Sistema Hidraulico PDF

Technical Handbook
RH 200
8. Hydraulic system
TEREX Germany GmbH & Co. KG
3 663 488.00 en
Editor:
TEREX Germany GmbH & Co. KG

Department 910 Product Support
D-44149 Dortmund, Karl-Funke-Str. 36
Phone:
Fax:
++49 / 231 / 922-4901

++49 / 231 / 922-5900
Copyright by TEREX, Printed in Germany
CONTENTS
8.
HYDRAULIC SYSTEM
8.1
8.2
8.3
8.3
8.4
Introduction ......................................................................................8.1 - 1
8.1.1
Foreword ...........................................................................8.1 - 1
8.1.2
Safety ................................................................................8.1 - 1
8.1.3
General..............................................................................8.1 - 5
Depressurizing, bleeding, flushing .................................................8.2 - 1

8.2.1
Depressurizing of the hydraulic system .............................8.2 - 1
8.2.2
Bleeding of the hydraulic system .......................................8.2 - 3
8.2.3
Flushing of the hydraulic system .......................................8.2 - 5
Description (Faceshovel).................................................................8.3 - 1
8.3.1
Technical data ...................................................................8.3 - 1
8.3.2
Components of the hydraulic schematic ............................8.3 - 1
8.3.3
Components of the hydraulic system.................................8.3 - 5
8.3.4
Hydraulic circuit diagram .................................................8.3 - 13
Description (Backhoe) .....................................................................8.3 - 1

8.3.1
Technical data ...................................................................8.3 - 1
8.3.2
Components of the hydraulic schematic ............................8.3 - 1
8.3.3
Components of the hydraulic system.................................8.3 - 5
8.3.4
Hydraulic circuit diagram .................................................8.3 - 13
Hydraulic components.....................................................................8.4 - 1
8.4.1
Main pumps .......................................................................8.4 - 1
8.4.2
Swing pump.......................................................................8.4 - 2
8.4.3
Rotor..................................................................................8.4 - 3
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Page 8 - 1
CONTENTS
8.5
8.6
8.4.4
Valve blocks ......................................................................8.4 - 5
8.4.5
Other components ...........................................................8.4 - 34
Description of hydraulic circuits.....................................................8.5 - 1

8.5.1
Load limiting system .......................................................8.5.1 - 1
8.5.2
Pressure cut off system ..................................................8.5.2 - 1
8.5.3
Servo system..................................................................8.5.3 - 1
8.5.4
Working functions (Faceshovel) .....................................8.5.4 - 1
8.5.4
Working functions (Backhoe)..........................................8.5.4 - 1
8.5.5
Travel system .................................................................8.5.5 - 1
8.5.6
Swing system .................................................................8.5.6 - 1
8.5.7
Track tensioning system .................................................8.5.7 - 1
8.5.8
Cooling system for hydraulic oil ......................................8.5.8 - 1
8.5.9
Cooling system for engines ............................................8.5.9 - 1
8.5.10
Cooling system for pump gearbox ................................8.5.10 - 1
Pressure checking and setting........................................................8.6 - 1

8.6.1
Introduction........................................................................8.6 - 1
8.6.2
Pressure settings...............................................................8.6 - 3
8.6.3
Tools..................................................................................8.6 - 4
8.6.4
Hydraulic systems .............................................................8.6 - 5
8.7
Installation of hydraulic pumps.......................................................8.7 - 1
8.8
Hydraulic cylinders (Faceshovel)....................................................8.8 - 1
Page 8 - 2
8.8.1
Introduction........................................................................8.8 - 1
8.8.2
Design configuration ..........................................................8.8 - 3
8.8.3
Assembly .........................................................................8.8 - 11
RH 200 Diesel - 3657790e.doc - (00) - 09.03
CONTENTS
8.8.4
8.8
Tightening torques...........................................................8.8 - 24
Hydraulic cylinders (Backhoe) ........................................................8.8 - 1

8.8.1
Introduction........................................................................8.8 - 1
8.8.2
Design configuration ..........................................................8.8 - 3
8.8.3
Assembly ...........................................................................8.8 - 9
8.8.4
Tightening torques...........................................................8.8 - 22
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Page 8 - 3
CONTENTS
Page 8 - 4
RH 200 Diesel - 3657790e.doc - (00) - 09.03
8.1
HYDRAULIC SYSTEM
8.1
Introduction
8.1.2
Safety Instructions
8.1.1
Foreword
8.1.2.1
Danger in the event of non-observance of the safety instructions
The Technical Handbook contains important information for personnel servicing the machine.
Machine specifications listed elsewhere in the
machine documents are not always repeated in
this book.
This TEREX hydraulic excavator

has been built in accordance with
state-of-the-art standards and the
recognized safety rules.
the operating instructions
However, operating the machine if

a fault is suspected or has occurred, or carrying out repair work
inexpertly may
the spare-parts list
endanger the lives of persons in

contact with it
the technical handbook
damage the machine and other

property.
The present brochure does not contain the specifications of auxiliary units for the operation of additional or optional equipment or the specifications of
individual machines.
The hydraulic excavator must be

stopped immediately on any damage being suspected or occurring
to ensure that the safety of the operator, of other persons at the
place of use or of other material
property is not compromised.
The documentation of an TEREX Mining machine

includes:
The refilling quantities specified for consumables

are approximate quantities which are intended as a
help for planning consumable requirements.
Each unit is equipped with suitable checking devices, e.g. dipstick or checking plugs, permitting
the operator to check proper filling of the units.
2440575e - (00) - 11.96
All components of TEREX machines are carefully co-ordinated.

Trouble-free operation and a long
service life can only be achieved
with original TEREX spare parts.
Page 8.1 - 1
8.1
HYDRAULIC SYSTEM
8.1.2.2
Rules for safety at work
Personnel
Personnel
The machine must not be started
by unauthorized persons.
It must therefore be secured.
Observe the accident prevention
regulations.
The hydraulic excavator may be
operated, serviced or repaired only
by specially trained and authorized
personnel with the appropriate
technical know-how.
If such know-how is lacking, meticulous instruction must be given
by experienced personnel, e.g.
from TEREX.
The personnel must have read and
understood the operating instructions and in particular the chapter
Fundamental
Safety Instructions.
Only such persons may start up
the machine during assembly work
in order to adjust the attachments.
Personal protective
working clothing:
gear
and
Wear a safety helmet, safety footwear and gloves.

Wear closely fitting working clothing when working on the machine.
Loose, wide garments may catch
on machine parts and result in injury.
Persons carrying out work at
greater heights must be equipped
with safety harnesses. Always put
on a tested harness which must be
equipped with fall arrestors and
safety lines.
If the work to be carried out requires auxiliaries, e.g. marshallers,
the competences of each individual helper must be clearly defined
beforehand. The individual responsibilities must be meticulously observed to avoid unclear
competences endangering safety.
Incorrect operation of the machine

or the attachments may give rise to
life-threatening situations.
During all works, always observe
the start-up and shut-down procedures prescribed in the operating
instructions.
Page 8.1 - 2
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8.1
HYDRAULIC SYSTEM
Tools and auxiliaries

Tools, hoists, slings, trestles and
other devices must be in a reliable,
safe state.
Metal splinters may cause injury
when attachment bolts are being
driven in or out. A brass or copper
mandrel should therefore be used
for this purpose, and goggles must
be worn.
For climbing onto or off the machine, use only the ladders, steps,
platforms and handrails provided
for this purpose.
Always keep ladders, steps and
platforms in a non-slip state. Remove any oil, grease, earth, clay,
snow, ice and other foreign matter
immediately.
Securing the working equipment

Before carrying out assembly
work, the machine and the attachments must be secured against inadvertent and unauthorized starting, e.g. by placing chocks under
the wheels or tracks and by standing the working equipment on the
ground.
Stand the working equipment on
the ground in such a way that no
movements can be made when
mechanical or hydraulic connections become detached.
Secure any equipment or component which is to be mounted or
dismantled or whose position is to
be changed using hoists or appropriate slinging/supporting devices
to prevent them from moving, slipping or falling inadvertently.
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Systems and units (e.g. pipes,

coolers,
hydraulic
reservoirs,
compressed-air reservoirs) must
be properly depressurized before
being opened.
Protective devices on moving machine parts may be opened or removed only when the drive unit is
stationary and protected against
inadvertent starting.
Before recommissioning, all protective devices must be refitted.
Before carrying out assembly
work, the machine and the equipment must be secured against inadvertent starting, e.g. by placing
chocks under the wheels or tracks
and by standing the working
equipment on the ground.
Hydraulic and lubricating system:

Always observe the safety regulations applicable to the product
when handling oils, greases and
other chemical substances.
Unused but open bores, pipelines
and hose connections must be
closed in a pressure-tight manner.
Refill collected hydraulic oil back
into the hydraulic system only
through the return-flow filters. Dispose of waste oil without polluting
the environment.
Observe the correct working sequence when fitting or replacing
components or equipment. The
working sequence has been specified and tested by qualified experts.
.
Page 8.1 - 3
8.1
HYDRAULIC SYSTEM
8.1.2.3
When carrying out work and especially work on the electrical system
involving tools, spare parts, etc.
coming into contact with electric
cables, the battery main switch
must be set to the 'OFF' position.
Unauthorized conversions or modifications of the hydraulic excavator

are forbidden for reasons of safety.
The nominal pressure of pressure
relief valves must not be modified
without explicit approval from
TEREX. Do not remove the lead
seals from pressure-relief valves
and pressure accumulators.
Replace defective, mechanically

prestressed units only as an entirety. Never open them. In exceptional cases, open only when the
system and the operating sequence are precisely known. The
Technical Manual contains no information on such work.
When the machine is at operating
temperature, the consumables are
at least at the same temperature.
Precautions must therefore be
taken to prevent burning or scalding.
Be careful when handling acids,
e.g. battery acid. Acid splashes
may injure the eyes and the skin.
Do not smoke when
flammable liquids.
handling
Be careful with naked flames and

unprotected light. Not only fuel but
also other consumables often have
a low flash point and catch fire
easily.
Page 8.1 - 4
Conversions or modifications to the

machine
8.1.2.4
Recommissioning
Prior to recommissioning:
Grease all lubricating points.
Check all oil levels and make the

necessary corrections.
Carry out function checks of all

repaired components
Check all functions of the excavator including the brakes during

a test run. Release the hydraulic
excavator for recommissioning
only after all functions have been
found to work perfectly.
2440575e - (00) - 11.96
8.1
HYDRAULIC SYSTEM
8.1.3
General
In addition to the operating instructions and the

spare-parts list, the present Technical Manual
contains information enabling the user of the
TEREX hydraulic excavator to safely operate,
maintain and repair the machine in accordance
with the specifications.
The information supplied in the Technical Manual
represents the standard version of the machine as
delivered.
All sketches and drawings are merely schematic.
They do not necessarily represent the machine's
actual state of design and must not be used as
manufacturing documents.
No reference is made to special versions.
2440575e - (00) - 11.96
After delivery, the Technical Manual is not subject to revision.

Technical changes introduced into the series production after delivery of the machine may also be
implemented in machines already in use.
In such case, already delivered Technical Manuals are normally not automatically updated.
All technical documents issued by TEREX Germany GmbH are written in German and then
translated.
Even a good translation may give rise to questions
which your TEREX dealer or your TEREX distributing centre will be pleased to answer.
This Technical Manual has been carefully prepared by the competent divisions.
If any points are nevertheless unclear or incorrect,
please contact your local TEREX dealer or your
TEREX distributing centre.
Page 8.1 - 5
8.1
HYDRAULIC SYSTEM
Page 8.1 - 6
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8.2
DEPRESSURIZING, BLEEDING, FLUSHING
8.2
Depressurizing, bleeding,
flushing of the hydraulic
system
All personnel carrying out commissioning, operation, inspection,
service and repair must have read
and understood the operating instructions and in particular the
chapter
Fundamental Safety Instructions.
before starting any work.
8.2.1 Depressurizing of the hydraulic

system
Hydraulic systems are only to be opened up when
they are free of pressure. It is possible for considerable back pressure to be present in the hydraulic-systems, e.g. primary pressure from the last
movement, even when the excavator is parked on
a level surface with its equipment on the ground
(Figs. 1 and 2).
Residual pressure drops only gradually. If work is
to be carried out on the hydraulic system(s) immediately after stopping the excavator, then the system(s) is/are to be freed of pressure.
Before working on the hydraulic

system make sure, that the system
is depressurized and remaining
pressures are relieved.
Shut off the engine(s).
Components (e.g. hydraulic tank,
cylinders, valves) may be hot and
cause severe burns.
Secure the machine before working on it.
Avoid contact of hydraulic oil with
the skin. This can be harmful.
Always wear safety glasses, safety
gloves and firm protective clothing.
630213.SKD
Fig. 1
Parking position of FS-machine
630214.SKD
Fig. 2
RH 200 Diesel - 2471385e - (00) 10.99
Parking position of BH-machine
Release pressure from the part of the system (it may be necessary to use several
procedures).
Carefully open up the part of the system.
Page 8.2 - 1
8.2
Examples for system sections:

1) Main working circuit
2) Servo control circuit
3) Track tensioning system
4) Swing circuit
5) Cooling circuit
Depressurizing:
Park the excavator on a level surface
Lower the working equipment to the ground
Shut of the engine(s)
Fig. 4
Safety switch in seat
Section 1) and 2): Main working circuit and servo

control circuit
With key-switch ON and safety switch active
(86, Fig. 4) shift all control levers and pedals
repeatedly into all directions (Fig. 3).
Section 3): Track tensioning system

The track tensioning circuit has to be depressurized by completely opening (screwing out) the
safety valves in the undercarriage.
Section 4): Swing circuit
The swing system has to be depressurized with
help of the Minime-ports (test-ports).
Section 5): Cooling circuit
Depressurizing of the cooling circuit is not required.
Fig. 3
Operation of joysticks and pedals
The servo system is SHUT OFF, when the

driver is leaving the seat and thus the safety
switch is not operated (86, Fig. 4).
Page 8.2 - 2
Be extreme carefully when working

on hydraulic cylinders or pressure
lines of the equipment!
Even when following the safety
procedure, there may still a certain
pressure be left in the system!
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8.2
8.2.2

Bleeding air from the hydraulic
system
Bleed air from hydraulic pumps, hydraulic motors,

hydraulic cylinder and servo circuits:
before commissioning the excavator, e.g.

following major servicing/repair to the hydraulics, or after a long period out of operation.
after each oil change
Check the hydraulic system under load. Listen for

noises in the pumps of motors. Jerky movements
are an indication of air pockets in the system. Actuate all hydraulic functions several times to eliminate the air pockets.
The intake and running characteristics of the hydraulic components can otherwise be greatly affected. Hydraulic oil also serves as a lubricant for
these components. A dry run can lead to total
failure in a very short time.
Hydraulic pumps and -motors
Bleed air from pumps and motors after each oil
change. To bleed, fill clean oil through the highest
leakage oil port up to the bottom edge of the port.
Main pumps:
Swing pumps:
Fig. 5
Port (T, Fig. 5)

Port (T1, Fig. 5)
Bleeding points
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Page 8.2 - 3
8.2

The first operation of the cylinders has to be carried out with reduced oil flow, to extend or extract
the piston rod as slowly as possible.
Hydraulic cylinders
1
Servo circuit
On machines with pilot lines connected to the side
of the servo cap loosen the bleeder plug (5, Fig. 8)
with engine running until oil emerges without bubbling.
2
3
630254.SKD
Fig. 6
cylinder retracted
Before oil is admitted to a cylinder for the first time,

the piston must be in one of the two end positions.
In other words, the piston rod (1, Fig. 6 + 7) must
be either fully extended or fully retracted.
1
4
2
Fig. 8
Bleeding plugs
When the pilot lines are connected to the upper

ports of the servo caps the system is bleeding air
automatically.
630255.SKD
Fig. 7
cylinder extended
Always admit oil to the side of the cylinder where

the piston (2) is positioned.
With the rod (1) retracted, admit oil to the

piston end (3).
With the rod (1) extended, admit oil to the

rod end (4).
If the piston rod is in the half-way position (for installation reasons), admit oil to the rod side (4) first.
Page 8.2 - 4
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8.2
8.2.3
Flushing the hydraulic system
The following instructions are a brief compilation of

the procedures needed to clean/flush the hydraulic
system. The functions and the designs of the individual components are described in the relevant
sections of the Technical Handbook.
It is assumed that the machine remains on site
while flushing is being carried out. Hydraulic components, e.g. cylinders, should only be overhauled/repaired in an enclosed, clean workshop.
If the hydraulic component (e.g. pump or cylinder)
is damaged, the system(s) must be checked to see
whether any chips from the component have entered into the system. To do this, remove and inspect the magnetic rods and return flow filters.
2. Type and source of contamination
Blank metal particles:

Damaged bearings in pumps or motors.
Steel particles that look like machine turnings:

Internal components in a cylinder have
seized. Pieces of guide bands, O-rings and
seals are then often to be found in the filters.
Individual parts that appear to be pieces of

springs or valve plates:
Damaged valve(s).
These are only guidelines. When damage is extensive, all of these symptoms can appear at once.
1. Flushing is required under following conditions:
If the quantity, size and appearance of the

metal particles on the magnetic rod is different
to that arising in normal operation, or if they
are of completely different nature.
If the amount of magnetic and non-magnetic

debris caught in the return flow filter is
greater than usual.
Whenever a damaged hydraulic component

has been changed. Flushing can be limited to
the immediate and upline vicinities of the
component, as long as these can be isolated
completely.
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Page 8.2 - 5
8.2
3. Steps in case of pump damage
4. Steps in case of cylinder damage
3.1 Determine damaged pump, typical symptoms are:
Remove and check return flow filter.
Trace damaged cylinder. Remove, strip, clean

and check all components.
Also remove, strip, clean and check any cylinders connected in parallel.
When reassembling, cylinders are always to

be fitted with new seals and guides.
Fit the cylinder but do not connect the oil

lines.
Flush and check operation (see section 8).
If further contamination is found when flushing, remove all cylinders, and strip, clean and
inspect.
Drain and clean the oil.
chip indicator ON for main pump or swing

pump
vibrating hydraulic hoses
fluctuating pressure readings on gauges
abnormal noises
noticeable loss in output
excessive temperature
excessive load on engine(s)
3.2 Pumps without high pressure filters:
Remove return flow filters and check for contamination.
Check by-pass valve for correct seating

change valve if damaged.
Drain and clean oil tank.
Remove the damaged pump.
Remove and clean pump intake line.
Fit and bleed new pump.
If metal contamination from the pump has got

into the hydraulic system, carry out all of the
procedures from section 4 to 8 even if damage to other components has not been identified.
3.3 Pumps with high pressure filters
Remove the damaged pump.
Remove/clean HP filter(s).
Remove and clean line between pump and

HP filter.
Remove new pump, clean HP filter and clean

connecting lines.
Fit new return filter elements.
Fill oil through return flow filters.
Put machine back to work.
Page 8.2 - 6
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8.2
5. Steps in case of valve damage
6. Further steps
Locate the damaged valve(s).
If all of the missing parts are found, it is only

necessary to change the valve. Further action
is not needed.
If the hydraulic system has been extensively contaminated with chips, the following procedures are
also necessary:
If all of the parts cannot be found, continue

the search at the following points:
Return flow filter

Oil tank
Components downline of the damaged
valve, e.g. cylinders, valves, motors.
Strip, clean and re-install the primary relief

valves.
Strip, clean and re-install the secondary relief

valves.
Clean and check the cooling circuit if contamination is found in the oil tank:
Remove the cooler. Clean outside and inside in both directions of flow. The cooler is
to be changed if the contamination cannot
be completely removed from the cooling fins.
Flush the hydraulic lines or blow through
with compressed air.
RH 200 Diesel - 2471385e - (00) 10.99
Check and clean the servo control valves.
If hydraulically driven ancillary attachments

are fitted, their systems must also be
checked, especially if the cause of the contamination cannot be traced in the excavators
systems. Follow the relevant manufacturers
instructions.
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):
7.2 In case of pump damage (pump with high

pressure filter):
In this case flushing is not required, but check
operation (see section 8).
7.3 In case of cylinder damage (see section 4):
Fit new return flow element.
Short circuit the connections to the replacement cylinder.
Fit a new return flow element.
Fill fresh oil through the return flow filter.
Connect the lines to individual consumers

directly (short circuit). Disconnect lines that
are still connected to consumers.
Run the engine up to max. speed.

Wait until filter warning light has gone out and
the summon the cylinder function.
Run the cylinder in each direction for approx.

1 minute each. Shift briefly into neutral.
Each consumer should be flushed for at least
5 minutes.
Change return flow element and clean magnetic rod.
Repeat flushing procedure, with all consumers

being actuated briefly, one after the other.
Check return flow filter and magnetic rod

again.
Connect cylinder correctly and bleed air.
Check oil level in tank.
Put excavator back to work.
Run the engine up to max. speed.

