Hydraulic system Basic

As You Go Through This Course

Do not simply look at the pictures, but study them, for each picture tells you
something about hydraulics. Read the notes with each picture carefully.
At the end of this course we will ask some questions to see if you have
increased your understanding of hydraulics.
 In The Beginning…

In the 17th century Pascal developed the law of confined fluids.

Pascal’s Law, simply stated, says:

“Pressure applied on a confined fluid is transmitted

undiminished in all directions, and acts with equal force on
equal areas, and at right angles to them”.
Pascal’s Law
1. The bottle is filled
with a liquid, which
is not compressible,
for example, 4. If the bottom has an
hydraulic oil. area of 20 square
inches and each
2. A 10 lb. force square inch is
applied to a stopper pushed on by the 10
with a surface area lb. of force, the
of one square inch. entire bottom
3. Results in 10 lb. of receives a 200 lb.
force on every push.
square inch
(pressure) of the
container wall. 10 lbs. x 20 sq. in.= 200

“Pressure applied on a confined fluid is transmitted undiminished in all

directions, and acts with equal force on equal areas, and at right angles to
them”.
Table Of Contents
1. Introduction Hydraulics
2. Basic Symbols of Hydraulics
3. Hydraulic Fluids
4. Plumbing and Seals
5. Reservoirs
6. Hydraulic contamination
7. Actuators
8. Hydraulic Pumps / Motors
9. Directional valves
10. Pressure controls
11. Flow Controls
12. Accessories
13. Hydraulic Circuits
INTRODUCTION TO HYDRAULICS
Pascal’s Law: A Closer Look
Pascal’s Law Explained Using A Fulcrum
Explaining Piston Displacement
Force
Force. The relationship of force, pressure, and area is as
follows:
F = PA
where-

F = force, in pounds
P = pressure, in psi
A = area, in square inches

Example:
Figure 1-6 shows a pressure of 50 psi being applied to an
area of 100 square inches. The total force on the area is-
F = PA
F = 50 x 100 = 5,000 pounds
Solving For Pressure
F = PA solves for Force. Shifting the same equation will
allow you to solve for Force or Pressure.

F
P= Solves for Pressure
A
F = Force
P = Pressure Cylinder

A = Area in sq. inches R

O
F = PA Solves Force D
P = F/A Solves Pressure
A= F/P Solves Area
piston
How Many Cubic Inches Of Oil Is In One
Gallon?

231 cubic inches

How Hydraulics Performs Work
Using A Linear Actuator
(Cylinder)
How Hydraulics Works To Rotate A Motor

Motor is turned by oil from pump.

Pump is turned by diesel engine.

Once oil has turned motor, it returns to the

reservoir via the return line.
Understanding Gallons Per Minute (GPM)
How Flow Restriction Effects Speed Or
Distance
How A Directional Valve Works
The Directional Valve Switches The Oil
Direction
Red color
means pressure
What A Relief Valve Does
A Pump Doing Work
Work Even When Seals Leak Slightly
Calculating Speed Per Minute
Based On Flow Per Minute
Calculating Speed
Understanding Unrestricted Flow And
Why There Is No Pressure Build Up

This is like our drive manifold when the vibro is not running. The oil goes through
the valve and dumps right back to the tank without building any pressure.
Understanding Pressure And
Where It Comes From
Reading The Relief Valve Setting
Oil Goes To The Path Of Least Resistance

Ball Check
with spring

Stronger
Spring

Strongest
Spring
Path Of Least Resistance
Understanding
What Your Are
Reading On The
Pressure Gauge
Understanding Atmospheric Pressure
Oil Has Weight
Weight of Fluid
Weight of Air
Using The Weight Of Oil To Help Feed A
Pump
Lifting Oil
Air Intake From Loose Connections

Charged from oil above Vacuum required to feed pump

The drawing on the left provides some charged pressure, while the drawing on
the right requires vacuum. In either case, if there is any leaks on the suction
hose leading to the pump, the leak could draw air into the system. Air in the
system can cause pump failure due to cavitation (air in system).
When There Is No Movement Of
Oil Then The Pressure Is The Same
How Pressure Is Lost Through An Orifice
Larger Orifices Steal Less Pressure Or Work
Flow Blocked, Pressure Equalized!
A Review Of Flow
Fast Moving Oil May Become Turbulent
Slow Moving Oil
Basic Symbols of Hydraulics
Basic Symbols: Lines
Line

