Escolar Documentos
Profissional Documentos
Cultura Documentos
RH 200
8. Hydraulic system
TEREX Germany GmbH & Co. KG
3 663 488.00 en
Editor:
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
8.2.2
8.2.3
Description (Faceshovel).................................................................8.3 - 1
8.3.1
8.3.2
8.3.3
8.3.4
8.3.2
8.3.3
8.3.4
Hydraulic components.....................................................................8.4 - 1
8.4.1
8.4.2
Swing pump.......................................................................8.4 - 2
8.4.3
Rotor..................................................................................8.4 - 3
Page 8 - 1
CONTENTS
8.5
8.6
8.4.4
8.4.5
8.5.2
8.5.3
Servo system..................................................................8.5.3 - 1
8.5.4
8.5.4
8.5.5
8.5.6
8.5.7
8.5.8
8.5.9
8.5.10
Introduction........................................................................8.6 - 1
8.6.2
Pressure settings...............................................................8.6 - 3
8.6.3
Tools..................................................................................8.6 - 4
8.6.4
8.7
8.8
Page 8 - 2
8.8.1
Introduction........................................................................8.8 - 1
8.8.2
8.8.3
Assembly .........................................................................8.8 - 11
CONTENTS
8.8.4
8.8
Tightening torques...........................................................8.8 - 24
Introduction........................................................................8.8 - 1
8.8.2
8.8.3
Assembly ...........................................................................8.8 - 9
8.8.4
Tightening torques...........................................................8.8 - 22
Page 8 - 3
CONTENTS
Page 8 - 4
8.1
HYDRAULIC SYSTEM
8.1
Introduction
8.1.2
Safety Instructions
8.1.1
Foreword
8.1.2.1
The Technical Handbook contains important information for personnel servicing the machine.
Machine specifications listed elsewhere in the
machine documents are not always repeated in
this book.
The present brochure does not contain the specifications of auxiliary units for the operation of additional or optional equipment or the specifications of
individual machines.
Page 8.1 - 1
8.1
HYDRAULIC SYSTEM
8.1.2.2
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
Page 8.1 - 2
8.1
HYDRAULIC SYSTEM
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.
handling
Page 8.1 - 4
8.1.2.4
Recommissioning
Prior to recommissioning:
8.1
HYDRAULIC SYSTEM
8.1.3
General
Page 8.1 - 5
8.1
HYDRAULIC SYSTEM
Page 8.1 - 6
8.2
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.
630213.SKD
Fig. 1
630214.SKD
Fig. 2
Release pressure from the part of the system (it may be necessary to use several
procedures).
Page 8.2 - 1
8.2
Fig. 4
Fig. 3
Page 8.2 - 2
8.2
8.2.2
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
Bleeding points
Page 8.2 - 3
8.2
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
1
4
2
Fig. 8
Bleeding plugs
Fig. 7
cylinder extended
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
8.2
8.2.3
These are only guidelines. When damage is extensive, all of these symptoms can appear at once.
Page 8.2 - 5
8.2
Also remove, strip, clean and check any cylinders connected in parallel.
If further contamination is found when flushing, remove all cylinders, and strip, clean and
inspect.
Remove/clean HP filter(s).
Page 8.2 - 6
8.2
6. Further steps
If the hydraulic system has been extensively contaminated with chips, the following procedures are
also necessary:
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.
Page 8.2 - 7
8.2
7. Flushing procedure
The extent of flushing required depends upon the
point at which the contamination has entered. All
downline and branching systems are to be flushed
back to the filter(s). The filter(s) must be checked
thoroughly to determine whether they have
stopped all contamination from flowing further:
7.1 In case of pump damage (pump without
high pressure filter):
Page 8.2 - 8
8.2
8.
After working for approx. 1 minute, check the magnetic rod. Clean the rod if contamination is found.
Monitoring in operation
Page 8.2 - 9
8.2
Page 8.2 - 10
8.3
8.3
8.3.1
Technical data
The technical data of the hydraulic system are listed in chapter 2 Technical Data.
8.3.2
The position nos. refer to circuit diagram No. 3 672 750 (03) in chapter 8.3.4
Position
Quantity
Engine
Engine module
Engine module
Pump gearbox
Pump gearbox
Designation
Location
----
Servo pump
Pump gearbox
Pump gearbox
----
----
10
Pump gearbox
11
Pump gearbox
12 - 22
23
---2
24
Engine module
----
25
Operator module
26
Operator module
27
----
28
Engine module
29
Engine module
30
Position 29
31
2 way valve
Position 29
32
Position 29
33
----
34
Filter
35
Operator module
36
Operator module
37
Check valve
38
Engine module
----
Page 8.3 - 1
8.3
Position
Quantity
39
40
Designation
----
41
----
42
----
43
Check valve
44
Check valve
45
Engine module
Position 40
----
46
47
Shuttle valve
48 49
----
50
51
52
53 55
56
Location
---1
57 - 59
Shuttle valve
Engine module
----
60
61
Gate valve
62
63
Bypass valve
64
65
66
Superstructure
---2
67 - 79
Check valve
----
80
81
Fan motor
82
----
83
----
84
Fan
85
86
Position 85
87
Thermostat
Position 85
88
----
89
----
90
Travel block
Superstructure
91
Rotor
Superstructure
Page 8.3 - 2
8.3
Position
Quantity
92
Rotor
93
Rotor
94
Designation
Location
----
95
Travel block
96
Travel block
97
Travel block
98
----
99
----
100
Swing gearbox
101
Shuttle valve
102
Swing motor
Swing gearbox
103
Blocking valve
Engine module
104
Superstructure
----
105
Engine module
106
Flushing valve
Engine module
107
Superstructure
108
109
---1
110 - 119
Engine module
----
120
Travel gearbox
Undercarriage
121
Travel motor
Travel gearbox
122 - 124
----
125
126
127 - 129
Undercarriage
Position 125
----
130
Undercarriage
131
Diaphragm accumulator
Undercarriage
132
----
133
134
135 - 139
Undercarriage
----
140
141
Counterweight
Position 140
142 - 160
161
162
Boom
----
Page 8.3 - 3
8.3
Position
Quantity
163
164
Designation
----
Float valve
165
----
166
----
167
Location
Boom
Check valve
168
----
169
----
170 - 181
----
182
Boom cylinder
Boom
183
Stick cylinder
Boom
184
Boom
186
Clam cylinder
Backwall
187
Backwall
185
188
189
Page 8.3 - 4
---2
Boom
8.3
8.3.3
Attention!
Position nos. are referred to circuit diagram
Part-No. 3 672 750 (03) in chapter 8.3.4.
Some items are numbered on the schematic
but not mentioned here. They are not important
for the hydraulic functioning.
Drive unit
Pos. 1
The two water - cooled Cummins engines are 12 cylinder V engines with turbo-charging and inter cooling.
Pos. 2
Pos. 3
Servo pump
The 4 servo pumps are fixed - displacement gear type pumps that are mounted on the pump transfer
gearboxes (2) and that supply the servo circuit (40
bar) and the auxiliary circuit (70 bar).
free
Pos. 8
free
Pos. 9
Pos. 10
Fan pump A 10 V
Pos. 11
The fan wheel for water cooling of the diesel engine is driven by an adjustable axial-piston pump
per drive unit. The volume flow of the pump and
thus the speed of the fan wheel is electronically
controlled as a function of the water temperature.
Pos. 12 - 22
Pos. 4
Pump governing valve
free
Pos. 7
free
Swing pump
Pos. 6
Pos. 5
Pos. 23
Page 8.3 - 5
8.3
free
Pos. 24
2 - way valve
Pos. 25
Pos. 26
Pos. 31
Pos. 27
Pos. 28
The valve is changing the track tensioning pressure between 50 bar and 70 bar mode.
Pos. 30
Page 8.3 - 6
Pos. 32
free
Pos. 33
Filter
Pos. 34
Pos. 35
Filter
Pos. 36
8.3
Check valve
Pos. 37
The check valve prevents loss of oil out of the accumulator (52) for the access ladder.
free
Shuttle valve
Pos. 38
free
free
Pos. 40
The complete assembly group comprises two filters, two pressure relief valves, two check valves
and a housing.
free
Pos. 41
free
Pos. 42
Check valve
Pos. 43
Pos. 50
Control valve
Pos. 51
Accumulator
Pos. 52
The accumulator supplies pressure oil for emergency lowering of the access ladder in case of a
sudden engine shut-down.
free
Check valve
Pos. 48 - 49
Pos. 39
Cylinder for access ladder
Pos. 47
Pos. 53 - 55
Pos. 44
Shuttle valve
free
Pos. 45
Pos. 46
Pos. 56
free
Hydraulic oil tank
Pos. 57 - 59
Pos. 60
The tank stores all of the oil for the system and
contains two return flow filters (62), six by - pass
valves (63), four tank line pressurizing valves (64),
a check valve (66) and a pressure switch.
Page 8.3 - 7
8.3
Pos. 61
The gate valves can be used to isolate the hydraulic pumps from the oil tank. This makes it possible
to remove pumps without having to drain all of the
oil from the tank.
