8.

3 DESCRIPTION OF THE HYDRAULIC SYSTEM - FS

8.3 Description of the hydraulic system

8.3.1 Technical data

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

8.3.2 Circuit diagram

Components of the hydraulic circuit diagram RH 340 electric drive (FS) / 6060 AC FS
The position nos. refer to circuit diagram No. 3 719 200 (00)

Position Quantity Designation Location

1 1 Electric motor Engine module
2 1 Pump gearbox Engine module
3 4 Main pump A7V - SL - 1000 Pump gearbox
4 3 Swing pump A4VG 250 Pump gearbox
5 ----
6 Servo Pump (double pump) Pump gearbox
7–9 ----
10 4 Cooling pump KP 5 - 300/250 Pump gearbox
11 - 18 ----
19 Central greasing system Superstructure
20 – 22 ----
23 1 Proportional valve Engine module
24 ----
25 1 Proportional valve plate Operator modul
26 2 Solenoid valve bank Operator modul
27 ----
28 1 Distributor block Engine module
29 1 Distributor block (main pumps) Engine module
30 4 Pressure relief valve Engine module
31 ----
32 4 High pressure filter Engine module
33 ----
34 3 Filter Engine module
35 1 Emergency lowering valve Operator modul
36 1 Filter Operator modul
37 3 Check valve Operator modul
38 4 Diaphragm accumulator Engine module

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8.3 DESCRIPTION OF THE HYDRAULIC SYSTEM - FS

Position Quantity Designation Location

39 1 Check valve Engine module
40 ----
41 1 Pressure relief valve Engine module
42 1 Pressure relief valve Engine module
43 1 Check valve Engine module
44 ----
45 2 Proportional pressure reducing valve (Thermostat) Engine module
46 – 59 ----
60 1 Hydraulic oil tank Superstructure
61 2 Gate valve Hydraulic oil tank
62 2 Return oil filters Hydraulic oil tank
63 6 Bypass valve Hydraulic oil tank
64 4 Tank line pressurizing valve Hydraulic oil tank
65-74 ----
75 1 Gearbox oil cooler Engine modul
76 1 Thermostat valve Engine modul
77 1 Filter Oil cooler module
78 1 Distributor Oil cooler module
79 ----
80 2 Hydraulic Oil cooler Oil cooler module
81 4 Fan motor Oil cooler module
82 - 83 ----
84 4 Fan Oil cooler module
85 2 Distributor plate (oil cooling) Oil cooler module
86-88 ----
89 4 Pressure relief valve Oil cooler module
90 1 Travel block Superstructure
91 1 Rotor Superstructure
92 1 Travel valve block RH Rotor
93 1 Travel valve block LH Rotor
94 ----
95 1 Travel retarder valve RH Travel block
96 1 Travel retarder valve LH Travel block
97 4 Anti – cavitation valve Travel block
98 - 99 ----
100 4 Swing gearbox Superstructure

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8.3 DESCRIPTION OF THE HYDRAULIC SYSTEM - FS

Position Quantity Designation Location

101 ----
102 4 Swing motor Swing gearbox
103 - 104 ----
105 1 Pressure regulating valve (swing balance valve) Engine module
106 1 Flushing valve (swing) Engine module
107 ----
108 ----
109 1 Pressure relief valve (swing) Engine module
110 2 Safety solenoid valve (swing) Engine module
111 - 119 ----
120 2 Travel gearbox Undercarriage
121 4 Travel motor Travel gearbox
122 - 124 ----
125 1 Secondary relief valve block Undercarriage
126 4 Pressure relief valve in pos. 125
127 - 129 ----
130 2 Track tensioning cylinder Undercarriage
131 2 Diaphragm accumulator Undercarriage
132 ----
133 1 Track tensioning block Undercarriage
134 2 Track tensioning relief valve Undercarriage
135 - 144 ----
145 1 Cylinder (service lift) Superstructure
146 1 Valve Superstructure
147 1 Check valve Superstructure
148 - 149 ----
150 1 Cylinder (ladder) Superstructure
151 1 Control valve Superstructure
152 1 Bladder accumulator Superstructure
153 - 160 ----
161 2 4-spool control valve Boom
162 - 163 ----
164 4 Float valve Boom
165 - 166 ----
167 2 Check valve Superstructure
168 - 181 ----

