HSV5 TB
HSV5 TB
HSV5 TB
CompuDraulic LLC
www.CompuDraulic.com
CompuDraulic LLC
Hydraulic System Volume 5
No part of this book may be reproduced or utilized in any form or by any means, electronic or
physical, including photocopying and microfilming, without written permission from
CompuDraulic LLC at the address above.
Disclaimer
It is always advisable to review the relevant standards and the recommendations from the
system manufacturer. However, the content of this book provides guidelines based on the
author's experience.
Any portion of information presented in this book might not be suitable for some applications
due to various reasons. Since errors can occur in circuits, tables, and text, the author/publisher
assumes no liability for the safe and/or satisfactory operation of any system designed based on
the information in this book.
The author/publisher does not endorse or recommend any brand name product by including
such brand name products in this book. Conversely the author/publisher does not disapprove
any brand name product not included in this book. The publisher obtained data from catalogs,
literatures, and material from hydraulic components and systems manufacturers based on
their permissions. The author/publisher welcomes additional data from other sources for
future editions. This disclaimer is applicable for the workbook (if available) for this textbook.
1 Hydraulic Systems Volume 5: Safety and Maintenance
Table of Contents
PREFACE, 7
ACKNOWLEDGEMENT, 8
ABOUT THE BOOK, 10
ABOUT THE AUTHOR, 13
Chapter 1: Hydraulic System Safety, 14
1.1- Introduction
1.2- Why Hydraulic Systems Safety is Important?
1.3- Who is Responsible for Hydraulic Systems Safety?
1.4- Where to Find General Industry Safety and Health Standards?
1.5- What are the Sources of Best Practices for Hydraulic Systems Safety?
1.6- When to Apply Hydraulic Systems Safety Best Practices?
1.7- BP-Safety-01: Design for Safe and Reliable Hydraulic Systems
1.8- BP-Safety-02: Safety of Hydraulic System Operators
1.9- BP-Safety-03: Safety of Hydraulic System Work Environment
1.10- BP-Safety-04: Safety of Hydraulic System Workspace
1.11- BP-Safety-05: Safe Startup of Hydraulic Systems
1.12- BP-Safety-06: Safe Operation of Hydraulic Systems
1.13- BP-Safety-07: Safe Servicing of Hydraulic Systems
1.14- BP-Safety-08: Oil Injection Avoidance and Treatment
1.15- BP-Safety-09: Safe usage of Hydraulic Powered Tools
1.16- BP-Safety-10: Safe Storage and Transportation of Hydraulic Systems
APPENDIXES, 352
APPENDIX A: LIST OF FIGURES, 352
APPENDIX B: LIST OF TABLES, 362
APPENDIX B: LIST OF STANDARD TEST METHODS, 363
APPENDIX D: LIST OF REFERENCES, 67
INDEX, 377
7 Hydraulic Systems Volume 5: Safety and Maintenance
Preface
PREFACE
Safety and maintenance are very important experience to whoever involved in designing,
commissioning, operating, and servicing hydraulic systems. Gaining such experience help to
avoid future unexpected shutdowns, hence improve system reliability and safety of work
environment. This book introduces the concept and best practices of hydraulic components
and system maintenance.
The book presents five sets of best practices for each of the following components: pumps,
motors, cylinders valves, accumulators, reservoirs, transmission lines, heat exchangers, and
filters. The five sets of best practices are as follows:
This book is targeting industry professionals who are in charge for operating, maintaining, and
troubleshooting hydraulic systems. This book is also a great resource for mechanical engineers
and service manuals technical writers.
The author is working hard to finish his goal of supporting fluid power professional education
by developing the following series of volumes and relevant software:
ACKNOWLEDGEMENT
All praises are to Allah who granted me the knowledge, resources and health to finish this
work
To my wife who offered me all the best she can to make this work completed
The author also thanks the following gentlemen for their effective support in developing this
book:
▪ Thomas Bray, former Dean of Applied Technology Center at Milwauke School of Eng.
▪ Kamara Sheku, Dean of Applied Researches at Milwaukee School of Engineering.
▪ Tom Wanke, CFPE, Director of Fluid Power Industrial Consortium and Industry
Relations at Milwaukee School of Engineering.
The author also thanks the following companies (listed alphabetically) for granting the
permission to use portions of their copyrighted literatures in this book.
Lastly, the author extends his thanks to the following sources of public information used to
enrich the contents of the book.
▪ www.dgdfluidpower.com
▪ https://www.noshok.com
▪ www.flender.com
▪ wastewater101.net
▪ www. degelman.com
▪ www.ame.com
▪ www.machinerylubrication.com
▪ www.stahlbus.com
▪ www.hydrauliccylindersinc.com
▪ dietzautomation.com
▪ www.bondfluidaire.com
▪ mac-hyd.com
▪ www.new-line.com
▪ www.Flaretite.com
▪ www.aircraftsystemstech.com
▪ hcheattransfer.com/fouling1.html
10 Hydraulic Systems Volume 5: Safety and Maintenance
About the Book
Book Description:
This book is targeting industry professionals who are in charge of operating, maintaining, and
troubleshooting hydraulic systems. This book is also a great resource for mechanical engineers
and service manuals technical writers. The books start by introducing best practices for safe
design, commissioning, operating and servicing hydraulic components. The book then presents
the maintenance concepts and measuring instruments commonly applicable for hydraulic
system maintenance. The book follows that by presenting five sets of best practices for each of
the following components: pumps, motors, cylinders valves, accumulators, reservoirs,
transmission lines, heat exchangers, and filters. It is to be noted that, the listed best practices
and maintenance actions are based on the author’s experience and may not be applicable in
each case. Therefore, the author is highly recommending reviewing the instructions from
component and system manufacturers as considered the main and first source of information.
This book is colored and has the size of standard A4. The book contains a total of twelve
chapters distributed over 350 pages with very demonstrative figures and tables. The contents
of the book are brand non-biased and intends to introduce the latest technologies related to
the subject of the book. The book is the fifth in a series that the author plans to publish to offer
a complete and comprehensive teaching curriculum for fluid power industry. The book is
associated with a separate colored workbook. The workbook contains printed power point
slides, chapter reviews and assignments.
Book Objectives:
Chapter 01: Hydraulic System Safety
Hydraulic equipment is widely used daily at almost all industrial sectors. Hydraulic power
units range from a simple fraction of horsepower such as in a hydraulic hand tool to a large
500 horsepower machine. Lack of training, understanding how it works, and awareness of the
associated hazards are reflected on increasing number of annual related injuries. The objective
of this chapter is to increase the awareness about the hydraulic system safety during different
phases including system design, startup, normal operation, and servicing. This chapter also
explores the safety of the individuals, workplace, equipment, and the public.
Book Statistics:
Chapter 5 7 4 1 1037 91
Chapter 9 6 3 1 1469 95