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Liebherr R9250 Hydraulic Excavator Service Manual 2007 - 10070168

Liebherr R9250 Hydraulic Excavator Service Manual 2007 – 10070168

Name: Liebherr R9250 Hydraulic Excavator Service Manual 2007 - 10070168
SKU: LIE-R9250-SM-10070168-2007-HD
Availability: InStock

Original price was: $44.95.Current price is: $26.95.

Complete Liebherr service manual for the R 9250 hydraulic excavator and material handler, document 10070168, edition 08/2007, valid from serial number 13466. Full hydraulic, engine, swing, electrical, cooling, track and uppercarriage mechanical coverage across 972 pages.

SKU: LIE-R9250-SM-10070168-2007-HD Category: Heavy Equipment Service Manuals Tags: Liebherr R 9250 workshop manual 2007, Liebherr R9250 service manual, R9250 hydraulic excavator repair manual PDF, R9250 material handler service documentation Vendor: Motor Pool Manuals

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Description

Complete Liebherr R9250 hydraulic excavator and material handler service manual, document order number 10070168, edition 08/2007, valid for machines from serial number 13466. This 972-page workshop manual covers every major system on the R 9250, from the Cummins QSK 45 diesel engine and splitterbox through the working pumps, control valve blocks, swing system, cooling circuits, track tensioning, electrical system and uppercarriage mechanical assembly. Written by LFR Technical Documentation for Liebherr France SAS, it is the reference document technicians use for adjustment, diagnosis, repair and rebuilding of this 960 kW (1304 HP) excavator.

File Details

Manual type: Service manual / workshop manual
Brand: Liebherr
Model: R 9250 (type no. 437)
Document order number: 10070168
Edition / version: 08 / 2007
Valid for: R 9250 from serial number 13466
Language: English
Page count: 972 pages
File format: PDF
Author: LFR – Technical documentation department
Manufacturer: Liebherr France SAS, Colmar Cedex

Chapters Covered

Chapter 1 – General: safety information and signage, tightening torques (metric, SAE fittings, hexagon socket head cap screws), HYTORC torque machine operation, welding procedures, electrode classification, reinforcement plates
Chapter 2 – Safe work procedure / Risk assessment: 38 individual SWPs including machine isolation, hydraulic repair isolation, engine removal, track component isolation, welding repair isolation, hydraulic cylinder removal, bucket and link removal, suction valve repair, load roller replacement, track chain replacement, track drive sprocket change, counterweight removal, boom removal, stick removal, splitterbox input shaft, idler replacement, carrier roller, bucket change, work pump, cabin, swing box, main valve bank, swing pump, splitterbox gears, HYTORC operation, centre girder and side frames, boom fitment, uppercarriage assembly, undercarriage assembly, faceshovel/backhoe assembly
Chapter 3 – Technical Data: machine weight, engine data (Cummins QSK 45), splitterbox, hydraulic system (main circuit, swing circuit, servo control oil circuit, cooling circuit), adjustment procedure 9250 (initial adjustment, working pumps, primary and secondary valves, ladder and service trap, swing, cooling)
Chapter 4 – Operating / Maintenance: lubrication chart, service trap, control and maintenance chart, oil sampling procedure (splitterbox, engine)
Chapter 5 – Tooling: hydraulic, general, electric tooling; special wrench for cylinder piston; mounting device for swing gear brake; slotted nut tools; pump control box installation for R/P 996, 995, 9250 and 9350
Chapter 6 – Engine: technical data, cooling system (schematic, function, coolant capacity, cleaning, antifreeze and corrosion protection), fuel system (schematic, capacity, draining condensation, filter change, bleeding)
Chapter 7 – Attachment / Travel system: hydraulic pump assembly, functional description, working pumps A20 VSO 520 and A11 VLO 260, pressure cut-off, power regulation, flow limitation, attachment function (boom, stick, bucket tilt, shovel tilt, shovel flap), travel, troubleshooting, adjustment, control valves 4 MO 40 and 4 MO 32, hydraulic cylinders, primary and secondary pressure relief valves, suction valve, geared pump, joystick and pedal transmitters, FSG plate A1020
Chapter 8 – Swing system: swing pumps A4 VG 125, swing motors FMF 250, swing gears SAT 450/257, swing ring, functional description, troubleshooting, adjustment, detailed component description
Chapter 9 – Cooling system: hydraulic and electric schematics, component location, functional description, temperature regulation, troubleshooting, adjusting, hydraulic pump A11VO75DRX, hydraulic fixed displacement motor FMF 90
Chapter 10 – Grease systems: Lincoln centralized lubrication system, hydraulic drum pump, injectors SL-1 and LM-5, progressive metering devices SSV, ultrasonic sensor, digital pressure switch, piston detector
Chapter 11 – Ladder / Service trap systems: schematics, component location, functional description (electrical and hydraulic), troubleshooting, pressure control valve adjustment, electro-hydraulic gear pump, rotating cylinder, hydraulic cylinder removal, pressure relief valve, solenoid valve
Chapter 12 – Hydraulic track tensioning system: description, function, temperature-dependent pressure adjustment
Chapter 13 – Electric systems: main components location, cabin electric, switching box E1005, washer/wipers, analog monitoring, lighting, power pack, engine start and prelub, RPM control, sensors, emergency stop, solenoid valves, alternator and battery, display/sensors, BST, CAN BUS, BBT, components
Chapter 14 – Pneumatic control: technical data, pneumatic schematic, component location, functional description, troubleshooting, adjustment, pressure regulator, air dryer, check valve
Chapter 15 – Uppercarriage mechanical: coupling, splitterbox GFC 320/1002, swing gear SAT 450/257, swing bearing ROD 1304 DJ, engine / splitterbox mounting, preassembled modules (rotating deck, counterweight, cab, powerpack, hydraulic tank, fuel tank, cab elevation, catwalk boxes)
Chapter 21 – Schematics: electrical diagrams, hydraulic schematics

Across its 972 pages this service manual delivers the complete technical picture of the R 9250. Every hydraulic circuit is documented – the two A20 VSO 520 working pumps, the single A11 VLO 260 pump, the A4 VG 125 swing pumps, the A11VO75DRX cooling pumps, the geared servo and lubrication pumps – with adjustment values, test points and troubleshooting flowcharts. The 4 MO 40 and 4 MO 32 control valve blocks are broken down to component level, with leak oil specifications, secondary and primary valve setting procedures, spool removal and resealing. The Cummins QSK 45 engine chapter covers cooling, low-temperature aftercooling (LTA), fuel, and the two-circuit cooling system with capacities. The electrical chapter documents every board – FSG A1020, ESP01 A1001, A1016 interface, A1019 regulation, BST U16 – through to the CAN BUS and BBT, including the display error code list (E501 to E598). The mechanical chapter covers the swing ring bearing, gear pinion backlash, swing gear sealing, and bolt tensioning values for M36 and M42 mounting bolts.

