Troubleshooting General Troubleshooting Charts ...

10 downloads 91682 Views 2MB Size Report
Symbols. Hydraulic. Lines, Pumps, Motors and Cylinders, Valves,. Miscellaneous Units ... .T8. Pneumatic. Air Prep Units, Pneumatic Valves and Valve Actuators,.
Troubleshooting General Troubleshooting Charts . . . . . . . . . . . . . . . . . . . . . . . . . .T2 Symbols Hydraulic Lines, Pumps, Motors and Cylinders, Valves, Miscellaneous Units and Methods of Operation . . . . . . . . . . . .T8 Pneumatic Air Prep Units, Pneumatic Valves and Valve Actuators, Lines and Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .T10 Cylinders Fundamental Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .T12 Hydraulic Cylinder Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . .T13 Theoretical Push and Pull Forces for Cylinders . . . . . . . . . . . . . .T14 How to Select a Hydraulic Cylinder and Power Unit. . . . . . . . . .T15 Pumps Electric Motor Horsepower . . . . . . . . . . . . . . . . . . . . . . . . . . . . .T16 Valves How to Determine Proper Air Valve Size. . . . . . . . . . . . . . . . . . .T17 Formulas Basic and Fluid Formulas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .T18 Pump and Actuator Formulas . . . . . . . . . . . . . . . . . . . . . . . . . . .T19 Thermal Formulas, Accumulator Formulas, and Volume and Capacity Equivalents Table. . . . . . . . . . . . . . . .T20

FPC05_QUICK INDEX.indd 13

10/27/04 11:53:26 AM

General Troubleshooting Charts General Troubleshooting Charts Use the charts on the following pages to help in listing all the possible causes of trouble when you begin diagnosing and testing of a machine. Once you have located the cause, check the item in the chart again for the possible remedy. The technical manual for each machine supplements these charts by giving more detailed and specific causes and remedies.

System Inoperative Possible Causes: a. No oil in system.

Fill to full mark. Check system for leaks.

b. Oil low in reservoir.

Check level and fill to full mark. Check system for leaks.

c. Oil of wrong viscosity.

Refer to specifications for proper viscosity.

d. Filter dirty or plugged.

Drain oil and replace filters. Try to find source of contamination.

e. Restriction in system.

Oil lines could be dirty or have inner walls that are collapsing, cutting off oil supply. Clean or replace lines. Clean orifices.

f. Air leaks in suction line.

Repair or replace lines.

g. Dirt in pump.

Clean and repair pump. If necessary, drain and flush hydraulic system. Try to find source of contamination.

h. Badly worn pump.

Repair or replace pump. Check for problems causing pump wear such as misalignment or contaminated oil.

i. Badly worn components.

Examine and test valves, motors, cylinders, etc. for external and internal leaks. If wear is abnormal, try to locate the cause.

j. Oil leak in pressure lines.

Tighten fittings or replace defective lines. Examine mating surfaces on couplers for irregularities.

k. Components not properly adjusted.

Refer to machine technical manual for proper adjustment of components.

l. Relief valve defective.

Test relief valves to make sure they are opening at their rated pressure. Examine seals for damage that could cause leaks. Clean relief valves and check for broken springs, etc.

m. Pump rotating in wrong direction.

Reverse to prevent damage.

n. Excessive load on system.

Check specification of unit for load limits.

o. Hoses attached improperly.

Attach properly and tighten securely.

p. Slipping or broken pump drive.

Replace couplers or belts if necessary. Align them and adjust tension.

q. Pump not operating.

Check for shut-off device on pump or pump drive.

T2

XXXX_FPC05_TECH SECTION.indd T2

Visit Us Online: www.Applied.com

11/11/04 8:47:16 AM

General Troubleshooting Charts System Operates Erratically Possible Causes:

Remedy:

a. Air in system.

Examine suction side of system for leaks. Make sure oil level is correct. Oil leaks on the pressure side of system could account for loss of oil.

b. Cold oil.

Viscosity of oil may be too high at start of warm-up period. Allow oil to warm up to operating temperature before using hydraulic functions.

c. Components sticking or binding.

Check for dirt or gummy deposits. If contaminated, try to find the source of contamination. Check for worn or bent parts.

d. Pump damaged.

Check for broken or worn parts. Determine cause of pump damage.

e. Dirt in relief valves.

Clean relief valves or replace.

f. Restriction in filter or suction line.

Suction line could be dirty or have inner walls that are collapsing, cutting off oil supply. Clean or replace suction line. Also, check filter line for restrictions.

Overheating of Oil in System Possible Causes:

Remedy:

a. Operator holds control valves in power position too long, causing relief valve to open.

Return control lever to neutral position when not in use.

b. Using incorrect oil.

Use oil recommended by manufacturer. Be sure oil viscosity is correct.

c. Low oil level.

Fill reservoir. Look for leaks.

d. Dirty oil.

Drain and refill with clean oil. Look for source of contamination and replace filters.

e. Engine running too fast.

Reset governor or reduce throttle.

f. Incorrect relief valve pressure.

Check pressure and clean or replace relief valves.

g. Internal component oil leakage.

Examine and test valves, cylinders, motors, etc. for external and internal leaks. If wear is abnormal, try to locate cause.

h. Restriction in pump suction line.

Clean or replace.

i. Dented, obstructed or undersized oil lines.

Replace defective or undersized oil lines. Remove obstructions.

j. Oil cooler malfunctioning.

Clean or repair.

k. Control valve stuck open.

Free all spools so that they return to neutral position.

l. Heat not radiating properly.

Clean dirt and mud from reservoir, oil lines, coolers, and other components.

m. Automatic unloading control inoperative (if equipped).

Repair valve.

Call Your Local Service Center to Order: 1-877-279-2799

XXXX_FPC05_TECH SECTION.indd T3

T3

11/11/04 8:47:17 AM

General Troubleshooting Charts System Operates Slowly Possible Causes:

Remedy:

a. Cold oil.

Allow oil to warm up before operating machine.

b. Oil viscosity too heavy.

Use oil recommended by the manufacturer.

c. Insufficient engine speed.

