14 RH 120-E Pressure Checking and Setting

8.
6 PRESSURE CHECKING AND SETTING - FS
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 (TBH) 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 RH 120 E – serial-no. 120 073
120 086 The rated pressure relief valve set-
120 091 ting must not be modified without
120 098 explicit approval by TEREX.
120 103
120 104 All personnel carrying out com-
120 114 missioning, operation, inspection,
120 116 service and repair must have read
120 117 and understood the operating in-
and structions and in particular the
chapter
RH 120 E from – serial-no. 120 121 'Fundamental Safety Instructions'
before starting any work.
The illustrations, descriptions and explanations Unauthorized conversions or modi-
reflect the current standard configuration. Some of fications of the hydraulic excavator
the illustrations can show details that differ from a are forbidden for reasons of safety.
particular machine, but that does not affect the
validity of the information given. Secure the machine and the work-
If any points are nevertheless unclear or seem to ing attachment against inadvertent
be incorrect, please contact your local TEREX and unauthorized starting. Place
dealer or your TEREX distributing centre. working attachment on the ground
in such way as that no movements
Further developments and alterations introduced can be made when mechanical or
into the standard series production will be imple- hydraulic connections become
mented into later re-prints of the TBH. detached.
Tools, hoists, slings, trestles and
When setting the pressure relief valves the other devices must be in a reliable
hydraulic oil temperature has to be higher than safe state.
50°C.
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 .
RH 120 E - Diesel - 3668597en.doc- (00) - 09.08 Page 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. 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 4 main pumps are numbered in travel direction
The excavator operator must oper-
from left to right P1, P2, P3, and P4 (Fig.1),
ate the relevant function gently
thus P1 and P2 are driven by the LH engine, and
(gradual application of pressure)
P3 and P4 are driven by the RH engine.
and then shift the joystick/pedals
fully to their end position.
All Pressure test points on the ex- Numbering of swing pumps
cavator have Minimess connec-
tions. Pressure gauges used for Each drive unit is equipped with 2 swing pumps
checking must therefore have cor- (double pump). The swing pumps on the LH pump
responding fittings. gearbox are named SP1 / SP2, the pumps on the
RH pump gearbox are named SP3 / SP4 (Fig. 1).
Always connect the Minimess-hose
first to the gauge and then to the
Auxiliary pumps (Fig. 1)
test point on the machine to avoid
spillage of pressurized oil!
- Double gear pump for the pilot pressure and
The springs in pressure relief PTO cooling system. (6)
valves must never be tightened - Fan pump for hydraulic oil cooler (7)
fully to "block". The windings of - Hydraulic oil cooling pump (10)
the spring are then jammed so that - Charge pump (13)
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)
= 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
Fig. 1 2804594c
tighten the counter nut again.
When checking/setting pressures
the hydraulic oil temperature must
be above 50°C.
Page 8.6 - 2 RH 120 E - Diesel - 3668597en.doc- (00) - 09.08

8.6.2 Pressure setting
Description Unit RH 120 E

From No. 120 073
Pressure cut-off – main pumps Cylinders bar 310
Travel bar 360
Primary relief for main pumps Cylinders bar 330
Travel bar 380
Secondary relief for Boom cylinders bar 360
Stick cylinders bar 360
Bucket cylinders bar 360
Clam cylinders (1-spool valve) bar 350
Clam cylinders (back wall) bar 330
Travel motors bar 400
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 40
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 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 Tools
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 3.2.2 in THB)
Table 2

8.6.4 Hydraulic circuits The locations of the valves on the machine are
shown in fig. 3 to 7.
In table 3 the various valves are listed which are
used for the pressure setting of the different hy-
draulic circuits.
Section Figure Valve function Setting

