CHAPTER 2

TYPES AND PARTS OF HYDRAULIC JACK

2.1. Historical Background

The history of the hydraulic jacks can be dated many years ago when French
mathematician and philosopher by the name Blaise Pascal illustrated the principle of
hydraulic jack in the 17th century. Later in 1795, Joseoh Bramah the British engineer
obtained a patent for certain new methods of producing and application of more
power to all machinery that requiring motion and force, and this involved the first
hydraulic press. Richard Dudgeon incorporation started in New York as a machine
shop and on July 8, 1851, inventor and founder Richard Dudgeon awarded a patent
for ‘portable hydraulic presses’. These jacks were operated by water or any other
fluids as whiskey and whale oil; the heads device was the location for fluid reservoir.
During the winter, other liquid tend to freeze and thicken hence the most applied fluid
was whiskey and the name whiskey jack came into existence.
Dudgeon’s hydraulic jack had some weakness like the device seemed to be
heavy especially on the top part due to the presence of reservoir on the head. Dudgeon
corrected this problem 14 years later where he designed the fluid reservoir on the
base, making the device improved and new model. The invented 1851 jack has proved
more powerful, portable and easily operated as compared to screw jacks that require
great effort while lifting heavy devices. Dudgeon jacks functions in railroad shops and
industries for shipbuilding. His jack, however, has been of high performance and
functional everywhere enough to guarantee the upcoming inventor of successful
financially just from the start point.

2.2. Hydraulic jacks

Hydraulic jack is a short stroke hydraulic lift which is fed from hand pump.
The hydraulic jack may be portable. This is extensively used for lifting automobiles
usually to facilitate, repair and for replacing the punctured wheels. The hydraulic jack
is perhaps one of the simplest forms of a fluid power system. By moving the handle of
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a small device, an individual can lift a load weighing several tons. A small initial
force exerted on the handle is transmitted by a fluid to a much larger area.
The operation of hydraulic jack depends on Pascal’s law. This states that when
a fluid is at rest in a closed vessel and if a certain pressure is applied at any point the
pressure will be transmitted equally in all direction. Mechanical advantage is obtained
by a practical application of Pascal’s law of transmission of fluid pressure. Two
pistons of different sizes operate inside two cylinders suitably connected with a pipe
so that pressure in each is the same. The most common types of hydraulic jack are
1. Hydraulic Bottle Jack
2. Floor Jack
3. Strand Jack
4. Air Hydraulic Jack

2.2.1. Hydraulic Bottle Jack

These jacks have outweighed conventional screw jacks that were in use at
some point in time. They consist of two cylinders joined together. It works on the
principle of Pascal's law which suggests that when there is an increase in pressure at
any point in a container of fluid, there is an equal increase in pressure at every other
point in the container.
Pressure on a confined fluid is transmitted undiminished and acts with equal
force on equal areas and at 90 degrees to the container wall. A fluid such as hydraulic
oil, is displaced when either piston which is proportional to the ratio of areas of the
heads of the pistons. Therefore, the small piston must be moved a large distance to get
the large piston to move significantly. The distance the large piston will move is the
distance that the small piston is moved divided by the ratio of the areas of the heads of
the pistons. This is how energy, in the form of work in this case, is conserved and the
Law of Conservation of Energy is satisfied. Work is force times distance, and since
the force is increased on the larger piston, the distance the force is applied over must
be decreased.
This jack also known as a whiskey jack is a hydraulic jack which resembles a
bottle shape, having a cylindrical body and a neck, from which the hydraulic ram
emerges. They have a capacity of up to 50 tons and may be used to lift a variety of
objects. Typical uses include the repair of automobiles and house foundations. These
are fully self-contained jacks with integral pumping units and oil reservoirs. A
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detachable hand lever is provided for operation of pump. A calibrated load gauge is
supplied with each jack. Lifting handle is also provided on the jack.

Figure 2.1.Hydraulic Bottle Jack

2.2.2. Floor Jack

In a floor jack a horizontal piston pushes on the short end of a bellcrank, with
the long arm providing the vertical motion to a lifting pad, kept horizontal with a
horizontal linkage. Floor jacks usually include castors and wheels, allowing
compensation for the arc taken by the lifting pad. This mechanism provides a low
profile when collapsed, for easy maneuvering underneath the vehicle, while allowing
considerable extension. Floor jacks typically provide a greater range of vertical lift
than bottle jacks, and are available in two sizes. The original jack is about four feet
long, a foot wide, and weights around 200 pounds which can lift 4-10 tons. A more
compact model was later made, which is about three feet in length, and can lift 11/2
tons. Although mini jack are also produced, they are not a recognized standard type of
floor jack. Typically, one of the first two sizes should be used.

