Fluid Power (Part 1) – Hydraulic Principles Course No: M04-016

Credit: 4 PDH

A. Bhatia

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NAVEDTRA 12964Naval Education and July 1990 Training ManualTraining Command 0502-LP-213-2300 (TRAMAN)

Fluid Power

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FLUID POWER

NAVEDTRA 12964

1990 Edition Prepared byMWC Albert Beasley, Jr.

CHAPTER 1

INTRODUCTION TO FLUID POWER

Fluid power is a term which was created toinclude the generation, control, and applicationof smooth, effective power of pumped orcompressed fluids (either liquids or gases) whenthis power is used to provide force and motionto mechanisms. This force and motion maybe inthe form of pushing, pulling, rotating, regulating,or driving. Fluid power includes hydraulics, whichinvolves liquids, and pneumatics, which involvesgases. Liquids and gases are similar in manyrespects. The differences are pointed out in theappropriate areas of this manual.

This manual presents many of the funda-mental concepts in the fields of hydraulics andpneumatics. It is intended as a basic reference forall personnel of the Navy whose duties andresponsibilities require them to have a knowledgeof the fundamentals of fluid power. Conse-quently, emphasis is placed primarily on thetheory of operation of typical fluid power systemsand components that have applications in navalequipment. Many applications of fluid power arepresented in this manual to illustrate the functionsand operation of different systems and com-ponents. However, these are only representativeof the many applications of fluid power in navalequipment. Individual training manuals for eachrate provide information concerning the applica-tion of fluid power to specific equipment forwhich the rating is responsible.

A brief summary of the contents of thistraining manual is given in the followingparagraphs:

Chapter 2 covers the characteristics of liquidsand the factors affecting them. It also explainsthe behavior of liquids at rest, identifies thecharacteristics of liquids in motion, and explainsthe operation of basic hydraulic components.

Chapter 3 discusses the qualities of fluidsacceptable for hydraulic systems and the types offluids used. Included are sections on safetyprecautions to follow when handling potentially

hazardous fluids, liquid contamination, andcontrol of contaminants.

Chapter 4 covers the hydraulic pump, thecomponent in the hydraulic system whichgenerates the force required for the system toperform its design function. The informationprovided covers classifications, types, operation,and construction of pumps.

Chapter 5 deals with the piping, tubing andflexible hoses, and connectors used to carry fluidsunder pressure.

Chapter 6 discusses the classification, types,and operation of valves used in the control offlow, pressure, and direction of fluids.

Chapter 7 covers the types and purposes ofsealing devices used in fluid power systems,including the different materials used in theirconstruction. Additionally, the guidelines forselecting, installing, and removing O-rings areincluded.

Chapter 8 discusses the operation of devicesused to measure and regulate the pressure of fluidsand to measure the temperature of fluids.

Chapter 9 describes the functions and typesof reservoirs, strainers, filters, and accumulators,and their uses in fluid power systems.

Chapter 10 discusses the types and operationof actuators used to transform the energygenerated by hydraulic systems into mechanicalforce and motion.

Chapter 11 deals with pneumatics. It discussesthe origin of pneumatics, the characteristics andcompressibility of gases, and the most commonlyused gases in pneumatic systems. Also, sectionsare included to cover safety precautions and thepotential hazards of compressed gases.

Chapter 12 identifies the types of diagramsencountered in fluid power systems. This chapteralso discusses how components of chapters 4, 5,6, 8, 9, and 10 are combined to form and operatetogether as a system.

A glossary of terms commonly used in fluidpower is provided in appendix I. Appendix IIprovides symbols used in aeronautical mechanical

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systems, and appendix III provides symbols usedin nonaeronautical mechanical systems.

The remainder of chapter 1 is devoted to theadvantages and problems of fluid power appli-cations. Included are brief sections on the history,development, and applications of hydraulics,the states of matter.

ADVANTAGES OF FLUID POWER

and

The extensive use of hydraulics and pneuma-tics to transmit power is due to the fact thatproperly constructed fluid power systems possessa number of favorable characteristics. Theyeliminate the need for complicated systems ofgears, cams, and levers. Motion can be trans-mitted without the slack inherent in the use ofsolid machine parts. The fluids used are notsubject to breakage as are mechanical parts, andthe mechanisms are not subjected to great wear.

The different parts of a fluid power systemcan be conveniently located at widely separatedpoints, since the forces generated are rapidlytransmitted over considerable distances with smallloss. These forces can be conveyed up and downor around corners with small loss in efficiency andwithout complicated mechanisms. Very largeforces can be controlled by much smaller ones andcan be transmitted through comparatively smalllines and orifices.

If the system is well adapted to the work it isrequired to perform, and if it is not misused, itcan provide smooth, flexible, uniform actionwithout vibration, and is unaffected by variationof load. In case of an overload, an automaticrelease of pressure can be guaranteed, so that thesystem is protected against breakdown or strain.Fluid power systems can provide widely variablemotions in both rotary and straight-line trans-mission of power. The need for control by handcan be minimized. In addition, fluid powersystems are economical to operate.

The question may arise as to why hydraulicsis used in some applications and pneumatics inothers. Many factors are considered by the userand/or the manufacturer when determining whichtype of system to use in a specific application.There are no hard and fast rules to follow;however, past experience has provided somesound ideas that are usually considered when suchdecisions are made. If the application requiresspeed, a medium amount of pressure, and onlyfairly accurate control, a pneumatic system maybe used. If the application requires only a medium

amount of pressure and a more accurate control,a combination of hydraulics and pneumatics maybe used. If the application requires a great amountof pressure and/or extremely accurate control, ahydraulic system should be used.

SPECIAL PROBLEMS

The extreme flexibility of fluid power elementspresents a number of problems. Since fluids haveno shape of their own, they must be positivelyconfined throughout the entire system. Specialconsideration must be given to the structuralintegrity of the parts of a fluid power system.Strong pipes and containers must be provided.Leaks must be prevented. This is a seriousproblem with the high pressure obtained in manyfluid power installations.

The operation of the system involves constantmovement of the fluid within the lines andcomponents. This movement causes frictionwithin the fluid itself and against the containingsurfaces which, if excessive, can lead to seriouslosses in efficiency. Foreign matter must not beallowed to accumulate in the system, where it willclog small passages or score closely fitted parts.Chemical action may cause corrosion. Anyoneworking with fluid power systems must know howa fluid power system and its components operate,both in terms of the general principles commonto all physical mechanisms and of the peculiaritiesof the particular arrangement at hand.

HYDRAULICS

The word hydraulics is based on the Greekword for water, and originally covered the studyof the physical behavior of water at rest and inmotion. Use has broadened its meaning to includethe behavior of all liquids, although it is primarilyconcerned with the motion of liquids.

Hydraulics includes the manner in whichliquids act in tanks and pipes, deals with theirproperties, and explores ways to take advantageof these properties.

DEVELOPMENT OF HYDRAULICS

Although the modern development ofhydraulics is comparatively recent, the ancientswere familiar with many hydraulic principles andtheir applications. The Egyptians and the ancientpeople of Persia, India, and China conveyed water

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along channels for irrigation and domesticpurposes, using dams and sluice gates to controlthe flow. The ancient Cretans had an elaborateplumbing system. Archimedes studied the laws offloating and submerged bodies. The Romansconstructed aqueducts to carry water to theircities.

After the breakup of the ancient world, therewere few new developments for many centuries.Then, over a comparatively short period,beginning near the end of the seventeenth century,Italian physicist, Evangelista Torricelle, Frenchphysicist, Edme Mariotte, and later, DanielBernoulli conducted experiments to study theelements of force in the discharge of waterthrough small openings in the sides of tanks andthrough short pipes. During the same period,Blaise Pascal, a French scientist, discovered thefundamental law for the science of hydraulics.

Pascal’s law states that increase in pressure onthe surface of a confined fluid is transmittedundiminished throughout the confining vessel orsystem (fig. 1-1). (This is the basic principle ofhydraulics and is covered in detail in chapter 2of this manual.)

For Pascal’s law to be made effective forpractical applications, it was necessary to have apiston that “fit exactly.” It was not until the latterpart of the eighteenth century that methods werefound to make these snugly fitted parts requiredin hydraulic systems. This was accomplished bythe invention of machines that were used to cutand shape the necessary closely fitted parts and,particularly, by the development of gaskets andpackings. Since that time, components such asvalves, pumps, actuating cylinders, and motorshave been developed and refined to makehydraulics one of the leading methods of trans-mitting power.

Figure 1-1.—Force transmitted through fluid.

Use of Hydraulics

The hydraulic press, invented by EnglishmanJohn Brahmah, was one of the first work-able pieces of machinery developed that usedhydraulics in its operation. It consisted of aplunger pump piped to a large cylinder and a ram.This press found wide use in England because itprovided a more effective and economical meansof applying large forces in industrial uses.

Today, hydraulic power is used to operatemany different tools and mechanisms. In agarage, a mechanic raises the end of an auto-mobile with a hydraulic jack. Dentists and barbersuse hydraulic power, through a few strokes of acontrol lever, to lift and position their chairs toa convenient working height. Hydraulic doorstopskeep heavy doors from slamming. Hydraulicbrakes have been standard equipment on auto-mobiles since the 1930s. Most automobiles areequipped with automatic transmissions that arehydraulically operated. Power steering is anotherapplication of hydraulic power. Constructionworkers depend upon hydraulic power for theoperation of various components of theirequipment. For example, the blade of a bulldozeris normally operated by hydraulic power.

During the period preceding World War II,the Navy began to apply hydraulics to navalmechanisms extensively. Since then, navalapplications have increased to the point wheremany ingenious hydraulic devices are used in thesolution of problems of gunnery, aeronautics, andnavigation. Aboard ship, hydraulic power is usedto operate such equipment as anchor windlasses,cranes, steering gear, remote control devices, andpower drives for elevating and training guns androcket launchers. Elevators on aircraft carriers usehydraulic power to transfer aircraft from thehangar deck to the flight deck and vice versa.

Hydraulics and pneumatics (chapter 11) arecombined for some applications. This combina-tion is referred to as hydropneumatics. A nexample of this combination is the lift used ingarages and service stations. Air pressure isapplied to the surface of hydraulic fluid in areservoir. The air pressure forces the hydraulicfluid to raise the lift.

STATES OF MATTER

The material that makes up the universe isknown as matter. Matter is defined as anysubstance that occupies space and has weight.

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Matter exists in three states: solid, liquid, and gas;each has distinguishing characteristics. Solids havea definite volume and a definite shape; liquidshave a definite volume, but take the shape of theircontaining vessels; gases have neither a definiteshape nor a definite volume. Gases not only takethe shape of the containing vessel, but also expandand fill the vessel, regardless of its volume.Examples of the states of matter are iron, water,and air.

Matter can change from one state to another.Water is a good example. At high temperaturesit is in the gaseous state known as steam. Atmoderate temperatures it is a liquid, and at lowtemperatures it becomes ice, which is definitelya solid state. In this example, the temperature isthe dominant factor in determining the state thesubstance assumes.

