Unit 2: Hydraulic Principles

UNIT 2
Hydraulic Principles

Introduction:
Hydraulic systems are extremely important to the operation of heavy
equipment. Basic hydraulic principles are used when designing
hydraulic implement systems, steering systems, brake systems, and
power train systems. An understanding of the basic hydraulic
principles must be accomplished before continuing into machine
systems.
Unit Objectives:
At the completion of this unit, the student will be able to:
1. Demonstrate an understanding of the basic hydraulic principles.
 Lesson 1: Hydraulic Principles
Lesson 1: Hydraulic Principles

Introduction:
We all know that hydraulic principles are demonstrated when using a
liquid under controlled pressure to do work. There are laws that
state the action of liquids under conditions of changing flows and
increasing and decreasing pressures. The student must be able to
state and understand these laws to become successful as a heavy
equipment technician.
Objectives:
At the 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.
Unit 2 2-1-2 Hydraulic Fundamentals
Lesson 1

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.

Fig. 2.1.1 Liquid Containers

Liquids Conform to Shape

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.

INCOMPRESSIBLE 50 lbs.
WEIGHT

FORCE

LIQUID

Fig. 2.1.2 Liquid Under Pressure

Practically Incompressible

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."
Unit 2 2-1-3 Hydraulic Fundamentals
Lesson 1

50 lbs.
WEIGHT
FORCE

GAS

Fig. 2.1.3 Gas is Compressible

Gas is compressible
Gas is compressible. When gas is compressed, it takes up less space
and it’s 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.

1130 lbs

500 lbs

40 psi

3 in. radius 2 in. radius

Fig. 2.1.4 Hydraulics Doing Work

Hydraulics Doing Work

According to Pascal’s 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 500 pound force acting upon a piston with a
2 in. radius creates a pressure of approximately 40 pounds per square
inch (psi) in a confined liquid. The same 40 psi acting upon a piston
with a 3 in. radius supports a 1130 pound weight.
NOTE: At this time, perform Lab 2.1.1.
Unit 2 2-1-4 Hydraulic Fundamentals
Lesson 1

Force = Pressure x Area

F
Pressure = Force ÷ Area

Area = Force ÷ Pressure P A

Fig. 2.1.5 Pascal's Law

A simple formula allows us to determine the Force, the Pressure, and

the Area when two of the three are known. Understanding these
terms is necessary to understand the fundamentals of hydraulics.
Force is the push or pull acting upon a body. Force is usually
expressed in pounds (lbs.) or Newtons (N). Force is equal to the
pressure times the area (F = P x A).
Pressure is the force of a fluid per unit area, usually expressed in
pounds per square inch (psi) or kilopascal (kPa).
Area is a measurement of surface space. The area is calculated in
square inches or square centimeters. Sometime the surface area is
referred to as effective area. The effective area is the total surface
that is used to create a force in the desired direction.
The surface area of a circle is calculated with the formula:
Area = Pi (3.14) times radius-squared
If the radius of the circle is 2 inches, Figure 2.1.4,
A = Pi x r square
A = 3.14 x (2" x 2")
A = 12.5 sq. in.

With the knowledge of the surface area, it is possible to determine

how much system pressure it will take to lift a given weight.
Pressure is the force per unit and is expressed in pounds per square
inch (psi) or kilopascal (kPa).
If a force of 500 pounds was acting upon an area of 12.5 sq. in., the
pressure created would be 40 psi.
The pressure is calculated with the formula:
Pressure = Force divided by Area
P = 500 lbs./12.5 sq. in.
P = 40 psi
Unit 2 2-1-5 Hydraulic Fundamentals
Lesson 1

Solving for the large piston we find:

Pressure x Area = Force

40 x (3x3) x 3.14 = Force.
40 x 28.26 = 1130 lbs.

?
FROM
PUMP

? ?
? 100 lbs
FORCE 50 lbs

FORCE

FORCE
FORCE
5 sq. in. 1 sq. in. 3 sq. in. ?

