Instructor's Manuscript Service Meeting Guide No. 3 Introduction In the two previous service meetings we have discussed precision measuring tools and their importance in our daily work. During the next few meetings we will discuss another engineering subject which has become very important in our service work with Caterpillar equipment. This is the subject of Power Hydraulics. Ask the group: What is the purpose of hydraulic equipment on Caterpillar machines? Search for this fact: The hydraulic equipment is a convenient method of transmitting pover from the engine to various attachment tools or machine components in order to do work. uphasize the fact that the entire hydraulic system is a method of transmitting engine power. Ask for other methods of transmitting power: 1) Mechanical - gears, shafts, chains, belts; 2) Electrical - generator-conducting wires, motors; or 3) combinations of these two. Presentation To fully understand the function of the hydraulic systems used in Caterpillar Equipment, a knowledge of hydraulic principles is essential. A second meeting will follow which will tie the principles to the actual circuitry of hydraulic systems used in the equipment we sell. Note to Instructor: The examples included in this outline are simple and can be placed on the blackboard for discussion purposes. The accompanying filmstrip contains the nine figures shown, These frames can be used to help illustrate the examples. Hydraulic Principles I. Power Hydraulics A. Definition: Using the physical characteristics of liquids at rest and in motion to transfer forces or power from one location to another. II. What is Power? A. Power is a measure of a given force moving through a distance at a given speed. III. what is Force? A. The application of force to a body tends to produce or alter motion of that body. Force is usually expressed in pounds. (fxample in Fig. 1, force applied is 100 Ibs.IV. What is Pressure? Pressure is the force per unit area and is expressed in pounds per square inch (psi) or Kilograms per square centineter. Example: At sea level, a one square inch column of air extended to the upper limit of the atmosphere weighs 14.7 lbs. We use this as our standard. However, in most hydraulic work, ve can disregard atmospheric pressure because gauge calibrations or pressure readings are the dif- ference between atmospheric pressure and the pressure inside some container. The gauge pressure plus the atmospheric pressure gives vhat is known as "absolute pressure". Most published pressures are listed as “gauge pressure". Mathematically - Force (1bs.) = Pressure (psi) x Area (sq. in.) Figure 2 illustrates a simple way to remember what to combine to acquire the alternate value. Example: F Fr BCA fe PaniF= PA as initially stated.c. Helpful formas to use when dealing with hydraulics are: Square or Rectangle Area (Area = Width x Length) Circle Area = diameter® x ddeneter T= 3.14 Example: If 1000 psi pressure is applied to a cylinder 6” in diameter, what would be the resulting force? Force = Pressure x Area = 1000 x 6 x 6 x 3.14 = 26,260 see pound force or slightly more than 1 Tons. NOTE TO INSTRUCTOR: At this point it is advisable to keep the group alert to the tremendous forces that can be gained. The foregoing example can be expanded by showing vhat would happen Af the same pressure (1000 psi) was applied to @ cylinder having a7" diameter é x 3.1h x 1000 psi = 38,500 (approx. ) ibs. force or over 19 Tons. Thus ~ one inch diameter increase results in 5 Tons more force. Take another example; this time increasing the pressure on @ 6" diameter cylinder to gain the same force of 38,500 38,500 = d® x 3.14 x Pressure r = 36 x 3.24 x Pressure a 38,500 = 28.6 x Pressure 3Bys00 = 1350 psi V. What is Work? A. Work is a measure of accomplishment. An object must be moved a @istance to perform work. a. In fig. 3, if ve apply 1000 lbs. to move a ram 12 in., we have accomplished 1000 x 12 or 12,000 in. Ibs. of work or1000 ft. lbs. of work (Formila: W (Work) = F (Force) x D (Distance) (Inch pounds can be converted to foot-pounds by dividing the inch-pounds figure by 12) ue i b. Torque - This is force through a rotary motion. Example: Tightening a nut with a torque wrench. The common unit measurement being lbs. ft. or Ibs. in. VI. What is Power? A, Work as stated above mikes no allowance for time in the above formula, a. A person running 1/4 mile uses more power than one who walks 1/4 of a mile. Power is a measurement of work per unit time. Power is a measure of the rate of energy transferred. In Figure 4, 2 lbs. pushed the block 5 ft. in 5 seconds. 