Modern Hydraulic Systems for

Wheeled and Crawler Excavators

Modern Hydraulic Systems for

Wheeled and Crawler Excavators

Standard Excavator

The special features, differences and possibilities

offered by hydraulic drive and control systems in
the different categories of excavators are described
below, with reference to the most popular sizes of
machine worldwide (fig. 1).

Compact Excavator

The functionality of throttle control systems with

two 4-spool MO control blocks and, later, the series
M8 compact control blocks has been continually
improved over the years. However, with growing
demands for excavator controllability and optimum
flow distribution to the individual actuators, many
leading excavator manufacturers took the decision
to go over to load sensing systems and variations
of these. Rexroth developed the LUDV system
(load-pressure independent flow distribution) to
meet this need and has implemented it in several
machines with varying requirements.

Mini Excavator

Excavators with fully hydraulic working equipment

have been around for the last 50 years or so. Multiple circuit systems were built, initially with a
number of gear pumps which were deactivated as
a function of pressure in order to achieve a form
of power control. With the introduction of control
hydraulics and high pressure, standard excavators
came to feature almost exclusively dual-circuit
throttle control systems with axial piston pumps
and motors. The power supply to the implements
was in most cases by means of a double pump in
bent axis design, for instance the A8VO model, still
in use today in open centre systems on many
excavators, cranes and similar machines.

Fig. 1: Modern hydraulic systems for wheeled and crawler excavators

Werner Herfs / RMH-V1

Mannesmann Rexroth / Lohr
Control technology
Phone +49 (0) 9352 / 18-2380
Fax
+49 (0) 9352 / 18-2159
E-Mail: [email protected]

Gnter Fertig / RMH-V1

Mannesmann Rexroth / Lohr
Control technology
Phone +49 (0) 9352 / 18-2353
Fax
+49 (0) 9352 / 18-2159
E-Mail: [email protected]

Helmut Funk / RMH-L

Mannesmann Rexroth / Parchim
Steerings
Phone +49 (0) 3871 / 606-235
Fax
+49 (0) 3871 / 606-201
E-Mail: [email protected]

Egon Rill / VMT1/H

Brueninghaus Hydromatik GmbH
Horb plant
Axial piston units
Phone +49 (0) 7451 / 92-14 63
Fax
+49 (0) 7451 / 92-82 21
E-Mail: [email protected]

Ralf Uhde / LVV-M

Lohmann + Stolterfoht GmbH
Witten
Gear technology
Phone +49 (0) 2302 / 877-457
Fax
+49 (0) 2302 / 877-404
E-Mail: [email protected]

Gilles Chetail
Mannesmann Rexroth S. A.
France
Control technology
Phone +33 / 47878 -5248
Fax
+33 / 47878-5271
E-Mail: [email protected]

RE 00 207/10.00

Dirk van Aalst / VMT1/E

Brueninghaus Hydromatik GmbH
Elchingen plant
Axial piston units
Phone +49 (0) 7308 / 82-25 63
Fax
+49 (0) 7308 / 53 38
E-Mail: [email protected]

37

Modern Hydraulic Systems for

Wheeled and Crawler Excavators

1. Control System for Mini

Excavators
Mini excavators in the weight class from 2.5 to
approx. 5 metric tonnes are still predominantly
fitted with multiple circuit open centre systems. To
achieve the performance and manoeuvrability that
the market demands, 3-circuit pump systems are
mostly used (fig. 2).
Double variable displacement pumps such as the
A12VO and an attached gear pump for the slew
drive with a single suction port are widely used. A
second gear pump with integral pressure relief
valve serves the pilot oil circuit.
The ever-more compact, modern design of todays
mini excavators with a high proportion of zero tail
models calls for new solutions requiring less room
for components and in particular for the pump and
control block.
Unit numbers of mini excavators equipped with a
variable displacement pump and closed centre
directional control valve have increased worldwide
in recent years. Rexroth is one of the first hydraulics
manufacturers to have developed this concept for
mini excavators, and the present-day-success of

this system is confirmation that we took the right

decision (fig. 3).
The mini excavator characteristics which the
market demands are importantly determined by
the features that are already taken for granted on
standard excavators:
greater operation comfort
improved precision control, manoeuvrability and
accuracy of the machines
cost reduction by simplifying the hydraulic circuit
increased reliability
The path more and more of our customers are
taking in order to achieve these performance
characteristics is the Rexroth single-circuit LUDV
system. This principally comprises the A10VO variable displacement pump and model SX12 closed
centre directional control valve with integral LUDV
function.
The swashplate medium-pressure pump A10VO
series 31 currently in use has been modified and
in series 53 it now features an even more compact
shape with a constant power control integrated

into the housing with no external piping (fig. 4).

For some models the connecting plate has been
designed to enable a special gear pump also to be
attached to the through-drive, sharing a common
suction port with the main pump (fig. 5).

GFT + A10VT
(Travel drive)
MCR
(Slew drive)
SM 12
(Control)

A12VO
(Travel and implement hydraulics)

4TH5
(Pilot control units)

Fig. 2: Throttle control three-circuit system

38

RE 00 207/10.00

Modern Hydraulic Systems for

Wheeled and Crawler Excavators

GFT + A10VT
(Travel drive)
MCR
(Slew drive)
9SX12
(Control)

A10VO
(Travel and implement hydraulics)

4TH5

2TH6R
(Pilot control units)

4TH5

MHSTE
(Pilot oil supply)

Fig. 3: 1-circuit LUDV system

A10VO/53

Technical data:

Size ________________ 10...85

Nominal pressure pN _____ 250 bar
High pressure

pmax ___ 315 bar

Fig. 4: A10VO for mini excavator

RE 00 207/10.00

A10VO 28 DFLR/53
Size
28 + 8
Nominal pressure: 250 bar
Peak pressure:
315 bar
single suction port
pressure controller
flow controller
constant power control
Fig. 5: A10VO with integral gear pump

