Service Manual

Chapter 14 - Pneumatic control

Pneumatic system............................................................................................................................................. 14-3
1 Technical data .................................................................................................................................. 14-4
2 Pneumatic schematic........................................................................................................................ 14-5
3 Component location.......................................................................................................................... 14-6
4 Functional description....................................................................................................................... 14-9
4.1 Air pressure system function, see also schematic.................................................................. 14-9
4.2 Horn valves............................................................................................................................. 14-9
5 Troubleshooting ................................................................................................................................ 14-10
5.1 Compressor and pressure regulator (insufficient operating pressure) ................................... 14-10
6 Adjustment instructions..................................................................................................................... 14-11
6.1 Adjustment of operating pressure........................................................................................... 14-11
7 Component description..................................................................................................................... 14-12
7.1 Pressure regulator .................................................................................................................. 14-12
7.2 Air dryer .................................................................................................................................. 14-14
7.3 Check valve ............................................................................................................................ 14-15
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14 Pneumatic system
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Technical data

14.1Technical data

Machine model R 9250

Serial No

Component Operating pressure in bar (PSI)

Pressure regulator
• Cut-in pressure 6,2 (90)
• Cut-out pressure 7,25 (105)

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Pneumatic schematic

14.2Pneumatic schematic
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Component location

14.3Component location

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Component location
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Component location

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Functional description

14.4Functional description

14.4.1Air pressure system function, see also schematic

The pneumatic circuit feeds in air pressure the signal horns.
The following describes the air pressure system assuming zero pressure throughout, with all components, in-
cluding valves, in their normal rest position.
• The air compressor, driven directly by the diesel engine, delivers filtered air through the air dryer and the
check valve to the signal horns.
• The pressure regulator maintains the required opearting pressure range.
–At maximum permissible pressure (cut-out pressure, see operating pressure chart), the pressure regu-
lator releases air from compressor through air dryer and threw the compressor unloading valve into
the atmosphere. The compressor shifts in neutral position and the air dryer is automatically purged
(see air dryer).
–If operating pressure drops below a specific minimum value (regulator cut-in pressure setting), the com-
pressor shifts to working cycle and so supplies air to the signal horns.
–Operating pressure is indicated by the both pressure gauges.
• An air container is installed on the circuit to have a shorter reaction time of the circuit.

14.4.2Horn valves
Depressing the switch S4 (horn button) on left hand side joystick, installed in the cab, allows air pressure to
sound the signal horn through the solenoid valve Y11-1 and Y11-2.

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Troubleshooting

14.5Troubleshooting

14.5.1Compressor and pressure regulator (insufficient operating pressure)

If the air system operating pressure does not build up to specification or (with engine running or stopped) drops
rapidly, check the following before attempting any adjustments :
Check all air pressure lines, fittings and system components for leaks. With the compressor operating,
there should be no sounds of escaping air in the circuit.
Leaking lines, fittings and system components should be sealed. Defective valves should be repaired or
replaced if necessary.
If these preliminary checks fail to indicate the cause of a particular problem, proceed in according with
the following troubleshooting chart.
Problem : air system pressure for the powerpack (indicated by the pressure gauges) does not reach the spe-
cified value (see pressure chart).

Test Result Cause and corretive action

A. At pressure regulator, After adjustment, operating

adjust pressure to specifi-
cations (indicated by the
pressure gauge).
pressure is correct.
Operating pressure still too
low and can not be adjusted See B.
at pressure regulator.

B. Disconnect pressure line Compressor delivers insuffi- Compressor is defective.

between compressor and
air dryer. Check if com-
pressor delivers sufficient
amount of compressed
air.
cient amount or no com-
pressed air.
Compressor delivers suffi-
cient amount of compressed
air.
Check compressor and com-
pressor unloading valve;
replace if necessary.
Pressure regulator or air
dryer is defective. Check
pressure regulator and air
dryer. Replace if necessary.

14.6Adjustment instructions

Before attempting any adjustment to the air pressure system, make sure that the pressure regulator opens at
maximum permissible pressure and unloads the compressor into idle function.
Conversely, the regulator must again shift at minimum permissible pressure and return the compressor to its
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working function.
Only LIEBHERR dealer service personnel are permitted to perform pressure adjustments during the machine
warranty period.

14.6.1Adjustment of operating pressure

The specified operating pressure is obtained by adjusting the pressure regulator.

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Component description

• Start engine and bring it to high idle.

• Remove the protective cap and loosen the lock nut 3b at pressure regulator.
• Turn adjustment screw 3a until the right indicator pressure gauge indicates the specified cut out pressure.
The left indicator pressure gauge indicates if the compressor supplies the circuit or not :
–When the compressor supplies the circuit, the pressure on the left indicator is the atmospheric pressu-
re.
–When the compressor does not supply the circuit, the pressure on the left indicator is the pressure of
the circuit.
• Turn clockwise = reduce pressure.
• Turn counterclockwise = increase pressure.
• After adjustment, tighten lock nut 3b and replace protective cap.

