What is a Hydraulic Valve and Why Do You

Need It?
A hydraulic valve properly directs the flow of a liquid medium, usually oil,
through your hydraulic system. The direction of the oil flow is determined by
the position of a spool. A hydraulic system can only function - as per
requirements - by using valves. Thus, you should always look for the correct
type of hydraulic valve to serve your intended purpose.
Hydraulic valves are available in a variety of sizes. The size required is
determined by the maximum flow of the hydraulic system through the valve
and the maximum pressure in the hydraulic system. Hydraulic valves are
available with different mountings: e.g. mounting in pipe lines, threaded

Different Types of Hydraulic Valves

Hydraulic valves are sometimes referred to as hydraulic components. These
are subdivided into three main categories: directional control valves, pressure
control valves and flow control valves. We have added proportional and servo
control hydraulic valves as a separate category below:
Directional Control Valves

 Check valve;
 Directional spool valve
 Directional poppet valve

Pressure Control Valves

 Control task: variable throttle valve

 Switching task: fixed throttle valve

Flow Control Valves

 Throttle valve: flow Δp dependent

 Control valve: flow Δp independent

Electro Hydraulic Valves

 Servo hydraulic valve

 Proportional hydraulic valve
Different valves function in different ways. Check valves permit free flow in
one direction and block flow in the opposite direction. The directional control
valve is used to pass on the pressure medium (i.e. flow) in an orderly fashion
to a particular direction. Pressure control valves switch (or control) at a certain
pressure; the switching pressure may be adjusted on the valve. Flow control
valves regulate the flowthis is done by adjusting the size of the bores
(orifices).
Note that proportional hydraulic valves and servo control valves may be used
to perform a directional control, pressure control or flow control function.
Back to hydraulics overview - Hydraulic Parts

Directional Control Valves

Directional control valves can control the start, stop and change in direction of
flow of a pressure medium (i.e. hydraulic oil). For this reason, they are also
referred to as switching valves. Directional control valves are available as
spool valves, poppet valves or rotary slide valves. Rotary slide valves,
however, are no longer commonly used due to low operating pressure (up to
70 bar).
The performance of a directional control valve depends on the following:

 Dynamic power limit (as a function of maximum flow and pressure)

 Static power limit (adhesive force may be produced between the spool and
housing due to standstill)
 Resistance to flow (internal resistance, i.e. pressure drop)
 Leakage (spool valves only)
 Switching time (time between the actuating force and the completion of the
stroke of the control element)

The function of a directional control valve is determined by the number of

working ports (excluding control ports) and the number of spool positions. A
directional control valve comprises at least two spool (switching) positions and
two working ports. The most common directional control valve is a 4/3-way
valve, which means the valve has four working ports and three spool
positions, in accordance with DIN ISO 1219.
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Check Valve
A check valve is the simplest type of directional control valve used in hydraulic
systems. Check valves stop the flow of fluid in one direction and allow free
flow in the opposite direction. They are also known as non-return valves.
Check valves may be used as:

 Prefill valves (anti-cavitation)

 Bypass valves (e.g. throttling points or return-line filters)
 Stops for flow in one direction
 Pre-tensioning by creating a certain backpressure
 Protection of hydraulic components against pressure surges

Most check valves are spring-loaded and use a ball or plate to seal the flow in
one direction. Check valves are designed with seats and thus are able to
isolate circuits with no leakage. Balls, plates, poppets or poppets with soft
seals are used as isolating elements.
There is a special type of check valve that prevents pistons or cylinder
plungers from coming down and causing accidents. This is called a line
rupture valve. When the line ruptures, the flow through the line rupture valve
increases substantially, causing an increased pressure drop. This in turn
creates a stronger force on the ball, which will close immediately.
Other special types of check valves are pilot-operated check valves and
shuttle valves. A pilot-operated check valve allows flow in either direction by
application of an external pilot pressure signal. A shuttle valve permits free
flow at the highest operating pressure.
Back to top - Directional Control Valves

Directional Spool Valve

Directional spool valves comprise a moving spool situated in the valve
housing. When an actuating force moves the control spool, the annular
channels in the housing are connected or separated. Directional spool valves
have several unique features, such as:

 Low cost due to simple design

 Low actuating force (due to good pressure compensation)
 High switching power
 Low losses (even though oil leakage flows continuously from the high
pressure to the low pressure side)
 Wide variety of control functions

