Liebherr R 9250 1357 Hydraulic Excavator Operating Manual SN 30616 - PDF DOWNLOAD

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Operating manual Hydraulic excavator R 9250 from serial number 30616

Document identification ORIGINAL MANUAL Order number:

11211522

Edition:

12 / 2020

Valid for:

R 9250 from serial number 30616

Author:

LEC - Technical documentation department

Product identification Manufacturer:

Liebherr-Mining Equipement Colmar SAS

Type:

R 9250

Type no.:

1357

Conformity: 0

N

0

N

C:

~

Address

'5

~

Liebherr-Mining Equipment Colmar SAS

c:5

49 rue Frederic Hartmann

UJ ....J

CS 50038, F-68025 Colmar Cedex

copyright© Liebherr-Mining Equipment Colmar SAS 2020

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Fig. 1-1

Machine and construction equipment - backhoe attachment

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Fig. 1-2

Machine and construction equipment - shovel attachment

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Fig. 1-3

Uppercarriage

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Fig. 1-4

Undercarriage

Tab. 1-1

Vibration emissions

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Fig. 1-5

Sample EC Declaration of Conformity

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Tab. 1-2

Working technical data

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Fig. 2-1

Arrangement of signs on the machine

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Fig. 2-2

Arrangement of signs on the machine

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Fig. 2-3

Arrangement of signs on the machine

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Fig. 2-4

Arrangement of signs on the machine

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Fig. 3-1

Control cab

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Fig. 3-2

Standing position from operator’s point of view

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Fig. 3-3

Joystick, right (3) and left (4)

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Fig. 3-4

Excavator keyboard

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Fig. 3-5

Control board

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Fig. 3-6

Monitoring display

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Fig. 3-7

Screen menu control

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Fig. 3-8

Main screen

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Fig. 3-9

Main screen

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Fig. 3-10

Menu selection in the operator’s menu.

Tab. 3-1

Overview of menu options

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Fig. 3-11

Resetting the daily operating hours counter

Fig. 3-12

Service intervals menu

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Fig. 3-13

Work equipment quantity limitation menu

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Fig. 3-14

Engine service life menu (example)

Fig. 3-15

Operating hours menu

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Fig. 3-16

Technical data

Fig. 3-17

Quantum system menu

Fig. 3-18

Quantity limitation menu

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Fig. 3-19

LR magnet menu

Fig. 3-20

Fan speed current values menu

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Fig. 3-21

Electrical inputs

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Fig. 3-22

Recorded errors menu

Fig. 3-23

Error list (Fig. left) and Error occurrence (Fig. right) menu

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Fig. 3-24

Occurrence of electrical error

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Fig. 3-25

Call up service operation error list menu

Fig. 3-26

Information about the Diesel engine menu

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Fig. 3-27

Idle time setting menu

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Fig. 3-28

Display for monitoring cameras

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Fig. 3-29

Full screen display

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Fig. 3-30

Enter or leave the cab

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Fig. 3-31

Control box E1022_1

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Fig. 3-32

Button S122: Disable of ladder control position

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Fig. 3-33

Emergency valves of access ladder

Fig. 3-34

Safety lever

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Fig. 3-35

Standard operator’ seat

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Fig. 3-36

Setting the armrests

Fig. 3-37

Setting the seat and backrest

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Fig. 3-38

Setting the horizontal

Fig. 3-39

Switch bar on the air-cushioned operator’s seat

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Fig. 3-40

Safety belt

Fig. 3-41

Auxiliary seat

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Fig. 3-42

Windscreen and side windows sunshade

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Fig. 3-43

Emergency handle on the rear emergency exit

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Fig. 3-44

Emergency hammer for the lateral emergency exit

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Fig. 3-45

Interior lightings

Fig. 3-46

Fire extinguisher fixing location

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Fig. 3-47

Windscreen washing fluid container

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Fig. 3-48

Field of view

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Fig. 3-49

Arrangement of lighting

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Fig. 3-50

Arrangement of lighting for the uppercarriage

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Fig. 3-51

Front panel of the heating/air conditioning control unit

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Fig. 3-52

S26 button on control board

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Fig. 3-53

Ignition switch

Fig. 3-54

Main batteries switch

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Fig. 3-55

Diesel engine switch

Fig. 3-56

Ignition key

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Fig. 3-57

Service interval request

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Fig. 3-58

S149 on control board

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Fig. 3-59

Speed adjustment and mode functions

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Fig. 3-60

Indicator lights H2, H12 and P2 on display

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Fig. 3-61

S100-1 on control board

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Fig. 3-62

Emergency operation on control board

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Fig. 3-63

Control board for safety operation E52

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Fig. 3-64

Emergency control of the engine RPM

Fig. 3-65

Safety mode of servo circuits - Safety switch and symbols at the display

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Fig. 3-66

Driving straight ahead

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Fig. 3-67

Turning on the spot

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Fig. 3-68

Turning with a crawler

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Fig. 3-69

Rotating the uppercarriage

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Fig. 3-70

Working position – machine

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Fig. 3-71

Operating the stick cylinder

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Fig. 3-72

Operating the boom cylinder

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Fig. 3-73

Operating the bucket cylinder

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Fig. 3-74

Cylinders configurations for shovel bucket

Fig. 3-75

Selection key S232

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Fig. 3-76

Operating the bottom dump shovel bucket

Fig. 3-77

Float position

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Fig. 3-78

Lowering the equipment when engine is not running

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Fig. 3-79

Working position – machine

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Fig. 3-80

Hazard area

Fig. 3-81

Recommended digging

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Fig. 3-82

Optimal angle for digging

Fig. 3-83

30° forward to the vertical.

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Fig. 3-84

Taking up grab material

Fig. 3-85

45° backward to the vertical

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Fig. 3-86

Emptying grab material

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Fig. 3-87

Digging

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Fig. 3-88

Unloading of the bucket

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Fig. 3-89

Hazard area r

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Fig. 3-90

Sticker for lifting and lashing operations

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Fig. 4-1

LIEBHERR service

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Fig. 4-2

Power electrical box E1003

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Fig. 4-3

Fuses and relays of cab connection box E1005

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Fig. 4-4

Fuses and relays of heating / air conditioning electrical box E1006

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Fig. 5-1

Access doors for the engine room

Fig. 5-2

Access doors for the cab elevation and for the hydraulic tank installation

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Fig. 5-3

Access door for the left catwalk

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Fig. 5-4

Access door for the radiator

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Fig. 5-5

Access for main pumps and splitterbox

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Fig. 5-6

Horizontal middle bar on handrail (example)

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Fig. 5-7

Welded anchor point (example)

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Fig. 5-8

Drilled anchor point (example)

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Fig. 5-9

Lubrication chart - R9250

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Tab. 5-1

Lubrication chart key

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Tab. 5-2

Major components of the service trap

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Fig. 5-10

Major components of the service trap

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Tab. 5-3

Lubricant chart

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Tab. 5-4

Operating material chart

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Fig. 5-11

Control box E1022_2 and disable lock button S122 on control board

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Fig. 5-12

LIEBHERR oils for hydraulic system

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Fig. 5-13

Engine oils for hydraulic system

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(ISO VG68)

(ISO VG100) (ISO VG46)

Fig. 5-14

Hydraulic oil for hydraulic system

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Fig. 5-15

Oil changes at pre-set intervals

Fig. 5-16

Oil changes at optimized intervals

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Fig. 5-17

Swing gear and travel gear oils

Tab. 5-5

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Tab. 5-6

Tab. 5-7

Tab. 5-8

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Fig. 5-18

Gear oils for use as splitterbox oil

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Fig. 5-19

Sampling pump

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Fig. 5-20

Sampling valve 1 for splitterbox oil

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Fig. 5-21

Oil sampling points 1 for travel gear oil

Fig. 5-22

Sampling valve 1 for hydraulic oil

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Fig. 5-23

Sampling valve 1 for Diesel engine oil

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Fig. 5-24

Oil level markings on the dipstick

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Fig. 5-25

Filler neck and service trap

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Fig. 5-26

Oil filter elements

Fig. 5-27

Filler neck and service trap

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Fig. 5-28

Engine mounting screws

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Fig. 5-29

Engine elastic bedding

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Fig. 5-30

Belt

Fig. 5-31

Splitterbox mounting screws

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Fig. 5-32

Mounting screws

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Fig. 5-33

Elastic bedding

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Fig. 5-34

Breather filter on splitterbox

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Fig. 5-35

Cooler assembly

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Fig. 5-36

Expansion tank

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Fig. 5-37

Draining the coolant

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Fig. 5-38

Coolant filters location

Fig. 5-39

Coolant filters

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Fig. 5-40

Fuel filler cap

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Fig. 5-41

Service trap

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Fig. 5-42

Draining the fuel tank

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Fig. 5-43

Fuel tank

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Fig. 5-44

Fuel filter cartridges

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Fig. 5-45

Air intake system

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Fig. 5-46

Primary filter element

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Fig. 5-47

Safety element

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Fig. 5-48

Air channels for the precleaner

Fig. 5-49

Rubber hoses

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Fig. 5-50

Machine position for checking the oil level or for adding oil

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Fig. 5-51

Hydraulic tank oil level

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Fig. 5-52

Hydraulic oil change couplings on service trap

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Fig. 5-53

Return filter on the hydraulic tank

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Fig. 5-54

Filters on the hydraulic tank

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Fig. 5-55

Servo oil filter

Fig. 5-56

Replenishing oil filters

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Fig. 5-57

High pressure filter on valve bank

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Fig. 5-58

High pressure filter parts

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Fig. 5-59

Accumulator on the valve bank

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Fig. 5-60

Pumps aspiration (intake hoses)

