Oshkosh Corp’s Mobil Hydraulics Course

• Evening # 1
– Schedule 5-7:30ish
– Introductions, References, General Info.,
– Chapters 1 & 2 F.P. Basics & Principles
• Fluid Mechanics (as related to Hydraulics)
• Symbol
• Schematics
 Week by Week Topics
• 1 Basics (Chapters 1 & 2)
• 2 Actuators (Cylinder Chapter 3 & Motors Chapter 4)
• 3 Pumps (Chapters 12 & 13)
• 4, 5, & 6 Valves (Press,Flow,Directional,LoadHolding)
– (Chapters 7, 9, &10)

• 7 Fluids & Fluid Conditioning (Chapters 17 & 18)

• 8 Accumulators, Fluid Conveyance, Reservoirs
– (Chapters 11, 15, &16)
• 9 Circuits (Chapters 6, 14 & 19)
• 10 Circuit Presentations
 References
• Mobile Hydraulics Manual (Eaton)
• Lightning Reference Handbook
• Designers Handbook for EH Systems
• Hydraulic Control Systems
• Hydraulic Systems Analysis
• Fluid Power Design Handbook
• Bird Bones and Sludge
• Others Found on www.hydraulicspneumatics.com
 Origin
The word "hydraulics" originates from the Greek
word ὑδραυλικός (hydraulikos) which in turn
originates from ὕδωρ (hydor, Greek for water) and
αὐλός (aulos, meaning pipe).

Definitions
Fluid Power is a form of power transmission that uses
a pressurized liquid (hydraulics) or gas (pneumatics)
to perform thousands of different tasks in mobile,
industrial and other machines & equipment.
 Science and Engineering
Hydraulics, from a worldly view, is a topic in applied science and
engineering utilizing the mechanical properties of liquids. Fluid
mechanics provides the theoretical foundation for hydraulics.
Hydraulic topics range through some parts of science but mostly
through engineering covering concepts that include:
Motion
. Control Computational Fluid Dynamics
Pipe Flow Flow Measurement,
Dam Design River Channel Behavior
Fluidics Erosion
Fluid Control Circuitry Certain Mining Methods
Pumps,Turbines & Hydropower, Fracking

Hydraulics in my world, is the generation, control, and

transmission of power by the use of pressurized liquids often
called POWER HYDRAULICS.
 History
Ancient and Medieval Era
Early uses of water power date back to Mesopotamia and ancient Egypt, where irrigation has been used since the
6th millennium BC and water clocks had been used since the early 2nd millennium BC. Other early examples of
water power include the Qanat system in ancient Persia and the Turpan water system in ancient China.
Greek/Hellenistic Age
The Greeks constructed sophisticated water and hydraulic power systems. An example is the construction by
Eupalinos, under a public contract, of a watering channel for Samos, the Tunnel of Eupalinos. An early example
of the usage of hydraulic wheel, probably the earliest in Europe, is the Perachora wheel (3rd c. BC).[2]
Notable is the construction of the first hydraulic automata by Ctesibius (flourished c. 270 BC) and Hero of
Alexandria (c. 10–80 AD). Hero describes a number of working machines using hydraulic power, such as the
force pump, which is known from many Roman sites as having been used for raising water and in fire engines.
China
In ancient China there was Du Shi (circa 31 AD) who employed a waterwheel to power the bellows of a blast
furnace producing cast iron. Zhang Heng was the first to employ hydraulics to provide motive power in rotating
an armillary sphere for astronomical observation.
Sri Lanka
In ancient Sri Lanka, hydraulics was widely used in the ancient kingdoms of Anuradhapura and Polonnaruwa.
The discovery of the principle of the valve tower, or valve pit, for regulating the escape of water is credited to
ingenuity more than 2,000 years ago. By the first century A.D, several large-scale irrigation works had been
completed. Macro- and micro-hydraulics to provide for domestic horticultural and agricultural needs, surface
drainage and erosion control, ornamental and recreational water courses and retaining structures and also cooling
systems were in place in Sigiriya, Sri Lanka. The coral on the massive rock at the site includes cisterns for
collecting water.
Ancient Rome
In Ancient Rome many different hydraulic applications were developed, including public water supplies, aqueducts,
power using watermills and hydraulic mining. They were among the first to make use of the siphon to carry water
across valleys, and used hushing (mining with water) on a large scale to prospect for and then extract metal ores.
Hydraulic mining was used in the gold-fields of northern Spain. It was worked by at least 7 long aqueducts, and the
water streams were used to erode the soft deposits, and then wash the tailings for the valuable gold content.
Modern era (1600-1870)
In 1619 Benedetto Castelli (1576 - 1578–1643), a student of Galileo, published the book Della Misura dell'Acque
Correnti or "On the Measurement of Running Waters", one of the foundations of modern hydrodynamics.
Blaire Pascal (1623–1662) studied fluid hydrodynamics and hydrostatics, centered on the principles of hydraulic
fluids. His inventions include the hydraulic press, which multiplied a smaller force acting on a larger area into the
application of a larger force totaled over a smaller area, transmitted through the same pressure (or same change of
pressure) at both locations.
A French physician, Poiseuille researched the flow of blood through the body and discovered an important law
governing the rate of flow with the diameter of the tube in which flow occurred.
Joseph Bramah patented the hydraulic press in 1795. While working at Bramah's shop, Henry Maudslay suggested
a cup leather packing. Because it produced superior results, the hydraulic press eventually displaced the steam
hammer for metal forging.
To supply small scale power that was impractical for individual steam engines, central station hydraulic systems
were developed. Hydraulic power was used to operate cranes and other machinery in British ports and elsewhere in
Europe. The largest hydraulic system was in London. Hydraulic power was used extensively in Bessemer steel
production. Hydraulic power was also used for elevators, to operate canal locks and rotating sections of bridges.
Some of these systems remained in use well into the twentieth century.
 Google
AMAZING Liebherr Excavator Climbs
Cat Caterpillar Free Style
Unloading a Herzog Cartopper
Cat 319D LN climbing onto rail car
Scarifier Bracke Forest T26.a - Disc trencher
Tesmec-TRS 1475 Bucket-Gammond UK
Bandit Model 5000 Forestry Mower
Giant Tree Spade at Work. Move trees up to 45
SNOW HOW - this is how you do it!
World's largest snow blower HD
Biggest wheel loader 70 yard super high lift LeTourneau
ETF Mining Trucks MT-240 full turning circle
John Deere H414 harvester head
 Industry Size

