HYDRAULIC SYSTEM

! Hydraulic Fluid Functions

● Hydraulic fluid must perform vital functions within the system. It must:
• Transmit energy throughout the system
• Provide lubrication for moving parts
• Protect components from rust and corrosion
• Carry heat away from components
! Viscosity
● Viscosity refers to an oil’s thickness, or its resistance to flow and is
directly related to how well an oil will protect and lubricate components.
Temperature affects oil viscosity, so it is important to use the proper
weight of oil for your machine and climate.
HYDRAULIC SYSTEM

! Additives
● Chemical additives are used in oil to…..
• Control viscosity;
• Reduce wear;
• Increase chemical stability;
• Inhibit corrosion and oxidation;
• Keep components clear; and
• Suspend particles until they reach the filter.
FIVE BASIC ELEMENTS IN HYDRAULIC
SYSTEM

! Generally, a Hydraulic system consists of the following elements:

● Hydraulic Pump
● Control Valve
● Hydraulic Cylinder & Hydraulic Motor
● Hydraulic Tank
● Piping & Other Accessories
 FIVE BASIC ELEMENTS IN HYDRAULIC
SYSTEM
! The relation among these elements is shown in the following figure
Pressure control valve: Determine size of work
Flow control valve: Determine speed of the work
Direction control valve: Determine direction of the work

Control Valves control

pressure, flow rate,
direction

Hydraulic Hydraulic Cylinder &

POWER
Pump Motor Work

(Hydraulic motor rotates)

