HYDRAULICS

TRAINING

Contents
Theory

Components

Hydraulics Systems
Hydraulics
Pascal Law
Hydraulics Principals

Pump
Relief valve
Solenoid valve
Pilot operated valve
Flow control valve
Hydraulic motor
Cylinder

Hydraulics Systems

Bulldozers

Hydraulics Systems

Fork Lifter

Hydraulics Systems

Cranes

Hydraulics Systems
Vehicle Brakes, Jacks, Dental and Barber
Chairs, Cardiovascular System, Airplanes,
Theatrical presentations, Elevators,
Amusement park rides, Bucket trucks etc

What is Hydraulics?

Number of Responses

12
10

10

6
4

2
0
didn't know

incorrect
Adult Responses

correct

Hydraulics???
Hydraulics is the branch of physics having
to do with the mechanical properties of
water and other liquids and the application
of these properties in engineering.

Hydraulics???
The word "hydraulics" comes from the
Greek words "Hydro" means water and
Aulics" means pipes. Hydraulics pertains
to power transmitted and controlled
through the use of a pressurized liquid. So
hydraulics can be defined as a means of
transmission and control of forces and
movement of fluids

Hydraulics advantages

Multiplying forces
Fast response to controls
Accurate
Compatible with electrical and mechanical
Freedom in machine design
ease of installation and maintenance

Pascals Law
Pressure applied on a confined fluid is transmitted
undiminished in all directions, and acts with equal
force on equal areas, and at right angles to them

Pascals Law
A 10 lb force is applied to a
stopper with an area of one
square inch

Results in 10 lb force on
every square inch of the
container wall

This bottle is filled with

liquid that is noncompressible

If the bottom has an area

of 20 sq. in. and each
square inch is pushed by
a 10 lb of force, the entire
bottom receives a 200 lb
push

PASCALS LAW
Pressure = Force / Area
Pressure = lb/in2 (psi)
Area
= in2
Force
= pounds (lb)

10 lb

INPUT

100 lb

OUTPUT

Hydraulics Principals

0 Psi

Purpose of Pumps To create flow and not pressure.

Pressure is created when the flow is restricted

Hydraulics Principals

Hydraulics Principals

Hydraulics Principals

Hydraulics Principals

Hydraulics Principals

Hydraulics Principals

Hydraulics Principals

Hydraulics Principals
Parallel Flow Paths

Hydraulics Principals
Parallel Flow Paths

Hydraulics Principals
Parallel Flow Paths

Hydraulics Principals
Series Flow Path

0 Psi

100 Psi

300 Psi

600 Psi

Hydraulics Principals
Pressure development.
Pressure increases, time of travel of piston decreases,
provided system is constant.
Cylinder size increases, time of travel of piston will
increase, provided pressure is constant.
Flow will take easiest path in parallel flow paths
Pressure will drop in series flow path

Hydraulics Components

Pump
Relief valve
Solenoid valve
Pilot operated valve
Flow control valve
Hydraulic motor
Cylinder
Blocks

PUMPS

Functions of a valve
regulate the pressure
direct the flow of fluid
control volume

Three types of valves

Pressure adjust psi for some purpose
Directional -- route the fluid to the desired actuator
Volume Control or Flow Control -- control the amount of
flow

Uses of pressure control valves

Limit system pressure

Reduce pressures
Set pressure at which oil enters a circuit
Unload a pump

Types of Direction valves, and their

uses
Direct acting -- used with low volume and
infrequent use
Pilot operated -- used with high volume
with little pressure difference

Two main types of pressure reducing

valves

Constant reduced Set to reduce a certain amount below the

operating system pressure.
Ex. 1, Set constant reduced pressure at 500 psi and the system
pressure is 2000 pressure, the valve will keep the system pressure at
1500
Ex. 2, Set at 500 psi and system pressure is 3000 pressure is reduced
to 2500
Ex. 3, set at 250 psi and system pressure is 3000, the pressure is
reduced to 2750
Also is ______ below the system pressure,

Fixed amount pressure Set to be one pressure no matter what

the system pressure is.
Ex. 1, Fixed pressure is set for 1500 psi and the system pressure goes
to 2000 psi the pressure in the circuit stays the same at 1500
Ex. 2, using info from Ex. 1, if the pressure goes to 3000 the pressure
stays the same in the circuit at 1500 psi.
1500 no matter what (unless total system pressure drops below 1500)

Obj 7. Function of a pressure

sequencing valve
controls flow between branches/circuits
first one then another branches/circuits

Basic Symbols: Lines

-continuous line - flow line

-dashed line - pilot, drain

-long chain thin Enclosure of two or more

functions contained in one unit.

