Americas Training

GROVE
HYDRAULICS
 GROVE HYDRAULICS

INDEX

Theory and Principle

Components and Circuits

Pressure Check Procedures and Adjustments

Hydraulic Schematics
Grove Training Institute Grove Hydraulics

50ft. 1ft.
MECHANICAL LEVER

HYDRAULIC LEVER

FORCE

2 LB.
100 LB.

1 50
sq. in. sq. in.

P=F/A F=PxA

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Introduction

As we look around at the work environment of today's world, we can find hydraulics
at work in one form or another. Hydraulics like electricity is almost a necessity in
any work area.
With this in mind it is important for a mobile hydraulic equipment technician to
have an understanding of the basic principles of hydraulics and how fluids react
when force is applied to them, in the first portion of this manual we will attempt to
explain the principles of Pascal's law , Hydrodynamics vs. Hydrostatics,
Mechanical Leverage vs. Hydraulic Leverage etc.
With the basic understanding of the principles of hydraulics and combined with
the understanding of hydraulic schematics and symbols the mobile hydraulic
equipment technician will become a more effective troubleshooter.

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 Grove Training Institute Grove Hydraulics

Principles of Hydraulics
In its most basic definition, hydraulics is the use of
liquids to perform a task, the use of hydraulics to
simplify work, multiply human efforts and transmit
power
goes back as far as recorded history. Nature has used
water power to carve out its splendor over the
centuries, this is natures form of hydraulic power.
The human circulatory system is a hydraulic system,
more than that it is a very sophisticated
hydraulic system.
Discovery of Hydraulics
Hydraulics is not a invention; it was a discovery. Blaise Pascal is credited for applying some basic
mathematical principles to hydraulics that are still in use today.
The culmination of Pascal’s effort is the primary law of hydraulics, know n as Pascal’s law.

Hydrodynamics VS. Hydrostatics

The field of hydraulics can be divided into two areas:
: is the study and use of liquids in motion.
Energy is transmitted by the impact of a moving fluid against liquid
blades or vanes, (figure 1) in this case we are using the
kinetic energy of the fluid to produce power.
turbine
Figure 1

: power is transmitted by pushing on a

confined liquid (figure 2). The liquid must move or flow
to cause motion. A transfer of energy takes place
because a quantity of liquid is subject to pressure.

Figure 2

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As we know most hydraulic machines in use today operate hydrostatically: that is, though
pressure. Technically they should be referred to as hydrostatics or pressure hydraulics.
But as tradition would have it the term hydraulics has become customary in the industry,
so as not to buck tradition we will use the terms “ hydraulic “ and “ hydraulics “ in this manual.

Pressure and Flow :

In the discussion and study circles of hydraulics, four terms will be of concern, forces, energy transfer,
work and power and how they relate to the two fundamental conditions within a hydraulic system,
Pressure and Flow . Pressure and flow must be inner- related when considering
work, energy and power. each has its own particular job to do within a hydraulic system.

• Flow is responsible
• Pressure is responsible for
for causing motion.
pushing or exerting a force.
(flow makes it go)
Figure 3

What is Pressure ?

To an engineer, pressure is a term used to define how much force is exerted against a specific
area. The technical definition of pressure, is force per unit area.

Example of Pressure
Pressure has the tendency to expand ( or resistance to compression ) that is present in a fluid
which is being squeezed. A fluid , by definition is a liquid or gas (vapor).
The air that we put in our tires is a gas, and obeys the law of fluids. When we inflate a tire, we
are squeezing in more air than the tire would like to hold. The air inside the tire resists this
squeezing by pushing outward on the tire. This outward push is pressure.
Air like all gases is compressible. You can squeeze it into a smaller volume or more air into
the same space.
As you squeeze more air into a tire, it takes a greater force, and the pressure within the tire
increases.

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Pascal’s Law
Pascal’s law is stated as : Pressure applied to a confined liquid is transmitted
undiminished in all directions, and acts with equal force on all equal directions,
and at right angled to those areas.