Pressure is another important factor that willaffect changes in the state of matter. At pressureslower than atmospheric pressure, water will boiland thus change into steam at temperatures lowerthan 212° Fahrenheit (F). Pressure is also a criticalfactor in changing some gases to liquids or solids.Normally, when pressure and chilling are bothapplied to a gas, the gas assumes a liquid state.Liquid air, which is a mixture of oxygen andnitrogen, is produced in this manner.

In the study of fluid power, we are concernedprimarily with the properties and characteristicsof liquids and gases. However, you should keepin mind that the properties of solids also affectthe characteristics of liquids and gases. The linesand components, which are solids, enclose andcontrol the liquid or gas in their respectivesystems.

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CHAPTER 2

FORCES IN LIQUIDS

The study of liquids is divided into two mainparts: liquids at rest (hydrostatics) and liquids inmotion (hydraulics).

The effects of liquids at rest can oftenbe expressed by simple formulas. The effectsof liquids in motion are more difficult toexpress due to frictional and other factorswhose actions cannot be expressed by simplemathematics.

In chapter 1 we learned that liquids have adefinite volume but take the shape of theircontaining vessel. There are two additionalcharacteristics we must explore prior to pro-ceeding.

Liquids are almost incompressible. Forexample, if a pressure of 100 pounds per squareinch (psi) is applied to a given volume of waterthat is at atmospheric pressure, the volume willdecrease by only 0.03 percent. It would take aforce of approximately 32 tons to reduce itsvolume by 10 percent; however, when this forceis removed, the water immediately returns to itsoriginal volume. Other liquids behave in aboutthe same manner as water.

Another characteristic of a liquid is thetendency to keep its free surface level. If thesurface is not level, liquids will flow in thedirection which will tend to make the surfacelevel.

LIQUIDS AT REST

In studying fluids at rest, we are con-cerned with the transmission of force andthe factors which affect the forces in liquids.Additionally, pressure in and on liquids andfactors affecting pressure are of great im-portance.

PRESSURE AND FORCE

The terms force and pressure are usedextensively in the study of fluid power. Itis essential that we distinguish between theterms. Force means a total push or pull.It is the push or pull exerted against thetotal area of a particular surface and is expressedin pounds or grams. Pressure means the amountof push or pull (force) applied to each unit areaof the surface and is expressed in pounds persquare inch (lb/in 2) or grams per squarecentimeter (gm/cm2). Pressure maybe exerted inone direction, in several directions, or in alldirections.

Computing Force, Pressure, and Area

A formula is used in computing force,pressure, and area in fluid power systems. In thisformula, P refers to pressure, F indicates force,and A represents area.

Force equals pressure times area. Thus, theformula is written

Equation 2-1.

Pressure equals force divided by area. Byrearranging the formula, this statement may becondensed into

Equation 2-2.

Since area equals force divided by pressure,the formula is written

Equation 2-3.

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Figure 2-1.—Device for determining the arrangement of theforce, pressure, and area formula.

Figure 2-1 illustrates a memory device forrecalling the different variations of this formula.Any letter in the triangle may be expressed as theproduct or quotient of the other two, dependingon its position within the triangle.

For example, to find area, consider the letterA as being set off to itself, followed by an equalsign. Now look at the other two letters. The letterF is above the letter P; therefore,

NOTE: Sometimes the area may not beexpressed in square units. If the surface isrectangular, you can determine its area bymultiplying its length (say, in inches) by its width(also in inches). The majority of areas you willconsider in these calculations are circular in shape.Either the radius or the diameter may be given,but you must know the radius in inches to findthe area. The radius is one-half the diameter. Todetermine the area, use the formula for findingthe area of a circle. This is written A = rmz, whereA is the area, n is 3.1416 (3.14 or 3 1/7 for mostcalculations), and r2 indicates the radius squared.

Atmospheric Pressure

The atmosphere is the entire mass of air thatsurrounds the earth. While it extends upward forabout 500 miles, the section of primary interestis the portion that rests on the earth’s surface andextends upward for about 7 1/2 miles. This layeris called the troposphere.

If a column of air 1-inch square extending allthe way to the “top” of the atmosphere couldbe weighed, this column of air would weighapproximately 14.7 pounds at sea level. Thus,atmospheric pressure at sea level is approximately14.7 psi.

As one ascends, the atmospheric pressuredecreases by approximately 1.0 psi for every 2,343feet. However, below sea level, in excavations anddepressions, atmospheric pressure increases.Pressures under water differ from those under aironly because the weight of the water must beadded to the pressure of the air.

Atmospheric pressure can be measured by anyof several methods. The common laboratorymethod uses the mercury column barometer. Theheight of the mercury column serves as anindicator of atmospheric pressure. At sea level andat a temperature of 0° Celsius (C), the height ofthe mercury column is approximately 30 inches,or 76 centimeters. This represents a pressure ofapproximately 14.7 psi. The 30-inch column isused as a reference standard.

Another device used to measure atmosphericpressure is the aneroid barometer. The aneroidbarometer uses the change in shape of anevacuated metal cell to measure variations inatmospheric pressure (fig. 2-2). The thin metal ofthe aneroid cell moves in or out with the variationof pressure on its external surface. This movementis transmitted through a system of levers to apointer, which indicates the pressure.

The atmospheric pressure does not varyuniformly with altitude. It changes more rapidlyat lower altitudes because of the compressibilityof the air, which causes the air layers close to theearth’s surface to be compressed by the air massesabove them. This effect, however, is partiallycounteracted by the contraction of the upper

Figure 2-2.—Simple diagram of the aneroid barometer.

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layers due to cooling. The cooling tends toincrease the density of the air.

Atmospheric pressures are quite large, but inmost instances practically the same pressure ispresent on all sides of objects so that no singlesurface is subjected to a great load.

Atmospheric pressure acting on the surface ofa liquid (fig. 2-3, view A) is transmitted equallythroughout the liquid to the walls of the container,but is balanced by the same atmospheric pressureacting on the outer walls of the container. In viewB of figure 2-3, atmospheric pressure acting onthe surface of one piston is balanced by the samepressure acting on the surface of the other piston.The different areas of the two surfaces make nodifference, since for a unit of area, pressures arebalanced.

TRANSMISSION OF FORCESTHROUGH LIQUIDS

When the end of a solid bar is struck, the mainforce of the blow is carried straight through thebar to the other end (fig. 2-4, view A). Thishappens because the bar is rigid. The directionof the blow almost entirely determines thedirection of the transmitted force. The more rigid

Figure 2-4.—Transmission of force: (A) solid; (B) fluid.

the bar, the less force is lost inside the bar ortransmitted outward at right angles to thedirection of the blow.

When a force is applied to the end of a columnof confined liquid (fig. 2-4, view B), it istransmitted straight through to the other end andalso equally and undiminished in every directionthroughout the column—forward, backward, andsideways—so that the containing vessel is literallyfilled with pressure.

An example of this distribution of force isillustrated in figure 2-5. The flat hose takes on

Figure 2-3.—Effects of atmospheric pressure. Figure 2-5.—Distribution of force.

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a circular cross section when it is filled with waterunder pressure. The outward push of the wateris equal in every direction.

So far we have explained the effects ofatmospheric pressure on liquids and how externalforces are distributed through liquids. Let us nowfocus our attention on forces generated by theweight of liquids themselves. To do this, we mustfirst discuss density, specific gravity, and Pascal’slaw.

Density and Specific Gravity

The density of a substance is its weight per unitvolume. The unit volume in the English systemof measurement is 1 cubic foot. In the metricsystem it is the cubic centimeter; therefore, densityis expressed in pounds per cubic foot or in gramsper cubic centimeter.

To find the density of a substance, you mustknow its weight and volume. You then divide itsweight by its volume to find the weight per unitvolume. In equation form, this is written as

Equation 2-4.

EXAMPLE: The liquid that fills a certaincontainer weighs 1,497.6 pounds. Thecontainer is 4 feet long, 3 feet wide, and2 feet deep. Its volume is 24 cubic feet(4 ft x 3 ft x 2 ft). If 24 cubic feet of thisliquid weighs 1,497.6 pounds, then 1 cubicfoot weighs

or 62.4 pounds. Therefore, the density ofthe liquid is 62.4 pounds per cubic foot.

This is the density of water at 4°C and isusually used as the standard for comparingdensities of other substances. The temperature of4°C was selected because water has its maximumdensity at this temperature. In the metric system,the density of water is 1 gram per cubiccentimeter. The standard temperature of 4°C isused whenever the density of liquids and solidsis measured. Changes in temperature will notchange the weight of a substance but will changethe volume of the substance by expansion orcontraction, thus changing the weight per unitvolume.

In physics, the word specific implies a ratio.Weight is the measure of the earth’s attraction fora body. The earth’s attraction for a body is calledgravity. Thus, the ratio of the weight of a unitvolume of some substance to the weight of anequal volume of a standard substance, measuredunder standard pressure and temperature con-ditions, is called specific gravity. The termsspecific weight and specific density are sometimesused to express this ratio.

The following formulas are used to find thespecific gravity (sp gr) of solids and liquids, withwater used as the standard substance.

or,

The same formulas are used to find the specificgravity of gases by substituting air, oxygen, orhydrogen for water.

If a cubic foot of a certain liquid weighs 68.64pounds, then its specific gravity is 1.1,

Thus, the specific gravity of the liquid is theratio of its density to the density of water. If thespecific gravity of a liquid or solid is known, thedensity of the liquid or solid maybe obtained bymultiplying its specific gravity by the density ofwater. For example, if a certain hydraulic liquidhas a specific gravity of 0.8, 1 cubic foot of theliquid weighs 0.8 times as much as a cubic footof water—0.8 times 62.4, or 49.92 pounds. In themetric system, 1 cubic centimeter of a substancewith a specific gravity of 0.8 weighs 1 times 0.8,or 0.8 grams. (Note that in the metric system thespecific gravity of a liquid or solid has the samenumerical value as its density, because waterweighs 1 gram per cubic centimeter.)

Specific gravity and density are independentof the size of the sample under consideration anddepend only on the substance of which it is made.

A device called a hydrometer is used formeasuring the specific gravity of liquids.

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Pascal’s Law

Recall from chapter 1 that the foundation ofmodern hydraulics was established when Pascaldiscovered that pressure in a fluid acts equally inall directions. This pressure acts at right anglesto the containing surfaces. If some type ofpressure gauge, with an exposed face, is placedbeneath the surface of a liquid (fig. 2-6) at aspecific depth and pointed in different directions,the pressure will read the same. Thus, we can saythat pressure in a liquid is independent ofdirection.

Pressure due to the weight of a liquid, at anylevel, depends on the depth of the fluid from thesurface. If the exposed face of the pressure gauges,figure 2-6, are moved closer to the surface of theliquid, the indicated pressure will be less. Whenthe depth is doubled, the indicated pressure isdoubled. Thus the pressure in a liquid is directlyproportional to the depth.

Consider a container with vertical sides(fig. 2-7) that is 1 foot long and 1 foot wide. Letit be filled with water 1 foot deep, providing 1cubic foot of water. We learned earlier in thischapter that 1 cubic foot of water weighs 62.4pounds. Using this information and equation 2-2,P = F/A, we can calculate the pressure on thebottom of the container.

