Training Basic Hydraulics

Table of Contents
Description
Best Power to Weight Ratio Simple Hydraulic System Hydraulic Symbols Dump Pumps Gear Pumps Accumulators Directional Control Valves Double Acting Cylinders Fixed Displacement Motor In Cab Control Valves Electronic Controls How Much Oil What Kind of Oil How to Check Oil When to Replace the Filter What Size Tank What Should Be Included In the Tank What Kind of Hoses Type of Pump Pumps Used With Open Center Valves

Pg
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Pumps Used With Closed Center Valves What Kind of valve Valve Size and Pressure Single Double Acting Valve Hydraulic Mid Inlets Power Beyond Open Center Schematic Closed Center LS Schematic Horse Power Consumption Hydraulic Cylinders Single Acting Double Acting Cylinders Bleeding Air Hydraulic Motor Types How Motors Work Filtration How Filters are Selected PTO Types Manual PTOs

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PTOs for Automatic Transmissions Dump Truck 2 Line System Dump Truck 3 Line System QDB Manual Spreader Valve with Power Beyond PSM 1000 Spreader Valve No In Cab Hydraulics PSM Spreader Valve With LS Questions

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The Best Power to Weight Ratio of All Energy Conversion Systems

Hydraulic motor: - displacement: 5 cm/r (0.30 in/r) - continuous speed 8500 rpm - continuous power 13kW (17.5 hp) - length 134mm (5.28 in) - weight 5 kg (11 lb)

Electric motor: - speed 2900 rpm - power 11kW (15 hp) - length 320mm (12.6 in) - weight 65 kg (145 lb)
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Simple Hydraulic System

Hydraulic Schematic Symbols

Accumulator

Cylinder Double acting

Directional Control Valve (manually operated)

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Dump Pumps

Hydraulic System Components: Gear Pump

Hydraulic Pump Symbol

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Hydraulic System Components : Accumulator

Accumulator symbol

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Hydraulic System Components : Directional Control Valve

Electrohydraulic solenoid

Spool Housing

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Hydraulic System Components : Double Acting Cylinder

Cylinder barrel Front end bearing Piston Piston rod Cylinder symbol Rear end bearing

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Hydraulic System Components : Fixed Displacement Motor

LSHT Motor

Gear Motor

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Hydraulic System Components: Pilot Control Valves

VP04 Pneumatic Controls

PCL04 Hydraulic Controls

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Hydraulic System Components: Electronic Controls

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Hydraulic Oil How Much

General Rule 1 X the Rated Flow of the Pump at 1200 rpms Example P51 Pump with 6.38 Cubic Inches of Displacement [6.38 cid x 1200 rpm / 231] x 1.5 = 50 Gallons
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HYDRAULIC OIL WHAT KIND

Grade AW22 Very Cold Temperature (Northern Canada) Grade AW32 - Good All Temperature ( Most Common) Grade AW68 - Extremely High Temperatures (Florida-New Mexico-Arizona- Texas-Southern California) Make Sure To Use Non-Foaming Hydraulic Oil
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HYDRAULIC OIL HOW TO CHECK

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HYDRAULIC OIL WHEN TO REPLACE

When these gauges are in the red it is time to replace the filter element If you have no gauge on the filter make it a point to go and purchase one from your nearest distributor
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HYDRAULIC TANKS - WHAT SIZE

If the cylinder requires 50 gallons or more to extend you will need a 70 to 75 gallon tank, or the bed will not fully extend. General rule works most of the time, but make sure you do not run out of fluid when operating the equipment
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HYDRAULIC TANKS WHAT SHOULD BE INCLUDED

Breather / Filler Cap

Sight and Temperature Gage Suction and Return Line Ports

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HYDRAULIC HOSES WHAT KIND

Since we are using hydraulic oil we need a hydraulic hose Suction Hose 100R4 Medium Pressure Hose up to 3000 PSI 100R17 All Hoses Listed are for Standard Dump Truck/ Trailer

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HYDRAULIC PUMPS - WHAT DETERMINES THE TYPE OF PUMP

Gear Vane Piston Variable Volume Piston

Least

Most Expensive

Flow Required RPMs the Pump will operate Hydraulic System Pressure Requirement Type of Hydraulic Valve [Open or Closed] Budget / Hours of Operation When full flow is not required, variable volume piston pumps are more attractive
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HYDRAULIC PUMPS USED WITH OPEN CENTER VALVES

Gear Pump Vane Pumps Fixed Displacement Piston

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HYDRAULIC PUMPS USED WITH CLOSED CENTER VALVES

Variable Volume Pressure Compensated Piston Pump Variable Volume Load Sense Controls

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HYDRAULIC VALVES- WHAT KIND OF VALVE

V040

V20

DVA/DVG 20/35

VP170

System Flow Requirement System Pressure Requirement Amount of Operator Control Required HP Efficiency Heat Issues
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HYDRAULIC VALVES SIZE & SYSTEM PRESSURE

