RH200 Sistema Hidraulico
Short Description
mineria y alguito mas...
Description
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 Phone: Fax:
++49 / 231 / 922-4901 ++49 / 231 / 922-5900
Copyright by TEREX, Printed in Germany
CONTENTS
8.
HYDRAULIC SYSTEM 8.1
8.2
8.3
8.3
8.4
Introduction ......................................................................................8.1 - 1 8.1.1
Foreword ...........................................................................8.1 - 1
8.1.2
Safety ................................................................................8.1 - 1
8.1.3
General..............................................................................8.1 - 5
Depressurizing, bleeding, flushing .................................................8.2 - 1 8.2.1
Depressurizing of the hydraulic system .............................8.2 - 1
8.2.2
Bleeding of the hydraulic system .......................................8.2 - 3
8.2.3
Flushing of the hydraulic system .......................................8.2 - 5
Description (Faceshovel).................................................................8.3 - 1 8.3.1
Technical data ...................................................................8.3 - 1
8.3.2
Hydraulic schematic ..........................................................8.3 - 1
8.3.3
Components ......................................................................8.3 - 5
Description (Backhoe) .....................................................................8.3 - 1 8.3.1
Technical data ...................................................................8.3 - 1
8.3.2
Hydraulic schematic ..........................................................8.3 - 1
8.3.3
Components ......................................................................8.3 - 5
Hydraulic components.....................................................................8.4 - 1 8.4.1
Main pumps .......................................................................8.4 - 1
8.4.2
Swing pump.......................................................................8.4 - 2
8.4.3
Rotor..................................................................................8.4 - 3
8.4.4
Valve blocks ......................................................................8.4 - 5
8.4.5
Other components ...........................................................8.4 - 34
RH 200 Diesel - 3657790e (00) - 09.03
Page 8 - 1
CONTENTS 8.5
8.6
Description of hydraulic circuits.....................................................8.5 - 1 8.5.1
Load limiting system .......................................................8.5.1 - 1
8.5.2
Pressure cut off system ..................................................8.5.2 - 1
8.5.3
Servo system..................................................................8.5.3 - 1
8.5.4
Working functions (Faceshovel) .....................................8.5.4 - 1
8.5.4
Working functions (Backhoe)..........................................8.5.4 - 1
8.5.5
Travel system .................................................................8.5.5 - 1
8.5.6
Swing system .................................................................8.5.6 - 1
8.5.7
Track tensioning system .................................................8.5.7 - 1
8.5.8
Cooling system for hydraulic oil ......................................8.5.8 - 1
8.5.9
Cooling system for engines ............................................8.5.9 - 1
8.5.10
Cooling system for pump gearbox ................................8.5.10 - 1
Pressure checking and setting........................................................8.6 - 1 8.6.1
Introduction........................................................................8.6 - 1
8.6.2
Pressure settings...............................................................8.6 - 3
8.6.3
Tools..................................................................................8.6 - 4
8.6.4
Hydraulic systems .............................................................8.6 - 5
8.7
Installation of hydraulic pumps.......................................................8.7 - 1
8.8
Hydraulic cylinders (Faceshovel)....................................................8.8 - 1
Page 8 - 2
8.8.1
Introduction........................................................................8.8 - 1
8.8.2
Design configuration ..........................................................8.8 - 3
8.8.3
Assembly .........................................................................8.8 - 11
8.8.4
Tightening torques...........................................................8.8 - 24
RH 200 Diesel - 3657790e - (00) - 09.03
CONTENTS
8.8
Hydraulic cylinders (Backhoe) ........................................................8.8 - 1 8.8.1
Introduction........................................................................8.8 - 1
8.8.2
Design configuration ..........................................................8.8 - 3
8.8.3
Assembly ...........................................................................8.8 - 9
8.8.4
Tightening torques...........................................................8.8 - 22
RH 200 Diesel - 3657790e (00) - 09.03
Page 8 - 3
CONTENTS
Page 8 - 4
RH 200 Diesel - 3657790e - (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.
This TEREX hydraulic excavator has been built in accordance with state-of-the-art standards and the recognized safety rules.
• the operating instructions
However, operating the machine if a fault is suspected or has occurred, or carrying out repair work inexpertly may
• the spare-parts list
•
endanger the lives of persons in contact with it
• the technical handbook
•
damage the machine and other property.
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 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.
The documentation of an TEREX Mining machine includes:
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
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 injury. 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
2440575e - (00) - 11.96
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.
2440575e - (00) - 11.96
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. No reference is made to special versions.
2440575e - (00) - 11.96
After delivery, the Technical Manual is not subject 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. If any points are nevertheless unclear or incorrect, please contact your local TEREX dealer or your TEREX distributing centre.
Page 8.1 - 5
8.1
HYDRAULIC SYSTEM
Page 8.1 - 6
2440575e - (00) - 11.96
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. Always wear safety glasses, safety gloves and firm protective clothing.
630213.SKD
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
DEPRESSURIZING, BLEEDING, FLUSHING
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 − With key-switch ON and safety switch active (86, Fig. 4) shift all control levers and pedals repeatedly into all directions (Fig. 3).
Section 3): Track tensioning system 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
DEPRESSURIZING, BLEEDING, FLUSHING
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
DEPRESSURIZING, BLEEDING, FLUSHING
3. Steps in case of pump damage
4. Steps in case of cylinder damage
3.1 Determine damaged pump, typical symptoms are:
•
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.
•
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.
• • • • • • •
chip indicator ON for main pump or swing pump vibrating hydraulic hoses fluctuating pressure readings on gauges abnormal noises noticeable loss in output excessive temperature excessive load on engine(s)
3.2 Pumps without high pressure filters: •
Remove return flow filters and check for 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.
•
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
DEPRESSURIZING, BLEEDING, FLUSHING
5. Steps in case of valve damage
6. Further steps
•
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 the hydraulic system has been extensively contaminated with chips, the following procedures are also necessary:
•
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.
•
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: − 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.
RH 200 Diesel - 2471385e - (00) – 10.99
•
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
DEPRESSURIZING, BLEEDING, FLUSHING
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 new return flow element.
•
Short circuit the connections to the replacement cylinder.
•
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 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.
•
•
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.
•
Check filter and magnetic rod again.
•
Connect all consumers correctly and bleed air from the system.
•
Check oil level in tank.
•
Put excavator back to work.
Page 8.2 - 8
RH 200 Diesel - 2471385e - (00) – 10.99
8.2
DEPRESSURIZING, BLEEDING, FLUSHING
7.4 In case of damage of hydraulic motor:
8.
•
Fit new return flow element.
•
Short circuit the connections to the replacement motor.
After working for approx. 1 minute, check the magnetic rod. Clean the rod if contamination is found.
•
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.
•
Check return flow filter and magnetic rod again.
•
Connect motor correctly and bleed air.
•
Check oil level in tank.
•
Put excavator back to work.
RH 200 Diesel - 2471385e - (00) – 10.99
Monitoring in operation
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.
Page 8.2 - 9
8.2
DEPRESSURIZING, BLEEDING, FLUSHING
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
Technical data
The technical data of the hydraulic system are listed in chapter 2 ‘Technical Data’.
8.3.2
Circuit diagram Components of the hydraulic circuit diagram RH 200 (FS) The position nos. refer to circuit diagram No. 3 672 750 (02)
Position
Quantity
Designation
1
2
Engine K 1500 E
Engine module
2
2
Pump transfer gearbox
Engine module
3
4
Main pump A7V - SL - 1000
Pump gearbox
4
2
Charge pump for swing system
Pump gearbox
5
2
Fan pump for radiator fan
Pump gearbox
6
4
Swing pump A4V 250 with adapter
Pump gearbox
7
4
Cooling pump KP 5 - 300
Pump gearbox
8
2
Servo pump
Pump gearbox
9
2
Gear motor for radiator fan
Counterweight
10
4
Filter
Engine module
11
2
Filter
Engine module
12
4
Blocking valve
Engine module
13
----
14
----
Location
15
1
Servo oil valve block
16
1
Differential pressure valve
Position 15
17
1
Servo circuit pressure relief valve
Position 15
18
2
Check valve
Position 15
19
----
20
2
Pump governing valve
21
2
Proportional valve
22
----
23
----
24
----
25
----
26 27
Engine module
2
Gate valve
Engine module Position 20
Hydraulic oil tank
----
RH 200 Diesel (FS) - 3657771e - (00) - 07.03
Page 8.3 - 1
8.3
DESCRIPTION OF THE HYDRAULIC SYSTEM - FS
Position
Quantity
28
1
Hydraulic oil tank
29
2
Return oil filters
Hydraulic oil tank
30
6
Bypass valve
Hydraulic oil tank
31
4
Tank line pressurizing valve
Hydraulic oil tank
32
2
Check valve
Hydraulic oil tank
33
1
Pressure switch
Hydraulic oil tank
34
Designation
Location Superstructure
----
35
1
Distributor plate (main pumps)
36
5
Pressure relief valve
Position 36
37
4
2 – way valve
Position 36
38
4
Cap
Position 36
39
4
High pressure filter
Position 36
40
4
Check valve
Position 36
41
1
Block for solenoid valve
42
2
Distributor plate (oil cooling)
43
4
Pressure relief valve
Position 42
44
4
Thermostat
Position 42
45
1
Solenoid valve for logic valves
46
4
Fan motor
Oil cooler module
47
4
Fan
Oil cooler module
48
4
Hydraulic oil cooler
Oil cooler module
49
Engine module
Engine module Oil cooler module
Engine module
----
50
4
Swing gearbox
Superstructure
51
4
Swing motor
Swing gearbox
52
4
Swing parking brake
Swing gearbox
53
----
54
1
Pressure governing valve
Engine module
55
1
Pressure relief valve
Engine module
56
1
Shuttle valve
Engine module
57
1
Flushing valve
Engine module
58
----
59
----
60
2
High pressure filters
61
2
Check valve
62
----
63
----
Page 8.3 - 2
Superstructure
RH 200 Diesel (FS) - 3657771e - (00) - 07.03
8.3
DESCRIPTION OF THE HYDRAULIC SYSTEM - FS
Position
Quantity
Designation
64
----
65
----
Location
66
2
Track tensioning cylinder
Undercarriage
67
2
Connector block
Undercarriage
68
2
Diaphragm accumulator
Undercarriage
69
1
Track tensioning group
Undercarriage
70
----
71
----
72
2
Travel gearbox
Undercarriage
73
4
Travel motor
Travel gearbox
74
4
Travel parking brake
Travel gearbox
75
----
76
1
Valve block
77
4
Pressure relief valve
78
----
79
----
Undercarriage Position 76
80
1
Travel block
Superstructure
81
1
Rotor
Superstructure
82
1
Travel valve block RH
Rotor
83
1
Travel valve block LH
Rotor
84
1
Travel retarder valve RH
Travel block
85
1
Travel retarder valve LH
Travel block
86
4
Anti – cavitation valve
Travel block
87
4
Cover plate
Travel block
88
4
Throttle check valve
Travel block
89
----
90
2
4-spool control valve
Boom
91
16
Pressure relief valve
4-spool control valve
92
4
Float valve
93
----
94
----
Boom
95
2
Boom cylinder
Boom
96
2
Arm cylinder
Boom
97
2
Crowd cylinder
Boom
98
2
Clamshell cylinder
Backwall
99
1
Distributor
Backwall
RH 200 Diesel (FS) - 3657771e - (00) - 07.03
Page 8.3 - 3
8.3
DESCRIPTION OF THE HYDRAULIC SYSTEM - FS
Position
Quantity
100
Designation
Location
----
101
2
Joy stick
Operator cab
102
3
Treadle pedal
Operator cab
103
1
Proportional valve plate
Operator module
104
2
Valve bank, compl.
Operator module
105
1
Filter for proportional valve plate
Operator module
106
----
107
----
108
----
109
1
Check valve
110
1
Throttle valve
111
3
Twin check valves
112
----
113
----
114
----
115
2
Internal anti cavitation valve for fan motor
116
----
117
----
118
----
119
----
120
----
121
----
122
1
Microprocessor GLR 200
123
----
124
----
125
----
126
----
127
----
128
----
129
----
Position 9
Operator module
130
5
Reducer flange
Position 4 & 90
131
4
Reducer flange
Position 7
132
----
133
4
Block
Position 51
134
4
Block
Position 51
135
4
Distributor
Page 8.3 - 4
Boom
RH 200 Diesel (FS) - 3657771e - (00) - 07.03
8.3
DESCRIPTION OF THE HYDRAULIC SYSTEM - FS
Position
Quantity
Designation
136
----
137
----
138
2
139 140
Block
Location
Position 90
---2
141
Block
Position 92
----
142
2
Block
143
2
Orifice
144
8
Reducer flange
145
1
Block
Superstructure
146
1
Block
Superstructure
147
1
Track tensioning block
Undercarriage
148
1
Solenoid valve
Engine modul
149
1
Pressure reduction valve
Engine modul
RH 200 Diesel (FS) - 3657771e - (00) - 07.03
Page 8.3 - 5
8.3 8.3.3
DESCRIPTION OF THE HYDRAULIC SYSTEM - FS Components of the hydraulic system of the RH 200 (FS)
Attention! Position nos. are referred to circuit diagram Part-No. 3 672 750 (02). Some items are numbered on the schematic but not mentioned here. They are not important for the hydraulic functioning.
Drive unit
Pos. 1
stroking cylinder (4. 2). At operating pressures under 60 bar, chamber © is fed with oil from the servo circuit (60 bar) through port (X2). It would otherwise not be possible to tilt the pumps. When the pump receives a signal to „tilt out“, i. e. the governing pressure on port (X1) is 10 - 43 bar, the spool (4. 1) is shifted against the force of the spring. Oil in chamber © flows into chamber (A) until equilibrium is reached between the governing pressure and the force of the spring. As the spool (B) has reaction surfaces of different size, the forces in chamber (A) „win“. The rotary group is tiled out (oil flow increased) until equilibrium is restored.
The two water - cooled Cummins engines are 12 cylinder „V“ engines with turbo-charging and inter cooling.
The works - set orifices (4.3) determine the tilting speed of the pump.
Pump transfer gearbox
If PMS then reduces the governing pressure on port (X1), spool (4.1) is shifted to the right. Chamber (A) of the governing cylinder (4.2) is connected to the oil tank. The rotary group is then de stroked (i. e. tilted back to a lower flow) until an equilibrium is reached.
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.
Variable - displacement pump
Pos. 3
The 4 main pumps (4) for working equipment and travel movements are axial - piston swashplate pumps with slipper bearing. Slipper bearings are hydraulically „swimming“ bearings that increase the pump`s service life. Each pump has its own pressure - dependent regulator (4. 1, Fig. 1) with a regulating range of between 8 and 43 bar. At 43 bar, the pump`s rotary group is at its maximum swashplate angle (13° 15`) and therefore at maximum flow. At 8 bar, the rotary group is at „zero“ oil flow. The governors are actuated by the electronic load - limit governor (122) in the PMS systems, and by the proportional valves (21).
Function Pressure oil required to tilt (alter the angle) of the rotary group is drawn from the pump`s own main flow. It is continually available in chamber © of de Page 8.3 - 6
Pressure cut - off Pressure cut - off comes into effect as soon as the system pressure reaches 300 bar. Pressure sequence valve (4.4) is opened by the system pressure and connects chambers (A & C) of the governing cylinder (4.2) with the tank. The pump is tiled back to such a reduced flow that only the pressure in the system is maintained.
Pressure increase „Travel“ The pressure sequence valve (4.4) is put under a pressure of 60 bar (from the servo circuit) as soon as a „Travel“ function is summoned. Pressure switch (115/S 81) reacts to the „Travel“ function, shifts solenoid valve (105/Y 31) and allows pressure oil to flow to the sequence valve. Pressure cut - off then only comes into action at 360 bar. The pressure sequence valve can be put out of action with shut - off cock (5).
