Chapter 7 - Attachment / Travel System: Service Manual

Service Manual
Chapter 7 - Attachment / Travel system

Attachment / Travel systems ........................................................................................................................... 7-2
1 Adjustment........................................................................................................................................ 7-2
1.1 Adjustment values .................................................................................................................. 7-2
LFR/en/version: 08 / 2007
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Service Manual
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Service Manual Attachment / Travel systems
Schematic
7 Attachment / Travel systems
7.1 Schematic
Hydraulic cylinders Hydraulic pumps

CB1 right boom cylinder PL1 lubrication pump
CB2 left boom cylinder P1 working pump no. 1
CBT1 right bucket tilt cylinder P2 working pump no. 2
CBT2 left bucket tilt cylinder P3 working pump no. 3
CS1 right crowd cylinder P5.1 rear swing pump
CS2 left crowd cylinder P5.2 front swing pump
CF1 right shovel flap cylinder P6.1 water cooler fan pump
CF2 left shovel flap cylinder P6.2 oil cooler fan pump
CLL ascent ladder lock cylinder P8 splitterbox lubrification pump
CLS service station lock cylinder P9 pilot oil pump
CS1 right stick cylinder P12 electro-hydraulic pump. ladder + service

CS2 left stick cylinder station
CSS service station cylinder
CBT1 right shovel tilt cylinder Hydraulic motors

CBT2 left shovel tilt cylinder MF1 oil fan motor
RCL rotating cylinder ladder MF2 water fan motor
MS1 left swing motor
Hydraulic valves MS2 right swing motor
SU1 servo oil unit MTL1 front left travel motor
RC rotary connection MTL2 rear left travel motor
DBF distribution block shovel flap cylinders MTR1 front right travel motor
UBV overspeed shut off valve MTR2 rear right travel motor
VB1 control valve 1
VB2 control valve 2 Tank / collecting pipe

VB3 control valve 3 CP0 collecting pipe servo oil
VB4 control valve 4 CP1 collecting pipe. hydraulic tank
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Attachment / Travel systems Service Manual
Schematic
COP1 control plate ladder CP2 lower collecting pipe. support control val-
COP2 control plate service station ves
CP3 collecting pipe power pack
Gears CP4 collecting pipe before oil cooler
GS1 swing gear left CP5 collecting pipe after oil cooler
GS2 swing gear right CP6 collecting pipe for control valves
GTR travel gear right HT hydraulic tank
GTL travel gear left LF leakoilfilter
HF hydraulic filter
Oil sample points SP suction pipe
OSP1 oil sample point. hydraulic oil
OSP2 oil sample point splitterbox
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Hydraulic pump assembly
7.2 Hydraulic pump assembly
7.2.1 Technical data
Machine model / Serial No R 9250 Litronic / 13466
Splitterbox Type Rexroth mobilex GFC 320 1002

Direction of rotation (seeing splitterbox pump side) Counterclockwise

Nominal RPM at drive shaft Min-1 1800
Reduction ratio, engine to main pumps P1 & P2 1.213
Reduction ratio, engine to main pump P3 0.809
Reduction ratio, engine to swing pumps Ps1, Ps2 0.638
Reduction ratio, engine to cooling pumps P6.1 & P6.2 0.809
Reduction ratio, engine to auxiliary pumps P8 & P9 0.638
Splitterbox description, see chapter 15
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Main pumps (P1 & P2) Number Type 1 double pump A 20 VSO 520
Nominal RPM Min-1 1484
Direction of rotation (seeing splitterbox pump side) Clockwise
Regulation beginning at 161 bar L/min 1508
Regulation end at 300 bar (pressure cut off) L/min 810
Flow at 320 bar (primary pressure relief valve L/min 100
Max. power consumed kW 879
Main pumps description, see subgroup
Main pumps (P3) Number Type 1 pump A 11 VLO 260

Pump delivery max Cm3 260
Pump flow max L/min 580
Swing pumps (Ps1 & Ps2) Number Type 1 double pump A 4 VG 125
Cooling pumps (P6.1 & P6.2) Number Type 1 double pump A 11 VO 75 DRX
Geared oil pump (P8 & P9) Number Type 1 pump AZPNF-12-028
Pump delivery max Cm3 28(P8)+19(P9)=47
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P1 Working pump Nb 1
2 Pump gear
3 Positioning piston
4 Power regulator
5 Piloting valve
6 Switching valve - Flow control
7 Pressure control valve
Pst Test point / Flow adjustment
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Mst Test point / Pump high pressure
MB Test point / Pump high pressure
P Test point / Control pressure
2 Pump gear
4 Power regulator
Ps1 Swing pump Nb1
Ps2 Swing pump Nb 2
P6.1 Water cooler fan pump
P6.2 Oil cooler fan pump
P8 Splitterbox lubrification pump
P9 Pilot oil pump
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Functional description
7.3 Functional description
The attachment and travel system on the excavator can be separated in two parts :
– the power circuit composed of pumps, valve blocks, motor, cylinder, etc.
– the electro-hydraulic control system.
7.3.1 Electro-hydraulic system

The purpose of the electric pilot system is to activate the different attachment, travel and swing movements of
the machine, proportionally to the deflection of the servo control levers and pedals.
Each servo control unit delivers an electrical signal depending on its deflection.
The FSG plate amplifies this signal so that it is sufficient strength to supply the regulating solenoid valve Yr...
and the switching solenoid valves Y... which are mounted in series.
The regulating solenoid valves Yr... control the spools in the 3 control valve blocks and distributor block on the
attachment, and swing pumps via the torque control regulators (TCV).
The logical solenoid valves Y... prevent the concerned movement to be supplied when the servo unit controlling
this movement is in neutral position.
The FSG plate A1020 also elaborates the switching logic determining the priorities in the summation of the dif-
ferent hydraulic pump flows. This switching logic is used to commute the switching solenoid valves Y... and so
to control the oil flow supplying a movement.
The hydraulic part of the system consists of the servo oil circuit (i.e. of the pump P9, servo oil unit SU1) which
supplies the servo pressure to the regulating solenoid valves Yr... via the switching solenoid valves Y... .
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7.3.2 Power circuit
7.3.2.1 Hydraulik tank and oil filters
The hydraulic tank 1 contains the hydraulic oil for the complete system. Baffle plates inside the tank prevent
hydraulic oil turbulence during machine operation.
The three return oil filter housings 2 are located on top of the tank. They consist in magnetic rods and paper
filter.
All return oil flows via the collector pipe and the filters back to the tank.
The leak oil filter housing 3 is located on top of the hydraulic tank. It consists in magnetic rods and paper filter.
All leak oil flows via this filter back to the tank.
During cold start, or if the filter element is contaminated, the oil can return to the tank via a bypass valve which
is integrated in the filter.
For the maintenance of tank 1 and filters 2 and 3, see maintenance schedule and instruction manual.
7.3.2.2 The hydraulic working pumps
Hydraulic pumps convert mechanical energy into hydraulic energy. They are driven by the diesel engine via
the splitterbox. The working pump assembly consists of two double variable displacement pumps.
Each pump unit is designed as a pump in axial piston swash plate design. The pump flow is in proportion to
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the output RPM and the pump angle.

Pump regulation can be separated in three parts :
– power regulation
– pump pressure limitation
– flow regulation
For description of construction and function see subgroup working pump.
7.3.2.3 Control valve blocks
The oil from each working pump flows directly to the pressure connection on the corresponding control valve
block (one working pump supplies one control valve block).
When all spool valves are in neutral position, oil issued from the working pumps, flow via the spool valves di-
rectly to connection T and from there to the tank.

The spool valves are actuated hydraulically via the pressures applied to the connections from the electro-hy-
draulic control system (Solenoid valves, servo pressure, logic control and joysticks) and control all excavator-
working functions.
The primary pressure relief valves, which are installed in the control valves blocks, protect the hydraulic system
against pressure peaks above 320 bar between pump unit and control valves blocks.
Suction valves are integrated in the valve blocks to prevent cavitation during certain working movements in cy-
linders and travel motors.
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The spool valves for right and left travel are fitted with hydraulic brake valves. They prevent the travel motors
from overspeeding when travelling on steep inclines. These spool valves are equipped with secondary pressu-
re relief valves to protect the travel circuits and to reduce pressure peaks between the control valve blocks and
the hydraulic motors when the spool valves are closed.
The control valve blocks are maintenance free. For description of use, function and resealing see subgroup.
The secondary pressure relief valves are also installed in the control valve blocks. They protect the different
circuits and reduce the pressure peaks between the control valve blocks and the hydraulic cylinders when the
spool valves are closed.
7.3.2.4 Hydraulic oil cooling
The return oil from control valve blocks, connection T, is collected and return to tank (collecting pipe CP1),
either via oil coolers or via pretension valves.
The oil coolers are cooled by outside air with two fans, which are driven hydraulically (see chapter Cooling Sys-
tems).
In order to prevent pressure peaks in the oil coolers when the hydraulic oil is cold (high viscosity), the check
valves (pretension valves), which are adjusted to 3 bar, opens and allows the return oil from the control valve
blocks to flow directly to the collecting pipe CP1.
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7.3.2.5 Hydraulic rotary connection
The rotary connection is special connection, which transfers hydraulic oil from the uppercarriage to the under-
carriage. The rotary connection has 6 inlets (from uppercarriage) and 6 outlets (to the undercarriage).
Pressurised oil is led to the four travel motors via four inlets (1, 2, 3 and 4) and four outlets (1, 2, 3 and 4)
The pressurised oil necessary to the tensioning unit is also led to the track tension cylinders via four inlets (1,
2, 3 and 4) and four outlets (1, 2, 3 and 4).
The pressurised oil necessary to release the travel brakes is also led to the brakes via four inlets (1, 2, 3 and
4) and four outlets (1, 2, 3 and 4).
The servo oil necessary to shift the excavator from moderate travel speed to maximum travel speed flow throu-
gh one of the two central channels.
The leak oil from travel motors and tensioning unit flows through the second central channel.
The rotary connection is maintenance free.
7.3.2.6 Attachment cylinders and motors

Hydraulic actuators convert hydraulic energy into mechanical energy. We differantiate two kinds :
Hydraulic actuators, which transfer force in a straight line with a limited stroke, as hydraulic cylinders. For des-
cription of function or resealing of hydraulic cylinders, see subgroup.
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Hydraulic actuators, which transfer torque in a continuously rotating motion, as oil motors. For a description of
function, see subgroup.
7.3.3 Electro-hydraulic pilot control system

The purpose of the electric pilot control system is to activate the different attachments, travel and swing move-
ments of the machine, proportionally to the deflection of the servo control levers and pedals.
Each servo control unit delivers an electrical signal depending on its instantaneous deflection.
The FSG plate amplifies this signal so that it is sufficient strenght to supply the regulating solenoid valves Yr...
and the switching solenoid valves Y... which are mounted in series.
The solenoid valves are located on the control valve console (attachment and travel movements) and on the
torque control valves for the swing pumps (swing movements).
The regulating solenoid valves Yr... control the spools in the 3 control valve blocks and distributor block on the
attachment, and swing pumps.
The logical solenoid valves Y... prevent the concerned movement to be supplied when the servo unit controlling
this movement is in neutral position.
The FSG plate A1020 elaborates the switching logic determining the priorities in the summation of the different
hydraulic pump flows. This switching logic is used to commute the switching solenoid valves Y... and so to con-
trol the oil flow supplying a movement (see chapter logic system).
7.3.3.1 Pilot control units

Both electronic and mechanical remote control components are integrated in each pilot control unit.
Mechanical components
• Joysticks :
The mechanical component consists of a joystick, which can be deflected, in any direction. A spring returns the
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hand lever to its center (neutral) position.

The deflection of the joystick is transmitted to two stroke sensors which provide the input signals for the elec-
tronic components.
The hand lever is moved through a gate, which ensure that full diagonal deflection results in full x- and y-axis
movement.
• Pedals :
The mechanical component consists of a footplate, which is movable around an axis.
A spring returns the footplate to its center (neutral) position.
The deflection of the footplate is transmitted to a stroke sensor, which provides the input signal for the electro-
nic components of the pedal transmitter.
Electronic components
• In each pilot control unit (joystick or pedal), the output signal of each stroke sensor is applied to a compo-
nent. This component delivers an output proportionally to the deflection of the pilot control unit.
• This signal is then amplified by the FSG plate A1020 in order to be sufficient strength to supply the regu-
lating solenoid valves on the control valve console (attachment and travel movements) and on the torque
control valves for the swing pumps (swing movements).
Since the regulating solenoid valves are driven with impressed current, the influence of resistance changes in
the coils (for example, due to temperature differences) is suppressed.
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7.3.3.2 Servo oil circuit
Technical data
Control oil pump P9
Nominal RPM min-1 2820
Pump delivery max cm3 19
The servo pressure is used for :

– spool valves movements.
– centralised lubrication.
– swing control (torque control).
– pressureless falling for boom.
– swing brake.
– travel speed.
– regulation of the working pumps.
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Schematic servo oil circuit
B84 Pressure switch / servo control Y100 Solenoid valve boom extend 1
CP0 Collecting pipe servo oil YR100 Adjustment solenoid valve extend 1
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CP2 Lower collecting pipe support control val- Y101 Solenoid valve boom extend 2
ves YR101 Adjustment solenoid valve extend 2
CP6 Collecting pipe for control valves Y102 Solenoid valve boom extend 3
GS1/2 Swing gear left and right YR102 Adjustment solenoid valve extend 3
P1 Control pressure port on working pumps Y105 Solenoid valve boom retract 1
P1, P2 Working pumps YR105 Adjustment solenoid valve boom retract 1
P6.1 Water cooler fan pump Y106 Solenoid valve boom retract 2
P6.2 Oil cooler fan pump YR106 Adjustment solenoid valve boom retract 2
P9 Pilot oil pump Y107 Solenoid valve boom retract 3
PL1 Lubrification pump YR107 Adjustment solenoid valve boom retract 3
RC Rotary connection Y110 Solenoid valve crowd extend 1
SU1 Servo oil unit YR110 Adjustment solenoid valve crowd extend 1
VB1 Control valve 1 Y111 Solenoid valve crowd extend 2
VB2 Control valve 2 YR111 Adjustment solenoid valve crowd extend 2
VB3 Control valve 3 Y112 Solenoid valve crowd extend 3
VB4 Control valve 4 YR112 Adjustment solenoid valve crowd extend 3
Y3.1 Regulation solenoid valve - flow control on Y115 Solenoid valve crowd retract 1
P1 YR115 Adjustment solenoid valve crowd retract 1
Y3.2 RSV - flow control on P2 Y116 Solenoid valve crowd retract 2
Y4.1 RSV - power regulation for working pumps YR116 Adjustment solenoid valve crowd retract2
Y7 SV - swing brake Y120 Solenoid valve shovel tilt extend 1
Y94 RSV - high speed travel YR120 Adjust. solenoid valve shovel tilt extend1
Y136 RSV - pressure cut off elevation Y121 Solenoid valve shovel tilt extend 2
YR121 Adjust. solenoid valve shovel tilt extend 2
Y122 Solenoid valve shovel tilt extend
YR122 Adjust. solenoid valve shovel tilt extend 3
Y125 Solenoid valve shovel tilt retract 1
YR125 Adjust. solenoid valve shovel tilt retract1
YR126 Adjust. solenoid valve shovel tilt retract 2
YR127 Adjust. solenoid valve shovel tilt retract 3
Y130 Solenoid valve shovel flap in
YR130 Adjust. solenoid valve shovel flap in
Y132 Solenoid valve shovel flap out
YR132 Adjustment solenoid valve shovel flap out
Y140 Solenoid valve travel right backward
YR140 Adjust. solenoid val. travel right backward
Y141 Solenoid valve travel right forward
YR141 Adjust. solenoid valve travel right forward
Y142 Solenoid valve travel left backward
YR142 Adjust. solenoid valve travel left backward
Y143 Solenoid valve travel left forward

