Mobile Hydraulics PDF

Mobile Hydraulics
Workbook
TP 800
With CD-ROM
C (X1)
D (X2)
LS
P
T
T
C
LS
LS1
LS2
Festo Didactic
574166 en
Order No.:
Edition:
Authors:
Graphics:
574166
11/2011 (V0.9)
Levent Unan
Levent Unan
Festo Didactic GmbH & Co. KG, 73770 Denkendorf, Germany, 2011
Internet: www.festo-didactic.com
E-mail: did@de.festo.com
The copying, distribution and utilization of this document as well as the communication of its contents to
others without expressed authorization is prohibited. Offenders will be held liable for the payment of
damages. All rights reserved, in particular the right to carry out patent, utility model or ornamental design
registration.
Contents
Use for intended purpose _________________________________________________________________ VII
Preface ________________________________________________________________________________ VIII
Introduction ______________________________________________________________________________X
Work and safety instructions ________________________________________________________________ XI
Training package for mobile hydraulics (TP 800) _______________________________________________ XIII
Equipment set TP 801 ______________________________________________________________________1

Allocation of components to exercises _________________________________________________________2
Notes for the teacher/trainer_________________________________________________________________3
Exercises and solutions TP 801 ______________________________________________________________5
Exercise 1 Earth driller (uncompensated pressure) _______________________________________________5
Exercise 2 Earth driller (compensated pressure) _______________________________________________ 13
Exercise 3 Earth driller (proportional control) _________________________________________________ 19
Exercise 5 Earth driller (proportional control with open-centre load-sensing system) _________________ 27
Exercise 6 Earth driller (6/3-way proportional valve) ____________________________________________ 31
Exercise 7 Boom cylinder of an excavator _____________________________________________________ 35
Exercise 8 Boom cylinder of an excavator (pilot check valve) _____________________________________ 39
Exercise 9 Boom cylinder of an excavator (counterbalance valve) _________________________________ 43
Exercise 10 Boom cylinder of an excavator (piloted counterbalance valve) __________________________ 49
Exercise 11 Two hydro motor of a crane system (various valve configurations) ______________________ 55
Equipment set TP 802 ____________________________________________________________________ 61

Allocation of components to exercises _______________________________________________________ 61
Notes for the teacher/trainer_______________________________________________________________ 62
Exercises and solutions TP 802 ____________________________________________________________
Exercise 1 Steering system of an agricultural machine __________________________________________
Exercise 2 Calculating the turning of the steering wheel _________________________________________
Exercise 3 Steering system of an off-road vehicle (shock valve) ___________________________________
Exercise 4 Steering system of a street sweeping vehicle (priority function) __________________________
Exercise 5 Steering system of an articulated vehicle ____________________________________________
Festo Didactic GmbH & Co. KG 574166
65
65
71
75
79
83
III
Equipment set TP 803 ____________________________________________________________________ 87

Allocation of components to exercises _______________________________________________________ 88
Notes for the teacher/trainer_______________________________________________________________ 89
Exercises and solutions TP 803 ____________________________________________________________ 91
Exercise 1 Mobile block on an excavator (with load-sensing unit) _________________________________ 91
Exercise 3 Remote control of mobile valves (hydraulic joystick) ___________________________________ 99
Exercise 4 Earth driller (load and speed) ____________________________________________________ 103
Exercise 5 Earth driller (pre-compensation) __________________________________________________ 107
Exercise 6 Earth driller (Pressure compensation with LS system) _________________________________ 111
Exercise 7 Two hydro motors of a crane system (with LS system) ________________________________ 115
Exercise 8 Two hydro motors of a crane system (pre-compensation) ______________________________ 119
Exercise 9 Two hydro motors of a crane system (mobile block with pre-compensation for each actuator) 123
Exercise 10 Two hydro motor of a crane system (post-compensation) _____________________________ 127
Exercises and worksheets TP 801

Exercise 2 Earth driller (compensated pressure) _________________________________________________9

IV
63
69
73
77
81

Exercise 4 Earth driller (load and speed) _____________________________________________________ 97
Fundamentals
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Definition________________________________________________________________________ I-1
Hydraulics fundamentals ___________________________________________________________ I-3
Closed Hydrostatic System ________________________________________________________ I-10
Load-sensing systems ____________________________________________________________ I-19
Variable-displacement pumps ______________________________________________________ I-34
Unloading system ________________________________________________________________ I-39
Flow-dividing valves ______________________________________________________________ I-41
Mobile valve blocks ______________________________________________________________ I-47
6/3-way directional control valves and valve configurations ______________________________ I-63
Pressure compensation ___________________________________________________________ I-70
Load holding and motion control ____________________________________________________ I-79
Hydraulic joystick ________________________________________________________________ I-87
Priority valve ____________________________________________________________________ I-90
Steering ________________________________________________________________________ I-95
VI
Use for intended purpose

The training package for mobile hydraulics may only be used:
For its intended purpose in teaching and training applications
When its safety functions are in flawless condition
The components included in the training package are designed in accordance with the latest technology, as
well as recognised safety rules. However, life and limb of the user and third parties may be endangered, and
the components may be impaired, if they are used improperly.
The training system from Festo Didactic has been developed and manufactured exclusively for training and
vocational education in the fields of automation and technology. The respective training companies and/or
trainers must ensure that all trainees observe the safety precautions which are described in this workbook.
Festo Didactic hereby excludes any and all liability for damages suffered by trainees, the training company
and/or any third parties, which occur during use of the equipment set in situations which serve any purpose
other than training and/or vocational education, unless such damages have been caused by Festo Didactic
due to malicious intent or gross negligence.
VII
Preface
Festo Didactics learning system for automation and technology is geared towards various educational
backgrounds and vocational requirements. Correspondingly, the training system is broken down as follows:
Technology oriented training packages
Mechatronics and factory automation
Process automation and control technology
Mobile robotics
Hybrid learning factories
The training system for automation and technology is continuously updated and expanded in accordance
with developments in the field of education, as well as actual professional practice.
The technology packages deal with various technologies including pneumatics, electro-pneumatics,
hydraulics, electro-hydraulics, proportional hydraulics, mobile hydraulics, programmable logic controllers,
sensor technology, electrical engineering, electronics and electric drives.
The modular design of the training system allows for applications which go above and beyond the
limitations of the individual training packages. For example, PLC actuation of pneumatic, hydraulic and
electric drives is possible.
VIII
All training packages are comprised of the following elements:

Hardware
Media
Seminars
Hardware
Hardware included in the training packages consists of industrial components and systems that are
specially designed for training purposes. The selection and design of the components encompassed by the
training packages are especially well matched to the projects included in the accompanying media.
Media
The media provided for the individual groups of topics are allocated to the teachware and software
categories. The practically oriented teachware includes:
Technical books and textbooks (standard works for imparting basic knowledge)
Workbooks (practical exercises with supplementary instructions and sample solutions)
Lexicons, manuals and technical books (which provide technical information on groups of topics for
further exploration)
Transparency sets and videos (for easy-to-follow, dynamic instruction)
Posters (for clear-cut representation of facts)
From the software category, programmes are made available for the following applications:
Digital training programmes (didactically and medially prepared learning content)
Simulation software
Visualisation software
Software for measurement data acquisition
Project engineering and design engineering software
Programming software for programmable logic controllers
The teaching and learning media are available in several languages. They are intended for use in classroom
instruction, but are also suitable for self-study.
Seminars
Comprehensive seminar offerings covering the contents of the training packages round out the programme
for training and vocational education.
Do you have suggestions or criticism regarding this manual?