Figure 2.2.Floor Jack

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2.2.3. Strand Jack

Figure 2.3.Strand Jack

A strand jack is a specialized hydraulic jack that grips steel cables. Often used
in concert, strand jacks can lift hundreds of tons and are used in engineering and
construction. Strand jacking was invented by VSL Australia's Patrick Kilkeary &
Bruce Ramsay in 1969 for concrete post tensioning systems, and are now used all
over the world for heavy lifting, to erect bridges, offshore structures, refineries, power
stations, major buildings and other structures where the use of conventional cranes is
either impractical or too expensive.

2.2.4. Air Hydraulic Jack

Figure 2.4.Air Hydraulic Jack

An air hydraulic jack is a hydraulic jack that is actuated by compressed air -

for example, air from a compressor - instead of human work. This eliminates the need
for the user to actuate the hydraulic mechanism, saving effort and potentially
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increasing speed. Sometimes, such jacks are also able to be operated by the normal
hydraulic actuation method, thereby retaining functionality, even if a source of
compressed air is not available.

2.3. Different Parts of Hydraulic Jack

All hydraulic jacks consist of at least six main components, according to
hydraulic jacks. The main components of hydraulic jacks include a reservoir to hold
hydraulic fluid. A pump that draws fluid from the reservoir to it’ up, suction or intake
stoke that create pressure on its down or power stoke pushing the fluid through a
check valve which after allowing fluid to pass from the reservoir to the pump now
‘check’ off the return port to the reservoir and directs the pressured fluid to the main
cylinder where the ram or piston is forced out or upwards the main cylinder fills with
pressure fluid. After the jack has done its job and it is time to release the pressure
allow the ram piston to return back into the main cylinder the release valve is opened
and the fluid is ported back into the reservoir so the jacking cycle can be operated.

2.4. Reservoir

Figure 2.5.Reservoir

All hydraulic systems have a reservoir. A reservoir is similar to an

accumulator, except that the fluid pressure is constant over all fluid levels. A reservoir
performs several functions. First and foremost, the reservoir holds fluid not required
by the system under any given operating condition accounts for fluid capacity needs
over time in the system. Fluid volume needs will vary different operational scenarios.
Secondly, the reservoir provides for thermal expansion of the fluid over the
operational temperature range of the system. Thirdly, the reservoir provides fluid to
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the inlet side of the hydraulic pump. Reservoir pressurization levels are a critical
aspect of reservoir installation.

2.5. Pump

Figure 2.6.Hydraulic Pump

Hydraulic pumps are used in hydraulic drive systems and can be hydrostatic or
hydrodynamic. A hydraulic pump is a mechanical source of power that converts
mechanical power into hydraulic energy (hydrostatic energy i.e. flow, pressure). It
generates flow with enough power to overcome pressure induced by the load at the
pump outlet. When a hydraulic pump operates, it creates a vacuum at the pump inlet,
which forces liquid from the reservoir into the inlet line to the pump and by
mechanical action delivers this liquid to the pump outlet and forces it into the
hydraulic system.
Hydrostatic pumps are positive displacement pumps while hydrodynamic
pumps can be fixed displacement pumps, in which the displacement (flow through the
pump per rotation of the pump) cannot be adjusted, or variable displacement pumps,
which have a more complicated construction that allows the displacement to be
adjusted. Hydrodynamic pumps are more frequent in day-to-day life. Hydrostatic
pumps of various types all work on the principle of Pascal's law.
There are six types of hydraulic pump: they are
1. Gear Pumps
2. Rotary Vane Pumps
3. Screw Pumps
4. Axial Piston Pumps
5. Radial Piston Pumps
6. Peristaltic Pumps
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2.5.1. Gear Pumps

Gear pumps (fixed displacement) are simple and economical pumps. The
swept volume or displacement of gear pumps for hydraulics will be between about 1
and 200 milliliters. These pumps create pressure through the meshing of the gear
teeth, which forces fluid around the gears to pressurize the outlet side. For lubrication,
the gear pump uses a small amount of oil from the pressurized side of the gears,
bleeds this through the hydrodynamic bearings, and vents the same oil either to the
low pressure side of the gears, or through a dedicated drain port on the pump housing.
Some gear pumps can be quite noisy, compared to other types, but modern
gear pumps are highly reliable and much quieter than older models. This is in part due
to designs incorporating split gears, helical gear teeth and higher precision tooth
profiles that mesh and unmesh more smoothly, reducing pressure ripple and related
detrimental problems. Another positive attribute of the gear pump, is that catastrophic
breakdown is a lot less common than in most other types of hydraulic pumps. This is
because the gears gradually wear down the housing and main bushings, reducing the
volumetric efficiency of the pump gradually until it is all but useless. This often
happens long before wear causes the unit to seize or break down.