Wait until the filter warning light has gone out
and then summon the relevant functions.
Summon each hydraulic function one at a
time and for approx. 1 minute in each direction. Shift several times briefly into neutral.
Each consumer should be run for at least 5
minutes.
Change return filter element and clean magnetic rod.
Repeat the flushing procedure. Again actuate

all consumers, one after the other, but this
time only for a short period.
Check filter and magnetic rod again.
Connect all consumers correctly and bleed air

from the system.
Page 8.2 - 8
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8.2
7.4 In case of damage of hydraulic motor:
8.
Fit new return flow element.
Short circuit the connections to the replacement motor.
After working for approx. 1 minute, check the magnetic rod. Clean the rod if contamination is found.
Summon hydraulic function of the replaced

motor in both directions for approx. 1 minute.
Shift several times briefly into neutral.
Change return flow element and clean magnetic rod.
Repeat flushing procedure, with all consumers

being actuated briefly, one after the other.
Check return flow filter and magnetic rod

again.
Connect motor correctly and bleed air.
RH 200 Diesel - 2471385e - (00) 10.99
Monitoring in operation
Check again in increasing intervals.
If the amount of contamination

does not drop noticeably, or if it
even increases, it must be assumed that the real cause of the
damage has not been located and
removed.
Check and flush again.
Page 8.2 - 9
8.2
Page 8.2 - 10
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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. 3 672 750 (03) in chapter 8.3.4
Position
Quantity
Engine
Engine module
Pump transfer gearbox
Engine module
Main pump A7V - SL - 1000
Pump gearbox
Swing pump A4V 250
Pump gearbox
Designation
Location
----
Servo pump
Pump gearbox
Charge pump for swing system
Pump gearbox
----
----
10
Cooling pump KP 5 - 300
Pump gearbox
11
Fan pump A 10 V for radiator fan
Pump gearbox
12 - 22
23
---2
24
Pump governing valve
Engine module
----
25
Proportional valve plate
Operator module
26
Solenoid valve bank
Operator module
27
----
28
Track tensioning block
Engine module
29
Distributor plate (main pumps)
Engine module
30
Pressure relief valve
Position 29
31
2 way valve
Position 29
32
High pressure filter
Position 29
33
----
34
Filter
35
3/2 way solenoid valve for emergency lowering
Operator module
36
Filter for proportional valve plate
Operator module
37
Check valve
38
Engine module
----
RH 200 Diesel (FS) - 3657771e.doc - (01) - 07.03
Page 8.3 - 1
8.3
Position
Quantity
39
40
Designation
----
Servo oil valve block
41
----
42
----
43
Check valve
44
Check valve
45
Engine module
Position 40
----
46
Block with 4/2 way solenoid valve
47
Shuttle valve
48 49
----
50
Hydraulic cylinder for access ladder
51
Control valve for access ladder
52
Accumulator for access ladder
53 55
56
Location
---1
57 - 59
Shuttle valve
Engine module
----
60
Hydraulic oil tank
61
Gate valve
Hydraulic oil tank
62
Return oil filter
Hydraulic oil tank
63
Bypass valve
Hydraulic oil tank
64
Tank line pressurizing valve
Hydraulic oil tank
65
66
Superstructure
---2
67 - 79
Check valve
Hydraulic oil tank
----
80
Hydraulic oil cooler
Oil cooler module
81
Fan motor
Oil cooler module
82
----
83
----
84
Fan
Oil cooler module
85
Distributor plate (oil cooling)
Oil cooler module
86
Position 85
87
Thermostat
Position 85
88
----
89
----
90
Travel block
Superstructure
91
Rotor
Superstructure
Page 8.3 - 2
RH 200 Diesel (FS) - 3657771e.doc - (01) - 07.03
8.3
Position
Quantity
92
Travel valve block RH
Rotor
93
Travel valve block LH
Rotor
94
Designation
Location
----
95
Travel retarder valve RH
Travel block
96
Travel retarder valve LH
Travel block
97
Anti cavitation valve
Travel block
98
----
99
----
100
Swing gearbox
101
Shuttle valve
102
Swing motor
Swing gearbox
103
Blocking valve
Engine module
104
Superstructure
----
105
Pressure governing valve
Engine module
106
Flushing valve
Engine module
107
High pressure filters
Superstructure
108
109
---1
110 - 119
Engine module
----
120
Travel gearbox
Undercarriage
121
Travel motor
Travel gearbox
122 - 124
----
125
Valve block (secondary relief)
126
127 - 129
Undercarriage
Position 125
----
130
Track tensioning cylinder
Undercarriage
131
Diaphragm accumulator
Undercarriage
132
----
133
Track tensioning group
134
135 - 139
Undercarriage
----
140
Gear motor for radiator fan
141
Block with anti cavitation valve for fan motor
4-spool control valve
Counterweight
Position 140
142 - 160
161
162
Boom
----
RH 200 Diesel (FS) - 3657771e.doc - (01) - 07.03
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
Bucket crowd cylinder
Boom
186
Clam cylinder
Backwall
187
Distributor with relief valve
Backwall
185
188
189
Page 8.3 - 4
---2
Distributor with check point
Boom
RH 200 Diesel (FS) - 3657771e.doc - (01) - 07.03
8.3
8.3.3

Components of the hydraulic
system of the RH 200 (FS)
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
Each of the 3 - stage spur - wheel gearboxes is

driven via a diaphragm coupling from one of the
engines and distributes engine output to the relevant hydraulic pumps.
Variable - displacement pump
Pos. 3
The 4 main pumps for working equipment and

travel movements are axial - piston bent axis
pumps with slipper bearing. Slipper bearings are
hydraulically swimming bearings that increase
the pump`s service life.
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).
Axial piston pump A 10 V
free
Pos. 8
free
Pos. 9
Oil cooling pump
Pos. 10
Four fixed - displacement gear - type pumps are

mounted onto the swing pumps (4). They constantly draw oil from the tank and pump it to the
fan motors and the oil coolers.
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
The 4 swing pumps to move the superstructure are

variable - displacement axial - piston swash plate
pumps. They are especially suited for operation in
closed circuits. The pump flow is infinitely variable
and increases from 0 to max while the pump
rotary group is being tilted out. If the swash plate is
de-stroked through the zero position, the direction of the oil flow is altered smoothly.
free
Pos. 7
The 2 pressure regulated axial piston pumps are

working as charge pumps for the swing circuit.
free
Swing pump
Pos. 6
Pos. 5
RH 200 Diesel (FS) - 3657771e.doc - (01) - 07.03
Pos. 23
The group comprises two proportional valves, two

metering connections and a housing.
These valves control the main pumps (3). They are
controlled by the microprocessor in the PMS system and govern the flows from the main pumps
depending upon the actual pressure. Each pair of
main pumps is governed by one proportional valve.
The valves are actuated by adjustable, oil - immersed DC solenoids and transform electrical
currents proportionally into hydraulic pressure.
Page 8.3 - 5
8.3
A solenoid current of 830 mA corresponds to a

pressure of 42 bar in the pump governors. A current of 230 mA corresponds to 10 bar.
The valves are pilot controlled and have variable

settings.
free
Pos. 24
2 - way valve
Pos. 25
Four valves for the logical co - ordination of the

main pumps (3).
They isolate the main pumps against one another
and prevent a stationary engine from being turned
over by it's pumps when only the other engine is
running.
The valve plate contains the proportional valves

and the 3/2 way valves for operation of cylinders,
swing and travel function.
Valve bank, compl.
Pos. 26
Pos. 31
The 2 - way valves are shifted by solenoids (24/Y

32 & Y 33).
Co - ordination of the valves - see solenoid valve
(24).
An assembly group comprising four solenoid

valves and a housing.
High - pressure filter

free
Pos. 27
Pos. 28
The valve is changing the track tensioning pressure between 50 bar and 70 bar mode.
Distributor plate for main pumps

Pos. 29
An assembly group comprising four primary pressure relief valves (36), four two - way valves (37),
four caps (38), four high - pressure filters (39) and
a housing with two check valves. The two check
valves isolate the main pumps (3/P1 & P2) from
the pumps (3/P3 & P4) when only the right - hand
engine is running.
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.
Page 8.3 - 6
Pos. 32
The high - pressure filters in the high - pressure

lines from the main pumps protect the downline
units (e. g. control blocks and cylinders) against
metal chips and particles from the pumps (3). 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
Pos. 34
Filter the oil flows from the 4 swing circuit charge

pumps.
3/2 way solenoid valve
Pos. 35
The solenoid valve is operated with a button in the

joy stick. It allows lowering of the attachment in
case of a sudden engine shut-down.
Filter
Pos. 36
This filter is filtering the oil which is feeding the

proportional valve plate (25).
RH 200 Diesel (FS) - 3657771e.doc - (01) - 07.03
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
The shuttle valve is connecting either the control

pressure for the travel brakes or the control pressure for the 2-speed operation to the travel motors.
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
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. 50
The hydraulic cylinder is operating the access

ladder.
Control valve
Pos. 51
With the control valve the cylinder for the access

ladder is operated.
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
These two valves prevent either of the servo

pumps (6) from affecting the other, e. g. when only
one engine is running, they prevent oil being
pumped back into the tank through the stationary
servo pump.
free
Pos. 45
Block with solenoid valve
Pos. 46
The block carries the solenoid valves for the logical

co - ordination of the four main pumps (3).
RH 200 Diesel (FS) - 3657771e.doc - (01) - 07.03
Pos. 56
Via this shuttle valve the Y1 & Y2 ports of the

pressure governing valve (54) are connected with
the pressure relief valve (55)
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
Gate valve for intake line
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.
The hydraulic oil coolers pass the heat generated

in the hydraulic system on to the atmosphere using
the air flows created by the fans.
Fan motor
Return flow filter
Pos. 81
Pos. 62
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.
By - pass valve
Pos. 80
Four fixed - displacement gear - type motors are

used to drive the fans on the oil coolers.
free
Pos. 82
free
Pos. 83
Fan
Pos. 84
Pos. 63
The six by - pass valves open at a pressure of 1.5

bar and prevent the return flow filters (62) bursting,
e. g. due to clogging. Oil then flows unfiltered back
into the tank.
The fan produces the air flow to cool down the

hydraulic oil.
Pos. 64
Distributor plate for oil cooling Pos. 85
These four 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 system.
Each of the two plates contains two thermostats

(87), two pressure relief valves (86) and two check
valves. The check valves function as anti - cavitation valves while the engines are being shut down.
free
Pos. 65
Check valve
Pos. 66
These two valves have a cracking pressure of

approx. 1 bar and prevent oil escaping from:
the servo caps on control block (161) for boom and
stick float functions (164)
free
Page 8.3 - 8
Pos. 67 - 79
Pos. 86
The two pilot controlled, variable setting pressure

relief valves protect the cooler circuit against overpressure, e. g. in case of a line blockage.
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
See travel retarder valve (95).
Travel block
Pos. 90
Anti - cavitation valve
A complete group comprising rotor (91), the

Travel spools (92 & 93), the travel retarder valves
(95 & 96), anti - cavitation valves (97) and cover
plates.
Rotor
Pos. 91
Conducts hydraulic oil flows between superstructure and undercarriage. The seven ring channels
are for:
Pos. 96
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
Travel (4 channels)
Track parking brakes/Track motor adjustment
The gearbox are 2 - stage planetary reducers.
Track tensioning
Leakage oil
The spring applied multi disc brakes on the swing

gearboxes serve to hold the superstructure stationary (parking brakes). They are actuated by a
toggle switch in the cab.
The brake must only be actuated when the superstructure has stopped swinging.
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).
RH 200 Diesel (FS) - 3657771e.doc - (01) - 07.03
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
The swing motors are 40, fixed - displacement

axial piston pumps whose output speed is proportional to the flow of oil. The output torque increases
with the pressure drop over the motor.
Blocking valve
Pos. 103
These valves are leak free and are opened fully by

oil from the servo pumps (6) as soon as the enPage 8.3 - 9
8.3
gines are running. If one of the engines is shut

down, the relevant blocking valves close absolutely
tightly and prevent the stationary engine from being turned over by pressure oil acting in reverse
through swing motor, swing pump and transfer
gearbox.
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 setting.
free
free
Pos. 104
Pos. 105
Governs the torque in the closed - loop swing circuit.

The valve governs the pressure and direction of oil
flow (and therefore extent and direction of the
swing motors` output ) depending upon the selected control pressure
The radio between control pressure and working
pressure is approx. 1 : 12, i. e. 10 bar control pressure on ports (Y 1 or Y 2) corresponds to 120 bar
operating pressure in the swing circuit.
Flushing valve
Pos. 106
The valve flushes the oil in the closed - loop swing

circuit. Each time a swing function is summoned, a
certain amount of oil is flushed out of the low pressure side. The charge pumps mounted on the
swing pumps replace this oil with filtered, cooled oil
from the tank.
Travel gearbox
Pos. 110 - 119

Pos. 120
3 - stage planetary reducer with integrated parking

brake.
The four track parking brakes are wet, multi - disk
brakes that are engaged under spring force and
released by hydraulic pressure (18 - 20 bar).
Travel motor
Pos. 121
The four track motors are variable - displacement,

bent - axis motors with tandem bearing arrangements. Servo pressure at port (X) sets the motors
to either of two mechanically limited tilt angles. The
maximum tilt angle is selected when servo pressure is O . The minimum tilt angle is reached
when servo pressure rises above 40 - 45 bar.
max. tilt angle = max. motor displacement = max.
output torque = min. output speed
min. tilt angle = min. motor displacement = min.
output torque = max. output speed
The governing pressure (at least 15 bar) is tapped
out of the respective high - pressure side using
check valves.
Pos. 107
free
The two HP filters in the swing circuit clean both

sides of the swing circuit. The check valves in the
filter heads lead the oil flows to the correct side to
flow through the filters. This is necessary as the
high and low - pressure sections of the circuit
change depending upon the direction of swing.
free
Pos. 108
Pos. 109
Secondary relief block
Pos. 122 - 124

Pos. 125
Assembly group comprising four pressure relief

valves (126), two metering connections and a
housing.
Pos. 126
Secondary pressure relief valves for the four track

motors that protect the motors against external
Page 8.3 - 10
RH 200 Diesel (FS) - 3657771e.doc - (01) - 07.03
8.3
forces. Excess oil is cracked off into the relevant

low pressure side of the motors.
free
4-spool control block
free
Pos. 130
Pos. 131
The nitrogen accumulators act as shock absorbers

to dampen external forces acting on the crawler
tracks.
free
Pos. 132
Pos. 133
The block contains the valves for the automatic

track tensioning system.
Fan motor
Servo controlled 4-spool blocks for the functions:

Boom, Stick, Shovel tip and Shovel dump.
With anti - cavitation valves and secondary relief
valves. They are pilot controlled with variable settings.
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
Pos. 127 - 129
Single - acting (plunger) cylinders that keep the

crawler tracks tensioned.
Pos. 142 - 160
Pos. 135 - 139

Pos. 140
The gear motor with anti-cavitation valve is driving

the fans for the radiators.
free
Pos. 165
free
Pos. 166
Check valve
Pos. 167
These two check valves protect the two HP filters

(32) for main pumps (P 3 & P 4). When the excavator is being run on only one engine, the flows
from the relevant main pumps would run through
the control blocks (161) and then into the filters in
the wrong direction. This would destroy the filters.
free
Pos. 168
Pos. 141
free
Pos. 169
The check valve acts as an anti-cavitation valve for

the fan motor when the engine is shut down.
free
Pos. 170- 181
RH 200 Diesel (FS) - 3657771e.doc - (01) - 07.03
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
The block is installed in the backwall and contains

a pressure relief valve.
The pressure relief valve secures the clamshellcylinder rod-side against pressure peaks.
free
Pos. 188
Distributor
Pos. 189
The block allows for pressure balance between

both bucket crowd cylinders (184).
Page 8.3 - 12
RH 200 Diesel (FS) - 3657771e.doc - (01) - 07.03
8.3
8.3.4

Hydraulic circuit diagram
The position nos. in the circuit diagram PartNo. 3 672 750 are referred to chapter 8.3.2.
RH 200 Diesel (FS) - 3657771e.doc - (01) - 07.03
Page 8.3 - 13
8.3
Page 8.3 - 14
RH 200 Diesel (FS) - 3657771e.doc - (01) - 07.03
8.3
DESCRIPTION OF THE HYDRAULIC SYSTEM - BH
8.3
Description of the hydraulic system
8.3.1
Technical data
The technical data of the hydraulic system are listed in chapter 2 Technical Data.
8.3.2
Components of the circuit diagram
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
Swing pump A4V 250
Pump gearbox
Designation
Location
----
Servo pump
Pump gearbox
Pump gearbox
----
----
10
Cooling pump KP 5 - 300
Pump gearbox
11
Fan pump A 10 V for radiator fan
Pump gearbox
12 - 22
23
---2
24
Engine module
----
25
Operator module
26
Solenoid valve bank
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
3/2 way solenoid valve for emergency lowering
Operator module
36
Operator module
37
Check valve
38
Engine module
----
RH 200 Diesel (BH) - 3657772e.doc - (01) - 07.03
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
Block with 4/2 way solenoid valve
47
Shuttle valve
48 49
----
50
Hydraulic cylinder for access ladder
51
Control valve for access ladder
52
Accumulator for access ladder
53 55
56
Location
---1
57 - 59
Shuttle valve
Engine module
----
60
Hydraulic oil tank
61
Gate valve
Hydraulic oil tank
62
Return oil filter
Hydraulic oil tank
63
Bypass valve
Hydraulic oil tank
64
Hydraulic oil tank
65
66
Superstructure
---2
67 - 79
Check valve
Hydraulic oil tank
----
80
Oil cooler module
81
Fan motor
Oil cooler module
82
----
83
----
84
Fan
Oil cooler module
85
Distributor plate (oil cooling)
Oil cooler module
86
Position 85
87
Thermostat
Position 85
88
----
89
----
90
Travel block
Superstructure
91
Rotor
Superstructure
Page 8.3 - 2
RH 200 Diesel (BH) - 3657772e.doc - (01) - 07.03
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
High pressure filters
Superstructure
108
109
---1
110 - 119
Engine module
----
120
Travel gearbox
Undercarriage
121
Travel motor
Travel gearbox
122 - 124
----
125
Valve block (secondary relief)
126
127 - 129
Undercarriage
Position 125
----
130
Undercarriage
131
Undercarriage
132
----
133
Track tensioning group
134
135 - 139
Undercarriage
----
140
Gear motor for radiator fan
141
Block with anti cavitation valve for fan motor
Counterweight
Position 140
142 - 160
161
162
Boom
----
RH 200 Diesel (BH) - 3657772e.doc - (01) - 07.03
Page 8.3 - 3
8.3
Position
Quantity
163
164
Designation
----
Float valve
165
----
166
----
167
Location
Check valve
168
----
169
----
170
Throttled check valve
171
172 - 181
Boom
Pos. 161 & 164
----
182
Boom cylinder
Boom
183
Stick cylinder
Boom
184
185
---2
Bucket cylinder
186
----
187
----
188
Page 8.3 - 4
Distributor
Stick
Boom
RH 200 Diesel (BH) - 3657772e.doc - (01) - 07.03
8.3
8.3.3

Components of the hydraulic
system of the RH 200 (BH)
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
Each of the 3 - stage spur - wheel gearboxes is

driven via a diaphragm coupling from one of the
engines and distributes engine output to the relevant hydraulic pumps.
Variable - displacement pump
Pos. 3
The 4 main pumps for working equipment and

travel movements are axial - piston bent axis
pumps with slipper bearing. Slipper bearings are
hydraulically swimming bearings that increase
the pump`s service life.
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).
Axial piston pump A 10 V
free
Pos. 8
free
Pos. 9
Oil cooling pump
Pos. 10
Four fixed - displacement gear - type pumps are

mounted onto the swing pumps (4). They constantly draw oil from the tank and pump it to the
fan motors and the oil coolers.
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
The 4 swing pumps to move the superstructure are

variable - displacement axial - piston swash plate
pumps. They are especially suited for operation in
closed circuits. The pump flow is infinitely variable
and increases from 0 to max while the pump
rotary group is being tilted out. If the swash plate is
de-stroked through the zero position, the direction of the oil flow is altered smoothly.
free
Pos. 7
The 2 pressure regulated axial piston pumps are

working as charge pumps for the swing circuit.
free
Swing pump
Pos. 6
Pos. 5
RH 200 Diesel (BH) - 3657772e.doc - (01) - 07.03
Pos. 23
The group comprises two proportional valves, two

metering connections and a housing.
These valves control the main pumps (3). They are
controlled by the microprocessor in the PMS system and govern the flows from the main pumps
depending upon the actual pressure. Each pair of
main pumps is governed by one proportional valve.
The valves are actuated by adjustable, oil - immersed DC solenoids and transform electrical
currents proportionally into hydraulic pressure.
Page 8.3 - 5
8.3
A solenoid current of 830 mA corresponds to a

pressure of 42 bar in the pump governors. A current of 230 mA corresponds to 10 bar.
The valves are pilot controlled and have variable

settings.
free
Pos. 24
2 - way valve
Pos. 25

main pumps (3).
running.
The valve plate contains the proportional valves

and the 3/2 way valves for operation of cylinders,
swing and travel function.
Valve bank, compl.
Pos. 26
Pos. 31

32 & Y 33).
(24).
An assembly group comprising four solenoid

valves and a housing.

free
Pos. 27
Pos. 28
The valve is changing the track tensioning pressure between 50 bar and 70 bar mode.
Distributor plate for main pumps

Pos. 29
four caps (38), four high - pressure filters (39) and
a housing with two check valves. The two check
valves isolate the main pumps (3/P1 & P2) from
the pumps (3/P3 + P4) when only the right - hand
engine is running.
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.
Page 8.3 - 6
Pos. 32

metal chips and particles from the pumps (3).
Other than in the return flow filters (29), the oil
flows through the HP filters from outside to in.
free
Pos. 33
Filter
Pos. 34
Filter the oil flows from the 4 swing circuit charge

pumps.
3/2 way solenoid valve
Pos. 35
The solenoid valve is operated with a button in the

joy stick. It allows lowering of the attachment in
case of a sudden engine shut-down.
Filter
Pos. 36
This filter is filtering the oil which is feeding the

proportional valve plate (25).
RH 200 Diesel (BH) - 3657772e.doc - (01) - 07.03
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
The shuttle valve is connecting either the control

pressure for the travel brakes or the control pressure for the 2-speed operation to the travel motors.
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
Block with solenoid valve
Pos. 46
Hydraulic oil tank
RH 200 Diesel (BH) - 3657772e.doc - (01) - 07.03
Pos. 50
With the control valve the cylinder for the access

ladder is operated.

servo pump.
The block carries the solenoid valves for the logical

co - ordination of the four main pumps (3).
Pos. 48 - 49
The hydraulic cylinder is operating the access

ladder.
Accumulator
at approx. 1 bar.
Pos. 47
Pos. 53 - 55
Pos. 56
Via this shuttle valve the Y1 & Y2 ports of the

pressure governing valve (54) are connected with
the pressure relief valve (55)
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
Gate valve for intake line
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.
Pass the heat generated in the hydraulic system

on to the atmosphere using the air flows created
by the fans.
Fan motor
Return flow filter
Pos. 81
Pos. 62
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.
By - pass valve
Pos. 80
Pos. 63
The six by - pass valves open at a pressure of 1.5

bar and prevent the return flow filters (62) bursting,
e. g. due to clogging. Oil then flows unfiltered back
into the tank.
Four fixed - displacement gear - type motors are

used to drive the fans on the oil coolers.
free
Pos. 82
free
Pos. 83
Fan
Pos. 84
The fan produces the air flow to cool down the

hydraulic oil.
Distributor plate for oil cooling Pos. 85

Pos. 64
These four 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 system.

free
Pos. 65
Pos. 86
Check valve
Pos. 66

These two valves have a cracking pressure of

approx. 1 bar and prevent oil escaping from:
the servo caps on control block (161) for boom and
stick float functions (164)
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.
RH 200 Diesel (BH) - 3657772e.doc - (01) - 07.03
8.3
free
Pos. 88
free
Pos. 89
See travel retarder valve (95).
Travel block
Pos. 90
Anti - cavitation valve
A complete group comprising rotor (91), the

Travel spools (92 & 93), the travel retarder valves
(95 & 96), anti - cavitation valves (97) and cover
plates.
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
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
Swing gearbox
Pos. 98
Pos. 100
The gearbox are 2 - stage planetary reducers.

