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
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 (electric drive) / 6040 AC
from serial-no. 170 075 The nominal pressure relief valve
settings must not be modified
without explicit approval from Cat-
The illustrations, descriptions and explanations erpillar.
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 Caterpillar chapter
dealer or your Caterpillar distributing centre.
'Fundamental Safety Instructions.'
Further development and alternations that intro- before starting any work.
duce into the standard series production will be
implemented into later re-prints of the THB. Unauthorized conversions or modi-
fications of the hydraulic excavator
When setting the pressure relief valves the are forbidden for reasons of safety.
hydraulic oil temperature has to be higher than Secure the machine and the work-
50°C. ing attachment against inadvertent
and unauthorized starting. Stand
working attachment on the ground
in such way as that no movements
can be made when mechanical or
hydraulic connections become
detached.
Tools, hoists, slings, trestles and
other devices must be in a reliable
safe state.
Systems and units (e.g. pipes,
coolers, hydraulic reservoirs,
compressed-air reservoirs ) must
be properly depressurized before
being opened.
Protective devices on moving ma-
chine parts may be opened or re-
moved only when the drive unit is
stationary and protected against
inadvertent starting.

3721550en - (00) Page 8.6 - 1

8.6 PRESSURE CHECKING AND SETTING (FS)

Before re-commissioning, all pro-

tective devices must be refitted.
Catwalks on the boom are only to
be walked on when the excavator's
working attachment has been
brought into the position required
for checking/settings pressures.
Hydraulic cylinders must be
brought into their end positions
before pressures are checked or
set to ensure that working attach-
ment does not move when pres-
sure is applied.
The excavator operator must oper-
ate the relevant function gently
(gradual application of pressure)
and the shift the joystick/pedals
fully to their end position.
All Pressure test points on the ex-
cavator have Minimess connec-
tions. Pressure gauges used for
checking must therefore have cor-
responding fittings.
Always connect the Minimess-hose
first to the gauge and then to the
test point on the machine to avoid
spillage of pressurized oil!
The springs in pressure relief
valves must never be tightened
fully to "block". The windings of
the spring are then jammed so that
the valve cannot open.
Before setting/resetting a relief
valve (primary or secondary) loos-
en 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
the hydraulic oil temperature must
be above 50°C.

Page 8.6 - 2 3721550en - (00)

8.6 PRESSURE CHECKING AND SETTING (FS)

8.6.1.3 General Numbering of main pumps

The reference numbers used in the text and illus-
The 4 main pumps are numbered in travel direction
trations correspond to those used in the hydraulic
from front to back P1, P2, P3, and P4 (Fig.1).
circuit diagram.

Since the machine is equipped with the BCS-Board

Numbering of swing pumps
Control System, most pressures are available on
the BCS display.
The drive unit is equipped with 3 swing pumps.
If pressure must be reset, in any case calibrated
The swing pumps are named SP1; SP2 and SP3
gauges have to be used; they have to be connect-
(Fig. 1).
ed to the relevant test points.

Auxiliary pumps (Fig. 1)

- Gear pump for the pilot pressure system (6A)

- Gear pump for the greasing system. (6B)
- Hydraulic oil cooling pumps (10)
- Fan drive pumps (8)

Fig. 1 6422670

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8.6 PRESSURE CHECKING AND SETTING (FS)

8.6.2 Pressure setting

Description Unit from No. 170 075

Pressure cut-off – main pumps Cylinders bar 300
Travel bar 350
Primary relief for main pumps bar 380
Secondary relief for Boom cylinders bar 350
Stick cylinders bar 350
Bucket cylinders bar 350

Clam cylinders (4-spool valve) bar 350

Clam cylinders (back wall) bar 330

Travel motors bar 360

Main pump control pressure bar 8 – 43

Primary relief for pilot pressure pump 6A (Servo system) bar 90

Primary relief for pilot pressure pump 6B (Grease system) bar 60

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 Operating pressure (approx.) bar 200

hydraulic oil cooling
Safety valve setting bar 280

Cooling circuit pressure Hydraulic oil cooling bar ≤8

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- Ladder bar (N2) 65
draulic accumulator
pre-charge pressure of hy- Track tensioning system bar (N2) 55
draulic accumulator
pre-charge pressure of hy- Swing system bar (N2) 30
draulic accumulator
Table 1

Page 8.6 - 4 3721550en - (00)

