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60301 g

Millwright

Accessories, Fluids and

Seals r Part A

Hydraulics and Pneumatics

Third Period

Table of Contents
Problerns

Materials Used in

Metal-to-Metal

Sea1s............

Seals.......

Sources of Contamination............
How Contamination Levels are Measured
How to Read ISO Cleanliness Codes..........

Target Cleanliness

Ler.'els

Construction of a Filter
Locations of Fluid Filters..........

..........5

................12

........................20
...........25
.........27
..............28
....................31
..........................34

Pressure Lirre Filters

Retum Line

It

Fiiters

How Filters are Rated

How to Select a Filter ...........

..........................36

.......................37
...........39

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Accessories, Fluids and

Seals - Part A
Rationale
Why is it important for you to learn this skill?

Hydraulic systems are designed to leak internally. and not to leak externally. H;,draulic
fluid is costl1' and is designed to be used over and over. Leaks in hydraulic systems are an
unnecessary, but chronic problem. Although most leaks are minor, they often present a
safeq* hazard and can lead to catastrophic failure of the system. For these two reasons it
is essential for you to know horv to install and maintain seals that do not leak.

Dirt destroys h1,'drauiic systems more than an-v" other cause. Hotv well you control
contaminatiorr in ahydraulic system deterrnines the reliabilitl'of the svsteln. In l-act, at
least one major hydraulics manufacturer doubles the u,arranty on their components if you
meet the ISO cleanliness levels generally accepted by industry. To meet these standards
you rnust knor.l' how clear.rliness is measured and hou' to select the correct filters.

A major pump failure generates considerable debris. lt is very impoftant to have a filter
located just after the pump discharge to capture an.v debris before it damages components
in the rest of the system. You must be sure to flush the system after a catastrophic faiiure
to ensure that an1'debris that rnay have been forced past the filter is removed.

Accumulators. reservoirs and fluids are components of a hy'draulic system that you must
understand in order to maintain them. Problems with any of these directly affects the
operation of the system.

Outcome
When 1'ou have completed this module vou tt'ill be oble to:

Describe accessories, fluids and methods of sealing these fluids in hydraulic systeurs.

Objectives
1.

2.
3.

Describe the characteristics, applications and installation procedures for various seals
used in hydraulic components.
Describe the methods used 1o specif,,particulate fluid contamination.
Describe the tvpes, purpose, application and rnethods of specifl,'ing filters used in
hy'draulic s),stems.

lntrod uction
In this rnodule vou leam the lvpes of seals to use in hy'draulics and horv to install them so
that they do not leak. You also learn about the t-r'pes of reservoirs and accessories that are
ar,'ailable to help you get the most out of your h,""draulic system. Bur the most impofiant
rnaintenance information presented is hou' to keep the fluid in l our h,vdraulic s)'sten.l
clean. This will enable ),ou to double the u arran[' titne on son]e colnponents.

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Objective One
llthen l,ou ltave completed this objectitte I'ou wiil be uble to:
Describe the characteristics. applications and installation procedures for various seals
used in hydraulic components.

Problems with Leaks

Besides being messv. leaks at seals and connections are hazards to y'our safety and reduce
the reliability of the system.

Safety Problems
when 1,ou approach an area that has hydraulic leaks you should be au,'are of the
following four hazards: slipping. pinhole leaks, fluid contact ivith your skin. and fire and
explosions.

Slipping Hazard
One function of a hydraulic fluid is to lubricate. You can easily slip on leaked fluid and
fal1 onto machinery in congested areas. ln some cases ,vou may get off with minor
injuries. but in other cases you can be seriously injured or killed.

Pinhole Leaks
High-pressure fluid that jets through a pinhole leak is usually not visibie (Figure 1).
Hou'ever, tliis fine stream offluid at pressures around 2000 psi can pierce your skin and
enter your bloodstream. This can lead to _qangrene. aurputation or death.

L-

NOTE
Never attempt to locate a pinhole leak rvith your hand (Figure

1).

Pinhole leaks
are often invi sible- .;'
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Fluid Contact with your Skin

Hydraulic fluids can be carcinogenic. There are docurnented cases of hydraulic fluids that
have caused skin cancer. This is true for common hvdrocarbon-based fluids. but even
more so for synthetic fluids.

Fire and Explosion Hazards

The commonly used hvdrocarbon-based fluids are flammable and can be ignited with a
flame or by contact with objects at telnperature above 250"C. You should also be arvare
that hydrocarbons can explode when they contact pure oxygen (e.g., from a cutting

torch).

Problems with Reliability in a System

Burst lines and seals and even pinhole leaks can quickly cause the system to shut down.
but so-called rninor leaks also reduce the reliabiliq' of a system. Contaminants such as air
and dirt are sucked into the system through leaky connections and seals when the
pressure drops at the iniets to pumps and actuators. Tl-Lis is referred to as ingested
contamination (Fieure 2).

Work Hardened Particles

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Ingested
Contaminants
ated Dirt
Leaky Fitting
Figure

2'

Ingested contaminants.

Abrasive parlicles that get into the system u'i1l remove rnetal frorn the r.r'orking parts of
valves. pumps and actuators. The metal that is removed rvork-hardens and be very
ef-fective in removing more metal. In this way. wear and damage to the parts accelerates
until a component fails.

NOTE
Dirty gritry'oil acts verl,rvell

as a grinding compound.
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60301 gp4.0.doc

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Air in the

system is carried by the fluid into high-pressure regions, where the bubbles
collapse violently and remove metal from cornponents. The destruction of the component
ploceeds in the sarne way as it does with abrasive contaminants.

Air also causes rapid wear in working parts because it drasticallir reduces the ability
the fluid to lubricate. Abrasive u,'ear and generation of heat will resuh.

of

As you can see, the minor leaks cause serious (costly) damage to any hydraulic system.
Effective sealing is the answer to this problem. The aircraft industry has dernonstrated
that you can virtually elir-ninate all leaks since they have s1,'stems that do not leak. Your
commitment to effbctive sealing u'ill result in large pay,backs in tenns of uptirne, reduced
maintenance costs and the elirnination of untimel_v svstern failures.

Cost of Lost Fluid

In most cases the cost of fluid lost from srnall leaks goes unnoticed since this cost
accumulates gradually. However, there are savings to be gained by eliminating leaks over
the course of a year. The magnitude of this saving can be seen from an estimate that over
a hundred million gallons of fluid are lost in the hydraulics industry through leaks each
vear. Also- a Mobil Oil Corporation survel' found that the average plant used four times
the amount of h-vdraulic oil than its n-rachines can hold!
On larger leaks, the cost is tnore noticeable. For example. the seal on a large cvlinder at a
steel mill r.vas allowed to leak a thousand litres per eight-hour shift for a month. The cost
of the fluid and cleanup were noticeabie. Another source of large leaks that is not
uncolnmon is burst hoses. Many s1'stems have hoses that cary flows of over a hundred
sallons per ntinute. When one of these hoses bursts. most of the contents of the resert,oir
are lost before the system is shut down.

Finding Leaks
Wlren you look at a machine that y,ou know has leaked (because you can see oil spread
over numerous pipes. on the sides of the rnachine, on the u'iring and on tire floor), you
may be hard pressed to point to the exact source of the leak. Ti-re following steps can help
)ou locate the leak.
r Clean the area as best you can and rvatch keenly,' for the leak.
r Focus on fittings first and then hoses and seals.
. Suspect the fitting that is rnost difficult to get at since it will have been tlre
hardest to tighten properly..

Types of Seals
There are a number of different t1,pes of seals. Positite seals are designed for zero
leakage. wh1le non-posirn,e seals allou'contlolled leakage. Two major ciasses of seals
used in rotary pumps are stalic and d.vnantic seais. Sralic seals seal between stationaryr
parts and d),namic seals seal betrveen moving parts. Also. seals will be made of specific
materiais that are compatibie u'ith the telnperatures, pressures and products that they''
lrust seal asainst.

