Professional Documents
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Unidad 1
Unidad 1
Unidad 1
INTRODUCTION
Hydraulic power technology is used to power machines in almost every
manufacturing plant in the world. It has many unique features that have caused its use to
continue to grow rapidly.
This module is going to teach you the basic skills in hydraulics. You will learn to
connect and operate basic components and systems, read circuit diagrams, monitor
system operation, and design circuits.
To learn these skills you will be working with the Amatrol 850 series hydraulic
trainer. This trainer is designed with real world industrial components that will allow you
to set up actual circuits and test their operation.
In this first hydraulic LAP, you will learn how to start up and operate a hydraulic
power supply and then connect a basic circuit.
ITEMS NEEDED
Amatrol Supplied:
1 85-BH Basic Hydraulic Training System
1 85-HPS Hydraulic Power Unit
1 94-VF-1 Video - Fluid Power: It Works For You (optional)
1 94-VF-2 Video - Hydraulic Trainer Operation (optional)
School Supplied
Shop Towels or Rags
ELECTRIC
MOTOR
CONVEYOR
PUMP HYDRAULIC
MOTOR
RESERVOIR
OIL
Manufacturing
· Some industrial robots are powered by hydraulics.
· Many industrial machines use hydraulics for their power source.
· Plastic injection molding machines use hydraulics to close the
mold.
· Lifting devices, including fork trucks, use hydraulic power.
Transportation
· Commercial airplanes use hydraulics to control the moving
surfaces and for lowering and raising the landing gear.
· The shock absorbers used on cars and trucks use hydraulics.
· Brake systems for cars and trucks are powered by hydraulics.
Construction
· Digging equipment such as backhoes use hydraulics.
· Bulldozers, graders, and dump trucks use hydraulics.
___________________________________________________
B. What is the total value of all fluid power products sold
worldwide as of 1996?
___________________________________________________
C. Name two applications shown in the video.
___________________________________________________
❑ 3. When the tape is finished, rewind it and return it to the library.
LINEAR
MOTION
FLOW OF ROD
CONTROL
VALVES
SUPPLY
OIL
LINE
FLOW
RELIEF
ELECTRIC VALVE DIRECTIONAL
MOTOR CONTROL VALVE
CYLINDER
RETURN
LINE
PUMP
RESERVOIR
Procedure Overview
In this activity, you will identify the components of the
Amatrol 850 series hydraulic trainer. This activity will
familiarize you with the components used in a hydraulic
system.
HYDRAULIC
INSTRUMENTATION
HYDRAULIC MODULE
ACTUATOR
MODULE
BASIC HYDRAULIC
VALVE MODULE
HOSE RACK
HYDRAULIC
POWER
UNIT
COMPONENT LETTER
PRESSURE GAGE
MOTOR
CYLINDER
DIRECTIONAL CONTROL VALVE
PRESSURE REDUCING VALVE
FLOW CONTROL VALVE
CHECK VALVE
A B
A G C
WEIGHT OF
CUBE 32N
PRESSURE
2
8 N/m
1 SQUARE
METER
2m 2m
To further see how pressure and force are different but related, look at
figure 7. When the weight is laid on its side, it creates a pressure of 2 N/m2
(5 ÷ 2.5 = 2). But when it is laid on its end, the pressure is 5 N/m2 (5 ÷ 1 =
5). The same force creates two different pressures by acting over different
amounts of area.
This same result occurs in people’s shoes. If a woman with a
high-heeled shoe steps on you, it hurts much more than if it is a flat-soled
shoe. This is because the pressure is higher with the smaller heel.
2
A1 = 2.5 m
10 N
LOAD
FLUID
PRESSURE
STOPPER
AREA = 0.1m 3
OIL
BOTTLE
Procedure Overview
A pressure gage indicates the pressure in the hydraulic
system. Technicians read pressure gages in industry to
determine if the machine is operating correctly.
In this procedure, you will learn how to read a pressure
gage using the Amatrol hydraulic trainer.
