Beruflich Dokumente
Kultur Dokumente
^^II^Y^{11 WI
STEP I
TRAWL GEA=
STEP 2
, STEP ]
Canada: $2.00
Other countries: $2.40
Printed in Canada
by
Friesen Printers
Altona, Manitoba, Canada
Contract No. KF 801-8-0161
Published by
Publi par
Depa rt ment of Fisheries and the Environment. 1978. Installation of hydraulic power transmission systems, 26
p. In Hydraulics manual for fishermen. Fish. Mar.
Serv. Misc. Spec. Publ. 37 (Booklet 5).
Pches et Environnement
Canada
Canada
Fisheries and
Marine Service
Scientific Information
and Publications Branch
Direction de l'information
et des publications scientifiques
NOTICE
The use of proprietary names does not imply
endorsement of the product or company. No reference
to the Department of Fisheries and the Environment
(DFE), or to this publication, shall be made in any
advertising or sales promotion which would indicate
or imply that DFE approves, recommends, or endorses
any proprietary product or proprietary material mentioned herein, or which has as its purpose an intent to
cause directly or indirectly the advertised product to be
used or purchased because of this DFE publication.
CONTENTS
FOREWORD
Vi
1
1.
INTRODUCTION
2.
INSTALLATION MECHANIC
3.
1
1
Installing Cylinders
2
2
5.1.1 Rigidly mounted cylinders
2
5.1.1.1 Avoid distorting cylinder
3
5.1.2 Pivot-mounted cylinders
3
5.1.2.1 Fixed clevis-mounted cylinders
3
5.1.2.2 Trunnion-mounted cylinders
3
5.1.2.3 Universal clevis-mounted cylinders
3
5.1.3 Cylinder port positions
3
5.2 Installing Hydraulic Motors and Rotary Actuators
4
5.2.1 Motor mounting types
4
5.2.2 Motor shaft alignment
4
5.2.3 Side loads on motor shafts
5.2.4 Flexible couplings
4
5.1
Splined-shaft couplings
6.1
6.2
6.3
6.4
Direction of Rotation
5
Side Loads on Pump Shaft
Pump Suction Line
5
Installing Reservoir
5
INSTALLING ACCUMULATORS
6
6
7
7
9.3.1
10.
8.1
9
9
11
CONTENTS (continued)
12
10.2.3.5.1 NPT threads
10.2.3.5.2 SAE straight pipe thread, 0-ring boss type
13
10.2.3.5.3 BSP parallel threads
10.3 Pipe Installation
13
10.3.1 Pipe material
13
13
10.3.2 Problems with pipe
10.3.2.1 Pipe condition
13
13
10.3.2.1.1 Pickling process
14
10.3.2.2 Pipe joining methods
10.3.2.2.1 Screwed joints
14
10.3.2.2.2 Flanged joints
14
14
10.3.2.2.3 Assembly of 4-bolt, split-flange joint
10.3.2.3 Pipe fabricating
14
10.3.2.3.1 Pipe fittings
14
10.3.2.3.2 Bending pipe
15
10.3.2.3.3 Pickling pipe assemblies
15
10.4 Rigid Piping Installation
15
15
10.4.1 Clamping lines
10.5 Flexible Hose Installation
16
16
10.5.1 Flexible hose for hydraulic systems
10.5.2 Flexible hose storage
17
10.5.3 Installing couplings on hose
17
10.5.3.1 Attaching hose couplings
17
17
10.5.3.1.1 Reusable couplings
17
10.5.3.1.2 Permanent-type couplings
18
10.5.3.1.3 Checking the assembly
10.5.4 Installing flexible hose assemblies
18
10.5.4.1 Attaching hose assemblies
18
10.5.4.2 Mounting hose assemblies
18
18
10.5.4.2.1 Avoid abrasion damage
18
10.5.4.2.2 Allow for changes in hose length
19
10.5.4.2.3 Avoid overflexing hose
20
10.5.4.2.4 A neat assembly
10.5.4.2.5 Safety precautions
20
10.5.4.3 Clamps for flexible hoses
20
10.6 Air-Bleed Points
20
10.7 Pressure Tappings
20
10.8 Installation of Component Drain Lines
21
10.9 Checking Reservoir
21
11. RECOMMENDED HYDRAULIC OIL 21
21
11.1 Oil Storage
21
11.2 Use New Quality Oil
11.3 Cleanliness of Oil Transfer Equipment
11.4 Oil Transfer Equipment
22
11.5 Points for Filling System
22
11.6 Filling System Reservoir
22
12. CHECKING PIPING SYSTEM 22
12.1 Pressure Testing
22
12.1.1 Pressure testing requirements
12.2 Flushing Piping System
23
12.2.1 Alternative flushing equipment
21
22
23
24
12
CONTENTS ( concluded)
15.