Because this is the manufacturer’s own service documentation, every adjustment value, tightening torque, pressure setting and clearance is presented exactly as the workshop floor expects it. That is what separates a working service manual from a generic repair book – the R 9250 is a large machine with hydraulic pressures up to 380 bar, cylinder screw torques up to 3200 Nm, swing ring bolt tensioning at 1350 bar, and Cummins engine settings that cannot be guessed.

What This Manual Lets You Do

With the Liebherr R9250 service manual on hand a qualified technician can:

Carry out the complete initial adjustment sequence for the R 9250 – servo pressure at 55 bar, swing brake at 30 bar, working pump flow switching point, Qmin/Qmax hydraulic settings, power regulator LR, pressure cut-off DR, and the primary and secondary valve pressures on all four control valve blocks
Remove and reinstall the engine, splitterbox, main pumps, swing pumps, swing gear, counterweight, boom, stick, bucket, travel gears, track chains, load rollers, idlers, carrier rollers and the cabin following the SWP (Safe Work Procedure) steps
Diagnose and repair hydraulic faults across the attachment, travel, swing, cooling and grease circuits using the supplied troubleshooting charts, test points and leak oil measurement procedures
Reseal hydraulic cylinders with either new-fixation or old-fixation pistons, including the correct seal orientation for rod step seals, glyd rings and support rings, plus the tightening torques for the piston and bearing head screws
Service the Cummins QSK 45 diesel engine cooling system, LTA aftercooling circuit, fuel filters and the bleed procedure
Set up the Lincoln centralized lubrication system – pump cycle times, grease quantities, injector output adjustment, SSV progressive divider diagnosis and blockage location
Work through the electrical system with the correct fuse and relay assignments, connector pin-outs, CAN BUS layout, Quantum and BST error codes, and emergency-stop wiring
Adjust the ladder and service trap circuits including the pressure control valve at 110 bar, and diagnose the safety interlock that prevents machine operation unless both are locked in the upper position
Rebuild the track tensioning system – the elastomer tensioner pressure curve from -20 degrees C to +50 degrees C and the correct filling/reducing procedure
Check and tension the swing ring bearing bolts with the bolt tensioning cylinder procedure, measure axial, radial and backlash play and compare against the wear limits

Why It Matters

The R 9250 is a 250-tonne class machine. Wrong hydraulic pressure settings, incorrect cylinder torque values or mis-tensioned swing ring bolts do not fail gently – they damage pumps, cylinders, bearings and structural components. The pressures, clearances and torque figures in this manual are the ones that keep the excavator inside its design envelope. Having the actual Liebherr settings at the bench means the difference between a repair that holds and a repair that comes back.

Complete PDF Bookmark Tree

Complete Bookmarks

The complete bookmarks in the “Liebherr R9250 Hydraulic Excavator Service Manual 2007 – 10070168” are as follows:

