011 - RH340B - #340085 - Pressure Checking and Setting - 08 - 06-3720618en

8.
6 PRESSURE CHECKING AND SETTING - BH
8.6 Pressure checking and set- 8.6.1.2 Safety

ting Observe accident prevention
8.6.1 Introduction and safety regulations at all
8.6.1.1 Foreword
times.
The pressure checking and setting
This Technical Handbook (THB) describes the
may only be done by special
pressure checking and setting procedures on the
trained and authorized personnel
excavator ´s hydraulic system.
with the appropriate technical
know-how.
It is valid from RH340B – serial-no. 340 032 The rated pressure relief valve set-
ting must not be modified without
explicit approval by Bucyrus.
The illustrations, descriptions and explanations
reflect the current standard configuration. Some of All personnel carrying out com-
the illustrations can show details that differ from a missioning, operation, inspection,
particular machine, but that does not affect the service and repair must have read
validity of the information given. and understood the operating in-
If any points are nevertheless unclear or seem to structions and in particular the
be incorrect, please contact your local Bucyrus chapter
dealer or your Bucyrus distributing centre. 'Fundamental Safety Instructions'
Further developments and alterations introduced before starting any work.

into the standard series production will be imple- Unauthorized conversions or modi-
mented into later re-prints of the THB. fications of the hydraulic excavator
are forbidden for reasons of safety.
When setting the pressure relief valves the
hydraulic oil temperature has to be higher than Secure the machine and the work-
50°C. ing attachment against inadvertent
and unauthorized starting. Place
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 ma-
chine parts may be opened or re-
moved only when the drive unit is
stationary and protected against
inadvertent starting.
RH340B - Diesel - 3720618en - (01) - 04.09 Page 8.6 - 1

8.6 PRESSURE CHECKING AND SETTING - BH
8.6.1.3 General
Before recommissioning, all pro-
tective devices must be refitted. The reference numbers used in the text and illus-
trations correspond to those used in the hydraulic
Catwalks on the boom are only to
circuit diagram.
be walked on when the excavator's
working attachment has been
Since the machine is equipped with the BCS-Board
brought into the position required
Control System, most pressures are available on
for checking/settings pressures.
the BCS display. If pressure must be reset, in any
Hydraulic cylinders must be case calibrated gauges have to be used, they have
brought into their end positions to be connected to the relevant test points.
before pressures are checked or
set to ensure that working attach-
ment does not move when pres- Numbering of main pumps
sure is applied.
The 8 main pumps (4 double pumps) are num-
The excavator operator must oper-
bered in travel direction from left to right and from
ate the relevant function gently
front to rear (Fig.1),
(gradual application of pressure)
thus P1/P2 and P3/P4 are driven by the LH en-
and then shift the joystick/pedals
gine, and P5/P6 and P7/P8 are driven by the RH
fully to their end position.
engine.
All Pressure test points on the ex-
cavator have Minimess connec-
tions. Pressure gauges used for Numbering of swing pumps
checking must therefore have cor-
responding fittings. Each drive unit is equipped with 2 swing pumps.
The swing pumps on the LH pump gearbox are
Always connect the Minimess-hose
named SP1 / SP2, the pumps on the RH pump
first to the gauge and then to the
gearbox are named SP3 / SP4 (Fig. 1).
test point on the machine to avoid
spillage of pressurized oil!
Auxiliary pumps (Fig. 1)
The springs in pressure relief
valves must never be tightened - Gear pump for the pilot pressure. (6)
fully to "block". The windings of - Charge pump (7)
the spring are then jammed so that - Hydraulic oil cooling pump (10)
the valve cannot open. - Variable displacement pump for the fan drive
of the engine radiator. (11)
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)
= 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 Fig. 1 642112
the hydraulic oil temperature must
be above 50°C.
Page 8.6 - 2 RH340B - Diesel - 3720618en- (01) - 04.09

8.6.2 Pressure setting
Description Unit RH 340 B

From No. 340 054
Pressure cut-off – main pumps Cylinders bar 320
Travel bar 370
Primary relief for main pumps Cylinders bar 380
Travel bar 380
Secondary relief for Boom cylinders bar 360
Stick cylinders bar 360
Bucket cylinders bar 360
Travel motors bar 380
Main pump control pressure XLR bar 8 – 43
PST bar 8 – 43
P bar 80
Pilot pressure bar 35
Auxiliary pressure 1 bar 50
Swing system – working pressure max. bar 370
Swing system – charge pressure (approx.) bar 50
Swing system – pilot pressure (approx.) bar 23
Travel system – parking brake release pressure bar 30
Fan drive - pressure Hydraulic oil cooling bar 65
Engine cooling bar 280
Track tensioning system Change over valve bar 70
pre-charge pressure of hy- Pilot pressure system - emer- bar (N2) 30

draulic accumulator gency lowering
pre-charge pressure of hy- Auxiliary pressure 2 bar (N2) 50
draulic accumulator
pre-charge pressure of hy- Ladder bar (N2) 65
draulic accumulator
pre-charge pressure of hy- Track tensioning system bar (N2) 55
draulic accumulator
Table 1

8.6.3 Tools
For pressure checking and setting the tools listed in table 2 are required.
Fig. 2 630640
Item Quantity Designation Part-No.
1 2 Test kit with gauges and hoses 1 476 323

2 1 Test adapter for proportional valve 1 433 919
3 1 Multimeter 1 088 932
4 1 O/E-ring spanner, 10 mm 0 717 903
9 1 Allan Key, 3 mm 0 014 122
10 1 Allan Key, 4 mm 0 014 123
11 1 Allan Key, 5 mm 0 014 124
12 1 Allan Key, 6 mm 0 014 125
13 1 Accumulator test and charging device 1 438 546
---- 1 Adapter for nitrogen cylinder (see chapter 3.2 in THB)
Table 2

8.6.4 Hydraulic circuits

The locations of the valves on the machine are
In table 3 the various valves are listed which are shown in fig. 3 to 5.
used for the pressure setting of the different hy-
draulic circuits.
Section Figure Valve function

A 3 Primary relief valves
B 3 Pump support pressure for main pumps 1 - 4
C 3 Pump support pressure for main pumps 5 - 8
D 3 Pressure limiting for the pilot pressure system „swing“
E 3 Flushing valve for swing system
F 3 Swing balance valve
G 3 Proportional valves (pump regulation)
H 4 Pilot pressure limiting
Auxiliary pressure 1 limiting
J 5 Pressure limiting for L.H. charge pump, swing system
K 5 Pressure limiting for R.H. charge pump, swing system
Table 3
Fig. 3 642113
The primary relief valves for main pumps P 1 to P8

are located on top of the HP-Filter block in front of
the Hydraulic tank. (Fig. 3).