Since there are 144 square inches in 1 square foot,

This can be stated as follows: the weight of acolumn of water 1 foot high, having a cross-sectional area of 1 square inch, is 0.433 pound.

If the depth of the column is tripled, theweight of the column will be 3 x 0.433, or 1.299pounds, and the pressure at the bottom will be1.299 lb/in2 (psi), since pressure equals the forcedivided by the area. Thus, the pressure at anydepth in a liquid is equal to the weight of thecolumn of liquid at that depth divided by the

Figure 2-6.—Pressure of a liquid is independent of direction.

cross-sectional area of the column at that depth.The volume of a liquid that produces the pressureis referred to as the fluid head of the liquid. Thepressure of a liquid due to its fluid head is alsodependent on the density of the liquid.

If we let A equal any cross-sectional area ofa liquid column and h equal the depth of thecolumn, the volume becomes Ah. Using equation2-4, D = W/V, the weight of the liquid above areaA is equal to AhD.

Figure 2-7.—Water pressure in a 1-cubic-foot container.

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Since pressure is equal to the force per unit area,set A equal to 1. Then the formula pressurebecomes

P = h D Equation 2-5.

It is essential that h and D be expressed in similarunits. That is, if D is expressed in pounds percubic foot, the value of h must be expressed infeet. If the desired pressure is to be expressed inpounds per square inch, the pressure formula,equation 2-5, becomes

Equation 2-6.

Pascal was also the first to prove byexperiment that the shape and volume of acontainer in no way alters pressure. Thus in figure2-8, if the pressure due to the weight of the liquidat a point on horizontal line H is 8 psi, thepressure is 8 psi everywhere at level H in thesystem. Equation 2-5 also shows that the pressureis independent of the shape and volume of acontainer.

Pressure and Force in Fluid Power Systems

Figure 2-9.—Force transmitted through fluid.

of the shape of the container. Consider the effectof this in the system shown in figure 2-9. If thereis a resistance on the output piston and the inputpiston is pushed downward, a pressure is createdthrough the fluid, which acts equally at rightangles to surfaces in all parts of the container.

If force 1 is 100 pounds and the area of theinput piston is 10 square inches, then the pressurein the fluid is 10 psi

Recall that, according to Pascal’s law, anyforce applied to a confined fluid is transmittedin all directions throughout the fluid regardless

NOTE: Fluid pressure cannot be createdwithout resistance to flow. In this case, resistance

Figure 2-8.—Pressure relationship

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with shape.

is provided by the equipment to which theoutput piston is attached. The force of re-sistance acts against the top of the outputpiston. The pressure created in the systemby the input piston pushes on the underside ofthe output piston with a force of 10 pounds oneach square inch.

In this case, the fluid column has a uniformcross section, so the area of the output pistonis the same as the area of the input piston,or 10 square inches. Therefore, the upwardforce on the output piston is 100 pounds(10 psi x 10 sq. in.), the same as the force appliedto the input piston. All that was accomplished inthis system was to transmit the 100-pound forcearound the bend. However, this principle under-lies practically all mechanical applications of fluidpower.

At this point you should note that sincePascal’s law is independent of the shape ofthe container, it is not necessary that thetube connecting the two pistons have the samecross-sectional area of the pistons. A connectionof any size, shape, or length will do, as long asan unobstructed passage is provided. Therefore,the system shown in figure 2-10, with a relativelysmall, bent pipe connecting two cylinders,will act exactly the same as the system shown infigure 2-9.

MULTIPLICATION OF FORCES.— Con-sider the situation in figure 2-11, where the inputpiston is much smaller than the output piston.Assume that the area of the input piston is 2square inches. With a resistant force on the outputpiston a downward force of 20 pounds acting on

the input piston creates a pressure of ~ or 10 psi

Figure 2-10.—Transmitting force through a small pipe.

Figure 2-11.—Multiplication of forces.

in the fluid. Although this force is much smallerthan the force applied in figures 2-9 and 2-10, thepressure is the same. This is because the force isapplied to a smaller area.

This pressure of 10 psi acts on all parts of thefluid container, including the bottom of theoutput piston. The upward force on the outputpiston is 200 pounds (10 pounds of pressure oneach square inch). In this case, the original forcehas been multiplied tenfold while using the samepressure in the fluid as before. In any system withthese dimensions, the ratio of output force toinput force is always ten to one, regardless of theapplied force. For example, if the applied forceof the input piston is 50 pounds, the pressure inthe system will be 25 psi. This will support aresistant force of 500 pounds on the output piston.

The system works the same in reverse. If wechange the applied force and place a 200-poundforce on the output piston (fig. 2-11), making itthe input piston, the output force on the inputpiston will be one-tenth the input force, or 20pounds. (Sometimes such results are desired.)Therefore, if two pistons are used in a fluid powersystem, the force acting on each piston is directlyproportional to its area, and the magnitude ofeach force is the product of the pressure and thearea of each piston.

Note the white arrows at the bottom of figure2-11 that indicate up and down movement. Themovement they represent will be explained laterin the discussion of volume and distance factors.

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DIFFERENTIAL AREAS.— Consider thespecial situation shown in figure 2-12. Here, asingle piston (1) in a cylinder (2) has a piston rod(3) attached to one of its sides. The piston rodextends out of one end of the cylinder. Fluid underpressure is admitted equally to both ends of thecylinder. The opposed faces of the piston (1)behave like two pistons acting against each other.The area of one face is the full cross-sectional areaof the cylinder, say 6 square inches, while the areaof the other face is the area of the cylinder minusthe area of the piston rod, which is 2 squareinches. This leaves an effective area of 4 squareinches on the right face of the piston. The pressureon both faces is the same, in this case, 20 psi.Applying the rule just stated, the force pushingthe piston to the right is its area times the pressure,or 120 pounds (20 x 6). Likewise, the forcepushing the piston to the left is its area times thepressure, or 80 pounds (20 x 4). Therefore, thereis a net unbalanced force of 40 pounds acting tothe right, and the piston will move in thatdirection. The net effect is the same as if the pistonand the cylinder had the same cross-sectional areaas the piston rod.

VOLUME AND DISTANCE FACTORS.—You have learned that if a force is applied to asystem and the cross-sectional areas of the inputand output pistons are equal, as in figures 2-9 and2-10, the force on the input piston will support

an equal resistant force on the output piston. Thepressure of the liquid at this point is equal to theforce applied to the input piston divided by thepiston’s area. Let us now look at what happenswhen a force greater than the resistance is appliedto the input piston.

In the system illustrated in figure 2-9, assumethat the resistance force on the output piston is100 psi. If a force slightly greater than 100 poundsis applied to the input piston, the pressure in thesystem will be slightly greater than 10 psi. Thisincrease in pressure will overcome the resistanceforce on the output piston. Assume that the inputpiston is forced downward 1 inch. The movementdisplaces 10 cubic inches of fluid. The fluid mustgo somewhere. Since the system is closed and thefluid is practically incompressible, the fluid willmove to the right side of the system. Because theoutput piston also has a cross-sectional area of10 square inches, it will move 1 inch upward toaccommodate the 10 cubic inches of fluid. Youmay generalize this by saying that if two pistonsin a closed system have equal cross-sectional areasand one piston is pushed and moved, the otherpiston will move the same distance, though in theopposite direction. This is because a decrease involume in one part of the system is balanced byone equal increase in volume in another part ofthe system.

Apply this reasoning to the system in figure2-11. If the input piston is pushed down a distance

Figure 2-12.—Differential areas on a piston.

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of 1 inch, the volume of fluid in the left cylinderwill decrease by 2 cubic inches. At the same time,the volume in the right cylinder will increase by2 cubic inches. Since the diameter of the rightcylinder cannot change, the piston must moveupward to allow the volume to increase. Thepiston will move a distance equal to the volumeincrease divided by the surface area of the piston(equal to the surface area of the cylinder). In thisexample, the piston will move one-tenth of an inch(2 cu. in. ÷ 20 sq. in.). This leads to the secondbasic rule for a fluid power system that containstwo pistons: The distances the pistons move areinversely proportional to the areas of the pistons.Or more simply, if one piston is smaller than theother, the smaller piston must move a greaterdistance than the larger piston any time the pistonsmove.

LIQUIDS IN MOTION

In the operation of fluid power systems, theremust be a flow of fluid. The amount of flow willvary from system to system. To understand fluidpower systems in action, it is necessary tounderstand some of the characteristics of liquidsin motion.

Liquids in motion have characteristics dif-ferent from liquids at rest. Frictional resistanceswithin a fluid (viscosity) and inertia contribute tothese differences. (Viscosity is discussed in chapter3.) Inertia, which means the resistance a massoffers to being set in motion, will be discussedlater in this section. There are other relationshipsof liquids in motion with which you must becomefamiliar. Among these are volume and velocityof flow, flow rate and speed, laminar andturbulent flow, and more importantly, the forceand energy changes which occur in flow.

VOLUME AND VELOCITY OF FLOW

The volume of a liquid passing a point in agiven time is known as its volume of flow or flowrate. The volume of flow is usually expressed ingallons per minute (gpm) and is associated withrelative pressures of the liquid, such as 5 gpm at40 psi.

The velocity of flow or velocity of the fluidis defined as the average speed at which the fluidmoves past a given point. It is usually expressedin feet per second (fps) or feet per minute (fpm).Velocity of flow is an important consideration insizing the hydraulic lines. (Hydraulic lines arediscussed in chapter 5.)

Volume and velocity of flow are oftenconsidered together. With other conditionsunaltered—that is, with volume of inputunchanged—the velocity of flow increases as thecross section or size of the pipe decreases, and thevelocity of flow decreases as the cross sectionincreases. For example, the velocity of flow is slowat wide parts of a stream and rapid at narrowparts, yet the volume of water passing each partof the stream is the same.

In figure 2-13, if the cross-sectional area ofthe pipe is 16 square inches at point A and 4square inches at point B, we can calculate therelative velocity of flow using the flow equation

Q = v A Equation 2-7.

where Q is the volume of flow, v is the velocityof flow and A is the cross-sectional area of theliquid. Since the volume of flow at point A, Q1,is equal to the volume of flow at point B, Q2, wecan use equation 2-7 to determine the ratio of the

Figure 2-13.—Volume and velocity of flow.

2-9

velocity of flow at point A, v1, to the velocity offlow at point B, v2.

Since Q 1 = Q2, A1v 1 = A2v 2

From figure 2-13; A1 = 16sq. in., A2 = 4sq. in.

Substituting: 16v1 = 4V 2 or v 2 = 4vI

Therefore, the velocity of flow at point B is fourtimes the velocity of flow at point A.

VOLUME OF FLOW AND SPEED

If you consider the cylinder volume you mustfill and the distance the piston must travel, youcan relate the volume of flow to the speed of thepiston. The volume of the cylinder is found bymultiplying the piston area by the length the pistonmust travel (stroke).

