8.

3 HYDRAULIC CIRCUIT DIAGRAM

8.3 Hydraulic circuit diagram

8.3.1 Technical data

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

8.3.2 Hydraulic circuit diagram

The following item numbers refer to circuit diagram Part-No. 3 693 380 (00).

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 Drivers cab module
26 2 Solenoid valve bank Drivers cab 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 ----
34 2 Filter for servo oil
35 1 Emergency lowering unit
36 1 Filter for proportional valve plate Drivers cab module
37 1 Check valve Drivers cab module
38 1 Accumulator for pilot oil Drivers cab module

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8.3 HYDRAULIC CIRCUIT DIAGRAM

Position Quantity Designation Location

39 - 43 ----
44 2 Check valve RHZ 12 Hydraulic tank (60)
45 2 Pressure reducing valve (proportional valve)
46 - 49 ----
50 1 Distributor block Drivers cab module
51 - 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 (81)
85 1 Distributor plate (hydraulic oil cooling) Oil cooler module

86 2 Pressure relief valve Oil cooler module

87 ----
88 ----
89 2 Gearbox oil cooler Oil cooler module
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
101 1 Shuttle valve Superstructure
102 2 Swing motor A2F 125 Swing gearbox (100)

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8.3 HYDRAULIC CIRCUIT DIAGRAM

Position Quantity Designation Location

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 2 Safety valve
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 block Undercarriage
134 2 Pressure relief valve Undercarriage
135 - 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
184 2 Bucket crowd cylinder Boom
185 ----
186 2 Clam cylinder Backwall

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8.3 HYDRAULIC CIRCUIT DIAGRAM

Position Quantity Designation Location

187 ----
188 1 Distributor block Boom

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8.3 HYDRAULIC CIRCUIT DIAGRAM
8.3.3 Components of the hydraulic
system
Attention!
The following item numbers refer to hydraulic
circuit diagram Part-No. 3 693 380 (00) in chap-
ter 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 (102) to be
steplessly controlled depending on the preselected
RH 90 C Diesel - 3720172en.doc - (00) 10.06
- control pressure
- operating pressure
- torque magnitude and direction
Each swing pump has 2 pressure relief-
anticavitation valves. They have the following
function:
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-/ gear oil pump Pos. 6
The double gear pumps are directly driven
(through drive) from main pump (P1 & P3). One
segment of the pumps supply oil to the entire
servo-, auxiliary- and track tensioning circuits. The
other segment is circulating the oil of the pump
gearbox.
free Pos. 7 - 9
Oil cooling pump 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.
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8.3 HYDRAULIC CIRCUIT DIAGRAM

free Pos. 11 - 15 free Pos. 28

Check valve Pos. 16 Pump distributor plate Pos. 29

Through the check valves the auxiliary pressure is The pump distributor plate for the main pumps
fed into the main pump regulator. The check contains 2 pressure relief valves (30), 2 high pres-
valves protect the servo circuit against high pres- sure filters (32) and 4 non-return valves.
sure produced by the main pumps.

free Pos. 17 -22 Pressure relief valve Pos. 30

Proportional valve Pos. 23
The proportional valve controls the regulators of
the main pumps (3). It converts electrical signals.
The valve receives signals from the load limit regu-
lator (110) of the PMS system and produces rele-
vant hydraulic pressure to control the flow rate of
the main pumps.
The primary relief valves are set to 330 bar. They
protect the hydraulic system against pressure
peaks occurring as a consequence of pressure
cut-off valve inertia under certain high pressure
and fluid flow conditions.
free Pos. 31

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

free Pos. 24 The high - pressure filters in the high - pressure

Proportional valve plate Pos. 25
The servo control block contains the pressure re-
lief valves for the servo- and auxiliary circuits and
the proportional valves to control the servo valves
of the control blocks.
lines from the main pumps protect the downline
units (e. g. control blocks and cylinders) against
metal chips and particles from the pumps (3). The
filter elements are differential pressure resistant
and do not have a bypass valve. The oil flows
through the HP filters from outside to inside.
free Pos. 33

Filter for servo oil Pos. 34

Valve bank, compl. Pos. 26
These filters are mounted to clean the oil flow of
An assembly group comprising four solenoid the servo pumps (6).
valves and a housing with following functions:

Port A1 is not used.

Valve for emergency lowering Pos. 35
Port A2 is not used.

Port A3 is used for operation of the swing
parking brake.
Port A4 is used for operation of the travel park-
ing 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 HYDRAULIC CIRCUIT DIAGRAM

Filter Pos. 36 free Pos. 51 59

This filter is filtering the oil which is feeding the Hydraulic tank Pos. 60
proportional valve plate (25).

