Pre Evaluation

Agenda
• Hydraulic Symbols
• Calculation Formulas
• Pump Types
• Pump Brands
• Pump Controls
• Pump Schematics
• D&A Pump
• Motor Schematics
• D&A Motor
• Contamination Control
Hydraulic Symbols
Fluid Power Symbols
Fluid Power Symbols
Fluid Power Symbols
Fluid Power Symbols
Fluid Power Symbols
Fluid Power Symbols
Fluid Power Symbols
Questions?
CALCULATION FORMULAS
English-Metric Conversions
1 Bar = 14.5 PSI
6.9 Kpa = 1 PSI
3.8 Liters = 1 Gallon
1 Cubic Inch = 16.4 Cubic Centimeters
ºC = 5/9 (ºF – 32)
ºF = 9(ºC) / 5 + 32
 Hydraulic Pump Formulas
• Cubic in. Per. Rev. = GPM x 231 / RPM

• GPM = Cubic in. Per. Rev. x RPM / 231

• RPM = GPM x 231 / Cubic in. Per. Rev.

• HP = GPM x PSI / 1714

• Torque (in/lb) = HP x 63025 / RPM

• Torque (ft/lb) = HP x 5252 / RPM 264-3172

Calculation Exercises
1. How many horsepower are needed to drive
a 10-gpm pump at 1750 psi?
 1. How many horsepower are needed to drive
a 10-gpm pump at 1750 psi?

GPM = 10
PSI = 1750

10 X 1750 / 1714= 10.21 horsepower

2. How much oil will be produced by a 2.21
cubic inch pump operating at 1120 rpm?
 2. How much oil will be produced by a 2.21
cubic inch pump operating at 1120 rpm?

RPM = 1120
Pump Displacement = 2.21 cubic inches

1120 X 2.21 / 231 = 10.72 gpm

3. What displacement is needed to produce 7
gpm at 1740 rpm?
 3. What displacement is needed to produce 7
gpm at 1740 rpm?

GPM = 7
RPM = 1740

231 X 7 / 1740 = 0.93 cubic inches per revolution

4. How fast will a 0.95 cubic inch motor turn
with 8-gpm input?
 4. How fast will a 0.95 cubic inch motor turn
with 8 gpm input?

GPM = 8
Motor Displacement = 0.95 cubic inches per revolution

231 X 8 / 0.95 = 1945 rpm

5. How fast will a 0.95 cubic inch pump turn to
produce 10 gpm output?
 5. How fast will a 0.95 cubic inch pump turn to
produce 10 gpm output?

GPM = 10
Pump Displacement = 0.95 cubic inches per revolution

231 X 10 / 0.95 = 2432 rpm

6. How much torque is developed by a pump at
15 horsepower and 1500 rpm?
 6. How much torque is developed by a pump at
15 horsepower and 1500 rpm?

Horsepower = 15
RPM = 1500

15 X 63025 / 1500 = 630.25 inch pounds

Questions?
Pump and Motor
 Pump Definition
• The hydraulic pump transfers mechanical energy into hydraulic energy. The
pump is a device that takes energy from one source (i.e. engine, electric motor, etc.)
and transfers that energy into a hydraulic form. The pump takes oil from a storage
container (i.e. tank) and then pushes the oil into a hydraulic system as flow.

• All pumps produce oil flow in the same way. A vacuum is created at the pump
inlet. The higher atmospheric pressure or tank pressure will push the oil through the
inlet passage and into the pump inlet chambers. The pump gears carry the oil to the
pump outlet chamber. The volume of the chamber decreases as the chamber
approaches the outlet. This decrease in chamber size will push the oil out of the
outlet.