If so, send us an e-mail at did@de.festo.com.
The authors and Festo Didactic look forward to your feedback.
IX
Introduction
This workbook is part of the training system for automation technology from Festo Didactic GmbH & Co. KG.
The system provides a solid basis for practice oriented training and vocational education.
The TP 501 basic level is suitable for fundamental training in the field of hydraulic control technology.
Knowledge regarding the fundamentals of hydraulics, as well as the function and use of hydraulic
components, is imparted. Simple hydraulic controllers can be set up with the equipment set. TP 801, 802
and 803 is targeted at vocational training in the field of mobile hydraulics.
This workbook imparts knowledge regarding the physical relationships which prevail in the field of
hydraulics, and its most important basic circuits. Topics covered by the exercises include:
Recording the characteristic curves of individual components
Comparing usage of various components
Setting up various basic circuits
Applying basic hydraulic equations
Technical prerequisites for setting up the controllers include:
A Learnline workstation equipped with a Festo Didactic slotted profile plate. The slotted profile plate
has 14 parallel T-slots at 50 mm intervals.
A hydraulic power unit (operating voltage: 230 V, 50 Hz, operating pressure: 6 MPa (60 bar),
volumetric flow rate: 4 l/min.)
A power pack with short-circuit protection (input: 230 V, 50 Hz, output: 24 V, max. 5 A) for supplying
power to the flow sensor
Laboratory safety cables
You will need components included in equipment set TP 801, 802 and 803 in order to complete the
exercises. The theoretical fundamentals for understanding these exercises are included in the workbook.
Data sheets for the individual components are also available (cylinders, valves etc.).
Work and safety instructions
General
Trainees should only work with the circuits under the supervision of a trainer.
Operate electrical devices (e.g. power supply units, compressors, hydraulic power units) only in
laboratories that are equipped with a Residual Current Device (RCD).
Observe specifications included in the technical data for the individual components, and in particular all
safety instructions!
Faults which may impair safety must not be generated in the training environment and must be
eliminated immediately.
Wear your personal protective equipment (safety goggles, safety shoes) if you are working on the
circuits.
Mechanical setup
Only reach into the setup when it is at a complete standstill.
Mount all of the components securely onto the slotted profile plate.
Limit switches may not be actuated frontally.
Danger of injury during troubleshooting!
Use a tool to actuate the limit switches, for example a screwdriver.
Set all components up so that activation of switches and disconnectors is not made difficult.
Adhere to the instructions regarding positioning of the components.
Always set up cylinders together with the appropriate cover.
Electrical specifications
Only use extra low voltages: max. 24 V DC.
Electrical connections may only be established and interrupted in the absence of voltage!
Only use connecting cables with safety plugs for electrical connections.
Pull the plug only when disconnecting connector cables never pull the cable.
Hydraulics
Limit system pressure to 6 MPa (60 bar).
Maximum permissible pressure for all devices included in the training package is 12 MPa (120 bar).
Danger of injury from oil temperatures > 50 C!
Hydraulic oil with a temperature > 50 C can cause burns or scalding.
Danger of injury when switching on the hydraulic power unit!
Cylinders may advance and retract automatically.
All valves, devices and hose lines are equipped with self-sealing quick-connect couplings.
XI
Connecting hose lines

Never connect or disconnect hose lines when the hydraulic power unit is running,
or while under pressure!
Couplings must be connected in the unpressurised state.
Set the coupling socket squarely onto the coupling nipple!
The coupling socket and the coupling nipple must not be fitted askew.
Setting up hydraulic circuits
The hydraulic power unit and the electrical power pack must be switched off when assembling the
circuit.
Before commissioning, make sure that all tank lines have been connected and that all couplings
have been securely fitted.
Commissioning
Cylinders may only be commissioned with their covers in place.
Switch on the electrical power pack first, and then the hydraulic power unit.
Dismantling hydraulic circuits
Assure that pressure has been relived before dismantling the circuit.
Switch off the hydraulic power unit first, and then the electrical power pack.
If connections are decoupled while under pressure, pressure is trapped in the device by the non-return
valve in the coupling. This pressure can be vented with the pressure relief unit.
Mounting technology
The mounting boards for the components are equipped with mounting variant A, B or C:
Variant A, snap-in system
Lightweight components that are not load-bearing (e.g. directional control valves and sensors). Simply
clip the components into the slots on the slotted profile plate. Release the components by turning the
blue lever.
Variant B, bolt system
Components with medium load capacity (e.g. hydraulic or pneumatic cylinder). These components are
clamped onto the profile plate using T-head bolts. The blue, knurled nut is used for clamping and
loosening.
Variant C, screw system
For components with high load capacity and components which are seldom removed from the profile
plate (for example on-off valve with filter-regulator). The devices are secured with socket head screws
and T-head bolts.
Required accessories
A digital multimeter is required in order to evaluate exercises which make use of the flow sensor.
The output voltage of the flow sensor is measured with the multimeter.
You will need a stopwatch in order to measure hydraulic cylinder retracting and advancing times.
XII
Training package for mobile hydraulics (TP 800)

The TP 800 training package consists of a multitude of individual training materials and seminars. The
subject matter of this package is strictly mobile hydraulics. Individual components from training package
TP 800 may also be included in other packages.
Important TP 800 components
Permanent workstation with Festo Didactic slotted profile plate
Equipment sets or individual components (e.g. cylinders, valves and pressure gauges)
Complete laboratory setups
Media
The workbook includes exercise sheets for each exercise, the solutions to each individual worksheet and a
CD-ROM. A set of ready-to-use exercise sheets and worksheets is included in each workbook for all of the
exercises.
Data sheets for the hardware components are made available along with the equipment set.
Available software for use in combination with training package TP 800 includes FluidLab M. With the help
of examples based on actual practice, the learner works through the basic principles of mobile hydraulics
and becomes familiar with components used in mobile hydraulic vehicles.
The media are offered in several languages. You will find further training materials in our catalogues and on
the Internet.
Component designations
Hydraulic components are designated in circuit diagrams in accordance with ISO 1219-2.
CD-ROM contents
The workbook is included on the CD-ROM as a PDF file.
XIII
Equipment set TP 801

The mobile hydraulic equipment set (TP 801) has been put together for basic training in the field of mobile
hydraulic. It includes all of the components which are necessary for mastering the learning objectives, and
can be supplemented with TP802 and 803 equipment sets.
Equipment set for mobile hydraulics, basic level (TP 801), order no. 574161
Designation
Order number
Quantity
Counterbalance valve
572149
Pressure compensator for open centre load sensing
572123
3-way pressure reducing valve
544337
Pressure relief valve
544335
Flow control valve
152842
Non-return valve, 0.6 MPa opening pressure
548618
Shuttle valve
572122
Double non-return valve, delockable
572151
Shut-off valve
152844
Proportional 6/3-way hand lever valve
572141
Loading unit/cylinder load simulator
572145
Diaphragm accumulator with shut-off block
152859
Hydraulic motor
152858
4-way distributor with pressure gauge
159395
T-distributor
152847
Pressure switch, electronic
548612
Flow sensor
567191
Allocation of components to exercises

TP 801 equipment set
Exercise
10
11
Component
Flow control valve
Non-return valve, 0.6 MPa opening pressure
Shuttle valve
Double non-return valve, delockable

Shut-off valve
1
1
Counterbalance valve
Pressure compensator for open centre load sensing
3-way pressure reducing valve

Pressure relief valve
1
1
Diaphragm accumulator with shut-off block
Pressure switch, electronic
Flow sensor
Proportional 6/3-way hand lever valve

