Unidad 2

BASIC
LEARNING
HYDRAULICS ACTIVITY
PACKET
BASIC HYDRAULIC CIRCUITS
TM
4
LEARNING ACTIVITY PACKET 2
BASIC HYDRAULIC CIRCUITS
INTRODUCTION
In this LAP, you are going to learn about two new components: motors and needle
valves. Both are often used in hydraulic circuits. Before you do this, however, you will
learn more about hydraulic pumps in segment 1.
In the last segment, you will strengthen your ability to interpret and create hydraulic
schematics. These are important skills you will need if you work with fluid power.
ITEMS NEEDED
You will need the following items in order to perform this LAP.
Amatrol Supplied
1 85-BH Basic Hydraulic Training System
1 85-HPS Hydraulic Power Unit
School Supplied
1 Allen Wrench Set
1 Stopwatch
1 Measuring Container (1-5 gal./3.78-18.9 liters)
Shop Towels or Rags
FOURTH EDITION, LAP 2, REV. E

Amatrol, AMNET, CIMSOFT, MCL, MINI-CIM, IST, ITC, VEST, and Technovate are trademarks or registered
trademarks of Amatrol, Inc. All other brand and product names are trademarks or registered trademarks of their
respective companies.
Copyright © 2005, 2003, 2002, 2000, 1991, 1988, 1986 by AMATROL, INC.
All rights Reserved. No part of this publication may be reproduced, translated, or transmitted in any form or by any
means, electronic, optical, mechanical, or magnetic, including but not limited to photographing, photocopying,
recording or any information storage and retrieval system, without written permission of the copyright owner.
Amatrol, Inc., P.O. Box 2697, Jeffersonville, Indiana 47131 USA, Phone 812-288-8285, FAX 812-283-1584
B831-XA LAP 2 BASIC HYDRAULIC CIRCUITS

Copyright © 2002 Amatrol, Inc. 2
TABLE OF CONTENTS
SEGMENT 1 PUMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
OBJECTIVE 1 Define flow rate and explain how it can be measured
OBJECTIVE 2 Describe the operation of two types of flowmeters and give their schematic symbol
SKILL 1 Connect and read a flow meter
Activity 1 Flowmeter accuracy
OBJECTIVE 3 Describe the operation of a fixed-displacement pump and give its schematic symbol
Activity 2 Fixed-displacement pump operation
OBJECTIVE 4 Describe the operation of three types of fixed displacement pumps and give an application
of each
SEGMENT 2 NEEDLE VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

OBJECTIVE 5 Describe the main function of a needle valve
OBJECTIVE 6 Describe the operation of a needle valve and give its schematic symbol
Activity 3 Needle valve operation
SKILL 2 Connect and operate a needle valve to control the speed of an actuator
SKILL 3 Control the speed of an actuator using a manually-operated DCV
SEGMENT 3 BASIC MOTOR CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

OBJECTIVE 7 Describe the function of a hydraulic motor and give an application
OBJECTIVE 8 Describe the operation of a hydraulic motor and give its schematic symbol
SKILL 4 Connect and operate a bi-directional hydraulic motor using a 3-position, manually-operated
DCV
OBJECTIVE 9 List three types of hydraulic motors and give an application of each
SEGMENT 4 HYDRAULIC SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

OBJECTIVE 10 Describe eight basic rules for drawing hydraulic schematics
SKILL 5 Draw a hydraulic schematic from the actual circuit connections on a pictorial
SKILL 6 Draw a hydraulic circuit given a schematic
SKILL 7 Design a multiple actuator hydraulic circuit

SEGMENT 1
PUMPS
OBJECTIVE 1 DEFINE FLOW RATE AND EXPLAIN HOW IT

CAN BE MEASURED
The flow rate of a fluid indicates the amount of fluid that passes past
a point in a certain amount of time. This amount can be measured as a
weight or volume. In hydraulics, flow is most often measured by volume.
The most common flow rate units of measure are gallons per minute
(gpm) in the English system and liters per minute (lpm) in the metric
system.
VOLUMETRIC FLOW RATE FORMULA

Volume
Flow Rate =
Time
Where:
English Units
Flow Rate = Gallons per Minute (GPM)
S.I. Units
Flow Rate = Liters per Minute (LPM)
TIME FOR THE

FLUID TO FLOW
PAST POINT A
POINT A
VOLUME OF FLUID
Figure 1. Volume Flow in a Tube

One way the flow rate in a system can be determined is by
measuring the amount of time it takes to fill a container of known
volume. For example, if the flow from a hydraulic pump fills a 5 liter
bucket in one minute, the pump’s flow rate is 5 liters per minute. This
method can be very accurate but is messy and time consuming. The
preferred method for measuring flow rate is a flowmeter, although this
method is not as accurate as measuring with a stopwatch and a container.
OBJECTIVE 2 DESCRIBE THE OPERATION OF TWO TYPES OF

FLOWMETERS AND GIVE THEIR SCHEMATIC SYMBOL
A flowmeter is a device that measures the flow rate of fluid.

Flowmeters are useful tools for troubleshooting hydraulic systems. They
can show that a pump is wearing out or that a line is blocked. They also
are used in the laboratory for testing.
The two common types of hydraulic flowmeters are the rotameter
and the turbine-type flowmeter.
Rotameter
The rotameter consists of a transparent tube which contains a
movable piston. The tube and piston are constructed so that the oil flows
through the tube around the piston, as shown in figure 2. The flow rate is
determined by measuring the height to which the piston is raised by the
force of the oil flow.
This type of flowmeter must be oriented in a vertical position and is
usually rated for low pressures. This means it can only be used in a return
line.

Another type of rotameter uses a spring against which the piston is
pushed to indicate flow rate. This type of flowmeter can be oriented in
any position. It is the type used in the 850 system.
OUTLET
TAPERED GLASS
METERING TUBE
FLUID PASSES THROUGH

THIS ANNULAR AREA
METERING
FLOAT
INLET
Figure 2. Rotameter

Turbine-Type Flowmeter
This type of flowmeter consists of a wheel with blades that rotate
inside a body as oil flows through it. The speed is usually measured by
an electronic sensor that sends an electrical pulse as each blade passes
by. The rate at which the pulses are generated is converted into a flow
reading.
This type of meter can be oriented in any position and can operate in
high pressure as well as low pressure lines.
MAGNETIC
PICKUP
TURBINE
WHEEL
Figure 3. Typical Turbine Flowmeter
The schematic symbol for all types of flowmeters is shown in figure

4. The inlet and outlet are not specified on the symbol but flowmeters are
usually read in only one flow direction.
Figure 4. Flowmeter Schematic Symbol

SKILL 1 CONNECT AND READ A FLOWMETER
Procedure Overview
In this procedure, you will connect the flowmeter to the
outlet of the pump and measure its flow rate.
❑ 1. Connect the flowmeter on the 850 trainer, as shown in figures 5

and 6.
This type of flowmeter is a rotameter type that indicates flow with
a magnetic ring that is positioned on the outside of the tube and
follows the piston. A second tube encases this ring.
The Amatrol flowmeter operates under normal system pressures.
The maximum pressure is 3000 psi/20,700 kPa.
In order to use the flowmeter in your system, connect the
flowmeter for the direction of flow you want to measure. The inlet
port is on the bottom. Inside the flowmeter a black mark on a silver
metal band indicates the amount of flow. The flowmeter has a dual
scale for gpm and lpm.
HYDRAULIC INSTRUMENTATION PANEL

