Sistema Hidraulico.pdf

Technical Handbook RH 200 8. Hydraulic system TEREX Germany GmbH & Co. KG

3 663 488.00 en

Editor:

TEREX Germany GmbH & Co. KG Department 910 – Product Support D-44149 Dortmund, Karl-Funke-Str. 36

 Copyright

Phone:

++49 / 231 / 922-4901

Fax:

++49 / 23 231 / 92 922-5900

by TEREX, Printed in Germany

Editor:

TEREX Germany GmbH & Co. KG Department 910 – Product Support D-44149 Dortmund, Karl-Funke-Str. 36

 Copyright

Phone:

++49 / 231 / 922-4901

Fax:

++49 / 23 231 / 92 922-5900

by TEREX, Printed in Germany

CONTENTS

8.

HYDRAULI AULIC C SYSTEM 8.1

8.2

8.3

8.3

8.4

In tr tr od od uc uc ti ti on on ......................................................................................8.1 - 1 8.1. 8.1.1 1

Fore Forewo word rd ...... ......... ...... ..... ..... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... ..... ...... ...... ...... ...... ...... ...... ...... ...... .....8. ..8.1 1-1

8.1. 8.1.2 2

Safe Safety ty ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... .....8. ..8.1 1 -1

8.1. 8.1.3 3

Gene Genera ral.... l....... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... .....8. ..8.1 1-5

Depressuriz pressurizing, ing, blee bleeding, flushing flushing ....................... ................................. ...................... ...............8.2 ....8.2 - 1 8.2. 8.2.1 1

Depr Depres essu suriz rizin ing g of the the hydr hydrau auli lic c syst system em ..... ........ ...... ...... ...... ..... ..... ...... ...... ....8.2 .8.2 - 1

8.2. 8.2.2 2

Blee Bleedi ding ng of the the hydr hydrau auli lic c syst system em ...... ......... ..... ..... ...... ...... ...... ...... ...... ...... ...... ...... ....8.2 .8.2 - 3

8.2. 8.2.3 3

Flus Flushi hing ng of the the hydr hydrau auli lic c syst system em ...... ......... ..... ..... ...... ...... ...... ...... ...... ...... ...... ...... ....8.2 .8.2 - 5

Description scription (Faceshove ceshovel). l)........... ..................... ...................... ...................... ...................... .....................8.3 ..........8.3 - 1 8.3. 8.3.1 1

Tech Techni nica call dat data a ..... ........ ...... ...... ..... ..... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ......8 ...8.3 .3 - 1

8.3. 8.3.2 2

Comp Compon onen ents ts of the the hydr hydrau auli lic c sche schema matic... tic...... ...... ...... ...... ...... ..... ..... ...... .....8. ..8.3 3-1

8.3. 8.3.3 3

Comp Compon onen ents ts of the the hydr hydrau auli lic c syst system.. em..... ...... ...... ...... ...... ...... ...... ..... ..... ...... .....8. ..8.3 3-5

8.3. 8.3.4 4

Hydr Hydrau aulic lic circ circui uitt diag diagra ram m ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ....8.3 .8.3 - 13

Descript scription ion (Backh Backhoe oe)) .....................................................................8.3 - 1 8.3. 8.3.1 1

Tech Techni nica call dat data a ..... ........ ...... ...... ..... ..... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ......8 ...8.3 .3 - 1

8.3. 8.3.2 2

Comp Compon onen ents ts of the the hydr hydrau auli lic c sche schema matic... tic...... ...... ...... ...... ...... ..... ..... ...... .....8. ..8.3 3-1

8.3. 8.3.3 3

Comp Compon onen ents ts of the the hydr hydrau auli lic c syst system.. em..... ...... ...... ...... ...... ...... ...... ..... ..... ...... .....8. ..8.3 3-5

8.3. 8.3.4 4

Hydr Hydrau aulic lic circ circui uitt diag diagra ram m ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ....8.3 .8.3 - 13

Hydra ydraul ulic ic comp compon one ents. nts.....................................................................8.4 ....................................................................8.4 - 1 8.4. 8.4.1 1

Main Main pump pumps s ...... ......... ...... ..... ..... ...... ...... ..... ..... ...... ...... ...... ...... ...... ...... ...... ..... ..... ...... ...... ..... ..... ...... ......8 ...8.4 .4 - 1

8.4. 8.4.2 2

Swin Swing g pum pump.... p....... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ....8.4 .8.4 - 2

8.4. 8.4.3 3

Roto Rotor.... r....... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ......8 ...8.4 .4 - 3

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

Page 8 - 1

CONTENTS

8.5

8.6

8.4. 8.4.4 4

Valv Valve e bloc blocks ks ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ....8. .8.4 4-5

8.4. 8.4.5 5

Other Other comp compon onen ents ts ...... ......... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... ..... ...... ...... ...... ......8 ...8.4 .4 - 34

Descript scription ion of hydra hydrauli ulic c circui circuits. ts............. ....................... ...................... ...................... ..................8.5 .......8.5 - 1 8.5.1

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

8.5.2

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

8.5.3

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

8.5.4

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

8.5.4

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

8.5.5

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

8.5.6

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

8.5.7

Track tensioning system ............ ....................... ...................... ...................... ...............8.5.7 ....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 ............................................8.5.9 - 1

8.5.10

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

Pressure ressure checking checking and setting. setting........................................................8.6 .......................................................8.6 - 1 8.6. 8.6.1 1

Intro Introdu duct ctio ion.... n....... ...... ...... ..... ..... ...... ...... ..... ..... ...... ...... ...... ...... ...... ...... ...... ..... ..... ...... ...... ..... ..... ...... ......8 ...8.6 .6 - 1

8.6. 8.6.2 2

Pres Pressu sure re set settin tings.... gs....... ...... ...... ...... ...... ...... ...... ..... ..... ...... ...... ...... ...... ...... ..... ..... ...... ...... ...... ...... ....8.6 .8.6 - 3

8.6. 8.6.3 3

Tool Tools... s...... ..... ..... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... ..... ...... ...... ......8 ...8.6 .6 - 4

8.6. 8.6.4 4

Hydr Hydrau aulic lic syst system ems s ...... ......... ...... ...... ...... ...... ..... ..... ...... ...... ...... ...... ...... ..... ..... ...... ...... ...... ...... ......8 ...8.6 .6 - 5

8.7

Installa nstallation tion of hydra hydraulic ulic pumps. pumps.......................................................8.7 - 1

8.8

Hydraulic ydraulic cylinde cylinders rs (Faceshov ceshove el). l)....................................................8.8 - 1

Page 8 - 2

8.8. 8.8.1 1


8.8. 8.8.2 2

Desi Design gn conf config igur urati ation.... on....... ...... ..... ..... ...... ...... ..... ..... ...... ...... ...... ...... ...... ..... ..... ...... ...... ...... ......8 ...8.8 .8 - 3

8.8. 8.8.3 3

Asse Assemb mbly ly ...... ......... ...... ...... ...... ...... ..... ..... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... .....8. ..8.8 8 - 11 11

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CONTENTS

8.8. 8.8.4 4 8.8

Tigh Tighte teni ning ng torq torque ues..... s........ ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... ..... ...... ...... ...... ...... ....8.8 .8.8 - 24 24

Hydraulic ydraulic cylinde cylinders rs (Backho Backhoe e) ........................................................8.8 - 1 8.8. 8.8.1 1


8.8. 8.8.2 2

Desi Design gn conf config igur urati ation.... on....... ...... ..... ..... ...... ...... ..... ..... ...... ...... ...... ...... ...... ..... ..... ...... ...... ...... ......8 ...8.8 .8 - 3

8.8. 8.8.3 3

Asse Assemb mbly ly ...... ......... ...... ..... ..... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... ..... ...... ...... ...... .....8. ..8.8 8-9

8.8. 8.8.4 4

Tigh Tighte teni ning ng torq torque ues..... s........ ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... ..... ...... ...... ...... ...... ....8.8 .8.8 - 22 22

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Page 8 - 3

CONTENTS

Page 8 - 4

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

8.1

HYDRAULIC SYSTEM

8.1

Introduction

8.1.2

Safety Instructions

8.1.1

Foreword

8.1.2.1

Danger in the event of non-observance of the safety instructions

The Technical Handbook contains important information for personnel servicing the machine. Machine specifications listed elsewhere in the machine documents are not always repeated in this book. The documentation of an TEREX Mining machine includes: •

the operating instructions

•

the spare-parts list

•

the technical handbook

The present brochure does not contain the specifications of auxiliary units for the operation of additional or optional equipment or the specifications of individual machines. The refilling quantities specified for consumables are approximate quantities which are intended as a help for planning consumable requirements. Each unit is equipped with suitable checking devices, e.g. dipstick or checking plugs, permitting the operator to check proper filling of the units.

2440575e - (00) - 11.96

This TEREX hydraulic excavator has been built in accordance with state-of-the-art standards and the recognized safety rules. However, operating the machine if a fault is suspected or has occurred, or carrying out repair work inexpertly may •

endanger the lives of persons in contact with it

•

damage the machine and other property.

The hydraulic excavator must be stopped immediately on any damage being suspected or occurring to ensure that the safety of the operator, of other persons at the place of use or of other material property is not compromised. All components of TEREX machines are carefully co-ordinated. Trouble-free operation and a long service life can only be achieved with original TEREX spare parts.

Page 8.1 - 1

8.1

HYDRAULIC SYSTEM

8.1.2.2

Rules for safety at work

Personnel Personnel The machine must not be started by unauthorized persons. It must therefore be secured. Observe the accident prevention regulations. The hydraulic excavator may be operated, serviced or repaired only by specially trained and authorized personnel with the appropriate technical know-how. If such know-how is lacking, meticulous instruction must be given by experienced personnel, e.g. from TEREX. The personnel must have read and understood the operating instructions and in particular the chapter ‘Fundamental Safety Instructions.’ Only such persons may start up the machine during assembly work in order to adjust the attachments.

Personal protective working clothing:

gear

and

Wear a safety helmet, safety footwear and gloves. Wear closely fitting working clothing when working on the machine. Loose, wide garments may catch on machine parts and result in in jury. Persons carrying out work at greater heights must be equipped with safety harnesses. Always put on a tested harness which must be equipped with fall arrestors and safety lines. If the work to be carried out requires auxiliaries, e.g. marshallers, the competences of each individual helper must be clearly defined beforehand. The individual responsibilities must be meticulously observed to avoid unclear competences endangering safety.

Incorrect operation of the machine or the attachments may give rise to life-threatening situations. During all works, always observe the start-up and shut-down procedures prescribed in the operating instructions.

Page 8.1 - 2

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8.1

HYDRAULIC SYSTEM

Tools and auxiliaries Tools, hoists, slings, trestles and other devices must be in a reliable, safe state. Metal splinters may cause injury when attachment bolts are being driven in or out. A brass or copper mandrel should therefore be used for this purpose, and goggles must be worn. For climbing onto or off the machine, use only the ladders, steps, platforms and handrails provided for this purpose. Always keep ladders, steps and platforms in a non-slip state. Remove any oil, grease, earth, clay, snow, ice and other foreign matter immediately.

Securing the working equipment Before carrying out assembly work, the machine and the attachments must be secured against inadvertent and unauthorized starting, e.g. by placing chocks under the wheels or tracks and by standing the working equipment on the ground. Stand the working equipment on the ground in such a way that no movements can be made when mechanical or hydraulic connections become detached. Secure any equipment or component which is to be mounted or dismantled or whose position is to be changed using hoists or appropriate slinging/supporting devices to prevent them from moving, slipping or falling inadvertently.

2440575e - (00) - 11.96

Systems and units (e.g. pipes, coolers, hydraulic reservoirs, compressed-air reservoirs) must be properly depressurized before being opened. Protective devices on moving machine parts may be opened or removed only when the drive unit is stationary and protected against inadvertent starting. Before recommissioning, all protective devices must be refitted. Before carrying out assembly work, the machine and the equipment must be secured against inadvertent starting, e.g. by placing chocks under the wheels or tracks and by standing the working equipment on the ground.

Hydraulic and lubricating system: Always observe the safety regulations applicable to the product when handling oils, greases and other chemical substances. Unused but open bores, pipelines and hose connections must be closed in a pressure-tight manner. Refill collected hydraulic oil back into the hydraulic system only through the return-flow filters. Dispose of waste oil without polluting the environment. Observe the correct working sequence when fitting or replacing components or equipment. The working sequence has been specified and tested by qualified experts. .

Page 8.1 - 3

8.1

HYDRAULIC SYSTEM

8.1.2.3 When carrying out work and especially work on the electrical system involving tools, spare parts, etc. coming into contact with electric cables, the battery main switch must be set to the 'OFF' position.

Unauthorized conversions or modifications of the hydraulic excavator are forbidden for reasons of safety. The nominal pressure of pressure relief valves must not be modified without explicit approval from TEREX. Do not remove the lead seals from pressure-relief valves and pressure accumulators.

Replace defective, mechanically prestressed units only as an entirety. Never open them. In exceptional cases, open only when the system and the operating sequence are precisely known. The Technical Manual contains no information on such work. When the machine is at operating temperature, the consumables are at least at the same temperature. Precautions must therefore be taken to prevent burning or scalding. Be careful when handling acids, e.g. battery acid. Acid splashes may injure the eyes and the skin. Do not smoke when flammable liquids.

handling

Be careful with naked flames and unprotected light. Not only fuel but also other consumables often have a low flash point and catch fire easily.

Page 8.1 - 4

Conversions or modifications to the machine

8.1.2.4

Recommissioning

Prior to recommissioning: •

Grease all lubricating points.

•

Check all oil levels and make the necessary corrections.

•

Carry out function checks of all repaired components

•

Check all functions of the excavator including the brakes during a test run. Release the hydraulic excavator for recommissioning only after all functions have been found to work perfectly.

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8.1

HYDRAULIC SYSTEM

8.1.3

General

In addition to the operating instructions and the spare-parts list, the present Technical Manual contains information enabling the user of the TEREX hydraulic excavator to safely operate, maintain and repair the machine in accordance with the specifications. The information supplied in the Technical Manual represents the standard version of the machine as delivered. All sketches and drawings are merely schematic. They do not necessarily represent the machine's actual state of design and must not be used as manufacturing documents.

After delivery, the Technical Manual is not sub ject to revision. Technical changes introduced into the series production after delivery of the machine may also be implemented in machines already in use. In such case, already delivered Technical Manuals are normally not automatically updated. All technical documents issued by TEREX Germany GmbH are written in German and then translated. Even a good translation may give rise to questions which your TEREX dealer or your TEREX distributing centre will be pleased to answer. This Technical Manual has been carefully prepared by the competent divisions.

No reference is made to special versions. If any points are nevertheless unclear or incorrect, please contact your local TEREX dealer or your TEREX distributing centre.

2440575e - (00) - 11.96

Page 8.1 - 5

8.1

HYDRAULIC SYSTEM

Page 8.1 - 6

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8.2

DEPRESSURIZING, BLEEDING, FLUSHING

8.2

Depressurizing, bleeding, flushing of the hydraulic system All personnel carrying out commissioning, operation, inspection, service and repair must have read and understood the operating instructions and in particular the chapter ‘Fundamental Safety Instructions.’ before starting any work.

8.2.1 Depressurizing of the hydraulic system Hydraulic systems are only to be opened up when they are free of pressure. It is possible for considerable back pressure to be present in the hydraulic-systems, e.g. primary pressure from the last movement, even when the excavator is parked on a level surface with its equipment on the ground (Figs. 1 and 2). Residual pressure drops only gradually. If work is to be carried out on the hydraulic system(s) immediately after stopping the excavator, then the system(s) is/are to be freed of pressure.

Before working on the hydraulic system make sure, that the system is depressurized and remaining pressures are relieved. Shut off the engine(s). Components (e.g. hydraulic tank, cylinders, valves) may be hot and cause severe burns. Secure the machine before working on it. Avoid contact of hydraulic oil with the skin. This can be harmful. 630213.SKD

Always wear safety glasses, safety gloves and firm protective clothing.

Fig. 1

Parking position of FS-machine

630214.SKD

Fig. 2

RH 200 Diesel - 2471385e - (00) – 10.99

Parking position of BH-machine

•

Release pressure from the part of the system (it may be necessary to use several procedures).

•

Carefully open up the part of the system.

Page 8.2 - 1

8.2


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)

Fig. 4

Safety switch in seat

Section 1) and 2): Main working circuit and servo control circuit Section 3): Track tensioning system −

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

The track tensioning circuit has to be depressurized by completely opening (screwing out) the safety valves in the undercarriage.

Section 4): Swing circuit The swing system has to be depressurized with help of the Minimeß-ports (test-ports).

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

Fig. 3

−

Operation of joysticks and pedals

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

Page 8.2 - 2

Be extreme carefully when working on hydraulic cylinders or pressure lines of the equipment! Even when following the safety procedure, there may still a certain pressure be left in the system!

RH 200 Diesel - 2471385e - (00) – 10.99

8.2 8.2.2

DEPRESSURIZING, BLEEDING, FLUSHING Bleeding air from the hydraulic system

Bleed air from hydraulic pumps, hydraulic motors, hydraulic cylinder and servo circuits: •

before commissioning the excavator, e.g. following major servicing/repair to the hydraulics, or after a long period out of operation.

•

after each oil change

Check the hydraulic system under load. Listen for noises in the pumps of motors. Jerky movements are an indication of air pockets in the system. Actuate all hydraulic functions several times to eliminate the air pockets.

The intake and running characteristics of the hydraulic components can otherwise be greatly affected. Hydraulic oil also serves as a lubricant for these components. A “dry run” can lead to total failure in a very short time. Hydraulic pumps and -motors Bleed air from pumps and motors after each oil change. To bleed, fill clean oil through the highest leakage oil port up to the bottom edge of the port. Main pumps: Swing pumps:

Fig. 5

Port (T, Fig. 5) Port (T1, Fig. 5)

Bleeding points

RH 200 Diesel - 2471385e - (00) – 10.99

Page 8.2 - 3

8.2

DEPRESSURIZING, BLEEDING, FLUSHING The first operation of the cylinders has to be carried out with reduced oil flow, to extend or extract the piston rod as slowly as possible.

Hydraulic cylinders

1

Servo circuit On machines with pilot lines connected to the side of the servo cap loosen the bleeder plug (5, Fig. 8) with engine running until oil emerges without bubbling. 2

3 630254.SKD

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) must be either fully extended or fully retracted.

1 4

2 Fig. 8

Bleeding plugs

When the pilot lines are connected to the upper ports of the servo caps the system is bleeding air automatically. 630255.SKD

Fig. 7

cylinder extended

Always admit oil to the side of the cylinder where the piston (2) is positioned. •

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

•

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

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

Page 8.2 - 4

RH 200 Diesel - 2471385e - (00) – 10.99

8.2


8.2.3

Flushing the hydraulic system

The following instructions are a brief compilation of the procedures needed to clean/flush the hydraulic system. The functions and the designs of the individual components are described in the relevant sections of the Technical Handbook. It is assumed that the machine remains on site while flushing is being carried out. Hydraulic components, e.g. cylinders, should only be overhauled/repaired in an enclosed, clean workshop. If the hydraulic component (e.g. pump or cylinder) is damaged, the system(s) must be checked to see whether any chips from the component have entered into the system. To do this, remove and inspect the magnetic rods and return flow filters.

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 have seized. Pieces of guide bands, O-rings and seals are then often to be found in the filters. Individual parts that appear to be pieces of springs or valve plates: Damaged valve(s).

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

1. Flushing is required under following conditions: •

•

•

If the quantity, size and appearance of the metal particles on the magnetic rod is different to that arising in normal operation, or if they are of completely different nature. If the amount of magnetic and non-magnetic “debris” caught in the return flow filter is greater than usual. Whenever a damaged hydraulic component has been changed. Flushing can be limited to the immediate and upline vicinities of the component, as long as these can be isolated completely.

RH 200 Diesel - 2471385e - (00) – 10.99

Page 8.2 - 5

8.2


3. Steps in case of pump damage 3.1 Determine damaged pump, typical symptoms are:

4. Steps in case of cylinder damage •

• •

• • • • • •

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)

•

•

•

Remove and check return flow filter. Trace damaged cylinder. Remove, strip, clean and check all components. Also remove, strip, clean and check any cylinders connected in parallel. When reassembling, cylinders are always to be fitted with new seals and guides. Fit the cylinder but do not connect the oil lines.

3.2 Pumps without high pressure filters: • •

•

Remove return flow filters and check for contamination.

•

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.

•

Flush and check operation (see section 8). If further contamination is found when flushing, remove all cylinders, and strip, clean and inspect. Drain and clean the oil.

If metal contamination from the pump has got into the hydraulic system, carry out all of the procedures from section 4 to 8 even if damage to other components has not been identified.

3.3 Pumps with high pressure filters •

Remove the damaged pump.

•

Remove/clean HP filter(s).

•

•

Remove and clean line between pump and HP filter. Remove new pump, clean HP filter and clean connecting lines.

•

Fit new return filter elements.

•

Fill oil through return flow filters.

•

Put machine back to work.

Page 8.2 - 6

RH 200 Diesel - 2471385e - (00) – 10.99

8.2


5. Steps in case of valve damage Locate the damaged valve(s).

•

If all of the missing parts are found, it is only necessary to change the valve. Further action is not needed.

•

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

•

− − −

Return flow filter Oil tank Components downline of the damaged valve, e.g. cylinders, valves, motors.

6. Further steps If the hydraulic system has been extensively contaminated with chips, the following procedures are also necessary: Strip, clean and re-install the primary relief valves.

•

Strip, clean and re-install the secondary relief valves.

•

Clean and check the cooling circuit if contamination is found in the oil tank:

•

−

−

•

•

RH 200 Diesel - 2471385e - (00) – 10.99

Remove the cooler. Clean outside and inside in both directions of flow. The cooler is to be changed if the contamination cannot be completely removed from the cooling fins. Flush the hydraulic lines or blow through with compressed air. Check and clean the servo control valves. If hydraulically driven ancillary attachments are fitted, their systems must also be checked, especially if the cause of the contamination cannot be traced in the excavator’s systems. Follow the relevant manufacturer’s instructions.

Page 8.2 - 7

8.2


7. Flushing procedure The extent of flushing required depends upon the point at which the contamination has entered. All downline and branching systems are to be flushed back to the filter(s). The filter(s) must be checked thoroughly to determine whether they have stopped all contamination from flowing further: 7.1 In case of pump damage (pump without high pressure filter):

7.2 In case of pump damage (pump with high pressure 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 a new return flow element.

•

Fill fresh oil through the return flow filter.

•

•

Connect the lines to individual consumers directly (short circuit). Disconnect lines that are still connected to consumers.

•

•

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

•

Summon each hydraulic function one at a time and for approx. 1 minute in each direction. Shift several times briefly into neutral. Each consumer should be run for at least 5 minutes.

•

• •

•

•

•

Change return filter element and clean magnetic rod. Repeat the flushing procedure. Again actuate all consumers, one after the other, but this time only for a short period.

Fit new return flow element. Short circuit the connections to the replacement cylinder. Run the engine up to max. speed. Wait until filter warning light has gone out and the 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 least 5 minutes. Change return flow element and clean magnetic rod. Repeat flushing procedure, with all consumers being actuated briefly, one after the other. Check return flow filter and magnetic rod again.

•

Connect cylinder correctly and bleed air.

•

Check oil level in tank.

•

Put excavator back to work.

Check filter and magnetic rod again. Connect all consumers correctly and bleed air from the system.

•


•


Page 8.2 - 8

RH 200 Diesel - 2471385e - (00) – 10.99

8.2


7.4 In case of damage of hydraulic motor: •

•

•

•

•

•

Fit new return flow element. Short circuit the connections to the replacement motor. Summon hydraulic function of the replaced motor in both directions for approx. 1 minute. Shift several times briefly into neutral. Change return flow element and clean magnetic rod. Repeat flushing procedure, with all consumers being actuated briefly, one after the other.

8.

Monitoring in operation

After working for approx. 1 minute, check the magnetic rod. Clean the rod if contamination is found. Check again in increasing intervals.

If the amount of contamination does not drop noticeably, or if it even increases, it must be assumed that the real cause of the damage has not been located and removed. Check and flush again.

Check return flow filter and magnetic rod again.

•

Connect motor correctly and bleed air.

•


•


RH 200 Diesel - 2471385e - (00) – 10.99

Page 8.2 - 9

8.2


Page 8.2 - 10

RH 200 Diesel - 2471385e - (00) – 10.99

8.3

DESCRIPTION OF THE HYDRAULIC SYSTEM - FS

8.3

Description of the hydraulic system

8.3.1

Tec hn ic al d at a

The technical data of the hydraulic system are listed in chapter 2 ‘Technic al Data’.

8.3.2

Components of the circuit diagram

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

Quantity

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

Designation

Location

----

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

24

Pump governing valve

Engine module

----

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

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

Engine module

----

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

Page 8.3 - 1

8.3


Position

Quantity

39 40

Designation ----

1

Servo oil valve block

41

----

42

----

43

4

Check valve

44

2

Check valve

45

Engine module

Position 40

----

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

Location

---1

57 - 59

Shuttle valve

Engine module

----

60

1

Hydraulic oil tank

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

Superstructure

---2

67 - 79

Check valve

Hydraulic oil tank

----

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

86

4


Position 85

87

4

Thermostat

Position 85

88

----

89

----

90

1

Travel block

Superstructure

91

1

Rotor

Superstructure

Page 8.3 - 2

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

8.3


Position

Quantity

92

1

Travel valve block RH

Rotor

93

1

Travel valve block LH

Rotor

94

Designation

Location

----

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

101

1

Shuttle valve

102

4

Swing motor

Swing gearbox

103

4

Blocking valve

Engine module

104

Superstructure

----

105

1

Pressure governing valve

Engine module

106

1

Flushing valve

Engine module

107

2

High pressure filters

Superstructure

108 109

---1

110 - 119


Engine module

----

120

2

Travel gearbox

Undercarriage

121

4

Travel motor

Travel gearbox

122 - 124

----

125

1

Valve block (secondary relief)

126

4


127 - 129

Undercarriage Position 125

----

130

2

Track tensioning cylinder

Undercarriage

131

2

Diaphragm accumulator

Undercarriage

132

----

133

1

Track tensioning group

134

2


135 - 139

Undercarriage

----

140

2

Gear motor for radiator fan

141

2

Block with anti cavitation valve for fan motor

2

4-spool control valve

Counterweight Position 140

142 - 160 161 162

Boom

----

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

Page 8.3 - 3

8.3


Position

Quantity

163 164

Designation ----

4

Float valve

165

----

166

----

167

Location

2

Boom

Check valve

168

----

169

----

170 - 181

----

182

2

Boom cylinder

Boom

183

2

Stick cylinder

Boom

184

2

Bucket crowd cylinder

Boom

186

2

Clam cylinder

Backwall

187

1

Distributor with relief valve

Backwall

185

188 189

Page 8.3 - 4

---2

Distributor with check point

Boom

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

8.3

8.3.3


Components of the hydraulic sys tem of t he RH 200 (FS)

At ten ti on ! Position nos. are referred to circuit diagram Part-No. 3 672 750 (03) in chapter 8.3.4. Some items are numbered on the schematic but n ot m entioned here. They are not important for 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 transf er gearbox

Pos. 2

Each of the 3 - stage spur - wheel gearboxes is driven via a diaphragm coupling from one of the engines and distributes engine output to the relevant hydraulic pumps.

Var iab le - d is pl ac em en t p um p

Po s. 3

The 4 main pumps for working equipment and travel movements are axial - piston bent axis pumps with slipper bearing. Slipper bearings are hydraulically „swimming“ bearings that increase the pump`s service life.

Servo pump

The 4 servo pumps are fixed - displacement gear type pumps that are mounted on the pump transfer gearboxes (2) and that supply the servo circuit (40 bar) and the auxiliary circuit (70 bar).