Directional spool valves may be direct-operated or pilot-operated. A direct-

operated spool valve is either electrically controlled with solenoids,
mechanically (e.g. manually) controlled with levers or rollers, or controlled with
hydraulics or pneumatics. Whether a directional spool valve is direct- or pilot-
operated depends on the actuating force needed to move the spool. Thus, this
is dependent on the flow, i.e. nominal size of the directional spool valve.
When valves are operated at higher hydraulic system operating pressures,
leakage losses around the spool and the housing should be taken into
account, especially at system pressures over 350 bar. The leakage loss is
determined by the size of the gap between the spool and the housing, the
viscosity of the hydraulic fluid and the hydraulic system pressure.
Typical parameters of spool valves are:

 Nominal sizes: NG6 and NG10 (up to NG120 for pilot-operated valves)
 Maximum flow: up to 150 l/min (up to 7,000 l/min for pilot-operated valves)
 Maximum pressure: up to 350 bar

Back to top - Directional Control Valves

Directional Poppet Valve

Directional poppet valves can operate at a maximum operating pressure of up
to 1,000 bar. Directional poppet valves are directional control valves that are
fitted into housing bores with a threaded connection. This is why they are
often referred to as hydraulic cartridge valves. The moveable seating
elements may consist of balls, poppets or plates.
Key features of hydraulic cartridge valves:

 No leakage
 Long product life
 High maximum and continuous operating pressures due to zero leakage
losses
 Very good sealing characteristics without additional isolating elements

The design permits the valve to become more tightly sealed when operating
pressure increases. The maximum flow of cartridge valves is limited
compared to spool valves. Larger flows would require larger cartridges to fit
into housing bores; the threaded connection will not hold.
Typical parameters of poppet valves are:

 Nominal size: NG6 and NG10, SAE, and ¼" - 2" BSP
 Maximum flow: up to 60 l/min (up to 400 l/min for pilot-operated valves)
 Maximum pressure: up to 1,000 bar

Back to top - Directional Control Valves

Pressure Control Valves

Every pressure control valve switches (or controls) at a predetermined
pressure setting. The switching pressure is generally a variable setting on the
valve itself. A change in position of the pressure control valve (i.e. open or
closed) occurs either gradually (by control) or suddenly (by switch). Pressure
control valves can be subdivided into control and switching task:
Control task (variable throttle)

 Pressure relief valves

 Pressure reducing valves
 Pressure drop valves
 Pressure difference valves
 Pressure valves with additional electric switch-off

Switching task (fixed throttle)

 Pressure shut-off valves

 Pressure sequence valves

Sequence valves are used to direct the flow to a secondary circuit. When the
primary hydraulic circuit reaches a preset pressure, flow is permitted to the
secondary circuit. Unloading valves are remotely-piloted pressure shut-off
valves that direct flow to the tank when the preset pressure in a particular
location of the hydraulic circuit has been reached.
The most common types of pressure control valves are the pressure relief
valve and the pressure reducing valve. Pressure relief valves control the
system pressure by relieving part, or all, of the flow to tank. Pressure reducing
valves reduce the pressure supplied to a sub-system of a hydraulic system.
Pressure control valves may be directly or pilot operated. Larger flows require
larger spools or poppets, which increases the area of the spring diameter: the
spring force increases proportionally. Pilot-operated pressure control valves
require only a small spring, are suitable for compact space requirements and
have maximum flows of up to 650 l/min.
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Pressure Relief Valve

There are two pressure control valves: one is a pressure relief valve, and the
other is a pressure reducing valve. Pressure relief valves have higher flow
capacities than pressure reducing valves because pressure relief valves have
to be capable of directing all flow to the tank.
Pressure relief valves are used in hydraulic systems to limit the system
pressure to a specific set level. If this set level is reached, the pressure relief
valve responds and feeds the excess flow from the system back to the tank.
Note: the pressure relief valve is a normally closed pressure control valve.
Back to top - Pressure Control Valves

Pressure Reducing Valve

In contrast to pressure relief valves, which affect the level of input pressure
(i.e. pump pressure) fed into the hydraulic system, pressure reducing valves
are used to influence the output pressure of the hydraulic system to a
subsystem (e.g. actuator pressure).
Reducing the input pressure (primary pressure) or maintaining a particular
output pressure (secondary pressure) is achieved at a set value which is
below the varying pressure occurring in the main hydraulic circuit. It is thus
possible to reduce the pressure in one part of the circuit to a lower level than
the system pressure.
Note: the pressure control valve is normally open.
Back to top - Pressure Control Valves