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Positive Seals
Any

seal that does not allow any leakage is classed as a positive seal. In hydraulics, you

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metal-to-rnetal joints on housings,

sealant between rnetal surfaces;

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on PiPes' tubes and hoses'

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Non-Positiye Sea/s

Non-positive seals allou'controlled leakage for lubrication. In hydraulics, you will find
them used between surfaces in which one surface is rnoving. The foilorving are examples

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pistons against the cylinder walls.

gear teeth against the casing and against each other at the rnesh point,
the drive shaft on pumps and motors and

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Static Seals

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Static seals provide a seal between two surfaces that do not move rvith respect to each
other. The seals listed as positive are exarnples of tliis class of seal.

Dynamic Seals
Dynamic seals must seal against a moving surface. ln order to reduce the heat and rvear
from contact u'ith a movinq surface. these seals allow controlled leakage for iubrication.
The seals listed for tlre non-oositive seals are dvnarnic seals.

Materials Used in Seals

Seal materials must stand up to the operating conditions to which they are exposed. These

conditions include the follorvins:

. temperature.

.
o
.

pressure.

chemical action of the product and

surface speed and finish ofthe moving surface that it contacts.

Installation of Seals
Many seals fail because of improper installation. If you scratch a seal surface or nick,
distort or wrinkle a seal. 1'ou will create a potential leak path. To elirninate these
problems 1,'ou must take the time and care to follow the proper installation procedures.

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Copl'ri ght Alberta Advanced Educatron

60301 gp4 0 doc

Stafic Seals
Most static seals that you rvill install require sufficient clamping pressure to resist the
pressure of the fluid that 1,su are sealing. 'fhis clarnping pressure is provided either by
bolts or by thread engagement on fifiings.
M

etal -to-Mefal Seal Sudaces

Metal-to-metal seals are used in high-pressure applications in which the pressure is

steady. The bolts must be sufficiently tight to resist any separation ofthe seal surfaces
due to fluid pressure inside the component.
Metal-to-meta1 seal surfaces are very rigid and do not seal if they are scratched, distorted
or if thev have any deposits such as difi or corrosion on thern. When you assernble these
surfaces you must take the following steps.
l. lnspect the surfaces for any imperfections and stone out any burrs or scratches.
2. Thoroughly u'ash the housing to ensure that there is no residual grit frorn the
stoning that could enter the working parts.
3. Assemble and snug up the bolts evenly.
4. Torque the bolts to a third of the recommended torque in the recornrnended
sequence. ln most cases, this will be in a star pattern on a circular assembly and
in a spiral frorn the centre of a rectangular assembly' (Pigure 3).

Star Pattern

Spiral Pattern

Figure 3 - Tightening sequence.

). Tighten to two thirds of the specified torque and then to the full torque that is
specified in the service manual.

NOTE
Alwal's consult the service manual when y,'ou assemble a hydraulic
component and follow the bolting procedure specified. You ma1, find
that the torque on the sarle sized bolts used on differerrt cotnponents
can vary by 150 foot-pounds. In other cases a thread adhesive may be
specified.

Gaskets
Gaskets are nrade of softer material than the surfaces that they seal. Their softness allows
them to conform to irregularities. Gaskets are used in the follou'ing situations.
. Rising and falling internal pressure causes the surfaces to move apart slightl,v and
corne together as the pressure falis. The gasket can expand and compress to
maintain a seal between the surfaces. An erampie u,ould be the gasket of the
head end cover olt a piston pulxp or nrotor (Figure 4).
i 6030i gn-4.0.doc

Copvright Alberta Adlanced Educatjon

Compresses
Gask

Low Pressure

High

Pressure

Bolt Pressure

Lifts Head
Slightly
Allows
\rd

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to Expand

Gasket

Figure 4 - Gasket sealing under a changing load.

They are used to seal between surfaces made of lightweight or weak materials
such as aluminum alloys. Examples include alloy housings, stamped metal or
plastic covers and sheet metal covers.
They ale used to seal a specific area of the surf-ace. Examples include tl.re seals
between stack valves (Figure 5a) or between the flex plates and support plates on
a cartridge style vane pump (also shown in Figure 5b).
a) O-Ring Gaskets

ry

Lonc
Tie Bolts

b) Balanced Vane Pump Gaskets

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Drive End
Support Plate

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lt

Flex Plate
I

Rotor with
vdilE> rearn

Rinn

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Figure 5 - Gaskets to seal a specific area.

Flat Gaskets
Flat gaskets are very versatile seals. They are available in a wide variet.v of rnaterials and
designs to seal against a large range ofpressures. temperatures and fluids.

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Although flat gaskets are simple to install. you must observe the foilowing points to
ensure a good seal.
o Clean the surfaces.

'

Ifyou have anv doubt about the flatness ofthe surfaces. check them u'ith a
straight edge. If it is not practical to make a distorted surface flat, then you must

If you have a gasket made of a hard material (for high-pressure service), you u,ill

replace the defecrive pan.

have to stone out any scratches, nicks or burrs.

'
.

Set the gasket in place. Most high-pressure joints in hydraulic pumps, motors and
valves are doweled for alignment of the bearing that they house. These dowels
also serve to aiign the gasket.
Bolt up the,ioint to the torque specified in the service manual and as described
for metal-to-metal ioints.

O-Ring Gaskefs
O-ring gaskets are referred to as static O-rings because they do not seal between moving
parts. Static O-rinss have become popular in hydraulics as a stationary seal instead of
using a gasket across the entire face ofmating surfaces. They consist ofa ring ofsoft
material seated in a groove. They are very effective seals because they are soft enough to
conform to inaccuracies in machining. but can seal against high pressures since they are
supported by the sides of the groove in which they are seated (Figure 6). As a result, they
do not require as high a bolt load as a flat gasket.

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Groove-

O-Ring (Cross Section)

Figure 6 - Static O-ring seal.

When they are used as stationary seals. about 10% of their diameter must project above
the groove in u'hich they are seated (Figure 7). This allou,s for compression of the O-ring
in order to seal.
1Or/o

of Diameter

Before Compression

After Compression

Figure 7 - O-ring compression.

O-rings are available in a u'ide range of materials to seal against various pressures and
types of fluid. It is very important that 1.ou use O-rings made of the material that is
specified for the component and the application. Examples of some of the materials that
you will find in h1'draulic components are as follou,s.
r Fluorocarbon (Viton) is used for high-pressure seais between support plates and
flex plates in vane pumps or motors. \riton is resistant to chemical reaction u,ith
rnost h1'draulic fl uids.

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Copl'ight Alberta Advanced Education

Artificial rubber (Neoprene) is used for low-pressure seals between housings

and

cartridges on cartridge-sq'le vane pumps. Neoprene is a less expensive, rubberlike material that is resistant to chemical reaction with mineral oil.
PTFE (Teflon) is used for backup rings to provide support for neoprene O-rings
in high-pressure applications (Figure 8).

prgs.gulg

\Vider Groove

Pressure

Standard
Groove

Figure 8 - Neoprene O-ring with Teflon backup ring.

ln Figure 8. tire hard 'leflon backup ring supports the softer O-ring to prevent it frorn

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being ertruded. Notice that the O-ring groove is u'ider to accommodate both rings. If you
notice a groove that is wider than the O-ring ahvays install a backup rin-e. When you
replace O-rings it is very easy to damage the groove and the new O-ring unless you
observe the following points.
1. Use an O-ring pick to remove an O-ring (Figure 9). Do not use a tool that can
scratch the O-ring seat and create a leak path. Avoid prying O-rings out with
tools like scribers. screwdrivers or knives.
Never use a screwdriverl
Damaged seat creates

leak path.

Use an

Figure 9 - Use an O-ring pick.

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2.

Clean and lubricate the O-ring groove and the surfaces that the O-ring must pass
over to install it.
Tape any sharp edges or use a sleeve to avoid cutting the O-ring on these edges.
Tape over sharp edges.

