ee054 hydraulic 1 pr inst
TRANSCRIPT
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SRI LANKA INSTITUTE OF ADVANCED TECHNOLOGICAL EDUCATION
Training Unit
Hydraulic 1
Practice
No: EE 054
ELECTRICAL and ELECTRONIC
ENGINEERING
Instructor Manual
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1
Training Unit
Hydraulic 1
Practical Part
No.: EE 054
Edition: 2008Al l Rights Reserved
Editor: MCE Industrietechnik Linz GmbH & CoEducation and Training Systems, DM-1Lunzerstrasse 64 P.O.Box 36, A 4031 Linz / Austr iaTel. (+ 43 / 732) 6987 3475Fax (+ 43 / 732) 6980 4271Website: www.mcelinz.com
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HYDRAULIC 1
TABLE OF CONTENT
CONTENTS Page
Learning objectives 3
PRACTICAL EXERCISE 1
Pipe connection by ferrule compression fitting 4
PRACTICAL EXERCISE 2
Ferrule compression fittings 5
PRACTICAL EXERCISE 3
Fitting hydraulic hoses 6
PRACTICAL EXERCISE 4
Pipe bending 8
PRACTICAL EXERCISE 5
Pipework practice 9
PRACTICAL EXERCISE 6
Supporting frame 11
PRACTICAL EXERCISE 7
Pipe clamps 12
PRACTICAL EXERCISE 8
Assembly of practices 5, 6, 7, 8 13
PRACTICAL EXERCISE 9
Gear pump 15
PRACTICAL EXERCISE 10
Double-acting hydraulic cylinder 16
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HYDRAULIC 1
LEARNING OBJECTIVES
The trainee should
create pipe connections by means of ferrule compression fittings.
prepare pipe bends from a drawing.
prepare hydraulics hoses and lay them in accordance with a drawing.
dismantle a gear pump, evaluate its condition, and reassemble it in the reverse
sequence.
dismantle a hydraulic cylinder, name the parts, and reassemble it again.
prepare pipe clamps for securing hydraulics lines.
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1 Steel Pipe 2 DIN 2391 St 35 15 x 2 x 1001 Ermetto fitting GE 15 LM 1 DIN 2353 St
Piece Designation Part Standard-Nr. Material Base sizes Notes
XXX Place for marking - number DM1 - Training Department - MCE Date Name
WorkedScale :
1:1
Pipe Connection by FerruleCompression Fitting
PRACTICAL EXERCISE 1Checked
100
Visible collar
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Ermeto fitting T 10 L 34 Ermeto fitting W 10 L 2
1 Steel Pipe 1 DIN 2391 St 35 10 x 1.5 x 1045Piece Designation Part Standard-Nr. Material Base sizes Notes
XXX Place for marking - number DM1 - Training Department - MCE Date Name
WorkedScale :
1:2Ferrule compression fittings PRACTICAL EXERCISE 2
Checked
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Piece Designation Part Standard-Nr. Material Base sizes Notes
XXX Place for marking - number DM1 - Training Department - MCE Date Name
WorkedScale :1:2.51:1
Fitting hydraulics hoses PRACTICAL EXERCISE 3Checked
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ITEM LIST
Drawing
No:
Part
No:Item Article
Material standard
No:Remarks
3 1 1 Sheet 8 x 130 x 350 St 360 C
2 4 Ermeto fitting GE 8 LM VK / UZ
3 2 Socket piece B 8 ELM 8 90
4 1 Rubber hose TAC 1 R B Approx. 260 lg
5 2 Socket piece B 8 ELM
6 1 Rubber hose TAC 1 R 8 45 Approx. 330 lg
7 4 Sealing ring 17 / 13 / 1 Klingerit
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1 Pipe 1 DIN 2391 C St 35 10x1.5x~1200Piece Designation Part Standard-Nr. Material Base sizes Notes
XXX Place for marking - number DM1 - Training Department - MCE Date Name
WorkedScale :1:2
Pipe bending PRACTICAL EXERCISE 4Checked
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Piece Designation Part Standard-Nr. Material Base sizes Notes
XXX Place for marking - number DM1 - Training Department - MCE Date Name
WorkedScale :1:2
Pipework practice PRACTICAL EXERCISE 5Checked
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ITEM LIST
Drawing
No:
Part
No:Item Article
Material standard