39

Modern Hydraulic Systems for

Wheeled and Crawler Excavators

/max

EP

I/Imax 1

Fig. 6: A10VOEP series 53

Microcontroller

Control
block SX

A10VO series 53 also offers electro-proportional

pump control (EP) for nominal sizes 28, 45, 60 and
85 (fig. 6). The swivel angle control is
proportionately adjustable via an electric current,
thus expanding the control range for the A10VO
pump.
Internal mechanical swivel angle feedback ensures
permanent transient load adjustment of the force
supplied via the proportional solenoid valves.
The mechanical/hydraulic pressure and volume
controller can also be attached to the pump and
is effective below the electrical flow limiting
system.
EP controller can be upgraded to speed-sensing
control by recording the diesel engine drive speed
and pedal position (fig. 7).
This means that when the diesel engine is under
load and the diesel engine speed is under strain,
the input power of the pump is adjusted by
reducing the flow volume.
The advantage is that the power of the diesel
engine is used as efficiently as possible at all times.
Although electronic speed-sensing control still
affects the cost of a mini excavator at present, new
regulations on exhaust and noise emissions and
reduced energy consumption could make
electronic speed-sensing control cost-effective if
energy costs continue to rise.

Accelerator pedal position

Speed sensor

A10VO...EPDF/53

Diesel engine

Gearbox

Fig. 7: A10VOEP with speed sensing control GLB

40

RE 00 207/10.00

Modern Hydraulic Systems for

Wheeled and Crawler Excavators

The good controllability of the machines is

achieved through volume flow control in the
directional control valve SX12. The characteristics
of this remain optimal irrespective of the load
pressure (fig. 8). The LUDV function allows the flow
distribution desired by the driver to be guaranteed
independently of the combination of machine
movements. Even if the pump volume flow is
insufficient, the speed of the movements initiated
remains constant with respect to one another.
On the tracked excavator, straight-line travel is still
ensured even if several operating functions are
activated at the same time.
Moreover, the improved and simplified operation
of the controls makes it easier to learn how to
operate the machine, an additional advantage with
regard to the growth of the hire market.
The patented design principle of the Rexroth valves
with the directly controlled LUDV pressure
compensator enables the necessary functions, such
as control, pressure selection and pressure
compensation, to be implemented in a simple and
hence a reliable way.
The single-circuit LUDV system simplifies
installation (the directional control valve comprises
a single inlet component) and component
assembly.
The pump has no need for the costly cross-sensing
controller that has to be used in a multiple pump
circuit.
The whole system requires fewer components and
is less expensive than a comparable open centre
multiple circuit system.
Optimisation of the directional control valve spools
also includes an extension of the fine control range.
The improved pilot properties are for example
achieved by reducing the dead strokes (effect on
the chain between the operating angle on the pilot
control and the actuator speed).
The 4-spool control system in the closed centre
design allows faster optimisation of the control
characteristics of each individual directional control
valve piston in comparison with the conventional
6-spool valve (open centre). This is a significant
advantage if the shorter development lead-times
expected for new machine models are to be
achieved. The LUDV principle also allows different
speeds to be set for each actuator spool and
direction of movement. This enables the
excavators movement sequence to be precisely coordinated.
The power requirements made of the slew drive
function are also derived from the standard
excavator class.

RE 00 207/10.00

Fig. 8: 9SX12 LUDV-control block

Fig. 9: Section of SX12

By means of a specially developed slew drive piston

co-ordination system, we are able to offer ideal
solutions according to the machine manufacturers
requirements and machine size.
Unlike conventional 3-circuit systems, the slew
drive does not have full priority. Sub-priority
achieved via the pressure compensator gives the
mini excavator satisfactory function.
Furthermore, the LUDV load sensing concept
provides the necessary flexibility for the adding of
extra functions.
The SX12 directional control valve, designed for a
flow volume of 120 l/min at the pump inlet and
80 l/min per directional control valve element, can
be used for mini excavators from 1.5 t to about 6 t
with an operating pressure up to 250 bar.

41

Modern Hydraulic Systems for

Wheeled and Crawler Excavators

The 4TH5 pilot control unit (fig. 10) is a new

development which has considerably improved the
controllability of mini excavators. The reduction in
the operating forces and reduced power
fluctuation when the lever is operated improve the
conditions of use and increase convenience of
operation.
With regard to triggering the crawler travel
function, the new 4TH6NR foot pedal unit (fig. 11)
in monobloc construction with integral damping
function provides a further improvement in
convenience of operation. Even jerky movements
of the levers, for instance when returning to neutral, are damped, thus avoiding oscillation.
The 4TH6NR unit is more compact than two
individual 2TH6R units fitted side by side and the
use of a single fastening plate simplifies installation
on the machine. The valve can be equipped with
various pedals according to the customers
requirements.
Mini excavators offer various possibilities for pilot
oil supply. With the MHSTE model pilot oil unit
(data sheet RD/E 64571) the pilot oil is drawn off
through a pressure-reducing valve connected with
the main circuit and the pressure is limited by a
pressure-limiting valve. Two electrically operated
switching functions can also be integrated into the
unit. One is designed for the safety function of the
armrest position, and the other, which is optional,
serves to switch the 2-step travel motors.
The scope which Rexroth offers for supplying a
complete system from a single source represents
a further advantage in terms of machine planning
thanks to a co-ordinated range of components.
The GFT track drives for this application are
characterised by remarkable compactness and
expand the product range for mini excavators
(fig. 12).
Such compactness is achieved in particular by the
use of hydraulic motors specially developed for this
application, which function as an integral part of
the driving gear and thus form an ultra-compact
drive in conjunction with the planetary gear
construction.
By adapting the carrying axle inner contour to the
requirements of the hydraulic motor, there is no
need to use a separate motor housing.
The result of this coordinated component
development between LST and BHY is a product
range from GFT 3 to GFT 9 with the following
characteristics:
compact, space-saving two-stage planetary
construction
rugged bearings

