Beruflich Dokumente
Kultur Dokumente
Hydraulics
1 of 1
5 Days
Audience
Prerequisites
None
At the completion of the course, the Field Service Engineers will be able to
Comments
Suggested Handouts / reference material
Think Big CDs
Cat Basics Library
SEEV0529
SENR3981
Revision 1.0
14-11-01
UNIT 2
Introduction
We all know that hydraulic principles are demonstrated when using a
liquid under controlled pressure to do work. There are laws that
state the action of liquids under conditions of changing flows and
increasing and decreasing pressures. The student must be able to
state and understand these laws to become successful as a heavy
equipment technician.
Objectives
Upon completion of this lesson, the student will be able to:
1. State why liquid is use in hydraulic systems.
2. Identify Pascal's Law as applied to hydraulic principles.
3. State the characteristics of oil flow through an orifice.
4. Demonstrate an understanding of the basic hydraulic
principles.
Hydraulic Principles
Unit 2
Lesson 1
2-1-4
Hydraulic Fundamentals
Using a Liquid
There are several advantages for using a liquid.
1. Liquids conforms to the shape of the container.
2. Liquids are practically incompressible.
3. Liquids apply pressure in all directions.
50 lbs.
WEIGHT
FORCE
LIQUID
Practically Incompressible
A liquid is practically incompressible. When a substance is
compressed, it takes up less space. A liquid occupies the same
amount of space or volume even when under pressure. The space or
volume that any substance occupies is called "displacement."
Unit 2
Lesson 1
2-1-5
Hydraulic Fundamentals
50 lbs.
WEIGHT
FORCE
GAS
Gas is compressible
Gas is compressible. When gas is compressed, it takes up less space
and its displacement becomes less. The space previously occupied
by the gas may be occupied by another object. Therefore, a liquid is
best suited for the hydraulic system because it continually occupies
the same volume or displacement.
1130 lbs
40 psi
3 in. radius
FORCE
FORCE
500 lbs
2 in. radius
Unit 2
Lesson 1
2-1-6
Hydraulic Fundamentals
Unit 2
Lesson 1
2-1-7
Hydraulic Fundamentals
?
FROM
PUMP
5 sq. in.
1 sq. in.
3 sq. in.
FORCE
100 lbs
FORCE
50 lbs
FORCE
FORCE
Mechanical Advantage
Figure 2.1.6 demonstrates how liquid in a hydraulic system provides a
mechanical advantage.
Since all cylinders are connected, all areas must be filled before the
system pressurizes.
Use the hydraulic formula and calculate the items in question.
Cylinders are counted from left to right.
When calculating the pressure in the system, we use the two known
values of the second cylinder from the left. The formula used is
"pressure equals force divided by area."
Pressure = Force
Area
Pressure = 50 lbs
1 sq. in.
Pressure = 50 psi
Now that we know the pressure in the system, we can calculate the
force of the load for cylinders one and three and the piston area for
container four.
Calculate cylinders one and three loads using the formula, force
equals pressure times area (Force = Pressure x Area).
Calculate cylinder four piston area using the formula, area equals
force divided by pressure (Area = Force / Pressure).
The correct answers are: cylinder one load is 250 lbs, cylinder
three load is 150 lbs and cylinder four piston area is 2 sq. in.
At this time, perform Lab 2.1.2
Unit 2
Lesson 1
2-1-8
Hydraulic Fundamentals
60
60
120
120
FLOW
1 GPM
ORIFICE EFFECT
When discussing hydraulics, it is a common practice to use the term
"pump pressure." However, the pump does not produce pressure.
The pump produces flow. When flow is restricted, pressure is
produced.
In Figures 2.1.7 and 2.1.8, the pump flow through the pipe is 1 gpm.
In Figure 2.1.7, there is no restriction to the flow through the pipe.
Therefore, the pressure reading is zero for both gauges.
60
30
0
60
90
120
120
FLOW
1 GPM
Unit 2
Lesson 1
2-1-9
Hydraulic Fundamentals
60
30
0
60
90
30
120
90
120
FROM
PUMP
60
30
0
60
90
120
30
0
90
120
FROM
PUMP
Unit 2
Lesson 1
2-1-10
60
60
30
0
90
PSI
Hydraulic Fundamentals
60
30
90
30
PSI
120
90
PSI
120
120
FLOW
1 GPM
60
60
30
0
90
PSI
30
0
120
60
90
PSI
30
90
PSI
120
120
FLOW
1 GPM
207 kPa (30 psi)
Restrictions In Series
There are two basic types of circuits, series and parallel.
In Fig. 2.1.10, a pressure of 620 kPa (90 psi) is required to send 1
gpm through either circuit.
Orifices or relief valves in series in a hydraulic circuit offer a
resistance that is similar to resistors in series in an electrical circuit in
that the oil must flow through each resistance. The total resistance
equals to the sum of each individual resistance.
At this time, perform Lab 2-1-3
CIRCUIT
ONE
207 kPa (30 PSI)
CIRCUIT
TWO
FROM
PUMP
CIRCUIT
THREE
620 kPa (90 PSI)
Restrictions In Parallel
In a system with parallel circuits, pump oil follows the path of least
resistances. In figure 2.1.11, the pump supplies oil to three parallel
circuits. Circuit three has the lowest priority and circuit one has the
highest priority.
Objectives
Upon completion of this unit, the students will be able to:
1. State how basic hydraulic principles are used in the operation of
hydraulic system components.
2. State the function of hydraulic tanks, fluids, pumps and motors,
various valves and cylinders.
3. Identify the different hydraulic tanks, pumps and motors, fluids,
valves and cylinders.
4. Identify the ISO symbol for the hydraulic tank, the pump and/or
motor, the various valves and the cylinders.
Introduction
Mobile construction machines are designed using various hydraulic
components (tanks, fluids, pumps and motors, valves and cylinders).
Some components when used in different parts of the circuit perform
different functions. Although these components may look alike, they
may be given different names. The ability to identify the component,
state the component's function and describe the component's
operation will allow the serviceman to reduce complex circuits to
several simple circuits that may be more easily understood.
UNIT 3
Hydraulic Tank
Hydraulic Tank
Hydraulic Fluids
HydraulicPumps and Motors
Pressure Control Valves
Directional Control Valves
Flow Control Valves
Cylinders
Introduction
When construction machines and equipment are in the design stage,
considerable thought is given to the type, size and location of the
hydraulic oil tank. Once the machine or equipment is in operation,
the hydraulic tank functions as a storage place for the hydraulic oil, a
device to remove heat from the oil and a seperator to remove air
from the oil. This unit will discuss some of the characteristics of the
hydraulic tank.
Objectives
Upon completion of this lesson, the student will be able to:
1. Identify the common components of the hydraulic tank and
state the component function.
2. State the characteristics of the vented and the pressurized
hydraulic tank.
Unit 3
Lesson 1
3-1-4
Hydraulic Fundamentals
FILL CAP
SIGHT GLASS
SUPPLY AND
RETURN LINES
DRAIN
Hydraulic Tank
The hydraulic oil tank main function is to store oil, however, it has
some other functions as well. The tank must remove heat and
separate air from the oil.
Tanks must have sufficient strength, adequate capacity and keep dirt
out. Hydraulic tanks are usually but not always sealed.
Tank components seen in figure 3.1.1 are:
Fill Cap - Keeps contaminants out of the opening that's used to fill
and add oil to the tank and seals pressurized tanks.
Sight Glass - Used to check the oil level. The oil level should be
checked when the oil is cold. The oil level is usually correct when
the oil is in the middle of the sight glass.
Supply and Return Lines - The supply line allows oil to flow from
the tank to the system. The return line allows oil to flow from the
system to the tank.
Drain - Located at the lowest point in the tank, the drain is used to
remove old oil from the tank. The drain also allows for the removal
of water and sediment from the oil.
Unit 3
Lesson 1
3-1-5
VACUUM
RELIEF VALVE
Hydraulic Fundamentals
FILL CAP
FILLER SCREEN
FILLER TUBE
BAFFLES
RETURN
SCREEN
RETURN
TO PUMP
ECOLOGY
DRAIN
PRESSURIZED TANK
Pressurized Tank
The two main types of hydraulic tanks are pressurized and vented
(unpressurized).