8.6 PRESSURE CHECKING AND SETTING (FS)

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 (see chapter 3.2 „Tools“) 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
5 1 O/E-ring spanner, 13 mm 0 559 698
6 1 O/E-ring spanner, 17 mm 0 559 702
7 1 O/E-ring spanner, 19 mm 0 717 908
8 1 O/E-ring spanner, 24 mm 0 717 913
9 1 Allan Key, 3 mm 0 014 122
10 1 Allan Key, 4 mm 0 014 123
11 1 Allan Key, 5 mm 0 014 124
12 1 Allan Key, 6 mm 0 014 125
13 1 Accumulator test and charging device 1 438 546
---- 1 Adapter for nitrogen cylinder (see chapter 3.2 in THB)
Table 2

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8.6 PRESSURE CHECKING AND SETTING (FS)

8.6.4 Hydraulic circuits

Fig. 3 642680

Section Valve function Section Valve function

A Primary relief valves D Proportional valves (pump regulating)
Supply pressure, swing balance
B Pressure relief “pilot pressure pumps” E
valve
B1 Pilot- and auxiliary pressure F Swing balance valve
C Flushing valve for swing system G Pilot pressure for „swing“
Table 3

Page 8.6 - 6 3721550en - (00)

8.6 PRESSURE CHECKING AND SETTING (FS)

8.6.4.1 Pilot pressure system

Layout and function of the pilot pressure system is Auxiliary pressure 3 of 80 bar
described in chapter 8.5.3. 8. Activate service switch S31 (Fig. 5) and check
the pressure at test point M1,
Since the delivered oil from the pilot pressure required value: 80 bar. If necessary adjust
pumps has to be adjusted to the different pres- valve 1.10 (Fig. 6).
sures required of the various auxiliary systems, it is
recommendable to adjust all involved valves to- Auxiliary pressure 2 of 60 bar
gether in the sequence as mentioned below. 9. With service switch S31 (Fig. 5) deactivated,
check the pressure at test point M1,
Pressure checking and setting required value: 60 bar. If necessary adjust
Ladder (Option) must be in the upper position valve 1.11 (Fig. 6).

Primary relief valves for pilot pressure pumps Auxiliary pressure 1 of 50 bar
6A (90 bar) and 6B (60 bar) 10. With service switch S31 (Fig. 5) deactivated,
1. Connect pressure gauges to test points M1 check the pressure at test point M3,
(range up to 150 bar), M2, M3 and M4 (range required value: 50 bar. If necessary adjust
up to 60 bar, Fig. 4 & 5) for the pilot pressure valve 1.30 (Fig. 6).
system.
2. Open valves PRV-6A and PRV-6B (Fig.4)
completely, to prevent pressure peaks during
start up.
3. Start electric motor.
4. Check the pressure at test points M1 and M2.
Required value: ~ 0 bar.
5. Screw the adjuster of valves 1.10; 1.11; 1.20
and 1.30 (Fig. 6) completely in and then ¼
turn back.
This is to avoid any influence of these valves
while setting PRV-6A and PRV-6B.
6. Adjust a pressure of 90 bar at relief valve Fig. 5 642665
PRV-6A
Check the pressure at test points M1.
7. Adjust a pressure of 60 bar at relief valve
PRV-6B
Check the pressure at test points M2.

Fig. 6 642151

Pilot pressure of 35 bar

11. With service switch S31 (Fig. 5) deactivated,
check the pressure at test point M4, required
Fig. 4 642664 value: 35 bar. If necessary adjust valve 1.20
(Fig. 6).

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8.6 PRESSURE CHECKING AND SETTING (FS)

Note: 8.6.4.2 Load limit system (PMS)

Layout and function of the load limit system is de-
Gear pump 6A (Fig. 1) delivers the oil exclusively
scribed in chapter 8.5.1.
to the pilot control system.

Gear pump 6B (Fig. 1) delivers the oil exclusively An electronic load limit system is installed to pre-
to the central greasing system. vent an overload of the motor.
The current from the electronic load limit system is
converted into hydraulic pressure by a proportional
valve (23, Fig. 8).
The pilot pressure of 35 bar is used for the follow-
ing functions:  The proportional valve Y17 (23, Fig. 8), which is
linked to the load limit system of the electric
motor, delivers a pressure signal to port X1 on
- Supply of the proportional valves to control the the main pump regulators P1 to P4.
work functions. The pressure level is related to the load factor
- Displacement of the swing balance valve (Y1 / of the motor.
Y2). Pressure sensor B1 (Fig. 7 + 8) is installed to
monitor the control pressure.
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.

