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Troubleshooting Hydraulic Circuits: Fluid Power

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The document discusses troubleshooting hydraulic circuits and presents several faulty hydraulic components that can be used for training exercises.

The document discusses directional valves, pressure reducing valves, double-acting cylinders, bidirectional motors/flywheels.

The Troubleshooting Hydraulic Circuits system is used to allow students to develop their skills in troubleshooting hydraulic circuits by incorporating components with intentional faults.

Fluid Power

1-800-Lab-Volt Troubleshooting Hydraulic Circuits


www.labvolt.com

86271-10
Instructor Guide
|3086271100000>~
Fluid Power

Troubleshooting Hydraulic Circuits


Instructor Guide
86271-10

A
First Edition
Published May 2013

© 2009 by Lab-Volt Ltd.


Printed in Canada
All rights reserved

ISBN 978-2-89640-342-4 (Printed version)


ISBN 978-2-89640-674-6 (CD-ROM)

Legal Deposit – Bibliothèque et Archives nationales du Québec, 2009


Legal Deposit – Library and Archives Canada, 2009

No part of this publication may be reproduced, stored in a retrieval system, or transmitted in


any form by any means, electronic, mechanical, photocopied, recorded, or otherwise, without
prior written permission from Lab-Volt Ltd.

Information in this document is subject to change without notice and does not represent a
commitment on the part of Lab-Volt. The Lab-Volt® materials described in this document are
furnished under a license agreement or a nondisclosure agreement.

The Lab-Volt® logo is a registered trademark of Lab-Volt Systems.

Lab-Volt recognizes product names as trademarks or registered trademarks of their


respective holders.

All other trademarks are the property of their respective owners. Other trademarks and trade
names may be used in this document to refer to either the entity claiming the marks and
names or their products. Lab-Volt disclaims any proprietary interest in trademarks and trade
names other than its own.
Safety and Common Symbols

III
Safety and Common Symbols

IV
To the Instructor

The Troubleshooting Hydraulic Circuits system, Model 6080-F, is an add-on to the


Hydraulics Fundamentals system, Model 6080-1. It is used to allow students to
develop their skills in troubleshooting.

The components that have been modified to include faults are:

C Directional Valve, Lever-Operated, Model 6320


C Pressure Reducing Valve, Model 6323
C Double-Acting Cylinder, 2.54-cm Bore, Model 6340
C Double-Acting Cylinder, 3.81-cm Bore, Model 6341
C Bidirectional Motor and Flywheel, Model 6342

How to Use the Faulty Components

In this guide, the faulty components are presented by numerical order with a
description of the mechanical modification, an exercise suggesting where to use the
faulty components, the answers to procedure step questions obtained with the faulty
components, and the answers to Troubleshooting Reports.

The exercises suggested in this manual are taken from the conventional manual
Hydraulics Fundamentals, part number 30794, or from the manuals in job sheet
format corresponding to the five units of the manual Hydraulics Fundamentals. The
manuals in job sheet formats are titled Introduction to Hydraulics (part
number 39888), Fundamentals (part number 39889), Basic Circuits (part
number 39890), Functional Circuits (part number 39891), and Troubleshooting (part
number 39892).

Once the students have completed the Procedure steps of the suggested exercise,
they must complete the Troubleshooting Report shown in Appendix A to demonstrate
that they have correctly identified the component in trouble. It is suggested that you
duplicate the Appendix A and supply a copy to each student group who begins to
troubleshoot a circuit.

Since the students should not know which component is faulty when they perform
the exercises, it is suggested that you setup the circuits to troubleshoot when the
students are absent.

The order in which the faulty components are used is not important.

If you have many hydraulic systems, you can set up many faulty circuits to provide
work for many student groups. In this case, it is suggested to also set up some
circuits without faulty component.

Identification

The faulty components are identified by the letter F or G in the base of the
component. The component must be turned over to see the letter. On the cylinders,
the letter is also engraved on the flange of the cylinder. See Figure 1.

