SUB GROUP INDEX 16.03. Overload Warning Device ........ .... A/R900,A/ R902 Litronic/ 101 —> 16.05. Overload Warning Device AJ/R912-R942 Litronic / 101 > 16.10. Load Check Valve / Rexroth . A/R912-R9A42 Litronic/ 101 — 16.12. Load Check Valve / Oil contro! ..... AJ R900 - R942 Litronic / 101 —> 16.13. Load Check Valve / Oil contro! seeeees AIR900 Litronic/ 101 > Load & pressure independent A/R902 Litronic / 07.93 > 16.20. Hydr. Installation Kit AS 1 A/ R900 - R942 Litronic / 101 > 16.25. Hydr. Installation KitASH .......... R900 - R 942 Litronic / 101 —> 16.30. Hydr. Installation Kit AHS 1 R900 - R 942 Litronic / 101 —> 16.32. Hydr. Installation Kit AHS 11 R900 - R 922 Litronic / 3001 —> 16.33. Hydr. Installation Kit AHS 11 R932 - R942 Litronic / 3001 > 16.35. Hydr. Installation Kit AHS 2 R900 - R942 Litronic / 101—> 16.37. Hydr. Installation Kit AHS 12 R900 - R922 Litronic / 3001 > 16.38. Hydr. Installation Kit AHS 12... R932 -R 942 Litronic / 3001 —> 16.40. Hydr. installation Kit AHS 3 R900 -R 942 Litronic / 101 —> 16.44. Hydr. Installation Kit AHS 5. R900 -R 942 Litronic / 101 > 16.46. Hydr. installation KitAHS6 ...... R900 -R 942 Litronic / 101 16.50. Hydr. Installation Kit - Flow Reduction R900 - R942 Litronic / 101» 16.58. Variable displacement travel motor . « R900-R942 Litronic / 101 > 16.60. Centralized lubricating system A/ R900 - R942 Litronic / 101 —> 16.61. Centralized lubricating system A/R900- R942 Litronic / 04.96 > 16.72. Pressure Cut in “Lift” R902 - R942 Litronic / 101 -> 2999 16.73. Pressure CutIn “Travel” R900 - R942 Litronic / 101 + 2999 16.75. Forward / Reverse / hight adjustable Operator's cab A/R902-R 942 Litronic/101—> 16.77. _ Elevated Cab, hydr. adjustable A/R902-R 942 Litronic / 101 —> 16.79. Quick change coupling .. A/R900- R942 Litronic / 101 > 16.80. Quick change coupler . A/R900 - R942 Litronic / 101 > 16.90. Hydraulic hammer - General data A/R900 - R942 Litronic / 101 > Penennung/Descipion/Dénomination ye, 900/982 LIEBHERR Type Litronic Special Installations ‘Abita partir de Datum/Edition/Date Hydr. Installation Kits 06.96 1 Blatt/Page/FeuilleGeneral Special safety regulations ( UVV - VBG 40) have been developed for excavators, especially when working with the attachments, lifting and transporting loads Lifting and transporting loads with the excavator (for example, pipes, girders, etc.) constitutes an attachment function, differing from loosening, lifting and carrying dirt, rocks, minerals and other materials, In order to protect personnel when lifting and carrying loads within the danger zone (swing range) of the excavator, certain prerequisites have to be established for the attachments. Hydraulic excavators without line operation have to be fitted with an “overload warning device", which warns the operator visually and acoustically, with a buzzer and a warning light, when the excavator operates at or above the limit or danger zone. Benennung/Description/Dénomination yp See page 16. Model Sub Group Index" LIEBHERR te ‘Abifromia partir de Overload Warning Device DatumEditoniDate slatuPagerFeuille a 16.03.01A. rvortane The overload warning device does not stop the excavator when the load limit has been reached. The operator is, only informed about this situation! ‘The overload warning device should only be used for load lifting work. When performing excavating functions, disconnect the overload warning device. 1. Operating Instruction: All accident prevention regulations have to be observed when lifting loads. Only lift known loads! Check the permissible load limits for each excavator type, as noted in attachment data brochures. Check the overload warning device (Switch $18 on display panel in cab) before initial start up of the excavator. Check the function of the warning device daily. Extend the hoist cylinder fully, building up maximum operating pressure. The overload warning device indicator light must light up and the buzzer must sound. If the excavator is used for excavating work (digging) for a longer period of time, turn shut off lever 67 to turn the warning device off. The warning device is turned off via switch $18. The load limit of the overload warning device must be tested once a year . Be very accurate and proceed as follows: Determine the permissible load limit on the chart either for full swing (without outriggers) or side to side and multiply by 1,25 and add 150 kg, Attach this test load with this weight and given reach (see chart) to the excavator, check if a bucket or a grapple is installed, Carefully rotate the uppercarriage with this load (close to the ground) by 360° The excavator may not tip, one wheel or part of the chain may lift off the ground The warning device must actuate. The adjustment of the warning device must be checked once @ year by expert personnel, and adjusted if necessary, using the adjustment guidelines Check the Operation and Maintenance Manual for your machine. 1602012. Function and Operating Principle, see also schematic on page 16.03.04 ‘The overload warning device warns the operator when he has reached the permissible payload limit, as per DIN 15 019, page 2, by the means of a warning lamp and a buzzer. The overload warning device does not turn the excavator off! The optical and acoustical warning signal is given by switch 45. Switch 45 (B21) is connected via distributor 161 with the piston bottom side pressure connection of both boom cylinders 160. If a certain load is attached to the attachment, a certain pressure is created in both lift cylinders. When this pressure reaches ‘the shift pressure, switch 45 sends an electrical signal via relay 50 ( K9) to buzzer H9 and indicator light H16 and the operator is informed that the load limit has been reached. This shifting pressure, adjusted on switch 45 of the overload warning device, is identical with the machine, i fe. when the warning device actuates, the max. permissible load for this machine at largest reach has been reached. The load limit values includes a stability margin of 25% on firm, flat ground for the total swing range Shifting pressure engraved (inbar) Benennung/Description/Dénomination See page 16. Model Sub Group index” LIEBHERR nee ‘Abifromia partir de Overload Warning Device Datumveaiion/Date BlatuPage/Feuille 16.03.02 07.913. Installation - Retrofit Install switch 45 on the boom - bearing mount -see fig. 1, after removing cover E. DRE~ Note: To match the overload warning device with the stability factor and carrying capacity for each machine, the switch must be properly adjusted. see paragraph 4. Establish the hydraulic connection with shut off lever 67 and test connection 66 between lift cylinder connection on the piston bottom side (via distributor 161) and switch 45. Establish leak oil connection via line between switch * connection L"and hydraulic tank Connect electrical connections as shown on page 16.03.04. 