4-way distributor with pressure gauge
T-distributor
Loading unit/cylinder load simulator

Hydraulic motor
2
1
Required accessories
Exercise
10
11
10
10
10
10
10
Component
Hose line with quick release couplings, 600 mm
Set of safety laboratory cables
Multimeter
Hydraulic power pack with constant displacement pump
1*
1*
1*
1*
1*
1*
1*
1*
1*
1*
1*
Hydraulic power pack with LS variable and constant

displacement pump combination
1*
1*
1*
1*
1*
1*
1*
1*
1*
1*
1*
Hydraulic oil (DIN 51524), HLP22, 20 Litres
Power supply unit for mounting frame
(> 3.5 l/min)
* for TP 801 and TP 802 a hydraulic power pack with a constant displacement pump with 3.5 l/min flow is required. Order number
572128 is recommended to cover TP 803 also.
Notes for the teacher/trainer

Learning objectives
The basic learning goal of this workbook is to become familiar with the fundamentals of mobile hydraulics,
as well as the practical setup of circuits on the slotted profile plate. This direct interaction involving both
theory and practice ensures faster progress and longer-lasting learning. Concrete, individual learning
objectives are assigned to each exercise.
Required time
The time required for working through the exercises depends on the learners previous knowledge of the
subject matter. Apprentices in the field of metalworking or electrical installation: approx. 4 days. With
training as skilled engineers: approx. 2 days.
Device set components
The workbook and the equipment set are matched to each other. Only the components included in TP 801
equipment set are required for all exercises.
Each exercise can be set up on a slotted profile plate with a width of at least 1100 mm.
Standards
The following standards are used in this workbook:
ISO 1219-1: Fluid power systems and components Graphic symbols and circuit diagrams, symbols
ISO 1219-2: Fluid power systems and components Graphic symbols and circuit diagrams,
circuit diagrams
EN 60617-7: Graphical symbols for circuit diagrams
EN 81346-2 Industrial systems, installations and equipment and industrial products
Structuring principles and reference designations
Identification of the solutions
Solutions and supplements in graphics or diagrams appear in red.
Designations in the worksheets
Texts which require completion are identified with a grid or grey table cells.
Graphics which require completion include a grid.
Training notes
Additional information is provided here regarding the individual components and the completed controllers.
These notes are not included in the exercise book.
Solutions
The solutions given in this workbook result from test measurements. The results of your measurements may
deviate from these.
Exercises and solutions TP 801

Exercise 1
Earth driller (uncompensated pressure)
Learning objectives
After completing this exercise you will:
Be familiar with the relationship between flow, pressure and energy consumption.
Be able to calculate the energy consumption of a hydraulic system under various conditions
Be familiar with the energy waste of flow sharing
Presentation of the application

The motor speed of an earth driller is to be controlled by a flow control valve.
Layout
Earth driller
Application
1. The constant pump has a flow of (qP) 4 l/min.
2. The motor rotates as soon as the pump starts running.
3. The motor rotates in one direction only.
Exercises and solutions TP 801: Exercise 1 Earth driller (uncompensated pressure)
4.
5.
6.
7.
The speed of the motor is adjusted by turning a flow control valve.

The load acting on the motor changes dependent on soil conditions.
The pressure acting on the pump is indicated by pressure sensor p1.
The pressure of the load is indicated by pressure sensor p2.
Tasks
Measure the pressure acting on the pump and calculate the energy consumption of the pump when:
1.1 The motor rotates at full speed without load. (qA = 4 l/min)
2.1 The motor rotates at full speed with a load of 30 bar. (3 MPa). (qA = 4 l/min)
3.1 The motor rotates at half speed without load. (qA = 2 l/min)
4.1 The motor rotates at half speed with a load of 30 bar (3 MPa). (qA = 2 l/min)
Read the flow on the flow meter when
5.1 The load is increased to 40 bar (4 MPa) (qA = ?)
6.1 Calculate the wasted energy for each task and show graphically.
Hints
Build the circuit shown on the next page.
For the tasks 2 and 4, the relief valve (1V2) for load simulation should be set to 30 bar (3 MPa) which is
read on p2.
During load simulation setting, the motor should be run at the desired speed (full speed for 1 and 2, half
speed for 3 and 4) and the setting adjusted so that 30 bar (3 MPa) of load is obtained at p2 in all cases.
In the tasks where no load should be acting on the motor, valve 1V2 should be turned until the
minimum pressure is reached. (Note: It is not possible to get 0 bar (0 MPa).)
The theory related to this exercise can be found in chapter 2.3, 4.1
Safety note
Limit the pump pressure to 60 bar (6 MPa) by adjusting 0Z1.
Circuit for Exercise 1
Calculating the energy consumption of the pump:

The theoretical energy requirement (P) of the pump can be calculated by the following formula:
Ppump =
qP p
600
Ppump =
Hydraulic power (kW)
qp
Pump flow (l/min)
Pressure difference between two points where the hydraulic power is converted into
mechanical energy (bar (MPa))
Efficiency of the pump (will be neglected for all exercises/ = 1)
1.1 Measure the pressure acting on the pump and calculate the energy consumption of the pump when
the motor rotates at full speed without load.
qP = 4 l/min
qA = 4 l/min
p1 = 15 bar (1.5 MPa)
p2 = 13 bar (1.3 MPa)
Ppump =
415
= 0.1 kW
600
In this task, the pump flow is 4 l/min and the tank pressure is assumed to be 0 (thats why p is 15 0). So
the power required to drive the pump under the given conditions depends on flow of 4 l/min at 15 bar (1.5
MPa) acting on the pump.
the motor rotates at full speed with a load of 30 bar (3 MPa).
qP = 4 l/min
qA = 4 l/min
p1 = 33 bar (3.3 MPa)
p2 = 30 bar (3 MPa)
Ppump =
433
= 0,22 kW
600
In this task, the power required to drive the pump under the given conditions depends on flow of 4 l/min at
30 bar (3 MPa) acting on the pump. As the pressure acting on the pump is more than the double the value
from the previous exercise, the power required to drive the pump has increased proportionally.
the motor rotates at half speed without load.
qP = 4 l/min
qA = 2 l/min
p1 = 57 bar (5.7 MPa)
p2 = 5 bar (MPa) (5 MPa)
Ppump =
457
= 0,38 kW
600
In this task, to achieve the flow sharing between the motor and the pressure relief valve, the cracking
pressure should be reached by turning the flow control valve to raise the system pressure to a high level.
Because of the increased pressure acting on the pump, the power required to drive the pump is almost at its
maximum. The pressure p2 decreases because the resistance created by the oil flow has also decreased.
the motor rotates at half speed with a load of 30 bar (3 MPa).
qP = 4 l/min
qA = 2 l/min
p1 = 57 bar (5.7 MPa)
p2 = 30 bar (3 MPa)
Ppump =
457
= 0,38 kW
600
In this task, although there is 3 bar (0.3 MPa) of load acting on the motor, the pressure acting on the pump
is at its highest. The cracking pressure has to be reached any way to achieve flow sharing.
1.5 Read the flow on the flow meter when the load is increased to 40 bar (4 MPa).
qP = 4 l/min
qA = 1.5 l/min
p1 = 57 bar (5.7 MPa)
p2 = 40 bar (4 MPa)
When the load is increased from 30 bar (3 MPa) to 40 bar (4 MPa), the pressure drop across the flow control
valve decreases (57 to 40 bar (5.7 to 4 MPa)). When the pressure drop decreases, the flow also decreases,
which causes the motor flow to decrease to 1.5 l/min. If the pressure drop was constant, the motor would
rotate at the same speed although the load has increased.
The useful energy of the system is the energy that is converted into mechanical energy by the hydro motor.
The pressure to calculate this energy can be read on pressure sensor p2. The wasted energy is the difference
between the pump power and the motor power. Or in other words, there is waste whenever there is a
pressure difference without conversion to mechanical energy. (In tasks 4 and 5 such energy waste is caused
by the pressure relief valve and the flow control valve.)
1.1
413
Pmotor =
= 0,086 kW
600
Ppump Pmotor = 0,1- 0,086 = 0,014 kW
1.2
430
Pmotor =
= 0,2 kW
600
Ppump Pmotor = 0,22 - 0,2 = 0,02 kW
1.3
25
Pmotor =
= 0,016 kW
600
Ppump Pmotor = 0,38 - 0,016 = 0,364 kW
Another way to calculate the wasted energy is:
257
Prelief valve =
= 0,19 kW
600
2( 57 -5)
Pthrottle alve =
= 0,173 kW
600
Prelief valve + Pthrottle valve = 0,19 + 0,173 = 0,364 kW
1.4
230
Pmotor =
= 0,1 kW
600
Ppump Pmotor = 0,38 - 0,1 = 0,28 kW
Pthrottle alve =
2( 57 - 30)
= 0,09 kW
600
10
0,4
0,35
0,3
0,25
Useful Energy
0,2
Wasted Energy
0,15
0,1
0,05
0
Task 1
Task 2
Task 3
Task 4
In tasks 1.1and 1.2, the wasted energy is the energy used to overcome the natural flow resistance of the
system. But as seen in the tasks 1.3 and 1.4, the wasted energy is the energy used to open the relief valve
by a flow control valve to achieve flow division.
11
12
Exercise 2
Earth driller (compensated pressure)
Learning objectives
Be familiar with the relationship between flow, pressure and energy consumption when the system has
pressure compensation (open-centre load sensing)
Be familiar with the amount of energy waste caused by flow sharing when the system has an opencentre load sensing)

