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 Components of the circuit diagram

The position nos. refer to circuit diagram No. 3 677 219 (00) in chapter 8.3.4.

Position Quantity Designation Location

1 2 Diesel engine Superstructure
2 2 Pump gearbox Superstructure
3 4 Main pump A4V SO 250 HD Pump gearbox
4 2 Swing pump A 4 V 125 MS Pump gearbox
5 ----
6 2 Servo pump Pump gearbox
7-9 ----
10 2 Oil cooling pump KP 5 / 250 Pump gearbox
11 - 15 ----
16 4 Check valve Main pumps
17 - 22 ----
23 2 Proportional valve Hydraulic tank (60)
24 ----
25 1 Proportional valve plate Operator module
26 2 Solenoid valve bank Operator module
27 ----
28 ----
29 1 Pump distributor plate Hydraulic tank (60)
30 2 Pressure relief valve, 330 bar Pump distributor plate (29)
31 ----
32 2 High pressure filter Pump distributor plate (29)
33 2 Filter for servo oil Valve block (40)
34 ----
35 1 Emergency lowering unit
36 1 Filter for proportional valve plate Operator module
37 1 Check valve Operator module

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8.3 DESCRIPTION OF THE HYDRAULIC SYSTEM - FS

Position Quantity Designation Location

38 ----
39 ----
40 1 Servo oil valve block
41 1 Pressure reducing valve Servo oil valve block (40)
42 1 Pressure relief valve Servo oil valve block (40)
43 ----
44 2 Check valve RHZ 12 Hydraulic tank (60)
45 - 59 ----
60 1 Hydraulic tank Superstructure
61 2 Gate valve Hydraulic tank (60)
62 4 Return filter Hydraulic tank (60)
63 2 Bypass valve Hydraulic tank (60)
64 2 Tank line pre-charging valve Hydraulic tank (60)
65 - 79 ----
80 2 Hydraulic oil cooler Oil cooler module
81 2 Fan motor KM 5 / 250
82 ----
83 ----
84 2 Fan Fan motor
85 1 Distributor plate (hydraulic oil cooling) Oil cooler module

86 2 Pressure relief valve Oil cooler module

87 2 Expansion element (40° C) Oil cooler module

88 ----
89 ----
90 1 Travel block compl. Superstructure
91 1 Rotor Travel block (90)
92 1 Travel valve block (RH) Travel block (90)
93 1 Travel valve block (LH) Travel block (90)
94 ----
95 1 Travel retarder valve (RH) Travel block (90)
96 1 Travel retarder valve (LH) Travel block (90)
97 4 Anti-cavitation valve Travel block (90)
98 ----
99 ----
100 2 Swing gearbox S – 2P – 30 Superstructure

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8.3 DESCRIPTION OF THE HYDRAULIC SYSTEM - FS

Position Quantity Designation Location

101 2 Shuttle valve Superstructure
102 2 Swing motor A2F 125 / 6 Swing gearbox (100)
103 4 Blocking valve
104 ---
105 1 Pressure control valve (MS control) Hydraulic tank (60)
106 1 Flushing valve Hydraulic tank (60)
107 ----
108 ----
109 1 Pressure relief valve, 31 bar
110 ----
111 1 Fitting with orifice Flushing valve (106)
112 - 119 ----
120 2 Travel gearbox Undercarriage
121 2 Travel motor A 2 FE 355 Travel gearbox (120)
122 2 Travel parking brake Travel gearbox (120)
123 - 129 ----
130 2 Track tensioning cylinder Undercarriage
131 2 Diaphragm accumulator Undercarriage
132 ----
133 1 Track tensioning assembly Undercarriage
134 2 Pressure relief valve Undercarriage
135 2 Check valve RHD 12 Undercarriage
136 - 145 ----
146 1 Service station Superstructure
147 - 159 ----
160 1 3-spool control valve (RH) Boom
161 1 3-spool control valve (LH) Boom
162 ----
163 ----
164 1 Float valve (boom) Boom
165 1 Float valve (arm) Boom
166 1 1-spool control valve Boom
167 - 181 ----
182 2 Boom cylinder Boom
183 2 Arm cylinder Boom/Arm