V
To the Instructor

Two Directional Valves, Lever-Operated have been modified. One is identified by the
letter F, and the second by the letter G.

Figure 1. The arrow points toward the letter identifying a faulty component.

Answers to Procedure Step Questions

The answers to procedure step questions that are not affected by the faulty
components are not included in this guide.

Prerequisite

Before performing the troubleshooting tasks suggested in this guide, the students
should have completed the conventional manual Hydraulics Fundamentals, part
number 30794 [or the corresponding manuals in job sheet format titled Introduction
to Hydraulics (part number 39888), Fundamentals (part number 39889), Basic
Circuits (part number 39890), Functional Circuits (part number 39891), and
Troubleshooting (part number 39892)]. This manual (or the corresponding manuals
in job sheet format) is(are) required to perform the exercises suggested in this guide.

Security

C Before a student begins an exercise, ensure that the equipment is in good


condition and does not represent any risk when used.

C Make sure that the students understand the objectives of the work to be done.

VI
Table of Contents

Directional Valve, Lever-Operated, Model 6320-F . . . . . . . . . . . . . . . . . . . . . . 1


Directional Valve, Lever-Operated, Model 6320-G . . . . . . . . . . . . . . . . . . . . . . 3
Pressure Reducing Valve, Model 6323-F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Double-Acting Cylinder, 2.54-cm Bore, Model 6340-F . . . . . . . . . . . . . . . . . 11
Double-Acting Cylinder, 3.81-cm Bore, Model 6341-F . . . . . . . . . . . . . . . . . 13
Bidirectional Motor and Flywheel, Model 6342-F . . . . . . . . . . . . . . . . . . . . . . 17

Appendix A Troubleshooting Report

We Value Your Opinion!

VII
VIII
Troubleshooting Hydraulic Circuits

DIRECTIONAL VALVE, LEVER-OPERATED

Model 6320-F

FAULT DESCRIPTION

The port A of the Directional Valve, Lever-Operated has been partially blocked,
causing an important oil flow rate reduction through this port.

APPLICATION

If you are using the conventional manual Hydraulics Fundamentals, part


number 30794, perform the following:

C Set up the circuit shown in Figure 4-11 of Exercise 4-2 using the faulty
Directional Valve, Lever-Operated, Model 6320-F.
C Ask the students to perform Procedure steps 1 to 19 of Exercise 4-2,
Hydraulic Motor Circuits.

If you are using the manuals in job sheet format, perform the following:

C Set up the circuit shown in Figure 2-4 of Job Sheet 2 in the manual
Functional Circuits (part number 39891) using the faulty Directional
Valve, Lever-Operated, Model 6320-F.
C Ask the students to perform Procedure steps 1 to 19 of Job Sheet 2,
Hydraulic Motor Circuits.

ANSWERS TO PROCEDURE STEP QUESTIONS

G 11.
Note: The students should observe that the flow rate is limited
to approximately 1.3 L/min (0.34 gal(US)min) when the Relief
Valve is set to 2800 kPa (400 psi). They may stop their
experimentation at this moment and start with the
troubleshooting, or continue to detect other symptoms.

1
Troubleshooting Hydraulic Circuits

G 12. With a standard component:

THEORETICAL VOLUMETRIC
FLOW RATE ACTUAL SPEED
SPEED EFFICIENCY

2.0 L/min 920 r/min @


1134 r/min 81% @ 38EC (100EF)
(0.53 gal(US)/min) 38EC (100EF)

2.5 L/min 1250 r/min @


1411 r/min 86% @ 38EC (100EF)
(0.66 gal(US)/min) 38EC (100EF)

3.0 L/min 1580 r/min @


1690 r/min 93% @ 38EC (100EF)
(0.79 gal(US)/min) 38EC (100EF)

Table 4-4 (or job sheet Table 2-2). Motor speed and efficiency versus flow rate.