Fan motor
Return flow filter
Pos. 81
Pos. 62
By - pass valve
Pos. 80
free
Pos. 82
free
Pos. 83
Fan
Pos. 84
Pos. 63
Pos. 64
free
Pos. 65
Check valve
Pos. 66
free
Page 8.3 - 8
Pos. 67 - 79
Pos. 86
Thermostat
Pos. 87
The four thermostats are fully open at oil temperatures under 40C. 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 52C the thermostats
are fully closed and the full oil flow passes through
the fan motors to the coolers.
RH 200 Diesel (FS) - 3657771e.doc - (01) - 07.03
8.3
free
Pos. 88
free
Pos. 89
Travel block
Pos. 90
Anti - cavitation valve
Rotor
Pos. 91
Conducts hydraulic oil flows between superstructure and undercarriage. The seven ring channels
are for:
Pos. 96
Pos. 97
free
Pos. 98
free
Pos. 99
Swing gearbox
Pos. 100
Travel (4 channels)
Track tensioning
Leakage oil
Pos. 92
A servo - controlled single - spool block that actuates the right - hand track.
Pos. 93
A servo - controlled single - spool block that actuates the left - hand track.
free
Pos. 94
Pos. 95
Prevents the excavator from running away downhill and keeps the track motors full of oil (to avoid
cavitation). The speed of the track motors is then
always determined by the working pressure of the
pumps (3).
Shuttle valve
Pos. 101
The shuttle valve is connecting the control pressure lines Y1 and Y 2 of the pressure governing
valve (105) to the pressure relief valve (109).
Swing motor
Pos. 102
Blocking valve
Pos. 103
8.3
free
free
Pos. 104
Pos. 105
Flushing valve
Pos. 106
Travel gearbox
Travel motor
Pos. 121
Pos. 107
free
free
Pos. 108
Pos. 109
Pos. 126
8.3
free
4-spool control block
free
Track tensioning cylinder
Pos. 130
Pos. 131
free
Pos. 132
Pos. 133
Fan motor
free
Pos. 162
free
Pos. 163
Float valve
Pos. 164
The float valves save time and energy when lowering the boom or the arm. The valves connect the
piston and rod sides of the cylinders so that the
piston rods retract only as a result of the attachment`s own dead weight. Only the excess oil (piston - side chamber has a greater volume than the
rod - side) is allowed to escape to the tank. The
main pumps (3) are not activated. If it is required to
lower the boom or the arm with pressure, the
float valves can be switched off using solenoid
valve (105/Y 10).
Pos. 134
The track-tensioning assembly comprises 2 pressure-relief valves with hand wheel and 2 test
points.
The hand wheels can be used to relieve the hydraulic track tension independently for each track.
free
Pos. 161
Diaphragm accumulator
free
Pos. 165
free
Pos. 166
Check valve
Pos. 167
free
Pos. 168
Pos. 141
free
Pos. 169
free
Page 8.3 - 11
8.3
Boom cylinder
Pos. 182
The two double-acting hydraulic cylinders are installed between superstructure and boom. They
are lifting or lowering the boom and thus the complete working equipment.
Arm cylinder
Pos. 183
The two double-acting hydraulic cylinders are installed between boom and arm and ensure extension and retraction of the arm.
Pos. 184
The two double-acting hydraulic cylinders are installed between the TriPower and the bucket
backwall and are used to turn the bucket.
free
Pos. 185
Clamshell cylinder
Pos. 186
The two double-acting hydraulic cylinders are installed between backwall and frontlip and are used
to open and close the bucket.
Distributor block
Pos. 187
free
Pos. 188
Distributor
Pos. 189
Page 8.3 - 12
8.3
8.3.4
The position nos. in the circuit diagram PartNo. 3 672 750 are referred to chapter 8.3.2.
Page 8.3 - 13
8.3
Page 8.3 - 14
8.3
8.3
8.3.1
Technical data
The technical data of the hydraulic system are listed in chapter 2 Technical Data.
8.3.2
The position nos. refer to circuit diagram No. 3 672 770 (03) in chapter 8.3.4
Position
Quantity
Engine
Engine module
Engine module
Pump gearbox
Pump gearbox
Designation
Location
----
Servo pump
Pump gearbox
Pump gearbox
----
----
10
Pump gearbox
11
Pump gearbox
12 - 22
23
---2
24
Engine module
----
25
Operator module
26
Operator module
27
----
28
Engine module
29
Engine module
30
Position 29
31
2 way valve
Position 29
32
Position 29
33
----
34
Filter
35
Operator module
36
Operator module
37
Check valve
38
Engine module
----
Page 8.3 - 1
8.3
Position
Quantity
39
40
Designation
----
41
----
42
----
43
Check valve
44
Check valve
45
Engine module
Position 40
----
46
47
Shuttle valve
48 49
----
50
51
52
53 55
56
Location
---1
57 - 59
Shuttle valve
Engine module
----
60
61
Gate valve
62
63
Bypass valve
64
65
66
Superstructure
---2
67 - 79
Check valve
----
80
81
Fan motor
82
----
83
----
84
Fan
85
86
Position 85
87
Thermostat
Position 85
88
----
89
----
90
Travel block
Superstructure
91
Rotor
Superstructure
Page 8.3 - 2
8.3
Position
Quantity
92
Rotor
93
Rotor
94
Designation
Location
----
95
Travel block
96
Travel block
97
Travel block
98
----
99
----
100
Swing gearbox
101
Shuttle valve
102
Swing motor
Swing gearbox
103
Blocking valve
Engine module
104
Superstructure
----
105
Engine module
106
Flushing valve
Engine module
107
Superstructure
108
109
---1
110 - 119
Engine module
----
120
Travel gearbox
Undercarriage
121
Travel motor
Travel gearbox
122 - 124
----
125
126
127 - 129
Undercarriage
Position 125
----
130
Undercarriage
131
Diaphragm accumulator
Undercarriage
132
----
133
134
135 - 139
Undercarriage
----
140
141
Counterweight
Position 140
142 - 160
161
162
Boom
----
Page 8.3 - 3
8.3
Position
Quantity
163
164
Designation
----
Float valve
165
----
166
----
167
Location
Check valve
168
----
169
----
170
171
172 - 181
Boom
----
182
Boom cylinder
Boom
183
Stick cylinder
Boom
184
185
---2
Bucket cylinder
186
----
187
----
188
Page 8.3 - 4
Distributor
Stick
Boom
8.3
8.3.3
Attention!
Position nos. are referred to circuit diagram
Part-No. 3 672 770 (03) in chapter 8.3.4.
Some items are numbered on the schematic
but not mentioned here. They are not important
for the hydraulic functioning.
Drive unit
Pos. 1
The two water - cooled Cummins engines are 12 cylinder V engines with turbo-charging and inter cooling.
Pos. 2
Pos. 3
Servo pump
The 4 servo pumps are fixed - displacement gear type pumps that are mounted on the pump transfer
gearboxes (2) and that supply the servo circuit (40
bar) and the auxiliary circuit (70 bar).
free
Pos. 8
free
Pos. 9
Pos. 10
Fan pump A 10 V
Pos. 11
The fan wheel for water cooling of the diesel engine is driven by an adjustable axial-piston pump
per drive unit. The volume flow of the pump and
thus the speed of the fan wheel is electronically
controlled as a function of the water temperature.
Pos. 12 - 22
Pos. 4
Pump governing valve
free
Pos. 7
free
Swing pump
Pos. 6
Pos. 5
Pos. 23
Page 8.3 - 5
8.3
free
Pos. 24
2 - way valve
Pos. 25
Pos. 26
Pos. 31
Pos. 27
Pos. 28
The valve is changing the track tensioning pressure between 50 bar and 70 bar mode.
Pos. 30
Page 8.3 - 6
Pos. 32
free
Pos. 33
Filter
Pos. 34
Pos. 35
Filter
Pos. 36
8.3
Check valve
Pos. 37
The check valve prevents loss of oil out of the accumulator (52) for the access ladder.
free
Pos. 38
free
Pos. 39
Pos. 40
The complete assembly group comprises two filters, the differential pressure valve, a pressure
relief valve, two check valves and a housing.
free
Pos. 41
free
Pos. 42
Check valve
Pos. 43
Shuttle valve
free
Cylinder for access ladder
Check valve
Pos. 44
Control valve
Pos. 51
Pos. 52
The accumulator supplies pressure oil for emergency lowering of the access ladder in case of a
sudden engine shut-down.
free
Shuttle valve
free
Pos. 45
free
Pos. 46
Pos. 50
Pos. 48 - 49
Accumulator
The four valves prevent negative influencing of
main pump pressures (3/P1 & P2) when only one
Travel pedal is actuated. The valves crack open
at approx. 1 bar.
Pos. 47
Pos. 53 - 55
Pos. 56
Pos. 57 - 59
Pos. 60
The tank stores all of the oil for the system and
contains two return flow filters (62), six by - pass
valves (63), four tank line pressurizing valves (64),
a check valve (66) and a pressure switch.
Page 8.3 - 7
8.3
Pos. 61
The gate valves can be used to isolate the hydraulic pumps from the oil tank. This makes it possible
to remove pumps without having to drain all of the
oil from the tank.
