Hydraulic Systems

Hydraulics: What
you Need to Know

to Troubleshoot
Ron McGary
TPC Instructor
2
What is Fluid Power?

Fluid Power is the technology that deals with the generation,
control, and transmission of power using pressurized fluids. It
can be said that fluid power is the muscle that moves industry.
This is because fluid power is used to push, pull, regulate, or
drive virtually all the machines of modern industry.
The first hydraulic fluid was water.
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3
What is Fluid Power?

There are actually two different types of fluid systems; Fluid Transport
and fluid power.
Fluid Transport systems have as their sole objective the delivery of a

fluid from one location to another to accomplish some useful purpose.
Fluid Power systems are designed specifically for work.

4
Hydraulic System Components

What are the 5 basic hydraulic system components?
1. Power Input Device
2. Control Devices
3. Power Output Device
4. Conductors
5. Liquid

5

1. Power Input Device

Pumps provide power to a hydraulic system by
pumping oil from a reservoir into the supply lines.
2. Control Devices
Valves control direction, pressure, and flow of pressurized oil in
the actuator of the hydraulic system

6

3. Power Output Device

The power output device is where hydraulic power is
converted into mechanical power. i.e. cylinders and motors.
4. Conductors
Conductors are pipes or hoses needed to transmit liquid
between hydraulic components
5. Liquid
A liquid is used as a medium to transmit the power, i.e. oil
in a reservoir.

7
Fluid Power System

8
Fluid Power System

9
Hydraulic Physics
Maintaining hydraulic systems requires calculations to give
the 21st century maintenance technician a foothold in
determining which pumps and motors to use in their
applications. Don’t worry we will guide you through each
step. Physics involves just about every aspect of our lives,
especially when it comes to the forces that are acting within a
hydraulic system or any other fluid power system, such as
pneumatics.

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Calculating Horsepower
Horsepower (General): Horsepower (Hydraulic):
DxF QxPx7 QxP

Where: Hp = Where: Hp =  QxPx0.000583 
Tx550 12,000 1714
Hp is the Power in Horsepower Hp is the Power in Horsepower
D is the Distance in feet Q is the Flow Rate in Gallons Per Minute and
F is the Force in pounds and P is the Pressure in psi
T is the Time in Seconds
Horsepower (Mechanical): Horsepower (Electrical):
Ft xS r ExI
Where: Hp = Where: Hp =
63,025 746
Hp is the Power in Horsepower Hp is the Power in Horsepower
Ft is the Torque in Pound Inches and E is the Electro-Motive Force in Volts and
Sr is the Rotation Speed in Rotations Per Min. I is the Intensity of Current in Amperes (or Amps)
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11
Pascal’s Law
Pressure is transmitted undiminished in a confined body of
fluid and acts at right angles to all surfaces containing the
confined fluid!
In the 17th century, 1650, Blaise Pascal discovered
a fundamental law of physics which is the basis of
fluid power operation

12
Basic Formulas
F = PA Where F = Force (in pounds)

A = Area (square inches) F
P = Pressure (PSI)
P A
V = AD Where V = Volume (cu.in.)
D = Distance (movement in inches)
The above formulas can be changed around (by simple algebra)

to give any third factor - if the other two
factors are known.

13

14
Terminology
As the FP industry continues to grow and the types and

number of equipment and features also grows… a standard
of terminology became evident.
This standardization is the “glossary of terms” that has

become a common “language” for users of FP.
A copy of this standardization is available from

www.nfpa.com

15
Directional Control Valves

16
Basic Hydraulic System

17
Purpose of Reservoirs
• Serve as heat sink

• Settling area for solids in
fluid
• Positive suction head for
pump
• Provide for secondary
cooling system
• Provide for addition of
fluid
• Indicate fluid level

18
HI-Lo Pump Control
• Loading of hydraulic
system changes
• Different flow rates
needed
• Low-flow pump
supplies pressure
• High-flow pump
supplies flow

19
General Symbols
• ISO – Means International Standards Organization
• ANSI – Means American National Standards Institute
• Most graphic symbols are shown in ISO 1219-1976
• The NFPA (National Fluid Power Association (now the IFPA – The
International Fluid power Association) has adopted ISO as it’s
standard.

