BASIC HYDRAULICS

BASIC HYDRAULICS
 INTRODUCTION:

Hydraulics systems transfer the power by feeding a

hydraulic fluid from a closed vessel with variable
displacement to another closed vessel.

BASIC HYDRAULICS
 CONTENT
1.HYDRAULIC PUMP
2.PRESSURE CONTROL VALVES
3.DIRECTIONONAL CONTROL VALVES
4.FLOW CONTROL VALVES
5.MODULAR VALVES
6.PROPORTIONAL CONTROL VALVES
7.SERVO VALVES
8.ACTUATORS
9.HYDRAULICS ACCESSORIES
10.HYDRAULICS FLUIDS
11.SIMPLE HYDRAULIC CIRCUITS
12.TROUBLESHOOTING FOR HYDRAULICS
EQUIPMENT

BASIC HYDRAULICS
1.HYDRAULIC PUMP

BASIC HYDRAULICS
1.HYDRAULIC PUMP
Hydraulic pumps convert mechanical energy from a prime mover (engine or
electric motor) into hydraulic (pressure) energy. The pressure energy is used then
to operate an actuator.
Pumps push on a hydraulic fluid and create flow.
PUMP CLASSIFICATIONS:.
All pumps create flow.
They operate on the displacement principle. Fluid is taken in and displaced to
another point.
Pumps that discharge liquid in a continuous flow are no positive-displacement
type.
Pumps that discharge volumes of liquid separated by periods of no discharge are
positive-displacement type.

BASIC HYDRAULICS
 NONPOSITIVE-DISPLACEMENT PUMPS

 Volume of liquid delivered for each cycle depends on the

resistance offered to flow.
 A pump produces a force on the liquid that is constant for each
particular speed of the pump. Resistance in a discharge line produces a
force in the opposite direction. When these forces are equal, a liquid is in
a state of equilibrium and does not flow.

 If the outlet of a non positive-displacement pump is completely closed,

the discharge pressure will rise to the maximum for a pump operating at
a maximum speed.

 pump will churn a liquid and produce heat.

BASIC HYDRAULICS
 POSITIVE-DISPLACEMENT PUMPS

In this pump, a definite volume of liquid is delivered for each cycle of pump
operation, regardless of resistance, as long as the capacity of the power unit
driving a pump is not exceeded.

If an outlet is completely closed, either the unit driving a pump will stall or
something will break.

Therefore, a positive-displacement-type pump requires a pressure regulator

or pressure-relief valve in the system.

BASIC HYDRAULICS
INTERNAL GEAR PUMP:
Shows an internal gear
pump. The teeth of one gear
project outward, while the
teeth of the other gear project
inward toward the center of
the pump.

One gear wheel stands inside the other. This type of gear can rotate, or be rotated by, a
suitably constructed companion gear. An external gear is directly attached to the drive
shaft of a pump and is placed off-center in relation to an internal gear. The two gears
mesh on one side of a pump chamber, between an inlet and the discharge.
On the opposite side of the chamber, a crescent shaped form stands in the
space between the two gears to provide a close tolerance.

BASIC HYDRAULICS
LOBE PUMP:

Figure shows a lobe pump. It differs from other gear

pumps
because it uses lobed elements instead of gears. The
element drive also differs in a lobe pump. In a gear pump,
one gear
drives the other. In a lobe pump, both elements are driven LOBE PUMP:
through suitable external gearing.

BASIC HYDRAULICS
 VANE PUMPS

In a vane-type pump, a slotted rotor splined to a drive shaft rotates between closely
fitted side plates that are inside of an elliptical- or circular-shaped ring. Polished,
hardened vanes slide in and out of the rotor slots and follow the ring contour by
centrifugal force. Pumping chambers are formed between succeeding vanes, carrying oil
from the inlet to the outlet. A partial vacuum is created at the inlet as the space between
vanes increases.
The oil is squeezed out at the outlet as the pumping chamber’s size decreases. Because
the normal wear points in a vane pump are the vane tips and a ring’s surface, the vanes
and ring are specially hardened and ground. A vane pump is the only design that has
automatic wear compensation built in. As wear occurs, the vanes simply slide farther out
of the rotor slots and continue to follow a ring’s contour.
Thus efficiency remains high throughout the life of the pump.

BASIC HYDRAULICS
 BALANCED VANE PUMPS

Balanced Vane Pumps. In the balanced design a

pump has a stationary, elliptical cam ring and
two sets of internal ports. A pumping chamber
is formed

between any two vanes twice in each revolution. The two inlets and outlets are 180
degrees apart. Back pressures against the edges of a rotor cancel each other.
Recent design improvements that allow high operating speeds and pressures have
made this pump the most universal in the mobile equipment field.