Fig. 2.1.6 Mechanical Advantage

Mechanical Advantage
Figure 2.1.6 demonstrates how liquid in a hydraulic system provides a
mechanical advantage.
Since all cylinders are connected, all areas must be filled before the
system pressurizes.
Use the hydraulic formula and calculate the items in question.
Cylinders are counted from left to right.
When calculating the pressure in the system, we use the two known
values of the second cylinder from the left. The formula used is
"pressure equals force divided by area."
Pressure = Force Pressure = 50 lbs Pressure = 50 psi
Area 1 sq. in.
Now that we know the pressure in the system, we can calculate the
force of the load for cylinders one and three and the piston area for
container four.
Calculate cylinders one and three loads using the formula, force
equals pressure times area (Force = Pressure x Area).
Calculate cylinder four piston area using the formula, area equals
force divided by pressure (Area = Force / Pressure).
INSTRUCTOR NOTE: The correct answers are: cylinder one
load is 250 lbs, cylinder three load is 150 lbs and cylinder four
piston area is 2 sq. in.
NOTE: At this time, perform Lab 2.1.2.
Unit 2 2-1-6 Hydraulic Fundamentals
Lesson 1

60 60

0 120 0 120

FLOW
1 GPM

Fig. 2.1.7 No Restriction

ORIFICE EFFECT
When discussing hydraulics, it is a common practice to use the term
"pump pressure." However, the pump does not produce pressure.
The pump produces flow. Pressure is produced when flow is
restricted.
In Figures 2.1.7 and 2.1.8, the pump flow through the pipe is 1 gpm.
In Figure 2.1.7, there is no restriction to the flow through the pipe.
Therefore, the pressure reading is zero for both gauges.

60 60
30 90

0 120 0 120

FLOW
1 GPM

Fig. 2.1.8 Orifice Offers Restriction

Orifice Offers Restriction

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 figure 2.1.8, there is an orifice in the pipe between the two gauges.
The gauge up stream of the orifice shows that a pressure of 207 kPa
(30 psi) is needed to send a flow of 1 gpm through the orifice. There
is no restriction to flow after the orifice. The gauge down stream of
the orifice shows 0 pressure.
Unit 2 2-1-7 Hydraulic Fundamentals
Lesson 1

60 60

30 90 30 90

0 120 0 120

FROM
PUMP

60 60

30 90 30 90

0 120 0 120

FROM
PUMP

Fig. 2.1.9 Blocked Flow

Oil Flow to Tank Blocked

When the end of either pipe is plugged, oil flow to the tank is
blocked.
The positive displacement pump continues pumping at 1 gpm 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 Pascal’s 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.
The pressure will increase until the pump flow is diverted from the
pipe to another circuit or to the tank. This is usually done with a
relief valve to protect the hydraulic system.
If total pump flow was not diverted from the pipe, pressure in the
pipe would continue to rise and cause an eruption of the circuit.
Unit 2 2-1-8 Hydraulic Fundamentals
Lesson 1

60 60 60

30 90 30 90 30 90
PSI PSI
PSI
0 120 0 120 0 120

FLOW
1 GPM

60 60 60

30 90 30 90 30 90

PSI PSI PSI

0 120 0 120 0 120

FLOW
1 GPM

207 kPa (30 psi) 207 kPa (30 psi) 207 kPa (30 psi)

Fig. 2.1.10 Restrictions in Series

Restrictions In Series
There are two basic types of circuits, series and parallel.
In Figure 2.1.10, a pressure of 620 kPa (90 psi) is required to send 1
gpm 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.
NOTE: At this time, perform Lab 2-1-3.