Chip/contamination switch Any metallic contamination of the hydraulic oil in the pump causes the chip/contamination switch (4.5) to send a warning signal to the BCS (Board Control Systems).
RH 200 Diesel (FS) - 3657771e - (00) - 07.03
8.3
DESCRIPTION OF THE HYDRAULIC SYSTEM - FS
Axial piston pump A 10 V
Pos. 4
the BCS system if metal chips or excessive oil temperatures are detected.
The 2 pressure regulated axial piston pumps are working as charge pumps for the swing circuit.
Oil cooling pump Axial piston pump A 10 V
Pos. 5
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.
Swing pump
Pos. 6
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. The pumps are fitted with a torque control that is controlled by the pressure regulating valve (54). Depending upon the pre - selected control pressure, the valve allows infinite governing of - operating pressure and - torque magnitude and direction
Pos. 7
Four fixed - displacement gear - type pumps are mounted onto the swing pumps (6). They constantly draw oil from the tank and pump it to the fan motors and the oil coolers.
Servo pump
Pos. 8
The 2 servo pumps (8) are fixed - displacement gear - type double pumps that are mounted on the pump transfer gearboxes (2) and that supply the whole servo circuit with oil.
Fan motor
Pos. 9
The gear motor with internal anti-cavitation valve is driving the fans for the radiators.
Filter
Pos. 10
Filter the oil flows from the 4 swing circuit charge pumps.
on the swing motors (51). Each swing pump has two pressure relief/anti cavitation valves.
Filter
Pos. 11
The functions of these valves are:
Two filters clean the oil flows of the two servo pumps (8).
1) To protect the swing circuit from overpressure (max. 400 bar) 2) To ensure that the closed loop of oil in the swing circuit remains full. A gear - type pump is also mounted on each swing pump, and serves as a charge pump for the closed circuit. The charge pressure of the pumps is limited by pressure relief valves integrated into the pumps. The pumps also have chip/contamination and temperature switches which send warning signals to RH 200 Diesel (FS) - 3657771e - (00) - 07.03
Blocking valve
Pos. 12
These valves are leak free and are opened fully by oil from the servo pumps (8) 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
Page 8.3 - 7
8.3
DESCRIPTION OF THE HYDRAULIC SYSTEM - FS
through swing motor, swing pump and transfer gearbox.
free
Pos. 13
free
Pos. 14
Servo oil valve block
Pos. 15
The complete assembly group comprises two filters (11), the differential pressure valve (16), a pressure relief valve (17), two check valves (18) and a housing.
Differential pressure (booster) valve (16) Pos. 16 This valve (set to 25 bar) increases the servo pressure from 35 to 70 bar. The higher pressure is needed to govern the main pumps (3) and to shift the track motors (73).
Servo circuit pressure relief valve Pos. 17 The valve limits the pressure in the servo circuit to 35 bar. The valve is pilot controlled and has a variable setting.
Check valve
Pos. 18
These two valves prevent either of the servo pumps (8) 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. 19
Pump governing valve, compl. Pos. 20 The group comprises two proportional valves (21), two metering connections and a housing.
Page 8.3 - 8
Proportional valve
Pos. 21
These valves control the main pumps (3). They are controlled by the microprocessor (122) 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. 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.
free
Pos. 22
free
Pos. 23
free
Pos. 24
free
Pos. 25
Gate valve in intake line
Pos. 26
The shut - off cocks 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.
free
Pos. 27
Hydraulic oil tank
Pos. 28
The tank stores all of the oil for the system and contains two return flow filters (29), six by - pass valves (30), four tank line pressurizing valves (31), a check valve (32) and pressure switch (33).
Return flow filter
Pos. 29
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.
RH 200 Diesel (FS) - 3657771e - (00) - 07.03
8.3
DESCRIPTION OF THE HYDRAULIC SYSTEM - FS
By - pass valve
Pos. 30
Pressure relief valve
Pos. 36
The relief valves (36) are used as: The six by - pass valves open at a pressure of 1.5 bar and prevent the return flow filters (29) bursting, e. g. due to clogging. Oil then flows unfiltered back into the tank.
Tank line pressurizing valve
Pos. 31
These four valves have fixed settings of approx. 10 bar. They are arranged in the return lines and keep a constant level of pressure in the hydraulic system.
- primary relief valves (4 in all) - secondary relief valve (1 in all) for shovel dump cylinder The valves are pilot controlled and have variable settings.
Primary pressure relief valves Limit the maximum pressure that can be reached by the pumps (3) and therefore protect the primary movers against overload.
Secondary pressure relief valves Check valve
Pos. 32
Protect the working hydraulics against external brute forces.
These two valves have a cracking pressure of approx. 1 bar and prevent oil escaping from: the servo caps on control block (90) for boom and stick „float“ functions (1 valve)
2 - way valve
the servo line to solenoid valve (107/Y 7) for servo circuit ON/OFF (1 valve).
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.
Pressure switch
Pos. 33
Closes at a pressure of 1.5 bar and signals the BCS systems that return flow filters (29) are contaminated (blocked). The filter elements must then be changed immediately.
free
Pos. 34
Distributor plate (compl.) for main pump Pos. 35 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.
RH 200 Diesel (FS) - 3657771e - (00) - 07.03
Pos. 37
The 2 - way valves are shifted by solenoids (24/Y 32 & Y 33). Co - ordination of the valves - see solenoid valve (24).
Protection cap
Pos. 38
Cap for 2 - way valves (37) with connection for pilot line (from solenoid valve 24).
High - pressure filter
Pos. 39
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).
Page 8.3 - 9
8.3
DESCRIPTION OF THE HYDRAULIC SYSTEM - FS
Other than in the return flow filters (29), the oil flows through the HP filters from outside to in.
Solenoid valve
Pos. 45
The valve controls the 2 - way valves (37) for the logical co - ordination of the four main pumps (3).
Check valve
Pos. 40
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.
Block for solenoid valve
Pos. 41
The block carries the solenoid valve (45) for the logical co - ordination of the four main pumps (3).
Distributor plate for oil cooling Pos. 42 Each of the two plates contains two thermostats (44), two pressure relief valves (43) and two check valves. The check valves function as anti - cavitation valves while the engines are being shut down.
Pressure relief valve
Pos. 43
The two pilot controlled, variable setting pressure relief valves protect the cooler circuit against overpressure, e. g. in case of a line blockage.
Fan motor
Four fixed - displacement gear - type motors are used to drive the fans on the oil coolers.
Fan
Pos. 47
The fan produces the air flow to cool down the hydraulic oil.
Oil cooler
Pos. 48
Pass the heat generated in the hydraulic system on to the atmosphere using the air flows created by the fans.
free
Pos. 49
Swing gearbox
Pos. 50
The gearbox are 2 - stage planetary reducers.
Swing motor Thermostat
Pos. 46
Pos. 51
Pos. 44
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.
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.
Swing parking brake
Pos. 52
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. Page 8.3 - 10
RH 200 Diesel (FS) - 3657771e - (00) - 07.03
8.3
DESCRIPTION OF THE HYDRAULIC SYSTEM - FS
The superstructure is braked from it’s swing hydraulically (countering) by servo valve (101).
High - pressure filter
free
Pos. 53
Pressure governing valve
Pos. 54
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.
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.
Pressure relief valve
Pos. 55
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.
Shuttle valve
Pos. 56
Via this shuttle valve the Y1 & Y2 ports of the pressure governing valve (54) are connected with the pressure relief valve (55)
Flushing valve
Pos. 57
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.
free
Pos. 58
free
Pos. 59
RH 200 Diesel (FS) - 3657771e - (00) - 07.03
Check valve
Pos. 60
Pos. 61
These two check valves protect the two HP filters (39) 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 (90) and then into the filters in the wrong direction. This would destroy the filters.
free
Pos. 62
free
Pos. 63
free
Pos. 64
free
Pos. 65
Track tensioning cylinder
Pos. 66
Single - acting (plunger) cylinders that keep the crawler tracks tensioned.
Connecting block
Pos. 67
Blocks that connect the hydraulic lines to the track tensioning cylinders.
Diaphragm accumulator
Pos. 68
The nitrogen accumulators act as shock absorbers to dampen external forces acting on the crawler tracks.
Page 8.3 - 11
8.3
DESCRIPTION OF THE HYDRAULIC SYSTEM - FS
Track tensioning group
Pos. 69
Travel parking brake
Pos. 74
A complete group comprising a pressure relief valve (70), two check valves and two metering connections M 14 x 1.5.
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 two check valves keep the track tensioning pressure at a constant level.
free
Pos. 75
Secondary relief block
Pos. 76
Pressure relief valve
Pos. 70
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. 71
Travel gearbox
Pos. 72
- stage planetary reducers with integrated parking brakes.
Travel motor
Pos. 73
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.
Assembly group comprising four pressure relief valves (77), two metering connections and a housing.
Pressure relief valve
Pos. 77
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.
free
Pos. 78
free
Pos. 79
Travel block
Pos. 80
A complete group comprising rotor (81), the „Travel“ spools (82 & 83), the travel retarder valves (84 & 85), anti - cavitation valves (86) and cover plates (87).
Rotor
Pos. 81
Conducts hydraulic oil flows between superstructure and undercarriage. The seven ring channels are for: Travel (4 channels) Track parking brakes/Track motor adjustment Track tensioning Leakage oil
Page 8.3 - 12
RH 200 Diesel (FS) - 3657771e - (00) - 07.03
8.3
DESCRIPTION OF THE HYDRAULIC SYSTEM - FS
Travel valve block RH
Pos. 82
A servo - controlled single - spool block that actuates the right - hand track.
Travel valve block LH
Pos. 83
A servo - controlled single - spool block that actuates the left - hand track.
Travel retarder valve RH
Pos. 84
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).
Travel retarder valve LH
Pos. 85
See travel retarder valve (84).
Anti - cavitation valve
Pos. 86
The four valves mounted on the „Travel“ spools (82 & 83) 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.
Cover plate
Pos. 87
4-spool control block
Pos. 90
Servo controlled 4-spool blocks for the functions: „Boom“, „Stick“, „Shovel tip“ and „Shovel dump“. With anti - cavitation valves.
Pressure relief valve
Pos. 91
Secondary relief valves. Pilot controlled with variable settings.
Float valve
Pos. 92
Save time and energy when lowering the boom and 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 equipment`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).
free
Pos. 93
free
Pos. 94
Boom cylinder
Pos. 95
The two double-acting hydraulic cylinders are installed between superstructure and TriPower. They are lifting or lowering the boom and thus the complete working equipment.
Covers on the anti - cavitation valves (86).
Arm cylinder Throttle check valve
Pos. 88
Pos. 96
The two double-acting hydraulic cylinders are installed between boom and arm and ensure extension and retraction of the arm.
The check valves in the servo lines of the travel valve block ensure smooth operation of the spools.
free
Pos. 89
RH 200 Diesel (FS) - 3657771e - (00) - 07.03
Page 8.3 - 13
8.3
DESCRIPTION OF THE HYDRAULIC SYSTEM - FS
Crowd cylinder
Pos. 97
The double-acting hydraulic cylinders are installed between TriPower and bucket backwall and are used to turn the bucket.
Clamshell cylinder
Pos. 98
The two double-acting hydraulic cylinders are installed between backwall and frontlip and are used to open and close the bucket.
Distributor
Pos. 104
An assembly group comprising four solenoid valves and a housing.
Filter
Pos. 105
This filter is filtering the oil which is feeding the proportional valve plate (103).
free
Pos. 106
fee
Pos. 107
free
Pos. 108
Check valve
Pos. 109
Pos. 99
The distributor on the backwall of the bucket supplies oil to the clamshell cylinders. It also carries the relief valve pos. 36.
free
Pos. 100
Joy stick
Pos. 101
4 - way joy sticks control the spools in the control blocks (90) and the governors in the swing pumps via the proportional valves in plate (103).
Treadle pedal
Valve bank, compl.
Pos. 102
2 - way pedals that control the spools in the
The check valve keeps the track tensioning system under pressure.
Throttle valve
Pos. 110
Is used to pressurize the servo caps in the control blocks (90), for boom, stick and shovel tip cylinders, to 1.0 - 1.3 bar. This ensures optimum oil flow characteristics.
Twin check valve
Pos. 111
„Travel“ blocks (82 & 83) and in control block (90) for ' Bucket dump' via the proportional valves in plate (103).
Proportional valve plate
Pos. 103
The valve plate contains the proportional valves and the 3/2 way valves for operation of cylinders, swing and travel function .
Page 8.3 - 14
The unlockable twin check valves serve two functions. 1) They give the way free for return line oil to flow from control blocks (90) to the tank when the boom, stick or shovel tip cylinders are actuated. 2) They act as anti - cavitation valves when the spools in the control blocks are shifted back to „neutral“.
free
Pos. 112
free
Pos. 113
RH 200 Diesel (FS) - 3657771e - (00) - 07.03
8.3
DESCRIPTION OF THE HYDRAULIC SYSTEM - FS
free
Pos. 114
free
Pos. 128
Anti cavitation valve
Pos. 115
free
Pos. 129
The check valve acts as an anti-cavitation valve for the fan motor when the engine is shut down.
Reducer flange
Pos. 130
free
Pos. 116
For main pumps (3).
free
Pos. 117
Reducer flange
free
Pos. 118
For cooling pumps (7).
free
Pos. 119
free
Pos. 120
free
Pos. 121
Microprocessor GLR 200
Pos. 122
The load limit governor contains two extensively independent governors, each of which is responsible for one of the engines and the pumps connected to it. The magnitudes to be governed are the speeds of the engines. These speeds are monitored by inductive sensors. The engine speeds are governed by altering the settings of the main pumps (3). The pump settings are altered by proportional valves (21) which convert electrical currents into hydraulic pressure signals which alter the pump settings until an equilibrium is reached between engines and hydraulic consumers.
free free free
Pos. 123
Pos. 131
free
Pos. 132
Blocks
Pos. 133
For rear swing motors (51).
Blocks
Pos. 134
For front swing motors (51).
Distributor
Pos. 135
For pressure balance between the crowd cylinders (97).
free
Pos. 136
free
Pos. 137
Blocks
Pos. 138
Connect tank lines to control blocks (90).
free
Pos. 139
Blocks
Pos. 140
Pos. 124 Pos. 125 Connect tank lines to boom „float“ valves (92).
free
Pos. 126
free
Pos. 127
RH 200 Diesel (FS) - 3657771e - (00) - 07.03
free
Pos. 141
free
Pos. 142 Page 8.3 - 15
8.3
DESCRIPTION OF THE HYDRAULIC SYSTEM - FS
free
Pos. 143
Reducer flange
Pos. 144
For swing pumps (6).
Block
Pos. 145
Connects pump and return line of main pump (3/P 4) to left - hand control block (90).
Block
Pos. 146
Connects pump and return line of main pump (3/P 3) to left - hand control block (90).
Track tensioning block
Pos. 147
The block contains the valves for the automatic track tensioning system.
Solenoid valve
Pos. 148
The Valve is changing the track tensioning pressure between 50 bar and 70 bar mode.
Pressure reduction valve
Pos. 149
The valve is reducing the 70 bar auxiliary pressure to 50 bar.
Page 8.3 - 16
RH 200 Diesel (FS) - 3657771e - (00) - 07.03
8.3
DESCRIPTION OF THE HYDRAULIC SYSTEM - BH
8.3
Description of the hydraulic system
8.3.1
Technical data
The technical data of the hydraulic system are listed in chapter 2 ‘Technical Data’.