Suppose you have determined that twocylinders have the same volume and that onecylinder is twice as long as the other. In this case,the cross-sectional area of the longer tube will behalf of the cross-sectional area of the other tube.If fluid is pumped into each cylinder at the samerate, both pistons will reach their full travel at thesame time. However, the piston in the smallercylinder must travel twice as fast because it hastwice as far to go.

There are two ways of controlling the speedof the piston, (1) by varying the size of the cylinderand (2) by varying the volume of flow (gpm) tothe cylinders. (Hydraulic cylinders are discussedin detail in chapter 10. )

STREAMLINE ANDTURBULENT FLOW

At low velocities or in tubes of small diameter,flow is streamlined. This means that a givenparticle of fluid moves straight forward withoutbumping into other particles and without crossingtheir paths. Streamline flow is often referred toas laminar flow, which is defined as a flowsituation in which fluid moves in parallel laminaor layers. As an example of streamline flow,consider figure 2-14, which illustrates an openstream flowing at a slow, uniform rate with logsfloating on its surface. The logs represent particlesof fluid. As long as the stream flows at a slow,uniform rate, each log floats downstream in its

Figure 2-14.—Streamline flow.

own path, without crossing or bumping into theother.

If the stream narrows, however, and thevolume of flow remains the same, the velocityof flow increases. If the velocity increasessufficiently, the water becomes turbulent. (Seefig. 2-15.) Swirls, eddies, and cross-motions areset up in the water. As this happens, the logs arethrown against each other and against the banksof the stream, and the paths followed by differentlogs will cross and recross.

Particles of fluid flowing in pipes act in thesame manner. The flow is streamlined if the fluidflows slowly enough, and remains streamlined atgreater velocities if the diameter of the pipe issmall. If the velocity of flow or size of pipe isincreased sufficiently, the flow becomes turbulent.

While a high velocity of flow will produceturbulence in any pipe, other factors contributeto turbulence. Among these are the roughness ofthe inside of the pipe, obstructions, the degree ofcurvature of bends, and the number of bends inthe pipe. In setting up or maintaining fluid powersystems, care should be taken to eliminate or

Figure 2-15.—Turbulent flow.

2-10

minimize as many causes of turbulence aspossible, since the energy consumed by turbulenceis wasted. Limitations related to the degreeand number of bends of pipe are discussed inchapter 5.

While designers of fluid power equipment dowhat they can to minimize turbulence, it cannotbe avoided. For example, in a 4-inch pipe at 68°F,flow becomes turbulent at velocities over approxi-mately 6 inches per second or about 3 inches persecond in a 6-inch pipe. These velocities are farbelow those commonly encountered in fluid powersystems, where velocities of 5 feet per second andabove are common. In streamlined flow, lossesdue to friction increase directly with velocity. Withturbulent flow these losses increase much morerapidly.

FACTORS INVOLVED IN FLOW

An understanding of the behavior of fluids inmotion, or solids for that matter, requires anunderstanding of the term inertia. Inertia is theterm used by scientists to describe the propertypossessed by all forms of matter that makes thematter resist being moved if it is at rest, andlikewise, resist any change in its rate of motionif it is moving.

The basic statement covering inertia isNewton’s first law of motion—inertia. Sir IsaacNewton was a British philosopher and mathe-matician. His first law states: A body at rest tendsto remain at rest, and a body in motion tends toremain in motion at the same speed and direction,unless acted on by some unbalanced force.This simply says what you have learned byexperience—that you must push an object to startit moving and push it in the opposite directionto stop it again.

A familiar illustration is the effort a pitchermust exert to make a fast pitch and the oppositionthe catcher must put forth to stop the ball.Similarly, considerable work must be performedby the engine to make an automobile beginto roll; although, after it has attained a certainvelocity, it will roll along the road at uniformspeed if just enough effort is expended toovercome friction, while brakes are necessary tostop its motion. Inertia also explains the kick orrecoil of guns and the tremendous striking forceof projectiles.

Inertia

To

and Force

overcome the tendency of an object toresist any change in its state of rest or motion,some force that is not otherwise canceled orunbalanced must act on the object. Someunbalanced force must be applied whenever fluidsare set in motion or increased in velocity; whileconversely, forces are made to do work elsewherewhenever fluids in motion are retarded orstopped.

There is a direct relationship between themagnitude of the force exerted and the inertiaagainst which it acts. This force is dependenton two factors: (1) the mass of the object(which is proportional to its weight), and (2)the rate at which the velocity of the objectis changed. The rule is that the force inpounds required to overcome inertia is equalto the weight of the object multiplied by thechange in velocity, measured in feet per second,and divided by 32 times the time in secondsrequired to accomplish the change. Thus, the rateof change in velocity of an object is proportionalto the force applied. The number 32 appearsbecause it is the conversion factor between weightand mass.

There are five physical factors that can act ona fluid to affect its behavior. All of the physicalactions of fluids in all systems are determined bythe relationships of these five factors to eachother. Summarizing, these five factors are asfollows:

1. Gravity, which acts at all times on allbodies, regardless of other forces

2. Atmospheric pressure, which acts onany part of a system exposed to the openair

3. Specific applied forces, which mayor maynot be present, but which, in any event, areentirely independent of the presence or absenceof motion

4. Inertia, which comes into play wheneverthere is a change from rest to motion or theopposite, or whenever there is a change indirection or in rate of motion

5. Friction, which is always present wheneverthere is motion

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Figure 2-16 illustrates a possible relationshipof these factors with respect to a particle of fluid(P) in a system. The different forces are shownin terms of head, or in other words, in terms ofvertical columns of fluid required to providethe forces. At the particular moment underconsideration, a particle of water (P) is being actedon by applied force (A), by atmospheric pressure(B), and by gravity (C) produced by the weightof the fluid standing over it. The particle possessessufficient inertia or velocity head to rise to levelP1, since head equivalent to F was lost in frictionas P passed through the system. Since atmosphericpressure (B) acts downward on both sides of thesystem, what is gained on one side is lost on theother.

If all the pressure acting on P to force itthrough the nozzle could be recovered in the formof elevation head, it would rise to level Y. Ifaccount is taken of the balance in atmosphericpressure, in a frictionless system, P would rise tolevel X, or precisely as high as the sum of thegravity head and the head equivalent to theapplied force.

Kinetic Energy

It was previously pointed out that a force mustbe applied to an object in order to give it a velocity

or to increase the velocity it already has. Whetherthe force begins or changes velocity, it acts overa certain distance. A force acting over a certaindistance is work. Work and all forms into whichit can be changed are classified as energy.Obviously then, energy is required to give anobject velocity. The greater the energy used, thegreater the velocity will be.

Disregarding friction, for an object to bebrought to rest or for its motion to be sloweddown, a force opposed to its motion must beapplied to it. This force also acts over somedistance. In this way energy is given up by theobject and delivered in some form to whateveropposes its continuous motion. The moving objectis therefore a means of receiving energy at oneplace (where its motion is increased) and deliveringit to another point (where it is stopped orretarded). While it is in motion, it is said tocontain this energy as energy of motion or kineticenergy.

Since energy can never be destroyed, it followsthat if friction is disregarded the energy deliveredto stop the object will exactly equal the energythat was required to increase its speed. At all timesthe amount of kinetic energy possessed by anobject depends on its weight and the velocity atwhich it is moving.

Figure 2-16.—Physical factors governing fluid flow.

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The mathematical relationship for kineticenergy is stated in the rule: “Kinetic energy infoot-pounds is equal to the force in pounds whichcreated it, multiplied by the distance throughwhich it was applied, or to the weight of themoving object in pounds, multiplied by the squareof its velocity in feet per second, and divided by64.s”

The relationship between inertia forces,velocity, and kinetic energy can be illustrated byanalyzing what happens when a gun fires aprojectile against the armor of an enemy ship. (Seefig. 2-17.) The explosive force of the powder inthe breach pushes the projectile out of the gun,giving it a high velocity. Because of its inertia,the projectile offers opposition to this suddenvelocity and a reaction is set up that pushes thegun backward (kick or recoil). The force of theexplosion acts on the projectile throughout itsmovement in the gun. This is force acting througha distance producing work. This work appears askinetic energy in the speeding projectile. Theresistance of the air produces friction, which usessome of the energy and slows down the projectile.Eventually, however, the projectile hits its targetand, because of the inertia, tries to continuemoving. The target, being relatively stationary,tends to remain stationary because of its inertia.The result is that a tremendous force is set up thateither leads to the penetration of the armor orthe shattering of the projectile. The projectileis simply a means of transferring energy, inthis instance for destructive purpose, from thegun to the enemy ship. This energy is transmittedin the form of energy of motion or kineticenergy.

A similar action takes place in a fluid powersystem in which the fluid takes the place of theprojectile. For example, the pump in a hydraulic

Figure 2-17.—Relationship of inertia, velocity, and kineticenergy.

system imparts energy to the fluid, whichovercomes the inertia of the fluid at rest andcauses it to flow through the lines. The fluid flowsagainst some type of actuator that is at rest. Thefluid tends to continue flowing, overcomes theinertia of the actuator, and moves the actuatorto do work. Friction uses up a portion of theenergy as the fluid flows through the lines andcomponents.

RELATIONSHIP OF FORCE,PRESSURE, AND HEAD

In dealing with fluids, forces are usuallyconsidered in relation to the areas over which theyare applied. As previously discussed, a forceacting over a unit area is a pressure, and pressurecan alternately be stated in pounds per square inchor in terms of head, which is the vertical heightof the column of fluid whose weight wouldproduce that pressure.

In most of the applications of fluid power inthe Navy, applied forces greatly outweigh all otherforces, and the fluid is entirely confined. Underthese circumstances it is customary to think of theforces involved in terms of pressures. Since theterm head is encountered frequently in the studyof fluid power, it is necessary to understand whatit means and how it is related to pressure andforce.

All five of the factors that control the actionsof fluids can, of course, be expressed either asforce, or in terms of equivalent pressures or head.In each situation, the different factors are referredto in the same terms, since they can be added andsubtracted to study their relationship to eachother.

At this point you need to review some termsin general use. Gravity head, when it is importantenough to be considered, is sometimes referredto as head. The effect of atmospheric pressure isreferred to as atmospheric pressure. (Atmosphericpressure is frequently and improperly referred toas suction.) Inertia effect, because it is alwaysdirectly related to velocity, is usually calledvelocity head; and friction, because it representsa loss of pressure or head, is usually referred toas friction head.

STATIC AND DYNAMIC FACTORS

Gravity, applied forces, and atmosphericpressure are static factors that apply equally to

2-13

fluids at rest or in motion, while inertia andfriction are dynamic factors that apply only tofluids in motion. The mathematical sum ofgravity, applied force, and atmospheric pressureis the static pressure obtained at any one pointin a fluid at any given time. Static pressure existsin addition to any dynamic factors that may alsobe present at the same time.

Remember, Pascal’s law states that a pressureset up in a fluid acts equally in all directions andat right angles to the containing surfaces. Thiscovers the situation only for fluids at rest orpractically at rest. It is true only for the factorsmaking up static head. Obviously, when velocitybecomes a factor it must have a direction, andas previously explained, the force related to thevelocity must also have a direction, so thatPascal’s law alone does not apply to the dynamicfactors of fluid power.

