Liebherr R 9200 Hydraulic excavator Operating Manual 40083 – PDF DOWNLOAD
FILE DETAILS:
Liebherr R 9200 Hydraulic excavator Operating Manual 40083 – PDF DOWNLOAD
Language : English
Pages :500
Downloadable : Yes
File Type : PDF
Size: 101 MB
DESCRIPTION:
Liebherr R 9200 Hydraulic excavator Operating Manual 40083 – PDF DOWNLOAD
Product identification
Manufacturer: Liebherr-Mining Equipment Colmar SAS
Type: R 9200
Type no.: 1625
from serial number:4083
Preface
This operating manual has been written for the driver and for the maintenance personnel of the machine.
It contains the following descriptions:
- Chapter 1 – Product description
- Chapter 2 – Safety regulations
- Chapter 3 – Handling and operation
- Chapter 4 – Malfunctions
- Chapter 5 – Maintenance
This operating manual must be carefully read before initial operation and should be read and used later at regular intervals by anyone who carries out work on the machine.
Working with or on the machine includes:
- Operation, including equipping, troubleshooting during operation, removing production debris, maintenance, removing operating and auxiliary materials.
- Servicing, including maintenance, inspection, and repairs.
- Transport or loading the machine.
This manual helps the driver to become acquainted with the machine and prevents malfunctions due to incorrect operation.
Observation of the operating and maintenance manual by maintenance staff:
- Increases reliability during operation.
- Extends the service life of your machine.
- Reduces repair costs and downtime.
This manual must be kept with the machine. Make sure a copy is always kept in the glove compartment of the driver’s cab.
In addition to the operating and maintenance manual, follow the instructions based on existing national accident prevention and environmental protection regulations.
In addition to the operating manual and applicable national and local legal accident prevention rules, observe the recognized technical regulations for safe and correct operation.
This operating and maintenance manual contains all the information you need to operate and service your machine.
- Some illustrations in this manual may show details and equipment that are different from those on your machine.
On some pictures, protective devices and covers have been removed for a better view.
We constantly make improvements to our machines, which means there may have been modifications to your machine that are not mentioned in this manual.
However, if you should require explanations or information, the Liebherr technical information and customer services departments will be happy to provide assistance.
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Liebherr R 9200 Hydraulic excavator Operating Manual 40083 – PDF DOWNLOAD
1 Product description . 1-1
1.1 Overview 1-1
1.1.1 Machine 1-1
1.1.2 Uppercarriage . 1-3
1.1.3 Undercarriage . 1-4
1.2 Vibration emission . 1-4
1.3 Technical data . 1-5
1.3.1 Working technical data . 1-5
1.3.2 Technical description 1-6
2 Safety instructions . 2-1
2.1 Meaning of the symbols in this manual . . 2-1
2.2 Use in accordance with the regulations . 2-2
2.3 Safety Instructions . 2-3
2.4 Servicing the machine safely . 2-16
2.5 Signs on the machine 2-22
2.5.1 Introduction . 2-22
2.5.2 Arrangement and explanations of signs . 2-24
3 Control and operation . 3-1
3.1 Operating and control elements . 3-1
3.1.1 Overview of the control cab 3-1
3.1.2 Arrangement of joysticks 3-4
3.1.3 Keyboard 3-5
3.1.4 Cab control board . 3-11
3.1.5 Monitoring display 3-13
3.1.6 Menus and functions of the display 3-13
3.2 The access and the outfit of the cab 3-40
3.2.1 Enter or leave the cab 3-41
3.2.2 Safety lever 3-48
3.2.3 Operator’s seat . 3-49
3.2.4 Auxiliary seat 3-56
3.2.5 Sunshade . 3-57
3.2.6 Emergency exit. 3-58
3.2.7 Internal lighting . 3-59
3.2.8 Fire extinguisher . 3-59