We know that (1) pressure is force per unit area, expressed as psi and (2) that force
is push or pull, measured in pounds. Lets apply force to a confined liquid through a
piston. The resulting pressure in the fluid, by Pascal’s Law, is equal throughout.
And, every square inch of the container wall is subject to an equal force because of
the pressure.
The Hydraulic Lever

Most likely the apparatus Pascal used

HYDRAULIC LEVER in his work consisted of two cylinders
of different diameters connected as
FORCE shown figure 4, with a liquid trapped
between them.
2 LB.
100 LB. He could have called his apparatus
the hydraulic lever, since it proved
1 50 that leverage can be gained hydraulically
sq. in. sq. in. as well as mechanically. Pascal found
that a small force on a small piston will
balance a larger force on a larger piston…
provided the piston areas are in proportion
to the forces. As in figure 4 a two-pound
force on a one square inch piston will
balance a 100 pound force on a 50 square
P=F/A F=PxA inch piston

Figure 4

Lets suppose that the force exerted on the small piston is the pressure source, the pressure
would be the force divided by the piston area.
Pressure = 2 pounds = 2 psi
1 sq. in.
The force on the large piston is equal to this pressure multiplied by the piston area.
pounds
Force = 2 sq.in. x 50 sq. in. = 100 lbs

Now we have multiplied force 50 times in this ; in other words, we obtained leverage or
mechanical advantage of .

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MECHANICS VS. HYDRAULICS

Now let’s compare a mechanical

lever ( figure 5 ) to the hydraulic
lever ( figure 6 ),Pascal’s law
still applies in this case, 100 lbs can
still be balanced or lifted with 2 lbs.
50ft. 1ft. but the 2 lbs. needs placed 50 ft.
from the fulcrum and the 100 lbs.
MECHANICAL LEVER needs placed only one ft. from the
fulcrum.
Figure 5

HYDRAULIC LEVER

FORCE

2 LB.
100 LB. The biggest advantage of hydraulics
over mechanical is less room, and
1
sq. in.
50 human effort needs to be applied to
sq. in.
do the same amount of work.

P=F/A F=PxA

Figure 6

The previous examples of hydraulic force multiplication has given us two important relationships
from Pascal’s law.
We can express these relationships as equations to solve simple problems of pressure and force.
First, pressure is equal to force divided by area
P= F
A
Second, the force on any area is equal to the area multiplied by the pressure on the area:
F=PXA

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 Grove Training Institute Grove Hydraulics

The outward push of the air in a tire is uniform though out. That is all the inner surface
of the tire is subject to the same amount of pressure,(upper portion figure 4) if it weren’t
the tire would be pushed into odd shapes due to its elasticity.
Equal pressure throughout an area of confinement is a characteristic of any
pressurized fluid (gas or liquid). Only difference is liquids are only very slightly compressible.

A GAS IS COMPRESSIBLE

As we see in this portion of figure 7, we are trying

to compress the liquid in the containers, as we said
before liquids are only slightly compressible, as we
apply more pressure the more the liquid resists
the compression, pressure builds in the container
until the weakest point gives way.
A LIQUID RESISTS COMPRESSION

Figure 7

Figure 8 shows us two ways to apply

pressure.
FORCE 1. By using a weight we can apply
43.3 LBS
pressure of 4.33 P.S.I. by using a
AREA
10 SQ IN
force of 43.3 lbs. against a piston
area of 10 sq. in. mechanically we
are showing the same principle.
PRESSURE
4.33 PSI The 4.33 P.S.I. is the original equation
using water. One cubic foot of water
weights 62.4 lbs., divided by 144
Figure 8 ( amount of sq. in.) the force would be
.433 P.S.I. remember oil is slightly
lighter than water which creates slightly
less pressure from the force exerted by
its weight. A foot of oil is approximately
0.4 P.S.I., 57.6 lbs.

