J4011 HIDRAULIC SYSTEM

JABATAN KEJURUTERAAN MEKANIKAL

POLITEKNIK UNGKU OMAR
Rusmay Bin Abdullah
The following characteristics and properties are
important for hydraulic oils:
Low temperature sensitivity of viscosity;
Thermal and chemical stability;
Low compressibility;
Good lubrication (anti-wear and anti-stick properties,
low coefficient of friction);
Hydrolitic stability (ability to retain properties in the
high humidity environment);
Low pour point (the lowest temperature, at which the oil
may flow);
Water emulsifying ability;
Filterability;
Rust and oxidation protection properties;
Low flash point(the lowest temperature, at which the oil
vapors are ignitable);
Resistance to cavitation;
Low foaming;
Compatibility with sealant materials.
The advantages of hydraulic systems over other methods of
power transmission are-

Simpler design.
In most cases, a few pre-engineered components will replace
complicated mechanical linkages.
Flexibility.
Hydraulic components can be located with considerable flexibility. Pipes
and hoses instead of mechanical elements virtually eliminate location
problems.
Smoothness.
Hydraulic systems are smooth and quiet in operation. Vibration is kept
to a minimum.
Control.
Control of a wide range of speed and forces is easily possible.
Cost.
High efficiency with minimum friction loss keeps the cost of a power
transmission at a minimum.

Overload protection.
Automatic valves guard the system against a breakdown from
 BASIC HYDRAULIC SYSTEM
A. OPEN-CENTER SYSTEM

Cylinder

Directional Control Valve

4/3

Accumulator Pressure regulating valve

Check valve

Motor

Filter

Tank
A. OPEN-CENTER
SYSTEM
Definition:
An open center hydraulic system has a system relief
valve that maintains 0 pressure and full flow at times
when there is no need for hydraulic pressure .

It has a pump and a sump which is at atmospheric

pressure to collect and reuse the oil after it travels
through the system. This is the typical system found on
backhoes and other types of heavy machinery.

The hydraulic system runs the Flaps, speed brakes and

landing gear of the small airplane. If none of them are in
motion you will have 0 pressure since the relief valve
will be open.
If the gear control handle is moved, the system relief
valve will power closed and the system will build
pressure until the gear is in the position commanded,
then the system relief valve will open up and hydraulic
A. OPEN-CENTER
SYSTEM

Another way of illustrating an open

system is to pump water from a pond
and pour that water over a water wheel
to do some work. The water would then
drain back to the pond. The pond in this
case is the sump and serves to collect
and store water (the hydraulic fluid) for
use by the pump.
B. CLOSED-CENTER SYSTEM

Cylinder

Directional Control Valve 4/3

Accumulator

Pressure Motor Switch

Check valve

Motor

Filter

Tank
B. CLOSE-CENTER
SYSTEM

An close-center hydraulic system

has no relief valve other than over-
pressure, which only opens if the
pressure exceeds the preset limit.
All hydraulic components have full
pressure at the control valve at all
times. This system used on aircraft
using hydraulic flight controls.
B. CLOSED-CENTER
SYSTEM
A simple closed hydraulic system is to use two
syringes connected together with a piece of
tubing and filled with liquid. Pushing the plunger
of one syringe forces the liquid into the other
and moves the plunger of the other. The system
is closed because the liquid stays contained
within the two syringes and tube. Depending on
how you operate the two syringe plungers the
same liquid can be passed back and forth.

Another way to have a closed system is to pipe a

pump and hydraulic motor together so that the
oil leaving the motor is returned directly to the
inlet of the pump and the pump discharge is
piped directly to the inlet of the hydraulic motor.
 B. CLOSED-CENTER
SYSTEM
Closed systems tend to be those hydraulic systems that have a
hydraulic pump with a electric or gas motor powering it. The reason
you need a closed system has to with the way you use hydraulic
power. If you have a hydraulic cylinder that is lifting something, the
motor turns the pump and supplies hydraulic fluid to reach whatever
cylinder length is needed ( like a lifting bucket on a backhoe) . But
when you get to the height you need, the motor is still running, so
you need to divert that hydraulic fluid back to the storage tank
instead of continuing to push on the cylinder. A closed system has a
diverter valve to redirect that fluid away from the cylinder so you
can precisely control the extension and contraction of that cylinder.