FLOW
GAGE A GAGE B GAGE C METER
OUT
IN
SUPPLY
MANIFOLD
RELIEF \ SEQUENCE PRESSURE REDUCING

VALVE VALVE
1 1 SHUTOFF
VALVE
2 2
3 3
NEEDLE
VALVE
A B RETURN
MANIFOLD
D.C.V. IN
#1
CHECK VALVE #1
A B B A
CHECK VALVE #2
OUT
B A
BASIC HYDRAULIC VALVE MODULE
Figure 5. Pictorial of Circuit for Measuring Flow Rate with a Flowmeter

SUPPLY
MANIFOLD IN OUT
SHUTOFF
VALVE
RETURN
MANIFOLD
Figure 6. Schematic Diagram of Circuit Setup
❑ 2. Perform the following checkout procedures for the power unit:

A. Check the oil level. Fill if necessary.
B. Press the stop push button on the motor starter to make sure it
is in the off position.
C. Plug in the power cord to a wall outlet.
D. Reduce the relief valve to its minimum pressure setting (turn
CCW fully).
❑ 3. Make sure the shutoff valve is closed.
❑ 4. Turn on the power unit.
❑ 5. Turn the relief valve’s adjustment knob CW until the pressure at
gage S reads 500 psi/3447 kPa.
This makes sure that the relief valve is closed and the full pump
flow will flow through the flowmeter in the next step.
❑ 6. Open the shutoff valve and record the reading you now observe on
the flowmeter.
Flow rate = ___________________________________( gpm/lpm)
You should observe the full pump flow. This should be in the
range of 2.5 to 2.8 gpm or 9.5 to 11.0 lpm.
❑ 7. Reduce the relief valve setting to its minimum (turn fully CCW).
❑ 8. Close the shutoff valve.
❑ 9. Turn off the power unit.

❑ 10. Now connect the flowmeter into the circuit shown in figure 7.
Be sure to use the small bore cylinder.
This location allows you to measure the return line flow of the
circuit.
IN A
OUT B
IN
OUT
SMALL CYLINDER
Figure 7. Circuit Setup
❑ 11. Turn on the power unit and adjust the pressure to 500 psi/3447 kPa.
❑ 12. Open the shutoff valve.
❑ 13. Now cycle the cylinder and observe the flowmeter reading.
Record the flow rate when the cylinder extends, retracts and stops.
OPERATION FLOW RATE

(gpm/lpm)
Extending
Retracting
Stopped
Did you notice that the flow rate is different when the cylinder
extends and retracts? The rate you measured should have been
approximately 2.5 gpm/9.5 lpm extending and 2.7 gpm/10.2 lpm
retracting. You will learn in the next LAP why there is a difference
between retracting and extending flow rates.
❑ 14. Reduce the relief valve setting to its minimum.
❑ 15. Close the shutoff valve and turn off the power unit.
❑ 16. Move the DCV handle back and forth to remove all pressure.
❑ 17. Disconnect the hoses and proceed to the activity.

Activity 1. Flowmeter Accuracy
Procedure Overview
In this procedure, you will verify the accuracy of the
flowmeter by comparing the flowmeter’s reading at several
flow rates to the actual flow rate measured using a
container and a stopwatch.
❑ 1. Connect the flowmeter in the 850 Trainer as shown in figures 8

and 9. The Amatrol 850 Basic Hydraulic System flowmeter is
accurate to 5% of full scale, typical accuracy for industrial
flowmeters. This means that whatever reading you observe on this
meter, the actual reading could be as much as 0.25 gpm/0.95 lpm
(5 gpm x .05 = 0.25 gpm) difference.

FLOW
OUT
IN
SUPPLY
MANIFOLD
SUPPLY
LINE OPEN END
FITTING
CAP
FILLER/
BREATHER
OPENING
POWER MEASURING
UNIT CONTAINER
Figure 8. Pictorial of a Circuit for Measuring Flow Rate

FLOW
METER
SUPPLY
MANIFOLD IN OUT
OPEN-END
FITTING
SHUTOFF
VALVE
MEASURING
CONTAINER
RETURN
MANIFOLD
Figure 9. Schematic Diagram of a Circuit for Measuring Flow Rate
❑ 2. Before restarting the power unit, unscrew the filler-breather cap on

the reservoir and direct the open end of the hose into it.
❑ 3. Place a clean measuring container near the reservoir.
❑ 4. Record the volume of the measuring container below.
Volume of Container _____________________________gal./liters
❑ 5. Perform the following checkout procedures for the power unit.
B. Press the stop pushbutton on the motor starter to make sure it is
in the Off position.
C. Plug in the power cord to the wall outlet.
D. Reduce the relief valve to its minimum pressure setting. (Turn
CCW fully).
❑ 6. Make sure the shutoff valve is closed. (Handle perpendicular to the
flow path).
The shutoff valve will be used to change the flow rates through the
flowmeter.
❑ 8. Turn the relief valve adjustment knob CW until the pressure at
Gage S reads 200 psi/1380 kPa.
❑ 9. Holding the open end of the hose directed into the filler-breather
opening, slowly open and adjust the shutoff valve until 0.5
gpm/1.9 lpm is shown as flowing through the flowmeter.
Oil will be flowing out the open end fitting back into the tank
through the filler-breather opening.

❑ 10. Quickly redirect the open end of the hose into the measuring
container and with a stopwatch, measure the time required to fill it.
Direct the hose back to the filler-breather opening. Record the time
to fill the container in the chart below:
FLOWMETER TIME TO FILL

gpm lpm seconds
2.5 9.5
2.0 7.6
1.0 3.8
0.5 1.9
❑ 11. Close the shutoff valve, empty the container back into the power
unit tank through the filler-breather opening and place the
container next to the reservoir.
❑ 12. Again, while directing the open hose end into the filler-breather
opening, slowly open and adjust the shutoff valve to set the flow to
1.0 gpm/3.8 lpm through the flowmeter.
❑ 13. Switch the hose back to the container and again measure the time
required to fill it. Direct the hose back to the filler-breather
opening and record this time in the chart.
❑ 14. Repeat steps 11, 12 and 13 for the other two flow rates listed in the
chart.
❑ 15. Close the shutoff valve and reduce the power unit relief valve
setting to minimum (turn fully CCW).
❑ 17. Empty the container back into the power unit tank through the
filler-breather opening.
❑ 18. Replace the filler-breather cap on the reservoir and clean up any
spilled oil, using clean shop rags.

❑ 19. Now calculate the actual flow rates for each flowmeter reading,
using the following formula. Record your answers in the chart
provided.
volume of container (gal / liters)
Actual flow rate (gpm/lpm) =
time to fill (minutes)
NOTE
Seconds must be converted to minutes for this formula.
FLOWMETER FLOW RATE ACTUAL FLOW RATE DIFFERENCE

gpm lpm gpm lpm gpm lpm
2.5 9.5
2.0 7.6
1.0 3.8
0.5 1.9
❑ 20. Using your data from step 19, calculate the difference in flow rate
between the flowmeter reading and the actual. Record in the chart
in step 19.
None of your differences should exceed 0.25 gpm/0.95 lpm for
this flowmeter. Slight differences exceeding the stated accuracy of
±5% of full flow could be attributed to measuring and timing
inaccuracies.