Fan motor
Return flow filter
Pos. 81
Pos. 62
By - pass valve
Pos. 80
Pos. 63
free
Pos. 82
free
Pos. 83
Fan
Pos. 84
Pos. 64
free
Pos. 65
Pos. 86
Check valve
Pos. 66
free
Page 8.3 - 8
Pos. 67 - 79
Thermostat
Pos. 87
The four thermostats are fully open at oil temperatures under 40C. 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 52C the thermostats
are fully closed and the full oil flow passes through
the fan motors to the coolers.
8.3
free
Pos. 88
free
Pos. 89
Travel block
Pos. 90
Anti - cavitation valve
Rotor
Pos. 91
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
Pos. 97
free
Swing gearbox
Pos. 98
Pos. 100
free
Pos. 101
Swing motor
Pos. 102
Pos. 92
A servo - controlled single - spool block that actuates the right - hand track.
Pos. 96
Pos. 93
A servo - controlled single - spool block that actuates the left - hand track.
free
Pos. 94
Pos. 95
Prevents the excavator from running away downhill and keeps the track motors full of oil (to avoid
cavitation). The speed of the track motors is then
always determined by the working pressure of the
pumps (3).
Blocking valve
Pos. 103
free
Pos. 104
Page 8.3 - 9
8.3
Pos. 105
Travel motor
Pos. 121
Pos. 106
Flushing valve
Pos. 107
free
Secondary relief block
free
Pos. 108
Pos. 109
free
free
Pos. 120
Page 8.3 - 10
Travel gearbox
Pos. 126
Pos. 130
8.3
Diaphragm accumulator
Pos. 131
free
Pos. 162
free
Pos. 163
Float valve
Pos. 164
free
Pos. 132
Pos. 133
The float valves save time and energy when lowering the boom. The valves connect the piston and
rod sides of the cylinders so that the piston rods
retract only as a result of the attachment`s own
dead weight. Only the excess oil (piston - side
chamber has a greater volume than the rod - side)
is allowed to escape to the tank. The main pumps
(3) are not activated. If it is required to lower the
boom with pressure, the float valves can be
switched off using solenoid valve (105/Y 10).
Pos. 134
free
Pos. 165
The track-tensioning assembly comprises 2 pressure-relief valves with hand wheel and 2 test
points.
The hand wheels can be used to relieve the hydraulic track tension independently for each track.
free
Pos. 166
Check valve
Pos. 167
free
Fan motor
free
Pos. 168
free
Pos. 169
Pos. 170
Pos. 141
free
Pos. 171
free
Page 8.3 - 11
8.3
Boom cylinder
Pos. 182
The two double-acting hydraulic cylinders are installed between superstructure and boom. They
are lifting or lowering the boom and thus the complete working equipment.
Stick cylinder
Pos. 183
The two double-acting hydraulic cylinders are installed between boom and stick and ensure extension and retraction of the arm.
free
Pos. 184
Bucket cylinder
Pos. 185
The two double-acting hydraulic cylinders are installed between the linkage of the bucket and the
stick and are used to turn the bucket.
free
Pos. 186
free
Pos. 187
Distributor
Pos. 188
Page 8.3 - 12
8.3
8.3.4
The position nos. in the circuit diagram PartNo. 3 672 770 are referred to chapter 8.3.2.
Page 8.3 - 13
8.3
Page 8.3 - 14
8.4
HYDRAULIC COMPONENTS
8.4
Hydraulic components
8.4.1
Main pumps
Pressure cut-off
When the maximum working pressure of 320 bar is
reached in the system, the automatic pressure cutoff becomes active.
The pressure cut-off valve (4) is opened by the
system pressure and connects the chambers (A +
C) of the regulator cylinder (2) with each other. The
pump now swings to such a small output that the
system pressure is reliably maintained.
Via port Pst the cut-off pressure is increased during travel mode to 360 bar.
Important:
The engine speed is increasing to approx. 1 900
rpm, as less power is needed by the pumps.
Contamination switch
Fig. 1
If the oil in a pump is contaminated with metal particles, the contamination switch (S 64) switches on
a relevant warning indicator in the cab.
Function
The pressure oil required to swing out the pumps is
taken from the pump flow. It is constantly available
in chamber (C) of the regulator cylinder (2). At
operating pressures below 60 bar, chamber (C) is
pressurized via connection (X 2) with oil from the
auxiliary circuit. Otherwise it would be impossible
to swing out the pump.
At the same time the regulator piston (1) is pressurized via the proportional valve and connection
(X 1) with oil (max. 42.5 bar). It now connects the
chamber (A) of the regulator cylinder with the tank.
The pump swings out completely and supplies its
maximum output.
RH 200 Diesel - 3657769e.doc - (02) 09.03
Page 8.4 - 1
8.4
8.4.2
HYDRAULIC COMPONENTS
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 utilisation of
the drive system for both acceleration and braking
operations. No power is converted into heat by
means of pressure relief valves, and during the
braking operation the braking energy is fed back
into the pump transfer gearbox and relieves the
drive motor.
High pressure and control pressure are in a ratio of
12:1, i.e. the high pressure available at the hydraulic motor is theoretically approx. 12 times as high
as the control pressure applied at the pump regulator.
Page 8.4 - 2
8.4
HYDRAULIC COMPONENTS
8.4.3
Rotor
Numbering of ports
Ref. No.
Quantity
Designation
Further remarks
left reverse
right forward
right reverse
Weight
[kg]
left forward
Table 1
Fig. 1
Grooves in rotor
Page 8.4 - 3
8.4
HYDRAULIC COMPONENTS
Components
Ref. No.
Quantity
Piston
99
Housing
229
Cover plate
Cover plate
Disc
Designation
Further remarks
Weight
[kg]
----
Ball bearing
Ball bearing
V - ring
10
Sealing ring
11
Rotor seal
12
O-ring
13
O-ring
14
Bottom plate
15 20
30
----
21
Block
22
Securing ring
23
----
24
Tightening torque Md = 46 Nm
25
26
Lifting eye M 16
27
28
Straight pin
29
Sealing ring
30
Plug
Tightening torque Md = 46 Nm
Table 2
Page 8.4 - 4
8.4
HYDRAULIC COMPONENTS
24, 25, 27
Fig. 2
Rotor
Page 8.4 - 5
8.4
HYDRAULIC COMPONENTS
24, 25, 27
Fig. 3
Page 8.4 - 6
Rotor
8.4
HYDRAULIC COMPONENTS
Removal (Figs. 4 + 5)
Fig. 4
Fig. 5
Page 8.4 - 7
8.4
HYDRAULIC COMPONENTS
8.4.4
Hydraulic valves
Ref.-no.
Quantity
Pos. 25
Designation
Housing
16
4
5
The complete assembly group comprises 16 electro-hydraulic proportional valves and 16 safety
valves (3/2 way valves).
further remarks
Weight
[kg]
---16
----
----
16
O-ring
32
Plug
10
Plug
11
Plug
12
12
Plug
13
16
Plug
Table 1
Page 8.4 - 8
8.4
HYDRAULIC COMPONENTS
Fig. 1
Page 8.4 - 9
8.4
HYDRAULIC COMPONENTS
Fig. 2
Page 8.4 - 10
8.4
HYDRAULIC COMPONENTS
Pos. 26/1
Ref.-no.
Quantity
Designation
further remarks
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 - 11
8.4
HYDRAULIC COMPONENTS
Pos. 26/2
Ref.-no.
Quantity
Designation
further remarks
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 - 12
8.4
HYDRAULIC COMPONENTS
Pos. 29
An assembly group comprising four primary pressure relief valves (30), four two - way valves (31),
four high - pressure filters (32) and a housing with
two check valves. The two check valves isolate the
main pumps (3/P1 & P2) from the pumps (3/P3 +
P4) when only the right - hand engine is running.
Pos. 30
Check valves
2 - way valves
Pos. 31
Designation
Pos. 32
Pos. 43
Ref.-no.
Quantity
Housing
340
Plate
54
Flange
Cone
Spring seat
Cover
----
----
Spring
10
11
12
2-way valve
13
further remarks
Weight
[kg]
39 each
----
14
Test point
15
Plug
16
Plug
17
Plug
18
Sealing ring
Minime M 14 x 1,5
Page 8.4 - 13
8.4
HYDRAULIC COMPONENTS
Ref.-no.
Quantity
19
O-ring
20
Sealing ring
21 - 24
Designation
further remarks
Weight
[kg]
----
25
26
27
16
28
29
30
Lifting eye M 16
Table 1
Page 8.4 - 14
8.4
HYDRAULIC COMPONENTS
Page 8.4 - 15
8.4
HYDRAULIC COMPONENTS
Pos. 40
The complete assembly group comprises two filters, the differential pressure valve, a pressure
relief valve, two check valves and a housing.
Filter
Check valves
Ref.-no.
Quantity
Designation
Housing
Pos. 16
Pos. 17
Filter
Pos. 11
Test point
Minimess M 14 x 1,5
Check valve
Pos. 18
Tightening torque Md = 40 Nm
O-ring
10
Filter element
11
O-ring
12
13
Plug M 16 x 1,5
14
Bushing
15
16
Locking plate
17
O-ring
18
O-ring
19
O-ring
further remarks
Weight
[kg]
Table 1
Page 8.4 - 16
8.4
HYDRAULIC COMPONENTS
Fig. 1
Page 8.4 - 17
8.4
HYDRAULIC COMPONENTS
Fig. 2
Page 8.4 - 18
8.4
HYDRAULIC COMPONENTS
Bypass valve
Pos. 63
Ref.-no.
