Industrial Hydraulic Mechanic Certification

INDUSTRIAL HYDRAULIC
MECHANIC CERTIFICATION
Manual
Including Study Guide,

Solutions, & Pre-Tests
Manual # 402 - 01/00

FLUID POWER CERTIFICATION BOARD
FLUID POWER SOCIETY
The International Organization for Fluid Power and Motion Control Professionals
FLUID POWER SOCIETY

Headquarters: 2433 North Mayfair Road, Suite 111 Milwaukee, WI 53226-1406
Phone: 800-303-8520 414-257-0910 Fax: 414-257-4092
Eastern Office: 4544 Pheasant Run Bethlehem, PA 18020-9512
Phone: 610-694-0950 Fax: 610-694-0611
E-mail: ASKUS@IFPS.org Web: http://www.IFPS.org
Fax-On-Demand: 800-214-2958
Printed in USA
Copyright 2000
Manual #402 - 01/00
Industrial Hydraulic Mechanic

Certification Study Guide
FOREWORD
questions correctly should gain access to the

references and study these for a more thorough
This Study Guide has been written for candidates understanding of the subject matter.
preparing for the Industrial Hydraulic Mechanic
Certification exam. It contains Task Statements which
Candidates may also wish to consider participating
describe specific skills typical of the work of an in a Review Training Seminar. Those who have had
Industrial Hydraulic Mechanic. Outcome statements little or no formal training in the area of industrial
appear after each task statement. Test items on the hydraulics have found the Review Training Seminars
exam were written from the outcome statements. The to be particularly helpful in preparing for the exam.
manual also contains a discussion of the related subject Review Training Seminars provide a more thorough
matter with illustrations, references for additional discussion of the subject matter, the opportunity to ask
study, and review questions.
specific questions, and time to interact with other
participants.
This Study Guide is intended to provide a review
of the major topics covered on the exam. By reading
To learn more about the other certification exams,
through the discussion of the subject matter following Review Training Sessions, Instructor Training
each Outcome statement, the candidate should be able Workshops, or study materials, contact the Fluid
to answer the study questions which follow. The Power Certification Board c/o FPS at the address
candidate should also become familiar with the material below.
covered by the exam questions through this process.
Finally, while a concerted effort has been made to
By necessity, the discussions in this Study Guide present technical information accurately, errors and
are not extensive. Additional references which provide oversights invariably creep into most manuscripts.
a more thorough discussion on each subject are listed. Please use the form at the end of this document to
Candidates are encouraged to consult these references. report any errors for future updates.
Candidates who are unable to answer the review
Copyright 2000, 1994 by Fluid Power Society. All rights reserved. No part of this book may be reproduced or used in any form without permission in writing from the publisher. Address information to Fluid Power
Society, 2433 North Mayfair Road, Suite 111, Milwaukee, WI 53226-1406.
IHM Manual # 402 - 01/00
Industrial Hydraulic Mechanic Study Guide 3
INTRODUCTION
Field repairs - involves the ability to fix
This Study Guide consists of approximately 100 inoperable machinery at the worksite. Tasks include
questions written from 49 tasks and related outcomes changing hoses and hard plumbing hoses that have
that were used to structure the written portion of the failed, as well as pumps, cylinders, motors, couplings,
Industrial Hydraulic Mechanic Test. Each question seals, and gauges.
has been written from the outcomes for a particular
task, and these same outcomes were used to construct
Major repairs - consists of overhaul procedures on
the written test items. Thus, when the review questions major components, usually installing a kit of replacecan be answered correctly, one should be prepared to ment parts.
take the examination.
Minor repairs - requires the ability to fix minor
Eight job responsibilities have been used to classify components and make simple adjustments to machinery.
industrial hydraulic subject matter. The 49 tasks are
organized under these headings, and review questions
Replace components - means to exchange one
have been written for each task. A brief definition of component for another using a change-out procedure.
each job responsibility is given here to focus attention The essence of the job responsibility is to replace
on major areas covered by the examination.
faulty components using change-out procedures.
Preventive maintenance - means to inspect and
Troubleshooting - means to find and fix the failure in
check the machine.
a component or system. The steps used to isolate component and system malfunctions are followed.
Fluid filtration and maintenance - deals with conditioning hydraulic fluids.
Following the subject matter discussion for each
topic is a list of references. These references contain
Assemble components - requires inspection and information related to the task. Use of the references
replacement of defective parts, including installation is recommended for further study of the subject matter.
and adjustment of components.
4 Industrial Hydraulic Mechanic Study Guide
IHM Manual # 402 - 01/00
Contents
Preventive Maintenance
Task:Page
1.0
Adjust hydraulic hose and fittings for proper position and alignment....................................................10
2.0
Adjust the charge pressure on a bladder type accumulator. ....................................................................12
3.0
Torque bolts on a circular pattern............................................................................................................13
4.0
Add hydraulic fluid to the reservoir. .......................................................................................................15
5.0
Check machine hydraulic filtration system condition and filter saturation level. ..................................17
6.0
Change spin-on and cartridge type hydraulic filters. ..............................................................................19

Fluid Filtration and Maintenance
7.0
Draw a hydraulic pressure line sample using a sampling valve. ............................................................22
8.0
Examine hydraulic fluid for water and contaminants. ............................................................................24
9.0
Transfer fluid through a portable filtration unit. .....................................................................................26
10.0 Label fluid sample for laboratory analysis. .............................................................................................27

11.0 Prepare a hydraulic fluid sample container in the field...........................................................................29
12.0 Convert petroleum-based system to high water content fluid (HWCF) system. ....................................30
13.0 Draw a hydraulic fluid sample from the reservoir. .................................................................................32
Assemble Components
14.0 Assemble a hydraulic fixed displacement unbalanced gear pump..........................................................33
15.0 Assemble a hydraulic balanced-piston pressure relief valve. .................................................................36
16.0 Assemble a three-position, four-way, solenoid operated directional control valve. ...............................38
17.0 Make a hydraulic hose assembly with permanent ends. .........................................................................40
18.0 Make a hydraulic hose assembly with reusable ends..............................................................................43
19.0 Make a flared hydraulic tubing assembly................................................................................................44
Field Repairs
20.0 Check a hydraulic valve spool for obstruction........................................................................................45
21.0 Adjust a balanced piston hydraulic pressure reducing valve. .................................................................47
22.0 Adjust a balanced piston pressure relief valve. .......................................................................................48
23.0 Replace the shaft seal in a vane pump. ...................................................................................................49
24.0 Drain and recharge a piston accumulator. ...............................................................................................51
25.0 Set the pressure on a hi-low double pump. .............................................................................................53
IHM Manual # 402 - 01/00
Contents
Major Repairs
26.0 Overhaul a pressure balanced, fixed displacement vane pump...............................................................55
27.0 Install a rebuild kit in a fixed displacement, axial piston, swash plate pump.........................................57
28.0 Overhaul a hand operated hydraulic jack. ...............................................................................................59
29.0 Overhaul a double-acting industrial cylinder. .........................................................................................60
Minor Repairs
30.0 Replace an O-ring on a straight thread fitting. ........................................................................................61
31.0 Replace a directional control valve solenoid...........................................................................................62
32.0 Seal a hydraulic pipe fitting with sealing tape. .......................................................................................63
33.0 Maintain a hydraulic reservoir.................................................................................................................64
Replace Components and Fluids
34.0 Drain, flush, and replace hydraulic fluid. ................................................................................................65
35.0 Replace a hydraulic pump and align the coupling. .................................................................................66
36.0 Determine specifications from a component code breakdown. ..............................................................68
37.0 Replace a hydraulic V-packing. ...............................................................................................................70
38.0 Replace a pipe system with a custom made tube assembly. ...................................................................71
39.0 Replace a pressure gauge.........................................................................................................................72
40.0 Identify components from a circuit diagram. ..........................................................................................73
41.0 Replace and align a foot mounted hydraulic cylinder. ............................................................................74
42.0 Replace a hydropneumatic accumulator bladder. ....................................................................................75
Troubleshooting
43.0 Determine why a cylinder fails to move the load when the directional control
valve is shifted. ........................................................................................................................................76
44.0 Check a cylinder piston for bypass leakage. ...........................................................................................78
45.0 Check a hydraulic pump or motor for bypass leakage............................................................................80
46.0 Determine the cause of erratic pressure, low pressure, or high pressure in a
balanced piston pressure relief valve.......................................................................................................82
47.0 Isolate solenoid control valve failures.....................................................................................................84
48.0 Verify that hydraulic lines meet size requirements. ................................................................................86
49.0 Distinguish between aeration and cavitation...........................................................................................89
IHM Manual # 402 - 01/00
Figures
Page
Figure 1. ............Proper Hose Installation ........................................................................................................11
Figure 2. ............Bladder Type Accumulator....................................................................................................12
Figure 3. ............Average Torque Values for Grade 2 Bolts.............................................................................14
Figure 4. ............Torque Circular Bolt Patterns in a Criss-Cross Pattern ........................................................14
Figure 5. ............Common Industrial Hydraulic Fluids....................................................................................16
Figure 6. ............Location of System Filters ....................................................................................................17
Figure 7. ............Beta Ratio ..............................................................................................................................20
Figure 8. ............Taking Pressure Line Sample ................................................................................................22
Figure 9. ............Portable Filter Cart ................................................................................................................26
Figure 10. ..........Oil Sample Label...................................................................................................................27
Figure 11. ........Preparing a Fluid Sample Container .....................................................................................29
Figure 12. ..........Overhead Reservoir for HWCF Fluids .................................................................................30
Figure 13. ..........How to Take a Reservoir Sample..........................................................................................32
Assemble Components
Figure 14. ..........Gear Pump Assembly ............................................................................................................33
Figure 15. ..........Direct Acting and Pilot Operated Relief Valves....................................................................36
Figure 16. ..........Four- Way Directional Control Valve Assembly....................................................................38
Figure 17. ..........Center Position Flow Options for a Four- Way Directional Control Valve...........................39
Figure 18. ..........SAE 100R-Type Hoses..........................................................................................................42
Figure 19. ..........Reusable Type Hose Fittings.................................................................................................43
Figure 20. ..........Flared Fitting Assembly ........................................................................................................44
Field Repairs
Figure 21. ..........Pilot Operated Directional Control Valve .............................................................................45
Figure 22. ..........Pressure Reducing Valve .......................................................................................................47
Figure 23. ..........Detailed Schematic of Pilot Operated Relief Valve ..............................................................48
Figure 24. ..........Balanced Vane Pump.............................................................................................................49
Figure 25. ..........Piston Type Accumulator ......................................................................................................52
Figure 26. ..........Hydraulic Hi-Low Pump Circuit...........................................................................................53
IHM Manual # 402 - 01/00
Figures
Major Repairs
Figure 27. ..........Balanced Vane Pump.............................................................................................................55
Figure 28. ..........Axial Piston Pump.................................................................................................................57
Figure 29. ..........Hand Operated Hydraulic Jack .............................................................................................59
Figure 30. ..........Tie-Rod Industrial Cylinder ..................................................................................................60
Minor Repairs
Figure 31. ..........Straight Thread O-Ring Hydraulic Fitting ............................................................................61
Figure 32. ..........Air Gap and Wet Armature Solenoids...................................................................................62
Figure 33. ..........Sealing Tapered Thread Fittings............................................................................................63
Figure 34. ..........Industrial Hydraulic Reservoir ..............................................................................................64
Figure 35. ..........Axial and Angular Misalignment ..........................................................................................66
Figure 36. ..........Methods of Checking Shaft Alignment.................................................................................67
Figure 37. ..........Typical Hydraulic Pump Model Code Breakdown ...............................................................68
Figure 38. ..........Hydraulic V-Packing .............................................................................................................70
Figure 39. ..........Major Advantages of Tubing Over Pipe ...............................................................................71
Figure 40. ..........Proper Flare Length...............................................................................................................71
Figure 41. ..........Bourdon Tube Pressure Gauge..............................................................................................72
Figure 42. ..........Simple Hydraulic Circuit Diagram .......................................................................................73
Figure 43. ..........Foot Mounted Hydraulic Cylinders.......................................................................................74
Figure 44. ..........Bladder Type Accumulator....................................................................................................75
Troubleshooting
Figure 45. ..........Simple Hydraulic Press .........................................................................................................76
Figure 46. ..........Effect of Pressure and Viscosity on Pump Performance.......................................................80
Figure 47. ..........Pilot Operated Pressure Relief Valve ....................................................................................82
Figure 48. ..........Measuring Solenoid Resistance.............................................................................................85
Figure 49. ..........Conductor Inside Diameter Selector Chart ...........................................................................87
Figure 50. ..........Vacuum at Pump Inlet ...........................................................................................................89
IHM Manual # 402 - 01/00
Reference Equations
Calculator
FPS Industrial Hydraulic Mechanic Certification

Equations
Page #
Eq. #1
18
Equation
Torque (ft. lb. ) = Force (lb. ) Lever Arm (ft. )
T= FL
or
Torque (in. lb. ) = Force (lb. ) Lever Arm (i n. )
Eq. #2
32
Eq. #3
32
Theoretical Flow Rate (gpm) = Dis placement (CID)

N
Q= D
231
Pump Vol. Effic. (Ev) (%) =
Ev =
Eq. #4
32
Eq. #5
36
Q Act.
Q Theor.
Actual flow
Theoretical flo w
S peed (rpm)
231
1 00
100
Ev
Actual Flow Rate (gpm) = Dis placement (CID) S peed (rpm)
23 1
Ev
Q Act. = D N
231
Operating Pres s ure (ps i) =
Burs t Pres s ure (ps i)

S afety Factor
Flow Rate (gpm)
1714
Eq. #6
48
Hydraulic HP = Pres s ure (ps i)

Q
HP = P
1714
Eq. #7
51
Dis placement (CID) = b ore area (in.
) s troke (in. ) no. of cyl inders
D = A S N umber of Cylinders
Eq. #8
51
Eq. #9
53
Area (pis ton) (in. ) = (radius (in. ))
Pres sure (ps i) =
Force (lb. )
2
Area (in. )
A = (r)
P= F
A
2
71
Velocity ( sft.
ec. ) = Q (gpm)
F= PA
. 3208
2
Area (in. )
Eq. #11
72
Bypas s flow (pump) (gpm) = Theoretical flow - Actual flow
Eq. #12
73
By pas s flow (motor) (gpm) = Input flow - U s able flow
Eq. #13
73
Vo l. Effic. (%) (motor) =
Eq. #14
73
Eq. #15
75
IHM Manual # 402 - 01/00
= d . 7854
or
Force (lb .) = Pres s ure (ps i) Area (in. )

Eq. #10
Theor. flow
Actual flow
Actual S peed
100
) ( Theoretical
S peed )
or
Actual Flow (motor) (gpm) = Dis placement (CID)

E (volts ) = I (amps ) R (ohms ) (Ohm' s Law )
S peed ( rpm)
231 Ev
E= I R
Preventive maintenance activities include those tasks typically performed on machines and the associated
hydraulic systems to insure optimum performance and maximum component life. This covers periodic and
routine checks of fluid and components on operational machinery including; 1) making adjustments, 2) predicting
repairs, 3) adding fluid and 4) checking fluid and filter condition.
Task 1.0
Outcome 1.1.
Outcome 1.2.
Adjust hydraulic hose and fittings for proper position

and alignment.
Knows which factors can influence hose life.
Understands hose terminology.
Hoses are routed, aligned, and secured to achieve maximum possible performance. The pressure rating and
quality of a hose can be used to predict its service life. Not much can be done to extend the life of a hose, but
improper mounting and alignment can significantly reduce hose life.
Flexible hydraulic hose consists of three major elements. The inner tube is the liner of the hose through
which the fluid flows. The reinforcing section of the hose, sometimes called a carcass, provides the strength of
the hose to contain pressure. The outer cover protects the reinforcing layer from corrosion and abrasion.
Many specifications must be observed to insure maximum hose life. The hose must not be installed with a
bend tighter than the minimum bend radius prescribed for the hose. The bending radius is measured from the
center of the bend to the inner edge of the hose. Hose manufacturer's provide this information for each type of
hose. Overbending shortens hose life. So does twisting the hose during installation.
Hoses should not be installed with a twist in the hose. The lay line (or identification printing) of a
hose should not rotate or twist when the hose is installed. A slight twist in the hose can significantly
reduce hose life. Some sources predict a 90% reduction in life with a 7-10% twist in the hose.
When a hydraulic line must make a tight corner, use of adapter fittings or a length of tubing is recommended.
Since hose failure is most likely on the outside of a bend, use of a fitting or length of tubing minimizes the risk.
When connecting to a component such as a pump, valve, or motor, always use angle fittings when the hose has
to make a sharp bend to connect.
The Society of Automotive Engineers (SAE) and the International Standards Organization (ISO) have standards
for fittings and port connections. These standards prescribe minimum thread engagement and tightening of various
fittings. For large fittings, the SAE "Split Flange" system is most common.
Be sure to properly secure fluid lines using clamps. Excess hose abrasion on moving parts will cause early
failure. Never secure a hose at a bend since the hose stretches the most here.
IHM Manual # 402 - 01/00
Right
Wrong
Wrong
Wrong
Bend
Radius
Right
Right
Wrong
Right
Wrong
Right
Fig. 1. Proper Hose Installation
Review: 1.1.
Review: 1.2.
The bend radius of a hydraulic hose is measured from: Twisting a hydraulic hose:
a. the centerline of the hose.
a. does not affect the hose.
b. the inside edge of the hose.
b. causes fittings to work loose.
c. the outside edge of the hose.
c. increases the pressure drop.
d. the end of the fitting.
d. restricts fluid flow.
e. one end of the hose to the other end.
e. shortens hose life.
Animation
IHM Manual # 402 - 01/00
Task 2.0
Outcome 2.1.
Outcome 2.2.
Gas
Charging
Valve
Shell
Adjust the charge pressure on a bladder type accumulator.

Understands how an accumulator operates.
Knows how an accumulator may fail.
There are three major types of accumulators. These are: dead-weight,
spring loaded, and gas charged. Gas charged accumulators are by
far the most common. These may be either the bladder type or piston
type accumulators. Occasionally, the pre-charge of an accumulator
must be reset. This requires draining the accumulator of fluid and
then recharging the accumulator with dry nitrogen.
The accumulator must be charged with dry nitrogen
only, to prevent explosion and/or deterioration of sealing
materials. Never use compressed air or oxygen.
Poppet (Foot)
Valve
Drain Plug
Accumulators should be mounted vertically. All fluid must be

drained from the accumulator before charging. The pre-charge pressure
of the accumulator is part of the system design. The specific pre-charge
pressure is a unique value for each accumulator. Many factors are
considered when determining the pre-charge. This value should
always be maintained. It is important to refer to the machine manual to
determine pre-charge pressure specifications.
Fluid Port
Proper safety practices, including locking out a system and wearing

Fig. 2. Bladder Type Accumulator
eye protection, are necessary when working with accumulators.
(Courtesy of Greer Hydraulics, Inc.)
Accumulators must be checked for leaking pre-charge valves and
bladders. A leaking bladder results in fluid inside the bladder. Leakage in the pre-charge valve causes the
nitrogen charge in the accumulator to diminish. A leaking bladder will also allow gas charge to leak off, but
leaking valves do not result in fluid getting inside the bladder. (Refer also to Task 24 for additional information.)
Review: 2.1.
Nitrogen is used to charge accumulators because it:
a. will not leak off.
b. preserves the bladder.
c. will not mix with oil.
d. is inexpensive.
e. does not support combustion.
Review: 2.2.
If the accumulator bladder becomes pinched in the
poppet (foot) valve:
a. the bladder may rupture.
b. all of the oil will leak out of the bladder.
c. nitrogen will escape out the gas charging
valve.
d. the reservoir fluid level will drop.
e. all of the above.
Animation
Movie
3D Model
IHM Manual # 402 - 01/00
Task 3.0
Outcome 3.1.
Outcome 3.2.
Torque screws on a circular pattern.

Calculates torque values using basic formulas.
Knows how screws size and strength affect torque values.
Tightening bolts to the proper torque is important, regardless of the component being serviced or repaired.
Proper torque is necessary to ensure distribution of forces and loads, to insure sealing between mating surfaces,
and to prevent components and bolt failure.
Torque is defined as a turning or twisting force, sometimes called a rotary force. A torque wrench is necessary
to actually measure the torque being exerted on a screw. The proper torque is normally determined by the component
manufacturer and will depend on the size of the screw, thread pitch and bolt hardness.
Torque (ft. lb. ) = Force (lb. ) Lever Arm (ft. )
T= FL
or
(Eq. 1)
Torque (in. lb. ) = Force (lb. ) Lever Arm (i n. )
Screws oriented on a circular pattern are torqued in a cross-pattern sequence to draw the parts together
evenly. OVER TORQUING WILL DAMAGE THE COMPONENT because it will strip and break screws, as
well as deform gaskets and mating surfaces. In severe cases, over torquing or uneven torquing will break the
component.
The best way to tighten screws to a uniform torque is with a torque wrench using a cross pattern sequence
that tightens all screws evenly. If a gasket or seal leaks, and the screws are tight, over torquing will NOT stop
the leak. Rather, it can result in damage to the screws or component.
Generally, National Coarse (NC) thread screws have a higher torque value than National Fine (NF) thread
screws of the same size. This is because NC thread screws have more material in the thread, and thus more
strength in shear than NF threads.
Higher strength screws have higher torque values than softer screws. Grade 2 screws have no markings
on the head. Grade 5 screws have a higher strength and approximately 50% higher torque values. They have
three marks on the head. Grade 8 screws have six marks on the head and have approximately 100% higher
torque values than grade 2 screws. The grade of a screw is two higher than the number of marks on the head.
Where higher strength screws are found, higher torque values may be used. Metric screws utilize an MPA
number for grading the torque value.
IHM Manual # 402 - 01/00
The average torque values for Grade 2 screw threads are indicated below:
ISO
Certification
Petroleum Jelly
Not Applicable
High Water Fluids
HFA
Water In Oil (Invert Emulsion)
HFB
Water -Gylcol
HFC
Synthetic (Phosphate Ester)
HFD
Fluid
Type
Percent
Water
(Approx.)
0
95
40
40
0
Major
Concern
Flammability
Lubrication and Density
Density
Evaporation
Seal Compatibility
Fig. 3. Average Torque Values for Grade 2 Bolts
It is important that the torque wrench be calibrated before starting to torque screws. There are a number of
ways to check the accuracy. One is to use another torque wrench to see if both wrenches yield the same value.
Another is to use a force scale to pull the handle 1-foot from the socket and to compare several values on the
force gauge with the values on the torque wrench.
It is also important to use a wrench sized for the job. An in-lb wrench is more
appropriate for 1/4-in. and 5/16-in. screws than a torque wrench calibrated in ft-lb
because the wrench is smaller and the torque value is more accurate. There also is
less chance of over tightening the screws. To convert ft-lb torque values to in-lb
values, multiply by 12, the number of inches in a foot.
Fig. 4. Torque Circular

Screw Patterns in a
Criss-Cross Pattern
To tighten screws arranged in a circular pattern where several screws are used to
attach the part, or to fasten two major components together, torque the screws in
sequence opposite each other. This is done to prevent cocking the part by putting
uneven pressure both on the seals and the part. Do not torque screws sequentially
around the part. This will result in uneven pressure on the part and seal. Severe
cases of uneven tightening will break machine parts, strip threads, and break screws.
Review: 3.2.
Review: 3.1.
The grade number of an SAE screw:
If the Torque of 60 ft. lb. is needed on the bolt, how
a. indicates whether it has coarse or fine threads. much force will be needed on the wrench?
a. 5 pounds.
b. is an indication of strength.
b. 10 pounds.
c. is the proper torque value in foot-pounds.
c. 20 pounds.
d. distinguishes between metric and non-metric bolts.
e. predicts how many times the bolt may be
d. 40 pounds.
e. 60 pounds.
reused without failure.
IHM Manual # 402 - 01/00
Task 4.0
Outcome 4.1.
Outcome 4.2.
Outcome 4.3.
Add hydraulic fluid to the reservoir.

