HYdrAUliC SYSTEm rEqUirEmEnTS

Hydraulic systems come in many formsfrom those found in the simple hydraulic jack to the more sophisticated systems found in earth moving equipment. The system required to operate most hydraulic tools found in this catalog would require 8 gpm / 30 lpm and be capable of providing system pressure up to 2000 psi / 140 bar.. This system is referred to as a Type II, as classified by the Hydraulic Tool Manufacturers Association (HTMA). But there are also 3 other classifications. They are discussed below.

rETUrn PrESSUrE:
The hydraulic systems should generate no more than 250 psi / 17 bar return pressure (back pressure) at the tool when operating at maximum flow for the tool type. System conditions for this pressure are at maximum hydraulic fluid viscosity of 400 SUS (SSU) at minimum operating temperature.

COOlinG:

HYdrAUliC TOOl mAnUFACTUrErS ASSOCiATiOn (HTmA) rEqUirEmEnTS

Hydraulic tools fall into 4 classifications, Type I, Type II, Type III, and Type RR as set by HTMA. The system requirements for powering these tools are as follows: Type I Type II Type III Type RR 5 8 12 10 gpm 10% / 19 lpm gpm 10% / 30 lpm gpm 10% / 45 lpm gpm 10% / 38 lpm

The hydraulic systems should have sufficient heat rejection capacity to limit maximum oil temperature to 140F/60C at the maximum expected ambient temperature. Recommended minimum cooling capacities to dissipate toolgenerated heat are: Type I Type II Type III Type RR 3 Horsepower / 2.24 kW 5 Horsepower / 3.73 kW 7 Horsepower / 5.22 kW 6 Horsepower / 5.22 kW

When determining cooling capacity, the intended duty cycle and the system generated heat must both be considered.

OPErATinG PrESSUrE:
Hydraulic systems should be capable of providing the appropriate operating pressure and flow for the system types noted above when measured across the tool connections. Deviation from the nominal flow rates should be no more than plus or minus 10% at a operating pressure of 2000 psi / 138 bar. This is the pressure that the tools will normally operate at which is not to be confused with the relief pressure.

FilTrATiOn:
Systems should have 25 micron nominal filtration for the hydraulic fluid. Recommended filter element size is at least three times system rated flow to prevent filter bypass under low temperature start-up.

FlUid: rEliEF PrESSUrE:

Hydraulic systems should be capable of limiting the maximum pressure by using either a pressure compensating pump or a relief valve with a nonpressure compensating pump. The system pressure limiting component shall begin to control the maximum pressure at no less than 2150 psi. This is commonly known as the cracking pressure. The system pressure limiting component shall limit the maximum pressure to 2250 psi for a Type I, Type II, or Type III tool. The system pressure limiting component shall limit the maximum pressure to 2500 psi for a Type RR tool. Hydraulic systems should use hydraulic fluid that has a viscosity of 130-225 SSU / 27-42 cst at l00 F / 38 C. Hydraulic fluids of petroleum base with antiwear properties and high viscosity indexes over 140 will meet recommended hydraulic fluid requirements over a wide range of operating temperatures. They should be demulsifying type to allow water to settle out of the fluid.

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HYdrAUliC BASiCS
THE BASiC PrinCiPlE OF HYdrAUliCS FOr TOOl OPErATiOn
The basic principle of hydraulics used for tool operation can be compared with a typical household water system. The typical rotary car-wash brush tool, that is operated from water through a garden hose, is in actuality a hydraulic tool. Water rushing through the garden hose drives a small motor in the car-wash tool which, in turn, rotates the brush. However, it is not just the rushing water that is driving the motor. There is also pressure associated with the rushing waterabout 60 pounds per square inch (psi). Without the pressure, the tool would have no power. Without pressure, any force applied to the tool, such as pushing down on the tool, would stall the tool. Water rushing through the hose (or the flow of water) is measured in gallons per minute (gpm) and results in the speed of the tool (in the case of the car-wash tool, the speed of the brush). Pressure associated with the water provides power to the tool. The same principle applies in one of our tools. In a breaker, for example, the flow results in the speed of the tool and the resistance to that flow creates a demand for pressure. If the system has the capacity to deliver the pressure, power is transmitted to the tool to do work. Hydraulic tools actually use less flow (gpm) than that produced through a garden hose. The pressure, however, is considerably higher. Hydraulic tools require pressures up to 2000 psi but only need 5 to 10 gpm to operate effectively. Of course, a typical HTMA hydraulic system returns fluid to a reservoir for re-use as opposed to the household water system that spills fluid to waste. the tool causing the tool to operate, and then returns to the reservoir. Pressure tends to be constant in the system. Pressure will increase as the tool needs it up to the settings in the hydraulic system. And if pressures higher than the system setting are demanded by the work, flow will decrease.

