Chapter 5: Tooling: Service Manual

Service Manual
Chapter 5: Tooling
Tools ........................................................................................................................................5.10
1 Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10.3
2 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10.22
3 Electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10.51
Annexes...................................................................................................................................5.20
1 Special wrench to remove and install the piston on hydraulic cylinders . . . . . . . . . . . . . . . . . . . . . . 5.20.65
2 Mounting device for disassembly and assembly of brake housing/ disk brake . . . . . . . . . . . . . . . . . 5.20.66
3 To remove or/and tighten of the slotted nut on the output/swing gear . . . . . . . . . . . . . . . . . . . . . . . 5.20.67
4 Installation of the pump control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.20.69
4.1 Installation of the pump control box for R/P 996 and 996B . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.20.69
4.2 Installation of the pump control box for R/P 995 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.20.70
4.3 Installation of the pump control box for R/P 9250, 9350 and 9400 . . . . . . . . . . . . . . . . . . . . . 5.20.71
Mining Excavators 5.00.1

copyright by
MJFCIFSS
Service Manual
5.00.2 Mining Excavators

copyright by
MJFCIFSS
Service Manual Tools
Hydraulic
R9800
R996
R996B
R995
R994B
R9350
R9400
R9250
R994
R9150
R984C
R9100
Mining Excavators MJFCIFSS 5.10.3

Tools Service Manual
Hydraulic
R9800
R996
R996B
R995
R994B
R9350
R9400
R9250
R994
R9150
R984C
R9100
5.10.4 MJFCIFSS Mining Excavators