BASIC HYDRAULICS
UN BALANCED VANE PUMP

In the unbalanced design, a cam ring’s shape is a true circle that is on a different
centerline from a rotor’s. Pump displacement depends on how far a rotor and ring
are eccentric.
The advantage of a true-circle ring is that control can be applied to vary the
eccentricity and thus vary the displacement.
A disadvantage is that an unbalanced pressure at the outlet is effective against a
small area of the rotor’s edge, imposing side loads on the shaft. Thus there is a limit
on a pump’s size unless very large Bearings and heavy supports are used.

BASIC HYDRAULICS
IN-LINE PISTON PUMP
WORKING PRINCIPLE:
NEUTRAL POSITION:
In an in-line piston pump a drive shaft and cylinder block are on the same
centerline. Reciprocation of the pistons is caused by a swash plate that the
pistons run against as a cylinder block rotates. A drive shaft turns a cylinder
block, which carries the pistons around a shaft. The piston shoes slide against
a swash plate and are held against it by a shoe plate. A swash plate’s angle
causes the cylinders to reciprocate in their bores. At the point where a piston
begins to retract, an opening in the end of a bore slides over an inlet slot in a
valve plate, and oil is drawn into a bore through somewhat less than half a
revolution. There is a solid area in a valve plate as a piston becomes fully
retracted.
As a piston begins to extend, an opening in a cylinder barrel moves over an
outlet slot, and oil is forced out a pressure port.

BASIC HYDRAULICS
Pump displacement depends on the bore and stroke of a piston and the number
of pistons.
A swash plate’s angle (diagram B) determines the
stroke, which can vary by changing the angle.
In a fixed angle’s unit, a swash plate is stationary in the housing. In a variable
unit’s, it is mounted on a yoke, which can turn on pintles.
Different controls can be attached to the pintles to vary pump delivery from zero
to the maximum. With certain controls, the direction of flow can be reversed by
swinging a yoke past center.
In the center position, a swash plate is perpendicular to the cylinder’s, and there
is no piston reciprocation; no oil is pumped.

BASIC HYDRAULICS
BASIC HYDRAULICS
SINGLE PUMPS

These pumps are of high pressure and high

performance, which have been developed
especially for low noise operation. To comply
with a variety of applications including
injection moulding machines, PV2R series
single pumps provide the output flow of such
a wide range as from 5.8 to 237 cc/rev.

BASIC HYDRAULICS
HYDRAULIC GEAR PUMPS
Vajra hydraulic gear pumps are particularly well suited
for heavy-duty mobile equipment applications: they are
designed for extreme duty cycles, and continuous heavy-
duty operation.
It is of simple yet rugged design, but precision
manufactured.
These are available with capacities ranging from 11 cc /
rev to 148 cc / rev for each gear section.
Several sections can be combined in to one assembly.
Interchangeability with ANSI and SAE mounting flanges
and drive shafts for most drive units.
These pumps are manufactured under strict quality
control systems.

BASIC HYDRAULICS
MONOBLOCK DIRECTION CONTROL VALVE
VALVES FOR MOBILE APPLICATION:
1)Main applications are for drill rigs back hoe loaders fork
lifts mobile cranes, scissor lifts mobile lift platforms etc .
2)Internal leakage between spool and body much less then the
ordinary industrial direction control valves hence these are
more widely used in low leakage applications.
3)Valve also got a in built relief valve so that a separate
piping is avoided.
4)Compact in design, sandwiching is possible and individual
T / P line is not required.
5)Comparitively less sensitive contamination. .
6)Rugged in design
7)Spool bodies can give longer life as body spool body are
made with high wear resistance quality hard chrome plated
spools.

BASIC HYDRAULICS
 VALVE

PRESSURE FLOW CONTROL DIRECTION CONTROL

CONTROL VALVE VALVE VALVE

BASIC HYDRAULICS
DIRECTION CONTROL VALVES

BASIC HYDRAULICS
 VALVE INSTALLATION

Since a flow-control valve meters flow in one direction only, the inlet and outlet
ports must be correctly connected in a circuit in relation to the flow direction to
be metered.
A valve's drain connection must be piped to a tank so that a connection will not
be subjected to possible pressure surges.
The location of a flow-control valve with respect to workload has an affect on a
circuit's operating characteristics. The three basic types of flow-control valve
installations are

METER-IN, METER-OUT AND BLEED OFF CIRCUITS.

