Hyd Data PDF
Hyd Data PDF
DATA BOOK
TABLE OF CONTENTS
What is Hydraulics? 3
Hydraulic Graphic Symbols 4
Hydraulic Pumps 9
Pump Formulas 10
Horsepower to Drive a Pump/Quick Reference Chart: 11
Determining Pump Displacement 12
Hydraulic Cylinders (Actuators) 13
Cylinder Formulas 14
Cylinder Force / Quick Reference Chart 15
Hydraulic Cylinder Speed / Quick Reference Chart 17
Power Unit Reservoir Requirements 19
Hydraulic Motors (Actuators) 20
Motor Formulas 21
Hydraulic Directional Control Valve Definitions 22
Valve Spool Configurations Definitions 23
Power Unit Battery Cable Selection 25
Hydraulic Fittings 27
Proper Hydraulic Hose Installation Guidelines 32
Hose Size Selection Tool 34
Hose Size Selection Nomograph 35
Hydraulic System Pressure Drop 36
Hydraulic Hose Presure Drop Chart 37
Hydraulic Oil and Filtration 38
Viscosity Comparison Chart 38
What is Beta Ratio? 39
ISO Cleanliness Code for Hydraulic Oil 40
Selecting Your Hydraulic Filter 41
The Hydraulic Reservoir 43
Seal Compatibility Table 44
Hydraulic System Troubleshooting 45
Conversion Tables 48
Hydraulic Oil and Filtration 38
How to Determine Belt Length 52
How To Determine The Size and Speed of Pulleys and Sprockets 52
Electrical 55
Basic Electrical Formulas 56
The Electrical Formula Wheel 57
Ongoing Commitment To Training 58
Glossary 59
2 TABLE OF CONTENTS
WHAT IS HYDRAULICS? HYDRAULICS
Hydraulics in its most basic definition is the use of liquids to perform work.
Reservoir Directional
Control Valve
1 Filter
Strainer
Load
2
4 6
Pump
Cylinder
3
Relief 7
Valve
Prime Mover
Hydraulics 3
HYDRAULIC GRAPHIC SYMBOLS
PUMPS
A B C
A One flow direction Fixed Displacement
B Two flow directions Pump
C One flow direction Variable
D Two flow directions Displacement Pump
E One flow direction Hand Pump
D E
MOTORS
A B One rotation
A
direction Fixed Displacement
Two rotation Motor
B
directions
One rotation
C Variable
C D direction
Displacement
Two rotation Motor
D
directions
CHECK VALVES
Standard
Spring
Piloted with drainage
Pilot Operated Pilot with Drainage
Piloted operatedLoaded
-42ways
ways 2-Way - 3-Way
2 positions
positions 4 ways4-Way
- 3 positions
4-Way
2 Position 2 Position 2 Position 3 Position
am
Spring
ElectricCam(solenoid)
Electro-hydraulic
Electric (Solenoid) Electro-hydraulic
Electric Electro-hydraulic
Pneumatic Hydraulic
Electric (proportional)
ydraulic Electro-hydraulic (proportio
(Proportional) (Proportional)
Pressure
Crossover Relief Valve Counterbalance Valve
Reducing Valve
Pressure
Pressure Compensated
Throttle with
Throttle Valve Compensated Flow Control
Reverse Check
Flow Control with
Reverse Check
Return Stroke by
External Force
Single-acting Cylinder
Return Stroke
Through a Spring
Single Rod
Double-acting Cylinder
Double Rod
Single-acting
Telescopic Cylinder
Double-acting
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Your source for a huge inventory of hydraulic components
and power equipment. We carry hydraulic cylinders, directional
control valves, hose and fittings, power units, pressure washers,
gas engines, electric motors, concrete and landscaping equipment,
bearings, sprockets, roller chain, pulleys and v-belts.
A Electric Motor
M Prime Mover
B Gas Engine
A B
C Main
C D D Pilot
Q S Heater
R
Heat Exchanger T Cooler
U Liquid Operated Cooler
Pressure Gauge V ---
S T
Pressure Switch W Adjustable
X 1 Direction
Rotating Shaft
Y 2 Direction
U V
W X Y
Rotor
Vane
Vane Pump
Idler Gear
Valve Plate Cylinder Block
Inlet
Inlet
Outlet
Piston Swashplate
Slipper
Control Journal
Inlet
Piston
Hydraulic Pumps 9
PUMP FORMULAS
Calculating Pump Flow
To determine the flow of a pump you need to know the displacement of the pump and the
speed (RPM) of the prime mover.
Example: How many gallons per minute (GPM) can a pump produce that has a
displacement of 0.269 cu. in./rev. and is running at 3,000 RPM?
Pump efficiency
Example: How many horsepower would I require to drive a gear Gear - 0.85
pump that will produce 15 GPM at 2,500 PSI? Vane - 0.90
Piston - 0.95
HYDRAULIC TIP:
Approximate horsepower requirements for a hydraulic system can be calculated with
this simple formula:
This easy formula will allow you to make quick mental calculations to determine the
approximate HP requirements of a hydraulic system.
10 Hydraulic Pumps
HORSEPOWER TO DRIVE A PUMP/QUICK
REFERENCE CHART: (USING 85% PUMP EFFICIENCY)
1-1/2 0.52 0.77 1.0 1.3 1.5 1.8 2.1 2.6 3.0
2-1/2 0.86 1.3 1.7 2.1 2.6 3.0 3.4 4.3 5.2
3-1/2 1.2 1.8 2.4 3.0 3.6 4.2 4.8 6.0 7.2
Hydraulic Pumps 11
HYDRAULICS
DETERMINING PUMP DISPLACEMENT
D
Gear Pump D Vane Pump
L L
W W
1. Measure the gear width (W). 1. Measure the rotor width (W).
2. M
easure bore diameter of one of the 2. Measure the shortest diameter of the
gear chambers (D). elliptical bore (D).