FlUid TEmPErATUrE
The following information will serve to assist those installing hydraulics in mobile applications for handheld tools. While many hydraulic circuits can run upwards to 200F, temperatures over 110F / 43C are uncomfortable to human touch. Our desire is to hold oil temperature to a maximum of 140F / 43C. In almost any hydraulic tool circuit, oil cooling methods will be required except for very short periods of operation or in underwater and extreme cold environments. If you are involved in the design of a hydraulic tool circuit, use the following as guidelines.

BASiC dOnTS FOr COOl Oil COnTrOl

1. dOnT Rely on a large reservoir to control oil heating. Large reservoirs, even with good air circulation, do not adequately dissipate heat. 2. dOnT Set relief pressure too low (open-center circuits) for percussion type tools (breakers, hammer drills, etc.). Pressure peaks may run up to 350 PSI over gauge pressure, popping the relief and causing heat as well as low tool performance. 3. dOnT Pump more oil than the tool should use and avoid flow controls if possible. Instead, size the pump for desired flow volume. Gear type flow dividers can be used to reduce flow more efficiently than valves, reducing heat. 4. dOnT Use heavy oils such as 30W or 10W30 engine oils. These will cause resistance in lines and add to backpressure and heat. 5. dOnT Run return oil through control valves or other circuit components, except coolers and return line filters.

OPEn-CEnTEr And ClOSEd-CEnTEr SYSTEmS

There are two basic types of hydraulic systems Open-Center and Closed-Center.

OPEn-CEnTEr iS COnSTAnT FlOw VAriABlE PrESSUrE

When a tool valve is in the OFF position, hydraulic oil flows through the ON/OFF valve ports of the tool and back to the reservoir. The system is constantly flowing oil through the tool valve ports and back to the reservoir at no pressure. When the tool valve is ON, oil circulates through the tool causing the tool to operate, and then returns to the reservoir. Pressure is created when resistance to flow is sensed by the system. This occurs when the tool is put to work. Pressure will increase as the tool needs it up to the relief setting in the hydraulic system.

dO THE FOllOwinG TO rEdUCE HEAT GEnErATiOn

1. Operate pumps at moderate speed gear pumps usually generate less heat and are less prone to cavitation at speeds of 1,000-2,000 RPM. 2. Use generous line sizes Especially on pump suction and return from tool to tank. 3. Use oils in 130-225 SSU at l00 F / 38 C range with high viscosity index. (see hydraulic fluid recommendations at the end of this section)

PrOVidE GOOd COOlinG FOr HYdrAUliC Oil ClOSEd-CEnTEr iS COnSTAnT PrESSUrE VAriABlE FlOw
When a tool valve is in the OFF position, hydraulic oil flow stops at the ON/ OFF valve port of the tool. The system will build and hold pressure without returning oil to the reservoir. When the tool valve is ON, oil circulates through 1. Use an air-to-oil cooler of maximum size for space available. Use a shrouded, high capacity fan. Many vehicles do not cool well when parked with engine at low speed. Do NOT use a thermal viscous-drive fan because these fans do not draw air unless the engine is hot.

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HYdrAUliC BASiCS
FlOw COnTrOlS
1. General Notes To reduce or control flow rate through Stanley Tools, flow control valves are sometimes necessary. All possible effort should be made to avoid use of flow control valves where appropriate pump volume can be used because: A. Excess oil volume and subsequent pressure drop generates heat. B. When percussion type tools that generate pressure pulses are used, flow controls may oscillate and cause flow changes which reduce tool performance and add increased heating. 2. Flow Control of Open-Center Circuits Always use a priority type pressure-compensated flow control. This will prevent relief popping and reduce heat build-up. The excess flow should be routed in an unrestricted manner to the reservoir. 3. Flow Control of Closed-Center Circuits Use a two-port, pressurecompensated flow control. Some of these are very compact, in the range of 1-1/4 diameter by 5 long, and can be attached to the tool pressure pigtail. Do not use priority type controls on closed-center circuits, as this will cause the pump to operate at full volume further heating the oil.