BASIC HYDRAULICS
METER-IN CIRCUIT:

1. With this circuit, a flow-control valve is installed in a pressure line that

leads to a work cylinder. All flow entering a work cylinder is first metered
through a flow-control valve.
2.Since this metering action involves reducing flow from a pump to a work
cylinder, a pump must deliver more fluid than is required to actuate a cylinder at
the desired speed.
3.Excess fluid returns to a tank through a relief valve.
4. To conserve power and avoid undue stress on a pump, a relief valve’s setting
should be only slightly higher than a working pressure’s, which a cylinder
requires.

BASIC HYDRAULICS
 A meter-in circuit is ideal in applications where a load always offers a
positive resistance to flow during a controlled stroke. Examples would be
feeding grinder tables, welding machines, milling machines, and rotary
hydraulic motor drives.

A flow-control-and-check valve used in this type of circuit would

allow reverse free flow for the return stroke of a cylinder, but it would not
provide control of return stroke speed.

BASIC HYDRAULICS
METER-OUT CIRCUIT:
With a meter-out circuit, a flow-control valve is installed on the return side of a
cylinder so that it controls a cylinder's actuation by metering its discharge flow.
A relief valve is set slightly above the operating pressure that is required by the type
of work. This type of circuit is ideal for overhauling Load applications in which a
workload tends to pull an operating piston faster than a pump' delivery would
warrant.
Examples would be for drilling, reaming, boring, turning, threading, tapping,
cutting off, and cold sawing machines. A flow-control-and-check valve used in this
circuit would allow reverse free flow, but it would not provide a control of return
stroke speed.

BASIC HYDRAULICS
BLEED-OFF CIRCUIT:
A typical bleed-off circuit is not installed directly in a feed line. It is Td into
this line with its outlet connected to a return line.
A valve regulates flow to a cylinder by diverting an adjustable portion of a
pump’s flow to a tank.
Since fluid delivered to a work cylinder does not have to pass through a
flow-control valve, excess fluid does not have to be dumped through a relief
valve.
This type of circuit usually involves less heat generation because pressure on
a pump equals the work resistance during a feed operation.

BASIC HYDRAULICS
 DIRECTION CONTROL VALVES:

These valve are used for shifting oil flow direction in hydraulic
circuits and for a control of actuator starting / stopping as well as the
operating direction shifting of actuator.
These valves are classified in the following five types depending on the
operational method.

1.Solenoid operated direction control valves

2.Solenoid controlled pilot operated direction control valves
3. pilot operated direction control valves
4. manually operated direction control valves
5. mechanically operated direction control valves.

BASIC HYDRAULICS
1.Solenoid operated direction control valves
Wide range of models - choose the optimum valve to meet your needs from a
large selection available Including Low leakage type.
The DSG-01 50 series solenoid operated direction control valve come with two
basic models:
Standard type--High pressure, high flow
[315 Kgf / Cm2 , 63 lpm]
Shock less type--which greatly reduces noise which is a result of spool changeover
and vibrating pipes.
The optimum valve for any operation can be utilized since many spool types and
various solenoids are all available along with other optional functions

BASIC HYDRAULICS
 T B p A

SPOOL

BASIC HYDRAULICS
 2.SOLENOID CONTROLLED PILOT OPERATED DIRECTION VALVE

These valves are composed of a solenoid operated pilot

valves and a pilot operated slave valve. When a solenoid
is energized the pilot valve directs the flow to move the
spool of the slave valve, thus changing the direction of
flow in the hydraulic circuit.

ADVANTAGES:

HIGH PRESSURE HIGH FLOW

High pressure [315 Kgf/cm2] along with high flow
means compact system design.

LOWER PRESSURE DROP

System energy saving increased as pressure drop of
each valve has greatly reduced.

BASIC HYDRAULICS
3.Manually operated direction control valves

BASIC HYDRAULICS
4.Mechanically operated direction control valves.
CAM OPERATED DIRECTION CONTROL VALVE:

These valves may be used to shift

the direction of oil flow by
depressing the spool by way of a
cam.

BASIC HYDRAULICS
 o
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5.Poppet Type Solenoid Operated Directional Valves

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i
These are Solenoid Operated Directionalre
Valves of No Leak Type developed with the c
aim of responding the demand of the ageti
including energy saving. o
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Because these valves are of no leak type they
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allow the low viscosity hydraulic fluids tov be
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used as well as the circuit construction which
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cannot be used by the conventional spoolv High Response High
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type directional valves because of too muchs Reliability
internal leak of pressure oil. b
Because these valves are of
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The use of the low viscosity hydraulic fluids poppet type, there is no
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reduces the pressure loss which can ariseu overlap, high response can be
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from the passage resistance of the hydraulic achieved. At the same time,
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fluids, leading to the system energy saving.
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hydraulic lock is eliminated.
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BASIC HYDRAULICS
c
FLOW CONTROL VALVES

BASIC HYDRAULICS
PRESSURE & TEMPRATURE
COMPENSATOR FLOW CONTROL
VALVES

These valves are pressure and temperature

compensator type valves and maintain a constant
flow rate independent of change in system pressure
INPUT
(load) and temperature (viscosity of the fluid).
They control flow rate of the hydraulic circuit and
eventually controls the speed of actuator precisely.
Valves with an integral check valve allow a
controlled flow and reverse free flow.

