Training
Mobile Fluid PowerAfternoon Session
2017 FTTC
F8 – Hydraulic Systems
Mobile H
ydraulic
s Manual
Chapter 16
Hydraulic Fluids
John Hart – DTS Fluid Power, LLC
1:00
Hydraulic Fluid
• Means of Power Transmission
– Largely incompressible (stiffness)
• Lubrication
– Inherent property
• Sealing
• Cooling
• Contamination Removal
COPYRIGHT (1998) VICKERS, INCORPORATEDC 16-1
16-2COPYRIGHT (1998) VICKERS, INCORPORATEDC
Compressibility
16-3COPYRIGHT (1998) VICKERS, INCORPORATEDC
Full-Film Lubrication
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Boundry Lubrication
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Sealing
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4
1000
6
2000
8
3000
10
4000
12
5000
14
6000
16
7000
18
8000
20
9000
22
10,000
24
26
22.7
16.8
9600
12.9
4800
5.7
12009.6
2400
Summer Winter
16-7COPYRIGHT (1998) VICKERS, INCORPORATEDC
10
20
30
40
50
60
70
80
90
100
110
120
110
90
74.8
61.2
50.6
41.4
35.2
28.8
24.2
19.8
KinematicViscosity
cSt @ 40 deg. C.
16-8COPYRIGHT (1998) VICKERS, INCORPORATEDC
Eaton / Vickers Vane Pump Viscosity Recommendations
16-9COPYRIGHT (1998) VICKERS, INCORPORATEDC
16-9COPYRIGHT (1998) VICKERS, INCORPORATEDC
Fluid selection is an educated tradeoff!
Consult the experts before initial
selection or changing fluid from
recommendation!
Mobile H
ydraulic
s Manual
Chapter 17
Fluid Conditioning
John Hart – DTS Fluid Power, LLC
1:15
Cooling & Contamination Removal
Introduction to Mobile Fluid Power
• Fluid Conditioning
“Cooling & Contamination Removal”
Contamination Definition
• Contamination: “anything that’s not supposed to be in the fluid.”
• Common contaminants: Solid particles (visible and microscopic), entrapped air, bacteria, water, ferrous and non-ferrous silt & incompatible fluids.
• Solid particles are measured in micrometers
(.0000394 inch.) There are 25,400 microns/ inch
Built-In Contamination
Component manufacturing processes
– Cast components: casting process material
– Machined components: machine chips, burrs and large other particles from milling, drilling and threading.
Fabricated components: weld slag, die grinding, cut scrap
Hose and tubing/ pipe cut-off: rubber carcass,
braid, carbon, rust, scale and tailings
Other debris: shop towels, tools, fasteners…
External Contamination
• Contamination
entering from the
environment
– Airborne dirt,
moisture, metal
particles, industrial
pollutants and
bacteria
• Ingression points:
Reservoir breather and
cylinder rod seals,
pump suction ports
and pump shaft seal
17-11
A: Full-Film Lubrication B: Boundary Lubrication
C: Mixed Film LubricationCOPYRIGHT (1998) VICKERS, INCORPORATEDC
COMPONENT MICRONS INCHES
Gear Pump
CLEARANCELOCATION
Gear to side plate
Gear tip to case
1/2 - 5
1/2 - 5
0.00002-0.0002
0.00002-0.0002
0.00002-0.0002
Vane Pump
Piston Pump
Servo Valve
Control Valve
Actuators
Hydrostatic Bearings
Antifriction Bearings
Slide Bearings
Tip of vane
Sides of vane
1/2 - 1
1/2 - 1
5 - 13
0.00002-0.00004
0.00002-0.00004
0.0002-0.0005
Piston to bore
Valve plate to cylinder
5 - 40
1/2 - 5
0.0002-0.0015
Orifice
Orifice
Flapper wall
Spool sleeve
Spool sleeve
130 - 450
18 - 63
1 - 4
0.005-0.018
0.0007-0.0025
0.00005-0.00015
Disk type
Poppet type
130 - 10,000
1 - 23
13 - 40 0.0005-0.0015
0.00005-0.0009
0.005-0.4
50 - 250
0 - 25
1/2
1/2
0.002-0.01
0.00005-0.001
0.00002-
0.00002-
17-3COPYRIGHT (1998) VICKERS, INCORPORATEDC
17-1
Component Micron
100 mesh screen
Grain of table salt
Smog particle
Machining particle
200 mesh screen
Human hair
Pollen
Fog droplet
Particle visible to unaided eye
White blood cell
Grinding particles
Red blood cell
Honing particles
Yeast cells
Bacteria
Viruses
159
100
90
80+
74
70
60
50
40
24
10+
6
2+
1
0.2+
0.1+
COPYRIGHT (1998) VICKERS, INCORPORATEDC
Particle nearclearance size
Silt particlesParticle largerthan clearance
COPYRIGHT (1998) VICKERS, INCORPORATEDC 17-2
In both rolling and siding contact bearings, a thin oil film separates the ball from the race or the journal surfaces from the shaft. In most bearings, particles as small as 3µm can have a negative impact on the life of the bearing or system.