Open systems are usually hand powered pumps, like bottle jacks,
where you supply the power to lift the piston and it stops when you
stop supplying power. This actually is more what you need. Bottle
jacks are only about 10 bucks and the cylinder retreats with a little
bit of weight on it. Easy to control for small distances
PRESSURE AND FLOW CONTROL HYDRAULIC SYSTEM
A. METER - IN

Cylinder

One way flow control

Valve

Directional Control Valve

4/3

Accumulator

Check valve

Motor

Filter

Tank
B. METER - OUT

Cylinder

One way flow control

Valve

Directional Control Valve

4/3

Accumulator

Check valve

Motor

Filter

Tank
C. BLEED-OFF

Cylinder

Adjustable flow control

Valve

Directional Control Valve

4/3

Accumulator

Check valve

Motor

Filter

Tank
 COMPONENTS ON HYDRAULIC SYSTEM
1. FILTERS.
A filter removes small foreign particles from a hydraulic fluid and is most
effective as a safeguard against contaminants.

2. ACCUMULATORS.
Like an electrical storage battery, a hydraulic accumulator stores potential
power, in this case liquid under pressure, for future conversion into useful
work.

3. PUMPS.
Hydraulic pumps convert mechanical energy from a prime mover (engine
or electric motor) into hydraulic (pressure) energy.

4. HYDRAULIC ACTUATORS.
A hydraulic actuator receives pressure energy and converts it to
mechanical force and motion.

5. VALVES
Valves are used in hydraulic systems to control the operation of the
actuators.
 TYPES OF HYDRAULIC PUMPS
A. GEAR PUMP
B. VANE PUMP
 C. PISTON

THE AXIAL PISTON PUMP

INTERNAL RADIAL PISTON MOTOR:

D. SKREW

Screw pumps carry fluid

in the spaces between
the screw threads.
The fluid is displaced
axially as the screws
mesh.
 PUMP OPERATION
The following address some of the problems that could occur
when a pump is operating:

a. Overloading.
One risk of overloading is the danger of excess torque on a drive
shaft.(You may need a larger pump)

b. Excess Speed.
Running a pump at too high a speed causes loss of lubrication,
which can cause early failure.
Excess speed also runs a risk of damage from cavitation. (use a
higher displacement pump).

c. Pressure Loss.
Pressure loss means that there is a high leakage path in a system.
(relief valve, cylinders, motors, & A badly worn pump).

d. Slow Operation.
This can be caused by a worn pump or by a partial oil leak in a
system.
e. Cavitation noise.
. Cavitation noise is caused by a restriction in an inlet line, a dirty
inlet filter, or too high a drive speed.
. Air in a system also causes noise.
. Noise can be caused by worn or damaged parts, which will spread
harmful particles through a system, causing more damage if an
operation continues.

f. Cavitation.
. Cavitation occurs where available fluid does not fill an existing
space.
. Most of the time cavitation occurs in the suction part of the system.
. When cavitation takes place the pressure in the fluid decreases to
a level below the ambient pressure thus forming 'vacuumholes' in
the fluid.
. When the pressure increases, for example in the pump, these
'vacuumholes' implode.
.
Cavitation can be caused by:

acceleration of the oil flow behind a throttle / when the oil

contains water or air
high fluid temperature
a resistance in the suction part of the system
a suction line which is to small in diameter
a suction hose with a damaged inside liner
a suction filter which is saturated with dirt
high oil viscosity
insufficient breezing of the reservoir
Hydraulic cylinders are compact and relatively simple. The following lists
service tips in maintaining cylinders:

a. External Leakage.
If a cylinder's end caps are leaking, tighten them. If the leaks still do not
stop, replace the gasket. If a cylinder leaks around a piston rod, replace
the packing.

b. Internal Leakage.
Leakage past the piston seals inside a cylinder can cause sluggish
movement or settling under load. Piston leakage can be caused by worn
piston seals or rings or scored cylinder walls. The latter may be caused
by dirt and grit in the oil.

c. Creeping Cylinder.
If a cylinder creeps when stopped in midstroke, check for internal
leakage Another cause could be a worn control valve.
d. Sluggish Operation.
Air in a cylinder is the most common cause of sluggish action. Internal
leakage in a cylinder is another cause. If an action is sluggish when
starting up a system, but speeds up when a system is warm, check for oil
of too high a viscosity. If a cylinder is still sluggish after these checks, test
the whole circuit for worn components.

e. Loose Mounting.
Pivot points and mounts may be loose. The bolts or pins may need to be
tightened, or they may be worn out. Too much slop or float in a cylinder's
mountings damages the piston-rod seals. Periodically check all the
cylinders for loose mountings.