LIEBHERR Printed by: Zovallos Romulo (LPS) (Romula Zevalos@licbher-com) (Chapter 3 Tochnicl dara 4 | Adjustment procedure From: Service manual R 9200 - 410 4.1 | General information From: Service manual R 9200 - 410 > Adjustment procedure 4.1.1| Structure of the procedure ‘This secton is divided into two parts +The first part isthe adjustment sheet which summarizes the machine data and all adjustment values, Each value is linked to an agjustment procedure given in the second part + The second part gives the adjustment procedures which show you how you must adjust the different functions or components. + > Fil in the adjustment sheet each time you do an adjustment on the machine. + b The adjustment sheet should be printed or saved after each adjustment. Ths isn order to have a record ofthe adjustments made ‘and to be able to give correct feedback ta the Customer Service, This record must be forwarded to the Customer Service it necessary. From: Service manual R 9200 - 410 > Adjustment procedure > General information 4.1.2 | Tools ‘Special tools can be specified in the adjustment procedures but a standard tool set is always necessary, ‘The pressure gauges which are usually used are 0-600 bar, class 1, with 10 to 10 graduations. To reduce the uncertainty of measurement, Liebherr recommends to use the "Muli Handy" tol ID. 10288229 or similar. Use the same pressure measurement device to measure equivalent pressures, for example + power regulator of pressure regulator on the diferent working pumps + left and right working pressures on the different swing pumps This to make sure that all hese pressures are adjusted equally, wit the same uncertainty of measurement, From: Service manual R 9200 - 410 > Adjustment procedure > General information 4.2 | Adjustment sheet From: Service manual R 9200 - 410 > Adjustment procedure 4.2.1 | Machine identification iether or Deales eted by Dau [ I I ue Eieat N° | aachine by eavel “Tavel cat ofthe adjustment excavator dalveny swing. x etal Loaded materia Li " 1 condition | ambient 15) [Latitude fn) IL I I IL ‘Copyright © Liebherr Mang Zauipment SAS Page 6B of 28LIEBHERR Printed by: Zovallos Romulo (LPS) (Romula Zevalos@licbher-com) Chapter 3 Tochnicl ara From: Service manual R 9200 - 410 > Adjustment procedure > Adjustment sheet, 4.2.2 | Adjustment values @ NOTE! eae — le Pre-requirements Lo Make sue these values are correct helore you do aby ustment Maximum Diesel engine speed 11900 + 10 check IE Operating temperature (hydraulic oi) || sac > T > ‘check nC +» For the oil temperature ofthe arctic machines, refer to the Operating Manual. servo pressure (/efer 12 8) sue MI 2 2hae pumps_(referio § pL low contol valve (SD) Check Mi Check 1 ai Mi Check >a0 bar check low contol valve (SD) Adjustment Power regulator (12) M21 (PRVI1} 90 + 2a ML Pressure cutat (DA) M21 (PRVA1) 0 S has low contol valve (SD) = Check Mi_- Check 1 bay heck Mi Check > cheek low contol valve (SD) = Adjustment Mi bi lator (LR) 122 (PRV21) 90 + 2a Ma 10+ 2b: Pressure cutatt (DA) ze (pven) 120 + 5 ba ML 150+ 10. Pa low contol valve (SD) - Check MI_= Checke 1 Shar check [tow contol valve (SD) = Adjustment ‘Copyright © Liebherr Mining Hquipmont SASLIEBHERR Printed by: Zovallos Romulo (LPS) (Romula Zevalos@licbher-com) (Chaptor 3 Tobit data component ue | Measured value |_Adjustedvalue wt by Ma 20 bat lator 8) oa (pry) 0 7 ba wi 0.82 cessute cut (DA) 12a (PRv22) 0. Shas wa 50+ 10. 4 iow cant vale (SD) Chace Check Adjustment procedure > Adjustment sheet, 4.3 | Adjustment procedures Figure 1. Pumps installation 1 Working pump 1 6.2 Oil cooling pump P2 Working pump 2 8 Spliterbox lubricating pump 3 Working pump 3 P9 Servo oil pump PA Working pump 4 P10 Replenishing pump 5 Swing pump P70 Pump for the air-conditioning system 6.1 Engine cooling pump From: Service manual R 9200 - 410 > Adjustment procedure 4.3.1 | Initial adjustments Fim: Service manual R $200 - 420 > Adjustment procedure > Adjustment procedures 4.3.1.1 | Deactivate the Liebherr Power Efficiency (LPE) (if installed) It installed, the Liebherr Power Eficiency (LPE) must be deactivated at al imes during the adjustment procedures. Deactivate the Liebherr Power Efficiency (LPE) with the "Wizard" computer tool (on your computer: +b Star the software "Scull, + b Select and start the tool Wizard” ‘Copyright © Liebherr Mining Hquipmont SASPrinted by: Zovallos Romulo (LPS) (Romula Zevalos@licbher-com) (Chapter 3 Tochnicl dara + & Go to the “Diagnostic” menu, +» Deactivate the