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Fig. 5-61

Shutoff valves of the hydraulic tank

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Fig. 5-62

Bleeding points of the working pumps

Fig. 5-63

Bleeding points of the swing pumps

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Fig. 5-64

Bleeding points of the cooling pumps

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Fig. 5-65

Oil cooler protection filter

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Fig. 5-66

Piston rod mount

Fig. 5-67

Machine with piston rods drawn in

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Fig. 5-68

SAE flanges

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Tab. 5-9

Tightening torques for SAE flanges

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Fig. 5-69

Sealing flange 1 and hydraulic block 2

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Fig. 5-70

Criss-cross tightening

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Fig. 5-71

Oil change on the swing gear

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Fig. 5-72

Expansion tank

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Fig. 5-73

Travel gear - adding and draining oil

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Fig. 5-74

Special expansion tank of Lifetime interspace

Fig. 5-75

Oil change on the Lifetime interspace

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Fig. 5-76

Oil change on the splitterbox

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Fig. 5-77

Travel gear components (right and left sides)

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Fig. 5-78

Track components

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Fig. 5-79

Track pad

Fig. 5-80

Idler wheel and tension unit

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Fig. 5-81

Check the track tension

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Fig. 5-82

Tightening the track

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Fig. 5-83

Cylinder shutoff valves CVTL and CVTR

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Fig. 5-84

Main battery switch

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Fig. 5-85

Battery care

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Fig. 5-86

Electrical components location

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Fig. 5-87

Aeration device

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Fig. 5-88

Coolant shut-off valves 1 on Diesel engine

Fig. 5-89

Heater

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Fig. 5-90

Evaporator filter

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Fig. 5-91

Filter/dryer/receiver unit

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Fig. 5-92

Condenser

Fig. 5-93

Compressor for the air conditioning system

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Fig. 5-94

Condenser unit for optional dual air conditioning-system

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Fig. 5-95

Protection device for boom cylinders

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Fig. 5-96

Protection device for stick cylinders

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Fig. 5-97

Counterweight bolts

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Fig. 5-98

Threaded studs of the swing ring

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Fig. 5-99

Fuel tank bolts

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Fig. 5-100 Hydraulic oil tank bolts

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Fig. 5-101 Frame mounting bolts

Fig. 5-102 Bolts of swing gear and swing motor

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Fig. 5-103 Hydraulic pumps bolts

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Fig. 5-104 Screws and mounts of the cab

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Fig. 5-105 Cab elevation bolts

Fig. 5-106 Side frames bolts

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Fig. 5-107 How to use the check lists (in addition to the daily maintenance)

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Tab. 5-10 Daily maintenance schedule - R9250

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Tab. 5-11 250 Hours maintenance schedule - R9250

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Tab. 5-12 500 Hours maintenance schedule - R9250

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Tab. 5-13 1000 hours maintenance schedule - R9250

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Tab. 5-14 2000 hours maintenance schedule - R9250

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Fig. 6-1

Hydraulic tube and hose assembly

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Fig. 6-2

Marking of hose

Fig. 6-3

Marking of hose assembly

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1. Main Screens and Control Buttons

Menu: Used to Enter into Menu List and return to Previous Menu.

Up: Used to move up cursor in the Menu Lists and to increase a Value.

Down: Used to move down cursor in the Menu Lists and to decrease a Value.

The main menu is accessed through the "Menu" button; all the menus are displayed on the right display.

In a given Menu list, you can press the "Up" and "Down" buttons to scroll through menus. Pressing the button will then scroll through menus from top of screen to the last menu on screen; but if the button is pressed, selection will scroll from top to bottom of menus list.

The active line is "inverse video" (white text, black highlighted), use the "Menu" key to get inside the selected submenu.

The last line of a menu list is always defined as "Back", it is used to move to the previous menu by pressing the "Menu" button when highlighted.

Within a given Menu where the value can be changed, the change can be made by using the "Up" button to increase the value and using the "Down" button to decrease the value. Changes are immediately registered in controller. Pressing the "Menu" button returns you to the previous menu.

Start Cycle The three keys "Start Cycle PX" can be used to start a new lubrication cycle at the corresponding pump. Pushing this buttons acts like simulating an Enabling signal coming to the greasing controller, for each pump independently. The chosen pump will start if the Pilot pressure is sufficient.

If pump PX is in safety mode, a three seconds activation of the button the normal mode.

Description of the software menus

makes the pump PX return to

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2. Start Screens Left Start Screen : G r e a s e C o n t r o l l e r S t a r t i n g

Right Start Screen : I n f o S y s t em F am 1 Mo d u l e

s y s t e m P1 P2 E xe c 2

P 3 EM E xe c 2

V1 . 03

3. Main Screens Left Main Screen : P 1 O F F 1 2 3 b a r P 2

4 5 6 s e c

O N b a r

S a f e t y 0 s e c

P 3 O N 1 p u l s e

2 0 0 s e c

Right Main Screen : L e v e l

P 1 P 3

1 0 0 % 9 5 % P i l o t P 4 2 b a r B 1 5 0 1 2 p u l s e B 1 5 0 2 1 p u l s e P 2 S a f e t y s e r v __________________________________________________________________________________

Description of the software menus

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4. Architecture of Menus

Description of the software menus

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5. Menu I n A c S e S e E r P

f t t t r s

o s y s i v e e P a u s m a x o r h i a f e t y

t e m r r o r s e t i m e p r e s s s t o r y s e r v

S e t P a u s e t i m e S e t m a x p r e s s E r r o r h i s t o r y P s a f e t y s e r v C h e c k B a c k

Info System : I n f o S y s t em F am 1 Mo d u l e B a c k

s y s t e m P1 P2 E xe c 2

P 3 EM E xe c 2

V1 . 03

Config P1/P2

Config P3

Active Errors : A c t i v e

e r r o r s

G 1 : P r e s s P 1 s t a y l ow G3 : No f e e dba c k P3 l i ne G4 : No p r e s s d r op P1 B a c k

Description of the software menus

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Set Pause Time : S e t P1 P2 P3

P a u s e

se t t i ng s se t t i ng s se t t i ng s

t i m e 600se c 600se c 600se c

B a c k

P a u s e

2 4 5

Set max Press : S e t

m a x

2 4 0

Description of the software menus

P r e s s

b a r

t i m e

s e c

P X

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Error History : E r r o r

h i s t o r y

G 1 : P r e s s P 1 s t a y l ow G 2 : P r e s s P 2 s t a y l ow G3 : No f e e dba c k P3 l i ne G4 : No p r e s s d r op P 1 G5 : No p r e s s d r op P2

E r r o r

h i s t o r y

G14 : Le v s e n s o r G17 : Le v s e n s o r G28 : G r e a s e l e v G29 : G r ea s e l ev G33 : G r e a s e l e v

E r r o r

P1 P3 P1 P3 P1

NC NCe f ew f ew l ow

h i s t o r y

G 3 4 : G r e a s e l e v P 3 l ow G 3 6 : P i l o t p r e s s l ow n e G3 7 : No f e e dba c k B1 5 0 1 G3 8 : No f e e dba c k B1 5 0 2 B a c k

G34 : G r e a s e

l ev

P3

l ow

Nb r o f o c c u r e n c e s La s t hour 00003 La s t 10 hour s 00015 Tota l h i s tor i c 01224 B a c k

Safety Function : P

s a f e t y P 1 P 2 O F F

B a c k

Description of the software menus

s e r v

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Check : Upon entering the Check menu, the statuses of the analogue sensors are shown.

B 6 9 O K B 7 1 O K B 1 8 4 O K B 5 0 1 O K B 5 0 2 E R R

To represent Sensor values in mA, press and hold both "Up" and "Down" arrow buttons for more than three seconds. This will only apply when a service or inspector dongle is plugged.

B69 1 2 mA B71 B184 1 6 mA B51 B50_1 2 1 mA B50_2 1 9 mA B150 1 9 mA B150 2 9 mA

3 4 mA 1 2 mA

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6. Appendix Error List : G1 : P r e s s

P1

s tay

l ow

G2 : P r e s s

P2

s tay

l ow

G3 : No

f eedba ck

P3 l i ne

G4 : No

pres s

dr op

P1

G5 : No

pres s

dr op

P2

G14 : Le v

sensor

P1

NC

G17 : Lev

sensor

P3

NC

G28 : G r e a s e

l ev

P1

f ew

G29 : G r e a s e

l ev

P3

f ew

G33 : G r e a s e

l ev

P1

l ow

G34 : G r e a s e

l ev

P3

l ow

G36 : P i l o t

pres s

l ow

G3 7 : No

f eedba ckB150

1

G3 8 : No

f eedba ckB150

2

Description of the software menus

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Operating Manual

en

Operating Manual Centralized Lubrication Systems R9250

LEC / en / Edition: 03 / 2018

Product identification Manufacturer:

SKF Lubrication Systems Germany GmbH

Type:

R9250, R9250E

Type no.:

R9250: 437 and 1357, R9250E: 1129

Address Heinrich-Hertz-Str. 2-8 69190 Walldorf - Germany

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Operating Manual

Table of Contents:

1

Guidelines --------------------------------------------------------------------------------------- 5 Explanation of symbols and signs ----------------------------------------------------------------- 5 Illustrations ---------------------------------------------------------------------------------------------- 7 Abbreviations ------------------------------------------------------------------------------------------- 7 Manufacturer and Service addresses ------------------------------------------------------------ 8 Warranty ------------------------------------------------------------------------------------------------- 8 Copyright ------------------------------------------------------------------------------------------------ 8

2

Safety information ----------------------------------------------------------------------------- 9 Disclaimer ----------------------------------------------------------------------------------------------- 9 Emergency stopping of the centralized lubrication system ---------------------------------- 9 Intended use -------------------------------------------------------------------------------------------- 9 Operation of the lubrication system or single components of it ---------------------------- 9 Foreseeable misuse ---------------------------------------------------------------------------------- 9 Unauthorised activities ----------------------------------------------------------------------------- 10 Conversions or modifications --------------------------------------------------------------------- 10 Inspections -------------------------------------------------------------------------------------------- 10 Warning labels on the centralized lubrication pump or system --------------------------- 11 Other applicable documents ---------------------------------------------------------------------- 11 Sources of hazard ----------------------------------------------------------------------------------- 11 Moving or rotating parts ---------------------------------------------------------------------------- 11 Energies ----------------------------------------------------------------------------------------------- 12 Lubricants --------------------------------------------------------------------------------------------- 12 Existing residual risks ------------------------------------------------------------------------------ 12 Persons authorized to operate the pump ------------------------------------------------------ 17 Protection of special groups of persons-------------------------------------------------------- 17

3

Safety recommendations to be complied with ---------------------------------------- 18 General behaviour when handling the system ----------------------------------------------- 18 Explosion protection -------------------------------------------------------------------------------- 18 Transport / installation / maintenance / repairs / servicing -------------------------------- 19 Laying of the lubrication lines --------------------------------------------------------------------- 21 Initial commissioning / daily start-up ------------------------------------------------------------ 22

4

Operator obligations ------------------------------------------------------------------------ 23 Determination of hazards -------------------------------------------------------------------------- 23 Provision of necessary information ------------------------------------------------------------- 23 Inspection for correct use -------------------------------------------------------------------------- 23 Briefing of external technicians ------------------------------------------------------------------ 23 Provision of personal protective equipment --------------------------------------------------- 23 Training courses ------------------------------------------------------------------------------------- 23 Inspection of the delivery / returns -------------------------------------------------------------- 24

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Lubricant --------------------------------------------------------------------------------------- 25 Copyright © Liebherr Mining Equipment Colmar SAS 2018

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Cleaning ----------------------------------------------------------------------------------------------- 22

Operating Manual Filling of the reservoir------------------------------------------------------------------------------- 26 Inadvertent filling with incorrect lubricant ------------------------------------------------------ 26 Inspections prior to initial start-up --------------------------------------------------------------- 26 Activation of the pump------------------------------------------------------------------------------ 27

6

Standard operation -------------------------------------------------------------------------- 28 Daily start-up ----------------------------------------------------------------------------------------- 28 Inspections -------------------------------------------------------------------------------------------- 28 Filling of the reservoir during operation -------------------------------------------------------- 28 Cleaning ----------------------------------------------------------------------------------------------- 28

7

Maintenance and repairs ------------------------------------------------------------------ 29 Safety instructions for maintenance and repairs --------------------------------------------- 29 Maintenance of the system ----------------------------------------------------------------------- 29

8

Technical data and operating instructions --------------------------------------------- 30 Operating pressure / operating temperature -------------------------------------------------- 30 Installation position, sound pressure level, weight, dimensions -------------------------- 30 Tightening torques ---------------------------------------------------------------------------------- 30 Output / connections -------------------------------------------------------------------------------- 30 Filling possibilities ----------------------------------------------------------------------------------- 30 Electrical connection (electrically driven products) ------------------------------------------ 30 Air pressure and air quality (air-operated products) ---------------------------------------- 30

9

Lubrication System: Description --------------------------------------------------------- 31 General design --------------------------------------------------------------------------------------- 31 9.1.1 Systems 31 9.1.2 Allocation of the lubrication points ---------------------------------------------------------------------- 31 9.1.3 Characteristics of lubrication points on the excavator --------------------------------------------- 33 System P1: Automatic lubrication --------------------------------------------------------------- 34 9.2.1 Configuration ------------------------------------------------------------------------------------------------ 34 9.2.2 Greasing cycle ---------------------------------------------------------------------------------------------- 36 9.2.3 Single-line system ------------------------------------------------------------------------------------------ 38 9.2.4 Pump station 200L ----------------------------------------------------------------------------------------- 39 Level II (R9250) ---------------------------------------------------------------------------------------------------- 41 Level III (R9250)---------------------------------------------------------------------------------------------------- 43 9.3.5 Electronic Controller -------------------------------------------------------------------------------------- 45

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System P3: Swing ring and swing gear lubrication ------------------------------------------ 47 Grease cycle

47

Pump P3 - Multi-line pump type P203-15XYB -------------------------------------------------------------- 48

10

Operation -------------------------------------------------------------------------------------- 49 Greasing system – Cabin Location ------------------------------------------------------------- 49 System P1: Automatic lubrication --------------------------------------------------------------- 50 Pump P3 ----------------------------------------------------------------------------------------------- 51

11

Inspection and Maintenance -------------------------------------------------------------- 52

12

Troubleshooting ------------------------------------------------------------------------------ 53

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Operating Manual

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Operating Manual

1 Guidelines As you read these instructions, you will notice a number of depictions and symbols which are to facilitate the navigation and understanding of these instructions.

For reasons of better legibility, in these instructions we mainly use the male form for general references. Of course, the female form is also always intended.

Please read these instructions thoroughly and heed the warning and safety notes. Please observe the warning and safety notes and exercise particular caution in these cases.

Inform also other users accordingly.

Text representations

Meaning

Bold print

Highlighting of particularly important words or passages Marks lists

List 1 o

List 2

Marks lists

(parenthesis)

Item numbers

Instructions

Instructions to personnel. These always appear in chronological order.

Explanation of symbols and signs Activities which generate actual hazards (to life and limb or possible damage to the material) are marked by warnings. Definitely observe the instructions given in the warnings.

You will find these symbols, which warn of specific dangers to persons, material assets, or the environment, next to all safety instructions in these operating instructions.

Please read these instructions thoroughly and heed the warning and safety notes. Please observe the warning and safety notes and exercise particular caution in these cases.

Inform also other users accordingly.

The following warnings are possible.

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Warning level

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Consequence

Probability

DANGER

Death/ serious injury

imminent

WARNING

Serious injury

possible

CAUTION

Minor injury

possible

ATTENTION

Property damage

possible

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Operating Manual Symbol

Meaning General warning Activities which generate actual hazards (to life and limb or possible damage to the material)

Warning of suspended load

Risk of explosion Carry out work on electrical parts only if the atmosphere is not potentially explosive. Work has to be carried out by a specialist for maintenance and repairs in potentially explosive atmospheres.

Electrical component hazard, electrical shock hazard Make sure to disconnect the system or component from the power supply before carrying out works on electrical parts.

Do not use steam jet or high pressure cleaners for cleaning. Otherwise electrical components may be damaged. Do not touch cables or electrical components with wet or damp hands.

Cleaning work on energized components may be carried out by electrical specialists only.

Risk of fire Risk of fire and explosion when using inflammable cleaning agents.

Health hazard Hazard due to spouting lubricant / pressure injection due to a leakage (defective fitting, too high system pressure or other damages).

Crushing hazard

Slipping hazard

Symbol

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Hot surfaces

Meaning Disposal Environmentally sound disposal and recycling

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Operating Manual Disposal Environmentally sound disposal of waste electrical and electronic equipment

Illustrations The illustrations used refer to a specific product. In the case of other products or product versions they may have a schematic character only. The basic function, however, does not change.

Abbreviations

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The following abbreviations may be used within these instructions:. max. maximum Nm Newtonmeter

R 9250

min.

minimum

incl.

including

min

minutes

i.e.

this means

s

seconds

rh

relative humidity

etc.

and so on

approx. approximately

poss.

possibly

Ø

diameter

e.g.

for example

®

ml

millilitre

registered trademark

ccm

cubic cm

©

Copyright

mm

millimetre

TM

Trademark

°C

degrees Celsius

%

per cent

°F

degrees Fahrenheit

dB (A)

sound pressure level

K

Kelvin

>

greater than

inch

inch

<

less than

etc.

et cetera

kg

kilogram

± SW

plus minus width across flats

l

litre

ESD

Electrostatic Discharge

N/A

not applicable

mbar

millibar

no.

Number

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Operating Manual

Manufacturer and Service addresses Manufacturer

Customer Service

SKF Lubrication Systems Germany GmbH Heinrich-Hertz-Str. 2-8 DE - 69190 Walldorf

SKF Lubrication Systems Germany GmbH Heinrich Hertz Straße 2-8 DE - 69183 Walldorf +49 (0)6227-330

SKF Lubrication Systems Germany GmbH 2. Industriestraße 4 DE - 68766 Hockenheim +49 (0)620527101

SKF Lubrication Systems Germany GmbH Motzener Straße 35-37 DE - 12277 Berlin +49 (0)30-720020

Warranty The installation instructions do not contain any information on the warranty. This can be found in our general terms and conditions.

Copyright © Copyright SKF Lubrication Systems Germany GmbH. These installation instructions are copyright-protected. All rights reserved.

The integration of the content into the manufacturer's installation instructions of the machine, into which the pump shall be integrated, is expressly allowed.

