Service Manual

Chapter 3 - Technical data

Technical data.........................................................................................................................3.00
1 Machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.00.3
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.00.3
1.2 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.00.3
1.3 Splitterbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.00.3
1.4 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.00.4
2 Component lifting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.00.9
2.1 Lifting precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.00.9
2.2 Uppercarriage parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.00.9
2.3 Undercarriage parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.00.18
2.4 Attachment parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.00.19
3 Adjustment procedure 9200. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.00.21
3.1 Initial adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.00.22
3.2 Adjust the working pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.00.22
3.3 Adjust the swing pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.00.31
3.4 Adjust the cooling pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.00.34
3.5 Adjust the primary and secondary valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.00.36
3.6 Track tensioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.00.42
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3.00.2 R 9200
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 Service Manual Technical data
Machine data

3.00: Technical data

1 Machine data

1.1 General

R9200 - General data Unit

Machine weight backhoe attachment t 225
Machine weight shovel attachment t 231
Length without attachment mm 9599
Width of the undercarriage mm 5502
Height without attachment mm 6930
Tail swing mm 5800
Ground clearance mm 832
Digging force / breakout force (backhoe attachment) kN 650 / 740
Crowd force at ground level / max. crowd force / breakout kN 868 / 924 / 750
force (shovel attachment)

1.2 Engine

R9200 - Engine Unit

Trademark CUMMINS
Model QSK 38
Type 4-cycle, 60° 12-cylin-
der Diesel V-engine
Rating at nominal per SAE J 1995 kW 810 (1086 HP)
Nominal speed RPM 1800
Idle speed RPM 650 to 725
High idle RPM 1900
Maximal torque (at 1500 RPM) Nm 4745
Displacement L 37,7
Bore / stroke mm 159 x 159
Oil quantity Refer to the Operating Manual.
Oil change intervals Refer to the Operating Manual.
Oil viscosity (above -25°C / -13°F) Refer to the Operating Manual.
Diesel fuel tank capacity Refer to the Operating Manual.
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Firing order 2-11-10-3-6-7-12-1-4-9-8-5

Valve adjustment intake / exhaust mm 0,36 / 0,69
Maximum supply fuel flow kg / h 434

1.3 Splitterbox

R9200 - Splitterbox Unit

Trademark Liebherr

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Technical data Service Manual
Machine data

R9200 - Splitterbox Unit

Type PVG 450 C 470
Oil quantity Refer to the Operating Manual.
Oil viscosity Refer to the Operating Manual.

1.4 Hydraulic system

1.4.1 Main circuit

R9200 - Hydraulic system - Main circuit Unit

Hydraulic pumps type 4 x Liebherr DPVO
215
(2363 min-1)
Pumps output (for one pump) kW 298
Max. flow (for one pump) L/min 512
Regulation begin at nominal engine power bar 199
Max. operating pressure (primary relief valves) bar 350 ± 5
Pressure regulator adjustment bar 330
Secondary pressure bar 380 ± 5
Hydraulic oil quantity in the whole system Refer to the Operating Manual.
Hydraulic oil quantity in tank Refer to the Operating Manual.
Hydraulic oil change intervals Refer to the Operating Manual.
Leakage oil and return oil filters change intervals Refer to the Operating Manual.
Control valves type (2x) Rexroth 8M8-32
Hydraulic cylinders
Boom cylinder Ø piston / Ø rod / stroke (backhoe attach- mm (2x) 280 / 200 / 2450
ment)
Boom cylinder Ø piston / Ø rod / stroke (shovel attachment) mm (2x) 280 / 200 / 1750
Stick cylinder Ø piston / Ø rod / stroke (backhoe attachment) mm (2x) 240 / 160 / 2000
Crowd cylinder Ø piston / Ø rod / stroke (shovel attachment) mm (2x) 190 / 140 / 2330
Bucket tilt cylinder Ø piston / Ø rod / stroke (backhoe attach- mm (2x) 190 / 140 / 1910
ment)
Bucket tilt cylinder Ø piston / Ø rod / stroke (shovel attach- mm (2x) 190 / 140 / 2330
ment)
Shovel tilt cylinder Ø piston / Ø rod / stroke mm (2x) 200 / 150 / 2345
Shovel flap cylinder Ø piston / Ø rod / stroke mm (2x) 180 / 110 / 520

1.4.2 Swing circuit

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R9200 - Hydraulic system - Swing circuit Unit

Swing circuit type Closed circuit
Swing pump type Liebherr DPVG 280
(2268 min-1)
Swing pump design Double swash plate
type axial piston
pumps

