Service Manual

Chapter 3 - Technical Data

Technical data....................................................................................................................... 3-3
1 Machine data ....................................................................................................................................... 3-3
1.1 General...................................................................................................................................... 3-3
1.2 Engine ....................................................................................................................................... 3-3
1.3 Splitterbox.................................................................................................................................. 3-4
1.4 Hydraulic system ....................................................................................................................... 3-4
2 Adjustment procedure 9250................................................................................................................. 3-7
2.1 Initial adjustment........................................................................................................................ 3-7
2.2 Working pumps adjustment ....................................................................................................... 3-11
2.3 Primary and secondary valves adjustment................................................................................ 3-14
2.4 Ladder and service trap adjustment .......................................................................................... 3-18
2.5 Swing adjustment ...................................................................................................................... 3-18
2.6 Cooling adjustment.................................................................................................................... 3-20
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R 9250 3.00.1
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LFR / en / version: 09 / 2007

3.00.2 R 9250
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 Service Manual Technical data
Machine data

3.10: Technical data

1 Machine data

1.1 General

Machine weight backhoe attachment t (lb) 250 (551,155)

Machine weight shovel attachment t (lb) 253,5 (558,870)

Length without attachment mm (ft.in) 10240 (33’ 7’’)

Width of the undercarriage (... mm track pads) mm (ft.in) 6040 (19’ 10’’)

Height without attachment mm (ft.in) 7250 (23’ 9’’)

Tail swing mm (ft.in) 6140 (20’ 2’’

Ground clearance mm (ft.in) 625 (2’ 1’’)

Digging force / breakout force (backhoe attachment) kN 780 / 859

Crowd force at ground level / max. crowd force / breakout force kN 1050 / 1210 / 935
(shovel attachment)

1.2 Engine

Trademark CUMMINS

Model QSK 45

Type 12 cylinders, V-engine

Rating at nominal per SAE J 1995 kW 960 (1304 HP)

Nominal speed RPM 1800

Idle speed RPM 700±25

High idle RPM 1900

Maximal torque (at 1500 RPM) mN 5800

Stroke volume l (cu, in) 45 (2745)

Bore / stroke mm 159 / 190

Oil quantity l 182

Oil change intervals hrs 250 or chart method

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Oil viscosity (above -25°C / -13°F) SAE 15 W 40

Firing order 1R - 6L - 5R - 2L - 3R - 4L
6R - 1L - 2R - 5L - 4R - 3L

Valve adjustment intake / exhaust mm 0,36 / 0,81

Maximum supply fuel flow kg / h 1,066

Diesel fuel tank capacity l 5440

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Machine data

1.3 Splitterbox

Trademark Lohmann

Type GFC 320 1002

Oil quantity l 60

Oil viscosity SAE 90 or SAE 80W-90

1.4 Hydraulic system

1.4.1 Main circuit

Hydraulic pumps type (2x) A20VSO520 + (1x)

A11VLO260 at 1800 RPM

Pumps output kW 797,23 (1083 HP)

Max flow l/min 2122,42

Regulation begin at nominal engine power bar 214,11

Max. operating pressure (primary relief valves) bar 320±5

Regulation end (pressure cut off) bar 300±5

Secondary pressure bar 380±10

Hydraulic oil quantity when maximum level in the tank l 5440

Hydraulic oil quantity to change l 3650

Hydraulic oil change intervals hrs 2000

Filter change intervals hrs first at 500 / every 1000

Control valves for backhoe attachment type Rexroth : 2x (4MO - 40) + 1x

(4MO - 32) + 1x (1MO - 32)

Control valves for shovel attachment type Rexroth : 2x (4MO - 40) + 1x

(4MO - 32) + 1x (1MO - 32)

Hydraulic cylinders

Boom cylinder Ø piston / Ø rod / stroke (backhoe attachment) mm 320 / 220 / 2850

Boom cylinder Ø piston / Ø rod / stroke (shovel attachment) mm

Stick cylinder Ø piston / Ø rod / stroke (backhoe attachment) mm 260 / 180 / 2250
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Crowd cylinder Ø piston / Ø rod / stroke (shovel attachment) mm

Bucket tilt cylinder Ø piston / Ø rod / stroke mm 230 / 160 / 1950

Shovel tilt cylinder Ø piston / Ø rod / stroke mm

Shovel flap cylinder Ø piston / Ø rod / stroke mm

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Machine data

1.4.2 Swing circuit

Closed circuit

Swing pump type (2x) A4VG 125 (2820 RPM)

