Hydraulic Training Wirgent Document

TRAINING DOCUMENT
Basic Hydraulics
Wirtgen GmbH 2014

This training document is not a substitute for technical documentation
(instruction manual, safety instruction and spare parts catalogue).
It is not subject of the technical modification service. All technical
instructions for description, operation, maintenance, etc. are taken by the
instruction manual, the safety manual or the spare parts list.
Publisher Reinhard-Wirtgen-Strae 2
53578 Windhagen Germany
Phone:: +49 (0) 2645 / 131 - 0
http://www.wirtgen.de
Document name Handout_Basic Hydraulics_2364339_V01_en

Translation of the original training document
Module HYD 1 Basic Hydraulics
Date of first issue 15.11.2012
Date of amendment 30.04.2014
Copyright Wirtgen GmbH 2014

Distribution and copying of this document, usage and communication
of its content are forbidden, unless specifically permitted.
Infringements will result in the obligations to pay damages. All rights
reserved in case of a patent, utility model or registration of a design.
Wirtgen GmbH 2014

WIRTGEN GROUP TRAINING
2364339_V01
Content
1 Introduction ............................................................................................................................................................ 3
2 Basic physics of hydraulics.................................................................................................................................... 4
2.1 Mass m .......................................................................................................................................................... 4
2.2 Force F .......................................................................................................................................................... 4
2.3 Pressure p ...................................................................................................................................................... 4
2.4 Energy E ........................................................................................................................................................ 5
2.5 Power P ......................................................................................................................................................... 5
2.6 Velocity v ........................................................................................................................................................ 5
3 Hydro-mechanics ................................................................................................................................................... 6
4 Hydro-kinetics ........................................................................................................................................................ 8
4.1 Flow-through theory ....................................................................................................................................... 8
4.2 Friction and pressure losses .......................................................................................................................... 9
4.3 Flow types ....................................................................................................................................................10
5 Hydraulic systems ...............................................................................................................................................11
6 Pressure fluids .....................................................................................................................................................13
6.1 Tasks of pressure fluids ...............................................................................................................................13
6.1.1 Types of pressure fluids ........................................................................................................................13
6.2 Technical data of pressure fluids .................................................................................................................14
6.2.1 Viscosity ................................................................................................................................................14
6.2.2 Lubricating capability of pressure fluids ................................................................................................14
6.2.3 Air exclusion capability ..........................................................................................................................15
6.2.4 Durability ...............................................................................................................................................15
7 Hydraulic pumps ..................................................................................................................................................16
7.1 Outer gear pump ..........................................................................................................................................17
7.2 Inner gear pump ...........................................................................................................................................19
7.3 Axial piston pumps .......................................................................................................................................20
7.3.1 Angled plate pump ................................................................................................................................20
7.3.2 Angled axle pump .................................................................................................................................20
7.3.3 Tumbler plate pump ..............................................................................................................................21
8 Hydraulic motors ..................................................................................................................................................23
8.1 Gear motor ...................................................................................................................................................27
8.2 Annular gear motor.......................................................................................................................................28
8.3 Radial piston motor (multi-stroke principle) ..................................................................................................29
9 Valves ..................................................................................................................................................................30
9.1 Check valves ................................................................................................................................................30
9.1.1 Simple check valve ...............................................................................................................................31
9.1.2 Hydraulic releasable check valves ........................................................................................................33
9.1.3 Twin check valves .................................................................................................................................37
9.2 Directional valves .........................................................................................................................................38
9.2.1 Directional gate valves ..........................................................................................................................39
9.2.2 Directional seat valves ..........................................................................................................................43
9.3 Pressure valves ............................................................................................................................................45
9.3.1 Pressure limitation valves (PLV) ...........................................................................................................45
9.3.2 Pressure limitation valves (pre-controlled) ............................................................................................48
9.4 Pressure switch-on / cut-off valves ..............................................................................................................49
9.4.1 Pressure switch-on valves ....................................................................................................................49
9.4.2 Pressure cut-off valves .........................................................................................................................50
9.5 Pressure reduction valves ............................................................................................................................51
9.5.1 Pressure reduction valves (directly controlled) .....................................................................................51
10 Flow valves ......................................................................................................................................................55
10.1 Throttle valves ..........................................................................................................................................56
10.1.1 Twin throttle check valves .....................................................................................................................57
10.2 Flow regulation valves ..............................................................................................................................59
10.2.1 2-way flow regulation valve ...................................................................................................................60
10.2.2 3-way flow regulation valve ...................................................................................................................62
11 Hydro-pneumatic reservoir...............................................................................................................................65
12 Hydraulic filters ................................................................................................................................................70
1 / 77
2364339_V01
12.1 Suction filters ............................................................................................................................................71

12.2 Line filters / pressure filters .......................................................................................................................73
12.3 Ancillary / return flow filters .......................................................................................................................75
12.4 Filler and ventilation filters ........................................................................................................................77
2 / 77
2364339_V01
1 Introduction
The word "Hydraulic" derives from the Greek word HYDRO (which means water) and, in a scientific sense,
determines the theory governing stationary and moving liquids (hydrostatics and hydrodynamics).
When referring to hydraulics in machines and vehicles, this involves the practical application of physics concerning
power transmission as well control and regulation technology.
In order to divide this vast range of applications, the terms "stationary hydraulics" and "mobile hydraulics" are
commonly used. "Mobile hydraulics" propels itself on wheels or crawler units, whereas "stationary hydraulics" is
located in one position. Although the equipment for these two systems differs enormously, their boundaries cannot
be clearly marked. A machine based on mobile hydraulics can consist of mobile hydraulics and stationary
hydraulics.
Wirtgen road construction machines combine the application of mobile hydraulics and stationary hydraulics.
Example 1: Road Milling machine W 2000 is propelled on crawler units and must be mobile in order to fulfil its
requirements. This is a typical example of a product being driven by mobile hydraulics.
W 2000
Example 2: The Cold Mixing Plant KMA 200 remains stationary at one location when operating. This machine
is therefore equipped with a stationary hydraulic system.
KMA 200
3 / 77
2364339_V01
2 Basic physics of hydraulics

In order to understand the sections to follow, it is of advantage to firstly look at the basic physics of hydraulics. The
following is an explanation of the most important basic physics.
2.1 Mass m
All substances have a mass. One of the accepted units for determining a mass is kilogram (kg).
2.2 Force F
According to the theory of Newton, a force (F) is the product of mass (m) and acceleration (a).
Force = Mass * Acceleration
F = ma
If general acceleration (a) is replaced by the earth's gravitation (g), force (F) then becomes the product of mass (m)
and the earth's gravity (g). The earth's gravity has a constant value of 9.81 m/s.
Force = Mass Gravity
F = m g
m
F = m 9.81
s
NOTE! The measuring unit for force is Newton (N) !
In everyday practise, it is acceptable to use to value of 10 m/s instead of 9.81 m/s for the earth's gravity. Therefore,
one Newton is a force that is necessary to accelerate an object weighing 1 kg over a distance of 1 metre.
2.3 Pressure p
A pressure occurs when a force is working at a right-angle against a surface area. A pressure (P) is the quotient of
the force (F) and the surface area (A).
F
P=
A
The accepted unit for determining a pressure is Pascal (Pa). A pressure of 1 Pa is generated when a force of 1 N
works on a surface area 1 m.
[Pa] = N2
m
As one Pascal is an extremely small value, the unit of bar is usually applied in general practise.
4 / 77
2364339_V01
[bar ] = daN2
cm
NOTE! Although the unit for pressure is Pascal, bar is commonly used.
2.4 Energy E
If an object is capable of independently carrying out work, it must have work stored inside itself. This stored work is
called energy. Work and energy both use the same unit; a Joule (Nm Newton meter).
2.5 Power P
Power (P) is the quotient of work (W) and time (t).
W
P=
t
1J
1W =
1s
2.6 Velocity v
Velocity (v) is the quotient of distance (s) in metres and time (t) in seconds during which a distance is overcome.
s
v=
t
5 / 77
2364339_V01
3 Hydro-mechanics
Hydro-mechanics is the theory of the physical relationships and characteristics of liquids.
The major difference between liquids and solid bodies is that the particles in liquids can be easily moved and
therefore do not possess a certain shape. A liquid will always adapt its shape to the vessel in which it is contained.
Contrary to gases, liquids cannot be so easily compressed.
The effect of a force on a stationary fluid is distributed equally within the liquid in all directions. The size of the
pressure within the liquid equals the force of weight relative to the active surface. The pressure is always active at
right-angles against the surface.
NOTE! A pressure is always active at right-angles against the surface of a "container". The pressure is
distributed equally in all directions. Therefore, the pressure against the surface of a container is
always identical at any point.
As the pressure is distributed equally in all directions, the shape of the container has no importance. Despite
various container shapes, the pressure at any point inside the container is always the same.
A pressure will be generated when force F1 makes contact with surface A1.
F1
P=
A1
The pressure P is active on all points of the system; also on surface A2. The achievable force, which has the same
importance as a weight to be lifted, can therefore be calculated via the pressure P and the area A2.
F 2 = P A2
6 / 77
2364339_V01
F 2 A2
NOTE! The forces inside this system have the same behaviour as the surfaces = !
F1 A1
The pressure inside such a system always behaves according to the size of the force F and the active area A. This
means that the pressure inside a system will increase until the pressure is larger than the force of the resistance
which is active against the pressure.
NOTE! The pressure inside a hydraulic system can only be correctly measured when the counter pressure
against the pressure is larger than the pressure to be measured.
7 / 77
2364339_V01
4 Hydro-kinetics
Hydro-kinetics is the theory of the rules governing the movement of liquids and the thereby generated forces.
4.1 Flow-through theory

