Brueninghaus Hydromatik

Hydrostatic Drive Systems for Fork Lift Trucks

RE 98069/04.95

Hydrostatic Drive Systems for Fork Lift Trucks

Drives, Control, Movement.

A complete transmission
system from a single
supplier. For
Industrial fork lift trucks
Rough terrain fork lift trucks
Telescopic fork lift trucks
Side lift trucks
Transportable fork lift trucks
2

In order to ensure integration into complex

logistic systems increased demands are placed
on the drive hydraulics of the new generation
fork truck with respect to
Economics
High rate of continuous performance
Low consumption of energy
Extremely flexible
Eccologically acceptable
Reduced noise and
exhaust emission
Ease of operation and travel
Simple operation

Hydrostatic drive systems from Brueninghaus

Hydromatik fulfil these requirements to a large
extent and offer special advantages when used
in transmission drives of for steering and service
hydraulics:
k Maximum tractive effort even at lower diesel
speed
k Closed loop load limiting control of diesel
engine
k Sensitive manoeuvring by "inching" even
at high engine speeds
k Freedom of design regarding positioning
of hydraulic components in vehicle chassis

k Automotive travel, travel as comfortable

as with a private motor car with automatic
gears
k Smooth change of direction of travel by
altering swivel angle of variable pump
k Reduced brake wear due to hydrostatic
deceleration in closed loop circuit
k Optimum power distribution between drive
and service hydraulics
k Full power usage even in lower speed
range

As part of the Mannesmann Rexroth group of

companies we are in a position of being able
to also supply serveral control devices, valves
and mechanical drives, such as splitter gear
box, wheel motors, etc.

The Mannesmann Rexroth group of companies

is able to offer a complete solution for any drive
application.
Why not talk to our fork lift truck sales
department?

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 logical result of our extensive quality
assurance strategy.
3

Industrial fork lift trucks load capacity up to approx. 7.5 tons

sp
ee
d
Di
es
el

Block curve

Tractive effort / Operating pressure p/pmax

Single wheel drive

BKM

Differential effect through single wheel drive, low centre of gravity of vehicle

Hydrostatic drive (mobile transmission)

Speed v (km/h)

Travel speed / displacement Vg/Vg max

Revolutions n (rpm)

Variable displacement pump A4VG

Closed loop circuit
Nominal pressure 400 bar
Peak pressure 450 bar
See data sheet RE 92 003

Hydraulic motor MCR

Low speed high torque
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
Drum drive with integral plug-in fixed
displacement motor A2FE

Rough terrain fork lift trucks load capacity up to approx. 8 tons

Axle drive

BKM

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

Hydrostatic drive (mobile transmission)

k Large control range through use of variable displacement pump
and variable displacement motor

Freedom of design regarding positioning of drive components in vehicle chassis

Motor (diesel)
Axial piston pump
Flexible high pressure lines

Axial piston motor

Axle
Service hydraulics

Cooler

Variable dispalcement pump A4VG...DAD

For further information see
data sheet RE 92 003
Selection of travel direction
Selection of speed, dependent on
no. of revolutions
Closed loop load limiting control
Integral inching function
Pressure cut-off

Variable displacement motor A6VM...DA

For further information see
data sheet RE 91 604
Selection of speed, dependent on
no. of revolutions

Hydraulic inching and brake function

Hydraulic fine inching valve

By operating the brake pedal the hydraulic fine
inching valve, together with the operating brake,
causes a reduction of the swivel angle at the
pump outside the response range of the
operating brake.
DA

This means:

DA

k secure deceleration / braking

Brake cylinder

BKM
A4VG

k less wear on the brake

k sensitive shunting

A6VM

Hydraulic rotary inching valve

Actuation of the rotary inching valve causes a
proportional reduction in the pump pilot
pressure, causing the pump to swivel back to
Vg min = 0.