• Pumps produce only the flow (i.e. gallons per minute, liters per minute, cubic
centimeters per revolution, etc.) used in the hydraulic system. Pumps DO NOT
produce or cause pressure. Pressure is caused by the resistance to the flow.
Resistance can be caused by flow through hoses, orifices, fittings, cylinders, motors,
or anything in the system that slows down free flow to the tank.
• The hydraulic motor transfers hydraulic
energy into mechanical energy. It uses
the oil flow being pushed into the hydraulic
system by a pump and transfers it into a
rotary motion to drive another device
(final drives, differential, transmission,
wheel, fan, etc.).
 Pump Types
1. Piston Pump
2. Gear Pump
3. Vane Pump
 Pump Brands
1. Bondioli
2. Caterpillar
3. Cessna
4. Eaton
5. Kawasaki
6. Linde
7. Nachi
8. Parker
9. Rexroth
10. Sauer-Danfoss
11. Uchida
12. Vickers
Pump Controls
 Pump Controls
1. Pressure Compensator
2. Load Sensing
3. Torque Control
4. Power Shift Control
5. Negative Flow Control
6. Cross Sensing Control Signal
7. Pressure Override Valve
8. High Pressure Cut
9. Crossover Relief and Makeup Valves
10. Charge Pump/Charge Relief Valve
11. Speed Sensing
12. Closed/Open Loop System
 Pressure Compensator Control

 Known as Pressure Control or pressure Limiting

Compensator

 Senses Pump Outlet pressure

 At the preset pressure level, the compensator

applies flow and pressure to the control piston to
reduce pump displacement.
 Load Sensing Compensator

• Designed to automatically sense the load

pressure and to set the pump outlet pressure
accordingly
• Addresses the element of waste.
 Torque Control
 A torque control is designed to prevent high
pressure and high flow occurring at the same
time. Either one can occur independently, that is
high flow or high pressure but not simultaneously.

 Never requires maximum flow and maximum

pressure at the same time

 Used on excavators and cranes

 Power Shift Signal
• The power shift signal to the pump
regulators enables the machine to maintain
a desired engine speed for maximum
productivity.
 Negative Flow Control
• The use of a negative flow control hydraulic
system maximizes the efficiency of
machines by only producing flow from the
pumps when the flow is needed.

• A high negative flow control signal always

overcomes the horsepower control.
 Cross sensing control signal
• To maintain the engine horsepower to the pumps
at a constant rate, the pump regulators receive
average delivery pressure of the right pump and
the left pump through the cross sensing orifices.
The downstream pressure from two orifices is then
combined. This creates an average pressure of
the output of the two pumps.

• This pressure signal is used to keep the required

horsepower of the pumps from exceeding the
horsepower of the engine.
 Pressure Override Valve
• The POR valve limits the maximum drive
loop pressure.
Crossover Relief and Makeup Valves
• The combination crossover relief and makeup
valves will open to protect the system by
controlling maximum pressure and reducing
pressure spikes in the drive loop.
• At machine start-up, the valves open to direct oil
to both sides of the pump.
Charge Pump/Charge Relief Valve
• Charge Pump fills the system at start-up and
provides makeup oil.

• Charge Relief Valve limits the maximum

charge pressure.
 Speed Sensing Valve

• Senses the charge flow and converts some

of it to signal oil. The orifice in the speed
sensing valve creates a pressure
differential which is proportional to
engine speed. This pressure differential is
then multiplied by the speed sensing valve
and becomes signal oil. This signal is then
used to control the pump and motor.
Closed/Open Loop System
1. Fig. A: ________ Loop System with ___ -Directional,
_________ Displacement Pump and ___ -Directional,
_________ Displacement Motor
1. Fig. A: _Closed_ Loop System with _Bi -Directional,
_Variable_ Displacement Pump and _Bi -Directional,
__Fixed___ Displacement Motor
2. Fig. B:____ Loop System with ____ -Directional, _____
Displacement Pump and _____ Directional, ___ Displacement
Motor
2. Fig. B: _Open_ Loop System with _Uni_ -Directional,
_Variable_ Displacement Pump and _Bi_ Directional,
_Fixed__ Displacement Motor
Pump Schematics
 Load Sensing Compensator