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Machine data

R9200 - Hydraulic system - Swing circuit Unit

Swing pump output kW (1x) 389
Max. displacement cm³ (1x) 283
Max. flow L/min 643
Max. operating pressure bar 350
Secondary pressure bar 420
Replenishing pump type Bosch-Rexroth AZP-
GF 22 - 056 / 028
(2300 min-1)
Replenishing pump design Double geared pump
Replenishing pump cubic capacity cm3/rev 56
Replenishing pump flow L/min 132
Replenishing pressure bar 35

1.4.3 Servo control oil circuit

R9200 - Hydraulic system - Servo control oil circuit Unit

Control pump type Bosch-Rexroth AZP-
GF 22 - 056 / 028
(2300 min-1)
Control pump design Double geared pump
Max. flow / servo L/min 66

1.4.4 Cooling circuit

R9200 - Hydraulic system - Cooling Unit Oil cooling Water cooling

Cooling pump Type Liebherr LPVD 045

Design Hydraulic double pump

Nominal RPM* min-1 2268 2268

Max. pump cubic capacity* cm3/rev 45,6 45,6
Pump flow max* L/min 103 103
Hydraulic motors Nb / Type (1x) FMF 064 (1x) FMF 064

Cubic capacity cm³ 64 64

Cooling fans Nb / Type (1x) BZI 1120 (1x) BZI 1120

Fan speed min-1 1460 1428

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R9200 - Hydraulic system - Splitterbox cooling circuit Unit

Splitterbox cooling pump type Type Liebherr ZPA 5
Design Geared pump
Pump cubic capacity cm3/rev 5
Pump flow L/min 9

* These data are correct when engine operates at nominal speed.

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Machine data

1.4.5 Electrical system

R9200 - Electrical system Unit

Voltage V 24
Batteries arrangement (4x) 180 Ah/12V prin-
cipal batteries
Battery capacity Ah (4x) 590
Alternator voltage / maximal current V/A 28 / 260

1.4.6 Swing gear

R9200 - Swing gear Unit

Swing gear Type (2x) SAT 450 / 256
Swing motor Type (2x) FMF 250
Swing brake Type multi-disc, hydrauli-
cally released
Maximal swing speed min-1 4,1
Swing gear oil change intervals Refer to the Operating Manual.
Swing gear oil quantity Refer to the Operating Manual.
Swing gear oil quality / viscosity Refer to the Operating Manual.
Swing ring Type ROD 1354 DJ
Swing ring Design Triple race roller
bearing with internal
teeth

1.4.7 Travel gear

R9200 - Travel gear Unit

Travel gear Type FAT 800 P 100
Travel motor Type (1x) DMVA 355
Travel brake Type Disk brake / spring
applied, pressure re-
leased
Maximum travel speed km/h 2,8
Travel gear oil change intervals Refer to the Operating Manual.
Travel brake oil change intervals Refer to the Operating Manual.
Travel gear oil quantity Refer to the Operating Manual.
Travel brake oil quantity Refer to the Operating Manual.
Travel gear oil quality / viscosity Refer to the Operating Manual.
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Travel brake oil type Refer to the Operating Manual.

Minimal oil pressure to release brake bar 19

1.4.8 Track components

R9200 - Track components Unit

Track chain Type B11, forged double grouser pad
Track pad width mm 800

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Machine data

R9200 - Track components Unit

Track roller Quanti- 16 (8 per side frame)
ty
Track roller oil quantity* L Refer to the Operating Manual.
Track roller oil type* Refer to the Operating Manual.
Carrier roller Quanti- 4 (2 per side frame)
ty
Carrier roller oil quantity* L Refer to the Operating Manual.
Carrier roller oil type* Refer to the Operating Manual.
Ground pressure / backhoe attachment kg/cm² 1,98
Ground pressure / shovel attachment kg/cm² 2,02

* According to installed roller type.

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 Service Manual
Component lifting

2 Component lifting

2.1 Lifting precautions

Obey all lifting precautions given in the Operating manual (which is included in the chapter "Op-
erating maintenance" of this Service manual).

2.2 Uppercarriage parts

2.2.1 Informations in Safe Work Procedures

For lifting information about the parts that follow, refer to the related Safe Work Procedure in the chap-
ter 2 of this Service Manual:
– diesel engine (4100 kg wet)
– splitterbox (402 kg without pumps)
– hydraulic pumps:
• one single working pump (128 kg)
• swing pump (136 kg)
• cooling pump (72 kg)
– valve bank (2079 kg complete with valve blocs, filters, accumulator and piping)
– swing gear (944 kg complete with motor and brake)
– battery box (complete with batteries)

2.2.2 Informations on transport drawings

For lifting information about the parts that follow, refer to the related transport drawing given in the
Operating manual (refer to the chapter 4 "Operating maintenance" of this Service Manual):
– rotating deck
– cab
– cab elevation
– counterweight
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Component lifting

2.2.3 Coupling

Fig. 1 Coupling lifting points

– weight of outer part: 10,1 kg / mass moment of inertia: 0,6 kgm²
– weight of inner part: 27,4 kg / mass moment of inertia: 0,4 kgm²
Screw the lifting lungs in the threads indicated below.
Do not lift the total mass on one lifting appliance only.