CIRCUIT
ONE
207 kPa (30 PSI)

CIRCUIT
TWO
414 kPa (60 PSI)
FROM
PUMP

CIRCUIT
THREE
620 kPa (90 PSI)

Fig. 2.1.11 Restrictions In Parallel

Restrictions In Parallel
In a system with parallel circuits, pump oil follows the path of least
resistance. In figure 2.1.11, the pump supplies oil to three parallel
circuits. Circuit three has the lowest priority and circuit one has the
highest priority.
Unit 2 2-1-9 Hydraulic Fundamentals
Lesson 1

When the pump oil flow fills the passage to the left of the three
valves, pump oil pressure increases to 207 kPa (30 psi). 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 414 kPa (60 psi) 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 620 kPa (90 psi) 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.

NOTE: At this time, perform Lab 2.1.4.

Unit 2 -1- Hydraulic Fundamenal
Instructor Copy Lab 2.1.1

Instructor Copy Lab 2.1.1

Name________________________
FIRST IN-LINE SECOND IN-LINE
PRESSURE PRESSURE
GAUGE GAUGE

SYSTEM
PRESSURE
GAUGE

SYSTEM
RELIEF
2
VALVE
BACKUP
RELIEF
VALVE 1 1

PUMP

TANK

Fig. 2.1.12

LAB 2.1.1: PASCAL’S LAW

Purpose:
The purpose is to demonstrate Pascal's law. When lines are connected and filled with blocked oil, the
pressure is the same throughout the circuit
Materials Needed:
1. Basic Hydraulic Training Unit
Procedure:
1. Use the shortest hose possible when making hose connections.
2. Connect a hose from the pump output to the No. 1 port on the system relief valve.
3. Connect a hose from the opposite No. 1 port on the system relief valve to the pressure
manifold.
4. Connect a hose from the No. 2 port on the system relief valve to the return manifold.
5. Connect a hose from the pressure manifold to the left side first in-line pressure gauge port.
6. Connect a hose from the right side first in-line pressure gauge port to the left side second in-
line pressure gauge port.
7. Turn the system pressure relief valve adjustment screw counter-clockwise until it stops.
Then turn the adjustment screw clockwise two turns.
8. Turn ON the training unit and wait 10 seconds.
9. Read the pressures on the system pressure gauge and the two in-line gauges. Record each
pressures in the appropriate space below.
System pressure gauge _____________ Second in-line pressure gauge _______

First in-line pressure gauge _________

10. Turn OFF the training unit and disconnect the hoses.
Unit 2 -1- Hydraulic Fundamenals
Student Copy Lab 2.1.1

Name________________________

Student Copy Lab 2.1.1

FIRST IN-LINE SECOND IN-LINE
PRESSURE PRESSURE
GAUGE GAUGE

SYSTEM
PRESSURE
GAUGE

SYSTEM
RELIEF
2
VALVE
BACKUP
RELIEF
VALVE 1 1

PUMP

TANK

Fig. 2.1.12

LAB 2.1.1: PASCAL’S LAW

Purpose:
The purpose is to demonstrate Pascal's law. When lines are connected and filled with blocked oil, the
pressure is the same throughout the circuit
Materials Needed:
1. Basic Hydraulic Training Unit
Procedure:
1. Use the shortest hose possible when making hose connections.
2. Connect a hose from the pump output to the No. 1 port on the system relief valve.
3. Connect a hose from the opposite No. 1 port on the system relief valve to the pressure
manifold.
4. Connect a hose from the No. 2 port on the system relief valve to the return manifold.
5. Connect a hose from the pressure manifold to the left side first in-line pressure gauge port.
6. Connect a hose from the right side first in-line pressure gauge port to the left side second in-
line pressure gauge port.
7. Turn the system pressure relief valve adjustment screw counter-clockwise until it stops.
Then turn the adjustment screw clockwise two turns.
8. Turn ON the training unit and wait 10 seconds.
9. Read the pressures on the system pressure gauge and the two in-line gauges. Record each
pressures in the appropriate space below.

