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

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 specic causes and remedies.

System Inoperative
Possible Causes: a. No oil in system. b. Oil low in reservoir. c. Oil of wrong viscosity. d. Filter dirty or plugged. e. Restriction in system. f. Air leaks in suction line. g. Dirt in pump. h. Badly worn pump. i. Badly worn components. j. Oil leak in pressure lines. k. Components not properly adjusted. Fill to full mark. Check system for leaks. Check level and ll to full mark. Check system for leaks. Refer to specications for proper viscosity. Drain oil and replace lters. Try to nd source of contamination. Oil lines could be dirty or have inner walls that are collapsing, cutting off oil supply. Clean or replace lines. Clean orices. Repair or replace lines. Clean and repair pump. If necessary, drain and ush hydraulic system. Try to nd source of contamination. Repair or replace pump. Check for problems causing pump wear such as misalignment or contaminated oil. Examine and test valves, motors, cylinders, etc. for external and internal leaks. If wear is abnormal, try to locate the cause. Tighten ttings or replace defective lines. Examine mating surfaces on couplers for irregularities. Refer to machine technical manual for proper adjustment of components. 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. Reverse to prevent damage. Check specication of unit for load limits. Attach properly and tighten securely. Replace couplers or belts if necessary. Align them and adjust tension. Check for shut-off device on pump or pump drive.

l. Relief valve defective. m. Pump rotating in wrong direction. n. Excessive load on system. o. Hoses attached improperly. p. Slipping or broken pump drive. q. Pump not operating.

T2

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General Troubleshooting Charts System Operates Erratically

Possible Causes: a. Air in system. Remedy: 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. 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. Check for dirt or gummy deposits. If contaminated, try to nd the source of contamination. Check for worn or bent parts. Check for broken or worn parts. Determine cause of pump damage. Clean relief valves or replace. Suction line could be dirty or have inner walls that are collapsing, cutting off oil supply. Clean or replace suction line. Also, check lter line for restrictions.

b. Cold oil.

c. Components sticking or binding. d. Pump damaged. e. Dirt in relief valves. f. Restriction in lter or suction line.

Overheating of Oil in System

Possible Causes: a. Operator holds control valves in power position too long, causing relief valve to open. b. Using incorrect oil. c. Low oil level. d. Dirty oil. e. Engine running too fast. f. Incorrect relief valve pressure. g. Internal component oil leakage. h. Restriction in pump suction line. i. Dented, obstructed or undersized oil lines. j. Oil cooler malfunctioning. k. Control valve stuck open. l. Heat not radiating properly. m. Automatic unloading control inoperative (if equipped). Remedy: Return control lever to neutral position when not in use.

Use oil recommended by manufacturer. Be sure oil viscosity is correct. Fill reservoir. Look for leaks. Drain and rell with clean oil. Look for source of contamination and replace lters. Reset governor or reduce throttle. Check pressure and clean or replace relief valves. Examine and test valves, cylinders, motors, etc. for external and internal leaks. If wear is abnormal, try to locate cause. Clean or replace. Replace defective or undersized oil lines. Remove obstructions. Clean or repair. Free all spools so that they return to neutral position. Clean dirt and mud from reservoir, oil lines, coolers, and other components. Repair valve.

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T3

General Troubleshooting Charts System Operates Slowly

Possible Causes: a. Cold oil. b. Oil viscosity too heavy. c. Insufcient engine speed. d. Low oil supply. e. Adjustable orice restricted too much. f. Air in system. g. Badly worn pump. Remedy: Allow oil to warm up before operating machine. Use oil recommended by the manufacturer. Refer to operators manual for recommended speed. If machine has a governor, it may need adjustment. Check reservoir and add oil if necessary. Check system for leaks that could cause loss of oil. Back out orice and adjust it. Check machine specications for proper setting. Check suction side of the system for leaks. Repair or replace pump. Check for problems causing pump wear such as misalignment or contaminated oil. Suction line could be dirty or have inner walls that are collapsing to cut off oil supply. Clean or replace suction line. Examine lter for plugging. Test relief valves to make sure they are opening at their rated pressure. Examine valves for damaged seats that could leak. Examine and test valves, motors, cylinders, etc. for external and internal leaks. If wear is abnormal, try to locate the cause. Clean dirt from components. Clean orices. Check for source of dirt and correct. Tighten ttings or replace defective lines. Examine mating surfaces on couplers for irregularities. Refer to machine technical manual for proper adjustment of components.

h. Restriction in suction line or lter.

i. Relief valves not properly set or leaking. j. Badly worn components. k. Valve or regulators plugged. l. Oil leak in pressure lines. m. Components not properly adjusted.