Hydraulic
R9800
R996
R996B
R995
R994B
R9350
R9400
R9250
R994
R9150
R984C
R9100

Hydraulic
R9800
R996
R996B
R995
R994B
R9350
R9400
R9250
R994
R9150
R984C
R9100

Hydraulic
R9800
R996
R996B
R995
R994B
R9350
R9400
R9250
R994
R9150
R984C
R9100

Hydraulic
R9800
R996
R996B
R995
R994B
R9350
R9400
R9250
R994
R9150
R984C
R9100

Hydraulic
R9800
R996
R996B
R995
R994B
R9350
R9400
R9250
R994
R9150
R984C
R9100

Hydraulic
R9800
R996
R996B
R995
R994B
R9350
R9400
R9250
R994
R9150
R984C
R9100

Hydraulic
R9800
R996
R996B
R995
R994B
R9350
R9400
R9250
R994
R9150
R984C
R9100

Hydraulic
R9800
R996
R996B
R995
R994B
R9350
R9400
R9250
R994
R9150
R984C
R9100

Hydraulic
R9800
R996
R996B
R995
R994B
R9350
R9400
R9250
R994
R9150
R984C
R9100

Hydraulic
R9800
R996
R996B
R995
R994B
R9350
R9400
R9250
R994
R9150
R984C
R9100

Hydraulic
R9800
R996
R996B
R995
R994B
R9350
R9400
R9250
R994
R9150
R984C
R9100

Hydraulic
R9800
R996
R996B
R995
R994B
R9350
R9400
R9250
R994
R9150
R984C
R9100

Hydraulic
R9800
R996
R996B
R995
R994B
R9350
R9400
R9250
R994
R9150
R984C
R9100

Hydraulic
R9800
R996
R996B
R995
R994B
R9350
R9400
R9250
R994
R9150
R984C
R9100

Hydraulic
R9800
R996
R996B
R995
R994B
R9350
R9400
R9250
R994
R9150
R984C
R9100

Hydraulic
R9800
R996
R996B
R995
R994B
R9350
R9400
R9250
R994
R9150
R984C
R9100

Hydraulic
R9800
R996
R996B
R995
R994B
R9350
R9400
R9250
R994
R9150
R984C
R9100

General
R9800
R996
R996B
R995
R994B
R9350
R9400
R9250
R994
R9150
R984C
R9100

General
R9800
R996
R996B
R995
R994B
R9350
R9400
R9250
R994
R9150
R984C
R9100

General
R9800
R996
R996B
R995
R994B
R9350
R9400
R9250
R994
R9150
R984C
R9100

General
R9800
R996
R996B
R995
R994B
R9350
R9400
R9250
R994
R9150
R984C
R9100

General
R9800
R996
R996B
R995
R994B
R9350
R9400
R9250
R994
R9150
R984C
R9100

General
R9800
R996
R996B
R995
R994B
R9350
R9400
R9250
R994
R9150
R984C
R9100

General
R9800
R996
R996B
R995
R994B
R9350
R9400
R9250
R994
R9150
R984C
R9100

General
R9800
R996
R996B
R995
R994B
R9350
R9400
R9250
R994
R9150
R984C
R9100

General
R9800
R996
R996B
R995
R994B
R9350
R9400
R9250
R994
R9150
R984C
R9100

General
R9800
R996
R996B
R995
R994B
R9350
R9400
R9250
R994
R9150
R984C
R9100

General
R9800
R996
R996B
R995
R994B
R9350
R9400
R9250
R994
R9150
R984C
R9100

General
R9800
R996
R996B
R995
R994B
R9350
R9400
R9250
R994
R9150
R984C
R9100

General
R9800
R996
R996B
R995
R994B
R9350
R9400
R9250
R994
R9150
R984C
R9100

General
R9800
R996
R996B
R995
R994B
R9350
R9400
R9250
R994
R9150
R984C
R9100

General
R9800
R996
R996B
R995
R994B
R9350
R9400
R9250
R994
R9150
R984C
R9100

General
R9800
R996
R996B
R995
R994B
R9350
R9400
R9250
R994
R9150
R984C
R9100

General
R9800
R996
R996B
R995
R994B
R9350
R9400
R9250
R994
R9150
R984C
R9100

General
R9800
R996
R996B
R995
R994B
R9350
R9400
R9250
R994
R9150
R984C
R9100

General
R9800
R996
R996B
R995
R994B
R9350
R9400
R9250
R994
R9150
R984C
R9100

General
R9800
R996
R996B
R995
R994B
R9350
R9400
R9250
R994
R9150
R984C
R9100

General
R9800
R996
R996B
R995
R994B
R9350
R9400
R9250
R994
R9150
R984C
R9100

General
R9800
R996
R996B
R995
R994B
R9350
R9400
R9250
R994
R9150
R984C
R9100

General
R9800
R996
R996B
R995
R994B
R9350
R9400
R9250
R994
R9150
R984C
R9100

General
R9800
R996
R996B
R995
R994B
R9350
R9400
R9250
R994
R9150
R984C
R9100

General
R9800
R996
R996B
R995
R994B
R9350
R9400
R9250
R994
R9150
R984C
R9100

General
R9800
R996
R996B
R995
R994B
R9350
R9400
R9250
R994
R9150
R984C
R9100

General
R9800
R996
R996B
R995
R994B
R9350
R9400
R9250
R994
R9150
R984C
R9100

General
R9800
R996
R996B
R995
R994B
R9350
R9400
R9250
R994
R9150
R984C
R9100

General
R9800
R996
R996B
R995
R994B
R9350
R9400
R9250
R994
R9150
R984C
R9100

Electric
R9800
R996
R996B R9800
R995 R996
R996B
R994B R995
R9350
R9400 R994B
R9350
R9250 R9400
R994 R9250
R9150 R994
R984C R9150
R9100 R984C
R9100