Refer to operator’s manual for recommended speed. If machine has a governor, it may need adjustment.

d. Low oil supply.

Check reservoir and add oil if necessary. Check system for leaks that could cause loss of oil.

e. Adjustable orifice restricted too much.

Back out orifice and adjust it. Check machine specifications for proper setting.

f. Air in system.

Check suction side of the system for leaks.

g. Badly worn pump.

Repair or replace pump. Check for problems causing pump wear such as misalignment or contaminated oil.

h. Restriction in suction line or filter.

Suction line could be dirty or have inner walls that are collapsing to cut off oil supply. Clean or replace suction line. Examine filter for plugging.

i. Relief valves not properly set or leaking.

Test relief valves to make sure they are opening at their rated pressure. Examine valves for damaged seats that could leak.

j. Badly worn components.

Examine and test valves, motors, cylinders, etc. for external and internal leaks. If wear is abnormal, try to locate the cause.

k. Valve or regulators plugged.

Clean dirt from components. Clean orifices. Check for source of dirt and correct.

l. Oil leak in pressure lines.

Tighten fittings or replace defective lines. Examine mating surfaces on couplers for irregularities.

m. Components not properly adjusted.

Refer to machine technical manual for proper adjustment of components.

System Operates Too Fast Possible Causes:

Remedy:

a. Adjustable orifice installed backward or not installed.

Install orifice parts correctly and adjust.

b. Obstruction or dirt under seat of orifice.

Remove foreign material. Readjust orifice.

c. Overspeeding of engine.

Refer to operator’s manual for recommended speed. If machine has a governor, it may need adjustment.

T4

XXXX_FPC05_TECH SECTION.indd T4

Visit Us Online: www.Applied.com

11/11/04 8:47:17 AM

General Troubleshooting Charts Foaming of Oil in System Possible Causes:

Remedy:

a. Low oil level.

Fill reservoir. Look for leaks. Drain and replace oil.

b. Water in oil.

Check filler breather on reservoir. Heat exchanger may be cracked.

c. Wrong kind of oil being used.

Use oil recommended by manufacturer.

d. Air leak in line from reservoir to pump.

Tighten or replace suction line.

e. Kink or dent in oil lines.

Replace oil lines.

f. Worn pump shaft seal.

Clean sealing area and replace seal. Check oil for contamination or pump for misalignment.

Pump Makes Noise Possible Causes:

Remedy:

a. Low oil level.

Fill reservoir. Check system for leaks.

b. Oil viscosity too high.

Change to lighter oil.

c. Pump speed too fast.

Operate pump at recommended speed.

d. Suction line plugged or pinched.

Clean or replace line between reservoir and pump.

e. Sludge and dirt in pump.

Disassemble and inspect pump and lines. Clean hydraulic system. Determine cause of dirt.

f. Reservoir air vent plugged.

Remove breather cap, flush, and clean air vent.

g. Air in oil.

Tighten or replace suction line. Check system for leaks. Replace pump shaft seal.

h. Worn or scored pump bearings or shafts.

Replace worn parts or complete pump if parts are badly worn or scored. Determine cause of scoring.

i. Inlet screen plugged.

Clean screen.

j. Broken or damaged pump parts.

Repair pump. Look for cause of damage such as contamination or too much pressure.

k. Sticking or binding parts.

Repair binding parts. Clean parts and change oil if necessary.

Pump Leaks Oil Possible Causes:

Remedy:

a. Damaged seal around drive shaft.

Tighten packing or replace seal. Trouble may be caused by contaminated oil. Check oil for abrasives and clean entire hydraulic system. Try to locate source of contamination. Check the pump drive shaft. Misalignment could cause the seal to wear. If shaft is not aligned, check the pump for other damage.

b. Loose or broken pump parts.

Make sure all bolts and fittings are tight. Check gaskets. Examine pump castings for cracks. If pump is cracked, look for a cause like too much pressure or hoses that are attached incorrectly.

Call Your Local Service Center to Order: 1-877-279-2799

XXXX_FPC05_TECH SECTION.indd T5

T5

11/11/04 8:47:17 AM

General Troubleshooting Charts Load Drops with Control Valve in Neutral Position Possible Causes:

Remedy:

a. Leaking or broken oil lines from control valve to cylinder.

Check for leaks. Tighten or replace lines. Examine mating surfaces on couplers for irregularities.

b. Oil leaking past cylinder packings or O-rings.

Replace worn parts. If wear is caused by contamination, clean hydraulic system and determine the contamination source.

c. Oil leaking past control valve or relief valves.

Clean or replace valves. Wear may be caused by contamination. Clean hydraulic system and determine the contamination source.

d. Oil leaking past load holding valve.

Check for proper adjustment. Remove and replace cartridge with spare. (Support boom before removing cartridge.) Do not attempt to repair.

e. Control lever not centering when released.

Check linkage for binding. Make sure valve is properly adjusted and has no broken or binding parts.

Control Valve Sticks or Works Hard Possible Causes:

Remedy:

a. Misalignment or seizing of control linkage.

Correct misalignment. Lubricate linkage joints.

b. Tie bolts too tight (on valve stacks).

Use manufacturer’s recommendation to adjust tie bolt torque.

c. Valve broken or scored internally.

Repair broken or scored parts. Locate source of contamination that caused scoring.

Control Valve Leaks Oil Possible Causes:

Remedy:

a. Tie bolts too loose (on valve stacks).

Use manufacturer’s recommendation to adjust tie bolt torque.

b. Worn or damaged O-rings.

Replace O-rings, especially between valve stacks. If contamination has caused O-rings to wear, clean system and look for source of contamination.

c. Broken valve parts.

If valve is cracked, look for a cause like too much pressure or pipe fittings that are over tightened.

T6

XXXX_FPC05_TECH SECTION.indd T6

Visit Us Online: www.Applied.com

11/11/04 8:47:17 AM

General Troubleshooting Charts Cylinders Leak Oil Possible Causes:

Remedy:

a. Damaged cylinder barrel.

Replace cylinder barrel. Correct cause of barrel damage.

b. Rod seal leaking.