System Operates Too Fast

Possible Causes: a. Adjustable orice installed backward or not installed. b. Obstruction or dirt under seat of orice. c. Overspeeding of engine. Remedy: Install orice parts correctly and adjust. Remove foreign material. Readjust orice. Refer to operators manual for recommended speed. If machine has a governor, it may need adjustment.

T4

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General Troubleshooting Charts Foaming of Oil in System

Possible Causes: a. Low oil level. b. Water in oil. c. Wrong kind of oil being used. d. Air leak in line from reservoir to pump. e. Kink or dent in oil lines. f. Worn pump shaft seal. Remedy: Fill reservoir. Look for leaks. Drain and replace oil. Check ller breather on reservoir. Heat exchanger may be cracked. Use oil recommended by manufacturer. Tighten or replace suction line. Replace oil lines. Clean sealing area and replace seal. Check oil for contamination or pump for misalignment.

Pump Makes Noise

Possible Causes: a. Low oil level. b. Oil viscosity too high. c. Pump speed too fast. d. Suction line plugged or pinched. e. Sludge and dirt in pump. f. Reservoir air vent plugged. g. Air in oil. h. Worn or scored pump bearings or shafts. i. Inlet screen plugged. j. Broken or damaged pump parts. k. Sticking or binding parts. Remedy: Fill reservoir. Check system for leaks. Change to lighter oil. Operate pump at recommended speed. Clean or replace line between reservoir and pump. Disassemble and inspect pump and lines. Clean hydraulic system. Determine cause of dirt. Remove breather cap, ush, and clean air vent. Tighten or replace suction line. Check system for leaks. Replace pump shaft seal. Replace worn parts or complete pump if parts are badly worn or scored. Determine cause of scoring. Clean screen. Repair pump. Look for cause of damage such as contamination or too much pressure. Repair binding parts. Clean parts and change oil if necessary.

Pump Leaks Oil

Possible Causes: Remedy: 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. Make sure all bolts and ttings 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.

a. Damaged seal around drive shaft.

b. Loose or broken pump parts.

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T5

General Troubleshooting Charts Load Drops with Control Valve in Neutral Position
Possible Causes: a. Leaking or broken oil lines from control valve to cylinder. b. Oil leaking past cylinder packings or O-rings. Remedy: Check for leaks. Tighten or replace lines. Examine mating surfaces on couplers for irregularities. Replace worn parts. If wear is caused by contamination, clean hydraulic system and determine the contamination source. Clean or replace valves. Wear may be caused by contamination. Clean hydraulic system and determine the contamination source. Check for proper adjustment. Remove and replace cartridge with spare. (Support boom before removing cartridge.) Do not attempt to repair. Check linkage for binding. Make sure valve is properly adjusted and has no broken or binding parts.

c. Oil leaking past control valve or relief valves.

d. Oil leaking past load holding valve.

e. Control lever not centering when released.

Control Valve Sticks or Works Hard

Possible Causes: a. Misalignment or seizing of control linkage. b. Tie bolts too tight (on valve stacks). c. Valve broken or scored internally. Remedy: Correct misalignment. Lubricate linkage joints. Use manufacturers recommendation to adjust tie bolt torque. Repair broken or scored parts. Locate source of contamination that caused scoring.

Control Valve Leaks Oil

Possible Causes: a. Tie bolts too loose (on valve stacks). Remedy: Use manufacturers recommendation to adjust tie bolt torque. Replace O-rings, especially between valve stacks. If contamination has caused O-rings to wear, clean system and look for source of contamination. If valve is cracked, look for a cause like too much pressure or pipe ttings that are over tightened.

b. Worn or damaged O-rings.

c. Broken valve parts.

T6

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General Troubleshooting Charts Cylinders Leak Oil

Possible Causes: a. Damaged cylinder barrel. b. Rod seal leaking. c. Loose parts. d. Piston rod damaged. Remedy: Replace cylinder barrel. Correct cause of barrel damage. 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. Tighten parts until leakage has stopped. 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: a. Damaged check valve in lift circuit. b. Leaking cylinder packing. c. Leaking lines or ttings to cylinder. Remedy: Repair or replace check valve. Replace packing. Check oil for contamination that could cause wear. Check alignment of cylinder. Check and tighten. Examine mating surfaces on couplers for irregularities.

