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Hydraulic Hints & Trouble Shooting Guide: General Product Support
Hydraulic Hints & Trouble Shooting Guide: General Product Support
Hydraulic Hints & Trouble Shooting Guide: General Product Support
Quiet Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Contamination Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Aeration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Leakage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Pump Test Procedure for Evaluation of Antiwear Fluids for Mobile Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Conversion Factors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Hydraulic Formulas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2
General Hydraulic Hints
3
Troubleshooting Guide & Maintenance Hints
General 1. Know the capabilities of the system. 1. Excessive heat means trouble. A
Each component in the system has a misaligned coupling places an
The troubleshooting charts and maximum rated speed, torque or excessive load on bearings and can
maintenance hints that follow are of a pressure. Loading the system beyond be readily identified by the heat
general system nature but should the specifications simply increases generated. A warmer than normal
provide an intuitive feeling for a specific the possibility of failure. tank return line on a relief valve
system. More general information is indicates operation at relief valve
covered in the following paragraphs. 2. Know the correct operating pressures. setting. Hydraulic fluids which have a
Effect and probable cause charts Always set and check pressures with a low viscosity will increase the internal
appear on the following pages. gauge. How else can you know if the leakage of components resulting in a
operating pressure is above the heat rise. Cavitation and slippage in a
maximum rating of the components? pump will also generate heat.
System Design The question may arise as to what the
correct operating pressure is. If it isn’t 2. Excessive noise means wear,
There is, of course, little point in correctly specified on the hydraulic misalignment, cavitation or air in the
discussing the design of a system which schematic, the following rule should be fluid. Contaminated fluid can cause a
has been operating satisfactorily for a applied: relief valve to stick and chatter. These
period of time. However, a seemingly noises may be the result of dirty filters,
uncomplicated procedure such as The correct operating pressure is the or fluid, high fluid viscosity, excessive
relocating a system or changing a lowest pressure which will allow drive speed, low reservoir level, loose
component part can cause problems. adequate performance of the system intake lines or worn couplings.
Because of this, the following points function and still remain below the
should be considered: maximum rating of the components
and machine. Maintenance
1. Each component in the system must
be compatible with and form an Once the correct pressures have been Three simple maintenance procedures
integral part of the system. For established, note them on the hydraulic have the greatest effect on hydraulic
example, an inadequate size filter on schematic for future reference. system performance, efficiency and life.
the inlet of a pump can cause
cavitation and subsequent damage to 3. Know the proper signal levels, 1. Maintaining a clean sufficient quantity
the pump. feedback levels, and dither and gain of hydraulic fluid of the proper type
settings in servo control systems. If and viscosity.
2. All lines must be of proper size and they aren’t specified, check them
free of restrictive bends. An when the system is functioning 2. Changing filters and cleaning
undersized or restricted line results in correctly and mark them on the strainers.
a pressure drop in the line itself. schematic for future reference.
3. Keeping all connections tight, but not
3. Some components must be mounted to the point of distortion, so that air is
in a specific position with respect to excluded from the system.
other components or the lines. The Developing Systematic
housing of an in-line pump, for Procedures
example, must remain filled with fluid
to provide lubrication. Analyze the system and develop a Guidelines
logical sequence for setting valves, The following charts are arranged in five
4. The inclusion of adequate test points mechanical stops, interlocks and main categories. The heading of each
for pressure readings, although not electrical controls. Tracing of flow paths one is an effect which indicates a
essential for operation, will expedite can often be accomplished by listening malfunction in the system. For example,
troubleshooting. for flow in the lines or feeling them for if a pump is exceptionally noisy, refer to
warmth. Develop a cause and effect Chart 1 titled Excessive Noise. The
troubleshooting guide similar to the noisy pump appears in Column A under
charts appearing on the following pages.
Knowing the System The initial time spent on such a project
the main heading. In Column A there are
four probable causes for a noisy pump.
Probably the greatest aid to could save hours of system down-time. The causes are sequenced according to
troubleshooting is the confidence of the likelihood of happening or the ease
knowing the system. The construction and of checking it. The first cause is
operating characteristics of each one Recognizing Trouble cavitation and the remedy is “a”. If the
should be understood. For example, first cause does not exist, check for
knowing that a solenoid controlled Indications cause number 2, etc.
directional valve can be manually actuated The ability to recognize trouble
will save considerable time in isolating a indications in a specific system is
defective solenoid. Some additional usually acquired with experience.
practices which will increase your ability However, a few general trouble
and also the useful life of the system indications can be discussed.
follow:
4
Troubleshooting Guide & Maintenance Hints
Chart 1
EXCESSIVE NOISE
A B C
4. Pump worn or
damaged
Remedy: e
Remedies:
a. Any or all of the following: b. Any or all of the following: c. Align unit and check condition of
seals, bearings and coupling.
