HYD0001 Basic Hydraulics

Level 1 Basic Hydraulics
Feb, 2009
Overseas Product Support Team
Text No. HYD0001
Table of Contents
Chapter I. Hydraulic Principles

Chapter II. Hydraulic Symbols
Chapter III. Basic Hydraulic System
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There are several advantages for using a liquid.
1. Liquids conforms to the shape of the container.

2. Liquids are practically incompressible.
3. Liquids apply pressure in all directions.
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1) Liquids comport to shaft
Liquids will conform to the shape of any container.

Liquids will also flow in any direction through lines and hoses of various sizes and shapes.
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2) Practically incompressible
50Kg
A liquid is practically incompressible. When a substance is compressed, it takes up less space. A liquid occupies
the same amount of space or volume even when under pressure. The space or volume that any substance
occupies is called "displacement."
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2) Practically incompressible
50Kg
Gas is compressible. When gas is compressed, it takes up less space and it’s displacement becomes less. The
space previously occupied by the gas may be occupied by another object. Therefore, a liquid is best suited for
the hydraulic system because it continually occupies the same volume or displacement.
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3) Hydraulics doing work
112 Kg
50 Kg
16 bar
3 Cm Radius 2 Cm Radius
According to Pascal’s Law, "Pressure exerted on a confined liquid is transmitted undiminished in all directions
and acts with equal force on all equal areas." Therefore, a force exerted on any part of an enclosed hydraulic oil
system transmits equal pressure in all directions throughout the system.
In the above example, a 50 Kg force acting upon a piston with a 2 Cm. radius creates a pressure of
approximately 16 Kg per square centimeter in a confined liquid. The same 16Kg/Cm² acting upon a piston with a
3 Cm. radius supports a 112Kg weight.
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3) Hydraulics doing work
zForce (F) = Pressure (P) X Area (A)

zPressure (P) = Force (F) / Area (A)
zArea (A) = Force (F) / Pressure (P)
112 Kg
50 Kg
16 bar
3 Cm Radius 2 Cm Radius
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4) Orifice effect
Flow Flow
1 LPM 1 LPM
An orifice offers a restriction to the pump flow. When oil flows through an orifice, pressure is produced on the upstream
side of the orifice.
In right figure, there is an orifice in the pipe between the two gauges.
The gauge up stream of the orifice shows that a pressure of 30 bar is needed to send a flow of 1 LPM through the
orifice. There is no restriction to flow after the orifice. The gauge down stream of the orifice shows 0 pressure.
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4) Orifice effect
From From
Pump Pump
When the end of either pipe is plugged, oil flow to the tank is blocked.
The positive displacement pump continues pumping at 1 LPM and fills the pipe. When the pipe is filled, the
resistance to any additional flow into the pipe produces pressure. The pressure reaction is the same as Pascal’s
Law which states that "pressure exerted on a confined liquid is transmitted undiminished in all directions and acts
with equal force on all equal areas." The two gauge readings are the same.
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4) Orifice effect
Bar Bar Bar

Bar Bar Bar
Flow Flow
1 LPM 1 LPM
30 bar 30 bar 30 bar
There are two basic types of circuits, series and parallel.

In Figure, a pressure of 90 bar is required to send 1 LPM through either circuit.
Orifices or relief valves in series in a hydraulic circuit offer a resistance that is similar to resistors in series in an
electrical circuit in that the oil must flow through each resistance. The total resistance equals to the sum of each
individual resistance.
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4) Orifice effect
30 bar
60 bar
90 bar
In a system with parallel circuits, pump oil follows the path of least resistance. In figure , the pump supplies oil to
three parallel circuits. Circuit three has the lowest priority and circuit one has the highest priority.
When the pump oil flow fills the passage to the left of the three valves, pump oil pressure increases to 30 bar.
The pump oil pressure opens the valve to circuit one and oil flows into the circuit. When circuit one is filled, the
pump oil pressure begins to increase. The pump oil pressure increases to 60 bar and opens the valve to circuit
two. The pump oil pressure can not continue to increase until circuit two is filled. The pump oil pressure must
exceed 90 bar to open the valve to circuit three.
There must be a system relief valve in one of the circuits or at the pump to limit the maximum pressure in the
system.
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▶ Denotes : Enclosure Enveope