Fig. 4 642114
Fig. 5 642115

8.6.4.1 Pilot pressure system

Layout and function of the pilot pressure system is
described in chapter 8.5.3.
Since the delivered oil from the pilot pressure

pumps has to be adjusted to the different pres-
sures required of the various auxiliary systems, it is
recommendable to adjust all involved valves lo-
cated in the central control valve block (1.10; 1.11;
1.20 and 1.30, Fig. 6) together in the sequence as
mentioned below.
Pressure checking and setting

Ladder (Option) must be in the upper position
Fig. 7 642116
Auxiliary pressure 3 of 80 bar
1. Connect pressure gauges to test points M1
(range up to 150 bar, Fig. 7), M2 and M3
(range up to 60 bar, Fig. 8 & 9) for the pilot
pressure system.
2. Start the both engines and let them run with

maximum speed.
3. Activate service switch S31 (Fig. 4) and check

the pressure at test point M1,
required value: 80 bar. If necessary adjust
valve 1.10.
Auxiliary pressure 2 of 60 bar

4. With service switch S31 (Fig. 4) deactivated,
check the pressure at test point M1, Fig. 8 642117
valve 1.11.
Pilot pressure of 35 bar
Auxiliary pressure 1 of 50 bar 6. With service switch S31 (Fig. 4) deactivated,
5. With service switch S31 (Fig. 4) deactivated, check the pressure at test point M2,
check the pressure at test point M3, required value: 35 bar. If necessary adjust
required value: 50 bar. If necessary adjust valve 1.20.
valve 1.30.
Fig. 6 642051 Fig. 9 642052

Pump support pressure of main pumps 1 - 4

7. Connect a pressure gauge to test point M4.
(range up to 150 bar, Fig. 10)
8. With service switch S31 (Fig. 4) activated,

check the pressure at test point M4,
valve 51.1 (Fig. 10).
Pump support pressure of main pumps 5 - 8

9. Connect a pressure gauge to test point M5.
(range up to 150 bar, Fig. 10)
10. With service switch S31 (Fig. 4) activated,

required value: 80 bar. If necessary adjust Fig. 12 642120
valve 51.2 (Fig. 10).
Note:
The pilot pressure of 35 bar is used for the follow-

ing functions:
- Supply of the proportional valves to control the

work functions.
- Displacement of the swing balance valve (Y1 /
Y2).
The auxiliary pressure 1 of 50 bar is used for the

following functions:
Fig. 10 642118
- Servicelift
Travel brake release pressure - Pressure increase of the main pumps for trav-
11. Connect a pressure gauge to test point M6. eling
(range up to 60 bar, Fig. 12) - Travel motor speed control (2. travel speed)
- Releasing the swing parking brake.
12. With toggle switch S27 (Fig. 11) activated, - Supply of the swing balance valve.
required value: 30 bar. If necessary adjust The auxiliary pressure 2 of 60 bar is used for the
valve 53 (Fig. 12). following functions:
- Track tensioning system.

- Activation of the „swing blocking valve“.
- Grease pump of the „central greasing system“
The auxiliary pressure 3 of 80 bar is used for the

following functions:
- Pressure relief of the track tensioning system

after traveling.
- Pressure increase to lift the ladder.
Fig. 11 642119

8.6.4.2 Load limit system (PMS) 3. Check pressure.

Both gauges must indicate approx. 8 bar
Layout and function of the load limit system is de-
(225 mA).
scribed in chapter 8.5.1.
4. Extend the stick cylinders.
For each engine an electronic load limit system is
installed.
5. Check pressure (Stick cylinders are in end-
The current from the electronic load limit system is
position; pressure cut-off in function):
converted into hydraulic pressure by proportional
valves (23.1 / Y71 & 23.2 / Y17, Fig. 13) and
(820 mA).
(23.3 /Y72 & 23.4 / Y18, Fig. 14).
Checking the load limit pressure for the RH
 The proportional valves, which are linked to the drive unit:
load limit system of the LH engine, are deliver-
ing pressure signals to the governor of main 1. Connect gauges (range 60 bar) to the test
pumps P1/P2 & P3/P4. points (M, 23.3 & 23.4, Fig. 14).
Valve Y17 is connected to port XLR at the
main pump governors and the pressure level at
is related to the load factor of the engine.
Valve Y71 is connected to port PST at the
main pump governors and the pressure level at
is related to the deflection of the joystick.
 The load limit system of the RH engine is regu-

lating the main pumps P5/P6 & P7/P8 with pro-
portional valves Y18 and Y72.
Fig. 14 642122
2. Run RH engine with maximum speed. The LH

engine has to be shut off.
3. Check pressure.
(225 mA).
Fig. 13 642121 4. Extend the stick cylinders.
Checking the load limit pressure for the LH 5. Check pressure (Stick cylinders are in end-
drive unit: position; pressure cut-off in function):
1. Connect gauges (range 60 bar) to the test (820 mA).
points (M, 23.1 & 23.2, Fig. 13).
2. Run LH engine with maximum speed. The RH In case the required pressures are not achieved
engine has to be shut off. the proportional valves must be checked.