25
25
26
FIGURES
1
Rigid cylinder mountings
2 Fixed clevis mounting
3
3
4
5
6
7
8
9
10
11
12
Trunnion mounting
3
Universal clevis mounting
3
Location of cylinder oil ports
3
Mounting a hydraulic pump, motor, or rotary actuator
4
General requirements for a pump suction line and reservoir installation
Mounting an accumulator
6
Charging an accumulator
7
Valve mounting types
8
Standard power unit
8
Fabricated tubing run
10
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
11
Bench-mounted bending machine
Examples of good and bad tube bends
11
11
The 37 flared-tube fitting assembly
Hand-held flaring tool
11
Good and bad tube flares
12
Method of checking tightness of joints
12
How the straight-thread O ring seals
13
Effect of insufficient clearance for O ring
13
Assembly of SAE 4-bolt flange connection
14
SAE 4-bolt flange assembly guidelines
15
Align tubing accurately with fittings
15
Hydraulic piping clamps
16
17
Hose end fittings
Hose installation requirements
18
Avoid abrasion damage
19
Allow for changes in hose length
19
Avoid overflexing hose
19
Route hose for neat appearance
20
Protect hose from heat
20
21
Hose clamps
Typical pressure test circuit
22
Typical flushing circuit
23
10
FOREWORD
vi
1. INTRODUCTION
This Booklet deals with the installation of components commonly used in hydraulic systems. To maintain efficiency and reliability of components, a system
must be cleaned and checked after assembly, and this
is discussed together with piping materials and the
installation itself.
2. INSTALLATION MECHANIC
The conditions of the area where hydraulic systems are to be installed are far dirtier than can be
tolerated by clearances inside the components. Therefore, it is advisable not to unpack any component until
immediately before its installation. Often boxes and
packing cases are removed so the equipment can be
moved onto the site in preparation for installation, but
there is no reason to remove any port caps or packaging
from the smaller components until installation actually
takes place. A component left lying around in the
working area with the ports open becomes contaminated in a very short time. When caps are removed
keep them in a clean bag until the installation job is
completed. Clean plastic caps are often handy for other
temporary capping jobs.
Although it is extremely important to keep the
ports capped, it is equally important to remember to
remove them at the proper time. A cap left in place
after the hydraulic lines are attached causes faulty
operation of the transmission, and creates many problems before the cause of trouble is located.
FLANGE MOUNTING
RIGID SUPPORT--+
5. INSTALLING ACTUATORS
Hydraulic cylinders, motors, and rotary actuators
are connected to the devices they drive and there can
be little choice in their location. However, it is necessary to ensure there is adequate space for the piping
and for servicing.
l
^
l)
5.1.2 Pivot-Mounted Cylinders When movement of 5.1.3 Cylinder Port Positions When cylinders are
the driven mechanism is not a straight line, or if accu- mounted horizontally, ports should face upward so the
rate alignment is difficult to achieve, pivot-mounted
air, trapped inside when the system is filled with oil, is
cylinders are used. The three commonly used types of easily released. Hydraulic cylinders should be installed
pivot mounting are: (1) fixed Clevis mounting, (2) so unwanted air can be purged with no problem (Fig. 5).
trunnion mounting, and (3) universal clevis mounting.
