Professional Documents
Culture Documents
1
Hydraulic Fluid Check Valve
Least Resistance Relief Valve
Pascal’s Law Pressure Differential Relief
Application Principles Conditioners
JIC Open vs Closed
Pumps Hydraulic Valve JIC
Axial Piston Pump Hydraulic Cylinder Principles
Gear Pump Cylinder Leakage Test
Motors Build With JIC’s
Reservoirs
Lines and Connections
Liquids Have no Shape of their own
3
Liquids are
Practically Incompressible
4
Liquids under pressure follow
what path?
5
Path of Least Resistance
10 lbs
6
Imperial
7
This slide illustrates one of the basic principles of hydraulics;
LIQUIDS TRANSMIT APPLIED PRESSURE EQUALLY IN ALL
DIRECTIONS.
BUILDS:
1. When a 1 lb (.45kg) force is applied to this handle and the area of the
piston is 1sq in (.65cm2), with the confined fluid, what PSI (kpa)
pressure will be produced? (1psi (6.9kpa))
Note that this pressure is exerted in every direction.
2. With a 10 sq in (6.5cm2) piston, how much weight will this system
lift? This principle is what allows us to multiple our work efforts.
With 1 lb (.45kg) of down pressure, we are able to lift 10 lbs (4.5kg).
Pressure is caused by a resistance to flow, in this case the 10 lb
(4.5kg) weight. Point out that resistance to flow is what causes
pressure. In this example, if there were a 100 lb (45kg) weight on the
right side (in place of the 10 lb (4.5kg) weight), how much pressure
would be required to lift it. (10 PSI (69kpa)).
IMPERIAL
--Hydraulics is a means of power transmission
--Oil is the most commonly used medium because it serves as a lubricant
and is practically non-compressible (it will compress approximately 1/2
of a 1 percent per 1000 PSI).
--Weight of oil varies with viscosity, but averages between 55 to 55 lbs
per cubic foot. (at 100 degrees F).
NOTE: A cubic foot of oil is 1728 Cu.In (12x12x12). A gallon is 231
Cu.In., so a Cubic Foot of oil is equivalent to 7.48 Gallons.
--A liquid is pushed, NOT DRAWN, into a pump. Atmospheric pressure
equals 14.7 PSI at sea level.
--Oil takes the course (path) of least resistance.
FORMULAS;
1. H.P. = GPM x Pressure x .000583 -or- H.P. = GPM x PSI / 1714
2. One H.P. = 33000 ft./lbs. per minute (33000 lbs raised 1 ft in 1 minute)
One H.P. = 746 Watts, One H.P. = 42.4 BTU per minute
3. Required Area of a transmission line;
Area = GPM x .3208 / velocity (ft./sec) -or- Velocity (ft./sec) = GPM / 3.117 x Area
Pascal’s Law, named after Blaise Pascal (French 1623-1662)
METRIC
--Hydraulics is a means of transmitting power.
--Oil is the most commonly used medium because it serves as a lubricant
and is practically non-compressible (it will compress approximately 1/2
of 1 percent per 690 kpa).
--Weight of oil varies with viscosity, but averages between 23 to 25 kg
per cubic foot. (at 100 degrees F).
NOTE: A cubic foot of oil is 1728 Cu.In (12x12x12). A gallon is 231
Cu.In., so a Cubic Foot of oil is equivalent to 7.48 Gallons.
--Liquid is pushed (by Atmospheric Pressure), NOT DRAWN, into a
pump. Atmospheric pressure equals 14.7 PSI at sea level.
--Oil takes the path (line) of least resistance.
FORMULAS;
1. H.P. = GPM x Pressure x .000583 -or- H.P. = GPM x PSI / 1714
2. One H.P. = 33000 ft./lbs. per minute (33000 lbs raised 1 ft in 1 minute)
One H.P. = 746 Watts, One H.P. = 42.4 BTU per minute
3. Required Area of a transmission line;
Area = GPM x .3208 / velocity (ft./sec) -or- Velocity (ft./sec) = GPM / 3.117 x Area
Pascal’s Law, named after Blaise Pascal (French 1623-1662)
Application Principles
1 lb (.45kg)
Force 10 lbs (4.5kg)
10 sq in
(6.5cm2)
1 sq in Piston Area
(.65cm2)
Piston Area
1 psi
(6.9kpa)
11
THE TWO MAIN TYPES OF PUMPS:
2. The non-positive pump can rotate all day and not necessarily cause
fluid to flow.
13
JIC Symbols
14
J I C Symbols
Joint Industrial Council
2139 Wisconsin Ave, NW
Washington, DC 20007
This organization was founded in 1965. JIC standards replaced those
written by the Joint Industrial Conference (mostly auto manufacturing)
BUILDS
1. Circle, the major components in a JIC schematic are circles. For a
pump with start with a circle.
2. Then we add an arrow head. The arrow pointing out of the circle
signifies the direction of the fluid flow. OUT, indicating a pump
3. Continue to build showing two arrows heads, meaning this pump is
capable of pumping oil in two directions
4. The arrow signifies that this pump is capable of varying the amount of
flow, so it is a variable displacement pump.
