BENHA UNIVERSITY BANHA FACULTY OF ENGINEERING MECHANICAL ENGINEERING DEPARTMENT

M578 HYDRAULIC POWER SYSTEMS 5 YEAR PRODUCTION ENGINEERING DR. H. EL-BATSH | ENG. ABDALLA MOHAMED
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LAB1: EQUIPMENT FAMILIARIZATION

OBJECTIVES After completing this experiment, you will be able to: 1. Identify each component in the hydraulic system. 2. Setup the hydraulic system. 3. Know the cautions and precautions. 4. Prepare a hydraulic power unit for use. 5. Operate a hydraulic power unit. EQUIPMENT LIST You will need the following components in order to perform the experiment: 1) Hydraulic Power Unit, consists of: A. Pump, Flow Rate: 2.5 gpm / 9.46 lpm, Theoretical Displacement: 0.316 in3/rev, Max. Operating Pressure: 500 psi / 3447 kPa. B. Electric Motor, 1 hp, 115/120 volt, 1 phase, 60 cycle, 1725 rpm. C. Reservoir, Size: 5 gallon / 18.9 liters. D. Liquid Level Gage. E. Filler/Breather. F. Relief Valve. G. Pressure Gage. H. Suction Strainer. I. Supply Manifold. J. Return Manifold. K. Shutoff Valve. 2) Motor, bi-directional, gear-type, 0.203 cubic inch (3.33 cm3) displacement. 3) 1-Cylinder, double-acting, 1.5 inch (3.81 cm) bore, 4.0 inch (10.2 cm) stroke, 0.44 inch (1.12 cm) rod diameter. 4) 1-Cylinder, double-acting, 1.125 inch (2.86 cm) bore, 6.0 inch (15.24 cm) stroke, 0.31 inch (0.79 cm) rod diameter.

5) 1-Directional Control Valve, 3-position, lever-operated, 4-way, closed center. 6) 1-Sequence Valve / Relief Valve, pilot-operated, Pressure Range: 25 800 psi / 172 5516 kPa. 7) 1-Pressure Reducing Valve, pilot-operated, Pressure Range: 25 800 psi / 172 5516 kPa. 8) 3-Pressure Gages, liquid filled, Range: 0 1000 psi / 0 6900 kPa. 9) 2-Flow Control Valves with reverse check valve. 10) 1-Needle Valve. 11) 2-Check Valve. 12) 1-Flow Meter, Range: 0.5 5 gpm / 2 20 lpm. 13) 3-Hose, length 5.0 ft. / 1.52 m. 14) 6-Hose, length 4.0 ft. / 1.22 m. 15) 2-Hose, length 3.0 ft. / 0.91 m. 16) 2-Open-end Quick Connect Fitting. 17) 3-Fitting Tee, two ends male, and one end female. 18) 1-Cylinder Load Spring. 19) 1-Motor Flywheel. 20) 1-Rod Extender. PRECAUTIONS Hydraulic devices use high pressure. Be careful in practice. Oils are very slippery materials. Keep the floor clean with no oil on the floor. All the hydraulic devices, including working boards, should be kept in clean state: dust or impurities in fluids can lower the performance of hydraulic devices and make trouble. Always check the fluid level in tank. Oil temperature in tank should be kept in between from 30 c to 55 c. To prevent cavitation, check strainer regularly, and check if filter is clogged. Do not drop modules in experiment. Severe impact on the modules should be avoided. The modules used in this electro-hydraulic device arc set for DC 24V for safely reason. Therefore, you should use DC 24V, and should be careful about polarities when they connect wires.

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CAUTIONS FOR OPERATION 1. Check if the pump is rotating in right direction. 2. Check if the revolution rate is in preset range. 3. Before starts, turn the motor on and off several times for enough oil to be flown to the pump. 4. Especially when viscosity is high due to oil temperature drops in cold weather; turn the motor on and off several times to circulate fluids. 5. When you start this system, open unloading valve or bypass valve to have unloading operation. After the start, keep the unloading operation to slowly increase the output pressure. Do not increase the pump output pressure rapidly. 6. When you install each module, try to place the modules distanced enough to prevent interference. Especially when you install the device like cylinder, which moves externally, special attention will be needed. 7. When you install the module, place it firmly, so it won't be accidentally disengaged during practice. 8. If the allowed maximum pressure in a double acting cylinder is set for 70 (kgf/cm2) for safety, so keep the pressure in relief valve lower than that with exception of some characteristic tests. 9. Do not rapidly close shut-off valve which delivers fluids to system. Close the valve slowly. 10. Do not apply too much force in rotating the adjusting screw attached on pressure control valve or flow-rate control valve. 11. Stick to the practice sequence written in each practice subjects. 12. Careful when you use the weight for load in practice. 13. Check if there are remaining pressure in each devices and hoses before disassemble circuit. EXPERIMENT PROCEDURES A. Identification of Components and Setup. B. Power Unit Checkout: 1) Before starting the hydraulic power unit, perform the following checkout procedures: a) Check the oil level in the reservoir. Fill if necessary. b) Press the stop pushbutton on the motor starter to make sure the starter is in the off position. c) Plug the power cord of the power units electric motor into a 115 V AC outlet.

d) Reduce the relief valve to its minimum pressure setting (turn CCW fully). 2) To make sure that the pump is generating flow, attach an open-end male quick connect fitting into the other end so that the hose now has an open end. Remove the filler/breather cap and direct the open end of the hose into the reservoir. 3) Start up the hydraulic power unit by pressing the green pushbutton labeled Start on the motor starter. 4) Turn the relief valves adjustment knob one full turn clockwise. 5) If there is a stream of oil, shut down the power unit by pressing the stop pushbutton. 6) Turn the relief valve back to its minimum setting by turning the adjustment nut fully CCW. 7) Turn off the power unit. 8) Remove the open-end fitting from the hose. 9) Close the filler/breather cap. 10) Connect the previous hose to the movable manifold having an isolation valve. 11) Close the isolation valve. 12) Restart the hydraulic power unit. 13) Record the reading. Gage S Pressure --------------------- psi/kPa 14) Increase the relief valve pressure. If the pressure increases, the relief valve is working properly. 15) Reduce the relief valves setting back to the minimum. 16) Turn off the power unit. C. Basic Circuit Operation: 1) Build a hydraulic system as required. 2) Start the pump, and slowly rotate the adjusting screw of relief valve in clockwise direction to set a pressure of 200 psi/1380 kPa. Gage C = -------------------- psi/kPa Gage S = -------------------- psi/kPa 3) Test your circuit by pushing in on the lever of the dcv to extend the cylinders rod. 4) Retract the cylinder by pulling out on the lever of the DCV. 5) Shut down the power unit.

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LABWORK ASSIGNMENTS Where is the pump located on the power unit? What was the minimum pressure obtained at the pump outlet from B, step 13 of the experiment? Did gages S and C have the same reading in C, step 2 of the experiment? Why or why not? Write in your words, what do you conclude? And what did you learn from this experiment? HOMEWORK ASSIGNMENTS How is energy transmitted in a hydraulic system? Why are some industrial pressure gages liquid filled? How is the pumps maximum discharge pressure controlled? What procedure is to be followed if a leak is discovered in the circuit? What are 3-purposes of the reservoir in a hydraulic machine? What purpose does the breather serve on a hydraulic system reservoir? Which direction is the relief valve adjustment turned to decrease pressure?

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