Lubricate
O-ring

Figure 10 - Avoid cutting an O-ring.

Lubricate the O-ring with the fluid to be used in the system: then carefully slide it
into the groove.

I.

NOTE

Do not twist the O-ring and do not stretch it any more than is
necessary to get it to the groove.

Sealants
ln hydraulics. sealants are used on tapered threads and betu,een high-pressure iip

seals

and the casing when the seal is being replaced.

Sealin g Tapered Threads

As you can see in Figure 11. there is a clearance between the crest and the root of the
thread that creates a spiral leak path. You can apply liquid PTFE (Teflon) to the male
threads to seal this leak path.
Spiral clearance
allows leak

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Figure 11 - Spiral leak path in a tapered pipe thread.

(Courtesy Eaton Corporation, Hydraulics Operations)
NOTE
When ,vou apply sealant to a pipe thread ,vou must avoid the first two
threads from the end (see Figure 12) to prevent sealant getting into the
system. When sealant gets into the svstem it clogs pilot passages.
causes valve spools to stick, or prevents poppets from seating properly.
10

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In hydraulics. you should apply liquid sealant to tapered pipe threads instead ofPTFE
(Teflon) tape. Bits of Teflon tape can shred and get into the bore of the pipe when 1,ou
engage and tighten the threads.
No sealant on these two threads

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wa,
fitting.

Figure 12 - How to apply sealant to pipe threads.

Sealing High-Pressure Lip Sea/s to the Casing

When you replace a high-pressure lip seal you will find that it has a press fit into the
housing. Hou,ever, after the seal has been replaced a f-erv times the housing fit may not be
tight enough to retain tire seal securely. In order to avoid the chance that the seal might
rotate in the housing during operation you rnust apply a hardening gasket type sealant to
the housing before you install the seal (Figure 1 3).

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Hardening type sealant on seal housing

Figure 13 - Sealing the lip seal to the housing.

Dynamic Seals
Dynamic seals must seal to a rnoving surface with as little friction as possible. To reduce
friction and r.l'ear as much as possible the seals must exert a rninimum arnount of pressure
on the surface to be sealed. In hvdraulics. rnost dynarnic seals require lubrication. To
faciiitate lubrication. d1'namic seals allou,controlled leakage. The surface must be free of
irregularities that create leak paths.

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Metal-to-Metal Seals
A4etal-to-metal seals are used to control leakage between parts inside the components. In
pumps and motors. the total amount of controlled leakage through all the rnetal to metal
seals is typically 5Yo to 15% of the flow that enters the component.

Hardened Sfeel Valve Plates and Pressure Plates

These seals consist of a flat plate rvith ports cut in it that must seal against the rotor in a
vane pump or motor. Figure l4 shows that the seal surfaces are spring-loaded as u'ell as
h1'draulically balanced.
Pressurized
Film of Fluid

Spring

Pressure
Plate

Pressurized Fluid

Figure l4 - Pressure plate seal.

To ensure that there is no leak path between the ports you rnust lap these surfaces and
polish them with crocus cloth on a flat surface. This is normally part of an overhaul
procedure that may be done in anoti.rer location than in )'our plant. You should inspect
these surfaces for uneven ll'ear and for score marks or scratches that fonn a leak path
betra'een ports.

As you can see. the seal surfaces are separated by'a thin film ofpressurized fluid to
provide lubrication at all times. The spring pressure prevents the suri'aces frorn separating
bey6n6 the gap necessary for the t'ilm of lubricant.

Brass FIex Plates and Wear Plates

Brass flex plates seal against the rotor in a vane purxp or motor ra'hile brass rvear plates
seal against the gears in an extemal gear pump. Tliey' seal in the same \\'ay as the valve
plate and rotating group seals in a piston pump or motor (Figure 15). lnspect the surfaces
of these parts for leak paths as you would for the r,alve plate in a piston pump or motor.

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Face of

Brass Wear

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--

fr' !
f

Brass Flex Plate

Face of Rotor

Figure 15 - Flex plates and wear plates.

Shaft Seals
Shaft seals can be either high-pressure lip seals or mechanical seals.
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gh-Press u re Li p Seals

High-pressure /rp seals are used to seal against the case pressure in hydrauiic pumps or
motors. The pressure in the case is rnuch lower than the system pressure and should not
exceed 150 psi; otherwise, the shaft seal will blow out.

Low Pressure

tt

Metal Retainer

rter Spring

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High Pressure

Figure 16 - High-pressure lip seal.

(Courtesy Eaton Corporation, Hvdraulic Operations)
The high-pressure lip seal design contacts the shaft by means of a very thin lip
(Figure 16). The garler spring hotds the lip in contact u'ith the shaft u.hen the purnp or
motor is shut down and the case is depressurized. When the pump or motor is operating,
the case pressures up and the case pressure acts to press the lip against the shaft. In this
way the seal is pressure-activated. But in order for the lip to seal and not burn out u'ith
the friction, it rnust ride on a thin film of oil. Therefore. you must al*'ays prelubricate
the lip and the seal when you replace a seal.

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Copvright Alberta.Adr,anced Education

Installation of a High-Pressure Lip Seal

A lip seal is very easiiy damaged u'hen it is installed and if damaged, will f-ail very
quickly, if not irnmediately. Therefore. you must take tlre follou.ing steps to ensure that
the seal does not leak.
1.
c lean the bore in the casing for the sear to relnove all burrs and deposits.
2. Remove any remaining grit from cleaning and coat the bore with hardenine
gasket t1 pe sealanr.
3. Place the seal square with the casing bore and with the open side of the seal
facing into the bore towards the pressure (Figure l7).

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Open side towards pressure

Use a press

Qloorro

Seal

Figure l7 - Correct wa1' to install a lip seal.

1.

Select a sleeve u,ith an outside diarneter 0.010 inches srnaller than the bore
diameter and use it to press the seal into the bore. use a press whenever possible
to install a seal (Figure I7). Never hammer directll on a seal without using a
sleer e.

). Remove all deposits and burrs from the shaft u,ith fine emer1., cloth and porish
rl,'ith crocus cloth.

NOTS
When rou ernerl'the shaft. keep the strip of errery'at right angles to
the axis of the shaft to ai'oid creatin-g spiral or longitudinal scrarches
that provide ieak paths through the seal (Figure I 8).

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Do not use
spiral marks.

Make the marks

circumferential.

Emery at right angles

to the shaft.
Figure l8 - How to emery a shaft.

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6.

Wipe any' remaining grit from the shaft and install a thimble. The purpose of the
thimble is to prevent the lip frorn beirrg darnaged by the edge of the shoulder
(Figure l9). Do not attempt to install the seal without protecting it from the
edge on the shoulder. It has been proven that, even after taking every other
orecaution. the seal leaks after installation when a sleeve is not used.

Figure 19 - Use a thimble to install a lip seal.

(Courtesy Eaton Corporation, Hydraulics Operations)

7.

Lubricate the seal, the shaft and the thimble with the s,vsteln fluid and carefully
slide the thirnble and shaft throush the seal.

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Mechanical Seals
Figure 20 shows a mechanical seai. This type of seal is more elaborate than the lip seal
and more expensive. lt is used on pumps or motors that are designed to allow case
pressures over 150 psi.
Housing

Wave washer
provides spring tension
to force stationary face
against rotating face

O-rings provide
static seal.

Shaft
This part of seal
remains stationary
in housing.
Sealing
Surface

This part of seal

rotates with shaft

Figure 20 - Mechanical seal for high pressures.