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8.3 DESCRIPTION OF THE HYDRAULIC SYSTEM - FS

Position Quantity Designation Location

182 2 Boom cylinder Boom
183 2 Arm cylinder Boom
184 2 Crowd cylinder Boom
185 ----
186 2 Clamshell cylinder Backwall
187 1 Distributor Backwall
188 ----
189 2 Block Attachment

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8.3 DESCRIPTION OF THE HYDRAULIC SYSTEM - FS
8.3.3 Components of the hydraulic
system
Attention
The following item numbers refer to hydraulic
circuit diagram Part-No.
3 719 200 (00)
Some items are numbered in the diagram but
not mentioned here since they have less sig-
nificance for the hydraulic functioning se-
quence.
Drive unit Pos. 1
One Electric motor (squirrel cage type).
Pump gearbox Pos. 2
The pump transfer gearbox is driven via an elastic
coupling by the electric motor and distributes the
motor's output to the relevant hydraulic pumps.
Main pump Pos. 3
The pump batteries each comprises a variable -
displacement pump, a 2-stage pressure sequence
valve and a shut-off valve.
The 4 main pumps for attachment and travel are
axial-piston variable displacement pumps in bent-
axis design with slipper bearing.
The shut-off valves can be used to switch off the
pressure cut - off function for the main pumps.
Each pump has its own pressure - dependent reg-
ulator with a regulating range between 7,5 and
42,5 bar. At 42,5 bar, the pump`s rotary group is at
its maximum and therefore at maximum flow. At
7,5 bar, the rotary group is at „zero“ oil flow. The
regulators are actuated by the proportional valve
(23) via the electronic load - limit governor in the
PMS system.
3721440en - (00) - 11.09
Swing pump Pos. 4
The 4 swing pumps to move the superstructure are
variable - displacement axial - piston swashplate
pumps. They are especially suited for operation in
closed circuits. The pump flow is infinitely variable
and increases from „0“ to „max“ while the pump
rotary group is being tilted out. If the swashplate is
de-stroked through the „zero“ position, the direc-
tion of the oil flow is altered smoothly.
The pumps are fitted with a torque control that is
controlled by the pressure regulating valve (105).
Depending upon the pre - selected control pres-
sure, the valve allows infinite governing of
- operating pressure and
- torque magnitude and direction
on the swing motors (102).
Each swing pump has two pressure relief/anti -
cavitation valves.
The functions of these valves are:
1) To protect the swing circuit from overpressure
(max. 400 bar)
2) To ensure that the closed loop of oil in the
swing circuit remains full.
A gear - type pump is also mounted on each swing
pump, and serves as a charge pump for the closed
circuit. The charge pressure of the pumps is limited
by pressure relief valves integrated into the pumps.
The pumps also have chip/contamination and tem-
perature switches which send warning signals to
the BCS system if metal chips or excessive oil
temperatures are detected.
free Pos. 5
Servo pump Pos. 6
The servo pump is a tandem gear pump which is
mounted to one of the swing pumps (4) and sup-
plies the whole servo circuit with oil.
free Pos. 7 – 9
Page 8.3 - 5
8.3 DESCRIPTION OF THE HYDRAULIC SYSTEM - FS

Oil cooling pump Pos. 10  Travel parking brakes

 Pressure boost for travel

Four gear pumps constantly draw oil from the tank
and pump it to the fan motors and the oil coolers.  Track motor adjustment ( 2 speed travel)
Two pumps are mounted directly on the gearbox,
the other two pumps are mounted onto the swing
 Pressure boost for clam cylinder (P 1)
pumps (4).
 Superstructure parking brakes
free Pos. 11 – 18
free Pos. 27
Greasing system Pos. 19
Distributor block Pos. 28
Hydraulic oil of the pilot pressure system is used to
operate the grease pump and the control valve of
The distributor block is supplying the connected
the central greasing system.
components with 50 bar pilot pressure.

