Basic Machinery Hydraulics 2014 ACPA Basic Machinery Hydraulics www.concrete-pipe.org www.concrete-pipe.org

Basic Machinery Hydraulics 2 Automation is almost an assumption with industrial machinery in the 21st century. Whether you have new equipment or old, the basic principles of hydraulic systems remain the same. This session will be an overview of hydraulic systems found on most machinery in our industry.  The class will consist of  topics including a basic introduction to hydraulics, an overview on reading and understanding hydraulic schematics, maintenance and troubleshooting topics, and safety.  Whether you are in maintenance or production, a basic knowledge of hydraulic systems will increase uptime through proper maintenance and faster diagnosis of the issues you may run into – ultimately having machinery working efficiently at making quality products. Basic Machinery Hydraulics www.concrete-pipe.org

Goals of This Presentation 3 Goals of This Presentation Introduce basic hydraulic information and theory. Help understand the basic control valves, pumps, and actuators. Introduce schematics and the symbols associated with them. Discuss hydraulic maintenance. Look at safety in regard to hydraulic systems and maintenance. www.concrete-pipe.org

Introduction to Basic Hydraulics How does it work? Key point to keep in mind: Fluid is not compressible. Pascal’s Law: Pressure applied on a confined fluid is transmitted undiminished in all directions, and acts with equal force on equal areas, and at right angles to them. What does this mean and why do we need to know this? www.concrete-pipe.org www.concrete-pipe.org

Introduction to Basic Hydraulics Pascal’s Law Results in 10 lb force on every square inch of the container wall A 10 lb force is applied to a stopper with an area of one square inch If the bottom has an area of 20 sq. in. and each square inch is pushed by a 10 lb of force, the entire bottom receives a 200 lb push This bottle is filled with liquid that is non-compressible www.concrete-pipe.org

Basic Hydraulic Information 6 Basic Hydraulic Information Topics for this section: Oil Motors Cylinders Directional Valves Load Controls www.concrete-pipe.org www.concrete-pipe.org

Basic Hydraulic Information 7 Basic Hydraulic Information Hydraulic Oil Basics Different types of oil. Different oil applications. Changing oil. www.concrete-pipe.org www.concrete-pipe.org

Basic Hydraulic Information 8 Basic Hydraulic Information Hydraulic Actuators Motors www.concrete-pipe.org www.concrete-pipe.org

Basic Hydraulic Information 9 Basic Hydraulic Information Hydraulic Actuators Cylinders www.concrete-pipe.org www.concrete-pipe.org

Basic Hydraulic Information 10 Basic Hydraulic Information Hydraulic Actuators Manual Directional Valves www.concrete-pipe.org www.concrete-pipe.org

Basic Hydraulic Information 11 Basic Hydraulic Information Hydraulic Actuators Solenoid Controlled Directional Valves www.concrete-pipe.org www.concrete-pipe.org

Basic Hydraulic Information 12 Basic Hydraulic Information Hydraulic Actuators Load Controls Line mounted or valve stack (cartridge) mounted. Pressure reducers. Flow control valves. Counterbalance valves. Check valves. www.concrete-pipe.org www.concrete-pipe.org

Basic Hydraulic Information 13 Basic Hydraulic Information Hydraulic Actuators Load Controls (cont.) Sandwich bodies Meter in/ Meter out Notch O-ring plate on D03 www.concrete-pipe.org www.concrete-pipe.org

Topics for this section: 14 Hydraulic Schematics Topics for this section: Overview Schematic vs. Pictorial Diagram vs. Routing Drawing Symbols How to Use Your Hydraulic Schematics www.concrete-pipe.org

15 Hydraulic Schematics Overview Schematics show all components in a hydraulic system, how the pressure is supplied, how the system is controlled, and details about the actuator. Schematics do not show how the hoses or tubing is routed www.concrete-pipe.org