42

Fig. 10: 4TH5 Joystick

Fig. 11: 4TH6NR foot pedal remote control

valve for track drive

Fig. 12: HYDROTRAC GFT travel drive for mini excavators

Driving gear

Drive torque
T2

Two-step motor
capacity
Vg max Vg min
cm3

Excavator
weight

GFT 3 *

3000

18

GFT 4 *

4000

28

14

GFT 7

7000

28

14

GFT 9

9500

45

22,5

* in preparation

Fig. 13: Table of HYDROTRAC driving gear for mini and compact excavators

integral medium-pressure hydraulic two-step

motors in swashplate design
counter balance valve and secondary relief valve
integrated into the motor plate
integrated multiple-disc parking brake
(not GFT 3)
high starting efficiency
simple assembly
simple oil change
low-noise running

Development work continues with the aim of

adapting the MCR type radial piston motors to the
special requirements of the slew drive in the mini
excavator class. It will then be possible to create
the entire hydraulic system with components made
by Rexroth.

RE 00 207/10.00

Modern Hydraulic Systems for

Wheeled and Crawler Excavators

2. Compact Excavators, 7 to
Approximately 10 Tonnes
The compact excavator class is a growing market
segment, because:
mini excavators under 5 tonnes do not deliver
sufficient power
standard excavators over 10 tonnes are too big
and thus not manoeuvrable enough for urban
use
the excavator-loaders still widely used in many
countries are losing market share to specialised
machines like excavators and wheel loaders.
Compact excavator manufacturers vary in their
views of how an excavator in this weight class
should work. Such differences are due in part to:
manufacturers extending their product range
downwards from the standard excavator class
or
mini excavator manufacturers expanding their
existing product line upwards.

Fig. 14: 7 tonne tracked excavator

GFB + A10FD
(Slew drive)

9SX14
(Control)

A6VM + MHB
(Travel drive)

Brake Steering

A11VO / A10VO + G2
(Travel and implement hydraulics)

4TH6N

2TH6R
4TH6N
(Pilot control units)

MHSTE
(Pilot oil supply)

Fig. 15:1-circuit LUDV-system

RE 00 207/10.00

43

Modern Hydraulic Systems for

Wheeled and Crawler Excavators

Rexroth rises to these different challenges with

standard products perfectly matched to market
requirements.
The existing components that can be used in this
excavator class are the SX14 or M6-15 valves, both
with LUDV technology.
The pumps used are the A10VO up to a pump
pressure of 280 / 315 bar or the A11VO up to 350
/ 400 bar.
Fig. 16: 6SX14

Fig. 17: 4M6-15

Fig. 18: A10VO

Fig. 19: A11VO

7
4

Swing

It is important to consider at the design stage what

outlay (cost) corresponds to what power and
operability, especially as regards the slew drive.
The solution illustrated is a system comprising an
A11VO or A10VO pump with constant power and
flow controller and a series SX14 sandwich control
block suitable for high pressure for a section
volume of approximately 150 l/min.
The primary (1) and LS pressure cut-off valves (2),
LS flow controller (3) and unloading valve (4)
needed for a 1-circuit LUDV are implemented in
the combined inlet and slew control element.
Moreover, the slew drive has priority supply via the
connection as a LS function to the rest of the LUDV.
The LS meter-in pressure compensator (5) and the
torque control valve (6) for fine control and lossfree acceleration are housed in the combination
element (7). The directional function for the slew
drive is implemented using a standard SX14
sandwich element (8), but the LUDV pressure
compensator is not fitted.

MHSTE
Pilot
pressure
A10VO
or
A11VO
Fig. 20: LUDV block for crawler excavator

44

RE 00 207/10.00

Modern Hydraulic Systems for

Wheeled and Crawler Excavators

3. Standard Excavators
(Wheeled and Tracked),
12 to 24 Tonnes
We do not propose to discuss the single-circuit
LUDV system in detail with respect to standard
excavators. Naturally, Rexroth can supply the
necessary components for crawler and wheeled
excavators, as may be seen from the system circuit
diagram in fig. 21.
What we would like to do is discuss the new
products and features and look at some of the
important details of various components used in
LUDV systems.
In the 1.5-circuit and single-circuit LUDV system
Rexroth uses the A11VO swashplate type pump for
the open circuit. This pump has special features
that offers advantages to both the manufacturer
and the operator of the excavator. The A11VO
pump will be described more fully below.
In the 1.5 circuit the slew drive makes use of the
A10VO already described in the open circuit or the
A4VG high-pressure pump for the closed circuit.
The control of the A4VG has been further refined
and the size range now also additionally includes
nominal sizes 90 to 250.
Fig. 23 shows the available nominal sizes of the
axial piston units used in excavators. The proven
bent axis variable displacement motor type A6VM
for long travel drives in the wheeled excavator is
now available with brake pressure dependent
adjustment for more efficient braking on
downward slopes.

