Sistema Hidraulico.pdf

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Technical Handbook

RH 200

8. Hydraulic system

TEREX Germany GmbH & Co. KG

3 663 488.00 en
http://rh200-thb-titel_3663480_00_en.pdf/


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Editor: TEREX Germany GmbH & Co. KG

Department 910 Product Support

D-44149 Dortmund, Karl-Funke-Str. 36

Phone: ++49 / 231 / 922-4901

Fax: ++49 / 231 / 922-5900

Copyright by TEREX, Printed in Germany


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CONTENTS

RH 200 Diesel - 3657790e.doc (00) - 09.03 Page 8 - 1

8. HYDRAULIC SYSTEM

8.1 Introduction ......................................................................................8.1 - 1

8.1.1 Foreword ...........................................................................8.1 - 1

8.1.2 Safety ................................................................................8.1 - 1

8.1.3 General..............................................................................8.1 - 5

8.2 Depressurizing, bleeding, flushing .................................................8.2 - 1

8.2.1 Depressurizing of the hydraulic system.............................8.2 - 1

8.2.2 Bleeding of the hydraulic system.......................................8.2 - 3

8.2.3 Flushing of the hydraulic system .......................................8.2 - 5

8.3 Description (Faceshovel).................................................................8.3 - 1

8.3.1 Technical data ...................................................................8.3 - 1

8.3.2 Components of the hydraulic schematic............................8.3 - 1

8.3.3 Components of the hydraulic system.................................8.3 - 5

8.3.4 Hydraulic circuit diagram .................................................8.3 - 13

8.3 Description (Backhoe) .....................................................................8.3 - 1

8.3.1 Technical data ...................................................................8.3 - 1

8.3.2 Components of the hydraulic schematic............................8.3 - 1

8.3.3 Components of the hydraulic system.................................8.3 - 5

8.3.4 Hydraulic circuit diagram .................................................8.3 - 13

8.4 Hydraulic components.....................................................................8.4 - 1

8.4.1 Main pumps .......................................................................8.4 - 1

8.4.2 Swing pump.......................................................................8.4 - 2

8.4.3 Rotor..................................................................................8.4 - 3


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CONTENTS

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8.4.4 Valve blocks ......................................................................8.4 - 5

8.4.5 Other components ...........................................................8.4 - 34

8.5 Description of hydraulic circuits.....................................................8.5 - 1

8.5.1 Load limiting system.......................................................8.5.1 - 1

8.5.2 Pressure cut off system ..................................................8.5.2 - 1

8.5.3 Servo system..................................................................8.5.3 - 1

8.5.4 Working functions (Faceshovel) .....................................8.5.4 - 1

8.5.4 Working functions (Backhoe)..........................................8.5.4 - 1

8.5.5 Travel system .................................................................8.5.5 - 1

8.5.6 Swing system .................................................................8.5.6 - 1

8.5.7 Track tensioning system.................................................8.5.7 - 1

8.5.8 Cooling system for hydraulic oil ......................................8.5.8 - 1

8.5.9 Cooling system for engines ............................................8.5.9 - 1

8.5.10 Cooling system for pump gearbox................................8.5.10 - 1

8.6 Pressure checking and setting........................................................8.6 - 1

8.6.1 Introduction........................................................................8.6 - 1

8.6.2 Pressure settings...............................................................8.6 - 3

8.6.3 Tools..................................................................................8.6 - 4

8.6.4 Hydraulic systems .............................................................8.6 - 5

8.7 Installation of hydraulic pumps.......................................................8.7 - 1

8.8 Hydraulic cylinders (Faceshovel)....................................................8.8 - 1

8.8.1 Introduction........................................................................8.8 - 1

8.8.2 Design configuration..........................................................8.8 - 3

8.8.3 Assembly.........................................................................8.8 - 11


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CONTENTS

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8.8.4 Tightening torques...........................................................8.8 - 24

8.8 Hydraulic cylinders (Backhoe) ........................................................8.8 - 1

8.8.1 Introduction........................................................................8.8 - 1

8.8.2 Design configuration..........................................................8.8 - 3

8.8.3 Assembly...........................................................................8.8 - 9

8.8.4 Tightening torques...........................................................8.8 - 22


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CONTENTS

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8.1 HYDRAULIC SYSTEM

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8.1 Introduction

8.1.1 Foreword

The Technical Handbook contains important in-formation for personnel servicing the machine.Machine specifications listed elsewhere in themachine documents are not always repeated inthis book.

The documentation of an TEREX Mining machineincludes:

the operating instructions

the spare-parts list

the technical handbook

The present brochure does not contain the specifi-cations of auxiliary units for the operation of addi-tional or optional equipment or the specifications ofindividual machines.

The refilling quantities specified for consumablesare approximate quantities which are intended as ahelp for planning consumable requirements.

Each unit is equipped with suitable checking de-vices, e.g. dipstick or checking plugs, permittingthe operator to check proper filling of the units.

8.1.2 Safety Instructions

8.1.2.1 Danger in the event of non-obser-

vance of the safety instructions

This TEREX hydraulic excavatorhas been built in accordance withstate-of-the-art standards and therecognized safety rules.

However, operating the machine ifa fault is suspected or has oc-curred, or carrying out repair workinexpertly may

endanger the lives of persons in

contact with it

damage the machine and otherproperty.

The hydraulic excavator must bestopped immediately on any dam-age being suspected or occurringto ensure that the safety of the op-erator, of other persons at theplace of use or of other materialproperty is not compromised.

All components of TEREX ma-

chines are carefully co-ordinated.Trouble-free operation and a longservice life can only be achievedwith original TEREX spare parts.


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Page 8.1 - 2 2440575e - (00) - 11.96

8.1.2.2 Rules for safety at work

Personnel

The machine must not be startedby unauthorized persons.

It must therefore be secured.

Observe the accident preventionregulations.

The hydraulic excavator may beoperated, serviced or repaired onlyby specially trained and authorizedpersonnel with the appropriatetechnical know-how.

If such know-how is lacking, me-ticulous instruction must be givenby experienced personnel, e.g.from TEREX.

The personnel must have read andunderstood the operating instruc-tions and in particular the chapter

Fundamental

Safety Instructions.

Only such persons may start upthe machine during assembly work

in order to adjust the attachments.

Incorrect operation of the machineor the attachments may give rise tolife-threatening situations.

During all works, always observethe start-up and shut-down proce-dures prescribed in the operatinginstructions.

Personnel

Personal protective gear and

working clothing:

Wear a safety helmet, safety foot-wear and gloves.

Wear closely fitting working cloth-ing when working on the machine.Loose, wide garments may catchon machine parts and result in in-jury.

Persons carrying out work atgreater heights must be equippedwith safety harnesses. Always put

on a tested harness which must beequipped with fall arrestors andsafety lines.

If the work to be carried out re-quires auxiliaries, e.g. marshallers,the competences of each individ-ual helper must be clearly definedbeforehand. The individual re-sponsibilities must be meticu-lously observed to avoid unclearcompetences endangering safety.


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2440575e - (00) - 11.96 Page 8.1 - 3

Tools and auxiliaries

Tools, hoists, slings, trestles and

other devices must be in a reliable,safe state.

Metal splinters may cause injurywhen attachment bolts are beingdriven in or out. A brass or coppermandrel should therefore be usedfor this purpose, and goggles mustbe worn.

For climbing onto or off the ma-chine, use only the ladders, steps,platforms and handrails provided

for this purpose.Always keep ladders, steps andplatforms in a non-slip state. Re-move any oil, grease, earth, clay,snow, ice and other foreign matterimmediately.

Securing the working equip-ment

Before carrying out assemblywork, the machine and the attach-ments must be secured against in-advertent and unauthorized start-ing, e.g. by placing chocks underthe wheels or tracks and by stand-ing the working equipment on theground.

Stand the working equipment onthe ground in such a way that nomovements can be made whenmechanical or hydraulic connec-tions become detached.

Secure any equipment or compo-nent which is to be mounted ordismantled or whose position is tobe changed using hoists or appro-priate slinging/supporting devicesto prevent them from moving, slip-ping or falling inadvertently.

Systems and units (e.g. pipes,coolers, hydraulic reservoirs,

compressed-air reservoirs) mustbe properly depressurized beforebeing opened.

Protective devices on moving ma-chine parts may be opened or re-moved only when the drive unit isstationary and protected againstinadvertent starting.

Before recommissioning, all pro-tective devices must be refitted.

Before carrying out assemblywork, the machine and the equip-ment must be secured against in-advertent starting, e.g. by placingchocks under the wheels or tracksand by standing the workingequipment on the ground.