3. M
easure distance across both gear 3. Measure the longest diameter of the
chambers (L). elliptical bore (L).
(R) Holes
A A
12 Hydraulic Pumps
HYDRAULIC CYLINDERS (ACTUATORS)
Hydraulic cylinders are linear actuators. When they are exposed to hydraulic
pressure they produce a pushing or pulling force. The three basic types of
hydraulic cylinders are single acting, double acting and telescopic.
SINGLE
Piston Seals Rod Seals
DOUBLE
Piston Seals Rod Seals
Oil Port
Rod #1
TELESCOPIC
Cylinder Tube
Oil Port
Rod #2
Guides
Actuators 13
CYLINDER FORMULAS
Calculating Cylinder Force (Extension)
In order to calculate the maximum force a cylinder can produce while extending
you need to know the area of the cylinder’s piston and the system’s maximum
pressure.
Example: If a cylinder has a 3 in. bore in a system that is delivering 3,000 PSI,
how much force can it produce while extending?
Radius 3 in.
Piston Radius = = 1.5 in.
Bore 2
Cylinder Force =
3,000 PSI x 7.065 sq. in.
Inlet Outlet = 21,195 lb
14 Actuators
CYLINDER FORCE/QUICK REFERENCE CHART
To determine the max. extension force of the cylinder (in pounds), find the row with
the Cylinder Bore in the Bore Dia. column. Choose “None” in the Rod Dia. column next
to the bore dimension. Follow across to the column with the pressure (PSI) being used
to determine the correct amount of force. For the max. retraction force, repeat the
previous instructions and use the closest rod dimension under the Rod Dia. column.
Bore Dia. Rod Dia. Effective Area 1,000 1,500 2,000 2,500 3,000
(in.) (in.) (sq. in.) PSI PSI PSI PSI PSI
1 None 0.79 790 1,185 1,580 1,975 2,370
5/8 0.48 480 720 960 1,200 1,440
1-1/2 None 1.76 1,760 2,640 3,520 4,400 5,280
1 0.98 980 1,470 1,960 2,450 2,940
2 None 3.14 3,140 4,710 6,280 7,850 9,420
1-1/8 2.15 2,150 3,225 4,300 5,375 6,450
1-1/4 1.91 1,910 2,865 3,820 4,775 5,730
2-1/2 None 4.91 4,910 7,365 9,820 12,275 14,730
1-1/8 3.92 3,920 5,880 7,840 9,800 11,760
1-1/4 3.68 3,680 5,520 7,360 9,200 11,040
1-1/2 3.14 3,140 4,710 6,280 7,850 9,420
3 None 7.07 7,070 10,605 14,140 17,675 21,210
1-1/4 5.84 5,840 8,760 11,680 14,600 17,520
1-1/2 5.30 5,300 7,950 10,600 13,250 15,900
1-3/4 4.67 4,670 7,005 9,340 11,675 14,010
3-1/2 None 9.62 9,620 14,430 19,240 24,050 28,860
1-1/4 8.39 8,390 12,585 16,780 20,975 25,170
1-3/4 7.22 7,220 10,830 14,440 18,050 21,660
2 6.48 6,480 9,720 12,960 16,200 19,440
4 None 12.56 12,560 18,840 25,120 31,400 37,680
1-1/4 11.33 11,330 16,995 22,660 28,325 33,990
1-1/2 10.79 10,790 16,185 21,580 26,975 32,370
1-3/4 10.16 10,160 15,240 20,320 25,400 30,480
2 9.42 9,420 14,130 18,840 23,550 28,260
2-1/4 8.58 8,580 12,870 17,160 21,450 25,470
5 None 19.63 19,630 29,445 39,260 49,075 58,890
2 16.49 16,490 24,735 32,980 41,225 49,470
2-1/2 14.72 14,720 22,080 29,440 36,800 44,160
Actuators 15
Calculating Cylinder Force (Retraction)
In order to calculate the maximum force a cylinder can produce while retracting
you need to know the effective area of the piston and the system’s maximum
pressure.
The following formulas are used in the calculation:
Piston Effective Area (sq. in.) = Piston Area (sq. in.) - Rod Area (sq. in.)
Example: A cylinder has a 4 inch bore and a rod 2 inches in diameter, in a system
that is delivering 3,000 PSI. How much force can it produce while
retracting?
4 in.
Piston Radius = = 2 in.
Radius 2
Bore
Rod Radius = 2 in.
= 1 in.
2
Piston Area = π x 22
= 3.14 x (2 x 2)
= 12.56 sq. in.
Rod Area = π x 12
= 3.14 x (1 x 1)
= 3.14 sq. in.
Outlet Inlet
Effective Area = 12.56 sq. in. – 3.14 sq. in.
= 9.42 sq. in.
16 Actuators
Calculating Cylinder Speed
To calculate the time it takes a cylinder to fully extend, you need to know the
area of the piston, the stroke of the cylinder and the pump’s flow.
The following formulas are used in the calculation:
Cylinder Volume (cu. in.) = Piston Area (sq. in.) x Cylinder Stroke (in.)
Cylinder Volume (Gal) x 60
Cylinder Speed (sec.) =
Pump Flow (GPM) Cubic Inches
Gallons =
231
Example: A cylinder has a piston area of 7.065 sq. in. and a stroke of 12 inches
(the stroke is the distance between the centres of the 2 ports). If the
pump’s rate of flow is 2 GPM, how many seconds will it take for the
cylinder to extend?
Actuators 17
Pump Flow (GPM)
Bore Rod Effective
1 3 5 8 12 15 20
Dia. Dia. Area
GPM GPM GPM GPM GPM GPM GPM
(in.) (in.) (sq. in.)
Cylinder Speed (inches per minute)
1-1/8 2.15 107 321 535 856 1,284 1,605 2,140
18 Actuators
POWER UNIT RESERVOIR REQUIREMENT
These calculations will help you determine the volume of the cylinder’s rod
Actuators 19
HYDRAULIC MOTORS (ACTUATORS)
Hydraulic motors transform hydraulic working energy into rotary mechanical
working energy, which is applied to a resisting object by means of a shaft. All
motors consist of a housing with inlet and outlet ports and a rotating shaft.