The spring applied multi disc brakes on the swing
gearboxes serve to hold the superstructure stationary (parking brakes). They are actuated by a
toggle switch in the cab.
The brake must only be actuated when the superstructure has stopped swinging.
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).
RH 200 Diesel (BH) - 3657772e.doc - (01) - 07.03
The swing motors are 40, fixed - displacement

axial piston pumps whose output speed is proportional to the flow of oil. The output torque increases
with the pressure drop over the motor.
Blocking valve
Pos. 103
These valves are leak free and are opened fully by

oil from the servo pumps (6) as soon as the engines are running. If one of the engines is shut
down, the relevant blocking valves close absolutely
tightly and prevent the stationary engine from being turned over by pressure oil acting in reverse
through swing motor, swing pump and transfer
gearbox.
free
Pos. 104
Page 8.3 - 9
8.3
Pos. 105
Governs the torque in the closed - loop swing circuit.

The valve governs the pressure and direction of oil
flow (and therefore extent and direction of the
swing motors` output ) depending upon the selected control pressure
The radio between control pressure and working
pressure is approx. 1 : 12, i. e. 10 bar control pressure on ports (Y 1 or Y 2) corresponds to 120 bar
operating pressure in the swing circuit.
The four track parking brakes are wet, multi - disk

brakes that are engaged under spring force and
released by hydraulic pressure (18 - 20 bar).
Travel motor
Pos. 121
The four track motors are variable - displacement,

bent - axis motors with tandem bearing arrangements. Servo pressure at port (X) sets the motors
to either of two mechanically limited tilt angles. The
maximum tilt angle is selected when servo pressure is O . The minimum tilt angle is reached
when servo pressure rises above 40 - 45 bar.
Pos. 106
max. tilt angle = max. motor displacement = max.

output torque = min. output speed
The valve flushes the oil in the closed - loop swing

circuit. Each time a swing function is summoned, a
certain amount of oil is flushed out of the low pressure side. The charge pumps mounted on the
swing pumps replace this oil with filtered, cooled oil
from the tank.
min. tilt angle = min. motor displacement = min.

output torque = max. output speed
Flushing valve
Pos. 107
The two HP filters in the swing circuit clean both

sides of the swing circuit. The check valves in the
filter heads lead the oil flows to the correct side to
flow through the filters. This is necessary as the
high and low - pressure sections of the circuit
change depending upon the direction of swing.
The governing pressure (at least 15 bar) is tapped

out of the respective high - pressure side using
check valves.
free
Pos. 122 - 124

Pos. 125

valves (77), two metering connections and a
housing.
free
Pos. 108
Pos. 109

lowpressure side of the motors.
The valve limits the pressure that controls the

pressure governing valve (54) to max. 31 bar. The
valve is direct acting and has a variable setting.
free
free
Pos. 120
3 - stage planetary reducer with integrated parking

brake.
Page 8.3 - 10
Pos. 127 - 129
Pos. 110 - 119

Travel gearbox
Pos. 126
Pos. 130
Single - acting (plunger) cylinders that keep the

crawler tracks tensioned.
RH 200 Diesel (BH) - 3657772e.doc - (01) - 07.03
8.3
Pos. 131
free
Pos. 162
The nitrogen accumulators act as shock absorbers

to dampen external forces acting on the crawler
tracks.
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).
The block contains the valves for the automatic

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
Pos. 135 - 139

Pos. 140
The gear motor with anti-cavitation valve is driving

the fans for the radiators.
free
Pos. 168
free
Pos. 169
Pos. 170
Pos. 141
The check valve acts as an anti-cavitation valve for

the fan motor when the engine is shut down.
free
These two check valves protect the two HP filters

(32) for main pumps (P 3 & P 4). When the excavator is being run on only one engine, the flows
from the relevant main pumps would run through
the control blocks (161) and then into the filters in
the wrong direction. This would destroy the filters.
The check valves in the cylinder lines ensure

smooth operation of the attachment.
Pos. 142 - 160

Pos. 161
Servo controlled 4-spool blocks for the functions:

Boom, Stick, Shovel tip and Shovel dump.
With anti - cavitation valves and secondary relief
valves. They are pilot controlled with variable settings.
RH 200 Diesel (BH) - 3657772e.doc - (01) - 07.03
Pos. 171
The check valves in the cylinder lines ensure

smooth operation of the attachment.
free
Pos. 172- 181
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
The block allows for pressure balance between

both stick cylinders (183) and also between both
bucket cylinders (185).
Page 8.3 - 12
RH 200 Diesel (BH) - 3657772e.doc - (01) - 07.03
8.3
8.3.4

Hydraulic circuit diagram
The position nos. in the circuit diagram PartNo. 3 672 770 are referred to chapter 8.3.2.
RH 200 Diesel (BH) - 3657772e.doc - (01) - 07.03
Page 8.3 - 13
8.3
Page 8.3 - 14
RH 200 Diesel (BH) - 3657772e.doc - (01) - 07.03
8.4
HYDRAULIC COMPONENTS
8.4
Hydraulic components
8.4.1
Main pumps
Each pump is equipped with a pressure-controlled

regulator (1, Fig. 1) with a control range of between
7,5 and 42,5 bar. At a control pressure of 42,5 bar
at the X1 port of the regulator, the pump is swivelled out to maximum flow-rate. At a control pressure of 7,5 bar, it is swivelled back to "zero" flowrate.
The regulator is controlled by an electro-magnetic
proportional valve connected to the electronic loadlimit regulator. (See also THB "PMS - Pump Managing System").
If the pressure at the connection (X 1) is reduced

by the load limit regulator, the regulator piston (1)
is operated by spring force. The chambers (A + C)
of the regulator cylinder (2) are interconnected. As
piston (B) has adjusting areas of different sizes,
the forces in chamber (A) are predominant. The
pump is reset to a smaller output until there is a
balance of forces.
With the restrictors (3) the swing speed of the
pump has been set at the factory.
Pressure cut-off
When the maximum working pressure of 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
Main pump regulator
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
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
RH 200 Diesel - 3657769e.doc (02) 09.03
8.4
8.4.3
Rotor
The rotor is connecting the hydraulic systems of

the superstructure and the undercarriage.
The components of the rotor are listed in table 2

and shown in fig. 1 & 2.
The numbers of the ports and oil grooves and their

function is listed in table 1.
Numbering of ports
Ref. No.
Quantity
Designation
Further remarks
Groove for travelling
left reverse
right forward
right reverse
Groove for track tensioning system
Groove for travel parking brake
Groove for leakage oil
Weight
[kg]
left forward
Table 1
Fig. 1
RH 200 Diesel - 3657769e.doc - (02) 09.03
Grooves in rotor
Page 8.4 - 3
8.4
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
Cyl. Head bolt M 10 x 30 - 8.8
Tightening torque Md = 46 Nm
25
Cyl. Head bolt M 16 x 45 - 8.8
26
Lifting eye M 16
27
Hex. bolt M 10 x 30 - 8.8
28
Straight pin
29
Sealing ring
30
Plug
Table 2
Page 8.4 - 4
RH 200 Diesel - 3657769e.doc (02) 09.03
8.4
24, 25, 27
Fig. 2
RH 200 Diesel - 3657769e.doc - (02) 09.03
Rotor
Page 8.4 - 5
8.4
24, 25, 27
Fig. 3
Page 8.4 - 6
Rotor
RH 200 Diesel - 3657769e.doc (02) 09.03
8.4
Remove rotor seals

If worn seals are removed from the rotor housing
with a mandrel or a marking tool, the edges or
groove boards in the rotor housing might be damaged.
This can be prevented by using a bracket made of
welding wire 4 mm, against which the mandrel is
supported as the seals are lifted out.
Removal (Figs. 4 + 5)
Knock mandrel (14) carefully into sealing ring

(12).
Insert wire bracket (13) over mandrel (14) and

push to centre of groove board.
Lever sealing ring (12) with mandrel (14) out of

groove, then press or draw out of rotor housing
(10).
Check groove boards (11) and groove edges

for damage, deburring carefully and then
cleaning thoroughly if necessary.
RH 200 Diesel - 3657769e.doc - (02) 09.03
Fig. 4
Removing the rotor seals
Fig. 5
Removal of the rotor seals
Page 8.4 - 7
8.4
8.4.4
Hydraulic valves
Ref.-no.
Quantity
Pos. 25
Designation
Servo valve block
Housing
16
3/2 way valve
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
electro-hydraulic proportional valve
----
----
16
O-ring
32
Plug
10
Plug
11
Plug
12
12
Plug
13
16
Plug
Table 1
Page 8.4 - 8
RH 200 Diesel - 3657769e.doc (02) 09.03
8.4
Fig. 1
RH 200 Diesel - 3657769e.doc - (02) 09.03
Servo valve block wit proportional solenoids
Page 8.4 - 9
8.4
Fig. 2
Page 8.4 - 10
Servo valve block wit proportional solenoids
RH 200 Diesel - 3657769e.doc (02) 09.03
8.4
Pos. 26/1
The valve block contains 4 solenoid valves.

Both ports P1 and P2 are connected to the auxiliary system (70 bar).
Solenoid valve block
The solenoid valves operate the following functions:
Ref.-no.
Quantity
Outlet A5: not used.

Outlet A6: Pressure boost of main pump 3 for
function open clam.
Outlet A7: Pressure boost of main pump 1 for
function open clam.
Outlet A8: Actuation of the swing parking
brake.
Designation
further remarks
Electrical data:
Voltage: 24 V
Output: 16 W
Switch-on time: 100 %
Weight
[kg]
Hydraulical data:
Max. pressure: 210 bar
Rated flow (p = 5 bar):
26 l/min.
Max. flow: 35 l/min.
Table 1
Fig. 1
RH 200 Diesel - 3657769e.doc - (02) 09.03
Page 8.4 - 11
8.4
Pos. 26/2
The valve block contains 4 solenoid valves.

The port P1 for then solenoid valves Y3 & Y4 is
connected to the auxiliary system (70 bar).
The port P2 for then solenoid valves Y1 & Y2 is
connected to the servo system (40 bar).
The solenoid valves operate the following functions:
Ref.-no.
Quantity
Outlet A1: Actuation of the travel parking

brake.
Outlet A2: not used.
Outlet A3: Shifting of the 2-speed travel motors.
Outlet A4: Travel pressure increase.
Designation
further remarks
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
RH 200 Diesel - 3657769e.doc (02) 09.03
8.4
Pump distributor block
Pos. 29
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.
Primary pressure relief valves
Pos. 30
Limit the maximum pressure that can be reached

by the pumps (3) and therefore protect the primary
movers against overload.

32 & Y 33).
(46).

metal chips and particles from the pumps (3).
Other than in the return flow filters, the oil flows
through the HP filters from outside to in.
Check valves
2 - way valves
Pos. 31

main pumps (3).
running.
Designation
Pos. 32
Pos. 43

at approx. 1 bar.
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
RH 200 Diesel - 3657769e.doc - (02) 09.03
Minime M 14 x 1,5
Page 8.4 - 13
8.4
Ref.-no.
Quantity
19
O-ring
20
Sealing ring
21 - 24
Designation
further remarks
Weight
[kg]
----
25
Cyl. head bolt M 5 x 16 8.8
Tightening torque Md = 4,9 Nm
26
27
16
Hex. Bolt M 16 x 255 10.9
28
29
Hex. Bolt M 8 x 75 8.8
30
Lifting eye M 16
Table 1
25, 26, 27,

28, 29
Fig. 1
Page 8.4 - 14
RH 200 Diesel - 3657769e.doc (02) 09.03
8.4
25, 26, 27,

28, 29
Fig. 2
RH 200 Diesel - 3657769e.doc - (02) 09.03
Page 8.4 - 15
8.4
Pos. 40
Servo circuit pressure relief valve
The complete assembly group comprises two filters, the differential pressure valve, a pressure
relief valve, two check valves and a housing.
The valve limits the pressure in the servo circuit to

40 bar. The valve is pilot controlled and has a variable setting.
Filter
Check valves
Two filters clean the oil flows of the two servo

pumps (6).

servo pump.
Differential pressure (booster) valve

This valve increases the servo pressure from 40 to
70 bar. The higher pressure is needed to regulate
the main pumps (3) and to shift the travel motors
(121).
Ref.-no.
Quantity
Designation
Housing
Differential pressure valve
Pos. 16
Pos. 17
Filter
Pos. 11
Test point
Minimess M 14 x 1,5
Check valve
Pos. 18
O-ring
10
Filter element
11
O-ring
12
Cylinder head bolt M 6 x 60 8.8
13
Plug M 16 x 1,5
14
Bushing
15
Cyl. head bolt M x
16
Locking plate
17
O-ring
18
O-ring
19
O-ring
further remarks
Weight
[kg]
Table 1
Page 8.4 - 16
RH 200 Diesel - 3657769e.doc (02) 09.03
8.4
Fig. 1
RH 200 Diesel - 3657769e.doc - (02) 09.03
Valve block servo- and auxiliary pressure
Page 8.4 - 17
8.4
Fig. 2
Page 8.4 - 18
Valve block servo- and auxiliary pressure
RH 200 Diesel - 3657769e.doc (02) 09.03
8.4
Bypass valve
Pos. 63
The by - pass valve opens at a pressure of 1.5 bar

and prevents the return flow filters (62) bursting, e.
g. due to clogging. Oil then flows unfiltered back
into the tank.
Ref.-no.
Quantity
Designation
Plate
Bottom plate
Housing
Valve body
Spring
O-ring
Seal
further remarks
Weight
[kg]
Table 1
Fig. 1
RH 200 Diesel - 3657769e.doc - (02) 09.03
Bypass valve
Page 8.4 - 19
8.4
Tank-line pre-charging valve
Pos. 64
This ensures that sufficient oil is available at the

anti-cavitation valves of cylinders and travel valves.
The tank-line pre-charging valve pre-pressurises

the oil in the return lines. The valve is set 12 bar.
Ref.-no.
Quantity
Designation
Valve housing
Flange
Lid
Bushing
Piston
----
----
further remarks
Weight
[kg]
9
10
Sealing ring
11
O-ring
12
O-ring
13
Cylinder head bolt M 6 x 35
Table 1
Page 8.4 - 20
RH 200 Diesel - 3657769e.doc (02) 09.03
8.4
6, 13
Fig. 1
Tank-line pre charging valve
6, 13
Fig. 2
RH 200 Diesel - 3657769e.doc - (02) 09.03
Tank-line pre charging valve
Page 8.4 - 21
8.4
Valve block for oil cooling
Pos. 85

Pressure relief valves
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
Opening pressure: 4 bar
----
Spring
Spring
10
----
11
----
12
----
13
Test point
Minime M 14 x 1,5
14
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
RH 200 Diesel - 3657769e.doc (02) 09.03
8.4
14, 20
Fig. 1
RH 200 Diesel - 3657769e.doc - (02) 09.03
Hydraulic oil cooling - thermostat valve
Page 8.4 - 23
8.4
14
Fig. 2
Page 8.4 - 24
Hydraulic oil cooling - thermostat valve
RH 200 Diesel - 3657769e.doc (02) 09.03
8.4
Travel block, compl.
Pos. 90
(93), anti-cavitation valves (97), travel retarder

valve RH (95) and travel retarder valve LH (96).
The complete travel block comprises rotor (91),

travel control block RH (92) travel control block LH
Ref.-no.
Quantity
Rotor
Cover plate
Designation
further remarks
Weight
[kg]
----
16
Cyl. Head bolt M 10 x 60 10.9
10
Cyl. Head bolt M 16 x 220 10.9
11
10
Hex. bolt M 12 x 120 8.8
Table 1
RH 200 Diesel - 3657769e.doc - (02) 09.03
Page 8.4 - 25
8.4
9, 10, 11
Fig. 1
Page 8.4 - 26
Rotor mounting components
RH 200 Diesel - 3657769e.doc (02) 09.03
8.4
Travel control block RH
Pos. 92
Servo-controlled single control block for operation

of the right track.
Ref.-no.
Quantity
2
3
Designation
Travel control block LH

See Pos. 92
further remarks
Spool
Bonnet with spring assembly

----
Travel valve block
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
36
37
Eye Bolt M 12
1
39
40
Weight
[kg]
----
38
Pos. 93
Plug
----
Sealing ring
Table 1
RH 200 Diesel - 3657769e.doc - (02) 09.03
Page 8.4 - 27
8.4
35, 36
Fig. 1
Page 8.4 - 28
Travel valve block
RH 200 Diesel - 3657769e.doc (02) 09.03
8.4
35, 36
Fig. 2
RH 200 Diesel - 3657769e.doc - (02) 09.03
Travel valve block
Page 8.4 - 29
8.4
Travel retarder valves
Pos. 95 & 96
One travel retarder valve each is flanged to the

travel control blocks (Pos. 92 & 93). When going
downhill the pressure from the pumps to the travel
motors decreases and the travel retarder valves
cause the oil flow returning from the travel motor to
the tank to be reduced. This prevents the excavator from picking up inadmissible speed.
Ref.-no.
Quantity
Guide
Travel retarder valve
Cap
Spool
5
6
Designation
26
Plug
----
10
Spring
11
Bleeder valve
12
Valve
O-ring
13
Install valve (A) with Omnifit

Part-no. 900 257
----
15 - 25
----
26
Hex. bolt M 8 x 75 8.8
27
Hex. bolt M 8 x 50 8.8
28
----
29
----
30
Weight
[kg]
----
7-9
14
further remarks
Eye bolt M 12
Table 1
Page 8.4 - 30
RH 200 Diesel - 3657769e.doc (02) 09.03
8.4
26, 27
12
Fig. 1
RH 200 Diesel - 3657769e.doc - (02) 09.03
Page 8.4 - 31
8.4
26, 27
Fig. 2
Page 8.4 - 32
12
RH 200 Diesel - 3657769e.doc (02) 09.03
8.4
Pos. 103
closed and prevent the engine from being driven

via the swing pumps and the pump gearbox.
The 2 blocking valves belonging to each drive unit

are controlled and opened by the servo pumps of
the drive unit when the engine is running. When
the engine is stopped, the locking valves are
The ports are marked with A, B and R.