- Definition
- Diagram
 Load Sensing Compensator

• Designed to automatically sense the load

pressure and to set the pump outlet pressure
accordingly
• Addresses the element of waste.
 F1 = Spring Tension @ 300 PSI
F2 = Spring Tension @ 3300 PSI
P1 = Discharge Pressure F1
P2 = Load Pressure/Sense Line
P1 P2
CID = 3
RPM = 600 =>1800 F2
PSI = 2000 => 3300
GPM = ?
HP = ?
Torque (in/lb) = ? P1
P1 = 250 PSI
P2 = Zero P1 < F1 + P2
F1 = 300
F2 = 3300 PSI
F1
CID = 3
RPM = 600 =>1800
PSI = 2000 => 3300
P1 P2
GPM = ?
HP = ?
Torque (in/lb) = ? F2

P1
P1 = 400 PSI P1 > F1 + P2
P2 = Zero F1
F1 = 300 PSI
F2 = 3300 PSI P1 P2
CID = 3
RPM = 600 =>1800
PSI = 2000 => 3300
F2
GPM = ?
HP = ? P1
Torque (in/lb) = ?
P1 = PSI ?
P2 = 1000 PSI P1 < F1 + P2
F1 = 300 PSI
F1
F2 = 3300 PSI
CID = 3
P1 P2
RPM = 600 to 1800
PSI = 2000 => 3300
Margin PSI = 300 F2
GPM = ?
HP = ? P1
Torque (in/lb) = ?
P1 = PSI ?
P2 = 3000 PSI P1 = F1 + P2
F1 = 300 PSI F1
F2 = 3300 PSI
CID = 3
P1 P2
RPM = 600 to 1800
PSI = 2000 to 3300
F2
Margin PSI = 300
GPM = ?
HP = ? P1
Torque (in/lb) = ?
P1 = 3350 PSI
P2 = 3100 PSI P1 > F2
F1 = 300 PSI F1
F2 = 3300 PSI
CID = 3 P1 P2
RPM = 600 to 1800
PSI = 2000 to 3300
F2
Margin PSI = 300
GPM = ?
HP = ? P1
Torque (in/lb) = ?
Questions?
A10VO PUMP
Disassembly
A10VO PUMP
Assembly
Gear Pump Disassembly
Gear Pump Assembly
Gear Pump Disassembly
Gear Pump Assembly
Vane Pump Disassembly
Vane Pump Assembly
Pump Schematics
CID = 3 F1 = Spring Tension @ 50 PSI
RPM = 600 to 1500 F2 = Spring Tension @ 200 PSI
PSI = 450 to 5000 F3 = Spring Tension @ 450 PSI
GPM = ? F4 = Spring Tension @ 5000 PSI
HP = ? F5 = Spring Tension @ 6000 PSI
Torque (in/lb) = ? P1 = ?
P2 = ?
P3 = ?
Discharge Pressure (A)
Discharge Pressure (B)

(A)
P3
F1
F2
P2 P1
F5

F4

F3
(B)
CID = 3 F1 = 50 PSI
RPM = 600 to 1500 P2 + P3 + F2 > P1 + F1 F2 = 200 PSI
PSI = 450 to 5000 F3 = 450 PSI
GPM = ? F4 = 5000 PSI
HP = ? F5 = 6000 PSI
Torque (in/lb) = ? P1 = 200 PSI
P2 = 200 PSI
P3 = Zero
Discharge Pressure (A)
Discharge Pressure (B)

(A)
P3 F1
F2
P2 P1
F5

F4

F3
(B)
CID = 3
RPM = 600 =>1500
P2 + P3 + F2 < P1 + F1 F1 = 50 PSI
F2 = 200 PSI
PSI = 450 => 5000 F3 = 450 PSI
GPM = ? F4 = 5000 PSI
HP = ? F5 = 6000 PSI
Torque (in/lb) = ? P1 = 650 PSI
P2 = 450 PSI or less
P3 = ?
Discharge Pressure (A)
Discharge Pressure (B)

(A)
P3 F1
F2
P2 P1
F5

F4

F3
(B)
CID = 3 F1 = 50 PSI
RPM = 600 =>1500 P2 + P3 + F2 < P1 + F1 F2 = 200 PSI
PSI = 450 => 3300
Right Solenoid Energized F3 = 450 PSI
GPM = ? F4 = 5000 PSI
HP = ? F5 = 6000 PSI
Torque (in/lb) = ? P1 = 650 PSI
P2 = 450 PSI
P3 = ?
Discharge Pressure (A)
Discharge Pressure (B)

