014 - Pressure Checking and Setting - 8 - 06-3746300en

8.
6 PRESSURE CHECKING AND SETTING - FS
8.6 Pressure checking and 8.6.1.2 Safety
setting Observe accident prevention

and safety regulations at all
8.6.1 Introduction times.
8.6.1.1 Foreword 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 for RH170B – from serial-no. 170 088 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, coo-
lers, hydraulic reservoirs, com-
pressed-air reservoirs) must be
properly depressurized before be-
ing 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.
RH170B Diesel – 3746300en - (00) – 08.11 Seite 8.6 - 1

8.6 PRESSURE CHECKING AND SETTING - FS
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.
Hydraulic cylinders must be If pressure must be reset, in any case calibrated
brought into their end positions gauges have to be used, they have to be con-
before pressures are checked or nected to the relevant test points.
set to ensure that working attach-
ment does not move when pres-
sure is applied. Numbering of main pumps
The excavator operator must oper-
The 4 main pumps are numbered in travel direction
ate the relevant function gently
from left to right P1, P2, P3, and P4 (Fig.1),
(gradual application of pressure)
thus P1 and P2 are driven by the LH engine, and
and then shift the joystick/pedals
P3 and P4 are driven by the RH engine.
fully to their end position.
All pressure test points on the ex-
cavator have Minimess connec- Numbering of swing pumps
tions. Pressure gauges used for
checking must therefore have cor- Each drive unit is equipped with 2 swing pumps
responding fittings. (double pump). The swing pumps on the LH pump
gearbox are named SP1 / SP2, the pumps on the
Always connect the Minimess-hose
RH pump gearbox are named SP3 / SP4 (Fig. 1).
first to the gauge and then to the
test point on the machine to avoid
Auxiliary pumps (Fig. 1)
spillage of pressurized oil!
The springs in pressure relief - Double gear pump for the pilot pressure and
valves must never be tightened PTO cooling system. (6)
fully to "block". The windings of - Double pump for the fan drives of the hydraulic
the spring are then jammed so that oil cooler and the engine radiator. (7)
the valve cannot open. - Hydraulic oil cooling pump (12)
- Charge pump (13)
Before setting/resetting a relief
valve (primary or secondary) loo-
sen 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 642066
the hydraulic oil temperature must
be above 50°C.
Seite 8.6 - 2 RH170B Diesel – 3746300en - (00) – 08.11

8.6.2 Pressure setting
Description Unit RH170B

from No.170 088
Pressure cut-off – main pumps Cylinders bar 300
Travel bar 350
Primary relief for main pumps bar 380
Secondary relief for Boom cylinders bar 360
Stick cylinders bar 360
Bucket cylinders bar 360
Clam cylinders (4-spool valve) bar 360
Clam cylinders (back wall) bar 330
Travel motors bar 390
Main pump control pressure bar 8 – 43
Pilot pressure bar 35
Auxiliary pressure 1 bar 50
Swing system – working pressure max. bar 350
Swing system – charge pressure (approx.) bar 25
Swing system – safety valve (approx.) bar 22
Fan drive - pressure Hydraulic oil cooling bar 280
Engine cooling bar 280
Cooling circuit pressure Hydraulic oil cooling bar ≤5
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 1 bar (N2) 40
draulic accumulator
Pre-charge pressure of hy- Track tensioning system bar (N2) 55
draulic accumulator
Pre-charge pressure of hy- Ladder (Option) bar (N2) 65
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 3.2.8 in THB)
Table 2

8.6.4 Hydraulic circuits
Fig. 3 642712
Fig. 4 642713; 642068
Section Valve function

A Primary relief valves
B Swing balance valve
C Solenoid valve for logic valves
D Flushing valve for swing system
E Proportional valves (pump regulating)
F Pilot pressure for „swing“
G Pilot- and auxiliary pressure
Table 3

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. 5) together in the sequence as
mentioned below.
Pressure checking and setting