The auxiliary pressure 2 of 60 bar is used for the

following functions:

- Track tensioning system.

The auxiliary pressure 3 of 80 bar is used for the Fig. 7 642666

following functions:
Checking the load limit pressure
- Pressure relief of the track tensioning system
after traveling. 1. Connect a gauge (range 60 bar) to the test
- Pressure increase to lift the ladder. point (M 23, Fig. 7 + 8).

2. Switch on electric motor.

3. Check pressure.
The gauge must indicate approx. 8 bar
(200 mA).

4. Extend the stick cylinders.

5. Check pressure (Stick cylinders are in end-

position; pressure cut-off in function):
Nominal pressure: approx. 43 bar (820 mA).

Page 8.6 - 8 3721550en - (00)

8.6 PRESSURE CHECKING AND SETTING (FS)

Fig. 8 642667

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) supplied by the load
limit system.

Fig. 9 630782

Connect adapter (A).

Carry out checks 1 to 5 as described before and

measure the current direct at the terminals of pro-
portional valve 23.

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

reached, there is a defect in the load limit cir-
cuit, 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

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8.6 PRESSURE CHECKING AND SETTING (FS)

8.6.4.3 Pressure cut-off system

Checking and setting
Layout and function of the pressure cut-off system
is described in chapter 8.5.2.
1. Start electric motor
The pressure cut-off function for the 4 main pumps
2. Lower the working equipment to the ground.
(3, Fig. 10) is managed by the pressure cut-off
valves (3.1, Fig. 10). They are set to 300 bar and
3. Connect 4 gauges (range: 400 bar) to the high
limit thus the working pressure for the hydraulic
pressure circuits of main pumps P1 to P4. The
cylinders.
relevant test points MP1, MP2, MP3 & MP4 are to
be found close to the high pressure filter block
When operating the travel system the pressure cut-
(Fig. 11).
off valves are hydraulically adjusted to 350 bar via
solenoid valve (Y31).
The electronic system of the machine ensures, that
the pressure increase is not operational, when the
attachment is operated at the same time, so that
operation of the hydraulic cylinders with 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.

Fig. 11 642668

4. Extend the stick cylinders completely and posi-

tion the attachment on the ground.

5. Activate function "stick cylinder out" and check

pressures (rated: 300 bar).
If necessary adjust the pressure cut-off valve
(3.1, Fig. 10) of the respective pump.

6. To check the "pressure increase travel" operate

the travel pedals with the attachment placed on
the ground and swing parking brake applied.
Check pressures (rated 350 bar):

7. Stop the electric motor and remove the gauges.

Fig. 10 621211

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8.6 PRESSURE CHECKING AND SETTING (FS)

8.6.4.4 Primary relief system

 Switch off the pressure cut-off function by shift-
Primary pressure relief for the four main pumps ing cock 5 (Fig. 14) on P1 into position “0”. This
(P1 – P4) is controlled by four pressure relief is to raise the set value of this valve above 350
valves (PRV1, PRV2, PRV3, PRV4, Fig. 12). bar.

Fig. 12 642144

The pumps are coded P1 - P4 from front to back

(see section 8.6.1.3).

Checking and setting

1. Connect 4 gauges (range: 400 bar) to the high Fig. 14 621211

pressure circuits of main pumps P1 to P4. The
relevant test points MP1, MP2, MP3 & MP4 are to  Screw the adjuster of the two secondary relief
be found close to the high pressure filter block valves “Bucket cylinder piston side” completely
(Fig. 13). in and then ¼ turn back (Pos. 2 + 8, Fig. 15
chapter 8.6.4.5). This is to raise the set value of
2. Start the electric motor and lower the working these valves above 380 bar.
equipment to the ground. Activate the swing
parking brake to avoid turning of the superstruc-  Activate BCS Test mode. (see chapter 8.6.4.12)
ture.
 Activate function "bucket fill" until the cylinders
are completely extended.

 Check pressure (rated 380 bar).

 If necessary reset primary relief valve PRV 1.

 Reset the two secondary relief valves “Bucket

cylinder piston side” (Pos. 2 + 8, Fig. 15 chapter
8.6.4.5) back to 350 bar.

 Switch on pressure cut-off function by shifting

cook 5 (Fig. 14) on P1 back into position “1”.

 After the settings are finished, stop the motor

and interrupt the power supply with the key
Fig. 13 642668 switch, to deactivate the BCS Test mode.

