2.

Chassis components of construction

equipment
2.1 Hydraulic system
Hydraulics :Study of fluid at rest and in motion and
ability to perform work.
Hydraulic system: It is the system by means of
which mechanical energy is converted into
pressure or fluid energy and fluid energy is
converted into mechanical energy to perform
work.
Mechanical energy-pressure energy –mechanical
energy
Hydraulic system
Hydraulic system
Main components of hydraulic system
1. Pump
2. Cylinder or motor
3. Control valve
4. Reservoir
5. Hoses and coupler
6. Seal
7. Hydraulic oil or fluid
Main components of hydraulic system
• Pump : Move oil from one to another place.
• Pump: Convert mechanical force into fluid
force or hydraulic force
• Cylinder: Converts fluid pressure or hydraulic
power into mechanical energy to do work
using moving fluid.
• Cylinder: arms or actuator of hydraulic system
Main components of hydraulic system
• Control valve:
Control pressure, direction and volume
Reservoir: Collect sufficient hydraulic oil for the
system
Hoses: passage or route for moving oil from one
place to another places
Hoses: absorb hydraulic shocks ,vibrations and
noises
Main components of hydraulic system
• Hydraulic seals: prevent the leakage of
hydraulic oil from hoses and couples to keep
sufficient fluid pressure in the system.
• Hydraulic seals :prevent dirt and grime
entering into the system.
• Hydraulic oil: working medium to perform
mechanical work
• Hydraulic oil : like blood in human body
 Why hydraulic system is used?
• Flexibility – Flexible hoses for power
transmission
• Multiplication or amplification of force: using
various sizes of cylinders or actuators
• Compactness
• Economy due to simplicity and compactness
• Safety: fewer moving parts
Open system hydraulic system
Open center hydraulic system
Closed center hydraulic system
Closed centre system
Hydraulic circuit
 Pump
• Moves hydraulic oil to whole circuit or system
• Converts mechanical energy or force into
hydraulic power to do task.
• So it works as the heart of human body for
the hydraulic system
• It takes in fluid from reservoir and force out
or displaced to another point
 Types of pumps
• According to way of displacement
• Non positive and positive displacement
• Types of positive displacement pump
• Fixed displacement and variable displacement
pump
• Fixed displacement: volume –constant, pressure –
variable, Volume variable at different speed
• Variable displacement: Volume –variable but
Pressure-Constant
 Types of pumps
1. Piston pumps
2. Gear pump
3. Vane pump
Gear pump
Exploded view of external gear pump
Internal gear pump
Vane pumps
Radial Piston pump
Axial piston pump
 Selection of hydraulic Pump
• Physical size, Pump delivery , pressure and
speed

Types of Delivery Pressure(Psi) Speed (rpm)

pump (Gpm)
Gear 0.2-150 250-2500 800-3500

vane 0.5-250 250-2500 1200-4000

Piston 0.5-450 750-5000 600-6000
 Valve
• Valve is a device which controls or regulates:
1. Pressure
2. Direction
3. Volume of fluid flow in hydraulic circuit or
system.
 Types of valves
• Pressure control valve
• Directional control valve
• Flow control valve
Directional control valve
Rotary directional control valve
Types of valves
 Functions of Pressure control valves
• Limit system pressure
• Reduce pressure
• Set pressure at which oil enters a circuit
• Unload pump
Pressure relief valve
Pressure sequence valve
Direction control valve
Volume control valve
 Volume control valve