Understands how contaminants enter a hydraulic system.
Knows that new fluid may be contaminated.
Knows the procedure to add new fluid to a system.
Adding make-up fluid to the reservoir ranks among the most important maintenance tasks because of the
consequences of doing it incorrectly. First, a system that needs make-up fluid has a leak. Discovering the
source of that leak and fixing it is necessary to keep the system operating properly. Second, adding only the
correct fluid is important because many fluids are not compatible with each other. Incorrect fluids can severely
damage or ruin a system, take it out of service, and require costly repairs. Third, adding fluid without introducing
dirt and contamination is sometimes difficult. Much contamination is introduced while the fluid is being
stored, transported, and added to the system.
A variety of fluids are used in hydraulic systems. The most common fluids are petroleum base oils. These
fluids have excellent lubrication properties, acceptable viscosities, and, if properly maintained, an excellent
life expectancy in the system. Systems using fluids other than petroleum oils typically are in areas where a fire
hazard exists or where the environmental consequences associated with a leak are significant.
Water glycol fluids are a mixture of water and glycol (glycerine, alcohol, and thickeners). Water typically
constitutes 40% of the fluid. These fluids are fire resistant, but evaporation can be a problem. Water glycol fluids
must be monitored for water and additive loss, especially where high operating temperatures exist.
High water content fluids (HWCF) are an oil-in-water emulsion. These fluids typically are 95% water. The
oil is dispersed throughout the water phase as tiny droplets. The additive package contains viscosity improvers
and rust inhibitors, along with biocides and fungicides. These fluids are obviously fire resistant and have
attractive heat dissipation properties. Maximum operating temperatures should not exceed 120F.
Another category of fluids which contain water are the invert emulsions. Invert emulsions consist of
approximately 40% water dispersed as tiny droplets in the oil. The advantage of invert emulsions is that the
continuous phase is an oil. Therefore, these fluids have good lubrication properties while enjoying the
enhanced cooling capability of water. Rust inhibitors must be used and the fluid must be monitored for water
loss. Addition of water is necessary and the fluid must be carefully monitored and filtered.
Synthetic fluids are chemical compounds which are fire resistant. Synthetic fluids typically encountered
are phosphate esters and polyol esters. It is particularly important to check for seal compatibility when using
synthetic fluids.
Hydraulic Fluid Table
IHM Manual # 402 - 01/00
Fluid Type
ISO
Classification
Percent
Water (Approx.)
Major
Concern
Petroleum Oil....................Not Applicable....................0 ..........................................Flammability

High Water Fluids .............HFA ....................................95 ........................................Lubrication and Density
Water In Oil ......................HFB ....................................40 ........................................Density
(Invert Emulsion)
Water-Glycol .....................HFC ....................................40 ........................................Evaporation
Synthetics..........................HFD ....................................0 ..........................................Seal Compatibility
(Phosphate Ester)
Fig. 5. Common Industrial Hydraulic Fluids
Make-up fluid, regardless of the type of fluid, should always be pumped through a filter as it is
introduced into the reservoir, this includes new systems and new fluids from the fluids manufacturer.
This insures that contaminants which are in the new fluid are not induced into the system. If possible,
a sealable coupling should be provided through which to add fluid. This allows the filler/breather to be eliminated
and replaced with a breather assembly equipped with a changeable filter. This eliminates contamination introduced
into the system through air turnover in the reservoir.
Escaped contaminants include trapped particles and silt in pressure line filters that are set free and
migrate down stream in the system by pressure surges, as well as other particulates that are jarred
loose from the inside of fluid pipes and tubing. Pressure shocks in systems that have pressure line
filters located down stream of the pump can cause the filter to release bursts of particles into the fluid stream
as shock waves propagate through the system. The same is true when shock waves rattle pipes and tubing,
causing particles to be released from joints and crevised inside the conductor wall joints into the fluid stream.
Checking for system leaks and testing for contamination are recommended practices, especially when adding
new fluid. Contamination in the system may be: 1) built in, 2) internally generated, 3) ingressed, 4) induced,
and 5) escaped from filter. By carefully commissioning a new system and following good maintenance
practices, failures due to contamination may be greatly reduced.
Review: 4.1.
Review: 4.2.
New hydraulic fluid in the drum:
Contaminants added to a hydraulic system with make-up
a. is clean and may be added directly to a system. fluid are called:
b. should be tested for contamination before using.
a. ingressed.
c. should be stirred to mix additives before using.
b. built-in.
d. must be filtered when added to a reservoir.
c. induced.
e. will evaporate if not sealed.
d. internally generated.
e. escaped.
IHM Manual # 402 - 01/00
Task 5.0
Outcome 5.1.
Outcome 5.2.
Check machine hydraulic filtration system condition and

filter saturation level.
Knows the various filter locations and purposes for each.
Understands filter pressure drop and how to determine
when a filter needs to be changed.
Return Line Filter
Strainers and filters must be identified on

the machine, and their condition verified by
visual inspection or from instrumentation such
as condition indicators or differential pressure
gauges. Filters are located in various places in a
circuit.
Inlet filters and strainers are mounted in the
pump inlet and submerged in oil. The pump
inlet operates below atmospheric pressure if the
reservoir is mounted below the pump. If the
reservoir is mounted above the pump to flood
the inlet, or if the pump is supercharged by an
auxiliary pump, the pump inlet is above
atmospheric pressure.
Animation
Pressure
Filter
Off-Line
Filter
Inlet
Strainer
Return Line
Filter
Fig. 6. Location of System Filters
By definition, a filter directs the fluid in a tortuous path. Depending upon the rating, filters are designed to
trap hard particles down to 10 microns (micrometers) or less and silt in the range of 5 microns (micrometers)
or less. A strainer directs the fluid in a straight path through the element. Strainers are made from wire mesh
and trap only large particles. Some strainers have magnets that trap ferrous (iron) particles.
Pressure filters are located downstream of the pump and are rated at system pressure. Pressure filters are
sized to carry pump delivery. They protect components downstream of the pump from debris that would result
from catastrophic failure of the pump. Pressure filters are also used ahead of sensitive components such as
servo-valves which can tolerate very little contamination.
Return line filters are the last component before the fluid enters the reservoir. Return line filters catch
debris from all components in the system and thus protect the pump and help to keep the reservoir clean.
A filter in a relief line may classify as either a pressure or return line filter depending on its location with
respect to the relief valve. It is important to note that a filter installed in a relief line must not be allowed to
block flow, even if the filter becomes saturated with contaminants. Anything which restricts a relief line could
have a serious impact on safety.
Off-line or kidney loop filter circuits consist of a separate pump, filter, and connecting lines to operate as
an independent system. Typically, the off-line filter cleans the fluid from the reservoir. Off-line filtration is an
excellent way to finely filter the hydraulic fluid as well as condition the fluid thruogh a heat exchanger, heater,
etc. Other advantages are reduction in flow surges and continual filtration of the return flow even in a deadheaded
condition.
IHM Manual # 402 - 01/00
Many filters are equipped with an element condition indicator which signals when the filter element
has become loaded with contamination and should be cleaned or replaced. Indicators may give a visual
or electrical signal. Indicators are usually calibrated to show increases in the differential pressure
across the filter. Some indicators show if the filter by-pass valve is opening. The indicator is a pressure device
that normally works only when flow is going through the filter.
Most filter units are available with a by-pass valve. The by-pass valve protects the filter from collapsing
or bursting when it becomes loaded with contaminants. On inlet filters, the by-pass valve opens to protect the
pump from cavitation with normally less than 6 inches of Mercury or 3 psid filters. Some filters do not have
a by-pass valve. Most manufacturers do not recommend the use of inlet filters (suction strainers)
Filter manufacturers prescribe a Terminal Pressure Drop for filter elements. This is the maximum pressure
differential for the filter. When the terminal pressure drop is reached, the filter is saturated with contaminants
and should be changed. If so equipped, the element condition indicator should signal this condition. The filter
by-pass valve also will begin to direct flow around the filter at this point, allowing unfiltered oil to pass
through the system.
Some equipment manufacturers specify filter change intervals by hours of machine operation. This practice
is less desirable because all machines operate in different environments. Filters replaced after a prescribed
number of hours may not yet be saturated or may have already reached the point of by-passing fluid. Neither
situation is desirable or economical.
When checking filter condition, the machine must be operating and at normal operating temperature. Cold
oil is thicker than warm oil and will show a higher pressure differential on the indicator. Checking filter condition
when the oil is cold may lead to premature filter changes.
Review: 5.1.
Review: 5.2.
Which filter is used in front of a valve to ensure it
A differential pressure indicator:
does not receive contaminated fluid?
a. should always be checked with the machine off.
a. Inlet Strainer
b. shuts off the system when the filter becomes
b. Pressure
saturated.
c. Return
c. should be checked with the system at normal
d. Pilot
operating temperature.
e. Off-Line
d. indicates when the system relief valve has
been set too high.
e. will not provide any indication of a problem
until the by-pass has opened.
IHM Manual # 402 - 01/00
Task 6.0
Outcome 6.1.
Outcome 6.2.
Change spin-on and cartridge type hydraulic filters.

Knows filter terminology.
Understands how filters are evaluated and specified.
The purpose for changing filters is to keep the hydraulic fluid clean. This prevents damage to the pump
and other hydraulic components. To do this, the system must be clean at the start, and the contamination taken
out by the filter must equal the particles generated by the system plus the contamination entering the system
from the outside environment in which the machine operates.
A working knowledge of filter terminology and filtration principles is critical to understanding fluid
filtration and being able to compare filters for use in a system. The most important terms are defined here:
a. Disposable filter element - a filter element that is replaced after one service cycle. They are manufactured
as spin-on units and as cartridge elements.
b. Filter medium - the porous materials that perform the actual filtration process.
c. Micrometer (micron) - one millionth of a meter. One micrometer = 0.000 039 inches. The smallest
particle the eye can see is about 40 micrometers.
d. Ingression - the rate at which contaminants enter the system through cylinders, air breathers, and as moisture.
e. Absolute filtration rating - the diameter of the largest hard spherical particle that will pass through a filter
under the specified test conditions. This is an indication of the largest opening in the filter element. This
is normally a b ratio of 75 (98.67% efficient in the first pass).
f. Mean filtration rating - this is the average pore size opening in the filter. It is measured by passing air
through a filter under pressure until air bubbles appear over the entire surface of the filter element.
g. Beta ratio - ratio of the number of particles larger than a specified size per unit volume in the fluid flowing
into the filter to the number of particles larger than the same size particles per unit volume in fluid leaving
the filter.
b ratio = No. of particles upstream larger than micron rating / No. of particles downstream larger than
micron rating
Animation Micron
IHM Manual # 402 - 01/00
Beta () Ratio
100 particles
larger than 3m
3=200=2
100
1 particles
larger than 3m
3=200=2
1
200 particles
larger than 3m
Animation Beta Ratio
Fig. 7. Beta Ratio (Courtesy of Pall Industrial Hydraulics Company)
The contaminant capacity of a filter is commonly defined as the weight of a specified contaminant that can
be trapped by the filter element before a designated terminal pressure drop across the filter is reached. Factors
that affect the length of time a filter element can be used (useful service life) include flow fatigue, collapse and
burst pressures, and end load. Factors that affect how much contaminant a filter can remove from the system
include the filter capacity, cold starts, contaminant particle size, and rate at which contaminants enter the filter.
It is generally accepted that most hydraulic system problems are contamination related. Contamination:
a.
b.
c.
d.
e.
f.
g.
Wears cylinders, rods, and packings.

Wears check valve seats and elements.
Plugs directional control valve orifices and sticks spools.
Erodes flow control orifices.
Acts as a catalyst to break down the fluid.
Wears pumps and motors.
Is catastrophic to servo valves.
When selecting a filter for use in a system, it is important to consider the micron size rating of the
filter element along with beta ratio(s) of the filter. Seals used in filter elements must be compatible with the
fluid in use. Replacement filters must also have an acceptable collapse pressure rating, particularly if they are
to be used in a pressure or return line situation.
Cleanliness and safety are of the utmost importance when changing filters. The filter housing and surrounding
area should be thoroughly cleaned before removing the oil filter. The system must be disabled such that it cannot be
started while service personnel are working. Used filter elements and fluid drained from the filter should be
handled according to environmental standards. Seals should be changed and installed carefully to guard against
damage. Check the filter assembly for proper tightening of the element or canister assembly before restarting
the system.
In many cases, filter changes must be recorded in a maintenance log. Appropriate information to record
includes the date, hour meter reading, name of person performing the service, and the model number of the
replacement filter. If a maintenance log is not maintained, the same information should be written on a tag and
attached to the filter housing.
IHM Manual # 402 - 01/00
Much can be learned about a hydraulic system by examining used filters. Carefully cut the filter element
free and cut down one side of the element so as to "unroll" the element. The element may now be laid flat for
careful study. Metallic particles will shine under light. Non-metallic particles may also be found. These may
provide insight into pending component failures and sources of contaminant ingression.
Review: 6.2.
Review: 6.1.
The b Ratio of a hydraulic filter is:
A filter with a 20 micron(micrometer) rating:
a. the ratio of contaminant concentration (at a
a. will remove all particles over 20 microns in size.
given size) upstream and downstream of a filter.
b. will remove all metallic particles over 20
microns in size.
b. an indication of how much dirt the filter can hold.
c. a comparison of the flow rate through the filter
c. will not work properly if the flow rate is over
20 gpm.
to the corresponding pressure drop.
d. will remove silt.
d. often referred to as the absolute rating of the filter.
e. will not provide meaningful information if the
e. a predictor of service life of the element.
b ratio is unknown.
IHM Manual # 402 - 01/00
FLUID FILT R ATION AND MAINTENANCE

Proper maintenance of a hydraulic system is necessary to insure long life and peak component efficiencies.
Making adjustments, changing filters, and repairing any leaks are all necessary functions of system maintenance.
Since the fluid is like the life blood of the system, particular attention must be given to insuring that it is at an
appropriate cleanliness level, has not oxidized, and that the additives are still performing their function. This
involves drawing fluid samples for analysis, examining the fluid for contaminants, preparing samples for laboratory
analysis, and in some cases, changing a hydraulic system over from one fluid to another.
Task 7.0
Outcome 7.1.
Outcome 7.2.
Draw a hydraulic pressure line sample using a sampling valve.

Knows the causes and recognizes the signs of fluid failure.
Understands the benefits of sampling fluid from a pressure line.
Pressure line fluid samples are drawn and analyzed to determine the condition of both the fluid and the
hydraulic components. Other methods can be used to sample the fluid, but the pressure line method provides
the best data. The procedure followed to take the sample is important because the sample analysis data
describes the condition of all the fluid in the system. Thus, to be of any value, the sample must be representative of
all the fluid in the system. Any outside source of contamination invalidates the sample. This could include a
dirty sample container, taking the sample while the machine is cold, or disturbing the position of the valve
while the sample is being taken.
Ball Valve
System
Line
Movie
Hypodermic
Needle
Plastic
Film
Sample
Container
Fig. 8. Taking Pressure Line Sample
Periodic analysis of system fluid is helpful, not only in determining

when the fluid needs to be changed, but also in monitoring component
wear in the system. A thorough laboratory analysis will provide
information such as the ISO cleanliness code, the neutralization number,
the concentration of additive compounds, and the type of wear metals
found in the sample. The presence of water in petroleum oil samples
will also be detected.
Oxidation is a critical factor in fluid life. Additive depletion is
accelerated when the fluid begins to oxidize. All fluids oxidize, but the
process occurs at a faster rate as the operating temperature of the fluid
rises. When fluid oxidation is permitted to continue, the result may be
varnish (brown deposits on internal surfaces) build up in the system. In
severe cases, varnish will impede the operation of valves in the system.
A good sample must be representative of the fluid in service if the data are to be meaningful. Samples are
normally taken from pressurized lines using specially designed sampling valves located at strategic points in
the system. Periodic samples should be taken from the same sampling point and after approximately the same
running period, which should not be less than thirty minutes after start-up.
Bottles used for sampling must be clean as any contaminant left in the bottle or entering the bottle during
the sampling process can significantly alter the results. After opening the sampling valve, at least 3 1/2 oz. (200
milliliters) of fluid should be allowed to flow into a spare container; then the sampling bottle should be filled. Do
not touch the sampling valve while the sample is being taken, as this may dislodge internal contaminants. Keep
IHM Manual # 402 - 01/00
sampling bottles capped until immediately prior to taking the samples, and always replace the cap as soon as
the sample has been taken.
A sample must be documented fully to describe the type of equipment in which the fluid is working, the type of
fluid, operating conditions, and time interval since the last sample was taken. There are three fundamental
techniques to determine fluid analysis sample intervals:
1) Sampling when a problem is suspected.
2) Analysis on a "spot check" basis.
3) Trendline analysis.
Samples should not be taken immediately downstream of the filter as this will not give a representative
sample of the fluid in the system. The sample should be taken where there is constant flow in the system. This
means that the fluid should be constantly circulating, for example, downstream of a constant displacement
pump. The sample would not be taken after the pressure ports of a four-way control valve because the flow is
intermittent. If possible, samples should be taken where there is turbulent flow, thus insuring that any contaminants
will be well dispersed in the sample.
Review: 7.1.
Review: 7.2.
Fluid sampling from a pressure line is desirable because: Fluid oxidation causes the:
a. the fluid runs out easily since it's pressurized.
a. viscosity to decrease.
b. it saves opening the reservoir.
b. additives to deplete more rapidly.
c. pressure lines are always more accesible.
c. oil to turn milky.
d. the fluid is most representative of that which
d. flash point to decrease.
the components see.
e. viscosity index to increase.
e. the oil is warmer than at any other point in the
system.
IHM Manual # 402 - 01/00
Task 8.0
Outcome 8.1.
Outcome 8.2.
Examine hydraulic fluid for water and contaminants.

Understands the problems caused by water in a hydraulic system.
Knows how contaminants, including water, get into the
fluid and knows how to remove them.
The two main causes of (oil) hydraulic fluid degradation are water and contamination. Oxidation, a condition
caused by overheating the hydraulic fluid, is a third but less severe cause than water and contamination. Each
cause of degradation leaves tell-tale signs in the fluid. Water, depending upon the amount, causes the fluid to
be hazy or milky. Contamination increases the viscosity and acid number. Oxidation discolors the hydraulic
oil, making it darker. Varnish deposits also show up on valve spools and close fitting pistons.
The presence of water in hydraulic fluid accelerates fluid oxidation, loss of anti-wear protection, and corrosion.
When the fluid is heated, the water combines with the air to oxidize the base stock. It also changes the composition
of rust inhibitors and viscosity improvers to form slimes and sludges.
Early detection is the key to solving water and contamination problems. Laboratory analysis is necessary
to identify the exact type and concentration of contaminants, but inspection at the site and a few simple tests
can identify the warning signs of water, contamination, and oxidation problems.
Contaminants in a hydraulic system come for a variety of sources. These are:
Built-in contaminants - initial residual contamination in a component, fluid, or system.
Typical built-in contaminants are: burrs, chips, flash, dirt, dust, fiber, sand, moisture,
pipe dope, weld starter, paints, solvents, flushing solutions, incompatible fluids, and
operating fluid impurities.
Generated contaminants - contamination created by the operation of a fluid system or
component. Generated contaminants are products of erosion, fretting, scoring, wear,
corrosion, decomposition, oxidation, and fluid-breakdown. Air bubbles also may be
generated under some operating conditions. At temperature over 135F the typical oxidation
rate of most fluids doubles with every 18 increase of fluid temperature. This shortens the
life of seals, components and also presents a safety hazard.
Induced contaminants - contaminants added with the fluid or during service. Induced
contaminants usually enter the system through improper service and repair techniques.
Externally infiltrated contaminants - water and particulates that enter the system
through cylinder seals, reservoir breathers, and other components that ingest contaminants
from the surrounding atmosphere during operation.
Escaped contaminants - contaminants that dislodge inside the system and are
transported through conductors and components. Pressure surges and shock loading cause
contaminants to be released downstream from filters and fluid conductors.
Water may enter a hydraulic system in several ways. It may be present in make-up fluid added to the system. Condensation in the reservoir is another way water gets into the oil. Lastly, leakage through rod seals,
shaft seals, and past the filler/breather cap on the reservoir may provide a path for water to enter a system.
IHM Manual # 402 - 01/00
Most petroleum-based oils can absorb a small amount (approximately 200-300 ppm) of water. Below this
level, the water cannot be seen. This is known as dissolved water. When water concentrations exceed the saturation
point of the fluid, the free water will cause a discoloration of the oil, normally a hazy or milky appearance.
This water will separate from the fluid when the system is not in operation.
Water in concentrations of 50 to 100 parts per million can reduce the life of components as much as 50%
by neutralizing the anti-wear protection of additives, causing wear from boundary layer breakdown and
contaminants, even before the water can be detected in the fluid.
Water in the fluid will accelerate silting and component lock-up. It can also etch components and
cause pitting.
A desiccant breather, necessary in high humidity climates, can prevent water from entering the reservoir
with incoming air; the breather removes both moisture and contamination from air. Water absorbent filters are
effective in removing water from the oil. They use a polymer consisting of a starch-based molecule in powder form
that can absorb between 100 and 1000 times its weight in water. The polymer combines with the water to form a gel.
A few simple tests will permit an on-site evaluation of a fluid. Visually inspect the fluid sample. Hold it
up to the light, and examine for a hazy appearance that would indicate the presence of water. If the fluid is
darkening (compared with a new sample of the same fluid), it could indicate the presence of oxidation as well
as contamination. Smell the fluid for a pungent or "burned" odor, and observe for unusual colors. This could
indicate the fluid has been overheated and oxidized.
Perform a blotter test for sludge and contamination. Place a drop of oil from the sample on blotter paper.
Inspect the dried blotter for a defined ring around the oil wetted area. This would indicate the presence of sludge.
Perform a crackle test. FACE PROTECTION MUST BE WORN. Place drops of the fluid sample
on a 250F hotplate surface. Listen for the crackling or popping sound of water vaporizing. This would
indicate the presence of water in the sample.
Perform a patch test for contamination. Patch testing procedures vary from one manufacturer to another.
Review: 8.1.
One result of having water in a hydraulic fluid is:
a. fluid becomes thinner.
b. oxidation is accelerated.
c. increased power consumption.
d. saturation point of the oil is raised.
e. entrained air is more easily dispersed.
Review: 8.2.
Water absorbent filters:
a. use a starch-based molecule to absorb water.
b. separate the water using a centrifuge type action.
c. may be equipped with an automatic drain.
d. have a lower pressure drop than non- absorbent
filters.
e. may not filter out contaminants effectively.
In each case, follow the manufacturer's procedure.
IHM Manual # 402 - 01/00
Task 9.0
Outcome 9.1.
Transfer fluid through a portable filtration unit.

Understands the application and purpose of a portable filter unit.
Portable filtration units are used to tranfser make-up fluid to hydraulic machinery and to remove water and
contaminants from fluid in the reservoir that cannot be removed by the machine filters. The effectiveness of
the unit depends upon which filter elements are used. The objective is to remove the water and contaminants
without removing the anti-wear and other additives. Super absorbent polymer elements remove water. Fine filtration
ratings also ensure that the filter will remove silt.
A portable filtration unit is one of the most economical ways to keep fluid clean, keep machinery in use,
and avoid excessive replacement costs. It consists of one or two oversize filter elements, an electric motor driven
pump, hose, and the couplings to tap into a hydraulic system or draw oil from a drum.
Filter Vessel
Gauge
Indicator
Motor
Portable filtration units are used to transfer fluid and

deliver it clean from a drum to a reservoir, to clean systems
after maintenance, to periodically clean inadequately filtered
systems, to provide convenient portable versatility, to save
wear on components, to help prevent downtime, and to save
on maintenance.
The filter elements are the key to any filtration system.
Filter(s) used on the portable unit must have the correct rating for
the application (size, capacity, beta ratio, and structural integrity).
Inlet
Strainer
Pump
Tire
Front
Rest
Heavy Duty
Electrical Cord
When using a portable filter unit to clean the fluid in an

exisiting system, the fluid should be circulated through the
filter unit a minimum of five times. More passes are
required as the coarseness of the filter increases. This means
that in a flushing operation the filter must remain in service
long enough to bring the contamination level down to the
rating given on the filter. Laboratory analysis of a fluid sample
is the best way to insure that the appropriate cleanliness
level has been achieved.
Fig. 9. Portable Filter Cart
Highly oxidized oil, indicated by a burned odor, dark color and thickening, cannot be reclaimed. In fact,
most oil companies agree that the major factor limiting the useful life of hydraulic oil is oxidation.
Review: 9.1.
A portable filter unit is used to:
a. transfer fluid from drums to the reservoir.
b. serve as the main source of filtration for a system.
c. reclaim oxidized oil.
d. remove only very large contaminants.
e. prime pumps.
Review: 9.2.
Oxidized oil:
a. can be salvaged if passed through the filter
cart enough times.
b. is not necessarily contaminated and can be reused.
c. has no outwardly visible indication that oxidation
has occured.
d. cannot be reclaimed by filtering.
e. can be reclaimed by mixing with new oil.
IHM Manual # 402 - 01/00
Task 10.0
Outcome 10.1.
Outcome 10.2.
Label fluid sample for laboratory analysis.

Knows what information must be included with a fluid sample.
Understands the value of laboratory fluid analysis and
knows how to use the results.
Periodic fluid sampling and analysis are undertaken to establish a controlled maintenance program. Several
basic steps in the procedure must be followed for the benefits of a fluid analysis program to be realized. One
such task is labeling the sample for laboratory analysis. As simple as this may seem, errors in labeling cause
samples to become separated from the owner so that the person who needs the information never receives it.
The point is that to be beneficial, each of the steps must be completed in a routine and timely manner for the
ongoing program to reduce maintenance and capital costs associated with fluid power machinery.
Section I
Section II
Customer: ___________________________________
Attn: ________________________________________
Address: _____________________________________
City: ________________________________________
PERSON(S) TO NOTIFY:
(1) __________________________________________
(2) __________________________________________
PHONE: Area Code: ______ No. _________________
Section III
Section IV
Sample identification: ___________________________

Manufacturer: _________________________________
Model: ______________________________________
Hydraulic System Capacity: _________________ gals.
Type of Fluid: _________________________________
Operating Pressure: ________________________ psi.
Fluid Change interval: _______________________ hrs.
Type Filters in
Service: ______________ Location: ______________
Service Interval: _______________________________
Operating Conditions: __________________________
Additional Comments:
____________________________________________
____________________________________________
____________________________________________
HAS THIS UNIT BEEN SAMPLED BEFORE?

YES_____ NO_____
Fig. 10. Oil Sample Label
A fluid sample indicates the condition of the fluid and the equipment at the time it is taken. It is important
to send the fluid sample promptly to the laboratory for analysis. Samples should be analyzed shortly after they
are taken because they become less significant as time goes by. Laboratories receive hundreds of fluid samples each
day and most look very similar. It is essential to properly label the fluid sample from your machine.
Periodic fluid analysis is used primarily to establish a controlled maintenance program. This would include
determining when to change the fluid and to detect contamination before it seriously affects system components.
Typical laboratory results of analyzed oil will report the following conditions:
Normal - physical properties of the fluid are within acceptable limits.
Abnormal - physical and lubricating properties, contamination, and component wear
are clearly above normal, but not at the critical stage.
IHM Manual # 402 - 01/00
Critical - physical properties, contamination, and component wear are serious enough to
require immediate correction to prevent major shut down and component failure.
The basic steps to insure that the maximum benefit is derived from fluid analysis include:
*Label each sample properly and completely. If the machine has an identification number,
record the number on the form which accompanies the sample. Be sure to include company
name, address, phone number, and contact person on the form.
*Sample correctly, insuring a representative sample is collected.
*Read and retain the laboratory report with the machine's maintenance records.
*Advise the laboratory of any repairs or modifications to the hydraulic system. This work
may affect the data of the machine and fluid.
Review: 10.1.
Review: 10.2.
Which of the following would be required on a A laboratory analysis report should be:
laboratory fluid sample form?
a. sent to the fluid supplier.
a. Company identification and address
b. compared to previous reports.
b. Machine identification
c. sent to corporate archives.
c. Type of fluid in use
d. kept for warranty purposes only.
d. Date of sampling or hourmeter reading
e. filed with the filter supplier.
e. All of the above
IHM Manual # 402 - 01/00
Task 11.0
Outcome 11.1.
Prepare a hydraulic fluid sample container in the field.

