How to Read

Hydraulic
Schematics

Brendan Casey

Copyright Brendan Casey 2014

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 authors views acquired through his
experience in the field under discussion. The information in this book 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,
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agents.

First published in 2014 by

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

Copyright 2014 Brendan Casey; HydraulicSupermarket.com

How to Read
Hydraulic Schematics
Brendan Casey, HydraulicSupermarket.com

In the introduction of The Hydraulic Troubleshooting Handbook, I explain that in

the hydraulics world, the ability to read a schematic diagram and the ability
to troubleshoot effectively are often considered to go together, hand in glove.
But this is not the case. The ability to read a hydraulic schematic is merely an
indication of a certain level of system knowledge. And this makes a schematic
diagram nothing more than a troubleshooting aid.
But even though the ability to read a schematic is not the key to effective
troubleshooting, it is usually helpful in a hydraulic troubleshooting situation.
Schematic diagrams are the shorthand system of the hydraulics industrysee
exhibit 1. They comprise simple, geometric symbols, drawn to ANSI or ISO
standards. These symbols represent the components, their controls and
connections.
A schematic diagram is a road
map of the hydraulic system.
And to someone skilled in
reading and interpreting them,
they can be a valuable aid in
identifying possible causes of a
problem.
And
as
already
mentioned, this can save a lot of
time
and
money
in
a
troubleshooting situation.
If a schematic diagram is not
available, the troubleshooter must
trace the hydraulic circuit and
identify its components in order to isolate possible causes of the problem. This
can be a very time-consuming process, depending on the complexity of the
system.
Exhibit 1. Hydraulic schematic diagram.

Worse still, if the circuit contains a valve manifold, the manifold may have to
be removed and dismantled, just to establish what it's supposed to do.

Copyright 2014 Brendan Casey; HydraulicSupermarket.com

Reason being, if the function of a component within a system is not known, it

can be difficult to discount it as a possible cause of the problem. Schematic
circuit diagrams eliminate the need to reverse engineer the hydraulic system.
When reading and interpreting a hydraulic schematic diagram, the following
should be kept in mind:
1.

2.

3.
4.

5.
6.

Symbols can be drawn any size (scale). And they can be orientated
in increments of 90-degrees (except accumulator, reservoir, and
pressure gauge).
Each symbol is drawn to show the normal (neutral) position of the
component, i.e. with the system shutdown, de-pressurized and all
power off. Visualization is required in order to see the component
symbol in its other functional position(s) or state(s).
Multiple symbols for reservoir (tank) can be used to represent the
one (same) reservoir.
The conductors (pipes, tubes and hoses) are represented by straight
lines. The specific symbol for a hose may be used if required.
Interconnections between conductors are shown with small, shaded
circles (dots).
Symbols do not give any indication of the design, size, orientation,
or location of the actual components they represent.
Symbols do not indicate the exact location of ports or control
elements.

A list of common hydraulic symbols, along with explanation of how to read

and interpret them, are included on the following pages.

Copyright 2014 Brendan Casey; HydraulicSupermarket.com

ISO Hydraulic Symbols and Their Meanings

Reservoir (tank); vented to atmosphere. Note that the vertical line
touching the bottom of the tank symbol indicates a penetration extending
below oil level.
Same vented reservoir symbol as above but with penetration terminating
above oil level. This is generally not desirable because it can result in
churning and aeration of the hydraulic fluid.
Reservoir; pressurized. A pressurized tank can also be represented by an
enclosed rectangle.
Filter. This same symbol is used for surface filters e.g. suction strainer;
depth filters e.g. pressure and return filters; and air filters i.e. tank
breather.
Heat exchanger (cooler). Absent additional detail, this generic symbol
does not distinguish between air-blast or water-to-oil type.

Oil heater. Notice the arrow heads point inwardthe opposite of the
heat exchanger symbol above.
Accumulator; generic symbol. Additional detail may be added to indicate
gas, mass or spring loaded.
Pressure source; simplified symbol.
This can also be represented by a solid dot inside a circle:

Pressure gauge.

Differential pressure gauge. Displays the difference between two, discrete

pressures.

Pressure switch.

Flow meter (flow measurement turbine).

Adjustable (variable) setting.

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Working line: suction, pressure and return.

Pilot or control line (long dash).
Drain line (short dash).

Lines crossing (not connected).

Lines connecting.

Enclosure indicating two or more components integral to the one

assemblysee below.