(A)
P3 F1
F2
P2 P1
F5

F4

F3
(B)
CID = 3
RPM = 600 =>1500
P2 + P3 + F2 < P1 + F1 F1 = 50 PSI
F2 = 200 PSI
PSI = 450 => 3300 Left Solenoid Energized F3 = 450 PSI
GPM = ? F4 = 5000 PSI
HP = ? F5 = 6000 PSI
Torque (in/lb) = ? P1 = 650 PSI
P2 = 450 PSI or less
P3 = ?
Discharge Pressure (A)
Discharge Pressure (B)

(A)
P3
F1
F2
P2 P1
F5

F4

F3
(B)
CID = 3
RPM = 600 =>1500
F5 < Discharge Pressure (A) F1 = 50 PSI
F2 = 200 PSI
PSI = 450 => 3300 F3 = 450 PSI
GPM = ?
HP = ?
Left Solenoid Energized F4 = 5000 PSI
F5 = 6000 PSI
Torque (in/lb) = ? P1 = 650 PSI
P2 = 450 PSI
P3 = ?
Discharge Pressure (A)
Discharge Pressure (B)

(A)
P3 F1
F2
P2 P1
F5

F4

F3
(B)
CID = 3
RPM = 600 to 1500
F4 < Discharge Pressure (A) F1 = 50 PSI
F2 = 200 PSI
PSI = 450 to 3300 Left Solenoid Energized F3 = 450 PSI
GPM = ?
F4 = 5000 PSI
HP = ?
F5 = 6000 PSI
Torque (in/lb) = ?
P1 = 650PSI
P2 = 450 PSI
P3 = ?
Discharge Pressure (A)
Discharge Pressure (B)

(A)
P3 F1
F2
P2 P1

F5

F4

F3
(B)
A4VG PUMP

Disassembly
A4VG PUMP

Assembly
Questions?
Motor Schematics
 Motor

Motor Input (GPM) Output (RPM

100 gpm  1000 rpm (stroked)
100 gpm  2000 rpm (destroked)

Pump Input (RPM) Flow (GPM)

rpm = 1000  100 gpm (stroked)
rpm = 1000  50 gpm (destroked)
 Motor
(1) 2 Speed Control Valve
(2) Crossover Relief Valve
(3) Directional Valve
(4) Brake Relief Valve
A & B Discharge Port/Supply Port
F1 = 430 PSI (2965 kpa)
F2 = 430 PSI (2965 kpa)
F3 = 5200 PSI (35850 kpa)

F2
(1)
(4)
F1

(2)
F3 (2)
F3

(3)

A B
 Low Speed (Left Forward)
(1) 2 Speed Control Valve
(2) Crossover Relief Valve
(3) Directional Valve
(4) Brake Relief Valve
A & B Discharge Port/Supply Port
F1 = 430 PSI (2965 kpa)
F2 = 430 PSI (2965 kpa)
F3 = 5200 PSI (35850 kpa)

F2
Max. Angle/Slow Speed
(1) (4)
GPM = 150 lpm (39.6 gpm)
F1
RPM = ?

(2)
F3 (2)
F3

(3)

A B
 Low Speed (Left Reverse)

(1) 2 Speed Control Valve

(2) Crossover Relief Valve
(3) Directional Valve
(4) Brake Relief Valve
A & B Discharge Port/Supply Port
F1 = 430 PSI (2965 kpa)
F2 = 430 PSI (2965 kpa)
F3 = 5200 PSI (35850 kpa)
F2
Max. Angle/Slow Speed (1) (4)
GPM = 150 lpm (39.6 gpm)
F1
RPM = ?

(2)
F3 (2)
F3

(3)

A B
 High Speed (Left Forward)
Speed Control Valve Activated

(1) 2 Speed Control Valve

(2) Crossover Relief Valve
(3) Directional Valve
(4) Brake Relief Valve
A & B Discharge Port/Supply Port
F1 = 430 PSI (2965 kpa)
F2 = 430 PSI (2965 kpa)
F3 = 5200 PSI (35850 kpa)
F2

(1) (4)
Min. Angle/Max. Speed
GPM = 150 lpm (39.6 gpm) F1
B
RPM = ?