Quantity
Designation
Plate
Bottom plate
Housing
Valve body
Spring
O-ring
Seal
further remarks
Weight
[kg]
Table 1
Fig. 1
Bypass valve
Page 8.4 - 19
8.4
HYDRAULIC COMPONENTS
Pos. 64
Ref.-no.
Quantity
Designation
Valve housing
Flange
Lid
Bushing
Piston
----
----
further remarks
Weight
[kg]
Tightening torque Md = 70 Nm
9
10
Sealing ring
11
O-ring
12
O-ring
13
Table 1
Page 8.4 - 20
8.4
HYDRAULIC COMPONENTS
6, 13
Fig. 1
6, 13
Fig. 2
Page 8.4 - 21
8.4
HYDRAULIC COMPONENTS
Pos. 85
Pos. 86
Thermostats
Pos. 87
The four thermostats are fully open at oil temperatures under 40C. 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 52C the thermostats are
fully closed and the full oil flow passes through the
fan motors to the coolers.
Ref.-no.
Quantity
Designation
Valve block
Lid
Lid
Check valve
Piston
Thermostat
further remarks
Weight
[kg]
17
----
Spring
Spring
10
----
11
----
12
----
13
Test point
Minime M 14 x 1,5
14
Tightening torque Md = 80 Nm
15
O-ring
16
O-ring
17
O-ring
18
Lifting eye
19
Hex. bolt M 8 x 30
20
Table 1
Page 8.4 - 22
8.4
HYDRAULIC COMPONENTS
14, 20
Fig. 1
Page 8.4 - 23
8.4
HYDRAULIC COMPONENTS
14
Fig. 2
Page 8.4 - 24
8.4
HYDRAULIC COMPONENTS
Pos. 90
Ref.-no.
Quantity
Rotor
Cover plate
Designation
further remarks
Weight
[kg]
----
16
Tightening torque Md = 69 Nm
10
11
10
Tightening torque Md = 86 Nm
Table 1
Page 8.4 - 25
8.4
HYDRAULIC COMPONENTS
9, 10, 11
Fig. 1
Page 8.4 - 26
8.4
HYDRAULIC COMPONENTS
Pos. 92
Ref.-no.
Quantity
2
3
Designation
further remarks
Spool
Bonnet
Disc
Disc
9 - 13
167
----
14
Test point
15
Plug
16
Plug
17 - 23
----
24
O-ring
25
O-ring
26
O-ring
27
Sealing ring
28
Sealing ring
29 - 34
----
35
Tightening torque Md = 71 Nm
36
Tightening torque Md = 71 Nm
37
Eye Bolt M 12
1
39
40
Weight
[kg]
----
38
Pos. 93
Plug
----
Sealing ring
Table 1
Page 8.4 - 27
8.4
HYDRAULIC COMPONENTS
35, 36
Fig. 1
Page 8.4 - 28
8.4
HYDRAULIC COMPONENTS
35, 36
Fig. 2
Page 8.4 - 29
8.4
HYDRAULIC COMPONENTS
Pos. 95 & 96
Ref.-no.
Quantity
Guide
Cap
Spool
5
6
Designation
26
Plug
----
10
Spring
11
Bleeder valve
12
Valve
O-ring
13
----
15 - 25
----
26
Tightening torque Md = 23 Nm
27
Tightening torque Md = 23 Nm
28
----
29
----
30
Weight
[kg]
----
7-9
14
further remarks
Eye bolt M 12
Table 1
Page 8.4 - 30
8.4
HYDRAULIC COMPONENTS
26, 27
12
Fig. 1
Page 8.4 - 31
8.4
HYDRAULIC COMPONENTS
26, 27
Fig. 2
Page 8.4 - 32
12
Travel retarder valve
8.4
HYDRAULIC COMPONENTS
Pos. 103
Blocking valve
Ref.-no.
Quantity
Valve
Orifice
Plug
5
6
Designation
further remarks
Weight
[kg]
7,5
0,8 mm
---1
Spring
----
----
Plug
10
----
11
Sealing ring
12
O-ring
13
Back ring
14
Plug
15
16
Sealing kit
17
----
18
Tightening torque Md = 10 Nm
19
20
Loctite
Table 1
Page 8.4 - 33
8.4
HYDRAULIC COMPONENTS
Fig. 1
Blocking valve
Fig. 2
Blocking valve
Page 8.4 - 34
8.4
HYDRAULIC COMPONENTS
Pos. 105
Quantity
Designation
Main spool
Spool
Spring
Spring
Spool
Adjuster screw
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]
Table 1
Fig. 1
Page 8.4 - 35
8.4
HYDRAULIC COMPONENTS
Flushing valve
Pos. 106
Ref. no.
Quantity
Designation
Valve housing
Sealing ring
Plug
Sealing ring
Orifice
Relief valve
Spool
further remarks
Weight
[kg]
Table 1
Fig. 1
Page 8.4 - 36
Flushing valve
8.4
HYDRAULIC COMPONENTS
Pos. 107
Ref.-no.
Quantity
Designation
Housing
O-ring
Filter element
O-ring
Bushing
O-ring
Check valve
Spring
10
Filter head
11
Sealing ring
12
13
Sealing ring
14
Plug
further remarks
Weight
[kg]
18
Table 1
Page 8.4 - 37
8.4
HYDRAULIC COMPONENTS
Fig. 1
Page 8.4 - 38
8.4
HYDRAULIC COMPONENTS
Pos. 125
Ref.-no.
Quantity
Designation
Pos. 126
further remarks
Weight
[kg]
Housing
----
Plug
Table 1
3
Fig. 1
Page 8.4 - 39
8.4
HYDRAULIC COMPONENTS
Pos. 161
Ref.-no.
Quantity
Designation
Valve housing
Spools
Bonnet
further remarks
Weight
[kg]
Table 1
Page 8.4 - 40
8.4
HYDRAULIC COMPONENTS
Fig. 1
Fig. 2
Page 8.4 - 41
8.4
HYDRAULIC COMPONENTS
Pos. 164/1
Pos. 164/2
Ref.-no.
Quantity
Designation
Valve housing
Spool
Bonnet
Check valve
Flange
further remarks
Weight
[kg]
76
----
Spring
Spring
Test point
10
O-ring
11
O-ring
12
O-ring
19
Pipe
20
21
Nut M 10
22
23
Tightening torque Md = 49 Nm
13 - 18
Minime M 14 x 1,5
----
Table 1
Page 8.4 - 42
8.4
HYDRAULIC COMPONENTS
22, 23
Fig. 1
Float valve
22, 23
Fig. 2
Float valve
Page 8.4 - 43
8.4
HYDRAULIC COMPONENTS
Pos. 187
The distributor on the backwall of the bucket supplies oil to the clamshell cylinders.
It also carries a relief valve.
Ref.-no.
Quantity
Designation
----
---1
5-7
8
9 - 16
17
Weight
[kg]
Housing
2
4
further remarks
Seal
----
Table 1
Page 8.4 - 44
8.4
HYDRAULIC COMPONENTS
17
Fig. 1
Page 8.4 - 45
8.4
HYDRAULIC COMPONENTS
Page 8.4 - 46
8.5
8.5
8.5.1
Load-Limit Regulation
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)
Page 8.5 - 1
8.5
8.5.2
Pressure cut-off
Page 8.5 - 2
8.5
8.5.3
Servo system
Remark:
Regulators of the main pumps to enable regulation at low working pressure (fig. 1 & fig. 2).
Proportional valves (25) for operation of the 4spool control blocks (161) of the attachment.
Operation of the swing parking brake via solenoid control block (26/1).
Page 8.5.3 - 1
8.5
Colour
Code
Designation
70 bar circuit
40 bar circuit
RP
Ref.-no.
Quantity
Designation
further remarks
Main pumps
Gear pump
23
25
26
36
40
47
Check valve
91
Rotor
105
109
121
Travel motor
Proportional valves
Solenoid valves
Table 1
Page 8.5.3 - 2
8.5
Fig. 1
Fig. 2
Page 8.5.3 - 3
8.5
Fig. 3
Fig. 4
Page 8.5.3 - 4
8.5
Fig. 5
Fig. 6
Page 8.5.3 - 5
8.5
Fig. 7
Fig. 8
Page 8.5.3 - 6
8.5
Fig. 9
Fig. 10
Page 8.5.3 - 7
8.5
Fig. 11
Fig. 12
Page 8.5.3 - 8
8.5
Fig. 13
Page 8.5.3 - 9
8.5
Page 8.5.3 - 10
8.5
8.5.4
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 (3), all of which are feeding into open circuits - that means that oil flows from the consumers back into the tank (fig. 1 & fig. 2 & fig. 3).
Main pump P1:
In the neutral position of the control valves, but
after activation of the main pumps by PMS, oil
coming from the main pump P1 flows through a
high-pressure filter (32) to the RH 4-spool control
valve (161).
Connections from pumps to cylinders are closed.
The oil flows in idle circuit (free flow) from (P) to (T)
and then through the tank line pre-charging valves
(64) and return flow filters (62) back into the tank
(60).