Circle, Semi-Circle

-circle - energy conversion units (pump, compressor, motor)

-circle - Measuring instruments
-semi-circle - rotary actuator

Square, Rectangle, Diamond

Square, Rectangle

squares - control components

Diamond
diamond Condition apparatus (filter,
separator, lubricator, heat exchanger

Miscellaneous
Symbols
Spring

Restriction

Restriction

Pump Symbols
Fixed Displacement Hydraulic
Pump-unidirectional (pumps only when
rotated in one direction. Will not pump if turned backwards)

Variable Displacement
Hydraulic Pump-bidirectional
(pumps when rotated in both forward and reverse rotation)

Motors-Fixed
Displacement
Unidirectional
(rotates only one direction)

Bidirectional (rotates in both directions)

Reading Lines

Reading Symbols For

Pumps And Motors

[9] Circuit symbols for energy

conversion

Hydraulic pumps are shown by

a circle with a part
representation of a drive shaft.
Triangles in the circles show
the direction of flow. The
triangles are shown solid,
since pressure fluid is used in
hydraulics.

If the pressure medium is

gaseous, as in the case of
pneumatics, the triangles are
shown in outline.

[11] Circuit symbols for single

acting cylinders
Single acting cylinders
have one port, i.e.
pressure fluid can be
applied only to the piston
side. With these
cylinders, the return
stroke is produced either
by external force, shown
in the symbol by an
opening bearing cap, or
by a spring is shown
within the symbol in this
latter case.

[12] Circuit symbols for double

acting cylinders

Double acting cylinders have

two ports to allow pressure
fluid to be applied to both
cylinder chambers. The
symbol for a differential
cylinder is distinguished from
the symbol for a double acting
cylinder by the two lines added
to the end of the piston rod.
The area ratio is generally 2:1.
In the case of cylinders with
double- ended piston rods, the
symbol shows that the piston
areas are of equal size
(synchronous cylinders).

Reading Symbols For

Cylinders

[19] Circuit symbols for flow

control valves

A distinction is made in flow

control valves between types
which are affected by viscosity
and those which are unaffected.
Flow control valves unaffected by
viscosity are termed orifices. A 2way flow control valve consists of
restrictors, one adjustable
restrictor which is unaffected by
viscosity (orifice) and a regulating
restrictor (pressure compensator).
These valves are represented by
a rectangle containing the symbol
for the adjustable restrictor and an
arrow to represent the pressure
compensator. The diagonal arrow
through the rectangle indicates
that the valve is adjustable.

[18] Circuit symbol for pressure

valves

Pressure valves are

represented using squares.
The flow direction is indicated
by an arrow. The valve ports
can be designated as P
(supply port) and T (tank return
port) or as A and B. The
position of the arrow within the
square indicates whether the
valve is normally open or
normally closed. Adjustable
pressure valves are indicated
by a diagonal arrow through
the spring. Pressure valves are
divided into pressure relief
valves and pressure
regulators.

[20] Circuit symbols for nonreturn valves

The symbol for non-return
valves is a ball which is
pressed against a seat.
Delockable non-return
valves are shown by a
square containing the
symbol for a non- return
valve. The pilot control for
unlocking the non- return
valve is indicated by a
broken line at the pilot
port. The pilot port is
designated by the letter
X.

[21] Circuit symbols for

measuring devices
The illustration shows
the symbols for
measuring devices
used in hydraulics.

[31.1] Hydraulic power unit

The hydraulic power unit

(power supply unit) provides
the energy required for the
hydraulic installation. Its most
important components are the
reservoir (tank) , drive (electric
motor), hydraulic pump,
pressure relief valve (safety
valve), filter and cooler. The
hydraulic power unit may also
act as a carrier for other
devices (gauges, directional
control valves).

[32] Externally toothed gear

pump
The increase in volume
which results when a
tooth moves out of mesh
produces a vacuum in the
suction area. The
hydraulic fluid is
conveyed into the
pressure area. The
hydraulic fluid is then
forced out of the tooth
gaps by the meshing of
the teeth and displaced
into the above supply
line.

