Service

Basic Training

Hydraulics

5.905-842
02/03
Foreword

Foreword

Good servicing work calls for comprehensive and practically-oriented training as well as clear
and manageable documentation.
For this reason, we offer regular training courses and further education events covering the
whole product range to all service technicians.
We additionally compile servicing manuals for the most important devices which serve initially
as instructions and can later be used for reference purposes.
We also provide regular service information bulletins reporting on product further development.

The text and pictures may not be copied, duplicated or made available to third parties without the
express consent of:

ALFRED KÄRCHER GmbH & Co.

KUNDENDIENSTSCHULUNG
Postfach 160
D-71349 Winnenden
www.karcher.de

2 Service Basic Training Hydraulics 02/03

 Contents

Contents

General ...................................................................................................... 5
Benefits/drawbacks of hydraulics/fluid technology ............................................... 5
Benefits ................................................................................................................................ 5
Drawbacks .......................................................................................................................... 5
Basic hydromechanics ............................................................................................. 6
Pressure due to fluid height ................................................................................................. 6
Pressure due to outside forces ............................................................................................ 6
Basic hydromechanics ............................................................................................. 7
Power transmission ............................................................................................................. 7
Circulatory law .....................................................................................................................7
Basic hydromechanics ............................................................................................. 8
Pressure loss ...................................................................................................................... 8
Structure of a hydraulic system ............................................................................... 9
Energy - conversion ........................................................................................................... 9
Energy - control ................................................................................................................... 9
Energy - transport ................................................................................................................9
Others .................................................................................................................................. 9
Hydraulic circuit symbols ......................................................................................... 9

Hydraulic circuit symbols ..................................................................... 10

Line types .......................................................................................................................... 10
Flow paths of lines ............................................................................................................. 10
Function symbols ............................................................................................................... 10
Drive motors ...................................................................................................................... 11
Hydraulic pumps ................................................................................................................ 11
Hydraulic cylinders ............................................................................................................ 11
Possible combinations ....................................................................................................... 12
Flow possibilities ................................................................................................................ 12
Switching possibilities ........................................................................................................ 12
Directional valves – example ............................................................................................. 13
Flow rate valves................................................................................................................. 13
Non-return valves .............................................................................................................. 14
Twin non-return valves ....................................................................................................... 14
Pressure control valve ....................................................................................................... 14
Pressure control valve – non-return valve / flow control valve – non-return valve ............ 15
Blower fan / impeller fan ..................................................................................................... 15
Oil tanks ............................................................................................................................. 15
Oil filter / oil cooler .............................................................................................................. 16
Oil tank and components ................................................................................................... 16
Function of an oil tank ........................................................................................................ 16
Tasks of an oil tank ............................................................................................................ 16

Routing of hydraulic hoses .................................................................. 18

Service Basic Training Hydraulics 02/03 3

Contents

Structure of a hydraulic plan ................................................................ 20

Basic hydraulic plan ........................................................................................................... 20
Electric motor ..................................................................................................................... 20
Pressure control valve ....................................................................................................... 21
4/3 directional valve ........................................................................................................... 21
Flow rate valve................................................................................................................... 22
Oil filter ............................................................................................................................... 22
Safety valve for oil filter ...................................................................................................... 23
4/3 directional valve in neutral position .............................................................................. 23
Pipe break valve ................................................................................................................ 24

Functional sequence hydraulic plan ................................................... 25

Example KMR 1250 ................................................................................................. 25
Hydraulic plan pressureless condition ............................................................................... 25
Raising the debris container .............................................................................................. 26
Electric circuit diagram ...................................................................................................... 26
Hydraulic plan .................................................................................................................... 26
Tilting out the debris container ........................................................................................... 27
Electric circuit diagram ...................................................................................................... 27
Hydraulic plan .................................................................................................................... 27
Tilting back the debris container ........................................................................................ 28
Electric circuit diagram ...................................................................................................... 28
Hydraulic plan .................................................................................................................... 28
Lowering the debris container ............................................................................................ 29
Electric circuit diagram ...................................................................................................... 29
Hydraulic plan .................................................................................................................... 29