free Pos. 20 – 22
Distributor block (main pumps) Pos. 29

Proportional valve Pos. 23 An assembly group comprising

These valve controls the main pumps (3). They are
controlled by the microprocessor in the PMS sys-
tem and govern the flows from the main pumps
depending upon the actual pressure. The valve is
actuated by an adjustable, oil - immersed DC sole-
noid and transforms electrical current proportional-
ly into hydraulic pressure.
A solenoid current of 830 mA corresponds to a
pressure of 42 bar in the pump governors. A cur-
rent of 230 mA corresponds to 10 bar.
free Pos. 24
Servo control block Pos. 25
 4 primary pressure relief valves (30)
 4 high - pressure filters (39)
 1 Housing
Pressure relief valve Pos. 30
The relief valves are used as primary pressure
relief valves for the main pumps. They limit the
maximum pressure that can be reached by the
pumps (3) and therefore protect the system
against overload.
The valves are pilot controlled and have variable
settings.

The servo control block contains the pressure re- free Pos. 31
lief valves for the servo- and auxiliary circuits and
the proportional valves to control the servo valves
of the control blocks. High - pressure filter Pos. 31

The high - pressure filters in the high - pressure

Solenoid valve bank Pos. 26
lines from the main pumps protect the downline
units (e. g. control blocks and cylinders) against
2 assembly groups are comprisiesng four solenoid metal chips and particles from the pumps (3). Oth-
valves and a housing each. er than in the return flow filters (62), the oil flows
through the HP filters from outside to in.
The 4/2 - way valves control the functions:

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8.3 DESCRIPTION OF THE HYDRAULIC SYSTEM - FS

free Pos. 33 pumps (6) and therefore protect the system

against overload.

Check (Non-return) valve Pos. 43

Filter Pos. 34

The 3 filters are filtering the oil from the 3 swing

circuit charge pumps. free Pos. 44

Proportional solenoid valve Pos. 45

Emergency lowering valve Pos. 35
The proportional valves (thermostats) are regulat-
The valve block consists of a solenoid valve, a ing the control spools in the distributor plate (85)
non-return valve and an accumulator. depending on the hydraulic oil temperature.
Lowering of the attachment is possible with the
drive unit at a standstill, when operating the joy-
stick while the solenoid valve is activated. free Pos. 46 – 59
The solenoid valve will be activated by using a
press-button switch located in the control column
in the driver’s cab. Hydraulic oil tank Pos. 60

The tank stores all of the oil for the system and
contains two return flow filters (62), six by - pass
Filter (Servo control block) Pos. 36 valves (63), four tank line pressurizing valves (64),
2 shut-off gate valves (Pos. 61) and 2 tank breath-
Through this filter the servo control block (25) will er filters .
be supplied with servo oil.

Gate valve in intake line Pos. 61

Check (Non-return) valve
Diaphragm accumulator
Pos. 37 The shut - off cocks can be used to isolate the
hydraulic pumps from the oil tank. This makes it
possible to remove pumps without having to drain
all of the oil from the tank.
Pos. 38
Return flow filter Pos. 62

Check (Non-return) valve Pos. 39 Each return flow filter contains 7 filter elements to
clean the oil returning from inside to out. Any metal
chips are trapped by the magnetic rods installed
above the filters.

free Pos. 40
By - pass valve Pos. 63
Pressure relief valve Pos. 41 + 42
The six by - pass valves open at a pressure of 1.5
bar and prevent the return flow filters (62) bursting,
The relief valves are used as primary pressure e. g. due to clogging. Oil then flows unfiltered back
relief valves for the servo pumps. They limit the into the tank.
maximum pressure that can be reached by the

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8.3 DESCRIPTION OF THE HYDRAULIC SYSTEM - FS

Tank line pressurizing valve Pos. 64 Fan motor Pos. 81

These four valves have fixed settings of approx. 10
bar. They are arranged in the return lines and keep
a constant level of pressure in the hydraulic sys-
tem.
free Pos. 65 - 74
The fixed-displacement geared motors are driven
by the oil cooling pump (10) and drive the fan
wheel of the hydraulic oil cooler.
free Pos. 82 - 83

Fan Pos. 84
Gear box oil cooler Pos. 75
The fan produces the air flow to cool down the
A gear pump is pumping the gear oil through filter hydraulic oil.
(77) and via thermostat valve (76) to the gear oil
cooler (75) and back into the pump gearbox (2).