Replace seal. If contamination caused seal to wear, look for source. Wear may be caused by external as well as internal contaminants. Check piston rod for scratches or misalignment.

c. Loose parts.

Tighten parts until leakage has stopped.

d. Piston rod damaged.

Check rod for nicks or scratches that could cause seal damage or allow oil leakage. Replace defective rods.

Cylinders Lower when Control Valve is in “Slow Raise” Position Possible Causes:

Remedy:

a. Damaged check valve in lift circuit.

Repair or replace check valve.

b. Leaking cylinder packing.

Replace packing. Check oil for contamination that could cause wear. Check alignment of cylinder.

c. Leaking lines or fittings to cylinder.

Check and tighten. Examine mating surfaces on couplers for irregularities.

Call Your Local Service Center to Order: 1-877-279-2799

XXXX_FPC05_TECH SECTION.indd T7

T7

11/11/04 8:47:18 AM

Hydraulic Symbols Lines

Hydraulic Pumps Line, Working (Main)

Miscellaneous Units

Fixed Displacement

Cooler

Variable Displacement

Temperature Controller

Line, Pilot or Drain Flow Direction Hydraulic Pneumatic

Filter, Strainer

Motors and Cylinders Lines Crossing

Pressure Switch

Hydraulic Fixed Displacement

Pressure Indicator

Variable Displacement

Temperature Indicator

Cylinder, Single-Acting

Component Enclosure

Lines Joining

Lines With Fixed Restriction

Line, Flexible Cylinder, Double-Acting Station, Testing, Measurement or Power Take-Off Variable Component (run arrow through symbol at 45°)

Pressure Compensated Units (Arrow parallel to short side of symbol)

Temperature Cause or Effect

Single End Rod

Double End Rod

Methods of Operation

Adjustable Cushion Advance Only

Spring

Differential Piston

Manual

Push Button

Miscellaneous Units

Reservoir

Vented

Direction of Shaft Rotation (assume arrow on near side of shaft)

Push-Pull Lever Electric Motor Pedal or Treadle

Pressurized

Accumulator, Spring Loaded Mechanical

Line, To Reservoir

Accumulator, Gas Charged Detent

Above Fluid Level Below Fluid Level

Heater Pressure Compensated

Vented Manifold

T8

XXXX_FPC05_TECH SECTION.indd T8

Visit Us Online: www.Applied.com

11/11/04 8:47:18 AM

Hydraulic Symbols Methods of Operation Solenoid, Single Winding

Servo Control

Color Code for Fluid Power Schematic Drawings

Valves Check

On-Off (manual shut-off)

Pilot Pressure Pressure Relief

Black

Intensified Pressure

Red

Supply

Intermittent Red

Charging Pressure

Intermittent Red

Reduced Pressure

Intermittent Red

Pilot Pressure

Yellow

Metered Flow

Blue

Exhaust

Green

Intake

Green

Drain

Blank

Inactive

Remote Supply Pressure Reducing Internal Supply Flow Control, Adjustable - Non-Compensated Flow Control, Adjustable (Temperature and pressure compensated) Two-Position Two Connection Two-Position Three Connection Two-Position Four Connection Three-Position Four Connection Two-Position In Transition Valves Capable of Infinite Positioning (Horizontal bars indicate infinite positioning ability)

Call Your Local Service Center to Order: 1-877-279-2799

XXXX_FPC05_TECH SECTION.indd T9

T9

11/11/04 8:47:18 AM

Pneumatic Symbols Air Prep Units

Pneumatic Valves

Valve Actuators

Filter/Separator with manual drain

Check

Manual General Symbol

Filter/Separator with automatic drain

Flow Control

Push Button

Oil Removal Filter

Relief Valve

Lever

Automatic Drain

2-Position, 2-Way

Pedal or Treadle

Lubricator less drain

2-Position, 3-Way

Mechanical Cam, Toggle, etc.

Lubricator with manual drain

2-Position, 4-Way 4-Ported

Spring

Lubricator with automatic filling

2-Position, 4-Way 5-Ported

Detent - Line indicates which detent is in use

Air Line Pressure Regulator adjustable, relieving

3-Position, 4-Way ports closed, center position

Solenoid

Air Line Pressure Regulator pilot controlled, relieving

3-Position, 4-Way, 5-Ported cylinder ports open to pressure in center position

Filter/Regulator (piggyback) Manual Drain Relieving (without gauge) Filter/Regulator (piggyback) Auto Drain Relieving

Remote Pilot Supply Quick Exhaust

Shuttle

XXXX_FPC05_TECH SECTION.indd T10

And/Or Composite solenoid and pilot or manual override And/Or Composite solenoid and pilot or manual override and pilot

Air Line Combo F-R-L simplified

T10

Internal Pilot Supply

Visit Us Online: www.Applied.com

11/11/04 8:47:18 AM

Pneumatic Symbols Lines & Functions

Lines & Functions

Main Line

Quick Disconnect without checks Connected

Pilot Line

Quick Disconnect without checks Disconnected

Exhaust or Drain Line

Quick Disconnect with checks Connected

Enclosure Line

Quick Disconnect with checks Disconnected

Lines Crossing

Quick Disconnect with one check Connected Quick Disconnect with one check Disconnected

Lines Joining

Flow Direction Hydraulic Medium Flow Direction Gaseous Medium

Energy Source

Line with Fixed Restriction Line with Adjustable Restriction

Flexible Line

Plugged Port, Test Station, Power Take-Off

Call Your Local Service Center to Order: 1-877-279-2799

XXXX_FPC05_TECH SECTION.indd T11

T11

11/11/04 8:47:18 AM

Fundamental Cylinders

Standard Double-Acting Power stroke is in both directions and is used in the majority of applications.

Single-Acting When thrust is needed in only one direction, a single-acting cylinder may be used. The inactive end is vented to atmosphere through a breather/filter for pneumatic applications, or vented to reservoir below the oil level in hydraulic applications.

Double Rod Used when equal displacement is needed on both sides of the piston, or when it is mechanically advantageous to couple a load to each end. The extra end can be used to mount cams for operating limit switches, etc.