16 Hydraulic Schematics Overview Schematics www.concrete-pipe.org

Overview Pictorial Diagram Hydraulic Schematics 17 www.concrete-pipe.org

18 Hydraulic Schematics Overview Routing Drawing www.concrete-pipe.org

Hydraulic Schematics Following Power Flow on Typical Schematics 19 www.concrete-pipe.org

Hydraulic Schematics Following Power Flow on Typical Schematics 20 www.concrete-pipe.org

Hydraulic Schematics Following Power Flow on Typical Schematics 21 www.concrete-pipe.org

Hydraulic Schematics Following Power Flow on Typical Schematics 22 Hydraulic Schematics Following Power Flow on Typical Schematics Taking time to learn and understand your machine schematics will help with your own troubleshooting, help you diagnose failed or worn parts, and make communication with a service or parts technician on the phone easier. All of this will save your company down time and money in the long run! www.concrete-pipe.org

Maintenance and Troubleshooting 23 Maintenance and Troubleshooting Topics for this section General Information Pumps and Reservoirs Actuators Hydraulic Conduits Valve and Manifold Component Replacement Troubleshooting Hydraulic Systems www.concrete-pipe.org www.concrete-pipe.org

Maintenance and Troubleshooting 24 Maintenance and Troubleshooting When properly maintained, a hydraulic system will operated efficiently and safely for many years without major breakdown. There are important steps to take and things to know about proper maintenance and parts replacement in hydraulic systems. www.concrete-pipe.org www.concrete-pipe.org

Maintenance and Troubleshooting 25 Maintenance and Troubleshooting Pump Replacement and Reservoirs Pump failure What causes a pump to fail? What should you watch out for when replacing a pump? How do you set the system pressure on pressure compensated pumps? Reservoir cleaning and inspection How and when should the tank be cleaned or inspected? www.concrete-pipe.org www.concrete-pipe.org

Maintenance and Troubleshooting 26 Maintenance and Troubleshooting Actuator Replacement Cylinder or Motor Failure Determine whether an actuator can be rebuilt or if it needs to be replaced. Be sure to use the correct replacement actuator for the application. Consider the safest way to remove and replace an actuator. www.concrete-pipe.org www.concrete-pipe.org

Maintenance and Troubleshooting 27 Maintenance and Troubleshooting Hoses, Tubing, and Collectors There is more to fixing leaks than simply removing and replacing hoses! www.concrete-pipe.org www.concrete-pipe.org

Maintenance and Troubleshooting 28 Maintenance and Troubleshooting Valve and Manifold Component Replacement Always verify that the new directional valve is the same as the one being replaced. Check the o-rings on the bottom of the valve and sandwich body. Use proper torque for cartridges and fasteners. www.concrete-pipe.org www.concrete-pipe.org

Maintenance and Troubleshooting 29 Maintenance and Troubleshooting Troubleshooting Hydraulic Systems Scenario #1 Older production machine, manual valve control with a conveyor that will not run with concrete on it. All other machine functions work fine. Bad belt motor. Bad belt speed control valve. Bad flow divider. Low system pressure. What should we check? Check the main system pressure at the pump. www.concrete-pipe.org www.concrete-pipe.org

Maintenance and Troubleshooting 30 Maintenance and Troubleshooting Troubleshooting Hydraulic Systems Scenario #2 Rotating feeder chute will not move in forward direction, will work in reverse. Sometimes forward will work after the control switch is bumped in reverse. Possible solutions? Bad switch or wiring. Motor is worn internally. Incorrect speed control settings in the PLC program. Failing directional control valve. What should we check? Check the directional valve for a sticking spool. www.concrete-pipe.org www.concrete-pipe.org

Maintenance and Troubleshooting 31 Maintenance and Troubleshooting Troubleshooting Hydraulic Systems Scenario #3 Rotating feeder chute will move slowly in forward and reverse. Possible solutions? Bad switch or wiring. Motor is worn internally. Incorrect speed control settings in the PLC program. Failing directional control valve. Improper oil flow to the motor. What should we check? Check the path of the oil from the valve to the motor. www.concrete-pipe.org www.concrete-pipe.org