The dynamic factors of inertia and friction arerelated to the static factors. Velocity head andfriction head are obtained at the expense of statichead. However, a portion of the velocity head canalways be reconverted to static head. Force, whichcan be produced by pressure or head when dealingwith fluids, is necessary to start a body movingif it is at rest, and is present in some form whenthe motion of the body is arrested; therefore,whenever a fluid is given velocity, some part ofits original static head is used to impart thisvelocity, which then exists as velocity head.

BERNOULLI’S PRINCIPLE

Consider the system illustrated in figure 2-18.Chamber A is under pressure and is connected bya tube to chamber B, which is also under pressure.The pressure in chamber A is static pressure of100 psi. The pressure at some point (X) along theconnecting tube consists of a velocity pressure of

Figure 2-18.—Relation of static and dynamic factors—Bernoulli’s principle.

10 psi exerted in a direction parallel to the lineof flow, plus the unused static pressure of 90 psi,which still obeys Pascal’s law and operates equallyin all directions. As the fluid enters chamber Bit is slowed down, and its velocity is changed backto pressure. The force required to absorb itsinertia equals the force required to start the fluidmoving originally, so that the static pressure inchamber B is equal to that in chamber A.

This situation (fig. 2-18) disregards friction;therefore, it would not be encountered in actualpractice. Force or head is also required toovercome friction but, unlike inertia effect, thisforce cannot be recovered again, although theenergy represented still exists somewhere as heat.Therefore, in an actual system the pressure inchamber B would be less than in chamber A bythe amount of pressure used in overcomingfriction along the way.

At all points in a system the static pressure isalways the original static pressure, less any velocityhead at the point in question and less the frictionhead consumed in reaching that point. Since boththe velocity head and the friction head representenergy that came from the original static head,and since energy cannot be destroyed, the sum ofthe static head, the velocity head, and the frictionhead at any point in the system must add up tothe original static head. This is known asBernoulli's principle, which states: For thehorizontal flow of fluid through a tube, the sumof the pressure and the kinetic energy per unitvolume of the fluid is constant. This principlegoverns the relations of the static and dynamicfactors concerning fluids, while Pascal’s law statesthe manner in which the static factors behavewhen taken by themselves.

MINIMIZING FRICTION

Fluid power equipment is designed to reducefriction to the lowest possible level. Volume andvelocity of flow are made the subject of carefulstudy. The proper fluid for the system is chosen.Clean, smooth pipe of the best dimensions for theparticular conditions is used, and it is installedalong as direct a route as possible. Sharp bendsand sudden changes in cross-sectional areas areavoided. Valves, gauges, and other componentsare designed to interrupt flow as little as possible.Careful thought is given to the size and shape ofthe openings. The systems are designed so they

2-14

can be kept clean inside and variations fromnormal operation can easily be detected andremedied.

OPERATION OF HYDRAULICCOMPONENTS

To transmit and control power throughpressurized fluids, an arrangement of inter-connected components is required. Such anarrangement is commonly referred to as a system.The number and arrangement of the componentsvary from system to system, depending on theparticular application. In many applications, onemain system supplies power to several subsystems,which are sometimes referred to as circuits. Thecomplete system may be a small compact unit;more often, however, the components are locatedat widely separated points for convenient controland operation of the system.

The basic components of a fluid power systemare essentially the same, regardless of whether thesystem uses a hydraulic or a pneumatic medium.There are five basic components used in a system.These basic components are as follows:

1.

2.

3.

4.

5.

Reservoir or receiver

Pump or compressor

Lines (pipe, tubing, or flexible hose)

Directional control valve

Actuating device

Several applications of fluid power requireonly a simple system; that is, a system which usesonly a few components in addition to the fivebasic components. A few of these applications arepresented in the following paragraphs. We willexplain the operation of these systems briefly atthis time so you will know the purpose of eachcomponent and can better understand howhydraulics is used in the operation of thesesystems. More complex fluid power systems aredescribed in chapter 12.

HYDRAULIC JACK

The hydraulic jack is perhaps one of thesimplest forms of a fluid power system. Bymoving the handle of a small device, an individual

can lift a load weighing several tons. A smallinitial force exerted on the handle is transmittedby a fluid to a much larger area. To understandthis better, study figure 2-19. The small inputpiston has an area of 5 square inches and isdirectly connected to a large cylinder with anoutput piston having an area of 250 square inches.The top of this piston forms a lift platform.

If a force of 25 pounds is applied to the inputpiston, it produces a pressure of 5 psi in the fluid,that is, of course, if a sufficient amount ofresistant force is acting against the top of theoutput piston. Disregarding friction loss, thispressure acting on the 250 square inch area of theoutput piston will support a resistance force of1,250 pounds. In other words, this pressure couldovercome a force of slightly under 1,250 pounds.An input force of 25 pounds has been transformedinto a working force of more than half a ton;however, for this to be true, the distance traveledby the input piston must be 50 times greater thanthe distance traveled by the output piston. Thus,for every inch that the input piston moves, theoutput piston will move only one-fiftieth of ani n c h .

This would be ideal if the output piston neededto move only a short distance. However, in mostinstances, the output piston would have to becapable of moving a greater distance to serve apractical application. The device shown in figure2-19 is not capable of moving the output pistonfarther than that shown; therefore, some othermeans must be used to raise the output piston toa greater height.

Figure 2-19.—Hydraulic jack.

2-15

The output piston can be raised higher andmaintained at this height if additional componentsare installed as shown in figure 2-20. In thisillustration the jack is designed so that it can beraised, lowered, or held at a constant height.These results are attained by introducing a numberof valves and also a reserve supply of fluid to beused in the system.

Notice that this system contains the five basiccomponents—the reservoir; cylinder 1, whichserves as a pump; valve 3, which serves as adirectional control valve; cylinder 2, which servesas the actuating device; and lines to transmit thefluid to and from the different components. Inaddition, this system contains two valves, 1 and2, whose functions are explained in the followingdiscussion.

As the input piston is raised (fig. 2-20, viewA), valve 1 is closed by the back pressure fromthe weight of the output piston. At the same time,valve 2 is opened by the head of the fluid in thereservoir. This forces fluid into cylinder 1. Whenthe input piston is lowered (fig. 2-20, view B), apressure is developed in cylinder 1. When thispressure exceeds the head in the reservoir, it closesvalve 2. When it exceeds the back pressure fromthe output piston, it opens valve 1, forcing fluidinto the pipeline. The pressure from cylinder 1 is

Figure 2-20.—Hydraulic jack; (A) up stroke; (B) downstroke.

thus transmitted into cylinder 2, where it acts toraise the output piston with its attached liftplatform. When the input piston is again raised,the pressure in cylinder 1 drops below that incylinder 2, causing valve 1 to close. This preventsthe return of fluid and holds the output pistonwith its attached lift platform at its new level.During this stroke, valve 2 opens again allowinga new supply of fluid into cylinder 1 for the nextpower (downward) stroke of the input piston.Thus, by repeated strokes of the input piston, thelift platform can be progressively raised. To lowerthe lift platform, valve 3 is opened, and the fluidfrom cylinder 2 is returned to the reservoir.

HYDRAULIC BRAKES

The hydraulic brake system used in theautomobile is a multiple piston system. A multiplepiston system allows forces to be transmitted totwo or more pistons in the manner indicated infigure 2-21. Note that the pressure set up by theforce applied to the input piston (1) is transmittedundiminished to both output pistons (2 and 3),and that the resultant force on each piston isproportional to its area. The multiplication offorces from the input piston to each output pistonis the same as that explained earlier.

The hydraulic brake system from the mastercylinders to the wheel cylinders on most

Figure 2-21.—Multiple piston system.

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automobiles operates in a way similar to thesystem illustrated in figure 2-22.

When the brake pedal is depressed, thepressure on the brake pedal moves the pistonwithin the master cylinder, forcing the brake fluidfrom the master cylinder through the tubing andflexible hose to the wheel cylinders. The wheelcylinders contain two opposed output pistons,each of which is attached to a brake shoe fittedinside the brake drum. Each output piston pushesthe attached brake shoe against the wall of thebrake drum, thus retarding the rotation of thewheel. When pressure on the pedal is released, thesprings on the brake shoes return the wheel

cylinder pistons to their released positions. Thisaction forces the displaced brake fluid backthrough the flexible hose and tubing to the mastercylinder.

The force applied to the brake pedal producesa proportional force on each of the outputpistons, which in turn apply the brake shoesfrictionally to the turning wheels to retardrotation.

As previously mentioned, the hydraulic brakesystem on most automobiles operates in a similarway, as shown in figure 2-22. It is beyond thescope of this manual to discuss the various brakesystems.

Figure 2-22.—An automobile brake system.

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CHAPTER 3

HYDRAULIC FLUIDS

During the design of equipment that requiresfluid power, many factors are considered inselecting the type of system to be used—hydraulic,pneumatic, or a combination of the two. Someof the factors are required speed and accuracy ofoperation, surrounding atmospheric conditions,economic conditions, availability of replacementfluid, required pressure level, operating tempera-ture range, contamination possibilities, cost oftransmission lines, limitations of the equipment,lubricity, safety to the operators, and expectedservice life of the equipment.

After the type of system has been selected,many of these same factors must be consideredin selecting the fluid for the system. This chapteris devoted to hydraulic fluids. Included in it aresections on the properties and characteristicsdesired of hydraulic fluids; types of hydraulicfluids; hazards and safety precautions for workingwith, handling, and disposing of hydraulicliquids; types and control of contamination; andsampling.

PROPERTIES

If fluidity (the physical property of a substancethat enables it to flow) and incompressibility werethe only properties required, any liquid not toothick might be used in a hydraulic system.However, a satisfactory liquid for a particularsystem must possess a number of other properties.The most important properties and some charac-teristics are discussed in the following paragraphs.

VISCOSITY

Viscosity is one of the most importantproperties of hydraulic fluids. It is a measure ofa fluid’s resistance to flow. A liquid, such asgasoline, which flows easily has a low viscosity;

and a liquid, such as tar, which flows slowly hasa high viscosity. The viscosity of a liquid isaffected by changes in temperature and pressure.As the temperature of a liquid increases, itsviscosity decreases. That is, a liquid flows moreeasily when it is hot than when it is cold. Theviscosity of a liquid increases as the pressure onthe liquid increases.

A satisfactory liquid for a hydraulic systemmust be thick enough to give a good seal atpumps, motors, valves, and so on. These com-ponents depend on close fits for creating andmaintaining pressure. Any internal leakagethrough these clearances results in loss of pressure,instantaneous control, and pump efficiency.Leakage losses are greater with thinner liquids(low viscosity). A liquid that is too thin will alsoallow rapid wearing of moving parts, or of partsthat operate under heavy loads. On the otherhand, if the liquid is too thick (viscosity too high),the internal friction of the liquid will cause anincrease in the liquid’s flow resistance throughclearances of closely fitted parts, lines, andinternal passages. This results in pressure dropsthroughout the system, sluggish operationof the equipment, and an increase in powerconsumption.