In 2016, the manufacture of fluid power components was a $19.0 billion business in the United States.
It was the second year of decline after five straight years of industry growth, but still remains 14.5% higher than its
pre-recession high in 2008.

© NFPA, 2016 Annual Report on the U.S. Fluid Power Industry

 Industry Size

The manufacture of hydraulic products was a $14.2 billion business The manufacture of pneumatic products was a $4.8 billion
in 2016, 75% of the fluid power total. business in 2016, 25% of the fluid power total.

© NFPA, 2016 Annual Report on the U.S. Fluid Power Industry

 Exports

In 2016, the value of U.S. exports of fluid power was The top ten destinations for export growth
$5.5 billion. Exports have increased 17% since the 2011, over the last five years account for 48% of all
and are 62% higher than pre-recession high in 2008. U.S. fluid power exports.

© NFPA, 2016 Annual Report on the U.S. Fluid Power Industry

Jobs & Economic Impact
Based on 2015 U.S. Census Bureau data, it can be estimated that 862 companies employ 67,149 people in the
manufacture of fluid power pumps, motors, valves, cylinders, actuators, hoses, and fittings, with an annual
payroll of more than $4.3 billion.

© NFPA, 2016 Annual Report on the U.S. Fluid Power Industry

 Fluids of Fluid Power
• Hydraulics • Pneumatics
– Petroleum – Air
– Synthetics – Nitrogen
– Bio-Degradables
– Water Emulsions
– Water Glycols
– Water
Major difference between the two types of fluid is
the compressibility.
Advantages of Hydraulic Systems (pg5)
• High Power to Weight Ratio
• Various Operating Environments
• Low Speed High Torque
• Almost Instantaneous Reversibility
• Various Speed/Torque/Force Contrl.Algrthms.
• Failsafe Features
• Rugged
• Heat is Removed by Fluid
• Cost (above 15 hp)
 Disadvantages of Hydraulic Systems
• Leakage (Internal & External)
• Plumbing (Running Wires is Easier)
• Noise (Pumping Chamber)
• Fluid Conditioning (Reservoirs & Filters)
• Cost (for Low Power Systems)

Cautions to Consider with Hydraulic Systems

• Contamination
• Cavitation/Aeration
• Pressure Spikes
• Inefficiencies
 Fluid Mechanics for FP (pg 6 & 28)
Specific Weight and Specific Gravity
• γ = Weight/Unit Volume
– Water = 62.4 lbs/ft3
– Air = .075 lbs/ft3
– Mineral Oil = 58 lbs/ft3 Note:
1 Gal of Water
– Synthetic Oil = 75 lbs/ft weighs 8.36lbs
1 Gal of Oil
• SG = γ of Fluid / γ of Water weighs ~ 7.5lbs
SG of Typical Hydraulic Oil = .85-.94

Example: SG of Synthetic Oil = 75 lbs/ft3 = ??