Filter with bypass valve. The enclosure indicates the filter and
bypass valve are not separate components, but are part of the same
assembly.

Pump; fixed displacement.

Pump; variable displacementsimplified symbol. Additional detail may

be added to show the configuration of the pumps control mechanism.
See for example, the variable pump shown in exhibit 1 on page one, and
the symbol below.
Pump; variable displacement. Additional information indicates this
pumps displacement-control mechanism is proportional, electrohydraulic.
Pump; variable displacement, flow possible in two directions. This is
the symbol for a pump used in closed-circuit, hydrostatic transmissions.
Additional detail may be added to show the configuration of the
pumps control mechanism.

Motor; fixed displacement.

Copyright 2014 Brendan Casey; HydraulicSupermarket.com

Motor; variable displacementsimplified symbol. Additional

detail may be added to show the configuration of the motors
displacement-control mechanism.

Rotary actuator. Device capable of rotational movement of less the

one revolution.

Cylinder; single-acting: hydraulically powered in one direction

only.

Cylinder; single-acting, spring returned.

Cylinder; double-acting: hydraulically powered in both directions.

Cylinder; double-acting, double-rod.

Cylinder; double-acting with cushions installed to control

deceleration at the end of stroke.
Check valve. Allows flow in one direction; blocks flow in the reverse
direction.
Check valve; spring loaded.

Check valve; pilot-operated (pilot to open). Allows flow in one

direction. External pilot-pressure opens the check to allow flow in the
reverse direction.

Check valve; pilot-operated (pilot to open); spring-loaded.

Check valve; pilot-operated (pilot to close). Allows flow in one direction

absent external pilot-pressure which closes the check.

Check valve; pilot-operated (pilot to close); spring-loaded.

Copyright 2014 Brendan Casey; HydraulicSupermarket.com

Shuttle valve. The higher of two pressures is directed to the branch of

the tee.

Throttle (orifice); fixed.

Throttle (orifice); fixednot affected by changes in oil viscosity, e.g.

sharp-edged orifice.
Throttle; adjustable. Typically a needle valve.

Throttle; adjustablewith reverse-flow check valve. Controls flow

in one direction only.

Adjustable flow control (throttle); pressure compensated. Throttle

opening is automatically adjusted to compensate for changes in
pressure. This results in more accurate control of flow.
Adjustable flow control; pressure compensated; 3-way bypass type.
Excess flow not required by the primary function is bypassed to
tank.

Flow divider valve. Positively divides a single flow into two,

separate flows.

Shut-off valve. Typically a ball valve, but can also be butterfly or

shear-valve design.

Pressure relief valve; direct-acting.

Pressure relief valve; pilot-operated (two-stage), internally drained.

Copyright 2014 Brendan Casey; HydraulicSupermarket.com

Pressure relief valve; pilot-operated (two-stage), externally drained.

Pressure sequence valve. Externally piloted (to open) and externally

drained.

Pressure reducing valve. Maintains reduced pressure downstream.

Pressure reducing/relieving valve. Maintains reduced pressure

downstream. And if downstream pressure rises above the setting of the
spring, excess pressure is relieved to tank.

Counterbalance valve; internally piloted, internally drained.

Counterbalance valve; internally piloted, externally drained.

Over-center counterbalance valve; externally piloted, internally

drained.

Over-center counterbalance valve; externally piloted, externally

drained.

Copyright 2014 Brendan Casey; HydraulicSupermarket.com

Opening logic element (slip-in cartridge valve); poppet has three areas.

Opening logic element (slip-in cartridge valve); poppet has two equal
areas.

Closing logic element (slip-in cartridge valve).

2-way, 2-position directional control valve (2/2 valve). The valve

shown is hand operated and spring returned.
3-way, 2-position directional control valve (3/2 valve). The valve
shown is lever operated with detent (mechanical position holding).

4-way, 2-position directional control valve (4/2 valve). The valve

shown is roller operated and spring returned.

4-way, 3-position directional control valve (4/3 valve). The valve

shown is solenoid operated and spring centered.
4-way, 3-position directional control valve (4/3 valve). The
valve shown is pilot-operated and spring centered.
4-way, 3-position proportional valve. The parallel lines indicate
proportional spool. And the arrow through the solenoid symbol
indicates proportional solenoids.
6-way, 3-position directional control valve (6/3 valve). The
valve shown is hydraulic pilot operated and spring
centered.