Hydraulic Tank (Hydraulic Cylinder moves straight
HYDRAULIC SYSTEM
! Tank
● The tank is the primary storage area for the hydraulic system oil. Other
functions of the tank include cooling of the oil, allowing air to separate
from the oil, and allowing particles suspended in the oil to settle to the
bottom of the tank.
! Filter
● The filter removes contaminants from the hydraulic fluid. This prevents
component damage and ensures proper system operation.
! Pump
● The pump is driven by an external power source and converts mechanical
energy into fluid energy. The fluid energy is in the form of hydraulic oil
flow.
! Control Valve
● The directional control valve determines the path that fluid takes through
the system
HYDRAULIC SYSTEM
! Actuator
● The actuator converts hydraulic energy into mechanical energy. Cylinders
are actuators that produce linear motion; hydraulic motors are actuators
that produce rotary motion.
! Lines
● Hydraulic lines are hoses or tubes through which hydraulic fluid moves.
Hoses are flexible; tubes are rigid.
! Relief Valve
● The relief valve (also called the pressure control valve) limits system
pressure by opening if pressure exceeds a predetermined set point.
! Cooler
● The cooler removes heat from the hydraulic fluid, thus improving
component life.
HYDRAULIC SYSTEM
! Tank
● The tank is the primary storage area for the hydraulic system oil. Other
functions of the tank include cooling of the oil, allowing air to separate
from the oil, and allowing particles suspended in the oil to the bottom of
the tank.
! Vented Tank
● The vented tank breathes, allowing for pressure compensation under
changing oil levels and temperatures
! Pressurized Tank
● The pressurized tank is sealed from the atmosphere, keeping dirt and
humidity out of the tank. The internal pressure also forces oil toward the
pump, avoiding pump cavitation.
HYDRAULIC SYSTEM
! Fill Tube
● The fill tube is the opening for adding oil. The fill tube screen strains
contaminants out of oil being added, and the tube cap prevents airborne
contaminants from entering the tank.
! Internal Filters
● The internal filters clean the return oil.
! Sight Gauge
● The sight gauge allows visual inspection of the current oil level in the tank
as well as maximum and minimum oil levels.
! Return Line
● The return line returns hydraulic oil to the tank from the system.
HYDRAULIC SYSTEM
! Spring Accumulator
● The spring accumulator consists of a spring, a piston, and a cylinder. As
system pressure rises, oil fills the cylinder, forcing the piston up and
compressing the spring. When system pressure drops, the spring
decompresses, forcing oil back into the system. Spring accumulators are
seldom used in mobile hydraulic systems.
HYDRAULIC SYSTEM
! Gas-Charged Accumulator
● The gas-charged accumulator is the type most commonly used in
Caterpillar machines. It consists of a cylinder, a piston or bladder, and a
charging valve. Oil entering the cylinder pushes the piston or bladder up
and compresses the gas. As oil pressure drops, the gas expands, pushing
the oil out. The gas-charged accumulator is versatile, powerful, and
accurate, but it requires careful maintenance
HYDRAULIC SYSTEM
! Accumulators Compensate for Variations in Flow
● In some systems, demand for flow can occasionally exceed the
capabilities of tanks and pumps. In these cases, an accumulator can
supply temporary flow requirements. When operation returns to normal,
the accumulator refills with oil.
HYDRAULIC SYSTEM
! Accumulators maintain constant pressure
● Accumulators compensate for variations in system pressure by supplying
additional pressure and absorbing excess pressure as needed
HYDRAULIC SYSTEM
! Accumulators absorb shocks
● Sudden load changes can cause pressure surges in the system. The
accumulator works as a shock absorber by taking in surging oil and letting
it out after the surge.
HYDRAULIC SYSTEM
! Accumulators provide emergency pressure and flow
● If engine power is lost, the accumulator can supply hydraulic flow and
pressure to the system for a limited time. This is often used to supply
emergency oil to brakes and steering.
HYDRAULIC SYSTEM
! Hydraulic Tank Failure
● Hydraulic tank failure is rare and typically involves some type of
externally caused damage. Repair options are generally obvious and
straight forward.
● Accumulators, however, require careful maintenance.
! How accumulators fail
● Internal or external gas leak or oil leak
● Bladder rupture
● External damage
● Broken or weak springs
! Why accumulators fail
● Improper installation
● Overcharging or undercharging
● Piston seal failure
● Charging valve failure
● Bladder cracking / fatigue
HYDRAULIC SYSTEM
! Oil Cooler
● Oil Coolers are heat exchangers (similar to car radiators) that use air or
water to maintain safe operating temperatures.
! Air-to-Oil Cooler
● In an air to oil cooler, oil passes through a tube covered with cooling fins.
A fan blows air over the tube and fins, cooling the oil.
HYDRAULIC SYSTEM
! Water-to-Oil Cooler
● In a water-to-oil cooler, oil passes through a series of tubes that are cooled
by water.
CALCULATING SYSTEM PERFORMANCE
! Actuator Speed
● The speed of an actuator (cylinder or motor) is a function of its
displacement (volume) and the flow rate (quantity of fluid moved in a
given time)
! Displacement
● The formula for calculating displacement is:
• Displacement = Piston Area X Piston Travel
Example:
Piston Area = 5 in2
Piston Travel = 20 in
Displacement = 5 in2 x 20 in = 100 in3
CALCULATING SYSTEM PERFORMANCE
! Cycle Time
● The formula for calculating cycle time is:

Displacement
Cycle Time = X 60 Sec / min
Flow Rate

● Knowing the actuator displacement and the rate of flow entering the
actuator (available in service manual), you can calculate the optimum
cycle time for any cylinder.
Example:
Displacement = 100 in3
Flow Rate= 460 in3/min