▶ Explanation : Components in assembly
▶ Denotes : Lines Crossing

▶ Explanation : Lines cross each other
▶ Denotes : Lines Connecting with a dot

▶ Explanation : Junction of Lines
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▶ Denotes : Lines to Tank

▶ Explanation
(a) : Tank symbol
(b) : Line terminating below fluid level
(c) : Line terminating above fluid level
▶ Denotes : Prime mover

▶ Explanation
(a) : Electric motor
(b) : Heat engine
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▶ Denotes : Fixed Orifice

▶ Explanation : Throttles line
▶ Denotes : Variable Orifice

▶ Explanation : Throttle adjusted
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▶ Denotes : Pump
▶ Explanation :Fixed displacement pump
with liquid medium
▶ Denotes : Pump
▶ Explanation :Variable displacement pump
with liquid medium
☞ Pump Displacement?
▷ unit : cc/rev
▷ meaning : discharged fluid amount per 1 revolution of pump shaft
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▶ Denotes : Pump and prime mover connected

▶ Explanation : One directional drive
▶ Denotes : Pumps and prime mover

▶ Explanation :Two or more pumps share
a common drive
☞ Liquid or Gas Medium?

▷ Solid equilateral triangle : Liquid medium
▷ Hollow equilaterial triangle : Gas medium
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▶ Denotes : Hydraulic motor

▶ Explanation
(a) : Fixed displacement hydraulic motor
(b) : Variable displacement hydraulic motor
☞ Motor Displacement?
▷ unit : cc/rev
▷ meaning : Fluid amount needed to turn the motor shaft by 1 revolution
or Consumed fluid amount in turning the motor shaft by 1 rev.
▶ Denotes : Hydraulic Cylinder

▶ Explanation : Double acting hydraulic
cylinder
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▶ Denotes : Basic symbol of normally-closed & two-way valve

▶ Explanation
The right angle tail does abut the input line indicating that the input flow is contained
within the valve but blocked from the output connection in the rest position.
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▶ Denotes : Relief valve

▶ Explanation
A relief valve senses pressure level upstream from the valve.
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▶ Denotes : Sequence valve

▶ Explanation
(a) : Internal pilot, external drain
(b) : External pilot, external drain
▶ Denotes : Holding valve

▶ Explanation - Located in a cylinder line
▶ Denotes : Unloading valve

▶ Explanation – External pilot
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▶ Denotes : Reducing valve

▶ Explanation
- Normally open passage
- Operating signal from control outlet of valve
▶ Denotes : Reducing valve with check

▶ Explanation : for free flow return
▶ Denotes : Pressure switch

▶ Explanation
- A pressure signal actuates the unit to make or
break an electric contact.
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▶ Denotes : Check valve

▶ Explanation
- Free, poppet opens if the inlet pressure is higher
than the outlet pressure

▶ Explanation
- Spring loaded, opens if the inlet pressure is
greater than the outlet pressure plus the bias
spring value.

▶ Explanation
- Free flow in one direction
- Restricted flow in the other direction.
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▶ Denotes : Pilot Operated Check valve

▶ Explanation
- Pressure applied to open valve
▶ Denotes : Pilot Operated Check valve

▶ Explanation
- When pilot pressure is relieved, valve opens.
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▶ Denotes : Shuttle valve

▶ Explanation
- C is higher one between A and B
▶ Denotes : Manual Shutoff
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▶ Denotes : Envelope
▶ Explanation
(a) Basic envelope
(b) Multiple basic envelope
▶ Denotes : Envelope with ports attached

▶ Explanation
- Flow lines to the valve ports are added
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▶ Explanation : A variety of valve-port conditions

(a) Blocked port : arrow does not line up with the lines coming to square
(b) Blocked port, two positions
(c) Three position, blocked ports in neutral position.
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▶ Explanation : A variety of valve-port conditions