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8.3 DESCRIPTION OF THE HYDRAULIC SYSTEM - FS

Position Quantity Designation Location

184 2 Bucket crowd cylinder Boom
185 ----
186 2 Clam cylinder Backwall
187 ----
188 1 Distributor block Boom

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8.3 DESCRIPTION OF THE HYDRAULIC SYSTEM - FS
8.3.3 Components of the hydraulic
system RH 90 C (FS)
Attention!
Position nos. are referred to circuit diagram
Part-No. 3 677 219 (00) 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 drive units are water-cooled and turbocharged
6-cylinder in-line diesel engines.
Pump gearbox Pos. 2
The pump transfer gearbox is a 2-stage spur gear-
box driven by the engine via a flexible coupling, it
powers the flanged-on hydraulic pumps.
Main pump Pos. 3
The 4 main pumps for equipment and travel are
axial-piston variable displacement pumps of swash
plate design.
Each pump has a contamination switch. In the
event of metal contamination a warning indication
lights up in the cab.
Swing pump Pos. 4
The swing pumps for the closed swing circuit of the
superstructure are of axial-piston variable-
displacement swashplate design. The flow rate is
steplessly variable and increases from zero to
maximum flow with the swivelling angle increasing.
If the swash plate is tilted through the zero posi-
tion, the flow is smoothly reversed.
The pumps have been fitted with a torque control
system that enables the swing motors (30) to be
steplessly controlled depending on the pre-
selected
RH 90 C Diesel - 3657775e.doc - (00) – 11.03
- control pressure
- operating pressure
- torque magnitude and direction
Each swing pump has 2 pressure relief-
anticavitation valves.
Duty:
1. As relief valves they limit the swing circuit on
the high-pressure side to 420 bars.
2. As anti-cavitation valves they prevent the oil
column in the swing circuit from being cut off.
Swinging of the superstructure is decelerated via
servo-valve adjustment. the maximum brake pres-
sure equals the maximum swing pressure (approx.
370 bar).
A geared pump has been flanged to each swing
pump. It serves as charge pump for the closed oil
circuit. This charge pressure is limited by a relief
valve (appr. 25 bar) integrated into the pump.
The swing pumps are also equipped with a con-
tamination switch and a temperature switch. In
case of metallic contamination of the oil or an ex-
cessive oil temperature, a warning is displayed on
the panel in the driver's cab.
free Pos. 5
Servo pump Pos. 6
The fixed-displacement gear pumps are directly
driven (through drive) from main pump (3/P1&P3).
The pumps supply oil to the entire servo-, auxiliary-
and track tensioning circuits.
free Pos. 7 - 9
Hydraulic pump – oil cooling Pos. 10
The fixed-displacement gear pumps are directly
driven (through-drive) from main pumps (3/P2 and
P4). The pumps take oil from the hydraulic tank,
drive the fan motor and circulate the oil through the
oil cooler.
Page 8.3 - 5
8.3 DESCRIPTION OF THE HYDRAULIC SYSTEM - FS

free Pos. 11 - 15 free Pos. 28

Check valve Pos. 16 Distributor plate for main pumps

Through the check valves the auxiliary pressure is
fed into the main pump regulator. The check
valves protect the servo circuit against high pres-
sure produced by the main pumps.
Pos. 29
An assembly group comprising 2 primary pressure
relief valves (30), 2 high - pressure filters (32) and
4 check valves.

free Pos. 17 -22

Primary pressure-relief valve Pos. 30
Proportional valve Pos. 23
The primary relief valves are set to 330 bar. They
protect the hydraulic system against pressure
The proportional valve controls the regulators of
peaks occurring as a consequence of pressure
the main pumps (3). It converts electrical signals.
cut-off valve inertia under certain high pressure
The valve receives signals from the load limit
and fluid flow conditions.
regulator (110) of the PMS system and produces
relevant hydraulic pressure to control the flow rate
of the main pumps.