System pressure gauge _____________ Second in-line pressure gauge _______

First in-line pressure gauge _________

10. Turn OFF the training unit and disconnect the hoses.
Unit 2 -1- Hydraulic Fundamenals
Instructor Copy Lab 2.1.2

Instructor Copy Lab 2.1.2

Name_______________________
NUT AND
WASHERS
ROD END
SYSTEM
RELIEF 2
PRESSURE SPRING
VALVE
GAUGE
WASHER

1 1

SYSTEM
RELIEF
VALVE 2
CYLINDER
1-1/16" BORE
BACKUP
RELIEF
VALVE 1 1

PUMP

TANK

Fig. 2.1.13

LAB 2.1.2: BASIC HYDRAULIC PRINCIPLES

Purpose:
The purpose is to demonstrate a basic hydraulic principle, force = pressure x area.
Materials Needed:
1. Basic Hydraulic Training Unit
Procedure:
In this lab, a compression spring will be used to simulate a load on a cylinder. When the cylinder rod
is retracted, the rod compresses the spring and produces a load on the cylinder.
Before starting the lab, try compressing the spring with your fingers. This will give you some idea of
the amount of force that can be generated by a small cylinder.
1. Use the shortest hose possible when making hose connections.
2. Connect a hose from the pump output to the No. 1 port on the system relief valve.
3. Connect a hose from the the No. 2 port on the system relief valve to the return manifold.
4. Connect a hose from the opposite No. 1 port on the system relief valve tee to the pressure
manifold.
5. Turn ON the training unit.
6. Adjust the system pressure relief valve until the pressure gauge reads 5856 kPa (850 psi).
7. Turn OFF the training unit.
8. Connect a hose from the pressure manifold to the No. 1 port on the rod end relief valve.
9. Connect a hose from the opposite No. 1 port on the rod end relief valve to the rod end port on the
1-1/16" bore cylinder.
10. Connect a hose from the No. 2 port on the rod end relief valve to the return manifold.
11. Connect a hose from the head end of the 1-1/16" bore cylinder to the return manifold.
Unit 2 -2- Hydraulic Fundamenals
Instructor Copy Lab 2.1.2

12. Extend the rod on the cylinder with the 1-1/16" bore. (To extend the rod, disconnect both hoses
from the cylinder, switch the hoses by connecting the supply hose to the head end port (bottom)
and connecting the return hose to the rod end port (top). Turn ON the training unit and allow the
cylinder rod to become fully extended. Turn OFF the training unit.) Reconnect hoses as in Steps 9
and 11.
13. Attach the load spring assembly to the rod of the hydraulic cylinder as shown in Figure 2.1.13.
14. Turn the rod end pressure relief valve clockwise until it stops.
15. Turn ON the training unit.
16. Turn the rod end pressure relief valve counter-clockwise until it stops.
17. Measure the length of the spring.
18. Record the spring measurement and the gauge pressure in the chart below.
19. Turn the rod end pressure relief valve clockwise until the gauge pressure reads 1380 kPa (200 psi).
20. Measure the length of the spring.
21. Record the spring measurement and the gauge pressure in the chart below.
22. Turn the rod end pressure relief valve clockwise until the gauge pressure reads 2756 kPa (400 psi).
Repeat Steps 17 and 18.
23. Turn the rod end pressure relief valve clockwise until the gauge pressure reads 4134 kPa (600 psi).
Repeat Steps 17 and 18.
24. Turn the rod end pressure relief valve clockwise until the gauge pressure reads 5510 kPa (800 psi).
Repeat Steps 17 and 18.

