DSL 606 - Hydraulics and Brakes

1. Calculate the force of a given cylinder under given pressures.
   1. Compute the area of a piston.
   2. Calculate the force of the cylinder using the force-area pressure formula.
   3. Compute the effective area on the rod side of the piston.
   4. Calculate the force of the cylinder when retracting using the force-area pressure formula.
2. Inspect a hydraulic jack.
   1. Exmaine the seals on the pump and piston.
   2. Examine the valves.
   3. Trace the hydraulic oil passage ways.
3. Evaluate a gear pump for possible repairs.
   1. Disassemble the gear pump.
   2. Inspect the pump for wear patterns.
   3. Make any necessary gear pump repairs.
   4. Reassemble the gear pump.
   5. Explain the operation of the gear pump.
4. Evaluate a vane pump for possible repairs.
   1. Identify this pump as a balanced or unbalanced pump.
   2. Disassemble the vane pump.
   3. Inspect the pump for wear patterns.
   4. Make any necessary repairs.
   5. Reassemble the vane pump.
5. Examine a piston pump for possible repairs.
   1. Identify this pump as a radial or an axial piston pump.
   2. Disassemble the piston pump.
   3. Inspect wear patterns.
   4. Make any necessary repairs.
   5. Reassemble the piston pump.
6. Examine a hydraulic cylinder.
   1. Disassemble the hydraulic cylinder.
   2. Analyze the piston seal.
   3. Reassemble the cylinder.
   4. Inspect cylinder condition.
   5. Make any repairs to cylinder.
   6. Reassemble the hydraulic cylinder.
7. Flow rate a pump on the test stand (Megatech).
   1. Connect the flow meter to obtain the proper readings.
   2. Compare flow rate readings with specifications.
   3. Assess the condition of the pump.
8. Explore the principals of the Vickers RC valve.
   1. Convert Vickers RC valve to a sequence valve.
   2. Connect a sequence valve circuit on the test stand (Megatech).
   3. Use the Vickers RC valve to sequence two double acting cylinders.
   4. Convert Vickers RC valve to a counterbalance valve.
   5. Connect a counterbalance valve circuit on the test stand (Megatech).
   6. Demonstrate the use of a counterbalance valve.
9. Analyze the principals of circuits on the test stand (Amatrol).
   1. Connect a pressure relief valve and pump flow rate circuit.
   2. Predict which vlave is passing oil.
   3. Adjust relief valves.
   4. Check the flow rate of the pump.
   5. Connect a cylinder cushion circuit on the test stand.
   6. Observe the cushion action of the cylinder.
   7. Adjust the cushion.
   8. Connect a regenerative circuit on the test stand.
   9. Compute the extending time and retracting time of the cylinder.
   10. Time the extending and retracting times of the cylinder.
   11. Connect a non-compensated flow control circuit on the test stand.
   12. Adjust cylinder extension time.
   13. Explain the use of a needle valve.
   14. Connect a compensated flow control valve on the test stand.
   15. Adjust the cylinder extension time.
   16. Explain the use of a pressure comprensated flow control vlave.
   17. Explain the use of a reverse free flow check valve.
10. Explore the fundamentals of hydraulic ISO symbols.
    1. Identify hydraulic component symbols.
    2. Identify hydraulic line symbols.
    3. Interpret the meaning of hydraulic symbols.
    4. Draw a schematic of each of the test stand exercises using symbols.
11. Explore the fundamentals of the JD backhoe.
    1. Time the extension and retrction of the cylinders on the JD backhoe.
    2. Compare the actual times to the specifications.
    3. Analyze the readings for any problems.
    4. Check the cylinder drift of the cylinders on the JD backhoe.
    5. Analyze the readings for any problems.
12. Examine the fundamentals of the air system.
    1. Identify the major components of an air compressor.
    2. Describe the operation of an air dryer.
    3. Name the various pneumatic valves and cotnrols used in a air brake system.
    4. Explain the operation of a dual circuit air brake system.
    5. Explain the operation of an air brake chamber.
    6. Describe the operation of cam actuated drum brakes.
    7. Describe the components and operation of praking and emergency braking systems.
    8. Define the operation of manual and automatic slack adjuster.s
    9. Define brake balancing.
13. Explain the operation of brake valves.
    1. Explain proportioning valve.
    2. Explain pressure differential valve.
    3. Explain metering valve.
    4. Explain combination valve.
14. Explore the principals of brakes.
    1. Explain the factors the effect braking.
    2. Understand friction.
    3. Determine the effects of speed and weight.
    4. Describe fluid vapor lock.
    5. List the types of brake fluid.
    6. Explain dual master cylinder operation.
    7. Explain the operation of wheel cylinders.
    8. Explain the operation of drum brakes.
    9. Understand the operation of hydraulic anti-lock brakes.
15. Understand the hydraulic drum brake rebuild procedure.
    1. Remove drum brakes.
    2. Inspect lining and components.
    3. Machine the brake drums.
    4. Assemble drum brakes.
    5. bleed the brakes.
    6. Adjust the brakes.
16. Understand the hydraulic disc brake rebuild procedure.
    1. Explain the operation of hydraulic disc brakes.
    2. Remove calipers.
    3. Inspect brake pads and components.
    4. Machine brake rotors.
    5. Assemble the disc brakes.
    6. Bleed the brakes.
17. Understand different types of power brakes.
    1. Explain vacuum suspended.
    2. Explain air suspended.
    3. Explain hydraulic booster.
    4. Explain electro-hydraulic booster.