Replace dirty filters; wash strainers in Tighten leaking connections; fill
solvent compatible with system fluid; reservoir to proper level (with rare d. Install pressure gauge and adjust to
clean clogged inlet line; clean or exception all return lines should be correct pressure.
replace reservoir breather vent; below fluid level in reservoir); bleed
change system fluid; change to air from system; replace pump shaft e. Overhaul or replace.
proper pump drive motor speed; seal (and shaft if worn at seal
overhaul or replace supercharge journal).
pump; fluid may be too cold.
5
Troubleshooting Guide & Maintenance Hints
Chart 2
EXCESSIVE HEAT
A B C D
3. Air in fluid 3. Excessive load 3. Worn or damaged valve 3. Fluid dirty or low supply
Remedy: b Remedy: c Remedy: e Remedy: f
6
Troubleshooting Guide & Maintenance Hints
Chart 3
INCORRECT FLOW
A B C
1. Pump not receiving fluid 1. Flow control set too low 1. Flow control set too high
Remedy: a Remedy: d Remedy: d
4. Pump drive motor turning 4. External leak in system 4. Improper size pump
in wrong direction Remedy: b used for replacement
Remedy: g Remedy: h
Remedies:
a. Any or all of the following: c. Check for damaged pump or pump f. Check position of manually operated
drive; replace and align coupling. controls; check electrical circuit on
Replace dirty filters; clean clogged solenoid operated controls; repair or
inlet line; clean or replace reservoir d. Adjust. replace pilot pressure pump.
breather vent; fill reservoir to proper
level; overhaul or replace e. Overhaul or replace. g. Reverse rotation.
supercharge pump.
b. Tighten leaking connections. h. Replace with correct unit.
7
Troubleshooting Guide & Maintenance Hints
Chart 4
INCORRECT PRESSURE
A B C D
Remedies:
a. Replace dirty filters and system fluid.
8
Troubleshooting Guide & Maintenance Hints
Chart 5
FAULTY OPERATION
A B C D
2. Limit or sequence 2. Fluid viscosity too high 2. Air in fluid 2. Feedback transducer
device (mechanical, Remedy: a Remedy: See Chart I malfunctioning
electrical or hydraulic) Remedy: e
inoperative or
misadjusted
Remedy: e
4. No command signal 4. No lubrication of machine 4. Erratic command signal 4. Over-riding work load
to servo amplifier ways or linkage Remedy: f Remedy: h
Remedy: f Remedy: g
8. Worn or damaged
cylinder or motor
Remedy: e
Remedies:
a. Fluid may be too cold or should be c. Adjust, repair or replace. f. Repair command console or
changed to clean fluid of correct interconnecting wires.
viscosity. d. Clean and adjust or replace; check
condition of system fluid and filters. g. Lubricate.
b. Locate bind and repair.
e. Overhaul or replace. h. Adjust, repair or replace
counterbalance valve.
9
Quiet Hydraulics
10
Contamination Control
11
Fluid degradation by:
Solid High Water Air
Preventive Measures Contam. Temp.
For Hydraulic Systems:
– Remove protective caps only just before connecting
mating components.
– Use a portable filtration and transfer unit to fill the
reservoir system.
– Flush new systems, and those that have undergone
major repairs, before starting up. Temporarily
remove actuators and replace with flushing
manifolds or valves. Servo valves and similar high
precision units should also be replaced with
flushing manifolds or valves for flushing operations.
Make sure that actuators are clean internally before
connecting to the system.
– Make sure that air breathers and reservoir covers
are at all times properly installed and tightly
secured.
– Stop any leakage of water into the system from
coolers or other sources. Make a leak-tight repair.
– By planned maintenance, ensure that clean filter
elements are applied (or metallic elements cleaned
when appropriate) when indicators or visual
inspection shows this to be necessary.
– Take fluid samples periodically and analyze to
determine whether effects of particle contaminant,
heat, water and air indicate need for more control of
those factors or replacement of the fluid.
– Whenever the reservoir is emptied, clean it out
thoroughly and remove all residual contaminant. If
necessary, restore protective paint or other finishes.
On completion, cap all openings unless the system
is to be refilled immediately.