Ax ial pi st on pu mp A 10 V

free

Pos. 8

free

Pos. 9

Oil cooling pump

Pos. 10

Four fixed - displacement gear - type pumps are mounted onto the swing pumps (4). They constantly draw oil from the tank and pump it to the fan motors and the oil coolers.

Fan pump A 10 V

Pos. 11

The fan wheel for water cooling of the diesel engine is driven by an adjustable axial-piston pump per drive unit. The volume flow of the pump and thus the speed of the fan wheel is electronically controlled as a function of the water temperature.

Pos. 12 - 22

Pos. 4 Pump governing valve

The 4 swing pumps to move the superstructure are variable - displacement axial - piston swash plate pumps. They are especially suited for operation in closed circuits. The pump flow is infinitely variable and increases from „0“ to „max“ while the pump rotary group is being tilted out. If the swash plate is de-stroked through the „zero“ position, the direction of the oil flow is altered smoothly.

free

Pos. 7

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

free Swing pump

Pos. 6

Pos. 5

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

Pos. 23

The group comprises two proportional valves, two metering connections and a housing. These valves control the main pumps (3). They are controlled by the microprocessor in the PMS system and govern the flows from the main pumps depending upon the actual pressure. Each pair of main pumps is governed by one proportional valve. The valves are actuated by adjustable, oil - immersed DC solenoids and transform electrical currents proportionally into hydraulic pressure.

Page 8.3 - 5

8.3


A solenoid current of 830 mA corresponds to a pressure of 42 bar in the pump governors. A current of 230 mA corresponds to 10 bar.

The valves are pilot controlled and have variable settings.

free

Pos. 24

2 - way valve


Pos. 25

Four valves for the logical co - ordination of the main pumps (3). They isolate the main pumps against one another and prevent a stationary engine from being turned over by it's pumps when only the other engine is running.

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

Valve bank, compl.

Pos. 26

Pos. 31

The 2 - way valves are shifted by solenoids (24/Y 32 & Y 33). Co - ordination of the valves - see solenoid valve (24).

An assembly group comprising four solenoid valves and a housing.

High - pressure filter free Track tensioning block

Pos. 27 Pos. 28

The valve is changing the track tensioning pressure between 50 bar and 70 bar mode.

Distributor plate for main pumps Pos. 29 An assembly group comprising four primary pressure relief valves (36), four two - way valves (37), four caps (38), four high - pressure filters (39) and a housing with two check valves. The two check valves isolate the main pumps (3/P1 & P2) from the pumps (3/P3 & P4) when only the right - hand engine is running.


Pos. 32

Pos. 30

The relief valves are used as primary pressure relief valves for the main pumps. They limit the maximum pressure that can be reached by the pumps (3) and therefore protect the system against overload.

The high - pressure filters in the high - pressure lines from the main pumps protect the downline units (e. g. control blocks and cylinders) against metal chips and particles from the pumps (3). The filter elements are differential pressure resistant and do not have a bypass valve. The oil flows through the HP filters from outside to inside.

free

Pos. 33

Filter

Pos. 34

Filter the oil flows from the 4 swing circuit charge pumps.

3/2 way solenoid valve

Pos. 35

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

Filter

Pos. 36

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

Page 8.3 - 6

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

8.3


Check valve

Pos. 37

The check valve prevents loss of oil out of the accumulator (52) for the access ladder.

free

Pos. 38

free

Pos. 39


Pos. 40

The complete assembly group comprises two filters, two pressure relief valves, two check valves and a housing.

Shuttle valve

The shuttle valve is connecting either the control pressure for the travel brakes or the control pressure for the 2-speed operation to the travel motors.

free Cylinder for access ladder

Pos. 41

free

Pos. 42

Check valve

Pos. 43

The four valves prevent negative influencing of main pump pressures (3/P1 & P2) when only one „Travel“ pedal is actuated. The valves crack open at approx. 1 bar.

Pos. 50

Pos. 51

With the control valve the cylinder for the access ladder is operated.

Ac cu mu lat or

Pos. 52

The accumulator supplies pressure oil for emergency lowering of the access ladder in case of a sudden engine shut-down.

free Check valve

Pos. 48 - 49

The hydraulic cylinder is operating the access ladder.

Control valve free

Pos. 47

Pos. 53 - 55

Pos. 44 Shuttle valve

These two valves prevent either of the servo pumps (6) from affecting the other, e. g. when only one engine is running, they prevent oil being pumped 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 logical co - ordination of the four main pumps (3).

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

Pos. 56

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

free Hydraulic oil tank

Pos. 57 - 59 Pos. 60

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

Page 8.3 - 7

8.3


Gate valve for intake line

Pos. 61

The gate valves can be used to isolate the hydraulic pumps from the oil tank. This makes it possible to remove pumps without having to drain all of the oil from the tank.


The hydraulic oil coolers pass the heat generated in the hydraulic system on to the atmosphere using the air flows created by the fans.

Fan motor Return flow filter

Po s. 64

These four valves have fixed settings of approx. 12 bar. They are arranged in the return lines and keep a constant level of pressure in the hydraulic system.

free

Pos. 65

Check valve

Pos. 66

These two valves have a cracking pressure of approx. 1 bar and prevent oil escaping from: the servo caps on control block (161) for boom and stick „float“ functions (164)

free

Page 8.3 - 8

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

free

Pos. 82

free

Pos. 83

Fan

Pos. 84

Pos. 63

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

Tan k l in e p res su ri zi ng v al ve

Pos. 81

Pos. 62

Each return flow filter contains 7 filter elements to clean the oil returning from inside to out. Any metal chips are trapped by the magnetic rods installed above the filters.

By - pass valve

Pos. 80

Pos. 67 - 79

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

Distributor plate for oil cooling Pos. 85 Each of the two plates contains two thermostats (87), two pressure relief valves (86) and two check valves. The check valves function as anti - cavitation valves while the engines are being shut down.


Pos. 86

The two pilot controlled, variable setting pressure relief valves protect the cooler circuit against overpressure, e. g. in case of a line blockage.

Thermostat

Pos. 87

The four thermostats are fully open at oil temperatures under 40°C. The majority of the oil then flows directly back into the tank. As the temperature rises, the thermostats begin to close so that an increasing amount of oil flows through the fan motors and the coolers. At 52°C the thermostats are fully closed and the full oil flow passes through the fan motors to the coolers. RH 200 Diesel (FS) - 3657771e.doc - (01) - 07.03

8.3


free

Pos. 88


free

Pos. 89

See travel retarder valve (95).

Travel block

Pos. 90 An ti - cav itat io n v alv e

A complete group comprising rotor (91), the „Travel“ spools (92 & 93), the travel retarder valves (95 & 96), anti - cavitation valves (97) and cover plates.

Rotor

Pos. 96

Pos . 97

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

Pos. 91

free

Pos. 98

Conducts hydraulic oil flows between superstructure and undercarriage. The seven ring channels are for:

free

Pos. 99

Swing gearbox

•

Travel (4 channels)

•

Track parking brakes/Track motor adjustment

•

Track tensioning

•

Leakage oil


The gearbox are 2 - stage planetary reducers. The spring applied multi disc brakes on the swing gearboxes serve to hold the superstructure stationary (parking brakes). They are actuated by a toggle switch in the cab. The brake must only be actuated when the superstructure has stopped swinging.

Pos. 92

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


Pos. 100

Pos. 93

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

free

Pos. 94


Pos. 95

Prevents the excavator from „running away“ downhill and keeps the track motors full of oil (to avoid cavitation). The speed of the track motors is then always determined by the working pressure of the pumps (3).

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

Shuttle valve

Pos. 101

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

Swing motor

Pos. 102

The swing motors are 40°, fixed - displacement axial piston pumps whose output speed is proportional to the flow of oil. The output torque increases with the pressure drop over the motor.

Blocking valve

Pos. 103

These valves are leak free and are opened fully by oil from the servo pumps (6) as soon as the enPage 8.3 - 9

8.3


gines are running. If one of the engines is shut down, the relevant blocking valves close absolutely tightly and prevent the stationary engine from being turned over by pressure oil acting in reverse through swing motor, swing pump and transfer gearbox.

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

free free

Pos. 104


Pos. 105

Governs the torque in the closed - loop swing circuit. The valve governs the pressure and direction of oil flow (and therefore extent and direction of the swing motors` output ) depending upon the selected control pressure The radio between control pressure and working pressure is approx. 1 : 12, i. e. 10 bar control pressure on ports (Y 1 or Y 2) corresponds to 120 bar operating pressure in the swing circuit.

Flushing valve

Pos. 106

The valve flushes the oil in the closed - loop swing circuit. Each time a swing function is summoned, a certain amount of oil is flushed out of the low pressure side. The charge pumps mounted on the swing pumps replace this oil with filtered, cooled oil from the tank.

High - pressure filter

Pos. 107

The two HP filters in the swing circuit clean both sides of the swing circuit. The check valves in the filter heads lead the oil flows to the correct side to flow through the filters. This is necessary as the high and low - pressure sections of the circuit change depending upon the direction of swing.

free Pressure relief valve

Travel gearbox

Pos. 110 - 119 Pos. 120

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

Travel motor

Pos. 121

The four track motors are variable - displacement, bent - axis motors with tandem bearing arrangements. Servo pressure at port (X) sets the motors to either of two mechanically limited tilt angles. The maximum tilt angle is selected when servo pressure is „O“ . The minimum tilt angle is reached when 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 tapped out of the respective high - pressure side using check valves.

free Secondary relief block

Pos. 122 - 124 Pos. 125

Assembly group comprising four pressure relief valves (126), two metering connections and a housing.

Pos. 108 Pos. 109


Pos. 126

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

Page 8.3 - 10

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

8.3


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

free 4-spool control block

free Track tensioning cylinder

Pos. 130

Pos. 131

The nitrogen accumulators act as shock absorbers to dampen external forces acting on the crawler tracks.

free

Pos. 132


Pos. 133

The block contains the valves for the automatic track tensioning system.


Pos. 134

The track-tensioning assembly comprises 2 pressure-relief valves with hand wheel and 2 test points. The hand wheels can be used to relieve the hydraulic track tension independently for each track.

free Fan motor

Pos. 161

Pos. 127 - 129

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


Pos. 142 - 160

Pos. 135 - 139 Pos. 140

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

free

Pos. 162

free

Pos. 163

Float valve

Pos. 164

The float valves save time and energy when lowering the boom or the arm. The valves connect the piston and rod sides of the cylinders so that the piston rods retract only as a result of the attachment`s own dead weight. Only the excess oil (piston - side chamber 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 or the arm with pressure, the „float“ valves can be switched 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 excavator is being run on only one engine, the flows from the relevant main pumps would run through the control blocks (161) and then into the filters in the wrong direction. This would destroy the filters.

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

free

Pos. 168

Pos. 141

free

Pos. 169

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

free

Pos. 170- 181

An ti c avi tati on val ve

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

Page 8.3 - 11

8.3


Boom cylinder

Pos. 182

The two double-acting hydraulic cylinders are installed between superstructure and boom. They are lifting or lowering the boom and thus the complete working equipment.

Ar m c yl in der

Pos. 183

The two double-acting hydraulic cylinders are installed between boom and arm and ensure extension and retraction of the arm.


Pos. 184

The two double-acting hydraulic cylinders are installed between the TriPower and the bucket backwall and are used to turn the bucket.

free

Pos. 185

Clamshell cylinder

Pos. 186

The two double-acting hydraulic cylinders are installed between backwall and frontlip and are used to open and close the bucket.

Distributor block

Pos. 187

The block is installed in the backwall and contains a pressure relief valve. The pressure relief valve secures the clamshellcylinder rod-side against pressure peaks.

free

Pos. 188

Distributor

Pos. 189

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

Page 8.3 - 12

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

8.3

8.3.4


Hydraulic circuit diagram

The position nos. in the circuit diagram PartNo. 3 672 750 are referred to chapter 8.3.2.

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

Page 8.3 - 13

8.3


Page 8.3 - 14

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

8.3

DESCRIPTION OF THE HYDRAULIC SYSTEM - BH

8.3


8.3.1

Tec hn ic al d at a


8.3.2



Quantity

1

2

Engine

Engine module

2

2


Engine module

3

4


Pump gearbox

4

4

Swing pump A4V 250

Pump gearbox

5

Designation

Location

----

6

4

Servo pump

Pump gearbox

7

2


Pump gearbox

8

----

9

----

8.3


8.3


8.3.1

Tec hn ic al d at a


8.3.2



Quantity

1

2

Engine

Engine module

2

2


Engine module

3

4


Pump gearbox

4

4

Swing pump A4V 250

Pump gearbox

5

Designation

Location

----

6

4

Servo pump

Pump gearbox

7

2


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

24

Pump governing valve

Engine module

----

25

1


Operator module

26

2

Solenoid valve bank

Operator module

27

----

28

1


Engine module

29

1


Engine module

30

4


Position 29

31

4

2 – way valve

Position 29

32

4


Position 29

33

----

34

4

Filter

35

1

3/2 way solenoid valve for emergency lowering

Operator module

36

1


Operator module

37

1

Check valve

38

Engine module

----

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

Page 8.3 - 1

8.3


Position

Quantity

39 40

Designation ----

1


41

----

42

----

43

4

Check valve

44

2

Check valve

45

Engine module

Position 40

----

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

Location

---1

57 - 59

Shuttle valve

Engine module

----

60

1

Hydraulic oil tank

61

2

Gate valve

Hydraulic oil tank

62

2

Return oil filter

Hydraulic oil tank

63

6

Bypass valve

Hydraulic oil tank

64

4


Hydraulic oil tank

65 66

Superstructure

---2

67 - 79

Check valve

Hydraulic oil tank

----

80

4


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

86

4


Position 85

87

4

Thermostat

Position 85

88

----

89

----

90

1

Travel block

Superstructure

91

1

Rotor

Superstructure

Page 8.3 - 2

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

8.3


Position

Quantity

92

1


Rotor

93

1


Rotor

94

Designation

Location

----

95

1


Travel block

96

1


Travel block

97

4

Anti – cavitation valve

Travel block

98

----

99

----

100

4

Swing gearbox

101

1

Shuttle valve

102

4

Swing motor

Swing gearbox

103

4

Blocking valve

Engine module

104

Superstructure

----

105

1


Engine module

106

1

Flushing valve

Engine module

107

2

High pressure filters

Superstructure

108 109

---1

110 - 119


Engine module

----

120

2

Travel gearbox

Undercarriage

121

4

Travel motor

Travel gearbox

122 - 124

----

125

1

Valve block (secondary relief)

126

4


127 - 129

Undercarriage Position 125

----

130

2


Undercarriage

131

2


Undercarriage

132

----

133

1

Track tensioning group

134

2


135 - 139

Undercarriage

----

140

2

Gear motor for radiator fan

141

2

Block with anti cavitation valve for fan motor

2


Counterweight Position 140

142 - 160 161 162

Boom

----

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

Page 8.3 - 3

8.3


Position

Quantity

163 164

Designation ----

2

Float valve

165

----

166

----

167

Location

2

Check valve

168

----

169

----

170

4

Throttled check valve

171

4


172 - 181

Boom

Pos. 161 & 164

----

182

2

Boom cylinder

Boom

183

2

Stick cylinder

Boom

184 185

---2

Bucket cylinder

186

----

187

----

188

Page 8.3 - 4

4

Distributor

Stick

Boom

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

8.3

8.3.3


Components of the hydraulic sys tem of the RH 200 (BH)

At ten ti on ! Position nos. are referred to circuit diagram Part-No. 3 672 770 (03) in chapter 8.3.4. Some items are numbered on the schematic but n ot m entioned here. They are not important for 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 transf er gearbox

Pos. 2

Each of the 3 - stage spur - wheel gearboxes is driven via a diaphragm coupling from one of the engines and distributes engine output to the relevant hydraulic pumps.

Var iab le - d is pl ac em en t p um p

Po s. 3

The 4 main pumps for working equipment and travel movements are axial - piston bent axis pumps with slipper bearing. Slipper bearings are hydraulically „swimming“ bearings that increase the pump`s service life.

Servo pump

The 4 servo pumps are fixed - displacement gear type pumps that are mounted on the pump transfer gearboxes (2) and that supply the servo circuit (40 bar) and the auxiliary circuit (70 bar).

Ax ial pi st on pu mp A 10 V

free

Pos. 8

free

Pos. 9

Oil cooling pump

Pos. 10

Four fixed - displacement gear - type pumps are mounted onto the swing pumps (4). They constantly draw oil from the tank and pump it to the fan motors and the oil coolers.

Fan pump A 10 V

Pos. 11

The fan wheel for water cooling of the diesel engine is driven by an adjustable axial-piston pump per drive unit. The volume flow of the pump and thus the speed of the fan wheel is electronically controlled as a function of the water temperature.

Pos. 12 - 22

Pos. 4 Pump governing valve

The 4 swing pumps to move the superstructure are variable - displacement axial - piston swash plate pumps. They are especially suited for operation in closed circuits. The pump flow is infinitely variable and increases from „0“ to „max“ while the pump rotary group is being tilted out. If the swash plate is de-stroked through the „zero“ position, the direction of the oil flow is altered smoothly.

free

Pos. 7

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

free Swing pump

Pos. 6

Pos. 5

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

Pos. 23

The group comprises two proportional valves, two metering connections and a housing. These valves control the main pumps (3). They are controlled by the microprocessor in the PMS system and govern the flows from the main pumps depending upon the actual pressure. Each pair of main pumps is governed by one proportional valve. The valves are actuated by adjustable, oil - immersed DC solenoids and transform electrical currents proportionally into hydraulic pressure.

Page 8.3 - 5

8.3


A solenoid current of 830 mA corresponds to a pressure of 42 bar in the pump governors. A current of 230 mA corresponds to 10 bar.

The valves are pilot controlled and have variable settings.

free

Pos. 24

2 - way valve


Pos. 25


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

Valve bank, compl.

Pos. 26

Pos. 31


An assembly group comprising four solenoid valves and a housing.

High - pressure filter free Track tensioning block

Pos. 27 Pos. 28

The valve is changing the track tensioning pressure between 50 bar and 70 bar mode.

Distributor plate for main pumps Pos. 29 An assembly group comprising four primary pressure relief valves (36), four two - way valves (37), four caps (38), four high - pressure filters (39) and a housing with two check valves. The two check valves isolate the main pumps (3/P1 & P2) from the pumps (3/P3 + P4) when only the right - hand engine is running.


Pos. 30

The relief valves are used as primary pressure relief valves for the main pumps. They limit the maximum pressure that can be reached by the pumps (3) and therefore protect the system against overload.

Page 8.3 - 6

Pos. 32

The high - pressure filters in the high - pressure lines from the main pumps protect the downline units (e. g. control blocks and cylinders) against metal 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 charge pumps.

3/2 way solenoid valve

Pos. 35

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

Filter

Pos. 36

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

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

8.3


Check valve

Pos. 37

The check valve prevents loss of oil out of the accumulator (52) for the access ladder.

free

Pos. 38

free

Pos. 39


Pos. 40

The complete assembly group comprises two filters, the differential pressure valve, a pressure relief valve, two check valves and a housing.

free

Pos. 41

free

Pos. 42

Check valve

Pos. 43

Shuttle valve

The shuttle valve is connecting either the control pressure for the travel brakes or the control pressure for the 2-speed operation to the travel motors.

free Cylinder for access ladder

Check valve

Pos. 44


Control valve

Pos. 51

Pos. 52

The accumulator supplies pressure oil for emergency lowering of the access ladder in case of a sudden engine shut-down.

free Shuttle valve

Pos. 53 - 55 Pos. 56

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

Pos. 45

free

Block with solenoid valve

Pos. 46

Hydraulic oil tank

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

Pos. 50

With the control valve the cylinder for the access ladder is operated.

free

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

Pos. 48 - 49

The hydraulic cylinder is operating the access ladder.

Ac cu mu lat or The four valves prevent negative influencing of main pump pressures (3/P1 & P2) when only one „Travel“ pedal is actuated. The valves crack open at approx. 1 bar.

Pos. 47

Pos. 57 - 59 Pos. 60

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

Page 8.3 - 7

8.3


Gate valve for intake line

Pos. 61

The gate valves can be used to isolate the hydraulic pumps from the oil tank. This makes it possible to remove pumps without having to drain all of the oil from the tank.


Pass the heat generated in the hydraulic system on to the atmosphere using the air flows created by the fans.

Fan motor Return flow filter

Pos. 81

Pos. 62

Each return flow filter contains 7 filter elements to clean the oil returning from inside to out. Any metal chips are trapped by the magnetic rods installed above the filters.

By - pass valve

Pos. 80

Pos. 63

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

Four fixed - displacement gear - type motors are used 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 the hydraulic oil.

Distributor plate for oil cooling Pos. 85 Tan k l in e p res su ri zi ng v al ve

Po s. 64

These four valves have fixed settings of approx. 12 bar. They are arranged in the return lines and keep a constant level of pressure in the hydraulic system.

free

Pos. 65

Check valve

Pos. 66

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


Pos. 86


These two valves have a cracking pressure of approx. 1 bar and prevent oil escaping from: the servo caps on control block (161) for boom and stick „float“ functions (164)

free

Page 8.3 - 8

Pos. 67 - 79

Thermostat

Pos. 87

The four thermostats are fully open at oil temperatures under 40°C. The majority of the oil then flows directly back into the tank. As the temperature rises, the thermostats begin to close so that an increasing amount of oil flows through the fan motors and the coolers. At 52°C the thermostats are fully closed and the full oil flow passes through the fan motors to the coolers.

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

8.3


free

Pos. 88


free

Pos. 89

See travel retarder valve (95).

Travel block

Pos. 90 An ti - cav itat io n v alv e

A complete group comprising rotor (91), the „Travel“ spools (92 & 93), the travel retarder valves (95 & 96), anti - cavitation valves (97) and cover plates.

Rotor

Pos. 91

Conducts hydraulic oil flows between superstructure and undercarriage. The seven ring channels are for:

Pos. 96

Pos . 97

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

free Swing gearbox

Pos. 98 Pos. 100

The gearbox are 2 - stage planetary reducers. Travel (4 channels) Track parking brakes/Track motor adjustment Track tensioning Leakage oil


Pos. 92

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


Pos. 93

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

free

Pos. 94


Pos. 95

Prevents the excavator from „running away“ downhill and keeps the track motors full of oil (to avoid cavitation). The speed of the track motors is then always determined by the working pressure of the pumps (3).

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

The spring applied multi disc brakes on the swing gearboxes serve to hold the superstructure stationary (parking brakes). They are actuated by a toggle switch in the cab. The brake must only be actuated when the superstructure has stopped swinging.

free

Pos. 101

Swing motor

Pos. 102

The swing motors are 40°, fixed - displacement axial piston pumps whose output speed is proportional to the flow of oil. The output torque increases with the pressure drop over the motor.

Blocking valve

Pos. 103

These valves are leak free and are opened fully by oil from the servo pumps (6) as soon as the engines are running. If one of the engines is shut down, the relevant blocking valves close absolutely tightly and prevent the stationary engine from being turned over by pressure oil acting in reverse through swing motor, swing pump and transfer gearbox.

free

Pos. 104 Page 8.3 - 9

8.3



Pos. 105

Governs the torque in the closed - loop swing circuit.

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

The valve governs the pressure and direction of oil flow (and therefore extent and direction of the swing motors` output ) depending upon the selected control pressure The radio between control pressure and working pressure is approx. 1 : 12, i. e. 10 bar control pressure on ports (Y 1 or Y 2) corresponds to 120 bar operating pressure in the swing circuit.

Travel motor

Flushing valve

Pos. 106

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

The valve flushes the oil in the closed - loop swing circuit. Each time a swing function is summoned, a certain amount of oil is flushed out of the low pressure side. The charge pumps mounted on the swing pumps replace this oil with filtered, cooled oil from the tank.

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


Pos. 107

The two HP filters in the swing circuit clean both sides of the swing circuit. The check valves in the filter heads lead the oil flows to the correct side to flow through the filters. This is necessary as the high and low - pressure sections of the circuit change depending upon the direction of swing.

Pos. 121

The four track motors are variable - displacement, bent - axis motors with tandem bearing arrangements. Servo pressure at port (X) sets the motors to either of two mechanically limited tilt angles. The maximum tilt angle is selected when servo pressure is „O“ . The minimum tilt angle is reached when servo pressure rises above 40 - 45 bar.

The governing pressure (at least 15 bar) is tapped out of the respective high - pressure side using check valves.

free Secondary relief block

Pos. 122 - 124 Pos. 125

Assembly group comprising four pressure relief valves (77), two metering connections and a housing.

free

Pos. 108



Pos. 109

Secondary pressure relief valves for the four track motors that protect the motors against external forces. Excess oil is cracked off into the relevant lowpressure side of the motors.

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

free free Travel gearbox

Pos. 110 - 119 Pos. 120

3 - stage planetary reducer with integrated parking brake.

Page 8.3 - 10


Pos. 126

Pos. 127 - 129 Pos. 130

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

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

8.3



Pos. 131

free

Pos. 162

The nitrogen accumulators act as shock absorbers to dampen external forces acting on the crawler tracks.

free

Pos. 163

Float valve

Pos. 164

free

Pos. 132


Pos. 133

The block contains the valves for the automatic track tensioning system.


The float valves save time and energy when lowering the boom. The valves connect the piston and rod sides of the cylinders so that the piston rods retract only as a result of the attachment`s own dead weight. Only the excess oil (piston - side chamber 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 be switched off using solenoid valve (105/Y 10).

Pos. 134

free

Pos. 165

The track-tensioning assembly comprises 2 pressure-relief valves with hand wheel and 2 test points. The hand wheels can be used to relieve the hydraulic track tension independently for each track.

free

Pos. 166

Check valve

Pos. 167

free Fan motor

Pos. 135 - 139 Pos. 140

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

An ti c avi tati on val ve

4-spool control block

free

Pos. 168

free

Pos. 169


Pos. 170

Pos. 141

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

free

These two check valves protect the two HP filters (32) for main pumps (P 3 & P 4). When the excavator is being run on only one engine, the flows from the relevant main pumps would run through the control blocks (161) and then into the filters in the wrong direction. This would destroy the filters.

The check valves in the cylinder lines ensure smooth operation of the attachment.

Pos. 142 - 160 Pos. 161

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

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


Pos. 171

The check valves in the cylinder lines ensure smooth operation of the attachment.

free

Pos. 172- 181

Page 8.3 - 11

8.3


Boom cylinder

Pos. 182

The two double-acting hydraulic cylinders are installed between superstructure and boom. They are lifting or lowering the boom and thus the complete working equipment.

Stick cylinder

Pos. 183

The two double-acting hydraulic cylinders are installed between boom and stick and ensure extension and retraction of the arm.

free

Pos. 184

Bucket cylinder

Pos. 185

The two double-acting hydraulic cylinders are installed between the linkage of the bucket and the stick and are used to turn the bucket.

free

Pos. 186

free

Pos. 187

Distributor

Pos. 188

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

Page 8.3 - 12

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

8.3

8.3.4


Hydraulic circuit diagram

The position nos. in the circuit diagram PartNo. 3 672 770 are referred to chapter 8.3.2.

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

Page 8.3 - 13

8.3


Page 8.3 - 14

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

8.4

HYDRAULIC COMPONENTS

8.4

Hydraulic component s

8.4.1

Main pumps

Each pump is equipped with a pressure-controlled regulator (1, Fig. 1) with a control range of between 7,5 and 42,5 bar. At a control pressure of 42,5 bar at the X1 port of the regulator, the pump is swivelled out to maximum flow-rate. At a control pressure of 7,5 bar, it is swivelled back to "zero" flowrate. The regulator is controlled by an electro-magnetic proportional valve connected to the electronic loadlimit regulator. (See also THB "PMS - Pump Managing System").