Rotary inching valve

Vg max (Zero position)

Vg min = 0

k Reduction of travel speed until the vehicle

comes to standstill
k Reduction in wear of brake

Electronic control of fork lift trucks

Drive pedal

Inching/
brake pedal

Direction of travel
forwards/neutral/reverse

Emergency off

+
Battery 12/24 V
-

Seat switch

Tilt

Potentiometer

Switch

Potentiometer

Lift

Extra

Function

Switch

Microcontroller MC
+
Software FGR

RS 232

BB-3

Command value

Brake control

Actual value

EP

MHCSP

Speed sensor

EP

BKM
Electrohydraulic
positioning system

Mechanical
injection pump
or throttle valve

A4VG/
A10VG
EP

k Automotive travel characteristic

Travel velocity dependent on diesel engine
speed

k Constant Speed Drive (CSD) on increasing

engine speed by operation of service
hydraulics

k Adjustable DA characteristic

k On request various acceleration and

deceleration parameters may be set
externally via control box BB-3

k Load limiting control

Diesel pull-down may be selected for any
value over complete range
k Controlled selection of travel velocity
independent of diesel engine speed
Microcontroller MC7

k Diesel engine speed control dependent on

usage and power requirement of service
hydraulics
k Hydraulic variable displacement motor
linked to control concept
k Optional integral brake control

Control box BB-3

10

A2FM/E A6VM/E
A4FM MCR

Var. displ. pump

T1

max

+L
ift

T1

ndiesel / vtruck

Diesel motor

p (bar)

T (Nm)

Microprocessor Control

Vg (cm3)

n (rpm)
Solenoid current

max
2

Travel

Permissible push down

Gas potent.

Load limiting control function

Speed sensor
e.g. Inductive impulse detector ID
See data sheet RE 95 038

Control box VT 12321 (BB-3)

for diagnostics and for setting
parameters in combination with the MC
For further information see data sheets
RE 29 798 and RE 95 080

Constant
travel speed
t (time)

Hall effect speed sensor HD

See data sheet RE 95 042
Gas potentiometer
e.g. Encapsulated potentiometer GP
See data sheet RE 95 037

Microcontroller MC7
For further information
see data sheet RE 95 050

Variable displacement pump A4VG...EPD

For further information
see data sheet RE 92 003
Positioning cylinder
e.g. Electrohydraulic positioning cylinder
type MHCSP, see data sheet RE 64 568

Selection of travel direction and

speed
Pressure cut-off
11

Service Hydraulics for Fork Lift Trucks

open loop circuit - drive with fixed or variable displacement pumps

Control devices
Rexroth pilot devices for hydraulic control
e.g. TH5, TH6 or TH7
For further information see data sheets
RE 64 552 / RE 64 556 / RE 64 558

Tilt

Priority flow divider

Steering

Lift

Example: Combination pump A4VG + G3

Fixed or variable displacement pumps for the

service hydraulics may be mounted onto the
through drive of the variable pump for the drive
k no splitter gearbox required

12

Gear pump G2/G3

For further information see data sheets
RE 10 030 and RE 10 039

Variable displacement pump A10VO

For further information
see data sheet RE 92 701

Basic circuit diagram for service hydraulics, with priority flow divider
Lift

Tilt

Steer

Internal gear pump GF3

Compact brake valve LT 13

Valve block M2-10

Accumulator charging valve

13

Filtration
Criteria for functional safety of axial piston units

Filter pore size

In order to ensure the functional safety of axial piston units the following cleanliness
classes are the minimum requirement:
9 to NAS 1638
6 to SAE
18/15 to ISO/DIS 4406
In addition, for the A4VG/A10VG we recommend that (depending on the system and
application):
filter elements 20 ... 30 100

The finer the filtration the better the fluid

cleanliness class obtained 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.