1 Generalp. 7

1.1 Safety information, signagep. 7

1.1.1 Symbols in the operating instructionsp. 7

1.1.2 Use in accordance with the regulationsp. 8

1.1.3 Safety instructionsp. 8

1.1.3.1 General safety instructionsp. 8

1.1.3.2 Avoidance of crushing and burnsp. 9

1.1.3.3 Avoidance of fire and explosionsp. 10

1.1.4 Servicing the machine safelyp. 10

1.1.4.1 General safety instructionsp. 10

1.1.4.2 Cleaningp. 11

1.1.4.3 Crack testingp. 11

1.1.4.4 Welding, drilling, firing and grinding workp. 12

1.1.4.5 Process materialsp. 12

1.1.5 Repair workp. 12

1.1.6 Electrical systemp. 13

1.1.7 Hydraulic accumulatorp. 13

1.1.8 Hydraulic hoses and sheathed cables.p. 14

1.2 Tighteningp. 16

1.2.1 Tightening torquesp. 16

1.2.1.1 Factory standards WN 4037 – Tightening forces and torques of metric screwsp. 16

1.2.1.2 Torque values for the mounting screws on the SAE fittingsp. 18

High pressure fittingsp. 18

Low pressure half flangesp. 19

1.2.1.3 Hexagon – socket – head cap screwp. 19

1.2.1.4 Notesp. 20

1.2.1.5 Wrench size for metric screwp. 20

1.2.2 Hytorcp. 21

1.2.2.1 Safetyp. 21

1.3 Weldingp. 44

1.3.1 Electrical isolation prior to weldingp. 44

1.3.2 Welding proceduresp. 44

1.3.2.1 Preparation of a crackp. 44

1.3.2.2 Preparation of the weldp. 44

1.3.2.3 Classification of the welding electrodesp. 45

1.3.2.4 Storing electrodesp. 46

1.3.2.5 Welding techniquep. 46

1.3.2.6 Reinforcement of the welding seamp. 47

1.3.2.7 General application of reinforcement platesp. 47

Shape of reinforcement platesp. 47

Plate thicknessp. 47

Plate qualityp. 47

Plate installationp. 48

Plate weldingp. 48

2 Safe work proceduresp. 51

2.1 Safe work procedures SWP 001 – Safety check listp. 53

2.2 Safe work procedures SWP 002 – Basic R 9250 machine isolationp. 54

2.3 Safe work procedures SWP 003 – R 9250 Isolate for hydraulic repairp. 55

2.4 Safe work procedures SWP 004 – remove R 9250 enginep. 56

2.5 Safe work procedures SWP 005 – Isolate machine for track component repairsp. 58

2.6 Safe work procedures SWP 006 – Isolate machine for welding repairsp. 59

2.7 Safe work procedures SWP 007 – Remove and replace hydraulic cylinderp. 60

2.8 Safe work procedures SWP 008 – Removal of bucket levers and linksp. 62

2.9 Safe work procedures SWP 009 – Repair / replacement of suction valvep. 63

2.10 Safe work procedures SWP 010 – Remove and replace load rollersp. 64

2.11 Safe work procedures SWP 011 – Remove and replace track chainp. 66

2.12 Safe work procedures SWP 012 – R 9250 track drive sprocket change outp. 68

2.13 Safe work procedures SWP 013 – Remove counterweightp. 71

2.14 Safe work procedures SWP 014 – Remove boomp. 72

2.15 Safe work procedures SWP 015 – Remove stickp. 74

2.16 Safe work procedures SWP 016 – Change splitterbox input shaft assemblyp. 76

2.17 Safe work procedures SWP 017 – Remove idler and replacep. 77

2.18 Safe work procedures SWP 018 – Change carrier rollerp. 78

2.19 Safe work procedures SWP 019 – Bucket change outp. 79

2.20 Safe work procedures SWP 020 – Change out work pumpp. 81

2.21 Safe work procedures SWP 021 – Change cabinp. 83

2.22 Safe work procedures SWP 022 – R 9250 remove and replace enginep. 84

2.23 Safe work procedures SWP 023 – Remove and replace swing boxp. 86

2.24 Safe work procedures SWP 024 – Change main valve bankp. 88

2.25 Safe work procedures SWP 025 – Change swing pumpp. 89

2.26 Safe work procedures SWP 026 – Change splitterboxp. 90

2.27 Safe work procedures SWP 027 – Change splitterbox Gearsp. 92

2.28 Safe work procedures SWP 028 – Change splitterbox input shaft assemblyp. 93

2.29 Safe work procedures SWP 029 – Hy-torc operationp. 94

2.30 Safe work procedures SWP 030 – Remove and replace centre girder and side framesp. 95

2.31 Safe work procedures SWP 031 – Fit stick assembly to boomp. 100

2.32 Safe work procedures SWP 032 – Assemble uppercarriagep. 102

2.33 Safe work procedures SWP 033 – Assemble undercarriagep. 104

2.34 Safe work procedures SWP 034 – Assemble boom, faceshovel or backhoep. 106

2.35 Safe work procedures SWP 035 – Assemble stick, faceshovel or backhoep. 107

2.36 Safe work procedures SWP 036 – Fit boom assembly to uppercarriagep. 108

2.37 Safe work procedures SWP 037 – Assemble LIEBHERR R 9250p. 110

2.38 Risk assessmentp. 114

3 Technical datap. 121

3.1 Machine datap. 121

3.1.1 Generalp. 121

3.1.2 Enginep. 121

3.1.3 Splitterboxp. 122

3.1.4 Hydraulic systemp. 122

3.1.4.1 Main circuitp. 122

3.1.4.2 Swing circuitp. 123

3.1.4.3 Servo control oil circuitp. 123

3.1.4.4 Cooling circuitp. 123

3.2 Adjustment procedure 9250p. 125

3.2.1 Initial adjustmentp. 125

3.2.1.1 Pre-requirementp. 125

Adjustment of servo pressurep. 126

Adjustment of swing brakep. 127

Check of the good working of the pump control boxp. 127

Initial adjustmentp. 128

Installation of the pump control box for R/P 9250p. 128

Pre-adjustment on the displayp. 128

3.2.2 Working pumps adjustmentp. 129

3.2.2.1 Pumps P1 and P2p. 129

Adjustment of switching point for flow controlp. 129

Hydraulic adjustment for Qminp. 130

Hydraulic adjustment for Qmaxp. 130

Adjustment of the power regulatorp. 130

Adjustment of the pressure regulatorp. 131

3.2.2.2 Pump P3p. 131

Beginning of regulationp. 131

Cut off adjustmentp. 132

3.2.3 Primary and secondary valves adjustmentp. 132

3.2.3.1 Secondary valves adjustmentp. 133

Travel adjustmentp. 133

Attachment adjustmentp. 133

3.2.3.2 Primary valves adjustmentp. 135

Simple primary values adjustmentp. 135

3.2.4 Ladder and service trap adjustmentp. 136

3.2.5 Swing adjustmentp. 136

3.2.5.1 Replenishing pressurep. 137

3.2.5.2 Swing working pressurep. 137

3.2.6 Cooling adjustmentp. 138

4 Operating maintenancep. 141

4.1 The lubrication chartp. 143

4.1.1 The service trapp. 143

4.2 Control and maintenance chartp. 145

4.3 Oil sampling procedurep. 151

4.3.1 Oil sample extraction valvep. 151

4.3.2 Splitterboxp. 152

4.3.3 Enginep. 153

5 Toolingp. 157

5.1 Hydraulicp. 159

5.2 Generalp. 177

5.3 Annexesp. 201

5.3.1 Special wrench to remove and install the piston on hydraulic cylindersp. 201

5.3.2 Mounting device for disassembly and assembly of brake housing / disk brake on swing gear Liebherr SAT 220 / 225 / 250 / 275 / 300 / 325 / 350 / 400 /450p. 202

5.3.3 To remove or / and tighten of the slotted nut on the output / swing gear SAT 225 / 250 / 275 / 300 / 325 / 350 / 400 / 450p. 202