-continuous line - flow line

-dashed line - pilot, drain

-long chain thin Enclosure of two or

more
functions contained in one unit.
Circle, Semi-Circle

-circle - energy conversion units (pump, compressor, motor)

-circle - Measuring instruments

-semi-circle - rotary actuator

Square, Rectangle, Diamond
Square, Rectangle

squares - control components

Diamond

diamond – Condition apparatus (filter,

separator, lubricator, heat exchanger
Miscellaneous Symbols

Spring

Restriction

Restriction
Pump Symbols

Fixed Displacement Hydraulic

Pump-unidirectional (pumps only when
rotated in one direction. Will not pump if turned backwards)

Variable Displacement
Hydraulic Pump-bidirectional
(pumps when rotated in both forward and reverse rotation)
Motors-Fixed Displacement

Unidirectional
(rotates only one direction)

Bidirectional (rotates in both directions)

Reading Lines
Reading Symbols For Pumps And Motors
Reading Symbols For Cylinders
Symbols For Pilot Operated
Relief Valves
Understanding Valves
Understanding Valves
Understanding Reservoir
Lines And Symbols
Spool Valve Positions- Finite &
Transition

in/out Stop Reverse Directions

Hand Operated
(could be electric solenoid or even air operated)
Hydraulic Fluids
APE Hydraulic Fluids

All APE units use biodegradable hydraulic fluids,

and it is friendly to the environment when spills
do occur.
Function Of Hydraulic Oil
How Hydraulic Oil Works To Lubricate
Moving Parts
How Hydraulic Oil
Effects A Spool Valve
What Happens When Water Gets Into
The Oil
Corrosion From Bad Oil
 Chapter 4
Hydraulic Fluid Conductors And Seals
Pipe Fitting
Explanation Of Thread Types
Hydraulic Hose Components
Hose Specifications 100R1 and 100R2
100R3, 100R4, 100R5, 100R6
100R9, 100R10, 100R11, 100R12
Understanding Speed Of
Hydraulic Oil Through Hoses
And Why Diameter Matters
Understanding Resistance
Through Hoses And Why
Diameter Is Key To Reducing
Back Pressure
 The longer the hose, the more
resistance or friction which means less
available pressure to do work.

The longer the hose bundle, the more pressure drop you will have. This is why
we do not want to run our vibros or drills or hydraulic impact hammers with more
than 150 feet of hose. You can have so much hose that there is no available
pressure left to do the work of turning the eccentrics or drill. Vibros and drills
work better with larger hoses or shorter lengths.
 Check Your Pressure With The Oil
Flow By-Passing the Vibro.
Vibro temporarily disconnected.

1300 psi

QD’s Pressure hose

Drive Gauge

Power Unit with engine

at full rpm.
Return Coupler fitting to by-pass vibro for flushing oil

During new production of vibros and drills, we always flush the hose bundle by putting a coupler at the end
of the hose bundle. This allows the oil to pass through the drive line hose an go back to the power unit
through the return line. We put a in-line filter on the return line to catch the dirt.
This should be done each time a new hose section on. New hoses are dirty from the work of cutting them
and installing fittings. Next time you flush the hoses please take a look at the drive pressure gauge and
read the drive pressure. You can then see how much pressure it takes just to push the oil through the
hoses.
Note also that this pressure is higher when the oil is cold. Super high back pressure could mean that you
have a restriction, like a faulty quick disconnect that is blocking the free flow of the oil. Experiences APE
employees know the approximate pressure it takes to push oil through the hoses and can see a problem
fast.
One can calculate the friction of oil going through the hoses by reading a chart and doing some math.
Pressure Drop Through
Hydraulic Hoses.
Tubing Is Quoted In Outside
Diameter. Hydraulic Hose Is
Not!
Therefore, when calculating tubing flow restrictions keep in mind
that hoses called the same size will actually be less restrictive.
How O-Ring Seals Work
The Need For Back-Up Rings
T-Seals With Back-Up Rings On Piston
How A Seal Works On a Rotating Shaft
How Clip Seals Work
How Piston Rings Work
How Packing Seals Work
Chapter 5
Reservoirs
APE Reservoirs
APE reservoirs are specially designed to separate dirt,
water and any contamination from entering the
hydraulic system.
We actually use the oil tank as a trap for filtering out
this contamination.
That is why we ask you to open your oil tanks and clean
them out once a year.
Hydraulic Tank
Function
How Reservoirs Work
 Chapter 6
Contamination Control
Particles In Hydraulic Oil
Contaminant Types And Causes
Abrasion Classes
Particles Bigger Than Oil Film
Trouble Shooting Contaminates
Troubleshoot Contaminates
Pump And Motor Clearances That Fail When Oil Is
Contaminated
Wear-In Points
Where Piston Pumps And Motors Fail When Oil Is
Bad
Contaminates From Manufacturing

