Hydraulic Principles: Service Manual-Electronics

SERVICE MANUAL- ELECTRONICS
HYDRAULIC PRINCIPLES
2005-02 Hydraulic Principles 1 (25)

The manufacturer accepts no liability for any consequences resulting from inappropriate, negligent, or incorrect
operation of the equipment or from misuse of the equipment.
Every effort has been made to ensure the accuracy the contents of this Manual, however the manufactures,
publishers and author accept no liability for any loss, damage or injury caused by any errors in or omissions
from the information contained within this document.
The contents of this Manual are believed to be correct at the time of printing. In the interests of a commitment
to a policy of continuous development and improvement , the manufacturer reserves the right to change the
specification of the products or their performance or the contents of this Manual, without notice.
All rights reserved. No part of this Manual may be stored, reproduced or transmitted in any form or by any
means, electronically or mechanically including photocopying, recording or by any information retrieval system,
without permission in writing from the publisher.
Copyright © HIAB AB February 2005
HIAB AB
SE-824 83
Hudiksvall
Sweden
Telephone +46 (0) 650 91000

FAX: +46 (0) 650 12174
Author: CLM
Date of Issue: February 2005
2 (25) Hydraulic Principles 2005-02

Hydraulic principles
CONTENTS
Safety regulations ............................................................................................................ 4
Energy transfer by oil 5
Transmission of force 5
Hydraulic principles......................................................................................................... 5
Pressure 6
Force 6
Pressure x cylinder area = Force 7
Force = Pressure x cylinder area 7
Displacement 8
Flow 8
Speed 9
Work 10
Power 10
Power (cont.) 12
Hydraulic system 14
Check valve 15
Single-acting cylinder, idling 17
Single-acting cylinder, lifting 18
Single-acting cylinder, lowering 19
Single-acting cylinder, overload 20
Double-acting cylinder, idling 21
Double-acting cylinder, lifting 22
Double-acting cylinder, lowering 23
Double-acting cylinder, overload 24

SAFETY REGULATIONS
Read this for your safety

The HIAB Cargo Handling Equipment can be hazar-
dous if it is not operated correctly. Make sure you
read and understand the general safety information
given in this chapter.
The equipment must be operated in accordance
with the instructions given in the relevant Operator’s
Manual. Using the equipment in any other way or for
any other purpose is prohibited.
Warnings, cautions, notes and tips are given in this
manual. Their meanings are as follows:
WARNING
A Warning is given where wrong action could
result in death or injury to the operator and nearby
personnel. Warnings must always be adhered
to, and given precedence over written and verbal
instructions as well as Cautions.
CAUTION
A Caution is given where wrong action could result
in damage to the equipment. Cautions must always
be adhered to, and given precedence over Notes,
and written and verbal instructions.
NOTE!
A note emphasises an important piece of
information or an instruction.
Warnings and Cautions that apply to the general
operation of the HIAB Cargo Handling
Equipment are given in the relevant Operators
Manual.
TIP!
Tip to make work easy to carry out.
Excluded personnel
Untrained personnel must not operate or carry out
repairs to the Cargo Handling Equipment.

HYDRAULIC PRINCIPLES
Energy transfer by oil
The advantage of using oil to transmit force is in its

unlimited mobility. These qualities are shown in fig.1.
1. It can easily change form.

2. It can be divided up to enable it to work in
several places at once.
3. It can be moved quickly from one point to
another.
4. It will work in any direction or angle.
fig.1 H001-7
Transmission of force
In simplified form as in figs.1&2 the transmission of
force is achieved by putting the oil under pressure
so that the work, such as lifting a load is carried out.
The load is moved when the pressure created by the

force acting on the left-hand piston is higher than
the pressure generated by the load on the right-
hand piston.
If the same force is applied to a smaller piston the fig.2 H002-7

pressure created will be higher and a bigger load
can be moved using the same force.
fig.3 H003-7