The orifice (2) is installed with Loctite (20) and
punch-secured.
Blocking valve
Ref.-no.
Quantity
Valve
Orifice
Check valve cone
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
2/2 wax valve
16
Sealing kit
17
----
18
Cyl.-head bolt M 6 x 30 8.8
19
Cyl.-head bolt M 5 x 30 8.8
20
Loctite
Table 1
RH 200 Diesel - 3657769e.doc - (02) 09.03
Page 8.4 - 33
8.4
Fig. 1
Blocking valve
Fig. 2
Blocking valve
Page 8.4 - 34
RH 200 Diesel - 3657769e.doc (02) 09.03
8.4
Pos. 105
The pressure balance valve continuously varies

the magnitude and the direction of the swing pressure and thus the magnitude and the direction of
the momentum at the swing motors depending on
the pre-selected control pressure.
Ref.-no.
Quantity
Designation
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]
To adjust the centre position of

the main spool
Table 1
Fig. 1
RH 200 Diesel - 3657769e.doc - (02) 09.03
Pressure balance valve
Page 8.4 - 35
8.4
Flushing valve
Pos. 106
The flushing- and feed-pressure valve ejects a

defined amount of oil from the close swing circuit at
the low-pressure side during each swing operation.
Ref. no.
Quantity
Designation
Valve housing
Sealing ring
Plug
Sealing ring
Orifice
Relief valve
Spool
The corresponding amount of filtered and cooled

oil from the hydraulic reservoir is fed back into the
swing system by the charging pumps.
further remarks
Weight
[kg]
Table 1
Fig. 1
Page 8.4 - 36
Flushing valve
RH 200 Diesel - 3657769e.doc (02) 09.03
8.4
Pos. 107
The high pressure filters are installed between the

two front swing motors and are separating each
two swing motors and each two swing pumps from
the other components. Thus 50 % of the swing
Ref.-no.
Quantity
Designation
Housing
O-ring
Filter element
O-ring
Bushing
O-ring
Check valve
Spring
10
Filter head
11
Sealing ring
12
Hex. head bolt
13
Sealing ring
14
Plug
system is protected against contamination in case

of a swing pump or swing motor failure.
Because the oil flow is passing through the filter in
both directions the filter head contains 2 check
valves to ensure that the oil is flowing always in
one direction through the filter element.
further remarks
Weight
[kg]
18
Table 1
RH 200 Diesel - 3657769e.doc - (02) 09.03
Page 8.4 - 37
8.4
Fig. 1
Page 8.4 - 38
Filter for swing system
RH 200 Diesel - 3657769e.doc (02) 09.03
8.4
Pos. 125

valves (126), 4 test points and a housing.
Ref.-no.
Quantity
Designation
Pos. 126

low pressure side of the motors.
further remarks
Weight
[kg]
Housing
----
Pressure relief valve (Pos. 77)
Plug
Table 1
3
Fig. 1
RH 200 Diesel - 3657769e.doc - (02) 09.03
Secondary relief valve - travel
Page 8.4 - 39
8.4
Pos. 161
The control block (Fig. 1) consists essentially of the

housing (1), the control pistons (2), the actuating
and resetting elements (3), flange-mounted replenishing valves (4) and flange-mounted secondary pressure relief valves (5).
When not activated, the control piston is kept in
neutral position by the resetting spring. In this position the connection between pump and consumer
is closed; the 2/2-way component is opened and
allows the oil to flow in free circulation from P to T.
If the control piston (2) is moved out of its neutral
position, the connection from pump to consumer is
opened by means of precision control grooves and
the 2/2-way component is throttled by means of
precision control grooves (negative overlap). The
pump pressure rises. When the pressure acting on
Ref.-no.
Quantity
Designation
Valve housing
Spools
Bonnet
the consumer connection is reached, the oil starts

to flow to the consumer. Further shifting of the
control piston (2) results in the way to the tank
being opened via precision control grooves for the
oil coming from the consumer and gradual redirecting of the oil flow from the 2/2-way groove to
the consumer groove (precision control).
The max. travel of the control piston is 28mm.
The piston travel is divided into ca. 1/3 control
ledge overlap and 1/2 precision control range, with
the residual travel serving to produce the full
opening cross-section. The leakage-oil losses are
reduced by the overlap and a slight piston clearance.
The consumers can be sensitively controlled
through the large precision-control range.
further remarks
Weight
[kg]
Table 1
Page 8.4 - 40
RH 200 Diesel - 3657769e.doc (02) 09.03
8.4
Fig. 1
Fig. 2
RH 200 Diesel - 3657769e.doc - (02) 09.03
Page 8.4 - 41
8.4
Boom float valve
Pos. 164/1
Arm float valve (only FS)
Pos. 164/2
The float valve permits pressure-less retraction of

the boom cylinders by gravity. The valve opens a
connection between the piston- and the rod-side of
the cylinders to ensure the supply of oil to the rodside without having to use the main pumps.
The spool travel is 17 mm.
The float valve permits pressure-less retraction of

the arm cylinders by gravity. The valve opens a
connection between the piston- and the rod-side of
the cylinders to ensure the supply of oil to the rodside without having to use the working pumps.
The spool travel is 17 mm.
For pressure-supported lowering of the boom, the

lowering function of the hand-lever can be
switched over from float valve to main control spool
by pressing the button in the hand-lever.
For pressure-supported retraction of the arm, the

lowering function of the hand-lever can be
switched over from float valve to main control spool
by pressing the button in the hand-lever.
Ref.-no.
Quantity
Designation
Valve housing
Spool
Bonnet
Check valve
Flange
further remarks
Weight
[kg]
76
only in Backhoe attachment
----
Spring
Spring
Test point
10
O-ring
11
O-ring
12
O-ring
19
Pipe
20
Stud bolt M 10 x 170
21
Nut M 10
22
Hex. bolt M 16x 55
23
Hex. bolt M 10x 50
13 - 18
Minime M 14 x 1,5
----
Table 1
Page 8.4 - 42
RH 200 Diesel - 3657769e.doc (02) 09.03
8.4
22, 23
Fig. 1
Float valve
22, 23
Fig. 2
RH 200 Diesel - 3657769e.doc - (02) 09.03
Float valve
Page 8.4 - 43
8.4
Distributor (FS only)
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
RH 200 Diesel - 3657769e.doc (02) 09.03
8.4
17
Fig. 1
RH 200 Diesel - 3657769e.doc - (02) 09.03
Pressure relief valve in FS backwall
Page 8.4 - 45
8.4
Page 8.4 - 46
RH 200 Diesel - 3657769e.doc (02) 09.03
8.5
8.5
DESCRIPTION OF HYDRAULIC CIRCUITS

Description of the hydraulic
circuits
For the following description, the hydraulic circuit

diagram has been separated into individual function circuits.
The item numbers refer to the hydraulic- or electric
circuit diagram.
The complete hydraulic circuit diagram can be
found in chapter 8.3.
This brief description is an additional information to
the training offered by the Service department. It
can not be a substitute for a detailed training
course!
8.5.1
Load-Limit Regulation
The excavator is fitted with two diesel engines (1),

each of which drives a transfer gearbox (2) to
which 2 main pumps (4), 2 swing pumps (6), 2
cooling pumps (7), 1 pump (8) for servo pressure
and 1 pump for gearbox oil cooling are attached.
Load-limit regulation (PMS 3) makes it possible to
fully utilize the available engine output. Any number of governed hydraulic pumps and consumers
without governors can be driven from one engine
on the condition that the overall power consumption of all non-governed consumers is lower than
the max. output of the motor, as the load-limit
regulation can only influence regulated pumps.
Load-limit regulation uses the actual electric power
consumption of the motor as a signal to start governing, and comes into action as soon as consumers demand more power than the available motor
output.
and finally through the return flow filters (29) back

into the tank.
The main pump P3 is passing through the RH 4spool valve block (90), the tank line pre-charging
valve (31) and finally through the return flow filters
(29) back into the tank.
The main pump P4 is passing through the LH 4spool valve block (90), the tank line pre-charging
valve (31) and finally through the return flow filters
(29) back into the tank.
Each of the two suction manifolds is provided with
a gate valve (26).
Non-return valves (40) are installed to prevent oil
from flowing back into a pump in case of single
engine operation.
The 4 main pumps are protected by pressure relief
valves (36) set at 380 bar (primary relief valves).
The high-pressure filters (39) have a filtering rate
of 100 m.
The tank line pre charging valves (31) have a fixed
setting of 10 bar and ensure that sufficient oil is
available to prevent consumer cavitation (see also
section Working functions).
The return flow filters (29) are monitored by a
pressure switch which reacts (at a switch pressure
of 1.5 bar) on filter contamination and releases a
warning signal in the cab. When filter contamination is excessive, by-pass valves (30) open and
allow the oil flow unfiltered back into the tank.
Oil circuits
With the engines (1) running, and a function is
activated, the main pumps (P1, P2, P3 and P4)
feed oil into the distributor plate (35) with pressure
relief valves (36), logic valves (37) and high pressure filters (39).
When both engines are running the main pump P1
is passing through a high-pressure filter (39), the
LH travel control block (83), the LH 4-spool valve
block (90), the tank line pre-charging valve (31)
and finally through the return flow filters (29) back
into the tank.
The main pump P2 is passing through the RH
travel control block (82), the RH 4-spool valve
block (90), the tank line pre-charging valve (31)
RH 200 Diesel - 3663421e - (00) 09.03
Page 8.5 - 1
8.5
DESCRIPTION OF HYDRAULIC CIRCUITS
8.5.2
Pressure cut-off
On each main pump a pressure cut-off valve is

installed. The pressure cut-off is activated as soon
as the system pressure reaches its max. level of
300 bar for the cylinder functions and 360 bar for
the travel function.
The pressure cut-off valve is mounted on the
regulator of the main pump. It is opened under
system pressure and the pump then de-strokes to
such a reduced flow that only the pressure in the
system is maintained.
Page 8.5 - 2
RH 200 Diesel - 3663421e - (00) 09.03
8.5
HYDRAULIC CIRCUITS - SERVO SYSTEM
8.5.3
Servo system
70 bar - auxiliary pressure
Remark:
Auxiliary oil is required for the following functions:
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.
Regulation of the main pumps via proportional

valves (23)
Operation of the pressure increase to 340 bar

for the travel system via solenoid control block.
Solenoid valve (26/2) for 2-stage regulation of

the travel motors.
The 4 gear pumps (6) for the servo system are

driven by the engines (1) via the pump gearboxes
(2).
The pumps (6) suck the oil through the suction
manifolds from the hydraulic tank and feed into the
servo- and auxiliary pressure valve (40).
40 bar - Servo-pressure
Servo pressure is supplied for the following functions:
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.
Proportional valves (25) for operation of the

travel control blocks (92 & 93).
Proportional valves (25) for operation of the

swing system.
Supply of the pressure regulating valve (105)

for the swing circuit.
Solenoid valve (26/2) for travel parking brake.
Operation of the swing parking brake via solenoid control block (26/1).
The servo system is functional when the safety

switch in the operators seat is activated. Then
opening of the safety valves on plate (25) is possible.
An accumulator with valve (35) stores and provides
hydraulic energy for lowering the attachment or
depressurising the hydraulic cylinders in case the
engines are switched off.
RH 200 Diesel - 3664264e.doc - (00) - 06.04
Examples for servo oil circuits:

Regulation of the main pumps (fig. 3 & fig. 4)
The regulators of the main pumps are connected to
the pump governing valves (23)
The input of the proportional valves (23) is connected to the 70 bar system. The output to the
regulators is governed by the PMS-system. Depending on the load situation of the engines the
output is regulated between 7,5 bar and 42,5 bar.
Solenoid valve bank (26)
Swing parking brake (Solenoid Y 11) (fig. 6)

Parking brake released:
The solenoid valve is energised and oil flows
to the swing parking brakes (port A2). They
are hydraulically released and held in the released position.
Parking brake applied:
Solenoid valve (Y 11) is not energised. The
swing brake pistons are connected to the hydraulic tank.
The swing brakes are applied by spring force.
Travel parking brake (Solenoid Y 12)

(fig. 7)
Parking brake released:
The solenoid valve is energised and oil flows
to the travel parking brakes (port A1). They
are hydraulically released and held in the released position.
Page 8.5.3 - 1
8.5

Parking brake applied:
Solenoid valve (Y 12) is not energised. The
travel brake pistons are connected to the hydraulic tank.
The travel brakes are applied by spring force.
2-speed travelling (Solenoid Y 13)

(fig. 7)
The solenoid valve (Y 13) is operating the 2stage regulator of the travel motors for 2speed travelling.
When the operator is shifting the switch in the
cab from 'low speed' (turtle) to 'high speed'
(rabbit) the pressure in the lines to the travel
parking brakes and travel motor regulators is
increased to 70 bar and the regulators are
shifting to low displacement.
Other servo oil circuits are described in the sections

8.5.4 - Working functions
8.5.5 - Travel system
8.5.6 - Swing system
8.5.7 - Track tensioning system
Remark:
The following colour code refers only to hydraulic
lines and not to components!
Travel boost (Solenoid Y 31) (fig. 11)

The solenoid valve (Y 31) is operating the
pressure cut-off valves of the main pumps P 2
and P 3 so that the travel pressure is increased to 340 bar.
Colour
Code
Designation
70 bar circuit
40 bar circuit
RP
Regulating pressure for

main pumps
Return oil circuit
Leak oil circuit
Ref.-no.
Quantity
Designation
further remarks
Main pumps
Gear pump
23
Pump governing valves
25
26
Valve bank, complete
36
40
47
Check valve
91
Rotor
105
Swing balance valve
109
For pressure governing valve
121
Travel motor
Swing parking brake
Proportional valves
Solenoid valves
Table 1
Page 8.5.3 - 2
RH 200 Diesel - 3664264e.doc - (00) - 06.04
8.5
Fig. 1
Pumps for servo- and auxiliary pressure 3664702c-01
Fig. 2
Pumps for servo- and auxiliary pressure 3664702d-01
RH 200 Diesel - 3664264e.doc - (00) - 06.04
Page 8.5.3 - 3
8.5
Fig. 3
Regulation of main pumps via proportional valves 3664702c-02
Fig. 4
Regulation of main pumps via proportional valves 3664702d-02
Page 8.5.3 - 4
RH 200 Diesel - 3664264e.doc - (00) - 06.04
8.5
Fig. 5
Lines from operators cab - 3664731-01
Fig. 6
Swing parking brake - 3664749-01
RH 200 Diesel - 3664264e.doc - (00) - 06.04
Page 8.5.3 - 5
8.5
Fig. 7
Travel parking brake and 2-speed function - 3664702a-01
Fig. 8
Page 8.5.3 - 6
RH 200 Diesel - 3664264e.doc - (00) - 06.04
8.5
Fig. 9
Travel parking brake and 2-speed function 3664495b-02
Fig. 10
Travel parking brake and 2-speed function 3664495c-02
RH 200 Diesel - 3664264e.doc - (00) - 06.04
Page 8.5.3 - 7
8.5
Fig. 11
Travel boost for main pumps 3664702a-02
Fig. 12
Travel boost for main pumps 3664702c-03
Page 8.5.3 - 8
RH 200 Diesel - 3664264e.doc - (00) - 06.04
8.5
Fig. 13
RH 200 Diesel - 3664264e.doc - (00) - 06.04
Travel boost for main pumps 3664702d-03
Page 8.5.3 - 9
8.5
Page 8.5.3 - 10
RH 200 Diesel - 3664264e.doc - (00) - 06.04
8.5
HYDRAULIC CIRCUITS - WORKING FUNCTIONS (FS)
8.5.4
Working functions (FS)
Remark:
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:
high-pressure filter (32) and the RH travel control
valve (92) to the RH 4-spool control valve (161).
(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).
(60).
RH 200 Diesel - 3663424e.doc - (01) 09.03
Main pump P4:

high-pressure filter (32) to the LH 4-spool control
valve (161).
(60).
The 4 circuits supply the following working functions:
a) Boom - raise and lower
b) Arm - extend and retract
c) Shovel - crowd in and tip back
d) Bottom dump bucket- open and close
e) Travel (see section Travelling)
The functions listed under a) - c) are supplied with
oil from both circuits when only one function is
being operated (automatic double flow).
All cylinders fitted in pairs are interconnected by
compensating lines.
4-spool control valves
The 4-spool control valves (161) are directional
valves, designed with multiple spools in one housing.
The individual spools are actuated hydraulically
and allow sensitive controlling of the speed and
direction of the oil flow passing through the block.
Description of the function see chapter 8.4
When a working function is idle, the respective
spool is held in its initial (neutral) position by the
return springs. The connecting channel from pump
to consumer is blocked. The 2/2 way valve is open
and allows the oil to pass from P to T (free flow or
idle circuit).
When the control spool is moved out of its initial
(neutral) position, the connecting channel from
pump to consumer opens via fine control grooves
and the 2/2 way section is throttled with help of fine
control grooves (negative overlap).
Circuit pressure is increasing.
When the same pressure is reached as acting on
the consumer connection, the check (non-return)
Page 8.5.4 - 1
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:
Colour
Code
Designation
P1
Main pump P1
P2
Main pump P2
P3
Main pump P3
P4
Main pump P4
Return oil circuit
Ref.-no.
Quantity
further remarks
29
30
Relief valve
32
64
91
Rotor
92
93
95
96
161
164/1
Float valve
Boom cylinder function
164/2
Float valve
Arm cylinder function
182
Boom cylinder
183
Arm cylinder
184
Crowd cylinder
186
Clam cylinder
187
Distributor with relief valve
189
Distributor
Table 1
Page 8.5.4 - 2
RH 200 Diesel - 3663424e.doc - (01) 09.03
8.5
Fig. 1
Main pump lines - 3664705a-01
Fig. 2
Main pump lines 3666204-01
RH 200 Diesel - 3663424e.doc - (01) 09.03
Page 8.5.4 - 3
8.5
Fig. 3a
Main pump lines 3664517a-01
Fig. 3b
Page 8.5.4 - 4
RH 200 Diesel - 3663424e.doc - (01) 09.03
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.
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
The circuit pressure rises.
Pressure oil circuit
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).
Return oil circuit
Servo oil circuit
Compensation line
Pilot-controlled pressure relief valves safeguard

the boom cylinders against forces acting externally
Fig. 4
RH 200 Diesel - 3663424e.doc - (01) 09.03
Extending the boom cylinders 3664144a-01
Page 8.5.4 - 5
8.5
Fig. 5
Fig. 6
Page 8.5.4 - 6
RH 200 Diesel - 3663424e.doc - (01) 09.03
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.
Float valve Lowering

In order to save energy, Lower commands for the
boom are passed to the float valves (164/1) and
not to the 4-spool control valves (fig. 7).
Servo circuit oil flows to the boom float valves
(164/1). The valves shift over. Piston and rod sides
of the boom cylinders (182) are then connected to
one another (fig. 8 & fig. 9). The weight of the
working attachment forces the piston rods of the
cylinders to retract of their own, whereby the oil
being displaced from the piston side flows directly
into the vacant space on the rod side.
Because the chamber on the rod side of the cylinder is smaller than that on the piston side, the ex-
Fig. 7a
RH 200 Diesel - 3663424e.doc - (01) 09.03
Colour
Code
Designation
Return oil circuit
Servo oil circuit
Compensation line
Retracting the boom cylinders via float valves 3664144a-02
Page 8.5.4 - 7
8.5
Fig. 7b
Retracting the boom cylinders via float valves 3664144b-01
Fig. 8
Retracting the boom cylinders via float valve 2800823a-03
Page 8.5.4 - 8
RH 200 Diesel - 3663424e.doc - (01) 09.03
8.5
Fig. 9
RH 200 Diesel - 3663424e.doc - (01) 09.03
Retracting the boom cylinders via float valve - 2800824a-02
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.
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

Colour
Code
Designation
Return oil circuit
Servo oil circuit
Compensation line
RH 200 Diesel - 3663424e.doc - (01) 09.03
8.5
Fig. 10
Retracting the boom cylinders via main valve 3664144a-03
Fig. 11
RH 200 Diesel - 3663424e.doc - (01) 09.03
Page 8.5.4 - 11
8.5
Fig. 12
Page 8.5.4 - 12
RH 200 Diesel - 3663424e.doc - (01) 09.03
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).
Fig. 13
RH 200 Diesel - 3663424e.doc - (01) 09.03

the arm cylinders against forces acting externally
Colour
Code
Designation
Return oil circuit
Servo oil circuit
Compensation line
Extending the arm cylinders 3664144a-04
Page 8.5.4 - 13
8.5
Fig. 14
Fig. 15
Page 8.5.4 - 14
RH 200 Diesel - 3663424e.doc - (01) 09.03
8.5
Function:
Retracting the arm cylinders via float valve

arm are passed to the float valves (164/2) and not
to the 4-spool control valves (fig. 16).
Servo circuit oil flows to the arm float valves
of the arm cylinders (183) are then connected to
one another (fig. 17 & fig. 18). The weight of the
Fig. 16a
RH 200 Diesel - 3663424e.doc - (01) 09.03
Colour
Code
Designation
Return oil circuit
Servo oil circuit
Compensation line
Retracting the arm cylinders via float valves 3664144a-05
Page 8.5.4 - 15
8.5
Fig. 16b
Retracting the arm cylinders via float valves 3664144b-02
Fig. 17
Page 8.5.4 - 16
RH 200 Diesel - 3663424e.doc - (01) 09.03
8.5
Fig. 18
RH 200 Diesel - 3663424e.doc - (01) 09.03
Page 8.5.4 - 17
8.5
Function:
Retracting the arm cylinders via main valve
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
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).
Page 8.5.4 - 18

Colour
Code
Designation
Return oil circuit
Servo oil circuit
Compensation line
RH 200 Diesel - 3663424e.doc - (01) 09.03
8.5
Fig. 19
Retracting the arm cylinders via main valve 3664177a-06
Fig. 20
RH 200 Diesel - 3663424e.doc - (01) 09.03
Page 8.5.4 - 19
8.5
Fig. 21
Page 8.5.4 - 20
RH 200 Diesel - 3663424e.doc - (01) 09.03
8.5
Function:
Extending the bucket crowd cylinders
spools for crowd function (161) are shifted by servo
pumps to the piston sides of the crowd cylinders
fig. 24).
Fig. 22
RH 200 Diesel - 3663424e.doc - (01) 09.03

the crowd cylinders against forces acting externally
Colour
Code
Designation
Return oil circuit
Servo oil circuit
Extending the bucket crowd cylinders 3664144a-07
Page 8.5.4 - 21
8.5
Fig. 23
Extending the bucket crowd cylinders 2800823a -08
Fig. 24
Extending the bucket crowd cylinders 2800827a -01
Page 8.5.4 - 22
RH 200 Diesel - 3663424e.doc - (01) 09.03
8.5
Function:
Retracting the bucket crowd cylinders
fig. 27).
Fig. 25
RH 200 Diesel - 3663424e.doc - (01) 09.03

the crowd cylinders against forces acting externally
Colour
Code
Designation
Return oil circuit
Servo oil circuit
Retracting the bucket crowd cylinders 3664144a-08
Page 8.5.4 - 23
8.5
Fig. 26
Fig. 27
Page 8.5.4 - 24
RH 200 Diesel - 3663424e.doc - (01) 09.03
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).