Identical volumes flow through a pipe during an identical period. This means that the flow speed must increase
where the passage is narrower.
The flow volume (Q) is the quotient of the fluid volume (V) and the time (t).
V
Q=
t
The flow volume Q (L / min) is identical at any point inside a pipe. If the pipe cross-sections A1 and A2, the two
cross-sections will generate their own flow speeds.
This results in the following equation:
Q1 = Q 2
Q1 = A1 V 1 Q 2 = A2 V 2
8 / 77
2364339_V01
4.2 Friction and pressure losses

In order to observe the rules governing flowing fluids, it is assumed that the fluids can be moved friction-free
against each other and against objects.
Hydraulic energy cannot be transmitted without losses through pipes or hoses. Friction occurs against the inner
walls and inside the fluids themselves. The friction during transmission of hydraulic energy is converted into heat.
This loss of energy can be noticed as a loss of energy. The loss of pressure (pressure difference) is depicted as
Delta P (P).
NOTE! When the friction of fluids against each other increases, the more its viscosity (fluid toughness) will
increase.
The size of the friction losses greatly depend on the following values:
- Length of the pipes / hoses
- Cross-section of the pipes / hoses
- Roughness of inner wall of pipes / hoses
- Quantity of bends in pipes / hoses
- Flow speed
- Fluid viscosity
9 / 77
2364339_V01
4.3 Flow types

The type of flow is also decisive for energy losses inside a hydraulic system. There are two different types of flow:
the laminar flow and the turbulent flow.
Laminar flow
Turbulent flow
Fluids will move up to a certain speed in layers (laminar) through a pipe or hose. The inner fluid layer moves
fastest, whereby the most outer layer remains stationary against the inner wall. When increasing the flow speed
beyond the critical speed, the flow characteristics of the fluid will change from laminar to turbulent.
When changing to turbulent flow, the flow resistance and the resulting hydraulic energy losses will increase. For
this reason, it should always be an objective to avoid a turbulent flow in as far as possible.
10 / 77
2364339_V01
5 Hydraulic systems
Inside hydraulic systems, mechanical energy is transformed into hydraulic energy, where after it is transported,
controlled and regulated. Afterwards, the hydraulic energy is converted back into mechanical energy.
Characteristics of hydraulic systems:

- Transmission of large forces (torque) while using relatively small component dimensions
- Its functions under full load are immediately available from a machine that was previously stationary
- Infinitely variable regulation and control of speeds and torque
- Simple overload protection
- Realisation of fast and extremely slow movements
- Energy storage with gases
- Simple and centralised drive systems
- Non-central transformation of hydraulic energy into mechanical energy is easily possible
11 / 77
2364339_V01
The illustration shows the components that can be used in a hydraulic system to ensure the transformation of
energy. A schedule of the components are shown at the right, and at the left there are their respective symbols
which are used in hydraulic diagrams according to DIN standards.
1, 2 The tank and filer components are responsible for preparing the fluid
3 The hydraulic pump is responsible for the necessary energy transformation
4 The pressure limitation valve is responsible for energy control
5 The direction valve is responsible for energy control
6 The non-return valve (check valve) is responsible for energy control
7 The throttle valve is responsible for energy control
8, 9 The cylinder or hydraulic motor is responsible for energy transformation
12 / 77
2364339_V01
6 Pressure fluids
The correct function, life-expectancy, operational reliability and economy of a hydraulic system is decisively
influenced by the choice of a suitable pressure fluid.
In general, the applied fluids are based on mineral oil, and are called hydraulic oils. Apart from these oils, liquids
that are difficult to ignite are also used. For some time, Wirtgen introduced biological decomposable fluids in their
machines to protect the environment.
The table below contains a list of the hydraulic oils that are applied in Wirtgen machines:
Manufacturer Type Designation

DEA Astron HVLP 46
Bechem Hydrostar HEP 46
Panolin HLP SYNTH 68
6.1 Tasks of pressure fluids

The tasks of pressure fluids vary and are important to ensure the correct function of hydraulic systems. These
functions are:
- Lubrication of moving parts, such as pistons, valves, bearings, etc.
- Anti-corrosion protection of contacted surfaces
- Transmission of the pump's hydraulic output
- Flushing out any contamination
- Conduction of frictional heat
In accordance to the tasks, certain oil characteristics must be adhered to which are partly expressed by their grade
designations.
6.1.1 Types of pressure fluids
Mineral-based hydraulic oils: The following hydraulic oils are defined according to DIN standards.
Designation Description
H Hydraulic oils without additives. Their characteristics can be compared with
C lubricants and today are rarely used in hydraulics
HL Hydraulic oils with additive to increase anti-corrosion and life-expectancy.
These oils are generally used in hydraulic systems with pressures up to
approx. 200 bar and fulfil the general thermal load requirements.
HLP Hydraulic oils with special high-pressure additives to offer high protection
against wear. These oils are used in hydraulic systems with pressures
exceeding 200 bar.
HV Hydraulic oils of particularly low viscosity and temperature dependency.
Other characteristics are like HLP oils.
13 / 77
2364339_V01
6.2 Technical data of pressure fluids

6.2.1 Viscosity
Viscosity defines the toughness of a pressure fluid.
Example: Using hydraulic oil DEA Astron HLVP 46

The stated figure of 46 designates the viscosity grade of the oil. The unit used for the viscosity of
hydraulic oil is mm /s. The higher the unit value, the higher the viscosity.
The following table includes a few viscosity grades and the respective applications. This table offers a rough idea of
the resulting effects when filling a hydraulic system with unsuitable hydraulic oil.
The viscosity of hydraulic oil increases with increasing pressure; a fact that must be observed with pressures
exceeding 200 bar. At around 400 bar, the viscosity could be doubled.
6.2.2 Lubricating capability of pressure fluids
A pressure liquid must be capable of sufficiently lubricating and creating surface adhesion on moving parts of a
hydraulic system; in particular the inner components pumps and motors.
If the lubrication film should collapse due to insufficient viscosity or excessive surface pressure, the moving parts
will come into contact with each other. This can cause extreme wear on the contoured surfaces and then result in a
function fault of hydraulic components.
14 / 77
2364339_V01
6.2.3 Air exclusion capability
Under normal atmospheric conditions, hydraulic oils contain approximately 90% depleted air. This is not
detrimental for a hydraulic system. The depletion rate will increase when the pressure and temperature increases.
When a pressure decrease occurs, for example behind throttles or with a vacuum inside a suction hose, the air
saturation limit will drop rapidly and the depleted air inside the hydraulic oil will be released as air bubbles.
Air can also enter a hydraulic system through leaking suction lines or shaft seals. This released air, which is visible
as foam, is a particular hazard for hydraulic systems because it can cause the dreaded CAVITATIONS. As
cavitations can lead to material abrasions, pressure impacts and noise, the development of foam inside a hydraulic
oil tank must be avoided.
IMPORTANT! Development of foam must be avoided!
This can be achieved by a sufficiently dimensioned hydraulic oil tank from which any released air can escape. In
addition, the hydraulic oil must be capable of allowing the air bubbles inside the tank to float to the surface and then
explode.
6.2.4 Durability
Durability of a pressure fluid means its resistance to chemical changes under high temperatures and to catalytic
(non-ferrous) metals.
In general, its durability at a temperature above 70 Celsius will be halved by every further 10 C increase of
temperature. This ageing processing is also accelerated by contamination due to abrasions and rust, etc.
NOTE! Old hydraulic oil will darken and appears resinous, which can lead to malfunction of hydraulic
valves.
15 / 77
2364339_V01
7 Hydraulic pumps
As already described in a previous section, hydraulic pumps have the task of transforming mechanical energy into
hydraulic energy. This involves transforming torque (mechanical) into flow volume (hydraulic).
The following criteria must be considered when choosing hydraulic pumps:

