AMERICAN TECHNICAL PUBLISHERS Orland Park, Illinois
Patrick J. Klette
Fluid Power Systems contains procedures commonly practiced in industry and the trade. Specific procedures vary with each task and must be performed by a qualified person. For maximum safety, always refer to specific manufacturer recommendations, insurance regulations, specific job site and plant procedures, applicable federal, state, and local regulations, and any authority having jurisdiction. The material contained herein is intended to be an educational resource for the user. American Technical Publishers assumes no responsibility or liability in connection with this material or its use by any individual or organization.
Cover Photo Credits: kubais/shutterstock.com
American Technical Publishers Editorial Staff Editor in Chief: Peter A. Zurlis Assistant Production Manager: Nicole D. Burian Technical Editor: James T. Gresens Supervising Copy Editor: Catherine A. Mini Copy Editor: Dane K. Hamann Editorial Assistant: Erin E. Bello
Art Manager: Sarah E. Kaducak Cover Design: Steven E. Gibbs Illustration/Layout: Nick G. Doornbos Steven E. Gibbs Digital Media Manager: Adam T. Schuldt Digital Resources: James V. Cashman Lauren M. Lenoir Tim A. Miller
Teflon and Viton are registered trademarks of E. I. Du Pont de Nemours and Company, Wilmington, DE 19898. Quad-Ring is a registered trademark of Minnesota Rubber & Plastics, Minneapolis, MN 55441. FPSI is a trademark of the Fluid Power Safety Institute, Salt Lake City, UT. Quick Quiz and Quick Quizzes are registered trademarks of American Technical Publishers.
© 2022 by American Technical Publishers All rights reserved 3 4 5 6 7 8 9 – 22 – 9 8 7 6 5 4 3 2 1 Printed in the United States of America ISBN 978-0-8269-3637-0 eISBN 978-0-8269-9622-0 This book is printed on recycled paper.
Acknowledgments The author and publisher are grateful for the photographs and technical information provided by the following companies and organizations: Atlas Copco Atlas Technologies, Inc. Boeing Commercial Airplane Group Briggs & Stratton Corporation Chicago Pneumatic CNH America Curtis-Toledo, Inc. Enerpac Flow Ezy Filters, Inc. Fluke Corporation GOMACO Corporation Harrington Hoists, Inc. Hurst Jaws of Life Hyster Company
Klein Tools, Inc. Lift-All Company, Inc. The Lincoln Electric Company Parker Motion & Control Power Team, Division of SPX Corporation Prince Manufacturing Corporation Ridge Tool Company Rothenberger USA, Inc. Safetronics Inc. Salisbury Saylor-Beall Manufacturing Company SKF Condition Monitoring The Snell Group
About the Author Patrick J. Klette is the program coordinator of the electrical engineering technology program at Kankakee Community College in Illinois. Pat holds degrees in electronics systems technology and technology education and has taught fluid power for over 18 years. In addition, Pat teaches electrical installation practices, electricity and electronics, and industrial controls. Pat is also the author of Electrical Math Principles and Applications published by ATP.
Technical Reviewer The author and publisher are grateful for the technical review provided by the following individual: Jean K. Muenchen Adjunct Associate Professor, Computer, Engineering/Manufacturing Industrial Technologies Lansing Community College (MI)
Contents
1
CHAPTER
2
CHAPTER
3
CHAPTER
Fluid Power Systems in Industry
Fluid Power • History of Fluid Power • Future of Fluid Power • Fluid Power System Applications • Advantages and Disadvantages of Fluid Power Applications • Fluid Power Safety • Personal Protective Equipment • Lockouts and Tagouts • Fluid Power Hazards • Fluid Power Safety Training • Fluid Power Safety Standards • Fluid Power Associations and Certifications • Fluid Power System Troubleshooting • Fluid Power System Troubleshooting Methods • Fluid Power System Troubleshooting Procedures Chapter Review.........................................................................................................................19 Activities....................................................................................................................................23
Fluid Power System Principles
Hydraulic System Fundamentals
5
Hydraulic Pumps
6
Directional Control
CHAPTER
61
Hydraulic Principles • Properties of Liquids • Principles of Fluid Flow • Pressure and Resistance Relationship • Pressure Control • Maximum Resistance • Hydraulic System Pressure Supplements • Accumulators • Force Multiplication Systems • Intensifiers • Hydraulic Power Units • Pressurized Equipment Safety • Fluid Power System Diagrams • Pictorial Diagrams • Cutaway Diagrams • Schematic Diagrams Chapter Review.........................................................................................................................85 Activities....................................................................................................................................91
4
CHAPTER
25
Energy • Forms of Energy • Fluid Power Energy Transmission • Fluid Power System Efficiency • Resistance • Work • Power • Energy Transmission Safety • Fluid Power System Variables • Force • Area • Pressure • Fluid Power Formulas • Pressure Types • Pressure Measurement • Vacuum • Pressure Gauge Safety Chapter Review.........................................................................................................................47 Activities....................................................................................................................................51