Understands the purpose of flushing a fluid sample container.
There are many ways to obtain clean hydraulic fluid sample containers. Some are supplied by the testing
laboratory. Others are purchased directly as "clean" new bottles. A third method is to have containers prepared
by a local laboratory using one of the standard practices. And finally, sample bottles are sometimes prepared
in the field by the person who takes the sample. Typically this involves the use of a new bottle with a sealed cap.
The bottle is visually clean, but must be prepared to reduce background contamination at least to the contamination
level of the fluid being sampled. This procedure is adequate for machinery in the field that is assumed to have
moderate to very contaminated fluid, such as may be found on off-road, construction, and heavy manufacturing
equipment.
To establish the condition of the fluid, it is necessary to extract a representative sample of the system fluid.
Bottles used for sampling must be clean, as any contaminants left in the bottle or entering the bottle during the
sampling process can significantly alter analysis results.
Normally, "clean" new bottles with a screw on lid are used to take fluid samples. When laboratory clean
sample bottles are not available, a field sample container can be prepared from an 8 oz. bottle with a sealed screwon lid. The practice of flushing field-prepared sample containers cleans the sample container to the contamination
level of the fluid. This is adequate for most purposes. When the sample container is cleaned by flushing, the
operation is done three times (filling the container half-full, shaking, and emptying the container).
Fill 1/2 Full
Shake 2 min. and Empty Repeat Twice
Fill 2/3 Full

and seal
Fig. 11. Preparing a Fluid Sample Container
A minimum of 4 oz. (118 ml) of hydraulic fluid is required to perform a particle count. A good sample size bottle is 8
oz. (236 ml), which should never be filled more than 2/3 full. Leave enough air space in the bottle to shake the sample.
Review: 11.1.
The purpose of flushing a fluid sample container with
system fluid prior to saving a sample for analysis is to:
a. practice so that no oil is spilled.
b. insure that the contamination in the container
is the same as the system fluid.
IHM Manual # 402 - 01/00
c. warm up the container gradually.

d. clean the sample line of any non-representative
contaminants.
e. give the system time to warm up.
Task 12.0
Outcome 12.1.
Outcome 12.2
Convert petroleum-based system to high water content fluid

(HWCF) system.
Knows the necessary steps to switch from petroleum fluid
to a HWCF fluid.
Understands how HWCF performs differently from
petroleum base fluids in a hydraulic system.
High water content fluids are used where fire protection and cost are the main considerations. The fluids
are used indoors at temperatures between 40 and 120F. Water transmits power effectively, but additives are
necessary to improve viscosity, wear, and other service related properties. Because high water content fluids
promote microbial growth, a biocide is necessary. To use high water content fluids successfully, the water must
be clean with less than 300 parts per million hardness, and the ratio of soluble concentrates maintained
between 5% and 10%. Less than 5% concentrate does not provide adequate protection, while more than 10%
does not improve component life or system performance.
Common hydraulic fluids utilizing water are:
Tank
HWCFs. These fluids are 95% water into which a soluble

oil is dispersed (95/5). These are emulsions.
Stack Rack
Invert Emulsions. These fluids are typically 40% water dispersed

in an oil solution.
Water Glycols. These fluids are also about 40% water, but
the remaining 60% is a glycol (synthetic) as opposed to an oil.
Base Rack
Drip Stand
Drain
Fig. 12. Overhead reservoir for HWCF Fluids
(Courtesy of Eaton Corporation)
It is essential to locate the pump so that its inlet is flooded and

to use compatible sealing materials to prevent the system from
leaking. Paint inside the reservoir, for example, must be removed
to prevent fluid contamination. Even with these safeguards, and
operating pressures in the 1000 psi range at speeds of less than
1500 rpm, pump life is commonly 50% of that in oil filled systems.
Extreme temperature ranges may cause evaporation, bacteria growth, freezing, or emulsion separation.
The operating temperature range in HWCFs is limited to the range of about 40 to 120 F.
Pump inlet pressure is one of the most critical factors influencing pump life. All hydraulic fluids contain
some air in solution. High temperatures and/or high vacuum cause air and fluid vapor to be released from the
fluid in the form of bubbles. These bubbles cause cavitation, noise, erosion, and wear. Since HWCFs are more
dense than petroleum oils, increased vacuum will result in cavitation in the suction line unless the reservoir is
positioned above the pump inlet.
The following steps are recommended when converting a petroleum-base hydraulic system to a high water
content (HWCF) system:
Drain the petroleum-based fluid from system.

Flush the system with an approved flushing oil.
IHM Manual # 402 - 01/00
Remove all paint from inside of reservoir. After the reservoir has been sealed, paint
it orange on the outside with an approved paint to indicate HWCF fluids are being used.
Clean the reservoir with an approved disinfectant.
Replace the filter elements.
To ensure laminar flow at the pump inlet, a good rule of Thumb is to keep the piping
straight for a length which is equal to 10x the diameter of the inlet piping.
Replace seals that are incompatible with HWCF's.
Be sure the pump inlet is flooded and the reservoir is filled to the proper level.
Review: 12.1.
Review: 12.2.
Why is the reservoir mounted above the pump when Which of the following should be done when changing
using HWCFs?
to HWCFs?
a. It makes replenishing water easier
a. Oversize electric motor
b. It prevents separation of oil and water
b. Change to HWCF compatible seals
c. It reduces the risk of cavitation
c. Repaint inside of the reservoir
d. It minimizes evaporation
d. Use charge filters
e. It enhances cooling of the reservoir
e. Install a fluid cooler
IHM Manual # 402 - 01/00
Task 13.0
Outcome 13.1.
Outcome 13.2.
Draw a hydraulic fluid sample from the reservoir.

Knows where to take a reservoir fluid sample.
Understands the advantages and disadvantages
of reservoir sampling.
The purpose of the procedure is to take a sample from the reservoir that is representative of the fluid in the
system. Pressure tap samples are considered most desirable, followed by reservoir samples. The basic procedure
syphons a sample from the reservoir near the pump inlet. The fluid must be at operating temperature and the
sample taken while the system is operating, or shortly thereafter, while contaminants are still in suspension.
In no case should the fluid sample be taken near the bottom of the reservoir (which could introduce water and
heavy contaminants), or near the top (which could sample fluid that is not representative of what is passing
through the system).
As a rule of thumb, samples should be taken at least 6 inches from any inside surface. A sample
from a reservoir should be taken from the middle of the reservoir, if possible, to ensure that it is
representative. Reservoir samples should be taken in the vicinity of the inlet tube. When taking a
fluid sample from a reservoir, the sample can be drawn through a plastic tube using a valve and any of
several sample-taking devices.
The sample container is as important as
the sample itself. Use the sample containers
provided by the oil laboratories or oil
vendors, if possible. It is recommended
that a minimum of one quart of fluid be
allowed to drain through the sampling
line before taking the sample, so that any
contamination in the sampling device
and line will be purged.
Name_____________
Sampler ID:_________
Date
System Charged:_____
Date
Sampled:_________
STEP 4
Compress to fill to
three quarters full
The fluid must be at operating

temperature before taking the
sample, and the sample must be
taken near the pump inlet. The sample
can also be taken with the machine
running, but often this does not allow
convenient access through the cover
opening. When the fluid is to be sent to
a laboratory for analysis, it must be
properly labeled and shipped promptly.
Refer to Task 10.0 for further study.
Review: 13.1.
A reservoir sample:
a. is preferred over a pressure line sample.
b. can be done even if the machine has been idle
for an extended period.
STEP 1
Fill out label on bottom of
sample container
STEP 2
Insert plastic
tube securely
STEP 3
Insert Tube into
reservoir
STEP 5
Cap securely and mail
in the box provided
Fig. 13. How to Take a Reservoir Sample
c. is best done by dipping the container into the oil.

d. is acceptable if a pressure line sample is difficult
or unsafe to obtain.
e. won't provide any useful information about
the system.
IHM Manual # 402 - 01/00
ASSEMBLE COMPONENTS
Hydraulic circuits and systems consist of components that have been assembled, installed, and adjusted.
Assembly drawings and illustrations are commonly used to show the positions of the respective parts in an
assembly. Components such as valves are shown as assemblies for this purpose. New components are assembled as
well. Hoses and fittings, for example, are made to length with crimped and/or reusable fittings. Proper assembly of
components requires using assembly drawings, written procedures, hand and machine tools, and gauges.
Craftsmanship and cleanliness are important to assure that the work meets safety specifications and workmanship
standards.
Task 14.0
pump.
Outcome 14.1.
Assemble a hydraulic fixed displacement unbalanced gear

Understands how pump displacement speed, and volumetric
efficiency affect flow rate.
Solves basic mathematical relationships to determine
flow rate, efficiency, speed, and displacement.
Outcome 14.2.
Of all pumps, gear pumps are the simplest and least expensive. Traditionally, gear pumps have a pressure
range up to about 2500 psi, and volumetric efficiencies in the range of 85% to 90%, but recent developments
have increased their pressure range to 4000 psi with efficiencies above 90%. One major advance has been the
use of pressure compensated wear plates at the ends of the gears. Another has been the re-design of the tooth
profile which reduces noise and pressure surges that are common with this type of pump.
Assembling a fixed displacement unbalanced gear pump consists of inspecting the gears and wear surfaces,
and replacing the seals and those parts that show greater than allowable wear. The two major wear sufaces are
the inside of the housing around the gears, and where the gears meet the wear plates.
Shaft
Seals
Outboard
Bearing
Check
Assemblies
Integral Shaft
and Gear Set
Thrust
Plates
Gear
Housing
Gasket
Seals
Gasket
Seals
Thrust
Plate
Snap
Ring
Rolling
Bearings
Double
Lip Seal
Pocket
Seals
Shaft End
Cover
Cap
Screws
Washers
Shaft
Seals
Port End
Cover
Fig. 14. Gear Pump Assembly
It is important to recognize that all pumps leak, or "slip." As the pump wears, internal leakage increases.
This means that the volumetric efficiency (the actual flow delivered divided by the theoretical or predicted
IHM Manual # 402 - 01/00
delivery) decreases. The result is that less flow is delivered out the pressure port of the pump. Testing flow
rate, or volumetric efficiency, is a necessary step to determine if a pump is bypassing fluid internally and needs
to be rebuilt.
Fluid in an external gear pump is picked up and trapped between the gear teeth on both shafts and the housing.
As the pump shafts rotate, the gear teeth will mesh, forcing the trapped fluid out the pressure port. Fluid may
leak back to the inlet port along any of three paths: between the teeth where they are meshed, around the gear
between the tips of the teeth and the housing, and across the ends of the gears.
The seal between the inlet and outlet chambers is maintained by the tooth-to-tooth contact between the
gears, the close tolerance around the outside of the gears, the close tolerance between the gears and wear plates,
and the static seal behind the wear plates that allows pressurized fluid to force the end plates against the ends
of the gear teeth.
The theoretical flow from a fixed displacement gear pump is proportional to the displacement and speed
of rotation such that:
Theoretical Flow Rate (gpm) = Dis placement (CID)
N
Q= D
231
S peed (rpm)
231
(Eq. 2)
The number 231 is the number of cubic inches in one gallon.

The volumetric efficiency of a pump is proportional to the actual flow and inversely proportional to the
theoretical flow such that:
Ev =
Q Act.
Q Theor.
Actual flow
Theoretical flo w
1 00
100
(Eq. 3)
Stated another way:

Ev
Actual Flow Rate (gpm) = Dis placement (CID) S peed (rpm)
23 1
Ev
Q Act. = D N
231
(Eq. 4)
Ev must be expressed as a percentage.

An example of these principles follows:
A pump with a displacement of 2.56 cubic inches per revolution operates at 2400
rpm and has an output of 22.5 gpm.
1. Calculate the theoretical flow rate in gal/min.
Calculate
IHM Manual # 402 - 01/00
Q Theor (gpm) = (2400 x 2.56) / 231 = 26.6 gpm

2. Calculate the volumetric efficiency:
Calculate
Vol. Effic. (%) = (22.5 / 26.6) x 100 = 84.5%

Review: 14.1.
A 2.0 cubic inch CID (or CIR) gear pump which has been
in service for many years has an output flow of 13.8 gpm
under load at 1800 rpm. When new, the pump had a
volumetric efficiency of 90%. The manufacturer
recommends rebuilding when the volumetric efficiency
drops below 83%. This pump:
a.
b.
c.
d.
e.
is slightly worn, but still within specifications.

should be rebuilt immediately.
should be discarded.
is better than when new.
not enough information is given to tell.
Calculate
IHM Manual # 402 - 01/00
Task 15.0
Outcome 15.1.
Outcome 15.2.
Assemble a hydraulic pilot operated pressure relief valve.

Understands the operation of a pilot operated relief valve.
Recognizes valve problems and their cause.
Relief valves are used to limit maximum pressure in hydraulic systems. When system pressure begins to
exceed the pressure setting of the relief valve, a controlled amount of hydraulic fluid by-passes through the
relief valve to the tank port and limits the system pressure to the valve setting. The two basic types of relief
valves are direct acting (simple) and pilot operated (compound).
Animation
Pilot Poppet
Vent
Connection
Pilot
Orifice
Bias Spring
Main Piston
PILOT
OPERATED
DIRECT
ACTING
Animation
Main
Poppet
Fig. 15. Direct Acting and Pilot Operated Relief Valves (Also called balanced Piston, compound, or two stage valves) (Courtesy of Eaton Corporation)
Several important terms must be understood with respect to the operation of relief valves. These are: cracking
pressure, full-flow pressure, and closing pressure.
Cracking pressure - pressure at which the poppet valve unseats.
Full-flow pressure - pressure at which a relief valve diverts full flow to the reservoir.
Reseat pressure - pressure at which a relief valve closes after being open.
In a simple relief valve, a spring holds the poppet against a seat. When system pressure is high enough to
overcome the spring force, the poppet moves off the seat to allow fluid flow through the bypass. The spring
compression is set so that the poppet opens to divert sufficient flow to limit the pressure to the preset value.
In a compound relief valve, a light spring holds the main stage piston so that the discharge port is normally
blocked. A small amount of fluid flows past the main stage piston through an orifice in the main piston to the
pilot stage of the relief valve. The pressure of the fluid on the pilot valve exerts a force on the pilot valve poppet. If
the force exceeds the spring force, the poppet is unseated, allowing a small amount of fluid to flow through
the drain. The vent port on a ventable pilot operated remote control valve may be used as a remote control or
plugged if not used.
The pressure drop resulting from flow past the pilot valve poppet is experienced on the back side of the
main stage piston, and the piston shifts, opening the valve. In operation, the compression on the pilot stage
IHM Manual # 402 - 01/00
spring is adjusted so that the main stage piston opens at a specified pressure.
As with all precision machined components, care must be exercised when assembling a pilot-operated
relief valve. Cleanliness is of the utmost importance. Components, particularly the balanced piston, should be
lubricated with clean oil prior to assembly. The cap or pilot section of the valve must be carefully aligned over
the piston. Some relief valves use locator pins to assure alignment. Bolts must be torqued properly.
Operation of the valve should be tested before placing the valve back in service. If the valve fails to function
properly due to piston binding, the cap may be loosened and tapped gently to achieve proper alignment. Bolts
must be retorqued following this adjustment.
Review: 15.1.
Review: 15.2.
What would happen if the pilot orifice in the main piston What do you do with the vent port on a pilot operated
of a pilot operated relief valve became plugged?
relief valve?
a. Valve would function normally.
a. connect to tank above fluid level.
b. connect to tank below fluid level.
b. Valve would never open.
c. Valve would work normally but would only
c. use as a remote control port.
divert a small amount of fluid to the tank port.
d. always use a gauge port.
e. vent to atmosphere.
d. Increasing the pressure on the pilot stage
spring would decrease the cracking pressure
of the valve.
e. Valve would by-pass flow to tank at low pressure.
IHM Manual # 402 - 01/00
Task 16.0
Outcome 16.1.
Outcome 16.2.
Assemble a three-position, four-way, solenoid operated

directional control spool valve.
Understands the terminology related to directional control
spool valves.
Recognizes the symbols for directional control spool valves
and their meaning.
Four-way solenoid actuated directional control spool valves are used to operate double-acting hydraulic
cylinders and bi-directional motors. Large valves of this type consist of a solenoid actuated pilot stage and a
pilot operated main stage. Both valves have precision ground spools to direct the flow of fluid.
Animation
Identification Plate
Body
Solenoid
O-Ring
Plunger
Retainer
Spool
O-Ring
Spring
Guide
Plug
Push Pin
Fig. 16. Four- Way Directional Control Valve Assembly (Courtesy of Eaton Corporation)
Each operating position of the spool causes flow to be directed to different ports. This is referred to as the
number of valve positions. Many flow choices exist for center positions. Figure 17 shows some of these possible
conditions. In one shifted position, pressure is directed to A and B is connected to tank. In the other shifted
position, pressure is connected to B and flow into A goes to tank.
This type of valve would be referred to as a four-way valve because there are four different lines connected
to the valve. It is possible to have valves with less or more than three positions and four ways. The schematic
symbol for the valve provides the user with the number of positions and ways.
It is customary to show a directional control valve on a schematic diagram in its "centered" or "neutral"
position. Most three-position valves use springs or detents to center the spool when it is not actuated. The flow
paths which occur in the centered position of the valve are of particular importance. Definitions of the most
common center configurations follow:
Open center condition - directional control valve that connects all ports together
when the valve is in the center or neutral position.
Closed center condition - directional valve with all ports blocked or closed in the
center position.
IHM Manual # 402 - 01/00
Tandem center condition - directional valve that can be positioned to end the motion of
an actuator while it simultaneously unloads the pump. Tandem center valves must have
a through passage and are commonly stacked to direct the fluid flow to one of several
actuators on demand.
Float center valve - valve that can block the pressure port of a valve while concurrently
interconnecting the actuator ports to the reservoir.
Animation
OPEN
TYPE
CLOSEDTYPE
TANDEMTYPE
FLOAT
TYPE
Fig. 17. Center Position Flow Options for a Four- Way Directional Control Valve
Critical to proper assembly are cleanliness of the parts; proper lubrication of the spools, valve body, and
seals; and proper assembly, which includes checking the sliding fit of the spools to insure they are not rough,
scratched, or binding. The O-rings must be positioned properly to prevent leaks, and the body screws must be
torqued to the proper specifications and in the proper order to prevent distortion of the valve body.
Review: 16.1.
Review: 16.2.
When a closed center, four-way, three-position, directional Which of the following center configurations allows
control valve is centered:
pump flow to pass through to the tank port?
a. flow is blocked to A and B ports only.
a. Pressure compensated
b. all ports are blocked.
b. Closed
c. pump flow is directed to tank unrestricted.
c. Float
d. all ports are interconnected.
d. Tandem
e. the actuator will "float."
e. Parallel
IHM Manual # 402 - 01/00
Task 17.0
Outcome 17.1.
Outcome 17.2.
Make up a hydraulic hose assembly with permanent ends.

Understands the relationship between working pressure,
safety factor, and burst pressure.
Interprets hose specifications from recognized standards.
Making up a hydraulic crimped hose to length is a common task, particularly when other repairs are made
to the machine, or when a hose bursts or leaks and must be replaced. When a hose is replaced, the pressure rating,
flow capacity, fluid compatibility, and length must all be verified for the new hose. Some applications require
non-conductive hoses which don't use steel wire braids for reinforcement.
Non-conductive hoses must not be replaced with a conductive hose. (Follow manufacturers
specifications for assembly of non-conductive hose.)
The flow capacity of a hose is determined by its inside diameter. The dash number (-#) of a hose is
its inside diameter in 16ths of an inch. Thus a dash 8 (-8) hose has an I.D. of 1/2 inch. A dash 16 (-16) hose is a 1
inch hose.
Most applications require a hose Safety Factor (SF) of 4:1. The minimum burst pressure (pressure at which
the hose may fail) divided by the safety factor gives the maximum allowable working pressure for the hose.
Thus, a hose with a minimum burst pressure of 12,000 psi would have a maximum operating pressure of 3,000
psi at a safety factor of 4. Some applications require that a higher safety factor be used. Safety factors below 4
are not recommended since all systems are subject to pressure spikes and pulsations.
Operating Pres s ure (ps i) =
Burs t Pres s ure (ps i)

S afety Factor
(Eq. 5)
Hoses are constructed of three major elements. The inner tube is the liner which carries the fluid. The
reinforcement layer provides the strength. An outer cover protects the reinforcement from corrosion and damage.
The outer cover must be removed at the ends of some hoses before end fittings are crimped onto the hoses.
This is referred to as "skiving." The Society of Automotive Engineers (SAE) provides standards regarding the
construction, pressure capability, and performance of hydraulic hoses. These are referred to as the SAE 100R
standards. Figure 18 provides information on the SAE 100R standard.
Getting the finished length of a hose assembly correct is important so that the hose can be routed and
mounted on the machine properly. The length of the hose cannot be taken from the old assembly because the
cut-off length cannot be measured. Rather, the hose length is determined by measuring the finished length and
subtracting the cut-off length for each of the new fittings. There is only a slight margin for error in measuring,
cutting the hose to length, and assembling the socket, nipple and hose in a crimping machine, if the assembly
is to have the holding strength and sealing power necessary for trouble free operation.
Different end fittings have different cut-off allowances. This is the length the fitting extends beyond the cut
end of the hose when assembled. The cut-off allowance for each end fitting must be subtracted from the desired
finished length of the hose assembly to determine the length to which to cut the hose. A hose saw is the only
accepted device for cutting hose. Other methods are not approved.
It is important to use compatible hose, fittings, and crimpers when making hose assemblies. The crimper
and crimping dies must be in good condition and properly lubricated. The crimp diameter of the finished
assembly should be checked against manufacturer specifications.
SAE Hose Specifications
IHM Manual # 402 - 01/00
Hose failures can be costly and dangerous. Manufacturer instructions should be carefully followed.
Finished hoses are always contaminated with metal particles and/or rubber or plastic from the cutting operation.
Hoses must be thoroughly flushed after assembly and capped until installation. New hose assemblies may be
tested to twice the working pressure to proof pressure to ensure safety without damaging the integrity of the hose.
Review: 17.1.
Review: 17.2.
A hose with a minimum burst pressure of 16,000 psi A dash 12 (-12) hose which complies with SAE 100
is used in an application requiring a 4:1 safety factor. R2 is required. The inside diameter of the hose is:
The maximum working pressure of the hose is:
a. 1/2 inch.
a. 64,000 psi.
b. 3/4 inch.
b. 16,000 psi.
c. 12 millimeters.
c. 8,000 psi.
d. 12/100 inch.
d. 4,000 psi.
e. Not enough information given to tell.
e. 1,600 psi.
IHM Manual # 402 - 01/00
SAE 100R1
Type A This hose shall consist of an inner tube of oil resistant synthetic rubber, a single wire braid reinforcement, and an
oil and weather resistant synthetic rubber cover. A ply or braid of suitable material may be used over the inner tube and/or
over the wire reinforcement to anchor the synthetic rubber to the wire.
Type AT This hose shall be of the same construction as Type A, except having a cover designed to assemble with fittings
which do not require removal of the cover or a portion thereof.
SAE 100R2
The hose shall consist of an inner tube of oil resistant synthetic rubber, steel wire reinforcement according to hose type as
detailed below, and oil and weather resistant synthetic rubber cover. A ply or braid of suitable material may be used over the
inner tube and/or over the wire reinforcement to anchor the synthetic rubber to the wire.
Type A This hose shall have two braids of wire reinforcement.
Type B This hose shall have two spiral plies and one braid of wire reinforcement.
Type BT This hose shall be of the same construction as Type B, except having a cover designed to assemble with fittings
which do not require removal of the cover or portion thereof.
SAE 100R3
The hose shall consist of an inner tube of oil resistant synthetic rubber, two braids of suitable textile yarn, and an oil and
weather resistant synthetic rubber cover.
SAE 100R4
The hose shall consist of an inner tube of oil resistant synthetic rubber, a reinforcement consisting of ply or plies of woven or
braided textile fibers with a suitable spiral of body wire, and an oil and weather resistant synthetic rubber cover.
SAE 100R5
The hose shall consist of an inner tube of oil resistant synthetic rubber and two textile braids separated by a high tensile steel
wire braid. All braids are to be impregnated with an oil and mildew resistant synthetic rubber compound.
SAE 100R6
The hose shall consist of an inner tube of oil resistant synthetic rubber, one braided ply of suitable textile yarn, and an oil and
weather resistant synthetic rubber cover.
SAE 100R7
The hose shall consist of a thermoplastic inner tube resistant to hydraulic fluids with suitable synthetic fiber reinforcement and
a hydraulic fluid and weather resistant thermoplastic cover.
SAE 100R8
The hose shall consist of a thermoplastic inner tube resistant to hydraulic fluids with suitable synthetic fiber reinforcement and
a hydraulic fluid and weather resistant thermoplastic cover.
SAE 100R9
Type A This hose shall consist of an inner tube of oil resistant synthetic rubber, 4-spiral plies of wire wrapped in alternating
directions, and an oil and weather resistant synthetic rubber cover. A ply or braid of suitable material may be used over the
SAE 100R10
Type A This hose shall consist of an inner tube of oil resistant synthetic rubber, 4-spiral plies of heavy wire wrapped in
alternating directions, and an oil and weather resistant synthetic rubber cover. A ply or braid of suitable material may be used
over the inner tube and/or over the wire reinforcement to anchor the synthetic rubber to the wire.
SAE 100R11
This hose shall consist of an inner tube of oil resistant synthetic rubber, 6-spiral plies of heavy wire wrapped in alternating
directions and an oil and weather resistant synthetic rubber cover. A ply or braid of suitable material may be used over the
SAE 100R12
This hose shall consist of an inner tube of oil resistant synthetic rubber, 4-spiral plies of heavy wire wrapped in alternating
directions, and an oil and weather resistant synthetic rubber cover. A ply or braid of suitable material may be used over or
within the inner tube and/or over the wire reinforcement to anchor the synthetic rubber to the wire.
Fig. 18. SAE 100R-Type Hoses (Courtesy of Eaton Corporation)
IHM Manual # 402 - 01/00
Task 18.0
Outcome 18.1.
Outcome 18.2.
Make up a hydraulic hose assembly with reusable ends.

Knows the procedure for making a hose assembly.
Recognizes causes of hose failures.
Reusable hydraulic hose fittings allow the mechanic to replace a hose without replacing the fittings.
However, care must be exercised both in the selection of the proper hose to match the fittings and in the assembly
procedure, to ensure that the finished product will withstand the pressure requirements of the system without
failing, blowing off, or leaking. The two main screw types of fittings are no-skive and skive, where the socket grips
the reinforcement. A third type of screw fitting, called an over the cover fitting, grips the outer cover itself.
Clamp type fittings are used less frequently. The convenience of a clamp type hose fitting is the ease with
which it can be assembled in the field.
It is important to examine the failed assembly being replaced and the machine to determine if a correctable fault contributed to the
failure. The following conditions will cause
hose life to be reduced:
Pressure surges.
Installing the hose with a bend radius
which is too tight (small).
Improperly matched or crimped ends.
High temperatures.
Mechanical abrasion.
Operating pressure too high for the hose.
7 to 10 Twist = up to 90% loss of life.
Hose
Coupling Socket
Nipple
Male
Pipe
Threads
Fig. 19. Reusable Type Hose Fittings
For further study, review Task 17.0.

Review: 18.1.
Hose failure can result from:
a. low system temperatures.
b. fluid which is too thick.
IHM Manual # 402 - 01/00
c. fluid which is too thin.

d. pressure surges in the system.
e. passing fluid over the relief valve.

Sleeve
Task 19.0
Outcome 19.1.
Outcome 19.2.
Nut
Make a flared hydraulic tubing assembly.