8.3.2
Circuit diagram Components of the hydraulic circuit diagram RH 200 (BH) The position nos. refer to circuit diagram No. 3 672 770 (02)
Position
Quantity
Designation
1
2
Engine K 1500 E
Engine module
2
2
Pump transfer gearbox
Engine module
3
4
Main pump A7V - SL - 1000
Pump gearbox
4
2
Charge pump for swing system
Pump gearbox
5
2
Fan pump for radiator fan
Pump gearbox
6
4
Swing pump A4V 250 with adapter
Pump gearbox
7
4
Cooling pump KP 5 - 300
Pump gearbox
8
2
Servo pump
Pump gearbox
9
2
Gear motor for radiator fan
Counterweight
10
4
Filter
Engine module
11
2
Filter
Engine module
12
4
Blocking valve
Engine module
13
----
14
----
Location
15
1
Servo oil valve block
16
1
Differential pressure valve
Position 15
17
1
Servo circuit pressure relief valve
Position 15
18
2
Check valve
Position 15
19
----
20
2
Pump governing valve
21
2
Proportional valve
22
----
23
----
24
----
25
----
26 27
Engine module
2
Gate valve
Engine module Position 20
Hydraulic oil tank
----
RH 200 Diesel (BH) - 3657772e - (00) - 07.03
Page 8.3 - 1
8.3
DESCRIPTION OF THE HYDRAULIC SYSTEM - BH
Position
Quantity
28
1
Hydraulic oil tank
29
2
Return oil filters
Hydraulic oil tank
30
6
Bypass valve
Hydraulic oil tank
31
4
Tank line pressurizing valve
Hydraulic oil tank
32
2
Check valve
Hydraulic oil tank
33
1
Pressure switch
Hydraulic oil tank
34
Designation
Location Superstructure
----
35
1
Distributor plate (main pumps)
36
4
Pressure relief valve
Position 36
37
4
2 – way valve
Position 36
38
4
Cap
Position 36
39
4
High pressure filter
Position 36
40
4
Check valve
Position 36
41
1
Block for solenoid valve
42
2
Distributor plate (oil cooling)
43
4
Pressure relief valve
Position 42
44
4
Thermostat
Position 42
45
1
Solenoid valve for logic valves
46
4
Fan motor
Oil cooler module
47
4
Fan
Oil cooler module
48
4
Hydraulic oil cooler
Oil cooler module
49
Engine module
Engine module Oil cooler module
Engine module
----
50
4
Swing gearbox
Superstructure
51
4
Swing motor
Swing gearbox
52
4
Swing parking brake
Swing gearbox
53
----
54
1
Pressure governing valve
Engine module
55
1
Pressure relief valve
Engine module
56
1
Shuttle valve
Engine module
57
1
Flushing valve
Engine module
58
----
59
----
60
2
High pressure filters
61
2
Check valve
62
----
63
----
Page 8.3 - 2
Superstructure
RH 200 Diesel (BH) - 3657772e - (00) - 07.03
8.3
DESCRIPTION OF THE HYDRAULIC SYSTEM - BH
Position
Quantity
Designation
64
----
65
----
Location
66
2
Track tensioning cylinder
Undercarriage
67
2
Connector block
Undercarriage
68
2
Diaphragm accumulator
Undercarriage
69
1
Track tensioning group
Undercarriage
70
----
71
----
72
2
Travel gearbox
Undercarriage
73
4
Travel motor
Travel gearbox
74
4
Travel parking brake
Travel gearbox
75
----
76
1
Valve block
77
4
Pressure relief valve
78
----
79
----
Undercarriage Position 76
80
1
Travel block
Superstructure
81
1
Rotor
Superstructure
82
1
Travel valve block RH
Rotor
83
1
Travel valve block LH
Rotor
84
1
Travel retarder valve RH
Travel block
85
1
Travel retarder valve LH
Travel block
86
4
Anti – cavitation valve
Travel block
87
4
Cover plate
Travel block
88
4
Throttle check valve
Travel block
89
----
90
2
4-spool control valve
Boom
91
16
Pressure relief valve
4-spool control valve
92
2
Float valve
93
4
Throttled check valve
Position 90 & 92
94
4
Throttled check valve
Position 135
95
2
Boom cylinder
Boom
96
2
Stick cylinder
Boom
97
2
Bucket cylinder
Stick
98
----
99
----
RH 200 Diesel (BH) - 3657772e - (00) - 07.03
Boom
Page 8.3 - 3
8.3
DESCRIPTION OF THE HYDRAULIC SYSTEM - BH
Position
Quantity
100
Designation
Location
----
101
2
Joy stick
Operator cab
102
3
Treadle pedal
Operator cab
103
1
Proportional valve plate
Operator module
104
2
Valve bank
Operator module
105
1
Filter for proportional valve plate
Operator module
106
----
107
----
108
----
109
1
Check valve
110
1
Throttle valve
111
3
Twin check valves
112
----
113
----
114
----
115
2
Internal anti cavitation valve for fan motor
116
----
117
----
118
----
119
----
120
----
121
----
122
1
Microprocessor GLR 200
123
----
124
----
125
----
126
----
127
----
128
----
129
----
Position 9
Operator module
130
5
Reducer flange
Position 4 & 90
131
4
Reducer flange
Position 7
132
----
133
4
Block
Position 51
134
4
Block
Position 51
135
4
Distributor
Page 8.3 - 4
Boom
RH 200 Diesel (BH) - 3657772e - (00) - 07.03
8.3
DESCRIPTION OF THE HYDRAULIC SYSTEM - BH
Position
Quantity
Designation
136
----
137
----
138
2
Block
139
----
140
----
141
----
Location
Position 90
142
2
Block
143
2
Orifice
144
8
Reducer flange
145
1
Block
Superstructure
146
1
Block
Superstructure
147
1
Track tensioning block
Undercarriage
148
1
Solenoid valve
Engine modul
149
1
Pressure reduction valve
Engine modul
RH 200 Diesel (BH) - 3657772e - (00) - 07.03
Page 8.3 - 5
8.3 8.3.3
DESCRIPTION OF THE HYDRAULIC SYSTEM - BH Components of the hydraulic system of the RH 200 (BH)
Attention! Position nos. are referred to circuit diagram Part-No. 3 672 770 (02). Some items are numbered on the schematic but not mentioned here. They are not important for the hydraulic functioning.
Drive unit
Pos. 1
stroking cylinder (4. 2). At operating pressures under 60 bar, chamber © is fed with oil from the servo circuit (60 bar) through port (X2). It would otherwise not be possible to tilt the pumps. When the pump receives a signal to „tilt out“, i. e. the governing pressure on port (X1) is 10 - 43 bar, the spool (4. 1) is shifted against the force of the spring. Oil in chamber © flows into chamber (A) until equilibrium is reached between the governing pressure and the force of the spring. As the spool (B) has reaction surfaces of different size, the forces in chamber (A) „win“. The rotary group is tiled out (oil flow increased) until equilibrium is restored.
The two water - cooled Cummins engines are 12 cylinder „V“ engines with turbo-charging and inter cooling.
The works - set orifices (4.3) determine the tilting speed of the pump.
Pump transfer gearbox
If PMS then reduces the governing pressure on port (X1), spool (4.1) is shifted to the right. Chamber (A) of the governing cylinder (4.2) is connected to the oil tank. The rotary group is then de stroked (i. e. tilted back to a lower flow) until an equilibrium is reached.
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.
Variable - displacement pump
Pos. 3
The 4 main pumps (4) for working equipment and travel movements are axial - piston swashplate pumps with slipper bearing. Slipper bearings are hydraulically „swimming“ bearings that increase the pump`s service life. Each pump has its own pressure - dependent regulator (4. 1, Fig. 1) with a regulating range of between 8 and 43 bar. At 43 bar, the pump`s rotary group is at its maximum swashplate angle (13° 15`) and therefore at maximum flow. At 8 bar, the rotary group is at „zero“ oil flow. The governors are actuated by the electronic load - limit governor (122) in the PMS systems, and by the proportional valves (21).
Function Pressure oil required to tilt (alter the angle) of the rotary group is drawn from the pump`s own main flow. It is continually available in chamber © of de Page 8.3 - 6
Pressure cut - off Pressure cut - off comes into effect as soon as the system pressure reaches 300 bar. Pressure sequence valve (4.4) is opened by the system pressure and connects chambers (A & C) of the governing cylinder (4.2) with the tank. The pump is tiled back to such a reduced flow that only the pressure in the system is maintained.
Pressure increase „Travel“ The pressure sequence valve (4.4) is put under a pressure of 60 bar (from the servo circuit) as soon as a „Travel“ function is summoned. Pressure switch (115/S 81) reacts to the „Travel“ function, shifts solenoid valve (105/Y 31) and allows pressure oil to flow to the sequence valve. Pressure cut - off then only comes into action at 360 bar. The pressure sequence valve can be put out of action with shut - off cock (5).
Chip/contamination switch Any metallic contamination of the hydraulic oil in the pump causes the chip/contamination switch (4.5) to send a warning signal to the BCS (Board Control Systems).
RH 200 Diesel (BH) - 3657772e - (00) - 07.03
8.3
DESCRIPTION OF THE HYDRAULIC SYSTEM - BH
Axial piston pump A 10 V
Pos. 4
the BCS system if metal chips or excessive oil temperatures are detected.
The 2 pressure regulated axial piston pumps are working as charge pumps for the swing circuit.
Oil cooling pump Axial piston pump A 10 V
Pos. 5
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.
Swing pump
Pos. 6
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. The pumps are fitted with a torque control that is controlled by the pressure regulating valve (54). Depending upon the pre - selected control pressure, the valve allows infinite governing of - operating pressure and - torque magnitude and direction
Pos. 7
Four fixed - displacement gear - type pumps are mounted onto the swing pumps (6). They constantly draw oil from the tank and pump it to the fan motors and the oil coolers.
Servo pump
Pos. 8
The 2 servo pumps (8) are fixed - displacement gear - type double pumps that are mounted on the pump transfer gearboxes (2) and that supply the whole servo circuit with oil.
Fan motor
Pos. 9
The gear motor with internal anti-cavitation valve is driving the fans for the radiators.
Filter
Pos. 10
Filter the oil flows from the 4 swing circuit charge pumps.
on the swing motors (51). Each swing pump has two pressure relief/anti cavitation valves.
Filter
Pos. 11
The functions of these valves are:
Two filters clean the oil flows of the two servo pumps (8).
1) To protect the swing circuit from overpressure (max. 400 bar) 2) To ensure that the closed loop of oil in the swing circuit remains full. A gear - type pump is also mounted on each swing pump, and serves as a charge pump for the closed circuit. The charge pressure of the pumps is limited by pressure relief valves integrated into the pumps. The pumps also have chip/contamination and temperature switches which send warning signals to RH 200 Diesel (BH) - 3657772e - (00) - 07.03
Blocking valve
Pos. 12
These valves are leak free and are opened fully by oil from the servo pumps (8) 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
Page 8.3 - 7
8.3
DESCRIPTION OF THE HYDRAULIC SYSTEM - BH
through swing motor, swing pump and transfer gearbox.
free
Pos. 13
free
Pos. 14
Servo oil valve block
Pos. 15
The complete assembly group comprises two filters (11), the differential pressure valve (16), a pressure relief valve (17), two check valves (18) and a housing.
Proportional valve
Pos. 21
These valves control the main pumps (3). They are controlled by the microprocessor (122) 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. 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.
free
Pos. 22
Pos. 16
free
Pos. 23
This valve (set to 25 bar) increases the servo pressure from 35 to 60 bar. The higher pressure is needed to govern the main pumps (3) and to shift the track motors (73).
free
Pos. 24
free
Pos. 25
Gate valve in intake line
Pos. 26
Differential pressure valve
Servo circuit pressure relief valve Pos. 17 The valve limits the pressure in the servo circuit to 35 bar. The valve is pilot controlled and has a variable setting.
Check valve
Pos. 18
These two valves prevent either of the servo pumps (8) 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. 19
Pump governing valve, compl. Pos. 20 The group comprises two proportional valves (21), two metering connections and a housing.
Page 8.3 - 8
The shut - off cocks 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.
free
Pos. 27
Hydraulic oil tank
Pos. 28
The tank stores all of the oil for the system and contains two return flow filters (29), six by - pass valves (30), four tank line pressurizing valves (31), a check valve (32) and pressure switch (33).
Return flow filter
Pos. 29
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.
RH 200 Diesel (BH) - 3657772e - (00) - 07.03
8.3
DESCRIPTION OF THE HYDRAULIC SYSTEM - BH
By - pass valve
Pos. 30
The six by - pass valves open at a pressure of 1.5 bar and prevent the return flow filters (29) bursting, e. g. due to clogging. Oil then flows unfiltered back into the tank.
Pressure relief valve
Pos. 36
The relief valves (36) are used as: - primary relief valves (4 in all) - secondary relief valve (1 in all) for shovel dump cylinder
Tank line pressurizing valve
Pos. 31
These four valves have fixed settings of approx. 10 bar. They are arranged in the return lines and keep a constant level of pressure in the hydraulic system.
Check valve
Pos. 32
These two valves have a cracking pressure of approx. 1 bar and prevent oil escaping from: the servo caps on control block (90) for boom and stick „float“ functions (1 valve) the servo line to solenoid valve (107/Y 7) for servo circuit ON/OFF (1 valve).
The valves are pilot controlled and have variable settings.
Primary pressure relief valves Limit the maximum pressure that can be reached by the pumps (3) and therefore protect the primary movers against overload.
Secondary pressure relief valves Protect the working hydraulics against external brute forces.
2 - way valve
Pos. 37
Pos. 33
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.
Closes at a pressure of 1.5 bar and signals the BCS systems that return flow filters (29) are contaminated (blocked). The filter elements must then be changed immediately.
The 2 - way valves are shifted by solenoids (24/Y 32 & Y 33). Co - ordination of the valves - see solenoid valve (24).
Pressure switch
free
Pos. 34
Distributor plate (compl.) for main pumps Pos. 35 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.
RH 200 Diesel (BH) - 3657772e - (00) - 07.03
Protection cap
Pos. 38
Cap for 2 - way valves (37) with connection for pilot line (from solenoid valve 24).
High - pressure filter
Pos. 39
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).
Page 8.3 - 9
8.3
DESCRIPTION OF THE HYDRAULIC SYSTEM - BH
Other than in the return flow filters (29), the oil flows through the HP filters from outside to in.
Solenoid valve
Pos. 45
The valve controls the 2 - way valves (37) for the logical co - ordination of the four main pumps (3).
Check valve
Pos. 40
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.
Block for solenoid valve
Pos. 41
The block carries the solenoid valve (45) for the logical co - ordination of the four main pumps (3).
Distributor plate for oil cooling Pos. 42 Each of the two plates contains two thermostats (44), two pressure relief valves (43) and two check valves. The check valves function as anti - cavitation valves while the engines are being shut down.
Pressure relief valve
Pos. 43
The two pilot controlled, variable setting pressure relief valves protect the cooler circuit against overpressure, e. g. in case of a line blockage.
Fan motor
Four fixed - displacement gear - type motors are used to drive the fans on the oil coolers.
Fan
Pos. 47
The fan produces the air flow to cool down the hydraulic oil.
Oil cooler
Pos. 48
Pass the heat generated in the hydraulic system on to the atmosphere using the air flows created by the fans.
free
Pos. 49
Swing gearbox
Pos. 50
The gearbox are 2 - stage planetary reducers.
Swing motor Thermostat
Pos. 46
Pos. 51
Pos. 44
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.
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.
Swing parking brake
Pos. 52
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. Page 8.3 - 10
RH 200 Diesel (BH) - 3657772e - (00) - 07.03
8.3
DESCRIPTION OF THE HYDRAULIC SYSTEM - BH
The superstructure is braked from it’s swing hydraulically (countering) by servo valve (101).
High - pressure filter
free
Pos. 53
Pressure governing valve
Pos. 54
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.
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.
Pressure relief valve
Pos. 55
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.
Shuttle valve
Pos. 56
Via this shuttle valve the Y1 & Y2 ports of the pressure governing valve (54) are connected with the pressure relief valve (55)
Flushing valve
Pos. 57
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.
free
Pos. 58
free
Pos. 59
RH 200 Diesel (BH) - 3657772e - (00) - 07.03
Check valve
Pos. 60
Pos. 61
These two check valves protect the two HP filters (39) 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 (90) and then into the filters in the wrong direction. This would destroy the filters.
free
Pos. 62
free
Pos. 63
free
Pos. 64
free
Pos. 65
Track tensioning cylinder
Pos. 66
Single - acting (plunger) cylinders that keep the crawler tracks tensioned.