16-5COPYRIGHT (1998) VICKERS, INCORPORATEDC
17-13COPYRIGHT (1998) VICKERS, INCORPORATEDC
11-22
Normal Wear Wear OutBreak In
Time
Number Of Contamination Particles
17-8COPYRIGHT (1998) VICKERS, INCORPORATEDC
1-50 Hours
5,000 10,000 20
RangeCode
Number of particles per1 ml of fluid
More than Up to =
20
40 12
19
18
17
16
15
14
13
11
10
9
8
7
6
5
4
3
2
1
5,0002500
25001300
1300640
640320
320160
16080
8040
10
105
52.5
2.51.3
1.3.64
.64.32
.32.16
.16.08
.08.04
.04.02
.02.01
RangeCode
Number of particles per1 ml of fluid
More than Up to =
80,000 160,000 24 20
40,000 80,000 23
22
21
20
20,000 40,000
10,000 20,000
10,0005,000
17-14COPYRIGHT (1998) VICKERS, INCORPORATEDC
Filtration Rating
System
Sample number
Particle Count / Milliliter
> >10 micron5 micron
1
2
3
4
5
6
7
8
9
10
180 20
21401 4087
1703 342
11230
309
2303
1933
2437
3342
963
3209
63
406
313
183
419
155
Average of all Samples 4580 920
17-9COPYRIGHT (1998) VICKERS, INCORPORATEDC
RangeNumber
80k40k20k
10k5k
2,500
1,300640320
1608040
20105
2.51.30.64
0.320.160.08
0.040.020.01
160k80k40k
20k10k5k
2,5001,300640
32016080
402010
52.51.3
0.640.320.16
0.080.040.02
242322
212019
181716
151413
121110
987
654
321
k = thousand
ParticleSize'x'in
micrometers
No. ofParticles
> 'x'in 1ml
sample
2510
152550
1,800390114
658.50.6
2 m 5 m 15 m
17-15COPYRIGHT (1998) VICKERS, INCORPORATEDC
ISO 4406:1999
17-16
Fixed Gear 20/18/15 19/17/15Fixed Vane 20/18/15 19/17/14 18/16/13
1000 PSI 2000 PSI 3000 PSI+PUMPS
Fixed Piston 19/17/15 18/16/14 17/15/13Variable Vane 18/16/14 17/15/13Variable Piston 18/16/14 17/15/13 16/14/12
Directional (solenoid) 20/18/15 19/17/14Pressure Control (modulating) 19/17/14 19/17/14Flow Controls (standard) 19/17/14 19/17/14Proportional Directional (throttle valves) 17/15/12 15/13/11*Check Valves 20/18/15 20/18/15Servo Valves 16/14/11* 15/13/10*Cartridge Valves 18/16/13 17/15/12H.R.C. 18/16/13 17/15/12Proportional Pressure Controls 16/14/12* 15/13/11*Flow controls (pressure compensating) 17/15/13 17/15/13Proportional Cartridge Valves 17/15/12 16/14/11*
Cylinders 20/18/15 20/18/15 20/18/15Vane Motors 20/18/15 19/17/14 18/16/13Axial Piston Motors 19/17/14 18/16/13 17/15/12Gear Motors 21/19/17 20/18/15 19/17/14Radial Piston Motors 20/18/14 19/17/13 18/16/13Cam Wave Motors 18/16/14 17/15/13 16/14/12*
Hydrostatic Transmissions (in loop fluid) 17/15/13 16/14/12* 16/14/11*
Ball Bearing Systems 15/13/11*Roller Bearing Systems 16/14/12*Journal Bearings (high speed) 17/15/13Journal Bearings low speed) 18/16/14General Industrial Gearboxes 17/15/13
*Requires precise sampling practices to verify cleanliness levels.