For this checking an adapter (A, Fig. 15) is re-

quired to measure the current (mA) supplied by the
load limit system.
Fig. 15 630782
Connect adapter (A).
Do checks 1 to 5 as described before and measure

the current direct at the terminals of the propor-
tional valves 23.1, 23.2, 23.3 and 23.4.
 If the mA-values according to 3 & 5 are not

reached, there is a defect in the load limit cir-
cuit.
 If the mA-values are reached, but not the re-

quired pressure, the proportional valve is defec-
tive and has to be replaced.
Note:
It is also possible to check and read the current
values via the BCS

8.6.4.3 Pressure cut-off system

7. Check and set pressure cut-off valves of the RH
Layout and function of the pressure cut-off system
main pumps P5, P6, P7 & P8 (A, Fig. 18) ac-
is described in chapter 8.5.2.
cordingly with gauge connected to test points
M5, M6, M7 & M8 (Fig. 16).
The pressure cut-off function for the main pumps is
managed by the pressure cut-off valves A (Fig. 17
& 18). They are set to 320 bar and limit thus the
working pressure for the hydraulic cylinders.
When operating the travel system the pressure cut-

off valves are hydraulically adjusted to 370 bar via
a solenoid valve (Y31).
The electronic system of the machine ensures, that
the pressure increase is not operational, when the
attachment is operated at the same time, so that
operation of the hydraulic cylinders with 370 bar is
prevented.
Note:
Fig. 16 642123
As a precondition for the following tests and set-
tings it is essential that all primary- and secondary
valves are correctly adjusted.
Checking and setting
1. Connect 4 gauges (range: 400 bar) to the high

pressure circuits of pumps P1, P2, P3 & P4.
The relevant test points M1, M2, M3 & M4 are
to be found close to the high pressure filter-
housings (Fig. 16 & 17).
2. Start LH engine and bring it to maximum speed.
3. Extend the stick cylinders completely and posi-

tion the attachment on the ground.
Fig. 17 642124
4. Activate function "stick cylinder out" and check
pressure (rated: 320 bar).
If necessary adjust the valve for pump P1, P2,
P3 or P4 (A, Fig. 17).
5. To check the "pressure increase travel" operate

one travel pedal at the time with the attachment
placed on the ground and swing parking brake
applied.
The indicated pressure must then be 370 bar.
The travel parking brake must be

released. Press travel pedal gently
until pressure rise is recognized.
Machine might travel!
Fig. 18 642125
6. Shut of LH engine.

8.6.4.4 Primary relief system

 When a new primary relief valve is installed
Primary pressure relief for the main pumps is con-
screw the adjuster 1 turn out, to avoid pressure
trolled by 4 pressure relief valves. Each valve limits
peaks.
the pressure of two pumps.
The relief valves (PRV) are located on top of the
high pressure filter block (Fig. 20).  Screw the adjuster of the pressure cut-off
valve A at pump P1 & P7 completely in and
then ¼ turn back (Fig. 17 & 18). This is to raise
the set value of this valve above 380 bar.
 Screw the adjuster of the four secondary relief

valves “Bucket cylinder piston side” completely
in and then ¼ turn back (Pos. 3 + 9 + 15 + 21,
Fig. 24 chapter 8.6.4.5). This is to raise the set
value of these valves above 380 bar.
 Activate BCS Test mode. (see chapter

8.6.4.12)
 Start one engine (LH or RH) and bring it to

maximum speed.
Fig. 19 642123  Activate function "bucket fill" until the cylinders

are completely extended.
Test points to check the pump pressure:
 Check pressure (rated 380 bar).
Test Both engines Engine 1 Engine 2 If necessary reset primary relief valve PRV 1/7.
point ON ON ON
Pump pressure: Pump pressure: Pump pressure:
 Reset the four secondary relief valves “Bucket
M1/7 P1 & P7 P1 P7 cylinder piston side” back to 360 bar.
M2/8 P2 & P8 P2 P8
 After setting all secondary relief valves reduce
M3/5 P3 & P5 P3 P5 pressure cut-off valve back to 320 bar.
M4/6 P4 & P6 P4 P6
 After the settings are finished, stop the engine
Table 4 and interrupt the power supply with the key
switch, to deactivate the BCS Test mode.
Setting of PRV 1/7 (330 bar)
1. Connect a gauge (range: 400 bar) to test point

M 1/7. The test point is installed close to the
high pressure filter block (Fig. 19).
2. Start one engine. The other engine must be

switched off. The shovel teeth must be pushed
into the ground and the travel parking brake
must be applied (remove plug connector of so-
lenoid valve Y12), so that travel movements
are avoided during the check. The undercar-
riage has to be positioned with final drives at
the rear. The parking brake "swing" must be
activated to avoid turning of the superstructure.
3. Set primary relief valve of main pumps (P1/7)

Fig. 20 642126
at the high pressure filter block (PRV 1/7 Fig.
20) as follows:

