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Brueninghaus Hydromatik

R E 980 69/04.95

H yd rostatic D rive S ystem s forFork Lift Trucks

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Hydrostatic Drive Systems for Fork Lift Trucks

In order to ens ure integration into com plex

logistic systems increased d emands are placed

on the d rive hydraulics of the new generation

fork truck with respect to

Economics

High rate of continuou s pe rformance

Low consumption of energy

Extremely flexible

Eccologically acceptableReduced noise and

exhaust emission

Ease of operation and travel

Simple operation

Hydrostatic drive systems from Brueninghau s

Hydromatik fulfil these requirements to a large

extent and offer special advantages when us ed

in transmission drives of for steering and service

hydraulics:

Maximum tractive effort even at lower d iesel

speed

Closed loop load limiting co ntrol of diesel

engine

Sens itive manoeu vring b y "inching" even

at high engine speeds

Freedom of design regarding positioning

of hydraulic compon ents in vehicle chass is

Drives, Co ntrol, Movem ent.

A com plete transm ission

system from a s ingle

s up plier. For

Ind us trial fork lift trucks

Ro ugh terrain fork lift trucksTeles copic fork lift trucks

Side lift trucks

Transportable fork lift trucks

k

k

k

k

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As pa rt of the Mannes mann Rexroth group of

companies we are in a position of being able

to also sup ply serveral control devices, valves

and mechanical drives, such as splitter gear

box, wheel motors, etc.

The quality of the Brueninghaus Hydromatik

products is along with the high level of

technologies the reason for content customers

worldwide.

The certification as to DIN ISO 9001 therefore

is the log ical result of our extensive quality

assurance strategy.

Automotive travel, travel as comfortable

as with a private motor car with automatic

gears

Smo oth chan ge of direction o f travel by

altering swivel angle of variable pump

Reduced b rake wear due to hydrostatic

deceleration in closed loop circuit

Optimum po wer distribution between d rive

and s ervice hydraulicsFull power usage even in lower speed

range

k

k

k

k

k

3

The Mannesmann Rexroth group of companies

is ab le to offer a co mplete s olution for any drive

application.

Why no t talk to our fork lift truck sa les

department?

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Sing le wheel drive

Hydros tatic drive (m obile transmis sion)

Indus trial fork lift trucks -

load cap acity up to ap prox. 7.5 ton s

Diffe ren tial effec t th rou gh s ingle wh ee l d rive , low ce ntre of g ravi ty of v eh icle

Travel speed / displacement Vg/Vg max

Tractiveeffort/Operatingpressurep

/pmax

Blo

ck

curve

Diesel

speed

BKM

Speedv(km/h)

Revolutions n (rpm)

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Variable displac eme nt pump A4VG

Closed loop circuit

Nominal pressure 400 bar

Peak pressure 450 bar

See data sheet RE 92 003

Variable displacement pump A10VG

Sizes 28 and 45

Closed loop circuit

Nominal pressure 300 bar

Peak pressure 350 bar

See data sheet RE 92 750

Hydraulic mot or MCR

Low speed high torque

Drum drive with integral plug-in fixed

displacement motor A2FE

5

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Roug h terrain fork lift trucks -

load ca pac ity up to ap prox. 8 tons

Axle drive

Hydros tatic drive (mobile transm ission)

Large control range through use of variable displacement pumpand variable displacement motor

Travel on rough terrain by means of axle drive (optional mechanical differential locking)

k

BKM

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Motor (diesel)

Axial piston pum p

Flexible high pres sure lines

Axial piston m otor

Axle

Service hydraulics

Cooler

Freedom o f des ign regarding pos itioning of drive com ponen ts in vehicle chas sis

7

Varia ble dispa lce men t pump A4VG...DAD

For further information s ee

data sh eet RE 92 00 3

Selection of travel direction

Selection of speed, dependent on

no. o f revolutions

Closed loop load limiting control

Integral inching function

Pressure cut-off

Variable displacement motor A6VM...DA

For further information s ee

data sh eet RE 91 60 4

Selection of speed, dependent on

no. of revolutions

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Hydraulic inching and brake function

Hydraulic fine inc hing valveBy operating the brake pedal the hydraulic fine

inching valve, together with the operating brake,

caus es a redu ction of the swivel angle at the

pump o utside the respons e range of the

operating brake.

This means :

secu re deceleration / b raking

less wear on the b rake

sensitive shunting

k

k

k

Hydraulic rotary inching valveActuation of the rotary inching valve causes a

proportional reduction in the pump pilot

pressure, causing the pump to swivel back to

Vg min= 0 .