Knows how tubing assemblies seal to the fittings.
Understands the relationship between tubing wall thickness
and pressure capability.
Body
There are many types of rigid tube fittings: flared, flareless,

and welded or brazed-on fittings that seal with a union type
connection. Flared type fittings seal at one area, between the flare
at the end of the tube and the cone. This allows them to be reused
without much wear. Flareless type fittings on the other hand, use
a ferrule that either grips or bites into the outside of the tube. They
seal at two areas: between the ferrule and tube, and between the
ferrule and the cone. They are reusable but must be over-tightened
more each time to maintain the ferrule-to-tube seal. Welded or
brazed fittings typically seal by metal to metal contact, or O-ring
contact, between the two parts of a SAE thread union.
Fig. 20. Flared Fitting Assembly
Hydraulic tubing is sized by the outside diameter. Wall thicknesses vary, allowing for different pressure
capabilities. The same nut/sleeve assemblies may be used on any wall thickness tubing with the specified outside
diameter. For a given outside diameter, the inside diameter decreases as wall thickness increases. Flow capacity also
declines with thicker walls. Using the proper diameter tubing along with the appropriate wall thickness is important.
The most critical step in making a hydraulic single flare tube fitting is forming the flare. The tube
must be cut square, cleaned free of burrs, measured exactly, and flared without galling, over-thinning,
or splitting the end of the tube.
Designs of flare fittings include the 37 degree, the 45 degree, inverted and self flare fittings. The 37 degree
fitting is used for pressures above 1000 psi, seals with less tightening torque, and is reusable. The 45 degree
flare fitting is generally used with copper and brass fittitngs at pressures below 1000 psi.
Proper flaring is important. If the flare extends past the sleeve it will interfere with the threads of
the nut when it is assembled. If the flare is too short, the tube will pull out of the sleeve when the fitting is
pressurized. The range of acceptable flare length is from the outside diameter of the sleeve to the outside
diameter of the sleeve flare.
Review: 19.1.
As the wall thickness of hydraulic tubing increases the:
a. outside diameter gets bigger.
b. inside diameter gets bigger.
c. inside diameter gets smaller.
d. tubing has the same wall thickness.
e. pressure capability goes down.
Review: 19.2.
A 45 degree flare is associated with pressure:
a. over 2000 psi.
b. over 1000 psi.
c. between 1000 and 2000 psi.
d. below 2000 psi.
e. below 1000 psi.
Animation
IHM Manual # 402 - 01/00
FIELD REPAIRS
Field repairs take place at the worksite to fix machinery that is not operating properly or has become inoperable
because of component failures or improper settings. Most of these problems do not require shop facilities.
Where parts must be replaced, their identification must be known, and equipment such as gauges, hand tools,
and supplies must be available.
Task 20.0
Outcome 20.1.
Check a hydraulic valve spool for obstruction.

Understands the causes of a pilot operated directional
control valve failure to shift.
Recognizes the symptoms of failures in a directional valve.
Outcome 20.2.
A typical solenoid operated directional control valve will have a spring centered spool valve shifted by
solenoids at each end of the valve. Single stage solenoid valves are used in application to approximately 20
gpm, and two- or even three-stage valves are used for larger flows. Staging is used because the force to shift
the valve spool increases beyond the capacity of solenoids as the spool size and flow rate increase.
Two-stage valves are pilot pressure operated. In a two-stage valve a pilot valve is mounted on top of a main
stage valve. The pilot stage is spring centered and solenoid operated, and directs fluid to the ends of the second stage
spool. Main spools use four basic spool centering arrangements: 1) no spring (floating), 2) spring centered, 3)
spring offset, and 4) pressure centered.
Some two-stage valves are equipped with a pilot choke block to meter the flow to the second stage in order
to control the shifting rate of the second stage. Another common feature is a stroke adjustment screw on the
second stage spool to control the travel of the spool.
Control valves are equipped with manual overrides
to shift the pilot stage by hand when the solenoids
fail to operate and to check for a stuck valve spool.
The main stage of some valves also may be
equipped with a manual lever connected to a
special end cover.
Pilot
Stage
Spool
P
Required for
minimum pilot
pressure.
Main Stage Spool
Adjustable orifice
restricts pilot exhaust
flow to slow main
stage spool shift.
Free flow through this

check valve when pilot
pressure is directed in.
Fig. 21. Pilot Operated Directional Control Valve, detailed schematic

IHM Manual # 402 - 01/00
One of the purposes for shifting a solenoid operated, pilot valve, or main stage valve manually is to
determine why it is not shifting when the machine
is operating. If the valve is stuck, the spool is binding for some reason. But if it is not, this does not
determine if the problem is with the solenoid,
switch, reversed spool, or incorrect pilot flow orifices.
Before shifting a solenoid valve or pilot solenoid
valve manually, make sure the solenoids are receiving
current from the control switch. Look at the indicator
lights, for example, to be sure the valve has
received the signal to shift.
The spools in hydraulic valves are selected to fit with clearances in the range of 0.00005 inches to 0.0001
inches in the bore. For this reason care should be taken not to force them past obstructions that could score
the spool lands. Reversing the spool on some valves could cause an incorrect flow path or change metering
characteristics.
Other causes that can be associated with failure of the valve to shift are:
Improper adjustment of the pilot exhaust flow orifices.
Blocked pilot passage.
Switching failure.
Solenoid failure.
Improper stroke adjustment on the main stage spool.
Reversing the spool on some valves could cause an incorrect
flow path or change metering.
Bolts torqued improperly.
Review: 20.1.
Which of the following is not a possible cause of a
pilot-operated directional control valve failing to shift?
a. Cylinder is binding
b. Solenoid is burned out
c. Pilot orifice in the valve is blocked
d. Switching failure (to the solenoids)
e. Stroke adjusters turned in too far
Review: 20.2.
The spool of a directly actuated solenoid operated
directional valve moves when activated manually, but
the load doesn't move. The problem may be:
a. solenoids are burned out.
b. switching failure.
c. pilot orifice is plugged.
d. solenoids are connected backwards.
e. pump is turned off.
IHM Manual # 402 - 01/00
Task 21.0
Outcome 21.1.
Outcome 21.2.
Adjust a balanced piston hydraulic pressure reducing valve.

Understands the operation of a pressure reducing valve.
Knows the procedure to adjust a pressure reducing valve.
Pressure reducing valves are used to supply branch circuits with fluid at a pressure lower than system pressure.
Essentially, they step the pressure down to the requirements of the branch circuit by restricting the flow of fluid
when the branch circuit reaches the pre-set limit determined by the setting of the spool positioning spring.
Pressure reducing valves sense the pressure on the outlet port to control the valve spool. The spool is balanced
much the same as the piston in a balanced pressure relief valve, but, instead of dumping the fluid to tank as a
relief valve does, the pressure reducing valve throttles the flow which causes the pressure to drop at the outlet.
Pilot oil at outlet pressure is fed through a passage in the valve spool to the poppet valve. A light bias spring
keeps the valve open until fluid pressure is sufficient to overcome the poppet valve spring and vent the pilot
oil. This changes the balance on the spool which moves in the direction to close the outlet port and throttle the
outlet flow.
Drain
Adjusting
Screw
Pilot
Valve
Inlet
(High
Pressure)
Outlet
(High
Pressure)
Outlet
(Reduced
Pressure)
Throttling
Spool
Metering
Orifice
Adjustment of a pressure reducing valve can

only be accomplished in a circuit where the
upstream pressure exceeds the desired setting of
the valve. A method of restricting downstream
flow must be provided so that the downstream
pressure may be raised to check the valve setting.
Always start with the adjuster backed out (low
pressure). With downstream flow restricted,
adjust the valve until the downstream pressure is
equal to the desired setting. Ensure that
upstream pressure remains above the valve setting.
Further restrict the downstream flow to verify
that the valve maintains the pre-set pressure
downstream.
Control
Pressure
Fig. 22. Pilot Operated Directional Control Valve
Review: 21.1.
Review: 21.2.
A pressure reducing valve:
If the throttling spool in a pressure reducing valve
a. is often used in place of a relief valve.
sticks in its normal position, the valve will:
b. provides a lower pressure for a branch circuit.
a. not allow any fluid to pass.
c. will discharge an accumulator.
b. maintain a constant downstream, but at a low
d. will relieve excessive pressure to tank.
value.
e. is often used in place of a sequence valve.
c. direct all flow to tank.
d. force fluid over the relief valve.
e. provide no control of downstream pressure.
Animation
IHM Manual # 402 - 01/00
Task 22.0
Outcome 22.1.
Outcome 22.2.
Adjust a balanced piston pressure relief valve.

Knows how a relief valve is connected in a circuit.
Understands what controls the pressure setting on a
balanced piston relief valve.
Most pressure relief valves use the balanced piston design. This means that at system operating pressure,
the piston is pressure balanced in a state of equilibrium, which prevents hydraulic fluid from flowing through
the drain port. Fluid pressure is the same on both sides of the piston, and the bias spring on main stage prevents the
valve from opening when the pilot stage is closed.
Reservoir
Fig. 23. Detailed Schematic of
Pilot Operated Relief Valve
The setting of a balanced relief valve is

normally set at 150 psi to 200 psi above system
operating pressure to prevent erratic valve
action. The valve will open when system pressure
exceeds the setting of the poppet (pilot) valve
spring, forcing the poppet valve off its seat and
venting fluid in the upper chamber to reservoir.
This unbalances the pressure on the balanced
spool, which will shift to relieve fluid until the
overpressure condition has been reduced to the
setting of the poppet valve spring.
Setting a balanced piston relief valve

involves adjusting the compression on the poppet valve spring and then cycling the valve to see that it
operates properly. The system must have a pressure gauge and a restrictor valve in the pressure line downstream of
the pressure relief valve (not in the reservoir line).
Loosen the locknut and turn the adjusting knob out to relieve spring pressure on the poppet valve. This
should relieve all pressure in the system. Close the downstream restrictor valve slowly, observing that the pressure
does not rise in the system. This is because the fluid is being diverted to reservoir through the pressure control
valve. If the pressure rises, the pressure control valve is not operating properly. Slowly turn the control knob in
(clockwise). This will cause the pressure to rise. Continue the adjustment until the relief valve setting is reached.
Refer to Task 15.0 for further study of balanced piston relief valves.
Review: 22.1.
Review: 22.2.
The tank line from a balanced piston relief valve The pressure setting of a balanced piston relief valve
should be:
is determined by:
a. restricted to check operation of the valve.
a. the bias spring in the main stage.
b. smaller in size than the pressure line.
b. spring tension on the pilot poppet.
c. plumbed directly to tank with no restrictions.
c. the size of the mainstage piston.
d. connected to the downstream port of an "in
d. the pressure capability of the pump.
line" valve.
e. the size of the orifice in the pilot stage.
e. plugged if not needed.
IHM Manual # 402 - 01/00
Task 23.0
Outcome 23.1.
Outcome 23.2.
Replace the shaft seal in a vane pump.

Recognizes the causes of shaft seal failure.
Knows the proper procedure to install a shaft seal in a housing.
Replacing a leaking shaft (front) seal in a hydraulic vane pump is both simple and inexpensive. The primary
considerations are to keep contaminants from entering the system, and replace the faulty seal without damaging the
pump. Just because the pump seal leaks does not mean the seal is at fault. A loose bearing, for example, can
prevent a seal from maintaining the proper contact, causing it to leak. When the seal is changed, the bearing
must be checked for side-play that would allow the shaft to wobble and distort the seal. It also is necessary to
replace the static seals (if present) to prevent the bearing retainer from leaking.
Seals are normally press fit in the housings around their outer perimeter. This provides a static seal between
the rigid body of the seal and the case. The inner lip of shaft seals is flexible and faces the pressure. Installed
in this position, fluid pressure acts against the seal, forcing it against the rotating member. Lip seals will seal
only if the lip faces the pressure.
To replace a shaft seal, wipe the recess clean with a lint-free shop towel, lubricate the outer face of the seal,
and drive it into the recess. Be sure the seal lip faces the bearing. To prevent damage to the seal and housing,
be sure to use a driver with an outside diameter size just under the outside diameter of the seal. Drive the seal
square with the housing until it bottoms in the recess. Lubricate the seal lip, and replace the shaft and bearing.
Install the bearing retainer, if one is used. Some seals may not have a lip. In this case, manufacturer's instructions
for direction of seal installation must be followed.
Figure 24 provides an illustration of vane pump components, including the shaft seal.
Body
Shaft Seal
Shaft Bearing
Retaining Ring
Spirolox Ring
Back-up Ring
Retainer
Key
Shaft
O-Ring
Sealing Ring
O-Ring
Cover
Rotor
Pin
Pressure Plate
Bolt
Ring
Screw
Vane Kit
Wear Plate
Fig. 24. Balanced Vane Pump (Courtesy of Eaton Corporation)
IHM Manual # 402 - 01/00
Review: 23.1.
Review: 23.2.
A leaking shaft seal in a vane pump could mean that the: A shaft seal installed with the single lip facing out will:
a. pump outlet pressure is too high.
a. wear the shaft.
b. shaft bearing is worn out.
b. blow out.
c. splines on shaft are worn out.
c. work fine.
d. case bolts were improperly torqued.
d. leak.
e. seal is not receiving lubrication.
e. wear out prematurely.
IHM Manual # 402 - 01/00
Task 24.0
Outcome 24.1.
Outcome 24.2.
Drain and recharge a piston accumulator.

Recognizes problems with a piston accumulator
and their symptoms.
Knows which gas is used to charge an accumulator.
A gas charged piston accumulator consists of a free floating piston in a precision bore cylinder that separates
the charge gas from the hydraulic fluid. The piston seal consists of packings or piston rings. The end caps are
attached to the cylinder by threads, lock rings, tie rods or, in some cases, they are welded.
NOTE: before charging make sure all pressure is bled.

Gas charged piston accumulators require recharging from time to time because the charge gas leaks past the
close fitting piston or out through the charge valve. As the piston seals wear, leakage increases, requiring more
frequent recharging.
Terminology pertaining to gas charged accumulators which must be understood includes the following:
Minimum system pressure - the lowest working pressure at which the system can accomplish
the work.
Maximum available pressure - is the pressure setting of the relief valve.
Precharge pressure - the pressure of the nitrogen charge gas in the accumulator when the
fluid has been discharged.
Charge gas is an inert gas, typically dry nitrogen, which is used to charge the accumulator.
The appropriate procedure for recharging a piston accumulator includes the following steps:
Safety precaution - Safety goggles must be worn at all times.
External leaks must be stopped before recharging the accumulator.
The precharge gas must be released before the accumulator is recharged.
If liquid is present with the precharge gas from a piston type accumulator, it
indicates fluid is by-passing the piston seal. Seals should be replaced before recharging.
Drain any fluid present on the gas side of the piston on piston type accumulators.
This can be accomplished either by removing the accumulator or syphoning. If oil
is present, it is important to know if it is from slight or severe leakage. This can
be determined by examining service records.
Precharge the accumulator by cracking the valve on the nitrogen bottle. Bring the charge
up slowly to prevent bottoming the piston rapidly.
Record the precharge pressure and charge (system) pressure for the application.
IHM Manual # 402 - 01/00
Gas Valve
Aux. Port for gauge,

pressure switch or relief
valve.
Split Shear Ring

O Ring
Set Screw
End Cap
Stop Tube
Wear Ring
Steel Tube
O Ring
Aluminum Piston
Piston Poppet
Spring
Poppet
Seal
Poppet Retaining
Ring
Poppet Seal
O Ring
Cushing Retainer
Screw
Poppet Seal
Cushion Retainer
Steel End Head

Discharge Port
Fig. 25. Piston Type Accumulator (Courtesy of Chicago Fluid Power Corp.)
Follow manufacturers guidelines for charging & recharging

Refer to Task 5.0 to study bladder type accumulators.
Review: 24.1.
If fluid is found on the gas side of a piston type accumulator:
a. the charge valve is leaking.
b.
c.
d.
e.
system operating pressure is too high.

the piston seals are leaking.
a larger accumulator is necessary.
the accumulator does not need service.
IHM Manual # 402 - 01/00
Task 25.0
Outcome 25.1.
Outcome 25.2.
Set the pressure on a hi-low double pump.

Understands how a hi-low pump system works.
Calculates hydraulic horsepower delivered by a
hi-low pump at different pressures.
A hi-low double pump system provides a high volume flow at low pressure and low volume flow at high
pressure. These pump units are used to advance and retract workpieces quickly at low pressure, followed by a
high pressure, low volume cycle to do work. Since the power required is the product of pressure and flow, a
hi-low circuit allows components and drive motors to be kept small which increases operating efficiency by
sizing the system to load requirements.
Consider the following system at 100% efficiency. In a typical system, such as shown in Figure 26, a double
pump might provide 50 gpm from two pumps; one a 45 gpm low pressure pump, and the other a 5 gpm high
pressure, low flow pump. At pressures below 500 psi both pumps deliver full flow. At pressures between 500
psi and relief valve pressure, flow is checked between the pumps, the high pressure pump operates an unloading
valve to dump flow from the low pressure high volume pump, and flow from the high pressure pump completes the
work portion of the cycle. If the pressure rises above the relief valve setting, the pressure relief valve dumps
the remaining flow to reservoir.
The unloading valve is sized to handle the flow from the low pressure pump while the main relief valve is
sized to handle the flow from the high pressure pump. The unloading valve opens before the main
pressure relief valve opens because they are set at two different pressures.
Animation
1500 PSI
To set a hi-low circuit, insert a pressure

gauge in the line leading from each pump. That
will place one pressure gauge on each side of the
flow check valve. There must be some means
available to increase the resistance to flow in
the main line downstream of the system pressure
relief valve (with the pressure relief valve still
in the circuit to protect the high pressure pump).
The line can be restricted with a test valve that
closes off the flow. Basically, the procedure
restricts the line leading to the actuator while
both pressure gauges are observed.
The control of a hi-low circuit is a pressure
sensitive relationship - this means that the
resistance offered by the circuit determines
when flow from the low pressure pump will be
unloaded and limit the fluid power output.
500 PSI
M
The maximum fluid power output from a
hi-low circuit is reached when the product of
the pressure and flow is at the highest value.
That is:
Fig. 26. Hydraulic Hi-Low Pump Circuit
IHM Manual # 402 - 01/00

Q
HP = P
1714
Flow Rate (gpm)

1714
(Eq. 6)
As an example, consider the following system: A hi-low circuit with a combined flow from a double pump
of 36 gpm unloads when the 30 gpm low pressure pump reaches 450 psi. If the main pressure relief valve is
set at 1500 psi, what is the maximum fluid horsepower available from the circuit?
The fluid horsepower developed during the low pressure portion of the cycle is:
Fluid HP = (450 x 36) / 1714 = 9.45 HP
And the fluid horsepower developed during the high pressure portion of the cycle is:
Fluid HP = (1500 x 6) / 1714 = 5.25 HP
Thus the maximum fluid horsepower is developed during the low pressure portion of the cycle.
Calculate
Review: 25.2.
Review: 25.1.
The high pressure relief valve in a hi-low double A hi-low pump circuit incorporates a 20 gpm pump
which unloads at 1000 psi and a 10 gpm pump which
pump system must be sized to handle:
is relieved at 2500 psi. What is the maximum fluid
a. the combined flow of both pumps.
b. the flow from the high pressure pump.
horsepower delivered?
c. the flow from the low pressure pump.
a. 17.5 HP
b. 11.7 HP
d. 150% of the combined flow.
c. 14.6 HP
e. 50% of the combined flow.
d. 43.8 HP
e. 5.8 HP
IHM Manual # 402 - 01/00
MAJOR REPAIRS
Major repairs consist of bench work that requires inspection and replacement of defective parts when a
used unit is overhauled. It also includes adjustment, installation, and testing to ensure that the unit operates
properly. In a typical application, a rebuild kit is installed to replace the worn parts in a unit, eliminating the
need for machine work. A number of components are overhauled, including pumps, motors, cylinders, and
even hydraulic tools.
Task 26.0
Outcome 26.1.
Outcome 26.2.
Overhaul a pressure balanced, fixed displacement vane pump.

Understands how a vane pump is balanced for pressure.
Knows how to reverse the direction of rotation of a
balanced vane pump.
Hydraulic vane pumps are used in both mobile and industrial applications. Fixed displacement pumps are
pressure balanced with an elliptic cam ring to reduce shaft side loads and extend the life of the unit. This provides
two inlet and two outlet chambers in the pumping unit. These pumps are assembled for a specific direction of
rotation. The pump can be assembled to operate with either direction of shaft rotation.
Most balanced vane pumps utilize a cartridge design. All parts of the pumping unit (vanes, rotor, cam ring,
and port plates) make up the cartridge. The manner in which the cartridge is assembled dictates the shaft rotation of
the pump. Other than checking the input shaft and bearing for wear and replacing the shaft seal, these pumps
are overhauled by simply replacing the cartridge and case seal ring.
When installing a new cartridge, the displacement or size of the new cartridge must be the same as the old
cartridge. Most balanced vane pumps accept more than one size cartridge. Although the physical external
dimensions of the various cartridges are the same within a family (frame size) of pumps, the internal pumping
geometry varies, changing the displacement.
Rotation must also be checked. Generally the direction of rotation will be stamped with an arrow on the
cam ring. To reverse the direction of rotation, the cam ring is turned over which also rotates the pumping chambers
90 degrees and the rotor/vane assembly is reversed on the pump shaft.
When reassembling the pump, care should be taken when installing all seals, bearings, and O-rings. Case
bolts must be uniformly torqued to the proper specifications. The input shaft of a balanced vane pump should
be able to be turned by hand if the pump is
Rotation
properly assembled.
Cam Ring
Rotation
Inlet
Vane
Animation
Unbalance Pump
Outlet
Inlet
Outlet
Rotor
Drive Shaft
Inlet
Opposing pressure
ports cancel side
loads on shaft.
Animation
Balance Pump
Fig. 27. Balanced Vane Pump (Courtesy of Eaton Corporation)

IHM Manual # 402 - 01/00
Review: 26.1.
Review: 26.2.
A single cartridge fixed displacement balanced vane To successfully reverse the direction of rotation of
pump:
most balanced vane pumps, one must:
a. uses an elliptical cam ring.
a. turn the input shaft around.
b. uses a round cam ring.
b. move the suction and pressure ports in the
c. cannot be overhauled.
housing.
d. has four pumping chambers.
c. rotate the cartridge 90 in the housing.
e. has one suction and two pressure ports.
d. reverse the direction of the electric motor.
e. flip the rotor/vane assembly and the cam ring.
IHM Manual # 402 - 01/00

Animation
Task 27.0
Install a rebuild kit in a fixed displacement, axial piston,

swash plate pump.
Recognizes causes of internal leakage in an axial piston pump.
Solves equations for flow, displacement, speed, and
volumetric efficiency.
Outcome 27.1.
Outcome 27.2.
Spring Force Transmitting Pin
In an in-line (axial) piston pump,

the shaft and cylinder block share a
common centerline. Reciprocation
of the pistons is caused by a swash
plate that the piston shoes run
against as the cylinder block rotates.
The driveshaft turns the cylinder
block which carries the pistons
around the shaft. The piston shoes
slide against the swash plate and are
held against it by the shoe retainer
plate. The angle of the swash plate
causes the cylinders to reciprocate in
their bores.
Shoe Retainer Plate

(retracts Piston)
Swashplate
Cylinder Block
Spring
Valve Plate
Spherical Washer
Cylinder
Piston
Shoe
Block
Fig. 28. Axial Piston Pump (Courtesy of Eaton Corporation)
The first objective is to determine

if a used pump is in need of being rebuilt. Pump wear will be evidenced by decreased output flow under load
and possibly increased noise emission. If specifications for pump displacement or output flow are not available, it
is helpful to be able to calculate pump displacement. For axial piston pumps, the displacement is proportional
to the area of the bore, the number of cylinders, and the stroke, such that,
Dis placement (CID) = b ore area (in.
) s troke (in. ) no. of cyl inders
(Eq. 7)
D = A S N umber of Cylinders
where the bore diameter and stroke are in inches, and the pump displacement will be in cubic inches per revolution
(CID). The following equation is used to calculate bore area.
2
Area (pis ton) (in. ) = (radius (in. ))
A = (r)
= d . 7854
(Eq. 8)
Note: radius = Piston Bore / 2

An example of this calculation follows:
What is the displacement of an axial piston pump having a 9 piston cylinder group, with
each having a 0.375 in. bore and a 0.250 in. stroke?
Area (in.2) = p x (.375 in. / 2)2 = 0.1104 in.2
Displacement (CID) = 0.1104 in.2 x .250 in. x 9 = 0.249 cubic inches/rev
IHM Manual # 402 - 01/00
The expected (or theoretical) flow rate from a pump can be calculated if the displacement (CID) and shaft
speed (rpm) are known. See Task 14.0 to review the equation used to calculate flow rate.
If an axial piston pump is not delivering fluid flow within specifications, check the fluid level, suction line
(and filter) and pump shaft coupling first. Problems in these areas may have other visible or audible signs, but
rebuilding a pump will yield little benefit if the suction filter is blocked.
All internal components of the pump must be carefully evaluated. In addition to examining bearings and
the pump shaft, look for evidence of wear on the swash plate, piston slippers, pistons, cylinder bores, valve
plate (if used) between the cylinder barrel and the pump cover, and the pump cover itself. Some pumps use
changeable valve and port plates between the cylinder barrel and pump cover. These parts have a lapped fit.
Small amounts of wear or grooving can cause large losses in volumetric efficiency (reduced flow) in the pump.
Worn parts, including bearings and seals should be replaced. Overhauling typically involves replacing the
cylinder block assembly, including pistons, and sometimes the swash plate and valve plate(s) if one is used.
Assembly procedures vary. The manufacturer's procedures should be closely followed. All piston pumps have
little tolerance for contamination. Cleanliness is of the utmost importance.
Calculate
Review: 27.2.
Review: 27.1.
The output flow of a fixed displacement axial piston The theoretical output flow of a 1.5 CID pump operating at 1750 rpm is:
pump will decline if:
a. 26.25 gpm.
a. the pistons become scored.
b. 11.36 gpm.
b. the shaft seal leaks.
c. 2.62 gpm.
c. the valve plate becomes grooved.
d. 1.14 gpm.
d. the shaft bearing wears slightly.
e. Not enough information given.
e. both (a) and (c) are correct.
IHM Manual # 402 - 01/00

Saddle
Task 28.0
Outcome 28.1.
Adjusting
Screw Sleeve,
Plunger
Single Piston,
Pump
Ram
O-Ring
Top Cap
Cylinder
tube
Overhaul a hand operated hydraulic jack.

Solves basic equations in the relationship among force, area,
and pressure.
Pump
Assembly
Pump
Reservoir
Ring
Cup
Washer
Nut
Beam
Oil
Level
Link
Pin
A hand operated single-acting hydraulic jack is

probably the simplest example of a hydraulic
system. It contains a piston pump driven by a
handle through a beam and linkage arrangement;
two check valves to direct the fluid from the
Handle,
reservoir into the pumping chamber and then out
Solid
again to the ram and a release valve to permit the
fluid to be drained from the ram directly back to the
Handle,
Hollow reservoir.
The pressure developed in a hydraulic jack is
proportional to the force and inversely proportional
to the plunger cylinder area such that:
Beam
Pin
Link
Release valve
Plug
Gasket
Ball
Spring
Pin
Groove
Base
Fig. 29. Hand Operated Hydraulic Jack
Pres sure (ps i) =
Force (lb. )
2
Area (in. )
P= F
A
or
(Eq. 9)
2
Force (lb .) = Pres s ure (ps i) Area (in. )
F= PA
where the force is in pounds and the area of the cylinder is in square inches.
As an example:
A hand operated hydraulic jack with a 1.5 in. diameter ram exerts a force of 5 tons. What is the pressure
in the cylinder tube?
Area (in.2) = ! x (1.5 in. / 2)2 = 1.767 in.2
Pressure (psi) = force (lb.) / area (in.2) = 10,000 / 1.767 = 5659 psi
Calculate
To overhaul a hydraulic jack the unit is disassembled, the parts are cleaned, and the seals are replaced.
Usually, hydraulic jacks are trouble free. However, overhaul is required after extended use if the jack has
become damaged or if the wrong fluid has been added to the reservoir, which softens and dissolves the seals.
Calculate
Review: 28.1.
A hydraulic jack is capable of exerting a force of 10
tons. A pressure gauge installed on the jack shows a
pressure of 2500 psi at full load. What diameter
(inches) is the cylinder ram?
IHM Manual # 402 - 01/00
a.
b.
c.
d.
e.
2.50 inches
0.40 inches
0.25 inches
3.19 inches
8 inches
Task 29.0
Outcome 29.1.
Outcome 29.2.
Overhaul a double-acting industrial cylinder.