YR143 Adjust. solenoid valve travel left forward
Y144 Solenoid valve sum travel forward
YR144 Adjust. solenoid valve sum travel forward
Y148 Solenoid valve parallel travel
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Servo oil circuit : components location
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The geared pump P9 feeds the servo oil unit SU1.
The pressure relief valve in SU1 limits the servo pressure to 55 bar. The hydraulic oil flow through the filter
mounted in by-pass with a check valve and feeds in parallel the different outputs for SU1 and the RSV Y3.1,
Y3.2, Y3.3, Y4, Y7, Y94 and Y136.
The different outputs are :
– P1 : connection for grease system, spool valves DBB (Distribution Block - Boom) and Y136 (cut off pressure
elevation) supply.
– P2 : not used.
– P3 : connection with servo control pressure port P1 of working pumps.
– P4 and P5 : not used.
– P6 : connection with control pressure port P1 of torque control valve.
– A1 : connection between Y94 (high speed RSV) and rotary connection.
– A2 : connection between Y3.1 and port PST of P2.
– A3 : connection between Y3.2 and port PST of P4.
– A4 : connection between Y3.3 and port PST of P1 and P3.
– A5 : connection between Y7 and GS1/2 (swing brake).
– A6 : connection between Y4 and port XLR of P1, P2, P3 and P4.
The hydro-accumulator is used like an oil pressure reserve for the servo pressure circuit. In case of engine stop
(emergency shutdown, engine failure, ...) the operator can use this oil pressure reserve to activate the spool
valves and thus to move the equipment (to let the boom go down for example).
7.3.3.3 Logic system

On the hydraulic excavator R 9250, the spool valves are controlled electronically (joysticks, prinplates and so-
lenoid valves).
A movements combination is possible but it is controlled by a switching logic which determines the priority for
the movements in relation with the input (movement which are commanded from the operator through the joys-
ticks pedals).
This switching logic is necessary to distribute equitably the oil flows of the different working pumps in the diffe-
rent receivers (cylinders, hydraulic motors).
Without this switching logic, some of movement combinations are impossible and the speeds of the movements
are uncoordinated (for example : flow from 5 pumps for one movement and flow from 2 pumps for another).
The switching logic use the logical outputs of the servo control units to commute the switching solenoid valve
Y..., which are mounted in series with the regulating solenoid valves Yr... .
The priority list of the switching logic is programmed in the FSG plate A1020.
Proximity switches are installed on the attachment in order to amortise the end strokes of the cylinders.
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Solenoid valves function

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To read and understand the priority list

Movement :
– h : Boom
– v : Stick / Crowd
– s : Shovel / Bucket tilt
– f : Travel
– k : Shovel flap / Option
1 LED ON, solenoid valve ON, control block switched ON / output ON

Controlled full rate pumps / input ON
1/0 0 : cutoff by : 1. Boom up and shovel tilt
2. Boom down and no signal from B76 (attachment on floor) and shovel tilt
Y94 : at travel forward dependent from S21

at travel backward / automatically ON
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Proximity transmitters
The excavator R9250 is equipped with proximity transmitters for each cylinder movement. These transmitters
detect the end stroke of the cylinder.
When a cylinder stroke end is detected, the information is sent to the FSG plate A1020 (connector X82). The
FSG plate A1020 closes completely or partially the solenoid valves which control the movement.
These transmitters allow to prevent the shocks when the cylinders come to end stroke.
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• Board of the proximity transmitter effects on the solenoid valves for backhoe attachment
Beginning of End of the
the movement movement
Y100 Y101 Y102 Y100 Y101 Y102 Y100 Y101 Y102

YR100 YR101 YR102 YR100 YR101 YR102 Boom out YR100 YR101 YR102
Boom out
Boom out P1 P2 P3 P1 P2 P3 +B115_1 P1 P2 P3
+B115_1
+B115_2
1 1 1 1 1 0 % 0 0
Y110 Y111 Y112 Y110 Y111 Y112 Y110 Y111 Y112

YR110 YR111 YR112 YR110 YR111 YR112 Stick in YR110 YR111 YR112
Stick in
Stick in P2 P1 P3 P2 P1 P3 +B116_1 P2 P1 P3
+B116_1
+B116_2
1 1 1 1 0 1 % 0 0
Y115 Y116 Y115 Y116 Y115 Y116

YR115 YR116 YR115 YR116 Stick out YR115 YR116
Stick out
Stick out P2 P1 P2 P1 +B116_2 P2 P1
+B116_2
+B116_1
1 1 1 0 % 0
Y120 Y121 Y122 Y120 Y121 Y122 Y120 Y121 Y122

YR120 YR121 YR122 YR120 YR121 YR122 Shovel close YR120 YR121 YR122
Shovel close
Shovel close P3 P2 P1 P3 P2 P1 +B117_1 P3 P2 P1
+B117_1
+B117_2
1 1 1 1 1 0 % 0 0
Y125 Y126 Y127 Y125 Y126 Y127 Y125 Y126 Y127

YR125 YR126 YR127 YR125 YR126 YR127 Shovel open YR125 YR126 YR127
Shovel open
Shovel open P3 P2 P1 P3 P2 P1 +B117_2 P3 P2 P1
+B117_2
+B117_1
1 1 1 1 1 0 % 0 0
0 Solenoid valve is not supplied (current I=0)
1 Solenoid valve is fully supplied with a current I=750 mA
% Solenoid valve is supplied with a flowing out current adjusted

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• Location of the proximity transmitters for a backhoe attachment
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• Location of the proximity transmitters for a backhoe attachment

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Working pumps
7.4 Working pumps
7.4.1 Description
There are 3 working pumps, one double pump A20 VSO 520 and one single pump A11 VLO 260.
The working pump A20 VSO 520 is a double variable displacement axial piston in swash plate design. And the
working pump A11 VLO 260 is a single variable displacement axial piston in swash plate design. These pumps
supply the main hydraulic circuit (attachment movements, travel).
The flow is in proportion to the input RPM and increases as the pump is shifted from the minimum to the maxi-
mum output.
7.4.2 Double pump A20 VSO 520
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Working pumps
7.4.2.1 Function
Rotary group
The A20 VSO 520 is a double pump. This scheme shows the section of a single pump. The two single pumps
are monted in mirror about the axe.
1 Piston with glide shoe 18 O-ring

2 Housing 19 Plug
3 Cylinder 20 Shim
4 Control lens 21 Threaded pin
5 Input shaft 22 Fixing screw
6 Swash plate 25 Roller bearing

7 Centring pin 26 Roller bearing
8 Slide ring 27 Positioning piston
9 Retaining plate 28 Spring
10 Retaining ball 29 Shaft seal
11 Distance segment 31 Indicator unit
12 Segment 32 O-ring
13 Closure shim 34 Circlip
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Working pumps
14 Crade shell 35 Circlip

15 Slide plate 42 Socket screw
16 Shim 43 Socket screw
17 Shim 45 Circlip
In the pump housing 2, parallel to the input shaft 5, are nine circular arranged pistons 1. The pistons move axial-
ly in the cylinder barrel 3 that in turn is firmly connected to the input shaft 5 via splines. The end of the pistons
are shaped in a ball joint which in turn is mounted in a ball socket / glide shoe. The glide shoes are held against
the variable, but non-rotating slide plate 15 (fixed on the swash plate 6) by the retainer plate 9.
The swash plate 6 may be shifted from the minimum to the maximum angle by the positioning piston 27 through
the centring pin 7 and the slide ring 8.
The regulation of the pump is performed by the positioning piston, located in the pump housing and controlled
by the different valves (pressure regulator, flow regulator, power regulator, ...).
The axial piston unit moves the oil via kidney shaped control inlets in the control lens 4. During the revolution
of the cylinder 3, oil corresponding to the area and stroke of the piston 1 is sucked in by four pistons through
the kidney shaped control ports on the suction side of the pump. The other four pistons displace the oil that is
supplied via the kidney shaped oil outlets to the pressure side of the pump, moving oil via pressure connection
into the hydraulic system. A ninth piston is moving between the upper and the lower limit, at dead centre, i.e.
just changing directions.
Pump displacement
The oil flow of the pump is depending on the stroke of the piston 1.
When the positioning piston 27 is shifted from its minimum to its maximum position, it swivels out the swash
plate 6 via the centring pin 7 and the slide ring 8 and the pump flow is increased correspondingly.
The port X1 of the positioning piston is connected in permanence with the pump high pressure B (or the servo
control pressure P if B<P).
The port X2 of the positioning piston is connected either with the pump high pressure B or with the tank pres-
sure via the different regulator.
When the port X1 is at tank pressure, the pump is in maximum angle. When the port X2 is at high pressure,
the pump is swivelled back to reduced angle due to the section difference of the both side of the positioning
piston.
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Working pumps
7.4.2.2 Working pump regulation

The regulation on the working pumps can be separated in three parts :
– Power regulation : constant power regulation p*Q=cste.
power reduction stage through pressure XLR (solenoid valve Y4).
– Pump pressure limitation (via pressure cut off DR).
– Flow regulation (controlled by solenoid valves Y3.1, Y3.2 and Y3.3).
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Working pumps
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Working pumps
Test points - ports

Pst Flow adjustment
Mst Flow switching v. adj
MB Pump high pressure
B Pump high pressure
P Control pressure
M Positioning pressure
S Suction port
Adjustment screws
Qmax Mechanical stop - flow max.
Qmin Mechanical stop - flow min.
DW Switching point - flow control
Hmax Flow max. - hydraulic
Hmin Flow min. - hydraulic
LR Power regulator
DR Pressure regulator
2 Pump gear
4 Power regulator
5 Piloting valve
6 Switching valve - flow control
7 Pressure control valve
Y3 Solenoid valve - power regu-
lation
Y4 Solenoid valve - power regu-
lation
Y136 Solenoid valve - pressure cut
off increase
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Working pumps
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Working pumps
7.4.2.3 Pressure cut-off
Functioning in normal conditions

The pressure cut off DR swivels the pump back to minimum angle to secure the circuit if the pressure increases
somewhat above the normal working range.
The port X2 of the positioning piston is connected to the middle groove of the regulation piston DR.
When the piston DR is moved to the left, the middle groove (and thus the port X2) of the regulator piston is
connected to the pump high pressure MB : the pump swivels to minimum angle.
When the piston DR is moved to the right, the middle groove (and thus the port X2) of the regulator piston is
connected to the tank pressure : the pump swivels to maximum angle.
The piston is held to the right by the force of the spring, and the other side is pushed by the force of the working
pressure applied on the piston surface.
If the working pressure MB of the pump increases above the value given by adjustment screw DR, the piston
moves and allows the working pressure to flow to the port X2 of the positioning piston. The positioning piston
moves the swash plate 6 so to displace the rotary group to the smallest pump angle. The working pressure
remains constant.
Elevation of the pressure cut-off

It is possible to increase the value of the cut off pressure by supplying the port Xd with the servo pressure P.
The piston is then held to the right by the force of the spring and by servo pressure P that is applied on the
piston surface.
The other side is pushed by the force of the working pressure applied on the piston surface and servo pressure
P that is applied on a part of the piston surface.
The value of the pressure cut-off is then greater than its initial value.
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Working pumps
If the working pressure MB of the pump increases above the new value of the pressure cut-off, the piston mo-
ves and allows the working pressure to flow to the port X2 of the positioning piston. The positioning piston mo-
ves the swash plate 6 so to displace the rotary group to the smallest pump angle. The working pressure
remains constant.
7.4.2.4 Power regulation

On the hydraulic pumps, the power regulation can be separated in two parts :
– a regulation at constant power.
– the power reduction stage (with the impressed current LR on Y4).
The constant power regulation

The constant power regulation means that the same power is available for the pumps and thus that the relation
(--------------
pxQ )- = Power = cste
600
p : pressure in bar
Q : oil flow in l/min
P : power in kW
The characteristic curve of this regulation is a hyperbola.
The purpose is to align the oil flow of the pumps to the resistance force (pressure) of the movements so that
Q.p=cste.
Function
We suppose that the current LR is constant and thus that XLR is constant and that the pump are in maximum
angle (Pst>20 bar).
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Working pumps
The system pressure (MB) of the pump is applied in permanence to the port X1 of the positioning piston.
The port X2 of the positioning piston is connected via the pressure cut off regulator DR to the middle groove of
the regulation piston LR.
When the piston LR is moved to the left, the middle groove (and thus the port X2) of the regulator piston is
connected to the tank pressure : the pump swivels to maximum angle.
When the piston LR is moved to the right, the middle groove (and thus the port X2) of the regulator piston is
connected to the pump high pressure : the pump swivels to minimum angle.
The regulator LR is pushed to the left by the force FLR.
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Working pumps
FLR = Fspring + FXLR Fspring : force of the springs