(Courtesy Eaton Corporation, Hydraulics Operations)

Rod Sea/s
Figure 21 shows that the rod bushing contains O-rings on the outside to prot'ide a
stationary seal to the rod end head. lnside the bushing )'ou can see t$,o sets of dy'narnic
seals that seal against the rod. The seals that are located torvards the inside ofthe c1'linder
are the high-pressure seais. They must seal against the load pressure on the fluid inside
the cvlinder. The pressure seals require support. so they contain backup rings. Backup
rings are made of a strong stiff material such as PTFE, (Teflon) to support the seal ring.
The backup ring has a small clearance to the rod. The seal ring may'be of various
designs.
Stationary O-Ring Seal
to Cylinder

Back-Up
Ring for Seal
High Pressure

Seal(U-Ring)

per Seal
Pressure Holes to
Activate U-Ring Seal

Figure 21 - Rod bushing.

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ln Figure 22 aIJ-ring design is used. Figure 22 also shows five other types of

seals that

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can be used.
O-Ring

V-Ring
Packing

,at

v-1,

ompression
Packing

M,
/t/''

U-Ring

Back-up Rings for Support

T-Ring

f-..

l-\*
X-Ring

Figure 22 - T1'pes of rod seals.

(Courtesy Eaton Corporation, Hydraulics Operations)
The seals located towards the outside are r.viper seals. These are lip-type seals and their

job is to seal out dirt that is carried on the surface ofthe rod. The wiper seals are very
important. If they fail and allow abrasive dirt to be forced under tire pressure seals by the
rod. the pressure seals will be damaged. This u'ill cause two serious and costly problems.
First, the damaged seals will allow more dirt and air into the system during each intake
cycle of the rod end of the cylinder. Both air and dirt u'ill migrate through the entire
system and damage all the components. Second, when the rod end is under conrpressive
load, fluid will discharge through the damaged seals.

When you install these seals you must take the same precautions that are described for
the lip seals.

Dynamic O-Rings
Dynarnic O-rings are used to seal surfaces that move in a straight line at iow speed. A
colnnron example in h1'draulics is the O-ring on the spindle to adjust the pilot setting on a
pressure control valve (Figure 23).
a,'::,a

*.ifri'

..

%d',

Figure 23 - Dynamic O-ring seals.

''

:
I

Copl'right Alberta Advanced Education

6tli0l gp4.0.doc

, X| !

The dynamic O-ring has a smoother finish than a static O-ring to reduce wear and to
minimize lrictional resistance to movement.
When you fit dynamic O-rings you
static O-rings (Figure 24).
10o/o

will find that they'operate with

of Diameter

less compression than

Assembled Joint

Distance 'C' inches

Distance'C' - 0.005 inches

Figure 24 - Dynamic O-ring compression.

In cases where the ring must seal against a surface that moves more frequently and at
higher speeds (such as a cylinder rod), the dynamic O-ring requires a backup ring for
suppofi (Figure 25).

Pressure

Wider Groove

Pressure

R
I

Standard
Groove

Figure 25 - D1'namic O-ring and backup ring.

This backup ring serves three purposes.

It allou's more clearance betrveen the moving surfaces to reduce the compression
and friction at the O-ring.

r lt supports the O-ring against extrusion into the clearance betu,een the surfaces.
r It acts as a *'iper to exclude abrasives from damaging the O-ring.
Piston Rings

Piston seals are intemal seals that prevent or minirnize fluid by'passing from one side of
tbe piston to the other. Althoughthere are rnany'differentty'pes of piston seals. thel'can
be divided into tu'o general classes: metallic and non-metallic.
18
1

6L),i0I gp4.0.doc

Cop\,right Albena Advanced Education

The metaliic piston seals have a simple rectangular or square cross-section. They are
usually cast iron, but can be steel or chrome-plated steel for harder wear. Metaliic seals

n*

".'n',fi

.
o
.

l""li x?,?

T#:;'-':"''

i,ittr high temperatures,

they withstands high pressures and
they allow some leakage.
ttr"y

are compatibte

Because metallic seals allou,some leakage. they creep under load. lf creep cannot be
tolerated these seals should not be used. Non-metallic piston seals offer many' different
designs. You can see two of these designs in Figure 26.
Cup seals ate pressure actuated

Cylinder
Barrel

Backing plate dnd retainers

clamp cups tghtly in place

A) Cup Seal
Backup Ring

T-Ring Seal

B)T-Ring Seal
Figure 26 - Non-metallic piston seals.
(Courtesl' Eaton Corporation, Hydraulics Operations)
Figure 26,4 shou's that the cups are supported by steel backing plates; in Figure 268. the

T-ring seals are supported by backup rings.

l6030igp4 0.doc
Copl'right Alberta Advanced Educatron

.,IO
....:: .::::::

Objective Two
When ltou ltave completed this objective you

will be able to:

Describe the methods used to specifu particulate fluid contamination.

Since about 80% of hydraulic cornponent failures are due to contamination. you can
increase the reliability of a system significantly by reducing contarnination in the fluid.
To do this you must know how the contamination gets into the system. and how to
lneasure the amor,rnt and size of tlre contaminants in order to knorv u,hat lneasures to take
to reduce the contarlination to an acceptable level.

Sources of Contamination
Figure 27 shou's the four sources of contarnination.

''.-.--

A) New Oil

uilt in during assembly

Dirt at rod and fittirigs

Wear Debris

\-

C) Ingressed

D) Generated

Figure 27 - Four sources of contamination.

There are simple. relatively inexpensive

\\,a_vs

to reduce contamination from each of these

sources.

lb0i0l

gp-+.0.doc

Cop),rlght Alberta Advanced Education

New Oil
As you can see frorn Figure 28 new oil contains considerabie contamination. A drum
new oil tvoicallv contains one and a haif billion particles of dirt.

Drum Of Clean Oil

of

Cylinder Rod

llt
!l'

A major source
of ingested dirt.

Figure 28 - Contamination in new oil.

(Courtesy Eaton Corporation, Hydraulics Operations)
The particles shown in Figure 29 are rust, scale. fibres and sand. The size of these
particles has only been magnified 100 times. Therefore, all of these particles can easily
clog or darnage components in a hydraulic systern.

Abrasive Wear

vEot

Surfaces

Figure 29 - Particles in new oil.

(Courtesy Eaton Corporation, Hydraulics Operations)

Copr right .Albena Adr anced Lducarion

60301 gp,l 0 doc

You cannot prevent the contaminants from getting into the new oil, but you can prevent
these contaminants from being transferred to the system. In Figure 30 a filter cart is used
to filter and transfer the oil to the reservoir.

New Oil

Suction H

Iter Hose
tt

eservoir

Filter

Figure 30 - Filter cart.

The filter carl is simple to make u'ith readily available components. You can install as
t-rne a fi1ter as you require to meet the cieanliness level that you need for your s),stem.

NOTE

''

in order to prevent a fine filter frorr becoming clogged too quickly.

install a coarse fi1ter betu'een the uurno and the fine filter.

:::i
i:;ii.r'l

::/:I;l:t,

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gp4.0.doc

Conln ght Alberta

A dvanced Educatjon

\-

Besides removing contaminants from new oil, filter carls have other advantages.
. They make it easy to transfer oii with a minimum amount of spillage.
. They can be used to empty a reservoir for servicing with a minirnum of spillage.
. They enable you to pre-filter the oil before start-up. This is simpll.accomplished
by operating the filter cart with both the inlet and discharge hoses in the reservoir

(Figure

3 1).

Figure 31 - Pre-filtering oil using a filter cart.

(Courtesl' Eaton Corporation, Hl,draulics Operations)
B ui lt-l

n Contam

in ati

Built-in contantinalior'l is contamination that gets into

a component u'hen it is being

assembled. This can happen even in factory conditions u,hen new components are being
assembled. The contaminants can include burrs, chips. rnoisture. paint, dust. fibres. pipe
sealants. weld splatter and flushing sol_utions. This is one major source of particles is in
pipe fittings. When you assemble one '/6 inch threaded pipe fitting you introduce 60 000
pal'ticles into the svsteln that are over 5 microns in size. This is one source that can be
eliminated b1'using ORB (O-ring boss) fittings to get away frorn abrasive thread
engagement.