CYLINDER FREE TO
SWING IN THIS PLANE
3B-
LOAD MOTION
-I
LIMITED MOVEMENT
T IN THIS PLANE
5.2.4.1.2
MACHINE
OR
PRIME MOVER
\-
SHORT, LARGE-BORE,
FLEXIBLE SUCTION LINE.
OIL SPEED 5 ft/s MAX
IF POSSIBLE, INSTALL RESERVOIR SO
OIL LEVEL IS ABOVE PUMP
FIG. 7. General requirements for a pump suction line and rescrvoir installation
7. INSTALLING ACCUMULATORS
Accumulators in a hydraulic power transmission
system store oil at high pressure and must be handled
with respect and installed carefully. If the line or connection to a charged-up accumulator fails, the oil in
the accumulator is ejected from the break at great
speed. The accumulator attempts to "take off like a
rocket" and continues to do so until all the oil is discharged. This is extremely dangerous and creates a
serious fire hazard.
7.1 Mounting Accumulators
An accumulator should be mounted standing on
end rather than on its side. It is important to mount the
accumulator firmly so that it will not break away if the
oil line fractures. This means there must be a strong
mounting bracket at the end of the accumulator opposite the oil connection. Piston-type accumulators must
never be clamped with U bolts, because the piston that
separates the nitrogen gas from the oil fits closely inside
PANEL MOUNTING
LINE MOUNTING
1114111.111
UM
1111.1.13.1111.11
0
SUB PLATE
PIPING CONNECTIONS
CLAMPS
Ecpj,( Q
FOOT MOUNTING
BACK
MOUNTING
Back-mounted valves do
not contain their own piping connections. These are
contained in a separate subplate bolted to the back of
the valve. The faces of the valve and the subplate are
machined flat and highly finished, and these mate
together. The oil passages between the valve and subplate are sealed with 0 rings. This type of mounting
is preferred because it minimizes the possibility of valve
distortion and also permits removal of the valve for
servicing without the necessity to disconnect the piping.
8.1.4
Back-Mounted Valve
Before installing a hydraulic valve, become familiar with the porting arrangement so there is no danger
of errors when connecting the valve into the circuit.
On good quality valves each main port is clearly
marked but often drainline and external pilot connections are not. It is advisable to clarify the locations of
all ports with the manufacturer's catalog, or the supplier if necessary. Check valves and valves containing
8
SIDE VIEW
END VIEW
INSERTING TUBE
READY TO BEND
10
COMPLETED 90 BEND
WRINKLED BEND
NOT ACCEPTABLE
/ TWISTING TUBING
TUBE
10.2.3.3
^ ^3
^^^^i
10.2.3.4 Checking Joint Tightness In a hydraulic piping system there are many fittings to be tightened
11
OD OF
SLEEVE -y
TOE OF
SLEEVE
02/ OF
I- SLEEVE ---1
.--FLARE(
- .
MAXIMUM FLARE DIAMETER
EQUAL TO OD OF SLEEVE,
MINIMUM FLARE DIAMETER
EQUAL TO MAXIMUM
INSIDE DIAMETER OF SLEEVE
MAX FLARE
MIN FLARE
MARK LINE
BEFORE TORQUING
(2)
(3)
MISALIGNMENT
OF MARKS SHOWS
JOINT IS TIGHT
Teflon tape. Pipe thread sealant also acts as a lubricant and it is easy to overtighten the fitting and destroy
the mating component. This occurs most often when
the fitting is an elbow or a tee because the outlet must
point in a particular direction and must be tightened
until it points in that direction. Never undo a pipe
fitting to achieve the correct direction of the outlet;
but if it is too tight to screw up the fitting another turn,
remove it, reapply thread sealant, and reinstall the
fitting.