The speed of the motor of an earth driller is to be controlled by a flow control valve. To reduce energy waste,
the system is equipped with an open-centre load-sensing unit.
1.
2.
3.
4.
5.
6.
7.
8.
Application
The pump has a flow of (qP) 4 l/min.
The motor rotates as soon as the pump starts running.
The motor rotates in one direction only.
The system has an open centre pressure compensator (Load sensing)
Tasks
2.2 The motor rotates at full speed with a load of 30 bar (3 MPa). (qA = 4 l/min)
2.5 Read the flow meter when the load is increased to 40 bar (4 MPa) (qA = ?)
2.6 Compare the results with the results of Exercise 1 graphically; show the wasted energy for each result.
Hints
All the tasks are the same as the tasks in the Exercise 1, allowing you to compare the results.
indicated on p2.
During load simulation setting, the motor should be run at the desired speed (full speed for 2.1 and 2.2,
half speed for 2.3 and 2.4) and the setting adjusted so that 30 bar (3 MPa) of load is obtained on p2 in all
cases.
13
Exercises and solutions TP 801: Exercise 2 Earth driller (compensated pressure)
In the tasks where no load should be acting on the motor, the valve 1V2 should be turned until the
The theory related to this exercise can be found in chapter 4.1, 4.2.
Safety note
p2
p1
14
As the above example shows, the flow that is not needed by the actuator is dumped to tank via the pressure
compensator without having to actuate the pressure relief valve.. The pressure compensator maintains a
constant pressure drop (p1 p2 = constant) across the flow control valve. The pressure acting on the pump
is always equal to the load pressure plus the spring setting of the compensator.
Theoretical energy requirement (P) of the pump can be calculated by the following formula:
Ppump =
qP p
600
Ppump =
qp
Pump flow (l/min)
15
qP = 4 l/min
qA = 4 l/min
p1 = 15 bar (1.5 MPa)
p2 = 13 bar (1.3 MPa)
Ppump =
415
= 0,1 kW
600
In this task, the pump flow is 4 l/min and the tank pressure is assumed to be 0 (that is why p is 15-0). So
the power required to drive the pump under the given conditions depends on flow of 4 l/min at 15 bar (1.5
MPa) acting on the pump.
the motor rotates at full speed with a load of 30 bar (MPa)
qP = 4 l/min
qA = 4 l/min
p1 = 33 bar (3.3 MPa)
p2 = 30 bar (3 MPa)
Ppump =
433
= 0,22 kW
600
In this task, the power required to drive the pump under the given conditions depends on flow of 4 l/min
and 30 bar (MPa) acting on the pump. As the pressure acting on the pump is more than the double value
from the previous exercise, the power required to drive the pump is also proportionally increased.
qP = 4 l/min
qA = 2 l/min
p1 = 12 bar (1.2 MPa)
p2 = 7 bar (0.7 MPa)
Ppump =
412
= 0,08 kW
600
In this task, the flow sharing does not take place between the motor and the pressure relief valve, but
between the motor and the pressure compensator. In such a system, the excess flow from the pump is
dumped to tank without being having to reach a higher pressure. On the other hand, the compensator
maintains a constant pressure drop across the flow control valve which is equal to the spring setting of the
compensator (approx. 5 bar (0.5 MPa)).
16
the motor rotates at half speed with a load of 30 bar (3 MPa)
qP = 4 l/min
qA = 2 l/min
p1 = 35 bar (3.5 MPa)
p2 = 30 bar (3 MPa)
Ppump =
435
= 0,23 kW
600
In this task, there is a load of 30 bar (3 MPa) acting on the motor while the pressure acting on the pump is
only 5 bar higher than the load pressure (0.5 MPa) (equal to the spring setting of the compensator).
qP = 4 l/min
qA = 2 l/min
p1 = 45 bar (4.5 MPa)
p2 = 40 bar (4 MPa)
As the compensator maintains a constant pressure drop across the flow control valve (p1 p2), the flow
passing through also remains constant, independent of the load. If we raise or lower the load value, the flow
remains constant, because the compensator will always maintain a pressure drop of 5 bar (0.5 MPa) across
the flow control valve.
2.6 Calculate the wasted energy for each task and show graphically
Make the calculations as they are done in the previous exercise.
2.1
413
Pmotor =
= 0,086 kW
600
Ppump Pmotor = 0,1- 0,086 = 0,014 kW
2.2
430
Pmotor =
= 0,2 kW
600
Ppump Pmotor = 0,22 - 0,2 = 0,02 kW
17
2.3
27
Pmotor =
= 0,023 kW
600
Ppump Pmotor = 0,08 - 0,023 = 0,057 kW
2.4
230
Pmotor =
= 0,1 kW
600
Ppump Pmotor = 0,23 - 0,1 = 0,13 kW
0,4
0,35
0,3
0,25
Useful Energy
0,2
Wasted Energy
0,15
0,1
0,05
2.
4
Ta
sk
1.
4
Ta
sk
Ta
sk
2.
3
1.
3
Ta
sk
2.
2
Ta
sk
1.
2
Ta
sk
2.
1
Ta
sk
Ta
sk
1.
1
In tasks 1and 2, the wasted energy is the energy used to overcome the natural flow resistance of the system.
But as seen in tasks 3 and 4, the wasted energy for Exercise 2 is much smaller compared to Exercise 1. The
energy efficiency benefits of an open-centre load-sensing system can clearly be seen.
18
Contents
Exercise 2 Earth driller (compensated pressure) _________________________________________________9

63
69
73
77
81

Exercise 4 Earth driller (load and speed) _____________________________________________________ 97
II

Exercise 1
Earth driller (uncompensated pressure)
Learning objectives
Be familiar with the relationship between flow, pressure and energy consumption.
Be able to calculate the energy consumption of a hydraulic system under various conditions
Be familiar with the energy waste of flow sharing

The motor speed of an earth driller is to be controlled by a flow control valve.
Layout
Earth driller
Application
1. The constant pump has a flow of (qP) 4 l/min.
2. The motor rotates as soon as the pump starts running.
3. The motor rotates in one direction only.
Exercises and worksheets TP 801: Exercise 1 Earth driller (uncompensated pressure)
4.
5.
6.
7.