5.4 Installation of the pump control boxp. 206

5.4.1 Installation of the pump control box for R/P 996p. 206

5.4.1.1 Connectionp. 206

5.4.1.2 Verification of the flow reduction valuesp. 206

5.4.1.3 Adjustment of the flow reduction values for input 3 and 4p. 207

5.4.2 Installation of the pump control box for R/P 995p. 207

5.4.2.1 Connectionp. 207

5.4.2.2 Verification of the flow reduction valuesp. 207

5.4.2.3 Adjustment of the flow reduction values for input 3 and 4p. 208

5.4.3 Installation of the pump control box for R/P 9250 and 9350p. 208

5.4.3.1 Connectionp. 208

5.4.3.2 Verification of the flow reduction valuesp. 209

5.4.3.3 Adjustment of the flow reduction values for input 3 and 4p. 209

6 Enginep. 249

6.1 Technical datap. 249

6.2 Cooling systemp. 251

6.2.1 Cooling schematicp. 251

6.2.2 Functionp. 253

6.2.2.1 Principal circuitp. 254

6.2.2.2 Low Temperature Aftercooling (LTA) circuitp. 254

6.2.3 Coolant capacityp. 254

6.2.4 Cleaning system and changing antifreezep. 255

6.2.4.1 To drain the coolantp. 256

6.2.4.2 To clean the cooling circuitp. 257

6.2.4.3 To refill the cooling circuitp. 258

6.2.5 Antifreeze and corrosion protection of coolantp. 259

6.2.5.1 Coolant filtersp. 259

6.2.5.2 To change the coolant filtersp. 259

6.3 Fuel systemp. 261

6.3.1 Fuel schematicp. 261

6.3.2 Fuel capacityp. 261

6.3.3 To drain condensationp. 261

6.3.3.1 To drain and clean the fuel tankp. 262

6.3.3.2 Draining and changing fuel filter cartridgesp. 263

6.3.4 Fuel filter changep. 264

6.3.5 Bleeding procedurep. 265

7 Attachment / Travel systemsp. 269

7.1 Schematicp. 269

7.2 Hydraulic pump assemblyp. 271

7.2.1 Technical datap. 271

7.3 Functional descriptionp. 275

7.3.1 Electro-hydraulic systemp. 275

7.3.2 Power circuitp. 276

7.3.2.1 Hydraulik tank and oil filtersp. 276

7.3.2.2 The hydraulic working pumpsp. 276

7.3.2.3 Control valve blocksp. 277

7.3.2.4 Hydraulic oil coolingp. 278

7.3.2.5 Hydraulic rotary connectionp. 279

7.3.2.6 Attachment cylinders and motorsp. 279

7.3.3 Electro-hydraulic pilot control systemp. 280

7.3.3.1 Pilot control unitsp. 280

Mechanical componentsp. 280

Electronic componentsp. 281

7.3.3.2 Servo oil circuitp. 283

Technical datap. 283

Schematic servo oil circuitp. 284

Servo oil circuit : components locationp. 286

Functional descriptionp. 288

7.3.3.3 Logic systemp. 288

Solenoid valves functionp. 289

To read and understand the priority listp. 290

Proximity transmittersp. 292

7.4 Working pumpsp. 296

7.4.1 Descriptionp. 296

7.4.2 Double pump A20 VSO 520p. 296

7.4.2.1 Functionp. 297

Rotary groupp. 297

Pump displacementp. 298

7.4.2.2 Working pump regulationp. 299

7.4.2.3 Pressure cut-offp. 303

Functioning in normal conditionsp. 303

Elevation of the pressure cut-offp. 303

7.4.2.4 Power regulationp. 304

The constant power regulationp. 304

Functionp. 304

Power reduction stagep. 307

7.4.2.5 Flow limitation stagep. 307

7.5 Attachment functionp. 312

7.5.1 Boom cylindersp. 312

7.5.1.1 Boom up movementp. 315

7.5.1.2 Pressureless lower boom cylinderp. 315

7.5.1.3 Boom down movementp. 315

7.5.2 Stick cylinders for backhoe attachmentp. 316

7.5.3 Bucket tilt cylinders for backhoe attachmentp. 318

7.5.4 Shovel tilt cylinders for shovel attachmentp. 320

7.5.4.1 Shovel bucket parellelogram functionp. 322

7.5.5 Shovel flap cylinders for shovel attachmentp. 324

7.6 Travelp. 326

7.6.1 Travel motorsp. 326

7.6.2 Primary pressure relief valve controlled with pilot pressurep. 329

7.6.3 Hydraulic brakingp. 330

7.6.4 Travel brakingp. 331

7.6.5 Travel speed increasep. 332

7.7 Troubleshootingp. 334

7.7.1 Hydraulic cylinder chartp. 334

7.7.2 Extension and retraction time of hydraulic cylinderp. 335

7.7.2.1 Extension time of hydraulic cylinderp. 335

7.7.2.2 Retraction time of hydraulic cylinderp. 335

7.7.2.3 Determination of extension and retraction time with the chartp. 335

7.7.2.4 Examplep. 338

7.7.2.5 Number of pumps and oil flow max for the different movementsp. 338

7.7.3 Control valve block leak oil measurementp. 338

7.7.3.1 Examplep. 339

7.8 Adjustmentp. 341

7.8.1 Adjustment valuesp. 341

7.8.1.1 Excavator’s adjustmentsp. 341

7.9 Component descriptionp. 343

7.9.1 4-ways control valve 4 MO 40p. 343

7.9.1.1 Technical datap. 343

7.9.1.2 Conceptionp. 346

7.9.1.3 Functionp. 346

Spool valves in neutral positionp. 346

Working position of spool valvesp. 346

7.9.1.4 Repairsp. 349

Spool valves 14 and 15p. 349

Replacing regulating springs 20 / 21p. 349

Primary pressure relief valve, pilot operated 28p. 351

Anti-cavitation check valves 29p. 351

Secondary pressure relief valve 30p. 352

Check valve 32p. 353

Proportional pressure reducing valve 34p. 353

3/2 way directional valve 35p. 354

Locking screw 50p. 355

7.9.1.5 Control valve installationp. 355

7.9.1.6 Maintenancep. 355

7.9.2 4-ways control valve 4 MO 32p. 356

7.9.2.1 Technical datap. 356

7.9.2.2 Conceptionp. 358

7.9.2.3 Functionp. 358

Spool valves in neutral positionp. 358

Working position of spool valvesp. 358

7.9.2.4 Repairsp. 360

Spool valves 36, 37, 38 and 39p. 360

Primary pressure relief valve, pilot operated 60p. 363

Control valve 117p. 364

Pressure reducer valve 118p. 365