Pressure Spring Length Change In Spring

kPa (psi) cm (inches) Length cm (inches)
689 kpa (100 psi) 11.1 cm (4.4) 0.0 cm (0.0)
1378 kPa (200 psi) 10.6 cm (4.2) .508 cm (.2)
2756 kPa (400 psi) 9.6 cm (3.8) 1.016 cm (.4)
4134 kPa (600 psi) 8.6 cm (3.4) 1.016 cm (.4)
5512 kPa (800 psi) 7.6 cm (3.0) 1.016 cm (.4)

The above chart readings may differ slightly from the readings on your training unit. The changes
in the spring length should be constant.
25. Turn OFF the training unit and disconnect the hoses.
Unit 2 -1- Hydraulic Fundamenals
Student Copy Lab 2.1.2

Name_______________________

Student Copy Lab 2.1.2

NUT AND
WASHERS
ROD END
SYSTEM
RELIEF 2
PRESSURE SPRING
VALVE
GAUGE
WASHER

1 1

SYSTEM
RELIEF
VALVE 2
CYLINDER
1-1/16" BORE
BACKUP
RELIEF
VALVE 1 1

PUMP

TANK

Fig. 2.1.13

LAB 2.1.2: BASIC HYDRAULIC PRINCIPLES

Purpose:
The purpose is to demonstrate a basic hydraulic principle, force = pressure x area.
Materials Needed:
1. Basic Hydraulic Training Unit
Procedure:
In this lab, a compression spring will be used to simulate a load on a cylinder. When the cylinder rod
is retracted, the rod compresses the spring and produces a load on the cylinder.
Before starting the lab, try compressing the spring with your fingers. This will give you some idea of
the amount of force that can be generated by a small cylinder.
1. Use the shortest hose possible when making hose connections.
2. Connect a hose from the pump output to the No. 1 port on the system relief valve.
3. Connect a hose from the the No. 2 port on the system relief valve to the return manifold.
4. Connect a hose from the opposite No. 1 port on the system relief valve tee to the pressure
manifold.
5. Turn ON the training unit.
6. Adjust the system pressure relief valve until the pressure gauge reads 5856 kPa (850 psi).
7. Turn OFF the training unit.
8. Connect a hose from the pressure manifold to the No. 1 port on the rod end relief valve.
9. Connect a hose from the opposite No. 1 port on the rod end relief valve to the rod end port on the
1-1/16" bore cylinder.
10. Connect a hose from the No. 2 port on the rod end relief valve to the return manifold.
11. Connect a hose from the head end of the 1-1/16" bore cylinder to the return manifold.
Unit 2 -2- Hydraulic Fundamenals
Student Copy Lab 2.1.2

12. Extend the rod on the cylinder with the 1-1/16" bore. (To extend the rod, disconnect both hoses
from the cylinder, switch the hoses by connecting the supply hose to the head end port (bottom)
and connecting the return hose to the rod end port (top). Turn ON the training unit and allow the
cylinder rod to become fully extended. Turn OFF the training unit.) Reconnect hoses as in Steps 9
and 11.
13. Attach the load spring assembly to the rod of the hydraulic cylinder as shown in Figure 2.1.13.
14. Turn the rod end pressure relief valve clockwise until it stops.
15. Turn ON the training unit.
16. Turn the rod end pressure relief valve counter-clockwise until it stops.
17. Measure the length of the spring.
18. Record the spring measurement and the gauge pressure in the chart below.
19. Turn the rod end pressure relief valve clockwise until the gauge pressure reads 1380 kPa (200 psi).
20. Measure the length of the spring.
21. Record the spring measurement and the gauge pressure in the chart below.
22. Turn the rod end pressure relief valve clockwise until the gauge pressure reads 2756 kPa (400 psi).
Repeat Steps 17 and 18.
23. Turn the rod end pressure relief valve clockwise until the gauge pressure reads 4134 kPa (600 psi).
Repeat Steps 17 and 18.
24. Turn the rod end pressure relief valve clockwise until the gauge pressure reads 5510 kPa (800 psi).
Repeat Steps 17 and 18.