View Of Hydraulic Reservoir

Main Sources Of Contamination
More Sources Of Contamination
Filters
 Chapter 7
Hydraulic Actuators
Cylinder Actuator
Telescopic Cylinder
Cylinder
Cylinder With Two Equal Power
Strokes
Cylinder Components
Understanding What Pressure, GPM,
And Displacement Means
How A Vane Motor Works
Understanding Torque
 Chapter 8
Hydraulic Pumps / Motors
APE Gear Pumps
The next slide shows a gear pump and how it works.
This type of pump is used on all APE power units to
provide flow to run vibros, hammers and drills.
There are several of these pumps mounted on the
engine rear to provide the flow required for APE units.
How A Gear Pump Works
APE Piston Pumps
APE units may use a piston pump (usually for clamp
flow) and the next slide shows how they work.
They are different in design but still produce flow only,
the same as a gear pump shown earlier.
How A
Piston
Pump
Works
APE Vibro Motor
The next slide shows what a vibro hydraulic motor looks
like. It simply takes fluid pressure and converts it to
rotational torque to turn the vibro eccentrics in the vibro.
When the eccentrics turn you get the up and down
motion required to vibrate the pile into the ground.
How A
Piston
Motor
Works
What Motors Turn In The APE Vibro

APE eccentric used in vibros turned by hydraulic

motor.
Gear Pump

A Gallon
Has 231
Cubic
Inches

The above pump is very simple. Rotating the drive shaft causes the gears to rotate
and move oil. The faster the shaft rotates, the more oil it displaces. Output is
measured by counting the amount of oil it pumps in one revolution. Gears come in
different widths so a wider gear set will move or pump more oil per revolution.
Pump output is measured in cubic inches.
 Gear Pump Output:
Cubic Inches X RPM

A Gallon
Has 231
Cubic
Inches

Gear sets are sized in accordance to their cubic inch of output (displacement) per
revolution. Therefore, these gears could be size 3.6 which would mean 3.6 cubic
inches of displacement per revolution. Total output is measured by calculating total
cubic inches per minute so you would multiply 3.6 times the rotational speed per
minute to get the total output.
How To Calculate Gallons Per Minute (GPM)

A Gallon
Has 231
Cubic
Inches

If the gears In this pump are size 3.6 then it displaces 3.6 cubic inches of oil per revolution.
To find total gallons per minute (GPM) just multiply the cubic inches of displacement of the
gears by the total speed the shaft turns in one minute. Example: Lets say the shaft turns
2100 rpm. The math would look like this: 3.6 X 2100 = 7,560 cubic inches.
There are 231 cubic inches in one gallon so divide 231 into 7,560 as follows:
7,560/231= 32.72 gallons per minute. (theoretical only)
 Pump Drives Are Not Always 1:1
When calculating the
flow of a gear pump
you must consider the
ratio of the pump
drive. APE pump
drives are suppose to
be 1:1 with the engine
crank shaft. Some
pump drives may turn
the pump faster (or
slower) than the
engine is turning. For
example, the J&M
(ICE) 1412 power unit
pump drive ratio was Gear pumps Pump drive Engine
actually a reduction.
The engine turned Do not always assume that the pump drive is turning at
faster than the the same rpm as the engine. Ratios are stamped on the
pumps. pump drive.
How To Calculate Gallons Per Minute (GPM)

