INTRODUCTION TO

HYDRAULIC SYSTEM
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Hydraulic Pumps : Principles

Output

Control

Power
Supply
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Type of Valves

Output
FCV

DCV
Control

PCV
Power
Supply
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Type of Valves
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Directional Control Valve : Check valve

 Basic DCV is A Check valve.

 A Check Valve allows flow in
one direction.
 The diagram show a basic inline
check valve.

Free-flow direction No-flow direction

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Directional Control Valve : Check valve

Free-flow direction No-flow direction

 In the free-flow direction, the fluid pressure

overcomes the spring forces.
 The higher the pressure, the greater will be
the force pushing the poppet against it seat
 If flow is attempted in the opposite direction,
the fluid pressure pushes the poppet (along
with the spring force) in the close position.
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Check Valves in Circuit
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Bypassing using Check valve

 A Check Valve can be used for

component bypass, since it give
the circuit line the lowest
resistance to the line.
 Check valve = Injap sehala
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Pilot check valve

 Another type of Check Valve is

pilot to open check valve.
 The pilot line refers to a line where
it received command from the fluid
itself.
 It always permits free flow in one
direction but permits flow in the
normally blocked opposite direction
only if pilot pressure is applied at
the pilot pressure port of the valve.
 Pilot to Open Check Valve = Injap
sehala buka kendalian pandu.
 Pilot to close check valve will
block the free flow if the pilot
pressure is applied.
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Pilot to Open Check Valve in Counterbalance Circuit.

What happened if the NORMAL check valve is used or without check valve?
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Pilot to Open Check Valve in Counterbalance Circuit.
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Shuttle Valve

Shuttle Valve allow two alternated flow to

be connected into the line.
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DCV Valves : How to Classified?

In Short : 2/2 DCV, 2/2 Way Valve.

In Full : 2 Way, 2 “Spool” Position Valve.
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Type of 2/2 Way Valve. (Normally Open and Normally Closed)

2/2 Way Valve (Normally Close) type 2/2 Way Valve (Normally Open) type
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Type of 3/2 Way Valve. (Normally Open and Normally Closed)

3/2 Way Valve (Normally Open) type 3/2 Way Valve (Normally Closed) type
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3/2 Valve (Normally Closed)

Use for single acting cylinder

NORMAL POSITION ACTUATED

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3/2 Valve (Normally Closed )

NORMAL POSITION ACTUATED

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4/2 Valve (PB Type )
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4/2 Valve (Lever type ) NORMAL POSITION

Use for double acting cylinder

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4/2 Valve (Lever type ) ACTUATED
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NEUTRAL POSITION

The four way, two position DCV used in previous circuit are sometime impractical
since they continuously sending flow and pressure into hydraulic actuator. The should
give a relief to the actuator, a NEUTRAL position should be used, where the actuator is
not subjected to pump pressure.

4/2 Valve

4/3 Valve
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4/3 Valve With Closed Neutral Position

Closed Neutral Position:

(1) The Pump is blocked.
(2) The flow goes to Pressure Relief
Valve.
(3) The maximum allowed pressure
of the system is set by the
pressure relief valve.
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4/3 Valve With Tandem Neutral Position

Open Neutral Position:

(1) A desirable condition where the
only pressure involve line
resistance.
(2) The power consumption is
reduced. Is said to be
UNLOADED.
(3) Less energy wasted.
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Valve Actuated: Direct and Pilot

Push button 4/2 way directional

control valve with spring return

Hydraulic oil in Pilot Line only

help in changing the position of
the valve, it does not get mixed
with the oil that is flowing
inside the valve.

Pilot 3/2 way directional

control valve with spring return
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The way to actuate the Valves.
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The way to the actuated valve RETURN to normal position.
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Example of Directional Control Valve.
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FLOW CONTROL VALVE : Needle valve.

 Basic FCV is a needle valve.

 A needle valve control the flow
rate in the circuit.
 By controlling the flow rate, the
speed of the actuator can be
controlled.

 Controlling the flow rate is called metering the flow, in hydraulics.