Servicing work on hydraulic systems ................................................. 30

Safety and maintenance instructions .................................................................... 30

4 Service Basic Training Hydraulics 02/03


General
The terms hydraulics or fluid technology are
used to describe all drive, control and regula-
ting components of a device in which power is
generated and transmitted by pressure in a
fluid.
With the aid of electrical devices, hydraulics/
fluid technology can be used to achieve a high
degree of positioning and velocity accuracy.
In order to engender greater understanding of
hydraulics/fluid technology, this basic training
program will initially provide an explanation of
fundamental hydromechanical principles.
Primarily, this basic training program will be
explaining the hydraulic circuit symbols which
represent the components currently used in
our devices.
In addition, two examples will be used to
explain the technical structure of the individual
components and the sequence of a hydraulic
plan.
This basic training program encompasses
also certain laws of physics, for example of
- Mass, force
- Work, energy, output
- Velocity, acceleration
Service Basic Training Hydraulics 02/03
Basics
Benefits/drawbacks of
hydraulics/fluid technology
Benefits
- Space and weight-saving components
capable of transmitting high forces
- Fast, precise and steplessly adjustable
cylinder and motor speeds
- Simple overload prevention by pressure
limitation
- Function at full load is possible from stand-
still
- Suitable for fast and also extremely slow,
controllable movement sequences
Drawbacks
- Temperature dependence of the hydraulic
oil
- Loss due to leakage oil
- Friction loss which converts into heat and
raises the temperature of the system
- Vibration and noise creation tendency
5
Basics

Basic hydromechanics
Hydromechanics is the science of the
physical characteristics and behaviour of fluids
in a static (hydrostatics) and dynamic
(hydrokinetics) status.

Pressure due to fluid height

If the pressure (p1 = p2 = p3) acts on sur-
faces of equal size (A1 = A2 = A3), the
resulting forces are equally high (F1 = F2 =
F3).
Here, the shape of the vessel is of no
significance, only the height of the fluid (h)
h p1 p2 p3 determines the extent of the pressure.

A1 F1 A2 F2 A3 F3

Pressure due to fluid height

Pressure due to outside forces
The effect of a force (F) on a static fluid
spreads evenly in all directions within the fluid.
F The level of the pressure (p) in the fluid is
equal to the force due to weight (F) relative to
the surface upon which it acts (A). The pres-
A sure (p) always acts vertically on the adjoining
surfaces of the tank.

Pressure due to outside forces

6 Service Basic Training Hydraulics 02/03

 Basics

Basic hydromechanics
Power transmission
As the pressure spreads evenly to all sides,
the shape of the tank is of no significance.
If force (F1) acts on surface (A1), pressure (p)
1 F1 S2 F2 2 is created.
p = F1 / A1
Pressure (p) acts on every point of the
S1 system, i.e. also on surface (A2). The
achievable force (F2) (synonymous with a load
p A1 A2 to be lifted) is
F2 = p x A2
If it is possible using force (F1) and surface
(A1) to achieve the pressure needed to over-
come the load (F2) (above surface (A2)), then
the load (F2) can be lifted. (Leaving friction
loss out of account).
The paths (S1) and (S2) of the two pistons
Power transmission perform the reverse action to the surfaces
(A1) and (A2).
S1 / S2 = A1 / A2
Therefore
S1 x A1 = S2 x A2

Circulatory law
The same volume of fluid flows in the same
period of time through a pipe with differing
cross-sections. This means that the flow rate
of the fluid in the smaller cross-section must
A1 increase.
A2 The volumetric flow (Q) corresponds to the
product of the cross-sectional surface of pipe
Q1 Q2 (A) times the velocity of the fluid (v)
v2 Q=Axv
v1 The volumetric flow (Q) is the same at all
points of the pipe.
Q1 = Q2
The two cross-sections (A1) and (A2) of the
pipe behave in opposition to the velocities of
the fluids (v1) and (v2).
Circulatory law A1 x v1 = A2 x v2