Hydraulic motors can be uni-directional or bi-directional.
Outlet
Cam Outlet
Ring
Vane Motor
Gear Motor
Driven
Gear
Vane Inlet
Idler Gear
Rotor
Inlet
Gerotor
Gerotor Motor
Geroler Motor
Ring Geroler
Ring
Roller(s)*
Control Compensator
Case
Bent Axis Motor
Drain Piston
Outlet
Control
Piston
*IMPORTANT! The addition of the rollers to the Geroler motor significantly reduces the friction
between the Geroler Star and Geroler Ring. This makes the Geroler motor easier to turn, which saves
energy and creates less wear compared to the Gerotor motor.
20 Actuators
MOTOR FORMULAS
Calculating Motor Torque
To calculate a motor’s torque, you need to know the motor’s displacement
(cu. in./rev.) and inlet pressure (PSI).
Example: What is the speed of a hydraulic motor with an inlet flow of 10 GPM
and a displacement of 5.9 cu.in. /rev?
10 GPM x 231
Motor Speed (RPM) = = 391.5 RPM
5.9 cu. in./rev.
Actuators 21
HYDRAULIC DIRECTIONAL CONTROL
VALVE DEFINITIONS
Load Checks
While it is often thought the purpose of a load check in a directional control valve
is to hold the load in position, this is not the case. The load check function is to
prevent the load from falling when the valve handle is shifted. It accomplishes this
by temporarily stopping the oil flow when the valve handle is shifted, until the
pump can develop enough pressure to push oil past the check and extend
the cylinder.
22 Valves
VALVE SPOOL CONFIGURATIONS DEFINITIONS
There are four primary types of valve spool configurations.
Double Acting
The double acting spool directs flow to either
port of a hydraulic cylinder or motor. The low pressure
flow from the other cylinder or motor port is returned
back through the valve to the reservoir.
When the spool is in the centre neutral position, both of the ports
are blocked and oil flows through the valve back to the reservoir.
Single Acting
The single acting spool directs flow to the port of the
single acting cylinder, or to only one port of a unidirectional
motor. The return flow from the cylinder goes through the
same port of the valve, relying on gravity or load on the
cylinder to push it back to the reservoir.
The return flow from the motor goes directly to the reservoir.
When the spool is in the centre neutral position, the port is
blocked and oil flows through the valve back to the reservoir.
Motor Spool
The motor spool is typically used to direct flow to a
hydraulic motor. It acts the same as the double acting
spool, allowing the motor to turn in either direction.
The difference between the motor spool and double acting
spool is the centre neutral position. The motor spool
has both work ports connected back to the tank in
this position. This allows the motor to freewheel to
a stop, instead of the ports being blocked and the motor
being brought to an abrupt stop. This prevents pressure
spikes in the system that can damage hydraulic components.
Float Spool
The float spool is a double acting spool with an
additional position. This fourth position is similar to
the centre neutral position of the motor spool,
which has both of the work ports connected back
to the tank. Float spools are used in applications
like front end loaders or graders where the bucket
or blade must follow the contour of the ground.
Valves 23
14
22
34°
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24
POWER UNIT BATTERY
CABLE SELECTION
One of the most important steps
when installing a 12V DC power unit is
selecting the cables that run from the
battery to the power unit. These cables
must be the proper gauge to prevent
voltage drop from occurring, which
can negatively affect the solenoids
and cause the cartridge valves not to
operate properly. This may result in
the power unit not functioning
correctly, preventing the cylinder
from retracting, or causing it to
continue extending when either of
the remote buttons are pushed.
The 1,600W power unit motor can
draw up to 270A under full load. Refer
to the Cable Selection Chart to choose
the correct gauge cable based on the
maximum current draw and cable
length.
Power Units 25
CABLE SELECTION CHART
70
60
50
Cable Length (ft.)
40
30
20
#4 #2 #1 #0 #00
10
26 Power Units
HYDRAULIC FITTINGS
THE MOST COMMON TYPES OF FITTING THREADS IN HYDRAULICS
ARE JIC 37°, NPT, ORB, ORFS, BSPP AND METRIC
37° 37°
Thread
O.D./I.D.
Male Female
Size Dash Size Thread Size Male Thread O.D. Female Thread I.D.
(inches) (inches) (inches)
1/8 02 5/16 – 24 0.31 0.27
3/16 03 3/8 – 24 0.38 0.34
1/4 04 7/16 – 20 0.44 0.39
5/16 05 1/2 – 20 0.50 0.45
3/8 06 9/16 – 18 0.56 0.51
1/2 08 3/4 – 16 0.75 0.69
5/8 10 7/8 – 14 0.88 0.81
3/4 12 1-1⁄16 – 12 1.06 0.98
7/8 14 1-3⁄16 – 12 1.19 1.10
1 16 1-5⁄16 – 12 1.31 1.23
1-1/4 20 1-5⁄8 –12 1.63 1.54
1-1/2 24 1-7⁄8 – 12 1.88 1.79
2 32 2-1⁄2 – 12 2.50 2.42
!
DO NOT use Thread Tape or Sealant as it can
NOTICE introduce contaminates into the system and cause
leakage at the fitting.
HYDRAULIC FITTINGS 27
NATIONAL PIPE THREAD FITTING (NPT)
The male and female halves of this fitting are tapered.
When they are threaded together they seal by
deformation of the threads.
Tapered Tapered
Thread
O.D./I.D.
Female Male 90° Male
Size Dash Size Thread Size Male Thread O.D. Female Thread I.D.