Call Your Local Service Center to Order: 1-877-279-2799

T7

Hydraulic Symbols
Lines
Line, Working (Main) Line, Pilot or Drain Flow Direction Hydraulic Pneumatic Variable Displacement Temperature Controller

Hydraulic Pumps
Fixed Displacement

Miscellaneous Units
Cooler

Filter, Strainer

Motors and Cylinders

Lines Crossing Pressure Switch

Hydraulic
Fixed Displacement Lines Joining Variable Displacement Temperature Indicator Pressure Indicator

Lines With Fixed Restriction

Cylinder, Single-Acting Line, Flexible Cylinder, Double-Acting Station, Testing, Measurement or Power Take-Off Variable Component (run arrow through symbol at 45) Single End Rod

Component Enclosure Direction of Shaft Rotation (assume arrow on near side of shaft)

Double End Rod

Methods of Operation
Spring

Pressure Compensated Units (Arrow parallel to short side of symbol)

Adjustable Cushion Advance Only

Differential Piston

Manual

Temperature Cause or Effect Reservoir

Push Button

Miscellaneous Units
Push-Pull Lever Electric Motor Pedal or Treadle

Vented

Pressurized

Accumulator, Spring Loaded Mechanical Accumulator, Gas Charged Detent Heater Pressure Compensated

Line, To Reservoir Above Fluid Level Below Fluid Level

Vented Manifold

T8

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Hydraulic Symbols
Methods of Operation
Solenoid, Single Winding

Valves
Check

Color Code for Fluid Power Schematic Drawings

Black Red Intensied Pressure Supply Charging Pressure Reduced Pressure Pilot Pressure Metered Flow Exhaust Intake Drain Inactive

Servo Control Pilot Pressure

On-Off (manual shut-off)

Intermittent Red Intermittent Red

Pressure Relief Remote Supply

Intermittent Red Yellow

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 Innite Positioning (Horizontal bars indicate innite positioning ability) Blue Green Green Blank

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T9

Pneumatic Symbols
Air Prep Units
Filter/Separator with manual drain Filter/Separator with automatic drain

Pneumatic Valves
Check

Valve Actuators
Manual General Symbol

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 Lubricator with automatic lling Air Line Pressure Regulator adjustable, relieving Air Line Pressure Regulator pilot controlled, relieving Filter/Regulator (piggyback) Manual Drain Relieving (without gauge) Filter/Regulator (piggyback) Auto Drain Relieving Air Line Combo F-R-L simplied

2-Position, 4-Way 4-Ported 2-Position, 4-Way 5-Ported 3-Position, 4-Way ports closed, center position 3-Position, 4-Way, 5-Ported cylinder ports open to pressure in center position

Spring

Detent - Line indicates which detent is in use

Solenoid

Internal Pilot Supply

Remote Pilot Supply Quick Exhaust And/Or Composite solenoid and pilot or manual override And/Or Composite solenoid and pilot or manual override and pilot

Shuttle

T10

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Pneumatic Symbols
Lines & Functions
Main Line

Lines & Functions

Quick Disconnect without checks Connected Quick Disconnect without checks Disconnected Quick Disconnect with checks Connected Quick Disconnect with checks Disconnected Quick Disconnect with one check Connected Quick Disconnect with one check Disconnected

Pilot Line

Exhaust or Drain Line

Enclosure Line

Lines Crossing

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

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T11

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/lter 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 uid 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

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Cylinders Cylinders
Hydraulic Cylinder Speeds Inches/Minutes
This chart is based on the formula: Piston Diameter Rod Diameter
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

V (Velocity) =

231 X GPM Eff. Cyl. Area (Sq. In.) Flow-GPM 5

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

1
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

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

3
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

10

12

15

20

25

50

75

1 1 1/2

2 1/2

3 1/2

10

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

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T13

Cylinders
Theoretical Push and Pull Forces for Pneumatic and Hydraulic Cylinders Forces for Pneumatic and Hydraulic Cylinders
The cylinder output forces are derived from the formula: F=PXA 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 = (P2 + 14.7)V2 14.7

