Industrial Fluidpower

Table of Contents

Chapter 1: Principles of Hydraulics

Topics: Force, weight, mass, pressure, work, power, and energy; Incompressibility; Nondiffusion; Hydrostatic pressure; Pascal's Law; Fluid power transmission; Bernoulli's principle

Learning Objectives:

• Explain the difference between absolute and gauge pressure.
• Demonstrate how power is calculated.
• Explain Pascal's Law.
• Describe the difference between laminar and turbulent flow.
• Name the main components of a hydraulic system.

Chapter 2: Hydraulic Diagrams

Topics: Definition, kinds, and characteristics of schematics; Lines; Symbols; Flow patterns; Tracing a circuit; Sequence valve circuit

Learning Objectives:

• Name three basic types of hydraulic diagrams, and explain the purposes of each.
• Describe how a valve symbol is constructed.
• List the steps to follow when reading a schematic diagram.
• Identify common hydraulic symbols.

Chapter 3: Hydraulic Fluids

Topics: Viscosity; Pour point; Fluid selection; Chemical properties; System contamination; Dissolved air; Foaming; Corrosion and rusting

Learning Objectives:

• List the most important properties of hydraulic fluids.
• Explain how viscosity is measured.
• Explain the meaning of the viscosity index.
• Describe the effect of fluid temperature on viscosity.
• Name the causes of corrosion and fluid oxidation.
• Identify various types of hydraulic fluids.

Chapter 4: Strainers and Filters

Topics: Contaminant removal; Strainer performance; Types of strainers; Fibrous and nonfibrous filter media; Magnetic media; Installation

Learning Objectives:

• Name contaminants found in hydraulic systems.
• Explain the difference between a strainer and a filter, and describe the main function of each.
• Describe the two basic types of filter/strainer media.
• Draw graphic symbols for strainers and filters.

Chapter 5: Reservoirs and Accumulators

Topics: Reservoir, air separation requirements; Baffles; Reservoir cooling methods and accessories; Accumulators; Schematic symbols

Learning Objectives:

• Explain the functions of fluid reservoirs.
• Explain the purpose of reservoir baffles.
• Describe various methods of counteracting high operating temperatures.
• Identify important accessories used with reservoirs.
• Demonstrate pressure ratio calculation for a differential-piston accumulator.

Chapter 6: Hydraulic Pumps

Topics: Pump varieties, functions, and selection; Gear, screw, cycloidal, vane, axial-piston, and radial-piston pumps

Learning Objectives:

• Name the main classification of hydraulic pumps.
• List factors affecting pump selection and pump performance.
• Define volumetric efficiency and overall efficiency.
• Identify the most common types of positive-displacement pumps, and describe their operation.

Chapter 7: Hydraulic Directional-Control Valves

Topics: Valve classification; Automatic, two-way, check, pilot-operated, and spool valves; Hydraulic motors; NO, NC, holding valves; Symbols; Flow ratings

Learning Objectives:

• Explain the classification of directional control valves.
• Describe how manually operated valves work.
• Explain the difference between direct-acting and pilot-operated valves.
• Describe the operation of a check valve, a spool valve, a three-way valve, a four-way valve, and a rotary valve.
• Explain the difference between normally closed and normally open valves.

Chapter 8: Hydraulic Pressure-Control Valves

Topics: Poppet, spool, sequence, counterbalance, holding, unloading, and pressure-reducing valves; Shock suppressors; Flow-control valves

Learning Objectives:

• Explain the functions of a pressure-control valve, a pressure-relief valve, and a pressure-reducing valve.
• Describe the operation of a spool valve, a poppet valve, and a sequence valve.
• Explain the purpose of holding valves, unloading valves, and counterbalance valves.
• Name the operations performed by flow-control valves.
• Describe how pressure compensation and temperature compensation work.

Chapter 9: Hydraulic Cylinders

Topics: Double-, single-acting cylinders; Two-piston cylinders; Positional cylinders; Cylinder construction; Rings, seals, and packing; Cylinder mounting and selection; Flow capacity; Cushioning

Learning Objectives:

• Describe the purpose of a hydraulic cylinder, and explain how a double-acting cylinder works.
• Explain the difference between "pull-type" and "push-type" single-acting cylinders.
• Describe the construction of a hydraulic cylinder.
• Explain the various methods of mounting cylinders.
• Demonstrate how to calculate the flow capacity of a hydraulic cylinder.

Chapter 10: Hydraulic Motors

Topics: Performance specifications; Starting, running, and stalling torque; Volumetric efficiency; Hydraulic motor construction; Gear, vane, and piston motors

Learning Objectives:

• Explain the classification of hydraulic motors.
• Demonstrate how the torque of a hydraulic motor is calculated.
• Calculate the horsepower output of a hydraulic motor.
• Discuss cost factors and other considerations affecting motor selection.
• Describe the construction of a hydraulic motor.
• Explain the operating principles of a gear motor, a vane motor, and a piston motor.

Chapter 11: Maintaining Hydraulic Systems

Topics: Inspections; Maintenance requirements; Fluid level; External leaks; Operating pressure; Fluid quality; Filter maintenance; Reconditioning

Learning Objectives:

• List the major categories of hydraulic system maintenance.
• Name and describe the six essential items in a maintenance file.
• List the steps involved in reconditioning a hydraulic component.
• Explain how to set up a maintenance plan for a typical hydraulic system.