[34] Circuit diagram: Return flow

filter
An oil filter situated in the
return line to the tank has
the advantage that the
filter is thus easy to
maintain. A disadvantage,
however, is that
contamination is removed
from the hydraulic fluid
only after it has passed
through the hydraulic
components.
This configuration is often
used.

[35] Circuit diagram : Pump inlet

filter
With this configuration,
the pump is protected
from contamination. The
filter is, on the other
hand, less easily
accessible.
If these filters have a too
fine mesh, suction
problems and cavitation
effects may occur.
Additional coarse filters
upstream of the pump are
recommended.

[36] Circuit diagram: Pressure

line filter
Pressure filters can be
installed selectively
upstream of valves which
are sensitive to
contamination; this also
enables smaller mesh
sizes to be used.
A pressure-resistant
housing is required,
which makes this
configuration more
expensive.

[37] Circuit diagram:

Contamination indicator

It is important that the

effectiveness of a filter can be
checked by a contamination
indicator. The contamination of a
filter is measured by the pressure
drop; as the contamination
increases, the pressure upstream
of the filter increases. The
pressure acts on a spring- loaded
piston. As the pressure increases,
the piston is pushed against a
spring.
There are a number of different
display methods. Either the piston
movement is directly visible or it is
converted into an electrical or
visual indication by electrical
contacts.

[38] Water cooler

With this design of cooler,

hydraulic fluid is fed through tubes
over which coolant (water) flows.
The heat which is discharged can
be re-used.
The operating temperature in
hydraulic installations should not
exceed 50 - 60C, since this would
cause an unacceptable reduction
in viscosity, leading to premature
aging of the fluid. In comparison
with air cooling, operating costs a
higher due to the required coolant
and the susceptibility to corrosion.
Temperature difference of up to
approx. 35C can be handled.

Symbols For Pilot

Operated Relief Valves

Understanding Valves

DCV Flow Path Terminology

Valve type

2-way

Valve use
On-Off functions for fluid supply

3-way

Single acting cylinders, uni-directional motors

4-way

Double acting cylinders, bi-directional motors

5-way

Pneumatic systems with dual air pressure

The above descriptions refer to the total number of directions in

which a fluid can travel through a directional control valve.

DCV Flow Path Terminology

2-Position
3-Position
4-Position
The positions refer to which direction the fluid happens to be
going when a valve is shifted. The position corresponds to
a envelope in the schematic symbol.

Three ways valves can be

actuated/operated
Operators for directional-control valves are
either;
Mechanical or manual (many different ways to
manually operate a valve).
Pilot makes use of low volume system
pressure
Electrical or Electronic
A combination of the above

DCV Operators

An operator is a device that physically moves a spool

or poppet. These are examples of the kinds of
operators that might be found on DCVs.

Valve Operators

Manual operators such as the push button, hand lever,

and foot pedal, use human power for actuation.
Mechanical operators use a machine component to
contact a roller or ball bearing. Pilot operators use a fluid
to move the spool. A solenoid uses electro-mechanical
force to move a spool or poppet.

Spring Operator

In DCVs and other valves, springs are used to return oroff-set

the spool or poppet to ensure a home or rest position. When
reading a schematic symbol, remember that the envelop to which
the spring is attached is the home position. The terms normally
and normally closed relate to whether or not the valve will permit
flow in a given position. If the valve will not allow flow in the
normal position we say it is normally closed or not passing. The
opposite is said for the normally open position and we say
normally passing.

Other Operators
Detents

Detents are used to hold a valve spool in place. They serve a

safety function in that the spool is held positively in place to keep it
from moving due to vibration or possibly from gravity where the
valve is mounted in an up right position. Shown above is a ball
and spring detent but there are other designs as well.

Solenoid Controlled, Pilot Operated

DCV

Although a valve could be shifted directly by the force of a

solenoid, large flow DCVs are most often shifted using fluid at
system pressure. Large flow valves demand larger shifting forces
and it no longer practical to use a solenoid. Illustrated on the left
is a typical mounting arrangement for such a valve. On the left is
the schematic symbol. Can you tell what the normal position is?