FXLR : force of the pressure XLR applied on the piston LR surface
The other side of the regulator is held with a pin maintained by a lever 4.1. The force F2 is applied to this lever
via the position feedback 3.1.
F2 = PxS3.1 working pressure P applied on S3.1 : surface of the position feedback piston 3.1.
The force F1 that pushed the regulator piston LR to the right is proportional with the force F2 and with the po-
sition of the positioning piston (i.e. with the pump angle). At regulation, the piston LR is just balanced with the
force FLR and the force F1.
F1 = FLR = cste and F1xd = F2xa
F1 and d are constant, so we have : F2xa = cste and F2 = PxS3.1
PxS3.1xa = cste Pxa = cste (while S3.1 = cste)
So if P increases, a decreases (the pump swivels to minimum angle until a new equilibrium is established).
Once this force (F1) exceeds the set preload value of the spring and the force of the XLR pressure, the piston
LR move to the right and the port X2 becomes the high pressure.
The positioning piston is than moved to the right (away from Qmax) and is displaced so to reduce the pump
angle until a new equilibrium between the position of the positioning piston and the pump high pressure is es-
tablished.
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Working pumps
Within the whole regulating range, to each value of the pump high pressure corresponds one position of the
positioning piston so that the regulating piston LR is in balanced condition under the pretension of the spring
and the pressure XLR on one side and the force of the working pressure through the position feedback piston
3.1 and the lever 4.4 on the other side.
The power curve of the pump is than exactly the curve for constant power, which is a hyperbola. The hydraulic
pumps power remains constant and the flow is adjusted to the pressure necessary for the movements.
Power reduction stage

This stage makes it possible to change hydraulically the regulation characteristics (pump power curve) during
working.
When servo pressure XLR is applied to the regulator LR via the port XLR, the force that pushed the regulator
piston to the left increases. This force is proportional to the pressure XLR and is equal to the tension of the
spring if XLR = 0 bar. The higher the pressure at XLR is, the higher is the pressure for which the regulation
begins will happen.
The pump regulation will further happen as described before (in § constant power regulation). However on the
P-Q diagram, the pump power curve will be shifted towards higher pressure (i.e. towards higher power) by a
value, which is directly proportional to the pressure at port XLR.
The XLR pressure is the output pressure of the power regulating solenoid valve Y4.
The inputs of the regulation solenoid valve Y4 are the servo pressure P (55 bar) and the current ILR. This cur-
rent is issued from the BST (U16) and is in relation with the diesel engine RPM. If the power request for the
hydraulic pumps (for example in case of simultaneity attachment and swing movements) is higher than the
power output of the diesel engine, the RPM will decrease. The BST plate reduces then the ILR current to lower
the working pump power curve (the current decreases until the engine RPM increases to its nominal value).
The purpose of this power reduction stage is to avoid the stall or the overload of the diesel engine.
The adjustment of the power regulator is made with XLR = 0 bar (see working pump adjustment). The regula-
tion beginning is adjusted to occur at a system pressure of about 55 bar if XLR = 0 bar (the spring in the power
regulator LR just balances the force of the servo pressure P applied to the lever 4.1 via the position feedback
piston 3.1).
7.4.2.5 Flow limitation stage

This function makes it possible to shift the pump to reduced or to minimum flow even at low pressure, as an
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Working pumps
example when operating an hydraulic hammer (reduced flow), or when no movement is actuated (flow mini, no
joysticki or pedal signal).
The port X2 of the positioning piston is connected via the pressure cut off regulator DR and the power regulator
LR to the middle groove of the regulation piston DW.
When the piston DW is moved to the right, the middle groove (and thus the port X2) of the regulator piston is
connected to the pump high pressure : the pump swivel to minimum angle.
When the piston DW is moved to the left, the middle groove (and thus the port X2) of the regulator piston is
connected to the tank pressure : the pump swivel to maximum angle.
The piston of the regulator DW is pushed permanently to the right by the force of the servo pressure P (55 bar)
applied on the piston surface.
The piston of the regulator DW is pushed to the left by the force of the spring and by the force of the pressure
MST applied on the piston surface.
The MST pressure is given by the regulator 5, the MST line is connected to the servo pressure P (via the thrott-
le) and to the lower groove of the regulator 5.
When the piston 5.8 of the regulator 5 is moving up in comparison to its sleeve 5.6, the lower groove is con-
nected to the tank pressure, the pressure MST decrease : the piston DW is moved to the right.
When the piston 5.8 of the regulator is in lower position in comparaison to its sleeve 5.6, the lower groove is
closed, the pressure MST than increase to the pressure P : the piston DW is moved to the left.
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Working pumps
The PST pressure is used to move up the sleeve

5.6 on the regulator 5. If PST pressure is low, the
sleeve is in lower position (due to the spring 5.5).
The piston 5.8 of the regulator 5 is in contact with
the slope surface of the positioning piston 3. The
lower groove is closed, the pressure MST in-
creases and thus the piston DW is moved to the
left (the port X2 becomes the tank pressure) : the
pump swivel out.
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Working pumps
However, if the pump swivel out, the piston 5.8 of

the regulator 5 is moved up (due to the slope on
the positioning piston 3) in comparaison of the
sleeve 5.6 who is in lower position (low PST pres-
sure). The lower groove of the piston (MST pres-
sure) is connected to the tank; the piston DW
moves to the right (the port X2 becomes the high
pressure) : the pump swivel to minimum angle.
If the sleeve 5.6 of the regulator 5 is in lower position, the pump remains in minimum angle. The sleeve is mo-
ved up with the PST pressure; if PST<10 bar : the sleeve is in lower position.
To have different flow, the sleeve must be moved upwards against the pretension of the spring 5.5 (with PST
pressure).
The vertical level from the piston 5.8 of regulator 5 must then be upper than before (when sleeve 5.6 is in lower
position) to have the flow regulation.
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Working pumps
While the vertical position of the piston 5.8 depends on the pump angle (because of the slope surface on the
positioning piston : the greater is the pump angle, the more the piston 5.8 of the regulator 5 is pushed vertically),
we have then a different oil flow for each position of the sleeve 5.6 (if PST>20 bar : maximal flow while the
sleeve 5.6 is in upper position).
The PST pressure is the output pressure of the flow regulating solenoid valve Y3.
The inputs of the regulation solenoid valve Y3 are the servo pressure P (55 bar) and the current IEL. This cur-
rent is issued from the BST (U16) and is in relation with different entries :
If no joystick or pedal movement is detected, the current IEL is at its minimum value (400 mA), the pressure
PST is then inferior to 10 bar and the pump is in minimum angle.
– If joystick or pedal deflection reaches more than 10%, the current IEL is at its maximum value (650 mA), the
pressure PST is then superior to 20 bar and the pump is in maximum angle.
– If an external flow limitation is activated, the current IEL is adjusted (between 400 and 650 mA) from the
BST to obtain the flow limitation preadjusted with the help of the display (see subgroup Monitoring Display
in chapter Electrical System).
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Attachment function
7.5 Attachment function
7.5.1 Boom cylinders

One extremity of the both cylinders CB1 and CB2 is fixed on the uppercarriage, the other extremity is fixed on
the boom. The complete attachment is raised or lowered via the boom. The boom movements are limited by
proximity transmitters, which detect the cylinders end stroke (see logic system).
The boom up movement is supplied with the three working pumps through the three control valve blocks.
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Attachment function
The boom down movement is generated by the attachment weight until the attachment reaches the ground.
Then the dig movement is feed with one working pump through one control valve block.
B76 Proximity switch pressureless fall Y100 SV / Boom cylinder extend

CB1 Right boom cylinder Y101 SV / Boom cylinder extend
CB2 Left boom cylinder Y105 SV / Boom cylinder retract
P1 Working pump Nb 1 Y106 SV / Boom cylinder retract
P2 Working pump Nb 2 YR100 RSV / Boom cylinder extend
VB1 Valve block 1 YR101 RSV / Boom cylinder extend
VB2 Valve block 2 YR105 RSV / Boom cylinder retract
YR106 RSV / Boom cylinder retract
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Attachment function
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Attachment function
7.5.1.1 Boom up movement

• Move the joystick of right pilot control U22 backward.
• The electronic FSG plate A1020 controls the solenoid valves Y100, Y101 and the regulation solenoid val-
ves YR100, YR101 proportionally to the deflection of the joystick U22. If the boom up movement is done
simultaneously with others movements, some of these solenoid valves may not be supplied (see priority
list in § logic system).
• Thanks to a primary pressure relief valve installed on each control valve block, the pressure issued from
the working pumps can not exceed 320 bar.
• The oil issued from the working pumps can now flow threw the control valve blocks to the distribution of
the boom cylinders CB1 and CB2.
• The control valve blocks VB1 and VB2 are connected together so that the oil flow issued from the pumps
is equally distributed between the two cylinders CB1 and CB2.
• The working pressure is then applied on the piston side of the cylinders : the boom is raising.
7.5.1.2 Pressureless lower boom cylinder

The pressureless lower boom cylinder is used to lower the attachment with a reduced power thanks to its own
weight.
The advantages are :
– a lower fuel consumption.
– a more important oil flow available to do other movements at the same time.
• Move the joystick of right pilot control U22 forward.

• When the attachment does not touch the ground, the weight of the boom applies a pressure on the bottom
side of the cylinders and so on pressure sensor B76. The pressure sensor is on.
ves YR105, YR106 proportionally to the deflection of the joystick U22 (see priority list in § logic system).
• The control oil flows threw Y105 and Y106 to the port Pst of the two distribution blocks.
• The hydraulic oil can flow from piston bottom to piston rod side through the throttle of the two distribution
blocks and the excess of oil can flow to the tank via the check valve integrated in the two distribution
blocks : the attachment goes down.
• The control valve blocks VB1 and VB2 are connected together so that the oil flow issued from the piston
bottom is equally distributed between the piston rod side of the two cylinders CB1 and CB2.
• When the attachment touches the ground, the pressure on the bottom side of the cylinders decreases.
The pressure sensor B76 switches off.
• The electronic FSG plate A1020 switches off the solenoid valves Y105, Y106 and the regulation solenoid
valves YR105, YR106. The control oil does not flow threw Y105 and Y106 to the port Pst of the two dis-
tribution blocks any more.
7.5.1.3 Boom down movement

• When the attachment touches the ground, the pressure on the bottom side of the cylinders decreases.
The pressure sensor B76 is switched off.
• Move the joystick of right pilot control U22 forward.
ves YR105, YR106 proportionally to the deflection of the joystick U22 (see priority list in § logic system).
• The working pumps P1, P2 feed the movement in making the hydraulic oil flows to piston rod side threw
the control valve blocks VB1, VB2. Hydraulic oil return to the tank via the distribution blocks.
• Thanks to a primary pressure relief valve installed on the control valve block VB1 and VB2, the pressure
issued from the working pumps can not exceed 320 bar.
• Due to the secondary pressure relief valve, the pressure can not excees 380 bar in the circuit. These val-
ves prevent mechanical damages due to a too high pressure.
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Attachment function
7.5.2 Stick cylinders for backhoe attachment

One extremity of the both stick cylinders CS1 and CS2 is fixed on the boom, the other extremity is fixed on the
stick. These cylinders move the stick around its axis.
On the backhoe attachment, the stick movements are limited by proximity transmitters, which detect the cylin-
ders end stroke (see logic system).
Throttle check valves are installed in the hydraulic line on the rode side of the cylinders to control the lowering
speed (cylinder extend).
The stick in movement is supplied with the two working pumps P1 and P2 through the two control valve blocks
VB1 and VB2.
The stick out movement is supplied with the three working pumps P1, P2 and P3 through the three control valve
blocks VB1, VB2 and VB3.
Thanks to a primary pressure relief valve installed on each control valve block, the pressure issued from the
working pumps can not exceeds 320 bar.
The distribution blocks distribute the oil flow equally between the stick cylinders CS1 and CS2.
CS1 Right stick cylinder Y112 SV / Stick cylinder extend

CS2 Left stick cylinder Y115 SV / Stick cylinder retract
Pst Servo pressure Y116 SV / Stick cylinder retract
P1 Working pump Nb 1 YR110 RSV / Stick cylinder extend
Y110 SV / Stick cylinder extend YR115 RSV / Stick cylinder retract
Y111 SV / Stick cylinder extend YR116 RSV / Stick cylinder retract
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Attachment function
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Attachment function
7.5.3 Bucket tilt cylinders for backhoe attachment

One extremity of both tilt cylinders CBT1 and CBT2 is fixed on the stick, the other extremity is fixed on the buc-
ket. With the bucket tilt cylinders, the bucket is tilted in or out via a lever and linkage. The bucket tilt movements
are limited by proximity transmitters, which detect the cylinders end stroke (see logic system).
Throttle check valves are installed in the hydraulic line on the rod side of the cylinders to control the lowering
speed.
The bucket tilt in movement is fed with the three working pumps P1, P2 and P3 through the three control valve
blocks VB1, VB2, and VB3.
The bucket tilt out movement is fed with the three working pumps P1, P2 and P3 through the three control valve
working pumps can not exceed 320 bar.
If the bucket movement is done simultaneously with others movements, the movement may not be supplied by
these three pumps (see priority list in § logic system).
The distribution blocks distribute the oil flow equally between the bucket tilt cylinders CBT1 and CBT2.
CBT1 Right bucket tilt cylinder Y125 SV / Bucket tilt cylinder retract
CBT2 Left bucket tilt cylinder Y126 SV / Bucket tilt cylinder retract
P1 Working pump Nb 1 Y127 SV / Bucket tilt cylinder retract
P2 Working pump Nb 2 YR120 RSV / Bucket tilt cylinder extend
P3 Working pump Nb 3 YR121 RSV / Bucket tilt cylinder extend
Pst Servo pressure YR122 RSV / Bucket tilt cylinder extend
Y120 SV / Bucket tilt cylinder extend YR125 RSV / Bucket tilt cylinder retract
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Attachment function
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Attachment function
7.5.4 Shovel tilt cylinders for shovel attachment

One extremity of both shovel tilt cylinders CBT1 and CBT2 is fixed on the boom; the other extremity is fixed on
the shovel. This allows the shovel bucket to remain at a constant position in relation to the ground when exten-
ding or retracting the crowd cylinders (parallelogram function). The shovel tilt movements are limited by proxi-
mity transmitters, which detect the cylinders end stroke (see logic system).
The shovel tilt in movement is fed with the three working pumps P1, P2 and P3 through the three control valve
The shovel tilt out movement is fed with the three working pumps P1, P2 and P3 through the three control valve
working pumps can not exceed 320 bar.
If the shovel movement is done simultaneously with others movements, the movement may not be supplied by
these three pumps (see priority list in § logic system).
The distribution blocks distribute the oil flow equally between the bucket tilt cylinders CBT1 and CBT2.
Moving the crowd cylinders without simultaneously moving the tilt shovel bucket cylinders will automatically de-
crease relief pressure of the secondary relief valves for the bottom side from 380 bar to 140 bar. With the shovel
bucket at its mechanical front-end stop, this allows the tilt cylinders pistons to yield freely into any position as
the crowd retracts.
CBT1 Right shovel tilt cylinder Y125 SV / Shovel tilt cylinder retract
CBT2 Left shovel tilt cylinder Y126 SV / Shovel tilt cylinder retract
P1 Working pump Nb 1 Y127 SV / Shovel tilt cylinder retract
P2 Working pump Nb 2 YR120 RSV / Shovel tilt cylinder extend
Pst Servo pressure YR122 RSV / Shovel tilt cylinder extend
Y120 SV / Shovel tilt cylinder extend YR125 RSV / Shovel tilt cylinder retract
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Attachment function
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Attachment function
7.5.4.1 Shovel bucket parellelogram function

