Service Manual INDEX Pneumatic System

PNEUMATIC SYSTEM

PNEUMATIC SYSTEM ............................................................................................................................ 1

1 Technical data............................................................................................................................... 3
2 Pneumatic schematic .................................................................................................................... 4
3 Component location ...................................................................................................................... 7
4 Functional description ................................................................................................................... 9
4.1 Air pressure system function, see also schematic................................................................. 9
4.2 Horn valves ............................................................................................................................ 9
5 Troubleshooting .......................................................................................................................... 11
5.1 Compressor and pressure regulator (insufficient operating pressure) ................................ 11
5.2 Hydraulic tank pressure ....................................................................................................... 12
6 Adjustment instructions ............................................................................................................... 13
6.1 Adjustment of operating pressure........................................................................................ 13
6.2 Adjustment of hydraulic tank pressure (pressure reducing valves 13)................................ 14
6.3 Adjustment of safety relief valves 17 ................................................................................... 14
7 Component description ............................................................................................................... 13
1.1 Pressure regulator ............................................................................................................... 15
1.2 Air dryer ............................................................................................................................... 17
1.3 Check valve ......................................................................................................................... 19
1.4 Safety relief valve ................................................................................................................ 21
1.5 Automatic drain valve .......................................................................................................... 23
1.6 Pressure reducing valve ...................................................................................................... 25

R 996 Litronic LIEBHERR 14.01-1

From Date: 11 / 2001
INDEX CHAPTER
Service Manual INDEX CHAPTER
Pneumatic System

1 Technical data

Machine model R 996

Serial No 101

Component Operating pressure in bar (PSI)

Pressure regulator 3 on powerpack 1

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

Pressure regulator 3 on powerpack 2

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

Hydraulic oil tank pressure

• Pressure reducing valves 13 .................................................. .........................0,2 (2,9)
• Safety valves 17 – opening pressure ..................................... .........................0,4 (5,8)

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Pneumatic System

2 Pneumatic schematic

1 Air filter 20.2 Horn right

2 Compressor 21 Fast evacuation valve
2.1 Compressor unloading valve 22 Manual air outleet valve
3 Pressure regulator 23 Fuel tank
4 Air filter / dryer
5 Non return valve B38 Pressure switch / tank pressurization •
11 Air pressure tanks M1 Diesel engine 1
12 Drain valves M2 Diesel engine 2
13 Pressure reducing valves PP1 Power Pack 1
14 Non return valve PP2 Power Pack 2
15 Pressure gauge
16 Hydraulic tank Y11.1 Solenoid valve / horn left •
17 Safety valves Y11.2 Solenoid valve / horn right •
20.1 Horn left Y13 Pilote valve / fast evacuation •

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Pneumatic System

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From Date: 11 / 2001
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Service Manual INDEX CHAPTER
Pneumatic System

3 Component location

Fig. 2: Air dryer (4) and non return valve (5)

Fig. 1: Compressor (2), unloading valve (2.1)

And pressure regulator (3)

Fig. 4: Drain valve

Fig. 3: Air tanks (11) and solenoid valves (Y11.1

and Y11.2)

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Pneumatic System

Fig. 6: Manual air vent valve

Fig. 5: Pressure reducing valves (13), non return

valves (14) and pressure gauges (15)

Fig. 7: Pressure switch (B38) and

safety valves (17)

Fig. 8: Emergency evacuation valve (21)

and pilot valve (Y13)
Fig. 9: Horn

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Pneumatic System

4 Functional description

4.1 Air pressure system function, see also schematic

On R996, there are two independent pneumatic circuit which feed simultaneously in air pressure the
hydraulic tank 16 (the hydraulic tank pressurization is possible with just one powerpack).
The following describes the air pressure system assuming zero pressure throughout, with all
components, including valves, in their normal rest position.

• The air compressor 2, driven directly by the diesel engine, delivers filtered air through air dryer 4
and check valves 5, to the air tanks 11.