3. Set primary relief valve (PRV 1) of pump P1: 4. Check primary relief settings for pumps P2, P3
& P4 in the same way.
 When a new primary relief valve is installed
screw the adjuster 1 turn out, to avoid pressure
peaks.

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8.6 PRESSURE CHECKING AND SETTING (FS)

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. 15). The 4-spool
control blocks are located on the boom.

Fig. 15 642078

Valve arrangement for face shovel configuration (Fig. 15)

Position Relief valve for Position Relief valve for

1 Clam cylinder – piston side 9 Clam cylinder – rod 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 Spool not connected 13 Spool not connected
Table 4
* Switch off “float” for checking and setting

Note: distributor at the back wall of the bucket (187, Fig.

18).
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

Page 8.6 - 12 3721550en - (00)

8.6 PRESSURE CHECKING AND SETTING (FS)

The pressure cut-off function should be switched

off on one main pump only. The smaller flow rate
of one pump only allows a more accurate pressure
setting.
Check pressures with main pump (P3), because
this pump supplies oil to all cylinders of the at-
tachment.

Fig. 17 642668

Example – stick cylinder rod side:

Cancel 'stick float' and carefully apply pressure

to rod side of stick cylinders by shifting the joy-
stick smoothly to the end position “Stick IN”.

Check pressure (rated: 350 bar).

6. Because the pair of cylinders is connected via

compensating lines and secured by 2 relief
valves (3 & 7, Fig. 15), the gauge on the test
Fig. 16 621211 point always indicates the lowest pressure set-
ting of the 2 valves. Therefore it is possible
that, even with an indicated pressure of 350
To check the valves for
bar, one valve is still set too high.
Rod side: retract cylinders fully Therefore reduce the pressure setting on the
Piston side: extend cylinders fully 1st valve (Pos.3, Fig. 15) of the pair to less
than 350 bar. Gauge reading must drop no-
Location of the secondary relief valves is shown in ticeably. Increase pressure setting back up to
Fig. 15. 350 bar.
Checking and setting 7. Set pressure on 2nd valve (Pos.7, Fig. 15) in
the same way: Lower it firstly, and than in-
1. Connect gauge (Range: 400 bar) to test point crease back up to 350 bar.
MP3 (Fig. 17).
8. After checking all secondary relief valves,
2. Switch off the pressure cut-off function by shift- switch on pressure cut-off function by shifting
ing cock 5 (Fig. 16) on P3 into position “0”. cook 5 (Fig. 16) on P3 back into position “1”.
This is to rise the set value of this valve above
350 bar (secondary relief setting). 9. After the checks and settings are finished, stop
the motor and interrupt the power supply with
3. Start electric motor. the key switch, to deactivate the BCS Test
mode.
4. Activate BCS Test mode. (see chapter
8.6.4.12)

5. Check pressures and reset if required

(see table 4).

3721550en - (00) Page 8.6 - 13

8.6 PRESSURE CHECKING AND SETTING (FS)

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. 18).
The relief valve enables that oil flows 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).

Checking and setting:

1. Connect a gauge (range: 400 bar) to check

point MP3 (Fig. 17).

2. Screw the adjuster of the secondary relief

valve (187, Fig. 18) completely in and then ¼
turn back.
Fig. 18 630480
3. Switch off the pressure cut-off function by
shifting cock 5 (Fig. 16) on P3 into position
“0”. This is to rise the set value of this valve
above 350 bar (secondary relief setting).

4. Start electric motor and place the attachment

on the ground.

5. Activate BCS Test mode. (see chapter

8.6.4.12)

6. Operate the function 'open bucket'.

7. The pressure at check point MP3 must read

350 bar.
If required adjust the relief valve (9, Fig. 15) at
control block 161-1 accordingly.

8. Now adjust the relief valve (187, Fig. 18) to

the required pressure of 330 bar.

9. After checking the secondary relief valves,

switch on pressure cut-off function by shifting
cook 5 (Fig. 16) on P3 back into position “1”.