(d) Open port, infinite position
(e) Normally open, two positions
(f) Open center, three positions
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▶ Explanation
(a) Normal position of a
two-position, three-connection,
three-way valve
(b) Actuated position of it.
▶ Explanation
(c) Normal position of a
two-position, four-connection,
four-way valve
(d) Actuated position of it.
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▶ Explanation
(a) Normal position of a
three-position, four-connection,
four-way directional control valve
(b) Actuated position to the right.
(c) Actuated position to the left.
▶ Explanation
- Two position, four connection,
spring offset, pilot operated valve
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▶ Explanation
(a) Spring actuator
(b) Attached to the box
▶ Explanation
- Pilot pressure operated function
▶ Explanation
- Spring centered, pilot operated assembly
- Three position control valve
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▶ Explanation
- Solenoid
- Operation by electric signal
▶ Explanation
(h) : Lever
(I) : Pedal or treadle
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▶ Denotes : Accumulator
▶ Explanation
(a) Spring loaded accumulator
(b) Gas loaded accumulator
▶ Denotes : Cooler
▶ Explanation
- Inside triangles indicate
heat dissipation.
▶ Denotes : Filter or strainer
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▶ Double pump with integral ▶ Regenerative circuit with

check valve, unloading and separate components.
relief valves
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▶ Parallel supply and

parallel return
- Combined operation
is possible
▶ Series pressure,
parallel tank line.
- Combined operation
is impossible
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1) Hydraulic tank
The main function of the hydraulic oil tank is to store oil. The tank also removes heat and air from the oil.
Tanks must have sufficient strength, adequate capacity and keep dirt out.
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1) Hydraulic tank
Fill cover - Keeps contaminants out of the opening that's
Fill Cover used to fill and add oil to the tank and seals pressurized
tanks.
Sight Glass Sight Glass - Used to check the oil level. The oil level
should be checked when the oil is cold. The oil level is
usually correct when the oil is in the middle of the sight glass.
Return line
Suction and Return Lines - The supply line allows oil to
flow from the tank to the system. The return line allows oil to
flow from the system to the tank.
Suction line
Drain - Located at the lowest point in the tank, the drain is

used to remove old oil from the tank. The drain also allows
for the removal of water and sediment from the oil.
Drain
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1) Hydraulic tank
Pressurized Tank
Air breather
The two main types of hydraulic tanks are pressurized and
vented (un pressurized).
The pressurized tank is completely sealed. Atmospheric
pressure does not effect the pressure in the tank. However,
when the oil is sent through the system, it absorbs heat and
expands.
The expanding oil compresses the air in the tank. The
compressed air forces the oil out of the tank and into the
system.
The vacuum relief valve serves two purposes. It prevents a
vacuum and limits the maximum pressure in the tank.
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2) Hydraulic fluids
The primary functions of hydraulic fluids are
• Power transmission
• Lubrication
• Sealing
• Cooling
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2) Hydraulic fluids
Power Transmission
Because hydraulic fluids are virtually incompressible, once the hydraulic system is filled with fluid it can
instantly transmit power from one area to another. However, this does not mean that all hydraulic fluids
are equal and will transmit power with the same efficiency. Choosing the correct hydraulic fluid depends
on the application and the operating conditions.
Lubrication
Hydraulic fluid must lubricate the moving parts of the hydraulic system. The rotating or sliding
components must be able to function without touching other surfaces. The hydraulic fluid must maintain
a thin film between the two surfaces to prevent friction, heat and wear.
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2) Hydraulic fluids
Sealing
Many hydraulic components are designed to use hydraulic fluid instead of mechanical seals within the
component. The viscosity of the fluid helps to determine its ability to function as a seal.
Cooling
The hydraulic system develops heat as it transfers mechanical energy to hydraulic energy and hydraulic
energy back to mechanical energy.
As the fluid moves throughout the system, heat flows from the warmer components to the cooler fluid.
The fluid gives up the heat to the reservoir or to coolers that are designed to maintain fluid temperatures
within design limits.
Other properties expected of the hydraulic fluid are the prevention of rust and corrosion on metal parts,
the resistance to foaming and oxidation, the ability to separate air, water and other contaminates from
the fluid, and the ability to maintain stability over a wide range of temperatures
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3) Hydraulic pump
The hydraulic pump transfers mechanical energy into hydraulic energy. It is a device that takes energy
from one source (i.e. engine, electric motor, etc.) and transfers that energy into a hydraulic form. The
pump takes oil from a storage container (i.e. tank) and pushes it into a hydraulic system as flow.
All pumps produce oil flow in the same way. A vacuum is created at the pump inlet. The higher
atmospheric or tank pressure pushes the oil through the inlet passage and into the pump inlet chambers.
The pump carry the oil to the pump outlet chamber. The volume of the chamber decreases as the
chamber approaches the outlet. This decrease in chamber size pushes the oil out the outlet. Pumps
produce only the flow (i.e. gallons per minute, liters per minute, cubic centimeters per revolution, etc.)
used in the hydraulic system. Pumps DO NOT produce or cause "pressure". Pressure is caused by the
resistance to the flow. Resistance can be caused by flow through hoses, orifices, fittings, cylinders,
motors, or anything in the system that hinders free flow to the tank.
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3) Hydraulic pump
Engine
PUMP
Tank
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3) Hydraulic pump
Gear pump Axial propeller pump
Vain pump Internal gear pump