• The pressure regulator 3 maintains the required operating pressure range. At maximum
permissible pressure (cut-out pressure, see operating pressure chart), the pressure regulator
releases air from compressor 2 through air dryer 4 and compressor unloading valve 2.1 into the
atmosphere. The air dryer 4 is than automatically purged (see Air Dryer).
• If operating pressure drops below a specific minimum value (regulator cut-in pressure setting), the
compressor 2 again supplies air to air tanks 11. Operating pressure is indicated by the indicator
pressure gauge 15.

• The automatic drain valves 12 regularly dumps condensation moisture from the air tanks. By
manually operating drain valves 12, all air pressure can be relieved from air tanks 11.

• The pressure reducing valves 13 lowers nominal operating air pressure to the amount needed for
hydraulic oil tank pressurization.

• Check valves 14 prevents hydraulic oil from entering the air pressure system.

• Safety valves 17 opens at 0,4 bar and prevents possible excessive hydraulic tank air pressures.

• The pneumatic pressure switch B38, installed in the hydraulic tank, detect if the pressure is to low.
A warning symbol appears on the display.

• With the shutoff valve 22, the hydraulic tank air pressure can be relieved.

• The tank pressure release valve 21 is used to depressurized the hydraulic tank quickly. This
operation can be made manually with the lever or automatically through the solenoid valve Y13
after a emergency shut down switch is activated.

4.2 Horn valves

Depressing the switch S5 (horn button) on Left Hand Side Joystick, installed in the cab, allows air
pressure to sound the signal horns 20.1 and 20.2 (through solenoid valves Y11.1 and Y11.2).

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Pneumatic System

5 Troubleshooting

5.1 Compressor 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
accordance with the following troubleshooting chart.

Problem: Air system pressure for PP1 or PP2 (indicated by the pressure gauges 15) does not reach
the specified value (see pressure chart).

Test Result Cause and corrective action

A. At pressure regulator 3, adjust After adjustment, operating
pressure to specifications pressure is correct
(indicated by the pressure
gauge 15)
Operating pressure still too low See B.
and can not be adjusted at
pressure regulator 3

B. Disconnect pressure line Compressor 2 delivers Compressor 2 is defective. Check

between compressor 2 and air insufficient amount or no compressor and compressor
dryer 4. Check if compressor 2 compressed air. unloading valve; replace if
delivers sufficient amount of necessary.
compressed air.
Compressor 2 delivers Pressure regulator 3 or air dryer 4
sufficient amount of is defective. Check pressure
compressed air. regulator and air dryer. Replace if
necessary.

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5.2 Hydraulic tank pressure
Problem: With proper air system operating pressure, hydraulic tank 16 air pressure is higher or lower
that the prescribed value.
Test
A. Check adjustment of upper
pressure reducing valve 13 (for
PP1); readjust if necessary,
PP2 must be stopped.
B. Check hydraulic tank 16, safety
valves 17, manual air vent
valve 22, fast evacuation valve
21, solenoid valve Y13, air
pressure lines and fittings
between pressure reducing
valves 13 and tank 16 for air
leaks.
Check adjustment of safety
valves 17.
C. Stop PP1 and check
adjustment of lower pressure
reducing valve 13 (for PP2);
readjust if necessary
R 996 Litronic
From
Result
Reduction from operating
pressure not sufficient (more
that prescribed value).
Hydraulic tank pressure to low.
After adjustment, hydraulic tank
pressure is correct
Hydraulic tank 16, safety valves
17, manual air vent valve 22,
fast evacuation valve 21,
solenoid valve Y13, or air
pressure lines and fittings are
leaking or safety valves 17 are
not properly adjusted.
The components are not
leaking and safety valves 17
are properly adjusted.
After adjustment, hydraulic tank
pressure is not correct (to high
or to low).
After adjustment, hydraulic tank
pressure is correct.
LIEBHERR
Pneumatic System
Cause and corrective action
Upper pressure reducing valve 13
defective. Check valve and
replace if necessary and see C.
See B.
See C.
Seal leaking components,
pressure lines and fittings or
replace safety valves and see C.
Upper pressure reducing valve 13
defective. Check valve and
replace if necessary and see C.
Lower pressure reducing valve 13
defective. Check valve and
replace if necessary.
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Service Manual INDEX CHAPTER
Pneumatic System

6 Adjustment instructions
Before attempting any adjustment to the air pressure system, make sure that the pressure regulator 3
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 working function.
Only LIEBHERR dealer service personnel are permitted to perform pressure adjustments during the
machine warranty period.