Pumps (JIC Symbols)
■ Constant
Displacement
Single Direction Arrow
Showing
Oil Flow
OUT
■ Bi-Directional,
Variable
Displacement
1. Rotating group
2. Swash plate
3. Pistons
Axial Piston Pump
■ Neutral Position Pressure Oil
Vertical Swashplate Each Piston
Piston
Piston
Charge Oil
Pressure
Rotating Group
20
Typically 9 Pistons
Axial Piston Pump
■ Reverse Position
Angled Swashplate
Pressure
Charge
Rotating Group
21
Typically 9 Pistons
Before going back into JIC symbols, lets show another very popular
type of pump or motor.
2. If this were a Pump and with the pump turning in the direction
illustrated by the arrows, which side is the inlet and which side is
the outlet?
In Out
23
BUILDS:
2. Add an arrow head, but note how this arrow head differs from the
pump shown earlier .. it points “IN”.
4. Second arrowhead.
What type of motor is this? (bi-directional)
24
Motors (JIC Symbols)
◆ Single Direction ◆ Bi-Directional
Arrow Showing
Oil Flow IN
1. Vented 2. Pressurized
or
Working Line (Main)
Crossing Lines
Flexible Line
Flow Direction
27
Check Valve
Spring Assisted
Pilot Operated
28
Relief Valves
29
Relief Valve
Supply Return to
Reservoir
Pilot supply
30
Pressure Differential Valve
Supply
32
Fluid Conditioners
Filter
Oil Cooler 33
Filters
Internal Filter
Bypass Valve
(Optional)
■ Micron
■ 1 Millionth
of a Meter or
1 Thousandth
of a Millimeter 34
Types of Hydraulic Systems
Open Center
Closed Center
The control valve that regulates the flow from the pump
determines if system is open or closed.
35
Hydraulic Valve JIC
Closed
Open
Center
Center
Hydraulics
Flow in Neutral
Trapped Oil
36
OPEN CENTER VALVE:
Extend 38
Hydraulic Valve JIC
Retract 39
Hydraulic Valve JIC
Neutral Again 40
Let’s examine what happens when a cylinder is extended. Pressure oil is
routed to the piston end. Oil from the rod end is allowed to return to the
reservoir.
Lift Cylinder
■ Extend
42
When cylinders “leak down” over a period of time, it is commonly
believed that the cylinder piston “packings” (O-ring seals) are the cause
of the problem.
44
This illustration goes beyond the practical but makes the point. Because
of the volume of oil trapped in the cylinder, the rod CANNOT retract
any further unless the trapped oil is allowed to escape somewhere. In
this case and always with cylinders that leak down by retracting, the
control valve is leaking allowing the oil out of the cylinder.
Remember, this rule applies only when the cylinder rod retracts (oil
leaking from the piston end to the rod end and out through the control
valve). Oil can leak from the rod side to the piston side (allowing the
rod to extend) because the rod side with less volume of oil can leak into
the piston side with a greater area.
Lift Cylinder
■ Is it Possible for
This Rod to Retract
Even With
the Piston
Removed??
46
Cylinder Hose Failures
■ Effects On Line
Pressure When a 15000 lbs
of Down
Cylinder Piston Force
Packing is
Leaking 1.5” Diameter Rod
.75 x .75 x 3.1416 = 1.77 sq.in.
Results in 8475 PSI
3” Diameter Piston
1.5 x 1.5 x 3.1416 = 7.07 sq.in.
Results in 2122 PSI
47
To test a cylinder for internal leakage (past the piston seals), remove the
cylinder pin from the rod (what ever the cylinder works on will have to
be supported). Either extend or retract the rod completely. Then remove
the oil line closest to the cylinder’s internal piston. Connect a hydraulic
hose to the cylinder where the line was removed. Place the other end of
the hydraulic hose in a clean bucket. Pressurize the opposite side of the
cylinder with hydraulic oil. Measure leakage into the bucket. If
excessive leakage is observed into the bucket, replace cylinder piston
seals.
NOTE: On some systems, such as the John Deere light weight fairway
mowers, the line returning the lift valve will need to be capped to
prevent return oil from flowing out the line.
Hydraulic Cylinder
Leakage Test
Depending on the
System, You May
Have to Cap This Line
To Prevent Return
Oil From Leaking Out
Retract 49
JIC Symbols
50
JIC Symbols
PM
Hill Simulation
PM
Hill Simulation
Inlet
Check
PM
Common
Reservoir Inlet
Check Common
Reservoir
Leak off lines are NOT shown, but are required to provide;
1. Lubrication
2. Cooling
3. Cleaning
JIC Symbols Oil Filter
Oil Cooler
Bypass
Valve
PM
Charge
Relief
Valve
Filter
Bypass
Valve
Oil Cooler
Bypass
Valve
PM
Charge
Relief
Valve
Filter
Bypass
Valve
■ Hydrostatic
Oil Cooler
Transmission
Components 57