GFB + A10FD
(Slew drive)
A6VM + BVD
(Travel drive)

1M7 + 5M7 + 1M7

(Control)

A11VO
(Travel and implement
hydraulics)

TH6
(Pilot control units)

Fig. 21: 1-circuit LUDV-system

A2FE...192

A6VM...380K+BVD

A11VO...LE2S2

GFT+A10VT

A10VO...DFLR/53

GFB+A10FD
A4VG...DWD

A6VE...HZ3...22

Fig. 22: Axial piston units for Excavators

Implement hydraulic
pump

Medium pressure
High pressure

A10VO...DFLR
A11V/L)O...LE2S2

Sizes
28
45
40
60

Slew pump
Slew motor

Closed circuit
Swashplate
Bent axis

A4VG...DWD
A10FD...
A2FE...192

28
45
28

Integral version
Plug-in version

A10VT...HZ
A6VE...HZ3
A6VM...HA1

Track drive motor

Axle drive motor

60
75

85
95

(mini- and compact excavators)

130
190
260

40
85
32

56

71

90

125

180

250

45

56

63

80

90

107

18
55

28
80

45
107

(mini- and compact excavators)

160

55

80

107

140

125

160

180

160

Fig. 23: Nominal sizes of axial piston units

RE 00 207/10.00

45

Modern Hydraulic Systems for

Wheeled and Crawler Excavators

3.1 A11VO as LS Pump in

the LUDV System
The A11VO swashplate type pump for the open
circuit (fig. 24) was designed in the form shown
specifically for LUDV systems. The diesel engine
flange and the pump housing are one component.
This gives the pump as a whole a very short, rigid
construction. The flat-design controller lies in the
contour of the pump body and does not pretrude
beyond the end of the pump. The controller has
only a small number of ports and these lie parallel
to the pump to save space. The drain and bleed
ports are arranged in such a way that the pump
can be fitted in any desired position in the
excavator. This construction allows considerable
possibility in the design of the oil tank
compartment and position.
Demand for higher power makes larger diesel
engines necessary in some cases. The more stringent noise emission regulations mean that more
room is needed for encapsulation of the IC engine
and pump. This increasingly eats into the space
available for mounting the pump, so that a
compact pump such as the A11VO is needed.
In addition, diesel engine speeds are reduced due
to pollutant emissions. This in turn calls for larger
pumps in order to main comparable flows. A
streamlined pump compartment together with the
compact A11VO allow larger pump sizes to be
achieved, as well as making assembly and service
easier.
The A11VO pump comprises three main groups
(fig. 25):
the one-part housing with the integrally cast
diesel engine flange, containing the rotary
group,
the port plate with the positioning cylinder
chambers and machining for the through-drive,
the one-part flat-design controller, which is
bolted directly on to the port plate.
All the sealing points between these main groups
are, without exception, sealed by O-rings. This
guarantees a dry pump and ensures a perfect seal
is maintained even when components are replaced.
The longitudinally arranged positioning cylinders
project into the port plate, where they are supplied
with positioning oil through channels. All the supply
channels are securely housed in the stable port plate.
This eliminates the need for external pipes, which
could be a possible leak source.
The housing incorporates two stable, adjustable
stops for Vg min and Vg max. This allows the necessary
specific flow volume to be adjusted as desired from
outside, without having to dismantle or open up the
pump.

46

Fig. 24: Variable displacement pump

A11VO...LE2S2

Fig. 25: Variable displacement pump

A11VO...LE2S2 - section

X (Load-sensing)

Load-sensing
controller with
differential
pressure lowering
Constant power
controller with
electric override

Fig. 26: Constant power controller with electric override

When using the A11VO pump in the LUDV system

we recommend the LE2S2 controller design
(fig. 26). This controller comprises the hyperbolic
constant power controller with electric override via
a directly mounted round solenoid. The hyperbolic
constant power controller enables very good
power use in any power mode. As a result,
electronic speed-sensing control is not absolutely
necessary in a single-circuit system. In the absence
of electronic function both in power mode and in
speed-sensing control, the hyperbolic constant
power controller offers very good emergency
operating functions.
The mounted solenoids avoid the need for control
pipes and separate pressure reducing valves, and
can be operated directly from the cab. The round

solenoids can be rotated at will, enabling the cast

cables to be positioned in the optimum
arrangement.
The differential pressure setting override on the
load-sensing controller is implemented in a similar
way with a round solenoid, again saving many additional components and much installation work.
A shuttle orifice is fitted inside the controller in the
pump positioning oil channel. This is accessible
from the outside in order to optimise the size
selection. The pump response time can thus be
matched to the system.

RE 00 207/10.00

Modern Hydraulic Systems for

Wheeled and Crawler Excavators

RE 00 207/10.00

X
2

1 A11VO basic pump for constant power

controller
2 LE2S2 controller

3 Mechano-hydraulic-hyperbolic constant
power controller

4 Power adjusting spring

M

G
1

5 Power override with proportional solenoid

6 Shuttle orifice for adjusting time control

Vg max

Vg min

7 Load-sensing controller
8 Differential pressure setting spring

9 Differential pressure override with solenoid

R T 1 T2

M1

Fig. 27: Variable displacement pump A11VOLE2S circuit diagram

Flow reduction

Power reduction

Operating pressure pB (bar)

LE2

qV
x%
x%

x%

x%

Pilot current I

Volume flow qV (L/min)

qV max

Differential pressure reduction

pLS (bar)

Fig. 27 shows the circuit diagram of pump A11VO

with controller LE2S2.
In fig. 28 the upper diagram shows the power
curve with LE2 controller design.
The top start of control (basic setting) is achieved
by the initial force of the control start spring. As
the current at the override solenoid increases, the
spring force and hence the start of control is
reduced. The pump is thus set to a lower power
curve. In the event of power failure or a broken
cable, the pump goes over to the highest power
curve specified by the mechanical setting.
This controller design has a number of special
features in relation to speed-sensing control:
If the diesel engine is overloaded, the engine speed
drops. This signal is picked up by the microcontroller and reduces the start of control and
hence the power input. If, for instance, the pump
is at Vg max and the operating pressure suddenly
rises, the A11VO pump is adjusted to a smaller
swivel angle by means of the integral mechanical
constant power controller and the rising pressure.
In this case, the speed-sensing controller does not
have to respond at this stage. Only when additional power is drawn from the diesel engine does
the speed-sensing controller alter the start of
control and set the A11V0 constant power
controller to a new value.
With other speed-sensing control systems, the
pump swivel angle is altered by the control signal.
In this case, if the pump is at max. flow volume, a
sudden high pressure increase causes the power
to rise, up to the corner power. This is when the
speed of the diesel engine has to be reduced so
that a signal is generated via the speed-sensing
controller to swivel back the pump. Heavy
overloads may occur briefly.
Speed-sensing control based on the hyperbolic
constant power controller produces stable control
behaviour, less overloading and less speed
fluctuation for the diesel engine.
Differential pressure adjustment on the load-sensing controller of the variable displacement pump
is achieved by means of an adjustable spring force
(fig. 28, bottom). This mechanical setting can be
reduced to a lower differential pressure value with
the aid of a solenoid located opposite. Here too,
the advantage of the directly mounted solenoid is
evident, in avoiding the need for piping and
enabling precision control from the cab.
Fig. 29 top shows the influence of differential
pressure override. The effect of reducing the differential pressure setting is that each individual
actuator is limited in the same percentage
proportion in the maximum flow volume. This does
not impair movement harmony, but only slows