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Back - Pressure

Lets connect two cylinders to 500 lbs 500 lbs

operate in , LOAD LOAD

the pressure needed to move 1 SQ. IN.

the second cylinder is effective

SURFACE
AREA

against the first cylinder as back

pressure. Now lets add a 500 lb FROM
PUMP 1 SQ. IN.
load to each cylinder. SURFACE
AREA gauge 1

The surface areas are equal (1sq in ) the pressure in gauge 2

gauge #1 will be psi ; the pressure in gauge# 2
will be psi Figure 9

Why is the pressure greater in gauge #1, then in gauge #2 ?

In the hydraulic world, series operation is not common. We used it here to illustrate a
principle; pressures add up in series. Anything that creates a back pressure on the
device that moves or lifts the load, in effect, adds to the load, and increases the pressure
requirement of the system.

WHAT WILL THE PRESSURE READING BE ON THE GAUGES in Figure 10 ?

#1 1 2 3 4
#2
#3
ww ww ww
#4 30 PSI 20 PSI 10 PSI
SPRING SPRING SPRING

tu rn
Re

supply line

Figure 10

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Grove Training Institute Grove Hydraulics

500 LBS
750 LBS 1000 LBS The most common connection in a
hydraulic system is illustrated in
figure 11, the three cylinders are
connected in .
A B C

The study of hydraulics has proved

that oil will always take the path of
least resistance, with this in mind, lets
take a look at the three cylinders in
figure 12.
In what order would each load be raised?
. . .
Figure 11 Why ?

Now we want to be able to control the speed and which cylinder raises its load first, how can we
do this in the least expensive way ?

FLOW
( Flow makes it go )

Visualize turning the faucet on at home, are we seeing pressure or flow ? The flow of fluid in a
hydraulic system is caused by a difference in pressure at two points.
Lets go back to our faucet, the water in the main line has built up pressure, waiting at the tap, the only
pressure outside our tap is atmospheric pressure. When we open the tap, the pressure difference
forces the water out. ( moving fluid from a high pressure area to a low pressure area ).
In a hydraulic system, flow is usually created by the pump; a device used to continuously push on
the hydraulic fluid.

VELOCITY and FLOW RATE

There are two ways flow can be measured: velocity and flow rate.
Velocity of fluid is the average speed of its particles past a given point. It is usually measured in
feet-per-second (fps). Velocity is an important factor in the sizing of hydraulic lines that carry
fluid between components.
Flow rate is the measure of how much volume of liquid passes a point in a given time. It is
measured in gallons per minute. (gpm).
Flow rate determines the speed in which the load moves, it is important in the consideration of
power.

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FLOW
ORIFICE
CONTINUOUS
A orifice is a restriction that is placed in a line
to create a pressure difference.
As long as there is flow, there will be a pressure
drop across an orifice. If flow is blocked beyond
PRESSURE DROP
the orifice, Pascal's law will prevail, pressure will
equalize on both sides.
A pressure drop will happen when fluid passes
FLOW through a hose or a valve, the smaller the passage
BLOCKED
the greater the restriction, the greater the pressure.
The valve or line is acting as a orifice in this case.
PRESSURE EQUAL

Figure 12

FLOW RATE and SPEED

We can relate flow rate (gpm) to the speed at which the load must move, if we consider the
cylinder volume that must be filled and the distance the cylinder piston travels figure 13.
The volume of the cylinder is simply the length of the stroke multiplied by the piston area.
The piston area can be found by squaring the diameter and multiplying by 0.7854.

Lets take a look at the two cylinders in figure 13,

2 ft. Cylinder A is two feet long and holds one gallon
of oil, cylinder B is one foot long and also holds
1 GALLON LOAD A one gallon of oil.
1 GPM
Which cylinder will reach its full stroke first?
Which cylinder will need to travel faster?

To change the speed of a cylinder we can,

1 GALLON LOAD B or the size of the cylinder.
1 GPM
or flow to the cylinder.

Figure 13

Remember a gear pump creates flow; not pressure, Flow is speed, flow makes it go.