Liebherr Power Efficiency (LPE), Deactivate the Liebherr Power Efficiency (LPE) with the machine keypad ast ~~, CD ‘A171 Optional function keypad 4 Special button for maintenance + b Push the special button for maintenance 1 on keypad A171 From: Service manual R 9200 - 410 > Adjustment procedure > Adjustment procedures > inal adjustments 4.3.1.2 | Deactivate the attachment damping system The damping system of the machine stops the movement of the attachment cyinders before they get suddenly the end positon of the piston rods. necessary, the deactivation ofthis protection is possible. /\ CAUTION! ‘Repetitive movements without the atactiment damping system cause fast wear af she components. Depending onthe machines, the deticated contol can have diferent locations Deactivate the attachment damping system with the machine keypad +» Refer tothe section “Deactivate the Lieber Power Eien (LPE) wth the machine keypad! Deactivate the attachment damping system with the joystick + Move the attachment until the damping system stops it. + > The oyiinders are in thei end stroke position + b Let the two joysticks and pedals in neutral position. | Figure 1, Deactivate the attachment damping system withthe joystick ‘Copyright © Liebherr Moning Hquipment SAS Page 73 0f 98LIEBHERR Printed by: Zovallos Romulo (LPS) (Romula Zevalos@licbher-com) (Chapter 3 Tochnicl dara 555 Down, deactivation ofthe attachment damping system 4 Lett joystick + b Push down rocker switch $55 on left joystick 4 (8) + b The attachment damping system is of + Move back the attachment to automatically start the damping system again ‘Copyright © Liebherr Moning Hquipment SAS Page 74 of 38LIEBHERR Printed by: Zovallos Romulo (LPS) (Romula Zevalos@licbher-com) Chapter 3 Tochnicl ara From: Service manual R 9200 - 410 > Adjustment procedure > Adjustment procedures > Inial adjustments 4.3.2 | Adjust the servo pressure From: Service manval R $200 -410 > Adjustment procedure > Adjustment procedures 4.3.2.1 | Location of components ‘The servo unit SUI is located inside the pumps box. sur Figure 2. Servo pressure adjustment 4 Adjustment screw Ma Test point From: Service manual R 9200 - 410 > Adjustment procedure > Adjustment procedures > Adjust the servo pressure 4.3.2.2 | Adjust the servo pressure +b Install a 100 bar gauge on Ma. + > Operate the engine at maximum RPM, + b Turn the adjustment screw 1 on the servo unit until you get the correct servo pressure on MI, From: Service manual R 8200 - 410 > Adjustment procedure > Adjustment procedures > Adjust the servo pressure 4.3.3 | Adjust the working pumps ‘The procedures that follow are applicable forall working pumps. ‘Copyright © Liebherr Mining Hquipmont SAS Page 75 of 20EBHERR Printed by: Zovallos Romulo (LPS) (Romula Zevalos@licbher-com) Chapter 3 Tochnicl ara From: Service manual R 9200 - 410 > Adjustment procedure > Adjustment procedures. 4.3.3.1 | Location of components Figure 2. Test and adjustment points on working pumps. DA Pressure cut-off adjustment LR Power regulator adjustment 'SD Adjustment of ow contra valve Ma Test point WPF,2,4 HPF (if 4| Figure 2. Primary relief valves and test points onthe high pressure fiters The tables that follow give the relations between the working pumps and the related high pressure fiters, primary relief valves and test points. Working pump 2 -M2i___Test pointon HPE1 related to PRIA __ Working pump 2 -P2__Working pump 2 HPF; efter for ‘Copyright © Liebherr Mining Hquipmont SAS Page 76 of 28EBHERR Printed by: Zovallos Romulo (LPS) (Romula Zevalos@licbher-com) Chapter 3 Tochnicl dara Working pump 2 -vB2___Valve block 2 -PRV21___Primaty relief valve-on VB2 for P2__ -M22_Test point on HPF? related to PRV2L__ Working pump 3 yRe Figure 3. Test points and solenoid valve YR& on servo unit The table that follows gives the relations between the working pumps and the elated test points on the servo unit. [Mz Test point for pumps P2 and P3 [M3 Test point for pumps P1. and Pa ‘YR& Solenoid valve LR. ‘Copyright © Liebherr Mining Hquipmont SASFrom: Service manual R 9200 - 410 > Adjustment procedure > Adjustment procedures > Adjust the working pumps: 4.3.3.2 | Flow control valves (SD) Check the flow control valves + b Install a 100 bar gauge on M1. + Make sure that you have the correct servo pressure. Refer to the section above. + b Operate the engine at maximum RPM, +b check 1 + Do not operate the attachment. + Make sure that you have the correct positioning pressure on M2. +b Check 2 + Lower the