OBJECTIVE 3 DESCRIBE THE OPERATION OF A FIXED DISPLACEMENT
PUMP AND GIVE ITS SCHEMATIC SYMBOL
The pump generates fluid flow in a hydraulic system. Industrial

hydraulic pumps use a positive displacement design. This means that if
the shaft of the pump is turned at a constant speed by the electric motor,
the pump produces a near-constant flow at its outlet regardless of the
pressure.
There are two categories of positive displacement pumps: variable
displacement and fixed-displacement. A variable displacement pump can
change its flow rate, a fixed-displacement pump cannot. Its flow rate is
fixed.
It is important to note that a fixed-displacement pump does not
create pressure, only flow. Hydraulic system pressure develops only
when there is a resistance to flow. This resistance can be caused by a
load on an actuator or fluid friction. You will learn more about resistance
in a later LAP.
The operation of a typical pump is shown in figure 10. It has a
housing with an inlet and an outlet port. Inside the housing are rotating
parts connected to a shaft that extends through the pump’s housing. An
electric motor turns the pump’s shaft to create flow.
PUMP
PARTIAL
VACUUM PRESSURE
LINE
TO SYSTEM
INLET OUTLET
SUCTION
LINE
ATMOSPHERIC
PRESSURE
30 in Hg
RESERVOIR
Figure 10. Basic Pump Operation
In order for the pump to supply flow to the system, oil must flow
from the reservoir to the pump’s inlet. The pump causes this oil to flow
through the suction line by creating a partial vacuum at its inlet. This
allows the atmospheric pressure pressing on the oil in the reservoir to
force oil through the suction line into the pump’s inlet port. The pump
then pushes the oil through to the outlet and discharges it into the
pressure line.

With all types of hydraulic pumps, the vacuum at the inlet is created by
increasing the volume inside the pump. The fluid then discharges to the
system at the outlet port when the pump decreases the volume. The
operation of a syringe, as shown in figure 11 demonstrates this principle.
It is important to remember that the pump does not develop pressure
at its outlet. It only discharges the oil at a certain flow rate. Pressure
develops at the pump’s outlet only when there is a resistance to flow.
DRAWING FLUID IN PUSHING FLUID OUT

(INCREASING VOLUME) (DECREASING VOLUME)
Figure 11. Pump Action of a Syringe
The schematic symbol for a fixed-displacement hydraulic pump is

shown in figure 12 along with symbols for a coupling, electric motor,
reservoir, and filter.
PUMP
ELECTRIC
MOTOR OUTLET
SOLID ARROW INDICATES
MEDIUM IS LIQUID
INLET CIRCLE
INDICATES
COUPLING ROTATING DRIVE
SUCTION
FILTER
RESERVOIR
Figure 12. Schematic Symbols for Fixed-Displacement Hydraulic Pump

and Power Unit Components

Activity 2. Fixed-Displacement Pump Operation
Procedure Overview
In this procedure, you will show that a fixed
displacement pump produces the same flow regardless of
pressure.
❑ 1. Set up the circuit shown in figure 13.

This is the same circuit used in figure 6 except that the schematic
symbols for the power unit components have been added.
The oil flows from the pump through the supply line to the supply
manifold. It then goes through the flowmeter and back to the
reservoir from the return manifold.
When the shutoff valve is closed, the oil pressure increases and
causes the relief valve to open. The oil from the pump then returns
to the reservoir through the relief valve.
In this circuit there is no resistance to flow when the shutoff valve
is open, other than the resistance of the fittings and the flowmeter.
SUPPLY
MANIFOLD
SHUTOFF
VALVE FLOW
METER
RETURN
SUPPLY
MANIFOLD
LINE
RELIEF
VALVE
GAGE
S
RETURN
M LINE
Figure 13. Circuit Setup

❑ 2. Perform the following checkout procedures for the power unit.
CCW fully).
❑ 3. Turn on the hydraulic power unit.
❑ 4. Make sure the shutoff valve is closed.
❑ 5. Adjust the relief valve pressure to 500 psi/3447 kPa.
❑ 6. Open the shutoff valve fully.
The pump should now be pumping its full flow through the flow
meter. The pressure reading at gage S should be less than 200
psi/1380 kPa. This pressure is caused by the resistance of the
quick-connect fittings and the flowmeter.
❑ 7. Turn the handle of the shutoff valve slightly until the pressure at
gage S reaches 200 psi/1380 kPa. Record the flow rate in the
following chart.
Partially closing the shutoff valve creates a resistance to flow
which causes a back pressure at the pump’s outlet. You should still
observe, however, that the flow does not change or, if it does, it is
only small.
PRESSURE FLOW RATE

(psi/kPa) (gpm/lpm)
200/1380 /
250/1725 /
300/2070 /
350/2415 /
400/2760 /
❑ 8. Increase the pressure at gage S to 250 psi/1725 kPa by turning the

shutoff valve.
The flow reading you are now observing is again the full flow of
the pump except the pump is pumping against a pressure of 250
psi/1725 kPa.
Examine the flowmeter’s reading carefully to see if it has changed
from the flow rate at 200 psi/1380 kPa. Then record this flow rate
in the chart.

❑ 9. Repeat step 8 for each of the other pressures listed in the chart.
You should observe that the flow rate stays nearly the same
because pump flow is constant regardless of pressure. However, as
you increase the pressure, you may notice a slight drop in flow
because the pump is less efficient at higher pressures. Some oil
will slip back to the inlet from the outlet.
❑ 10. Reduce the relief valve’s setting to minimum.
❑ 11. Close the shutoff valve completely.
❑ 13. Disconnect the hoses and store them.
OBJECTIVE 4 DESCRIBE THE OPERATION OF THREE TYPES OF FIXED

DISPLACEMENT PUMPS AND GIVE AN APPLICATION OF EACH
There are three common types of fixed displacement pumps used in

hydraulic systems: gear, vane, and piston. As shown in figure 14, the
main difference between these three types is the design of the internal
rotating parts.
All three of these pump types use positive displacement designs.
GEAR
PISTON
VANE
Figure 14. Types of Hydraulic Pumps

Gear Pump
Gear pumps use two meshing gears. One of the gears directly
attaches to the pump’s shaft while the other gear acts as an idler gear. At
the inlet side of the pump, the meshing gear teeth of the two gears rotate
away from each other. This creates an increasing volume which causes a
partial vacuum or suction at the inlet. The atmospheric pressure at the
reservoir then pushes the oil into the inlet.
As oil enters the inlet, it is trapped between the gear teeth and the
housing. The rotating gear teeth carry the oil around to the outlet side
where it is pushed into the system.
This pump type is the least expensive and is used in low to medium
pressure applications, such as a trash compactor.
HOUSING IDLER
GEAR
OIL FLOW INLET OUTLET
INCREASING
VOLUME
ROTARY
DRIVE GEAR MOTION
SHAFT
CONNECTED TO DRIVE
(ELECTRIC MOTOR)
Figure 15. Gear Pump Design
Vane Pump
Vane pumps have a rotor containing movable vanes that slide in and
out in radial slots of a rotor. As the shaft turns the rotor, the centrifugal
force throws the vanes out against a surrounding cam ring or housing.
The suction at the inlet is created when the vanes rotate around toward
the inlet. Because the rotor is positioned off center, these vanes create an
increasing volume at the inlet which creates a partial vacuum.