100 in3
Cycle Time = X 60 Sec / min
460 in3/min
HYDRAULIC SYSTEM
! How coolers fail
● Internal clogging
● External clogging
● Tube/fin fatigue
● Damaged tubes
! Why Coolers fail
● Improper Maintenance
● External damage
! Failure Indicators
● Leaking Oil
● High oil Temperature
● Sticky, varnish-coated valve spools
● Abnormal cooler inlet-to-outlet temperature differential
! Service Options
● Clean fins
● Replacement
FILTERS
! Filter
● The filter removes contaminants from the hydraulic system oil. This
prevents component damage and ensures proper system operation. The
element, or mesh, is given a rating according to its ability to trap particles.
The smaller the micron rating, the smaller the particle that will be trapped.
! Filter Design
● Surface filters trap contaminants on the surface of the filter element or
mesh
● Depth-type filters trap contaminants of different sizes at different levels
within the elements
! Filter Types
● The cartridge filter has a replaceable element that fits into a housing
● The canister filter is a one-piece filter and housing that is similar to an
automobile filter
● The screen filter is a metallic mesh that traps large oil contaminants before
they enter the system
FILTERS
! Pressurized Filter
● A pressurized filter protects valves and actuators from fine contaminant
particles, and it may be either a surface-type or a depth-type cartridge
filter.
! Suction Filter
● The suction filter protects pumps and other components from coarse
contaminants. Suction filters are usually surface filters.
! Pump/Motor Case Drain Filter
● The pump/motor case drain filter removes debris caused by pump or
motor wear or failure. It is a low-volume, low-pressure filter and can be a
cartridge or canister filter.
! Return Filter
● A return filter removes contaminants that enter the system during
operation and keeps them from entering the tank. The return filter is
usually a surface filter
FILTERS
! Bypass Valve
● Most cartridge and canister filters are equipped with filter bypass valves to
ensure that system flow is never blocked. Two conditions could cause
such blockage:
• A buildup of contaminants may clog the filter
• Cold oil may be too thick to pass through the filter
● Either condition could affect system performance or cause component
damage.
Bypass valve
 FILTERS
! How Filters fail Failure Indicators
Dirty Oil
● Clogging Accelerated wear on valve
● Collapsing components
● Improper seating Noisy pump
! Why Filters fail Bypass valve alarm
Service Options
● Ignoring filter service requirements Follow service recommendations
● External damage Use correct Cat filters
● Improper installation Keep oil clean
● Unusual contaminants
● Component failure
 PUMP TYPES & THEIR OPERATION
! Hydraulic Pressure
● Hydraulic pressure is created when the hydraulic fluid encounters some
resistance to its flow. Generally, the higher the operating pressure rating,
the more durable the pump is under pressure.
! Positive-Displacement Pump
● Positive-displacement pumps always generate flow when operating. Most
of the pumps used in Cat machines are this type.
! Fixed-Displacement Pump
● Fixed-displacement pumps are those that move a constant or fixed volume
of fluid for each pump revolution.
! Variable-Displacement Pump
● Variable-displacement pumps can adjust the volume of fluid pumped
during each revolution
 PUMP TYPES & THEIR OPERATION
! Bi-Directional Pump
● Bi-directional pumps are reversible and can be driven in either direction
! Pressure-Compensated Pump
● Pressure-compensated pumps are variable-displacement pumps equipped
with a control device that adjusts pump output in order to maintain a
desired system pressure and/or flow.
● There are three pump configurations that can be considered pressure
compensated:
• A pump with pressure-compensated valve
• A pump that changes output flow
• A pump that maintains specified flow rate
! Pump Displacement
● Pump displacement is the volume of fluid moved in one pump revolution.
At Caterpillar, pump displacement is expressed in gallons or liters per
minute.
COMPARISON OF PROPERTIES OF
VARIOUS PUMPS

ITEM GEAR TYPE VANE TYPE PISTON TYPE

Pressure Low Medium High

Structure Simple Medium Complicated

Size Medium Small Large

Noise Medium Small Large

Load on Bearing Medium Small Large

Effect of Dust Small Medium Large

Price Low Medium High

HYDRAULIC SYSTEM
! How Pumps and Motors Fail
● Leakage
● Wear
● Broken or failed components
! Why Pumps and Motors Fail
● Cavitation
● Aeration
● Contamination
● Improper Fluid
● Excessive heat / Pressure
● Normal Wear
! Pumps and Motor Cavitation
● Cavitation occurs when a pump or motor receives little or no oil. Vapor
cavities form and collapse in the pump, causing implosions that wear
away the internal components of the pump or motor. In addition,
components become scored because of lack of lubrication.
HYDRAULIC SYSTEM
! Symptoms of Pump and Motor Cavitation
● Distinctive rattling sound
● Erratic implement operation
● Heat buildup at pump
! Cause of Cavitation
● Restricted inlet line
● Excessive speed
● Low oil level
● Too-high oil viscosity
● Tank pressurization failure
● Unauthorized system change and/or substandard replacement
! Aeration
● Aeration is the entrapment of air in the oil and is caused by air leaks in the
system. When air bubbles enter the pump or motor, they burst, causing
the internal components to wear away.
HYDRAULIC SYSTEM
! Symptoms of Pump and Motor Aeration
● Pump or motor noise
● Erratic implement operation
● Heat buildup at pump
● Spongy implement control
● Foamy oil
! Causes of pump and motor oil contamination
● Poor maintenance
● Loose line connections
● Damaged seals
● Careless work habits
HYDRAULIC SYSTEM

