Heavy Equipment Technician

Hydraulic
Fundamentals

Hydraulic 1
First Period
Module 190105a
Objective One
Define hydraulic terminology.

Actuator: A device that converts hydraulic

power into mechanical force.

Flow Rate: The volume of fluid passing a given

point in a given amount of time.
Measured in GPM or LPM
Fluid: Any substance that flows.
Both liquids and gases are fluids.
 Hydraulic Terminology
Force: A push or a pull.
Measured in: Pounds ( lbs.)
Newtons ( N ).
Hydraulics The science that pertains to the
: transmission of force and / or
motion through a fluid.

Hydrodynamics The area of hydraulics that

: pertains to the transmission
of force, using liquid motion.
 Hydraulic Terminology
Hydrostatics: The area of hydraulics that
pertains to the transmission
of force, using a confined fluid.
Mass: Amount an object weighs in
Pounds ( lbs.) or Grams. ( g, kg )
Orifice A device used to create a restriction
: to fluid flow.

Work: Is force acting through a distance.

 Hydraulic Terminology
Power: Amount of work done in a given period
of time.
Measured in: Horsepower ( hp)
Watts ( W )
Pressure: Force per unit area.
Measured in:
Pounds per square inch ( psi )
Newtons per square meter,
which is called a Pascals ( Pa )
 Hydraulic Terminology
Pump: A device that converts mechanical
power into hydraulic power.
( creates flow only )
Torque: A turning or twisting force.
Measured in: Inch pound ( in lb. )
Foot pound ( ft lb. )
Newton meter ( N· m )
Vacuum: A pressure less than atmospheric
pressure. ( 14.7 Hg )
 Hydraulic Terminology
Velocity: The rate of motion. ( Speed )
Measured in: Feet per second ( ft/sec )
Meters per second ( m/sec ).

Volume: The internal capacity of a space or

chamber.
Measured in:
Cubic inches ( in³ ), Gallons ( gal. )
Cubic centimeters ( cm³ ), Liters ( L )
Objective Two
Using mathematical calculations, explain the
principles of pressure, force, area, volume,
flow rate, cycle times and power.
Characteristics of Fluids
Fluids are substances that flow.
Can be gases or liquids.
Have no shape of their
own.
Seek their own level.
Characteristics of Fluids
The major difference between liquids and
gases is that: A Gas will Compress

Liquids are Virtually Incompressible

Pascal’s Law

Transmitting power through liquids provides

greater flexibility than using solid means,
like belts, linkage, gears etc.
Pascal’s Law

Pressure applied to a confined fluid is

transmitted equally and undiminished
in all directions, at right angles to all
surfaces.

Pressure = Force
Area
Relationship of Pressure, Area and Force
Pressure: Pressure is caused by a resistance to
fluid flow.

Resistance to flow comes from system

components (lines, fittings) or a load.
Relationship of Pressure, Area and Force
Pressure created by resistances of system
components to flow, is called a pressure loss,
and generates heat.

Total Pressure =
Pressure Loses + Pressure required to overcome load
Relationship of Pressure, Area and Force
Pressure
Formula

Pressure = Force ÷ Area

F
P A

Force = Pressure x Area

Area = Force ÷ Pressure
Relationship of Pressure, Area and Force
Pressure = Force ÷
Area

Using the same area,

increasing force, increases pressure.
Relationship of Pressure, Area and Force
Pressure = Force ÷
Area

Using same force,

increasing area,
decreases pressure.
Points to Remember

Pressure is caused by resistances to flow.

Total System Pressure equals pressure losses,

plus the pressure required to overcome the
load.