Reduction of travel speed until the vehicle

comes to standst i llReduction in wear of brake

k

k

BKM

A4VG A6VM

DA DA

Brake cylinder

Rotary inching valve

Vg max

(Zero position)

Vg min

= 0

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Electron ic control of fork lift trucks

Automotive travel characteristic

Travel velocity depend ent on d iesel eng ine

speed

Adjustable DA characteristic

Load limiting control

Diesel pull-down may be s elected for any

value over complete range

Controlled s election of travel velocity

independent of diesel engine speed

Diesel engine speed control dependent on

usage and power requirement of service

hydraulics

Hydraulic variable displacement m otor

linked to con trol concept

Optional integral brake control

k

k

Microc on troller M C7

Cons tant Speed Drive (CSD) on increasing

engine speed by operation of service

hydraulics

On request various acceleration and

deceleration parameters may be set

externally via control box BB-3

k

k

k

k

k

k

k

Control box BB-30

A4VG/

A10VG

MHCSP

Mechanicalinjection pum por thro ttle valve

Battery 12/24 V-

Speed sensor

Mic roco ntrol ler MC+

Softwa re FGR

EP

BKM

Direction of travel

forwards/neutral/reverse

Function

Brake control

Inching/brake pedal

EP

EP

+

Emergency off

SwitchSwitch

Tilt ExtraLiftDrive pedal

Potentiometer

Potentio-meter

Electrohydraulicpositioning system

A2FM/E A6VM/E

A4FM MCR

Command value

Actual value

Seat s witch

RS 232

BB-3

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Microprocessor Control

Positioning cylinder

e.g. Electrohydraulic positioning cylinder

type MHCSP, see data sheet RE 64 568

Control box VT 12321 (BB-3)

for diagno stics an d for setting

parameters in combination with the MC

For further information s ee data s heets

RE 29 79 8 and RE 95 080

Load limiting con trol func tion

S pe e d se nso re.g. Ind uctive im puls e dete ctor ID

See data sheet RE 95 038

Hall ef fec t s pe ed sen s or HD

See data sheet RE 95 042

Gas potent iomete r

e.g. Encapsu lated potentiometer GP

See data sheet RE 95 037

11

+L

ift

T(Nm)

p(bar)

P e r m i s s i b l e p u s h d o w n

Solenoid current

Var. displ. pumpDiesel motorT1T1

Gas potent.

Constant

travel spe ed

t (time)

ndiesel

/

vtruck

ma x

m ax2

Travel

Microcont roller MC7For further information

see data s heet RE 95 050

n (rpm) Vg(cm3)

Varia ble displa ce men t pu mp A4VG...EPD

For further informationsee data sheet RE 92 003

Selection of travel direction an d

speed

Pressure cut-off

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S ervice Hydrau lics for Fork Lift Trucksopen loop circuit - drive with fixed or variable displacement pumps

Control device s

Rexroth p ilot devices for hydraulic con trol

e.g. TH5, TH6 or TH7

For further information s ee data s heetsRE 64 55 2 / RE 64 556 / RE 64 558

Gear pum p G2/G3

For further information s ee data s heets

RE 10 03 0 and RE 10 039

Variable d isplac eme nt pump A10VO

For further information

see data sheet RE 92 701

Examp le: Com bination pum p A4VG + G3

Fixed or variable displacemen t pump s for the

service hydraulics may be mounted onto the

through drive of the variable pum p for the drive

k no s plitter gearbox required

2

Steering

Lift Tilt

Priority flow divider

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Inte rnal g ear pum p GF3

Valve block M 2-10 Accum ulator charging valve

Compact brake valve LT 13

Basic circuit diagram for service h ydraulics, with priority flow divider

13

Lift Tilt

Steer

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FiltrationCriteria for functional s afety of axial piston units

4

B

A

B

A

Filter pore sizeIn orde r to ens ure the functional safety of axial piston units the following cleanliness

classes are the minimum requirement:9 to NAS 16 38

6 to S AE

18/15 to ISO/DIS 4406

In add ition, for the A4VG/A10VG we recommen d that (depending on the s ystem and

application):

filter elements 20 ... 30 1 00

As the pres sure difference at the filter element increas es, is not allowed to decrease.At very high fluid temperatu res (90C up to maximum 115C) the following cleanlinessclasses are the minimum requirement:

8 to NAS 16 38

5 to S AE

17/14 to ISO/DIS 4406

The finer the filtration th e be tter the fluid

cleanliness class o btained and the higher the

service life of the axial piston units.