OUT PUT

BASIC HYDRAULICS
FLOW CONTROL VALVES

These valves are the combination

of flow control valve, a deceleration valve
and a check valve and used mainly for
controlling rapid traverse and feed
cycles in machine tools. Switching from
rapid traverse to feed is made by a cam
operation, and fine feed control is
accomplished by dial rotation regardless
of pressure and oil temperature variation.
Rapid return is free of cam actuation.

BASIC HYDRAULICS
 Throttle and check valves

This valve is used to regulate an actuator

speed in a circuit where line pressure is
almost steady and small fluctuation of oil
flow due to pressure changes is permitted.
Integrated check valve allows reversed free
flow from outlet to inlet.
Pressure balanced construction provides less
effort in adjustment at high pressure port.

BASIC HYDRAULICS
Deceleration and Check Valves

These valves are available either with or

without an integral check valve which allows
free reverse flow.
Flow rate through the valve is regulated by the
movement of the spool, which is operated by a
cam.
When the spool is depressed, the flow is
decreased in Normally Open type valves and
increased in Normally Closed type valves.
Their principal use is to control the speed of
actuators in machine tools and similar
application

NORMALLY NORMALLY
CLOSED OPEN

BASIC HYDRAULICS
PRESSURE CONTROL VALVES

BASIC HYDRAULICS
REMOTE CONTROL VALVE

This valve is used as a remote control valve

for pilot operated type pressure control
valves
FUNCTION:
•To adjust the pressure,
loosen the lock nut and
turn the pressure
adjustment handle slowly
clockwise for higher
pressures or anti- Ratings Model number
clockwise for lower Max. Flow 4 lpm
pressures. Max. Operating Pressure
•After adjustments, do not 250 Kgf / Cm2
forget to tighten the lock
nut.
•Connect the drain port
directly to the tank

BASIC HYDRAULICS
PILOT OPERATED RELIEF VALVES

These valves protect the hydraulic system from

excessive pressure & can be used to maintain
constant pressure in a hydraulic system.
Remote control and unloading are permitted by
vent circuit

BASIC HYDRAULICS
There are two threaded ports. they can be connected to each other in line; one as
inlet and other as an out let or the valve can be used by plugging one of the
pressure ports

BASIC HYDRAULICS
SOLENOID CONTROLLED
RELIEF VALVE

These valves are a combination of relief valve

and solenoid valve.
Piping between the two is eliminated as the
solenoid valve is directly mounted on the relief
valve and connected with the relief valve vent
port.
Pump pressure may be unloaded remotely by
an electrical signal to the solenoid, or by
connecting pilot relief valves to the solenoid
valve ports.

BASIC HYDRAULICS
PRESSURE REDUCING VALVE

Pressure reducing and check valves are used to

set the pressure of a hydraulic circuit below
that of the main circuit.
They have check valves, which allow a free
flow from the secondary side to the primary.
Operation under remote control is also possible
by using the remote control port.

BASIC HYDRAULICS
WORKING:
The maximum flow rates are those shown at the
primary pressure at 210 Kgf / Cm2
The drain flow rates are equal to pilot flow rates
when differential pressure between primary and PRESSURE REDUCING VALVE
secondary pressure is at 205 Kgf / Cm2
To adjust the pressure, loosen the lock nut and turn the
pressure adjustment handle slowly clockwise for
higher pressures and anti-clockwise for lower
pressures. After adjustments, do not forget to
tighten the lock nut.
Connect the drain port directly to the tank in which
case the pressure at the drain port should be kept at a
low back pressure close to the atmospheric pressure.
There are two threaded connection type primary
pressure ports. They can be connected each other in-
line; one as an inlet and the other as an outlet or the
valve can be used by plugging one of the pressure
ports.

BASIC HYDRAULICS
 COUNTER BALANCE
AND
SEQUENCE VALVES
These valves are hydraulically damped, direct
operated pressure control valves which can be
actuated by internal or external pilot pressure. They
are available with integral check valves for use when
free reverse flow from secondary port to the primary
port is desired. There are various types of valve
including sequence and counterbalance valves, all of
which are operated by a pressure rise in the circuit,
sensed either internally or remotely.