Setting of PRV 2/8 Setting of PRV 3/5
1. Connect a gauge (range: 400 bar) to test point 1. Connect a gauge (range: 400 bar) to test point
M 2/8. The test point is installed close to the M 3/5. The test point is installed close to the
high pressure filter block (Fig. 19). high pressure filter block (Fig. 19).
2. Start one engine. The other engine must be 2. Start one engine. The other engine must be
switched off. The shovel teeth must be pushed switched off. The shovel teeth must be pushed
into the ground and the travel parking brake into the ground and the travel parking brake
must be applied (remove plug connector of so- must be applied (remove plug connector of so-
lenoid valve Y12), so that travel movements lenoid valve Y12), so that travel movements
are avoided during the check. The undercar- are avoided during the check. The undercar-
riage has to be positioned with final drives at riage has to be positioned with final drives at
the rear. The parking brake "swing" must be the rear. The parking brake "swing" must be
activated to avoid turning of the superstructure. activated to avoid turning of the superstructure.
3. Set primary relief valve of main pumps (P2/8) 3. Set primary relief valve of main pumps (P3/5)
at the high pressure filter block (PRV 2/8 Fig. at the high pressure filter block (PRV 3/5 Fig.
20): 20):
 When a new primary relief valve is installed  When a new primary relief valve is installed
screw the adjuster 1 turn out, to avoid pressure screw the adjuster 1 turn out, to avoid pressure
peaks. peaks.
 Screw the adjuster of the pressure cut-off  Screw the adjuster of the pressure cut-off
valve A, at pump P2 & P8 completely in and valve A, at pump P3 & P5 completely in and
then ¼ turn back (Fig. 17 & 18). This is to raise then ¼ turn back (Fig. 17 & 18). This is to raise
the set value of this valve above 380 bar. the set value of this valve above 380 bar.
 Screw the adjuster of the four secondary relief  Screw the adjuster of the four secondary relief
valves “Bucket cylinder piston side” completely valves “Bucket cylinder piston side” completely
in and then ¼ turn back (Pos. 3 + 9 + 15 + 21, in and then ¼ turn back (Pos. 3 + 9 + 15 + 21,
Fig. 24 chapter 8.6.4.5). This is to raise the set Fig. 24 chapter 8.6.4.5). This is to raise the set
value of these valves above 380 bar. value of these valves above 380 bar.
 Activate BCS Test mode. (see chapter  Activate BCS Test mode. (see chapter
8.6.4.12) 8.6.4.12)
 Start one engine (LH or RH) and bring it to  Start one engine (LH or RH) and bring it to
maximum speed. maximum speed.
 Activate function "bucket fill" until the cylinders  Activate function "bucket fill" until the cylinders
are completely extended. are completely extended.
 Check pressure (rated 380 bar).  Check pressure (rated 380 bar).
If necessary reset primary relief valve PRV 2/8 If necessary reset primary relief valve PRV 3/5
 Reset the four secondary relief valves “Bucket  Reset the four secondary relief valves “Bucket
cylinder piston side” back to 360 bar. cylinder piston side” back to 360 bar.
 After setting all secondary relief valves reduce  After setting all secondary relief valves reduce
pressure cut-off valve back to 320 bar. pressure cut-off valve back to 320 bar.
 After the settings are finished, stop the engine  After the settings are finished, stop the engine
and interrupt the power supply with the key and interrupt the power supply with the key
switch, to deactivate the BCS Test mode. switch, to deactivate the BCS Test mode.

Setting of PRV 4/6
1. Connect a gauge (range: 400 bar) to test point

M 4/6. The test point is installed close to the
high pressure filter block (Fig. 19).
2. Start one engine. The other engine must be

switched off. The shovel teeth must be pushed
into the ground and the travel parking brake
must be applied (remove plug connector of so-
lenoid valve Y12), so that travel movements
are avoided during the check. The undercar-
riage has to be positioned with final drives at
the rear. The parking brake "swing" must be
activated to avoid turning of the superstructure.
3. Set primary relief valve of main pumps (P4/6)

at the high pressure filter block (PRV 4/6 Fig.
20):
 When a new primary relief valve is installed
screw the adjuster 1 turn out, to avoid pressure
peaks.
 Screw the adjuster of the pressure cut-off

valve A, at pump P4 & P6 completely in and
then ¼ turn back (Fig. 17 & 18). This is to raise
the set value of this valve above 380 bar.
 Screw the adjuster of the four secondary relief

valves “Bucket cylinder piston side” completely
in and then ¼ turn back (Pos. 3 + 9 + 15 + 21,
Fig. 24 chapter 8.6.4.5). This is to raise the set
value of these valves above 380 bar.
 Activate BCS Test mode. (see chapter

8.6.4.12)
 Start one engine (LH or RH) and bring it to

maximum speed.
 Activate function "bucket fill" until the cylinders

are completely extended.
 Check pressure (rated 380 bar).

If necessary reset primary relief valve PRV 4/6
 Reset the four secondary relief valves “Bucket

cylinder piston side” back to 360 bar.
 After setting all secondary relief valves reduce

pressure cut-off valve back to 320 bar.
 After the settings are finished, stop the engine

and interrupt the power supply with the key
switch, to deactivate the BCS Test mode.

Test points to check the individual pump pressure Checking the pressure difference:
at the inlet and outlet of the HP-filters and to check
the function of the internal check valves. Pump Test point Fig. Test point Fig.
filter inlet filter outlet
1 MP1 21 MP1/1 21
2 MP2 21 MP2/1 22
3 MP3 22 MP3/1 22
4 MP4 22 MP4/1 22
5 MP5 23 MP5/1 23
6 MP6 23 MP6/1 23
7 MP7 21 MP7/1 23
8 MP8 21 MP8/1 23
Table 5
Fig. 21 642127 Checking the check valve function:
Engine 1 Engine 2
ON OFF
MP1 & MP1/1 MP7 & MP7/1
1 0
MP2 & MP2/1 MP8 & MP8/1
1 0
MP3 & MP3/1 MP5 & MP5/1
1 0
MP4 & MP4/1 MP6 & MP6/1
1 0
Table 6
Fig. 22 642128
1 = pressure
0 = no pressure
Engine 1 Engine 2
OFF ON
MP1 & MP1/1 MP7 & MP7/1
0 1
MP2 & MP2/1 MP8 & MP8/1
0 1
MP3 & MP3/1 MP5 & MP5/1
0 1
MP4 & MP4/1 MP6 & MP6/1
0 1
Fig. 23 642129 Table 7

1 = pressure
0 = no pressure

8.6.4.5 Secondary relief system for attachment two valves installed per section i.e. 12 at the A-
side and 12 at the B-side. The 3-spool control
The secondary relief valves (SRV) for the attach-
blocks are located on the boom.
ment are screwed into the 3-spool control blocks
(160, 161,162 & 163, Fig. 24). There are always
Fig. 24 642131
Valve arrangement for backhoe configuration (Fig. 24)
Position Relief valve for Position Relief valve for

1 + 11 + 13 + 23 Boom cylinder – piston side 2 + 12 + 14 + 24 Boom cylinder – rod side*
5 + 7 + 17 + 19 Stick cylinder – piston side 6 + 8 + 18 + 20 Stick cylinder – rod side
3 + 9 + 15 + 21 Bucket cylinder – piston side 4 + 10 + 16 + 22 Bucket cylinder – rod side
Table 8
* Switch off “float” for checking and setting