Knows how to test a cylinder for leaking piston seals.
Describes the proper procedure to assemble an industrial
type tie-rod cylinder.
Industrial hydraulic cylinders are commonly rebuilt. This requires inspecting the assembly for damage,
replacing faulty parts with a rebuild kit, and assembling the cylinder. The critical steps in the task are: inspection of
the parts, lubrication and installation of the seals to face the pressure, and torquing the various threaded connections
when the cylinder is assembled.
Double-acting, single rod cylinders must seal against external leakage at three locations; where each end
cap joins the barrel and at the rod bushing. Internal seals prevent leakage past the piston and where the piston
attaches to the rod.
Hardened & Chromed
Plated Piston Rod
Piston Seals
End Cap
Ports
Rod Bushing
Cushion Plunger
Rod Wiper
Animation
Barrel Seals
Rod Seal
Rod End Cap
Floating Cushion Ring
Piston Assembly
Heavy Wall Seamless Steel Tubing
Fig. 30. Tie-Rod Industrial Cylinder
External leaks are obvious. Before replacing external seals, check for wear or damage which may have
caused the leak. Rod bushings wear. As they do, the seal becomes damaged. Excessively worn rod bushings
can cause other problems and should be replaced before installing a new rod seal.
Internal leakage may be checked by blocking one port completely and pressurizing the other port with the
cylinder at any position except fully extended. Regardless of which port is pressurized, the cylinder will
extend if an internal leak exists.
Installation of the seals and reassembly of the cylinder is critical. Lips of seals must face pressure. Square
capped cylinders should be assembled on a flat surface so that the caps and tie rods are straight. Tie rods must
be torqued uniformly.
Review: 29.2.
Review: 29.1.
The blind end cap of a cylinder is blocked. The rod Tie rod bolts:
end is pressurized. If the piston seals are leaking, the
a. must be properly torqued.
cylinder will:
b. don't require torquing.
a. retract.
c. are always Grade 5.
d. aren't used on industrial cylinders.
b. extend.
c. do nothing.
e. should be welded after tightening so as not
d. blow out the rod seal.
to vibrate loose.
e. chatter.
IHM Manual # 402 - 01/00
MINOR REPAIRS
Minor repairs include simple tasks that return the machinery to proper working order with a minimum of
downtime. The tasks are more complex than routine maintenance but less complicated than major repairs or
replacing components. Stopping leaks, resealing fittings, calibrating gauges, and such hand skills as removing a
broken cap screw are typical of the work performed under this job responsibility.
Task 30.0
Outcome 30.1.
Outcome 30.2.
Replace an O-ring on a straight thread fitting.

Understands the advantages of using straight thread O-ring
type fittings.
Distinguishes between static and dynamic seals.
S.A.E. straight thread hydraulic fittings are used to make reusable connections between tube and hose and
the machine components. They are leak-free and make the seal without forcing the fitting and machine member
together as is required with tapered thread fittings.
Fittings with straight threads are assembled by turning the locknut, back-up washer, and O-rings as far back
on the fitting as possible and lubricating the O-ring with system fluid. The fitting is threaded into the port until
the back-up washer just contacts the port boss. It can then be positioned by backing the fitting out up to one
turn. The mechanical stability and seal are made by holding the fitting with a wrench and tightening the locknut
to seal the back-up washer on the face of the port boss. The O-ring is thus squeezed into the counterbore
cavity to make a leak-free seal.
When changing the O-ring on a fitting,
remove the old O-ring from the fitting
using a special O-ring tool. Be careful not to
scratch the fitting. Clean the recess on the
fitting and counterbore in the machine
using a lint-free shop towel. Inspect the
O-ring recess on the fitting and counterbore
for sharp edges, nicks, or burrs. Remove
Fig. 31. Straight Thread O-Ring Hydraulic Fitting
imperfections on the fitting with a file and
imperfections in the counterbore with a scraper. Be sure to prevent filings and debris from entering the port.
After removing the imperfections, clean the counterbore with the lint-free shop towel.
Lubricate the new 900 series O-ring with system fluid. Care must be taken when installing the
O-ring over the fitting that it is not cut or twisted and that it seats properly. Plastic protection caps
installed over the fitting threads significantly reduce the possibility of O-ring damage during installation.
Review: 30.1.
Review: 30.2.
SAE Straight Thread O-ring fittings are preferred over A static seal is defined as a seal:
tapered thread fittings because:
a. designed to dissipate static electricity.
a. component housings aren't distorted.
b. between two moving parts.
b. angled fittings are easier to align.
c. between one stationary and one moving
c. o-rings are easily changed if damaged.
part.
d. large wrenches are not required to tighten
d. held in place by gravity.
the fittings.
e. between two stationary parts.
IHM Manual # 402 - 01/00
Task 31.0
Outcome 31.1.
Outcome 31.2.
Replace a directional control valve solenoid.

Recognizes solenoid coil failures and their symptoms.
Understands the operation of pilot operated directional
control valves.
Control valves that employ solenoids are used both directly and as pilot valves for larger flow two-stage valves.
AC solenoids fail because of high voltage, high in-rush currents, low voltage, and voltage surges caused by
locating the valves too close to other high current components, such as electric motors. Switching failures which
allow both solenoids to be simultaneously energized will cause solenoid failure. Failure also can be caused by
high cycle rates. A hydraulic directional control valve solenoid is replaced when it has burned out, shorted,
overheated, or buzzes with a 60 cycle hum (a.c. solenoids), indicating an insulation breakdown. Dry solenoids
may also fail due to dust and metal particles entering the solenoid.
Dynamic Seal
AIR GAP TYPE

Armature
Coil
Static Seal
Frame
Manual
Override
Hydraulic Fluid
It is necessary to determine
which solenoid is defective if a
three position valve is involved.
For an "open circuit" solenoid,
this can be done by disconnecting
one wire from each solenoid and
checking the resistance of each
coil with an ohm meter. Consult the
manufacturer's resistance chart for
the particular coil on the valve.
For a shorted coil, check between
both coil wires. Coils may also
short to ground.
WET ARMATURE TYPE

Match the solenoid assembly
and part number against the
Fig. 32. Air Gap and Wet Armature Solenoids
replacement. If the valve has two
solenoids, check the resistance to
be sure it approximately matches the other solenoid on the valve. Exercise care when replacing the solenoid,
clean all surfaces and avoid damage to solenoid leads.
Frame
Review: 31.1.
When connected to a volt-ohm meter, the electrical leads
of a solenoid show infinite resistance. The coil is:
a. shorted.
b. grounded.
c. new.
d. open.
e. none of the above.
Core Tube
Review: 31.2.
A pilot operated directional control valve fails to shift
when the switch is pushed to send power to one of the
solenoids. The problem may be the:
a. oil is too thick.
b. pressure is too high.
c. main spool is stuck.
d. pilot drain line is open.
e. main stage spool is in backward.
IHM Manual # 402 - 01/00
Task 32.0
Outcome 32.1.
Outcome 32.2.
Seal a hydraulic pipe fitting with sealing tape.

Understands the difference between NPT and NPTF thread
forms.
Knows how to apply sealing tape to a tapered thread fitting.
Tapered thread pipe systems leak. They also have other disadvantages. Positioning fittings is
difficult to do without over- or under-torquing pipe joints. Pipe wrenches also leave marks. Fittings are tightened to
make a proper seal by wedging the tapered pipe thread in the recess of the fitting or machine component. This
deforms the external thread and may break the recessed fitting. Tape or sealant is used to seal pipe threads.
Typically this works well as long as the machine is not subjected to shock or vibration, which can loosen the
fittings and cause them to leak.
With all the disadvantages, there still are many pipe systems around, and these must either be replaced with
tubing or the threaded fittings must be resealed periodically. The pupose of this procedure is to learn the proper way
to reseal these fittings without damaging or contaminating the system.
Threaded hydraulic pipe uses two types of pipe threads: National or American Standard Taper Pipe Thread
(NPT) and The Dryseal American National Standard Taper Pipe Thread (NPTF). The NPTF thread was used
originally for fuel service. Both pipe threads are interchangeable; the difference is that NPT threads are rounded so
they have no contact at the crown and root. NPTF is preferred as it reduces spiral leakage at the fitting.
Spiral leakage may also be minimized or eliminated by using sealing tape on the threads. When applying
sealing tape, start two threads back from the end, and wrap the exposed threads of the pipe with approximately one
and a half turns of sealing tape. The tape will be wrapped with the direction and cut of the threads. Separate the
tape by holding fast on the threads with one hand and pulling the tape spool away with the other. Apply pressure
with the fingers pushing the tape into the threads. Be sure the tape does not slip or cover the first two threads.
This will ensure that the tape does not get pulled into the system.
Caution should be used to make sure female port is clean when reassembling.
Tape or thread sealer on this area only
Movie
Direction of wrap
Sealing Tape
Fig. 33. Sealing Tapered Thread Fittings
Review: 32.1.
Review: 32.2.
When installing sealing tape on a tapered thread fitting: The "F" in the NPTF thread designation stands for:
a. overlap the tape over the end of the fittings.
a. fuel.
b. start right at the end of the threads.
b. fire.
c. start two threads back from the end.
c. free.
d. start half way up the threads.
d. fitting.
e. wrap the tape opposite of the direction of
e. fast.
the threads.
IHM Manual # 402 - 01/00
Task 33.0
Outcome 33.1.
Outcome 33.2.
Pump Inlet Line

(option)
Animation
Maintain a hydraulic reservoir.

Knows the functions of the reservoir.
Understands the differences between vented and pressurized
reservoirs.
Riser (option)
Drain Return
Return Line
Air Filler/Filter/
Breather
Sealed Flange
Drain Plug
Clean Out Plate
Strainer Baffle Plate)
(Both Ends)
Thermometer and
Sight Glass
End Plate
Extention
The purpose of the hydraulic reservoir is to

supply fluid to replace system leakage, store
excess fluid when system volume changes, help
cool the fluid, and separate contaminants and air
from the fluid.
There are two types of reservoirs: vented and
pressurized. Vented reservoirs are open to the
atmosphere. Pressurized reservoirs offer advantages
over vented reservoirs in that contaminants and
condensation are reduced, and pressure within the
reservoir helps force fluid into the pump inlet.
One of the most criticized problems experienced

with hydraulic systems is leakage. Leaks occur at
both static and dynamic seals. The reservoir has a
Fig. 34. Industrial Hydraulic Reservoir (Courtesy of Eaton Corporation)
number of static seals and is no exception when it
comes to leaks. Reservoir drain plugs and clean-out covers may require periodic resealing. Most standard
clean-out covers come equipped with a replaceable off-the-shelf gasket made of neoprene impregnated cork or
a synthetic rubber, depending on the style of the reservoir cover.
Additional maintenance tasks associated with the reservoir such as adding fluid and maintaining filters are
covered separately. See Preventive Maintenance and Fluid Filtration and Maintenance sections for further study.
Review: 33.1.
A hydraulic reservoir should be:
a. mounted far from the pump.
b. filled completely to the top.
c. equipped with a cooler.
d. painted on the side.
e. equipped with a clean-out cover.
Review: 33.2.
Pressurized reservoirs:
a. experience more condensation.
b. help deliver fluid to the pump inlet.
c. must be mounted above the pump.
d. use the same schematic symbol as a
vented reservoir.
e. allow more contaminants into the fluid.
IHM Manual # 402 - 01/00
REPLACE COMPONENTS AND FLUIDS

"Replace components" means to exchange one component for another, including scheduled and unscheduled
exchange of fluids and components on a fluid power system using approved procedures and without damaging
the machine. The essence of the job responsibility is to replace faulty components using change-out procedures.
For example, replace a hydraulic pump and align the coupling.
Task 34.0
Outcome 34.1.
Outcome 34.2.
Drain, flush, and replace hydraulic fluid.

Understands fluid properties and how they affect
system operation.
Recognizes the importance of and reasons for
additives to the fluid.
The hydraulic fluid is considered to be the "lifeblood" of the system. This means the composition of the fluid,
including contaminants, is the best indicator of system condition. Draining, flushing, and replacing the hydraulic fluid
is common, particularly for new machinery put into service, when there has been a pump failure, or when one type of
fluid is replaced with another. Cleanliness is important when changing the fluid and cleaning the system so as not to
introduce additional contamination. Sealing the reservoir properly also is important for leak prevention.
Most hydraulic equipment manufacturers issue a fluid recommendation list for use in their equipment. This
list states the specifications for fluid used in the system. Next to using the correct type of fluid, fluid viscosity
is the most important consideration. The additive package, including anti-wear, anti-oxidation, viscosity index
improver additives also must be considered. The manufacturer typically specifies the fluid cleanliness level that
should be maintained.
When draining, flushing, and replacing fluid, a few simple guidelines must be followed:
Always transfer fluid using a filter cart.

Ensure that the reservoir is cleaned and filters are changed.
Flush the system if necessary to remove severely contaminated fluid from the
lines and components.
Use flushing blocks to bypass sensitive components when restarting.
Use high quality fluids which meet the manufacturer's specifications.
Operate the system at no load or reduced load until the fluid has circulated
several times through the circuit.
Check filter condition soon after start-up and at short intervals thereafter.
Observe appropriate safety precautions.
For further study, review Tasks 1.0, 2.0, 3.0, 8.0, 9.0, 13.0, and 33.0.
Review: 34.1.
Review: 34.2.
The most important property of a hydraulic fluid is its: Which of the following is considered an additive?
a. viscosity index.
a. Pour point
b. pour point.
b. Base stock
c. color.
c. Oxidation inhibitor
d. specific gravity.
d. Flash point
e. viscosity/lubricity.
e. Viscosity
IHM Manual # 402 - 01/00
Task 35.0
Outcome 35.1.
Outcome 35.2.
Replace a hydraulic pump and align the coupling.

Knows the reasons why couplings must be
carefully aligned.
Understands coupler alignment terminology and how
to check for misalignment.
Each time a pump is replaced, the coupling must be aligned. If the replacement pump is of the same type and
size as the original, the task consists of setting the angular and offset alignment, and then tightening the assembly with
the pump and coupling in position. If a different pump is installed, then the pump is mounted first, followed by
mounting of the prime mover. This requires that the pump be bolted in a rigid position as close to the base as
possible, with alignment of the prime mover made using shims under the base to set the proper height.
Correct shaft alignment is important. Pump-and-drive-unit shafts must be concentric to within specified
tolerances to prevent unusual end loads from being transmitted to pump and drive-unit bearings. No end thrust
or push-pull action on the pump shaft must be allowed. This means that coupling halves must be mated so the
coupling does not wedge the pump and drive it apart.
Offset misalignment concerns the pump shaft being higher, lower, or to one side with respect to the prime
mover shaft, with the two shafts aligning axially. They are aligned in one plane. Offset is checked by measuring
the run out between the coupling rims.
Shafts Misaligned Axially And

Shafts Aligned Angularly But
Angularly
Misaligned Axially
Fig. 35. Axial and Angular Misalignment
Animation
IHM Manual # 402 - 01/00
End Cap
Thickness Gauge
Angular misalignment concerns the pump and motor shaft

pointing in different directions axially. That is, they do not
align in either plane. Angular offset is checked by measuring
the distance between the coupling faces in two or more
places.
When a pump is first installed, pumping cavities are
filled with air. This air must be expelled before the pump can
perform properly. Oil must be drawn into the cavities to replace
the air. This is called "pump priming." Pumps should be
primed manually before starting.
Dial Indicator
3-5 Thousand Alignment

with Finger Gauge
Straight Edge
When pump installation and alignment is complete, and

after the pump case is filled (if appropriate), the electric motor
should be "jogged" to check for pump priming and previously unobserved problems. Always start the pump with the
hydraluic load removed.
Motor Shaft
Machined Surface
Fig. 36. Methods of Checking Shaft Alignment
Review: 35.1.
Review: 35.2.
If the pump and motor shafts are axial misaligned, they When a pump has angular misalignment the pump:
are:
a. and motor shafts are still parallel.
a. at an angle to each other.
b. and motor shafts are touching.
b. parallel.
c. and motor shafts are too far apart.
c. too far apart.
d. and motor shafts don't align in any plane.
d. different sizes.
e. coupler will not go together.
e. uncoupled.
IHM Manual # 402 - 01/00
Task 36.0
Determine specifications from a component code

breakdown.
Reads model number and a catalog description to
determine important component specifications.
Calculates flow rate for a pump given displacement
and speed information.
Outcome 36.1.
Outcome 36.2.
Components are ordered from manufacturers using code specifications. This means that to order the component,
certain information about its size and operational characteristics are necessary. These same code specifications
are given both in the manufacturer's catalog and on the identification tags of respective components. If a
component of unknown specifications is given, along with the manufacturer's name, the mechanic can determine
the specifications of the component by breaking down the code and then finding the respective numbers and
letters in the manufacturer's catalog literature. Each manufacturer has a particular way of assembling the code.
To become proficient in ordering new or replacement components and identifying existing components on a
machine, some familiarity with several manufacturers' literature is necessary.
A code breakdown identifies components by style, size, pressure rating, and optional features. Both letters
and numbers are used in the component code.
237
15
Displacement Code
Pump Type Series
Mounting - SAE B (2) Bolt
Porting - Standard Cover - (Code I)
1-5/8 -12 Inlet, 1-5/16 -12 Outlet, Str. Thd., Side Porting
Flow Divider Cover - (Code I)
1-5/8 Inlet, 3/4-16 Priority, 7/8-14 Sec., Str. Thd., Side Porting
Shaft - 7/8 Dia. SAE B Spline, 1-3/4 extention (Code A)
1 Dia. 1/4 Key Shaft 2.50 extension (Code B)
1 Dia. SAE BB Spline, 1-3/4 extension (Code D)
Flow divider
Code
1=
2=
3=
4=
priority flow - (Code

Flow
Code
2GPM
5=
4GPM
6=
6GPM
7=
8GPM
X = No Flow Divider
Flow
Code
10GPM 8=
12GPM 9=
14GPM 10=
- Standard Cover)
Flow
16GPM
18GPM
20GPM
Rotation (Viewed from Shaft End) Clockwise Right Hand Rotation (Code R)
Counterclockwise Left Hand Rotation (Code L)
Note: This ordering code applies to dual or triple models with respective
modifications for each. For example:
Dual without flow divider
Triple with flow divider
237B8BX/237KXIXX-L
237KB8BX/237KX8BX/237KXIB6-L06
Pumps are often sized from horsepower

requirements, given the pump speed from the
operating range of the prime mover and the
pressure limitations of system components.
Pump type (gear, vane, piston, etc.) is selected
from size, weight, precision, tolerance for
contaminants, and cost considerations. The
need for fixed or variable displacement also
influences the choice of pumps.
When matching a pump to an electric motor,
one must be assured that the motor is adequately
sized. Fluid horsepower must be calculated to
do this. The fluid horsepower of a pump is
proportional to the pressure and flow rate such that:
Fig. 37. Typical Hydraulic Pump Model Code Breakdown
Flow Rate (gpm)

1714
Q
(Eq. 6)
HP = P
1714
The displacement of a hydraulic pump is proportional to the flow rate and inversely proportional to the speed
such that:
Di s placement (CID) = Flow Rate (gpm)
231
S haft S peed (rpm)
Equation 2 (Rewritten)
IHM Manual # 402 - 01/00
Calculate
Review: 36.1.
Review: 36.2.
Which of the following is a specification usually indicated A pump must produce 20 gpm at 1750 rpm.
by a pump model number?
displacement is:
a. Weight
a. 0.01 CID.
b. Overall length
b. 0.38 CID.
c. Shaft rotation
c. 2.64 CID.
d. Compensator length
d. 4.62 CID.
e. Paint color
e. 20.00 CID.
IHM Manual # 402 - 01/00
Its
Task 37.0
Outcome 37.1.
Replace a hydraulic V-packing.

Knows how to install and adjust V-packings for
proper operation.
"Compression" or V-packings consist of a minimum of three seals, with the maximum number determined
by pressure, temperature, and operating conditions. V-packings are installed in packing glands or cases that hold
them together as an assembly.
Cylinder rod V-packing assemblies are usually made to the correct length to have the proper squeeze when
they are assembled. When installed in packing glands to seal reciprocating piston rods or rotating shafts, provisions are often made to compensate for wear by tightening a gland nut or supporting flange. A major problem
with adjustable V-packings is over-tightening, which reduces the supply of controlled lubricaton and increases friction and shaft wear. In some installations, over-tightening of the gland nut, which would result in excessive
force, lack of necessary lubrication, high friction, and abnormal wear at the seal are avoided by substituting a
compensating spring of appropriate strength supported by the gland nut bottomed flush with the mounting surface.
Lead in champfer
Static surface finish 32 RMS

Dynamic surface
finish - 16 RMS
V-packings are installed with the open side, or lip,

facing system pressure. This allows the fluid under
pressure to push the lip against the mating surface to
form a tight seal.
One major advantage of V-packings is that dissimilar
but compatible seals of different materials may be used
in combination to offer the system the best available
pressure, wear, and friction service characteristics
associated with respective seals in the stack.
Shim
Gland should fit snugly against

packing. If necessary to prevent
crushing the rings use shims at
this point.
Fig. 38. Hydraulic V-Packing
On installations where pressure is exerted in both

directions, such as a double-acting cylinder, opposing
sets of packings should be installed so that the sealing
lips face away from each other. The female adapters
should be located adjacent to a fixed or rigid part of the
piston or gland so that no pressure loads will be
transmitted to the other set of rings.
Staggering of the joints of adjacent pairs of split rings 180 degrees is recommended. The next ring joint
should be 90 degrees from the first pair, and the fourth ring 180 degrees from the third, and so on.
Review: 37.1.
Failure to stagger the joints on adjacent rings in a Vpacking may lead to:
a. excessive shaft wear.
b. contaminant ingression.
c. seal wear.
d. over tightening.
e. leakage.
Review: 37.2.
The open side of a V-packing must face:
a. the gland.
b. out.
c. the lowest pressure in the system.
d. pressure.
e. the gland bolts.
IHM Manual # 402 - 01/00
Task 38.0
Outcome 38.1.
Outcome 38.2.
Replace a pipe system with a custom made tube

assembly.
Knows the reasons why tubing is preferred over pipe.
Understands how to fabricate a flared tube assembly.
Threaded pipe systems leak more often than tubing assemblies, in part because there are several more joints
in each assembly, and in part because 37 degree flare tube joints are better able to withstand machine vibration
without leaking than tapered pipe thread joints. Bendable tubing needs fewer fittings and no threading is
required. There are a number of other reasons why pipe assemblies are often replaced with tube assemblies, but
stopping leaks is a major reason.
Making up a tube assembly consists of preparing a layout drawing, taking accurate measurements, and then
bending, flaring, and assembling the two end joints.
Old Method - Each connection is
threaded - requires numerous
fittings - system not flexible or
easy to install and service.
Connections not smooth inside pockets obstruct flow.
Modern Method - Bendable

tubing needs fewer fittings - no
threading required - system light
and compact - easy to install and
service - no internal pockets or
obstructions to free flow.
Fig. 39. Major Advantages of Tubing Over Pipe
Tubing runs are designed to follow the

contour of the equipment in the system.
Tubes are aligned with the center line of the
fittings, without distortion, strain or stress.
Tubing is bent whenever possible to reduce
the number of fittings used in a tube assembly. Brackets or clamps must be used to support long runs of tubing.
Important steps of flaring tubing include
making sure the ends are cut square and
deburred. The flare must be of proper size.
Always remember to install the nut and
sleeve on the tube before flaring.
Review Task 19.0 for further study.
Animation
Maximum Flare Length

Minimum Flare Length
Fig. 40. Proper Flare Length (Courtesy of Parker Hannifin)
Review: 38.1.
Review: 38.2.
A threaded pipe system which is replaced with a tubing Failure to debur tubing prior to flaring may result in:
system will have:
a. leakage.
a. more fittings.
b. a cracked nut.
b. less pressure capability.
c. interference with the threads on the nut.
c. fewer bends.
d. the tube pulling out.
d. more vibration.
e. enhanced sealing.
e. fewer leaks.
IHM Manual # 402 - 01/00

Case
Task 39.0
Outcome 39.1.
Replace a pressure gauge.

Understands how a Bourdon Tube gauge works
and where it is most accurate.
Knows how to properly install a pressure gauge.
Outcome 39.2.
Bourdon Tube
Animation
Movement
Dial
Connection
Link
The bourdon tube pressure gauge is the simplest and

least expensive monitoring device used, and for these
reasons nearly every hydraulic system comes so
equipped. Pressure gauges are sized to operate in their
mid-range at system operating pressure, and they are
protected by the pressure relief valve for the system.
Their most common use is in setting the relief valve
pressure (which limits the maximum load or force the
machine can handle), and protecting the system from
over pressure. Replacing the pressure gauge is a common
practice when the gauge is re-calibrated, damaged, or
the system is refitted to operate at a new pressure.
Gauges are selected with the proper bourdon tube

metal and joint metal for the particular application.
Standard range gauges are selected with graduations to
Fig. 41. Bourdon Tube Pressure Gauge
approximately double the average working pressure.
This assures reserve strength to make the gauge last longer, and the pointer will be easier to read at about top
center of the dial. Bourdon tube gauges also are most accurate in the center half of the scale.
Dial Pin
Process Connection
Applying force to the gauge case will twist the gauge and render it inaccurate or inoperative. Always use a
wrench on the socket pipe flats or square shank to torque the gauge in place. Gauges are precision instruments
and must be treated accordingly. Dropping or hitting a gauge can cause calibration shift.
The most likely source of damage to a properly sized pressure gauge is shockloading, which will destroy the
gear mechanism if the gauge is not dampened. Most gauges are glycerine filled to dampen the needle.
Review: 39.1.
A pressure gauge is most accurate when reading:
a. close to zero.
b. at about 1/4 scale.
c. at about 1/2 scale.
d. at about 3/4 scale.
e. close to full scale.
Review: 39.2.
Gauges are tightened:
a. by turning the case by hand.
b. using a wrench on the flats at the base.
c. with a pipe wrench.
d. by turning the case with a wrench.
e. tighter than any other fitting.
IHM Manual # 402 - 01/00
Task 40.0
Outcome 40.1.
Outcome 40.2.
Identify components from a circuit diagram.