- Operational media
- Required operational pressure
- Expected speed range
- Minimum and maximum operational temperatures
- Installation situation
- Drive type (coupling)
- Expected durability
- Maximum noise level
- Service convenience
- Costs
This list could be extended. The multitude of requirements clearly shows that a single pump cannot perfectly fulfil
every criteria. This is why various pump designs are available. All designs have one thing in common; they function
according to the displacement principle. They are equipped with mechanically sealed chambers in which the fluid is
transported from the input side (suction connection) to the output side (pressure connection). As there is no direct
connection between these two connections, pumps of displacement principle are suitable for high system
pressures and are therefore ideal for hydraulic applications.
The illustration below contains various types of hydraulic pumps which function according to the displacement
principle. From this vast range of hydraulic pumps, Wirtgen uses only a few types. These types will be explained
later in more detail.
Principle Type Design Volume
Outer gear pump Constant
Gear pump Inner gear pump Constant
Gear ring pump Constant

Gear
Spiral pump Spindle pump Constant
Single stroke Constant / Variable

Wing Wing cell pump
Double stroke Constant
Outer piston support Constant / Variable

Radial piston pump
Inner piston support Constant / Variable
Piston
Angled plate pump Constant / Variable

Axial piston pump
Angled axle pump Constant / Variable
16 / 77
2364339_V01
7.1 Outer gear pump

Outer gear pumps function according to the displacement principle just like all hydraulic pumps. The flow volume
(displacement volume) of outer gear pumps is constant because the same volume of oil is displaced by its
chambers per pump rotation. Under high pressure, internal oil leakages will occur at the seals and the flow volume
will decrease.
The pump consists of two gear wheels (1) which are supported by four bearings (2) with an axial field seal (7), as
well as a housing (3) with a front and rear lid (4.1 and 4.2).
The drive shaft passes through the front lid where it is sealed by a shaft seal (5). The bearing forces are absorbed
by so-called DU-bushes equipped with Teflon inlays.
Outer gear pumps are commonly used in hydraulics. The characteristics of these pumps are:
- Relatively high pressure of approx. 300 bar with small installation dimensions
- Low price
- Large speed range (500 6000 rpm)
- Large temperature and viscosity range
Inside the displacement chambers, the air which is inside the suction line is firstly transported from the suction side
to the pressure side. This will generate a vacuum inside the suction line. When the vacuum increases, the fluid will
be extracted from the tank into the suction line until it reaches the pump. The gear chambers will fill with oil and
then displace the oil around the outside to the pressure side. The combing of the gear teeth will prevent the oil from
flowing back.
17 / 77
2364339_V01
This type of outer gear pump is used in almost every Wirtgen machine.
Some examples: W 600 DC Cylinder functions

W 2000 Fan drive
WR 2500 Oil feed pump
SP 250 Screw conveyor drive
18 / 77
2364339_V01
7.2 Inner gear pump

This type of gear pump is frequently used as an oil feed pump in addition to an axial piston pump.
The displacement volume is generated between the gear flanks and the walls of the housing. The flow volume is
constant.
Here are some examples of inner gear pumps as auxiliary pumps for axial piston pumps:
- W 2000 Advance drive pump

- W 500 Milling drum drive pump
- WR 2500 Advance drive pump
19 / 77
2364339_V01
7.3 Axial piston pumps

Axial piston pumps are displacement pumps inside which the pistons are configured parallel to the rotary axis of a
cylinder drum. The drive movement is generated according to three basic principles as illustrated below:
7.3.1 Angled plate pump
This type of pump is used more frequently in Wirtgen products. The cylinder drum (1) is driven so that the pistons
(2), which are guided inside it, are also driven. The axial movements of the pistons are determined by an angled
plate (3) inside the pump housing which can be tilted away from right-angle position to the drive axis.
The pistons move along an elliptical orbit against the stationary angled plate (deflection plate). The generated
friction is controlled by a friction disk (4) and the axial bearing. During the suction phase, the pistons move
outwards while being held against the deflection plate by retainer devices. During the pressure phase, the pistons
are forced inwards by the plate.
The direction of oil flow for each piston, meaning either to a pressure or suction port, is governed by control slots.
They are located in a rigid control plate (5) against which the free end of the cylinder drum will rotate.
The subject of axial piston pumps will be looked at in more detail later in this document.
7.3.2 Angled axle pump
With this type of pump, the cylinder drum (1) is driven by the pistons (5) which are themselves driven via a drive
flange (2). The cylinder drum is guided either by a central trunnion or by a needle bearing around its circumference
and it tilted away from the axis of the drive shaft. The displacement volume varies according to the deflection angle.
This principle enables these pumps to run in reverse direction.
20 / 77
2364339_V01
The connection between the piston and drive flange is carried out by a ball-joint (6) which pulls the piston inside its
cylinder during the suction phase and pushes the piston during the pressure phase. A further joint is necessary
between the actual piston and ball-joint in order to equalise any circular or elliptical orbits.
The suction and pressure side of the pump are divided, just like the angled plate principle, by a slotted plate. This
flat or spherical control plate (7) deflects with the cylinder drum meaning that the pressure port must pass through
the deflection bearing or be connected to the control plate via a sealed friction guide.
7.3.3 Tumbler plate pump
With this pump, the shaft (1) drives a tumbler plate (2) which transmits its axial movement to a non-rotating pistons.
The pistons are pressed via springs against the tumbler plate. The forces between the piston and the tumbler plate
when pressing against each other are transmitted by an axial bearing (3).
The flow direction from each piston is governed either by control valves (6) or via control slots in each piston.
The angle of the rotating tumbler plate cannot be changed, which means that the displacement volume of this type
of pump remains constant.
21 / 77
2364339_V01
22 / 77
2364339_V01
8 Hydraulic motors
Hydraulic motors transform hydraulic energy into mechanical energy. Just like hydraulic pumps, there are various
types and design available on the market. As no single hydraulic motor can perfectly fulfil all requirements, an
optimum compromise must be found for every application when selecting a hydraulic motor.
Only very few hydraulic motors can cover a speed range from very slow to over 1000 rpm. Therefore, hydraulic
motors can be divided into fast-running types (n = 500 to 10000 rpm) and slow-running types (n = 0.5 to 1000 rpm).
The torque produced by a hydraulic motor depends on its consumption volume and the pressure difference inside
the motor. Slow-running hydraulic motors are generally designed so that they produce high torque when running at
slow speeds.
The performance of a hydraulic motor depends on its flow volume and the pressure difference inside the motor. As
its performance is proportional to its rotation speed, fast-running motors are highly suitable for applications that
require a high performance.
Not all types are used in Wirtgen machines. For this reason, this training documentation - in particular in this
section - will only deal with hydraulic motors in more detail that are used in Wirtgen machines. Here are some
examples of hydraulic motors:
Gear motor
Gear ring or planetary motor
23 / 77
2364339_V01
Wing cell motor
Radial piston motor with inner piston support
Axial piston motor with angled plate
24 / 77
2364339_V01
Multi-stroke radial piston motor with outer piston support
Multi-stroke axial piston motor with static shaft
Multi-stroke axial piston motor with static housing
25 / 77
2364339_V01
Axial piston motor with angled axis
26 / 77
2364339_V01
8.1 Gear motor

A gear motor is designed very similar to a gear pump. The differences can be found in the axial pressure field as
well as the fact that gear motors are designed for changing its sense of direction and therefore is equipped with a
leakage oil connection.
The pressurised fluid flowing into hydraulic motor is active on the gear wheels. This generates a torque which is
then transmitted to the motor output shaft.
Gear motors are frequently installed in mobile hydraulic systems and agricultural machinery to drive conveyor belts,
cooling fans, screw conveyors or air blower fans.
Important nominal values for gear motors are its consumption volume (approx. 1 to 200 cm), its maximum
operational pressure and its speed range (500 to 10000 rpm).
Gear motors and axial piston motors belong to the fast-running family. Fast-running hydraulic motors operate as
speeds higher than 500 rpm.
27 / 77
2364339_V01
8.2 Annular gear motor

The main components of this motor consist of a free-standing displacement ring (1), its inner teeth made up of 7
rollers and a moving gear wheel (3) equipped with 6 outer teeth. When the tooth cavities are subjected to pressure,
the gear wheel will rotate and simultaneously circulate in an eccentric orbit around the centre of the gear wheel.
These two movements take place in opposite directions. With a tooth ratio of 7:6, this will result in a transmission
ratio of 6:1, which means that every time the shaft rotates, each chamber is pressurised and relieved six times.
This system produces a down-gearing function. The motor is classified as a slow-running motor.
The rotary movement of the gear wheel is guided by a jointed shaft (4) in order to equalise the eccentric
movements before the drive shaft (5). The input and output flow is governed by control slots which are located on a
rotating control bush (6). It is then dog-driven by the drive shaft via a pin (7). Two non-return valves inside the
motor housing release the flow of leakage oil.
28 / 77
2364339_V01
8.3 Radial piston motor (multi-stroke principle)