Tasks
2.1 The motor rotates at full speed with a load of 30 bar. (3 MPa). (qA = 4 l/min)
Read the flow on the flow meter when
5.1 The load is increased to 40 bar (4 MPa) (qA = ?)
Hints
read on p2.
During load simulation setting, the motor should be run at the desired speed (full speed for 1 and 2, half
speed for 3 and 4) and the setting adjusted so that 30 bar (3 MPa) of load is obtained at p2 in all cases.
In the tasks where no load should be acting on the motor, valve 1V2 should be turned until the
The theory related to this exercise can be found in chapter 2.3, 4.1
Safety note

The theoretical energy requirement (P) of the pump can be calculated by the following formula:
Ppump =
qP p
600
Ppump =
qp
Pump flow (l/min)
qP = 4 l/min
qA = 4 l/min
Ppump =
p1 =
p2 =
Conclusion:
the motor rotates at full speed with a load of 30 bar (3 MPa).
qP = 4 l/min
qA = 4 l/min
Ppump =
p1 =
p2 =
Conclusion:
qP = 4 l/min
qA = 2 l/min
ppump =
p1 =
p2 =
Conclusion:
the motor rotates at half speed with a load of 30 bar (3 MPa).
qP = 4 l/min
qA = 2 l/min
ppump =
p1 =
p2 =
Conclusion:
qP = 4 l/min
p2 = 40 bar (4 MPa)
ppump =
qA =
p1 =
Conclusion:
The useful energy of the system is the energy that is converted into mechanical energy by the hydro motor.
The pressure to calculate this energy can be read on pressure sensor p2. The wasted energy is the difference
between the pump power and the motor power. Or in other words, there is waste whenever there is a
pressure difference without conversion to mechanical energy. (In tasks 4 and 5 such energy waste is caused
by the pressure relief valve and the flow control valve.)
1.1
Pmotor =
Ppump pmotor =
1.2
Pmotor =
Ppump pmotor =
1.3
Pmotor =
Ppump pmotor =

prelieff valve =
pthrottle valve =
prelieff valve + pthrottle valve =
1.4
Pmotor =
Ppump pmotor =

prelieff valve =
pthrottle valve =
prelieff valve + pthrottle valve =
Example
0,4
0,35
0,3
0,25
Useful Energy
0,2
Wasted Energy
0,15
0,1
0,05
0
Task 1
Task 2
Task 3
Task 4
Conclusion:
Exercise 2
Earth driller (compensated pressure)
Learning objectives
Be familiar with the relationship between flow, pressure and energy consumption when the system has
pressure compensation (open-centre load sensing)
Be familiar with the amount of energy waste caused by flow sharing when the system has an opencentre load sensing)

The speed of the motor of an earth driller is to be controlled by a flow control valve. To reduce energy waste,
the system is equipped with an open-centre load-sensing unit.
1.
2.
3.
4.
5.
6.
7.
8.
Application
The pump has a flow of (qP) 4 l/min.
The motor rotates as soon as the pump starts running.
The motor rotates in one direction only.
The system has an open centre pressure compensator (Load sensing)
Tasks
2.2 The motor rotates at full speed with a load of 30 bar (3 MPa). (qA = 4 l/min)
2.5 Read the flow meter when the load is increased to 40 bar (4 MPa) (qA = ?)
2.6 Compare the results with the results of Exercise 1 graphically; show the wasted energy for each result.
Hints
All the tasks are the same as the tasks in the Exercise 1, allowing you to compare the results.
indicated on p2.
During load simulation setting, the motor should be run at the desired speed (full speed for 2.1 and 2.2,
half speed for 2.3 and 2.4) and the setting adjusted so that 30 bar (3 MPa) of load is obtained on p2 in all
cases.
Exercises and worksheets TP 801: Exercise 2 Earth driller (compensated pressure)
In the tasks where no load should be acting on the motor, the valve 1V2 should be turned until the
The theory related to this exercise can be found in chapter 4.1, 4.2.
Safety note
p2
p1
10
As the above example shows, the flow that is not needed by the actuator is dumped to tank via the pressure
compensator without having to actuate the pressure relief valve.. The pressure compensator maintains a
constant pressure drop (p1 p2 = constant) across the flow control valve. The pressure acting on the pump
is always equal to the load pressure plus the spring setting of the compensator.
Theoretical energy requirement (P) of the pump can be calculated by the following formula:
Ppump =
qP p
600
Ppump =
qp
Pump flow (l/min)
11
qP = 4 l/min
qA = 4 l/min
ppump =
p1 =
p2 =
Conclusion:
the motor rotates at full speed with a load of 30 bar (MPa)
qP = 4 l/min
qA = 4 l/min
ppump =
p1 =
p2 =
Conclusion:
12
qP = 4 l/min
qA = 2 l/min
ppump =
p1 =
p2 =
Conclusion:
the motor rotates at half speed with a load of 30 bar (MPa)
qP = 4 l/min
qA = 2 l/min
p2 = 30 bar (3 MPa)
ppump =
p1 =
Conclusion:
qP = 4 l/min
PA =
P1 =
p2 = 40 bar (4 MPa)
13
Conclusion:
2.6 Calculate the wasted energy for each task and show graphically
Make the calculations as they are done in the previous exercise.
2.1
Pmotor =
Ppump pmotor =
2.2
Pmotor =
Ppump pmotor =
2.3
Pmotor =
Ppump pmotor =
2.4
Pmotor =
Ppump pmotor =
14
Example
0,4
0,35
0,3
0,25
Useful Energy
0,2
Wasted Energy
0,15
0,1
0,05
2.
4
Ta
sk
1.
4
Ta
sk
Ta
sk
2.
3
1.
3
Ta
sk
2.
2
Ta
sk
1.
2
Ta
sk
Ta
sk
Ta
sk
1.
1
2.
1
Conclusion:
15
16
Fundamentals
1
Definition________________________________________________________________________ I-1
2
2.1
2.2
2.3
Hydraulics fundamentals ___________________________________________________________

Pressure, flow, relief valve fundamentals ______________________________________________
Pressure drop (p) ________________________________________________________________
Heat generation due to the pressure drop _____________________________________________
3
3.1
3.2
3.3
3.4
3.5
Closed Hydrostatic System ________________________________________________________

Building a closed hydraulic circuit ___________________________________________________
Closed-circuit hydraulic pumps _____________________________________________________
Charge pumps ___________________________________________________________________
Flushing valves __________________________________________________________________
Shock valves ____________________________________________________________________
4
4.1
4.2
Load-sensing systems ____________________________________________________________ I-19

Pump performance _______________________________________________________________ I-19
Load sensing systems: ____________________________________________________________ I-27
Variable-displacement pumps ______________________________________________________ I-34
Unloading system ________________________________________________________________ I-39
7
7.1
7.2
7.3
Flow-dividing valves ______________________________________________________________