Distinguishes between graphic, pictorial and
cutaway drawings.
Identifies components from a graphic circuit schematic.
There are three types of fluid power drawings: pictorial,
cutaway, and graphic symbol diagrams. These three types of
representation for components and circuits are used to communicate
how the fluid power circuit is constructed and operates. The most
common symbols are the standard graphic symbols.
Graphic symbols show connections, flow paths, and functions
of components represented. They can indicate conditions occurring
during transition from one flow path arrangement to another.
Symbols do not indicate construction, nor do they indicate values,
such as pressure, flow rate, and other component settings.
Pictorial diagrams show the general location, function and
appearance of parts and assemblies through component drawings.
Cutaway diagrams show in more detail the positions of parts
and assemblies for components and how they operate in a circuit.
Their use is limited to individual components.
Fig. 42. Simple Hydraulic Circuit Diagram
To identify components in a circuit diagram, each basic symbol

must be recognized. This requires some memorization of the symbols.
Once understood, however, the symbols lead to an understanding
about how each component functions, how the fluid power system
operates, and how components interact with each other.
Review: 40.1.
Which is the most common system used to show
information regarding component and circuit operation?
a. Pictorial drawings
b. Cutaway
c. Graphic symbols
d. Manufacturing prints
e. Isometric diagram
Review: 40.2.
The symbol shown is a:
a. directional valve.
b. pump.
c. motor.
d. pressure relief valve.
e. accumulator.
Animation Symbols
Animation Circuit
IHM Manual # 402 - 01/00
Task 41.0
Outcome 41.1.
Outcome 41.2.
Replace and align a foot mounted hydraulic cylinder.

Understands cylinder mounting terminology.
Knows potential problems associated with
misaligning cylinders.
Replacing a worn hydraulic cylilnder is a common task. It consists of removing the cylinder,
identifying the cause of failure, comparing the specifications of the replacement cylinder to the existing one,
mounting the cylinder, and aligning it. Because foot mounted cylinders are mounted rigidly to the machine
member along one side or at one end, the load is not applied to the centerline of the cylinder. And if the rod end
of the cylinder is not supported, this can cause misalignment and side loading damage. Thus, an important step
of the replacement process is to determine if the cylilnder has failed from normal wear or has been subjected to
side loading. When the replacement cylinder is mounted, be sure the cylinder remains in alignment as it extends
and retracts.
When attaching machinery components or rod clevises, rod eyes and cylinder piston rods, the attachments
should be tightened to the specifications given by the manufacturer.
End Lug
Foot mounting secures the cylinder

along its side. Foot mounts are rigid,
requiring accurate cylinder alignment.
Since the mounting surface plane is not
centered directly on the line of force, the
mounting bolts are subjected to significant
shear stress. The cylinder should be pinned
or keyed to absorb the shear loads to allow
the mounting bolts to be subjected only to
tensile loading.
Side Lug Mounts
Integral
Key
Lugs, either welded onto the sides or

attached to the ends of the cylinder, are the
usual form of foot mounts. As an alternative
to the use of lugs, flush mounting incorporates
tapped mounting holes on the sides of the
blind and rod end.
Fig. 43. Foot Mounted Hydraulic Cylinders
Review: 41.1.
Foot mounted cylinders attach:
a. along their centerline.
b. with lugs along one side.
c. at the blind end.
d. with trunions.
e. with clevises.
Review: 41.2.
Flush mounted cylinders:
a. use an integral key.
b. are fastened on two sides of the cap.
c. have a threadedblind and rod end.
d. can't be mounted vertically.
e. align automatically when tightened.
IHM Manual # 402 - 01/00
Task 42.0
Outcome 42.1.
Outcome 42.2.
Charging Valve
Shell
Bladder
Poppet
Spring
Replace a hydropneumatic accumulator bladder.

Understands the function of accumulator components.
Knows proper procedures for accumulator service.
Hydropneumatic accumulators with replaceable bladders are used
throughout industry as auxiliary power sources, for leakage compensation,
thermal expansion compensation, emergency power sources, fluid
make-up devices, hydraulic shock absorbers, holding devices, transfer
barriers, and fluid dispensers. Periodically, the replaceable bladder
fails and must be replaced. This task requires removing the accumulator
from its mounting, disassembly and removal of the bladder for testing,
and then reassembly with a new bladder and pre-charging. Proper
procedures are required to ensure that the shell and bladder are not
damaged, and that the accumulator is restored to serviceable
condition.
Safety is an important part of working with accumulators.
Specific precautions include wearing safety goggles to
prevent eye injury and using only dry nitrogen to charge the
accumulator to prevent oxidation and deterioration.
Caution also must be exercised not to overcharge the

accumulator, (which can cause premature failure), or charging
Hydraulic Cap
it with compressed air, oxygen or other gases introduces the
possibility of an explosion.
Fig. 44. Bladder Type Accumulator
Overinflating a bladder outside of the accumulator shell may cause the bladder to fail. The bladder is
inspected by inflating it to normal size (3 psi maximum pressure) and checking the surface with a soapy
solution. Deflate immediately after testing.
Review: 42.1.
Review: 42.2.
A bladder is prevented from extruding into the Pressurizing a bladder outside of the shell:
hydraulic system by the:
a. should never be done.
a. foot or poppet valve.
b. will force any oil out of the bladder.
b. charging valve.
c. can be done with oxygen.
c. spring.
d. is done at very low pressures to check for
d. bleeddown orifice.
leaks.
e. hydraulic cap.
e. will damage the charge valve.
IHM Manual # 402 - 01/00
TROUBLESHOOTING
The purpose of this job responsibility is to find and fix the failure. What the troubleshooter does is focus
attention on the symptoms, formulate problem statements that account for these symptoms, and then follows a
procedure to identify the component or condition that is causing the problem.
Task 43.0
Outcome 43.1.
Outcome 43.2.
Determine why a cylinder fails to move the load when

the directional control valve is shifted.
Understands how pressurized fluid causes cylinder
movement.
Calculates cylinder extension and retraction forces
given dimensions and pressures.
Cylinders fail to move the load for a number of reasons. Obvious problems include broken or damaged fluid
lines and external leaks. Less obvious problems include faults with internal parts that require using a
troubleshooting procedure. Figure 45 demonstrates the Force-Pressure-Area relationship of hydraulic cylinders.
1. An input force of 10
lb. on a one square inch
piston...
10 lb.
1 sq. in.
INPUT
3. This pressure
will support a
100 lb. weight if
this is a 10 sq.
in. piston.
2. develops a pressure
of 10 pounds per square
inch (psi) throughout the
container
4. The forces are proportional

to the piston areas.
10 lb.
100 lb.
1 sq. in.
10 sq. in.
100 lb
If the cylinder fails to move when the directional

control valve is shifted:
Check the fluid pressure at cylinder. It may be
too low.
10 sq. in.
Make sure the load is not binding. Sometimes a

load can become cocked beause of misalignment
and bind the machine.
OUTPUT
Check to see if the piston is bypassing fluid.

Disconnect the return line from the cylinder to the
control valve to determine if fluid is bypassing the
piston or connect a flow meter in series with the
return line. Replace the seals if flow exceeds
more than a few cubic inches per minute.
Fig. 45. Simple Hydraulic Press (Courtesy of Eaton Corporation)
CAUTION: could possibly still move.

Determine if the cylinder is undersized for the load. Compute the force required to move the load. Multiply
operating pressure by the area of the cylinder. This value should exceed the value of the load by 25% or more.
Make sure the cylinder rod is not broken. This will require disconnecting the cylinder from the load or
disassembling the cylinder.
Check the cylinder bore. If the piston rings or seals are okay, and the cylinder still bypasses fluid past the
piston, check the cylinder bore for scoring and the static seal between the piston and cylinder rod for leakage.
Check the return line for a restriction. If the load will move with the return line to the directional control
valve disconnected, there may be a restriction in the return line. This could include a bent or pinched line.
IHM Manual # 402 - 01/00
On telescoping (double acting) cylinders, increasing the pressure to extend a cylinder with a blocked return
line can ruin the cylinder.
Calculate
Review: 43.1.
Review: 43.2.
The extension force of a 4" bore hydraulic cylinder To extend a single rod hydraulic cylinder, the fluid acts
with a 1 1/2" rod and 2000 psi oil is:
on the:
a. 2,546 lb.
a. entire piston area.
b. 6,283 lb.
b. rod area.
c. 8,000 lb.
c. rod end area (piston area minus rod area).
d. 25,140 lb.
d. combined rod and piston area.
e. 32,000 lb.
e. circumference of the cylinder.
IHM Manual # 402 - 01/00
Task 44.0
Outcome 44.1.
Outcome 44.2.
Outcome 44.3.
Check a hydraulic cylinder piston for bypass leakage.

Understands where cylinders must seal, both internally
and externally.
Recognizes the symptoms of cylinder leakage and how
to check for leakage.
Calculates cylinder velocity given cylinder dimensions
and flow rate information.
A hydraulic cylinder is a linear actuator. It reciprocates the load as the cylinder rod extends and retracts. In
a single rod cylinder, which is the typical arrangement, fluid is directed to the cap end of the piston to extend the
rod and to the rod end of the piston to retract the rod. Some bypass leakage is normal, particularly with industrial
cylinders that use metallic piston rings, but if the amount is excessive, the action of the cylinder to move the load
will be slow.
The symptom for a bypassing piston seal is local heat rise and "slow movement" or "no movement" of the
cylinder rod. However, these same symptoms can be caused by other problems.
"Slow movement" also can be caused by:
Dirty filter or reservoir vent

Oversize cylinder bore
Undersize pump
Incorrect flow settings
Restriction in the line
Directional control valve not shifting completely
Fluid viscosity too low (from selection or overheating)
Inappropriate circuit
"No movement" also can be caused by:
Load too great

Load binding
Cylinder undersized
Cylinder rod overextended (cocked)
Another symptom of a bypassing problem is "cylinder drifting." This can occur if:
The cylinder is supporting a vertical load (but if it drifts too much, the rod seal or control
valve must also allow fluid to by-pass).
Fluid is directed to both ports at the same time (a regenerative circuit).
To determine that a cylinder may be leaking or to make a determination of the expected velocity of a cylinder
given a flow rate and cylinder area, equation 10 is used.
Velocity ( sft.
ec. ) = Q (gpm)
. 3208
2
Area (in. )
(Eq. 10)
Note: The constant "0.3208" applies only when area is measured in square inches, flow rate is in gallons per
minute, and velocity is to be calculated in feet per second. Review Tasks 29.0 and 43.0 for further study.
IHM Manual # 402 - 01/00
Review: 44.1.
A single rod cylinder is suspected of piston leakage.
The cylinder is positioned at mid-stroke with no load.
The blind end port is blocked. The rod is pressurized.
If the piston seals leak, the cylinder will:
a. retract slowly.
b. blow the rod seal.
c. do nothing.
d. extend.
e. oscillate back and forth.
Calculate
Review: 44.3.
30 gpm is provided to a 6 inch bore cylinder at the cap
end of a cylinder. The cylinder should extend at a rate
of:
a. 0.34 in./sec.
b. 4.1 in./sec.
c.
5 in./sec.
d. 19.3 in./sec.
e. 245 in./sec.
Review: 44.2.
As pressure in the cylinder with metallic piston rings
increases, by-pass leakage pass the metallic piston ring
will:
a. stay the same.
b. increase.
c. decrease.
d. stop.
e. not enough information to tell.
IHM Manual # 402 - 01/00
Task 45.0
Outcome 45.1.
Outcome 45.2.
Check a hydraulic pump or motor for bypass leakage.

Recognizes the symptoms of bypass leakage.
Solves equations for displacement, speed, or
volumetric efficiency.
The symptom of bypass leakage in a positive displacement hydraulic pump or motor is low volume output
for a pump, and slow speed for a motor. All pumps and motors slip because they have clearance between the
close fitting parts. The problem is to determine how much slippage the unit has at system operating pressure
and temperature, and then to decide if this is acceptable.
By-pass leakage is defined as the fluid that passes the close fitting parts of the pump or motor as the unit
operates at system pressure and temperature. All positive displacement pumps have some internal slippage.
Gear and vane pumps typically have the most; piston pumps have the least.
Slippage and bypass leakage increases as the fluid temperature increases because the fluid thins as the
viscosity decreases, and "thinner" fluid passes more easily between the close fitting parts of the hydraulic pump
or motor.
Pump Displacement 4.63 in3/rev (76 ml/rev)
2200 rpm
Volumetric Efficiency
100
To determine the slippage and volumetric efficiency in

a hydraulic pump:
120F (50C)
Viscosity 25cSt
Find the displacement in the pump specifications.
98
96
Measure the drive speed of the prime mover.

Be sure the coupling between the prime mover and
hydraulic motor is not slipping.
200F (95C)
Viscosity 7cSt
94
92
1000
(70)
2000
(140)
3000
(210)
Calculate the theoretical flow rate from the pump in

gal/min from Equation 2:
4000
(280)
Pressure - psi (bar)

Fig. 46. Effect of Pressure and Viscosity on Pump Performance.
(Courtesy of Marcel Dekker, Inc.)
Theoretical Flow Rate (gpm) = Displacement (CID) x

Speed (rpm)/231
Or measure the speed of the hydraulic pump operating at low pressure to be sure the volumetric
efficiency is near 100%. Measure the actual gpm output from the pump with a flow meter. To keep
the pump at rated pressure, a pressure relief valve may have to be installed between the hydraulic
pump and the flow meter to raise the pressure at the pump.
Use the actual and theoretical flow from the pump to compute the bypass flow from Equation 11:
Bypas s flow (pump) (gpm) = Theoretical flow - Actual flow
Compute the volumetric efficiency from Equation 3:

Ev =
Q Act.
Q Theor.
Actual flow
Theoretical flo w
1 00
(Eq. 11)
(Eq. 3)
100
IHM Manual # 402 - 01/00
The process is the same for a motor except that the actual flow for a motor is higher than the theoretical flow
at a given speed. Therefore:
By pas s flow (motor) (gpm) = Input flow - U s able flow
Vo l. Effic. (%) (motor) =
Theor. flow
Actual flow
Actual S peed
100
) ( Theoretical
S peed )
or
Actual Flow (motor) (gpm) = Dis placement (CID)
S peed ( rpm)
231 Ev
(Eq. 12)
(Eq. 13)
(Eq. 14)
Review Tasks 26.0 and 27.0 for further study.
Calculate
Review: 45.1.
A 2.0 CID pump turning at 1800 rpm should
theoretically deliver:
a. 2.0 gpm.
b. 3.6 gpm.
c. 7.8 gpm.
d. 15.6 gpm.
e. 36 gpm.
IHM Manual # 402 - 01/00
Calculate
Review: 45.2.
The theoretical flow for a 10 CID motor to turn at 1000
rpm is 43.3 gpm. When this flow is supplied to the
motor, it turns at 940 rpm. The volumetric efficiency is:
a. 106%.
b. 94%.
c. 90%.
d. 86%.
e. 80%.
Task 46.0
Determine the cause of erratic pressure, low pressure,

or high pressure in a pilot operated (balanced piston)
pressure relief valve.
Recognizes the causes of improper relief valve
operation.
Outcome 46.1.
Pilot Operated
Pilot Valve
Piston
Control
Chamber
Fixed Orifice
Main Valve
From Pump
To Reservoir
To Machine
The relief valve protects the pump and circuit

against overpressure. Pressure is set at a value higher than
anticipated operating pressure. If the setting is too
high, needless power is wasted when fluid is dumped
over the relief valve. If the setting is too low, the load
cannot be moved, or movement will be erratic, and the
relief valve will chatter.
"Balanced" means that pressure on both sides of a
common piston or spool "balances," and in so doing,
controls the movement of the spool. Balanced relief
valves use a venting arrangement on a piston or spool
valve for finer regulation of the pressure than could be
accomplished with a direct-acting relief valve.
When there is a pressure imbalance, the piston or
spool moves in the direction of lower pressure. Unless
the valve has an external pilot operator, it is drained
internally. This drain must be open to the reservoir for
the valve to effectively regulate pressure.
Fig. 47. Pilot Operated Pressure Relief Valve
To check a pilot operated relief valve:
Check the valve setting. A relief valve pressure setting too close to system operating pressure will
cause the valve to chatter. Set the pressure 200-300 psi ABOVE system operating pressure.
Undersized relief valve provides loss of control. Be sure the valve is the correct size. Undersized
valves increase fluid velocity. High velocity fluid through the valve will increase the noise level.
Check for obstructions in the tank line. An obstructed tank line will interfere with the action of the
valve, and high velocity fluid will increase the noise level. Back pressure in the tank line is additive to
the pressure setting of the valve.
Check for foreign matter in the fluid. Check the condition of the filters first. If they are loaded and
debris is by-passing into the relief valve, the fluid should be drained, the system flushed, the filter
elements replaced, and the reservoir refilled with clean fluid.
If necessary, disassemble the valve. Check for plugged orifices, free movement of the piston, and evidence
of contamination. Insure that the springs in the main and pilot stage are not broken.
IHM Manual # 402 - 01/00
Always release pressure on the pilot poppet (back out adjusting screw) when restarting the
system. Slowly adjust the valve to the proper setting.
Review Tasks 15.0 and 22.0 for further study.

Review: 46.1.
Review: 46.2.
If a pressure relief valve operates erratically, the If the tank line from the relief valve is partially restricted,
problem could be the:
the valve may:
a. open at a low pressure.
a. pump is bad.
b. tank line is plugged.
b. increase pressure setting.
c. main piston is stuck open.
c. never close.
d. pressure setting is too close to working system
d. work fine.
e. cool off.
pressure.
e. orifice in the passage leading to the pilot
section is plugged.
IHM Manual # 402 - 01/00
Task 47.0
Outcome 47.1.
Outcome 47.2.
Isolate solenoid control valve failures.

Understands how solenoids activate a directional
control valve.
Solves Ohm's Law for resistance, current, or voltage values.
Single and double solenoid control valves are available with DC solenoids and AC 50 and 60 cycle 120
volt solenoids. Both dry and wet armature valves are common. Valve spools can be spring-returned,
spring-centered, or detented in the shifted position. When it is suspected that the solenoid valve has failed, tests
must be made to verify that the valve is working properly or to pinpoint the failure.
Heat is generated in the solenoid by current flowing to energize and hold in the solenoid. Most of the heat
(per unit time) in an AC solenoid is generated when the coil is energized. Current decreases when the
solenoid shifts completely.
The valve spool is shifted by the action of the core against the push pins that move the valve spool. The
shifting time of a solenoid varies but usually is in the range of 6-16 milliseconds.
Both low and high voltage will overheat an AC solenoid coil. Voltage levels of plus or minus 10% are
considered high and low, respectively. Over voltage increases the shifting force exerted by the solenoid but
shortens its life. Low voltage decreases the solenoid force. Thus, it may not complete its full travel distance.
This will burn out the coil.
If both solenoids are energized at the same time, (not properly interlocked), the valve cannot shift. Both
coils receive a high surge of current, and one or the other will burn out.
Problems causing a solenoid activated valve not to shift can usually be traced to one of the following causes:
Main or pilot spool stuck.

Switching failure.
Solenoid failure.
Improper pilot pressure or back pressure on the drain line (pilot operated valves).
Check the easiest items first. Manual overrides will allow the spool(s) to be shifted by hand. Solenoid and
switching failures can be checked with a volt-ohmmeter. Pilot pressure problems will require installation of
gauges to check. These are best tried last.
If a solenoid failure is suspected, check the resistance between the two leads and from both leads to ground.
Solenoid resistance can be calculated from the equation:
E (volts ) = I (amps ) R (ohms ) (Ohm' s Law )
E= I R
(Eq. 15)
Where E is voltage, I is current in amperes, and R is resistance in Ohms. Specifications on solenoid voltage
and current are normally available. If solenoid resistance varies greatly from the results of this calculation or
is grounded, it is faulty and must be replaced.
IHM Manual # 402 - 01/00
Two paths with R2

left in circuit
One path with R2

disconnected
POWER OFF
POWER OFF
S1
S1
R1
R2
When connecting an ohmmeter across a

component (R2), a false reading will be
obtained if the component is not disconnected from the circut. When the ohmmeter is
connected as shown above, meter current
can flow through both R2 and R1. The measurement will be a combination of R1 and R2
values resulting in a false reading - lower
than that expected.
R1
R2
When the component to be measured with

ohmmeter is disconnected from the circuit,
meter current has only one path it can follow.
This allows a true measurement of the component with the ohmmeter.
Fig. 48. Measuring Solenoid Resistance (Courtesy of Eaton Corporation)
Before replacing the solenoid, check for other problems such as voltage variations or stuck spools which
may have caused the solenoid to fail.
Review: 47.1.
Review: 47.2.
A direct operated solenoid activated valve may not A 12 volt DC solenoid has a resistance of 6 ohms. The
shift to the power position if the:
current will be:
a. supply voltage is incorrect.
a. 0.5 amps.
b. if the pump is on.
b. 1.0 amps.
c. spool centering spring is too light.
c. 2 amps.
d. pressure is too low.
d. 6 amps.
e. indicator lights are wired backwards.
e. 12 amps.
IHM Manual # 402 - 01/00
Task 48.0
Outcome 48.1.
Outcome 48.2.
Verify that hydraulic lines meet size requirements.

Calculates fluid velocity in hydraulic lines.
Verifies the lines meet accepted size limits.
Sizing guidelines set limits for inlet and pressure lines. The fluid velocity in inlet lines should not exceed
4 feet per second (fps). Oil return lines should keep the fluid velocity within the 10 - 15 fps range. The velocity in
medium pressure lines (500 psi -2000 psi) should be kept within 15 - 20 fps. The velocity in high pressure
lines (3000 psi - 5000 psi) should not exceed 30 fps. The verification process attempts to determine that fluid
velocity in the inlet, return, and pressure lines is within these limits.
Higher than recommended velocities in inlet lines cause high vacuum readings at the pump inlet. A high
vacuum at the pump inlet will cause cavitation and sometimes aeration.
Higher than recommended fluid velocities in pressure lines cause increased pressure losses, generate
unnecessary heat, and waste power, both to pump the fluid and to cool it if it overheats.
If the flow rate in a system is not known, it may be necessary to calculate flow rates from pump
displacements and speeds, cylinder sizes and speeds, or motor displacements and speeds (see Tasks 14.0, 26.0,
27.0, 43.0, 44.0, and 45.0). The inside diameter of the line must be known. For hoses, the dash number will
provide this information (see Task 4.0). For tubing, the inside will have to be measured unless the wall thickness
is known or measured.
The velocity in feet per second (fps) in hydraulic lines is computed from Equation 10:
Velocity ( sft.
ec. ) = Q (gpm)
. 3208
2
(Eq. 10)
Area (in. )
Per Equation 8; Area (in.2) = p x (radius (in.))2

Compare this velocity with the limitation of 2-4 fps recommended for inlet lines, and recommended velocities
in pressure and return lines.
Figure 49 may also be used to help size hydraulic lines.
IHM Manual # 402 - 01/00
Based On Formula
Area (SQ. IN.) = G.P.M. x 0.3208
Velocity (Ft./Sec.)
100
20000
1. If the line
must handle
14 gpm...
90
80
70
60
2. and a line with 3/4

inch I.D. will be used...
50
10000
9000
40
8000
20
7000
15
30
6000
10
9
8
7
6
5
5000
20
4000
3. a flow velocity
of 10 fps will
result.
4
2
3000
10
2000
1
1
900
800
700
500
2
400
300
1
200
.75
.5
100
.4
Flow - Gallons Per Minute
Flow - Cubic Inches Per Minute
600
1
.9
.8
.7
.6
.5
.4
.3
3
Maximum
Recommended
Velocity For Intake
Lines
7/16
5/16
4
5
9/16
Actual Inside Diameter Of

Fluid Conductor - Inches
1000
Nominal Standard Pipe Size (Sch. 40 Only)
8
7
.2
6
7
.1
.09
.08
.07
.06
.05
.04
.03
.02
.01
.009
.008
.007
.006
.005
.004
8
9
10
15
20
30
40
50
Velocity - Feet Per Second
Area Of Fluid Conductor - SQ. IN.
15
Fig. 49. Conductor Inside Diameter Selector Chart (Courtesy of Eaton Corporation)
IHM Manual # 402 - 01/00
Calculate
Calculate
Review: 48.1.
Review: 48.2.
The inlet line for a flow rate of 10 gpm is to be sized. How much flow will a 3/4 inch tube with a wall thickness
The velocity is to be 3 fps. The inside diameter of the of 0.095 inches carry at a velocity of 20 fps?
required line is:
a. 1.3 gpm
a. 0.28 in.
b. 15.4 gpm
b. 1.07 in.
c. 20.0 gpm
c. 1.17 in.
d. 26.0 gpm
d. 1.28 in.
e. 27.5 gpm
e. 3.33 in.
IHM Manual # 402 - 01/00
Task 49.0
Outcome 49.1.
Outcome 49.2.
Distinguish between aeration and cavitation.