Connecting block
Pos. 67
Blocks that connect the hydraulic lines to the track tensioning cylinders.
Diaphragm accumulator
Pos. 68
The nitrogen accumulators act as shock absorbers to dampen external forces acting on the crawler tracks.
Page 8.3 - 11
8.3
DESCRIPTION OF THE HYDRAULIC SYSTEM - BH
Track tensioning group
Pos. 69
Travel parking brake
Pos. 74
A complete group comprising a pressure relief valve (70), two check valves and two metering connections M 14 x 1.5.
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 two check valves keep the track tensioning pressure at a constant level.
free
Pos. 75
Secondary relief block
Pos. 76
Pressure relief valve
Pos. 70
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. 71
Travel gearbox
Pos. 72
- stage planetary reducers with integrated parking brakes.
Travel motor
Pos. 73
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.
Assembly group comprising four pressure relief valves (77), two metering connections and a housing.
Pressure relief valve
Pos. 77
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.
free
Pos. 78
free
Pos. 79
Travel block
Pos. 80
A complete group comprising rotor (81), the „Travel“ spools (82 & 83), the travel retarder valves (84 & 85), anti - cavitation valves (86) and cover plates (87).
Rotor
Pos. 81
Conducts hydraulic oil flows between superstructure and undercarriage. The seven ring channels are for: Travel (4 channels) Track parking brakes/Track motor adjustment Track tensioning Leakage oil
Page 8.3 - 12
RH 200 Diesel (BH) - 3657772e - (00) - 07.03
8.3
DESCRIPTION OF THE HYDRAULIC SYSTEM - BH
Travel valve block RH
Pos. 82
A servo - controlled single - spool block that actuates the right - hand track.
Travel valve block LH
4-spool control block
Pos. 90
Servo controlled 4-spool blocks for the functions: „Boom“, „Stick“, „Shovel tip“ and „Shovel dump“. With anti - cavitation valves.
Pos. 83
A servo - controlled single - spool block that actuates the left - hand track.
Pressure relief valve
Pos. 91
Secondary relief valves. Pilot controlled with variable settings.
Travel retarder valve RH
Pos. 84
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).
Travel retarder valve LH
Pos. 85
See travel retarder valve (84).
Anti - cavitation valve
Pos. 86
The four valves mounted on the „Travel“ spools (82 & 83) 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.
Cover plate
Pos. 87
Covers on the anti - cavitation valves (86).
Throttle check valve
Pos. 92
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).
Throttle check valve
Pos. 93
The check valves in the cylinder lines ensure smooth operation of the attachment.
free
Pos. 94
Boom cylinder
Pos. 95
The two double-acting hydraulic cylinders are installed between superstructure and TriPower. They are lifting or lowering the boom and thus the complete working equipment.
Pos. 88
The check valves in the servo lines of the travel valve block ensure smooth operation of the spools.
free
Float valve
Pos. 89
RH 200 Diesel (BH) - 3657772e - (00) - 07.03
Stick cylinder
Pos. 96
The two double-acting hydraulic cylinders are installed between boom and stick and ensure extension and retraction of the arm.
Page 8.3 - 13
8.3
DESCRIPTION OF THE HYDRAULIC SYSTEM - BH Bucket cylinder
Pos. 97
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. 98
free
Pos. 99
free
Pos. 100
Joy stick
Pos. 101
4 - way joy sticks control the spools in the control blocks (90) and the governors in the swing pumps via the proportional valves in plate (103).
Treadle pedal
Pos. 102
2 - way pedals that control the spools in the „Travel“ blocks (82 & 83) and in control block (90) for ' Bucket dump' via the proportional valves in plate (103).
Proportional valve plate
Pos. 103
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. 104
An assembly group comprising four solenoid valves and a housing.
Filter
Pos. 105
This filter is filtering the oil which is feeding the proportional valve plate (103).
Page 8.3 - 14
RH 200 Diesel (BH) - 3657772e - (00) - 07.03
8.3
DESCRIPTION OF THE HYDRAULIC SYSTEM - BH
free
Pos. 106
free
Pos. 118
fee
Pos. 107
free
Pos. 119
free
Pos. 108
free
Pos. 120
Check valve
Pos. 109
free
Pos. 121
Microprocessor GLR 200
Pos. 122
The check valve keeps the track tensioning system under pressure.
Throttle valve
Pos. 110
Is used to pressurize the servo caps in the control blocks (90), for boom, stick and shovel tip cylinders, to 1.0 - 1.3 bar. This ensures optimum oil flow characteristics.
Twin check valve
Pos. 111
The unlockable twin check valves serve two functions.
The load limit governor contains two extensively independent governors, each of which is responsible for one of the engines and the pumps connected to it. The magnitudes to be governed are the speeds of the engines. These speeds are monitored by inductive sensors. The engine speeds are governed by altering the settings of the main pumps (3). The pump settings are altered by proportional valves (21) which convert electrical currents into hydraulic pressure signals which alter the pump settings until an equilibrium is reached between engines and hydraulic consumers.
free
Pos. 123
free
Pos. 124
2) They act as anti - cavitation valves when the spools in the control blocks are shifted back to „neutral“.
free
Pos. 125
free
Pos. 112
free
Pos. 126
free
Pos. 113
free
Pos. 127
free
Pos. 114
free
Pos. 128
Anti cavitation valve
Pos. 115
free
Pos. 129
Reducer flange
Pos. 130
1) They give the way free for return line oil to flow from control blocks (90) to the tank when the boom, stick or shovel tip cylinders are actuated.
The check valve acts as an anti-cavitation valve for the fan motor when the engine is shut down.
free
Pos. 116
free
Pos. 117
RH 200 Diesel (BH) - 3657772e - (00) - 07.03
For main pumps (3).
Page 8.3 - 15
8.3
DESCRIPTION OF THE HYDRAULIC SYSTEM - BH
Reducer flanges
Pos. 131
For cooling pumps (7).
Pos. 132
Blocks
Pos. 133
For rear swing motors (51).
Block
Pos. 146
Connects pump and return line of main pump (3/P 3) to left - hand control block (90).
Pos. 134 Track tensioning block
For front swing motors (51).
Distributor
Pos. 145
Connects pump and return line of main pump (3/P 4) to left - hand control block (90).
free
Blocks
Block
Pos. 135
For pressure balance between the crowd cylinders (97).
free
Pos. 136
free
Pos. 137
Blocks
Pos. 138
Connect tank lines to control blocks (90).
free
Pos. 139
free
Pos. 140
free
Pos. 141
free
Pos. 142
free
Pos. 143
Reducer flange
Pos. 144
Pos. 147
The block contains the valves for the automatic track tensioning system.
Solenoid valve
Pos. 148
The Valve is changing the track tensioning pressure between 50 bar and 70 bar mode.
Pressure reduction valve
Pos. 149
The valve is reducing the 70 bar auxiliary pressure to 50 bar.
For swing pumps (6).
Page 8.3 - 16
RH 200 Diesel (BH) - 3657772e - (00) - 07.03
8.4
HYDRAULIC COMPONENTS
8.4
Hydraulic components
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 300 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 switch
Fig. 1
Main pump regulator
If the oil in a pump is contaminated with metal particles, the contamination switch (3.5-S63) 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 - 2471392e - (02) - 10.99
Page 8.4 - 1
8.4
HYDRAULIC COMPONENTS
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 adjustably. This control permits virtually loss-free utilization 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 - 2471392e - (02) - 10.99
8.4
HYDRAULIC COMPONENTS
8.4.3
Rotor
The rotor is connecting the hydraulic systems of the superstructure and the undercarriage.
Ref. no.
Quantity
Designation
1
1
Groove for travelling
2
1
Groove for travelling
3
1
Groove for travelling
4
1
Groove for travelling
5
1
Groove for track tensioning system
6
1
Groove for track unit brake
7
1
Groove for leakage oil
10
Cylinder head bolt M 10 x 30
11
Cylinder head bolt M 16 x 45
12
Lifting eye M 16
Fig. 1
RH 200 Diesel - 2471392e - (02) - 10.99
Further remarks
Weight [kg]
Tightening torque Ma = 210 Nm
Rotor
Page 8.4 - 3
8.4
HYDRAULIC COMPONENTS
Remove rotor 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. 2 + 3)
•
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 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.
Page 8.4 - 4
Fig. 2
Removing the rotor seals
Fig. 3
Removal of the rotor seals
RH 200 Diesel - 2471392e - (02) - 10.99
8.4
HYDRAULIC COMPONENTS
8.4.4
Hydraulic valves
Blocking valve
closed and prevent the engine from being driven via the swing pumps and the pump gearbox.
Pos. 12
The 2 locking valves belonging to each drive unit are controlled and opened by the servo pumps (8) of the drive unit when the engine is running. When the engine is stopped, the locking valves are
Ref.-no.
Quantity
1
1
Valve
2
1
Orifice
3
1
Check valve cone
4
1
Plug
5 6
Designation
The ports are marked with ‘A’, ‘B’ and ‘R’. The orifice (2) is installed with Loctite (20) and punch-secured.
further remarks
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
Tightening torque Md = 10 Nm
19
4
Cyl.-head bolt M 5 x 30 – 8.8
Tightening torque Md = 4,9 Nm
20
Weight [kg]
Loctite
Table 1
RH 200 Diesel - 2471392e - (02) - 10.99
Page 8.4 - 5
8.4
HYDRAULIC COMPONENTS
Fig. 1
Blocking valve
Fig. 2
Blocking valve
Page 8.4 - 6
RH 200 Diesel - 2471392e - (02) - 10.99
8.4
HYDRAULIC COMPONENTS
Servo oil valve block
Pos. 15
Servo circuit pressure relief valve Pos. 17
The complete assembly group comprises two filters (11), the differential pressure valve (16), a pressure relief valve (17), two check valves (18) and a housing.
The valve limits the pressure in the servo circuit to 35 bar. The valve is pilot controlled and has a variable setting.
Filter
Check valves
Pos. 11
Two filters clean the oil flows of the two servo pumps (8). Two filters clean part of the oil flows returning from the oil coolers. This oil is then available to flush and cool the slipper bearings of the main pumps (ports U on main pumps 3).
Pos. 18
These two valves prevent either of the servo pumps (8) 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.
Differential pressure (booster) valve Pos. 16 This valve (set to 25 bar) increases the servo pressure from 35 to 60 bar. The higher pressure is needed to regulate the main pumps (3) and to shift the travel motors (73).
Ref.-no.
Quantity
1
1
Housing
2
1
Differential pressure valve
Pos. 16
3
1
Pressure relief valve
Pos. 17
4
2
Filter
Pos. 11
5
2
Test point
Minimess M 14 x 1,5
6
2
Check valve
Pos. 18
7 – 11
Designation
further remarks
Weight [kg]
----
12
4
Cylinder head bolt M 6 x 60
13
1
Plug M 16 x 1,5
Table 1
RH 200 Diesel - 2471392e - (02) - 10.99
Page 8.4 - 7
8.4
HYDRAULIC COMPONENTS
Fig. 1
Page 8.4 - 8
Valve block – servo- and auxiliary pressure
RH 200 Diesel - 2471392e - (02) - 10.99
8.4
HYDRAULIC COMPONENTS
Fig. 2
RH 200 Diesel - 2471392e - (02) - 10.99
Valve block – servo- and auxiliary pressure
Page 8.4 - 9
8.4
HYDRAULIC COMPONENTS
Bypass valve
Pos. 30
The by - pass valve opens at a pressure of 1.5 bar and prevents the return flow filters (29) 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
Page 8.4 - 10
Bypass valve
RH 200 Diesel - 2471392e - (02) - 10.99
8.4
HYDRAULIC COMPONENTS
Tank-line pre-charging valve
Pos. 31
This ensures that sufficient oil is available at the anti-cavitation valves of cylinders and travel valves.
The tank-line pre-charging valve pre-pressurizes 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
Pressure relief valve
7
----
8
----
further remarks
Weight [kg]
Tightening torque Md = 70 Nm
9 10
1
Sealing ring
11
1
O-ring
12
1
O-ring
13
2
Cylinder head bolt M 6 x 35
Tightening torque Md = 8,5 Nm
Table 1
RH 200 Diesel - 2471392e - (02) - 10.99
Page 8.4 - 11
8.4
HYDRAULIC COMPONENTS
6, 13 Fig. 1
Tank-line pre charging valve
6, 13 Fig. 2
Page 8.4 - 12
Tank-line pre charging valve
RH 200 Diesel - 2471392e - (02) - 10.99
8.4
HYDRAULIC COMPONENTS
Pump distributor block
Pos. 35
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.
Primary pressure relief valves
Pos. 36
Limit the maximum pressure that can be reached by the pumps (3) and therefore protect the primary movers against overload.
The 2 - way valves are shifted by solenoids (24/Y 32 & Y 33). Co - ordination of the valves - see solenoid valve (24).
High - pressure filter
Pos. 39
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.
Check valves 2 - way valves
Pos. 37
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. Ref.-no.
Quantity
Designation
1
1
Housing
2
1
Plate
3
2
Flange
4
2
Cone
5
2
Spring seat
6
4
Cover
4
Pressure relief valve
Pos. 40
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.
further remarks
Weight [kg]
9 10 11 12 14 15 16 17 18 19 20 25
Cyl. head bolt M 5 x 16 – 8.8
26
Cyl. head bolt M 12 x 60 – 12.9
RH 200 Diesel - 2471392e - (02) - 10.99
Tightening torque Md = 145 Nm Page 8.4 - 13
8.4
HYDRAULIC COMPONENTS
Ref.-no.
Quantity
Designation
further remarks
27
Weight [kg]
16
Hex. Bolt M 16 x 150 – 10.9
Tightening torque Md = 295 Nm
28
6
Cyl. head bolt M 20 x 120 – 12.9
29
8
Hex. Bolt M 8 x 75 – 8.8
30
2
Lifting eye
Table 1
Fig. 1
Page 8.4 - 14
Pump distributor block
RH 200 Diesel - 2471392e - (02) - 10.99
8.4
HYDRAULIC COMPONENTS
Fig. 2
RH 200 Diesel - 2471392e - (02) - 10.99
Pump distributor block
Page 8.4 - 15
8.4
HYDRAULIC COMPONENTS
Valve block for oil cooling
Pos. 42
Each of the two plates contains two thermostats (44), two pressure relief valves (43) and two check valves. The check valves function as anti - cavitation valves while the engines are being shut down.
Pressure relief valves
Pos. 43
Thermostats
Pos. 44
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.
The two pilot controlled, variable setting pressure relief valves protect the cooler circuit against overpressure, e. g. in case of a line blockage.
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
Pressure relief valve
Tightening torque Md = 80 Nm
15
2
O-ring
16
2
O-ring
17
2
O-ring
18
1
Lifting eye
19
6
Hex. bolt M 8 x 30
Tightening torque Md = 20,5 Nm
20
4
Cylinder head bolt M 6 x 25
Tightening torque Md = 8,5 Nm
Table 1
Page 8.4 - 16
RH 200 Diesel - 2471392e - (02) - 10.99
8.4
HYDRAULIC COMPONENTS
14, 20 Fig. 1
RH 200 Diesel - 2471392e - (02) - 10.99
Hydraulic oil cooling - thermostat valve
Page 8.4 - 17
8.4
HYDRAULIC COMPONENTS
14 Fig. 2
Page 8.4 - 18
Hydraulic oil cooling - thermostat valve
RH 200 Diesel - 2471392e - (02) - 10.99
8.4
HYDRAULIC COMPONENTS
Pressure balance valve
Pos. 54
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 - 2471392e - (02) - 10.99
Pressure balance valve
Page 8.4 - 19
8.4
HYDRAULIC COMPONENTS
Flushing valve
Pos. 57
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 - 20
Flushing valve
RH 200 Diesel - 2471392e - (02) - 10.99
8.4
HYDRAULIC COMPONENTS
High pressure filter
Pos. 60
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
High pressure filter
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 - 2471392e - (02) - 10.99
Page 8.4 - 21
8.4
HYDRAULIC COMPONENTS
Fig. 1
Page 8.4 - 22
Filter for swing system
RH 200 Diesel - 2471392e - (02) - 10.99
8.4
HYDRAULIC COMPONENTS
Secondary relief block
Pos. 76
Assembly group comprising four pressure relief valves (77), 4 test points and a housing.