VALVES
ACTUATORS
HYDROSTATIC TRANSMISSIONS 4000 PSI
BEARINGS
COPYRIGHT (1998) VICKERS, INCORPORATEDC
FILTER
TYPES
Full flowpressure
or return line
Full flowpressure
and return line
Pressure lineand recirculating
loop a 20% system volume
per minute
Pressure lineplus return
line plusrecirculating
loop
Recirculatingloop at 20% of system
volume
Recirculatingloop at 10% of system
volume
Recommendedfor high
ingressionsystems with fixed volume
pumps
Recommendedfor high
ingressionsystems with
variable volumepumps
Recommendedfor systemswith fixed
volume pumps
14/12/10
15/13/11
16/14/12
17/15/13
18/16/14
19/17/15
Ta
rge
t C
lea
nlin
ess
17-18COPYRIGHT (1998) VICKERS, INCORPORATEDC
Beta Ratio Efficiency
1
2
5
10
20
75
100
200
1000
5000
0%
50.00%
80.00%
90.00%
95.00%
98.70%
99.00%
99.50%
99.90%
99.98%
17-23COPYRIGHT (1998) VICKERS, INCORPORATEDC
Down-streamParticleCounter
Up-streamParticleCounter
Known contaminant
17-22COPYRIGHT (1998) VICKERS, INCORPORATEDC
Zinga – AE Filter Elements (Cellulose Media)
Zinga – ZAE Filter Elements (Z-glass Media)
Other Considerations
� Pressure Rating of the Filter
�Pressure Drop Across the Element
�Dirt Holding Capacity
�Commonly expressed in “grams of dirt”
�Collapse, or “Crush” rating of the filter
�Pressure differential across the filter
SUPPORTMESH
SUPPORTMESH
DIFFUSERLAYER
DIFFUSERLAYER
MEDIA
17-21COPYRIGHT (1998) VICKERS, INCORPORATEDC
WELL SUPPORTED ELEMENT POORLY SUPPORTED ELEMENT
FULL FLOW LIMITED FLOW PLEAT FAILURE
FLOW FATIGUE FAILURE ISCOMMON AT ROOT OF PLEAT
17-19COPYRIGHT (1998) VICKERS, INCORPORATEDC
Supported fiber matrix after repeated stess
Inadequately supported matrix after repeated stress
17-20COPYRIGHT (1998) VICKERS, INCORPORATEDC
Supported fiber matrix after repeated stess
Inadequately supported matrix after repeated stress
17-20COPYRIGHT (1998) VICKERS, INCORPORATEDC
Mobile H
ydraulic
s Manual
Chapter 18
Circuits
Brian Burgess – DTS Fluid Power, LLC
1:35
Circuits Review• Proper Design: Regulates or alters the behavior of
all the components in the system for the desired behavior.
– Actuators (cylinders & motor)“provides the muscle”
– Directional Controls
“the command center
of the fluid power system”
– Control Valves
“the brains of the fluid power system”
Circuits Review
• Proper Design: Regulates or alters the behavior of
all the components in the system for the desired
behavior.
– Hydraulic Fluid
“transmits the power…”
– Fluid Conductors & Connectors
“connects the system together”
– Fluid Conditioning & Aux. Components
“keeps it running”
Typical Systems
• Pulling it together!
COPYRIGHT 1998 VICKERS, INC.C 1-6
6-8COPYRIGHT (1998) VICKERS, INCORPORATEDC
SERIES -VS-PARALLEL
PARALLEL CIRCUITRY
SERIES -VS-PARALLEL
PARALLEL CIRCUITRY
Basic Hydraulic Principles
• Prior Discussions Open
Loop Systems
• Closed Loop
COPYRIGHT C 2-19(1998) VICKERS, INC.
COPYRIGHT C 2-20(1998) VICKERS, INC.