See also THB "PMS - Pump Managing System". High - pressure filter Pos. 32

The high - pressure filters in the high - pressure

free Pos. 24 lines from the main pumps protect the downline
units (e. g. control blocks and cylinders) against
metal chips and particles from the pumps (3). The
Proportional valve plate Pos. 25 filter elements are differential pressure resistant
and do not have a bypass valve. The oil flows
The valve plate contains the proportional valves through the HP filters from outside to inside.
and the 3/2 way valves for operation of cylinders,
swing and travel function.

Filter for servo oil Pos. 33

Valve bank, compl. Pos. 26 These filters are mounted to clean the oil flow of
the servo pumps (6).
An assembly group comprising four solenoid
valves and a housing with following functions:
free Pos. 34
• Port A1 is not used.

• Port A2 is not used.

Valve for emergency lowering Pos. 35

• Port A3 is used for operation of the swing
parking brake.
• Port A4 is used for operation of the travel
parking brake.
The assembly consists of a solenoid valve, a
check valve and an accumulator. The solenoid
valve is operated with a button in the joy stick. It
allows lowering of the attachment in case of a sud-
den engine shut-down.

free Pos. 27

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8.3 DESCRIPTION OF THE HYDRAULIC SYSTEM - FS

Filter Pos. 36 Check valve Pos. 44

This filter is filtering the oil which is feeding the Check valves prevent oil from being supplied to a
proportional valve plate (25). stationary motor.

free Pos. 45 - 59
Check valve Pos. 37
Hydraulic tank Pos. 60
The check valve prevents pressure loss when the
engines are shut off and the emergency lowering
system (35) is activated. The hydraulic oil storage tank comprises the fol-
lowing components:

free Pos. 38 - 4 return-flow filter elements (62)

- 2 bypass valves (63)
- 1 magnetic rod
free Pos. 39 - 2 tank-line pre-charging valves (64)
- 2 high-pressure filters (32)
- 2 primary relief valves (30)
Servo oil valve block Pos. 40 - 2 shut-off gate valves (61)
- 2 breather filters
The complete assembly group comprises two fil-
ters, two pressure relief valves, two check valves
and a housing.
Gate valve for intake line Pos. 61

The hydraulic tank can be separated from the suc-

Pressure reducing valve Pos. 41 tion lines of the hydraulic pumps by means of the
shut-off gate valves. This enables the oil to be left
in the hydraulic tank when, for example, a pump is
With this valve the auxiliary pressure of 60 bar is to be removed.
set. The pressure level is related to the pressure
setting of the servo pressure relief valve (42). All-
ways when the servo pressure has been adjusted
at the relief valve (42) also the setting of the pres-
sure reducing valve (41) is to be checked. Return flow filter Pos. 62

The return-flow filters serve to clean the oil return-

ing from the consumers. The oil passes through
Pressure relief valve Pos. 42 the filter elements from the inside to the outside.
Metallic contamination collects on the magnetic rod
located above the filter elements.
With this valve the servo pressure of 35 bar is set.
The pressure level of the servo system is also
influencing the pressure of the auxiliary system.
Therefore always the setting of the pressure re-
ducing valve (41) is to be checked. Bypass valve Pos. 63

The bypass valves prevent bursting of the return-

free Pos. 43 flow filter elements (62). The opening pressure is
1.5 bars. In this case, the oil flows back unfiltered
into the tank.

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8.3 DESCRIPTION OF THE HYDRAULIC SYSTEM - FS

Tank line pressurizing valve Pos. 64 Thermostat Pos. 87

These two valves have fixed settings of approx. 12
bar. They are arranged in the return lines and keep
a constant level of pressure in the hydraulic sys-
tem.
free Pos. 65 - 79
The four thermostats are fully open at oil tem-
peratures under 40°C. The majority of the oil then
flows directly back into the tank. As the tempera-
ture 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.