No:Remarks
3 1 1 Steel pipe 12 x 1.5 x 1100 St 35/DIN 2391
2 4 Steel pipe 12 x 1.5 x 1050 St 35/DIN 2391
3 2 Steel pipe 12 x 1.5 x 900 St 35/DIN 2391
4 1 Steel pipe 12 x 1.5 x 850 St 35/DIN 2391
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2 Angle Steel 5 DIN 1028 St 37/ Z L 30 x 4 4001 Angle Steel 6 DIN 1028 St 37/ Z L 30 x 4 400
1 Angle Steel 7 DIN 1028 St 37/ Z L 30 x 4 500Piece Designation Part Standard-Nr. Material Base sizes Notes
XXX Place for marking - number DM1 - Training Department - MCE Date Name
WorkedScale :1:5
Supporting Frame(Existing)
PRACTICAL EXERCISE 6Checked
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1 Steel 9 St 37 F 2 x 20 x 170
1 Steel 8 St 37 F 2 x 20 x 225Piece Designation Part Standard-Nr. Material Base sizes Notes
XXX Place for marking - number DM1 - Training Department - MCE Date Name
WorkedScale :1:22:1
Pipe clamps PRACTICAL EXERCISE 7Checked
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Piece Designation Part Standard-Nr. Material Base sizes Notes
XXX Place for marking - number DM1 - Training Department - MCE Date Name
WorkedScale :1:5
Assembly ofPractices 5, 6, 7, 8
PRACTICAL EXERCISE 8Checked
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ITEM LIST
Drawing
No:
Part
No:Item Article
Material standard
No:Remarks
5 1 1 Steel pipe
5 2 1 Steel pipe
5 3 1 Steel pipe
5 4 1 Steel pipe
6 5 1 Frame
7 8 1 Clamp
7 9 1 Clamp
8 10 6 Hexagonal bolt M5 x 16 4.66 DIN 601
8 11 6 Nut M5
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1 Gear pump HY/ZFS1Piece Designation Part Standard-Nr. Material Base sizes Notes
XXX Place for marking - number DM1 - Training Department - MCE Date Name
WorkedScale :Gear pump PRACTICAL EXERCISE 9
Checked
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1 Double-acting hydraulic cyl.Piece Designation Part Standard-Nr. Material Base sizes Notes
XXX Place for marking - number DM1 - Training Department - MCE Date Name
WorkedScale : Double-actinghydraulic cylinder
PRACTICAL EXERCISE 10Checked
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Hydraulic 1
Instructions for Practical Exercises
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HYDRAULIC 1
INSTRUCTION for practical exercise 1
Pipe connection by ferrule compression fitting
1. TOOLS AND MACHINERY
Workbench with parallel vice Pipe cutter
Triangular scraper
Marking tool
Open-ended spanner set
2. INSTRUCTIONS
Working procedures:
1. Cut the pipe into 100 mm lengths and slightly chamfer the ends.
2. Lubricate the compression ring and the coupling nut, and slide them over the pipe
end.
3. Adjust union nut by hand, and tighten 1 3/4 turns with the open-ended spanner.
4. Loosen screw connection. A continuously projecting collar must be visible on the
pipe.
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3. SUMMARY AND ADDITIONAL REMARKS
Safety precautions:
Ferrule compression fittings are among the most frequently used type of pipe
connections.
Each time the connection is loosened, the union nut is to be retightened, but without
excessive use of force.
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HYDRAULIC 1
INSTRUCTION for practical exercise 2
Ferrule compression fittings
1. TOOLS AND MACHINERY
Workbench with parallel vice Pipe cutter
Triangular scraper
Marking tool
Open-ended spanner set
2. INSTRUCTIONS
Working procedures:
1. Cut the pipe pieces with the pipe cutter.
2. Connect the pipes as shown on the drawing.
3. Tighten the union nuts with 1 3/4 turns and adjust them.
4. Carry out a pressure test with a high-pressure hand pump at 60 bar.
3. SUMMARY AND ADDITIONAL REMARKS
Safety precautions:
If thin-walled pipes are being used, there is a risk of compression when they are
tightened.