(inches) (inches) (inches)
1/8 02 1/8 – 27 0.41 0.38
1/4 04 1/4 – 18 0.54 0.49
3/8 06 3/8 – 18 0.68 0.63
1/2 08 1/2 – 14 0.84 0.77
3/4 12 3/4 – 14 1.05 0.98
1 16 1 – 11-1/2 1.32 1.24
1-1/4 20 1-1/4 – 11-1/2 1.66 1.58
1-1/2 24 1-1/2 – 11-1/2 1.90 1.82
2 32 2 – 11-1/2 2.38 2.30
28 Hydraulic Fittings
O-RING FACE SEAL FITTING (ORFS)
The male fitting has a straight thread and an O-Ring in the face. The female fitting has a
straight thread and a machined flat face. The seal takes place by compressing the O-Ring on
the flat face of the female. The threads hold the fitting mechanically.
Thread
O.D./I.D.
Male Female
Size Dash Size Thread Size Male Thread O.D. Female Thread I.D.
(inches) (inches) (inches)
1/4 04 9/16 – 18 0.56 0.51
3/8 06 11/16 – 16 0.69 0.63
1/2 08 13/16 – 16 0.82 0.75
5/8 10 1 – 14 1.00 0.93
3/4 12 1-3⁄16 – 12 1.19 1.11
1 16 1-7⁄16 – 12 1.44 1.36
1-1/4 20 1-11⁄16 – 12 1.69 1.61
1-1/2 24 2 – 12 2.00 1.92
!
DO NOT use Thread Tape or Sealant as it can
NOTICE introduce contaminates into the system and
cause leakage at the fitting.
Hydraulic Fittings 29
O-RING BOSS FITTING (ORB)
The male fitting has a straight thread and an O-Ring. The female fitting has a
straight thread, a machined surface, and is chamfered to accept the O-Ring.
The seal takes place by compressing the O-Ring into the chamfer, while the
threads hold the connection mechanically.
O-Ring Chamfer
Thread
O.D./I.D.
Male Female
Size Dash Size Thread Size Male Thread O.D. Female Thread I.D.
(inches) (inches) (inches)
1/8 02 5/16 – 24 0.31 0.27
3/16 03 3/8 – 24 0.38 0.34
1/4 04 7/16 – 20 0.44 0.39
5/16 05 1/2 – 20 0.50 0.45
3/8 06 9/16 – 18 0.56 0.51
1/2 08 3/4 – 16 0.75 0.69
5/8 10 7/8 – 14 0.88 0.81
3/4 12 1-1/16 – 12 1.06 0.98
7/8 14 1-3/16 – 12 1.19 1.10
1 16 1-5/16 – 12 1.31 1.23
1-1/4 20 1-5/8 – 12 1.63 1.54
1-1/2 24 1-7/8 – 12 1.88 1.79
2 32 2-1⁄2 – 12 2.50 2.42
!
DO NOT use Thread Tape or Sealant as it can
NOTICE introduce contaminates into the system and
cause leakage at the fitting. !
30 Hydraulic Fittings
BRITISH STANDARD PARALLEL PIPE FITTING (BSPP)
The male and female halves of this fitting both have straight threads. The female
swivel has a tapered nose, which seals on the cone seat of the male. The threads
hold the fitting mechanically.
Tapered Nose/Globeseal
30°
60°
Thread Thread
O.D. I.D.
Male Female
!
Size (inches) Dash Size Thread Size Male Thread O.D. (inches) Female Thread I.D. (inches)
Metric Fitting (M) The male and female halves of this fitting both have
straight threads. A washer with a bonded seal is used to seal the male and female
threads. The threads hold the fitting mechanically.
Bonded
Seal Washer
Thread
I.D.
Male Female !
Spotface
Male Female Male Female
Thread Thread
Size Thread Thread Size Thread Thread
Size Size
O.D. (mm) I.D. (mm) O.D. (mm) I.D. (mm)
M8 M8X1.0 8 7 M20 M20X1.5 20 18.5
M10 M10X1.0 10 9 M22 M22X1.5 22 20.5
M12 M12X1.5 12 10.5 M24 M24X1.5 24 22.5
M14 M14X1.5 14 12.5 M26 M26X1.5 26 24.5
M16 M16X1.5 16 14.5 M27 M27X2.0 27 25
M18 M18X1.5 18 16.5 M33 M33X2.0 33 31
HYDRAULIC FITTINGS 31
PROPER HYDRAULIC HOSE
INSTALLATION GUIDELINES
Following these guidelines will help you to extend the life of your hose(s) and
avoid costly equipment breakdowns.
WRONG
RIGHT
WRONG RIGHT
When hose installation is straight, allow
enough slack in hose line to provide for Adequate hose length is necessary
length changes that will occur when to distribute movement on flexing
pressure is applied. applications, and to avoid abrasion.
WRONG RIGHT
RIGHT
WRONG
When radius is below the required Avoid twisting of hose lines bent in
minimum, use an angle adapter to avoid two planes by clamping hose at change
sharp bends. of plane.
RIGHT
WRONG RIGHT
32 Hydraulic Hose
Reduce Number of Pipe Fittings Use 45° and/or 90° Adapters
WRONG RIGHT
WRONG RIGHT
Reduce number of pipe thread joints by • Route hose directly by using 45° and/
using proper hydraulic adapters instead or 90° adapters and fittings.
of pipe fittings. • Avoid excessive hose length to
improve appearance.
WRONG
WRONG
RIGHT
RIGHT
HIGH RIGHT
PRESSURE WRONG
Hydraulic Hose 33
Avoid Collapse and Restriction Avoid Abrasion
WRONG RIGHT
WRONG RIGHT
34 Hydraulic Hose
HOSE SIZE SELECTION NOMOGRAPH
m/sec ft/sec
Hydraulic Hose 35
HYDRAULIC SYSTEM PRESSURE DROP
Pressure drop in a hydraulic system can be defined as the difference between the
upstream and downstream pressure within the hydraulic system. This reduction
in pressure is caused by the restriction(s) to the oil flow. When the pressure in the
fluid is lowered by a restriction(s) then the energy stored in that fluid is less. This
loss of energy is in the form of heat.