Hydraulic and lubricating sys-tem:

Always observe the safety regula-tions applicable to the productwhen handling oils, greases andother chemical substances.

Unused but open bores, pipelinesand hose connections must beclosed in a pressure-tight manner.

Refill collected hydraulic oil backinto the hydraulic system onlythrough the return-flow filters. Dis-pose of waste oil without pollutingthe environment.

Observe the correct working se-quence when fitting or replacingcomponents or equipment. Theworking sequence has been speci-fied and tested by qualified ex-perts.

.


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Page 8.1 - 4 2440575e - (00) - 11.96

When carrying out work and espe-cially work on the electrical system

involving tools, spare parts, etc.coming into contact with electriccables, the battery main switchmust be set to the 'OFF' position.

Replace defective, mechanicallyprestressed units only as an en-tirety. Never open them. In excep-tional cases, open only when thesystem and the operating se-quence are precisely known. TheTechnical Manual contains no in-formation on such work.

When the machine is at operatingtemperature, the consumables areat least at the same temperature.Precautions must therefore betaken to prevent burning or scald-ing.

Be careful when handling acids,e.g. battery acid. Acid splashesmay injure the eyes and the skin.

Do not smoke when handlingflammable liquids.

Be careful with naked flames andunprotected light. Not only fuel butalso other consumables often havea low flash point and catch fireeasily.

8.1.2.3 Conversions or modifications to themachine

Unauthorized conversions or modi-fications of the hydraulic excavatorare forbidden for reasons of safety.

The nominal pressure of pressurerelief valves must not be modifiedwithout explicit approval fromTEREX. Do not remove the leadseals from pressure-relief valvesand pressure accumulators.

8.1.2.4 Recommissioning

Prior to recommissioning:

Grease all lubricating points.

Check all oil levels and make thenecessary corrections.

Carry out function checks of allrepaired components

Check all functions of the exca-vator including the brakes duringa test run. Release the hydraulicexcavator for recommissioningonly after all functions have beenfound to work perfectly.


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8.1.3 General

In addition to the operating instructions and thespare-parts list, the present Technical Manualcontains information enabling the user of theTEREX hydraulic excavator to safely operate,maintain and repair the machine in accordancewith the specifications.

The information supplied in the Technical Manualrepresents the standard version of the machine asdelivered.

All sketches and drawings are merely schematic.They do not necessarily represent the machine'sactual state of design and must not be used asmanufacturing documents.

No reference is made to special versions.

After delivery, the Technical Manual is not sub-ject to revision.Technical changes introduced into the series pro-duction after delivery of the machine may also be

implemented in machines already in use.In such case, already delivered Technical Manu-als are normally not automatically updated.

All technical documents issued by TEREX Ger-many GmbH are written in German and thentranslated.

Even a good translation may give rise to questionswhich your TEREX dealeror your TEREX distrib-uting centrewill be pleased to answer.

This Technical Manual has been carefully pre-pared by the competent divisions.

If any points are nevertheless unclear or incorrect,please contact your local TEREX dealer or yourTEREX distributing centre.


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Page 8.1 - 6 2440575e - (00) - 11.96


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8.2 DEPRESSURIZING, BLEEDING, FLUSHING

RH 200 Diesel - 2471385e - (00) 10.99 Page 8.2 - 1

8.2 Depressurizing, bleeding,flushing of the hydraulicsystem

All personnel carrying out com-missioning, operation, inspection,service and repair must have readand understood the operating in-structions and in particular thechapter

Fundamental Safety Instructions.

before starting any work.

Before working on the hydraulic

system make sure, that the systemis depressurized and remainingpressures are relieved.

Shut off the engine(s).

Components (e.g. hydraulic tank,cylinders, valves) may be hot andcause severe burns.

Secure the machine before work-ing on it.

Avoid contact of hydraulic oil withthe skin. This can be harmful.

Always wear safety glasses, safetygloves and firm protective cloth-ing.

8.2.1 Depressurizing of the hydraulicsystem

Hydraulic systems are only to be opened up when

they are free of pressure. It is possible for consid-erable back pressure to be present in the hydrau-lic-systems, e.g. primary pressure from the lastmovement, even when the excavator is parked ona level surface with its equipment on the ground(Figs. 1 and 2).

Residual pressure drops only gradually. If work isto be carried out on the hydraulic system(s) imme-diately after stopping the excavator, then the sys-tem(s) is/are to be freed of pressure.

630213.SKD

Fig. 1 Parking position of FS-machine

630214.SKD

Fig. 2 Parking position of BH-machine

Release pressure from the part of the sys-tem (it may be necessary to use severalprocedures).

Carefully open up the part of the system.


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Page 8.2 - 2 RH 200 Diesel - 2471385e - (00) 10.99

Examples for system sections:

1) Main working circuit

2) Servo control circuit

3) Track tensioning system

4) Swing circuit

5) Cooling circuit

Depressurizing:

Park the excavator on a level surface

Lower the working equipment to the ground

Shut of the engine(s)Section 1) and 2): Main working circuit and servocontrol circuit

With key-switch ON and safety switch active(86, Fig. 4) shift all control levers and pedalsrepeatedly into all directions (Fig. 3).

Fig. 3 Operation of joysticks and pedals

The servo system is SHUT OFF, when thedriver is leaving the seat and thus the safetyswitch is not operated (86, Fig. 4).

Fig. 4 Safety switch in seat

Section 3): Track tensioning systemThe track tensioning circuit has to be depressur-ized by completely opening (screwing out) thesafety valves in the undercarriage.

Section 4): Swing circuitThe swing system has to be depressurized withhelp of the Minime-ports (test-ports).

Section 5): Cooling circuitDepressurizing of the cooling circuit is not required.

Be extreme carefully when workingon hydraulic cylinders or pressurelines of the equipment!

Even when following the safetyprocedure, there may still a certainpressure be left in the system!


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RH 200 Diesel - 2471385e - (00) 10.99 Page 8.2 - 3

8.2.2 Bleeding air from the hydraulicsystem

Bleed air from hydraulic pumps, hydraulic motors,

hydraulic cylinder and servo circuits:

before commissioning the excavator, e.g.following major servicing/repair to the hy-draulics, or after a long period out of opera-tion.

after each oil changeThe intake and running characteristics of the hy-draulic components can otherwise be greatly af-fected. Hydraulic oil also serves as a lubricant for

these components. A dry run can lead to totalfailure in a very short time.Hydraulic pumps and -motorsBleed air from pumps and motors after each oilchange. To bleed, fill clean oil through the highestleakage oil port up to the bottom edge of the port.Main pumps: Port (T, Fig. 5)Swing pumps: Port (T1, Fig. 5)

Fig. 5 Bleeding points

Check the hydraulic system under load. Listen fornoises in the pumps of motors. Jerky movementsare an indication of air pockets in the system. Ac-tuate all hydraulic functions several times to elimi-

nate the air pockets.


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Page 8.2 - 4 RH 200 Diesel - 2471385e - (00) 10.99

Hydraulic cylinders

630254.SKD

2

3

1

Fig. 6 cylinder retracted

Before oil is admitted to a cylinder for the first time,the piston must be in one of the two end positions.In other words, the piston rod (1, Fig. 6 + 7) mustbe either fully extended or fully retracted.

630255.SKD

2

1

4

Fig. 7 cylinder extended

Alwaysadmit oil to the side of the cylinder wherethe piston (2) is positioned.

With the rod (1) retracted, admit oil to thepiston end (3).

With the rod (1) extended, admit oil to therod end (4).

If the piston rod is in the half-way position (for in-stallation reasons), admit oil to the rod side (4) first.

The first operation of the cylinders has to be car-ried out with reduced oil flow, to extend or extractthe piston rod as slowly as possible.

Servo circuitOn machines with pilot lines connected to the sideof the servo cap loosen the bleeder plug (5, Fig. 8)with engine running until oil emerges without bub-bling.

Fig. 8 Bleeding plugs

When the pilot lines are connected to the upperports of the servo caps the system is bleeding airautomatically.


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RH 200 Diesel - 2471385e - (00) 10.99 Page 8.2 - 5

8.2.3 Flushing the hydraulic system

The following instructions are a brief compilation ofthe procedures needed to clean/flush the hydraulic

system. The functions and the designs of the indi-vidual components are described in the relevantsections of the Technical Handbook.It is assumed that the machine remains on sitewhile flushing is being carried out. Hydraulic com-ponents, e.g. cylinders, should only be over-hauled/repaired in an enclosed, clean workshop.If the hydraulic component (e.g. pump or cylinder)is damaged, the system(s) must be checked to seewhether any chips from the component have en-tered into the system. To do this, remove and in-

spect the magnetic rods and return flow filters.