4. Adjustment, see fig. 1 and 2 Remove cap on test point 66 and connect 0-400 bar pressure gauge, position the gauge so is visible from the cab. Turn on warning device via switch $18 and open shut off valve 67 between warning device and boom cylinder connection. Extend boom cylinder all the way and check to see if overload warning device actuates indicator light and buzzer. Build up pressure by slowly moving the right servo control (extend boom cylinder) to the pressure given on pressure chart. The shifting pressure (for example 160 bar) is engraved on the mounting plate for the switch 45, see drawing on front page. DIEE~ Note: If the overload warning device is installed as a retrofit, then this shifting pressure must be taken from the installation drawing and engraved on the mounting plate (enclosed in the installation kit). If the warning device does not actuate at this pressure, adjust the shifting pressure. Remove cover E (with data tag) and loosen lock screw o. Turn adjustment screw C to change the shifting pressure. Turn adjustment screw C to the right (clockwise) to increase shifting pressure. ‘Turn adjustment screw C to the left (counterclockwise) to decrease shifting pressure. Recheck function with proper pressure. If the warning device actuates at a higher pressure, readjust the shifting pressure again A lower actuation point is permissible. After completed adjustment, secure adjustment screw C via screw D and reinstall cover € (with seal) and tighten, 160302,Switch $18 to turn overload warning device on or off - located ‘on the instrument display panel Indicator light H16 - in the display panel - optical signal for overload warning device Switch 45 ( 821 )- on boom bearing - sends electrical contact to indicator light H16 and buzzer H9 when the maximum shift pressure is reached (= max. carrying capacity ) Benennung/Description/Dénomination Typ See page 16. ee LIEBHERR Model Sub Group index Overload Warning Device Abstromis partir de BlatuPagerrouile one 16.03.03 DatumiedioniDate45. Switch (B21*) FIt Fuse(7,5A) (*) 50 Relay(K9*) FIT Fuse(2A) (*) 66 Test connection H9 Buzzer ( *) 67 Shut off valve H16 Indicator light ( +) 101. from spool valve/ boom cylinder KI15 Terminal /starter switch ( *) 160 Boom cylinder 34 Switch/ buzzer ( *) 161 Distributor 518 Switch ( *) 162. Restrictor check valve * Positions from electrical schematic on section 8.31 /8.41 Benennung/Description/Dénomination Typ See page 16 “Sub Group index’ LIEBHERR ‘Abitrom” parti de Overload Warning Device Datum@dition/Date BlattPagerteuile 6.03.04 07.91General Special safety regulations ( UVV - VBG 40) have been developed for excavators, especially when working with the attachments, lifting and transporting loads. Lifting and transporting loads with the excavator (for example, pipes, girders, etc.) constitutes an attachment function, differing from loosening, lifting and carrying dirt, rocks, minerals and other materials. In order to protect personnel when lifting and carrying loads within the danger zone (swing range) of the excavator, certain prerequisites have to be established for the attachments, Hydraulic excavators without line operation have to be fitted with an “overload warning device", which warns the operator visually and acoustically, with a buzzer and a warning light, when the excavator operates at or above the limit or danger zone. Benennung/Description/Denomination See Page 16 ‘Mode! ‘Sub group Type Index LIEBHERR Overload Warning Device ‘Abstromia partir de Datum/Eawion/Date BiatuPagerteuille, 16.05.01 01.92Important! The overload warning device does not stop the excavator when the load limit has been reached. The operator is only informed about this situation! The overload warning device should only be used for load lifting work. When performing excavating functions, disconnect the overload warning device 1. Operating instructions All accident prevention regulations have to be observed when lifting loads. Only lift known loads! Check the permissible load limits for each excavator type, as noted in attachment data brochures. Check the overload warning device (Switch $18 on display panel in cab) before initial start up of the excavator. Check the warning device adjustment weekly, if the excavator is used daily. Check the function of the device daily. Extend the hoist cylinder fully, building up maximum operating pressure. The overload warning device indicator light must light up and the buzzer must sound. Check all movable parts regularly for free movement and lubricate them regularly. If the excavator is used for excavating work (digging) for a longer period of time, turn shut off lever 67 to ‘turn the warning device off. Lever 45 (B21) is moved to “off” position and locked. The warning device is turned off via switch $18. ‘The overload warning device must be tested once a year by expert personnel and also must be tested after repairs or problems. Be very accurate and proceed as follows: Determine the permissible load limit on the chart either for full swing (without outriggers) or side to side and multiply by 1,25 and add 150 kg. Attach this test load with this weight and given reach (see chart) to the excavator, check if a bucket or a grapple is installed Carefully rotate the uppercarriage with this load (close to the ground) by 360° The excavator may not tip, one wheel or part of the chain may lift off the ground, 1605012. Function and Operating Principle, see also schematic on page 16.05.04 ‘The overload warning device warns the operator when he has reached the permissible payload limit, as per DIN 15 019, page 2, by the means of a warning lamp and a buzzer. The overload warning device does not turn the excavator off! ‘The optical and acoustical warning signal is given by switch 45 with cam plate 2. Every reach corresponds to a given load (stability factor). To correspond the warning device with the load values, the shift point of the switch 45 changes depending on the boom position (reach) via a cam plate 2 and a lever. The cam plate is designed that it always adjusts a certain pressure corresponding to the load for each boom position The load limit values include a stability margin of 25% on firm, flat ground for the total swing range of 360°. Switch 45 (821) is connected via distributor 161 with the piston bottom side of both boom cylinders 160. If a certain load is attached to the attachment, a certain pressure is created in both lift cylinders. ‘When this pressure reaches the shift pressure, switch 45 sends an electrical signal via relay 50 ( K9) to buzzer H9 and indicator light H16 and the operator is informed that the load limit has been reached. Benennung/Description/Dénomination yp See Pago 16, Model subgroup index’ LIEBHERR ie ‘Abrfrom/ partir de Overload Warning Device DatumiEsitionDate BiatvPagerFeuille 16.05.02 02.913. Installation ‘The bearing pin (swing ring - swing arm) is fitted with a bore hole for the overload warning device. Mount pin 4with sleeve 5 and screws 7 on bearing pin. Install bracket 9 with premounted switch on stud of pin 4. Tension pin 8 must be inserted in bore hole. Mount cam plate 2 with roll pin 23 and Allen head screws 25 ( with washers 24 ) on rotating fitting 20. Note: To match the overload warning device with the stability factor and carrying capacity for each machine, the correct cam plate for each machine must be used. The Id. No. is embossed in each cam plate. Install complete rotating fitting 20 on greased stud of switch bracket 9 and secure with washer 26 and screw 27, Establish the hydraulic connection with shut off lever 67 and test connection 66 between lift cylinder connection on the piston bottom side (via distributor 161) and switch 45. Connect electrical connections ‘as shown on page 16.05.05 Turn the eccentric screw 36 until the mark on point A matches the contact point on the switch roller when the boom is extended all