Suction valve 143p. 366

7.9.2.5 Control valve installationp. 366

7.9.2.6 Maintenancep. 366

7.10 Hydraulic cylinderp. 367

7.10.1 Construction of hydraulic cylindersp. 367

7.10.2 Functionp. 368

7.10.3 Function of hydraulic cylinderp. 368

7.10.3.1 To extend piston rod 8p. 368

7.10.3.2 To retract the piston rod 8p. 368

7.10.4 General maintenancep. 369

7.10.4.1 Anti-rotation protectionp. 369

7.10.4.2 Transportationp. 369

7.10.4.3 Storagep. 370

7.10.4.4 Installationp. 370

7.10.4.5 Start upp. 370

7.10.4.6 Maintenancep. 370

7.10.5 Removal and installation of the hydraulic cylindersp. 371

7.10.5.1 Removalp. 371

7.10.5.2 Installationp. 371

7.10.6 Resealing the hydraulic cylinder with new fixationp. 372

7.10.6.1 Disassemblyp. 372

7.10.6.2 Assemblyp. 373

7.10.7 Resealing the hydraulic cylinder with old fixationp. 375

7.10.7.1 Disassemblyp. 375

7.10.7.2 Assemblyp. 376

7.10.8 Schematic for cylinder with new fixationp. 379

7.10.9 Schematic for cylinder with old fixationp. 381

7.10.10 Torque values of the mounting screws (new fixation)p. 383

7.10.11 Torque values the piston and the piston nut (old fixation)p. 384

7.11 Primary valve : Pilot operated pressure limiting valvep. 385

7.11.1 Usep. 385

7.11.2 Functionp. 385

7.11.3 Pressure adjustmentp. 385

7.12 Primary valve : Two-stage pilot operated pressure limiting valvep. 387

7.12.1 Usep. 387

7.12.2 Functionp. 387

7.12.2.1 Stage I – Reduced pressurep. 387

7.12.2.2 Stage II – High pressurep. 387

7.12.2.3 Pressure adjustmentp. 387

7.13 Secondary pressure relief valve pilot controlledp. 388

7.13.1 Usep. 388

7.13.2 Functionp. 388

7.13.3 Pressure adjustmentp. 388

7.14 Secondary valve : Two-stage pilot operated pressure limiting valvep. 390

7.14.1 Function of pressure cut offp. 390

7.14.1.1 Stage 2 (normal pressure = high pressure)p. 390

7.14.1.2 Cut off stage or stage 1 (low pressure)p. 390

7.14.1.3 Pressure check and adjustmentp. 390

To check and adjust high pressure (stage 2)p. 390

To check and adjust low pressure (stage 1)p. 391

7.15 Suction valvep. 392

7.15.1 Task and functionp. 392

7.15.1.1 Sealing or closing functionp. 392

7.15.1.2 Suction functionp. 392

7.15.2 Repairsp. 392

7.16 Geared pumpp. 393

7.16.1 Principlep. 393

7.16.2 Maintenance and repairp. 393

7.17 Joystick and pedal transmittersp. 395

7.17.1 Functionp. 395

7.17.2 Shovel flap pedals U20p. 396

7.17.3 Left joystick U21p. 397

7.17.4 Right joystick U22p. 398

7.17.5 Right travel pedal U23p. 399

7.17.6 Left travel pedal U24p. 401

7.17.7 The FSG plate A1020p. 402

7.17.7.1 Characteristic curvesp. 403

7.17.7.2 Adjustmentp. 405

8 Swing Systemp. 409

Technical datap. 409

Hydraulic motorsp. 409

Swing gearsp. 409

Swing ringp. 409

8.1 Schematicp. 410

8.1.1 Electricp. 410

8.1.2 Hydraulicp. 413

8.2 Location of componentsp. 415

8.3 Functional descriptionp. 418

8.3.1 System controlp. 418

8.3.2 Pumpsp. 419

8.3.3 Motorsp. 419

8.3.4 Swing brakep. 419

Optional equipment : swing brake controlled in semi automaticp. 420

8.4 Troubleshootingp. 421

8.5 Adjustmentp. 422

8.5.1 Specificationsp. 422

8.6 Detailed component descriptionp. 423

8.6.1 Swing pumop A4 VG 125p. 423

8.6.1.1 Rotary groupp. 424

8.6.1.2 Pump displacementp. 425

8.6.2 Hydraulic fixed displacement motor FMF with dischargep. 426

8.6.2.1 General datap. 426

8.6.2.2 Descriptionp. 427

8.6.2.3 Function of oil motorp. 427

8.6.2.4 Maintenance and repairsp. 427

8.6.2.5 Function of discharge valves in connector platep. 430

8.6.2.6 Repairs and adjustments on discharge valvesp. 430

8.6.2.7 Variation with integrated impulse transmitterp. 431

9 Cooling Systemp. 435

9.1 Schematicp. 436

9.1.1 Electric schematicp. 436

9.1.2 Hydraulicp. 439

9.2 Location of the componentsp. 441

9.3 Functional descriptionp. 445

9.3.1 Hydraulic pumpsp. 445

9.3.1.1 Descriptionp. 445

9.3.1.2 Regulationp. 446

Pressure regulationp. 446

Flow regulationp. 446

Situation for cold temperaturep. 448

Situation for intermediate temperaturep. 449

Situation for hot temperaturep. 449

9.3.2 Temperature regulationp. 450

9.3.2.1 Hydraulic oilp. 450

9.3.2.2 Engine coolantp. 452

Relation between measured values and PWMp. 453

Pulse Wide Modulated 5%p. 453

Pulse Wide Modulated 95%p. 453

Relation between PWM and IA1019 and IY10.1p. 454

9.4 Troubleshootingp. 455

9.4.1 Overheating in the hydraulic oil cooling circuitp. 455

9.4.2 Overheating in the engine cooling circuitp. 456

9.5 Adjustingp. 458

9.5.1 Specificationsp. 458

9.6 Components descriptionp. 459

9.6.1 Hydraulic pump A11VO75DRXp. 459

9.6.1.1 Construction of variable displacement pump A11VOp. 460

9.6.1.2 Function of hydraulic pumpp. 462

Function of the pump power gearp. 462

Pump displacementp. 462

9.6.1.3 Function of hydraulic pumpp. 463

9.6.2 Hydraulic fixed displacement motor «FMF»p. 465

9.6.2.1 Descriptionp. 466

9.6.2.2 Function of oil motor, see diagrammp. 466

9.6.2.3 Maintenance and repairsp. 466

10 Grease systemsp. 471

11 Access ladder and service trapp. 615

The access ladderp. 616

The service trapp. 616

11.1 Schematicsp. 618

11.1.1 Hydraulicp. 618

11.1.2 Electricp. 622

11.2 Location of componentsp. 624

11.3 Functional descriptionp. 630

11.3.1 Electrical partp. 630