10. After the checks and settings are finished,

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

Page 8.6 - 14 3721550en - (00)

8.6 PRESSURE CHECKING AND SETTING (FS)

8.6.4.6 Secondary relief system for travel

6. Check pressure.
Note:
At the check point MP3 (Fig. 17) the pressure
must read 360 bar.
The check of the travel secondary relief valves
If required adjust valves A1 / A2 (Fig. 19) ac-
should only be carried out in case of travel perfor-
cordingly.
mance- or temperature problems.
Because each crawler has installed two travel
Layout and function of the travel system is de-
motors, the gauge on the check point always
scribed in chapter 8.5.5.
indicates the lowest pressure setting of the 2
valves. Therefore it is possible that, even with
For securing the travel system each travel motor is
an indicated pressure of 360 bar, one valve is
equipped with 2 relief valves (Fig. 19).
still set too high.
The valves (A + B) are screwed into the travel re-
Therefore reduce pressure setting on 1st valve
tarder valves of the travel motors.
A1, Fig.19) of the pair to less than 360 bar.
Gauge reading must drop noticeably. Increase
pressure setting back up to 360 bar.
Set pressure on 2nd valve (A2, Fig. 19) in the
same way: Lower it firstly, and than increase
back up to 360 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. After checking / setting secondary pressures,

switch on pressure cut-off for main pumps (P2
& P3) by shifting cooks 5 (Fig. 16) back into
position “1”.
Fig. 19 642085
9. After the checks and settings are finished, stop
Checking and setting the engine and interrupt the power supply with
the key switch, to deactivate the BCS Test
1. Connect two gauges (range: 400 bar) to the mode.
check points MP2 and MP3 (Fig. 17) at the high
pressure filter block.
The travel parking brake must be
2. Switch off pressure cut-off for main pumps (P2 released. Press travel pedal gently
& P3) by shifting the cocks (5, Fig. 16) into po- until pressure rise is recognized.
sition “0”. This is to rise the set value of this
valve above 360 bar (secondary relief setting). Machine might travel!

3. Start electric motor and place the attachment

on the ground. The bucket teeth must be
pushed into the ground to brake the machine
and to prevent travel of the machine during the
test. The parking brake "swing" must be acti-
vated to avoid turning of the superstructure.

4. Activate BCS Test mode. (see chapter

8.6.4.12)

5. Engage the function 'LH travel forward' by

depressing the foot-pedal slowly into the end
position.

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8.6 PRESSURE CHECKING AND SETTING (FS)

8.6.4.7 Swing system 6. Check pressure; both gauges must indicate

the same pressure.
Layout and function of the swing system is de-
scribed in chapter 8.5.6. 6.1 If pressures are not equal:
Checking and setting Swing balance valve (105, Fig. 21) and swing
pumps are not exactly in the middle position
1. Place attachment on the ground and block the (Superstructure tries to turn).
superstructure (bucket in digging material). Adjust valve with adjuster screw (A Fig. 21)
The swing parking brake must be released. until both gauges indicate the same pressure.

2. Connect a gauge (range: 60 bar) to the test 6.2 If pressures are equal:
points (M5) in the supply line of swing balance
Replace the 400-bar gauges with 60-bar
valve (Fig. 20).
gauges (more accurate reading).
3. Switch on electric motor.
Do not operate the function 'swing'
4. Check pressure (rated: 35 bar). as this would destroy the gauges!
If required adjust pressure reducing valve
(112, Fig. 20) accordingly.
The charge pressure will be indicated. The
required value must be 25 bar.

6.3 Remove the gauges:

Charge pressure is limited by the pressure relief

valves (4.2, Fig. 22) - one valve for each swing
pump. The valves are works set to 25 bar. The
setting must not be altered.

If 25 bar charge pressure is not reached, call in

Caterpillar Service.

Fig. 20 642681

5. Connect two gauges (range: 400 bar) to the

test points (MX5 & MX6, Fig. 24) of the swing
balance valve (105).

Fig. 22 642674

Note:

In case one charge pressure limiting valve of a

swing pump is set to low, the required charge
pressure for the swing system cannot be reached.
In this case check the charge pressure limiting
Fig. 21 642673 valves in the housings of the swing pumps.

Page 8.6 - 16 3721550en - (00)

8.6 PRESSURE CHECKING AND SETTING (FS)

Adjustments at the pumps may

only be done with the appropriate
technical knowledge!
The secondary relief valves (4.1,
Fig. 22) of the swing system (2
valves for each swing pump) are
set at 400 bar. This setting must
not be altered!

7. Check pilot pressure for swing:

 Connect a pressure gauge (range: 60 bar)
to test point MY1 or MY2 (Fig. 23) of the
pressure relief valve 109 (Fig. 23). Fig. 23 642675

 Activate 'swing left or right' and move joy For cooling of the closed swing circuit a certain
stick slowly into the end position. volume of oil is flushed out by the flushing valve
 Check pressure (rated; 22 bar). 106 (Fig. 24 & 25) and replaced by the charge
 If necessary adjust pressure relief valve circuit.
109 (Fig. 23).
Adjustment: Space "S" of the adjuster screw of
8. To check the high pressure, connect two 400- flushing valve 106 (Fig. 25) has to be 15 mm.
bar gauges to test points MX5 & MX6 at the
swing balance valve 105 (Fig. 21).