With his type of motor, the that radial configured pistons (3) are supported on the stroke radius (4) by rollers (8).
The cylinder chamber is supplied with fluid via axial bore holes in the control unit (5). Per rotation, every piston is
pressurised and then relieved according to the quantity of actuation cams. The resulting torque generated by the
shape of the stroke ring is then transmitted via teeth (6) from the rotor / piston group (3) to the drive shaft. A conical
roller bearing is integrated inside the housing (1) to absorb the high axial and radial forces.
It is technically possible to install a multi-disk brake (9) on an extending drive shaft passing through the housing (2).
If the air pressure inside the ring chamber (10) falls below a certain value, the spring plate (11) will force the disk
pack (12) together and the brake will be actuated. If the air pressure exceeds a certain value, the brake piston (13)
will be forced against the spring plate. The disk pack will then be relieved and the brake will be released.
This type of hydraulic motor is used, for example, in the following Wirtgen machines:
- W 500 Milling drum drive
- SP 250 and SP 500 Trimmer drive
29 / 77
2364339_V01
9 Valves
In the previous sections of this document, it was clearly stated that a hydraulic system is designed to transform
mechanical energy into hydraulic energy, and then later to transform the hydraulic energy back into mechanical
energy.
Between the components that are necessary to carry out these transformations, other components are necessary
to govern and control the transformed energy. One of these component types is the hydraulic valve. As Wirtgen
machines use valves of various types and designs, it is necessary to divide this large valve group into various sub
groups.
- Check valves
- Directional valves
- Pressure valves
- Flow valves
9.1 Check valves

The function of check valves in a hydraulic system is to stop the flow of hydraulic fluid in one direction and to allow
its flow in the other direction. This is why check valves are also known as non-return valves.
Check valves are flushly seated and therefore function without causing a flow of leakage oil. Their shut-off
elements can consist of either balls, plates, cones or cones with shaft seals.
A ball as shut-off element has the advantage that it can be economically produced. The disadvantage of a ball is
that it can slightly deform during operation. The ball seat will press itself into the ball. As the ball will not always
take on the same position, this can lead to leakages over the course of time. The ball must also be guided so that it
will not become worn by the spring pressure or flow pressure.
A cone is guided and will therefore always take on the same position. After a short operational time, the cone will
adapt to the cone seat and form a perfect seal. Although the production expenditure for a cone is higher than for a
ball, the cone system is preferably used in Wirtgen machines due to its higher reliability.
Check valves can be divided into different groups according to their applications:
Check valves
Simple Hydr. releaseable

Filler valves
check valves check valves
30 / 77
2364339_V01
9.1.1 Simple check valve
Check valve as pipe fitting
This valve consists of a housing (1) and a hardened piston (2) which is forced by a spring (3) against a seat (4).
When fluid flows in the required direction, the fluid pressure will force the piston cone away from its seat to allow
the fluid to pass through. If the fluid flows in the other direction, the spring and fluid pressure will force the piston
cone against its seat and stop the flow of fluid.
The opening pressure of the check valve depends on the force of the spring and therefore cannot be influenced
externally. Depending on their applications, the pre-tension of these springs can be between 0.5 bar and 5.0 bar. If
the check valve is not equipped with a spring, it must always be installed vertically so that the weight of its internal
closing element determines its opening pressure.
Important nominal values for check valves are the nominal size (6 - 150), flow volume (up to 15000 l/min),
operational pressure (up to 315 bar) and the opening pressure without a spring (0.5, 1.5, 3.0 or 5.0 bar).
Check valves are mainly installed in Wirtgen machines:
- to bypass a throttle
- to stop flow direction
- as bypass valve to bypass a return flow filter after a certain back-pressure is achieved to contamination
31 / 77
2364339_V01
Example for the application of a check valve in the hydraulic circuit diagram of Cold Milling Machine W 1000 F to
protect the hydraulic oil cooler (1) and to protect the hydraulic oil filter (2) against excessive back-pressure.
Check valve 2
Check valve 1
32 / 77
2364339_V01
9.1.2 Hydraulic releasable check valves
Contrary to simple check valves, the non-flow direction of releasable check valves can be activated.
These valve are used:

- to hold the pressure inside operational circuits
- to secure raised components against lowering in the event of a pipe fracture
- to prevent creeping movements of involved consumers
There are two different types of releasable check valves:

- Releasable check valves without leakage oil connection
- Releasable check valves with leakage oil connection
Releasable check valves without leakage oil connection (valve type SV)
Design without leakage oil connection and without pre-opening of main cone (including the respective symbol used
in hydraulic diagrams).
A X
In the above illustration, the free volume flows from A to B. The fluid is active on surface A1 of the main cone (1)
and forces it against the spring (3) away from its seat. With a volume flow from B to A, the flow is interrupted
according to a normal check valve.
The flow release in direction B to A is carried via the control piston (4). The necessary control oil pressure coming
from connection X will move the control piston to the right to open the main cone (1).
33 / 77
2364339_V01
The necessary control pressure equals the surface area ratio between surface A1 and the opening control piston.
This ratio is usually 1:3.
The total cross-section of surface A is instantly opened during the opening function. This could result in pressure
relief impacts, particularly when large volumes under pressure are released. Such relief impacts not only produce
noise, they also create peak loads in the total hydraulic system; in particular in hydraulic connectors and moving
parts.
In applications where these relief impacts are not compensated, the valve goes through a pre-opening phase (see
illustration and symbol below).
A X
When control connection X is subjected to pressure, the control piston (4) firstly forces the pre-opening ball (2)
away before forcing the main cone (1) from its seat.
The pre-opening ball uncovers only a small cross-section. This enables the cylinder to extend slowly before the
main cones moves and uncovers the total cross-section. Such designs enables dampened pressure relief of the
pressurised fluid.
34 / 77
2364339_V01
This is an example of a releasable check valve which is frequently used in Wirtgen machines. Here it is in the
hydraulic system of the Cold Milling Machine W 1000 F
The check valve used here has the task of holding the laden conveyor at the selected height and preventing it from
lowering when its height regulation system UP/DOWN has not been adjusted.
Design with leakage oil connection (valve type SL)
Releasable check valve with pre-opening of main cone and leakage oil connection.
35 / 77
2364339_V01
B Y
A X
The difference to valve type SV is the additional leakage oil connection Y. The ring surface of the control piston is
separated from connection A. Any pressure at connection A is only active on surface A4 of the control piston.
Important nominal sizes of SV and SL check valves
- Nominal size 6 150

- Flow volume up to approx. 6400 l/min.
- Operational pressure up to 315 bar
36 / 77
2364339_V01
9.1.3 Twin check valves
Twin or double check valves are created by assembling two releasable check valves (1 and 2) inside one valve
housing.
In flow direction A1 to A2 or B1 to B2 the fluid flow is unrestricted, and in flow direction A2 to A1 or B2 to B1 the
fluid flow is interrupted.
When, for examples, the fluid flows through the valve from A1 to A2, the control piston (3) is move by the pressure
to the right and pushes the cone (2) of the check valve against its seat. Unrestricted flow is now possible from B1 to
B2. This procedure functions in the same manner when fluid flows from B1 to B2.
37 / 77
2364339_V01
9.2 Directional valves