GAGE A
500
0 60
40 0
0 400
300 0
70
0
30
0
0
500
200
0
200
800
1000
600
0
90
0
10
0
70
0 00
kPa 00
10
0
psi
NOTE
The gages on your trainer may show a kPa scale with units of
0 to 70. If so, notice that “100x kPa” is printed at the bottom of
the gage face. This means that the kPa readings you take from
the scale must be multiplied by 100 to get the actual reading. For
example, a reading of 14 is really 1400 kPa.
70
70
0
0
30
30
30
0
0
0
0
500
500
500
200
200
200
0
0
200
200
200
800
800
800
1000
1000
1000
600
600
600
0
0
90
90
90
0
0
10
10
10
0
0
0
70 0
70 0
70
00 00 00
kPa 00
10 kPa 00
10 kPa 00
10
0 0 0
psi psi psi
70
70
0
0
30
30
30
0
0
0
0
500
500
500
200
200
200
0
0
200
200
200
800
800
800
1000
1000
1000
600
600
600
0
0
90
90
90
0
0
10
10
10
0
0
70 0
70 0
70
00 00 00
kPa 00
10 kPa 00
10 kPa 00
10
0 0 0
psi psi psi
The answers for these are Gage 1 = 300 psi / 2100 kPa, Gage 2 =
150 psi / 1000 kPa, Gage 3 = 250 psi / 1700 kPa, Gage 4 = 70 psi
/ 500 kPa, Gage 5 = 160 psi / 1100 kPa, Gage 6 = 400 psi / 2800
kPa.
❑ 3. Now locate gage S on the hydraulic trainer’s power unit, as shown
in figure 12. The pointer on this gage should be indicating 0, as
shown in figure 12.
Notice that the unit of bar is used instead of the kPa unit for one of
the scales. A bar is approximately equal to 1 standard atmosphere,
which is about 14.7 psi or 100 kPa. To convert this scale to kPa,
just add two zeroes to the reading. For example, 10 bar is
approximately 1000 kPa.
GAGE S
ACTUATOR
HYDRAULIC
POWER UNIT
ACTUATOR
CONTROL
VALVES
RETURN LINE
OIL RETURNING
FROM ACTUATORS
RETURN
FILTER
SAFETY
RELIEF OIL
GAGE VALVE COOLER
ELECTRIC
MOTOR
PUMP
SUCTION
FILTER
RESERVOIR
Procedure Overview
It is very important to know every aspect of the
operation of the hydraulic power unit. In this activity, you
are going to begin learning about the 850 series hydraulic
power unit by inspecting it. This unit is a small industrial
model.
RELIEF VALVE
FILLER/BREATHER
LIQUID LEVEL GAGE
ELECTRICAL
STARTER BOX
RESERVOIR
HYDRAULIC
FILLER/
PUMP
BREATHER
RELIEF
SUCTION VALVE
LINE
SUPPLY LIQUID
LINE
LEVEL
GAGE
SUCTION
STRAINER RESERVOIR
RETURN
LINE
Current Draw______________________________________Amps
Shaft Speed________________________________________RPM
❑ 3. Locate the Hydraulic Pump in figure 17.
In this case, you will not be able to actually see it because it is
mounted inside the reservoir.
The hydraulic pump supplies oil to the hydraulic system. When the
electric motor drives the pump shaft, the pump draws oil from the
reservoir into its inlet and discharges it into the system from its
outlet. The power unit design in the 850 power unit is a vertical
design where the electric motor and pump are mounted vertically.
The pump is located underneath the electric motor inside the
reservoir, as shown in figure 17.
SUCTION
LINE
SUPPLY/
PRESSURE
LINE
RETURN
LINE
NOTE
It is important to note that the return line and supply lines run
straight through the relief valve block. The relief valve is actually
mounted in the block so that it provides a way to let the supply
line oil short circuit to the return line. These two lines are not
actually running through the relief valve itself, only through the
block.