Figure 2.7.Gear Pump

2.5.2. Rotary Vane Pumps

Rotary vane pumps (fixed and simple adjustable displacement) have higher
efficiencies than gear pumps, but are also used for mid pressures up to 180 bar in
general. Modern units can exceed 300 bar in continuous operation, although vane
pumps are not regarded as "high pressure" components. Some types of vane pumps
can change the center of the vane body, so that a simple adjustable pump is obtained.
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These adjustable vane pumps are in general constant pressure or constant power
pumps: the displacement is increased until the required pressure or power is reached
and subsequently the displacement or swept volume is decreased until an equilibrium
is reached. A critical element in vane pump design is how the vanes are pushed into
contact with the pump housing, and how the vane tips are machined at this very point.
Several type of "lip" designs are used, and the main objective is to provide a tight seal
between the inside of the housing and the vane, and at the same time to minimize
wear and metal-to-metal contact. Forcing the vane out of the rotating center and
towards the pump housing is accomplished using spring-loaded vanes, or more
traditionally, vanes loaded hydrodynamically (via the pressurized system fluid).

Figure 2.8.Rotary Vane Pump

2.5.3. Screw Pumps

Screw pumps (fixed displacement) consist of two Archimedes' screws that
intermesh and are enclosed within the same chamber. These pumps are used for high
flows at relatively low pressure (maximum 100 bars). They were used on board ships
where a constant pressure hydraulic system extended through the whole ship,
especially to control ball valves but also to help drive the steering gear and other
systems. The advantage of the screw pumps is the low sound level of these pumps;
however, the efficiency is not high.

Figure 2.9.Screw Pump

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The major problem of screw pumps is that the hydraulic reaction force is
transmitted in a direction that's axially opposed to the direction of the flow. There are
two ways to overcome this problem:
1. put a thrust bearing beneath each rotor
2. Create a hydraulic balance by directing a hydraulic force to a piston under the
rotor.

2.5.4. Axial Piston Pumps

Axial piston pumps using the swashplate principle (fixed and adjustable
displacement) have a quality that is almost the same as the bent axis model. They
have the advantage of being more compact in design and also allow use of "through-
drive" series mounted auxiliary rotating equipment, based on their in-line design. The
pumps are easier and more economical to manufacture; the disadvantage is that they
are more sensitive to oil contamination. The axial piston pump is likely the most
widely used variable displacement type, being found in everything from heavy
industrial to mobile applications. By using different compensation techniques, the
variable displacement type of these pumps can continuously alter fluid discharge per
revolution and system pressure based on load requirements, maximum pressure cut-
off settings, horsepower by ratio control, and even fully electro proportional systems,
requiring no other input than electrical signals. This makes them potentially hugely
power saving compared to other constant flow pumps in systems where prime mover
rotational speed is constant and required fluid flow is non-constant.

Figure 2.10.Axial Piston Pump

2.5.5. Radial Piston Pumps

Radial piston pumps are used especially for high pressure and relatively small
flows. Pressures of up to 650 bar are normal. In fact variable displacement is possible.
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The pump is designed in such a way that the plungers are connected to a floating ring.
This floating ring can be moved horizontally by a control lever and thus causes an
eccentricity in the center of rotation of the plungers. The amount of eccentricity can
be controlled to vary the discharge. The suction & discharge can be totally reversed
seamlessly by shifting the eccentricity to the opposite side. Hence both quantity and
direction can be varied in a radial piston pump, just as in the Swash plate pump.

Figure 2.11.Radial Piston Pump

2.5.6. Peristaltic Pumps

Peristaltic pumps are not generally used for high pressures.

Figure 2.12.Peristaltic pumps

2.6. Check Valve

A passage connecting between the oil reservoir and the pump has a check
valve for preventing a reverse flow through this passage, that is, a flow of oil from the
pump to the reservoir. A passage from the pump to the cylinder is provided with a
check valve to prevent a reverse flow there through, that is, a flow of oil from the
cylinder to the pump. These check valves are provided directing in a casting of the
hydraulic jack, thus requiring considerable small machine work thereon. This tends to
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increase the cost of the jack and places the check valves in inaccessible positions so
that the jack must be entirely disassembled to get at these valves.

