USE OF ENERPAC HYDRAULIC EQUIPMENT 1
PASCAL S LAW Pressure applied at any point upon a confined liquid, is transmitted equally in all the directions & acts perpendicular to the surfaces with equal force. 2
WORKING PRINCIPLE OF HYDRAULICS 3
SINGLE ACTING CYLINDER 4
SINGLE ACTING SPRING RETURN CYLINDER Advance Port 5
DOUBLE ACTING PUSH AND PULL TYPE SOLID CYLINDER 6
DOUBLE ACTING PUSH AND PULL TYPE HOLLOW CYLINDERS 7
TYPES OF PUMPS Hand pumps. Electric Pumps. Air-Driven pumps. Battery and gas powered pumps. 8
HIGH PRESSURE HYDRAULIC HOSES - Max. Operating Pressure = 10,000 psi(700 Kg/Cm2) - Length availability = 2 to 50 ft.( 0.6m to 15m) - Inside diameter = 0.25 to 0.38 (6mm to 9.5mm) - End connections = 1/4 NPT = 3/8 NPT Note : When using greater hose lengths, it is sometimes necessary to fill the pump reservoir after filling the hoses. 9
HYDRAULIC COUPLERS 1/4 COUPLER - For use with small cylinders and hand pumps. - Includes female dust caps. 3/8 High Flow couplers - Standard accessory on most of Enerpac Cylinders - Includes 2-in-1 dust cap for use on male 10 female coupler halves.
3/8 High Flow couplers 11
1/4 COUPLER 12
BASIC SYSTEM SET-UP - Hydraulic Cylinder - Cylinder Base Plate - Pump - Hose - Male Coupler - Female Coupler - Gauge : Applies Hydraulic Force. : For application like lifting where additional cylinder stability is required. : Develops hydraulic pressure. : Transport hydraulic fluid. : For quick connection of the hose to system components. : For quick connection of the hose end to the system components. : To monitor pressure of the 13 hydraulic circuit.
SIMPLE HYDRAULIC CIRCUIT FOR SINGLE ACTING CYLINDER 14
SIMPLE HYDRAULIC CIRCUIT FOR DOUBLE ACTING CYLINDER 15
ADVANCE - HOLD - RETRACT. Single Acting Double Acting 16
ADVANCE - HOLD - RETRACT. Single Acting Double Acting 17
ADVANCE - HOLD - RETRACT. Single Acting Double Acting T B 18
PULL CYLINDERS. 19
PULL CYLINDER - APPLICATION 20
LIST OF HIGH PRESSURE HYDRAULIC EQUIPMENT COMMONLY USED AT L&T HAZIRA WORKS Cylinders : Capacity/ Stroke Price RC-1006 1. RC1006 RCS-502 2. RCS-502 RCS-1002 3. RCS-1002 CLR-2006 4. CLR-2006 100 MT/ 6 50 MT/ 2 100 MT/ 2 200 MT/ 6 Rs. 45,000/Rs. 25,000/Rs. 35,000/Rs.1,10,000/- P-464 Rs. 45,000/- Pumps : 1 Hand Pump Hand Pump 2 Motorized Motorized pump Pump PER-3410E Rs.1,60,000/- 21
SPECIFICATIONS OF RC-1006 CYLINDER Model No. = RC-1006 (Single acting) Cylinder Effective Area = 20.65 in2 (133 sq cm) Oil Capacity = 136.91 in3 (2.25 liter) Collapsed Height = 14.06 in. (35.7cm) Extended Height = 20.69 in. (52cm) Weight = 132 lbs. (60kgs) 22
SPECIFICATIONS OF RCS-502 CYLINDER Model No. acting) = RC-502 (Single Cylinder Effective Area = 9.63 in2 (63 sq cm) Oil Capacity (0.375 liter) = 22.91 in3 Collapsed Height (12cm) = 4.81 in. Extended Height (18cm) Weight (10.9kgs) = 7.10 in. = 24 lbs. 23
SPECIFICATIONS OF RCS-1002 CYLINDER Model No.= RCS-1002 (Single acting) Cylinder Effective Area (126.5 sq cm) = 19.61 in2 Oil Capacity (0.725 liter) = 44.25in3 Collapsed Height (14cm) = 5.56 in. Extended Height (19.8cm) = 7.81 in. = 50 lbs. Weight (22.6kgs) 24
SPECIFICATIONS OF CLR-2006 CYLINDER Model No.= CLR - 2006 acting) (Double Cylinder Effective Area= 44.31 in2 (Push) (285.8 sq cm) Cylinder Effective Area= 19.69 in2 (Pull ) (127 sq cm) Oil Capacity (4 liter) = 244 in3 (Push) Oil Capacity (2 liter) = 116 in3 (Pull) Collapsed Height (31 cm) = 12.21 in. Extended Height (46 cm) = 18.11 in.. Weight = 203 lbs. (92kgs) 25
KEY TO CYLINDER DIMENSIONS. A = Collapsed Height B = Extended height C = Cyl. Body length D = Cylinder outside diameter. D1=Cylinder inside diameter T= Cylinder Thickness (D-D1) B C D1 D A 26