12
Hints On Maintenance Of Hydraulic Fluid In The System
Hydraulic Fluid Changes finer) can be used. It is important that Preparation of pipes, tubes and fittings
fluid be clean and free of all substances in this catalog should be referred to and
Good maintenance procedures make it which will cause improper operation. followed. This will lower the possibility
mandatory to keep the hydraulic fluid of premature failure due to
clean. A daily, weekly or monthly log contamination of the system.
should be kept on the hydraulic fluid Fluid Contamination –
condition. Causes and Effects Adverse Operating Conditions
No hard and fast rules can be Contamination From experience, we have found that
established for changing the fluid machines used in a very dusty
because of the great variety of operating A contaminated system can be the result atmosphere and in windy areas require
conditions. However, we do know that of several factors; system design special components. For example,
when filter elements are replaced inadequate, poor maintenance of the heavy duty breathers, chrome plated
frequently, service life of a system system, poor housekeeping of the system piston rods, plus frequent changes of
increases. Periodic testing of the fluid by and adverse operating conditions. the filter cartridges are also required.
the supplier is recommended to confirm
suitability for continued use and to
establish the correct fluid and filter
System Design Inadequate Effects of Contamination
element replacement interval. – Reservoirs which cannot be cleaned.
– Breathers that permit abrasives Contamination affects all types of
inherent in the atmosphere to enter hydraulic equipment adversely.
Some of the considerations affecting Precision high tolerance parts are very
hydraulic fluid are: operating the system.
susceptible to the effects of
temperature, type of service, – Poor cylinder packing design (no contamination. Dirty fluid causes wear
contamination levels, filtration, and the wiper to clean dirt from the piston which accelerates leakage and the
chemical composition of the fluid. rod). development of heat in a system. Heat
– Improper piston rod design (piston lowers the lubricity of a hydraulic fluid
Fluid Recommendations rods with poor wear characteristic). and causes additional wear.
– Improper valving (anti–cavitation
The basic recommendations for fluid checks omitted from cylinder circuits If a hydraulic pump or motor should fail,
are stipulated in the Hydraulic Fluid and with rapid drop characteristics). the system becomes contaminated.
Temperature Recommendations for Remove the unit for repair. The
– Failure to provide adequate filtration. reservoir must be drained, flushed, and
Industrial Machinery in this catalog.
The fluids recommended give the cleaned. All hoses, lines, cylinders and
Poor Maintenance of the System valves should be inspected for wear
assurance of adequate wear protection
and excellent chemical stability under – Improper and unclean practices when and particles of the unit that failed.
the most adverse operating conditions. adding fluid to the system. Flush all components of the complete
– Failure to clean breathers. system to remove metallic particles.
On mobile applications, the viscosity – Failure to change pitted cylinder rods
grade of the fluid should be changed in Replace filter elements. Dispose of the
and worn cylinder packings. fluid removed from the system and fill
spring and autumn as is done with – Failure to use good cleanliness
automotive engines. Hydrostatic the reservoir with clean hydraulic fluid.
practices when changing system Install a new or rebuilt unit and start-up
transmissions and control mechanisms components.
may require a different viscosity fluid. the system. Allow the system to run for
Fluid requirements are normally – Failure to change filter cartridges a period of time to verify normal
outlined in the original equipment and/or filter at proper intervals. operation. Filter elements should be
manufacturers operation and – Failure to purge debris from the changed after 40 or 50 hours of
maintenance manuals. system after a pump failure. operation. This guarantees that the
system is essentially clean and free of
Poor Housekeeping of the any residue of the failed unit.
Draining The System System A very good reference catalog on
The system should be started and fluid Surgical cleanliness is not required, contamination is available titled Vickers
heated before draining. This will lower however, ordinary clean practices Guide to Systemic Contamination
the time it takes to drain the system and during assembly will pay off in Control. This catalog describes types
allow impurities suspended in the fluid increased service life of the equipment. and sources for contamination, effects
to be removed. It is desirable to remove of types and sizes of particles,
all fluid from the system. Bleeding of Excessive and improper use of pipe specifying contamination levels,
the fluid at the lowest point in the thread sealer on lines and gaskets in selecting a filter, locating a filter, design
system will help in most cases. the system can cause pump failures. steps and worked examples of fluid
This is especially true when a type of sampling analysis. Order catalog 561
Systems which have accumulated sealer is used that hardens. from your local Vickers representative.
deposits that were not removed during
draining must be flushed with a light Another source of contamination is
viscosity fluid. The fluid should contain fittings, hoses and lines which are
a rust inhibitor to protect metal surfaces received from a vendor uncapped. The
against rust formation after draining. use of brazed or welded fittings, and
unpickled steel plating can also
When hydraulic fluid is added to
contribute to the contamination.
replenish the system, it should be
pumped through a 25 micron filter. If
such a filter is not available, a funnel
with a fine wire screen (200 mesh or
13
Aeration
Aeration have a high sulphur content tend to Reservoir must be deep enough to
accelerate “O” ring hardness. This is one prevent aeration.
