Liebherr PR764 Crawler Dozer Service Repair Manual.pdf

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                                                          

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              

Service Manual Table of contents

Section

Pages from to

Title

Date of issue

0.1. 0.1.00 00

1

8

In Inde dex x

02.2 02.201 010 0

1.0.00 1.0.00

1

2

Sub group group index index "Genera "Generall Informat Information" ion"

03.2007 03.2007

1.1.00 1.1.0 0

1

2

Foreword Foreword and explanatio explanations ns

03.2007 03.2 007

1.2.00 1.2 .00

1

14

Safety Saf ety guide guidelin lines es

01.20 01.2007 07

1.3.01 1.3 .01

1

10

Servic Service e items items

03.20 03.2006 06

1.3.02 1.3 .02

1

2

Servi Service ce items items

01.20 01.2009 09

1.4.01 1.4 .01

1

4

Tighte Tightenin ning g torqu torques es

05.20 05.2008 08

1.4.03 1.4 .03

1

2

Conver Conversio sion n cha chart rt

01.200 01. 2009 9

1.4.04 1.4 .04

1

2

Tapp Tapping ing holes holes

01.20 01.2004 04

1.5.00 1.5 .00

1

6

Storag Sto rage e guide guidelin lines es

02.20 02.2010 10

1.6.00 1.6 .00

1

2

Weigh We ights ts of Ma Mater terial ial

03.20 03.2009 09

2.0.00 2.0.00

1

2

Sub group group index index "Special "Special Tools, Tools, Applicat Application ion Guideline Guidelines" s"

02.2008 02.2008

2.1.00 2.1 .00

1

20

Specia Spe ciall too tools ls

01.20 01.2010 10

2.2.00 2.2 .00

1

6

Repair Repair weldi welding ng

02.20 02.2007 07

2.3.00 2.3.0 0

1

6

Installati Insta llation on instructio instructions ns – slip ring sea seals ls

02.2010 02.2 010

3.0.00

1

2

Sub group index "Technical data - maintenance maintenance guidelines" guidelines"

03.2007

3.1.20 3.1 .20

1

2

Techn Technica icall data data

03.20 03.2006 06

3.1.21 3.1 .21

1

2


01.20 01.2007 07

3.1.22 3.1 .22

1

4


03.20 03.2009 09

3.1.23 3.1 .23

1

4


03.20 03.2009 09

3.1.30 3.1 .30

1

2


03.20 03.2006 06

3.1.31 3.1 .31

1

4


01.20 01.2009 09

3.1.40 3.1 .40

1

2


01.20 01.2008 08

3.1.50 3.1 .50

1

2


02.20 02.2008 08

3.1.60 3.1 .60

1

2


01.20 01.2009 09

3.1.61 3.1 .61

1

2


02.20 02.2009 09

3.2.20 3.2.2 0

1

2

Maintena Main tenance nce and inspecti inspection on schedule schedule

01.2009 01.2 009

3.2.21 3.2.2 1

1

4


02.2010 02.2 010

3.2.60 3.2.6 0

1

4


02.2010 02.2 010

3.3.20 3.3.2 0

1

8

Maintena Main tenance nce and inspectio inspection n gui guideli delines nes

03.2007 03.2 007

3.3.21 3.3.2 1

1

10

Maintena Main tenance nce and inspectio inspection n guid guidelin elines es

01.2010 01.2 010

3.4.00 3.4.0 0

1

6

Quick Quick referenc reference e for mach machine ine adju adjustmen stmentt

02.2009 02.2 009

3.5.20 3.5 .20

1

4

Adjus Adjustme tment nt che check ck list list

01.20 01.2009 09

3.5.21 3.5 .21

1

6


01.20 01.2009 09

3.5.30 3.5 .30

1

6


01.20 01.2009 09

3.5.40 3.5 .40

1

6


01.20 01.2009 09

3.5.50 3.5 .50

1

6


01.20 01.2009 09

3.5.60 3.5 .60

1

6


01.20 01.2009 09

3.5.61 3.5 .61

1

6


01.20 01.2009 09


4.0.00 4.0.00

1

2

Sub group group index index "Engine" "Engine"

03.2007 03.2007

4. 4.1. 1.00 00

1

6

Data Data page page

03.2 03.200 007 7

4.2.00 4.2.0 0

1

4

Fan and cylinder cylinder conf configu iguratio ration n

03.2007 03.2 007

4.3.00 4.3.0 0

1

10

Installati Insta llation on kit Lieb Liebherr herr – Diesel Diesel particle particle filter filter

01.2009 01.2 009

4.4.00 4.4.0 0

1

4

Installati Insta llation on and check check list for Diesel Diesel particle particle filter filter

05.2008 05.2 008

5.0.00 5.0.00

1

2

Sub group group index index "Couplin "Coupling g and splitterb splitterbox" ox"

03.2007 03.2007

5. 5.1. 1.00 00

1

2

Data Data page page

02.2 02.200 009 9

5. 5.2. 2.20 20

1

2

Coup Coupli ling ng

01.2 01.200 006 6

5. 5.2. 2.40 40

1

2

Coup Coupli ling ng

02.2 02.200 006 6

5.3.20 5.3 .20

1

4

Split Splitter terbo box x

01.20 01.2007 07

5.3.30 5.3 .30

1

4


01.20 01.2006 06

5.3.40 5.3 .40

1

4


02.20 02.2006 06

5.4.00 5.4 .00

1

4

Coupli Coupling ngs s pump pump outpu outputt

04.20 04.2008 08

6.0.00 6.0.00

1

2

Sub group group index index "Travel "Travel hydrauli hydraulic" c"

03.2007 03.2007

6. 6.1. 1.20 20

1

2

Data Data page page

01.2 01.200 009 9

6. 6.1. 1.30 30

1

2

Data Data page page

01.2 01.200 009 9

6. 6.1. 1.40 40

1

2

Data Data page page

01.2 01.200 008 8

6.2.20 6.2 .20

1

6

Descri Descripti ption on

01.20 01.2006 06

6.2.21 6.2 .21

1

6

Descri Descripti ption on

04.20 04.2008 08

6.2.22 6.2 .22

1

6

Descr Descript iption ion

04.20 04.2008 08

6.2.30 6.2 .30

1

6


04.20 04.2008 08

6.2.40 6.2 .40

1

8


01.20 01.2009 09

6.2.50 6.2 .50

1

8


04.20 04.2008 08

6.2.60 6.2 .60

1

8


01.20 01.2009 09

6.2.61 6.2 .61

1

8


01.20 01.2009 09

6. 6.3. 3.20 20

1

8

Func Functi tion on

01.2 01.200 008 8

6. 6.3. 3.21 21

1

8

Func Functi tion on

01.2 01.200 009 9

6. 6.3. 3.22 22

1

8

Func Functi tion on

01.2 01.200 009 9

6. 6.3. 3.30 30

1

8

Func Functi tion on

01.2 01.200 008 8

6. 6.3. 3.31 31

1

8

Func Functi tion on

01.2 01.200 008 8

6. 6.3. 3.32 32

1

8

Func Functi tion on

01.2 01.200 009 9

6.3.40 6.3 .40

1

10

Functi Function on

01.20 01.2009 09

6.3.50 6.3 .50

1

10

Functi Function on

01.20 01.2009 09

6.3.60

1

10

Function

01.2009

6.4.20 6.4 .20

1

12

Test Test and and adjus adjustme tment nt

05.20 05.2008 08

6.4.21 6.4 .21

1

18


01.20 01.2009 09

6.4.60 6.4 .60

1

18


05.20 05.2008 08

6.5.20 6.5 .20

1

2

Compo Compone nent nt locati location on

01.20 01.2006 06

6.5.21 6.5 .21

1

2


01.20 01.2007 07

6.5.22 6.5 .22

1

2


01.20 01.2007 07

6.5.30 6.5 .30

1

2


03.20 03.2008 08


6.5.40 6.5 .40

1

2


02.20 02.2006 06

6.5.50 6.5 .50

1

2


02.20 02.2006 06

6.5.60 6.5 .60

1

2


01.20 01.2009 09

6.5.61 6.5 .61

1

2


01.20 01.2009 09

7.0.00 7.0.00

1

2

Sub group group index index "Working "Working hydraul hydraulic" ic"

03.2007 03.2007

7.1. 7.1.20 20

1

2

Data Data page page

03.2 03.200 009 9

7.1. 7.1.30 30

1

2

Data Data page page

03.2 03.200 009 9

7.1. 7.1.40 40

1

2

Data Data page page

03.2 03.200 009 9

7.2.20 7.2 .20

1

4


01.20 01.2007 07

7.2.21 7.2 .21

1

4


03.20 03.2009 09

7.2.30 7.2 .30

1

4


02.20 02.2008 08

7.2.40 7.2 .40

1

4


02.20 02.2008 08

7.2.50 7.2 .50

1

4


02.20 02.2008 08

7.2.60 7.2 .60

1

4


03.20 03.2006 06

7.2.61 7.2 .61

1

4


03.20 03.2007 07

7.3. 7.3.20 20

1

10

Func Functi tion on

01.2 01.200 008 8

7.3. 7.3.21 21

1

10

Func Functi tion on

01.2 01.200 008 8

7.3. 7.3.22 22

1

10

Func Functi tion on

01.2 01.200 008 8

7.3. 7.3.30 30

1

10

Func Functi tion on

01.2 01.200 008 8

7.3. 7.3.31 31

1

10

Func Functi tion on

01.2 01.200 008 8

7.3. 7.3.40 40

1

12

Func Functi tion on

01.2 01.200 008 8

7.3. 7.3.50 50

1

10

Func Functi tion on

01.2 01.200 008 8

7.3. 7.3.60 60

1

10

Func Functi tion on

01.2 01.200 008 8

7.3. 7.3.61 61

1

10

Func Functi tion on

01.2 01.200 009 9

7.4.20 7.4 .20

1

8


05.20 05.2008 08

7.4.30 7.4 .30

1

8


05.20 05.2008 08

7.4.40 7.4 .40

1

10


05.20 05.2008 08

7.5.20 7.5 .20

1

2


01.20 01.2006 06

7.5.21 7.5 .21

1

2


01.20 01.2007 07

7.5.22 7.5 .22

1

2


03.20 03.2009 09

7.5.23 7.5 .23

1

2


03.20 03.2009 09

7.5.30 7.5 .30

1

2


01.20 01.2006 06

7.5.40 7.5 .40

1

2


02.20 02.2006 06

7.5.50

1

2

Component location

02.2006

7.5.60

1

2


03.20 03.2006 06

7.5.61 7.5 .61

1

2


03.20 03.2006 06

8.0.00 8.0.00

1

2

Sub group group index index "Hydraulic "Hydraulic componen components" ts"

03.2007 03.2007

8.1.20 8.1 .20

1

8

Varia Variabl ble e pum pump p

03.20 03.2006 06

8.1.40 8.1 .40

1

6

Varia Variabl ble e pum pump p

01.20 01.2009 09

8.2.20 8.2 .20

1

4

Varia Variabl ble e mo motor tor

01.20 01.2005 05

8.2.21 8.2 .21

1

6


02.20 02.2008 08

8.2.22 8.2 .22

1

6


02.20 02.2008 08

8.2.30 8.2 .30

1

4


01.20 01.2006 06


8.2.31 8.2 .31

1

6


03.20 03.2009 09

8.2.40 8.2 .40

1

6


03.20 03.2007 07

8.2.50 8.2 .50

1

6


02.20 02.2008 08

8.2.51 8.2 .51

1

6


02.20 02.2008 08

8.3.20 8.3 .20

1

8

Regula Regulatin ting g pump pump

03.20 03.2009 09

8.3.21 8.3 .21

1

6


03.20 03.2009 09

8.3.30 8.3 .30

1

6


03.20 03.2006 06

8.3.31 8.3 .31

1

10


02.20 02.2009 09

8.3.60 8.3 .60

1

6


03.20 03.2006 06

8.4.20 8.4. 20

1

4

Double Double gear pum pump– p– fan drive drive

03.2006 03.2 006

8.4.25 8.4 .25

1

4

Gear Ge ar mo motor tor – fan drive drive

03.20 03.2008 08

8.4.26 8.4 .26

1

4

Gear Ge ar mo motor tor – fan drive drive

03.20 03.2008 08

8.4.40 8.4. 40

1

4

Double Double gear pump – Replenish Replenishing ing

02.2006 02.2 006

8.4.45 8.4. 45

1

4

Axial Axial piston piston fixed displace displacemen mentt moto motorr – fan drive

02.2006 02.2 006

8.4.50 8.4. 50

1

4

Double Double gear pump – Replenish Replenishing ing

02.2006 02.2 006

8.4.55 8.4. 55

1

4

Gearr moto Gea motorr – fan drive exte external rnal oil cooler cooler

02.2006 02.2 006

8.5.20 8.5 .20

1

8

Pilot Pilot con contro troll valve valve

01.20 01.2008 08

8.5.21 8.5 .21

1

8

Pilot Pilot con contro troll valve valve

01.20 01.2008 08

8.6.20 8.6 .20

1

6

Contro Controll valve valve blo block ck

02.20 02.2006 06

8.6.21 8.6 .21

1

6


01.20 01.2007 07

8.6.22 8.6 .22

1

6


01.20 01.2007 07

8.6.40 8.6 .40

1

6


03.20 03.2006 06

8.6.41 8.6 .41

1

6


03.20 03.2006 06

8. 8.7. 7.00 00

1

12

Valv Valves es

02.2 02.200 009 9

8.8.00 8.8 .00

1

12

Hydrau Hydraulic lic cylind cylinder er

01.20 01.2010 10

9.0.00 9.0.00

1

2

Sub group group index index "Electri "Electrical cal system system – Plans Plans and componen components" ts"

03.2007 03.2007

9.1.20 9.1. 20

1

6

Code Code lett letter er explana explanation tions s

02.2010 02.2 010

9.1.30 9.1. 30

1

8


02.2010 02.2 010

9.1.60 9.1. 60

1

6


02.2009 02.2 009

9.2.20 9.2 .20

1

2

Funct Function ion list list

02.20 02.2007 07

9.2.30 9.2 .30

1

2


02.20 02.2007 07

9.2.40 9.2 .40

1

2


03.20 03.2008 08

9.2.60 9.2 .60

1

2


02.20 02.2009 09

9.3.20 9.3. 20

1

2

Fuses, Fuses, cross poin points, ts, note notes s

02.2007 02.2 007

9.3.30 9.3.3 0

1

2

Fuses, Fuses, cross poi points, nts, note notes s

03.2007 03.2 007

9.3.40 9.3.4 0

1

2


03.2008 03.2 008

9.3.60 9.3.6 0

1

2


02.2007 02.2 007

9.4.20 9.4 .20

1

16

Curren Currentt flow flow dia diagra gram m

02.20 02.2007 07

9.4.20

1/02

Current flow diagram Addendum

02.2007

9.4.20

2/02


02.2007

9.4.20

3/02


02.2007

9.4.20

15/02


02.2007

9.4.21 9.4 .21

1

62


03.20 03.2008 08

9.4.22 9.4 .22

1

76


03.20 03.2009 09


9.4.23 9.4 .23

1

76

Curre Current nt flow flow dia diagra gram m

03.200 03. 2009 9

9.4.30 9.4 .30

1

22


02.200 02. 2007 7

9.4.31 9.4 .31

1

62


03.200 03. 2008 8

9.4.40 9.4 .40

1

18


03.200 03. 2008 8

9.4.50 9.4 .50

1

80


02.201 02. 2010 0

9.4.51 9.4 .51

1

80


02.201 02. 2010 0

9.4.60 9.4 .60

1

18


03.200 03. 2006 6

9.4.61 9.4 .61

1

80


02.200 02. 2009 9

9.5.20 9.5 .20

1

2

Instru Ins trume ment nt pane panell

01.20 01. 2007 07

9.5.21 9.5 .21

1

2

Instru Ins trume ment nt pane panell

03.20 03. 2007 07

9.6.20 9.6.2 0

1

16

Componen Componentt arrangem arrangement ent

05.2008 05.2 008

9.6.21 9.6.2 1

1

16


05.2008 05.2 008

9.6.22 9.6.2 2

1

18


02.2010 02.2 010

9.6.30 9.6.3 0

1

18


02.2010 02.2 010

9.6.40 9.6.4 0

1

14


02.2010 02.2 010

9.6.41 9.6.4 1

1

16


02.2010 02.2 010

9.6.50 9.6.5 0

1

14


02.2010 02.2 010

9.6.60 9.6.6 0

1

16


05.2008 05.2 008

9.6.61 9.6.6 1

1

18


02.2010 02.2 010

9.7.00 9.7 .00

1

4

Travel Travel joysti joystick ck

02.20 02.2010 10

9.7.25 9.7 .25

1

4

Inchin Inc hing g - brake brake ped pedal al

03.20 03.2007 07

9.7.26 9.7 .26

1

4

Inchin Inc hing g - brake brake ped pedal al

04.20 04.2008 08

10.0.00 10.0.00

1

2

Sub group group index index "Electric "Electrical al system system descript descriptions ions" "

01.2008 01.2008

10.1.00 10.1 .00

1

70

Applicati Application on Software Software – travel travel drive

01.2010 01.2 010

10.2.00 10.2 .00

1

20

Software Software PDL – Diesel Diesel particle particle filter filter

01.2010 01.2 010

11.0.00 11.0.00

1

2

Sub group group index index "Final "Final drive" drive"

03.2007 03.2007

11.1. 11.1.20 20

1

2

Data Data page page

01.20 01.2010 10

11.1. 11.1.30 30

1

2

Data Data page page

01.20 01.2007 07

11.1. 11.1.40 40

1

2

Data Data page page

02.20 02.2008 08

11.1. 11.1.50 50

1

2

Data Data page page

01.20 01.2008 08

11.2. 11.2.20 20

1

4

Desig Design n and and fun functi ction on

03.20 03.2006 06

11.2. 11.2.21 21

1

4


01.20 01.2007 07

11.2. 11.2.22 22

1

6


02.20 02.2008 08

11.2. 11.2.40 40

1

4


03.200 03. 2007 7

11.2. 11.2.41 41

1

4


03.200 03. 2007 7

11.2. 11.2.50 50

1

4


04.200 04. 2008 8

11.2. 11.2.51 51

1

4


05.200 05. 2008 8

11.2. 11.2.60 60

1

6


03.200 03. 2006 6

11.2. 11.2.61 61

1

6


02.200 02. 2008 8

11.3. 11.3.20 20

1

4

Secti Sectiona onall view view

01.20 01.2006 06

11.3. 11.3.21 21

1

4


03.20 03.2007 07

11.3. 11.3.40 40

1

4


01.20 01.2009 09

11.3. 11.3.41 41

1

4


01.20 01.2009 09


11.3. 11.3.42 42

1

4


01.20 01.2009 09

11.3. 11.3.50 50

1

4


01.20 01.2009 09

11.3. 11.3.51 51

1

4


01.20 01.2009 09

11.3. 11.3.60 60

1

4


01.20 01.2009 09

11.3. 11.3.61 61

1

4


01.20 01.2009 09

12.0.00 12.0.00

1

2

Sub group group index index "Track "Track componen components" ts"

03.2007 03.2007

12.1. 12.1.00 00

1

2

Data Data page page

02.20 02.2010 10

12.2.00 12.2 .00

1

26

Descriptio Description, n, func function, tion, wear and evaluatio evaluation n

03.2008 03.2 008

12.3. 12.3.00 00

1

4

Inspe Ins pecti ction on che checkl cklist ist

01.201 01. 2010 0

12.3. 12.3.01 01

1

6

Wear We ar cha chart rt

01.20 01.2009 09

12.4.20 12.4 .20

1

8

Track Track roller roller frame and idler idler unit

03.2009 03.2 009

12.4.50 12.4 .50

1

8

Track Track roller roller frame and idler idler unit

02.2010 02.2 010

12.5. 12.5.00 00

1

2

Track Track roller roller

01.20 01.2006 06

12.6. 12.6.00 00

1

2

Carrie Carrierr roller roller

02.20 02.2007 07

12.8. 12.8.50 50

1

6

Tensi Tension on uni unitt

02.200 02. 2007 7

12.8. 12.8.60 60

1

6

Tensi Tension on uni unitt

03.200 03. 2007 7

13.0.00

1

2

Sub group index "Working Attachments - front"

03.2007

13.1. 13.1.00 00

1

6

Straig Straight ht bla blade de

02.20 02.2007 07

13.2. 13.2.20 20

1

6

6 way bla blade de

01.20 01.2008 08

13.4.40 13.4 .40

1

6

Hydraulic Hydraulic cutting cutting angl angle e adju adjustmen stmentt

01.2008 01.2 008

13.4.50 13.4 .50

1

8


02.2008 02.2 008

13.4.60 13.4 .60

1

6


01.2008 01.2 008

14.0.00 14.0.00

1

2

Sub group group index index "Attachme "Attachments nts - rear" rear"

03.2007 03.2007

14.1 14.1.2 .20 0

1

4

Ripp Ripper er

01.2 01.200 006 6

14.1 14.1.2 .21 1

1

8

Ripp Ripper er

02.2 02.200 007 7

14.1 14.1.4 .40 0

1

14

Ripp Ripper er

01.2 01.200 008 8

14.1 14.1.6 .60 0

1

12

Ripp Ripper er

01.2 01.200 008 8

15.0.00 15.0.00

1

2

Sub group group index index "Main "Main frame frame compone components nts" "

03.2007 03.2007

15.1. 15.1.20 20

1

2

Coole Coolerr arran arrange geme ment nt

01.200 01. 2006 6

15.1. 15.1.21 21

1

2


01.200 01. 2007 7

15.1. 15.1.22 22

1

2


01.200 01. 2007 7

15.1. 15.1.30 30

1

2


03.200 03. 2008 8

15.1. 15.1.40 40

1

2


02.200 02. 2006 6

15.1. 15.1.50 50

1

2


03.200 03. 2006 6

15.1. 15.1.60 60

1

2


01.200 01. 2009 9

15.1. 15.1.61 61

1

2


01.200 01. 2009 9

15.2.00 15.2 .00

1

2

Hoist Hoist cylinder cylinder suspensi suspension on

02.2006 02.2 006

15.3. 15.3.20 20

1

2

Equal Equalize izerr bar bar

01.20 01.2006 06

15.3. 15.3.40 40

1

2


01.20 01.2006 06

15.3. 15.3.50 50

1

2


02.20 02.2006 06

15.3. 15.3.60 60

1

2


01.20 01.2010 10

15.4. 15.4.20 20

1

2

Engin Engine e mo mount unt

01.20 01.2007 07


15.4. 15.4.21 21

1

2

Engin Engine e mou mount nt

01.20 01.2007 07

15.4. 15.4.30 30

1

2


01.20 01.2006 06

15.4. 15.4.40 40

1

2


02.20 02.2006 06

15.4. 15.4.60 60

1

2


02.20 02.2010 10

16.0.00 16.0.00

1

2

Sub group group index index "Tank "Tank arrangem arrangement" ent"

03.2007 03.2007

16.1. 16.1.20 20

1

4

Hydrau Hydraulic lic tan tank k

05.20 05.2008 08

16.1. 16.1.21 21

1

4


05.20 05.2008 08

16.1. 16.1.30 30

1

4


05.20 05.2008 08

16.1. 16.1.40 40

1

4


05.20 05.2008 08

16.1. 16.1.50 50

1

4


05.20 05.2008 08

16.1. 16.1.60 60

1

4


05.20 05.2008 08

16.2. 16.2.20 20

1

2

Fuel Fuel tan tank k

01.20 01.2007 07

16.2. 16.2.30 30

1

2


01.20 01.2007 07

16.2. 16.2.40 40

1

2


02.20 02.2006 06

16.2. 16.2.50 50

1

2


03.20 03.2006 06

16.2. 16.2.60 60

1

2


03.20 03.2007 07

16.2. 16.2.61 61

1

2


03.20 03.2007 07

16.3. 16.3.20 20

1

2

Batte Battery ry box

01.20 01.2007 07

16.3. 16.3.21 21

1

2


03.20 03.2008 08

16.3. 16.3.22 22

1

2


03.20 03.2008 08

16.3. 16.3.30 30

1

2


03.20 03.2008 08

16.3. 16.3.31 31

1

2


03.20 03.2008 08

16.3. 16.3.40 40

1

2


01.20 01.2006 06

16.3. 16.3.50 50

1

2


02.20 02.2006 06

16.3. 16.3.60 60

1

2


03.20 03.2007 07

16.3. 16.3.61 61

1

2


03.20 03.2007 07

17.0.00

1

2

Sub group index "Operator’s "Operator’s platform, heater, air conditioner" conditioner"

03.2007

17.1. 17.1.00 00

1

6

Opera Op erator tor’s ’s pla platfo tform rm

01.20 01.2008 08

17.2. 17.2.00 00

1

4

Heater Heater and and blowe blowerr

01.20 01. 2007 07

17.3.00 17.3 .00

1

10

Air cond condition itioning ing system system

01.2009 01.2 009

17.4.00 17.4 .00

1

2

Operator Ope rator’s ’s seat – air cushion cushioned ed

03.2006 03.2 006

17.5. 17.5.20 20

1

4

Throt Throttle tle con contro troll

01.200 01. 2007 7

17.5. 17.5.21 21

1

2

Throt Throttle tle con contro troll

01.200 01. 2007 7

18.0.00

1

2

Sub group index "Special equipment"

01.2009

18.2. 18.2.00 00

1

4

Refue Refuelin ling g pump pump

02.20 02.2007 07

18.3. 18.3.20 20

1

4

Revers Reversibl ible e fan

02.20 02.2008 08

18.3. 18.3.21 21

1

4


02.20 02.2008 08

18.3. 18.3.30 30

1

4


02.20 02.2008 08

18.3. 18.3.31 31

1

4


02.20 02.2008 08

18.3. 18.3.32 32

1

4


02.20 02.2008 08

18.3. 18.3.40 40

1

4


02.20 02.2008 08

18.3. 18.3.50 50

1

4


02.20 02.2008 08


18.3. 18.3.60 60

1

4


02.20 02.2008 08

18.3. 18.3.61 61

1

4


02.20 02.2008 08

18.4. 18.4.20 20

1

12

Cable Cable winch winch

01.200 01. 2009 9

19.0.00 19.0.00

1

2

Sub group group index index "Addition "Additional al document documentatio ation" n"

03.2008 03.2008

6.3.20 6.3.2 0

1

1

Schematic Schematic Travel Travel hydrauli hydraulic c

01.2008 01.2 008

6.3.21 6.3.2 1

1

1


01.2009 01.2 009

6.3.22 6.3. 22

1

1


01.2009 01.2 009

6.3.30 6.3. 30

1

1

Schemati Schematic c Travel Travel hydraulic hydraulic

03.2006 03.2 006

6.3.31 6.3. 31

1

1


03.2006 03.2 006

6.3.32 6.3. 32

1

1


01.2009 01.2 009

6.3.40 6.3. 40

1

2


01.2009 01.2 009

6.3.50 6.3. 50

1

2


01.2009 01.2 009

6.3.60 6.3. 60

1

3


01.2009 01.2 009

7.3.20 7.3. 20

1

1

Schemati Schematic c Working Working hydrauli hydraulic c

03.2006 03.2 006

7.3.21 7.3. 21

1

1


01.2007 01.2 007

7.3.22 7.3. 22

1

1


01.2008 01.2 008

7.3.30 7.3. 30

1

1


03.2006 03.2 006

7.3.31 7.3. 31

1

1


01.2008 01.2 008

7.3.40 7.3. 40

1

2


01.2008 01.2 008

7.3.50 7.3. 50

1

1


01.2008 01.2 008

7.3.60 7.3. 60

1

1


03.2006 03.2 006

7.3.61 7.3. 61

1

1


01.2008 01.2 008

9.4.20 9.4 .20

1

16


02.20 02.2007 07

9.4.21 9.4 .21

1

61


03.20 03.2008 08

9.4.22 9.4 .22

1

76


03.20 03.2009 09

9.4.23 9.4 .23

1

76


03.20 03.2009 09

9.4.30 9.4 .30

1

21


02.20 02.2007 07

9.4.31 9.4 .31

1

61


03.20 03.2008 08

9.4.40 9.4 .40

1

18


03.20 03.2008 08

9.4.50 9.4 .50

1

80


02.20 02.2010 10

9.4.51 9.4 .51

1

80


02.20 02.2010 10

9.4.60 9.4 .60

1

17


03.20 03.2006 06

9.4.61 9.4 .61

1

80


02.20 02.2009 09

Service-Manual

General Information Sub Group Index

Sub Group Index - General Information Foreword and explanation

1.1

Safety guidelines

1.2

Service Items

1.3

Table - charts

1.4

Tightening torques

1.4.01

Conversion table

1.4.03

Hole diameter before tapping

1.4.04

Storage (preservation) guidelines

1.5

Weight of materials

1.6

Service-Manual

General Information Foreword and explanation

For your information This manual contains technical data, descriptions of design and function, repair and adjustment guidelines as well as numerous drawings, functional views and illustrations LIEBHERR - crawler dozers (PR) serial 4.