11.3.1.1 Ladderp. 630

Ladder up motionp. 630

Ladder in upper positionp. 630

Ladder lockingp. 630

Ladder lockedp. 631

Ladder unlockingp. 631

Ladder unlockedp. 631

Ladder descending motionp. 631

11.3.1.2 Service trapp. 632

Trap unlockingp. 632

Trap unlockedp. 632

Trap descending motionp. 632

Trap up motionp. 632

Trap in upper positionp. 633

Trap lockingp. 633

Trap lockedp. 633

11.3.1.3 Safety measurep. 634

11.3.2 Hydraulic partp. 635

11.4 Troubleshootingp. 637

11.4.1 Ladderp. 637

Problem : the ladder does not go up.p. 637

Problem : the ladder can not be lockedp. 638

Problem : ladder can not be unlockedp. 639

Problem : the ladder does not go down.p. 640

11.4.2 Service trapp. 641

Problem : the service trap can not be unlockedp. 641

Problem : the service trap does not go down.p. 642

Problem : the service trap does not go up.p. 643

Problem : the service trap can not be locked.p. 644

11.5 Adjustment instructionsp. 645

11.5.1 Adjustment of the pressure control valvep. 645

11.6 Detailed component descriptionp. 646

11.6.1 Electro-hydraulic gear pumpp. 646

11.6.1.1 Descriptionp. 646

11.6.1.2 Functionp. 647

11.6.1.3 Maintenance and repairp. 647

11.6.2 Rotating cylinderp. 649

11.6.2.1 Functional descriptionp. 649

11.6.2.2 Cushioning end positionsp. 649

11.6.2.3 Cushioning adjustmentp. 649

11.6.3 Removal of the hydraulic cylinderp. 650

11.6.4 Pressure relief valvep. 651

11.6.4.1 Usep. 651

11.6.4.2 Functionp. 651

11.6.4.3 Pressure adjustmentp. 651

11.6.5 Solenoid-valvep. 652

11.6.5.1 Descriptionp. 652

12 Track tensioning systemp. 655

12.1 Descriptionp. 655

12.2 Fonctionp. 656

12.3 Temperature dependent pressure adjustmentp. 657

12.3.1 Increase in pressurep. 657

12.3.2 To reduce pressurep. 658

13 Electrical systemp. 661

13.1 Main components locationp. 662

13.2 Cabin electricp. 664

13.2.1 Control and cab instrumentationp. 664

13.2.2 Switching box E1005p. 665

13.2.2.1 Platesp. 667

13.2.2.2 Fuses and relaysp. 668

13.2.2.3 Connectorsp. 668

13.2.3 Washer / wipersp. 671

13.2.3.1 Electric schematicp. 671

13.2.3.2 Components locationp. 672

13.2.3.3 Functional descriptionp. 673

Windshield wiperp. 673

Winshield waterp. 673

13.2.3.4 Troubleshootingp. 674

13.2.4 Analog monitoringp. 675

13.2.4.1 Components locationp. 675

13.2.4.2 Functional descriptionp. 677

Clock and volmeterp. 677

The hour meterp. 678

The buzzerp. 680

13.2.4.3 The cigarette lighterp. 681

13.2.4.4 The radiop. 681

13.3 Lightingp. 683

13.3.1 Attachmentp. 684

13.3.1.1 Electric schematicp. 684

13.3.1.2 Component locationp. 686

13.3.1.3 Functional descriptionp. 688

13.3.1.4 Troubleshootingp. 688

13.3.2 Uppercarriagep. 690

13.3.2.1 Electric schematicp. 690

13.3.2.2 Component locationp. 692

13.3.2.3 Functional descriptionp. 694

13.3.2.4 Troubleshootingp. 694

13.3.3 Access ladder lighting, engine and control valvep. 696

13.3.3.1 Schematicp. 696

13.3.3.2 Component locationp. 698

13.3.3.3 Functional descriptionp. 703

13.3.3.4 Troubleshootingp. 704

13.3.4 Cabin lighting – dome lightp. 706

13.3.4.1 Electric schematicp. 706

13.3.4.2 Component locationp. 706

13.3.4.3 Functional descriptionp. 706

13.3.4.4 Troubleshootingp. 707

13.3.5 Electric box lightingp. 708

13.3.5.1 Electric schematicp. 708

13.3.5.2 Components locationp. 708

13.3.5.3 Functional descriptionp. 709

13.3.5.4 Troubleshootingp. 709

13.3.6 Travel alarmp. 711

13.3.6.1 Electric schematicp. 711

13.3.6.2 Component locationp. 711

13.3.6.3 Functional descriptionp. 713

13.4 Power packp. 714

13.4.1 Enginep. 714

13.4.1.1 Start and prelub systemp. 714

Schematicp. 716

Component locationp. 718

Functionp. 722

13.4.1.2 RPM controlp. 724

Schematicp. 724

Component locationp. 726

Functionp. 727

13.4.2 The sensorsp. 728

13.4.2.1 The enginep. 728

13.4.2.2 Splitterbox and pumpsp. 730

13.4.3 Emergency stopp. 733

13.4.3.1 Schematicp. 733

13.4.3.2 Component locationp. 735

13.4.3.3 Functionp. 739

13.4.4 Solenoid valvesp. 740

13.5 Alternator – batteryp. 745

13.5.1 Schematicp. 746

13.5.2 Components locationp. 748

13.5.3 Functionp. 751

13.5.3.1 Batteriesp. 751

13.5.3.2 Alternatorp. 751

13.5.3.3 Groundp. 751

13.5.3.4 The cut off switchesp. 751

13.6 Display / sensorsp. 752

13.6.1 Electric schematicp. 752

13.6.2 Principle schematicp. 753

13.6.3 Component locationp. 754

13.6.4 Displayp. 757

13.6.4.1 Electric schematicp. 757

13.6.4.2 Functional descriptionp. 758

Area A : Diesel engine monitoringp. 759

Area B : Indicator lightsp. 759

Area D : Screen menu controlp. 760

Area C : Screenp. 760

To change the screen contrast:p. 760

To alter the brightness of the main screen :p. 760

Main screenp. 761

Main screen designp. 761

SY fieldp. 761

EC fieldp. 761

INF fieldp. 761

TI fieldp. 761

Menu navigation in the event of an error displayp. 762

Warning symbols in the SY fieldp. 762

Information symbols in the INF fieldp. 765

Getting information from the operator’s menu on the main screenp. 765

Main screen menu selectionp. 765

Reset daily operating hours counter menup. 766

Confirm service interval menup. 767

This menu is used for information on service intervals and to confirm service work which has been carried out.p. 767