Main pump P2:
In the neutral position of the control valves, but
after activation of the main pumps by PMS, oil
coming from the main pump P2 flows through a
high-pressure filter (32) and the RH travel control
valve (92) to the RH 4-spool control valve (161).
Connections from pumps to cylinders are closed.
The oil flows in idle circuit (free flow) from (P) to (T)
and then through the tank line pre-charging valves
(64) and return flow filters (62) back into the tank
(60).
Main pump P3:
In the neutral position of the valve blocks, but after
activation of the main pumps by PMS, oil coming
from the main pump P3 flows through a highpressure filter (32), the LH travel control valve (93)
to the LH 4-spool control valve (161).
Connections from pumps to cylinders are closed.
The oil flows in idle circuit (free flow) from (P) to (T)
and then through the tank line pre-charging valves
(64) and return flow filters (62) back into the tank
(60).
8.5
valve opens so that oil starts flowing to the consumer. When the control spool is moved further,
fine control grooves allow oil coming from the consumer to flow to the tank and gradually shift the oil
flow from the 2/2 way channel (fine-control facility).
The maximum spool stroke is 28 mm.
The spool stroke can be divided into approx. 1/3
control edge overlap and 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
Ref.-no.
Quantity
further remarks
29
30
Relief valve
32
64
91
Rotor
92
93
95
96
161
164/1
Float valve
164/2
Float valve
182
Boom cylinder
183
Arm cylinder
184
Crowd cylinder
186
Clam cylinder
187
189
Distributor
Table 1
Page 8.5.4 - 2
8.5
Fig. 1
Fig. 2
Page 8.5.4 - 3
8.5
Fig. 3a
Fig. 3b
Page 8.5.4 - 4
8.5
Function:
Extending the boom cylinders
When the function is summoned (Fig. 4), both
control spools for boom function are shifted by
servo pressure out of their neutral positions against
springs. The connection from the main pumps to
the piston sides of the boom cylinders (182) is
opened via fine-control grooves.
At the same time, the connection (P) to (T) is throttled by fine-control grooves (Fig. 5 & Fig. 6).
Via the CMS-card the signals from the joysticks
inform the PMS about the summoned working
function, consequently the main pumps are swung
out and oil is being delivered.
Colour
Code
Designation
Compensation line
Fig. 4
Page 8.5.4 - 5
8.5
Fig. 5
Fig. 6
Page 8.5.4 - 6
8.5
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 (64) to the tank.
Fig. 7a
Colour
Code
Designation
Compensation line
Page 8.5.4 - 7
8.5
Fig. 7b
Fig. 8
Page 8.5.4 - 8
8.5
Fig. 9
Page 8.5.4 - 9
8.5
Function:
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 (161) is shifted by
servo pressure out of the neutral position against
springs (fig. 10). The boom spool in the RH 4spool valve is connected to the leak oil line and not
operated. The connection from the main pumps to
the rod sides of the boom cylinders is opened via
fine-control grooves (fig. 11 & fig. 12).
At the same time, the connection (P) to (T) is throttled by fine-control grooves.
Via the CMS-card the signals from the joysticks
inform the PMS about the summoned working
function, consequently the main pumps are swung
out and oil is being delivered.
The circuit pressure rises.
As soon as it reaches the pressure which exists on
the rod sides of the cylinders oil flows to the cylinders. With further movement of the control spool,
fine-control grooves allow oil coming from the piston sides of the cylinders to flow to tank and
Page 8.5.4 - 10
Code
Designation
Compensation line
8.5
Fig. 10
Fig. 11
Page 8.5.4 - 11
8.5
Fig. 12
Page 8.5.4 - 12
8.5
Function:
Extending the arm cylinders
When the function is summoned, both control
spools for arm function (161) are shifted by servo
pressure out of their neutral positions against
springs (fig. 13). The connection from the main
pumps to the piston sides of the arm cylinders
(183) is opened via fine-control grooves (fig. 14 &
fig. 15).
At the same time, the connection (P) to (T) is throttled by fine-control grooves.
Via the CMS-card the signals from the joysticks
inform the PMS about the summoned working
function, consequently the main pumps are swung
out and oil is being delivered.
The circuit pressure rises.
As soon as it reaches the pressure which exists on
the piston sides of the cylinders oil flows to the
cylinders. With further movement of the control
spools, fine-control grooves allow oil coming from
the rod sides of the cylinders to flow to tank and
gradually shift the oil flow from the channel (P/T) to
the channel for the consumer (fine-control facility).
Fig. 13
Colour
Code
Designation
Compensation line
Page 8.5.4 - 13
8.5
Fig. 14
Fig. 15
Page 8.5.4 - 14
8.5
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 (64) to the tank.
Fig. 16a
Colour
Code
Designation
Compensation line
Page 8.5.4 - 15
8.5
Fig. 16b
Fig. 17
Page 8.5.4 - 16
8.5
Fig. 18
Page 8.5.4 - 17
8.5
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 (161) is shifted by
servo pressure out of the neutral position against
springs (fig. 19). The arm spool in the RH 4-spool
valve is connected to the leak oil line and not operated. The connection from the main pumps to the
rod sides of the arm cylinders is opened via finecontrol grooves (fig. 20 & fig. 21).
At the same time, the connection (P) to (T) is throttled by fine-control grooves.
Via the CMS-card the signals from the joysticks
inform the PMS about the summoned working
function, consequently the main pumps are swung
out and oil is being delivered.
The circuit pressure rises.
As soon as it reaches the pressure which exists on
the rod sides of the cylinders oil flows to the cylinders. With further movement of the control spool,
fine-control grooves allow oil coming from the piston sides of the cylinders to flow to tank and
Page 8.5.4 - 18
Colour
Code
Designation
Compensation line
8.5
Fig. 19
Fig. 20
Page 8.5.4 - 19
8.5
Fig. 21
Page 8.5.4 - 20
8.5
Function:
Extending the bucket crowd cylinders
When the function is summoned, both control
spools for crowd function (161) are shifted by servo
pressure out of their neutral positions against
springs (fig. 22). The connection from the main
pumps to the piston sides of the crowd cylinders
(184) is opened via fine-control grooves (fig. 23 &
fig. 24).
At the same time, the connection (P) to (T) is throttled by fine-control grooves.
Via the CMS-card the signals from the joysticks
inform the PMS about the summoned working
function, consequently the main pumps are swung
out and oil is being delivered.
The circuit pressure rises.
As soon as it reaches the pressure which exists on
the piston sides of the cylinders oil flows to the
cylinders. With further movement of the control
spools, fine-control grooves allow oil coming from
the rod sides of the cylinders to flow to tank and
gradually shift the oil flow from the channel (P/T) to
the channel for the consumer (fine-control facility).
Fig. 22
Colour
Code
Designation
Page 8.5.4 - 21
8.5
Fig. 23
Fig. 24
Page 8.5.4 - 22
8.5
Function:
Retracting the bucket crowd cylinders
When the function is summoned, both control
spools for crowd function (161) are shifted by servo
pressure out of their neutral positions against
springs (fig. 25). The connection from the main
pumps to the piston sides of the crowd cylinders
(184) is opened via fine-control grooves (fig. 26 &
fig. 27).
At the same time, the connection (P) to (T) is throttled by fine-control grooves.
Via the CMS-card the signals from the joysticks
inform the PMS about the summoned working
function, consequently the main pumps are swung
out and oil is being delivered.
The circuit pressure rises.
As soon as it reaches the pressure which exists on
the piston sides of the cylinders oil flows to the
cylinders. With further movement of the control
spools, fine-control grooves allow oil coming from
the rod sides of the cylinders to flow to tank and
gradually shift the oil flow from the channel (P/T) to
the channel for the consumer (fine-control facility).
Fig. 25
Colour
Code
Designation
Page 8.5.4 - 23
8.5
Fig. 26
Fig. 27
Page 8.5.4 - 24
8.5
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
(161) 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 (186) is opened via fine-control
grooves (fig. 29 to fig. 33).
At the same time, the connection (P) to (T) is throttled by fine-control grooves.
Via the CMS-card the signals from the joysticks
inform the PMS about the summoned working
function, consequently the main pumps are swung
out and oil is being delivered.
Code
Designation
Fig. 28
Page 8.5.4 - 25
8.5
Fig. 29
Fig. 30
Page 8.5.4 - 26
8.5
Fig. 31a
Fig.31b
Page 8.5.4 - 27
8.5
Fig. 32
Fig. 33
Page 8.5.4 - 28
8.5
Function:
Retracting the clam cylinder (opening the
bucket)
When the function is summoned, the control spool
for clam function in the RH 4-spool control valve
(161) is shifted by servo pressure out of the neutral
positions against springs (fig. 34). The connection
from the main pump P2 to the rod sides of the clam
cylinders (186) is opened via fine-control grooves
(fig. 35 to fig. 37).
At the same time, the connection (P) to (T) is throttled by fine-control grooves.
Via the CMS-card the signals from the joysticks
inform the PMS about the summoned working
function, consequently the main pumps are swung
out and oil is being delivered.
Colour
Code
Designation
Fig. 34
Page 8.5.4 - 29
8.5
Fig.35
Fig. 36
Page 8.5.4 - 30
8.5
Fig. 37
Page 8.5.4 - 31
8.5
Page 8.5.4 - 32
8.5.4
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 (3), all of which are feeding into open circuits - that means that oil flows from the consumers back into the tank (fig. 1 to fig. 4).