Apply pipe thread sealant (1) To male threads
only. (2) Start two threads back from the end of the
male thread. Sealant applied too close to the end of
the male fitting is squeezed into the bore and contaminates the system. (3) Teflon tape is a clean, handy
method to seal and lubricate pipe threads. As some
brands are better than others try a few different types
to obtain the best results. Tightly wrap one or two
layers of tape around the clean pipe thread starting
two threads back from the end of the male thread, and
making a right-hand helix. Press firmly into the threads
without splitting the tape.
FLAT FACE
LUBRICATE
0 RING WHEN
CONNECTION
MADE
FIG. 20.
NFIT I G
NUT USING UP
0-RING GROOVE
BODY
,.%
e
WAGNER
0 RING
FIG. 21.
.
0 RING
PINCHED_ .
AS FITTING
TIGHTENED
10.2.3.5.3 BSP parallel threads These are similar to the SAE threads because they also employ a
separate soft sealing component and a parallel thread
connection. The sealing component is either a steelbacked rubber washer called a bonded seal or a simple,
soft metal crush washer. These sealing devices do not
require a specially chamfered tapping in the matching
component.
13
14
ey
- OVERTORQUING
CAUSES FLANGES
AND BOLT TO SEND
NO CLAMPING AT
CENTER OF SHOULDER
FIG.
-8
-12
-16
-20
-24
-32
21
40
40
60
90
90
HEAD MARKING
OF GRADE 5 BOLTS
is usually
best to pickle pipe assemblies after the fabrication process (welding or bending) is completed, but before
the end fittings are attached. End flanges with tapped
holes should be welded to the cleaned pipe. As they
are at each end of the pipe assembly, the joints are
easily inspected for contamination and easily cleaned.
10.3.2.3.3
TORQUE (lb - H)
CONNECTION SIZE
......4
mum
fier
delta"
131
TUBING ALIGNED
CORRECTLY WITH
FITTING
Ii
CONNECTES
1 in
s- 11
e
-
LU
iiIIf
In.
awl
siniti
MT'
FIG.
15
Construction
SAE 100R1
Rubber covered,
single wire
SAE 100R2
Rubber covered,
two wires
Rubber covered,
single wire
Textile covered,
single wire
SAE 100R4
Tube OD
(in.)
I/4 , 3/8
1/8, 1/4
5
7
I/2 - 1
I/4 &Up
1&Up
Pipe size
(in.)
SAE 100R5
SAE 100R9
Rubber covered,
four light wires
Rubber covered,
four heavy wires
Rubber covered,
six heavy wires
SAE 100R10
SAE 100R11
Type of service
Low to medium
pressure
Medium to high
pressure
Vaccuum to
medium pressure
Low to medium
pressure
Bore reduced to
suit tube sizes
High pressure,
heavy duty
Very high pressure,
heavy duty
STANDARD
ATTACHING
BOLTS
EXPLODED VIEW OF
TYPICAL MULTICLAMP
16
10.5.3 Installing couplings on hose Some wellknown manufacturers of flexible hose and hose
couplings are Aeroquip, Anchor Coupling, Gates,
Parker Hannifin, Imperial Eastman, Stratollex, and
Weatherhead. The hose and couplings of different
manufacturers are not interchangeable so do not use
one manufacturer's hose with another's couplings.
REUSABLE SCREWED
REUSABLE CLAMPED
twisting occurs if the elbows are not in proper relationship with each other. To correct this, turn one nipple
in its sleeve until twist is removed (Fig. 27).
After install-
1) Thoroughly clean hose bore. Clean, dry compressed air is best but if not available hot (but not
boiling) water can be used. Drain and dry hose.
2) Inspect hose assembly bore. Reject hose if lining
is cut or bulges. If assembly is satisfactory be sure bore
is clean, then cap each end, and store hose until
required.
