Troubleshooting General Troubleshooting Charts

Transcription

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
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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
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
T3
11/11/04 8:47:17 AM
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
11/11/04 8:47:17 AM
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.
T5
11/11/04 8:47:17 AM
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
11/11/04 8:47:17 AM
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.
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
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)
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
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
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
checks Disconnected
Lines Crossing
one check Connected
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
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
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
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
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
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
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
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
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
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
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
11/11/04 8:47:22 AM

Troubleshooting General Troubleshooting Charts

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