Distributor plate for oil cooling Pos. 85

Thermostat valve Pos. 76
The thermostat-valve (76) with an opening tem-
perature of 55° C protects the oil cooler (75)
against pressure peaks especially when the elec-
tric motor is started under cold weather conditions.
Each of the two plates contains two pressure relief
valves (89) and two check valves. The check
valves function as anti - cavitation valves while the
drive units are being shut down.

free Pos. 86 - 88
Filter (Gear oil cooling) Pos. 77

Through this filter the gear oil cooling system will

be supplied with gear oil. Pressure relief valve Pos. 89

Distributor Pos. 78 Each fan motor (81) is protected by a pressure

relief valve with a setting of 65 bar.

This distributor contains the temperature sensor of

the gear oil cooling system.
Travel block Pos. 90
free Pos. 79
A complete group comprising rotor (91), the „Trav-
el“ spools (92 & 93), the travel retarder valves (95
& 96) and anti - cavitation valves (97).

Hydraulic oil cooler Pos. 80

The hydraulic oil coolers transferring the heat,
generated in the hydraulic system, from the hy-
draulic oil to the atmosphere.
Cooling is achieved through the air stream pro-
duced by the fan wheel.
Rotor Pos. 91
The rotor is the hydraulic connection between su-
perstructure and undercarriage. The rotor has 7
channels for the following functions:
 4 x travelling (4 channels)
 1 x travel motor control

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8.3 DESCRIPTION OF THE HYDRAULIC SYSTEM - FS

 1 x hydraulic track tensioning
 1 x leakage-oil return
Travel valve block RH
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-
Pos. 92 structure has stopped swinging.

A servo - controlled single - spool block that actu-

ates the right - hand track. free Pos. 101

Travel valve block LH Pos. 93

Swing motor Pos. 102
A servo - controlled single - spool block that actu-
ates the left - hand track. 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
free Pos. 94 with the pressure drop over the motor.

free Pos. 103 – 104

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).
Pressure regulating valve Pos. 105
The valve governs the torque in the closed-loop
swing circuit depending on the selected control
pressure. A pressure relief valve (109) is limiting
the servo pressure to 31 bar. The ratio between
control pressure and working pressure is 1 : 12
and with a max. servo pressure of 31 bar the max.
working pressure on swinging resp. counter-
swinging is approx. 370 bar.

Anti - cavitation valve Pos. 97

Flushing valve Pos. 106
The four valves mounted on the „Travel“ spools
The flushing valve serves the oil flow in the closed
(92 & 93) keep a constant column of oil in the track
swing circuit. During each swing operation the
motors. They open at very low pressure so that oil
valve flushes out a small oil volume from the low-
can be drawn in from the tank line.
pressure side of the swing circuit. The charge
pump replaces this oil volume by cooled oil from
the hydraulic tank.
free Pos. 98 – 99

free Pos. 107 – 108

Swing gearbox Pos. 100

The gearboxes are 2 - stage planetary reducers.

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8.3 DESCRIPTION OF THE HYDRAULIC SYSTEM - FS

Pressure relief valve Pos. 109 Pressure relief valve Pos. 126

The pressure relief valve limits the control pressure Secondary pressure relief valves for the four track
to 31 bar to be used for the pressure regulating motors that protect the motors against external
valve (105). The valve is direct acting and has a forces. Excess oil is cracked off into the relevant
variable setting. low pressure side of the motors.

Solenoid valve Pos. 110 free Pos. 127 – 129

The 3/2-solenoid valves serve the servo circuit

‘swinging’ with oil pressure.
Track tensioning cylinder Pos. 130

free Pos. 111 – 119 Single - acting (plunger) cylinders that keep the
crawler tracks tensioned.