The pressurized tank is completely sealed. Atmospheric pressure
does not effect the pressure in the tank. However, when the oil is
sent through the system, it absorbs heat and expands. The expanding
oil compresses the air in the tank. The compressed air forces the oil
out of the tank and into the system.
The vacuum relief valve serves two purposes. It prevents a vacuum
and limits the maximum pressure in the tank.
The vacuum relief valve prevents a vacuum by opening and allowing
air to enter the tank when the tank pressure drops to 3.45 kPa (.5 psi).
When pressure in the tank reaches the vacuum relief valve pressure
setting, the valve opens and vents compressed air to the atmosphere.
The vacuum relief valve pressure setting may vary from 70 kPa (10
psi) to 207 kPa (30 psi).
Other tank components are:
Filler screen - keeps large contaminants from entering the tank when
the fill cap is removed.
Filler tube - allows the tank to be filled to the correct level, but not
over filled.
Baffles - prevents the return oil from flowing directly to the tank
outlet, allowing time for bubbles in the return oil to rise to the top.
Also, prevents the oil from sloshing which helps reduce forming of
the oil.
Ecology Drain - used to prevent accidental spills when removing
water and sediment from the tank.
Return screen - prevents larger particles from entering the tank, but
does not provide fine filtering,
Unit 3
Lesson 1
3-1-6
Hydraulic Fundamentals
BREATHER
RETURN
TO PUMP
VENTED TANK
Fig. 3.1.3 Vented Tank
Vented Tank
The vented or un-pressurized tank differs from the pressurized tank in
that the vented tank has a breather. The breather allows air to enter
and exit freely. Atmospheric pressure on the top of the oil forces the
oil out of the tank and into the system. The breather has a screen that
prevents dirt from entering the tank.
VENTED
TANK
PRESSURIZED
ISO Symbol
Figure 3.1.4 shows the ISO symbol for the vented and the pressurized
hydraulic tanks.
The vented hydraulic tank symbol is merely an open-topped box or
rectangle. The pressurized tank symbol is drawn as a completely
closed box or rectangle. Tanks are shown with hydraulic lines to
enhance understanding.
Hydraulic Tank
Hydraulic Fluids
HydraulicPumps and Motors
Pressure Control Valves
Directional Control Valves
Flow Control Valves
Cylinders
Introduction
The selection and care of the hydraulic fluid will have an important
effect on the life of the system. Just like the hardware components
of a hydraulic system, the hydraulic fluid must be selected on the
basics of its characteristics and properties to accomplish the designed
task.
Objectives
Upon completion of this lesson the student will:
1. State the functions of hydraulic fluids.
2. Measure the viscosity of fluids.
3. State the meaning of viscosity index.
4. List the types of fire resistant hydraulic fluids.
Hydraulic Fluids
Unit 3
Lesson 2
3-2-2
Hydraulic Fundamentals
5,000
lbs
FORCE
Unit 3
Lesson 2
3-2-3
Hydraulic Fundamentals
Cooling
The hydraulic system develops heat as it transfers mechanical energy
to hydraulic energy and hydraulic energy back to mechanical energy.
As the fluid moves throughout the system, heat flows from the
warmer components to the cooler fluid. The fluid gives up the heat
to the reservoir or to coolers that are designed to maintain fluid
temperatures within design limits.
Other properties expected of the hydraulic fluid are the prevention of
rust and corrosion on metal parts, the resistance to foaming and
oxidation, the ability to separate air, water and other contaminates
from the fluid, and the ability to maintain stability over a wide range
of temperatures.
Viscosity
Viscosity is the measurement of a fluid's resistance to flow at a
specific temperature. A fluid which flows easily has a low viscosity.
A fluid which does not flow easily has a high viscosity.
A fluid's viscosity is affected by temperature. When a fluid becomes
warmer, the fluid's viscosity becomes lower. Likewise, when a fluid
cools, the viscosity increases. Vegetable oil is a very good example
of how viscosity changes with a change in temperature. When
vegetable oil is very cold, vegetable oil thickens and is very slow to
pour. As vegetable oil is heated, vegetable oil becomes thinner and
pours more readily.
Unit 3
Lesson 2
3-2-4
Hydraulic Fundamentals
HEATER
THERMOMETER
ORIFICE
SAYBOLT
VISCOSIMETER
60 ml. FLASK
Saybolt Viscosimeter
The most common tool of measuring viscosity is the Saybolt
Viscosimeter (Figure 3.2.2). The Saybolt Viscosimeter was invented
by and named after George Saybolt.
The Saybolt Viscosimeter unit of measurement is the Saybolt
Universal Second (SUS). In the original viscosimeter a container of
fluid was heated to a specific temperature. When the temperature
was reached, a stopcock (orifice) was opened and the fluid flowed out
of the container and into a 60 ml. flask. A stopwatch was used to
measure the time it took to fill the flask. The viscosity was recorded
as the number of seconds the flask took to fill at a given temperature.
If a fluid, when heated to a temperature of 75F, took 115 seconds to
fill the flask, it's viscosity was 115 SUS @ 75F. If the same fluid
was heated to 100F and took 90 seconds to fill the flask, it's
viscosity would be 90 SUS @ 100F.
Viscosity Index
Viscosity index (VI) is a measure of a fluid's change in thickness with
respect to changes in temperature. If a fluid's consistency remains
relatively the same over varying temperatures, the fluid has a high
VI. If a fluid becomes thick at low temperatures and very thin at
high temperatures,the fluid has a low VI. In most hydraulic systems,
fluids with a high VI is desirable over fluids with a low VI.
Petroleum Oil
All petroleum oil becomes thin as the temperature goes up and
thickens as the temperature goes down. If the viscosity is too low,
there may be excessive leakage past seals and from joints. If the
viscosity is too high, sluggish operation may be the results and extra
power is needed to push the oil through the system. Viscosity of
petroleum oil is expressed by the Society of Automotive Engineers
(SAE) numbers: 5W, 10W, 20W, 30W, 40W, etc. The lower the
Unit 3
Lesson 2
3-2-5
Hydraulic Fundamentals
number, the better the oil will flow at low temperatures. The higher
the number, the more viscous the oil and the more suited to high
temperatures.
Synthetic Oils
Synthetic oils are formed by processes which chemically react
materials of a specific composition to produce a compound with
planned and predictable properties. Synthetic oils are specifically
blended for extreme service at both high and low temperatures.
Fire Resistant Fluids
There are three basic types of fire resistant fluids: water-glycols,
water-oil emulsions and synthetics.
Water-glycol fluids contains 35% to 50% water (water inhibits
burning), glycol (synthetic chemical similar to some anti-freeze) and
a water thickener. Additives are added to improve lubrication and to
prevent rust, corrosion and foaming. Water-glycol fluids are heavier
than oil and may cause pump cavitation at high speeds. These fluids
may react with certain metals and seals and cannot be used with some
types of paints.
Water-oil emulsion are the least expensive of the fire resistant fluids.
A similar amount (40%) of water is used as in water-glycol fluids to
inhibit burning. Water-oil can be used in typical hydraulic oil
systems. Additive may be added to prevent rust and foaming.
Certain conditions may require that synthetic fluids be used to meet
specific requirements. The fire resistive synthetic fluids are less
flammable than oil and more suitable for used in areas of high
pressure and high temperature.
Many times fire resistant fluids react to polyurethane seals and may
require that special seals be used.
Oil Life
The hydraulic oil never wears out. The use of filters to remove solid
particles and some chemicals add to the useful life of the oil.
However, eventually the oil will become so contaminated that it will
have to be replaced. In construction machines, the oil is replaced at
regular time intervals.
The contaminates in the oil may also be used as indicators of high
wear and prospective problem areas. One such program that uses oil
contaminates as its source of information is the Caterpillar Schedule
Oil Sampling Program (SOS).
At this time do Lab 3-2-1 and 3-2-2
Hydraulic Tank
Hydraulic Fluids
HydraulicPumps and Motors
Pressure Control Valves
Directional Control Valves
Flow Control Valves
Cylinders
Introduction
The selection and care of the hydraulic fluid will have an important
effect on the life of the system. Just like the hardware components
of a hydraulic system, the hydraulic fluid must be selected on the
basics of its characteristics and properties to accomplish the designed
task.