Allocation of quantity limitation options to external input I1 menup. 768

Operating hours menup. 768

Status of hydraulic pumps and electrical inputs and outputs menup. 770

Error menu (operating errors and electrical system errors)p. 773

13.6.5 The BSTp. 776

13.6.6 The CAN BUSp. 776

13.6.6.1 Definitionp. 776

13.6.6.2 Principlep. 776

13.6.7 The BBTp. 778

13.6.7.1 Functionp. 778

13.6.7.2 Functional descriptionp. 778

13.7 Componentsp. 782

13.7.1 Alternatorp. 782

13.7.1.1 Hazard definitionsp. 783

CAUTIONp. 783

NOTICEp. 783

13.7.1.2 Table of contentsp. 783

13.7.1.3 Battery Conditionsp. 783

NOTICEp. 783

13.7.1.4 Charge Volt and Amp Valuesp. 783

13.7.1.5 CEN C653A alternator description and operationp. 784

13.7.1.6 Basic troubleshootingp. 785

Tools and Equipment for Jobp. 785

Preliminary Check-outp. 785

Basic troubleshootingp. 786

13.7.1.7 Advanced troubleshootingp. 787

13.7.2 Batteriesp. 789

13.7.2.1 Technical datap. 789

13.7.2.2 Battery maintenancep. 789

14 Pneumatic systemp. 793

14.1 Technical datap. 794

14.2 Pneumatic schematicp. 795

14.3 Component locationp. 796

14.4 Functional descriptionp. 800

14.4.1 Air pressure system function, see also schematicp. 800

14.4.2 Horn valvesp. 800

14.5 Troubleshootingp. 801

14.5.1 Compressor and pressure regulator (insufficient operating pressure)p. 801

14.6 Adjustment instructionsp. 801

14.6.1 Adjustment of operating pressurep. 801

14.7 Component descriptionp. 802

14.7.1 Pressure regulatorp. 802

14.7.1.1 Applicationp. 802

14.7.1.2 Functionp. 802

Cut outp. 803

Cut inp. 803

14.7.2 Air dryerp. 804

14.7.2.1 Applicationp. 804

14.7.2.2 Functionp. 804

Compresssion cyclep. 804

Purge cyclep. 804

14.7.3 Check valvep. 805

14.7.3.1 Applicationp. 805

14.7.3.2 Functionp. 805

14.7.3.3 Maintenancep. 805

15 Uppercarriage – Mechanicalp. 809

15.1 Couplingp. 809

15.1.1 Function / operationp. 809

15.1.1.1 Components locationp. 809

15.1.1.2 Usep. 810

15.2 Splitterboxp. 811

15.2.1 Technical datap. 811

15.3 Swing gearp. 812

15.3.1 Technical datap. 812

15.3.2 Function / operationp. 813

15.3.2.1 Functionp. 813

15.3.2.2 Component locationp. 813

15.3.2.3 Functional descriptionp. 815

15.3.2.4 Function of lubrication systemp. 815

15.3.3 Installation / removalp. 816

15.3.3.1 Installation of swing gearp. 816

15.3.3.2 Removal of swing gearp. 816

15.3.4 Sealing of the swing brakep. 817

15.3.4.1 To seal the gearp. 817

Drivep. 817

Disk brakep. 818

15.3.5 Swing brakep. 819

15.3.5.1 Component locationp. 819

15.3.5.2 Functional descriptionp. 819

15.4 Swing bearingp. 820

15.4.1 Component locationp. 820

15.4.2 General datap. 821

15.4.2.1 Max. axial playp. 821

15.4.2.2 Backlashp. 821

15.4.3 Function / operationp. 822

15.4.3.1 Functional descriptionp. 822

15.4.4 Installation / removalp. 822

15.4.4.1 Installationp. 822

15.4.4.2 Removing the swing ringp. 823

15.4.4.3 Mounting the bolts of the swing ringp. 824

15.4.4.4 Swing ring bolts tensioning procedurep. 824

15.4.5 Inspection / wear reportingp. 825

15.4.5.1 Measuring the clearancesp. 825

Max. clearancep. 825

15.4.5.2 Measuring the radial playp. 825

Measuring the backlashp. 826

15.5 Engine / splitterbox mountingp. 827

15.5.1 Technical datap. 827

15.5.2 Function / operationp. 829

15.5.3 Installation / removalp. 829

15.5.3.1 Removalp. 829

Removal of the powerpackp. 829

Removal of the enginep. 829

Removal of the splitterboxp. 830

15.5.3.2 Installationp. 830

Installation of the powerpackp. 830

Installation of the enginep. 830

Installation of the splitterboxp. 831

15.5.3.3 Component locationp. 832

15.5.4 Inspection wear reportingp. 833

15.5.4.1 Engine and splitterbox mounting screwsp. 833

15.5.4.2 Splitterbox mounting screwsp. 835

15.5.4.3 Elastic bedding of the engine and splitterbox – replacement of the rubber buffersp. 835

15.6 To Preassembled modulesp. 836

15.6.1 Mounting / Dismounting modulesp. 837

15.6.1.1 Rotating deckp. 837

15.6.1.2 Counterweightp. 838

15.6.1.3 Driver’s cabp. 838

15.6.1.4 Powerpacksp. 839

15.6.1.5 Hydraulic tankp. 840

15.6.1.6 Fuel tankp. 841

15.6.1.7 Cab elevationp. 842

15.6.1.8 Left catwalk boxp. 844

15.6.1.9 Right catwalk boxp. 845

21 Schematicsp. 849

21.1 Electrical system – electrical diagrams – chartp. 849

21.2 Hydraulic system – hydraulic schematicsp. 963

05_Tooling_ITH.pdfp. 1

1p. 211

2p. 212

3p. 213

4p. 214

5p. 215

6p. 216

7p. 217

8p. 218

9p. 219

10p. 220

11p. 221

12p. 222

13p. 223

14p. 224

15p. 225

16p. 226

17p. 227

18p. 228

19p. 229

20p. 230

21p. 231

22p. 232

23p. 233

24p. 234

25p. 235

26p. 236

27p. 237

28p. 238

29p. 239

30p. 240

31p. 241

32p. 242

33p. 243

34p. 244

35p. 245

Manual R9250 English.pdfp. 1

R9250

1.3 Schema

CAUTION

4Inspection and maintenance

41A-68608-A05.pdfp. 1

Table of Contentsp. 482

Itemp. 482

Pagep. 482

1Safety Instructionsp. 483

Designationp. 486

2.6Mode of operationp. 486

3Erection and installationp. 486

21A-30001-F03_TB_P203.pdfp. 1

Titlep. 501

Imprintp. 502

Fields of Applications of the QUICKLUB Progressive Central Lubrication Pumpsp. 503