Causes of the principle reasons for keeping
Vortexing Fluid in the Reservoir
system operating temperatures down.
The following are candidates for the Normal operating temperature of a
If the fluid level in the reservoir is low
formation of air in a system. system is 90 degrees above ambient.
and the inlet demand is great, a vortex
– Leaking inlet lines. When operating temperatures are in
condition can develop which pulls air
– Control valve “O” rings leaking. excess of this value, trouble may result.
into the pump inlet. In a hydraulic
Maximum operating temperatures should
– Shaft seal leakage. system, vortexing is normally the result
be checked at the pump outlet port.
– Leaking cylinder packings caused of low fluid or poor reservoir design.
by cavitating cylinders. Shaft Seal Leakage One of the best ways of curing a
– Turbulence or sloshing in the vortex problem is to place an
reservoir. Most vane pumps are internally drained.
The shaft seal cavity is connected to the anti-cavitation plate over the outlet of
– Vortexing fluid in the reservoir pump inlet. Excessively high inlet the reservoir. This is a common piece
– Release of air suspended within vacuums can cause air leakage at the of sheet metal at lease 1/8 inch thick
the fluid. shaft seal. The maximum vacuum set over and above the outlet opening.
measured at the pump inlet should not This plate will allow flow into the outlet
Effects exceed five inches of mercury. from a horizontal direction and
effectively extends and enlarges the
Aeration can be in many forms; large Shaft misalignment can increase the reservoir opening. This prevents the
bubbles, foam or in various degrees of probability of air leakage past the shaft vortex condition from developing.
suspension. It usually causes pump noise seal. Universal jointed couplings or
(cavitation). Small bubbles cause extreme splined couplings can cause seal Release of Air Suspended in Fluid
and rapid ring wear, with corresponding leakage if not properly aligned. Straight
vane tip wear. Larger bubbles cause vanes (direct) coupling should never be used. There is considerable air suspended in
to collapse and pound. This pounding cold hydraulic fluid. As the fluid warms,
effect develops rippling in the ring and the The use of the wrong type of tools can air is released into the system. A
ring will have a dull appearance. This is cause distortion or mutilation of a shaft reduction of fluid pressure will also
more apparent on straight vane rings seal at installation. The outer diameter of release air out of suspension. A simple
which are hardened cast iron. With the shaft should be lightly polished before relief valve poppet can create an orifice
extreme aeration cases, the wear is so installation to remove any burrs or that increases velocity of the fluid and
rapid that a ring and vanes can be roughness in the area of the shaft seal. lowers its pressure. The reduced
destroyed within an hour. In many cases, a Shaft seals must be made of the correct pressure condition releases air out of
large step will be worn in the ring contour material for a given application. A material suspension into the system. Relief valves
at the pressure quadrant. When the step that is not compatible with system fluid can should be returned below the fluid level
reaches a depth where the vane extends deteriorate and result in a leakage of the reservoir as far from the reservoir
and locks, the vane and/or ring will break. problem. outlet as possible. This allows time for
Also, the shaft can break where it enters the air released by the relief valve to be
the rotor if the torque is great enough. Leaking Cylinder Packings removed before leaving the reservoir and
entering the inlet area of the pump.
Caused By Cavitating Cylinders
Cures In some cases, special return line
On applications where a rapid raise and configurations are needed, or air bleed
Leaking Inlet Lines lower cycle is experienced, air can enter valves used, to remove air from the
the system through a cylinder rod seal. system.