Service Basic Training Hydraulics 02/03 7

Basics

Basic hydromechanics
Pressure loss
In order to explain these physical laws, we
assumed that no friction or pressure loss
occurs.
p2 p3 p4 p5 p6 Hydraulic energy cannot be transmitted
through pipes without loss.
Due to friction on the pipe walls or due to a
restriction of the cross-section (flow control
p1 p7 valve), hydraulic energy is transformed into
heat. For hydraulically operated systems, the
loss of hydraulic energy created in this way
∆p = p1 - p7 means a loss of pressure and a reduction of
the flow rate.
Pressure loss is represented by the symbol
Dp. Its extent depends primarily upon:
- The line length
- The cross-section of the pipe
Pressure loss
- Surface roughness of the pipe wall
- Number of bends in the pipe
- Flow rate
- Fluid velocity

8 Service Basic Training Hydraulics 02/03


Structure of a hydraulic system
In hydraulic systems, mechanical energy is
converted into hydraulic energy, transported in
this form and controlled or regulated, then
converted back into mechanical energy again.
Energy - conversion
To convert energy, on the primary side pumps
are used, and on the secondary side cylinders
and motors.
Energy - control
The extent of the hydraulic energy and the
direction in which it acts, and thus also the
transmitted output are influenced in the form of
pressure and volumetric flow by variable
displacement pumps and by control and
regulating valves.
Energy - transport
The pressure fluid which is guided through
pipes, hoses and holes in control blocks or
control plates, assumes the function of energy
transport or also only of pressure conduction.
Others
A series of supplementary devices such as
tanks, filters, coolers, heating elements,
measuring and test units are required for
storage and maintenance of the pressure fluid.
Service Basic Training Hydraulics 02/03
Basics
Hydraulic circuit symbols
To illustrate hydraulic correlations in
accordance with DIN ISO 1219, nowadays in
the majority of cases hydraulic circuit dia-
grams with standardized circuit symbols are
used.
The circuit symbols are neither to scale, nor
do they claim to correspond to the actual
position of the component in question. They
are intended only to indicate a function.
The components of a hydraulic plan are
arranged from bottom to top in the direction of
the energy flow:
- Energy source: bottom left
- Control elements in progressive sequence:
upwards, from left to right
- Drive systems: at the top from left to right
A hydraulic circuit diagram is interpreted in a
similar way to an electrical circuit diagram, the
difference here being that actually visible fluid
currents and pressures act as well as
mechanical components.
Hydraulic components are shown in the
starting position of the system with pressure
applied.
Elements or assemblies of the same type
should be indicated at the same height within a
hydraulic plan.
The following breakdown of circuit symbols
makes no claim to completeness, and
contains only the most commonly used
symbols. It is intended as a tool to
understanding a hydraulic circuit plan.
9
Hydraulic circuit symbols

Hydraulic circuit symbols

Line types
1 1 Working line (continuous line = delivery or
pressure line)
2 Control line (dash line = to actuate valves
or other components)
2 3 Dot and dash lines = used to draw a
frame around an assembly

Line types
Flow paths of lines
1 Line connections
2 Line crossing points
1 3 Flexible lines

Flow paths of lines

Function symbols
1 1 Direction of volumetric flow
2 Current direction of flow
3 Sense of rotation
4 Adjustment facility

Function symbols

10 Service Basic Training Hydraulics 02/03

 Hydraulic circuit symbols

Hydraulic circuit symbols

Drive motors
1 Electric motor, drive shaft turns in two
1 M directions
2 Combustion engine, two cylinders (no. of
squares on the motor)
drive shaft turns in two directions
3 Hydraulic motor,
2 two volumetric flow directions,
M drive shaft turns in two directions

Drive motors
Hydraulic pumps
1 One volumetric flow direction, drive shaft
1
turns in one direction
2 Two volumetric flow directions, drive shaft
turns in one direction
3 Two adjustable volumetric flow directions,
drive shaft turns in one direction
2

Hydraulic pumps
Hydraulic cylinders
1 Single-acting cylinder with piston rod on
one side (retraction stroke powered by
integrated spring)
1
2 Double-acting cylinder with piston rod on
one side

