(Oto-Hui - Com) Doosan Hydraulic Basic

Basic hydraulic system (Excavator)
Understanding hydraulic basic system
Jan., 24th,2007
Overseas P/S Team
Docu. No : DXT HB 07 06 - Rev03
1. Hydraulic principles
2. Basic hydraulic system
1.
Hydraulic principles
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.
1.
1)
Liquids comport to shaft
Liquids will conform to the shape of any container.

Liquids will also flow in any direction through lines and hoses of various sizes and shapes.
1.
2)
Practically incompressible
50Kg
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."
5
1.
2)
Practically incompressible
50Kg
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.
1.
3)
Hydraulics doing work
112 Kg.f
50
Kg.f
4Kg.f/cm
3 Cm Radius
2 Cm Radius
According to Pascals Law, "Pressure exerted on a confined liquid is transmitted undiminished in all directions
and acts with equal force on all equal areas." Therefore, a force exerted on any part of an enclosed hydraulic oil
system transmits equal pressure in all directions throughout the system.
In the above example, a 50 Kg force acting upon a piston with a 2 Cm. radius creates a pressure of
approximately 4 Kg per square centimeter in a confined liquid. The same 4Kg/Cm acting upon a piston with a 3
Cm. radius supports a 112Kg force weight.
1.
3)
Hydraulics doing work

Force (F) = Pressure (P) X Area (A)
Pressure (P) = Force (F) / Area (A)
Area (A) = Force (F) / Pressure (P)
112 Kg.f
50 Kg.f
4Kg.f/cm
3 Cm Radius
2 Cm Radius
1.
4)
Orifice effect
Flow
Flow
1 LPM
1 LPM
An orifice offers a restriction to the pump flow. When oil flows through an orifice, pressure is produced on the upstream
side of the orifice.
In right figure, there is an orifice in the pipe between the two gauges.
The gauge up stream of the orifice shows that a pressure of 30 bar is needed to send a flow of 1 LPM through the
orifice. There is no restriction to flow after the orifice. The gauge down stream of the orifice shows 0 pressure.
1.
4)
Orifice effect
From
From
Pump
Pump
When the end of either pipe is plugged, oil flow to the tank is blocked.
The positive displacement pump continues pumping at 1 LPM and fills the pipe. When the pipe is filled, the
resistance to any additional flow into the pipe produces pressure. The pressure reaction is the same as Pascals
Law which states that "pressure exerted on a confined liquid is transmitted undiminished in all directions and acts
with equal force on all equal areas." The two gauge readings are the same.
10
1.
4)
Orifice effect
Bar
Bar
Bar
Bar
Bar
Flow
Flow
1 LPM
1 LPM
30 bar
Bar
30 bar
30 bar
There are two basic types of circuits, series and parallel.

In Figure, a pressure of 90 bar is required to send 1 LPM 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.
11
1.
4)
Orifice effect
30 bar
60 bar
90 bar
In a system with parallel circuits, pump oil follows the path of least resistance. In figure , the pump supplies oil to
three parallel circuits. Circuit three has the lowest priority and circuit one has the highest priority.
When the pump oil flow fills the passage to the left of the three valves, pump oil pressure increases to 30 bar.
The pump oil pressure opens the valve to circuit one and oil flows into the circuit. When circuit one is filled, the
pump oil pressure begins to increase. The pump oil pressure increases to 60 bar and opens the valve to circuit
two. The pump oil pressure can not continue to increase until circuit two is filled. The pump oil pressure must
exceed 90 bar to open the valve to circuit three.
There must be a system relief valve in one of the circuits or at the pump to limit the maximum pressure in the
system.
12
1.
4)
Orifice effect
Please write down system pressure on pressure gauge