When designing a hydraulic system, you must allow for pressure drop as oil flows
through the valves, fittings, hose, etc. If you start off with 3,000 PSI at your
pump, you may only have 2,500 PSI at your actuator due to pressure drop. This
loss of pressure must always be allowed for and is the reason you always design
a hydraulic system by working from the actuator (cylinder, motor) back. In our
previous example if you did need 3,000 PSI at the actuator to do the work you
would need the pump to produce 3,500 PSI as 500 PSI is being lost to pressure
drop and given off as heat.
Since the loss of pressure and creation of heat is both inefficient and can be
harmful to a hydraulic system we want to eliminate pressure drop as much as
possible. This involves selecting large enough hoses, as few fittings as possible,
eliminating or reducing 90° fittings and making sure components match your
maximum pump flow. By paying attention to pressure drop when building your
hydraulic system, you will save energy, eliminate excess heat that could damage
your oil and components and save money.
36 Hydraulic Hose
HYDRAULIC HOSE PRESSURE
HYDRAULIC DROPDROP
HOSE PRESSURE CHART
CHART
1-1/2 1-13/16 2
500
1-3/8 400
1-1/4
300
1-1/8
200
1
7/8
100
3/4 90
80
70
60
5/8 50
HOSE I.D. (INCHES)
40
1/2 30
20
GPM
7/16
15
3/8
10
5/16 9
8
7
6
1/4 5
4
3
3/16
2
1
.9
.8
.7
.6
.5
.9
.8
.7
.6
.5
.4
.3
.2
.1
10
9
8
7
6
5
1
4
Hydraulic Hose 37
HYDRAULIC OIL AND FILTRATION
VISCOSITY COMPARISON CHART
Kinematic Saybolt
Viscosities Viscosities
cSt cSt ISO AGMA SAE SAE SUS SUS
@40°C @100°C VG Grade Crankcase Gear @100°C @210°C
2000 10000
70
1500 8000 300
60
6000
1000 50 1000 8A 250 5000
800 4000 200
40 680 8
600 3000
30
500 140
460 7
400 2000
300 320 6 60 1500
20 100
200 220 5 50 90 1000 90
150 4
800 80
40
85W
600 70
100 100 3 500
80 10 30 60
400
9 68 2 80W 55
60 8 300
7 20 50
50 200
40 6 46 1 45
32 75W 150
30 5 15W
10W
4 22 100 40
20 5W, 0W
15
10 10 60
The Saybolt Universal Second (SUS or SSU) and Centistoke (cSt) ratings are both
measures of kinematic viscosity, which describes the oils flow behavior under the
influence of Earth’s gravity.
Rating Efficiency
2 - 50%
10 - 90%
75 - 98.7%
100 - 99%
200 - 99.5%
1,000 - 99.9%
Example: ß4 =200 signifies that there are 200 times as many particles that are
4 µm and larger upstream as downstream. This is 99.5% efficiency.
Example: ß5 = 1
,000 indicates that there are 1,000 times as many particles
that are 5 µm and larger upstream as downstream. This is 99.9%
efficiency.
IMPORTANT! The three figures of the ISO code numbers represent ISO level
contamination grades for particles of >4μm, >6μm and >14μm
respectively.
RESERVOIR
Sight
Glass
Outlet Drain
Strainer
F D
B
PRESSURE RELIEF
GAUGE VALVE
A
PUMP
DIRECTIONAL WORK
CONTROL VALVE CYLINDER
SUCTION
STRAINER
E
C
BASIC HYDRAULIC SYSTEM
Step 2
• If cleaning the suction strainer does not correct the trouble, test the pump and
relief valve.
• Disconnect at point B so that only the pump, relief valve, and pressure gauge
remain in the pump circuit.
• Plug both ends of the plumbing that were disconnected.
Step 3
Test the pump
• Disconnect the reservoir return line from the relief valve at point C.
• Attach a short length of hose to the relief valve outlet. Hold the open end of this
hose over the reservoir filler opening so the rate of oil flow can be observed.
• Start the pump and run the relief valve adjustment up and down while observing
the flow through the hose.
• If the pump is bad, there will probably be a full stream of oil when the relief
adjustment is backed off, but this flow will diminish or stop as the adjustment is
increased.
• This decrease in oil flow is caused by the oil slipping across the pumping
elements inside the pump. This can mean a worn-out pump. High slippage in the
pump will also cause the pump to run considerably hotter than the oil reservoir
temperature. In normal operation a good pump will probably run about 11°C
(20°F) above the reservoir temperature. If greater than this, excess slippage,
caused by wear, may be the cause.
• Check also for slipping belts, sheared shaft pin or key, broken shaft, broken
coupling, or loosened set screw.
Step 4
• If the pump and relief valve are good, test the cylinder for worn-out or
defective seals.
• Extend the cylinder all the way out until it is at the end of its stroke.
• Remove the rod end hose at point D from the cylinder and place it in the fill
port of the reservoir.
• While watching for any leakage from the end of the hose use the directional
control valve to dead head the cylinder until it is at maximum system pressure
(oil will go over the relief). If no oil comes out of the hose the oil is not bypassing
the cylinder seals so they are OK.
14
22
34°
A place where
“figure-it-outers”
like you can show off your
incredible ingenuity
and creativity.
WINTER PROJ
ECT WORK SA
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DER
TRACTOR WITH LOA
48 Conversion Tables
TO CONVERT >>> INTO >>> MULTIPLY BY...
Into <<< To Convert <<< Divide by...