Hydraulic cylinders

Service Basic Training Hydraulics 02/03 11

Hydraulic circuit symbols

Hydraulic circuit symbols

Possible combinations
1 Directional valve with two switching
1 positions
2 Directional valve with three switching
position

Possible combinations
Flow possibilities
1 Flow possibilities for one switching
1 position with two connections
2 Flow possibilities for one switching
position with three connections
3 Flow possibilities for one switching
position with four connections
2

Flow possibilities
Switching possibilities
1 Actuation by electric solenoid valve
2 Actuation by spring
1 2 3 Actuated hydraulically
4 Actuation by lever

3 4

Switching possibilities

12 Service Basic Training Hydraulics 02/03

 Hydraulic circuit symbols

Hydraulic circuit symbols

Directional valves – example
4/3 directional valve
4 = number of connections
3 = number of switching positions
1 a o b 1 A Connections for consumers
A B
B Connections for consumers
P Pressure connection (pump)
T Return line connection
a Switch position (left)
P T o Switch position (idle position)
2 3
b Switch position (right)
1 Compression springs for switching
position (o)
2 Solenoid valve for switch position (a)
3 Solenoid valve for switch position (b)
Directional valves - example
If solenoid valve (2) is energized, switch
position (a) applies. If solenoid valve (3) is
energized, switch position (b) applies. In the
idle position, the valve is moved to the central
switch position (o) by the two compression
springs (1).

Flow rate valves

1 1 Flow rate valve not adjustable (reduces
the pressure and the flow rate)
2 Flow rate valve adjustable (reduces the
pressure and the flow rate)
3 Flow control valve with regulation output
current (reduces pressure and flow rate)
2 4 Flow control valve with regulation output
flow and relief opening (reduces pressure
and flow rate)

Flow rate valves

Service Basic Training Hydraulics 02/03 13

Hydraulic circuit symbols

Hydraulic circuit symbols

Non-return valves
1 1 Stop valve (manual interruption of the
delivery line. Stop valve is either
completely open or closed).
2 Non-return valve, unloaded
2 (Flow only possible in one direction)
3 Non-return valve, spring-loaded
(Flow only possible in one direction)
3 4 Shuttle valve (volumetric flow can flow
downwards from the left or right)
5 Pipe break valve (in case of high
4 pressure drop, the ball presses against
the spring and prevents return flow)
6 Pipe break valve (in the operating mode,
the integrated control line does not press
5 the non-return ball into its seat, allowing
oil to flow. An integrated flow rate valve
prevents the non-return ball from being
pressed into its seat during return flow. In
6 case of a high pressure drop, the ball
presses into the seat and prevents return
flow.
Non-return valves
Twin non-return valves
A2 B2 A twin non-return valve is used to move a
hydraulic cylinder or to block it in an
unpressurized condition.
Non-return valve (A) opens when the
A B volumetric flow runs from (A1) to (A2).
A control piston opens the non-return valve (B)
slightly via a control line, to permit return flow
from (B2) to (B1).
The same applies when the volumetric flow
runs from (B1) to (B2). Then the control piston
opens non-return valve (A).

A1 B1
Twin non-return valve
Pressure control valve
1 Pressure control valve with internal
control line (is intended to limit the
pressure in the system)
2 Pressure control valve with external
1 2 control line (is intended to limit the
pressure in the system)

Pressure control valve

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 Hydraulic circuit symbols

Hydraulic circuit symbols

Pressure control valve – non-return valve /
flow control valve – non-return valve
1 Pressure control valve – non-return valve
(the pressure is limited in one direction,
flow is free in the other direction. Spring
1 adjustable).
2 Flow control valve – non-return valve
(the pressure and flow rate are reduced in
one direction, flow is free in the other
direction. Throttle adjustable)

Pressure control / flow control non-retrn valves

Blower fan / impeller fan
1 Blower fan, e.g. for ventilation, extraction,
compression
2 Impeller fan, e.g. for cooling

1 2

Blower fan / impeller fan

Oil tanks
1 Oil tank
1 2 Oil tank (for the sake of clarity small oil
tanks are additionally drawn at the ends
of lines in the hydraulic plan, but what is
meant is the actual oil tank.