Flow Control Valves

Flow control valves manage the flow by decreasing or increasing the opening
at the throttling point. This helps to determine speed of movement for the
actuators. The simplest design for a flow control valve is a needle or
longitudinal slot mounted in the pipeline and connected to a screw that adjusts
the opening at the throttling point.
These are called throttle valves and they are regularly used in combination
with a check valve, i.e. the throttle check valve for speed control in one
direction of flow. A disadvantage of throttle valves is that at varying loads a
change in pressure drop will change the flow; thus, the speed of the moving
actuator will also be affected. Flow control valves are divided into two types:
Throttle valves (flow depends on Δp)

 Viscosity dependent
 Viscosity independent

Flow control valves (independent of Δp)

 2-way flow control valves

 3-way flow control valves

The difference in pressure before and after the throttling point, i.e. the
pressure drop (Δp), determines the rate of flow through the throttle valve at a
particular setting. If the pressure drop over the throttling point remains the
same, the flow of oil that passes the throttling point remains the same as well.
This allows operation at constant speeds, regardless of the load.
Flow control valves are used to influence the speed of movement of actuators
by changing the opening for the flow (decreasing or increasing it) at the
throttling point. In fact, these are two flow control valves placed in series and
built together. The throttling point operates at a fixed setting, but the throttle
opening before the throttling point varies with pilot pressure of the load.
Note that flow dividers have a certain special standing: they divide an
oncoming flow into two or more flows. Usually it is used to distribute the flow
of a single pump to two or more sub-systems that have different operating
pressures.
Back to top - Hydraulic Valves

Throttle Valve
Throttle valves come in piston and needle-valve structures, but we also know
them as turn plugs with axial or radial grooves. The smothering of grooves is
more accurate but provides more variability than those with piston structures.
The needle throttle has one disadvantage: a great deal of power is required to
move the needle only a slight amount.
The pressure difference (Δp) determines the amount of flow that passes the
throttle. In systems with varying loads (and therefore varying pressures), the
flow passing the throttle will always be different.
You can find non-adjustable (fixed) smothering in situations where it is needed
to gauge against excessive pressure surges. Also, one can find non-
adjustable throttles in control systems.
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Flow Control Valve

A pressure-compensated flow control valve has a fixed throttling flow at all
pressures. The two-way pressure-compensated flow control valve is also
called a series valve. The pressure reducing valve and the smothering of this
valve are placed in series with each other. At a three-way pressure control
valve, the pressure relief valve and the throttle in this valve are parallel to
each other.
The two-way and three-way pressure compensated flow control valves are
quite similar. The only difference is that in the latter type, the excess oil flow is
not drained through the pumps safety valve but through the flow control valve
itself. The pump pressure for a three-way pressure compensated flow control
valve is always equal to the pressure exerted by the actuator plus the spring
pressure.
Note that using three-way flow control valves increases efficiency because the
system pressure will never be higher than as required for moving the load.
With two-way flow control valves, this is not the case because the pump
keeps feeding the system with oil until the preset pressure of the pump's
safety - pressure relief - valve has been reached.
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Electro Hydraulic Valves

When your hydraulic application requires a very accurate control of the flow,
hydraulic valves may be equipped with advanced control electronics. This
allows the use of inductive path measuring devices that monitor the position of
the spool continuously to ensure optimum position of the spool.
Proportional hydraulic valves are able to control the opening to flow
proportionally instead of gradually, as is the case for most standard hydraulic
valves. The simplest type of proportional hydraulic valve is a variable throttle
controlled by a manual lever, as illustrated below:
Proportional and servo hydraulic valves are usually classified as high-
performance valves. This distinction gives an expected indication of
performance, which tends to generalise the true differences between various
types of servo and proportional hydraulic valves. Each type has its own
unique performance characteristics either in controlling pressure or controlling
flow.
Servo hydraulic valves use closed-loop control to monitor and feed back the
main-stage spool position to a pilot stage (hydraulic/pneumatic) or driver
(electronic). Proportional hydraulic valves, on the other hand, move the main-
stage spool in direct proportion to an external piloted control signal and do not
have any means of feedback within the valve.
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Servo Hydraulic Valve