Swing pump design Double swash plate type axial

piston pumps

Swing pump output kW (2x) 220 (2x 299 HP)

Max. displacement cm³ 2x 125

Max. flow l/min 705

Max. operating pressure bar 350

Secondary pressure - swing circuit bar 400

1.4.3 Servo control oil circuit

Hydraulic pump type HY / Z GS 11 / 22.5 (2820

RPM)

Hydraulic pump design Geared pump

Max. flow / servo l/min 63

1.4.4 Cooling circuit

Oil cooler pump type A11VO75 (2226 RPM)

Oil cooler pump design variable flow axial piston

pump

Oil cooler pump output kW 110 (149 HP)

Oil cooler pump volume cm³ 74

Oil cooler pump flow l/min 280

Oil cooler motor volume l/min (FMF90)

Water cooler pump type A11VO75 (2226 RPM)

Water cooler pump design variable flow axial piston

pump

Water cooler pump output kW 110 (149 HP)

Water cooler pump volume cm³ 74

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Water cooler pump flow l/min 280

Water cooler motor volume cm³ (FMF90)

Splitterbox oil cooling pump type HYZGS11/28

Splitterbox oil cooling pump design Geared pump

Splitterbox oil cooler pump volume cm³ (FMF90)

Splitterbox oil cooler pump flow l/min 79

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Adjustment procedure 9250

2 Adjustment procedure 9250

Fig. 1 Pumps installation

2.1 Initial adjustment

2.1.1 Pre-requirement

Nominal value Measured Adjusted

valu valu
e e

Hydraulic tank pressurisation 0 bar

Minimal RPM on the display 800 + 50 RPM

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Nominal RPM on the display 1800 ±10 RPM charged

Maximal RPM on the display 1870 ±20 RPM

Servo pressure 55 bar

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2.1.2 Adjustment of servo pressure

Fig. 2 Servo unit

• Gauge on P (60 bar).
• Engine at 1800 ±50 RPM.
• Adjust the screw 9 on the servo unit so to obtainP = 55 +3 bar
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Adjustment procedure 9250

2.1.3 Adjustment of swing brake

Fig. 3 Servo unit

Nominal value Measured value Adjusted value

Swing brake (valve Y7 on the servo unit) open 30 bar

for 30 bar

Adjustment :
• Gauge on A5 (60 bar).
• Engine at 1200 ±50 RPM.
• Unplug the valve Y7 at E1038.
• Adjust the screw 6 on the servo unit so to obtainP at A5 = 30 ±2 bar
• Plug back the valve Y7.

2.1.4 Check of the good working of the pump control box

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Fig. 4 Working pumps

Check of the pressure Pst : use a 60 bar gauge (precision : ±0,6 bar).

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Position Pst required (bar) Measured value Procedure if the required value is not reached

0 <10 Can not be modified

1 15±2 Adjustment of I4 on the display (from EV1 to EV2) at 40%

I4 adjusted at : _ _ % = _ _ bar

2 >20 Adjustment of the maximal current in the BST (U16) at 650

mA

2.1.5 Initial adjustment

Fig. 5

2.1.6 Installation of the pump control box for R/P 9250

Connect the control box (Ident. Nr.) to the connectors XT103 and XT104 in the switching box E1005
of the cab.

2.1.7 Pre-adjustment on the display

• Install Green Access Key at X30 or X31 on ESP01 (A1001) cards.
• Enter into «SET PUMPS» Menu :
Enter in «I3» and thanks to the arrows up and down, set EV1, EV2 at 100%.
Enter in «I4» and thanks to the arrows up and down, set EV1, EV2 at 40%.
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Adjustment procedure 9250

2.2 Working pumps adjustment

2.2.1 Pumps P1 and P2

Fig. 6 Servo unit

Fig. 7 Working pumps P1 and P2

For the pumps adjustment, the oil temperature value must be : 55 +5°C.

2.2.2 Adjustment of switching point for flow control

LFR / en / version: 09 / 2007

Tool requirement : open-end wrench 13 and 19.