The term "directional valves" includes all valves that can start, stop or alter the flow direction of a hydraulic
pressure medium.
Directional valves are designated according to the quantity of their switching positions and connections, whereby
the control connections are disregarded. A directional valve with four consumer connections and three switching
positions is therefore designated as a 4/3 directional valve.
The switching positions and the respective actuation elements are designated with the small letter "a" and "b".
a b
When a valve has three positions, the central position is "neutral" and is usually designated with figure "0".
a 0 b
"Neutral" is the position where moving components remain in non-active condition (e.g. by the force of a spring,
pressure or flow, etc.)
When in horizontal position, the sequence of descriptions (switching positions) is always carried out according to
the alphabet from left to right.
A B
a b
a b
P T
Directional valves are divided into the various groups and are described in more detail in the next section of this
document.
Directional valves
Directional gat valves Directional seat valves
Direct control Pre-control Direct control Pre-control
38 / 77
2364339_V01
9.2.1 Directional gate valves
Direction gate valves are valves with a gate piston inside the bore hole of their housing. Depending on the quantity
of channels to be controlled, their housings of cast graphite, steel or other suitable materials are equipped with two
or more cast or screw-in ring channels. These channels run concentric or eccentric around a bore hole. This will
result in control edges inside the housing which function together with the edges of the control piston.
The ring cavities inside the housing are separated or connected by displacing the control piston. Sealing is carried
out along a gap between the moving piston and the housing. The sealing effect depends on the size of the gap, the
viscosity of the fluid and, in particular, the prevailing hydraulic pressure.
Directional gate valves can be controlled directly or be pre-controlled. Whether a directional gate valve is directly or
pre-controlled initially depends on the size of the necessary actuation force an therefore on the component size
(nominal size) of the valve.
Directly controlled directional gate valves
The term "directly controlled directional gate valve" means a directional gate valve in which its control piston is
actuated either by a solenoid, pneumatic, hydraulic or via any other mechanical device without assistance of an
amplifier.
Due to the static and dynamic forces generated inside directional gate valves as a result of pressure and fluid flow,
directly controlled directional gate valves are normally available up to nominal size 10. This limit equals a
performance of approximately 120 l/min with an operational pressure of 2350 bar, and applied in particular to
directional gate valves that are actuated by solenoids.
Electro-magnetic (solenoid) actuation is available in numerous designs. Due to the numerous automatic functions,
this type of actuation is most common. Solenoids are usually available in four basic designs:
- Direct current solenoids inside a chamber containing air. Also known as a dry solenoid.
- Direct current solenoid inside a chamber containing oil. Also known as wet or pressure-sealed solenoid. The
solenoid anchor moves in oil while the anchor chamber is connected to the T-channel.
- Alternating current solenoid inside a chamber containing air.
- Alternating current solenoid inside a chamber containing oil.
Direct current solenoids are very reliable and enable soft switching function. They will not burn out if, for example,
the piston jams when switching. They are suitable for precise switching requirements.
Alternating current solenoids have a short switching phase. If the solenoid cannot fully switch to end position, the
valve will burn out after approximately 1 to 1.5 hours.
REMARKS! Wirtgen machines are only equipped with direct current solenoids.
39 / 77
2364339_V01
The above illustration shows a directional gate valve with three switching positions, and is equipped with an oil
chamber direct current solenoid at the left (4), and an oil chamber alternating current solenoid at the right (5). The
anchor chamber of the each valve is connected to the tank inside the valve housing. These valves are therefore
called 3-chamber valves.
The springs are supported by the housing and align the piston over a disk (8) at central position. The illustrated
solenoids are equipped with manual emergency actuation (7) so that the control piston can be actuated externally.
The channels P, A and B are separated from each other by webs inside the housing. The T-channel does not have
a separating web. It is connected by a bypass channel inside the valve to the two tank chambers which are sealed
by installing actuating elements or lids.
With type equipped with five chambers, as illustrated above, the T-channel (1)is formed just like P, A and B as
webs at both sides of the housing and designed as chambers.
The two end chambers (2) are connected to each other via a bore hole. When the control piston is moved, the
hydraulic fluid is displaced from one chamber to the other.
40 / 77
2364339_V01
When installing a nozzle or adjustable throttle (3) in this connection bore hole, the switching duration can be
influenced according to the nozzle design or throttle setting.
Example of a directional gate valve with mechanical actuation:
The valve is actuated via the control lever (1). The control piston (2) is connected to the actuation mechanism and
will therefore follow its movements. The piston is returned to starting position at the centre via springs (3) after the
actuating movement, meaning the movement of the control lever, has finished.
Example of a directional gate valve with hydraulic actuation:
This type of directional gate valve is actuated by pressure in the connections at the sides. The actuation cylinder
will be forced against the spring and force the control piston (1) in the required direction. When the control pressure
reduces, the control piston (1) will be moved by the centralising spring back to central (starting) position.
41 / 77
2364339_V01
Pre-controlled directional gate valves
It is necessary to use directional gate valves of pre-controlled design when controlling large hydraulic fluid volumes.
The reason for this is the higher force that is necessary to move the control piston.
Directional gate valves with a nominal size up to 10 are directly controlled. Above the value, pre-control is used. An
exception to this rule is manually (mechanically) actuated directional gate valves that need not be pre-controlled up
to a nominal size of 32.
A pre-controlled directional gate valve is normally equipped with a solenoid valve as pre-control valve, and a main
valve. When the pre-control valve is actuated, the main valve is subjected to pressure so that the control piston of
the main valve can be moved.
The pre-control valve in the above illustrated is marked as (1). The main valve, which carried out the main work, is
marked as (2).
42 / 77
2364339_V01
9.2.2 Directional seat valves
Directional seat valves are directional valves with one or more exactly fitting but moving control pistons inside the
bore(s) of the valve housing. These control pistons can be designed as balls, cones or plates. With this type, an
increase of pressure will in increased tightness.
Directional seat valves have the following features:

- No leakages
- High durability because there are no leakage oil channels or throttle gaps that can become clogged
- Locking function without additional locking elements
- Suitable for high hydraulic pressures because no hydraulic jamming (deformations under pressure) or
leakages can occur
- High pressure losses due to short strokes
- Performance losses due to insufficient pressure equalisation
Directional seat valves are directly or indirectly (pre-control) actuated. Whether a valve is actuated directly or with
pre-control mainly depends on the nominal size of the valve and, therefore, on the actuation force that is necessary
to operate the valve.
Directly controlled directional seat valves
These are directional seat valves that are actuated by mechanically operated devices. An example is an electrically
actuated 3/2-way seat valve (in ball valve design).
43 / 77
2364339_V01
P T
As directional seat valves are rarely used In Wirtgen machines, this type of directional valve will not be explained in
more detail.
44 / 77
2364339_V01
9.3 Pressure valves

"Pressure valves" is a general term for ALL valves that directly or indirectly influence a part of or the total system
pressure inside a hydraulic system. This is carried out exclusively by changing the throttle cross-section by means
of either mechanical, hydraulic or electrical control elements.
When the throttle cross-section is closed, all pressure valves can be divided into gate valves and seat valves in a
similar way to directional valves. Pressure valves can be divided into sub-groups according to their functions:
- Pressure limitation valves (PLV)
- Pressure switch-in valves
- Pressure reduction valves (PRV)
- Pressure cut-off valves
These valves can be either directly or pre-controlled
9.3.1 Pressure limitation valves (PLV)
Inside a hydraulic system, a PLV has the task of limiting a pressure to a certain value. If the required pressure is
exceeded, the PLV will be actuated and directs the excessive flow volume out of the hydraulic circuit back to the oil
tank.
Consumer
Directional valves
Pressure
Flow valve Limitation
valves
Check valve
Pump
The above illustration shows a simple circuit of a pressure limitation valve. It is always located in a bypass line.
According to its task, a pressure limitation valves can also be called a safety valve.
The principle common to all pressure limitation valves is that the input pressure is guided onto a surface which is
subjected to a force.
45 / 77
2364339_V01
Seat valve Gate valve

As long as the spring force is higher than the force of pressure, the control element will remain on its seat. If the
force of the pressure exceeds the spring force, the excessive hydraulic fluid will be directed back to the tank. When
flowing back to the tank, the hydraulic energy inside the fluid will be transformed into heat.
The illustrated PLVs are directly controlled PLVs according as can be seen by their functions. This type of pressure
limitation valve is frequently used in Wirtgen machines. Examples are as twin pressure limitation valve for the
conveyor UP/DOWN function in Cold Milling Machine W 2200, or as a safety valve inside the advance drive pump
of the same machine (see extract of hydraulic circuit diagram).
46 / 77
2364339_V01
47 / 77
2364339_V01
9.3.2 Pressure limitation valves (pre-controlled)
The possibility of constructing directly controlled valves for large flow volumes is limited, just like directional valves,
by the space requirement of the control spring. Large flow volumes require larger valve seats or gate diameters.
The surface area and therefore the spring forces increase in square of the diameter. In order to remain within
acceptable design dimensions, these valves are pre-controlled. They are used for pressure limitation or for
pressure limitation and pressure relief via solenoids of the operational pressure.
The illustrated pre-controlled pressure limitation valve consists of a main (1) and a pre-control stage (2), whereby
the latter involves a simple pressure limitation valve of seat design.
It is a measuring unit within a system because the setting of its spring (3) is decisive for the actuation pressure of
the total valve. The input pressure reaches the lower end of the valve and, via a throttle (4), to the upper end. From
here, there is a connection to the pre-control valve. As long as this valve is not actuated, the pressure is balanced
and its closed switching position can be maintained by the relatively weak spring (5).
When the opening pressure is achieved at the input of the of the valve, a small control pressure will flow through
the throttle and the pre-control valve. This will generate a pressure drop at the throttle - therefore a force difference
between the upper and lower ends of the valve - which will cause the throttle to be forced upwards against its
spring and open a connection between the input and the output.
The main and pre-control valves can be illustrated separately or combined in hydraulic circuit diagrams. In general,
the preferred method of illustration is the simple method shown at the right.
48 / 77
2364339_V01
9.4 Pressure switch-on / cut-off valves