To remove existing built-in contamination, flush the component u'ith filtered oil before
vou install it. Alternativel,v. run the system and change the return line fi1ter after a tew
hours ofooeration.

Copvright Alhena Adranceo Fducatron

6030 i gp4 0 doc

In

g ressed Co nta m i n ati o n

[rtgressed contaminanls are contaminants that get into a system from outside.
Figure 32 shows where contaminants can enter the systelr.

Fittings

Leaky
Pump
Seal

Dirty Cylinder

Rod

Dirty Fittings

Pouring Oil

Figure 32 - Entry points for ingressed contamination.

l-he following is a list of measures that you can take to reduce ingressed contamination.
o Filter new oil as it is put into the s1,sterr.
r Use a good quality breather cap with a moisture trap on the reservoir.
r Change rod seals at the first sign ofleakage or preferably before the end oftheir
service life.
r Change purnp and motor shaft seals before the end of their service life.
. KeeP cylinder rods and fittings clean. Dirt gets pulled into the system at these

.
.
o

points.
Keep all fittings tight and leak-free.
Keep the hl"draulic system clean on the outside as u,ell as the surrounding area.
Thoroughiy clean pipejoints or components and the surrounding area before you
disassemble these parts.

rL

24
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Educatron

en

erated

:"i

Co n ta m i n ati o n

Generctted contaminatior is contamination that is created by the moving parts in a

system. Table 1 lists the rval's in which components generate contaminants.
Type of Action that Creates Contminants
Abrasion

Cause
Particles grinding between movinq parts.

Erosion

High-velocity particles striking surfaces

Adhesion

Metal-to-metal contact.

Fatigue

Repeated stressinq of a surface.

Cavitation

High pump inlet vacuum.

Corrosion

Foreign substances in fluid (water or chemical).

Aeration

Gas bubbles in fluid, inkoduced from outside

Table

I - Contaminant

generating mechanisms.

How Contamination Levels are Measured

In order to operate your car rvithin the speed limits 1'ou need a speedometer to measure
the speed. You must be able to measure the contarnination level in your hydraulic system
in order to operate it ri'ithin acceptable limits of contarnination.
Contamination is measured by'particie size and the number of parlicles of a particular
size or sizes.

How the Size of the Particle is Specified

The size of contarninant panicles is rneasured inmicron.s.Its sl,rnbol is p. A micron (also
called a micrometre) is t-rne rnillionth of a metre in size. Since this unit is used in filter
specifications as u'eil as in target cleanliness levels. 1'ou should have some concept of the
actual size of a micron. Figure 33 gives you an idea of the size of particles that you wili
be concemed about in contamination controi.

Grain of Salt 100 Microns

Limit of Visibility
40 Microns

than Smaller than a

blood red blood cell
microns 5 microns

Smaller
a white
cell 15

Size of
bacteria
2 microns

Figure 33 - Relative size of particles measured in microns.

i 60301 gp-l 0.doc

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lben3 .qd\ anccd tducarron

25

i.

i,

As a millwright you will be famiiiar with inch dimensions expressed in thousandths of an

inch. For example, when you handle a 0.001 inch shirn it feels like a piece of thin foil. A
micron would be about 25 times thinner.

\-

The particle sizes that are particuiarly harrnful to hydraulic components are frorn 5
microns to 15 microns in size. Therefore. the ISO cleanliness codes specify tlre number of
particles of 15 microns and 5 microns. At least one major hydraulics manufacturer has
added 2-micron particles to their specifications. This code has been certihed by the
National lnstitute of Standards and Technology (NIST) and wiil be adopted under ISO
4406 (FDIS) standards. Although 2-micron particles cause very little wear, they are a
concern because the particles cause parts to stick when they accumulate in the clearance
between moving parts. This is of particular concern in servo valves that have very close
spool clearances.

NOTE
Notice that the 15. 5 and 2 micron particle sizes that do most of the
damage in a hydraulic system are well belou,the limit of visibility
(Figure 33). Therefore, the fluid may look clean, but the contamination
can be unacceptably high.

How the Number of Particles is Specified

The number of particles is specdied by ISO standards by arange code (Table 2). If you
look at range 2A you will see (on the left of the chart) that it specifies a range of 5000 to
10 000 particles in a one-millilitre sarnple.
These parlicles are counted electronically under conditions that have been standardized
by ISO. Portable particle counters are available and major h1'draulic shops offer onsite
testin-q of fluid to determine the contamination level. The particle counter is set to count
2, 5 and 15 micron particles and provides a printout that gives the range code for each of
these sizes.

26'

!.*

i{.0301gp4 0 doc

Copyright Alberta Advanced Education

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Parlicle siz in mic.orE ers

20t14112
Cleanliness Code

Table 2 - ISO cleanliness code chart.

(Courtesl' Eaton Corporationo Hydraulics Operations)

How to Read ISO Cleanliness Codes

a parlicle counter could be 18116 13. When you read this
code. the number on the 1eft (18) is the range code ofthe nuurber ofparlicles greater than
2 microns in a 1-millilitre sample. The middle number (16) is the range code for particles
greater than 5 microns and the number on the right ( 1 3 ) is for particles greater than 1 5

An example of the printout from

rnicrons.

l6030lgp4 O.doc
Copl'right Alberta Advanced Educadon

2t

Target Cleanliness Levels

Target cleanliness levels are set by the hydraulics industry to tell you at what level the
fluid in a hydraulic system is too dirry. They are expressed as an ISO cleanliness code
(explained in the previous topic). Table 2 is a chart of these target cleanliness levels.

Pressure

<2m0

20m - 3000

Fixed Gear

20t18t15

19t17 t15
19t17 t14

18t16t13

18116t14

17

Fixed Vane

20118t15

Fixed Piston

19117

Variable Vane

18t16t14

17

Variable Piston

18t16t14

17115t13

16t14t12

<2000

2000 .3000

3000+

Directional (solenoid)

20t18t15

19t17 t14

Pressure Control (modulatinq)

19t17 t14

19t17 t14

Flow Controls (standard)

19t17 t14

19117 t14

Pressure

t1s

t15t13

t15t13

Proportional Directional (throttle valves)

17

Check Valves

20t18t15

20t18t15

Servo Valves

16t14t11

15t13t10.

t15t12

15t13t11

Cartridqe Valves

H.R C

18t16t13

17 t15t12

1st13t11

8/1 6/1 3

17

t15t12

Proportional Pressure Controls

16t14t12.

Flow Controls (pressure compensatinq)

17

Proportional Cartridge Valves

17 t15t12

16t14t11

Pressure

t15t13

17

t15t13

<2000

2000 - 3000

3000+

Cylinders

20t18t15

20t18t15

20t18t1s

Vane Motors

20t18t15

19t17 t14

Axial Piston Motors

19t17 t14

Gear Motors

21119t17

20t18t15

Radial Piston Motors

20t18t14

19t17 t13

18t16t13

Cam Wave Motors

18t16t14

17t15113

16t14112.

<3000

3000-4000

4000+

16114112.

16t14t11

Pressure
Hydrostatic Transmissions (in-loop fluid)

is'

3000+

17

t15t13

Ball Bearino Svstems

15t13t11

Roller Bearinq Svstems

16t14t12.

Journal Bearings (high speed)

17 t15t13

Joumal Bearings (low speed)

18116t14

General lndustrial Gearboxes

17 i15t13

8/1 6/1 3

8/1 6/1 3

17

t15t12

19t17 t14

Table 3 - Recommended cleanliness levels.

(Courtesy Eaton Corporation, Hydraulics Operations)
I

6(rJOt gp4 0.doc

Copvr ght Alberta Advanced Educarion

\-

The cleanliness levels that are recommended in the chart are for a system that uses
petroleum oil for fluid, runs continuousiy and is not critical to the process operation.