This manual should simplify competent competent customer service of our products, does however, not replace expert and qualified training and an attendance of our factory schools. Information which is in trade considered basic knowledge is not included. Operation and spare parts information can be found in separate manuals. The manual will be updated as necessary when changes occur in series. This symbol is used in the manual for very important notes.

Note! This sign marks special important notes in the manual.

During the activities on the machine, accident prevention regulations and safety guidelines must be strictly observed. This manual is intended for the exclusive use of the registered owner and may not be reproduced complete or in part or passed on a third person without written permission. This manual is still on property of LIEBHERR-Werk Telfs GmbH . All rights reserved - Printed in Austria. Austria. We reserve the right to make changes of technical details on the machine in comparison to the information and drawings in this manual. Printed and published by LIEBHERR-Werk Telfs GmbH., Technical Documentation Documentation Department.

Explanation of structure (page numbers) In order to find specific information and add supplements more easily, the following numbering system is being used:

main group

sub group

model group

page no.

6.3.10 - 01/02 main group according to manual index

sub group of main group according to sub group index

division based on information content or machine model group

continuous running number and complete number of pages within the model group

Sometimes there is a number behind the page number, e.g. 9.4.20 - 13/15 - 02. This number stands for supplements, especially at current flow diagrams, when only one page is supplemented to the schematic. Updated pages retain the same page number, but receive a more recent date when mailed. Supplements have a new number. If the page is only valid for a certain machine model group, it will so be indicated on the page.

General Information

Service-Manual

Foreword and explanation

This note shows that the detail view of an illustration is turned by the stated angle, as compared to the actual installation position. (in this case 180°)

We hope that with the enclosed information we have taken yet another step to improve the service on the LIEBHERR - crawler dozers, crawler loaders pipe layers and telescopic handlers. handlers.

LIEBHERR-Werk Telfs GmbH. Technical Documentation Dept.

Service-Manual

General Information Safety guidelines

A. Prior and during the performance of tests, adjustments, and repairs, the following guidelines must be followed: Any type of work work may only be performed by qualified personnel or under the supervision of such personnel. Qualified personnel personnel are persons who - based on specialized training and experience - have sufficient knowledge knowledge in the general area of earthmoving equipment equipment and the specific technology of LIEBHERR machines. They must also have knowledge of all applicable laws and general work protection regulations, accident prevention regulations, guidelines and generally approved rules concerning technology, and be able to evaluate if earthmoving equipment equipment is safe to operate and if the necessary work can performed without endangering themselves or third persons. Never operate a machine with a raised cab or canopy! The machine may only be operated with a lowered and secured cab or canopy. Always adhere adhere to the LIEBHERR LIEBHERR adjustment adjustment values when performing performing adjustment adjustment work. When performing a Delivery Inspection on a machine, the operator(s) must be trained using a current Operation Manual. The safety guidelines in that manual must be particularly observed and followed as listed. The same safety guidelines must also be observed when performing repair work. On the other hand, there are instances of specific repair and/or maintenance which, in the judgment of qualified personnel, require steps and procedures other than as specified in the safety guidelines. guidelines. in such event, qualified personnel or individuals performing said work under the supervision of such personnel, should assure that additional safety precautions precautions necessary to insure the safety of those involved in the repair are taken. Such items of repair and/or maintenance include, but are not limited to, the following :

- It may be necessary to open the side engine compartment doors while the engine is running for diagnostic and/or component adjustment reasons. In such event, care should be taken to assure that the engine compartment compartment doors are fully secured from unexpected and/or unintended unintended closing during the diagnostic and/or adjustment work effort. Care should also be exercised to assure that there will be no inadvertent i nadvertent or unintended unintended contact of any part of the body with any moving and/or heated parts of the engine. Along these lines, loose clothing, scarves, open jackets, ties and jewelry should be be avoided. avoided.

- It may be necessary necessary for purposes purposes of performing performing repairs, adjustments adjustments and/or and/or troubleshooting to start the engine of the machine and to actuate the travel drive with the cab or canopy tilted. Such should never be done unless the machine has been raised completely off the ground and supported properly and according to all applicable guidelines. However, this procedure can only be performed by a factory certified service mechanic. Following please find the Safety Guidelines as listed in the present Operation Manual. Liebherr Liebherr reserves the right to update any Operation Manual, including but not limited to the revision or addition of safety guidelines. It Operation Manual Manual of the machine involved. is, therefore, strongly recommended to also consult the latest Operation

General Information

Service-Manual

Safety guidelines

B. General General safety information (Abstract of the Operation Manual Issue 10/2003) Working with earth moving machinery can be dangerous, dangerous, it could result in injury or death if proper precautions precautions are not taken by you, the operator and/or maintenance personnel. We urge you to read these safety notes repeatedly and carefully, and to observe them to prevent danger and accidents. This is especially important for any personnel that works on the machine only occasionally, such as during set up and / or maintenance. Careful adherence to the below listed safety information will insure safe operation and maintenance and potentially prevent personal injury to yourself and others and possible damage to your machine. CAUTION, WARNING WARNING or NOTE. Important safety notes are used throughout this manual, such as DANGER , CAUTION,

In this Operation Manual, these safety notes are defined as follows: DANGER Denotes and extreme intrinsic hazard, which could result in a high probability of death or serious injury if proper precautions are not taken. CAUTION Denotes a reminder of safety practices or directs attention to unsafe practices if proper precaution are not taken, which could result in personal injury and / or damage or destruction of the machine. NOTE This symbol is used to describe operational or maintenance procedures which should be followed to keep our machine operational and to insure long service life and /or to facilitate certain operating procedures. Danger! Warns that certain working procedures could result in death or serious injury if proper precautions are not taken. Warning! Warns that certain working procedures could result in serious injury if certain precautions are not taken. Caution! Warns that certain working procedures could result in personal injury or damage to the machine if certain precautions are not taken. In addition to these instructions you must follow the safety regulations applicable to your work environment and job site, any federal, state and local laws governing travel on public roads and highways, and any guidelines issued by trade or professional associations. 0.1. Proper and destined use

With the standard dozer attachment, the machine may only be used to loosen, l oosen, move and dump dirt, gravel, broken rocks, or other similar material. Other use for which this machine is not designed, such as breaking rocks, demolishing buildings, buildings, driving dri ving piles, transporting personnel, personnel, etc. are considered to be improper and unsafe use. Neither the manufacturer manufacturer nor the dealer can be held responsible for any damage or accident resulting from such or any other unauthorized use of the machine. Any risk in improperly using this machine is the responsibility of the user. Machines used in special applications are subject to additional special conditions and guidelines and, among other things, must be equippe equipped d with special safety devices. Proper and destined use also includes observance of Operation Manual Guidelines issued in this Operation Manual and careful adherence to inspection and maintenance schedules and guidelines.

Service-Manual


1. Decals Decals on the the mac machin hine e

Several safety decals are attached on the machine. They must be strictly observed to prevent death or serious injury. The decals and the location of the decals on the machine are shown in the Operation Manuals. (Please use them for more information). These safety decals must be checked regularly to insure they are still complete and legible. Missing or illegible safety decals must always be replaced immediately. 2. General General safe safety ty regul regulatio ations ns

Study the Operation Manual before operating the machine. - Make sure that you have additional information for special attachments attachments on your machine, that you have read it and that you understand it. Allow only trained trained and authorized authorized personnel personnel to operate operate the machine, machine, to maintain, maintain, service or repair repair it. - Be aware of the minimum age requirements for machine operators. Allow only trained trained and authorized authorized personnel personnel to operate, operate, set up, maintain maintain and and repair the machine, machine, make sure all all personnel have specific job assignments. Determine the responsibility of the machine operator (also regarding the traffic regulations) and allow him to refuse to follow unsafe instructions given by a third party. Always have an experienced person on the machine machine to supervise personnel personnel still in training. training. Periodically observe and check if all persons working on the machine observe the safety and danger notes and instructions given in the " Operating Manual ". Wear proper work clothing when operating or working on the machine. - Rings, watches, watches, bracelets and and loose clothing clothing such as as ties, scarves, unbuttoned unbuttoned or unzipped unzipped shirts shirts or jackets are dangerous and could cause serious injury! - Utilize proper proper safety equipment equipment for certain tasks: safety glasses, hard hat, gloves, reflector reflector vest, ear ear protection or respirator, .... Consult your employer or site supervisor for specific specif ic safety equipment requirements requirements and safety regulations on the jobsite. When entering or leaving the machine, machine, never use the safety lever, control levers or joysticks as handholds. This could cause the machine to move inadvertently, which could lead to a serious accident. Never jump off the machine. Climb on and off the machine using only the steps, ladders, rails and handles provided. Use both hands for support and face the machine. Keep steps, ladders, handrails and handles handles free of oil, grease, mud, snow and ice. These precautions will minimize the danger of slipping, stumbling or falling. Make yourself familiar with the emergency exit through the right cab door. If no other instructions are given, proceed as follows for maintenance and repairs: Procedure: - Park the machine machine on on firm and and level ground ground and and lower the attachm attachment ent to the ground. - Bring all control levers into neutral position. - Turn the the engine engine off, leave the the starter key in contact contact position. position. - Actuate the control control levers several times times to relieve relieve the pressure in the system. - Bring all control levers into neutral position. - Before leaving the machine, move the safety lever up. - Remove the starter key. Before accessing the hydraulic circuit, with the engine turned off and the starter key in contact position, actuate all pilot controls (joysticks and pedals) in both directions to relieve the servo pressure and back pressures in the working circuits. Then relieve the pressure in the hydraulic tanks.

General Information

Service-Manual

Safety guidelines

Always place the safety lever up before before leaving the operator's operator's seat. Secure all loose parts on the machine. Never operate a machine until you have performed a complete walk around inspection. Check if all warning wa rning decals are on the machine and are legible. Observe the instructions on all danger and safety labels and decals. For certain applications, the machine must be equipped with specific safety devices. Never utilize the machine if they are not installed or fully functioning. Do not make any changes on the machine, add or remove r emove items which could reduce the safety, without permission of the manufacturer. This also applies to the installation and adjustment of safety devices and valves as well as to welding on load carrying parts. 3. Crushing Crushing and burn burn preve preventio ntion n

Never work underneath the attachment unless it is placed on the ground or properly supported. Never use damaged or insufficient load tackle (such as ropes, ro pes, chains, ...). Always wear gloves when handling wire ropes. When working on the attachment, never align bores with your fingers or hands. Use proper alignment tools when installing, changing or servicing attachments. When the engine is running, make sure to keep objects away from the radiator fan. Rotating fans wil l swirl and throw out objects, which can become very dangerous and cause severe injury to yourself and others and damage the fan. At or near operating operating temperature, temperature, the engine engine cooling system is hot and and under pressure. pressure. Avoid contact contact with components componen ts containing coolant, it could cause severe burns. Check the coolant level only after the cap on the expansion tank is cool enough to touch. Remove the cover carefully and slowly to relieve pressure. At or near operating operating temperature, temperature, the engine and hydraulic hydraulic oil is hot. Do not allow allow your skin to come into contact with hot oil or componen components ts containing hot oil. Always wear safety glasses glasses and gloves gloves when handling handling batteries. batteries. Keep sparks sparks and open open flames away. away. Never permit anyone to hand guide the attachment into position. Check if the engine compartment door is held in open position by the safety strut. - If the fun function ction is not not ensured, ensured, find the problem and and remedy remedy it immediately. immediately. Make sure that all engine compartment doors and covers are closed and locked before operating the machine. Never work or lay underneath the machine machine if it i t is raised ra ised with the attachment, the machine must always be properly blocked and supported. 4. Fire and explo explosion sion preventio prevention n

Always shut the engine engine off before before refueling. refueling. - In addition, addition, the heater must must also be turned turned off before refueling. Never smoke or allow an open flame in refueling areas and / or where batteries or flammable materials are being charged or stored. Always use the proper proper engine engine starting procedure, procedure, as described described in the "Operating Manual ". Check the electrical system frequently. frequently. Correct any defects, such as loose connections, chafed wiring, or burnt out fuses and bulbs immediately. Never store or carry any flammable fluids on the machine, except in the storage tank intended for machine operation.

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Regularly check all components, lines, tubes, and hoses for oil and fuel leaks and / or damage damage.. Replace Repl ace or repair damaged components immediately. - Oil and fuel leaks can cause fires. Be certain that all clamps, guards and heat shields are installed. These components prevent vibration, rubbing and heat build up. Install tie wraps to fasten hoses and wires, as required. Cold start ether is extremely flammable! flammable! Never use cold co ld start ether near heat sources, open flames, or near anyone who is smoking cigarettes. Use only in well ventilated area and as directed. Never use the flame glow plug or preheat system when you use an ether cold start aid. Danger of explosion! Know the location of the fire extinguishers; extinguishers; make sure su re you know how to use them properly. Check out the location of where to report a fire and inform yourself about fire fighting capabilities on the job site before you start to work. 5. Machine Machine start start up safe safety ty

Before starting the machine, perform a thorough walk-around walk-around inspection. Check the machine for loose bolts, cracks, wear, leaks and any evidence of vandalism. vandalism. Never start or operate an unsafe or damaged machine. Be certain that all defects are taken care of immediately. Make sure that all covers and doors are closed and locked. Check if all warning and safety decals are on the machine, make sure that all of them are legible. Clean all windows and mirrors, secure all doors and windows to prevent any inadvertent movement. Always enter and leave the cab cab through the left door. Use the right right door only in emergencies. emergencies. Make sure that no one is on or under the machine. Warn all personnel in the surrounding surrounding area on the job site before operating the machine. After entering the the operator's cab, cab, adjust the operator's operator's seat, the mirrors, the arm rests and and the seat belt belt so you can work comfortably. All noise level protection devices devices on the machine machine mu must st be operational operational when operating operating the machine. Never operate the machine without a cab or canopy. 6. Engine Engine start start up safet safety y

Before starting the engine, check all indicator lights and instruments for proper function. Place all operating and control levers into neutral position. Before starting the engine, warn any personnel in the surroundin s urrounding g area by sounding the horn. Start the machine only while seated in the operator's seat. If no other instructions were given, follow the engine starting instructions are outlined in the " Operating Manual ". Start the engine and check all indictor lights, gauges, instruments instruments and controls. Start the engine only in a well ventilated area. If necessary, open doors and windows to assure a sufficient fresh air supply Warm up the engine and hydraulic system to bring the engine and hydraulic oil to operating temperature, as low oil temperatures cause the machine to be unresponsive. Check that all attachment functions are operating properly. Move the machine slowly and carefully into an open area and check the travel and brake functions, the steering function as well as the turn signals and lights.

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Safety guidelines

7. Machine Machine operati operating ng safety safety

Before starting to work, make sure that you area aware of any special conditions at the jobsite, as well w ell as special regulations, federal, state and local safety requirements and warning signals. The work environment includes any obstacles in the working and traffic area, ar ea, the load carrying capacity of the ground, and any necessary guard rails to protect the jobsite from close-by traffic. Always keep sufficient sufficient and safe distance to overhangs, overhangs, walls, walls, drop offs and and unstable ground. Be especially alert in changing ground conditions, unfavorable visual conditions and changing weather. Be aware of utility lines and the location of supply lines on the jobsite and work especially careful near them. If necessary, check with the appropriate agency for details. Keep sufficient distance to electrical wires. When working near high voltage lines, do not get near them with the attachment. attachment. - There is a DANGER OF LOSS OF LIFE! - You must inform yourself yourself of proper proper distances distances to assure your safety while working. working. If you do touch a high voltage wire: - Do not leave the machine! - If possible, move the machine a sufficient distance distance away away from the danger area. area. - Warn all personnel personnel in the surrounding surrounding area not to come too close close to the machine machine and / or touch the machine. - Instruct somebod somebody y to turn the the electrical electrical power off. - Do not leave the machine machine until you are are assured that the electrical electrical line, which which has been touched or or damaged, is no longer energized and the power has been turned off!

Before moving or working, make sure you always check that the attachments can be operated safely. Before moving or working, make sure you always check that the attachments can be operated safely. Always turn on the the light if visibility is poor poor or as dusk approaches. approaches. Never allow another person to ride along on the machine. Always work while seated seated in the operator's seat and and with the seatbelt seatbelt secured. In the event the machine should tip, remain in t he operator's seat with the seatbelt securely fastened. Experience has shown that that it is safest to remain in the cab in the event of an overturn. Report any functional problems or defects immediately, and make sure that all necessary repairs are completed before resuming operation. Be certain that no one is endangered by moving the machine. Never get up and leave the operator's seat as long as the machine is still moving. Never leave the machine unattended, with the engine running. When traveling, make sure that the attachment is in transport position and keep the load as close to the ground as possible. The maximum permissible drivable incline incline / side slope of the machine depends on the installed attachment as well as the ground conditions! Avoid any working working movements, movements, which could cause the machine machine to tip or slide or slip on a grade. grade. Immediately Immediately lower the attachment and load to the ground and turn the machine downhill. If possible, work downhill or uphill, never sideways on a slope. Always move slowly and carefully carefully on rocky, rough or slippery ground ground or on a slope. Always adapt the travel speed to the working conditions. conditions. Never travel on slopes that exceed the maximum permissible grade ability of the machine.

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Drive downhill only at low speed to prevent loss of control over the machine. The engine must be at high idle and the speed must be reduced by preselecting the low speed range. Always change to the low speed range before reaching a downhill slope, never move onto a slope and then change to the low speed range. When loading a truck, the driver of the truck must leave the cab, even if the cab is FOPS protected. The machine must always be equipped with the proper protective devices designed for specific purposes, especially when it is utilized in demolition work, land clearing, crane operation, operation, etc. Always have another another person guide you if visibility is restricted. Always take signals from one one person only. Utilize only experienced personnel personnel to attach loads and direct operators. The person giving signals must be visible to the operator or equipped with two way radios. 8. Machine Machine parking parking safety safety

Park the machine only on firm and level ground. If it becomes necessary to park the machine on a grade, it must be properly blocked with wedges to secure it and prevent any unintentional unintentional movement. Lower the attachment to the ground and lightly anchor it in the ground. Bring all operating levers and controls into neutral position, place the safety lever up and turn the engine off, as outlined in the Operating Manual, before you leave the operator's seat. Lock the machine, remove all keys and secure the machine against vandalism and unauthorized use. Never park the machine in such a way as to block access to entrances, exits, ramps, fire hydrants, hydrants, etc. 9. Machine Machine trans transport porting ing safety safety

Use only safe transportation and lifting devices with adequate carrying load capacity. Park the machine on level ground and use wedges to hold chains or wheels. If necessary, remove part of the attachment of the machine for transport. Never use a ramp that is steeper than 30° to move the machine onto the transporting vehicle, the ramp should be covered with wooden planks to prevent slipping. Before moving onto the ramp, remove any snow, ice and / or mud from chains or wheels. Align the machine machine with the ramp. Use another person as a guide to signal you, the operator. Move very slowly slow ly and carefully towards the ramp and the transporting vehicle. Raise the attachment and move onto the ramp. Hold the attachment as close as possible to the loading platform. After the loading procedure, lower the attachment onto the trailer platform. Secure the machine and all remaining parts with chains and wedges to prevent any slipping or movement during transport. Relieve pressures from hydraulic liens and hoses, remove the ignition key, lock the operator's cab and covers before leaving the machine. Carefully check out the transporting route beforehand, check any regulations regarding width, height and weight. Make sure that there is enough clearance underneath all bridges and underpasses, utility lines and tunnels.

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Safety guidelines

During off loading, use the same care and caution as during the loading procedure. Procedure: - Remove all chains, wedges and blocks. Start the engine as noted in the Operating Manual. - Carefully move from the trailer platform platform do down wn the ramp. - Hold the attachment as close as possible above the ground. - Use a guide to signal you. 10.Machine towing safety

Always follow the correct procedure procedure as noted in in the "Operating "Operating Manu Manual", al", see "Towing "Towing the machine". machine". Tow the machine only in exceptional cases, such as removing the machine from a dangerous dangerous area to ha ve the machine repaired. Be sure that all towing and pulling devices, such as cables, hooks, etc. are safe and adequate. The cable or towing bar, which is used to tow the machine, must be adequate to pull the machine and must be connected to the appropriate bores or couplers. Any damage or accident which is the direct result of towing this machine is expressly excluded from the manufacturer's and / or LIEBHERR warranty. Notes for towing with a cable: - Make sure that no one is near the tensioned cable when pulling or towing the machine. - Keep the cable tight and free of kinks. - Carefully pull the the cable tight, do not jerk! jerk! - A sudden jerk can cause a slack cable to snap. When towing, keep the machine in the correct transport position, and maintain the permissible permissible speed and route. When returning the machine to operation, proceed as noted in the Operating Manual. After towing the machine, machine, and and before continuing continuing operation, operation, be certain to return the machine machine to a safe safe operating condition. 11.Machine maintenance safety

Never perform any maintenance or repairs for which you are not qualified or which you do not understand. Any maintenance maintenance / inspection inspection should be be performed in the intervals noted noted in the Operating Operating Manual. Manual. To perform perform any repairs, you must have the proper tools. Maintenance work should be performed performed according to the chart ch art in this Operating Manual, Manual, it is also noted who should or may perform what type of work. The operator should only perform items marked OM on the Maintenance and Inspection Schedule, the remaining work should be performed only by especially trained personnel. All spare parts must must conform to the the technical requirements requirements set forth by by the manufa manufacturer. cturer. This is only only assured by using original spare parts. Always wear proper proper and safe work clothing. clothing. For certain jobs, in addition addition to hard hats hats and safety shoes, shoes, additional safety equipment is required, such as safety glasses and gloves. Keep unauthorized personnel from the machine during maintenance and repair work. Secure the maintenance area, as necessary. Inform operators if any special task or maintenance maintenance work is required. Appoint one supervisory person to assure that this work has been done properly. properly. If not otherwise noted in this Operating Manual, perform all maintenance work on the machine on firm and level ground, with the engine turned off.

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The cab may only be tilted if the machine is parked on firm and level ground and with the engine turned off! When tilting the cab, make sure that there is no one within wi thin the danger zone! Always secure the raised cab with the safety bar before working under the raised cab! The machine may NEVER be started or moved when the cab is raised. The safety lever must remain in the fully raised position! After any maintenance maintenance and repair work, make make sure that all screw connections connections or or fittings, which had had to be loosened, are retightened. If it becomes necessary necessary to remove any safety devices during maintenance and repair, the safety devices, which were removed must be reinstalled immediately and then be inspected for proper function. Before servicing the machine, especially when working underneath underneath the machine, attach an easily visible warning sign DO NOT OPERATE to the ignition switch. Remove the ignition key. Before any maintenance or repair, clean off any oil, fu el or service fluids from connections and couplings. couplings. Do not use any harsh cleaning fluids. Use only lint free cleaning rags to clean the machine. Never use flammable fluids to clean the machine! Before any welding, cutting or grinding, clean the machine and surrounding area of dust and remove flammable fluids, assure adequate ventilation. - Otherwise, there is a DANGER OF EXPLOSION! Before cleaning the machine with water, steam (high pressure cleaning) or other cleaning fluids, cover or tape all openings. Make sure no water, steam or cleaning fluid enters these openings for safety and functional reasons. Electrical motors, switch boxes and battery compartments are especially endangered. In addition: - Make sure that that during cleaning, cleaning, the temperature sensors sensors of the fire warning and sprinkler sprinkler system do not not come in contact with the hot cleaning fluid or the sprinkler system could be activated. - After the clearing procedure, remove all covers covers and tape. - After cleaning the machine, machine, check all fuel, fuel, engine oil, oil, and hydraulic lines lines for leaks, loose connections connections and for chafed and damaged areas. - All problems must be remedied immediately. Adhere to product product safety instructions instructions issued for handling handling oils, greases greases and other other chemical substances. substances. Make sure to dispose of any operating and service fluids as well as replacement parts properly and in an environmentally sound manner. Be very careful when handling any hot components or fluids on the machine as there is a danger of burns and scalding! Be very careful when handling any hot components or fluids on the machine as there is a danger of burns and scalding! Perform any welding, cutting and grinding work on the machine only if i f this work has been explicitly authorized, as there can be danger of fire and explosion! The windows in the operator's cab are made of safety glass. Always replace damaged window panes immediately. - Only safety glass may be used for the window panes in the operator's cab. - Use only Original Liebherr spare parts. Never try to lift heavy parts. Always use appropriate appropriate lifting devices with sufficient carrying capacity. Procedure: - To lift spare parts parts and component component assem assemblies blies for replacement replacement on the machine, machine, they must must be securely mounted and secured onto the lifting devices, to prevent accidents. - Use only suitable suitable and technically technically flawless flawless lifting devices as well as tackle tackle with sufficient load lifting capacity. - Do not allow anyone to work or remain underneath the lifted load!