The hydraulic oil storage tank comprises the fol-

lowing components:
Check valve Pos. 37
- 4 return-flow filter elements (62)
- 2 bypass valves (63)
The check valve prevents pressure loss when the - 1 magnetic rod
engines are shut off and the emergency lowering - 2 tank-line pre-charging valves (64)
system (35) is activated. - 2 high-pressure filters (32)
- 2 primary relief valves (30)
- 2 shut-off gate valves (61)
- 2 breather filters
Diaphragm accumulator Pos. 38

This accumulator is compensating pressure drops Gate valve for intake line Pos. 61
in the servo- and auxiliary system when various
consumers are activated at the same time.
The hydraulic tank can be separated from the suc-
tion lines of the hydraulic pumps by means of the
free Pos. 39 - 43 shut-off gate valves. This enables the oil to be left
in the hydraulic tank when, for example, a pump is
to be removed.
Check valve Pos. 44

Check valves prevent oil from being supplied to a

stationary engine. Return flow filter Pos. 62

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

Pressure reducing valve Pos. 45
The pressure reducing valve is receiving an elec-
trical signal from the Board Control System (BCS).
The signal is related to the temperature of the hy-
draulic oil. The valves are pressurising the pistons
in the distributor plate (85). The pistons are moved
against springs and control the volume flow and
thus the speed to the fan motors (81).
free Pos. 46 49
ing from the consumers. The oil passes through
the filter elements from the inside to the outside.
Metallic contamination collects on the magnetic rod
located above the filter elements.
Bypass valve Pos. 63
The bypass valves prevent bursting of the return-
flow filter elements (62). The opening pressure is
1.5 bars. In this case, the oil flows back unfiltered
into the tank.

Distributor Pos. 50
The distributor is feeding the grease pump of the
central greasing system and the cylinder of the
service station with auxiliary pressure.
Tank line pressurising valve Pos. 64
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.

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8.3 HYDRAULIC CIRCUIT DIAGRAM

free Pos. 65 - 79 Gearbox oil cooler Pos. 89

Hydraulic oil cooler Pos. 80 The gearbox oil coolers are installed in the oil
cooler module and are cooling the gear oil using
the air flow of the hydraulic oil cooler fans.
The hydraulic oil coolers pass the heat generated
in the hydraulic system transferring the heat from
the hydraulic oil to the atmosphere. Cooling is
achieved through the air stream produced by the Travel block Pos. 90
fan wheel.

A complete group comprising rotor (91), the

Travel spools (92 & 93), the travel retarder valves
Fan motor Pos. 81 (95 & 96), anti - cavitation valves (97) and cover
plates.

The fixed-displacement geared motors are driven

by the oil cooling pump (10) and drive the fan
wheel of the hydraulic oil cooler. Rotor Pos. 91

free Pos. 82 The rotor is the hydraulic connection between su-

perstructure and undercarriage. The rotor has 7
channels for the following functions:
free Pos. 83
- 4 x traveling

Fan Pos. 84 - 1 x travel parking brake

The cooler fans produce the air flow needed to - 1 x hydraulic track tensioning
cool the hydraulic oil.
- 1 x leakage-oil return

Distributor plate for oil cooling Pos. 85

The distributor plate is installed in on the cooler
module. The plate contains two pressure relief
valves (86) and two check valves. The check
valves function as anti - cavitation valves while the
engines are being shut down.
Travel valve block RH Pos. 92
Servo-controlled single control block for operation
of the right track with integrated pressure relief
valve and flanged on anti-cavitation valves.
The control is made by electro-hydraulic propor-
tional valves.

Pressure relief valve Pos. 86

Travel valve block LH Pos. 93
Each hydraulic oil cooling circuit is secured by a
pressure relief valve. Servo-controlled single control block for operation
Opening pressure: appr. 65 bars. of the left track with integrated pressure relief valve
and flanged on anti-cavitation valves.
The control is made by electro-hydraulic propor-
tional valves.
free Pos. 87

free Pos. 88 free Pos. 94

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8.3 HYDRAULIC CIRCUIT DIAGRAM

Travel retarder valve RH Pos. 95 Swing motor Pos. 102

When going downhill the pressure from the pumps
to the travel motors decreases and the travel re-
tarder valves cause the oil flow returning from the
travel motor to the tank to be reduced. This pre-
vents the excavator from getting inadmissible
speed.
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

Travel retarder valve LH
See travel retarder valve (95).
Anti - cavitation valve
Pos. 96
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
Pos. 97 stationary engine when the machine is powered by
one engine only.

The four anti-cavitation valves flanged on the con-

trol blocks (Pos. 92 and 93) prevent cavitation on free Pos. 104
the hydraulic travel motors.