The pump moves oil through it by trapping the oil between the vanes
and the pump housing. The oil is pushed out of the pump at the outlet by
the decreasing volume created as the vanes slide back into the rotor.
Applications where efficiency is somewhat important use these vane
pumps.
HOUSING
INLET OUTLET
INCREASED
VOLUME VANES
PUMP SHAFT ROTOR

SMALL
VOLUME
Figure 16. Vane Pump Design
Piston Pump
Piston pumps use a number of pistons which each create a pumping
action. As the pistons are rotated by the barrel they move in and out
because they are held on one end by an angled swashplate. This creates
an increasing and decreasing volume action similar to a syringe.
BARREL
PISTONS
SWASHPLATE
SHAFT
VALVE PLATE
Figure 17. A Piston Pump Design
High pressure applications such as presses and molding machines

often use piston pumps. They are the most efficient but also the most
expensive.
SEGMENT 1
SELF REVIEW
1. Hydraulic flow rate can be measured by _________ or

___________.
2. The two types of flowmeters used in hydraulics are

____________ and _____________.
3. A ________________ pump is the least expensive.
4. A ________________ pump is the most efficient.
5. A fixed displacement pump creates _______________ not

____________.
6. A pump creates oil flow at its inlet by creating an

___________ volume.

SEGMENT 2
NEEDLE VALVES
OBJECTIVE 5 DESCRIBE THE MAIN FUNCTION OF A NEEDLE VALVE
The main function of a needle valve is to control the speed of an

actuator by controlling the flow rate of oil to that actuator. A typical
needle valve is shown in figure 18.
Figure 18. Needle Valve Used in the 850 System

OBJECTIVE 6 DESCRIBE THE OPERATION OF A NEEDLE VALVE
AND GIVE ITS SCHEMATIC SYMBOL
The needle valve controls flow rate by causing a restriction in the

line. A typical valve consists of two major components, as shown in
figure 19: a valve body and an adjustment screw.
The valve body consists of two ports with a passage connecting
them. This passage provides a flow path for the fluid. The adjustment
screw can be turned in or out to vary the passage opening in the body
from blocked to fully open. The adjustment screw has a tapered end for
very fine control of this orifice.
The needle valve controls the flow rate by adjusting the size of the
opening or orifice. This will be explained in more detail in the activity.
ADJUSTMENT
SCREW
PORT A
OIL
PORT B
FLOW
VALVE BODY
Figure 19. Needle Valve Construction
The schematic symbol for a needle valve is shown in figure 20. It

shows two ports and an orifice. The angled arrow across the flow path
indicates that the orifice is variable.
SYMBOL EXPLANATION
VARIABLE
ORIFICE
PORT PORT
A B
ORIFICE
Figure 20. Needle Valve Schematic Symbol

Activity 3. Needle Valve Operation
Procedure Overview
In this procedure, you will use a needle valve to control
flow rate through a flowmeter. You will also demonstrate
that the flow is controlled in both directions through the
valve.
❑ 1. Set up the circuit shown in figures 21 and 22.

The flowmeter will indicate the flow rate.

FLOW
SUPPLY
MANIFOLD

VALVE VALVE
1 1 SHUTOFF
VALVE
2 2
3 3
NEEDLE
VALVE
A B RETURN
MANIFOLD
D.C.V. IN
#1
CHECK VALVE #1
A B B A
CHECK VALVE #2
OUT
B A
BASIC HYDRAULIC VALVE MODULE
Figure 21. Pictorial of Circuit for Measuring Needle Valve Flow Rate

NEEDLE
VALVE
FLOW
METER
Figure 22. Schematic Diagram for Measuring Needle Valve Flow Rate
The long and short dashed lines drawn around the power unit
components tell you that these components are mounted together.
CCW fully).
❑ 3. Open the needle valve by turning the adjustment knob fully CCW.
❑ 4. Close the shutoff valve fully.
❑ 5. Turn on the hydraulic power unit.
❑ 6. Increase the pressure setting on the relief valve to 500 psi/3447
kPa.
❑ 7. Open the shutoff valve and observe the flow rate through the
flowmeter.
Gage S Pressure _________________________________(psi/kPa)
Flow Rate ____________________________________(gpm/lpm)

You should observe that the flow rate indicates that the maximum
flow of the pump is flowing through the needle valve.
The needle valve controls the flow rate by causing a restriction of
the flow. When the adjustment screw is turned all the way out, the
passage is unblocked with a lower resistance to flow.

❑ 8. Turn the needle valve clockwise while observing the pressure on
gage S. Stop when gage S reads 300 psi/2070 kPa.
Then record the flow rate displayed on the flowmeter.
Flow Rate ____________________________________(gpm/lpm)

You should observe that the flow rate does not change (or very
little) because the pump is a positive displacement type.
The further the adjustment screw is turned in (CW), the more the
passage is blocked. This blockage causes more resistance to fluid
flow, as shown in figure 23.
You should note that this valve restricts flow regardless of which
direction the oil flows through it.
ADJUSTMENT KNOB
(TURNED IN)
FLOW RESTRICTED
HERE
Figure 23. Needle Valve Shown Controlling Fluid Flow by Restricting the
Passage

❑ 9. Continue turning the needle valve clockwise. Observe the flow rate
as the pressure on gage S increases to 450 psi/3105 kPa.
You should observe that the upstream pressure continues to rise as
the needle valve’s opening gets smaller, as shown in figure 24.
However, the flow rate should stay nearly constant because the
pump is a positive displacement type and we have not yet reached
the relief valve’s setting of 500 psi/3447 kPa.
RELIEF LOW
VALVE PRESSURE
RESERVOIR
Figure 24. Relief Valve Closed, Flow Constant Through Needle Valve

❑ 10. Now keep turning the needle valve’s adjustment knob clockwise
slowly and watch the flow rate reading as the pressure gets very
near to the relief valve setting (500 psi/3447 kPa).
You should observe that the flow rate starts to reduce noticeably.
This occurs because the relief valve opens partially and allows part
of the pump flow to bypass the flowmeter and go directly to the
reservoir as shown in figure 25.
HIGH LOW
RELIEF
PRESSURE PRESSURE
VALVE
RESERVOIR
Figure 25. Relief Valve Partially Open, Flow Reduced Through Needle
Valve
❑ 11. See if you can adjust the flow rate, using the needle valve, to each
of the following flow rates: 2.0 gpm/7.6 lpm, 1.5 gpm/5.7 lpm, 1.0
gpm/3.8 lpm and 0.5 gpm/1.9 lpm.
This will give you more experience with the adjustment of the
needle valve.
You should observe that the pressure continues to rise as the
needle valve’s opening gets smaller.
❑ 12. Reduce the relief valve to its minimum pressure setting (turn CCW
fully).
❑ 14. Switch the hoses at the needle valve so that the supply hose
connects to port B and the hose to the flowmeter connects to port
A. This will allow oil to flow in the other direction through the
needle valve.

❑ 15. Turn on the hydraulic power unit and increase the pressure setting
on the relief valve to 500 psi/3447 kPa.
❑ 17. Adjust the needle valve to provide 2.0 gpm/7.6 lpm, 1.5 gpm/5.7
lpm, 1.0 gpm/3.8 lpm and 0.5 gpm/1.9 lpm just as you did in step
11.
This will verify the ability of the needle valve to control flow
when the flow is reversed through it.
❑ 18. Reduce the relief valve to its minimum pressure setting (turn CCW
fully).
SKILL 2 CONNECT AND OPERATE A NEEDLE VALVE TO CONTROL

THE SPEED OF AN ACTUATOR
Procedure Overview
In this procedure, you will use a needle valve to control
the speed of a cylinder. This is a common task done every
day in industry.
❑ 1. Set up the circuit, as shown in figures 26 and 27.

In this circuit, the needle valve restricts the flow to the DCV and
on to the cylinder.