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This also includes the creation of training material for internal, non-commercial purposes. Any other use without the written consent of the copyright holder - of whatever kind - is prohibited and is regarded as a violation of copyright.

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2 Safety information Safety information is to be read and observed by any persons entrusted with works on the centralized lubrication system or by those persons who supervise or instruct the beforementioned group of persons.

It is prohibited to commission or operate the machine, the centralized lubrication system or single components prior to reading the installation instructions. The installation instructions must be kept at an accessible location for further use.

Disclaimer Observation of these installation instructions is the prerequisite for safe operation and the achievement of product characteristics and performance levels.

The manufacturer shall not be held responsible for damages caused by: o non appropriate use, faulty assembly, operation, setting, maintenance, repair or accidents o improper or late response to malfunctions o unauthorized modifications of the product o intent or negligence o Use of non-original SKF spare parts.

Liability for loss or damage resulting from the use of our products is limited to the maximum purchase price. Liability for consequential damages of whatever kind is excluded.

Emergency stopping of the centralized lubrication system In case of an emergency stop the centralized lubrication system by: switching off the machine, system or vehicle, into which the SKF centralized lubrication system or its components have been integrated. separating the supply of power, compressed air or hydraulic pressure (depending on the system) to the centralized lubrication system or the corresponding components. actuating the emergency-off switch, if any, of the machine, system or vehicle.

Intended use ATTENTION All products may be used only for their intended purpose and in accordance with the instructions.

Intended use is the use of the products to lubricate bearings and friction points with lubricants within the physical limits that can be found in the relevant product documentation, e. g. operating instructions and product descriptions, e. g. technical drawings and catalogues.

Operation of the lubrication system or single components of it LEC / en / Edition: 03 / 2018

Operation is permitted only, if in compliance with: All information given in these installation instructions or stated in the referenced documents.

All laws and regulations to be complied with by the user.

Properly and appropriately conducted installation of the system.

Foreseeable misuse Any other use and purpose of the centralized lubrication system or its components than the ones described before are strictly prohibited.

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Operating Manual Use is expressly forbidden: in a potentially explosive atmosphere, unless the centralized lubrication system or its components are expressly suitable for it and have been approved accordingly. in a working environment or condition that corresponds to the required protection types IP (International Protection) and Nema (National Electrical Manufacturers Association) only in parts or not at all. to use the CLS to feed, forward, or store hazardous substances and mixtures in accordance with annex I part 2-5 of the CLP regulation (EC 1272/2008).

For the supply, transport, stockpiling of gases, liquefied gases, dissolved gases, vapours, and fluids whose vapour pressure exceeds normal atmospheric pressure (1013 mbar) by more than 0.5 bar at the maximum admissible operating temperature. to use the CLS to feed, forward, or store glycol- or polyglycol based oils and greases. to use inadmissible components or components expressly not suitable for the purpose.

Unauthorised activities The following activities may be carried out by SKF manufacturer specialists or authorized persons only due to potential sources of faults that may not be visible for the user, or due to legal regulations: Removal, replacement or changes to the centralized lubrication system or components integrated or connected to it.

Changes to the control printed circuit board or the power supply board exceeding the adjustment of lubrication and pause times or the replacement in case of defects.

Dismantling of individual components of the centralized lubrication system.

Changes to the power supply or to the admissible input voltage.

Changes to the admissible or specifically required operating pressure for the supplied centralized lubrication system.

Conversions or modifications Unauthorized conversions or modifications may result in unforeseeable impacts on safety and functionality. Therefore, any unauthorized reconstructions or changes are expressly prohibited.

Inspections

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The following inspections were carried out prior to delivery: Electrical inspections following EN 60204-1 (depending on the type of component supplied) Tests made in accordance with ATEX (depending on the type of component supplied) Safety and functional tests (depending on the type of component supplied)

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Warning labels on the centralized lubrication pump or system Hand injury warning During operation of the centralized lubrication system, particularly of the pump, never remove the lid or the barrel and reach into the reservoir or the barrel. Risk of trapping or shearing off hands and fingers!

Electric shock Connection of 24 V DC components must be provided by a safe galvanic isolation PELV (Protective Extra Low Voltage) or SELV (Safety Extra Low Voltage) always.

Other applicable documents In addition to these installation instructions, the following documents must be observed by the respective target group: Operational instructions and release provisions by the operator.

Safety data sheet and operating instructions of the lubricant or material used. The operator must ensure adding them to these installation instructions.

Operating instructions and technical descriptions of the components used in the centralized lubrication system.

Operating instructions and technical descriptions of purchased parts.

Where appropriate: Project planning documents.

Other relevant documents for the integration of the centralized lubrication system into the superior machine or system.

The owner must supplement these documents by the respective valid national or regional regulations laid down by the country in which the centralized lubrication system is to be used.

If the centralized lubrication system is sold or transferred, any associated documents must be passed on to the subsequent operator as well.

Sources of hazard The centralized lubrication system and the components used have been designed, built and tested using state-of-the-art technology.

Depending on their version and necessity, they will have left our company only after having passed stringent safety and reliability tests. Like for all complex machines, also for this system there may still be involved potential sources of hazard.

Moving or rotating parts LEC / en / Edition: 03 / 2018

Drive Tooth wheels Stirring paddle Shovel foot Piston Guides Articulations etc.

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Energies Electricity

Temperature (hot or cold surfaces)

Position energy (raised components)

Parts subject to pressure (operating pressure, oil pressure, grease pressure, air pressure, etc.)

Bursting reservoir if filled by a high-performance pump Parts subject to spring tension

Lubricants Greases Oils Transport lifecycle Residual risks Tilting or falling of parts during transport, e.g. over inclines.

Remedy Secure parts against tilting or falling during transport (e.g. using tapes, belts, ropes, etc.).

Dropping of lifted parts or tools.

No people may remain under suspended loads. Keep unauthorized persons away.

Secure suspended loads using suitable hoisting equipment (e.g. tapes, belts, ropes, etc.).

Existing residual risks Installation life cycle Remedy Take care when filling. Bind and remove leaked or spilled lubricant immediately with a suitable agent.

Follow the operational instructions for handling lubricants and contaminated parts.

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Residual risks People slipping due to floor contamination with spilled or leaked lubricant

Operating Manual Installation life cycle Residual risks Deviating installation position.

- Foreign objects falling into the motor air intake or into other components.

Remedy Installation of a suitable protective roof over the air intake.

- Borehole for drainage of condensation water is no longer at the lowest point of the motor.

Deviating installation position only, if the formation of condensation water has been completed. Remove condensation with suitable suction device.

Tearing or damaging of lines when installed on moving machine parts (e.g. pivot arm).

If possible, do not mount onto movable parts. Should this not be possible, use flexible hose lines of sufficient length.

Tearing or damaging of lines due to installation on chafing points or installation with too little bending radius

Use protective pipes or spring coils.

Falling of parts due to insufficient fixing to the machine.

Fix parts only to machine parts with sufficient load capacity. Observe the weight and the stated tightening torques.

If no tightening torques are stated, the tightening torques are to be applied to the screw size for 8.8 screws.

Electric shock through reduced insulation resistance.

Literature, see screw manufacturer.

Check the formation of condensation water in the motor regularly.

If applicable, drain off condensation water at the drain plug. Check the insulation resistance regularly.

Prior to connection of electrical components (pump, switch cabinet, valves, etc.) de-energize all affected electrical components. If necessary, please observe discharge times. The electrical connection may be carried out by commissioned and qualified electricians only and in accordance with the connection diagram.

Electric shock when connecting the pump.

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Life cycle - commissioning Residual risks Electrical shock due to defective connection cable

Remedy Before installation and start-up check all cables with regard to possible damages.

In case of damage, properly replace affected cable.

Immediately switch off the centralized lubrication system.

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Operating Manual Life cycle - commissioning Residual risks Lubricant spraying out due to incorrect screw connection of components or lines.

Remedy Tighten all parts with appropriate tightening torques.

Use suitable hydraulic screw connections and lines for the stated pressures.

Check these prior to commissioning for correct connection and damage.

Contact with corrosive or toxic substances that may be set free by a defective battery.

Wear protective clothes.

People slipping due to floor contamination with spilled or leaked lubricant.

Take care when filling. Bind and remove leaked or spilled lubricant immediately with a suitable agent.

Ensure sufficient ventilation. Storage and disposal of defective batteries in accordance with the corresponding safety data sheets for lithium.

Observe the legal or company regulations on dealing with oils and greases and contaminated parts.

Falling of parts due to insufficient fixing to the machine.

Fix parts only to machine parts with sufficient load capacity. Observe the weight and the stated tightening torques.

If no tightening torques are stated, the tightening torques are to be applied to the screw size for 8.8 screws.

Bursting reservoir if filled by a high-performance pump

Monitor the filling procedure and stop it when reaching the max marking of the reservoir

Contact with stirring paddle or shovel foot during "test operation" without lubricant reservoir or barrel

Always operate pump with lubricant reservoir or barrel.

Do not reach into the stirring paddle, the drive or the supply piston.

Tearing or damaging of lines when installed on moving machine parts (e.g. pivot arm).

If possible, do not mount on moveable parts.

Should this not be possible, use flexible hose lines of sufficient lengths.

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Literature, see screw manufacturer.

Operating Manual

Life cycle - operation, maintenance, repair Residual risks Contact to the shovel foot during change of barrel of a pneumatic, hydraulic or electric barrel pump.