Objectives
Upon completion of this lesson the student will:
1. State the functions of hydraulic fluids.
2. Measure the viscosity of fluids.
3. State the meaning of viscosity index.
4. List the types of fire resistant hydraulic fluids.
Hydraulic Fluids
Unit 3
Lesson 2
3-2-2
Hydraulic Fundamentals
5,000
lbs
FORCE
Unit 3
Lesson 2
3-2-3
Hydraulic Fundamentals
Cooling
The hydraulic system develops heat as it transfers mechanical energy
to hydraulic energy and hydraulic energy back to mechanical energy.
As the fluid moves throughout the system, heat flows from the
warmer components to the cooler fluid. The fluid gives up the heat
to the reservoir or to coolers that are designed to maintain fluid
temperatures within design limits.
Other properties expected of the hydraulic fluid are the prevention of
rust and corrosion on metal parts, the resistance to foaming and
oxidation, the ability to separate air, water and other contaminates
from the fluid, and the ability to maintain stability over a wide range
of temperatures.
Viscosity
Viscosity is the measurement of a fluid's resistance to flow at a
specific temperature. A fluid which flows easily has a low viscosity.
A fluid which does not flow easily has a high viscosity.
A fluid's viscosity is affected by temperature. When a fluid becomes
warmer, the fluid's viscosity becomes lower. Likewise, when a fluid
cools, the viscosity increases. Vegetable oil is a very good example
of how viscosity changes with a change in temperature. When
vegetable oil is very cold, vegetable oil thickens and is very slow to
pour. As vegetable oil is heated, vegetable oil becomes thinner and
pours more readily.
Unit 3
Lesson 2
3-2-4
Hydraulic Fundamentals
HEATER
THERMOMETER
ORIFICE
SAYBOLT
VISCOSIMETER
60 ml. FLASK
Saybolt Viscosimeter
The most common tool of measuring viscosity is the Saybolt
Viscosimeter (Figure 3.2.2). The Saybolt Viscosimeter was invented
by and named after George Saybolt.
The Saybolt Viscosimeter unit of measurement is the Saybolt
Universal Second (SUS). In the original viscosimeter a container of
fluid was heated to a specific temperature. When the temperature
was reached, a stopcock (orifice) was opened and the fluid flowed out
of the container and into a 60 ml. flask. A stopwatch was used to
measure the time it took to fill the flask. The viscosity was recorded
as the number of seconds the flask took to fill at a given temperature.
If a fluid, when heated to a temperature of 75F, took 115 seconds to
fill the flask, it's viscosity was 115 SUS @ 75F. If the same fluid
was heated to 100F and took 90 seconds to fill the flask, it's
viscosity would be 90 SUS @ 100F.
Viscosity Index
Viscosity index (VI) is a measure of a fluid's change in thickness with
respect to changes in temperature. If a fluid's consistency remains
relatively the same over varying temperatures, the fluid has a high
VI. If a fluid becomes thick at low temperatures and very thin at
high temperatures,the fluid has a low VI. In most hydraulic systems,
fluids with a high VI is desirable over fluids with a low VI.
Petroleum Oil
All petroleum oil becomes thin as the temperature goes up and
thickens as the temperature goes down. If the viscosity is too low,
there may be excessive leakage past seals and from joints. If the
viscosity is too high, sluggish operation may be the results and extra
power is needed to push the oil through the system. Viscosity of
petroleum oil is expressed by the Society of Automotive Engineers
(SAE) numbers: 5W, 10W, 20W, 30W, 40W, etc. The lower the
Unit 3
Lesson 2
3-2-5
Hydraulic Fundamentals
number, the better the oil will flow at low temperatures. The higher
the number, the more viscous the oil and the more suited to high
temperatures.
Synthetic Oils
Synthetic oils are formed by processes which chemically react
materials of a specific composition to produce a compound with
planned and predictable properties. Synthetic oils are specifically
blended for extreme service at both high and low temperatures.
Fire Resistant Fluids
There are three basic types of fire resistant fluids: water-glycols,
water-oil emulsions and synthetics.
Water-glycol fluids contains 35% to 50% water (water inhibits
burning), glycol (synthetic chemical similar to some anti-freeze) and
a water thickener. Additives are added to improve lubrication and to
prevent rust, corrosion and foaming. Water-glycol fluids are heavier
than oil and may cause pump cavitation at high speeds. These fluids
may react with certain metals and seals and cannot be used with some
types of paints.
Water-oil emulsion are the least expensive of the fire resistant fluids.
A similar amount (40%) of water is used as in water-glycol fluids to
inhibit burning. Water-oil can be used in typical hydraulic oil
systems. Additive may be added to prevent rust and foaming.
Certain conditions may require that synthetic fluids be used to meet
specific requirements. The fire resistive synthetic fluids are less
flammable than oil and more suitable for used in areas of high
pressure and high temperature.
Many times fire resistant fluids react to polyurethane seals and may
require that special seals be used.
Oil Life
The hydraulic oil never wears out. The use of filters to remove solid
particles and some chemicals add to the useful life of the oil.
However, eventually the oil will become so contaminated that it will
have to be replaced. In construction machines, the oil is replaced at
regular time intervals.
The contaminates in the oil may also be used as indicators of high
wear and prospective problem areas. One such program that uses oil
contaminates as its source of information is the Caterpillar Schedule
Oil Sampling Program (SOS).
At this time do Lab 3-2-1 and 3-2-2
Hydraulic Tank
Hydraulic Fluids
Hydraulic Pumps and Motors
Pressure Control Valves
Directional Control Valves
Flow Control Valves
Cylinders
Fig. 3.3.0
Introduction
Pumps and motors are similar in construction but different in
operational characteristics. Therefore, most of the material in this
lesson will concentrate on the nomenclature and operation of pumps.
Objectives
Upon completion of this lesson, the student will be able to:
1. State the differences between non-positive and positive
displacement pumps;
2. State the differences between fixed displacement and variable
displacement pumps;
3. State the operation of different types of pumps;
4. State the similarity and differences between pumps and
motors; and
5. State how pumps are rated.
Unit 3
Lesson 3
3-3-2
Hydraulic Fundamentals
HOUSING
DRIVE GEAR
OUTLET OIL
INLET OIL
IDLER GEAR
Hydraulic Pump
The hydraulic pump transfers mechanical energy into hydraulic
energy. It is a device that takes energy from one source (i.e. engine,
electric motor, etc.) and transfers that energy into a hydraulic form.
The pump takes oil from a storage container (i.e. tank) and pushes it
into a hydraulic system as flow.
All pumps produce oil flow in the same way. A vacuum is created at
the pump inlet. The higher atmospheric pressure pushes the oil
through the inlet passage and into the pump inlet chambers. The
pump gears carry the oil to the pump outlet chamber. The volume of
the chamber decreases as the chamber approaches the outlet. This
decrease in chamber size pushes the oil out the outlet.
Pumps produce only the flow (i.e. gallons per minute, liters per
minute, cubic centimeters per revolution, etc.) used in the hydraulic
system. Pumps DO NOT produce or cause "pressure". Pressure is
caused by the resistance to the flow. Resistance can be caused by
flow through hoses, orifices, fittings, cylinders, motors, or anything
in the system that hinders free flow to the tank.
Pumps can be classified into two types: Non-positive displacement
and positive displacement.
Unit 3
Lesson 3
3-3-3
Hydraulic Fundamentals
HOUSING
DRIVE GEAR
PUMP OIL
TANK OIL
IDLER GEAR
Hydraulic Motor
The hydraulic motor transfers hydraulic energy into mechanical
energy. It uses the oil flow being pushed into the hydraulic system by
a pump and transfers it into a rotary motion to drive another device
(i.e. final drives, differential, transmission, wheel, fan, another pump,
etc.).
Unit 3
Lesson 3
3-3-4
Hydraulic Fundamentals
Unit 3
Lesson 3
3-3-5
Hydraulic Fundamentals
PROPELLER
FLOW
INLET
FLOW
INLET
Unit 3
Lesson 3
3-3-6
Hydraulic Fundamentals
Volumetric Efficiency
As pressure increases, the close clearances between the parts in a
positive displacement pump do not produce the same output flow as
input flow. Some oil will be forced back through the clearances
between the high pressure chamber and the low pressure chamber.