Ladder (Option) must be in the upper position
Fig. 5 642051
Auxiliary pressure 3 of 80 bar
1. Connect pressure gauges to test points M1
(range up to 150 bar, Fig. 6), M2 and M3
(range up to 60 bar, Fig. 7) for the pilot pres-
sure system.
2. Start the both engines and let them run with

maximum speed.
3. Activate service switch S31 (Fig. 7) and check

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

4. With service switch S31 (Fig. 7) deactivated,
check the pressure at test point M1,
required value: 60 bar. If necessary adjust Fig. 6 642116
valve 1.11.

valve 1.30.
Pilot pressure of 35 bar

valve 1.20.
Fig. 7 642709

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:
- Servicelift
- Pressure increase of the main pumps for trav-
eling
- Travel motor speed control (2. travel speed)
- Releasing the swing parking brake.
- Supply of the swing balance valve.

- Track tensioning system.

- Activation of the „swing blocking valve“.
- Grease pump of the „central greasing system“

- Pressure relief of the track tensioning system

after traveling.
- Pressure increase to lift the ladder.

8.6.4.2 Load limit system (PMS)

4. Extend the stick cylinders.
Layout and function of the load limit system is de-
scribed in chapter 8.5.1.
5. Check pressure (Stick cylinders are in end-
position; pressure cut-off in function):
For each engine an electronic load limit system is
Nominal pressure: approx. 43 bar (820 mA).
installed.
The current from the electronic load limit system is
Checking the load limit pressure for the RH
converted into hydraulic pressure by a proportional
drive unit:
valve (23, Fig. 8 + 9).
1. Connect a gauge (range 60 bar) to the test
 The proportional valve (23.1, Fig. 9), which is point (M, 23.2, Fig. 9).
linked to the load limit system of the LH engine,
is delivering a pressure signal for main pumps
P1 & P2 via port X1 on the main pump regula-
tors.
The pressure level is related to the load factor
of the engine.
 The load limit system of the RH engine is regu-

lating the main pumps P3 & P4 in the same way
using proportional valve (23.2, Fig. 9).
Fig. 9 642711
2. Run RH engine with maximum speed. The LH

engine has to be shut off.
3. Check pressure.
The gauge must indicate approx. 8 bar
Fig. 8 642710 (225mA).
4. Extend the stick cylinders.

Checking the load limit pressure for the LH
drive unit: 5. Check pressure (Stick cylinders are in end-
position; pressure cut-off in function):
1. Connect a gauge (range 60 bar) to the test Nominal pressure: approx. 43 bar (820 mA).
point (M, 23.1, Fig. 9).
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 valve must be checked.
For this checking an adapter (A, Fig. 10) is re-
3. Check pressure. quired, to measure the current (mA) supplied by
The gauge must indicate approx. 8 bar the load limit system.
(225 mA).

Fig. 10 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 and 23.2.
 If the mA-values according to 3 & 5 are not

reached, there is a defect in the load limit circuit
,or the pressure cut-off function of the main
pumps will not be active. (see chapter 8.6.4.3)
 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

Layout and function of the pressure cut-off system The travel parking brake must be
is described in chapter 8.5.2. released. Press travel pedal gently
until pressure rise is recognized.
The pressure cut-off function for the 4 main pumps
Machine might travel!
(3, Fig. 12) is managed by the pressure cut-off
valves (A). They are set to 300 bar and limit thus
the working pressure for the hydraulic cylinders.
6. Shut of LH engine.
When operating the travel system the pressure cut-
off valves are hydraulically adjusted to 350 bar via 7. Check and set pressure cut-off valves of the RH
solenoid valve (Y31). main pumps (P3 & P4) accordingly with gauges
The electronic system of the machine ensures, that connected to test points M3 & M4 (Fig. 11).
the pressure increase is not operational, when the
attachment is operated at the same time, so that
operation of the hydraulic cylinders with 350 bar is
prevented.
Note:
As a precondition for the following tests and set-

tings it is essential that all primary- and secondary
valves are correct adjusted.
Checking and setting