BASIC HYDRAULICS
FUNCTION:
To adjust the pressure, loosen the lock nut and COUNTER BALANCE
turn the pressure adjustment screw slowly AND
clockwise to increase pressures or anti- SEQUENCE VALVES
clockwise to decrease pressures. After
adjustments, do not forget to tighten the lock
nut.
Connect the secondary side pressure ports of
types 1 and 4 (internal drain) and the drain
ports of types 2 and 3 (external drain) directly
to the tanks with a back pressure close to the
atmospheric pressure.
There are two threaded connection primary
pressure ports. They can be connected each
other in-line; one as inlet and the other as an
outlet or the valve can be used by plugging one
of the pressure ports.

BASIC HYDRAULICS
CARTRIDGE TYPE REMOTE RELIEF VALVE
This valve is used in a hydraulic system to
prevent damage due to over pressure and to
adjust the maximum system pressure of small
capacity.
These valves can be screwed inside the
manifold.
they can also be used as back pressure valves.

FUNCTION:

To adjust the pressure, loosen the lock nut and turn the pressure adjustment
handle slowly clockwise for higher pressures or anti-clockwise for lower
pressures.
After adjustments, do not forget to tighten the lock nut.
Before the valve is assembled into the manifold care should be taken to see that
inside the manifold dust or chips should not be present.

BASIC HYDRAULICS
 DIRECT TYPE RELIEF VALVE

This valve is used in a hydraulic system to

prevent damage due to over pressure and to
adjust the maximum system pressure of small
capacity.
FUNCTION:

1.To adjust the pressure, loosen the lock nut

and turn the pressure adjustment handle
slowly clockwise for higher pressures or anti-
clockwise for lower pressures.
2.After adjustments, do not forget to tighten
the lock nut.
3.Connect the drain port directly to the tank

BASIC HYDRAULICS
SOLENOID CONTROLLED RELIEF LOGIC VALVES

These solenoid controlled relief logic valves

are composite control valves having solenoid
controlled directional and pilot relief valves
and vent restrictors combined together. This
configuration eliminates pipes from the vent
circuits of relief logic valves. They are used
to put pumps into unloading operation, with the
solenoid controlled directional valves serving
to select pilot lines, or to place hydraulic
system two or three pressure controls, with the
pilot relief valves in action.
RATTINGS:
Maximum operating pressure 315 Kgf / Cm2
(If the pressure is above 250 Kgf / sq. Cm,
keep the flow rate above 15 lpm for all models)
Pressure adjustment range 4 ~ 315 Kgf / Cm2

BASIC HYDRAULICS
PRESSURE SWITCHES

Pressure switches are used to switch electric

circuits in accordance with the pressures of
hydraulic circuits.
A Pressure switch has two micro switches each
capable of detecting pressure setting on high or
low pressure side. The micro switch structure
is dust and drip proof.

BASIC HYDRAULICS
HIGH PRESSURE, HIGH FLOW RATE
MODULAR VALVES
FEATURES:
Installation and mounting space can be minimized.
No special skill is required for assembly and any addition or alternation of the
hydraulic circuit can be made quickly and easily.
Problems such as oil-leaks, vibration and noise which may be caused by piping
are minimized, increasing the reliability of the hydraulic system.
Maintenance and system check-ups can be easily carried out as they are normally
installed in stackable units

BASIC HYDRAULICS
 RELIEVING AND REDUCING VALVE

These valves consist of a small size

but high performance 1/8 electro-
hydraulic proportional pilot relief
valve and a reducing valve with
relief function. The valves can
control the pressure in a hydraulic
system proportionally through a
controlled input current. As the
valves have a relieving mechanism, a
good response speed in reducing the
pressure even at a large load
capacity can be obtained.

BASIC HYDRAULICS
PRIMARY PRESSURE REQUIRED FOR PRESELECTED
PRESSURE
The primary pressure must be 10 Kgf / Cm2 higher than the
preselected pressure.

DRAIN BACK PRESSURE

Check that the drain back pressure does not exceed 2 Kgf / Cm2

TRAPPED OIL VOLUME

The recommended secondary side trapped oil volume is about 20
liters. Note that the trapped oil volume must not be lower than
1.4 liters

BASIC HYDRAULICS
FLOW CONTROL AND RELIEF VALVES

These valves control the pump pressure

effectively by responding to a small pressure
difference against the load pressure.
Therefore, it can be said that they are energy-
saving meter-in type flow control valves which
can be operated at a low power consumption.

Furthermore, as the valves have temperature

compensator, the stable control of the flow rate
is possible irrespective of change in the oil
temperature.

