Presents practical methods for detecting, diagnosing and correcting fluid power problems within a system. The work details the design, maintenance, and troubleshooting of pneumatic, hydraulic and electrical systems and components. This second edition stresses: developments in understanding the complex interactions of components within a fluid power system; cartridge valve systems, proportional valve and servo-systems, and compressed air drying and filtering; noise reduction and other environmental concerns; and more.;This work should be of interest to mechanical, maintenance, manufacturing, system and machine design, hydraulic, pneumatic, industrial, chemical, electrical and electronics, lubrication, plastics processing, automotive, process control, and power system engineers; manufacturers of hydraulic and pneumatic machinery; systems maintenance personnel; and upper-level undergraduate and graduate students in these disciplines.
Foreword Z. J. Lansky
Preface
1 Fluid Power Principles: A Review
Hydraulic Principles
Basic Laws of Fluids
Pneumatic Principles
Hydraulic System Operation
Advantages and Disadvantages of Hydraulic System
Comparing Hydraulic Systems
Pneumatic System Operation
Compressors
Heat Exchangers (Aftercoolers)
Storage Tanks
Air Drying Equipment
Comparison of Air Systems to Electric and Hydraulic Systems
Air Versus Electric Systems
Air Versus Hydraulic Systems
2 Hydraulic Systems: Operation, Maintenance, and Troubleshooting
Hydraulic Pumps
Gear Pumps
Vane Pumps
Piston Pumps
Hydraulic Motors
Motor Ratings
Vane Motors
Gear Motors
Piston Motors
Rotary Motion (Fluid Motors and Rotary Actuators)
Startup, Operation, and Maintenance of Hydraulic Pumps and Motors
General Instructions
Pump Malfunction
Hydraulic Motor Malfunction
Troubleshooting Pumps and Motors
Hydraulic Valves
Directional Control Valves
Check Valves
Flow Control Valves
Pressure Control Valves
Solenoid Valves
Servicing, Repairing, and Troubleshooting Hydraulic Valves
Hydraulic and Pneumatic Cylinders
Description and Terminology
Cylinder Ratings
Cylinder Cushions
Cylinder Piston Seals
Installation and Maintenance of Hydraulic Cylinders
Troubleshooting Hydraulic and Pneumatic Cylinders
Hydraulic Accumulators
Types and Applications
Servicing and Repairing of Accumulators
Hydraulic System Reservoirs
Construction and Design
Accessories
Location
Cleaning
3 Pneumatic Systems: Operation, Maintenance, and Troubleshooting
Air Compressors
Reciprocating Piston Compressors
Rotary Compressors
Installation, Maintenance, and Troubleshooting
Pneumatic Valves
Valve Operation
Maintenance and Troubleshooting
Air Motors
Types of Air Motors
Air Motor Characteristics
Maintaining Air Motors
Maintenance of Air Tools
4 Contaminants in a Hydraulic System
Sources
Effects Control
Filter Types
Filter Bypass Valve
Filter Condition Indicator
Installation, Maintenance, and Troubleshooting of Hydraulic Filters
Installation
Maintenance
Troubleshooting
5 Compressed Air Filtration, Lubrication, and Moisture Control
Contaminants in the Air System
Air Line Filters, Lubricators, and Pressure Regulators
Compressed Air Filters
Lubricators
Pressure Regulators
Choosing a F-R-L
Routine Maintenance of F-R-L Units
Maintenance of Compressed Air Filters
Aftercoolers and Air Driers
Aftercoolers
Air Driers
6 Hydrostatic Transmissions
Principles of Operation
Circuit Development
Comparison of Hydrostatic Transmission Types
Hydrostatic Transmission Controls
Hydrostatic Transmission Start-up Procedure
Hydrostatic Transmission Maintenance
Troubleshooting Hydrostatic Transmissions
Troubleshooting Guidelines
7 Temperature Considerations
Heat Generation
Heat Dissipation
Heat Exchangers: Coolers
Heat Exchanger Types
Adding a Second Heat Exchanger
Miscellaneous Tips on Heat Exchangers
Tips on Heat Dissipation by Radiation
Maintenance and Service
Replacement of Zinc Anodes
Cleaning Shell-and-Tube Heat Exchangers
Cleaning Air-Oil Heat Exchangers
Checking for Leaks
8 Hydraulic System Fluids: Selection and Care
Fluid Types and Properties
Fluid Properties
Petroleum Oils
Fire-Resistant Fluids
Water
Maintaining Fluid Performance
9 Fluid Conductors and Connectors
Pipe, Tubing, and Hose
Pipe
Tubing
Hose
Connectors
Tube Fittings
Straight Thread O-Ring Fittings
Hose Fittings and Couplers
Installation Considerations
Pipe Installation
Tubing Installation
Hose Installation
Hose Fitting Installation
Plant Air Line Piping Systems
Use and Care of Hose and Fittings
House Assembly Failures
Improper Application
Improper Assembly and Installation
External Damage
Faulty Equipment
Faulty Hose
Analyzing Hose Failures
Modular Manifold Hydraulic Systems
10 Seals for Fluid Power Equipment
Seal Forms
Dynamic Seal Application and Failure
Radial Lip Seals
Face Seals
Packings
Static Seal Application and Failure
Gaskets
O-Rings
Checking for Leaks
Seal Materials
Elastomeric Seal Materials
Tips to Avoid Premature Seal Failure
Exclusion Rings, or Wiper or Scraper Rings
11 Fluid Power Systems: Operation, Maintenance, and Troubleshooting
System Design Considerations
Installation, Start-up, and Operation of Hydraulic Systems
Installation
Start-up
Operation
Knowing the System
Maintenance of Hydraulic Systems
Maintenance Procedures and Hints
Hydraulic System Maintenance Accessories
Fluid Storage and Handling
Troubleshooting Guides
12 Fluid Power System Malfunction Detection and Diagnosis
Malfunction Detection
Using a Hydraulic Tester to Troubleshoot
Application of a Tester
Diagnostic Instrumentation
Bourdon Tube Pressure Gauge
Viscosity Measurement
Liquid-Level and Temperature Indicators
Flowmeters
13 Fluid Power System Noise Control
Pump Noise
Hydraulic System Noise Control
Vibration Noise Control
Fluidborne Noise Control
Noise Measurement
Research to Reduce Noise
14 Electrohydraulic Servo Systems, Proportional Valve Systems, and Load-Sensing Systems
Description
Control System Types
Electrohydraulic Equipment
Properties of Feedback Control Systems
Objectives
Open-Loop Versus Closed-Loop System Characteristics
Stability and Dynamic Response
Electrohydraulic Proportional and Servo Valves
Proportional Valve Construction
Servo Valve Construction
Servo Valve Characteristics
Flow Control Servo Valves
Pressure-Control Servo Valves
Installation, Operation, Maintenance, and Troubleshooting of Servo Valves
Installation and Start-up
Operation
Maintenance and Troubleshooting
Servo-system Terminology
Appendix A. Fluid Power Symbols and Glossary
Fluid Power Symbols
Fluid Power Graphic Symbols
American National Standards Institute Symbols
Glossary of Fluid Power Terms
Appendix B. Hydraulic Facts and Technical Data
Hydraulic Facts
Miscellaneous Technical Data
Helpful Tables for Fluid Power Systems
Index
Biography
Anton Hehn
". . .provides practical explanations of component and system function, failure modes encountered in this operation of systems, and methods for locating and isolating fluid power problems."
---IASI Polytechnic Magazines
