PDF Service Manual Liebherr R9400 Hydraulic Excavator - 9 MB
This service manual provides in-depth technical information for the Liebherr R9400 Hydraulic Excavator.
It is an essential resource for qualified technicians performing maintenance and repairs.
The guide covers systems such as hydraulics, engine, and electronics with detailed procedures.
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Service manual
en
Service manual
Hydraulic excavator
R9400
from serial number 26377
Document identification
Order number: 11000050
Version: 0 / 2019
Valid for: R9400 from serial number 26377
Author: LEC - Technical documentation department
Product identification
Manufacturer: Liebherr-Mining Equipment Colmar SAS
Type: R9400
Type no.: 1257 / 1407
Conformity:
Address
Liebherr-Mining Equipment Colmar SAS
49 rue Frédéric Hartmann
CS17:03
Sunday, 06.October 2019 50038, F-68025
printed Colmar document!
this protected Cedex SM_R9400_1257-1407_26377_08-2019_en[1].pdf Admin2008
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Service Manual
Welding
Wear items
Tooth retainer and bucket corners
Material Electrode
24 Cr Ni Mo 445 V E 51 53 B 10 DIN 1913 (E Kb XIIs)
Tempered fine grain steel with a tensile strength of 780 See the chart «Basic machine and attachments». If this
- 930 N/mm² and yield point of 690 N/mm² type of electrode is not available, use the following :
Example : H 14
Analysis :
C = 0,2% Si = 0,5% Mn = 1,6% Analysis :
Lightly alloyed with Cr, Ni and Mo C = 0,1% Si = 0,8% Mn = 6,5%
Cr = 19,0% Ni= 9,0%
Or Fox A 7
Analysis :
C = 0,15% Si= 1,0% Mn = 6,0%
Cr = 19,0% Ni = 8,5%
Important!
If steel with a tensile strenght above 550 N/mm² is welded to each other, a Kb - electrode according
to ASTM - AWS : E 11018 - G must be used!
ASTM = American Society Technical Material
AWS = American Welding Society
Example :
OK 75.75
Tensile strength = 775 - 860 N/mm²
Yield point = 710 - 730 N/mm²
4.3.1 Storing electrodes
Use only dry and undamaged electrodes. Electrodes, which are rusty or damaged, should not be
used. Electrodes should be stored in a dry room with a minimum temperture of 59°F (15°C). Open
packages should be carefully closed and stored after the welding work is completed.
4.3.2 Welding technique
Fig. 4 Welding technique
The welding of material with the necessary electrodes (see table under the chapter general applica-
tion of reinforcement plates) is in accordance with EN 22253 (DIN 1912).
The
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be taken from the table of the electrode package.
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Service manual
Main components location
4 Main components location
Fig. 1 Electrical components location
A1001 ESP01 Platine S9_1 Engine battery switch
E1003
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E1005 Cabin connection box S2 Keyboard
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Service manual
Bleeding of the cylinders and check of the movements
Yes
Step Description Value Tools and remarks
/No
05 Do the «First time adjustment» of the Refer to Service Manual, chapter
track tensioning procedure. 3 «Technical data», section
«Track tensioning adjustment».
Only for undercarriage 1407, and
undercarriage 1029 with a
grease cylinder.
06 Move slowly forward and backwards
to tense the tracks.
Bleeding of the cylinders and check of the
Check operated by Signature
movements
Date:
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Service manual
Adjustment sheet
Nominal Measured Adjusted
Function / component
value value value
Attachment proximity switches (refer to § “Damping system adjustment” on page 38)
Backhoe
Boom up 120 mm
Stick in 100 mm
Stick out 150 mm
Bucket close 95 mm
Bucket open 160 mm
Shovel
Boom up 120 mm
Stick in (depending on the use) 150 or 500 mm
Stick out 100 mm
Shovel tilt close 100 mm
Shovel tilt open 140 mm
Shovel flap close 100 mm
Shovel flap open 80 mm
Swing system (refer to § “Swing adjustment” on page 41)
Replenishing pressure 30 +2 bar
PS1
Swing working pressure left (MB) 350 ±5 bar
Swing working pressure right (MA) 350 ±5 bar
Swing braking torque left* 140-150 bar
Swing braking torque right* 140-150 bar
PS2
Swing working pressure left (MB) 350 ±5 bar
Swing working pressure right (MA) 350 ±5 bar
Swing braking torque left* 140-150 bar
Swing braking torque right* 140-150 bar
SU1
Swing brake pressure 30 ±1 bar
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Cooling system (refer to § “Cooling adjustment” on page 45)
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Service manual
Adjustment procedures
Fig. 20 Primary valves adjustment on valve blocks VBx
Note!