BASIC HYDRAULICS
STABLE PERFORMANCE, IT IS RECOMMENDED THAT YUKEN' S
APPLICABLE POWER AMPLIFIERS BE USED
AMP-W-1040-24-10
YU-AMP-DRT
INSTRUCTIONS:
Drain Back Pressure
Check that the drain back pressure dose not exceed 2 Kgf / Cm2.
When Relief Valve Passing Flow Rate is Low in Pressure Control State.
To avoid preselected pressure instability, use a passing flow rate of 10 lpm or higher for
nominal sizes 03 and 06 or 15 lpm or higher for nominal size 10. Further, check that the
tank-line back pressure does not exceed 5 Kgf / Cm2.
Safety Valve Pressure Setting
The pressure of the safety valve is preset at the value equal to the upper limit of the
pressure adjustment range plus 20 Kgf / Cm2. Please adjust the pressure of the valve so
preset to meet the pressure to be used actually to lower the pressure setting, turn the
safety valve pressure adjustment screw anti-clockwise. After adjustment, be sure to
tighten the lock nut.

BASIC HYDRAULICS
 FLOW CONTROL / FLOW CONTROL AND CHECK VALVES

These valves vary their output flow proportional to an input

current, therefore, by controlling the input current from the
power amplifier, the flow rate in the system can be
continuously, remotely and optionally regulated.
Furthermore, as the valves have the functions of pressure and
temperature compensation, the flow rate is not affected by the
variation in the pressure (load) and temperature (viscosity of
hydraulic fluids).

These valves are optimal for such a usage where the start-up,
stop and speed change of the actuator are required to be done
without shocks.

The valves are used together with the applicable power

amplifiers.

BASIC HYDRAULICS
DIRECTION AND FLOW CONTROL VALVES

High Response Type l/8, Proportional Electro-Hydraulic Directional

and Flow Control Valves

High response, high accuracy, high reliability by employing a closed

loop systems for feed back control.
Especially , the valves of zero-lap type (Spool type 3C2P) are suitable
for position control or pressure control. In combination with a small
type intensified solenoid and a differential transducer for detecting
spool position, high response, high accuracy and high reliability are
realized.

BASIC HYDRAULICS
Response characteristics of 52Hz/-3dB (± 25 %amplitude) equivalent to those
for servo valves.
The valves can be used in place of servo valves of 5OHz response class for
position control or pressure control.

Excellent resistance to contamination

Troubles caused by contamination can be reduced as the valves are superior in
anti-contamination to servo valves.

BASIC HYDRAULICS
 RELIEVING AND REDUCING VALVE

These valves consist of a small size but high

performance 1/8 electro-hydraulic proportional
pilot relief valve and a reducing valve with relief
function.

The valves can control the pressure in a

hydraulic system proportionally through a
controlled input current.

As the valves have a relieving mechanism, a good

response speed in reducing the pressure even at a
large load capacity can be obtained.

BASIC HYDRAULICS
HYDRAULIC ACTUATORS

A hydraulic actuator receives pressure energy and converts it to mechanical

force and motion.
An actuator can be linear or rotary. A linear actuator gives force and motion
outputs in a straight line. It is more commonly called a cylinder but is also
referred to as a ram,
reciprocating motor, or linear motor. A rotary actuator produces torque and
rotating motion.
It is more commonly called a hydraulic motor or motor.

BASIC HYDRAULICS
Cylinders. A cylinder is a hydraulic actuator that is constructed of a
piston or plunger that operates in a cylindrical housing by the action
of liquid under pressure.
shows the basic parts of a cylinder. A cylinder housing is a tube in
which a plunger (piston) operates.
In a ram-type cylinder, a ram actuates a load directly. In a piston
cylinder, a piston rod is connected to a piston to actuate a load.
An end of a cylinder from which a rod or plunger protrudes is a rod
end. The opposite end is a head end

BASIC HYDRAULICS
SINGLE-ACTING CYLINDER.

This cylinder (Figure) only has a head-end port and is operated

hydraulically in one direction.
When oil is pumped into a port, it pushes on a plunger, thus extending it.
To return or retract a cylinder, oil must be released to a reservoir.
A plunger returns either because of the weight of a load or from some
mechanical force such as a spring. In mobile equipment, flow to and from a
single-acting cylinder is controlled by a reversing directional valve of a
single-acting type.

BASIC HYDRAULICS
DOUBLE-ACTING CYLINDER.
This cylinder (Figure ) must have ports at the head and rod ends. Pumping oil
into
the head end moves a piston to extend a rod while any oil in the rod end is
pushed
out and returned to a reservoir.
To retract a rod, flow is reversed. Oil from a pump goes into a rod end, and a
head-end port is connected to allow return flow.
The flow direction to and from a double-acting cylinder can be controlled by a
double-acting directional valve or by actuating a control of a reversible pump.