The resultant output flow, when compared to the input flow, is called
"volumetric efficiency". (Input flow is generally defined as the
"output flow @ 100 psi".) "Volumetric efficiency" changes as
pressure changes and must be specified for a given pressure. When a
pump that is rated at 100 gpm @ 2000 rpm @ 100 psi is operated
against 1000 psi, its output may drop to 97 gpm. This pump would
have a "volumetric efficiency" of 97% (97/100) @ 1000 psi.
Volumetric efficiency @ 1000 psi = output flow
input flow
Volumetric efficiency @ 1000 psi = 97
100
Volumetric efficiency @ 1000 psi = .97 or 97% efficient at 1000 psi
When the pressure increases to 2000 psi, the output may drop to 95
gpm. It would then have a "volumetric efficiency" of .95 or 95%
@ 2000 psi. The rpm must remain constant when measuring
"volumetric efficiency".
Unit 3
Lesson 3
3-3-7
Hydraulic Fundamentals
FIXED DISPLACEMENT
VARIABLE DISPLACEMENT
EXHAUST
SWASH
PLATE
SLIPPER
PISTON
EXHAUST
CONTROL LEVER
SWASH
PLATE
DRIVE
SHAFT
RETAINING
PLATE
BARREL
ASSEMBLY
INTAKE
INTAKE
Unit 3
Lesson 3
3-3-8
Hydraulic Fundamentals
8
6
7
11
10
Gear Pumps
The gear pump consists of seal retainers (1), seals (2), seal back-ups
(3), isolation plates (4), spacers (5), a drive gear (6), an idler gear (7),
a housing (8), a mounting flange (9), a flange seal (10) and pressure
balance plates (11) on either side of the gears. Bearings are mounted
in the housing and mounting flange on the sides of the gears to
support the gear shafts during rotation.
Gear pumps are positive displacement pumps. They deliver the same
amount of oil for each revolution of the input shaft. The pump output
is controlled by changing the speed of rotation. The maximum
operating pressure for gear pumps is limited to 4000 psi. This
pressure limitation is due to the hydraulic unbalance that is inherent
in the gear pump design. The hydraulic unbalance produces a side
load on the shafts that is resisted by the bearings and the gear teeth to
housing contact. The gear pump maintains a "volumetric efficiency"
above 90% when pressure is kept within the designed operating
pressure range.
Unit 3
Lesson 3
3-3-9
Hydraulic Fundamentals
HOUSING
DRIVE GEAR
OUTLET OIL
INLET OIL
IDLER GEAR
Unit 3
Lesson 3
3-3-10
Hydraulic Fundamentals
HOUSING
DRIVE GEAR
INLET OIL
OUTLET OIL
FORCE
Unit 3
Lesson 3
3-3-11
Hydraulic Fundamentals
PRESSURE BALANCE
PLATES
CHAMFERED EDGE
HEAD
SHARP EDGE
Unit 3
Lesson 3
3-3-12
Hydraulic Fundamentals
Vane Pumps
Vane pumps are positive displacement pumps. The pump output can
be either fixed or variable.
9
10
11
12
4
13
9
Fig. 3.3.11 Vane Pump
Both the fixed and variable vane pumps use common part
nomenclature. Each pump consists of the housing (1), the cartridge
(2), the mounting plate (3), the mounting plate seal (4), the cartridge
seals (5), the cartridge backup rings (6), the snap ring (7) and the
input shaft and bearing (8). The cartridge consists of the support
plates (9) the ring (10), the flex plates (11), the slotted rotor (12) and
the vanes (13).
The slotted rotor is turned by the input shaft. The vanes move in and
out of the slots in the rotor and seal on the outer tips against the cam
ring. The inside of the fixed pump displacement ring is elliptical in
shape. The inside of the variable pump displacement ring is round in
shape. The flex plates seal the sides of the rotor and the ends of the
vanes. In some lower pressure designs, the support plates and
housing seal the sides of the rotating rotor and the ends of the vanes.
The support plates are used to direct the oil into the proper passages
in the housing. The housing, in addition to providing support for the
other parts of the vane pump, directs the flow in and out of the vane
pump.
Unit 3
Lesson 3
3-3-13
Hydraulic Fundamentals
Vanes
The vanes are initially held against the cam ring by centrifugal force
created by the rotation of the rotor. As flow increases, the resultant
pressure that builds from the resistance to that flow is directed into
passages in the rotor beneath the vanes (1). This pressurized oil
beneath the vanes keep the vane tips pushed against the cam ring to
form a seal. To prevent the vanes from being pushed too hard against
the cam ring, the vanes are beveled back (arrow) to permit a balancing
pressure across the outer end.
Pressur
e
Pressure
Flex Plates
The same pressurized oil is also directed between the flex plates and
the support plates to seal the sides of the rotor and the end of the
vanes. The size of the seal area between the flex plate and the support
plates is what controls the force that pushes the flex plates against the
sides of the rotor and the end of the vanes. The kidney shaped seals
must be installed in the support plates with the rounded o-ring side
into the pocket and the flat plastic side against the flex plate.
Unit 3
Lesson 3
3-3-14
Hydraulic Fundamentals
OUTLET
PORT
INLET PORT
ROTOR
CAM
RING
VANES
Unit 3
Lesson 3
3-3-15
Hydraulic Fundamentals
OUTLET
PORT
INLET PORT
RING
ROTOR
VANES
Piston Pumps
Most piston pumps and motors have similar or common parts and use
the same nomenclature. The pump parts in Figure 3.3.17 are the head
(1), the housing (2), the shaft (3), the pistons (4), the port plate (5),
the barrel (6) and the swashplate (7).
The two designs of piston pumps are the axial piston pump and the
radial piston pump. Both pumps are highly efficient, positive
displacement pumps. However, the output of some pumps are fixed
and the output of some pumps are variable.
Unit 3
Lesson 3
3-3-16
Hydraulic Fundamentals
FIXED DISPLACEMENT
VARIABLE DISPLACEMENT
EXHAUST
SWASH
PLATE
SLIPPER
PISTON
EXHAUST
CONTROL LEVER
SWASH
PLATE
DRIVE
SHAFT
RETAINING
PLATE
BARREL
ASSEMBLY
INTAKE
INTAKE
Unit 3
Lesson 3
3-3-17
RETAINING PLATE
Hydraulic Fundamentals
LINK
PISTON
PORT PLATE
HEAD
SHAFT
CASE
BARREL
FLUSHING VALVE
(INSIDE HEAD)
Unit 3
Lesson 3
3-3-18
Hydraulic Fundamentals
Some smaller piston pumps are designed for pressures of 10000 psi
or more. Piston pumps used in mobile equipment are designed for a
maximum pressure of 7000 psi or less.
CAM FOLLOWER
PISTON
CAM RING
VALVE
Unit 3
Lesson 3
3-3-19
Hydraulic Fundamentals
DRIVE GEAR
HOUSING
INLET
OUTLET
CRESCENT
RING GEAR
Fig. 3.3.21
Unit 3
Lesson 3
3-3-20
INNER
GEAR
Hydraulic Fundamentals
OUTER
GEAR
Fig. 3.3.22
Unit 3
Lesson 3
3-3-21
MONO-DIRECTIONAL
FIXED DISPLACEMENT
PUMP
BI-DIRECTIONAL
FIXED DISPLACEMENT
PUMP
Hydraulic Fundamentals
MONO-DIRECTIONAL
VARIABLE DISPLACEMENT
PUMP
BI-DIRECTIONAL
VARIABLE DISPLACEMENT
PUMP
MONO-DIRECTIONAL
FIXED DISPLACEMENT
MOTOR
BI-DIRECTIONAL
FIXED DISPLACEMENT
MOTOR
MONO-DIRECTIONAL
VARIABLE DISPLACEMENT
MOTOR
BI-DIRECTIONAL
VARIABLE DISPLACEMENT
MOTOR
Hydraulic Tank
Hydraulic Fluids
Hydraulic Pumps and Motors
Pressure Control Valves
Directional Control Valves
Flow Control Valves
Cylinders
Introduction
Pressure Control Valves are used to control the pressure in a circuit
or in a system. The valve function will remain the same although the
design may change. Examples of pressure control valves include
relief valves, sequence valves, pressure reducing valves, pressure
differential valves and unloading valves.
