011 - CAT-6018 - Pressure Checking - BH - 08-06-3720177

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 for RH 90 C from serial-no. 90 101
The rated pressure relief valve set-
The illustrations, descriptions and explanations ting must not be modified without
reflect the current standard configuration. Some of explicit approval by Bucyrus.
the illustrations can show details that differ from a
particular machine, but that does not affect the All personnel carrying out com-
validity of the information given. missioning, operation, inspection,
If any points are nevertheless unclear or seem to service and repair must have read
be incorrect, please contact your local Bucyrus and understood the operating in-
dealer or your Bucyrus distributing centre. structions and in particular the
chapter
Further developments and alterations introduced 'Fundamental Safety Instructions'
into the standard series production will be imple-
mented into later re-prints of the THB. before starting any work.
Unauthorized conversions or modi-
When setting the pressure relief valves the fications of the hydraulic excavator
hydraulic oil temperature has to be higher than are forbidden for reasons of safety.
50°C.
Secure the machine and the work-
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. Before re-
commissioning, all protective de-
vices must be refitted.
RH90C - Diesel – 3720177en - (00) - 12.08 Seite 8.6 - 1

8.6 PRESSURE CHECKING AND SETTING - BH
8.6.1.3 General
Catwalks on the boom are only to
be walked on when the excavator's The reference numbers used in the text and illus-
working attachment has been trations correspond to those used in the hydraulic
brought into the position required circuit diagram.
for checking/settings pressures.
Since the machine is equipped with the BCS-Board
Hydraulic cylinders must be
Control System, most pressures are available on
brought into their end positions
the BCS display. If pressure must be reset, in any
before pressures are checked or
case calibrated gauges have to be used, they have
set to ensure that working attach-
to be connected to the relevant test points.
ment does not move when pres-
sure is applied.
The excavator operator must oper- Numbering of main pumps
ate the relevant function gently
(gradual application of pressure) The 4 main pumps are numbered in travel direction
and then shift the joystick/pedals from left to right P1, P2, P3, and P4 (Fig.1),
fully to their end position. thus P1 and P2 are driven by the LH engine, and
P3 and P4 are driven by the RH 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.
Always connect the Minimess-hose The swing pumps on the LH pump gearbox are
first to the gauge and then to the named SP1, the pumps on the RH pump gearbox
test point on the machine to avoid are named SP2 (Fig. 1).
spillage of pressurized oil!
Auxiliary pumps (Fig. 1)
The springs in pressure relief
valves must never be tightened
- Double gear pump for the pilot pressure and
fully to "block". The windings of
PTO cooling system. (6)
the spring are then jammed so that
- Hydraulic oil cooling pump (10)
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
tighten the counter nut again.
Fig. 1 642093
When checking/setting pressures
the hydraulic oil temperature must
be above 50°C.
Seite 8.6 - 2 RH90C - Diesel – 3720177en - (00) - 12.08

8.6.2 Pressure setting
Description Unit RH 90 C
From No. 90 101
Pressure cut-off – main pumps bar 300
Primary relief for main pumps bar 330
Secondary relief for Boom cylinders bar 350
Stick cylinders bar 350
Bucket cylinders bar 350
Clam cylinders bar 330
Pilot pressure bar 35
Auxiliary pressure 1 bar 50
Main pump control pressure bar 8 – 43
Swing system – working pressure max. bar 370
Swing system – charge pressure (approx.) bar 30
Oil cooling circuit - pressure relief bar 65
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 3.2.8 in THB)
Table 2

8.6.4 Hydraulic circuits

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. 3) together in the sequence as
mentioned below.
Pressure checking and setting
Ladder (Option) must be in the upper position.
Fig. 4 642098
Auxiliary pressure 3 of 80 bar
1. Connect pressure gauges to test points M1
(range up to 150 bar, Fig. 4), M2 and M3
(range up to 60 bar, Fig. 5 & 6) 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. 5 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. 3 642051 Fig. 6 642052

Fig. 7 642100
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
- Releasing the swing parking brake.
- Releasing the travel parking brake.