Table of Contentsp. 504

Introductionp. 505

Safety Instructionsp. 506

Installationp. 508

Specifications for the installation of electric equipment for ADR-application in comercial vehiclesp. 508

Mounting of the Pump – Areas of Risk, continuationp. 509

Pump Typesp. 510

Identification Code – Pump Models 203p. 511

Descriptionp. 512

Electric connections for pump 203p. 512

The QUICKLUB 203 central lubrication pumpp. 513

Low-level control (optional)p. 513

Mode of Operationp. 514

Pump elements with fixed lubricant outputp. 514

Suction phasep. 514

Delivery phasep. 514

Check valvep. 515

Arrangement of the pump elementsp. 515

Pump element with adjustable lubricant outputp. 515

Setting of adjustable pump elementsp. 516

Retrofit adjustment of max. lubricant outputp. 516

Adjusting of small lubricant outputsp. 517

Pressure Relief Valvep. 517

Return Line Connectionp. 518

Control Unitp. 518

Low-Level Control (optional)p. 519

Low-level control for greasep. 519

Low-level control for Oilp. 520

Contact protection measuresp. 520

Maintenance, Repair and Testsp. 521

Maintenancep. 521

Pump Fillingp. 521

Repairp. 521

Testsp. 522

Operational Test / Triggering an Additional Lubrication Cyclep. 522

To Check the Safety Valvep. 522

Troubleshootingp. 523

Technical Datap. 524

Torsion torquesp. 524

Weightsp. 524

Connection Diagram – Pump without Control Unitp. 525

Dimensionsp. 526

Lubricantsp. 532

22A-10001-F03_TB SSV.pdfp. 1

Titlep. 564

Imprintp. 565

Table of Contentsp. 566

Introductionp. 567

Explanation of Symbols Usedp. 567

User's Responsibilityp. 567

Environmental Protectionp. 567

Servicep. 567

Safety Instructionsp. 568

Appropriate Usep. 568

General Safety Instructionsp. 568

Regulations for Prevention of Accidentsp. 568

Operation, Repair and Maintenacep. 568

Installationp. 568

Installationp. 569

Tube Fittings, Screw-Typep. 569

Main- and secondary Metering devicesp. 569

Tube Fittings, Push-in Typep. 569

Metering Devicesp. 569

Connection of the High-pressure Plastic Hose and the Pressure Plastic Tubep. 570

Pressure Plastic Tubes and High-pressure Plastic Hosesp. 571

Descriptionp. 572

Progressive Metering Devices Model SSV and SSV Mp. 572

Progressive Plunger Metering Devices – Generalp. 572

Features of a Progressive Metering Devicep. 572

Operationp. 574

Applicationsp. 574

Lubricant Distribution within the metering Devicep. 576

Phase 1+2p. 576

Phase 3+4p. 577

Phase 5p. 577

Monitoring of the Operationp. 578

System-dependent monitoringp. 578

Visual monitoringp. 578

Electrical monitoring (microprocessor control) SSV onlyp. 579

Pressure relief valvep. 579

Determining the Lubricant Output by Combining Outletsp. 580

Tube Fittings, Screw-Typep. 580

Tube Fittings, Push-in-Type (main metering device)p. 581

Tube Fittings, Push-in Type (secondary metering devices)p. 582

Planning and Layoutp. 583

Instructions for QUICKLUB Progressive Systemsp. 583

1. Selecting the pumpp. 583

2. Determining the number of lubrication points to be connectedp. 583

3. Combining the lubrication points into groupsp. 583

4. Determining the lubricant requirement of the combined lubrication pointsp. 584

5. Allocating a metering device with the appropriate number of outlets to each groupp. 584

6. Connecting the metering device outlets with the lubrication points to be connectedp. 584

7. Determining the size of the main metering devicep. 585

8. Dividing the lubricant quantityp. 585

9. Lubricant output of the pumps 203* and 205**p. 586

10. Adjusting the running time (operating time) of the pump (not for pumps with microprocessor control)p. 587

11. Connecting machine bearingsp. 588

12. Connecting a fifth-wheelp. 588

13. Connecting a liftgatep. 588

14. Using a second pump element (2nd lubrication circuit)p. 589

15. Verwendung der Schnellkupplung 504-36804-1p. 589

16. Max. Leitungslängenp. 590

17. Pressure lossesp. 590

Troubleshootingp. 592

Technical Datap. 594

Metering Devicesp. 594

Screw-Type and Push-inType Tube Fittingsp. 594

Linesp. 594

Tightening torquesp. 594

Dimensionsp. 595

Metering Devices Model SSV 6 to SSV 22 (Blocks)p. 595

Metering Devices SSV 14 to 22 (assembled)p. 595

Metering Devices Model SSV M 6 to SSV M 12p. 596

Lubricantsp. 596

Recommended grease for QUICKLUB systems down to -25 °Cp. 597

Biodegradablep. 597

Lincoln worldwidep. 599

93A-50012-B04.pdfp. 1

Factory setting: Switching point 220 bar, Hysteresis 40 barp. 609

Dimensionsp. 609

Mounting holep. 609

Benutzerinfo 9250.pdfp. 1

R9250p. 472

1.3 Schemap. 475

CAUTIONp. 477

4Inspection and maintenancep. 478

Delivery

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The Liebherr R9250 service manual is supplied as an instant PDF download. No shipping, no waiting. Read it on a workshop laptop, a tablet on the machine, or print the sections you need for the job. Every page is exactly as published in the 08/2007 edition.

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