• Gauge on P (60 bar)P = 55 bar
• Gauge on Mst (60 bar).
• Gauge on Pst (60 bar).
• Engine at 1800 ±50 RPM, control box on position 1 :
Angle indicator of the pump7,5 ±2,5°
• Adjust the screw DW so to obtainMst = 25 bar
P - Mst = 30 ±2 bar

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Pump P1 Pump P2

Nominal value Measured value Adjusted value Nominal value Measured value Adjusted value

Pst = 15 ±2 bar Pst = 15 ±2 bar

Mst = 25 bar Mst = 25 bar

ðP = P - Mst = ðP = P - Mst =
30 ±2 bar 30 ±2 bar

2.2.3 Hydraulic adjustment for Qmin

Tool requirement : open-end wrench 46 and 30.
• Gauge on P (60 bar)P = 55 bar
• Gauge on Mst (60 bar).
• Gauge on Pst (60 bar).
• Engine at 1800 ±50 RPM, control box on position 0 :
• Unplug the valve Y3 corresponding to the pump to adjust.
• Adjust the screw Hmin so to obtain10 bar < Mst < 15 bar
• Plug back the valve Y3 corresponding to the pump to adjust.

Pump P1 Pump P2

Nominal value Measured Adjusted Nominal value Measured Adjusted

value value value value

Pst < 10 bar Pst < 10 bar

10 bar < Mst < 15 bar 10 bar < Mst < 15 bar

2.2.4 Hydraulic adjustment for Qmax

Tool requirement : imbus wrench 3.
• Gauge on P (60 bar)P = 55 bar
• Gauge on Mst (60 bar).
• Gauge on Pst (60 bar).
• Engine at 1800 ±50 RPM, control box on position 2 :
• Unplug the valve Y3 corresponding to the pump to adjust.
• Adjust the screw Hmax so to obtainMst = 45 ±3 bar
• Plug back the valve Y3 corresponding to the pump to adjust.

Pump P1 Pump P2

Nominal value Measured Adjusted value Nominal value Measured Adjusted value
value value

Pst >20 bar Pst >20 bar

LFR / en / version: 09 / 2007

Mst = 45 ±3 bar Mst = 45 ±3 bar

2.2.5 Adjustment of the power regulator

Tool requirement : open-end wrench 13 and 19.
• Unplug the valve Y4XLR = 0
• Gauge on P (60 bar)P = 55 bar
• Gauge on Mst (60 bar).
• Gauge on Pst (60 bar).
• Engine at 1800 ±50 RPM, control box on position 2 :

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• Turn in the screw LR all the way in order to have the lowest pressure Mst.
• Slowly turn out the screw LR until the pressure Mst begins to increase.
• Search the point at which the pressure decreases.
• Plug back the valve Y4.

Pump P1 Pump P2

Nominal value Measured value Adjusted value Nominal value Measured value Adjusted value

Pst >20 bar Pst >20 bar

2.2.6 Adjustment of the pressure regulator

• Engine at 1800 ±50 RPM
• Loosen the screw DR one turn
• Adjust the corresponding primary pressure relief valve at 300 bar (see procedure). Don’t plug
X82 (on E1005).
• Gauge on MB (use the same gauge as before for the primary valve).
• Tighten the screw DR until the pressure MB increasesDA = 300 +5 bar
• Do this adjustment for each working pump.
• Plug back the connector X82.

Nominal value Measured value Adjusted value

DA 300 bar

Pump P3

Fig. 8 Working pump P3

For the adjustment of the working pump P3, don’t unplug the valve Y4_2.

2.2.7 Beginning of regulation

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• Gauge on M (600 bar).

• Gauge on M1 (600 bar).
• In the display menu «power test» register0 %
Information : on the valve Y4_2300 mA
• Start the engine.
• Engine at 1800 ±50 RPM.
• Adjust the primary pressure relief valve on VB3 so to obtain130 bar
• At the pump regulation begin, the pressure at M1 pass from 0 to 70 bar.

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• If the beginning of the regulation isn’t correct, adjust the screw opposed to the solenoid valve.
• Readjust the primary relief valve to the prescribed value.

2.2.8 Cut off adjustment

• Engine at 1800 ±50 RPM.
• Turn counterclockwise one or two turns the screw of the pressure regulator.
• Discharge primary pressures on VB3 at305 bar
• Gauge on M (600 bar).
• Gauge on M1 (600 bar).
• Fully retract the stick cylinders supplied by the pump and maintain the joystick actuated.
• Slowly turn the screw clockwise on the regulator while observing the pressure at gauge M1 drop
to 150 bar
• Readjust the primary relief valve to the prescribed value.