- 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) Checking the load limit pressure for the RH
drive unit:
Layout and function of the load limit system is de-
scribed in chapter 8.5.1. 1. Connect a gauge (range 60 bar) to the test
point (M, 23.2, Fig. 8).
For each engine an electronic load limit system is
installed. 2. Run RH engine with maximum speed. The LH
The current from the electronic load limit system is engine has to be shut off.
converted into hydraulic pressure by a proportional
valve (23, Fig. 8). 3. Check pressure.
The gauge must indicate approx. 8 bar
 The proportional valve, which is linked to the (225mA).
load limit system of the LH engine, is delivering
a pressure signal for main pumps P1 & P2 via 4. Extend the stick cylinders.
port X1 on the main pump regulators. 5. Check pressure (Stick cylinders are in end-
The pressure level is related to the load factor position; pressure cut-off in function):
of the engine. Nominal pressure: approx. 43 bar (820 mA).
 The load limit system of the RH engine is regu-
lating the main pumps P3 & P4. In case the required pressures are not achieved
the proportional valve must be checked.
For this checking an adapter (A, Fig. 9) is required
to measure the current (mA) delivered by the load
limit system.
Fig. 8 642096
Checking the load limit pressure for the LH

Fig. 9 630782
drive unit:
Connect adapter (A).
1. Connect a gauge (range 60 bar) to the test
point (M, 23.1, Fig. 8). Do checks 1 to 5 as described before and measure
the current direct at the terminals of the propor-
2. Run LH engine with maximum speed. The RH tional valves 23.1 and 23.2.
engine has to be shut off.
 If the mA-values according to 3 & 5 are not
3. Check pressure. reached, there is a defect in the load limit cir-
The gauge must indicate approx. 8 bar cuit.
(225 mA).
 If the mA-values are reached, but not the re-
4. Extend the stick cylinders. quired pressure, the proportional valve is defec-
tive and has to be replaced.
5. Check pressure (Stick cylinders are in end- Note:
position; pressure cut-off in function): It is also possible to check and read the current
Nominal pressure: approx. 43 bar (820 mA). values via the BCS.

8.6.4.3 Pressure cut off 5. Check pressure. Required pressure is 300 bar
Pressure cut-off valves (Fig. 10) flanged to the
If the pressure is to be varied, reset the cut-off
pump regulator serve to interrupt the fluid flow to
valve on main pump P1 or P2 as required.
the four main pumps P1, P2, P3 and P4.
(Arrows in Fig. 10)
 Via test point A (Fig. 11) the pressure appli-

cable to main pump P1 is measured.
 Via test point B (Fig. 11) the pressure appli-

 Shut off the left engine.
Fig.10 635394
When the maximum working pressure (300 bar)

has been reached the pressure cut-off valves bring
the main pump delivery flow rate down hydrauli-
cally to almost zero.
The main pumps then produce just the flow neces-
sary to compensate losses due to system leakage
oil.
In this situation there is only a small power demand
so that the engine speed will increase to 1920 rpm.
Checking and setting Fig. 11 635392
1. Lower attachment to the ground and apply the

swing parking brake. 6. Rev the right engine up to maximum speed.
2. Connect two pressure gauges (range up to 400 7. Apply pressure to piston side of stick cylinder.
bar) to the test points (A and B, Fig. 11) on the
primary pressure relief valves. 8. Check pressure. Required pressure is 300 bar
3. Rev the left engine up to maximum speed. If the pressure is to be varied, reset the cut-off
valve on main pump P3 or P4 as required.
4. Apply pressure to piston side of stick cylinder. (Arrows in Fig. 10)
 Via test point A (Fig. 11) the pressure appli-

 Via test point B (Fig. 11) the pressure appli-

 Stop the right-hand engine.