1. Flushing is required under follow-ing conditions:

If the quantity, size and appearance of themetal particles on the magnetic rod is differentto that arising in normal operation, or if theyare of completely different nature.

If the amount of magnetic and non-magneticdebris caught in the return flow filter is

greater than usual.

Whenever a damaged hydraulic componenthas been changed. Flushing can be limited tothe immediate and upline vicinities of thecomponent, as long as these can be isolatedcompletely.

2. Type and source of contamination

Blank metal particles:Damaged bearings in pumps or motors.

Steel particles that look like machine turnings:Internal components in a cylinder haveseized. Pieces of guide bands, O-rings andseals are then often to be found in the filters.

Individual parts that appear to be pieces ofsprings or valve plates:Damaged valve(s).

These are only guidelines. When damage is exten-sive, all of these symptoms can appear at once.


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3. Steps in case of pump damage3.1 Determine damaged pump, typical symp-

toms are:

chip indicator ON for main pump or swing

pump

vibrating hydraulic hoses

fluctuating pressure readings on gauges

abnormal noises

noticeable loss in output

excessive temperature

excessive load on engine(s)

3.2 Pumps without high pressure filters:

Remove return flow filters and check for con-

tamination.

Check by-pass valve for correct seating change valve if damaged.

Drain and clean oil tank.

Remove the damaged pump.

Remove and clean pump intake line.

Fit and bleed new pump.

If metal contamination from the pump has gotinto the hydraulic system, carry out all of theprocedures from section 4 to 8 even if dam-age to other components has not been identi-fied.

3.3 Pumps with high pressure filters

Remove the damaged pump.

Remove/clean HP filter(s).

Remove and clean line between pump andHP filter.

Remove new pump, clean HP filter and cleanconnecting lines.

Fit new return filter elements.

Fill oil through return flow filters.

Put machine back to work.

4. Steps in case of cylinder damage

Remove and check return flow filter.

Trace damaged cylinder. Remove, strip, cleanand check all components.

Also remove, strip, clean and check any cylin-ders connected in parallel.

When reassembling, cylinders are always tobe fitted with new seals and guides.

Fit the cylinder but do not connect the oillines.

Flush and check operation (see section 8).

If further contamination is found when flush-ing, remove all cylinders, and strip, clean andinspect.

Drain and clean the oil.


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RH 200 Diesel - 2471385e - (00) 10.99 Page 8.2 - 7

5. Steps in case of valve damage

Locate the damaged valve(s).

If all of the missing parts are found, it is onlynecessary to change the valve. Further actionis not needed.

If all of the parts cannot be found, continuethe search at the following points:

Return flow filter

Oil tank

Components downline of the damagedvalve, e.g. cylinders, valves, motors.

6. Further stepsIf the hydraulic system has been extensively con-taminated with chips, the following procedures are

also necessary:

Strip, clean and re-install the primary reliefvalves.

Strip, clean and re-install the secondary reliefvalves.

Clean and check the cooling circuit if con-tamination is found in the oil tank:

Remove the cooler. Clean outside and in-

side in both directions of flow. The cooler isto be changed if the contamination cannotbe completely removed from the cooling fins.

Flush the hydraulic lines or blow throughwith compressed air.

Check and clean the servo control valves.

If hydraulically driven ancillary attachmentsare fitted, their systems must also bechecked, especially if the cause of the con-tamination cannot be traced in the excavators

systems. Follow the relevant manufacturersinstructions.


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7. Flushing procedureThe extent of flushing required depends upon thepoint at which the contamination has entered. All

downline and branching systems are to be flushedback to the filter(s). The filter(s) must be checkedthoroughly to determine whether they havestopped all contamination from flowing further:7.1 In case of pump damage (pump without

high pressure filter):

Fit a new return flow element.

Fill fresh oil through the return flow filter.

Connect the lines to individual consumersdirectly (short circuit). Disconnect lines thatare still connected to consumers.

Run the engine up to max. speed.Wait until the filter warning light has gone outand then summon the relevant functions.

Summon each hydraulic function one at atime and for approx. 1 minute in each direc-tion. Shift several times briefly into neutral.Each consumer should be run for at least 5minutes.

Change return filter element and clean mag-

netic rod.

Repeat the flushing procedure. Again actuateall consumers, one after the other, but thistime only for a short period.

Check filter and magnetic rod again.

Connect all consumers correctly and bleed airfrom the system.

Check oil level in tank.

Put excavator back to work.

7.2 In case of pump damage (pump with highpressure filter):

In this case flushing is not required, but check

operation (see section 8).

7.3 In case of cylinder damage (see section 4):

Fit new return flow element.

Short circuit the connections to the replace-ment cylinder.

Run the engine up to max. speed.Wait until filter warning light has gone out andthe summon the cylinder function.

Run the cylinder in each direction for approx.1 minute each. Shift briefly into neutral.Each consumer should be flushed for at least5 minutes.

Change return flow element and clean mag-netic rod.

Repeat flushing procedure, with all consumersbeing actuated briefly, one after the other.

Check return flow filter and magnetic rodagain.

Connect cylinder correctly and bleed air.




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RH 200 Diesel - 2471385e - (00) 10.99 Page 8.2 - 9

7.4 In case of damage of hydraulic motor:

Fit new return flow element.

Short circuit the connections to the replace-ment motor.

Summon hydraulic function of the replacedmotor in both directions for approx. 1 minute.Shift several times briefly into neutral.

Change return flow element and clean mag-netic rod.

Repeat flushing procedure, with all consumersbeing actuated briefly, one after the other.

Check return flow filter and magnetic rodagain.

Connect motor correctly and bleed air.



8. Monitoring in operation

After working for approx. 1 minute, check the mag-netic rod. Clean the rod if contamination is found.

Check again in increasing intervals.

If the amount of contaminationdoes not drop noticeably, or if iteven increases, it must be as-sumed that the real cause of thedamage has not been located andremoved.

Check and flush again.


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8.3 DESCRIPTION OF THE HYDRAULIC SYSTEM - FS

RH 200 Diesel (FS) - 3657771e.doc - (01) - 07.03 Page 8.3 - 1

8.3 Description of the hydraulic system

8.3.1 Technical data

The technical data of the hydraulic system are listed in chapter 2 Technical Data.

8.3.2 Components of the circuit diagram

The posit ion nos. refer to c ircu it d iagram No. 3 672 750 (03) in chapter 8.3.4

Position Quantity Designation Location

1 2 Engine Engine module

2 2 Pump transfer gearbox Engine module

3 4 Main pump A7V - SL - 1000 Pump gearbox

4 4 Swing pump A4V 250 Pump gearbox

5 ----

6 4 Servo pump Pump gearbox

7 2 Charge pump for swing system Pump gearbox

8 ----

9 ----

10 4 Cooling pump KP 5 - 300 Pump gearbox

11 2 Fan pump A 10 V for radiator fan Pump gearbox

12 - 22 ----

23 2 Pump governing valve Engine module

24 ----

25 1 Proportional valve plate Operator module

26 2 Solenoid valve bank Operator module

27 ----

28 1 Track tensioning block Engine module

29 1 Distributor plate (main pumps) Engine module

30 4 Pressure relief valve Position 29

31 4 2 way valve Position 29

32 4 High pressure filter Position 29

33 ----

34 4 Filter Engine module

35 1 3/2 way solenoid valve for emergency lowering Operator module

36 1 Filter for proportional valve plate Operator module

37 1 Check valve

38 ----


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Page 8.3 - 2 RH 200 Diesel (FS) - 3657771e.doc - (01) - 07.03


39 ----

40 1 Servo oil valve block Engine module41 ----

42 ----

43 4 Check valve

44 2 Check valve Position 40

45 ----

46 1 Block with 4/2 way solenoid valve

47 1 Shuttle valve

48 49 ----

50 1 Hydraulic cylinder for access ladder

51 1 Control valve for access ladder

52 1 Accumulator for access ladder

53 55 ----

56 1 Shuttle valve Engine module

57 - 59 ----

60 1 Hydraulic oil tank Superstructure

61 2 Gate valve Hydraulic oil tank

62 2 Return oil filter Hydraulic oil tank

63 6 Bypass valve Hydraulic oil tank

64 4 Tank line pressurizing valve Hydraulic oil tank

65 ----

66 2 Check valve Hydraulic oil tank

67 - 79 ----

80 4 Hydraulic oil cooler Oil cooler module

81 4 Fan motor Oil cooler module

82 ----

83 ----

84 4 Fan Oil cooler module

85 2 Distributor plate (oil cooling) Oil cooler module


87 4 Thermostat Position 85

88 ----

89 ----

90 1 Travel block Superstructure

91 1 Rotor Superstructure


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92 1 Travel valve block RH Rotor