9. Activate 'swing right'. Move joy stick slowly into

the end position.

10. Checking pressures: The gauge related to the

high pressure side at the swing balance valve
105 (Fig. 21) 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 (reduced
pilot pressure) and the swing balance valve ra- Fig. 24 642678
tio (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.

Note:

If the swing pressure varies from the rated

pressure (350 bar), the feed pressure must be
checked and if necessary corrected at pres-
sure relief valve 109 (Fig. 23).

Fig. 25 642110

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8.6 PRESSURE CHECKING AND SETTING (FS)

8.6.4.8 Track tensioning system

2. Switch on electric motor.
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 button S31 (Fig. 27) and
circuit 3.
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 3 (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

5. Connect gauges (range: 150 bar) to test points

M-A2 and M-B1 (Fig. 28).

6. Switch on electric motor.

7. Check pressures.
Rated:
At test point M-A2 = 60 bar
At test point M-B1 = 0 bar

8. Activate service button S31 and check the

pressures.
Rated:
At test point M-A2 = 80 bar
Fig. 26 642664 At test point M-B1 = 80 bar

Overview:
S31 M-A2 M-B1
OFF 60 bar 0 bar
ON 80 bar 80 bar
Table 5

Fig. 27 642665

Checking and setting

Ladder (Option) must be in the upper position
Fig. 28 642062

Inlet pressure:

1. Connect gauge (range: 150 bar) to test point

M1 (Fig. 26).

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8.6 PRESSURE CHECKING AND SETTING (FS)

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)

9. Switch on electric motor.

10. Adjust auxiliary pressure 2 to 70 bar (see

chapter 8.6.4.1).

11. Connect gauges (range: 150 bar) to test

points M-A2 and M-B1 (Fig. 28).

12. Check pressures.

There are two possible situations:
a) At test point M-A2 = 70 bar
At test point M-B1 = 0 bar
or Fig. 29 630776a
b) At test point M-A2 = 70 bar
At test point M-B1 = 70 bar

13. If the pressure at test point M-B1 is not 0 bar,

the set screw of the change over valve (SV, Tensioning the tracks
Fig. 28) has to be turned out (ccw) until the
valve switches over to 0 bar. Tensioning and slackening the tracks is described
in the operator's manual.
14. 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.

15. Readjust auxiliary pressure 2 back to 60 bar.

16. Check the discharge function (see chapter

8.6.4.8).

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8.6 PRESSURE CHECKING AND SETTING (FS)

8.6.4.9 Hydraulic oil cooling Pressure cut-off

Layout and function of the hydraulic oil cooling
The fan pumps are equipped with a pressure cut-
system is described in chapter 8.5.8.
off valve (A, Fig. 30), which is set at the factory to
280 bar.
The hydraulic oil is cooled by two independent
The adjustment of minimum flow is done at valve B
circuits.
(Fig. 30). This valve is also set at the factory.
1. Hydraulic oil circulation with two gear
pumps for each cooler section. Each circuit
is protected by one relief valve. (fixed set-
ting of 8 bar)

2. Fan drive with two variable piston pumps,

to drive two fan drive motors, one for each
cooler section.
Fan pump (8/1) drives the front fan motor and fan
pump (8/2) the rear fan motor.
The variable oil flow of the fan pumps (and in turn
the speed of the fan motors) is in relation to the
hydraulic oil temperature electronically controlled.

Fig. 30 is showing fan pump (8/1) with flanged on

proportional valve and its coil (C).

Fig. 31 642679

Fig. 31 is showing the distributor block for both

cooling circuits which are protecting the cooler
elements by two pressure relief valves (68a + 68b)
The circulating pressure of the cooling pumps
(10/1 &10/3) for the front cooler section, can be
checked at test point MP1/2.
The circulating pressure of the cooling pumps
(10/2 &10/) for the rear cooler section, can be
checked at test point MP3/4.
The pressure in the tank line can be checked at
test points MT1 and MT2.
Fig. 30 642669

Pressure relief
Checking and setting
Pressure relief valves (68) are works set to approx.
1. Connect a gauge (range: 400 bar) to the rele- 8 bar, to . To check, proceed as follows:
vant test point at the fan motor.
1. Connect pressure gauges (range: 25 bar) to
2. Ensure, that the hydraulic oil temperature is the relevant test points at the distributor block
above 70°C, so that the fan motors run with of the cooling circuit to be checked.
maximum rpm.
2. Ensure, that the hydraulic oil temperature is
above 50°C, so that the fan motors are run-
3. Check pressure.
ning with maximum speed.
With an oil temperature of approx. 50° C the 3. Check pressure:
pressure at the fan motor is approx. 200 bar. Circulating pressure should be approx. 5 bar.