BASIC HYDRAULICS
 TELESCOPING, RAM-TYPE, ACTUATING CYLINDER

telescoping, ram-type, actuating cylinder, which can be a single- or double acting

type.
In this cylinder, a series of rams are nested in a telescoping assembly. Except for the
smallest ram, each ram is hollow and serves as a cylinder housing for the next
smaller ram. A ram assembly is contained in a main cylinder housing, which also
provides the fluid ports.
Although an assembly requires a small space with all of the rams retracted, a
telescoping action of an assembly provides a relatively long stroke when the rams
are extended.

BASIC HYDRAULICS
 CUSHIONED CYLINDER.

To slow an action and prevent shock at the end of a piston stroke, some
actuating cylinders are constructed with a cushioning device at either or
both ends of a cylinder.
This cushion is usually a metering device built into a cylinder to restrict
the flow at an outlet port, thereby slowing down the motion of a piston.
Figure 4-7 shows a cushioned actuating cylinder.

BASIC HYDRAULICS
TROUBLE SHOOTING

BASIC HYDRAULICS
ACTUATOR

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A. EXTERNAL LEAKAGE:
If a cylinder’s end caps are leaking, tighten them. If the leaks still do not stop,
replace the gasket. If a cylinder leaks around a piston rod, replace the
packing. Make sure that a seal lip faces toward the pressure oil. If a seal
continues to leak, check
B. INTERNAL LEAKAGE.
Leakage past the piston seals inside a cylinder can cause sluggish movement
or settling under load. Piston leakage can be caused by worn piston seals or
rings or scored cylinder walls. The latter may be caused by dirt and grit in the
oil.
NOTE: (When repairing a cylinder, replace all the seals and packing
before reassembly).
C. CREEPING CYLINDER:
If a cylinder creeps when stopped in mid stroke, check for internal leakage,
Another cause could be a worn control valve.

BASIC HYDRAULICS
D. SLUGGISH OPERATION:
Air in a cylinder is the most common cause of sluggish action.
Internal leakage in a cylinder is another cause. If an action is sluggish when
starting up a system, but speeds up when a system is warm, check for oil of
too high a viscosity (see the machine's operating manual). If a cylinder is still
sluggish after these checks, test the whole circuit for worn components.
E. LOOSE MOUNTING:
Pivot points and mounts may be loose. The bolts or pins may need to be
tightened, or they may be worn out. Too much slop or float in a cylinder’s
mountings damages the piston-rod seals. Periodically check all the cylinders
for loose mountings.

BASIC HYDRAULICS
DIRECTION CONTROL
VALVE

BASIC HYDRAULICS
DIRECTIONAL-CONTROL VALVES

Directional-control valves include spool, rotary, and check valves.

Consider the following when troubleshooting these valves because there is faulty
or incomplete shifting:

• Control linkage is worn or is binding.

• Pilot pressure is insufficient.
• Solenoid is burned out or faulty.
• Centering spring is defective.
• Spool adjustment is improper

BASIC HYDRAULICS
CONSIDER THE FOLLOWING WHEN TROUBLESHOOTING
DIRECTIONAL-CONTROL VALVES BECAUSE THE ACTUATING
CYLINDER CREEPS OR DRIFTS:

• Valve spool is not centering properly.

• Valve spool is not shifted completely.

• Valve-spool body is worn.

• Leakage occurs past the piston in a cylinder.

• Valve seats are leaking.

BASIC HYDRAULICS
FLOW CONTROL
VALVE

BASIC HYDRAULICS
PRESSURE CONTROL
VALVE

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RELIEF VALVES.
CONSIDER THE FOLLOWING, WHEN TROUBLESHOOTING RELIEF
VALVES BECAUSE THEY HAVE LOW OR ERRATIC PRESSURE:
• Dirt, chip, or burrs are holding the valve partially open.

• Poppets or seats are worn or damaged.

• Valve piston in the main body is sticking.

• Spring is weak.

• Spring ends are damaged.

• Valve in the body or on the seat is cocking.

• Orifice or balance hold is blocked.

BASIC HYDRAULICS
Consider the following when troubleshooting relief valves because they have
no pressure:
• Orifice or balance hole is plugged.
• Poppet does not seat.
• Valve has a loose fit.
• Valve in the body or the cover binds.
• Spring is broken.
• Dirt, chip, or burrs are holding the valve partially open.
• Poppet or seat is worn or damaged.
• Valve in the body or on the seat is cocking.

