Fluid Power Troubleshooting, Second Edition,  book cover
2nd Edition

Fluid Power Troubleshooting, Second Edition,

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ISBN 9780824792756
Published December 1, 1994 by CRC Press
664 Pages

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Book Description

Presents practical methods for detecting, diagnosing and correcting fluid power problems within a system. The work details the design, maintenance, and troubleshooting of pneumatic, hydraulic and electrical systems and components. This second edition stresses: developments in understanding the complex interactions of components within a fluid power system; cartridge valve systems, proportional valve and servo-systems, and compressed air drying and filtering; noise reduction and other environmental concerns; and more.;This work should be of interest to mechanical, maintenance, manufacturing, system and machine design, hydraulic, pneumatic, industrial, chemical, electrical and electronics, lubrication, plastics processing, automotive, process control, and power system engineers; manufacturers of hydraulic and pneumatic machinery; systems maintenance personnel; and upper-level undergraduate and graduate students in these disciplines.

Table of Contents

Foreword Z. J. Lansky


1 Fluid Power Principles: A Review

Hydraulic Principles

Basic Laws of Fluids

Pneumatic Principles

Hydraulic System Operation

Advantages and Disadvantages of Hydraulic System

Comparing Hydraulic Systems

Pneumatic System Operation


Heat Exchangers (Aftercoolers)

Storage Tanks

Air Drying Equipment

Comparison of Air Systems to Electric and Hydraulic Systems

Air Versus Electric Systems

Air Versus Hydraulic Systems

2 Hydraulic Systems: Operation, Maintenance, and Troubleshooting

Hydraulic Pumps

Gear Pumps

Vane Pumps

Piston Pumps

Hydraulic Motors

Motor Ratings

Vane Motors

Gear Motors

Piston Motors

Rotary Motion (Fluid Motors and Rotary Actuators)

Startup, Operation, and Maintenance of Hydraulic Pumps and Motors

General Instructions

Pump Malfunction

Hydraulic Motor Malfunction

Troubleshooting Pumps and Motors

Hydraulic Valves

Directional Control Valves

Check Valves

Flow Control Valves

Pressure Control Valves

Solenoid Valves

Servicing, Repairing, and Troubleshooting Hydraulic Valves

Hydraulic and Pneumatic Cylinders

Description and Terminology

Cylinder Ratings

Cylinder Cushions

Cylinder Piston Seals

Installation and Maintenance of Hydraulic Cylinders

Troubleshooting Hydraulic and Pneumatic Cylinders

Hydraulic Accumulators

Types and Applications

Servicing and Repairing of Accumulators

Hydraulic System Reservoirs

Construction and Design




3 Pneumatic Systems: Operation, Maintenance, and Troubleshooting

Air Compressors

Reciprocating Piston Compressors

Rotary Compressors

Installation, Maintenance, and Troubleshooting

Pneumatic Valves

Valve Operation

Maintenance and Troubleshooting

Air Motors

Types of Air Motors

Air Motor Characteristics

Maintaining Air Motors

Maintenance of Air Tools

4 Contaminants in a Hydraulic System


Effects Control

Filter Types

Filter Bypass Valve

Filter Condition Indicator

Installation, Maintenance, and Troubleshooting of Hydraulic Filters




5 Compressed Air Filtration, Lubrication, and Moisture Control

Contaminants in the Air System

Air Line Filters, Lubricators, and Pressure Regulators

Compressed Air Filters


Pressure Regulators

Choosing a F-R-L

Routine Maintenance of F-R-L Units

Maintenance of Compressed Air Filters

Aftercoolers and Air Driers


Air Driers

6 Hydrostatic Transmissions

Principles of Operation

Circuit Development

Comparison of Hydrostatic Transmission Types

Hydrostatic Transmission Controls

Hydrostatic Transmission Start-up Procedure

Hydrostatic Transmission Maintenance

Troubleshooting Hydrostatic Transmissions

Troubleshooting Guidelines

7 Temperature Considerations

Heat Generation

Heat Dissipation

Heat Exchangers: Coolers

Heat Exchanger Types

Adding a Second Heat Exchanger

Miscellaneous Tips on Heat Exchangers

Tips on Heat Dissipation by Radiation

Maintenance and Service

Replacement of Zinc Anodes

Cleaning Shell-and-Tube Heat Exchangers

Cleaning Air-Oil Heat Exchangers

Checking for Leaks

8 Hydraulic System Fluids: Selection and Care

Fluid Types and Properties

Fluid Properties

Petroleum Oils

Fire-Resistant Fluids


Maintaining Fluid Performance

9 Fluid Conductors and Connectors

Pipe, Tubing, and Hose





Tube Fittings

Straight Thread O-Ring Fittings

Hose Fittings and Couplers

Installation Considerations

Pipe Installation

Tubing Installation

Hose Installation

Hose Fitting Installation

Plant Air Line Piping Systems

Use and Care of Hose and Fittings

House Assembly Failures

Improper Application

Improper Assembly and Installation

External Damage

Faulty Equipment

Faulty Hose

Analyzing Hose Failures

Modular Manifold Hydraulic Systems

10 Seals for Fluid Power Equipment

Seal Forms

Dynamic Seal Application and Failure

Radial Lip Seals

Face Seals


Static Seal Application and Failure



Checking for Leaks

Seal Materials

Elastomeric Seal Materials

Tips to Avoid Premature Seal Failure

Exclusion Rings, or Wiper or Scraper Rings

11 Fluid Power Systems: Operation, Maintenance, and Troubleshooting

System Design Considerations

Installation, Start-up, and Operation of Hydraulic Systems




Knowing the System

Maintenance of Hydraulic Systems

Maintenance Procedures and Hints

Hydraulic System Maintenance Accessories

Fluid Storage and Handling

Troubleshooting Guides

12 Fluid Power System Malfunction Detection and Diagnosis

Malfunction Detection

Using a Hydraulic Tester to Troubleshoot

Application of a Tester

Diagnostic Instrumentation

Bourdon Tube Pressure Gauge

Viscosity Measurement

Liquid-Level and Temperature Indicators


13 Fluid Power System Noise Control

Pump Noise

Hydraulic System Noise Control

Vibration Noise Control

Fluidborne Noise Control

Noise Measurement

Research to Reduce Noise

14 Electrohydraulic Servo Systems, Proportional Valve Systems, and Load-Sensing Systems


Control System Types

Electrohydraulic Equipment

Properties of Feedback Control Systems


Open-Loop Versus Closed-Loop System Characteristics

Stability and Dynamic Response

Electrohydraulic Proportional and Servo Valves

Proportional Valve Construction

Servo Valve Construction

Servo Valve Characteristics

Flow Control Servo Valves

Pressure-Control Servo Valves

Installation, Operation, Maintenance, and Troubleshooting of Servo Valves

Installation and Start-up


Maintenance and Troubleshooting

Servo-system Terminology

Appendix A. Fluid Power Symbols and Glossary

Fluid Power Symbols

Fluid Power Graphic Symbols

American National Standards Institute Symbols

Glossary of Fluid Power Terms

Appendix B. Hydraulic Facts and Technical Data

Hydraulic Facts

Miscellaneous Technical Data

Helpful Tables for Fluid Power Systems


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". . .provides practical explanations of component and system function, failure modes encountered in this operation of systems, and methods for locating and isolating fluid power problems."
---IASI Polytechnic Magazines