A Gallon
Has 231
Cubic
Inches

If the gears In this pump are 4.5 cubic inch then it pumps 4.5 cubic inches per revolution.
To find total gallons per minute (GPM) just multiply the cubic inches of the gears by the
total speed the shaft turns in one minute. Example: Lets say the shaft turns 2100 rpm.
The math would look like this: 4.5 X 2100 = 9450 cubic inches.
There are 231 cubic inches in one gallon so divide 231 into 9,450 as follows:
9.450/213= 40.90 gallons per minute. (theoretical only)
Nature Of A Fixed Pump

Symbol

What does “fixed pump” mean? It means the pump displaces a fixed amount of oil per
revolution. Much like a squirt gun. Squeeze the trigger and it pumps the same amount
every time. This pump displaces the same amount every time it rotates. It pumps the
moment the shaft turns and keeps pumping until the shaft stops. The faster you turn it,
the more oil it displaces. You can slow down the output by slowing down the shaft
speed. (turning down the rpm of the engine)
Call A Pump A Pump And
A Motor A Motor. Know The Difference!
Outlet

Inlet
Gear Pump (This Turns That) Gear Motor

Pumps get turned by engines, motors get

turned by pump displacement.
 Squirt Gun Hydraulics (Piston
Pump)
Barrel Check Valve

Gun Housing
Squeezing the trigger moves the
hydraulic piston inward which forces Check Valve
he compressed water to squirt out
he barrel check valve. Water
When the trigger is released, the
spring moves the piston out, creating
a vacuum that opens the tank check
valve, sucking new water in the
cylinder for the next shot.
Notice the check valves are the key to
Hydraulic Piston Tank or
making hydraulics work.
(Pump)
Reservoir
Cylinder
This is a simple check valve type hydraulic system just like our fuel pump on the diesel
hammers; check valves that stop one direction and open in another. The injector on the diesel
is really a check valve that works just like the check valve in the barrel of this squirt gun.
Squirt Guns With larger Pistons Can
Squirt More Water Per Stroke

1 inch 2 inch
Changing piston diameter will increase volume of area. In this case, more water will be
trapped in the cylinder on the gun to the right so it will spray more water per stroke.
However, it will take more finger muscle to squeeze the one on the right, just as it takes
more horsepower to increase pump output. Gear pumps increase with gear size, piston
pumps increase with piston size or length of stroke or by adding more pistons.
 Chapter 9
Directional Valves
Spool Valves
Spool Valves
Spool Valves
Hand Operated Spool Valves
How Hand
Operated
Spool Valve
Works
Detented Hand Operated Spool Valve
Spool
Types
Spool Types
Solenoid Operated Spool Valves
Pilot Operated Spool Valves
Pilot Operated Spool Valves
Check Valves
In Line Check Valves
Spool And
Check
Valves
Electric Symbols
Shown On
Hydraulic
Schematics
Electrical
Symbols
 Chapter 10
Pressure Controls
Relief
Valves
 Pressure-Control Valves
Pressure-Control Valves
A pressure-control valve may limit or regulate pressure, create a particular pressure condition required for
control, or cause actuators to operate in a specific order. All pure pressure-control valves operate in a
condition approaching hydraulic balance. Usually the balance is very simple: pressure is effective on one side
or end of a ball, poppet, or spool and is opposed by a spring. In operation, a valve takes a position where
hydraulic pressure balances a spring force. Since spring force varies with compression, distance and pressure
also can vary. Pressure-control valves are said to be infinite positioning. This means that they can take a
position anywhere between two finite flow conditions, which changes a large volume of flow to a small volume,
or pass no flow.
Most pressure-control valves are classified as normally closed. This means that flow to a valve's inlet port is
blocked from an outlet port until there is enough pressure to cause an unbalanced operation. In normally open
valves, free flow occurs through the valves until they begin to operate in balance. Flow is partially restricted or
cut off. Pressure override is a characteristic of normally closed-pressure controls when they are operating in
balance. Because the force of a compression spring increases as it lowers, pressure when the valves first
crack is less than when they are passing a large volume or full flow. The difference between a full flow and
cracking pressure is called override.
Relief Valves. Relief valves are the most common type of pressure-control valves. The relief valves' function
may vary, depending on a system's needs. They can provide overload protection for circuit components or limit
the force or torque exerted by a linear actuator or rotary motor.
The internal design of all relief valves is basically similar. The valves consist of two sections: a body section
containing a piston that is retained on its seat by a spring's), depending on the model, and a cover or pilot-
valve section that hydraulically controls a body piston's movement. The adjusting screw adjusts this control
within the range of the valves.
Valves that provide emergency overload protection do not operate as often since other valve types are used to
load and unload a pump. However, relief valves should be cleaned regularly by reducing their pressure
adjustments to flush out any possible sludge deposits that may accumulate. Operating under reduced
pressure will clean out sludge deposits and ensure that the valves operate properly after the pressure is
adjusted to its prescribed setting.
Relief Valve, Simple Type

