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Automotive Lift Repair Tampa Florida | Understanding Hydraulic Systems Part 1

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Step-by-Step Guide to Hydraulic Schematics

Diesel technicians face several challenges when repairing the hydraulic systems of construction or farming equipment. This blog post aims to clarify the components of a hydraulic system, explain their functionality, and provide a foundational understanding of how to read hydraulic schematics.

 What is a Automotive Lift Repair Tampa Florida Hydraulic System?

Hydraulic systems operate by utilizing force generated from compressed fluid. They include a reservoir to store non-pressurized hydraulic fluid and a motor that pumps this fluid out during the piston’s upstroke. As the piston descends, the oil is transferred into the hydraulic cylinder, increasing pressure. This pressurized fluid generates the mechanical force necessary to lift a load.

 Understanding Automotive Lift Repair Tampa Florida Hydraulics

Tip: Exercise caution when working with hydraulic systems, as they are highly pressurized (2,000-3,000 PSI) and can reach extreme temperatures. Always relieve pressure and allow the system to cool before changing lines, connections, filters, or fittings.

Hydraulic systems consist of several key components:

– Fluid: Typically hydraulic oil

– Reservoir: Holds the fluid

– Pump: Forces the fluid through the system

– Valves: Control the flow

– Motor/Actuator

– Cylinder

– Hose

– Filter

1. Directional Control Valves: Determine the flow path of the hydraulic oil.

2. Pressure Relief Valves: These open when system pressure exceeds a set value, preventing overloads and limiting output force. When opened, oil flows back into the reservoir.

 Reading a Hydraulic Schematic for Beginners

Click the button below to download a comprehensive guide that outlines fluid power symbols and electrical symbols.

Download the guide.

A fundamental understanding of Automotive Lift Repair Tampa Florida hydraulic system components and how to interpret them on a schematic is crucial for making repairs. To simplify this, let’s break down the basic components of the system.

 Hydraulic Reservoirs

Every hydraulic reservoir will feature at least two connecting lines, and it is the only component that appears more than once in a schematic.

 Hydraulic Pumps

In a hydraulic pump schematic, the triangle indicates the direction of oil flow. If the pump is reversible or pumps in multiple directions, it will display two triangles pointing in opposite directions, indicating bidirectional flow. An arrow through the pump denotes a variable displacement pump.

Automotive Lift Repair Tampa Florida Hydraulic Motors

Unlike hydraulic pumps, the triangles on a hydraulic motor point inward, signifying oil flowing into the motor. A single triangle indicates a non-reversible motor, while two triangles signify a reversible motor. An arrow through the motor indicates a variable-speed motor.

 Automotive Lift Repair Tampa Florida Hydraulic Valves

– Valve Envelopes: These are represented by squares that indicate each position for the valve.

– Control Valves: These show the flow to pressurized passages or return pathways for hydraulic oil.

– Valve Ports: The inlets and outlets where hydraulic flow enters or exits the valve.

Check Valves (Bottom Right Quadrant): The basic symbol illustrates a free-flowing direction and a non-flowing direction for oil. Spring-loaded check valves hold a ball against a seat to prevent backflow. Shuttle valves connect two flow sources into one branch of the hydraulic circuit. Pilot-controlled check valves allow flow in one direction but permit reverse flow if pilot pressure is applied.

 Hydraulic Cylinder

The rectangle symbolizes the cylinder’s barrel, while the rod and piston are depicted with a tee positioned inside the rectangle.

 Performing Hydraulic System Diagnostics and Repairs

We hope this provides a basic understanding of hydraulic systems. At Diesel Laptops, our mission is to equip mechanics and equipment owners with the tools they need for diagnostics and repairs.

Many of our customers have expressed a desire to learn more about these systems, leading us to develop a hands-on training program. It consists of two classes: Automotive Lift Repair Tampa Florida Hydraulic System Fundamentals and Hydraulic System Diagnostics. By the end of these courses, students will gain a comprehensive understanding of hydraulic systems and learn to diagnose issues effectively, saving both time and money.

Explore all our upcoming courses, including those on aftertreatment systems, electrical diagnostics, and more, by clicking here.

 Components of a Hydraulic System

A hydraulic system consists of several key components that maintain fluid under the desired pressure, keep it clean, and ensure it flows in the correct direction. Here’s a brief overview of these components:

 Reservoir Tank

The hydraulic reservoir tank stores the fluid and is directly connected to the pump. It allows air bubbles to dissipate and contaminants to settle while also facilitating oil cooling during periods of non-circulation. A vented filter cap regulates airflow, and a filter or strainer prevents contaminants from entering the hydraulic fluid.

 Pump and Engine

The hydraulic pump is responsible for moving liquid from the reservoir through the system, powered by an engine. Common pump designs include two-stage, PTO, or manual hydraulic options, while the engine can be gas, diesel, or electric, depending on power availability, required horsepower, and mounting configuration.

 Automotive Lift Repair Tampa Florida Pressure Gauges and Relief Valve

Once the liquid circulates, pressure gauges can be placed throughout the system to monitor pressure levels. A relief valve manages the fluid pressure that powers the hydraulic cylinder, returning excess fluid to the reservoir. This helps prevent pressure buildup and potential equipment damage.

 Valve Assembly

The hydraulic valve assembly governs the direction, pressure, and flow rate of the fluid within the hydraulic circuit. It controls the speed of motors and the movement of cylinders. Directional control valves are the most common, directing fluid flow from the pump to the cylinders and other system components.

 Cylinder

A hydraulic cylinder functions as an actuator, converting hydraulic energy into linear movement, which is essential for the operations of mobile equipment. These cylinders can lift, push, pull, and press loads that require significant force.

 Motor

Like cylinders, hydraulic motors are actuators that convert hydraulic pressure and flow into movement, but they generate torque and angular displacement (rotation) instead of linear motion. The pressure and displacement of a motor determine the torque produced, while the flow rate influences the speed.

 Flow Control Valve

The flow control valve regulates the flow rate to motors and cylinders, thereby controlling the speed of these components.

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