the clam cylinders against forces acting externally
Colour
Code
Designation

Return oil circuit
Leak oil circuit
Servo oil circuit
Fig. 28
RH 200 Diesel - 3663424e.doc - (01) 09.03
Extending the clam cylinders 3664144a-09
Page 8.5.4 - 25
8.5
Fig. 29
Fig. 30
Extending the clam cylinders 3666204-02
Page 8.5.4 - 26
RH 200 Diesel - 3663424e.doc - (01) 09.03
8.5
Fig. 31a
Fig.31b
RH 200 Diesel - 3663424e.doc - (01) 09.03
Page 8.5.4 - 27
8.5
Fig. 32
Fig. 33
Page 8.5.4 - 28
RH 200 Diesel - 3663424e.doc - (01) 09.03
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).

the clam cylinders against forces acting externally
Colour
Code
Designation

the rod sides of the cylinders oil flows to the cylinders. With further movement of the control spools,
fine-control grooves allow oil coming from the rod
sides of the cylinders to flow to tank and gradually
shift the oil flow from the channel (P/T) to the
channel for the consumer (fine-control facility).
Return oil circuit
Leak oil circuit
Servo oil circuit
Fig. 34
RH 200 Diesel - 3663424e.doc - (01) 09.03
Retracting the clam cylinders 3664144a-10
Page 8.5.4 - 29
8.5
Fig.35
Fig. 36
Page 8.5.4 - 30
RH 200 Diesel - 3663424e.doc - (01) 09.03
8.5
Fig. 37
RH 200 Diesel - 3663424e.doc - (01) 09.03
Page 8.5.4 - 31
8.5
Page 8.5.4 - 32
RH 200 Diesel - 3663424e.doc - (01) 09.03
8.5 HYDRAULIC CIRCUITS - WORKING FUNCTIONS (BH)
8.5.4
Working functions (BH)
Remark:
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:
high-pressure filter (32) to the RH 4-spool control
valve (161).
(60).
Main pump P2:

high-pressure filter (32) and the RH travel control
valve (92) to the RH 4-spool control valve (161).
(60).
Main pump P4:

high-pressure filter (32) to the LH 4-spool control
valve (161).
(60).
The 4 circuits supply the following working functions:

a) Boom - raise and lower
b) Stick - extend and retract
c) Bucket - crowd in and tip back
d) Travel (see section Travelling)
The functions listed under a) - c) are supplied with
oil from both circuits when only one function is
being operated (automatic double flow).
All cylinders fitted in pairs are interconnected by
compensating lines.
4-spool control valves

The 4-spool control valves (161) are directional
valves, designed with multiple spools in one housing.
The individual spools are actuated hydraulically
and allow sensitive controlling of the speed and
direction of the oil flow passing through the block.
Description of the function see chapter 8.4
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 (83)
to the LH 4-spool control valve (161).
(60).
RH 200 Diesel - 3663430e.doc - (01) 09.03
When a working function is idle, the respective

spool is held in its initial (neutral) position by the
return springs. The connecting channel from pump
to consumer is blocked. The 2/2 way valve is open
and allows the oil to pass from P to T (free flow or
idle circuit).
When the control spool is moved out of its initial
(neutral) position, the connecting channel from
pump to consumer opens via fine control grooves
and the 2/2 way section is throttled with help of fine
control grooves (negative overlap).
Circuit pressure is increasing.
When the same pressure is reached as acting on
the consumer connection, the check (non-return)
valve opens so that oil starts flowing to the con-
Page 8.5.4 - 1

sumer. 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).
Remark:
Colour
Code
Designation
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.
Ref.-no.
Quantity
Designation
29
30
Relief valve
32
64
91
Rotor
92
93
95
96
161
164
Float valve
170
Throttled non return valve
171
Throttled non return valve
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
Return oil circuit
further remarks
Boom cylinder function
Table 1
Page 8.5.4 - 2
RH 200 Diesel - 3663430e.doc - (01) 09.03
Fig. 1
Fig. 2
Main pump lines - 3666204-01
RH 200 Diesel - 3663430e.doc - (01) 09.03
Page 8.5.4 - 3
Fig. 3
Main pump lines 3664517a-01
Fig. 4
Main pump lines 3664517b-01
Page 8.5.4 - 4
RH 200 Diesel - 3663430e.doc - (01) 09.03

Function:
Extending the boom cylinders
When the function is summoned (fig. 5), both control spools for boom function are shifted by servo
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. 6 to fig. 8).

Colour
Code
Designation
Return oil circuit
Servo oil circuit
Compensation line

Fig. 5
RH 200 Diesel - 3663430e.doc - (01) 09.03
Page 8.5.4 - 5
Fig. 6
Extending the boom cylinders 3664517b-02
Fig. 7
Extending the boom cylinders 3664517c-01
Page 8.5.4 - 6
RH 200 Diesel - 3663430e.doc - (01) 09.03
Fig. 8
RH 200 Diesel - 3663430e.doc - (01) 09.03
Extending the boom cylinders 3664518c-01
Page 8.5.4 - 7

Function:
Retracting the boom cylinders via float valve

boom (on FS and BH attachment) are passed to
the float valves (92) and not to the 4-spool control
valves (fig. 9).
Servo circuit oil flows to the boom float valves
of the boom cylinders (182) are then connected to
one another (fig. 10 to fig. 12). The weight of the
Fig. 9
Page 8.5.4 - 8
Colour
Code
Designation
Return oil circuit
Servo oil circuit
Compensation line
Retracting the boom cylinders via float valves - 3663578a-02
RH 200 Diesel - 3663430e.doc - (01) 09.03
Fig. 10
Retracting the boom cylinders via float valve 3664517b-03
Fig. 11
Retracting the boom cylinders via float valve 3664517c-01
RH 200 Diesel - 3663430e.doc - (01) 09.03
Page 8.5.4 - 9
Fig. 12
Page 8.5.4 - 10
Retracting the boom cylinders via float valve 3664518c-02
RH 200 Diesel - 3663430e.doc - (01) 09.03

Function:

Retracting the boom cylinders via main valve

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
springs (fig. 13). 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. 14 to fig. 16).
RH 200 Diesel - 3663430e.doc - (01) 09.03
Pilot-controlled pressure relief valves (91) safeguard the boom cylinders against forces acting
externally on the working circuit. Pilot-controlled
valves are used to ensure that large quantities of
oil can escape in an absolute minimum of time.
Colour
Code
Designation
Return oil circuit
Servo oil circuit
Compensation line
Page 8.5.4 - 11
Fig. 13
Fig. 14
Retracting the boom cylinders via main valve 3664517b-04
Page 8.5.4 - 12
RH 200 Diesel - 3663430e.doc - (01) 09.03
Fig. 15
Retracting the boom cylinders via main valve 3664517c-03
Fig. 16
Retracting the boom cylinders via main valve 3664518c-03
RH 200 Diesel - 3663430e.doc - (01) 09.03
Page 8.5.4 - 13

Function:
Extending the stick cylinders
spools for stick function (161) are shifted by servo
pumps to the piston sides of the stick cylinders
(183) is opened via fine-control grooves (fig. 18 to
fig. 20).
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
Colour
Code
Designation
Return oil circuit
Servo oil circuit
Compensation line
Extending the stick cylinders - 3663578a-04
RH 200 Diesel - 3663430e.doc - (01) 09.03
Fig. 18
Extending the stick cylinders 3664517b-05
Fig. 19
Extending the stick cylinders 3664517c-04
RH 200 Diesel - 3663430e.doc - (01) 09.03
Page 8.5.4 - 15
Fig. 20
Page 8.5.4 - 16
Extending the stick cylinders 3664518a-01
RH 200 Diesel - 3663430e.doc - (01) 09.03

Function:
Retracting the stick cylinders via main valve
of the working attachment, the operator has to
press a button in the control lever
When the function is summoned, the stick spool in
the LH 4-spool control valve (161) is shifted by
springs (fig. 21). The stick spool in the RH 4-spool
valve is connected to the leak oil line and not operated. The connection from the main pumps to the
rod sides of the stick cylinders is opened via finecontrol grooves (fig. 22 to fig. 24).
RH 200 Diesel - 3663430e.doc - (01) 09.03

Pilot-controlled pressure relief valves (91) safeguard the boom cylinders against forces acting
Colour
Code
Designation
Return oil circuit
Servo oil circuit
Compensation line
Page 8.5.4 - 17
Fig. 21
Retracting the stick cylinders via main valve 3663578a-05
Fig. 22
Retracting the stick cylinders via main valve 3664517b-06
Page 8.5.4 - 18
RH 200 Diesel - 3663430e.doc - (01) 09.03
Fig. 23
Retracting the stick cylinders via main valve 3664517c-05
Fig. 24
Retracting the stick cylinders via main valve 3664518a-02
RH 200 Diesel - 3663430e.doc - (01) 09.03
Page 8.5.4 - 19

Function:
Extending the bucket cylinders
fig. 30).
Fig. 25
Page 8.5.4 - 20
Pilot-controlled pressure relief valves (91) safeguard the crowd cylinders against forces acting
Colour
Code
Designation
Return oil circuit
Servo oil circuit
Extending the bucket cylinders 3663578a -06
RH 200 Diesel - 3663430e.doc - (01) 09.03
Fig. 26
Extending the bucket cylinders 3664517b -07
Fig. 27
Extending the bucket cylinders 3664517c -06
RH 200 Diesel - 3663430e.doc - (01) 09.03
Page 8.5.4 - 21
Fig. 28
Extending the bucket cylinders 3664518a-03
Fig. 29
Extending the bucket cylinders 3664518b-01
Page 8.5.4 - 22
RH 200 Diesel - 3663430e.doc - (01) 09.03
Fig. 30
RH 200 Diesel - 3663430e.doc - (01) 09.03
Extending the bucket cylinders 3664536-01
Page 8.5.4 - 23

Function:
Retracting the bucket cylinders
fig. 36).
Fig. 31
Page 8.5.4 - 24
Pilot-controlled pressure relief valves (91) safeguard the crowd cylinders against forces acting
Colour
Code
Designation
Return oil circuit
Servo oil circuit
Retracting the bucket cylinders 3663578a-07
RH 200 Diesel - 3663430e.doc - (01) 09.03
Fig. 32
Retracting the bucket cylinders 3664517b -08
Fig. 33
Retracting the bucket cylinders 3664517c -07
RH 200 Diesel - 3663430e.doc - (01) 09.03
Page 8.5.4 - 25
Fig. 34
Retracting the bucket cylinders 3664518a-04
Fig. 35
Retracting the bucket cylinders 3664518b-02
Page 8.5.4 - 26
RH 200 Diesel - 3663430e.doc - (01) 09.03
Fig. 36
RH 200 Diesel - 3663430e.doc - (01) 09.03
Retracting the bucket cylinders 3664536-02
Page 8.5.4 - 27
Page 8.5.4 - 28
RH 200 Diesel - 3663430e.doc - (01) 09.03
8.5
HYDRAULIC CIRCUITS - TRAVEL SYSTEM
8.5.5
Travel system
Remark:
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).
In this case the main pumps P3 is feeding the RH

travel control block (92) and the main pump P4 is
feeding the LH travel control block (93) (fig. 8 to fig.
10).
Travel parking brake / 2-speed travel
The travel parking brake and the shifting of the 2stage travel motors are operated via the same
hydraulic line (fig. 11 to fig. 14). When a pressure
of 40 bar is applied the travel parking brake is released and the travel motors stay in 'low speed
mode'. If the speed switch is activated the pressure
is increased to 70 bar and the travel motors
change to 'high speed mode'.
Leakage oil from the control blocks flows back to
the tank.
Anti-cavitation valves flanged onto the travel control blocks prevent cavitation in the travel motors.
Travel boost
A solenoid valve (Y 31) on plate (26/2) is operating
the pressure cut-off valves of the main pumps P 2
and P 3 so that the travel pressure is increased to
360 bar (fig. 15 to fig. 17).
Travel retarder valves
The travel retarder valves (95 & 96) flanged onto
the travel valve blocks (92 & 93) prevent the excavator from running away when travelling downhill,
and ensure positive travel drive down the slope.
The travel retarder valves are installed in the circuits in such a way that oil flowing from the travel
motors must flow through them in order to get to
the tank.
The control piston determines the amount of oil
which can flow through the valve. When system
pressure drops (e.g. excavator travelling downhill),
pressure spring pushes the control piston back.
When the excavator is travelling, the control piston
of the retarder valve adopts a so-called float position which is determined by the resistance to excavator travel and the pump oil pressure resulting
from it.
When only the RH engine is running a solenoid

valve (46) is operating the logic valves on the distributor plate (29).
RH 200 Diesel - 3663425e.doc - (01) - 09.03
Page 8.5.5 - 1
8.5
Remark:
Colour
Code
Designation
P1
Main pump P1
P2
Main pump P2
Return oil circuit
40 bar circuit
70 bar circuit
Components of the travel system

Ref.-no.
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
Secondary relief valve block
Distributor
further remarks
Travel boost
Operation of logic valves
Travel function
Table 1
Page 8.5.5 - 2
RH 200 Diesel - 3663425e.doc - (01) - 09.03
8.5
Fig. 1
Logic valves with solenoid - 3664705b-01
Fig. 2
Main pumps for travel 3664705a-03
RH 200 Diesel - 3663425e.doc - (01) - 09.03
Page 8.5.5 - 3
8.5
Fig. 3
Main pumps for travel 3666204-03
Fig. 4
Servo lines for travel system - 3666203-01
Page 8.5.5 - 4
RH 200 Diesel - 3663425e.doc - (01) - 09.03
8.5
Fig. 5
Travel system in undercarriage - 3664495a-01
Fig. 6
Travel system in undercarriage 3664495b-01
RH 200 Diesel - 3663425e.doc - (01) - 09.03
Page 8.5.5 - 5
8.5
Fig. 7
Travel system in undercarriage 3664495c-01
Fig. 8
Logic valves with solenoid - 3664705b-02
Page 8.5.5 - 6
RH 200 Diesel - 3663425e.doc - (01) - 09.03
8.5
Fig. 9
Main pumps for travel - 3664705a-04
Fig. 10
Main pumps for travel - 3666204-04
RH 200 Diesel - 3663425e.doc - (01) - 09.03
Page 8.5.5 - 7
8.5
Fig. 11
Travel parking brake and 2-speed function 3664702a-01
Fig. 12
Page 8.5.5 - 8
RH 200 Diesel - 3663425e.doc - (01) - 09.03
8.5
Fig. 13
Travel parking brake and 2-speed function 3664495b-02
Fig. 14
Travel parking brake and 2-speed function 3664495c-02
RH 200 Diesel - 3663425e.doc - (01) - 09.03
Page 8.5.5 - 9
8.5
Fig. 15
Travel boost for main pumps 3664702a-02
Fig. 16
Travel boost for main pumps 3664702c-03
Page 8.5.5 - 10
RH 200 Diesel - 3663425e.doc - (01) - 09.03
8.5
Fig. 17
RH 200 Diesel - 3663425e.doc - (01) - 09.03
Travel boost for main pumps 3664702d-03
Page 8.5.5 - 11
8.5
Page 8.5.5 - 12
RH 200 Diesel - 3663425e.doc - (01) - 09.03
8.5
HYDRAULIC CIRCUITS - SWING SYSTEM
8.5.6
Swing system
Remark:
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.
Swinging to the right

When the left hand joystick is actuated to the right
servo oil flows to the pressure regulating valve
(105, port Y1).
The pressure from the joystick is defining the pressure level in the swing system.
The main piston (11.1, fig. 1) is displaced against
the spring (11.3).
Connections (X1 & P) and (X2 & T) are thereby
established. Line (X2) between pressure regulating
valve (105) and the regulators of the swing pumps
(4) is pressurised. The pressure in the circuit is no
longer balanced.
The swing pumps (4) tilt out (altered pump flow)
and feed into line (B). The pressure which builds
up in the line is led to the pressure regulating valve
(105) through line (X 5) and acts on the pilot piston
(11.2). The pilot piston has a ratio of 1:12 to the
main piston (11.1).
When a state of balance is reached between the
pilot force (X5) plus spring force (11.3), and pressure (Y1), a state of balance is also reached in the
chambers of the pump regulator (4).
The pumps stop tilting out.
The pumps only continue tilting out when the reaction pressure (X5) drops. In this way, the pumps
only supply so much oil as is being consumed by
the swing motors (102).
When the swing movement is to be interrupted, the
joystick is returned to its neutral 0-position. The
swing motors (102) are then driven by the swinging
superstructure so that they pump oil back to the
swing pumps. The previous pressure line (B) is
freed of pressure is led through (X6) to pilot piston
(11.5). The position of the pressure regulating
valve is thereby retained and the superstructure
can continue to swing until its rotation energy
(momentum) has dropped to zero.
Pressure relief valves in the swing pumps (4) limit
the max. pressure in the swing circuit to 400 bar.
At the same time, they serve as anti-cavitation
valves in the system (to compensate for leakage oil
losses). Oil feed to the system is carried out by the
charge pumps through connection (Fa) on the
swing pumps.
The pressure in the swing circuit is 50 bar, pressure being applied from the charge pumps.
RH 200 Diesel - 3663426e.doc - (01) 09.03
Page 8.5.6 - 1
8.5
The swing pumps (4) are fitted with thermal

switches, which pass a warning signal to the cab
when the oil temperature exceeds 92 C. The
warning in the cab is switched off again when the
temperature drops back below 87 C.
Leakage oil from the swing motors (102) is conducted back to the tank through the leak line (fig.
12).
Charge system (fig. 8 & 9)

Each swing pump has an internal charge pump,
which is replacing loss of oil in the closed swing
circuit because of internal leakage of swing pumps
and swing motors. The charge pressure of 50 bar
is set by an internal pressure relief valve at each
swing pump.
The charge system is equipped with chip indicators
and filters (34) to avoid contamination of the closed
swing circuit in case of a charge pump failure
Flushing valve (fig. 10 & 11)
The flushing valve (106) ejects a defined amount
of oil from the closed swing circuit at the lowpressure side during each swing operation. The
corresponding amount of filtered and cooled oil
from the hydraulic tank is fed back into the swing
system by the charging pumps.
Leak oil of swing motors (fig. 12)
Fig. 1
Pressure regulating valve
Swinging to the left

Swinging to the left follows in the same manner as
already described, but through the relevant connections for left.
Countering
The excavator operator can shorten the time taken
to brake the swinging superstructure by countering
- i.e. by summoning the opposite direction of
swing.
Separate leak oil lines transport the leak oil of the

swing motors (102) back to the hydraulic tank.
Swing parking brakes (fig. 13)
The swing parking brake (B) between swing motor
and gearbox is operated by a solenoid valve
(26/1). The parking brakes are opened by auxiliary
pressure (70 bar) when the solenoid valve is active.
When the solenoid valve is inactive the hydraulic
pressure is released to the tank and the parking
brakes are closed by internal springs.
This means that the brakes are automatically
closed when the machine is shut off or the solenoid valve fails.
The pressure regulating valve (105) receives a

reverse signal so that the regulator of the swing
pumps are commanded to tilt back.
The swing motors (102) start to work as pumps
and drive the swing pumps themselves, which in
turn feed their energy back into the drive system.
Sensitive braking is possible. Brake torque in
crease / decrease is possible using the control
lever. When the superstructure has come to a
standstill, the pumps have returned to their zero-tilt
angle. The servo valve must then be shifted back
to its neutral 0-position so as to prevent the superstructure swinging off again in the direction which
was necessary to counter.
Page 8.5.6 - 2
RH 200 Diesel - 3663426e.doc - (01) 09.03
8.5
Remark:
Colour
Code
Designation
Return oil circuit
Leak oil circuit
Servo oil circuit (40 bar)
Auxiliary oil circuit (70 bar)
Flushing system
Charge system
Ref.-no.
Quantity
Designation
Swing pump
11
Servo- and charge pump
25
26
Valve bank, complete
34
Filter for charge oil
40
Servo pressure valve block
100
Swing gearbox
102
Swing motor
103
Blocking valve
105
106
Flushing valve
107
Swing parking brake
further remarks
Solenoid valves
Swing balance valve
Table 1
RH 200 Diesel - 3663426e.doc - (01) 09.03
Page 8.5.6 - 3
8.5
Fig. 2
Swing pumps - 630833a-02
Fig. 3
Swing pumps and swing motors 3664754b-01
Page 8.5.6 - 4
RH 200 Diesel - 3663426e.doc - (01) 09.03
8.5
Fig. 4
Swing pumps and swing motors - 3664754a-01
Fig. 5
Pilot lines for swing system 3664731-01
RH 200 Diesel - 3663426e.doc - (01) 09.03
Page 8.5.6 - 5
8.5
Fig. 6
Pilot lines for swing system - 3664754f-01
Fig. 7
Pilot lines for swing system - 3664754g-01
Page 8.5.6 - 6
RH 200 Diesel - 3663426e.doc - (01) 09.03
8.5
Fig. 8
Charge system for swing circuit 3664754d-01
Fig. 9
Charge system for swing circuit 3664754e-01
RH 200 Diesel - 3663426e.doc - (01) 09.03
Page 8.5.6 - 7
8.5
Fig. 10
Flushing valve for swing system 3664754f-02
Fig. 11
Flushing valve for swing system 3664754g-02
Page 8.5.6 - 8
RH 200 Diesel - 3663426e.doc - (01) 09.03
8.5
Fig. 12
Leak oil lines for swing motors 3664754c-01
Fig. 13
Swing parking brake - 3664749-01
RH 200 Diesel - 3663426e.doc - (01) 09.03
Page 8.5.6 - 9
8.5
Page 8.5.6 - 10
RH 200 Diesel - 3663426e.doc - (01) 09.03
8.5
HYDRAULIC CIRCUITS - TRACK TENSIONING SYSTEM
8.5.7
Track tensioning system
Remark:
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).
losses are automatically replaced by the system