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Component lifting

2.2.4 Engine and oil cooler boxes / radiators

Engine cooler box (without engine radiator)

Fig. 2 Lifting points of engine cooler box

Weight: 902 kg
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Component lifting

Engine radiator

Fig. 3 Lifting points of engine radiator

Weight: 435 kg

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Component lifting

Oil cooler box (without radiator)

Fig. 4 Lifting points of oil cooler box

Weight: 667 kg
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Component lifting

Oil radiator

Fig. 5 Lifting points of engine radiator

Weight: 421 kg

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Component lifting

2.2.5 Swing ring

Fig. 6 Swing ring lifting

Weight: 2470 kg
Screw four lugs on appropriate threads.
Use these lugs to lift the swing ring.
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Component lifting

2.2.6 Fuel tank

Fig. 7 Lifting points of fuel tank

Weight: 1937 kg

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Component lifting

2.2.7 Hydraulic tank

Fig. 8 Lifting points of hydraulic tank

Weight: 1431 kg
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Component lifting

2.2.8 Pumps box (without pumps and batteries)

Fig. 9 Lifting points of pumps box

Weight: 1131 kg

2.3 Undercarriage parts

2.3.1 Informations in Safe Work Procedures

For lifting information about the parts that follow, refer to the related Safe Work Procedure in the chap-
ter 2 of this Service Manual:
– travel motor (195 kg)
– travel brake (61 kg)
– travel gear (1862 kg)
– sprocket wheel (668 kg)
– idler wheel (1643 kg with slider)
– carrier roller (190 kg)
– track roller (405 kg)
– travel motor cover (55 kg)
– complete rotary connection (411 kg with support)

2.3.2 Informations on transport drawings

LEC / en / Edition: 03 / 2016

For lifting information about the parts that follow, refer to the related transport drawing given in the
Operating manual (refer to the chapter 4 "Operating maintenance" of this Service Manual):
– side frame
– central part

2.3.3 Track components

Track chain
Weight: 10535 kg (complete chain with 50 track pads of 800 mm)

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Component lifting

Track guide
Weight: 735 kg

Track tensioning cylinder

Weight: 389 kg

2.4 Attachment parts

2.4.1 Informations on transport drawings

For lifting information about the parts that follow, refer to the related transport drawing given in the
Operating manual (refer to the chapter 4 "Operating maintenance" of this Service Manual):
– boom
– stick
– bucket

2.4.2 Distribution blocs

Distribution bloc for the boom cylinder

Weight: 36 kg

Distribution bloc for the stick cylinder

Weight: 77 kg

Distribution bloc for the bucket tilt cylinder

Weight: 77 kg
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Adjustment procedure 9200

3 Adjustment procedure 9200

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Fig. 10 Pumps installation

P1 Working pump 1 P6.1 Engine cooling pump

P2 Working pump 2 P6.2 Oil cooling pump
P3 Working pump 3 P8 Splitterbox lubrication pump
P4 Working pump 4 P9 Control oil pump
P5 Swing pump P10 Replenishing pump

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Adjustment procedure 9200

3.1 Initial adjustment

3.1.1 Pre-requirements

Requirement Nominal value Adjusted value

Diesel engine maximum RPM 1900 ± 10 RPM

Oil temperature (T) 50°C > T > 70°C

For the oil temperature of the arctic excavators, refer to the Operating Manual.

3.1.2 Adjust the servo pressure

The servo unit SU1 is located inside the pumps box.

Fig. 11 Servo pressure adjustment

Operate the engine at maximum RPM.
Install a 100 bar gauge on M1.
Adjust the screw 1 on the servo unit to get M1 = 32 + 2 bar.

Requirement Nominal value Measured value Adjusted value

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Servo pressure M1 = 32 + 2 bar

3.2 Adjust the working pumps

The procedures that follow are applicable for all working pumps.
Use the same pressure gauges to adjust all working pumps.
This to make sure that all pumps are adjusted equally, with the same measurement uncertainly.