6.1 Adjustment of operating pressure.

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

6.1.1 Adjustment of the pressure regulator for PP1

• Start powerpack PP1 and bring it to high idle.

• Remove the protective cap and loosen the locknut 3b at pressure regulator 3 on PP1.
• Turn adjustment screw 3a until the needle of the left indicator pressure gauge 15 indicates the
specified operating pressure.
• Turn clockwise = reduce pressure
• Turn counterclockwise = increase pressure
• After adjustment, tighten locknut 3b and replace protective cap.

Fig. 10

6.1.2 Adjustment of the pressure regulator for PP2

• Start powerpack PP2 and bring it to high idle.

• Remove the protective cap and loosen the locknut 3b at pressure regulator 3 on PP2.
• Turn adjustment screw 3a until the needle of the right indicator pressure gauge 15 indicates the
specified pressure.
• Turn clockwise = reduce pressure
• Turn counterclockwise = increase pressure
• After adjustment, tighten locknut 3b and replace protective cap.

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Pneumatic System

6.2 Adjustment of hydraulic tank pressure (pressure reducing valves 13)

Loosen the locknut 13b on the pressure reducing valves 13.
Shut off both engines, open the manual air vent valve 22 to depressurize the hydraulic tank. Install a
pressure gauge (0 – 1bar) between one of the non return valve 14 and the hydraulic tank.

6.2.1 Adjustment of the upper pressure reducing valve 13 (for PP1)

• Close the manual air outleet valve 22 and start powerpack PP1
• If the pressure on pressure gauge is higher than the specified value, shut off the engine and open
the manual air outleet valve 22 to depressurize the hydraulic tank. Unscrew the adjustment screw
13a on the pressure reducing valve 13 which correspond to the powerpack PP1. Close the manual
air outlet valve 22 and start PP1, bring it to high idle. Turn adjustment screw 13a on the valve until
the needle of the pressure gauge indicates the specified pressure (procedure needs to be done in
small increments as hydraulic tank requires time to pressurize).

Fig. 11
• If the pressure on pressure gauge is lower than the specified value, turn adjustment screw 13a on
the pressure reducing valve 13 which correspond to the powerpack PP1 until the needle of the
pressure gauge indicates the specified value.
• Shut off PP1.

6.2.2 Adjustment of the lower pressure reducing valve 13 (for PP2)

• Open the manual air vent valve 22 to depressurize the hydraulic tank. Close the manual air outlet
valve 22 and start powerpack PP2.
• If the pressure on pressure gauge is higher than the specified value, shut off the engine and open
the manual air outlet valve 22 to depressurize the hydraulic tank. Unscrew the adjustment screw
13a on the lower pressure reducing valve 13 (which correspond to the powerpack PP2). Close the
manual air outlet valve 22 and start PP2, bring it to high idle. Turn adjustment screw 13a on the
valve until the needle of the pressure gauge indicates the specified pressure.
• If the pressure on pressure gauge is lower than the specified value, turn adjustment screw 13a on
the lower pressure reducing valve 13 until the needle of the pressure gauge indicates the specified
value.
After adjustment, tighten locknut 13b on the pressure reducing valves 13. Shut off both engines and
open the manual air outlet valve 22 to depressurize the hydraulic tank. Remove the pressure gauge
between the non return valve 14 and the hydraulic tank.

6.3 Adjustment of safety relief valves 17

The safety relief valve are factory adjusted and leaded. Readjustment is not allowed since the relief
valve has a safety function for the hydraulic tank. If you are in doubt, that one valve does not work
correctly, please replace it by a new one and check the setting of the old one on test bench.

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Service Manual INDEX CHAPTER
Pneumatic System

7 Component description

1.1 Pressure regulator

1.1.1 Application

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.