10 ft. Ibs./5 sec. or 2 ft. Ibs./sec. = Power = aten Stte 10 fi lbs. WORK Ls If done in 6 seconds time: TOW tht ess 28lbts= powERvit. Physical Properties of Liquids Ae Definitions a be Solia - A substance with a rigid molecular structure. The molecules are held rigid with a fixed distance between each molecule. This tends to resist any physical change in the physical shape of the solid. Example: 100 marbles placed in a box with glue poured in to fill the empty spaces. When this glue hardens, the marbles act the same as the molecules in a solid = they cannot move. Gases - Here the molecules move freely in relation to each other. ‘The distance between molecules will change by exerting « force com- pressing the gas or by the molecules repelling each other. (Expanding the gas.) Picture in the last example the marbles being rubber with no glue in between each marble, We then push down on the marbles compressing each one, making the space they are contained in, smaller. Liquid - A fluia is characterized by the ability of its molecules to move freely in relation with each other. These molecules are held ina state of balance. ‘The molecules may move in relation with each other, but the distance between the molecules is fixed. Example: Place the marbles in a cloth bag filling it to the top. You can press the bag into any shape. The marbles roll over one another, but if they are snugly fitted into the bag, they will all retain the same respective distance from each other. As you can see, a liguid has a characteristic of a solid and one of the gas. (1) From the solid it has the property of being a non-compressible material. (2) From the gas it has the property of free movement of the molecules, but maintaining the same distance in respect toB. A liguid subjected to a Force will seek the path of least resistance. If the Force is gravity, it will seek a conmon level as illustrated in Fig. 5. The pressures at A, B, C, & D are all equal. PRESSURES ARE ALL EQUAL C, A basic fundamental - Pressure at any one point in a static liquid is ‘the same in every direction and pressure exerted on an enclosed liquid is transmitted in every direction and acts with equal force on equal areas. Frame 6 illustrates that 2 lbs. of force applied on 1 sq. in. of area exerts 2 lbs. on every sq. in. in the container. 2ibs.Liguid as a Force Multiplier as compared to Mechanical Advantage 1. We all know that by using a lever we can move an object too heavy to move directly by hand. Let's look at a hydraulic lever: j+-———_ 254s. We have 100 lbs. we wish to move, The weight being one ft. from the fulcrum. By applying slightly more than a four Ibs. weight 25' from the fulcrum we can lift the 100 Ib. weight. Write on Board: 4 Ibs. x 25 ft. = 100 lb. ft. and 100 lbs. x 1! = 100 lb. ft. By using a mechanical advantage of 25 to 1, we have to sacrifice the distance upward the 100 lb. weight will be moved. This will be 1/25 of the distance the 4 1b, weight is moved dovnvard. Everyone is familiar with an example of this principle: What are some? Ans. "Cat" bar, screw pullers, bumper Jack etc. 2. Liguid as a Force miltiplier - Due to its non-compressibility, a Liquid fills ali areas of the container or circuit it may be in. Pressure exerted on an enclosed liquid is transmitted undiminished in every direction and acts as equal force on equal areas. In Fig. 8, the 4 ibs. pressure exerted is comparable to the 4 Ibs.in Fig. 7 as all the weights and distances are shown. Again using the formula F = P x A, our initial force is 4 lbs. pressing down on 1 sq.in. of area, developing a pressure of 4 1b./sq.in. in cylinder A. Since pressure is equal on every sq.in. in the container, cylinder B has | Ibs. exerted on every sa.in, in the container. ‘The base of the 100 lbs.wt. has 25 sq.inj therefore, P (l psi x 25 sqvin. = 100 Ibs. Force). By applying more than 4 psi and moving piston A downvani a total distance of 25", we have forced 25 cu.in. of liquid from the A cylinder. This displaced 25 cu.in., is forced under piston B which is 25 sa.in. Thus, moving the piston one inch (25 eq.in. x 1 in. = cu.in.). The same amount as displaced from cylinder A. Sumary Let's review these three important properties of liguids: 1. A Liquid conforms to the shape of the container. 2. For our purposes liquids are incompressible. 3. Equal pressure is transmitted throughout the entire container. Make sure this subject is understood by everyone.In Meeting Guide No. 4 we will discuss the parts of a simple hydraulic system and their function. A Service Shortout Im many cases ve can look to the alert serviceman to find an improved method of doing a service job. This serviceman does a better and faster job relining brake bands by using strips of two inch msking tape to hold rivets in place on D6 and D9 dry-type brake bands. Assembly time is cut by 25 minutes. Service Literature Review Instructor should review selected information from current service literature. Summary Sumarize any foregoing points as n Then tell the group the next two meetings will include some information on the components of hydraulic circuits.