Pressure governing valve Pos. 105

free Pos. 98
The valve governs the torque in the closed-loop
free Pos. 99 swing circuit depending on the selected control
pressure. The ratio between control pressure and
working pressure is approx. 1 : 12 and with a max.
Swing gearbox Pos. 100 servo of 31 bar the max. working pressure on
swinging resp. counter-swinging is approx. 370
bar.
The swing gearboxes are of 2-stage planetary
design.
To prevent inadvertent swing movements of the
superstructure, the machine has multiple-disk
parking brakes arranged between swing motor and Flushing valve Pos. 106
swing gearbox.
It will be activated by a rocker switch on the opera- The flushing valve serves to flush the closed swing
tor desk in the drivers cab and may only be used circuit. During each swing operation the valve
when the superstructure is in standstill position. 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.
Shuttle valve Pos. 101

The shuttle valve is connecting the control pres- free Pos. 107
sure lines Y1 and Y 2 to the pressure relief valve
((109). free Pos. 108

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8.3 HYDRAULIC CIRCUIT DIAGRAM

Pressure relief valve Pos. 109 free Pos. 123 - 129

The pressure relief valve reduce the servo pres- Track tensioning cylinder Pos. 130
sure from 60 bar to 31 bar to be used for the pres-
sure governor valve (Pos. 105).
A single-acting hydraulic cylinder tensions each
track.

Safety valve Pos. 110

Diaphragm accumulator Pos. 131
The 3/2 way solenoid valves are installed in line
with the proportional valves for the swing function.
The function as safety valves in case of a malfunc- Impacts produced by external influences acting on
tion of a proportional valve. the tracks are compensated by the diaphragm
accumulators.

Orifice Pos. 111 free Pos. 132

The fitting with orifice is limiting the oil flow which is Track tensioning block Pos. 133
flushed out of the system by the flushing valve
(106).
The block contains the valves for the automatic
track tensioning system.
free Pos. 112 - 119 Pressure relief valve Pos. 134

The track-tensioning assembly comprises 2 pres-

Travel gearbox Pos. 120 sure-relief valves with hand wheel and 2 test
points.
The travel gearboxes with an integrated multi-disk The hand wheels can be used to relieve the hy-
brake (parking brake) are of 3-stage planetary draulic track tension independently for each track.
design.

free Pos. 135 145

Travel motor Pos. 121

Service station Pos: 146
The 2 travel motors are 40 fixed-displacement
axial-piston units. The hydraulic cylinder for lifting and lowering the
The output speed is proportional to the oil flow. service station is activated by manually operated
The produced torque increases as a function of the valve.
pressure difference encountered between the A check valve prevents pressure loss.
high- and low-pressure side.

free Pos. 147 - 159

Travel parking brake Pos. 122 3-spool control block (RH) Pos. 160

Each travel gearbox is equipped with a mechanical
holding brake (multiple disk brake) which is applied
by springs and released by servo pressure when
the travel system is actuated.
The servo-controlled 3-spool valve block controls
the working cylinders for boom, arm (stick) and
bucket.
For each function a secondary pressure-relief
valve and an anti-cavitation valve is installed.

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8.3 HYDRAULIC CIRCUIT DIAGRAM

3-spool control block (LH) Pos. 161 Boom cylinder Pos. 182

See Pos. 160 The two double-acting hydraulic cylinders are in-
stalled between superstructure and the TriPower.
They are lifting or lowering the boom and thus the
free Pos. 162 complete working equipment.

free Pos. 163

Stick cylinder Pos. 183
Float valve boom Pos. 164
The 2 double-acting hydraulic cylinders are in-
stalled between boom and arm and serve to ex-
The float valves save time and energy when lower- tend and retract the arm.
ing 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) Bucket crowd cylinder Pos. 184
is allowed to escape to the tank. The main pumps
(3) are not activated. If it is required to lower the The two double-acting hydraulic cylinders are in-
boom or the arm with pressure, the float valves stalled between the TriPower and the bucket
can be switched off using solenoid valve (Y 10). backwall and are used to turn the bucket.

free Pos. 185

Float valve arm Pos. 165
Clamshell cylinder Pos. 186
The float valves save time and energy when lower-
ing the arm. The valves connect the piston and rod
sides of the cylinders so that the piston rods retract The two double-acting hydraulic cylinders are in-
only as a result of the attachment`s own dead stalled between backwall and frontlip and are used
weight. Only the excess oil (piston - side chamber to open and close the bucket.
has a greater volume than the rod - side) is al-
lowed 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

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8.3 HYDRAULIC CIRCUIT DIAGRAM

8.3.4 Hydraulic circuit diagram

The position nos. in the circuit diagram Part-

No. 3 693 380 are referred to chapter 8.3.2.

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8.3 HYDRAULIC CIRCUIT DIAGRAM

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