1.1.2 Function

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 pressure in the circuit to cut out level, each moving part is
positioned as indicated in the sectioned diagram.
1.1.2.1 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 stem. Further increase in pressure enables the exhaust
stem to push the disc valve off its seat, and compressed air from the circuit is allowed into chamber
"D". This air passes to the compressor, via the unloader port, and brings the unloader mechanism into
operation allowing the compressor to "run light" while the tanks are fully charged.
1.1.2.2 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.

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Pneumatic System

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

Fig. 1

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Pneumatic System

1.2 Air dryer

1.2.1 Application

The air cleaner cleans the air from moisture, dust and oil.

1.2.2 Function

1.2.2.1 Compression 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 droplets that
condense, drop to the bottom sump of the
container 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 dessiccant 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 without
necessity of further condensation.
As the air continues to pass through the drying
bed, it encounters dryer dessiccant, and its
moisture content is progressively reduced, 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 temperature can drop an
additional 22° C ( 40° F ) or more, before
condensation occurs.
1.2.2.2 Purge cycle
When the system reaches the governor cut out
pressure, air pressure from 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 through the dessiccant
bed is very efficient in removing desorbing water Fig. 12
on its reverse flow through the dessiccant bed.

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Pneumatic System

1.3 Check valve

1.3.1 Application

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

1.3.2 Function

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 retourning to the inlet port "A".

1.3.3 Maintenance

This valve requires no regular maintenance.

Fig. 13

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Pneumatic System

1.4 Safety relief valve

1.4.1 Application

Safety limits the maximum pressure in a pneumatic circuit to a specific value.

1.4.2 Maintenance

The pressure setting is factory adjusted.

Readjustment is not allowed since the relief valve has a safety function for the hydraulic tank.

3 Control lever
7 Sleeve
8 Adjustment screw
11 Spring retainer
12 Rod
13 Spring
14 Housing
16 Spool
17 Housing
18 Sealing washer
20 Nameplate

Fig. 14

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Pneumatic System

1.5 Automatic drain valve

1.5.1 Application

This valve is used to automatically drain condense water from the air tanks. This valve eliminates
having to drain the air tank by hand and prevents condense water from entering the pneumatic
system.

1.5.2 Function

Air flows from tank via filter 1 into space "A" and diaphragm 3 which lifts off its seat 2. Air pressure
flows with the water collected in the tank into space "B". The water is collecting in the upper part of the
outlet port 4.
After the pressure is equalized between the two spaces, diaphragm 3 will close inlet 2.
If the pressure drops in the air tank, the pressure in space "A" is lower, while in space "B", the full
pressure is existing.
The higher pressure in space "B" pushes the diaphragm 3 upward and lifts it from outlet 4.
To check for proper function, the valve can also be operated manually, by pushing the pin 5 in, and
open the valve.

1.5.3 Maintenance

Under normal conditions, the valve should be removed from the air tank and both tank and valve
should be cleaned every three to four months.

Fig. 15

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Pneumatic System

1.6 Pressure reducing valve

1.6.1 Application

To provide an adjustable - constant outlet pressure, which is lower than the variable supply pressure,
this normally open valve fluctuates or closes to maintain a constant pressure on the outlet side.

1.6.2 Function

Air flows via connection "P" and the open valve seat 1 to connection "A" and at the same time to the
spring loaded membrane 3.
As soon as the adjusted pressure setting is reached the membrane 3 pushes against spring pressure
4 the valve seat 1 closes and the connection between "A" and "P" is closed. Loos of air pressure at
connection "A" is replenished via connection "P" until the air pressure and spring pressure are
balanced once again.
The pressure setting can be adjusted with screw 5. If the pressure at connection "A" increases above
the pressure setting, the excess pressure is vented to atmosphere. The excess pressure acts on the
membrane 3 and spring pressure 4. As the spring 4 is compressed, the valve seat 1 is lifted from the
plunger 2 and the excess pressure is vented, via the spring, to atmosphere.

1.6.3 Maintenance

Check pressure setting periodically - See instruction schedule.

Fig. 16

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From Date: 11 / 2001