With the faulty component:

THEORETICAL VOLUMETRIC
FLOW RATE ACTUAL SPEED
SPEED EFFICIENCY

1.3 L/min 630 r/min @


736 r/min 86% @ 38EC (100EF)
(0.34 gal(US)/min) 38EC (100EF)

Unable to set the flow rate to more than 1.3 L/min (0.34 gal(US)/min)

Table 4-4 (or job sheet Table 2-2). Motor speed and efficiency versus flow rate.

TROUBLESHOOTING REPORT

G 1. No. Unable to set the flow rate to the values asked in the exercise
procedure.

G 2. The Power Unit; Supply and/or Return Manifolds; Directional Valve,


Lever-Operated; Motor; Flowmeter; and Flow Control Valve.

G 3. The flow rate is limited by the Directional Valve, Lever-Operated.

Note: The results obtained in Exercise 4-2 of the conventional


manual Hydraulics Fundamentals, part number 30794 (or in
Job Sheet 2 of the manual Function Circuits, part
number 39891) using the faulty Directional Valve, Lever-
Operated, Model 6320-F, are the same as those obtained with
the faulty Bidirectional Motor and Flywheel, Model 6342-F. You
may mention to the students that different components can
cause the same symptom.

2
Troubleshooting Hydraulic Circuits

DIRECTIONAL VALVE, LEVER-OPERATED

Model 6320-G

FAULT DESCRIPTION

The identification of ports A and B has been reversed on the subplate of the
valve. The valve operation is reversed. See Figure 2.

Figure 2. The identification of the ports A and B on the subplate is reversed.

APPLICATION

If you are using the conventional manual Hydraulics Fundamentals, part


number 30794, perform the following:

C Set up the circuit shown in Figure 3-5 of Exercise 3-1 using the faulty
Directional Valve, Lever-Operated, Model 6320-G.

Note: Make sure to connect the hoses as identified on the subplate of


the directional valve to insert the fault in the circuit.

C Ask the students to perform Procedure steps 1 to 30 of Exercise 3-1, Cylinder


Control.

3
Troubleshooting Hydraulic Circuits

If you are using the manuals in job sheet format, perform the following:

C Set up the circuit shown in Figure 1-5 of Job Sheet 1 in the manual Basic
Circuits (part number 39890) using the faulty Directional Valve,
Lever-Operated, Model 6320-G.

Note: Make sure to connect the hoses as identified on the subplate of


the directional valve to insert the fault in the circuit.

C Ask the students to perform Procedure steps 1 to 30 of Exercise 3-1, Cylinder


Control.

ANSWERS TO PROCEDURE STEP QUESTIONS

G 10. With a standard component: Port P connected to port B. Port T


connected to port A.

With the faulty component: Port P connected to port A. Port T


connected to port B.

G 11. With a standard component: Port P connected to port A. Port T


connected to port B.

With the faulty component: Port P connected to port B. Port T


connected to port A.

G 12. With a standard component:

LEVER POSITION POWER UNIT ACTION

MOVED TOWARD VALVE BODY Go down

MOVED OUTWARD FROM VALVE BODY Go up

CENTERED Stationary

Table 3-1 (or job sheet Table 1-1). Power Unit action versus lever position.

With the faulty component:

LEVER POSITION POWER UNIT ACTION

MOVED TOWARD VALVE BODY Go up

MOVED OUTWARD FROM VALVE BODY Go down

CENTERED Stationary

Table 3-1 (or job sheet Table 1-1). Power Unit action versus lever position.

4
Troubleshooting Hydraulic Circuits

G 16. With a standard component:

LEVER POSITION POWER UNIT ACTION

MOVED TOWARD VALVE BODY Go up

MOVED OUTWARD FROM VALVE BODY Go down

CENTERED Stationary

Table 3-2 (or job sheet Table 1-2). Power Unit action versus lever position.

With the faulty component:

LEVER POSITION POWER UNIT ACTION

MOVED TOWARD VALVE BODY Go down

MOVED OUTWARD FROM VALVE BODY Go up

CENTERED Stationary

Table 3-2 (or job sheet Table 1-2). Power Unit action versus lever position.