Pressure = Force ÷ Area

(Force per Unit Area)
Metric (SI) Units for Force, Area and Pressure

Force
Gravity changes 1 kg of
mass or weight of an object,
to a force of 9.8 N
Metric (SI) Units for Force, Area and Pressure
Area

8 cm

Change diameter to
meters: 8 cm ÷ 100 = 0.08 m
Formula: Area = .7854 x Dia²
Area = .7854 X 0.08 m x 0.08 m
Area = .005 m²
Metric (SI) Units for Force, Area and Pressure
Pressure is measured in Mass 150 kg
Pascals ( Pa )
1 kg = 9.8 N of Force Diameter
20 cm
Force (N) =
150 kg x 9.8 = 1470 N

Diameter in metres
=20 cm ÷ 100 = .20 m

Area = .7854 x .20 m x .20 m = 0.031 m²

Metric (SI) Units for Force, Area and Pressure

Pressure is measured in Force 1470 N

Pascals ( Pa )
1 N· m² = 1 Pa
Area
0.031 cm

F
P A
1470 N
Pressure = = 47,419.4 N· m²
0.031 m²
Pressure: 47,419.4 Pa ÷ 1000 = 47.42 kPa
Hydraulic Force Generation:Imperial (Standard)

Force = Pressure x Area

F Force = 1000 psi x 10 in²
P A Force = 10,000 lb
Hydraulic Force Generation:
Facts:
The amount of applied force to a surface area,
directly affects pressure.
ℴ Doubling force will double pressure, if
the area remains the same.

The amount of surface area to which a force

is applied inversely affects pressure.
ℴ Doubling area will decrease pressure by
half, if the applied force remains the same.
Hydraulic Force Metric (SI)
Generation: Area = 0.009 m²
4 MPa Force = 36 kN

Extension
Force = Pressure x Area
Force = 4 MPa x 0.009 m2
Force = 0.036 MPa· m²
Force = 0.036 MPa· m² x 1000 = 36 kN
Hydraulic Force Metric (SI)
Generation: A = 0.006 m²

Rod Area .003 m²

Area =
0.009 m²
Retraction 4 MPa

Force = P x (Area of Piston – Area of Rod)

Force = 4 MPa x 0.006 m²
Force = 0.024 MN· m²
Force = 0.024 MN· m² x 1000 = 24 kN
Hydraulic Force
Generation:

Z Bar
Linkage

The retraction force of a double ended cylinder

will be reduced because of surface area
taken up by the rod.
Cylinder extension piston’s larger surface area is
used were greater force is required.
Hydraulic Force Generation:
Reducing piston diameter by 1/2 will reduce the
area to a 1/4 of the original size.

“A” = .7854 x 4” x 4” = 12.5664 in²

“B” = .7854 x 2” x 2” = 3.1416 in²
Force Multiplication using Hydraulic
Principals: 14 lb
5 : 1 Ratio (10 in² ÷ 2 in²)
70 lb
7 psi
A 1 2 in² A 2 10 in²

P = F ÷ A F = P x A
P = 14 lb ÷ 2 in2 F = 7 lb/in2 x 10 in2
P = 7 lb/in2 F = 70 lb
Distance is Sacrificed for Force Multiplication

A 2 = 9 in²
A 1 = 2 in²
8 in
1.78 in

Volume = Area x Distance D = V ÷ A

V = 2 in² x 8 in D = 16 in³ ÷ 9 in2
V = 16 in³ D = 1.78 in
Reaction of Pressures in Series & Parallel Circuits

Series Circuit

Double ended cylinders

used in series move at
the same time.

The pressure at P1
equals pressure
required to overcome
load 1, plus pressure
created by load 2 (P2)
Back pressure adds an extra load to a system.
Reaction of Pressures in Series & Parallel Circuits

Parallel Circuit

As pressure increases, lightest load will move

first, and progressively the heavier loads.
When cylinder # 3 reaches the end of its travel,
pressure will continues to rise, until the relief
valve’s preset limit specification is exceeded.
Measuring Pressure Head Pressure (Head)
Gravity causes: 1 ft³ of water to weigh 62.4 lb (277.569 N)

A 10 ft‫܁‬column of water weighs 624 lbs (2775.69 N) at

sea level.
Measuring Pressure Head Pressure (Head)
Gravity causes: 1 in³ of water to exert .433 psi (2.985 kPa)
of pressure at sea level.