Fig. 11 642076
1. Connect 2 gauges (range: 400 bar) to the high
pressure circuits of pumps P1 & P2. The rele-
vant test points M1 & M2 are to be found on the
high pressure filter-housings (Fig. 11).
2. Start LH engine and bring it to maximum speed.
3. Extend the stick cylinders completely and posi-

tion the attachment on the ground.
4. Activate function "stick cylinder out" and check

pressure (rated: 300 bar).
If necessary adjust valve (A, Fig. 12) at the re-
spective for pump.
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
Fig. 12 630638.TIF
applied.
The indicated pressure must then be 350 bar.

8.6.4.4 Primary relief system

3. Set primary relief valve (PRV1, Fig. 13) of
Primary pressure relief for the four main pumps
main pump P1:
(P1 – P4) is controlled by four pressure relief
valves (PRV1, PRV2, PRV3, PRV4, Fig. 13).
 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, Fig. 15) of pump (P1) completely in.
This is to raise the set value of this valve
above 380 bar.
Fig. 13 642077
Setting of PRV 1:
1. Connect a gauge (range: 400 bar) to test point Fig. 15 630638.TIF

M1. The test points are installed on the high
pressure filter blocks (Fig. 14).
 Start LH engine and bring it to maximum speed.
 Activate function "RH travel" forward or reverse.
 Check pressure (rated; 380 bar).
 If necessary reset valve.
 Turn pressure cut-off valve again down to 300

bar.
The travel parking brake must be

Fig. 14 642076 released. Press travel pedal gently
Machine might travel!
2. Start the LH engine. The attachment must be
placed on the ground and the parking brake
"swing" must be activated to avoid turning of
the superstructure.

Setting of PRV 2: This is to raise the set value of this valve

above 380 bar.
1. Connect a gauge (range: 400 bar) to test point
M2. The test points are installed on the high  Start RH engine and bring it to maximum
pressure filter blocks (Fig. 14). speed.
2. Start the LH engine. The attachment must be  Activate function "RH travel" forward or re-
placed on the ground and the parking brake verse.
the superstructure.  Check pressure (rated; 380 bar).
3. Set primary relief valve (PRV2, Fig. 13) of  If necessary reset valve.
main pump P2:
 When a new primary relief valve is installed bar.
peaks.
Setting of PRV 4:
valve (A, Fig. 15) of pump (P2) completely in. 1. Connect a gauge (range: 400 bar) to test point
This is to raise the set value of this valve M4. The test points are installed on the high
above 380 bar. pressure filter blocks (Fig. 14).
 Start LH engine and bring it to maximum 2. Start the RH engine. The attachment must be
speed. placed on the ground and the parking brake
 Activate function "LH travel" forward or re- the superstructure.
verse.
3. Set primary relief valve (PRV4, Fig. 13) of
 Check pressure (rated; 380 bar). main pump P4:
 If necessary reset valve.  When a new primary relief valve is installed

 Turn pressure cut-off valve again down to 300 peaks.
bar.
Setting of PRV 3: This is to raise the set value of this valve
above 380 bar.
1. Connect a gauge (range: 400 bar) to test point
M3. The test points are installed on the high  Start RH engine and bring it to maximum
pressure filter blocks (Fig. 14). speed.
2. Start the RH engine. The attachment must be  Activate function "LH travel" forward or re-
placed on the ground and the parking brake verse.
the superstructure.  Check pressure (rated; 380 bar).
3. Set primary relief valve (PRV3, Fig. 13) of  If necessary reset valve.
main pump P3:
 When a new primary relief valve is installed bar.
peaks.