93 1 Travel valve block LH Rotor 94 ----

95 1 Travel retarder valve RH Travel block

96 1 Travel retarder valve LH Travel block

97 4 Anti cavitation valve Travel block

98 ----

99 ----

100 4 Swing gearbox Superstructure

101 1 Shuttle valve

102 4 Swing motor Swing gearbox

103 4 Blocking valve Engine module

104 ----

105 1 Pressure governing valve Engine module

106 1 Flushing valve Engine module

107 2 High pressure filters Superstructure

108 ----

109 1 Pressure relief valve Engine module

110 - 119 ----

120 2 Travel gearbox Undercarriage

121 4 Travel motor Travel gearbox

122 - 124 ----

125 1 Valve block (secondary relief) Undercarriage


127 - 129 ----

130 2 Track tensioning cylinder Undercarriage

131 2 Diaphragm accumulator Undercarriage

132 ----

133 1 Track tensioning group Undercarriage

134 2 Pressure relief valve

135 - 139 ----

140 2 Gear motor for radiator fan Counterweight

141 2 Block with anti cavitation valve for fan motor Position 140

142 - 160

161 2 4-spool control valve Boom

162 ----


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163 ----

164 4 Float valve Boom165 ----

166 ----

167 2 Check valve

168 ----

169 ----

170 - 181 ----

182 2 Boom cylinder Boom

183 2 Stick cylinder Boom

184 2 Bucket crowd cylinder Boom

185

186 2 Clam cylinder Backwall

187 1 Distributor with relief valve Backwall

188 ----

189 2 Distributor with check point Boom


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8.3.3 Components of the hydraulicsystem of the RH 200 (FS)

At tention!

Position nos. are referred to circuit diagramPart-No. 3 672 750 (03) in chapter 8.3.4.

Some items are numbered on the schematicbut not mentioned here. They are not importantfor the hydraulic functioning.

Drive unit Pos. 1

The two water - cooled Cummins engines are 12 -cylinder V engines with turbo-charging and inter -cooling.

Pump transfer gearbox Pos. 2

Each of the 3 - stage spur - wheel gearboxes isdriven via a diaphragm coupling from one of theengines and distributes engine output to the rele-vant hydraulic pumps.

Variable - d isplacement pump Pos. 3

The 4 main pumps for working equipment andtravel movements are axial - piston bent axispumps with slipper bearing. Slipper bearings arehydraulically swimming bearings that increasethe pump`s service life.

Swing pump Pos. 4

The 4 swing pumps to move the superstructure arevariable - displacement axial - piston swash platepumps. They are especially suited for operation inclosed circuits. The pump flow is infinitely variableand increases from 0 to max while the pumprotary group is being tilted out. If the swash plate isde-stroked through the zero position, the direc-tion of the oil flow is altered smoothly.

free Pos. 5

Servo pump Pos. 6

The 4 servo pumps are fixed - displacement gear -

type pumps that are mounted on the pump transfergearboxes (2) and that supply the servo circuit (40bar) and the auxiliary circuit (70 bar).

Axial piston pump A 10 V Pos. 7

The 2 pressure regulated axial piston pumps areworking as charge pumps for the swing circuit.

free Pos. 8

free Pos. 9

Oil cooling pump Pos. 10

Four fixed - displacement gear - type pumps aremounted onto the swing pumps (4). They con-stantly draw oil from the tank and pump it to thefan motors and the oil coolers.

Fan pump A 10 V Pos. 11

The fan wheel for water cooling of the diesel en-gine is driven by an adjustable axial-piston pumpper drive unit. The volume flow of the pump andthus the speed of the fan wheel is electronicallycontrolled as a function of the water temperature.

free Pos. 12 - 22

Pump governing valve Pos. 23

The group comprises two proportional valves, twometering connections and a housing.These valves control the main pumps (3). They arecontrolled by the microprocessor in the PMS sys-tem and govern the flows from the main pumpsdepending upon the actual pressure. Each pair ofmain pumps is governed by one proportional valve.The valves are actuated by adjustable, oil - im-

mersed DC solenoids and transform electricalcurrents proportionally into hydraulic pressure.


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A solenoid current of 830 mA corresponds to apressure of 42 bar in the pump governors. A cur-rent of 230 mA corresponds to 10 bar.

free Pos. 24

Proportional valve plate Pos. 25

The valve plate contains the proportional valvesand the 3/2 way valves for operation of cylinders,swing and travel function.

Valve bank, compl. Pos. 26

An assembly group comprising four solenoidvalves and a housing.

free Pos. 27

Track tensioning block Pos. 28

The valve is changing the track tensioning pres-

sure between 50 bar and 70 bar mode.

Distributor plate for main pumpsPos. 29

An assembly group comprising four primary pres-sure relief valves (36), four two - way valves (37),four caps (38), four high - pressure filters (39) anda housing with two check valves. The two checkvalves isolate the main pumps (3/P1 & P2) fromthe pumps (3/P3 & P4) when only the right - handengine is running.

Pressure relief valve Pos. 30

The relief valves are used as primary pressurerelief valves for the main pumps. They limit themaximum pressure that can be reached by thepumps (3) and therefore protect the systemagainst overload.

The valves are pilot controlled and have variablesettings.

2 - way valve Pos. 31

Four valves for the logical co - ordination of themain pumps (3).They isolate the main pumps against one anotherand prevent a stationary engine from being turnedover by it's pumps when only the other engine isrunning.

The 2 - way valves are shifted by solenoids (24/Y32 & Y 33).

Co - ordination of the valves - see solenoid valve(24).

High - pressure filter Pos. 32

The high - pressure filters in the high - pressurelines from the main pumps protect the downlineunits (e. g. control blocks and cylinders) againstmetal chips and particles from the pumps (3). Thefilter elements are differential pressure resistant

and do not have a bypass valve. The oil flowsthrough the HP filters from outside to inside.

free Pos. 33

Filter Pos. 34

Filter the oil flows from the 4 swing circuit chargepumps.

3/2 way solenoid valve Pos. 35

The solenoid valve is operated with a button in thejoy stick. It allows lowering of the attachment incase of a sudden engine shut-down.

Filter Pos. 36

This filter is filtering the oil which is feeding theproportional valve plate (25).


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Check valve Pos. 37

The check valve prevents loss of oil out of the ac-

cumulator (52) for the access ladder.

free Pos. 38

free Pos. 39

Servo oil valve block Pos. 40

The complete assembly group comprises two fil-ters, two pressure relief valves, two check valvesand a housing.

free Pos. 41

free Pos. 42

Check valve Pos. 43

The four valves prevent negative influencing of

main pump pressures (3/P1 & P2) when only oneTravel pedal is actuated. The valves crack openat approx. 1 bar.

Check valve Pos. 44

These two valves prevent either of the servopumps (6) from affecting the other, e. g. when onlyone engine is running, they prevent oil beingpumped back into the tank through the stationary

servo pump.

free Pos. 45

Block with solenoid valve Pos. 46

The block carries the solenoid valves for the logicalco - ordination of the four main pumps (3).

Shuttle valve Pos. 47

The shuttle valve is connecting either the control

pressure for the travel brakes or the control pres-sure for the 2-speed operation to the travel motors.

free Pos. 48 - 49

Cylinder for access ladder Pos. 50

The hydraulic cylinder is operating the accessladder.

Control valve Pos. 51

With the control valve the cylinder for the accessladder is operated.

Accumulator Pos. 52

The accumulator supplies pressure oil for emer-

gency lowering of the access ladder in case of asudden engine shut-down.

free Pos. 53 - 55


Via this shuttle valve the Y1 & Y2 ports of thepressure governing valve (54) are connected withthe pressure relief valve (55)

free Pos. 57 - 59

Hydraulic oil tank Pos. 60

The tank stores all of the oil for the system andcontains two return flow filters (62), six by - passvalves (63), four tank line pressurizing valves (64),a check valve (66) and a pressure switch.


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Gate valve for intake line Pos. 61

The gate valves can be used to isolate the hydrau-

lic pumps from the oil tank. This makes it possibleto remove pumps without having to drain all of theoil from the tank.

Return flow filter Pos. 62

Each return flow filter contains 7 filter elements toclean the oil returning from inside to out. Any metalchips are trapped by the magnetic rods installedabove the filters.

By - pass valve Pos. 63

The six by - pass valves open at a pressure of 1.5bar and prevent the return flow filters (62) bursting,e. g. due to clogging. Oil then flows unfiltered backinto the tank.