Horsepower Foot-Pounds per Minute 33,000
– – –
Conversion Tables 49
TEMPERATURE CONVERSION TABLE
°C °F °C °F °C °F °C °F °C °F °C °F °C °F
-40 -40 -10 14 20 68 50 122 80 176 110 230 140 284
-39 -38.2 -9 15.8 21 69.8 51 123.8 81 177.8 111 231.8 141 285.8
-38 -36.4 -8 17.6 22 71.6 52 125.6 82 179.6 112 233.6 142 287.6
-37 -34.6 -7 19.4 23 73.4 53 127.4 83 181.4 113 235.4 143 289.4
-36 -32.8 -6 21.2 24 75.2 54 129.2 84 183.2 114 237.2 144 291.2
-35 -31 -5 23 25 77 55 131 85 185 115 239 145 293
-34 -29.2 -4 24.8 26 78.8 56 132.8 86 186.8 116 240.8 146 294.8
-33 -27.4 -3 26.6 27 80.6 57 134.6 87 188.6 117 242.6 147 296.6
-32 -25.6 -2 28.4 28 82.4 58 136.4 88 190.4 118 244.4 148 298.4
-31 -23.8 -1 30.2 29 84.2 59 138.2 89 192.2 119 246.2 149 300.2
-30 -22 0 32 30 86 60 140 90 194 120 248 150 302
-29 -20.2 1 33.8 31 87.8 61 141.8 91 195.8 121 249.8 151 303.8
-28 -18.4 2 35.6 32 89.6 62 143.6 92 197.6 122 251.6 152 305.6
-27 -16.6 3 37.4 33 91.4 63 145.4 93 199.4 123 253.4 153 307.4
-26 -14.8 4 39.2 34 93.2 64 147.2 94 201.2 124 255.2 154 309.2
-25 -13 5 41 35 95 65 149 95 203 125 257 155 311
-24 -11.2 6 42.8 36 96.8 66 150.8 96 204.8 126 258.8 156 312.8
-23 -9.4 7 44.6 37 98.6 67 152.6 97 206.6 127 260.6 157 314.6
-22 -7.6 8 46.4 38 100.4 68 154.4 98 208.4 128 262.4 158 316.4
-21 -5.8 9 48.2 39 102.2 69 156.2 99 210.2 129 264.2 159 318.2
-20 -4 10 50 40 104 70 158 100 212 130 266 160 320
-19 -2.2 11 51.8 41 105.8 71 159.8 101 213.8 131 267.8 161 321.8
-18 -0.4 12 53.6 42 107.6 72 161.6 102 215.6 132 269.6 162 323.6
-17 1.4 13 55.4 43 109.4 73 163.4 103 217.4 133 271.4 163 325.4
-16 3.2 14 57.2 44 111.2 74 165.2 104 219.2 134 273.2 164 327.2
-15 5 15 59 45 113 75 167 105 221 135 275 165 329
-14 6.8 16 60.8 46 114.8 76 168.8 106 22.8 136 276.8 166 330.8
-13 8.6 17 62.6 47 116.6 77 170.6 107 224.6 137 278.6 167 332.6
-12 10.4 18 64.4 48 118.4 78 172.4 108 226.4 138 280.4 168 334.4
-11 12.2 19 66.2 49 120.2 79 174.2 109 228.2 139 282.2 169 336.2
50 Conversion Tables
WIRE MESH CONVERSIONS
U.S. Mesh Microns Inches U.S. Mesh Microns Inches
3 6730 0.2650 50 297 0.0117
4 4760 0.1870 60 250 0.0098
5 4000 0.1570 70 210 0.0083
6 3360 0.1320 80 177 0.0070
7 2830 0.1110 100 149 0.0059
8 2380 0.0937 120 125 0.0049
10 2000 0.0787 140 105 0.0041
12 1680 0.0661 170 88 0.0035
14 1410 0.0555 200 74 0.0029
16 1190 0.0469 230 62 0.0024
18 1000 0.0394 270 53 0.0021
20 840 0.0311 325 44 0.0017
25 710 0.0280 400 37 0.0015
30 590 0.0232 550 25 0.0009
35 500 0.0197 800 15 0.0006
40 420 0.0165 1250 10 0.0004
45 350 0.0137 – – –
IMPORTANT! The Wire Mesh Chart shows the filtration size of strainers
and filters in micron and inch ratings.
CUBIC CENTIMETERS TO HORSEPOWER
CONVERSION TABLE (APPROXIMATION)
CC HP CC HP CC HP
29 1 174 6 319 11
58 2 203 7 348 12
87 3 232 8 377 13
116 4 261 9 406 14
145 5 290 10 435 15
This table is a rough guideline to compare small gas engine cubic centimeter
displacement to horsepower. Actual horsepower can vary due to compression
differences, altitude, fuel/air mixture, etc.
CONVERSION TABLES 51
HOW TO DETERMINE BELT LENGTH
This formula will calculate the length of a belt required to fit a two pulley
drive system.
Pulley A
Diameter x 1.57
Distance Pulley B
between shafts x 2 Diameter x 1.57
( O.D. of + O.D. of
small pulley large pulley )
x 1.57 +
2 x distance
between shaft centres
= O.D. belt length
HYDRAULICS
HOW TO DETERMINE THE SIZE AND
SPEED OF PULLEYS AND SPROCKETS
The driving pulley/sprocket is called the Driver and the driven pulley/sprocket
the Driven.
ELECTRIC MOTOR/
GAS ENGINE DRIVER
PULLEY/SPROCKET
DRIVEN PULLEY/SPROCKET
IMPORTANT! Use the number of teeth for sprockets instead of the pulley’s
diameter for the Driver and Driven formulas.
Example: You have a 4 inch pulley (Driven) on your hydraulic pump that you want
to turn 1,750 RPM. The electric motor you are using is 3,450 RPM.
What diameter of pulley (Driver) would you need on the electric motor?
Formula #2
Diameter of the Driven (in.) = Diameter of Driver (in.) x Speed of Driver (RPM)
Speed of Driven (RPM)
Example: You have an 8 inch pulley (Driver) on your electric motor that runs at
1,800 RPM. You want your pump to turn at 600 RPM. What diameter
of pulley (Driven) do you need on the pump?
Formula #3
Example: You have a 6 inch pulley (Driven) on your hydraulic pump that you want
to turn 1,200 RPM. You have a 10 inch pulley (Driver) on your electric
motor. What RPM would the electric motor need to run at?