P1 / P3 3 Primary relief valves for P1 and P3 in travel control blocks 380 bar
P3 (P2) 4 Primary relief valves in clam control block 330 bar
A 5 Pressure limiting for charge pump, swing system 40 bar
B 6 Primary relief valves for P2 and P4 330 bar
C 6 Pressure limiting for the pilot pressure system „swing“ 22 bar
D 7 Pilot pressure limiting 35 bar
Auxiliary pressure 1 limiting 50 bar
Table 3
The primary relief valve for main pump P 3 is lo-

cated at the front end of the LH travel control block
(Fig. 3).
The primary relief valve for main pump P 1 is lo-
cated at the rear end of the RH travel control block
(Fig. 3).
Fig. 4 630809
The charge pressure is to be set on the pressure

cut-off valve (A, Fig. 5) of the charge pump.
Fig. 3 63762
An additional primary relief valve is located in the

clam control block (Fig. 4).
Fig. 5 630827

Fig. 6 642055
Fig. 7 642056

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

Ladder (Option) must be in the upper position
Fig. 9 642054
Auxiliary pressure 3 of 80 bar
1. Connect pressure gauges to test points M1
(range up to 150 bar, Fig. 9), M2 and M3
(range up to 60 bar, Fig. 10 & 11) for the pilot
pressure 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.
Auxiliary pressure 2 of 60 bar

4. With service switch S31 (Fig. 7) deactivated,
check the pressure at test point M1, Fig. 10 642053
required value: 60 bar. If necessary adjust
valve 1.11.
Pilot pressure of 35 bar
Auxiliary pressure 1 of 50 bar 6. With service switch S31 (Fig. 7) deactivated,
5. With service switch S31 (Fig. 7) 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. 8 642051 Fig. 11 642052

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-
5. Check pressure (Stick cylinders are in end-
scribed in chapter 8.5.1.
position; pressure cut-off in function):
Nominal pressure: approx. 43 bar (820 mA).
For each engine an electronic load limit system is
installed.
Checking the load limit pressure for the RH
The current from the electronic load limit system is
drive unit:
converted into hydraulic pressure by a proportional
valve (23, Fig. 12).
1. Connect a gauge (range 60 bar) to the test
point (M, 23.2, Fig. 13).
• The proportional valve, which is 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 regulators.
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.
Fig. 13 642057
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. 12 642057 (225mA).
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):
Nominal pressure: approx. 43 bar (820 mA).
1. Connect a gauge (range 60 bar) to the test
point (M, 23.1, Fig. 12).
In case the required pressures are not achieved
2. Run LH engine with maximum speed. The RH the proportional valve must be checked.
engine has to be shut off. For this checking an adapter (A, Fig. 14) is re-
quired to measure the current (mA) supplied by the
3. Check pressure. load limit system.
The gauge must indicate approx. 8 bar
(225 mA).

Fig. 14 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 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

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!
(Fig. 15) is managed by the pressure cut-off valves
(A / B). They are set to 310 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 360 bar via 7. Check and set pressure cut-off valves of the RH
a solenoid valve. main pumps (P3 & P4) accordingly with gauges
The electronic system of the machine ensures, that connected to test points M3 & M4.
the pressure increase is not operational, when the
attachment is operated at the same time, so that
operation of the hydraulic cylinders with 360 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
1. Connect 2 gauges (range: 400 bar) to the high Fig. 15 630793

pressure circuits of pumps P1 & P2. The rele-
vant test points M1 & M2 are to be found on the
high pressure filter-housings (Fig. 16a & b).
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: 310bar).
If necessary adjust the valve for pump P1 (A,
Fig. 15) or pump P2 (B, Fig. 15).I
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. Fig. 16a 630828
The indicated pressure must then be 360 bar.

8.6.4.4 Primary relief system

Primary pressure relief for the 4 main pumps is
controlled by pressure relief valves.
The relief valves for P2 and P4 are located at the
high pressure filter blocks (Fig. 16a & b, Fig. 17).
The relief valves for P1 and P3 are located at the
travel valve blocks (Fig. 18).
This arrangement is valid when both engines are

running.
In case of single engine operation the oil flows to
the travel control valves first.
A further primary relief valve is installed in the

'clam' control block.
Fig. 16b 630829
Í Front Bottom View RearÎ
Fig. 17 630764
Setting of P1
1. Connect a gauge (range: 400 bar) to test point