Tank l ine pressurizing valve Pos. 64

These four valves have fixed settings of approx. 12bar. They are arranged in the return lines and keepa constant level of pressure in the hydraulic sys-tem.

free Pos. 65

Check valve Pos. 66

These two valves have a cracking pressure ofapprox. 1 bar and prevent oil escaping from:

the servo caps on control block (161) for boom andstick float functions (164)

free Pos. 67 - 79

Hydraulic oil cooler Pos. 80

The hydraulic oil coolers pass the heat generated

in the hydraulic system on to the atmosphere usingthe air flows created by the fans.

Fan motor Pos. 81

Four fixed - displacement gear - type motors areused to drive the fans on the oil coolers.

free Pos. 82

free Pos. 83

Fan Pos. 84

The fan produces the air flow to cool down thehydraulic oil.

Distributor plate for oil cooling Pos. 85

Each of the two plates contains two thermostats(87), two pressure relief valves (86) and two checkvalves. The check valves function as anti - cavita-tion valves while the engines are being shut down.


The two pilot controlled, variable setting pressure

relief valves protect the cooler circuit against over-pressure, e. g. in case of a line blockage.

Thermostat Pos. 87

The four thermostats are fully open at oil tem-peratures under 40C. The majority of the oil thenflows directly back into the tank. As the tempera-ture rises, the thermostats begin to close so thatan increasing amount of oil flows through the fan

motors and the coolers. At 52C the thermostatsare fully closed and the full oil flow passes throughthe fan motors to the coolers.


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free Pos. 88

free Pos. 89

Travel block Pos. 90

A complete group comprising rotor (91), theTravel spools (92 & 93), the travel retarder valves(95 & 96), anti - cavitation valves (97) and coverplates.

Rotor Pos. 91

Conducts hydraulic oil flows between superstruc-ture and undercarriage. The seven ring channelsare for:

Travel (4 channels)

Track parking brakes/Track motor adjustment

Track tensioning

Leakage oil

Travel valve block RH Pos. 92

A servo - controlled single - spool block that actu-ates the right - hand track.

Travel valve block LH Pos. 93

A servo - controlled single - spool block that actu-ates the left - hand track.

free Pos. 94

Travel retarder valve RH Pos. 95

Prevents the excavator from running away down-hill and keeps the track motors full of oil (to avoidcavitation). The speed of the track motors is then

always determined by the working pressure of thepumps (3).

Travel retarder valve LH Pos. 96

See travel retarder valve (95).

Anti - cavitat ion valve Pos. 97

The four valves mounted on the Travel spools(92 & 93) keep a constant column of oil in the trackmotors. They crack open at the slightest pressureso that oil can be drawn in from the tank line.

free Pos. 98

free Pos. 99

Swing gearbox Pos. 100

The gearbox are 2 - stage planetary reducers.

The spring applied multi disc brakes on the swinggearboxes serve to hold the superstructure sta-tionary (parking brakes). They are actuated by atoggle switch in the cab.

The brake must only be actuated when the super-structure has stopped swinging.


The shuttle valve is connecting the control pres-sure lines Y1 and Y 2 of the pressure governingvalve (105) to the pressure relief valve (109).

Swing motor Pos. 102

The swing motors are 40, fixed - displacementaxial piston pumps whose output speed is propor-tional to the flow of oil. The output torque increaseswith the pressure drop over the motor.

Blocking valve Pos. 103

These valves are leak free and are opened fully byoil from the servo pumps (6) as soon as the en-


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gines are running. If one of the engines is shutdown, the relevant blocking valves close absolutelytightly and prevent the stationary engine from be-ing turned over by pressure oil acting in reverse

through swing motor, swing pump and transfergearbox.

free Pos. 104

Pressure governing valve Pos. 105

Governs the torque in the closed - loop swing cir-cuit.

The valve governs the pressure and direction of oilflow (and therefore extent and direction of theswing motors` output ) depending upon the se-lected control pressure

The radio between control pressure and workingpressure is approx. 1 : 12, i. e. 10 bar control pres-sure on ports (Y 1 or Y 2) corresponds to 120 baroperating pressure in the swing circuit.

Flushing valve Pos. 106

The valve flushes the oil in the closed - loop swingcircuit. Each time a swing function is summoned, acertain amount of oil is flushed out of the low pres-sure side. The charge pumps mounted on theswing pumps replace this oil with filtered, cooled oilfrom the tank.


The two HP filters in the swing circuit clean bothsides of the swing circuit. The check valves in thefilter heads lead the oil flows to the correct side toflow through the filters. This is necessary as thehigh and low - pressure sections of the circuitchange depending upon the direction of swing.

free Pos. 108


The valve limits the pressure that controls thepressure governing valve (105) to max. 31 bar.The valve is direct acting and has a variable set-ting.

free Pos. 110 - 119

Travel gearbox Pos. 120

3 - stage planetary reducer with integrated parkingbrake.The four track parking brakes are wet, multi - diskbrakes that are engaged under spring force andreleased by hydraulic pressure (18 - 20 bar).

Travel motor Pos. 121

The four track motors are variable - displacement,bent - axis motors with tandem bearing arrange-ments. Servo pressure at port (X) sets the motorsto either of two mechanically limited tilt angles. Themaximum tilt angle is selected when servo pres-sure is O . The minimum tilt angle is reachedwhen servo pressure rises above 40 - 45 bar.

max. tilt angle = max. motor displacement = max.output torque = min. output speed

min. tilt angle = min. motor displacement = min.output torque = max. output speed

The governing pressure (at least 15 bar) is tappedout of the respective high - pressure side usingcheck valves.

free Pos. 122 - 124

Secondary relief block Pos. 125

Assembly group comprising four pressure reliefvalves (126), two metering connections and ahousing.


Secondary pressure relief valves for the four trackmotors that protect the motors against external


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forces. Excess oil is cracked off into the relevantlow pressure side of the motors.

free Pos. 127 - 129

Track tensioning cylinder Pos. 130

Single - acting (plunger) cylinders that keep thecrawler tracks tensioned.

Diaphragm accumulator Pos. 131

The nitrogen accumulators act as shock absorbersto dampen external forces acting on the crawlertracks.

free Pos. 132


The block contains the valves for the automatictrack tensioning system.


The track-tensioning assembly comprises 2 pres-sure-relief valves with hand wheel and 2 testpoints.The hand wheels can be used to relieve the hy-draulic track tension independently for each track.

free Pos. 135 - 139

Fan motor Pos. 140

The gear motor with anti-cavitation valve is drivingthe fans for the radiators.

Anti cavitation valve Pos. 141

The check valve acts as an anti-cavitation valve forthe fan motor when the engine is shut down.

free Pos. 142 - 160

4-spool control block Pos. 161

Servo controlled 4-spool blocks for the functions:Boom, Stick, Shovel tip and Shovel dump.With anti - cavitation valves and secondary reliefvalves. They are pilot controlled with variable set-tings.

free Pos. 162

free Pos. 163

Float valve Pos. 164

The float valves save time and energy when low-ering the boom or the arm. The valves connect thepiston and rod sides of the cylinders so that thepiston rods retract only as a result of the attach-ment`s own dead weight. Only the excess oil (pis-ton - side chamber has a greater volume than therod - side) is allowed to escape to the tank. Themain pumps (3) are not activated. If it is required tolower the boom or the arm with pressure, the

float valves can be switched off using solenoidvalve (105/Y 10).

free Pos. 165

free Pos. 166

Check valve Pos. 167

These two check valves protect the two HP filters(32) for main pumps (P 3 & P 4). When the exca-vator is being run on only one engine, the flowsfrom the relevant main pumps would run throughthe control blocks (161) and then into the filters inthe wrong direction. This would destroy the filters.

free Pos. 168

free Pos. 169

free Pos. 170- 181


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Boom cylinder Pos. 182

The two double-acting hydraulic cylinders are in-

stalled between superstructure and boom. Theyare lifting or lowering the boom and thus the com-plete working equipment.

Arm cyl inder Pos. 183

The two double-acting hydraulic cylinders are in-stalled between boom and arm and ensure exten-sion and retraction of the arm.

Bucket crowd cylinder Pos. 184

The two double-acting hydraulic cylinders are in-stalled between the TriPower and the bucketbackwall and are used to turn the bucket.

free Pos. 185

Clamshell cylinder Pos. 186

The two double-acting hydraulic cylinders are in-stalled between backwall and frontlip and are usedto open and close the bucket.

Distributor block Pos. 187

The block is installed in the backwall and containsa pressure relief valve.

The pressure relief valve secures the clamshell-cylinder rod-side against pressure peaks.

free Pos. 188

Distributor Pos. 189

The block allows for pressure balance betweenboth bucket crowd cylinders (184).