G 23.
Note: In this step, the students should observe that the Power
Unit is lowering instead of raising when the lever of the
directional valve is moved outward from the valve body.

G 24.
Note: In this step, the students should observe that the Power
Unit is raising instead of lowering when the lever of the
directional valve is moved toward the valve body.

TROUBLESHOOTING REPORT

G 1. No. The Power Unit lowers when it should raise, and raises when it
should lower.

G 2. Bad connections, and the Directional Valve, Lever-Operated.

G 3. Directional Valve, Lever-Operated.

5
6
Troubleshooting Hydraulic Circuits

PRESSURE REDUCING VALVE

Model 6323-F

FAULT DESCRIPTION

The O-rings of the main spool have been removed. This fault allows the oil to
bypass the main spool, and to simultaneously flow through the regulated and tank
ports. The pressure regulation is erratic, and the circuit pressure is limited
because of the oil flow that continuously returns to the tank. See Figure 3.

Figure 3. The O-rings of the main spool have been removed.

APPLICATION

If you are using the conventional manual Hydraulics Fundamentals, part


number 30794, perform the following:

C Set up the circuit shown in Figure 4-18 of Exercise 4-3 using the faulty
Pressure Reducing Valve, Model 6323-F.
C Ask the students to perform Procedure steps 1 to 21 of Exercise 4-3,
Pressure Reducing Valves.

If you are using the manuals in job sheet format, perform the following:

C Set up the circuit shown in Figure 3-6 of Job Sheet 3 in the manual
Functional Circuits (part number 39891) using the faulty Pressure
Reducing Valve, Model 6323-F.
C Ask the students to perform Procedure steps 1 to 21 of Job Sheet 3,
Pressure Reducing Valves.

7
Troubleshooting Hydraulic Circuits

ANSWERS TO PROCEDURE STEP QUESTIONS

G 12. With a standard component: Increasing the circuit pressure does not
increase the pressure level downstream
from the Pressure Reducing Valve since the
pressure reading at Pressure Gauge B
remains stuck at 1400 kPa (200 psi) as the
circuit pressure is increased to 3500 kPa
(500 psi).

With the faulty component: No. Unable to increase the circuit pressure
to 3500 kPa (500 psi).

Note: The students should observe that the circuit pressure is


limited to approximately 3500 kPa (500 psi). They may stop
their experimentation at this moment and start with the
troubleshooting, or continue to observe other symptoms.

G 13. With a standard component: The pressure level downstream from the
Pressure Reducing Valve (Pressure Gauge
B) should still be 1400 kPa (200 psi).

With the faulty component: No, it slightly decreases to 1240 kPa


(180 psi).

G 14. With a standard component: As the load (pressure demand) is


decreased, the oil flow rate increases
downstream from the Pressure Reducing
Valve and the pressure reading at Pressure
Gauge B remains stuck on 1400 kPa
(200 psi). When the pressure demand
becomes lower than the 1400-kPa (200-psi)
setting of the Pressure Reducing Valve, the
oil flow rate stops increasing and the
pressure reading at Pressure Gauge B
begins to drop off until the Flow Control
Valve is fully open. At that point, the load
(pressure demand) is minimum, and the
flow rate is maximum (about 3.5 L/min or
0.92 gal(US)/min), while the pressure level
at Pressure Gauge B is minimum (about
400 kPa (60 psi)).

8
Troubleshooting Hydraulic Circuits

With the faulty component: As the load (pressure demand) is


decreased, the pressure reading at
Pressure Gauge B drops off until the Flow
Control Valve is fully open. At that point, the
load (pressure demand) is minimum, and
the flow rate is about 3.0 L/min
(0.8 gal(US)/min) which is slightly less than
the flow obtained with the standard
component, while the pressure level at
Pressure Gauge B is minimum (about
400 kPa (60 psi)).