attachment until it touches the ground and keep the related joystick actuated + Make sure that you have the correct positioning pressure on Mi +b Ifyou do not find these values, move tothe next section below: Adjust the flow control valves +b Refer to the lacation of components above forthe relations between the working pumps and the related test points on the servo uni. + > Install a 10 bar gauge on M2 and M3, + b Install a 100 bar gauge on M1. +b Make sure that you have the correct servo pressure. Refer to the section above, +b Operate the engine at maximum RPM, + b Do not operate the attachment, eck Figure 1. Pumps settings menu On your computer: + b Star the software *Seul +b Select and start the tool "Wizard +» Goto "Pumps settings” menus + Push butions "+" and" ofthe graph “D1 untl you get the correct pressure on MS + Push butions "+" and ™" ofthe graph °SD2" untl you get the correct pressure on M2.LIEBHERR “apr toehnvat an Printed by: Zovallos Romulo (LPS) (Romula Zevalos@licbher-com) (On each working pum + b Turn the adjustment screw SD until you get the correct pressure on M1 From: Service manual R 8200 - 410 > Adjustment procedure > Adjustment procedures > Adjust the working pumps: 4.3.3.3 | Adjust the power regulators (LR) Make sure thatthe folowing preconcitions are met (© The attachment damping system is deactivated, +b install a 100 bar gauge on Ma. +b Refer to the lacation of components above forthe relations between the working pumps and the related high pressute fers, primary reliet valves and test points M2x +b Install a 600 bar gauge onthe test point Max on the related HPF. +b Make sure that you have the carect servo pressure. Refer tothe section above. + b Operate the engine at 1250 # 5 RPM +b Liftup the attachment and keep the related joystick actuated. + > Turn the related adjustment serew PRV on valve block to get 90 + 2 bar onthe ralated test point M2x + m Disconnect ¥R4 on the servo unit + > Turn the adjustment screw LR untl you get the correc pressure on Mi. +b Connect back RA. +b Adjust again the primary rele valves PRV as given in the section "Primary valves adjustment” From: Service manual R 8200 - 410 > Adjustment procedure > Adjustment procedures > Adjust the working pumps: 4.3.3.4 | Adjust the pressure cut-off (DA) Make sure thatthe folowing preconcitions are met (© The attachment damping system is deactivated. + b Install a 600 bar gauge on Mt. + b Refer to the lcation of components above forthe relations between the working pumps and the related high pressure fiers, primary relief valves and test points M2x. +b Install a 600 bar gauge onthe test point Max on the related HPF. + b Operate the engine at maximum RPM, + b Fully loosen the screw DA. +b Tighten it of two tums. + > Turn the related adjustment serew PRV on valve block to get 330 + S bar on the related test point M2x. + > Lit up the attachment and keep the related joystick actuated, +» Tighten the screw DA to increase the positioning pressure on Mi unt it becomes stable In this case, M2 must be equal to the adjustment value + b Then, slowly loosen DA until M1 pressure stats to decrease, Stop just before Mi pressure starts to decrease, ‘Copyright © Liebherr Mang Zauipment SAS Page 79 0f 98LIEBHERR Printed by: Zovallos Romulo (LPS) (Romula Zevalos@licbher-com) (Chapter 3 Tochnicl dara IML must continue to be equal tothe adjustment value, +b Adjust again the primary relief valves PRV as given in the section “Primary valves adjustment ‘Copyright © Liebherr Mang Zauipment SAS Page 80 of 28(Chapter 3 Tochnicl dara From: Service manual R 9200 - 410 > Adjustment procedure > Adjustment procedures > Adjust the working pumps: 4.3.4| Adjust the swing pump From: Service manual R 8200 - 410 > Adjustment procedure > Adjustment procedures 4.3.4.1 | Location of components Figure 1. Swing pump Dal Pressure cutoff screw 1 - acceleration ff screw 2 - swing deceleration HOVE High pressure ralit serew 1 - secondary valve HDV2 High pressure relief screw 2- secondary valve M1 Test point ofthe pressure M2 Test point ofthe pressure MB Test point ofthe replenishing pressure SDV Replenishing pressure relief valve a2 Pressure cut Figure 2. Solenoid valve ¥7 on servo unit ‘Y7 Solenoid valve swing brake ‘Copyright © Liebherr Mang Zauipment SAS EBHERR: Printed by: Zovallos Romulo (LPS) (Romula Zevalos@licbher-com)LIEBHERR Printed by: Zovallos Romulo (LPS) (Romula Zevalos@licbher-com) (Chapter 3 Tochnicl dara Figure 3, Hose of pressure cutoff valve on swing pump PS