Recognizes symptoms and causes of aeration.
Recognizes symptoms and causes of cavitation.
Aeration and cavitation are two problems that affect the operation of hydraulic systems and damage the
pump. Aeration is a condition during which air is entrained in the fluid. Cavitation is a condition during which
bubble-like pockets are formed on the suction side of the pump due to vacuum and then collapse (implode) in
the pumping chamber. Either condition will destroy the pump and may damage other components. Aeration
is defined as the presence of entrained air, greater than 10% by volume. Cavitation involves the formation of
bubbles on the suction side of the pumping chamber.
7 Hg. Vacuum
23 Hg. Abs. Press
Sea Level
Atmosphere
Fig. 50. Vacuum at Pump Inlet

(Courtesy of Parker Hannifin)
Aeration is accompanied by the presence of air bubbles in the fluid stream,

and the hydraulic oil turns a milky color. Aeration causes the pump to whine.
The sound can be distinguished from cavitation, which makes a higher-pitched
shriek. Aeration can be caused by low fluid level, broken inlet line, cracked
fitting, faulty pump shaft seal, case leak,worn bearings, over-reving (too many
RPMs) or return line above the fluid level in the reservoir, which mixes in air in
the reservoir.
Cavitation can be caused by high suction lifts (higher than recommended by
the manufacturer), bent or restricted inlet, undersized inlet, high viscosity fluid,
cold starting, breather clogged on the reservoir, collapsed inlet hose, and clogged
inlet strainer or line.
Cavitation is accompanied by a high vacuum at the pump inlet. The fluid vaporizes under the vacuum
created, and then the bubbles travel through the high pressure chamber and collapse (implode). This action
erodes metal from the pump housing near where the bubbles collapse, sending particles downstream with the
fluid. Cavitation for any period of time will destroy the pump. High water base fluids have a low vapor
pressure and thus are more likely to cavitate.
A system that is aerating, that is, drawing air at the inlet, will have the following symptoms:
The fluid will contain foam.
The pump will have an abnormal whine.
If the pump continues to whine, the source of aeration is still present. Aeration will usually clear up
soon after the problem is fixed.
Operation of actuators will be spongy.
A vacuum gauge at the pump inlet will show that the pump is operating within the allowable limits of
vacuum (usually 5-7 in. Hg).
A system that is cavitating will have the following symptoms:
The pump will shriek while it is cavitating, particularly if the condition is severe.
IHM Manual # 402 - 01/00
The fluid in the reservoir will appear normal.
A vacuum gauge in the inlet will show a high reading.
A sight glass in the inlet will show no bubbles.
Review: 49.1.
Review: 49.2.
All of the following are symptoms of cavitation, Aeration may be caused by:
except:
a. high suction vacuum.
b. excessive system pressure.
b. milky appearance in the oil.
c. plugged suction filter.
c. slow system operation.
d. a leaky fitting in the suction line.
d. a noise at the pump
e. the reservoir being overfilled.
e. none of the above.
IHM Manual # 402 - 01/00
References
Aeroquip Training Bulletin 2019, (1985). How to Identify and Cure Piping Leaks. Jackson, MI: Aeroquip Corporation. - Task 40
Aeroquip (1986). (Catalog 261E). Hose and Reusable Fittings. Jackson, MI: Aeroquip Corporation. - Task 17, 18, 19
Analyzing Hydraulic Systems (1987). (Bulletin 0222-B1). Cleveland, OH: Parker Hannifin Corporation. - Task 36, 44, 49
Basic Hydraulics (1971). (Lesson Six - Piping, Tubing, and Fittings). Barrington, IL: Technical Publishing Company, 83-87. - Task 32
Bensch, L.E. (1985). Dirt Capacity: the Misused Filter Selection Factor. Hydraulics & Pneumatic, Penton Publishing, 38,(11), 55-59. - Task 5
Design Engineers Handbook (1979). (Publication No. 0224-81). Cleveland, OH: Parker Hannifin Corporation. - Task 6, 48
Engineering Data Ashkroft Gauges, Maintenance and Repair, Form number 250-1353-H. Stratford, CT:
Valve & Instrument Division. - Task 39
Dresser Industries, Industrial
Evans, W.I. (1982). High Water Content Systems for Profit-Making Design. Hydraulics & Pneumatics, Penton Publishing, 35(4), HP1-HP32. Task 12
Fairey Arlon, Inc. (1981). Engineering Data: Guidelines for Taking a Fluid Sample. Sturtevant, WI: Fluid Marketing Corporation - Task 7, 11
Fitch, J.C. (1989). Filters Can Remove Water from Hydraulic Fluid. Hydraulics & Pneumatics, Penton Publishing, 42(1), 79-80, 220. - Task 8
Fitch, J.C., and J.B. Allred (1988). Hydraulic Fluid Analysis: Avoiding the Potential Pitfalls. Part 2: Interpretation of Test Results, Plus
Do-It-Yourself on Site Tests. Hydraulics & Pneumatics, Penton Publishing, 42(1), 79-80, 220. - Task 7
Flippo, W. & J. Chamberlain (1988). Hydraulic Accumulators, Making the Choice: Piston or Bladder Accumulators. Hillsboro, NC:
Parker Hannifin Corporation. - Task 24
Fluid Power 1: An Introduction to Hydraulics & Pneumatics, Penton Publishing, (1974). (Bulletin 0225-B1). Cleveland, OH: Parker Hannifin
Corporation. - Task 39
Fluid Power 2 (1988). (Bulletin 0266-B1). Cleveland, OH: Parker Hannifin Corporation, 11-1 through 11-7. - Task 31, 43, 44
Fluid Power Data Book. (1987). Dallas, TX: Womack Educational Publications. - Task 45, 48
FOS/Fundamentals of Service - Hydraulics (1967). Moline, IL: Deere and Company. 3-6 through 3-7. - Task 1
Fox, J. (1982). Choosing the Right Hose is Easy. Hydraulics & Pneumatics, Penton Publishing, 35(2), 62. - Task 17, 18
Fox, J. (1982). A Guide for Selecting the Right Hose Assemblies. Hydraulics & Pneumatics, Penton Publishing, 40(1), 115-118, 276. - Task 17, 18
Frankenfield, T.C. (2nd ed.) (1984). Using Industrial Hydraulics, Penton Publishing, Cleveland, OH - Task 15
George, S. (1977). Electric Motors for Fluid Power. Cleveland, OH: Parker Hannifin Corporation. - Task 35
Guerre, John, (1993) Plastic Cap Protects O-ring, Hydraulics & Pneumatics, Penton Publishing, 46, (12), 10. - Task 30
Hedges, C.S. (1988). Industrial Fluid Power - Volume 1 (3rd ed.). Dallas, TX: Womack Educational Publications, 171-207. - Task 29, 35, 43
High Water Base Fluid Application Guide (1979). (Bulletin 81-210). Troy, MI: Vickers, Inc. - Task 12
Hose and Fittings Assembly Manual (1980). Bulletin 3401-B4. Cleveland, OH: Parker Hannifin Corporation - Task 1, 19
Hose Fitters Handbook (1977). (Bulletin 4407-B10). Cleveland, OH: Parker Hannifin Corporation. - Task 17, 18
Hose Handbook (3rd ed.). Hose and Fitting Assembly Manual, Washington, D.C., Rubber Manufacturer's Association.
Industrial Hydraulics Manual (2nd ed.) (1989). Troy, MI: Vickers, Incorporated. - Task 4, 6,14,16, 20, 22, 23, 26, 27, 31, 33, 37, 39, 46, 48
Installation and Maintenance Manual (1980). City of Commerce, CA: Greer Olaer Products Division. - Task 2
IHM Manual # 402 - 01/00
International Standards Organization (ISO), Standard 1219, Graphic Symbols for Fluid Power. NFPA, Milwaukee, WI. - Task 40
National Fluid Power Association (1976). (NFPA T2.9.9). Method for Extracting Fluid Samples from a Reservoir of an Operating
Hydraulic Fluid Power System. Milwaukee, WI. - Task 13
Overhaul Manual No. 1-3300-S (1985). Troy, MI: Vickers, Inc. - Task 15
Parker Hannifin (1987). (Catalog 1630-1). Piston and Bladder Type Accumulators. Des Plaines, IL: Parker Hannifin Corporation. - Task 24
Parker Hose and Fittings Assembly Manual. Cleveland, OH: Parker Hannifin Corporation. - Task 38
Parker Industrial Tube Fitters' Manual. (1977). (Bulletin 4306-B2). Cleveland, OH: Parker Hannifin Corporation. -Task 38
Paule, B. (1984). Fluid Power Systems Maintenance and Operations. Columbia, MO: Instructional Materials Laboratory, University of
Missouri-Columbia. -Task 33
Pease, D.A., and J.J. Pippenger (2nd ed.) (1987). Basic Fluid Power, Englewood Cliffs, NJ: Prentice-Hall -Task 14, 15, 16, 25
Pippenger, J.J. (1989). Zero Downtime Hydraulics. Jenks, OK: Amalgam Publishing Co. - Task 2, 4, 5, 6, 9, 34,
Pippenger. J.J. and G.P. Gordon (1993). Basics for the Fluid Power Mechanic. Jenks, OK: Amalgam Publishing/FPS. - Task 3, 5, 9, 10, 16, 20,
21, 25, 27, 29, 31, 32, 34, 42, 46, 49
Smith, M. (1988). Basics of Oil Anaylsis. Torrance, CA: Analysts, Inc. - Task 7, 10, 11
Solenoid Valve Assembly and Maintenance Manual (Model DG4S). Troy, MI: Vickers Incorporated. - Task 47
Solenoid Valves (1993). 1992-93 Fluid Power Handbook and Directory. Cleveland, OH: Penton Publishing - Task 47
Spencer, J. (1980). (Pub. 348A-K85d). Active Contamination Control in Fluid Power Systems. Troy, MI: Vickers Systems Ltd. - Task 8
Sperry Vickers. (1968). Vickers Service Manual M-2000-S. Troy, MI: Vickers Incorporated. - Task 26
Sullivan, James A. (1989). Fluid Power: Theory and Applications. Englewood Cliffs, NJ: Prentice Hall, 160-179. - Task 20, 28, 45
T-J Cylinders: Installation and Service Manual (1985). (Bulletin 4059A). Jackson, MI: Aeroquip Corporation. - Task 41
Taft, G. (1980). How to Make the Change to Synthetics. Hydraulics & Pneumatics, Penton Publishing, 33(6), 70A.- Task 12
The Design Engineer's Cylinder Guide (1982). Cudahy, WI: Milwaukee Cylinder. - Task 41
Top Repairable Bladder Accumulator Installation, Operation and Service Manual (1980). Commerce, CA: Greer Hydraulics, Incorporated. - Task 42
USA Standard Graphic Symbols for Fluid Power Diagrams (USAS Y32.10-1967). New York, NY: The American Society of Mechanical
Engineers. - Task 40
V-Ring Packings (Bulletin No. P-420-2). Morton Grove, IL: Crane Packing Company. - Task 37
Vickers Incorporated. Applications Data for Pressure Reducing Valve. Troy, MI: Vickers, Incorporated. - Task 21
Vickers Incorporated. (1985). (Bulletin 0221-B1) Overhaul Manual: Balanced Piston Relief Valve. Troy, MI: Vickers Incorporated. - Task 22
IHM Manual # 402 - 01/00
Industrial Hydraulic Mechanic Certification Answer Manual

Solutions to Review Questions and Problems
Review #
7.1. d.
1.1.
b.
7.2. b.
1.2.
e.
8.1. b.
2.1.
e.
8.2. a.
2.2.
a.
9.1. a.
3.1.
b.
9.2. d.
3.2.
e.
10.1. e.
4.1.
d.
10.2. b.
4.2.
c.
11.1. b.
5.1.
b.
12.1. c.
5.2.
c.
12.2. b.
6.1.
a.
13.1. d.
6.2.
e.
14.1. a.
Torque may be thought of as a rotary force. The

force tending to cause rotation is applied
perpendicular to the lever arm with the lever arm
defined as the perpendicular distance from the point
of application of the force to the center of rotation.
Solving Eq. 1 for torque,
Torque (ft. lb.) = Force (lb.) x Lever Arm (ft.)
(Eq. 1)
Torque may also be expressed in inch pounds with the
lever arm being measured in inches.
Since a torque of 60 ft. lb. is needed and a lever arm
of 1 foot (12 inches) is provided, Equation 1 is solved
as: F = T / L = 60 ft. lb. / 1 ft.; so the
necessary force is 60 pounds.
Three equations are in use here.

Theoretical Q (gpm) = D (CID) x N (rpm) / 231
(Eq. 2)
Actual Q (gpm) = D (CID) x N (rpm) x Ev / 231
(Eq. 3)
The volumetric efficiency (Ev) must be in a decimal
form (from 0 to 1.0) instead of a percentage form.
Equation 4 provides the relationship between volumetric efficiency, theoretical flow, and actual flow for
a pump.
(Ev) (%) = Actual Q (gpm) / Theoretical Q (gpm) x
100 (for a pump)
(Eq. 4)
Therefore, for this pump:
Theoretical Q (gpm) = 2.0 CID x 1800 rpm / 231 =
IHM Manual # 402 - 01/00
Industrial Hydraulic Mechanic Answer Manual 93

15.6 gpm
24.1. c.
Since the actual flow is 13.8 gpm, the Volumetric

Efficiency is 13.8 / 15.6 x 100 = 88%. This is
above the 83% cut off point, so the pump output is
still acceptable.
25.1. b.
25.2. a.
Solving Eq. 5 for horsepower,
15.1 e.
15.2. c.
16.1. b.
16.2. d.
Hydraulic Horsepower (HP) = Pressure (psi) x Flow

Rate (gpm) / 1714
(Eq. 5)
Since one pump unloads at 1000 psi, the
combined flow at 1000 psi must be checked and then
the high pressure pump flow at relief valve setting of
2500 psi.
17.1. d.
a.) 30 gpm x 1000 psi / 1714 = 17.5 HP
Equation 5 must be solved for working pressure.
b.) 10 gpm x 2500 psi / 1714 = 14.6 HP
Operating Pressure (psi) = Burst Pressure (psi) /
Safety Factor
(Eq. 5)
Operating Pressure (psi) = 16,000 psi / 4 = 4000 psi
So the horsepower developed is highest at 1000 psi,

just before the high flow/low pressure pump
unloads.
17.2. b.
26.1. a.
18.1. d.
26.2. e.
19.1. c.
27.1. e.
19.2. e.
27.2. b.
20.1. a.
Solving Eq. 2 for flow,
20.2. e.
Theoretical Q (gpm) = D (CID) x N (rpm) / 231

(Eq. 2)
21.1. b.
1.5 CID x 1750 rpm / 231 = 11.36 gpm
21.2. e.
28.1. d.
22.1. c.
Two equations are involved.
22.2. b.
23.1. b.
Force (lb.) = Pressure (psi) x Area (in.2)

(Eq. 6)
Area (in.2) = ! x (Radius (in.))2
(Eq. 7)
23.2. d.
If 10 tons (20,000 lb.) is needed at a pressure of 2500
94 Industrial Hydraulic Mechanic Answer Manual
IHM Manual # 402 - 01/00

psi, then
A = F / P = 20,000 / 2500 = 8 in.2
38.1. e.
38.2. a.
The radius of an 8 square inch cylinder is r(in) =

8 / ! = 1.6 inches so the diameter is
3.2 inches.
39.1. c.
39.2. b.
29.1. b.
40.1. c.
29.2. a.
40.2. d.
30.1. e.
41.1. b.
30.2. e.
41.2. c.
31.1. d.
42.1. a.
31.2. c.
42.2. d.
32.1. c.
43.1. d.
32.2. a.
Equations 6 and 7 apply:
33.1. e.
Area (in.2) = ! x (r (in.))2
(Eq. 6)
33.2. b.
3.14 x (2 in.)2 = 12.57 in.2
34.1. e.
F (lb.) = P (psi) x A (in.2)
(Eq. 7)
34.2. c.
2000 psi x 12.57 in.2 = 25,140 lb.
35.1. b.
43.2. a.
35.2. d.
44.1. d.
36.1. c.
44.2. b.
36.2. c.
Solving Eq. 2 for displacement,
44.3. b.
D (CID) = Q (gpm) x 231 / N (rpm) (Eq. 2)
Equation 10 is a formula which relates flow rate,

cylinder size, and extension or retraction speed.
20 x 231 / 1750 = 2.64 CID

37.1. e.
Velocity (ft./sec.) = Q (gpm) x .3208 / Area (in.2)

(Eq. 10)
37.2. d.
IHM Manual # 402 - 01/00
Industrial Hydraulic Mechanic Answer Manual 95

A 6 inch bore cylinder has an area of 28.27 in.2 .
47.2. c.
Vel. (ft./sec.) = 30 gpm x .3208 / 28.27 in.2
Solve Eq. 15 for current,
= 0.34 ft. / sec.
I (amps) = E (volts / R (ohms)
Multiply by 12 to get 4.1 inches/second velocity.
(Eq. 15)
In this problem, E = 120 volts and R (ohms) = 12

ohms. Therefore, I = E / R = 120 volts / 12 ohms = 10
amps
45.1. d.
48.1. c.
Equation 2 is solved for flow,
Q (gpm) = D (CID) x N (rpm) / 231 (Eq. 2)
Equation 10 specifies that the area (in.2) of a line is

determined by:
2.0 CID X 1800 rpm / 231 = 15.6 gpm
A (in.2) = Q (gpm) x .3208 / Vel. (ft./sec.)

(Eq. 10)
45.2. b.
A = 10 x .3208 / 3 = 1.07 in.2
Equation 2 applies to both pumps and motors.

However, equations 3 and 4 are rewritten for motors.
For a motor:
Using Eq. 8 to solve for diameter
Actual Q (gpm) = D (CID) x N (rpm) / 231 x Ev

(Eq. 4)
so: r = 1.07 in2 / ! = 0.58 inches
A (in.2) = ! x (radius in.)2
(Eq. 8)
and the diameter = 1.17 inches

Solving Equation 4 at Ev = 100%:
Q (gpm) = 10 CID x 1000 rpm / 231 = 43.3 gpm
48.2. b.
Note: 100% Ev = 1.0
The same formulas used in 48.1 apply. One must

remember to subtract the wall thickness from the tubing diameter. So the inside diameter of the tube is
actually 0.56 inches. The area = 0.25 in.2 and the
velocity is set at 20 ft./sec., so Eq. 10 must be solved
for flow,
Ev (%) = Theoretical Q / Actual Q x 100 = Actual N /

Theoretical N x 100
(Eq. 3)
In this case actual and theoretical speeds are known,
so
Q (gpm) = A (in.2) x Vel. (ft./sec.) / .3208

(Eq. 10)
Ev (%) = 940 rpm / 1000 rpm x 100 = 94%

46.1. d.
.25 x 20 / .3208 = 15.4 gpm
46.2. b.
49.1. b.
47.1. a.
49.2. d.
96 Industrial Hydraulic Mechanic Answer Manual
IHM Manual # 402 - 01/00
Industrial Hydraulic Mechanic Certification Pre-Tests
Introduction
Pre-tests are used to evaluate candidate preparedness
for certification tests. Pre-tests may be either taken
individually or in a group setting such as during a
Review Training Session (RTS). As a part of an RTS,
Pre-tests are used to allow the instructor to tailor the
subject matter coverage to the needs of the audience.
When a candidate is studying individually or in a small
group, pre-tests provide insight into which areas
require further study and whether the candidate should
consider other study options, such as an RTS.
take all three pre-tests at different times during the

study process to better access preparedness and
effectiveness of study.
The answer sheets provided have been developed

such that each question is referenced to a particular
subject matter area of the study manual and of the test.
The candidate is encouraged to fold the answer sheet
vertically along the dotted line before taking the pre-test.
This will eliminate any bias that may occur by having
the appropriate outcome statement appear with the
answers and more closely mimics actual test conditions.
After checking the answers, the answer sheet may be
Included in this manual are three separate pre-tests opened to reveal the areas where further study is needed.
for the Industrial Hydraulic Mechanic certification This should enable directed study in the areas where a
test. Each pre-test has its own separate answer sheet deficiency exists.
which appears at the end of the pre-tests. Individual
pre-tests are numbered IHM-1, IHM-2, and IHM-3.
Candidates should be advised that each pre-test
The answer key for all three pre-tests appears at the covers only a representative sample of the types of
end of the manual.
questions found on the test. Due to the need to keep
the pre-test brief, not all subject matter is covered on
Candidates are encouraged to take a pre-test every pre-test. Thorough preparation for the certification
early in the study process. Pre-tests should be taken test is strongly encouraged.
under timed conditions. A maximum of forty-five
minutes should be allotted for each pre-test. This
The experience of taking pre-tests under timed
should be sufficient time to answer all twenty-five conditions should reduce test anxiety associated with
questions on the pre-test. The results of the pre-test the actual certification test. If necessary, candidates
will guide the candidate to one of four possible courses may wish to retake the pre-tests after some period of
of action regarding test preparation.
time has elapsed to recheck their knowledge.
1. Take the test: Preparation is sufficient.
2. Study the material using the Study Manual.
3. Attend a Review Training Session (RTS):
Preparation is good, but not sufficient to pass
the test.
4. Participate in a formal (general) course: A
Review Training Session would not provide
adequate preparation to pass the test.
Additional pre-tests should be taken after individual
study or attendance at an RTS to further evaluate test
readiness. In some instances, it may be desirable to
IHM Manual # 402 - 01/00
Suggestions or comments for improvements of

these pre-tests and other certification materials should
be sent to:
Fluid Power Society Education Institute
c/o FPS
2433 N. Mayfair Rd. Suite 111
Milwaukee, WI 53226
800-303-8520
Fax:414-257-4092
Web: www.ifps.org
askus@ifps.org
Fax on Demand
Industrial Hydraulic Mechanic Pre-Test 97
Industrial Hydraulic Mechanic Certification Pre-Test - IHM - 1

1. New hydraulic fluid in the drum:
a. is clean and may be added directly to a system.
b. should be tested for contamination before
using.
c. should be stirred to mix additives before using.
d. must be filtered when added to a reservoir.
e. will evaporate if not sealed.
5. A portable filter unit is used to:

a. transfer fluid from drums to the reservoir.
b. serve as the main source of filtration for a
system.
c. reclaim oxidized oil.
d. remove only very large contaminants.
e. prime pumps.
2. The Beta Ratio of a hydraulic filter is:
6. The purpose of flushing a fluid sample container

with system fluid prior to saving a sample for
a. the ratio of contaminant concentration (at a
analysis is to:
given size) upstream and downstream of a
filter.
a. practice so that no oil is spilled.
b. an indication of how much dirt the filter can
b. insure that the contamination in the container is
hold.
the same as the system fluid.
c. a comparison of the flow rate through the filter
c. warm up the container gradually.
to the corresponding pressure drop.
d. clean the sample line of any non-representative
d. often referred to as the absolute rating of the
contaminants.
filter.
e. give the system time to warm up.
e. a predictor of service life of the element.
7. A reservoir sample:
3. Nitrogen is used to charge accumulators because it:
a. is preferred over a pressure line sample.
a. will not leak off.
b. can be done even if the machine has been idle
b. preserves the bladder.
for an extended period.
c. will not mix with oil.
c. is best done by dipping the container into the oil.
d. is inexpensive.
d. is acceptable if a pressure line sample is
e. does not support combustion.
difficult or unsafe to obtain.
e. won't provide any useful information about the
4. Fluid sampling from a pressure line is desirable
system.
because:
8. What would happen if the pilot orifice in the main
a. the fluid runs out easily since it's pressurized.
piston of a balanced-piston relief valve became
b. it saves opening the reservoir.
plugged?
c. pressure lines are always more accessible.
d. the fluid is most representative of that which
a. Valve would function normally
the components see.
b. Valve would never open
e. the oil is warmer than at any other point in the
c. Valve would work normally but would only
system.
divert a small amount of fluid to the tank port
d. Increasing the pressure on the pilot stage spring
would decrease the cracking pressure of the valve
e. Valve would by-pass flow to tank at low
pressure
98 Industrial Hydraulic Mechanic Pre-Test
IHM Manual # 402 - 01/00

9. A hose with a minimum burst pressure of 16,000 14. The output flow of a fixed displacement axial
psi is used in an application requiring a 4:1 safety
piston pump will decline if:
factor. The maximum working pressure of the
hose is:
a. the pistons become scored.
b. the shaft seal leaks.
a. 64,000 psi.
c. the valve plate becomes grooved.
b. 16,000 psi.
d. the shaft bearing wears slightly.
c. 8,000 psi.
e. both (a) and (c) are correct.
d. 4,000 psi.
e. 1,600 psi.
15. The blind end of a cylinder is blocked. The rod end
is pressurized. If the piston seals are leaking, the
10. As the wall thickness of hydraulic tubing increases the:
cylinder will:
a.
b.
c.
d.
e.
outside diameter gets bigger.

inside diameter gets bigger.
inside diameter gets smaller.
tubing has the same wall thickness.
pressure capability goes down.
11. A pressure reducing valve:

a.
b.
c.
d.
e.
is often used in place of a relief valve.

provides a lower pressure for a branch circuit.
will discharge an accumulator.
will relieve excessive pressure to tank.
is often used in place of a sequence valve.
12. A leaking shaft seal in a vane pump could mean

that the:
a.
b.
c.
d.
e.
retract.
extend.
do nothing.
blow out the rod seal.
chatter.
16. When connected to a volt-ohm meter, the electrical

leads of a solenoid show infinite resistance. The
coil is:
a.
b.
c.
d.
e.
shorted.
grounded.
new.
open.
none of the above.
17. A hydraulic reservoir should be:

a.
b.
c.
d.
e.
pump outlet pressure is too high.

shaft bearing is worn out.
splines on shaft are worn out.
case bolts were improperly torqued.
seal is not receiving lubrication.
a.
b.
c.
d.
e.
mounted below the pump.

filled completely full.
equipped with a cooler.
painted on the side.
equipped with a clean-out cover.
13. The high pressure relief valve in a hi-low double

pump system must be sized to handle:
18. If the pump and motor shafts are offset due to axial
misalignment, they are:
a. the combined flow of both pumps.
b. the flow from the high pressure pump.
a. at an angle to each other.
c. the flow from the low pressure pump.
b. parallel.
d. 150% of the combined flow.
c. too far apart.
e. 50% of the combined flow.
d. different sizes.
e. uncoupled.
IHM Manual # 402 - 01/00

19. Failure to stagger the joints on adjacent rings in a 24. A 12 volt DC solenoid has a resistance of 6 ohms.
V-packing may lead to:
The current will be:
a.
b.
c.
d.
e.
excessive shaft wear.

contaminant ingression.
seal wear.
over tightening.
leakage.
20. A pressure gauge is most accurate when reading:

a.
b.
c.
d.
e.
close to zero.
at about 1/4 scale.
at about 1/2 scale.
at about 3/4 scale.
close to full scale.
a. 0.5 amps.
b. 1.0 amps.
c.
2 amps.
d.
6 amps.
e. 12 amps.
25. All of the following are symptoms of cavitation,
except:
a.
b.
c.
d.
e.
high suction vacuum.

milky appearance in the oil.
slow system operation.
a noise at the pump.
none of the above.
21. Foot mounted cylinders attach:

a.
b.
c.
d.
e.
along their centerline.

with lugs along one side.
at the cap end.
with trunions.
with clevises.
22. The extension force of a 4" bore hydraulic cylinder

with a 1 1/2" rod and 2000 psi oil is:
a. 2,546 lb.
b. 6,283 lb.
c. 8,000 lb.
d. 25,140 lb.
e. 32,000 lb.
23. A 2.0 CID pump turning at 1800 rpm should
theoretically deliver:
a. 2.0 gpm.
b. 3.6 gpm.
c. 7.8 gpm.
d. 15.6 gpm.
e. 36.0 gpm.
IHM Manual # 402 - 01/00
Industrial Hydraulic Mechanic Pre-Test Answer Sheet - IHM - 1

Outcome:
1.2 Knows that new fluid may be contaminated.
3.1 Knows filter terminology.
5.1 Understands how an accumulator operates.
Page
8 1.
11 2.
15 3.
Answers
A B C D E
A B C D E
A B C D E
20
24
27
30
4.
5.
6.
7.
A
A
A
A
34
8.
A B C D E
38
9.
A B C D E
42
10. A B C D E
Field Repairs
21.1 Understands the operation of a pressure reducing valve.
23.1 Recognizes the causes of a shaft seal failure.
25.1 Understands how a hi-low pump system works.
45
47
51
11. A B C D E
12. A B C D E
13. A B C D E
Major Repairs
27.1 Recognizes causes of internal leakage in an axial piston pump.
29.1 Knows how to test a cylinder for leaking piston seals.
55
58
14. A B C D E
15. A B C D E
Minor Repairs
31.1 Recognizes solenoid coil failures and their symptoms.
33.1 Knows the functions of the reservoir.
60
62
16. A B C D E
17. A B C D E
64
68
18. A B C D E
19. A B C D E
70
72
20. A B C D E
21. A B C D E
74
78
82
87
22.
23.
24.
25.
7.2
9.1
11.1
13.1

Understands the benefits of sampling from a pressure line.
Understands the application and purpose of a portable filter unit.
Understands the purpose of flushing a fluid sample container.
Knows where to take a reservoir fluid sample.
Assemble Components
15.2 Recognizes valve problems and their causes.
17.1 Understands the relationship between working pressure,
safety factor, and burst pressure.
19.2 Understands the relationship between tubing wall thickness
and pressure capability.
35.2
37.1
39.1
41.1
43.2
45.2
47.2
49.2

Understands coupler alignment terminology and how to check
for misalignment.
Knows how to install and adjust V-packings for proper operation.
Understands how a Bourdon Tube gauge works and where
it is most accurate.
Troubleshooting
Calculates cylinder extension and retraction forces given
dimensions and pressures.
Solves equations for displacement, speed, and volumetric efficiency.
Solves Ohms Law for resistance, current, or voltage values.
Recognizes symptoms and causes of cavitation.
IHM Manual # 402 - 01/00
A
A
A
A
B
B
B
B
B
B
B
B
C
C
C
C
C
C
C
C
D
D
D
D
D
D
D
D
E
E
E
E
E
E
E
E