BASIC HYDRAULICS
CONSIDER THE FOLLOWING WHEN TROUBLESHOOTING RELIEF
VALVES BECAUSE THEY HAVE EXCESSIVE NOISE OR CHATTER:

• Oil viscosity is too high.

• Poppet or seat is faulty or worn.

• Line pressure has excessive return.

• Pressure setting is too close to that of another valve in the circuit.

• An improper spring is used behind the valve.

BASIC HYDRAULICS
CONSIDER THE FOLLOWING WHEN TROUBLESHOOTING RELIEF
VALVES BECAUSE THEY MIGHT BE OVERHEATING THE SYSTEM:

• Operation is continuous at the relief setting.

• Oil viscosity is too high.

• Valve seat is leaking.

BASIC HYDRAULICS
PRESSURE-REDUCING VALVES:
WHEN TROUBLESHOOTING PRESSURE REDUCING VALVES
BECAUSE THEY HAVE ERRATIC PRESSURE:
• Dirt is in the oil.
• Poppet or seat is worn.
• Orifice or balance hole is restricted.
• Valve spool binds in the body.
• Drain line is not open freely to a reservoir.
• Spring ends are not square.
• Valve has an improper spring.
• Spring is fatigued.
• Valve needs an adjustment.
• Spool bore is worn.

BASIC HYDRAULICS
BASIC HYDRAULICS
VALVE FAILURES AND REMEDIES.
Hydraulic valves are precision-made and must be very accurate in
controlling a fluid’s pressure, direction, and volume within a system.
Generally, no packing are used on valves since leakage is slight, as long as
the valves are carefully fitted and kept in good condition.
Contaminants, such as dirt in the oil, are the major problems in valve
failures. Small amounts of dirt, lint, rust, or sludge can cause annoying
malfunctions and extensively damage valve parts.
Such material will cause a valve to stick, plug small openings, or abrade the
mating surfaces until a valve leaks. Any of these conditions will result in
poor machine operation, or even complete stoppage. This damage may be
eliminated if operators use care in keeping out dirt.
Use only the specified oils in a hydraulic system. Follow the
recommendations in a machine’s operator's manual. Because oxidation
produces rust particles, use an oil that will not oxidize.
Change the oil and service the filters regularly.

BASIC HYDRAULICS
SERVICING VALVES:
DO THE FOLLOWING BEFORE SERVICING A VALVE:

• Disconnect the electrical power source before removing a hydraulic valve’s

components.
Doing so eliminates starting the equipment accidentally or shorting out
the tools.
• Move a valve's control lever in all directions to release the system’s hydraulic
pressure before disconnecting any hydraulic valve components.
• Block up or lower all hydraulic working units to the ground before disconnecting
any parts.

BASIC HYDRAULICS
• Clean a valve and its surrounding area before removing any part for
service. Use steam-cleaning equipment if available; however, do not allow
water to enter a system.

Be certain that all hose and line connections are tight.

• Use fuel oil or other suitable solvents to clean with if steam cleaning is not
possible. However, never use paint thinner or acetone. Plug the port holes
immediately after disconnecting the lines.

BASIC HYDRAULICS
 DISASSEMBLING VALVES:
DO THE FOLLOWING WHEN DISASSEMBLING A VALVE:

. • Do not perform service work on a hydraulic valve’s interior on the shop

floor, on the ground, or where there is danger of dust or dirt being blown into
the parts.
Use only a clean bench area. Be certain that all tools are clean and free of
grease and dirt.
• Be careful to identify the parts when disassembling for later reassembly.
Spools are selectively fitted to valve bodies and must be returned to those same
bodies.
You must reassemble the valve sections in the same order.
CAUTION
Be very careful when removing a backup plug on a
spring-loaded valve. Personal injury could result.

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Directional-Control Valves. Directional-control- valve spools are installed in the valve
housing by a select hone fit. This is done to provide the closest possible fit between a
housing and a spool for minimum internal leakage and maximum holding qualities. To
make this close fit, you would need special factory techniques and equipment.
Therefore, most valve spools
and bodies are furnished for service only in matched sets and are not available
individually
for replacement.
When repairing these valves, inspect the valve spools and bores for burrs and scoring as
shown in Figure 5-40. The spools may become coated with impurities from the
hydraulic oil.
When scoring or coating is not deep enough to cause a leakage problem, polish the
surfaces
with crocus cloth. Do not remove any of the valve material. Replace a valve’s body and
spool
if scoring or coating is excessive. If a valve’s action was erratic or sticky before you
removed
it, it may be unbalanced because BASIC
of wear on the spools or body; replace the valve.
HYDRAULICS