Objectives
Upon completion of this lesson the student will:
1. List the four most common pressure control valves.
2. State the functions of the relief valve, sequence valve,
pressure reducing valve and the pressure differential valve.
3. Identify the ISO symbol for the four most common pressure
control valves.
Unit 3
Lesson 4
3-4-2
Hydraulic Fundamentals
Relief Valves
Hydraulic systems are designed to operate within a certain pressure
range. Exceeding this range can damage the system components or
become dangerous to personnel. The relief valve maintains the
pressure within the designed limit by opening and allowing excessive
oil to flow either to another circuit or back to the tank.
Unit 3
Lesson 4
3-4-3
Hydraulic Fundamentals
Unit 3
Lesson 4
3-4-4
Hydraulic Fundamentals
PILOT VALVE
SPRING
PILOT VALVE
UNLOADING
VALVE SPRING
UNLOADING
VALVE
UNLOADING
VALVE ORIFICE
PUMP FLOW
TO
TANK
TO
SYSTEM
Unit 3
Lesson 4
3-4-5
PILOT VALVE
SPRING
Hydraulic Fundamentals
PILOT VALVE
ORIFICE
PILOT
VALVE
UNLOADING
VALVE SPRING
UNLOADING
VALVE
PUMP
FLOW
UNLOADING
VALVE ORIFICE
TO
TANK
TO
SYSTEM
Unit 3
Lesson 4
3-4-6
FROM
PUMP
Hydraulic Fundamentals
TO
TANK
FROM
PUMP
TO
TANK
Unit 3
Lesson 4
3-4-7
Hydraulic Fundamentals
TO
TANK
FROM
PUMP
PILOT
VALVE
TO TANK
FROM
PUMP
OUTPUT TO
CIRCUIT 2
TO
CIRCUIT 1
UNLOADING
VALVE
Unit 3
Lesson 4
3-4-8
UNLOADING
VALVE SPRING
CHAMBER
Hydraulic Fundamentals
PILOT
VALVE
TO TANK
FROM
PUMP
OUTPUT TO
CIRCUIT 2
TO
CIRCUIT 1
UNLOADING
VALVE
FROM
PUMP
TO
CIRCUIT 2
Unit 3
Lesson 4
3-4-9
Hydraulic Fundamentals
DRAIN
SHIMS
VALVE VALVE
SPRING SPOOL
SUPPLY
OIL
CONTROLLED
OIL CIRCUIT
DRAIN
PISTON
PISTON
CHAMBER
Pump Start-up
Figure 3.4.11 shows the pressure reducing valve in the normally open
position.
At pump start-up, the valve spring force holds the valve spool and the
piston to the right. The supply oil flows around the pressure reducing
valve spool to the controlled oil circuit (downstream side of the
valve). The supply oil also flows through the oil passage to the
piston chamber at the right of the valve spool. Any change in the
controlled oil circuit pressure is sensed in the piston chamber. At
pump start-up, the supply oil pressure and the controlled oil pressure
are the same.
Unit 3
Lesson 4
3-4-10
DRAIN
SHIMS
VALVE VALVE
SPRING SPOOL
Hydraulic Fundamentals
ORIFICE
SUPPLY
OIL
CONTROLLED
OIL CIRCUIT
DRAIN
PISTON
PISTON
CHAMBER
Unit 3
Lesson 4
3-4-11
FROM
PUMP
Hydraulic Fundamentals
TO CONTROLLED
OIL CIRCUIT
Unit 3
Lesson 4
3-4-12
Hydraulic Fundamentals
SUPPLY OIL
50 PSI
SPRING
VALVE
SPOOL
VALVE
BODY
Pump Start-up
Figure 3.4.14 shows a pressure differential valve. The pressure
differential valve maintains a specified difference in pressure between
two circuits.
At pump start-up and whenever the pressure in the primary circuit is
less than 345 kPa (50 psi), the spring force holds the valve spool to
the right. The oil flow is blocked to the secondary circuit. Any
change in the primary circuit pressure is sensed at the valve spool.
Unit 3
Lesson 4
3-4-13
Hydraulic Fundamentals
SECONDARY PRIMARY
CIRCUIT
CIRCUIT
SUPPLY OIL
50 PSI
SPRING
VALVE
BODY
VALVE
SPOOL
Fig. 3.4.15
Unit 3
Lesson 4
3-4-14
INLET
Hydraulic Fundamentals
OUTLET
Hydraulic Tank
Hydraulic Fluids
Hydraulic Pumps and Motors
Pressure Control Valves
Directional Control Valves
Flow Control Valves
Cylinders
Introduction
Directional control valves are used to direct oil into separate circuits
of a hydraulic system. The maximum flow capacity and the pressure
drop through the valve are the first considerations. Directional
control valves may be interfaced with manual, hydraulic, pneumatic
and electronic controls. These factors are mostly determined during
the initial system design.
Objectives
Upon completion of this lesson the student will:
1. State the function of the manual spool type control valve, the
rotary type control valve and the solenoid actuated control
valve.
2. State the function of the simple check valve, the pilot
operated check valve and the shuttle valve
3. Identify the ISO symbols for the various directional control
valves.
Unit 3
Lesson 5
3-5-2
Hydraulic Fundamentals
VALVE BODY
SPOOL GROOVE
VALVE BORE
SPOOL LANDS
Valve Spool
The valve spool (Figure 3.5.1) consist of lands and groves. The spool
lands block the oil flow through the valve body. The spool groves
allow oil to flow around the spool and through the valve body.
The position of the spool when not activated is called the "normal"
position.
When an "open center" valve is in the normal position, the supply oil
flows through the valve and back to the tank. When a "close center"
valve is in the normal position, the supply oil is blocked by the valve
spool.
Unit 3
Lesson 5
3-5-3
FROM
CYLINDER
HEAD END
Hydraulic Fundamentals
FROM
PUMP
FROM
CYLINDER
ROD END
VALVE
SPOOL
VALVE
BODY
LOAD
CHECK
VALVE TO
TANK
TO
TANK
TO TANK
FROM
PUMP
FROM
CYLINDER
ROD END
VALVE
SPOOL
VALVE
BODY
LOAD
CHECK
VALVE
TO
TANK
TO
TANK
TO TANK
Unit 3
Lesson 5
3-5-4
Hydraulic Fundamentals
the oil in the head end of the cylinder from flowing into the
pump oil passage. The blocked pump oil flow causes an
increase in the oil pressure
FROM
CYLINDER
HEAD END
FROM
PUMP
FROM
CYLINDER
ROD END
VALVE
SPOOL
VALVE
BODY
LOAD
CHECK
VALVE
TO
TANK
TO
TANK
TO TANK
ONE
POSITION
TWO
POSITION
THREE
POSITION
Unit 3
Lesson 5
3-5-5
TWO-WAY
Hydraulic Fundamentals
THREE-WAY
FOUR-WAY
SIX-WAY
Valve Port
Shown in Figure 3.5.6 are the valve ports for attaching working lines.
A valve with two ports is commonly referred to as a two-way valve.
This is not to be confused with a two-position valve shown in Figure
3.5.5. Valves may have as many positions and ports as needed.
However, most valve positions are in the range of one to three and
valve ports in the range of two to six.
FLOW IN
ONE
DIRECTION
FLOW IN
EITHER
DIRECTION
PARALLEL
FLOW
CROSS
FLOW
FLOW
BLOCKED
Flow Path
In Figure 3.5.7, the lines and arrows inside the envelopes are used
basically to represent the flow paths and directions between ports.