Oil tanks

Service Basic Training Hydraulics 02/03 15

Hydraulic circuit symbols

Hydraulic circuit symbols

Oil filter / oil cooler
1 Oil filter (frequently arranged in the return
line)
Causes of contamination in a hydraulic
system
- production, assembly
- creation of abraded particles during
operation
1 2 - environment, maintenance, servicing
2 Oil cooler

Oil filter / oil cooler

Oil tank and components

1 Pump
2 Filter
1 2 3 Air cushion
4 Level fluctuation
3
5 Drainage screw

4 Function of an oil tank

The pump draws the oil out of the tank.
Once it has passed through the consumers,
the oil flows back to the oil tank via a filter.

5 Tasks of an oil tank

- To accommodate the entire oil volume in the
system
Components of an oil tank
- To separate air by providing the greatest
possible oil surface and a long dwell period
of the oil in the tank
- It allows contamination particles not caught
in the filter to settle on the tank floor. This is
why the tank has a sloping floor
- Separation of condensation which forms
due to temperature fluctuations in the oil
tank. It collects at the deepest point of the
tank, another reason why the oil tank has a
sloping floor.

16 Service Basic Training Hydraulics 02/03

 Hydraulic circuit symbols

Service Basic Training Hydraulics 02/03 17

Routing of hydraulic hoses

Routing of hydraulic hoses

1 4

Never install hydraulic hoses pulled tight Avoid kinks

2 5

Never install hydraulic hoses pulled tight Avoid kinks

3 6

Avoid kinks Avoid kinks

18 Service Basic Training Hydraulics 02/03

 Routing of hydraulic hoses

Routing of hydraulic hoses

Hydraulic hoses are used as flexible
connecting lines between hydraulic devices
which move in opposition to each other, or
where spatial circumstances are unfavourable
for laying lines.
They are also used as a way of reducing noise
and vibrations.

When laying hydraulic hoses, they must never

be twisted or installed with an excessively
long loop.

Figs. (1) and (2) illustrate that hoses should

never be installed pulled tight, so as to avoid
elongation and to ensure that pressure shocks
are absorbed.
Figs. (3), (4), (5) and (6) illustrate that kinks
must be avoided.

As a measure to avoid abrasion of the hose,

clamping clips should never be used. Hoses
which can rub against other components must
be provided with a protective sheathing.

Service Basic Training Hydraulics 02/03 19

Structure of a hydraulic plan

Structure of a hydraulic plan

Basic hydraulic plan
5 The basic hydraulic plan consists of

1 Oil tank
2 Working line
3 Pump
4 4 4 / 3 directional valve
5 Cylinder

Basic hydraulic circuit diagram

Electric motor
In order to drive the pump, an electric motor is
connected upstream.
The pump now draws the oil from the oil tank
and transports it to the 4 / 3 directional valve.

Electric motor

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 Structure of a hydraulic plan

Structure of a hydraulic plan

Pressure control valve
In order to prevent damage to the hydraulic
components through excess pressure, a
pressure control valve is used. If the pressure
exceeds the limit, the oil is now able to flow
back into the oil tank through the pressure
control valve.

Pressure control valve

4/3 directional valve

The right-hand solenoid valve is energized and
switches the 4/3 directional valve to the right-
hand switch position.
The oil is now able to flow through the 4/3
directional valves, allowing the cylinder to
extend. The oil then flows back into the oil tank
from the unpressurized side.
With the hydraulic plan structure shown here,
the cylinder has been extended in rapid
traverse, as the pressure is acting completely
on the cylinder.

4 / 3 - directional valve

Service Basic Training Hydraulics 02/03 21

Structure of a hydraulic plan

Structure of a hydraulic plan

Flow rate valve
If a flow rate valve is integrated, the cylinder
extends more slowly. The speed at which the
cylinder extends cannot be regulated by this
flow control valve, as this has been
permanently set by the manufacturer.