62.4 lbs/ft3
 Head Pressure (pg 6)
1 cubic foot of oil weighs approximately 58 lbs

1. If this weight is divided equally over the 144 sq in the

0.4 psi
force on the bottom of each square inch is .4 lbs
Thus the pressure at the bottom is .4 psi

12 in

12 in

2 psi

12 in

Force 58 lbs Area = 144 in2

Pressure = Area = 144 in
2
= 0.4 psi
4 psi

2. If the fluid column height is 10 ft then the pressure at

the base of the column will be 4 psi. It is the height of
the column, not its volume that determines the
pressure.
Figure 1-7 Weight of oil creates pressure
COPYRIGHT C (2001) EATON CORPORATION
Example Problem: Assuming the tower is full of water, what does the
pressu pressure gage read?

Answer:
100’

Water Line
 Pressure
• Head Pressure is pressure created in a system due to
gravity acting on the fluid. (often measured in feet of oil and
converted to psig (1ft = .4psig))
• Gauge Pressure is the most common form of pressure
measurement in the FP industry. Typically we use psig in the
English system to signify gauge pressure. Other common
units include Bar, kPa and MPa.
• Differential Pressure is the difference in pressure
between two specific nodes in a system. We use psid in the
English system to describe it.
• Absolute Pressure is rarely used in the Hydraulics
Industry (sometimes use to describe the suction characteristics
of a pump)
 Comparing Gauge Pressures (pg9)

Typical FP inches Hg inch Hg

Pressures psig Bar kPa MPa (vacuum) (Absolute)
High End 10,000 689.5 68,950 68.9

Mobil Hydraulics 5,075 350 35,000 35

Low End 1,000 68.95 6895 6.89

Atomospheric 0 0.0 0.00 0.00 0 29.2

Inlet -2 -0.1379 -13.79 -0.0138 -4.07 25.13

Perfect Vacuum -14.7 -1.0 -101 -0.10 -29.92 0

Pascal’s Law Pressure applied to a fluid in a confined object
is transmitted undiminished in all directions and is acting at right
angles to its boundaries. (pg 2)

2. A 10 lb. force is applied to the

stopper with a surface area of
one square inch

1. The bottle is filled

with liquid, which is
3. This results in 10 lb of force not compressible
on every square inch of
surface area in the container

4. If the bottom has an area of

20 sq. in. and each square
inch is pushed on by 10lbs.
of force, the entire bottom
of the container receives
200 lbs push
1-1
 Force( lb f )
P ( psi) 
Area( in 2 )

Force( lb f )  Pressure ( psi)*Area ( in2 )

1-3

Copyright  Eaton Corporation 2006 (pg 3)

 Mechanical Lever
(lever arm length is the ratio)

2-16

Copyright  Eaton Corporation 2006 (pg 41)

Hydraulic “Lever” or Leverage
(area differential is the ratio)

1-5

(pg 41)
 Differential
Pressure
(pg35)

2-9

Deadhead
Pressure
(pg36)
 Laminar Flow (pg34)

Turbulent Flow (pg34)

 Fluid Power Flow-rates

Typical Hydraulic
System Flowrates gpm in^3/sec liters/min cc/sec
BIG Pump 100 385 378.00 6301

Medium Pump 50 192.5 189.00 3151

Small Pump 5 19.3 18.90 315

 Power (pg21)
• Power in the form of hydraulics • Using English units
is calculated by multiplying the power is calculated using
(differential) pressure and the flow-
pressure in psig and flow in
rate of the fluid in the system.
GPM. The constant that
• W = ΔP x Q takes care of the units is
1714.
– Where
• W is Power WHP  PPSI • QGPM
• P is Pressure
• Q is Flowrate 1714

1714 is derived from:

(1728in3/ft3*60sec/min*550ft-lbs/sec/HP)/(231in3/gal*144in2/ft2)
 Flow Equation
(from Fluid Mechanics)

2 • P
Q  cA

Where:
Q is Flowrate
c is the Orifice Coefficient
A is the Area
ΔP is the Differential Pressure
ρ is the Mass Density of the Fluid
Orifice Equation for Turbulent Flow
Q  k P
Where:
Q is Flow-rate (in3/sec)
k is the Orifice Constant (in3/sec/psi½)
ΔP is the Differential Pressure (psid)
Example: 20gpm is flowing across an orifice. The upstream
pressure is 100psi and the downstream pressure 90psi. What is
the orifice constant?

Example: If Q is raised to 40gpm what is ΔP?

 Merritt’s Equation

Q  100 A P
Where:
Q is Flowrate (in3/sec)
100 is an Empirical Fluids Constant
A is the Area in (in2)
ΔP is the Differential Pressure

Example: 10gpm is flowing through an 1/8” diameter orifice.

