Basic Hydraulic Systems

Caterpillar Institute
BASIC HYDRAULIC
SYSTEMS
SAFETY AND HYDRAULIC TRAINING

UNIT
Objectives
Upon completion of this lesson,

the student will:
1. State the work area safety
practices.
2. Locate and identify the
components of the hydraulic
training unit.
3. Operate the basic hydraulic
training unit.
Basic Safety Procedures

It is important that safety procedures are followed when working in
the lab, in the shop or other work area.
Practice the following procedures until they become habits.
In any work area, you must:
1. Wear safety glasses or goggles at all times.
2. ALWAYS turn off the training unit before making or breaking

connections with the components.
3. ALWAYS wipe your hands completely before touching electrical

equipment, including the solenoid valve and the switch controlling
the training unit.
4. Keep all body parts and loose objects away from operating
cylinders.
5. If you are not sure about the operation of a circuit, consult your
instructor before turning on the pump.
UNIT 2
Hydraulic Fundamentals -
Hydraulic Principles
Objectives
Upon completion of this lesson, the
student will be able to:
1. State why liquid is used 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.
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.
Practically
incompresssable
Gas is compressable
Pascals Law
"Pressure exerted on a confined

liquid is transmitted undiminished in
all directions and acts with equal
force on all equal areas."
Pascals Law
Mechanical advantage
Orifice effect
Blocked flow
Restrictions in series
Restrictions in parallel
As the check
valve in circuit
one is set at 30
psi it will open
first and give oil
flow priority to
circuit one.
Circuit three
will not receive
oil flow until
system pressure
reaches 90 psi.
Complete Quiz 2.1.1

Unit 3
Lesson 1
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
Hydraulic tank
The main function of the hydraulic oil tank

is to store oil. The tank also removes heat
and air from the oil.
Tanks must have sufficient strength,
adequate capacity and keep dirt out.
Pressurised tank
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
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
ISO schematic symbol

Complete quiz 3.1.1

Lesson 2
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
Function of hydraulic
fluid
Fluids are virtually incompressible.
Therefore, fluids can transmit
power instantaneously in a hydraulic
system. The primary functions of
hydraulic fluids are:
Power transmission
Lubrication
Sealing
Cooling
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.
The most common tool of measuring

viscosity is the Saybolt
The Saybolt Viscosimeter was
invented by and named after George
Petroleum products
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
number, the better the oil will flow at low
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
Fire resistant fluids
There are three basic types of

fire resistant fluids:
water-glycols,
water-oil emulsions
and synthetics.
Water-glycols
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
Water oil emulsion

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.
Synthetic oils
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.
Complete quiz 3.2.1

Lesson 3
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.
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.
Pumps
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:
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.).
Non-positive displacement
pumps
Non-positive displacement pumps have more

clearances between the moving and
stationary parts than positive
displacement pumps.
The extra clearance allows more oil to be
pushed back between the parts as the
outlet pressure (resistance to flow)
increases.
Positive displacement
pumps
There are three basic types of positive
displacement pumps:
gear, vane and piston.
Positive displacement pumps have much
smaller clearances between
components.
This reduces leakage and provides a
much higher efficiency when used in a
high pressure hydraulic system.
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".
Fixed displacement v
variable displacement
The output flow of a fixed displacement pump is only

changed by varying the speed of the pump rotation. It must be
rotated faster to increase the flow or rotated slower to
decrease the flow.
The gear type pump is a fixed displacement pump.
The vane type and piston type pumps may be fixed or variable.
The output flow from a variable displacement pump may be
increased or decreased independent of the speed of
rotation.
The output flow may be manual controlled, automatic
Gear pump operation

Pressure plates
Vane pump operation

Vane pumps
Vane operation
Pressure plates
Balanced vane pump

Variable vane pump

Variable output
vane pumps are
controlled by
shifting a round
ring back and
forth in relation
to the rotor
centerline.
Variable output
vane pumps are
seldom, if ever,
used in mobile
hydraulic
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
Fixed v Variable
Internal gear pump

Gerotor pump
Pump ISO symbols

Motor ISO symbols

Complete quiz 3.3.1

Lesson 4
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.
Relief valves
Pilot operated relief

valve
Relief valve ISO symbol

Variable ISO relief valve

symbol
Sequence valve
The sequence valve (Figure 3.4.8) is simply a

pilot operated relief valve in series with
the second circuit. The sequence valve is
use when two circuits are supplied by one
pump and one circuit has priority over the
Sequence valve ISO

symbol
Pressure reducing valve

The pressure reducing valve
allows two circuits of
different pressures to be
supplied by the same pump.
The maximum supply oil pressure
is controlled by the system
relief valve.
The pressure reducing valve
controls the maximum pressure
in the controlled oil circuit.
Pressure reducing valve