Spring Return, Single-Acting Usually limited to very small, short stroke cylinders used for holding and clamping. The length needed to contain the return spring makes them undesirable when a long stroke is needed.

Ram Type, Single-Acting Containing only one fluid chamber, this type of cylinder is usually mounted vertically. The weight of the load retracts the cylinder. They are sometimes known as “displacement cylinders”, and are practical for long strokes.

Telescoping Available with up to 4 or 5 sleeves; collapsed length is shorter than standard cylinders. Available either as single or doubleacting, they are relatively expensive compared to standard cylinders.

Tandem A tandem cylinder is made up of two cylinders mounted in line with pistons connected by a common piston rod and rod seals installed between the cylinders to permit double acting operation of each. Tandem cylinders allow increased output force when mounting width or height are restricted.

Duplex A duplex cylinder is made up of two cylinders mounted in line with pistons not connected and with rod seals installed between the cylinders to permit double acting operation of each. Cylinders may be mounted with piston rod to piston (as shown) or back to back and are generally used to provide three position operation.

T12

XXXX_FPC05_TECH SECTION.indd T12

Visit Us Online: www.Applied.com

11/11/04 8:47:19 AM

Cylinders Cylinders Hydraulic Cylinder Speeds — Inches/Minutes This chart is based on the formula: Piston Diameter

1 1 1/2

2

2 1/2

3

3 1/2

4

5

6

8

10

V (Velocity) =

231 X GPM Eff. Cyl. Area (Sq. In.) Flow-GPM

Rod Diameter

1

2

3

5

10

12

15

20

25

50

75

1/2 5/8 1 3/4 1 1 3/8 1 1 3/8 1 3/4 1 1 1/2 2 1 1/4 1 3/4 2 1 1/4 1 3/4 2 2 1/2 1 1/2 2 2 1/2 3 3 1/2 1 3/4 2 1/2 3 3 1/2 4 3 1/2 4 5 5 1/2 4 1/2 5 5 1/2 7

298 392 130 158 235 73 85 97 139 47 56 67 92 32 36 43 58 24 27 32 35 18 20 22 24 30 12 13 14 16 18 22 8 9 10 11 12 15 4 5 1/2 6 7 1/2 8 1/2 3 3 1/2 4 4 1/2 5 1/2

596 784 260 316 470 146 170 184 278 94 112 134 184 64 72 86 116 48 54 64 70 36 40 44 48 60 24 26 28 32 36 44 16 18 20 22 24 30 8 11 12 15 17 6 7 8 9 11

849 1176 392 476 706 221 257 294 418 141 168 203 277 98 110 131 176 72 82 96 107 55 61 68 73 90 35 39 42 47 55 66 24 27 30 33 37 44 14 17 18 22 26 9 11 12 13 17

149 196 654 792 1176 368 428 490 697 235 280 339 463 163 184 218 294 120 137 160 178 92 102 113 122 150 58 64 70 78 92 111 41 45 50 54 62 73 23 28 30 38 43 15 18 20 21 29

1308 1584 2352 736 956 980 1394 470 560 678 926 326 368 436 588 240 274 320 356 184 240 226 244 300 116 128 140 156 184 222 82 90 100 108 124 146 46 56 60 76 86 30 36 40 42 58

883 1025 1175 1673 565 672 813 1110 392 440 523 705 288 330 384 428 220 244 273 294 362 141 155 168 188 220 266 98 107 118 130 148 176 55 68 73 90 104 35 44 47 50 69

1120 1283 1465 2090 675 840 1015 1385 490 551 655 882 360 411 480 534 276 306 339 366 450 174 193 210 235 275 333 123 135 150 165 185 220 69 85 90 114 129 44 55 60 63 87

940 1120 1355 1850 653 735 872 1175 480 548 640 712 368 408 452 488 600 232 258 280 315 365 444 162 180 200 206 245 295 92 115 122 150 172 60 75 80 84 115

1175 1400 1695 2310 817 920 1090 1470 600 685 800 890 460 510 565 610 750 290 320 350 390 460 555 202 225 250 270 310 365 115 140 150 185 215 73 92 100 105 145

1200 1370 1600 1780 920 1020 1130 1220 1500 580 640 700 780 920 1110 404 450 500 540 620 730 230 280 300 375 430 146 184 200 210 290

870 960 1050 1170 1380 1665 606 675 750 810 930 1095 345 420 450 555 645 220 275 300 315 435

Call Your Local Service Center to Order: 1-877-279-2799

XXXX_FPC05_TECH SECTION.indd T13

T13

11/11/04 8:47:19 AM

Cylinders Theoretical Push and Pull Forces Forces for for Pneumatic Pneumaticand andHydraulic HydraulicCylinders Cylinders The cylinder output forces are derived from the formula: F=PXA

V1 = (P2 + 14.7)V2 14.7

F = Force in pounds P = Pressure at the cylinder in pounds per sq. inch, gauge A = Effective area of cylinder piston in sq. inches Free air refers to normal atmospheric conditions of the air at sea level (14.7 psi). Use cu. ft. free air required data (see chart below) to compute CFM required from a compressor at 80 cu. ft. of free air required. Other pressures can be calculated using the information below.

V1 = Free air consumption per inch of stroke (cubic feet) V2 = Cubic feet displaced per inch of stroke P2 = Gauge pressure required to move maximum load

Push Force and Displacement Cylinder Push Stroke Force in Pounds at Various Pressures Cyl. Bore Size (In.)

Piston Area (Sq. In.)