FLOW
SUPPLY
MANIFOLD

CYLINDER VALVE VALVE
1 1
FLOW FLOW 2 2
CONTROL CONTROL SHUTOFF
3 3 VALVE
#1 #2
A A
NEEDLE
VALVE
A B RETURN
B B
MANIFOLD
MOTOR
D.C.V. IN
#1
CHECK VALVE #1
A B B A
CHECK VALVE #2
OUT
CYLINDER B A
HYDRAULIC ACTUATOR MODULE BASIC HYDRAULIC VALVE MODULE
Figure 26. Circuit for Controlling the Speed of a Cylinder with the Needle
Valve

IN A
OUT B
SMALL BORE
CYLINDER
Figure 27. Schematic of Circuit for Controlling the Speed of a Cylinder

with a Needle Valve

CCW fully).
❑ 4. Increase the pressure setting on the relief valve to 500 psi/3447
kPa.
❑ 6. Open the needle valve fully (CCW).
❑ 7. Cycle the cylinder back and forth by shifting the lever of the DCV.
Notice the speed of the cylinder.
It should be relatively fast (less than a second) because full pump
flow is going to the cylinder.

❑ 8. As you continue to cycle the DCV, turn the needle valve’s
adjustment knob CW until it takes approximately four seconds for
the cylinder to extend. You may have to turn it several turns before
you start to see any speed change at all.
The flow rate of oil into the actuator determines the speed of a
hydraulic actuator. To show how this works, consider the cylinder
shown in figure 28. In order to extend the cylinder, the oil must fill
the volume created when the cylinder extends. The rate at which
the oil flows determines how fast this volume can fill. For
example, if our cylinder in figure 28 creates a total volume of 2
liters when extended and the flow rate is 1 lpm, the time to extend
is 2 minutes (2 ÷ 1 = 2). If the flow rate is higher, it will take less
time to fill the volume and the faster the actuator speed will be.
CYLINDER
RETRACTED
CYLINDER
EXTENDED
2 LITERS OF OIL
Figure 28. Volume of Oil to Extend
❑ 9. Test your ability to provide other cylinder speeds by adjusting the

needle valve to other openings.
❑ 10. Open the needle valve by turning the adjustment knob fully CCW.
Leave the system running and continue to the next skill.

SKILL 3 CONTROL THE SPEED OF AN ACTUATOR USING
A MANUALLY-OPERATED DCV
Procedure Overview
In this procedure, you will use the directional control
valve to control the speed of the cylinder by opening it
partially. This action causes the DCV spool to restrict the
flow similar to the needle valve. Hydraulic systems in
construction equipment such as backhoes often use this
technique.
❑ 1. Continuing from the previous skill, gently push the lever of the
DCV slightly off center so that the spool of the DCV is only
partially shifted. Observe the speed of the cylinder.
NOTE
Control of cylinder speed may be sensitive because this DCV
was not made with tapers on the spool.
You should observe that the cylinder extends at a slower speed.

This technique is called feathering a directional control valve. It is
commonly used on mobile equipment, such as tractors and
backhoes, to control the speed of an actuator. In these applications,
the needle valve is not needed. The spool inside the DCV has long
tapers that provide a gradually increasing path for the oil to flow.
This technique works because the valves are manually shifted
allowing you to move the spool to any position you desire.
❑ 2. After the cylinder is extended, pull the lever out so that the spool is
shifted only slightly in the other direction. Observe the cylinder’s
speed as it retracts.
❑ 3. Repeat steps 1 and 2 several times and try different lever positions
to observe your ability to change the speed of the cylinder by
controlling the amount of DCV shift.
❑ 4. Retract the cylinder rod fully.
❑ 5. Reduce the relief valve’s pressure setting to the minimum setting
(turn CCW).
❑ 8. Move the handle of the DCV back and forth to remove any
pressure in the circuit.
❑ 9. Disconnect the circuit and store the components.

SEGMENT 2
SELF REVIEW
1. The __________ of an actuator is determined by the flow

rate of oil into the actuator.
2. To close a needle valve, turn the adjustment knob ________.
3. Controlling the amount of DCV shift to control the speed of

an actuator is called _____________.
4. The needle valve controls the flow rate by causing a

__________.
5. The needle valve body has __________ ports.
6. Flow is restricted through a __________ __________

regardless of which direction the oil flows through it.

SEGMENT 3
BASIC MOTOR CIRCUITS
OBJECTIVE 7 DESCRIBE THE FUNCTION OF A HYDRAULIC MOTOR

AND GIVE AN APPLICATION
The hydraulic motor is an actuator that converts fluid power into

rotary mechanical power. Applications use motors where rotary output is
needed. A typical motor is shown in figure 29. As you can see, it looks
very much like a pump. In fact, most motor designs are modified pump
designs.
Figure 29. Typical Hydraulic Motor

Hydraulic motors often drive winches on ships and devices on
construction equipment because they can create high torque output when
they are running at slow speeds.
They also drive conveyors in food processing plants where the
equipment must be washed down frequently. Using electric motors
would be a shock hazard.
Figure 30. Hydraulic Motor Application

OBJECTIVE 8 DESCRIBE THE OPERATION OF A HYDRAULIC MOTOR
AND GIVE ITS SCHEMATIC SYMBOL
The basic operation of a hydraulic motor is just the opposite of a

pump. While the pump generates flow from its rotating shaft, the motor
rotates its shaft when oil flows through it, as shown in figure 31.
ELEC.
LOAD
MOTOR
MOTOR MOTOR
DRIVES DRIVES
PUMP LOAD
IN OUT IN OUT
PRESSURE
LINE
PUMP MOTOR
SUCTION
LINE
RETURN
LINE
RESERVOIR
Figure 31. Basic Operation of a Hydraulic Motor
Hydraulic motors are positive displacement devices. This means that

higher flow rates cause higher shaft speeds.
Unlike a pump, many hydraulic motors’ shafts can turn in either
direction. These types are called bi-directional motors and include most
of the motors supplied to industry. In some cases, where cost is a factor,
motors that turn in only one direction are supplied. These are called
uni-directional motors.

The schematic symbols for uni-directional and bi-directional motors
are shown in figure 32. Notice that the solid arrow points inward
indicating flow goes into the motor. This is the basic difference in how
pump and motor symbols are shown.
UNI-DIRECTIONAL BI-DIRECTIONAL
IN
OUT
Figure 32. Hydraulic Motor Schematic Symbols

SKILL 4 CONNECT AND OPERATE A BI-DIRECTIONAL HYDRAULIC
MOTOR USING A 3-POSITION, MANUALLY-OPERATED DCV
Procedure Overview
In this procedure, you will set up a basic hydraulic
circuit that will allow you to stop, start, and operate a motor
in both directions of rotation. This circuit uses a 4-way,
3-position DCV to control a bi-directional motor.
❑ 1. Set up the hydraulic motor circuit shown in figures 33 and 34.