Pressure reducing valve ISO

symbol
Pressure differential
valve
The pressure differential valve

maintains a specified difference in
pressure between two circuits.
Pressure differential ISO

symbol
Complete quiz 3.4.1

3.4.2
3.4.3
Lesson 5
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.
Directional control
valve
The directional control valve is use

to direct the supply oil to the
actuator in a hydraulic system.
Open Center Directional

Control Valve in HOLD
Position
Open Center Directional
Control Valve in RAISE

Position
ISO directional control

valve symbols
ISO Ports
3 position valve
Directional control valve

actuators
Three Position, Six Way, Open

Center, Manual Controlled
Valve
Rotary valves
Check valve
Pilot operated check

valve
Check valve ISO symbols

Make-up valve
Solenoid actuators
Solenoid actuated
directional control valve
Solenoid actuated ISO

control valve
Complete quiz 3.5.1

Lesson 6
Objectives
the student will:
1. State the function of the
orifice, the needle valve, the
flow control valve, the
pressure compensated flow
control valve, and the quick-
drop valves.
2. Identify the ISO symbols for
the various flow control
Orifice
An orifice is a small opening in the
oil flow path.
Flow through an orifice is affected
by several factors.
Three of the most common are:
1. The temperature of the oil.
2. The size of the orifice.
3. The pressure differential across
the orifice.
Variable orifice
Pressure differential
Flow through an orifice is affected by the pressure

differential across the orifice.
The greater the pressure differential across the
orifice, the greater the flow through the orifice.
In Figure 3.6.5, pressure differential is illustrated
using the two tubes of tooth paste. When the tube
of toothpaste is gently squeezed as in A, the
pressure difference between the inside of the tube
and the outside of the tube is small.
Therefore, only a small amount of tooth paste is
forced out. When the tube is squeezed with greater
force as in B, the pressure difference between the
inside of the tube and the outside of the tube
Pressure compensated flow

control valve
Quick drop valve

Flow control ISO symbols

Complete quiz 3.6.1

Lesson 7
Objectives
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.
Single acting cylinders

Double acting cylinders

Effective area of a
cylinder
Cylinder seals
Snubbers (Dampers)
Complete quiz 3.7.1

Practical exercises pump and
valve operation. In the hydraulics
test room.
3.3.1
3.3.2
3.3.3
3.4.1
3.4.2
3.4.2
3.4.4
3.5.1
3.5.2
Unit 4
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.
Hydraulic colours
Green Tank oil or oil connected

to the tank.
Blue Blocked oil
Red High pressure oil or pump
oil
Red and White Stripe High
pressure oil but less than Red
oil.
Orange Pilot pressure oil
Lesson 1
928G wheel loader hold

position
Pilot control valve

Metering stem
Main control valve

Main control valve

Combination valve
Control valve (lower)

Control valve float


Basic Hydraulic Systems

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Caterpillar Institute

SAFETY AND HYDRAULIC TRAINING

Upon completion of this lesson,

Basic Safety Procedures

1. Wear safety glasses or goggles at all times.

2. ALWAYS turn off the training unit before making or breaking

3. ALWAYS wipe your hands completely before touching electrical

"Pressure exerted on a confined

Complete Quiz 2.1.1

The main function of the hydraulic oil tank

The pressurized tank is completely sealed.

The vented or un-pressurized tank differs from the

ISO schematic symbol

Complete quiz 3.1.1

Upon completion of this lesson

The most common tool of measuring

Synthetic oils are formed by

Fire resistant fluids

There are three basic types of

Water oil emulsion

Complete quiz 3.2.1

The hydraulic pump transfers mechanical energy

The hydraulic motor transfers hydraulic energy

Non-positive displacement pumps have more

The output flow of a fixed displacement pump is only

Gear pump operation

Vane pump operation

Balanced vane pump

Variable vane pump

Most piston pumps and motors have similar

Internal gear pump

Pump ISO symbols

Motor ISO symbols

Complete quiz 3.3.1

Pilot operated relief

Relief valve ISO symbol

Variable ISO relief valve

The sequence valve (Figure 3.4.8) is simply a

Sequence valve ISO

Pressure reducing valve

Pressure reducing valve

Pressure reducing valve ISO

The pressure differential valve

Pressure differential ISO

Complete quiz 3.4.1

The directional control valve is use

Open Center Directional

Control Valve in RAISE

ISO directional control

Directional control valve

Three Position, Six Way, Open

Pilot operated check

Check valve ISO symbols

Solenoid actuated ISO

Complete quiz 3.5.1

Flow through an orifice is affected by the pressure

Pressure compensated flow

Quick drop valve

Flow control ISO symbols

Complete quiz 3.6.1

Single acting cylinders

Double acting cylinders

Complete quiz 3.7.1