14.7Component description

14.7.1Pressure regulator
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14.7.1.1Application
The pressure regulator control the unloader mechanism fitted to the compressor, allowing the compressor to
run unloaded whilst a sufficient pressure level is maintained in the air tanks.
The valve consists of a cast aluminium body, together with a spring loaded piston and a soft seated disc valve.

14.7.1.2Function
At all times, chamber «A» is at circuit pressure, and chambers «B» and «C» are connected to atmosphere via
the exhaust port. When the air brake system is not pressurised or when the compressor has not raised the air

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Component description

pressure in the circuit to cut out level, each moving part is positioned as indicated in the sectioned diagram.

Cut out
As the pressure in the pneumatic circuit rises, the same pressure increase is apparent in chamber «A». When
a certain level is reached, the air pressure pushes the piston upwards, bringing the disc valve into contact with
the spring loaded exhaust system. Further increase in pressure enables the exhaust stem to push the disc val-
ve off its seat, and compressed air from the circuit is allowed into chamber «D». This air passes to the com-
pressor, via the unloader port, and brings the unloader mechanism into operation allowing the compressor to
«run light» while the tanks are fully charged.

Cut in
When the circuit pressure drops, the piston moves downwards under the force of the control spring. This result
in the disc valve being allowed to return to its seat on the piston, thereby isolating the unloader connection from
reservoir pressure. The exhaust stem is kept in contact with the end of the adjustable screw by a conical spring
in chamber «B». This enables the air pressure in the ports and passages leading to the unloader mechanism,
to exhaust to atmosphere through the hollow exhaust stem, the holes in the lower spring seats, and finally to
atmosphere via the exhaust port.
The range between cut in and cut out pressures, usually 1 to 1,4 bar (14,5 to 20,3 Psi), can be either raised or
lowered slightly by increasing or decreasing the load on the control spring. This is achieved by loosening the
adjusting nut, turning the adjusting screw and re-tightening the nut. To gain access to this screw, simply raise
the rubber cover on the top of the unit.

1 Disc valve
2 Exhaust stem
3 Adjusting screw
4 Retaining ring
5 Adjusting nut
6 Control spring
7 Exhaust port
8 Unloading valve port
9 Air circuit pressure port
A Chamber
B Chamber
C Chamber
D Chamber
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Component description

14.7.2Air dryer

14.7.2.1Application
The air cleaner cleams the air from moisture, dust and oil.

14.7.2.2Function

Compresssion cycle
Humid air enters from the compressor and air passes
through the space between the dessiccant canister and
outer shell, cooling in the process. The water and oil dro-
plets that condense, drop to the bottom sump of the contai-
ner as the air makes a 180° turn. The air then passes
through the oil separator which removes dirt particules, oil
and water mist. The air continues upward through the des-
siccant bed where it is exposed to the immense surface
area of the dessiccant which has a tremendous affinity for
the water molecule. Moisture is removed from the air wi-
thout necessity of further condansation. As the air conti-
nues to pass through the drying bed, it encounters dryer
dessiccant, and its moisture content is progressively redu-
ced, and the air becomes «super dry». At the top of the
unit, the air flows through the outlet and discharge line into
the reservoir. At this point, the air is so dry that its tempe-
rature can drop an additional 22°C (40°F) or more, before
condensation occurs.

Purge cycle
When the system reaches the governor cut out pressure,
air pressure from the unloader line enters the unloader line
enters the purge valve and moves the plunger off its seat.
The sudden opening of the valve permits the pressurized
air existing in the dryer and connecting air lines to flow
through the dessiccant in a inverse direction. The sudden
decompression of the drying bed removes moisture from
the pores of the dessiccant.
Via this rapid decompression, oil particules and moisture
are exhausted from the sump through the purge valve. The
pressurized air originally «super dryed» in passage throu-
gh the dessiccant bed is very efficient in removing desor-
bing water on its reverse flow through the dessiccant bed.
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Component description

14.7.3Check valve

14.7.3.1Application
The check valve allows air to flows in one direction, and prevents the drop or return of air pressure in the other
direction.

14.7.3.2Function
An increase in pressure (direction of arrow) lifts the poppet 2, against spring pressure 1, off its seat and air
flows to the end user until the pressure is balanced.
If the pressure in the inlet line «A» drops, the poppet 2 closes due to the spring pressure 1 and prevents air
from returning to the inlet port «A».

14.7.3.3Maintenance
This valve requires no regular maintenance.
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