How to Sef a Target

Different sJ-stems have different requirements for cleanliness, depending on the type of
service and the t1'pe of components. You can set yourtarget cleanliness level to increase
the life and reliabiliqv of your hydrauiic system by referring to the following steps.

1.

From the Recontmended Cleqnliness Code Chart select the cleanliness code for
the component in your hydraulic system that requires the highest level of
cleanliness. The highest cleanliness level is indicated by the code with the lowest
number. For example, if vour system operates at pressures below 2000 psi. you
u,ould look in the chart in the <2000 column and find the component in the
system with highest cleanliness requirement (lowest code number). If your
system has a variable displacement piston pump you would select the code
18/16t14.

2.

If your hydraulics do not run on 100% petroleum oil, then you must set the target
one range code lower (cleaner). Using the example in step one, the target level
would become 17115113.

3.

.'

If any two of the following conditions apply to your hydraulic system, set the
largel one range code lower again:
r frequent cold starts at <18oC,
. high vibration or shock operation,
. s).stem is a critical part ofthe operation or
. safeb. risk if the system fails.
lf ,vou used the example in step two you would set the code at 16114112.

How to Achieve a Target Cleanliness Leyel

To achieve an acceptable level ofcleanliness. follow these three steps.
l. Select the target level for your s)'stem as described under the previous topic.
2. Selectthe filters to achieve this target level. This is described in Objective 3.
3. Check the parlicle count in the oi1 to see if you have achieved the target
cleanliness.

In addition to using adequate filters. the foliowing is a summary of measures that I'ou can
take to keep the fluid clean u.hile the s).stem is operating.

.
r
o
.

Keep all fittings tight.

Filter the air that enters tire reservoir.
Change the fluid at intervals before it breaks dou'n. Lab tests are required to
determine the intert,als.
Keep the resen'oir fiiied to the proper leve1 to minimize condensation inside and
to maximize heat dissipation.
Repair all leaks as soon as possible.

Copr righi .Albena AJr anced EducaLion

6frlf,]

on-I n ,4^.

i4
?.

:.

i.

".

How to Confirm the Achievement of a Target

Now that portable particle counters are readily available either to purchase as part of your

shop equipment or through on-site service from a hydraulics service shop, you can

quickly have the system fluid sampled and tested (Figure 34).

Bailer Probe to

Vickers Target-Pro
Sample: NAITN 102
Date: 04106/01 Time: 02:36:16
Sample Volume: 30ML
Flow
S0MLlMin

Rate:

MIN Max AVG

2u 2108 2184 2147
5u 451 5A7 472
10u 107 115 109
15u 41 42 41
25u9119
50u010

ISO Range Numbers

Figure 34 - Portable particle counter.

3n:
:

:::::::::::::::::::::;J:!:t".

:,iil
I

60i01 gp4.0.doc
Copr rig6l Albena .Adranced EdLr;auon

.}

Objective Three
PI/hen

you have completed this objective you will be able to:

Describe the g'pes. purpose. application and methods of specif ing filters used in

hydraulic s)'stems.

Construction of a Filter
You u'il1 hear the Iern)s strainer and/ilter used and may run into some controversy as to
the difference beni'een the trvo. To distinguish a strainer from a filter, use the guideline
that a strainer is usually a u-ire mesh with pore sizes larger than 50 microns. Strainers are
designed to reriove coarse contaminants while filters are intended to remove fine
contaminants.
In hydraulics, filters consist of a metal case containing a filter element to trap dir1. They
also contain a bypass valve to protect the elernent from collapse when the pressure drop
across the filter gets too high (Figure 35).

lndicator rotates showing:

Green for clean element
Yellow for partial bypass
Red for complete bypassing

r-a

Air Ble_ed Passage

a-------l

r<)

Outlet

Hypass

Symbol

Check valve close

when element is ciean.

lnl^+
lt ltEL

Figure 35 - A hvdraulic filter.

(Courtesy' Eaton Corporation, H.vdraulics Operations)

b1'pass indicator tells 1'ou u,hen the

filter is operating on

b1,'pass

(Figure 35).

d:l

Copvrrght Aiberta Advanced Educatron

6rl

l[] I (.nl n ,i^.

::=

Filter Element

\"

In a strainer a simple rvire screen is used to capture coarse contaminants (Figure 36). The
wire screen offers the least amount ofresistance to flou'and has accurately sized pores.
Another feature of a strainer is that it can be q'ashed and reused.

Figure 36 - Strainer used on a pump inlet.

(Courtesy Eaton Corporationo Hydraulics Operations)
The most popular design for the filter element in hydraulic filters is a pleated fibreglass
cloth supported by a metallic mesh (Figure 37).
Metallic Suppoft Mesh
Diffuser Layer
Filter Media
Diffuser Layer
Metallic Support

Mesh

Figure 37 - Filter element. (Courtesy Eaton Corporation, Hydraulics Operations)

ln connection with fi1ter media you may hear the rerm deprh fi,pe media. Depth g,pe media
(Figure 38) consist of a matrix of fibres that capture dirt as fluid passes through.
Fntrannce{

,Particle

\.
\Fibre

Matrix

Figure 38 - Depth tlpe filter media.

(Courtesy Eaton Corporation, Hydraulics Operations)
iX:..
5Z::
I

60J0 I gp-4 0 doc

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li::

Although depth qvpe filter media does not have a constant pore size, it is very effective in
capturing dirt. This media captures dirt particles by forcing the flow througl-r a tortuous
path and har ing manv areas in u'hich dirt becomes trapped. Depth type hydraulic filters
are not u'ashable. and rnust be discarded after use. Fibreglass is superior to paper because
the glass fibres can be produced rrrnch more frnely than paper fibres, the1, can be laid
rnuch more uniforulv and thel'resist the chemical action of tlre fluid.

The support mesh shou n in Figure 37 is very important to the operation of the filter.
must be strong enoush to prevent the pleats frorn buckling and collapsing at the line
pressures. The n-resh also offers some extra filtration.

It

Bypass Valve
The bypass ralte is a spring-loaded check valve that opens as the filter becomes clogged.
The valve is opened by the increased pressure drop (usually about 45 psi) as the
resistance to flow of the clogged tllter increases (Figure 39). This allows f'luid to flow
fi'eely through the centre of the filter, protecting tlie element from collapsing or rupturing.
Indicator rotates showing:
Green for clean element
Yellow for partial bypass
Red for complete bypassing

Filter Element
Air Blged Passage

Outlet
Bypass Check
Symbol

Bypass check valve closed

when element is clean.

Indicator rotates showing:

Green for clean element
Yellow for partial bypass
Red for complete bypassing

Filter

Air Bleled Passage

mr
V

Bypass Check
Synrbol

Bypass check valve opens

to bypass if element becomes
ctoseo.

Figure 39 - Operation of the by'pass in a filter.

(Courtesl' Eaton Corporation, Hvdraulics Operations)
'::-'

160301gp4.0 doc

Copvright Aiberta Advanced Education

,,

NOTE
A pressure drop of over 45 psi is hard on the filter elernent and wastes
power. For erample, a pressure drop of 85 psi at 20 GPM will

consume

horsepower.

Bypass Indicators
Hydraulic filter manufacturers strongll' recomrnend that you include a bypass indicator.
sometimes called a filter condition monitor. The fype shown in Figure ,10 has different
coloured stripes to indicate u'hetherthe bypass valve is opening ornot. Greer.r indicates
that the full flow is passing through the filter element. Yellow indicates that the by'pass
valve is beginning to open and the filter is starting to clog, Red indicates that the filter is
clogged, causing the valve to be fully open.