25

50

65

80

100

250

500

1000

2000

3000

1 1 1/2 2 2 1/2 3 1/4 4 5 6 7 8 10 12 14

0.785 1.767 3.14 4.91 8.30 12.57 19.64 28.27 38.49 50.27 78.54 113.10 153.94

20 44 79 123 208 314 491 707 962 1257 1964 2828 3849

39 88 157 245 415 628 982 1414 1924 2513 3927 5655 7697

51 115 204 319 540 817 1277 1838 2502 3268 5105 7652 10006

65 142 251 393 664 1006 1571 2262 3079 4022 6283 9048 12315

79 177 314 491 830 1257 1964 2827 3849 5027 7854 11310 15394

196 443 785 1228 2072 3143 4910 7068 9623 12568 19635 28275 38485

392 885 1570 2455 4150 6285 9820 14135 19245 25135 39270 56550 76970

785 1770 3140 4910 8300 12570 19640 28270 38490 50270 78540 113100 153940

1570 3540 6280 9820 16600 25140 39280 56540 76980 100540 157080 226200 307880

2355 5310 9420 14730 24900 37710 58920 84810 115470 150810 235620 339300 461820

Cu. Ft. Free Air at 80 Lbs. Pressure, Required to move Max. Load 1 Inch

Displace. Per Inch of Stroke (Gallons)

.00293 .00659 .01171 .01830 .03093 .04685 .07320 .10540 .14347 .18740 .29280 .42164 .57389

.00340 .00765 .0136 .0213 .0359 .0544 .0850 .1224 .1666 .2176 .3400 .4896 .6664

Deductions for Pull Force and Displacement

Piston Piston Rod Rod Area Dia. (Sq. In.) (Inches)

1/2 5/8 1 1 3/8 1 3/4 2 2 1/2 3 3 1/2 4 4 1/2 5 5 1/2 7 8 1/2

0.196 0.307 0.785 1.49 2.41 3.14 4.91 7.07 9.62 12.57 15.90 19.64 23.76 38.49 56.75

T14

XXXX_FPC05_TECH SECTION.indd T14

Piston Rod Diameter Force in Pounds at Various Pressures To determine Cylinder Pull Force or Displacement, deduct the following Force or Displacement corresponding to Rod Size, from selected Push Stroke Force or Displacement corresponding to Bore Size in the table above 25

50

65

80

100

250

500

1000

2000

3000

5 8 20 37 60 79 123 177 241 314 398 491 594 962 1419

10 15 39 75 121 157 245 354 481 628 795 982 1188 1924 2838

13 20 51 97 157 204 319 460 625 817 1033 1277 1544 2502 3689

16 25 65 119 193 251 393 566 770 1006 1272 1571 1901 3079 4540

20 31 79 149 241 314 491 707 962 1257 1590 1964 2376 3849 5675

49 77 196 373 603 785 1228 1767 2405 3143 3975 4910 5940 9623 14187

98 154 392 745 1205 1570 2455 3535 4810 6285 7950 9820 11880 19245 28375

196 307 785 1490 2410 3140 4910 7070 9620 12570 15900 19640 23760 38490 56750

392 614 1570 2980 4820 6280 9820 14140 19240 25140 31800 39280 47520 76980 113500

588 921 2355 4470 7230 9420 14730 21210 28860 37710 47708 58920 71280 115470 170250

Cu. Ft. Free Air at 80 Lbs. Displace. Pressure, Per Inch Required of Stroke to move (Gallons) Max. Load 1 Inch .00073 .00114 .00293 .00554 .00897 .01171 .01830 .02635 .03587 .04685 .05929 .07320 .08857 .14347 .21157

.0009 .0013 .0034 .0065 .0104 .0136 .0213 .0306 .0416 .0544 .0688 .0850 .1028 .1666 .2455

Visit Us Online: www.Applied.com

11/11/04 8:47:19 AM

Cylinders How to Select a Hydraulic Cylinder and Power Unit Selection of the proper components for a hydraulic system is quite simple when you use the accompanying table and chart. Here is an example to illustrate their use. Assume your requirements are: 20,000 lbs. of force, 28” stroke, and 7.5 seconds for full cylinder extension. Step One: The table below shows a 3” diameter cylinder will develop 21,204 lbs. of force with 3000 psi pressure.

Step Three: By continuing this line, it intersects 200 cubic inch displacement.

Step Two: A line has been drawn on the chart from 3” diameter through 28” stroke.

Step Four: Another line drawn from 200 cubic inches through 7.5 seconds intersects 7 GPM.

Cylinder push in pounds

Cylinder Bore 2 2½ 3 4 5 6 7

@ 1000 psi 3141 4908 7068 12566 19635 28274 38465

@ 2000 psi 6282 9816 14136 25132 39270 56548 76930

@ 3000 psi 9423 14724 21204 37698 58905 84822 115395

Your Answer: Using this example, the chart and table show that your components should be a 3” diameter 3000 psi cylinder and a hydraulic power unit with approximately 7 GPM and 3000 psi rating. Theoretical horsepower for these values would be 12.25 HP. However, since most applications usually require maximum GPM and pressure for only a very short portion of each cycle, the electric motor of the hydraulic power unit will usually be considerably smaller (one half or less.)

Displacement (in cubic inches) 3.5

7

Cylinder Bore (in inches) 8 6 5

Stroke (in inches)

20

.1

1 30 50

3

2 4 6 10

2 1/2

20

100

4

2 1 1/2

40 60 100

Time (in seconds)

70

200 250 300 500 700

.2 .4 .6 1

GPM 100 50 25 18

2

10

4 6 10

5

20 40 60 100 200 400

1.5 .6

1000

2000

.25 .18

Call Your Local Service Center to Order: 1-877-279-2799

XXXX_FPC05_TECH SECTION.indd T15

T15

11/11/04 8:47:20 AM

Pumps Electric Motor Horsepower Required to Drive a Hydraulic Pump This chart is based on the formula: HP =

GPM X psi 1714 X Efficiency

For the purposes of this chart, pump efficiency was assumed to be 85%. As horsepower varies directly with flow or pressure, multiply proportionately to determine values not shown. For instance, at 4000 psi, multiply 2000 psi values by 2. GPM

1/2 1 1 1/2 2 2 1/2 3 3 1/2 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 25 30 35 40 45 50 55 60 65 70 75 80 90 100

Pump Pressure psi 100

200

250

300

400

500

750

1000

1250

1500

2000

0.04 0.07 0.10 0.14 0.17 0.21 0.24 0.28 0.34 0.41 0.48 0.55 0.62 0.69 0.76 0.83 0.89 0.96 1.03 1.10 1.17 1.24 1.30 1.37 1.72 2.06 2.40 2.75 3.09 3.43 3.78 4.12 4.46 4.81 5.15 5.49 6.18 6.86