Piggy-Back DCV

Piggy-backing is a term used to describe a two valves connected

as a unit where a small valve controls the operation of a larger
valve. This arrangement makes used of the powerful force of
fluids in order to actuate a large flow DCV.

Center Conditions
1.Open Center
2.Closed Center
3.Float Center
4.Tandom Center

Open Center

This spool is sometimes called a motor spool because

it is often used to control a hydraulic motor and minimize
shock that may be encountered as the valve returns to
the center position. It is usually not recommended for
cylinders because of the possibility of drift while in the
center position.

Closed Center

While in the center position the closed center valve allows

no flow to the system because all ports are blocked off
from one another. This spool is used where multiple stop
positions are required.

Float Center

The chief advantage of a float center valve is the

ability of the actuator move freely. It is used to
control cylinders on mobile equipment where a
blade cylinder must be permitted to move freely
in order to scrape or level.

Tandem Center

The tandem center spool is an energy conservative design used

on low power equipment. When in the center position this valve
allows the flow of the pump to return to tank at low pressure thus
reducing system pressure.

Completed DCV Symbols

3-position, Blocked Center 4-way valve, Direct Solenoid

Operation and Spring Centered

3-position, Open Center 4-way valve, Direct Solenoid Operation and

Spring Centered

3-position, Tandem Center 4-way valve, Direct Solenoid Operation

and Spring centered

Pneumatic Valves

The operating principles of pneumatic valves are identical to the

ones used in hydraulics but there does exist a difference in the
schematic symbology. First, you may notice that the arrows are
canted or at an angle. This serves only to Distinguish them
from hydraulic DCVs and nothing more. Second, these valves are
often referred to as 4-way valves although they have 5 ports. The
reason is that there is an additional exhaust port, usually not found
in hydraulic valves.

Directional valves

Hydraulic and Pneumatic

Systems

77

Understanding
Reservoir Lines And
Symbols

Understanding What Pressure,

GPM, And Displacement Means

Spool Valves

Spool Valves

Spool Valves

Hand Operated Spool Valves

Detented Hand Operated Spool Valve

Directional valves

Kind of governing and positioning unit:

2005/2006 I.

Hydraulic and Pneumatic

Systems

85

Spool valves

2005/2006 I.

Directional valves

Hydraulic and Pneumatic

Systems

86

Proportional valves
Proportional
directional valve

2005/2006 I.

Hydraulic and Pneumatic

Systems

87

Spool
Types

Spool Types

Solenoid Operated Spool Valves

Pilot Operated Spool

Valves

Check Valves

In Line Check Valves

Chapter 10
Pressure Controls

Relief
Valves

Pressure-Control Valves
Pressure-Control Valves
A pressure-control valve may limit or regulate pressure, create a particular pressure condition required for
control, or cause actuators to operate in a specific order. All pure pressure-control valves operate in a
condition approaching hydraulic balance. Usually the balance is very simple: pressure is effective on one side
or end of a ball, poppet, or spool and is opposed by a spring. In operation, a valve takes a position where
hydraulic pressure balances a spring force. Since spring force varies with compression, distance and
pressure also can vary. Pressure-control valves are said to be infinite positioning. This means that they can
take a position anywhere between two finite flow conditions, which changes a large volume of flow to a small
volume, or pass no flow.
Most pressure-control valves are classified as normally closed. This means that flow to a valve's inlet port is
blocked from an outlet port until there is enough pressure to cause an unbalanced operation. In normally
open valves, free flow occurs through the valves until they begin to operate in balance. Flow is partially
restricted or cut off. Pressure override is a characteristic of normally closed-pressure controls when they are
operating in balance. Because the force of a compression spring increases as it lowers, pressure when the
valves first crack is less than when they are passing a large volume or full flow. The difference between a full
flow and cracking pressure is called override.
Relief Valves. Relief valves are the most common type of pressure-control valves. The relief valves' function
may vary, depending on a system's needs. They can provide overload protection for circuit components or
limit the force or torque exerted by a linear actuator or rotary motor.
The internal design of all relief valves is basically similar. The valves consist of two sections: a body section
containing a piston that is retained on its seat by a spring's), depending on the model, and a cover or pilotvalve section that hydraulically controls a body piston's movement. The adjusting screw adjusts this control
within the range of the valves.
Valves that provide emergency overload protection do not operate as often since other valve types are used
to load and unload a pump. However, relief valves should be cleaned regularly by reducing their pressure
adjustments to flush out any possible sludge deposits that may accumulate. Operating under reduced
pressure will clean out sludge deposits and ensure that the valves operate properly after the pressure is
adjusted to its prescribed setting.

