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Introduction

Nine typical hydraulic circuits will be


investigated
Several problem scenarios will be presented for
each circuit
Each problem scenario is independent and does
not relate to any previous one for the same
circuit
The class will participate in determining the
possible solution(s) for each problem

Unloading Relief
Valve Circuit
2,000 psi
a

Unloading Relief Valve Circuit


Problem #1: When we start the machine, we find that there is

not any flow indicated by the flowmeter when the directional


control valve is in the neutral position.
Solutions:

Problem #2: We find that the system is operating at 2,000 psi

when the directional control valve is in the neutral position.


Solutions:

Problem #3: The system is suppose to operate at 1,800 psi to

extend the cylinder, the pressure gauge only indicates 30 psi.


The cylinder will not extend.
Solutions:

1,000 psi
2,000 psi
b

Relief Valve Multiple (3)


Pressure Circuit

3,000 psi

Multiple Pressure Relief Circuit


Problem #1: Look at the Multiple Pressure Relief Valve Circuit

to determine what the maximum pressure in the system


should not exceed when the solenoid operated directional
control valve on the relief solenoid(s):
a is energized = __________________ psi
b is energized = __________________ psi
both are at rest, not energized = _______ psi

Problem #2: System will only operate at 2,000 or 3,000 psi, we

are unable to get the 1,000 psi setting.


Solutions:

Multiple Pressure Relief Circuit


Problem #3: System will only operate at a maximum

pressure of 1,000 psi when 2,000 psi is required in the


system.
Solutions:

Problem #4: System will only operate at 3,000 psi, we are

unable to adjust to 1,000 or 2,000 psi.


Solutions:

2,400 psi

Pressure
Compensated
Pump

Pressure Compensated
Pump Circuit
Problem #1: Normal pump flow is 10 GPM at 2,000 psi, when a

pump test is performed. Due to an operator complaint of slow


cylinder speed, flow was found to be 5.5 GPM at 2,000 psi.
Solution:

Problem #2: Normal operating temperature of the system was

110F when the system was installed four years ago. A


temperature check of the system indicates an operating
temperature of 155F.
Solution:

Pressure Compensated Pump Circuit


Problem #3: With the directional control valve in the neutral

position, the pressure gauge indicated 2,200 psig.


Solution:

Problem #4: The machine operator has called you over to

examine his machine, you find that the maximum pressure


obtainable is 1,500 psi.
Solution:

High Low
Pump Circuit

500 psi

2,500 psi

High Low Pump Circuit


Problem #1: High volume pump does not unload.

Solution:
Problem #2: System pressure will not exceed 500 psi for

the feed stroke.


Solution:

Problem #3: High volume pump is not putting flow into

the circuit when the pressure is less than 500 psi.


Solution:

Counterbalance
Valve Circuit

Load
a

1,650 psi

Counterbalance Valve Circuit


Problem #1: The cylinder does not retract.

Solution:
Problem #2: The cylinder will not remain in fully retracted

position when directional control valve is in the neutral


position, it drifts down.
Solution:

Problem #3: The cylinder will not extend or lower the load.

Solution:

Accumulator
Circuit

A B
c

b
P T
1,200 psi

1,000 psi

Accumulator Circuit
Problem # 1: The cylinder will not move, no pressure indicated

in system.
Solution:

Problem #2: The cylinder extends, the maximum pressure

indicated in circuit is 1,000 psi.


Solution:

Problem #3: The cylinder fails to move at rapid traverse speeds.

Solution:

1,000 psi

Sequencing
Circuit

1,200 psi

2,350 psi

Sequencing Circuit
Problem #1: The clamp cylinder crushes the work piece.

Solution:
Problem #2: The drill cylinder is not extending at the proper

time.
Solution:

Problem #3: The system operates at a reduced speed.

Solution:
Problem #4: The pump is noisy.

Solution:

Wire Winding
Machine Circuit
b

Wire Winding Machine Circuit


Problem #1: The system does not operate, but the electric motor

runs.
Solution:
Problem #2: The motor does not decelerate.
Solution:
Problem #3: The directional control valve will not shift.
Solution:
Problem #4: The hydraulic motor operates erratically.
Solution:
Problem #5: The hydraulic motor will not start under load.
Solution:
Problem #6: The system is overheating.
Solution:

Closed Circuit Hydrostatic


Transmission

220 psi

180 psi

Closed Circuit Hydrostatic


Transmission
Problem #1: The system will not operate in either direction.

Solution:
Problem #2: The system only operates in one direction.
Solution:
Problem #3: There is a loss of power in both directions.
Solution:
Problem #4: There is a loss of power in one direction only.
Solution:
Problem #5 System operating hot.
Solution:

Thank you

a
V2

Drill and Ream


Circuit

ream

Drill
coarse
feed

fine feed
a
V3

Drill and Ream Circuit


Problem #1: The system has a rapid traverse cycle, the system

operates in the coarse feed, fine feed, and ream cycles only.
Solution:

Problem #2: The system is rapid traverse, coarse feed, and

ream, we cannot obtain the fine feed part of the cycle.


Solution:

Problem #3: The system is operating in the rapid traverse

mode only, we are unable to get the coarse feed, fine feed, and
ream cycles.
Solution:

Drill and Ream Circuit


Problem #4: The system is operating in the rapid traverse and

ream cycles only, we are unable to get the coarse or fine feed
part of the normal cycle.
Solution:

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