Pressure
Pressure is the load per unit of surface.
F
P=
A
It follows that a small diameter piston produces
a higher pressure compared to one with a large
diameter when subjected to the same load.
The example in fig.4 shows pistons having an area
of 500 mm2 and 5000 mm2. When subjected to
a force of 100 N a pressure of 0.2 and 0.02 Mpa
respectively will be generated. fig.4 H004-7
Force
Inversely, pressure against a surface will produce
a force.
F= p x A
Assuming as in (fig.4) a force of 100 N on the

small piston, thereby producing a pressure of 0.2
Mpa and letting this pressure act on the larger
piston having a surface 10 times larger, a force of
1000 N is produced, this corresponds to a weight
of 100 kgs. (fig.5)
This demonstrates the force is in direct proportion

to the pressure and the area. fig.5 H005-7

fig.6 H006-7
Pressure x cylinder area = Force

If this theory is applied to a practical crane application fig.6 it can be seen that a certain oil pressure can lift or,
stop and hold a load.
fig.7 H007-7
Force = Pressure x cylinder area

The force exerted by a crane inner boom (fig.7) depends on oil pressure and piston area. Nothing else. For
example increasing a trucks engine speed will not affect the pressure in the cylinder.

fig.8 H008-7
Displacement
Displacement is the same thing as swept volume.
The swept volume is calculated by multiplying the piston area by the stroke. (fig.8)
In a hydraulic pump the displacement is taken to be the swept volume per revolution, which is the volume of
oil that the pump moves in one revolution of the shaft.
fig.9 H009-7
Flow
Flow is the volume passing per unit time. (fig.9)
If the displacement is two litres per stroke, and the pump does 10 strokes per min, the flow will be 2 x 10 = 20
Litres/min.
A hydraulic pump with a displacement of 53 cm3 per rev, and running at 1000 rpm, delivers 53,000 cm3 per min
or 53 litres/min.

fig.10 H010-7
Speed
At a given flow to a cylinder we get a particular speed. The speed will be inversely proportional to the piston
area. (fig.10)
flow
Speed=
area
If we open the throttle of a truck and increase engine/pump speed, the flow will increase and we achieve more
speed.
fig.11 H011-7

Work
The work of a crane requires the lifting of a wieght over a certain distance (s =distance).
To achieve this it is necessary to lift with a certain force (f = force) using these factors we use the formula,
Work = force x distance (fig. 11).
As shown in fig.7 hydraulic force is equal to pressure x area, F = p x A.
Combining these two formulas results in W = p x A x s. It is also known that displacement is equal to area x
distance D = A x s. This leads to the conclusion that work is equal displacement x pressure. W = D x p.
From this it can be seen that the factors that do the work are the displacement of the pump and the working
pressure. The speed that results will depend on how fast we pump, as speed is dependent on the flow.
fig.12 H012-7
Power
A job can be done quickly or slowly. If done quickly, more power is required as shown in fig.12.

fig.13 H013-7
fig.14 H014-7

Power (cont.)
Here follows a more complete definition:
W
P=
Power (P) is most simply defined as work t
(W) per unit time (t).
Since work (W) is force (F) times Fxs

distance (s) we get, after combining P=
t
the formulas, the expression
s
Everyone knows that speed (v) is V=
distance (s) divided by time (t), i.e. t
We are familiar with kilometres

per hour. If we substitute v for s/t
we get the formula: power (P) is
equal to force (F) times speed (v) P= F x V
Assume that the horse lifts a weight of 75 kg through a height of 1 metre in a time of 1 second. The horse will
then be lifting with a force of 75 kgf, which is equivalent to 736 N, and a speed of 1 m/s.
If we substitute these figures in the formula we find that the power developed by the horse was 736 watts, or, if
we employ an older unit, 1 horse-power (hp).
If the weight weighed 100 kg we see at once that at the same speed the horse will develop a power of 1,000
watts (W) or 1 kilowatt (kW). Doubling this speed to 2 rn/s would raise the power to 2 kW.
Power is thus dependent on time.
The power formula for a crane is

p = Qxp
60
Flow is given in litres/mm, pressure
in MPa. Power is received in kW.
fig.15 H015-7

fig.16 H016-7
Power (cont.)
A derivation of the formula leads to the following:
The crane is lifting with a force F and a speed V.

We already know these three formulas:
Power is equal to force times speed. P= F x V Thus power is dependent on time. This means that the
power will vary with the speed (RPM).
Force is equal to pressure times area.

F= p x A
Speed is equal to flow divided by area. Q
v=
A
In order to arrive at a power formula that will apply in hydraulics we combine these three expressions.
pxAxQ
The result is P=
A
Cancelling out A leaves us with the basic formula: P=Qxp
Power is equal to flow times pressure. Using the standard units of these formulas, flow is measured in cubic
metres per second.
In our pump world, however, we are concerned with cubic decimetres, which is the same thing as litres, and
with minutes.
To be able to calculate, we must first convert to the right units. A cubic metre is the same as a thousand cubic
decimeters.