G 15. With a standard component: As the pressure demand increases, the


pressure at Pressure Gauge B increases
until it reaches 1400 kPa (200 psi), while
the Flowmeter reading remains at the
maximum flow value. The oil flow rate then
decreases, while the pressure at Pressure
Gauge B remains at 1400 kPa (200 psi).
This is because as the pressure demand
increases downstream from the valve, the
spool inside the Pressure Reducing Valve
moves toward its completely-closed
position, allowing less oil to pass into the
valve to limit the downstream pressure at
the 1400-kPa (200-psi) setting of the valve.

With the faulty component: Conversely to the readings obtained with


the standard component, the Flowmeter
reading does not remain at the maximum
flow value until the pressure at Pressure
Gauge B increases until it reaches
1400 kPa (200 psi). The oil flow rate
decreases as soon as the pressure at
Pressure Gauge B increases.

G 16.
Note: With the faulty component, the circuit pressure at
gauge A is about 2100 kPa (300 psi) instead of 3500 kPa
(500 psi) as obtained with a standard component.

9
Troubleshooting Hydraulic Circuits

TROUBLESHOOTING REPORT

G 1. No. The pressure regulation is erratic, and the circuit pressure is limited
to about 2100 kPa (300 psi).

G 2. The Power Unit; Relief Valve; Pressure Reducing Valve; Pressure


Gauge A; and Pressure Gauge B.

G 3. The Pressure Reducing Valve is leaking.

10
Troubleshooting Hydraulic Circuits

DOUBLE-ACTING CYLINDER, 2.54-CM BORE

Model 6340-F

FAULT DESCRIPTION

The U-cup packings and the magnet of the cylinder piston have been removed.
This modification allows the oil to bypass the piston. The lack in sealing causes a
reduction in power capability of the cylinder. See Figure 4.

Figure 4. The U-cup packings and the magnet of the cylinder piston have been removed.

APPLICATION

If you are using the conventional manual Hydraulics Fundamentals, part


number 30794, perform the following:

C Set up the circuit shown in Figure 1-26 of the Exercise 1-2 using the faulty
Double-Acting Cylinder, 2.54-cm Bore, Model 6340-F.
C Ask the students to perform Procedure steps 12 to 25 of Exercise 1-2,
Demonstration of Hydraulic Power.

If you are using the manuals in job sheet format, perform the following:

C Set up the circuit shown in Figure 2-7 of Job Sheet 2 in the manual
Introduction to Hydraulics (part number 39888) using the faulty Double-Acting
Cylinder, 2.54-cm Bore, Model 6340-F.
C Ask the students to perform Procedure steps 12 to 25 of Job Sheet 2,
Demonstration of Hydraulic Power.

11
Troubleshooting Hydraulic Circuits

ANSWERS TO PROCEDURE STEP QUESTIONS

G 16. With a standard component: The Power Unit should go up until the
piston rod is fully retracted, then it should
stop.

With the faulty component: The Power Unit should go up until the
piston rod is fully retracted. Once the lever
of the Directional Control Valve is released,
the Power Unit should slowly move
downward.

G 18. With a standard component: The cylinder rod should stop. Thereafter,
the Power Unit should remain immobile

With the faulty component: Momentarily, the cylinder rod should stop.
Thereafter, the Power Unit should move
downward because of the lack in sealing.

G 19. With a standard component: No, it should not.

With the faulty component: Yes. The Power Unit may be already lying
on the floor.

TROUBLESHOOTING REPORT

G 1. No. The Power Unit moves downward when the Directional Valve, Push-
Button Operated is at the center position (which is a blocked center).

G 2. The Directional Valve, Lever-Operated, and the Double-Acting Cylinder,


2.54-cm Bore.

G 3. The piston of the Double-Acting Cylinder, 2.54-cm Bore is leaking.

Note: The students may use another Directional Valve, Lever-


Operated or Double-Acting Cylinder, 2.54-cm Bore to identify
the faulty component with certitude.