50/50 spool flow divider __________________________________________________________
Rotary flow divider _______________________________________________________________
Rotary flow divider (pressure intensification) __________________________________________
I-41
I-42
I-44
I-45
8
8.1
8.2
8.3
8.4
8.5
8.6
Mobile valve blocks ______________________________________________________________

Definition_______________________________________________________________________
Symbol for a mobile valve _________________________________________________________
Valve construction _______________________________________________________________
Directional control valve spool _____________________________________________________
Side modules ___________________________________________________________________
Shock and anti-cavitation valve _____________________________________________________
I-47
I-47
I-49
I-50
I-52
I-55
I-60
9
9.1
9.2
9.3
9.4
9.5
6/3-way directional control valves and valve configurations ______________________________

Definition of 6/3-way valves _______________________________________________________
Parallel configuration _____________________________________________________________
Tandem configuration ____________________________________________________________
Series configuration ______________________________________________________________
Basic design of a 6/3-way valve ____________________________________________________
I-63
I-63
I-64
I-65
I-66
I-67
I-3
I-3
I-7
I-9
I-10
I-10
I-13
I-16
I-16
I-18
I-I
I-II
10
10.1
10.2
Pressure compensation ___________________________________________________________ I-70

Pre-compensation________________________________________________________________ I-75
Post compensation _______________________________________________________________ I-77
11
11.1
11.2
11.3
11.4
Load holding and motion control ____________________________________________________

Delockable non return valve _______________________________________________________
Direct-acting counterbalance valve __________________________________________________
Delockable counter balance valve (overcentre valve) ___________________________________
Pilot ratio _______________________________________________________________________
12
Hydraulic joystick ________________________________________________________________ I-87
13
13.1
13.2
13.3
Priority valve ____________________________________________________________________

3-way compensator ______________________________________________________________
Priority valve ____________________________________________________________________
Dynamic priority valve ____________________________________________________________
14
14.1
14.2
14.3
14.4
14.5
Steering ________________________________________________________________________ I-95

The steering unit _________________________________________________________________ I-95
Open-centre systems _____________________________________________________________ I-98
Closed-centre systems ___________________________________________________________ I-100
Reaction and non-reaction steering units ____________________________________________ I-101
Steering types __________________________________________________________________ I-102
I-79
I-79
I-80
I-83
I-86
I-90
I-90
I-92
I-93
1 Definition
The biggest difference between industrial and mobile systems is that mobile systems do not follow a regular
work cycle or use as many actuators. The number of actuators etc. used varies depending on the conditions
such as load, working surface, ground slope, cycle time, and pressure. And the machine must meet certain
demands even in the worst combination of conditions.
The most important consideration in mobile systems is efficiency: As mobile machines move independently
from any power source, the power supply is limited. In most cases, the only power source is an internal
combustion engine with a limited fuel supply.
For this reason, components of a mobile system including reservoirs, pumps, motors and valves should
be as small and light possible. But higher pressures are required to achieve the same performance from a
smaller component,. Higher pressures require smaller clearances to prevent leakages and smaller
clearances require cleaner, cooler oil.
In industrial hydraulic systems, the force acting on an actuator is usually constant but in mobile applications
this force varies a lot. If the pressure relief valve should be set for the highest load, a lot of power will be
wasted for the smaller loads, this problem should also be overcome in mobile systems.
As the figure below shows, a mobile hydraulic system comprises three main parts:
1. Closed hydrostatic transmission
2. Working hydraulics
3. Steering
There are two different types of pumps when classified by duty:
The main pump supplies hydraulic power for the motors which make the wheels turn. It is an axial piston
pump which allows the direction of flow to be reversed and the flow rate to be adjusted. .
The other pumps are called auxiliary pumps. Depending on the application, there may be one auxiliary
pump for both working hydraulics and steering or one pump for each application.
The working hydraulics parts of mobile applications that resemble industrial hydraulics comprise various
valves (mostly proportional) and actuators. The directional control valves used in mobile hydraulics are
special designs for mobile applications and are called mobile valve blocks instead of directional control
valves.
I-1
I-2
2 Hydraulics fundamentals
2.1 Pressure, flow, relief valve fundamentals
It is helpful to remember some basic hydraulics fundamentals before proceeding to mobile hydraulics. Some
of the fundamentals play an important role in understanding the logic behind the mobile applications.
The diagram below shows a mobile application. In mobile applications, the pump is either a gear pump as
shown below or a variable-displacement pump. The flow control valve below represents a proportional
directional control valve where the oil is throttled to adjust the speed of the actuator.
Relief valve setting = 275 bar (27.5 MPa)
Cracking pressure = 250 bar (25 MPa)
Pump flow= 100 l/min
Lets find answers to some basic questions:

1. What makes the value of p2 to rise or fall?
2. What is the pressure difference between p1 and p2 if the flow control valve is fully open?
3. What happens to the actuator speed if the flow control valve is partially closed to raise p1 to 200 bar (20
MPa)?
4. What is the pressure at p1 if the cylinder is extending at half speed?
5. What happens if the load on the cylinder increases?
6. What happens at p2 if the load changes position?
The answers to these questions can be as follows:
1. The pressure value of p2 is determined by the load weight, its position, and the piston diameter. Any
change in the load weight or position will affect the pressure of p2.
2. The pressure difference between two points is determined by the resistance between them. If the flow
control valve is fully open it creates no resistance and if we neglect the friction due to oil flow, the value
of p1 and p2 is same.
I-3
3. The speed of the actuator depends on oil flow into the cylinder. If the pressure value of p1 is higher than
the cracking pressure, the relief valve opens partially or fully and the cylinder only receives part or none
of the flow, causing the piston to slow or stop.
In the question, the pressure value of p2 is below the cracking pressure, so the cylinder is moving at full
speed (if we neglect the leakage losses due to high pressures). The circuit diagram shows that the relief
valve is closed, and the cylinder is receiving the full flow from the pump.
4. If the cylinder is extending less than full speed, the pressure at p1 is above the cracking pressure value
and below the fully open pressure and 50 l/min is dumped to tank via the relief valve. Half-speed
corresponds to a point between these two which is approximately 260 bar (26 MPa). This value may
also be found on the characteristics curve of the relevant relief valve. As seen in the illustration below,
the relief valve is open due to high pressure and a part of the pump flow is dumped to tank via the relief
valve. The flow control valve or the proportional directional control valve plays an important role here,
such as changing the resistance value to change the pressure value of p2 .
The opening characteristic curve of a relief valve is shown below. The curve corresponds to a flow rate which
passes through the relief valve at certain pressures at a certain preset value (at certain oil viscosity and a
certain temperature). When we examine the curve, we can see that the 50 l/min flows to tank when the
pressure at the relief valve inlet port is as high as 260 bar (26 MPa) when the maximum setting is 275 bar
(27.5 MPa).
I-4
q: Nominal flow
p: Operating pressure
pc: Cracking pressure
pf: Fully open pressure
A curve from a catalogue is shown below. In the catalogue the curves starting point is the cracking pressure
as the useful area is that between the cracking pressure and fully open points. In the catalogue curve we can
also find the corresponding pressure for 50 l/min flow: It is also 260 bar (26 MPa).
I-5
5. If the load on the cylinder increases, this eventually increases the pressure of p2. The increased
pressure affects the whole system and P1 also rises. The increasing pressure of p1 causes the relief valve
to open further. This causes the relief valve will dump more oil to tank, which slows the piston travel.
We can also see this in the curve.
pA = 260 bar (26 MPa) - Before the load increased, the cylinder was travelling at half speed.
pB = 270 bar (27 MPa) - Because of the increasing load, p2 rises to 270 bar (27 MPa) and the relief valve opens further and dumps 70
l/min to tank.
6. If the load changes position, this will have the same effect as question 5. As the load is moved away
from the boom cylinder, the lever arm becomes longer, applying greater force to the piston. The further
away the load, the slower the cylinder moves.
I-6
2.2 Pressure drop (p)