Ref.-no.
Quantity
1
1
2
Designation
Pressure relief valve
Pos. 77
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
Tightening torque Md = 300 Nm
Table 1
3 Fig. 1
RH 200 Diesel - 2471392e - (02) - 10.99
Secondary relief valve - travel
Page 8.4 - 23
8.4
HYDRAULIC COMPONENTS
Travel retarder valve
Pos. 84 / 85
The travel retarder valve prevents the excavator from „running away“ downhill and keeps the travel motors full of oil (to avoid cavitation). The speed of the travel motors is then always determined by the working pressure of the pumps (3).
Ref.-no.
Quantity
1
1
Guide
2
1
Housing
3
3
Cap
4
1
Piston
5 6
Designation
further remarks
Weight [kg]
---1
Plug
1
Spring
7–9 10 11
1
Bleeder valve
12
1
Valve
13 14
---2
15 - 25
O-ring ----
26
4
Hex. Bolt M 8 x 75
Tightening torque Md = 25 Nm
27
4
Hex. Bolt M 8 x 50
Tightening torque Md = 25 Nm
28
----
29
----
30
1
Lifting eye M 12
Table 1
Page 8.4 - 24
RH 200 Diesel - 2471392e - (02) - 10.99
8.4
HYDRAULIC COMPONENTS
26, 27 Fig. 1
RH 200 Diesel - 2471392e - (02) - 10.99
12 Travel retarder valve
Page 8.4 - 25
8.4
HYDRAULIC COMPONENTS
26, 27 Fig. 2
Page 8.4 - 26
12 Travel retarder valve
RH 200 Diesel - 2471392e - (02) - 10.99
8.4
HYDRAULIC COMPONENTS
4-spool control block
Pos. 90
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
Pressure relief valve
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]
Tightening torque Md = 150 Nm
Table 1
RH 200 Diesel - 2471392e - (02) - 10.99
Page 8.4 - 27
8.4
HYDRAULIC COMPONENTS
Fig. 1
4-spool control valve
Fig. 2
4-spool control block
Page 8.4 - 28
RH 200 Diesel - 2471392e - (02) - 10.99
8.4
HYDRAULIC COMPONENTS
Boom float valve
Pos. 92/1
Arm float valve
Pos. 92/2
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
Designation
1
1
Valve housing
2
1
Spool
3
1
Bonnet
4
1
Check valve
5
1
Flange
6
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
19
1
Pipe
20
4
Stud bolt M 10 x 170
21
4
Nut M 10
22
4
Hex. bolt M 16x 55
Tightening torque Md = 310 Nm
23
4
Hex. bolt M 10x 50
Tightening torque Md = 49 Nm
13 - 18
Minimeß M 14 x 1,5
----
Table 1
RH 200 Diesel - 2471392e - (02) - 10.99
Page 8.4 - 29
8.4
HYDRAULIC COMPONENTS
22, 23 Fig. 1
Float valve
22, 23 Fig. 2
Page 8.4 - 30
Float valve
RH 200 Diesel - 2471392e - (02) - 10.99
8.4
HYDRAULIC COMPONENTS
Distributor (FS only)
Pos. 99
The distributor on the backwall of the bucket supplies oil to the clamshell cylinders. It also carries the relief valve pos. 36.
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
Cylinder head bolt M 12 x 60
Tightening torque Md = 145 Nm
Table 1
RH 200 Diesel - 2471392e - (02) - 10.99
Page 8.4 - 31
8.4
HYDRAULIC COMPONENTS
17 Fig. 1
Page 8.4 - 32
Pressure relief valve in FS backwall
RH 200 Diesel - 2471392e - (02) - 10.99
8.4
HYDRAULIC COMPONENTS
Proportional valve plate
Pos. 103
The complete assembly group comprises 16 electro-hydraulic proportional valves and 16 safety valves (3/2 way valves).
Ref.-no.
Quantity
Designation
1
Servo valve block
2
1
Housing
3
16
3/2 way valve
4 5
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
RH 200 Diesel - 2471392e - (02) - 10.99
Page 8.4 - 33
8.4
HYDRAULIC COMPONENTS
Fig. 1
Page 8.4 - 34
Servo valve block wit proportional solenoids
RH 200 Diesel - 2471392e - (02) - 10.99
8.4
HYDRAULIC COMPONENTS
Fig. 2
RH 200 Diesel - 2471392e - (02) - 10.99
Servo valve block wit proportional solenoids
Page 8.4 - 35
8.4
HYDRAULIC COMPONENTS Pos. 104/1
• •
The valve block contains 4 solenoid valves. Both ports P1 and P2 are connected to the auxiliary system (60 bar).
•
Solenoid valve block
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
Solenoid valve block
Electrical data: Voltage: 24 V Output: 16 W Switch-on time: 100 %
Weight [kg]
Hydraulical data: Max. pressure: 210 bar Rated flow (∆p = 5 bar): 26 l/min. Max. flow: 35 l/min. Table 1
Fig. 1
Page 8.4 - 36
Solenoid valve block
RH 200 Diesel - 2471392e - (02) - 10.99
8.4
HYDRAULIC COMPONENTS
Solenoid valve block
Pos. 104/2
The valve block contains 4 solenoid valves. The port P1 for then solenoid valves Y3 & Y4 is connected to the auxiliary system (60 bar). The port P2 for then solenoid valves Y1 & Y2 is connected to the servo system (35 bar).
The solenoid valves operate the following functions: • • • •
Ref.-no.
Quantity
1
1
Outlet A1: Actuation of the travel parking brake. Outlet A2: not used. Outlet A3: Shifting of the 2-speed travel motors. Outlet A4: Travel pressure increase.
Designation
further remarks
Solenoid valve block
Electrical data: Voltage: 24 V Output: 16 W Switch-on time: 100 %
Weight [kg]
Hydraulical data: Max. pressure: 210 bar Rated flow (∆p = 5 bar): 26 l/min. Max. flow: 35 l/min. Table 1
Fig. 1
RH 200 Diesel - 2471392e - (02) - 10.99
Solenoid valve block
Page 8.4 - 37
8.4
HYDRAULIC COMPONENTS
Page 8.4 - 38
RH 200 - 2471392e – (02) – 10.99
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
Servo 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 - ‘Description of the hydraulic system’.
60 bar - auxiliary pressure Auxiliary oil (60 bar) is required for the following functions: •
Regulation of the main pumps via proportional valves (20)
•
Operation of the pressure increase to 360 bar for the travel system via solenoid control block.
The 2 gear pumps (8) for the servo system are driven by the engines (1) via the pump gearbox (2).
•
Solenoid valve for 2-stage regulation of the travel motors.
The pumps (8) suck the oil through the suction manifolds from the hydraulic tank and feed into the servo- and auxiliary pressure valve (15).
Examples for servo oil circuits: Regulation of the main pumps (fig. 2)
35 bar - Servo-pressure Servo pressure (35 bar) is supplied for the following functions: •
Regulators of the main pumps to enable regulation at low working pressure (fig. 1).
•
Proportional valves (103) for operation of the 4-spool control blocks (90) of the attachment.
•
Proportional valves (103) for operation of the travel control blocks (82 & 83).
•
Proportional valves (103) for operation of the swing system.
•
Supply of the pressure regulating valve (54) for the swing circuit.
•
Solenoid valve for travel parking brake regulation of the travel motors.
•
Operation of the swing parking brake via solenoid control block (104).
The servo system is functional when the safety switch in the operator’s seat is activated. Then opening of the safety valves on plate (103) is possible. An accumulator (34) stores and provides hydraulic energy for lowering the attachment or depressurising the hydraulic cylinders in case the engines are switched off.
RH 200 Diesel - 3663423e - (01) - 09.03
The regulators of the main pumps are connected to the pump governing valves (20) The input of the proportional valves (20) is connected to the 60 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. Solenoid valve bank (104) (fig. 3 & fig. 4) •
Swing parking brake (Solenoid Y 11) (fig. 4) Parking brake released: 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. 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.
•
Travel parking brake (Solenoid Y 12) (fig. 5 & fig. 6) Parking brake released: 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.
Page 8.5.3 - 1
8.5
HYDRAULIC CIRCUITS - SERVO SYSTEM Parking brake applied: 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. 5 & fig. 6) 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 60 bar and the regulators are shifting to low displacement.
Other servo oil circuits are described in the sections 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! Colour
Code
Designation
P
60 bar circuit
P
35 bar circuit
RP •
Travel boost (Solenoid Y 31) (fig. 7) 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 360 bar.
Ref.-no.
Quantity
Designation
8
2
Gear pump
15
1
Servo oil valve block
20
2
Pump governing valves
52
4
Swing parking brake
54
1
Pressure governing valve
103
1
Proportional valve plate
104
1
Valve bank, complete
146
1
Filter for proportional valve plate
147
1
Check valve
148
1
Soleniod valve
Regulating pressure for main pumps
R
Return oil circuit
L
Leak oil circuit
further remarks
Proportional valves Swing balance valve Solenoid valves
Travel boost
Table 1
Page 8.5.3 - 2
RH 200 Diesel - 3663423e - (01) - 09.03
8.5
HYDRAULIC CIRCUITS - SERVO SYSTEM
Fig. 1
Pumps for servo- and auxiliary pressure - 3663522a-01
Fig. 2
Pumps for servo- and auxiliary pressure - 3663522b-01
RH 200 Diesel - 3663423e - (01) - 09.03
Page 8.5.3 - 3
8.5
HYDRAULIC CIRCUITS - SERVO SYSTEM
Fig. 3
Regulation of main pumps via proportional valves - 3663522a-02
Fig. 4
Regulation of main pumps via proportional valves - 3663522b-02
Page 8.5.3 - 4
RH 200 Diesel - 3663423e - (01) - 09.03
8.5
HYDRAULIC CIRCUITS - SERVO SYSTEM
Fig. 5
Lines from operators cab - 3663041a-01
Fig. 6
Swing parking brake - 3663061a-01
RH 200 Diesel - 3663423e - (01) - 09.03
Page 8.5.3 - 5
8.5
HYDRAULIC CIRCUITS - SERVO SYSTEM
Fig. 7
Travel parking brake and 2-speed function - 3663522a-03
Fig. 8
Travel parking brake and 2-speed function - 3664495a-02
Page 8.5.3 - 6
RH 200 Diesel - 3663423e - (01) - 09.03
8.5
HYDRAULIC CIRCUITS - SERVO SYSTEM
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 - 3663423e - (01) - 09.03
Page 8.5.3 - 7
8.5
HYDRAULIC CIRCUITS - SERVO SYSTEM
Fig. 11
Travel boost for main pumps - 3663522a-04
Fig. 12
Travel boost for main pumps - 3663522b-04
Page 8.5.3 - 8
RH 200 Diesel - 3663423e - (01) - 09.03
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 - ‘Description of the hydraulic system’. Working functions are carried out with 4 main pumps (4), 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 3, oil coming from the main pump P1 flows through a high-pressure filter (39) to the RH 4-spool control valve (90). 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 (31) and return flow filters (29) back into the tank (28).
In the neutral position of the control valves, but after activation of the main pumps by PMS 3, oil coming from the main pump P4 flows through a high-pressure filter (39) to the LH 4-spool control valve (90). 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 (31) and return flow filters (29) back into the tank (28). 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.
Main pump P2: In the neutral position of the control valves, but after activation of the main pumps by PMS 3, oil coming from the main pump P2 flows through a high-pressure filter (39) and the RH travel control valve (82) to the RH 4-spool control valve (90). 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 (31) and return flow filters (29) back into the tank (28). Main pump P3: In the neutral position of the valve blocks, but after activation of the main pumps by PMS 3, oil coming from the main pump P3 flows through a highpressure filter (39), the LH travel control valve (83) to the LH 4-spool control valve (90). 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 (31) and return flow filters (29) back into the tank (28). Main pump P4:
RH 200 Diesel - 3663424e - (00) – 09.03
4-spool control valves The 4-spool control valves (90) 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) valve opens so that oil starts flowing to the consumer. When the control spool is moved further, Page 8.5.4 - 1
8.5
HYDRAULIC CIRCUITS - WORKING FUNCTIONS (FS)
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
4
4
Main pump A7V - SL - 1000
31
4
Tank line pressurizing valve
35
1
Distributor plate (main pumps)
36
1
Relief valve
39
4
High pressure filter
81
1
Rotor
82
1
Travel valve block RH
83
1
Travel valve block LH
84
1
Travel retarder valve RH
85
1
Travel retarder valve LH
90
2
4-spool control valve
92/1
2
Float valve
Boom cylinder function
92/2
2
Float valve
Arm cylinder function
95
2
Boom cylinder
96
2
Arm cylinder
97
2
Crowd cylinder
98
2
Clam cylinder
99
1
Distributor with relief valve (36)
135
1
Distributor
Table 1
Page 8.5.4 - 2
RH 200 Diesel - 3663424e - (00) – 09.03
8.5
HYDRAULIC CIRCUITS - WORKING FUNCTIONS (FS)
Fig. 1
Main pump lines - 3663047a-01
Fig. 2
Main pump lines - 3663045a-01
RH 200 Diesel - 3663424e - (00) – 09.03
Page 8.5.4 - 3
8.5
HYDRAULIC CIRCUITS - WORKING FUNCTIONS (FS)
Fig. 3
Page 8.5.4 - 4
Main pump lines - 2800823a-01
RH 200 Diesel - 3663424e - (00) – 09.03
8.5
HYDRAULIC CIRCUITS - WORKING FUNCTIONS (FS)
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 (95) 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 3 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).
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 (31) 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 (91) safeguard the boom cylinders against forces acting
Fig. 4
RH 200 Diesel - 3663424e - (00) – 09.03
Extending the boom cylinders – 2800822a-01
Page 8.5.4 - 5
8.5
HYDRAULIC CIRCUITS - WORKING FUNCTIONS (FS)
Fig. 5
Extending the boom cylinders – 2800823a-02
Fig. 6
Extending the boom cylinders – 2800824a-01
Page 8.5.4 - 6
RH 200 Diesel - 3663424e - (00) – 09.03
8.5
HYDRAULIC CIRCUITS - WORKING FUNCTIONS (FS)
Function: Retracting the boom cylinders 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 (31) to the tank.
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. 7). Servo circuit oil flows to the boom float valves (92/1). The valves shift over. Piston and rod sides of the boom cylinders (95) 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. 7
RH 200 Diesel - 3663424e - (00) – 09.03
Colour
Code
Designation
P
Pressure oil circuit
R
Return oil circuit
S
Servo oil circuit
A
Compensation line
Retracting the boom cylinders via float valves - 2800822a-02
Page 8.5.4 - 7
8.5
HYDRAULIC CIRCUITS - WORKING FUNCTIONS (FS)
Fig. 8
Retracting the boom cylinders via float valve – 2800823a-03
Fig. 9
Retracting the boom cylinders via float valve - 2800824a-02
Page 8.5.4 - 8
RH 200 Diesel - 3663424e - (00) – 09.03
8.5
HYDRAULIC CIRCUITS - WORKING FUNCTIONS (FS)
Function:
gradually shift the oil flow from the channel (P/T) to the channel for the consumer (fine-control facility).