8.6.4.5 Secondary relief system for attachment

The secondary pressure relief valves for the at-
tachment are flanged onto the 4-spool control
blocks (161-1 and 161-2, Fig. 16). The 4-spool
control blocks are located on the boom.
The secondary relief valves are located on the control blocks on the boom (Fig. 16).
Fig. 16 642078
Valve arrangement for faceshovel configuration (Fig. 16)
Position Relief valve for Position Relief valve for

1 Clam cylinder – rod side 9 Clam cylinder – piston side
2+8 Bucket crowd cylinder – piston side 10 + 16 Bucket crowd cylinder – rod side
3+7 Stick cylinder – rod side 11 + 15 Stick cylinder – piston side
4+6 Boom cylinder – piston side 12 + 14 Boom cylinder – rod side
5 + 13 Spool not connected
Table 4
Note:
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. 20).

This pressure check has to be done with only one

engine running. The pressure cut-off function
should be adjusted over 360 bar on one main
pump only. The smaller flow rate of one pump
only allows a more accurate pressure setting.
Check pressures with LH engine running and main

pump (P2) or with RH engine and main pump (P4),
because these pumps supply oil to all cylinders of
the attachment.
Fig. 18 642076
Example – stick cylinder rod side:
Cancel 'arm float' and carefully apply pressure

to rod side of arm cylinders by shifting the joy-
stick smoothly to the end position “Stick IN”.
Check pressure (rated: 360 bar).
5. Because the pair of cylinders is connected via

compensating lines and secured by 2 relief
valves, the gauge on the test point always in-
dicates the lowest pressure setting of the 2
Fig. 17 630638.TIF valves. Therefore it is possible that, even with
an indicated pressure of 360 bar, one valve is
still set too high.
To check the valves for
Therefore reduce pressure setting on 1st valve
Rod side: retract cylinders fully (Pos.3, Fig. 16) of the pair to less than 360
Piston side: extend cylinders fully bar. Gauge reading must drop noticeably. In-
crease pressure setting back up to 360 bar.
Location of the secondary relief valves is shown in
Fig. 16.
Checking and setting (with LH engine)
1. Connect gauge (Range: 400 bar) to test point

M2 (Fig. 18).
2. Screw the adjuster of the pressure cut-off

valve (A, Fig. 17) of pump P2 completely in.
This is to raise the pressure above 360 bar
(secondary relief setting).
Fig. 19 630622a
3. Start LH engine and bring to maximum speed.

6. Set pressure on 2nd valve (Pos.7, Fig. 16) in
4. Check pressure and reset if required the same way: Lower it firstly, and than in-
(see table 4). crease back up to 360 bar.
7. After checking all secondary relief valves re-

duce pressure cut-off valve back to 300 bar.

Secondary relief valves for clam cylinder rod-

side.
The face shovel attachment is equipped with an

additional secondary relief valve for the rod side at
the clamshell cylinders (function 'open bucket'),
which is installed on the distributor in the back wall
of the bucket (187, Fig. 20).
The relief valve enables oil flow from the rod side
to the piston side in case of wrong operation (dig-
ging into the material, before the front lip is com-
pletely closed and thus closing the bucket by ex-
ternal force).
Checking and setting:
1. Connect a gauge (range: 400 bar) to check

point M2 (Fig. 18).
2. Screw the adjuster of the secondary relief

valve (187, Fig. 20) completely in and then ¼
turn back.
Fig. 20 630480
valve (A, Fig. 17) of pump P2 completely in.
This is to raise the pressure above 360 bar
(secondary relief setting).
4. Start the LH engine and place the attachment

on the ground.
5. Operate the function 'open bucket'.
6. The pressure at check point M2 must read

360 bar.
If required adjust the relief valve (1, Fig. 16) at
control block 161-1 accordingly.
7. Now adjust the relief valve (187, Fig. 20) to

the required pressure of 330 bar.
8. After checking the secondary relief valves,

reduce pressure cut-off valve (A, Fig. 17) of
pump P2 back to 300 bar.