0.07 0.14 0.21 0.28 0.34 0.41 0.48 0.55 0.69 0.82 0.96 1.10 1.24 1.37 1.51 1.65 1.79 1.92 2.06 2.20 2.33 2.47 2.61 2.75 3.43 4.12 4.81 5.49 6.18 6.86 7.55 8.24 8.92 9.61 10.30 11.00 12.40 13.70

0.09 0.17 0.26 0.34 0.43 0.52 0.60 0.69 0.86 1.03 1.20 1.37 1.55 1.62 1.89 2.06 2.23 2.40 2.57 2.75 2.92 3.09 3.26 3.43 4.29 5.15 6.01 6.86 7.72 8.58 9.44 10.30 11.20 12.00 12.90 13.70 15.40 17.20

0.10 0.21 0.31 0.41 0.52 0.62 0.72 0.82 1.03 1.24 1.44 1.65 1.85 2.06 2.27 2.47 2.68 2.88 3.09 3.30 3.50 3.71 3.91 4.12 5.15 6.18 7.21 8.24 9.27 10.30 11.30 12.40 13.40 14.40 15.40 16.50 18.50 20.60

0.14 0.28 0.41 0.55 0.69 0.83 0.96 1.10 1.32 1.65 1.92 2.20 2.47 2.75 3.02 3.30 3.57 3.84 4.12 4.39 4.68 4.94 5.22 5.49 6.86 8.24 9.61 11.00 12.40 13.70 15.10 16.50 17.80 19.20 2.60 22.00 24.70 27.50

0.17 0.34 0.52 0.69 0.86 1.03 1.20 1.37 1.72 2.06 2.40 2.75 3.09 3.43 3.78 4.12 4.46 4.81 5.15 5.49 5.83 6.18 6.52 6.86 8.58 10.30 12.00 13.70 15.40 17.20 18.90 20.60 22.30 24.00 25.70 27.50 30.90 34.40

0.26 0.52 0.77 1.03 1.29 1.54 1.80 2.06 2.57 3.09 3.60 4.12 4.63 5.15 5.66 6.18 6.69 7.21 7.72 8.24 8.75 9.27 9.78 10.30 12.90 15.40 18.00 20.60 23.20 25.70 28.30 30.90 33.50 36.00 38.60 41.20 46.30 51.50

0.34 0.69 1.03 1.37 1.72 2.06 2.40 2.75 3.43 4.12 4.81 5.49 6.18 6.86 7.55 8.24 8.92 9.61 10.30 11.00 11.70 12.40 13.00 13.70 17.20 20.6 24.00 27.50 31.00 34.30 37.80 41.20 44.60 48.00 51.40 54.90 61.80 68.60

0.43 0.86 1.29 1.72 2.15 2.57 3.00 3.43 4.29 5.15 6.01 6.86 7.72 8.58 9.44 10.30 11.20 12.00 12.90 13.70 14.60 15.40 16.30 17.20 21.50 25.70 30.00 34.30 38.60 42.90 47.20 51.50 55.80 60.10 64.30 68.60 77.20 85.80

0.52 1.03 1.54 2.06 2.58 3.09 3.60 4.12 5.15 6.18 7.21 8.24 9.27 10.30 11.30 12.40 13.40 14.40 15.40 16.50 17.50 18.50 19.60 21.60 25.80 30.90 36.00 41.20 46.30 51.50 56.60 61.80 66.90 72.10 77.20 82.40 92.70 103.00

0.69 1.37 2.06 2.75 3.43 4.12 4.81 5.49 6.86 8.24 9.61 11.00 12.40 13.80 15.10 16.50 17.80 19.20 20.60 22.00 23.30 24.70 26.10 27.50 34.30 41.20 48.00 54.90 61.80 68.60 75.50 83.40 89.20 96.10 103.00 109.80 123.60 137.30

T16

XXXX_FPC05_TECH SECTION.indd T16

Visit Us Online: www.Applied.com

11/11/04 8:47:20 AM

Valves How to Determine Proper Air Valve Size Most manufacturers’ catalogs provide flow ratings for valves in Cv, based on National Fluid Power Association (NFPA) standard T3.21.3. The following tables and formulas will enable you to quickly size a valve properly. The traditional, often used approach of using the valve size equivalent to the port in the cylinder can be very costly. Cylinder speed, not port size, should be the determining factor.

Select a valve that has a Cv factor of .7 or higher. In most cases a 1/4” valve would be sufficient.

The following Cv calculations are based upon simplified formulas which yield results with acceptable accuracy under the following standard condition:

After the minimum required Cv has been calculated, the proper size valve can be selected from the catalog. Table 1:

Air at a temperature of 68°F (20°C) Absolute downstream or secondary pressure must be 53% of absolute inlet or primary pressure or greater. Below 53%, the air velocity may become sonic and the Cv formula does not apply. Nomenclature: B Pressure drop factor C Compression factor Cv Flow factor D Cylinder Diameter F Cylinder Area L Cylinder Stroke p1 Inlet or Primary Pressure p2 Outlet or Secondary Pressure Δp Pressure differential (p1- p2) q Air flow at actual condition Q Air flow of free air t Time to complete one cylinder stroke T Absolute temperature at operating pressure. Deg R = Deg F + 460

(I N) (SQ IN) (I N) (PS I G) (PS I G) (psiD) (CFM) (SCFM) (SEC) (°R)

Valve Sizing for Cylinder Actuation Direct Formula Cylinder Area (F) (Sq. In.) (See Table 1)

Pressure Drop (B) Factor (See Table 2)

X

Cylinder Stroke (L) (In.)