(1) Simple Type. Figure shows a simple-type

relief valve. This valve is installed so that one
port is connected to the pressure line or the
inlet and the other port to the reservoir. The
ball is held on its seat by thrust of the spring,
which can be changed by turning the adjusting
screw. When pressure at the valve's inlet is
insufficient to overcome spring force, the ball
remains on its seat and the valve is closed,
preventing flow through it. When pressure at
the valve's inlet exceeds the adjusted spring
force, the ball is forced off its seat and the
valve is opened. Liquid flows from the pressure
line through the valve to the reservoir. This
diversion of flow prevents further pressure
increase in the pressure line. When pressure
decreases below the valve's setting, the spring
reseats the ball and the valve is again closed.
Pilot Operated Relief Valve
Stages Of
A Relief
Valve As
It Opens
 Compound Type Relief Valve
(2) Compound Type. Figure shows a
compound-type relief valve. Passage C is
used to keep the piston in hydraulic balance
when the valve's inlet pressure is less than
its setting (diagram A). The valve setting is
determined by an adjusted thrust of spring 3
against poppet 4. When pressure at the
valve's inlet reaches the valve's setting,
pressure in passage D also rises to
overcome the thrust of spring 3. When flow
through passage C creates a sufficient
pressure drop to overcome the thrust of
spring 2, the piston is raised off its seat
(diagram B). This allows flow to pass
through the discharge port to the reservoir
and prevents further rise in pressure.
Venting A Relief Valve
Chapter 11
Flow Controls
Flow Controls
Chapter 12
Accessories
 Chapter 13
Hydraulic Circuits
How the Hydraulic Circuits Work
The next few slides will explain how the APE clamp and
drive hydraulic circuits and why.
The reading of hydraulic schematics is not optional, but
required to adjust or troubleshoot any hydraulic
system.
APE drive manifold circuit showing all the working
components.
Item #33 is the main directional valve spool, and item
#31 is the pilot valve that controls the main drive spool.
We use item #32 to sense pressure in forward or reverse
lines and send a signal to item #28 the relief valve. We
can energize item #31 to either forward or reverse and
send pump flow out the main directional control valve
item #33.
When item #31 is de-energized the vibro will cost to a
stop. All flow in returned through item #33 back to tank.
During this de-energizing we sense the line pressure in
forward or reverse depending which way we selected
item #31, and make the relief valve item #28 dump the
pump flow back to tank, which provides a smooth stop of
the pump flows. The pump flows now can go to tank
both through item #33 and item #28, which reduces
hydraulic shock. Item #30 is a needle valve and controls
how fast or slow item #28 gets the signal from item #32
shuttle valve. Sometime item #30 requires adjustment,
to reduce hydraulic shock when shifting item #33. Either
adjust it in or out just a little, you will know when it is set
correctly when item #33 can be shifted without hearing
any bang or shock.
Item #28, main relief valve controls the maximum
hydraulic system pressure, which is set to 4500 psi.
APE Clamp manifold circuit shown to the
left.
The new APE clamp manifold circuit is
designed to run (shift) a two speed drill
whether one is used or not. The pump
flow enters at (CP) and part of the pump
flow is, about 2-gpm is sent to item #2 for
drill two speed shifting. This flow is
limited to 375-400 psi maximum by item
#7. There is no adjustment on item #1, it
is pre-set at 2-gpm. Item #7 is normally
pre-set at 375-400 psi and can be
adjusted in the field if needed. Item #7
should never be adjusted above 400 psi
regardless.
The remaining pup flow (8-12 gpm) is
sent to item #4 the clamp open or close
directional control valve. Item #3 limits
the maximum clamp pressure to 4800 psi
maximum and can be adjusted in the
field.

