Monozukuri DOJO text Internal use only

Hydraulic operation (Elementary)

(Revision History)

Prepared on Apr. 1st , 2008

Prepared by K. Takagi DOJO master
Dojo Name ＰＴ plant, Maintenance DOJO
Rev. No. Rev. Date Reason for Revision / Revised Contents Revised by Dojo Name Rev. Page
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Contents
1． Maintenance training P4
schedule
2． Safety P5
3． Structure of hydraulic P6
tool
4． Pascal’s law P7
5． Hydraulic tank P8
6． Drive part P9
7． Pressure control P10, 11
8． Flow control P12
9． Direction control P13, 14
10．Hydraulic actuator P15
11．Other accessories P16
12．Circuit P17
13．Hydraulic fluid P18
14．Preparation for P19
disassembly and
assembly
15．Disassembly P20, 21
16．Assembly P22 - 24
17．Cylinder P25 - 30
18．Piston pump P31, 32
19．Vane pump P33, 34
20．Gear pump P35
21．Practical test procedure P36
22．Judgment P37
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 Maintenance training schedule
Title Hydraulic operation (Elementary) Training time 14H
１． Contents Time

１ Structure of hydraulic tool １Ｈ

２ Parts name and functions １Ｈ
３ Structure of hydraulic actuator １Ｈ
４ Other accessories name and functions １Ｈ
５ Example of hydraulic circuit １Ｈ
６ Operation procedure of disassembly and assembly １Ｈ
７ Disassembly and assembly of cylinders and pumps ４Ｈ
８
２． Training ① Practical room
② Pumps, Cylinders, Speed controlers
① Place
② Materials
③ How to

③ Disassembly and assembly, Circuit

assembly

３． Acceptance
criteria
１ Know the type and functions of each control
instrument
２ Disassemble and assemble a hydraulic
machine by himself
３ Assemble a simple hydraulic circuit
４． Judgment Judgment Time
１ Disassemble and assemble operation for a4 hydraulic machine ２Ｈ
２ Assemble a circuit ２Ｈ
 Safety points
• Be sure to check cutting off of power source and hydraulic supply for removing a machine.
• Especially, be sure to release an accumulator because it keeps high pressure.
• Be sure to take a lot of care not to injure your self and surrounding people when you remove
packing by a packing remover or other sharp pointed scratch gauges.
• Be sure to check the inner structure of a valve to decide disassembling procedure and the place
and direction because some parts can fly out by a spring in a valve.
• Be sure not to soil the floor by remaining oil in parts because it makes the floor slippy.
• Be sure to wear safety glasses to clean parts by kerosene or other oil.
• Be sure to take care a work area and your position because parts are lubricated by grease and
oil so they can drop off.
• Be sure to check the machine by breaking in by the hand.
• Be sure not to hit and chop off your finger because the close-fitting part as a sealing part is hard
to disassemble and assemble.
• Be sure to take a lot of care an oil leak at piping and each machine part on a trial running.
• Be sure to apply a power in a condition of you can cut off the power after checking the circuit
and the wiring.
• Be sure to remove the air in an actuator by an air bleeder.

5
 Structure of hydraulic tool

• Power source: This part feeds operating oil. The operating oil is fed by
an operating oil pump driven by an electric motor.
• Controller: A controller includes three parts that each of them controls
the output, the speed, and the direction and they are controlled by each
controlling valve. They are remote operated by combination of the
electrical system.
(1)Output control: This part preserves the machines and hydraulic
circuits by controlling the output by rising and falling the pressure and
this part also controls the operation process. Pressure control valves
are used for this part.
(2)Speed control: This part controls the oil quantity in the oil circuit to
adjust the operation speed. Flow control valves are used for this part.
(3)Direction control: This part controls the direction of oil which flows in
a hydraulic circuit to start and stop an operation and to change the
operating direction. Directional control valves are used for this part.
• Drive part: This part is called as hydraulic actuator, constructed by
hydraulic cylinders or hydraulic motors. This part transforms a hydraulic
energy to a mechanical energy.

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 Pascal’s law
• “Pressure exerted anywhere in a confined incompressible fluid is
transmitted equally in all directions throughout the fluid such that the
pressure ratio (initial difference) remains the same”
W1 W2
To increase the area of A2 twice as large as
A1 also increases W2 twice as strong as W1.

A1 A2

It means that you can apply a large force

to an object by a small force.