1. Which filter is used in front of a sensitive valve to
ensure it does not receive highly contaminated fluid?
a.
b.
c.
d.
e.
Inlet Strainer
Pressure
Return
Pilot
Off-Line
6. Why is the reservoir mounted above the pump

when using HWCFs?
a.
b.
c.
d.
e.
It makes replenishing water easier

It prevents separation of oil and water
It minimizes the risk of cavitation
It minimizes evaporation
It enhances cooling of the reservoir
2. The bend radius of a hydraulic hose is measured 7. A 2.0 cubic inch CID (or CIR) gear pump which
from:
has been in service for many years has an output
flow of 13.8 gpm under load at 1800 rpm. When
a. the centerline of the hose.
new, the pump had a volumetric efficiency of 90%.
b. the inside edge of the hose.
The manufacturer recommends rebuilding when the
c. the outside edge of the hose.
volumetric efficiency drops below 83%. This
d. the end of the fitting.
pump:
e. one end of the hose to the other end.
a. is slightly worn, but still within specifications.
3. The grade of an SAE screw:
b. should be rebuilt immediately.
c. should be discarded.
a. indicates whether it has coarse or fine threads.
d. is better than when new.
b. is an indication of strength.
e. not enough information is given to tell.
c. is the proper torque value in foot-pounds.
d. distinguishes between metric and non-metric 8. When a closed center, four-way, three-position,
bolts.
directional control valve is centered:
e. predicts how many times the bolt may be
reused without failure.
a. flow is blocked to A and B ports only.
b. all ports are blocked.
4. One result of having water in a hydraulic fluid is:
c. pump flow is directed to tank unrestricted.
d. all ports are interconnected.
a. fluid becomes thinner.
e. the actuator will "float."
b. oxidation is accelerated.
c. increased power consumption.
9. Hose failure can result from:
d. saturation point of the oil is raised.
e. entrained air is more easily dispersed.
a. low system temperatures.
b. fluid which is too thick.
5. Which of the following would be required on a
c. fluid which is too thin.
laboratory fluid sample form?
d. pressure surges in the system.
e. passing fluid over the relief valve.
a. Company identification and address
b. Machine identification
c. Type of fluid in use
d. Date of sampling or hourmeter reading
e. All of the above
IHM Manual # 402 - 01/00

10. Which of the following is not a possible cause of a 15. SAE Straight Thread O-ring fittings are preferred
pilot-operated directional control valve failing to
over tapered thread fittings because:
shift?
a. component housings aren't distorted.
a. Cylinder is binding
b. angled fittings are easier to align.
b. Solenoid is burned out
c. o-rings are easily changed if damaged.
c. Pilot orifice in the valve is blocked
d. large wrenches are not required to tighten the
d. Switching failure (to the solenoids)
fittings.
e. Stroke adjusters turned in too far
11. The tank line from a balanced piston relief valve 16. When installing sealing tape on a tapered thread
should be:
fitting:
a.
b.
c.
d.
restricted to check operation of the valve.

smaller in size than the pressure line.
plumbed directly to tank with no restrictions.
connected to the downstream port of an "in
line" valve.
e. plugged if not needed.
a. overlap the tape over the end of the fittings.

b. start right at the end of the threads.
c. start one or two threads back of the end.
d. use four wraps of tape.
e. wrap the tape opposite of the direction of the
threads.
12. If fluid is found on the gas side of a piston type 17. The most important property of a fluid is its:
accumulator:
a. viscosity index.
a. the charge valve is leaking.
b. pour point.
b. system operating pressure is too high.
c. color.
c. the piston seals are leaking.
d. specific gravity.
d. a larger accumulator is necessary.
e. viscosity.
e. the accumulator does not need service.
18. Which of the following is a specification indicated
13. A fixed displacement balanced vane pump:
by a pump model number?
a.
b.
c.
d.
e.
uses an elliptical cam ring.

uses a round cam ring.
cannot be overhauled.
has four pumping chambers.
has one suction and pressure port.
a.
b.
c.
d.
e.
Weight
Overall length
Shaft rotation
Size of shaft keyway
Paint color
14. A hydraulic jack is capable of exerting a force of 19. A threaded pipe system which is replaced with a
10 tons. A pressure gauge installed on the jack
tubing system will have:
shows a pressure of 2500 psi at full load. What
diameter (inches) is the cylinder ram?
a. more fittings.
b. less pressure capability.
a. 2.50 inches
c. fewer bends.
b. 0.40 inches
d. more vibration.
c. 0.25 inches
e. fewer leaks.
d. 3.19 inches
e. 8.30 inches
IHM Manual # 402 - 01/00

20. Which is the most common system used to show 24. The inlet line for a flow rate of 10 gpm is to be
information regarding component and circuit
sized. The velocity is to be 3 fps. The inside
operation?
diameter of the required line is:
a.
b.
c.
d.
e.
Pictorial drawings
Cutaway
Graphic symbols
Manufacturing prints
Isometric diagram
a.
b.
c.
d.
e.
0.28 in.
1.07 in.
1.17 in.
1.28 in.
3.33 in.
21. A bladder is prevented from extruding into the 25. Aeration may be caused by:
hydraulic system by the:
a. foot or poppet valve.
b. excessive system pressure.
b. charging valve.
c. plugged suction filter.
c. spring.
d. a leaky fitting in the suction line.
d. bleeddown orifice.
e. the reservoir being overfilled.
e. hydraulic cap.
22. A single rod cylinder is suspected of piston
leakage. The cylinder is positioned at mid-stroke
with no load. The cap end port is blocked. The rod
end is pressurized. If the piston seals leak, the
cylinder will:
a.
b.
c.
d.
e.
retract slowly.
blow the rod seal.
do nothing.
extend.
oscillate back and forth.
23. If a pressure relief valve operates erratically, the

problem could be the:
a.
b.
c.
d.
e.
pump is bad.
tank line is plugged.
main piston is stuck open.
pressure setting is too close to system pressure.
orifice in the passage leading to the pilot
section is plugged.
IHM Manual # 402 - 01/00

Outcome:
2.1 Knows the various filter locations and purposes for each.
4.1 Knows which factors can influence hose life.
6.2 Knows how bolt size and strength affect torque values.
Page
Answers
10 1. A B C D E
13 2. A B C D E
17 3. A B C D E
Fluid Filtration And Maintenance

8.1 Understands the problems caused by water in a hydraulic system.
10.1 Knows what information must be included with a fluid sample.
12.1 Knows the necessary steps to switch from petroleum fluid to HWCF fluid.
22
25
28
4.
5.
6.
A B C D E
A B C D E
A B C D E
Assemble Components
14.2 Solves basic mathematical relationships to determine flow rate,
efficiency, speed, and displacement.
16.1 Understands the terminology related to directional control valves.
18.2 Recognizes causes of hose failures.
31
36
41
7.
8.
9.
A B C D E
A B C D E
A B C D E
Field Repairs
20.1 Understands the causes of a pilot operated directional control
valve failure to shift.
22.1 Knows how a relief valve is connected in a circuit.
24.1 Recognizes problems with a piston accumulator and their symptoms.
43
46
49
10. A B C D E
11 A B C D E
12. A B C D E
Major Repairs
26.1 Understands how a vane pump is balanced for pressure.
53
28.1 Solves basic equations in the relationship among force, area, and pressure. 57
13. A B C D E
14. A B C D E
Minor Repairs
30.1 Understands the advantages of using straight thread O-ring type fittings.
32.2 Knows how to apply sealing tape to a tapered thread fitting.
59
61
15. A B C D E
16. A B C D E
63
17. A B C D E
66
69
71
73
18.
19.
20.
21.
76
22. A B C D E
80
84
87
23. A B C D E
24. A B C D E
25. A B C D E
34.1
36.1
38.1
40.1
42.1
44.2
46.1
48.1
49.1

Understands fluid properties and how they affect system operation.
Reads model number and a catalog description to determine important
component specifications.
Knows the reasons why tubing is preferred over pipe.
Distinguishes between graphic, pictorial, and cutaway drawings.
Understands the function of accumulator components.
Troubleshooting
Recognizes the symptoms of cylinder leakage and how to check
for leakage.
Recognizes the causes of improper relief valve operation.
Recognizes symptoms and causes of aeration.
IHM Manual # 402 - 01/00
A
A
A
A
B
B
B
B
C
C
C
C
D
D
D
D
E
E
E
E

1. Contaminants added to a hydraulic system with 6. Which of the following should be done when
make-up fluid are called:
changing to HWCFs?
a.
b.
c.
d.
e.
ingressed.
built-in.
induced.
internally generated.
escaped.
2. A filter with a 20 micron rating will:

a. remove all particles over 20 microns in size.
b. remove all metallic particles over 20 microns in
size.
c. not work properly if the flow rate is over 20 gpm.
d. remove silt.
e. not provide meaningful information if the
beta ratio is unknown.
3. If the accumulator bladder becomes pinched in the
poppet (foot) valve:
a.
b.
c.
d.
e.
the bladder may rupture.

all of the oil will leak out of the bladder.
nitrogen will escape out the charging valve.
the reservoir fluid level will drop.
all of the above.
4. Fluid oxidation causes the:

a.
b.
c.
d.
e.
viscosity to decrease.
additives to deplete more rapidly.
oil to turn milky.
flash point to decrease.
viscosity index to increase.
a.
b.
c.
d.
e.
Oversize electric motor

Change to HWCF compatible seals
Repaint inside of the reservoir
Use charge filters
Install a fluid cooler
7. What do you do with the vent port on a pilot

operated relief valve?
a.
b.
c.
d.
e.
Connect to tank above fluid level.

Connect to tank below.
Used as a remote control port.
Always use a gauge port.
Vent to atmosphere.
8. A dash 12 (-12) hose which complies with SAE

100 R2 is required. The inside diameter of the
hose is:
a.
b.
c.
d.
e.
1/2 inch.
3/4 inch.
12 millimeters.
12/100 inch.
Not enough information given to tell.
9. A 45 degree flare is associated with pressure:

a.
b.
c.
d.
e.
over 2000 psi.

over 1000 psi.
between 1000 and 2000 psi.
below 2000 psi.
below 1000 psi.
5. Oxidized oil:
a.
b.
c.
d.
e.
10. The spool of a directly actuated solenoid operated

directional valve moves when activated manually,
can be salvaged if passed through the filter cart
but the load doesn't move. The problem may be:
enough times.
is not necessarily contaminated and can be
a. solenoids are burned out.
reused.
b. switching failure.
has no outwardly visible indication that
c. pilot orifice is plugged.
oxidation has occurred.
d. solenoids are connected backwards.
cannot be reclaimed by filtering.
e. pump is turned off.
can be reclaimed by mixing with new oil.
IHM Manual # 402 - 01/00

11. The pressure setting of a balanced piston relief
valve is determined by:
a.
b.
c.
d.
e.
the bias spring in the main stage.

spring tension on the pilot poppet.
the size of the mainstage piston.
the pressure capability of the pump.
the size of the orifice in the pilot stage.
12. A shaft seal installed with a single lip facing out

will:
a.
b.
c.
d.
e.
wear the shaft.

blow out.
work fine.
leak.
wear out prematurely.
16. Pressurized reservoirs:

a.
b.
c.
d.
experience more condensation.

help deliver fluid to the pump inlet.
must be mounted above the pump.
use the same schematic symbol as a vented
reservoir.
e. allow more contaminants into the fluid.
17. Which of the following is considered an additive?
a.
b.
c.
d.
e.
Pour point
Base stock
Oxidation inhibitor
Flash point
Viscosity
18. When a pump has angular misalignment the pump:

13. To successfully reverse the direction of rotation of
most balanced vane pump one must:
a.
b.
c.
d.
e.
and motor shafts are still parallel.

and motor shafts are touching.
and motor shafts are too far apart.
and motor shafts don't align in any plane.
coupler will not go together.
a. turn the input shaft around.

b. move the suction and pressure ports in the
housing.
c. rotate the cartridge 90 in the housing.
d. reverse the direction of the electric motor.
19. A pump must produce 20 gpm at 1750 rpm. Its
e. flip the rotor/vane assembly and the cam ring.
displacement is:
14. The theoretical output flow of a 1.5 CID pump
operating at 1750 rpm is:
a. 26.25 gpm.
b. 11.36 gpm.
c. 2.62 gpm.
d. 1.14 gpm.
e. Not enough information given.
15. A static seal is defined as a seal:
a.
b.
c.
d.
e.
designed to dissipate static electricity.

between two moving parts.
between one stationary and one moving part.
held in place by gravity.
between two stationary parts.
IHM Manual # 402 - 01/00
a. 0.01 CID.
b. 0.38 CID.
c. 2.64 CID.
d. 4.62 CID.
e. 20.00 CID.
20. The open side of a V-packing must face:
a.
b.
c.
d.
e.
the gland.
out.
the lowest pressure in the system.
pressure.
the gland bolts.

21. Flush mounted cylinders:
a.
b.
c.
d.
e.
use an integral key.

are fastened on two sides of the cap.
have a threaded cap and head.
can't be mounted vertically.
align automatically when tightened.
22. To extend a single rod end hydraulic cylinder, the

fluid acts on the:
a.
b.
c.
d.
e.
entire piston area.

rod area.
rod end area (piston area minus rod area).
combined rod and piston area.
circumference of the cylinder.
23. The theoretical flow for a 10 CID motor to turn at

1000 rpm is 43.3 gpm. When this flow is supplied
to the motor, it turns at 940 rpm. The volumetric
efficiency is:
a. 106%.
b. 94%.
c. 90%.
d. 86%.
e. 80%.
24. A direct operated solenoid activated valve may not
shift to power position if the:
a.
b.
c.
d.
e.
supply voltage is incorrect.

solenoid voltage is too high.
spool centering spring is too light.
pressure is too low.
indicator lights are wired backwards.
25. How much flow will a 3/4 inch tube with a wall
thickness of 0.095 inches carry at a velocity of
20 fps?
a.
b.
c.
d.
e.
1.3 gpm
15.4 gpm
20.0 gpm
26.0 gpm
27.5 gpm
IHM Manual # 402 - 01/00

Outcome:
1.1 Understands how contaminants enter a hydraulic system.
3.2 Understands how filters are evaluated and specified.
5.2 Knows how an accumulator may fail.
Page Answer
8 1 A B C D E
11 2 A B C D E
15 3 A B C D E

7.1 Knows the causes and recognizes the signs of fluid failure.
9.1 Understands the application and purpose of a portable filter unit.
12.2 Understands how HWCF performs differently from petroleum
based fluids in a hydraulic system.
20
24
4
5
A B C D E
A B C D E
28
A B C D E
34
38
42
7
8
9
A B C D E
A B C D E
A B C D E
43
10 A B C D E
46
47
11 A B C D E
12 A B C D E
Major Repairs
26.2 Knows how to reverse the direction of rotation of a balanced vane pump.
27.2 Solves equations for flow, displacement, speed, and volumetric efficiency.
53
55
13 A B C D E
14 A B C D E
Minor Repairs
30.2 Distinguishes between static and dynamic seals.
33.2 Understands the differences between vented and pressurized reservoirs.
59
62
15 A B C D E
16 A B C D E
63
17 A B C D E
64
18 A B C D E
66
68
72
19 A B C D E
20 A B C D E
21 A B C D E
73
78
82
84
22
23
24
25
Assemble Components
15.2 Recognizes valve problems and their causes.
17.2 Interprets hose specifications from recognized standards.
19.1 Knows how tubing assemblies seal to the fitting.
Field Repairs
20.2 Recognizes the symptoms of failure in a directional valve.
22.2 Understands what control the pressure setting on a balanced
piston relief valve.
23.2 Knows the proper procedure to install a shaft seal in a housing.
37.1
41.1

Recognizes the importance of and reasons for additives.
Understands coupler alignment terminology and how to check
for misalignment.
Calculates flow rate for a pump given displacement and
speed information.
Knows how to install and adjust V-packing for proper operation.
43.1
45.2
47.1
48.1
Troubleshooting
Understands how pressurized fluid causes cylinder movement.
Solves equations for displacement, speed, or volumetric efficiency.
Understands how solenoids activate a directional control valve.
34.2
35.2
36.2
IHM Manual # 402 - 01/00
A
A
A
A
B
B
B
B
C
C
C
C
D
D
D
D
E
E
E
E
Industrial Hydraulic Mechanic Pre-Test Answer Key

IHM-1
IHM-2
IHM-3
1.
1.
1.
2.
2.
2.
3.
3.
3.
4.
4.
4.
5.
5.
5.
6.
6.
6.
7.
7.
7.
8.
8.
8.
9.
9.
9.
10.
10.
10.
11.
11.
11.
12.
12.
12.
13.
13.
13.
14.
14.
14.
15.
15.
15.
16.
16.
16.
17.
17.
17.
18.
18.
18.
19.
19.
19.
20.
20.
20.
21.
21.
21.
22.
22.
22.
23.
23.
23.
24.
24.
24.
25.
25.
25.
IHM Manual # 402 - 01/00
Notes
IHM Manual # 402 - 01/00
Notes
IHM Manual # 402 - 01/00
Notes
IHM Manual # 402 - 01/00
Help Improve This Guide

Updates, corrections and revisions to this Manual are requested and encouraged. This Manual is an
on-going attempt at developing support materials for Certified Fluid Power candidates. It will undoubtedly
require improvement. It is up to Certified Fluid Power candidates and Accredited Instructors to provide input and
suggestions for improvement. The Fluid Power Certification Board, composed of industry volunteers, is responsible
for determining what revisions and improvements are made to this Manual. The Manuals are updated on a
regular basis and date stamped on each page.
Please send your suggestions for improvement to the executive director who is coordinating input on
behalf of the Fluid Power Certification Board.
Thank you very much for helping us improve these materials for future candidates.
ATTN: Executive Director
Fluid Power Society
4544 Pheasant Run, Bethlehem, PA 18020-9512
Phone: 610-694-0950 Fax: 610-694-0611
PaulPrass@ifps.org
Comments
F LUID P OWER C ERTIFICATION

Setting competitive standards for Fluid Power Professionals
Fluid Power Certification ...
How Can I Benefit?
Fluid Power Certification is a fastgrowing educational movement in the
industry today - and it's not surprising
why.
Much of the traditional training from
manufacturers, technical schools, and
universities has been of high quality,
but limited in its availability.
Consequently, few of the 350,000 people
working in the industry have been able
to take full advantage of Fluid Power
training. Many of today's fluid power
professionals learned about the
technology on the job and often did not
receive the recognition they deserved
for their educational accomplishments.
If the majority of your professional
training was on-the-job or limited to
short courses and workshops, then
fluid power certification may be just what
you need to stay competitive in today's
marketplace. Fluid power certification
gives you an opportunity to demonstrate
your extraordinary effort to enhance
your professionalism through education,
training, and peer review. It may provide
you with the credential you need to
open the door for career advancement.
For fluid power distributors, manufacturers and end-users, certification
offers a multitude of benefits:
Provides another measure with
which to assess new employees.
Establishes a minimal level of
Fluid Power knowledge and skills.
Educates your customers - so
you don't have to.
Helps satisfy requirements for
employee qualifications.
Demonstrates an individual's
efforts to achieve and maintain
the highest professional
proficiency available in the industry.
What's Involved in Certification?

Fluid power certification consists of
an optional review session, followed by
a three-hour written test and recognition
upon successful completion. For
Mechanic certification, an additional
three-hour job performance test is also
required.
How Many Kinds of Tests Are Offered?

The Fluid Power Certification Board
currently offers seven Certification
Tests at four levels:
Mechanic: fabricates, assembles,

tests, maintains and repairs
systems and components, etc.
Master Mechanic
- Mobile Hydraulic Mechanic
- Industrial Hydraulic Mechanic
- Pneumatic Mechanic
Technician: troubleshoots systems,
tests and modifies systems,
prepares reports, etc.
Master Technician
- Mobile Hydraulic Technician
- Industrial Hydraulic Technician
- Pneumatic Technician
Specialist: analyzes and designs
systems, selects components,
instructs others in operations and
maintenance, etc.
Fluid Power Specialist
- Hydraulic Specialist
- Pneumatic Specialist
Engineer: has a technology or
engineering degree or is a current
Professional Engineer, has eight
years of work experience and has
passed the Hydraulic &
Pneumatic Specialist exams.
What Technologies are Covered

by the Tests?
Fluid power and motion control
technologies include questions on
hydraulics, pneumatics, electronic control,
and vacuum.
Who May Organize

a Review Training Session?
Educational institutions, end-user
companies, fluid power distributors,
fluid power component manufacturers,
for-profit educational organizations and
the Fluid Power Society (local chapters
or the national Headquarters), can
organize review training sessions.
How Will My Accomplishments

be Recognized?
Certified fluid power professionals
are encouraged to include their
certification on their business cards and
letterhead - even on work vehicle signage.
Certification patches are also available
for use on uniforms, as well as other
promotional items. All Certified
Professionals receive a certificate suitable
for framing, wallet card, are recognized
in the Fluid Power Journal, are listed in
the annual Certification Directory, and
on the Fluid Power Societys web site.
Will I Have to Renew My Certification?

Yes - Certifications are valid for five
years. After that time, you must apply
for re-certification based on a point
system. On the re-certification form,
you will be asked to list job responsibilities,
additional educational courses you
have taken or taught, and professional
involvement in Fluid Power or allied
organizations.
What Will This Cost Me?

The Fluid Power Certification Board
has made every effort to keep costs low
and make Certification available to as
many fluid power professionals as
possible. Many manufacturers and
distributors subsidize or even reward
this program because it provides a
great return on investment. A contribution
to the fluid power certification program
helps upgrade the skills of those
professionals committed to the industry
and elevates the level of professionalism
throughout the entire Fluid Power
Industry.
How Can I Receive More Information?
Who Administers the Tests?
For fee schedules, review sessions,

manuals and other information, please
visit
our
web
site
at
http://www.IFPS.org, call our Fax-onDemand at 1-800-214-2958, contact
Headquarters at 1-800-330-8520 or
write to:
Written testing is conducted under

the supervision of local proctors
retained by the Fluid Power Certification
Board. Job performance testing may
only be administered by an FPS
Accredited Instructor. Tests are scheduled throughout the world in over 138
cities throughout the year.
Fluid Power Certification Board

2433 North Mayfair Road, Suite 111
Milwaukee, WI 53226-1406
Phone: 800-330-8520, 414-257-0910;
Fax: 414-257-4092 E-mail:
FPS@IFPS.org;
Web: http://www.IFPS.org;
Fax-on-Demand: 800-214-2958
For a listing of review training sessions, check out the web site or call our
Fax-on-Demand line.
CERTIFICATION APPLICATION FORM
CIETY
FL
FL
SO
D POW
UI
SO
ER
ER
D POW
UI
CIETY
FPCB Coordinator c/o FPS, 2433 North Mayfair Road, Suite 111, Milwaukee, WI, 53226 Phone: 414-257-0910 FAX: 414-257-4092
Certification Test Application

Please fully complete form.
Preferred mailing address:
Name
Employer
Home Address
Work Address
City
State
Phone
Fax
Zip
Home
Work
City
State
Phone
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E-mail address
E-mail address
Social Security Number (Serves as your Test ID Number)
Present Job/Title
Zip
Check highest level attained:

(Educational Information)
Grade School
Years_____
Send me complete membership information.
High School
Years_____ Diploma_________
Send me information on other levels of Certification.
Technical Institute
Years_____ Degree__________
Send me information on the Instructor Accreditation

Program.
College
Years_____ Degree__________
Which test do you intend to take?
(Check one)
Mobile Hydraulic Mechanic

Industrial Hydraulic Mechanic
Pneumatic Mechanic
Mobile Hydraulic Technician
Industrial Hydraulic Technician
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Hydraulic Specialist
Pneumatic Specialist
Job Performance Test Hyd. Pneu.
Item
Amount
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Retake Fee - Written Test
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Pre-Test # ___________
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TOTAL DUE :
Test Date:
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Industrial Hydraulic Mechanic Certification

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INDUSTRIAL HYDRAULIC

Including Study Guide,

Manual # 402 - 01/00

FLUID POWER SOCIETY

Manual #402 - 01/00

Industrial Hydraulic Mechanic

questions correctly should gain access to the

IHM Manual # 402 - 01/00

Industrial Hydraulic Mechanic Study Guide 3

4 Industrial Hydraulic Mechanic Study Guide

IHM Manual # 402 - 01/00

Adjust the charge pressure on a bladder type accumulator. ....................................................................12

Torque bolts on a circular pattern............................................................................................................13

Add hydraulic fluid to the reservoir. .......................................................................................................15

Change spin-on and cartridge type hydraulic filters. ..............................................................................19

Draw a hydraulic pressure line sample using a sampling valve. ............................................................22

Examine hydraulic fluid for water and contaminants. ............................................................................24

Transfer fluid through a portable filtration unit. .....................................................................................26

10.0 Label fluid sample for laboratory analysis. .............................................................................................27

IHM Manual # 402 - 01/00

Industrial Hydraulic Mechanic Study Guide 5

6 Industrial Hydraulic Mechanic Study Guide

IHM Manual # 402 - 01/00

IHM Manual # 402 - 01/00

Industrial Hydraulic Mechanic Study Guide 7

8 Industrial Hydraulic Mechanic Study Guide

IHM Manual # 402 - 01/00

FPS Industrial Hydraulic Mechanic Certification

Torque (ft. lb. ) = Force (lb. ) Lever Arm (ft. )

Torque (in. lb. ) = Force (lb. ) Lever Arm (i n. )

Theoretical Flow Rate (gpm) = Dis placement (CID)

Operating Pres s ure (ps i) =

Burs t Pres s ure (ps i)

Hydraulic HP = Pres s ure (ps i)

Dis placement (CID) = b ore area (in.

) s troke (in. ) no. of cyl inders

Area (pis ton) (in. ) = (radius (in. ))

Pres sure (ps i) =

Bypas s flow (pump) (gpm) = Theoretical flow - Actual flow

By pas s flow (motor) (gpm) = Input flow - U s able flow

IHM Manual # 402 - 01/00

Force (lb .) = Pres s ure (ps i) Area (in. )

Actual Flow (motor) (gpm) = Dis placement (CID)

Industrial Hydraulic Mechanic Study Guide 9

Adjust hydraulic hose and fittings for proper position

10 Industrial Hydraulic Mechanic Study Guide

IHM Manual # 402 - 01/00

IHM Manual # 402 - 01/00

Industrial Hydraulic Mechanic Study Guide 11

Adjust the charge pressure on a bladder type accumulator.

Accumulators should be mounted vertically. All fluid must be

Proper safety practices, including locking out a system and wearing

IHM Manual # 402 - 01/00

Torque screws on a circular pattern.

Torque (in. lb. ) = Force (lb. ) Lever Arm (i n. )

IHM Manual # 402 - 01/00

Industrial Hydraulic Mechanic Study Guide 13

Fig. 3. Average Torque Values for Grade 2 Bolts

Fig. 4. Torque Circular

14 Industrial Hydraulic Mechanic Study Guide

IHM Manual # 402 - 01/00

Add hydraulic fluid to the reservoir.

Hydraulic Fluid Table

IHM Manual # 402 - 01/00