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3.2.1 Location of components

Measurement and adjustment points on working pumps

Fig. 12 Working pumps P1, P2, P3 and P4

The four working pumps P1, P2, P3 and P4 are the same:
– Points M1_1, DA_1, LR_1 and SD_1 are related to working pump P1.
– Points M1_2, DA_2, LR_2 and SD_2 are related to working pump P2.
– Points M1_3, DA_3, LR_3 and SD_3 are related to working pump P3.
– Points M1_4, DA_4, LR_4 and SD_4 are related to working pump P4.
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Primary relief valves and measurement points on the high pressure filters

Fig. 13 Primary relief valves and high pressure filters

M21 Measurement point on high pressure fil- PRV11 Primary Relief Valve 1 on VB1
ter related to working pump P1
M22 Measurement point on high pressure fil- PRV12 Primary Relief Valve 2 on VB1
ter related to working pump P2
M23 Measurement point on high pressure fil- PRV21 Primary Relief Valve 1 on VB2
ter related to working pump P3
M24 Measurement point on high pressure fil- PRV22 Primary Relief Valve 2 on VB2
ter related to working pump P4
P1 Working pump P1 VB1 Valve block 1
P2 Working pump P2 VB2 Valve block 2
P3 Working pump P3
P4 Working pump P4

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Solenoid valve YR4 on servo unit

Fig. 14 Solenoid valve YR4 on servo unit

3.2.2 Flow control valves (SD)

Check the flow control valves

Make sure the servo pressure M1 = 32 + 2 bar. Refer to the section above.
Operate the engine at maximum RPM.
Install a 100 bar gauge on:
– M1_1 on pump P1
– M1_2 on pump P2
– M1_3 on pump P3
– M1_4 on pump P4
Check 1: Do not operate the attachment.
In this case, the positioning pressure on M1_1, M1_2, M1_3 and M1_4 must not be more than 5 bar.
Check 2: Lower the attachment until it touches the ground and keep the related joystick actuated.
In this case, the positioning pressure on M1_1, M1_2, M1_3 and M1_4 must be more than 30 bar.
If you do not find these values, move to the next section below.
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Adjust the flow control valves

Fig. 15 Measurement points M2 and M3 on servo unit

Make sure the servo pressure M1 = 32 + 2 bar. Refer to the section above.
Operate the engine at maximum RPM.
Install a 10 bar gauge on:
– M2 on servo unit for pumps P2 and P3
– M3 on servo unit for pumps P1 and P4.
Install a 100 bar gauge on:
– M1_1 on pump P1
– M1_2 on pump P2
– M1_3 on pump P3
– M1_4 on pump P4
Do not operate the attachment.

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Fig. 16 Pumps settings menu

On your computer:
Start the software "Sculi".

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Select and start the tool "Wizard".

Go to "Pumps settings" menu.
Adjust with buttons "+" and "-" the current value for the graph "SD1" to get M3 = 5 bar.
Adjust with buttons "+" and "-" the current value for the graph "SD2" to get M2 = 5 bar.
On each working pump:
Adjust the screw SD_1 to get M1_1 = 20 bar.
Adjust the screw SD_2 to get M1_2 = 20 bar.
Adjust the screw SD_3 to get M1_3 = 20 bar.
Adjust the screw SD_4 to get M1_4 = 20 bar.

Pump P1 / SD_1

Nominal value Measured value Adjusted value

M3 = 5 bar

M1_1 = 20 bar

Pump P2 / SD_2
Nominal value Measured value Adjusted value
M2 = 5 bar

M1_2 = 20 bar

Pump P3 / SD_3
Nominal value Measured value Adjusted value
M2 = 5 bar

M1_3 = 20 bar

Pump P4 / SD_4

Nominal value Measured value Adjusted value

M3 = 5 bar
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M1_4 = 20 bar

3.2.3 Adjust the power regulators (LR)

Make sure the servo pressure M1 = 32 + 2 bar. Refer to the section above.
Operate the engine at 1250 ± 5 RPM.
Install a 100 bar gauge on:

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– M1_1 on pump P1.

– M1_2 on pump P2.
– M1_3 on pump P3.
– M1_4 on pump P4.
Install a 600 bar gauge on:
– M21 on high pressure filter for pump P1.
– M22 on high pressure filter for pump P2.
– M23 on high pressure filter for pump P3.
– M24 on high pressure filter for pump P4.
Use the deactivation of the attachment damping system. Refer to the Operating Manual.
Lift up the attachment and keep the related joystick actuated.
Adjust the screw PRV11 on valve block to get M21 = 90 + 2 bar.
Adjust the screw PRV21 on valve block to get M22 = 90 + 2 bar.
Adjust the screw PRV22 on valve block to get M23 = 90 + 2 bar.
Adjust the screw PRV12 on valve block to get M24 = 90 + 2 bar.
Disconnect the sensor YR4 on the servo unit.
Adjust the screw LR_1 to get M1_1 = 70 ± 2 bar.
Adjust the screw LR_2 to get M1_2 = 70 ± 2 bar.
Adjust the screw LR_3 to get M1_3 = 70 ± 2 bar.
Adjust the screw LR_4 to get M1_4 = 70 ± 2 bar.
Connect YR4 again.
Adjust again the primary relief valves PRV as given in the section "Primary valves adjustment".