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 Hydraulic tank

Drain return
Pump mount
Return pipe Stage
Motor mount
Air breather Pump suction pipe

Filler neck

Oil level gauge

Strainer
Oil tank window
Partition board Drain port
Oil drain port

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 <Drive part> Hydraulic pump
Vane pump Gear pump Piston pump
Type

Characteristics

Volume change between Movement of area which is Volume change by reciprocating

Principle of operation a vane and a cam ring surrounded by a tooth and a casing motion of a piston

Average efficiency It is low existing the pressure

It is high on average Generally highest
loading type
Efficiency

Viscosity &
Influential Very influential Very small effect
efficiency

Wearing & Not decrease by wearing

Decreases with wearing Decreases with wearing
efficiency of a cam ring and vanes

It can be affected by a comparatively Low pressure type is hardly

Resistance property Parts are constituted with small
small dusts, but it is smaller than affected but pressure loading
to dusts clearance so it is most sensitive.
piston type type is sensitive.

Possible or impossible Possible Impossible Possible

of variable displacement

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 <Pressure control> Relief valve

• This valve limits the pressure of the hydraulic circuit less than the set
value. If the pressure gets over that value, it releases a part or all of
pressure oil to the return side to get down the pressure. So it doubles
as a safety equipment and an output adjustment equipment.
• An arrow from P is the entry of pressure oil, from R is the oil relief, and
A, H, W, and B is the adjustment route of pressure controlled by a pilot
valve.

Pilot valve

Ｗ
Spring
Ｂ
Ｈ

Balance piston
Ａ
Ｐ

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<Pressure control> Pressure reducing valve

• This valve is used for reducing the pressure of pressure oil at a part of
oil pressure circuit. If that pressure exceeds the set pressure value of
secondary pressure reducing valve, it operates to close the flow
channel of pressure oil.

Pilot valve

Drain

Spool

Primary side

Secondary side

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<Flow control> Flow control valve with check valve
• This valve adjusts the flowing oil quantity by narrowing down the
section area of piping. Its structure is shown in the picture. Adjusting
the spool by an adjusting handle changes the gap of a sheet and it
changes the section area of piping.
• The opposite side is a check valve function, the pressure oil flows
freely.
Flow quantity control
valve

Adjusting screw

Push down by pilot pressure

Pilot pressure
Check valve

Throttle valve

12
<Direction control> Magnetic change valve
• A slide spool type magnetic change valve is generally used for
the direction control because of the convenience of remote
control and the easiness of changing.
• It changes and stops the moving direction of cylinder and
others.
Electric circuit board

Magnet coil

Spool

Solenoidal coil
R port Push rod
B port A port
Spring
P port

13
<Direction control> Check valve with pilot valve

• A check valve prevents to limit the flow direction of pressure oil.

This valve is used to keep the oil pressure cylinder at one point
and to keep the pressure of oil in the oil pressure circuit at 200
to 1000kPa.

Pilot pressure

When the pilot pressure applies, the cylinder Cylinder

opens the check valve forcibly so this part
can flow the oil from the crack port.

Passing port

Crack port
The oil can flow to the opposite side by pressing
Crack port side cannot press down down the check valve from the passing port.
the check valve so the oil doesn’t
flow.
Check valve
Spring

14
<Hydraulic actuator> Hydraulic cylinder

• This part changes the oil pressure to the reciprocating straight motion to
generate mechanical energy.
• There are two types sorted by the method of operation, one of them is the single
action type that the pressure oil is applied to one side of the piston and another
type is the double action type that the oil is applied to the both side.

Tube Piston packing

Dust seal Piston

Cylinder rod

Bush

Rod packing Cushion mechanism

Cushion adjusting screw

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 <Others, accessories>

Filler neck: It is the part to feed the Air breather: It has a filter as a gateway
pressure oil to the pressure oil tank. of air at the upper part of a tank.
It doubles as the air breather.

Filter

Level gauge: The window to Line filter: It filtrates the oil

check the oil level in the oil tank. pressed by a pump.

Strainer: It is set on the intake side of pump. It is

usually set below the oil in a pressure oil tank.

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<Circuit> Meter-in circuit and meter-out circuit
Unsteady

• Meter-in circuit
(1)Pressure inside the cylinder rises
slowly.
(2)Atmospheric pressure of exhaust side
goes down quickly.
(3)Piston is unsteady because the
Differential pressure pressure of both side loses the balance
between 1 & 2 is constant easily.
② • Meter-out circuit
①
(1)Pressure inside the cylinder rises
quickly.
(2)Exhaust speed is limited by narrowing
down at the outlet port.
(3)Piston can move smoothly by the
differential pressure of its both sides.
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<Hydraulic fluid> Degradation of hydraulic fluid
• Be sure to take care the degradation of hydraulic fluid in
hydraulic machine maintenance because it mainly leads to the
trouble in a hydraulic machine. The causes of degradation are
expected as below.
(1)Impurity
• The impurities as welding scales, cracks, casting sand, chips,
fiber dusts, rusts, and sealing materials can come in the circuit
when the circuit is made. But there are any other causes to
degrade the oil as the rising of oil temperature by using and
coming in of dusts from outside. For them countermeasure, be
sure to seal the tank, to filtrate, and to cool.
(2)Bubble
• If bubbles are generated in the hydraulic fluid, an actuator
operates uncertainly and the bubble can occur cavitation. So be
sure to take care not to generate bubbles and you need to take
a countermeasure to set the air-bleeding hole. In the
maintenance of hydraulic machine, be sure to take care for the
degradation of hydraulic fluid which can be a major cause of
that.
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 <Preparation for disassembly and assembly>