8.6.4.4 Primary relief system 4. To check the primary pressure for main pumps
(P1 to P4) proceed as follows:
Two relief valves (30/1 und 30/2, Fig. 12) serve to
 Increase pressure cut-off for pump (P1 and
limit the primary pressure of the four main pumps.
P2) to approx. 360 bar.
 For this purpose, fully tighten the setscrew of

the pressure cut-off valve on P1 and P2 and
then slacken screw by a ½ turn.
 Apply pressure to stick cylinder piston side.
 Check primary pressure. Required pressure

is 330 bar
 If necessary, adjust valve (30/1 und 30/2,

Fig. 12) as required.
 Set test point A via valve 1.
Fig. 12 635260a  Set test point B via valve 2.
 1/8 turn of the setscrew results in a pressure

Checking and setting variation of approx. 10 bar.
1. Lower attachment to the ground and apply the  Reset the pressure cut-off of the main
swing parking brake. pumps (P1 and P2) to 300 bar.
2. Connect two pressure gauges (range up to 400 5. Stop the engine.

bar) to the test points (A and B, Fig. 12).
3. Rev the left engine up to maximum speed.

8.6.4.5 Secondary pressure relief system for

attachment Checking and setting
1. To enable the secondary pressure of 350 bar to

The relief valves safeguarding the secondary pres-
be measured, the primary pressure (330 bar)
sure of the attachment are located on the two con-
and the pressure cut-off limit (300 bar) of P1
trol blocks mounted on the boom.
and P2 or P3 and P4 has to be increased to
360 bar.
2. For this purpose, fully tighten the setscrew of

the pressure cut-off valve (Fig. 10) on P1 and
P2 and then slacken screw by a ½ turn.
3. Carefully tighten the primary pressure relief

valves (30/1 and 30/2, Fig. 14) fully and then
slacken screw by 1/8 turn.
4. Start left-hand engine and rev up to maximum

speed.
5. When making checks and settings observe the

sequence 1 – 6 as shown in the following table.
Fig. 13 635259a
The control blocks (160 + 161, Fig. 13) are of iden-

tical design. They govern the functioning of the
boom, stick and bucket cylinders.
The allocation of the pressure relief valves can be

seen from Table 3.
Pressure re-
Cylinder Side
lief valve
1 Stick Rod
Fig. 14 635260a
2 Stick Piston
3 Boom Rod
4 Boom Piston
9 Bucket Rod
10 Bucket Piston
Table 3
To set the secondary relief valves to
R – Rod side of cylinder: Retract cylinder fully

K – Cylinder piston side: Extend cylinder fully
(See arrows in Fig. 13)

Recommended Required value

Cylinder Side Valve Fig.
sequence: (bar)
1 Stick – S Rod – R 160/1 + 161/1 15 350
2 Stick – S Piston – K 160/2 + 161/2 15 350
3 Bucket cylinder – L Rod – R 161/9 15 350
4 Bucket cylinder – L Piston – K 160/10 + 161/10 15 350
5 Boom – A Rod – R 160/3 15 350
6 Boom – A Piston – K 160/4 + 161/4 15 350
Table 4
Follow the above specified sequence when check-  Set the pressure on the 2nd valve in the
ing and, if necessary, resetting all secondary relief same way. First lower the pressure, and
valves. then raise it again to 350 bar.
Attention! When the pressure is below or above 350 bar

In case of valve pairs (e.g. 160/2 & 161/2) both
pressure gauges show the pressure of the valve  Tighten 1st valve fully.
with the lowest setting.
 Set 2nd valve to 350 bar.
Checking of valve pairs  Now set 1st valve to 350 bar. At first, lower
the pressure below 350 bar and then raise it
to 350 bar.
When adjusting the secondary relief valves for

rod side of boom cylinder disable the boom
floating function via micro switch in the hand
lever.
Fig. 15 635259a
1. Connect two pressure gauges (range up to 400

bar) to the test points (A and B, Fig. 16).
2. Apply pressure to the respective cylinder side.

Fig. 16 635392
3. Check the pressure:
4. Reset the primary relief valves (30/1 & 30/2,
When the pressure is 350 bar Fig. 16) to 330 bar.
 Lower pressure to below 350 bar on the 1st
valve. The pressure indication on both 5. Reset the pressure cut-off of the main pumps
gauges must fall significantly. Now raise the (P1 and P2) to 300 bar.
pressure again to 350 bar.
6. Stop engine or select idling speed.