– Pipe threaded fittings can be porous. Vacuums in excess of 20 inches of
Use an approved type of pipe thread mercury have been recorded in systems A special baffle made of 60 mesh screen
sealer on all pipe threads. without anti-cavitation check valves. This is can be installed into the reservoir. This
– If the pump inlet flange surface is enough to force dirt particles past the shaft baffle should be positioned at a 30 angle
rough, scored or mutilated, air leakage seal into the system with the air. An in the reservoir so that inlet oil is above the
past the “O” ring seal can result. anti-cavitation check will allow flow from screen and outlet oil is below the screen.
the reservoir to enter the rod area of the The top of the screen should be below the
With any of the above defects, air can cylinder during a vacuum condition from reservoir fluid level far enough to prevent
be pulled into the system. developing. This will lower the possibility of surface foam from coming in contact with
fluid contamination through the rod seal of the screen. Surface foam can penetrate
Control Valve “O” Rings Leaking a working cylinder. through the screen into the outlet area.
“O” rings are used to seal against port The screen baffle will eliminate all
leakage in many control valves. These Turbulence or Sloshing in the bubbles except the very small ones
seals can be checked by applying heavy Reservoir from the fluid if designed properly.
grease around the part to be checked. If
Return lines, if improperly located,
the noise stops, the trouble has been can cause turbulence and aeration. A
located and repair can be initiated. Plexiglass window should be placed
On systems which have been operating in the prototype reservoir to study flow
at excessive high temperatures, the “O” conditions. Return lines emptying
rings can harden and take a set. If this above the fluid level cause bubbles to
occurs, air leakage can result. This is form in the system. Return lines
true not only in a pump, but also in the should always be terminated below
rest of the components of the system. the fluid level. Vehicle movement can
Another factor enhancing air leakage is cause sloshing within the reservoir.
the actual fluid composition. Fluids which
14
Leakage Control
15
Hydraulic Fluid And Temperature
Recommendations For Industrial Machinery
General Data Some of the factors especially important Two specific types of oil meet the
in the selection of oil for use in an requirements of modern industrial
industrial hydraulic system are: hydraulic systems:
Oil in hydraulic systems performs the
dual function of lubrication and 1. The oil must contain the necessary 1. Antiwear type industrial hydraulic oils.
transmission of power. It constitutes a additives to ensure high antiwear A new generation of industrial
vital factor in a hydraulic system, and characteristics. Not all hydraulic oils hydraulic oils containing adequate
careful selection should be made with contain these in sufficient amounts. quantities of antiwear compound is
the assistance of a reputable supplier. recommended by VIckers for general
Proper selection of oil assures 2. The oil must have proper viscosity to hydraulic service.
satisfactory life and operation of the maintain adequate sealing and
system components with particular lubricating quality at the expected
emphasis on hydraulic pumps and operating temperature of the
motors. Generally, oil selected for use hydraulic system.
with pumps and motors are acceptable
for use with valves. Critical servo 3. The oil must have rust and oxidation
valves may need special consideration. inhibitors for satisfactory system
operation.
16
Hydraulic Fluid And Temperature
Recommendations For Industrial Machinery
These oils are generally developed maximum and minimum viscosity ranges Cleanliness
and evaluated on the basis of pump of the oil at start-up and during running be
wear tests such as the Vickers maintained. (See chart) Very high Thorough precautions should always be
35VQ25A and ASTM D-2882. These viscosities at start-up temperatures can observed to ensure that the hydraulic
oils offer superior protection against cause noise and cavitational damage to system is clean.
pump and motor wear and the pumps. Continuous operation at
advantage of long service life. In moderately high viscosities will tend to hold 1. Clean (flush) entire system to remove
addition, they provide good air in suspension in the oil as well as paint, metal chips, welding shot, lint,
demulsibility as well as protection generate higher operating temperatures. etc.
against rust. This can cause noise and early failure of
pumps, motors and erosion of valves. Low 2. Filter each change of oil to prevent
2. Automotive type crankcase oils viscosities result in decreased system introduction of contaminant into the
having API letter designation “SE”, efficiency and impairment of dynamic system.
“SF”, “SG”, “SH”, per SAE J183. lubrication which causes wear. 3. Provide continuous oil filtration to
remove sludge and products of wear
The above classes of oils in the Choose the proper oil viscosity for your and corrosion generated during the
10W and 20-20W SAE viscosity particular system so that over the entire life of the system.
ranges are for severe hydraulic temperature range encountered, the
service where there is little or no start-up viscosity and the running 4. Provide continuous protection of
water present. The only adverse viscosity range shown in the chart is system from entry of airborne
effect is that the “detergent” met. This is important, and assurance contamination by proper filtration of
additive tends to hold water in a should be obtained from your oil air through breathers.
tight emulsion and prevents supplier that the viscosity of the oil being 5. During usage, proper oil filling of
separation of water, even on long used will not be less than the minimum reservoir and servicing of filters,
time standing. recommended at maximum oil breathers, reservoirs, etc. cannot be
temperature encountered. over emphasized.