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Safety guidelines

Do not use damaged or insufficient wire ropes. Always wear gloves when handling wire ropes and cables. Only experienced personnel personnel may attach loads and signal the operator. The person used as a guide must be visible by the operator or be in direct voice contact with the operator via a two way radio. When installing parts higher up or when working overhead, always use safe scaffolding, ladders or working platforms suited for this purpose. Do not step s tep on any machine parts or compone components nts to get closer to the working area. Always wear safety harnesses or similar safety sa fety equipment when working higher higher up. Make sure all handles, steps, walkways, catwalks, ladders etc. are always free of dirt, snow and ice. When working or changing any part of the attachment (for example when changing the teeth) make sure that the attachment is properly supported. Never use metal on metal supports! Never work underneath the machine if the machine has been raised with its attachment. attachment. The machine and a nd / or its attachment must always be properly blocked and supported with wooden blocks or beams. Always block the machine machine in such such a way that any any change in the center of gravity gravity will not endanger endanger its stability. Never use metal on metal supports! Only authorized, specially trained personnel personnel may work on the travel gear, brake and steering system. If the machine must be repaired while parked on a slope, the track chains or wheels must be blocked with wedges to prevent any movement. Bring the attachment into maintenance position. Only authorized, especially trained and experienced personnel may work on the hydraulic system. Always wear gloves gloves when checking checking for leaks. A thin stream of fluid escaping escaping from a small small hole can have enough force to penetrate the skin. Never loosen any hydraulic lines or connections until the attachment has been lowered to the ground and the engine has been turned off. Then, with the starter key in contact position, actuate all pilot controls (joysticks and pedals) into both directions to relieve the servo pressure and back pressure in the working circuits, circ uits, then relieve the tank pressure in the hydraulic tank by slowly turning the bleeder screw. Regularly check all hydraulic lines, hoses and connections for any leaks or external damage. Any defects must be repaired immediately. Any escaping fluid can cause serious injury and fire. Before beginning any repairs, you must also ensure that all air pressures are relieved in any of the systems you need to gain access to. To be certain refer to the description of the various compone component nt groups and assemblies. Route and install all hydraulic and air pressure lines properly. Mark and check all connections to prevent any mix-ups. All fittings, including length and quality or type of hoses must match the requirements set forth by the manufacturer. Use only LIEBHERR spare parts. Replace hydraulic hoses and lines in regular intervals, as stated, even if no defects can be seen. Work on electrical components of the machine may only be performed by a certified electrician or by a person working under the guidance and supervision of such an electrician, and according to electro-technical procedures, rules and regulations. regulations. Use only Original fuses with the same amperage. amperage. In case of problems in the electrical power supply, turn the machine off immediately. Inspect / check the electronic components components of the machine regularly. Repair any problems or defects, such as loose connections or chafed wires and replace any burnt out fuses and bulbs immediately. immediately. If any work is necessary on energized, voltage carrying parts, a second person must be utilized to disconnect disconnect the main battery switch or emergency off switch in case a problem should arise. Rope the work area off with a red / white safety chain and a warning sign. Use only insulated tools!

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When working on high voltage carrying components components or sections, turn off the power supply, then connect the supply cable to the ground wire and use the grounding rod to ground these parts, such as condensers, etc. Check the disconnected parts first to see if they are really voltage free, ground them and then short circuit them. Insulate neighboring voltage carrying parts. 12.Safety guidelines to be observed when welding on the machine

Disconnect the battery first, when working on the electrical system or before any arc welding on the machine. - Always disconnect disconnect the negative negative (-minus) (-minus) terminal terminal first, and and reconnect reconnect it last. - In addition, before any welding, always unplug the plugs on the electronic boxes. 13.Safety guidelines to be observed when working on the attachment

Never work underneath the attachment unless it is placed on the ground or properly supported. When replacing or changing any part of the attachment, such as blade, cutting edges, teeth, ...) never use metal on metal support. Never try to lift heavy parts. Always select and use appropriate lifting devices with sufficient lifting capacity. When handling wire ropes, always wear gloves! Do not disconnect any lines or hoses or remove fittings, caps or covers before the attachment has been placed down and the engine has been turned off. To release pressures -with the ignition key in contact position -move - move all servo controls (joystick and pedals) in both directions to release the servo pressure and any pressure remaining in the hydraulic circuit, then release the tank pressure by turning the bleeder screw. After completion completion of all maintenance maintenance and and repairs, make sure that that all lines and and hoses and and fittings are properly properly connected and retightened. Removing and installing the steel pins with a hammer can be very dangerous. Metal chips can cause injury. - Always wear gloves and safety glasses. If possible, use appropriate tools for the job, j ob, such as pin pullers, punches, etc.). 14.Safety 14.Safety guidelines to be observed when loading the machine with a crane

Lower the attachment to the ground. Bring all control levers into neutral position. position. Turn the engine off, as described in the Operating Manual and place the safety lever in the up position before you leave the operator's seat. Securely close all doors, covers and hoods on the machine. Utilize only experienced personnel personnel to attach loads and direct operators. The person giving signals must be visible to the operator or equipped with two way radios. Install the shackles and hooks to the t he appropriate and designated designated brackets / bore holes on the machine. Make sure the length of the lifting device or tackle is sufficient. Carefully lift the machine. DANGER! Make sure no one is near or underneath the raised machine.

When returning the machine to operation, proceed as noted in the Operating Manual.

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Safety guidelines

15.Safe maintenance of hydraulic hoses and lines

Hydraulic hoses and lines may never be repaired! All hoses, lines and and fittings must must be checked checked regularly, but at least least once a year for leaks and any any externally visible damage! Any damaged sections must be replaced immediately! Escaping oil can cause injuries and fire. Even if hoses and lines are stored and used properly, they undergo a natural aging process. For that reason, their service life is limited. Improper storage, mechanical mechanical damage and improper use are the most frequent causes of hose failures. The service life of a hose may not exceed six years, including a storage period of no more than two years (always check the manufacturing date on the hoses). Using hoses and lines close to the limit ranges of permitted use can shorten the service life (for example at high temperatures, frequent working cycles, extremely high impulse frequencies, frequencies, multi-shift or around the clock c lock operation). Hoses and lines must be replaced if any of the following points are found during an inspection: Criteria: - Damage on the external layer layer into the inner layer (such (such as chafing, chafing, cuts and and rips ); - Brittle outer outer layers layers (crack (crack formation formation of of the hose material); - Changes in shape, which differ from the natural shape of the hose or line, when under pressure or when not under pressure, or in bends or curves, such as separation of layers, blisters or bubble formation; - Leaks; - Non-observance Non-observance of installation requirements; requirements; - Damage or or deformation of hose fittings, which might reduce reduce the strength strength of the fitting or the connection connection between the hose and the fitting; - Any movement of the hose away from the fitting; - Corrosion on on the fittings, fittings, which might reduce reduce the function or the strength strength of the the fitting; - Storage or service life has been exceeded. When replacing hoses or lines, use only Original replacement parts. Route and install the hoses and lines properly. Do not mix up the connections. 16.Roll over protection (ROPS) and falling object protection (FOPS)

These are protective devices, which are integrated in the operator's cab. To reduce a weakening of the roll over or falling object protection, always check with your LIEBHERR dealer or Service Department before making any changes. - Do not attach attach fire extinguishers, extinguishers, first aid kits, floodlights or similar similar objects objects to these protective structures. structures. - Welding points or drilling of holes holes could weaken the structure. For similar work, always consult with your LIEBHERR dealer. Any changes, which have not not been explicitly explicitly approved approved by LIEBHERR would invalidate the roll over or falling falling object protection permit. - Damage to the structure structure can also also be caused caused by a roll roll over accident accident or falling falling objects, objects, etc. 17.Attachments 17.Attachments and installatio i nstallations ns

Attachments and and installations installations from other sources sources or parts which have have not been approved by LIEBHERR for installation may not be installed on the machine without prior written permission by LIEBHERR. The necessary technical documentation must be forwarded to LIEBHERR.

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18.Protection from vibration

The vibration exposure on mobile construction machinery machiner y is generally the result of the way they are used. Especially the following parameters have a significant influence: - Environmental Environmenta l conditions Unevenness and potholes; - Operating techniques: techniques: speed, steering, steering, brakes, control of operating elements elements of the machine while driving as well as when working. The machine operator operator himself affects the actual vibration vibrati on exposure to a great degree himself, since he selects the speed, the gear ratio, the working mode mode and the travel route. This results in a wide range of various vibration exposure for the same type of machine. The full body vibration exposure for the machine operator can be reduced if the following recommendations recommendations are observed: Select the correct machine, attachment attachment parts and auxiliary equipment equipment for the current task. Use a machine, which is equipped with a suitable seat (i.e. for earth moving machinery, for example for a hydraulic excavator, a seat which meets EN ISO 7096). Keep the seat in good order and adjust it as follows: - The adjustment adjustment of the seat and its suspension should be matched to the weight and size of the operator. operator. - Check the suspension and the adjustment mechanism of the seat regularly and make sure that these properties of the seat still correspond to the specifications of the seat manufacturer. Check the maintenance condition of the machine, especially regarding: tire pressure, brakes, steering, mechanical mechanical connections, etc. Do not steer, brake, accelerate and shift as well w ell as move and load the working attachments of the machine abruptly. Match the machine speed to the travel route, to reduce vibration exposure: exposure: - Decrease the speed speed when driving on on pathless terrain. - Drive around obstacles and avoid very impassable terrain. Keep the properties of the terrain, where your machine works and drives in good condition: - Remove large rocks and obstacles. - Fill furrows furrows and holes. - Have machines available available to establish and keep suitable suitable terrain conditions and leave leave enough time to do this. Drive longer distances (for example on public roads) with suitable (medium) speed. For machines, which are predominately predominately used for driving, drivi ng, use special auxiliary systems (if available), which make it possible to reduce vibration exposure for this type of application. If such s uch auxiliary systems are not available, regulate the speed, to avoid “build up” of the machine.

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General Information Service Items

Service Items Notes for the disposition of service fluids and filter: Service fluids may not be discharged into the ground, drainage drainage system or waterways. Different service fluids and filters should be collected co llected and disposed of in separate containers. Do not use containers, which previously held food items or drinks - to t o prevent danger of mix-ups. Dispose of these items in an environmentally friendly manner according to applicable guidelines and regulations. Observe all state, local and national regulations. regulations. Do not use old or incorrectly stored service fluids and filters, dispose of them properly. 1. Service fluids for Diesel engines with turbo chargers 1.1. Engine lube oil

Engine lube oils must meet a certain quality and a certain viscosity, depending on their use and ambient temperatures. temperatures. Problem-free operation can only be ensured only if the requirements for both areas are met. 1.1.1 Oil quality To meet the technical demands, only highly alloyed lube oils are used in modern Diesel engines. They consists of high-quality base oils, mixed with additives. These additives provide the required properties for these oils. For LIEBHERR Diesel engines with turbo chargers, oils of the following specifications specifications are approved, the higher quality oils are preferred: API - classification (American Petroleum Institute)

: CF-4, CG-4, CH-4, CI-4, CI-4,

ACEA (CCMC) - classification classification : E2 (D4), E3 (D5), E4, E4, E5 (Association des Constructeurs Européens Européens de l´Automobile) Note:

For older older machines machines / Diesel engines, engines, if still in in use, engine engine oils according according to the lower lower specification specification as noted in the original operation manuals may be used. However, we recommend the use of these new oils, since the service life of the engine can be extended significantly by using these higher quality oils. The originally noted oil and filter change intervals may be extended. extended.

1.1.2 Oil viscosity Z In addition to the quality, the oil must also provide a certain viscosity the selection is made according to the SAE - classification (Society of Automotive Engineers). The determining factor for the correct selection of the SAE classification is the ambient temperature. In most regions, SAE 10W-40 is recommended recommended (see chart c hart below). If the viscosity is too high, starting problems can occur, if it is too low, the lubrication efficiency can be endangered, both factors can lead to increased engine wear. The temperature ranges shown in the following chart are guidelines and may be exceeded or fallen below for a short time.

For the operation in extreme climate zones, such as in arctic regions, special guidelines apply and are available from the manufacturer.

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Service Items

1.1.3 Oil change intervals The oil change intervals noted in the Maintenance and Inspection schedules always apply to "normal operating conditions". They apply for normal, central European temperatures, annual operation of approx. 1000 operating hours, use of oils of the required minimum quality and fuels with a sulfur content of less than 0.5%. When using higher quality oils, the operating hours per interval may be doubled - see the following chart. However, the 500 hour interval may not be exceeded. Engine oil and filters must be changed at least once a year, even if the given change interval has not yet been reached. In difficult circumstances, such as repeated cold start, higher sulfur content (above 05.%) in the fuel, more severe climatic conditions (for example continuous temperatures below -10°C) etc., the intervals must be cut in half. This means, for each difficulty, the permitted operating hours per interval must be multiplied by a factor of 0.5. Permissible oil change intervals in operating hours : Oil quality: Applications

Ambient temperature

Sulfur content in fuel

Oil quality:

CF-4, CG-4, CH-4, CI-4, E2 (D4))

E3 (D5), E4, E5,

Change interval

Change interval

above -10°C

to 0,5%

250 hrs.

500 hrs.

(Normal temperature)

above 0,5%

125 hrs.

250 hrs.

below -10°C

to 0,5%

125 hrs.

250 hrs.

Continuous temperature

above 0,5%

60 hrs.

125 hrs.

1.2. Diesel fuels

Diesel fuels must meet the minimum requirements of the following specifications. specifications. The sulfur content may not exceed 0.5%. A higher sulfur content has negative effects on oil change intervals and engine service life. A higher sulfur content above 1% is not permitted. Fuels with low sulfur content (for example, according to European regulations <0.05 %) must contain additives to retain the lubrication lubrication efficiency efficiency according to HFRR(60°)-Test HFRR(60°)-Test <400 m - . Insufficient lubrication lubrication causes causes premature wear of the injection system components, especially distributor injection pumps. The additives should be added by the fuel supplier, as he is responsible for the quality of the fuel. We do not recommend addition of secondary lubrication additives by the user. Approved fuel specifications :

DIN EN 590 + HFRR(60 HFRR(60°)-Te °)-Test st <400 <400 m ASTM D 975 - 89a 89a 1D and 2D + HFRR(60°)-Test HFRR(60°)-Test <400 m + cetane rating >45 (recommenda (recommendation: tion: >50)

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Diesel fuels in very low temperatures

At ambient temperatures below freezing (0 C), the flow properties of warm temperature Diesel fuel can become insufficient due to paraffin excretion. The same applies to cold temperature Diesel fuels in temperatures below. -15 C. In order to prevent operating problems in even lower temperatures, Diesel fuel with an additive is sometimes available, for use in temperatures temperatures to -20 C. In order to prevent operating problems in even lower temperatures, mix Diesel fuel with normal gasoline or petroleum. Addition of normal gasoline is a makeshift measure and may not exceed 30% per volume. Do not use Super gasoline for mixing. Mixing fuel can diminish engine performance, for that reason, keep the added fuel as low as possible, depending on the ambient temperatures. For safety reasons, mix fuel only in the fuel tank. When refueling, add the lighter additive before the Diesel fuel. Then let the engine run for a short time until the mixture mixt ure has been distributed throughout the fuel system. Diesel fuels - Mixing ratio ( Vol.-%)

Ambient temperature °C

Summer Diesel fuel

Winter Diesel fuel to -15°C % Fuel % Additive 100 --

Winter Diesel fuel to -20°C % Fuel % Additive 100 --

0 to -10

% Fuel 70

% Additive 30

-10 to -15

50

50*

100

--

100

--

-15 to -20

--

--

70

30

100

--

-20 to -25 --50 50* 70 30 * = If an addition of more than 50% is required, use only petroleum (no regular gasoline). The Diesel fuel part may never be more than 50% . Additives to Diesel fuel (flow improvers)

Commercially available flow improvers can also improve Diesel fuel properties in cold temperatures. Always read and observe the manufacturers user guidelines and quantities.

1.3. Coolant

Coolants, containing unsuitable anti corrosion / antifreeze fluids or wrong mixed coolants could damage the engine or its parts, caused by cavitation or corrosion. Additionally heat isolating deposits could be created on heat transferring parts, which overheat and lead to the damage of the engine. For a long term, fault free operation, the coolant must be filled year round with a mixture of at least 50% anticorrosion/antifreeze anticorrosion/antifreeze fluid. This concentration protects the system to approx. -37°C / -34°F. - 34°F. Antifreeze protection chart

Protection to Percentage of antifreeze (%)

Note:

Do not use more than 60% anti-corrosion / antifreeze fluids, a higher percentage would actually reduce the cooling and antifreeze protection and causes gel formation in the coolant fluid. Danger of engine damage!

General Information

Service-Manual

Service Items

Coolant filters are used on some engine series, which filter the coolant in the auxiliary flow and in addition, a chemical additive in the filter (DCA 4) reinforces the protection against cavitation, corrosion, scale deposits deposits and foam formation. The DCA4 concentration must be between 0.3 and 0.8 units per liter of coolant. See the following chapter Coolant with DCA4. This results in a mixing ration of approx. 48.5 % water, 48.5 % anti corrosion /antifreeze fluid and 3 % DCA4. Check the mixing ratio regularly during maintenance work. See instructions in section 3.4. If coolant must be replaced, make sure that the given mixing ratios are retained. Do not fall below this ratios nor exceed it. Due to the natural aging process of the coolant, it must be replaced at least once every 2 years. Use only suitable coolant, free of contaminants. Clean contaminated cooling systems. Note the following regulations. To replace or add coolant in larger quantities, mix the t he given parts outside the cooling circuit in a suitable, clean container first. Fresh water guidelines :

To mix coolant fluid, use clean, clear water, which is not too hard. Often, but not always, regular tap water may be used. Seawater, brine, brackish water, or industrial waste water is not suitable. Approved fresh water quality (as of 2001) for use with anti corrosion / antifreeze fluid - without DCA4

- with DCA4

Sum of alkaline earths (water hardness):

: 0,6 to 3,6 mmol/l (3 to 20°d)

0,6 to 2,7 mmol/l (3 to 15°d)

Ph - value at 20° C

: 6,5 to 8,5

6,5 to 8,0

Chloride / ion content

: max. 80 mg/l

max. 80 mg/l

Sulfate / ion content

: max. 100 mg/l

max. 80 mg/l

Presently approved anti corrosion / antifreeze fluids (as of December 2003):

Brand name

Manufacturer Manufactur er

Agip Antifreeze Antifreeze Plus Agip Langzeit-Frostschutz Langzeit-Frostschutz Antigel DB 486 486 Aral Kühler-Frostschutz Kühler-Frostschutz A AVIA Frostschutz APN APN (G48-00)

Agip Petroli S.p.A, Rom Rom / Italien Autol-Werke GmbH., GmbH., Würzburg / BRD BRD Sotragal SA, SA, St. Priest / Frankreich Aral AG, Bochum Bochum / BRD Deutsche AVIA-Mineralöl AVIA-Mineralöl GmbH, München München / BRD

BP Antifrost X 2270 A BP Napgel C 2270/1

Deutsche BP AG, Hamburg / BRD BP Chemicals Ltd., London / England

Caltex Engine Coolant DB Caltex Extended Life Coolant Castrol Anti-Freeze O Century F.L. Antifreeze Chevron DEX-COOL Extended Life Anti-Freeze/Coolant Anti-F reeze/Coolant

Caltex (UK) ltd., London / England Caltex Deutsche Castrol Vertriebs-GmbH, Vertriebs-GmbH, Hamburg /BRD Century Oils, Hanley, Stoke-on-Trent Stoke-on-Trent / England Chevron Texaco

Deutz Kühlschutzmittel Kühlschutzmittel 0101 1490

DEUTZ Service International International GmbH, Köln / BRD

Esso Kühlerfrostschutz Kühlerfrost schutz

Esso AG, Hamburg / BRD

Fricofin Fricofi n Frostschutz Motorex (G48-00) Frostschutz 500

Fuchs Mineraloelwerke Mineraloelwer ke GmbH, Mannheim / BRD Bucher+Cie, Langenthal Langenthal / Schweiz Mobil Oil AG, Hamburg / BRD

Glacelf Auto Supra Glycoshell AF 405

Total Shell

Service-Manual


Glycoshell N Glysantin (G 48-00)

Shell BASF AG, Ludwigshafen Ludwigshafen / BRD

Havoline XLC Havoline DEX-COOL Extended Life Anti-Freece/Coolant Anti-Freece/Coolant

ARTECO Chevron Texaco

Igol Antigel Type DB

Igol France, Paris / Frankreich

Labo FP 100

Labo Industrie, Industri e, Nanterre / Frankreich Frankreic h

Motul Anti-freeze

Motul SA, Aubervilliers Cedex / Frankreich

OMV-Kühlerfrostschutzmittel OMV-Kühlerfrostschutzmittel Organifreeze OZO Frostschutz S

OMV AG, Schwechat / Österreich Total Total Deutschland GmbH, Düsseldorf / BRD

Total Antigel S-MB 486 Total Frostfrei

Total Deutschland GmbH, Düsseldorf / BRD Total Deutschland GmbH, Düsseldorf / BRD

Veedol Antifreeze Antifreez e O

Deutsche Veedol GmbH, Hamburg / BRD

Wintershall Kühlerschutz Kühlerschutz

Wintershall Mineralöl GmbH, Düsseldorf / BRD

Presently approved anti corrosion / antifreeze fluids / 50:50 Premix (as of December 2003): (50 % water : 50 % corrosion/antifreeze fluids)

Brand name

Manufacturer

Liebherr Anti-Freeze APN mix Id.Nr. 8611 045 - 20 l bundle Caltex Extended Life Coolant Pre-Mixed 50/50 (ready-to-use-version) (ready-to-use-version) Chevron DEX-COOL Extended Life Prediluted Predilut ed 50/50 Antifreeze coolant Havoline XLC, 50/50 Havoline DEX-COOL Extended Prediluted 50/50 Antifreece coolant Organicool 50/50

LIEBHERR Caltex Chevron Texaco ARTECO Chevron Texaco Total

Presently approved anti corrosion / antifreeze fluids with DCA4 - ready to use (as of December 2003):

Brand name

Manufacturer

Liebherr Anti-Freeze "pret a l'emploi" Id.Nr. 10 005 347 - 20 l bundle

LIEBHERR

The given anti corrosion / antifreeze fluids are approved for all Liebherr Diesel engines (with and without coolant filter / DCA4).

1.3.1 Coolant with DCA4 (DCA = Diesel Coolant Additive) The additive DCA4 is "used up" during use. The DCA4 concentration in the filter compensates for this loss accordingly, if there is no loss of coolant and the correct filter is used at the given change interval. The DCA4 concentration must be between 0.3 and 0.8 units per liter of coolant. To check, refer to the "Maintenance and inspection guidelines", section 3.4. For change intervals for filter and coolant, see Maintenance and inspection schedule schedule , section 3.2. If the cooling system is filled initially or refilled after repairs, then DCA 4 in liquid form must be added to the 50% anticorrosion / antifreeze and 50% water mixture. The mixture should be mixed outside the cooling system. Note the safety guidelines issued by the additive manufacturer. manufacturer.

General Information

Service-Manual

Service Items

This results in a coolant mixture ration of approx. 48.5 % water, 48.5 % anticorrosion / antifreeze fluid and 3% DCA4. In addition, use a new coolant filter, according to the filling quantity. The correct Id. No. of the filter can be found in the Parts Manual or the Operation and Maintenance manual of the machine. Overview chart DCA4 and filter requirements (as of 2001) Coolant system contents Required quantity of liquid DCA 4 Liter

Container approx.0.5 liter

DCA 4 - water filter

appr. liter

24-39 3 oder 1,5 40-59 4 oder 2,0 60-79 5 oder 2,5 80-115 8 oder 4 Container liquid DCA4 at approx. 0.5 l -Id. No. 7363 898 Liebherr coolant (ready to use, 20 liter, above mixing ratio) - Id. No. 10 005 347

Id. No. 7367 045 7381 493 7367 052 7367 052

1.3.2 Coolant - special filling - with anti corrosion fluids, without antifreeze antifreeze fluids In exceptional cases and if ambient temperatures are constantly above the freezing point , for example in tropical regional, where no anticorrosion / antifreeze fluids is proofed available, fresh water and watersoluble anticorrosion anticorrosion fluids (Inhibitors) may be used as coolant. Do not use coolant refiners (anticorrosion oils) with emulsifying capacity. If necessary, flush the cooling system before refilling. The fresh water quality must meet use with DCA4 - see chart Approved fresh water quality. The coolant must be changed once a year .

Use of DCA4 To provide sufficient protection against corrosion, approximately twice the amount of DCA4 must be used as compared to the above mixing ration, when using anticorrosion / antifreeze fluids and DCA4 - see above "overview chart and filter requirements". requirements". The DCA4 concentration must be between 0.6 and 1.06 units. It must be checked during maintenance work or when the coolant filter is changed, and corrected, as necessary. This results in a mixing ratio of max. 94 % fresh water and min. 6 % DCA4 additive Use of products from Caltex / Chevron Texaco / Havoline / Total To provide sufficient protection against corrosion with these products, a mixture of 92,5 vol.% coolant and 7,5 vol.% anti corrosion fluid must be kept. The mixture ratio must be checked during maintenance work and corrected, as necessary. The concentration of the anti corrosion fluid must not fall below 5 vol.% nor exceed 10 vol.%. Presently approved anti corrosion fluids (as of December 2003) :

Brand name

Manufacturer

DCA4 Diesel Coolant Additives Caltex CL Corrosion Inhibitor Concentrate Chevron Texaco Heavy Duty Extended Life Corrosion Inhibitor Nitrite Free Havoline Extended Life Corrosion Inhibitor (XLI) Total WT Supra

Fleetguard Caltex Chevron Texaco ARTECO Total

Service-Manual


2. Oil for hydraulic system

In the hydraulic system, use only Diesel engine lube oils or special approved oils. 2.1. Oil quality

2.1.1 Approved engine oil classifications classifications API - classification (American Petroleum Institute)

: CF-4, CG-4, CH-4, CI-4,

ACEA (CCMC) - classification classification : E2 (D4), E3 (D5), E4, E4, E5, (Association des Constructeurs Européens Européens de l´Automobile) Note:

The API classifications CC, CD, CE and CF are now now obsolete, however, in quality, they had been approved for use in the hydraulic system.