8.6.4.6 Swing system
When making the swing system pressure settings Checking and setting the charge pressure
apply the swing parking brake and lower the at-
tachment to the ground.
 Connect two pressure gauges, range 60 bar, to
Checking and setting the swing pilot-pressure the test points provided at the swing motors (ar-
rows Fig. 18).
 Connect two 60-bar pressure gauges to the test
points (MY1 und MY2, Fig. 17) of the swing bal-
ance valve.
Fig. 18 635262a
 Start up left-hand engine.

Fig. 17 642094
Required value on both gauges: 30 bar.
If a correction is required, adjust the pressure
 Start one of the two engines and rev up to on the charge pressure relief valve of the left
maximum speed. swing pump (arrow, Fig. 19) as necessary.
 Initiate the anti-clockwise or clockwise swinging

function.
 Required relief valve pressure: 31 bar
 If necessary correct the setting at pressure

reducing valve 109 (Fig. 17).
 Stop the engine.
Fig. 19 635265a
 Stop the left-hand engine and start the right-

hand one.
In the event of a pressure deviation readjust the
right-hand swing pump as required.
 Shut off engine.

Checking high pressure ratings Secondary relief valves
 Connect two pressure gauges, range 400 bar, Two secondary pressure relief valves (arrows, Fig.
to the test points provided on the swing motors 22) are mounted on each swing pump.
(arrows Fig. 20).
Fig. 22 635207a
Fig. 20 635262a
These relief valves are Factory set to 400 bar.
 High pressure is governed by the swing pilot- Valve adjustments must exclusively be made by
pressure (31 bar, Fig. 17) and the area ratio of Bucyrus Mining service personnel.
1:12 existing on the piston in pressure compen-
sator (Pos. 105, Fig. 21).
Checking the flushing valve
Via the flushing valve a small amount of oil is de-

livered from the closed circuit of the low-pressure
side into the tank each time a swinging movement
is performed. These oil losses are made up by the
charge pumps arranged on the swing pumps.
The flushing valve setting is correct if the setscrew

projects 15 mm above the locknut (A, Fig. 23).
Fig. 21 642095
 Start left-hand engine and rev up to maximum

speed.
 Initiate the anti-clockwise or clockwise swinging

function.
Required value: 370 bar
 Stop left-hand engine and perform the same Fig. 23 635207a

checks on the right-hand one.

Mechanical neutral position
Resetting of the mechanical neutral is called for if

the superstructure turns without powering when the
engines are running and parking brake has been
released.
In such a case, readjust the setscrew (A, Fig. 24)
at the swing balance valve (105 Fig. 24) with en-
gines running and parking brake released until the
superstructure is stationary.
Fig. 24 642095

8.6.4.7 Track tensioning system

Discharge function
Layout and function of the track tensioning system
is described in chapter 8.5.7.
5. Connect gauges (range: 150 bar) to test points
M-A2 and M-B1 (Fig. 26).
The pressure for the hydraulic track tensioning
system is taken from the 60-bar auxiliary circuit 2.
6. Start both engines and let them run with ma-
The pressure to discharge the hydraulic track ten-
ximum speed.
sioning system is taken from the 80-bar auxiliary
circuit 3.
7. Check pressures.
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. 27), installed
in the carbody..
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. 26) has to be checked.
To make the switch point of the change over valve
Fig. 25 642098
visible, the auxiliary pressure 2 has to be tempo-
rary increased to 70 bar (see chapter 8.6.4.1).
Checking and setting

Ladder (Option) must be in the upper position
Inlet pressure:
1. Connect gauge (range: 150 bar) to test point

M1 (Fig. 25).

ximum speed.
3. Check pressure.
Rated: 60 bar;
If necessary adjust auxiliary pressure 2 (see
chapter 8.6.4.1). Fig. 26 642062
4. Activate service switch S31 and check the

pressure at test point M1.
Change over pressure (70 bar)
Rated: 80 bar;
If necessary adjust auxiliary pressure 3 (see
9. Adjust auxiliary pressure 2 to 70 bar (see
chapter 8.6.4.1).
chapter 8.6.4.1).