This pressure check has to be done with only one Example – stick cylinder rod side:
engine running. The pressure cut-off function
should be adjusted over 360 bar on one main Carefully apply pressure to rod side of stick
pump only. The smaller flow rate of one pump cylinders by shifting the joystick smoothly to
only allows a more accurate pressure setting. the end position “Stick OUT”.
Check pressure (rated: 360 bar), when cylin-
Check pressures with LH engine running and main ders are in end-position.
pump (P2) or with RH engine and main pump (P8),
because these pumps supply oil to all cylinders of 6. Because the pair of cylinders is connected via
the attachment. compensating lines and secured by 4 relief
valves, the gauge on the test point always in-
dicates the lowest pressure setting of the 4
valves. Therefore it is possible that, even with
an indicated pressure of 360 bar, one valve is
still set too high.
Therefore reduce pressure setting on 1st valve

of the valve-set to less than 360 bar. Gauge
reading must drop noticeably. Increase pres-
sure setting back up to 360 bar.
7. Set pressure on 2nd, 3rd, and 4th valve in the

same way: Lower it firstly, and than increase
back up to 360 bar.
8. After checking all secondary relief valves re-

Fig. 25 642124 duce pressure cut-off valves back to 320 bar.
To check the valves for 9. After the checks and settings are finished, stop
the engine and interrupt the power supply with
Rod side: retract cylinders fully the key switch, to deactivate the BCS Test
Piston side: extend cylinders fully mode.
Location of the secondary relief valves is shown in
Fig. 24. Valves are also installed on the opposite
side (bottom) of the main control blocks.
Checking and setting (with LH engine)
1. Connect gauge (Range: 400 bar) to test point

M2/8 (Fig. 26).
2. Screw the adjuster of the pressure cut-off

valve AP2 (Fig. 25) of pump (P2) completely in
and then ¼ turn back. This is to raise the pres-
sure above 360 bar (secondary relief setting).
3. Activate BCS Test mode. (see chapter

8.6.4.12)
Fig. 26 642123
4. Start LH engine and bring to maximum speed
5. Check pressures and reset if required

(see table 8).

8.6.4.6 Secondary relief system for travel

Note:
The check of the travel secondary relief valves

should only be carried out in case of travel per-
formance- or temperature problems.
Layout and function of the travel system is de-

The four secondary relief valves (126.1 to 126.4,

Fig. 27) for the travel motors are located in the
undercarriage module.
The valves (126.2 & 126.3) are on the rear side of

Fig. 28 642124
the housing.
Check pressures with LH engine running and main 5. Start LH engine and bring to maximum speed.
pumps (P3 & P4) or with RH engine and main The bucket teeth must be pushed into the
pumps (P5 & P6) ground to brake the machine and to prevent
travel of the machine during the test. The park-
ing brake "swing" must be activated to avoid
turning of the superstructure.
6. Engage the function 'LH travel forward' by

depressing the foot-pedal slowly into the end
position.
Press travel pedal gently until

pressure rise is recognized.
Machine might travel!
7. Check pressure on relief valve (126.1, Fig. 27).

It should be: 380 bar. Re-set the valve if nec-
essary.
Fig. 27 620280a
8. Activate the following functions, one after the
other:
Checking and setting (with LH engine) LH track reverse (valve 126.2)
RH track forwards (valve 126.3)
1. Engage travel parking brakes (remove plug RH track reverse (valve 126.4)
connector of solenoid valve Y12) and lower
working equipment to the ground. and check pressures in the same manner.
2. Activate BCS Test mode. (see chapter 9. After checking all secondary relief valves re-
8.6.4.12) duce pressure cut-off valve back to 320 bar.
3. Connect four 400 bar pressure gauges to the 10. After the checks and settings are finished, stop
check points (M1 to M4, Fig. 27) for the pres- the engine and interrupt the power supply with
sure relief valves. the key switch, to deactivate the BCS Test
mode.
4. Screw the adjuster of the pressure cut-off
valve AP3 & AP4 (Fig. 28) of pumps (P3 & P4)
completely in and then ¼ turn back. This is to
raise the pressure above 380 bar (secondary
relief setting).

8.6.4.7 Swing system

6.3 Pressures are identical:
Layout and function of the swing system is de-
Replace the 400-bar gauges with 60-bar
gauges (more accurate reading).
Do not operate the function 'swing'
1. Place attachment on the ground and block the as this would destroy the gauges!
superstructure (bucket in digging material).
The swing parking brake must be released.
The charge pressure will be indicated. The re-
2. Connect two gauges (range: 400 bar) to the quired value must be 50 bar at full engine RPM.
test points (MX5 & MX6, Fig. 29) of the swing The charge pressure is limited by the pressure cut-
balance valve (105). off valves of the charge pumps.
If the charge pressure differs from 50 bar the pres-
sure cut-off valve (J or K, Fig. 30) of the respective
charge pump (left or right) has to be adjusted.
Fig. 29 642132
3. Start LH engine and run at maximum speed.

Fig.30 642133
4. Check pressure; both gauges must indicate
the same pressure.
Note:
5. Start RH engine and run at maximum speed
In case one charge pressure limiting valve of a
6. Check pressure; both gauges must indicate swing pump is set to low, the required charge pres-
the same pressure. sure for the swing system cannot be reached. In
this case check the charge pressure limiting valves
6.1 If pressures are not equal with one engine in the housings of the swing pumps.
running:
One or both swing pumps are mechanically Adjustments at the pumps may
out of neutral. (Superstructure tries to turn) only be done with the appropriate
Correct the adjustment at the pump regulator. technical knowledge!
6.2 If pressures are not equal with any engine
running:
Swing balance valve (105, Fig. 29) is not ex-
actly in neutral position (not centered; the su-
perstructure tries to turn).
Connect two gauges (range: 60 bar) to the
test points (MX5 & MX6, Fig. 29) of the swing
balance valve (105). Adjust valve with ad-
juster screw (A Fig. 29) until both gauges in-
dicate the same pressure.