the way. 4, Adjustment Remove cap on test point 66 and connect 0-400 bar pressure gauge, position the gauge so is visible from the cab. Extend the boom all the way and adjust the cam plate on adjustment screw 36 until the switch roller is located exactly on the marked point. ‘Actuate the warning device via switch $18 and open the shut off lever 67 between warning device and boom cylinder connection, Extend boom cylinder all the way and check to see if overload warning device actuates indicator light and buzzer. Raise the attachment all the way and build up pressure on point A on cam plate 2 by slowly ‘moving the right joystick. This pressure is shown on pressure gauge. If the warning device is not actuated, remove front of switch 45 (after removing protective cap F) see front page, and adjust the pressure. Turn screw to the right (clockwise) to increase pressure. Turn screw to the left (counterclockwise) to decrease pressure. Lower boom until point B on cam plate is reached. Close restrictor check valve 162 between spool 104 and distributor 161. Slowly move the right joystick (retract boom cylinder) to obtain the pressure shown (on the pressure gauge on the cam plate. When the correct pressure is reached, the overload warning device must actuate If the warning device actuates at a higher pressure, readjust shift pressure, A lower actuation point is permissible. Reinstall cap F. Remove pressure gauge and check all moving parts for easy movement. 1605 02weorvaus 20 2 2 23 LIEBHERR Datumieaiion/Date Pin Roll pin Lock washer Allen head screw Roll pin Switch mount Rotating fitting Bushing Grease fitting Tension pin 01.92 24 25 26 27 35, 36 45 46 a7 Benennung/Description/Dénomination Overloading Warning Device Lock washer Allen head screw Washer Hex head screw Hex head nut Adjustment screw Switch Hex head nut Lock washer Allen head screw Wiring Fitting Reducer fitting Hose Fitting Test fitting Shut off lever Fitting Fitting Reducer fitting Typ. Mode! Type See page 16. “Sub Group Index” ‘Abrtromia partirde BlattPagerFoulle 16.05.03‘Switch $18 to turn overload warning device on or off - located on the instrument display pane! Indicator light H16 - in the display panel - optical signal for overload warning device Switch 45 ( B21 ) - on boom bearing sends electrical contact to indicator light and buzzer when the maximum shift pressure (carrying capacity) has been reached Benennung/DescriptionDénomination LIEBHERR Overload Warning Device DatumEditonDate 01.92 3 he. See page 16 Model -Sub Group Index Type ‘Abrtromia partir de BiatvPagerFeuille 16.05.04Cam plate 2 with Id.No. and both shift points A and B with shift pressures (d.No. per Partstist 60504H16 50 (K9) rm 2 Camplate 45. Switch(821*) 50 Relay(K9*) 66 Test connection 67 Shutoff lever 101 von From spool/boom cylinder 160 Boom cylinder 161 Distributor 162 Restrictor check valve + Positions in Electrical schematic in group 8. Benennung/Description/Dénomination LIEBHERR DatumiEdivonibate 01.92 Overload Warning Device F141 tha 162 mes Fapo ey 101 ey i" tol 160 Fuse (7.58) (*) Fuse(2A) (*) Buzzer ( *) Indicator light ( +) Starter switch terminal ( *) Switch buzzer ( *) Switch (*) yp Model Sees nde Type ‘Abvtromia partiede BlatvPagerFeuille 6.05.05The load check valve is combined in a special attachment kit for each machine. Included are the MHRB 22 FG 22, 32 FG 22 check valves and the necessary hydraulic hoses with fittings and mounting brackets, Use The load check valve is installed directly on the hydraulic connection of the boom cylinder (piston bottom side), the stick cylinder (piston bottom and piston rod side) and bucket cylinder (piston rode side) The load check valve consists of a brake piston with load holding valve, a leak oil free releasable check valve and a direct acting secondary pressure relief valve. The valve prevents uncontrolled lowering of the attachment or load, in case a hydraulic line breaks. The load check valve closes off the appropriate cylinder connection leak oil free if the control pressure connection is without pressure, Function, see diagram on page No. 16.10.02 and schematics on pages No. 16.10.03 and 04. 1. To "lift" attachments Hydraulic oil flows from connection A via radial bore holes in piston 2 and opens the load holding valve (Poppet 24) and check valve (poppet 36) and actuates the cylinder via connection B. After the lifting movement is completed, the check valve poppet 36 and load holding valve poppet 24 close. The return line is closed off, this means the load is held leak oil free. BenennngDesription/Dénomination Ty, Seepage 16 Model St groupindex LIEBHERR Load check valve Leak oil free ‘Abstrom/a partir de DatumEaitionDate PlatvPage/roule 16.10.01 01.902. To “lower” attachments The servo pressure to move the spool valves to lower the attachments also actuates the brake piston 2 and piston 32 via connection Pst. The piston 2 is moved against the spring 6 and releases the oil to flow via radial bore holes in the piston. The stroke of piston 2 and the attachment lowering speed is set by stop screw 7. The piston 32 is also moved by the servo pressure and lifts via the pin 33 first poppet 34, then poppet 36 (check vaive) from their seat. The oil flows from cylinder (from connection 8 to connection A of the load check valve) back to the tank The direct acting secondary pressure relief valve 12 reduces pressure peaks from the cylinder side to the tank. Disassembly of load check valve for sealing and repair 1. Removal of brake piston 2 Remove screw 8 with stop screw 7, remove spring 6 and spring washer 5. Remove connector screw 3 and piston 2 from housing 1. If necessary, carefully hold the piston 2 to remove screw 27 and valve poppet 24 with spring 25. 2. Removal of pressure relief and check valve Remove cap 23, lock nut 21 and adjustment screw 22. Remove shim 20, spring 18, spring washer 16, and Poppet 13. Remove valve seat 17, pull off poppet 36 and remove poppet 34 and spring 35. Remove screw 30, take piston 32 and pin 33 from housing. Assembly of load check valve after sealing and repair Before assembly, check all parts if they can be reused. Replace and lightly lubricate all seals before assembly. 1. Installation of pressure relief and check valves Push pin 33 and piston 32 into housing, insert screw 30 with O-Ring and tighten to 60 Nm. Push the Poppet 36 with poppet 34 and spring 35 on the valve seat and attach the valve seat with O-ring 14 and supporting ring 15 to housing. Insert poppet 13, spring washer 16, spring 18 and shim 20 into valve seat and attach adjustment screw 22 with O-ring 19 and lock nut 21 Adjust the pressure relief valve to correct setting, see adjustment procedure 2. Installation of brake piston 2 Set poppet 24 and spring 25 into screw 27 and attach screw 27 to piston 2 NOTE : Be careful no to damage the piston ! Push piston 2 into housing and attach connector screw 3 with O-ring 4 to housing, Insert spring washer 5 and spring 6. Attach screw 8 with stop 7 into housing. Adjust the attachment lowering speed, per chart in section 2.3, on the adjustment screw 7, see adjustment procedure.30. 