12
Troubleshooting Hydraulic Circuits

DOUBLE-ACTING CYLINDER, 3.81-CM BORE

Model 6341-F

FAULT DESCRIPTION

A restriction has been added to the quick-connect fitting at the rod-end of the
cylinder. This restriction limits the oil flow rate causing the extension and
retraction times of the cylinder rod to be longer.

APPLICATION

If you are using the conventional manual Hydraulics Fundamentals, part


number 30794, perform the following:

C Set up the circuit shown in Figure 3-5 of Exercise 3-1 using the faulty Double-
Acting Cylinder, 3.81-cm Bore, Model 6341-F.
C Ask the students to perform the Procedure steps of Exercise 3-1, Cylinder
Control.

If you are using the manuals in job sheet format, perform the following:

C Set up the circuit shown in Figure 1-5 of Job Sheet 1 in the manual Basic
Circuits (part number 39890) using the faulty Double-Acting Cylinder, 3.81-cm
Bore, Model 6341-F.
C Ask the students to perform the Procedure steps of Job Sheet 1, Cylinder
Control.

ANSWERS TO PROCEDURE STEP QUESTIONS

G 23. With a standard component:

PRESSURE
SYSTEM PRESSURE RETRACTION TIME
CYL. MOVING CYL. STOPPED

2800 kPa (400 psi) 2.5 s @ 38EC (100EF) 1700 kPa (250 psi) 2800 kPa (400 psi)

3500 kPa (500 psi) 2.5 s @ 38EC (100EF) 1700 kPa (250 psi) 3500 kPa (500 psi)

Table 3-3 (or job sheet Table 1-3). Effect of pressure control on cylinder speed.

13
Troubleshooting Hydraulic Circuits

With the faulty component:

PRESSURE
SYSTEM
RETRACTION TIME
PRESSURE
CYL. MOVING CYL. STOPPED

2800 kPa (400 psi) 5 s @ 38EC (100EF) 2700 kPa (390 psi) 2800 kPa (400 psi)

3500 kPa (500 psi) 5 s @ 38EC (100EF) 3400 kPa (490 psi) 3500 kPa (500 psi)

Table 3-3 (or job sheet Table 1-3). Effect of pressure control on cylinder speed.

G 29. With a standard component: Pressure Gauge A showed the pressure


needed to overcome the resistance of the
load on the cylinder. This resistance
corresponds to the weight of the Power Unit
plus the resistance of the Flow Control
Valve. The pressure will not change
because the weight of the Power Unit and
the resistance of the Flow Control Valve do
not change as the Relief Valve pressure
setting is modified.

With the faulty component: Pressure Gauge A shows different pressure


values for the two relief valve settings. This
means that the pressure indicated by this
meter does not correspond only to the
weight of the Power Unit plus the resistance
of the Flow Control Valve. Another
resistance is present in the circuit.

G 34. With a standard component:

FLOW CONTROL VALVE SETTING RETRACTION TIME

1 TURN OPEN 3 s @ 38EC (100EF)

3 TURNS OPEN 2 s @ 38EC (100EF)

Table 3-4 (or job sheet Table 1-4). Effect of flow control on cylinder speed.

With the faulty component:

FLOW CONTROL VALVE SETTING RETRACTION TIME

1 TURN OPEN 6 s @ 38EC (100EF)

3 TURNS OPEN 4 s @ 38EC (100EF)

Table 3-4 (or job sheet Table 1-4). Effect of flow control on cylinder speed.

14
Troubleshooting Hydraulic Circuits

TROUBLESHOOTING REPORT

G 1. No. The extension and retraction times of the cylinder rod are much
longer than normal. The cylinder seems to operate with difficulty.

G 2. The Power Unit; Supply and/or Return Manifolds; Directional Valve,


Lever-Operated; Flowmeter; Flow Control Valve; and Double-Acting
Cylinder, 3.81-cm Bore.

G 3. The Double-Acting Cylinder, 3.81-cm Bore operation is erratic.