Pump P1 / LR_1

Nominal value Measured value Adjusted value

M1_1 = 70 ± 2 bar

Pump P2 / LR_2

Nominal value Measured value Adjusted value

M1_2 = 70 ± 2 bar

Pump P3 / LR_3
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Nominal value Measured value Adjusted value

M1_3 = 70 ± 2 bar

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Adjustment procedure 9200

Pump P4 / LR_4

Nominal value Measured value Adjusted value

M1_4 = 70 ± 2 bar

3.2.4 Adjust the pressure cut-off (DA)

Operate the engine at maximum RPM.
Install a 600 bar gauge on:
– M1_1 on pump P1.
– M1_2 on pump P2.
– M1_3 on pump P3.
– M1_4 on pump P4.
Install a 600 bar gauge on:
– M21 on high pressure filter for pump P1.
– M22 on high pressure filter for pump P2.
– M23 on high pressure filter for pump P3.
– M24 on high pressure filter for pump P4.
Fully loosen the screws DA_1, DA_2, DA_3 and DA_4.
Tighten it of two turns.
Adjust the screw PRV11 on valve block to get M21 = 330 + 5 bar.
Adjust the screw PRV21 on valve block to get M22 = 330 + 5 bar.
Adjust the screw PRV22 on valve block to get M23 = 330 + 5 bar.
Adjust the screw PRV12 on valve block to get M24 = 330 + 5 bar.
Use the deactivation of the attachment damping system. Refer to the Operating Manual.
Lift up the attachment and keep the related joystick actuated.

Tighten the screw DA_1 to increase the positioning pressure on M1_1 until it becomes stable.
In this case, M1_1 must be equal to 150 ± 10 bar.
Then, slowly loosen DA_1 until M1_1 pressure starts to decrease. Stop just before M1_1 pressure
starts to decrease.
M1_1 must continue to be equal to 150 ± 10 bar.

Tighten the screw DA_2 to increase the positioning pressure on M1_2 until it becomes stable.
In this case, M1_2 must be equal to 150 ± 10 bar.
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Then, slowly loosen DA_2 until M1_2 pressure starts to decrease. Stop just before M1_2 pressure
starts to decrease.
M1_2 must continue to be equal to 150 ± 10 bar.

Tighten the screw DA_3 to increase the positioning pressure on M1_3 until it becomes stable.
In this case, M1_3 must be equal to 150 ± 10 bar.
Then, slowly loosen DA_3 until M1_3 pressure starts to decrease. Stop just before M1_3 pressure
starts to decrease.

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M1_3 must continue to be equal to 150 ± 10 bar.

Tighten the screw DA_4 to increase the positioning pressure on M1_4 until it becomes stable.
In this case, M1_4 must be equal to 150 ± 10 bar.
Then, slowly loosen DA_4 until M1_4 pressure starts to decrease. Stop just before M1_4 pressure
starts to decrease.
M1_4 must continue to be equal to 150 ± 10 bar.

Adjust again the primary relief valves PRV as given in the section "Primary valves adjustment".

Pump P1 / DA_1

Nominal value Measured value Adjusted value

M1_1 = 150 ± 10 bar

Pump P2 / DA_2

Nominal value Measured value Adjusted value

M1_2 = 150 ± 10 bar

Pump P3 / DA_3

Nominal value Measured value Adjusted value

M1_3 = 150 ± 10 bar

Pump P4 / DA_4

Nominal value Measured value Adjusted value

M1_4 = 150 ± 10 bar

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3.3 Adjust the swing pump

Fig. 17 Swing pump

Da1 Pressure cut-off screw 1 - acceleration

Da2 Pressure cut-off screw 2 - swing deceleration
HDV1 High pressure relief screw 1 - secondary valve
HDV2 High pressure relief screw 2 - secondary valve
M1 Test point of the pressure
M2 Test point of the pressure
M3 Test point of the replenishing pressure
SDV Replenishing pressure relief valve

3.3.1 Adjust the replenishing pressure

Operate the engine at maximum RPM.
Install 100 bar gauge on M3.
If necessary, adjust the replenishing pressure with the screw SDV at 35 + 2 bar.