Main pump P1:
In the neutral position of the control valves, but
after activation of the main pumps by PMS, oil
coming from the main pump P1 flows through a
high-pressure filter (32) to the RH 4-spool control
valve (161).
Connections from pumps to cylinders are closed.
The oil flows in idle circuit (free flow) from (P) to (T)
and then through the tank line pre-charging valves
(64) and return flow filters (62) back into the tank
(60).
Page 8.5.4 - 1
Remark:
The following colour code refers only to hydraulic
lines and not to components!
Colour
Code
Designation
Ref.-no.
Quantity
Designation
29
30
Relief valve
32
64
91
Rotor
92
93
95
96
161
164
Float valve
170
171
182
Boom cylinder
183
Stick cylinder
185
Bucket cylinder
188
Distributor
P1
Main pump P1
P2
Main pump P2
P3
Main pump P3
P4
Main pump P4
further remarks
Table 1
Page 8.5.4 - 2
Fig. 1
Fig. 2
Page 8.5.4 - 3
Fig. 3
Fig. 4
Page 8.5.4 - 4
Colour
Code
Designation
Compensation line
Fig. 5
Page 8.5.4 - 5
Fig. 6
Fig. 7
Page 8.5.4 - 6
Fig. 8
Page 8.5.4 - 7
cess oil is allowed to escape through the tank connections (T) of the float valve and then through the
tank line pre-charging valves (64) to the tank.
Fig. 9
Page 8.5.4 - 8
Colour
Code
Designation
Compensation line
Fig. 10
Fig. 11
Page 8.5.4 - 9
Fig. 12
Page 8.5.4 - 10
Pilot-controlled pressure relief valves (91) safeguard the boom cylinders against forces acting
externally on the working circuit. Pilot-controlled
valves are used to ensure that large quantities of
oil can escape in an absolute minimum of time.
Anti-cavitation valves prevent vacuum (below atmospheric pressure) occurring in the working lines
to the cylinders, as this would be a negative influence on the controlling of the consumer flows. The
valves draw oil, as required, from the tank line.
Tank line pre-charging valves (64) with a fixed
setting of 12 bar, ensure, that sufficient oil is always available to be fed into the relevant circuit.
Colour
Code
Designation
Compensation line
Page 8.5.4 - 11
Fig. 13
Fig. 14
Page 8.5.4 - 12
Fig. 15
Fig. 16
Page 8.5.4 - 13
Fig. 17
Page 8.5.4 - 14
Pilot-controlled pressure relief valves (91) safeguard the stick cylinders against forces acting externally on the working circuit. Pilot-controlled
valves are used to ensure that large quantities of
oil can escape in an absolute minimum of time.
Anti-cavitation valves prevent vacuum (below atmospheric pressure) occurring in the working lines
to the cylinders, as this would be a negative influence on the controlling of the consumer flows. The
valves draw oil, as required, from the tank line.
Tank line pre-charging valves (64) with a fixed
setting of 12 bar, ensure, that sufficient oil is always available to be fed into the relevant circuit.
Colour
Code
Designation
Compensation line
Fig. 18
Fig. 19
Page 8.5.4 - 15
Fig. 20
Page 8.5.4 - 16
Colour
Code
Designation
Compensation line
Page 8.5.4 - 17
Fig. 21
Fig. 22
Page 8.5.4 - 18
Fig. 23
Fig. 24
Page 8.5.4 - 19
Fig. 25
Page 8.5.4 - 20
Pilot-controlled pressure relief valves (91) safeguard the crowd cylinders against forces acting
externally on the working circuit. Pilot-controlled
valves are used to ensure that large quantities of
oil can escape in an absolute minimum of time.
Anti-cavitation valves prevent vacuum (below atmospheric pressure) occurring in the working lines
to the cylinders, as this would be a negative influence on the controlling of the consumer flows. The
valves draw oil, as required, from the tank line.
Tank line pre-charging valves (64) with a fixed
setting of 12 bar, ensure, that sufficient oil is always available to be fed into the relevant circuit.
Colour
Code
Designation
Fig. 26
Fig. 27
Page 8.5.4 - 21
Fig. 28
Fig. 29
Page 8.5.4 - 22
Fig. 30
Page 8.5.4 - 23
Fig. 31
Page 8.5.4 - 24
Pilot-controlled pressure relief valves (91) safeguard the crowd cylinders against forces acting
externally on the working circuit. Pilot-controlled
valves are used to ensure that large quantities of
oil can escape in an absolute minimum of time.
Anti-cavitation valves prevent vacuum (below atmospheric pressure) occurring in the working lines
to the cylinders, as this would be a negative influence on the controlling of the consumer flows. The
valves draw oil, as required, from the tank line.
Tank line pre-charging valves (64) with a fixed
setting of 12 bar, ensure, that sufficient oil is always available to be fed into the relevant circuit.
Colour
Code
Designation
Fig. 32
Fig. 33
Page 8.5.4 - 25
Fig. 34
Fig. 35
Page 8.5.4 - 26
Fig. 36
Page 8.5.4 - 27
Page 8.5.4 - 28
8.5
8.5.5
Travel 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 free ends of the hydraulic pipes and hoses
are marked with capital letters for easier identification of the connecting points on the various
pictures.
When both engines or the LH engine only are running the oil of two main pumps (3) flows through
the high pressure filters (32) to the travel control
blocks (92 & 93) (fig.1 to fig. 3).
Main pump P1 is feeding the RH travel control
block (92).
Main pump P2 is feeding the LH travel control
block (93).
When the Travel function is not operated the oil
flows via (C) to the 4-spool control blocks (161)
and via (T) back to the tank.
As long as the function Travel is summoned with
the treadle valves, servo oil flows to the travel
valve blocks (92 & 93) (fig. 3).
The travel valve blocks (92 & 93) shift so that connection (C) is blocked (fig. 4). Oil flows to the travel
motors either through (B) - forward, or (A) backwards.
Travel motors (121) and travel control blocks are
connected via the rotor (91) and the secondary
relief valve block (125) (fig. 5 to fig. 7).
In the secondary relief valve block (125) pilotoperated pressure relief valves are installed for
each direction of travel. The valves are set to 380
bar. When this pressure is reached relief oil is fed
via the relief valve to the relevant low-pressure
side of the motors.
Oil returning from the travel motors flows through
the secondary relief valve (125), the rotor (91) to
the travel retarder valves (95 & 96) and the return
lines to the tank.
Leakage oil from the travel motors is returned to
the tank through (T).
Page 8.5.5 - 1
8.5
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
40 bar circuit
70 bar circuit
Quantity
Designation
Main pump
25
26/2
Soleniod valve
29
32
36
43
Check valves
46
Solenoid valve
47
Shuttle valve
64
91
Rotor
92
93
95
96
121
Travel motor
125
Distributor
further remarks
Travel boost
Travel function
Table 1
Page 8.5.5 - 2
8.5
Fig. 1
Fig. 2
Page 8.5.5 - 3
8.5
Fig. 3
Fig. 4
Page 8.5.5 - 4
8.5
Fig. 5
Fig. 6
Page 8.5.5 - 5
8.5
Fig. 7
Fig. 8
Page 8.5.5 - 6
8.5
Fig. 9
Fig. 10
Page 8.5.5 - 7
8.5
Fig. 11
Fig. 12
Page 8.5.5 - 8
8.5
Fig. 13
Fig. 14
Page 8.5.5 - 9
8.5
Fig. 15
Fig. 16
Page 8.5.5 - 10
8.5
Fig. 17
Page 8.5.5 - 11
8.5
Page 8.5.5 - 12
8.5
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 (4, fig 2) are variabledisplacement pumps with torque control system
(see description in separate chapter). The changeable internal mass of the superstructure can be
efficiently rotated or braked with a variable torque.
Special features of torque control:
When the superstructure is being accelerated (i.e.
brought into movement) or retarded (i.e. braked
from swing), the output of the swing pumps (4) is
always the same as the energy consumption of the
swing motors (102, fig. 3).
Altering the pressure of the control signal makes it
possible to achieve any required, alterable torque
of acceleration or retardation, even when the inertial mass of the superstructure is changing.
The torque control valve (105, fig. 1) limits the
maximum torque and thereby the maximum pressures available on the swing motors (102). This, in
turn, avoids any opening of the pressure relief
valves in the swing pumps.
In the neutral position, ports (Y1) and (Y2) on the
torque control valve (105) are free of pressure, i.e.
the balance is in the middle position, whereby ports
(X1 and X2) are connected to (P). The control
chambers in the swing pump regulators are subject
to balanced pressure (40 bar servo circuit pressure) so that the swing pumps (4) have zero flow.
The pressure in the swing circuit is 50 bar, pressure being applied from the charge pumps.
Page 8.5.6 - 1
8.5
Fig. 1
Page 8.5.6 - 2
8.5
Remark:
The following colour code refers only to hydraulic
lines and not to components!
Colour
Code
Designation
Flushing system
Charge system
Ref.-no.