Valve blocks VB1 and VB2 (left figure) are fitted with single stage primary valve while VB3 and VB4
(right figure) are fitted with two-stage primary valves.
To adjust the single stage primary valve (for VB1 and VB2):
Install a 600 bar pressure gauge on the test point P.
Start the Diesel engine and set the engine speed to 1800 ±50 RPM.
Disconnect the connector X82 to deactivate the attachment proximity switches.
Fully extend the boom or the stick and keep the joystick actuated.
Loosen the locknut and turn the adjustment screw PRV until you get the correct pressure on P.
Tighten the locknut.
Connect back the connector X82.
To adjust the two-stage primary valve (for VB3 and VB4):
Install a 600 bar pressure gauge on the test point P.
Stop the Diesel engine.
Open printed
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Service manual
Chapter 4 - Operating Maintenance
Operating maintenance..........................................................................................................4.00
General information ...............................................................................................................4.10
1 Function of preventive maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10.1
1.1 General information about maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10.1
1.2 The importance of preventive maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10.2
1.3 The role of parts stock management in preventive maintenance . . . . . . . . . . . . . . . . . . . . . . . 4.10.2
1.4 Preventive maintenance software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10.2
2 Documents, tools and software available for the maintenance of the excavator . . . . . . . . . . . . . . . . . 4.10.3
2.1 Documents available for preventive maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10.3
2.2 Tools for preventive maintenance tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10.4
2.3 Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10.4
Additional maintenance task planning: schedule backlogs and tasks related to wear or
damage ....................................................................................................................................4.20
Replace major components of the machine ........................................................................4.30
1 Recommended intervals to replace major components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.30.1
2 Calculate the next date you will replace a major component. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.30.3
Non-Destructive Test (NDT)...................................................................................................4.40
1 Structural inspection - Backhoe Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.40.1
1.1 Range of use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.40.1
1.2 Scope of inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.40.1
1.3 Inspection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.40.2
1.4 Inspection documents:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.40.4
2 Structural inspection - Shovel Attachment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.40.17
2.1 Range of use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.40.17
2.2 Scope of inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.40.17
2.3 Inspection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.40.18
2.4 Inspection documents:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.40.20
Operating manual ...................................................................................................................4.50
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Service manual Non-Destructive Test (NDT)
Structural inspection - Backhoe Attachment
Machine serial N°: Machine hours: Travel hours: Completed by: Date:
Rotating deck Article N°: Index N°:
Serial N°: Component
hours:
Find the defect coordinates on the grid and report them in the following table.
(Mark the following options: location a, b, c or d; defect longitudinal, perpendicular to the seam direction and/or on
the plate or in another position.
Defect Side of the Details of the Picture N°
coordinates defect(s) R defect(s):
or L (a),(b),(c),(d) or
other
Do a description of the defect(s):
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en
Operating manual
Hydraulic excavator
R9400
from serial number 26377
Document identification
ORIGINAL MANUAL
Order number: 11000047
Edition: 08 / 2019
Valid for: R9400 from serial number 26377
Author: LEC - Technical documentation department
Product identification
Manufacturer: Liebherr-Mining Equipment Colmar SAS
Type: R9400
Type no.: 1257 / 1407
Conformity:
Address
Liebherr-Mining Equipment Colmar SAS
49 rue Frédéric Hartmann
CS 50038, F-68025 Colmar Cedex
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Operating manual Safety instructions
Safety Instructions
task.
Only use attachment or special tool approved by Liebherr.
Only operate the attachment or the special tool with closed windshield and with a
front protective grid.
Only operate the attachment or the special tool with closed door.
Do not clean the ground with the special tool.
Make sure that the special tool works in its specified limits. For more information,
also refer to the Operators Manual of the tool manufacturer.
Safe use of a hydraulic hammer or a hydraulic ripper
According to the severity of the application, the use of a hydraulic hammer or a
hydraulic ripper can result in vibrations, shocks or stresses which are higher than
in normal use. It may reduce the expected lifetime of structures and/or compo-
nents.
The hydraulic hammer or the hydraulic ripper must be selected with particular
care. When using a hydraulic hammer or a hydraulic ripper not permitted by Lieb-
herr, warranty for steel structures and machine components will be ceased.
Before beginning breaking tasks, position the machine on firm and level ground.