II
Actuator
Fine control expansion

III

p= x bar

S2

Spring force

qV red

p= < x bar
Pilot current I (mA)

Lever stroke

max

Fig. 28: Displacement pump A11VOLE2S

performance curve

Fig. 29: Displacement pump A11VOLE2S

differential pressure shifting

down the movements so that all the controlled

actuators are affected equally.
Fig. 29 bottom shows the influence of differential
pressure reduction on precision controllability. As
described above, in case of differential pressure
reduction the maximum flow volume for the
controlled actuators is reduced. The effect of this
is that if an excursion of the joystick, a smaller
volume is now allocated to the actuator. Fine
control is thus enhanced. The start of movement
of the actuator, in relation to the excursion of the
joystick, is not altered and remains independent
of the high pressure.

This fine mode enables lifting work or other

operations where increased fine controllability is
required to be performed very successfully.
The A11VO pump is also available with a swivel
angle sensor. This allows the momentary position
of the pump or the momentary flow volume to be
recorded via an electrical signal. This makes it
possible in an excavator system for instance to
control the engine idle speed.

47

Modern Hydraulic Systems for

Wheeled and Crawler Excavators

As a rule each A11VO pump is machined for

through-drive attachment (fig. 30). This allows simple retrofitting of through-drive parts of size SAEA to through-drives for pumps of the same nominal size. Many machine manufacturers are already
making use of this possibility, frequently with
varying requirements as regards the pump
equipment.
The symmetrical construction the flange can be
turned through 90 - enables the pressure and
suction port of the attached pump to be arranged
in the optimum position. This cuts down on piping
and assembly.
The availability of a large number of through-drives
gives the machine manufacturer a flexible choice
of attached pumps.

Through-drive
hub

Through-drive
flange

Fig. 30: Variable displacement pump A11VO through-drive

3.2 Slew Drive

The A2FE fixed displacement motor in bent axis
design with integral one-stage or two-stage
pressure valves is available for the slew drive.
One new development is the swashplate fixed
displacement motor model A10 FD 85, designed
specifically for slew drives in the open circuit.
In conjunction with another new development, the
Mobilex GFB 17 T2 slew drive gearbox, a 1.5-litre
drive is thus available for the 13 18 tonne
excavators (fig. 31).
This slew drive is a combination of an ultracompact 2-stage planetary gear with an
A10 FD 85 medium-pressure transmission (Pnom =
320 bar / Pmax = 350 bar).
The driving gear features the proven short-design
output housing. The bearings used for the output
shaft are high-capacity tapered roller bearings. The
multiple-disc parking brake, which was part of the
driving gear in the slew drives with A2FE motors
previously presented, is now mounted on the
cylinder in this rotary group to save space. The front
flange of the motor housing is conceived as the
gearbox cover. In this design, all necessary valves
are integrated into the motor port plate.
This includes:
pressure relief valves with damping (prevents
overloading of the motor, pipes and valves due
to pressure peaks, while two-stage opening of
the pressure relief valves prevents load peaks
for the transmission and boom when
accelerating)
anti-cavitation valves (to prevent leakage oil
cavitation when braking)
brake release valve (electrically or hydraulically
operated, to actuate the release pressure to the
multiple-disc parking brake)
anti-reaction valve (prevents the upper body
swinging back when decelerating).

48

There is thus no need for the conventional piping

with this integrated drive solution (fig. 32). It
covers a transmission range from 17.3 to 23.6 : 1.
The next-smallest size of motor at 45 cc is designed
to expand the slew gear series downwards in
conjunction with an appropriately adapted
gearbox. The construction and valve gear will
correspond to that of the GFB 17 T2 described
above.

Fig. 31: Mobilex GFB slew drive gearbox

5
1
2
3
4
5

Ports
A,B
L
PB
MA, MB

Pressure relief valve with

damping
Anti cavitation valve
Brake release valve
Antireaction valve
Parking brake

Hydraulic ports
Case drain port
Brake release pressure port
Measuring ports
Operating pressure
Boost port