Fluid Conductors and Connectors
CHAPTER
1
97
Velocity and Conductors • Velocity • Conductors and Connectors • Piping • Tubing • Hoses • Connector Thread Identification • Thread Types • Cleaning Conductors before Installation • Pressurized Hydraulic Equipment Safety Chapter Review.......................................................................................................................117 Activities..................................................................................................................................121
123
Hydraulic Pumps • Hydraulic Pump Ratings • Positive-Displacement Pumps • Positive-Displacement Pump Operation • Hydraulic Pump Types • Gear Pumps • Gear Pump Assembly • Vane Pumps • Vane Pump Assembly • Piston Pumps • Double and Triple Pumps • Hydraulic Pump Schematic Symbols • Pump Operation Safety • Pump Removal and Repair Safety • Installation Safety • Operational Safety Chapter Review.......................................................................................................................153 Activities..................................................................................................................................159
165
Check Valves • Direct-Acting Check Valves • Pilot-Operated Check Valves • Directional Control Valves • Directional Control Valve Schematic Diagrams • Two-Position, Two-Way Directional Control Valves • TwoPosition, Three-Way Directional Control Valves • Two-Position, Four-Way Directional Control Valves • ThreePosition, Four-Way Directional Control Valves • Directional Control Valve Mounting Methods • Directional Control Valve Actuators • Spring Actuators • Pilot Pressure Actuators • Solenoid Actuators • Detent Actuators • Proportional Actuators • Logic Valves • AND Logic Valves • Shuttle Valves • Hydraulic Valve Operation Safety • Directional Control Valve Operation • Directional Control Valve Repair and Replacement Chapter Review.......................................................................................................................195 Activities..................................................................................................................................201
7
Flow Control
8
Hydraulic Actuators
9
Pressure Control
CHAPTER
CHAPTER
CHAPTER
Hydraulic Flow Control • Pressure Differential • Orifices • Flow Control Valves • Piston Speed • Metering Fluid Flow • Metering Single-Acting Cylinders • Metering Double-Acting Cylinders • Bleed-Off Systems • Flow Dividers • Spool-Type Flow Dividers • Rotary-Type Flow Dividers • Flow Control Safety Chapter Review.......................................................................................................................231 Activities..................................................................................................................................237
11
Pneumatic System Fundamentals
12
Pneumatic System Compression and Control
CHAPTER
279
Direct-Acting Pressure Control Valves • Direct-Acting Relief Valves • Sequence Valves • Counterbalance Valves • Pressure-Reducing Valves • Unloading Valves • Remote-Controlled Sequence Valves • RemoteControlled Counterbalance Valves • Brake Valves • Pilot-Operated Pressure Control Valves • Pilot-Operated Relief Valves • Pilot-Operated Pressure-Reducing Valves • Other Pilot-Operated Pressure Control Valves • Pressure Control Valve Safety • Relief and Unloading Valve Adjustment • Sequence Valve Adjustment • Counterbalance Valve Adjustment • Pressure-Reducing Valve Adjustment Chapter Review.......................................................................................................................299 Activities..................................................................................................................................305
10 CHAPTER
241
Hydraulic Cylinders • Ram Cylinders • Single-Acting Cylinders • Double-Acting Cylinders • Seals • Cylinder Mounting Methods • Hydraulic Cylinder Safety • Cylinder Operation • Cylinder Installation • Cylinder Repair • Hydraulic Motors • Motor Torque • Hydraulic Motor Types • Hydraulic Motor Safety • Motor Installation Safety • Runaway Loads Chapter Review.......................................................................................................................267 Activities..................................................................................................................................273
Hydraulic Fluid Maintenance
CHAPTER
207
311
Contaminants • Sizing Contaminants • Contaminant Sources • Contaminant Effects • Contaminant Protection • Filter and Strainer Ratings • Hydraulic System Filtration • Hydraulic Fluid Cleanliness Ratings • Hydraulic System Heat • Hydraulic System Heat Generation • Heat Exchangers • Reservoirs • Hydraulic Fluid Storage • Breather/Filler Cap Assemblies • Hydraulic Fluid Cooling and Cleaning • Receiving Hydraulic Fluid from the System • Sending Hydraulic Fluid to the Pump • Other Reservoir Components • Hydraulic Fluid Equipment Installation Safety • Equipment Weight • Equipment Alignment • Equipment Operation Safety • Hydraulic System Maintenance • Troubleshooting Hydraulic Systems Chapter Review.......................................................................................................................345 Activities..................................................................................................................................353