KEY TO CYLINDER DIMENSIONS. F = Plunger Rod Diameter. G = Oil inlet thread H = Cylinder Bottom to advance port. I = Cylinder top to retract Port. J = Saddle Outside Diameter. 27
KEY TO CYLINDER DIMENSIONS. Protrusion at K = Cylinder Rod collapsed height. L = Plunger center to side base. M = Mounting holes to Center of Plunger N = Length of smaller cylinder Part. 28
SPECIFICATIONS OF HAND - PUMP Model No. = P- 464 Oil Capacity = 453 in3 (7.42 liter) Pressure Rating = 10,000 psi.(700kg/cm2) Max. handle effort = 110 lbs. (49.9 kgs) Weight = 61 lbs. (27.7 kgs) 29
SPECIFICATIONS OF MOTORISED-PUMP Model No. = PER-3410 Type = Double Acting Valve function = Adv/hold/retract Reservoir Oil Cap.= 10 gallon. ( cm3) Motor HP = 1.5 Pressure Rating = 10,000 psi. Flow Rate = 60 to120 in3/min. ( 1 to 2 liter/min.) ( 112 kgs) = 246 lbs. Weight (700 kg/ cm2) 30
How to Select Hydraulic Cylinder? Total force required in Tons. No. of cylinders required. Force per cylinder in Tons. Stroke required. Single / Double acting Type of plunger required. Collapsed height required. Cylinder attachments. 31
How to Select Pumps? A. Hand Pump Single or double acting operation. 2 way valve for single acting application. 4 way valve for double acting application. 32
How to Select Pumps? A. Electric Pump Duty cycle. Required usable oil capacity. Available voltage Lifting Speed. Type of Control Type of Actuation /Function. 33
How to Select System Components? No. of Hoses & Length required. Manifold or Tee Extra hose per Manifold. Gauges ( PSI ) Fittings, Pressure relief valve & Load holding valves. Hydraulic Oil (Servo-68) 34
MULTILIFTING APPLICATION THROUGH COMMON MANIFOLD 35
FORCE The amount of force a hydraulic cylinder can generate is equal to the hydraulic pressure times the effective area of the cylinder 36
MEASUREMENTS Pressure : 1 PSI = 0.069 Bar 1 Bar = 14.50 PSI 1 kpa = 0.145 PSI Volume : 1 In3 = 16.387 cm3 1 Cm3 = 0.061 in3 1 Liter = 61.02 in3 1 Liter = 0.264 gal 37
MEASUREMENTS Weight : 1 Pound = 0.4536 Kgs. 1 Kg = 2.205 lbs... 1 Metric Ton = 2,205 lbs... 1 Ton = 2,000 lbs... 1 Ton MT = 1000 Kgs. 38
CALCULATIONS OF ACTUAL LOAD Example 1. An RCS-502 Cylinder with 9.63 in2 effective area operating at 8000 psi. will generate what force? Force = Pressure x Effective Area. = 8000 x 9.63 = 77040 lbs. (35 ton) Example 2. An RCS-1002 Cylinder lifting 14000 lbs. load with effective area of 19.67 in2, what is the operating pressure require? Force = Pressure x Effective Area. 14000 = Pressure x 19.67 Pressure = 711.75 psi. (50 kg/cm2) 39
WEIGHT MEASUREMENT BY HYDRAULIC JACKS 40
OFFSET CORRECTION 41
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ENERPAC JACK & PUMP SELECTION 43
HYDRAULIC OIL Use only genuine Hydraulic oil. The use of any other fluid may affect our cylinder, pumps and coupler life. For more details ask oil specification chart from maintenance dept. 44
Dos & Don ts 45
Dos & Don ts 46
Dos & Don ts 47
Dos & Don ts 48
Dos & Don ts 49
Dos & Don ts 50
Dos & Don ts 51
Dos & Don ts 52
HIGH PRESSURE HYDRAULIC COUPLERS Couplers should be pressurized only when completely connected. Always keep Plastic dust caps on coupler head. 53
HIGH PRESSURE HYDRAULIC COUPLERS Thread Sealer : To seal NPT threads use Teflon paste. When using: TeflonTape, apply the tape one thread from the end of fitting to prevent it from winding up in the hydraulic system. 54
HIGH PRESSURE HYDRAULIC HOSES Do not exceed maximum pressure of 10,000 psi. Do not handle hoses which are under pressure. When using longer hose length, it is sometimes necessary to fill the pump reservoir after filling the hoses. 55
IMPROPER STORAGE (JACK) 56
IMPROPER STORAGE (PUMP) 57
LACK OF MAINTENANCE 58
LACK OF MAINTENANCE 59
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