when the required track tensioning pressure is
going below 70 bar.
Tensioning the tracks
See directions in Operating Instructions.
The tracks are automatically tensioned.
After starting one of the engines the auxiliary pressure (70 bar) is fed through the rotor(91) to the
After pressure built up in the track tensioning cylinders (130) and accumulators (131) the tracks are
tensioned.
Remark:
Colour
Code
Designation
70 bar circuit
Return oil 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
Pressure reduction valve
installed in superstructure
40
91
Rotor
130
Track tensioning cylinders
131
133
Valve plate
installed in undercarriage
134
Secondary relief valve
Table 1
RH 200 Diesel - 3664265e.doc - (00) - 06.04
Page 8.5.7 - 1
8.5
Fig. 1
Pumps for track tensioning system 3664708-01
Fig. 2
3664702c-04
Page 8.5.7 - 2
RH 200 Diesel - 3664265e.doc - (00) - 06.04
8.5
Fig. 3
3664702d-04
Fig. 4
Track tensioning lines 3664702a-03
RH 200 Diesel - 3664265e.doc - (00) - 06.04
Page 8.5.7 - 3
8.5
Fig. 5
Page 8.5.7 - 4
Track tensioning system in undercarriage 3664335-01
RH 200 Diesel - 3664265e.doc - (00) - 06.04
8.5 HYDRAULIC CIRCUITS - COOLING SYSTEM FOR HYDR. OIL
8.5.8
Cooling system for hydraulic oil
Remark:
The 4 cooling pumps (10) are gear-type pumps

with fixed displacement.
They are flanged directly onto the 4 swing pumps
(fig. 1).
The setup of the cooling system is shown in fig.2 &
fig. 3.
an increasing oil flow is driving the fan motor (81)

and then flowing through the cooler.
At temperatures above 52 C the full flow is passing through the fan motor and the oil cooler.
Pressure relief valves (43) set to 65 bar is protecting the cooling circuit.
An example for the cooling oil flow is shown in fig.
4 & fig. 5.
Remark:
Colour
Code
Each 2 pumps are pumping the hydraulic oil into a

distributor plate (85) with thermostats (87).
The regulating range of the thermostats is +40 C
to +52 C.
At temperatures below +40 C the position of the
spool in the valve allows the oil to return directly to
the hydraulic tank without flowing through fan motor and oil cooler.
Designation
Cooling oil circuit
Return oil circuit
Leak oil circuit
With rising temperature the thermostat is shifting

the spool an thus closing the port to the tank and
Ref.-no.
Quantity
Designation
further remarks
10
Cooling pump
Gear pump
85
Distributor plate with thermostat
81
Fan motor
Gear motor
Table 1
RH 200 Diesel - 3664276e.doc - (00) - 07.05
Page 8.5.8 - 1
Fig. 1
Location of pumps for oil cooling - 630833b-02
Fig. 2
Fan pumps and thermostat valve blocks - 3666305a-01
Page 8.5.8 - 2
RH 200 Diesel - 3664276e.doc - (00) - 07.05
Fig. 3
Thermostat valve blocks and fan motors 3666305b-01
Fig. 4
Example for cooling oil flow - 3666305a-02
RH 200 Diesel - 3664276e.doc - (00) - 07.05
Page 8.5.8 - 3
Fig. 5
Page 8.5.8 - 4
Example for cooling oil flow - 3666305b-02
RH 200 Diesel - 3664276e.doc - (00) - 07.05
8.5 HYDRAULIC CIRCUITS - COOLING SYSTEM FOR ENGINES
8.5.9
Cooling system for engines
Remark:
The 2 cooling pumps (11) are axial piston pumps

with variable displacement.
On each drive unit one cooling pump is flanged
directly onto one of the swing pumps (fig. 1).
Each cooling pump is driving a gear motor (140).
The gear motors are driving the fans for the radiators of the engines.
The flow of the cooling pumps is regulated with
help of proportional valves which are directly
flanged onto the pump regulators. Depending on
the actual temperature in the engine cooling system the Pump Managing System (PMS) is regulating the speed of the fans. The temperature
range for the regulation is + 85 C to + 92 C.
At coolant temperatures below 85 C in the engine
cooling system the fan pumps are regulated to
minimum flow so that the fans are only turning very
slowly (200 rpm) the warm-up period of the engines is shortened.
At temperatures above 92 C the maximum flow is

passing through the fan motors and they are turning with 815 rpm.
With low engine temperature the PMS is supplying
maximum current (580 mA) to the proportional
valve of the cooling pump and the pump is at
minimum flow.
With increasing engine temperature the PMS is
reducing the current for the proportional valves to
150 mA and the cooling pumps are increasing the
flow to the fan motors.
This fail-save system ensures that in case of an
electric problem (e.g. a broken cable to the proportional valve) the fan pump stays at maximum flow
so that maximum cooling for the engine is
achieved.
Remark:
Colour
Code
Designation
Fan pump circuit
Return oil circuit
Leak oil
With rising temperature in the cooling system the

flow of the cooling pumps and consequently the
speed of the fans are increasing to their maximum.
Ref.-no.
Quantity
Designation
further remarks
11
Cooling pump
Axial piston pump
140
Fan motor
Axial piston motor
141
Anti cavitation block
Table 1
RH 200 Diesel - 3664277e.doc - (00) - 07.05
Page 8.5.9 - 1
8.5 HYDRAULIC CIRCUITS - COOLING SYSTEM FOR ENGINES
Fig. 1
Fan pumps and fan motors - 3664958-01
Fig. 2
Fan pump with electronic regulator
Page 8.5.9 - 2
RH 200 Diesel - 3664277e.doc - (00) - 07.05
8.5
HYDRAULIC CIRCUITS - COOLING FOR PUMP GEARBOX
8.5.10 Cooling system for

pump gearbox
Remark:
section are not shown in the hydraulic circuit
diagram and the components are not listed in
chapter 8.3 - Description of the hydraulic system.
the gear oil temperature. The data is displayed on

the BCS. Depending on the gearbox version the
components are either installed in a block at the
gear pump or in the gearbox housing.
To avoid, that the gear oil is pumped out of the
system (e.g. because of leaks) the system is preloaded to 1,0 bar by a check valve ( R ) and a
pressure switch (E) is indicating loss of pressure in
the whole system.
Remark:
The pump gearbox is equipped with a cooling

system for the gear oil. A gear pump (E) is pumping the gear oil through a filter (C) to the gear oil
cooler (A) and back into the pump gearbox (B) (fig.
1).
The oil cooler is installed as a separate heat exchanger in the hydraulic oil tank. A thermostatvalve (G) with an opening temperature of 55 C
protects the oil cooler against pressure peaks especially when the engine is started under cold
weather conditions.
A chip indicator is monitoring the condition of the
gear pump (E). A temperature sensor is monitoring
Ref.-no.
Quantity
Designation
Gear oil cooler section
Pump gear box
Filter for gear oil
Pressure switch
Gear pump
Thermostat valve
Check valve

Colour
Code
Designation
Return oil circuit
further remarks
Setting: 0,5 bar
Opening pressure: 1,0 bar
Table 1
RH 200 Diesel - 3664266e.doc - (00) - 06.04
Page 8.5.10 - 1
8.5
HYDRAULIC CIRCUITS - COOLING FOR PUMP GEARBOX
Fig. 1
Page 8.5.10 - 2
System for gear oil cooling of pump gearbox - 3663056-01
RH 200 Diesel - 3664266e.doc - (00) - 06.04
8.6
PRESSURE CHECKING AND SETTING
8.6
Pressure checking and setting
8.6.1
Introduction
8.6.1.1
Foreword
This Technical Handbook (TBH) describes the

pressure checking and setting procedures on the
excavator s hydraulic system.
It is valid for RH 200
serial-no. 40 029 to 40 068
and from serial-no. 200 069
The illustrations, descriptions and explanations
reflect the current standard configuration. Some of
the illustrations can show details that differ from a
particular machine, but that does not affect the
validity of the information given.
If any points are nevertheless unclear or incorrect,
please contact your local TEREX dealer or your
TEREX distributing centre.
Further development and alternations that introduce into the standard series production will be
implemented into later re-prints of the TBH.
When setting the pressure relief valves the
hydraulic oil temperature has to be higher than
52C.
8.6.1.2
Safety
Observe accident prevention

and safety regulations at all
times.
The pressure checking and setting
may only be done by special
trained and authorized personnel
with the appropriate technical
know-how.
The nominal pressure relief valves
must not be modified without explicit approval form TEREX.
All personnel carrying out commissioning, operation, inspection,
service and repair must have read
and understood the operating instructions and in particular the
chapter
'Fundamental Safety Instructions.'
before starting any work.
Unauthorized conversions or modifications of the hydraulic excavator
are forbidden for reasons of safety.
Secure the machine and the working attachment against inadvertent
and unauthorized starting. Stand
working attachment on the ground
in such way as that no movements
can be made when mechanical or
hydraulic connections become detached.
Tools, hoists, slings, trestles and
other devices must be in a reliable
safe state.
Systems and units (e.g. pipes,
coolers,
hydraulic
reservoirs,
compressed-air reservoirs ) must
be properly depressurized before
being opened.
Protective devices on moving machine parts may be opened or removed only when the drive unit is
stationary and protected against
inadvertent starting .
RH 200 Diesel - 2471390e.doc - (02) 01.98
Page 8.6 - 1
8.6
Before recommissioning, all protective devices must be refitted.

Catwalks on the boom are only to
be walked on when the excavator's
working attachment has been
brought into the position required
for checking/settings pressures.
Hydraulic cylinders must be
brought into their end positions
before pressures are checked or
set to ensure that working attachment does not move when pressure is applied.
The excavator operator must operate the relevant function gently
(gradual application of pressure)
and the shift the joystick/pedals
fully to their end position.
All Pressure test points on the excavator have Minimess connections (M14 x 1,5). Pressure gauges
used for checking must therefore
have corresponding fittings.
Always connect the Minimess-hose
first to the gauge and then to the
test point on the machine to avoid
spillage of pressurized oil!
8.6.1.3
General
The reference numbers used in the text and illustrations correspond to those used in the hydraulic
circuit diagram.
Since the machine is equipped with the BCS-Board
Control System, most pressures are available on
the BCS display. If pressure must be reset, in any
case calibrated gauges have to be used, they have
to be connected to the relevant test points.
Numbering of main pumps

The 4 main pumps are numbered in travel direction
from left to right P1, P2, P3, and P4 (Fig.1 ),
thus P1 and P2 are driven by the engine, and P3
and P4 are driven by the right engine.
Numbering of swing pumps

Each drive unit is equipped with a swing pumps
(double pumps). The swing pumps on the left
pump gear are named SP1 and SP2, the pumps
on the right pump gear are SP3 and SP4 (Fig. 1).
The springs in pressure relief

valves must never be tightened
fully to "block". The windings of
the spring are then jammed so that
the valve cannot open.
Before setting/resetting a relief
valve (primary or secondary)
loosen the valve insert by approx.
2 turns:
Turning anti-clockwise (loosening)
=lower pressure setting
Turning clockwise (tightening)
Fig. 1
=increase pressure setting

To set/reset a pressure relief valve
loosen the counter nut on the valve
insert, set the opening pressure
using the setting crew, and then
tighten the counter nut again.
When checking/setting pressures
the hydraulic oil temperature must
be above 50C.
Page 8.6 - 2
RH 200 Diesel - 2471390e.doc - (02) 01.98
8.6
8.6.2

Pressure setting
Description
Unit
RH 200
Cylinder
bar
300
Travel
bar
340
Primary relief for main pumps
bar
380
Secondary relief for
Boom cylinders
bar
350
Arm / Stick cylinders
bar
350
Bucket croud cylinders
bar
350
Backhoe cylinders
bar
350
Clam cylinders (4-spool

valve)
bar
350
Clam cylinders (Backwall)
bar
330
Travel system
bar
380
Proportional valve feed pressure main pumps
bar
7.5 42,5
Servo pressure
Attachment
bar
40
Main pumps
bar
70
Swing system working pressure max.
bar
375
Swing system charge pressure (approx.)
bar
50
Fan drive - pressure
bar
approx. 35
Pressure cut-off main pumps
Hydraulic oil cooling
Table 1
RH 200 Diesel - 2471390e.doc - (02) 01.98
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.
Test kit with gauges and hoses

Test adapter for proportional valve
Multimeter
O/E-ring spanner, 10 mm
Allan Key, 3 mm
Allan Key, 4 mm
Allan Key, 5 mm
Allan Key, 6 mm
Accumulator test and charging device
Adapter for nitrogen cylinder (see chapter 3.2.2 in THB)
1 476 323
1 433 919
1 088 932
0 717 903
0 559 698
0 559 702
0 717 908
0 717 913
0 014 122
0 014 123
0 014 124
0 014 125
1 429 836
Table 2
Page 8.6 - 4
RH 200 Diesel - 2471390e.doc - (02) 01.98
8.6
8.6.4.1

Servo control system
Servo pressure is to be set on valve combination

(16 & 17, Figs. 1 & 2).
Fig. 2
Checking and setting pressures

Fig. 1
Pressure relief valve (17):

Limits the Servo pressure for the functions Working equipment, Swing and Travel to 35 bar.
Differential pressure valve (16):
Increases servo pressure by 25 bar to 60 bar. The
higher pressure is needed for the regulation of the
working pumps, the increase of travel pressure and
the switch-over of travel motors.
Connect a 100 bar pressure gauge to point

(16.1, Fig. 1) for differential valve (16) and a 60
bar gauge to point (17.1) for pressure relief
valve (17).
Run both engines up to top speed.
Check pressures.
Pressure relief valve (17): pressure should be
35 bar.
If a correction is necessary, re-set valve (17).
Differential valve (16): pressure should be 60

bar.
If 60 bar is not reached (with relief valve (17)

correctly set), re-set valve (16). Unscrew nut
(16.2, Fig. 1) and re-set valve using the setting
screw.
Pressure loading in control spool servo caps

Restrictor valve (110, Figs. 3 & 4) keeps the servo
caps (90.1, Fig. 3) of control blocks (90) under a
pressure load of 1,5 bar.
RH 200 Diesel - 2471390e.doc - (02) 01.98
Page 8.6 - 5
8.6
Fig. 3
Checking pressure load
Connect a 10 bar pressure gauge to point

(110.1, Fig. 3).
Extend and retract boom, stick and bucket

cylinders several times.
Check pressure
It should be: 1,5 bar
Re-set the restrictor if necessary. To re-set,

loosen lock (1, Fig. 4) and alter the valve setting by turning knob (2).
Fig. 4
Turning clockwise: Closes the restrictor =

higher pressure
Turing anti-clockwise:
Opens the restrictor = lower pressure
Page 8.6 - 6
RH 200 Diesel - 2471390e.doc - (02) 01.98
8.6
8.6.4.2

Load limit system
The governing current output by the GLR 200 load

limit governor (black box) is converted by the
proportional valves (21, Figs. 1 & 2) into hydraulic
signals that are sent to the main pumps (P1 - P4).
Checking
Connect two 100 bar pressure gauges to

points (21.1 & 21.2, Fig. 2).
Check pressure
It should be: approx. 8 bar (230 mA)
Apply pressure to piston side of stick cylinders.
Check pressure
It should be: approx. 43 bar (850 mA)
If the required pressures are not reached, the

proportional valves are to be checked.
A metering adapter (Fig. 3) is needed to
measure the current arriving at the valves from
the GLR-box.
Fig. 1
Arrangement (Fig. 2):

21.1 (Y 18) = main pumps P1 + P2
21.2 (Y 17) = main pumps P3 + P4
Fig. 3
Connect metering adapter.
Re-run the checks described above. Measure

the currents at contacts (A, Fig. 3) each time.
If the electrical currents stated are not

reached, there is a fault somewhere in the load
limit circuit.
If the electrical currents are reached, but not

the hydraulic pressures, a fault is present in
the proportional valve and it needs to be
changed.
Fig. 2
RH 200 Diesel - 2471390e.doc - (02) 01.98
Page 8.6 - 7
8.6
8.6.4.3
Pressure cut-off system
The pressure cut-off function for the main pumps

(3, Fig. 1) is managed by the sequence valves
(3.1).
Fig. 1
Checking pressure
equipment.
Apply pressure to piston sides of stick cylinders. Shift the joystick gently into the end position.
Check pressures:
They should be 300 bar.
If a correction is necessary, re-set the respective valve as described.
Checking pressure cut-off for track drives.
Apply pressure to track drives. Depress the

treadle valves gently into the end positions.
Check pressures:
They should be 360 bar. If correction is required, check setting of valve combination (16
& 17, Fig. 3) (cf. section on servo-control).
cut-off
for
working-
Pressure cut-off valve
Checking and setting
Engage track parking brakes (using toggle

switch) and lower working equipment to the
ground.
Connect four 400 bar pressure gauges to the

test points (36.1, Fig. 2) for the relief valves
(36).
Fig. 3
Fig. 2
Page 8.6 - 8
Relief valves
RH 200 Diesel - 2471390e.doc - (02) 01.98
8.6
8.6.4.4
Primary pressure relief
The primary pressure of the four main pumps is

limited by four pressure relief valves (36, Fig. 1).
Fig. 1
Primary relief valves

Fig. 2
The pumps are coded P1 - P4 from left to right in

direction of travel.
Checking conditions:
Connect four 400 bar pressure gauges to metering points (36.1, Fig. 1).
Primary relief (P2):
Engage track parking brakes (with toggle

switch) and lower working equipment to the
ground.
RH engine stopped
LH engine at full speed
LH track forwards or reverse
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
Check primary relief settings for pumps (P2,

P3 & P4) in the same way.
Primary relief for main pump (P1)

- Switch off the pressure cut-off by shifting
cock (5, Fig. 2) on P1 into position 0.
- Run left-hand engine up to full speed. Shut
down the right-hand engine.
- Summon Right-hand track - forwards or
reverse.
- Check pressure.
- It should be: 370 bar. If correction is necessary, re-set primary valve.
Note:
When checking primary relief pressure (P3 & P4),
all pressure gauges show the pressures for (P3 &
P4).
- Switch on pressure cut-off by shifting cook

(5, Fig. 2) back into position 1.
RH 200 Diesel - 2471390e.doc - (02) 01.98
Page 8.6 - 9
8.6
8.6.4.5
Secondary relief system

for attachment
The secondary pressure relief valves for the attachment are flanged onto the 4-spool control
blocks (90, Fig. 1). The 4-spool control blocks are
located on the boom.
The faceshovel attachment is equipped with an

additional secondary relief valve for the rod side of
the clamshell cylinders, which is installed on the
distributor at the backwall of the bucket (Fig. 2).
Fig. 1
Secondary relief valve
Valve arrangement for faceshovel configuration (Fig. 1)

Position
1
Relief valve for

Spool not connected
Position
9
Relief valve for

Spool not connected
4+6
Bucket croud cylinder piston side
12 + 14
Bucket croud cylinder rod side
3+7
Arm cylinder rod side
11 + 15
Arm cylinder piston side
2+8
Boom cylinder piston side
10 + 16
Boom cylinder rod side
Clam cylinder piston side
13
Clam cylinder rod side
Table 3a
Valve arrangement for backhoe configuration (Fig. 1)

Position
Relief valve for
Position
Relief valve for
11 + 15
Bucket cylinder piston side
3+7
Bucket cylinder rod side
12 + 14
Stick cylinder piston side
4+6
Stick cylinder rod side
10 + 16
Boom cylinder piston side
2+8
Boom cylinder rod side
1, 5, 9, 13 Spools not connected

Table 3b
Page 8.6 - 10
RH 200 Diesel - 2471390e.doc - (02) 01.98
8.6
Table 4: Secondary pressure relief valves

* Switch off float when checking
To check valves for
Rod sides: retract cylinders fully
Piston sides: extend cylinders fully
Fig. 4

Fig. 2
Secondary relief valve at backwall
Connect 400 bar pressure gauges.
Switch off pressure cut-off on pump (P2) by

shifting cock (5, Fig. 4) into position 0.
In the case of the dump cylinders, also switch
off pressure cut-off for pump (P1).
Run left-hand engine up to full speed.
Check and set pressures

- Recommended sequence - see Table 1.
- Example: piston side of stick cylinders
Fig. 3
Test points on float valves
- Switch off stick float; shift joystick gently

into end position.
- Check pressure: it should be 350 bar.
- Because the piston sides of the stick
cylinders are protected by a pair of
valves (11 & 15, Fig. 1), the pressure
gauge on port (15.1) always registers the
pressure of the valve with the lower setting. Even when the gauge shows 350
bar, it is still possible for one of the
valves to have a higher setting.
- For this reason, lower the pressure on
the 1st valve to below 350 bar. The pres-
RH 200 Diesel - 2471390e.doc - (02) 01.98
Page 8.6 - 11
8.6

sure on the gauge must drop noticeably.
Then increase back up to 350 bar.
- Set the 2nd valve in the same way.
After checking / setting secondary pressures,

shift cocks for pressure cut-off (5, Fig. 4) back
into position 1.
8.6.4.6
Secondary relief system for travel
The four secondary relief valves (77.1 - 77.4, Fig.