2.1.2 Special oils Approval is given given for each machine type separately. Special Special guidelines guidelines are issued with with the release. release. The following product presently considered to be an environmentally environmentally friendly hydraulic fluid: Panolin - HLP Synth - VG 46 2.2. Oil viscosity

In addition to the quality, the oil must also provide a certain viscosity, the selection is made according to the SAE classification (Society of Automotive Engineers). Engineers). The determining factor for the correct selection of SAE classification is the ambient temperature, single grade oils are preferred. If the viscosity is too high, it can cause cavitations, if it is too low, the lubrication efficiency efficiency may be endangered. Both can cause failure of hydraulic components. The temperature ranges shown in the following chart are guidelines. When operating the machine within the black temperature range, the following warm up procedure should be carried out. Single grade oils

Multi grade oils

Viscosity for environmentally friendly hydraulic hydraulic fluids according to ISO: ISO : VG 46 (covers SAE 10W and SAE 20W-20 or SAE 10W-30) For operation in extreme climate zones, such as arctic regions, special guidelines are available from the manufacturer. Warm up procedure:

a) In temperatures up to 10° C below the given limit (black range) After starting, run the Diesel engine at medium speed. Warm up the hydraulic system by carefully actuating the hydraulic cylinders. Extend and retract the hydraulic cylinders fully for short periods. After 5 minutes, carefully engage the travel hydraulic as well. Total warm up period is approximately 10 minutes. b) At even lower temperatures: temperatures: Before starting the Diesel engine, preheat the oil in the hydraulic tank, then proceed as described in paragraph a).

General Information

Service-Manual

Service Items

Gear oil

The lube oil specification for gears is based on API and SAE classification. The oil chamber in travel gears for double lifetime seal is filled with oil from the hydraulic system - see section 2. 2.1. Oil quality

As a general general rule, only oils meeting meeting API - classification GL-5 may be used. 2.2. Oil viscosity

The following oils must be used in travel gears, and are highly recommended for use in splitter boxes: Viscosity classification SAE 85 W - 140 EP For splitter boxes, oils of

Viscosity classification SAE 90 EP or SAE 80 W - 90 EP may also be used.

For the operation in extreme climatic conditions, such as in arctic regions or in extreme temperatures temperatures ranges, such as in slag applications, special oils may be approved if the prevailing ambient temperatures are known operations. 2.3. Lube oil for final drive - sealing chamber

For oil quality and viscosity see section 2, Oil for hydraulic system, but do not use special oils. 3. Lube oil for support shaft bearing

For oil quality and viscosity see section 2, Oil for hydraulic system, but do not use special oils. 4. Hoist gear oil - pipe layers

As a general rule, the guidelines guidelines noted in the Operation and Maintenance manual and the winch manufacturer manufacturer should be observed. For lubrication technical reasons, we recommend the use of Diesel lube oil, which meets at least one of the following quality and viscosity classifications. 4.1. Oil quality

according to

API - classification

: CF, CF-4, CG-4, CH-4, CI-4,

ACEA (CCMC) - classification classification

: E2 (D4), E3 (D5), E4, E4, E5,

4.2. Oil viscosity

according to SAE - classification ISO - classification

: 10W : VG 32

5. Grease 5.1. General lubrication points and track tensioner

The grease must meet specification KP 2 k - consistency 2 according to NL GI - class and DIN 51818 and DIN 51825 or EP 2 according to NF-T-60 132 . The grease must also be lithium based, with a VKA value of at least 2300 N according to DIN 51350 or ASTM D 2596. 5.2. Long term grease / grease to protect against corrosion

For the lifetime lubrication of bearing points of lift cylinder suspensions and to protect against corrosion at the initial installation of dry bearing points, to protect exposed piston rods, to prevent rust formation, etc., a special calcic, acid free grease should be used. We recommend LIEBHERR's special paste CTK - Id. No. 8613 313 01 For general conservation - see section 19, Conservation guidelines - other acid free anticorrosion grease may be used.

Service-Manual


6. Miscellaneous

Always observe all guidelines guidelines issued in the Operation and Maintenance Maintenance manuals, repair manuals and on drawings. 6.1. Rubber seals on doors and covers

Use silicon spray or Talcum powder. 6.2. Hydraulic cylinder installation

Lubricant for threads of pistons, piston nuts and piston rod bearings Liebherr High performance lubricant Id. No. 8300 004 Special protection against corrosion for installation of sealing elements -Liebherr Special anticorrosion grease Id. No. 8300 005

Service-Manual


Service Items see operation and maintenance manual.


Service-Manual

Service-Manual

General Information Tightening Torques

The preload and tightening torques listed in the chart are from VDI guidelines 2230 of July 1986. Installation preload F M and tightening torques M A for shaft screws with metric standard or fine thread per DIN ISO 262 and DIN ISO 965 T2 (replacement for DIN 13 part 13) and screw head dimension of hex head screws with shaft DIN EN 24014 (replacement for DIN 931 part 1) or so cket head screws DIN EN ISO 4762 (replacement (replacement for DIN 912). The chart values are valid for lubricated screws, surface black treated, phosphated or galvanic zinc plated and for dry screws, surface according to flZn - LH-Norm 10021432 (replaces DACROMET 500) Medium friction

G =

0,12.

Always observe the tightening torques and/ or procedures listed in drawings / parts lists, instructions of component descriptions, if noted, they override the factory standards listed in the torque charts. Never use a standard lock washer with 10.9 or 12.9 screws. If a washer is necessary, use only "heavy duty" washers, made from hardened material. Always use torque torque wrenches wrenches with the correct correct range - the upper third third of the range range should include the listed torque torque value according to the chart. When using impact screws, make sure that the given tightening torque is observed - should be checked before and during the tightening procedure with torque wrench (Nm x 0,7375 = ft.lbs.)!

Preload forces and tightening torques for screws with standard metric thread according to factory standard WN 4037 I

Standard metric thread

Preload values FM based on Tightening torques MA are screw grades and are given based on screw grades and in N are given given in Nm

Wrench size (x) = per DIN931, for DIN931, for Hex head screws

8.8

10.9

12.9

8.8

10.9

12.9

Socket head screws

mm

Inch

mm

Inch

M

4 x 0,7

4 050

6 000

7 000

2,8

4,1

4,8

7

9/32

3

--

M

5 x 0,8

6 600

9 700

11 400

5,5

8,1

9,5

8

5/16

4

5/32

M

6 x1

9 400

13 700

16 100

9,5

14,0

16,5

10

--

5

--

M

7 x1

13 700

20 100

23 500

15,5

23,0

27,0

11

--

--

--

M

8 x 1,25

17 200

25 000

29 500

23

34

40

13

1/2

6

--

M 10 x 1,5

27 500

40 000

47 000

46

68

79

(17) 16

(11/16) --

8

5/16

M 12 x 1,75

40 000

59 000

69 000

79

117

135

(19) 18

(3/4) --

10

--

M 14 x 2

55 000

80 000

94 000

125

185

215

(22) 21

(7/8) --

12

--

M 16 x 2

75 000

111 000

130 000

195

280

330

24

--

14

9/16

M 18 x 2,5

94 000

135 000

157 000

280

390

460

27

1-1/16

14

9/16

M 20 x 2,5

121 000

173 000

202 000

390

560

650

30

1-3/16

17

--

M 22 x 2,5

152 000

216 000

250 000

530

750

880

(32) 34

--

17

--

M 24 x 3

175 000

249 000

290 000

670

960

1120

36

1-7/16

19

3/4

M 27 x 3

230 000

330 000

385 000

1000

1400

1650

41

1-5/8

19

3/4

M 30 x 3,5

280 000

400 000

465 000

1350

1900

2250

46

1-13/16

22

7/8

M 33 x 3,5

350 000

495 000

580 000

1850

2600

3000

50

2

24

--

M 36 x 4

410 000

580 000

680 000

2350

3300

3900

55

2-3/16

27

1-1/16

M 39 x 4

490 000

700 000

820 000

3000

4300

5100

60

2-3/8

27

1-1/16

General Information

Service-Manual

Tightening Torques

Preload forces and tightening torques for screws with fine metric thread according to factory standard WN 4037 I

Fine metric thread

Wrench size (x) = per DIN931, for DIN931, for

Preload values values FM based on Tightening torques MA are screw grades and are given based on screw grades and in N are given given in Nm

Hex head screws

8.8

10.9

12.9

8.8

Socket head screws

10.9

12.9

mm

Inch

mm

Inch

M

8 x1

18 800

27 500

32 500

24,5

36

43

13

1/2

6

--

M

9 x1

24 800

36 500

42 500

36

53

62

--

--

--

--

M 10 x 1

31 500

46 500

54 000

52

76

89

17

11/16

8

5/16

M 10 x 1,25

29 500

43 000

51 000

49

72

84

17

11/16

8

5/16

M 12 x 1,25

45 000

66 000

77 000

87

125

150

19

3/4

10

--

M 12 x 1,5

42 500

62 000

73 000

83

122

145

19

3/4

10

--

M 14 x 1,5

61 000

89 000

104 000

135

200

235

22

7/8

12

--

M 16 x 1,5

82 000

121 000

141 000

205

300

360

24

--

14

9/16

M 18 x 1,5

110 000

157 000

184 000

310

440

520

27

1-1/16

14

9/16

M 18 x 2

102 000

146 000

170 000

290

420

490

27

1-1/16

14

9/16

M 20 x 1,5

139 000

199 000

232 000

430

620

720

30

1-3/16

17

--

M 22 x 1,5

171 000

245 000

285 000

580

820

960

32

--

17

--

M 24 x 1,5

207 000

295 000

346 000

760

1090

1270

36

1-7/16

19

3/4

M 24 x 2

196 000

280 000

325 000

730

1040

1220

36

1-7/16

19

3/4

M 27 x 1,5

267 000

381 000

445 000

1110

1580

1850

41

1-5/8

19

3/4

M 27 x 2

255 000

365 000

425 000

1070

1500

1800

41

1-5/8

19

3/4

M 30 x 1,5

335 000

477 000

558 000

1540

2190

2560

46

1-13/16

22

7/8

M 30 x 2

321 000

457 000

534 000

1490

2120

2480

46

1-13/16

22

7/8

M 33 x 1,5

410 000

584 000

683 000

2050

2920

3420

50

2

24

--

M 33 x 2

395 000

560 000

660 000

2000

2800

3300

50

2

24

--

M 36 x 1,5

492 000

701 000

820 000

2680

3820

4470

55

2-3/16

27

1-1/16

M 36 x 3

440 000

630 000

740 000

2500

3500

4100

55

2-3/16

27

1-1/16

M 39 x 1,5

582 000

830 000

971 000

3430

4890

5720

60

2-3/8

27

1-1/16

M 39 x 3

530 000

750 000

880 000

3200

4600

5300

60

2-3/8

27

1-1/16

Note: Observe notes on front page!

Service-Manual


Tightening torques for screws for SAE split flange installation Not part of factory standard WN 4037 I Listing per LFR - Quality service 2QA 6 051 00 as of Oct. 2001 1. Flange and and half flange for for high pressure pressure (Norm 62) 62) Tightening torques in Nm for screw grade 10.9 Flange nominal size

Screw size

½"

Half flange

flat flange without reinforcement

Flange with reinforcement

M8

31

--

--

¾"

M 10

62

45

65

1"

M 12

108

70

110

1 ¼"

M 14

172

120

180

1 ½"

M 16

264

170

250

2"

M 20

350

250

450

2. Half flange flange for for low low pressu pressure re (Norm (Norm 61) 61)

Flange nominal size

Screw size

½"

Tightening torques in Nm for Screw grade 8.8

Screw grade 10.9

M8

22

31

¾"

M 10

44

62

1"

M 10

44

62

1 ¼"

M 10

44

62

1 ½"

M 12

76

108

2"

M 12

76

108

2 ½"

M 12

76

108

3"

M 14

122

172

3 ½"

M 16

187

264

4"

M 16

187

264

5"

M 16

187

264

Tightening torques for cutting edges, end bits and bolt- on adapters inch

mm

Tightening torque [Nm]

5/8"

16

270

3/4"

19

475

7/8"

22

750

1"

25

1-1/4"

32

Tightening torque [ft. lbs.]

±40

200

±30

±60

350

±90

550

1125

±150

825

1850

±300

1350

±45 ±65

±110 ±220


Service-Manual

Service-Manual

General Information Conversion table

Unit of Measure

Length

Multiply

by

To obtain Multiply

To obtain

by

mm

0,039

inch

25,4

m

3,281

feet

0,305

m

m

1,093

yard

0,914

m

km

0,621

mile

1,609

km

cm²

0,155

sq. inch

6,452

cm²

m²

10,764

sq. feet

0,093

m²

m²

1,196

sq. yard

0,863

m²

km²

0,386

sq. mile

2,59

km²

cm³

0,061

cu. inch

16,387

cm³

m³

35,314

cu. feet

0,028

m³

m³

1,308

cu. yard

0,764

m³

l

61,025 61,0 25

cu. inch

l

0,035

cu. feet

28,316

l

l

0,264

gallon

3,785

l

l

1,057

quart

0,946

l

g

0,035

oz.

28,349

g

kg

2,204

lbs.

0,453

kg

t

1,102

short t

0,907

t

N

0,225

lbs.

4,449

N

kN

224,732

lbs.

0,0044

kN

Torque

Nm

0,737

ft. lbs.

1,356

Nm

Power

kW

1,342

HP

0,745

kW

PS

0,736

kW

1,358

PS

PS

0,986

HP

1,014

PS

Pressure

bar

14,5

PSI

0,069

bar

(hydraulic)

kpa

0,145

PSI

6,896

kpa

Grou round pres ressure

kg/cm /cm²

14,223

kg/m²

0,205

g/cm³

Area

Volume

Weight

Force

Compression

Speed

Temperature Temperature

lbs. sq. inch

l

0,0703

kg/cm /cm²

lbs. sq. ft.

4,878

kg/m²

0,036

lbs. cu. inch

27,78

g/cm³

kg/m³

0,062

lbs. cu. ft.

16,13

kg/m³

km/h

0,621

mph

1,609

km/h

m/min

3,281

ft. / min

0,305

m/min

°C

(°Cx1,8) + 32

°F

(°F-32)/1,8

°C

°C

°C+273

°K

°K-273

°C

General Information Conversion table

Service-Manual

Service-Manual

General Information Hole diameter before tapping

Hole diameter before tapping 1. Hole diameter for tapping ISO standard Metric (internal) thread Thread size M1 M 1,1 M 1,2 M 1,4 M 1,6 M 1,7 M 1,8 M2 M 2,2 M 2,3 M 2,5 M 2,6 M3 M 3,5 M4 M 4,5 M5 M6 M7 M8 M9 M 10 M 11 M 12 M 14 M 16 M 18 M 20 M 22 M 24 M 27 M 30 M 33 M 36 M 39 M 42 M 45 M 48 M 52 M 56 M 60 M 64 M 68

Hole diameter limits max. min. 0,785 0,729 0,885 0,829 0,985 0,929 1,160 1,075 1,321 1,221 1,346 1,258 1,521 1,421 1,679 1,567 1,838 1,713 1,920 1,795 2,138 2,013 2,176 2,036 2,599 2,459 3,010 2,850 3,422 3,242 3,878 3,688 4,334 4,134 5,153 4,917 6,153 5,917 6,912 6,647 7,912 7,647 8,676 8,376 9,676 9,376 10,441 10,106 12,210 11,835 14,210 13,835 15,744 15,294 17,744 17,294 19,744 19,294 21,252 20,752 24,252 23,752 26,771 26,211 29,771 29,211 32,270 31,650 35,270 34,670 37,799 39,129 40,799 40,129 43,297 42,587 47,297 46,587 50,796 50,046 54,796 54,046 58,305 57,505 62,305 61,505

Dimensions are in mm mm x 0,03937 = inches

Drill bit Ø 0,75 0,85 0,95 1,1 1,25 1,30 1,45 1,6 1,75 1,9 2,05 2,10 2,5 2,9 3,3 3,7 4,2 5 6 6,8 7,8 8,5 9,6 10,2 12 14 15,5 17,5 19,5 21 24 26,5 29,5 32 35 37,5 40,5 43,0 47,0 50,5 54,1 57,6 61,6

General Information

Service-Manual

Hole diameter before tapping

2. Hole diameter for tapping ISO fine Metric (internal) thread Thread size M 1 x 0,2 M 1,1 x 0,2 M 1,2 x 0,2 M 1,4 x 0,2 M 1,4 x 0,25 M 1,6 x 0,2 M 1,8 x 0,2 M 2 x 0,25 M 2,2 x 0,25 M 2,5 x 0,35 M 3 x 0,35 M 3,5 x 0,35 M 4 x 0,5 M 4,5 x 0,5 M 5 x 0,5 M 5,5 x 0,5 M 6 x 0,75 M 7 x 0,75 M 8 x 0,75 M8x1 M 9 x 0,75 M9x1 M 10 x 0,75 M 10 x 1 M 10 x 1,25 M 11 x 0,75 M 11 x 1 M 12 x 1 M 12 x 1,25 M 12 x 1,5 M 14 x 1 M 14 x 1,25 M 14 x 1,5 M 15 x 1 M 15 x 1,5 M 16 x 1 M 16 x 1,5 M 17 x 1 M 17 x 1,5 M 18 x 1 M 18 x 1,5 M 18 x 2 M 20 x 1 M 20 x 1,5 M 20 x 2 M 22 x 1 M 22 x 1,5 M 22 x 2 M 24 x 1 M 24 x 1,5 M 24 x 2

Hole diameter limits max. min. 0,821 0,783 0,921 0,833 1,021 0,983 1,221 1,183 1,185 1,129 1,421 1,383 1,621 1,583 1,785 1,729 1,985 1,929 2,201 1,121 2,721 2,621 3,221 3,121 3,599 3,459 4,099 3,959 4,599 4,459 5,099 4,959 5,378 5,188 6,378 6,188 7,378 7,188 7,153 6,917 8,378 8,188 8,153 7,917 9,378 9,188 9,153 8,917 8,912 8,647 10,378 10,188 10,153 9,917 11,153 10,917 10,912 10,647 10,676 10,376 13,153 12,917 12,912 112,647 12,676 12,376 14,153 13,917 13,676 13,376 15,153 14,917 14,676 14,376 16,153 15,917 15,676 15,376 17,153 16,917 16,676 16,376 16,210 15,835 19,153 18,917 18,676 18,376 18,210 17,835 21,153 20,917 20,676 20,376 20,210 19,835 23,153 22,917 22,676 22,376 22,210 21,835

Drill bit Ø 0,8 0,9 1 1,2 1,15 1,4 1,6 1,75 1,95 2,15 2,65 3,15 3,5 4 4,5 5 5,2 6,2 7,2 7 8,2 8 9,2 9 8,8 10,2 10 11,1 10,8 10,5 13 12,8 12,5 14 13,5 15 14,5 16 15,5 17 16,5 16 19 18,5 18 21 20,5 20 23 22,5 22

Thread size M 25 x 1 M 25 x 1,5 M 25 x 2 M 26 x 1,5 M 27 x 1 M 27 x 1,5 M 27 x 2 M 28 x 1 M 28 x 1,5 M 28 x 2 M 30 x 1 M 30 x 1,5 M 30 x 2 M 30 x 3 M 32 x 1,5 M 32 x 2 M 33 x 1,5 M 33 x 2 M 33 x 3 M 35 x 1,5 M 36 x 1,5 M 36 x 2 M 36 x 3 M 38 x 1,5 M 39 x 1,5 M 39 x 2 M 39 x 3 M 40 x 1,5 M 40 x 2 M 40 x 3 M 42 x 1,5 M 42 x 2 M 42 x 3 M 42 x 4 M 45 x 1,5 M 43 x 2 M 45 x 3 M 45 x 4 M 48 x 1,5 M 48 x 2 M 48 x 3 M 48 x 4 M 50 x 1,5 M 50 x 2 M 50 x 3 M 52 x 1,5 M 52 x 2 M 52 x 3 M 52 x 4

Hole diameter limits max. min. 24,153 23,917 23,676 23,376 23,210 22,835 24,676 24,376 26,153 25,917 25,676 25,376 25,210 24,835 27,153 26,917 26,676 26,376 26,210 25,835 29,153 28,917 28,676 28,376 28,210 27,835 27,252 26,752 30,676 30,376 30,210 29,835 31,676 31,376 31,210 30,835 30,252 29,752 33,676 33,376 34,676 34,376 34,210 33,835 33,252 32,752 36,676 36,376 37,676 37,376 37,210 36,835 36,252 35,752 38,676 38,376 38,210 37,835 37,252 36,752 40,676 40,376 40,210 39,835 39,252 38,752 38,270 37,670 43,676 43,376 43,210 42,835 42,252 41,752 41,270 40,670 46,676 46,376 46,210 45,835 45,252 44,752 44,270 43,670 48,676 48,376 48,210 47,835 47,252 46,752 50,676 50,376 50,210 49,835 49,252 48,752 48,270 47,670

Drill bit Ø 24 23,5 23 24,5 26 25,5 25 27 26,5 26 29 28,5 28 27 30,5 30 31,5 31 30 33,5 34,5 34 33 36,5 37,5 37 36 38,5 38 37 40,5 40 39 38 43,5 43 42 41 46,5 46 45 44 48,5 48 47 50,5 50 49 48

Service Manual

General Conservation guidelines

1.5.00 Conservation guidelines 1

General All parts of a construction machine are exposed to corrosion, especially when the machine is taken out of service. Corrosion can can be compared to wear. However, the effects of corrosion corrosion can greatly exceed that of mechanical wear and shorten the service life of the affected parts significantly. For that reason, for for longer longer shut down, down, the ma machines chines and its componen components ts must be preserved according to certain guidelines. guidelines. In general, these guidelines are tiered according to the following times: Taking the machine out of service – for an unknown duration Shut down of the machine Shut down for up to 2 months Shut down for up to 12 months Shut down for longer than 12 months Return to operation The required measures are graduated depending on the different different time frames. The conservation measures measures cannot be strictly standardized and they must be shorted or lengthened depending on the assessment of necessity (such as environmental influences). Such influences are, for example: Placement location of machine (for example in unprotected surrounding, in closed areas, protected by a roof, temperate surrounding) Type of climate (for example extreme temperatures, location in water / near the coast, etc.) Note! For conservation for sea transport, special guidelines must be observed, which are not included in these instructions. Refer to the special operating instructions.

2

Taking the machine out of service – for an unknown duration If a machine is taken out of service for a longer period of time without conservation, then it must be operated in intervals not to exceed 14 days , to prevent abnormal corrosion and its effects. Before putting the machine back into service, check all oil levels and correct them, if necessary. Always carry out the specified daily daily maintenance maintenance work before putting putting the machine machine back into into service. In addition, carry out the time limited maintenance work according to the inspection schedule and additional Diesel engine Operating instructions no later than the specified intervals. Put the machine into operation according to the Operating instructions and operate it until the Diesel engine and the hydraulic system has reached the specified operating temperature in the hydraulic tank and in the coolant circuit. Actuate all functions functions of the travel, travel, working hydraulic hydraulic as well as as functions of additionall additionally y installed hydraulic components and alternately operate them over a period of approx. 20 minutes. The hydraulic cylinders must be extended and retracted over their full stroke length. When turning the machine off, retract all hydraulic cylinders fully, if possible, and fill the fuel tank. If the machine is parked on soft ground, park the machine on wooden planks or similar and secure it to prevent it from rolling off. Check the batteries batteries and remove remove them and and recharge them, if necessary. necessary. Check the electrical electrical contact points and grease them, if necessary.

General

Service Manual

Conservation guidelines

3

Shut down of the machine Preparations for shut down Park the machine on horizontal, dry and solid ground and secure it to prevent it from rolling off. Lower the working attachment to the ground level so that there is no longer any residual pressure of the hydraulic. Clean the machine diligently according to the procedure outlined in the Operating instructions. The machine must be completely dry before starting the conservation measures. Dry electronic components and damp areas on the machine with pressurized air. If freezing temperatures are expected for the intended duration of shut down, then the fuel tank must be filled with winter fuel. Then start the Diesel engine and let it run for some time to bring the winter fuel into the fuel circuit. Then add enough fuel to the fuel tank until it is full. Note! When a conserved machine is moved for loading or transport, then the conservation protection on the piston rods of the cylinders will most often be removed by the scraper ring. For that reason, if the machine is transported, the conservation of the piston rods must be rechecked after loading and carried out again, if necessary. Note! Despite completed conservations conservations measures, the machine must still be inspected in certain intervals and touched up, if necessary. This is wi thin left to the discretion of the operator, but these inspections should be carried out r egularly (monthly), especially in aggravated conditions (cold, heat, near the coast, etc.).

3.1

Shut down for up to 2 months Required tools / Service items Description

Id. No.

Description

See section 2.1

To check the battery condition and the antifreeze in the coolant

WAXOYL 120-4 Anti corrosion wax wax

8504472

Ballistol Spray Corrosion protection Dehumidification capsule

10025514

Spray can 500ml Long term protection for up to 2 years Application area: Door locks Prevents infiltration of moisture over an extended period of time

Optical charge tester

10013313

Display

Check the entire machine for damage and remedy, if necessary. Check the machine for paint damage and remedy, if necessary. Take care of any maintenance work which would fall within the timeframe of the planned shut down. Due to the UV exposure of the components, synthetic materials, such as plastic parts, hoses, rubber etc. must be covered with suitable aids. Electrical components, contact points and plug connections which are not sealed must be sealed with conservation wax „Waxoyl 120-4“.

Service Manual


Apply a thick layer layer of conservation conservation wax „Waxoyl 120-4“ 120-4“ to cover ball ball joints, hinges, hinges, blank parts and exposed piston rods. (Do not protect ball bearings with Waxoyl!) Place a dehumidification capsule into the central electric box. Protect all door and container locks with „Ballistol Spray“. Set the battery master switch (if present) to position „0“ and then remove the batteries. Check the battery acid level level and add distilled distilled water, if necessary. Always store the batteries batteries in a cool and and dry area. Check the load current regularly every every 6 weeks and recharge, if necessary. Close the exhaust outlet with an air and watertight cover. Pay attention to any additional additional guidelines for special compone components nts or special local conditions.

3.2

Shut down for up to 12 months Carry out all measures according to paragraph 3.1. In addition, the following is required: Clean the Diesel engine externally. Drain water from the fuel tank or condensation of the Diesel engine prefilter (see Operating instructions). Add commercially commercially available Diesel fuel to the the fuel tank until it is completely full. full. If the shut down is during the cold time of the year, fill the fuel dank with winter Diesel fuel (Winter Diesel fuel is suitable up to a temperature of -22°C / -7.6°F). Then start the Diesel engine and let it run for some time to bring the winter fuel into the fuel circuit. Then add enough fuel to the fuel tank until it is full. Check the coolant to ensure it has sufficient corrosion and antifreeze protection - at least 50% corrosion inhibitor antifreeze fluid (for guidelines refer to the Operating instructions). Seal the entire machine (Diesel engine, hydraulic aggregates, aggregates, main frame, tank, travel gear / axles, equalizer bar, working attachments, etc.) with preservation wax „Waxoyl 120-4“. (Amount of preservative agent: An area of approx. 5m² can be treated with one liter Waxoyl) Note! The following points must be observed when applying the corrosion inhibitor wax: Observe a drying time of 3 hours. Ambient temperature temperature at least least +15°C / 59°F. Use protective equipment (breathing protection, safety glasses, respirator, etc.). The solvents of the anti corrosion wax are flammable! (Do not smoke and avoid open flames!) Cold resistant to a temperature of -40°C / -40°F.