8.6.4.6 Secondary relief system for travel 5. Engage the function 'LH travel forward' by
depressing the foot-pedal slowly into the end
Note:
position.
The check of the travel secondary relief valves
6. Check pressure.
should only be carried out in case of travel per-
At the check point M2 (Fig. 18) the pressure
formance- or temperature problems.
must read 390 bar.
If required adjust valve A (Fig. 21) accordingly.
Layout and function of the travel system is de-
Because each crawler has installed two travel
motors, the gauge on the check point always
For securing the travel system each travel motor is
indicates the lowest pressure setting of the 2
equipped with 2 relief valves (Fig. 21).
valves. Therefore it is possible that, even with
an indicated pressure of 390 bar, one valve is
The valves (A + B) are screwed into the travel re-
still set too high.
tarder valves of the travel motors.
Therefore reduce pressure setting on 1st valve
A1, Fig.21) of the pair to less than 360 bar.
Gauge reading must drop noticeably. Increase
pressure setting back up to 390 bar.
Set pressure on 2nd valve (A2, Fig. 21) in the
same way: Lower it firstly, and than increase
back up to 390 bar.
7. Check the following functions in the same way:
LH travel reverse (B1 / B2)

RH travel reverse (A1/ A2)
RH travel forward (B1 / B2)
8. Reset primary relief valves PRV1 and PRV2

back to 380 bar (see chapter 8.6.4.4)
Fig. 21 642085
9. Reset pressure cut-off valve back to 300 bar.
1. Connect two gauges (range: 400 bar) to the

check points M1 and M2 (Fig. 18) at the high The travel parking brake must be
pressure filter blocks. released. Press travel pedal gently
valve (A, Fig. 17) of pump P1 and P2 com- Machine might travel!
pletely in.
3. Screw the adjuster of primary relief valves

PRV1 and PRV2, Fig. 13) a ¼ turn in.
4. Start LH engine and bring to maximum speed.

The bucket teeth must be pushed into the
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.

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 25 bar at full engine RPM.
test points (MX5 & MX6, Fig. 22) of the swing The charge pressure is limited by pressure relief
balance valve (105). valves (one for each swing pump).
The valves are set at 25 bar by the manufacturer.
Note:
In case one charge pressure limiting valve of a

swing pump is set below 25 bar, the 25 bar charge
pressure for the swing system cannot be reached.
In this case check and increase setting of the
charge pressure limiting valves (L1 & L2, Fig. 23)
in the housings of the swing pumps.
Fig. 22 642715
3. Start LH engine and run at maximum speed.
4. Check pressure; both gauges must indicate

the same pressure.
5. Start RH engine and run at maximum speed
6. Check pressure; both gauges must indicate

Fig. 23 630806
the same pressure.
6.1 If pressures are not equal with one engine

running: Adjustments at the pumps may
One or both swing pumps are mechanically only be done with the appropriate
out of neutral. (Superstructure tries to turn) technical knowledge!
Correct the adjustment at the pump regulator.
The secondary relief valves of the
6.2 If pressures are not equal with any engine swing system (2 valves for each
running: swing pump) are set at 400 bar.
Swing balance valve (105, Fig. 22) is not ex- This setting must not be altered!
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. 22) of the swing
balance valve (105). Adjust valve with ad-
juster screw (A Fig. 22) until both gauges in-
dicate the same pressure.

7. Check pilot pressure for swing:

 Connect a pressure gauge (range: 60 bar)
to test point M (Fig. 24) of the pressure re-
lief valve (109, Fig. 24).
 Run both engines with maximum speed.
 Activate 'swing left or right' and move joy
stick slowly into the end position.
 Check pressure (rated; 22 bar).
 If necessary adjust pressure relief valve
(109, Fig. 24).
8. To check the high pressure, replace the two