Retracting the boom cylinders via 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 (90) 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 3 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 - 3663424e - (00) – 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 (31) 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
Page 8.5.4 - 9
8.5
HYDRAULIC CIRCUITS - WORKING FUNCTIONS (FS)
Fig. 10
Retracting the boom cylinders via main valve – 2800822a-03
Fig. 11
Retracting the boom cylinders via main valve – 2800823a-04
Page 8.5.4 - 10
RH 200 Diesel - 3663424e - (00) – 09.03
8.5
HYDRAULIC CIRCUITS - WORKING FUNCTIONS (FS)
Fig. 12
RH 200 Diesel - 3663424e - (00) – 09.03
Retracting the boom cylinders via main valve – 2800824a-03
Page 8.5.4 - 11
8.5
HYDRAULIC CIRCUITS - WORKING FUNCTIONS (FS)
Function: Extending the arm cylinders When the function is summoned, both control spools for arm function (90) 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 (96) 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 3 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
Page 8.5.4 - 12
Pilot-controlled pressure relief valves (91) 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 (31) 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
Extending the arm cylinders - 2800822a-04
RH 200 Diesel - 3663424e - (00) – 09.03
8.5
HYDRAULIC CIRCUITS - WORKING FUNCTIONS (FS)
Fig. 14
Extending the arm cylinders – 2800823a-05
Fig. 15
Extending the arm cylinders – 2800824a-04
RH 200 Diesel - 3663424e - (00) – 09.03
Page 8.5.4 - 13
8.5
HYDRAULIC CIRCUITS - WORKING FUNCTIONS (FS)
Function: Retracting the arm cylinders 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 (31) to the tank.
Float valve – ‘Lowering’ In order to save energy, ‘Lower’ commands for the arm (on FS attachment) are passed to the float valves (92) and not to the 4-spool control valves (fig. 16). Servo circuit oil flows to the arm float valves (92/2). The valves shift over. Piston and rod sides of the arm cylinders (96) 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. 16
Page 8.5.4 - 14
Colour
Code
Designation
P
Pressure oil circuit
R
Return oil circuit
S
Servo oil circuit
A
Compensation line
Retracting the arm cylinders via float valves – 2800822a-05
RH 200 Diesel - 3663424e - (00) – 09.03
8.5
HYDRAULIC CIRCUITS - WORKING FUNCTIONS (FS)
Fig. 17
Retracting the arm cylinders via float valves – 2800823a-06
Fig. 18
Retracting the arm cylinders via float valves – 2800824a-05
RH 200 Diesel - 3663424e - (00) – 09.03
Page 8.5.4 - 15
8.5
HYDRAULIC CIRCUITS - WORKING FUNCTIONS (FS)
Function: Retracting the arm cylinders 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 ‘arm spool’ in the LH 4-spool control valve (90) 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 grooves. Via the CMS-card the signals from the joysticks inform the PMS 3 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 - 16
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 (31) 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
RH 200 Diesel - 3663424e - (00) – 09.03
8.5
HYDRAULIC CIRCUITS - WORKING FUNCTIONS (FS)
Fig. 19
Retracting the arm cylinders via main valve – 2800822a-06
Fig. 20
Retracting the arm cylinders via main valve – 2800823a-07
RH 200 Diesel - 3663424e - (00) – 09.03
Page 8.5.4 - 17
8.5
HYDRAULIC CIRCUITS - WORKING FUNCTIONS (FS)
Fig. 21
Page 8.5.4 - 18
Retracting the arm cylinders via main valve – 2800824a-06
RH 200 Diesel - 3663424e - (00) – 09.03
8.5
HYDRAULIC CIRCUITS - WORKING FUNCTIONS (FS)
Function: Extending the bucket crowd cylinders When the function is summoned, both control spools for crowd function (90) 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 (97) is opened via fine-control grooves (fig. 23 & 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 3 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. 22
RH 200 Diesel - 3663424e - (00) – 09.03
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 (31) 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
Extending the bucket crowd cylinders – 2800822a -07
Page 8.5.4 - 19
8.5
HYDRAULIC CIRCUITS - WORKING FUNCTIONS (FS)
Fig. 23
Extending the bucket crowd cylinders – 2800823a -08
Fig. 24
Extending the bucket crowd cylinders – 2800827a -01
Page 8.5.4 - 20
RH 200 Diesel - 3663424e - (00) – 09.03
8.5
HYDRAULIC CIRCUITS - WORKING FUNCTIONS (FS)
Function: Retracting the bucket crowd cylinders When the function is summoned, both control spools for crowd function (90) 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 (97) 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 3 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 - (00) – 09.03
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 (31) 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
Retracting the bucket crowd cylinders – 2800822a-08
Page 8.5.4 - 21
8.5
HYDRAULIC CIRCUITS - WORKING FUNCTIONS (FS)
Fig. 26
Retracting the bucket crowd cylinders – 2800823a-09
Fig. 27
Retracting the bucket crowd cylinders – 2800827a-02
Page 8.5.4 - 22
RH 200 Diesel - 3663424e.doc - (00) – 09.03
8.5
HYDRAULIC CIRCUITS - WORKING FUNCTIONS (FS)
Function: Extending the clam cylinder (closing the bucket) When the function is summoned, the control spool for clam function in the RH 4-spool control valve (90) is shifted by servo pressure out of the neutral positions against springs (fig. 28). The connection from the main pump P1 to the piston sides of the clam cylinders (98) 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 3 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 - (00) – 09.03
Pilot-controlled pressure relief valves (91) 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 (31) 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
L
Leak oil circuit
S
Servo oil circuit
Extending the clam cylinders – 2800822a-09
Page 8.5.4 - 23
8.5
HYDRAULIC CIRCUITS - WORKING FUNCTIONS (FS)
Fig. 29
Extending the clam cylinders – 3663047a-02
Fig. 30
Extending the clam cylinders – 3663045a-02
Page 8.5.4 - 24
RH 200 Diesel - 3663424e - (00) – 09.03
8.5
HYDRAULIC CIRCUITS - WORKING FUNCTIONS (FS)
Fig.31
Extending the clam cylinders – 2800823a-10
Fig. 32
Extending the clam cylinders – 2800827a-03
RH 200 Diesel - 3663424e - (00) – 09.03
Page 8.5.4 - 25
8.5
HYDRAULIC CIRCUITS - WORKING FUNCTIONS (FS)
Fig. 33
Page 8.5.4 - 26
Extending the clam cylinders – 2800828a-01
RH 200 Diesel - 3663424e - (00) – 09.03
8.5
HYDRAULIC CIRCUITS - WORKING FUNCTIONS (FS)
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 (90) is shifted by servo pressure out of the neutral positions against springs (fig. 34). The connection from the main pump P2 to the rod sides of the clam cylinders (98) 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 3 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 - (00) – 09.03
Pilot-controlled pressure relief valves safeguard the clam cylinders against forces acting externally on the working circuit. Pilot-controlled valves (91) 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 (31) 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
L
Leak oil circuit
S
Servo oil circuit
Retracting the clam cylinders – 2800822a-10
Page 8.5.4 - 27
8.5
HYDRAULIC CIRCUITS - WORKING FUNCTIONS (FS)
Fig.35
Retracting the clam cylinders – 2800823a-11
Fig. 36
Retracting the clam cylinders – 2800827a-04
Page 8.5.4 - 28
RH 200 Diesel - 3663424e - (00) – 09.03
8.5
HYDRAULIC CIRCUITS - WORKING FUNCTIONS (FS)
Fig. 37
RH 200 Diesel - 3663424e - (00) – 09.03
Retracting the clam cylinders – 2800828a-02
Page 8.5.4 - 29
8.5
HYDRAULIC CIRCUITS - WORKING FUNCTIONS (FS)
Page 8.5.4 - 30
RH 200 Diesel - 3663424e - (00) – 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 - ‘Description of the hydraulic system’. Working functions are carried out with 4 main pumps (4), 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 3, oil coming from the main pump P1 flows through a high-pressure filter (39) to the RH 4-spool control valve (90). 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 (31) and return flow filters (29) back into the tank (28). Main pump P2: In the neutral position of the control valves, but after activation of the main pumps by PMS 3, oil coming from the main pump P2 flows through a high-pressure filter (39) and the RH travel control valve (82) to the RH 4-spool control valve (90). 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 (31) and return flow filters (29) back into the tank (28). Main pump P3: In the neutral position of the valve blocks, but after activation of the main pumps by PMS 3, oil coming from the main pump P3 flows through a highpressure filter (39), the LH travel control valve (83) to the LH 4-spool control valve (90). 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 (31) and return flow filters (29) back into the tank (28). Main pump P4:
RH 200 Diesel - 3663430e - (00) – 09.03
In the neutral position of the control valves, but after activation of the main pumps by PMS 3, oil coming from the main pump P4 flows through a high-pressure filter (39) to the LH 4-spool control valve (90). 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 (31) and return flow filters (29) back into the tank (28). 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 (90) 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) 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 conPage 8.5.4 - 1
8.5 HYDRAULIC CIRCUITS - WORKING FUNCTIONS (BH) sumer 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.
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
Remark: Ref.-no.
Quantity
Designation
4
4
Main pump A7V - SL - 1000
31
4
Tank line pressurizing valve
35
1
Distributor plate (main pumps)
36
1
Relief valve
39
4
High pressure filter
81
1
Rotor
82
1
Travel valve block RH
83
1
Travel valve block LH
84
1
Travel retarder valve RH
85
1
Travel retarder valve LH
90
2
4-spool control valve
92
2
Float valve
93
4
Throttled non return valve
94
4
Throttled non return valve
95
2
Boom cylinder
96
2
Stick cylinder
97
2
Bucket cylinder
135
4
Distributor
further remarks
Boom cylinder function
Table 1
Page 8.5.4 - 2
RH 200 Diesel - 3663430e - (00) – 09.03
8.5 HYDRAULIC CIRCUITS - WORKING FUNCTIONS (BH)
Fig. 1
Main pump lines - 3663047a-01
Fig. 2
Main pump lines - 3663045a-01
RH 200 Diesel - 3663430e - (00) – 09.03
Page 8.5.4 - 3
8.5 HYDRAULIC CIRCUITS - WORKING FUNCTIONS (BH)
Fig. 3
Page 8.5.4 - 4
Main pump lines - 3659215a-01
RH 200 Diesel - 3663430e - (00) – 09.03
8.5 HYDRAULIC CIRCUITS - WORKING FUNCTIONS (BH) 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 (95) 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 3 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).
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 (31) 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 (91) safeguard the boom cylinders against forces acting
Fig. 4
RH 200 Diesel - 3663430e - (00) – 09.03
Extending the boom cylinders – 3663578a-01
Page 8.5.4 - 5
8.5 HYDRAULIC CIRCUITS - WORKING FUNCTIONS (BH)
Fig. 5
Extending the boom cylinders – 3659215a-02
Fig. 6
Extending the boom cylinders – 3659216a-01
Page 8.5.4 - 6
RH 200 Diesel - 3663430e - (00) – 09.03
8.5 HYDRAULIC CIRCUITS - WORKING FUNCTIONS (BH) Function: Retracting the boom cylinders 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 (31) to the tank.
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. 7). Servo circuit oil flows to the boom float valves (92/1). The valves shift over. Piston and rod sides of the boom cylinders (95) 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. 7
RH 200 Diesel - 3663430e - (00) – 09.03
Colour
Code
Designation
P
Pressure oil circuit
R
Return oil circuit
S
Servo oil circuit
A
Compensation line
Retracting the boom cylinders via float valves - 3663578a-02
Page 8.5.4 - 7
8.5 HYDRAULIC CIRCUITS - WORKING FUNCTIONS (BH)
Fig. 8
Retracting the boom cylinders via float valve – 3659215a-03
Fig. 9
Retracting the boom cylinders via float valve - 3659216a-02
Page 8.5.4 - 8
RH 200 Diesel - 3663430e - (00) – 09.03
8.5 HYDRAULIC CIRCUITS - WORKING FUNCTIONS (BH) Function:
gradually shift the oil flow from the channel (P/T) to the channel for the consumer (fine-control facility).
Retracting the boom cylinders via 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 (90) 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 3 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 - (00) – 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 (31) 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
Page 8.5.4 - 9
8.5 HYDRAULIC CIRCUITS - WORKING FUNCTIONS (BH)
Fig. 10
Retracting the boom cylinders via main valve – 3663578a-03
Fig. 11
Retracting the boom cylinders via main valve – 3659215a-04
Page 8.5.4 - 10
RH 200 Diesel - 3663430e - (00) – 09.03
8.5 HYDRAULIC CIRCUITS - WORKING FUNCTIONS (BH)
Fig. 12
RH 200 Diesel - 3663430e - (00) – 09.03
Retracting the boom cylinders via main valve – 3659216a-03
Page 8.5.4 - 11
8.5 HYDRAULIC CIRCUITS - WORKING FUNCTIONS (BH) Function: Extending the stick cylinders When the function is summoned, both control spools for stick function (90) 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 stick cylinders (96) 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 3 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
Page 8.5.4 - 12
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 (31) 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
Extending the stick cylinders - 3663578a-04
RH 200 Diesel - 3663430e - (00) – 09.03
8.5 HYDRAULIC CIRCUITS - WORKING FUNCTIONS (BH)
Fig. 14
Extending the stick cylinders – 3659215a-05
Fig. 15
Extending the stick cylinders – 3659216a-04
RH 200 Diesel - 3663430e - (00) – 09.03
Page 8.5.4 - 13
8.5 HYDRAULIC CIRCUITS - WORKING FUNCTIONS (BH) Function: Retracting the stick cylinders 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 (90) is shifted by servo pressure out of the neutral position against springs (fig. 19). 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. 20 & fig. 21). 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 3 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 - 14
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 (31) 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
RH 200 Diesel - 3663430e - (00) – 09.03
8.5 HYDRAULIC CIRCUITS - WORKING FUNCTIONS (BH)
Fig. 16
Retracting the stick cylinders via main valve – 3663578a-05
Fig. 17
Retracting the stick cylinders via main valve – 3659215a-06
RH 200 Diesel - 3663430e - (00) – 09.03
Page 8.5.4 - 15
8.5 HYDRAULIC CIRCUITS - WORKING FUNCTIONS (BH)
Fig. 18
Page 8.5.4 - 16
Retracting the stick cylinders via main valve – 3659216a-05
RH 200 Diesel - 3663430e - (00) – 09.03
8.5 HYDRAULIC CIRCUITS - WORKING FUNCTIONS (BH) Function: Extending the bucket cylinders When the function is summoned, both control spools for crowd function (90) 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 (97) is opened via fine-control grooves (fig. 23 & 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 3 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. 19
RH 200 Diesel - 3663430e - (00) – 09.03
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 (31) 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
Extending the bucket cylinders – 3663578a -06
Page 8.5.4 - 17
8.5 HYDRAULIC CIRCUITS - WORKING FUNCTIONS (BH)
Fig. 20
Extending the bucket cylinders – 3659215a -07
Fig. 21
Extending the bucket cylinders – 3659216a -06
Page 8.5.4 - 18
RH 200 Diesel - 3663430e - (00) – 09.03
8.5 HYDRAULIC CIRCUITS - WORKING FUNCTIONS (BH)
Fig. 22
RH 200 Diesel - 3663430e - (00) – 09.03
Extending the bucket cylinders – 3664536-01
Page 8.5.4 - 19
8.5 HYDRAULIC CIRCUITS - WORKING FUNCTIONS (BH) Function: Retracting the bucket cylinders When the function is summoned, both control spools for crowd function (90) 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 (97) 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 3 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. 23
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 (31) 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
Retracting the bucket cylinders – 3663578a-07
RH 200 Diesel - 3663430e - (00) – 09.03
8.5 HYDRAULIC CIRCUITS - WORKING FUNCTIONS (BH)
Fig. 24
Retracting the bucket cylinders – 3659215a -08
Fig. 25
Retracting the bucket cylinders – 3659216a -07
RH 200 Diesel - 3663430e - (00) – 09.03
Page 8.5.4 - 21
8.5 HYDRAULIC CIRCUITS - WORKING FUNCTIONS (BH)
Fig. 26
Page 8.5.4 - 22
Retracting the bucket cylinders – 3664536-02
RH 200 Diesel - 3663430e - (00) – 09.03
8.5
HYDRAULIC CIRCUITS - TRAVEL SYSTEM
8.5.5
Travel system
is increased to 60 bar and the travel motors change to 'high speed mode'.