HOSE TYPES
The rated working pressure of the hydraulic hose must be equal to or higher than the relief valve setting on the hydraulic system. There are three types of hydraulic hose that meet this requirement and are authorized for use with Stanley Hydraulic Tools. They are: Certified non-conductive - constructed of thermoplastic or synthetic rubber inner tube, synthetic fiber braid reinforcement, and weather resistant thermoplastic or synthetic rubber cover. Hose labeled certified non-conductive is the only hose authorized for use near electrical conductors. Wire-braided (conductive) - constructed of synthetic rubber inner tube, single or double wire braid reinforcement, and weather resistant synthetic rubber cover. This hose is conductive and must never be used near electrical conductors. Fabric-braided (not certified or labeled non-conductive) - constructed of thermoplastic or synthetic rubber inner tube, synthetic fiber braid reinforcement, and weather resistant thermoplastic or synthetic rubber cover. This hose is not certified non-conductive and must never be used near electrical conductors.

qUiCk diSCOnnECTS
1. Only use quick disconnects matching hose diameters. i.e. 1/2 inch port quick disconnect for 1/2 inch inside diameter hose. 2. Use as few quick disconnects as possible and avoid using adapter fittings with quick disconnects. Fittings and quick disconnects, while necessary, create flow restriction which causes heat and reduced tool performance. 3. Always use HTMA recommended quick disconnects that are flush-faced and dripless.

TOOl TO CirCUiT HOSE rECOmmEndATiOnS

Oil Flow gPM 5-8 5-8 lPM 19-30 19-30 Each Hose length FEET up to 50 51-100 METErS up to 15 15-30 inside diameter USE INCH 1/2 5/8 5/8 5-8 19-30 100-300 30-90 3/4 NOTE: SAE 100R16 may be used in place of SAE 100R2 19 return SAE 100r1-12 1250 86 SAE 100r7-12 1250 86 MM 13 16 16 Both Both Pressure wire Braid Hose Spec SAE 100r17-8 SAE 100r17-10 SAE 100r2-10 working Pressure PSI 3000 3000 2750 BAr 230 230 190 Fiber Braid Hose Spec SAE 100r7-8 SAE 100r8-10 SAE 100r8-10 Operating Pressure PSI 2000 2750 2750 BAr 140 190 190

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SYSTEm SPECiFiCATiOnS
FlUidS FOr mOBilE HYdrAUliC TOOl CirCUiTS
The specification listed here will provide good all season operation if your circuit is of proper design and normal maintenance is performed. (Periodic filter change, draining of condensate, etc.)
SPECiFiCATiOnS item
Viscosity (Fluid Thickness) Viscosity (Fluid Thickness) Viscosity (Fluid Thickness) Pour Point (Min.for cold startup) Viscosity Index demulsibility Flash Point rust Inhibition oxidation Pump Wear Test Biodegradability

rECOmmEndEd FlUidS
The fluids listed here work well over a wide temperature range at start-up, allow moisture to settle out, and resist biological growth likely in cool-operating hydraulic circuits. These fluids are recommended by Stanley Hydraulic Tools for use in our tools. Other fluids that meet or exceed the specifications of these fluids may also be used. Biodegradable fluids listed are compatible with all tool seals and hoses.
rECOmmEndEd FlUidS

U.S.A.
50 F 450 SSu Max. 100 F 130-225 SSu 140 F 85 SSE Min. -10 F (ASTM d2220) (ASTM d1401) (ASTM d92) (ASTM d665 A&B) (ASTM d943) (ASTM d2882) CEC-l-33-A94

metric
10 C 95 Centistokes Max. 38 C 27-42 Centistokes 60 C 16.5 Centistokes Min. 23 C 140 Minimum 30 Minutes Max. 340 F Min. Pass 1000 Hours Min. 60 mg Max. >60%

Brand
AMS-oil Chevron Exxon Mobil gulf Shell Sun Texaco union Mobil Texaco Terresolve Shell Pennzoil