Remedy Change barrel only with the centralized lubrication system and pump being de-pressurized.

Contact with the stirring paddle when filling a reservoir pump from the top during pump operation.

Fill preferably via the filling connection.

Switch off the pump before changing the barrel and relieve existing system pressure.

Filling from the top or changing of barrel in case of barrel pumps only while the pump is idle.

When filling, do not reach into the reservoir.

Electrical shock due to defective connection cable

Switch off the centralized lubrication system and check connection cable for damage.

People slipping due to floor contamination with spilled or leaked lubricant

Exercise caution when connecting the system.

Promptly apply suitable binding agents to remove the leaked or spilled lubricant.

Follow the operational instructions for handling lubricants and contaminated parts.

Tearing or damaging of lines

Switch of the centralized lubrication system, check the routing of the hose lines and optimize or replace defective hose or line, if necessary.

Should this not be possible, use flexible hose lines of sufficient lengths.

Fault lifecycle Too strong heating up of the motor or other electrical components.

Too strong heating up of hydraulically driven components

Switch off the pump and system. Let parts cool down, eliminate cause. Replace defective motor or other defective components.

Switch of the system or the affected component.

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Ensure proper functioning of the oil cooler.

Strong cooling down and formation of ice on sound absorber and air leakage on pneumatically driven pumps or other components

Check the compressor and the drier of the compressed air supply. Reduce the operating speed of the affected pump.

Shortly switch off the system or heat it, if necessary.

Inadmissible lubricant leakage on components or lubricant lines of the centralized lubrication system R 9250

Switch off the centralized lubrication system and determine cause. Replace defective lines or components.

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Operating Manual Fault lifecycle Lubricant spraying out due to incorrect screw connection of components or lines.

Tighten all parts with appropriate tightening torques.

Use suitable hydraulic screw connections and lines for the stated pressures.

Check these prior to commissioning for correct connection and damage.

Disposal lifecycle Contamination of the environment with lubricant and wetted parts People slipping due to floor contamination with spilled or leaked lubricant.

Dispose of the parts following the valid legal and company regulations.

Exercise caution when disconnecting the lines.

Promptly apply suitable binding agents to remove the leaked or spilled lubricant.

Follow the operational instructions for handling lubricants and contaminated parts.

Dispose of used batteries following the valid legal and company regulations.

Until disposal, store used battery, e.g. in a closed polyethylene bag , in order to avoid any damages.

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Contamination of the environment due to used batteries on control printed circuit boards

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Persons authorized to operate the pump Only qualified technical personnel may install, operate, maintain, and repair the products described in this document. The core principles of these country-specific qualification requirements for technical personnel cannot be below those of the two standards mentioned above.

Operator A person who is qualified by training and experience to carry out the functions and activities related to normal operation.

This includes avoiding possible hazards that may arise during pump operation.

Specialist for maintenance and repairs Qualified technical personnel are persons who have been trained, assigned, and instructed by the operator of the final product. Such persons are familiar with the relevant standards, rules, accident prevention regulations, and assembly conditions as a result of their training, experience, and instruction.

They are qualified to carry out the required activities and in doing so recognize and avoid any potential hazards.

Specialist in electrics The definition of qualified personnel and the prohibition against employing non-qualified personnel are laid down in DIN VDE 0105 and IEC 364. Relevant country specific definitions of qualified technical personnel apply for countries outside the scope of DIN VDE 0105 or IEC 364.

Protection of special groups of persons

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The respective legal employment restrictions do apply.

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Operating Manual

3 Safety recommendations to be complied with General behaviour when handling the system The centralized lubrication system, pump or single components may be used only in awareness of the potential dangers, in proper technical condition, and according to the information in these installation instructions.

Familiarize yourself with the functions and operation of the product. The specified assembly and operating steps and their sequences must be observed.

Any unclear points regarding proper condition or correct assembly/ operation must be clarified. Operation is prohibited until issues have been clarified.

Keep unauthorized persons away from the centralized lubrication system.

Precautionary operational measures and instructions for the respective work must be observed.

Responsibilities for different activities must be clearly defined and observed. Uncertainty seriously endangers safety.

Safety-related protective and emergency devices must not be removed, modified or affected otherwise in their function and are to be checked at regular intervals for completeness and function.

Remedy occurring faults in the frame of responsibilities. Immediately inform your superior in the case of faults beyond your competence.

Do not reach into the system during operation.

Wear personal protective equipment always.

When handling lubricants observe the relevant safety data sheets and operating instructions by the lubricant manufacturer or supplier.

Never use parts of the centralized lubrication system or of the machine as standing or climbing aids.

Explosion protection Always behave so that fire and explosion hazards are avoided.

A written work approval from the operator is required prior to working in potentially explosive areas.

There must be no indications that parts of the explosion protection are missing or are not working. Should such indications become apparent, switch off the machine and inform a superior without delay. Keep unauthorized persons away.

Measures for explosion protection must never be deactivated, modified or bypassed.

It is forbidden to bring in ignition sources such as sparks, open flames and hot surfaces in potentially explosive areas.

The ignition temperature of the lubricant must lie at least 50 K over the maximum admissible surface temperature of the components.

Only use tools and clothing which are permitted for use in potentially explosive areas (ESD).

Transport, installation, repairs and work on electrical components may only be carried out, if it has been ensured that the atmosphere is not potentially explosive.

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Check the machine at regular intervals for damage which may represent an ignition risk.

Operating Manual Repairs or modifications to machines which are protected against explosions may be carried out only by the manufacturer or by a workshop recognized by a named institution and confirmed in writing.

If the work is not carried out by the manufacturer, the repairs must be approved by a named expert and confirmed in writing. The repairs are to be marked by a repair sign on the machine, stating the following: o Date o Executing company o Type of repair o If applicable, expert's code Transport damages can result in the loss of the explosion protection. If transport damages can be seen, do not assemble the machine or put it into operation All parts of the earthing concept must be correctly available and connected with the superordinate machine.

If transport lugs are dismantled after set-up, the threaded bores must be permanently sealed in accordance with the protection class.

Handle the materials so that no sparks are generated by tilting, falling, sliding, rubbing, impacting, etc. If needed, cover materials with suitable means.

Never disconnect plug-in connections when energized. Secure plug-in connections against inadvertent manual disconnection with the safety clips included in the delivery.

The operator must check critically whether operation without a low-level signal might lead to a new risk potential (e.g. through heat-up of bearing points on the machine in the area of ignition temperature, poor lubrication or bearing damage). If this cannot be ascertained, provide a low-level signal or suitable organisational measures for monitoring of the bearing point temperature.

Avoid dust accumulation and remove dust immediately. Dust accumulations have a thermally insulating effect and, if whirled up, generate the formation of a potentially explosive atmosphere.

The pump should be integrated into the operator's lightning protection concept.

All parts are to be checked regularly for corrosion. Replace the affected parts.

Terminal boxes must be firmly closed and the cable breakthroughs correctly sealed.

Additional electrical monitoring devices must be firmly connected and correctly adjusted.

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Protect the motor with a motor circuit breaker against inadmissible heating up. When reaching their nominal life, the motor bearings have to be replaced or inspected to ensure their suitability for further utilisation.

Transport / installation / maintenance / repairs / servicing All relevant persons (e.g., operating personnel, supervisors) must be informed of the respective activity prior to starting any work. Observe the precautionary operational measures and work instructions.

If protective and safety equipment has to be dismantled, it must be reassembled immediately after finishing the work, and then checked for correct function.

Ensure through suitable measures that movable or detached parts are immobilized during the work and that no limbs can be caught in between by inadvertent movements.

Carry out transport using only suitable hoisting equipment.

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Operating Manual If transported separately (e. g. repair) lift the motor by means of the transport lugs or eye bolts. Ensure that transport lugs or eye bolts are firmly seated. Do not carry any further load on the transport lugs or eye bolts. Do not transport motors on the fan cover.

Assemble the pumps and other components only outside of the operating range of moving parts, at an adequate distance from sources of heat or cold.

Dry wet, slippery surfaces.

Cover hot or cold surfaces accordingly.

Prior to performing work, de-energize and depressurize the pump and secure it against unauthorized switch-on. Work on electrical components must be carried out by electrical specialists only. Observe any waiting periods for discharging, if necessary.

Carry out electrical connections only according to the information in the valid wiring diagram and taking into account the relevant regulations, the local connection conditions and legal prescriptions (e.g. DIN, VDE). Electrical connections must be done in such way that no forces are transferred to the product (tension-free connection).

Do not touch cables or electrical components with wet or damp hands.

Maintenance and repair work can be subject to restrictions at low or high temperatures (e.g. changed flow properties of the lubricant). Therefore, where possible, try to carry out maintenance and repair work at room temperature.

Carry out all works on electrical components using adequate, voltage insulated and technically proper tools only.

Fuses must never be bridged but have to be replaced by the same type of fuse always.

Determine the cause of the failure of the fuse.

Ensure correct earthing of the electrical system.

Undertake drilling at non-critical, non-load bearing parts only. Use any available boreholes. Do not damage lines and cables when drilling. It is essential to observe the machine manufacturer's installation instructions and to consult the machine designer in case of doubts.

Observe possible abrasion points. Protect the parts accordingly.

Other units of the machine or vehicle must not be damaged or impaired in their function by the installation of the centralized lubrication system.

o

maximum operating pressure

o

lubricant to be supplied

o

maximum/ minimum temperature

o

corresponding supply voltage available on site

o

operating and ambient conditions at the location of use

o

required lubricant volume

Parts of the centralized lubrication system must never be subjected to torsion, shearing or bending.