Basic Hydraulic Principles• Fluid Power component: Other controls
• Motion control, load holding and special
cases, variations will be covered later
Fluid Power Controls Circuits
• Integrated function blocks (manifolds)
8-9
COPYRIGHT (1998) VICKERS, INCORPORATEDC 18-1
To circuit
Orifice sized fordesired flow
Variable displacementpump with pressurelimiting and loadsensing compensator
Load sensingspring
PTDR
C1
S1
C2
DRLS
HRC
Pilot Pump
Boom Cylinders
EmergencyLowering Valve
18-2COPYRIGHT (1998) VICKERS, INCORPORATEDC
Auger DriveMotor
Valvistor proportionalflow control valve
Variable displacementpressure compensated,load sensing pump
Pressure reducingvalve
Prime Mover
18-3COPYRIGHT (1998) VICKERS, INCORPORATEDC
To temperature sensorand controller
Variable displacementpressure limiting, loadsensing pump
0.030 inchdiameterorifice
18-4COPYRIGHT (1998) VICKERS, INCORPORATEDC
PTDR
C1C2
DRLS
Pilot Pump
Boom Cylinders
Float Valve
18-5
S1
COPYRIGHT (1998) VICKERS, INCORPORATEDC
Pump 1
LoadSense 1
LoadSense 2
Pump 2
X
X
HRC
HRC
CONTROL 1
CIRCUIT 1 CIRCUIT 2
CONTROL 2
CircuitSelector
Valve
CircuitCombining
ValveLoad Sense
SelectorValve
18-6COPYRIGHT (1998) VICKERS, INCORPORATEDC
T P
LS
To Actuator
1:2
Load SensingValve Manifold
18-7COPYRIGHT (1998) VICKERS, INCORPORATEDC
18-8COPYRIGHT (1998) VICKERS, INCORPORATEDC
To lift, tilt,auxiliary System
C1 C2
Forward
Reverse
Left Propel
TractionControlValve
Right Propel
ParkingBrake
Propel SpeedControl
PowerSteering
Motor
X
SteeringCylinders
18-9COPYRIGHT (1998) VICKERS, INCORPORATEDC
Power SteeringMotor
T P
Steering ModeSelector Valve
Articulated/Conventional/Crab
Left Front
Left RearRight Rear
Right Front
18-10COPYRIGHT (1998) VICKERS, INCORPORATEDC
18-11
WaterPump
Water PumpFlow Adjustment
COPYRIGHT (1998) VICKERS, INCORPORATEDC
PT DR
C1C2
DR
LS
A
B
ToActuator
MomentaryHighPressureSwitch
Set toOperatingPressure
Set toIntermittentHighPressure
18-12COPYRIGHT (1998) VICKERS, INCORPORATEDC
VelocityController
SpeedSensor
Valvistor
AC Generator
18-13COPYRIGHT (1998) VICKERS, INCORPORATEDC
1:2
RegenerationSelectorManifold
18-14COPYRIGHT (1998) VICKERS, INCORPORATEDC
PT DR
C1
C2
DR LS
PropelMotor
Creep ControlForward, Reverse
18-15COPYRIGHT (1998) VICKERS, INCORPORATEDC
Applications & Capabilities
• From individual products to complete designs Fluid Power Specialists have products and expertise to provide complete fluid power system solutions.
Circuits Review
John Hart – DTS Fluid Power, LLC
2:15
Item Description - See attached Spec Sheet
M +
_
1
Item Qty Description
1 1 12 VDC Power Unit
Title
Part Number
Drawing Number Rev.
Scale: Size: C
DRWN
AP'D
Material Spec.
Heat Treat
Finish
N/A
N/A
Std Black
12VDC Cab-Tilt Power Unit
DTS-CT101
JGH 02/18/10
N / A
P7
Item Description - See attached Spec Sheet
M +
_
1
2 2
3 3
4
4
Item Qty Description
1 1 12 VDC Power Unit
2 2 Cab-Tilt Cylinder
3 2 Velocity Fuse
4 2 Customer Supplied Cab Latches
Title
Part Number
Drawing Number Rev.
Scale: Size: C
DRWN
AP'D
Material Spec.
Heat Treat
Finish
N/A
N/A
Std Black
12VDC Cab-Tilt Power Unit
DTS-CT102
JGH 02/18/10
N / A
Item Description - See attached Spec Sheet
M +
_
1
4
2 2
3 3
5
5
Optional Hand Pump
Item Qty Description
1 1 12 VDC Power Unit
2 2 Cab-Tilt Cylinder
3 2 Velocity Fuse
4 1 Optional Back-up Hand Pump
5 2 Customer Supplied Cab Latches
Title
Part Number
Drawing Number Rev.
Scale: Size: C
DRWN
AP'D
Material Spec.
Heat Treat
Finish
N/A
N/A
Std Black
12VDC Cab-Tilt Power Unit
DTS-CT103
JGH 02/18/10
N / A
Circuits Review
Brian Burgess – DTS Fluid Power, LLC
Aerial Circuit
3:00
Meet outside @ 3:45 pm
3:30