15
16
Troubleshooting Hydraulic Circuits

BIDIRECTIONAL MOTOR AND FLYWHEEL

Model 6342-F

FAULT DESCRIPTION

One of the quick-connect fittings of the Motor has been partially blocked causing
an important oil flow rate reduction through this fitting.

APPLICATION

If you are using the conventional manual Hydraulics Fundamentals, part


number 30794, perform the following:

C Set up the circuit shown in Figure 4-11 of Exercise 4-2 using the faulty
Bidirectional Motor and Flywheel, Model 6342-F.
C Ask the students to perform Procedure steps 1 to 19 of Exercise 4-2, Hydraulic
Motor Circuits.

If you are using the manuals in job sheet format, perform the following:

C Set up the circuit shown in Figure 2-4 of Job Sheet 2 in the manual Functional
Circuits (part number 39891) using the faulty Bidirectional Motor and Flywheel,
Model 6342-F.
C Ask the students to perform Procedure steps 1 to 19 of Job Sheet 2, Hydraulic
Motor Circuits.

ANSWERS TO PROCEDURE STEP QUESTIONS

G 11.
Note: The students should observe that the flow rate is limited
to approximately 1.3 L/min (0.34 gal(US)/min) when the Relief
Valve is set to 2800 kPa (400 psi). They may stop their
experimentation at this moment and start with the
troubleshooting, or continue to detect other symptoms.

17
Troubleshooting Hydraulic Circuits

G 12. With a standard component:

THEORETICAL VOLUMETRIC
FLOW RATE ACTUAL SPEED
SPEED EFFICIENCY

2.0 L/min 920 r/min @


1134 r/min 81% @ 38EC (100EF)
(0.53 gal(US)/min) 38EC (100EF)

2.5 L/min 1250 r/min @


1411 r/min 86% @ 38EC (100EF)
(0.66 gal(US)/min) 38EC (100EF)

3.0 L/min 1580 r/min @


1690 r/min 93% @ 38EC (100EF)
(0.79 gal(US)/min) 38EC (100EF)

Table 4-4 (or job sheet Table 2-2). Motor speed and efficiency versus flow rate.

With the faulty component:

THEORETICAL VOLUMETRIC
FLOW RATE ACTUAL SPEED
SPEED EFFICIENCY

1.3 L/min 630 r/min @ 86% @


736 r/min
(0.34 gal(US)/min) 38EC (100EF) 38EC (100EF)

Unable to set the flow rate to more than 1.3 L/min (0.34 gal(US)/min)

Table 4-4 (or job sheet Table 2-2). Motor speed and efficiency versus flow rate.

TROUBLESHOOTING REPORT

G 1. No. Unable to set the flow rate to the values shown in the exercise
procedure.

G 2. The Power Unit; Supply and/or Return Manifolds; Directional Valve,


Lever-Operated; Motor; Flowmeter, and Flow Control Valve.

G 3. The flow rate is limited by the Motor.

Note: The results obtained in Exercise 4-2 of the conventional


manual Hydraulics Fundamentals, part number 30794 (or in
Figure 2-4 of Job Sheet 2 of the manual Function Circuits, part
number 39891) using the faulty Directional Valve, Lever-
Operated, Model 6320-F, are the same as those obtained with
the faulty Bidirectional Motor and Flywheel, Model 6342-F. You
may mention to the students that different components can
cause the same symptom.

18
Appendix A
Troubleshooting Report

G 1. Once the Procedure steps are completed, can you conclude that the
circuit operates normally? If not, describe the symptom(s).

G 2. Identify the component(s) that can cause the fault.

G 3. Analyze your circuit and/or test the suspected components (out of the
circuit or by modifying the circuit connections) to identify the component
that is the most probable cause of the fault. You may also compare the
actual results with those previously obtained with the standard
components.

Name the faulty component and give a brief description of the fault
(where applicable, describe your approach to identify the component).

G 4. Ask the instructor to validate your conclusion.

A-1
We Value Your Opinion!

Your comments and suggestions help us produce better manuals and develop
innovative systems to meet the needs of our users. Please contact us by e-mail at:

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