Valve Type V040 Open V20 Open V20LS Closed/LS DVA20 Open DVG20 Open DVA35 Open DVG35 Open VP170 Closed/LS Flow 10.6 GPM 25.0 GPM 25.0 GPM 40.0 GPM 40.0 GPM 70.0 GPM 70.0 GPM 60.0 GPM Max PSI 4350 PSI 3500 PSI 3500 PSI 2500 PSI 3500 PSI 2500 PSI 3500 PSI 5000 PSI

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HYDRAULIC VALVE SINGLE ACTING / DOUBLE ACTING

Single Acting B Port Only Double Acting A and B Port

Single acting valves only have one work port [Generally the B Port] Double acting valves have two work ports [A Port and B Port]
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HYDRAULIC MID INLETS

Mid Inlet

Main Inlet

Types
Combined Flow - Mid Inlet (Inlet 1 + Inlet 2) Split Flow - Mid Inlet (Inlet 1 separate Inlet 2)
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HYDRAULIC VALVE POWER BEYOND

Power Beyond Port to additional valve

Return Line Port

Purpose
Allow for multiple valve sections to be run from a single section pump
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Open Center Schematic

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Closed Center LS Schematic

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Horse Power Consumption GPM X PSI

HP =

----------------------

1714

Rule of Thumb Gear Pumps are ideal when full pump flow is being used LS Pumps are ideal when full pump flow is not used
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HYDRAULIC CYLINDERS - Rod and Telescopic

Rod Cylinder

Telescopic Cylinder Multiple Stages

Rod Single Ram Telescopic Multiple Stages

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MOBILE CYLINDERS SINGLE ACTING DOUBLE ACTING

Single Acting Cylinders
Power Up Gravity Down Single Hose Connection 3 Way Valve Work Section

Double Acting Cylinders

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Power Up Power Down Two Hose Connection 4 Way Valve Work Section

CYLINDERS BLEEDING AIR FROM THE CYLINDER

A messy job but has to be done

Reasons telescopic cylinders require bleeding air To avoid spongy action To avoid cylinders raising in the wrong sequence To avoid costly repairs How to bleed a telescopic cylinder (Single Acting) Raise the cylinder almost to the top Lower the bed to about 2 feet from the bottom Turn the adjustment screw CCW and then close Repeat if necessary
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Hydraulic Motors - Types

LSHT MOTOR

GEAR MOTOR

LSHT Motors Gear Motors

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HYDRAULIC MOTORS HOW MOTORS WORK

Hydraulic Motors provide rotary motion Pressurized oil drives the rotating group for desired rotary motion This is not a pump

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HYDRAULIC FILTRATION SPIN ON & CANISTER

Spin on filtration [generally low pressure return line filters] Canister filtration [medium to high pressure inline filtration located between the hydraulic pump and the hydraulic valve]
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HYDRAULIC FILTRATION HOW FILTERS ARE SELECTED

Flow and Pressure Microns Degree of Filtration Absolute versus Nominal

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PTOS TYPES

Manual PTOs

Used with manual transmissions

Six or Eight Bolt Opening Pneumatic Actuator or Cable Truck Clutch must be disengaged Hot Shifts for manual transmission are available in pneumatically engage clutch packs Truck Clutch does not need to be disengaged

Hot Shift PTOs

Used with automatic transmissions

Six or Ten Bolt openings Recommended Engagement less than 1000 rpms
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PTO MANUAL MOST POPULAR

Six Bolt 442 - Eight Bolt 489 Rugged Cast Iron construction versus aluminum Grease able Flanges Available without pump removal Note: PTO Torque ratings must meet application Pump, Compressors, Blowers, Water Pumps, Propane Pumps, etc. Note: 489 Must have pump support bracket for pumps in excess of 40 lbs.

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PTOS for Automatic Transmissions

270/271 Six Bolt Aisin, Allison, Dodge, GM, Mitsubishi 277/278 10 Bolt Wet Spine extending Shaft life by a factor of 10 Allison World Transmission, Caterpillar Automatic Popular with large fleets, maintenance issues with manual transmissions 246 Ford
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DUMP TRUCK - Three Line System

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Dump Trailer Three Line System One Line to the Trailer

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QDB Manual Spreader Valve with Power Beyond

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PSM 1000 Spreader Valve No In Cab Hydraulics

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PSM1000 Spreader Valve with LS

Drain

LS Line

Note: Minimum of 3 work sections / Plow Up-Down / Plow Left-Right / Hoist / PSM 1000
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Questions

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Dump Truck / Trailer Application

September 2009

Parker Hannifin Corporation 595 Schelter Road Lincolnshire, IL 60069 Tel: (847)955-5253 Fax: (847) 821-9564 www.parker.com/hydraulics