Electric
R9800
R996
R996B
R995
R994B
R9350
R9400
R9250
R994
R9150
R984C
R9100

Electric
R9800
R996
R996B
R995
R994B
R9350
R9400
R9250
R994
R9150
R984C
R9100

Electric
R9800
R996
R996B
R995
R994B
R9350
R9400
R9250
R994
R9150
R984C
R9100

Electric
R9800
R996
R996B
R995
R994B
R9350
R9400
R9250
R994
R9150
R984C
R9100

Electric
R9800
R996
R996B
R995
R994B
R9350
R9400
R9250
R994
R9150
R984C
R9100

Electric
R9800
R996
R996B
R995
R994B
R9350
R9400
R9250
R994
R9150
R984C
R9100

Electric
R9800
R996
R996B
R995
R994B
R9350
R9400
R9250
R994
R9150
R984C
R9100

Electric
R9800
R996
R996B
R995
R994B
R9350
R9400
R9250
R994
R9150
R984C
R9100

Electric
R9800
R996
R996B
R995
R994B
R9350
R9400
R9250
R994
R9150
R984C
R9100

Electric
R9800
R996
R996B
R995
R994B
R9350
R9400
R9250
R994
R9150
R984C
R9100

Electric
R9800
R996
R996B
R995
R994B
R9350
R9400
R9250
R994
R9150
R984C
R9100

Electric
R9800
R996
R996B
R995
R994B
R9350
R9400
R9250
R994
R9150
R984C
R9100

Electric
R9800
R996
R996B
R995
R994B
R9350
R9400
R9250
R994
R9150
R984C
R9100

Service Manual Annexes
Special wrench to remove and install the piston on hydraulic cylinders
5.20: Annexes
1 Special wrench to remove and install the piston on hydraulic cylin-

ders
Dimensions are in mm (mm x 0. 3937 = inches)
Ø Piston* a b c d e f g h Id. No.
70 52 38 75 200 10 8 8 15 9131359
85 - 90 60 44 85 200 14 10 10 15 9131362
90 68 52 100 220 14 10 10 15 9231993
100 - 110 75 - 80 54 110 200 14 12 10 20 8007364
120 - 125 88 63 120 250 14 12 10 20 8007365

130 - 160 100 78 135 260 14 14 10 20 8007366
140 115 88 150 300 14 14 10 20 9919856
150 - 180 125 97 170 320 14 14 10 25 9196978
150 - 180 130 97 170 320 14 18 15 25 9196978
180 - 210 145 113 185 380 14 18 15 25 8007367
210 - 260 175 135 215 450 14 20 19 25 9131373
280 - 310 220 156 280 500 14 30 28 40 9131376
320 240 184 310 600 14 30 30 90 10379837
320 250 204 310 600 14 30 28 30 9249886#
320 260 176 330 600 19 36 35 40 9249741
340 - 420 280 206 354 650 19 36 35 40 9243215
* The indication of the piston diameter related to the wrench size is only for your guidance. For indi-
cation of the piston wrench Id. No., refer to the spare part list of the corresponding hydraulic cylinder.
# This wrench is used for the hydraulic cylinder of the track tension unit.

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MJFCIFSS
Annexes Service Manual
Mounting device for disassembly and assembly of brake housing/disk brake
2 Mounting device for disassembly and assembly of brake housing/

disk brake
For swing gear Liebherr SAT 220 / 225 / 250 / 275 / 300 / 325 / 350 / 400 /450
Id. No.
Size
Mounting A B C D E F G H
Swing gear
device
SAT 200 9206110 252 40 12 10 10 14 90 110
SAT 225 9202825 268 40 12 10 10 16 100 117
SAT 250 9199319 300 40 12 10 10 18 110 131

SAT 275 9202826 326 40 12 10 10 18 120 143
SAT 300 9202827 364 50 20 15 15 22 130 157
SAT 325 / 204 9202828 390 50 20 15 15 22 142 170

SAT 350 / 205 9202829 410 50 20 15 15 22 154 180
SAT 400 / 206 9393900 440 50 20 15 15 18 175 202.5

SAT 450 / 207

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MJFCIFSS
To remove or/and tighten of the slotted nut on the output/ swing gear
3 To remove or/and tighten of the slotted nut on the output/swing

gear
For swing gear Liebherr SAT 225 / 250 / 275 / 300 / 325 / 350 / 400 / 450
Gear - Typ. Id. No.
SAT 225 9202820