M1. The test points are installed on the high
pressure filter blocks (Fig. 17).
2. The shovel teeth must be pushed into the

ground and the travel parking brake must be
applied. For this purpose it is necessary to dis-
connect and plug the hoses from the travel
motors to the brakes (Arrows, Fig. 28 & 29) so
that travel movements are avoided during the
check. The undercarriage 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 pump (P1) at • Start LH engine and bring it to maximum speed.
the RH travel valve block: (P1, Fig. 18):
• Activate function "travel forward".
• When a new primary relief valve is installed • Check pressure (rated; 380 bar).
screw the adjuster 1 turn out, to avoid pressure
peaks. • If necessary reset valve.
• Screw the adjuster of the pressure cut-off • Turn pressure cut-off valve again down to 310
valve of pump (P1) completely in. This is to ri- bar.
se the set value of this valve above 380 bar.
Setting of P2:
Fig. 18 630762
The precise location of the primary relief valve for Fig. 20 630766
P1 is shown in fig. 19.
1. Connect a gauge (range: 400 bar) to test point
2. The shovel teeth must be pushed into the

ground and the travel parking brake must be
connect and plug the hoses from the travel
motors to the brakes (Arrows, Fig. 28 & 29) so
that travel movements are avoided during the
with final drives at the rear. The parking brake
the superstructure.
Fig. 19 630763

3. Set primary relief valve of main pump (P2) at 1. Connect a gauge (range 400 bar) to test point
the LH high pressure filter block (P2, Fig. 20): M3. The test points are installed on the high
• When a new primary relief valve is installed
screw the adjuster 1 turn out, to avoid pressure 2. The shovel teeth must be pushed into the
peaks. ground and the travel parking brake must be
• Screw the adjuster of the pressure cut-off valve connect and plug the hoses from the travel
of pump (P2) completely in. This is to raise the motors to the brakes (Arrows, Fig. 28 & 29) so
pressure above 330 bar. that travel movements are avoided during the
• Start LH engine and bring it to maximum speed. with final drives at the rear. The parking brake
• Start also RH engine and run at low idle. the superstructure.
• Activate function "stick cylinder out" until the 3. Set primary relief valve of main pump (P3) at
cylinders are completely extended. the LH travel valve block (P3, Fig. 21):
• Check pressure (rated 330 bar). • When a new primary relief is installed screw
the adjuster 1 turn out, to avoid pressure
• If necessary reset valve. peaks.
• Turn pressure cut-off valve again down to 310 • Screw the adjuster of the pressure cut-off
bar. valve of pump (P3) completely in. This is to rai-
se the pressure over 380 bar.
• Start RH engine and bring to maximum speed.

Setting of P3:
• Activate function "travel forward".
• Check pressure (rated 380 bar).
• If necessary reset valve.
• Turn pressure cut-off valve again down to 310

bar.
Fig. 21 630762

Setting of P4
Fig. 22 630765
1. Connect a gauge (range 400 bar) to test point

2. The bucket teeth must be pushed into the

ground to brake the machine and to prevent
travel of the machine during the test. The un-
dercarriage has to be positioned with final
drives at the rear. The parking brake "swing"
must be activated to avoid turning of the su-
perstructure.
3. Set primary relief valve of main pump (P4) at

the high pressure filter block (Fig. 22):
• When a new primary relief valve is installed

screw adjuster 1 turn out to avoid pressure
peaks.
• Screw the adjuster of the pressure cut-off

valve of pump (P4) completely in. This is to rai-
se the pressure above 330 bar.
• Start RH engine and bring to maximum speed.
• Start also LH engine and run at low idle.
• Activate function "stick cylinder out" until the

cylinders are completely extended.

bar.

Setting of 'clam' primary relief valve
1. Connect a gauge (range 400 bar) to test point

2. The attachment must be placed on the ground

and the parking brake "swing" must be acti-
vated to avoid turning of the superstructure.
3. Set primary relief valve 'clam' at the 'clam'

main control block. (166, Fig. 23):
• When a new primary relief is installed screw

the adjuster 1 turn out, to avoid pressure
peaks.
• Screw the adjuster of the pressure cut-off

valve of pump (P2) in (above 330 bar)
• Start LH engine and bring to maximum speed.
• Activate function "close bucket" until the bu-

cket is completely closed.