The main stage spool of a servo hydraulic valve is equipped with a path
measuring system for accurate adjustment. This system measures the exact
position of the main-stage spool and feeds its position directly to the electronic
control unit. If sworn position is not consistent, the control signal corrects the
position of the main-stage spool.
Servo hydraulic valves are widely used in aerospace and industrial
applications.
Back to top - Electro Hydraulic Valves

Proportional Hydraulic Valve

The most common proportional hydraulic valves are directional control valves,
pressure relief valves, flow controllers and adjustable throttling. Proportional
hydraulic valves convert an incoming mechanical or electrical signal directly
proportional to a shear mode. The movement follows a continuously incoming
signal. Different types of available proportional hydraulic valves are:
 Various directional control valves
 Flow control valves
 Pressure relief valves
 Pressure reducing valves
 Counter balance valves

Typical applications of proportional hydraulic valves include cranes and

industrial applications such as injection moulding.

What is a Hydraulic Filter and Why Do You

Need It?
Every minute, approximately one million particles that are larger than 1 micron
(0.001 mm or 1 μm) can enter a hydraulic system. These particles can cause
damage to hydraulic system components because hydraulic oil is easily
contaminated. The wear of hydraulic system components is dependent on this
contamination, and the existence of metal parts in hydraulic system oil (iron
and copper are particularly powerful catalysts) accelerates its degradation.
Hydraulic filters remove dirt and particles from fluid in a hydraulic
system.
A hydraulic filter helps to remove these particles and clean the oil on a
continuous basis. The performance for every hydraulic filter is measured by its
contamination removal efficiency, i.e. high dirt-holding capacities. Almost
every hydraulic system contains more than one hydraulic filter.

How DTA Can Help You:

DTA has considerable expertise in filtration technology and carries an
extensive inventory of hydraulic filter elements from several different vendors.
DTA can help you select the correct filter which will provide the optimal
cleanliness solution for your hydraulic system. DTA also offers the tools
required for troubleshooting and addressing the cleanliness or performance
demands of any hydraulic system.
DTA recommends replacing hydraulic filter elements on a regular basis.
Depending on your requirements, DTA can supply high-quality hydraulic filters
from well-established manufacturers such as Hydac, Mahle, Eppensteiner,
Argo Hytos, Pall, Racor, Fairey Arlon, Internormen, Racor, Domnick Hunter
and more. We keep stock of hydraulic filter interchange elements as cost-
effective alternative to brands like Eppensteiner, Hydac, Internormen or
Mahle.

Different Types of Hydraulic Filters

We supply different types of hydraulic filters as mentioned below:

 Suction filters
 Pressure filters
 Return line filters
 Bypass filter systems
 Fillers and breathers
 Filter elements

Additionally, DTA supplies Parker Par<>Fit interchange elements at

competitive prices and equivalent or better quality compared to the OEM's
hydraulic filter elements originally installed. DTA can also supply the indicators
that monitor a system's contamination level. Contamination indicators ensure
that our customers can maintain the cleanliness of their hydraulic systems.
Back to hydraulics overview - Hydraulic Parts

Suction Filter
The suction filter provides protection to the hydraulic pump from particles
larger than 10 microns. You should use a suction filter if there is any likelihood
of pump damage due to larger particles or pieces of dirt. For example, this
may occur when it is difficult to clean the tank or if several hydraulic systems
use the same tank for oil supply.
Characteristics of a suction filter:

 Low cost
 Servicing difficulty, since mounting is below fluid level
 Grade of filtration: Coarse Filtration
o 25 to 90 μm, using stainless steel filter mesh
o 10 μm, using paper
o 10 to 25 μm, using glass fibre
 Equipped with bypass check valve, opening pressure very low (anti-
cavitation)

Note: Suction filters have to be mounted well below the oil level of the tank in
the suction line of the pump.
Back to top - Hydraulic Filters

Pressure Line Filter

The pressure line filter, also referred to as a high pressure filter, is most
commonly used in a hydraulic system. This type of filter is also equipped with
a bypass check valve. When a pressure line filter is installed directly in back of
the pump, it acts as the main filter for the complete flow and protects hydraulic
components against wear.
Characteristics of a pressure line filter:

 Medium cost (depending on size and excess pressure)