Example: You have a 10 in. pulley (Driver) on a 3,450 RPM electric motor and a
4 inch pulley (Driven) on hydraulic pump. What RPM would the pump
rotate?
SAFETY TIPS:
HYDRAULIC LEAKS
DANGER
A Potential Leak in a Hose — Never check for hydraulic leaks with your
hands of fingers. This could result in burns or even worse an injection injury
that could be fatal. The best way to check is to use a piece of cardboard
and run it along the suspected area. The cardboard will absorb the fluid,
pinpointing the leak’s location.
A Potential Leak in a Fitting — If the leak appears to be coming from
a fitting, do not tighten it. One extra turn of the wrench could cause a
greater leak or cause the fitting to fail entirely. It is highly recommended
to drain the system of hydraulic fluid before attempting to repair the
connection.
HYDRAULIC TIP:
OVERHEATING IN HYDRAULIC SYSTEMS:
Some common causes are low reservoir levels, air contaminating the system,
build-up of dirt in the air flow passages and excess friction within the
components. As the temperature of the hydraulic fluid increases, the
viscosity decreases and the friction within the components increase.
If the temperature of the oil exceeds 82°C (180°F), it can seriously damage
the system. Fix the problem by cleaning the air flow passages, checking and
fixing any leaks in the system and decreasing the heat load by increasing
heat dissipation.
ELECTRICAL 55
BASIC ELECTRICAL FORMULAS
Interesting Fact:
When describing electrical voltage, current and resistance, a common analogy
is a hydraulic system. In this analogy, voltage is represented by the hydraulic
oil pressure, current is represented by the hydraulic oil flow and resistance is
represented by the hydraulic system pressure drop (back pressure).
VOLTS WATTS
Volts = Watts
Watts = Volts x Amps
Amps
AMPS RESISTANCE
Amps = Watts Resistance Ohms = Volts²
Volts Watts
You have a 240V AC water heater element that uses 4,500 Watts of power.
How many Amps will it require?
Watts 4,500
Amps = Amps = = 18.75
Volts 240
Watts 3,600
Volts = Volts = = 120
Amps 30
You have a 240V AC, 4,500 Watt heater element that you want to test to
make sure it is still OK. You measure the resistance of the element with your
Ohm metre. What should the Ohm reading be?
56 Electrical
THE ELECTRICAL FORMULA WHEEL
P = Power Cur
a tts ren I = Current
W t
in VxI V
in
R
er
V2 P
Am
Pow
R V
ps
P I P
I2 x R Watts Amps R
Volts Ohms V2
IxR
VR P
s
Ohm
Vo l
PxR V
I
tag
P P
in
in c
e
Vo I I2 an
V = Voltage l t s t R = Resistance
s R e si
Electrical 57
ONGOING COMMITMENT TO TRAINING
Princess Auto offers a comprehensive hydraulics training program
to our Team Members. The program objectives include hydraulic
systems, design and troubleshooting at various levels of experience.
Team Members are able to earn certification after completing both
a hands-on practical application and written test to verify their
technical competency.
58 TRAINING
GLOSSARY
Actuator -A device that converts hydraulic power into mechanical
force and motion. (Examples: hydraulic cylinders and motors.)
Amperage - The strength of an electric current expressed in amperes.
Area - The amount of space inside the boundary of a flat (2-dimensional)
object such as a triangle or circle.
Beta Ratio - The amount, expressed as a ratio, of particles in a fluid
upstream of a filter, divided by the amount of particles downstream, for a
particular size particle.
Bi-Directional - Capable of functioning in two directions. Clockwise and
counterclockwise.
Bore Diameter - The internal diameter of a tube, hose or pipe.
Circuit -A series of component parts connected to each other by fluid
lines or passages. Usually part of a “system”.
Closed Center System - A hydraulic system in which the control valves
are closed in neutral, stopping oil flow. Flow in this system is varied, but
pressure remains constant.
Cleanliness Code - Is used to quantify particulate contamination levels
per milliliter of fluid at three sizes: 4µ[c], 6µ[c], and 14µ[c]. This ISO code is
expressed in 3 numbers: 19/17/14.
Cylinder - A device for converting fluid power into linear motion.
Single Acting - A cylinder that can apply force in one direction only.
Double Acting - A cylinder that can apply force in either direction.
Telescopic - Telescopic cylinders are a segmented cylinder that
provides an exceptionally long output travel from a very
compact retracted length.
Dash Size - Dash size is an industry standard measuring system for hoses
and fittings.
Displacement -The volume of oil displaced by one complete stroke or
revolution (of a pump, motor, or cylinder).
Duty Cycle - Is the proportion of time that a component, device or system
is operated. The duty cycle can be expressed as a ratio or as a percentage.
Directional Control Valve - A device for directing or preventing the oil flow
in a system.
GLOSSARY 59
Efficiency -The ratio of output to input. Volumetric efficiency of a pump is
the actual output, in GPM, divided by the theoretical or design output. The
overall efficiency of a hydraulic system is the output power divided by the
input power. Efficiency is usually expressed as a percent.
Effective Area - The surface area of the cylinder piston face that fluid
pressure acts upon to provide force.
Filter - A mechanical device used to house a filter element.
Filter Element - A series of wire or fabric meshes that are bonded
together by caps or perforated cylinders and are fitted into hydraulic system
passages to strain fine particles and silt from fluid passed through the
passage.
Float Spool - A spool valve design that connects the work ports to
tank, usually in a detented fourth position, allowing a cylinder or motor to
“float”.
Flow Control Valve, Pressure Compensated - A valve used to cause a variable
pressure drop in a fluid passage, thus reducing the amount of
fluid that may pass through the passage regardless of the pressure level at
the inlet of the valve. Often fitted with a check valve that permits free flow
of fluid in the opposite direction.
Flow Rate - The volume of fluid passing a point in a given time.