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8.3.4 Hydraulic circuit diagram

The position nos. in the circuit diagram Part-No. 3 672 750 are referred to chapter 8.3.2.


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8.3 DESCRIPTION OF THE HYDRAULIC SYSTEM - BH

RH 200 Diesel (BH) - 3657772e.doc - (01) - 07.03 Page 8.3 - 1

8.3 Description of the hydraulic system

8.3.1 Technical data

The technical data of the hydraulic system are listed in chapter 2 Technical Data.

8.3.2 Components of the circuit diagram

The posit ion nos. refer to c ircu it d iagram No. 3 672 770 (03) in chapter 8.3.4


1 2 Engine Engine module

2 2 Pump transfer gearbox Engine module

3 4 Main pump A7V - SL - 1000 Pump gearbox

4 4 Swing pump A4V 250 Pump gearbox

5 ----

6 4 Servo pump Pump gearbox

7 2 Charge pump for swing system Pump gearbox

8 ----

9 ----

10 4 Cooling pump KP 5 - 300 Pump gearbox

11 2 Fan pump A 10 V for radiator fan Pump gearbox

12 - 22 ----

23 2 Pump governing valve Engine module

24 ----

25 1 Proportional valve plate Operator module

26 2 Solenoid valve bank Operator module

27 ----

28 1 Track tensioning block Engine module

29 1 Distributor plate (main pumps) Engine module


31 4 2 way valve Position 29

32 4 High pressure filter Position 29

33 ----

34 4 Filter Engine module

35 1 3/2 way solenoid valve for emergency lowering Operator module

36 1 Filter for proportional valve plate Operator module

37 1 Check valve

38 ----


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Page 8.3 - 2 RH 200 Diesel (BH) - 3657772e.doc - (01) - 07.03


39 ----

40 1 Servo oil valve block Engine module41 ----

42 ----

43 4 Check valve

44 2 Check valve Position 40

45 ----

46 1 Block with 4/2 way solenoid valve

47 1 Shuttle valve

48 49 ----

50 1 Hydraulic cylinder for access ladder

51 1 Control valve for access ladder

52 1 Accumulator for access ladder

53 55 ----

56 1 Shuttle valve Engine module

57 - 59 ----

60 1 Hydraulic oil tank Superstructure

61 2 Gate valve Hydraulic oil tank

62 2 Return oil filter Hydraulic oil tank

63 6 Bypass valve Hydraulic oil tank

64 4 Tank line pressurizing valve Hydraulic oil tank

65 ----

66 2 Check valve Hydraulic oil tank

67 - 79 ----

80 4 Hydraulic oil cooler Oil cooler module

81 4 Fan motor Oil cooler module

82 ----

83 ----

84 4 Fan Oil cooler module

85 2 Distributor plate (oil cooling) Oil cooler module


87 4 Thermostat Position 85

88 ----

89 ----

90 1 Travel block Superstructure

91 1 Rotor Superstructure


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92 1 Travel valve block RH Rotor

93 1 Travel valve block LH Rotor 94 ----

95 1 Travel retarder valve RH Travel block

96 1 Travel retarder valve LH Travel block

97 4 Anti cavitation valve Travel block

98 ----

99 ----

100 4 Swing gearbox Superstructure

101 1 Shuttle valve

102 4 Swing motor Swing gearbox

103 4 Blocking valve Engine module

104 ----

105 1 Pressure governing valve Engine module

106 1 Flushing valve Engine module

107 2 High pressure filters Superstructure

108 ----

109 1 Pressure relief valve Engine module

110 - 119 ----

120 2 Travel gearbox Undercarriage

121 4 Travel motor Travel gearbox

122 - 124 ----

125 1 Valve block (secondary relief) Undercarriage


127 - 129 ----

130 2 Track tensioning cylinder Undercarriage

131 2 Diaphragm accumulator Undercarriage

132 ----

133 1 Track tensioning group Undercarriage

134 2 Pressure relief valve

135 - 139 ----

140 2 Gear motor for radiator fan Counterweight

141 2 Block with anti cavitation valve for fan motor Position 140

142 - 160

161 2 4-spool control valve Boom

162 ----


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163 ----

164 2 Float valve Boom165 ----

166 ----

167 2 Check valve

168 ----

169 ----

170 4 Throttled check valve Pos. 161 & 164

171 4 Throttled check valve

172 - 181 ----

182 2 Boom cylinder Boom

183 2 Stick cylinder Boom

184 ----

185 2 Bucket cylinder Stick

186 ----

187 ----

188 4 Distributor Boom


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8.3.3 Components of the hydraulicsystem of the RH 200 (BH)

At tention!

Position nos. are referred to circuit diagramPart-No. 3 672 770 (03) in chapter 8.3.4.

Some items are numbered on the schematicbut not mentioned here. They are not importantfor the hydraulic functioning.

Drive unit Pos. 1

The two water - cooled Cummins engines are 12 -cylinder V engines with turbo-charging and inter -cooling.

Pump transfer gearbox Pos. 2

Each of the 3 - stage spur - wheel gearboxes isdriven via a diaphragm coupling from one of theengines and distributes engine output to the rele-vant hydraulic pumps.

Variable - d isplacement pump Pos. 3

The 4 main pumps for working equipment andtravel movements are axial - piston bent axispumps with slipper bearing. Slipper bearings arehydraulically swimming bearings that increasethe pump`s service life.

Swing pump Pos. 4

The 4 swing pumps to move the superstructure arevariable - displacement axial - piston swash platepumps. They are especially suited for operation inclosed circuits. The pump flow is infinitely variableand increases from 0 to max while the pumprotary group is being tilted out. If the swash plate isde-stroked through the zero position, the direc-tion of the oil flow is altered smoothly.

free Pos. 5

Servo pump Pos. 6

The 4 servo pumps are fixed - displacement gear -

type pumps that are mounted on the pump transfergearboxes (2) and that supply the servo circuit (40bar) and the auxiliary circuit (70 bar).

Axial piston pump A 10 V Pos. 7

The 2 pressure regulated axial piston pumps areworking as charge pumps for the swing circuit.

free Pos. 8

free Pos. 9

Oil cooling pump Pos. 10

Four fixed - displacement gear - type pumps aremounted onto the swing pumps (4). They con-stantly draw oil from the tank and pump it to thefan motors and the oil coolers.

Fan pump A 10 V Pos. 11

The fan wheel for water cooling of the diesel en-gine is driven by an adjustable axial-piston pumpper drive unit. The volume flow of the pump andthus the speed of the fan wheel is electronicallycontrolled as a function of the water temperature.

free Pos. 12 - 22

Pump governing valve Pos. 23

The group comprises two proportional valves, twometering connections and a housing.These valves control the main pumps (3). They arecontrolled by the microprocessor in the PMS sys-tem and govern the flows from the main pumpsdepending upon the actual pressure. Each pair ofmain pumps is governed by one proportional valve.The valves are actuated by adjustable, oil - im-

mersed DC solenoids and transform electricalcurrents proportionally into hydraulic pressure.


44/278



A solenoid current of 830 mA corresponds to apressure of 42 bar in the pump governors. A cur-rent of 230 mA corresponds to 10 bar.

free Pos. 24

Proportional valve plate Pos. 25

The valve plate contains the proportional valvesand the 3/2 way valves for operation of cylinders,swing and travel function.

Valve bank, compl. Pos. 26

An assembly group comprising four solenoidvalves and a housing.

free Pos. 27


The valve is changing the track tensioning pres-

sure between 50 bar and 70 bar mode.

Distributor plate for main pumpsPos. 29

An assembly group comprising four primary pres-sure relief valves (36), four two - way valves (37),four caps (38), four high - pressure filters (39) anda housing with two check valves. The two checkvalves isolate the main pumps (3/P1 & P2) fromthe pumps (3/P3 + P4) when only the right - handengine is running.


The relief valves are used as primary pressurerelief valves for the main pumps. They limit themaximum pressure that can be reached by thepumps (3) and therefore protect the systemagainst overload.

The valves are pilot controlled and have variablesettings.

2 - way valve Pos. 31

Four valves for the logical co - ordination of themain pumps (3).They isolate the main pumps against one anotherand prevent a stationary engine from being turnedover by it's pumps when only the other engine isrunning.

The 2 - way valves are shifted by solenoids (24/Y32 & Y 33).

Co - ordination of the valves - see solenoid valve(24).


The high - pressure filters in the high - pressurelines from the main pumps protect the downlineunits (e. g. control blocks and cylinders) againstmetal chips and particles from the pumps (3).Other than in the return flow filters (29), the oil

flows through the HP filters from outside to in.

free Pos. 33

Filter Pos. 34

Filter the oil flows from the 4 swing circuit chargepumps.