Release the chain tension by relieving r elieving the tension cylinder (see Operating instructions). instructions). Check the machine monthly and reapply conservation protective measures if necessary.

General

Service Manual

Conservation guidelines

3.3

Shut down for longer than 12 months Carry out all measures according to paragraph 3.1 and 3.2. In addition, the following is required: Note! If a shut down for longer than 12 months is scheduled, then contact the Service Dept. of the Diesel engine manufacturer.

Close off all openings, such as air filter, exhaust pipe, vent openings on components, etc. airtight. The vent for the fuel tank (if present) must remain open for safety reasons! Rub the rubber seal of the cab and containers with talcum powder, close the doors. If the cab is not installed, installed, cover the operator’s operator’s platform properly. properly. If necessary, remove remove the operator’s operator’s seat. Cover the instrument panel and protect it.

4 4.1

Return to operation After a shut down of 2 months Remove the dehumidification capsule from the electronic box. Check the fill levels and lubricate the machine according to the Operating instructions. Install the batteries and clean / grease the battery terminals. Open the exhaust outlet. Drain water from the fuel tank or drain any condensation condensation of the Diesel engine prefilter (see Operating instructions). Clean anti corrosion wax from ball joints, hinges, blank parts and exposed piston rods. Put the machine back into service as outlined in the Operating instructions. Before working with the machine, check all functions of the machine and remedy and defects immediately. Carry out a thorough visual inspection on the machine. Actuate all functions functions of the travel, travel, working hydraulic hydraulic as well as functions of additionally additionally installed hydraulic components and alternately operate them over a period of approx. 20 minutes. The hydraulic cylinders must be extended and retracted over their full stroke length. Observe any additional guidelines for special components or special local conditions.

4.2

After a shut down of 12 months Carry out the items according to paragraph 4.1. Take an oil sample of the hydraulic oil and send it in for analysis. Carry out the scheduled maintenance maintenance and inspection work on the machine before putting it back into service. On the Diesel engine, mechanically actuate the AGR flap (exhaust return) and the engine brake flap and check for easy movement. Grease the V-belts! Use a high pressure cleaner with steam (at least 120°C) as well as 5% additive of solvent (such as petroleum) to clean the anti corrosion wax from the machine and aggregates. (Caution when walking on surfaces, there is a danger of slipping due to the wax residue.) Check the V-belt of the Diesel engine and replace it if necessary. Carry out a Diesel engine test run: Increase the Diesel engine rpm only slowly to ¾ of the high idle rpm until the operating temperature is reached. Check the oil pressure display immediately after starting the Diesel engine. Check the vacuum display of the air filter. Adjust the chain chain tension to suit the application application (see Operating Operating instructions). instructions).

Service Manual


4.3

After shut down of longer than 12 months Complete all items outlined in paragraph 4.2 and 4.1. Note! After a scheduled scheduled shut down down of longer than than 12 months months contact the Service Service Dept. of the Diesel engine manufacturer. Remove all covers and closures, which were installed for conservation measures. measures.

Turn the Diesel engine manually a few turns (use the turning device - flywheel – see Special tools). Start the machine and bring it to operating temperature. After the machine machine was brought brought to operating operating temperature, change change all lube and service service fluids as well as filters fil ters according to the Operating instructions Check the entire machine for function and for leaks. If necessary, carry out any time limited maintenance work at this time.


Service Manual

Service-Manual

General Information Weight of materials

Weight of materials 1)

Material

Basalt Bauxite, kaolin Carnotite, uranium ore Cinders Clay - natural bed - dry - wet Clay with gravel - dry - wet Coal - anthracite - raw - washed Coal - ash - bituminous coal Coal - bituminous coal - raw - washed Earth - dry packed - wet excavated - loam Granite - broken Gravel - pitrun - dry - wet 6-50mm - dry 6-50mm Gypsum - broken - crushed Hematite, iron ore Limestone - broken - crushed Magnetite, iron ore Pyrite, iron ore Rock - decomposed 75% rock, 25% earth Rock - decomposed 50% rock, 50% earth Rock - decomposed 25% rock, 75% earth Sand - dry , loose - damp - wet Sand with clay - loose - compacted Sand with gravel - dry - wet Sandstone Shale Slag - broken Snow - dry - wet Stone - crushed Top soil Trapp rock - broken

Bank 3 kg/m 2970 1900 2200 860 2020 1840 2080 1660 1840 1600 590 - 890 1280 1900 2020 1540 2730 2170 1690 1900 2260 3170 2790 2130 - 2900 2610 3260 3030

Swell in % 52 33 35 54 22 24 24 17 19 35 35 8 35 35 26 26 23 64 12 12 12 12 75 75 18 69 17 18

Swell Factor 0,66 0,75 0,74 0,65 0,82 0,80 0,80 0,86 0,84 0,74 0,74 0,93 0,74 0,74 0,79 0,79 0,81 0,61 0,89 0,89 0,89 0,89 0,57 0,57 0,85 0,59 0,86 0,85

Loose 3 kg/m 1960 1420 1630 1560 1660 1480 1660 1420 2540 1190 1100 550 - 830 950 830 1510 1600 1250 1660 1930 1510 1690 2020 1810 1660 1810 - 2450 1540 1540 2790 2580

2790

42

0,70

1960

2280

33

0,75

1720

1960

24

0,80

1570

1600 1900 2080 2020 1930 2230 2520 1660 2940 2670 1370 2610

12 12 13 26 12 10 67 33 68 67 44 49

0,89 0,89 0,88 0,79 0,89 0,91 0,60 0,75 0,59 0,60 0,69 0,67

1420 1690 1840 1600 2400 1720 2020 1510 1250 1750 130 520 1600 950 1750

1) Varies with moisture moisture content, content, grain size, degree degree of compaction, compaction, etc.. Test must be made to determine exact material characterics.

General Information Weight of materials

Service-Manual

Service Manual

Tools and work instructions Sub group index

Sub group index – Tools and work instructions Special tools

2.1

Repair welding

2.2

Installation instructions

2.3

Tools and work instructions Sub group index

Service Manual

Service Manual

Tools and work instructions Special tools

2.1.00 Special tools General The following section is divided into three sections: 1 Special tools - Maintenance 2 Special tools - Repairs 3 Special tools for in-house manufacture Special tools for maintenance are a must-have to carry out the maintenance and inspection schedule. In addition, some tools are necessary aids for troubleshooting. troubleshooting. Special tools for repairs are only required in case of a repair of the affected components. Special tools for in-house manufacture can be made in-house as necessary. The drawings to make them are made available by the manufacturer.

1 1.1

Special tools - maintenance Diesel engine

Description

Id. No.

M-Type

Sculi – Diagnostics software accessories Consists of: Sculi License with USB Dongle for Engine Service  Level (LH ECU UPCR-, DC4-, DC5- Engine control units and Master 4 controls)

Communication cable for LH-ECU-UPCR  control units

Communication cable for DC4 / DC5  control units

10450054

LR Series 4 RL Series 4 PR 724 S/Nxxx724 S/Nxxx9200 PR 734 S/Nxxx734 S/Nxxx8220 PR 744 S/Nxxx744 S/Nxxx7356 PR 754 S/Nxxx754 S/Nxxx6924 PR 764 S/Nxxx764 S/Nxxx6888

10035410

10035411

LR Series 4 RL Series 4 PR 724 S/Nxxx724 S/Nxxx9200 PR 734 S/Nxxx734 S/Nxxx8220 PR 744 S/Nxxx744 S/Nxxx7356 PR 754 S/Nxxx754 S/Nxxx6924 PR 764 S/Nxxx764 S/Nxxx9506 PR 764 S/Nxxx764 S/Nxxx6 88 8 9 5 05

Remarks

Diagnostics software for Diesel engine maintenance and adjustment. For ordering, a Liebherr form from Mjfcifss Bulle must be filled out. Download the current software version with the aid of the Lidos DVD.

Use of Sculi software also possible with the previous DC-Desk Dongle.

Illustration Illustratio n

Tools and work instructions

Service Manual

Special tools

Description Digital RPM gauge „Shimpo“

Id. No. 7364284

M-Type

Remarks

PR Series 4 LR Series 4 RL Series 4

To measure the RPM with Reflexion strip Test range: 6-8300 rpm ±1 rpm

Reflexion strip

614063201

Digital RPM gauge „Piezzo A2106“

10286429

PR 724 S/Nxxx724 S/Nxxx66 00 9 19 9 PR 734 S/Nxxx734 S/Nxxx62 00 8 21 9 PR 764 S/Nxxx764 S/Nxxx68 88 9 50 5

To measure the engine RPM via the impulse frequency of the injection line

DCA 4 Test Kit „CC2602M“ Consists of: Container 50 Test strips Clear plastic container Pipette

5608459


To check the DCA4 concentration concentration in the coolant

Hand pump [1]

8145666


To take oil samples for oil analysis

Oil sample valve for oil samples [2]

7019068


Analysis at WEAR WEAR CHECK Germany

Oil analysis set – Mineral oil (green lid) Individual set 4 Sets 6 Sets 12 Sets Oil analysis set – Bio oil (yellow lid) Individual set 6 Sets

8145660 10029626 7018368 7018369

7026817 7026088


Service Manual


Description

Id. No.

M-Type

Remarks

V-belt tester „Krikit2“

8042829


To check the Vbelt tension

Optical battery charge tester

7408922


To check the condition of the battery charge and the antifreeze in the coolant

0524045

LR Series 4

To be installed on the flywheel housing instead of the cover

Turning device to check / adjust the valve play Pos. 1

RL Series 4 PR Series 4 except Pos. 2

10490350 10116805

Hand pump with pressure gauge

10454803

PR 764 S/Nxxx764 S/Nxxx9506 RL 64 (can also be used for PR 724 F/Nxxx724 F/Nxxx9200 PR 734 F/Nxxx734 F/Nxxx8220 PR 744 PR 754 LR 624 LR 634 RL 44 )

To be installed on the V-belt crankshaft


For optional Diesel particle filter. Can be used for leak tests of counter-pressure line



Service Manual

Special tools

1.2

Hydraulic system

Description Vacuum pump, cpl. with accessories

Consists of: Vacuum pump with electrical cable Hose fitting Hose fitting Fitting S8M Fitting L6R PVC hose Terminal clamp, positive Terminal clamp, negative Plug 2-pin Temperature gauge

Id. No. 7408148

M-Type

Remarks


To bleed the hydraulic system quickly, can create a slight overpressure (approx. 0.4 bar) by changing over the PVC hose. Connection point for the vacuum pump on the machine is the breather screw on the hydraulic tank


Accuracy: 2% / 2°

7407987 7407985 10301165 7404619 4901110 7360127 10038447 10038448 7408151 10024185

Test range: -18°C to +260°C

Difference pressure test kit 230V/120V

10288229

Consists of: Test unit Multi-Handy Multi-Handy 2045 2 Pressure sensors 0600 bar 2 Mini test connections connections 2 Test cable 12m long KFZ Connector cable Data cable Power unit Scale pressure gauge 0-10 0-25 0-40 0-60 0-100 0-160 0-250 0-400 0-600 0-1000

5002865 7361289 7361288 5002867 5602903 7361286 7361285 7500002 7361294 4601115


To measure pressure, pressure peaks and pressure difference and suitable for data transfer to PC


Accuracy: 1% of scale limit value All pressure gauges are glycerin filled


Service Manual


Description Pressure gauge connection R½

Id. No. 7002436

Test fitting cpl.

R6L R 10 L R 12 L

7409916 7406864 7409918

Screw coupling

M 8x1 M 10x1 M 12x1,5 M 14x1,5 R¼

7615321 5608462 7407071 7406865 7409720

Bulkhead screw coupling

M 16x2

Remarks


To seal at pressure checks, a square seal ring Id.No. 7409794 must be inserted


Union nut and cutting ring are permanently installed on the test fitting


To connect to additional additional test points on the machine


To connect shorter test lines or for connections between test connection and pressure sensor


To keep the loss of pressure to a minimum during tests, use shorter test hoses, if possible


To loosen / counter when setting the pump regulating range


To loosen / counter when adjusting the pump limit stop

7407070

Test hose NW 2

1000 mm 1500 mm 4000 mm 5000 mm

M-Type

7002437 7002475 7009134 7363732

Hook wrench

58 - 62 mm

7900282

Socket wrench for grooved nut variable displacement pump HPV

9792711

Use with hook wrench Id. No. 7900282



Service Manual

Special tools

Description Socket wrench for 0-position grooved nut - variable displacement pump HPV

Id. No. 9749025

Test plates For SAE-flange ¾ A 90mm B 40mm C,r 5mm For SAE-flange 1 A 90mm B 44mm C,r 5mm For SAE-flange 1¼ A 90mm B 52mm C,r 5mm Line wrench SW 30/32

7370092

M-Type

Remarks


To loosen / counter the grooved nut when setting the 0position


To close off high pressure connections Material: Spring steel (ground), taper rounded off plate end (simplifies installation, prevents damage to the seal ring)


Line wrench to check or replace the return filters. Can also be used for other connections.

7370093

7370094

Or make in-house 8006305


Service Manual


1.3

Electrical system

Description LinDiag Diagnostics Diagnostics KIT

Id. No. 9413782

Consists of: Data carrier with current software version + Dongle Adapter cable cable LinDiag Diagnostics KIT

9410472

M-Type

Remarks

PR 724 S/Nxxx724 S/Nxxx6 6 00 9 1 9 9 PR 734 S/Nxxx734 S/Nxxx6 2 00 8 2 1 9 PR 764 S/Nxxx764 S/Nxxx6 8 88 9 5 0 5

To adjust the travel hydraulic, read out Service Codes and for troubleshooting in Series 4 machines of exhaust stage Tier2

LR Series 4 RL Series 4

To adjust the travel hydraulic, read out Service Codes and for troubleshooting in Series 4 machines of exhaust stage Tier3

9932747 9413763

Consists of: Data carrier with current software version + Dongle Adapter cable cable

10035410 10035410

USB – adapter

693190714


Intermediate adapter from serial interface to USB

Digital multi meter complete with cable and bag

10018500


for Voltage (V) Amperage (A)(A)Resi Resist stan ance ce ( )Frequency Frequency (Hz)(H z)tests

see Pt. 1.1 Diesel engine


To check the battery charge and the antifreeze in the coolant

Optical charge tester

9410472

PR 724 S/Nxxx724 S/Nxxx9200 PR 734 S/Nxxx734 S/Nxxx8220 PR 744 S/Nxxx744 S/Nxxx7356 PR 754 S/Nxxx754 S/Nxxx6924 PR 764 S/Nxxx764 S/Nxxx9506



Service Manual

Special tools

1.4

Mechanical components

Description

Id. No.

Test tool for tracks

7402603

M-Type

Remarks


To measure track wear


For applications, applications, see section 12.2

2 2.1

Special tools - Repairs Diesel engine Note! The special tools for Diesel engine repair are listed in the Diesel engine workshop manual.

2.2

Hydraulic system

Description Pressurized air cartridge

Brake vent adapter

Id. No. 10045498

9401975

Socket wrench Valve sleeve Valve – 3 Slits

10430260

Valve – 2 Slits

10491131

M-Type

Remarks

LR Series 4 RL Series 4

CO2 cartridge to vent the parking brake for towing operation.

PR 724 S/Nxxx724 S/Nxxx7697 PR 734 S/Nxxx734 S/Nxxx8220 PR 744 S/Nxxx744 S/Nxxx7356 PR 754 S/Nxxx754 S/Nxxx6924 PR 764 S/Nxxx764 S/Nxxx6888


Adapter for pressurized air cartridge (part of tool kit)

For repair of var. displ. motor HMV For removal and installation of the valve sleeve of the directional valve See section 8.2 Position 73


Service Manual


Description

Id. No.

M-Type

Mandrel Thrust ring

HPV 105

10472254

HPV 135

10472255

HPV 210

10472257

HMV 165

10472261

HMV 210

10472266

HPV 280

10472269

HMV 280

PR 724 LR 624 PR 734 LR 634 RL 44 PR 744 PR 764 PR 744 LR 624 PR 724 PR 754 LR 634 RL 64 PR 754 RL 64 PR 734 PR 764 RL 44

Remarks

For repairs of var. displ. pump HPV or var. displ. motor HMV For the installation of the hot thrust ring onto the drive shaft. See section 8.1 or 8.2. Position 11

For repairs of var. displ. pump HPV or var. displ. motor HMV

Mandrel [1] and protective sleeve [2] for shaft seal ring

HPV 105 HPV 105

1 2

10472303 10411001

PR 724 LR 624

HPV 135 HPV 135

1 2

10472310 10411002

HMV 165 HMV 165

1 2

10472316 10410291

PR 734 LR 634 RL 44 PR 744 LR 624

HMV 210

1

10472317

HPV 210

1

HMV 210

2

HPV 210

2

HMV 280

1

HPV 280

1

HMV 280

2

HPV 280

2

10410295

10472318

10411003

PR 724 PR 754 LR 634 RL 64 PR 744 PR 764 PR 724 PR 754 LR 634 RL 64 PR 744 PR 764 PR 734 PR 764 RL 44 PR 754 RL 64 PR 734 PR 764 RL 44 PR 754 RL 64

For pressing in the radial shaft seal ring to push over the drive shaft (in connection with the corresponding protective sleeve) See section 8.1 or 8.2 Position 12



Service Manual

Special tools

Description

Id. No.

M-Type

Installation aid seal ring on oil guide tubes

Pos.1 HPV + HMV

10472322

Pos.2 HPV 105

10472321

Spindle device for swash plate mount

10324938

RL Series 4 LR Series 4 PR Series 4 except PR 724 LR 624


Remarks

For repairs of var. displ. pump HPV or var. displ. motor HMV The installation aid is used to install the O-rings onto the oil guide tubes See section 8.1 Position 46 or section 8.2. Position 45 For repairs of var. displ. pump HPV

With this device, the swash plate mount can be aligned and lowered properly onto the pump housing at installation. Centering pins for swash plate mount

M12

HPV

10472319

M14

HPV

10472320

M14

HMV

M16

HPV

M16

HMV

10347066

PR 724 LR 624 PR 734 PR 744 PR 764 LR 634 RL 44 PR 724 PR 744 PR 754 LR 624 LR 634 RL 64 PR 754 RL 64 PR 734 PR 764 RL 44

For repairs of var. displ. pump HPV or var. displ. motor HMV The guide pins are used to guide the swash plate mount with the pump housing at assembly. minimum 2 each maximum 4 each required


Service Manual


Description

Id. No.

Centering device for swash plate mount

10324937

M-Type

Remarks


For repairs of var. displ. pump HPV or var. displ. motor HMV


Device to affix the oil guide tubes at installation of the swash plate mount 2 each required Note! The Id. Numbers for the following tools are listed in the spare parts list for the hydraulic cylinders. Installation Installati on sleeve

See spare parts list

To install the Oring and step seal ring on pistons of hydraulic cylinders

Spreader sleeve


To install the Oring and step seal ring on pistons of hydraulic cylinders

Installation wrench Piston


To tighten the pistons of hydraulic cylinders For tightening torques, see section 8 Hydraulic cylinders

Installation wrench Piston nut


To tighten the piston nut of hydraulic cylinders For tightening torques, see section 8 Hydraulic cylinders


Service Manual

Special tools

2.3

Electrical system

Description

Id. No.

Crimper for MATE-N-LOK Crimp contacts

M-Type

Remarks


To make proper crimp connections connections on MATE-N-LOK plug connections


To remove crimp contacts from plug connector

For 1.5 mm² For 2.5 mm²

7367025 7366314

Removal tool AMP for MATE-N-LOK Crimp contacts

7366655

Spare insert

7015180

Installation tool AMP for MATE-N-LOK Crimp contacts

8145432


To insert pin and bushing contacts into the MATE-N-LOK plug connectors

Hand crimper for plug connector „Deutsch“

8503647


To make proper crimp connections connections


To remove pin and bushing contacts in „Deutsch“ plug connectors


To remove pin and bushing contacts in „Deutsch“ plug connectors (Alternative)

Removal tool Cannon for Crimp contacts „Deutsch“

AWG 12 AWG 16 AWG 20

10114733 885563714 10114732

Removal tool Cannon for Crimp contacts „Deutsch“ ( Alternative) Alternative)

AWG 12 AWG 16 AWG 20

8145674 8145673 8503630


Service Manual


Description Crimper AMP AMP Certi-Lock

Id. No. 7415333

Removal tool AMP

AMP 726 503-1 503-1 AMP 726 534-1 534-1

7026266 7027340

Crimper

ESA 0760 CRB 0560

7409781 7409782

M-Type

Remarks


To crimp the contacts „JUNIOR POWER TIMER“


To remove contacts from „JUNIOR POWER TIMER“ housing


To crimp insulated cable shoes 0.5  6.0 mm² Or cable connector, CRB 0560 also windshield wiper motor

Coding plug Inching / brake pedal

X46

9813111

X46.1

9413850

PR Series 4 RL Series 4 LR Series 4

In case of defective inching / brake pedal for continued operation of the machine. See section 9. Inching / brake pedal



Service Manual

Special tools

2.4

Mechanical components

Description

Id. No.

M-Type

To properly install the slip ring seals on travel gears

Installation device for slip ring seal – travel gear FAT 400 E 511 Slip ring seal Id.No. 7361 197 outside 7109 24901 inside FAT 450 E 504/505 FAT 450 E 510 Slip ring seal Id.No. 7109 25201 outside 7109 26301 inside FAT 500 E 502/503 FAT 500 E 517/518 Slip ring seal Id.No. 7610 242 outside 7361 197 inside FAT 600 E 506 Slip ring seal Id.No. 7610 244 outside 7610 240 inside FAT 650 E 508 Slip ring seal Id.No. 7610 245 outside 7610 241 inside FAT 700 E 501 Slip ring seal Id.No. 7610 237 outside 7610 243 inside

LR 624

Device No.: 07590 45459 07590 45458

10467795 10467796 PR 724 LR 634

Device No.: 07590 38616 07590 43327

10219780 10219779 PR 734 RL 44

Device No.: 07590 39022 07590 43326

10017428 10219781 PR 744

Device No.: 07590 38891 07590 38472

10017436 10303340 PR 754 RL 64 10017433 10017472

B

Pos.2 Screw in handle for all installation flanges

Device No.: 07590 39023 00100 01300

PR 764

Device No.: 07590 41338 07590 38886

10017468 10017430

Mandrel Pos.1 Installation flange A

Remarks

9786683 9786685 9786686

9786684 9786687 9411074

9786688

PR 724 PR 734 PR 744 PR 754 PR 764 PR 724 PR 734 PR 744 PR 754 PR 764 PR Series 4

To install the radial shaft seal rings into the hoist cylinder bearing See section 15.2 A= for Pos.10 B= for Pos.7 For dimensions for in-house manufacture, see 3.


Service Manual


Description

Id. No.

Puller

Commercially available tool

M-Type

Remarks

PR Series 4

To pull out bushings Pos.3 und Pos.4 from the hoist cylinder bearing


To install and remove the elastic bearing of the operators platform

Pos.1 with support Pos.2 for the following dimensions (in mm)

A B C D

PR 724

PR 734

90 70 247 89,5

90 70 273 96

Puller Elastic bearing  operators platform

Installation sleeve Equalizer bar bearing

PR744 PR754 PR764 120 90 273 114

9404645

9415227

In-house manufacture

Installation wrench Tension unit

Installation tool Tension unit

9416915

PR 764

LR Series 4 RL Series 4 PR 724 PR 734 PR 744 PR 754 PR 764 PR 754 RL 64

9416913

PR 764

9416922

PR 754 RL 64

9416921

PR 764

For dimensions for in-house manufacture, see Pt. 3. To install the outer equalizer bar bearing For dimensions for in-house manufacture manufacture of installation sleeve, see 3.

Special hook wrench to loosen and attach the ring nut

Sleeve to push on the ring nut  prevents twisting of the ring nut



Service Manual

Special tools

Description

Id. No.

M-Type

Remarks

PR 754 RL 64

To remove / install the tension unit – chain tensioner is required!


Pos.1 Installation flange Pos.2 Bar Pos.3 Hex head screw 6 each M16x310 mm  10.9

9798353 9798352 4601217

Installation tool cpl.

9415198

PR 764

Mechanical device (without hydraulic components)

10303939

LR Series 4

10307625

RL 44

Hydraulic components for installation tool

10303852

LR Series 4 RL 44


Consists of: Hydraulic cylinder Enerpac RC 506 Hydraulic hose Enerpac HC- 7206 Pressure gauge Enerpac GF- 50B Intermediate section Enerpac GA-2 Hand pump Enerpac P80


For application, see section 12 Tension unit To remove / install the tension unit – chain tensioner is required!

For application, see section 12 Tension unit

Technical data – Hydraulic components Hydraulic cylinder

Hand pump

Hydraulic hose

Pressure gauge

Enerpac RC 506 (50 t simple acting)

Enerpac P80 (two stage hand pump)

Enerpac HC-7206

Enerpac GF-50B

3

Piston surface

71,2 cm

Oil volume

1131cm Leve Leverr fo forc rce e ma max. x.

Weig We ight ht Overall height Retracted Extended outside

Operating pressure max.700ba

3

23,1 23,1kg kg 282mm 441mm 127mm

Weig We ight ht

47.0 47.0kg kg 10.9 10.9kg kg

9,5 x 1800mm

Pressure range 0-700bar

Service Manual


Description Installation sleeve Equalizer bar

Id. No.

M-Type

Remarks


10306449

PR 754

To press the equalizer bar in or out at oscillating track rollers. For dimensions for in-house manufacture, see 3.

3 3.1

Special tools for in-house manufacture Installation sleeve for equalizer bar bearing, outside For installation of the outer equalizer bar bearing  see section 15.3.

Fig. 1 Dimensions of installation sleeves

Type

Machine

1

PR 724 LR 624 PR 734 LR 634 PR 744 PR 754 RL 44 RL 64 PR 764

2

3

A

B

C

D

E

F

G

H

100

130

75

---

---

---

---

---

---

120

150

100

---

---

---

---

---

---

81,5

137

120

91

115

35

7

13

129

83

149

120

101

135

---

7,5

12,8

---

I


Service Manual

Special tools

3.2

Mandrels For the installation of the radial shaft seal rings into the hoist cylinder bearing.