Quantity
Designation
Swing pump
11
25
26
34
40
100
Swing gearbox
102
Swing motor
103
Blocking valve
105
106
Flushing valve
107
further remarks
Solenoid valves
Table 1
Page 8.5.6 - 3
8.5
Fig. 2
Fig. 3
Page 8.5.6 - 4
8.5
Fig. 4
Fig. 5
Page 8.5.6 - 5
8.5
Fig. 6
Fig. 7
Page 8.5.6 - 6
8.5
Fig. 8
Fig. 9
Page 8.5.6 - 7
8.5
Fig. 10
Fig. 11
Page 8.5.6 - 8
8.5
Fig. 12
Fig. 13
Page 8.5.6 - 9
8.5
Page 8.5.6 - 10
8.5
8.5.7
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 free ends of the hydraulic pipes and hoses
are marked with capital letters for easier identification of the connecting points on the various
pictures.
Each crawler track is kept constantly tensioned by
oil from the servo circuit.
The tracks are tensioned with a pressure of 70 bar.
Pressure oil comes from the gear pumps (6) on the
transfer gearbox.
The pumps (6) suck the oil through the suction
manifolds from the hydraulic tank and feed into the
servo- and auxiliary pressure valve (40).
Oil of the 70 bar system flows through the rotor
(91) and distributor assembly with secondary relief
valves (134) to the tensioning cylinders (130) and
diaphragm accumulators (131).
Code
Designation
70 bar circuit
The diaphragm accumulators (131) are shock absorbers that dampen the horizontal movement of
the idlers in case of external forces. If the shock
forces are excessive, oil is cracked off through
safety valves (134) in the distributor assembly,
which are set at 330 bar, into the tank. Such oil
Ref.-no.
Quantity
Designation
further remarks
Gear pump
28a
Solenoid valve
installed in superstructure
28b
installed in superstructure
40
91
Rotor
130
131
Diaphragm accumulator
133
Valve plate
installed in undercarriage
134
Table 1
Page 8.5.7 - 1
8.5
Fig. 1
Fig. 2
3664702c-04
Page 8.5.7 - 2
8.5
Fig. 3
3664702d-04
Fig. 4
Page 8.5.7 - 3
8.5
Fig. 5
Page 8.5.7 - 4
8.5.8
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.
Code
Designation
Ref.-no.
Quantity
Designation
further remarks
10
Cooling pump
Gear pump
85
81
Fan motor
Gear motor
Table 1
Page 8.5.8 - 1
Fig. 1
Fig. 2
Page 8.5.8 - 2
Fig. 3
Fig. 4
Page 8.5.8 - 3
Fig. 5
Page 8.5.8 - 4
8.5.9
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.
Code
Designation
Leak oil
Ref.-no.
Quantity
Designation
further remarks
11
Cooling pump
140
Fan motor
141
Table 1
Page 8.5.9 - 1
Fig. 1
Fig. 2
Page 8.5.9 - 2
8.5
Ref.-no.
Quantity
Designation
Pressure switch
Gear pump
Thermostat valve
Check valve
Code
Designation
further remarks
Table 1
Page 8.5.10 - 1
8.5
Fig. 1
Page 8.5.10 - 2
8.6
8.6
8.6.1
Introduction
8.6.1.1
Foreword
8.6.1.2
Safety
Page 8.6 - 1
8.6
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.
Fig. 1
Page 8.6 - 2
8.6
8.6.2
Unit
RH 200
Cylinder
bar
300
Travel
bar
340
bar
380
Boom cylinders
bar
350
bar
350
bar
350
Backhoe cylinders
bar
350
bar
350
bar
330
Travel system
bar
380
bar
7.5 42,5
Servo pressure
Attachment
bar
40
Main pumps
bar
70
bar
375
bar
50
bar
approx. 35
Table 1
Page 8.6 - 3
8.6
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.
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
8.6
8.6.4.1
Fig. 2
Check pressures.
Pressure relief valve (17): pressure should be
35 bar.
Page 8.6 - 5
8.6
Fig. 3
Check pressure
It should be: 1,5 bar
Fig. 4
Page 8.6 - 6
8.6
8.6.4.2
Checking
Check pressure
It should be: approx. 8 bar (230 mA)
Check pressure
It should be: approx. 43 bar (850 mA)
Fig. 1
Fig. 3
Fig. 2
Page 8.6 - 7
8.6
8.6.4.3
Fig. 1
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.
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-
Fig. 2
Page 8.6 - 8
Relief valves
8.6
8.6.4.4
Fig. 1
Checking conditions:
Connect four 400 bar pressure gauges to metering points (36.1, Fig. 1).
RH engine stopped
LH engine at full speed
LH track forwards or reverse
LH engine stopped
RH engine at full speed
RH track forwards or reverse
LH engine stopped
RH engine at full speed
LH track forwards or reverse
Note:
When checking primary relief pressure (P3 & P4),
all pressure gauges show the pressures for (P3 &
P4).
Page 8.6 - 9
8.6
8.6.4.5
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.
Fig. 1
Position
9
4+6
12 + 14
3+7
11 + 15
2+8
10 + 16
13
Table 3a
Position
11 + 15
3+7
12 + 14
4+6
10 + 16
2+8
Page 8.6 - 10
8.6
Fig. 4
Fig. 3
Page 8.6 - 11
8.6
8.6.4.6
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
Page 8.6 - 12
8.6
Fig. 2
Page 8.6 - 13
8.6
8.6.4.7
Swing system
2.
Fig. 1
Fig. 2
3.
4.
Page 8.6 - 14
8.6
6.
Leave the superstructure holding brake engaged and summon Swing right. Shift joystick gently into the end position.
7.
Check pressure: the gauge for the highpressure side on swing motor (51, Fig. 1)
must register approx. 350 bar. The other
gauge (low pressure side) must register approx. 25 bar. The pressure on relief valve (55,
Fig. 6) is then approx. 31 bar.
If the high pressure on motor (51) is higher or
lower than approx. 350 bar, re-set valve (55,
Fig. 6) until approx. 350 bar is reached.
Fig. 4
Flushing valve
Fig. 5
8.
Summon swing left. Shift the joystick gradually into the end position. This time the other
gauge on the swing motor (51, Fig. 1) must
register approx. 350 bar. The other one approx. 25 bar.
Relief valve
Page 8.6 - 15
8.6
8.6.4.8
8.6.4.9
Fig. 1
Fig. 1
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
8.7
8.7
Installation of hydraulic
pumps
8.7.1
General
8.7.2
Components
Quantity
Designation
Further remarks
16
16
Washer
O-ring
4-8
Weight
[kg]
----
O-ring
10
Washer
11
12
O-ring
13
Washer
14
15
O-ring
16
Washer
17
18
O-ring
19
20
Tightening torque Md = 71 Nm
Tightening torque Md = 71 Nm
Tightening torque Md = 41 Nm
----
21
Main pump
22
Swing pump
23
24
25
26
Table 1
Page 8.7 - 1
8.7
1, 11, 14,
17, 19
Fig. 1
8.7.3
Installation of a pump
Removal of a pump
Page 8.7 - 2
8.7
5. Bleed pumps!
Fig. 2
Page 8.7 - 3
8.7
Page 8.7 - 4
8.7
8.7
Installation of hydraulic
pumps
8.7.1
General
8.7.2
Components
Quantity
Designation
Main pump
Swing pump
----
----
Further remarks
Double pump
10
Washer
11
16
Washer
12
16
13
Tightening torque Md = 41 Nm
14
Tightening torque Md = 71 Nm
15
Washer
16
17
Washer
18
---
19
---
20
O-ring
21
O-ring
22
O-ring
23
O-ring
24
O-ring
Weight
[kg]
Tightening torque Md = 71 Nm
Table 1
Page 8.7 - 1
8.7
9, 12, 13,
14, 16
Fig. 1
8.7.3
Installation of a pump
Removal of a pump
Page 8.7 - 2
8.7
5. Bleed pumps!
Fig. 2
Page 8.7 - 3
8.7
Page 8.7 - 4
8.8
HYDRAULIC CYLINDERS - FS
8.8
Hydraulic cylinders
8.8.1
Introduction
8.8.1.1
Foreword
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.