3.2.9 Windscreen 3-61
3.2.10 Field of view . 3-64
3.2.11 Lighting . 3-65
3.2.12 Heating and air-conditioning system 3-67
3.3 Setting the machine into operation 3-71
3.3.1 Start and stop the machine 3-73
3.3.2 Selective Catalytic Reduction (SCR) system 3-81
3.3.3 Warm-up procedure for Diesel engine and hydraulic circuit . 3-83
3.4.1 Uppercarriage swing movements . 3-105
3.4.2 Working position . 3-107
3.4.3 Joystick functions when setting up the machine 3-107
3.4.4 Lowering the work equipment when the engine is not running 3-114
3.5 General working methods 3-115
3.5.1 Minimum impact working methods for your machine . 3-115
3.5.2 Preparatory activities 3-116
3.5.3 Positioning of the machine . 3-117
3.5.4 Working with the backhoe bucket . 3-117
3.5.5 Working with the Shovel bucket . 3-120
3.6 Transport 3-123
3.6.1 Travelling procedures for mining machine 3-123
3.6.2 Excavator lifting and lashing operations . 3-125
4 Malfunctions . 4-1
4.1 Error code charts . 4-2
4.1.1 Heating and air-conditioning system 4-2
4.2 Faults and remedies 4-3
4.2.1 Diesel engine and fuel system 4-3
4.2.2 Hydraulic system 4-4
4.2.3 Transmission 4-4
4.2.4 Electrical system . 4-5
4.2.5 Heating/air-conditioning system . 4-5
4.2.6 Work equipment . 4-5
4.3 Fuses and relays 4-6
4.3.1 Power electrical box E1003 4-6
4.3.2 Electrical plate E1003_ 1 for the Selective Catalytic Reduction (SCR) system . 4-9
4.3.3 Cab connection box E1005 4-10
4.3.4 Electrical box E1091 for the Selective Catalytic Reduction (SCR) system . 4-11
5 Maintenance . 5-1
Servicing the machine safely . 5-1
Access points for the maintenance 5-7
5.2.1 Access points overview 5-7
Maintenance anchor points 5-8
5.3.1 Approved anchor points 5-9
5.3.2 Use the anchor points . 5-12
Lubricants and operating fluids 5-13
5.4.1 General information on changing lubricants and operating fluids . 5-13
5.4.2 Lubricating chart . 5-14
5.4.3 Lubricant chart 5-15
5.4.4 Operating material chart . 5-16
5.4.5 Service trap 5-17
Lubricating and operating material specifications 5-25
5.5.1 Lubricating oil for the Diesel engine . 5-25
5.5.2 Fuel . 5-26
5.5.3 Coolant . 5-26
5.5.4 Diesel Exhaust Fluid (DEF) 5-26
5.5.5 Hydraulic oil specifications for LIEBHERR Mining excavators . 5-26
5.5.6 Swing and travel gear oils 5-32
5.5.7 Splitterbox oil 5-34
5.5.8 Lubricating grease 5-35
5.5.9 Other lubricants 5-36
Condition monitoring with oil analysis 5-37 ~
5.6.1 General information 5-37 C”II 5.6.2 Oil sampling 5-38 8–
5.6.3 Sample processing . 5-44 g
Diesel engine . 5-48 :;:::;
5.7.1 Check the oil level of the Diesel engine 5-48 ;
5. 7 .2 Change the Diesel engine oil. . 5-49 ~
5.7.3 Mounting screws . 5-52 ~
5.7.4 Elastic bedding . 5-54
5.7.5 Belts 5-54
5.8 Splitterbox 5-54
5.8.1 Splitterbox mounting screws 5-54
5.8.2 Elastic bedding . 5-57
5.8.3 Breather filter 5-58
5.9 Coupling . 5-59
5.9.1 Check the coupling rubber rollers . 5-59
5.10 Cooling system 5-59
5.10.1 Check and clean the cooling system 5-59
5.10.2 Check the coolant level 5-60
5.10.3 Coolant antifreeze and anti-corrosion fluid . 5-61
5.10.4 Change the coolant 5-61
5.10.5 Replace the coolant filters 5-62
5.11 Fuel system . 5-64
5.11.1 Refuel . 5-64
5.11.2 Drain the fuel tank 5-66
5.11.3 Clean the fuel tank . 5-67
5.11.4 Fuel filtering system . 5-67
5.11.5 Replace the dust filter for the vent valve 5-72
5.12 Selective Catalytic Reduction (SCR) system . 5-72
5.12.1 Check the level of the Diesel Exhaust Fluid (DEF) . 5-73
5.12.2 Change the Diesel Exhaust Fluid (DEF) 5-73
5.12.3 Replace the Diesel Exhaust Fluid (DEF) filter elements . 5-76
5.12.4 Coolant shutoff valves 5-78
5.13 Dry air filter 5-78
5.13.1 Replace the primary filter element . . 5-80
5.13.2 Replace the safety element 5-81
5.13.3 Clean the precleaner 5-82
5.13.4 Clean the housing of the air filter elements 5-83