Check all parts prior to use for contamination and clean, if necessary. Lubricant lines should be primed with lubricant prior to installation. This makes the subsequent ventilation and commissioning of the system easier.

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All components used must be designed for:

Operating Manual Observe the specified tightening torques. When tightening, use a calibrated torque wrench.

When working with heavy parts use suitable lifting tools. If need be, consult the responsible safety officer.

Avoid mixing up or wrong assembly of dismantled parts. Mark these parts accordingly.

Laying of the lubrication lines When laying the lubrication lines, observe the following information in order to warrant troublefree function of the entire centralized lubrication system.

CAUTION Environmental pollution Lubrication lines must be absolutely leakproof. Lubricants may pollute ground and waters. Lubricants have to be handled and disposed of properly. Observe all applicable prescriptions and laws regarding disposal of lubricants as well as the relevant safety data sheets.

Slipping hazard Centralized lubrication systems must be absolutely leakproof. Leaking lubricant is hazardous due to the risk of slipping and injury. During assembly, operation, maintenance and repair of centralized lubrication systems watch out for leaking lubricant. Leaks must be sealed immediately.

Dimension the lubrication line according to the maximum pressure and the output volume of the pump unit used.

Starting from the pump unit the main lubrication line should be laid preferably rising with a possibility to vent it at the highest point of the lubrication line system.

Mount the lubricant metering devices at the end of the main lubrication line in such way that the outlets of the lubricant metering devices show upwards. If lubricant metering devices have to be mounted below the main lubrication line, then this should not be done at the end of the main lubrication line.

The tube lines, hoses, shut-off and way valves, fittings, etc. have to be laid out according to the maximum operating pressure of the pump unit, the admissible temperatures and the lubricants to be supplied. Furthermore, the lubrication line system must be protected against inadmissibly high pressure.

Before the assembly thoroughly clean all components of the lubrication line system like tube lines, hoses, shut-off and way valves, fittings, etc. In the lubrication line system no seals should protrude towards the inside, as the lubricant flow could be impeded and contaminations could enter the lubrication line system.

LEC / en / Edition: 03 / 2018

Lubrication lines shall generally be laid in such way that there can never be created air pockets at any point. Avoid changing the cross sections of the lubrication line from smaller to larger cross sections in the lubricant flow direction. Design cross section transitions as smooth as possible.

The lubricant flow in the lubrication lines should not be impeded by the installation of sharp elbows, angle valves and check valves. Provide unavoidable changes of the cross sections in the lubrication lines with as smooth transitions as possible. Avoid sudden changes of direction, if possible.

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Operating Manual

Initial commissioning / daily start-up Ensure that: The machine manufacturer's instructions regarding the lubricants to be used are observed.

All safety devices are completely available and functional.

All connections are correctly connected.

All parts are correctly installed.

All warning labels on the centralized lubrication system are completely available, highly visible and undamaged.

Illegible or missing warning labels are to be replaced without delay.

The system pressure specified for proper operation is adhered to and neither exceeding nor falling below specification.

Cleaning Risk of fire and explosion when using inflammable cleaning agents. Only use nonflammable cleaning agents suitable for the purpose.

Do not use any aggressive cleaning agents.

Do not use steam jet or high pressure cleaners. Otherwise electrical components may be damaged. Observe the protection classes, e.g. IP (International Protection) and NEMA (National Electrical Manufacturers Association), required for proper operation.

Cleaning work on energized components may be carried out by electrical specialists only.

Do not touch cables or electrical components with wet or damp hands.

LEC / en / Edition: 03 / 2018

Mark damp areas accordingly.

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4 Operator obligations Determination of hazards The operator must determine all hazards resulting from the integration of the pump into the superordinate machine and the hazards at the location of operation of the machine, and carry out the measures necessary to ensure safety and health protection.

Provision of necessary information The operator must make the installation instructions required for the respective activity accessible to all people commissioned with operation, maintenance and repairs.

He must ensure that these people have read and understood the necessary installation instructions.

The same applies for all relevant safety data sheets, company instructions, accident prevention regulations, instructions from suppliers of purchase parts and utilities.

Depending on the business organization, the relevant installation instructions may have to be made accessible to other people and departments.

Inspection for correct use The operator must check at regular intervals through suitable measures that the centralized lubrication system is being used according to its intended purpose, that no conversions or manipulations have been made to the centralized lubrication system or to single components and that all parts are fully functional.

Briefing of external technicians Prior to commencing the activities, external technicians must be informed by the operator of the company safety provisions, the applicable accident prevention regulations to be maintained, and the functions of the centralized lubrication system and protective devices.

Provision of personal protective equipment The operator must provide suitable personal protective equipment for the respective location of operation and the purpose of operation.

Training courses

LEC / en / Edition: 03 / 2018

In order to provide a maximum of safety and economic viability, SKF carries out detailed product training courses. It is recommended that the training courses are attended. Please contact SKF Customer Service for information.

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Operating Manual

Inspection of the delivery / returns The delivery must be inspected for completeness based on the delivery papers. Transport damages must be reported to the forwarder immediately. Keep the packaging material until any discrepancies are resolved.

Returns Clean all parts and pack them properly, i.e. following the regulations of the recipient country, before returning them. Mark returns on the packaging as follows; Do not burden / this side up!

Protect against moisture!

Handle with care!

Fragile, do not throw!

Disposal

At the end of their service life, the centralized lubrication system and its components must be dismantled and disposed of according to the respective valid provisions in an environmentally friendly manner. It is forbidden to use parts of a centralized lubrication system that is to be disposed of or to assemble these parts to build a new system.

In case of a final shutdown follow the applicable rules and regulations on the disposal of contaminated parts or means of operation. The product can also be returned to SKF for proper disposal, in which case the customer is responsible for reimbursing the costs incurred. The parts are recyclable.

CAUTION Lubricants may pollute ground and waters. Lubricants have to be handled and disposed of properly.

LEC / en / Edition: 03 / 2018

Observe the instructions by the machine manufacturer regarding the lubricants to be used.

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5 Lubricant

LEC / en / Edition: 03 / 2018

For lubricant information, refer to chapter 5.3 “Lubricants and operating fluids” of the Liebherr Operating Manual

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Operating Manual

Filling of the reservoir

WARNING Risk of hand injuries caused by the stirring paddle or shovel foot Fill lubricant via the lid only when pump is idle. Never reach into the reservoir or grease barrel while the pump is running.

Observe extreme cleanliness when topping up the grease reservoirs.

Contaminated lubricant causes malfunctions and premature wear of the grease pump and other components of the system.

Clean surroundings before exchanging or topping up Switch off centralized lubrication system Filling of the container through service-plate Remove dust protective cap at the filling coupling and the dust protective cap at the filling nipple Couple the filling hose for P1 resp. P2 and switch on the filling pump When the reservoir is full, the sensor transmits an electric signal to the control unit. Visual control is possible by using the dipstick When the filling pump is switched off Disconnect the filling coupling and reinstall the dust protective caps

Inadvertent filling with incorrect lubricant Should incorrect lubricant have been filled, please proceed as follows: Switch off the pump or centralized lubrication system and secure it against being switched on.

Remove lubricant.

Clean the entire centralized lubrication system (lubricant reservoir, pump housing, metering devices and line systems).

Fill in lubricant of correct specification.

Switch the system or pump on.

Vent lubrication system.

Inform your superior to ensure that the error won't occur again.

Inspections prior to initial start-up

Risk of damage to the machine Fill the feed lines and bearing housings with lubricant to specification and lubricate the lubrication points by hand. Otherwise the bearing points may become damaged due to a lack of lubricant.

Check the entire system for accordance with the intended purpose and the planning documentation. Ensure that all parameters, characteristic values and means of operation are present and have been correctly adjusted. If deviations are detected, they must be remedied without delay.

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ATTENTION

Operating Manual In order to warrant safety and function, a person assigned by the operator must inspect certain areas of the central lubrication system prior to initial commissioning. Report any detected deficiencies immediately to your superior and remedy them. Deficiencies may be remedied by an authorized and qualified specialist only.

Check the following points prior to initial commissioning.

Electrics: Electrical connections carried out correctly.

Cable entries sealed correctly.

The voltage and frequency of the power network correspond to the information on the type identification plate of the motor.

Monitoring devices and additional equipment (e.g. motor circuit breaker) are correctly connected and adjusted.

All parts such as lines, cables, metering devices, etc. have been correctly installed and are undamaged.

Mechanics: No loose or missing parts remaining (e.g. pressure relief valves, feed lines).

No damages, deformations, cracks, burnt and smoky points.

No discolorations, contaminations and/or corrosion.

No unusual humidity accumulations, odours, vibrations, or sounds.

No leakages of lubricant at connections and from lines.

Activation of the pump

LEC / en / Edition: 03 / 2018

Depending on the version the centralized lubrication system or pump is activated: By installing it into a machine By switching on the machine contact By a control provided by the customer By manual activation

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6 Standard operation Daily start-up Below find the activities to be carried out in case of standard operation.

Inspections With regard to the actions listed below "Inspections prior to commissioning" the operator has to determine adequate control intervals depending on the respective operating situation of the pump or centralized lubrication system.

Filling of the reservoir during operation Fill the reservoir as described in chapter "Installation and commissioning".

Cleaning Execution, required protective clothes, cleaning agents and devices following the valid operational regulations of the operator.