Pressure switch-on and cut-off valves are installed in the main flow of a hydraulic system and are actuated when a
certain pressure is achieved to switch on or switch off another hydraulic system.
9.4.1 Pressure switch-on valves
It is generally possible to use pressure limitation valves as a replacement for pressure switch-on valves. A
requirement for this is that the pressure inside channel T (with directly controlled PLV) or inside channel B (with
pre-controlled PLV) cannot change the pre-selected pressure setting. This can be achieved when the leakage oil of
a directly controlled pressure limitation valve, or the control oil of a pre-controlled pressure limitation valve, is
returned externally to the hydraulic tank.
Directly controlled pressure switch-on valve
Directly controlled pressure switch- Pre-controlled pressure cut-off valve

on valve with internal control oil input with internal control oil input and
and external control oil output external control oil output
Settings of the switch-on pressure are carried out on the adjuster element (4). The compression spring (3) will hold
the control piston (2) at starting position. The valve is closed.
The pressure inside channel P passes through the control line (6) and is active on surface (8) of control piston (2),
therefore against the spring force (3). If the pressure in channel P exceeds the value of the spring, the control
piston (2) will be forced away against the spring (2). The connection between channel P and channel A is opened.
The hydraulic system connected to channel A will be switched in without any pressure loss in channel P.
The control signal is received internally via the control line (6) and the nozzle (7) from channel P, or externally via
connection B (X). Depending on the application, the leakage oil is returned via connection T (Y), or internally via
connection A. In order to ensure an unrestricted return flow from channel A to channel P, it is possible to install a
check valve. The manometer connection (1) is designed to check the switch-on pressure.
49 / 77
2364339_V01
9.4.2 Pressure cut-off valves
Pressure cut-off valves, also known as reservoir charging valves, are mainly used in hydraulic systems equipped
with a pressure reservoir. Their task is to switch over the flow volume to pressure-free circulation when the
pressure reservoir has achieved its nominal pressure.
Pressure cut-off valves are also used in hydraulic systems equipped with high-pressure and low-pressure pumps
(twin circuit systems). In this case, the low-pressure is switched over to pressure-free circulation when the pressure
range of the high-pressure has been achieved.
Pre-controlled pressure cut-off valve
A pressure cut-off valve mainly consists of a main valve (1) with a main piston unit (3), a pre-controlled valve (2)
with a pressure adjuster element (16) and a check valve (4). With valves of nominal size 10, the check valve is
installed in the main valve. With valves exceeding nominal size 10, the check is located in a separate intermediate
plate.
The hydraulic pumps feed the flow volume via the check valve (4) in the hydraulic system. The pressure in channel
A passes through control line (5) to the control piston (6). At the same time, the pressure is active in channel P via
the nozzles (7) and (8) on the spring-loaded side of the main piston (3) and the ball (9) inside the pre-control valve.
As soon the pre-selected cut-off pressure of the pre-controlled valve is achieved, the ball will move from its seat
against the spring (10). The fluid will then flow via the nozzles (7) and (8) into the spring chamber (11). From here,
the fluid flows internally or externally via the control line (12) and channel T back to the tank.
50 / 77
2364339_V01
9.5 Pressure reduction valves

Contrary to pressure limitation valves, pressure reduction valves have the task of reducing the input pressure in
certain sections of a hydraulic system. The reduction of the input pressure (primary pressure) and maintaining the
output pressure (secondary pressure) is carried out at a value which is lower than the value of the pressure inside
the main hydraulic circuit. It is therefore possible to use a pressure reduction valve to reduce the pressure inside a
certain section of a hydraulic system.
This is frequently the case in Wirtgen machines; as explained by the application examples that follow more.
In order to reduce and maintain the output pressure at a certain level, the pressure input pressure works against
the end of the control valve (piston or cone) where it is compared with the force of the regulation spring. If the
hydraulic force pA * AK exceeds the spring force, the piston will move upwards towards closing position. While
regulating, the control gate is in a balance of pressure. The average cross-section that is necessary to hold pA at a
constant value is regulated according to the flow volume Q and input pressure pE.
9.5.1 Pressure reduction valves (directly controlled)
51 / 77
2364339_V01
In principle, directly controlled pressure reduction valves are produced in 3-way design, meaning that the pressure
safeguarding of the secondary circuit is carried out via the adjuster element. The design of the adjuster element
can vary according to the customer or application requirements.
The valve is open at starting position; meaning that the flow volume can flow unrestricted from channel P to
channel A. The pressure in channel A is simultaneously active via the control line (2) and the piston surface against
the spring (3). When the pressure inside channel A increases above the pressure value of the spring (3), the
control piston (4) will move to regulation position in order to hold a constant pressure inside channel A. The signal
and control flow volume is monitored internally via the control line (2) from channel A.
If the pressure increases in channel A due to external influences on a consumer, the control piston (4) will adjust
even further against the spring (3). Channel A will then be connected to the tank via the control edge (5) of the
control piston (4). The necessary quantity of fluid will flow back to the tank to prevent the pressure from increasing.
The leakage oil will flow out of the spring chamber (6) via channel T(Y). If required, a check valve can be installed
to allow the fluid to flow freely back from channel A to channel P. The manometer connection (8) is designed to
monitor the reduced pressure.
Directly controlled pressure reduction valves (left with and right without check valve)
Important nominal values:
- Nominal size NG 5,6 and 10

- Max. input pressure 315 bar
- Max. output pressure 210 bar
- Flow volume up to 80 l/min.
52 / 77
2364339_V01
The following are some examples in which Wirtgen machines and for which functions pressure reduction valves are
used:
Example 1: Pressure reduction valve in SP 500. The valve has the task of reducing the pressure to the set
value of 70 bar in order to release the hydrostatic brakes of the advance drive gearbox. If the
system pressure of 190 bar was used for this purpose, the gearbox would be damaged.
53 / 77
2364339_V01
Example 2: Pressure reduction valves in Cold Milling Machine W 2200. As can be seen here, different
consumers require different output pressures.
54 / 77
2364339_V01
10 Flow valves
Flow valves are designed to alter (increase or decrease) their throttle cross-sections and thereby influence
movement speeds of consumers. A flow distributor has a special function in that is divides an incoming flow volume
into two or more outgoing flow volumes. Flow valves can be divided into four groups according to their operational
characteristics.
Flow valves
Throttle valves Flow control valves
Pressure ratio dependent Pressure ratio independent
Direct control Pre-control Direct control Pre-Control
55 / 77
2364339_V01
10.1 Throttle valves

The flow volume of throttle valves depends on the difference of pressure; which means that a larger pressure
difference will result in a larger flow volume.
In numerous control systems where a constant speed is not decisive, throttles are used because flow regulation
valves would be too expensive for such purposes. Throttle valves are used when:
- A constant working resistance is available.
- A speed change with a fluctuating load is not important or can be disregarded.
As can be seen in the illustration on the previous page, the viscosity is the influencing factor. When the throttle
distance is shorter, a change of viscosity will have less influence. It should be noted that the flow volume will
increase as the fluid viscosity decreases. Whether a valve is dependent or not dependent on the fluid viscosity, this
depends on the design of the throttle distance.
Aperture and throttle valves
An ideal throttle, meaning it is less

dependent on the viscosity, is a circular
aperture (1) with a short throttling distance.
This design will offer the maximum ratio of
surface area and circumference.
Long throttle distances (2) are highly

dependent on fluid viscosity.
Adjustable throttle cross-sections are

virtually impossible to produce as infinitely
adjustable circular areas. Adjustable needle
throttles (3), particularly with small
adjustment ranges, have a poor ratio of
surface area and circumference. They are
therefore highly dependent on viscosity and
also have poor resolution at small settings.
An acceptable compromise is a triangle with

equal sides. This type of cross-section can
be achieved with piston throttles (4).
Throttles and flow control valves are often
required for only one flow direction. They are
then combined with check valves to produce
throttle check valves (5).
In the event of flow direction B > A, the

bushing in the illustrated type will lift and
enable the full flow volume.
Throttle check valves of intermediate plate design are frequently used in Wirtgen machines because they can be
easily integrated in the modular valve blocks. Their task is to limit the main and control flow of one or two consumer
connections. In the illustration below, two symmetric throttle check valves are installed to limit the flow volume in
one direction and to enable unrestricted return flow in the other direction.
56 / 77
2364339_V01
The fluid in channel A reaches consumer A2 via the throttle unit (1) consisting of the valve seat (2) and the throttle
piston (3). The throttle piston (3) can be axially adjusted via the adjuster screw (4) in order to adjust the throttle
cross-section (1).
The fluid returning from consumer B2 will force the valve seat against the spring (5) in the direction of the throttle
piston (3) to enable an unrestricted return flow. Depending on its installation configuration, the throttling effect will
take place in the feed or return flow direction.
10.1.1 Twin throttle check valves
In order to alter the speed of a consumer (main flow limitation), a twin throttle check valve is installed between the
directional valve and the connection plate. With pre-controlled directional valves, the twin throttle check valve can
be utilised to set the switching time (control flow limitation). It is then installed between the pre-control valve and
main valve.
57 / 77
2364339_V01
This is an example for the application of twin throttle check valves in Wirtgen machines. The illustration is an
extract from the hydraulic circuit diagram of Cold Milling Machine W 2000.
The twin throttle check valve is installed here in the function "Rear height adjustment". It has the task of limiting the
return flow and enabling it to be adjusted. This valve will enable the speed of the rear height adjustment cylinder
and front height adjustment cylinder to be adapted to each other.
58 / 77
2364339_V01
10.2 Flow regulation valves