3/2 way solenoid valve Pos. 35

The solenoid valve is operated with a button in thejoy stick. It allows lowering of the attachment incase of a sudden engine shut-down.

Filter Pos. 36

This filter is filtering the oil which is feeding the

proportional valve plate (25).


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Check valve Pos. 37

The check valve prevents loss of oil out of the ac-

cumulator (52) for the access ladder.

free Pos. 38

free Pos. 39

Servo oil valve block Pos. 40

The complete assembly group comprises two fil-ters, the differential pressure valve, a pressurerelief valve, two check valves and a housing.

free Pos. 41

free Pos. 42

Check valve Pos. 43

The four valves prevent negative influencing ofmain pump pressures (3/P1 & P2) when only one

Travel pedal is actuated. The valves crack openat approx. 1 bar.

Check valve Pos. 44

These two valves prevent either of the servopumps (6) from affecting the other, e. g. when onlyone engine is running, they prevent oil beingpumped back into the tank through the stationaryservo pump.

free Pos. 45

Block with solenoid valve Pos. 46

The block carries the solenoid valves for the logicalco - ordination of the four main pumps (3).


The shuttle valve is connecting either the control

pressure for the travel brakes or the control pres-sure for the 2-speed operation to the travel motors.

free Pos. 48 - 49

Cylinder for access ladder Pos. 50

The hydraulic cylinder is operating the accessladder.

Control valve Pos. 51

With the control valve the cylinder for the accessladder is operated.

Accumulator Pos. 52

The accumulator supplies pressure oil for emer-

gency lowering of the access ladder in case of asudden engine shut-down.

free Pos. 53 - 55


Via this shuttle valve the Y1 & Y2 ports of thepressure governing valve (54) are connected withthe pressure relief valve (55)

free Pos. 57 - 59

Hydraulic oil tank Pos. 60

The tank stores all of the oil for the system andcontains two return flow filters (62), six by - passvalves (63), four tank line pressurizing valves (64),a check valve (66) and a pressure switch.


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Gate valve for intake line Pos. 61

The gate valves can be used to isolate the hydrau-

lic pumps from the oil tank. This makes it possibleto remove pumps without having to drain all of theoil from the tank.

Return flow filter Pos. 62

Each return flow filter contains 7 filter elements toclean the oil returning from inside to out. Any metalchips are trapped by the magnetic rods installedabove the filters.

By - pass valve Pos. 63

The six by - pass valves open at a pressure of 1.5bar and prevent the return flow filters (62) bursting,e. g. due to clogging. Oil then flows unfiltered backinto the tank.

Tank l ine pressurizing valve Pos. 64

These four valves have fixed settings of approx. 12bar. They are arranged in the return lines and keepa constant level of pressure in the hydraulic sys-tem.

free Pos. 65

Check valve Pos. 66

These two valves have a cracking pressure ofapprox. 1 bar and prevent oil escaping from:

the servo caps on control block (161) for boom andstick float functions (164)

free Pos. 67 - 79

Hydraulic oil cooler Pos. 80

Pass the heat generated in the hydraulic system

on to the atmosphere using the air flows createdby the fans.

Fan motor Pos. 81

Four fixed - displacement gear - type motors areused to drive the fans on the oil coolers.

free Pos. 82

free Pos. 83

Fan Pos. 84

The fan produces the air flow to cool down thehydraulic oil.

Distributor plate for oil cooling Pos. 85

Each of the two plates contains two thermostats(87), two pressure relief valves (86) and two checkvalves. The check valves function as anti - cavita-tion valves while the engines are being shut down.


The two pilot controlled, variable setting pressurerelief valves protect the cooler circuit against over-

pressure, e. g. in case of a line blockage.

Thermostat Pos. 87

The four thermostats are fully open at oil tem-peratures under 40C. The majority of the oil thenflows directly back into the tank. As the tempera-ture rises, the thermostats begin to close so thatan increasing amount of oil flows through the fanmotors and the coolers. At 52C the thermostats

are fully closed and the full oil flow passes throughthe fan motors to the coolers.


47/278



free Pos. 88

free Pos. 89

Travel block Pos. 90

A complete group comprising rotor (91), theTravel spools (92 & 93), the travel retarder valves(95 & 96), anti - cavitation valves (97) and coverplates.

Rotor Pos. 91

Conducts hydraulic oil flows between superstruc-ture and undercarriage. The seven ring channelsare for:

Travel (4 channels)

Track parking brakes/Track motor adjustment

Track tensioning

Leakage oil

Travel valve block RH Pos. 92

A servo - controlled single - spool block that actu-ates the right - hand track.

Travel valve block LH Pos. 93

A servo - controlled single - spool block that actu-ates the left - hand track.

free Pos. 94

Travel retarder valve RH Pos. 95

Prevents the excavator from running away down-hill and keeps the track motors full of oil (to avoidcavitation). The speed of the track motors is then

always determined by the working pressure of thepumps (3).

Travel retarder valve LH Pos. 96

See travel retarder valve (95).

Anti - cavitat ion valve Pos. 97

The four valves mounted on the Travel spools(92 & 93) keep a constant column of oil in the trackmotors. They crack open at the slightest pressureso that oil can be drawn in from the tank line.

free Pos. 98

Swing gearbox Pos. 100

The gearbox are 2 - stage planetary reducers.

The spring applied multi disc brakes on the swinggearboxes serve to hold the superstructure sta-tionary (parking brakes). They are actuated by atoggle switch in the cab.The brake must only be actuated when the super-structure has stopped swinging.

free Pos. 101

Swing motor Pos. 102

The swing motors are 40, fixed - displacementaxial piston pumps whose output speed is propor-tional to the flow of oil. The output torque increaseswith the pressure drop over the motor.

Blocking valve Pos. 103

These valves are leak free and are opened fully byoil from the servo pumps (6) as soon as the en-gines are running. If one of the engines is shutdown, the relevant blocking valves close absolutelytightly and prevent the stationary engine from be-ing turned over by pressure oil acting in reversethrough swing motor, swing pump and transfergearbox.

free Pos. 104


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Pressure governing valve Pos. 105

Governs the torque in the closed - loop swing cir-

cuit.

The valve governs the pressure and direction of oilflow (and therefore extent and direction of theswing motors` output ) depending upon the se-lected control pressureThe radio between control pressure and workingpressure is approx. 1 : 12, i. e. 10 bar control pres-sure on ports (Y 1 or Y 2) corresponds to 120 baroperating pressure in the swing circuit.

Flushing valve Pos. 106

The valve flushes the oil in the closed - loop swingcircuit. Each time a swing function is summoned, acertain amount of oil is flushed out of the low pres-sure side. The charge pumps mounted on theswing pumps replace this oil with filtered, cooled oilfrom the tank.


The two HP filters in the swing circuit clean bothsides of the swing circuit. The check valves in thefilter heads lead the oil flows to the correct side toflow through the filters. This is necessary as thehigh and low - pressure sections of the circuitchange depending upon the direction of swing.

free Pos. 108


The valve limits the pressure that controls thepressure governing valve (54) to max. 31 bar. Thevalve is direct acting and has a variable setting.

free Pos. 110 - 119

Travel gearbox Pos. 120

3 - stage planetary reducer with integrated parkingbrake.

The four track parking brakes are wet, multi - diskbrakes that are engaged under spring force andreleased by hydraulic pressure (18 - 20 bar).

Travel motor Pos. 121

The four track motors are variable - displacement,bent - axis motors with tandem bearing arrange-ments. Servo pressure at port (X) sets the motorsto either of two mechanically limited tilt angles. Themaximum tilt angle is selected when servo pres-sure is O . The minimum tilt angle is reachedwhen servo pressure rises above 40 - 45 bar.

max. tilt angle = max. motor displacement = max.output torque = min. output speed

min. tilt angle = min. motor displacement = min.output torque = max. output speed

The governing pressure (at least 15 bar) is tappedout of the respective high - pressure side usingcheck valves.

free Pos. 122 - 124

Secondary relief block Pos. 125

Assembly group comprising four pressure reliefvalves (77), two metering connections and ahousing.


Secondary pressure relief valves for the four trackmotors that protect the motors against externalforces. Excess oil is cracked off into the relevantlowpressure side of the motors.

free Pos. 127 - 129

Track tensioning cylinder Pos. 130

Single - acting (plunger) cylinders that keep thecrawler tracks tensioned.


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Diaphragm accumulator Pos. 131

The nitrogen accumulators act as shock absorbers

to dampen external forces acting on the crawlertracks.

free Pos. 132


The block contains the valves for the automatictrack tensioning system.