FLOW
SUPPLY
MANIFOLD

1 1
FLOW FLOW 2 2
CONTROL CONTROL SHUTOFF
3 3 VALVE
#1 #2
A A
NEEDLE
VALVE
A B RETURN
B B
MANIFOLD
MOTOR
D.C.V. IN
#1
CHECK VALVE #1
A B B A
CHECK VALVE #2
OUT
CYLINDER B A
Figure 33. Pictorial of a Basic Hydraulic Motor Circuit

DIRECTIONAL
CONTROL
SUPPLY VALVE
MANIFOLD
NEEDLE GAGE B
VALVE TEE
IN A
SHUTOFF
VALVE OUT B
TEE
GAGE A
RETURN
MANIFOLD
FLOW
METER
Figure 34. Schematic of Basic Hydraulic Motor Circuit
NOTE
Verify that the flywheel has been removed from the motor’s
shaft before continuing. This flywheel is shown in figure 35. If it is
attached, ask your instructor to assist you in removing it.
Figure 35. Motor Flywheel

❑ 2. Perform the following checkout procedures before starting the
hydraulic power unit:
B. Press the stop push button on the motor starter to make sure the
starter is in the off position.
CCW fully).
❑ 3. Close the needle valve completely and then open it 1/4 turn. This
should cause the motor to rotate at slow speed when the DCV is
operated and allow you to observe its operation.
❑ 5. Increase the relief valve’s pressure setting to 300 psi/2070 kPa.
❑ 7. Test the ability of the circuit to drive the motor in two directions
by operating the lever of the DCV. Record below which lever
position causes the motor’s shaft to turn in the CW direction and
then in the CCW direction when looking at the motor shaft from
the back of the motor.
MOTOR DIRECTION LEVER POSITION (IN/OUT)

CW
CCW
Like the double-acting cylinder, the motor’s direction of rotation

changes by reversing the hose connections.
❑ 8. Reduce the relief valve to minimum and turn off the power unit.
❑ 9. Reverse the hoses to the hydraulic motor.
❑ 10. Turn on the power unit and increase the pressure to 300 psi/2070
kPa.
❑ 11. Now test the motor’s operation by pushing the lever in and pulling
it out. Record below which lever position creates CW and CCW
rotation.
MOTOR DIRECTION LEVER POSITION (IN/OUT)

CW
CCW
You should observe that the motor runs in the opposite direction
for each position of the handle.

❑ 12. Perform the following substeps to adjust the speed of the motor
using the needle valve.
This will allow you to test the ability to measure motor speed.
A. Push the lever of the DCV in and hold it so that the motor runs.
B. Adjust the setting of the needle valve so that the flow rate is 0.5
gpm/1.9 lpm. The motor should be operating at a low speed.
Also, listen carefully to the pitch of the motor.
C. Test the effect that flow rate has on motor speed by opening the
needle valve CCW until the flow rate at the flowmeter reads
0.75 gpm/2.9 lpm. Listen for any change in speed in the motor.
A higher pitch indicates faster speed. A lower pitch indicates
slower speed.
Record your observations in the chart.
MOTOR FLOW MOTOR SPEED

(gpm/lpm) (Same/Increasing/Decreasing)
0.75 / 2.8
1.0 / 3.8
1.5 / 5.7
2.0 / 7.6
1.0 / 3.8
D. Repeat substep C adjusting the needle valve for each of the

other flow rates in the chart.
You should have observed that motor speed increases as flow
rate through the motor increases and the motor speed slows as
flow rate through the motor decreases.
E. Release the handle of the DCV.

NOTE
One of the features of a hydraulic system is that it can reverse
the actuator’s direction very suddenly without causing any
damage. In contrast, electric motors can burn up if they are
reversed suddenly and repeatedly. In the remaining steps of this
skill, you will demonstrate the ability of the motor to reverse
direction quickly.
❑ 13. Now adjust the circuit using the following substeps so that you can
observe the effects of rapidly reversing motor rotation.
A. Push the lever of the DCV in and hold it so the motor runs.
B. Adjust the needle valve so that the flow rate is 0.75 gpm/2.9
lpm.
❑ 14. Now test the ability of the motor to be quickly reversed by shifting
the lever of the directional control valve quickly from a full-in
position to a full-out position. Record the peak pressure reading on
gage A when you do this.
No flywheel, moderate speed:
Peak Pressure, Gage A ____________________________(psi/kPa)

❑ 15. Stop the motor and open the needle valve completely.
This valve setting will allow you to test the reversibility of the
motor at a high speed.
❑ 16. Repeat step 14 again to see how smoothly and quickly the motor
shifts direction at high speed. Record the new peak pressure.
No flywheel, high speed:

You should observe that the motor reverses very smoothly and
quickly. The peak pressure will be greater than that of step 14.
❑ 17. Release the lever of the DCV to stop the motor.
❑ 18. Reduce the relief valve pressure to minimum and turn off the
power unit.

❑ 19. Perform the following substeps to put the flywheel on the shaft of
the motor, as shown in figure 38.
NOTE
For safety and proper operation, the flywheel must be locked
firmly to the motor shaft. As shown in figures 37 and 38, the
flywheel is locked using slots in the flywheel, a slot in the shaft,
two set screws, and a key.
A. Locate the flywheel and remove the first set screw using a
3/32" Allen wrench, as shown in figure 36.
There are two set screws in the flywheel. One tightens against
the shaft. The other (the one you are removing) holds the
second set screw in place.
Figure 36. Removing a Set Screw from the Flywheel Using a 3/32” Allen
Wrench
B. Use a 3/32" Allen wrench to back the second set screw away
from the key slot of the flywheel.
This will allow the flywheel to slide onto the shaft easily. You
only need to turn the Allen wrench CCW a few turns to do this.
C. Verify that the key shown in figure 37 is in the key slot of the
motor shaft.
D. Orient the flywheel in your hand so that the set screw access
hole is closer to the motor as shown in figures 37 and 38.
E. Orient the flywheel in your hand so that the key slot is aligned
with the key on the motor shaft and slide the flywheel onto the
shaft.
F. Then position the flywheel on the shaft as shown in figure 38.
G. Tighten the second set screw.

H. Add and tighten the first set screw on top of the second set
screw to jam the set screws so the flywheel won’t come loose
(a safety precaution). This will make sure the flywheel is
securely mounted to the shaft.
The flywheel will show the effect of a load when a motor
reverses direction in the following steps.
SET SCREW
ACCESS HOLE
HYDRAULIC
MOTOR
KEY SLOTS
KEY
FLY WHEEL
Figure 37. Flywheel and Motor Showing Key Slots
HYDRAULIC
MOTOR
SET SCREW MOTOR

ACCESS HOLE SHAFT
FIRST
SET
SCREW
SECOND
SET
SCREW
KEY
FLYWHEEL
Figure 38. Proper Position of Flywheel on Motor Shaft

❑ 20. Turn on the power unit and set the relief valve pressure to 300
psi/2070 kPa.
❑ 21. Close the needle valve completely. Then open it 1/4 turn.
❑ 22. Push the lever of the DCV in and hold it so that the motor runs.
❑ 23. Adjust the setting of the needle valve so that the flowmeter reads
0.75 gpm/2.9 lpm.
❑ 24. Use the DCV to quickly reverse the motor direction. Observe to
see how the motor shifts direction with a load. Observe the peak
pressure.
Flywheel load, moderate speed.
Peak Pressure, Gage A ___________________________(psi/kPa)

You should observe that the motor smoothly and quickly reverses
direction, even though the peak pressure is higher.
❑ 25. Release the lever of the DCV.
❑ 26. Open the needle valve fully.
❑ 27. Repeat step 24 and observe.
Flywheel load, high speed.

You should observe that the motor smoothly reverses direction
even though it takes more time and the peak pressure is even
higher.
❑ 28. Release the lever of the DCV to stop the motor.
❑ 29. Reduce the relief valve setting to minimum.
❑ 32. Shift the lever of the DCV back and forth to remove any pressure
locked in the circuit.
❑ 33. Remove the flywheel.
❑ 34. Disconnect the circuit and store the components.