Chapter 12: Hydraulic System Troubleshooting

Topics: Diagnosis and symptoms; Evaluating machine history; Determining the cause; Providing the solution; Tools and gauges; Troubleshooting charts

Learning Objectives:

• Describe the troubleshooting process.
• Explain how to evaluate recent maintenance history.
• List typical symptoms of common hydraulic system problems.
• Explain how to determine the cause of and provide a solution to a problem.
• Explain how a portable tester works.
• Describe how to keep and use troubleshooting charts.

Chapter 13: Principles of Pneumatics

Topics: Fluid power systems; Force, weight, and mass; Pressure; Work and energy; Diffusion and dispersion; Compressibility; Laws of pneumatics; Leverage; Air properties and flow; Bernoulli's Law; Components

Learning Objectives:

• Explain how force is transmitted in a pneumatic system.
• Calculate force and work.
• List two factors that affect the results of pressure calculations.
• Explain pneumatic leverage.
• Briefly explain the physical laws affecting the behavior of a confined gas.

Chapter 14: Pneumatic Diagrams

Topics: Schematic symbol construction; Diagramming an air supply; Simple pneumatic systems; Timing and safety circuits; System schematics

Learning Objectives:

• Explain the different types of symbols used in pneumatic schematic diagrams-how they are constructed and what they show.
• Describe the operation of timing and safety circuits.
• Analyze the schematic diagram of a fluid-power system.

Chapter 15: Reciprocating Compressors

Topics: Compressor construction, classification, and operation; Single-, double-acting compressors; Cooling requirements; Lubrication; Controls

Learning Objectives:

• Differentiate between a positive-displacement compressor and a dynamic compressor.
• Describe the operation of a reciprocating compressor.
• List one advantage of using a multistage compressor.
• Identify the cooling arrangements for reciprocating compressors.
• Compare the operation of compressor controls in large and small units.

Chapter 16: Rotary Compressors

Topics: Vane, rotary-screw, low-pressure, high-volume, diaphragm, centrifugal, and axial-flow compressors; Compressor capacity; Accessories

Learning Objectives:

• Compare the power output of a single-stage vs a two-stage vane compressor.
• Describe the main types of positive-displacement rotary air compressors.
• Explain the advantages and disadvantages of both types of dynamic compressors.
• Describe four methods of controlling centrifugal compressor output.
• Tell how to compensate for a low-speed drive in rotary screw compressors.

Chapter 17: Pneumatic Directional-Control Valves

Topics: Manually and automatically operated valves; Control valve elements: spools, poppets, disks, and plates; Two-, three-, four-, and five-way valves; Accessories

Learning Objectives:

• Describe the four methods of identifying control valves.
• List four basic types of manually operated, two-way valves.
• Describe the operation of a two-position, direct acting, normally closed solenoid valve.
• Explain one major advantage of using a four-way valve.
• Describe the construction of a three-way valve.

Chapter 18: Pneumatic Pressure-Control Valves

Topics: Safety vs relief valves; Relief valve construction; Pressure regulators; Pilot-operated, remote-controlled regulators; Logic functions

Learning Objectives:

• List two ways a valve can control compressor pressure output.
• Describe construction of two basic types of pressure-relief valves.
• Contrast a pressure regulator with a pressure-relief valve.
• State the limit imposed by Federal Law on the pressure allowed when an air hose is used to blow off chips.

Chapter 19: Pneumatic Cylinders

Topics: Double-, single-acting cylinders; Two-piston cylinders; Cylinder construction, mounting, and selection; Performance charts; Cushioning

Learning Objectives:

• Tell the difference between pneumatic and hydraulic cylinders.
• Describe the construction and operation of a single-acting cylinder.
• State the purpose of an exhaust flow control metering valve.
• Describe the action of a pivoted cylinder.
• Explain the size relationship between a cylinder port and a valve port.

Chapter 20: Pneumatic Motors

Topics: Motor rating; Selection factors: pressure, speed, torque, horsepower, reliability, and service life; Rotary vane and piston motors; Air boosters

Learning Objectives:

• Explain pneumatic motor classification.
• Define torque.
• Describe pneumatic motor construction.
• Calculate a motor's horsepower, given its torque and speed.
• Differentiate between a pneumatic motor and a rotary actuator.

Chapter 21: Pneumatic System Maintenance

Topics: Control system maintenance; Cylinder maintenance; Tool maintenance; Logs and records; Automatic recorders and recording charts

Learning Objectives:

• Explain the concept of planned maintenance.
• Describe the basic procedures for maintaining the compressor and other important components in a pneumatic system.
• Describe the maintenance of industrial control circuit components.
• Explain the proper maintenance of pneumatic tools.
• Discuss the various types of maintenance logs and explain what kind of information is recorded in each.

Chapter 22: Pneumatic System Troubleshooting

Topics: Locating troubles; Operations manual; Checking the air supply; Troubleshooting valves and actuators; Interlocks; Final adjustments

Learning Objectives:

• List, in proper sequence, the steps to be taken in troubleshooting a pneumatic system.
• Name and describe the five important parts of every pneumatic system's operations manual.
• Describe procedures for troubleshooting the actuator.
• Explain how to check control valves, sequence valves, and interlocks.

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