During crowd movement without simultaneous shovel bucket tilt movement, the relief pressure setting of the
secondary relief valves of the shovel bucket tilt circuit is decreased from 380 bar to 140 bar. This is accom-
plished, depending on direction of movement (crowd retract or extend), by applied servo pressure to the se-
condary relief valves.
If the shovel bucket is not tilted to its mechanical end stop, the tilt cylinders remain at a constant length (no
piston movement) and the attachment linkage operates in a standard parallelogram fashion.
If the shovel buckets rests on its mechanical end stop, the bucket cylinder pistons must be able to yield freely
to accommodate the retract movements of the crowd. This is accomplished by oil going over one of the secon-
dary relief valves with its decreased relief pressure setting of 140 bar.
On the figure, the attachment position shows the configuration for which the pressure of the secondary valve
is used.
The crows is retracting and shovel is at its mechanical stop. Mechanical force will retract the bucket cylinders
and the secondary relief on the piston bottom side opens at 140 bar. To prevent insufficient oil filling at the pis-
ton bottom side of the bucket cylinders, suction valves has been installed on the control valve blocks.
A minimum relief pressure setting of 140 bar is required to support a fully loaded shovel bucket and to keep
system power demand to a minimum.
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Attachment function
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Attachment function
7.5.5 Shovel flap cylinders for shovel attachment

One extremity of the both shovel flap cylinders CF1 and CF2 is fixed on the shovel back; the other extremity is
fixed on the flap. These cylinders close or open the flap. The shovel tilt movements are limited by : proximity
transmitters, which detect the cylinders end stroke (see logic system).
The flap opening movement is fed with the working pump P3 through the control valve block VB3.
The shovel closing movement is fed with the working pump P3 through the control valve block VB3.
Thanks to a primary pressure relief valve installed on the control valve block, the pressure issued from the wor-
king pump can not exceed 320 bars.
CF1 Right shovel flap cylinder Y130 SV / Shovel tilt cylinder retract
CF2 Left shovel flap cylinder Y132 SV / Shovel tilt cylinder retract
Pst Servo pressure YR132 RSV / Shovel tilt cylinder extend
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Attachment function
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Travel
7.6 Travel
7.6.1 Travel motors

The travel motors MTR1 and MTR2 are integrated in the right travel gear GTR.
The travel motors MTL1 and MTL2 are integrated in the left travel gear GTL.
They turn the track chains via the travel gears and sprocket.
The right travel movement is fed with the working pump P2 through the control valve block VB2.
The left travel movement is fed with the working pump P1 through the control valve block VB1.
If there is no movement in addition to the travel movement and if the two pedals which command the travel of
each side of the excavator are at least pushed at 10%, the plate A1020 switches the solenoid valve Y144 (in
valve block 3). Then the pump P3 feeds also the left and the right travel movements.
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Travel
Component Ports
BV Brake valve A High pres. for forw. travel & for right side
GTR Travel gear right High pres. for backw. travel & for left side
GTL Travel gear left B High pres. for forw. travel & for left side
MTL1 Front left travel motor High pres. for backw. travel & for right side
MTL2 Rear left travel motor Br ext Mechanical brakes pressure
MTR1 Front right travel motor P1 High pressure : automatic speed decrease
MTR2 Rear right travel motor S Leak oil
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Travel
RC Servo pressure T1 Tank

SCV Speed control valve T2 Tank
UBV Overspeed shut off valve X Switch speed pressure
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Travel
7.6.2 Primary pressure relief valve controlled with pilot pressure

For a more efficient travel function, the primary pressure relief valves are controlled with the servo pressure.
As soon as a travel command is actuated, the servo pressure is applied on the corresponding primary pressure
relief valve that is then adjusted at 350 bar instead of 320 bar. It means that for a left travel movement (respec-
tively for a right travel movement), the primary pressure relief valve located in the valve block VB1 (respectively
in the valve block VB2) takes a value of 350 bar instead of 320 bar.
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Travel
7.6.3 Hydraulic braking

Releasing the foot pedals will automatically return them to neutral position. This is sufficient to stop the machine
on a level surface.
Run away of the machine travelling down a slope is prevented by the automatically acting brake valves inte-
grated in each travel motor. The maximum travel speed cannot be exceeded.
The brake valve BV for travel, integrated in each travel motor, prevents the hydraulic motor from overspeeding
when travelling downhill.
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Travel
• The left figure shows the forward travel functioning of an hydraulic motor in standard conditions. The
pumps feed the travel motor threw the rotary connection RC. The high pressure switches the brake valve
and allows the oil issued of the motor to go to the tank.
• The right figure shows the forward travel functioning of an hydraulic motor during a steep downhill travel.
The motor, driven by the sprocket, works like a pump. When the pressure issued from the working pumps
becomes too low (<40 bar) the brake valve BV begins to switch in central position and so restricts the oil
flow issued from the motor : the hydraulic braking is beginning. Nevertheless if the pressure continues to
decrease (<20 bar) due to a too high motor speed, the brake valve BV swithves completely in central po-
sition. The oil issued of the motor can no more go to the tank. In that case, the motor is blocked. A maxi-
mum hydraulic braking is achieved. If the motor continues to turn despite the hydraulic braking, the
pressure cut off valve (380 bar) allows the oil to circulate and so prevents mechanical damages int the
circuit. The hydraulic braking works alike for backward travel.
• In case of forward (resp. backward) travel, the left (resp. backward) travel, the left (resp. right) pressure
cut off valve protects the circuit.
7.6.4 Travel braking

The travel braking is done with disk brakes that are integrated in the travel gears FAT. The disk brakes act
directly on the gear drive. They are used as a spring applied brake and are vented hydraulically, i.e. if there is
no brake pressure, the disks are pressed together by springs and the brake is mechanically closed.
The brake is negatively acting, hydraulically actuated and serves as a holding or parking brake.
The travel brake is actuated as soon as the travel pedal corresponding to the movement returns to neutral po-
sition.
As soon as the travel pedal corresponding to the movement is actuated, a part of the oil under high pressure
issued of the working pumps flows from the port Br ext to the brakes thew a valve (see the precedent figure :
purple line). This valve prevents the pressure going to the brake exceed 30 bar and to do damage to the disks.
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Travel
7.6.5 Travel speed increase

The hydraulic motors mounted to the travel gears can work with two different displacements :
• Position 1 : maximum cubic capacity (maximum oil volume), this resulting in maximum track forces com-
bined with moderate travel speed.
• Position 2 : minimum cubic capacity (minimum oil volumes), this resulting in reduced track forces combi-
ned with maximum travel speed.
The travel speed increase is actuated by pushing the button S21.

When this push button is turned off, the two indicator lights are off.
When this push button is turned on, the left indicator light 1 is on.
The travel speed increase is available for all movements except for the swing movements of the undercarriage.
The travel speed increase is available for forward travel and automatic for backward travel.
• The left figure shows the hydraulic schematic when travelling in position 1 (moderate travel speed). A part
of the oil under high pressure issued from the working pumps flows to the rod side of the positioning piston
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Travel
of the hydraulic motor (green line). The motor is then in position 1 (Maximum cubic capacity).
• The right figure shows the hydraulic schematic when travelling in position 2 (maximum travel speed). The
solenoid valve Y94 located in SU1 limits the servo oil pressure to 25 bar and send it in the rotary connec-
tion RC. From there the oil goes to the speed control valve (SCV) via the overspeed shut off valve UBV
(orange line). The speed control valve (SCV) is then switched and allows the piston to be supplied with
the same pressure on its bottom side and on its rod side. As the piston bottom side surface is bigger as
the piston rod side surface, the piston goes up. The motor is then shifted in position 2 (Maximum travel
speed).
• The left figure shows the hydraulic schematic of the switch from maximum travel speed (position 2) to mo-
derate travel speed (position 1) during travel with difficult ground conditions. The pumps feed the travel
motor threw the rotary connection RC. As the ground conditions are difficult, the high pressure increases.
The overspeed shut off valve UBV is connected to the high pressure via the port P1. As soon as the high
pressure reaches 350 bar, the overspeed shut off valve UBV is switched. The oil issued from the solenoid
valve Y94 can no more push the speed control valve SCV. The piston bottom side is no more under pres-
sure. The hydraulic motor is shifted down in position 1 (moderate travel speed). In that case, even if the
push button is turn on, the motor is in position 1 (moderate travel speed). While the high pressure is grea-
ter than 120 bar, the overspeed shut off valve UBV will stay in «closed» position. It will be switched in
«opened» position as soon as the pressure issued from the motor is lower than 120 bar. The hydraulic
motor is shifted up in position 2 (maximum travel speed).
• The right figure shows the hydraulic schematic of the switch from maximum travel speed (position 2) to
moderate travel speed (position 1) during steep downhill. As in case described by the figure of the motor,
driven by the sprocket, works like a pump. If the action of the braking valve is not sufficient, the pressure
of the oil issued of the motor will continue to increase. The overspeed shut off valve UBV is connected to
this pressure via the port P1. As soon as the pressure reaches 350 bar, the overspeed shut off valve UBV
is switched. The oil issued from the solenoid valve Y94 can no more push the speed control valve SCV.
The piston bottom side is no more under pressure. The hydraulic motor is shifted down in position 1 (mo-
derate travel speed). In that case, even if the push button is turn on, the motor is in position 1 (moderate
travel speed). While the pressure issued from the motor is greater than 120 bar, the overspeed shut off
valve HV will stay in «closed» position. It will be switched in «opened» position as soon as the pressure
issued from the motor is lower than 120 bar. The hydraulic motor is shifted up in position 2 (maximum
travel speed).
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Troubleshooting
7.7 Troubleshooting
7.7.1 Hydraulic cylinder chart
D (mm)
Cylinders Excavator type Ident. L (mm) H (mm)
d (mm)
320
Boom Backhoe attachment 9603919 4140 2850
220
320
Boom Shovel attachment 9596502 3970 2500
220
260
Stick Backhoe attachment 9603922 3410 2250
180
220
Crowd Shovel attachment 9596513 3300 2250
160
230
Bucket tilt Backhoe attachment 9612558 3000 1950
160
240
Shovel tilt Shovel attachment 9596515 3490 1980
180
170
Shovel flap Shovel attachment 9621278 1160 515
125
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Troubleshooting
7.7.2 Extension and retraction time of hydraulic cylinder
7.7.2.1 Extension time of hydraulic cylinder
• Extension speed :
Q
Va = Q ⁄ ( Sa ) = ----------------------
-
2
π⁄4×D
• Extension time :
2
60 × π × ∆H ( dm ) × D ( dm )
T ( S ) = --------------------------------------------------------------
-
4 × Q ( l ⁄ ( min ) )
7.7.2.2 Retraction time of hydraulic cylinder
• Retraction speed :
Q Q
Ve = Q ⁄ ( Se ) = --------------------------------------- = -------------------------------
-
2 2 2
π ⁄ 4 × (D – d ) π ⁄ 4 × D equiv
• Retraction time :
2 2
60 × π × ∆H ( dm ) × ( D ( dm ) – d ( dm ) )
T ( S ) = -----------------------------------------------------------------------------------------
-
4 × Q ( l ⁄ ( min ) )
7.7.2.3 Determination of extension and retraction time with the chart

Extension and retraction speed of a cylinder can be read directly on overleaf chart, if knowing the values for D
(piston diameter), d (piston rod diameter), ∆H (piston stroke) and Q (oil flow per cylinder), see examples over-
leaf :
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Troubleshooting
Notice : For values D, d and H, refer to the subgroup «hydraulic cylinder chart».
Q is the oil flow per cylinder. Cut in two the flow of the pumps (the pumps feeds always two cy-
linders).
Take into account the difference between the oil flow to extend or retract the cylinders (the num-
ber of feeding pumps is not the same for extend or retract the cylinders : see chart on next sheet).
If necessary, take into accounts the installed pump flow reduction for the corresponding move-
ment.
The oil flows given in the chart next sheet is for nominal Rpm of diesel engine and hydraulic
pumps in new condition.
To consider overleaf chart, you must make sure that the system pressures remain below regu-
lation begin. Otherwise electronic horsepower limiter (as an example, this may happen due to
cushioning devices when cylinder is nearly fully extended or retracted), would reduce pump flow.
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Troubleshooting
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Troubleshooting
7.7.2.4 Example
D : cylinder pistin diameter
d : diameter of piston rod
Dequiv : equivalent diameter for retraction of cylinder
Dequiv2 : D2-d2
Example 1 : on R 9250, determination of extension time of boom cylinders (if stroke = 1600 mm)
D = 320 mm
Oil flow (3 pumps and 2 cylinders) : Q = 2123 / 2 = 1061,5 l/min
The time for an extension of 1600 mm is approximately 7,4 seconds (orange curve).
Example 2 : on R 9250, determination of retraction time of stick cylinders (if stroke = 1500 mm)
D = 260 mm, d = 180 mm
Oil flow (2 pumps and 2 cylinders) : Q = 1544 / 2 = 772 l/min
The time for a retraction of 1500 mm is approximately 3,0 seconds (green curve).
7.7.2.5 Number of pumps and oil flow max for the different movements
R 9250
Nb of pumps Flow max
Boom cylinders extend 3 2123
Boom cylinders retract 3 2123
Stick cylinders extend 3 2123
Stick cylinders retract 2 1544
Bucket tilt cylinders extend 3 2123
Bucket tilt cylinders retract 3 2123
7.7.3 Control valve block leak oil measurement