If the pressure at the connection (X 1) is reduced by the load limit regulator, the regulator piston (1) is operated by spring force. The chambers (A + C) of the regulator cylinder (2) are interconnected. As piston (B) has adjusting areas of different sizes, the forces in chamber (A) are predominant. The pump is reset to a smaller output until there is a balance of forces. With the restrictors (3) the swing speed of the pump has been set at the factory.

Pressure cut-off When the maximum working pressure of 320 bar is reached in the system, the automatic pressure cutoff becomes active. The pressure cut-off valve (4) is opened by the system pressure and connects the chambers (A + C) of the regulator cylinder (2) with each other. The pump now swings to such a small output that the system pressure is reliably maintained. Via port Pst the cut-off pressure is increased during travel mode to 360 bar.

8.4


8.4

Hydraulic component s

8.4.1

Main pumps

Each pump is equipped with a pressure-controlled regulator (1, Fig. 1) with a control range of between 7,5 and 42,5 bar. At a control pressure of 42,5 bar at the X1 port of the regulator, the pump is swivelled out to maximum flow-rate. At a control pressure of 7,5 bar, it is swivelled back to "zero" flowrate. The regulator is controlled by an electro-magnetic proportional valve connected to the electronic loadlimit regulator. (See also THB "PMS - Pump Managing System").

If the pressure at the connection (X 1) is reduced by the load limit regulator, the regulator piston (1) is operated by spring force. The chambers (A + C) of the regulator cylinder (2) are interconnected. As piston (B) has adjusting areas of different sizes, the forces in chamber (A) are predominant. The pump is reset to a smaller output until there is a balance of forces. With the restrictors (3) the swing speed of the pump has been set at the factory.

Pressure cut-off When the maximum working pressure of 320 bar is reached in the system, the automatic pressure cutoff becomes active. The pressure cut-off valve (4) is opened by the system pressure and connects the chambers (A + C) of the regulator cylinder (2) with each other. The pump now swings to such a small output that the system pressure is reliably maintained. Via port Pst the cut-off pressure is increased during travel mode to 360 bar. Important: The engine speed is increasing to approx. 1 900 rpm, as less power is needed by the pumps.

Contamination swit ch

Fig. 1

Main pump regulator

If the oil in a pump is contaminated with metal particles, the contamination switch (S 64) switches on a relevant warning indicator in the cab.

Function The pressure oil required to swing out the pumps is taken from the pump flow. It is constantly available in chamber (C) of the regulator cylinder (2). At operating pressures below 60 bar, chamber (C) is pressurized via connection (X 2) with oil from the auxiliary circuit. Otherwise it would be impossible to swing out the pump. At the same time the regulator piston (1) is pressurized 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 its maximum output. RH 200 Diesel - 3657769e.doc - (02) – 09.03

Page 8.4 - 1

8.4

8.4.2


Swing pump

The swing pump is a variable displacement axialpiston pump in swash-plate design for closedcircuits. The volume flow is proportional to the drive speed and displacement volume and is infinitely adjustable. With increasing swing-out, the swash-plate increases the volume flow from 0 up to its maximum value. If the swash-plate is adjusted through the zero position, the volume flow changes its direction of flow smoothly. To protect the drive system, the pump is equipped with two pressure relief valves for the respective high-pressure side. These valves act simultaneously as feed valves. An integrated auxiliary pump serves as a feed pump. The max. feed pressure is ensured by the installed feed-pressure relief valve.

Torque control Depending on the pre-selected control pressure, the service pressure as well as the pressure direction and thus the level and direction of the torque at the hydraulic motor are controlled infinitely ad justably. This control permits virtually loss-free utilisation of the drive system for both acceleration and braking operations. No power is converted into heat by means of pressure relief valves, and during the braking operation the braking energy is fed back into the pump transfer gearbox and relieves the drive motor. High pressure and control pressure are in a ratio of 12:1, i.e. the high pressure available at the hydraulic motor is theoretically approx. 12 times as high as the control pressure applied at the pump regulator.

Page 8.4 - 2

RH 200 Diesel - 3657769e.doc – (02) – 09.03

8.4


8.4.3

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

Rotor

The rotor is connecting the hydraulic systems of the superstructure and the undercarriage. The numbers of the ports and oil grooves and their function is listed in table 1.

Numbering of port s Ref. No.

Quantity

Designation

Further remarks

1

1

Groove for travelling

left forward

2

1


left reverse

3

1


right forward

4

1


right reverse

5

1

Groove for track tensioning system

6

1

Groove for travel parking brake

7

1

Groove for leakage oil

Weight [kg]

Table 1

Fig. 1

RH 200 Diesel - 3657769e.doc - (02) – 09.03

Grooves in rotor

Page 8.4 - 3

8.4


Components Ref. No.

Quantity

1

1

Piston

2

1

Housing

3

1

Cover plate

4

1

Cover plate

5

1

Disc

6

Designation

Further remarks

Weight [kg] 99 229

----

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

15 – 20

30

----

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


26

2

Lifting eye M 16

27

8

Hex. bolt M 10 x 30 - 8.8

28

2

Straight pin

29

4

Sealing ring

30

4

Plug


Table 2

Page 8.4 - 4

RH 200 Diesel - 3657769e.doc – (02) – 09.03

8.4


24, 25, 27 Fig. 2

RH 200 Diesel - 3657769e.doc - (02) – 09.03

Rotor

Page 8.4 - 5

8.4


24, 25, 27 Fig. 3

Page 8.4 - 6

Rotor

RH 200 Diesel - 3657769e.doc – (02) – 09.03

8.4


Remove rot or seals If worn seals are removed from the rotor housing with a mandrel or a marking tool, the edges or groove boards in the rotor housing might be damaged. This can be prevented by using a bracket made of welding wire ∅ 4 mm, against which the mandrel is supported 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) and push to centre of groove board.

• Lever sealing ring (12) with mandrel (14) out of

Fig. 4

Removing the rotor seals

Fig. 5

Removal of the rotor seals

groove, then press or draw out of rotor housing (10).

• Check groove boards (11) and groove edges for damage, deburring carefully and then cleaning thoroughly if necessary.

RH 200 Diesel - 3657769e.doc - (02) – 09.03

Page 8.4 - 7

8.4


8.4.4

Hy dr au li c val ves


Ref.-no.

Quantity

Pos. 25

Designation

1

Servo valve block

2

1

Housing

3

16

3/2 way valve

4 5

The complete assembly group comprises 16 electro-hydraulic proportional valves and 16 safety valves (3/2 way valves).

further remarks

Weight [kg]

---16

electro-hydraulic proportional valve

6

----

7

----

8

16

O-ring

9

32

Plug

10

2

Plug

11

8

Plug

12

12

Plug

13

16

Plug

Table 1

Page 8.4 - 8

RH 200 Diesel - 3657769e.doc – (02) – 09.03

8.4


Fig. 1

RH 200 Diesel - 3657769e.doc - (02) – 09.03

Servo valve block wit proportional solenoids

Page 8.4 - 9

8.4


Fig. 2

Page 8.4 - 10

Servo valve block wit proportional solenoids

RH 200 Diesel - 3657769e.doc – (02) – 09.03

8.4


Solenoid valve block

Pos. 26/1

• •

The valve block contains 4 solenoid valves. Both ports P1 and P2 are connected to the auxiliary system (70 bar). The solenoid valves operate the following functions:

Ref.-no.

Quantity

1

1

• •

Outlet A5: not used. Outlet A6: Pressure boost of main pump 3 for function ‘open clam’. Outlet A7: Pressure boost of main pump 1 for function ‘open clam’. Outlet A8: Actuation of the swing parking brake.

Designation

further remarks


Electrical data:

Weight [kg]

Voltage: 24 V Output: 16 W Switch-on time: 100 % Hydraulical data: Max. pressure: 210 bar Rated flow ( Δp = 5 bar): 26 l/min. Max. flow: 35 l/min. Table 1

Fig. 1

RH 200 Diesel - 3657769e.doc - (02) – 09.03


Page 8.4 - 11

8.4



Pos. 26/2

The valve block contains 4 solenoid valves. The port P1 for then solenoid valves Y3 & Y4 is connected to the auxiliary system (70 bar). The port P2 for then solenoid valves Y1 & Y2 is connected to the servo system (40 bar).

The solenoid valves operate the following functions: • • • •

Ref.-no.

Quantity

1

1

Outlet A1: brake. Outlet A2: Outlet A3: tors. Outlet A4:

Actuation of the travel parking not used. Shifting of the 2-speed travel moTravel pressure increase.

Designation

further remarks


Electrical data:

Weight [kg]

Voltage: 24 V Output: 16 W Switch-on time: 100 % Hydraulical data: Max. pressure: 210 bar Rated flow ( Δp = 5 bar): 26 l/min. Max. flow: 35 l/min. Table 1

Fig. 1

Page 8.4 - 12


RH 200 Diesel - 3657769e.doc – (02) – 09.03

8.4


Pump distributor block

Pos. 29

An assembly group comprising four primary pressure relief valves (30), four two - way valves (31), four high - pressure filters (32) and a housing with two check valves. The two check valves isolate the main pumps (3/P1 & P2) from the pumps (3/P3 + P4) when only the right - hand engine is running.

Primary pressure relief valves

Pos. 30

Limit the maximum pressure that can be reached by the pumps (3) and therefore protect the primary movers against overload.



The high - pressure filters in the high - pressure lines from the main pumps protect the downline units (e. g. control blocks and cylinders) against metal chips and particles from the pumps (3). Other than in the return flow filters, the oil flows through the HP filters from outside to in.

Check valves 2 - way valves

Pos. 31


Designation

Pos. 32

Pos. 43

The four valves prevent negative influencing of main pump pressures (3/P1 & P2) when only one „Travel“ pedal is actuated. The valves crack open at approx. 1 bar.

Ref.-no.

Quantity

1

1

Housing

340

2

1

Plate

54

3

2

Flange

4

2

Cone

5

2

Spring seat

6

4

Cover

7

----

8

----

Weight [kg]

9

2

Spring

10

4


11

4


12

4

2-way valve

13

further remarks

39 each

----

14

2

Test point

15

3

Plug

16

2

Plug

17

4

Plug

18

8

Sealing ring

RH 200 Diesel - 3657769e.doc - (02) – 09.03

Minimeß M 14 x 1,5

Page 8.4 - 13

8.4


Ref.-no.

Quantity

19

2

O-ring

20

3

Sealing ring

21 - 24

Designation

further remarks

Weight [kg]

----

25

Cyl. head bolt M 5 x 16 – 8.8

Tightening torque Md = 4,9 Nm

26



27

16

Hex. Bolt M 16 x 255 – 10.9


28

6



29

8

Hex. Bolt M 8 x 75 – 8.8


30

2

Lifting eye M 16

Table 1

25, 26, 27, 28, 29 Fig. 1

Page 8.4 - 14


RH 200 Diesel - 3657769e.doc – (02) – 09.03

8.4


25, 26, 27, 28, 29 Fig. 2

RH 200 Diesel - 3657769e.doc - (02) – 09.03


Page 8.4 - 15

8.4



Pos. 40

Servo c ircuit pressure relief valve

The complete assembly group comprises two filters, the differential pressure valve, a pressure relief valve, two check valves and a housing.

The valve limits the pressure in the servo circuit to 40 bar. The valve is pilot controlled and has a variable setting.

Filter

Check valves

Two filters clean the oil flows of the two servo pumps (6).


Differential pressure (booster) valve This valve increases the servo pressure from 40 to 70 bar. The higher pressure is needed to regulate the main pumps (3) and to shift the travel motors (121).

Ref.-no.

Quantity

Designation

further remarks

1

1

Housing

2

1

Differential pressure valve

Pos. 16

3

1


Pos. 17

4

2

Filter

Pos. 11

5

2

Test point

Minimess M 14 x 1,5

6

2

Check valve

Pos. 18

7

4



8

8



9

2

O-ring

10

2

Filter element

11

2

O-ring

12

4

Cylinder head bolt M 6 x 60 – 8.8

13

1

Plug M 16 x 1,5

14

2

Bushing

15

2

Cyl. head bolt M x

16

2

Locking plate

17

1

O-ring

18

2

O-ring

19

1

O-ring

Weight [kg]


Table 1

Page 8.4 - 16

RH 200 Diesel - 3657769e.doc – (02) – 09.03

8.4


Fig. 1

RH 200 Diesel - 3657769e.doc - (02) – 09.03

Valve block – servo- and auxiliary pressure

Page 8.4 - 17

8.4


Fig. 2

Page 8.4 - 18

Valve block – servo- and auxiliary pressure

RH 200 Diesel - 3657769e.doc – (02) – 09.03

8.4


Bypass valve

Pos. 63

The by - pass valve opens at a pressure of 1.5 bar and prevents the return flow filters (62) bursting, e. g. due to clogging. Oil then flows unfiltered back into the tank.

Ref.-no.

Quantity

Designation

1

1

Plate

2

1

Bottom plate

3

1

Housing

4

1

Valve body

5

1

Spring

6

1

O-ring

7

1

Seal

further remarks

Weight [kg]

Table 1

Fig. 1

RH 200 Diesel - 3657769e.doc - (02) – 09.03

Bypass valve

Page 8.4 - 19

8.4


Tank-line pre-charging valve

Pos. 64

This ensures that sufficient oil is available at the anti-cavitation valves of cylinders and travel valves.

The tank-line pre-charging valve pre-pressurises the oil in the return lines. The valve is set 12 bar.

Ref.-no.

Quantity

Designation

1

1

Valve housing

2

1

Flange

3

1

Lid

4

1

Bushing

5

1

Piston

6

1


7

----

8

----

further remarks

Weight [kg]


9 10

1

Sealing ring

11

1

O-ring

12

1

O-ring

13

2

Cylinder head bolt M 6 x 35


Table 1

Page 8.4 - 20

RH 200 Diesel - 3657769e.doc – (02) – 09.03

8.4


6, 13 Fig. 1

Tank-line pre charging valve

6, 13 Fig. 2

RH 200 Diesel - 3657769e.doc - (02) – 09.03

Tank-line pre charging valve

Page 8.4 - 21

8.4


Valve block for oil cooling

Pos. 85

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

Pressure relief valves

Pos. 86

Thermostats

Pos. 87

The four thermostats are fully open at oil temperatures under 40°C. The majority of the oil then flows directly back into the tank. As the temperature rises, the thermostats begin to close so that an increasing amount of oil flows through the fan motors and the coolers. At 52°C the thermostats are fully closed and the full oil flow passes through the fan motors to the coolers.


Ref.-no.

Quantity

Designation

1

1

Valve block

2

2

Lid

3

2

Lid

4

2

Check valve

5

2

Piston

6

2

Thermostat

7

further remarks

Weight [kg] 17

Opening pressure: 4 bar

----

8

2

Spring

9

2

Spring

10

----

11

----

12

----

13

2

Test point

Minimeß M 14 x 1,5

14

2



15

2

O-ring

16

2

O-ring

17

2

O-ring

18

1

Lifting eye

19

6

Hex. bolt M 8 x 30


20

4



Table 1

Page 8.4 - 22

RH 200 Diesel - 3657769e.doc – (02) – 09.03

8.4


14, 20 Fig. 1

RH 200 Diesel - 3657769e.doc - (02) – 09.03

Hydraulic oil cooling - thermostat valve

Page 8.4 - 23

8.4


14 Fig. 2

Page 8.4 - 24

Hydraulic oil cooling - thermostat valve

RH 200 Diesel - 3657769e.doc – (02) – 09.03

8.4


Travel block, compl.

Pos. 90

(93), anti-cavitation valves (97), travel retarder valve RH (95) and travel retarder valve LH (96).

The complete travel block comprises rotor (91), travel control block RH (92) travel control block LH

Ref.-no.

Quantity

1

1

Rotor

2

1


3

1


4

1


5

1


6

4

Anti cavitation valve

7

4

Cover plate

8

Designation

further remarks

Weight [kg]

----

9

16

Cyl. Head bolt M 10 x 60 – 10.9


10

8

Cyl. Head bolt M 16 x 220 – 10.9


11

10

Hex. bolt M 12 x 120 – 8.8


Table 1

RH 200 Diesel - 3657769e.doc - (02) – 09.03

Page 8.4 - 25

8.4


9, 10, 11 Fig. 1

Page 8.4 - 26

Rotor mounting components

RH 200 Diesel - 3657769e.doc – (02) – 09.03

8.4


Travel control block RH

Pos. 92

Servo-controlled single control block for operation of the right track.

Ref.-no.

Quantity

1

1

2 3

Designation

Travel control block LH See Pos. 92

further remarks

Spool

1

Bonnet with spring assembly ----

5

1

Travel valve block

6

1

Bonnet

7

1

Disc

8

1

Disc

9 - 13

167

----

14

3

Test point

15

2

Plug

16

1

Plug

17 - 23

----

24

1

O-ring

25

1

O-ring

26

2

O-ring

27

2

Sealing ring

28

4

Sealing ring

29 - 34

----

35

2



36

2



37

Eye Bolt M 12 1

39 40

Weight [kg]

----

4

38

Pos. 93

Plug ----

1

Sealing ring

Table 1

RH 200 Diesel - 3657769e.doc - (02) – 09.03

Page 8.4 - 27

8.4


35, 36 Fig. 1

Page 8.4 - 28

Travel valve block

RH 200 Diesel - 3657769e.doc – (02) – 09.03

8.4


35, 36 Fig. 2

RH 200 Diesel - 3657769e.doc - (02) – 09.03

Travel valve block

Page 8.4 - 29

8.4


Travel r etarder valves

Pos. 95 & 96

One travel retarder valve each is flanged to the travel control blocks (Pos. 92 & 93). When going downhill the pressure from the pumps to the travel motors decreases and the travel retarder valves cause the oil flow returning from the travel motor to the tank to be reduced. This prevents the excavator from picking up inadmissible speed.

Ref.-no.

Quantity

1

1

Guide

2

1

Travel retarder valve

3

1

Cap

4

1

Spool

5 6

Designation

further remarks

Weight [kg] 26

---1

7-9

Plug ----

10

1

Spring

11

1

Bleeder valve

12

1

Valve

Install valve ( A) with Omnifit Part-no. 900 257

13 14

---2

15 - 25

O-ring ----

26

4

Hex. bolt M 8 x 75 – 8.8


27

4

Hex. bolt M 8 x 50 – 8.8


28

----

29

----

30

1

Eye bolt M 12

Table 1

Page 8.4 - 30

RH 200 Diesel - 3657769e.doc – (02) – 09.03

8.4


26, 27

12

Fig. 1

RH 200 Diesel - 3657769e.doc - (02) – 09.03

Travel retarder valve

Page 8.4 - 31

8.4


26, 27 Fig. 2

Page 8.4 - 32

12 Travel retarder valve

RH 200 Diesel - 3657769e.doc – (02) – 09.03

8.4


Pos. 103

closed and prevent the engine from being driven via the swing pumps and the pump gearbox.

The 2 blocking valves belonging to each drive unit are controlled and opened by the servo pumps of the drive unit when the engine is running. When the engine is stopped, the locking valves are

The ports are marked with ‘A’, ‘B’ and ‘R’. The orifice (2) is installed with Loctite (20) and punch-secured.

Blocking valve

Ref.-no.

Quantity

1

1

Valve

2

1

Orifice

3

1

Check valve cone

4

1

Plug

5 6

Designation

further remarks

Weight [kg] 7,5

Ø 0,8

mm

---1

Spring

7

----

8

----

9

Plug

10

----

11

1

Sealing ring

12

1

O-ring

13

1

Back ring

14

1

Plug

15

1

2/2 wax valve

16

1

Sealing kit

17

----

18

4

Cyl.-head bolt M 6 x 30 – 8.8


19

4

Cyl.-head bolt M 5 x 30 – 8.8


20

Loctite

Table 1

RH 200 Diesel - 3657769e.doc - (02) – 09.03

Page 8.4 - 33

8.4


Fig. 1

Blocking valve

Fig. 2

Blocking valve

Page 8.4 - 34

RH 200 Diesel - 3657769e.doc – (02) – 09.03

8.4


Pressure governi ng valve

Pos. 105

The pressure balance valve continuously varies the magnitude and the direction of the swing pressure and thus the magnitude and the direction of the momentum at the swing motors depending on the pre-selected control pressure. Ref.-no.

Quantity

Designation

1

1

Main spool

2

1

Spool

3

1

Spring

4

1

Spring

5

1

Spool

6

1

Adjuster screw

7

1

Orifice ∅ 2,2 mm

The proportion between control pressure and operating pressure is 1:12, i.e. a control pressure of e.g. 10 bar at one of the control pressure ports (Y1 or Y2) corresponds to an operating pressure of ca. 120 bar at the swing motors.

further remarks

Weight [kg]

To adjust the centre position of the main spool

Table 1

Fig. 1

RH 200 Diesel - 3657769e.doc - (02) – 09.03

Pressure balance valve

Page 8.4 - 35

8.4


Flushing valve

Pos. 106

The flushing- and feed-pressure valve ejects a defined amount of oil from the close swing circuit at the low-pressure side during each swing operation.

Ref. no.

Quantity

Designation

1

1

Valve housing

2

2

Sealing ring

3

2

Plug

4

1

Sealing ring

5

1

Orifice

6

1

Relief valve

7

1

Spool

The corresponding amount of filtered and cooled oil from the hydraulic reservoir is fed back into the swing system by the charging pumps.

further remarks

Weight [kg]

Table 1

Fig. 1

Page 8.4 - 36

Flushing valve

RH 200 Diesel - 3657769e.doc – (02) – 09.03

8.4



Pos. 107

The high pressure filters are installed between the two front swing motors and are separating each two swing motors and each two swing pumps from the other components. Thus 50 % of the swing

Ref.-no.

Quantity

Designation

1

2


2

1

Housing

3

1

O-ring

4

1

Filter element

5

1

O-ring

6

2

Bushing

7

2

O-ring

8

2

Check valve

9

2

Spring

10

1

Filter head

11

2

Sealing ring

12

2

Hex. head bolt

13

1

Sealing ring

14

1

Plug

system is protected against contamination in case of a swing pump or swing motor failure. Because the oil flow is passing through the filter in both directions the filter head contains 2 check valves to ensure that the oil is flowing always in one direction through the filter element.

further remarks

Weight [kg] 18

Table 1

RH 200 Diesel - 3657769e.doc - (02) – 09.03

Page 8.4 - 37

8.4


Fig. 1

Page 8.4 - 38

Filter for swing system

RH 200 Diesel - 3657769e.doc – (02) – 09.03

8.4


Secondary relief block

Pos. 125

Assembly group comprising four pressure relief valves (126), 4 test points and a housing.

Ref.-no.

Quantity

1

1

2

Designation


Pos. 126

Secondary pressure relief valves for the four track motors that protect the motors against external forces. Excess oil is cracked off into the relevant low pressure side of the motors.

further remarks

Weight [kg]

Housing ----

3

4

Pressure relief valve (Pos. 77)

4

4

Plug


Table 1

3 Fig. 1

RH 200 Diesel - 3657769e.doc - (02) – 09.03

Secondary relief valve - travel

Page 8.4 - 39

8.4



Pos. 161

The control block (Fig. 1) consists essentially of the housing (1), the control pistons (2), the actuating and resetting elements (3), flange-mounted replenishing valves (4) and flange-mounted secondary pressure relief valves (5). When not activated, the control piston is kept in neutral position by the resetting spring. In this position the connection between pump and consumer is closed; the 2/2-way component is opened and allows the oil to flow in free circulation from P to T. If the control piston (2) is moved out of its neutral position, the connection from pump to consumer is opened by means of precision control grooves and the 2/2-way component is throttled by means of precision control grooves (negative overlap). The pump pressure rises. When the pressure acting on

Ref.-no.

Quantity

Designation

1

1

Valve housing

2

4

Spools

3

8

Bonnet

4

8

Anti cavitation valve

5

8


the consumer connection is reached, the oil starts to flow to the consumer. Further shifting of the control piston (2) results in the way to the tank being opened via precision control grooves for the oil coming from the consumer and gradual redirecting of the oil flow from the 2/2-way groove to the consumer groove (precision control). The max. travel of the control piston is 28mm. The piston travel is divided into ca. 1/3 control ledge overlap and 1/2 precision control range, with the residual travel serving to produce the full opening cross-section. The leakage-oil losses are reduced by the overlap and a slight piston clearance. The consumers can be sensitively controlled through the large precision-control range.

further remarks

Weight [kg]


Table 1

Page 8.4 - 40

RH 200 Diesel - 3657769e.doc – (02) – 09.03

8.4


Fig. 1


Fig. 2


RH 200 Diesel - 3657769e.doc - (02) – 09.03

Page 8.4 - 41

8.4


Boom float valve

Pos. 164/1

Ar m f lo at val ve (o nl y FS)

Pos . 164/2

The float valve permits pressure-less retraction of the boom cylinders by gravity. The valve opens a connection between the piston- and the rod-side of the cylinders to ensure the supply of oil to the rodside without having to use the main pumps. The spool travel is 17 mm.

The float valve permits pressure-less retraction of the arm cylinders by gravity. The valve opens a connection between the piston- and the rod-side of the cylinders to ensure the supply of oil to the rodside without having to use the working pumps. The spool travel is 17 mm.

For pressure-supported lowering of the boom, the lowering function of the hand-lever can be switched over from float valve to main control spool by pressing the button in the hand-lever.

For pressure-supported retraction of the arm, the lowering function of the hand-lever can be switched over from float valve to main control spool by pressing the button in the hand-lever.

Ref.-no.

Quantity

1

1

Valve housing

2

1

Spool

3

1

Bonnet

4

1

Check valve

5

1

Flange

6

Designation

further remarks

Weight [kg] 76

only in Backhoe attachment

----

7

1

Spring

8

1

Spring

9

2

Test point

10

1

O-ring

11

1

O-ring

12

1

O-ring

13 - 18

Minimeß M 14 x 1,5

----

19

1

Pipe

20

4

Stud bolt M 10 x 170

21

4

Nut M 10

22

4

Hex. bolt M 16x 55


23

4

Hex. bolt M 10x 50


Table 1

Page 8.4 - 42

RH 200 Diesel - 3657769e.doc – (02) – 09.03

8.4


22, 23 Fig. 1

Float valve

22, 23 Fig. 2

RH 200 Diesel - 3657769e.doc - (02) – 09.03

Float valve

Page 8.4 - 43

8.4


Distributor (FS only)

Pos. 187

The distributor on the backwall of the bucket supplies oil to the clamshell cylinders. It also carries a relief valve.

Ref.-no.

Quantity

1

1

Designation

----

3

---1

5-7 8

Pressure relief valve ----

1

9 - 16 17

Weight [kg]

Housing

2 4

further remarks

Seal ----

4



Table 1

Page 8.4 - 44

RH 200 Diesel - 3657769e.doc – (02) – 09.03

8.4


17 Fig. 1

RH 200 Diesel - 3657769e.doc - (02) – 09.03

Pressure relief valve in FS backwall

Page 8.4 - 45

8.4


Page 8.4 - 46

RH 200 Diesel - 3657769e.doc – (02) – 09.03

8.5 8.5

DESCRIPTION OF HYDRAULIC CIRCUITS Description of the hydraulic circuits

For the following description, the hydraulic circuit diagram has been separated into individual function circuits. The item numbers refer to the hydraulic- or electric circuit diagram. The complete hydraulic circuit diagram can be found in chapter 8.3. This brief description is an additional information to the training offered by the Service department. It can not be a substitute for a detailed training course!