60-bar gauges at the swing balance valve
(105, Fig. 22) again with 400-bar gauges.
9. Activate 'swing right'. Move joy stick slowly into Fig. 24 642716
the end position.
10. Checking pressures: The gauge related to the

high pressure side at the swing balance valve
(105, Fig. 22) must indicate approx. 350 bar;
the low pressure side must indicate approx. 25
bar.
The pilot pressure for the swing balance valve
will be approx. 22 bar at this stage.
The swing high pressure is determined by the
swing balance valve feed pressure (pilot) and
the swing balance valve ratio (1 : 16).
11. Activate 'swing left' and move joy stick slowly

into the end position.
Now the other gauge must indicate approx.
350 bar on the high pressure side; the second
gauge must indicate 25 bar.
Fig. 25 642110
Note:
If the swing pressure varies from the rated

pressure (350 bar), the feed pressure must be For cooling of the closed swing circuit a certain
checked and if necessary corrected at pres- volume of oil is flushed out by the flushing valve
sure relief valve (109, Fig. 24). (106, Fig. 24 & 25) and replaced by the charge
pumps (13).
Adjustment: Space "S" of the adjuster screw of

flushing valve (106, Fig. 24 & 25) has to be 15 mm.

8.6.4.8 Track tensioning system 2. Start both engines and let them run with max-
imum speed.
Layout and function of the track tensioning system
is described in chapter 8.5.7.
3. Check auxiliary pressure 2.
Rated: 60 bar;
The pressure for the hydraulic track tensioning
If necessary adjust auxiliary pressure 2 (see
system is taken from the 60-bar auxiliary circuit 2.
chapter 8.6.4.1).
The pressure to discharge the hydraulic track ten-
sioning system is taken from the 80-bar auxiliary
4. Activate service switch S31 (Fig. 27) and
circuit 1.
check the pressure at test point M1 (Fig. 26).
Rated: 80 bar;
The pilot controlled check valves and the change
If necessary adjust auxiliary pressure 1 (see
over valve, factory set to 70 bar, are located on the
chapter 8.6.4.1).
track tensioning valve block (133, Fig. 29).
Discharge function
1. Connect gauges (range: 150 bar) to test points

M-A2 and M-B1 (Fig. 28).
2. Start both engines and let them run with max-

imum speed.
3. Check pressures.
Rated:
At test point M-A2 = 60 bar
At test point M-B1 = 0 bar
4. Activate service switch S31 and check the

pressures.
Rated:
Fig. 26 642116 At test point M-A2 = 80 bar
Overview:
S31 M-A2 M-B1
OFF 60 bar 0 bar
ON 80 bar 80 bar
Table 5
Fig. 27 642714

Ladder (Option) must be in the upper position
Inlet pressure:
Fig. 28 642062
1. Connect gauge (range: 100 bar) to test point
M1 (Fig. 26).

Note: Secondary relief system
If the pressures will not appear as shown in table The track tensioning system is protected by two
5, the function and setting of the change over valve secondary relief valves, which are preset to 330
(SV, Fig. 28) has to be checked. bar.
To make the switch point of the change over valve
visible, the auxiliary pressure 2 has to be tempo- These valves are installed in the carbody (134, Fig.
rary increased to 70 bar (see chapter 8.6.4.1). 29).
Change over pressure (70 bar)
1. Start both engines and let them run with max-

imum speed.
2. Adjust auxiliary pressure 2 to 70 bar (see

chapter 8.6.4.1).
3. Connect gauges (range: 150 bar) to test points

M-A2 and M-B1 (Fig. 28).
4. Check pressures.
There are two possible situations:
a) At test point M-A2 = 70 bar
At test point M-B1 = 0 bar Fig. 29 630776a
or
b) At test point M-A2 = 70 bar
5. 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. 28) 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.
6. Slowly turn in (cw) the set screw of change

over valve (SV, Fig. 28) until the pressure at
test point M-B1 switches over to 70 bar. This
setting has to be secured with the lock nut.
7. Readjust auxiliary pressure 2 back to 60 bar

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

8.6.4.8).