Biodegradable
No No No No No No No No No Yes Yes Yes Yes Yes

description
Hydraulic Fluid MN 150 SSu,100 V.I. AW-MV-32 univis J-26 d.T.E.13 Harmony AW-HVI-1 50-32 lo-Hydraul 32 or Tellus T-32 Sunvis 805 Mg rando Hd-AZ unax AW-Wr-32 EAl 224H BioStar 32 Envirologic 132 Naturelle HF-E-32 Pennzsafe Sl200

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SYSTEm SPECiFiCATiOnS
HYdrAUliC SYSTEm SPECiFiCATiOnS SUiTABlE FOr POwErinG HTmA TYPE i HYdrAUliC TOOlS
GEnErAl SPECiFiCATiOnS
The following specifications are for a hydraulic system which will deliver the performance of an HTMA Type 1 system. The HTMA Type 1 system has a flow requirement of 5 gpm, plus or minus 10%. The hydraulic system shall be an open-center type system and deliver the design flow rate over a pressure load range of 1000 to 2000 psi. Alternatively, the system may be a closed-center type having the same hydraulic performance. The system pressure limiting component shall begin to control at a pressure no less than 2150 psi and shall limit the maximum pressure to no more than 2250 psi / 155 bar. This component may be a relief valve, used with a nonpressure compensating pump system, or the pressure control used with a pressure-compensating pump system. The flow loss in the return side of the system must be low enough so that the return pressure (back pressure), when measured at the tool end of the tool hose is not more than 250 psi. This measurement is to be made with the system at minimum operating temperature and the hydraulic oil viscosity no higher than 400 SSU / 86 cst. For ISO Grade 32 hydraulic oil, the system temperature will be approximately 50 deg F / 10 deg C. The hydraulic system shall have sufficient heat rejection capacity to limit the maximum oil temperature to 140 deg F / 60 deg C at the maximum expected ambient temperature. The minimum cooling capacity to dissipate tool-generated heat is 3 hp / 7,635 BTU/hr. This cooling capacity may be modified taking into consideration intended tool operation duty cycle and system generated heat. The hydraulic system shall have a return line filter rated for 25 micron nominal filtration. The filter shall have a flow capacity of at least 15 gpm. The hydraulic system shall use a fluid which has a viscosity of 150-225 SSU / 32-50 cst at 100 deg F / 38 deg C. Hydraulic fluids of petroleum base with anti-wear properties and high viscosity indexes over 140 will meet fluid requirements over an wide range of operating temperatures.

dETAil SPECiFiCATiOnS
The hydraulic reservoir shall be of a metal construction with a fluid holding capacity of 8 to 13 gallons. The reservoir shall include a vented filler/ breather with a filter basket. It shall have a 140-mesh or 125 micron pump suction strainer located near the bottom and a rigid internal baffle to prevent direct cross flow from return to suction. The fluid return shall be below the lowest fluid level in order to prevent air entrainment. The reservoir shall include a fluid level indicator to show fluid level from the minimum requiring fill to the maximum showing full. It shall include a drain, low near the bottom, to provide for draining settled-out water or complete emptying of the reservoir. There shall be provision for access to the inside for servicing the suction strainer and cleaning the reservoir. The fluid line from the reservoir to the pump suction port shall have an inside diameter of 1.25 inches / 32 mm. The pump shall be sized to deliver the system design flow at a shaft speed determined by the prime mover speed and any speed reduction between it and the pump. For vehicles with automatic transmissions, the engine speed should be between 1700 and 2000 rpm. For example, if the power takeoff speed ratio is .75, then the pump speed will be 1275 to 1500 rpm. The pump displacement will be between 0.770 and 0.906 cubic inches per rev. For a fixed-displacement pump, these displacements will be that of the pump. For variable-displacement pumps, these displacements with be the pump displacement setting while operating the hydraulic tool system. The pump shall have a maximum pressure rating of at least 3000 psi. The pressure line from the pump outlet to the directional valve shall have an inside diameter of 0.75 inches / 19 mm. The working pressure of the line shall be at least 2500 psi. If no bi-directional tools will be used, the directional control valve shall be -inch size two-position two-port or three-port diverter valve. Only the pressure side flow will go through the valve. For an open-center system, in the OFF position the valve will bypass flow to the system return; in the ON position the valve will block the bypass to the system return. For a closedcenter system, in the OFF position the valve will block the pump port and connect the tool to the return; in the ON position the valve will connect the pump to the tool. It must be rated for working pressure of at least 2500 psi. If bi-directional tools will be used, the directional control valve shall be a -inch size three-position, four-port valve. The valve spool shall be a motor spool. For an open-center system, all ports must be connected to the tank port in the neutral position. For a closed-center system, the tool ports must be connected together. It must be rated for working pressure of at least 2500 psi.