Measurement of Viscosity

Viscosity is normally determined by measuringthe time required for a fixed volume of a fluid(at a given temperature) to flow through acalibrated orifice or capillary tube. The instru-ments used to measure the viscosity of a liquidare known as viscometers or viscosimeters.

Several types of viscosimeters are in use today.The Saybolt viscometer, shown in figure 3-1,measures the time required, in seconds, for 60milliliters of the tested fluid at 100°F to passthrough a standard orifice. The time measured is

3-1

Figure 3-1.—Saybolt viscometer.

used to express the fluid’s viscosity, in Sayboltuniversal seconds or Saybolt furol seconds.

The glass capillary viscometers, shown infigure 3-2, are examples of the second type ofviscometer used. These viscometers are used to

measure kinematic viscosity. Like the Sayboltviscometer, the glass capillary measures the timein seconds required for the tested fluid to flowthrough the capillary. This time is multiplied bythe temperature constant of the viscometer in useto provide the viscosity, expressed in centistrokes.

The following formulas may be used toconvert centistrokes (cSt units) to approximateSaybolt universal seconds (SUS units).

For SUS values between 32 and 100:

For SUS values greater than 100:

Although the viscometers discussed above areused in laboratories, there are other viscometersin the supply system that are available for localuse. These viscometers can be used to test theviscosity of hydraulic fluids either prior to theirbeing added to a system or periodically after theyhave been in an operating system for a while.

Figure 3-2.–Various styles of glass capillary viscometers.

3-2

Additional information on the various typesof viscometers and their operation can be foundin the Physical Measurements Training Manual,NAVAIR 17-35QAL-2.

Viscosity Index

The viscosity index (V.I.) of an oil is a numberthat indicates the effect of temperature changeson the viscosity of the oil. A low V.I. signifiesa relatively large change of viscosity with changesof temperature. In other words, the oil becomesextremely thin at high temperatures and extremelythick at low temperatures. On the other hand, ahigh V.I. signifies relatively little change inviscosity over a wide temperature range.

An ideal oil for most purposes is onethat maintains a constant viscosity throughouttemperature changes. The importance of the V.I.can be shown easily by considering automotivelubricants. An oil having a high V.I. resistsexcessive thickening when the engine is cold and,consequently, promotes rapid starting and promptcirculation; it resists excessive thinning when themotor is hot and thus provides full lubrication andprevents excessive oil consumption.

Another example of the importance of the V.I.is the need for a high V.I. hydraulic oil for militaryaircraft, since hydraulic control systems may beexposed to temperatures ranging from below–65°F at high altitudes to over 100°F on theground. For the proper operation of the hydrauliccontrol system, the hydraulic fluid must have asufficiently high V.I. to perform its functions atthe extremes of the expected temperature range.

Liquids with a high viscosity have a greaterresistance to heat than low viscosity liquids whichhave been derived from the same source. Theaverage hydraulic liquid has a relatively lowviscosity. Fortunately, there is a wide choice ofliquids available for use in the viscosity rangerequired of hydraulic liquids.

The V.I. of an oil may be determined if itsviscosity at any two temperatures is known.Tables, based on a large number of tests, areissued by the American Society for Testingand Materials (ASTM). These tables permitcalculation of the V.I. from known viscosities.

LUBRICATING POWER

If motion takes place between surfaces incontact, friction tends to oppose the motion.When pressure forces the liquid of a hydraulicsystem between the surfaces of moving parts, the

liquid spreads out into a thin film which enablesthe parts to move more freely. Different liquids,including oils, vary greatly not only in theirlubricating ability but also in film strength. Filmstrength is the capability of a liquid to resist beingwiped or squeezed out from between the surfaceswhen spread out in an extremely thin layer. Aliquid will no longer lubricate if the film breaksdown, since the motion of part against part wipesthe metal clean of liquid.

Lubricating power varies with temperaturechanges; therefore, the climatic and workingconditions must enter into the determination ofthe lubricating qualities of a liquid. Unlikeviscosity, which is a physical property, thelubricating power and film strength of a liquidis directly related to its chemical nature.Lubricating qualities and film strength can beimproved by the addition of certain chemicalagents.

CHEMICAL STABILITY

Chemical stability is another property whichis exceedingly important in the selection of ahydraulic liquid. It is defined as the liquid’s abilityto resist oxidation and deterioration for longperiods. All liquids tend to undergo unfavorablechanges under severe operating conditions. Thisis the case, for example, when a system operatesfor a considerable period of time at hightemperatures.

Excessive temperatures, especially extremelyhigh temperatures, have a great effect on the lifeof a liquid. The temperature of the liquid in thereservoir of an operating hydraulic system doesnot always indicate the operating conditionsthroughout the system. Localized hot spots occuron bearings, gear teeth, or at other points wherethe liquid under pressure is forced through smallorifices. Continuous passage of the liquid throughthese points may produce local temperatures highenough to carbonize the liquid or turn it intosludge, yet the liquid in the reservoir may notindicate an excessively high temperature.

Liquids may break down if exposed to air,water, salt, or other impurities, especially if theyare in constant motion or subjected to heat. Somemetals, such as zinc, lead, brass, and copper, haveundesirable chemical reactions with certainliquids.

These chemical reactions result in the forma-tion of sludge, gums, carbon, or other depositswhich clog openings, cause valves and pistons tostick or leak, and give poor lubrication to moving

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parts. Once a small amount of sludge or otherdeposits is formed, the rate of formation generallyincreases more rapidly. As these deposits areformed, certain changes in the physical andchemical properties of the liquid take place. Theliquid usually becomes darker, the viscosityincreases and damaging acids are formed.

The extent to which changes occur in differentliquids depends on the type of liquid, type ofrefining, and whether it has been treated toprovide further resistance to oxidation. Thestability of liquids can be improved by theaddition of oxidation inhibitors. Inhibitorsselected to improve stability must be compatiblewith the other required properties of the liquid.

FREEDOM FROM ACIDITY

An ideal hydraulic liquid should be free fromacids which cause corrosion of the metals in thesystem. Most liquids cannot be expected to remaincompletely noncorrosive under severe operatingconditions. The degree of acidity of a liquid, whennew, may be satisfactory; but after use, the liquidmay tend to become corrosive as it begins todeteriorate.

Many systems are idle for long periods afteroperating at high temperatures. This permitsmoisture to condense in the system, resulting inrust formation.

Certain corrosion- and rust-preventive addi-tives are added to hydraulic liquids. Some of theseadditives are effective only for a limited period.Therefore, the best procedure is to use the liquidspecified for the system for the time specified bythe system manufacturer and to protect the liquidand the system as much as possible fromcontamination by foreign matter, from abnormaltemperatures, and from misuse.

FLASHPOINT

Flashpoint is the temperature at which a liquidgives off vapor in sufficient quantity to ignitemomentarily or flash when a flame is applied. Ahigh flashpoint is desirable for hydraulic liquidsbecause it provides good resistance to combustionand a low degree of evaporation at normaltemperatures. Required flashpoint minimumsvary from 300°F for the lightest oils to 510°F forthe heaviest oils.

FIRE POINT

Fire point is the temperature at which asubstance gives off vapor in sufficient quantityto ignite and continue to burn when exposed toa spark or flame. Like flashpoint, a high fire pointis required of desirable hydraulic liquids.

MINIMUM TOXICITY

Toxicity is defined as the quality, state, ordegree of being toxic or poisonous. Some liquidscontain chemicals that are a serious toxic hazard.These toxic or poisonous chemicals may enter thebody through inhalation, by absorption throughthe skin, or through the eyes or the mouth. Theresult is sickness and, in some cases, death.Manufacturers of hydraulic liquids strive toproduce suitable liquids that contain no toxicchemicals and, as a result, most hydraulic liquidsare free of harmful chemicals. Some fire-resistantliquids are toxic, and suitable protection and carein handling must be provided.

DENSITY AND COMPRESSIBILITY

A fluid with a specific gravity of less than 1.0is desired when weight is critical, although withproper system design, a fluid with a specificgravity greater than one can be tolerated. Whereavoidance of detection by military units is desired,a fluid which sinks rather than rises to the surfaceof the water is desirable. Fluids having a specificgravity greater than 1.0 are desired, as leakingfluid will sink, allowing the vessel with the leakto remain undetected.

Recall from chapter 2 that under extremepressure a fluid may be compressed up to 7percent of its original volume. Highly com-pressible fluids produce sluggish system operation.This does not present a serious problem in small,low-speed operations, but it must be consideredin the operating instructions.

FOAMING TENDENCIES

Foam is an emulsion of gas bubbles in thefluid. Foam in a hydraulic system results fromcompressed gases in the hydraulic fluid. A fluidunder high pressure can contain a large volumeof air bubbles. When this fluid is depressurized,as when it reaches the reservoir, the gas bubblesin the fluid expand and produce foam. Anyamount of foaming may cause pump cavitationand produce poor system response and spongy

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control. Therefore, defoaming agents are oftenadded to fluids to prevent foaming. Minimizingair in fluid systems is discussed later in thischapter.

CLEANLINESS

Cleanliness in hydraulic systems has receivedconsiderable attention recently. Some hydraulicsystems, such as aerospace hydraulic systems, areextremely sensitive to contamination. Fluidcleanliness is of primary importance becausecontaminants can cause component malfunction,prevent proper valve seating, cause wear incomponents, and may increase the response timeof servo valves. Fluid contaminants are discussedlater in this chapter.

The inside of a hydraulic system can only bekept as clean as the fluid added to it. Initial fluidcleanliness can be achieved by observing stringentcleanliness requirements (discussed later in thischapter) or by filtering all fluid added to thesystem.

TYPES OF HYDRAULIC FLUIDS

There have been many liquids tested for usein hydraulic systems. Currently, liquids being usedinclude mineral oil, water, phosphate ester,water-based ethylene glycol compounds, andsilicone fluids. The three most common types ofhydraulic liquids are petroleum-based, syntheticfire-resistant, and water-based fire-resistant.

PETROLEUM-BASED FLUIDS

The most common hydraulic fluids used inshipboard systems are the petroleum-based oils.These fluids contain additives to protect the fluidfrom oxidation (antioxidant), to protect systemmetals from corrosion (anticorrosion), to reducetendency of the fluid to foam (foam suppressant),and to improve viscosity.

Petroleum-based fluids are used in surfaceships’ electrohydraulic steering and deckmachinery systems, submarines’ hydraulicsystems, and aircraft automatic pilots, shockabsorbers, brakes, control mechanisms, and otherhydraulic systems using seal materials compatiblewith petroleum-based fluids.

SYNTHETIC FIRE-RESISTANT FLUIDS

Petroleum-based oils contain most of thedesired properties of a hydraulic liquid. However,they are flammable under normal conditions andcan become explosive when subjected to highpressures and a source of flame or high tempera-tures. Nonflammable synthetic liquids have beendeveloped for use in hydraulic systems where firehazards exist.