The amount of leak oil in a spool valve of a control valve block is determined by measuring the extension or
retraction speed of a hydraulic cylinder connected to this spool valve.
The maximum permissible leak oil quantity in the control valve should be checked at a load pressure of 150
bar and at an oil temperature of 50°C (122°F).
Before any leak oil test on the control valves, always check the secondary valves and the attachments cylinders
separately, because the quantity given in the leak oil chart is only for leakage of the control valves.
To check, install a 600 bar pressure gauge in the appropriate line between the attachment cylinder and the
control valve. Actuate the attachment cylinder several times all the way and extend the cylinder until a pressure
of 150 bar is shown on the pressure gauge (if necessary, add weight). Joystick in neutral position, mark the
piston rod and measure the piston rod travel per minute.
Compare the measurement with the maximum permissible piston rod travel given on the chart.
Use the chart overleaf to determine the maximal allowable speed of the hydraulic cylinder, and / or the actual
leak oil amount in the spool valve.
For the maximal allowable leak oil quantity, refer to the page «technical data» of the corresponding control val-
ve block.
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Troubleshooting
Notice : The chart overleaf can be used directly every time one hydraulic cylinder receives oil via one
spool valve.
If more that one spool valves is connected to the cylinder, you must multiply the maximum
allowable speed with the number of spool valves.
If two hydraulic cylinders are fed simultaneously with the same control valves, the maximum
allowable speed must be divided by two.
7.7.3.1 Example
On R9250, the two boom cylinders (piston diameter D = 320 mm and rod diameter d = 220 mm) are controlled
by 2 spool valves of control valve block 4MO40 and by 1 spool valve of control valve block 4MO32 for extension
and for retraction.
For the spool valves of the control valve block 4MO40, the maximum permissible leak oil per spool valve is 400
cm3/min.
For the spool valve of the control valve block 4MO32, the maximum permissible leak oil per spool valve is 280
cm3/min.
• a maximum permissible retraction speed of one cylinder with one spool valve of a control valve block
4MO40 of 5 mm / min.
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Troubleshooting
• a maximum permissible retraction speed of one cylinder with one spool valve of a control valve block
4MO32 of 3,5 mm / min.
• a maximum permissible extension speed of one cylinder with one spool valve of a control valve block
4MO40 of 10,5 mm / min.
• a maximum permissible extension speed of one cylinder with one spool valve of a control valve block
4MO32 of 7,4 mm / min.
The maximum permissible retraction speed of the cylinders is then :
(5×2 + 3,5×1)/2 = 6,75 mm / min.
The maximum permissible retraction speed of the cylinders is then :
(10,5×2 + 7,4×1)/2 = 14,2 mm / min.
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Adjustment
7.8 Adjustment
7.8.1 Adjustment values
7.8.1.1 Excavator’s adjustments
R 9250 Backhoe R 9250 Shovel
Servo pressure in bar 55+3 55+3
Secondary pressure in bar
Boom cylinders
Bottom side 380 380
First stage 380 380

Rod side
Second stage
Stick / crowd cylinders
First stage 380 380

Bottom side
Second stage
First stage 380 380

Rod side
Second stage
Bucket tilt cylinders
First stage 380 380

Bottom side
Second stage 140
First stage 380 380

Rod side
Second stage
Shovel flap cylinders
First stage 380

Bottom side
Second stage
First stage 340

Rod side
Second stage
Travel gear left

Forward 380 380
Backward 380 380
Travel gear right
Forward 380 380
Backward 380 380
Primary pressure in bar
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Adjustment
VB1 320 320
VB2 320 320
VB3 320 320
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Component description
7.9 Component description
7.9.1 4-ways control valve 4 MO 40
7.9.1.1 Technical data
Connections Nominal width / size Pressure range

P, A1 to B4 SAE 1 ½¨ 6000 PSI
T SAE 2 ½¨ 3000 PSI
Pst, L G 3/8
M G 1/4
Amount of leak oil - control valve 4 MO 40.

Maximum permissible leak oil at 150 bar and 50°C : 400 cm³/min.
For procedure and instructions to check the leak oil quantity with spools in neutral position, refer to subgroup
4.3.
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7.9.1.2 Conception
The control valve block contains, in a compact housing, directional valves necessary for the travel and attach-
ments movements of the machine and also pressure relief valves for the various circuits, such as :
– Four hydraulically actuated spool valves (14 and 15), which distribute the hydraulic flow from the main hy-
draulic pumps to the various cylinders or motors.
– One primary pressure relief valve 28 (pilot operated) controls the pressure between the main pumps and
the control valves. This valve is installed on the upper housing, directly above the high pressure connection.
– Six (or seven) secondary pressure relief valves 30 located on the spools 15 (or on the spools 14 and 15).
These valves limit the secondary pressure limit the secondary pressure to the adjusted maximum pressure
settings. They are mounted with anti-cavitation check valves 29.
– Eight proportional -pressure reducing valves 34 (two on of each spool). These valves determine the spools
position proportionally to the current, which they receive.
– Eight 3/2 way directional valves 35 (two on of each spool). Mounted in line with the proportional valves, the-
se valves ensure that the spool is in neutral position when no current is sent.
7.9.1.3 Function
Spool valves in neutral position

In neutral position, the connections between user and pumps and user and tank are closed.
The hydraulic oil from pumps comes to the pressure port of the control valve block. Nearly without pressure, it
flows threw the spools 14 and 15 to connection T. Then the oil returns to the tank.
Working position of spool valves

If a spool valve is moved from its neutral position, the connection from pump to user is opened and restricts at
the same time the flow to the tank.
The pump pressure rises until it reaches the pressure on the user connection. Oil starts to flow to the user.
When the spool valve moves further, the connection from pump to tank closes off and opens the connection
for the returning oil from the user to the tank.
The total oil flow from the pump is now available for the user.
The movement of the spool valve depends only on the available control pressure. This control pressure can be
changed continuously depending on the movement of the appropriate joystick (see description and function in
sub group Pilot Control System).
Due to a negative spool overlap, together with the metering notches, the oil flows to the users and thus all wor-
king and travel movements can be controlled by pistons in the control blocks.
Springs, which are installed on the upper end of the spool, return the spools to neutral position if control pres-
sure is not available.
Internal leakage on a user connection under pressure are influenced by the overlap and the play between hou-
sing and piston.
Maximum permissible leak oil, see «Technical Data».
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Control valve blocl VB2 for backhoe attachment :
Control valve block VB2 for shovel attachment :

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Depending on control pressure actuation, the following connections are possible.

Valve block 1 (VB1) : pressure from working pump P1.
Spool valve Control pressure Spool Connections

Pos Function on connection... moved Pressure side Return side
a4 Forward P-A4 B4-T
15 Travel left
b4 Backward P-B4 A4-T
a3 Up P-A3 B3-T
15 Crowd / stick
b3 Down P-B3 A3-T
a2 Up P-A2 B2-T
15 Bucket
b2 Down P-B2 A2-T
a1 Up P-A1 B1-T
14 Boom
b1 Down P-B1 A1-T

Valve block 2 (VB2) : pressure from working pump P2.

a4 Forward P-A4 B4-T
15 Travel right
b4 Backward P-B4 A4-T
a3 Up P-A3 B3-T
15 Bucket
b3 Down P-B3 A3-T
a2 Up P-A2 B2-T
15 Boom
b2 Down P-B2 A2-T
a1 Up P-A2 B2-T
14 Crowd / stick
b1 Down P-B2 A2-T
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7.9.1.4 Repairs
Item Description Item Description
10 Housing 29 Anti-cavitation check valve

11 Cover 30 Secondary pressure relief valve
12 Plate 31 SHCS
13 Cover 32 Check valve
14 Spool 33 SHCS
15 Spool 34 Proportional-pressure reducing valve
18 Bolt 35 3/2 way directional valve
19 Spring retainer 41 Locking screw
20 Compression spring 42 Locking screw
21 Compression spring 43 Cone
22 Locking screw 44 Compression spring
23 Locking screw 45 Locking screw
25 SHCS 50 Locking screw
26 SHCS 51 Locking screw
27 Ring screw
28 Primary pressure relief valve, pilot operated Seal kit
24 O-ring
40 O-ring
46 O-ring
Release system pressure by turning off the engine, turn the ignition key to contact position, move joysticks in
all directions.
Remove covers 11 and 12, replace seals 24.
If external leaks are found on the primary or secondary pressure relief valves, remove them and replace their
seals ring.
Spool valves 14 and 15

To remove spool valves
Remove servo pressure line Pst and the servo return line L from the plate 12.
Remove screws 26 and lift off the four covers 13 with the corresponding O-rings 24.
Lift off the plate 12 and the corresponding O-rings 24.
Pull spool from control valve housing 10.
To install spool valves
Lightly lubricate the spool and carefully insert it into the valve housing 10.
Install the plate 12 with the corresponding O-rings 24 on the valve housing.
Install the four covers 13 with the corresponding O-rings 24 on the plate 12 and tighten with the screws 26 to
the prescribed value.
Connect the hydraulic lines and bleed.
Note : in case more than one spool is removed, care must be taken that the spools are installed in their original
location.
Replacing regulating springs 20 / 21

Remove the affected spool valve.
Turn counterclockwise the screw 18 with an Allen wrench, and remove the spring unit.
Reinstall new springs 20 and 21 on the spool and tighten the screw 18 to the prescribed value.
Install the spool as described in previous §.
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Primary pressure relief valve, pilot operated 28

The complete valve can be removed from the control valve block 10. When reinstalling the valve, make sure
the o-rings and the thrust ring are seated correctly.
Torque the pressure relief valve to the prescribed value.
For function and pressure adjustment, see subgroup «primary pressure relief valve».
The seal kit consists of :
32 O-ring 34 Thrust ring

33 O-ring 37 O-ring
Anti-cavitation check valves 29

To remove check valves : remove screws 31 and lift off the corresponding secondary valve 30.
To replace check valve : assembly correctly the different parts of the valve, making sure that the O-rings are
seated correctly. Tighten the screws 31 to the prescribed value.
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Item Description
1 O-ring
2 Seal
Secondary pressure relief valve 30

To remove check valves : remove screws 31 and lift off the corresponding check valves 29.
To replace secondary pressure relief valve : assembly the different parts of the valve, making sure that the O-
rings are seated correctly. Tighten the screws 31 to the prescribed value.
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Item Description
2 O-ring
6 Valve
Check valve 32
To remove check valves : remove screws 33.
To replace check valve : assembly correctly the different parts of the valve, making sure that the O-ring an the
seal are seated correctly. Tighten the screws 33 to the prescribed value.
Item Description
9 O-ring
10 Seal
Proportional pressure reducing valve 34

To remove theses valves, unscrew the nut 30 and pull off the O-ring 40 and the coil 20.
Unscrew the principal element 10 with its O-ring 10.60, 10.70 and 10.80.
To replace the valve, put the principal element 10 with its O-rings 10.60, 10.70 and 10.80.
Tighten the element 10 to the prescribed value.
Put the coil 20, the O-ring 40 and the nut 30. Tighten the nut 30 by hand.
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Seal kit
10 Principal element
20 Coil 10.60 O-ring
30 Nut 10.70 O-ring
10.80 O-ring
40 O-ring
3/2 way directional valve 35

To remove theses valves, unscrew the nut 158 and pull off the O-ring 159 and the coil 157.
Unscrew the principal element with its seal kit.
To replace the valve, put the principal element with its seal kit.
Tighten the element to the prescribed value.
Put the coil 157, the O-ring 159 and the nut 158. Tighten the nut 158 by hand.
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Seal kit
157 Principal element
158 Coil 21 Thrust ring
159 Nut 36 O-ring
42 O-ring
73 Thrust ring
74 Thrust ring
Locking screw 50
Item Description
20 O-ring
30 O-ring
40 O-ring
7.9.1.5 Control valve installation

The control valve mounting surface must be clean and absolutely even.
The mounting screws must be tightened evenly and crosswise.
The mounting surfaces of the SAE connections must be clean.
Pipes and hoses must be routed so no tension is created.
Tighten screws, fittings, etc... according to torque listed on.
7.9.1.6 Maintenance
The control valves used in Liebherr hydraulic systems are maintenance free. Only the pressure settings of the
primary and secondary pressure relief valves must be checked periodically.
To check the secondary pressure relief valves, increase the adjustment value of the primary pressure relief
valves until the primary pressure is higher that the secondary pressure to be set, see page «Pressure adjust-
ment».
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7.9.2 4-ways control valve 4 MO 32
7.9.2.1 Technical data
Connections Nominal width / size Pressure range

P, A1 to B4 SAE 1 ½¨ 6000 PSI
T SAE 2 ½¨ 3000 PSI
Pst, L G 3/8
M G 1/4
Amount of leak oil - control valve 4 MO 32.