5.13.5 Check the air intake system, hoses, elbow tubes, clamps . 5-84
5.14 Hydraulic system . 5-85
5.14.1 Preparatory activities 5-85
5.14.2 Check the oil level in the hydraulic tank . 5-86
5.14.3 Release the pressure from the hydraulic system . 5-87
5.14.4 Drain and fill the hydraulic tank 5-88
5.14.5 Hydraulic oil coolers . 5-92
5.14.6 Leak oil filter and return filter 5-92
5.14.7 Servo oil and replenishing filters 5-94
5.14.8 High pressure filters in working circuit . . 5-95
5.14.9 Servo oil circuit . 5-98
5.14.10 Remove the pumps intake hoses . 5-99
5.14.11 Bleed the hydraulic pumps . 5-99
5.14.12 Bleed the hydraulic cylinders 5-102
5.14.13 Bleed the valve blocks 5-102
5.14.14 Oil cooler protection filters (optional) 5-103
5.14.15 Servicing the hydraulic cylinder 5-104
5.14.16 Replacement of the hydraulic hoses 5-105
5.14.17 Progressive criss-cross tightening procedure . 5-109
5.15 Oil changes on components 5-110
5.15.5 Splitterbox – Oil change . 5-115
Track components . 5-116
5.16.1 Check the track components mounting 5-116
5.16.2 Check the track tension 5-123
5.16.3 Increase the track tension 5-123
5.16.4 Decrease the track tension . 5-124
5.16.5 Clean the travel gear 5-125
5.17 Electrical system 5-126
5.17 .1 Notes on the electrical system 5-126
5.17 .2 Batteries switches and ECM connectors 5-126
5.17.3 Batterycare 5-128
5.17.4 Electrical components location . 5-130
5.17 .5 Cab pressurization 5-132
5.18 Heating and air-conditioning system 5-132
5.18.1 Possible configurations . 5-132
5.18.2 Heating system . 5-133
5.18.3 Air-conditioning system 5-135
5.18.4 Additional maintenance work 5-143
5.19 Greasing the machine 5-143
5.19.1 Lubrication of attachment bearing points 5-143
5.19.2 Lubricate the service trap . 5-144
5.20 Check mounting bolts for tightness 5-145
5.20.1 Counterweight mounting bolts 5-146
5.20.2 Mounting bolts of the swing ring . 5-14 7
5.20.3 Mounting bolts of the fuel tank 5-149
5.20.4 Mounting bolts of the hydraulic tank . 5-150
5.20.5 Mounting bolts of the engine cooler box . 5-151
5.20.6 Mounting bolts of the oil cooler box 5-151
5.20. 7 Mounting bolts of the pumps box 5-152
5.20.8 Mounting bolts of swing gear and swing motor 5-153
5.20.9 Mounting bolts of the cab elevation 5-153
5.20.10 Mounting bolts of the cab . 5-154
5.20.11 Mounting bolts of the service trap . 5-155
5.20.12 Mounting bolts of hydraulic pumps . 5-156
5.20.13 Mounting bolts of side frames . 5-157
5.21 Drive unit brakes and swing gear brakes . 5-157
5.22 General maintenance points 5-157
5.22.1 Replacing working parts . 5-157
5.22.2 Welding work on the machine 5-158
5.23 Control and maintenance chart 5-158
5.23.1 General information 5-159
5.23.2 How to use the maintenance chart . 5-159
5.23.3 Daily Maintenance Schedule – R9200 5-161
5.23.4 250 Hours Maintenance Schedule – R9200 5-167
5.23.5 500 Hours Maintenance Schedule – R9200 5-173
5.23.6 1000 Hours Maintenance Schedule – R9200 5-180
5.23.7 2000 Hours Maintenance Schedule – R9200 5-188
6 Appendix . 6-1
6.1 Visual check of the hydraulic hoses . 6-1
6.1.1 Preface . 6-1
6.1.2 General information 6-2
6.1.3 Components functions 6-4
6.1.4 Recommendations for hose assembly maintenance 6-5
6.2 Cleaning procedure for hydraulic circuits . 6-9 ~
6.2.1 Preface . 6-9 ~
6.2.2 General information about hydraulic oil contamination . 6-9 8i::::
6.2.3 General cleaning procedure . 6-11 ,g
6.2.4 Location of the hydraulic tank filters . 6-11 ;
6.2.5 Working pumps circuit 6-12 c3
6.2.6 Swing circuit . 6-16 UJ
I 6.2.7 Cooling pumps circuit . 6-20
6.2.8 Travel motors circuit . 6-25
6.2.9 Backhoe cylinders lines 6-30
6.2.10 Shovel cylinders lines . 6-36
6.2.11 Clean the hydraulic tank . 6-42
6.2.12 Restart the machine . 6-42
6.2.13 Monitor the restarted machine 6-44
6.3 Centralized lubrication system . 6-44
VIDEO PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
S.M