___________________________________________________
B. What is the step performed immediately before turning on the
power unit?
___________________________________________________
C. What are the six safety rules stated?
1. _____________________ 4. _____________________
2. _____________________ 5. _____________________
3. _____________________ 6. _____________________
❑ 3. When the tape is finished, rewind it and return it to the library.
Procedure Overview
In this procedure, you will check the level and
temperature of the oil in the reservoir of the hydraulic
trainer.
C F
THERMOMETER
RED MARK
❑ 2. Read the liquid level and describe the level relative to the two
marks.
_______________(above red mark, in between, below black mark)
You should observe that it is in between the marks. If it is not,
check with your instructor to correct this.
❑ 3. Read the oil temperature and record below.
______________________________________________(°F / ° C)
You should observe that it is near room temperature.
Procedure Overview
For most of the activities in this manual, you will use
the hydraulic power unit to supply power to your circuit. In
order to safely use this power supply, there are very
specific steps that must be followed. These steps are
basically the same ones you would use with any industrial
machine. In this procedure, you will perform these steps to
check out and then start up a hydraulic power unit.
CLOCKWISE (CW)
INCREASES
PRESSURE SETTING
SUPPLY RETURN
MANIFOLD MANIFOLD
RELIEF
VALVE
LOW
PRESSURE
OIL FLOWS
THROUGH
PUMP VALVE
RESERVOIR
SUPPLY RETURN
MANIFOLD MANIFOLD
RELIEF
VALVE
200 psi /
1380 kPa
OIL FLOWS
THROUGH
PUMP VALVE
RESERVOIR
CAUTION
Before turning off the power unit, the relief valve should be
reduced to the minimum pressure as you have just done. If this
is not done, the pressure in the system can cause the pump to
turn backwards and damage it!
❑ 7. Press the red “Stop” pushbutton on the motor starter to turn off the
power unit.
2. Power units normally are started and stopped with the relief
valve set at _____________.
4. The liquid level gage often gives you the oil’s __________
as well as its level.
SYMBOL SYMBOL
VALVE RESTRICTION
CYLINDER SPRING
FLOW DIRECTION
As you will see throughout these LAPs, the solid flow direction
arrow (triangle) is also used as a shortcut to indicate a partial circuit. This
allows you to show only the components and circuit necessary without
having to draw the complete circuit diagram.
Three standards that are most often referenced for symbols are those
developed by the National Fluid Power Association (N.F.P.A.),
American National Standards Institute (A.N.S.I.) and the International
Organization for Standardization (ISO).
The organization uses ISO instead of IOS because, although not a
correct acronym, it is easier to remember. ISO is from the Greek word
“isos”, meaning “equal”.
The United States uses NFPA and ANSI standards. The rest of the
world, as well as the U.S., uses the ISO standard.
NOTE
As you progress through the rest of this LAP, you will learn
the symbol for each component and how to read schematics that
contain them.
FEMALE QC
FITTING
MALE QC
FITTING
The schematic symbol for two quick connect fittings which are
connected is shown in figure 25. Each fitting shown has a valve called a
check valve which closes when the fittings are disconnected to keep oil
from leaking out.
Procedure Overview
In this procedure, you will learn to use quick-connect
fittings to connect components. To do this, you will hook up
a pressure gage.
❑ 1. Perform the following steps to inspect the quick fittings on the 850
hydraulic trainer.
Because you will need to change circuits frequently, the 850 basic
hydraulic system uses flexible hydraulic hoses and quick-connect
fittings.
A. Locate a quick connect fitting on the supply manifold, as
shown in figure 24. This is a male fitting.
One important feature of hydraulic quick connect fittings is
they have built in valves to keep oil from leaking out of the
hose or components when the hose connection is released. This
avoids messy oil spills. When the male and female ends are
connected, they each open their valves to allow oil to flow
freely.
B. Try pressing the top of the male fitting with your thumb to see
if you can open the valve.