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 fan pump on the LH engine drives the front
fan. The cooling pump on the RH engine drives the Fig. 31 is showing fan pump (7a) with flanged on
rear fan. proportional valve and its coil (C).
The flow of the fan pumps is in relation to the hy-
draulic oil temperature electronically controlled.
Fig. 30 is showing fan pump (7b) with flanged on

proportional valve and its coil (C).
Fig. 31 642084
1. Connect a gauge (range: 400 bar) to the rele-

Fig. 30 642083
vant test point at the fan motor.
Checking and setting 2. Ensure that the coolant temperature is above

95°C, so that the thermostats are closed
1. Connect a gauge (range: 400 bar) to the rele- completely.
vant test point at the fan motor.
3. Check pressure.
2. Ensure, that the hydraulic oil temperature is
above 70°C, so that the fan motors run with With a temperature of the coolant of approx.
maximum rpm. 98° C the pressure at the fan motor is approx.
200 bar.
3. Check pressure.
With an oil temperature of approx. 70° C the Pressure cut-off

pressure at the fan motor is approx. 200 bar.
The fan pumps are equipped with a pressure cut-
off valve (A, Fig. 31), which is set at the factory to
Pressure cut-off 280 bar.
The adjustment of minimum flow is done at valve B
The fan pumps are equipped with a pressure cut- (Fig. 31). This valve is also set at the factory.
off valve (A, Fig. 30), which is set at the factory to
280 bar.
The adjustment of minimum flow is done at valve B
(Fig. 30). This valve is also set at the factory.

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. 32) 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. 33 642060
b) In the auxiliary pressure system, a dia-
phragm accumulator (38, Fig. 32) 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. 33) 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.
34) is used to lower the access ladder
when the engines are shut down.
Gas pre-charge pressure: 65 bar Fig. 34 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 3.2.8
,THB).
A general procedure how to handle the “charging
and testing unit” is described on the following pag-
es:
Fig. 32 642708

Charging and testing unit for Charging and testing unit for
diaphragm accumulators bladder accumulators with
adaptor A3
Fig. 37 642065
Fig. 35 642063 Legend, Fig. 37

Legend, Fig. 35 1 = Hydr. accumulator 5 = Charging hose
A = Spindle 2 = Adaptor A 6 = Connector
B = Pressure release 3 = Charging and test- 7 = pressure reducer
C = Check valve ing unit 8 = Adaptor
D = screw connector 4 = Connector 9 = Nitrogen bottle
A3 = Adaptor
DESCRIPTION (Charging and testing unit)

Gas valve for diaphragm Gas valve for Bladder accu-
accumulators mulators FUNCTION
The charging and testing unit is used to charge
accumulators with nitrogen or to check or to
change the existing pre-charge pressure in accu-
mulators. For this purpose the charging and testing
unit is screwed onto the gas valve of the hydraulic
accumulator and connected to a commercial nitro-
gen bottle via a flexible charging hose. If the nitro-
gen 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 accumu-
lator gas valve to control the pressure. Piston and
diaphragm accumulators can be charged and
checked without the need for adaptors. Bladder
Fig. 36 642064 accumulators, however, require an adaptor A3.
Legend, Fig. 36
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  Connect the flexible charging hose to the
switched on. pressure reducer on the nitrogen bottle by
b) Releasing the auxiliary pressure system means of the connector (Pos. 6, Fig. 37). For
by shifting both control levers repeatedly nitrogen bottles from other countries the ap-
into all directions with the motor at stand- propriate adaptor is required see chapter
still, emergency switch S211 (attachment 3.2.8 ,THB). Connect connector (Pos. 4, Fig.
down) activated and the electric system 37) of the charging hose to the check valve C
switched on. of the charging and testing unit. Open the
c) Releasing the track tensioning system shut-off valve on the nitrogen bottle, and slow-
by opening the pressure relief valves (134, ly release nitrogen into the accumulator. Wait
Fig 33) with both engines at standstill. until approximately 1 bar has been reached
d) Releasing the hydraulic system of the before opening the shutoff valve of the nitro-
ladder by shifting the control lever (151, gen bottle further to enable faster charging.
Fig. 34) repeatedly with both engines at
standstill.  Interrupt the charging process from time to
time and check the pre-charge pressure
Unscrew the protective caps S and H (only on reached. Repeat this process until the re-
bladder accumulators). Remove the O-ring O on quired gas pre-charge pressure is achieved.
bladder accumulators. Slightly loosen the internal After temperature equalization has taken
hexagon screw P on piston and diaphragm accu- place, re-check the pre-charge pressure and
mulators by means of an Allen key SW 6, DIN 911 adjust if necessary. If the pressure is too high,
(approx. ½ turn). Place the charging and testing it can be lowered via the pressure release B
unit onto the accumulator and screw connector D of the charging and testing unit.
by hand onto accumulator gas valve. At the same
time, ensure that the release B of the charging and  If the required gas pre-charge pressure has
testing unit is closed. Turn charging and testing been reached, turn the spindle anticlockwise
unit to a position where the gauge can be easily to close the gas valve on bladder accumula-
read. tors. On piston or diaphragm accumulators
close the internal hexagon screw P by turning
TESTING the spindle clockwise. Discharge the charging
On bladder accumulators (Charging and testing and testing unit via the pressure release and
unit with adaptor A3) open valve by turning spindle remove it by loosening the connector. On
A clockwise. bladder accumulators, unscrew the adaptor
On piston and diaphragm accumulators (Charg- and replace the O-ring O. On piston and dia-
ing and testing unit) open valve V by turning the phragm accumulators, tighten the internal
internal hexagon screw anticlockwise with spindle hexagon screw P with Allen key [20 Nm].
A. When the needle of the gauge begins to move,  Check for leakages on the accumulator gas
give the spindle another complete turn. The gauge valve using a leak detector spray.
now shows the charging pressure in the accumula-
tor. The check valve C prevents any escape of  Screw on cap nut H (only on bladder accumu-
nitrogen. lators) and valve protection cap S onto the
gas valve of the accumulator and tighten.
REDUCING THE PRE-CHARGE PRESSURE
Carefully open release B. The nitrogen escapes into
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.