Flow control valve

Oil filter
In order to prevent damage to the hydraulic
system due to contamination, an oil filter is
integrated into the return line.

Oil filter

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 Structure of a hydraulic plan

Structure of a hydraulic plan

Safety valve for oil filter
If the pressure increases in the return line due
to a contaminated oil filter, a bypass with
safety valve is used (spring loaded non-return
valve). The hydraulic oil flows unfiltered
through this bypass valve into the oil tank.

M
x
Safety valve for oil filter

4/3 directional valve in neutral position

If the right-hand solenoid valve of the 4/3
directional valve is de-energized, the left-hand
spring sets the 4/3 directional valve to the
neutral position.
The oil flows back through the pressure
control valve. The cylinder remains extended.

4 / 3 - directional valve in neutral position

Service Basic Training Hydraulics 02/03 23

Structure of a hydraulic plan

Structure of a hydraulic plan

Pipe break valve
The pipe break valve prevents the cylinder
from retracting in an uncontrolled manner
under load (risk of accidents) in the event of a
defective or burst pressure pipe.

Pipe breakage valve

24 Service Basic Training Hydraulics 02/03

 Functional sequence hydraulic plan

Example KMR 1250

Hydraulic plan pressureless condition
This hydraulic plan illustrates the raising /
9 10 lowering and tilting action of a debris container.

1 Oil tank
8 2 Oil filter
11 3 Electric motor, hydraulic unit
4 Hydraulic pump
7 12
5 Non-return valve
6 4/2 directional valve, tilt debris container
6 7 2/2 directional valve, raise / lower debris
container
5 13
8 Pipe break valve
9 Hydraulic cylinder, raise debris container
14 10 Hydraulic cylinder with gas pressure
spring, tilt debris container
M
4 11 Hydraulic unit
3 12 Flow rate valve
13 Flow control valve
2 14 Pressure control valve
1
Hydraulic circuit diagram, pressureless condition The functions are explained step by step over
the next pages in conjunction with the
electrical circuit diagram.

Service Basic Training Hydraulics 02/03 25

Functional sequence hydraulic plan

Example KMR 1250

Raising the debris container
+
Electric circuit diagram
If the two switches (S5) and (S8) are pressed
S5 together, the motor (M2) is switched on
(build-up of hydraulic pressure).
The solenoid valves (Y2) and (Y1) are not
activated.

S6 S7 S8

Y2 Y1
M2
-

Switching on electric motor (M2)

Hydraulic plan
As soon as the electric motor (3) is running,
9 10 the pump (4) draws oil from the oil tank (1) and
through the filter (2). The pump (4) transports
the oil through the non-return valve (5), the 4/2
directional valve (6), the 2/2 directional valve
8 (7) and the pipe break valve (8) to the hydraulic
11 cylinder (9). This extends and raises the
debris container.
7 12
The two switches (S5) and (S8) must remain
6 depressed until the hydraulic cylinder (9) has
completely extended (two-hand safety
13 operation).
5

14
M
4
3

2
1
Raising the debris container

26 Service Basic Training Hydraulics 02/03

 Functional sequence hydraulic plan

Example KMR 1250

Tilting out the debris container
+
Electric circuit diagram
If the two switches (S5) and (S7) are pressed
S5 together, the motor (M2) is switched on
(build-up of hydraulic pressure) and the
solenoid valve (Y1) is activated at the same
time.

S6 S7 S8

Y2 Y1
M2
-

Activating solenoid valve (Y1)

Hydraulic plan
As soon as the solenoid valve (Y1) of the 4/2
9 10 way valve (6) is activated, it switches to the
left-hand switch position. The pump (4)
transports the oil to the hydraulic cylinder (10),
which extends and tilts the debris container.
8
11
The two switches (S5) and (S7) must remain
7 12 depressed until the hydraulic cylinder (10) has
completely extended (two-hand safety
operation).
6

5 13

14
M
4
3

2
1
Titing out the debris container

Service Basic Training Hydraulics 02/03 27

Functional sequence hydraulic plan

Example KMR 1250

Tilting back the debris container
+
Electric circuit diagram
If the two switches (S5) and (S7) are released,
S5 the motor (M2) is switched off (no hydraulic
pressure) and the solenoid valve (Y1) is de-
energized.