2.7. Cylinder
All cylinders are used for lifting of heavy loads, plus all cylinders can be used
horizontally for pushing. The function of hydraulic cylinder is to convert hydraulic
power into linear mechanical force or motion. Hydraulic cylinders extend and retract
a piston rod to provide a push or pull force to drive the external load along a straight-
line path. Hydraulic cylinders are of the following types:
1. Lock Nut Hydraulic Cylinders
2. Hollow Hydraulic Cylinders
3. Low Profile Hydraulic Cylinders

2.7.1. Lock Nut Hydraulic Cylinders

Figure 2.13.Lock Nut Hydraulic Cylinders

Lock Nut (also called “Locking Collar”) these hydraulic cylinders are used for
lifting and holding load over extended period of time. The plunger has a locking
collar (nut) for mechanical securing of load when extended period of non-hydraulic
support are required meaning the plunger is threaded and has a nut. Once you lift the
plunger out of the cylinder, you can the screw down the “locking” nut which will
permanently hold the load without creeping.

2.7.2. Hollow Hydraulic Cylinders

Hollow (also called “Center Hole”) these hydraulic cylinders are used for
pulling. The jack has a center hole that runs from the top of the ram through the
bottom which can be used to pull a chain or rope through the center hole to tug, pull
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and create tension. This is used, for example, to tighten the wire ropes on suspended
bridges.

Figure 2.14.Hollow Hydraulic Cylinder

2.7.3. Low Profile Hydraulic Cylinders

These hydraulic cylinders are used for lifting under low clearance. Low profile
hydraulic cylinders include ‘flat’ jacks and ‘pancake’ jacks. A jack labelled “low
profile” has the same shape as a standard cylinder; it is just shorter. A jack labelled
“flat” jack has more of an oval shape and a “pancake” jack has a standard cylindrical
shape but with a larger diameter making look more like a pancake. Usually the flat
jacks and the pancake jacks have the lowest overall height as low as 1.28 inches
consequently these are also referred to as “Ultra-low profile” jacks.

Figure 2.15.Low Profile Hydraulic Cylinders

2.8. Ram or Piston

The plunger is the part of the jack that rises out of the housing (cylinder body).
The plunger is also referred to as a “Piston” or “Ram”. The “stoke” means how high
the jack is able to lift from the retracted position. The “stroke” it is the height
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difference between a retracted and extended jack. Stroke completely depends upon the
working system as well as the ram design. Cylinders of hydraulic jacks which use the
piston or ram on cylinder are known as ram type hydraulic cylinders.
Ram type of hydraulic cylinder is considered as simplest type of hydraulic
actuator. A ram type of hydraulic cylinder will have a piston within its cylindrical
housing. Cross sectional area of piston rod will be more than half of cross-section area
of piston head. There are other design variations in ram type of hydraulic cylinder,
where cross sectional area of piston rod and piston head will be similar.
Types of ram type of hydraulic cylinders are:
1. Single-acting Ram Type of Hydraulic Cylinder
2. Double-acting Ram Type of Hydraulic Cylinder
3. Telescopic Ram Type of Hydraulic Cylinder
4. Tandem Ram Type of Hydraulic Cylinders

2.8.1. Single-acting Ram Type of Hydraulic Cylinder

Figure 2.16.Single-acting Ram Type of Hydraulic Cylinder

A single-acting ram type of hydraulic cylinder is simplest in design and is

shown schematically in Figure 2.16. It consists of a piston inside a cylindrical housing
called barrel. On one end of the piston there is a rod, which can reciprocate. At the
opposite end, there is a port for the entrance and exit of oil. Single-acting ram type of
hydraulic cylinders produce force in one direction by hydraulic pressure acting on the
piston. (Single-acting ram type of hydraulic cylinders can exert a force in the
extending direction only.) The return of the piston is not done hydraulically. In single-
acting ram type of hydraulic cylinders, retraction is done either by gravity or by a
spring.
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According to the type of return, single-acting ram type of hydraulic cylinders

are classified as follows:
1. Gravity-return single-acting ram type of hydraulic cylinder.
2. Spring-return single-acting ram type of hydraulic cylinder.