Copyright 2014 Brendan Casey; HydraulicSupermarket.com

10

Visualization of Symbols Change in State

Being able to recognize a symbol and the hydraulic component it represents is
the first step in reading a schematic diagram. But as already explained, each
symbol in the schematic is drawn in its normal (neutral) position with the
system shutdown, de-pressurized and all power off. So in order to truly
understand how the represented system operates, the functional positions of
the various component symbols must be visualized. With this in mind lets
consider a few examples.
Well begin by visualizing the two states of a spring-loaded check valve:
If pressure/flow is in the direction indicated by the
arrow, the checks poppet will be pushed open against
the spring, as shown on the right. And as a result,
pressure/flow is available downstream.
But if pressure/flow was to change direction, the poppet
is pushed against its seat as shown on the right. This
blocks (stops) pressure/flow from passing in the
opposite direction.
Now lets visualize the two states of a pressure relief valve:
In its normal or neutral state, pressure acts on the
underside of the poppet, against the setting of the
spring, as shown on the right.
When pressure acting on the underside of the
poppet overcomes the spring setting, the poppet is
shifted up, the spring is compressed and a flow
path is openedusually to tank.
A pressure reducing valve works in the opposite way:
In its normal or neutral state, a flow path is open
and downstream pressure acts on the underside of
the poppet, against the setting of the spring, as
shown on the right.
When downstream pressure acting on the
underside of the poppet overcomes the spring
setting, the poppet is shifted up, the spring is
compressed and the flow path is blocked.

Copyright 2014 Brendan Casey; HydraulicSupermarket.com

11

Lets now visualize the two states of a hand operated, 2/2 directional control
valve:

The bias of the spring ensures that the valves normal or

neutral state is flow path blocked, as shown on the right.
When applied hand force overcomes the spring, a flow
path is opened. If applied force is released, the valve shifts
back to its neutral position and blocks the flow path.

The next step is to apply this visualization technique to

understand the operation of a simple hydraulic circuit:
As you can see, the circuit on the right comprises: a
fixed-displacement pump, a pressure relief valve, a 4/3
directional control valve, a double-acting cylinder, a
return-line filter and a reservoir (one, not two!).
With the pump running, and the 4/3 valve in its center
position as shown on the right, pump flow circulates to
tank via the return filter.

With the 4/3 valve shifted to the left, pump flow is

directed to the cap-end of the cylinder, and the cylinder
extendssee diagram on the left.

With the 4/3 valve shifted to the right, pump flow is

directed to the rod-end of the cylinder, and the cylinder
retractssee diagram on the right.

Copyright 2014 Brendan Casey; HydraulicSupermarket.com

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And note that if the lever operated 4/3 valve is not

released from its detent at the end of the cylinders stroke,
the pump is dead-headed and the resulting pressure rise
will lift the relief valve poppet of its seat, opening a path
to tanksee diagram on the left.
As youve now seen, an understanding of the symbols
and their meanings, combined with visualization, means
you CAN read a hydraulic schematic. You just have!
This means theres really no need to get bamboozled or
befuddled when you come across a schematic with more
symbols and lines than the one shown to the left.
Consider the schematic shown in exhibit 2 below, which is discussed in
chapter 6 of The Hydraulic Troubleshooting Handbook:

Exhibit 2. Hydraulic schematic diagram.

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Whether you initially view this hydraulic circuit as simple or complex largely
depends on how practiced you are at reading schematics. But either way,
theres no need to fear it.
One way to gain a complete understanding of a hydraulic circuit represented
by a schematic diagram like the one shown in exhibit 2without getting lost
or confused, is by painting a picture. Youve likely seen an artist on TV
painting a canvas. Im certainly no artist but recall that the process involves
sketching an outline of the subject first, and then adding successive layers of
detail: color, contrast, shadow, etc. until the picture is vibrant and clear. This
same approach can be applied when decoding a hydraulic schematic,
regardless of its complexity.
The symbols in a schematic diagram are generally arranged in three sections
on the page:
1. Bottom section: hydraulic power supply unit (pump(s), reservoir and
accessories).
2. Middle section: control valves.
3. Top section: actuator/s (cylinder, motor, and/or semi-rotary actuator).
With the above in mind, a scan of these three, distinct sections is a good way
to sketch out the subject. Looking at exhibit 2, the main components in the
bottom section are: 4 pumps, a heat exchanger and a return filter.
In the middle section, the main components are: 2 proportional valves, 5
directional control valves, 4 pressure control valves, 2 accumulators, a
pressure switch and 2 pilot-operated check valves.
In the top section, the main components are: 2 single-acting cylinders, a motor
and a double-acting, double-rod cylinder.
As you can see, no mystery so far.
Having scanned the drawings horizontal sections to sketch out the systems
major components, lets now do the same vertically, from left to right. The
idea here is to start tying pump, control valve and actuator together.
For example, the single-acting cylinders (35) and (36) are controlled by
proportional valve (14) and powered by variable-displacement pump (1).
The motor (37) is controlled by proportional valve (15) and powered by
variable-displacement pump (1). AND motor (37) can also be controlled by
lever-operated directional control valve (20), powered by fixed-displacement
pumps (4) and/or (6).