Unit 3
Lesson 5
3-5-6
Hydraulic Fundamentals
A B
CLOSED CENTER
P T
A B
TANDEM CENTER
(CATERPILLAR
OPEN CENTER)
P T
A B
OPEN CENTER
P T
Unit 3
Lesson 5
3-5-7
TO
TANK
Hydraulic Fundamentals
LOWER
CHECK
VALVE
FROM
PUMP
RAISE
MANUAL CONTROL
PILOT OIL
TO
TANK
LOWER
CHECK
VALVE
FROM
PUMP
RAISE
PILOT CONTROL
PILOT OIL
Unit 3
Lesson 5
3-5-8
SOLENOID
ACTUATOR
MANUAL
ACTUATOR
SPRING
ACTUATOR
Hydraulic Fundamentals
PUSHBUTTON
ACTUATOR
PUSH-PULL LEVER
ACTUATOR
AIR
ACTUATOR
MECHANICAL
ACTUATOR
DETENTED
ACTUATOR
PEDAL
ACTUATOR
OIL
ACTUATOR
ROD END
TO TANK
PORT
PORT
TO TANK
PORT
PORT
VALVE
BODY
CHANNELS
VALVE
BODY
ROD END
CHANNELS
PLUG
PLUG
PORT
FROM PUMP
PORT
HEAD END
PORT
FROM PUMP
PORT
HEAD END
Rotary Valve
The rotary valve (Figure 3.5.12) consists of a round plug with
passages or channels. The channels in the plug connect with the ports
in the valve body. Instead of shifting to the right or to the left, the
valve rotates.
In the diagram on the left, the valve connects the pump to the rod end
of the cylinder. The oil in head end flows to the tank. When the
valve is rotated 90 degrees, the pump is connected to the head end
and the oil in the rod end flows to the tank.
The rotary valve shown is a four-way valve. However, rotary valves
may also be two-way or three-way. The rotary valve is used in low
pressure operations.
INSTRUCTOR NOTE: At this time, perform Lab 3.5.1
Unit 3
Lesson 5
3-5-9
Hydraulic Fundamentals
TO
IMPLEMENT
FROM
PUMP
FROM
IMPLEMENT
TO
PUMP
Check Valve
The purpose of a check valve is to readily permit oil flow in one
direction, but prevent (check) oil flow in the opposite direction. The
check valve is sometimes called a "one way" check valve.
Most check valves consist of a spring and a tapered seat valve as in
Figure 3.5.13 above. However, a round ball is sometimes used
instead of the tapered seat valve. In some circuits, the check valve
may be free floating (has no spring).
In the valve on the left, when the pump oil pressure overcomes the
oil pressure in back of the check valve plus the check valve slight
spring force, the check valve opens and allows the oil to flow to the
implement.
In the valve on the right, when the pressure of the pump oil is less
than the oil pressure in the implement, the check valve closes and
prevents implement oil flow back through the valve.
Unit 3
Lesson 5
3-5-10
Hydraulic Fundamentals
PILOT
VALVE
TO
CYLINDER
ROD
PILOT
OIL
CHECK VALVE
FROM CONTROL
VALVE
Forward Flow
Figure 3.5.14 shows a pilot operated check valve. The pilot operated
check valve consist of a check valve, a pilot valve and a rod. The
pilot operated check valve allows free flow from the control valve to
the cylinder.
PILOT VALVE
OIL CHAMBER
PILOT
VALVE
ROD
FROM
CYLINDER
PILOT
OIL
TO CONTROL
VALVE
CHECK VALVE
Flow Blocked
When oil flow from the control valve cease, the check valve seats as
shown on the right of Figure 3.5.15. The oil flow from the cylinder
to the control valve is blocked at the check valve.
The pilot operated check valve is most often used in operations where
load drift is a problem. The pilot operated check valve allows load
drift to be held to a very close tolerance.
Unit 3
Lesson 5
3-5-11
PILOT VALVE
OIL CHAMBER
Hydraulic Fundamentals
PILOT
VALVE
ROD
FROM
CYLINDER
PILOT
OIL
TO CONTROL
VALVE
CHECK VALVE
Reverse Flow
The valve in Figure 3.5.16, shows oil flow from the cylinder to the
control valve.
When flow is required, pilot oil is sent to the pilot valve oil chamber.
Pilot oil pressure moves the pilot valve and rod to the right and
unseats the check valve. The cylinder oil flows through the check
valve to the control valve and then to the tank.
The pressure ratio between the load pressure and the pilot pressure is
designed into the valve. The valve used on the Explorer training unit
has a pressure ratio of 3:1. The pressure needed to open the check
valve is equal to one-third of the load pressure. A load pressure of
4134 kPa (600 psi) requires a pilot pressure of 1378 kPa (200 psi) to
open the check valve.
Unit 3
Lesson 5
3-5-12
Hydraulic Fundamentals
CIRCUIT 1
CIRCUIT 2
C
CIRCUIT 3
SHUTTLE VALVE
(RESOLVER VALVE)
PILOT OPERATED
CHECK VALVE
Unit 3
Lesson 5
3-5-13
Hydraulic Fundamentals
TO
CYLINDERS
FROM
CYLINDER
TANK OIL
TANK OIL
Make-up Valve
The make-up valve in Figure 3.5.18, looks similar to the check valve.
The makeup valve is normally positioned in the circuit between the
implement and the tank. During normal operations, the pump or
cylinder oil fills the area behind the make-up valve. The pressure in
the cylinder keeps the valve CLOSED. When the cylinder pressure is
approximately 14 kPa (2 psi) lower than the tank pressure, the makeup valve will OPEN. The tank oil bypasses the pump and flows
directly through the make-up valve to the cylinder.
The make-up valve is used to prevent cavitation. For example, when
a loader bucket is RAISED and the operator moves the control to the
FULLY LOWER position, the gravitational force on the bucket is
transmitted through the cylinder piston to the return oil. The
increased pressure on the return oil increases the flow from the
cylinder. When the cylinder piston displaces the return oil faster than
the pump can send oil to displace the piston, a vacuum is formed in
the cylinder and lines. A vacuum can cause the cylinder and lines to
cavitate. When the pressure in the cylinder and lines decreases to 14
kPa (2 psi) less than tank pressure, the make-up valve opens and
allows tank oil to flow through the make-up valve to the lines and
cylinder. This procedure prevents cavitation in the cylinder and lines.
Makeup Valve ISO Symbol
The operation (function) of the make-up valve and the check valve is
the same. Therefore, the ISO symbol for the make-up valve is the
same as the ISO symbol for the check valve.
INSTRUCTOR NOTE: At this time, perform Lab 3.5.2 and Lab
3.5.3
Unit 3
Lesson 5
3-5-14
Hydraulic Fundamentals
ELECTRO-MAGNETIC
FIELD
COVER
MANUAL
OVERRIDE
PUSH
PIN
COIL
ARMATURE
Unit 3
Lesson 5
3-5-15
Hydraulic Fundamentals
TUBE
PUSH PIN
HYDRAULIC
FLUID
MANUAL
OVERRIDE
FRAME
COIL
ARMATURE
Unit 3
Lesson 5
3-5-16
Hydraulic Fundamentals
P
T
Unit 3
Lesson 5
3-5-17
Hydraulic Fundamentals
SOLENOID CONTROLLED
PILOT VALVE
SOLENOID
SOLENOID
P
T
Unit 3
Lesson 5
3-5-18
Hydraulic Fundamentals
Solenoid Failure
Most solenoid actuator failures occur when valves are stuck. The
stuck valve spool prevents the armature from closing properly. The
most likely cause of a stuck valve spool is contamination.
Contaminant such as silt, metal chips, and other particles may
become lodged between the spool and bore causing the spool to stick.
Also, oxidized oil particles can create a gooey varnish which clogs
the clearance between the spool and bore walls and cause the spool to
stick to the bore. Silt, metal chips, and other contaminating particles
can be removed by installing a filter. The varnish build-up can be
removed by washing the valve in lacquer thinner. The proper oil and
filter change intervals can help to eliminate most of this type
problems.
When the valve is stuck and the solenoid is energized, the solenoid
coil receives a constant high flow of current that generates excessive
heat. The solenoid is not designed to dissipate the excessive heat and
the coil burns out. Overheating problems most often occur during
periods of high ambient (environmental) temperatures, or system low
voltage.
Problems with solenoid failure due to high ambient temperatures may
be controlled by increasing the air flow across the solenoid. The
temperature of the hydraulic oil can be lowered to allow more heat to
be drawn from the solenoid through the hydraulic system.
Sometimes, a different valve design may be required when operating
during very hot weather. Some arrangement must be made to allow
the system to operate at a lower temperature.
When the voltage to the coil is too low, the electro-magnetic field is
not sufficiently strong to attract the armature. Just as when the spool
is stuck, the current continues flowing through the coil. The constant
flow of current generates the excessive heat.