3) Pressure test hose assembly before installation if
possible. A simple hydraulic hand pump system is all
that is necessary for this test. Test hose assemblies to
twice the working pressure to prove assembly is
acceptable and reduce chances of trouble at a later and
probably inconvenient time.
10.5.4 Installing Flexible Hose Assemblies A
hose assembly must be carefully installed in the system.
A hose assembly is flexible and must be supported and
guided to ensure that its flexibility does not become the
cause of its destruction.
10.5.4.1 Attaching Hose Assemblies These instructions will help ensure maximum life of the hose
assembly:
1) Use a regular open-ended or good adjustable
wrench on the nipple hexagon when screwing a
threaded hose assembly into a component. Do not use a
wrench on the sleeve hexagon and never use a pipe
wrench.
2) Carefully position elbow fittings in ports of components to point in required direction.
3) A hose assembly must have at least one swiveltype connection to permit it to be installed. If an
assembly has one swivel and one fixed connection (such
as a male pipe), attach fixed end to its component first.
4) Do not twist hose. Hose usually has a colored
line (layline) along the length to indicate whether the
hose is twisted when installed. If it is twisted, slacken a
swivel connection, remove the twist, and retighten. If
a hose assembly has an elbow coupling on each end,
18
BAD
BAD
BAD
ABRASION POINT
ABRASION POINT
GOOD
GOOD
AW
GOOD
E
USE CORRECT
SIZE CLAMPS
INSTALL HOSE TO
AVOID TWISTING
19
USE ELBOW
FITTINGS
SENSIBLY
BAD
GOOD
FIG.
31. Route
Some special
precautions must be observed when installing a system:
1) Avoid running hose in areas where it can be
stepped on, tripped over, or used as a hand hold.
2) Clamp hose so it will be restrained if it fails.
Usually failure occurs where couplings are attached. Oil
squirting from unrestrained broken hose causes the
hose to whip and is dangerous.
3) Keep hose away from engine exhaust systems and
other hot components. Construct a heat shield to protect
hose if necessary (Fig. 32).
10.5.4.2.5
Safety precautions
Simple
sheet metal hose clamps are available from hose suppliers. Clamps should have a plastic coating to prevent
damage to the hose. Use heavier steel clamps for hoses
larger than 1 in. Remove sharp corners to prevent the
clamp biting into the hose. The clamp must grip the
hose cover tightly as a loose clamp allows the hose to
move and wears away the cover, defeating the purpose
of the clamp (Fig. 33).
10.5.4.3
Clamps
for
Flexible Hoses
These are points in the hydraulic circuit where pressure gauges may be fitted. They are situated at points
where it is necessary to know the pressure for start-up
testing and for trouble-shooting operations. Pressure
tappings are always required at the pump discharge
port and at the actuator, but may also be useful at other
points. Tappings should be suitable for a 1/4-in. tube,
37 swivel nut connection because this is the most
convenient fitting for attaching and removing pressure
gauges.
HOSE UNPROTECTED FROM HEAT IS UNACCEPTABLE
HOT PIPE
FIG.
32.
TYPICAL
HOSE CLAMP
HEAVY CLAMP
FOR LAFid HOSES
PLASTIC COVER
TO PROTECT HOSE
SHEET METAL
FIG. 33.
Hose clamps
DISCONNECT
ACTUATORS
AND
PLUG ALL
THEIR
SUPPLY
LINES
DISCONNECT
SYSTEM
PUMP
22
23
24
15.2.1 Counterbalancing Hoisting Winches It is important to ensure that hoisting winches will not drop the
load. Some winches (Gearmatic for example) include
a friction brake inside the gearing to hold the load and
prevent uncontrolled lowering. Other winches may need
external counterbalancing and this is usually achieved
with hydraulic pressure control counterbalance valves,
adjusted to hold at least 11/4 times the rated hoisting
load just clear of the deck. Do not raise the load high
until the counterbalance system has been checked and
verified.