A 10 in³ column of water to exert 4.33 psi (29.85 kPa) of

pressure at sea level.
Measuring Pressure Head Pressure (Head)
Head pressure is important when installing
pumps.

Most manufactures will install pumps below

the reservoir to help prevent cavitation.
Atmospheric Pressure
Atmospheric pressure exerts a 14.7 lb (65.39 N)
force at sea level.

Atmospheric pressure
decreases when
elevation increases.
Atmospheric Pressure

Atmospheric pressure (14.75 psi) combined

with head pressure, helps to keep the inlet
to the pump filled with fluid (inlet flooding).
Pressure Gauges
Bourdon Tube Bourdon Tube

Pressurized fluid
enters the tube
causing it to
straighten out,
indicating
pressure reading.

Pressure Inlet

Most common tool used, to measure pressure.

Scales of Pressure Measurement
Gauge Pressure Measurement Psi or Psig

Pressure gauge reads

zero when exposed to
atmospheric pressure
(14.7 psi)

Most common gauge

used.
Scales of Pressure Measurement
Gauge Pressure Measurement ABSOLUTE

Includes atmospheric
pressure in the
pressure indicated.
Gauge is calibrated in
a perfect vacuum.
Can be used to
measure vacuums
or pressures.
Scales of Pressure Measurement
Inches of Mercury (in Hg) (Barometer Scale)

Used in hydraulics to measure pressures below

atmospheric pressure.
14.7 psi = 29.92 in (760 mm)

> 14.7 psi – positive pressure.

< 14.7 psi – low pressure.
< 0 psi – negative pressure.
(vacuum)
Inches of Mercury (in Hg)(Barometer Scale)

U-tube Manometers are

used to measure gas
pressures, and may use
mercury or water..

1” of mercury = .5 psi.
13.6” of water = 1”of mercury.
Measure twice the distance
the fluid rises up one side
of the tube.
Inches of Mercury (Hg)

Vacuum gauge calibrated in

Inches of Mercury (Hg).
Metric Units of Pressure
Bar
Bar is often used in high pressure hydraulic
systems to measure pressure.

1 Bar = 100,000 Pa
100 kPa
0.1 MPa
14.5 psia
Atmospheres
Relationship of Flow Rate, Actuator Volume
and Actuator Speed

Liquid Flow

Flow is caused by a difference in pressure at

the opening, known as a Pressure Drop.
Liquid Flow

If there is no pressure drop, there can be no

flow.

Liquids move from high to low pressure areas.

Measurement of Liquid
Movement
Flow Rate and Velocity are two ways liquid
movement can be measured.

Flow Rate: Volume of liquid passing a given

point in a given time.

Velocity: Speed of the liquid passing a

given point in a given time.
Measurement of Liquid
Movement
Flow Rate

A hydraulic pump is a positive displacement

type pump that maintains its Flow Rate
as system pressure increases.
Measurement of Liquid
Movement

Velocity: Speed at which fluid will pass a given

point, in a given period of time.
An increase in line diameter decreases velocity.
A decrease in line diameter increases velocity.
Cycle Time ( Actuator Speed
)

Actuator speed is
determined by pump
flow rate (10 L/min) and
actuator volume (10L).
Cycle Time ( Actuator Speed
)

Increasing pump flow

rate (20 L/min), increases
extension speed, and
reduces extension
time.
Cycle Time ( Actuator Speed
)

Increasing cylinder
volume, decreases
extension speed and
increases extension
time.
Cycle Time: Extending a Double Acting Cylinde
Area 20 cm²

Pump Flow
Rate120 L/min

80 Stroke 140 cm
cm²

Step 1: Calculate Cylinder Extension Volume.

Extension Volume = Area x Stroke
Extension Volume = 80 cm² x 140 cm = 11,200 cm³
Step 2: Convert Into Litres.
11,200 cm³ ÷ 1000 = 11.2 L
Cycle Time: Extending a Double Acting Cylinde
Area 20 cm²

Pump Flow
Rate120 L/min

80 Stroke 140 cm
cm²

Step 3: Calculate Extension Time.