SAT 250 9199665
SAT 275 9202821
SAT 300 9202822

SAT 325 9202823
SAT 350 9202824
SAT 400 9960374
SAT 450 9960410
Drawing, see overleaf

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MJFCIFSS
To remove or/and tighten of the slotted nut on the output/swing gear
SAT A B C D E F G H J K L M N O
225 90 50 30 55 71,5 77 100 95 3,8 80 35 30 40 7,8
250 100 55 46 60 81,5 86 110 105 3,8 90 35 30 50 7,8
275 110 55 46 70 92,2 95 120 105 3,8 90 35 30 50 7,8
300 125 55 46 80 106, 110 140 120 3,8 105 35 30 50 7,8

5
325 126,5 55,5 46 50 115 115, 150 115, 3,8 94 35 30 55 7,8

5 5
350 137,5 55,5 46 50 125 126, 160 113, 3,8 92 35 30 55 7,8

2 5
400 173,5 60 46 60 144, 146 189, 145 6,7 117 35 30 85 19,7

3 5
450 179 50 30 0 164 166 198 127 6,5 107 35,47 33 76 20

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MJFCIFSS
Installation of the pump control box
4 Installation of the pump control box
4.1 Installation of the pump control box for R/P 996 and 996B
Connection
Connect the control box (ident. Nr. 8504397) to the connectors X104 and X105 of the printplate in the
switching box E1005 of the cab.
Verification of the flow reduction values
On the display, select the i-machine.

Turn the rotary switch of the control box in the position 1 (middle position) : the flow reduction for all
pumps must be 35% (input I4 with option 1 activated). The left figure must be displayed on the screen.
Turn the rotary switch of the control box in position 2 (full position) : the flow reduction for all pumps
must be 100% (input I3 with option 1 activated). The middle figure must be displayed on the screen.
If necessary, activate the opt1 for in3 and in4 with the menu set option. For in4, opt1 the right figure
must be displayed on screen.

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MJFCIFSS
Adjustment of the flow reduction values for input 3 and 4
If the values are not correct, adjust the settongs with the menu set pumps (accessible in level 2 with
a coded plug). For the setting procedure see subgroup 13 (the frame on the figure must look like the
screen).
The pumps reduction valves have be setted separately for eng1 (engine 1) and eng2 (engine 2).
4.2 Installation of the pump control box for R/P 995
Connection
Connect the control box (Ident. Nr 8504397) to the connectors X104 and X105 of the printplate A1003
in the switching box E1005 of the cab (see subgroup 13 for connector location).
On the display, select the menu i-I/0.

Turn the rotary switch of the control box in position 1 (middle position) : the flow reduction for all
pumps must be 40% (input I4 activated for EV1, EV2 and EV3). The left figure must be displayed on
the screen.

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MJFCIFSS
Turn the rotary switch of the control box in position 2 (full position) : the flow reduction for all pumps
must be 100% (input I3 activated for EV1, EV2 and EV3). The right figure must be displayed on the
screen.
If the values are not correct, adjust the settings with the menu set pumps (accessible in level 2 with
a coded plug). For the setting procedure, see subgroup 13 (the frame on the screen must look like
the left figure for adjustment of I4 and to the right figure for adjustment of I3).
4.3 Installation of the pump control box for R/P 9250, 9350 and 9400
Connection
Connect the control box (Ident. Nr 8504397) to the connectors XT104 and XT105 in the switching box
E1005 of the cab (see electrical system chapter for connectors location).
On the display selct the menu i-I/0.