Diaphragm accumulator Pos. 131

Travel gearbox Pos. 120
The nitrogen accumulators act as shock absorbers
3 - stage planetary reducer with integrated parking to dampen external forces acting on the crawler
brake. tracks.
The four track parking brakes are wet, multi - disk
brakes that are engaged under spring force and
released by hydraulic pressure (18 - 20 bar). free Pos. 132

Travel motor Pos. 121

Track tensioning block Pos. 133
The four track motors are variable - displacement,
bent - axis motors with tandem bearing arrange-
ments. Servo pressure at port (X) sets the motors The block contains the valves for the automatic
to either of two mechanically limited tilt angles. The track tensioning system.
maximum tilt angle is selected when servo pres-
sure is „O“ . The minimum tilt angle is reached
when servo pressure rises above 40 - 45 bar. Pressure relief valve Pos. 134

The track-tensioning assembly comprises 2 pres-

free Pos. 122 – 124 sure-relief valves with hand wheel and 2 test
points.
The hand wheels can be used to relieve the hy-
draulic track tension independently for each track.
Secondary relief block Pos. 125
free Pos. 135 – 144
Assembly group comprising four pressure relief
valves (126), four test points and a housing.

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8.3 DESCRIPTION OF THE HYDRAULIC SYSTEM - FS

Hydraulic cylinder Pos. 145 The valve blocks are servo-controlled.

The double-acting hydraulic cylinder is installed on
the superstructure and moves the service station
up and down.
Hydraulic valve Pos. 146
The 3/2 way valve has the function to activate the
cylinder for the service station.
For each function a secondary pressure-relief- and
anti-cavitation valve is installed.
The pilot-controlled pressure-relief valves protect
the hydraulic cylinders of the working equipment
on the secondary side against too high pressures
which may be produced by external forces acting
on the working equipment.
The integrated suction valves protect the hydraulic
cylinders against cavitation.
free Pos. 162 – 163

Check (non-return) valve Pos. 147

The non-return valves are installed to avoid pres- Float valve Pos. 164
sure loss in the service system.
Save time and energy when lowering the boom
and the stick. The valves connect the piston and
free Pos. 148 - 149 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
Hydraulic cylinder Pos. 150 chamber has a greater volume than the rod - side)
is allowed to escape to the tank. The main pumps
The double-acting hydraulic cylinder is installed on (3) are not activated. If it is required to lower the
the superstructure and moves the access ladder boom or the stick with pressure, the „float“ valves
up and down. can be switched off using solenoid valves, activat-
ed by pressing buttons in the hand-levers.

Control valve Pos. 151

free Pos. 165 – 166
With the control valve the cylinder for the access
ladder is operated. The integrated pressure relief
valve protects the hydraulic cylinder against over-
load. Check (non-return) valve Pos. 167

Accumulator Pos. 152

free Pos. 168 – 181
The oil in the accumulator allows the lowering of
the access ladder when the drive unit is shut down.

Boom cylinder Pos. 182

free Pos. 153 – 160
The two double-acting hydraulic cylinders are in-
stalled between superstructure and boom. They
are lifting or lowering the boom and thus the com-
4-spool valve block Pos. 161 plete working equipment.

The two 4-spool valve blocks control the working

cylinders for boom, arm, bucket crowd and clam.

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8.3 DESCRIPTION OF THE HYDRAULIC SYSTEM - FS

Stick cylinder Pos. 183

The two double-acting hydraulic cylinders are in-

stalled between boom and stick and serve to ex-
tend and retract the stick.

Bucket cylinder Pos. 184

The two double-acting hydraulic cylinders are

mounted between boom and bucket and move the
bucket inwards and outwards.

free Pos. 185

Clamshell cylinder Pos. 186

The two double-acting hydraulic cylinders are

mounted on the back wall and open and close the
front lip.

Distributor block Pos. 187

The block is installed in the backwall and contains

a pressure relief valve.
The pressure relief valve secures the clamshell-
cylinder rod-side against pressure peaks.

free Pos. 188

Distributor block Pos. 189

The distributor block is mounted on the boom and

distributes the various oils flows from the control
blocks to the bucket cylinders.

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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. 3 719 200 (00)

are referred to chapter 8.3.2.

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8.3 DESCRIPTION OF THE HYDRAULIC SYSTEM - FS

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