7/8/2014 Excel Hydraulics - FAQs

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Q. Will increasing the hydraulic pressure make the machine go faster?
A. Generally, no. Speed is a factor of flow. You need more flow to make
things move faster (Rule 5). There is a possibility though, where increasing
the relief valve pressure setting may increase the speed. Some flow may be
being lost over the relief valve so therefore by increasing pressure the flow
will be available for useful work. Extra caution is required in these situations
so call an experienced hydraulic technician at Excel.

Q. Will putting a bigger (higher flow) pump on my machine give it
more force?

A. No. A bigger pump will displace more fluid and make cylinders extend
faster, but it is more pressure that will give you more force (Rule 6).
Q. My machine is getting hot, will fitting a heat exchanger help?

A. Yes. A heat exchanger is a device to reduce heat from a hydraulic
system. However a better question would be, why is my system getting hot?
Using the Excel rules, determination of the heat cause can be found. Better
still get an overall appraisal of your hydraulic system. This will save more
money than just installing a heat exchanger. Call Excel to help you with
that.
Q. A new installation incorporating a large hydraulic cylinder makes a
banging noise when in operation. What can we do to fix it?

A. Call Excel! As the cylinder has a large volume of oil within its body, under
pressure this oil compresses. When the directional valve shifts to allow the
cylinder's direction to change, this oil decompresses rapidly causing the
bang. With expert fitting of additional valving this fluid can be decompressed
and therefore do away with the destructive banging.
Q. One cylinder on my machine has no force, what could be the
problem, given that every thing else hydraulic is operating normally?

A. Force is a function of pressure (Rule 6). You only experience pressure
when there is a restriction to flow (Rule 1). Knowing that the fault is limited
to only one cylinder and that a system requires a restriction to flow, a
suggestion would be to start with the cylinder and its associated valve. The
problem could be with cylinder seals, a pressure valve failing to allow easy
passage of fluid or a directional valve not shifting. At EXCEL, our vans are
equipped with an array of test equipment to make these tests and checks
so much easier and more effective.
Q. Do EXCEL have the resources to successfully repair our hydraulic
components?

A. Yes! But don't take our word for it. Our Smithfield NSW workshop is open
typically longer than "normal" working hours. Come in and have a look a look
at the clean bright working environment and check out the hydraulic test
and data loggers.
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Q. Can I repair my own small hydraulic cylinder?

A. Yes. However the standard the hydraulic component maintains will
depend on the standard of the repair. To maximise a hydraulic component's
effectiveness and longevity, you need experts. Excel are the experts. We
have a standard series of checks and tests that are applied to all
component repairs large or small. These checks are performed throughout
the whole repair cylinder process. This enables Excel to provide a lifetime
warranty on all repairs.
Q. What does an accumulator do?

A. An accumulator stores hydraulic fluid under pressure. This stored fluid
can then be used for operations even when the pump is turned off.
Q. I have moved a three phase electrically powered hydraulic machine
from one position to another and now it will not operate. What is
wrong?

A. Hydraulic pumps operate correctly with their drive shaft rotating in one
direction only. Electric motors can easily rotate in either direction with the
reversal of any two electrical phases. Three phase electrical outlet sockets
have no commonality with phase rotations. Therefore, moving hydraulic
equipment from one electrical outlet to another could cause the equipment
to malfunction. With the equipment plugged into an alternative location, it is
possible for the electric motor to rotate in an opposite direction. Rotating
the pump backwards (sucking instead of blowing) causes the operational
fault. The fix is an easy one for a certified electrician. Exchanging any two
electrical phases will cause the pump to operate as designed.
Q. The hydraulic oil in my equipment has not been replaced for as long
as I can remember, should I replace it immediately?

A. Hydraulic oil is to machines as blood is to humans. Here at Excel
Hydraulics, experience has taught us that it is hugely worthwhile to have a
simple oil analysis performed before replacing the fluid. Just as your doctor
performs blood tests before ordering a complete transfusion, an oil test
should be done before you decide to replace any oil. It is useful as a vital
indicator of your machine's internal condition. For example, high particle
counts indicate either the unchecked integration of contamination or failure
of the filtration system. Metal levels help to identify unacceptable
component wear. Water levels above 0.10% are detrimental to component
wear. There are so many factors that throwing the fluid away without
testing first is like "throwing the baby out with the bath water". Have the oil
tested first, the results will then tell you if there are deeper issues to
resolve. This simple process will save you both time and money.
Q. Pressure intensification, what is that?