Go to the next slide and we will continue.

Item #5 is a pilot check valve used to
trap hydraulic pressure on the closed
side of the vibro clamp. There is also
another one located right on the vibro
clamp as well. If item #4 is in the center
position, pump flow back to tank, then
item #5 will trap any hydraulic pressure in
the clamp close line to assure clamp
remains closed.
Item #6 is an hydraulic pressure switch, it
does two things. 1.) when hydraulic
pressure in the clamp close line reaches
4500 psi (rising pressure) it will turn the
clamp close light to green. 2.) it will also
de-energize item #4 to the center
position directing pump flow back to tank.
At which time item #5 closes and traps
pressure in the clamp close line.
Should the trapped pressure in the clamp
close line fall below about 4400 psi, then
the pressure switch will sense this and
turn the clamp close light off and re-
energize item #4 to direct flow back to
the clamp close line. In simple terms,
the pressure switch keeps clamp
pressure on the vibro clamp close line
between 4500 psi and 4400 psi as long
as the clamp close switch is in the clamp
close position.
Typical circuit drawing
of APE power unit
hydraulic circuit.
Should you request a
hydraulic circuit, this
is what you will get.
All your
troubleshooting is
done from this
drawings, if you
cannot read this
circuit, you need to
study this power point
program until you
can.
Each field service
person is required to
have a book
containing all the
hydraulic circuits APE
use’s in their products
be able to read and
understand them.
Drive manifold

Electrical Solenoids
Pilot valve w/spool
Shuttle valve block
Snubber
Main pilot operated
spool body w/spool
Manifold body
Relief valve
Relief valve unloader
Relief valve setting
adjuster
Clamp
manifold Solenoid
Valve
Safety
Check
Clamp Manifold Pressure
Clamp open gauge hose Switch
Note: Turn slot
Clamp close gauge hose with screw
driver to adjust.
Main Clamp Relief Valve For driving wood piles
or other soft piles like
To adjust, loosen lock not and turn concrete, you may need
“in” to increase relief pressure or to lower the pressure.
Note: You cannot see
turn “out” to decrease pressure. the adjusting screw in
Note: Normal setting is 4800 psi and must this photo but it is
located where the arrow
be at least 300 psi higher than the pressure is pointing. Adjust with
switch or the switch will never “switch” to a straight slot screw
turn the green light on. driver. In to increase,
out to decrease.
Pressure Switches. Pressure switches are
used in various applications that require an
adjustable, pressure-actuated electrical switch
to make or break an electrical circuit at a
Pressure Switch
predetermined pressure.
The APE clamp pressure switch is designed to
turn off the clamp solenoid that is pushing the
valve to send oil to the clamp. Once the clamp
is closed the valve does not need to send any
more oil to the clamp so the pressure switch
cuts the power to the solenoid so the valve can
go to center. At the exact same time, the
same switch tells the green light to come on at
the pendant. The green light stays on if the
pressure does not drop below the pressure
switch setting. If the pressure does drop, the
switch will turn on the solenoid, sending more
oil to the clamp and during this process, the
green light will be turned off. The switch also
serves as a safety warning device to tell the
user that something is leaking or wrong.
A flashing green light on the pendant means
the switch is going on and off due to leakage
from a hose, seal, or quick disconnect.
 Note:

Clamp Manifold
Clamp relief valve Set all valves with
4800 psi no disconnects
Pressure switch connected.
Set this valve
Adjusting screw by reading When setting
“Clamp Open” clamp pressure,
for setting clamp gauge.
this pressure
pressure.
switch must be set
Solenoid Valve 300 psi below the
relief valve. You
SO Cord 4500 psi
must first set the
main relief valve
to 4800 psi and
then set the
pressure switch.

Clamp manifold (other than bulkhead mounted)

THE END