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.)
Cu. Ft. Free Air at 80 Lbs. Pressure, Required to move Max. Load 1 Inch .00293 .00659 .01171 .01830 .03093 .04685 .07320 .10540 .14347 .18740 .29280 .42164 .57389

25

50

65

80

100

250

500

1000

2000

3000

Displace. Per Inch of Stroke (Gallons)

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

.00340 .00765 .0136 .0213 .0359 .0544 .0850 .1224 .1666 .2176 .3400 .4896 .6664

Deductions for Pull Force and Displacement 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
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 5 8 20 37 60 79 123 177 241 314 398 491 594 962 1419 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

Piston Piston Rod Rod Area Dia. (Sq. In.) (Inches)

50
10 15 39 75 121 157 245 354 481 628 795 982 1188 1924 2838

65
13 20 51 97 157 204 319 460 625 817 1033 1277 1544 2502 3689

80
16 25 65 119 193 251 393 566 770 1006 1272 1571 1901 3079 4540

100
20 31 79 149 241 314 491 707 962 1257 1590 1964 2376 3849 5675

250
49 77 196 373 603 785 1228 1767 2405 3143 3975 4910 5940 9623 14187

500
98 154 392 745 1205 1570 2455 3535 4810 6285 7950 9820 11880 19245 28375

1000
196 307 785 1490 2410 3140 4910 7070 9620 12570 15900 19640 23760 38490 56750

2000
392 614 1570 2980 4820 6280 9820 14140 19240 25140 31800 39280 47520 76980 113500

3000
588 921 2355 4470 7230 9420 14730 21210 28860 37710 47708 58920 71280 115470 170250

T14

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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 Two: A line has been drawn on the chart from 3 diameter through 28 stroke.
Cylinder push in pounds @ 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

Step Three: By continuing this line, it intersects 200 cubic inch displacement. Step Four: Another line drawn from 200 cubic inches through 7.5 seconds intersects 7 GPM. 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.)

Cylinder Bore 2 2 3 4 5 6 7

Displacement (in cubic inches)

3.5

Cylinder Bore (in inches)

8 6 5 4 3 2 1/2 2 1 1/2

Stroke (in inches)

1 2 4 6 10 20 40 60 100

20 30 50 70 100 200 250 300 500 700 1000

Time (in seconds)

.1 .2 .4 .6 1 2 4 6 10 20 40 60 100 200 400

GPM
100 50 25 18 10 5

1.5 .6

2000

.25 .18

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T15

Pumps Electric Motor Horsepower

Required to Drive a Hydraulic Pump
This chart is based on the formula: HP =

GPM X psi 1714 X Efciency

For the purposes of this chart, pump efciency was assumed to be 85%. As horsepower varies directly with ow or pressure, multiply proportionately to determine values not shown. For instance, at 4000 psi, multiply 2000 psi values by 2.
GPM Pump Pressure psi 100 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 6.86 200 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 13.70 250 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 17.20 300 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 20.60 400 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 27.50 500 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 34.40 750 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 1000 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 1250 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 1500 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 2000 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

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

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Valves How to Determine Proper Air Valve Size

Most manufacturers catalogs provide ow 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. The following Cv calculations are based upon simplied formulas which yield results with acceptable accuracy under the following standard condition: Air at a temperature of 68F (20C) 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 p Pressure differential (p1- p2) q Air ow at actual condition Q Air ow of free air t Time to complete one cylinder stroke T Absolute temperature at operating pressure. Deg R = Deg F + 460 Valve Sizing for Cylinder Actuation Direct Formula
Cylinder Area (F) (Sq. In.) (See Table 1) Cv = Pressure Drop (B) Factor (See Table 2) X Time to Complete Cylinder Stroke (Sec) X 28.8 Cylinder Stroke (L) (In.) Compression (C) Factor (See Table 2)

Select a valve that has a Cv factor of .7 or higher. In most cases a 1/4 valve would be sufcient. 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. After the minimum required Cv has been calculated, the proper size valve can be selected from the catalog. Table 1:
Cylinder push bore area F for standard size cylinders Bore Size D (In.)
3/4 1 1 1/8 1 1/4 1 1/2 1 3/4 2 2 1/2 3 1/4

Cylinder Area F (Sq. In)

0.44 0.79 0.99 1.23 1.77 2.41 3.14 4.91 8.30

Bore Size D (In.)