From: Service manual R 9200 - 410 > Adjustment procedure > Adjustment procedures > Adjust the swing pump 4.3.4.2 | Adjust the replenishing pressure + b Install 100 bar gauge on M3, +b Operate the engine at maximum RPM, + b if necessary adjust the replenishing pressure with the adjustment screw SDV untl you get the correct pressure on M3. From: Service manual R 8200 - 410 > Adjustment procedure > Adjustment procedures > Adjust the swing pump 4.3.4.3 | Adjust the pressure cut-off - acceleration + > Install 600 bar gauge on Mand M2. + b Operate the engine at maximum RPM, + b Disconnect the solenoid valve Y7. +b Ltt the access ladder (installed) + > Fully actuate the joystick for the swing gear. For each swing direction, the working pressure on MI and M2 must be equal t the adjustment value you do not find this value: +b Tuin the adjustment screw Da untl you get correct pressure on Mand M2. + Connect back the solencid valve V7. ‘Copyright © Liebherr Mang Zauipment SAS Page 82 of 98LIEBHERR Printed by: Zovallos Romulo (LPS) (Romula Zevalos@licbher-com) (Chapter 3 Tochnicl dara From: Service manual R 9200 - 410 > Adjustment procedure > Adjustment procedures > Adjust the swing pump 4.3.4.4 | Adjust the pressure cut-off - swing deceleration + > Stop the engine +b Release hydraulic pressure. Refer tothe Operating Manual + instal 600 bar gauge on Ma and M2. +» Disconnect the hose which is connected to pressure cut-of screw (Oa and Daz). + b Puta cap on this hose + star the engine, Operate the engine at maximum RPM + P-Littup the access ladder (tf installed) + b Disconnect the solenoid valve ¥7 + > Fully actuate the joystick forthe swing gear For each suing direction, the working pressure on MIL and M2 must be equal tothe adjustment value Ifyou donot find this value: +b Tur the adjustment screw Daz untl you get correct pressure on Mi and M2 + > Stop the engine + P Connect the hose on pressure cutoff screw again. +» connect back the solenoid valve 7 From: Service manual R 9200 - 410 > Adjustment procedure > Adjustment procedures > Adjust the swing pump 4.3.4.5 | High pressure relief valves (secondary valves) ‘The high-pressure relief serews HDVI and HOV2 are factory adjusted and sealed + > Do not adjust these valves on a new machine. + Do not aust these valves on anew pump, Ifyou 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 (@ test bench can be used). The secondary valve is not resistant tothe maximum flow ofthe pump. From: Service manual R 9200 - 410 > Adjustment procedure > Adjustment procedures > Adjust the swing pump 4.3.5 | Adjust the cooling pumps The procedures tha follow are applicable for all cooling pumps. ‘Copyright © Liebherr Mang Zauipment SAS Page 83 of 98LIEBHERR Printed by: Zovallos Romulo (LPS) (Romula Zevalos@licbher-com) Chapter 3 Tochnicl ara From: Service manual R 9200 - 410 > Adjustment procedure > Adjustment procedures. 1 | Location of components ior DA P62 Figure 1. Cooling pumps The tables that follow give the relations between the cooling pumps and the related adjustment screws, regulation valves and test points. Engine cooling pump -PG.1_____Engine cooling puma —_ -DA_P6.1____Adjusiment sorew for P6.1__ -Ma2_Test point for 6.1 _ 40.1 Regulation valve for P61 __ il cooling pump -P6.2____oieooling pump __ DA P62 Adjustment serew for PS.2 -MA1____Test point for P62 —__ ¥40.2____Regulation vaive for P62 From: Service manual R 8200 - 410 > Adjustment procedure > Adjustment procedures > Adjust the cooling pumps 4.3.5.2| Adjust the engine cooling pump + > Install 600 bar gauge on MA2, +» Operate the engine at maximum RPM +» Disconnect the regulation valve ¥10.1, +» Control the direction of rotation ofthe fan: the flow must go from outside to inside. + » Turn the adjustment serew DA_P6.1 unti you get he correct pressure on MA2. +b Connect back the regulation valve Y10.1. ‘Copyright © Liebherr Mining Hquipmont SAS Page at of 28LIEBHERR Printed by: Zovallos Romulo (LPS) (Romula Zevalos@licbher-com) (Chapter 3 Tochnicl dara From: Service manual R 9200 - 410 > Adjustment procedure > Adjustment procedures > Adjust the cooling pumps 4.3.5.3 | Adjust the oil cooling pump + Install 600 bar gauge on MAL. +m Operate the engine at maximum RPM. + b Disconnect the regulation valve ¥10.2 +m Control tne drection of rotation ofthe fan the flow must go from outside to inside + Tum the adjustment screw DA_P6.2 unl you get the correct pressure on MAL. +m connect back the regulation valve Y102 From: Service manual R 9200 - 