C. Now locate a hose and inspect its quick connect fitting. This is
a female fitting.
D. Try pressing a ballpoint pen on the bottom of the inside of the
fitting to see if you can open its valve.
As you can see, both the male and female fittings have valves
to keep the oil from leaking. When these two fittings are
connected to each other, their valves are forced open so that oil
can flow through.
SUPPLY
MANIFOLD
1 1 SHUTOFF
VALVE
2 2
3 3
NEEDLE
VALVE
A B RETURN
MANIFOLD
D.C.V. IN
#1
CHECK VALVE #1
A B B A
CHECK VALVE #2
OUT
B A
BASIC HYDRAULIC VALVE MODULE
COLLAR
C. While holding the collar back, push the female end firmly onto
the male end of the pressure gage and release the collar. Your
completed assembly should appear as shown in figure 28.
NOTE
Make sure you push the two fittings together before pulling the
collar.
There are many times when you will need to connect two circuits to
the same supply line. A single fitting called a tee (and shaped like a “T”)
provides this connection.
The 850 hydraulics system includes three fitting tees equipped with
quick-connect fittings: two ends are male and one end is female, as
shown in figure 30. These fittings allow you to quickly connect these
components together.
SCHEMATIC
SYMBOL
BRANCH A
SUPPLY
LINE
TEE
BRANCH B
Procedure Overview
In this procedure, you will connect two pressure gages
to the same supply line using tee fittings. This procedure
will help you better understand how to use tees in a circuit.
TEE
SUPPLY
MANIFOLD
1 1 SHUTOFF
VALVE
2 2
3 3
NEEDLE
VALVE
A B RETURN
MANIFOLD
D.C.V. IN
#1
CHECK VALVE #1
A B B A
CHECK VALVE #2
OUT
B A
BASIC HYDRAULIC VALVE MODULE
Gage A ________________________________________(psi/kPa)
Gage B ________________________________________(psi/kPa)
Both gages should be close to the reading at gage S. If they are,
you have correctly connected a separate tee fitting in the circuit.
❑ 6. Turn the relief valve’s adjustment knob CW until the pressure at
gage S reads 500 psi/3447 kPa.
Record the pressures indicated at gages A and B.
Gage A ________________________________________(psi/kPa)
Gage B ________________________________________(psi/kPa)
Again, both gages should closely agree.
❑ 7. Turn the relief valve’s adjustment CCW fully to reduce the
pressure to a minimum.
❑ 8. Turn off the power unit and close the shutoff valve.
TEE
MACHINED
INSIDE OF
BLOCK
GAGE SUPPLY
BLOCK MANIFOLD
1 1 SHUTOFF
VALVE
2 2
3 3
NEEDLE
VALVE
A B RETURN
MANIFOLD
D.C.V. IN
#1
CHECK VALVE #1
A B B A
CHECK VALVE #2
OUT
B A
BASIC HYDRAULIC VALVE MODULE
Figure 33. Pictorial of Gages A and B Attached to the Supply Line Using
a Gage Block Tee
Gage B ________________________________________(psi/kPa)
Again, all gages should closely agree.
❑ 17. Turn the relief valve’s adjustment CCW fully to reduce the
pressure to a minimum.
❑ 18. Turn off the power unit and close the shutoff valve.
❑ 19. Now change the circuit to the one shown in figure 34.
In this circuit, gage block A’s tee is connected to the other side of
gage block B’s tee.
The purpose of testing this circuit is to show you that both sides of
the gage block tee are connected to each other and to the gage port.
TEE
MACHINED
INSIDE OF
BLOCK
GAGE SUPPLY
BLOCK MANIFOLD
1 1 SHUTOFF
VALVE
2 2
3 3
NEEDLE
VALVE
A B RETURN
MANIFOLD
D.C.V. IN
#1
CHECK VALVE #1
A B B A
CHECK VALVE #2
OUT
B A
BASIC HYDRAULIC VALVE MODULE
Gage A ________________________________________(psi/kPa)
Gage B ________________________________________(psi/kPa)
Both gages should be close to the reading at gage S.