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8.

6 PRESSURE CHECKING AND SETTING - FS

8.6 Pressure checking and 8.6.1.2 Safety

setting Observe accident prevention

Further developments and alterations introduced before starting any work.

RH170B Diesel – 3746300en - (00) – 08.11 Seite 8.6 - 1

Seite 8.6 - 2 RH170B Diesel – 3746300en - (00) – 08.11

8.6.2 Pressure setting

Description Unit RH170B

Clam cylinders (4-spool valve) bar 360

Clam cylinders (back wall) bar 330

Travel motors bar 390

Main pump control pressure 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 350

Swing system – charge pressure (approx.) bar 25

Swing system – safety valve (approx.) bar 22

Fan drive - pressure Hydraulic oil cooling bar 280

Engine cooling bar 280

Cooling circuit pressure Hydraulic oil cooling bar ≤5

Track tensioning system Change over valve bar 70

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

RH170B Diesel – 3746300en - (00) – 08.11 Seite 8.6 - 3

Item Quantity Designation Part-No.

1 2 Test kit with gauges and hoses 1 476 323

Seite 8.6 - 4 RH170B Diesel – 3746300en - (00) – 08.11

8.6.4 Hydraulic circuits

Fig. 4 642713; 642068

Section Valve function

RH170B Diesel – 3746300en - (00) – 08.11 Seite 8.6 - 5

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. 7) and check

Auxiliary pressure 2 of 60 bar

Auxiliary pressure 1 of 50 bar

Pilot pressure of 35 bar

Seite 8.6 - 6 RH170B Diesel – 3746300en - (00) – 08.11

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

The auxiliary pressure 2 of 60 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

RH170B Diesel – 3746300en - (00) – 08.11 Seite 8.6 - 7

8.6.4.2 Load limit system (PMS)

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

2. Run RH engine with maximum speed. The LH

4. Extend the stick cylinders.

Seite 8.6 - 8 RH170B Diesel – 3746300en - (00) – 08.11

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-

RH170B Diesel – 3746300en - (00) – 08.11 Seite 8.6 - 9

8.6.4.3 Pressure cut-off system

As a precondition for the following tests and set-