Other factors also affect the proper operation and life expectancy of
the solenoid actuator. The solenoid actuator may fail when cycled
excessively, when short-circuited, or when operated with an incorrect
electrical supply (wrong frequency, wrong voltage).
Unit 3
Lesson 5
3-5-19
Hydraulic Fundamentals
A B
A B
P T
Cylinders
Lesson 7: Cylinders
Basic Hydraulic Systems
Hydraulic Tank
Hydraulic Fluids
Hydraulic Pumps and Motors
Pressure Control Valves
Directional Control Valves
Flow Control Valves
Cylinders
Introduction
Cylinders are basically linear actuators. Their outputs are straight
line motion or force. The most common types are single acting
cylinders and double acting cylinders.
Objectives
Upon completion of this lesson the student will:
1. Identify the two basic types of hydraulic cylinders.
2. State the function of the two basic types of hydraulic
cylinders.
3. Identify the basic cylinder components.
Unit 3
Lesson 7
3-7-2
CYLINDER
BODY
Hydraulic Fundamentals
BORE SEAL
TANK
LOAD
HEAD END
ROD END
FROM
CONTROL VALVE
PISTON
ROD
GRAVITY
TO CONTROL
VALVE
FROM CONTROL
VALVE
EXTEND ROD
RETRACT ROD
Unit 3
Lesson 7
3-7-3
PISTON
PISTON
SEAL
HEAD
END
Hydraulic Fundamentals
ROD
ROD
END
LOAD
FROM
CONTROL VALVE
TO
CONTROL VALVE
Unit 3
Lesson 7
3-7-4
BORE
Hydraulic Fundamentals
EFFECTIVE
AREA
EFFECTIVE
AREA
FROM CONTROL
VALVE
TO CONTROL
VALVE
TO CONTROL
VALVE
FROM CONTROL
VALVE
Unit 3
Lesson 7
3-7-5
PISTON
SEAL
Hydraulic Fundamentals
HEAD SEAL
('O' RING)
ROD
GLAND
LOAD
ROD
SEAL
WIPER
SEAL
Seals
Seals are used in various places throughout the cylinder as shown in
Figure 3.7.5.
The piston seal is used between the piston and the cylinder wall. The
design is such that oil pressure spreads the seal against the cylinder
wall, thus the greater the pressure the greater the sealing force.
The head end ('O' ring) seal prevents oil escaping between the rod
gland and the cylinder wall.
The rod seal is a "U" shaped or u-cup shaped seal that wipes the oil
off the rod as the rod is extended from the cylinder.
The wiper seal is fitted to the cylinder and prevents dirt or grit being
drawn into the cylinder as the cylinder rod retracts.
Seals are made of polyurethane, nitrile or viton. The material should
be verified to be compatible with the fluid used and the operating
conditions.
Unit 3
Lesson 7
3-7-6
HEAD END
RETURN OIL
PASSAGE
Hydraulic Fundamentals
ROD END
RETURN OIL
PASSAGE
LOAD
HEAD END
SNUBBER
(DAMPER)
ROD END
SNUBBER
(DAMPER)
Objectives
Upon completion of this unit, the student will:
1. Trace the oil flow from the tank to the pump, through the various
hydraulic components, and back to the tank.
2. State the function of each component in the system.
3. State the system operation in the various modes.
Introduction
In this unit, students will use the basic hydraulic knowledge learned
in Unit I through Unit III to explain the functions of a pilot operated
implement hydraulic system.
The system components in this unit are colored dark gray, gray and
yellow. The yellow represents the current position of the
components in the ISO drawings and the movable parts of the
components in the orthographic drawings.
The hydraulic oil colors used in this unit are:
Green
Blue
Blocked oil
Red
UNIT 4
Introduction
The pilot operated implement hydraulic system is used on various
models of mobile construction equipment. The illustrations used in
this lesson are for the Caterpillar 928G Wheel Loader.
Students will identify the basic hydraulic components used in the
pilot operated implement hydraulic system, state the functions of the
various components and trace the hydraulic oil flow through the
systems.
Objectives
Upon completion of this lesson the student will:
1. State the hydraulic principles used in the operation of the
pilot operated hydraulic implement system.
2. Trace the oil flow and state the function of the components
of the pilot operated hydraulic implement system.
3. Identify the basic ISO symbols of the pilot operated
hydraulic implement system.
Unit 4
Lesson 1
4-1-2
Hydraulic Fundamentals
LOWERING
VALVE
PRESSURE
REDUCING
VALVE
TO
STEERING
MAIN
RELIEF
VALVE
FROM
STEERING
MANIFOLD
AUX.
VALVE
TILT
VALVE
LIFT
VALVE
PILOT SHUTOFF
VALVE
PILOT
VALVE
Unit 4
Lesson 1
4-1-3
PRESSURE
REDUCING
VALVE
TO
STEERING
Hydraulic Fundamentals
TO
TANK
MAIN
RELIEF
VALVE
FROM
STEERING
MANIFOLD
AUX.
VALVE
TILT
VALVE
LIFT
VALVE
PILOT SHUTOFF
VALVE
PILOT
VALVE
Unit 4
Lesson 1
4-1-4
Hydraulic Fundamentals
PRESSURE
REDUCING
VALVE
TO
TANK
TO
STEERING
MAIN
RELIEF
VALVE
MANIFOLD
AUX.
VALVE
TILT
VALVE
LIFT
VALVE
PILOT SHUTOFF
VALVE
PILOT
VALVE
In the HOLD position, the pilot and steering system pump draws oil
from the tank and sends supply oil flow to the steering system supply
port and the pressure reducing valve. The pressure reducing valve
controls the maximum pressure in the pilot system. (The pressure
reducing valve operation is explained in Unit 3, Lesson 6.) Oil flows
from the pressure reducing valve, through the check valve to the
accumulator and to the pilot shutoff valve.
The accumulator serves as an emergency pilot oil supply when the
pump is not pumping oil.
When the pilot shutoff valve is in the OFF position, the pilot oil is
blocked. The pilot system will not function. When the pilot shutoff
valve is in the ON position, the oil flows through the pilot shutoff
valve to the auxiliary, tilt and lift pilot control valves.
When the pilot control valves are in the HOLD position, the pilot oil
is blocked at the pilot control valves. This type system is a "closed
center" system.
Unit 4
Lesson 1
4-1-5
Hydraulic Fundamentals
PIVOT PLATE
UPPER PLUNGER
(Dump)
UPPER PLUNGER
(Tilt Back)
COIL ASSEMBLY
(Bucket Tilt Back kickout)
RETAINER
LOWER PLUNGER
RETAINER
METERING SPRING
RETAINER
TO
TANK
METERING STEM
(Dump)
PILOT OIL
TO MAIN CONTROL VALVE
Unit 4
Lesson 1
4-1-6
Hydraulic Fundamentals
TO
TANK
PILOT OIL
FROM MAIN
CONTROL VALVE
TO MAIN
CONTROL VALVE
Unit 4
Lesson 1
4-1-7
Hydraulic Fundamentals
LOWER
CENTERING
SPRING
METERING
SPRING
TO
TANK
METERING STEM
SPRING
TO
TANK
ORIFICE
METERING STEM
FROM
PUMP
FROM
PUMP
FROM MAIN
CONTROL VALVE
TO MAIN
CONTROL VALVE
Metering Spring
The job of the metering stem is to allow movement of the main
control valve spool in proportion to the movement of the pilot valve
lever. The metering stem and metering spring function as a pressure
reducing valve and control the oil pressure at the main control valve
spool.
When the metering stem moves down, pilot oil flows through the
orifice, the center of the metering stem and out to the main control
valve spool. The pilot oil is blocked at the main control valve spool
causing the pilot pressure to increase. The pressure increase
overcomes the main control valve spool spring and moves the main
control valve spool. The main control valve spool directs the main
system oil to the cylinder.
The pressure increase is also sensed against the metering stem. When
the pressure increase overcomes the applied force, the metering stem
moves up and compresses the metering spring. The movement
restricts pilot oil flow through the metering stem orifice. Restricting
the oil flow controls the pressure at the main control valve spool.