Automotive type crankcase oils
generally exhibit poorer shear stability A number of antiwear hydraulic oils
which could result in some loss of
viscosity during their service life.
containing polymeric thickeners (V.I. Sound Level
improvers) are available and are used for
More shear stable multiple viscosity low temperature application. The Noise can be an indication of system
industrial grade hydraulic fluids will temporary and permanent viscosity loss of problems. Fluid selection and the
provide improved viscosity control. some of these oils at operating condition of that fluid in service will
temperature may adversely affect the life affect the noise levels of your systems.
Over the years, Vickers hydraulic oil and performance of components. Be
recommendations have been based on certain you know the extent of loss of Some of the major factors affecting the
oils that: (1) provide adequate wear viscosity (shear stability) of polymer fluid conditions that cause the loudest
protection, (2) have proper viscosity, and containing oils under hydraulic service noises in a hydraulic system are:
(3) are sufficiently stable to withstand the before using them so that you do not
chemical, thermal and mechanical stresses operate below the recommended minimum 1. Very high viscosities at start-up
of severe hydraulic service. There are viscosity. The selection of an oil with good temperatures can cause pump noises
automotive crankcase oils that are outside shear stability, is recommended for low due to cavitation.
of the API SE, SF, SG and SH classes temperature applications.
that meet the above basis of 2. Running with moderately high
recommendation. viscosity fluid will impede the release
of entrained air. The fluid will not be
With these oils, it is highly desirable to Temperature completely purged of such air in the
have acceptable data from pump wear time it remains in the reservoir before
To obtain optimum service life from recycling through the system.
tests (35VQ25A and ASTM-D-2882). In both the oil and the hydraulic system,
exceptional cases where the requirements operate between 49C (120F) and
of speed, pressure, temperature and 54C (130F). The maximum oil
ambient conditions exceed the temperature normally recommended
recommendations for industrial machinery, is 66C (150F).
please refer to the oil recommendations.
These fluids must also pass the Vickers MHT motors are permitted to operate at
35VQ25 pump test. higher temperatures, but this is
permissible by meeting special
application requirements. For this
Viscosity service, oils should have antiwear
characteristics required to pass pump
Viscosity is the measure of the fluid’s test on page 20. Pumps can be
resistance to flow. The selection of a approved to operate MHT motors at
hydraulic oil of specific viscosity range these higher temperatures. Contact your
must be based on the needs of the Vickers representative for
system, limitations of critical components, recommendations.
or proper performance of specific types of
units. Vickers recommends that certain
17
3. Aerated fluid can be caused by Water Based Fluids Water-Glycol Fluids
ingestion of air through the pipe joints
of inlet lines, high velocity discharge Water-glycol fire-resistant fluids are
lines, cylinder rod packings, or by
General Data typically water and diethylene glycol
fluid discharging above the fluid level To assure an effective emulsion or mixtures. They have approximately 40%
in the reservoir. Air in the fluid will solution, the water should not have water content.
cause abnormal noise and wear in excessive hardness or have an acid
your system. nature, and it should be distilled or
Oil-In-Water Fluids
deionized with less than 300 parts per Oil-in-water fluids are emulsions of oil
4. Contamination fluids can cause million hardness. and water. When preparing these
excessive wear of internal pump mixtures, the soluble oil should always
parts which may result in increased Hard water containing excessive mineral be added to the water while maintaining
sound levels. content, such as calcium and iron, may good fluid agitation. The water should
cause deposits in the hydraulic system never be added to the soluble oil. Do not
5. Systems using water based fluids or result in additive separation or mix soluble oil brands.
are susceptible to noise created by emulsion breaking.
vaporization of the fluid if excessive Filters
vacuums and temperatures are Proper maintenance of water containing
encountered. fluids requires periodic testing for pH, oil Many Vickers standard indicating type
and water concentrations. The pH inlet filters and return line filters are
should be maintained at 8.0-9.5 in approved with water-based fluid types.