410 > Adjustment procedure > Adjustment procedures > Adjust the cooling pumps 4.3.5.4 | Cooling motors The cooler fan motors MF and ME2 are factory adjusted and sealed, + b Do not adjust these valves on a new machine + b Do not adjust these valves on a new pump you ave 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). From: Service manual R 9200 - 410 > Adjustment procedure > Adjustment procedures > Adjust the cooling pumps 4.3.6 | Adjust the primary and secondary valves From: Service manual R 8200 - 410 > Adjustment procedure > Adjustment procedures 4.3.6.1 | Location of components Figure 1. Valves and high pressure fiers instalation 1 Working pump PA PRVLI Primary telef valve 1 on VBI ‘Copyright © Liebherr Mang Zauipment SAS Page 85 of 98LIEBHERR Printed by: Zovallos Romulo (LPS) (Romula Zevalos@licbher-com) (Chapter 3 Tochnicl dara 2 Working pump P2 PRVI2 Primary relief valve 2 on VB 3 Working pump P3 PRV21 Primary relief valve 1 on VB2 4 Working pump Pa PRV22 Primary tellef valve 2-on VB2 HPF High pressure filer for PL SRV Secondary rele! valve HPF?2 High pressure fiter for P2_VB1 Valve block 1 HPE3 High pressure iter for P3__VB2 Valve block 2 HPF4 High pressure fitr for Pa ‘Copyright © Liebherr Mang Zauipment SAS Page 86 of 28EBHERR Printed by: Zovallos Romulo (LPS) (Romula Zevalos@licbher-com) (Chapter 3 Tochnicl dara From: Service manual R 9200 - 410 > Adjustment procedure > Adjustment procedures > Adjust the primary and secondary valves 4.3.6.2 | Adjust the secondary valves The secondary valves are factory adjusted and sealed + b Do not adjust these valves on a new machine. + b Do not adjust these valves on a new pump. 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). I 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. NOTE! AWD) te asiust ne secondary valves. the primary va tbe de-rated, then adjusted, er to the related sect Adjust the attachment secondary valves ‘The attachment secondary valves are adjusted on the valve blocks. + Install 600 bar gauge on all HPF. + b Operate the engine at maximum RPM. + > Fully ighten al he primary valves PRV and loosen itby one tun. + > Do the eelated movement +b Turn the adjustment screw SRV unl you get the corect pressure P. +b Adjust again the primary relief valves PRV as given in the section Primary valves adjustment Adjust the secondary valve of the shovel flap (with shovel attachment only) The secondary valve of the shovel fap is adjusted on the shovel back, Figure 1, Secondary valve of the shovel fap ‘Copyright © Liebherr Moning Hquipment SAS Page 87 of 98Printed by: Zovallos Romulo (LPS) (Romula Zevalos@licbher-com) LIEBHERR (Chapter 3 Tochnicl dara 1 Shovel back DBF Distribution block for shovel flap cylinder 2 Shovel lap cyinder SRV Secondary relief valve +b Insta a 600 bar gauge on HPF + b Operate the engine at maximum RPM, + > Fully ghten the primary valve PRVZ3 and loosen by one tur, + > Do the related movement + > Turn the adjustment serew SRV untll you get the corect pressure P. +b Adjust again the primary relief valve PRV23 as given in the section "Primary valves adjustment Adjust the travel secondary valves (motor integrated) ‘This section is applicable tothe travel secondary valves that are directly adjusted on the travel motor. Thus, this motor has dedicated adjustment screws and test points that are integrated on its housing, The procedures that follow are applicable for all travel gears + b Before you adjust the secondary valves on the travel gears, you can position the excavator against an appropriate obstacle to use it asa stop ifnecessary. If the hydraulic ois too hat, itis possible that you cannot get the correct pressure. +b ifnecessary, let the hydraulic oll temperature decrease. Location of components mi) sPRVE Figure 2. Secondary valves on right travel gear BWD — Rearward travel direction FWD — Forward travel drection Ma(B) Test point for rearward travel direction Ma(F) Test point for forward travel direction SPRVB_ Adjustment screw for rearward travel direction SPRVF Adjustment serew for foward vavel direction ‘Copyright © Liebherr Mang Zauipment SASLIEBHERR Printed by: Zovallos Romulo (LPS) (Romula Zevalos@licbher-com) ‘Chapter 3 Tochnical dara Figure 3, Secondary valves on left ravel gear WD — Rearward travel ditection FWD Forward travel direction M2(B) Test point for rearward travel direction MI(F) Test point for forward travel direction SPRVB_ Adjustment screw for rearward travel direction SPRVF Adjustment screw for foward