Sea Trials for Fishing Winches Dockside testing proves that fishing winches respond to controls
under lightly loaded conditions. It also allows the system pressure relief valves to be set at the recommended
level. These tests indicate the winch can operate at the
required speed and can develop the specified pressure.
Sea trials are usually conducted to verify that the winch
is capable of hauling the actual service loads and that
the control is acceptable. Pressure gauges should be
left in the circuit during sea trials to match system pressure to actual operating loads.
15.2.2
15.2.2.1
26
15.2.3
DATE DUE
REFERENCES
AEROQUIP CORPORATION. 1964. Piping fluid power system
1975.
TEXACO OIL COMPANY. 1970. Operation and care of hydraulic machinery. Montreal,
Que. 95 p.
TYRONE HYDRAULICS INCORPORATED. Undated. Diagnosing gear pump failures. Corinth,
Miss. 20 p.
1970. Reservoir design as viewed by a pump manufacturer. Corinth, Miss. SAE
Sept. meeting. Milwaukee, Wis. Pap. 700721.
U.S. BUREAU OF NAVAL PERSONNEL.
200 p.
WOMACK EDUCATIONAL PUBLICATIONS. 1973. Fluid power in plant and field. Dallas, Tex.
176 p.
Ninrea
USA
REFERENCES
1964. Piping fluid power systems. Bull. 770: 18 p.
1970. Guide for routing and installation of flexible hose assemblies. Bull. 5075:
AEROQUIP CORPORATION.
13 p.
1971. Piping leaks, causes and cures. Bull. 5026A: 12 p.
1972. Trouble-shooting hydraulic systems. Bull. 5215: 3 p.
1970. Reservoir design for mobile equipment hydraulic circuits. SAE Sept. meeting. Milwaukee, Wis. Pap. 700722.
DETROIT COIL COMPANY. Undated. What is a solenoid? Ferndale, Mich. Bull. 6 p.
DOWTY HYDRAULIC UNirrs. 1970. Modern high performance gear pumps. Cheltenham,
U.K. 24 p.
ENVIRONMENT CANADA.
1971. Hydraulics for small trawlers. Ind. Dev. Rep. 80 p.
1974. Small trawler hydraulic power system. Ind. Dey. Tech. Rep. 79: 9 p.
INDUSTRIAL PUBLISHING COMPANY.
1974/75. Fluid power handbook. Cleveland, Ohio.
500 p.
JAMES ROBERTSON LIMITED.
1974. Hydraulic installations. World Fish. Mag. May. 3 p.
JOINT INDUSTRIAL COUNCIL (JIC). 1973. Fluid power symbols and standards. McLean,
Va. STD. No. H-1-1973.
PARKER HANNIFIN CORPORATION.
1972. How to achieve reliability in fluid power lines.
Cleveland, Ohio. Bull. FC-1, FC-2.
1973. Fluid power designers handbook. Cleveland, Ohio. 200 p.
1975. Tube fitters manual. Cleveland, Ohio. Bull. 4306-B2: 44 p.
POLYPAC SEALING SYSTEMS.
1972. Common causes of seal failure. Bull. EE-HB-001-72:
67 1).
SHELL OIL COMPANY.
Que. 95 p.
TYRONE HYDRAULICS INCORPORATED.
Miss. 20p.
1970. Reservoir design as viewed by a pump manufacturer. Corinth, Miss. SAE
Sept. meeting. Milwaukee, Wis. Pap. 700721.
Undated. Fluid power. Navpers, Publ. 16193-A:
U.S. BUREAU OF NAVAL PERSONNEL.
200 p.
1973. Fluid power in plant and field. Dallas, Tex.
WOMACK EDUCATIONAL PUBLICATIONS.
176 p.
n
Hydraulics Manual for Fishermen
Booklet 1
Part I.
Part II.
Booklet 2
Booklet 3
oil=Conditioning Components
Booklet 4
Part I.
Part 11:
System Design
Booklet 5
Booklet 6