Phosphate Ester Fire-Resistant Fluid

Phosphate ester fire-resistant fluid forshipboard use is covered by specification MIL-H-19457. There are certain trade names closelyassociated with these fluids. However, the onlyacceptable fluids conforming to MIL-H-19457 arethe ones listed on the current Qualified ProductsList (QPL) 19457. These fluids will be deliveredin containers marked MIL-H-19457C or a laterspecification revision. Phosphate ester incontainers marked by a brand name without aspecification identification must not be used inshipboard systems, as they may contain toxicchemicals.

These fluids will burn if sufficient heat andflame are applied, but they do not supportcombustion. Drawbacks of phosphate ester fluidsare that they will attack and loosen commonlyused paints and adhesives, deteriorate many typesof insulations used in electrical cables, anddeteriorate many gasket and seal materials.Therefore, gaskets and seals for systems in whichphosphate ester fluids are used are manufacturedof specific materials. Naval Ships’ TechnicalManual, chapter 262, specifies paints to be usedon exterior surfaces of hydraulic systems andcomponents in which phosphate ester fluid is usedand on ship structure and decks in the immediatevicinity of this equipment. Naval Ships’ TechnicalManual, chapter 078, specifies gasket and sealmaterials used. NAVAIR 01-1A-17 also containsa list of materials resistant to phosphate esterfluids.

Trade names for phosphate ester fluids, whichdo not conform to MIL-H-19457 include Pydraul,Skydrol, and Fyre Safe.

PHOSPHATE ESTER FLUID SAFETY.—As a maintenance person, operator, supervisor,or crew member of a ship, squadron, or navalshore installation, you must understand thehazards associated with hydraulic fluids to whichyou may be exposed.

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Phosphate ester fluid conforming to specifi-cation MIL-H-19457 is used in aircraft elevators,ballast valve operating systems, and replenish-ment-at-sea systems. This type of fluid containsa controlled amount of neurotoxic material.Because of the neurotoxic effects that can resultfrom ingestion, skin absorption, or inhalation ofthese fluids, be sure to use the followingprecautions:

1. Avoid contact with the fluids by wearingprotective clothing.

2. Use chemical goggles or face shields toprotect your eyes.

3. If you are expected to work in anatmosphere containing a fine mist or spray,wear a continuous-flow airline respirator.

4. Thoroughly clean skin areas contaminatedby this fluid with soap and water.

5. If you get any fluid in your eyes, flush themwith running water for at least 15 minutesand seek medical attention.

If you come in contact with MIL-H-19457fluid, report the contact when you seek medicalaid and whenever you have a routine medicalexamination.

Naval Ships’ Technical Manual, chapter 262,contains a list of protective clothing, along withnational stock numbers (NSN), for use with fluidsconforming to MIL-H-19457. It also containsprocedures for repair work and for low-levelleakage and massive spills cleanup.

PHOSPHATE ESTER FLUID DISPOSAL.—Waste MIL-H-19457 fluids and refuse (rags andother materials) must not be dumped at sea. Fluidshould be placed in bung-type drums. Rags andother materials should be placed in open topdrums for shore disposal. These drums should bemarked with a warning label stating their content,safety precautions, and disposal instructions.Detailed instructions for phosphate ester fluidsdisposal can be found in Naval Ships’ TechnicalManual, chapter 262, and OPNAVINST 5090.1.

Silicone Synthetic Fire-Resistant Fluids

Silicone synthetic fire-resistant fluids arefrequently used for hydraulic systems whichrequire fire resistance, but which have onlymarginal requirements for other chemical orphysical properties common to hydraulic fluids.Silicone fluids do not have the detrimentalcharacteristics of phosphate ester fluids, nor

do they provide the corrosion protection andlubrication of phosphate ester fluids, but they areexcellent for fire protection. Silicone fluidconforming to MIL-S-81087 is used in the missileholddown and lockout system aboard submarines.

Lightweight Synthetic Fire-Resistant Fluids

In applications where weight is critical,lightweight synthetic fluid is used in hydraulicsystems. MIL-H-83282 is a synthetic, fire-resistanthydraulic fluid used in military aircraft andhydrofoils where the requirement to minimizeweight dictates the use of a low-viscosity fluid.It is also the most commonly used fluid in aviationsupport equipment. NAVAIR 01-1A-17 containsadditional information on fluids conforming tospecification MIL-H-83282.

WATER-BASED FIRE-RESISTANTFLUIDS

The most widely used water-based hydraulicfluids may be classified as water-glycol mixturesand water-synthetic base mixtures. The water-glycol mixture contains additives to protect it fromoxidation, corrosion, and biological growth andto enhance its load-carrying capacity.

Fire resistance of the water mixture fluidsdepends on the vaporization and smotheringeffect of steam generated from the water. Thewater in water-based fluids is constantly beingdriven off while the system is operating. There-fore, frequent checks to maintain the correct ratioof water are important.

The water-based fluid used in catapultretracting engines, jet blast deflectors, andweapons elevators and handling systems conformsto MIL-H-22072.

The safety precautions outlined for phosphateester fluid and the disposal of phosphate esterfluid also apply to water-based fluid conformingto MIL-H-22072.

CONTAMINATION

Hydraulic fluid contamination may bedescribed as any foreign material or substancewhose presence in the fluid is capable of adverselyaffecting system performance or reliability. It mayassume many different forms, including liquids,gases, and solid matter of various composition,sizes, and shapes. Solid matter is the type mostoften found in hydraulic systems and is generally

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referred to as particulate contamination. Con-tamination is always present to some degree, evenin new, unused fluid, but must be kept below alevel that will adversely affect system operation.Hydraulic contamination control consists ofrequirements, techniques, and practices necessaryto minimize and control fluid contamination.

CLASSIFICATION

There are many types of contaminants whichare harmful to hydraulic systems and liquids.These contaminants may be divided into twodifferent classes—particulate and fluid.

Particulate Contamination

This class of contaminants includes organic,metallic solid, and inorganic solid contaminants.These contaminants are discussed in the followingparagraphs.

ORGANIC CONTAMINATION.— Organicsolids or semisolids found in hydraulic systemsare produced by wear, oxidation, or polymeriza-tion. Minute particles of O-rings, seals, gaskets,and hoses are present, due to wear or chemicalreactions. Synthetic products, such as neoprene,silicones, and hypalon, though resistant tochemical reaction with hydraulic fluids, producesmall wear particles. Oxidation of hydraulic fluidsincreases with pressure and temperature, althoughantioxidants are blended into hydraulic fluids tominimize such oxidation. The ability of ahydraulic fluid to resist oxidation or poly-merization in service is defined as its oxidationstability. Oxidation products appear as organicacids, asphaltics, gums, and varnishes. Theseproducts combine with particles in the hydraulicfluid to form sludge. Some oxidation products areoil soluble and cause the hydraulic fluid toincrease in viscosity; other oxidation products arenot oil soluble and form sediment.

METALLIC SOLID CONTAMINATION.—Metallic contaminants are almost always presentin a hydraulic system and will range in size frommicroscopic particles to particles readily visibleto the naked eye. These particles are the result ofwearing and scoring of bare metal parts andplating materials, such as silver and chromium.Although practically all metals commonly usedfor parts fabrication and plating may be foundin hydraulic fluids, the major metallic materialsfound are ferrous, aluminum, and chromium

particles. Because of their continuous high-speedinternal movement, hydraulic pumps usuallycontribute most of the metallic particulatecontamination present in hydraulic systems. Metalparticles are also produced by other hydraulicsystem components, such as valves and actuators,due to body wear and the chipping and wearingaway of small pieces of metal plating materials.

INORGANIC SOLID CONTAMINA-TION.— This contaminant group includes dust,paint particles, dirt, and silicates. Glass particlesfrom glass bead peening and blasting may alsobe found as contaminants. Glass particles are veryundesirable contaminants due to their abrasiveeffect on synthetic rubber seals and the very finesurfaces of critical moving parts. Atmosphericdust, dirt, paint particles, and other materials areoften drawn into hydraulic systems from externalsources. For example, the wet piston shaft of ahydraulic actuator may draw some of theseforeign materials into the cylinder past the wiperand dynamic seals, and the contaminant materialsare then dispersed in the hydraulic fluid.Contaminants may also enter the hydraulic fluidduring maintenance when tubing, hoses, fittings,and components are disconnected or replaced. Itis therefore important that all exposed fluid portsbe sealed with approved protective closures tominimize such contamination.

Fluid Contamination

Air, water, solvent, and other foreign fluidsare in the class of fluid contaminants.

AIR CONTAMINATION.— Hydraulic fluidsare adversely affected by dissolved, entrained, orfree air. Air may be introduced through impropermaintenance or as a result of system design. Anymaintenance operation that involves breaking intothe hydraulic system, such as disconnecting orremoving a line or component will invariablyresult in some air being introduced into thesystem. This source of air can and must beminimized by prebilling replacement componentswith new filtered fluid prior to their installation.Failing to prefill a filter element bowl with fluidis a good example of how air can be introducedinto the system. Although prebilling will minimizeintroduction of air, it is still important to vent thesystem where venting is possible.

Most hydraulic systems have built-in sourcesof air. Leaky seals in gas-pressurized accumulatorsand reservoirs can feed gas into a system faster

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than it can be removed, even with the best ofmaintenance. Another lesser known but majorsource of air is air that is sucked into the systempast actuator piston rod seals. This usually occurswhen the piston rod is stroked by some externalmeans while the actuator itself is not pressurized.

WATER CONTAMINATION.— Water is aserious contaminant of hydraulic systems.Hydraulic fluids are adversely affected bydissolved, emulsified, or free water. Watercontamination may result in the formation of ice,which impedes the operation of valves, actuators,and other moving parts. Water can also cause theformation of oxidation products and corrosionof metallic surfaces.

SOLVENT CONTAMINATION.— Solventcontamination is a special form of foreign fluidcontamination in which the original contami-nating substance is a chlorinated solvent. Chlori-nated solvents or their residues may, whenintroduced into a hydraulic system, react with anywater present to form highly corrosive acids.

Chlorinated solvents, when allowed to com-bine with minute amounts of water often foundin operating hydraulic systems, change chemicallyinto hydrochloric acids. These acids then attackinternal metallic surfaces in the system,particularly those that are ferrous, and producea severe rust-like corrosion. NAVAIR 01-1A-17and NSTM, chapter 556, contain tables ofsolvents for use in hydraulic maintenance.

FOREIGN-FLUIDS CONTAMINATION.—Hydraulic systems can be seriously contaminatedby foreign fluids other than water and chlorinatedsolvents. This type of contamination is generallya result of lube oil, engine fuel, or incorrecthydraulic fluid being introduced inadvertently intothe system during servicing. The effects of suchcontamination depend on the contaminant, theamount in the system, and how long it has beenpresent.

NOTE: It is extremely important that thedifferent types of hydraulic fluids are not mixedin one system. If different type hydraulic fluidsare mixed, the characteristics of the fluid requiredfor a specific purpose are lost. Mixing thedifferent types of fluids usually will result in aheavy, gummy deposit that will clog passages andrequire a major cleaning. In addition, seals andpacking installed for use with one fluid usually

are not compatible with other fluids and damageto the seals will result.