1) for the track motors are located in the undercarriage module.
The valves (77.2 & 77.3) are on the rear side of the
housing.
Clam cylinders
To adjust the additional secondary relief valve for
the rod side of the clam cylinders installed in the
backwall open the bucket, keep the clam cylinder
rod-side pressurised and set the relief valve to 330
bar.
Fig. 1
Secondary relief valve for travel
Page 8.6 - 12
Engage the track parking brakes (with toggle

switch) and lower the working equipment to the
ground.
De-stroke the main pumps by shifting the

Power control / Eco Set switch to 60 % (see
Operating Instructions).
Connect four 400 bar pressure gauges to the

metering points for the pressure relief valves.
RH 200 Diesel - 2471390e.doc - (02) 01.98
8.6
Fig. 2
Pressure cut-off valve
Switch off pressure cut-off for main pumps (P1

& P2) by shifting the cocks (5, Fig. 2) into position 0.
Run left-hand engine up to top speed.
Leave the track brakes engaged and summon

left-hand track forwards. Depress treadle
valve gently into end position.
Check pressure on relief valve (77.1, Fig. 1).
It should be: 370 bar. Re-set the valve if necessary.
Summon following functions, one after the

other:
LH track
RH track
RH track
reverse (valve 77.2)

forwards (valve 77.3)
reverse (valve 77.4)
and check pressures in the same manner.
After checking / setting secondary pressures,

shift cocks for pressure cut-off (5, Fig. 2) back
into position 1.
RH 200 Diesel - 2471390e.doc - (02) 01.98
Page 8.6 - 13
8.6
8.6.4.7
Swing system

1.
2.
Lower working equipment to the ground and

engage the superstructure holding brake.
Connect two 400 bar pressure gauges to the
metering points (51.1, Fig. 1) on the balance
valve.
Connect two 60 bar pressure gauges to ports

(X1 and X2, Fig. 2) on pressure valve (54).
Re-set valve using setting screw (54.1) until
pressures are equal.
Proceed under 4.2
4.2 If pressures are equal: connect two 60 bar
gauges instead of the 400 bar gauges to the
ports on (51.1, Fig. 1). The 60 bar gauges
have a higher accuracy.
Do NOT summon a swing function as this will destroy the

gauges.
Fig. 1
Swing balance valve
Check charge pressure: at full engine speed

and with flushing valve (57, Figs. 2 & 3) correctly set, the charge pressure should be 25
bar.
Charge pressure is limited by the pressure relief valves (6.1, Fig. 3) - one valve for each
swing pump. The valves are works set to 25
bar. The setting must not be altered.
If 25 bar charge pressure is not reached, call
in TEREX Service.
Fig. 2
Swing balance valve
3.
4.
Check pressure with superstructure locked:

both gauges on the balance valve must register the same pressure.
Fig. 3
4.1 If pressures are not equal: Pressure valve (54,

Fig. 1 + 2) and swing pumps are not exactly in
the middle position (superstructure trying to
swing).
Page 8.6 - 14
RH 200 Diesel - 2471390e.doc - (02) 01.98
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
The primary relief valves (6.2, Fig.

5) for the swing circuit (2 valves
per swing pump) have fixed settings of 400 bar. Their settings
must NOT be altered.
Flushing valve (57, Figs. 2 & 3) flushes the oil

in the closed loop swing circuit. Each time a
swing function is summoned, a small quantity of oil is flushed out of the low-pressure
side.
Setting: dimension A on setting screw (57.1,
Fig. 3) must be 15 mm.
5.
Take the 60 bar gauges off the swing motor

(51) and connect the 400 bar gauges again.
Connect a 60 bar gauge to metering port
(55.1, Fig. 5) for pressure relief valve (55).
The valve is located in the cab module underneath the platform plate.
Fig. 5
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
RH 200 Diesel - 2471390e.doc - (02) 01.98
Page 8.6 - 15
8.6
8.6.4.8

Track tensioning system
The pressure for hydraulic track tensioning is taken

from the servo-circuit. The tracks are permanently
tensioned with approx. 60 bar when engine on the
left side is running.
8.6.4.9
Hydraulic oil cooling
The hydraulic oil is cooled in two separate circuits.

Each circuit is protected by two relief valves (43,
Fig. 1).
Arrangement: Front cooler = LH engine
Rear cooler = RH engine
Tensioning the tracks

See Operating Instructions
Check the gas pressure in the accumulator according to the Operating Instructions.
Secondary relief
The track tensioning systems are protected by two
secondary relief valves (70, Fig. 1) with fixed settings of 330 bar.
Fig. 1
Oil cooling - relief valve
Fig. 1
Relief valves - track tensioning
Connect four 60 bar pressure gauges to ports

(43.1). Fig. 1 shows one of the two distributor
plates.
Check that oil temperature is above 52 C and

that the thermostats are fully closed.
Check pressure. Circuiting pressure should be

approx. 35 bar.
Pressure relief
If the pressure-limiting valves (70)
are open there will be no servopressure and thus no possibility of
activating hydraulic functions.
Page 8.6 - 16
Pressure relief valves (43) are works set to approx.

65 bar. To check, proceed as follows:
Set valves to circuiting pressure. To do this,

reduce valve cracking pressure until the circuiting pressure starts to drop.
Then tighten valve inserts of a turn (cracking

pressure is increased again).
RH 200 Diesel - 2471390e.doc - (02) 01.98
8.7
INSTALLATION OF HYDRAULIC PUMPS
8.7
Installation of hydraulic
pumps
8.7.1
General
When removing or installing hydraulic pumps all

relevant safety regulations have to be observed.
8.7.2
Always observe the safety regulations applicable to

the product when handling oils, greases and other
chemical substances.
Components
Table for Fig. 1

Ref. no.
Quantity
Designation
Further remarks
16
Hex. bolt M 20 x 80 8.8
16
Washer
O-ring
4-8
Weight
[kg]
----
O-ring
10
Washer
11
Hex. bolt M 20 x 50 10.9
12
O-ring
13
Washer
14
Hex. bolt M 12 x 30 8.8
15
O-ring
16
Washer
17
Hex. bolt M 12 x 30 8.8
18
O-ring
19
Hex. bolt M 10 x 25 8.8
20
----
21
Main pump
22
Swing pump
23
24
Fan pump for radiator
25
Fan pump for hydraulic oil cooling
26
Gear pump for servo system
Table 1
RH 200 Diesel - 3664249e.doc - (00) 06.05
Page 8.7 - 1
8.7
1, 11, 14,
17, 19
Fig. 1
8.7.3
Installation of hydraulic pumps
Removal and installation of the

hydraulic pumps
Installation of a pump
Removal of a pump
1. Apply lubricating paste (Part-no. 244 905) to

splines of pump shaft, adapter and gearbox
shaft.
1. Disconnect electric cables.
2. Install new O-ring with grease.
2. Close gate valves between hydraulic tank and

suction line of the pump.
3. Attach lifting device to the pump and lower into

place. Insert and tighten mounting bolts with
required torque (see table).
3. Open hydraulic lines of the pump cautiously.

Collect hydraulic oil in suitable container.
4. Connect all hydraulic lines as market.
4. Remove hydraulic lines and mark them to avoid

mix up. Close all open hoses, lines bores and
housings carefully to prevent dirt from penetrating.
5. Attach lifting device to the pump; disassemble
mounting bolts and remove the pump.
Page 8.7 - 2
Open gate valves of the hydraulic tank!
All axial piston pumps have to be

filled with hydraulic oil before start
up to avoid damage of the pump
when running dry.
RH 200 Diesel - 3664249e.doc - (00) 06.05
8.7
5. Bleed pumps!
6. Connect electric cables again.
Filling and bleeding the pumps has to be done

through the ports for the lines or the bleeder
plugs (Fig. 2).
Fig. 2
RH 200 Diesel - 3664249e.doc - (00) 06.05
Filling and bleeding of the pumps
Page 8.7 - 3
8.7
Page 8.7 - 4
RH 200 Diesel - 3664249e.doc - (00) 06.05
8.7
8.7
Installation of hydraulic
pumps
8.7.1
General
When removing or installing hydraulic pumps all

relevant safety regulations have to be observed.
8.7.2
Always observe the safety regulations applicable to

the product when handling oils, greases and other
chemical substances.
Components
Table for Fig. 1

Ref. no.
Quantity
Designation
Main pump
Fan pump for hydraulic oil cooling
Swing pump
Fan pump for radiator
----
----
Further remarks
Gear pump for servo system
Double pump
Hex. bolt M 20 x 50 10.9
10
Washer
11
16
Washer
12
16
Hex. bolt M 20 x 80 8.8
13
Hex. bolt M 10 x 25 8.8
14
Hex. bolt M 12 x 30 8.8
15
Washer
16
Hex. bolt M 12 x 30 8.8
17
Washer
18
---
19
---
20
O-ring
21
O-ring
22
O-ring
23
O-ring
24
O-ring
Weight
[kg]
Table 1
RH 200 Diesel - 3657791e - (00) 09.03
Page 8.7 - 1
8.7
9, 12, 13,
14, 16
Fig. 1
8.7.3
Installation of hydraulic pumps
Removal and installation of the

hydraulic pumps
Installation of a pump
Removal of a pump
1. Apply lubricating paste (Part-no. 244 905) to

splines of pump shaft, adapter and gearbox
shaft.
1. Disconnect electric cables.
2. Install new O-ring with grease.
2. Close gate valves between hydraulic tank and

suction line of the pump.
3. Attach lifting device to the pump and lower into

place. Insert and tighten mounting bolts with
required torque (see table).
3. Open hydraulic lines of the pump cautiously.

Collect hydraulic oil in suitable container.
4. Connect all hydraulic lines as market.
4. Remove hydraulic lines and mark them to avoid

mix up. Close all open hoses, lines bores and
housings carefully to prevent dirt from penetrating.
Open gate valves of the hydraulic tank!
5. Attach lifting device to the pump; disassemble

mounting bolts and remove the pump.
All axial piston pumps have to be

filled with hydraulic oil before start
up to avoid damage of the pump
when running dry.
Page 8.7 - 2
RH 200 Diesel - 3657791e - (00) 09.03
8.7
5. Bleed pumps!
6. Connect electric cables again.
Filling and bleeding the pumps has to be done

through the ports for the lines or the bleeder
plugs (Fig. 2).
Fig. 2
RH 200 Diesel - 3657791e - (00) 09.03
Filling and bleeding of the pumps
Page 8.7 - 3
8.7
Page 8.7 - 4
RH 200 Diesel - 3657791e - (00) 09.03
8.8
HYDRAULIC CYLINDERS - FS
8.8
Hydraulic cylinders
8.8.1
Introduction
8.8.1.1
Foreword
This section describes the procedures necessary

when repairing hydraulic cylinders. The illustrations
and descriptions correspond to the current series
status. It is possible for some illustrations to show
details that differ from a particular machine or
component. This, however, is of no consequence
to the overall function.
In case of doubt, consult the TEREX Mining
Service.
Any alterations and up-grading introduced into the
series will be considered in future re-prints of the
Technical handbook (THB).
The required special tools can be found in
Chapter 3.2.8 cylinder tools
8.8.1.2
Safety
regulations at all times.
Any person involved in commissioning, operating, inspecting or
servicing the TEREX excavator
must have read through the Operating Instructions - especially the
chapter SAFETY - before starting
any work.
Personnel working on the machine
and its components must have
adequate knowledge of the procedures involved.
Tools, lifting equipment, rigging
tackle, trestles, working platforms
and other working aids must be in
a safe and reliable condition.
Depressurize any systems that are
to be opened for servicing or inspection work.
Before commencing an servicing
or inspection work, secure the machine and its equipment against
unintentional starting, e.g. place
chocks under the tracks and lower
the working equipment to the
ground.
Park the excavator on a level surface and block it to prevent it from
moving. Lock the superstructure,
lower the working equipment to the
ground, stop the engine(s) and secure it against unintentional starting.
RH 200 (FS) - 2471393e - (01) 01.98
Page 8.8 - 1
8.8
Do not loosen any fittings, pipes or

hoses until hydraulic pressure has
been released from the system.
Take care when hydraulic oil is hot.
Fully retract the piston rods of the
cylinder to be removed, and fasten
the piston rod to the cylinder so
that it cannot extent. The hydraulic
connections can then be loosened.
Use suitable containers to catch
spilling oil.
Use suitable lifting tackle to remove and install piston rods and
guide bushings.
Close up any open pipes, hoses

and housing ports to prevent dirt
from getting into the system.
When working on hydraulic cylinders (especially when removing
and fitting piston rods), keep the
cylinder in a vertical position.
Place long cylinders into inspection pits so that the piston rod eye
and guide bushing are accessible
from ground level.
8.8.1.3
General
All cylinder components are carefully matched to

one another. Long-term trouble-free operation can
only be ensured when genuine TEREX spare
parts are used.
The wear and spare parts necessary for the
cylinders are listed in the excavator's spare
parts list.
This section does not describe procedures necessary for overhauling damaged cylinders. Only specialist workshops can judge whether a damaged
component can be overhauled and which procedures are necessary. Work to be performed in your
own workshops should therefore be limited to the
installation of new TEREX wear and spare parts.
All procedures must be carried out carefully in a
clean workshop. Negligence can lead to major
damage to the whole hydraulic system.
After servicing, the hydraulic cylinders must be
bled of air prior to being used again. Air pockets
remaining in a cylinder can ignite (diesel effect)
and cause serious internal damage to the cylinder.
If any contamination of metal particles are found in
the cylinder, on the magnetic rods or in the filters,
the whole system must be flushed clean.
The procedure is described in chapter 8.2.
Cleanliness is of prime importance.

Use only fibre-free cloths and rags
(do NOT use cotton waste).
Always
tools.
use
the
recommended
When removing seals and wearing

parts, always use suitable tools,
e.g. snub-nosed screwdrivers, to
prevent damaging the sealing surfaces.
Page 8.8 - 2
RH 200 (FS) - 2471393e - (01) 01.98
8.8
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
RH 200 (FS) - 2471393e - (01) 01.98
4525838A.SKD
Boom cylinder
Page 8.8 - 3
8.8
Components of boom cylinder (Fig. 1)

Position
Quantity
Designation
Further remarks
Weight
[kg]
Position of pivot bearing split
A
1
Cylinder barrel
2 092
Piston rod
1 200
Bearing eye
Scraper
Sealing ring
Sealing ring
Guide
Guide ring for piston rod
Back ring
10
O-ring
11
Protection element
12
Guide ring for piston
13
Guide ring for piston (metal)
14
Piston seal
15
Bushing
16
----
17
----
18
Hex. bolt M 39 x 3 x 220
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
RH 200 (FS) - 2471393e - (01) 01.98
8.8
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
RH 200 (FS) - 2471393e - (01) 01.98
Arm cylinder
Page 8.8 - 5
8.8
Components of arm cylinder (Fig. 2)

Position
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
Double hex bolt M 27 x 2 x 160
19
15
Washer
20
Designation
Further remarks
Weight
[kg]
1 266
132
----
21
Dowel pin
22
15
Table 2
Page 8.8 - 6
RH 200 (FS) - 2471393e - (01) 01.98
8.8
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
RH 200 (FS) - 2471393e - (01) 01.98
Page 8.8 - 7
8.8
Components of bucket crowd cylinder (Fig. 3)

Position
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
RH 200 (FS) - 2471393e - (01) 01.98
8.8
8.8.2.4
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
RH 200 (FS) - 2471393e - (01) 01.98
Clam cylinder
Page 8.8 - 9
8.8
Components for clam cylinder (Fig. 4)

Position
Quantity
Designation
Further remarks
Weight
[kg]
Position of pivot bearing split
A
1
Cylinder barrel
216
Piston rod
109
Fork
153
Flange
10
Double hex. bolt M 27 x 2 x 140
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
RH 200 (FS) - 2471393e - (01) 01.98
8.8
8.8.3
Assembly
There are 3 different types of bearing eyes used:

1. Clevis type, 2-piece (Fig. 5)
2. Boss type, 1-piece (Fig. 6)
Fig. 7
Fig. 5
Clevis type, 2-piece
Fig. 6
Boss type, 1-piece
RH 200 (FS) - 2471393e - (01) 01.98
Page 8.8 - 11
8.8
8.8.3.1
Clevis type, 2-piece (Fig. 8)
Fig.9
Fig. 8
Disassembly of the fork
Disassembling and checking

1. Use petroleum to remove the coating of rust
inhibitor between flange (4, Fig. 8) and piston
rod (8) (see THB Sealing, protective, checking
and cleaning agents).
2. Attach lifting tackle to the bearing eye and
loosen bolts (5, Fig. 9).
3. Lift bearing eye off the piston rod.
4. Check bushing (10) and dowel pin (2) for damage - change if necessary.
5. Remove bushing (6) and replace O-rings and
back rings (Fig. 10).
6. Unscrew flange (4) from piston rod (Fig. 11).
Page 8.8 - 12
Fig. 10
Lifting of the fork
RH 200 (FS) - 2471393e - (01) 01.98
8.8
731 (see THB Sealing, protective, checking
Fig. 11
Put new O-ring (36, Fig. 8) around piston rod.
4.
Screw flange (4, Fig. 8) into place.
5.
Check that dowel pin (31, Fig. 12) is in position.
6.
Lift the bearing eye in lifting tackle.
7.
Lower eye (1, Fig. 8) into position. Seating

surfaces of eye (1) and piston rod (8) must lie
exactly plane on another in order to transfer
the high cylinder forces. Dowel pin (31, Fig.
12), which prevents the eye from rotation on
the rod, must fit in the opposite seating hole.
8.
Screw flange (4, Fig. 8) onto piston rod until it

is approx. 1.5 - 3 mm from eye (1). The gap
must be equal all round (the eye is otherwise
not seated fully on the rod).
9.
Pre-install bolts. The threads of the bolts (5,

Fig. 8) have to be free of grease and oil.
Disassembly of the flange
Assembly
1.
3.
Check bearing eye (3, Fig. 12).

The seating surface to the piston rod must be
free of any damage and corrosion.
The seating surface of the piston rod must
also be free of any damage and corrosion.
10. Pull O-ring (36) up into the gap outside of the

bolts (5). If necessary, lift the eye (1) slightly
in order to push the ring into the gap.
11. Tighten bolts (5) in opposite pairs by hand.
Check gap between eye (1) and flange (4). It
has to be between 1.5 and 3 mm. The gap
has to be equally all around.
12. Tighten bolts (5,) crosswise. To prevent the
eye (1) from seating skew, tighten the bolts in
3 stages.
Torque for bolts - see table 7.
13. Coat exposed ends of bolts (5) with the corrosion inhibitor mentioned under Point 2.
Fig. 12
2.
Bearing eye
Coat the thread of the piston rod (8, Fig. 8)

with SOLUTION 1 rust inhibitor, P/No. 153
RH 200 (FS) - 2471393e - (01) 01.98
Page 8.8 - 13
8.8
8.8.3.2
Boss type, 1-piece (Fig. 12)
Fig. 13
Fig. 14
Disassembly of the eye
Fig. 15
Lifting of the eye
Boss type, 1-piece

inhibitor in slot (A) of the bearing eye (1, Fig.
13). See THB Sealing, protective, checking
2. Lift the bearing eye in lifting tackle; loosen
mounting bolts (5, Fig. 14).
3. Unscrew slotted bearing eye (1) from the piston
rod (8). If necessary widen the slot with help of
a wedge.
4. Check bushing (10) for damage - change if
necessary.
Assembly
1. Coat the thread of the piston rod (8, Fig. 14)
2. Place bearing eye (1) onto the piston rod (8)
and screw on hand-tight to the mechanical stop.
Page 8.8 - 14
RH 200 (FS) - 2471393e - (01) 01.98
8.8
3. Insert bolts (5) and tighten in 3 stages. The

bolts have to be free of grease and oil!
8.8.3.3
Torque for bolts see table 7.

4. Coat exposed ends of bolts (5) and slot of the
bearing eye with the corrosion inhibitor Part-no.
1 570 254.
Fig. 16

mounting bolts (5, Fig. 17
a wedge.
necessary.
RH 200 (FS) - 2471393e - (01) 01.98
Page 8.8 - 15
8.8
Assembly
3. Insert bolts (5) and tighten crosswise in 3
stages. The bolts have to be free of grease and
oil!
1 570 254.
Fig. 17
Fig. 18
Lifting of the fork
Page 8.8 - 16
RH 200 (FS) - 2471393e - (01) 01.98
8.8
8.8.3.4
Piston rod guide
All Positions refer to Fig. 19
Fig. 19
RH 200 (FS) - 2471393e - (01) 01.98
Piston rod guide
Page 8.8 - 17
8.8
Components of piston rod guide (Fig. 19)

Position
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
Removing and checking

1. Drain hydraulic oil from the cylinder. Catch escaping oil in a suitable container.
5. Take off guide (4).

Remove all sealing and wear parts.
Use suitable tools to prevent damaging the
sealing surfaces in any way.
2. Remove bearing eye.