Pressure Spring Length Change In Spring

kPa (psi) cm (inches) Length cm (inches)
689 kpa (100 psi)
1378 kPa (200 psi)
2756 kPa (400 psi)
4134 kPa (600 psi)
5512 kPa (800 psi)

The above chart readings may differ slightly from the readings on your training unit. The changes
in the spring length should be constant.
25. Turn OFF the training unit and disconnect the hoses.
Unit 2 -1- Hydraulic Fundamenals
Instructor Copy Lab 2.1.3

Name______________________

Instructor Copy Lab 2.1.3

SYSTEM
PRESSURE
GAUGE

T - FITTING T - FITTING
FLOW
METER 1

SYSTEM COUPLING
RELIEF 2
VALVE
BACKUP
RELIEF
VALVE 1 1

PUMP IN-LINE
PRESSURE
GAUGE
COUPLING

TANK

FLOW
LAB 3 METER 2

Fig. 2.1.15
LAB 2.1.3: SYSTEM PRESSURE INCREASE

Purpose:
The purpose of this lab is to demonstrate how friction and restrictions in the hoses and fittings causes
the system pressure to increase.
Materials Needed:
1. Basic Hydraulic Training Unit
Procedure:
1. Construct the circuit in Figure 2.1.15.
2. Adjust system pressure to 5860 kPa (850 psi). (To adjust the system pressure, disconnect the hose
from the system relief valve to the pressure manifold. Turn ON the training unit and adjust the
system pressure relief valve. Turn OFF the training unit and reconnect the hose from the system
relief valve to the pressure manifold.)
3. Turn ON the training unit.
4. Read the pressure gauges and flow meters. Record the data in the space provided below Step 6.
5. Turn OFF the training unit.
6. Subtract the in-line pressure reading from the system pressure reading. Record this value in the line
labeled "Pressure drop." The amount of pressure drop will depend on the hoses used and the oil
temperature.
System pressure gauge reading 1034 kPa - 2068 kPa(150 psi - 300 psi)
Flow rate on flow meter 1 .9 gal
Flow rate on flow meter 2 .9 gal
In-line pressure gauge reading 345 kPa - 689 kPa (50 psi - 100 psi)
Pressure drop 689 kPa - 1378 kPa (100 psi - 200 psi)
8. What caused the difference in pressure between the system pressure gauge and the in-line pressure
gauge?The difference is caused by the resistance to oil flow through the hoses and fittings.
Unit 2 -1- Hydraulic Fundamenals
Student Copy Lab 2.1.3

Name______________________

Student Copy Lab 2.1.3

SYSTEM
PRESSURE
GAUGE

T - FITTING T - FITTING
FLOW
METER 1

SYSTEM COUPLING
RELIEF 2
VALVE
BACKUP
RELIEF
VALVE 1 1

PUMP IN-LINE
PRESSURE
GAUGE
COUPLING

TANK

FLOW
LAB 3 METER 2

Fig. 2.1.15

LAB 2.1.3: SYSTEM PRESSURE INCREASE

Purpose:
The purpose of this lab is to demonstrate how friction and restrictions in the hoses and fittings causes
the system pressure to increase.
Materials Needed:
1. Basic Hydraulic Training Unit
Procedure:
1. Construct the circuit in Figure 2.1.15.
2. Adjust system pressure to 5860 kPa (850 psi). (To adjust the system pressure, disconnect the hose
from the system relief valve to the pressure manifold. Turn ON the training unit and adjust the
system pressure relief valve. Turn OFF the training unit and reconnect the hose from the system
relief valve to the pressure manifold.)
3. Turn ON the training unit.
4. Read the pressure gauges and flow meters. Record the data in the space provided below Step 6.
5. Turn OFF the training unit.
6. Subtract the in-line pressure reading from the system pressure reading. Record this value in the line
labeled "Pressure drop." The amount of pressure drop will depend on the hoses used and the oil
temperature.
System pressure gauge reading __________________
Flow rate on flow meter 1 _______________________
Flow rate on flow meter 2 _______________________
In-line pressure gauge reading ___________________
Pressure required to send oil flow through hoses and fittings ________________.
8. What caused the difference in pressure between the system pressure gauge and the in-line pressure
gauge? ________________________________________________________________________
Unit 2 -1- Hydraulic Fundamenals
Instructor Copy Lab 2.1.4