2.8.1.1 Gravity-return single-acting ram type of hydraulic cylinder

(a) (b)
Figure 2.17.Gravity-return single-acting ram type of hydraulic cylinder

Figure 2.17 shows gravity-return single-acting ram type of hydraulic

cylinders. In the push type [Figure 2.17(a)], the cylinder extends to lift a weight
against the force of gravity by applying oil pressure at the blank end. The oil is passed
through the blank-end port or pressure port. The rod-end port or vent port is open to
atmosphere so that air can flow freely in and out of the rod end of the cylinder. To
retract the cylinder, the pressure is simply removed from the piston by connecting the
pressure port to the tank. This allows the weight of the load to push the fluid out of
the cylinder back to the tank.
In pull type gravity-return single-acting ram type of hydraulic cylinder, the
cylinder [Figure 2.17(b)] lifts the weight by retracting. The blank-end port is the
pressure port and blind-end port is now the vent port. This cylinder automatically
extends whenever the pressure port is connected to the tank.

2.8.1.2. Spring-return single-acting ram type of hydraulic cylinder

A spring-return single-acting ram type of hydraulic cylinder is shown in
Figure 2.18. The pressure is sent through the pressure port situated at the blank end of
the cylinder. When the pressure is released, the spring automatically returns the
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cylinder to the fully retracted position. The vent port is open to atmosphere so that air
can flow freely in and out of the rod end of the cylinder.
In this design, the cylinder retracts when the pressure port is connected to the
pump flow and extends whenever the pressure port is connected to the tank. Here the
pressure port is situated at the rod end of the cylinder.

Figure 2.18.Spring-return single-acting ram type of hydraulic cylinder

2.8.2. Double-acting Ram Type of Hydraulic Cylinder

There are two types of double-acting ram type of hydraulic cylinders:
1. Double-acting cylinder with a piston rod on one side.
2. Double-acting cylinder with a piston rod on both sides.

2.8.2.1. Double-acting cylinder with a piston rod on one side

Figure 2.19 shows the operation of a double-acting cylinder with a piston rod
on one side. To extend the cylinder, the pump flow is sent to the blank-end port. The
fluid from the rod-end port returns to the reservoir. To retract the cylinder, the pump
flow is sent to the rod-end port and the fluid from the blank-end port returns to the
tank.

Figure 2.19.Double-acting cylinder with a piston rod on one side

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2.8.2.2. Double-acting cylinder with a piston rod on both side

Figure 2.20.Double-acting cylinder with a piston rod on both side

A double-acting cylinder with a piston rod on both sides (Figure 2.20) is a cylinder
with a rod extending from both ends. This cylinder can be used in an application
where work can be done by both ends of the cylinder, thereby making the cylinder
more productive. Double-rod cylinders can withstand higher side loads because they
have an extra bearing, one on each rod, to withstand the loading.

2.8.3. Telescopic Ram Type of Hydraulic Cylinder

Figure 2.21.Telescopic Ram Type of Hydraulic Cylinder

A telescopic ram type of hydraulic cylinder (shown in Figure 2.21) is used

when a long stroke length and a short retracted length are required. The telescopic
ram type of hydraulic cylinder extends in stages, each stage consisting of a sleeve that
fits inside the previous stage. One application for this type of cylinder is raising a
dump truck bed. Telescopic ram type of hydraulic cylinders are available in both
single-acting and double-acting models. They are more expensive than standard
cylinders due to their more complex construction.
They generally consist of a nest of tubes and operate on the displacement
principle. The tubes are supported by bearing rings, the innermost (rear) set of which
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have grooves or channels to allow fluid flow. The front bearing assembly on each
section includes seals and wiper rings. Stop rings limit the movement of each section,
thus preventing separation. When the cylinder extends, all the sections move together
until the outer section is prevented from further extension by its stop ring. The
remaining sections continue out-stroking until the second outermost section reaches
the limit of its stroke; this process continues until all sections are extended, the
innermost one being the last of all.

2.8.4. Tandem Ram Type of Hydraulic Cylinders

Figure 2.22.Tandem Ram Type of Hydraulic Cylinders

A tandem ram type of hydraulic cylinder, shown in Figure 2.22, is used in

applications where a large amount of force is required from a small-diameter cylinder.
Pressure is applied to both pistons, resulting in increased force because of the larger
area. The drawback is that these cylinders must be longer than a standard cylinder to
achieve an equal speed because flow must go to both pistons.

2.9. Release Valve

The release valve is located on the power unit that you pumped the jack up
with. It will need to use the other side of the handle that is used to jack the car up and
fit it over the release valve and twist the handle counter clockwise to release the
pressure from the pump unit. Be cautious when releasing the valve as they can release
quickly and the car will drop abruptly. Small twist should be taken at a time and let it
come down gradually.
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