❑ 22. Turn the relief valve’s adjustment knob CW until the pressure at
gage S reads 500 psi/3447 kPa.
Record the pressures indicated at gages A and B.
Gage A ________________________________________(psi/kPa)
Gage B ________________________________________(psi/kPa)
Again, both gages should closely agree.
❑ 23. Turn the relief valve’s adjustment CCW fully to reduce the
pressure to a minimum.
❑ 24. Turn off the power unit and close the shutoff valve.
❑ 25. Disconnect the two hoses and store them.
The most common type of pressure gage is the bourdon tube gage, as
shown in figure 35. The main component of a bourdon tube is a curved
tube that works much like a party rollup horn. The curved tube in the
bourdon tube gage straightens slightly when exposed to fluid pressure.
This causes its mechanical linkage to move the pointer indicating the
amount of pressure in the tube. The higher the pressure the more the tube
straightens and the more the pointer rotates.
SCALE
1500
1000 2000
500 2500
0 3000
POINTER LINKAGE
FLUID IN
BOURDON
TUBE
SYMBOL
PORT PORT
A B
ROD
BODY
PISTON
Procedure Overview
In this procedure, you will connect and operate a
cylinder by switching two hoses between the ports of the
cylinder. This will demonstrate the basic operation of the
cylinder.
SUPPLY
MANIFOLD
1 1
FLOW FLOW 2 2
CONTROL CONTROL 3
3
#1 #2
A A
NEEDLE
VALVE
A B
B B RETURN
MOTOR MANIFOLD
D.C.V. IN
#1
CHECK VALVE #1
A B B A
CHECK VALVE #2
OUT
CYLINDER B A
HYDRAULIC ACTUATOR MODULE BASIC HYDRAULIC VALVE MODULE
ROD
EXTENDING
FLUID
PRESSURE
CAP
END
ROD
END
At this point, you may be wondering why the oil doesn’t leak out of
the cylinder around the rod. This is because there is a flexible seal
called a rod seal that is placed around the rod, as shown in figure 43.
To hold this seal in place, a rod bushing is needed. This bushing
also acts as a bearing to support the rod as it extends.
PISTON
SEALS
ROD
SEALS
ROD
BUSHING
In addition to the rod seal, there are also one or more piston seals.
The piston seals keep oil from leaking around the piston so that
pressure can build up to move the load.
B831-XA LAP 1 HYDRAULIC POWER SYSTEMS
Copyright © 2002 Amatrol, Inc. 53
❑ 6. Reduce the relief valve pressure to minimum.
❑ 7. Turn off the power unit and close the shutoff valve.
❑ 8. Now switch the two hoses at the cylinder so that the pressure line
from the pump connects to the rod end of the cylinder, as shown in
figure 44.
SUPPLY
MANIFOLD
1 1
FLOW FLOW 2 2
CONTROL CONTROL 3
3
#1 #2
A A
NEEDLE
VALVE
A B
B B RETURN
MOTOR MANIFOLD
D.C.V. IN
#1
CHECK VALVE #1
A B B A
CHECK VALVE #2
OUT
CYLINDER B A
HYDRAULIC ACTUATOR MODULE BASIC HYDRAULIC VALVE MODULE
ROD
RETRACTING
CAP
END
ROD
END
CYLINDER
OPERATOR CONNECTIONS
HANDLE
SPOOL
SPOOL
A B LAND
SPRING
P T
VALVE
TANK
BODY PRESSURE CONNECTION
CONNECTION
Notice in figure 48 that the ports are labeled. The P stands for the
“pressure” or inlet port. The T stands for the tank port. This is the port
that is connected to the reservoir.
There are also two actuator ports labeled A and B. These are usually
connected to the lines going to the cylinder or motor. They allow fluid to
flow to and from the cylinder or motor.