X

Compression (C) Factor (See Table 2)

X

Time to Complete Cylinder Stroke (Sec)

X

28.8

Cv =

Example: Cylinder size 4” Dia. x 10” stroke. Time to extend: 2 seconds. Inlet pressure 90 psiG. Allowable pressure drop 5 psiD. Determine Cv. Solution: F = 12.57 Sq. In. (Table 1) C = 7.1 (Table 2) B = 21.6

Cv=

12.57 21.6

X X

10 2

X X

7.1 28.8

It is considered good engineering practice to limit the pressure drop Dp to approximately 10% of primary pressure P1. The smaller the allowable pressure drop, the larger the required valve will become.

= 0.7

Cylinder push bore area F for standard size cylinders Bore Size D (In.)

Cylinder Area F (Sq. In)

Bore Size D (In.)

Cylinder Area F (Sq. In)

3/4 1 1 1/8 1 1/4 1 1/2 1 3/4 2 2 1/2 3 1/4

0.44 0.79 0.99 1.23 1.77 2.41 3.14 4.91 8.30

4 4 1/2 5 6 7 8 10 12 14

12.57 15.90 19.64 28.27 38.48 50.27 78.54 113.10 153.94

Table 2: Compression factor C and pressure drop factor B Inlet Compr. Pressure Factor C (psiG) 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250

1.7 2.4 3.0 3.7 4.4 5.1 5.8 6.4 7.1 7.8 8.5 9.2 9.8 10.5 11.2 11.9 12.6 13.2 13.9 14.6 15.3 16.0 16.7 17.3 18.0

Pressure Drop Factor B for Various Pressure Drops Δ p 2 psiD

5 psiD

10 psiD

15 psiD

20 psiD

6.5 7.8 8.9 9.9 10.8 11.7 12.5 13.2 13.9 14.5 15.2 15.8 16.4 16.9 17.5 18.0 18.5 19.0 19.5 20.0 20.4 20.9 21.3 21.8 22.2

11.8 13.6 15.3 16.7 18.1 19.3 20.5 21.6 22.7 23.7 24.7 25.6 26.5 27.4 28.2 29.0 29.8 30.6 31.4 32.1 32.8 33.5 34.2 34.9

18.0 20.5 22.6 24.6 26.5 28.2 29.8 31.3 32.8 34.2 35.5 36.8 38.1 39.3 40.5 41.6 42.7 43.8 44.9 45.9 46.9 47.9 48.9

23.6 26.4 29 31.3 33.5 35.5 37.4 39.3 41.0 42.7 44.3 45.9 47.4 48.9 50.3 51.7 53.0 54.3 55.6 56.8 58.1 59.3

29.0 32.0 34.8 37.4 39.9 42.1 44.3 46.4 48.4 50.3 52.1 53.9 55.6 57.2 58.9 60.4 62.0 63.5 64.9 66.3 67.7

Call Your Local Service Center to Order: 1-877-279-2799

XXXX_FPC05_TECH SECTION.indd T17

T17

11/11/04 8:47:21 AM

Basic Formulas Fluid Power Formulas Basis Formulas Basic FORMULA FOR:

WORD FORMULA:

LETTER FORMULA:

FLUID PRESSURE In Pounds/Square Inch

Pressure =

Force (Pounds) Unit Area (Square Inches)

P = F/A or psi = F/A

FLUID FLOW RATE In Gallons/Minute

Flow Rate =

Volume (Gallons) Unit Time (Minute)

Q = V/T

Pressure (psi) x Flow (GPM) 1714

HP = PQ/1714

FLUID POWER In Horsepower

Horsepower =

Fluid FluidFormulas Formulas FORMULA FOR: VELOCITY THROUGH PIPING In Feet/Second Velocity COMPRESSIBILITY OF OIL In Additional Required Oil to Reach Pressure

COMPRESSIBILITY OF A FLUID

SPECIFIC GRAVITY OF A FLUID

VALVE (Cv) FLOW FACTOR

WORD FORMULA: Velocity =

.3208 x Flow Rate through I.D. (GPM) Internal Area (Square Inches)

Pressure (psi) x Volume of Oil under Pressure 250,000 (approx.)

Additional Volume =

1 Bulk Modulus of the Fluid

Compressibility =

Specific Gravity =

Valve Factor =

LETTER FORMULA:

Weight of One Cubic Foot of Fluid Weight of One Cubic Foot of Water

Flow Rate (GPM) Specific Gravity Pressure Drop (psi)

V = .3208Q/A

VA = PV/250,000 (approx.)

C(ß) = 1/BM

SG = W/62.4283

Cv = (Q SG)/(

Δp)

For Viscosities of 32 to 100 Saybolt Universal Seconds: Centistokes = .2253 x SUS -

(

194.4 SUS

)

CS = .2253 SUS - (194.4/SUS)

For Viscosities of 100 to 240 Saybolt Universal Seconds: VISCOSITY IN CENTISTOKES

Centistokes = .2193 x SUS -

(

134.6 SUS

)

CS = .2193 SUS - (134.6/SUS)

For Viscosities greater than 240 Saybolt Universal Seconds: Centistokes =

(

SUS 4.635

)

CS = SUS/4.635

Note: Saybolt Universal Seconds can also be abbreviated as SSU.

T18

XXXX_FPC05_TECH SECTION.indd T18

Visit Us Online: www.Applied.com

11/11/04 8:47:22 AM

Pump Formulas Pump PumpFormulas Formulas FORMULA FOR: PUMP OUTLET FLOW In Gallons/Minute PUMP INPUT POWER In Horsepower Required PUMP EFFICIENCY Overall in Percent

WORD FORMULA:

LETTER FORMULA:

RPM x Pump Displacement (Cu. In./Ref.)

Flow =

Q = nd/231

231 Flow Rate Output (GPM) x Pressure (psi)

Horsepower Input =

1714 Efficiency (Overall)

(

Overall Efficiency =

Output Horsepower Input Horsepower

)

EffOV = (HPout /HPin) x 100

x 100

Effov = Effvol x Effmech

Overall Efficiency = Volumetric Eff. x Mechanical Eff.