Power (cont.)
A second is the same as one-sixtieth of a minute. If we substitute accordingly in the basic formula, we get a
thousand above the line and sixty below it.
1000 x Q x p
P= watt
60
“Kilo” means a thousand, so that the final formula will be:
Qxp
P= kW (kilowatt)
60
The pressure p is calculated in MPa.
We see, then, that the power increases if the flow increases. The flow is directly dependent on the speed and
the displacement. The power also increases if the pressure increases.
Hydraulic system
A hydraulic system, as used on a loader crane, is built up by:
A pump (A) to move the oil into the cylinder (B), which moves the boom.
A tank (C) to store the oil.
(D) and (E) are check valves, which stop oil flow in one direction and allow free flow in the opposite direction.
(Fig 17).
fig.17 H017-7

Hydraulic system (cont.)
When filling the pump with oil from the oil tank, the check valve under the tank opens and lets the oil pass.
The check valve on the cylinder side is closed because of lower pressure on the pump side.
fig. 18 H018-7
Check valve
In the left-hand picture (fig.19), the ball-
type check valve opens when the oil below
the ball (1) is sufficient under pressured to
depress the spring (2). The ball is lifted from
its seat (3) allows the oil to pass.
In the right hand picture, the oil pressure

above the ball has decreased and the ball
has been pushed back to its starting position
(4) by the spring and the oil pressure below
the ball. The connection is closed.
fig.19 H019-7

Hydraulic system (cont.)
When exerting a downward movement on the pump (fig.20), the oil pressure in the hydraulic circuit line increases.
The check valve (2) will close and prevent the oil returning to the tank.
The check valve (3) will be opened by the increased pressure above the ball and allow oil to flow to the cylinder.
The increased oil volume in the cylinder will make the piston move and the loader crane boom will be pushed
upwards.
fig.20 H020-7
In fig.21, the area of the pump piston is 1 cm2 and the one of the cylinder piston is 50 cm2.
When moving the pump piston down 5 cm (fig.22), an oil volume of 5 cm3 will be forced over to the cylinder
piston.
Since the cylinder piston has an area of 50 cm2, the volume of 5 cm3 can only raise this piston by 1 mm..
fig.21 H021-7 fig.22 H022-7

Single-acting cylinder, idling
fig.23 H023-7
In order to make the oil circulate in the hydraulic system and to direct it to the functions to move, some more
components have to be added to the system. (fig.23)
(F) is a pump giving a continuous flow of oil. (E) is a relief valve, which will open, if the oil pressure exceeds
the pre-set value, and allow excess oil to return to the tank. (G) is a control valve which starts, stops and
directs the oil flow in the system. In this picture, the valve spool allows the oil to go back to the tank. It is said
to be in neutral position.
Fig.24 shows how the previous figure looks in a hydraulic diagram. The 3-position valve is in neutral position.
Oil at a low pressure is circulated through the control valve and back to tank without pressure.
fig.24 H024-7

Single-acting cylinder, lifting
fig.25 H025-7
In this position, the valve spool closes the return line to the tank and opens the line to the underside of the
cylinder piston. The oil will press the piston upwards and thus obtain a movement from the cylinder.
Fig.26 shows that the valve spool has been moved to the right, making it possible for pressurised oil to flow
from the pump up to the cylinder. The tank port is closed.
fig.26 H026-7

Single-acting cylinder, lowering
fig.27 H027-7
With the valve slide in this position, the oil is pressed out of the cylinder by the weight of the boom and the load.
The oil is directed back to the tank.(fig.27)
Fig.28 shows that the valve spool has been moved to the left making it possible for oil to return from cylinder to
tank. You will note that also the pump flow is directed to the tank port inside the valve.
fig.28 H028-7

Single-acting cylinder, overload
fig.29 H029-7
The weight of the boom and the load is so big that the pressure created in the hydraulic line exceeds the pre-
set value of the relief valve. The relief valve will then open and allow the oil to escape to the tank instead of
creating excessive pressure in the system (fig.29)
Fig.30 shows the valve spool is moved to lift position but the load is too high. Oil from the pump is instead
directed through the main relief valve to the left.
fig.30 H030-7