NOTE
In the fluidpower industry the terms open and closed mean
just the opposite of the meaning in the electrical industry. An
electrical switch passes electricity when it is closed. A fluidpower
valve passes fluid when it is open.
LEVER
SPRING
A B
SPRING
P T ELECTRICAL
STRAIGHT CROSSED OPERATOR
ARROWS ARROWS
CONDITION CONDITION
ENERGIZED FLOW
A B PATH CONDITION
SPRING
P T
ELECTRICAL
OPERATOR
ENERGIZED
The schematic symbol for a 3-position valve adds one more flow
envelope and a second spring, as shown in figure 53. The details of the
operation will be explained further in the skill.
A B
P T
Procedure Overview
In this procedure, you will determine the flow paths of a
3-position, 4-way directional control valve for each of its
positions. This activity will help you better see how this
valve works.
❑ 1. Obtain the open-end fitting from the loose items of the 850 series
trainer.
When inserted into a hose end quick-connect, as shown in figure
54, this fitting opens the end of the hose.
SUPPLY
MANIFOLD
1 1
2 2
3 3
NEEDLE
VALVE
A B
RETURN
MANIFOLD
D.C.V. IN
#1
CHECK VALVE #1
A B B A
CHECK VALVE #2
OUT
B A
BASIC HYDRAULIC VALVE MODULE
OPEN-END
FITTINGS
DIRECTIONAL
SUPPLY CONTROL VALVE
MANIFOLD
A B IN A
OUT B
SHUTOFF
VALVE
RETURN
OPEN-END
MANIFOLD
FLOW FITTING
METER
Figure 57. Using the Open End Fitting to View Flow Returning to
Reservoir Through the Filler/Breather Opening
Procedure Overview
In this procedure, you will set up a basic hydraulic
circuit to reciprocate a cylinder using a 4-way, 3-position
directional control valve. You will find that this method is
much easier than switching hose connections as you did in
an earlier skill.
NOTE
Make sure all your hose connections are firmly made.
SUPPLY
MANIFOLD
1 1
FLOW FLOW 2 2
CONTROL CONTROL 3 3
#1 #2
A A
NEEDLE
VALVE
A B
B B RETURN
MOTOR MANIFOLD
D.C.V. IN
#1
CHECK VALVE #1
A B B A
CHECK VALVE #2
OUT
CYLINDER B A
HYDRAULIC ACTUATOR MODULE BASIC HYDRAULIC VALVE MODULE
NOTE
A 4-way DCV is the type needed to extend and retract a
double-acting cylinder. A 4-way DCV with 3-positions is used if
the cylinder must stop in mid-position.
NORMAL
CONDITION
A B
IN OUT
FROM TO
PUMP RESERVOIR
Gage C =_______________________________________(psi/kPa)
CYLINDER STOPPED
LEVER
HANDLE
IN MID
POSITION A B
P T
BLOCKED
RESERVOIR
CYLINDER EXTENDING
LEVER OPEN TO
HANDLE PORT T
A B
PUSHED IN
P T
OPEN TO
PORT A
RELIEF
VALVE
RESERVOIR
A B
IN OUT
FROM TO
PUMP RESERVOIR
CYLINDER RETRACTING
CONNECTED
TO PORT
T
LEVER
HANDLE
PULLED A B
OUT
P T
CONNECTED TO
PORT B
RELIEF
VALVE
PUMP
RESERVOIR
Figure 63. Pictorial of DCV with Spool Shifted to Crossed Arrows Condition
A B
IN OUT
FROM TO
PUMP RESERVOIR
NOTE
3-position valves are made with center conditions other than
the blocked center condition. You will learn more about the other
center conditions in a later LAP.
_____________________________________________________
Procedure Overview
In this procedure, you will further develop your
understanding of hydraulic circuits by designing a basic
circuit.
CYLINDER
2
CYLINDER
1
SUPPLY
MANIFOLD
CYL CYL
1 2
RETURN SHEAR
MANIFOLD