Flow Velocity - Is the speed that a fluid travels through a hose or pipe.
Force - A push or pull acting upon a body. In a hydraulic cylinder, it is the
product of the pressure on the fluid, multiplied by the effective area of the
cylinder piston. It is measured in pounds or tons.
GPM - Gallons per minute
Horsepower - The work produced per unit of time.
Hydraulics - The engineering science of liquid, pressure and flow.
ID - Inside Diameter
ISO - International Standards Organization
Kinematic Viscosity - A measure of the resistance to flow of a fluid, equal
to its absolute viscosity divided by its density.
Line - A tube, pipe or hose for conducting a fluid.
Linear Actuator - A device for converting hydraulic energy into linear
motion, e.g. a cylinder or ram.
Load Check -A device that prevents a load from dropping when a valve
is shifted, until ample pressure and flow is available to hold or move the load.
Micron - A unit of length equal to one millionth of a meter.
60 GLOSSARY
Motor (Hydraulic) - A device for converting fluid energy into mechanical
force and rotary motion. Basic design types include gear, vane and piston
units.
Motor Spool – The two work ports are connected to the tank in the
neutral position allowing a hydraulic motor to freewheel. Also prevents
“dead stop” in a hydraulic motor by allowing gradual slow down when the
valve is moved to neutral.
OD - Outside diameter
Ohm - Is the measurement of resistance in an electrical circuit. One ohm
is equal to the resistance of a conductor through which a current of one
ampere flows when a potential difference of one volt is applied to it.
Open Center System - A hydraulic system in which the control valves
are open to continuous oil flow, even in neutral. Pressure in this system is
varied, but flow remains constant.
O-Ring - A static and/or dynamic seal for curved or circular mating surfaces.
Particle Count - The visual or electronic summation of the quantity of
particles, grouped by size, in a fluid sample of specified size.
Pi - The ratio of a circle’s circumference to its diameter. Equal to 3.14.
Piston - A cylindrical part that moves or reciprocates in a cylinder and
transmits or receives force to do work.
Port - The open end of a fluid passage. May be within or at the surface of a
component.
Pour Point - The lowest temperature that a fluid will flow under specific
conditions.
Power Beyond - An adapting sleeve that opens a passage from one
circuit to another. Often installed in a valve port that is normally plugged.
Power Unit - An integral power supply unit usually containing a prime
mover, pump, reservoir, relief valve and directional control.
Pressure Compensated - Maintains the same flow of oil regardless of
pressure changes at the valves inlet or outlet ports.
Pressure Drop - The difference in pressure between any two points in a
system or a component.
Prime Mover - Is an electric motor or gas engine that drives a hydraulic
pump to convert mechanical energy into fluid energy.
PSI - Pounds per square inch
Pressure - Force of a fluid per unit area, usually expressed in pounds per
square inch (PSI).
GLOSSARY 61
Pump - A device which converts mechanical force into hydraulic fluid
power. Basic design types are gear, vane and piston units.
Fixed Displacement Pump - A pump in which the output per cycle cannot
be varied.
Variable Displacement Pump - A pump in which the output per cycle can
be varied.
Radius - The radius of a circle is the length of the line from the center
to any point on its edge.
Reservoir - A container for keeping a supply of working fluid in a hydraulic
system.
Rod - The chromed shaft attached to the piston inside the cylinder tube.
Rotary Actuator - A hydro-mechanical device that converts fluid flow
into incremental rotary motion.
RPM - Revolutions per minute.
Saybolt Viscosity - Viscosity as determined by the number of seconds
required for an oil heated to 54°C (130°F) for lighter oils and 99°C (210° F)
for heavier oils, to flow through a standard orifice and fill a 60 milliliter flask.
Solenoid - An electromagnetic device that positions a hydraulic valve.
Spool - A term loosely applied to almost any moving cylindrically shaped
part of a hydraulic component that moves to direct flow through the
component.
Strainer - A coarse filter.
Stroke - (1) The length of travel of a piston in a cylinder. (2) Sometimes
used to denote the changing of the displacement of a variable
displacement pump.
Symbols, Schematic - Used as a short-hand on drawings to represent
hydraulic system components.
Tank - See Reservoir.
Torque - The turning force of a hydraulic motor or rotary cylinder.
Usually given in inch-pounds (in-lb) or foot-pounds (ft-lb).
Unidirectional - Moving or rotating in one direction only.
Valve - A device that controls either 1) pressure of fluid, 2) direction
of fluid flow or 3) rate of flow.
Check Valve - A valve that permits flow in only one direction.
Cross-Over Relief Valve - Protects the hydraulic cylinder/motor, hoses,
pump, etc. from high pressure spikes caused by shock loads.
62 GLOSSARY
HYDRAULICS
Counterbalance Valve - Controls the rate of descent and prevents
chatter in cylinder load lowering applications including truck boxes, tilt
bed trailers and cranes.
Directional Control Valve - A valve that directs oil through selected
passages. (Usually a spool or rotary valve design.)
Pressure Reducing Valve - A pressure control valve which limits outlet
pressure.
Sequence Valve - A pressure control valve that directs flow in a preset
sequence.
Relief Valve - A valve that limits the pressure in a system, usually by
releasing excess oil.
Throttle Valve - Restrict the flow of oil to various components in a
hydraulic system. They are adjustable from 0 GPM to their maximum
rated capacity in one direction and capable of full flow in the other
direction.
Unloading Valve - A valve that allows a pump to operate at minimum
load by dumping the pump’s excess oil at a low pressure.
Volt - The difference of potential that would drive one ampere of current
against one ohm resistance.
Voltage Drop - The amount of voltage loss that occurs through all or part
of a circuit due to resistance.
Viscosity - The measure of resistance of a fluid to flow.
Volume - The amount of fluid flow per unit time. Usually given as gallons
per minute (GPM).
Watts - Is a unit of power that can be used to quantify the rate of energy
transfer. (Watts=Volts x Amps).
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GLOSSARY 63
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