Maximum permissible leak oil at 300 bar and 50°C : 280 cm³/min.
For procedure and instructions to check the leak oil quantity with spools in neutral position, refer to subgroup
4.3.
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7.9.2.2 Conception
The control valve block contains, in a compact housing, directional valves necessary for the travel and attach-
ments movements of the machine and also pressure relief valves for the various circuits, such as :
– Four hydraulically actuated spool valves (14 and 15), which distribute the hydraulic flow from the main hy-
draulic pumps to the various cylinders or motors.
– One primary pressure relief valve 28 (pilot operated) controls the pressure between the main pumps and
the control valves. This valve is installed on the upper housing, directly above the high pressure connection.
– One secondary pressure relief valve 30 located on a spool 15. This valve limit the secondary pressure limit
the secondary pressure to the adjusted maximum pressure settings. It is mounted with anti-cavitation check
valves 29.
– Eight proportional - pressure reducing valves 34 (two on of each spool). These valves determine the spools
position proportionally to the current, which they receive.
– Eight 3/2 way directional valves 35 (two on of each spool). Mounted in line with the proportional valves, the-
se valves ensure that the spool is in neutral position when no current is sent.
7.9.2.3 Function
Spool valves in neutral position

In neutral position, the connections between user and pumps and user and tank are closed.
The hydraulic oil from pumps comes to the pressure port of the control valve block. Nearly without pressure, it
flows threw the spools and to connection T. Then the oil returns to the tank.
Working position of spool valves

If a spool valve is moved from its neutral position, the connection from pump to user is opened and restricts at
the same time the flow to the tank.
The pump pressure rises until it reaches the pressure on the user connection. Oil starts to flow to the user.
When the spool valve moves further, the connection from pump to tank closes off and opens the connection
for the returning oil from the user to the tank.
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The total oil flow from the pump is now available for the user.
The movement of the spool valve depends only on the available control pressure. This control pressure can be
changed continuously depending on the movement of the appropriate joystick (see description and function in
sub group Pilot Control System).
Due to a negative spool overlap, together with the metering notches, the oil flows to the users and thus all wor-
king and travel movements, can be controlled by pistons in the control blocks.
Springs, which are installed on the upper end of the spool, return the spools to neutral position if control pres-
sure is not available.
Internal leakage on a user connection under pressure are influenced by the overlap and the play between hou-
sing and piston.
Maximum permissible leak oil, see «Technical Data».
Valve block (VB3) : pressure from working pump P3.

a4 Up P-A4 B4-T
15 Boom
b4 Down P-B4 A4-T
Travel front a3 Travel P-A3 B3-T
14
Stick out b3 Stick P-B3 A3-T
a2 Up P-A2 B2-T
15 Bucket
b2 Down P-B2 A2-T
a1 P-A1 B1-T
15 Not used
b1 P-B1 A1-T
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7.9.2.4 Repairs
36 Spool 175 Plate

37 Spool 300 LID construction kit
38 Spool 301 LID construction kit
39 Spool 302 Cover
60 Primary pressure relief valve 303 Cover
80 Socket HD screw 304 O-ring
81 Socket HD screw 305 Socket HD screw
117 Control valve 306 Socket HD screw
118 Pressure reducer valve 320 Cap nut
139 Plate 321 Nut
143 Suction valve 323 Adjusting screw
155 Pressure regulator valve 999 Sealing kit
Release system pressure by turning off the engine, turn the ignition key to contact position, move joysticks in
all directions.
Remove Cover 300 and 301, replace seals 999.
If external leaks are found on the primary or secondary pressure relief valves, remove them and replace their
seals ring
Spool valves 36, 37, 38 and 39

To remove spool valves :
Remove servo pressure line Pst and the servo return line L from the plate 300.
Remove screws 305 and lift off the three covers 303 and the cover 302 with the corresponding O-
rings 999.
Lift off the plate 300 and the corresponding O-ring 999.
Pull spool from control valve housing.
To install spool valves :
Lightly lubricate the spool and carefully insert it into the valve housing.
Install the plate 300 with the corresponding O-rings 999 on the valve housing.
Install the three covers 303 and the cover 302 with the corresponding O-rings 999 on the plate 300 and tighten
with the screws 305 to the prescribed value.
Connect the hydraulic lines and bleed.
Note : In case more than one spool is removed, care must be taken that the spools are installed in their original
location.
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Primary pressure relief valve, pilot operated 60

The complete valve can be removed from the control valve block. When reinstalling the valve, make sure the
o-rings and the thrust ring are seated correctly.
For function and pressure adjustment, see subgroup «primary pressure relief valve».
32 O-ring 34 Thrust ring

33 O-ring 37 O-ring
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Control valve 117

o-rings are seated correctly.
Item Description
999 Seal kit
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Pressure reducer valve 118

Item Description
999 Seal kit

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Suction valve 143

Item Description
999 Seal kit
7.9.2.5 Control valve installation

The control valve mounting surface must be clean and absolutely even.
The mounting screws must be tightened evenly and crosswise.
The mounting surfaces of the SAE connections must be clean.
Pipes and hoses must be routed so no tension is created.
Tighten screws, fittings, etc... according to torque listed on.
7.9.2.6 Maintenance
The control valves used in Liebherr hydraulic systems are maintenance free. Only the pressure settings of the
primary and secondary pressure relief valves must be checked periodically.
To check the secondary pressure relief valves, increase the adjustment value of the primary pressure relief
valves until the primary pressure is higher that the secondary pressure to be set, see page «Pressure adjust-
ment».
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Hydraulic cylinder
7.10Hydraulic cylinder
7.10.1Construction of hydraulic cylinders

See diagramm in § 6.3.8 and 6.3.9.
Liebherr hydraulic cylinders for earth moving machines are classified as differential cylinders.
The cylinders extend when hydraulic oil is pumped to the piston bottom side and retracts when oil is pumped
on the piston rod side.
The hydraulic cylinder consists of a cylinder housing 10 with welded cylinder bottom and bearing mount, piston
rod bearing 13, which is mounted with screws and is also the cylinder head, and piston rod 8 with bearing mount
and piston 12.
To seal the cylinders, O-rings with support rings, as well as seals in piston 12 and piston rod bearing 13 are
installed. The wiper ring in the piston rod bearing 13 protects the piston rod 8 from contamination.
Guide rings are installed on the piston 12 and piston rod bearing 13.
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Hydraulic cylinder
7.10.2Function
The maximum force depends on the actuated area and on the maximum permissible operating pressure (pri-
mary valve) :
To extend : the piston surface.
To retract : the rod surface.
The force is greater when extending than when retracting the cylinder because of the surface difference.
The speed of the extending or retracting cylinder depends on the oil quantity and surface area. It works in re-
verse to the force, i.e., it is faster when retracting the cylinder than when extending the cylinder.
The Liebherr hydraulic cylinders differ in the required stroke, diameter and damper system.
We use cushioned and non-cushioned hydraulic cylinders in our excavators.
The non-cushioned hydraulic cylinders are used mainly for outriggers and for certain (little used) attachment
cylinder (as grapples and cylinders for street travel). These cylinders are also mounted on the excavators
equipped with proximity transmitters. These excavators reduce automatically the oil flow coming to the cylin-
ders when they reaches their end stroke (see also logic system).
On single cushioned cylinders (when extending the piston rod) the cushioning sleeve 9 moves shortly before
the piston 12 stops on the piston rod bearing 13, into the piston rod bearing and reduces the diameter. This
greatly reduces the extension speed, see also description of function.
7.10.3Function of hydraulic cylinder
7.10.3.1To extend piston rod 8

The hydraulic oil from the control valves flows to the bottom side of cylinder 10 and actuates piston 12. The
piston rod extends and displaces the hydraulic oil in the piston rod side via control valve to the tank.
With single cushined cylinders : shortly before the end of the stroke, the cushioning sleeve 9 moves into the
cushioning bore on piston rod bearing 13. When cushioning sleeve 9 moves into the bore, the diameter is re-
duced, i.e. the oil returns from the hydraulic cylinder to the control valve via grooves in the sleeve 9. Because
of this restriction of return oil, the piston rod movement is slowed down and cushioned.
7.10.3.2To retract the piston rod 8

The hydraulic oil from the control valves flows to the piston rod side of cylinder 10 and actuates piston 12. The
piston rod retracts and displaces the hydraulic oil on the piston bottom side via the control valves to the tank.
With single cushioned cylinders : the hydraulic oil from the control valve flows to piston rod bearing 13, pushes
on the cushioning sleeve 9 and, via the clearance between cushioning sleeve 9 and piston rod 8, radial bore
holes and grooves in the cushioning sleeve, on piston 12.
The piston rod retracts and displaces the hydraulic oil on the piston bottom side via the control valves to the
tank.
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Hydraulic cylinder
7.10.4General maintenance
7.10.4.1Anti-rotation protection
• Shop conservation :
Hydraulic cylinders made by the MH group are internally preserved for up to half a year by the testing
fluid used. Longer storage periods are to be stated on the order form.
For a one-year-storage, cylinders will be tested with an anti-corrosion-protective oil; either ARAL
Konit W10 (alternatively Resilan M 46) or ESSO Rustban 335, and finally emptied again.
When a storing period longer than one year is requested, cylinders will be delivered with an oil
filling of above mentioned quality.
However, the storing instructions as under paragraph 3 are prerequisites for any period.
In case the cylinders are meant to be stored for more than 2 years it is highly recommended to
consult the manufacturer.
• Sealing :
The anti-corrosion-protection is only effective when airtight closing of all ports is ensured : Four-bolt flan-
ges are sealed with a synthetic plug retained by a metal plate; pipe- and thread connections are plugged
with synthetic couplings or plug caps.
Cylinders, which cannot be, emptied completely (e.g. cylinders with hollow rods) and oil-filled cylinders
(such as tele rams) will be plugged-off oiltight using plug screws with integrated seal rings for female
threads and plug caps with spigot nuts for threaded pipe ends.
• Surface protection :
External surfaces such as flange surfaces, bearings, untreated cylinder barrels and also the exposed
rod end section, in case the rod has no other corrosion protection, are all treated with ARAL Resilan WA
or ESSO Rustban 397.
In addition, when plunger cylinders are concerned, the plunger rod, its guiding parts and cylinder bore
interior surface are treated with an anti-corrosion-protective. All hydraulic cylinders will be dispatched
coated with a proven versatile primer, if not otherwise specified by the client.
7.10.4.2Transportation
• In preparation for transportation the hydraulic cylinders must be handled and packaged carefully. Any kind
of impact, including bumping against each other must be avoided by using adequate handling auxiliaries
and methods and also suitable packaging materials.
• Rods are to be secured adequately against self-extending.
• All ports are to be plugged (acc. to 1.2).
• Whenever rods project out of the cylinder like on twin-rod-cylinders, the projecting rod end must be pro-
tected against any damage by using appropriate packaging materials. Any contact with acids, which may
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Hydraulic cylinder
ham the chromium plating, must be strictly avoided.
7.10.4.3Storage
• Upon delivery the customer should check for any damage resulting from transportation. Damaged plugs
are to be renewed and damaged coating is to be touched-up, immediately.
• Hydraulic cylinders should only be stored in a dry, dust- and steam-free room at a constant temperature
ranging between 10 and 20°C.
• After the first year of storage the cylinders should be rotated (about 90°) in order to shift possible air bub-
bles and simultaneously re-oil these dried zones.
7.10.4.4Installation
• In case hydraulic cylinders have been stored for longer than 2 years, the manufacturer should be contac-
ted, because for some types it may be necessary to replace the seal kit prior to installation.
• In general, hydraulic cylinders may be installed in any desired position.
• In order to prevent premature wear or operational disturbances the hydraulic cylinders are to be installed
tension-free and without lateral forces acting.
• Before connecting the hydraulic cylinders to the system all lines should be thoroughly flushed using sui-
table cleansing agents in order to remove any possible deposits.
• External preservatives are to be removed using benzine or petroleum ether.
7.10.4.5Start up
• Regarding the little remaining anti-corrosion protective adhering to the cylinder’s internal surfaces, clean-
sing is not necessary, because it is compatible with most used mineral-oil-based pressure fluids. Cylin-
ders filled with protective oil are to be emptied and re-filled with the operating fluid, before taken into
operation. In order to achieve maximum endurance and operating reliability the operating fluid should be
(filtered grade nominal 10 µm).
• Only proven trademark brands of mineral-based-oils acc. to DIN 51524 and DIN 51525 should be used.
Whenever other hydraulic fluids are meant to be used, the manufacturer should be consulted first. The
rod should be free of any kind of deposits e.g. paint rests, dirt etc. resulting from installation. Otherwise
cleaning is necessary.
• Some cylinder types require locking the rod eye on-site.
• Before taken into operation the cylinder is to be vented at both ends stop position (screw 23) re-
peatedly until the operating fluid excludes free of air bubbles.
• The hydraulic cylinders are suitable for an operating temperature range of -10°C to +80°C unless speci-
fied otherwise. In case the temperature exceeds this range please contact the manufacturer.
7.10.4.6Maintenance
• The rod’s normal chromium layer does not provide an everlasting corrosion protection against aggressive
environmental influences, so therefore maintenance is important, especially when the rod remains in ex-
tended position.
• It is recommended to check the oil filter repeatedly during the start-up period.
• In general, following above-mentioned instructions as a prerequisite, MH hydraulic cylinders are designed
to be maintenance-free during operation.
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Hydraulic cylinder
7.10.5Removal and installation of the hydraulic cylinders

Note : before removing hydraulic cylinder, observe all safety requirements!
7.10.5.1Removal
• Park the machine on flat, solid ground and lower the attachment or outriggers to the ground (situate the
cylinder to facilitate installation or removal).
• Remove cylinder pin end caps.
• Remove grease line if necessary.
• Secure the hydraulic cylinder with a lift. If necessary, secure the attachment parts also.
• Remove rod end cylinder pin, use a pin puller if necessary.
• Start engine and retract cylinder.
• Turn the diesel engine off.
• Turn ignition key on, safety lever down and activate joysticks in all directions to expel stored energy in
hydraulic lines (circuit).
• Remove the hydraulic hoses and catch the hydraulic oil in an appropriate container.
• If necessary, remove connector with hose from piston rod bearing and cylinder bottom.
• Remove barrel end pin, use a pin puller if necessary.
7.10.5.2Installation
• Set the hydraulic cylinder into the bearing with a lift, align the bores of cylinder and attachment.
• Lightly grease the bearing pin and knock it in (use tool if necessary).
• Connect the piston bottom and piston rod side bore holes with connectors and pipes and connects hy-
draulic hoses.
• Start the diesel engine and retract or extend the hydraulic cylinder until the bearing boreholes of piston
rod and attachment are aligned.
• Lightly grease the bearing pin and knock it in.
• Install end caps.
• Install grease lines.
• Start the engine and move the attachment to check function and for leaks between the cylinder and hy-
draulic connections.
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Hydraulic cylinder
7.10.6Resealing the hydraulic cylinder with new fixation

Remove the hydraulic cylinder partly or all the way from the attachment.
Note : the following drawings are partial drawings.
7.10.6.1Disassembly
• Remove hex. head screws 20 and pull the piston rod bearing 13 with piston rod 8 and piston 12 from cy-
linder 10.
• Prepare a clean area for the piston rod and make sure it is not damaged.
• Remove the piston guide rings 25 and piston nut 4 from the piston.
• Remove hex. head screws 7 and remove piston 12 from the piston rod 8.
• On hydraulic cylinders with cushioning : pull off the cushioning sleeve 9.

• Pull piston rod bearing 13 from piston rod 8.
• Remove all seals from piston and piston rod bearing.
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Hydraulic cylinder
7.10.6.2Assembly
Before assembly, do the following :

Carefully clean all parts of the hydraulic cylinder. Check all parts for wear and damage.
If the piston rod is damaged in any way (grooves, marks, etc...) it has to be replaced.
• Lightly grease or oil all parts and seals before installation.
• Install seals 71 and 80 in piston rod bearing 13. Each seal consists in two parts : an O-ring and a step seal.
Insert step seals as shown in figures into the bearing 13.
Note : observe the correct installation direction.
• Also make sure the seals are inserted correctly :
–The yellow ring 71 has to be on the outside.
–The grey ring 80 on the inside.
• Compress the seal so no sharp kinks are caused.
• Push the compressed seal over the corresponding O-ring and push it into the groove in direction of the
arrow.
• Insert the rod wiper 70 into the bearing 13.

