1. Basic Machinery Hydraulics
2014 ACPA
Basic Machinery Hydraulics

2. Basic Machinery Hydraulics2
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

3. Goals of This Presentation3
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.

4. 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?

5. 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

6. Basic Hydraulic Information6
Basic Hydraulic Information
Topics for this section:
Oil
Motors
Cylinders
Directional Valves
Load Controls

7. Basic Hydraulic Information7
Basic Hydraulic Information
Hydraulic Oil Basics
Different types of oil.
Different oil applications.
Changing oil.

8. Basic Hydraulic Information8
Basic Hydraulic Information
Hydraulic Actuators
Motors

9. Basic Hydraulic Information9
Basic Hydraulic Information
Hydraulic Actuators
Cylinders

10. Basic Hydraulic Information10
Basic Hydraulic Information
Hydraulic Actuators
Manual Directional Valves

11. Basic Hydraulic Information11
Basic Hydraulic Information
Hydraulic Actuators
Solenoid Controlled Directional Valves

12. Basic Hydraulic Information12
Basic Hydraulic Information
Hydraulic Actuators
Load Controls
Line mounted or valve stack (cartridge) mounted.
Pressure reducers.
Flow control valves.
Counterbalance valves.
Check valves.

13. Basic Hydraulic Information13
Basic Hydraulic Information
Hydraulic Actuators
Load Controls (cont.)
Sandwich bodies
Meter in/ Meter out
Notch
O-ring plate on D03

14. 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

15. 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

16. 16
Hydraulic Schematics
Overview
Schematics

17. Overview Pictorial Diagram Hydraulic Schematics 17

18. 18
Hydraulic Schematics
Overview
Routing Drawing

19. Hydraulic Schematics Following Power Flow on Typical Schematics 19

20. Hydraulic Schematics Following Power Flow on Typical Schematics 20

21. Hydraulic Schematics Following Power Flow on Typical Schematics 21

22. Hydraulic Schematics Following Power Flow on Typical Schematics22
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!

23. Maintenance and Troubleshooting23
Maintenance and Troubleshooting
Topics for this section
General Information
Pumps and Reservoirs
Actuators
Hydraulic Conduits
Valve and Manifold Component Replacement
Troubleshooting Hydraulic Systems

24. Maintenance and Troubleshooting24
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.

25. Maintenance and Troubleshooting25
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?

26. Maintenance and Troubleshooting26
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.

27. Maintenance and Troubleshooting27
Maintenance and Troubleshooting
Hoses, Tubing, and Collectors
There is more to fixing leaks than simply removing and replacing hoses!

28. Maintenance and Troubleshooting28
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.

29. Maintenance and Troubleshooting29
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.

30. Maintenance and Troubleshooting30
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.

31. Maintenance and Troubleshooting31
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.

32. Maintenance and Troubleshooting32
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.

33. Maintenance and Troubleshooting33
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.

34. Maintenance and Troubleshooting34
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.

35. Maintenance and Troubleshooting35
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.

36. 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

37. Uncontrolled release of stored energy. Slip and Fall Fire Risk37
Hydraulic Safety
General Safety Risks:
Stored Energy.
Gravity.
Uncontrolled release of stored energy.
Slip and Fall
Fire Risk

38. Hydraulic Safety Health Hazards Penetration of skin38
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.

39. Environmental Hazards39
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.

40. 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.

41. 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

42. 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