Use a hydraulic hammer or a hydraulic ripper designed exclusively for breaking
stone, concrete and other breakable materials.
Only operate the hydraulic hammer or the hydraulic ripper in the longitudinal di-
rection of the machine and with the windshield closed or with a front protective
grid.
Ensure during hammer or ripper operation that no cylinder is entirely extended or
retracted and that the stick is not in the vertical position.
In order to avoid damages to the machine, try not to break stone or concrete while
performing retraction and extension motions of the hydraulic hammer.
Do not apply the hydraulic hammer uninterrupted for more than 15 seconds at a
time to the same place. Change the breaking point. Too long uninterrupted oper-
ation of the hydraulic hammer leads to an unnecessary overheating of the hydrau-
lic oil.
Do not use the drop force of the hydraulic hammer or of the hydraulic ripper to
break stone or other materials. Do not move obstacles with the hydraulic hammer.
Misuse of this nature would damage both the hammer and the machine.
Do not use the hydraulic hammer or the hydraulic ripper to lift objects.
Before beginning breaking tasks, the pressure of the dampening accumulator of
the hydraulic ripper must be adjusted depending on the nature of the ground and
the excavator model.
Safe use of a ripper
Rippers are generally used in applications where the use of a bucket is not effi-
cient to break out rocks. Thus, these applications are more severe than in normal
use.
According to the severity of the application, the use of a ripper can result in vibra-
tions, shocks or stresses which are higher than in normal use. It may reduce the
expected lifetime of structures and/or components.
Special hydraulic devices can be necessary. Contact the Liebherr customer ser-
vice.
The ripper must be selected with particular care. When using a ripper not permit-
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for steel structures and machine components will be
ceased.
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Operating manual Control and operation
Operating and control elements
S10 Working light / attachment floodlights
Press button.
Working light on the uppercarriage is activated.
LED 1 in the button illuminates.
Press button again.
Working light is disabled.
LED 1 in the button goes out.
Attachment floodlights are activated.
LED 2 in the button illuminates.
Press button again.
Working light and attachment floodlights are activated.
LEDs 1 and 2 in the button illuminate.
Press button again.
Working light and attachment floodlights are desabled.
LEDs 1 and 2 in the button go out.
S11 Windshield washer
Press and hold button.
Washing water will be sprayed onto the windshield through the outlet nozzles.
The windshield washer runs continuously.
Release the button.
Washing water will be stopped.
Windshield washer will run continuously for approx. another 3 seconds.
S12 Additional cabin heater (optional starting aids)
Press button.
Additional heater fan is set to stage 1.
LED L in the button illuminates.
Press button again.
Additional heater fan is set to stage 2.
LED H in the button illuminates.
LED L in the button goes out.
Press button again.
Additional heater is disabled.
LED H in the button goes out.
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Operating manual Control and operation
Operating and control elements
lected will be listed on the second page.
Press the Back button.
The first page of the submenu appears.
Press the Back button again to select another error type or press the Down or Up
arrow key to select a new error code.
s*: Error was indicated by a buzzer and was acknowledged using the Back button.
The duration is given in seconds.
m*: Error was indicated by a buzzer and was acknowledged using the Back button.
The duration is given in minutes.
Note!
Only operating errors with an error code E 5xx will be displayed in the list Exxx
menu.
Cable error list E-elec.:
Fig. 3-24 Occurrence of electrical error (Fig. left) and Error statistics (Fig. right)
Select Cable error list E-elec.:
Press the Menu button.
The submenu appears.
The column "Sum" shows the number of all errors that were ever noted.
The column "Test" shows the number of errors occurred since the last deletion of this
test error memory listing.
The operating hours above the test column show the operating hour when the last
test memory was deleted (reset).
Press the Back button.
A different error type may be selected.
Other errors list S-Exxx:
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Operating manual Control and operation
The access and the outfit of the cab
E4 Attachment floodlight (optional, not E23_1Counterweight floodlight
represented) (optional, not represented)
E5 Attachment floodlight (optional, not E23_2Counterweight floodlight
represented) (optional, not represented)
E6_1Hydraulic tank floodlight E58_1Top of cabin floodlight
E6_2Hydraulic tank floodlight (optional, E58_2Top of cabin floodlight
not represented)
Working light and attachment floodlights
Floodlights E1_1, E2, E3, E6_1, E58_1 and E58_2 as well as optional floodlights
E1_2, E4, E5 and E6_2 can be activated using button S10 on the control keyboard.
E1_1, E1_2, E6_1, E6_2, E58_1 and E58_2 constitute working light.