S6 S7 S8

Y2 Y1
M2
-

Keys in neutral position

9 10
8 back of the hydraulic cylinder (10). The oil
11
7 12
Hydraulic plan
The 4/2 directional valve (6) is pressed back
into the right-hand switch position again by its
spring. As soon as the 4/2 directional valve (6)
is in the right-hand switch position, the gas
pressure spring is able to press the piston
flows through the flow rate valve (12), the 4/2
directional valve (6) and the flow control valve
(13) back into the oil tank (1).

5 13

14
M
4
3

2
1
Tilting back the debris container

28 Service Basic Training Hydraulics 02/03

 Functional sequence hydraulic plan

Example KMR 1250

Lowering the debris container
+
Electric circuit diagram
If the two switches (S5) and (S6) are pressed
S5 together, the solenoid valves (Y2) and (Y1) are
activated. The motor (M2) remains deactivated
(no hydraulic pressure).

S6 S7 S8

Y2 Y1
M2
-

Activating solenoid valve (Y1) and (Y2)

9 10
8 the right switch position. The net weight of the
11
7 12
6
5 13
Hydraulic plan
As soon as the solenoid valves (Y1, Y2) of the
4/2 directional valve (6) and of the 2/2
directional valve (7) are activated, the 4/2
directional valve (6) switches to the left switch
position and the 2/2 directional valve (7) into
debris container presses the oil out of the
hydraulic cylinder (9), through the pipe break
valve (8), the 2/2 directional valve (7), the 4/2
directional valve (6) and the flow control valve
(13) back to the oil tank (1).
The pipe break valve (8) is not quite closed by
the system pressure, allowing the oil to flow
through at a lower velocity.

14 The two keys (S5) and (S6) must remain

depressed until the hydraulic cylinder (9) has
M completely retracted (two-hand safety
4
3 operation).

2
1
Lowering the debris container

Service Basic Training Hydraulics 02/03 29

Servicing work on hydraulic systems

Safety and maintenance instructions

For safety reasons, no pipe screw unions, - The water content can be verified by filling a
connections and devices may be loosened as test tube with a sample. The water will
long as the system is pressurized. If any work separate and sink to the bottom after a
has to be performed under a raised container, certain period. Cloudiness of the oil also
this must be carefully supported and the points towards a water content.
machine safeguarded against rolling away. - Contamination by foreign bodies and
oxidation cause the oil to turn dark in colour.
On principle, ensuring the greatest possible The coloration can be assessed by
degree of cleanliness during the comparing with the original oil. It is also
commissioning, repair and maintenance of possible to verify the existence of
hydraulic systems, use of the correct hydraulic contamination and oxidation by placing a
oil and the right operating temperature will drop of oil on white blotting paper. If more
guarantee a long service life. precise investigation is required, oil samples
can be sent in to the manufacturer (labora-
tory testing).
- Spare parts for the hydraulic system are
- The ideal temperature of the oil is around
supplied with closed connections. The
50°C. In practice, temperatures of 60-80°C
covers should remain in place until they are
are quite commonplace. Remember that
assembled with the connecting pipes.
working at higher temperatures accelerates
- If delivered unflushed and closed, hoses the ageing process of the oil.
and nipple connections should be flushed Should overheating occur, always
through with cleaning emulsion and dried investigate the root cause.
with compressed air before mounting.
- Objects used for filling (measuring cups,
funnels) should be used exclusively for new
oil of the same type. Prevent any
contamination due to old oil, motor oil or
dust.
- We recommend taking an oil sample of
every new device before delivery, in order
to discover the degree of new
contamination. This ensures that the quality
of workmanship is documented in the event
of any warranty disputes.
- Drained oil is generally contaminated by the
collecting container and must be filtered
before refilling.
- If defective hydraulic components are
exchanged, the system must always be
flushed through (if at all possible using the
same oil type) and filled with new oil.

30 Service Basic Training Hydraulics 02/03