In this case, reinforcement rings must be used, which must match the pipes concerned
both in materials and in dimensions.
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HYDRAULIC 1
INSTRUCTION for practical exercise 3
Fitting hydraulic hoses
1. TOOLS AND MACHINERY
Workbench with parallel vice
Hose press
Tape measure Marking tool Square
Centre punch
Table-mounted drill with accessories (hand drill)
Die M 12 x 1.5 Stock
2. INSTRUCTIONS
Working procedures:
1. Construct base plate as shown on the drawing.
2. Cut the hose pipes into length with the blade, and press the fittings onto them.
3. Assemble the hoses on the base plate.
3. SUMMARY AND ADDITIONAL REMARKS
Safety precautions:
Hoses are used to connect hydraulic elements which move against one another.
Care should be taken to ensure that they are fitted free of kinks and warps.
Free of kinks means that at least the minimum bend radius quoted by the
manufacturers is maintained.
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HYDRAULIC 1
INSTRUCTION for practical exercise 4
Pipe bending
1. TOOLS AND MACHINERY
Workbench with parallel vice Pipe cutter
Pipe bending device
Tape measure
Flat square
Pencil
Flat file
2. INSTRUCTIONS
Working procedures:
1. Cut the pipe into 1200 mm length.
2. Mark out the complete bending circumference on the pipe and bend it.
3. Check the angle, and correct it if necessary.
4. Manufacture the remaining bends in the same sequence, following the drawing.
3. SUMMARY AND ADDITIONAL REMARKS
Safety precautions:
The simplest and cheapest way of changing the direction of a pipe is by creating
bends.
It is essential, however, that the minimum radius be maintained.
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HYDRAULICS 1
INSTRUCTION for practical exercise 5
Pipework practice
1. TOOLS AND MACHINERY
Workbench with parallel vice Pipe cutter
Pipe bending device
Tape measure
Flat square
Flat file
Pencil
2. INSTRUCTIONS
Working procedures:
1. Cut the pipes about 50 mm longer than the length indicated.
2. Mark out the pipe bends.
3. Bend the pipes in accordance with the drawing.
4. Check the measurements and cut off the excessive lengths.
5. Deburr the ends.
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HYDRAULIC 1
INSTRUCTION for practical exercise 6
Supporting frame
1. TOOLS AND MACHINERY
Workbench with parallel vice Fiat square
Tape measure
Flat file
Metal saw
Marking tool
2. INSTRUCTIONS
Working procedures:
1. Mark angle steel T 5, 6, 7 and cut into lengths.
2. Deburr the ends.
3. Drill with twist drill with diameter of 8.5
4. Assemble and check angularity.
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HYDRAULIC 1
INSTRUCTION for practical exercise 7
Pipe clamps
1. TOOLS AND MACHINERY
Workbench with parallel vice
Vernier callipers
Tape measure
Table-mounted drill (hand drill)
Twist drill set
Centre punch
Hand hammer
Marking tool
Lever shear
2. INSTRUCTIONS
Working procedures:
1. Mark sheet, allowing extra length for manipulation.
2. Cut with lever shear.
3. Deburr.
4. Mark out bends and bend them in a vice around a 12 mm diameter bar.
5. Mark hole centres with a centre punch.
6. Use clamp or clamping pliers to hold pipe clamps onto frame.
7. Drill pipe clamps and frame together.
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HYDRAULIC 1
INSTRUCTION for practical exercise 8
Assembly of exercises 5, 6, 7, 8
1. TOOLS AND MACHINERY
Workbench with parallel vice
Tape measure
Flat square
Double-open ended spanner set
Hammer
Marking tool
2. INSTRUCTIONS
Working procedures:
1. Lay out pipes T 1 - 4 on the frame.
2. Fix the pipes onto the frame with the clamps.
3. Check the connection dimensions.
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HYDRAULIC 1
INSTRUCTION for practical exercise 9
Gear pump
1. TOOLS AND MACHINERY
Workbench with parallel vice
Torque wrench
C clip pliers
Double-open ended spanner set
Felt-tipped pen
2. INSTRUCTIONS
Working procedures:
1. Mark out thoroughly the drive-side cover, housing, and end plate with the felt-tipped
pen.