(2)
F3 (2)
F3

(3)

A
 High Speed (Left Reverse)
Speed Control Valve Activated

(1) 2 Speed Control Valve

(2) Crossover Relief Valve
(3) Directional Valve
(4) Brake Relief Valve
A & B Discharge Port/Supply Port
F1 = 430 PSI (2965 kpa)
F2 = 430 PSI (2965 kpa)
F3 = 5200 PSI (35850 kpa) F2

(1) (4)
Min. Angle/Max. Speed
F1
GPM = 150 lpm (39.6 gpm) B

RPM = ?
(2)
F3 (2)
F3

(3)

A B
 High Speed (Left Forward)
Crossover Relief Valve Activated

(1) 2 Speed Control Valve

(2) Crossover Relief Valve
(3) Directional Valve
(4) Brake Relief Valve
A & B Discharge Port/Supply Port
F1 = 430 PSI (2965 kpa)
F2 = 430 PSI (2965 kpa)
F2
F3 = 5200 PSI (35850 kpa)
(1) (4)
Min. Angle/Max. Speed F1
GPM = 150 lpm (39.6 gpm)
RPM = ?
(2)
F3 (2)
F3

(3)

A B
 High Speed (Left Reverse)
Crossover Relief Valve Activated

(1) 2 Speed Control Valve

(2) Crossover Relief Valve
(3) Directional Valve
(4) Brake Relief Valve
A & B Discharge Port/Supply Port
F1 = 430 PSI (2965 kpa)
F2 = 430 PSI (2965 kpa) F2
F3 = 5200 PSI (35850 kpa)
(1) (4)
Min. Angle/Max. Speed F1
GPM = 150 lpm (39.6 gpm)
RPM = ?
(2)
F3 (2)
F3

(3)

A B
 Motor

Motor Input (GPM) Output (RPM

100 gpm  1000 rpm (stroked)
100 gpm  2000 rpm (destroked)

Pump Input (RPM) Flow (GPM)

rpm = 1000  100 gpm (stroked)
rpm = 1000  50 gpm (destroked)
 Motor
(1) 2 Speed Control Valve
(2) Crossover Relief Valve
(3) Directional Valve
(4) Brake Relief Valve
A & B Discharge Port/Supply Port
F1 = 430 PSI (2965 kpa)
F2 = 430 PSI (2965 kpa)
F3 = 5200 PSI (35850 kpa)

F2
(1)
(4)
F1

(2)
F3 (2)
F3

(3)

A B
 Low Speed (Left Forward)
(1) 2 Speed Control Valve
(2) Crossover Relief Valve
(3) Directional Valve
(4) Brake Relief Valve
A & B Discharge Port/Supply Port
F1 = 430 PSI (2965 kpa)
F2 = 430 PSI (2965 kpa)
F3 = 5200 PSI (35850 kpa)

F2
Max. Angle/Slow Speed
(1) (4)
GPM = 150 lpm (39.6 gpm)
F1
RPM = ?

(2)
F3 (2)
F3

(3)

A B
 Low Speed (Left Reverse)

(1) 2 Speed Control Valve

(2) Crossover Relief Valve
(3) Directional Valve
(4) Brake Relief Valve
A & B Discharge Port/Supply Port
F1 = 430 PSI (2965 kpa)
F2 = 430 PSI (2965 kpa)
F3 = 5200 PSI (35850 kpa)
F2
Max. Angle/Slow Speed (1) (4)
GPM = 150 lpm (39.6 gpm)
F1
RPM = ?

(2)
F3 (2)
F3

(3)

A B
 High Speed (Left Forward)
Speed Control Valve Activated

(1) 2 Speed Control Valve

(2) Crossover Relief Valve
(3) Directional Valve
(4) Brake Relief Valve
A & B Discharge Port/Supply Port
F1 = 430 PSI (2965 kpa)
F2 = 430 PSI (2965 kpa)
F3 = 5200 PSI (35850 kpa)
F2

(1) (4)
Min. Angle/Max. Speed
GPM = 150 lpm (39.6 gpm) F1
B
RPM = ?