Pump P5 / SDV
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Nominal value Measured value Adjusted value

M3 = 35 + 2 bar

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3.3.2 Adjust the pressure cut-off - acceleration

Fig. 18 Solenoid valve Y7 on servo unit

Operate the engine at maximum RPM.
Install 600 bar gauge on M1 and M2.
Disconnect the solenoid valve Y7.
Lift the access ladder.
Fully actuate the joystick for the swing gear.
For each swing direction, the working pressure on M1 and M2 must be equal to 350 ± 5 bar.
If you do not find this value:
Turn the screw Da1 until you get correct pressure.
Connect the solenoid valve Y7 back.

Pump P5 / Da1
Nominal value Measured value Adjusted value
M1 = 350 ± 5 bar

M2 = 350 ± 5 bar
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3.3.3 Adjust the pressure cut-off - swing deceleration

Fig. 19 Hose of pressure cut-off valve on swing pump P5

Stop the engine.
Install 600 bar gauge on M1 and M2.
Release hydraulic pressure. Refer to the Operating Manual.
Disconnect the hose which is connected to pressure cut-off screw (Da1 and Da2).
Put a cap on this hose.
Start the engine. Operate the engine at maximum RPM.
Lift up the access ladder.
Disconnect the solenoid valve Y7.
Fully actuate the joystick for the swing gear.
For each swing direction, the working pressure on M1 and M2 must be equal to 200 ± 5 bar.
If you do not find this value:
Turn the screw Da2 until you get correct pressure.
Stop the engine.
Connect the hose on pressure cut-off screw again.
Connect the solenoid valve Y7 back.
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Pump P5 / Da2

Nominal value Measured value Adjusted value

M1 = 200 ± 5 bar

M2 = 200 ± 5 bar

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3.3.4 High pressure relief valves (secondary valves)

The high-pressure relief screws HDV1 and HDV2 are factory adjusted and leaded.
Do not adjust these valves on a new excavator.
Do not adjust these valves on a new pump.
If you are in doubt that it does not work correctly, it must be replaced by a new one and its adjustment
must be checked only by approved people (a test bench can be used). The secondary valve is not
resistant to the maximum flow of the pump.

3.4 Adjust the cooling pumps

The procedures that follow are applicable for all cooling pumps.
Use the same pressure gauges to adjust all cooling pumps.
This to make sure that all pumps are adjusted equally, with the same measurement uncertainly.

Fig. 20 Cooling pumps

P6.1 Engine cooling pump

P6.2 Oil cooling pump

3.4.1 Engine cooling pump

Operate the engine at maximum RPM.
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Disconnect the regulation valve Y10.1 for pump P6.1.

Install 600 bar gauge on MA2 for pump P6.1.
The pressure cut-off MA2 must be equal to 150 ± 5 bar for pump P6.1.
If you do not find this value:
Turn the screw DA_P6.1 until you get the correct RPM for the related fan = 1460 ± 50 RPM.
Connect the regulation valve Y10.1 again.
Control the direction of rotation of the fan: flow from outside to inside.

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Pump P6.1 / Engine cooling pump

Nominal value Measured value Adjusted value

MA2 = 150 ± 5 bar

Fan speed = 1460 ± 50

RPM

3.4.2 Oil cooling pump

Operate the engine at maximum RPM.
Disconnect the regulation valve Y10.2 for pump P6.2.
Install 600 bar gauge on MA1 for pump P6.2.
The pressure cut-off MA1 must be equal to 145 ± 5 bar for pump P6.2.
If you do not find this value:
Turn the screw DA_P6.2 until you get the correct RPM for the related fan = 1470 ± 50 RPM.
Connect the regulation valve Y10.2 again.
Control the direction of rotation of the fan: flow from outside to inside.

Pump P6.2 / Oil cooling pump

Nominal value Measured value Adjusted value

MA1 = 145 ± 5 bar

Fan speed = 1470 ± 50

RPM

3.4.3 Cooling motors

The cooler fan motors MF1 and MF2 are factory adjusted and leaded.
Do not adjust these valves on a new excavator.
Do not adjust these valves on a new pump.
If you are in doubt that it does not work correctly, it must be replaced by a new one and its adjustment
must be checked only by approved people (a test bench can be used).
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3.5 Adjust the primary and secondary valves

3.5.1 Location of components

Fig. 21 Valves installation

PRV Primary Relief Valve

SRV Secondary Relief Valve

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Fig. 22 High pressure filters installation

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HPF1 High Pressure Filter related to working HPF3 High Pressure Filter related to working
pump P1 pump P3
HPF2 High Pressure Filter related to working HPF4 High Pressure Filter related to working
pump P2 pump P4

3.5.2 Adjust the secondary valves

The secondary valves are factory adjusted and leaded.
Do not adjust these valves on a new excavator.
Do not adjust these valves on a new pump.
If you are in doubt that it does not work correctly, it must be replaced by a new one and its adjustment
must be checked only by approved people (a test bench can be used).
If you must do the related maintenance works, or you are in doubt that it does not work correctly, the
adjustment can be checked only by approved people.