OBJECTIVE 9 LIST THREE TYPES OF HYDRAULIC MOTORS
AND GIVE AN APPLICATION OF EACH
As with pumps, there are three basic designs of motors:

• Gear Motors
• Vane Motors
• Piston Motors
Gear Motors
There are two types of gear motors available: standard gear motors
and gerotor motors. A standard gear motor uses two meshing spur gears
that rotate inside a housing. This design is so similar to its pump
counterpart that many gear motors can be used as pumps.
The gerotor motor uses an internal gear that rotates inside a ring gear
similar to planetary gears (see figure 39). Gerotor motors are generally
less efficient than other types of motors but they are very inexpensive
and highly durable under extreme environmental conditions. Gerotor
motors are very popular for light duty mobile applications including
agriculture, mining, and construction.
Figure 39. The Gerotor Motor

Vane Motors
Vane motors are designed similar to vane pumps except for one
unique difference. A vane motor’s vanes have to be spring loaded so
they will fully extend when the motor is stopped. Vane pumps do not
require this because their vanes are naturally extended by the centrifugal
force generated by the turning of the shaft.
Vane motors are medium performance motors. They have better
leakage characteristics than gear motors but lower than piston motors.
Their price is higher than gear motors but lower than piston motors.
Vane motors are generally used in industrial environments where
efficiency is more important.
Figure 40. Vane Motor

Piston Motors
There are three types of piston motors available: in-line, bent axis,
and radial. An example of each type is shown in figure 41. The inline is
by far the most common.
Applications use piston motors where high performance is needed.
They give exact speed regulation, low speed-high torque, and high
speed-low torque. They have low internal friction and very close
tolerances yielding a very high efficiency.
BENT AXIS
INLINE RADIAL
Figure 41. Types of Piston Motors

SEGMENT 3
SELF REVIEW
1. The actuator that produces rotary motion is called a _____ .
2. To increase the speed of a hydraulic motor, increase the

_____ ____.
3. The three types of hydraulic motors are ____, ____, and

______.
4. The direction of rotation of a motor is determined by

viewing the shaft from the ______ of the motor.
5. A _________ is used to rapidly change direction of rotation

of a motor.
6. _________________ motors are inexpensive and highly

durable under extreme environmental conditions.

SEGMENT 4
HYDRAULIC SCHEMATICS
OBJECTIVE 10 DESCRIBE EIGHT BASIC RULES FOR DRAWING

HYDRAULIC SCHEMATICS
Up to this point you have learned a number of hydraulic schematic

symbols and worked with some basic schematics. However, we haven’t
discussed much about how to draw these circuits.
Eight new rules you should follow when drawing hydraulic
schematics are:
1. Symbols may be rotated or reversed without altering their
meaning except for the vented reservoir and the
accumulator.
The vented reservoir must always be shown in the up position,
as shown in figure 42.
VERTICAL ORIENTATION HORIZONTAL ORIENTATION
Figure 42. Two Versions of the Same Schematic

2. The vented reservoir symbol may be shown as many times
as desired without indicating that there is more than one
reservoir.
This allows you to make the drawing easier to read by showing
that a line returns to the tank without plumbing it back to the
one reservoir.
INDICATES THAT
RETURN LINE GOES
TO THE RESERVOIR
M
Figure 43. Reservoir Represented with More than One Symbol

3. Lines (conductors) are shown either horizontally or
vertically on the schematic diagram. Diagonal lines should
not be drawn.
4. Connecting lines, crossing lines, and blocked lines should be
drawn as shown in figure 44.
CONNECTED LINES BLOCKED LINE
CROSSING LINES BLOCKED LINE
Figure 44. Line Connections

5. Symbols show connections, flow paths and functions only.
They do not show construction, size, location of ports, flow rate
or pressures.
6. Each symbol is drawn to show normal, at rest, de-energized,

or neutral condition of the component.
The only exception is when multiple diagrams are drawn
showing various phases of circuit operation.
7. Letters may be used as part of graphic symbols but are not

necessary except M inside a circle to denote electric drive
motor and ∑ inside the flow meter symbol to show that it is
a totalizing flow meter.
8. A solid arrow or triangle, as shown in figure 45, can indicate
the flow direction of oil from the pump and the circuit. This
arrow can be used by itself to represent the power unit.
SUPPLY FROM
PUMP
RETURN TO
RESERVOIR
Figure 45. Oil Flow To and From the Pump

SKILL 5 DRAW A HYDRAULIC SCHEMATIC FROM THE ACTUAL
CIRCUIT CONNECTIONS ON A PICTORIAL
Procedure Overview
In this procedure, you will draw schematics by looking
at actual circuit connections on pictorials. This is a
common requirement in industry because the schematics
often are not readily available.
❑ 1. On a copy of figure 47, draw the circuit schematic for the pictorial
shown in figure 46. Start from the supply and return manifold
connections as shown. You may show flexible hoses as rigid
connectors (i.e. a straight line) and omit all quick-connect symbols.

FLOW
SUPPLY
MANIFOLD

1 1
FLOW FLOW 2 2
CONTROL CONTROL 3
3
#1 #2
A A
NEEDLE
VALVE
A B
B B RETURN
MOTOR MANIFOLD
D.C.V. IN
#1
CHECK VALVE #1
A B B A
CHECK VALVE #2
OUT
CYLINDER B A
Figure 46. Pictorial of a Basic Hydraulic Cylinder Circuit

Figure 47. Schematic of a Basic Hydraulic Cylinder Circuit
❑ 2. On a copy of figure 49, draw the circuit schematic for the pictorial
shown in figure 48. Start from the supply and return manifold

FLOW
SUPPLY
MANIFOLD

SHUTOFF
VALVE
1 1
FLOW FLOW 2 2
CONTROL CONTROL 3 3
#1 #2
A A
NEEDLE
VALVE
A B RETURN
B B
MANIFOLD
MOTOR
D.C.V. IN
#1
CHECK VALVE #1
A B B A
CHECK VALVE #2
OUT
CYLINDER B A
Figure 48. Pictorial of a Basic Hydraulic Motor circuit

Figure 49. Schematic of a Basic Hydraulic Motor Circuit
❑ 3. Draw the circuit schematic for the pictorial shown in figure 50 on a

copy of figure 51. Start from the supply and return manifold

FLOW
SUPPLY
MANIFOLD

SHUTOFF
VALVE
1 1
FLOW FLOW 2 2
CONTROL CONTROL 3 3
#1 #2
A A
NEEDLE
VALVE
A B RETURN
B B
MANIFOLD
MOTOR
D.C.V. IN
#1
CHECK VALVE #1
A B B A
CHECK VALVE #2
OUT
CYLINDER B A
Figure 50. Pictorial of a Hydraulic Circuit

Figure 51. Schematic of a Hydraulic Circuit
❑ 4. Draw the circuit schematic for the pictorial shown in figure 52 on a

copy of figure 53. Start from the supply and return manifold
connections as shown. You may show flexible hoses as a rigid
connector (i.e. a straight line) and omit all quick-connect symbols.

