How to

Interpret
Hydraulic
Control
Diagrams

Brendan Casey
Marian Tumarkin
 How to Interpret Hydraulic Control Diagrams 2

Copyright © 2006 Brendan Casey & Marian Tumarkin

All rights reserved. No part of this electronic book may be reproduced or

transmitted in any form or by any means, electronic, mechanical, photocopying, and
recording or otherwise, without the prior, written permission of the publisher.

The contents of this book reflect the author’s views acquired through his experience
in the field under discussion. The information in this document is distributed on an
“As is” basis, without warranty. Every effort was made to render this book free from
error and omission. However, the author, publisher, editor, their employees or agents
disclaim liability for any injury, loss, or damage to any person or body or organization
acting or refraining from action as a result of material in this book, whether or not
such injury loss or damage is in any way due to any negligent act or omission, breach
of duty, or default on the part of the author, publisher, editor or their employees or
agents.

First published in 2006 by

HydraulicSupermarket.com
PO Box 1029
West Perth WA 6872
Australia
Email: info@HydraulicSupermarket.com
Web: http://www.hydraulicsupermarket.com/books

About the Authors

Brendan Casey is the founder of HydraulicSupermarket.com and the best-selling author of
'Insider Secrets to Hydraulics' the most comprehensive guide to reducing hydraulic
equipment operating costs ever published. A fluid power expert with an MBA, he has more
than 18 years experience in the design, maintenance and repair of mobile and industrial
hydraulic equipment.

Dr Marian Tumarkin has over 35 years of experience in the field of Fluid Power with
a Ph.D. from the National Academy of Science in Moscow. He is an accomplished
scholar in the field with over 50 published papers and 10 patents to his name.

A highly experienced Fluid Power engineer, Marian has designed electro-hydraulic

systems for Russian and Australian Air Forces, Australian and American automotive
industries, as well as developing special purpose machines. In this role, he was
responsible for concept design and problem solving, calculations and component
selection, system testing and troubleshooting.

Marian has extensive teaching experience both in Europe and Australia, delivering
basic and advanced Fluid Power subjects to undergraduate and post-graduate
students as well as engineers and technicians.

Copyright © 2006 ─ www.HydraulicSupermarket.com

 How to Interpret Hydraulic Control Diagrams 3

HYDRAULIC SYSTEM DIAGRAMS

A variety of diagrams can be used to explain the function, operation, and assembly of
a hydraulic power system. These include:
• Circuit diagram
• Piping diagram
• Pictorial diagram
• Cut-away diagram
• Combination diagram
• Step diagram
• Block diagram

1.1. The hydraulic circuit diagram (schematic) is the main drawing relating
to the actual hydraulic system and is used in all stages of system design, installation,
and troubleshooting.

• To aid understanding of the hydraulic system function and operation,

mechanical, electrical, cutaway, and graphical symbols can be included in
the circuit diagram.

• For installation and maintenance, a piping diagram should be supplied

separately from the circuit diagram.

EXAMPLE 1.1. Hydraulic system of a forklift truck

A pictorial diagram (Fig. 1.1) shows the general location of each component and
interconnecting piping. The main purpose of this diagram is to guide installation and
assembly. Component locations are shown without any information about operation,
parameters, and manufacturer or supplier.

Hydraulic Hydraulic
Power Unit Cylinder

DCV

Flow Control
Valve

Fig. 1.1. Pictorial diagram of a forklift

Copyright © 2006 ─ www.HydraulicSupermarket.com

 How to Interpret Hydraulic Control Diagrams 4

The hydraulic circuit diagram of the forklift is shown in the Fig. 1.2. The circuit does
not provide enough information to understand cylinder retraction. Therefore, it should
be modified with the cylinder shown in a vertical position and include a graphical
symbol showing weight of the load (see Fig. 1.3).

3
2 4

4
2

6 5
6
1
1
7
7

8 8

Fig. 1.2. Hydraulic circuit diagram Fig. 1.3. Combined circuit diagram

Piping diagram for the forklift hydraulic system gives information about pipes/hoses
location, sizes and fittings.
3-Cylinder

2-1
4-DCV

3-1 4-1 5-Flow

4-2
control

6-2 4 -1

1-2
6-Pressure 5-1
relief valve
1-Pump
6 -1 7-Filter
1 -1
7-1

8-Reservoir

Fig. 1.4. Piping diagram

Copyright © 2006 ─ www.HydraulicSupermarket.com

 How to Interpret Hydraulic Control Diagrams 5

1.2. For sequential control, a displacement-step diagram provides information

about the sequence of steps. Whereas a displacement-time diagram provides
information not only about the sequence of steps, but also about the required stroke
and speed.

EXAMPLE 1.2. Molding press

The main specifications for press operation are shown in

the Table 1.1

Table 1.1. Specification for molding press

Parameters S t F
No Step m ft sec kN lbf
1 Fast approach 1.2 4 5 25 6,000
2 Final pressing 0.2 0.7 10 100 24.000
3 Holding 0 0 10 100 24,000
4 Return 1.4 4.7 5 5 1,000
5 Reload 0 0 10 0 0

A displacement-step diagram provides 1 2 3 4 5

information about the sequence of steps. A3
However, no information is provided about
A2
the required flow rate. Therefore, preference
should be given to a displacement-time
diagram.
A1

Steps 1 2 3 4 5 Start A2 A3 Time A1

1.6 5.3
Fig. 1.5. Displacement-step diagram
Displacement, m

Displacement, ft

1.2 4.0

0.8 2.6

0.4 1.3 A displacement-time diagram provides

information about the sequence of steps
0 0
0 10 20 30 40 and the required distance and speed.
Time, sec

Fig. 1.6. Displacement-time diagram

Copyright © 2006 ─ www.HydraulicSupermarket.com

 How to Interpret Hydraulic Control Diagrams 6

1.3. A block diagram shows the transmission of signals, energy, or power.

EXAMPLE 1.3. Power transmission in a hydraulic system

A hydraulic power system converts mechanical power into hydraulic power, transmits
it over a distance, and converts it back into mechanical power by means of a liquid
(mainly mineral oil). The general function of the system can be shown graphically
using a block diagram – Fig. 1.7.

HYDRAULIC POWER SYSTEM

hydraulic
mechanical
power
input
MECHANICAL POWER POWER
POWER SOURCE CONVERSION TRANSMISSION

mechanical hydraulic
output power
POWER
LOAD CONTROL
CONVERSION

output
control

Fig. 1.7. Block diagram for hydraulic system power transmission

EXAMPLE 1.4. Simple level regulator

The function of the regulator is to support a
constant level of liquid (water) in the tank:
H = constant

water
supply

control
input Fig. 1.8. Simple level regulator
VALVE

LEVEL
SENSOR
Block diagram of the regulator shows the regulator
operation from the signal transmission point of view
(Fig. 1.9). The functions of the main components
RESERVOIR
are shown independently of their design: level
level
sensor may not be a float valve, but rather an
water electrical transducer; water control valve could be a
consumption
solenoid operated DCV, etc.
Fig. 1.9. Block diagram of
This type of diagram is a standard tool for
the level regulator
proportional control functional description and
analysis.

Copyright © 2006 ─ www.HydraulicSupermarket.com

 How to Interpret Hydraulic Control Diagrams 7

FURTHER READING

‘Advanced Hydraulic Control’ by Brendan Casey & Marian Tumarkin

Available second half of 2007: http://www.HydraulicSupermarket.com/books

Copyright © 2006 ─ www.HydraulicSupermarket.com