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Figure 14

Atmospheric pressure is important to a

hydraulic system. The atmospheric pressure
that is pushing down on everything is
14.7 P.S.I. even though we don’t notice it.
the pressure gauges that we use in our daily
work environment do not include 14.7 P.S.I.A.
it is recognized as P.S.I.G..
A liquid will take the shape of any container
when no flow is present, and the levels will
be equal as in figure 14.
Lets add 4 p.s.i. to one closed container figure 15
the fluid levels in the other containers will increase. Figure 15

In figure 16, the fluid levels in the four

cylinders are the same, cylinder a is larger
than d,e,f, ports b & c are plugged.
Lets pull the plug on port b, free flow is
allowed, in what order will the cylinders
empty? .
Why?
Now lets plug port b, fill cylinders until
levels are equal again. Lets unplug port c
How will the cylinders empty?
.
Figure 16 Why?

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Hydrostatic systems can be divided into:
• Open loop systems
• Closed loop systems

Open loop system

In a open loop system the main system flow
circulates from the reservoir, though the
system and back to the reservoir. The pump
always has an inlet an outlet, representing the
low and high pressure sides respectively.

Open loop systems can be divided into

three groups:
• constant flow, “ CF ”
•constant pressure “ CP”
•load sensing, “ LS “

Figure 5

Closed loop system

In a closed loop system figure 6 the main flow
goes from the pump outlet, though
the system, and then back to the pump inlet.
The pump inlet and outlet ports interchange
as soon as the working directions change.
What common power source that we know, uses
the closed loop system?
Which system would you find on a Grove crane ?
• Open Loop or Closed Loop
Figure 6
The human circulatory system is a system.

Summary

We have now studied basic hydraulics and have a idea of how hydraulics work.
What are some of the advantages of hydraulics over mechanical ?
• Design, in most cases simpler.
• Flexibility, Components can be located with considerable flexibility.
• Smoothness, Operation is smooth and quit.
• Control, Control of a broader range of speeds and forces.
• Cost, High efficiency with minimum friction loss keeps cost of operation to a minimum.
• Protection, Relief valves guard against breakdowns caused by overloading the system.

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Grove Training Institute Grove Hydraulics

In chapter two of this manual we will look at the hydraulic components of a system ( Grove )
and their respective circuits.

As we know the mission of a hydraulic system is to transmit energy from a primary mover
to a location where this energy can do work.
A pump in the hydraulic system provides the flow, and the resistance to that
flow generates the pressure. The pump converts the mechanical power of
the prime mover (engine, motor) into hydraulic power.
A hydraulic cylinder or motor converts the hydraulic power back into mechanical
power, the work force of the system. Hydraulic valves direct the flow and
controls pressure in the system.
The reservoir is a storage and conditioning unit for the fluid, where a filter,
cooler or if required a heater can be installed
Through the discovery and development of a simple hydraulic system it is now
possible for the human race to perform work, in less time, space and effort.

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HYDRAULIC THEORY REVIEW ASSIGNMENT

1 2 3 4

2 1 5
4 2 10

A B C
IMMOVABLE
OBJECT
2000 PSI
Conditions:
a. All Cylinders are completely full of oil.
w

b. Pump is operating and the relief valve has opened properly.

c. Cylinder “C” is against the immovable object.
d. Numbers inside the cylinders are the area on the respective
piston and rod side in square inches.
e. The barrels of all cylinders are anchored.

What will the gauges read ? 1. psi

2. psi
3. psi
4. psi

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OBJECTIVE: To lift a load with a hand pump.

REQUIREMENTS: With each stroke of the hand lever (forward and return) the load must raise the same amount.
No additional components are necessary, except the hoses you add.
No hydraulic force needed to lower the load.
The load must not be allowed to drop when the hand pump is not pumping.

COMPLETE THE CIRCUIT: VENT MANUAL LOAD

SHUTOFF SINGLE
RESERVOIR ACTING
GRAVITY
RETURN

WORK
CYLINDER

ROD AREA PISTON AREA

1 SQ. IN. 2 SQ. IN.

Theory and principle