8.5.1

Load-Limit Regulation

The excavator is fitted with two diesel engines (1), each of which drives a transfer gearbox (2) to which 2 main pumps (4), 2 swing pumps (6), 2 cooling pumps (7), 1 pump (8) for servo pressure and 1 pump for gearbox oil cooling are attached. Load-limit regulation (PMS 3) makes it possible to fully utilize the available engine output. Any number of governed hydraulic pumps and consumers without governors can be driven from one engine on the condition that the overall power consumption of all non-governed consumers is lower than the max. output of the motor, as the load-limit regulation can only influence regulated pumps. Load-limit regulation uses the actual electric power consumption of the motor as a signal to start governing, and comes into action as soon as consumers demand more power than the available motor output.

and finally through the return flow filters (29) back into the tank. The main pump P3 is passing through the RH 4spool valve block (90), the tank line pre-charging valve (31) and finally through the return flow filters (29) back into the tank. The main pump P4 is passing through the LH 4spool valve block (90), the tank line pre-charging valve (31) and finally through the return flow filters (29) back into the tank. Each of the two suction manifolds is provided with a gate valve (26). Non-return valves (40) are installed to prevent oil from flowing back into a pump in case of single engine operation. The 4 main pumps are protected by pressure relief valves (36) set at 380 bar (primary relief valves). The high-pressure filters (39) have a filtering rate of 100 µm. The tank line pre charging valves (31) have a fixed setting of 10 bar and ensure that sufficient oil is available to prevent consumer cavitation (see also section „Working functions“). The return flow filters (29) are monitored by a pressure switch which reacts (at a switch pressure of 1.5 bar) on filter contamination and releases a warning signal in the cab. When filter contamination is excessive, by-pass valves (30) open and allow the oil flow unfiltered back into the tank.

Oil circuits With the engines (1) running, and a function is activated, the main pumps (P1, P2, P3 and P4) feed oil into the distributor plate (35) with pressure relief valves (36), logic valves (37) and high pressure filters (39). When both engines are running the main pump P1 is passing through a high-pressure filter (39), the LH travel control block (83), the LH 4-spool valve block (90), the tank line pre-charging valve (31) and finally through the return flow filters (29) back into the tank. The main pump P2 is passing through the RH travel control block (82), the RH 4-spool valve block (90), the tank line pre-charging valve (31)

RH 200 Diesel - 3663421e - (00) – 09.03

Page 8.5 - 1

8.5

DESCRIPTION OF HYDRAULIC CIRCUITS

8.5.2

Pressure cut-off

On each main pump a pressure cut-off valve is installed. The pressure cut-off is activated as soon as the system pressure reaches its max. level of 300 bar for the cylinder functions and 360 bar for the travel function. The pressure cut-off valve is mounted on the regulator of the main pump. It is opened under system pressure and the pump then de-strokes to such a reduced flow that only the pressure in the system is maintained.

Page 8.5 - 2

RH 200 Diesel - 3663421e - (00) – 09.03

8.5

HYDRAULIC CIRCUITS - SERVO SYSTEM

8.5.3

Ser vo s ys tem

Remark: The position numbers in the pictures of this section are referring to the hydraulic circuit diagram and the components listed in chapter 8.3 - ‘Descripti on of the hydraulic sys tem’. The free ends of the hydraulic pipes and hoses are marked with capital letters for easier identification of the connecting points o n the various pictures.

70 bar - auxiliary pressure Auxiliary oil is required for the following functions: •

•

•

Regulation of the main pumps via proportional valves (23) Operation of the pressure increase to 340 bar for the travel system via solenoid control block. Solenoid valve (26/2) for 2-stage regulation of the travel motors.

The 4 gear pumps (6) for the servo system are driven by the engines (1) via the pump gearboxes (2).

Examples for servo oil circuit s:

The pumps (6) suck the oil through the suction manifolds from the hydraulic tank and feed into the servo- and auxiliary pressure valve (40).

The regulators of the main pumps are connected to the pump governing valves (23) The input of the proportional valves (23) is connected to the 70 bar system. The output to the regulators is governed by the PMS-system. Depending on the load situation of the engines the output is regulated between 7,5 bar and 42,5 bar.

40 bar - Servo-press ure Servo pressure is supplied for the following functions: •

Regulators of the main pumps to enable regulation at low working pressure (fig. 1 & fig. 2).

Regulation of the main pumps (fig. 3 & fi g. 4)

Solenoid valve bank (26) •

Swing parking brake (Solenoid Y 11) (fig. 6) Parking brake released:

•

•

•

•

•

Proportional valves (25) for operation of the 4spool control blocks (161) of the attachment.

The solenoid valve is energised and oil flows to the swing parking brakes (port A2). They are hydraulically released and held in the released position.

Proportional valves (25) for operation of the travel control blocks (92 & 93). Proportional valves (25) for operation of the swing system.

Parking brake applied: Solenoid valve (Y 11) is not energised. The swing brake pistons are connected to the hydraulic tank. The swing brakes are applied by spring force.

Supply of the pressure regulating valve (105) for the swing circuit. Solenoid valve (26/2) for travel parking brake. •

•

Operation of the swing parking brake via solenoid control block (26/1).

Travel parking brake (Solenoid Y 12) (fig. 7) Parking brake released:

The servo system is functional when the safety switch in the operator’s seat is activated. Then opening of the safety valves on plate (25) is possible.

The solenoid valve is energised and oil flows to the travel parking brakes (port A1). They are hydraulically released and held in the released position.

An accumulator with valve (35) stores and provides hydraulic energy for lowering the attachment or depressurising the hydraulic cylinders in case the engines are switched off.

RH 200 Diesel - 3664264e.doc - (00) - 06.04

Page 8.5.3 - 1

8.5


Parking brake applied:

Other servo oil circuits are described in the sections

Solenoid valve (Y 12) is not energised. The travel brake pistons are connected to the hydraulic tank. The travel brakes are applied by spring force. •

2-speed travelling (Solenoid Y 13) (fig. 7) The solenoid valve (Y 13) is operating the 2stage regulator of the travel motors for 2speed travelling. When the operator is shifting the switch in the cab from 'low speed' (turtle) to 'high speed' (rabbit) the pressure in the lines to the travel parking brakes and travel motor regulators is increased to 70 bar and the regulators are shifting to low displacement.

•

8.5.4 - Working functions 8.5.5 - Travel system 8.5.6 - Swing system 8.5.7 - Track tensioning system Remark: The following colour code refers only to hydraulic lines and not to components!

Travel boost (Solenoid Y 31) (fig. 11) The solenoid valve (Y 31) is operating the pressure cut-off valves of the main pumps P 2 and P 3 so that the travel pressure is increased to 340 bar.

Colour

Code

Designation

P

70 bar circuit

P

40 bar circuit

RP

Regulating pressure for main pumps

R

Return oil circuit

L

Leak oil circuit

Ref.-no.

Quantity

Designation

further remarks

4

4

Main pumps

6

4

Gear pump

23

2

Pump governing valves

25

1


26

2

Valve bank, complete

36

1


40

1


47

2

Check valve

91

1

Rotor

105

1


Swing balance valve

109

1


For pressure governing valve

121

4

Travel motor

B

4

Swing parking brake

Proportional valves Solenoid valves

Table 1

Page 8.5.3 - 2

RH 200 Diesel - 3664264e.doc - (00) - 06.04

8.5


Fig. 1

Pumps for servo- and auxiliary pressure – 3664702c-01

Fig. 2

Pumps for servo- and auxiliary pressure – 3664702d-01

RH 200 Diesel - 3664264e.doc - (00) - 06.04

Page 8.5.3 - 3

8.5


Fig. 3

Regulation of main pumps via proportional valves – 3664702c-02

Fig. 4

Regulation of main pumps via proportional valves – 3664702d-02

Page 8.5.3 - 4

RH 200 Diesel - 3664264e.doc - (00) - 06.04

8.5


Fig. 5

Lines from operators cab - 3664731-01

Fig. 6

Swing parking brake - 3664749-01

RH 200 Diesel - 3664264e.doc - (00) - 06.04

Page 8.5.3 - 5

8.5


Fig. 7

Travel parking brake and 2-speed function - 3664702a-01

Fig. 8


Page 8.5.3 - 6

RH 200 Diesel - 3664264e.doc - (00) - 06.04

8.5


Fig. 9

Travel parking brake and 2-speed function – 3664495b-02

Fig. 10

Travel parking brake and 2-speed function – 3664495c-02

RH 200 Diesel - 3664264e.doc - (00) - 06.04

Page 8.5.3 - 7

8.5


Fig. 11

Travel boost for main pumps – 3664702a-02

Fig. 12

Travel boost for main pumps – 3664702c-03

Page 8.5.3 - 8

RH 200 Diesel - 3664264e.doc - (00) - 06.04

8.5


Fig. 13

RH 200 Diesel - 3664264e.doc - (00) - 06.04

Travel boost for main pumps – 3664702d-03

Page 8.5.3 - 9

8.5


Page 8.5.3 - 10

RH 200 Diesel - 3664264e.doc - (00) - 06.04

8.5

HYDRAULIC CIRCUITS - WORKING FUNCTIONS (FS)

8.5.4

Working functions (FS)

Remark: The position numbers in the pictures of this section are referring to the hydraulic circuit diagram and the components listed in chapter 8.3 - ‘Descripti on of the hydraulic sys tem’. Working functions are carried out with 4 main pumps (3), all of which are feeding into „open circuits“ - that means that oil flows from the consumers back into the tank (fig. 1 & fig. 2 & fig. 3). Main pump P1: In the neutral position of the control valves, but after activation of the main pumps by PMS, oil coming from the main pump P1 flows through a high-pressure filter (32) to the RH 4-spool control valve (161). Connections from pumps to cylinders are closed. The oil flows in idle circuit (free flow) from (P) to (T) and then through the tank line pre-charging valves (64) and return flow filters (62) back into the tank (60).

Main pump P2: In the neutral position of the control valves, but after activation of the main pumps by PMS, oil coming from the main pump P2 flows through a high-pressure filter (32) and the RH travel control valve (92) to the RH 4-spool control valve (161). Connections from pumps to cylinders are closed. The oil flows in idle circuit (free flow) from (P) to (T) and then through the tank line pre-charging valves (64) and return flow filters (62) back into the tank (60).

Main pump P3: In the neutral position of the valve blocks, but after activation of the main pumps by PMS, oil coming from the main pump P3 flows through a highpressure filter (32), the LH travel control valve (93) to the LH 4-spool control valve (161). Connections from pumps to cylinders are closed. The oil flows in idle circuit (free flow) from (P) to (T) and then through the tank line pre-charging valves (64) and return flow filters (62) back into the tank (60).

RH 200 Diesel - 3663424e.doc - (01) – 09.03

Main pump P4: In the neutral position of the control valves, but after activation of the main pumps by PMS, oil coming from the main pump P4 flows through a high-pressure filter (32) to the LH 4-spool control valve (161). Connections from pumps to cylinders are closed. The oil flows in idle circuit (free flow) from (P) to (T) and then through the tank line pre-charging valves (64) and return flow filters (62) back into the tank (60).

The 4 circuits supply the following working functions: a) Boom - raise and lower b) Arm - extend and retract c) Shovel - crowd in and tip back d) Bottom dump bucket- open and close e) Travel (see section „Travelling“) The functions listed under a) - c) are supplied with oil from both circuits when only one function is being operated (automatic double flow). All cylinders fitted in pairs are interconnected by compensating lines.

4-spool control valves The 4-spool control valves (161) are directional valves, designed with multiple spools in one housing. The individual spools are actuated hydraulically and allow sensitive controlling of the speed and direction of the oil flow passing through the block. Description of the function see chapter 8.4 When a working function is idle, the respective spool is held in its initial (neutral) position by the return springs. The connecting channel from pump to consumer is blocked. The 2/2 way valve is open and allows the oil to pass from P to T (free flow or idle circuit). When the control spool is moved out of its initial (neutral) position, the connecting channel from pump to consumer opens via fine control grooves and the 2/2 way section is throttled with help of fine control grooves (negative overlap). Circuit pressure is increasing. When the same pressure is reached as acting on the consumer connection, the check (non-return)

Page 8.5.4 - 1

8.5


valve opens so that oil starts flowing to the consumer. When the control spool is moved further, fine control grooves allow oil coming from the consumer to flow to the tank and gradually shift the oil flow from the 2/2 way channel (fine-control facility).

The maximum spool stroke is 28 mm. The spool stroke can be divided into approx. 1/3 control edge overlap and ½ fine control range, the remaining stroke length serving to open up the full cross section. Overlapping, and a minimum of spool play are positive factors for reduced internal leakage. The extensive fine control range available means that consumers can be moved sensitively.

Designation

Remark: The following colour code refers only to hydraulic lines and not to components! Colour

Code

Designation

P1

Main pump P1

P2

Main pump P2

P3

Main pump P3

P4

Main pump P4

R

Return oil circuit

Ref.-no.

Quantity

further remarks

3

4


29

1


30

1

Relief valve

32

4


64

4


91

1

Rotor

92

1


93

1


95

1


96

1


161

2


164/1

2

Float valve

Boom cylinder function

164/2

2

Float valve

Arm cylinder function

182

2

Boom cylinder

183

2

Arm cylinder

184

2

Crowd cylinder

186

2

Clam cylinder

187

1

Distributor with relief valve

189

1

Distributor

Table 1

Page 8.5.4 - 2

RH 200 Diesel - 3663424e.doc - (01) – 09.03

8.5


Fig. 1

Main pump lines - 3664705a-01

Fig. 2

Main pump lines – 3666204-01

RH 200 Diesel - 3663424e.doc - (01) – 09.03

Page 8.5.4 - 3

8.5


Fig. 3a

Main pump lines – 3664517a-01

Fig. 3b


Page 8.5.4 - 4

RH 200 Diesel - 3663424e.doc - (01) – 09.03

8.5


Function: Extending the boom cylinders When the function is summoned (Fig. 4), both control spools for boom function are shifted by servo pressure out of their neutral positions against springs. The connection from the main pumps to the piston sides of the boom cylinders (182) is opened via fine-control grooves. At the same time, the connection (P) to (T) is throttled by fine-control grooves (Fig. 5 & Fig. 6). Via the CMS-card the signals from the joysticks inform the PMS about the summoned working function, consequently the main pumps are swung out and oil is being delivered. The circuit pressure rises. As soon as it reaches the pressure which exists on the piston sides of the cylinders oil flows to the cylinders. With further movement of the control spools, fine-control grooves allow oil coming from the rod sides of the cylinders to flow to tank and gradually shift the oil flow from the channel (P/T) to the channel for the consumer (fine-control facility).

on the working circuit. Pilot-controlled valves are used to ensure that large quantities of oil can escape in an absolute minimum of time. Anti-cavitation valves prevent vacuum (below atmospheric pressure) occurring in the working lines to the cylinders, as this would be a negative influence on the controlling of the consumer flows. The valves draw oil, as required, from the tank line. Tank line pre-charging valves (64) with a fixed setting of 12 bar, ensure, that sufficient oil is always available to be fed into the relevant circuit.

Colour

Code

Designation

P

Pressure oil circuit

R

Return oil circuit

S

Servo oil circuit

A

Compensation line

Pilot-controlled pressure relief valves safeguard the boom cylinders against forces acting externally

Fig. 4

RH 200 Diesel - 3663424e.doc - (01) – 09.03

Extending the boom cylinders – 3664144a-01

Page 8.5.4 - 5

8.5


Fig. 5


Fig. 6


Page 8.5.4 - 6

RH 200 Diesel - 3663424e.doc - (01) – 09.03

8.5


Function: Retracting the boom c ylinders via float valve

cess oil is allowed to escape through the tank connections (T) of the float valve and then through the tank line pre-charging valves (64) to the tank.

Float valve – ‘Lowering’ In order to save energy, ‘Lower’ commands for the boom are passed to the float valves (164/1) and not to the 4-spool control valves (fig. 7). Servo circuit oil flows to the boom float valves (164/1). The valves shift over. Piston and rod sides of the boom cylinders (182) are then connected to one another (fig. 8 & fig. 9). The weight of the working attachment forces the piston rods of the cylinders to retract of their own, whereby the oil being displaced from the piston side flows directly into the vacant space on the rod side. Because the chamber on the rod side of the cylinder is smaller than that on the piston side, the ex-

Fig. 7a

RH 200 Diesel - 3663424e.doc - (01) – 09.03

Colour

Code

Designation

P


R

Return oil circuit

S

Servo oil circuit

A

Compensation line

Retracting the boom cylinders via float valves – 3664144a-02

Page 8.5.4 - 7

8.5


Fig. 7b

Retracting the boom cylinders via float valves – 3664144b-01

Fig. 8

Retracting the boom cylinders via float valve – 2800823a-03

Page 8.5.4 - 8

RH 200 Diesel - 3663424e.doc - (01) – 09.03

8.5


Fig. 9

RH 200 Diesel - 3663424e.doc - (01) – 09.03

Retracting the boom cylinders via float valve - 2800824a-02

Page 8.5.4 - 9

8.5


Function:

gradually shift the oil flow from the channel (P/T) to the channel for the consumer (fine-control facility).

Retracting the boom cylinders vi a main valve If, however, the cylinders are to be moved under pressure, e.g. when lifting the excavator with help of the attachment, the operator has to press a button in the control lever. When the function is summoned, the ‘boom spool’ in the LH 4-spool control valve (161) is shifted by servo pressure out of the neutral position against springs (fig. 10). The ‘boom spool’ in the RH 4spool valve is connected to the leak oil line and not operated. The connection from the main pumps to the rod sides of the boom cylinders is opened via fine-control grooves (fig. 11 & fig. 12). At the same time, the connection (P) to (T) is throttled by fine-control grooves. Via the CMS-card the signals from the joysticks inform the PMS about the summoned working function, consequently the main pumps are swung out and oil is being delivered. The circuit pressure rises. As soon as it reaches the pressure which exists on the rod sides of the cylinders oil flows to the cylinders. With further movement of the control spool, fine-control grooves allow oil coming from the piston sides of the cylinders to flow to tank and

Page 8.5.4 - 10

Pilot-controlled pressure relief valves safeguard the boom cylinders against forces acting externally on the working circuit. Pilot-controlled valves are used to ensure that large quantities of oil can escape in an absolute minimum of time. Anti-cavitation valves prevent vacuum (below atmospheric pressure) occurring in the working lines to the cylinders, as this would be a negative influence on the controlling of the consumer flows. The valves draw oil, as required, from the tank line. Tank line pre-charging valves (64) with a fixed setting of 12 bar, ensure, that sufficient oil is always available to be fed into the relevant circuit. Colour

Code

Designation

P


R

Return oil circuit

S

Servo oil circuit

A

Compensation line

RH 200 Diesel - 3663424e.doc - (01) – 09.03

8.5


Fig. 10

Retracting the boom cylinders via main valve – 3664144a-03

Fig. 11


RH 200 Diesel - 3663424e.doc - (01) – 09.03

Page 8.5.4 - 11

8.5


Fig. 12

Page 8.5.4 - 12


RH 200 Diesel - 3663424e.doc - (01) – 09.03

8.5


Function: Extending the arm cylind ers When the function is summoned, both control spools for arm function (161) are shifted by servo pressure out of their neutral positions against springs (fig. 13). The connection from the main pumps to the piston sides of the arm cylinders (183) is opened via fine-control grooves (fig. 14 & fig. 15). At the same time, the connection (P) to (T) is throttled by fine-control grooves. Via the CMS-card the signals from the joysticks inform the PMS about the summoned working function, consequently the main pumps are swung out and oil is being delivered. The circuit pressure rises. As soon as it reaches the pressure which exists on the piston sides of the cylinders oil flows to the cylinders. With further movement of the control spools, fine-control grooves allow oil coming from the rod sides of the cylinders to flow to tank and gradually shift the oil flow from the channel (P/T) to the channel for the consumer (fine-control facility).

Fig. 13

RH 200 Diesel - 3663424e.doc - (01) – 09.03

Pilot-controlled pressure relief valves safeguard the arm cylinders against forces acting externally on the working circuit. Pilot-controlled valves are used to ensure that large quantities of oil can escape in an absolute minimum of time. Anti-cavitation valves prevent vacuum (below atmospheric pressure) occurring in the working lines to the cylinders, as this would be a negative influence on the controlling of the consumer flows. The valves draw oil, as required, from the tank line. Tank line pre-charging valves (64) with a fixed setting of 12 bar, ensure, that sufficient oil is always available to be fed into the relevant circuit.

Colour

Code

Designation

P


R

Return oil circuit

S

Servo oil circuit

A

Compensation line

Extending the arm cylinders – 3664144a-04

Page 8.5.4 - 13

8.5


Fig. 14


Fig. 15


Page 8.5.4 - 14

RH 200 Diesel - 3663424e.doc - (01) – 09.03

8.5


Function: Retracting t he arm cyl inders via float valve


Float valve – ‘Lowering’ In order to save energy, ‘Lower’ commands for the arm are passed to the float valves (164/2) and not to the 4-spool control valves (fig. 16). Servo circuit oil flows to the arm float valves (164/2). The valves shift over. Piston and rod sides of the arm cylinders (183) are then connected to one another (fig. 17 & fig. 18). The weight of the working attachment forces the piston rods of the cylinders to retract of their own, whereby the oil being displaced from the piston side flows directly into the vacant space on the rod side. Because the chamber on the rod side of the cylinder is smaller than that on the piston side, the ex-

Fig. 16a

RH 200 Diesel - 3663424e.doc - (01) – 09.03

Colour

Code

Designation

P


R

Return oil circuit

S

Servo oil circuit

A

Compensation line

Retracting the arm cylinders via float valves – 3664144a-05

Page 8.5.4 - 15

8.5


Fig. 16b

Retracting the arm cylinders via float valves – 3664144b-02

Fig. 17


Page 8.5.4 - 16

RH 200 Diesel - 3663424e.doc - (01) – 09.03

8.5


Fig. 18

RH 200 Diesel - 3663424e.doc - (01) – 09.03


Page 8.5.4 - 17

8.5 8.5

HYDR HYDRAU AULI LIC C CIRC CIRCUI UITS TS - WOR WORKI KING NG FUNC FUNCTI TION ONS S (FS) (FS)

Function: Retracting Retracting the arm cyl inders via main valve If, however, the cylinders are to be moved under pressure, e.g. when lifting the excavator with help of the working attachment, the operator has to press a button in the control lever When the function is summoned, summoned, the ‘arm spool’ in the LH 4-spool control valve (161) is shifted by servo pressure out of the neutral position against springs (fig. 19). The ‘arm spool’ in the RH 4-spool valve is connected to the leak oil line and not operated. The connection from the main pumps to the rod sides of the arm cylinders is opened via finecontrol grooves (fig. 20 & fig. 21). At the same time, the connection (P) to (T) is throttled by fine-control fine-control grooves. Via the CMS-card the signals from the joysticks inform the PMS PMS about the summoned working function, consequently the main pumps are swung out and oil is being delivered. The circuit pressure rises. As soon as it reaches the pressure which exists on the rod sides of the cylinders oil flows to the cylinders. With further movement of the control spool, fine-control grooves allow oil coming from the piston sides of the cylinders to flow to tank and

Page 8.5.4 - 18

gradually shift the oil flow from the channel (P/T) to the channel for the consumer (fine-control (fine-control facility). Pilot-controlled pressure relief valves safeguard the boom cylinders against forces acting externally on the working circuit. Pilot-controlled valves are used to ensure that large quantities of oil can escape in an absolute minimum of time. Anti-cavitation valves prevent vacuum (below atmospheric pressure) occurring in the working lines to the cylinders, as this would be a negative influence on the controlling of the consumer flows. The valves draw oil, as required, from the tank line. Tank line pre-charging valves (64) with a fixed setting of 12 bar, ensure, that sufficient oil is always available to be fed into the relevant circuit.

Co l o u r

Co d e

Des i g n at i o n

P


R

Return oil circuit

S

Servo oil circuit

A

Compensation line

RH 200 Diesel - 3663424e.doc - (01) – 09.03

8.5 8.5


Fig. 19

Retracting the arm cylinders via main valve – 3664177a-06

Fig. 20


RH 200 Diesel - 3663424e.doc - (01) – 09.03

Page 8.5.4 - 19

8.5 8.5


Fig. 21

Page 8.5.4 - 20


RH 200 Diesel - 3663424e.doc - (01) – 09.03

8.5 8.5


Function: Extending the bucket bucket crow d cylinders When the function is summoned, both control spools for crowd function (161) are shifted by servo pressure out of their neutral positions against springs (fig. 22). The connection from the main pumps to the piston sides of the crowd cylinders (184) is opened via fine-control grooves (fig. 23 & fig. 24). At the same time, the connection (P) to (T) is throttled by fine-control fine-control grooves. Via the CMS-card the signals from the joysticks inform the PMS PMS about the summoned working function, consequently the main pumps are swung out and oil is being delivered. The circuit pressure rises. As soon as it reaches the pressure which exists on the piston sides of the cylinders oil flows to the cylinders. With further movement of the control spools, fine-control grooves allow oil coming from the rod sides of the cylinders to flow to tank and gradually shift the oil flow from the channel (P/T) to the channel for the consumer (fine-control (fine-control facility).

Fig. 22

RH 200 Diesel - 3663424e.doc - (01) – 09.03

Pilot-controlled pressure relief valves safeguard the crowd cylinders against f orces acting externally on the working circuit. Pilot-controlled valves are used to ensure that large quantities of oil can escape in an absolute minimum of time. Anti-cavitation valves prevent vacuum (below atmospheric pressure) occurring in the working lines to the cylinders, as this would be a negative influence on the controlling of the consumer flows. The valves draw oil, as required, from the tank line. Tank line pre-charging valves (64) with a fixed setting of 12 bar, ensure, that sufficient oil is always available to be fed into the relevant circuit.

Co l o u r

Co d e

Des i g n at i o n

P


R

Return oil circuit

S

Servo oil circuit

Extending the bucket crowd cylinders – 3664144a-07

Page 8.5.4 - 21

8.5 8.5


Fig. 23

Extending the bucket crowd cylinders – 2800823a -08

Fig. 24

Extending the bucket crowd cylinders – 2800827a -01

Page 8.5.4 - 22

RH 200 Diesel - 3663424e.doc - (01) – 09.03

8.5


Function: Retracting the bucket crow d cylinders When the function is summoned, both control spools for crowd function (161) are shifted by servo pressure out of their neutral positions against springs (fig. 25). The connection from the main pumps to the piston sides of the crowd cylinders (184) is opened via fine-control grooves (fig. 26 & fig. 27). At the same time, the connection (P) to (T) is throttled by fine-control grooves. Via the CMS-card the signals from the joysticks inform the PMS about the summoned working function, consequently the main pumps are swung out and oil is being delivered. The circuit pressure rises. As soon as it reaches the pressure which exists on the piston sides of the cylinders oil flows to the cylinders. With further movement of the control spools, fine-control grooves allow oil coming from the rod sides of the cylinders to flow to tank and gradually shift the oil flow from the channel (P/T) to the channel for the consumer (fine-control facility).

Fig. 25

RH 200 Diesel - 3663424e.doc - (01) – 09.03

Pilot-controlled pressure relief valves safeguard the crowd cylinders against f orces acting externally on the working circuit. Pilot-controlled valves are used to ensure that large quantities of oil can escape in an absolute minimum of time. Anti-cavitation valves prevent vacuum (below atmospheric pressure) occurring in the working lines to the cylinders, as this would be a negative influence on the controlling of the consumer flows. The valves draw oil, as required, from the tank line. Tank line pre-charging valves (64) with a fixed setting of 12 bar, ensure, that sufficient oil is always available to be fed into the relevant circuit.

Colour

Code

Designation

P


R

Return oil circuit

S

Servo oil circuit

Retracting the bucket crowd cylinders – 3664144a-08

Page 8.5.4 - 23

8.5


Fig. 26


Fig. 27


Page 8.5.4 - 24

RH 200 Diesel - 3663424e.doc - (01) – 09.03

8.5


Function: Extending bucket)

the

clam

cylinder

(closing

the

When the function is summoned, the control spool for clam function in the RH 4-spool control valve (161) is shifted by servo pressure out of t he neutral positions against springs (fig. 28). The connection from the main pump P1 to the piston sides of the clam cylinders (186) is opened via fine-control grooves (fig. 29 to fig. 33). At the same time, the connection (P) to (T) is throttled by fine-control grooves. Via the CMS-card the signals from the joysticks inform the PMS about the summoned working function, consequently the main pumps are swung out and oil is being delivered. The circuit pressure rises. As soon as it reaches the pressure which exists on the piston sides of the cylinders oil flows to the cylinders. With further movement of the control spools, fine-control grooves allow oil coming from the rod sides of the cylinders to flow to tank and gradually shift the oil flow from the channel (P/T) to the channel for the consumer (fine-control facility).