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8.6 PRESSURE CHECKING AND SETTING (FS)

8.6.4.10 Fan-drive for radiators

Not applicable

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8.6 PRESSURE CHECKING AND SETTING (FS)

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 (38/1, Fig. 32) is used
to ensure, that the attachment can be low-
ered in emergency cases with the electric
motor at standstill.
Gas pre-charge pressure: 30 bar
b) In the auxiliary pressure system, a dia- Fig. 32 642671
phragm accumulator (38/2, Fig. 32) is used
to compensate pressure drops when vari-
ous consumers are activated at the same
time.
Gas pre-charge pressure: 40 bar
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.
Gas pre-charge pressure: 55 bar
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. 33 642060
e) In the swing system, two diaphragm ac-
cumulators (38/3 & 38/4, Fig. 35) are in-
stalled. This is to ensure, that the counter
swing function can be performed in emer-
gency cases, when the electric power sup-
ply is interrupted.
Gas pre-charge pressure: 30 bar

Fig. 34 642061
Location of the accumulator below the cab module

Page 8.6 - 22 3721550en - (00)

8.6 PRESSURE CHECKING AND SETTING (FS)

Gas valve for diaphragm Gas valve for Bladder accu-

accumulators mulators

Fig. 35 642672
Fig. 37 642064

Legend, Fig. 37
Checking and setting: S= Protective cap
All hydraulic accumulators installed in the machine O= O-Ring
have to be checked at regular intervals and re- SW6 = Allen key
charged if necessary (see Operation and mainte- H= Hexagon cap nut
nance manual). P= Internal hexagon screw
For this work, the recommended “charging and V= Valve
testing unit” should be used. (see chapter 3.2
THB).
A general procedure how to handle the “charging
and testing unit” is described on the following pag-
es:

Charging and testing unit for Charging and testing unit for
diaphragm accumulators bladder accumulators with
adaptor A3

Fig. 38 642065

Legend, Fig. 38
1 = Hydr. accumulator 5 = Charging hose
2 = Adaptor A 6 = Connector
3 = Charging and test- 7 = Pressure reducer
ing unit 8 = Adaptor
4 = Connector 9 = Nitrogen bottle
Fig. 36 642063

Legend, Fig. 36
DESCRIPTION (Charging and testing unit)
A = Spindle
B = Pressure release
FUNCTION
C = Check valve
The charging and testing unit is used to charge
D = Screw connector
accumulators with nitrogen or to check or to
A3 = Adaptor
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

3721550en - (00) Page 8.6 - 23

8.6 PRESSURE CHECKING AND SETTING (FS)

accumulator and connected to a commercial nitro- OPERATINGINSTRUCTIONS

gen bottle via a flexible charging hose. If the nitro-
gen pressure is only to be checked or reduced, the PREPARATION
charging hose does not need to be connected. The Prior to each testing, topping-up or re-charging of
unit has a screw-type fitting with a built-in gauge, nitrogen, the accumulator must be isolated from
check valve and a spindle for opening the accumu- the pressurized system and the fluid released.
lator gas valve to control the pressure. Piston and
diaphragm accumulators can be charged and a) Releasing the pilot pressure system by
checked without the need for adaptors. Bladder shifting both control levers repeatedly into
accumulators, however, require an adaptor A3. all directions with the motor at standstill,
emergency switch S211 (attachment
down) activated and the electric system
switched on.
b) Releasing the auxiliary pressure system
by shifting both control levers repeatedly
into all directions with the motor at stand-
still, emergency switch S211 (attachment
down) activated and the electric system
switched on.
c) Releasing the track tensioning system
by opening the pressure relief valves (134,
Fig 33) with the motor at standstill.
d) Releasing the hydraulic system of the
ladder by shifting the control lever (151,
Fig. 34) repeatedly with the motor at
standstill.
e) Releasing the pilot pressure of the
swing system by shifting both control lev-
ers repeatedly into all directions with the
motor at standstill, emergency switch S211
(attachment down) activated and the elec-
tric system switched on.