• Pull on back up ring 73 and then O-ring 74 into the bearing 13.
• Push the piston rod bearing 13 with cushioning sleeve 9 (only on cushioned hydraulic cylinders) on piston
rod 8.
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Hydraulic cylinder
Pull piston glyd seal 75 onto piston 12, using a spreader sleeve (see § tooling). The glyd seal consists in two
parts : an O-ring and a glyd ring.
Note : For easier installation, lightly heat the glyd ring in oil or water, heated to no more than 120°C.
• Use a piston ring compressor to retighten the glyd ring after installation.
• Set the first back up ring 78, the O-ring 79 and the second back up ring 78 in this order into the piston 12.
Lightly lubricate the O-ring.
• Install piston 12 on piston rod 8. Insert the socket head screws 7 with their washers. Tighten the screws
to the prescribed torque value.
• Pull the piston wear rings 76 and 77 on the outside of the piston.
• Set the piston ring compressor on piston 12 and lightly tighten the wear rings on the piston.
• Push the piston rod 8 with piston 12 and piston rod bearing 13 carefully into cylinder 10 (make sure the
hydraulic connections are aligned properly).
• Remove the piston ring compressor.
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Hydraulic cylinder
• Insert the hex. head screws 20 with their washers. Tighten the screws to the prescribed torque value.
• Replace cylinder on the attachment.
7.10.7Resealing the hydraulic cylinder with old fixation

Remove the hydraulic cylinder partly or all the way from the attachment.
Note : The following drawings are partial drawings.
7.10.7.1Disassembly
• Remove hex. head screws 20 and pull the piston rod bearing 13 with piston rod 8 and piston 12 from cy-
linder 10.
• Prepare a clean area for the piston rod, make sure it is not damaged.
• Remove the piston guide rings 25 and piston nut 4 from the piston.
• Attach piston wrench (see tools section) and remove piston 12.1 from the piston rod 8.
• On hydraulic cylinders with cushioning : pull off the cushioning sleeve 9.
• Pull piston rod bearing 13.1 from piston rod 8.
• Remove all seals from piston and piston rod bearing.
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Hydraulic cylinder
7.10.7.2Assembly
Before assembly, do the following :

Carefully clean all parts of the hydraulic cylinder. Check all parts for wear and damage.
If the piston rod is damaged in any way (grooves, marks, etc...) it has to be replaced.
• Lightly grease or oil all parts and seals before installation.
• Install O-ring 13.11 in piston rod bearing 13.1. Insert turcon step seals 13.9 and 13.10 as shown in figures
into the bearing 13.1.
Note : Observe the correct installation direction.
• Also make sure the seals are inserted correctly :
–The yellow ring 13.9 has to be on the outside.
–The grey ring 13.10 on the inside.
• Compress the seal so no sharp kinks are caused.
• Push the compressed seal over o-ring 13.11 and push it into the groove in direction of the arrow.
• Insert the o-ring and the wiper ring 13.3 into the bearing as shown in figure.
• Pull on o-ring 13.7 and support ring 13.8.
• Push the piston rod bearing 13.1 with cushioning sleeve 9 (only on cushioned hydraulic cylinders) on pis-
ton rod 8.
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MJFCIFSS
Hydraulic cylinder
• Pull o-ring 12.3 and glyd ring 12.4 onto piston 12.1, using a spreader sleeve (see section tools).
Note : Lightly heat seal 12.4 for easier installation in oil or water, heated to no more than 120°C.
• Use a piston ring compressor to retighten glyd ring 12.4 after installation.
• Set the first support ring 12.7, o-ring 12.8 and the second support ring in this order into the piston. Lightly
lubricate the o-ring.
• Install piston 12 on piston rod 8. Set the piston wrench (see section tools) on the piston 12.
• Tighten it until it touches the rod shoulder.
• Remove piston wrench.
• Insert piston nut 4 with wrench on piston rod 8.
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Hydraulic cylinder
• Tighten the piston until it touches the rod shoulder.

• Mark the rod and the piston.
• Tighten the piston with the wrench until obtaining the given torsional path B.
• Install piston nut 4 on piston rod 8.
• Tighten nut 4 until it touches the piston.
• Mark the rod thread and the nut.
• Tighten the nut until obtaining the given torsional path C.
• Drill a hole for the hook on the snap ring 25 into the piston rod and insert the hook. Make sure the snap
ring is seated correctly.
• Pull the piston guide rings 12.6 (hard) and 12.2 (soft) on the outside of the piston.
• Set the piston ring compressor on piston 12 and lightly tighten the guide rings on the piston.
• Push the piston rod 8 with piston 12 and piston rod bearing 13 carefully into cylinder 10 (make sure the
hydraulic connections are aligned properly).
• Remove the piston ring compressor.
• Insert the hex. head screws 20 (see torque value in chapter 1).
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Hydraulic cylinder
7.10.8Schematic for cylinder with new fixation
1 Guide
2 Guide
7 Socket head screw
8 Piston rod
9 Damping bush
10 Tube
12 Piston
13 Cylinder head
20 Hex head screw
21 Washer
22 Washer
23 Lock screw for ventil
24 Lock screw
70 Rod wiper
71 Rod seal stepseal
72 Wear rings
73 Back up ring
74 O-ring
75 Piston seal Glyd
76 Wear rings
77 Wear rings
78 Back up ring
79 O-ring
80 Rod seal stepseal
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Hydraulic cylinder
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Hydraulic cylinder
7.10.9Schematic for cylinder with old fixation
I Single cushioned cylinder

II Not cushioned cylinder
1 Bushing
4 Piston nut
8 Piston rod
9 Sleeve
10 Cylinder
12 Piston, complete
12.1 Piston
12.2 Guide ring
12.3 O-ring
12.4 Turcon glyd ring
12.6 Guide ring
12.7 Support ring
12.8 O-ring
13 Piston rod bearing, complete
13.1 Bearing head
13.3 Scraper ring with o-ring
13.7 O-ring
13.8 Spiral ring
13.9 Turcon lifetime seal (yellow)
13.10 Turcon lifetime seal (grey)
13.13 Guide ring
15 Radial seal
20 Hex head screw
25 Ring
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Hydraulic cylinder
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Hydraulic cylinder
7.10.10Torque values of the mounting screws (new fixation)
Cylinder Screws 20 fixing the bea- Screws 7 fixing the piston to

LFR id. Montan id. Dimension ring head to the cylinder the piston rod
12 × M36×220-10.9 6 × M33×2×160-10.9
9004865 832846 Ø280 / 200×2000
3000 Nm 2500 Nm with loctite 245 blue
9211968 15 × M36×240-10.9 8 × M36×3×150-10.9
832844 Ø340 / 240×2450
9211969 11 × M30×200-10.9 7 × M30×140-10.9
832845 Ø260 / 180×1950
11 × M30×200-10.9 7 × M30×140-10.9
9211972 832843 Ø260 / 180×1950
15 × M36×240-10.9 8 × M36×3×150-10.9
9211974 832841 Ø340 / 240×3000
12 × M36×220-10.9 6 × M33×2×160-10.9
9211975 832842 Ø280 / 200×2250
17 × M36×300-10.9 12 × M33×2×150-10.9
9211993 832864 Ø380 / 260×3750
11 × M30×160-10.9 7 × M30×2×140-10.9
9923750 832874 Ø260 / 160×650
1700 Nm - Nm with loctite 245 blue
11 × M30×160-10.9 7 × M30×2×140-10.9
9923751 832873 Ø260 / 160×650
1700 Nm - Nm with loctite 245 blue
15 × M36×240-10.9 7 × M36×3×150-10.9
9923753 832867 Ø320 / 220×2250
12 × M36×220-10.9 7 × M33×2×150-10.9
9923754 823871 Ø300 / 200×2050
12 × M36×220-10.9 7 × M33×2×150-10.9
9923755 832822 Ø300 / 200×2050
12 × M36×220-10.9 7 × M33×2×150-10.9
9923756 832823 Ø300 / 200×2050
15 × M36×240-10.9 7 × M36×3×150-10.9
9923757 832866 Ø320 / 220×2700
15 × M36×240-10.9 7 × M36×3×150-10.9
9923758 832824 Ø320 / 220×2700
17 × M36×300-10.9 12 × M33×2×150-10.9
9923759 832863 Ø380 / 240×3250
11 × M30×200-10.9 7 × M30×140-10.9
9958001 578750 Ø260 / 180×1950
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Hydraulic cylinder
7.10.11Torque values the piston and the piston nut (old fixation)
Cylinder size Piston torsional path B (mm) Nut torsional path C (mm)
Ø250 18 8
Ø260 18 8
Ø280 18 10
Ø300 18 12
Ø310 18 12
Ø320 18 12
Ø340 18 14
Ø360 18 14
Ø380 18 14
Ø400 18 15
Ø420 18 15
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MJFCIFSS
Primary valve : Pilot operated pressure limiting valve
7.11Primary valve : Pilot operated pressure limiting valve
7.11.1Use
If the resistance, which acts against the load in a hydraulic system, were to rise to an undesirable and unac-
ceptable level, the weakest point in the hydraulic system would be destroyed. To prevent this, an artificial weak
point, a kind of circuit breaker (relief) is added. The object is locate this hydraulic component, which is initially
held in a closed position by adjustable spring pressure, so the fluctuating system of the whole hydraulic pres-
sure circuit can act on it. An increase in system pressure above the pressure setting of the relief valve lifts off
the poppet, ball or piston and directs the excess pressurized fluid, supplied by the pump but not accepted by
the end user, back to the tank. The hydraulic energy produced in this process is converted into heat.
This hydraulic component a pilot operated pressure-limiting valve (primary valve).
These cartridge types primary pressure relief valves in the control valve are located in front of the first piston.
A direct acting relief valve is installed as a control part in the pilot operated pressure relief valve, which triggers
an impulse to the second, larger valve. Both valves are normally open.
A characteristic of this valve is that once the valve has started to relieve and is contaminated; no further in-
crease in pressure is possible. This protects the system and damage to the components is avoided.
7.11.2Function
During operation, the system pressure pushes against the front side of piston 31. The same pressure is simul-
taneously applied via orifice A on the backside of piston 31, and via orifice B to poppet 33. Springs 32 and 14
move piston 31 and poppet 33 into closed position.
As soon as the system pressure exceeds the pressure setting of spring 14, the poppet 33 is lifted off its seat,
and some fluid escapes into the return line via orifice D. The previous static condition is now dynamic as fluid
is trying to flow via orifice A in order to compensate for the loss of volume and pressure. The size of the orifice
prevents immediate compensation, and a temporary difference in pressure between the top and bottom of the
main piston 31 exists.
The difference in pressure causes the system pressure, which is still pushing against the front of piston 31, to
lift the piston from its seat and large amounts of fluid can return to the tank via connection C.
7.11.3Pressure adjustment
To adjust pressure, remove cap 23, loosen lock nut 35 and turn the adjustment screw 34 clock- or countercloc-
kwise to lower or raise the pressure. After the adjustmnet has been made, secure screw with lock nut (torque
to 10 Nm) and install a lead seal.
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MJFCIFSS
Primary valve : Pilot operated pressure limiting valve
9 Primary valve 30 Valve body, incl. Items 31 and 32

10 O-ring 31 Main piston
11 Support ring 32 Spring
12 O-ring 33 Poppet
13 O-ring 34 Adjustment screw
14 Spring 35 Lock nut
23 Cap 36 Disc
29 Valve seat
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MJFCIFSS
Primary valve : Two-stage pilot operated pressure limiting valve
7.12Primary valve : Two-stage pilot operated pressure limiting

valve
7.12.1Use
The basic function and working principle of a two-stage relief valve is the same as the primary relief valve. In
order to have a higher pressure for certain functions -translation for R 9250- the standard relief valves are re-
placed with two-stage relief valves.
7.12.2Function
7.12.2.1Stage I - Reduced pressure

At this position NO servo pressure is applied to the piston 12 via the connection X.
The pressure of the spring 21 keeps the pistons 12 and 13 in the original position, which means that as long
as the piston 12 contacts the shoulder of the adjustment screw 11, the spring 21 retains a preload equal to the
« reduced pressure».
7.12.2.2Stage II - High pressure

A servo pressure is applied to the piston 12.
This pressure increases the preload on the spring 21 to the «high pressure» by pushing the two pistons 35 and
36 down.
7.12.2.3Pressure adjustment
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MJFCIFSS
Secondary pressure relief valve pilot controlled
10 Adjustment spindle 23 Support ring

11 Adjustment screw 24 O-ring
12 Piston 25 O-ring
13 Piston 27 O-ring
14.1 Lock nut 30 Valve body
14.2 Lock nut 31 Valve body
19.1 O-ring 32 Main piston
19.2 O-ring 33 Piston
20 Spring 34 Poppet
21 Spring
7.13Secondary pressure relief valve pilot controlled
7.13.1Use
If the resistance, which acts against the load in a hydraulic system, were to rise to an undesirable and unac-
ceptable level, the weakest point in the hydraulic system would be destroyed. To prevent this, an artificial weak
point, a kind of circuit breaker (relief) is added. The object is locate this hydraulic component, which is initially
held in a closed position by adjustable spring pressure, so the fluctuating system of the whole hydraulic pres-
sure circuit can act on it. An increase in system pressure above the pressure setting of the relief valve lifts off
the poppet, ball or piston and directs the excess pressurized fluid, supplied by the pump but not accepted by
the end user, back to the tank. The hydraulic energy produced in this process is converted into heat.
This hydraulic component is a pilot operated pressure limiting valve.
The cartridge type secondary pressure relief valves are flanged onto the added control block.
A direct acting relief valve is installed as a control part in the pilot operated pressure relief valve, which triggers
an impulse to the second, larger valve. Both valves are normally open.
A characteristic of this valve is that once the valve has started to relieve and is contamined, no further increase
in pressure is possible. This protects the system and damage to the components is avoided.
7.13.2Function
During operation, the system pressure pushes against the front side of piston 31. The same pressure is simul-
taneously applied via orifice A on the back side of piston 31, and via orifice B to poppet 33. Springs 32 and 14
move piston 31 and poppet 33 into closed position.
As soon as the system pressure exceeds the pressure setting of spring 14, the poppet 33 is lifted off its seat,
and some fluid escapes into the return line via orifice D. The previous static condition is now dynamic as fluid
is trying to flow via orifice A in order to compensate for the loss of volume and pressure. The size of the orifice
prevents immediate compensation, and a temporary difference in pressure between the top and bottom of the
main piston 31 exists.
The difference in pressure causes the system pressure, which is still pushing against the front of piston 31, to
lift the piston from its seat and large amounts of fluid can return to the tank via connection C.
7.13.3Pressure adjustment
To adjust pressure, remove cap 23, loosen lock nut 35 and turn adjustment screw 34 clock- or counterclockwi-
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MJFCIFSS
Secondary pressure relief valve pilot controlled
se to lower or raise the pressure. After the adjustment has been made, secure screw with lock nut (torque to
10 Nm) and install a lead seal.
10 O-ring 31 Main piston

11 O-ring 32 Spring
12 O-ring 33 Poppet
13 O-ring 34 Adjustment screw
14 Spring 35 Lock nut
23 Cap
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MJFCIFSS
Secondary valve : Two-stage pilot operated pressure limiting valve
7.14Secondary valve : Two-stage pilot operated pressure limi-

ting valve
The basic function and working principle of a two-stage secondary relief valve is the same as the secondary
relief valve.
A second stage, hydraulic controlled via pressure port is added to the standard relief valve in order to obtain a
reduced hydraulic system pressure for certain functions (two stage relief valve).
For use and function of pilot controlled pressure relief valve 9, refer to subgroup primary relief valve.
7.14.1Function of pressure cut off
7.14.1.1Stage 2 (normal pressure = high pressure)

At this position, no servo pressure is applied to connection Pst and the working surface of control piston 11 is
at tank pressure via the bore «a».
The force of spring 28 pushes the piston 11 to the left.
In this position, the pretension of spring 16 is maximal and so is the relief pressure.
7.14.1.2Cut off stage or stage 1 (low pressure)

Servo pressure can be applied to connection «Pst». It depends on specific application.
The pressure Pst builds up on working surface of control piston 11, which is pushed against the spring 28, this
decreasing the pretension of the springs 16 and thus the relief pressure.
7.14.1.3Pressure check and adjustment

For know how to measure pressure in circuit of relief valve, refer to subgroup «Adjustment».
To check and adjust high pressure (stage 2)

– Be sure that connection «Pst» is at tank pressure (otherwise you could screw in all way to the stop the ad-
justment screw 10).
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Secondary valve : Two-stage pilot operated pressure limiting valve
– Unlock the nut 13.