7. Check pilot pressure for swing:

 Connect pressure gauge (range: 60 bar) to
test points MY1 and MY2 (Fig. 31) of the
pressure relief valve 109 (Fig. 31).
 Run both engines with maximum speed.
 Activate 'swing left or right' and move joy
stick slowly into the end position.
 Check pressure (rated; 23 bar).
 If necessary adjust pressure relief valve
109 (Fig. 31).
8. To check the high pressure, replace the two

60-bar gauges (MX5 & MX6) at the swing bal-
ance valve 105 (Fig. 29) again with 400-bar
gauges. Fig. 31 642134
9. Activate 'swing right'. Move joy stick slowly into

the end position.
10. Checking pressures: The gauge related to the

high pressure side at the swing balance valve
105 (Fig. 29) must indicate approx. 370 bar;
the low pressure side must indicate approx. 50
bar.
The pilot pressure for the swing balance valve
will be approx. 23 bar at this stage.
The swing high pressure is determined by the
swing balance valve feed pressure (reduced
pilot pressure) and the swing balance valve ra-
tio (1 : 16).
11. Activate 'swing left' and move joy stick slowly

into the end position.
Fig. 32 642110
Now the other gauge must indicate approx.
370 bar on the high pressure side; the second
gauge must indicate approx. 50 bar.
Note: The secondary relief valves of the

swing system (2 valves for each
If the swing pressure varies from the rated swing pump) are set at 400 bar.
pressure (370 bar), the feed pressure must be This setting must not be altered!
checked and if necessary corrected at pres-
sure relief valve 109 (Fig. 31).
For cooling of the closed swing circuit a certain

volume of oil is flushed out by the flushing valve
106 (Fig. 31 & 32) and replaced by the charge
pumps (7).
Adjustment: Space "S" of the adjuster screw of

flushing valve 106 (Fig. 32) has to be 15 mm.

8.6.4.8 Track tensioning system Discharge function

Layout and function of the track tensioning system
5. Connect gauges (range: 150 bar) to test points
is described in chapter 8.5.7.
M-A2 and M-B1 (Fig. 34).
The pressure for the hydraulic track tensioning
6. Start both engines and let them run with ma-
system is taken from the 60-bar auxiliary circuit 2.
ximum speed.
The pressure to discharge the hydraulic track ten-
sioning system is taken from the 80-bar auxiliary
7. Check pressures.
circuit 3.
Rated:
The pilot controlled check valves and the change
At test point M-A2 = 60 bar
over valve, factory set to 70 bar, are located on the
At test point M-B1 = 0 bar
track tensioning valve block (133, Fig. 35).
8. Activate service switch S31 and check the
pressures.
Rated:
At test point M-A2 = 80 bar
Overview:
S31 M-A2 M-B1
OFF 60 bar 0 bar
ON 80 bar 80 bar
Table 9
Note:
If the pressures will not appear as shown in the

Fig. 33 642116 table, the function and setting of the change over
valve (SV, Fig. 34) has to be checked.
To make the switch point of the change over valve
Checking and setting visible, the auxiliary pressure 2 has to be tempo-
Ladder (Option) must be in the upper position rary increased to 70 bar (see chapter 8.6.4.1).
Inlet pressure:
1. Connect gauge (range: 150 bar) to test point

M1 (Fig. 33).

ximum speed.
3. Check pressure.
Rated: 60 bar;
If necessary adjust auxiliary pressure 2 (see
chapter 8.6.4.1).
4. Activate service switch S31 and check the

pressure at test point M1. Fig. 34 642062
Rated: 80 bar;
If necessary adjust auxiliary pressure 3 (see
chapter 8.6.4.1).

Change over pressure (70 bar)
9. Adjust auxiliary pressure 2 to 70 bar (see

chapter 8.6.4.1).
10. Connect gauges (range: 150 bar) to test point-

s M-A2 and M-B1 (Fig. 34).
ximum speed.
12. Check pressures.

There are two possible situations:
a) At test point M-A2 = 70 bar
or Fig. 35 630776a
b) At test point M-A2 = 70 bar
13. If the pressure at test point M-B1 is not 0 bar, Tensioning the tracks
the set screw of the change over valve (SV,
Fig. 34) has to be turned out (ccw) until the Tensioning and slackening the tracks is described
valve switches over to 0 bar. in the operator's manual.
14. Slowly turn in (cw) the set screw of change

over valve (SV, Fig. 34) until the pressure at
test point M-B1 switches over to 70 bar. This
setting has to be secured with the lock nut.
15. Readjust auxiliary pressure 2 to 60 bar (see

chapter 8.6.4.1).
16. Check the discharge function (see chapter

8.6.4.8).
Secondary relief system
The track tensioning system is protected by two

secondary relief valves, which are preset to 330
bar.
These valves are installed in the car body (134,

Fig. 35).

8.6.4.9 Hydraulic oil cooling 8.6.4.10 Fan-drive for radiators

Layout and function of the hydraulic oil cooling Layout and function of the fan-drive for radiators is
system is described in chapter 8.5.8. described in chapter 8.5.9.
The hydraulic oil is cooled by two independent The coolant of the engines is cooled by two inde-
cooling circuits. pendent cooling circuits.
Each circuit is related to one engine. Each circuit is related to one engine.
The two cooling pumps on the LH engine drive the
two front fan motors. The two cooling pumps on Fig. 37 is showing fan pump (11) with flanged on
the RH engine drive the two rear fan motors. proportional valve and its coil (C).
The fan speed is electronically controlled and var-
ies in relation to the hydraulic oil temperature.
Fig. 36 is showing the distributor block of one cool-

ing circuit which is protected by two pressure relief
valves (85-a + 85-b, Fig. 36). The circulating pres-
sure can be checked at test points Ma and Mb.
Fig. 37 642106
1. Connect a gauge (range: 400 bar) to the rele-

vant test point at the fan motor.
Fig. 36 620289a
2. Ensure that the coolant temperature is above
Checking and setting 95°C, so that the thermostats are closed com-
pletely.
1. Connect pressure gauges (range: 100 bar) to
the relevant test points at the distributor block 3. Check pressure.
of the cooling circuit to be checked.
With a temperature of the coolant of approx.
2. Ensure, that the hydraulic oil temperature is 98° C the pressure at the fan motor is approx.
above 52°C, so that the fan motors are run- 200 bar.
ning with maximum speed.
3. Check pressure: Pressure cut-off