bar.
Fig. 23 630811a

8.6.4.5 Secondary relief system for attachment block (166, Fig. 24) with secondary relief valves is
operating the clam cylinders.
The secondary relief valves for the attachment are
The face shovel attachment is equipped with an
screwed into the 3-spool control blocks (161/1 &
additional secondary relief valve for the rod side of
161/2, Fig. 24). The 3-spool control blocks are
the clam cylinders, which is installed on the dis-
located on the boom. An additional 1-spool control
tributor at the back wall of the bucket (187, Fig.
27).
Fig. 24 Relief valve allocation (630773a)
Valve arrangement for face shovel configuration (Fig. 24)
Position Relief valve for Position Relief valve for

1+7 Stick cylinder - piston side 2+8 Stick cylinder - rod side
3 + 11 Bucket cylinder - piston side 4 + 12 Bucket cylinder - rod side
5+9 Boom cylinder - piston side 6 + 10 Boom cylinder - rod side
13 Clam cylinder - piston side 14 Clam cylinder - rod side
Table 4

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.
only allows a more accurate pressure setting.
Check pressure (rated: 360 bar), when cylin-
ders are in end-position.
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
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 pair to less than 360 bar. Gauge reading
must drop noticeably. Increase pressure set-
ting back up to 360 bar.
6. Set pressure on 2nd valve in the same way:

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

duce pressure cut-off valve back to 310 bar.
Fig. 25 630774
To check the valves for

Secondary relief valve for clam cylinders
Rod side: retract cylinders fully (Fig. 26)
Piston side: extend cylinders fully
(Conditions as described under "Setting of clam
Location of the secondary relief valves is shown in primary relief valve).
Fig. 25. Valves are also on opposite side (bottom)
of the main control blocks.
1. Connect gauge (Range: 400 bar) to test point

M1 (Fig. 17).
2. Screw the adjuster of the pressure cut-off

valve of pump (P1) completely in. This is to
raise the pressure above 360 bar (secondary
relief setting).
3. Start LH engine and bring to maximum speed.
4. Check pressure and reset if required Fig. 26 630810

(see table 4).
1. Increase pressure setting of pressure cut-off

valve of P2 above 350 bar, by turning the set
screw complete in.

Checking and setting:

2. Increase pressure setting of primary relief
valve at the clam control block above 350 bar. 1. Connect a gauge (range: 400 bar) to test point
M2 (Fig. 17).
3. Increase pressure setting of additional rod
side valve at shovel back wall above 350 bar 2. Start the RH engine and place the attachment
(187, Fig. 27). on the ground.
4. Start LH engine and bring to maximum speed. 3. Operate the function 'bucket open'.
5. Check pressure and reset if required. 4. The pressure at test point M2 must read 330
Piston side: Clam closing, Valve 13 bar.
Rod side: Clam opening, Valve 14 (Fig. 26) If required adjust the relief valve (187, Fig. 27)
accordingly.
6. Lower pressure at additional rod side valve
(187, Fig. 27) to 330 bar. Cross check at the same time with the 'clam'
main relief valve (same setting).
7. Lower pressure at clam main relief valve to
350 bar.
Additional secondary relief valve for clam cyl-

inder rod-side.
The face shovel attachment is equipped with an

additional secondary relief valve for the rod side of
the clamshell cylinders, which is installed on the
distributor in the back wall of the bucket (187, Fig.
27). The relief valve enables oil flow from the rod
side to the piston side, in case of wrong operation
(digging into the material, before the front lip is
completely closed and thus closing the bucket by
external force).
Fig. 27 630761a

8.6.4.6 Secondary relief system for travel Checking and setting:

Note:
1. Connect two gauges (range: 600 bar) to the
test points M1 and M3 (Fig. 17) at the high
The check of the travel secondary relief valves
pressure filter blocks.
should only be carried out in case of travel per-
formance- or temperature problems.
2. The travel parking brake must be engaged.
This can only be achieved by disconnecting
Layout and function of the travel system is de-
and plugging the hoses from the travel motors
to the brakes (Arrows, Fig. 28 & 29)
For securing the travel system each travel motor is
3. Screw the adjusters of the pressure cut-off
equipped with 2 relief valves (Fig. 28 & 29).
valves of pumps P1 & P2 completely in (Fig.
15).
The valves (1 - 8) are screwed into the travel mo-
tors.
4. Start LH engine. For safety reasons turn the
superstructure 180°, so that the operator and
the service crew on the ground can see each
other. Place the attachment on the ground and
engage the swing parking brake, to avoid turn-
ing of the superstructure.
5. Bring engine to maximum speed.
6. Engage the function 'LH travel reverse' by