The term pressure drop plays an important role for the sound understanding of hydraulic systems. The
symbol for pressure drop is p and it simply refers to a pressure difference between two points. Although it
is mainly used to ensure proper valve sizing and selection, it is also used to explain some hydraulics
fundamentals.
In the above example, there is a valve with a certain resistance value and p1 is the valve inlet port and p2 is
the outlet port. Because of the resistance applied by the valve (this may be a flow control valve, an orifice, a
directional control valve or a proportional directional control valve), the pressure rises at the inlet of the
valve (assuming that the flow direction is always from inlet to outlet).
Back pressure is the pressure found at the outlet port of the valve (p2). This is caused by downstream
restrictions such as load on a cylinder, filter, reducing fittings anything that can cause a pressure drop.
The above system represents a hydraulic system with a flow control valve (it may also be a proportional
directional control valve) with a certain p and the PRV is not yet open. Lets examine the variables with the
above given condition (pump efficiency neglected):
1. What happens if the flow control valve is gradually closed?
If the flow control valve is gradually closed, p1 will increase, but p2 will remain the same. Consequently
the p will increase, but this will have no effect on the flow.
2. What happens when the back pressure at point 2 increases?
If P2 increases due to back pressure, p1 will increase by the same amount. Consequently p will remain
the same and this will also have no effect on the flow.
3. What happens if the flow increases?
If flow increases, the resistance at the throttling point increases. As a result, p will rise as seen in the
formulas or in the diagram below.
I-7
4. What happens if the viscosity decreases (due to heating of the oil)?

Oil with lower viscosity creates lower resistance which causes p1 to decrease, resulting in a decrease in
p. This will have no effect on the flow.
In the above given conditions, the change in p has no effect on flow, but the change in the flow has a large
effect on p (as also seen in the curve). In a flow controlled condition, the change in the flow causes a great
change in p.
Lets examine the condition where the PRV is already open to make flow sharing. Now, the changes in p
will affect the flow.
1. What happens if the flow control valve is gradually closed?

This will increase p1, consequently the p will increase. The increasing value of p1 causes the PRV to
open further, reducing flow to the system.
2. What happens when the back pressure at point 2 increases?
If p2 increases due to a back pressure, p1 also increases (but only a small amount, this can be found in
the characteristic curve of the pressure relief valve), which causes the PRV to open further. In this case,
p decreases and the flow also decreases.
3. What happens if the viscosity increases?
This causes less resistance in the flow control, consequently, p1 will fall. The fall in p1 causes the PRV to
close gradually, so flow through the system increases.
Consequently, in a fixed throttling condition (fixed resistance), keeping a constant p in the system will
result in a constant flow.
I-8
2.3 Heat generation due to the pressure drop

The pressure drop between two components results in wasted energy which is converted into heat when
there is no useful movement (such as extending of a cylinder or rotating of a hydraulic motor).
For example, the pressure relief valve is the greatest heat generator in the system, because the oil flows to
tank without doing any useful work. Also a flow control valve, a proportional valve which throttles the oil,
any orifice or any leakage causes heating of the oil due to a big pressure drop.
The power transferred to a fluid causing heat generation can be calculated by the formula given below.
P= Hydraulic power (kW)
q= Flow (l/min)
p= Pressure difference between two points (bar)
P=
qp
600
The energy which is converted into heat in a pressure relief valve is:
P=
qprv (p1 - p0 )
600
The energy which is converted into heat in a flow control valve is:
P=
qfc (p1 - p2 )
600
I-9
3 Closed Hydrostatic System

3.1 Building a closed hydraulic circuit
In many vehicles it is preferred to have hydrostatic transmission rather than mechanical transmission
despite its lower efficiency. This is because the benefits of hydrostatic transmission outweigh the
disadvantages: Hydrostatic transmission provides superior maneuvering abilities and continuously variable
speed control between minimum and maximum speeds. The direction of rotation of the wheels is easily
reversed by using the features of the variable mobile pump.
In mechanical transmission systems, the wheels of a vehicle are driven by shafts and gears from an internal
combustion engine. But in hydrostatic transmission, the combustion engine drives a pump and the pump
supplies oil for the hydraulic motor(s) which make the wheels turn. The pumps flow rate is proportional to
input speed.
But due to limitations of mobile hydraulics such as reservoir size, weight of components etc, the pump and
the motor(s) do not operate as they do in a conventional hydraulic system, which is known as an open
circuit. Instead, they operate in a closed circuit where both inlet and outlet ports of the pump and motor are
connected. In other words, the oil delivered by the pump makes the hydraulic motor rotate and the oil out of
the motor goes to the suction port of the pump again. The oil circulates between the pump and the motor in
a continuous loop.
The above diagram is the basic representation of a closed hydraulic circuit. The oil circulates in the circuit
making the motor(s) rotate. The flow direction is reversed and the flow is adjusted by tilting the swash plate
of the pump.
For various reasons, the circuit in the diagram cannot operate.
1. There are leakages in both pump and the motor. So the oil in the circuit gets less as the system runs,
which make the system impossible to operate. (These leakages are necessary for cooling and cleaning
functions.)
2. The suction side of the pumps in closed circuits must always have positive pressure, otherwise the
system may not run. But due to load on the motor, this pressure may be too low to make the system
run.
3. The oil in the system gets hotter due to extreme working conditions and pressures and has to be
replaced with fresh oil.
I-10
In closed circuits, a charge pump is necessary to overcome internal and auxiliary leakages, provide flow for
cooling and maintain pressure in the line which acts as a suction side (where the flow is into the pump).
As the flow direction should be reversible in closed circuits, two non return valves are used to ensure the
supply pump oil flows only in the suction side of the main pump as the non return valve connected to the
pressure line will close due to higher pressure and the one on the suction side will open due to lower
pressure.
In most mobile pumps (variable axial piston pump), the charge pump is in the main pump block and is
driven by the same shaft connected to internal combustion engine.
No oil can circulate in the main pump when it is idle. For this reason, the charge pump also lubricates the
main pump. The charge pump is usually placed in the main pump block, but is separate in some
applications.
As the diagrams show, the leakage lines from both pump and motors are connected to tank. These leakages
are intentionally built in for cooling and lubricating purposes, but as the system wears out, the amount of
leakage increases to undesirable levels. As the clearances in mobile applications are smaller, the cleanliness
of the oil affects the life of the components as well as the amount of leakage.
Because of higher pressures, smaller clearances and limited cooling sources, the oil very soon gets hot in
mobile systems. And because of the smaller clearances, the oil should always maintain a certain level of
cleanliness.
I-11
To ensure efficient cooling and removal of contamination, instead of running all the available oil in the
circuit, oil which is not required by the pump is flushed to tank, ensuring that the charge pump always
receives fresh oil from the tank.
The flushing is better done as soon as the oil gets hot. This is done by flushing valve as seen in the circuit.
The flushing valve receives relatively hot and contaminated oil from the outlet of the motor and immediately
diverts it to the tank. The flushing valve is pressure-operated by the pressure in the pressure line. In most
applications, the flushing valve is in the motor block as it has to be placed very near to where the oil gets
hot. There are cases where the flushing valve is in the pump block.
The setting of the pressure relief valve connected to the flushing valve determines the pressure of the
suction line.
The last important detail which was missing in the previous diagrams was the shock valve. As the wheels
connected to hydraulic motors can receive sudden and severe iMPacts as the result of surface conditions,
the pressure in the lines may go over the circuits limitations. For this reason, a relief valve is placed in each
line to protect the system pressure against spikes resulting from external effects. And these relief valves are
called shock valves and set at a higher value than the pumps pressure setting.
The major components in a closed transmission system are:

1
Main pump
2
Charge pump
3
Charge pump pressure relief valve
4
Non return valve
5
Flushing valve
6
Flush valve pressure relief valve
7
Shock valve
8
Hydraulic motor
9
Heat exchanger
10
Reservoir
11
Filter
I-12
Some of these components can also be seen on the following diagram.
10
11
9
2
1
3.2 Closed-circuit hydraulic pumps

These are usually axial piston hydrostatic pumps. The flow rate and the flow direction are controlled by
varying the swash plate angle. There are two basic types of displacement control: direct displacement
control and servo control.
Direct displacement control
In this type of control, a mechanical lever is attached to the swash plate which the operator controls via a
linkage assembly. The force required to engage a direct displacement control is a function of the system
pressure that the swash plate is working against. Because the required control force is a function of system
pressure, direct displacement controls are generally only suitable to light-duty applications.
Servo control
This is an interface between the operator and the swash plate. The operator input is a low-force device
which ports charge pressure to the servo piston to move the swash plate. As a result, the operator input is
not dependent on system pressure. Standard servo controls also have a mechanical feedback mechanism
which ensures that the swash plate position stays where set.
I-13
I-14
Main components in a closed-circuit pump
3
4
5
6
Charge pump
Valve plate
Cylinder block
Cradle swash plate
Piston
Ball bearing
I-15
3.3 Charge pumps

A charge pump is also a vital element for every closed hydrostatic circuit which is usually a gear or a gerotor
pump. It carries out the following functions:
1. Replenishing the fluid lost through the volumetric efficiency of the pump and the motors.
2. Replenishing the fluid lost through the flushing valve.
3. Providing make-up fluid in the loop for load-induced bulk modulus effects.
4. Providing constant flow for the pilot solenoids for the pump control.
5. Providing flow to the servo control actuator.
6. Providing flow for the auxiliary functions such as parking brakes or servo motor displacement.
7. Maintaining low loop pressure to ensure sufficient hold-down forces on the rotating groups.
8. Controlling flushing flow by means of the pressure differential between the charge relief valve and the
flushing relief valve.
3.4 Flushing valves
There are two primary fluid loops in a closed-circuit transmission

The main system power loop (which is delivered by the main pump, received by the motor(s) and again
received by the suction side of the main pump)
The charge/cooling loop (a portion of the main loop charged to tank via flushing valves).
Quality oil is required in the power loop, but the quality of the fluid is controlled by the charge/cooling loop.
The flushing valve removes a portion of the flow from power loop; this must be replenished by the charge
pump. The removed fluid is considered dirty and hot, while the power loop requires cool, clean oil.
Removing heat and contamination is the utmost priority for system operation, especially in hydrostatic
systems with small clearances. Although some systems may function without a flushing valve, adding one
increases the service life of components.
Flushing valves can either be separate or integrated to the body of a motor or a pump. They always divert
the low-pressure side of the power loop to the tank. The pressure side of the loop causes the flushing valve
to actuate and this causes the low-pressure side to be diverted to tank. There is always a pressure relief
valve in the same block which determines the pressure of the low-pressure side (suction side).
The flushing valve can be symbolised as below. The diagram shows that the flushing valve directs oil
through the motors drain line where the flushing valve is in the motor housing.
I-16
The spool valve housing contains a spool which is centred by the spring. The oil coming from 1 or 2 is
transmitted to 4 to be dumped to the tank, depending on which way the spool is actuated by the higherpressure side.
1, 2: System ports
4: Drain port
The oil coming from 2 at high pressure pushes the spool to the left causing the flow through 1 (low-pressure
side) being dumped into the tank.
The oil coming from 1 at high pressure pushes the spool to the left causing the flow through 2 (low-pressure
side) being dumped into the tank.
I-17
3.5 Shock valves

Shock valves (also called as crossover relief valves) are direct-acting pressure relief valves to protect the
circuit from sudden rises in pressure. The advantage of using a direct-acting relief valve is that they respond
much faster, they are contaminant-tolerant, and have less leakage.
In most closed circuits, bidirectional relief valves are used. The bidirectional poppet is a dual crossover relief
in a single cartridge. When pressure at 1 exceeds the nominal setting, the lower poppet acts as a directacting relief valve and opens flow from 1 to 2. When pressure at 2 exceeds the nominal setting, the upper
poppet acts as a differential area relief valve and opens flow from 2 to 1 . Note that the valve is designed so
that the crack pressure is the same in either direction.
Bidirectional shock valve
I-18

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Mobile Hydraulics

Equipment set TP 801 ______________________________________________________________________1

Equipment set TP 802 ____________________________________________________________________ 61

Festo Didactic GmbH & Co. KG 574166

Equipment set TP 803 ____________________________________________________________________ 87

Exercises and worksheets TP 801

Exercises and worksheets TP 802

Festo Didactic GmbH & Co. KG 574166

Exercises and worksheets TP 803

Festo Didactic GmbH & Co. KG 574166

Festo Didactic GmbH & Co. KG 574166

Use for intended purpose

Festo Didactic GmbH & Co. KG 574166

Festo Didactic GmbH & Co. KG 574166

All training packages are comprised of the following elements:

Do you have suggestions or criticism regarding this manual?

Festo Didactic GmbH & Co. KG 574166

Festo Didactic GmbH & Co. KG 574166

Work and safety instructions

Festo Didactic GmbH & Co. KG 574166

Connecting hose lines

Festo Didactic GmbH & Co. KG 574166

Training package for mobile hydraulics (TP 800)

Festo Didactic GmbH & Co. KG 574166

Equipment set TP 801

Pressure compensator for open centre load sensing

3-way pressure reducing valve

Pressure relief valve

Flow control valve

Non-return valve, 0.6 MPa opening pressure

Double non-return valve, delockable

Proportional 6/3-way hand lever valve

Loading unit/cylinder load simulator

Diaphragm accumulator with shut-off block

4-way distributor with pressure gauge

Pressure switch, electronic

Festo Didactic GmbH & Co. KG 574166

Equipment set TP 801

Allocation of components to exercises

Double non-return valve, delockable

Pressure compensator for open centre load sensing

3-way pressure reducing valve

Diaphragm accumulator with shut-off block

Pressure switch, electronic

Proportional 6/3-way hand lever valve

Loading unit/cylinder load simulator

Festo Didactic GmbH & Co. KG 574166

Equipment set TP 801

Hose line with quick release couplings, 1500 mm

Set of safety laboratory cables

Hydraulic power pack with constant displacement pump

Hydraulic power pack with LS variable and constant

Hydraulic oil (DIN 51524), HLP22, 20 Litres

Power supply unit for mounting frame

(> 3.5 l/min)

Notes for the teacher/trainer

Festo Didactic GmbH & Co. KG 574166

Equipment set TP 801

Festo Didactic GmbH & Co. KG 574166

Exercises and solutions TP 801

Presentation of the application

Festo Didactic GmbH & Co. KG 574166

Exercises and solutions TP 801: Exercise 1 Earth driller (uncompensated pressure)