4 4 1/2 5 6 7 8 10 12 14

Cylinder Area F (Sq. In)

12.57 15.90 19.64 28.27 38.48 50.27 78.54 113.10 153.94

(I N) (SQ IN) (I N) (PS I G) (PS I G) (psiD) (CFM) (SCFM) (SEC) (R)

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 p 2 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

5 psiD
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

10 psiD
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

15 psiD
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

20 psiD
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

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
12.57 21.6 X X 10 2 X X 7.1 28.8

Cv=

= 0.7

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T17

Basic Formulas Fluid Power Formulas

Basis Basic Formulas
FORMULA FOR: FLUID PRESSURE In Pounds/Square Inch FLUID FLOW RATE In Gallons/Minute FLUID POWER In Horsepower WORD FORMULA: Pressure = Force (Pounds) Unit Area (Square Inches) Volume (Gallons) Unit Time (Minute) Pressure (psi) x Flow (GPM) 1714 LETTER FORMULA: P = F/A or psi = F/A

Flow Rate =

Q = V/T

Horsepower =

HP = PQ/1714

Fluid Formulas Fluid Formulas

FORMULA FOR: VELOCITY THROUGH PIPING In Feet/Second Velocity COMPRESSIBILITY OF OIL In Additional Required Oil to Reach Pressure Velocity = WORD FORMULA: .3208 x Flow Rate through I.D. (GPM) Internal Area (Square Inches) LETTER FORMULA: V = .3208Q/A

Additional Volume =

Pressure (psi) x Volume of Oil under Pressure 250,000 (approx.)

VA = PV/250,000 (approx.)

COMPRESSIBILITY OF A FLUID

Compressibility =

1 Bulk Modulus of the Fluid

C() = 1/BM

SPECIFIC GRAVITY OF A FLUID

Specic Gravity =

Weight of One Cubic Foot of Fluid Weight of One Cubic Foot of Water

SG = W/62.4283

VALVE (Cv) FLOW FACTOR

Valve Factor =

Flow Rate (GPM) Specic Gravity Pressure Drop (psi)

Cv = (Q SG)/(

p)

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 = Note: Saybolt Universal Seconds can also be abbreviated as SSU.

SUS 4.635

CS = SUS/4.635

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Pump Formulas
Pump Formulas Pump Formulas
FORMULA FOR: PUMP OUTLET FLOW In Gallons/Minute PUMP INPUT POWER In Horsepower Required PUMP EFFICIENCY Overall in Percent PUMP EFFICIENCY Volumetric in Percent PUMP EFFICIENCY Mechanical in Percent PUMP LIFE B10 Bearing Life
Flow =

WORD FORMULA:
RPM x Pump Displacement (Cu. In./Ref.) 231 Flow Rate Output (GPM) x Pressure (psi) 1714 Efciency (Overall)

LETTER FORMULA:
Q = nd/231 Hpin = QP/1714Eff. or (GPM x psi)/1714Eff. EffOV = (HPout / HPin) x 100 Effov = Effvol x Effmech x 100 Effvol = (Qact/Qtheo) x 100 Effmech = (Ttheo/Tact) x 100 B10 = Rated Hrs x (RPMr/RPMn) x (Pr/Pn)3

Horsepower Input =

Overall Efciency =

Output Horsepower Input Horsepower

x 100

Overall Efciency = Volumetric Eff. x Mechanical Eff. Volumetric Efciency = Actual Flow Rate Output (GPM) Theoretical Flow Rate Output (GPM) Theoretical Torque to Drive Actual Torque to Drive
Rated Speed (RPM) New Speed (RPM) x

Mechanical Efciency =

x 100

B10 Hrs. Bearing Life = Rated Life Hrs. x

Rated Pressure (psi) New Pressure (psi)

Actuator Formulas Actuator Formulas

FORMULA FOR:
WORD FORMULA: Area = x Radius2 (Inches) LETTER FORMULA: A = r2

CYLINDER AREA In Square Inches

Area = (P/4) x Diameter2 (Inches) A = (D2)/4 or A = .785D2

CYLINDER FORCE In Pounds, Push or Pull CYLINDER VELOCITY or SPEED In Feet/Second

Area = Pressure (psi) x Net Area (sq in.) 231 x Flow Rate (GPM) 12 x 60 x Net Area (sq in.) x Radius2 (in.) x Stroke (in.) 231 Net Area (sq. in.) x Stroke (in.) 231