Instructor Copy Lab 2.1.4

Name_____________________

PRESSURE
GAUGE

CIRCUIT 1 CIRCUIT 2
RELIEF RELIEF
VALVE 2 VALVE 2

BACKUP
RELIEF
VALVE T - FITTING 1 1 1 1

PUMP
FLOW METER 1

FLOW METER 2

TANK

LAB 4

Fig. 2.1.16

LAB 2.1.4: RESISTANCE IN PARALLEL

Purpose:
The purpose is to demonstrate resistance in a parallel circuit.
Materials Needed:
1. Basic Hydraulic Training Unit
Procedure:
1. Construct the circuit in Figure 2.1.16.
2. Turn the adjustment on both relief valves fully counter-clockwise.
3. Disconnect the hose between flow meter 2 and the drain port.
4. Turn ON the training unit.
5. Turn the adjustment on circuit 1 relief valve clockwise until the pressure gauge reads
1378 kPa (200 psi).
6. Turn OFF the training unit.
7. Connect the hose between flow meter 2 and the drain port and disconnect the hose between flow
meter 1 and the drain port.
8. Turn ON the training unit.
9. Turn the adjustment on circuit 2 relief valve clockwise until the pressure gauge reads
2756 kPa (400 psi).
10. Turn OFF the training unit.
11. Connect the hose between flow meter 1 and the drain port.
12. Turn ON the training unit.
Unit 2 -2- Hydraulic Fundamenals
Instructor Copy Lab 2.1.4

13. Read the pressure gauge and flow meters. Record the readings in the spaces below.
Pressure 200 Flow Meter 1 .9 Flow Meter 2 0
14. Turn the adjustment on circuit 1 relief valve clockwise until the pressure gauge reads
approximately 2756 kPa (400 psi).
15. Read the pressure gauge and flow meters. Record the readings in the spaces below.
Pressure 400 Flow Meter 1 .45 Flow Meter 2 .45
16. Turn the adjustment on circuit 1 relief valve clockwise one turn.
17. Read the pressure gauge and flow meters. Record the readings in the spaces below.
Pressure 400 Flow Meter 1 0 Flow Meter 2 .9
Explain the gauge and flow meter readings in 13 above.
The system pressure of 1378 kPa (200 psi) is too low to open circuit 2 relief valve. The total
pump flow goes through circuit 1 relief valve and flow meter 1.
Explain the gauge and flow meter readings in 15 above.
The system pressure of 2756 kPa (400 psi) opens both circuit 1 and circuit 2 relief valves. The
pump flow takes parallel paths through both relief valves and both flow meters.
Explain the gauge and flow meter readings in 17 above.
The pressure needed to open circuit 1 relief valve exceeds the pressure needed to open circuit 2
relief valve. The pump flow takes the path of least resistance through circuit 2 relief valve and
flow meter 2.
Unit 2 -1- Hydraulic Fundamenals
Student Copy Lab 2.1.4

Name______________________

Student Copy Lab 2.1.4

PRESSURE
GAUGE

CIRCUIT 1 CIRCUIT 2
RELIEF RELIEF
VALVE 2 VALVE 2

BACKUP
RELIEF
VALVE T - FITTING 1 1 1 1

PUMP
FLOW METER 1

FLOW METER 2

TANK

LAB 4

Fig. 2.1.16

LAB 2.1.4: RESISTANCE IN PARALLEL

Purpose:
The purpose is to demonstrate resistance in a parallel circuit.
Materials Needed:
1. Basic Hydraulic Training Unit
Procedure:
1. Construct the circuit in Figure 2.1.16.
2. Turn the adjustment on both relief valves fully counter-clockwise.
3. Disconnect the hose between flow meter 2 and the drain port.
4. Turn ON the training unit.
5. Turn the adjustment on circuit 1 relief valve clockwise until the pressure gauge reads
1378 kPa (200 psi).
6. Turn OFF the training unit.
7. Connect the hose between flow meter 2 and the drain port and disconnect the hose between flow
meter 1 and the drain port.
8. Turn ON the training unit.
9. Turn the adjustment on circuit 2 relief valve clockwise until the pressure gauge reads
2756 kPa (400 psi).
10. Turn OFF the training unit.
11. Connect the hose between flow meter 1 and the drain port.
12. Turn ON the training unit.
Unit 2 -2- Hydraulic Fundamenals
Student Copy Lab 2.1.4