Relief Valve, Simple Type

(1) Simple Type. Figure shows a simple-type
relief valve. This valve is installed so that one
port is connected to the pressure line or the
inlet and the other port to the reservoir. The
ball is held on its seat by thrust of the spring,
which can be changed by turning the adjusting
screw. When pressure at the valve's inlet is
insufficient to overcome spring force, the ball
remains on its seat and the valve is closed,
preventing flow through it. When pressure at
the valve's inlet exceeds the adjusted spring
force, the ball is forced off its seat and the
valve is opened. Liquid flows from the pressure
line through the valve to the reservoir. This
diversion of flow prevents further pressure
increase in the pressure line. When pressure
decreases below the valve's setting, the spring
reseats the ball and the valve is again closed.

Pilot Operated Relief Valve

Stages Of
A Relief
Valve As It
Opens

Venting A Relief Valve

APE drive manifold circuit showing all the working

components.
Item #33 is the main directional valve spool, and item
#31 is the pilot valve that controls the main drive spool.
We use item #32 to sense pressure in forward or reverse
lines and send a signal to item #28 the relief valve. We
can energize item #31 to either forward or reverse and
send pump flow out the main directional control valve
item #33.
When item #31 is de-energized the vibro will cost to a
stop. All flow in returned through item #33 back to tank.
During this de-energizing we sense the line pressure in
forward or reverse depending which way we selected
item #31, and make the relief valve item #28 dump the
pump flow back to tank, which provides a smooth stop of
the pump flows. The pump flows now can go to tank
both through item #33 and item #28, which reduces
hydraulic shock. Item #30 is a needle valve and controls
how fast or slow item #28 gets the signal from item #32
shuttle valve. Sometime item #30 requires adjustment,
to reduce hydraulic shock when shifting item #33. Either
adjust it in or out just a little, you will know when it is set
correctly when item #33 can be shifted without hearing
any bang or shock.
Item #28, main relief valve controls the maximum
hydraulic system pressure, which is set to 4500 psi.

APE Clamp manifold circuit shown to the

left.
The new APE clamp manifold circuit is
designed to run (shift) a two speed drill
whether one is used or not. The pump
flow enters at (CP) and part of the pump
flow is, about 2-gpm is sent to item #2
for drill two speed shifting. This flow is
limited to 375-400 psi maximum by item
#7. There is no adjustment on item #1, it
is pre-set at 2-gpm. Item #7 is normally
pre-set at 375-400 psi and can be
adjusted in the field if needed. Item #7
should never be adjusted above 400 psi
regardless.
The remaining pup flow (8-12 gpm) is
sent to item #4 the clamp open or close
directional control valve. Item #3 limits
the maximum clamp pressure to 4800
psi maximum and can be adjusted in the
field.

Go to the next slide and we will continue.

Item #5 is a pilot check valve used to

trap hydraulic pressure on the closed
side of the vibro clamp. There is also
another one located right on the vibro
clamp as well. If item #4 is in the center
position, pump flow back to tank, then
item #5 will trap any hydraulic pressure
in the clamp close line to assure clamp
remains closed.
Item #6 is an hydraulic pressure switch,
it does two things. 1.) when hydraulic
pressure in the clamp close line reaches
4500 psi (rising pressure) it will turn the
clamp close light to green. 2.) it will also
de-energize item #4 to the center
position directing pump flow back to
tank. At which time item #5 closes and
traps pressure in the clamp close line.
Should the trapped pressure in the
clamp close line fall below about 4400
psi, then the pressure switch will sense
this and turn the clamp close light off and
re-energize item #4 to direct flow back to
the clamp close line. In simple terms,
the pressure switch keeps clamp
pressure on the vibro clamp close line
between 4500 psi and 4400 psi as long
as the clamp close switch is in the clamp
close position.

Spool
And
Check
Valves

Filters

Accessories

Hydraulic and Pneumatic

Systems

113

Filters

Accessories

Hydraulic and Pneumatic

Systems

114

American Piledriving Equipment, Inc.

THE END