depressing the foot-pedal slowly.
7. Check pressure.
At the test point M3 (Fig. 17) the pressure

must read 380 bar, (setting of the main relief
valve). Now the main relief valve must be set
Fig. 28 Left side (630794) over 400 bar, then the relevant travel motor
relief valves can be adjusted (1 + 2, Fig. 28).
8. Check the following functions in the same way:
LH travel forward (valves 3 + 4, Fig. 28)

RH travel forward (valves 7 + 8, Fig. 29)
RH travel reverse (valves 5 + 6, Fig. 29)
9. After checking all secondary relief valves re-

duce pressure setting of the primary relief
valves (see chapter 8.6.4.4) and pressure cut-
off valves (see chapter 8.6.4.3) back to the
rated values.
Fig. 29 Right side (630778)

8.6.4.7 Swing system Check rated charge pressure:

Layout and function of the swing system is de-
The value must be 40 bar at full engine
speed.
The charge pressure is limited by the pres-
sure cut-off valves of the charge pumps.
If the charge pressure differs from 40 bar the

pressure cut-off valve (A, Fig.31) of the re-
spective charge pump (left or right) has to be
adjusted.
Fig. 30 630771a
1. Place attachment on the ground and block the

superstructure (bucket in digging material).
The swing parking brake must be released.
2. Connect two gauges (range: 600 bar) to the Fig.31 630827

test points (X5 & X6, Fig. 30) of the swing bal-
ance valve (105).
Note:
3. Start LH engine and run at maximum speed.
In case one charge pressure limiting valve of a
4. Check pressure; both gauges must indicate
swing pump is set below 40 bar, the 40 bar charge
the same pressure (40 bar, charge pressure).
pressure for the swing system cannot be reached.
In this case check and increase setting of the
5. Start RH engine and run at maximum speed.
charge pressure limiting valves (L1 & L2, Fig. 32)
in the housings of the swing pumps.
6. Check pressure; both gauges must indicate
the same pressure (40 bar, charge pressure).
6.1 Pressures are equal:
Replace the 600-bar gauges with 60-bar gau-

ges (more accurate reading).
Do not operate the function 'swing'

as this would destroy the gauges!
Fig. 32 630806

6.2 If pressures are not equal with one engine If the swing pressure varies from the rated
running: pressure (350 bar), the feed pressure must be
checked and if necessary corrected at pres-
One or both swing pumps are mechanically sure relief valve (109, Fig. 34).
out of neutral.
Correct the adjustment at the pump regulator
(A + B, Fig. 33)
Fig. 34 642058
Fig. 33 630800a
The secondary relief valves of the
swing system (2 valves for each
swing pump) are set at 400 bar.
6.3 If pressures are not equal with any engine
This setting must not be altered!
running:
Swing balance valve is not in neutral.

Adjust at set screw (A, Fig. 30). 10. 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
7. Replace the two 60-bar gauges at the swing gauge must indicate 40 bar.
balance valve (105, Fig. 30) again with 600-bar
gauges.
8. Place attachment on the ground and activate

'swing right'. Move joy stick slowly into the end
position.
9. Checking pressures:
The gauge related to the high pressure side
must indicate approx. 350 bar; the low pres-
sure side must indicate approx. 40 bar. The
feed pressure (pilot Y1 / Y2) of the swing bal-
ance 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).
The maximum feed pressure is limited by the
pressure relief valve (109, Fig. 34) to 22 bar.