20
Lines

21
Energy Triangles
Pointing out =
PUMP or Compressor
Hydraulic Pump Hydraulic Motor
Pointing in =
MOTOR
Air Pump/Compressor Air Motor

22
Hydraulic Power Units

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Hydraulic Pumps
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Hydraulic Pumps
Hydraulic systems require pumps and air systems require compressors to provide
input energy to actuators (such as cylinders and motors).
Understanding pumps & Compressors will give you better knowledge of the
overall operation of the entire system.
We will discuss the basic structure

of: ❑ Positive & variable displacement pumps

25
Important!
Pumps Do Not Make Pressure!
When I discuss pumps making pressure it ALWAYS
assumes there is sufficient resistance downstream of
pump
• Resistance to flow allows pressure to build in the system
• As pressure builds – flow tends to slow
• When the restriction is removed or decreased –
• Flow tends to increase
• As a consequence, if the flow AND pressure must be

maintained ……
• More horsepower must be applied

26
PUMPS
THE HEART OF THE SYSTEM
Hydraulic systems require pumps and air systems require

compressors to provide input energy to actuators (such as
cylinders and motors).
Understanding pumps & Compressors will give you better

knowledge of the overall operation of the entire system.
We will discuss the basic structure of:
Positive & variable displacement pumps

Such as:

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Hydraulic Pumps
Pumps come in various types and styles.
Hydrodynamic - Non-Positive displacement
Resistance is usually just the weight of the fluid or resistance in the pipe.

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Hydraulic Pumps
External Gear Pumps

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Hydraulic Pumps
Internal Gear Pumps

30
Power Unit Start-Up
1. Fill pump with filtered fluid

2. Fill pump casing
3. Ensure lowest pressure setting
4. Start and stop system while venting
5. Adjust output pressure to system requirements
6. Run pump unloaded
7. Check for leaks
8. Observe reservoir temperature
31
Power Unit Start-Up
1. Fill pump with filtered fluid

2. Fill pump casing
3. Ensure lowest pressure setting
4. Start and stop system while venting
5. Adjust output pressure to system requirements
6. Run pump unloaded
7. Check for leaks
8. Observe reservoir temperature
32
Cleaning a Hydraulic System
1. Drain entire system into reservoir

2. Drain reservoir and use off-line filter
3. Replace all filters
4. Clean pump suction strainers
5. Clean reservoir and dry
6. Paint reservoir

33
Cleaning a Hydraulic System
7. Close reservoir and refill

8. Replace air breather
9. Restart system and take fluid sample
10.Consider adding more filters
11.Follow suggestions to meet cleanliness
levels

34
Valve Maintenance
• Silting
• Accumulation of fine particles in valve
• Valves operate erratically, partially, or stop
• Varnishing
• Hard coating from breakdown of fluid
• Increase diameters, reduce clearances

35
Fluid power deals with the transmission and

control of energy by a pressurized
__________.
A. vessel
B. Directional
control valve
C. Electric motor
D.fluid

36
Pressure is equal to force divided by

__________.
A. weight
B. liquid
C. gas
D.area

37
The spool of a directional control valve is

shifted to different positions by the
__________.
A. fluid
B. operator
C. conductor
D.cylinder

38
Cylinder Cross Section

39
SAFETY
• Oil leaks pose a safety hazard.

• Difficult to quantify – unless someone gets hurt.
• The danger of fire or worse.
• If you have multiple pieces of hydraulic equipment each with
several leaks, the cumulative costs over and
extended period of time is ALARMING.

40
Maintenance
Would you even think of letting your car go for 100K miles without an
oil change, checking brakes, flushing the radiator, transmission
check-up or the like?
OF COURSE NOT! WHY NOT?

It is amazing that people will only give their hydraulic equipment a
modicum of attention
UNTIL IT STOPS!
Oil needs to be checked for cleanliness and temperature
The oil needs to be changed or maintained
Maintenance REDUCES troubleshooting

41
A Word About Maintenance

Proper maintenance is one of the most important and yet most
overlooked requirement of a hydraulic system
Too often systems are put into operation and no further

maintenance is performed until a major breakdown occurs
Components in a hydraulic (or pneumatic) system – are
designed to do a specific job under certain (and specific)
operating conditions such as :
Pressure Load Voltage
If conditions are maintained, checked and controlled - all
other components and the entire system will have a
significantly longer service life.
Without maintenance, costly down-time occurs requiring
many troubleshooting hours (and dollars)

42
Troubleshooting
As with maintenance the common thread that ties failures of
hydraulic systems together is CONTAMINATION.
As long as we know that contamination is the greatest cause of

system failures; “WE NEED TO CLEAN IT UP”
If we could keep our oil clean and cool – we would never

need to change it
What causes the wear? Particulate!