PUMP EFFICIENCY Volumetric in Percent PUMP EFFICIENCY Mechanical in Percent PUMP LIFE B10 Bearing Life

Actual Flow Rate Output (GPM)

Volumetric Efficiency =

x 100

Theoretical Flow Rate Output (GPM)

Mechanical Efficiency =

Theoretical Torque to Drive Actual Torque to Drive

B10 Hrs. Bearing Life = Rated Life Hrs. x

Rated Speed (RPM) New Speed (RPM)

x

Hpin = QP/1714Eff. or (GPM x psi)/1714Eff.

x 100

Rated Pressure (psi) New Pressure (psi)

Effvol = (Qact/Qtheo) x 100 Effmech = (Ttheo/Tact) x 100 B10 = Rated Hrs x (RPMr/RPMn) x (Pr/Pn)3

Actuator ActuatorFormulas Formulas FORMULA FOR:

WORD FORMULA:

LETTER FORMULA:

Area = ∏ x Radius2 (Inches)

A = ∏r2

Area = (P/4) x Diameter2 (Inches)

A = (∏D2)/4 or A = .785D2

Area = Pressure (psi) x Net Area (sq in.)

F = psi x A or F = PA

CYLINDER AREA In Square Inches

CYLINDER FORCE In Pounds, Push or Pull CYLINDER VELOCITY or SPEED In Feet/Second

Velocity =

∏ x Radius2 (in.) x Stroke (in.)

Volume =

231

CYLINDER VOLUME CAPACITY In Gallons of Fluid

Net Area (sq. in.) x Stroke (in.)

Volume =

CYLINDER FLOW RATE In Gallons/Minute

231 Pressure (psi) x F.M. Displacement (Cu. In./Rev.) 2∏ Horsepower x 63025

Torque =

Torque =

FLUID MOTOR TORQUE/100 psi In Inch Pounds

231

12 x 60 x Velocity (Ft/Sec) x Net Area (sq. in.)

Flow Rate =

Torque =

FLUID MOTOR TORQUE In Inch Pounds

231 x Flow Rate (GPM) 12 x 60 x Net Area (sq in.)

RPM

Flow Rate (GPM) x Pressure (psi) x 36.77

Torque 100

RPM =

FLUID MOTOR SPEED In Revolutions/Minute

Speed =

FLUID MOTOR POWER In Horsepower Output

Horsepower =

F.M. Displacement (Cu. In./Rev.) .0628

v = 231Q/720A or v = .3208Q/A

V = (∏r2L)/231

V= (A L)/231

Q = (720vA)231 or Q = 3.117vA

T = psi d/2∏ or T = Pd/2∏

T = 63025 HP/n

T = 36.77QP/n or T = 36.77Qpsi/n

T100psi = d/.0628

231 Flow Rate (GPM) F.M. Displacement (Cu. In./Rev.) Torque Output (Inch Pounds) x RPM 63025

n = 231 Q/d

HP = Tn/63025

Call Your Local Service Center to Order: 1-877-279-2799

XXXX_FPC05_TECH SECTION.indd T19

T19

11/11/04 8:47:22 AM

Fluid Power Formulas Thermal ThermalFormulas Formulas FORMULA FOR:

WORD FORMULA:

LETTER FORMULA:

RESERVOIR COOLING CAPACITY Based on Adequate Air Circulation

Heat (BTU/Hr) = 2 x Temperature Difference Between Reservoir Walls and Air (Fº) x Area of Reservoir (Sq. Ft.)

BTU/Hr = 2.0 x DT x A

HEAT IN HYDRAULIC OIL Due to System Inefficiency (SG=.89-.92)

Heat (BTU/Hr) = Flow Rate (GPM) x 210 x Temp. Difference (Fº)

BTU/Hr = Q x 210 x DT

HEAT IN FRESH WATER

Heat (BTU/Hr) = Flow Rate (GPM) x 500 x Temp. Difference (Fº)

BTU/Hr = Q x 500 x DT

Note: One British Thermal Unit (BTU) is the amount of heat required to raise the temperature of one pound of water one degree Fahrenheit. One Horsepower = 2545 BTU/Hr.

Accumulator Formulas Accumulator Formulas FORMULA FOR:

WORD FORMULA:

LETTER FORMULA:

PRESSURE OR VOLUME With Constant T (Temperature)

Original Pressure x Original Volume = Final Pressure x Final Volume

P1V1 = P2V2 Isothermic

PRESSURE OR TEMPERATURE With Constant V (Volume)

Original Pressure x Final Temp. = Final Pressure x Original Temp.

P1T2 = P2T1 Isochoric

Original Volume x Final Temp. = Final Volume x Original Temp.

V1T2 = V2T1 Isobaric

Original Press. x Original Volumen = Final Press. x Final Volumen

P1V1n=P2V2n

Final Temp./Orig. Temp. = (Orig. Vol./Final Vol.)n-1 = (Final Press./Orig. Press.)(n-1)/n

T2/T1=(V1/V2)n-1 = (P2/P1)(n-1)/n

VOLUME OR TEMPERATURE With Constant P (Pressure) PRESSURE OR VOLUME With Temp. Change Due to Heat of Compression

Volumeand and Capacity Equivalents Volume Capacity Formulas Cubic Inches

Cubic Feet

Cubic Centimeters

Liters

U.S. Gallons

Imperial Gallons

Cubic Inches

1

0.0005787

16.384

0.016384

0.004329

Cubic Feet

1728

1

0.037037

28.317

Cubic Centimeters

0.0610

0.0000353

1

Liters

61.0234

0.0353145

U.S. Gallons

231

Imperial Gallons Pounds of Water

Water at Max Density Pounds of Water

Kilograms of Water

0.0036065

0.361275

0.0163872

7.48052

6.23210

62.4283

28.3170

0.001

0.000264

0.000220

0.002205

0.0001

0.001308

1

0.264170

0.220083

2.20462

1

0.133681

0.004951

3.78543

1

0.833111

8.34545

3.78543

277.274

0.160459

0.0059429

4.54374

1.20032

1

10.0172

4.54373

27.6798

0.0160184

0.0005929

0.453592

0.119825

0.0998281

1

0.453593

T20

XXXX_FPC05_TECH SECTION.indd T20

Visit Us Online: www.Applied.com

11/11/04 8:47:22 AM