EE054 Hydraulic 1 Pr Inst

7/25/2019 EE054 Hydraulic 1 Pr Inst

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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


Ferrule compression fittings 5


Fitting hydraulic hoses 6


Pipe bending 8


Pipework practice 9


Supporting frame 11


Pipe clamps 12


Assembly of practices 5, 6, 7, 8 13


Gear pump 15


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


WorkedScale :

1:2Ferrule compression fittings PRACTICAL EXERCISE 2

Checked


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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


WorkedScale :1:2

Pipe bending PRACTICAL EXERCISE 4Checked


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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




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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


WorkedScale :1:5

Supporting Frame(Existing)



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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


WorkedScale :1:22:1

Pipe clamps PRACTICAL EXERCISE 7Checked


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WorkedScale :1:5

Assembly ofPractices 5, 6, 7, 8



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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


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


WorkedScale : Double-actinghydraulic cylinder



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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


Ferrule compression fittings



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.


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


Fitting hydraulic hoses


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.


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


Pipe bending



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.


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


Pipework practice



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


Supporting frame


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


Pipe clamps



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


Assembly of exercises 5, 6, 7, 8



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


Gear pump



Torque wrench

C clip pliers


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.


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


Double-acting hydraulic cylinder




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.


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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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

Documents

EE054 Hydraulic 1 Pr Inst