Hydraulic oil cooler Pos. 80

free Pos. 88
The hydraulic oil coolers pass the heat generated
in the hydraulic system on to the atmosphere using free Pos. 89
the air flows created by the fans.

Travel block Pos. 90

Fan motor Pos. 81
A complete group comprising rotor (91), the
„Travel“ spools (92 & 93), the travel retarder valves
two fixed - displacement gear - type motors are (95 & 96), anti - cavitation valves (97) and cover
used to drive the fans on the oil coolers. plates.

free Pos. 82
Rotor Pos. 91
free Pos. 83
Conducts hydraulic oil flows between superstruc-
ture and undercarriage. The seven ring channels
Fan Pos. 84 are for:

• Travel (4 channels)
The cooler fans produce the air flow needed to
cool the hydraulic oil.
• Track parking brakes/Track motor adjustment

• Track tensioning
Distributor plate for oil cooling Pos. 85 • Leakage oil

The plate contains two thermostats (87), two pres-

sure relief valves (86) and two check valves. The
check valves function as anti - cavitation valves Travel valve block RH Pos. 92
while the engines are being shut down.
A servo - controlled single - spool block that actu-
ates the right - hand track.
Pressure relief valve Pos. 86

The two pilot controlled, variable setting pressure Travel valve block LH Pos. 93
relief valves protect the cooler circuit against over-
pressure, e. g. in case of a line blockage.
A servo - controlled single - spool block that actu-
ates the left - hand track.

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8.3 DESCRIPTION OF THE HYDRAULIC SYSTEM - FS
free Pos. 94
Travel retarder valve RH Pos. 95
Prevents the excavator from „running away“ down-
hill and keeps the track motors full of oil (to 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. 96
See travel retarder valve (95).
Anti - cavitation valve Pos. 97
The four valves mounted on the „Travel“ spools
(92 & 93) keep a constant column of oil in the track
motors. They crack open at the slightest pressure
so that oil can be drawn in from the tank line.
free Pos. 98
free Pos. 99
Swing gearbox Pos. 100
The gearbox are 2 - stage planetary reducers.
The spring applied multi disc brakes on the swing
gearboxes serve to hold the superstructure sta-
tionary (parking brakes). They are actuated by a
toggle switch in the cab.
The brake must only be actuated when the super-
structure has stopped swinging.
Shuttle valve Pos. 101
One of the two shuttle valves is connecting the
swing charge pressure of the swing charge pumps
to the pressure port P of the pressure governing
valve.
The other shuttle valve is connecting the control
pressure lines Y1 and Y 2 to the pressure relief
valve ((109).
RH 90 C Diesel - 3657775e.doc - (00) – 11.03
Swing motor Pos. 102
The swing motors are 40°, fixed - displacement
axial piston pumps whose output speed is propor-
tional to the flow of oil. The output torque increases
with the pressure drop over the motor.
Shut-off valve Pos. 103
The shut-off valves are flanged-mounted on the
swing pumps.
The valves are opened by means of servo oil after
the relevant engine has been started. The valves
shall rule out that the swing system acts on the
stationary engine when the machine is powered by
one engine only.
Pressure governing valve Pos. 105
Governs the torque in the closed - loop swing cir-
cuit.
The valve governs the pressure and direction of oil
flow (and therefore extent and direction of the
swing motors` output ) depending upon the se-
lected control pressure
The radio between control pressure and working
pressure is approx. 1 : 12, i. e. 10 bar control pres-
sure on ports (Y 1 or Y 2) corresponds to 120 bar
operating pressure in the swing circuit.
Flushing valve Pos. 106
The flushing valve serves to flush the closed swing
circuit. During each swing operation the valve
flushes a small oil volume from the low-pressure
side of the swing circuit. The charge pump flange-
mounted to the swing pump replaces this oil vol-
ume by cooled oil from the hydraulic tank.
free Pos. 107
free Pos. 108
Page 8.3 - 9
8.3 DESCRIPTION OF THE HYDRAULIC SYSTEM - FS