Fig. 32

RE 00 207/10.00

Modern Hydraulic Systems for

Wheeled and Crawler Excavators

3.3 Multi-Function Element

for Standard Excavators
As an addition to the 1.5-circuit and the singlecircuit LUDV system, work has forged ahead on
developing a multi-function element for the
operation of various working attachments. The idea
of developing this multi-function element arose
as a result of repeated market demands and the
growing variety of options for standard class
excavators.
The Rexroth multi-function element offers and
fulfils, in different stages of extension, all the
requirements made of a modern multi-function
machine such as the excavator.
This applies not only to wheeled excavators but
also to tracked excavators in the standard class,
which are tending to be used more and more for
all sorts of jobs. Faster ground speeds and the
associated increase in the flexibility of the crawler
excavator have played their part in this.
Rexroth has developed a modular principle in order
to fulfil the varying requirements with the most
effective solution in each case.
The remit was to permit easy preselection of the
flow and pressure for the particular attachment,
such as a hammer, scrap shears, mower, generator
for a magnet plate, etc. via the on-board computer.
This renders obsolete all the solutions currently in
use, such as mechanical stroke limiters on the
directional control valve, externally adjustable
pressure valves, etc., most of which cannot be
adjusted from the cab but require the use of tools.
Furthermore, the flow and pressure settings have
considerable tolerances, as both these values are
difficult to verify in the field. The cost of these
solutions is appreciable.
As a rule the multi-function element is designed
as an LS valve with meter-in pressure compensator.
This operating principle permits the priority desired
for many attachments with sufficient accuracy.
A choice of 3/4 SAE or 1" SAE actuator ports allows
use on the M7-20 and the M7-22 valve.
In the basic or standard version, the multi-function
element has been designed for a hammer. As is
usual with the hammer, the valve spool is operated
at one side. The supply pressure available at the
pst-port via a hydraulic remote control valve (joystick) is limited electrically by means of a proportional pressure valve (1) to the pilot pressure
corresponding to the volume.
Pressure limiting is effected via a fixed secondary
pressure relief valve (2).
The reason Rexroth has chosen a pressure-free
return flow to the tank (3) for the hydraulic
hammer via the control block is evident from the
next stage of extension.
RE 00 207/10.00

Hammer

RESET

v u

F
MODE

Man

BLTTERN

Concrete cutter
min

max

Display

Scrap shear

Magnet plate

Fig. 33: Working attachements

Semi priority

Sandwich design

Section flow adj. electrically

Port relief adj. manualy

Pressure free return flow

1
2
3

Slew
M7-20 or M7-22
Fig. 34: Hammer element for single-circuit LUDV system

49

Modern Hydraulic Systems for

Wheeled and Crawler Excavators

If other double-acting working attachments are

required as well as the hammer, the solution we
offer does not need a separate, costly hammer
return line. All that is necessary is to fit two high
pressure lines (5) via the boom and stick to the
front end of the equipment.
To prevent the oil, which in the case of worn
hammers is often contamination, from returning
to the tank via the control block and to keep the
back pressure below 5 bar, the hammer return
valve (6) is electro-hydraulically actuated in the
hammer preselection.
Secondary relief valves (7) and anti-cavitation
valves (8) are included for port A and B. If a fixed
setting of the pressure valves does not provide the
required convenience of operation, the pressure
setting can be freely selected by means of a proportional pressure relief valve (9).
When using the multi-function element a
distinction has to be made between use in a 1.5circuit or in a single-circuit LUDV system. The separate slew circuit in the 1.5-circuit system rules
out any influence between the slew drive and the
optional function.
In the single circuit with the LS slew drive solution
already described, measures have been taken to
co-ordinate the LS slew drive and the LS multifunction element.
Differently set pressure compensators (10) and
(11) give priority to the attachment over the slew
drive.
In practice, the parallel connection of slew drive
and option is barely discernible, since with an
attachment in full operation the slew drive is only
actuated in the fine control range, if at all.
Most working attachments can therefore be
operated efficiently with the system arrangement
shown.
If the priority for the working attachment has to
be increased further, a priority valve (12) is installed
to further reduce the volume of oil allocated to the
LUDV block.
The priority valve compares the current LS pressure
in the option spool with the pump pressure. If the
difference between the pump and the LS drops
below the value set on the spring (13), adjusting
energy is drawn from the pump circuit and the
current pressure in the LS line to the LUDV block
is increased. The effect of this increase is to reduce
the control differential pressure at the orifices in
the LUDV block, and hence the volume, in favour
of the LS actuator.
100% priority, for example to a generator, can be
achieved by means of:

50

9
4

4
7

Semi priority

Section flow

High pressure lines

Hammer return valve

Port relief valves

Anti cavitation valves

Port relief setting electrically

Semi priority

5
6

Slew
M7-20 or M7-22
Fig. 35: M7-20 Multi-function element

12
13
10 11 LS inlet compensator
12 Priority valve
13 Priority valve spring setting

11

10

Slew

Fig. 36: M7-20 Multi-function element with priority valve

a second priority valve, so that the slew drive

pressure compensator is down controlled earlier,
or
pilot pressure reduction on the slew drive.
Both solutions ensure that the volume is reduced
in favour of the option spool.
M6-15 sandwich elements using LUDV technology
can also be mounted on the multi-function
element for actuators with a smaller section flow
of up to about 180 l/min.
The components and system solutions described
are a fresh demonstration of the flexibility and
adaptability of the Rexroth LUDV system.

RE 00 207/10.00

Modern Hydraulic Systems for

Wheeled and Crawler Excavators

3.4 Steering Systems for

Wheeled Excavators
Hydrostatic steering systems in open centre non
reaction or closed centre non reaction
construction are used in wheeled excavators. Non
reaction means that the driver does not feel the
forces acting on the wheels at the steering wheel.
Closed centre steering units are supplied by means
of a constant or variable displacement pump via a
priority valve. The priority valve supplies the flow
demanded via the meter in orifice to the steering
gear according to the LS signal.
Secondary actuators can be connected to the
priority valve, but are subordinate to the supply to
the steering gear:
Wheeled excavators are subject to standards and
regulations relating to the steerability of the
excavator as well in emergency operation, when
the steering assembly is acting as a hand pump.
With excavators of about 15 tonnes and upwards
overall weight, predetermined axle loads and
kinematic conditions produce corresponding

steering pressures which make steering units with

emergency mode speed reduction necessary.
Rexroth LAGU steering gear with chamber
disconnection and LAGZ with rotor assembly
disconnection were developed for these
applications. In servo mode there is no difference
between the function of LAGU and LAGZ and other
steering gear.
In emergency mode, if the power supply fails, the
flow volume is reduced automatically. As a result,
the necessary drive energy = manual effort on the
steering wheel is halved compared to a
conventional steering unit.
In LAGU steering systems, in emergency mode
individual rotor assembly chambers are connected
to the tank, such that only, say, 50% of the servo
mode flow volume is sent to the steering cylinder.
With LAGZ, two rotor assemblies operate in servo
mode. In emergency operation, one disengages
completely. Different reduction ratios for the two
rotor assemblies enable the flow volume and the
manual effort required in emergency mode to be
optimally matched to the particular machine.