Bypass indicator rotates showing:

Green for clean element
Yellow for partial bypass
Red for complete bypassing

Filier Element
Passage

f--{ }------1

L/.\

-\iZ-

Bypass

Symbol

Check valve close

when element is clean.
Figure 40 - Bypass indicator. (Courtesy Eaton Corporation, Hydraulics Operations)
You should alu'ays change the fi1ter when the indicator tums yellow to minirnize the
amount of unfiltered oil circulating through the system.
Another u'ay to monitor the condition of the filter is to use a gauge at the inlet and outlet
ofthe filter so that you can see the difference in pressure across the filter. This pressure
differential is sometimes called psid or AP. Psid and a differential pressure indicator on a

filter should be checked at operating temperature

The bypass is also important to ensure full flow during cold start-ups u'hen the oil does
not flow easily.

Locations of Fluid Filters

Filters should be installed at the pump inlet. sometimes in the pressure line and a1u'ays in
the return line (Figure 41). In additionto these locations a filter is sornetimes installed
off-1ine.

54'.
:.t'

:a

60i01 gp4.0.doc

Copl'right Alberta Advanced Education

'rt

Return
Line

Filter

Figure 41 - Fluid filter locations.

(Courtesy Eaton Corporation, Hydraulics Operations)

Pump Inlets
!,

The pump inlet requires a strainer to rernove any coarse contarninants that might cause
catastrophic failure. A iO0-mesh filter is nonlally used to trap particles larger than 150
microns.

Requirements
The main requirement of the inlet strainer is that it passes the full inlet flou,within the
pressure drop permitted for that pump. If the pressure drop is too high the iniet flow is
reduced and cavitation occurs. On in-line axial piston pumps. the shoes separate from the
pistons, resulting in catastrophic failure if the inlet flow is insufficient and a vacuum is
created in the oump.
The strainer must also be equipped with a bypass. This is to ensure full flou'when the
strainer becomes clogged or durins cold starts when the oil is thick and u,ill not flow easily.

Pressure Line Filters

Pressure line.filters are used in the pressure line imnrediately after the pump (Figure 38).
These filters are intended to protect the system components from contamination
generated by the pump. You must always use a pressure line filter at each servo valve.

Requirements
Pressure line filters must be capabie of trapping fine contaminants. Thel' must also be
able to u'ithstand the operating pressure of the s1'stem as well as the load pulsations.
These filters are often specified u'ith no b1''pass valve since it is irnportant not to b1,'pass
any, contamination into erpensive valves.

Copvright Alberta Advanced Educatjon

6ft

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on-I O rlnn

Return Line Filters

A return line filter is intended to control the contamination in the entire system. lt does
this if at least20oh of the total system volume passes through the filter per minute. Most
industrial hydraulic systems require a retum line filter to trap very small particles and
protect high performance components.

Requirements and Types

The return line filter must be able to handle the maximurn return line flow with a
minimum pressure drop. This flow can be greater than the pump flow when a cylinder
retracts and discharges its cap end flow back to tank. For this reason it is important to size
this filter large enough to handle the flow so that it does not rupture and allow larse
amounts of contaminants back into the svstem.
The return line filter is required to be afull flow filler. The ternfull flow means that the
full flow generated by the system passes through the filter element. However, a return
line filter u,ill be equipped with a bypass valve that is pre-set to divert flow past the fiiter
element when the pressure drop gets above the setting of the vah,e. This protects the
element from excessive Dressure that could collaose it.

Off-Line Filters
Figure 42 shows two styles of off-linefihers.In Figure 42b permanent off-line system is
being used. In Figure 42a. apoftable unit is being used. The advantage of the porlable
unit is that it can be used to fill or empfv a reservoir at anv location.

L
Circulating

na Prrmn

ofr-Li

lnlet Stiainer

Portable Off-Line
Filter System

Permanent Off-Line
Filter System
(b)

(a)

Figure

,12

- Off-line filter systems.

(Cou rtesy Eaton Corporation, H.r'drau lics Operations)

The off-line filter pump is kept running continuousiy to circuiate the fluid frorr the
reservoir through the filter. The size of the pump and the fineness of the filter can be
selected to achieve the target cleanliness that -vou require.

:::i:::]!n

:,t|3,6
16030J gpl.0.doc

Cop)'right Alberta Advanced Educatron

Advantages
The off-line filter

sy

sterr has the follorving advantages.

o lt is free ofthe pressure pulsations that decrease a filter's abiliqv to trap particles.
o lt is essential u'hen 1ou use a pressure-compensated, variable displacement pump

.
r
r
o

in the sr slem rhat is running at standby (no flow) for extended periods. under
these conditions the pump generates contaminants but they do not pass through
the return line filter. In this case an off-line hlter continues to filter independently
of the main system pump.
It allou's you to change filters u'ithout shutting down the system.
The filter flow rate and type offilter can readily be changed to provide the best
filtration without rnodifying the system piping.
You can pre-filter the fluid before start-up.

Off-line filters can be located where they are most convenient to service.

Reservoir Filter
The filters that you have studied so far remove contaminants directly from the fluid. The
filter on the reservoir provides a valuable service b.v removing contaminants from the air
before the air carries contarninants to the fluid. This filter is often neglected and may
consist of a strainer to remove only coarse contaminants.

Hou'et'er, )'ou can drastically reduce this ingressed contamination by simply installing a
high efficiency air filter (Figure 43). A 3-micron filter with a moisture trap is
recomlnended to remove fine airborne solids and moisture that rvould otherwise condense
inside the resen.oir.

-v

- 3-micron air filter for the reservoir.

(Courtesy Eaton Corporationo Hvdraulics Operations)

Figure

,13

How Filters are Rated

Fiiters have the follou'ing specifications:

.
.
r
o
.
.

largest particle size thar the\ can trap.

efficiency in terrns of the number of particle ther.can trap.

holding capacity'in grams of dirt before the bvpass valve opens.
flow capacitf in gpm (ga11ons/minute) or LPM (litresiminute).
pressure rating and

fluid comparibilirJ".
;ta.:a:::aa.=

a;:

Coplright Alberta Advanced Education

't:;;,j;

Three Rating Sysfems

for Filters

ln the past, filters were rated using either a norninal rating or at absolute rating. These
two systems rated the filter b1'the size of the largest particle that the filter could
trao.
However, these systems did not tell you the efficiency of the filter in terrns of how
man,v
particles a filter could capture. Therefore, they have been replaced
by the beta (B) ratio
system that gives you the efficiency ofthe filter.

Beta Ratio
The beta ratio is the nunber of upstream particles above a given size compared to
the
nurrrber of do,u'nstream particles above a given size.

px=

of upstream particles > x

number of dou,nstream particles > x
number

*Note: x = particle size.

This beta ratio rating for a filter is determined from an ISO test called a Multi-pass Filter
Perfonrance Beta Test, ISO .1572. Figure 44 shou's horv this test is performed. The beta
ratio tells you how effective the filter is in removing particles. For example, if the filter
has a beta number of I 0 it would allou' one particle to escape doq,nstream for every 10
parlicles that entered the hlter frorn the upstrean side (Figure 44).
Example:10
(5 Micron Particles)

Exampie.l
(5 Micron Particles)

3
Known Contaminant
I
I

t4

Figure 44 - Multi-pass filter performance test to determine the beta ratio.

(Courtesy Eaton Corporation, Hydraulics Operations)
This rneans that the filter captures 9 out of 10 particles. which makes
Table 4 shows the efficiency,'that each beta number represents.

it 90% efficient.

Beta Ratio

Efficiency

Beta Ratio

Efficiency

0%o

75

98.70o/o

s0.00%
80.00%
90.00%
95.00%

100

99.00%
99.50%
99.90%
99.98%

'10

20

200
1

000

5000

Table 4 - Efficiencies for beta ratios.

i

Coplrirht Alberta Adr

anced Educatron

l)

How to Select a Filter

When vou select a t'ilter start b1 consulting a filter placement chart (Table 5) from a filter
supplier. This chart recotntnends u'here you should locate filters in the svstem and what
rnicron rating l ou should use at each location.
3;l 'tlw
or fetum line

:-C

flow
pfessure
and return line
Ful

Pressure line
and recirculating
system votume

Pressure line
pius return
line plus
recirculating

per minute

loop

loop al20%

14t12t10

03

03

15t13t11

UJ

05

16114t12

UJ

05

05

17 i15t13

03

08

05

(u 18t16t14

05

10

1117115 05 or 10

05or10

'10

'10

Recirculating

al20%
ofsystem
volume

loop

05 or 10

10
10

03

Recirculating
loop at 10%

ofsystem
volume

UJ

05

05 or

'10

UJ

Recommendedfilter Recommended Recommendedfor

placements for
rngression
with fixed

high

volume

systems

for
with
volume

systems

flxed

oumos

high ingression
systems with
variable volume

Table 5 - Filter placement chart.