Maintenance and Troubleshooting 32 Maintenance and Troubleshooting Troubleshooting Hydraulic Systems Scenario #4 Vertical machine mast drifts down when the machine is at idle (no commanded move inputs from the operator or PLC). Header puller. Glitch in the program. Bad directional valve. Failed counterbalance. Worn cylinder seals. What should we check? Sometimes two parts can have the same symptoms. In this case, replacing the counterbalance with a known good one. If not, check the cylinder for internal leaks. www.concrete-pipe.org www.concrete-pipe.org

Maintenance and Troubleshooting 33 Maintenance and Troubleshooting Troubleshooting Hydraulic Systems Scenario #5 Linear machine movement with a cylinder is extremely slow or inoperative. Glitch in the program. Bad directional valve. Worn cylinder seals. Incorrect flow control adjustment. Failed pressure reducer. How did we get to this conclusion? Check the pressure going to the cylinder with a pressure gauge. www.concrete-pipe.org www.concrete-pipe.org

Maintenance and Troubleshooting 34 Maintenance and Troubleshooting Troubleshooting Hydraulic Systems Scenario #6 Linear machine movement with a cylinder is extremely fast. Pallet stacker grippers. Bad directional valve. Worn cylinder seals. Incorrect speed control settings. Failed pressure reducer. How did we get to this conclusion? Check settings? Check pressure reducer. www.concrete-pipe.org www.concrete-pipe.org

Maintenance and Troubleshooting 35 Maintenance and Troubleshooting Troubleshooting Hydraulic Systems Scenario #7 Linear transfer cart movement with a motor on a gear rack is inoperative. Bad directional valve. Worn motor. Incorrect flow control/ speed setting adjustment. Damaged gear box. None of these. What was actually wrong in this case? The cart was mechanically stuck on a broken piece of concrete in it’s path. Often we forget to look at the simple issues before we start intense hydraulic or electrical diagnostics. www.concrete-pipe.org www.concrete-pipe.org

Topics for this section: General Safety Risks Health Hazards 36 Hydraulic Safety Topics for this section: General Safety Risks Health Hazards Environmental Hazards How to Reduce the Risks www.concrete-pipe.org www.concrete-pipe.org

Uncontrolled release of stored energy. Slip and Fall Fire Risk 37 Hydraulic Safety General Safety Risks: Stored Energy. Gravity. Uncontrolled release of stored energy. Slip and Fall Fire Risk www.concrete-pipe.org www.concrete-pipe.org

Hydraulic Safety Health Hazards Penetration of skin 38 Hydraulic Safety Health Hazards Penetration of skin Can cause serious infections. Can collect in vital organs (heart chambers) and cause irreversible damage or death. Burns from hot oil. www.concrete-pipe.org www.concrete-pipe.org

Environmental Hazards 39 Hydraulic Safety Environmental Hazards Oil spilled and washed down floor drains gets into the water supply. Oil spilled outside in the yard contaminates soil and water. Always use proper spill kits in the event on an oil spill. Dispose of used oil and used spill cleanup materials according to local laws. www.concrete-pipe.org www.concrete-pipe.org

Hydraulic Safety Reduce the Risks! “Take 5 to Stay Alive!” 40 Hydraulic Safety Reduce the Risks! “Take 5 to Stay Alive!” Perform risk assessments before carrying out any maintenance or parts replacement. www.concrete-pipe.org www.concrete-pipe.org

Reduce the Risks! (cont.) 41 Hydraulic Safety Reduce the Risks! (cont.) Make sure anything with the potential for uncontrolled release of stored energy is properly secured www.concrete-pipe.org www.concrete-pipe.org

Basic Machinery Hydraulics 2014 ACPA Basic Machinery Hydraulics Something to take away from all this? Most often observed issues or helps: Hoses Rubbing or being abused – add deliberate inspection to your routine Dirty, old, burnt, or hot oil When trouble shooting – consider recent history, did this concern develop suddenly or is it a pattern developing? Learn basic schematic symbols www.concrete-pipe.org www.concrete-pipe.org