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

s M-A2 and M-B1 (Fig. 26).
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
Fig. 27 630776a
13. If the pressure at test point M-B1 is not 0 bar,
the set screw of the change over valve (SV,
Fig. 26) has to be turned out (ccw) until the
valve switches over to 0 bar.
Tensioning the tracks
14. Slowly turn in (cw) the set screw of change
over valve (SV, Fig. 26) until the pressure at Tensioning and slackening the tracks is described
test point M-B1 switches over to 70 bar. This in the operator's manual.
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

8.6.4.7).
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.

27).

8.6.4.8 Hydraulic oil cooling

Layout and function of the hydraulic oil cooling Position Function
system is described in chapter 8.5.8.
10/1 + 10/2 Oil cooler pumps
The cooling circuit has been safeguarded by two
Cooler connector block with thermo-
pressure relief valves (86/1 + 86/2, Fig. 28). They
stat valves, pressure relief valves
are installed in the distributor plate (85). 85
(86/1 + 86/2), replenishment and
test points.
86/1 + 86/2 Pressure relief valves - 65 bar
81/1 + 81/2 Fan motors
80/1 + 80/2 Cooler
Checking and setting

1. Connect two pressure gauges (range up to 60
bar) to the test point (arrows, Fig. 28).
Fig. 28 635268a 2. Start both engines and run them at maximum

speed.
3. Check whether the oil temperature exceeds

Components of the oil cooling system 55°C and thermostats are thus fully closed posi-
tion.
4. Check the pressure

The circulation pressure is app. 25 bar.
5. The relief valves (86/1 + 86/2, Fig.28) are Fac-

tory set to app. 65 bar. For checking these
valves proceed as follows:
 Set valves to circulation pressure, i.e. make

sure the valve opening pressure is pre-
vented until the valves have caused the cir-
culation pressure to be lowered.
 Now raise pressure the circulation pressure

again (approx. 25 bar).
 Finally, tighten valves clockwise by half a

turn (to increase the opening pressure).
Fig. 29 635389a

8.6.4.9 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. 30) 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. 31 642060
b) In the auxiliary pressure system 2, a dia-
phragm accumulator (38, Fig. 30) 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. 31) 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.
32) is used to lower the access ladder
when the engines are shut down.
Gas pre-charge pressure: 65 bar Fig. 32 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
pages:
Fig. 30 642099

Charging and testing unit for Charging and testing unit for
diaphragm accumulators bladder accumulators with
adaptor A3
Fig. 35 642065
Fig. 33 642063
Legend, Fig. 35
Legend, Fig. 33 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
D = Screw connector 4 = Connector 9 = nitrogen bottle
A3 = Adaptor
DESCRIPTION (Charging and testing unit)

Gas valve for diaphragm Gas valve for diaphragm
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
A3.
Fig. 34 642064
Legend, Fig. 34
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. 35). 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
tachment down) activated and the electric 3.2.8 ,THB). Connect connector (Pos. 4, Fig.
system switched on. 35) of the charging hose to the check valve C
c) Releasing the track tensioning system of the charging and testing unit. Open the
by opening the pressure relief valves (134, shut-off valve on the nitrogen bottle, and
Fig 31) with both engines at standstill. slowly release nitrogen into the accumulator.
d) Releasing the hydraulic system of the Wait until approximately 1 bar has been rea-
ladder by shifting the control lever (151, ched before opening the shutoff valve of the
Fig. 32) repeatedly with both engines at nitrogen bottle further to enable faster charg-
standstill. ing.
Unscrew the protective caps S and H (only on  Interrupt the charging process from time to
bladder accumulators). Remove the O-ring O on time and check the pre-charge pressure rea-
bladder accumulators. Slightly loosen the internal ched. Repeat this process until the required
hexagon screw P on piston and diaphragm accu- gas pre-charge pressure is achieved. After
mulators by means of an Allen key SW 6, DIN 911 temperature equalization has taken place, re-
(approx. ½ turn). Place the charging and testing check the pre-charge pressure and adjust if
unit onto the accumulator and screw connector D necessary. If the pressure is too high, it can
by hand onto accumulator gas valve. At the same be lowered via the pressure release B of the
time, ensure that the release B of the charging and charging and testing unit
testing unit is closed. Turn charging and testing
unit to a position where the gauge can be easily  If the required gas pre-charge pressure has
read. been reached, turn the spindle anticlockwise
to close the gas valve on bladder accumula-
TESTING tors. On piston or diaphragm accumulators
On bladder accumulators (Charging and testing close the internal hexagon screw P by turning
unit with adaptor A3) open valve by turning spindle the spindle clockwise. Discharge the charging
A clockwise. and testing unit via the pressure release and
On piston and diaphragm accumulators (Charg- remove it by loosening the connector. On
ing and testing unit) open valve V by turning the bladder accumulators, unscrew the adaptor
internal hexagon screw anticlockwise with spindle and replace the O-ring O. On piston and dia-
A. When the needle of the gauge begins to move, phragm accumulators, tighten the internal
give the spindle another complete turn. The gauge hexagon screw P with Allen key [20 Nm].
now shows the charging pressure in the accumula-
tor. The check valve C prevents any escape of  Check for leakages on the accumulator gas
nitrogen. valve using a leak detector spray.
REDUCING THE PRE-CHARGE PRESSURE  Screw on cap nut H (only on bladder accumu-
Carefully open release B. The nitrogen escapes into lators) and valve protection cap S onto the
the atmosphere. gas valve of the accumulator and tighten.