Adjust the attachment secondary valves

The attachment secondary valves are adjusted on the valve blocks.
Operate the engine speed at maximum RPM.
Install 600 bar gauge on all HPF.
Fully tighten all the primary valves PRV and loosen it by one turn.
Do the movements that follow and adjust the screws SRV to get P = 380 ± 5 bar.
Adjust again the primary relief valves PRV as given in the section "Primary valves adjustment".

Measured value Adjusted value

Nominal
Movement of the VB1 VB2 VB1 VB2
value
attachment
(bar) HPF HPF HPF HPF HPF HPF HPF HPF
1 4 2 3 1 4 2 3
Boom Up 380 ± 5
Down 380 ± 5
Stick Extended 380 ± 5
Drawn in 380 ± 5
Bucket Tilted out 380 ± 5
Tilted in 380 ± 5
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Adjust the secondary valve of the shovel flap (with shovel attachment only)

Fig. 23 Secondary valve of the shovel flap

1 Shovel flap DBF Distribution block for shovel flap

2 Shovel flap cylinder SRV Secondary relief valve

Operate the engine at maximum RPM.

Install a 600 bar gauge on HPF3.
Fully tighten the primary valve PRV23 and loosen by one turn.
Do the movements that follow and adjust the screw SRV to get P = 380 ± 5 bar.
Adjust again the primary relief valve PRV23 as given in the section "Primary valves adjustment".

Measured value Adjusted value

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Nominal value
Movement of the shovel flap VB2 VB2
(bar)
HPF3 HPF3
Shovel flap Opened 380 ± 5
Closed 380 ± 5

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Adjust the travel secondary valves

The travel secondary valves are adjusted on the travel motors. The following procedure is applicable
for all travel gears.
Before you adjust the secondary valves on the travel gears, you can position the excavator against
an appropriate obstacle to use it as a stop if necessary.
If the hydraulic oil is too hot, it is possible that you cannot get the correct pressure.
If necessary, let the hydraulic oil temperature decrease.
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Fig. 24 Secondary valves on right travel gear

BWD Rearward travel direction M2(F) Test point for forward travel direction
FWD Forward travel direction SPRVB Adjustment screw for rearward travel
direction
M1(B) Test point for rearward travel direction SPRVF Adjustment screw for forward travel
direction

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Fig. 25 Secondary valves on left travel gear

BWD Rearward travel direction M1(F) Test point for forward travel direction
FWD Forward travel direction SPRVB Adjustment screw for rearward travel
direction
M2(B) Test point for rearward travel direction SPRVF Adjustment screw for forward travel
direction
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Fig. 26 Solenoid valve Y6

Make sure the related secondary valves on the valve blocks are fully tightened.
Operate the engine at maximum RPM.
Install a 600 bar gauge on the test points M(x)F and M(x)B.
Fully tighten all the primary valves PRV and loosen it by one turn.
Disconnect the travel brake solenoid valve Y6.
Lift up the access ladder.
Disable the travel brake with the related "Travel brake" button on the A168 keypad. Refer to the
Operating Manual.
Actuate the travel pedal in the forward travel direction. Keep actuated.
Monitor the pressure on the test point M(x)F.
In this case, the pressure must be equal to 380 ± 5 bar.
If you do not find this value:
Release the travel pedal.
Loosen the locknut. Turn the adjustment screw SPRVF on the travel motor.
Actuate the travel pedal again. Monitor the pressure on the test point M(x)F.
Tighten the locknuts again.
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Then:
Actuate the travel pedal in the rearward travel direction. Keep actuated.
Monitor the pressure on the test point M(x)B.
In this case, the pressure must be equal to 380 ± 5 bar.
If you do not find this value:
Release the travel pedal.
Loosen the locknut. Turn the adjustment screw SPRVB on the travel motor.

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Actuate the travel pedal again. Monitor the pressure on the test point M(x)B.
Tighten the locknuts again.
Connect the travel brake solenoid valve Y6 back.
Adjust again the primary relief valves PRV as given in the section "Primary valves adjustment".

Right travel motor

Nominal value Measured value Adjusted value

MF = 380 ± 5 bar

MB = 380 ± 5 bar

Left travel motor

Nominal value Measured value Adjusted value

MF = 380 ± 5 bar

MB = 380 ± 5 bar

3.5.3 Adjust the primary valves

Operate the engine at maximum RPM.
Install 600 bar gauge on all HPF.
Fully retract the stick cylinders supplied by the pump and keep the joystick actuated.
Adjust all the PRV screws to get P = 350 ± 5 bar.