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MJFCIFSS
Turn the rotary switch of the control box in position 1 (middle position) : the flow reduction for all
pumps must be 40% (input I4 activated for EV1, EV2 and EV3). The left figure must be displayed on
the screen.
Turn the rotary switch of the control box in position 2 (full position) : the flow reduction for all the
pumps must be 100% (input I3 activated for EV1, EV2 and EV3). The right figure must be displayed
on the screen.
If the values are not correct, adjust the settings with the menu set pumps (accessible in level II with
a coded plug). For the setting procedure, see subgroup (the frame on the screen must look like to the
left figure for adjustment of I4 and to right figure for adjustment of I3).

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MJFCIFSS

Chapter 5: Tooling: Service Manual

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Service Manual

Mining Excavators 5.00.1

5.00.2 Mining Excavators

Mining Excavators MJFCIFSS 5.10.3

5.10.4 MJFCIFSS Mining Excavators

Mining Excavators MJFCIFSS 5.10.5

5.10.6 MJFCIFSS Mining Excavators

Mining Excavators MJFCIFSS 5.10.7

5.10.8 MJFCIFSS Mining Excavators

Mining Excavators MJFCIFSS 5.10.9

5.10.10 MJFCIFSS Mining Excavators

Mining Excavators MJFCIFSS 5.10.11

5.10.12 MJFCIFSS Mining Excavators

Mining Excavators MJFCIFSS 5.10.13

5.10.14 MJFCIFSS Mining Excavators

Mining Excavators MJFCIFSS 5.10.15

5.10.16 MJFCIFSS Mining Excavators

Mining Excavators MJFCIFSS 5.10.17

5.10.18 MJFCIFSS Mining Excavators

Mining Excavators MJFCIFSS 5.10.19

5.10.20 MJFCIFSS Mining Excavators

Mining Excavators MJFCIFSS 5.10.21

5.10.22 MJFCIFSS Mining Excavators

Mining Excavators MJFCIFSS 5.10.23

5.10.24 MJFCIFSS Mining Excavators

Mining Excavators MJFCIFSS 5.10.25

5.10.26 MJFCIFSS Mining Excavators

Mining Excavators MJFCIFSS 5.10.27

5.10.28 MJFCIFSS Mining Excavators

Mining Excavators MJFCIFSS 5.10.29

5.10.30 MJFCIFSS Mining Excavators

Mining Excavators MJFCIFSS 5.10.31

5.10.32 MJFCIFSS Mining Excavators

Mining Excavators MJFCIFSS 5.10.33

5.10.34 MJFCIFSS Mining Excavators

Mining Excavators MJFCIFSS 5.10.35

5.10.36 MJFCIFSS Mining Excavators

Mining Excavators MJFCIFSS 5.10.37

5.10.38 MJFCIFSS Mining Excavators

Mining Excavators MJFCIFSS 5.10.39

5.10.40 MJFCIFSS Mining Excavators

Mining Excavators MJFCIFSS 5.10.41

5.10.42 MJFCIFSS Mining Excavators

Mining Excavators MJFCIFSS 5.10.43

5.10.44 MJFCIFSS Mining Excavators

Mining Excavators MJFCIFSS 5.10.45

5.10.46 MJFCIFSS Mining Excavators

Mining Excavators MJFCIFSS 5.10.47

5.10.48 MJFCIFSS Mining Excavators

Mining Excavators MJFCIFSS 5.10.49

5.10.50 MJFCIFSS Mining Excavators

Mining Excavators MJFCIFSS 5.10.51

5.10.52 MJFCIFSS Mining Excavators

Mining Excavators MJFCIFSS 5.10.53

5.10.54 MJFCIFSS Mining Excavators

Mining Excavators MJFCIFSS 5.10.55

5.10.56 MJFCIFSS Mining Excavators

Mining Excavators MJFCIFSS 5.10.57

5.10.58 MJFCIFSS Mining Excavators

Mining Excavators MJFCIFSS 5.10.59

5.10.60 MJFCIFSS Mining Excavators

Mining Excavators MJFCIFSS 5.10.61

5.10.62 MJFCIFSS Mining Excavators