The track-tensioning assembly comprises 2 pres-sure-relief valves with hand wheel and 2 testpoints.The hand wheels can be used to relieve the hy-draulic track tension independently for each track.

free Pos. 135 - 139

Fan motor Pos. 140

The gear motor with anti-cavitation valve is drivingthe fans for the radiators.

Anti cavitation valve Pos. 141

The check valve acts as an anti-cavitation valve for

the fan motor when the engine is shut down.

free Pos. 142 - 160

4-spool control block Pos. 161

Servo controlled 4-spool blocks for the functions:Boom, Stick, Shovel tip and Shovel dump.With anti - cavitation valves and secondary reliefvalves. They are pilot controlled with variable set-

tings.

free Pos. 162

free Pos. 163

Float valve Pos. 164

The float valves save time and energy when low-ering the boom. The valves connect the piston androd sides of the cylinders so that the piston rodsretract only as a result of the attachment`s owndead weight. Only the excess oil (piston - sidechamber has a greater volume than the rod - side)is allowed to escape to the tank. The main pumps(3) are not activated. If it is required to lower the

boom with pressure, the float valves can beswitched off using solenoid valve (105/Y 10).

free Pos. 165

free Pos. 166

Check valve Pos. 167

These two check valves protect the two HP filters(32) for main pumps (P 3 & P 4). When the exca-vator is being run on only one engine, the flows

from the relevant main pumps would run throughthe control blocks (161) and then into the filters inthe wrong direction. This would destroy the filters.

free Pos. 168

free Pos. 169

Throttled check valve Pos. 170

The check valves in the cylinder lines ensuresmooth operation of the attachment.

Throttled check valve Pos. 171

The check valves in the cylinder lines ensuresmooth operation of the attachment.

free Pos. 172- 181


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Boom cylinder Pos. 182

The two double-acting hydraulic cylinders are in-

stalled between superstructure and boom. Theyare lifting or lowering the boom and thus the com-plete working equipment.

Stick cylinder Pos. 183

The two double-acting hydraulic cylinders are in-stalled between boom and stick and ensure exten-sion and retraction of the arm.

free Pos. 184

Bucket cylinder Pos. 185

The two double-acting hydraulic cylinders are in-stalled between the linkage of the bucket and thestick and are used to turn the bucket.

free Pos. 186

free Pos. 187

Distributor Pos. 188

The block allows for pressure balance betweenboth stick cylinders (183) and also between bothbucket cylinders (185).


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8.3.4 Hydraulic circuit diagram

The position nos. in the circuit diagram Part-No. 3 672 770 are referred to chapter 8.3.2.


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8.4 HYDRAULIC COMPONENTS

RH 200 Diesel - 3657769e.doc - (02) 09.03 Page 8.4 - 1

8.4 Hydraulic components

8.4.1 Main pumps

Each pump is equipped with a pressure-controlledregulator (1, Fig. 1) with a control range of between7,5 and 42,5 bar. At a control pressure of 42,5 barat the X1 port of the regulator, the pump is swiv-elled out to maximum flow-rate. At a control pres-sure of 7,5 bar, it is swivelled back to "zero" flow-rate.

The regulator is controlled by an electro-magneticproportional valve connected to the electronic load-limit regulator. (See also THB "PMS - Pump Man-aging System").

Fig. 1 Main pump regulator

Function

The pressure oil required to swing out the pumps istaken from the pump flow. It is constantly availablein chamber (C) of the regulator cylinder (2). Atoperating pressures below 60 bar, chamber (C) ispressurized via connection (X 2) with oil from theauxiliary circuit. Otherwise it would be impossibleto swing out the pump.

At the same time the regulator piston (1) is pres-surized via the proportional valve and connection(X 1) with oil (max. 42.5 bar). It now connects the

chamber (A) of the regulator cylinder with the tank.The pump swings out completely and supplies itsmaximum output.

If the pressure at the connection (X 1) is reducedby the load limit regulator, the regulator piston (1)

is operated by spring force. The chambers (A + C)of the regulator cylinder (2) are interconnected. Aspiston (B) has adjusting areas of different sizes,the forces in chamber (A) are predominant. Thepump is reset to a smaller output until there is abalance of forces.

With the restrictors (3) the swing speed of thepump has been set at the factory.

Pressure cut-off

When the maximum working pressure of 320 bar isreached in the system, the automatic pressure cut-off becomes active.The pressure cut-off valve (4) is opened by thesystem pressure and connects the chambers (A +C) of the regulator cylinder (2) with each other. Thepump now swings to such a small output that thesystem pressure is reliably maintained.

Via port Pst the cut-off pressure is increased dur-ing travel mode to 360 bar.

Important:

The engine speed is increasing to approx. 1 900rpm, as less power is needed by the pumps.

Contamination switch

If the oil in a pump is contaminated with metal par-ticles, the contamination switch (S 64) switches ona relevant warning indicator in the cab.


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Page 8.4 - 2 RH 200 Diesel - 3657769e.doc (02) 09.03

8.4.2 Swing pump

The swing pump is a variable displacement axial-piston pump in swash-plate design for closed-

circuits.

The volume flow is proportional to the drive speedand displacement volume and is infinitely adjust-able.With increasing swing-out, the swash-plate in-creases the volume flow from 0 up to its maximumvalue.If the swash-plate is adjusted through the zeroposition, the volume flow changes its direction offlow smoothly.

To protect the drive system, the pump is equipped

with two pressure relief valves for the respectivehigh-pressure side.These valves act simultaneously as feed valves.An integrated auxiliary pump serves as a feedpump. The max. feed pressure is ensured by theinstalled feed-pressure relief valve.

Torque control

Depending on the pre-selected control pressure,the service pressure as well as the pressure direc-tion and thus the level and direction of the torqueat the hydraulic motor are controlled infinitely ad-justably.

This control permits virtually loss-free utilisation ofthe drive system for both acceleration and brakingoperations. No power is converted into heat bymeans of pressure relief valves, and during thebraking operation the braking energy is fed backinto the pump transfer gearbox and relieves thedrive motor.

High pressure and control pressure are in a ratio of12:1, i.e. the high pressure available at the hydrau-lic motor is theoretically approx. 12 times as highas the control pressure applied at the pump regu-lator.


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8.4.3 Rotor

The rotor is connecting the hydraulic systems ofthe superstructure and the undercarriage.

The numbers of the ports and oil grooves and theirfunction is listed in table 1.

The components of the rotor are listed in table 2and shown in fig. 1 & 2.

Numbering of ports

Ref. No. Quantity Designation Further remarks Weight[kg]

1 1 Groove for travelling left forward

2 1 Groove for travelling left reverse3 1 Groove for travelling right forward

4 1 Groove for travelling right reverse

5 1 Groove for track tensioning system

6 1 Groove for travel parking brake

7 1 Groove for leakage oil

Table 1

Fig. 1 Grooves in rotor


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Components

Ref. No. Quantity Designation Further remarks Weight

[kg]1 1 Piston 99

2 1 Housing 229

3 1 Cover plate

4 1 Cover plate

5 1 Disc

6 ----

7 1 Ball bearing

8 1 Ball bearing

9 1 V - ring

10 1 Sealing ring

11 7 Rotor seal

12 1 O-ring

13 1 O-ring

14 1 Bottom plate 30

15 20 ----

21 4 Block

22 1 Securing ring

23 ----

24 6 Cyl. Head bolt M 10 x 30 - 8.8 Tightening torque Md = 46 Nm

25 4 Cyl. Head bolt M 16 x 45 - 8.8 Tightening torque Md = 170 Nm

26 2 Lifting eye M 16

27 8 Hex. bolt M 10 x 30 - 8.8 Tightening torque Md = 46 Nm

28 2 Straight pin

29 4 Sealing ring

30 4 Plug

Table 2


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24, 25, 27

Fig. 2 Rotor


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24, 25, 27

Fig. 3 Rotor


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Remove rotor seals

If worn seals are removed from the rotor housingwith a mandrel or a marking tool, the edges or

groove boards in the rotor housing might be dam-aged.

This can be prevented by using a bracket made of

welding wire 4 mm, against which the mandrel issupported as the seals are lifted out.

Removal (Figs. 4 + 5)

Knock mandrel (14) carefully into sealing ring(12).

Insert wire bracket (13) over mandrel (14) andpush to centre of groove board.

Lever sealing ring (12) with mandrel (14) out ofgroove, then press or draw out of rotor housing(10).

Check groove boards (11) and groove edgesfor damage, deburring carefully and thencleaning thoroughly if necessary.

Fig. 4 Removing the rotor seals

Fig. 5

Documents

Sistema Hidraulico.pdf