The metering spring therefore adjusts the pressure at the main control
valve spool in proportion to the movement of the pilot valve lever
Unit 4
Lesson 1
4-1-8
Hydraulic Fundamentals
TILT
PILOT
PASSAGE
LINE RELIEF
AND MAKEUP
VALVE
TANK
DUMP
INLET
CHECK
VALVE
MAIN CONTROL
SPOOL
OUTLET TANK
Unit 4
Lesson 1
4-1-9
Hydraulic Fundamentals
CHECK
VALVE
INLET
ROD END
OUTLET
TANK
Unit 4
Lesson 1
4-1-10
Hydraulic Fundamentals
COMBINATION VALVE
ADJUSTMENT
PILOT VALVE
SPRING
MAIN VALVE
SPRING
MAIN VALVE
ORIFICE
MAKEUP
VALVE
PILOT
VALVE
MAIN VALVE
SPRING CHAMBER
Unit 4
Lesson 1
4-1-11
Hydraulic Fundamentals
COMBINATION VALVE
LINE RELIEF VALVE "OPEN"
MAKEUP
VALVE
PILOT VALVE
ORIFICE
MAKEUP VALVE
DUMP
MAIN VALVE
ORIFICE
MAKEUP VALVE
DUMP
Unit 4
Lesson 1
4-1-12
Hydraulic Fundamentals
COMBINATION VALVE
MAKEUP VALVE "OPEN"
MAIN VALVE
SPRING
EFFECTIVE
AREA
EFFECTIVE
AREA
MAKEUP Position
Figure 4.1.11 shows the combination line relief and makeup valve in
the MAKEUP position. The tank pressure is sensed on the effective
area of the combination valve at all times. When the oil pressure in
the cylinder, the connecting line and the relief valve spring chamber
decreases to 13.78 kPa (2 psi) less than the oil pressure in the tank,
the tank pressure moves the makeup valve and the main valve to the
left against the main valve spring. The tank oil flows through the
newly opened passage to the connecting line and cylinder.
Unit 4
Lesson 1
4-1-13
Hydraulic Fundamentals
INLET
ROD END
PILOT
PASSAGE
TANK
CHECK
VALVE
OUTLET
MAKEUP
VALVE
Unit 4
Lesson 1
4-1-14
Hydraulic Fundamentals
INLET
ROD END
PILOT
PASSAGE
CHECK
VALVE
OUTLET
MAKEUP
VALVE
Unit 4
Lesson 1
4-1-15
Hydraulic Fundamentals
LOWERING
VALVE
PRESSURE
REDUCING
VALVE
TO
STEERING
MAIN
RELIEF
VALVE
FROM
STEERING
MANIFOLD
AUX.
VALVE
TILT BACK
DUMP VALVE
LIFT/LOWER
VALVE
PILOT SHUTOFF
VALVE
AUX
CONTROL
TILT BACK
DUMP CONTROL
LIFT/LOWER
CONTROL
Fig. 4.1.14
In the HOLD position, the oil from the steering and pilot pump flows
to the steering system supply port and the pressure reducing valve.
The pressure reducing valve controls the maximum pressure in the
pilot system. (The pressure reducing valve operation is explained in
Unit 3, chapter 6.) Oil flows from the pressure reducing valve,
through the check valve to the accumulator and to the pilot shutoff
valve.
The accumulator serves as an emergency pilot oil supply when the
pump is off.
When the pilot shutoff valve is in the OFF position, the pilot oil is
blocked. The pilot system will not function. When the pilot shutoff
valve is in the ON position, the oil flows through the pilot shutoff
valve to the auxiliary, tilt back/dump and lift/lower pilot control
valves. When the pilot control valves are in the HOLD position, the
pilot oil is blocked at the pilot control valves. This type system is
called a "closed center" system.
Oil from the main implement pump flows past the test port and the
main relief valve to the main control valve.
The implement pump oil flows through the center of the auxiliary
valve spool, the center of the tilt back/dump valve spool, the center of
the lift/lower valve spool and returns to the tank. This type system is
called an "open center" system.
Unit 4
Lesson 1
4-1-16
Hydraulic Fundamentals
LOWERING
VALVE
TILT BACK
PRESSURE
REDUCING
VALVE
TO
STEERING
MAIN
RELIEF
VALVE
FROM
STEERING
MANIFOLD
AUX.
VALVE
TILT BACK
DUMP VALVE
LIFT/LOWER
VALVE
PILOT SHUTOFF
VALVE
AUX
CONTROL
TILT BACK
DUMP CONTROL
LIFT/LOWER
CONTROL
Fig. 4.1.15
This schematic shows the flow through the hydraulic system with the
tilt back/dump control lever in the TILT BACK position.
When the operator moves the tilt back/dump control lever to the TILT
BACK position, pilot oil flows past the tilt back/dump pilot control
valve to the end of the tilt back/dump valve spool in the main
implement control valve. Pilot oil moves the tilt back/dump valve
spool to the TILT BACK position. Oil from the opposite end of the
tilt back/dump valve spool flows past the tilt back/dump control valve
to the tank.
Movement of the tilt back/dump valve spool to the TILT BACK
position blocks the flow of implement pump oil to the tank and
directs implement pump oil to the head end of the tilt cylinder. Oil in
the rod end of the tilt cylinder is forced back past the tilt back/dump
valve spool to the tank.
The orifices in the pilot oil lines between the tilt back/dump pilot
control valve and the tilt back/dump valve spool causes a restriction
to the flow of pilot oil and provides better operator control of the tilt
back/dump valve spool.
Unit 4
Lesson 1
4-1-17
Hydraulic Fundamentals
LOWERING
VALVE
LIFT
PRESSURE
REDUCING
VALVE
TO
STEERING
MAIN
RELIEF
VALVE
FROM
STEERING
MANIFOLD
AUX.
VALVE
TILT BACK
DUMP VALVE
LIFT/LOWER
VALVE
PILOT SHUTOFF
VALVE
AUX
CONTROL
TILT BACK
DUMP CONTROL
LIFT/LOWER
CONTROL
Fig. 4.1.16
Unit 4
Lesson 1
4-1-18
Hydraulic Fundamentals
LOWERING
VALVE
LOWER
PRESSURE
REDUCING
VALVE
TO
STEERING
MAIN
RELIEF
VALVE
FROM
STEERING
MANIFOLD
AUX.
VALVE
TILT BACK
DUMP VALVE
LIFT/LOWER
VALVE
PILOT SHUTOFF
VALVE
AUX
CONTROL
TILT BACK
DUMP CONTROL
LIFT/LOWER
CONTROL
Fig. 4.1.17
Unit 4
Lesson 1
4-1-19
Hydraulic Fundamentals
LOWERING
VALVE
FLOAT
PRESSURE
REDUCING
VALVE
TO
STEERING
MAIN
RELIEF
VALVE
FROM
STEERING
MANIFOLD
AUX.
VALVE
TILT BACK
DUMP VALVE
LIFT/LOWER
VALVE
PILOT SHUTOFF
VALVE
AUX
CONTROL
TILT BACK
DUMP CONTROL
LIFT/LOWER
CONTROL
Fig. 4.1.18
In this schematic, the lift/lower control lever has been moved to the
FLOAT position.
When the operator moves the lift/lower control lever to the FLOAT
position, pilot oil flows past the lift/lower pilot control valve to the
end of the lift/lower valve spool in the main implement control valve.
Pilot oil moves the lift/lower valve spool to the FLOAT position. Oil
from the opposite end of the lift/lower valve spool flows past the
lift/lower control valve to the tank.
Movement of the lift/lower valve spool to the FLOAT position blocks
the flow of supply oil to the tank. Supply oil is directed to the rod
ends of the lift cylinders and to the tank. Oil in the head ends of the
cylinders is flows past the lift/lower valve spool to the tank.
When the machine is moved and the implement is in "float." The
bucket will follow the curvature of the ground. The slight pressure in
the rod ends of the lift/lower cylinders will not force the bucket into
the ground.
Main pump oil must flow through small orifices to fill the cavity
behind the makeup valve. With oil flowing from behind the makeup
valve faster than oil flows in, the pressure difference between the oil
around the makeup valve and the oil behind the makeup valve
becomes high enough to lift the makeup valve off its seat. When the
makeup valve moves off its seat, the oil from the implement pump
flows past the makeup valve to the tank. Both ends of the lift
cylinders are open to tank allowing the bucket to float along the
ground.