Page 8.8 - 1
8.8
HYDRAULIC CYLINDERS - FS
8.8.1.3
General
use
the
recommended
Page 8.8 - 2
8.8
HYDRAULIC CYLINDERS - FS
8.8.2
Design types
8.8.2.1
Boom cylinder
4
3
5
18
22
9
19
10
11
12
13
14
13
12
12
11
20
23
Fig. 1
4525838A.SKD
Boom cylinder
Page 8.8 - 3
8.8
HYDRAULIC CYLINDERS - FS
Quantity
Designation
Further remarks
Weight
[kg]
A
1
Cylinder barrel
2 092
Piston rod
1 200
Bearing eye
Scraper
Sealing ring
Sealing ring
Guide
Back ring
10
O-ring
11
Protection element
12
13
14
Piston seal
15
Bushing
16
----
17
----
18
19
15
Washer
20
Bearing eye
21
373
236
51
----
22
15
23
Circlip
24
Grease nipple
25
Reducer
26
Sealing ring
Table 1
Page 8.8 - 4
8.8
HYDRAULIC CYLINDERS - FS
8.8.2.2
Arm cylinder
3
17
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
Arm cylinder
Page 8.8 - 5
8.8
HYDRAULIC CYLINDERS - FS
Quantity
Cylinder barrel
Piston rod
833
Fork
379
Bushing
Scraper
Scraper
Guide
Sealing ring
Sealing ring
10
11
Back ring
12
O-ring
13
Protection element
14
15
16
Piston seal
17
Bushing
18
10
19
15
Washer
20
Designation
Further remarks
Weight
[kg]
1 266
132
----
21
Dowel pin
22
15
Table 2
Page 8.8 - 6
8.8
HYDRAULIC CYLINDERS - FS
8.8.2.2
3
17
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
Page 8.8 - 7
8.8
HYDRAULIC CYLINDERS - FS
Quantity
Cylinder barrel
Piston rod
833
Fork
379
Bushing
Scraper
Scraper
Guide
Sealing ring
Sealing ring
10
11
Back ring
12
O-ring
13
Protection element
14
15
16
Piston seal
17
Bushing
18
10
19
15
Washer
20
Designation
Further remarks
Weight
[kg]
1 266
132
----
21
Dowel pin
22
15
Table 3
Page 8.8 - 8
8.8
8.8.2.4
HYDRAULIC CYLINDERS - FS
Clam cylinder
7
8
10
5
11
12
4
11
9
12
13
14
15
16
2
17
13
18
14
4525841.SKD
Fig. 4
Clam cylinder
Page 8.8 - 9
8.8
HYDRAULIC CYLINDERS - FS
Quantity
Designation
Further remarks
Weight
[kg]
A
1
Cylinder barrel
216
Piston rod
109
Fork
153
Flange
10
Scraper
Scraper
Guide
10
Sealing ring
11
12
Back ring
13
O-ring
14
Protection element
15
16
Sealing ring
17
18
Bearing eye
19
Circlip
20
Dowel pin
Table 4
Page 8.8 - 10
8.8
8.8.3
HYDRAULIC CYLINDERS - FS
Assembly
Fig. 7
Fig. 5
Fig. 6
Page 8.8 - 11
8.8
8.8.3.1
HYDRAULIC CYLINDERS - FS
Clevis type, 2-piece (Fig. 8)
Fig.9
Fig. 8
Page 8.8 - 12
Fig. 10
8.8
HYDRAULIC CYLINDERS - FS
731 (see THB Sealing, protective, checking
and cleaning agents).
Fig. 11
4.
5.
6.
7.
8.
9.
Assembly
1.
3.
Fig. 12
2.
Bearing eye
Page 8.8 - 13
8.8
8.8.3.2
HYDRAULIC CYLINDERS - FS
Boss type, 1-piece (Fig. 12)
Fig. 13
Fig. 14
Fig. 15
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
8.8
HYDRAULIC CYLINDERS - FS
8.8.3.3
Fig. 16
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
Fig. 18
Page 8.8 - 16
8.8
8.8.3.4
HYDRAULIC CYLINDERS - FS
Piston rod guide
Fig. 19
Page 8.8 - 17
8.8
HYDRAULIC CYLINDERS - FS
Quantity
Designation
Cylinder barrel
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
29
O-ring
30
Back ring
36
Ring
37
Ring
Table 5
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!
Page 8.8 - 18
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
Fig. 20
Scraper
Fig. 22
Scraper
Page 8.8 - 19
8.8
HYDRAULIC CYLINDERS - FS
8.8.3.5
Fig. 25
Rod puller
Fig. 24
Page 8.8 - 20
8.8
HYDRAULIC CYLINDERS - FS
Fig. 26
Piston guide
Quantity
Designation
Cylinder barrel
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 - 21
8.8
HYDRAULIC CYLINDERS - FS
Fig. 27
Fig. 28
Fig. 29
Page 8.8 - 22
8.8
HYDRAULIC CYLINDERS - FS
Fig. 30
Fig. 33
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
Page 8.8 - 23
8.8
8.8.4
HYDRAULIC CYLINDERS - FS
Tightening torque
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.
120
140
170
160
190
220
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
8.8
HYDRAULIC CYLINDERS - BH
8.8
Hydraulic cylinders
8.8.1
Introduction
8.8.1.1
Foreword
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.
Page 8.8 - 1
8.8
HYDRAULIC CYLINDERS - BH
8.8.1.3
General
use
the
recommended
Page 8.8 - 2
8.8
HYDRAULIC CYLINDERS - BH
8.8.2
Design types
8.8.2.1
Boom cylinder
14
15
16
6,7
4
4
11
17
16
12
16
18
19
20
21
22
1
2
23
22
21
20
9
Fig. 1
2135918A.SKD
Boom cylinder
Page 8.8 - 3
8.8
HYDRAULIC CYLINDERS - BH
Quantity
Cylinder barrel
Piston rod
Bearing eye
482
Guide
545
Bushing
Washer
8
9
Designation
Further remarks
Weight
[kg]
3 438
2 445
---2
10
Bushing
----
11
23
12
23
Washer
14
Scraper
15
Sealing ring
16
17
Sealing ring
18
Back ring
19
O-ring
20
Protection element
21
22
23
Piston seal
Table 1
Page 8.8 - 4
8.8
8.8.2.2
HYDRAULIC CYLINDERS - BH
Stick cylinder
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
Stick cylinder
Page 8.8 - 5
8.8
HYDRAULIC CYLINDERS - BH
Quantity
Cylinder barrel
Piston rod
Fork
Flange
58
Bushing
253
Guide
12
Dowel pin
15
10
15
Washer
11
Bushing
12
Designation
Further remarks
Weight
[kg]
1 994
1 104
479
----
13
Scraper
14
Sealing ring
15
Sealing ring
16
17
Back ring
18
O-ring
19
Protection element
20
21
22
Piston seal
Table 2
Page 8.8 - 6
8.8
HYDRAULIC CYLINDERS - BH
8.8.2.2
Bucket cylinder
13
14
15
10
16
17
11
5
12
18
19
1
2
20
21
22
23
22
21
20
2135917A.SKD
Fig. 3
Bucket cylinder
Page 8.8 - 7
8.8
HYDRAULIC CYLINDERS - BH
Quantity
Designation
Further remarks
Weight
[kg]
1 266
Cylinder barrel
Piston rod
833
Bearing eye
373
Bushing
Guide
132
Flange
45
Bearing eye
Circlip
Dowel pin
10
10
11
15
12
15
Washer
13
Scraper
14
Scraper
15
Sealing ring
16
Scraper
17
18
Back ring
19
O-ring
20
Protection element
21
22
23
Piston seal
24
Sealing compound
Table 3
Page 8.8 - 8
8.8
8.8.3
HYDRAULIC CYLINDERS - BH
Assembly
Fig. 7
Fig. 5
Fig. 6
Page 8.8 - 9
8.8
8.8.3.1
HYDRAULIC CYLINDERS - BH
Clevis type, 2-piece (Fig. 8)
Fig.9
Fig. 8
Page 8.8 - 10
Fig. 10
8.8
HYDRAULIC CYLINDERS - BH
731 (see THB Sealing, protective, checking
and cleaning agents).
3.
4.
5.
6.
7.
8.
Assembly
9.
Pre-install bolts.
1.
Fig. 11
13. Coat exposed ends of bolts (5) with the corrosion inhibitor mentioned under Point 2.
31
4525806D.SKD
Fig. 12
2.
Bearing eye
Page 8.8 - 11
8.8
8.8.3.2
HYDRAULIC CYLINDERS - BH
Boss type, 1-piece (Fig. 12)
Fig. 13
Fig. 14
Fig. 15
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
8.8
HYDRAULIC CYLINDERS - BH
8.8.3.3
10
2
5
8
4525806C.SKD
Fig. 16
Page 8.8 - 13
8.8
HYDRAULIC CYLINDERS - BH
Fig.17
Fig. 19
Assembly
1.
Fig. 18
Fig. 20
Page 8.8 - 14
8.8
HYDRAULIC CYLINDERS - BH
2.
3.
4.
5.
6.
7.
8.
9.
Pre-install bolts.
Page 8.8 - 15
8.8
8.8.3.4
HYDRAULIC CYLINDERS - BH
Piston rod guide
Fig. 21
Page 8.8 - 16
8.8
HYDRAULIC CYLINDERS - BH
Quantity
Designation
Cylinder barrel
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
29
O-ring
30
Back ring
36
Ring
37
Ring
Table 5
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
Fig. 22
Scraper
Fig. 24
Scraper
Page 8.8 - 18
8.8
HYDRAULIC CYLINDERS - BH
8.8.3.5
Fig. 27
Rod puller
Fig. 26
Page 8.8 - 19
8.8
HYDRAULIC CYLINDERS - BH
Fig. 28
Piston guide
Quantity
Designation
Cylinder barrel
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
8.8
HYDRAULIC CYLINDERS - BH
Fig. 29
Fig. 30
Fig. 31
Page 8.8 - 21
8.8
HYDRAULIC CYLINDERS - BH
Fig. 32
Fig. 35
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
Page 8.8 - 22
8.8
8.8.4
HYDRAULIC CYLINDERS - BH
Tightening torque
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
170
160
190
190
220
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
Tightening torque
Table 7
Page 8.8 - 23
8.8
HYDRAULIC CYLINDERS - BH
Page 8.8 - 24