A. Pressure intensification is to hydraulics as a lever is to a builder.

Q. Is hydraulic oil harmful to humans?
A. Hydraulic oil can be present in a couple of states: under pressure and in
the drum. Lets answer the question looking at each state independently.
Harm may occur if high-pressure oil is able to penetrate the skin. This would
transpire in situations where a pin leak has formed and a jet of high-pressure
oil sprays from this leak. Oil at atmospheric pressure is not deemed a
hazardous product. If your were to swim in it there is a possibility of mild
irritation to the skin. When swimming wear goggles as if you were to get it in
your eyes you would need to irrigate with copious quantities of water to
prevent irritation. But keep your mouth closed, as either 46 or 68 grade
hydraulic oil is slightly toxic possibly causing some gastric irritation.
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Q. I know what a hydraulic cylinder is however what is a hydraulic
displacement cylinder?
A. Displacement cylinders are hydraulic actuators that have one fluid port.
Fluid entering this single port causes the rod to extend. Retraction of the
cylinder only occurs when some external force is applied such as springs
gravity or another external force. Construction is generally achieved by
either sealing the fluid around the rod area or sealing the piston against the
bore. There are advantages of each sealing technique. The rod sealing
option provides better lubrication outcomes as both the piston and rod areas
are constantly flushed with the hydraulic fluid. Rod sealing is generally a
more cost-effective alternative, as the design is simpler. Sealing the piston
against the bore however provides more force when equivalent pressures
are applied to both designs due to the increased diameter associated with
the piston. Applications of displacement cylinders are commonly found in
numerous applications such as portable jacking rams, hydraulic car jacks and
truck hoists to name a few.
Q. My hydraulic repair company informs me that the cause of my
cylinder malfunction was due to failure with a check valve. What is a
check valve?
A. One of the simplest hydraulic components is the check valve, a device
designed to allow fluid to flow in one direction only. This is achieved with
the aid of a seat, a ball or poppet and a spring. In the free flow direction
the fluid lifts the ball of its seat against the tension of the fixed force spring.
In the non-flow direction, also known as the checked direction, the fluid
acts on the spring side of the ball. This forces the ball into the seat
preventing the passage of fluid. For the electronics gurus, the check valve
is the hydraulic equivalent of the electronic diode.
Q. Can you please explain the difference between a hand operated
hydraulic Directional Control Valve with a detent option when
compared to a spring center option?

A. Good question, however first we need a basic understanding of a typical
hand controlled Directional Control Valve (DCV) operation. Let's assume this
DCV has three positions, four ports, open center configuration and is
connected to a double acting Hydraulic Cylinder. Flow is provided by a fixed
displacement pump with inbuilt relief valve.

There are three possible control positions for this DCV scenario:
1. Center
2. Cylinder Extend
3. Cylinder Retract

1. Center control position
Is where the DCV is in a neutral position; the hand leaver is neither pushed
nor pulled, raised nor lowered. The cylinder is also neither extending nor
retracting and generally remains in a fixed position (Dependant on the DCV's
center configuration). The pump flow is being diverted back to tank under
zero pressure. (Well not quite zero but pretty close)

2. Cylinder Extend
Is when the hand leaver is shifted in one direction, causing the cylinder to
extend. The pump flow is now connected to extension port of the cylinder
and the cylinder's retraction port is connected back to tank. If the cylinder
continues to be extended in this way it will only stop moving when either
the systems full designed load capacity is reached, or the cylinder's full
mechanical stroke limit is found. In either case the system pressure will climb
until the relief valve setting is achieved. All the pump flow will now pass
through the relief valve and begin to heat up as it passes through.

3. Cylinder Retract
Is the opposite to the extend operation with the hand leaver shifted in the
opposite direction. Instead of the pump flow being connected to the extend
port of the cylinder, it's now connected to the retract port and the
extension cylinder port now connected to tank. Again the cylinder's motion
will only stop if either the systems pressure is reached or the cylinders full
retraction stroke is achieved.

So back to the question:
What are the differences between a DCV with a spring center or detent
option?

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Spring centered option
This operation means that while ever the valve handle is released the DCV
will always spring back to the center neutral control position. Advantages
here are that the cylinder operation will always fail safe. Let go of the leaver
and the DCV will always finds its neutral position. This option does however
mean an operator needs to be continually present.

Detent option
A valve fitted with a detent option on the other hand will always be
mechanically held, by a simple mechanism, in whatever position the leaver
was last left in. The cylinder will continue to extend or retract depending on
what position the lever remains in. This allows the operator to walk away
and the cylinder will continue to either extend or retract without their
presence. Downside of course is there are no failsafe measures.


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