Fig. 28

RH 200 Diesel - 3663424e.doc - (01) – 09.03

Pilot-controlled pressure relief valves safeguard the clam cylinders against forces acting externally on the working circuit. Pilot-controlled valves are used to ensure that large quantities of oil can escape in an absolute minimum of time. Anti-cavitation valves prevent vacuum (below atmospheric pressure) occurring in the working lines to the cylinders, as this would be a negative influence on the controlling of the consumer flows. The valves draw oil, as required, from the tank line. Tank line pre-charging valves (64) with a fixed setting of 12 bar, ensure, that sufficient oil is always available to be fed into the relevant circuit. Colour

Code

Designation

P


R

Return oil circuit

L

Leak oil circuit

S

Servo oil circuit

Extending the clam cylinders – 3664144a-09

Page 8.5.4 - 25

8.5


Fig. 29


Fig. 30

Extending the clam cylinders – 3666204-02

Page 8.5.4 - 26

RH 200 Diesel - 3663424e.doc - (01) – 09.03

8.5


Fig. 31a


Fig.31b


RH 200 Diesel - 3663424e.doc - (01) – 09.03

Page 8.5.4 - 27

8.5


Fig. 32


Fig. 33


Page 8.5.4 - 28

RH 200 Diesel - 3663424e.doc - (01) – 09.03

8.5


Function: Retracting the clam cylinder (opening the bucket) When the function is summoned, the control spool for clam function in the RH 4-spool control valve (161) is shifted by servo pressure out of t he neutral positions against springs (fig. 34). The connection from the main pump P2 to the rod sides of the clam cylinders (186) is opened via fine-control grooves (fig. 35 to fig. 37). At the same time, the connection (P) to (T) is throttled by fine-control grooves. Via the CMS-card the signals from the joysticks inform the PMS about the summoned working function, consequently the main pumps are swung out and oil is being delivered. The circuit pressure rises. As soon as it reaches the pressure which exists on the rod sides of the cylinders oil flows to the cylinders. With further movement of the control spools, fine-control grooves allow oil coming from the rod sides of the cylinders to flow to tank and gradually shift the oil flow from the channel (P/T) to the channel for the consumer (fine-control facility).

Fig. 34

RH 200 Diesel - 3663424e.doc - (01) – 09.03

Pilot-controlled pressure relief valves safeguard the clam cylinders against forces acting externally on the working circuit. Pilot-controlled valves are used to ensure that large quantities of oil can escape in an absolute minimum of time. Anti-cavitation valves prevent vacuum (below atmospheric pressure) occurring in the working lines to the cylinders, as this would be a negative influence on the controlling of the consumer flows. The valves draw oil, as required, from the tank line. Tank line pre-charging valves (64) with a fixed setting of 12 bar, ensure, that sufficient oil is always available to be fed into the relevant circuit.

Colour

Code

Designation

P


R

Return oil circuit

L

Leak oil circuit

S

Servo oil circuit

Retracting the clam cylinders – 3664144a-10

Page 8.5.4 - 29

8.5


Fig.35


Fig. 36


Page 8.5.4 - 30

RH 200 Diesel - 3663424e.doc - (01) – 09.03

8.5


Fig. 37

RH 200 Diesel - 3663424e.doc - (01) – 09.03


Page 8.5.4 - 31

8.5


Page 8.5.4 - 32

RH 200 Diesel - 3663424e.doc - (01) – 09.03

8.5 HYDRAULIC CIRCUITS - WORKING FUNCTIONS (BH)

8.5.4

Working functions (BH)

Remark: The position numbers in the pictures of this section are referring to the hydraulic circuit diagram and the components listed in chapter 8.3 - ‘Descripti on of the hydraulic sys tem’. Working functions are carried out with 4 main pumps (3), all of which are feeding into „open circuits“ - that means that oil flows from the consumers back into the tank (fig. 1 to fig. 4). Main pump P1: In the neutral position of the control valves, but after activation of the main pumps by PMS, oil coming from the main pump P1 flows through a high-pressure filter (32) to the RH 4-spool control valve (161). Connections from pumps to cylinders are closed. The oil flows in idle circuit (free flow) from (P) to (T) and then through the tank line pre-charging valves (64) and return flow filters (62) back into the tank (60).

Main pump P2: In the neutral position of the control valves, but after activation of the main pumps by PMS, oil coming from the main pump P2 flows through a high-pressure filter (32) and the RH travel control valve (92) to the RH 4-spool control valve (161). Connections from pumps to cylinders are closed. The oil flows in idle circuit (free flow) from (P) to (T) and then through the tank line pre-charging valves (64) and return flow filters (62) back into the tank (60).

Main pump P4: In the neutral position of the control valves, but after activation of the main pumps by PMS, oil coming from the main pump P4 flows through a high-pressure filter (32) to the LH 4-spool control valve (161). Connections from pumps to cylinders are closed. The oil flows in idle circuit (free flow) from (P) to (T) and then through the tank line pre-charging valves (64) and return flow filters (62) back into the tank (60).

The 4 circuits supply the following working functions: a) Boom - raise and lower b) Stick - extend and retract c) Bucket - crowd in and tip back d) Travel (see section „Travelling“) The functions listed under a) - c) are supplied with oil from both circuits when only one function is being operated (automatic double flow). All cylinders fitted in pairs are interconnected by compensating lines.

4-spool control valves The 4-spool control valves (161) are directional valves, designed with multiple spools in one housing. The individual spools are actuated hydraulically and allow sensitive controlling of the speed and direction of the oil flow passing through the block. Description of the function see chapter 8.4

Main pump P3: In the neutral position of the valve blocks, but after activation of the main pumps by PMS, oil coming from the main pump P3 flows through a highpressure filter (32), the LH travel control valve (83) to the LH 4-spool control valve (161). Connections from pumps to cylinders are closed. The oil flows in idle circuit (free flow) from (P) to (T) and then through the tank line pre-charging valves (64) and return flow filters (62) back into the tank (60).

RH 200 Diesel - 3663430e.doc - (01) – 09.03

When a working function is idle, the respective spool is held in its initial (neutral) position by the return springs. The connecting channel from pump to consumer is blocked. The 2/2 way valve is open and allows the oil to pass from P to T (free flow or idle circuit). When the control spool is moved out of its initial (neutral) position, the connecting channel from pump to consumer opens via fine control grooves and the 2/2 way section is throttled with help of fine control grooves (negative overlap). Circuit pressure is increasing. When the same pressure is reached as acting on the consumer connection, the check (non-return) valve opens so that oil starts flowing to the con-

Page 8.5.4 - 1


sumer. When the control spool is moved further, fine control grooves allow oil coming from the consumer to flow to the tank and gradually shift the oil flow from the 2/2 way channel (fine-control facility).

The maximum spool stroke is 28 mm. The spool stroke can be divided into approx. 1/3 control edge overlap and ½ fine control range, the remaining stroke length serving to open up the full cross section. Overlapping, and a minimum of spool play are positive factors for reduced internal leakage. The extensive fine control range available means that consumers can be moved sensitively.

Ref.-no.

Quantity

Designation

3

4


29

1


30

1

Relief valve

32

4


64

4


91

1

Rotor

92

1


93

1


95

1


96

1


161

2


164

2

Float valve

170

4

Throttled non return valve

171

4

Throttled non return valve

182

2

Boom cylinder

183

2

Stick cylinder

185

2

Bucket cylinder

188

4


Code

Designation

P1

Main pump P1

P2

Main pump P2

P3

Main pump P3

P4

Main pump P4

R

Return oil circuit

further remarks

Boom cylinder function

Distributor

Table 1

Page 8.5.4 - 2

RH 200 Diesel - 3663430e.doc - (01) – 09.03


Fig. 1


Fig. 2

Main pump lines - 3666204-01

RH 200 Diesel - 3663430e.doc - (01) – 09.03

Page 8.5.4 - 3


Fig. 3

Main pump lines – 3664517a-01

Fig. 4

Main pump lines – 3664517b-01

Page 8.5.4 - 4

RH 200 Diesel - 3663430e.doc - (01) – 09.03


Function: Extending the boom cylinders When the function is summoned (fig. 5), both control spools for boom function are shifted by servo pressure out of their neutral positions against springs. The connection from the main pumps to the piston sides of the boom cylinders (182) is opened via fine-control grooves. At the same time, the connection (P) to (T) is throttled by fine-control grooves (fig. 6 to fig. 8). Via the CMS-card the signals from the joysticks inform the PMS about the summoned working function, consequently the main pumps are swung out and oil is being delivered. The circuit pressure rises. As soon as it reaches the pressure which exists on the piston sides of the cylinders oil flows to the cylinders. With further movement of the control spools, fine-control grooves allow oil coming from the rod sides of the cylinders to flow to tank and gradually shift the oil flow from the channel (P/T) to the channel for the consumer (fine-control facility).

on the working circuit. Pilot-controlled valves are used to ensure that large quantities of oil can escape in an absolute minimum of time. Anti-cavitation valves prevent vacuum (below atmospheric pressure) occurring in the working lines to the cylinders, as this would be a negative influence on the controlling of the consumer flows. The valves draw oil, as required, from the tank line. Tank line pre-charging valves (64) with a fixed setting of 12 bar, ensure, that sufficient oil is always available to be fed into the relevant circuit.

Colour

Code

Designation

P


R

Return oil circuit

S

Servo oil circuit

A

Compensation line

Pilot-controlled pressure relief valves safeguard the boom cylinders against forces acting externally

Fig. 5

RH 200 Diesel - 3663430e.doc - (01) – 09.03


Page 8.5.4 - 5


Fig. 6

Extending the boom cylinders – 3664517b-02

Fig. 7

Extending the boom cylinders – 3664517c-01

Page 8.5.4 - 6

RH 200 Diesel - 3663430e.doc - (01) – 09.03


Fig. 8

RH 200 Diesel - 3663430e.doc - (01) – 09.03

Extending the boom cylinders – 3664518c-01

Page 8.5.4 - 7


Function: Retracting the boom c ylinders via float valve


Float valve – ‘Lowering’ In order to save energy, ‘Lower’ commands for the boom (on FS and BH attachment) are passed to the float valves (92) and not to the 4-spool control valves (fig. 9). Servo circuit oil flows to the boom float valves (92/1). The valves shift over. Piston and rod sides of the boom cylinders (182) are then connected to one another (fig. 10 to fig. 12). The weight of the working attachment forces the piston rods of the cylinders to retract of their own, whereby the oil being displaced from the piston side flows directly into the vacant space on the rod side. Because the chamber on the rod side of the cylinder is smaller than that on the piston side, the ex-

Fig. 9

Page 8.5.4 - 8

Colour

Code

Designation

P


R

Return oil circuit

S

Servo oil circuit

A

Compensation line

Retracting the boom cylinders via float valves - 3663578a-02

RH 200 Diesel - 3663430e.doc - (01) – 09.03


Fig. 10

Retracting the boom cylinders via float valve – 3664517b-03

Fig. 11

Retracting the boom cylinders via float valve – 3664517c-01

RH 200 Diesel - 3663430e.doc - (01) – 09.03

Page 8.5.4 - 9


Fig. 12

Page 8.5.4 - 10

Retracting the boom cylinders via float valve – 3664518c-02

RH 200 Diesel - 3663430e.doc - (01) – 09.03


Function:

gradually shift the oil flow from the channel (P/T) to the channel for the consumer (fine-control facility).

Retracting the boom cylinders v ia main valve If, however, the cylinders are to be moved under pressure, e.g. when lifting the excavator with help of the attachment, the operator has to press a button in the control lever. When the function is summoned, the ‘boom spool’ in the LH 4-spool control valve (161) is shifted by servo pressure out of the neutral position against springs (fig. 13). The ‘boom spool’ in the RH 4spool valve is connected to the leak oil line and not operated. The connection from the main pumps to the rod sides of the boom cylinders is opened via fine-control grooves (fig. 14 to fig. 16). At the same time, the connection (P) to (T) is throttled by fine-control grooves. Via the CMS-card the signals from the joysticks inform the PMS about the summoned working function, consequently the main pumps are swung out and oil is being delivered. The circuit pressure rises. As soon as it reaches the pressure which exists on the rod sides of the cylinders oil flows to the cylinders. With further movement of the control spool, fine-control grooves allow oil coming from the piston sides of the cylinders to flow to tank and

RH 200 Diesel - 3663430e.doc - (01) – 09.03

Pilot-controlled pressure relief valves (91) safeguard the boom cylinders against forces acting externally on the working circuit. Pilot-controlled valves are used to ensure that large quantities of oil can escape in an absolute minimum of time. Anti-cavitation valves prevent vacuum (below atmospheric pressure) occurring in the working lines to the cylinders, as this would be a negative influence on the controlling of the consumer flows. The valves draw oil, as required, from the tank line. Tank line pre-charging valves (64) with a fixed setting of 12 bar, ensure, that sufficient oil is always available to be fed into the relevant circuit. Colour

Code

Designation

P


R

Return oil circuit

S

Servo oil circuit

A

Compensation line

Page 8.5.4 - 11


Fig. 13


Fig. 14

Retracting the boom cylinders via main valve – 3664517b-04

Page 8.5.4 - 12

RH 200 Diesel - 3663430e.doc - (01) – 09.03


Fig. 15

Retracting the boom cylinders via main valve – 3664517c-03

Fig. 16

Retracting the boom cylinders via main valve – 3664518c-03

RH 200 Diesel - 3663430e.doc - (01) – 09.03

Page 8.5.4 - 13


Function: Extending the stick cylind ers When the function is summoned, both control spools for stick function (161) are shifted by servo pressure out of their neutral positions against springs (fig. 17). The connection from the main pumps to the piston sides of the stick cylinders (183) is opened via fine-control grooves (fig. 18 to fig. 20). At the same time, the connection (P) to (T) is throttled by fine-control grooves. Via the CMS-card the signals from the joysticks inform the PMS about the summoned working function, consequently the main pumps are swung out and oil is being delivered. The circuit pressure rises. As soon as it reaches the pressure which exists on the piston sides of the cylinders oil flows to the cylinders. With further movement of the control spools, fine-control grooves allow oil coming from the rod sides of the cylinders to flow to tank and gradually shift the oil flow from the channel (P/T) to the channel for the consumer (fine-control facility).

Fig. 17

Page 8.5.4 - 14

Pilot-controlled pressure relief valves (91) safeguard the stick cylinders against forces acting externally on the working circuit. Pilot-controlled valves are used to ensure that large quantities of oil can escape in an absolute minimum of time. Anti-cavitation valves prevent vacuum (below atmospheric pressure) occurring in the working lines to the cylinders, as this would be a negative influence on the controlling of the consumer flows. The valves draw oil, as required, from the tank line. Tank line pre-charging valves (64) with a fixed setting of 12 bar, ensure, that sufficient oil is always available to be fed into the relevant circuit.

Colour

Code

Designation

P


R

Return oil circuit

S

Servo oil circuit

A

Compensation line

Extending the stick cylinders - 3663578a-04

RH 200 Diesel - 3663430e.doc - (01) – 09.03


Fig. 18

Extending the stick cylinders – 3664517b-05

Fig. 19

Extending the stick cylinders – 3664517c-04

RH 200 Diesel - 3663430e.doc - (01) – 09.03

Page 8.5.4 - 15


Fig. 20

Page 8.5.4 - 16

Extending the stick cylinders – 3664518a-01

RH 200 Diesel - 3663430e.doc - (01) – 09.03


Function: Retracting the sti ck cyl inders via main valve If, however, the cylinders are to be moved under pressure, e.g. when lifting the excavator with help of the working attachment, the operator has to press a button in the control lever When the function is summoned, the ‘stick spool’ in the LH 4-spool control valve (161) is shifted by servo pressure out of the neutral position against springs (fig. 21). The ‘stick spool’ in the RH 4-spool valve is connected to the leak oil line and not operated. The connection from the main pumps to the rod sides of the stick cylinders is opened via finecontrol grooves (fig. 22 to fig. 24). At the same time, the connection (P) to (T) is throttled by fine-control grooves. Via the CMS-card the signals from the joysticks inform the PMS about the summoned working function, consequently the main pumps are swung out and oil is being delivered. The circuit pressure rises. As soon as it reaches the pressure which exists on the rod sides of the cylinders oil flows to the cylinders. With further movement of the control spool, fine-control grooves allow oil coming from the piston sides of the cylinders to flow to tank and

RH 200 Diesel - 3663430e.doc - (01) – 09.03

gradually shift the oil flow from the channel (P/T) to the channel for the consumer (fine-control facility). Pilot-controlled pressure relief valves (91) safeguard the boom cylinders against forces acting externally on the working circuit. Pilot-controlled valves are used to ensure that large quantities of oil can escape in an absolute minimum of time. Anti-cavitation valves prevent vacuum (below atmospheric pressure) occurring in the working lines to the cylinders, as this would be a negative influence on the controlling of the consumer flows. The valves draw oil, as required, from the tank line. Tank line pre-charging valves (64) with a fixed setting of 12 bar, ensure, that sufficient oil is always available to be fed into the relevant circuit.

Colour

Code

Designation

P


R

Return oil circuit

S

Servo oil circuit

A

Compensation line

Page 8.5.4 - 17


Fig. 21

Retracting the stick cylinders via main valve – 3663578a-05

Fig. 22

Retracting the stick cylinders via main valve – 3664517b-06

Page 8.5.4 - 18

RH 200 Diesel - 3663430e.doc - (01) – 09.03


Fig. 23

Retracting the stick cylinders via main valve – 3664517c-05

Fig. 24

Retracting the stick cylinders via main valve – 3664518a-02

RH 200 Diesel - 3663430e.doc - (01) – 09.03

Page 8.5.4 - 19


Function: Extending the bucket cylinders When the function is summoned, both control spools for crowd function (161) are shifted by servo pressure out of their neutral positions against springs (fig. 25). The connection from the main pumps to the piston sides of the crowd cylinders (185) is opened via fine-control grooves (fig. 26 to fig. 30). At the same time, the connection (P) to (T) is throttled by fine-control grooves. Via the CMS-card the signals from the joysticks inform the PMS about the summoned working function, consequently the main pumps are swung out and oil is being delivered. The circuit pressure rises. As soon as it reaches the pressure which exists on the piston sides of the cylinders oil flows to the cylinders. With further movement of the control spools, fine-control grooves allow oil coming from the rod sides of the cylinders to flow to tank and gradually shift the oil flow from the channel (P/T) to the channel for the consumer (fine-control facility).

Fig. 25

Page 8.5.4 - 20

Pilot-controlled pressure relief valves (91) safeguard the crowd cylinders against forces acting externally on the working circuit. Pilot-controlled valves are used to ensure that large quantities of oil can escape in an absolute minimum of time. Anti-cavitation valves prevent vacuum (below atmospheric pressure) occurring in the working lines to the cylinders, as this would be a negative influence on the controlling of the consumer flows. The valves draw oil, as required, from the tank line. Tank line pre-charging valves (64) with a fixed setting of 12 bar, ensure, that sufficient oil is always available to be fed into the relevant circuit.

Colour

Code

Designation

P


R

Return oil circuit

S

Servo oil circuit

Extending the bucket cylinders – 3663578a -06

RH 200 Diesel - 3663430e.doc - (01) – 09.03


Fig. 26

Extending the bucket cylinders – 3664517b -07

Fig. 27

Extending the bucket cylinders – 3664517c -06

RH 200 Diesel - 3663430e.doc - (01) – 09.03

Page 8.5.4 - 21

8.5 HYDRAU HYDRAULIC LIC CIRCUI CIRCUITS TS - WORKIN WORKING G FUNCT FUNCTION IONS S (BH) (BH)

Fig. 28

Extending the bucket cylinders – 3664518a-03

Fig. 29

Extending the bucket cylinders – 3664518b-01

Page 8.5.4 - 22

RH 200 Diesel - 3663430e.doc - (01) – 09.03


Fig. 30

RH 200 Diesel - 3663430e.doc - (01) – 09.03

Extending the bucket cylinders – 3664536-01

Page 8.5.4 - 23


Function: Retracting Retracting t he bucket cylinders When the function is summoned, both control spools for crowd function (161) are shifted by servo pressure out of their neutral positions against springs (fig. 31). The connection from the main pumps to the piston sides of the crowd cylinders (185) is opened via fine-control grooves (fig. 32 to fig. 36). At the same time, the connection (P) to (T) is throttled by fine-control grooves. Via the CMS-card the signals from the joysticks inform the PMS PMS about the summoned working function, consequently the main pumps are swung out and oil is being delivered. The circuit pressure rises. As soon as it reaches the pressure which exists on the piston sides of the cylinders oil flows to the cylinders. With further movement of the control spools, fine-control grooves allow oil coming from the rod sides of the cylinders to flow to tank and gradually shift the oil flow from the channel (P/T) to the channel for the consumer (fine-control facility).

Fig. 31

Page 8.5.4 - 24

Pilot-controlled pressure relief valves (91) safeguard the crowd cylinders against forces acting externally on the working circuit. Pilot-controlled valves are used to ensure that large quantities of oil can escape in an absolute minimum of time. Anti-cavitation valves prevent vacuum (below atmospheric pressure) occurring in the working lines to the cylinders, as this would be a negative influence on the controlling of the consumer flows. The valves draw oil, as required, from the tank line. Tank line pre-charging valves (64) with a fixed setting of 12 bar, ensure, that sufficient oil is always available to be fed into the relevant circuit.

Co l o u r

Co d e

Des i g n at i o n

P


R

Return oil circuit

S

Servo oil circuit

Retracting the bucket cylinders – 3663578a-07

RH 200 Diesel - 3663430e.doc - (01) – 09.03


Fig. 32

Retracting the bucket cylinders – 3664517b -08

Fig. 33

Retracting the bucket cylinders – 3664517c -07

RH 200 Diesel - 3663430e.doc - (01) – 09.03

Page 8.5.4 - 25


Fig. 34

Retracting the bucket cylinders – 3664518a-04

Fig. 35

Retracting the bucket cylinders – 3664518b-02

Page 8.5.4 - 26

RH 200 Diesel - 3663430e.doc - (01) – 09.03


Fig. 36

RH 200 Diesel - 3663430e.doc - (01) – 09.03

Retracting the bucket cylinders – 3664536-02

Page 8.5.4 - 27


Page 8.5.4 - 28

RH 200 Diesel - 3663430e.doc - (01) – 09.03

8.5

HYDRAULIC CIRCUITS - TRAVEL SYSTEM

8.5.5

Tr av el s ys tem

Remark: The position numbers in the pictures of this section are referring to the hydraulic circuit diagram and the components listed in chapter 8.3 - ‘Descripti on of the hydraulic sys tem’. The free ends of the hydraulic pipes and hoses are marked with capital letters for easier identification of the connecting points o n the various pictures.

When both engines or the LH engine only are running the oil of two main pumps (3) flows through the high pressure filters (32) to the travel control blocks (92 & 93) (fig.1 to fig. 3). Main pump P1 is feeding the RH travel control block (92). Main pump P2 is feeding the LH travel control block (93). When the ‘Travel’ function is not operated the oil flows via (C) to the 4-spool control blocks (161) and via (T) back to the tank. As long as the function ‘Travel’ is summoned with the treadle valves, servo oil flows to the travel valve blocks (92 & 93) (fig. 3). The travel valve blocks (92 & 93) shift so that connection (C) is blocked (fig. 4). Oil flows to the travel motors either through (B) - „forward“, or (A) „backwards“. Travel motors (121) and travel control blocks are connected via the rotor (91) and the secondary relief valve block (125) (fig. 5 to fig. 7). In the secondary relief valve block (125) pilotoperated pressure relief valves are installed for each direction of travel. The valves are set to 380 bar. When this pressure is reached relief oil is fed via the relief valve to the relevant low-pressure side of the motors. Oil returning from the travel motors flows through the secondary relief valve (125), the rotor (91) to the travel retarder valves (95 & 96) and the return lines to the tank. Leakage oil from the travel motors is returned to the tank through (T).

In this case the main pumps P3 is feeding the RH travel control block (92) and the main pump P4 is feeding the LH travel control block (93) (fig. 8 to fig. 10). Travel parking brake / 2-speed t ravel The travel parking brake and the shifting of the 2stage travel motors are operated via the same hydraulic line (fig. 11 to fig. 14). When a pressure of 40 bar is applied the travel parking brake is released and the travel motors stay in 'low speed mode'. If the speed switch is activated the pressure is increased to 70 bar and the travel motors change to 'high speed mode'. Leakage oil from the control blocks flows back to the tank. Anti-cavitation valves flanged onto the travel control blocks prevent cavitation in the travel motors.

Travel boost A solenoid valve (Y 31) on plate (26/2) is operating the pressure cut-off valves of the main pumps P 2 and P 3 so that the travel pressure is increased to 360 bar (fig. 15 to fig. 17).

Travel retarder valves The travel retarder valves (95 & 96) flanged onto the travel valve blocks (92 & 93) prevent the excavator from „running away“ when travelling downhill, and ensure positive travel drive down the slope. The travel retarder valves are installed in the circuits in such a way that oil flowing from the travel motors must flow through them in order to get to the tank. The control piston determines the amount of oil which can flow through the valve. When system pressure drops (e.g. excavator travelling downhill), pressure spring pushes the control piston back. When the excavator is travelling, the control piston of the retarder valve adopts a so-called „float position“ which is determined by the resistance to excavator travel and the pump oil pressure resulting from it.

When only the RH engine is running a solenoid valve (46) is operating the logic valves on the distributor plate (29).

RH 200 Diesel - 3663425e.doc - (01) - 09.03

Page 8.5.5 - 1

8.5



Code

Designation

P1

Main pump P1

P2

Main pump P2

R

Return oil circuit

S

40 bar circuit

S

70 bar circuit

Components of the travel system Ref.-no.

Quantity

Designation

3

4

Main pump

25

1


26/2

1

Soleniod valve

29

1


32

4


36

1


43

4

Check valves

46

1

Solenoid valve

47

1

Shuttle valve

64

4


91

1

Rotor

92

1


93

1


95

1


96

1


121

4

Travel motor

125

1

Secondary relief valve block

V

4

Distributor

further remarks

Travel boost

Operation of logic valves

Travel function

Table 1

Page 8.5.5 - 2

RH 200 Diesel - 3663425e.doc - (01) - 09.03

8.5


Fig. 1

Logic valves with solenoid - 3664705b-01

Fig. 2

Main pumps for travel – 3664705a-03

RH 200 Diesel - 3663425e.doc - (01) - 09.03

Page 8.5.5 - 3

8.5


Fig. 3

Main pumps for travel – 3666204-03

Fig. 4

Servo lines for travel system - 3666203-01

Page 8.5.5 - 4

RH 200 Diesel - 3663425e.doc - (01) - 09.03

8.5


Fig. 5

Travel system in undercarriage - 3664495a-01

Fig. 6

Travel system in undercarriage – 3664495b-01

RH 200 Diesel - 3663425e.doc - (01) - 09.03

Page 8.5.5 - 5

8.5


Fig. 7

Travel system in undercarriage – 3664495c-01

Fig. 8

Logic valves with solenoid - 3664705b-02

Page 8.5.5 - 6

RH 200 Diesel - 3663425e.doc - (01) - 09.03

8.5


Fig. 9

Main pumps for travel - 3664705a-04

Fig. 10

Main pumps for travel - 3666204-04

RH 200 Diesel - 3663425e.doc - (01) - 09.03

Page 8.5.5 - 7

8.5


Fig. 11

Travel parking brake and 2-speed function – 3664702a-01

Fig. 12


Page 8.5.5 - 8

RH 200 Diesel - 3663425e.doc - (01) - 09.03

8.5


Fig. 13

Travel parking brake and 2-speed function – 3664495b-02

Fig. 14

Travel parking brake and 2-speed function – 3664495c-02

RH 200 Diesel - 3663425e.doc - (01) - 09.03

Page 8.5.5 - 9

8.5


Fig. 15

Travel boost for main pumps – 3664702a-02

Fig. 16

Travel boost for main pumps – 3664702c-03

Page 8.5.5 - 10

RH 200 Diesel - 3663425e.doc - (01) - 09.03

8.5


Fig. 17

RH 200 Diesel - 3663425e.doc - (01) - 09.03

Travel boost for main pumps – 3664702d-03

Page 8.5.5 - 11

8.5


Page 8.5.5 - 12

RH 200 Diesel - 3663425e.doc - (01) - 09.03

8.5

HYDRAULIC CIRCUITS - SWING SYSTEM

8.5.6

Sw ing s ys tem

Remark: The position numbers in the pictures of this section are referring to the hydraulic circuit diagram and the components listed in chapter 8.3 - ‘Descripti on of the hydraulic sys tem’.