Circulating pressure should be approx. 55 bar.
Pressure relief The fan pumps are equipped with a pressure cut-
off valve A (Fig. 37), which is set at the factory to
Pressure relief valves (85) are works set to approx. 280 bar.
65 bar. To check, proceed as follows: The adjustment of minimum flow is done at valve B
(Fig. 37). This valve is also set at the factory.
 Set valves to circuiting pressure. To do this,
reduce valve cracking pressure until the circuit-
ing pressure starts to drop.
 Then tighten valve inserts ½ of a turn (cracking

pressure is increased again).

8.6.4.11 Hydraulic accumulators

Layout and function of the hydro-pneumatic accu-
mulators within the hydraulic system is described
in chapter 8.5.3.
Hydraulic accumulators are used in the following

hydraulic systems:
a) In the pilot pressure system, a dia-

phragm accumulator (35, Fig. 38) is used
to ensure, that the attachment can be low-
ered in emergency cases with both en-
gines at standstill.
Gas pre-charge pressure: 30 bar
Fig. 39 642060
b) In the auxiliary pressure system 2, a dia-
phragm accumulator (38, Fig. 38) is used
to compensate pressure drops when vari-
ous consumers are activated at the same
time.
c) In the track tensioning system, one dia-

phragm accumulator (131, Fig. 39) per
crawler is used to compensate pressure
peaks which are produced by external
forces on the tracks.
d) In the hydraulic system of the ladder

(Option), a bladder accumulator (152, Fig.
40) is used to lower the access ladder
when the engines are shut down.
Gas pre-charge pressure: 65 bar Fig. 40 642061
Location of the accumulator below the cab module
Checking and setting:

All hydraulic accumulators installed in the machine
have to be checked at regular intervals and re-
charged if necessary (see Operation and mainte-
nance manual).
For this work, the recommended “charging and
testing unit” should be used. (see chapter 3.2,
THB).
A general procedure how to handle the “charging
and testing unit” is described on the following
pages:
Fig. 38 642135

Charging and testing unit for Charging and testing unit for
diaphragm accumulators bladder accumulators with
adaptor A3
Fig. 43 642065
Fig. 41 642063
Legend, Fig. 43
Legend, Fig. 41 1 = Hydr. accumulator 5 = charging hose
A = Spindle 2 = Adaptor A 6 = Connector
B = Pressure release 3 = Charging and test- 7 = pressure reducer l
C = Check valve ing unit 8 = adaptor
A3 = Adaptor 4 = Connector 9 = nitrogen bottle
Gas valve for diaphragm Gas valve for bladder accu- DESCRIPTION (Charging and testing unit)
accumulators mulators
FUNCTION
The charging and testing unit is used to charge ac-
cumulators with nitrogen or to check or to change the
existing pre-charge pressure in accumulators. For this
purpose the charging and testing unit is screwed onto
the gas valve of the hydraulic accumulator and con-
nected to a commercial nitrogen bottle via a flexible
charging hose. If the nitrogen pressure is only to be
checked or reduced, the charging hose does not
need to be connected. The unit has a screw-type
fitting with a built-in gauge, check valve and a spindle
for opening the accumulator gas valve to control the
pressure. Piston and diaphragm accumulators can be
charged and checked without the need for adaptors.
Bladder accumulators, however, require an adaptor
Fig. 42 642064
A3.
Legend, Fig. 42
S= Protective cap
O= O-Ring
SW6 = Allen key
H= Hexagon cap nut
P= internal hexagon screw
V= Valve

OPERATINGINSTRUCTIONS
INCREASING PRE-CHARGE PRESSURE
PREPARATION Only use nitrogen for charging accumulators.
Prior to each testing, topping-up or re-charging of
Never use oxygen! Danger of ex-
nitrogen, the accumulator must be isolated from the
pressurized system and the fluid released. plosion! If the gas pressure in the
nitrogen bottle is higher than the
a) Releasing the pilot pressure system by max. operating pressure of the
shifting both control levers repeatedly into accumulator, a gas pressure re-
all directions with both engines at stand- ducer must be fitted.
still, emergency switch S211 (attachment
down) activated and the electric system
switched on.  Connect the flexible charging hose to the
b) Releasing the auxiliary pressure system pressure reducer on the nitrogen bottle by
2 by shifting both control levers repeatedly means of the connector (Pos. 6, Fig. 43). For
into all directions with both engines at nitrogen bottles from other countries the ap-
standstill, emergency switch S211 (at- propriate adaptor is required (see chapter 3.2,
tachment down) activated and the electric THB). Connect connector (Pos. 4, Fig. 43) of
system switched on. the charging hose to the check valve C of the
c) Releasing the track tensioning system charging and testing unit. Open the shut-off
by opening the pressure relief valves (134, valve on the nitrogen bottle, and slowly re-
Fig 39) with both engines at standstill. lease nitrogen into the accumulator. Wait until
d) Releasing the hydraulic system of the approximately 1 bar has been reached before
ladder by shifting the control lever (151, opening the shutoff valve of the nitrogen bottle
Fig. 40) repeatedly with both engines at further to enable faster charging.
standstill.
 Interrupt the charging process from time to
Unscrew the protective caps S and H (only on time and check the pre-charge pressure rea-
bladder accumulators). Remove the O-ring O on ched. Repeat this process until the required
bladder accumulators. Slightly loosen the internal gas pre-charge pressure is achieved. After
hexagon screw P on piston and diaphragm accu- temperature equalization has taken place, re-
mulators by means of an Allen key SW 6, DIN 911 check the pre-charge pressure and adjust if
(approx. ½ turn). Place the charging and testing necessary. If the pressure is too high, it can
unit onto the accumulator and screw connector D be lowered via the pressure release B of the
by hand onto accumulator gas valve. At the same charging and testing unit
time, ensure that the release B of the charging and
testing unit is closed. Turn charging and testing  If the required gas pre-charge pressure has
unit to a position where the gauge can be easily been reached, turn the spindle anticlockwise
read. to close the gas valve on bladder accumula-
tors. On piston or diaphragm accumulators
TESTING close the internal hexagon screw P by turning
On bladder accumulators (Charging and testing the spindle clockwise. Discharge the charging
unit with adaptor A3) open valve by turning spindle and testing unit via the pressure release and
A clockwise. remove it by loosening the connector. On
On piston and diaphragm accumulators (Charg- bladder accumulators, unscrew the adaptor
ing and testing unit) open valve V by turning the and replace the O-ring O. On piston and dia-
internal hexagon screw anticlockwise with spindle phragm accumulators, tighten the internal
A. When the needle of the gauge begins to move, hexagon screw P with Allen key [20 Nm].
give the spindle another complete turn. The gauge
now shows the charging pressure in the accumula-  Check for leakages on the accumulator gas
tor. The check valve C prevents any escape of valve using a leak detector spray.
nitrogen.
 Screw on cap nut H (only on bladder accumu-
REDUCING THE PRE-CHARGE PRESSURE lators) and valve protection cap S onto the
Carefully open release B. The nitrogen escapes into gas valve of the accumulator and tighten.
the atmosphere.