Fig.2 Dimensions of mandrels – screw-in handle and punch

See also section 15.2 Hoist cylinder suspension. Punch A...... ............. ....... for Pos.10 Punch B...... ............. ....... for Pos.7

M-Type PR724 PR734 PR744 PR754 PR764

Punch A B A B A B A B A B

* Edges rounded off All dimensions dimensions in [mm]

Dimensions D -0,3 Ø119 -0,3 Ø71 -0,3 Ø139 -0,3 Ø89 -0,3 Ø149 -0,3 Ø94 -0,3 Ø149 -0,3 Ø94 -0,3 Ø149 -0,3 Ø94

E ±0,1 Ø89 ±0,1 Ø57 ±0,1 Ø109 ±0,1 Ø69 ±0,1 Ø119 ±0,1 Ø74 ±0,1 Ø119 ±0,1 Ø74 ±0,1 Ø119 ±0,1 Ø74

F 13 9 14 11 14 12 14 12 14 12

G 23 18 23 18 23 18 23 18 23 18

Service Manual


3.3

Removal tool – operator’s cab bearing To install and remove the elastic bearing of the operators platform. See section 17.1 Position 11 und 22.

Fig. 3

1 2 3

3.4

Dimensions of removal tool

Threaded rod M30 Sleeve Washer

4 Washer 5 Shim M30 6 Nut M30

Installation sleeve – Equalizer bar To press the equalizer bar in or out on oscillating track rollers. See section 2.3 Installation notes .

Fig. 4 Dimensions of installation sleeve for equalizer bar

Continuous fillet weld 4mm


Service Manual

Service-Manual

Special Tools, Application Guidelines Repair welding

Repair welding Before starting any welding work on PR Series 4 machines, various electronic parts and components must be unplugged to prevent damage to the machine. Note! See operating instructions: Preparations for maintenance In addition, for arc welding, the ground terminal of the welding unit should be connected in the immediate vicinity of the blank work piece, which is to be welded. 1. Prepa Preparat ration ion of of a crack crack The crack must be free of paint, grease and dirt. To prevent the crack from extending during the preparation or the welding process, the end of the cracks should be drilled with a hole of at least 0.32" (8mm) in diameter. The crack should now be ground, chiseled, torch cut or arced out at a 60° angle. Be certain the edges are clean and extend through the full cross section of the material, without exceeding the 0.04" (1 mm) space in the lower part. On larger grooves, a welding safety should be installed.

Certain materials must be preheated to 300°F (150°C) prior to welding. Special preparations are necessary when preparing a crack in manganese steel. Due to its hardness, mechanical preparation, such as a chisel or hobbing machine is not possible. We suggest that the crack is prepared with a slow running and water cooled grinding wheel to prevent overheating. Other possibilities for preparing cracks or removing high alloy welding seams are the use of cutting electrodes of the type UTP 82 AS. 2. Prepa Preparat ration ion of a weld weld The area to be welded must be free of paint, grease, oil, moisture and dirt. During rain, the area to be welded must be covered. Materials with a thickness above 0.60" (15 mm), high carbon steel or steel which is difficult to weld, the material must be preheated to approximately 176°- 392°F (80°- 200°C). Pre-heating is also necessary when the ambient or component temperature is below 40°F (5°C) or when the construction of the component prevent the welding stress to be released. 3. Storin Storing g Elect Electrod rodes es Use only dry and undamaged electrodes. Electrodes which are rusty or damaged should not be used. Electrodes should be stored in a dry room with a minimum temperature of 59°F (15°C). Open packages should be carefully closed and stored after the welding work is completed.

Special Tools, Application Guidelines

Service-Manual

Repair welding

4. Weldin Welding g Tec Techni hniqu que e The welding of material with the necessary electrodes (see table under paragraph 7) is in accordance with DIN 1912. The adjustment of the welding machine - dictated by the different thicknesses of the electrodes - can be taken from the table of the electrode package. Beginning with a material thickness of 1/4" (8 mm), butt welds must be made in several layers. The weld is applied in several beads. Wide butt welds are filled with several side by side beads, with the last layer covering the center. The electrode should melt evenly without creating burrs and peaks. The valley or crater, which is created when changing electrodes must be filled in and overlapped with the next electrode. To prevent cracks in those craters, care must betaken that they are properly filled. If the crack extends towards the outer edge of the material, slag may be trapped or burn holes may be created. To prevent this, the following aid may be used: Tack a piece of sheet metal to the outer edge of the material. The welding seam begins now at the sheet metal in the direction of the arrow. After the welding is completed, the sheet metal is removed and the edge of the material is ground smooth.

The weld must cool off slowly and should therefore be protected from rain and wind. 5. Reinforc Reinforceme ement nt of the the welding welding seam seam If the crack of the material is due to an overload or abuse, a reinforcement plate should be welded over the crack. The selection of the correct reinforcement plate is based on the construction and load factors of the component to be repaired. For this reason, only general recommendations can be made as to the size and shape of the reinforcement plates. 6. General General applicat application ion of reinforce reinforcement ment plates plates 6.1. Shape of reinforcement reinforcement plates plates The crossover or connection between the reinforced and not reinforced part should be as gradual as possible. This means that the size of the plate should be selected in such a way that new or unacceptable high stress in the repaired parts are avoided. Plates with sharp corners (such as a rectangular plate) should not be used.

Suitable reinforcement plate with high tensile strength.

Suitable reinforcement plate against bending and alternating loads.

Service-Manual


6.2. Plate Thickn Thickness ess The thickness of the reinforcement plate should be up to 2/3 (66%) of the thickness of the material to be reinforced. 6.3. Plate Quality Quality The yield and tensile strength of the reinforcement reinforcement plate should be equal to the material to be reinforced. 6.4. Plate Installa Installation tion The welded welded area of the crack should be ground so it is smooth and level. The size of the plate must be selected in such a way that the longer sides of the plate extend into the connecting construction of the material to be reinforced. The plate should also overlap the crack on each side by at least 1" (20 mm). The correct position and fit of the reinforcement plate is achieved through clamping and spot welding. 6.5. Plate Welding Welding The reinforcement plate should be welded on by running a welding bead alternately on both sides. The welding should always start in the middle of the plate and run towards the outside. Be certain to observe that each welding seam has proper run out.

Direction of weld

Direction of weld

The size of the welding run "a" is figured out in reference to the thickness "k" of the reinforcement reinforcement plate. Use formula: a=0,5 k Up to a welding run "a" of approx. 1/8" (3 mm) a single run can be made, however, as a general rule, a double run should be preferred. Above a welding run "a" of 1/8"(3 mm), the first run provides excellent penetration between the reinforcement reinforcement plate and the basic material. Subsequent runs are added on top of the first run.

After the welding is completed, completed, clean the welding welding seam as necessary. Grind the run run out between reinforcement reinforcement plate and basic material.


Service-Manual

Repair welding

7. Selectin Selecting g the corre correct ct electro electrodes des For repair welding, only lime based {Kb} electrodes should be used, and as a rule, the electrodes {additional material} should be "softer" than the basic material. Exceptions to this rule should be observed. Important:

To reach the theoretical welding quality, quality, the work must not only be performed in a professional manner, the electrode manufacturer's guidelines must absolutely be observed as well. Welding of vertical-down welds on steel components is not permissible!

7.1. Electrod Electrode e Selectio Selection n Welding area

Material

BASIC MACHINE Roller frame - Main frame

St 52 - 3 QStE 380 N

LH 690 preheat to app. 100-150°C (210-300°F) ATTACHMENT Blade Bucket

Push frame Bucket arm RL-Boom

Ripper

WEAR ITEMS Adapter, Tooth Tooth adapter adapter Ripper

Q St E 380 N HARDOX 400

St 52 - 3

LH 690 preheat to app. 100-150°C (210-300°F) St 52 - 3 Q St E 380 N HARDOX 400

Special steel

Electrode norm description

Protective gas welding wire norm description

according to EN 499: E42 5 B 4 2 H5 according to AWS A5.1-91: E7018-1 H4 R according to EN 757: E 69 6 Mn2NiCrMo B 4 2 H5 according to AWS A5.5-96: E 11018-G

according to EN 440: G4Si1 according to AWS A5.18-93: ER 70 S-6 according to EN 12534: G3CrNi1Mo according to AWS A5.28-96: ER110S-G

according to EN 499: E42 5 B 4 2 H5 according to AWS A5.1-91: E7018-1 H4 R according to EN 499: E42 5 B 4 2 H5 according to AWS A5.1-91: E7018-1 H4 R according to EN 757: E 69 6 Mn2NiCrMo B 4 2 H5 according to AWS A5.5-96: E 11018-G according to EN 499: E42 5 B 4 2 H5 according to AWS A5.1-91: E7018-1 H4 R

according to EN 440: G4Si1 according to AWS A5.18-93: ER 70 S-6 according to EN 440: G4Si1 according to AWS A5.18-93: ER 70 S-6 according to EN 12534: G3CrNi1Mo according to AWS A5.28-96: ER110S-G according to EN 440: G4Si1 according to AWS A5.18-93: ER 70 S-6

Root runs according to EN 499: E42 5 B 4 2 H5 according to AWS A5.1-91: E7018-1 H4 R Cover layers with high-strength electrode according to EN 1600: E 18 8 Mn B 2 2 according to AWS A5.4-92: E 307-15

Root runs according to EN 440: G4Si1 according to AWS A5.18-93: ER 70 S-6 Cover layers with high-strength electrode according to EN 12072: G 18 8 Mn according to AWS A5.9-93: ER307

Service-Manual


7.2. Steel Steel Table Table Description

Explanation

HARDOX 400

Weldable, low alloy special steel highly C 0,27% wear resistant, tensile strength 1250 N/mm² N/mm ² Mn 1,6% yield strength 1000 N/mm² Mo 0,6%

Q St E 380 N

Structural steel poured at low turbulence with a guaranteed minimum tensile strength of 500 - 640 N/mm² and minimum yield strength of 380 N/mm² Highly abrasion abrasion resistant steel with a tensile strength of 1720 N/mm²

Special steel

St 52 - 3 S355J2G3 LH 690

Analysis Si 0,7% Cr 1,4%

C 0,18% Si 0,5% Mn 1,6% C = 0,3% Si = 0,5% Mo = 0,3% C 0,22%

Mn = 0,7% Cu = 0,65% V = 0,05%

Structural steel poured at low turbulence with a guaranteed minimum tensile strength of 510 N/mm² Heat treated fine grain structural structura l steel with C 0,18% Si 0,50% a tensile strength of 770 - 940 N/mm² and Mn 1,5% Mo 0,5 % yield strength of 690 N/mm² Ni 1,5 % lightly alloyed with V, AI and Cu

7.3. Welding Welding addition addition chart 7.3.1 For arc welding

Description according to EN 499: E42 5 B 4 2 H5

Explanation E = Arc welding, Rod electrode 42 = 500-640 N/mm² Tensile strength 5 = Value for resistance to impact e.g. Böhler B = Shielded metal arc FOX EV 50 4 = Reference number for run out and type of flow 2 = Reference number for welding positions H5 = maximum hydrogen content according to EN 757: E = Arc welding, Rod electrode E 69 6 Mn2NiCrMo B 4 2 H5 69 = 760-960 N/mm² Tensile strength 6 = Value for resistance to impact e.g. Böhler Mn2NiCrMo = Chemical composition FOX EV 85 B = Shielded metal arc 4 = Reference number for run out and type of flow 2 = Reference number for welding positions H5 = maximum hydrogen content according to EN 1600: E 18 8 Mn B 2 2 e.g. Böhler FOX A 7

E = Arc welding, Rod electrode 18 = 620-770 N/mm² Tensile strength 8 = Value for resistance to impact Mn = Chemical composition B = Shielded metal arc 2 = Reference number for run out and type of flow 2 = Reference number for welding positions

Analysis - Value in % / Use C = 0,07, Si = 0,5, Mn = 1,1 For connection and application welding, especially for steel with low purity and higher carbon content. Weldable with direct current, electrode connected to plus terminal (+). No vertical seams C = 0,05, Si = 0,4, Mn = 1,5, Cr = 0,4, Ni = 2,0, Mo = 0,5 For welding, which require high viscosity and crack resistance. Use for high tensile refined fine-grained steel. Very low hydrogen content in weld metal. Weldable with direct current, electrode connected to plus terminal (+). No vertical seams C = 0,1, Si = 0,7, Mn = 6,5, Cr = 18,8, Ni = 8,8 For connections between various alloyed and steel which is difficult to weld. Weldable with direct current, electrode connected to plus terminal (+). No vertical seams


Service-Manual

Repair welding

7.3.2 For MIG welding with solid electrodes:

Description according to EN 440: G4Si1 e.g. Böhler EMK 8

according to EN 12534: G3CrNi1Mo

Explanation G = MIG welding with solid electrodes 4 = 500-640 N/mm² Tensile strength Si = Chemical composition composition 1 = Reference number for run out and type of flow

G = MIG welding with solid electrodes 3 = 900 N/mm² Tensile strength CrNi1Mo = Chemical composition

e.g. Böhler X 70 - IG

according to EN 12072: G 18 8 Mn e.g. Böhler A7 IG

G = MIG welding with solid electrodes 18 = 580-730 N/mm² Tensile strength 8 = Value for resistance to impact Mn = Chemical composition

Analysis - Value in % / Use C = 0,1, Si = 1,0, Mn = 1,7 For connection and application welding, especially for steel with low purity and higher carbon content. Weldable with direct current, c urrent, electrode connected to plus terminal (+). Protective gases: Argon + 15-20% CO 2 or 100% CO 2 No vertical seams C = 0,1, Si = 0,6, Mn = 1,6, Cr = 0,25, Ni = 1,3, Mo = 0,25, V = 0,1 For welding, which require high viscosity and crack resistance. Use for high tensile refined fine-grained steel. Weldable with direct current, c urrent, electrode connected to plus terminal (+). Protective gases: Argon + 15-20% CO 2 or 100% CO 2 No vertical seams C = 0,08, Si = 0,9, Mn = 7,0, Cr = 19,2, Ni = 9,0 For connections between various alloyed and steel which is difficult to weld. Weldable with direct current, c urrent, electrode connected to plus terminal (+). Protective gases: Argon+max. 2,5% CO 2 No vertical seams

Service Manual

Tools and work instructions Installation instructions

Installation instructions A. Duo Duo cone (slip ring) seals 1. Design and function

Due to the pretension of the O-rings 2, the two slip rings 3 are pushed against each other and thereby seal the bearing point via the sliding surface 4. Sealing variations Seal toward the outside

1 2

Seal mount O-ring

Seal toward the inside

3 4

Slip ring Sliding surface

Note! On Series 4 machines, due to design reasons, only seals toward the outside are used.

2. Installation 2.1. General installation notes

The slip rings rings of the seals are made as a pair. pair. For that reason, they may only only be used in the the original pairing, in new as well as in used condition. Avoid shock and and impact, since this could damage damage the sealing surfaces of the hard cast duo duo cone slip rings. Round off any sharp edges on the sealing mounts. Slip rings seals and their mounts must be absolutely clean and free of grease at installation. O-rings may not be lubricated with oil.

Slip ring seals should generally be installed with the aid of an installation device, see section 2.1 Special tools.

Caution! Without the aid of the installation device, the O-ring can roll up on the conical slip ring surface. If the pressure at installation is one-sided, one-sided, the s eal half can incline and/ or the O-ring can twist. These improper installations installations as well as damage to the sealing surfaces cause leaks.


Service Manual


Installation position correct

Installation position incorrect O-ring twisted

Installation position incorrect Seal half is inclined

2.2. Installation of the slip ring seal

A split device 5 is used as an installation aid, which is folded over over the slip ring 3 and transfers transfers the pressure at at installation directly to the O-ring 2. Push the seal halves with the appropriate installation aid into the seal mount 1. The required pressure must be exerted evenly over the entire circumference of the O-ring. If no matching installation aid is available, then a round rubber string 6 can be inserted as a makeshift spacer between the slip ring 3 and the O-ring 2 and affixed by hand, so that the O-ring cannot roll up on the conical slip ring surface when the seal halves are pushed in.

1 2 3

Seal mount O-ring Slip ring

5 6

Installation Installat ion device Aid round rubber string

Before assembly of the two seal mounts, check if the slip rings project evenly. To do so, measure the distance of the seal mount to the slip ring on at least 3 locations of the circumference, always always offset by 120°. Check the sealing surfaces again for absolute cleanliness cleanliness and apply a thin film of oil or grease.

Service Manual


B. Removal / installation of the equalizer bar (only PR 754) For replacement replacement of the equalizer bar, the entire bearing must be replaced. The equalizer bar and be removed removed and installed with the aid of the installation sleeve, see section 2.1 Special tools. 1. Removal of the equalizer bar

Tension the oscillating track roller with a suitable tool.

For removal, use the installation sleeve 10 on the housing side marked OUT. Set the installation installation sleeve 10 on the front side of the bearing 3. With the aid of a suitable press, press the bearing 3 together with the equalizer bar 2 from housing 1. 2. Installation Installati on of the equalizer bar

The installation is made on the opposite side of the housing. Hereby observe the following notes: The surfaces of the bearings must be free of oil and grease. Push the axle with the smaller diameter first into the bore. Press in the axle with the bearing until flush. Press in force: 100-150kN Press in speed: max. 2mm/sec.


Service Manual


C. Safety lever

1 2 3

Safety lever Hex Nut Allen screw

4 5 6

Hex Nut Limit Switch Hex Nut

To ensure a safety and error free function of the safety lever, the following must be observed at installation: When the safety lever is in the down position, adjust the Allen screw 3 on the limit switch 5. Tighten the hex nut 2 to the tightening torque of 8 Nm and then open by 1.25 turns. Insert hex nut 6 with w ith Loctite or similar product. Tighten the hex nut 4 to the tightening torque (see section 1.4) and then open by 1,5 to 2 turns.

Service Manual


D. Assembly Assembly instructions for travel gear (PR754 and PR764) Note! The assembly instructions for the travel gear is valid for the following machines: PR 754 F/N xxx-6924 PR 764 F/N xxx-6888

1 2 3 4 5

Travel gear frame Final drive Idler unit Axle bearing housing Axle bearing cover

6 7 8 9 10

Travel gear axle Installation screw with washer Hex head screw with washer Axle cover Hex head screw

For the assembly of the complete travel gear on the machine, observe the following points: Install the travel gear axle 6 into i nto the carrier frame. Align the equalizer equalizer bar bar in horizontal (center) (center) position. Lubricate the rubber elements of the travel gear axle 6 and the corresponding counter surfaces of the axle bearing with linseed oil (see detail A). Lift the travel gear onto the travel gear axle 6 which was installed in the carrier frame. Place the axle bearing cover 5 onto the axle bearing housing 4. Note! The installation screws may only be used for the assembly process. PR 754 S/N xxx-6924 xxx-6924 Insta Installati llation on screws 7, M24 M24x80, x80, 10.9 PR 764 S/N xxx-6888 xxx-6888 Insta Installati llation on screws screws 7, 7, M24 M24x100 x100,, 10.9 10.9

Tighten the axle bearing cover crosswise with four installation screws with washers 7 according to factory standards WN 4037 (see detail B).


Service Manual


Check the installation of the axle bearing cover 5 on the axle bearing housing 4. The gap between the two components must be evenly closed. Install all remaining hex head screws with washers 8 and tighten crosswise according to WN 4037. Remove the installation screws 7 (see detail C). Note! The installation screws may only be used for the assembly process.

Instead of the installation screws 7, install four f our new hex head screws with washers w ashers 8 and tighten according to WN 4037. Then check all hex head screws 8 for the specified tightening torque (see detail D). Attach the equalizer equalizer bar bearing bearing on the travel gear frame frame 1. Then tighten the hex head screws 10 crosswise according to WN4307. Repeat the installation procedure on the second travel gear side.

Service-Manual

Technical Data - Maintenance Guidelines Sub Group Index

Sub Group Index - Technical Data - Maintenance Guidelines Technical data

3.1

Maintenance and inspection guidelines

3.2

Maintenance and inspection instructions

3.3

Quick reference for machine adjustment

3.4

Adjustment checklist

3.5

Technical Data - Maintenance Guidelines Sub Group Index

Service-Manual

Service-Manual

Technical Data - Maintenance Guidelines Technical data

PR 724

L - F/N 753-

XL - F/N 754-

LGP - F/N 755-

6600

6600

6600

7696

7696

DIESEL ENGINE

Type Construction Rating Rating to ISO 9249 Rated Rated RPM Low idle RPM High idle RPM Displ Displac acem emen entt Oil qua quanti ntity ty incl. incl. filter filter Oil specification Max. machine inclination - all directions Valve clearance clearance - cold Firing order Coolant Coolant capacity capacity / DCA 4 Fuel Fuel tan tank k cap capaci acity ty Fuel consumption consumption

kW 1/min 1/min 1/min 1/min l l

intake intake / exhau exhaust st l l app. l/h

D 924 TI - E A2 4 cylinder in-line - intercooled 118 (160 HP) 1800 1800 +100 780 +100 1860 6,6 6,6 19 see lube oil - group 1.3 45° = 100% 0,25 / 0,30 1-3-4-2 30 / 1,4 365 365 15 - 30

SPLITTER BOX

Type Construction Rati Ratio o Oil quan quantit tity y Oil specification

351 B 366 1 stage spur gear i 0,78 0,784 4 l 3,2 3,2 see lube oil - group 1.3

HYDRAULIC SYSTEM

Travel Travel pum pumps ps max. flow - Q max max. operating pressure (M1 / M2) - p max Tandem gear pump - replenishing - coolant circuit / fan drive max. flow replenishing - Q max max. operating pressure (SP) - p max max. flow fan drive - Q max max. operating pressure (electronic regulated) - p max Gearr mot Gea motor or fan drive drive operat ope ration ion RPM Travel Travel mot motors ors Variable flow working hydraulic pump max. flow - Q max stand stand by pressu pressure( re(HD) HD) max. operating pressure (HD) - p max Servo - operating operating pressure pressure - working working hydraulic hydraulic (ND) Hydraulic tank capacity + circuit capacity Oil specification

type type l/mi l/min n bar ba mode modell l/min bar ba l /m /mi n bar ba model mod el 1/min 1/m in type type

l/min bar bar ba bar

2 x HPV 105 2 x 233 233 420 56 / 19 124 20 42 +10 150 16 +100 1850 185 0 2 x BMV 186 A 10 V 085 188 20 200 +4 20

l 144 l 70 see lube oil - group 1.3

ELECTRIC SYSTEM

Volt Voltag age e Battery Alternator Star Starte terr Automatic circuit breaker Fuses

V 24 2 x 12 V, 110 Ah (in series) 28 V, 55 A kW 5,4 5,4 A 35 A see operation operation and mainte maintenance nance manu manual al

/..

7696

Technical Data - Maintenance Guidelines

Service-Manual

Technical data

PR 724

L - F/N 753-

XL - F/N 754-

LGP - F/N 755-

6600

6600

6600

7696

7696

7696

FINAL DRIVE

Type Construction Parking brake (integrated) Ratio Ratio Oil quantity Oil specification

2 x FAT 450 E 504 spur + planetary gear, each 1 stage disk brake i tot total al 41, 41,4 4:1 l 2 x 18,5 see lube oil - group 1.3

2 x FAT 450 E 505

2 x 24,0

TRACK COMPONENTS

Track chain pitch Track Track cha chain in length length Track pad width ( single grouser) Track pad bolts Track rollers rollers - single flange (s) Track rollers - double flange (d) Track roller location Carrier Carrier rollers each side Max. roller frame oscillation

mm / inch links links mm thread. thread. size qty. qty.

190 / 7,5 42 46 508 / 560 / 610 / 660 ¾“ UNF 4 3 4 s-d-s-d-s-d-s s-d-s-d-d-s-d-s qty. 2 ± 3°

711/ 812/ 864/ 914

ATTACHMENT

Lift cylinder cylinder

6-way-blade 6-way-blade cyl. Ø / rod Ø / stroke Straight Straight blade cyl. Ø / rod Ø / stroke

mm 90 / 50 / 900 mm 90 / 50 / 1140

Tilt cylinder cylinder

6-way-blade 6-way-blade cyl. Ø / rod Ø / stroke Straight Straight blade cyl. Ø / rod Ø / stroke

mm 120 / 60 / 170 mm 140 / 70 / 100

Angle cylinder

6-way-blade cyl. Ø / rod Ø / stroke

mm 120 / 60 / 325


Ripper Ripper cyl. Ø / rod Ø / stroke

mm 140 / 70 / 490

90 / 50 / 900 90 / 50 / 1030

GENERAL DATA

Travel speed

normal range - III reduced range - II reduced range - I

Drawbar Drawbar pull max. due to ground ground condition condition Mud depth max. measured measu red horizontally horizontally - app. Basic machine: machine:

Semi-USemi-U- / Straight Straight blade blade:: blade width blade capacity weight weight - attac attachment hment comp complete lete ground pressure (varies due to pad width). length add. length add.(lower (lowered) ed) length length add add.(r .(raise aised) d) weig weight ht slope angle (with short tooth length length))

11,0 6,5 6,5 4,0 4,0

reve reverrse 0 reve reverrse 0

7,8 4,8

kN 227 mm 1000

height over cab mm overall overall length w/o attachment attachment (transpor (transportt dimension) dimension) mm overall overall length with straight straight blade mm track track gau gauge ge mm Width over trunnions trunnions mm ground ground cleara clearance nce mm

Operating weight with Semi-U- / Straight blade (track pad 610 mm)

Ripper(3): Ripper(3):

km/h 0 km/h 0 km/h 0

3197 4170 5369 1800 180 0 2648 475

5670

5624 2084 208 4 3248

kg 16400/16530/16660 17010/17150/17295 17740/18025/18310 mm 3 m kg kg/cm2 mm mm kg °

3204 3,17 2790 0,57 / 0,52 / 0,48 1428 1071 107 1 1500 1500 33

0,52 / 0,48 / 0,44

3790 3,39 2740 0,39 / 0,35 / 0,31

Service-Manual


PR 724

L - F/N 753-

XL - F/N 754-

LGP - F/N 755-

7697

7697

7697

DIESEL ENGINE

Type Construction Rating Rating to ISO 9249 Rated Rated RPM Low idle RPM High idle RPM Displacement Oil qua quantit ntity y incl. incl. filter filter Oil specification Max. machine inclination - all directions Valve clearance clearance - cold Firing order Coolant Coolant capacity capacity / DCA 4 Fuel Fuel tan tank k cap capacit acity y Fuel consumptio consumption n

kW 1/min 1/min 1/min 1/min l l

intake / exhau exhaust st l l app. l/h

D 924 TI - E A2 4 cylinder in-line - intercooled 118 (160 HP) 1800 180 0 +100 780 +100 1860 6,6 19 see lube oil - group 1.3 45° = 100% See data tag / engine 1-3-4-2 30 / 1,4 365 15 - 30

SPLITTER BOX

Type Construction Ratio Oil Oil quan quanti tity ty Oil specification

351 B 366 1 stage spur gear i 0,784 l 3,2 3,2 see lube oil - group 1.3

HYDRAULIC SYSTEM

Travel Travel pum pumps ps max. flow - Q max max. operating pressure (M1 / M2) - p max Tandem gear pump - replenishing - coolant circuit / fan drive max. flow replenishing - Q max max. operating pressure (SP) - pmax max. flow fan drive - Qmax max. operating pressure (electronic regulated) - pmax Gearr mot Gea motor or fan drive drive operat ope ration ion RPM Travel Travel mot motors ors Variable flow working hydraulic pump max. flow - Q max stand stand by pressu pressure(H re(HD) D) max. operating pressure (HD) - pmax Servo - operating operating pressure pressure - working working hydraulic hydraulic (ND) Hydrau Hydraulic lic tan tank k cap capacit acity y + circuit circuit cap capacit acity y Oil specification

type type l/mi l/min n bar ba mode modell l/min b ar ba l/min bar ba model mod el 1/min 1/m in type type


2 x HPV 105 2 x 233 233 420 56 / 1 19 9 124 20 42 +10 150 16 +100 1850 185 0 2 x HMV 210 A 10 V 085 188 20 200 +4 20


ELECTRIC SYSTEM

Voltage Battery Alternator Star Starte terr Automatic circuit breaker Fuses

V 24 2 x 12 V, 110 Ah (in series) 28 V, 55 A kW 5,4 kW 5,4 A 35 A see operation and maintenance manual

/..