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 - ‘Description of the hydraulic system’. When the LH engine is running the oil of two main pumps (4) flows through the high pressure filters (39) to the travel control blocks (82, 83) (fig.1). Main pump P1 is feeding the RH travel control block (82). Main pump P2 is feeding the LH hand travel control block (83). When the ‘Travel’ function is not operated the oil flows via (C) to the 4-spool control blocks (90) and via (T) back to the tank (fig. 2). As long as the function ‘Travel’ is summoned with the treadle valves, servo oil flows to the travel valve blocks (82 & 83) (fig. 3). The travel valve blocks (82 & 83) shift so that connection (C) is blocked. Oil flows to the travel motors either through (B) - „forward“, or (A) - „backwards“. Travel motors (73) and travel control blocks are connected via the rotor (81) and the secondary relief valve block (76) (fig. 4). In the secondary relief valve block (76) pilotoperated pressure relief valves are installed for each direction of travel. The valves are set to 370 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 block (76), the rotor (81) to the travel retarder valves (84 & 85) and the return lines to the tank. Leakage oil from the travel motors is returned to the tank through (T) (fig. 6). Travel parking brake / 2-speed travel The travel parking brake and the shifting of the 2stage travel motors are operated via the same hydraulic line (fig. 5 & fig. 6). When a pressure of 35 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
RH 200 Diesel - 3663425e - (00) - 09.03
Leakage oil from the control blocks flows back to the tank. Anti-cavitation valves flanged onto the travel control blocks (82 & 83) prevent cavitation in the travel motors. Travel boost 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 360 bar (fig. 7). Travel retarder valves The travel retarder valves (84 & 85) flanged onto the travel valve blocks (82 & 83) 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. 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
R
Return oil circuit
S
Servo oil circuit
Page 8.5.5 - 1
8.5
HYDRAULIC CIRCUITS - TRAVEL SYSTEM
Ref.-no.
Quantity
Designation
4
4
Main pump
15
1
Servo oil valve block
31
4
Tank line pressurizing valve
35
1
Distributor plate (main pumps)
39
4
High pressure filter
73
4
Travel motor
76
1
Secondary relief valve block
77
4
Secondary relief valves
81
1
Rotor
82
1
Travel valve block RH
83
1
Travel valve block LH
84
1
Travel retarder valve RH
85
1
Travel retarder valve LH
103
1
Proportional valve plate
105
1
Soleniod valve
146
1
Filter for proportional valve plate
further remarks
Travel boost
Table 1
Fig. 1
Page 8.5.5 - 2
3663047b-01
RH 200 Diesel - 3663425e - (00) - 09.03
8.5
HYDRAULIC CIRCUITS - TRAVEL SYSTEM
Fig. 2
Main pumps for travel - 3663047a-03
Fig. 3
Main pumps for travel - 3663045a-03
RH 200 Diesel - 3663425e - (00) - 09.03
Page 8.5.5 - 3
8.5
HYDRAULIC CIRCUITS - TRAVEL SYSTEM
Fig. 4
Servo lines for travel system - 3663522a-05
Fig. 5
Servo lines for travel system - 3663522b-05
Page 8.5.5 - 4
RH 200 Diesel - 3663425e - (00) - 09.03
8.5
HYDRAULIC CIRCUITS - TRAVEL SYSTEM
Fig. 6
Servo lines for travel system - 3663042a-01
Fig. 7
Travel system in undercarriage - 3664495a-01
RH 200 Diesel - 3663425e - (00) - 09.03
Page 8.5.5 - 5
8.5
HYDRAULIC CIRCUITS - TRAVEL SYSTEM
Fig. 8
Travel system in undercarriage – 3664495b-01
Fig. 9
Travel system in undercarriage – 3664495c-01
Page 8.5.5 - 6
RH 200 Diesel - 3663425e - (00) - 09.03
8.5
HYDRAULIC CIRCUITS - TRAVEL SYSTEM
Fig. 10
3663047b-02
Fig. 11
3663047a-04
RH 200 Diesel - 3663425e - (00) - 09.03
Page 8.5.5 - 7
8.5
HYDRAULIC CIRCUITS - TRAVEL SYSTEM
Fig. 12
3663045a-04
Fig. 13
Travel parking brake and 2-speed function - 3663522a-03
Page 8.5.5 - 8
RH 200 Diesel - 3663425e - (00) - 09.03
8.5
HYDRAULIC CIRCUITS - TRAVEL SYSTEM
Fig. 14
Travel parking brake and 2-speed function - 3664495a-02
Fig. 15
Travel parking brake and 2-speed function – 3664495b-02
RH 200 Diesel - 3663425e - (00) - 09.03
Page 8.5.5 - 9
8.5
HYDRAULIC CIRCUITS - TRAVEL SYSTEM
Fig. 16
Travel parking brake and 2-speed function – 3664495c-02
Fig. 17
Travel boost for main pumps - 3663522a-04
Page 8.5.5 - 10
RH 200 Diesel - 3663425e - (00) - 09.03
8.5
HYDRAULIC CIRCUITS - TRAVEL SYSTEM
Fig. 18
RH 200 Diesel - 3663425e - (00) - 09.03
Travel boost for main pumps - 3663522b-04
Page 8.5.5 - 11
8.5
HYDRAULIC CIRCUITS - TRAVEL SYSTEM
Page 8.5.5 - 12
RH 200 Diesel - 3663425e - (00) - 09.03
8.5
HYDRAULIC CIRCUITS - SWING SYSTEM
8.5.6
Swing 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 - ‘Description of the hydraulic system’. 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 (6, 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 (6) is always the same as the energy consumption of the swing motors (51, 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 (54, fig. 2) limits the maximum torque and thereby the maximum pressures available on the swing motors (51). 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 (54) 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 (54, 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 (54) and the regulators of the swing pumps (6) is pressurised. The pressure in the circuit is no longer balanced. The swing pumps (6) 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 (54) through line (X 5) and acts on the pilot piston (11.2). The pilot piston has a ratio of 1:16 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 (6). 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 (51). When the swing movement is to be interrupted, the joystick is returned to its neutral 0-position. The swing motors (51) 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 (6) 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 - (00) – 09.03
Page 8.5.6 - 1
8.5
HYDRAULIC CIRCUITS - SWING SYSTEM
The swing pumps (6) 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 (51) is conducted back to the tank through the leak line (fig. 6).
Charge system (fig. 4) 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 25 bar is set by an internal pressure relief valve at each swing pump. The charge system is equipped with chip indicators ( C ) and filters (10) to avoid contamination of the closed swing circuit in case of a charge pump failure Flushing valve (fig. 5) The flushing valve (57) ejects a defined amount of oil from the closed swing circuit at the low-pressure 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 of swing motors (fig. 6)
Fig. 1
Pressure regulating valve
Separate leak oil lines transport the leak oil of the swing motors (51) back to the hydraulic tank.
Swinging to the 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. The pressure regulating valve (54) receives a reverse signal so that the regulator of the swing pumps are commanded to „tilt back“. The swing motors (51) 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
Swing parking brakes (fig. 7) The swing parking brake (52) between swing motor and gearbox is operated by a solenoid valve (104). The parking brakes are opened by servo pressure (35 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. Gear oil reservoirs (fig. 8) The gear oil level is monitored via reservoirs in which the oil level is visible without using a dip stick. The reservoirs are connected with an filling line and a breather line
RH 200 Diesel - 3663426e - (00) – 09.03
8.5
HYDRAULIC CIRCUITS - SWING SYSTEM
Remark: The following colour code refers only to hydraulic lines and not to components! Colour
Code
Designation
P
Pressure oil circuit
R
Return oil circuit
S
Servo oil circuit
F
Flushing system
C
Charge system
Ref.-no.
Quantity
Designation
5
2
Servo- and charge pump
6
4
Swing pump
10
4
Filter for charge oil
12
4
Blocking valve
15
1
Servo pressure valve block
50
4
Swing gearbox
51
4
Swing motor
52
4
Swing parking brake
54
1
Pressure governing valve
57
1
Flushing valve
60
2
High pressure filter
103
1
Proportional valve plate
104
2
Valve bank, complete
R
4
Gear oil reservoir for swing gearbox
further remarks
Swing balance valve
Solenoid valves
Table 1
RH 200 Diesel - 3663426e - (00) – 09.03
Page 8.5.6 - 3
8.5
HYDRAULIC CIRCUITS - SWING SYSTEM
Fig. 2
Swing pumps - 630833a
Fig. 3
Swing pumps and swing motors - 3663060b-01
Page 8.5.6 - 4
RH 200 Diesel - 3663426e - (00) – 09.03
8.5
HYDRAULIC CIRCUITS - SWING SYSTEM
Fig. 4
Swing pumps and swing motors - 3663060a-01
Fig. 5
Pilot lines for swing system - 3663041a-02
RH 200 Diesel - 3663426e - (00) – 09.03
Page 8.5.6 - 5
8.5
HYDRAULIC CIRCUITS - SWING SYSTEM
Fig. 6
Pilot lines for swing system - 3663060f-01
Fig. 7
Pilot lines for swing system - 3663060g-01
Page 8.5.6 - 6
RH 200 Diesel - 3663426e - (00) – 09.03
8.5
HYDRAULIC CIRCUITS - SWING SYSTEM
Fig. 8
Charge system for swing circuit – 3663060d-01
Fig. 9
Charge system for swing circuit – 3663060e-01
RH 200 Diesel - 3663426e - (00) – 09.03
Page 8.5.6 - 7
8.5
HYDRAULIC CIRCUITS - SWING SYSTEM
Fig. 10
Flushing valve for swing system – 3663060f-02
Fig. 11
Flushing valve for swing system – 3663060g-02
Page 8.5.6 - 8
RH 200 Diesel - 3663426e - (00) – 09.03
8.5
HYDRAULIC CIRCUITS - SWING SYSTEM
Fig. 12
Leak oil lines for swing motors – 3663060c-01
Fig. 13
Swing parking brake - 3663061a-01
RH 200 Diesel - 3663426e - (00) – 09.03
Page 8.5.6 - 9
8.5
HYDRAULIC CIRCUITS - SWING SYSTEM
Fig. 14
Page 8.5.6 - 10
Gear oil reservoirs for swing gearboxes with vent lines - 3663060c-02
RH 200 Diesel - 3663426e - (00) – 09.03
8.5
HYDRAULIC CIRCUITS - TRACK TENSIONING SYSTEM
8.5.7
Track tensioning system
when the required track tensioning pressure is going below 60 bar.
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 - ‘Description of the hydraulic system’. Each crawler track is kept constantly tensioned by oil from the servo circuit. The tracks are tensioned with a pressure of 60 bar. Pressure oil comes from the gear pumps (8) on the transfer gearbox. The pumps (8) suck the oil through the suction manifolds from the hydraulic tank and feed into the servo- and auxiliary pressure valve (15).
Tensioning the tracks See directions in Operating Instructions. The tracks are automatically tensioned. After starting one of the engines the auxiliary pressure (60 bar) is fed through the rotor(81) to the track tensioning system. After pressure built up in the track tensioning cylinders (66) and accumulators (68) the tracks are tensioned. Remark: The following colour code refers only to hydraulic lines and not to components! Colour
Oil of the 60 bar system flows through the rotor (81) and distributor assembly with secondary relief valves (70) to the tensioning cylinders (66) and diaphragm accumulators (68).
Code
Designation
P
60 bar circuit
R
Return oil circuit
The diaphragm accumulators (68) 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 (70) in the distributor assembly, which are set at 330 bar, into the tank. Such oil losses are automatically replaced by the system
Ref.-no.
Quantity
Designation
further remarks
8
2
Gear pump
15
1
Servo oil valve block
66
2
Track tensioning cylinders
68
2
Diaphragm accumulator
70
2
Pressure relief valve
81
1
Rotor
147
1
Valve plate
installed in undercarriage
148
1
Solenoid valve
installed in superstructure
149
1
Pressure reduction valve
installed in superstructure
Secondary relief valve
Table 1
RH 200 Diesel - 3663427e - (00) - 09.03
Page 8.5.7 - 1
8.5
HYDRAULIC CIRCUITS - TRACK TENSIONING SYSTEM
Fig. 1
Pumps for track tensioning system - 2800807a-05
Fig. 2
3663522a-06
Page 8.5.7 - 2
RH 200 Diesel - 3663427e - (00) - 09.03
8.5
HYDRAULIC CIRCUITS - TRACK TENSIONING SYSTEM
Fig. 3
3663522b-06
Fig. 4
Track tensioning lines - 3663522c-01
RH 200 Diesel - 3663427e - (00) - 09.03
Page 8.5.7 - 3
8.5
HYDRAULIC CIRCUITS - TRACK TENSIONING SYSTEM
Fig. 5
Page 8.5.7 - 4
Track tensioning system in undercarriage - 3663559a-01
RH 200 Diesel - 3663427e - (00) - 09.03
8.5 HYDRAULIC CIRCUITS - COOLING SYSTEM FOR HYDR. OIL
8.5.8
Cooling system for hydraulic oil
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 - ‘Description of the hydraulic system’. The 4 cooling pumps (7) are gear-type pumps with fixed displacement. They are flanged directly onto the 4 swing pumps (fig. 1). The setup of the cooling system is shown in fig.2 & fig. 3.
an increasing oil flow is driving the fan motor (46) 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. Remark: The following colour code refers only to hydraulic lines and not to components! Colour
Code
Each 2 pumps are pumping the hydraulic oil into a distributor plate (42) with thermostats (44). 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
7
4
Cooling pump
Gear pump
42
2
Distributor plate with thermostat
46
4
Fan motor
Gear motor
Table 1
RH 200 Diesel - 3663428e - (00) - 09.03
Page 8.5.8 - 1
8.5 HYDRAULIC CIRCUITS - COOLING SYSTEM FOR HYDR. OIL
Fig. 1
Location of pumps for oil cooling - 630833b
Fig. 2
Fan pumps and thermostat valve blocks - 3663048a-01
Page 8.5.8 - 2
RH 200 Diesel - 3663428e - (00) - 09.03
8.5 HYDRAULIC CIRCUITS - COOLING SYSTEM FOR HYDR. OIL
Fig. 3
Thermostat valve blocks and fan motors – 3663048b-01
Fig. 4
Example for cooling oil flow - 3663048a-02
RH 200 Diesel - 3663428e - (00) - 09.03
Page 8.5.8 - 3
8.5 HYDRAULIC CIRCUITS - COOLING SYSTEM FOR HYDR. OIL
Fig. 5
Page 8.5.8 - 4
Example for cooling oil flow - 3663048b-02
RH 200 Diesel - 3663428e - (00) - 09.03
8.5 HYDRAULIC CIRCUITS - COOLING SYSTEM FOR ENGINES
8.5.9
Cooling system for engines
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 - ‘Description of the hydraulic system’. The 2 cooling pumps (5) 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 (115). 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
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
4
2
Cooling pump
Axial piston pump
115
2
Fan motor
Gear motor
Table 1
RH 200 Diesel - 3663429e - (00) - 09.03
Page 8.5.9 - 1
8.5 HYDRAULIC CIRCUITS - COOLING SYSTEM FOR ENGINES
Fig. 1
Fan pumps and fan motors - 3663049a-01
Fig. 2
Fan pump with electronic regulator
Page 8.5.9 - 2
RH 200 Diesel - 3663429e - (00) - 09.03
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 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
E
1
Gear pump
G
1
Thermostat valve
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) a pressure switch is indicating loss of pressure in the whole system. Remark: The following colour code refers only to hydraulic lines and not to components! Colour
Code
Designation
P
Pressure oil circuit
R
Return oil circuit
further remarks
Table 1
RH 200 Diesel - 3657789e - (00) - 05.03
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 - 2800809a-01
RH 200 Diesel - 3657789e - (00) - 05.03
8.6 8.6
PRESSURE CHECKING AND SETTING Pressure checking and setting
8.6.1
Introduction
8.6.1.1
Foreword
This Technical Handbook (TBH) describes the pressure checking and setting procedures on the excavator ´s hydraulic system. It is valid for RH 200 serial-no. 40 029 to 40 068 and from serial-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 oil temperature has to be higher than 52°C.