travel direction Figure 4. Solenoid valve ¥6 on servo unit Y6 Solenoid valve travel brake Adjust the travel secondary valves +b Make sure the related secondary valves on the vaive blocks are fully tightened. + b Install a 600 bar gauge on the test points M()F and MOB, +b Operate the engine at maximum RPM, + b uly tighten all the primary valves PRV and loosen itby one turn +b Disconnect the travel brake solenoid valve Y6, + b Lit up the access ladder. + b Disable the travel brake with the elated “Travel brake" button on the A168 keypad, Refer to the Operating Manual + b Actuate the travel pedal inthe forward travel direction, Keep actuated. + b Monitor the pressure on the test point M(x. In this case, the pressure on M(x)F must be equal to the adjustment value. ‘Copyright © Liebherr Mang Zauipment SAS Page 89 of 98LIEBHERR chaportortneat dni _‘P*Stet 3 Zeal Romulo LPH ManaloZavaex@dner:com) you do not find this value: + b Release the travel pedal + b Loosen the locknut. Turn the adjustment screw SPRVF on the travel motor. + b Actuate the travel pedal again. Monitor the pressure on the test point M(x). +b Tighten the locknuts again, Then: + b Actuate the travel pedal in the rearward travel drecton. Keep actuated +b Monitor the pressure on the test point M(x)B. In this case, the pressure on M(x)B must be equal to the adjustment value. Ifyou do not find this value: + b Release the travel pedal + b Loosen the locknut. Turn the adjustment screw SPRVB on the travel motor + b Actuate the travel pedal again, Monitor the pressure on the fest point M\()B. + b Tighten the locknuts again, + b Connect back the travel brake solenoid valve Y6. +b Adjust again the primary relief valves PRV as given in the section “Primary valves adjustment” From: Service manual R 9200 - 410 > Adjustment procedure > Adjustment procedures > Adjust the primary and secondary valves 4.3.6.3 | Adjust the primary valves +b instal 600 bar gauge on all HPF. +» Operate the engine at maximum RPM + > Fully retract he stck cylinders supplied by the purnp and keep the joystick actuated. + > Tum all the adjustment screws PRV unti you get the correct pressure P. From: Service manual R 8200 - 410 > Adjustment procedure > Adjustment procedures > Adjust the primary and secondary valves 4.3.7 | Track tensioning system This section is applicable tothe hycraulic rack tensioning system that i installed in the undercavtiage central par, with related shutoff valves and track tensioning blocks. From: Service manual R 9200 - 410 > Adjustment procedure > Adjustment procedures 4.3.7.1 | Location of components The two sides left and right ofthe tensioning unit are symmetrical ‘Copyright © Liebherr Mang Zauipment SAS Page 90 of 98LIEBHERR Printed by: Zovallos Romulo (LPS) (Romula Zevalos@licbher-com) ‘Chapter 3 Thiel dara Figure 1. Hydraulic components for tensioning unit (one side) 1 Hyraulic hose connected to the hyeraulic cylinder HC CVT Three-way valve 2 Hydraulle hose connected tothe hydraulic tank T HE Hydraulic cylinder 3 Hydraulic hose connecter the tack tensioning block KSB T Hydraulic tank (through the rotary connection) 4 Not used (hydraulic hose connected between KSB andT) KSB Track tensioning block From: Service manual R 8200 - 410 > Adjustment procedure > Adjustment procedures > Track tensioning system 4.3.7.2 | Adjust the track tension for the first time A CAUTION! ‘On new excavator, the grease cylinder can burst after only a small number of working hours. This damage is caused by ‘rack pre-lensioning done before the transport of the undercavriage, which is made with the grease cylinder (in this case, there is no hydraulic power and thus no pressure in the track tensioning eyinder) If the machine works in such conditions, the track tensioning cylinder does not ts function, and the diferent external stresses applied on the track are not absorbed, This can cause a grease cylinder falure. ‘You must do the procedure that follows before you start the excavator forthe ist time, + b Make sure thatthe to valves SVT (right and left) are fully tighten, + > Make sure that the wo three-way valves CVT (right and lef) are turned to connect the hose 4 tothe hose 3 + b Operate the engine at maximum RPM, +b Tuin the uppercarriage by 90°. Lit the side which has to be adjusted 2 Figure 1. Grease fiting for grease cylinder + b Loosen the grease fiting 2. D0 not remove the fiting fully. ‘Copyright © Liebherr Mang Zauipment SAS Page ot of 98LIEBHERR Printed by: Zovallos Romulo (LPS) (Romula