Use filters without bypass .

Recommendation: use clogging indicators.

For further information on filtration of the fluids

see the data sheets on the pumps.

In pres sure filtration, op timum co ld start

conditions are produced as a result of the

integrated filter short circuit valve.

Stand ard: su ction filtration

(A4VG / A10 VG)

Variation: pres su re filtration

(A4VG / A10 VG)

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FluidsCriteria for fluids for a xial piston units

15

Eccologically acceptab le fluids

Currently three different types of eccolog ically

acceptable fluids are a vailable:

k Hydraulic fluid bas ed o n vegetable oil,

HETG (e.g. rap e oil)

k Synthetic oil based o n po lyglycol, HEPG

(e.g. po lyethylen-eglycol P EG)

k Synthetic hydraulic fluid bas ed

on es ters, HEE

Note: Even eccologically acceptable fluids mus t

be disp osed of in accordance with the relevant

disposal regulat ions.

For further information

see data sheet RE 90 221.

Fluids bas ed on m ineral oils

There are many fluids bas ed on m ineral oils

which are more or less suitable for us e in

hydrostatic drives.

Their use is primarily decided upo n due to their

wear, viscosity and temperature characteristics

taking into acco unt protection agains t oxidation

and co rrosion, com patibility with other

materials, etc.

For further information

see data sheet RE 90 220.

Fire resis tant fluids

These hydraulic fluids are mainly used in

mining and machinery used underground. In

practice they are known as HF fluids (H =

hydraulics, F = fire resistan t) and they may be

sub-divided into four groups:

k HFA oil in water emulsion;

water content 95...98 % of weight

kHFB water in oil emulsion ;water content > 40 % of weight

k HFC water based solutions

(mainly with glycols);

water content 35...55 % of weight

k HFD synthetic fluid;

water content 0,1 % of weight

For further information

see data sheet RE 90 223.

Brueninghaus Hydromatik products may also

be operated using eccologically acceptable

fluids an d fire resis tant fluids as well as the

fluids based on mineral oils.

Operating viscosityWe recom mend that the operating viscos ity (at operating temperature) for optimum

efficiency and idle time is selected in the range of

op t= opt. operating viscos ity 16...36 mm

2/ s

with resp ect to the circuit tempe rature (close d loop) or tank temperature (open loop).

The following values are valid for limiting co nditions*:

min

= 5 mm 2/ s

for brief period a t max. permiss ible temperature of

tma x= 115C ,

ma x= 1600 mm

2/ s

for brief period at cold start (tmin

= 40C ).

Data sheet RE 90 27 0 includes installation

instructions for our axial piston units.

For further information co nsu lt our sales

department VEM3.

* not permis sible in g eeral for all axial piston

units

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Gear pump G2/G3

Single/double pump models or

for mounting onto axial piston units

Further information da ta she ets

RE 10 03 0 and RE 10 03 9

Mannesmann Rexroth

Valve block SP 12

Further information

data sh eet RE 77 10 3

Mannesmann Rexroth

Radial piston m otor MCR

(low speed, high torque)

Further information da ta she etsRE 09 72 7 and RE 15 21 7

Mannesmann Rexroth

Rototrac drive GFR for wheel drives

Further information

data sh eet RE 77 40 4

Lohmann + Stolterfoht

Components

Variable displacement pump A10VG

Closed loop circuit

Nominal pressure 300 b ar

Peak pressure 350 bar

Further informationdata shee t RE 92 750

Variable displacement pump A4VG

Closed loop circuit

Nominal pressure 400 b ar

Peak pressure 450 bar

Further information

data shee t RE 92 003

Variable displacemen t pum p A10VO

Open loop circuit

Nominal pressure 280 b ar

Peak pressure 350 bar

Further information

data shee t RE 92 701

Variable displacement motor A6VM

Open and closed loop circuits

Nominal pressure 400 b ar

Peak pressure 450 bar

Further information

data shee t RE 91 604

Plant Elchinge n

Glockeraustrae 2

D89275 Elchingen

Telephone (0 7 3 08) 8 20

Telefax (0 73 08) 72 74

Plant Horb

An d en Kelterwiesen 14

D72160 Horb

Telephone (0 74 51 ) 9 20

Telefax (0 74 51) 82 21

Brueningha us Hydromatik GmbH

D97813 Lohr am Main

Telephone (0 93 52 ) 18 0

Telefax (0 9 3 52 ) 18 21 59

Telex 689 418 -12

Mannesm ann Rexroth GmbH