46
3) Hydraulic pump
Axial piston pump Vent axis piston pump
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3) Hydraulic pump
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4) Control valve
Relief valve
Closed condition Open condition
Hydraulic systems are designed to operate within a certain pressure range.

Exceeding this range can damage the system components or become dangerous to personnel. The
relief valve maintains the pressure within the designed limit by opening and allowing excessive oil to
flow either to another circuit or back to the tank.
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4) Control valve
Relief valve
Closed condition Open condition
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4) Control valve
Relief valve
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4) Control valve
Relief valve * Overload valve?
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4) Control valve
Main relief valve

C: Orifice
D: Chamber
E: Sleeve
F: Poppet
G: Drain hole
Closed condition
Open condition
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4) Control valve
Main relief valve
Normal pressure (330 bar) Pressure up (350 bar)
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4) Control valve
Over load relief valve
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4) Control valve
Check valve
Open condition Closed condition
The purpose of a check valve is to readily permit oil flow in one direction, but prevent (check) oil flow
in the opposite direction. The check valve is sometimes called a "one way" check valve.
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4) Control valve
Check valve
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4) Control valve
Check valve
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4) Control valve
Load check valve
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4) Control valve
Pilot control check valve
The pilot operated check valve differs from the simple check valve in that the pilot operated check
valve allows oil flow through the valve in the reverse direction.
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4) Control valve
Pilot control check valve
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4) Control valve
Pilot control check valve (Holding valve)
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4) Control valve
Make up valve
The make-up valve, looks similar to the check valve. The makeup valve is normally positioned in the circuit between
the implement and the tank. During normal operations, the pump or cylinder oil fills the area behind the make-up valve.
The pressure in the cylinder keeps the valve CLOSED. When the cylinder pressure is lower than the tank pressure,
the makeup valve will OPEN. The tank oil bypasses the pump and flows directly through the make-up valve to the
cylinder.
The make-up valve is used to prevent cavitations.
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4) Control valve
Directional Control Valve
The directional control valve is use to direct he supply oil to the actuator in a hydraulic system.
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4) Control valve
65
4) Control valve
66
4) Control valve
67
4) Control valve
68
4) Control valve
Two position, 4-way pilot valve Three position, 4-way pilot valve
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4) Control valve
Neutral position Switched position
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4) Control valve
Tandem circuit Parallel circuit
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4) Control valve
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4) Control valve
Flow Control Valve
Orifice
An orifice is a small opening in the oil flow path. Flow through an orifice is affected by several factors.
Three of the most common are:
1. The temperature of the oil.

2. The size of the orifice.
3. The pressure differential across the orifice.
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4) Control valve
Flow Control Valve
• Temperature
The oil viscosity changes with changes in temperature. Viscosity is a measurement of the oil's resistance
to flow at a specific temperature.
Hydraulic oil becomes thinner and flows more readily as the temperature increases.
• Orifice Size
The size of the orifice controls the flow rate through the orifice. A common example is a hole in a garden
hose. A small pin hole will leak in the form of a drip or a fine spray. A larger hole will leak in the form of a
stream. The hole, whether small or large, meters a flow of water to the outside of the hose. The amount
of water metered depend on the size of the hole (orifice).
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4) Control valve
Flow Control Valve
Fixed orifice Variable orifice
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4) Control valve
Flow Control Valve