Further details about the LAGU and LAGZ steering

gear can be found in data sheets RE 11 867 and
RE 11 868.
The use of open centre steering gear is prevalent
in excavator applications. In view of the scope for
series connection with our hydraulic power brake
valves and/or the pilot oil supply, it offers an
inexpensive solution for various excavator subsystems.

Fig. 37: LAGU and LAGZ

Auxiliary hydraulics

EF

CF

LS

Priority valve
P

High pressure (regulated)

Low pressure
Suction pressure
Chamber oil
Ambient pressure
Fig. 38: Emergency operation LAGU

RE 00 207/10.00

51

Modern Hydraulic Systems for

Wheeled and Crawler Excavators

High pressure (regulated)

Low pressure
Suction pressure
Chamber oil
Ambient pressure

Fig. 39: Emergency operation LAGZ

In the system illustrated, a constant displacement

pump (1) supplies the power brake, e.g. LT 17 or
LT 13. The system is designed and optimised so that
the braking system is supplied as first priority via
the integral priority piston (2). The orifice (3) is
arranged so that only part of the total pump flow
is used to charge the accumulator. The remaining
oil flow via the N port of the compact brake to the
open centre steering unit has to be dimensioned
such that servo steerability is guaranteed even at
lower diesel engine speeds.

Brake light
switch
LAGC
Steering unit

Accumulator
pressure
warning
switch
2
3

2 circuit brake valve

Parking brake valve

Accumulator charching
valve

1
Fig. 40: Sub-system: wheeled excavator block diagram

52

RE 00 207/10.00

Modern Hydraulic Systems for

Wheeled and Crawler Excavators

3.5 LUDV Systems in Crawler

Machines
The two machines shown a crawler excavator
and a dragline excavator demonstrate the
existing LUDV systems and components for these
types of machines.
Fig. 43 shows a conventional 1-circuit LUDV
system of the kind used for crawler excavators up
to a machine size of about 24 tonnes.
The whole control system is supplied by a load-sensing controlled main pump. The familiar M7 LUDV
control block comprises all the control and
regulating functions. The single-circuit LUDV
system has already been described in detail in
previous presentations (see attached). The main
emphasis of this chapter will be on the track drive.
Since with the 1-circuit system the main pump flow
distribution to the track motors is via the LUDV
system, special demands are made of the technical
implementation of straight-line travel. Varying
motor leakages, mechanical tolerances and control
tolerances have to be compensated for to enable
each track motor to take 50% of the drive power.
If this is not the case, in other words different flows
are available to the two drive motors, then the
chain with the greater section flow takes over the
driving and the second chain is pulled along.
In the worst case the meter-in pressure can drop
so much that the counter balance valve of the
pulled track closes. The drive pressure of the driving
chain continues to increase and the pump
destrokes along power curve.
The result is that:
the speed of travel falls and
the excavator starts to corner
This problem is overcome by means of an internal
bypass system downstream of the pressure
compensator for both track drive control spool in
the LUDV control block. The flow differences are
compensated for and both track drive motors
transmit the drive torque non-positively. The size
of the bypass system is determined in the
prototype.
To enable the excavator to be run up to maximum
torque without a break, the long travel drive is
overridden by a shift valve which is dependent on
travel pressure. This switches the travel motor to
the maximum or minimum swivel angle. A differential surface in the shift valve distinguishes
between the respective shift pressures, in other
words creates a deliberate hysteresis, in order to
ensure stable travel behaviour.

Fig. 41: Crawler excavator

Fig. 42: Dragline excavator

Track
Option

left

right
HZ

Arm

Bucket Boom

Slew

HZ

LS

Fig. 43: 1-circuit LUDV system diagram

Fig. 44: Travel shift valve

RE 00 207/10.00

53

Modern Hydraulic Systems for

Wheeled and Crawler Excavators

Another criterion for assessing long travel drive is

cornering. In the single circuit the system-related
differential pressures, multiplied by the flow going
to the more slowly revolving chain, is a power loss.
By way of alternative fig. 45 shows a 2-circuit
LUDV system. The circuit diagram shows the
hydraulic system of a tracked crane or dragline
excavator. The two main pumps are switched to
either the 1-circuit or the 2-circuit system by means
of an electro-hydraulic proportionally controlled
directional control valve. The original idea of
powering winch drives with high differential
pressures in the 2-circuit system on the dragline
excavator in order to minimise power losses can
be transmitted to the track.
As may be seen from the diagram, all the additional functions necessary, such as double pressure
cut-off, primary valve and LS relief, separation of
pump and LS line are integrated into the control
block.
The electro-hydraulic actuation of the main
functions, already widely used in tracked cranes,
improves convenience of operation of the machine.
The electronics offer considerably greater scope for
optimisation of both individual and overridden
movements.
The design differences in the control block system
and associated circuit diagrams may be seen from
the figures 46 and 47.