The swing circuit is a closed circuit. When braking, the rotation energy, i.e. swing momentum, of the moving superstructure is transferred back to the swing pumps and is then assisting the engines. Such a transmission is not possible in open circuit swing systems. In open circuit systems, the rotation energy of the moving superstructure, when being braked, can only be absorbed by throttling the flow of oil which leads to an energy loss in form of heat. The swing pumps (4, fig 2) are variabledisplacement pumps with torque control system (see description in separate chapter). The changeable internal mass of the superstructure can be efficiently rotated or braked with a variable torque. Special features of torque control: When the superstructure is being accelerated (i.e. brought into movement) or retarded (i.e. braked from swing), the output of the swing pumps (4) is always the same as the energy consumption of the swing motors (102, fig. 3). Altering the pressure of the control signal makes it possible to achieve any required, alterable torque of acceleration or retardation, even when the inertial mass of the superstructure is changing. The torque control valve (105, fig. 1) limits the maximum torque and thereby the maximum pressures available on the swing motors (102). This, in turn, avoids any opening of the pressure relief valves in the swing pumps. In the neutral position, ports (Y1) and (Y2) on the torque control valve (105) are free of pressure, i.e. the balance is in the middle position, whereby ports (X1 and X2) are connected to (P). The control chambers in the swing pump regulators are subject to balanced pressure (40 bar servo circuit pressure) so that the swing pumps (4) have „zero“ flow.

Swinging to the right When the left hand joystick is actuated to the right servo oil flows to the pressure regulating valve (105, port Y1). The pressure from the joystick is defining the pressure level in the swing system. The main piston (11.1, fig. 1) is displaced against the spring (11.3). Connections (X1 & P) and (X2 & T) are thereby established. Line (X2) between pressure regulating valve (105) and the regulators of the swing pumps (4) is pressurised. The pressure in the circuit is no longer balanced. The swing pumps (4) tilt out (altered pump flow) and feed into line (B). The pressure which builds up in the line is led to the pressure regulating valve (105) through line (X 5) and acts on the pilot piston (11.2). The pilot piston has a ratio of 1:12 to the main piston (11.1). When a state of balance is reached between the pilot force (X5) plus spring force (11.3), and pressure (Y1), a state of balance is also reached in the chambers of the pump regulator (4). The pumps stop tilting out. The pumps only continue tilting out when the reaction pressure (X5) drops. In this way, the pumps only supply so much oil as is being consumed by the swing motors (102). When the swing movement is to be interrupted, the joystick is returned to its neutral 0-position. The swing motors (102) are then driven by the swinging superstructure so that they pump oil back to the swing pumps. The previous pressure line (B) is freed of pressure is led through (X6) to pilot piston (11.5). The position of the pressure regulating valve is thereby retained and the superstructure can continue to swing until its rotation energy (momentum) has dropped to zero. Pressure relief valves in the swing pumps (4) limit the max. pressure in the swing circuit to 400 bar. At the same time, they serve as anti-cavitation valves in the system (to compensate for leakage oil losses). Oil feed to the system is carried out by the charge pumps through connection (Fa) on the swing pumps.

The pressure in the swing circuit is 50 bar, pressure being applied from the charge pumps.

RH 200 Diesel - 3663426e.doc - (01) – 09.03

Page 8.5.6 - 1

8.5


The swing pumps (4) are fitted with thermal switches, which pass a warning signal to the cab when the oil temperature exceeds 92° C. The warning in the cab is switched off again when the temperature drops back below 87° C. Leakage oil from the swing motors (102) is conducted back to the tank through the leak line (fig. 12).

Charge system (fig . 8 & 9) Each swing pump has an internal charge pump, which is replacing loss of oil in the closed swing circuit because of internal leakage of swing pumps and swing motors. The charge pressure of 50 bar is set by an internal pressure relief valve at each swing pump. The charge system is equipped with chip indicators and filters (34) to avoid contamination of the closed swing circuit in case of a charge pump failure

Flushi ng valve (fig . 10 & 11) The flushing valve (106) ejects a defined amount of oil from the closed swing circuit at the lowpressure side during each swing operation. The corresponding amount of filtered and cooled oil from the hydraulic tank is fed back into the swing system by the charging pumps.

Leak oil o f swing motors (fig. 12)

Fig. 1

Pressure regulating valve

Swinging to t he left Swinging to the left follows in the same manner as already described, but through the relevant connections for „left“. Countering The excavator operator can shorten the time taken to brake the swinging superstructure by countering - i.e. by summoning the opposite direction of swing.

Separate leak oil lines transport the leak oil of the swing motors (102) back to the hydraulic tank.

Swing parking brakes (fig. 13) The swing parking brake (B) between swing motor and gearbox is operated by a solenoid valve (26/1). The parking brakes are opened by auxiliary pressure (70 bar) when the solenoid valve is active. When the solenoid valve is inactive the hydraulic pressure is released to the tank and the parking brakes are closed by internal springs. This means that the brakes are automatically closed when the machine is shut off or the solenoid valve fails.

The pressure regulating valve (105) receives a reverse signal so that the regulator of the swing pumps are commanded to „tilt back“. The swing motors (102) start to work as pumps and drive the swing pumps themselves, which in turn feed their energy back into the drive system. Sensitive braking is possible. Brake torque in crease / decrease is possible using the control lever. When the superstructure has come to a standstill, the pumps have returned to their zero-tilt angle. The servo valve must then be shifted back to its neutral 0-position so as to prevent the superstructure swinging off again in the direction which was necessary to „counter“.

Page 8.5.6 - 2

RH 200 Diesel - 3663426e.doc - (01) – 09.03

8.5


Remark: The following colour code refers only to hydraulic lines and not to components! Col our

Code

Des ignat ion

P


R

Return oil circuit

R

Leak oil circuit

S

Servo oil circuit (40 bar)

H

Auxiliary oil circuit (70 bar)

F

Flushing system

C

Charge system

Ref.-no.

Quantity

Designation

4

4

Swing pump

11

2

Servo- and charge pump

25

1


26

2

Valve bank, complete

34

4

Filter for charge oil

40

1

Servo pressure valve block

100

4

Swing gearbox

102

4

Swing motor

103

4

Blocking valve

105

1


106

1

Flushing valve

107

2


B

4

Swing parking brake

further remarks

Solenoid valves

Swing balance valve

Table 1

RH 200 Diesel - 3663426e.doc - (01) – 09.03

Page 8.5.6 - 3

8.5


Fig. 2

Swing pumps - 630833a-02

Fig. 3

Swing pumps and swing motors – 3664754b-01

Page 8.5.6 - 4

RH 200 Diesel - 3663426e.doc - (01) – 09.03

8.5


Fig. 4

Swing pumps and swing motors - 3664754a-01

Fig. 5

Pilot lines for swing system – 3664731-01

RH 200 Diesel - 3663426e.doc - (01) – 09.03

Page 8.5.6 - 5

8.5


Fig. 6

Pilot lines for swing system - 3664754f-01

Fig. 7

Pilot lines for swing system - 3664754g-01

Page 8.5.6 - 6

RH 200 Diesel - 3663426e.doc - (01) – 09.03

8.5


Fig. 8

Charge system for swing circuit – 3664754d-01

Fig. 9

Charge system for swing circuit – 3664754e-01

RH 200 Diesel - 3663426e.doc - (01) – 09.03

Page 8.5.6 - 7

8.5


Fig. 10

Flushing valve for swing system – 3664754f-02

Fig. 11

Flushing valve for swing system – 3664754g-02

Page 8.5.6 - 8

RH 200 Diesel - 3663426e.doc - (01) – 09.03

8.5


Fig. 12

Leak oil lines for swing motors – 3664754c-01

Fig. 13

Swing parking brake - 3664749-01

RH 200 Diesel - 3663426e.doc - (01) – 09.03

Page 8.5.6 - 9

8.5


Page 8.5.6 - 10

RH 200 Diesel - 3663426e.doc - (01) – 09.03

8.5

HYDRAULIC CIRCUITS - TRACK TENSIONING SYSTEM

8.5.7

Track tensioning system

Remark: The position numbers in the pictures of this section are referring to the hydraulic circuit diagram and the components listed in chapter 8.3 - ‘Descripti on of the hydraulic sys tem’. The free ends of the hydraulic pipes and hoses are marked with capital letters for easier identification of the connecting points o n the various pictures. Each crawler track is kept constantly tensioned by oil from the servo circuit. The tracks are tensioned with a pressure of 70 bar. Pressure oil comes from the gear pumps (6) on the transfer gearbox. The pumps (6) suck the oil through the suction manifolds from the hydraulic tank and feed into the servo- and auxiliary pressure valve (40).

Oil of the 70 bar system flows through the rotor (91) and distributor assembly with secondary relief valves (134) to the tensioning cylinders (130) and diaphragm accumulators (131).

losses are automatically replaced by the system when the required track tensioning pressure is going below 70 bar. Tensioning the tracks See directions in Operating Instructions. The tracks are automatically tensioned. After starting one of the engines the auxiliary pressure (70 bar) is fed through the rotor(91) to the track tensioning system. After pressure built up in the track tensioning cylinders (130) and accumulators (131) the tracks are tensioned. Remark: The following colour code refers only to hydraulic lines and not to components! Colour

Code

Designation

P

70 bar circuit

R

Return oil circuit

The diaphragm accumulators (131) are shock absorbers that dampen the horizontal movement of the idlers in case of external forces. If the shock forces are excessive, oil is cracked off through safety valves (134) in the distributor assembly, which are set at 330 bar, into the tank. Such oil

Ref.-no.

Quantity

Designation

further remarks

6

4

Gear pump

28a

1

Solenoid valve

installed in superstructure

28b

1

Pressure reduction valve

installed in superstructure

40

1


91

1

Rotor

130

2

Track tensioning cylinders

131

2


133

1

Valve plate

installed in undercarriage

134

2


Secondary relief valve

Table 1

RH 200 Diesel - 3664265e.doc - (00) - 06.04

Page 8.5.7 - 1

8.5


Fig. 1

Pumps for track tensioning system – 3664708-01

Fig. 2

3664702c-04

Page 8.5.7 - 2

RH 200 Diesel - 3664265e.doc - (00) - 06.04

8.5


Fig. 3

3664702d-04

Fig. 4

Track tensioning lines – 3664702a-03

RH 200 Diesel - 3664265e.doc - (00) - 06.04

Page 8.5.7 - 3

8.5


Fig. 5

Page 8.5.7 - 4

Track tensioning system in undercarriage – 3664335-01

RH 200 Diesel - 3664265e.doc - (00) - 06.04

8.5 HYDRAULIC CIRCUITS - COOLING SYSTEM FOR HYDR. OIL

8.5.8

Cooling system for hydraulic oil


The 4 cooling pumps (10) are gear-type pumps with fixed displacement. They are flanged directly onto the 4 swing pumps (fig. 1).

an increasing oil flow is driving the fan motor (81) and then flowing through the cooler. At temperatures above 52° C the full flow is passing through the fan motor and the oil cooler. Pressure relief valves (43) – set to 65 bar – is protecting the cooling circuit. An example for the cooling oil flow is shown in fig. 4 & fig. 5.

The setup of the cooling system is shown in fig.2 & fig. 3.


Code

Each 2 pumps are pumping the hydraulic oil into a distributor plate (85) with thermostats (87). The regulating range of the thermostats is +40° C to +52° C. At temperatures below +40° C the position of the spool in the valve allows the oil to return directly to the hydraulic tank without flowing through fan motor and oil cooler.

Designation

C

Cooling oil circuit

R

Return oil circuit

L

Leak oil circuit

With rising temperature the thermostat is shifting the spool an thus closing the port to the tank and

Ref.-no.

Quantity

Designation

further remarks

10

4

Cooling pump

Gear pump

85

2

Distributor plate with thermostat

81

4

Fan motor

Gear motor

Table 1

RH 200 Diesel - 3664276e.doc - (00) - 07.05

Page 8.5.8 - 1


Fig. 1

Location of pumps for oil cooling - 630833b-02

Fig. 2

Fan pumps and thermostat valve blocks - 3666305a-01

Page 8.5.8 - 2

RH 200 Diesel - 3664276e.doc - (00) - 07.05


Fig. 3

Thermostat valve blocks and fan motors – 3666305b-01

Fig. 4

Example for cooling oil flow - 3666305a-02

RH 200 Diesel - 3664276e.doc - (00) - 07.05

Page 8.5.8 - 3


Fig. 5

Page 8.5.8 - 4

Example for cooling oil flow - 3666305b-02

RH 200 Diesel - 3664276e.doc - (00) - 07.05

8.5 HYDRAULIC CIRCUITS - COOLING SYSTEM FOR ENGINES

8.5.9

Cooling system for engines


The 2 cooling pumps (11) are axial piston pumps with variable displacement. On each drive unit one cooling pump is flanged directly onto one of the swing pumps (fig. 1). Each cooling pump is driving a gear motor (140). The gear motors are driving the fans for the radiators of the engines. The flow of the cooling pumps is regulated with help of proportional valves which are directly flanged onto the pump regulators. Depending on the actual temperature in the engine cooling system the Pump Managing System (PMS) is regulating the speed of the fans. The temperature range for the regulation is + 85° C to + 92° C. At coolant temperatures below 85° C in the engine cooling system the fan pumps are regulated to minimum flow so that the fans are only turning very slowly (200 rpm) the warm-up period of the engines is shortened.

At temperatures above 92° C the maximum flow is passing through the fan motors and they are turning with 815 rpm. With low engine temperature the PMS is supplying maximum current (580 mA) to the proportional valve of the cooling pump and the pump is at minimum flow. With increasing engine temperature the PMS is reducing the current for the proportional valves to 150 mA and the cooling pumps are increasing the flow to the fan motors. This fail-save system ensures that in case of an electric problem (e.g. a broken cable to the proportional valve) the fan pump stays at maximum flow so that maximum cooling for the engine is achieved. Remark: The following colour code refers only to hydraulic lines and not to components! Colour

Code

Designation

C

Fan pump circuit

R

Return oil circuit

L

Leak oil

With rising temperature in the cooling system the flow of the cooling pumps and consequently the speed of the fans are increasing to their maximum.

Ref.-no.

Quantity

Designation

further remarks

11

2

Cooling pump

Axial piston pump

140

2

Fan motor

Axial piston motor

141

2

Anti cavitation block

Table 1

RH 200 Diesel - 3664277e.doc - (00) - 07.05

Page 8.5.9 - 1

8.5 HYDRAULIC CIRCUITS - COOLING SYSTEM FOR ENGINES

Fig. 1

Fan pumps and fan motors - 3664958-01

Fig. 2

Fan pump with electronic regulator

Page 8.5.9 - 2

RH 200 Diesel - 3664277e.doc - (00) - 07.05

8.5

HYDRAULIC CIRCUITS - COOLING FOR PUMP GEARBOX

8.5.10 Cooling system for pump gearbox Remark: The position numbers in the pictures of this section are not shown in the hydraulic circuit diagram and the components are not listed in chapter 8.3 - ‘Description of the hydraulic system’.

the gear oil temperature. The data is displayed on the BCS. Depending on the gearbox version the components are either installed in a block at the gear pump or in the gearbox housing. To avoid, that the gear oil is pumped out of the system (e.g. because of leaks) the system is preloaded to 1,0 bar by a check valve ( R ) and a pressure switch (E) is indicating loss of pressure in the whole system. Remark:

The pump gearbox is equipped with a cooling system for the gear oil. A gear pump (E) is pumping the gear oil through a filter (C) to the gear oil cooler (A) and back into the pump gearbox (B) (fig. 1). The oil cooler is installed as a separate heat exchanger in the hydraulic oil tank. A thermostatvalve (G) with an opening temperature of 55° C protects the oil cooler against pressure peaks especially when the engine is started under cold weather conditions. A chip indicator is monitoring the condition of the gear pump (E). A temperature sensor is monitoring

Ref.-no.

Quantity

Designation

A

1

Gear oil cooler section

B

1

Pump gear box

C

1

Filter for gear oil

D

1

Pressure switch

E

1

Gear pump

G

1

Thermostat valve

R

1

Check valve

The following colour code refers only to hydraulic lines and not to components! Colour

Code

Designation

P


R

Return oil circuit

further remarks

Setting: 0,5 bar

Opening pressure: 1,0 bar

Table 1

RH 200 Diesel - 3664266e.doc - (00) - 06.04

Page 8.5.10 - 1

8.5

HYDRAULIC CIRCUITS - COOLING FOR PUMP GEARBOX

Fig. 1

Page 8.5.10 - 2

System for gear oil cooling of pump gearbox - 3663056-01

RH 200 Diesel - 3664266e.doc - (00) - 06.04

8.6

PRESSURE CHECKING AND SETTING

8.6

Pressure checking and setting

8.6.1

Int roduct ion

8.6.1.1

Foreword

This Technical Handbook (TBH) describes the pressure checking and setting procedures on the excavator ´s hydraulic system. It is v alid f or RH 200 seri al-no. 40 029 to 40 068 and fro m seri al-no. 200 069 The illustrations, descriptions and explanations reflect the current standard configuration. Some of the illustrations can show details that differ from a particular machine, but that does not affect the validity of the information given. If any points are nevertheless unclear or incorrect, please contact your local TEREX dealer or your TEREX distributing centre. Further development and alternations that introduce into the standard series production will be implemented into later re-prints of the TBH. When setting the pressure relief valves the hydraulic oi l temperature has to be higher than 52°C.

8.6.1.2

Saf et y

Observe accident prevention and safety regulations at all times. The pressure checking and setting may only be done by special trained and authorized personnel with the appropriate technical know-how. The nominal pressure relief valves must not be modified without explicit approval form TEREX. Al l perso nnel carryin g out commissioning, operation, inspection, service and repair must have read and understood the operating instructions and in particular the chapter 'Fundamental Safety Instructions.' before starting any work . Unauthorized conversions or modifications of the hydraulic excavator are forbidden for reasons of safety. Secure the machine and the working attachment against inadvertent and unauthorized starting. Stand working attachment on the ground in such way as that no movements can be made when mechanical or hydraulic connections become detached. Tools, hoists, slings, trestles and other devices must be in a reliable safe state. Systems and units (e.g. pipes, coolers, hydraulic reservoirs, compressed-air reservoirs ) must be properly depressurized before being opened. Protective devices on moving machine parts may be opened or removed only when the drive unit is stationary and protected against inadvertent st arting .

RH 200 Diesel - 2471390e.doc - (02) – 01.98

Page 8.6 - 1

8.6 8.6

PRESS RESSU URE CHEC CHECKI KING NG AND AND SET SETTI TIN NG

Before recommissioning, all protective devices must be refitted. Catwalks on the boom are only to be walked on when the excavator's working attachment has been brought into the position required for checking/settings pressures. Hydraulic cylinders must be brought into their end positions before pressures are checked or set to ensure that working attachment does not move when pressure is applied. The excavator operator must operate the relevant function gently (gradual application of pressure) and the shift the joystick/pedals fully to their end position. Al l Pressu Pres su re tes t poin po in ts on th e excavator have Minimess connections (M14 x 1,5). Pressure gauges used for checking must therefore have corresponding fittings. Al w ays co nnect nn ect th e Min im ess-ho ess -hose se first to the gauge and then to the test point on the machine to avoid spillage of pressurized oil!

8.6.1.3

Genera nerall

The reference numbers used in the text and illustrations correspond to those used in the hydraulic circuit diagram. Since the machine is equipped with the BCS-Board Control System, most pressures are available on the BCS display. If pressure must be reset, in any case calibrated gauges have to be used, they have to be connected to the relevant test points.

Numbering Numbering of main pumps The 4 main pumps are numbered in travel direction from left to right P1, P2, P3, and P4 (Fig.1 ), thus P1 and P2 are driven by the engine, and P3 and P4 are driven by the right engine.

Numbering Numbering of swing pum ps Each drive unit is equipped with a swing pumps (double pumps). The swing pumps on the left pump gear are named SP1 and SP2, the pumps on the right pump gear are SP3 and SP4 (Fig. 1).

The springs in pressure relief valves must never be tightened fully to "block". The windings of the spring are then jammed so that the valve cannot open. Before setting/resetting a relief valve (primary or secondary) loosen the valve insert by approx. 2 turns: Turning anti-clockwise (loosening) =lower pressure setting Turning clockwi se (tightening) (tightening)

Fig. 1

=increase pressure setting To set/reset a pressure relief valve loosen the counter nut on the valve insert, set the opening pressure using the setting crew, and then tighten the count er nut again. When checking/setting pressures the hydraulic oil temperature must be abov e 50°C. 50°C.

Page 8.6 - 2

RH 200 Diesel - 2471390e.doc - (02) – 01.98

8.6 8.6 8.6.2

PRESS RESSU URE CHEC CHECKI KING NG AND AND SET SETTI TIN NG Pr es es su su re re se set ti ti ng ng Des c r i p t i o n

Un i t

RH 200

Cylinder

bar

300

Travel

bar

340

Primary relief for main pumps

bar

380

Secondary relief for

bar

350

bar

350

Bucket croud cylinders

bar

350

Backhoe cylinders

bar

350

Clam cylinders (4-spool valve)

bar

350

Clam cylinders (Backwall)

bar

330

Travel system

bar

380

Proportional valve feed pressure – main pumps

bar

7.5 – 42,5

Servo pressure

Attachment

bar

40

Main pumps

bar

70

Swing system – working pressure max.

bar

375

Swing system – charge pressure (approx.)

bar

50

Fan drive - pressure

bar

approx. 35

Pressure cut-off – main pumps

Boom cylinders Arm / Stick cylinders

Hydraulic oil cooling

Table 1

RH 200 Diesel - 2471390e.doc - (02) – 01.98

Page 8.6 - 3

8.6 8.6


8.6.3

To o l s

For pressure checking and setting the tools listed in table 2 are required.

Fig. 2

Tools

It em

Qu an t i t y

Des i g n at i o n

Par t -No .

1

2

Test kit with gauges and hoses

1 476 323

2

1

Test adapter for proportional valve

1 433 919

3

1

Multimeter

1 088 932

4

1

O/E-ring spanner, 10 mm

0 717 903

5

1


0 559 698

6

1


0 559 702

7

1


0 717 908

8

1


0 717 913

9

1

Allan Key, 3 mm

0 014 122

10

1

Allan Key, 4 mm

0 014 123

11

1

Allan Key, 5 mm

0 014 124

12

1

Allan Key, 6 mm

0 014 125

13

1

Accumulator test and charging device

1 429 836

----

1

Adapter for nitrogen cylinder (see chapter 3.2.2 in THB)

Table 2

Page 8.6 - 4

RH 200 Diesel - 2471390e.doc - (02) – 01.98

8.6 8.6

8.6.4.1


Servo cont control rol syste system m

Servo pressure is to be set on valve combination (16 & 17, Figs. 1 & 2).

Fig. 2

Checking Checking and setting pr essures Fig. 1 •

Pressure relief valve (17): Limits the Servo pressure for the functions “Working equipment”, “Swing” and “Travel” to 35 bar. •

Differential pressure valve (16): Increases servo pressure by 25 bar to 60 bar. The higher pressure is needed for the regulation of the working pumps, the increase of travel pressure and the switch-over of travel motors.

•

•

•

•

Connect a 100 bar pressure gauge to point (16.1, Fig. 1) for differential valve (16) and a 60 bar gauge to point (17.1) for pressure relief valve (17). Run both engines up to top speed. Check pressures. Pressure relief valve (17): pressure should be 35 bar. If a correction is necessary, re-set valve (17). Differential valve (16): pressure should be 60 bar. If 60 bar is not reached (with relief valve (17) correctly set), re-set valve (16). Unscrew nut (16.2, Fig. 1) and re-set valve using the setting screw.

Pressure Pressure loading in cont rol spool servo caps Restrictor valve (110, Figs. 3 & 4) keeps the servo caps (90.1, Fig. 3) of control blocks (90) under a pressure load of 1,5 bar.

RH 200 Diesel - 2471390e.doc - (02) – 01.98

Page 8.6 - 5

8.6 8.6


Fig. 3

Checking Checking pressure load •

•

•

•

Connect a 10 bar pressure gauge to point (110.1, Fig. 3). Extend and retract boom, stick and bucket cylinders several times. Check pressure It should be: 1,5 bar Re-set the restrictor if necessary. To re-set, loosen lock (1, Fig. 4) and alter the valve setting by turning knob (2).

Fig. 4

Turning clockwise: clockwise: Closes Closes the restrictor restrictor = higher pressure Turi Turing ng anti anti-c -clo lock ckwi wise se:: Open Opens s the the rest restri ricctor = lower pressure

Page 8.6 - 6

RH 200 Diesel - 2471390e.doc - (02) – 01.98

8.6

8.6.4.2


Load limit system

The governing current output by the GLR 200 load limit governor (“black box”) is converted by the proportional valves (21, Figs. 1 & 2) into hydraulic signals that are sent to the main pumps (P1 - P4).

Checking •

•

•

•

•

•

•

Connect two 100 bar pressure gauges to points (21.1 & 21.2, Fig. 2). Run both engines up to top speed. Check pressure It should be: approx. 8 bar (230 mA) Apply pressure to piston side of stick cylinders. Check pressure It should be: approx. 43 bar (850 mA) If the required pressures are not reached, the proportional valves are to be checked. A metering adapter (Fig. 3) is needed to measure the current arriving at the valves from the GLR-box.

Fig. 1

Arrangement (Fig. 2): 21.1 (Y 18) = main pumps P1 + P2 21.2 (Y 17) = main pumps P3 + P4

Fig. 3

•

•

•

Fig. 2

•

RH 200 Diesel - 2471390e.doc - (02) – 01.98

Connect metering adapter. Re-run the checks described above. Measure the currents at contacts (A, Fig. 3) each time. If the electrical currents stated are not reached, there is a fault somewhere in the load limit circuit. If the electrical currents are reached, but not the hydraulic pressures, a fault is present in the proportional valve and it needs to be changed.

Page 8.6 - 7

8.6


8.6.4.3

Pressure cut-off system

•

The pressure cut-off function for the main pumps (3, Fig. 1) is managed by the sequence valves (3.1).

•

•

•

•

•

•

Fig. 1

Run both engines up to top speed. Checking pressure equipment.

cut-off

for

working-

Apply pressure to piston sides of stick cylinders. Shift the joystick gently into the end position. Check pressures: They should be 300 bar. If a correction is necessary, re-set the respective valve as described. Checking pressure cut-off for track drives. Apply pressure to track drives. Depress the treadle valves gently into the end positions. Check pressures: They should be 360 bar. If correction is required, check setting of valve combination (16 & 17, Fig. 3) (cf. section on servo-control).