363
Basic Gas Physics • Volume • Absolute Pressure • Absolute Temperature • Boyle’s Law • Charles’s Law • Gay-Lussac’s Law • Combined Gas Law • Pneumatic Systems • Compressing Air • Airflow • Cfm Ratings • Pneumatic System Safety Chapter Review.......................................................................................................................379 Activities..................................................................................................................................385
389
Pneumatic Systems • Prime Movers • Air Compressor Types • Receivers • Air Power Unit Safety • Control Devices • Compressor Control • Directional Control Valves • Flow Control Valves • Pneumatic Control Device Safety • Pneumatic Actuators • Pneumatic Cylinders • Air Motors • Vacuum Cups • Pneumatic Actuator Safety Practices • Troubleshooting Pneumatic Systems Chapter Review.......................................................................................................................415 Activities..................................................................................................................................421
Contents (continued)
13
Pneumatic Fluid Conditioning
14
Fluid Power System Electrical Control
CHAPTER
CHAPTER
425
Pneumatic Contaminants • Solid Contaminants • Liquid Contaminants • Pneumatic Filters • Intake Filters • Inline Filters • Pneumatic Conditioning Devices • Intercoolers • Moisture Separators • Air Dryers • FilterRegulator-Lubricators (FRLs) • Pneumatic Conditioning Device Safety • Compressed Air Preparation Procedure • Pneumatic System Maintenance Chapter Review.......................................................................................................................443 Activities..................................................................................................................................447
451
Electrical Quantities • Current • Voltage • Resistance • Basic Electrical Circuits • Parallel Circuits • Series Circuits • Series-Parallel Circuits • Electrical Control Circuits • Electrical Control Circuit Components • Electric Diagrams and Applications • Single-Acting Cylinder Control Applications • Double-Acting Cylinder Control Applications • Troubleshooting Fluid Power Electrical Control Circuits • Hydraulic System Electrical Safety Chapter Review.......................................................................................................................475 Activities..................................................................................................................................481
Appendix
487
Glossary
517
Index
529
Online Learner Resources • Quick Quizzes®
• Chapter Activities
• Flash Cards
• Media Library
• Interactive Schematics
• Internet Resources
• Chapter Reviews
Book Features Chapter objectives provide goals for each chapter. Chapter introductions preview content to be covered.
Schematic diagrams illustrate common applications.
Tech Facts provide technical tips or background information.
Quick Response (QR) Codes at the beginning of each chapter enable access to digital resources.
Review questions and activites are included to test for chapter comprehension.
Detailed illustrations show various types of fluid power equipment.
Application photos supplement text and illustrations.
Online Learner Resources The Fluid Power Systems Learner Resources are self-study tools that reinforce the content covered in the book. These online resources can be accessed using either of the following methods: • Key atplearningresources.com into a web browser and then enter access code . • Use a Quick Response (QR) reader app to scan the QR Code with a mobile device.
This edition of Fluid Power Systems includes access to online learner resources that reinforce and enhance the content covered in this text/workbook. • Quick Quizzes® provide learners with multiple choice questions for each chapter, with each question linking to the referenced content from the text/workbook. • Flash Cards offer learners a simple method for reviewing the terms, definitions, symbols, abbreviations, tools, and equipment used in the text/workbook. • Interactive Schematics consist of schematic diagrams for fluid power equipment, with descriptions and photographs for a given part displayed when the part’s symbol is selected. • Chapter Reviews are PDF documents with interactive fields that learners can fill in to demonstrate comprehension of the content covered in each chapter of the text/workbook. • Chapter Activities provide learners opportunities to apply chapter concepts and test comprehension. • The Media Library consists of high-quality videos and animations that reinforce the content covered in the text/workbook. • Internet Resources link to organizations, associations, and companies related to the trade.