DANGER Danger to life Risk of fire and explosion when using inflammable cleaning agents.

Do not use steam jet or high pressure cleaners. Electrical components may be damaged. Do not touch cables or electrical components with wet or damp hands. Cleaning work on energized components may be carried out by electrical specialists only. Wear personal protective equipment always.

Exterior cleaning Thorough cleaning of all surfaces.

Mark and secure wet areas.

Interior cleaning Normally, interior cleaning is not required.

ATTENTION

LEC / en / Edition: 03 / 2018

Risk of damage to the machine If using solvents for cleaning, ensure compatibility with plastic parts and painting. Do not use polar organic solvents such as alcohol, methanol or acetone.

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Operating Manual

7 Maintenance and repairs Safety instructions for maintenance and repairs

WARNING Electric shock Make sure to disconnect the pump from the power supply before carrying out works on electrical parts.

Risk of injury Before carrying out any maintenance or repair work, take at least the following safety measures: o

Keep unauthorized persons away.

o

Mark and secure work area.

o

Depressurize the product.

o

Disconnect the product from the power supply and secure it against being switched on.

o

Verify that no power is being applied.

o

Earth and short-circuit the product.

o

Where needed, cover neighbouring units that are live.

Maintenance of the system Depending on the version our centralized lubrication systems require virtually no maintenance.

However, the following parts should be inspected and, if necessary, replaced by new parts at regular intervals: Pressure relief valves Check valves Pump elements

LEC / en / Edition: 03 / 2018

Pressure relief valve tolerance +5 %/ -10 % If this tolerance is exceeded, the pressure relief valves must be replaced.

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Operating Manual

8 Technical data and operating instructions Operating pressure / operating temperature All system components must be designed for the maximum operating pressure and must be secured by an adequate pressure relief valve against too high system pressures. For details see operating or installation instructions and data sheets of the respective product.

Installation position, sound pressure level, weight, dimensions For details see operating or installation instructions and data sheets of the respective product.

Tightening torques For details see operating or installation instructions and data sheets of the respective product.

Output / connections For details see operating or installation instructions and data sheets of the respective product.

Deviating conditions such as NLGI class, temperature and counter pressure may lead to a deviation in the flow rate. This should be taken into account when designing the lubrication points.

Filling possibilities For details see operating or installation instructions and data sheets of the respective product.

Electrical connection (electrically driven products) Following the respective applicable installation prescriptions for electrical systems. For details see operating or installation instructions and data sheets of the respective product.

IP type of protection Motor and system: For IP or NEMA protective class see type identification plate of motor or system respectively the Technical Data chapter of the individual components. For details see operating or installation instructions and data sheets of the respective product.

Air pressure and air quality (air-operated products) Filtered and oiled air according to DIN ISO 8573-1 not higher than class 5 Inlet air pressure

5.5 – 7 bar

Maximum particle density

10 mg / m3

Water content (pressure dew point)

+ 7 °C

Oil content (maximum oil concentration) 25 mg / m3

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Please follow the instructions of the respective product.

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Operating Manual

9 Lubrication System: Description General design 9.1.1 Systems The lubrication system of the R9250 excavator which provide lubricant to the lubrication points are supplied by two independent centralized lubrication systems: System P1, to lubricate the swing gear bearing and the attachment bushes (and options) System P3, to lubricate the swing ring teeth and the swing gear centering seat 9.1.2 Allocation of the lubrication points The lubrication points of the R9250 excavator described below are dispatched as follows: Backhoe attachment:

Position of lubrication points

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Fig. 1

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Operating Manual Shovel attachment:

Position of lubrication points

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Fig. 2

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Operating Manual 9.1.3 Characteristics of lubrication points on the excavator

LEC / en / Edition: 03 / 2018

All the necessary information regarding the greasing points and quantities are available in chapter 21 of the Liebherr Service Manual.

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System P1: Automatic lubrication In the automatic system, a central lubrication pump provides lubricant to each lubrication point through a single line via injectors model LM5 and subsequent metering devices model SSV. 9.2.1 Configuration

Legend: Equipment: Uppercarriage:

Fig. 3

34

Automatically operated single-line system with LM5 and subsequent progressive divider valve for backhoe attachment

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Injector model LM5 supplies lubricant to the progressive metering devices model SSV which distributes the lubricant to each lubrication point evenly. A control unit commands and monitors the entire system.

Operating Manual

Legend:

LEC / en / Edition: 03 / 2018

Equipment: Uppercarriage:

Fig. 4

R 9250

Automatically operated single-line system with LM5 and subsequent progressive divider valve for shovel attachment

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Operating Manual 9.2.2 Greasing cycle When the pause time has lapsed, the pump starts operating and supplies the lubricant via the main line to the LM5 injectors. The pistons inside the injectors are operated via lubricant pressure. A premetered amount of lubricant is dispensed to the connected SSV. After all injectors have operated, the pressure in the main line rises until the preset pressure on the pump is reached 240 bar. The control unit stops the pump via the pressure switch B69. The pump stops running and the relief valve is deactivated at the same time. The compressed lubricant in the main line can flow back into the reservoir, the pressure drops. When the pressure has fallen below 80 bar the pistons inside the LM5 injectors return to their initial positions by means of spring force and reload the adjustable amount of lubricant by this action.

The pause time can start and the system is now ready for another lubrication cycle.

Level I P1 with pressure control

Legend : T: running time Pause time: 6min A: pressure control device

LEC / en / Edition: 03 / 2018

P1 safety mode, without pressure control

Legend : T: running time 10sec – 250 sec Pause time: 4min-10min A: time control device, pressure switch off

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Operating Manual Level II

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Legend : D T Y95 Y79 Y114 B69 A B C E F G H I

Pause time 5 min – 15 min Running time for one lubrication cycle Pump Dump valve Valve Grease Pressure Cycle ends with max pressure after hold time Winter operation on Winter operation off Max pressure – 40 bar Max pressure Tempo Hold time Continous pumping (only with winter operation button on) Fig. 5

R 9250

Cycle: Equipment and uppercarriage

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Operating Manual 9.2.3 Single-line system The single-line system consists of a pump to supply lubricant under pressure to the injector metering devices via the supply line. The injector metering devices deliver lubricant to a secondary (progressive) metering device or to the bearing through feed lines.

The lubrication cycle is initiated by an automated pump. The injectors have indicator stems, which move in and out to indicate that they have been cycled.

A controller will control the automated system.

LEC / en / Edition: 03 / 2018

The time between on cycles and the length of off cycles is adjustable. The controller includes the timer function above with a monitor function and alarm capability. A pressure switch is used to indicate when system pressure has been reached to turn off the pump and verify that a lube cycle has been completed. If the pressure switch does not detect full pressure within a preset period of time, the controller goes into alarm state.

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Operating Manual 9.2.4 Pump station 200L

1

Level I 1

2

2 3

4 5

ContiMaster pump Hydaulic relief (vent) valve Grease reservoir 200L for FlowMaster II-pump Filtering unit Overflow pipe

3

5

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4

Central lubrication pump 200L Level I (hood transparent)

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Operating Manual

7

8

6

13 9

11

10

12

Central lubrication pump 200L (top view without hood)

40

Solenoid valve (pump control) Level sensor High-level sensor Pressure switch Dip stick (grease reservoir) Pump P1 – Model ContiMaster Relief valve Grease Filter (filling)

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6 7 8 9 10 11 12 13

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Operating Manual

1

Level II (R9250)

1 2 3

4 5

ContiMaster pump Electric relief (vent) 2/2 ways valve Grease reservoir 200L for FlowMaster II-pump Filtering unit Overflow pipe

2

5 3

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4

Central lubrication pump 200L Level II (hood tranparent)

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Operating Manual

11

2

6

7

14

8 9

13

10 12

Central lubrication pump 200L (top view without hood)

42

Solenoid valve (pump control) Level sensor High-level sensor Pressure switch Dip stick (grease reservoir) Pump P1 – Model ContiMaster Relief valve Grease Filter (filling) Electric 3/2 ways valve (winter circuit)*

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6 7 8 9 10 11 12 13 14

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Operating Manual Level III (R9250) 1 2 3

4 5 26 7

ContiMaster pump Electric relief (vent) 2/2 ways valve Grease reservoir 200L for ContimasterMaste r pump Filtering unit Overflow pipe Heating Jacket Thermostat

7 5

1

3 4

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6

Central lubrication pump 200L Level III (hood tranparent)

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Operating Manual

16

2

12

7

8

15

9 17 13 11

7

Solenoid valve (pump control)

8 9 10 11 12 13 14 15 16 17

Level sensor High-level sensor Pressure switch Dip stick (grease reservoir) Pump P1 – Model ContiMaster Relief valve Hydraulic coupling Electric 3/2 ways valve (winter circuit)* Air filter/breather Grease filter (filling)

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10

For information and descriptions of the components, refer to chapter 13. * refer to the user manual 9.3EN-98002-xx (page 19) 44

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Operating Manual 9.3.5 Electronic Controller

LEC / en / Edition: 03 / 2018

For more details: Operating elements Functions Refer to Manual 93EN-98002-A11_OpInst_LIEBHERR-LFR_Mining_664-36957-7_...

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Operating Manual Fault signals Each time a fault arises, an acoustic signal will be given by the controller (buzzer) and the two flashing lights on the pump stations will be activated. Buzzer and flashing lights can be deactivated by pressing the ENTER key.