31 2 1 24 26 2 27 5 Gia? On 9110) MI I “| pe To ae =A AN Le / / /*/ / ] 34 2 0 oa 6 7 mls we 1 22 2b 08 of 12 1 Housing 19 Oving 2 Brake piston 20 shim 3 Connector screw 21 Lock nut 4 O-ring 22 Adjustment screw 5 Spring washer 23° Cap 6 Spring 24 Poppet 7 Stopscrew 25 Spring 8 Screw 26 O-ring 9 O-ring 27 Screw 10 Lock nut 30 Screw 11 O-ring 31 O-ring 12 Pressure relief valve 32 Piston 13° Poppet 33 Pin 14 Oring 34 Poppet 15 Supporting ring 35 Spring 16 Spring washer 36 = Poppet 17 Valve seat 37 Piston guide 18 Spring BenennungyDescription/Dénomination Typ See page 16. Mode! -Sub group index” Type LIEBHERR Load check valve Leak oil free ‘Abyfromia partir de DatumEaitonDate BiatvPagerFeuil. 6.10.02 01.9012 24 7 38 40 101 |. Adjustment of lowering speed on stop screw 7 ‘Adjustment procedure of load check valve on boom cylinder, see page No. 16.10.03 1. Lower attachment to the ground and remove cap from test point M. If an overload warning device is installed, remove the hydraulic line for pressure compensation 165). Attach a 1/4" test fitting and a 600 bar pressure gauge. Open the restrictor on the restrictor check valve 162 all the way. |. Adjustment of secondary pressure relief valve 12 3.1. Adjust the engine speed to 1000 RPM (oil temperature should be > 50° C) 3.2. Raise the pressure for the secondary pressure relief valve 126 on the piston bottom side and the primary pressure relief valve 120. 3.3. Fully extend the boom cylinder. Adjust the pressure relief valve 12 on both adjustment screws 22 to 400 +20 bar. (Also extend the stick cylinder fully). 8e sure that the pressure relief valves are adjusted to exactly the same pressure setting. 3.4 Re-adjust the primary 121 and secondary 126 pressure relief valves again to 320 respec. 380 bar (Also extend the stick cylinder fully) 4.1 Adjust the engine speed to maximum speed (oil temperature should be = 50°C). 42 Check the time to lower attachments with the attachments fully extended, and com- Pare it with the time given on the pressure chart, section 2.3. 43° If necessary, adjust the stop screw 7until the correct lowering time is obtained Be sure, that both pressure settings are the same on test point M. Remove the pressure gauge. Remove the test fitting and reinstall the cap on test point M. (Reinstall the hydraulic line 165 for the overload warning device, if necessary) Brake piston 120 Primary relief valve Stop screw 126 Secondary relief valve /boom cylinder (piston Secondary pressure relief valve bottom side) Load check valve 160 Boom cylinder Check valve 161 Distributor block / boom cylinder Orifice diameter @1 mm 162 Restrictor check valve Load check valve, complete 163 Check valve/summation boom cylinder Spool valve / boom cylinder 165 Hydraulic line for pressure compensation‘Schematics for load check valve on boom cylinder (piston bottom side). BenennungDescription/Dénomination yp See page 16. Model -SUb group indew Type LIEBHERR ‘Abstromia partir de Load check valve DatumieawonDate SlatvPagerreusie 16.10.03 01.902 7 12 24 37 38 40 Adjustment procedure of load check valve on stick cylinder, see page No. 16.10.04 1. Lower attachment to the ground and remove caps from test points M. Attach 1/4" test fittings and 600 bar pressure gauges. 2. The load check valve on the piston rod side replaces the standard resctrictor check valve 3. Adjustment of secondary pressure relief valve 12, 34 32 33 34 Adjust the engine speed to 1000 RPM (oil temperature should be > 50°C) Raise the pressure for the secondary pressure relief valves 133 on the piston bottom side, 134 on the piston rod side and the primary pressure relief valve 121 Fully extend the stick cylinder. Adjust the pressure rel 400 #20 bar. (Also extend the bucket cylinder fully). ef valves 12 on both adjustment screws 22 to Re-adjust the primary and secondary pressure relief valves again to 320 or 380 bar (fully extend the bucket cylinder) 4. Restrictor adjustment 44 42 43 Adjust the Diesel engine to maximum speed. (Oil temperature = 50°). To adjust the restrictor on the piston rod side Fully extend the stick and then retract it. The stick has to move evenly, without jerks, and the pressure should not increase on the piston bottom side of the stick cylinder If necessary, adjust the stop screw 7.2 on the load check valve on the piston rod side ‘To adjust the restrictor on the piston bottom side Fully retract an then extend the stick ‘The stick has to move evenly without jerks, and the pressure should not increase on the piston rod side of the stick cylinder. If necessary, adjust the stop screw 7.1 on the load check valve on the piston bottom side. 5. Remove the pressure gauges. Remove the test fittings and reinstall the caps on test points M. Brake piston 107 Stop screw 121 Secondary pressure relief valve 133, Load check valve Check valve 134 Orifice diameter @1 mm. Load check valve, complete 170 Spo! valve /stick cylinder Primary relief valve Secondary relief valve /stick cylinder (piston bottom side) Secondary relief valve /stick cylinder (piston rod side) Stick cylinderSchematics for load check valve on stick cylinder (both sides : piston bottom and piston rod side) : aay Seepage 16. Load check valve ‘Abiromia part de LIEBHERR DatumeaitionDate BiatuPagerreuille ae 16.10.04‘The “load check valve” is combined in a kit especially designed for each machine. Included are load check valves 50 in addition to the necessary hydraulic hoses with fittings and mounting brackets. Use ‘The load check valve is installed directly on the hydraulic connection of the boom cylinder (piston bottom side), the stick cylinder (piston bottom and piston rod side) and the bucket cylinder (piston rod side). The load check valve consists of a brake piston with control piston and check valve. The brake piston is designed to simultaneously establish leak oil free shut off and secondary pressure relief The valve prevents uncontrolled lowering of the attachment or the load in the event _a hydraulic hose breaks. The load check valve 50 closes off the corresponding cylinder connection leak oil free in case there is no pressure in the control pressure connection. BenennungiDescription!Dénomination Load Check Valve Oil Control Typ see page 16 Model “Sub group index" LIEBHERR re ‘Abyfrom/a particde Datumiedition/Date BlattPagerreuile oes 16.12.01Funetion, see diagram on page 16.12.02 and schematic on page 16.12.04, 16.12.06 and 16.12. 08. 1. Tolower cylinder 160. ( function on the stick or bucket cylinder is similar ) Hydraulic oil flows from control block 100 “connection 81", restrictor check valve 162 and distributor 161 to both valves 50 “connection V2" and valve guide 13 moves sleeve 16 ( check valve ) and actuates the cylinder via connection C2 After completion of the working movement, the check valve 16 closes. The return flow is closed off, which means the load is held leak oil free. 2. Pressure relief The secondary pressure relief occurs due to pressure actuation of piston 9. If pressure peaks occur, piston 9 is pushed against the pretensioned spring 7 and pressure from the cylinder bottom side of the spool is relieved. Further relief to the tank is handled by the secondary pressure relief valve (extend boom cylinder) in the control block 3. Tolower cylinder 160. ( function for stick or bucket cylinder isthe similar) The servo pressure on control block 100 “connection at” to actuate the control piston 101 for the working movement "lower attachment” actuates the control piston 10 at the same time via connection Pand nozzle 14, Piston 10 pushes against brake piston 9 and moves it against spring 7. After a short stroke, the sleeve 16 hits valve guide 13 and the