Pressure cut-off valve

Checking and setting •

•

Engage track parking brakes (using toggle switch) and lower working equipment to the ground. Connect four 400 bar pressure gauges to the test points (36.1, Fig. 2) for the relief valves (36). Fig. 3

Fig. 2

Page 8.6 - 8

Relief valves

RH 200 Diesel - 2471390e.doc - (02) – 01.98

8.6


8.6.4.4

Primary pressure relief

The primary pressure of the four main pumps is limited by four pressure relief valves (36, Fig. 1).

Fig. 1

Primary relief valves Fig. 2

The pumps are coded P1 - P4 from left to right in direction of travel.


•

•

Connect four 400 bar pressure gauges to metering points (36.1, Fig. 1). Engage track parking brakes (with toggle switch) and lower working equipment to the ground.

•

Check primary relief settings for pumps (P2, P3 & P4) in the same way.

Checking conditions: Primary relief (P2):

RH engine stopped LH engine at full speed LH track forwards or reverse

Primary relief (P3):

LH engine stopped RH engine at full speed RH track forwards or reverse

Primary relief (P4):

LH engine stopped RH engine at full speed LH track forwards or reverse

Primary relief for main pump (P1) - Switch off the pressure cut-off by shifting cock (5, Fig. 2) on P1 into position 0. - Run left-hand engine up to full speed. Shut down the right-hand engine. - Summon “Right-hand track - forwards or reverse”. - Check pressure. - It should be: 370 bar. If correction is necessary, re-set primary valve.

Note: When checking primary relief pressure (P3 & P4), all pressure gauges show the pressures for (P3 & P4).

- Switch on pressure cut-off by shifting cook (5, Fig. 2) back into position 1.

RH 200 Diesel - 2471390e.doc - (02) – 01.98

Page 8.6 - 9

8.6


8.6.4.5

Second ary relief sys tem for attachment

The secondary pressure relief valves for the attachment are flanged onto the 4-spool control blocks (90, Fig. 1). The 4-spool control blocks are located on the boom.

The faceshovel attachment is equipped with an additional secondary relief valve for the rod side of the clamshell cylinders, which is installed on the distributor at the backwall of the bucket (Fig. 2).

Fig. 1

Secondary relief valve

Valve arrangement for faceshovel configuration (Fig. 1) Position 1

Relief valve for Spool not connected

Position 9

Relief valve for Spool not connected

4+6

Bucket croud cylinder – piston side

12 + 14

Bucket croud cylinder – rod side

3+7

Arm cylinder – rod side

11 + 15 Arm cylinder – piston side

2+8

Boom cylinder – piston side

10 + 16

Boom cylinder – rod side

5

Clam cylinder – piston side

13

Clam cylinder – rod side

Table 3a

Valve arrangement for backhoe configuration (Fig. 1) Position

Relief valve for

Position

Relief valve for

11 + 15

Bucket cylinder – piston side

3+7

Bucket cylinder – rod side

12 + 14

Stick cylinder – piston side

4+6

Stick cylinder – rod side

10 + 16

Boom cylinder – piston side

2+8

Boom cylinder – rod side

1, 5, 9, 13 Spools not connected Table 3b

Page 8.6 - 10

RH 200 Diesel - 2471390e.doc - (02) – 01.98

8.6


Table 4: Secondary pressure relief valves * Switch off “float” when checking To check valves for Rod sides: retract cylinders fully Piston sides: extend cylinders fully

Fig. 4

Checking and setting Fig. 2

Secondary relief valve at backwall •

•

Connect 400 bar pressure gauges. Switch off pressure cut-off on pump (P2) by shifting cock (5, Fig. 4) into position 0. In the case of the dump cylinders, also switch off pressure cut-off for pump (P1).

•

Run left-hand engine up to full speed.

•

Check and set pressures - Recommended sequence - see Table 1. - Example: piston side of stick cylinders

Fig. 3

Test points on float valves

- Switch off “stick float”; shift joystick gently into end position. - Check pressure: it should be 350 bar. - Because the piston sides of the stick cylinders are protected by a pair of valves (11 & 15, Fig. 1), the pressure gauge on port (15.1) always registers the pressure of the valve with the lower setting. Even when the gauge shows 350 bar, it is still possible for one of the valves to have a higher setting. - For this reason, lower the pressure on the 1st valve to below 350 bar. The pres-

RH 200 Diesel - 2471390e.doc - (02) – 01.98

Page 8.6 - 11

8.6


sure on the gauge must drop noticeably. Then increase back up to 350 bar. - Set the 2nd valve in the same way. •

After checking / setting secondary pressures, shift cocks for pressure cut-off (5, Fig. 4) back into position 1.

8.6.4.6

Secondary relief system for travel

The four secondary relief valves (77.1 - 77.4, Fig. 1) for the track motors are located in the undercarriage module. The valves (77.2 & 77.3) are on the rear side of the housing.

Clam c ylinders To adjust the additional secondary relief valve for the rod side of the clam cylinders – installed in the backwall – open the bucket, keep the clam cylinder rod-side pressurised and set the relief valve to 330 bar.

Fig. 1

Secondary relief valve for travel


•

•

Page 8.6 - 12

Engage the track parking brakes (with toggle switch) and lower the working equipment to the ground. De-stroke the main pumps by shifting the Power control / Eco Set switch to 60 % (see Operating Instructions). Connect four 400 bar pressure gauges to the metering points for the pressure relief valves.

RH 200 Diesel - 2471390e.doc - (02) – 01.98

8.6


Fig. 2

•

•

•

•

•

•

Switch off pressure cut-off for main pumps (P1 & P2) by shifting the cocks (5, Fig. 2) into position 0. Run left-hand engine up to top speed. Leave the track brakes engaged and summon “left-hand track forwards”. Depress treadle valve gently into end position. Check pressure on relief valve (77.1, Fig. 1). It should be: 370 bar. Re-set the valve if necessary. Summon following functions, one after the other: LH track RH track RH track

•

•

Pressure cut-off valve

reverse (valve 77.2) forwards (valve 77.3) reverse (valve 77.4)

and check pressures in the same manner. After checking / setting secondary pressures, shift cocks for pressure cut-off (5, Fig. 2) back into position 1.

RH 200 Diesel - 2471390e.doc - (02) – 01.98

Page 8.6 - 13

8.6


8.6.4.7

Swing system

Checking and setting 1.

2.

Lower working equipment to the ground and engage the superstructure holding brake. Connect two 400 bar pressure gauges to the metering points (51.1, Fig. 1) on the balance valve.

Connect two 60 bar pressure gauges to ports (X1 and X2, Fig. 2) on pressure valve (54). Re-set valve using setting screw (54.1) until pressures are equal. Proceed under 4.2 4.2 If pressures are equal: connect two 60 bar gauges instead of the 400 bar gauges to the ports on (51.1, Fig. 1). The 60 bar gauges have a higher accuracy.

Do NOT summon a “swing” function as this will destroy the gauges.

Fig. 1

Swing balance valve

Check charge pressure: at full engine speed and with flushing valve (57, Figs. 2 & 3) correctly set, the charge pressure should be 25 bar. Charge pressure is limited by the pressure relief valves (6.1, Fig. 3) - one valve for each swing pump. The valves are works set to 25 bar. The setting must not be altered. If 25 bar charge pressure is not reached, call in TEREX Service.

Fig. 2

Swing balance valve

3.

Run both engines up to top speed.

4.

Check pressure with superstructure locked: both gauges on the balance valve must register the same pressure. Fig. 3

4.1 If pressures are not equal: Pressure valve (54, Fig. 1 + 2) and swing pumps are not exactly in the middle position (superstructure “trying to swing”).

Page 8.6 - 14

RH 200 Diesel - 2471390e.doc - (02) – 01.98

8.6


6.

Leave the superstructure holding brake engaged and summon “Swing right”. Shift joystick gently into the end position.

7.

Check pressure: the gauge for the highpressure side on swing motor (51, Fig. 1) must register approx. 350 bar. The other gauge (low pressure side) must register approx. 25 bar. The pressure on relief valve (55, Fig. 6) is then approx. 31 bar. If the high pressure on motor (51) is higher or lower than approx. 350 bar, re-set valve (55, Fig. 6) until approx. 350 bar is reached.

Fig. 4

Flushing valve

The primary relief valves (6.2, Fig. 5) for the swing circuit (2 valves per swing pump) have fixed settings of 400 bar. Their settings must NOT be altered.

Flushing valve (57, Figs. 2 & 3) flushes the oil in the closed loop swing circuit. Each time a “swing” function is summoned, a small quantity of oil is flushed out of the low-pressure side. Setting: dimension “A” on setting screw (57.1, Fig. 3) must be 15 mm. 5.

Take the 60 bar gauges off the swing motor (51) and connect the 400 bar gauges again. Connect a 60 bar gauge to metering port (55.1, Fig. 5) for pressure relief valve (55). The valve is located in the cab module underneath the platform plate.

Fig. 5

8.

Summon “swing left”. Shift the joystick gradually into the end position. This time the other gauge on the swing motor (51, Fig. 1) must register approx. 350 bar. The other one approx. 25 bar.

Relief valve

RH 200 Diesel - 2471390e.doc - (02) – 01.98

Page 8.6 - 15

8.6

8.6.4.8


Track tensioning system

The pressure for hydraulic track tensioning is taken from the servo-circuit. The tracks are permanently tensioned with approx. 60 bar when engine on the left side is running.

8.6.4.9

Hydraulic oil cooling

The hydraulic oil is cooled in two separate circuits. Each circuit is protected by two relief valves (43, Fig. 1). Arrangement: Front cooler = LH engine Rear cooler = RH engine

Tensioning the tracks See Operating Instructions Diaphragm accumulator Check the gas pressure in the accumulator according to the Operating Instructions. Secondary relief The track tensioning systems are protected by two secondary relief valves (70, Fig. 1) with fixed settings of 330 bar.

Fig. 1

Oil cooling - relief valve


•

Fig. 1

Relief valves - track tensioning

•

Connect four 60 bar pressure gauges to ports (43.1). Fig. 1 shows one of the two distributor plates. Check that oil temperature is above 52° C and that the thermostats are fully closed. Check pressure. Circuiting pressure should be approx. 35 bar.

Pressure relief If the pressure-limiting valves (70) are open there will be no servopressure and thus no possibility of activating hydraulic functions.

Pressure relief valves (43) are works set to approx. 65 bar. To check, proceed as follows: •

•

Page 8.6 - 16

Set valves to circuiting pressure. To do this, reduce valve cracking pressure until the circuiting pressure starts to drop. Then tighten valve inserts ½ of a turn (cracking pressure is increased again).

RH 200 Diesel - 2471390e.doc - (02) – 01.98

8.7

INSTALLATION OF HYDRAULIC PUMPS

8.7

In st all at io n o f h yd rau li c pumps

8.7.1

General

When removing or installing hydraulic pumps all relevant safety regulations have to be observed.

8.7.2

Always observe the safety regulations applicable to the product when handling oils, greases and other chemical substances.

Components

Table for Fig. 1 Ref. no.

Quantity

Designation

Further remarks

1

16

Hex. bolt M 20 x 80 – 8.8


2

16

Washer

3

2

O-ring

4-8

Weight [kg]

----

9

2

O-ring

10

8

Washer

11

8

Hex. bolt M 20 x 50 – 10.9

12

2

O-ring

13

4

Washer

14

4

Hex. bolt M 12 x 30 – 8.8

15

2

O-ring

16

8

Washer

17

8

Hex. bolt M 12 x 30 – 8.8

18

1

O-ring

19

2

Hex. bolt M 10 x 25 – 8.8

20



Tightening torque Md = 71 Nm Tightening torque Md = 41 Nm

----

21

2

Main pump

22

2

Swing pump

23

1


24

1

Fan pump for radiator

25

2

Fan pump for hydraulic oil cooling

26

2

Gear pump for servo system

Table 1

RH 200 Diesel - 3664249e.doc - (00) – 06.05

Page 8.7 - 1

8.7


1, 11, 14, 17, 19 Fig. 1

8.7.3

Installation of hydraulic pumps

Removal and installation of the hydraulic pumps

Installation o f a pump 1.

Apply lubricating paste (Part-no. 244 905) to splines of pump shaft, adapter and gearbox shaft.

1. Disconnect electric cables.

2.

Install new O-ring with grease.

2. Close gate valves between hydraulic tank and suction line of the pump.

3.

Attach lifting device to the pump and lower into place. Insert and tighten mounting bolts with required torque (see table).

4.

Connect all hydraulic lines as market.

Removal of a pump

3. Open hydraulic lines of the pump cautiously. Collect hydraulic oil in suitable container. 4. Remove hydraulic lines and mark them to avoid mix up. Close all open hoses, lines bores and housings carefully to prevent dirt from penetrating. 5. Attach lifting device to the pump; disassemble mounting bolts and remove the pump.

Page 8.7 - 2

Open gate valves of the hydraulic tank!

Al l axial pi st on pumps have to be filled with hydraulic oil before start up to avoid damage of the pump when running dry.

RH 200 Diesel - 3664249e.doc - (00) – 06.05

8.7

5.


Bleed pumps!

6. Connect electric cables again.

Filling and bleeding the pumps has to be done through the ports for the lines or the bleeder plugs (Fig. 2).

Fig. 2

RH 200 Diesel - 3664249e.doc - (00) – 06.05

Filling and bleeding of the pumps

Page 8.7 - 3

8.7


Page 8.7 - 4

RH 200 Diesel - 3664249e.doc - (00) – 06.05

8.7


8.7


8.7.1

General

When removing or installing hydraulic pumps all relevant safety regulations have to be observed.

8.7.2

Always observe the safety regulations applicable to the product when handling oils, greases and other chemical substances.

Components

Table for Fig. 1 Ref. no.

Quantity

Designation

1

2

Main pump

2

2

Fan pump for hydraulic oil cooling

3

2

Swing pump

4

1

Fan pump for radiator

5

1


6

----

7

----

Further remarks

8

1

Gear pump for servo system

Double pump

9

8

Hex. bolt M 20 x 50 – 10.9


10

8

Washer

11

16

Washer

12

16

Hex. bolt M 20 x 80 – 8.8


13

2

Hex. bolt M 10 x 25 – 8.8


14

8

Hex. bolt M 12 x 30 – 8.8


15

8

Washer

16

4

Hex. bolt M 12 x 30 – 8.8

17

4

Washer

18

---

19

---

20

2

O-ring

21

2

O-ring

22

2

O-ring

23

2

O-ring

24

1

O-ring

Weight [kg]


Table 1

RH 200 Diesel - 3657791e - (00) – 09.03

Page 8.7 - 1

8.7


9, 12, 13, 14, 16 Fig. 1

8.7.3


Removal and installation of the hydraulic pumps

Installation of a pump 1.

Apply lubricating paste (Part-no. 244 905) to splines of pump shaft, adapter and gearbox shaft.

1. Disconnect electric cables.

2.

Install new O-ring with grease.

2. Close gate valves between hydraulic tank and suction line of the pump.

3.

Attach lifting device to the pump and lower into place. Insert and tighten mounting bolts with required torque (see table).

4.

Connect all hydraulic lines as market.

Removal of a pump

3. Open hydraulic lines of the pump cautiously. Collect hydraulic oil in suitable container. 4. Remove hydraulic lines and mark them to avoid mix up. Close all open hoses, lines bores and housings carefully to prevent dirt from penetrating.

Open gate valves of the hydraulic tank!

5. Attach lifting device to the pump; disassemble mounting bolts and remove the pump.

All axial piston pumps have to be filled with hydraulic oil before start up to avoid damage of the pump when running dry.

Page 8.7 - 2

RH 200 Diesel - 3657791e - (00) – 09.03

8.7 5.


Bleed pumps!

6. Connect electric cables again.

Filling and bleeding the pumps has to be done through the ports for the lines or the bleeder plugs (Fig. 2).

Fig. 2

RH 200 Diesel - 3657791e - (00) – 09.03

Filling and bleeding of the pumps

Page 8.7 - 3

8.7


Page 8.7 - 4

RH 200 Diesel - 3657791e - (00) – 09.03

8.8

HYDRAULIC CYLINDERS - FS

8.8

Hydraulic cylinders

8.8.1

Introduction

8.8.1.1

Foreword

This section describes the procedures necessary when repairing hydraulic cylinders. The illustrations and descriptions correspond to the current series status. It is possible for some illustrations to show details that differ from a particular machine or component. This, however, is of no consequence to the overall function. In case of doubt, consult the TEREX Mining Service. Any alterations and up-grading introduced into the series will be considered in future re-prints of the Technical handbook (THB).

The required special tools can be found in Chapter 3.2.8 ‘cylinder tools’

8.8.1.2

Safety

Observe the accident prevention regulations at all times. Any person involved in commissioning, operating, inspecting or servicing the TEREX excavator must have read through the Operating Instructions - especially the chapter ‘’SAFETY’’ - before starting any work. Personnel working on the machine and its components must have adequate knowledge of the procedures involved. Tools, lifting equipment, rigging tackle, trestles, working platforms and other working aids must be in a safe and reliable condition. Depressurize any systems that are to be opened for servicing or inspection work. Before commencing an servicing or inspection work, secure the machine and its equipment against unintentional starting, e.g. place chocks under the tracks and lower the working equipment to the ground. Park the excavator on a level surface and block it to prevent it from moving. Lock the superstructure, lower the working equipment to the ground, stop the engine(s) and secure it against unintentional starting.

RH 200 (FS) - 2471393e - (01) – 01.98

Page 8.8 - 1

8.8


Do not loosen any fittings, pipes or hoses until hydraulic pressure has been released from the system. Take care when hydraulic oil is hot. Fully retract the piston rods of the cylinder to be removed, and fasten the piston rod to the cylinder so that it cannot extent. The hydraulic connections can then be loosened. Use suitable containers to catch spilling oil. Use suitable lifting tackle to remove and install piston rods and guide bushings.

Close up any open pipes, hoses and housing ports to prevent dirt from getting into the system. When working on hydraulic cylinders (especially when removing and fitting piston rods), keep the cylinder in a vertical position. Place long cylinders into inspection pits so that the piston rod eye and guide bushing are accessible from ground level.

8.8.1.3

General

All cylinder components are carefully matched to one another. Long-term trouble-free operation can only be ensured when genuine TEREX spare parts are used. The wear and spare parts necessary for the cylinders are listed in the excavator's spare parts list. This section does not describe procedures necessary for overhauling damaged cylinders. Only specialist workshops can judge whether a damaged component can be overhauled and which procedures are necessary. Work to be performed in your own workshops should therefore be limited to the installation of new TEREX wear and spare parts. All procedures must be carried out carefully in a clean workshop. Negligence can lead to major damage to the whole hydraulic system. After servicing, the hydraulic cylinders must be bled of air prior to being used again. Air pockets remaining in a cylinder can ignite (diesel effect) and cause serious internal damage to the cylinder. If any contamination of metal particles are found in the cylinder, on the magnetic rods or in the filters, the whole system must be flushed clean. The procedure is described in chapter 8.2.

Cleanliness is of prime importance. Use only fibre-free cloths and rags (do NOT use cotton waste). Always tools.

use

the

recommended

When removing seals and wearing parts, always use suitable tools, e.g. snub-nosed screwdrivers, to prevent damaging the sealing surfaces.

Page 8.8 - 2

RH 200 (FS) - 2471393e - (01) – 01.98

8.8


8.8.2

Design types

8.8.2.1

Boom cylinder

4 3 5

18

6

6

7

8

22 9 19 10

11

12

13 2

14

13

12

12 11 20

23

A Fig. 1

RH 200 (FS) - 2471393e - (01) – 01.98

4525838A.SKD Boom cylinder

Page 8.8 - 3

8.8


Components of boom cylinder (Fig. 1) Position

Quantity

Designation

Further remarks

Weight [kg]

Position of pivot bearing split

A 1

1

Cylinder barrel

2 092

2

1

Piston rod

1 200

3

1

Bearing eye

4

1

Scraper

5

1

Sealing ring

6

1

Sealing ring

7

1

Guide

8

1

Guide ring for piston rod

9

1

Back ring

10

1

O-ring

11

2

Protection element

12

3

Guide ring for piston

13

2

Guide ring for piston (metal)

14

1

Piston seal

15

2

Bushing

16

----

17

----

18

2

Hex. bolt M 39 x 3 x 220

19

15

Washer

20

1

Bearing eye

21

373

236

51

----

22

15


23

1

Circlip

24

2

Grease nipple

25

2

Reducer

26

2

Sealing ring

Table 1

Page 8.8 - 4

RH 200 (FS) - 2471393e - (01) – 01.98

8.8


8.8.2.2

Arm cylinder 3 5 17

17

6 8 21

7 18

9 10

22 11 19 12

13

14

1

15 16

2 15

14

14 13 4

4 4525840A.SKD

Fig. 2

RH 200 (FS) - 2471393e - (01) – 01.98

Arm cylinder

Page 8.8 - 5

8.8


Components of arm cylinder (Fig. 2) Position

Quantity

1

1

Cylinder barrel

2

1

Piston rod

833

3

1

Fork

379

4

2

Bushing

5

1

Scraper

6

1

Scraper

7

1

Guide

8

1

Sealing ring

9

1

Sealing ring

10

1


11

1

Back ring

12

1

O-ring

13

2

Protection element

14

3


15

2


16

1

Piston seal

17

2

Bushing

18

10

Double hex bolt M 27 x 2 x 160

19

15

Washer

20

Designation

Further remarks

Weight [kg] 1 266

132

----

21

1

Dowel pin

22

15


Table 2

Page 8.8 - 6

RH 200 (FS) - 2471393e - (01) – 01.98

8.8


8.8.2.2

Bucket crowd cylinder 3 5

17

17

6 8 21

7 18

9 10

22 11 19 12

13

14

1

15 16

2 15

14

14 13 4

4 4525840A.SKD

Fig. 3

RH 200 (FS) - 2471393e - (01) – 01.98


Page 8.8 - 7

8.8


Components of bucket crowd cylinder (Fig. 3) Position

Quantity

1

1

Cylinder barrel

2

1

Piston rod

833

3

1

Fork

379

4

2

Bushing

5

1

Scraper

6

1

Scraper

7

1

Guide

8

1

Sealing ring

9

1

Sealing ring

10

1


11

1

Back ring

12

1

O-ring

13

2

Protection element

14

3


15

2


16

1

Piston seal

17

2

Bushing

18

10


19

15

Washer

20

Designation

Further remarks

Weight [kg] 1 266

132

----

21

1

Dowel pin

22

15


Table 3

Page 8.8 - 8

RH 200 (FS) - 2471393e - (01) – 01.98

8.8

8.8.2.4


Clam cylinder

6

3

7 8 10

5

5

11 12

4 11 9

12

1

13

14 15 16 2

17 13 18

A

14

4525841.SKD Fig. 4

RH 200 (FS) - 2471393e - (01) – 01.98

Clam cylinder

Page 8.8 - 9

8.8


Components for clam cylinder (Fig. 4) Position

Quantity

Designation

Further remarks

Weight [kg]

Position of pivot bearing split

A 1

1

Cylinder barrel

216

2

1

Piston rod

109

3

1

Fork

153

4

1

Flange

5

10

Double hex. bolt M 27 x 2 x 140

6

1

Scraper

7

1

Scraper

8

1


9

1

Guide

10

2

Sealing ring

11

1


12

1

Back ring

13

1

O-ring

14

2

Protection element

15

1


16

1

Sealing ring

17

1


18

1

Bearing eye

19

1

Circlip

20

1

Dowel pin

Table 4

Page 8.8 - 10

RH 200 (FS) - 2471393e - (01) – 01.98

8.8

8.8.3


Assembly

There are 3 different types of bearing eyes used: 1. Clevis type, 2-piece (Fig. 5) 2. Boss type, 1-piece (Fig. 6) 3. Clevis type, 1-piece (Fig. 7)

Fig. 7

Fig. 5

Clevis type, 2-piece

Fig. 6

Boss type, 1-piece

RH 200 (FS) - 2471393e - (01) – 01.98


Page 8.8 - 11

8.8

8.8.3.1


Clevis type, 2-piece (Fig. 8)

Fig.9

Fig. 8

Disassembly of the fork


Disassembling and checking 1. Use petroleum to remove the coating of rust inhibitor between flange (4, Fig. 8) and piston rod (8) (see THB „Sealing, protective, checking and cleaning agents“). 2. Attach lifting tackle to the bearing eye and loosen bolts (5, Fig. 9). 3. Lift bearing eye off the piston rod. 4. Check bushing (10) and dowel pin (2) for damage - change if necessary. 5. Remove bushing (6) and replace O-rings and back rings (Fig. 10). 6. Unscrew flange (4) from piston rod (Fig. 11).

Page 8.8 - 12

Fig. 10

Lifting of the fork

RH 200 (FS) - 2471393e - (01) – 01.98

8.8


731 (see THB „Sealing, protective, checking and cleaning agents“).

Fig. 11

Put new O-ring (36, Fig. 8) around piston rod.

4.

Screw flange (4, Fig. 8) into place.

5.

Check that dowel pin (31, Fig. 12) is in position.

6.

Lift the bearing eye in lifting tackle.

7.

Lower eye (1, Fig. 8) into position. Seating surfaces of eye (1) and piston rod (8) must lie exactly plane on another in order to transfer the high cylinder forces. Dowel pin (31, Fig. 12), which prevents the eye from rotation on the rod, must fit in the opposite seating hole.

8.

Screw flange (4, Fig. 8) onto piston rod until it is approx. 1.5 - 3 mm from eye (1). The gap must be equal all round (the eye is otherwise not seated fully on the rod).

9.

Pre-install bolts. The threads of the bolts (5, Fig. 8) have to be free of grease and oil.

Disassembly of the flange

Assembly 1.

3.

Check bearing eye (3, Fig. 12). The seating surface to the piston rod must be free of any damage and corrosion. The seating surface of the piston rod must also be free of any damage and corrosion.

10. Pull O-ring (36) up into the gap outside of the bolts (5). If necessary, lift the eye (1) slightly in order to push the ring into the gap. 11. Tighten bolts (5) in opposite pairs by hand. Check gap between eye (1) and flange (4). It has to be between 1.5 and 3 mm. The gap has to be equally all around.

12. Tighten bolts (5,) crosswise. To prevent the eye (1) from seating skew, tighten the bolts in 3 stages. Torque for bolts - see table 7. 13. Coat exposed ends of bolts (5) with the corrosion inhibitor mentioned under Point 2.

Fig. 12

2.

Bearing eye

Coat the thread of the piston rod (8, Fig. 8) with „SOLUTION 1“ rust inhibitor, P/No. 153

RH 200 (FS) - 2471393e - (01) – 01.98

Page 8.8 - 13

8.8

8.8.3.2


Boss type, 1-piece (Fig. 12)

Fig. 13

Fig. 14

Disassembly of the eye

Fig. 15

Lifting of the eye

Boss type, 1-piece

Disassembling and checking 1. Use petroleum to remove the coating of rust inhibitor in slot (A) of the bearing eye (1, Fig. 13). See THB „Sealing, protective, checking and cleaning agents“). 2. Lift the bearing eye in lifting tackle; loosen mounting bolts (5, Fig. 14). 3. Unscrew slotted bearing eye (1) from the piston rod (8). If necessary widen the slot with help of a wedge. 4. Check bushing (10) for damage - change if necessary.

Assembly 1. Coat the thread of the piston rod (8, Fig. 14) with „SOLUTION 1“ rust inhibitor, P/No. 153 731 (see THB „Sealing, protective, checking and cleaning agents“). 2. Place bearing eye (1) onto the piston rod (8) and screw on hand-tight to the mechanical stop.

Page 8.8 - 14

RH 200 (FS) - 2471393e - (01) – 01.98

8.8


3. Insert bolts (5) and tighten in 3 stages. The bolts have to be free of grease and oil!

8.8.3.3


Torque for bolts – see table 7. 4. Coat exposed ends of bolts (5) and slot of the bearing eye with the corrosion inhibitor Part-no. 1 570 254.