FLOW
SUPPLY
MANIFOLD

1 1 SHUTOFF
2 2 VALVE
FLOW FLOW
CONTROL CONTROL 3 3
#1 #2
A A
NEEDLE
VALVE
A B RETURN
B B
MANIFOLD
MOTOR
D.C.V. IN
#1
CHECK VALVE #1
A B B A
CHECK VALVE #2
OUT
CYLINDER B A
Figure 52. Pictorial of a Hydraulic Cylinder and Motor Circuit

Figure 53. Schematic of a Hydraulic Cylinder and Motor Circuit

SKILL 6 DRAW A HYDRAULIC CIRCUIT GIVEN A SCHEMATIC
Procedure Overview
In this procedure, you will draw pictorials of the
hydraulic trainer’s actual circuit connections given
schematics. This will help you develop your skills in
reading schematics.
❑ 1. Draw the circuit hose connections between circuit components on

a copy of the pictorial shown in figure 55 given the schematic of
figure 54.
Figure 54. Schematic of a Fluid Power Circuit

FLOW
SUPPLY
MANIFOLD

1 1 SHUTOFF
FLOW FLOW 2 2 VALVE
CONTROL CONTROL 3 3
#1 #2
A A
NEEDLE
VALVE
A B RETURN
B B
MANIFOLD
MOTOR
D.C.V. IN
#1
CHECK VALVE #1
A B B A
CHECK VALVE #2
OUT
CYLINDER B A
Figure 55. Pictorial of a Fluid Power Circuit

figure 56.
GAGE A
GAGE C
Figure 56. Schematic of a Two Cylinder Circuit

FLOW
SUPPLY
MANIFOLD

1 1
SHUTOFF
FLOW FLOW 2 2 VALVE
CONTROL CONTROL 3 3
#1 #2
A A
NEEDLE
VALVE
A B RETURN
B B
MANIFOLD
MOTOR
D.C.V. IN
#1
CHECK VALVE #1
A B B A
CHECK VALVE #2
OUT
CYLINDER B A
Figure 57. Pictorial of a Two Cylinder Circuit

figure 58.
GAGE B GAGE A
Figure 58. Schematic of a Fluid Power Circuit

FLOW
SUPPLY
MANIFOLD

1 1
SHUTOFF
FLOW FLOW 2 2 VALVE
CONTROL CONTROL 3 3
#1 #2
A A
NEEDLE
VALVE
A B RETURN
B B
MANIFOLD
MOTOR
D.C.V. IN
#1
CHECK VALVE #1
A B B A
CHECK VALVE #2
OUT
CYLINDER B A
Figure 59. Pictorial of a Fluid Power Circuit

SKILL 7 DESIGN A MULTIPLE ACTUATOR HYDRAULIC CIRCUIT
Procedure Overview
Now that you have learned how to draw schematics,
you will get a chance to combine this skill with your
creativity to design a more complex hydraulic circuit.
❑ 1. Read the following scenario.

Scenario: You work for a company that builds plastic injection
molding machines. Your job is to design a hydraulic circuit that
will perform the following operations:
• Open and close a mold with a hydraulic cylinder.
• Power a hydraulic motor to turn a large screw that feeds hot
plastic into the mold.
H. HYDRAULIC MOTOR
A. HYDRAULIC G
DRIVE
CLAMP
CYLINDER B D
C
N
F
L J
A. Hydraulic clamp cylinder F. Heating cylinder and Oil pressure:

B. Movable platen reciprocating screw J. Screw forward
C. Mold halves G. Hopper for Plastic Pellets L. Clamp
D. Fixed platen H. Hydraulic Screw drive N. No pressure
E. Injection nozzle
Figure 60. Plastic Injection Molding Machine
The motor and the cylinder should be capable of operating

separately, but the motor should only be able to turn when the
mold is clamped (cylinder extended). The speed of both the
cylinder and the motor must be separately adjustable.
A pressure gage should be located near each actuator.
The motor only needs to turn in one direction.
You can use more than one directional control valve if needed.
Use lever operated DCV’s.

❑ 2. Draw the circuit schematic that will perform the operation
described in step 1. Include the hydraulic power unit.
CLAMP
CYLINDER
MOTOR
Figure 61. Circuit Schematic

SEGMENT 4
SELF REVIEW
1. Unless specifically mentioned, schematic symbols are drawn

in the ______________ condition.
2. The one symbol which may be shown many times on a

schematic but does not mean that there are more than one is
the __________________.
3. The letter M inside of a circle indicates ____________.
4. Symbols may be rotated or reversed except for the ______

__________ which is always shown with an open side up.
5. An X across a conductor or connector indicates

___________.


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BASIC

BASIC HYDRAULIC CIRCUITS

BASIC HYDRAULIC CIRCUITS

FOURTH EDITION, LAP 2, REV. E

B831-XA LAP 2 BASIC HYDRAULIC CIRCUITS

SEGMENT 2 NEEDLE VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

SEGMENT 3 BASIC MOTOR CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

SEGMENT 4 HYDRAULIC SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

B831-XA LAP 2 BASIC HYDRAULIC CIRCUITS

OBJECTIVE 1 DEFINE FLOW RATE AND EXPLAIN HOW IT

VOLUMETRIC FLOW RATE FORMULA

TIME FOR THE

Figure 1. Volume Flow in a Tube

B831-XA LAP 2 BASIC HYDRAULIC CIRCUITS

OBJECTIVE 2 DESCRIBE THE OPERATION OF TWO TYPES OF

A flowmeter is a device that measures the flow rate of fluid.

B831-XA LAP 2 BASIC HYDRAULIC CIRCUITS

FLUID PASSES THROUGH

B831-XA LAP 2 BASIC HYDRAULIC CIRCUITS

Figure 3. Typical Turbine Flowmeter

The schematic symbol for all types of flowmeters is shown in figure

Figure 4. Flowmeter Schematic Symbol

B831-XA LAP 2 BASIC HYDRAULIC CIRCUITS

❑ 1. Connect the flowmeter on the 850 trainer, as shown in figures 5

HYDRAULIC INSTRUMENTATION PANEL

RELIEF \ SEQUENCE PRESSURE REDUCING

Figure 5. Pictorial of Circuit for Measuring Flow Rate with a Flowmeter

B831-XA LAP 2 BASIC HYDRAULIC CIRCUITS

Figure 6. Schematic Diagram of Circuit Setup

❑ 2. Perform the following checkout procedures for the power unit:

B831-XA LAP 2 BASIC HYDRAULIC CIRCUITS

Figure 7. Circuit Setup

OPERATION FLOW RATE

B831-XA LAP 2 BASIC HYDRAULIC CIRCUITS

❑ 1. Connect the flowmeter in the 850 Trainer as shown in figures 8

HYDRAULIC INSTRUMENTATION PANEL

Figure 8. Pictorial of a Circuit for Measuring Flow Rate

B831-XA LAP 2 BASIC HYDRAULIC CIRCUITS

Figure 9. Schematic Diagram of a Circuit for Measuring Flow Rate

❑ 2. Before restarting the power unit, unscrew the filler-breather cap on

B831-XA LAP 2 BASIC HYDRAULIC CIRCUITS

FLOWMETER TIME TO FILL

B831-XA LAP 2 BASIC HYDRAULIC CIRCUITS

FLOWMETER FLOW RATE ACTUAL FLOW RATE DIFFERENCE

B831-XA LAP 2 BASIC HYDRAULIC CIRCUITS

The pump generates fluid flow in a hydraulic system. Industrial

Figure 10. Basic Pump Operation

B831-XA LAP 2 BASIC HYDRAULIC CIRCUITS

DRAWING FLUID IN PUSHING FLUID OUT

Figure 11. Pump Action of a Syringe

The schematic symbol for a fixed-displacement hydraulic pump is

Figure 12. Schematic Symbols for Fixed-Displacement Hydraulic Pump

B831-XA LAP 2 BASIC HYDRAULIC CIRCUITS

❑ 1. Set up the circuit shown in figure 13.

Figure 13. Circuit Setup

B831-XA LAP 2 BASIC HYDRAULIC CIRCUITS

PRESSURE FLOW RATE

❑ 8. Increase the pressure at gage S to 250 psi/1725 kPa by turning the

6. Flow is restricted through a