(2)
F3 (2)
F3

(3)

A
 High Speed (Left Reverse)
Speed Control Valve Activated

(1) 2 Speed Control Valve

(2) Crossover Relief Valve
(3) Directional Valve
(4) Brake Relief Valve
A & B Discharge Port/Supply Port
F1 = 430 PSI (2965 kpa)
F2 = 430 PSI (2965 kpa)
F3 = 5200 PSI (35850 kpa) F2

(1) (4)
Min. Angle/Max. Speed
F1
GPM = 150 lpm (39.6 gpm) B

RPM = ?
(2)
F3 (2)
F3

(3)

A B
 High Speed (Left Forward)
Crossover Relief Valve Activated

(1) 2 Speed Control Valve

(2) Crossover Relief Valve
(3) Directional Valve
(4) Brake Relief Valve
A & B Discharge Port/Supply Port
F1 = 430 PSI (2965 kpa)
F2 = 430 PSI (2965 kpa)
F2
F3 = 5200 PSI (35850 kpa)
(1) (4)
Min. Angle/Max. Speed F1
GPM = 150 lpm (39.6 gpm)
RPM = ?
(2)
F3 (2)
F3

(3)

A B
 High Speed (Left Reverse)
Crossover Relief Valve Activated

(1) 2 Speed Control Valve

(2) Crossover Relief Valve
(3) Directional Valve
(4) Brake Relief Valve
A & B Discharge Port/Supply Port
F1 = 430 PSI (2965 kpa)
F2 = 430 PSI (2965 kpa) F2
F3 = 5200 PSI (35850 kpa)
(1) (4)
Min. Angle/Max. Speed F1
GPM = 150 lpm (39.6 gpm)
RPM = ?
(2)
F3 (2)
F3

(3)

A B
Questions?
CATERPILLAR MOTOR
DISASSEMBLY
CATERPILLAR MOTOR
ASSEMBLY
SERIES 90 PUMP
DISASSEMBLY
SERIES 90 PUMP
ASSEMBLY
 Contamination Control
• Definition
• Sources of Contamination
• Types of Contamination
• Effects of Contamination
• Scary Facts
• Dealer Responsibility
 What is Contamination?

• Definition
 Anything in a fluid that doesn’t belong
 Sources Of Contamination

• Design
• Manufacturing & Assembly
• New Fluids
• Machine Operation
• Maintenance and Service
 Types of Contamination
"Dirt You Can See" "Dirt You Can't See"
40 Microns & Larger Under 40 Microns

Weld Splatter Wear Metals

Shot Blast Silica
GROSS

Paint Chips Rocks

FINE
Machine Chips Coal
Dust on TV Screen Dirt
Effects of Contamination
• 75 to 85% of all component failures are
associated to particle contamination in the
fluid and not a weakness in the system
components.

-- Hydraulics & Pneumatics, June 1998

-- Equipment Today, August 1997
 Pump Manufacturer
ISO
C
22/19
Component Life
o
n
21/17
---- 2,500
t 20/15 -----
a
m 19/16
i
10,000
n
a
t
18/15
------------
i
17/14
25,000
o 16/13
n Clean New Oil
15/12
14/11
13/10
12/09

Component Life Over Time

 Scary Facts
(16.64 or 0.52 or 2.08) mg/L x 3.785 L/gal x 32 GPM = 93.3 mg/min
x 60 min/hr x 8 hr/day for 200 days/year =
193,481,933 mg/year divided 1000 mg/gal divided 454 gal/lb =

Amount of “Dirt” Flowing

Amount of “Dirt” in Oil Through Pump in One Year

ISO 21/17
426.2 lb/yr
ISO 18/15 53.2 lb/yr
ISO 16/13 13.3 lb/yr
 Dealer Responsibility

• Practice contamination prevention

– Correct shop/repair procedures
• Explain importance to customers
– Audit machines
– Promote Customer Service Agreement
• Benchmark with customers
Questions?