Extension Time = Extension Volume ÷ Flow Rate
11.2 L ÷ 120 L /min = .093 min
Step 4: Convert into Seconds.
Extension Time = .093 min x 60 sec = 5.6 sec
Cycle Time: Retracting a Double Acting Cylinde
Area 20 cm²

Pump Flow
Rate120 L/min

80 Stroke 140 cm
cm²

Step 1: Calculate Cylinder Retraction Volume.

Retraction Volume = Area of piston – Area of rod x Stroke
80 cm² – 20 cm² x 140 cm = 8400 cm³
Step 2: Convert into Litres
8400 cm³ ÷ 1000 = 8.4 L
Cycle Time: Retracting a Double Acting Cylinde
Area 20 cm²

Pump Flow
Rate120 L/min

80 Stroke 140 cm
cm²

Step 3: Calculate Retraction Time

Retraction Time = Retraction Volume ÷ Flow Rate
= 8.4 L ÷ 120 L /min = .07 min
Step 4: Convert into Seconds.
Retraction Time = .07 min x 60 sec = 4.2 sec
Cycle Time: Double Acting Cylinder

Exerting pressure on the smaller surface area of

the cylinder retraction (rod) side, causes faster
cycle times and less force generation
than the extension side.
Cycle Time ( Actuator Speed )

Internal leakage of system components will

create heat and reduce actuator speed.
Hydraulic Power

Work is force acting through a distance.

10 ft (3.05 m)

100 lb (444.82 N)

Power is the rate of doing work.

Hydraulic Power
Input The amount of power required to
Power: overcome flow losses, pressure, and
amount of output power.
Output Power: Power delivered by the actuators.
Units for power are:
Imperial: Horsepower
1 HP = 550 ft-lb/sec (33,000 ft-lb/min)
Metric: Watt
1 W = 1 Nm/sec (60 Nm/min)
Output Power (Imperial)
A flow rate of 1 GPM under 1 psi = 0.000583 hp
Output Power (hp) = 65.59 hp

Flow Rate
75 GPM

Pressure
1500 psi
Output Power (hp) =
Flow Rate (GPM) x Pressure (psi) x 0.000583 hp
75 GPM x 1500 psi x 0.000583 hp = 65.59 hp
Output Power (Metric)
A flow rate of 1L /min under 1 kPa = 0.0167 Watt
Output Power (hp) = 1878.75 W

Flow Rate
75 L/min

Pressure
1500 kPa
Output Power (hp) =
Flow Rate (L /min) x Pressure (kPa) x 0.0167 W
75 L /mim x1500 kPa x 0.0167 W = 1878.75 W
Input Power (hp)

It requires more input power to drive the

system than its actuators can generate.
Efficiency (%) will determine the amount of
input power the system requires.
The multipliers 0.000583 (Imperial) and 0.0167
(Metric) provide mathematical constants for
100% efficiency calculations.
Input Power (hp)
Input Power Formula

Imperial
Input Power (hp) =
Flow Rate (GPM) x Pressure (psi) x 0.000583 hp
Efficiency

Metric
Input Power (hp) =
Flow Rate (L /min) x Pressure (kPa) x 0.0167 W
Efficiency
Objective 3

Draw and interpret hydraulic schematics

Hydraulic Schematic Diagrams

Three Types:
Pictorial Schematic Diagram
Cutaway Schematic Diagram
Schematic Diagrams using Graphic Symbols
Pictorial Schematic
Diagram

Provides an external
representation, and a
diagram of component
location and plumbing.
Cutaway Schematic
Diagram

Shows the actual

internal parts and
passages of hydraulic
system components.
Schematic Diagrams using Graphic Symbols

Graphic symbols are used as a short hand

method of representing a hydraulic system

Graphic symbols show:

How system components are interconnected.
Paths of oil flow through the system.
General component operation.
Number of connecting ports on a component.
Schematic Diagrams using Graphic Symbols

There are several organizations that specify

standards for hydraulic graphic symbols.
International Standards Organization (ISO) is
the most common.
Graphic Symbols:
Graphic Symbols:
Graphic Symbols:

Flexible Hose

Dots are used to connect the hose to other connectors

Pilot Line

Drain Line

Vented Pressurized
Reservoir Reservoir
Graphic Symbols:

Hydraulic
Pumps

Pump
Pump driven by
driven by an internal
an electric motor.
combustion engine.