ORIGIN OF CONTAMINATION

Recall that contaminants are produced fromwear and chemical reactions, introduced byimproper maintenance, and inadvertently intro-duced during servicing. These methods of con-taminant introduction fall into one of the fourmajor areas of contaminant origin.

1. Particles originally contained in the system.These particles originate during the fabricationand storage of system components. Weld spatterand slag may remain in welded system com-ponents, especially in reservoirs and pipeassemblies. The presence is minimized by properdesign. For example, seam-welded overlappingjoints are preferred, and arc welding of opensections is usually avoided. Hidden passages invalve bodies, inaccessible to sand blasting or othermethods of cleaning, are the main source ofintroduction of core sand. Even the most carefullydesigned and cleaned casting will almost invari-ably free some sand particles under the action ofhydraulic pressure. Rubber hose assemblies alwayscontain some loose particles. Most of theseparticles can be removed by flushing the hosebefore installation; however, some particleswithstand cleaning and are freed later by theaction of hydraulic pressure.

Particles of lint from cleaning rags cancause abrasive damage in hydraulic systems,especially to closely fitted moving parts. Inaddition, lint in a hydraulic system packs easilyinto clearances between packing and contactingsurfaces, leading to component leakage anddecreased efficiency. Lint also helps clog filtersprematurely. The use of the proper wipingmaterials will reduce or eliminate lint contamina-tion. The wiping materials to be used for a givenapplication will be determined by

a.b.

c.

substances being wiped or absorbed,the amount of absorbency required,and/orthe required degree of cleanliness.

These wiping materials are categorized forcontamination control by the degree of lint ordebris that they may deposit during use. Forinternal hydraulic repairs, this factor itselfwill determine the choice of wiping material.

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NAVAIR 01-1A-17 and NSTM, chapter 556,provides information on low-lint wiping cloths.

Rust or corrosion initially present in ahydraulic system can usually be traced toimproper storage of materials and componentparts. Particles can range in size from large flakesto abrasives of microscopic dimensions. Properpreservation of stored parts is helpful in elimi-nating corrosion.

2. Particles introduced from outside sources.Particles can be introduced into hydraulic systemsat points where either the liquid or certain workingparts of the system (for example, piston rods) areat least in temporary contact with the atmosphere.The most common contaminant introductionareas are at the refill and breather openings,cylinder rod packings, and open lines wherecomponents are removed for repair or replace-ment. Contamination arising from carelessnessduring servicing operations is minimized by theuse of filters in the system fill lines and fingerstrainers in the filler adapter of hydraulicreservoirs. Hydraulic cylinder piston rodsincorporate wiper rings and dust seals to preventthe dust that settles on the piston rod during itsoutward stroke from entering the system when thepiston rod retracts. Caps and plugs are availableand should be used to seal off the open lines whena component is removed for repair orreplacement.

3. Particles created within the system duringoperation. Contaminants created during systemoperation are of two general types—mechanicaland chemical. Particles of a mechanical nature areformed by wearing of parts in frictional contact,such as pumps, cylinders, and packing glandcomponents. These wear particles can vary fromlarge chunks of packings down to steel shavingsthat are too small to be trapped by filters.

The major source of chemical contami-nants in hydraulic liquid is oxidation. Thesecontaminants are formed under high pressure andtemperatures and are promoted by the chemicalaction of water and air and of metals like copperand iron oxides. Liquid-oxidation products appearinitially as organic acids, asphaltines, gums,and varnishes—sometimes combined with dustparticles as sludge. Liquid-soluble oxidationproducts tend to increase liquid viscosity, whileinsoluble types separate and form sediments,especially on colder elements such as heatexchanger coils.

Liquids containing antioxidants have littletendency to form gums and sludge under normaloperating conditions. However, as the tempera-ture increases, resistance to oxidation diminishes.Hydraulic liquids that have been subjected toexcessively high temperatures (above 250°F formost liquids) will break down, leaving minuteparticles of asphaltines suspended in the liquids.The liquid changes to brown in color and isreferred to as decomposed liquid. This explainsthe importance of keeping the hydraulic liquidtemperature below specific levels.

The second contaminant-producing chemi-cal action in hydraulic liquids is one that permitsthese liquids to react with certain types of rubber.This reaction causes structural changes in therubber, turning it brittle, and finally causing itscomplete disintegration. For this reason, thecompatibility of system liquid with seals and hosematerial is a very important factor.

4. Particles introduced by foreign liquids. Oneof the most common foreign-fluid contaminantsis water, especially in hydraulic systems thatrequire petroleum-based liquids. Water, whichenters even the most carefully designed system bycondensation of atmospheric moisture, normallysettles to the bottom of the reservoir. Oilmovement in the reservoir disperses the water intofine droplets, and agitation of the liquid inthe pump and in high-speed passages forms anoil-water-air emulsion. This emulsion normallyseparates during the rest period in the systemreservoir; but when fine dust and corrosionparticles are present, the emulsion is chemicallychanged by high pressures into sludge. Thedamaging action of sludge explains the need foreffective filtration, as well as the need for waterseparation qualities in hydraulic liquids.

CONTAMINATION CONTROL

Maintaining hydraulic fluid within allowablecontamination limits for both water and particu-late matter is crucial to the care and protectionof hydraulic equipment.

Filters (discussed in chapter 9) will provideadequate control of the particular contaminationproblem during all normal hydraulic systemoperations if the filtration system is installedproperly and filter maintenance is performedproperly. Filter maintenance includes changingelements at proper intervals. Control of the sizeand amount of contamination entering the systemfrom any other source is the responsibility

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of the personnel who service and maintain theequipment. During installation, maintenance, andrepair of hydraulic equipment, the retention ofcleanliness of the system is of paramountimportance for subsequent satisfactory per-formance.

The following maintenance and servicingprocedures should be adhered to at all times toprovide proper contamination control:

1. All tools and the work area (workbenchesand test equipment) should be kept in a clean,dirt-free condition.

2. A suitable container should always beprovided to receive the hydraulic liquid that isspilled during component removal or disassembly.

NOTE: The reuse of drained hydraulicliquid is prohibited in most hydraulic systems. Insome large-capacity systems the reuse of fluid ispermitted. When liquid is drained from thesesystems for reuse, it must be stored in a clean andsuitable container. The liquid must be strainedand/or filtered when it is returned to the systemreservoir.

3. Before hydraulic lines or fittings aredisconnected, the affected area should be cleanedwith an approved dry-cleaning solvent.

4. All hydraulic lines and fittings should becapped or plugged immediately after discon-nection.

5. Before any hydraulic components areassembled, their parts should be washed with anapproved dry-cleaning solvent.

6. After the parts have been cleaned indry-cleaning solvent, they should be driedthoroughly with clean, low-lint cloths andlubricated with the recommended preservative orhydraulic liquid before assembly.

NOTE: Only clean, low lint type I or IIcloths as appropriate should be used to wipe ordry component parts.

7. All packings and gaskets should be replacedduring the assembly procedures.

8. All parts should be connected with care toavoid stripping metal slivers from threaded areas.All fittings and lines should be installed andtorqued according to applicable technicalinstructions.

9. All hydraulic servicing equipment shouldbe kept clean and in good operating condition.

Some hydraulic fluid specifications, such asMIL-H-6083, MIL-H-46170, and MIL-H-83282,contain particle contamination limits that are solow that the products are packaged under cleanroom conditions. Very slight amounts of dirt,rust, and metal particles will cause them tofail the specification limit for contamination.Since these fluids are usually all packaged inhermetically sealed containers, the act of openinga container may allow more contaminants into thefluid than the specification allows. Therefore,extreme care should be taken in the handling ofthese fluids. In opening the container for use,observation, or tests, it is extremely important thatthe can be opened and handled in a cleanenvironment. The area of the container to beopened should be flushed with filtered solvent(petroleum ether or isopropyl alcohol), and thedevice used for opening the container should bethoroughly rinsed with filtered solvent. After thecontainer is opened, a small amount of thematerial should be poured from the container anddisposed of prior to pouring the sample foranalysis. Once a container is opened, if thecontents are not totally used, the unused portionshould be discarded. Since the level of con-tamination of a system containing these fluidsmust be kept low, maintenance on the system’scomponents must be performed in a cleanenvironment commonly known as a controlledenvironment work center. Specific informationabout the controlled environment work center canbe found in the Aviation Hydraulics Manual,NAVAIR 01-1A-17.

HYDRAULIC FLUID SAMPLING

The condition of a hydraulic system, as wellas its probable future performance, can best bedetermined by analyzing the operating fluid. Ofparticular interest are any changes in the physicaland chemical properties of the fluid and excessiveparticulate or water contamination, either ofwhich indicates impending trouble.

Excessive particulate contamination of thefluid indicates that the filters are not keeping thesystem clean. This can result from improper filtermaintenance, inadequate filters, or excessiveongoing corrosion and wear.

Operating equipment should be sampledaccording to instructions given in the operating

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and maintenance manual for the particularequipment or as directed by the MRCs.

1. All samples should be taken from circu-lating systems, or immediately upon shutdown,while the hydraulic fluid is within 5°C (9°F) ofnormal system operating temperature. Systemsnot up to temperature may provide nonrepre-sentative samples of system dirt and watercontent, and such samples should either beavoided or so indicated on the analysis report. Thefirst oil coming from the sampling point shouldbe discarded, since it can be very dirty and doesnot represent the system. As a general rule, avolume of oil equivalent to one to two times thevolume of oil contained in the sampling line andvalve should be drained before the sample istaken.

2. Ideally, the sample should be taken froma valve installed specifically for sampling. Whensampling valves are not installed, the taking ofsamples from locations where sediment or watercan collect, such as dead ends of piping, tankdrains, and low points of large pipes and filterbowls, should be avoided if possible. If samplesare taken from pipe drains, sufficient fluid shouldbe drained before the sample is taken to ensurethat the sample actually represents the system.Samples are not to be taken from the tops ofreservoirs or other locations where the contami-nation levels are normally low.

3. Unless otherwise specified, a minimum ofone sample should be taken for each system

located wholly within one compartment. Forship’s systems extending into two or morecompartments, a second sample is required. Anexception to this requirement is submarineexternal hydraulic systems, which require only onesample. Original sample points should be labeledand the same sample points used for successivesampling. If possible, the following samplinglocations should be selected:

a. A location that provides a samplerepresentative of fluid being suppliedto system components

b. A return line as close to the supply tankas practical but upstream of any returnline filter

c. For systems requiring a second sample,a location as far from the pump aspractical

Operation of the sampling point should notintroduce any significant amount of externalcontaminants into the collected fluid. Additionalinformation on hydraulic fluid sampling can befound in NAVAIR 01-1A-17.

Most fluid samples are submitted to shorelaboratories for analysis. NAVAIR 17-15-50-1and NSTM, chapter 556, contain details oncollecting, labeling, and shipping samples.

NAVAIR 01-1A-17 contains procedures forunit level, both aboard ship and ashore, testingof aviation hydraulic fluids for water, particulate,and chlorinated solvent contamination.

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