13
2.
Basic hydraulic system
1)
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.
14
2.
1)
Hydraulic tank
Fill Cover
Sight Glass
Fill cover - 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.
Return line
Suction 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.
Suction line
Drain
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.
15
2.
1)
Hydraulic tank
Pressurized Tank
Air breather
The two main types of hydraulic tanks are pressurized and

vented (un pressurized).
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.
16
2.
2)
Hydraulic fluids
The primary functions of hydraulic fluids are
Power transmission
Lubrication
Sealing
Cooling
17
2.
2)
Hydraulic fluids
Power Transmission
Because hydraulic fluids are virtually incompressible, once the hydraulic system is filled with fluid it can
instantly transmit power from one area to another. However, this does not mean that all hydraulic fluids
are equal and will transmit power with the same efficiency. Choosing the correct hydraulic fluid depends
on the application and the operating conditions.
Lubrication
Hydraulic fluid must lubricate the moving parts of the hydraulic system. The rotating or sliding
components must be able to function without touching other surfaces. The hydraulic fluid must maintain
a thin film between the two surfaces to prevent friction, heat and wear.
18
2.
2)
Hydraulic fluids
Sealing
Many hydraulic components are designed to use hydraulic fluid instead of mechanical seals within the
component. The viscosity of the fluid helps to determine its ability to function as a seal.
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
19
2.
3)
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 or tank pressure pushes the oil through the inlet passage and into the pump inlet chambers.
The pump 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.
20
2.
3)
Hydraulic pump
Engine
PUMP
Tank
21
2.
3)
Hydraulic pump
Gear pump
Axial propeller pump
Vain pump
Internal gear pump

22
2.
3)
Hydraulic pump (Making flow)
Axial piston pump
Vent axis piston pump
23
2.
3)
Hydraulic pump symbol
24
2.
4)
Control valve
The control valve (Hydraulic system) has three control features
1)
Pressure control
2)
Directional control
3)
Flow control
25
2.
4)
Control valve
1) Pressure control - Relief valve
Closed condition
Open condition
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.
26
2.
4)
Control valve
1) Pressure control - Relief valve symbol
Closed condition
Open condition
27
2.
4)
Control valve
1) Pressure control Mail relief valve
28
2.
4)
Control valve
1) Pressure control - Over load relief valve
29
2.
4)
Control valve
1) Pressure control - Main relief valve
C: Orifice
D: Chamber
E: Sleeve
F: Poppet
G: Drain hole
Closed condition
Open condition
30
2.
4)
Control valve
1) Pressure control Main relief valve (2 stage)
Normal pressure (330 bar)
Pressure up (350 bar)
31
2.
4)
Control valve
1) Pressure control Overload relief valve
Make up function?
32
2.
4)
Control valve
1) Pressure control Check valve
Open condition
Closed condition
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.
33
2.
4)
Control valve
1) Pressure control Check valve symbol
34
2.
4)
Control valve
1) Pressure control Load check valve
35
2.
4)
Control valve
1) Pressure control Load check valve
36
2.
4)
Control valve
1) Pressure control Pilot control check valve
The pilot operated check valve differs from the simple check valve in that the pilot operated check
valve allows oil flow through the valve in the reverse direction.
35
37
2.
4)
Control valve
1) Pressure control Pilot control check valve
38
2.
4)
Control valve
1) Pressure control Pilot control check valve ( Holding valve)
39
2.
4)
Control valve
1) Pressure control Make up valve
The make-up valve, 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 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 cavitations.
40
2.
Directional control valve

4)
Control valve
2) Directional control - Directional control spool
The directional control valve is use to direct he supply oil to the actuator in a hydraulic system.
41
2.
4)
Control valve
2) Directional control - Directional control spool
42
2.
4)
Control valve
2) Directional control - Directional control spool (symbol)
43
2.
4)
Control valve
44
2.
4)
Control valve
45
2.
4)
Control valve
Two position, 4-way pilot valve
Three position, 4-way pilot valve
46
2.
4)
Control valve
2) Directional control
Neutral position
Switched position
47
2.
4)
Control valve
2) Directional control Parallel line
Tandem circuit
Parallel circuit
48
2.
4)
Control valve
2) Directional control Parallel line
49
2.