leak oil free shut off is opened. The oil from the cylinder area flows now via connection C2 and V2 to the control valve block and returns {from there to the hydraulic tank. The stroke of piston 9 and thus the restriction of the return oil (lowering speed of the attachment) is determined via stop screw 19. To remove load check valve for resealing and repairs Resealing can be done with the valve installed, Make sure to relieve hydraulic pressure, secure the hydraulic cylinder (by lowering the attachment), relieve tank pressure and catch oil in appropriate container. does not have to be removed 1. Toremove servo piston 10 Remove plug 11 and piston 10 from housing 5 (ifnecessary, apply air pressure to connection T), 2. To remove brake piston 9 Determine and note the measurement from stop screw 19 to lock nut 21 Remove nut 21 with seal and union nut 6, remove seal ring 32 Determine and note measurement from adjustment screw 15 to valve guide 13, Remove adjustment screw 15 complete with stop screw 19 ( Caution: Spring is pretensioned! ). Remove valve guide 13 complete with spring 7 and poppet 18. Push piston 9 and sleeve 16 with spring 8 from the opposite side from housing 5 Hf necessary, remove appropriate plug and remove seal rings. To install load check valve after resealing and repairs Carefully clean all parts Before installation, check all parts if they can be reused. Replace and lightly lubricate all seal rings before installation. 1.To install brake piston 9 Set spring 8 and sleeve 16 complete with seal rings 2 and 24 into housing bore. Set seal rings 23, 27 and 30 in or on valve guide 13, seal rings 4 and 22 on brake piston 9 . Push valve guide 13 complete with brake piston 9 into bore and screw in. Insert valve piston 18 and spring 7 and screw in adjustment screw 15 with stop screw 19 to original measurement, see above paragraph "To remove brake piston 9” Screw on union nut 6 with seal ring 32 and lock nut. 21 with seal ring 34 to original measurement, see “To remove brake piston 9” 16.22082. Toinstall servo piston 10 Set servo piston 10 complete with seal rings 3 and 25 into bore. Check nozzle 14 for cleanliness and reinstall. Reinstall plug 11 and all removed plugs with seal rings. Adjust secondary relief pressure on valve and adjustment lowering speed as described in adjustment procedure on page 16.12.02, 16.12.03 and 16.12.04 29 11 14 3 10 4 12 28 9 2 23 30 7 27 13 32 21 V yy \ Peed | ZA c2 28 12 25 26 1 #22 «31/33 8 16 24 5 18 19 15 6 34 1 Teflon ring 13 Valve guide 26 O-Ring 2. Teflon ring 14 Nozzle 27 O-Ring 3. Teflonring 15 Adjustment screw 28 O-Ring 4 Teflonring 16 Sleeve 29° O-Ring 5 Housing 18 Valve poppet 30 Seal 6 Union nut 19 Stopscrew 31 Plug 7 Spring 2 Lock nut 32 Seal 8 Spring 22 O-Ring 33 Seal 9 Brake piston 23° O-Ring 34 Seal 10 Servo piston 24 O-Ring 50 Load Check Valve, 11 Plug 25 O-Ring complete 12° Plug enennung/DesciptowDénominaton Typ spose LIEBHERR Mei ee Load Check Valve ‘bv paride DatumibawonDote Oil control BlatvPagereuile oe 16.12.02Adjustment guidelines for load check valve on boom cylinders, see page 16.12.04 1. Important adjustment guidelines 1.1 The valve is preadjusted by the manufacturer and normally does not need to be checked or readjusted. Should problems occur of after repairs, check and adjust the valve as described below. 1.2. Adjust the pressure when the hydraulic oil is at operating temperature and the engine at rated speed. 1.3. Use only glycerine filled pressure gauges with an accuracy of £ 1%. 1.4 During the warranty period of the machine, any work on valves may only be performed by authorized Liebherr personnel 2. To adjust secondary pressure on valve 50, see fig. 1-4 2.1. Lower attachment to the ground, turn the engine off and relief valve pressure. 2.2. Remove plug 31 on both connections E, see fig. 1. Insert 1/4" fitting ( tool no. 13) in both connections € of valve 50 2.3 Connect a 0-600 bar pressure gauge with 1,5 - 2,5 m long test hose to one of the two screw couplings (test point 48), 2.4. Remove cap from test point 40 (on control block 100 - left), see fig. 2, and connect mini test hose between test point 40 and the other fitting of valve 50 (connection E ). 25 Fully extend boom cylinder 160. 2.6 Raise the pressure on secondary pressure relief valve 128 (extend bucket cylinder). Make sure that the relief pressure is significantly higher than adjustment pressure of valve 50 2.7, Lower secondary pressure relief valve 126 ( extend boom cylinder ) by turning valve by at least 1 -2 turns 28 Fully extend bucket cylinder. Primary pressure builds up Via test hose on connection E of valve 50 ( and test point 48 with pressure gauge ). 2.9 Slowly increase pressure on primary pressure relief valve 120 and watch pressure gauge on test point 48. Pressure is now increasing until the adjustment pressure of valve 50 is reached. The adjustment pressure of valve 50 should be 390 + 5 bar. 16.12022.10 If measured pressure does not correspond to the given pressure, it can be adjusted on adjustment screw 15 with a SW10 socket wrench, Turn lock nut 21, union nut 6 and stop screw 19 out or in. If necessary, determine gap between screw 19 and nut 21 first. Turn adjustment screw 15 in = to increase pressure Turn adjustment screw 15 out = to lower pressure 2.11 After proper adjustment instal! union nut 6 with seal ring 32 on adjustment screw 15. Install stop screw 19 and bring to original measurement, tighten lock nut 21 with seal ring 34 ( hold stop screw 19) 2.12 Lower adjustment to the ground, turn the engine off and relieve system pressure. 2.13 Connect pressure gauge, remove screw coupling and install plug 31 with seal into housing 5. 2.14 Adjust second valve 50, see description in paragraph 2.2 -2.13 DER Note: The adjustment of both valves 50 must be exactly the same. 2.15 After completed adjustment of both valves 50, check attachment lowering speed and readjust, if necessary, see paragraph 3. 2.16 Adjust primary pressure relief valve 120 and secondary pressure relief valve 126 and 128 to correct pressure, see adjustment guidelines and hydraulic system ‘operating pressures, section 6. 3. To check and adjust adjustment lowering speed on stop screw 19, see fig. 5 3.1. Turn restrictor check valve 162 and / or lift limit/ control piston 101 ( drop restrictor ) to fully open it, see fig. 3 and 4 3.2. Fully extend and lift attachment and fully retract boom oylinder. 3.3. Lower the attachment until it touches the ground and compare the lowering time with the given value, see ‘operating pressure, in section 6. 3.4 If necessary, turn stop screw 19 until the correct lowe- ring time is reached. Turn stop screw 19 in - to increase lowering time Turn stop screw 19 out - to decrease lowering time BenennungiDescription/Dénomination LIEBHERR DatumiEaonibate Oil control 01.92 120. Load Check Valve Mose! See Page 16, Type “Sub group index” ‘Abitromis parti de BlatvPagerFeuille 16.12.0314 16 19 20 31 33 40 48 50 Brake piston Nozzle Sleeve ( Check valve) Stop screw ( Limit /piston stroke ) from Var. displacement pump P2 (*) Plug/ connection E Seal Test point Pump P2 ( standard ) (*) Test point (not standard ) Load check valve, complete 3.5 After correct adjustment, install lock nut 21 with seal 34. Hold stop screw 19 when tightening, 81 100 101 110 120 126 161 162 165 from right servo control (*) Control block 6 way or Jway (*) Control piston /Boom cylinder (*) Control piston /summation - Boom cylinder (*) Primary - pres. relief valve /left control block (*) Secondary pressure relief valve/ extend boom cylinder (*) Boom cylinder (*) Distributor / Boom cylinder (*) Restrictor check valve (*) Lift limit/ Control piston 101 (restrictor) - installed from Feb. 91 * Positions in hydraulic schematic, section 6. 