Enterprise based Vocational Education

Hydraulic Module
Instructors: MAJID
HENDRA
FAHRURROZY

Students Name: .
Students Nr: .

Module Hydraulic basic

1. Targets
Safety:
The student - understand the hazards in hydraulics
- Knows safety-regulations
- Knows how to act in an accident

Learning-targets:

After the training the student understand:

What are the main elements of a hydraulic circuit?

What are the different standards of pipes/ hoses/ connections/ seals and elements?
What is flow and how we measure flow?
What is pressure and how we measure pressure?
What is hydraulic energy?
What is hydraulic power?

Is able to
Assemble a hydraulic circuit according diagram
Make difference between different types of cylinder
Make difference between different types of pumps und understands its characteristics

Understand how works a pressure relief valve

Pressure valve
Flow control valve
Two way flow regulating valve
Three way flow regulating valve
2/2 directional valve
3/2 directional valve
4/2 directional valve
4/3 directional valve
check valve
Filter

Can identify different kind of joints and understand how the seals work

Exercise 1
1. Take the diagram of a hydraulic unit and identify all elements according the
symbols in the diagram and check if they are existent in our hydraulic unit.
2. Draw the correct diagram of the hydraulic unit used during our module
 Number Name of Function of Input 1st output 2nd output
of element the element connecto connecto connector
element r and r and
signal and signal
signal

3. identify all connecting-pipes

Element 1 Element 2 Type and dimension of Type and Type and

connecting pipe dimension of dimension of
 connector connector output
input

4. identify all types of seals

a. conical pipe-tread
b. metal-metal joint
c. O-ring-seals
d. packing-seals
e. gasket
f. static seal
g. dynamic seal
Element Name of seal Type of seal Function of seal What is important
for perfect function?
5. Make the diagram of our hydraulic press and identify the elements, connectors and
seals

Exercise 2
Assemble a circuit according to the diagram below
with 3 Pistons in parallel

A B

T P P

220V

S3 S4

S4 S3

piston 2 out piston 2 in

Measure the time for 1 full stroke of all 3 pistons and calculate the oil flow
pe1 Amps time Vol Q Position Position note
of flow- of flow-
control 1 control 2
valve valve
bar A s dm3 Lt/min o o
Draw the diagram Q = Q()

Exercise 3
Dismantle the pump (clean working!)

Measure the torque used for tightening the bolt of the cover-plate of the pump
Torque T1 = . Nm T2 = .Nm T3 = ..Nm T4 = .....Nm
Dismantle the Cover-plate according explosion drawing
Identify all parts body (do not dismantle the shaft)
Identify the type of the pump

 Identify the high-pressure und the low-pressure-side of the pump
..
..

Identify the working system of the pump

Explain how the Vanes are pushed to the outer ring
..
..
.

Explain how axial wear is compensated

..
..

Explain how the pump is sealed

..
..

Identify the critical mounting-bolts

Assemble the pump applying the required torque (one of the group is responsible
for quality, and 2 for assembling)

Exercise 4
Characteristic of the adjustable vane-pump

Assemble the circuit according diagram exercise 2 with 3 pistons in parallel and fill the
table of measurement

pe1 pmax Amps Amps time Vol Q Position of Position of

during end of pmax flow-
stroke stroke screw control 1
(pressure limit) valve
3 o o
bar bar A A s dm Lt/min
Make the diagram pmax = pmax()

Draw the diagram Q = Q(p) for 3 different positions of ()

Explain why the current is smaller, when the Pistons are in the end-position

Exercise 5
Characteristic of the
Pressure-relive valve

Assemble the circuit

according diagram
A B

T P P

Measure and fill the following table

Q p
pos of position position
M
flow- of flow- of
control control in pressure-
out relieve
valve
 Q p

Q p

Make the diagram p = p()

Exercise 6
 A B

T P P

Connect a piston to the pump according diagram with directional valve type
With flow-control at in-flow
What happen during out-stroke? .
What happen during in-stroke?
What happen during stop-position ?.
What happen at the end of the stroke and valve in out-position?

Exercise 7
Connect a piston to the pump according diagram with directional valve type
With flow-control at in flow

A B

T P P

What happen during out-stroke? .

What happen during in-stroke?
What happen during stop-position ?.
What happen at the end of the stroke and valve in out-position?
Exercise 8
Connect a piston to the pump according diagram with directional valve type
With flow-control at back-flow

A B

T P P

What happen during out-stroke? .

What happen during in-stroke?
What happen during stop-position ?.
What happen at the end of the stroke and valve in out-position?

Exercise 9
Connect 2 cylinders to the unit so we can operate both cylinders individually and also at
the same time.

220V

S1 S2 S3 S4

S2 S1 S4 S3

piston 1 out piston 1 in piston 2 out piston 2 in

N

Explain how it works
Piston 1 out, piston 2 stop
Piston 1 stop, piston 2 out
Piston 1 out, piston 2 out
Piston 1 in, piston 2 stop
Piston 1 stop, piston 2 in
Piston 1 in, piston 2 in
Piston 1 in, piston 2 out
Piston 1 out, piston 2 in
Exercise 10
Study the circuit: diagram.
M
speed ??pressure??..
speed ??pressure??..
speed ??pressure??..
speed ??pressure??..
speed ??pressure??..
speed ??pressure??..
speed ??pressure??..
speed ??pressure??..
 A B A B

T P T P P

Exercise 11
Make the description how the system works.
Draw the electric diagram for the conditions for the additional valve 3

A B A B

T P T P P

Conditions for the stroke forward of piston 1:

.
.
.
Condition for backstroke of piston 1
.
.
.
Conditions for the stroke forward of piston 2:
.
.
.
Condition for backstroke of piston 2
.
.

In case we use a constant volume pump, how can we make this circuit work?

Exercise 12
Connect a hydraulic gear-pump in function of a hydraulic motor to the circuit with-out a
counter-pressure-valve and flow-control-valve.
Find out why we are not allowed to install a counter-pressure-valve in this case
Draw the circuit
Make the installation and try it out
Test the installation with different pressure-settings and different settings of the flow-valve and count the RPM for the different settings. Draw the
characteristic curve RPM depending on flow-control valve and pressure p 1
 P