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.


011 - CAT-6018 - Pressure Checking - BH - 08-06-3720177

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8.

6 PRESSURE CHECKING AND SETTING - BH

8.6 Pressure checking and set- 8.6.1.2 Safety

RH90C - Diesel – 3720177en - (00) - 12.08 Seite 8.6 - 1

Seite 8.6 - 2 RH90C - Diesel – 3720177en - (00) - 12.08

8.6.2 Pressure setting

Clam cylinders bar 330

Pilot pressure bar 35

Auxiliary pressure 1 bar 50

Auxiliary pressure 2 bar 60

Auxiliary pressure 3 bar 80

Main pump control pressure bar 8 – 43

Swing system – working pressure max. bar 370

Swing system – charge pressure (approx.) bar 30

Oil cooling circuit - pressure relief bar 65

Track tensioning system Change over valve bar 70

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

RH90C - Diesel – 3720177en - (00) - 12.08 Seite 8.6 - 3

Item Quantity Designation Part-No.

1 2 Test kit with gauges and hoses 1 476 323

Seite 8.6 - 4 RH90C - Diesel – 3720177en - (00) - 12.08

8.6.4 Hydraulic circuits

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. 3 642051 Fig. 6 642052

RH90C - Diesel – 3720177en - (00) - 12.08 Seite 8.6 - 5

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

Seite 8.6 - 6 RH90C - Diesel – 3720177en - (00) - 12.08

Checking the load limit pressure for the LH

RH90C - Diesel – 3720177en - (00) - 12.08 Seite 8.6 - 7

 Via test point A (Fig. 11) the pressure appli-

 Via test point B (Fig. 11) the pressure appli-

 Shut off the left engine.

When the maximum working pressure (300 bar)

Checking and setting Fig. 11 635392

1. Lower attachment to the ground and apply the

 Via test point A (Fig. 11) the pressure appli-

 Via test point B (Fig. 11) the pressure appli-

 Stop the right-hand engine.

Seite 8.6 - 8 RH90C - Diesel – 3720177en - (00) - 12.08

 For this purpose, fully tighten the setscrew of

 Apply pressure to stick cylinder piston side.

 Check primary pressure. Required pressure

 If necessary, adjust valve (30/1 und 30/2,

 Set test point A via valve 1.

Fig. 12 635260a  Set test point B via valve 2.

 1/8 turn of the setscrew results in a pressure

2. Connect two pressure gauges (range up to 400 5. Stop the engine.

3. Rev the left engine up to maximum speed.

RH90C - Diesel – 3720177en - (00) - 12.08 Seite 8.6 - 9

8.6.4.5 Secondary pressure relief system for

1. To enable the secondary pressure of 350 bar to

2. For this purpose, fully tighten the setscrew of

3. Carefully tighten the primary pressure relief

4. Start left-hand engine and rev up to maximum

5. When making checks and settings observe the