161203Schematic for load check valve for boom cylinder ( piston bottom side ) P1 1 "| 100 7 ~ ~ ee Z z | 20-2 Senennung/DetciptionDénominaton OP Tee LIEBHERR ees wu ar0UP Load Check Valve Zbliromis por de DotumiéanonDate Oil control BlatvPagerFeuille one 16.12.04To adjust load check valve on stick cylinder, see page 16.12.06 1. Important adjustment guidelines 1.1 The valve is preadjusted by the manufacturer and normally does not need to be checked or readjusted, Should problems occur or after repairs, check and adjust, the valve as described below. 1.2 Adjust the pressure when the hydraulic ol is at operating temperature and the engine at rated speed. 1.3. Use only glycerine filled pressure gauges with an accuracy of 1%, 1.4 During the warranty period of the machine, any work on valves may only be performed by authorized Liebherr personnel. 2. To adjust secondary pressure on valve 50 - piston bottom side, seefig. 6-8 2.1 Lower attachment to the ground, turn the engine off and relief valve pressure 2.2 Remove plug 31 on both connections E, see fig. 6. Insert 1/4 * fitting (tool no. 13) in both connections E of valve 50. 2.3 Connect a 0-600 bar pressure gauge with 1,5 - 2,5 m long test hose to one of the two screw couplings (test point 48) 2.4 Remove cap from test point 40 ( on control block 100 - left), see fig. 7, and connect mini test hose between test point 40 and the other fitting of valve 50 (connection E). 25 Fully extend stick cylinder 170. 2.6. Raise the pressure on secondary pressure relief valve 128 (extend bucket cylinder). Make sure that the relief pressure is significantly higher than adjustment pressure of valve 40 2.7 Lower secondary pressure relief valve 133 ( extend stick cylinder ) by turning valve by at least 1 - 2 turns 2.8. Fully extend bucket cylinder. Primary pressure builds up via test hose on connection € of valve 50 ( and test point 48 with pressure gauge ). 2.9. Slowly increase pressure on primary pressure relief valve 120 and watch pressure gauge on test point 48. Pressure is now increasing until the adjustment pressure of valve 50is reached. The adjustment pressure of valve 50 should be 390 + 5 bar. 16.12082.10 If measured pressure does not correspond to the given Pressure, adjust screw 15 with a SW10 socket wrench. Turn lock nut 21, union nut 6 and stop screw 19 out or in. If necessary, determine gap between screw 19 and nut 21 first Turn adjustment screw 15 in = to increase pressure Turn adjustment screw 15 out = to lower pressure 2.11 After proper adjustment install union nut 6 with seal Fing 32 on adjustment screw 15. Install stop screw 19 and bring to original measurement, tighten lock nut 21 with seal ring 34 (hold stop screw 19 ). 2.12 Lower adjustment to the ground, turn the engine off and relieve system pressure 2.13 Connect pressure gauge, remove screw coupling and install plug 31 with seal into housing 5. 2.14 Return primary pressure relief valve 120 to original pressure setting, 2.15 Adjust piston rod side of valve 50, see 3 3. Adjust secondary pressure on piston rod side of valve 50, see fig. 6-8 3.1 Proceed as described in paragraph 2.1 - 2.13; however, in paragraph 2.7 turn the secondary pressure relief valve 134 out (retract stick cylinder). 3.2 After both valves 50 are adjusted properly, check and adjust restrictors,,ifnecessary, see paragraph 4. 3.2 Adjust primary pressure relief valves 120 and secondary pressure relief valves 128, 133 and 134 to given pressure, see adjustment guidelines and hydraulic system operating pressures, see section 6. 4. Toadjust restrictor on stop screw 19, see fig. 9 4.1 Toadjust restrictor on piston bottom side Fully extend stick cylinder and then retract the cylinder fully. The stick must retract smoothly and evenly on the stick cylinder, without an increase in pressure on the piston rod side. Benennung/Description/Dénomination LIEBHERR Datumibamion/Date Oil control 07.91 Load Check Valve 1 see page 16. Mode! “Subgroup index” type ‘Abstromia parurde BlatvPagerreuille 16.12.0542 9 14 16 19 20 40 a 48 50 If necessary, adjust stop screw 19 on the piston bottom side of valve 50 Alter proper adjustment, install lock nut 21 with seal 34 Hold stop screw 19 when tightening lock nut. To adjust restrictor on piston rod side Fully retract stick cylinder and then extend stick. The stick must move smoothly and evenly, without an increase in pressure on the piston bottom side of the stick cylinder. If necessary, adjust stop screw 19 for the piston rod side of valve 50 After correct adjustment, install lock nut 21 with seal 34. Hold stop screw 19 when tightening lock nut. od Brake piston 100 Control block 6 way or 7 way (+ Nozzle 107 Control piston Stick cylinder (*) Sleeve (Check valve) 111 Control piston Summation - stick cylinder (*) Stop screw (Limit Piston stroke) 120 primary pressure relief valve /control block - left from Var. double pump (+) a ee een "83 Secondary pesre reli valve extend stick Test point Pump Pt (standard) (*) 134 Secondary pressure relief valve / retract stick Test point (not standard) cylinder (*) Load check valve complete 170 Stick cylinder (*) 80 from servo control - left (*) * Positions in hydraulic schematic in section 6. 16.1205‘Schematic of load check valve for stick cylinder ( both sides ) eee t4ve__|p + ee J Pil 30 Pa 50 BenennungiDescription/Dénomination Load Check Valve Oil control typ See page 16 Mode! Sub group Type index’ LIEBHERR ‘Abitrom/a parti de Datum@dmonibate BlatuPagerreuile 07.91 i 6.12.06To adjust load check valve on bucket cylinder, see page 16.12.08 1. Important adjustment guidelines 1.1 The valve is preadjusted by the manufacturer and normally does not need to be checked or readjusted. Should problems occur or after repairs, check and adjust the valve as described below. 1.2. Adjust the pressure when the hydraulic oil is at operating temperature and the engine at rated speed. 1.3. Use only glycerine filled pressure gauges with an accuracy of £ 1%. 1.4 During the warranty period of the machine, any work on valves may only be performed by authorized Liebherr personnel 2. To adjust secondary pressure on valve 50, see fig. 10-12 2.1 Lower attachment to the ground, turn the engine off and relief valve pressure. 2.2. Remove plug 31 on both connections E, see fig. 10. Insert 1/4" fitting (tool no. 13) in both connections € of valve 50 2.3 Connect a 0-600 bar pressure gauge with 1,5 - 2,5 m long test hose to one of the two screw couplings (test point 48), 2.4. Remove cap from test point 40 ( on control block 100 - left), see fig. 11, and connect mini test hose between test point 40 and the other fitting of valve 50 (connection E ). 2.5 Fully retract bucket cylinder 180. 2.6 Raise the pressure on secondary pressure relief valve 126 {extend boom cylinder). Make sure that the relief pressure is significantly higher than adjustment pressure of valve 50 2.7 Lower secondary pressure relief valve 127 ( retract bucket cylinder ) by turning valve by at least 1-2 turns 2.8 Fully extend boom cylinder. Primary pressure builds up via test hose on connection € of valve 50 ( and test point 48 with pressure gauge ). 