Pressure relief valve Pos. 109 A single-acting hydraulic cylinder tensions each
track.
Diaphragm accumulator Pos. 131
The valve limits the pressure that controls the
pressure governing valve (105) to max. 31 bar.
The valve is direct acting and has a variable set- Impacts produced by external influences acting on
ting. the tracks are compensated by the diaphragm
accumulators.

free Pos. 110

Track tensioning assembly Pos. 133
Orifice Pos. 111
The hydraulic track-tensioning assembly com-
prises pressure-relief valves (134) and non-return
The fitting with orifice is limiting the oil flow which is valves (135) in the undercarriage.
flushed out of the system by the flushing valve
(106).

Pressure relief valve Pos. 134

free Pos. 112 - 119
The pressure relief valves protect the hydraulic
Travel gearbox Pos. 120 tensioning system against overload resulting from
external forces at the idler.
The travel gearboxes with an integrated multi-disk
brake (parking brake) are of 3-stage planetary
design.
Check valve Pos. 135

The check valves protect the hydraulic tensioning

Travel motor Pos. 121 system in the superstructure against overload re-
sulting from external forces at the idler.
The 2 travel motors are 40° fixed-displacement
axial-piston units.
The output speed is proportional to the oil flow. free Pos. 136 – 145
The produced torque increases as a function of the
pressure difference encountered between the Service station Pos: 146
high- and low-pressure side.

The hydraulic cylinder for lifting and lowering the

service station is activated by manually operated
Travel parking brake Pos. 122 valve.
A check valve prevents pressure loss.

Each travel gearbox is equipped with a mechanical

holding brake (multiple disk brake) which is applied free Pos. 147 - 159
by springs and released by servo pressure when
the travel system is actuated.
3-spool control block (RH) Pos. 160
free Pos. 123 - 129
The servo-controlled 3-spool valve block controls
the working cylinders for boom, arm (stick) and
Track tensioning cylinder Pos. 130 bucket.
For each function a secondary pressure-relief
valve and an anti-cavitation valve is installed.

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8.3 DESCRIPTION OF THE HYDRAULIC SYSTEM - FS

The two double-acting hydraulic cylinders are in-

stalled between superstructure and the TriPower.
3-spool control block (LH) Pos. 161 They are lifting or lowering the boom and thus the
complete working equipment.

See Pos. 160

Stick cylinder Pos. 183

free Pos. 162
The 2 double-acting hydraulic cylinders are in-
free Pos. 163 stalled between boom and arm and serve to ex-
tend and retract the arm.

Float valve – boom Pos. 164

The float valves save time and energy when low- Bucket crowd Pos. 184
ering the boom. The valves connect the piston and
rod sides of the cylinders so that the piston rods The two double-acting hydraulic cylinders are in-
retract only as a result of the attachment`s own stalled between the TriPower and the bucket
dead weight. Only the excess oil (piston - side backwall and are used to turn the bucket.
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 free Pos. 185
can be switched off using solenoid valve (Y 10).
Clamshell cylinder Pos. 186

Float valve – arm Pos. 165 The two double-acting hydraulic cylinders are in-
stalled between backwall and frontlip and are used
to open and close the bucket.
The float valves save time and energy when low-
ering 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 (Y 8.1).

1-spool control block Pos. 166

The servo-controlled 1-spool valve block controls

the clam cylinders of the bucket.
For each function a secondary pressure-relief
valve and an anti-cavitation valve is installed.

free Pos. 167 - 181

Boom cylinder Pos. 182

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8.3 DESCRIPTION OF THE HYDRAULIC SYSTEM - FS

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8.3 DESCRIPTION OF THE HYDRAULIC SYSTEM - FS

8.3.4 Hydraulic circuit diagram

The position nos. in the circuit diagram Part-

No. 3 677 219 are referred to chapter 8.3.2.

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8.3 DESCRIPTION OF THE HYDRAULIC SYSTEM - FS

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