Fire Resistant Fluids accordance with the supplier’s
A reduction of predicted life of hydraulic
recommendation. If the pH number
Hydraulic systems using fire resistant exceeds these limits, discard the fluid. components should be expected when
fluids require special engineering Always use a premixed fluid to replenish using water-based fluid types.
considerations. For applications using the system. The recommended storage
fire resistant fluids, consult Vickers or operating temperature range of water Synthetic Fluid Type
Guide to Alternative Fluids, Bulletin containing fluids is 4C (39F) to 49C
579, for the specific component being (120F), unless otherwise specified by Phosphate Ester
used or contact your local Vickers the fluid supplier.
representative for assistance. Phosphate ester type fluids are
manufactured from chemically produced
Proper design, operation and
Types Of Water Based esters. These types of fluids require
maintenance of fluid power systems is Fluids fluorocarbon seals. Consult your fluid
of paramount importance to obtain the supplier for the types of seals which are
optimum performance of fire resistant Invert Emulsions compatible.
fluids such as synthetics, water glycol Invert emulsions are inverted
and water-in-oil emulsion types. Environmental Hydraulic Oil
water-in-oil emulsions consisting of a
continuous oil phase surrounding finely If you have equipment that operates in
Additionally, you should consult your fluid divided water droplets that are uniformly environmentally sensitive areas, you may
supplier for specific fluid maintenance dispersed throughout the mixture. consider use of more environmentally
and application data on their fluid. aware fluids. These fluids perform well in
our hydraulic systems but may require
extra caution in order not to exceed their
performance capabilities.
18
Hydraulic Fluid And Temperature
Recommendations For Mobile Hydraulic Systems
The oil in a hydraulic system serves as index. The viscosity index of hydraulic Antiwear Hydraulic Oil
the power transmission medium. It is system oil should not be less than 90.
also the system’s lubricant and coolant. Multiple viscosity oils, such as SAE These oils are produced by all major oil
The selection of proper oil is a 10W-30, incorporate additives to improve suppliers and should consist of good
requirement for satisfactory system viscosity index (polymer thickened). These quality base stocks compounded with
performance and life. oils should have a minimum viscosity index antiwear, antioxidation, antifoam and
of 120. Oils of this type generally exhibit antirust additives. These may be
In most cases, use of these both a temporary and permanent decrease petroleum, vegetable or synthetic base oil.
recommendations will lead to selection of in viscosity due to oil shear encountered in
a suitable oil. However, due to the the operating hydraulic system. The actual Due to the large number of different
complex nature of oil formulation, the viscosity can, therefore, be far less in the antiwear hydraulic oils, it is impossible
variety of oils available and peculiarities of operating hydraulic system than what is for Vickers to test its products with all of
individual hydraulic applications, there will shown in normal oil data. Accordingly, the available fluids. Because of this, an
be rare instances where an oil selected when such oils are selected, it is evaluation procedure was developed for
on the basis of these recommendations necessary to use those with high shear fluid suppliers to establish the suitability
may yield unsatisfactory results. Vickers stability to insure that viscosity remains of their products for use in Vickers
cannot be responsible for such within recommended limits while in service. components. Refer to “Pump Test
exceptions. In this respect, the customer Procedure For Evaluation Of Antiwear
is encouraged to consult his Vickers Chemical Stability Hydraulic Fluids For Mobile Systems”,
representative or a reputable oil company page 20, for details of the 35VQ25 test
when selecting an oil. Oxidation and thermal stability are procedure. It is the responsibility of your
essential characteristics of oils for mobile oil supplier to assure that their fluids
hydraulic systems. The combination of meet Vickers requirements.
Important Factors In base stocks and additives should be
stable during the expected lifetime of the Environmental Hydraulic Oil
Selecting An Oil oil when exposed to the environment of
these systems. If you have equipment that operates in
Additives environmentally sensitive areas, you
may consider use of more
Hydraulic fluids contain a number of
additive agents which materially improve Suitable Types Of Oil envionmentally aware fluids. These
fluids perform well in our hydraulic
various characteristics of oil for systems but may require extra caution in
hydraulic systems. These additives are Crankcase Oil order not to exceed their performance
selected to reduce wear, increase capabilities. For further clarification,
chemical stability, inhibit corrosion and Oil having an API letter designation SE,
SF, SG or SH per SAE J183. Note that refer to Vickers Guide to Alternative
depress the pour point. Fluids, Bulletin 579.
one oil may meet one or more of these
designations.
Antiwear Other Oils
Pump performance and reliability are Certain other types of petroleum oil are
directly affected by the antiwear additive suitable if they meet the following
formulation contained in the oil. Oils provisions:
providing a high level of antiwear
protection are recommended for 1. Contain the type and content of
optimum performance and long life. antiwear additives found in the above
designated crankcase and antiwear
Viscosity hydraulic oils, and have passed the
pump tests.