Fig. 16


Disassembling and checking 1. Use petroleum to remove the coating of rust inhibitor in slot (A) of the bearing eye (1, Fig. 16). See THB „Sealing, protective, checking and cleaning agents“). 2. Lift the bearing eye in lifting tackle; loosen mounting bolts (5, Fig. 17 3. Unscrew slotted bearing eye (1) from the piston rod (8). If necessary widen the slot with help of a wedge. 4. Check bushing (10) for damage - change if necessary.

RH 200 (FS) - 2471393e - (01) – 01.98

Page 8.8 - 15

8.8


Assembly 1. Coat the thread of the piston rod (8, Fig. 17) with „SOLUTION 1“ rust inhibitor, P/No. 153 731 (see THB „Sealing, protective, checking and cleaning agents“). 2. Place bearing eye (1) onto the piston rod (8) and screw on hand-tight to the mechanical stop. 3. Insert bolts (5) and tighten crosswise in 3 stages. The bolts have to be free of grease and oil! Torque for bolts – see table 7. 4. Coat exposed ends of bolts (5) and slot of the bearing eye with the corrosion inhibitor Part-no. 1 570 254.

Fig. 17


Fig. 18

Lifting of the fork

Page 8.8 - 16

RH 200 (FS) - 2471393e - (01) – 01.98

8.8

8.8.3.4


Piston rod guide

All Positions refer to Fig. 19

Fig. 19

RH 200 (FS) - 2471393e - (01) – 01.98

Piston rod guide

Page 8.8 - 17

8.8


Components of piston rod guide (Fig. 19) Position

Quantity

Designation

1

Cylinder barrel

3

Bearing eye

4

Guide

8 14

see chapter 8.8.2

Washer

Further remarks

Weight [kg]

Hex. bolt

16

Hex. bolt

18

Scraper

19

Scraper

20

Sealing ring

21

Sealing ring

22


29

O-ring

30

Back ring

36

Ring

37

Ring

Table 5

Removing and checking 1. Drain hydraulic oil from the cylinder. Catch escaping oil in a suitable container.

5. Take off guide (4). Remove all sealing and wear parts. Use suitable tools to prevent damaging the sealing surfaces in any way.

2. Remove bearing eye. 3. Loosen bolts (16). 4. Remove the guide (4) from the cylinder barrel using 3 jacking bolts.

6. Check guide (4) for damage. If damage is visible, guide must be replaced. Seals and wearing parts will otherwise be destroyed in a very short time. ALWAYS change ALL wearing parts!

Depending on the type of cylinder the following completely threaded jacking bolts are to be used: Boom cylinder: M 12 x 190, 10.9, DIN 933, Part-no. 2 781 855 Arm cylinder: M 12 x 190, 10.9, DIN 933, Part-no. 2 781 855 Bucket cylinder: M 12 x 190, 10.9, DIN 933, Part-no. 2 781 855 Clam cylinder: M 12 x 150, 10.9, DIN 933, Part-no. 2 781 852

Page 8.8 - 18

RH 200 (FS) - 2471393e - (01) – 01.98

8.8


Assembly 1. Fit seal (29, Fig. 19) and back ring (30). Make sure that back ring is on the correct side. 2. Fit the split guide sleeve (22). 3. Coat guide with assembly paste P/No. 271 554 in area (4, Fig. 19). 4. Install V-rings (20 + 21, Fig. 19). Each V-ring (20 + 21) comprises V-ring (A) and back ring (B). Depending on the cylinder design the grove for the scrapers (14) and (15) can be part of the cylinder rod guide (Fig. 20).

Fig. 21

Installation of V-ring

If the scraper (20) is separately installed it is bolted with ring (8), disk (9) and bolts (14) onto the rod guide (Fig. 22). The mounting bolts are hand-tightened only.

Fig. 20

Scraper

In this case fold V-ring (A) into a kidney shape and place into groove (Fig. 21). Fig. 22

Scraper

Then fit the split back ring (B, Fig. 21). 5. Fit scrapers (14 + 15, Fig. 20). 6. Before fitting the guide, coat scrapers, seal and guide rings with hydraulic oil.

7. Place guard sleeve (C, Fig. 23) over thread of piston rod. The sleeve protects the seal and guide rings in the rod guide against being damaged on the rod threads. If a guard sleeve is not available, wrap adhesive tape around the rod threads.

RH 200 (FS) - 2471393e - (01) – 01.98

Page 8.8 - 19

8.8


8.8.3.5

Piston rod and piston

Removing and checking 1. Drain hydraulic oil from the cylinder. Catch escaping oil in a suitable container. 2. Remove rod head and rod guide. 3. Using a lifting device lift the piston rod (8, Fig. 25) with help of the lifting eye (D, Fig. 25) out of the cylinder barrel an place onto a prepared clean working bench. Fig. 23

Piston rod with guard sleeve

8. Push guide into cylinder barrel. 9. Insert bolts (6, Fig. 24) and tighten crosswise in 3 stages. The bolts have to be free of grease and oil! Torque for bolts – see table 7.

Fig. 25

Rod puller

4. Remove plastic guide rings (24, Fig. 26), OK piston seal (23) and guard rings (25). The cast iron ring (26, Fig. 26) often shows minor signs of use but without any measurable wear (less than 0.1 mm). In such a case, the ring can be used again. Cast iron rings are difficult to remove and the risk of piston damage is high. The rings should therefore only be removed with special pliers (Fig. 27).

Fig. 24

Flange with bearing eye

10. Install bearing eye (see chapter 8.8.3.1 to 8.8.3.3).

Page 8.8 - 20

RH 200 (FS) - 2471393e - (01) – 01.98

8.8


Fig. 26

Piston guide

Components of piston guide (Fig. 26) Location

Quantity

Designation

1

Cylinder barrel

2

piston rod

23 24 25 26

see chapter 8.8.2

Further remarks

Weight [kg]

Piston seal Guide ring Protection element Guide ring

Table 6

RH 200 (FS) - 2471393e - (01) – 01.98

Page 8.8 - 21

8.8


Fig. 27

Fig. 28

Installation of piston seal

Fig. 29


Spreader for guide ring (cast iron)

Thoroughly check piston, piston rod, dampener and cylinder barrel for signs of damage and wear. Also check the barrel for bulging. Replace all damaged parts. ALWAYS change plastic guide rings, guard rings and OK piston seals. Assembly The piston is sealed with an OK piston seal (23, Fig. 26), comprising:

− Plastic stepped seal ring (A) − Square tensioning ring (B). 1. Fit the tensioning ring (B) in the relevant groove:

− Fit approx. 1/5 of the tensioning ring into the groove.

− Push a smooth rod through the ring (Fig. 28)

2.

Fit guide rings (20 + 22, Fig. 30 + 31). Use special pliers (P/No. 1 709 183) to fit cast iron guide rings (22, Fig. 30). Do not open the guide rings too far as they could break. The gaps in the guide rings must be offset at 180° to one another.

and lever it into it’s seating with a circling action (arrow, Fig. 28) around the piston.

− Do not remove the bar until the tensioning ring is seated absolutely straight in it’s groove (Fig. 29).

Page 8.8 - 22

RH 200 (FS) - 2471393e - (01) – 01.98

8.8


OK-piston seals are installed with pre-load. Depending on the diameter the pre-load is 0,65 - 1 mm.

Fig. 30

Installation of guide ring (cast iron)

Fig. 33


Assembling without the sleeve can lead to the seal and guide rings jamming. Part-nos. for sleeves are listed in Chapter 3.2.8 ‘Cylinder tools’. Fig. 31

Installation of guide ring

3. Fit seal ring (21.2, Fig. 32) into OK piston seal.

5. Using rod puller (D, Fig. 25), lift piston rod and lower fully into the cylinder barrel. 6. Install rod guide and rod head (see chapter 8.8.3.4).

Fig. 32


4. Brush hydraulic oil onto seal, guide and guard rings. Push sleeve (E, Fig. 33) over the piston to fix seal and guide rings in position.

RH 200 (FS) - 2471393e - (01) – 01.98

Page 8.8 - 23

8.8

8.8.4


Tightening torque

In the following table the tightening torque for the bolts of the hydraulic cylinders can be found.

Bolt size

M 20

M 27 x 2

M 27 x 2

M 27 x 2

M 36 x 3

M 39 x 3

Bolt quality

10.9

10.9

10.9

10.9

10.9

10.9

Bolt type

hex.

double hex.

hex.

double hex.

hex.

hex.

Bolt length [mm]

120

140

170

160

190

220

Spanner size (SW)

17

32

41

32

55

60

Stage 1 [Nm]

280

650

750

650

1 750

2 300

Stage 2 [Nm]

420

900

1 100

900

2 700

3 500

Stage 3 [Nm]

560

1 135

1 500

1 135

3 500

4 600

Tightening torque

Table 7

Page 8.8 - 24

Tightening torque for bolts on cylinders

RH 200 (FS) - 2471393e - (01) – 01.98

8.8

HYDRAULIC CYLINDERS - BH

8.8

Hydraulic cylinders

8.8.1

Introduction

8.8.1.1

Foreword

This section describes the procedures necessary when repairing hydraulic cylinders. The illustrations and descriptions correspond to the current series status. It is possible for some illustrations to show details that differ from a particular machine or component. This, however, is of no consequence to the overall function. In case of doubt, consult the TEREX Mining Service. Any alterations and up-grading introduced into the series will be considered in future re-prints of the Technical handbook (THB).

The required special tools can be found in Chapter 3.2.8 ‘cylinder tools’

8.8.1.2

Safety

Observe the accident prevention regulations at all times. Any person involved in commissioning, operating, inspecting or servicing the TEREX excavator must have read through the Operating Instructions - especially the chapter ‘’SAFETY’’ - before starting any work. Personnel working on the machine and its components must have adequate knowledge of the procedures involved. Tools, lifting equipment, rigging tackle, trestles, working platforms and other working aids must be in a safe and reliable condition. Depressurize any systems that are to be opened for servicing or inspection work. Before commencing an servicing or inspection work, secure the machine and its equipment against unintentional starting, e.g. place chocks under the tracks and lower the working equipment to the ground. Park the excavator on a level surface and block it to prevent it from moving. Lock the superstructure, lower the working equipment to the ground, stop the engine(s) and secure it against unintentional starting.

RH 200 (BH) - 2471388e - (01) – 01.98

Page 8.8 - 1

8.8


Do not loosen any fittings, pipes or hoses until hydraulic pressure has been released from the system. Take care when hydraulic oil is hot. Fully retract the piston rods of the cylinder to be removed, and fasten the piston rod to the cylinder so that it cannot extent. The hydraulic connections can then be loosened. Use suitable containers to catch spilling oil. Use suitable lifting tackle to remove and install piston rods and guide bushings.

Close up any open pipes, hoses and housing ports to prevent dirt from getting into the system. When working on hydraulic cylinders (especially when removing and fitting piston rods), keep the cylinder in a vertical position. Place long cylinders into inspection pits so that the piston rod eye and guide bushing are accessible from ground level.

8.8.1.3

General

All cylinder components are carefully matched to one another. Long-term trouble-free operation can only be ensured when genuine TEREX spare parts are used. The wear and spare parts necessary for the cylinders are listed in the excavator's spare parts list. This section does not describe procedures necessary for overhauling damaged cylinders. Only specialist workshops can judge whether a damaged component can be overhauled and which procedures are necessary. Work to be performed in your own workshops should therefore be limited to the installation of new TEREX wear and spare parts. All procedures must be carried out carefully in a clean workshop. Negligence can lead to major damage to the whole hydraulic system. After servicing, the hydraulic cylinders must be bled of air prior to being used again. Air pockets remaining in a cylinder can ignite (diesel effect) and cause serious internal damage to the cylinder. If any contamination of metal particles are found in the cylinder, on the magnetic rods or in the filters, the whole system must be flushed clean. The procedure is described in chapter 8.2.

Cleanliness is of prime importance. Use only fibre-free cloths and rags (do NOT use cotton waste). Always tools.

use

the

recommended

When removing seals and wearing parts, always use suitable tools, e.g. snub-nosed screwdrivers, to prevent damaging the sealing surfaces.

Page 8.8 - 2

RH 200 (BH) - 2471388e - (01) – 01.98

8.8


8.8.2

Design types

8.8.2.1

Boom cylinder

5

3

5

14 15 16

6,7 4 4

11

17 16

12

16

18 19 20

21 22 1 2

23 22

21

20 9

9

Fig. 1

RH 200 (BH) - 2471388e - (01) – 01.98

2135918A.SKD Boom cylinder

Page 8.8 - 3

8.8


Components of boom cylinder (Fig. 1) Position

Quantity

1

1

Cylinder barrel

2

1

Piston rod

3

1

Bearing eye

482

4

1

Guide

545

5

2

Bushing

6

3


7

3

Washer

8 9

Designation

Further remarks

Weight [kg] 3 438 2 445

---2

10

Bushing ----

11

23


12

23

Washer

14

1

Scraper

15

1

Sealing ring

16

7


17

1

Sealing ring

18

1

Back ring

19

1

O-ring

20

2

Protection element

21

5


22

2


23

1

Piston seal

Table 1

Page 8.8 - 4

RH 200 (BH) - 2471388e - (01) – 01.98

8.8

8.8.2.2


Stick cylinder

5

5

13 3

8 4

7 9

14

15

16

10 6 17 18

19 1 20 2

21 22 21

20 11

11

19 2272608A.SKD

Fig. 2

RH 200 (BH) - 2471388e - (01) – 01.98

Stick cylinder

Page 8.8 - 5

8.8


Components of arm cylinder (Fig. 2) Position

Quantity

1

1

Cylinder barrel

2

1

Piston rod

3

1

Fork

4

1

Flange

5

2

Bushing

6

1

Guide

7

12


8

1

Dowel pin

9

15

Hex bolt M 36 x 3 x 190

10

15

Washer

11

2

Bushing

12

Designation

Further remarks

Weight [kg] 1 994 1 104 479 58 253

----

13

1

Scraper

14

1

Sealing ring

15

1

Sealing ring

16

1


17

1

Back ring

18

1

O-ring

19

2

Protection element

20

3


21

2


22

1

Piston seal

Table 2

Page 8.8 - 6

RH 200 (BH) - 2471388e - (01) – 01.98

8.8


8.8.2.2

Bucket cylinder

3

8

A

7

13 14 15

10

6

9

16 17

11 5

12 18 19

1 2

20 21 22 23 22

21

4

4

20 2135917A.SKD

Fig. 3

RH 200 (BH) - 2471388e - (01) – 01.98

Bucket cylinder

Page 8.8 - 7

8.8


Components of bucket cylinder (Fig. 3) Position

Quantity

Designation

Further remarks

Weight [kg] 1 266

1

1

Cylinder barrel

2

1

Piston rod

833

3

1

Bearing eye

373

4

2

Bushing

5

1

Guide

132

6

1

Flange

45

7

1

Bearing eye

8

1

Circlip

9

1

Dowel pin

10

10


11

15

Hex bolt M 27 x 2 x 170

12

15

Washer

13

1

Scraper

14

1

Scraper

15

1

Sealing ring

16

1

Scraper

17

1


18

1

Back ring

19

1

O-ring

20

2

Protection element

21

3


22

2


23

1

Piston seal

24

1

Sealing compound

Table 3

Page 8.8 - 8

RH 200 (BH) - 2471388e - (01) – 01.98

8.8

8.8.3


Assembly

There are 3 different types of bearing eyes used: 1. Clevis type, 2-piece (Fig. 5) 2. Boss type, 1-piece (Fig. 6) 3. Boss type, 2-piece (Fig. 7)

Fig. 7

Fig. 5


Fig. 6

Boss type, 1-piece

RH 200 (BH) - 2471388e - (01) – 01.98

Boss type, 2-piece

Page 8.8 - 9

8.8

8.8.3.1



Fig.9

Fig. 8



Disassembling and checking 1. Use petroleum to remove the coating of rust inhibitor between flange (4, Fig. 8) and piston rod (8) (see THB „Sealing, protective, checking and cleaning agents“). 2. Attach lifting tackle to the bearing eye and loosen bolts (5, Fig. 9). 3. Lift bearing eye off the piston rod. 4. Check bushing (10) and dowel pin (2) for damage - change if necessary. 5. Remove bushing (6) and replace O-rings and back rings (Fig. 10). 6. Unscrew flange (4) from piston rod (Fig. 11).

Page 8.8 - 10

Fig. 10

Lifting of the fork

RH 200 (BH) - 2471388e - (01) – 01.98

8.8


731 (see THB „Sealing, protective, checking and cleaning agents“). 3.


4.


5.


6.


7.


8.


Assembly

9.

Pre-install bolts.

1.

10. Pull O-ring (36) up into the gap outside of the bolts (5). If necessary, lift the eye (1) slightly in order to push the ring into the gap.

Fig. 11

Disassembly of the flange


11. Tighten bolts (5) in opposite pairs by hand. Check gap between eye (1) and flange (4). It has to be between 1.5 and 3 mm. The gap has to be equally all around. 12. Tighten bolts (5,) crosswise. To prevent the eye (1) from seating skew, tighten the bolts in 3 stages. Torque for bolts - see table 7.

3

13. Coat exposed ends of bolts (5) with the corrosion inhibitor mentioned under Point 2.

A

31

4525806D.SKD

Fig. 12

2.

Bearing eye

Coat the thread of the piston rod (8, Fig. 8) with „SOLUTION 1“ rust inhibitor, P/No. 153

RH 200 (BH) - 2471388e - (01) – 01.98

Page 8.8 - 11

8.8

8.8.3.2



Fig. 13

Fig. 14

Disassembly of the eye

Fig. 15

Lifting of the eye

Boss type, 1-piece

Disassembling and checking 1. Use petroleum to remove the coating of rust inhibitor in slot (A) of the bearing eye (1, Fig. 13). See THB „Sealing, protective, checking and cleaning agents“). 2. Lift the bearing eye in lifting tackle; loosen mounting bolts (5, Fig. 14). 3. Unscrew slotted bearing eye (1) from the piston rod (8). If necessary widen the slot with help of a wedge. 4. Check bushing (10) for damage - change if necessary.

Assembly 1. Coat the thread of the piston rod (8, Fig. 14) with „SOLUTION 1“ rust inhibitor, P/No. 153 731 (see THB „Sealing, protective, checking and cleaning agents“). 2. Place bearing eye (1) onto the piston rod (8) and screw on hand-tight to the mechanical stop.

Page 8.8 - 12

RH 200 (BH) - 2471388e - (01) – 01.98

8.8


3. Insert bolts (5) and tighten in 3 stages.

8.8.3.3


Torque for bolts – see table 7. 4. Coat exposed ends of bolts (5) and slot of the bearing eye with the corrosion inhibitor Part-no. 1 570 254.

1

10

A 2 5

4

8 4525806C.SKD

Fig. 16

Boss type, 2-piece

Disassembling and checking 1. Use petroleum to remove the coating of rust inhibitor between flange (4, Fig. 16) and piston rod (8). See THB „Sealing, protective, checking and cleaning agents“). 2. Lift the bearing eye in lifting tackle; loosen mounting bolts (5, Fig. 16 3. Lift the bearing eye from the piston rod. 4. Unscrew flange (4, Fig. 169 from piston rod (Fig. 19).

RH 200 (BH) - 2471388e - (01) – 01.98

Page 8.8 - 13

8.8


Fig.17

Mounting the eye

Fig. 19

Removing the flange

Assembly 1.

Fig. 18


Lifting the eye

Fig. 20

Page 8.8 - 14

Fork type bearing eye

RH 200 (BH) - 2471388e - (01) – 01.98

8.8


2.

Coat the thread of the piston rod (8, Fig. 8) with „SOLUTION 1“ rust inhibitor, P/No. 153 731 (see THB „Sealing, protective, checking and cleaning agents“).

3.


4.


5.


6.


7.


8.


9.

Pre-install bolts.

10. Pull O-ring (36) up into the gap outside of the bolts (5). If necessary, lift the eye (1) slightly in order to push the ring into the gap. 11. Tighten bolts (5) in opposite pairs by hand. Check gap between eye (1) and flange (4). It has to be between 1.5 and 3 mm. The gap has to be equally all around. 12. Tighten bolts (5,) crosswise. To prevent the eye (1) from seating skew, tighten the bolts in 3 stages. Torque for bolts - see table 7. 13. Coat exposed ends of bolts (5) with the corrosion inhibitor mentioned under Point 2.

RH 200 (BH) - 2471388e - (01) – 01.98

Page 8.8 - 15

8.8

8.8.3.4


Piston rod guide

All Positions refer to Fig. 19

Fig. 21

Page 8.8 - 16

Piston rod guide

RH 200 (BH) - 2471388e - (01) – 01.98

8.8


Components of piston rod guide (Fig. 21) Position

Quantity

Designation

1

Cylinder barrel

3

Bearing eye

4

Guide

8 14

see chapter 8.8.2

Washer

Further remarks

Weight [kg]

Hex. bolt

16

Hex. bolt

18

Scraper

19

Scraper

20

Sealing ring

21

Sealing ring

22


29

O-ring

30

Back ring

36

Ring

37

Ring

Table 5

Removing and checking 1. Drain hydraulic oil from the cylinder. Catch escaping oil in a suitable container. 2. Remove bearing eye.

Use suitable tools to prevent damaging the sealing surfaces in any way. 6. Check guide (4) for damage. If damage is visible, guide must be replaced. Seals and wearing parts will otherwise be destroyed in a very short time.

3. Loosen bolts (16). ALWAYS change ALL wearing parts! 4. Remove the guide (4) from the cylinder barrel using 3 jacking bolts. Depending on the type of cylinder the following completely threaded jacking bolts are to be used: Boom cylinder: M 12 x 230, 10.9, DIN 933, Part-no. 2 781 856 Stick cylinder: M 12 x 230, 10.9, DIN 933, Part-no. 2 781 856 Bucket cylinder: M 12 x 180, 10.9, DIN 933, Part-no. 2 781 854

5. Take off guide (4). Remove all sealing and wear parts.

RH 200 (BH) - 2471388e - (01) – 01.98

Page 8.8 - 17

8.8


Assembly 1. Fit seal (29, Fig. 21) and back ring (30). Make sure that back ring is on the correct side. 2. Fit the split guide sleeve (22). 3. Coat guide with assembly paste P/No. 271 554 in area (4, Fig. 21). 4. Install V-rings (20 + 21, Fig. 21). Each V-ring (20 + 21) comprises V-ring (A) and back ring (B). Depending on the cylinder design the grove for the scrapers (14) and (15) can be part of the cylinder rod guide (Fig. 22).

Fig. 23

Installation of V-ring

If the scraper (20) is separately installed it is bolted with ring (8), disk (9) and bolts (14) onto the rod guide (Fig. 24). The mounting bolts are hand-tightened only.

Fig. 22

Scraper

In this case fold V-ring (A) into a kidney shape and place into groove (Fig. 23). Fig. 24

Scraper

Then fit the split back ring (B, Fig. 23). 5. Fit scrapers (14 + 15, Fig. 22). 6. Before fitting the guide, coat scrapers, seal and guide rings with hydraulic oil.

7. Place guard sleeve (C, Fig. 25) over thread of piston rod. The sleeve protects the seal and guide rings in the rod guide against being damaged on the rod threads. If a guard sleeve is not available, wrap adhesive tape around the rod threads.

Page 8.8 - 18

RH 200 (BH) - 2471388e - (01) – 01.98

8.8


8.8.3.5

Piston rod and piston

Removing and checking 1. Drain hydraulic oil from the cylinder. Catch escaping oil in a suitable container. 2. Remove rod head and rod guide. 3. Using a lifting device lift the piston rod (8, Fig. 27) with help of the lifting eye (D, Fig. 27) out of the cylinder barrel an place onto a prepared clean working bench. Fig. 25


8. Push guide into cylinder barrel. 9. Insert bolts (6, Fig. 26) and tighten crosswise in 3 stages. The bolts have to be free of grease and oil! Torque for bolts – see table 7.

Fig. 27

Rod puller

4. Remove plastic guide rings (24, Fig. 28), OK piston seal (23) and guard rings (25). The cast iron ring (26, Fig. 28) often shows minor signs of use but without any measurable wear (less than 0.1 mm). In such a case, the ring can be used again. Cast iron rings are difficult to remove and the risk of piston damage is high. The rings should therefore only be removed with special pliers (Fig. 29).

Fig. 26

Flange with bearing eye

10. Install bearing eye (see chapter 8.8.3.1 to 8.8.3.3).

RH 200 (BH) - 2471388e - (01) – 01.98

Page 8.8 - 19

8.8


Fig. 28

Piston guide

Components of piston guide (Fig. 28) Location

Quantity

Designation

1

Cylinder barrel

2

piston rod

23 24 25 26

see chapter 8.8.2

Further remarks

Weight [kg]

Piston seal Guide ring Protection element Guide ring

Table 6

Page 8.8 - 20

RH 200 (BH) - 2471388e - (01) – 01.98

8.8


Fig. 29

Spreader for guide ring (cast iron)

Fig. 30


Fig. 31


Thoroughly check piston, piston rod, dampener and cylinder barrel for signs of damage and wear. Also check the barrel for bulging. Replace all damaged parts. ALWAYS change plastic guide rings, guard rings and OK piston seals. Assembly The piston is sealed with an OK piston seal (23, Fig. 28), comprising:

− Plastic stepped seal ring (A) − Square tensioning ring (B). 1. Fit the tensioning ring (B) in the relevant groove:

− Fit approx. 1/5 of the tensioning ring into the groove.

− Push a smooth rod through the ring (Fig. 30) and lever it into it’s seating with a circling action (arrow, Fig. 30) around the piston.

2.

Fit guide rings (20 + 22, Fig. 32 + 33). Use special pliers (P/No. 1 709 183) to fit cast iron guide rings (22, Fig. 32). Do not open the guide rings too far as they could break. The gaps in the guide rings must be offset at 180° to one another.

− Do not remove the bar until the tensioning ring is seated absolutely straight in it’s groove (Fig. 31).

RH 200 (BH) - 2471388e - (01) – 01.98

Page 8.8 - 21

8.8


OK-piston seals are installed with pre-load. Depending on the diameter the pre-load is 0,65 - 1 mm.

Fig. 32

Installation of guide ring (cast iron)

Fig. 35


Assembling without the sleeve can lead to the seal and guide rings jamming. Part-nos. for sleeves are listed in Chapter 3.2.8 ‘Cylinder tools’. Fig. 33

Installation of guide ring

3. Fit seal ring (21.2, Fig. 34) into OK piston seal.

5. Using rod puller (D, Fig. 27), lift piston rod and lower fully into the cylinder barrel. 6. Install rod guide and rod head (see chapter 8.8.3.4).

Fig. 34


4. Brush hydraulic oil onto seal, guide and guard rings. Push sleeve (E, Fig. 35) over the piston to fix seal and guide rings in position.

Page 8.8 - 22

RH 200 (BH) - 2471388e - (01) – 01.98

8.8

8.8.4


Tightening torque

In the following table the tightening torque for the bolts of the hydraulic cylinders can be found.

Bolt size

M 27 x 2

M 27 x 2

M 30 x 2

M 36 x 3

M 39 x 3

Bolt quality

10.9

10.9

10.9

10.9

10.9

Bolt type

hex.

hex.

hex

Bolt length [mm]

170

160

190

190

220

Spanner size (SW)

41

32

36

55

60

Stage 1 [Nm]

750

650

850

1 750

2 300

Stage 2 [Nm]

1 100

900

1 250

2 700

3 500

Stage 3 [Nm]

1 500

1 135

1 700

3 500

4 600

double hex. double hex.

Tightening torque

Table 7

RH 200 (BH) - 2471388e - (01) – 01.98

Tightening torque for bolts on – cylinders

Page 8.8 - 23

Sistema Hidraulico.pdf

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