8.6.1.2
Safety
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. 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. 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 starting .
RH 200 Diesel - 2471390e - (00) – 01.98
Page 8.6 - 1
8.6
PRESSURE CHECKING AND SETTING 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. All Pressure test points on the excavator have Minimess connections (M14 x 1,5). Pressure gauges used for checking must therefore have corresponding fittings. Always connect the Minimess-hose first to the gauge and then to the test point on the machine to avoid spillage of pressurized oil!
8.6.1.3
General
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 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 of swing pumps 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 clockwise (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 counter nut again. When checking/setting pressures the hydraulic oil temperature must be above 50°C.
Page 8.6 - 2
RH 200 Diesel - 2471390e - (00) – 01.98
8.6
PRESSURE CHECKING AND SETTING
8.6.2
Pressure setting Description
Unit
RH 200
Cylinder
bar
300
Travel
bar
360
Primary relief for main pumps
bar
380
Secondary relief for
Boom cylinders
bar
350
Arm / Stick cylinders
bar
350
Bucket croud cylinders
bar
350
Backhoe cylinders
bar
350
Clam cylinders (4-spool valve)
bar
350
Clam cylinders (Backwall)
bar
330
Proportional valve feed pressure – main pumps
bar
7.5 – 42,5
Servo pressure
Attachment
bar
35
Main pumps
bar
60
Swing system – working pressure max.
bar
375
Swing system – charge pressure (approx.)
bar
25
Fan drive - pressure
bar
approx. 35
Pressure cut-off – main pumps
Hydraulic oil cooling
Table 1
RH 200 Diesel - 2471390e - (00) – 01.98
Page 8.6 - 3
8.6
PRESSURE CHECKING AND SETTING
8.6.3
Tools
For pressure checking and setting the tools listed in table 2 are required.
Fig. 2
Tools
Item
Quantity
1 2 3 4 5 6 7 8 9 10 11 12 13 ----
2 1 1 1 1 1 1 1 1 1 1 1 1 1
Designation
Part-No.
Test kit with gauges and hoses Test adapter for proportional valve Multimeter O/E-ring spanner, 10 mm O/E-ring spanner, 13 mm O/E-ring spanner, 17 mm O/E-ring spanner, 19 mm O/E-ring spanner, 24 mm Allan Key, 3 mm Allan Key, 4 mm Allan Key, 5 mm Allan Key, 6 mm Accumulator test and charging device Adapter for nitrogen cylinder (see chapter 3.2.2 in THB)
1 476 323 1 433 919 1 088 932 0 717 903 0 559 698 0 559 702 0 717 908 0 717 913 0 014 122 0 014 123 0 014 124 0 014 125 1 429 836
Table 2
Page 8.6 - 4
RH 200 Diesel - 2471390e - (00) – 01.98
8.6
PRESSURE CHECKING AND SETTING
8.6.4.1
Servo control system
Servo pressure is to be set on valve combination (16 & 17, Figs. 1 & 2).
Fig. 2
Checking and setting pressures 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 loading in control 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 - (00) – 01.98
Page 8.6 - 5
8.6
PRESSURE CHECKING AND SETTING
Fig. 3
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: Closes the restrictor = higher pressure Turing anti-clockwise: Opens the restrictor = lower pressure
Page 8.6 - 6
RH 200 Diesel - 2471390e - (00) – 01.98
8.6
PRESSURE CHECKING AND SETTING
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 (830 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
•
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.
Fig. 2
RH 200 Diesel - 2471390e - (00) – 01.98
Page 8.6 - 7
8.6
PRESSURE CHECKING AND SETTING
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.
•
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).
cut-off
for
working-
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 - (00) – 01.98
8.6
PRESSURE CHECKING AND SETTING
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.
•
Checking and setting
Checking conditions:
•
Connect four 400 bar pressure gauges to metering points (36.1, Fig. 1).
Primary relief (P2):
•
Engage track parking brakes (with toggle switch) and lower working equipment to the ground.
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
•
Check primary relief settings for pumps (P2, P3 & P4) in the same way.
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 - (00) – 01.98
Page 8.6 - 9
8.6
PRESSURE CHECKING AND SETTING
8.6.4.5
Secondary relief system 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
2+8
Bucket croud cylinder – piston side
10 + 16
Bucket croud cylinder – rod side
3+7
Arm cylinder – rod side
11 + 15
Arm cylinder – piston side
4+6
Boom cylinder – piston side
12 + 14
Boom cylinder – rod side
5
Clam cylinder – rod side
13
Clam cylinder – piston 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 - (00) – 01.98
8.6
PRESSURE CHECKING AND SETTING
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 - (00) – 01.98
Page 8.6 - 11
8.6
PRESSURE CHECKING AND SETTING 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 cylinders 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
Checking and setting
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 - (00) – 01.98
8.6
PRESSURE CHECKING AND SETTING
Fig. 2
Pressure cut-off valve
•
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
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 - (00) – 01.98
Page 8.6 - 13
8.6
PRESSURE CHECKING AND SETTING
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 - (00) – 01.98
8.6
PRESSURE CHECKING AND SETTING
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
RH 200 Diesel - 2471390e - (00) – 01.98
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
Page 8.6 - 15
8.6
PRESSURE CHECKING AND SETTING
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
Checking and setting
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.
Page 8.6 - 16
Pressure relief valves (43) are works set to approx. 65 bar. To check, proceed as follows: •
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 - (00) – 01.98
8.7
INSTALLATION OF HYDRAULIC PUMPS
8.7
Installation of hydraulic 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
1
2
Main pump
2
2
Fan pump for hydraulic oil cooling
3
2
Swing pump
4
1
Fan pump for radiator
5
1
Charge pump for swing system
6
----
7
----
Further remarks
8
1
Gear pump for servo system
Double pump
9
8
Hex. bolt M 20 x 50 – 10.9
Tightening torque Md = 490 Nm
10
8
Washer
11
16
Washer
12
16
Hex. bolt M 20 x 80 – 8.8
Tightening torque Md = 350 Nm
13
2
Hex. bolt M 10 x 25 – 8.8
Tightening torque Md = 41 Nm
14
8
Hex. bolt M 12 x 30 – 8.8
Tightening torque Md = 71 Nm
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]
Tightening torque Md = 71 Nm
Table 1
RH 200 Diesel - 3657791e - (00) – 09.03
Page 8.7 - 1
8.7
INSTALLATION OF HYDRAULIC PUMPS
9, 12, 13, 14, 16 Fig. 1
8.7.3
Installation of hydraulic pumps
Removal and installation of the hydraulic pumps
Installation of a pump
Removal 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).
3. Open hydraulic lines of the pump cautiously. Collect hydraulic oil in suitable container.
4. Connect all hydraulic lines as market.
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
INSTALLATION OF HYDRAULIC PUMPS
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
INSTALLATION OF HYDRAULIC PUMPS
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
HYDRAULIC CYLINDERS - FS
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
HYDRAULIC CYLINDERS - FS
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
Fig. 1
RH 200 (FS) - 2471393e - (01) – 01.98
A
4525838A.SKD Boom cylinder
Page 8.8 - 3
8.8
HYDRAULIC CYLINDERS - FS
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
Hex. bolt M 36 x 3 x 190
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
HYDRAULIC CYLINDERS - FS
8.8.2.2
Arm cylinder
3 17
5
17
6 8 21 7
18
9 10
22 19
11 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
HYDRAULIC CYLINDERS - FS
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
Guide ring for piston rod
11
1
Back ring
12
1
O-ring
13
2
Protection element
14
3
Guide ring for piston
15
2
Guide ring for piston (metal)
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
Hex. bolt M 27 x 2 x 170
Table 2
Page 8.8 - 6
RH 200 (FS) - 2471393e - (01) – 01.98
8.8
HYDRAULIC CYLINDERS - FS
8.8.2.2
Bucket crowd cylinder
3 17
5
17
6 8 21 7
18
9 10
22 19
11 12 13
14 1
15 16
2 15 14 14 13 4
4 4525840A.SKD
Fig. 3
RH 200 (FS) - 2471393e - (01) – 01.98
Bucket crowd cylinder
Page 8.8 - 7
8.8
HYDRAULIC CYLINDERS - FS
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
Guide ring for piston rod
11
1
Back ring
12
1
O-ring
13
2
Protection element
14
3
Guide ring for piston
15
2
Guide ring for piston (metal)
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
Hex. bolt M 27 x 2 x 170
Table 3
Page 8.8 - 8
RH 200 (FS) - 2471393e - (01) – 01.98
8.8 8.8.2.4
HYDRAULIC CYLINDERS - FS 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
HYDRAULIC CYLINDERS - FS
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
Guide ring for piston rod
9
1
Guide
10
2
Sealing ring
11
1
Guide ring for piston rod
12
1
Back ring
13
1
O-ring
14
2
Protection element
15
1
Guide ring for piston (metal)
16
1
Sealing ring
17
1
Guide ring for piston
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
HYDRAULIC CYLINDERS - FS 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
Clevis type, 1-piece
Page 8.8 - 11
8.8 8.8.3.1
HYDRAULIC CYLINDERS - FS Clevis type, 2-piece (Fig. 8)
Fig.9
Fig. 8
Disassembly of the fork
Clevis type, 2-piece
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
HYDRAULIC CYLINDERS - FS 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
HYDRAULIC CYLINDERS - FS 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
HYDRAULIC CYLINDERS - FS
3. Insert bolts (5) and tighten in 3 stages. The bolts have to be free of grease and oil!
8.8.3.3
Clevis type, 1-piece (Fig. 16)
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
Clevis 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. 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
HYDRAULIC CYLINDERS - FS 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
Disassembly of the fork
Fig. 18
Lifting of the fork
Page 8.8 - 16
RH 200 (FS) - 2471393e - (01) – 01.98
8.8 8.8.3.4
HYDRAULIC CYLINDERS - FS 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
HYDRAULIC CYLINDERS - FS
Components of piston rod guide (Fig. 19) Position
Quantity
Designation
1
Cylinder barrel
3
Bearing eye
4 8 14 16
Further remarks
Weight [kg]
Guide see chapter 8.8.2
Washer Hex. bolt Hex. bolt
18
Scraper
19
Scraper
20
Sealing ring
21
Sealing ring
22
Guide ring for piston rod
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
HYDRAULIC CYLINDERS - FS
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). 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.
Fig. 22
Scraper
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
HYDRAULIC CYLINDERS - FS 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
HYDRAULIC CYLINDERS - FS
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
HYDRAULIC CYLINDERS - FS
Fig. 27
Fig. 28
Installation of piston seal
Fig. 29
Installation of piston seal
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) and lever it into it’s seating with a circling action (arrow, Fig. 28) around the piston.
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.
− 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
HYDRAULIC CYLINDERS - FS
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
Piston rod with guard sleeve
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
Installation of piston seal
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
HYDRAULIC CYLINDERS - FS 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
HYDRAULIC CYLINDERS - BH
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
HYDRAULIC CYLINDERS - BH
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
HYDRAULIC CYLINDERS - BH
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
Hex. bolt M 39 x 3 x 220
7
3
Washer
8 9
Designation
Further remarks
Weight [kg] 3 438 2 445
---2
10
Bushing ----
11
23
Hex. bolt M 36 x 3 x 250
12
23
Washer
14
1
Scraper
15
1
Sealing ring
16
7
Guide ring for piston rod
17
1
Sealing ring
18
1
Back ring
19
1
O-ring
20
2
Protection element
21
5
Guide ring for piston
22
2
Guide ring for piston (metal)
23
1
Piston seal
Table 1
Page 8.8 - 4
RH 200 (BH) - 2471388e - (01) – 01.98
8.8 8.8.2.2
HYDRAULIC CYLINDERS - BH Stick cylinder
5
5
13 3
8 4
7 9
14 15 16
10 6 17 18
1 2
19 20 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
HYDRAULIC CYLINDERS - BH
Components of arm cylinder (Fig. 2) Position
Quantity
1
1
Cylinder barrel
2
1
Piston rod
3
1
Fork
4
1
Flange
58
5
2
Bushing
253
6
1
Guide
7
12
Double hex bolt M 30 x 2 x 190
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
----
13
1
Scraper
14
1
Sealing ring
15
1
Sealing ring
16
1
Guide ring for piston rod
17
1
Back ring
18
1
O-ring
19
2
Protection element
20
3
Guide ring for piston
21
2
Guide ring for piston (metal)
22
1
Piston seal
Table 2
Page 8.8 - 6
RH 200 (BH) - 2471388e - (01) – 01.98
8.8
HYDRAULIC CYLINDERS - BH
8.8.2.2
Bucket cylinder
7
3
8
A
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
HYDRAULIC CYLINDERS - BH
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
Double hex bolt M 27 x 2 x 160
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
Guide ring for piston rod
18
1
Back ring
19
1
O-ring
20
2
Protection element
21
3
Guide ring for piston
22
2
Guide ring for piston (metal)
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
HYDRAULIC CYLINDERS - BH 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
Clevis type, 2-piece
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
HYDRAULIC CYLINDERS - BH Clevis type, 2-piece (Fig. 8)
Fig.9
Fig. 8
Disassembly of the fork
Clevis type, 2-piece
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
HYDRAULIC CYLINDERS - BH 731 (see THB „Sealing, protective, checking and cleaning agents“). 3.
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).
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
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.
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
HYDRAULIC CYLINDERS - BH 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 - 12
RH 200 (BH) - 2471388e - (01) – 01.98
8.8
HYDRAULIC CYLINDERS - BH
3. Insert bolts (5) and tighten in 3 stages.
8.8.3.3
Boss type, 2-piece (Fig. 16)
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
HYDRAULIC CYLINDERS - BH
Fig.17
Mounting the eye
Fig. 19
Removing the flange
Assembly 1.
Fig. 18
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.
Lifting the eye
Fig. 20
Page 8.8 - 14
Fork type bearing eye
RH 200 (BH) - 2471388e - (01) – 01.98
8.8
HYDRAULIC CYLINDERS - BH
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.
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.
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
HYDRAULIC CYLINDERS - BH 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
HYDRAULIC CYLINDERS - BH
Components of piston rod guide (Fig. 21) Position
Quantity
Designation
1
Cylinder barrel
3
Bearing eye
4 8 14 16
Further remarks
Weight [kg]
Guide see chapter 8.8.2
Washer Hex. bolt Hex. bolt
18
Scraper
19
Scraper
20
Sealing ring
21
Sealing ring
22
Guide ring for piston rod
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
HYDRAULIC CYLINDERS - BH
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). 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.
Fig. 24
Scraper
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
HYDRAULIC CYLINDERS - BH 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
Piston rod with guard sleeve
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
HYDRAULIC CYLINDERS - BH
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
HYDRAULIC CYLINDERS - BH
Fig. 29
Spreader for guide ring (cast iron)
Fig. 30
Installation of piston seal
Fig. 31
Installation of piston seal
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
HYDRAULIC CYLINDERS - BH
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
Piston rod with guard sleeve
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
Installation of piston seal
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
HYDRAULIC CYLINDERS - BH 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
8.8
HYDRAULIC CYLINDERS - BH
Page 8.8 - 24
RH 200 (BH) - 2471388e - (01) – 01.98
View more...
Comments