Viscosity is the measure of the fluid’s
resistance to flow. The oil selected must 2. Have sufficient chemical stability for
have proper viscosity to maintain an mobile hydraulic system service.
adequate lubricating film at system
operating temperature. 3. Meet the viscosity requirements
shown in the following tables.
In addition to dynamic lubricating
properties, oil must have sufficient body
to provide an adequate sealing effect
between working parts of pumps, valves,
clylinders and motors, but not enough to
cause pump cavitation or sluggish valve
action. Optimum operating viscosity of
the oil should be between 16 cSt (80
SUS) and 40 cSt (180 SUS).
1 Temperatures shown are cold (ambient) start-up to maximum operating. During cold start-up,
avoid high-speed operation of hydraulic components until the system is warmed up to provide
adequate lubrication.
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Pump Test Procedure For Evaluation Of
Antiwear Fluids For Mobile Systems
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Acceptable Rings Unacceptable Rings
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Oil Flow Velocity In Tubing
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Pipe Sizes And Pressure Ratings
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Preparation Of Pipes, Tubes, And Fittings
Before Installation In A Hydraulic System
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ISO/ANSI Basic Symbols
For Fluid Power Equipment And Systems
Lines Pumps
Line, Working Hydraulic Pump
(Main) Fixed
Displacement Heater
Line, Pilot
(For Control)
Line, Liquid Drain
Variable Cooler
Hydraulic
Displacement
Flow, Direction of
Pneumatic
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Flow Control, Definition Of Functions
Push-Pull Lever Adjustable
(temperature and
pressure
Function Definition
Pedal or Treadle compensated Intensified Pressure Pressure in
excess of supply
pressure which is
Two Position
induced by a
Mechanical Two Connection booster or
intensifier.
Two Position Supply Pressure Power-actuating
Detent Three Connection fluid.
Charging Pressure Pump-inlet
Pressure Two Position pressure that is
Compensated higher than
Four Connection
atmospheric
Solenoid, Single pressure.
Winding Three Position Reduced Pressure Auxiliary pressure
Four Connection which is lower
than supply
Servo Control
pressure.
Two Position
In Transition Pilot Pressure Control-actuating
pressure.
Pilot Pressure Metered Flow Fluid at controlled
Valves Capable Of
Remote Supply flow rate, other
Infinite Positioning
(horizontal bars than pump
Internal Supply delivery.
indicate infinite
positioning ability) Exhaust Return of power
and control fluid
to reservoir.
Valves Note Intake Sub-atmospheric
pressure, usually
Additional symbols are shown in on intake side of
Check Vickers Circuitool booklet available for pump.
a nominal charge. Ask for circuitool Drain Return of leakage
On–Off template kit 352. fluid to reservoir.
(manual shut-off)
Inactive Fluid which is
Color Code For Fluid within the circuit,
but which does
Power Schematic not serve a
Pressure Relief Drawings functional
purpose during
Function Color the phase being
represented.
Intensified Pressure . . Black
Supply . . . . . . . . . . . . . . Red
Pressure Reducing Charging Pressure . . . Intermittent Red
Reduced Pressure . . . . Intermittent Red
Pilot Pressure . . . . . . . . Intermittent Red
Metered Flow . . . . . . . . Yellow
Flow Control, Exhaust . . . . . . . . . . . . . Blue
Adjustable– Intake . . . . . . . . . . . . . . . Green
Non-Compensated Drain . . . . . . . . . . . . . . . Green
Inactive . . . . . . . . . . . . . Blank
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Conversion Factors
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Conversion Factors
Hydraulic Formulas
Horsepower: Conversion Factors: Pressure (PSI) = feet head 0.433
specific gravity.
Horsepower = GPM PSI 1 hp = 33,000 ft. lbs. per minute
1714 1 hp = 42.4 btu per minute Specific gravity of oil is approximately 0.85.
1 hp = 0.746 kwhr (kilowatt hours)
Torque: Thermal expansion of oil is
1 U.S. gallon = 231 cubic inches. approximately 1 cu.in. per 1 gal. per
Torque (lb. in.) = CU IN./REV. PSI Pipe volume varies as the square of the 10F rise in temperature.
2π diameter; volume in gallons = 0.0034 D2L
Torque (lb. in.) = HP 63025
RPM where: D = inside diameter of pipe in
inches
Flow: L = length in inches
Flow (gpm) = CU IN./REV. RPM Velocity in feet per second =
231 0.408 flow (gpm)
Overall Efficiency: D2
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