F = psi x A or F = PA

Velocity =

v = 231Q/720A or v = .3208Q/A

Volume =

V = (r2L)/231

CYLINDER VOLUME CAPACITY In Gallons of Fluid

Volume =

V= (A L)/231

CYLINDER FLOW RATE In Gallons/Minute

Flow Rate =

12 x 60 x Velocity (Ft/Sec) x Net Area (sq. in.) 231 Pressure (psi) x F.M. Displacement (Cu. In./Rev.) 2 Horsepower x 63025 RPM

Q = (720vA)231 or Q = 3.117vA

Torque =

T = psi d/2 or T = Pd/2

FLUID MOTOR TORQUE In Inch Pounds

Torque =

T = 63025 HP/n

Torque =

Flow Rate (GPM) x Pressure (psi) x 36.77 RPM = F.M. Displacement (Cu. In./Rev.) .0628 231 Flow Rate (GPM) F.M. Displacement (Cu. In./Rev.) Torque Output (Inch Pounds) x RPM 63025

T = 36.77QP/n or T = 36.77Qpsi/n

FLUID MOTOR TORQUE/100 psi In Inch Pounds FLUID MOTOR SPEED In Revolutions/Minute FLUID MOTOR POWER In Horsepower Output

Torque 100 Speed =

T100psi = d/.0628 n = 231 Q/d

Horsepower =

HP = Tn/63025

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T19

Fluid Power Formulas

Thermal Formulas Thermal Formulas
FORMULA FOR: RESERVOIR COOLING CAPACITY Based on Adequate Air Circulation HEAT IN HYDRAULIC OIL Due to System Inefciency (SG=.89-.92) HEAT IN FRESH WATER WORD FORMULA: Heat (BTU/Hr) = 2 x Temperature Difference Between Reservoir Walls and Air (F) x Area of Reservoir (Sq. Ft.) Heat (BTU/Hr) = Flow Rate (GPM) x 210 x Temp. Difference (F) Heat (BTU/Hr) = Flow Rate (GPM) x 500 x Temp. Difference (F) LETTER FORMULA: BTU/Hr = 2.0 x DT x A

BTU/Hr = Q x 210 x DT 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: PRESSURE OR VOLUME With Constant T (Temperature) PRESSURE OR TEMPERATURE With Constant V (Volume) VOLUME OR TEMPERATURE With Constant P (Pressure) PRESSURE OR VOLUME With Temp. Change Due to Heat of Compression WORD FORMULA: Original Pressure x Original Volume = Final Pressure x Final Volume LETTER FORMULA: P1V1 = P2V2 Isothermic

Original Pressure x Final Temp. = Final Pressure x Original Temp.

P1T2 = P2T1 Isochoric

Original Volume x Final Temp. = Final Volume x Original Temp. Original Press. x Original Volumen = Final Press. x Final Volumen
Final Temp./Orig. Temp. = (Orig. Vol./Final Vol.)n-1 = (Final Press./Orig. Press.)(n-1)/n

V1T2 = V2T1 Isobaric P1V1n=P2V2n T2/T1=(V1/V2)n-1 = (P2/P1)(n-1)/n

Volume and Capacity Equivalents Volume and Capacity Formulas

Cubic Inches Cubic Feet Cubic Centimeters Liters U.S. Gallons Imperial Gallons Water at Max Density Pounds of Water 0.361275 62.4283 0.002205 2.20462 8.34545 10.0172 1 Kilograms of Water 0.0163872 28.3170 0.0001 1 3.78543 4.54373 0.453593

Cubic Inches Cubic Feet Cubic Centimeters Liters U.S. Gallons Imperial Gallons Pounds of Water

1 1728 0.0610 61.0234 231 277.274 27.6798

0.0005787 1 0.0000353 0.0353145 0.133681 0.160459 0.0160184

16.384 0.037037 1 0.001308 0.004951 0.0059429 0.0005929

0.016384 28.317 0.001 1 3.78543 4.54374 0.453592

0.004329 7.48052 0.000264 0.264170 1 1.20032 0.119825

0.0036065 6.23210 0.000220 0.220083 0.833111 1 0.0998281

T20

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