Double-acting cylinder, idling
fig.31 H031-7
We have switched to a double-acting cylinder and increased the number of valve ports to 4. The valve is in
neutral position and the pump circulates oil through the valve. Fig.31 shows in more detail how the pump port
is connected to the return port in neutral position. The cylinder ports are closed.
To the left in fig.32 a cross-section of a real control valve is shown. The top part contains relief valves not
shown in the diagram.
fig.32 H032-7

Double-acting cylinder, lifting
fig.33 H033-7
Pulling the valve spool connects the pump channel with the cylinder channel. Pressurised oil (red) is pumped
to the cylinder bottom part. Simultaneously, the spool has opened the passage between return line and tank
line making it possible for return oil (blue) to re-circulate in the system (fig.33).
This is the same process in the hydraulic diagram (fig.34). The spool has been moved to the left and oil flows
crosswise up to the cylinder and out.
fig.34 H034-7

Double-acting cylinder, lowering
fig.35 H035-7
Here (fig.35) the valve spool is moved in the opposite direction opening channels for lowering the load.
In contrast to the single-acting cylinder, where load and dead weight pressed the piston back, here return
movement is effected by pressurised oil. The greatest advantage is the pulling force in the return movement.
The hydraulic diagram (fig.36) shows the spool moved to the right, giving straight channels from pump to the
cylinder top part and return from the cylinder bottom to tank. The advantage of a pulling cylinder is significant.
fig.36 H036-7

Double-acting cylinder, overload
fig.37 H037-7
Shown here (fig.37) is an overload situation where pump pressure is not capable of lifting the load. The main
relief valve E opens and pump oil circulates directly to the tank. The same situation is shown in the diagram
(fig.38) The control valve is actuated to lift the load, however, due to high resistance the main relief valve
opens and allows the oil directly to the tank.
fig.38 H038-7

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SERVICE MANUAL- ELECTRONICS

2005-02 Hydraulic Principles 1 (25)

Copyright © HIAB AB February 2005

Telephone +46 (0) 650 91000

Date of Issue: February 2005

2 (25) Hydraulic Principles 2005-02

2005-02 Hydraulic Principles 3 (25)

Read this for your safety

4 (25) Hydraulic Principles 2005-02

Energy transfer by oil

The advantage of using oil to transmit force is in its

1. It can easily change form.

The load is moved when the pressure created by the

If the same force is applied to a smaller piston the ﬁg.2 H002-7

2005-02 Hydraulic Principles 5 (25)

Assuming as in (fig.4) a force of 100 N on the

This demonstrates the force is in direct proportion

6 (25) Hydraulic Principles 2005-02

Pressure x cylinder area = Force

Force = Pressure x cylinder area

2005-02 Hydraulic Principles 7 (25)

8 (25) Hydraulic Principles 2005-02

2005-02 Hydraulic Principles 9 (25)

As shown in fig.7 hydraulic force is equal to pressure x area, F = p x A.

10 (25) Hydraulic Principles 2005-02

2005-02 Hydraulic Principles 11 (25)

Since work (W) is force (F) times Fxs

We are familiar with kilometres

Power is thus dependent on time.

The power formula for a crane is

12 (25) Hydraulic Principles 2005-02

A derivation of the formula leads to the following:

The crane is lifting with a force F and a speed V.

Force is equal to pressure times area.

2005-02 Hydraulic Principles 13 (25)

14 (25) Hydraulic Principles 2005-02

Hydraulic system (cont.)

In the right hand picture, the oil pressure

2005-02 Hydraulic Principles 15 (25)

Hydraulic system (cont.)

ﬁg.21 H021-7 ﬁg.22 H022-7

16 (25) Hydraulic Principles 2005-02

Single-acting cylinder, idling

2005-02 Hydraulic Principles 17 (25)

Single-acting cylinder, lifting

18 (25) Hydraulic Principles 2005-02

Single-acting cylinder, lowering

2005-02 Hydraulic Principles 19 (25)

Single-acting cylinder, overload

20 (25) Hydraulic Principles 2005-02

Double-acting cylinder, idling

2005-02 Hydraulic Principles 21 (25)

Double-acting cylinder, lifting

22 (25) Hydraulic Principles 2005-02

Double-acting cylinder, lowering

2005-02 Hydraulic Principles 23 (25)

Double-acting cylinder, overload

24 (25) Hydraulic Principles 2005-02

This page is intentionally