Slew
Aux.
winch

Boom
winch

Track
left

Track
right

LS

Main Winch
winch

LS

Fig. 45: 2-circuit LUDV system diagram

The basic block of the 1-circuit LUDV system is a

5-spool M7 monobloc nominal size 20 or nominal size 22 with scope for mounting individual
elements at both sides for additional functions or
slew drive (fig. 46).
The optional 1-circuit or 2-circuit LUDV control
concept is based on a 3-spool M7 monobloc nominal size 22 (fig. 47). In this construction, the
slewing module 1M7-20LS is mounted at one side
of the control block. On the other side is the
dividing plate with functions integrated as
appropriate for the 1-circuit or 2-circuit solution

and further mounting of sandwich elements. The

dividing plate lies between the two travel axes. It
is also possible as an option to fit a sandwich
element between the 3-spool monobloc and the
dividing plate.
Possible solutions for tracked excavators with different LUDV systems are shown. When choosing
between a 1-circuit and 2-circuit system, besides
the technical performance the cost-effectiveness
should be considered as a decision criterion.

Fig. 46: 1-circuit LUDV control block

54

RE 00 207/10.00

Modern Hydraulic Systems for

Wheeled and Crawler Excavators

Fig. 47: 2-circuit LUDV control block

Irrespective of the decision as to a 1-circuit or 2circuit system, Hydrotrac GFT travel gear is
successfully in use in many tracked excavators with
a wide range of operating weights.
The range of applications varies, as already
indicated, from the mini excavator with a machine
weight of approximately 3 tonnes to standard
excavators through to the large hydraulic
excavators, known as mining excavators, with an
operating weight of around 500 tonnes.
The table (fig. 48) shows the driving gear sizes
designed for use as an excavator track drive in the
weight class up to about 80 tonnes.
As the design of these driving gears depends on
such parameters as overall weight, traction, track
diameter, working pressure, etc., this table is
provided purely as a guide to planning the
machine. Due to the large number of different
transmission versions, in conjunction with various
motor nominal sizes, the machine manufacturers
requirements can as a rule be fulfilled sufficiently
accurately according to the modular principle.

RE 00 207/10.00

Driving gear
Gear Sizes

Excavator weight (t)

Gross Vehicle Weight (t)

1,5 2,0 2,5 3,5 4,5 6,0 8,0 10

GFT
GFT

12

15

18

21

25

30

35

45

55

65

75

90 100

3 T2
4 T2

GFT
7 T2
GFT
9 T2
GFT 17 T3
GFT 24 T3
GFT 28 T3
GFT 36 T3
GFT 50 T3
GFT 60 T3
GFT 80 T3
GFT 110 T3
GFT 160 T3

Fig. 48: HYDROTRAC driving gear/excavator weight chart

55

Modern Hydraulic Systems for

Wheeled and Crawler Excavators

For hydraulic excavators of an overall weight of

10 tonnes and upwards, a variety of crawler drive
gears are available, starting with GFT 17 T3
(17,000 Nm) with a variety of motor/driving gear
combinations.
The plug-in two-step motor in bent axis design,
model A6VE, has the brake valve and brake
actuating valve function integrated in the port
plate. This compact, high-performance motor is
used as a plug-in motor in larger tracked
excavators.
The illustration of the fitting arrangement (figs. 49
and 50) highlights the advantages of VEC/VT
technology when fitting the complete drive unit in
the chassis.
Driving gear systems with bent axis motors (A2FE,
A6VE) need to be separated for fitting in the space
available in the chassis. Driving gear systems with
swashplate motors can be fitted directly in the
chassis, as all the radial dimensions of the motor
connecting plate in relation to the motor axis are
within the centring diameters of the driving gear
contact area.
Fig. 51 shows the interior construction of the
driving gear in combination with the A2FE motor.
High-capacity tapered roller bearings, high-quality
axial face seal, integrated multiple-disc parking
brake and the use of case-hardened, sun and
planetary wheels are but a few characteristics of
these track drives.

Fig. 49: Motor / driving gear combination

HYDROTRAC GFT
with bent axis motor

HYDROTRAC GFT
with integral swashplate motor

Fig. 50: Mounting arrangement

Fig. 51: Hydrotrac GFT travel drive

56

RE 00 207/10.00

Modern Hydraulic Systems for

Wheeled and Crawler Excavators

3.6 Mining Excavators

Fig. 52: 250 tonne mining excavator

For mining excavators Rexroth can supply pumps,

control blocks and motors designed for the
demands of pit and quarry applications.
Lohmann & Stolterfoht have for years been
supplying drives for these severe demands that are
in use worldwide.
As in the case of lower-powered hydraulic
excavators, crawler track drives in the GFT form of
construction are flanged on to the chassis at one
side. These transmit the torque generated by
hydraulic motors via the crawler track drives
flanged on at the output side to the chain, and
transmit the externally acting reactive forces to the
chassis frame structure.
The use of this type of construction depends on the
use of correspondingly dimensioned torsionresistant chassis designs. These have to a large
extent replaced the GFA style crawler drive gears
(track drive hub bearing-mounted in the chassis on
both sides, torque transmission between track
drive hub and flange-mounted driving gear via
separate plug-in shaft).
Standard constructions such as the GFT 330 are
used nowadays in mining excavators up to
175 tonnes. Special constructions like the GFT 600
and GFT 800, comprising 2-stage planetary gears
with preliminary spur gear, plate-type brake and
two-motor drive are currently used in 255 tonne
and 320 tonne hydraulic mining excavators. Travel
drives up to GFT 1300 have been designed to date.
The rotary drives used in these large machines are
specially tailored to the requirements profile of
mining plant and are based on a 2-stage planetary
construction in conjunction with an integral platetype brake at the driving gear inlet. To keep the
gearbox dimensions compact, the necessary

RE 00 207/10.00

Fig. 53: 320 tonne mining excavator

superstructure torque is achieved by the use of up

to three rotary driving gears, depending on design.
The much longer service life expected of a mining
excavator compared to conventional excavators is
taken into account when designing the travel and
rotary driving gear.

Fig. 54: Hydrotrac GFT travel drive for mining

excavators

57

Modern Hydraulic Systems for

Wheeled and Crawler Excavators

58

RE 00 207/10.00