Hydraulic
Motors

Unidirectional Motor Reversible Motor

Graphic Symbols:

Hydraulic Cylinder Ports

Cylinders

Single Acting Double Acting

Graphic Symbols:
Pilot Line Envelope
Pressure
Control
Valve Adjustable
Spring
Normally Open Normally Closed
Graphic Symbols: Pressure Control Valves

By application, pressure control valves are either

“Normally Open” or “Normally Closed”
Pilot will make the:
“Normally Open” valve move to closed position.
“Normally Closed” valve move to open position.
Graphic Symbols: Hydraulic Valves

Flow Control
Valves

Fixed Orifice Variable Orifice

Size of orifice regulates flow

Directional Control
Valves

Check Valve: One-way directional control

Graphic Symbols:

Directional Control Valve Positions

Two Position Three Position Four Position

The number of envelopes graphically represents

the number of position the valve has.
Schematics always illustrates directional control
valves in their non-actuated or normal position.
Ways and Flow Paths
Two Position Two-way
P – Pressure / Inlet Port
Directional Control Valve
A – Outlet / Work Port
Manual P A P A
Lever
Flow Flow
P Blocked P Through
P A
Return In A A
In
Spring Out Out
ISO Non-Actuated Actuated Position
Schematic (normally closed) (open)
Diagram
Ways and Flow Path
P – Pressure / Inlet Port
Two Position Three-way
A – Outlet / Work Port
Directional Control T – Tank / Reservoir
Valve
Manual P P
A- A-
Lever T T
Flow Flow to
P P Through P Tank
T
A–
Return T A T A
Spring
ISO Non-Actuated Actuated Position
Schematic (normally open) (closed)
Diagram
Three Position Four-way Directional Control Valve
Graphic Symbols:
Directional Control
Valve
Directional Control Valve Actuating
Methods
Mechanical
Actuation
Push Button Lever Pedal

Pilot
Operated
External Internal External
Hydraulic Pilot Hydraulic Pilot Air Pilot

Electrical
Actuation
Solenoid Operated
Hydraulic
Accessories
Prime
M
Movers
Internal Combustion Engine Electric Motor

Hydraulic
Filters

Heat
Exchangers
Cooler Heater
Hydraulic
Accessories
Accumulator Gas Charge
Accumulator

Pressure Switches
Electrical
Contacts

Envelope lines are short &

Tandem
long dashed to differentiate
Hydraulic from Pilot and Drain lines.
Pump Enclosure
Basic Loader
Circuit
Objective 4

State the safety precautions that must be

observed when working with hydraulic
systems.
 Safety Information and
Instructions

Many warning labels are found on equipment.

 Safety Information and
Instructions

Check for safety hazards in service literature.

Hydraulic Pressure

Release hydraulic pressure before servicing.

High pressure will fling parts with

tremendous force.
Pinhole Leaks
Are very hard to see, fine stream of hydraulic
fluid that may be under extreme pressure and
velocity.

High pressures fluid will

penetrate the skin and
enter the bloodstream.
Hydraulically Supported Equipment

Loss of fluid due to leak, will cause the

equipment to fail, causing serious or fatal injury.
Securely block the equipment before servicing.
Pinch Points
Pinch Points

Use lock outs were possible.

Pinch Points

Never use fingers to line-up

hydraulically operated components.
Pressurized Hydraulic Lines

Keep flame and sparks away from hydraulic

lines and hoses, as fluid is flammable.
The End