lower position the fork drops due to its own weight.

6-13

4) TILT SECTION OPERATION (1) Tilt forward position

2B

2A

Tilt lock spool

Load check valve

20D7HS11

When the tilt control lever is pushed forward, the spool moves to the left and the neutral passage is closed. The oil supplied from the pump pushes up the load check valve and flow into tilt cylinder port(2B). The pump pressure reaches proportionally the load of cylinders and fine control finished by closing the neutral passage. The return oil from cylinder port(2A) flows into the tank through the hole of the tilt lock spool.

6-14

(2) Tilt backward position

2B

2A

Tilt lock spool

Load check valve

20D7HS12

When the tilt control lever is pulled back, the spool moves to the right and the neutral passage is closed. The oil supplied from the pump pushes up the load check valve and flows into tilt cylinder port(2A). The pump pressure reaches proportionally the load of cylinder and fine control finished by shut off of the neutral passage. The return oil from cylinder port(2B) flows into the tank via the low pressure passage.

6-15

5) MAIN RELIEF VALVE (1) Pressure setting A good pressure gauge must be installed in the line which is in communication with the work port relief. A load must be applied in a manner to reach the set pressure of the relief unit. Procedure Loosen lock nut. Set adjusting bar to desired pressure setting. Tighten lock nut. Retest in similar manner as above.

Relief plug Lock nut O-ring

Seat

Adjust bar

Pilot poppet Relief spring

T Main relief valve : 220 bar P

20L7hs08

(2) Operation Pressurized oil over the relief pressure pushes pilot poppet and flows to tank passage, therefore the system pressure keeps under the adjusted relief pressure.
Pilot poppet

HP

Relief spring

T
D255HS13

6-16

4. LIFT CYLINDER

10

11

13

12

14

15

4,5

D255HS18

1 2 3 4 5

Tube assembly Rod Piston Piston seal Back up ring

6 7 8 9 10

Wear ring Retaining ring Gland Dust wiper Rod seal

11 12 13 14 15

O-ring Guide DU bushing Spacer O-ring

5. TILT CYLINDER

23 18 19 20,21,22

11,10 13,12

17 16

15,14 9

1 3

20L7HS19

1 2 3 4 5 6 7 8

Tube assembly Rod Piston Glyd ring Wear ring O-ring Hexagon nut Gland

9 10 11 12 13 14 15 16

Bushing U-packing Back up ring Dust wiper Stop ring O-ring Back up ring O-ring

17 18 19 20 21 22 23

Washer Eye Bushing Hexagon bolt Spring washer Lock nut Grease nipple

6-17

6. FREE LIFT CYLINDER

11,12

10

9 13,14

20L7HS20

1 2 3 4 5

Tube assembly Rod Piston Piston seal Wear ring

6 7 8 9 10

Check valve Retaining ring Set screw Gland U-packing

11 12 13 14

Dust wiper Retaining ring O-ring Back up ring

6-18