• Work area: well lighted, indoors, dustless place

• Design drawing: to get to know the structure and the procedure
for disassembly and assembly
• Work station: to be well cleaned, put a rubber mat will be better
• Cleaning oil: light gas oil, kerosene, etc
• Grease: lithium grease
• Hydraulic oil: saturate the parts after cleaned
• Tools: hammer, plastic hammer, screw driver, spanner, wrench,
pliers, pipe wrench, ring remover, brush, file, oilstone
• Measuring tools: vernier caliper, micro gauge, dial gauge, gap
gauge
• Others: cleaning case, rag, plastic sheet, plastic bag, vinyl tape,
seal tape, electric torch, etc.

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<Disassembly> Precaution statements for disassembly

• Be sure to mark on a part which has a setting direction.

• Be sure to clean the outside of machine before disassembly.
• Be sure to set out the disassembled parts in order of
disassembled.
• Be sure to use a metal patch or a plastic hammer to remove by
hitting.
• Be sure to note the setup of scale, adjusting screws, and others
before disassembling.
• Be sure to remove a bearing by using a puller or a metal patch,
not to use a pinpoint punch.

20
<Disassembly> Checkup and repair of disassembled parts

• Be sure to check the excrescence on each part.

• Be sure to clean up a part and check the damage on its surface.

• Be sure to remove the light damage on a metal surface by using an

oilstone and a sandpaper.

• Be sure to replace the seal part to new one if it is damaged. But the

seal part must be replaced basically when it is disassembled.

• Be sure to replace the surface damaged part and the broken part to

new one.

21
<Assembly> Precaution statements for assembly

• Be sure to tighten bolts by working in a diagonal pattern and apply

the torque evenly.
• Be sure to tighten bolts with precisely applying a specific torque for
each bolt.
• Be sure to take care not to apply over tightening because it can
cause a scoring and an operation failure but less tightening can
cause an oil leakage and loosening.
• Be sure to assemble by a metal patch not to apply an undesired
force to a bearing part after checking the fitting condition of shaft and
burrs and chamfers.
• Be sure to apply force evenly to the inner sleeve when you assemble
to the shaft or to the outer sleeve when you assemble to the housing.

22
 <Assembly> Seal

• If a seal is used for a brief period, be sure to remove not to

damage it for a reuse.
• Be sure to use a rounded tip screw driver or a special jig.
• Be sure to prepare a new oil seal when you disassemble an oil
seal because most of them are difficult to disassemble.
• Below pictures show how to assemble an oil seal and a dust
seal.

Slide down by a press or

Hit circumference evenly Press hit by a hammer evenly
Correct way
Jig

Patch metal
10-20mm

Incorrect way Press with short diameter

deform an oil seal
Press

Don’t hit an oil seal Ripped Ripped

partly Jig

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Don’t press in on a slant
 <Assembly> Seal part protection

• Be sure to protect a seal part by using a protection

cylinder or wrapped by vinyl tape if that part passes the
part of width across flat as a screw part and a key part.
• Be sure to apply grease on a seal part and a shaft part.

24
<Cylinder> Structure of cylinder

Rod cover Cushion valve Set screw

Head cover Lock nut Piston packing

Cylinder tube Check plug Rod packing

Piston rod Check spring Dust seal

Piston Check ball O-ring (cover)

Retainer Air vent screw O-ring (bush)

Bush Air vent hole O-ring (in piston)

Cushion ring Hexagon nut Cushion valve seal

25 rod
Tie Spring washer Stopper
<Cylinder> Disassembly and assembly of hydraulic cylinder

• Disassembled parts

26
 <Cylinder> Rod cover

Rod cover

• Bush
• Cushion adjusting Rod packing

screw is set in a
dust seal

• Dust seal
• Rod cover
• Rod packing
• O-ring (bush) Cushion adjusting
screw
Bush O-ring

A bush is inserted to a rod cover to prevent an oil leak.