Nominal Measured value Adjusted value

value
(bar) VB1 VB2 VB1 VB2

Single stage primary 350 ± 5

valve

3.6 Track tensioning system

3.6.1 Location of components

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The two sides left and right of the tensioning unit are symmetrical.

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Fig. 27 Hydraulic components for tensioning unit (one side)

1 Hydraulic hose connected to the CVT Three-way valve

hydraulic cylinder HC
2 Hydraulic hose connected to the HC Hydraulic cylinder
hydraulic tank T
3 Hydraulic hose connected to the track T Hydraulic tank (through the rotary con-
tensioning block KSB nection)
4 Not used (hydraulic hose connected KSB Track tensioning block
between KSB and T)

3.6.2 Adjust the track tension for the first time

Caution!
On new excavator, the grease cylinder can burst after only a small number of working hours. This
damage is caused by track pre-tensioning done before the transport of the undercarriage, which is
made with the grease cylinder (in this case, there is no hydraulic power and thus no pressure in the
track tensioning cylinder).
If the machine works in such conditions, the track tensioning cylinder does not its function, and the
different external stresses applied on the track are not absorbed. This can cause a grease cylinder
failure.

You must do the procedure that follows before you start the excavator for the first time.
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Make sure that the two valves SVT (right and left) are fully tighten.
Make sure that the two three-way valves CVT (right and left) are turned to connect the hose 1 to
the hose 3.
Operate the engine at maximum RPM.
Turn the uppercarriage by 90°. Lift the side which has to be adjusted.

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Fig. 28 Grease fitting for grease cylinder

Loosen the grease fitting 2. Do not remove the fitting fully.

Danger!
Risk of injury because of:
– sudden falling of the track chain
– a spray of grease under high pressure

When you release the track tension:

Always wear protective gloves and glasses.
Keep your head away from the opening 1 in the track side frame.
Do not touch the grease nipple 2 with your hands. Always use an applicable tool to loosen or tight-
en it.
To tighten or loosen the grease nipple 2, always catch it at its rear part and never at its front part.
Actuate the travel pedal related to the side which has to be adjusted.
Grease and hydraulic cylinder rod come out.
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Fig. 29 Hydraulic cylinder position for the first time adjustment

Stop when the hydraulic cylinder rod is out by the correct distance A = 120 mm.
Tighten the grease fitting.
Adjust the track tension as given in the Operating Manual.
Repeat the same procedure for the other track chain.

Right chain
Nominal value Measured value
A = 120 mm

Left chain
Nominal value Measured value
A = 120 mm

3.6.3 Do a standard adjustment of the track tension

Danger!
The track chain will move during the adjustment of the tensioning system.
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Before you adjust the track tensioning system, you can position the excavator with the idler side
against an appropriate obstacle to use it as a stop if necessary.
Make sure that the two valves SVT (right and left) are fully tighten.
Make sure that the two three-way valves CVT (right and left) are turned to connect the hose 1 to
the hose 3.
Always adjust the track chains separately. Start by adjusting one track chain. Then adjust the oth-
er.

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Adjust the right side

All the components that follow are related to the right side.
Operate the engine at maximum RPM.
Install a 600 bar gauge on the test points M1 and M2 on KSB.
Disconnect the travel brake solenoid valve Y6.
Lift up the access ladder.
Disable the travel brake with the related "Travel brake" button on the A168 keypad. Refer to the
Operating Manual.
Actuate the travel pedal related to the track chain you want to adjust.
Loosen the locknut and fully tighten the PRV adjustment screw on KSB, in order to let the pres-
sure go totally through.
Turn CVT to connect the hose 1 to the hose 2.
Loosen the locknut and turn the LVT adjustment screw until you get the correct pressure on M2
= 220 ± 5 bar.
Tighten the locknut on LVT again.
Turn back CVT to connect the hose 1 to the hose 3.
Stop actuate the travel pedal.
Fully loosen the PRV adjustment screw.
Turn CVT to connect the hose 1 to the hose 2.
Turn back CVT to connect the hose 1 to the hose 3.
Turn the PRV adjustment screw until you get the correct pressure on M1 = 140 ± 5 bar.
Tighten the locknut on PRV again.
Connect the solenoid valve Y6 back.

Adjust the left side

Repeat the same procedure on the left track chain, with the components related to the left side.

Right chain
Nominal value Measured value Adjusted value
M1_KSB = 140 ± 5 bar

M2_KSB = 220 ± 5 bar

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Left chain

Nominal value Measured value Adjusted value

M1_KSB = 140 ± 5 bar

M2_KSB = 220 ± 5 bar

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