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. 36).
The pressure for the hydraulic track tensioning
6. Start both engines and let them run with ma-
system (Fig. 35) is taken from the 60-bar auxiliary
ximum speed.
circuit 2.
The pressure to discharge the hydraulic track ten-
7. Check pressures.
sioning system is taken from the 80-bar auxiliary
Rated:
circuit 3.
At test point M-A2 = 60 bar
The pilot controlled check valves and the change
At test point M-B1 = 0 bar
over valve, factory set to 70 bar, are located on the
track tensioning valve block (133, Fig. 37).
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
Note:
If the pressures will not appear as shown in the

table, the function and setting of the change over
valve (SV, Fig. 36) has to be checked.
Fig. 35 642054
To make the switch point of the change over valve
visible, the auxiliary pressure 2 has to be tempo-
rary increased to 70 bar (see chapter 8.6.4.1).
Ladder (Option) must be in the upper position
Inlet pressure:
1. Connect gauge (range: 150 bar) to test point

M1 (Fig. 35).

ximum speed.
3. Check pressure.
Rated: 60 bar;
If necessary adjust auxiliary pressure 2 (see
chapter 8.6.4.1).
Fig. 36 642062
4. Activate service switch S31 and check the
pressure at test point M1.
Rated: 80 bar;
Change over pressure (70 bar)
If necessary adjust auxiliary pressure 3 (see
chapter 8.6.4.1).
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. 36).
ximum speed.
12. Check pressures.

There are two possible situations:
a) At test point M-A2 = 70 bar
or
b) At test point M-A2 = 70 bar
13. If the pressure at test point M-B1 is not 0 bar,

the set screw of the change over valve (SV, Fig. 37 630776a
Fig. 36) has to be turned out (ccw) until the
valve switches over to 0 bar.
14. Slowly turn in (cw) the set screw of change Tensioning the tracks
over valve (SV, Fig. 36) until the pressure at
test point M-B1 switches over to 70 bar. This Tensioning and slackening the tracks is described
setting has to be secured with the lock nut. in the operator's manual.
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 carbody (134, Fig.

37).

8.6.4.9 Hydraulic oil cooling Checking and setting

Layout and function of the hydraulic oil cooling
1. Connect a gauge (range: 400 bar) to the test
system is described in chapter 8.5.8.
point on the fan motor (M, Fig. 39).
The hydraulic oil is cooled by two independent
2. Ensure, that the hydraulic oil temperature is
cooling circuits.
above 70°C, so that the fan motors run with
Each circuit is related to one engine.
maximum rpm.
The fan pump on the LH engine drives the front
fan. The cooling pump on the RH engine drives the
3. Check pressure.
rear fan.
The flow of the fan pumps is in relation to the hy-
With an oil temperature of approx. 70° C the
draulic oil temperature electronically controlled
pressure at the fan motor is approx. 200 bar.
Fig. 38 is showing a fan pump with flanged on
proportional valve.
Pressure cut-off
The fan pumps are equipped with a pressure cut-

off valve (A, Fig. 40), which is set at the factory to
280 bar.
The adjustment of minimum flow is done at valve B
(Fig. 40). This valve is also set at the factory.
Fig. 38 630830
Fig. 40 630832
Fig. 39 630807

8.6.4.10 Fan-drive for radiators Checking and setting

Layout and function of the fan-drive for radiators is
1. Connect a pressure gauge (range: 400 bar) to
described in chapter 8.5.9.
the relevant test point (M, Fig. 42) at the fan
motor.
The coolant of the engines is cooled by two inde-
pendent cooling circuits.
2. Ensure that the coolant temperature is above
Each circuit is related to one engine.
95°C, so that the thermostats are closed com-
pletely.
Fig. 41 is showing a fan pump with flanged on
proportional valve.
3. Check pressure.
4. With a temperature of the coolant of approx.

98° C the pressure at the fan motor is approx.
200 bar.
Pressure cut-off
The fan pumps are equipped with a pressure cut-

off valve (A, Fig. 43), which is set at the factory to
280 bar.
The adjustment of minimum flow is done at valve B
(Fig. 43). this valve is also set at the factory.
Fig. 41 630831
Fig. 43 630832
Fig. 42 630803

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. 44) 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. 45 642060
b) In the auxiliary pressure system 2, a dia-
phragm accumulator (38, Fig. 44) 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. 45) 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.
46) is used to lower the access ladder
when the engines are shut down.
Gas pre-charge pressure: 65 bar Fig. 46 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 3.2.2
,THB).
A general procedure how to handle the “charging
and testing unit” is described on the following
pages:
Fig. 44 642059