WARNING
 Nitrogen and operating fluid can
escape when filling or testing
the accumulator due to a faulty,
i.e. leaking, bladder, diaphragm
or piston seals.
Caution!
Risk to health in the case of
aggressive fluids!
 The check valve C must not be
removed. The valve has a safety
function for the whole charging
and testing unit.

8.6.4.12 BCS Test mode

Layout and function of the BCS-System is de-
scribed in the operation manual.
Certain settings and tests in the hydraulic system

should be performed only with a defined amount of
oil. For this purpose a test mode can be activated
by using the BCS-System, which limits the main
pumps to 30% displacement.
Activation of the test mode
a) Start the engine.
b) Activate button “SERV“.

Fig. 45 642088
c) Select submenu – 9 “SERVICE TEREX“
and confirm with “ENTER“.
d) Enter access code and confirm with

“ENTER“.
e) Select submenu – 9 “CMS CHECK“ and

confirm with “ENTER“.
f) Activate button “HOLD“ => TEST MODE

activated. (i.e. Button Testmode is blinking
green)
Fig. 46 642089
Fig. 44 642087
Fig. 47 642090
Deactivation of the test mode

a) Stop the engine.
b) Switch off key switch (S4) => TEST MODE

deactivated.

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8.

6 PRESSURE CHECKING AND SETTING - BH

8.6 Pressure checking and set- 8.6.1.2 Safety

Further developments and alterations introduced before starting any work.

RH340B - Diesel - 3720618en - (01) - 04.09 Page 8.6 - 1

Page 8.6 - 2 RH340B - Diesel - 3720618en- (01) - 04.09

8.6.2 Pressure setting

Description Unit RH 340 B

Travel motors bar 380

Main pump control pressure XLR bar 8 – 43

Pilot pressure bar 35

Auxiliary pressure 1 bar 50

Auxiliary pressure 2 bar 60

Auxiliary pressure 3 bar 80

Swing system – working pressure max. bar 370

Swing system – charge pressure (approx.) bar 50

Swing system – pilot pressure (approx.) bar 23

Travel system – parking brake release pressure bar 30

Fan drive - pressure Hydraulic oil cooling bar 65

Engine cooling bar 280

Track tensioning system Change over valve bar 70

pre-charge pressure of hy- Pilot pressure system - emer- bar (N2) 30

RH340B - Diesel - 3720618en - (01) - 04.09 Page 8.6 - 3

Item Quantity Designation Part-No.

1 2 Test kit with gauges and hoses 1 476 323

Page 8.6 - 4 RH340B - Diesel - 3720618en- (01) - 04.09

8.6.4 Hydraulic circuits

Section Figure Valve function

The primary relief valves for main pumps P 1 to P8

RH340B - Diesel - 3720618en - (01) - 04.09 Page 8.6 - 5

Page 8.6 - 6 RH340B - Diesel - 3720618en- (01) - 04.09

8.6.4.1 Pilot pressure system

Since the delivered oil from the pilot pressure

Pressure checking and setting

2. Start the both engines and let them run with

3. Activate service switch S31 (Fig. 4) and check

Auxiliary pressure 2 of 60 bar

Fig. 6 642051 Fig. 9 642052

RH340B - Diesel - 3720618en - (01) - 04.09 Page 8.6 - 7

Pump support pressure of main pumps 1 - 4

8. With service switch S31 (Fig. 4) activated,

Pump support pressure of main pumps 5 - 8

10. With service switch S31 (Fig. 4) activated,

The pilot pressure of 35 bar is used for the follow-

- Supply of the proportional valves to control the

The auxiliary pressure 1 of 50 bar is used for the

- Track tensioning system.

The auxiliary pressure 3 of 80 bar is used for the

- Pressure relief of the track tensioning system

Page 8.6 - 8 RH340B - Diesel - 3720618en- (01) - 04.09

8.6.4.2 Load limit system (PMS) 3. Check pressure.

 The load limit system of the RH engine is regu-

2. Run RH engine with maximum speed. The LH

Fig. 13 642121 4. Extend the stick cylinders.

RH340B - Diesel - 3720618en - (01) - 04.09 Page 8.6 - 9

For this checking an adapter (A, Fig. 15) is re-

Connect adapter (A).

Do checks 1 to 5 as described before and measure

 If the mA-values according to 3 & 5 are not

 If the mA-values are reached, but not the re-

Page 8.6 - 10 RH340B - Diesel - 3720618en- (01) - 04.09

8.6.4.3 Pressure cut-off system