In two cases this will not be possible: - very low grease level in the barrel (LL) - both sensors for monitoring the lubrication of the slewing rim are defective In these cases, buzzer and flashing lights will be deactivated when switching off the motor, however, will be activated again when starting the motor.

Adjusted values For service personnel with PC, corresponding software and authorization:

adjustable max. value adjustable min. value

LEC / en / Edition: 03 / 2018

adjusted value

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Operating Manual

System P3: Swing ring and swing gear lubrication In the automatic system P3, the central lubrication pump provides lubricant to the Progressive Metering Device (Progressive System) which distributes the lubricant to each lubrication point evenly (swing ring teeth and the swing gear centering seat).

Fig. 6

Schematic of lubrication: Swing ring teeth and swing box centering

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Grease cycle

Fig. 7

Grease cycle

When the pause time has lapsed, the pump P3 supplies lubricant to the connected progressive metering device. A progressive metering device type SSV 6 is provided with the proximity switch B51 for control and monitoring purposes. After two cycles of the SSV 6, which correspond to a full lubrication cycle, the pump P3 is switched off thanks to the proximity switch B51.

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Operating Manual Pump P3 - Multi-line pump type P203-15XYB

1 2 3 4 5

Reservoir 15 liters Level sensor High level sensor “Full” Overflow pipe Pump housing with integrated motor

Fig. 8 P203-15XYB The pump is a compact multiline pump consisting of the following components: · Reservoir with stirring paddle · Printed circuit board · Pump element · Pressure relief valve · Filling nipple · Electrical connection parts · Operates according to lubrication cycles (pause and operating times) · Designed for the delivery of greases up to NLGI 2 · Can be used at low temperatures down to -40 °C. · During the operating time the pump dispenses lubricant to the connected lubrication points via one device.

Number of outlets: Piston diameter: Lubricant output: Reservoir capacity:

1 7 mm approx. 4 cm³/min 15 liters

Description Mode of operation Maintenance Troubleshooting Technical data Refer to Technical Description: 21EN-30001-xxx; 20EN-20003-xxx; 26A-20003-xxx For information and descriptions of the components, refer to chapter 13.

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For more details:

Operating Manual

10 Operation Greasing system – Cabin Location

Fig. 9

Cabin location

For more details: Information regarding the operation of the control unit are available in the respective manual.

LEC / en / Edition: 03 / 2018

Refer to Data Sheet 93EN-98002-xxx for the Electronic Controller

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Operating Manual

System P1: Automatic lubrication CAUTION! Operation by authorized and instructed personnel only!

Never exceed the admissible system pressures!

Refill clean lubricant on time!

CAUTION! Do not interrupt the power supply (main switch of battery) while the pump is operating.

When starting the excavator, the centralized lubrication systems are connected to the power supply automatically. Each lubrication pump then starts a full lubrication cycle and is stopped during the preset pause time only, etc.

The pump P1 delivers lubricant via a single-line system to the lubrication points according to Chapter 9.2 Configuration.

Regarding the control and monitoring of the system refer to: Chapter 9.2. Cabin greasing module U41 or Electronic Controller If required, the operator can force the greasing cycle: for details refer to the respective data sheets.

See the characteristics of each lubrication points: Characteristics of lubrication points on the excavator.

For more details:

LEC / en / Edition: 03 / 2018

Chapter 9.2 Greasing cycle

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Pump P3 CAUTION! Operation by authorized and instructed personnel only!

Never exceed the admissible system pressures!

Refill clean lubricant on time!

CAUTION! Do not interrupt the power supply (main switch of battery) while the pump is operating.

When starting the excavator, the centralized lubrication systems are connected to the power supply automatically. The lubrication pump starts a full lubrication cycle and stops during the preset pause time only, etc.

The pause time is factory-set to 6 minutes.

In normal working condition, no actions are required from the operator.

The only useful information is the low level quantity of the pump P3 reservoir.

If required, the operator can force the greasing cycle: for details refer to the respective data sheets.

NOTE! DAILY:

DO A VISUAL CHECK OF THE RESERVOIR FOR GREASE LEVEL

For more details:

LEC / en / Edition: 03 / 2018

Chapter 9.3 Greasing cycle

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11 Inspection and Maintenance DANGER! DANGER! – Do not carry out any repair works while the system is pressurized – Grease: Relieve system from pressure by carefully opening a fitting and/or the manual vent valve(s) if installed (option) – Hydraulic Oil: Relieve hydraulic system from pressure as described in the Operator Manual – Warning: Lubricant may spurt out while system is under pressure..

NOTE! Regular inspection and maintenance intervals are prerequisites for the proper functioning of the centralized lubrication system over a longer period of time. Any claim for warranty or liability will be null and void, if the prescribed maintenance intervals are not adhered to.

Please observe the following regular inspections and maintenance works: Daily: Visually check the lubrication points with regard to leaking lubricant Visually check the hose connections with regard to leaks and abrasions Check movement of indicator pins: During the lubrication time the pins have to retract, in the pause time all pins have to be extracted.

Weekly: Visually check of tube fittings with regard to leaks Determine the time required for one lubrication cycle. If the determined time deviates much from the usual lubrication time, check each single component (pumps, metering devices, tube lines).

Every 1000 operating hours: Clean or replace strainer assembly Clean or replace lubricant filter (refilling) Check the oil level in the crankcase of the pump model FlowMaster (if applicable) at the dip stick

Change the oil in the crankcase of the pump model FlowMaster.

Use SAE 10W30 motor oil in all units used in an ambient temperature between –40° to 65°C. For ambient temperatures between 10° to 21°C uses Mobil Aero HFA low temperature oil.

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Every 2000 operating hours:

Operating Manual

12 Troubleshooting In the following, only malfunctions of the system as a whole are described. You will find detailed remedies for malfunctions of the individual units in the respective User’s Information.

Malfunction: No pressure build-up in the system Cause:

Remedy:

Malfunctions of the pump

See Troubleshooting: Pump

Leakage in the main line

Check main lines, eliminate leaks, tighten threaded connections, replace defective hoses

Air trapped in the main line

De-aerate the line

Injectors leaky or worn

See Troubleshooting: Injectors

Malfunction: No pressure relief or too slow pressure relief in the main line (automatic option only) Cause:

Remedy:

Pressure control device faulty

Replace pressure control device, check electric cable

Hydraulic vent valve faulty

Replace valve, check fluid supply

Grease too hard or not suitable for low temperatures

Change lubricant

Motor of pump does not run Possible cause

Visible

Remedy

Fault in the superior machine or external control unit.

No pump noise

Check the electrical lines and the external control unit

Check the motor circuit breaker

Motor circuit breaker has tripped

LEC / en / Edition: 03 / 2018

Motor runs, but pump does not supply lubricant

R 9250

Possible cause

Visible

Remedy

Reservoir empty

Visual check

Refill

Air pockets in the lubricant

Air bubbles in the lubricant

Vent

Suction bore of pump element is clogged.

After disassembling the pump element

Disassemble and clean the pump elements.

Defective or dirty system check valve

After disassembly of the check valve

Replace check valve.

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Operating Manual

Worn pump element

Little pressurization

Defective pressure relief valve or fault at the lubrication point

Lubricant leaking from the pressure relief valve

Blockade in the downstream lubrication system

Grease leaking from the pressure relief valve

Check pump element and replace, if necessary.

Determine cause.

Replace pressure relief valve Determine cause and eliminate it.

If the fault cannot be determined and remedied, contact our Customer Service.

Please follow the instructions of the respective product.

For more details: Regarding error codes (fault indications) Refer to 4.4DE_EN-68610-xxx or Refer to 93EN-98002-xxx

LEC / en / Edition: 03 / 2018

Fault indications (error codes)

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User Manual EC

Error Codes G

Fault

Cause

Displ ay E__

Display G__ to:

Signalisation

Lubrication

01

02

03

04

05

06

07

08

09

10

11

12

13

IMPORTANT NOTE Codings “B…“, “H…“, “S…“, “X…“, and “Y…“ refer to t he wiring diag ram (se e annex).

User Manual EC

Error Codes, continuation G

Fault

Cause

14

15

16

17

18

19

20

21

22

23

24

25

26

27 IMPORTANT NOTE C odings “B…“, “H…“, “S…“, “X… “, and “Y…“ refer to the wiring d iagram (see annex).

Displ ay E__

Display G__ to:

Signalisation

Lubrication

User Manual EC

Error Codes, continuation G

Fault

Caus e

28

29

30

31

32

33

34

35

36

37

38

39 40 41 42 43 44 45

IMPORTANT NOTE Codings “B…“, “H…“, “S…“, “X…“, and “Y…“ refer to the wiring diagram (see annex).

Display Display E_ _ G__ to:

Signal isation

Lubrication

User Manual EC

Error Codes, continuation G

Fault

Cause

46

47

48

49

50

51

52 53 54

55

56

57 58 59 60

61

81

82

IMPORTANT NOTE C odings “B…“, “H…“, “S…“, “X… “, and “Y…“ refer to the wiring d iagram (see annex).

Displ ay E__

Display G__ to:

Signalisations

Lubrication

User Manual EC

Error Codes, continuation G

Fault

Cause

83

84

85

86

87

88

89

90

IMPORTANT NOTE C odings “B…“, “H…“, “S…“, “X… “, and “Y…“ refer to the wiring d iagram (see annex).

Displ ay E__

Display G__ to:

Signalis ation

Lubrication

Conversion factors Pressure:

Length:

Volume:

Torque:

Weight:

Temperature:

MJFCIFSS