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SYSTEm SPECiFiCATiOnS
The relief valve may be a separate component or integral to the directional control valve. It may be either direct operating or pilot operated. It shall be set with the cracking pressure at 2150 psi. The maximum full-flow bypass pressure shall not be more than 2250 psi. The air-to-oil cooler must be sized and placed to have the required heat rejection capacity. If the vehicle engine does not have a temperaturecontrolled fan, the oil cooler may be mounted in front of the vehicle radiator. The cooler will be the largest that will cover the radiator and must be at least 1 inches thick. The oil cooler must have low enough air flow resistance so as not to seriously reduce the vehicle cooling capacity. If the vehicle has a temperature-controlled fan, then an air-to-oil cooler with fan(s) must be selected. This cooler must be installed where it will have unimpeded air flow. The ports in the cooler shall be at least 1-inch size. Integral to the cooler or separately installed with the cooler shall be a bypass check valve or thermal diverter valve to allow fluid to bypass the cooler at low temperatures and high viscosities until the fluid temperature reaches working temperatures. If a thermal diverter valve is used, it should have a temperature setting between 85 and 95 deg F / 29 and 35 deg C. If a separately-fanned cooler is selected, it shall have a thermal switch to turn on the fan(s) when oil flows through the cooler. The system return lines shall have an inside diameter of .75 or 1.00 inch. The lines shall have a working pressure rating of at least 250 psi. The hydraulic system shall have HTMA flush-face quick-acting couplers for connecting tools to the system. The coupler nose shall be on the pressure port and the coupler body shall be on the return port. These will be located according to the requirements of the end-user. All connections shall be assembled and sealed to assure there will be no leaks. All components shall be suitable for mobile hydraulic systems and have flow capacity and working pressures which meet the requirements of the system. All lines shall be installed and restrained to prevent contact with hot engine components and prevent fatigue failure due to vibration or abrasion. The system shall be flushed clean and filled with clean hydraulic fluid. The system will be accepted after verification by the customer that the system performance meets specifications.

HYdrAUliC SYSTEm SPECiFiCATiOnS SUiTABlE FOr POwErinG HTmA TYPE ii HYdrAUliC TOOlS
GEnErAl SPECiFiCATiOnS
The following specifications are for a hydraulic system which will deliver the performance of an HTMA Type 2 system. The HTMA Type 2 system has a flow requirement of 8 gpm, plus or minus 10%. The hydraulic system shall be an open-center type system and deliver the design flow rate over a pressure load range of 1000 to 2000 psi. Alternatively, the system may be a closed-center type having the same hydraulic performance. The system pressure limiting component shall begin to control at a pressure no less than 2150 psi and shall limit the maximum pressure to no more than 2250 psi / 155 bar. This component may be a relief valve, used with a nonpressure compensating pump system, or the pressure control used with a pressure-compensating pump system. The flow loss in the return side of the system must be low enough so that the return pressure (back pressure), when measured at the tool end of the tool hose is not more than 250 psi. This measurement is to be made with the system at minimum operating temperature and the hydraulic oil viscosity no higher than 400 SSU / 86 cst. For ISO Grade 32 hydraulic oil, the system temperature will be approximately 50 deg F / 10 deg C. The hydraulic system shall have sufficient heat rejection capacity to limit the maximum oil temperature to 140 deg F / 60 deg C at the maximum expected ambient temperature. The minimum cooling capacity to dissipate tool-generated heat is 5 hp / 12,725 BTU/hr. This cooling capacity may be modified taking into consideration intended tool operation duty cycle and system generated heat. The hydraulic system shall have a return line filter rated for 25 micron nominal filtration. The filter shall have a flow capacity of at least 25 gpm. The hydraulic system shall use a fluid which has a viscosity of 150-225 SSU / 32-50 cst at 100 deg F / 38 deg C. Hydraulic fluids of petroleum base with anti-wear properties and high viscosity indexes over 140 will meet fluid requirements over an wide range of operating temperatures.