! Importance of Proper Fluid Viscosity

● Problems may occur if:
• Fluid is too thin and causes:
– An increase in internal and external leakage;
– Pump or motor slippage
– Excessive component wear due to inadequate lubrication
– A reduction in system pressure; or
– Spongy implement control
• Fluid is too thick and causes:
– An increase in internal friction;
– Temperature increase with resulting sludge buildup;
– Sluggish and erratic operation; or
– More power to be required for operation.
HYDRAULIC SYSTEM

! Importance of Proper Fluid Viscosity

● Problems may occur if:
• Fluid is too thin and causes:
– An increase in internal and external leakage;
– Pump or motor slippage
– Excessive component wear due to inadequate lubrication
– A reduction in system pressure; or
– Spongy implement control
• Fluid is too thick and causes:
– An increase in internal friction;
– Temperature increase with resulting sludge buildup;
– Sluggish and erratic operation; or
– More power to be required for operation.
! Failure Indicators
● Noise
● Poor machine performance
● Excessive heat
● Excessive Leakage
● Foamy oil
HYDRAULIC SYSTEM
! Pump Repair Options Tree

Repair Determination
Inspection (RDI)

Gear Vane
Reseal Replace Cartridge
Minor Recondition Rebearing & Reseal
Major Recondition Major Recondition

Piston
Reseal
Salvage
Minor Recondition/Overhaul
Major Recondition
INTRODUCTION TO VALVES

! Valves are hydraulic system components that activate cylinders and

motors and control other fluid flow and pressure requirements of the
system
! Valves may be individual components, grouped within a single
housing, or stacked together in valve blanks.
ORIFICE EFFECT

! As the opening between the seat & stem becomes smaller, flow is
restricted, causing pressure to drop on the down stream side of the
valve. This phenomenon is called the “orifice effect”
● The amount of pressure drop across an orifice depends on both the flow
rate and the size of the orifice.
● Given constant flow, the smaller the orifice, the greater the pressure
differential.
● If flow rate drops, pressure differential drops
● If flow is blocked down stream, pressure becomes equalized on both sides
of the orifice.
● If flow remains constant, the differential remains constant.
THREE CATEGORIES OF VALVES

! Directional control valves control the path fluid takes through the
system
● Example: Selector valve, check valve, make-up valve
! Flow control valves are special valves that control the rate of flow
through a circuit.
! Pressure control valves can limit maximum pressure within a circuit or
maintain a desired pressure difference between two circuits.
● Example: Pressure reducing valve, pressure differential valves, various
types of pressure relief valves.
SELECTOR VALVES
! Selector valves control the operation of actuators & other components
by allowing the valve to determine the direction and rate of oil flow.
● Most have a spool that slides in a valve bore
● Spool has a large diameter called lands
● Lands block or open valve ports
● Some spools also have throttling slots
● Throttling slots allow gradual flow of oil to parts
● Some spools have lubricating grooves
● Lubrication grooves trap oil around spool
● Trapped oil causes spool to float.
● Floating spool is easy to move
● Spools are usually centered with springs
● Some spools are moved manually
● Some spools are moved electrically
● Some spools are moved hydraulically
CHECK VALVE
! Check valve can be classified as either a directional or a flow control
valve. Its primary function is to allow flow in only on direction.
● Design s usually a piston (or ball) and a spring
● Often used in combination with other valves
● Upstream pressure overcomes spring force
● Pressure pushes piston away from seat
● Allow flow through valve
● Flow in opposite direction works with the spring
● Downstream force closes valve & blocks flow.