Zevalos@licbher-com) (Chapter 3 Tochnicl dara A DANGER! Risk of injury because of + sudden falling of the track chain + aspray of grease under high pressure When you release the track tension: +» Aways wear protectve gloves and glasses. + > Keep your head away from the opening 2 in the track side tame. +m Do not touch the grease nipple 2 with your hands. Always use an applicable tool loosen oF tighten i +» To tighten or loosen the grease nipple 2, aways catch atts ear part and never a its front par. +» Actuate the travel pedal related tothe side which has to be adjusted Grease and hydraulic eyinder rod come out, Figure 2. Hydraulic ylinder postion forthe fist time adjustment +» Stop when the hycraulic cylinder rodis out by the correct distance A + b Tighten the grease fitina +» Adjust te tack tension as given in the Operating Manual. +b Repeat the same procedure forthe other track chain From: Service manual R 9200 - 410 > Adjustment procedure > Adjustment procedures > Track tensioning system 4.3.7.3 | Do a standard adjustment of the track tension A DANGER! +b Before you adjust the track tensioning system, you can position the excavator with the idler side against an appropriate obstacle to use tas a stop it necessary, +b Make sure that the two valves SVT (ight and left) are fully tighten. + Make sure thatthe two three-way valves CVT (right and let) are tuned to connect the hase 1 to the hose 3 +b Aiways adjust the track chains separately, Start by adjusting one track chain, Then adjust the other. ‘Copyright © Liebherr Mang Zauipment SAS Page 92 of 98LIEBHERR Printed by: Zovallos Romulo (LPS) (Romula Zevalos@licbher-com) (Chapter 3 Tochnicl dara Adjust the right side All the components that follow are retated tothe right sid. + b Install a 600 bar gauge on the test points ML and M2 on KSB. + b Operate the engine at maximum RPM, + b Disconnect the travel brake solenoid valve Y6. + b-Lit up the access ladder. + b Disable the travel brake with the related “Travel brake" button an the A168 keypad, Refer to the Operating Manual +b Actuate the travel pedal related to the track chain you want to adjust. +b Loosen the locknut and fully tighten the PRV adjustment screw on KSB, in order to let the pressure go totally through. + Tum CVF to connect the hose 2 tothe hose 2. +b Loosen the locknut and turn the LVT adjustment screw until you get the correct pressure on M2. +b Tighten the locknut on LVT again, + Turn back CVT to connect the hose 1 tothe hose 3, +b Stop actuate the travel pedal + b Fully loosen the PRV adjustment screw, +b Tuin CVT to connect the hose £ tothe hose 2 + b Tum back CVT to connect the hose 1 tothe hose 3 + b Tuin the PRV adjustment screw until you get the correct pressure on Mi. +b Tighten the locknut on PRV again + b Connect back the solencid valve ¥6. Adjust the left side + b Do the same procedure om the lft track chain, withthe components related tothe let side, From: Service manual R 8200 - 410 > Adjustment procedure > Adjustment procedures > Track tensioning system 4.3.8 | Adjust the displacement shift for travel motors Figure 1. Adjustment ofthe displacement shift for travel motors, ‘Copyright © Liebherr Mang Zauipment SAS Page 93 of 98LIEBHERR Printed by: Zovallos Romulo (LPS) (Romula Zevalos@licbher-com) (Chapter 3 Tochnicl dara PRV1 Pressure reducing valve 1 Valve bank M_PRV1 Test point 2 Adjustment screw + b Insta a 100 bar gauge on M_PRVLL +b stare the excavator + Operate the travel high speed withthe related "High speed gear” button on the A270 keypad. Refer tothe Operating Manual, +b Turn the adjustment screw 2 on the pressure reducing valve PRV1 until you get the correct pressure on M_PRV1 ‘Copyright © Liebherr Mang Zauipment SAS Page 94 of 28LIEBHERR Printed by: Zovallos Romulo (LPS) (Romula Zevalos@licbher-com) (Chapter 3 Tochnicl dara From: Service manual R 9200 - 410 > Adjustment procedure > Adjustment procedures 4.3.9 | Adjust the hydraulic air-conditioning system Depending an the machines, there can be an air-conditioning system that operates with hydraulically driven compressor(s) and a special hydraulic supply pump. A ‘CAUTION! Risk of damage, ‘On a new hydraulic pump, a too high speed can cause damage to the system +» When you start the air-conditioning system forthe frst time or after a replacement ofthe hydraulic pump P70, you must /oosen the speed adjustment screw X_P70 by three turns before you do the adjustments that follow. From: Service manual R 9200 - 410 > Adjustment procedure > Adjustment procedures 4.3.9.1 | Location of components The standard hydraulic at-condtioning system has a condenser unit, wich is installed on the outer side ofthe cab elevation, This condenser unit has a compressor with its hydraulic motor and a special hydrauile supply pump. This purnp is installed on the spliterbox. ‘The machine can have an optional second air-conditioning system. In this case, two condenser units are installed on the outer side of the cab elevation. The two condenser units are the same and they are supplied by the same special hydraulic pump. Test point on the compressor(s) Figure 1. Condenser unit(s) and compressor 1 Condenser unit of standard ai-consltioning system 3 Compressor 2 Condenser unit of optional second air-conditioning system (installed) 4 Hydraulic motor The housing of the compressor 3 has tow special openings to let access to the shaft ofthe motor 4 ‘Copyright © Liebherr Mang Zauipment SAS Page 95 of 98EBHERR: Printed by: Zovallos Romulo (LPS) (Romula Zevalos@licbher-com) Chapter 3 Tochnicl ara Test and adjustment points on the pump for the air-conditioning system Figure 2. Pump for the air-conditioning system P70 Pump forthe air-conditioning system DA Adjustment screw of pump pressure cutoff X_PTO Speed adjustment screw ‘M_P70 Pump test point ‘The hydraulic pump P70 is installed on the spliterbox. The pump P70 supplies the hydraulic motor of the compressor. Test point on the control valve SVC PRV_SVAC ves Figure 8, Location of the solenoid valve(s) ¥aao PRV_SVAC Adjustment screw V_SVAC Manual valve SVAC Selector valve -Y449 On-off solenoid valve “The solenoid valve 449 and the manual valve V_SVAC are installed in the cab elevation, This solenoid valve controls the hydraulc supply ofthe matar. Ifthe machine has an optional second air-conditioning system, it contrals the alternative operation of the two rotors. ‘Copyright © Liebherr Mining Hquipmont SASLIEBHERR Printed by: Zovallos Romulo (LPS) (Romula Zevalos@licbher-com) (Chapter 3 Tochnicl dara From: Service manual R 9200 - 410 > Adjustment procedure > Adjustment procedures > Adjust the hydraulic ar-condltioning system 4.3.9.2 | Pre-adjust the compressor speed +b Ifnot installed, atach a smal reflective target to the motor shaft ofthe condenser unt 1 oF 2. + b Make sure thatthe ol temperature is more than 60°C. + b Operate the Diesel engine at 1000 + 10 RPM, + b Start the air-conditioning unit related to te compressor which has the reflective target. Refer to the Operating manual + Fully loosen the screw X_P70 on the pump P70. Tighten it by 34% turns. +b Point a tachometer towards the target and turn the sctew X_P70 until you get the correct speed on the motor shat. +» Move to next section below. From: Service manual R 8200 - 410 > Adjustment procedure > Adjustment procedures > Adjust the hydraulic air-conditioning system 4.3.9.3 | Adjust the control valve pressure + b Install a 600 bar gauge on M_P70 on the pump P70. + b Loosen the screw PRV_SVAC on the selector valve SVAC. +b Fully tighten the serew DA on the pump P70, + b Operate the Diesel engine at 1000 + 10 RPM, +b Start the ai-conkltioning unit 1. Refer to the Operating manual + b Close the manual valve V_SVAC. +b Tuin the screw PRV_SVAC untl you get the correct pressure on M_P70. \When this adjustments completed: + b Let the manual valve V_SVAC closed + b Let the gauge installed on M_P70. + Move to next section below, From: Service manual R 9200 - 410 > Adjustment procedure > Adjustment procedures > Adjust the hystraulic ar-condltioning system 4.3.9.4 | Adjust the pump pressure cut-off + b Operate the Diesel engine at 1000 + 10 RPM, +b Star the air-conditioning unit 1. Refer to the Operating manual + b Tum the screw DA unti you get the correct pressure on M_P70. + b Open the manual valve V_SVAC. + Move to next section below, ‘Copyright © Liebherr Mang Zauipment SAS Page 97 of 98LIEBHERR Printed by: Zovallos Romulo (LPS) (Romula Zevalos@licbher-com) (Chapter 3 Tochnicl dara From: Service manual R 9200 - 410 > Adjustment procedure > Adjustment procedures > Adjust the hydraulic ar-condltioning system 4.3.9.5 | Check the compressor speed + b Operate the Diesel engine at maximum REM. + Do acheck of the motor shaft speed again as given above, +b ifnecessary, adjust the speed withthe screw X_P70 again, From: Service manual R 9200 - 410 > Adjustment procedure > Adjustment procedures > Adjust the hydraulic air-conditioning system ‘Copyright © Liebherr Mang Zauipment SAS Page 98 of 98