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SYSTEm SPECiFiCATiOnS
dETAil SPECiFiCATiOnS
The hydraulic reservoir shall be of a metal construction with a fluid holding capacity of 12 to 20 gallons. The reservoir shall include a vented filler/ breather with a filter basket. It shall have a 140-mesh or 125 micron pump suction strainer located near the bottom and a rigid internal baffle to prevent direct cross flow from return to suction. The fluid return shall be below the lowest fluid level in order to prevent air entrainment. The reservoir shall include a fluid level indicator to show fluid level from the minimum requiring fill to the maximum showing full. It shall include a drain, low near the bottom, to provide for draining settled-out water or complete emptying of the reservoir. There shall be provision for access to the inside for servicing the suction strainer and cleaning the reservoir. The fluid line from the reservoir to the pump suction port shall have an inside diameter of 1.25 inches / 32 mm. The pump shall be sized to deliver the system design flow at a shaft speed determined by the prime mover speed and any speed reduction between it and the pump. For vehicles with automatic transmissions, the engine speed should be between 1700 and 2000 rpm. For example, if the power takeoff speed ratio is .75, then the pump speed will be 1275 to 1500 rpm. The pump displacement will be between 1.449 and 1.232 cubic inches per rev. For a fixed-displacement pump, these displacements will be that of the pump. For variable-displacement pumps, these displacements with be the pump displacement setting while operating the hydraulic tool system. The pump shall have a maximum pressure rating of at least 3000 psi. The pressure line from the pump outlet to the directional valve shall have an inside diameter of 0.75 inches / 19 mm. The working pressure of the line shall be at least 2500 psi. If no bi-directional tools will be used, the directional control valve shall be -inch size two-position two-port or three-port diverter valve. Only the pressure side flow will go through the valve. For an open-center system, in the OFF position the valve will bypass flow to the system return; in the ON position the valve will block the bypass to the system return. For a closedcenter system, in the OFF position the valve will block the pump port and connect the tool to the return; in the ON position the valve will connect the pump to the tool. It must be rated for working pressure of at least 2500 psi. If bi-directional tools will be used, the directional control valve shall be a -inch size three-position, four-port valve. The valve spool shall be a motor spool. For an open-center system, all ports must be connected to the tank port in the neutral position. For a closed-center system, the tool ports must be connected together. It must be rated for working pressure of at least 2500 psi. The relief valve may be a separate component or integral to the directional control valve. It may be either direct operating or pilot operated. It shall be set with the cracking pressure at 2150 psi. The maximum full-flow bypass pressure shall not be more than 2250 psi. The air-to-oil cooler must be sized and placed to have the required heat rejection capacity. If the vehicle engine does not have a temperaturecontrolled fan, the oil cooler may be mounted in front of the vehicle radiator. The cooler will be the largest that will cover the radiator and must be at least 1 inches thick. The oil cooler must have low enough air flow resistance so as not to seriously reduce the vehicle cooling capacity. If the vehicle has a temperature-controlled fan, then an air-to-oil cooler with fan(s) must be selected. This cooler must be installed where it will have unimpeded air flow. The ports in the cooler shall be at least 1-inch size. Integral to the cooler or separately installed with the cooler shall be a bypass check valve or thermal diverter valve to allow fluid to bypass the cooler at low temperatures and high viscosities until the fluid temperature reaches working temperatures. If a thermal diverter valve is used, it should have a temperature setting between 80 and 90 deg F / 26 and 32 deg C. If a separately-fanned cooler is selected, it shall have a thermal switch to turn on the fan(s) when oil flows through the cooler. The system return lines shall have an inside diameter of .75 or 1.00 inch. The lines shall have a working pressure rating of at least 250 psi. The hydraulic system shall have HTMA flush-face quick-acting couplers for connecting tools to the system. The coupler nose shall be on the pressure port and the coupler body shall be on the return port. These will be located according to the requirements of the end-user. All connections shall be assembled and sealed to assure there will be no leaks. All components shall be suitable for mobile hydraulic systems and have flow capacity and working pressures which meet the requirements of the system. All lines shall be installed and restrained to prevent contact with hot engine components and prevent fatigue failure due to vibration or abrasion. The system shall be flushed clean and filled with clean hydraulic fluid. The system will be accepted after verification by the customer that the system performance meets specifications.