2.9. Slowly increase pressure on primary pressure relief valve 120 and watch pressure gauge on test point 48. Pressure is now increasing until the adjustment pressure of valve 50 is reached ‘The adjustment pressure of valve 50 should be 390 + 5 bar. 16.12062.10 If measured pressure does not correspond to the given pressure, adjust screw 15 with a SW10 socket wrench. Turn lock nut 21, union nut 6 and stop screw 19 out or in. If necessary, determine gap between screw 19 and nut 21 first. Turn adjustment screw 15 in = to increase pressure Turn adjustment screw 15 out = to lower pressure 2.11 After proper adjustment install union nut 6 with seal ring 32 on adjustment screw 15. Install stop screw 19 and bring to original measurement, tighten lock nut 21 with seal ring 34 (hold stop screw 19 ). 2.12 Lower adjustment to the ground, turn the engine off and relieve system pressure, 2.13 Connect pressure gauge, remove screw coupling and install plug 31 with seal into housing 5. 2.14 Adjust primary pressure relief valve 120 and secondary pressure relief valves 126 and 127 to correct pressure, see adjustment guidelines and hydraulic system operating pressures, section 6. 3. Adjust restrictor on stop screw 19, see fig. 13 3.1 Fully retract bucket cylinder and then fully extend the cylinder. The cylinder must extend smoothly and evenly, without an increase in pressure on the bucket cylinder piston bottom side If necessary, adjust stop screw 19 on piston rod side of, valve 5i Turn adjustment screw 15 in = to increase restriction Turn adjustment screw 15 out = to decrease restriction 3.2. After correct adjustment, install locknut 21 with seal 34 Hold stop screw 19 when tightening lock nut, Benennung/Description/Dénomination Load Check Valve Oil control LIEBHERR DatumEdionDate 07.91 Modet “Sub group Type Index” ‘Abyfroma parti de BlattPagerFeuille 16.12.074 16 19 20 40 48 50 Brake piston Nozzle Sleeve (Check valve) Stop screw ( Limit /Piston stroke) from Var. double pump (*) Test point Pump P2 (standard )(*) Test point (not standard ) Load check valve, complete 81 100 102 120 127 180 from servo control - right (*) Control block 6 or 7 way (*) Control piston / bucket cylinder (*) Primary pres. relief valve / Control block - left (*) Secondary pressure relief valve/ retract stick gylinder (*) Bucket cylinder (*) * Positions in hydraulic schematic, section 6. We 1207Schematic for load check valve for bucket cylinder ( piston rod side) 180 40, 100 typ Sco page 16 Mode! “Subgroup Benennung/Description/Dénomination Type nde” Load Check Valve Oil control LIEBHERR ‘Abitromia partie DatumEdwoniDate BiatuPagerFeuile 07.91 6.12.08Load holding valve for hoist cylinders The new version of the load holding valve is independent of load and flow pressure and differs in design by its usage. This RBS - valve is also independent of adjustment pressure. Its used to protect the hoist cylinder . Task The load holding valve is installed directly on the pressure connection of the hoist cylinder, on the piston bottom side. The load holding vaive consists of a brake piston with check valve and a control piston. The second piston in the housing takes over the secondary relief . The valve prevents uncontrolled dropping of the attachment or load if a hose or line should break. ff the control pressure connection is without pressure, the load holding valve 52 closes the corresponding cylinder connection off leakoil free. ‘Benennung/Description/Dénomination yp see page 16 Model “Sub gfoup Index" LIEBHERR aa Load Holding Valve Independent of Load and Outgoing Flow Pressure Oil Control ‘Ab/from/a partirde Datumi/Eaition/Date 01.94 Blatt/Page/Feullle 16.13.01Function, see diagram on page 16.13.02 and schematic on page 16.13.04 1. To actuate cylinder 160 in ‘down’ direction Hydraulic oil flows from control valve block 100 “connection 81 ” and distributor 161 to both valves 52 “connection V2" and via its valve guides 15, moves sleeves 18 ( check valves ) and actuates the cylinder via connection C2. After completing the working movement, the check valve 18 closes. ‘The return flow is closed off, which means the load is held leakoil free. 2. Pressure relief The secondary pressure relief occurs by the pressure actuation of piston 10. In case of pressure peaks, the piston 10 is moved against the pretensioned spring 8 and thereby relieves the pressure from the piston bottom side of the cylinder to the spool . Additional relief to the tank is provided by the secondary pressure relief valve ( extend hoist cylinder) in the control valve block. To actuate cylinder 160 in ‘down’ direction The servo pressure on control valve block 100 “connection a1” to actuate the control piston 101 for the working movement “lower attachment”, also actuates the control piston 12 at the same time, via connection Pand nozzle 16. ‘The piston 12 pushes against brake piston 11 and moves it against spring 8. After a short stroke, the sleeve 18 supports itself on valve guide 15 and the leakoil free shut off is opened. The oil from the cylinder area flows now via connection C2 and V2 to the control valve block and from there it returns into the hydraulic tank. Removal of the load holding valve for resealing and repair work The valve does not have to be removed for resealing . Secure the hydraulic cylinder (lower the attachment to the ground ), relieve tank pressure and hydraulically relief the valves ( loosen the plug on connection E and catch any emerging oil in appropriate container). 1. Removal of piston 12 Remove plug 13 and push piston 12 from the housing 6 ( if necessary, apply pressurized air to connection T). 2. Removal of valve piston 10 and brake piston 11 Remove valve guides 15, complete with spring 8 and valve poppet 20 ( Be careful, spring is under tension! ). Pull piston 10/11 from the housing 6 and remove the sleeves 18 with springs 9, use a magnet, if necessary. If necessary, remove the plugs and seal rings. Installation of load holding valve after resealing and repair work Clean all parts carefully Before reinstallation, check all parts carefully before reusing them. Replace all seal rings and lightly grease them before installation . Installation of valve piston 10 and brake piston 11 Install seal rings 2/ 22 and 4 / 23 onto pistons 10 and 11. Insert springs 9 and sleeves 18, complete with seal rings 3 /25 into the housing bore. Install seal rings 24, 26 and 31 into or on the valve guides 15 and push the valve guide 15, complete with piston s 10 / 11 into the bore and screw it in. 2. Installation of piston 12 Insert piston 12, complete with seal rings 5 and 27 into the bore. Check nozzle 16 for cleanliness and reinsert it. Insert the plug 13 andall other, previously removed plugs with seal rings . Adjust the required secondary pressure and the start of movement on the valve as described in the adjustment guidelines on pages 16.13.02 and 16.13.03. 