Flow control valve
4)
Control valve
3) 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.
50
2.
4)
Control valve
3) Flow control
Temperature
The oil viscosity changes with changes in temperature. Viscosity is a measurement of the oil's resistance
to flow at a specific temperature.
Hydraulic oil becomes thinner and flows more readily as the temperature increases.
Orifice Size
The size of the orifice controls the flow rate through the orifice. A common example is a hole in a garden
hose. A small pin hole will leak in the form of a drip or a fine spray. A larger hole will leak in the form of a
stream. The hole, whether small or large, meters a flow of water to the outside of the hose. The amount
of water metered depend on the size of the hole (orifice).
51
2.
4)
Control valve
3) Flow control - Orifice
Fixed orifice
Variable orifice
52
2.
4)
Control valve
3) Flow control - 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.
Below figure, 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 increases and a larger amount of toothpaste is forced out.
53
2.
4)
Control valve
3) Flow control Orifice symbol
54
2.
5)
Cylinder
Cylinder
Single acting cylinder
Double acting cylinder
55
2.
5)
Cylinder
Cylinder
Effective area
56
2.
5)
Cylinder
Cylinder (Cushion damping)
Head side damping
Rod side damping
57
2.
5)
Cylinder
Cylinder symbol
58
2.
6)
Motor
Axial piston motor
Bent axis piston motor
59
2.
6)
Motor
Fixed displacement HYD. motor
Variable displacement HYD. motor
60
2.
6)
Motor
61
2.
6)
Motor (Swing motor)
Rotating
Stop
62
2.
6)
Motor (Travel motor)
Rotating
Stop
63
2.
6)
Motor (Travel motor- Wheel type)
64
2.
7)
Remote control valve
65
2.
7)
Remote control valve
66
2.
8)
Center joint
Upper hydraulic power from hydraulic pump transmits to the lower hydraulic
actuator without any hydraulic hose connection
67
2.
9)
Cooler
Transfer heat into air

Keep machine operating within a desired
temperature range
68
2.
10)
Accumulator
Spring loaded type
Gas loaded type
Save Hydraulic energy.

Compensate system pressure
Absorption of hydraulic pick pressure on
system line
Remove pump pulsating pressure
69
2.
11)
Solenoid valve
70
2.
12)
Proportional valve
Out put
The out put pressure is depend on current value
(Variable out put pressure)
71
2.
13)
Filter
Filter
Strainer
To remove contaminants from hydraulic

fluid in system
72
2.
14)
Restriction valve
Control valve
tank line
Swing motor
make up port
Remain return line pressure (Back pressure) for making up

73
2.
15)
Steering unit
One of control valve for steering,

Steering power by operator control
is connected to steering cylinder.
74
2.
16)
Service brake valve
Brake supply power is connected to break actuator.

75
2.
17)
Shuttle valve
One of special connector.

S1 port is connected anytime if B1 or B2
pressure is high.
76

(Oto-Hui - Com) Doosan Hydraulic Basic

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Basic hydraulic system (Excavator)

Understanding hydraulic basic system

2. Basic hydraulic system

There are several advantages for using a liquid.

Liquids comport to shaft

Liquids will conform to the shape of any container.

Hydraulics doing work

Hydraulics doing work

There are two basic types of circuits, series and parallel.

Please write down system pressure on pressure gauge

Basic hydraulic system

Basic hydraulic system

Fill cover - Keeps contaminants out of the opening that's

Drain - Located at the lowest point in the tank, the drain is

Basic hydraulic system

The two main types of hydraulic tanks are pressurized and

Basic hydraulic system

The primary functions of hydraulic fluids are

Basic hydraulic system

Basic hydraulic system

Basic hydraulic system

Basic hydraulic system

Basic hydraulic system

Axial propeller pump

Internal gear pump

Basic hydraulic system

Hydraulic pump (Making flow)

Axial piston pump

Vent axis piston pump

Basic hydraulic system

Hydraulic pump symbol

Basic hydraulic system

Basic hydraulic system

Hydraulic systems are designed to operate within a certain pressure range.

Basic hydraulic system

Basic hydraulic system

Basic hydraulic system

Basic hydraulic system

Basic hydraulic system

Normal pressure (330 bar)

Pressure up (350 bar)

Basic hydraulic system

Basic hydraulic system

Basic hydraulic system

Basic hydraulic system

Basic hydraulic system

Basic hydraulic system

Basic hydraulic system

Basic hydraulic system

Basic hydraulic system

Basic hydraulic system

Directional control valve

Basic hydraulic system

Basic hydraulic system

Basic hydraulic system

Basic hydraulic system

Basic hydraulic system

Two position, 4-way pilot valve

Three position, 4-way pilot valve

Basic hydraulic system

Basic hydraulic system

Basic hydraulic system

Basic hydraulic system