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FLOW CONTROL VALVE : One way FCV

 A one way FCV is an integrated

needle valve with a check valve.
 A one way FCV give a controlled
flow direction from left to right
(A) and a free flow in reverse (B)
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“Meter-In” : Controlling the Flow into the Actuator (In case of extension only)

 The term “meter-in” or

“metering in” means that we
are controlling the flow that
goes INTO the cylinder.
 The Figure show “meter-in”
flow control during extension
only.
 The meter-in here is only for
extension of the cylinder.
 Remember that that is no
metering / no flow control is
done on the retraction of the
cylinder.
 HYDRAULIC SYSTEM “Meter-Out” : Controlling
the Flow out from the Actuator (In case of extension only)

 The term “meter-out” or

“metering-out” means that we
are controlling the flow that
goes OUT FROM the cylinder.
 The Figure show “meter-out”
flow control during extension
only.
 The meter-out here is only for
extension of the cylinder.
 Remember that that is no
metering / no flow control is
done on the retraction of the
cylinder.
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When to use Meter-In and Meter out ??

 It usually depends on the load.

 When we handle resistive load, we can use Meter In.
 Resistive load is the load that resist the oil flow.
 When we handle tractive load, we can use Meter Out.
 Tractive load is the load that follow the oil flow.

Resistive Load Tractive Load

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Consequence of Metering in and out.

 There is no consequence of using

“meter in” flow control for resistive
load.
 However, by using meter-out for
tractive load can cause pressure
intensification.
 This pressure intensification is ok if it
within the operating pressure limit of
the actuator, if it is out of the operating
pressure limit, the actuator can be
damaged/break /leak.
 REMEMBER!!!! The positioning of
metering in or out is also differ with the
position of the load, whether towards
upward, downwards or in horizontal
Pressure intensification. movement.
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PRESSURE CONTROL VALVE

 The most widely used of PCV is

Pressure Relief Valve.
 A Pressure Relief Valve limit the
maximum pressure in hydraulic circuit by
giving alternate direction to the flow when
it reach certain pre-set pressure level.
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Pressure Relief Valve : The Application in the Circuit

 Pressure control valve practically is

used in every hydraulic system.
 It is normally a closed valve whose
function is to limit the pressure to a
specified maximum value by diverting
oil from pump flow back to the tank.
 Refer to the circuit : When the motor is
Normal position
on and the control valve is un-actuated,
the fluid pressure in the pipe line will
increase. At the maximum pressure, the
pressure relief valve will open and
allow the fluid to return back to the
tank Without the pressure relief valve
PCV the pipe line may explode or the pump
damage.
 If the valve is actuated, the piston will
extend. When the piston fully extend
the pressure will also increase and
again the pressure relief valve will
open.
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PRESSURE CONTROL VALVE : Variation

Why do they
need external
drain?
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PRESSURE REDUCING VALVE
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PRESSURE REDUCING VALVE

These are used to provide a constant pressure to part of a system that is lower than the
pressure in the rest of the system.

The design is very similar to the two stage pressure relief valve but the motion of the
piston is controlled by the outlet pressure, not the system pressure.

The high pressure oil leaks through the restrictor and lifts the poppet. The pressure is
set by adjusting the spring behind the poppet.

The oil passing through is wasted to drain. The pressure drop through the restrictor
produces a force imbalance on the spool and it moves to partially block port B and so
reduce the pressure at port B.

If the pressure on port B rises, the leakage through the restrictor increases and the
pressure drop increases so the spool moves further close port B.

If the pressure on port B drops, the leakage drops and the pressure difference drops so
the spool moves to open port B and let more oil through.
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PRESSURE REDUCING VALVE

Pneumatic systems are low pressure systems and are supplied with air at a typical
pressure of 8 bar and this is reduced to supply the system typically at 3 bar.
The air is supplied to the system through a regulator which is a form of reducing
valve.
The pressure is reduced through the poppet valve (2). The valve is set by the spring
and adjuster (4).
Variations in the outlet pressure make the diaphragm (3) move up or down to open
and close the valve as required to keep the pressure constant.
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VALVE SYMBOLS
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VALVE SYMBOLS
THANK YOU

Please do some revision!!!!