16.13.011 Teflon ring 10. Valve piston 18 Sleeve 28 O-ring 2 Teflon ring 11 Brake piston 20° Valvepoppet 29 O-ring 3 Teflon ring 12 Piston 22 O-ring 30 O-ring 4 Teflon ring 13° Plug 23 O-ring 31 Seal 5 Teflon ring 14 Plug 24 O-ring 32 Plug 6 Housing 15 Valve guide 25 O-ring 33 Seal ring 7 Union nut 16 Nozzle 26 Orting 34 Seal ring 8 Spring 17 Adjustment screw 27 O-ting 52. Load holding 9 Spring valve, complete See page 16. “sub group Index* rennin 19 / Description / Denomination Load Holding Valve Independent of Load and Outgoing Flow | Pressure - Oil Control LIEBHERR ‘Datum/ Edition! Date 01.94Adjustment guidelines for load holding valve on hoist cylinders, see also page No. 16.13.04 1. Important adjustment guidelines 1 12 13 14 15 ‘The valve has been adjusted by the manufacturer. For adjustment, check adjustment screw length X. To do this, remove union nut 7, remove seal ring 33 and check ‘the measurement from the upper edge of the adjustment screw 17 tovalve guide 15, see fig. 1 and 2, ‘Adjustment screw A - Measurement X should be X = 8,1£0,5mm Adjustment screw B - Measurement X should be X = 10 ‘£0,5 mm, Only in case of problems or after repairing the valve is it necessary to check or readjust the valve, as described in paragraph 2. and 3. The pressure must be adjusted with the hydraulic oil at ‘operating temperature and at nominal RPM, To adjust the pressure, use only glycerine filled pressure gauges with a reading accuracy of + 1% . We explicitly note that during the warranty period , only authorized LIEBHERR dealer personnel may work on and / or adjust valves. Open the lift limit of the control piston 101 all the way (slip restrictor ), see fig. 4. 2. Adjustment of secondary relief pressure on adjustment screw A, see fig. 1-5 24 22 23 24. 25 26 27 28 Lower the attachment to the ground, turn the engine off and relieve the valve (loosen plug 32 on connection E - ‘catch any emerging oil ). Remove plug 32 of connection E on both valves, see fig. 2, insert 1/4" screw coupling ( Tool No. 14) into both connections E on valve 52. Remove the plug on test point 40 ( on control valve block 100 - left hand side ), see fig. 3, and connect a mini test hose between test point 40 and one of the two screw couplings ( test point 48) . Connect a 600 bar pressure gauge with test hose (1.5 - 2.5 m long) to the other screw coupling of valve 52 (connection ®. Extend hoist cylinder 160 all the way to the stop. ‘Turn up secondary pressure relief valve 128 (extend bucket gylinder). it must be assured that the relief pressure is measurably higher than the adjustment pressure of valve 52. Turn out the secondary pressure relief valve 126 ( extend the hoist cylinder ) by at least 1-2 turns (lowering it). Extend the bucket cylinder fully to the stop. Primary pressure will build up via test hose on connections E of valve 52(and test point 48 with pressure gauge ) . 16.13.022.9 Slowly turn the primary pressure relief valve 120 higher and observe the pressure gauge on test point 48. The pressure increases now until the adjustment pressure of valve 52 has been reached. ‘The adjustment pressure of valve 52 should be (lowe) 390 + 10 bar. 2.10 If the measured pressure does not match the prescribed pressure, then the pressure can be corrected by turning the adjustment screw 17 with a SW 8 socket wrench. Todo this, remove union nut 7 (from valve A, see fig. 5) [49o. and turn adjustment screw 17 accordingly. If necessary, check the distance from screw 17 to valve guide 15 first, see also paragraph 1 ‘Turn adjustment screw [120. to increase pressure P2 Turn adjustment screw 17 out = to decrease pressure 1 turn (360°) of screw17 = 110 bar 2.11 After correct adjustment, reinstall union nut 7 with seal ring 33 onto adjustment screw 17. 2.12 Lower the attachment again to the ground and turn the engine off, and release pressure from the system. 2.13 Disconnect the pressure gauge, remove the screw couplings and install plug 32 with seals into housing 6. 160 2.14 Adjust the second load holding valve 52, as described in paragraph 2.2- 2.13. Note: The adjustment of both valves 52 must be exactly the same. 2.15 Adjust the primary pressure relief valve 120 and the secondary pressure relief valves 126 and 128 to the correct pressure, see adjustment guidelines and opera- ting pressures for the hydraulic system, in section 6. 3. Adjustment of movement begin (Valve B), see fig. 6 and 7 3.1 Relieve pressure from servo control. 3.2 Install a T-fitting with test connection to control line to the connection of both valves 52, see fig. 7. Connect a 0-40 bar pressure gauge. 3.3. Carefully select the function - attachment down - with the right servo control and read the control pressure on the pressure gauge when the attachment begins to move. Control pressure should be = 1005 bar when the attachment begins to move. 160 3.4 If necessary, turn the adjustment screw 17(on valve B, see fig. 6 ) accordingly: Typ see page 16. Mode! “Sub Group Index” Type Benennung/Description/Dénomination Load Holding Valve Independent of Load and Outgoing Flow Pressure Oil Control LIEBHERR ‘Abifrom/a partir de Datum/Edition/Date 11.96 Blatt/Page/Feuille 16.13.03Tast point ‘Gntrol pressure 10 n 16 18 20 32 48 52 Valve piston Brake piston Nozzle Sleeve ( Check valve) from var. displ. pump P2 (*) Plug / Connection E Test point - Pump P2(*) Test point -( not standard installation ) Load holding valve, complete Turn adjustment screw 17 in = to increase pressure Turn adjustment screw 17 ou ‘1 turn ( 360°) of screw 17 3.5 After correct adjustment, determine the distance (measure- ment X) from screw 17 to valve guide 15, see also § 1.1. Install the union nut 7 with seal ring 33 to adjustment screw 7, 36 Relieve the pressure from the system, remove the pressure gauge and the T-fitting. 3.7 Adjust measurement X, see paragraph 3.5, on the second load holding valve 52. 81 fromservo control, right (*) 100 Control valve block 6-way or 7-way (*) 101 Control piston / Hoist cylinder (*) 110 Control piston / flow summation - hoist cylinder * 120 Primary pr. relief valve / Control valve block - left (*) 126 Secondary pr. relief valve / extend hoist cylinder (*) 160 Hoist cylinder (*) 161 Distributor / Hoist cylinder (*) 164 Hoist limit / Control piston 101 ( restrictor) Positions in hydraulic schematic, Section 6. 16.13.03Load holding valve for hoist cylinders ( piston bottom side ) Benennung/Description/Dénomination Typ see page 16. Mode! “Sub Group Index” HIEBHERR Load Holding Valve Tee paniicanianiOaie Independent of Load and Outgoing ‘Absfrom/a partir de Flow Pressure 01.94 Blatt/Page/Feuille Oil Control 16.13.04Load holding valve for stick and bucket cylinders The new version of the load holding valve its usage, This RBS - valve is used to protect the stick adjusting the flow quantity of the outgoing oil. Task jependent of load and flow pressure and differs in design by linder and the bucket cylinder. Cavitation is prevented by The load holding valve is installed directly on the pressure connection of the stick cylinder ( piston bottom and piston rod side) and on the bucket cylinder (piston rod side) . The load holding valve consists of a brake piston with check valve and a servo control piston. The brake piston is designed to provide leakoil free closure and secondary relief. The valve prevents uncontrolled dropping of the attachment or load if a hose or line should break. If the control pressure connection is without pressure, the load holding valve 50 closes the corresponding cylinder connection off leakoil free. Stick cylinder Bucket cylinder Benennung/Description/Dénomination yp see page 16 Model "Sub Group Index” Type LIEBHERR Load Holding Valve Oil Control ‘Ab/from/a partir de ‘Datum/Edition/Dae 01.94 Blatt/Page/Feuille 16.13.05