If there were absolutely no particulate - there would be no
abrasive wear.
WE CANT!

43
Pump Bearing Contamination

• This is the bearing
• That scored the shaft
• That seized the pump
• That shut down the process
• That depleted the inventory
• That couldn’t fill the orders

• That lost the customers
• That tanked the stock price

44
Fluid Contamination

45

46
Gruesome? Yes! & Unnecessary!

47
5 minute Pre-work Safety Checklist
I am wearing my safety glasses

I have PERSONALLY locked out and tagged out the
electric motor circuit and/or disconnected the battery.
I have PERSONALLY locked out and tagged out the

directional control valve circuit.
I have PERSONALLY depressurized and verified the

hydraulic pressure.
I have PERSONALLY installed mechanical locks or
blocks where necessary.

48
Troubleshooting Power Units

DIRTY OIL
• Components not properly cleaned after servicing
• Inadequate screening in fill pipe
• Air breather left off – environment sucked in
• Tank not properly gasketed
• Pipe lines left open during servicing
• Baffles do not allow for oil settling in tank
• Filter elements dirty – not replaced often enough

49
Thank You!
• If you’d like to learn more about hydraulic

systems, TPC can help!
Email: sales@tpctraining.com
Phone: (847) 808-4000

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Hydraulics: What

you Need to Know

What is Fluid Power?

The first hydraulic fluid was water.

IPHYB 201 0418 ©2016 TPC Training

What is Fluid Power?

Fluid Transport systems have as their sole objective the delivery of a

Fluid Power systems are designed specifically for work.

IPHYB 201 0418 ©2016 TPC Training

Hydraulic System Components

1. Power Input Device

3. Power Output Device

IPHYB 201 0418 ©2016 TPC Training

Hydraulic System Components

1. Power Input Device

IPHYB 201 0418 ©2016 TPC Training

Hydraulic System Components

3. Power Output Device

IPHYB 201 0418 ©2016 TPC Training

Fluid Power System

IPHYB 201 0418 ©2016 TPC Training

Fluid Power System

IPHYB 201 0418 ©2016 TPC Training

IPHYB 201 0418 ©2016 TPC Training

DxF QxPx7 QxP

Horsepower (Mechanical): Horsepower (Electrical):

WIPBE 300 1124 © 2021 TPC Training

IPHYB 201 0418 ©2016 TPC Training

F = PA Where F = Force (in pounds)

D = Distance (movement in inches)

The above formulas can be changed around (by simple algebra)

IPHYB 201 0418 ©2016 TPC Training

IPHYB 201 0418 ©2016 TPC Training

As the FP industry continues to grow and the types and

This standardization is the “glossary of terms” that has

A copy of this standardization is available from

IPHYB 201 0418 ©2016 TPC Training

Directional Control Valves

IPHYB 201 0418 ©2016 TPC Training

Basic Hydraulic System

IPHYB 201 0418 ©2016 TPC Training

• Serve as heat sink

IPHYB 201 0418 ©2016 TPC Training

HI-Lo Pump Control

IPHYB 201 0418 ©2016 TPC Training

• ISO – Means International Standards Organization

• ANSI – Means American National Standards Institute

• Most graphic symbols are shown in ISO 1219-1976

IPHYB 201 0418 ©2016 TPC Training

IPHYB 201 0418 ©2016 TPC Training

Hydraulic Pump Hydraulic Motor

IPHYB 201 0418 ©2016 TPC Training

Hydraulic Power Units

IPHYB 201 0418 ©2016 TPC Training

TheThe Total Training Solution

We will discuss the basic structure

WIPBE 300 1124 © 2021 TPC Training

• When the restriction is removed or decreased –

• Flow tends to increase

• As a consequence, if the flow AND pressure must be