(Courtesr, Eaton Corporation, H1'draulics Operations)
After 1'ou have determined where to locate each filter. you should select
filter. A good quaiity is indicated by a beta ratio of 100 (99y; efficient).

a good qualit-v

The next step is to determine each of the specifications listed in Table 6 to suit your

hvdraulic system.
Type of Rating
Holding capacity
Flow capacity

Pressure ratrng
Fluid compatibility

Operating Condition
Must be able to hold enough dirt to make change intervals a reasonable length of
time.

Must be big enoughto handle the flow at the iocation that it is used in.
Must be strong enough to withstand the pressures and pulses at the location that it is
located in,
Must be compatible with the hydraulic fluid that you are usrno,

Table 6 - Filter specifications.

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Self-Test
1.

How can hydraulic fluid that comes in contact with your skin for prolonged periods
harm you?

2.

How can

3.

Why should a dynamic seal have some leakage?

4.

What condition must the surfaces of a rletal-to-metal seal be in before assembly?

5.

What tightening pattern must )'ou use to avoid distortiorr when bolting rectangular
surfaces together?

6.

How can

a pinhole hydraulic leak harm you?

1.'ou

determine the correct torque value when you assemble a hydraulic

component?

L
What is the rnain purpose of a backup ring for an O-ring?

8.

What ty.'pe of sealant should you use on tapered pipe threads in hydraulics?

9.

Which should have the tightest fit?

a) dynarnic O-ring
b) static O-ring

10. What ry-pe of piston rings should you use u.hen no cy,linder creep can be tolerated?

I 1 . How can vou keep the contaminants in neu''

oil out of a hydraulic system?

12. Hou' can )i ou minimize contamination due to assernbly of pipe joints?

:='
4$
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!t

13. At r.r'hich three points can contaminants get into a hydraulic systern?
a)
Dl

c)

l-1. List three n'avs in ri'hich components can generate contarninants.

a)

b)
c)
I5

. What information does the code

I 8i i 6/

4 give you?

16. List three lactors that require a higher cleanliness level.

a)

b)
c)

t7. List three things you can do to meet target cleanliness leveis.
a)

b)

8. Wbat is the most convenient rvay to find out if you have achieved

a target cleanliness

level?

19. Why' should vou use a strainer instead of a filter on the pump inlet?

20. What is the purpose of a br,pass on filter?

21. How can you tell u'hen a filter needs to be changed?

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..

ti;i,ii;1;,

22. What is the best choice of hlter for a hydraulic system?

a) depth type
b) surface type filter

z)- What

are the four locations

for filters in

a hydraulic system?

a)
D)

c)

24. With respect to position, which type of filter is required for

a pressure-compensated

pump that frequently runs on standby?

25. Whv is an off-line filter more efficient than

a pressure line filter?

26. Which type of filter is recommended for the reservoir breather?

27. What information does p5

10 give you?

28. Besides efficiencv. which four other specifications are needed

r.vhen selecting filters?

a)

b)

d)

29. Name the two main reasons for eliminatine leaks in a hydraulic system.
a)

b)

30. Above what temperature can you expect petroleum-based hydraulic fluid to ignite?

31. How can minor leaks cause serious damage to a hydraulic system?

32. Name ts'o major classes of seals used in rotary pumps.

a)

b)

1Z
I

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33. Should

a valve poppet fomr a positive or a non-positive seal

with its

seat?

34. Hou. far should a static O-rins protrude above the sroove?

35. Which tool should you use to remove an O-ring?

36. When you install

a high-pressure lip seal on a shaft

use to prolecl the Iip fiorn damage?

u'ith

a shoulder. rvhat must you

37. Whv is it verr, important for the rod seals in a cvlinder to be in eood condition?

38. Is new oil clean enough to use in h1'draulic system or does it have to be filtered
before you install it?

39. What is a major source of built-in contarnination'/

-10. What causes qenerated contamination?

41. What three parlicle sizes are measured for ISO contamination level specifications?
a)

b)

42. Which type of fluid requires the highest cleanliness

1evel. petroleurn-based fluids or

non-petroleum based fluids?

43. Which g'pe of purnp requires an off-line filter?

't4. Whichfilterinthesysternhastoberatedatthereliefpressureofthesystem?

45. Which filter is best for the breather on

a reserr,oir?

'

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,rr

':::ll!.::::::l

*;

.-{"1.

Self-Test Answers

l.
2.

can cause cancer

High-pressure fluid can pierce your skin and enter ,vour bloodstream, rvhich in turn
can cause gangrene.

3. for lubrication
4. It must be flat with no scratches.
5. spiral from the centre
6. Consult the service manual.
1. support the O-ring against extrusion
8. liquid sealant
9. b) static O-ring
10. non-metallic

11. Use a hlter cart to install the oil.

12. Use straight thread with ORB fittings.
13. An,v three of the following are cotrect.
a) new oil

b)
c)
d)
e)

rod seals
shaft seals
loose fittings
reservoir breather

14. Any three of the following are correct.

a) aeration
b) cavitation
c) abrasion
d) corrosion
e) fatigue
0 erosion

C)

adhesion

15. In a 1 ml. test sarnple there are i8 parlicles over 2 microns in size, l6 pafticles over
microns and 14 particles over l5 microns.

i6. Any

three of the following are correct.

non-petroleum based fluid
frequent cold starls
equiprnent is critical to operation
shock loads

a)
b)
c)
d)
e)

safety

i60301 gn,l.0.doc
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17. Any three of the foilowing are conect.

a) Keep all fittings tight.
b) Filter the air that enters the reservoir.
c) Change the fluid at intervals before it breaks dou,n. This will require lab tests
to determine the intervals.
d) Keep the reservoir filled to the proper 1evel to minimize condensation inside
and to maximtze heat dissipation.
e) Repair all leaks as soon as possible.
18. use a portable particle counter
19. A strainer offers less resistance to flow.

20. to prevent collapse ofthe element ifthe pressure drop gets too high

21. q,hen the indicator shorvs that it is operating on bypass after warm-up

b) depth type
23. a) pump inlet
b) pressure line irrrnediately
c) return line
a) off-line

22.

after the pump

24. an off-line filter'

25. lt is free ofpressure pulsations.
26. 3-micron filter s,ith

a rnoisture trap

27. The efficienc,v is 90% for capturing particles over

a)
b)
c)
d)
29. a)
b)

28.

5 microns in size.

pressure rating

florv capacity

dirt holding capacity

fluid compatibiliq'
improve safety
remo\ie one cause of catastrophic failure of the sy'stem

30. 250"C
3

i . They allow contamination into the system.

32.

a)
b)

static seals
dynamic seals

33. positive

34.

10o/'o

seal

of its diarreter

35. an O-ring pick

36.

a thimbie

37. This is a rlajor area for dirt to enterthe

s1,stern.

38. fiiter it first

39. tapered thread pipe fittings

40. rnoving parts inthe system

Copyright A)berta Advanced Educarion

60.i01 gp4 0 doc

41

a)
b)
c)

2 rnicrons
5 microns
15 microns

42. non-petroleum based fluids

43.

a pressure-compensated pump

44. the pressure line filter

45.

a 3-micron

filter with

a moisture trap

4i:'l

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Coplright Alberta Advanced

Ed ucation