• Control the volume of oil flow in the circuit by

throttling or diverting it
• Regulate the volume of oil flow to the
actuator (Cylinder or motor)
Flow divider valve
 Hydraulic cylinder
• Converts fluid pressure or fluid energy or force
into mechanical energy to perform work such
as lowering or raising load , rotating wheel etc
• Hydraulic cylinders are the arms of the
hydraulic circuit to do work.
 Types of cylinder
1. Piston type cylinder : for straight movement
2. Vane type cylinder: for rotary movement
Piston type cylinder
Cylinder
Differential cylinder
Telescopic cylinder
Vane type cylinder
 Hydraulic motor
• It converts fluid energy into mechanical
energy. It converts hydraulic fluid flow into
mechanical work to do rotating job : rotating
wheel, rotating cab of excavator
 Vane motor
• Vane motor consists of housing with ports ,
inner rotor with slots for vanes, vanes and
output shaft for performing work ( rotating
job)
Geromotor (gear rotor motor)
Radial piston motor
 Hydraulic accumulator
• Uses of accumulators:
• Store energy
• Absorb shock
• Build pressure gradually
• Maintain Constant pressure
 Types of accumulator
• Pneumatic or gas loaded accumulator
• Weight loaded
• Spring loaded
accumulator
Pneumatic (compressed air)
accumulator
Bladder type accumulator
Diagram type accumulator
 Reservoir
• Reservoir is a container which :
1. stores sufficient hydraulic oil
2. Cleans oil or separates oil from foreign
material
3. Cool oil or dissipate excess heat from oil
4. Separate oil from air.
 Reservoir
• Main components: container with baffle,
return or inlet line, outlet line with filter to
pump, Filler cap with air vent, oil level gauge,
drain plug etc.
 Filter
• separates the contaminants of hydraulic fluid:
to prevent score or ruin the system
components: precisely fitted valves, cylinder ,
motor and pump
• To prevent closing of tiny control orifice or
obstruct oil passages.
• To prevent wear parts of the system.
 Types of filters
1. Surface filter: single surface catches and
remove dirt particles larger than filter hole
size : They are made of wire mesh or paper
disks, metal ribbon
2. Depth filter : larger surfaces or multiple
surfaces to separate dirt. Made of cotton,
wood pulp, paper, wool yarn etc.
 Hose
• Is flexible pipe which :
• connects system components
• carries hydraulic oil
• Allow the movement of oil from one
component to another
• Absorbs vibrations and noise
 Hoses
• It consists of three basic parts:
• Inner tube is made of synthetic rubber layer and
It should be: oil, heat and corrosion resistant and
smooth and flexible.
• Reinforcement layers are made of natural or
synthetic fibers or braided wire or combination of
these
• Outer cover: Special rubber is used to protect
reinforcement layers from abrasion and exposure
to weather, oil and dirt.
 Hoses
• It should withstand predetermined pressure
and temperature and alow sufficient oil flow.
 Hose couplers
• Are used to join or connect hoses or hose to
another part or component:
They have mainly two parts :
1. Fittings : end of hose and socket and nipple or
sleeves
2. Adaptors: a part for connecting the hose
fitting and another line (t-joint,elbow,reducer)
Types: Male and female couplers
Hose couplers
 Hose couplers
• Types of hose couplers: Male and female
• Types of hose fittings: Permanent and
reusable
• Materials of Hose couplers : brass, steel,
stainless steel, plastic etc
• Hose fitting and adaptor should be sealed to
prevent oil leakage.
Hose fittings ( male n femle)
 pipe
Is a fluid conductor or path for fluid flow .
It should be correct size according to system
pressure and fluid flow.
Pipe is used for larger volume of fluid flow under
higher pressure, for straight line and for more
permanent installation.
Pipe is cheaper than tubes.
Material of pipe : mild steel
 Tube
• Tube is a conductor or path for flowing fluid
• Tube is smaller than pipe.
• Tube material: copper, aluminium, plastic, steel
• Easy to make flare to joint
• Easy to bend
• Better appearance
• Better reusability
• Less leakage.
Tube
Oil seal
 Oil seal
• To seal joining components
• To prevent leakage of hydraulic fluid
• To hold oil under pressure in the hydraulic
circuit.
• Prevents dirt and grime (dust, mud ,fiber, lint)
enter into the hydraulic system
 Types of seals
Types of seals according to their uses:
1. Static seal: to seal fixed components : o-ring,
gaskets, packings
2. Dynamic seal: to seal moving parts (rotating
and reciprocating parts):U and V
packings,cup and flange packing etc
 Types of seal
• Types of seal according to form or design
1. O-ring : used as static and dynamic seal
2. U and V- packing : dynamic used : piston and cylinder
3. Spring loaded lip seal: Seal rotary shaft
4. Cup and flange packing: seal cylinder pistons and piston
rods
5. Mechanical seal: Dynamic seals made of the mixer of
metal and rubber: rotating shaft
6. Metallic seal : dynamic seals: made of metal: piston and
piston rods ( like as piston rings)
7. Compression packing : dynamic seal and (8)compression
gasket: Static seals
 Hydraulic fluids
It is medium to transfer power from pump to
actuators ( cylinder and hydraulic motor) to do
mechanical work.
Hydraulic fluid should do following :
1. Transmit power applied to it
2. Lubricate moving parts
3. Prevent rust and corrosion of machine parts
4. Resist foaming and oxidation
5. Separate from air , water and contaminants
6. Stable for long time or no chemical changes.
 Hydraulic oil
• SAE( society of automotive engineers)
Single grade fluid: SAE 5W,SAE 10W,SAE
20W,SAE30, SAE 40 ETC
Multiple grade fluid: SAE 20W40
JCV HVI Hydraulic oil: HVI 46
Hydraulic fluid should not change its fluidity
with temperature changes.
 General maintenance of hydraulic
system
Preventive maintenance:
1. Change hydraulic fluid periodically
2. Change filters or filtering element on time
3. Remove excessive fluid leakage
4. Correct low or erratic pressure, no pressure
5. Eliminate pump noise
6. Correct overheating of system
7. Correct sluggish operation ( air in oil) etc