• Pressure Differential
Flow through an orifice is affected by the pressure differential across the orifice. The greater the
pressure differential across the orifice, the greater the flow through the orifice.
Below figure, pressure differential is illustrated using the two tubes of tooth paste. When the tube of
toothpaste is gently squeezed as in A, the pressure difference between the inside of the tube and the
outside of the tube is small. Therefore, only a small amount of tooth paste is forced out.
When the tube is squeezed with greater force as in B, the pressure difference between the inside of
the tube and the outside of the tube increases and a larger amount of toothpaste is forced out.
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4) Control valve
Flow Control Valve
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5) Cylinder
Cylinder
Single acting cylinder Double acting cylinder
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5) Cylinder
Cylinder
Effective area
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5) Cylinder
Cylinder
Head side damping Rod side damping
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5) Cylinder
Cylinder
81
6) Motor
Axial piston motor Bent axis piston motor
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6) Motor
Fixed displacement HYD motor Variable displacement HYD motor
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7) Remote control valve
84
7) Remote control valve
85
8) Center joint
Upper hydraulic power from hydraulic pump transmits to the lower hydraulic
actuator without any hydraulic hose connection
86
9) Cooler
• Transfer heat into air

• Keep machine operating within a desired
temperature range
87
10) Accumulator
Spring loaded type Gas loaded type
• Save Hydraulic energy.

• Compensate system pressure
• Absorption of hydraulic pick pressure on
system line
• Remove pump pulsating pressure
88
11) Solenoid valve
89
12) Proportional valve
Out put
The out put pressure depends on current value

(Variable out put pressure)
90
13) Filter
Filter Strainer
To remove contaminants from hydraulic

fluid in system
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END OF DOCUMENT
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Level 1 Basic Hydraulics

Chapter I. Hydraulic Principles

There are several advantages for using a liquid.

1. Liquids conforms to the shape of the container.

1) Liquids comport to shaft

Liquids will conform to the shape of any container.

3) Hydraulics doing work

3) Hydraulics doing work

zForce (F) = Pressure (P) X Area (A)

Bar Bar Bar

30 bar 30 bar 30 bar

There are two basic types of circuits, series and parallel.

▶ Denotes : Enclosure Enveope

▶ Denotes : Lines Crossing

▶ Denotes : Lines Connecting with a dot

▶ Denotes : Lines to Tank

▶ Denotes : Prime mover

▶ Denotes : Fixed Orifice

▶ Denotes : Variable Orifice

▶ Denotes : Pump and prime mover connected

▶ Denotes : Pumps and prime mover

☞ Liquid or Gas Medium?

▶ Denotes : Hydraulic motor

▶ Denotes : Hydraulic Cylinder

▶ Denotes : Basic symbol of normally-closed & two-way valve

▶ Denotes : Relief valve

▶ Denotes : Sequence valve

▶ Denotes : Holding valve

▶ Denotes : Unloading valve

▶ Denotes : Reducing valve

▶ Denotes : Reducing valve with check

▶ Denotes : Pressure switch

▶ Denotes : Check valve

▶ Denotes : Check valve

▶ Denotes : Check valve

▶ Denotes : Pilot Operated Check valve

▶ Denotes : Pilot Operated Check valve

▶ Denotes : Shuttle valve

▶ Denotes : Manual Shutoff

▶ Denotes : Envelope with ports attached

▶ Explanation : A variety of valve-port conditions

▶ Explanation : A variety of valve-port conditions

▶ Denotes : Filter or strainer

▶ Double pump with integral ▶ Regenerative circuit with

▶ Parallel supply and

Drain - Located at the lowest point in the tank, the drain is

The primary functions of hydraulic fluids are

Gear pump Axial propeller pump

Vain pump Internal gear pump

Axial piston pump Vent axis piston pump

Closed condition Open condition

Hydraulic systems are designed to operate within a certain pressure range.

Closed condition Open condition

Relief valve * Overload valve?

Main relief valve

Main relief valve

Normal pressure (330 bar) Pressure up (350 bar)

Over load relief valve

Open condition Closed condition

Load check valve

Pilot control check valve

Pilot control check valve

Pilot control check valve (Holding valve)

Directional Control Valve