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SYSTEm SPECiFiCATiOnS
TESTinG A HYdrAUliC SYSTEm FOr COmPAriSOn TO HTmA rECOmmEndATiOnS
The objective of this test is to determine how your hydraulic system performance compares with HTMA (Hydraulic Tool Manufacturers Association) recommended hydraulic system performance. To perform these tests, you will need a flow and pressure tester such as our P/N 04182 or P/N 29085 shown below and two thermometers (the P/N 29085 has a built-in thermometer).

HTmA rECOmmEndATiOnS FOr A HYdrAUliC SYSTEm OPErATinG TYPE ii HYdrAUliC TOOlS:

8 gpm 10% / .8 gpm at 2000 psi measured at the tool inlet. 200 psi or less return pressure at 8.8 gpm, pressure measured at the tool outlet. Limit system temperature to 140 F on the hottest expected day. Choosing 100 F as the hottest expected days temperature, the hydraulic system must maintain a 40 degree temperature difference, air to oil. For example, if the ambient air temperature is 100 F, then the oil temperature should not exceed 140 F. To simulate tool-generated heat during operation, HTMA recommends using 5 hp, minimum. A reading of 1100 psi minimum at 8 gpm at the flow and pressure tester will achieve the recommended 5 hp, minimum. Select an open site where the air is relatively calm. Place one thermometer in the oil reservoir to measure the temperature of the circulating oil (surface mounted tank thermometers do not adequately measure the temperature of the bulk system oil). Hang the other thermometer in still air to measure the ambient air temperature. Connect the flow and pressure tester to the tool hoses. Fully open the load valve on the tester. Start up the system (with tool circuit control valve OFF) and warm the hydraulic fluid (if necessary) to a minimum of 50 F.

Stanley P/N 04182

Stanley P/N 29085

HTmA rECOmmEndATiOnS FOr A HYdrAUliC SYSTEm OPErATinG TYPE i HYdrAUliC TOOlS:

5 gpm 10% / .5 gpm at 2000 psi measured at the tool inlet. 200 psi or less return pressure at 5.5 gpmpressure measured at the tool outlet. Limit system temperature to 140 F on the hottest expected day. Choosing 100 F as the hottest expected days temperature, the hydraulic system must maintain a 40 degree temperature difference, air to oil. For example, if the ambient air temperature is 100 F, then the oil temperature should not exceed 140 F. To simulate tool-generated heat during operation, HTMA recommends using 3 hp, minimum. A reading of 1030 psi minimum at the flow and pressure tester will achieve the recommended 3 hp, minimum.

lOw TEmPErATUrE And mAXimUm ViSCOSiTY BACk PrESSUrE TEST

Turn ON the tool circuit control valve. Record oil temperature, ambient air temperature, flow rate, and back pressure. Air: ________________ F Oil: ________________ F Flow rate: ________________ gpm Back pressure: ________________ psi

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SYSTEm SPECiFiCATiOnS
HYdrAUliC SYSTEmS CAPACiTY TO dEliVEr FlOw AGAinST 2000 PSi TEST
Close the load valve to where the pressure gage reads 2000 psi. Record flow rate, back pressure, and oil temperature. Flow rate: ________________ gpm Back pressure: ________________ psi Oil: ________________ F

SYSTEm CAPACiTY TO COnTrOl TEmPErATUrE TEST

Raise the system temperature to 140 F by adjusting the pressure using the load valve on the flow and pressure tester. If it takes more than 1900 psi to get the system temperature to 140 F, adjust the pressure to stabilize the system temperature at some lower temperature, e.g. 120 F. When the system temperature has remained constant for about 15 minutes, record the flow rate, pressure, back pressure, oil temperature, and air temperature. Flow rate: ________________ gpm Pressure: ________________ psi Back pressure: ________________ psi Air: ________________ F Oil: ________________ F

CAlCUlATE THE TOOl lOAd HP COOlinG CAPACiTY FOr An EFFECTiVE 40 dEGrEE TEmPErATUrE diFFErEnCE, Air TO Oil USinG THE FOllOwinG FOrmUlA.
(Pressure Back pressure) x gpm 43 x (Oil temperature Air Temperature) Example: Flow rate: Pressure: Back pressure: Air: Oil: (1500 100) x 5 43 x (120 70) 5 1500 100 70 120 = gpm psi psi F F 3.3 hp at 40 deg F temperature difference = hp (horse power)

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