As the pressure difference at the filter element increases, is not allowed to decrease.
At very high fluid temperatures (90 C up to maximum 115 C) the following cleanliness
classes are the minimum requirement:
8 to NAS 1638
5 to SAE
17/14 to ISO/DIS 4406

Standard: suction filtration

(A4VG / A10VG)

Variation: pressure filtration

(A4VG / A10VG)

A
In pressure filtration, optimum cold start
conditions are produced as a result of the
integrated filter short circuit valve.
14

Fluids
Criteria for fluids for axial piston units

Operating viscosity
We recommend that the operating viscosity (at operating temperature) for optimum
efficiency and idle time is selected in the range of
opt = opt. operating viscosity 16...36 mm2/s
with respect to the circuit temperature (closed loop) or tank temperature (open loop).
The following values are valid for limiting conditions*:
min = 5 mm2/s
for brief period at max. permissible temperature of
tmax = 115 C,
max = 1600 mm2/s
for brief period at cold start (tmin = 40 C).

Brueninghaus Hydromatik products may also

be operated using eccologically acceptable
fluids and fire resistant fluids as well as the
fluids based on mineral oils.

Fluids based on mineral oils

Fire resistant fluids

Eccologically acceptable fluids

There are many fluids based on mineral oils

which are more or less suitable for use in
hydrostatic drives.

These hydraulic fluids are mainly used in

mining and machinery used underground. In
practice they are known as HF fluids (H =
hydraulics, F = fire resistant) and they may be
sub-divided into four groups:

Currently three different types of eccologically

acceptable fluids are available:

Their use is primarily decided upon due to their

wear, viscosity and temperature characteristics
taking into account protection against oxidation
and corrosion, compatibility with other
materials, etc.
For further information
see data sheet RE 90 220.

k HFA oil in water emulsion;

water content 95...98 % of weight
k HFB 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

k Hydraulic fluid based on vegetable oil,

HETG (e.g. rape oil)
k Synthetic oil based on polyglycol, HEPG
(e.g. polyethylen-eglycol PEG)
k Synthetic hydraulic fluid based
on esters, HEE
Note: Even eccologically acceptable fluids must
be disposed of in accordance with the relevant
disposal regulations.
For further information
see data sheet RE 90 221.

For further information

see data sheet RE 90 223.

Data sheet RE 90 270 includes installation

instructions for our axial piston units.
For further information consult our sales
department VEM3.

* not permissible in geeral for all axial piston

units
15

Components

Variable displacement pump A4VG

Closed loop circuit
Nominal pressure 400 bar
Peak pressure 450 bar

Radial piston motor MCR

(low speed, high torque)

Further information
data sheet RE 92 003

Mannesmann Rexroth

Variable displacement pump A10VG

Closed loop circuit
Nominal pressure 300 bar
Peak pressure 350 bar

Rototrac drive GFR for wheel drives

Further information
data sheet RE 92 750

Variable displacement pump A10VO

Open loop circuit
Nominal pressure 280 bar
Peak pressure 350 bar
Further information
data sheet RE 92 701

Further information
data sheet RE 77 404
Lohmann + Stolterfoht

Gear pump G2/G3

Single/double pump models or
for mounting onto axial piston units
Further information data sheets
RE 10 030 and RE 10 039
Mannesmann Rexroth

Variable displacement motor A6VM

Open and closed loop circuits
Nominal pressure 400 bar
Peak pressure 450 bar
Further information
data sheet RE 91 604

Brueninghaus Hydromatik GmbH

Mannesmann Rexroth GmbH

Plant Elchingen
Glockeraustrae 2
D89275 Elchingen
Telephone (0 73 08) 8 20
Telefax (0 73 08) 72 74
Telex 712 538

D97813 Lohr am Main

Telephone (0 93 52) 18 0
Telefax (0 93 52) 18 21 59
Telex 689 418-12

Plant Horb
An den Kelterwiesen 14
D72160 Horb
Telephone (0 74 51) 9 20
Telefax (0 74 51) 82 21
Telex 765 321

Further information data sheets

RE 09 727 and RE 15 217

Valve block SP 12
Further information
data sheet RE 77 103
Mannesmann Rexroth