Unscrew the protective caps S and H (only on

bladder accumulators). Remove the O-ring O on
bladder accumulators. Slightly loosen the internal
hexagon screw P on piston and diaphragm accu-
mulators by means of an Allen key SW 6, DIN 911
(approx. ½ turn). Place the charging and testing
unit onto the accumulator and screw connector D
by hand onto accumulator gas valve. At the same
time, ensure that the release B of the charging and
testing unit is closed. Turn charging and testing
unit to a position where the gauge can be easily
read.

TESTING
On bladder accumulators (Charging and testing
unit with adaptor A3) open valve by turning spindle
A clockwise.
On piston and diaphragm accumulators (Charg-
ing and testing unit) open valve V by turning the
internal hexagon screw anticlockwise with spindle
A. When the needle of the gauge begins to move,
give the spindle another complete turn. The gauge
now shows the charging pressure in the accumula-
tor. The check valve C prevents any escape of
nitrogen.

Page 8.6 - 24 3721550en - (00)

8.6 PRESSURE CHECKING AND SETTING (FS)

WARNING
REDUCING THE PRE-CHARGE PRESSURE
Carefully open release B. The nitrogen escapes  Nitrogen and operating fluid can
into the atmosphere. escape when filling or testing
the accumulator due to a faulty,
INCREASING PRE-CHARGE PRESSURE i.e. leaking, bladder, diaphragm
Only use nitrogen for charging accumulators. or piston seals.
Caution!
Never use oxygen! Danger of ex- Risk to health in the case of
plosion! If the gas pressure in the aggressive fluids!
nitrogen bottle is higher than the  The check valve C must not be
max. operating pressure of the removed. The valve has a safety
accumulator, a gas pressure re- function for the whole charging
ducer must be fitted. and testing unit.

 Connect the flexible charging hose to the

pressure reducer on the nitrogen bottle by
means of the connector (Pos. 6, Fig. 38). For
nitrogen bottles from other countries the ap-
propriate adaptor is required (see chapter 3.2
in THB). Connect connector (Pos. 4, Fig. 38)
of the charging hose to the check valve C of
the charging and testing unit. Open the shut-
off valve on the nitrogen bottle, and slowly re-
lease nitrogen into the accumulator. Wait until
approximately 1 bar has been reached before
opening the shutoff valve of the nitrogen bottle
further to enable faster charging.

 Interrupt the charging process from time to

time and check the pre-charge pressure
reached. Repeat this process until the re-
quired gas pre-charge pressure is achieved.
After temperature equalization has taken
place, re-check the pre-charge pressure and
adjust if necessary. If the pressure is too high,
it can be lowered via the pressure release B
of the charging and testing unit.

 If the required gas pre-charge pressure has

been reached, turn the spindle anticlockwise
to close the gas valve on bladder accumula-
tors. On piston or diaphragm accumulators
close the internal hexagon screw P by turning
the spindle clockwise. Discharge the charging
and testing unit via the pressure release and
remove it by loosening the connector. On
bladder accumulators, unscrew the adaptor
and replace the O-ring O. On piston and dia-
phragm accumulators, tighten the internal
hexagon screw P with Allen key [20 Nm].
 Check for leakages on the accumulator gas
valve using a leak detector spray.

 Screw on cap nut H (only on bladder accumu-

lators) and valve protection cap S onto the
gas valve of the accumulator and tighten.

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8.6 PRESSURE CHECKING AND SETTING (FS)

8.6.4.12 BCS Test mode

Layout and function of the BCS-System is de-
scribed in the operation manual.

Certain settings and tests in the hydraulic system

should be performed only with a defined amount of
oil. For this purpose a test mode can be activated
by using the BCS-System, which limits the main
pumps to 30% displacement.

Activation of the test mode

a) Switch on electric motor.

b) Activate button “SERV“.

Fig. 40 642088
c) Select submenu – 9 “SERVICE Caterpillar“
and confirm with “ENTER“.

d) Type in service code and confirm with

“ENTER“.

e) Select submenu – 9 “CMS CHECK“ and

confirm with “ENTER“.

f) Activate button “HOLD“ => TEST MODE

activated. (i.e. Button Testmode is blinking
green)

Fig. 41 642089a

Fig. 39 642087

Fig. 42 642090

Deactivation of the test mode

a) Stop the electric motor.

b) Switch off key switch => TEST MODE de-

activated.

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