Charging and testing unit for Charging and testing unit for
diaphragm accumulators bladder accumulators with
adaptor A3
Fig. 49 642065
Fig. 47 642063
Legend, Fig. 49
Legend, Fig. 47 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
A1 = Adaptor A3 4 = Connector 9 = nitrogen bottle
Gas valve for diaphragm Gas valve for diaphragm DESCRIPTION (Charging and testing unit)
accumulators accumulators
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. 48 642064
A3.
Legend, Fig. 48
S= Protective cap
O= O-Ring
SW6 = Allen key
H= Hexagon cap nut
P= internal hexagon screw
V= Valve

OPERATINGINSTRUCTIONS INCREASING PRE-CHARGE PRESSURE

Only use nitrogen for charging accumulators.
PREPARATION
Never use oxygen! Danger of ex-
Prior to each testing, topping-up or re-charging of
nitrogen, the accumulator must be isolated from the plosion! If the gas pressure in the
pressurized system and the fluid released. nitrogen bottle is higher than the
max. operating pressure of the
a) Releasing the pilot pressure system by accumulator, a gas pressure re-
shifting both control levers repeatedly into ducer must be fitted.
all directions with both engines at stand-
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. 49). For
2 by shifting both control levers repeatedly nitrogen bottles from other countries the ap-
into all directions with both engines at propriate adaptor is required see chapter
standstill, emergency switch S211 (at- 3.2.2 ,THB). Connect connector (Pos. 4, Fig.
tachment down) activated and the electric 49) of the charging hose to the check valve C
system switched on. of the charging and testing unit. Open the
c) Releasing the track tensioning system shut-off valve on the nitrogen bottle, and
by opening the pressure relief valves (134, slowly release nitrogen into the accumulator.
Fig 45) with both engines at standstill. Wait until approximately 1 bar has been rea-
d) Releasing the hydraulic system of the ched before opening the shutoff valve of the
ladder by shifting the control lever (151, nitrogen bottle further to enable faster charg-
Fig. 46) repeatedly with both engines at ing.
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.

14 RH 120-E Pressure Checking and Setting

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8.

6 PRESSURE CHECKING AND SETTING - FS

8.6 Pressure checking and set- 8.6.1.2 Safety

RH 120 E - Diesel - 3668597en.doc- (00) - 09.08 Page 8.6 - 1

Page 8.6 - 2 RH 120 E - Diesel - 3668597en.doc- (00) - 09.08

8.6.2 Pressure setting

Description Unit RH 120 E

Clam cylinders (1-spool valve) bar 350

Clam cylinders (back wall) bar 330

Travel motors bar 400

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 40

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

RH 120 E - Diesel - 3668597en.doc- (00) - 09.08 Page 8.6 - 3

Item Quantity Designation Part-No.

1 2 Test kit with gauges and hoses 1 476 323

Page 8.6 - 4 RH 120 E - Diesel - 3668597en.doc- (00) - 09.08

Section Figure Valve function Setting

The primary relief valve for main pump P 3 is lo-

The charge pressure is to be set on the pressure

An additional primary relief valve is located in the

RH 120 E - Diesel - 3668597en.doc- (00) - 09.08 Page 8.6 - 5

Page 8.6 - 6 RH 120 E - Diesel - 3668597en.doc- (00) - 09.08

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

Fig. 8 642051 Fig. 11 642052

RH 120 E - Diesel - 3668597en.doc- (00) - 09.08 Page 8.6 - 7

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

Page 8.6 - 8 RH 120 E - Diesel - 3668597en.doc- (00) - 09.08

8.6.4.2 Load limit system (PMS) 4. Extend the stick cylinders.

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

2. Run RH engine with maximum speed. The LH

4. Extend the stick cylinders.

RH 120 E - Diesel - 3668597en.doc- (00) - 09.08 Page 8.6 - 9

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 RH 120 E - Diesel - 3668597en.doc- (00) - 09.08

8.6.4.3 Pressure cut-off system

As a precondition for the following tests and set-

Checking and setting

1. Connect 2 gauges (range: 400 bar) to the high Fig. 15 630793

2. Start LH engine and bring it to maximum speed.

3. Extend the stick cylinders completely and posi-