2. Remove the end plate.
3. Mark and dismantle the bushings and gear wheels.
4. Remove all seals.
5. Check housing, bushings, gear wheels and cover for damage such as dirt abrasion,
evidence of cavitation, and fret damage to the faces or bearings.
6. Reassemble the pump in the reverse sequence, and secure the cover tightly in
position with the prescribed amount of torque.
3. SUMMARY AND ADDITIONAL REMARKS
In order to ensure that assembly is carried out correctly, all individual components such
as glands, bushings and gear wheels must be marked.
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HYDRAULIC 1
INSTRUCTION for practical exercise 10
Double-acting hydraulic cylinder
1. TOOLS AND MACHINERY
Workbench with parallel vice
Double-open ended spanner set
Combination pliers
Plastic hammer
2. INSTRUCTIONS
Working procedures:
1. Remove cover on piston rod side.
2. Dismantle piston rod.
3. Clean components.
4. Check sliding surfaces, seals and sliding path for damage or wear.
5. Reassemble in reverse sequence.
3. SUMMARY AND ADDITIONAL REMARKS
Care must be taken during assemble to ensure extreme cleanliness! Sliding surfaces
and sliding path are to be lightly oiled.
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Hydraulic 1
Evaluation Sheet for Practical Exercises
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EVALUATION SHEET
Name Control No. Group
FormNeat-
ness
Total
SheetNo.
Control
Tightness
Possiblepoints
Actualpoints
Dimension
Possiblepoints
Actualpoints
Construction
Possiblepoints
Actualpoints
Possiblepoints
Actualpoints
Possiblepoints
Actualpoints
Possiblepoints
Actualpoints
1 2 2
2Pressure
test2
250, 240,
130, 1204 2 2 10
3
350, 300,
130, 804 2 2 8
4200, 200,
150, 1654 4 2 10
5
25 x 3,
50 x 3,
674
2 4 2 8
6 460, 500 4 2 2 8
7 166, 20 4 4 2 10
8 2 4 2 8
9 6 2 8
10 6 2 8
Total : 2 22 18 18 20 80
Note: Date: Points:
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Hydraulic 1
Practical Test
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HYDRAULIC 1
TEST
1. Task:
A hydraulic line is to be prepared in accordance with drawing Pl.
2. The candidate is to be provided with:
Workbench
Bench vice
Hose press
Pipe bending appliance
Pipe cutter
Tape measure
Triangular scraper
Marking tool
File
Measuring square
Open-ended spanner
Oil
Pencil
Hand hammer
Cutting blade
Steel pipe
Tee fitting
Elbow 90
Socket piece
Rubber hose
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Piece Designation Part Standard-Nr. Material Base sizes Notes
XXX Place for marking - number DM1 - Training Department - MCE Date Name
WorkedScale :1:2.5
Hydraulic line PRACTICAL EXERCISE P1Checked
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ITEM LIST
Drawing
No:
Part
No:Item Article
Material standard
No:Remarks
P1 1 1 Steel pipe 0 10 x 1.5 x 1750 St35 / DIN2391
2 3 Ermeto fitting T 10 L
3 1 Ermeto fitting W 10 L
4 2 Socket piece B 10 ELM 10
5 1 Rubber hose TAC 1 R 10 approx. 550 Ig.
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HYDRAULIC 1
EVALUATION SHEET FOR PRACTICAL TEST
Actual P. Possible P.
1. Preparation of pipe ends for the
ferrule compression fittings;
one point for each pipe end 9
2. Maintaining given dimensions;
3 points per dimension 18
3. Precision of angles 15
4. Preparation of pipe bends;
3 points per bend 6
5. Press fittings;
4 points per fitting 8
6. General cleanliness 14
Name: TOTAL POINTS 70
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KEY TO EVALUATION
PER CENT MARK
88 100 1
75 87 2
62 74 3
50 61 4
0 49 5