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14

The double-rod cylinder (38) is controlled by directional control valve (34)

and powered by fixed-displacement pumps (4) and/or (6).
Lost anyone yet? Didnt think so. And as you can see, what Im seeking to do
here is build an understanding of the circuit, layer upon layer. In much the
same way an artist paints a picture. So lets make another sweep, adding more
detail to the canvas.
Single-acting cylinders (35) and (36) are fitted with piloted-operated check
valves (25) and (26). This, combined with the cylinders orientation on the
drawing and the fact theyre single-acting, tell us the function of these
cylinders is to raise and lower a load.
Motor (37) features an over-center counterbalance valve (27). This tells us the
load on the motor is overhanging or overrunningin one direction at least.
And although we cant say for sure, the function of adjustable throttle [needle
valve] (32) is probably emergency release (manual rotation of motor in case of
power failure).
Of course, at anytime we can zoom-in to any area of interest on the drawing.
For example, flow from fixed-displacement pump (3) passes directly through
the heat exchanger (5) to tank. So pump (3) is the hot-oil circulation pump.
Similarly, pumps (4) and (6) circuit features an accumulator (28). One-way
flow control (21) is orientated so charging of the accumulator is unrestricted,
but rate of discharge is controlled by the adjustable throttle. Shut-off valve
(16) is the accumulators manual-drain valve. And sequence valve (18)
unloads pumps (4) and/or (6) when the accumulator is charged.
Note that up to this point, my main focus has been getting familiar with the
major components in the system, their function and their connections. In other
words, a solid outline. The next layer of detail involves visualization of the
component symbols in operation.
For example, with pump (1) running and proportional valve (14) shifted to
the left, flow is directed to cylinders (35) and (36) via pilot-operated check
valves (25) and (26). In this state, the cylinders will extend.
But note that for the cylinders to retract, the solenoid on 4/2 valve (19) must
be energized first. This shifts its spool to right which pilots open check valves
(25) and (26). Then, with proportional valve (14) shifted towards the right, the
oil in the cylinders is directed to tank via return filter (2). In this state, the
cylinders will retract.

Copyright 2014 Brendan Casey; HydraulicSupermarket.com

15

That covers the main operation of cylinders (35) and (36). But there are other
components attached to this part of the circuit which we havent yet included
in the picture.
For example, hand-operated 2/2 valve (7). What does it do? Well this valve
tees in between cylinders (35) and (36) and their pilot-operated check valves
(25) and (26). So if the cylinders are extended and 2/2 valve (7) is manually
shifted to the right, the oil in the cylinders is directed to tank. In this state, the
cylinders will retractat a speed controlled by fixed orifice (24). From this we
can deduce that 2/2 valve (7) is an emergency lowering valve in case of
power failure.
Similarly, whats the story with check valves (30) and (31) and 4/2 valve (33)?
Well if the solenoid on 4/2 valve (33) is energized, its spool is shifted to the
right. This directs flow from pumps (4) and/or (6) to cylinders (35) and (36)
via check valves (30) and (31). In this state, the cylinders will extend. So these
valves provide an alternate means of extending the cylinderspresumably in
case of a failure of pump (1).
At this point I havent painted every part of the picture (exhibit 2) in full
detail. But my expectation is you now feel confident enough to add the
remaining layers of detail on your own.
In summary, reading and interpreting any hydraulic schematic, whether
simple or complex, involves:
1. Understanding the symbols and their meanings.
2. Visualization of a component symbols various operational states.
3. Compiling a complete operational picture one layer at a timethe
same way an artist paints a picture.
And if you keep the above in mind whenever youre reading a hydraulic
schematic you should never feel lost or overwhelmed.

Copyright 2014 Brendan Casey; HydraulicSupermarket.com

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