A rod packing and a dust seal is removed by a special seal remover or a
scratch gauge but they are not reused except a special case so you
need to prepare a spare seal. 27
 <Cylinder> Rod packing, Dust seal
• Be sure to assemble correct seals not to mistake the setting direction.
• Be sure to set a rod packing as a U-shape is set on a pressured side.
• Be sure to set a dust seal with correct direction not to let dusts adheres
on a rod into a cylinder and not to leak inside pressure.

Be sure to check uneven

wearing on grooves and
inner bush before setting
each seal.
Especially if there is an
uneven wearing, it may be
because centering of a
Be sure to set an
cylinder is not properly
O-ring without twisting
done. Then, if you don’t
take a countermeasure to
28
its cause, it will need to be
repaired in early time.
 <Cylinder> Piston packing

This side is
grooved-side.
This side is
grooved-side.

• Be sure to set two O-rings oppositely-directed.

• Be sure to set U or V-shaped grooved-side to pressured side.
• Be sure to take care not to scratch a lip or others.
(Its groove is deep so it is hard to assemble.)
• Be sure not to damage O-rings when you put a piston into a cylinder.
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<Cylinder> Check up after completion of assembly

• Operation check
• Oil leak check
• Speed adjusting method check (meter-in, meter-out)
• Air-bleeding check
• Smoothness check
• Cushion check

Air-bleeding hole
Be sure to master air-bleeding !
Air-bleeding hole

30
<Piston pump> Disassembly and assembly of piston pump

• Structure of piston pump M

Swash plate Oil hole plug
control piston Drain port
Flow quantity
adjusting screw
Swash plate

Pressure
adjusting Shaft
screw

Outlet port
Piston

Cylinder barrel

Supporting point of
swash plate

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<Piston pump> Disassembly and assembly of piston pump

• Disassembly / Assembly Slipper retainer

(2)There are some Piston

of pistons in a
cylinder barrel with Cylinder barrel
Spring hole a slipper retainer
pivot.
Bearing metal

Swash plate spring

Valve plate
Main unit of
port side
Swash plate
(1) A pump is split and
a cylinder barrel and a (3)Swash plate is
swash plate spring is released by removing
removed by removing a both sides of
bolt on a main unit of supporting pins.
port side. Remaining process is
only removing a
Supporting point pin pump shaft.
32
<Vane pump> Disassembly and assembly of vane pump

• Structure of vane pump M

Inlet port

Vane

Rotor Shaft

Bearing Bearing

Cam ring

Outlet port

33
 <Vane pump> Disassembly and assembly of vane pump

(2)You remove a positioning pin

• Disassembly / Assembly which reaches to a port plate and
to remove in order from a pump
Main unit of pump
shaft.
(3)A pump shaft can be removed
Bearing
Cam ring with its bearing by removing a
shaft side bracket. Be sure to
Rotor
maintain to replace a seal and
Vane bearing after checking up.
Pump shaft
(4)In assembly, you need to set a
Side plate seal, O-ring, and a bearing at first
after maintaining parts.
Port plate
Bearing bracket (5)You need to set a positioning
pin to a positioning hole not to set
a port plate, cam ring, and side
(1)You can see a side plate, cam ring, rotor, and plate in wrong position.
vane by removing a bearing bracket of main unit of
(6)You need to apply grease to
pump.
34 vane not to fall off.
 <Gear pump> Disassembly and assembly of gear pump

• Structure of gear pump,

Disassembly / Assembly
M
Bolts (2)You need to take
care for a bush, O-
Drive gear Pump shaft
ring, and an oil seal of
Case
main shaft on a cover
Main unit of cover
side.
(3)A drive gear on a
pump shaft and a
Inlet Outlet Bush driven gear on a driven
shaft are machined.
Driven gear
O-ring (4)In assembly, you
need to check
degradations of O-
rings on a bush and
wearing of an oil seal
(1)You can remove a cover by removing bolts. before assembling
them.
35
 Examination

Practical exam
• To disassemble and assemble a machine.
• To make requested hydraulic circuit.
Paper test
• To check whether structures of hydraulic
machines and their functions are understood.

36
 Judgment for practical exam

• To disassemble and assemble a machine.

• To make requested hydraulic circuit.

To judge an acquirement by above check points

37
 Scoring for judgment

Date: Name: Scored by: Time:

No. Operation Judgment standard Bad-mark Remarks

Disassemble and assemble Malfunction: 10 points,

１
of a hydraulic machine Oil leak: 5 points
To make requested hydraulic Wrong circuit: 10 points,
２
circuit Oil leak: 5 points

Total

Trainee can pass by getting 20 points or less of bad-mark.

38
Pass / Fail