Service Training

MALAGA

Telescopic Handlers

IX. HYDRAULIC SYSTEM

1.Introduction IX- 1
2.Directional Control Valve IX- 3
3.Pump Operation IX-23
4.Pilot System IX-32
5.Lock Valves IX-40
6.Implement System IX-44 Sara
7.Steering System IX-64 JUNE 1997
Telescopic Handlers
IMPLEMENT HYDRAULIC SYSTEM Boom Raise/Lower
Directional Control Valve Compensating Valve

Compensating
Cylinders Forks
Boom Tele In/Out

Attachment
Carrier
Rotate Tilt
Hydraulic
Pump

Joystick
Load Sensing Line

Tank Filter Frame Level

Manifold Block Frame Level Control Valve
Steering Hand Metering Unit Differential Lock

IX.HYDRAULIC SYSTEM
Section 1 - Introduction

1. Hydraulic Component Location Check List

2. General Hydraulic Schematic (TH62-83)

Page: IX-1
Page:

IMPLEMENT HYDRAULIC SYSTEM Boom Raise/Lower

IX-2

Directional Control Valve Compensating Valve

Compensating
Cylinders Forks
Boom Tele In/Out

Attachment
Carrier
Rotate Tilt
Hydraulic
Pump

CHAPTER : Introduction
Joystick

TELEHANDLERS 62-83
Load Sensing Line

Tank Filter Frame Level

Manifold Block Frame Level Control Valve
Steering Hand Metering Unit Differential Lock
Telescopic Handlers
Implement Pressure Relief Valve
Pressure reducing Valve

Auxiliary Relief Valve

Auxiliary Relief Valve

Compensating Valve Pistons

Load Sensing Passage

Directional Control Valve

IX.HYDRAULIC SYSTEM
Section 2 - Directional Control Valve

1.Directional Control Valve (TH62-83)

2.Directional Control Valve (TH 103)
3.Steering Priority Section (TH62-83)
4.Pilot Operated Section of Direction Control Valve
(TH62-103)
5.Proportional Priority Pressure Compensation (TH62-
103)
Page: IX-3
Page:
IX-4

Directional Control Valve

End Section
Auxiliary

Forks Tele In/Out

CHAPTER : Directional Control Valve

TELEHANDLERS 62-83
Boom

Steering Priority

Outriggers
Page:

Implement Pressure Relief Valve

IX-5

Pressure reducing Valve

Auxiliary Relief Valve

CHAPTER : Directional Control Valve

TELEHANDLERS 62-83
Auxiliary Relief Valve

Compensating Valve Pistons

Load Sensing Passage

Directional Control Valve

VALVE COMPONENTS
Page:

Implement Relief Passage

Port to Frame Levelling Control Valve Load Sense Passage

IX-6

CHAPTER : Directional Control Valve

TELEHANDLERS 62-83
Resolver Valves

INTERNAL PASSAGES
Load Sense Passage
Directional Control Valve
 TELEHANDLER 103
CHAPTER : Directional Control Valve

Page: IX-7
 TELEHANDLER 103
CHAPTER : Directional Control Valve

Page: IX-8
Page:

Main Pressure Gallery

IX-9

Steering Load
Sensing Line
Hand Metering Unit

CHAPTER : Directional Control Valve

TELEHANDLERS 62-83
STEERING
PRIORITY
VALVE
FROM
RESOLVER
Return to Tank NETWORK

Pump Oil Inlet

TO IMPLEMENTS

Steering Section FROM

RESOLVER
NETWORK

Engine Off TO HMU

FROM
STEERING SYSTEM
LOAD SENSING LINE

STEERING PRIORITY
Page:

Main Pressure Gallery

IX-10

Steering Load
Sensing Line
Hand Metering Unit

CHAPTER : Directional Control Valve

TELEHANDLERS 62-83
Return to Tank
Pump Oil Inlet

Steering Section
Engine Running - No Steering
Page:

Main Pressure Gallery

IX-11

Steering Load
Sensing Line
Hand Metering Unit

CHAPTER : Directional Control Valve

TELEHANDLERS
Return to Tank
Pump Oil Inlet

Steering Section
Engine Running - Steering Left
Page:

Main Pressure Gallery

IX-12

Steering Load
Sensing Line
Hand Metering Unit

CHAPTER : Directional Control Valve

TELEHANDLERS
Return to Tank
Pump Oil Inlet

Steering Section
Engine Running - Steering Left & Implement
Page:

Pilot Pressure Feeder Passage

Tank
IX-13

Pilot Oil Pressure Main Pressure Gallery Pilot Pressure

Oparated Sections
HOLD

CHAPTER : Directional Control Valve

Main Control Spool

TELEHANDLERS 62-103
Work Port Bridge Passage
Work Port

Resolver Valve

Pressure Compensating Check Valve

Signal Back to Pump
Page:

Pilot Pressure Feeder Passage

Tank
IX-14

Pilot Oil Pressure Main Pressure Gallery Pilot Pressure

Oparated Sections
START
To engage
Implement

CHAPTER : Directional Control Valve

TELEHANDLERS 62-103
Main Control Spool
Work Port Bridge Passage
Work Port

Resolver Valve

Signal Back to Pump Pressure Compensating Check Valve

Page:

Pilot Pressure Feeder Passage

Tank
IX-15

Pilot Oil Pressure Main Pressure Gallery Pilot Pressure

Oparated Sections
MOVING
the Implement

CHAPTER : Directional Control Valve

TELEHANDLERS 62-103
Main Control Spool
Work Port Bridge Passage
Work Port

Resolver Valve

Signal Back to Pump Pressure Compensating Check Valve

Page:

Proportional Priority Pressure Compensated

IX-16

Pilot Pressure Return toTank Pilot Pressure

Feeder Passage
Main Pressure Gallery

CHAPTER : Directional Control Valve

TELEHANDLERS 62-103
Bridge Passage Main Control Spool

Work Port Work Port

To Resolver Network Pressure Compensating

Check Valve
Pilot Oil Pressure Signal From Other
Oparated Sections Implement From Resolver Network

Implement in Hold - No other Implement Active

Page:

Proportional Priority Pressure Compensated

IX-17

Pilot Pressure Return toTank Pilot Pressure

Feeder Passage
Main Pressure Gallery

CHAPTER : Directional Control Valve

TELEHANDLERS 62-103
Bridge Passage Main Control Spool

Work Port Work Port

To Resolver Network Pressure Compensating

Check Valve
Signal From Other
Implement From Resolver Network

Pilot Oil Pressure

Oparated Sections Implement Initial Shift - No Other Implement Active
Page:

Proportional Priority Pressure Compensated

IX-18

Pilot Pressure Return toTank Pilot Pressure

Feeder Passage
Main Pressure Gallery

CHAPTER : Directional Control Valve

TELEHANDLERS 62-103
Bridge Passage Main Control Spool

Work Port Work Port

To Resolver Network Pressure Compensating

Check Valve
Signal From Other
Pilot Oil Pressure Implement From Resolver Network
Oparated Sections
Implement Fully Shifted - No Other Implement Active
Page:

Proportional Priority Pressure Compensated

Pilot Pressure
IX-19

Feeder Passage Return toTank Pilot Pressure

Main Pressure Gallery

CHAPTER : Directional Control Valve

TELEHANDLERS 62-103
Bridge Passage Main Control Spool

Work Port Work Port

To Resolver Network Pressure Compensating

Check Valve
Signal From Other
Implement From Resolver Network

Pilot Oil Pressure

Oparated Sections Implement in Hold - 2nd Implement Active
Page:

Proportional Priority Pressure Compensated

IX-20

Pilot Pressure Return toTank Pilot Pressure

Feeder Passage
Main Pressure Gallery

CHAPTER : Directional Control Valve

TELEHANDLERS 62-103
Bridge Passage Main Control Spool

Work Port Work Port

To Resolver Network Pressure Compensating

Check Valve
Signal From Other
Implement From Resolver Network
Pilot Oil Pressure
Oparated Sections Implement Initial Shift - 2nd Other Implement Active
Page:

Proportional Priority Pressure Compensated

IX-21

One Implement Fully Shifted

&
Pressure Compensating
Check Valve
Pilot Pressure One Implement On Hold

Pressure Compensating
Check Valve

CHAPTER : Directional Control Valve

TELEHANDLERS 62-103
Pilot Oil Pressure
Oparated Sections

From Resolver
Network
To Resolver
Network
Page:

Proportional Priority Pressure Compensated

IX-22

One Implement Fully Shifted

&
One Implement Partially Shifted
Pressure Compensating Pilot Pressure
Check Valve
Pressure Compensating
Check Valve

Metered Pilot
Pressure

CHAPTER : Directional Control Valve

TELEHANDLERS 62-103
Pilot Oil Pressure
Oparated Sections

From Resolver
Network
To Resolver
Network