3. Loosen bolts (16).
4. Remove the guide (4) from the cylinder barrel
using 3 jacking bolts.
6. Check guide (4) for damage. If damage is visible, guide must be replaced. Seals and wearing
parts will otherwise be destroyed in a very short
time.
ALWAYS change ALL wearing parts!
Depending on the type of cylinder the following

completely threaded jacking bolts are to be
used:
Boom cylinder:
M 12 x 190, 10.9, DIN 933, Part-no. 2 781 855
Arm cylinder:
M 12 x 190, 10.9, DIN 933, Part-no. 2 781 855
Bucket cylinder:
M 12 x 190, 10.9, DIN 933, Part-no. 2 781 855
Clam cylinder:
M 12 x 150, 10.9, DIN 933, Part-no. 2 781 852
Page 8.8 - 18
RH 200 (FS) - 2471393e - (01) 01.98
8.8
Assembly
1. Fit seal (29, Fig. 19) and back ring (30). Make
sure that back ring is on the correct side.
2. Fit the split guide sleeve (22).
3. Coat guide with assembly paste P/No. 271 554
in area (4, Fig. 19).
4. Install V-rings (20 + 21, Fig. 19).
Each V-ring (20 + 21) comprises V-ring (A) and
back ring (B).
Depending on the cylinder design the grove for
the scrapers (14) and (15) can be part of the
cylinder rod guide (Fig. 20).
Fig. 21
Installation of V-ring
If the scraper (20) is separately installed it is

bolted with ring (8), disk (9) and bolts (14) onto
the rod guide (Fig. 22).
The mounting bolts are hand-tightened only.
Fig. 20
Scraper
In this case fold V-ring (A) into a kidney shape

and place into groove (Fig. 21).
Then fit the split back ring (B, Fig. 21).
5. Fit scrapers (14 + 15, Fig. 20).
6. Before fitting the guide, coat scrapers, seal and
guide rings with hydraulic oil.
Fig. 22
Scraper
7. Place guard sleeve (C, Fig. 23) over thread of

piston rod.
The sleeve protects the seal and guide rings in
the rod guide against being damaged on the
rod threads.
If a guard sleeve is not available, wrap adhesive tape around the rod threads.
RH 200 (FS) - 2471393e - (01) 01.98
Page 8.8 - 19
8.8
8.8.3.5
Piston rod and piston

2. Remove rod head and rod guide.
3. Using a lifting device lift the piston rod (8, Fig.
25) with help of the lifting eye (D, Fig. 25) out of
the cylinder barrel an place onto a prepared
clean working bench.
Fig. 23
Piston rod with guard sleeve
8. Push guide into cylinder barrel.

9. Insert bolts (6, Fig. 24) and tighten crosswise in
3 stages. The bolts have to be free of grease
and oil!
Fig. 25
Rod puller
4. Remove plastic guide rings (24, Fig. 26), OK

piston seal (23) and guard rings (25).
The cast iron ring (26, Fig. 26) often shows
minor signs of use but without any measurable
wear (less than 0.1 mm). In such a case, the
ring can be used again. Cast iron rings are difficult to remove and the risk of piston damage is
high. The rings should therefore only be removed with special pliers (Fig. 27).
Fig. 24
Flange with bearing eye
10. Install bearing eye (see chapter 8.8.3.1 to

8.8.3.3).
Page 8.8 - 20
RH 200 (FS) - 2471393e - (01) 01.98
8.8
Fig. 26
Piston guide
Components of piston guide (Fig. 26)

Location
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
RH 200 (FS) - 2471393e - (01) 01.98
Page 8.8 - 21
8.8
Fig. 27
Fig. 28
Installation of piston seal
Fig. 29
Spreader for guide ring (cast iron)
Thoroughly check piston, piston rod, dampener

and cylinder barrel for signs of damage and wear.
Also check the barrel for bulging. Replace all damaged parts.
ALWAYS change plastic guide rings, guard rings
and OK piston seals.
Assembly
The piston is sealed with an OK piston seal (23,
Fig. 26), comprising:
Plastic stepped seal ring (A)
Square tensioning ring (B).
1. Fit the tensioning ring (B) in the relevant
groove:
Fit approx. 1/5 of the tensioning ring into the
groove.
Push a smooth rod through the ring (Fig. 28)
and lever it into its seating with a circling action
(arrow, Fig. 28) around the piston.
2. Fit guide rings (20 + 22, Fig. 30 + 31).

Use special pliers (P/No. 1 709 183) to fit cast
iron guide rings (22, Fig. 30).
Do not open the guide rings too far as they
could break.
The gaps in the guide rings must be offset at
180 to one another.
Do not remove the bar until the tensioning ring

is seated absolutely straight in its groove (Fig.
29).
Page 8.8 - 22
RH 200 (FS) - 2471393e - (01) 01.98
8.8
OK-piston seals are installed with

pre-load. Depending on the diameter the pre-load is 0,65 - 1 mm.
Fig. 30
Installation of guide ring (cast iron)
Fig. 33
Assembling without the sleeve can lead to the

seal and guide rings jamming.
Part-nos. for sleeves are listed in
Chapter 3.2.8 Cylinder tools.
Fig. 31
Installation of guide ring
3. Fit seal ring (21.2, Fig. 32) into OK piston seal.
5. Using rod puller (D, Fig. 25), lift piston rod and
lower fully into the cylinder barrel.
6. Install rod guide and rod head (see chapter
8.8.3.4).
Fig. 32
4. Brush hydraulic oil onto seal, guide and guard

rings. Push sleeve (E, Fig. 33) over the piston
to fix seal and guide rings in position.
RH 200 (FS) - 2471393e - (01) 01.98
Page 8.8 - 23
8.8
8.8.4
Tightening torque
In the following table the tightening torque for the

bolts of the hydraulic cylinders can be found.
Bolt size
M 20
M 27 x 2
M 27 x 2
M 27 x 2
M 36 x 3
M 39 x 3
Bolt quality
10.9
10.9
10.9
10.9
10.9
10.9
Bolt type
hex.
double hex.
hex.
double hex.
hex.
hex.
Bolt length [mm]
120
140
170
160
190
220
Spanner size (SW)
17
32
41
32
55
60
Stage 1 [Nm]
280
650
750
650
1 750
2 300
Stage 2 [Nm]
420
900
1 100
900
2 700
3 500
Stage 3 [Nm]
560
1 135
1 500
1 135
3 500
4 600
Tightening torque
Table 7
Page 8.8 - 24
Tightening torque for bolts on cylinders
RH 200 (FS) - 2471393e - (01) 01.98
8.8
HYDRAULIC CYLINDERS - BH
8.8
Hydraulic cylinders
8.8.1
Introduction
8.8.1.1
Foreword
This section describes the procedures necessary

when repairing hydraulic cylinders. The illustrations
and descriptions correspond to the current series
status. It is possible for some illustrations to show
details that differ from a particular machine or
component. This, however, is of no consequence
to the overall function.
In case of doubt, consult the TEREX Mining
Service.
Any alterations and up-grading introduced into the
series will be considered in future re-prints of the
Technical handbook (THB).
The required special tools can be found in
Chapter 3.2.8 cylinder tools
8.8.1.2
Safety
regulations at all times.
Any person involved in commissioning, operating, inspecting or
servicing the TEREX excavator
must have read through the Operating Instructions - especially the
chapter SAFETY - before starting
any work.
Personnel working on the machine
and its components must have
adequate knowledge of the procedures involved.
Tools, lifting equipment, rigging
tackle, trestles, working platforms
and other working aids must be in
a safe and reliable condition.
Depressurize any systems that are
to be opened for servicing or inspection work.
Before commencing an servicing
or inspection work, secure the machine and its equipment against
unintentional starting, e.g. place
chocks under the tracks and lower
the working equipment to the
ground.
Park the excavator on a level surface and block it to prevent it from
moving. Lock the superstructure,
lower the working equipment to the
ground, stop the engine(s) and secure it against unintentional starting.
RH 200 (BH) - 2471388e - (01) 01.98
Page 8.8 - 1
8.8
Do not loosen any fittings, pipes or

hoses until hydraulic pressure has
been released from the system.
Take care when hydraulic oil is hot.
Fully retract the piston rods of the
cylinder to be removed, and fasten
the piston rod to the cylinder so
that it cannot extent. The hydraulic
connections can then be loosened.
Use suitable containers to catch
spilling oil.
Use suitable lifting tackle to remove and install piston rods and
guide bushings.
Close up any open pipes, hoses

and housing ports to prevent dirt
from getting into the system.
When working on hydraulic cylinders (especially when removing
and fitting piston rods), keep the
cylinder in a vertical position.
Place long cylinders into inspection pits so that the piston rod eye
and guide bushing are accessible
from ground level.
8.8.1.3
General
All cylinder components are carefully matched to

one another. Long-term trouble-free operation can
only be ensured when genuine TEREX spare
parts are used.
The wear and spare parts necessary for the
cylinders are listed in the excavator's spare
parts list.
This section does not describe procedures necessary for overhauling damaged cylinders. Only specialist workshops can judge whether a damaged
component can be overhauled and which procedures are necessary. Work to be performed in your
own workshops should therefore be limited to the
installation of new TEREX wear and spare parts.
All procedures must be carried out carefully in a
clean workshop. Negligence can lead to major
damage to the whole hydraulic system.
After servicing, the hydraulic cylinders must be
bled of air prior to being used again. Air pockets
remaining in a cylinder can ignite (diesel effect)
and cause serious internal damage to the cylinder.
If any contamination of metal particles are found in
the cylinder, on the magnetic rods or in the filters,
the whole system must be flushed clean.
The procedure is described in chapter 8.2.
Cleanliness is of prime importance.

Use only fibre-free cloths and rags
(do NOT use cotton waste).
Always
tools.
use
the
recommended
When removing seals and wearing

parts, always use suitable tools,
e.g. snub-nosed screwdrivers, to
prevent damaging the sealing surfaces.
Page 8.8 - 2
RH 200 (BH) - 2471388e - (01) 01.98
8.8
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
RH 200 (BH) - 2471388e - (01) 01.98
2135918A.SKD
Boom cylinder
Page 8.8 - 3
8.8
Components of boom cylinder (Fig. 1)

Position
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
RH 200 (BH) - 2471388e - (01) 01.98
8.8
8.8.2.2
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
RH 200 (BH) - 2471388e - (01) 01.98
Stick cylinder
Page 8.8 - 5
8.8
Components of arm cylinder (Fig. 2)

Position
Quantity
Cylinder barrel
Piston rod
Fork
Flange
58
Bushing
253
Guide
12
Dowel pin
15
Hex bolt M 36 x 3 x 190
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
RH 200 (BH) - 2471388e - (01) 01.98
8.8
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
RH 200 (BH) - 2471388e - (01) 01.98
Bucket cylinder
Page 8.8 - 7
8.8
Components of bucket cylinder (Fig. 3)

Position
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
Hex bolt M 27 x 2 x 170
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
RH 200 (BH) - 2471388e - (01) 01.98
8.8
8.8.3
Assembly
There are 3 different types of bearing eyes used:

Fig. 7
Fig. 5
Fig. 6
Boss type, 1-piece
RH 200 (BH) - 2471388e - (01) 01.98
Boss type, 2-piece
Page 8.8 - 9
8.8
8.8.3.1
Fig.9
Fig. 8

rod (8) (see THB Sealing, protective, checking
2. Attach lifting tackle to the bearing eye and
loosen bolts (5, Fig. 9).
3. Lift bearing eye off the piston rod.
4. Check bushing (10) and dowel pin (2) for damage - change if necessary.
5. Remove bushing (6) and replace O-rings and
back rings (Fig. 10).
6. Unscrew flange (4) from piston rod (Fig. 11).
Page 8.8 - 10
Fig. 10
Lifting of the fork
RH 200 (BH) - 2471388e - (01) 01.98
8.8
3.
4.
5.
6.
7.

8.

Assembly
9.
Pre-install bolts.
1.

Fig. 11
Disassembly of the flange


3 stages.
31
4525806D.SKD
Fig. 12
2.
Bearing eye

RH 200 (BH) - 2471388e - (01) 01.98
Page 8.8 - 11
8.8
8.8.3.2
Fig. 13
Fig. 14
Disassembly of the eye
Fig. 15
Lifting of the eye
Boss type, 1-piece

mounting bolts (5, Fig. 14).
a wedge.
necessary.
Assembly
Page 8.8 - 12
RH 200 (BH) - 2471388e - (01) 01.98
8.8
3. Insert bolts (5) and tighten in 3 stages.
8.8.3.3

1 570 254.
10
2
5
8
4525806C.SKD
Fig. 16
Boss type, 2-piece

rod (8).
See THB Sealing, protective, checking and
cleaning agents).
mounting bolts (5, Fig. 16
3. Lift the bearing eye from the piston rod.
4. Unscrew flange (4, Fig. 169 from piston rod
(Fig. 19).
RH 200 (BH) - 2471388e - (01) 01.98
Page 8.8 - 13
8.8
Fig.17
Mounting the eye
Fig. 19
Removing the flange
Assembly
1.
Fig. 18

Lifting the eye
Fig. 20
Page 8.8 - 14
Fork type bearing eye
RH 200 (BH) - 2471388e - (01) 01.98
8.8
2.

3.
4.
5.
6.
7.

8.

9.
Pre-install bolts.

3 stages.
RH 200 (BH) - 2471388e - (01) 01.98
Page 8.8 - 15
8.8
8.8.3.4
Piston rod guide
All Positions refer to Fig. 19
Fig. 21
Page 8.8 - 16
Piston rod guide
RH 200 (BH) - 2471388e - (01) 01.98
8.8
Components of piston rod guide (Fig. 21)

Position
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

2. Remove bearing eye.
Use suitable tools to prevent damaging the

sealing surfaces in any way.
6. Check guide (4) for damage. If damage is visible, guide must be replaced. Seals and wearing
parts will otherwise be destroyed in a very short
time.
3. Loosen bolts (16).

ALWAYS change ALL wearing parts!
4. Remove the guide (4) from the cylinder barrel
using 3 jacking bolts.
Depending on the type of cylinder the following
completely threaded jacking bolts are to be
used:
Boom cylinder:
M 12 x 230, 10.9, DIN 933, Part-no. 2 781 856
Stick cylinder:
M 12 x 230, 10.9, DIN 933, Part-no. 2 781 856
Bucket cylinder:
M 12 x 180, 10.9, DIN 933, Part-no. 2 781 854
5. Take off guide (4).
Remove all sealing and wear parts.
RH 200 (BH) - 2471388e - (01) 01.98
Page 8.8 - 17
8.8
Assembly
1. Fit seal (29, Fig. 21) and back ring (30). Make
sure that back ring is on the correct side.
2. Fit the split guide sleeve (22).
3. Coat guide with assembly paste P/No. 271 554
in area (4, Fig. 21).
4. Install V-rings (20 + 21, Fig. 21).
Each V-ring (20 + 21) comprises V-ring (A) and
back ring (B).
Depending on the cylinder design the grove for
the scrapers (14) and (15) can be part of the
cylinder rod guide (Fig. 22).
Fig. 23
Installation of V-ring
If the scraper (20) is separately installed it is

bolted with ring (8), disk (9) and bolts (14) onto
the rod guide (Fig. 24).
The mounting bolts are hand-tightened only.
Fig. 22
Scraper
In this case fold V-ring (A) into a kidney shape

and place into groove (Fig. 23).
Then fit the split back ring (B, Fig. 23).
5. Fit scrapers (14 + 15, Fig. 22).
6. Before fitting the guide, coat scrapers, seal and
guide rings with hydraulic oil.
Fig. 24
Scraper
7. Place guard sleeve (C, Fig. 25) over thread of

piston rod.
The sleeve protects the seal and guide rings in
the rod guide against being damaged on the
rod threads.
If a guard sleeve is not available, wrap adhesive tape around the rod threads.
Page 8.8 - 18
RH 200 (BH) - 2471388e - (01) 01.98
8.8
8.8.3.5
Piston rod and piston

2. Remove rod head and rod guide.
3. Using a lifting device lift the piston rod (8, Fig.
27) with help of the lifting eye (D, Fig. 27) out of
the cylinder barrel an place onto a prepared
clean working bench.
Fig. 25
8. Push guide into cylinder barrel.

9. Insert bolts (6, Fig. 26) and tighten crosswise in
3 stages. The bolts have to be free of grease
and oil!
Fig. 27
Rod puller
4. Remove plastic guide rings (24, Fig. 28), OK

piston seal (23) and guard rings (25).
The cast iron ring (26, Fig. 28) often shows
minor signs of use but without any measurable
wear (less than 0.1 mm). In such a case, the
ring can be used again. Cast iron rings are difficult to remove and the risk of piston damage is
high. The rings should therefore only be removed with special pliers (Fig. 29).
Fig. 26
Flange with bearing eye
10. Install bearing eye (see chapter 8.8.3.1 to

8.8.3.3).
RH 200 (BH) - 2471388e - (01) 01.98
Page 8.8 - 19
8.8
Fig. 28
Piston guide
Components of piston guide (Fig. 28)

Location
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
RH 200 (BH) - 2471388e - (01) 01.98
8.8
Fig. 29
Spreader for guide ring (cast iron)
Fig. 30
Fig. 31
Thoroughly check piston, piston rod, dampener

and cylinder barrel for signs of damage and wear.
Also check the barrel for bulging. Replace all damaged parts.
ALWAYS change plastic guide rings, guard rings
and OK piston seals.
Assembly
The piston is sealed with an OK piston seal (23,
Fig. 28), comprising:
Plastic stepped seal ring (A)
Square tensioning ring (B).
1. Fit the tensioning ring (B) in the relevant
groove:
Fit approx. 1/5 of the tensioning ring into the
groove.
Push a smooth rod through the ring (Fig. 30)
and lever it into its seating with a circling action
(arrow, Fig. 30) around the piston.
2. Fit guide rings (20 + 22, Fig. 32 + 33).

Use special pliers (P/No. 1 709 183) to fit cast
iron guide rings (22, Fig. 32).
Do not open the guide rings too far as they
could break.
The gaps in the guide rings must be offset at
180 to one another.
Do not remove the bar until the tensioning ring

is seated absolutely straight in its groove (Fig.
31).
RH 200 (BH) - 2471388e - (01) 01.98
Page 8.8 - 21
8.8
OK-piston seals are installed with

pre-load. Depending on the diameter the pre-load is 0,65 - 1 mm.
Fig. 32
Installation of guide ring (cast iron)
Fig. 35
Assembling without the sleeve can lead to the

seal and guide rings jamming.
Part-nos. for sleeves are listed in
Chapter 3.2.8 Cylinder tools.
Fig. 33
Installation of guide ring
3. Fit seal ring (21.2, Fig. 34) into OK piston seal.
5. Using rod puller (D, Fig. 27), lift piston rod and
lower fully into the cylinder barrel.
6. Install rod guide and rod head (see chapter
8.8.3.4).
Fig. 34
4. Brush hydraulic oil onto seal, guide and guard

rings. Push sleeve (E, Fig. 35) over the piston
to fix seal and guide rings in position.
Page 8.8 - 22
RH 200 (BH) - 2471388e - (01) 01.98
8.8
8.8.4
Tightening torque
In the following table the tightening torque for the

bolts of the hydraulic cylinders can be found.
Bolt size
M 27 x 2
M 27 x 2
M 30 x 2
M 36 x 3
M 39 x 3
Bolt quality
10.9
10.9
10.9
10.9
10.9
Bolt type
hex.
hex.
hex
Bolt length [mm]
170
160
190
190
220
Spanner size (SW)
41
32
36
55
60
Stage 1 [Nm]
750
650
850
1 750
2 300
Stage 2 [Nm]
1 100
900
1 250
2 700
3 500
Stage 3 [Nm]
1 500
1 135
1 700
3 500
4 600
double hex. double hex.
Tightening torque
Table 7
RH 200 (BH) - 2471388e - (01) 01.98
Tightening torque for bolts on cylinders
Page 8.8 - 23
8.8
Page 8.8 - 24
RH 200 (BH) - 2471388e - (01) 01.98

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Technical Handbook

TEREX Germany GmbH & Co. KG

++49 / 231 / 922-4901

Copyright by TEREX, Printed in Germany

Depressurizing, bleeding, flushing .................................................8.2 - 1

Depressurizing of the hydraulic system .............................8.2 - 1

Bleeding of the hydraulic system .......................................8.2 - 3

Flushing of the hydraulic system .......................................8.2 - 5

Technical data ...................................................................8.3 - 1

Components of the hydraulic schematic ............................8.3 - 1

Components of the hydraulic system.................................8.3 - 5

Hydraulic circuit diagram .................................................8.3 - 13

Description (Backhoe) .....................................................................8.3 - 1

Technical data ...................................................................8.3 - 1

Components of the hydraulic schematic ............................8.3 - 1

Components of the hydraulic system.................................8.3 - 5

Hydraulic circuit diagram .................................................8.3 - 13

Main pumps .......................................................................8.4 - 1

RH 200 Diesel - 3657790e.doc (00) - 09.03

Valve blocks ......................................................................8.4 - 5

Other components ...........................................................8.4 - 34

Description of hydraulic circuits.....................................................8.5 - 1

Load limiting system .......................................................8.5.1 - 1

Pressure cut off system ..................................................8.5.2 - 1

Working functions (Faceshovel) .....................................8.5.4 - 1

Working functions (Backhoe)..........................................8.5.4 - 1

Travel system .................................................................8.5.5 - 1

Swing system .................................................................8.5.6 - 1

Track tensioning system .................................................8.5.7 - 1

Cooling system for hydraulic oil ......................................8.5.8 - 1

Cooling system for engines ............................................8.5.9 - 1

Cooling system for pump gearbox ................................8.5.10 - 1

Pressure checking and setting........................................................8.6 - 1

Hydraulic systems .............................................................8.6 - 5

Installation of hydraulic pumps.......................................................8.7 - 1

Hydraulic cylinders (Faceshovel)....................................................8.8 - 1

Design configuration ..........................................................8.8 - 3

RH 200 Diesel - 3657790e.doc - (00) - 09.03

Hydraulic cylinders (Backhoe) ........................................................8.8 - 1

Design configuration ..........................................................8.8 - 3

RH 200 Diesel - 3657790e.doc (00) - 09.03

RH 200 Diesel - 3657790e.doc - (00) - 09.03

Danger in the event of non-observance of the safety instructions

This TEREX hydraulic excavator

the operating instructions

However, operating the machine if

the spare-parts list

endanger the lives of persons in

the technical handbook

damage the machine and other

The hydraulic excavator must be

The documentation of an TEREX Mining machine

The refilling quantities specified for consumables

2440575e - (00) - 11.96

All components of TEREX machines are carefully co-ordinated.

Rules for safety at work

Wear a safety helmet, safety footwear and gloves.

Incorrect operation of the machine

2440575e - (00) - 11.96

Tools and auxiliaries

Securing the working equipment

2440575e - (00) - 11.96

Systems and units (e.g. pipes,