Service-Manual

Technical data

PR 724

L - F/N 753-

XL - F/N 754-

LGP - F/N 755-

7697

7697

7697

FINAL DRIVE

Type Construction Parking brake (integrated) Ratio Oil qua quanti ntity ty Oil specification

2 x FAT 450 E 504 spur + planetary gear, each 1 stage disk brake i total 41,4 : 1 l 2 x 18, 18,5 5 see lube oil - group 1.3

2 x FAT 450 E 505

2 x 24, 24,0 0

TRACK COMPONENTS

Track chain pitch Track chain length Track pad width ( single grouser) Track pad bolts Track rollers - single flang flange e (s) Track rollers - double flange (d) Track roller location Carrier Carrier rollers rollers each side Max. roller frame oscillation

mm / inch links mm thread. thread. size qty. qty.

190 / 7,5 42 46 508 / 560 / 610 / 660 ¾“ UNF 4 3 4 s-d-s-d-s-d-s s-d-s-d-d-s-d-s qty. 2 ± 3°

711/ 812/ 864/ 914

ATTACHMENT


6-way-blad 6-way-blade e cyl. Ø / rod Ø / stroke Straight Straight blade cyl. Ø / rod Ø / stroke

mm 90 / 50 / 900 mm 90 / 50 / 1140


6-way-blad 6-way-blade e cyl. Ø / rod Ø / stroke Straight Straight blade cyl. Ø / rod Ø / stroke

mm 120 / 60 / 170 mm 140 / 70 / 100

Angle cylinder

6-way-blade cyl. Ø / rod Ø / stroke

mm 120 / 60 / 325


Ripper Ripper cyl. Ø / rod Ø / stroke

mm 140 / 70 / 490

90 / 50 / 900 90 / 50 / 1030

GENERAL DATA

Travel speed


Drawbar Drawbar pull max. due to ground ground condition condition Mud dept depth h max. measured measu red horizontally horizontally - app. Basic machine: machine:

Semi-U- / Straight blade: blade width blade capacity weight - attachment complete ground pressure (varies due to pad width). length add. length add.(lowere (lowered) d) length length add add.(r .(raise aised) d) weigh weightt slope angle (with short tooth lengt length) h)

11,0 6,5 6,5 4,0 4,0

reve revers rse e0 reve revers rse e0

7,8 4,8

kN 227 mm 1000

height over cab height mm overall overall length w/o attachment attachment (transpor (transportt dimension) dimension) mm overall length with straight blade mm track gauge mm Width over trunni ons mm ground ground cleara clearance nce mm

Operating weight with Semi-U- / Straight blade (track pad 610 mm)



3197 4170 5369 1800 2648 26 475

5670

5624 2084 3248

kg 16400/16530/16660 17010/17150/17295 17740/18025/18310 mm 3 m kg kg/cm2 mm mm kg °

3204 3 ,1 7 2790 0,57 / 0,52 / 0,48 1428 1071 107 1 1500 1500 33

0,52 / 0,48 / 0,44

3790 3,39 2740 0,39 / 0,35 / 0,31

Service Manual

Technical data and Maintenance guidelines Technical data

PR 724

L - F/N 753-

XL - F/N 754-

LGP - F/N 755-

9200

9200

9200

11222

11222

DIESEL ENGINE

Type Version Performan Performance ce per ISO 9249 Nomina Nominall RPM Low idle idle RPM High High idle RPM Displ Displac acem emen entt Oil qua quanti ntity ty incl. incl. filter filter Oil quality / viscosity Max. permissible machine incline – all directions Valve clearance clearance - cold Firing order

kW 1/min 1/min 1/min 1/m in 1/min 1/m in l l

on/ off

D 934-L A6 4 cyl. In line – charge air cooled 120 (163 PS) 1800 180 0 +30/-30 830 +30/-30 1920 192 0 7,0 7,0 29 See Service fluids, section 1.3 45° = 100% See engine data tag 1-3-4-2

SPLITTERBOX

Type Version Rati Ratio o Oil quan quantit tity y Oil quality / viscosity

300 B 344 Spur gear drive – 1-rodge i 0,78 0,788 8 l 3 see Service fluids, section 1.3

HYDRAULIC SYSTEM

Variable Variable / travel travel pumps – travel hydraulic hydraulic Flow - Qmax Operating pressure (M1 / M2) pmax Tandem gear pumps - Replenishing – cooling circuit / fan drive Flow replenishing - Q max Operating pressure (SP) pmax Flow fan drive - Q max Operating pressure (electronically regulated) - p max Gear motor Fan drive Operat Ope rating ing RPM Variable Variable travel moto motors rs – travel hydraulic hydraulic Regulating pump – working hydraulic Flow - Qmax Stand Stand by pressur pressure e (HD) (HD) Operating pressure (HD) - p max Servo control control working working hydraulic hydraulic Operating Operating pressure pressure (ND) Hydrau Hydraulic lic tan tank k cap capaci acity ty - Add Additi itiona onall circuit circuit cap capaci acity ty Oil quality / viscosity

Type 2 x HPV 105 - 2 l/m l/min bar ba Type Type / size l/m l/min bar l /m /min bar ba Type / size 1/min 1/m in Type

ll/m /min in bar bar ba bar

2 x240 x240 420 55 + 19 / 56 + 16 117 117 20 43 ±5 185 16 +100 2150 215 0 2 x HMV 210 - 02 A 10 V 085 194 ±2 20 200 +4 20

l 144 l 70 see Service fluids, section 1.3

ELECTRICAL SYSTEM

Operat Ope rating ing voltag voltage e Batteries Alternator Star Starte terr Cent Centra rall fu fuse se Individual Individual fuses

V 24 2 x 12 V, 170 Ah (in Series) 28 V, 80 A kW 6,6 6,6 A 45 A See Operating Operating instructions instructions

/..

11222

Technical data and Maintenance guidelines

Service Manual

Technical data

PR 724

L - F/N 753-

XL - F/N 754-

LGP - F/N 755-

9200

9200

9200

11222

11222

11222

FINAL DRIVE

Type Version Parking brake integrated Ratio Ratio Oil qua quantit ntity y Oil quality / viscosity

2 x FAT 450 E 504 Spur gear + Planetary gear, per 1-stage Disk brake Total Total 38, 38,23 23 : 1 l 2 x 18, 18,5 5 see Service fluids, section 1.3

2 x FAT 450 E 505

2 x 24

TRACK COMPONENTS

Chain pitch Chain Chain length length Chain pad width (1 grouser) Track pad bolts Track rollers – single flange, per s ide (e) Track rollers – double flange, per side (d) Track roller arrangement Track rollers per side Track frame oscillation, max.

mm / inch links links mm Thread Thread size Qty. Qty.

190 / 7,5 42 508/560/610/660 3/4“ UNF 4 3 e-d-e-d-e-d-e 2 ± 3°

46 711/812/864/914 4 4 e-d-e-d-d-e-d-e

4 4 e-d-e-d-d-e-d-e

WORKING ATTACHMENTS - Cylinder


Straight Straight and Semi-U-blade Semi-U-blade Cyl. Cyl. Ø / Rod Ø / Strokem Strokem Tilt blade Cyl. Ø / Rod Ø / Stroke mm 6 – way blade inside Cyl. Ø / Rod Ø / Stroke Stroke mm 6 – way blade outside outside Cyl. Ø / Rod Ø / Stroke Stroke mm

90 / 50 / 1140 90 / 50 / 1140 90 / 50 / 950 90 / 50 / 1140

90 / 50 / 1140 90 / 50 / 1140 90 / 50 / 950 90 / 50 / 1140

90 / 50 / 1140 ---90 / 50 / 950 ----

Tilt cylinder

Straight and Semi-U-blade Cyl. Ø / Rod Ø / Strokem Tilt blade Cyl. Ø / Rod Ø / Stroke Stroke mm 6 – way blade Inside Cyl. Ø / Rod Ø / Stroke mm 6 – way blade outside outside Cyl. Ø / Rod Ø / Stroke Stroke mm

140 / 70 / 100 140 / 70 / 130 120 / 60 / 170 120 / 60 / 170

140 / 70 / 100 140 / 70 / 130 120 / 60 / 170 120 / 60 / 170

140 / 70 / 100 ---120 / 60 / 170 ----

mm 120 / 60 / 325

120 / 60 / 325

120 / 60 / 325

Swing cylinder cylinder


6 – way blade inside

Three tooth ripper ripper

Cyl. Ø / Rod Ø / Stroke


mm 140 / 70 / 490

WORKING ATTACHMENTS - Blades

Operating weight with straight blade

kg ( for chain pad width mm) 16400 / 16534 / 16662

16870 / 17017 / 17157 / 17298

17749 / 18041 / 18182 / 18322

Operating weight with Semi-U-blade


----

Operating weight with tilt blade


17000 / 17147 / 17287 / 17428 17301 / 17448 /

Operating weight with 6 – way blade


----

17588 / 17729 17140 / 17287 / 17427 / 17568

17864 / 18156 / 18297 / 18437

3000 3000 3900 3204

3000 3000 3900 3204

3600 ------3790

Blade width

Straight Straight blade Semi-U-bl ade Tilt blade 6 – way bl ade

mm mm mm mm

Blade capacity

Straight blade Semi-U-blade Tilt blade 6 – way blade

m 3 m 3 m 3 m

3,14 4,27 3,27 3,17

3,14 4,27 3,27 3,17

3,43 ------3,39

Weight of blades

Straight bl ade Semi-U-bl ade Tilt blade

kg 969 kg 1091 kg 1022

969 1091 1022

1143 -------

3

Service Manual


PR 724 Three tooth ripper ripper

6 – way blade Length addit Length additional ional (lowered) (lowered) Length Lengt h additional additional (raised) (raised) Weight Slope angle (for short tooth length)

kg mm mm kg °

Ground pressure² kg (for chain pad width mm) ² Lubricants/ service fluids, Semi-U-blade/straight blade/6-way blade ,

L - F/N 753-

XL - F/N 754-

LGP - F/N 755-

9200

9200

9200

11222

944 1427 1071 1480 35,4

11222

944

1060

See Operating instructions „Technical data“

GENERAL

Travel speed

Normal range - III Reduced range - II Reduced range - I


Traction Traction max. Fording Fording depth max.

depending on ground depending ground conditions conditions measured measured horizontally horizontally – approx. approx.

kN 235 mm 1000

Basic machine: machine:

Height Height over operator’s operator’s cab Length over lift cylinder (Transport length) Length with straight blade Length with Semi-U-blade Length with tilt blade Length with 6-way blade Track width Width over trunion Ground Ground cleara clearance nce

mm mm mm mm mm mm mm mm mm

11 reverse 0 6,5 6,5 reve revers rse e0 4,0 4,0 reve revers rse e0

3197 4114 4941 5155 5376 5369 1800 2648 475

11 7,8 7,8 4,8

4173 5321 5535 5756 5501 1800 2648

4173 5316 ------5468 2084 3248

11222


Service Manual

Service Manual


PR 724

L - F/N 753-

XL - F/N 754-

LGP - F/N 755-

11223

11223

11223

DIESEL ENGINE

Type Version Performan Performance ce per ISO 9249 Nomina Nominall RPM Low idle idle RPM High High idle RPM Displ Displac acem emen entt Oil qua quanti ntity ty incl. incl. filter filter Oil quality / viscosity Max. permissible machine incline – all directions Valve clearance clearance - cold Firing order


on/ off

D 934-L A6 4 cyl. In line – charge air cooled 120 (163 PS) 1800 180 0 +30/-30 830 +30/-30 1920 192 0 7,0 7,0 29 See Service fluids, section 1.3 45° = 100% See engine data tag 1-3-4-2

SPLITTERBOX


300 B 344 Spur gear drive – 1-rodge i 0,78 0,788 8 l 3 see Service fluids, section 1.3

HYDRAULIC SYSTEM

Variable Variable / travel travel pumps – travel hydraulic hydraulic Flow - Qmax Operating pressure (M1 / M2) pmax Tandem gear pumps - Replenishing – cooling circuit / fan drive Flow replenishing - Q max Operating pressure (SP) pmax Flow fan drive - Q max Operating pressure (electronically regulated) - p max Gear motor Fan drive Operat Ope rating ing RPM Variable Variable travel moto motors rs – travel hydraulic hydraulic Regulating pump – working hydraulic Flow - Qmax Stand Stand by pressur pressure e (HD) (HD) Operating pressure (HD) - p max Servo control control working working hydraulic hydraulic Operating Operating pressure pressure (ND) Hydrau Hydraulic lic tan tank k cap capaci acity ty - Add Additi itiona onall circuit circuit cap capaci acity ty Oil quality / viscosity

Type 2 x HPV 105 - 2 l/m l/min bar ba Type Type / size l/m l/min bar l /m /min bar ba Type / size 1/min 1/m in Type


2 x240 x240 420 55 + 19 / 56 + 16 117 117 20 43 ±5 185 16 +100 2150 215 0 2 x HMV 210 - 02 A 10 V 074 169 ±2 20 200 +4 20

l 144 l 70 see Service fluids, section 1.3

ELECTRICAL SYSTEM



/..


Service Manual

Technical data

PR 724

L - F/N 753-

XL - F/N 754-

LGP - F/N 755-

11223

11223

11223

FINAL DRIVE

Type Version Parking brake integrated Ratio Ratio Oil qua quantit ntity y Oil quality / viscosity

2 x FAT 450 E 504 Spur gear + Planetary gear, per 1-stage Disk brake Total Total 38, 38,23 23 : 1 l 2 x 18, 18,5 5 see Service fluids, section 1.3

2 x FAT 450 E 505

2 x 24

TRACK COMPONENTS

Chain pitch Chain Chain length length Chain pad width (1 grouser) Track pad bolts Track rollers – single flange, per s ide (e) Track rollers – double flange, per side (d) Track roller arrangement Track rollers per side Track frame oscillation, max.

mm / inch links links mm Thread Thread size Qty. Qty.

190 / 7,5 42 508/560/610/660 3/4“ UNF 4 3 e-d-e-d-e-d-e 2 ± 3°

46 711/812/864/914 4 4 e-d-e-d-d-e-d-e

4 4 e-d-e-d-d-e-d-e

WORKING ATTACHMENTS - Cylinder


Straight Straight and Semi-U-blade Semi-U-blade Cyl. Cyl. Ø / Rod Ø / Strokem Strokem Tilt blade Cyl. Ø / Rod Ø / Stroke mm 6 – way blade inside Cyl. Ø / Rod Ø / Stroke Stroke mm 6 – way blade outside outside Cyl. Ø / Rod Ø / Stroke Stroke mm

90 / 50 / 1140 90 / 50 / 1140 90 / 50 / 950 90 / 50 / 1140

90 / 50 / 1140 90 / 50 / 1140 90 / 50 / 950 90 / 50 / 1140

90 / 50 / 1140 ---90 / 50 / 950 ----

Tilt cylinder

Straight and Semi-U-blade Cyl. Ø / Rod Ø / Strokem Tilt blade Cyl. Ø / Rod Ø / Stroke Stroke mm 6 – way blade Inside Cyl. Ø / Rod Ø / Stroke mm 6 – way blade outside outside Cyl. Ø / Rod Ø / Stroke Stroke mm

140 / 70 / 100 140 / 70 / 130 120 / 60 / 170 120 / 60 / 170

140 / 70 / 100 140 / 70 / 130 120 / 60 / 170 120 / 60 / 170

140 / 70 / 100 ---120 / 60 / 170 ----

mm 120 / 60 / 325

120 / 60 / 325

120 / 60 / 325

Swing cylinder cylinder


6 – way blade inside

Three tooth ripper ripper



mm 140 / 70 / 490

WORKING ATTACHMENTS - Blades



16870 / 17017 / 17157 / 17298

17749 / 18041 / 18182 / 18322

Operating weight with Semi-U-blade


----

Operating weight with tilt blade


17000 / 17147 / 17287 / 17428 17301 / 17448 /

Operating weight with 6 – way blade


----

17588 / 17729 17140 / 17287 / 17427 / 17568

17864 / 18156 / 18297 / 18437

3000 3000 3900 3204

3000 3000 3900 3204

3600 ------3790

Blade width

Straight Straight blade Semi-U-bl ade Tilt blade 6 – way bl ade

mm mm mm mm

Blade capacity

Straight blade Semi-U-blade Tilt blade 6 – way blade

m 3 m 3 m 3 m

3,14 4,27 3,27 3,17

3,14 4,27 3,27 3,17

3,43 ------3,39

Weight of blades

Straight bl ade Semi-U-bl ade Tilt blade

kg 969 kg 1091 kg 1022

969 1091 1022

1143 -------

3

Service Manual


PR 724 Three tooth ripper ripper

6 – way blade Length addit Length additional ional (lowered) (lowered) Length Lengt h additional additional (raised) (raised) Weight Slope angle (for short tooth length)

kg mm mm kg °

Ground pressure² kg (for chain pad width mm) ² Lubricants/ service fluids, Semi-U-blade/straight blade/6-way blade ,

L - F/N 753-

XL - F/N 754-

LGP - F/N 755-

11223

11223

11223

944 1427 1071 1480 35,4

944

1060

See Operating instructions „Technical data“

GENERAL

Travel speed



Traction Traction max. Fording Fording depth max.

depending on ground depending ground conditions conditions measured measured horizontally horizontally – approx. approx.

kN 235 mm 1000


Height Height over operator’s operator’s cab Length over lift cylinder (Transport length) Length with straight blade Length with Semi-U-blade Length with tilt blade Length with 6-way blade Track width Width over trunion Ground Ground cleara clearance nce


11 reverse 0 6,5 6,5 reve revers rse e0 4,0 4,0 reve revers rse e0

3197 4114 4941 5155 5376 5369 1800 2648 475

11 7,8 7,8 4,8

4173 5321 5535 5756 5501 1800 2648

4173 5316 ------5468 2084 3248


Service Manual

Service-Manual


PR 734

L - F/N 724-

XL - F/N 725-

LGP - F/N 726-

6200

6200

6200

8219

8219

DIESEL ENGINE

Type Construction Rating Rating to ISO 9249 Rated Rated RPM Low idle RPM High High idle RPM Displacement Oil quantity incl. filter Oil specification Max. machine inclination - all directions Valve clearance clearance - cold Firing order Coolant capacity / DCA 4 Fuel tank capacity Fuel consumption


intake intake / exhau exhaust st l l app. l/h

D 926 TI - E A2 6 cylinder in-line - intercooled 147 (200 HP) 1800 1800 +50 800 +80 1900 190 0 9.96 22 see lube oil - group 1.3 45° = 100% 0,25 / 0,30 1-5-3-6-2-4 43 / 2.4 440 15 - 30

SPLITTER BOX

Type Construction Rati Ratio o Oil quantity Oil specification

350 B 374 1 stage spur gear i 0,86 0,86 l 3 see lube oil - group 1.3

HYDRAULIC SYSTEM

Travel Travel pum pumps ps max. flow - Q max max. operating pressure (M1 / M2) - p max Tandem gear pump - replenishing - coolant circuit / fan drive max. flow replenishing - Q max max. operating pressure (SP) - p max max. flow fan drive - Q max max. operating pressure (electronic regulated) - p max Gearr mot Gea motor or fan drive drive operat ope ration ion RPM Travel Travel mot motors ors Variable flow working hydraulic pump max. flow - Q max stand stand by pressu pressure( re(HD) HD) max. operating pressure (HD) - p max Servo - operating operating pressure pressure - working working hydraulic hydraulic (ND) Hydraulic tank capacity + circuit capacity Oil specification

type type l/mi l/min n bar ba mode modell l/min bar ba l /m /mi n bar ba model mod el 1/min 1/m in type type


2 x HPV 135 2 x 282 282 420 56 / 19 117 20 33 +10 210 16 +100 1730 173 0 2 x BMV 260 A 10 V 0100 209 25 200 +4 20


ELECTRIC SYSTEM


V 24 2 x 12 V, 143 Ah (in series) 28 V, 55 A kW 6,6 6,6 A 35 A see operation operation and mainte maintenance nance manu manual al

/..

8219


Service-Manual

Technical data

PR 734

L - F/N 724-

XL - F/N 725-

LGP - F/N 726-

6200

6200

6200

8219

8219

8219

FINAL DRIVE


2 x FAT 500 E 502 spur + planetary gear, each 1 stage disk brake i tot total al 38, 38,2 2:1 l 2 x 14 see lube oil - group 1.3

2 x FAT 500 E 503

2 x 18,5

TRACK COMPONENTS

Track chain pitch Track Track cha chain in length length Track pad width ( single grouser) grouser) Track pad bolts Track rollers rollers - single flang flange e (s) Track rollers rollers - doubl double e flang flange e (d) Track roller location Carrier Carrier rollers rollers each side Max. roller frame oscillation


203,2 / 8,0 40 508 / 560 / 610 3/4“ UNF 4 3 s-d-s-d-s-d-s qty. 2 ± 3°

44 712/ 812/ 914/ 965

4 s-d-s-d-d-s-d-s

ATTACHMENT

Lift cylinder cylinder straight straight blade cyl. Ø / rod Ø / stroke

mm 100 / 60 / 1300

Tilt cylinder cylinder straight straight blade cyl. Ø / rod Ø / stroke

mm 160 / 80 / 120

Ripper Ripper cylinder cylinder - cyl. Ø / rod Ø / stroke

mm 160 / 80 / 530

100 / 60 / 1165

GENERAL DATA

Travel speed



Drawbar Drawbar pull max. Mud depth max.

due to ground ground condition condition measured measu red horizontally horizontally - app.

Basic mach machine: ine:

heightt over cab heigh mm overall overall length w/o attac attachment hment (transport (transport dimen dimension)m sion)m overall lengt length h with straight straight blade mm track track gau gauge ge mm Width over trunnions trunnions mm ground ground cleara clearance nce mm

Operating weight with Semi-U- / Straight blade (track pad 610 mm) Semi-USemi-U- / Straight Straight blade: blade width blade capacity weight weight - attac attachment hment complete complete ground ground pressure pressure (varies (varies due to pad width). width). Ripper(3): Ripper(3):

length add. length add.(lowere (lowered) d) length length add add.(ra .(raise ised) d) weigh weightt slope angle (with short tooth lengt length) h)

11,0 6,5 6,5 4,0 4,0

reve reverrse 0 reve reverrse 0

7,8 4,8

kN 274 mm 1100 3266 4152 5532 1830 183 0 2724 500

kg 20 878 mm 3 m kg kg/cm2 mm mm kg °

3363 5,86 2790 0,60 (610) 1531 1193 119 3 1915 1915 33

4291 5950

5632 2180 218 0 3474

21 503

22 237

0,54 (610)

3995 4,1 2740 0,42 (812)

Service-Manual


PR 734

L - F/N 724-

L - F/N 725-

LGP - F/N 726-

8220

8220

8220

DIESEL ENGINE

Type Construction Rating Rating to ISO 9249 Rated Rated RPM Low idle RPM High High idle RPM Displacement Oil specification Max. machine inclination - all directions Valve clearance clearance - cold Firing order

kW 1/min 1/min 1/min 1/m in 1/min 1/m in l

intake / exhau exhaust st

D 936 LA6 6 cylinder in-line - intercooled 150 (204 HP) 1800 180 0 +50 900 +50 1900 190 0 10,5 see lube oil - group 1.3 45° = 100% See data tag / engine 1-5-3-6-2-4

SPLITTER BOX


351 B 374 1 stage spur gear i 0,86 0,86 l min. 2,6 – max. 3,0 see lube oil - group 1.3

HYDRAULIC SYSTEM

Travel Travel pum pumps ps max. flow - Q max max. operating pressure (M1 / M2) - p max Tandem gear pump - replenishing - coolant circuit / fan drive max. flow replenishing - Q max max. operating pressure (SP) - p max max. flow fan drive - Q max max. operating pressure (electronic regulated) - p max Gear moto motorr - fan drive operat ope ration ion RPM Travel Travel mot motors ors Variable flow working hydraulic pump max. flow - Q max stand stand by pressu pressure( re(HD) HD) max. operating pressure (HD) - p max Servo - operating operating pressure pressure - working working hydraulic hydraulic (NP) Hydraulic tank capacity + circuit capacity Oil specification

type type l/mi l/min n bar ba model mod el l/min bar ba l /m /mi n bar ba model 1/min 1/m in type type


2 x HPV 135 2 x 282 282 420 55 + 19 / 56 + 16 117 20 33 ±5 220 16 +100 1800 180 0 2 x HMV 280 A 10 V 0100 209 +2 -2 20 200 +4 20


ELECTRIC SYSTEM


V 24 2 x 12 V, 170 Ah (in series) 28 V, 80 A kW 7,8 7,8 A 45 A see operation operation and maint maintenanc enance e manua manuall

/..


Service-Manual

Technical data

PR 734

L - F/N 724-

L - F/N 725-

LGP - F/N 726-

8220

8220

8220

FINAL DRIVE

Type Construction Parking brake (integrated) Rati Ratio o Oil quantity Oil specification

2 x FAT 500 E 502 spur + planetary gear, each 1 stage disk brake i to tota tall 35,7 35,7:: 1 l 2 x 14 see lube oil - group 1.3

2 x FAT 600 E 503

TRACK COMPONENTS

Track chain pitch Track chain length Track pad width ( single grouser) grouser) Track pad bolts Track rollers - single flange (s) Track rollers - double flange (d) Track roller location Carrie Carrierr rollers rollers each side side Max. roller frame oscillation

mm / inch links mm thread. thread. size qty. qty.