– Turning adjustment screw 9 clockwise increases the relief pressure - stage 2.
One turn = 150 bar.
– Turning adjustment screw 9 counterclockwise decreases the relief pressure - stage 2.
One turn = 150 bar.
– After adjustment, torque lock nut 13 (10 Nm) while holding adjustment screw 9.
To check and adjust low pressure (stage 1)

– Apply servo pressure at connection «Pst».
– Unlock the nut 14.
– Turning adjustment screw 10 clockwise increases the relief pressure - stage 1.
One turn = 150 bar.
– Turning adjustment screw 10 counterclockwise decreases the relief pressure - stage 1.
One turn = 150 bar.
– After adjustment, torque lock nut 14 (15 Nm) while holding adjustment screw 10.
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Suction valve
7.15Suction valve
7.15.1Task and function

Check valves, used as suction valves, are integrated into the compact control valve block.
The suction valves compensate for any loss of hydraulic oil, which may be created by secondary relief valve
action by drawing oil from the return line, thus preventing cavitation.
7.15.1.1Sealing or closing function

The operating / load pressure in the corresponding working circuit A or B acts upon the surface of spring side
valve poppet 6. the action of the spring side of the valve poppet 6 and the additional spring force keep the pop-
pet in closed position. The working circuit A or B is closed off leak oil free from the tank return connection T.
7.15.1.2Suction function
If there is insufficient oil (cavitation) in the user circuit, then the pressure difference between connection A / B
(vacuum) and connection T (tank pre-pressurization) create a force onto the front surface of valve poppet 6.
This causes the valve poppet 6 to lift off its seat and to permit oil to flow from tank connection T into the working
circuit A / B, in order to compensate for the oil loss.
7.15.2Repairs
Remove the complete valve if leaks are found, replace the o-ring. Unscrew the valve guide 7 to replace the o-
ring 9 and the spring 8.
4 Sealing ring 7 Valve guide

5 Valve housing 8 Spring
6 Valve poppet 9 O-ring
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Geared pump
7.16Geared pump
The geared pump P8, P9, P10.1 and P10.2 supply respectively the splitterbox lube circuit, the control oil circuit
and the replenishing oil circuit.
7.16.1Principle
The functioning principle of a geared pump is illustrated by the following drawing.

This pump is made of a leading gear (1) which drags a second gear (2) both located in a housing. The gears
rotate in opposite sense and engage on a point located on the aspiration and discharge opening axe :
In A, the gears separate creating partial vacuum filled with hydraulic oil. The liquid is hold between the teeth
and the housing and transferred in B where it flows through ß. The precise gear engagement secures the oil-
tightness between the aspiration and discharging opening and minimises the internal leakage.
7.16.2Maintenance and repair

Some oil leakage can be found at the gear pump. To replace the faulty seal kit, remove the screw 16 and chan-
ge the defective seal kit.
The gear pump does not require further maintenance.
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MJFCIFSS
Geared pump
3 Oil seal 16 Hex HD screw

5 Spring clip 24 Protecting cap
10 Seal kit 25 Locking plug
15 Spring ring
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Joystick and pedal transmitters
7.17Joystick and pedal transmitters
7.17.1Function
By moving the hand lever or the pedal, the corresponding connections «X» or «Y» of the control unit are elec-
trivcally energised as follows.
For a neutral position and for a joystick deflection included between -10% and 10% (approx. -1,8° and 1,8°) the
joystick delivers an output signal of 12 mA.
For a range deflection from 1,8° to 18° (respect. from -1,8° to 18°), the joystick delivers a proportional output
signal from 13 mA to 20 mA (respect. from 11 mA to 4 mA).
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MJFCIFSS
7.17.2Shovel flap pedals U20
Type Ident.
Pedal DFS - WE - i - RS232 / 90d 120×25 6205165
Connector
DT 06-8S-W8S
X460
Connector / pin Connector / pin on

Signal
on control unit FSG plate A1020
X460 X102
1 +24V 24V supply shovel flap pedals 1
2 0V Earthing shovel flap pedals 2
3 X- Output signal left shovel flap pedal moved 3
4 X+ Output signal right shovel flap pedal moved 4
5, 6 Not used 5
7 Rxd Not used 7
8 Txd Not used 8
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MJFCIFSS
7.17.3Left joystick U21
Type Ident.
Joystick St - WE - ixy - RS232 / Ta / 80 FI 100l 6205166
Connector
DT 04-12P-W12P
X461

Signal
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MJFCIFSS
X461 X96 X97_1

1 +24V 24V supply joystick stick and swing 1
2 0V Earthing joystick stick and swing 2
3 X Output signal joystick moved to the left / to the right 3
4 Y Output signal joystick moved forward / backward 4
5 S1 24V supply push rocker switch 1
6 S2 Output signal rocker switch tilted down 2
7 S3 Output signal rocker switch tilted up 3
8 WW 24V supply push buttons top of handle 4
9 WS1 Output signal push button left 5
10 WS2 Output signal push button right 6
11 Rxd Not used
12 Txd Not used
7.17.4Right joystick U22
Type Ident.
Joystick St - WE - ixy - RS232 / Ta / 80 FI 100l 6205167
Connector
DT 04-12P-W12P
X462
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MJFCIFSS

Signal
X462 X98 X99_1
1 +24V 24V supply joystick boom and shovel tilt 1
2 0V Earthing joystick boom and shovel tilt 2
3 X Output signal joystick moved to the left / to the right 3
4 Y Output signal joystick moved forward / backward 4
5 S1 24V supply push rocker switch 1
6 S2 Output signal rocker switch tilted down 2
7 S3 Output signal rocker switch tilted up 3
8 WW 24V supply push buttons top of handle 4
9 WS1 Output signal push button left 5
10 WS2 Output signal push button right 6
11 Rxd Not used
12 Txd Not used
7.17.5Right travel pedal U23
Type Ident.
Pedal DFS - WE - i4.20 - RS232 / 128×58r 6205163
Connector
DT 06-8S-W8S
X463

Signal
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MJFCIFSS
X463 X101
1 +24V 24V supply right travel pedals 1
2 0V Earthing travel pedals 2
3 Y Output signal right travel pedal moved forward / backward 3
4, 5, 6 Not used
7 Rxd Not used
8 Txd Not used
7 - 134 R 9250 from 13466

MJFCIFSS
7.17.6Left travel pedal U24
Type Ident.
Pedal Fst - WE - i4.20 - RS232 / 128×58l 6205164
Connector
DT 06-8S-W8S
X464

Signal
X464 X101
1 +24V 24V supply left travel pedals 1
2 0V Earthing left travel pedals 2
3 Y Output signal left travel pedal moved forward / backward 3
4, 5, 6 Not used
7 Rxd Not used
8 Txd Not used
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MJFCIFSS
7.17.7The FSG plate A1020

Located under the cabin in the connection box E1005, the FSG plate A1020 makes the connection between
the pilot control units and the solenoid valves. This plate amplifies the pilot control unit output signals so that
they are sufficient strength to supply the concerned regulating solenoid valves Yr... and switching solenoid val-
ves Y... which are mounted in series.
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MJFCIFSS
7.17.7.1Characteristic curves
The FSG plate A1020 amplifies the pilot control unit output signals so that they are sufficient strength to supply
the concerned regulating solenoid valves «Yr...» and switching solenoid valves «Y...» which are mounted in
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MJFCIFSS
series.
The graphic shows the signal delivered to the solenoid valves as a function of the pilot control unit output signal.
To explain this graphic, we take for example a movement in the direction X+.
For a deflection included between 0 and 10%, the joystick output signal has a value of 12 mA. In this range,
the FSG plate does not send any current to the solenoid valves «Y...» and «Yr...» which are then closed. There
is no movement.
For a deflection included between 10% and 90%, the joystick output signal is included approx. between 13 and
19 mA. In this range, the FSG plate sends a current included between lmin and lmax to the solenoid valves.
This current is proportional to the joystick output signal. The switching solenoid valve «Y...» is opened and the
regulation solenoid valve «Yr...» is opened proportionally to the joystick output signal : the speed of the move-
ment is proportional to the joystick deflection. The lmin and lmax values are adjusted when the excavator gets
mounted (see the part adjustment).
For a deflection included between 90 and 100%, the joystick output signal is included approx. between 19 and
20 mA. In this range, the FSG plate sends a current greater than lmax to the solenoid valves. The switching
solenoid valve «Y...» is opened and the regulation solenoid valve «Yr...» is fully opened : a maximal speed
movement is achieved.
As a conclusion, the functioning range of the joystick corresponds to a deflection included between 10% and
90%.
The FSG plate A1020 elaborates the switching logic which determines the priority for the different pump flows
in case of simultaneity of movements via the switching solenoid valves «Y...» (see schedule chapter logic sys-
tem).
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MJFCIFSS
Service Manual
7.17.7.2Adjustment
The lmin and lmax values for the different movements are adjusted thanks to a computer connected on the
port RS 232 of the FSG plate. These values are adjusted when the excavator gets mounted. This schedule
gives default values of lmin and lmax for the different movements.
Control unit Moved to Actuated movement lmin (mA) lmax (mA)

U20 X+ Open shovel flap / /
Shovel flap pedal X- Close shovel flap / /
X+ Swing right 250 900
U21 X- Swing left 250 900
Left joystick Y+ Stick cylinder extend 280 700
Y- Stick cylinder retract 310 700
X+ Bucket cylinder retract 250 630
U22 X- Bucket cylinder extend 310 670
Right joystick Y+ Boom cylinder retract 330 600
Y- Boom cylinder extend 360 600
U23 Y+ Travel right forward 340 620
Right travel pedal Y- Travel right backward 340 620
U24 Y+ Travel left forward 342 620
Left travel pedal Y- Travel left backwards 355 619
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MJFCIFSS
Service Manual
7 - 140 R 9250 from 13466

MJFCIFSS

Chapter 7 - Attachment / Travel System: Service Manual

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Chapter 7 - Attachment / Travel System: Service Manual

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Service Manual

Chapter 7 - Attachment / Travel system

R 9250 from 13466 7 -1

7-2 R 9250 from 13466

7 Attachment / Travel systems

Hydraulic cylinders Hydraulic pumps

CB2 left boom cylinder P1 working pump no. 1

CBT1 right bucket tilt cylinder P2 working pump no. 2

CBT2 left bucket tilt cylinder P3 working pump no. 3

CS1 right crowd cylinder P5.1 rear swing pump

CS2 left crowd cylinder P5.2 front swing pump

CLL ascent ladder lock cylinder P8 splitterbox lubrification pump

CLS service station lock cylinder P9 pilot oil pump

CS1 right stick cylinder P12 electro-hydraulic pump. ladder + service

CSS service station cylinder

CBT1 right shovel tilt cylinder Hydraulic motors

RCL rotating cylinder ladder MF2 water fan motor

MS1 left swing motor

Hydraulic valves MS2 right swing motor

SU1 servo oil unit MTL1 front left travel motor

RC rotary connection MTL2 rear left travel motor

VB1 control valve 1

VB2 control valve 2 Tank / collecting pipe

VB4 control valve 4 CP1 collecting pipe. hydraulic tank

R 9250 from 13466 7 -3

CP3 collecting pipe power pack

Gears CP4 collecting pipe before oil cooler

GTR travel gear right HT hydraulic tank

GTL travel gear left LF leakoilfilter

Oil sample points SP suction pipe

OSP1 oil sample point. hydraulic oil

OSP2 oil sample point splitterbox

7-4 R 9250 from 13466

7.2 Hydraulic pump assembly

7.2.1 Technical data

Machine model / Serial No R 9250 Litronic / 13466

Splitterbox Type Rexroth mobilex GFC 320 1002

Direction of rotation (seeing splitterbox pump side) Counterclockwise

R 9250 from 13466 7 -5

Main pumps (P3) Number Type 1 pump A 11 VLO 260

7-6 R 9250 from 13466

6 Switching valve - Flow control

7 Pressure control valve

Pst Test point / Flow adjustment

R 9250 from 13466 7 -7

Mst Test point / Pump high pressure

MB Test point / Pump high pressure

P Test point / Control pressure

Ps1 Swing pump Nb1

Ps2 Swing pump Nb 2

P6.1 Water cooler fan pump

P6.2 Oil cooler fan pump

P8 Splitterbox lubrification pump

P9 Pilot oil pump

7-8 R 9250 from 13466

7.3 Functional description

7.3.1 Electro-hydraulic system

R 9250 from 13466 7 -9