What can you expect for a the pressure loss across the orifice?
 1 in dia

2 in dia

Continuity Equation
• For steady flow, flow-in must equal flow-out.
• Qin = Qout = Qat any cross section
3. If the velocity through this pipe is
20 fps and the flow is laminar
(smooth)
4. The same flow will have to go through the 1 inch
diameter portion of the pipe having only ¼ the
area of the 2 inch section. The velocity will have
to be 80 fps to allow the fluid to pass

2 in dia 1 in dia area

5. At this high
flow will be
(rough) this
the frictiona
the pipe and
undesirable

Laminar flow Transitional flow Turbulent Flow

• Where Q = v * A Figure 1-17 Fluid velocity is inversely proportional to pipe cross-sectional area

COPYRIGHT C (2001) EATON CORPORATION

Bulk Modulus (pg394)
The measure of how stiff the
fluid is.
0.5in 1.5in

General Rule of Thumb:

Typical hydraulic oil is ½% per
1000psi compressible.

Β = Vt Δp
ΔV
Β = 200,000-250,000psi
 Viscosity (pg398)
• Viscosity is the measure of a fluids resistance to flow. Thick
fluids flow more slowly than thin fluids due to the increased
internal friction of the fluid itself. Thick fluids have a higher
viscosity number assigned to them.
• There are two forms of viscosity measurement:
– Kinematic (used in Fluid Power)
– Dynamic
• The most common units of measure are:
– ISO VG (Viscosity Grade)
• Centistokes
– SAE Viscosity Grade
– SUS (Saybolt Universal Seconds)

Question: What is the SI Unit of Measure for Dynamic Viscosity?

(Go back to History for a hint)
 SAE SAE
ISO Gear Crankcase
Centistokes Centistokes Viscosity Viscosity SUS SU
Viscosity @ 100 F @ 210 F
@ 100 C @ 40 C Grade Number
Number
10,000
70 9000

Viscosity
1500 1500 8000
60 7000 300

6000
250 250
50 1000 1000
5000
900
45

Grades 40

35
700

600

500
680

140
4000

3000
200

30 460 150

400
2000
25
320
300
1500
20
100
220 50
90
17.5 200 90
1000
900
15 80
150 150 40 800
700
13
70
12 600
85W
11 100 100 30 or 500
90 25W-30
10
80 60
9.0 400
70
68 55
8.0 60
300
20 or

Range for 7.0 50

46
80W
15W-20 50

40
6.0 200

Hydraulics 5.5

5.0
30
32
45

43
150
4.5
22 75W 10W
4.0 20 100 40
5W
90 38
3.5
15 80

3.0 70
35
10 10 60
2.5

50
Most common viscosity ranges used in industrial systems
Viscosities at various temperatures assume 95 VI Oils.

NOTE: Viscosities at various temperatures are related horizontally. SAE gear and crankcase specifications
Viscosity and VI(Viscosity Index)

High VI

Low VI
Oshkosh Corp Symbol Library
Actuators
 Symbols: Cylinders

Piston rod

Port connection

Piston

Port connection Port connection

Single-acting Double acting

Cylinder Cylinder
A.
Valves
Adjustable

Spring
Flow path

Out
Relief Valve
B. Port connections are drawn in
the centered or neutral position

A B

Three boxes means the Arrows show flow paths and

valve has three positions direction of flow

P T

Directional Valve
(bang bang) type
C.

Horizontal bars show an ability

Springs to center to be infinitely positional
the valve (Servo, Proportional Valves)

Directional Valve
Proportional
Valves
Accessories
 Simple, Pump Motor Circuit
3. The pressure line is 4. Pilot lines operate valves or
a working line, so it other controls, they are long
is a solid line dashed lines. They operate with
low flows only

1. The pump inlet 5. Short dashed lines are 2. Return lines

is a working drain lines. They drain are working
line, so it is a leakage oil from pumps, lines, so they
solid line valves, and motors are solid lines
Simple, Pump with Reversing Motor

Directional Valve

Relief Valve P A
Pump Motor

T B

Reservoir
Reservoir
Reservoir

There is typically only one reservoir in a system though the symbol is redrawn for simplicity sake.
ARFF Power Divider
ARFF Back Up Steering
System
Color Key for Class
Color Key for OC
H-Series Broom Truck
H-Series Broom Truck
Ascendant Schematic (60revisions)
 Conclusions

• FP Industry is BIG and OLD

• Founded on Basic Principals
• We use Symbols to Describe Components
• The Schematic is our Design Path
• Equation Sheet
• HW Problem
Homework
 Homework Continued
1) What is the orifice for
the schematic to the right
in units of in3/sec/psi1/2 ?

2) For the same circuit,

what is delta-P if the flow
is increased to 40GPM?
 Homework Continued
1) What is the orifice size
for the schematic to the right
in units of in3/sec/psi1/2 ?

2) For the same circuit,

what is delta-P if the flow
is increased to 40GPM?
 Homework Continued
3) What is the differential
pressure across the orifice
for the schematic to the
right in units of psi?

4) Theoretically, how
much power is the pump
consuming in units of HP?