The task of a flow regulation valve is to maintain a constant selected flow volume independent of any pressure
fluctuations in the system. Apart from the adjustable measuring throttle (1), this task is achieved by installing an
additional moving throttle which works as a regulation throttle (pressure balance) and is therefore has a
comparison function in a circuit (see illustration below).
When these two throttles work together, the pressure load is separated by the varying pressure difference p 1 p3
into two branches:
- The inner and constant pressure difference p1 p3 at the adjustable measuring throttle, and
- the outer and varying pressure difference p1 p3
The flow regulation valve is designed as a regulator with the following main components:
- Measuring throttle (1)
- Pressure balance (2) with spring (3)
When temperature or viscosity fluctuations occur, the adjustable measuring throttle (1) will monitor a change of
pressure difference of p1 p2. The shape of the throttling point can counteract this influence. The configuration of
the pressure balance determines the type of flow regulation valve. If it is positioned in series with the measuring
throttle, the result is a 2-way flow regulation valve. If it is positioned parallel to the measuring throttle, the result is a
3-way flow regulation valve.
59 / 77
2364339_V01
10.2.1 2-way flow regulation valve
With 2-way valves, the measuring aperture and pressure balance are configured in series, whereby the pressure
balance can be at preceding or following side. Whether the pressure balance in a 2-way flow regulation valve
precedes or follows behind is a matter of design and has no influence in practical use.
There are three basic installation possibilities:

- Input control (primary control)
- Output control (secondary control)
- Input ancillary regulation (bypass)
Input control
The flow regulation takes place between the hydraulic pump and the respective consumer. This type of regulation
is recommended for hydraulic systems in which the consumer generates a positive resistance (counter force)
against the regulated flow volume.
The advantage of this switching system is that only the pressure is active between the flow regulation valve (1) and
the pressure cylinder (2) which results from the resistance of the pressure cylinder. As the pressure against the
cylinder seals is lower, the friction on the sleeves in the cylinder is also lower.
A disadvantage is that the pressure limitation valve (3) in front of the flow regulation valve must be adjusted
according to the largest consumer. The hydraulic pump (4) therefore always generates the maximum selected
pressure even at times when the consumer requires less pressure. The generated throttling heat is also transmitted
to the consumer, which can have a negative influence, for example, on hydraulic motors.
Input control
Output control
With this type, the flow regulation valve (1) is installed in the line between the consumer (2) and the tank. This type
of regulation is recommended for hydraulic systems with negative or precipitating (pulling) working loads, which
have the tendency to move the cylinder faster than is possible, by the displaced flow volume.
The advantage is that a counter valve is not necessary. The generated throttle heat is also directed back to the
hydraulic tank.
A disadvantage of this control type is the pressure limitation valve (3) must be set according to largest consumer
pressure (heat development). Even when idling, all components of the cylinder are subjected to the maximum
operational pressure (high friction).
60 / 77
2364339_V01
Output control
Input auxiliary control (bypass)
With this type, the flow regulation valve (1) is installed parallel to the consumer. The flow regulation valve can only
regulate the flow volume to the consumer in that a selectable amount of the flow volume is returned back to the
hydraulic tank.
The advantage is that only the necessary pressure is generated to move the load during the working stroke.
Therefore, less energy is transformed into heat. Only when the cylinder rests against the buffer will the set pressure
of the pressure limitation valve be achieved. The throttling heat of this control type is also directed back to the
hydraulic tank.
61 / 77
2364339_V01
10.2.2 3-way flow regulation valve
Contrary to a 2-way flow regulation valve, the measuring aperture A1 and the regulation aperture A2 of a 3-way
flow regulation valve are installed parallel and not in series.
The pressure balance returns the excess flow volume via an additional line back to the tank. In order to safeguard
the maximum pressure, a pressure limitation valve must be installed in the hydraulic circuit. This pressure limitation
valve is frequently included inside a flow regulation valve.
As the excess flow volume QR is directed back to the tank, 3-way flow regulation valves can only be installed in the
feed or leading lines. This type of valve also enables a relief connection X for virtually free circulation. The working
pressure of the hydraulic pump is only larger than the consumer pressure according to the reduction by the
measuring aperture, whereby the hydraulic pump with 2-way flow regulation valves must always generate the
pressure, which has been set on the pressure limitation valve.
A 3-way flow regulation valve therefore causes less losses in the lines, offers a preferable system efficiency and
has lower heat development.
62 / 77
2364339_V01
The hydraulic circuit diagram below shows the conveyor belt drive in machine Cold Milling Machine W 1000 which
is controlled by a flow regulation valve. This valve enables the conveyor belt speed to be infinitely adjusted.
63 / 77
2364339_V01
The hydraulic circuit diagram below of the SP 1600 shows various applications of flow regulation. As can be seen
by the ident numbers, different consumers requires different designs of flow control regulators.
64 / 77
2364339_V01
11 Hydro-pneumatic reservoir
The task of a hydro-pneumatic reservoir is to store hydraulic energy coming from the hydraulic pump and then
release this energy later when it is required.
Volume equalisation and the respective storage of energy inside a hydro-pneumatic reservoir is achieved by
subjecting the fluid to the pressure of a weight, spring or gas. The pressure of the fluid and the respective weight,
spring or gas is always in balance. Weight-loaded or spring-loaded reservoirs are only used for very special
industrial applications and are therefore of minor importance. Gas pressurised reservoirs without a separating
diaphragm are rarely used because hydraulic fluid will absorb gas.
The hydro-pneumatic reservoirs (gas-spring reservoir) in the majority of hydraulic systems are equipped with
separating elements. These reservoir designs, which are explained in this section in more detail, are divided into
bubble, piston and diaphragm reservoirs according to the type of separating elements used.
As previously explained, hydro-pneumatic reservoirs fulfil various tasks in hydraulic systems. These could be:
- Storing energy
- Reserve fluid
- Emergency actuation
- Force equalisation
- Damping mechanical impacts
- Damping hydraulic impacts
- Leakage oil compensation
- Impact and oscillation damping
- Pulsation damping
- Vehicle suspension springing
- Recycling braking energy
- Maintaining a constant pressure
- Flow volume compensation (expansion vessel)
65 / 77
2364339_V01
Hydro-pneumatic reservoirs as listed above are installed in various Wirtgen machines and carry out a wide range of
functions.
The application of hydro-pneumatic reservoirs enable the pump performance to be reduced to medium output. This
reduced flow volume will quickly fill the reservoir because the required flow volume during a working cycle us
mostly smaller than the flow volume generated by the pump. When the maximum flow volume is briefly required,
the hydraulic system will compensate the insufficient flow volume by extracting the missing amount from the
reservoir.
Important characteristics are:

- Application of smaller hydraulic pumps
- Lower installed output
- Reduced heat generation
- Simple maintenance and installation
The above advantages are also enhanced by damping pressure impacts and pulses, thereby increasing the life-
expectancy of the hydraulic system.
The application of hydro-pneumatic reservoirs also saves energy. Hydraulic systems with short operating cycles, or
those that require large flow volumes over brief periods, can only be economically realised by using hydro-
pneumatic reservoirs.
Example 1: Application of hydro-pneumatic reservoir in Wirtgen machine SP 1600. A reservoir (bubble

reservoir) is used in order to release an extremely large flow volume to quickly extend the hydraulic
cylinder to its final position. This cylinder is used to implant a metal rod (tie-bar) in the freshly paved
concrete surface. As this operation is carried out while the machine is moving forwards, the
insertion function must be carried out as fast as possible.
66 / 77
2364339_V01
If the reservoir is used as a safety element, it will not be applied as an energy source during normal machine
operation. It, nevertheless, is always directly connected to the hydraulic pump. Due to the application of high-
quality separation elements, the stored energy can be stored for virtually unlimited time and is immediately
available when required. Safety elements equipped with reservoirs are used as emergency actuators in hydraulic
systems so that they can immediately take over certain functions in the event of a fault or irregularity.
These functions could be:

- Closing bulkheads, flaps, bypasses, etc.
- Actuating gate valves
- Actuating high-performance switches
- Actuating rapid shut-down systems
Example 2: This hydraulic circuit diagram of Cold Milling Machine W 1000 demonstrates the use of a
diaphragm reservoir in the advance drive system
In the event of an emergency, such as loss of electrical power, the energy stored in the reservoir will be utilised to
finalise a working cycle. This can become necessary if the hydraulic pump or the surrounding hydraulic system (oil
feed) develops a fault. Emergency functions of hydraulic reservoirs are characterised by:
- Immediately available
- Unlimited durability
- No power fatigue
- No inertia problem
- High reliability and low maintenance requirement
67 / 77
2364339_V01
The most frequently used hydraulic reservoir in Wirtgen machines is the diaphragm reservoir.
An elastic diaphragm (2) is used inside the pressurised reservoir (1) to separate the hydraulic fluid from the
nitrogen filling. A shut-off button (3) is installed in the base of the diaphragm which will cover the connection port
when the diaphragm is fully expanded and thereby prevent the expanded diaphragm from being forced into the
connection port. At the gas side of the diaphragm, a plug-screw (4) enables the filling pressure of the reservoir to
be checked or re-filled via a testing and filling device. The reservoir technical data is V0=0.075 to 2.8 l and
Pmax =160 to 250 bar.
Pressurising and relieving a diaphragm reservoir
68 / 77
2364339_V01
As can be seen by the hydraulic circuit diagram of the SP 1600, bubble reservoirs are also used Wirtgen machines.
The elastic separating wall between the pressurised fluid and nitrogen, which develops a bubble (3), is affixed
inside the reservoir (1) via the vulcanised gas valve element (4) and can be removed or installed inside the
reservoir through the opening in the fluid valve (2). The fluid valve has the task of closing the input port when the
bubble is fully expanded, thereby preventing the bubble from being pressed into the opening. A damping device
protects the valve against hydraulic impacts when it is opened quickly.
69 / 77
2364339_V01
12 Hydraulic filters
In hydraulic systems, large volumes of hydraulic oil flow under high pressure through narrow gaps. The result is
that such systems are more sensitive to contamination in the oil, particularly solid particles, than other drive
systems.
Experience has shown that more than half of the faults that occur in hydraulic systems are caused by contaminated
fluids. The task of a hydraulic oil filter is to reduce the contamination in the oil to an acceptable minimum in order to
protect the hydraulic components against excessive wear.
These solid particles can consist of sand, dust, metal or rust. They accelerate the wear rate on the surfaces of
metal components that must move against each other, and on hydraulic seals. Contamination causes negative
effects on bearings, guides, rotors, pistons and the flanks of gear wheels in hydraulic pumps and motors, as well as
the pistons, piston rods and bushes of hydraulic cylinders.
The wear on friction surfaces increases their gaps and can lead to leakages. Larger solid particles (< 0,050 mm)
will frequently cause sudden failure of machine components, whereas smaller solid particles (> 0,010 mm)
generally cause slowly developing damage and component faults,
The damaging effect of solid contamination particles depends on the particle hardness, size and concentration, as
well as the sensitivity of the hydraulic components
Extensive wear is caused by particles that are of similar size as the gaps between moving components.
70 / 77
2364339_V01
12.1 Suction filters

Hydraulic systems must be equipped with a suction filter when there is a high risk of damage to a pump by large
contamination particles. This is particularly the case when:
- Numerous hydraulic circuits use the same hydraulic fluid
- Hydraulic tanks cannot be cleaned due to their shape
Pressure differences must not be too great because pumps are particularly sensitive to vacuums. This is why filters
with large filtering surfaces must often be installed. A bypass valve and/or a contamination indicator on the filter is
also necessary.
A suction filter will only safeguard the function of the pump. The necessary protection against wear must be
achieved by other filters.
The illustration below is a filter that is installed in Wirtgen machine RX 4500. Adjacent to it is the respective section
of the hydraulic circuit diagram.
71 / 77
2364339_V01
The switching symbol designates the return flow filter which is equipped with a bypass. Its flow direction must
always be upwards away from the tank.
72 / 77
2364339_V01
12.2 Line filters / pressure filters

This type of filter has the task of safeguarding all components that follow. For this reason, the filter must be
installed as close as possible to the components that require protection.
The following criteria are decisive for the application of line filters:
- Components are particularly sensitive to contamination, or are particularly important for the function of the
hydraulic system
- Components are particularly expensive and are decisive for the reliability of the hydraulic system
- Down-time costs are particularly high with this type of hydraulic system
- Line filters can be installed as safety filters or as operational filters
Filters have the following tasks:
Operational filters: Protection of components against wear. Maintaining the required grade of fluid cleanliness
Safety filters: Safeguarding the component function. Safety filters are only installed together with
operational filters
This type of line filter must be able to withstand maximum system pressure.
73 / 77
2364339_V01
The filter (illustrated below) consists mainly of an upper section (1), a screw-in lower section (2) and the filter
element (3). The standard design is without a bypass valve and without a pressure differential switch to safeguard
the filter.
74 / 77
2364339_V01
12.3 Ancillary / return flow filters

These filters are installed at the end of the return flow line and are generally designed as tank ancillary filters. This
means that all contamination that enter the system or are generated inside the system are filtered out of the fluid
before it flows back into the tank. The size of the filter mainly depends on the size of the flow volume.
In order to prevent the production of foam inside the tank, it must always be ensured that the return flow of fluid
always enters the tank below the fluid level. This is achieved in Wirtgen machines by a pipe inside the tanks that
extends below the fluid level. When such a pipe is installed, it must be ensured that the end of the pipe is 2-3 times
its own diameter above the bottom of the tank.
Illustration of return flow filters in RX 4500
The return flow filter illustrated below is affixed by a retainer flange (1) to the tank lid. The housing (2) with its filter
connection protrudes directly into the tank. An enormous advantage of this filter type is that it is easily accessible
and therefore easy to service. Its filter element (5) can be quickly extracted after removing the tank lid (3). It is
important that the filter element is surrounded by a dirt collection basket (4). This basket is extracted together with
the filter element so that the filtered particles cannot flow out of the filter back into the hydraulic tank. A connection
(6) for a contamination indicator is generally available.
75 / 77
2364339_V01
76 / 77
2364339_V01
12.4 Filler and ventilation filters

In the past, not much attention was paid to this type of filter. In the meantime, it is proven that it is one of the most
important filters in a hydraulic system.
A large amount of contamination in a hydraulic system enters via the surrounding air. Due to continuous
fluctuations of the fluid level inside the tank, a vacuum or pressure is generated against the air inside. It must
therefore be ensured that no contaminated air can enter the tank.
77 / 77

Hydraulic Training Wirgent Document

Încărcat de

Informații document

Drepturi de autor

Formate disponibile

Partajați acest document

Partajați sau inserați document

Opțiuni de partajare

Vi se pare util acest document?

Este necorespunzător acest conținut?

Drepturi de autor:

Formate disponibile

Hydraulic Training Wirgent Document

Încărcat de

Drepturi de autor:

Formate disponibile

TRAINING DOCUMENT

Wirtgen GmbH 2014

Document name Handout_Basic Hydraulics_2364339_V01_en

Module HYD 1 Basic Hydraulics

Date of first issue 15.11.2012

Date of amendment 30.04.2014

Copyright Wirtgen GmbH 2014

Wirtgen GmbH 2014

12.1 Suction filters ............................................................................................................................................71

2 Basic physics of hydraulics

Force = Mass * Acceleration

Force = Mass Gravity

NOTE! The measuring unit for force is Newton (N) !

4.1 Flow-through theory

This results in the following equation:

4.2 Friction and pressure losses

4.3 Flow types

Characteristics of hydraulic systems:

3 The hydraulic pump is responsible for the necessary energy transformation

4 The pressure limitation valve is responsible for energy control

5 The direction valve is responsible for energy control

6 The non-return valve (check valve) is responsible for energy control

7 The throttle valve is responsible for energy control

8, 9 The cylinder or hydraulic motor is responsible for energy transformation

Manufacturer Type Designation

6.1 Tasks of pressure fluids

6.1.1 Types of pressure fluids

6.2 Technical data of pressure fluids

Viscosity defines the toughness of a pressure fluid.

Example: Using hydraulic oil DEA Astron HLVP 46

6.2.2 Lubricating capability of pressure fluids

6.2.3 Air exclusion capability

IMPORTANT! Development of foam must be avoided!

The following criteria must be considered when choosing hydraulic pumps:

Outer gear pump Constant

Gear pump Inner gear pump Constant

Gear ring pump Constant

Spiral pump Spindle pump Constant

Single stroke Constant / Variable

Outer piston support Constant / Variable

Angled plate pump Constant / Variable

7.1 Outer gear pump

Some examples: W 600 DC Cylinder functions

7.2 Inner gear pump

- W 2000 Advance drive pump

7.3 Axial piston pumps

7.3.1 Angled plate pump

7.3.2 Angled axle pump

7.3.3 Tumbler plate pump

Gear ring or planetary motor

Wing cell motor

Radial piston motor with inner piston support

Axial piston motor with angled plate

Multi-stroke radial piston motor with outer piston support

Multi-stroke axial piston motor with static shaft

Multi-stroke axial piston motor with static housing

Axial piston motor with angled axis

8.1 Gear motor

8.2 Annular gear motor

8.3 Radial piston motor (multi-stroke principle)

- W 500 Milling drum drive

- SP 250 and SP 500 Trimmer drive

9.1 Check valves

Simple Hydr. releaseable