2.3 Primary and secondary valves adjustment

Fig. 9 Control valve block

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Fig. 10 test points travel motors

2.3.1 Secondary valves adjustment

Before adjusting the valves, unplug the connector X82 to inactivate the proximity switches. After ad-
justing, reconnect X82.

Travel adjustment
• Disconnect brake hoses and blank off the ports Br ext.
• Tighten completely the primary valves and loosen of a quarter turn.
• Gauge on MA and MB (600 bar).
• Engine at 1500 ±50 RPM.
• Actuate the movement corresponding to the valve and maintain actuated.
• Adjust the valve so to obtainMA = MB = 380 bar
• Do the same procedure for the other side.
• Reconnect brake hoses on the ports Br ext.

Attachment adjustment
• Gauge on P (600 bar).
• Tighten completely the primary valve on the valve block and loosen of a quarter turn.
• Engine at 1500 ±50 RPM.
• Do the movement corresponding to the secondary valve and maintain it actuated.
• Adjust the screw 30 so to obtainP = 380 bar
• Do the same procedure for all the secondary valves of all the valve blocks (VB1, VB2 and VB3).
LFR / en / version: 09 / 2007

Movement Nominal Measured value Adjusted value

value
(bar) VB1 VB2 VB3 VB1 VB2 VB3

Boom UP 380 +20

DOWN 380 +20

Stick OUT 380 +20

IN 380 +20

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Bucket OUT 380 +20

IN 380 +20

Shovel OUT 380 +20

140 +20

IN 380 +20

Trap CLOSE 380 +20

OPEN 340 +20

Transla- UP 380 +20

tion
left DOWN 380 +20

Transla- UP 380 +20

tion
right DOWN 380 +20

Transla- 380 +20

tion
left 380 +20
and
right
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Adjustment procedure 9250

2.3.2 Primary valves adjustment

Simple primary values adjustment

Fig. 11 Control valve installation

• Gauge on P (600 bar).
• Engine at 1800 ±50 RPM.
• Extend the boom or stick and maintain actuated.
• Adjust the valve so to obtainP = 320 bar
• Do the same procedure for the other simple primary valve.

Nominal value Measured value Adjusted value

(bar)
VB1 VB2 VB3 VB4 VB1 VB2 VB3 VB4
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Single stage primary valve 320 +10

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2.4 Ladder and service trap adjustment

Fig. 12 Ladder and service trap adjustment

• Gauge on test point (600 bar).
• Actuate the down motion for the ladder or for trap.
• When the ladder or the trap has reached its low position, continue to press the button.
• Adjust PRV to obtainTest point = 110 bar

Nominal value (bar) Measured value Adjusted value

Test point 110

2.5 Swing adjustment

Secondary relief valve (400 bar) are not adjustable. If necessary, command a new cartridge.
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Adjustment procedure 9250

Fig. 13 Swing adjustment

2.5.1 Replenishing pressure

• Gauge on G (60bar).
• Engine at 1800 ±50 RPM.
• Adjust the screw X so to obtainG = 30 bar
• Do the same procedure for the both swing pumps (P5.1 and P5.2).

Nominal value (bar) Measured value Adjusted value

Replenishing pressure P5.1 30

P5.2 30

2.5.2 Swing working pressure

• Gauge on MA and MB (600 bar).
LFR / en / version: 09 / 2007

• Engine at 1800 ±50 RPM.

• Fully actuate the swing joystick to the left.
• Adjust the screw DR so to obtainMA = 320 bar
• Fully actuate the swing joystick to the rightMA = MB

Nominal value (bar) Measured value Adjusted value

Swing working pressure 320

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2.6 Cooling adjustment

Fig. 14 Cooling pumps

• Run the diesel engine at high idle.
• Disconnect the regulation valve Y10.1 for pump P6.1 (Y10.2 for pump P6.2).
• Gauge on M (600 bar).
• Adjust RDA1 (or RDA2) to obtainM = 250 bar
• Check the way of rotation of the fan : flow from outside to inside.

Nominal value Measured value Adjusted value

High pressure M (P6.1) 250 bar

High pressure M (P6.2) 250 bar

Oil cooling fan speed 1200 RPM

Water cooling fan speed 1150 RPM

LFR / en / version: 09 / 2007

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Adjustment procedure 9250

LFR / en / version: 09 / 2007

3.10.20 R 9250
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