13. Read the pressure gauge and flow meters. Record the readings in the spaces below.
Pressure ________ Flow Meter 1 _________ Flow Meter 2 ________
14. Turn the adjustment on circuit 1 relief valve clockwise until the pressure gauge reads
approximately 2756 kPa (400 psi).
15. Read the pressure gauge and flow meters. Record the readings in the spaces below.
Pressure ________ Flow Meter 1 ________ Flow Meter 2 ________
16. Turn the adjustment on circuit 1 relief valve clockwise one turn.
17. Read the pressure gauge and flow meters. Record the readings in the spaces below.
Pressure ________ Flow Meter 1 ________ Flow Meter 2 _________
Explain the gauge and flow meter readings in 13 above.
________________________________________________________________________________
________________________________________________________________________________
Explain the gauge and flow meter readings in 15 above.
_________________________________________________________________________________
_________________________________________________________________________________
Explain the gauge and flow meter readings in 17 above.
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
Unit 2 -1- Hydraulic Fundamenals
Instructor Copy Unit 2 Quiz

Instructor Copy Unit 2 Quiz

HYDRAULIC PRINCIPLES
UNIT 2 QUIZ

Fill in the blanks. Name _________________________

1. List three systems found on heavy equipment that use hydraulic principles in their design.
Implement System

Steering System

Brake System or Power Train System

2. List two advantages for using a liquid.

Liquids will conform to the shape of the container

A liquid is practically incompressible

3. What is Pascal's Law? "Pressure exerted on a confined liquid is transmitted undiminished

in all directions and acts with equal force on all equal areas."

50,000
PISTON ROD END

F PISTON

ROD

P A
PISTON 8 IN. DIA ROD 3 IN. DIA

PISTON HEAD END

PISTON

8 IN.

GAUGE A

4. What is the area of the piston head end?

A = Pi x r2, A = 3.14 x 42
A = 50.24 sq. inches

5. What is the effective area of the piston rod end? Area = Total area of Piston
Minus the area of the rod = Effective Area = 50.24 - 7.06, A = 43.18

6. What is the pressure on gauge A? Pressure = Force , P = 50,000 , P = 995.22 psi

Area 50.24
Unit 2 -2- Hydraulic Fundamenals
Instructor Copy Unit 2 Quiz

150 psi 75 psi 25 psi

A B C

75 psi 50 psi 25 psi

orifice orifice orifice

7. On the line above each gauge, fill in the correct gauge reading.
Unit 2 -1- Hydraulic Fundamenals
Student Copy Unit 2 Quiz

HYDRAULIC PRINCIPLES

Student Copy Unit 2 Quiz

UNIT 2 QUIZ

Fill in the blanks. Name _________________________

1. List three systems found on heavy equipment that use hydraulic principles in their design.

2. List the advantages for using a liquid.

3. According to Pascal's Law,

50,000
PISTON ROD END

F PISTON

ROD

P A
PISTON 8 IN. DIA ROD 3 IN. DIA

PISTON HEAD END

PISTON

8 IN.

GAUGE A

4. What is the area of the piston head end?_______________________________________

_______________________________________________________________________

5. What is the effective area of the piston rod end?________________________________

_______________________________________________________________________

6. What is the pressure on gauge A?

Unit 2 -2- Hydraulic Fundamenals
Student Copy Unit 2 Quiz

A B C

75 psi 50 psi 25 psi

orifice orifice orifice

7. On the line above each gauge, fill in the correct gauge reading.