 High grade of filtration
 Easy use of clogging indicators
 Grade of filtration: Finest Filtration
o 25 to 660 μm, using stainless steel filter mesh
o 1 to 20 μm, using paper , glass fibre and polyester
 Equipped with bypass check valve that opens at 7 bar (maximum)

Note: A pressure line filter acts as a safety filter when installed in front of an
endangered component (e.g. servo control valve). To ensure maximum
functionality of these critical components, the normal practice is that the
pressure line safety filter must be fitted as close as possible to the component
it is protecting (e.g. in the housing bores).
Back to top - Hydraulic Filters

Return Line Filter

Almost every hydraulic system uses a return line filter. It's designed to mount
directly onto the tank cover. Therefore, you can easily replace filter element(s)
when needed; it's perfect for easy maintenance. Select your return line filter
based on the maximum flow of the hydraulic system.
Characteristics of a return line filter:

 Low cost
 Very easy servicing
 No downtime because it incorporates duplex filters
 Grade of filtration: Fine Filtration
o 40 to 90 μm, using stainless steel filter mesh
o 10 μm, using filter paper
o 10 to 25 μm, using glass fibre
 Equipped with a bypass check valve that opens at 2 bar (maximum)

Note: To prevent the hydraulic oil from foaming in the tank - in all operating
conditions - the return flow must come from below the fluid level in the tank.
As a general rule, the distance between the bottom of the tank and the end of
the pipeline should be more than 2 to 3 times the pipe diameter.
Back to top - Hydraulic Filters

Bypass Filtration
Modern hydraulic systems use bypass filters as main flow filters (i.e. system
filters or working filters). It usually consists of a bypass unit complete with
pump, filter and oil cooler. Bypass filters are also used in mobile hydraulics
where they are connected to the pressure side of the system. A flow control
valve ensures a constant flow with low-flow pulsation.
Characteristics of a bypass filter:

 High costs; however, high returns in terms of improving component lifetime

and considerable slow-down of the ageing process of the hydraulic fluid
 Very high grade of filtration: 0.5 μm
 Silt removal from the fluid
 Flow through bypass filter is completely free of pressure shocks
 Possibilities of offline filtration

Note: Bypass filters allow very dense hydraulic filtration by removing even the
smallest dirt particles. Silt would otherwise degrade the dopes, which are
added to the hydraulic oil to form a protecting layer for the moving parts in the
system. In general, the entire hydraulic system fluid can be flushed through
the bypass filter within 10 to 12 hours, which is approximately 1% of the main
flow.
Back to top - Hydraulic Filters

Fillers and Breathers

You should use breathers or fillers when the air compresses or expands due
to increasing/decreasing levels of fluid in the tank. The function of a breather
is to filter the air flowing in and out of the tank. Most breathers are also
designed to work as fillers. The filler must be easy to reach and should be
equipped with a filling strainer.
Breathers are currently considered to be the most important components for
filtration in hydraulic systems. A large amount of ambient contamination enters
hydraulic systems via unsuitable ventilation devices. Other constructive
measures, such as the pressurisation of oil tanks, are usually uneconomic
when viewed with respect to the highly effective breathers available today.
Back to top - Hydraulic Filters

Contamination Indicators
The grade of filtration determines the level of contamination in a filter element
to a large extend. Contamination indicators can determine the level of
contamination in a filter element. The contamination indicator consist of a
sensor and warning device.
How it works:
Under normal conditions, the fluid enters the inlet of the filter, passes through
the filter element, and leaves the filter through the outlet. As the fluid passes
through the filter element, impurities are deposited on the outside of the
element. As the deposits accumulate, they cause a differential pressure to
build up between the inlet and outlet of the filter. The pressure is sensed
across the contamination indicator switch, actuating a warning device (e.g.
lights, horns, etc.). In this situation, the hydraulic pump should be stopped and
the filter serviced, cleaned, or replaced.
A filter with a grade of filtration of 1 micron is more vulnerable to clogging than
a filter element with a filtration grade of 10 microns. The following three factors
cause contamination in a hydraulic system:

 Component contamination (e.g. chips, dust, fibres, preservatives as result

of production and storage)
 Assembly contamination (e.g. weld spatter, sealing material, pieces of
rubber from hydraulic hoses)
 Production contamination (e.g. ageing residues in fluids caused by high
operating temperatures)