203,2 / 8,5 40 508 / 560 / 610 3/4“ UNF 4 3 s-d-s-d-s-d-s qty. qty. 2 ± 3°

44 44

44 710/812/914/96 710/812/9 14/965 5

4 4 s-d-s-d-d-s-d-s

4 4 s-d-s-d-d-s-d-s

ATTACHMENT - cylinder

Lift cylinder

straight- and Semi-U-blade cyl. Ø / rod Ø / stroke angle cylinder cylinder cyl. Ø / rod Ø / stroke

mm 100 / 60 / 1230 mm 100 / 60 / 1300


straightstraight- and Semi-U-blade Semi-U-blade cyl. Ø / rod Ø / stroke angle blade cyl. Ø / rod Ø / stroke

mm 160 / 80 / 0120 mm 180 / 80 / 0200


ripper ripper (1) ripper (3)

mm 160 / 80 / 530 mm 160 / 80 / 530

cyl. Ø / rod Ø / stroke cyl. Ø / rod Ø / stroke

100 / 60 / 1230 100 / 60 / 1230

ATACHMENT - blades

Operating weight with straight- and Semi-U-blade

kg (track pad in mm) 20336/20460/2058

20848/20986/21122

21942/22216/22488 /22638


kg (track pad in mm) 20481/20605/2072

20993/21131/21267

21902/22176


kg (track pad in mm) 2813/20937/21061

21325/21463/21599 21325/21463/21599

Blade width

straight blade Semi-U-blade angle ang le blade blade

mm 3397 mm 3372 mm 424 4240 0

3397 3372 4240 424 0

3995 3747

Schildkapazität

straight blade Semi-U-blade angle blade

m 4,21 3 m 5,56 3 m 3,80

4,21 5,56 3,80

4,10 5,40

Weigth blade

straight blade Semi-U-blade angle ang le blade blade

kg 1417 kg 1504 kg 140 1403 3

1417 1504 1403 140 3

1544


length add.(lowered add.(lowered)) length length add add.(ra .(raise ised) d) weig weight ht slope slope angl angle e

mm mm kg kg °

1961 1671 167 1 1530 1530 19 / 23


length add.(lowered add.(lowered)) length length add add.(ra .(raise ised) d) weig weight ht slope angle (with short tooth length length))

mm mm kg kg °

1531 1199 119 9 1909 1909 33,3

3

/..

Service-Manual


PR 734

L - F/N 724-

L - F/N 725-

LGP - F/N 726-

8220

8220

8220

3258 8253 9804 5863 5093 3372 3372 1400 2 994 29 2724

3258 8521 10072 6133 5361 3372 3372 1400 2994 2724

3258 9136 10687 5878 5361 3995 3995 1150 3494 3474

ATTACHMENT – blades with hydraulic quick hitch

Height over cab Overall length, embarkation Overall length (with ripper (3), embarkation) Overall length, with bucket attachment Overall length, wi th hydraulic quick hitch without blade Blade width Blade heigth 1 Width hydraulic quick hitch width over ball trunnions


Operation weight² kg 21351/21475/2159 21863/2201/22137 Ground pressure² pressure² kg ( track pads in mm) 0,60 (610) 0,54 (610) 1 LGP version with max. track pads 812mm ² Lubrication and operating materials, semi-U-straight blade, operator

22832/23106 0,38 (914)

GENERAL DATA

Travel speed


Drawbar Drawbar pull max.

due to ground ground condition condition


height over cab length lengt h over lift cylinder cylinder (transport (transport dimen dimension) sion) length with straight blade length with Semi-U-blade length lengt h with angle blade track gauge width over ball trunnions ground ground cleara clearance nce


11, 11,0 6,5 6,5 4,0 4,0

reve revers rse e0 reve revers rse e0 reve revers rse e0

11, 11,0 7,8 7,8 4,5 4,5

kN 274

mm mm mm mm mm mm mm mm

3258 4335 5400 5678 5655 1830 2724 500

5670 5948 5295 1830 2724

5693 5954 2180 3474


Service-Manual

Service-Manual


PR 744

L - F/N 940-

LGP - F/N 942-

7356

7356

DIESEL ENGINE

Type Construction Rating Rating to ISO 9249 Rated Rated RPM Low idle RPM High High idle RPM Displacement Oil specification Max. machine inclination - all directions Valve clearance clearance - cold Firing order



D 936 LA6 6 cylinder in-line - intercooled 185 (252 HP) 1600 160 0 +50 900 900 +50 1700 1700 10,5 see lube oil - group 1.3 45° = 100% See data tag / engine 1-5-3-6-2-4

SPLITTER BOX


351 B 355 1 stage spur gear i 0,86 0,861 1 l 6,4 see lube oil - group 1.3

HYDRAULIC SYSTEM

Travel pump pumps s max. flow - Q max max. operating pressure (M1 / M2) - p max Axial piston pump – cooling circuit Flow quantity replenishing - Q max Operating pressure (LA electronically regulated) p max Stand by pressure pressure LA (at cold machine) machine) Tandem gear pumps – replenishing – servo control WH Flow quantity - Q max –ges (Qmax –ges =Q1 =Q1 + Q2) Q2) Operating pressure (SP) pmax

type 2 x HPV 210-02 210-02 l/mi l/min n 2 x 380 380 +30/-10 bar 420 A 10 V 28 l/min 57 +bar 205 +5 bar 30 mode modell 45 + 38 38 l/mi l/min n 150 150 + bar 20

Axial piston moto motorr (fan – water cooler) cooler) Operating speed Gear motor (fan – hydraulic oil cooler) Operat Ope rating ing spe speed ed

model 18 / 52 + RPM 1500

Var. displ. motors motors – Travel hydraulic hydraulic Variable flow working hydraulic pump max. flow - Q max stand stand by pressu pressure( re(HD) HD) max. operating pressure (HD) - pmax Servo - operating operating pressure pressure - working working hydraulic hydraulic (NP) Hydraulic tank capacity + circuit capacity Oil specification

RPM 2350 2350

+100

Type 4 x HMV 165-02 165-02


A 10 V 140 260 +2 20 +5 260 +4 20

l 167 l 136 See Service fluids, section 1.3

ELECTRICAL SYSTEM


V 24 2 x 12 V, 170 Ah (in series) 28 V, 80 A kW 7,8 7,8 A 45 A see Operation Operation and maint maintenanc enance e manu manual al


Service-Manual

Technical data

PR 744

L - F/N 940-

LGP - F/N 942-

7356

7356

FINAL DRIVE


2 x FAT 600 E 506 spur + planetary gear, each 2 stage disk brake i tot total al 45, 45,3 3:1 l 2 x 17,5 see lube oil - group 1.3

2 x FAT 600 E 507

2 x 19,5

TRACK COMPONENTS

Track chain pitch Track Track cha chain in length length Track pad width ( single grouser) grouser) Track pad bolts Track rollers rollers - single flang flange e (s) Track rollers rollers - doub double le flang flange e (d) Track roller location Carrier Carrier rollers rollers each side Max. roller frame oscillation


215,9 / 8,5 40 508 / 560 / 610 / 710 7/8“ UNF 4 3 s-d-s-d-s-d-s qty. 2 ± 3°

44 812/ 914 4 4 s-d-s-d-d-s-d-s

ATTACHMENT

Lift cylinder cylinder straight straight blade cyl. Ø / rod Ø / stroke Tilt cylinder cylinder straight straight blade cyl. Ø / rod Ø / stroke Cutting Cutting angle cylinder cylinder straight straight blade - cyl. Ø / rod Ø / stroke

mm 100 / 60 / 1345 mm 160 / 80 / 170 mm 180 / 80 / 110

Lift cylinder cylinder ripper - cyl. Ø / rod Ø / stroke Ripping Ripping angle cylinder cylinder - cyl. Ø / rod Ø / stroke

mm 160 / 95 / 380 mm 160 / 95 / 380

GENERAL DATA

Travel speed


Drawbar Drawbar pull max.

due to ground ground condition condition


height over cab height mm overall length w/o attachment (transport dimension)m overall overall lengt length h with straight straight blade mm track track gau gauge ge mm Width over trunnions trunnions mm ground ground cleara clearance nce mm

Operating weight with Semi-U- / Straight blade


11,0 6, 5 4,0 4,0

reverse 0 re ev verse 0 reve revers rse e0

11 8 4,5

kN 360

3434 4657 6050 1980 198 0 3000 546

kg (track pad in mm) 25620 (560)

Semi-USemi-U- / Straight Straight blade: blade width mm 3 blade capacity m weight weight - attac attachment hment complete complete kg ground ground pressure. pressure. kg/cm2 kg/cm2 (varies (varies due to pad width) width)

3690 7, 2 3803 0,76 (560)


1937 1586 3304 3304 28,5

length add.(lowere add.(lowered) d) length lengt h add.(raised add.(raised)) weigh weightt slope angle (with short tooth length length))

mm mm kg kg °

4692 5935 2180 218 0 3600

27000 (914) 4520 6,0 3940 0,45 (914)

Service Manual


PR 754 DIESEL ENGINE

Type Design Rated Rated to ISO 924 9249 9 Rate Rated d RPM RPM Low Low idle idle RPM RPM High High idle RPM Displacement Oil specification / viscosity Max. machine inclination - all directions Valve clearance clearance - cold Firing order

kW RPM RPM RPM RPM RPM l


D 946-L A6 6 cyl. in line – charge air cooled 250 (340 (340 PS) 1600 1600 +50 900 900 +50 1700 1700 12 See Service items, section 1.3 45° = 100% See Data tag / engin engine e 1-5-3-6-2-4

SPLITTERBOX

Type Design Rati Ratio o Oil qua quanti ntity ty Oil specification / viscosity

351 B 364 Spur gear 1-stage i 0,86 0,86 l Min Min.. 5 – Max Max.. 5,5 See Service items section 1.3

HYDRAULIC SYSTEM

Variable Variable pumps – travel travel hydraulic hydraulic Flow - Qmax Operating pressure (M1 / M2) p max Axial piston pump – cooling circuit Flow quantity replenishing - Q max Operating pressure (LA electronically regulated) p max Stand by pressure pressure LA (with cold machine) machine) Tandem gear pumps - Replenishing – Pilot control WH Flow quantity - Q max –ges (Qmax –ges =Q1 =Q1 + Q2) Q2) Operating pressure (SP) pmax

Type 2 x HPV 280-02 280-02 l/mi l/min n 2 x 518 518 +30/-10 bar 420 ba A 10 V 28 l/min 57 +/-5 bar 205 ba +5 bar 30 Size Size 55 + 38 l/mi l/min n 174 174 +4 bar 20

Axial piston motor (fan – water water cooler) Operat Ope rating ing spe speed ed Gear motor (fan – hydraulic hydraulic oil cooler) cooler) Operat Ope rating ing spe speed ed

Size 1/min 1/min Size 1/min 1/m in

Variable Variable displ. motors motors - Travel hydraulic hydraulic

Type 4 x HMV 210

Regulating pump – Working hydraulic Flow quantity - Q max Stand Stand by pressur pressure e (HD) (HD) Operating pressure (HD) - pmax Pilot control control working working hydraulic hydraulic operating operating pressure pressure (ND) Oil tank capacity capacity - circuit capacity capacity - addit additional ional Oil specification / viscosity


18/52 +100 1500 1500 19 +100 1800 180 0

A 10 V 140 260 260 +2 20 +5 260 +4 20

l 240 ( sight gauge top) l 180 See Service items section 1.3

ELECTRICAL SYSTEM




Service Manual

Technical data

PR 754 FINAL DRIVE

Type Design Parking brake integrated Ratio Ratio Oil qua quanti ntity ty Oil specification / viscosity

2 x FAT 650 E 508 Spur gear 1-stage + Planetary gear – 2 stage Disk brake Total Total 54, 54,3 3:1 l 2 x 18, 18,5 5 See Service items section 1.3

Fixed and single oscillating track rollers

TRACK COMPONENTS

Track chain pitch Track Track cha chain in length length Track pad width (1 grouser) grouser) Track pad bolts Track rollers – single flang flange e per side (e) Track rollers – double flang flange e per side (d) Track roller arrangement Carrier Carrier rollers rollers per side Max. roller frame oscillation

mm /inch Links Links mm Thread Thread size Qty. Qty.

215,9 / 8,5 44 560 / 610 / 660 / 711 M 24 x 1,5 4 3 e-d-e-d-e-d-e Qty. 2 ± 3°

WORKING ATTACHMENT

Lift cylinder cylinder U – and Semi-U-blad Semi-U-blade e cyl.. Ø / rod Ø / stroke Tilt cylinder U – and Semi-U-blade cyl. Ø / rod Ø / stroke Cutting angle cylinder U – and Semi-U-blade cyl. Ø / rod Ø / stroke

mm 110 / 70 / 1490 mm 160 / 80 / 195 mm 200 / 90 / 145

Lift cylindercylinder- ripper cyl. Ø / rod Ø / stroke Ripping Ripping angle cylindercylinder- ripper cyl. Ø / rod Ø / stroke

mm 160 / 95 / 495 mm 160 / 95 / 495 Track with fixed track rollers

GENERAL

Travel speed


Pull force max.

Depends Depends on ground condition condition


Height Height over cab Length Leng th over lift cylinder cylinder (Transport (Transport lengt length) h) Length Leng th with straight straight blade Track Track gau gauge ge Width Width via trunio trunion n Ground Ground clearan clearance ce

Operating weight with Semi-U-blade Semi-USemi-U- / straight straight blade blade:: Blade width Blade capacity Ground pressure Ripper(3): Ripper(3):


11,0 6,5 6,5 4,0 4,0

kN mm mm mm mm mm mm

3630 4875 6448 2180 218 0 3145 314 5 630

kg ( for track pad width 610 mm) 35225 mm 4030 3 m 8,9 2 kg/cm (for track pad width mm) 0,91

Length Leng th additional additional (lowered) (lowered) Length addit Length additional ional ( raised) raised) Weight Slop Slope e angle angle

Track with single oscillating track rollers reverse 0 11,0 reve revers rse e0 8,0 reve revers rse e0 4,5

mm mm kg °

2374 1821 4725 31

36120

0,93

Service Manual



Type Design Rated to ISO 9249 Rate Rated d RPM RPM Low idle idle RPM High High idle RPM Displacement Oil specification / viscosity Max. machine inclination - all directions Valve clearance clearance - cold Firing order

kW RPM RPM RPM RPM l


D 9408 TI – E A4 V8 engine – charge air cooled 310 ( 422 PS ) 1800 1800 900 900 +50 1700 1700 +50 17,18 see Service items section 1.3 45° = 100% See Data tag / engin engine e 1–8–4–2–7–3–6–5

SPLITTERBOX

Type Design Rati Ratio o Oil quan quantit tity y Oil specification / viscosity

PVG 351 B 355 Spur gear 1-stage i 0,86 0,8653 53 l 6,3 6,3 see Service items section 1.3

HYDRAULIC SYSTEM

Variable Variable pumps – travel hydraulic hydraulic Flow - Qmax Operating pressure (M1 / M2) p max Axial piston pump – cooling circuit Flow quantity replenishing - Q max Operating pressure (LA electronically regulated) p max Ground by pressure pressure LA (with cold machine) machine) Tandem gear pumps - Replenishing – Pilot control WH Flow quantity - Q max –ges (Qmax –ges =Q1 =Q1 + Q2) Q2) Operating pressure (SP) pmax

Type 2 x THPV 210 l/mi l/min n 4 x 437 437 +30/-10 bar 420 ba A 10 V 28 l/min 57 +/-5 bar 280 ba +5 bar 30 Size Size 55 + 55 l/mi l/min n 232 232 +4 bar 20

Axial piston moto motorr (fan – water cooler) cooler) Operat Ope rating ing spe speed ed Gear motor (fan – hydraulic hydraulic oil cooler) cooler) Operat Ope rating ing spe speed ed


Variable Variable displ. motors motors - Travel hydraulic hydraulic

Type 4 x HMV 280

Regulating pump – Working hydraulic Flow quantity - Q max Ground Ground by pressur pressure e (HD) Operating pressure (HD) - pmax Pilot control control working working hydraulic hydraulic operating operating pressure pressure (ND) Oil tan tank k cap capaci acity ty - circuit capacity capacity - addit additional ional Oil specification / viscosity


18/52 +100 1380 1380 19 +100 2000 200 0

A11 VL 190 395 395 +2 20 +5 260 +4 20

l 280 l 240 see Service items section 1.3

ELECTRICAL SYSTEM


V 24 2 x 12 V, 170 Ah (in Series) 28 V, 80 A kW 9 A 35 A See Operating Operating instructions instructions


Service Manual

Technical data

PR 764 FINAL DRIVE

Type Design Parking brake integrated Ratio Ratio Oil qua quantit ntity y Oil specification / viscosity

700 E 501 Spur gear 1-stage + Planetary gear – 2 stage Disk brake Total Total 54, 54,31 31 : 1 l 22, 22,5 5 + 7,5 See Service items section 1.3

Fixed - and single oscillating track rollers

TRACK COMPONENTS

Track chain pitch Track chain lengt length h Track pad width (1 grouser) grouser) Track pad bolts Track rollers – single flang flange e per side (e) Track rollers – doubl double e flang flange e per side (d) Track roller arrangement Carrier Carrier rollers per side Max. track oscillation

240 / 9,45 44 610 – 660 – 710 – 760 1“ – 14 UNF 4 3 e–d–e–d–e–d–e Qty. 2 ± 3°

Double oscillating track rollers

mm /inch Links mm Thread Thread size Qty. Qty.

e–e–d–d–e–d–e

WORKING ATTACHMENT

Lift cylinder cylinder U – and Semi-U-blad Semi-U-blade e cyl. Ø / rod Ø / stroke Tilt cylinder U – and Semi-U-blade cyl. Ø / rod Ø / stroke Cutting angle cylinder U – and Semi-U-blade cyl. Ø / rod Ø / stroke

mm 120 / 70 / 1490 mm 200 / 90 / 215 mm 220 / 90 / 165

Lift cylindercylinder- ripper cyl. Ø / rod Ø / stroke Ripping Ripping angle cylindercylinder- ripper cyl. Ø / rod Ø / stroke


GENERAL

Travel speed



Pull force max.

Depends Depends on ground condition condition


Height Height over cab Length Leng th over lift cylinder cylinder (Transport (Transport length length)) Length Leng th with straight straight blade Track Track gau gauge ge Width Width via trunio trunion n Ground Ground clearan clearance ce

Oper a atting weight wi th th Semi -U -U-bl ad ade

11,0 6,5 6,5 4,0 4,0

mm mm mm mm mm mm

7,8 7,8 4,8 4,8

3935 5280 7022 2240 224 0 3263 326 3 695

kg ( f or or track pad wi dt dt h 610 mm) 44720

Length addit Length additional ional (lowered) (lowered) Length Leng th additional additional ( raised) raised) Weight Slope angle (for short tooth lengt length) h)

reve revers rse e0 reve revers rse e0

Track with double oscillating track roller

kN 610

Semi-USemi-U- / straight straight blade blade:: Blade width mm 4370 3 Blade capacity m 14 Weight Weight – atta attachmen chmentt total kg 7806 2 Ground pressure kg/cm (for track pad width width 610 mm) 1,04 Ripper(3): Ripper(3):

Track with single oscillating track rollers

mm mm kg °

2494 1894 6160 31

45220

45620

1,05

1,06

Service Manual



Type Version Performan Performance ce according according to ISO 9249 Nomina Nominall RPM Low idle idle RPM High High idle RPM Displac Displaceme ement nt Oil quality / viscosity Max. permissible machine incline – all directions Valve clearance clearance - cold Firing order



D 9508 A7 8 cylinder V-engine 310 ( 422 PS ) 1600 160 0 900 +50 1700 170 0 +50 +50 16, 16,2 2 see Service items– Operating instructions 45° = 100% See data tag / engine 1–5–7–2–6–3–4–8

SPLITTERBOX


PVG 351 B 355 Spur gear 1-stufig i 0,86 0,8653 53 l 6,4 6,4 see Service items– Operating instructions

HYDRAULIC SYSTEM

Variable Variable / travel travel pumps – travel travel hydraulic hydraulic Flow - Qmax Operating pressure (M1 / M2) p max Axial piston pump – Cooling circuit Flow replenishing - Q max Operating pressure (LA electronically regulated) p max Stand by pressure pressure LA (at cold machine) machine) Tandem gear pumps - replenishing – Servo control WH Flow - Qmax –ges (Qmax –ges =Q1 =Q1 + Q2) Q2) Operating pressure (SP) pmax

Type 4 x HPV 210 l/mi l/min n 4 x 388 388 +30/-10 bar 420 ba A 10 V 28 l/ mi min 52 +/-5 bar 250 ba +5 bar 30 Size Size 56+ 56+ 56 l/mi l/min n 208 208 +5 bar 23

Axial piston moto motorr (fan – water cooler) cooler) Operat Ope rating ing RPM Gear motor (fan – hydraulic hydraulic oil cooler) cooler) Operat Ope rating ing RPM


Var. motors motors – Travel Travel hydraulic hydraulic

Type 4 x HMV 280

Regulating pump – Working hydraulic Flow - Qmax Stand Stand by pressur pressure e (HD) (HD) Operating pressure (HD) - pmax Servo control control - Working hydraulic hydraulic Operating Operating pressure pressure (ND) Oil cap capaci acity ty – tan tank k cap capacit acity y - add additi itiona onall circuit circuit cap capaci acity ty Oil quality / viscosity


18/52 +100 1350 1350 19 +100 2000 200 0

A11 VL 190 352 +2 20 +5 260 +5 23

l 280 l 230 see Service items– Operating instructions

ELECTRICAL SYSTEM


V 24 2 x 12 V, 225 Ah 28 V, 80 A kW 7,8 7,8 A 45 A see Operating Operating instructions instructions


Service Manual

Technical data

PR 764 FINAL DRIVE

Type Version Parking brake, integrated Ratio Ratio Oil quan quantity tity Oil quality / viscosity

700 E 501 Spur gear + Planetary gear, each 2-stage Disk brake i ges 54, 54,31 31 : 1 l See Service Service items – Operating Operating instructions instructions See Service items – Operating instructions Fixed and simple oscillating track rollers

TRACK COMPONENTS

Chain Chain pitch pitch Chain length Chain pad width (1 grouser) Track pad bolts Track rollers rollers – single flange flange,, per side (e) Track rollers rollers – doubl double e flang flange, e, per side (d) Track roller arrangement (from back to front) Track rollers per side Track frame oscillation, max. Sprocket Sprocket segme segments nts per side

mm 240 / 9,4 9,45 5 44 610 – 660 – 710 – 760 Thread Thread 1“ – 14 UNF Each 4 Each 3 e–d–e–d–e–d–e Each 2 ± 3° Each 3

Double oscillating track rollers

e–e–d–d–e–d–e

WORKING ATTACHMENT

Lift cylinder cylinder U – and Semi-U-blad Semi-U-blade e cyl. Ø / rod Ø / stroke Tilt cylinder cylinder U – and Semi-U-bla Semi-U-blade de cyl. Ø / rod Ø / stroke Cutting angle cylinder U – und Semi-U-blade cyl. Ø / rod Ø / stroke

mm 120 / 70 / 1490 mm 200 / 90 / 215 mm 220 / 90 / 165

Lift cylindercylinder- ripper cyl. Ø / rod Ø / stroke Ripper Ripper angle cylindercylinder- ripper ripper cyl. Ø / rod Ø / stroke


GENERAL

Travel speed


Traction Traction max.

depends depen ds on ground conditions conditions


Height Height over operator’s operator’s cab Length Lengt h over lift cylinder cylinder (Transport (Transport length length)) Length Lengt h with Semi-U-blad Semi-U-blade e Track Track width width Width over trunion trunion Ground Ground cleara clearance nce

Operating weight with Semi-U-blade Semi-U-blad Semi-U-blade: e:


11,0 6,5 6,5 4,0 4,0

Track with single oscillating track rollers Reverse 0 Reve Revers rse e0 Reve Revers rse e0

Track with double oscillating track rollers

11,0 7,8 7,8 4,8 4,8

kN 610 mm mm mm mm mm mm

3935 5280 7022 2240 224 0 3263 695

kg ( for 610mm plate width) 44720

Blade width mm 3 Blade capacity m Weight – attac attachmen hmentt total kg 2 Ground pressure kg/cm (for 610mm plate width) width)

4370 14 8100 1,04

Ripper Ripper 1 tooth tooth::

Length addit Length additional(l ional(lowere owered) d) Length Lengt h additional(ra additional(raised) ised) Weight Slope angle (for short tooth length length))

mm mm kg °

2494 1894 4786 31

Ripper Ripper 3 tooth tooth::

Length addit Length additional(l ional(lowere owered) d) Length Lengt h additional(ra additional(raised) ised) Weight Slope angle (for short tooth length length))

mm mm kg °

2494 1894 6160 31

45220

45620

1,05

1,06

Service Manual

Technical Data and Maintenance guidelines Maintenance and inspection schedule

Company:....................................................Mach.-Type..............S/N....................Hrs................Date............ Maintenance / inspection at operating hours

WORK TO BE CARRIED OUT by maintenance personnel First and only interval Repeat interval OI

by authorized trained personnel First and only interval Repeat interval

Operating instructions

SM Service manual

Reference see:

For correct fill quantities, use test marksfor procedure and quantities, see OI For quality and viscosity guidelines, see “Service fluids”, OI See data in SM

DIESEL ENGINE Check oil level and coolant level

OI

Check / clean Diesel engine, coolant assembly and belly pan for contamination

OI

Check fuel water separator on pre-filter / empty as necessary -immediately if indicator light lights up Drain fuel tank, condensation and sediments - but at least 1x week 1) Change engine oil - Specification: CI-4, CH-4

OI

1)

OI

Change engine oil - Specification: E4, E5, E6, E7 - Shorten interval in case of aggravating circumstances - but at least 1 x a year 1) Change lube oil filter - but at least 1 x a year Check corrosion inhibitor / antifreeze concentration in coolant

OI

Check V-belt condition

OI

Check control unit mounting, sensory and cable connections for condition

OI

Change / replace oil separator filter insert

OI

Check oil, cooling and fuel system for leaks and condition

OI

OI OI

Check intake and exhaust system – mounting and leaks

OI

Check engine mount

OI

Check engine RPM Change fuel pre-filter and fine filter - Observe bleeding instructions Check / adjust valve play – with cold engine

SM

Grease gear ring on flywheel

SM

Take oil sample before oil change and send it in for analysis Check vibration damper for leaks and distortion - 3000 hrs. Check heater flange – before start of cold season

OI

Change heater flange – 10000 hrs. Replace air filter inserts - as necessary, once a year Replace coolant with antifreeze - every 2 years

OI SM

OI SM OI OI OI

HYDRAULIC SYSTEM Check oil level in hydraulic tank Clean magnetic rod (also after repairs) - up to 50 hrs. daily Check oil cooler for contamination / clean

OI OI

Replace pressure filter for replenishing

OI

Replace main return filter insert or immediately after indicator light lights up Check working and travel hydraulic system for function and leaks, check hose routing for chafing Check / adjust all hydraulic pressures according to adjustment check list

OI

OI

OI / SM SM

Check mountings and fittings for tight seating

OI

Take oil sample (before oil change) and send it in for analysis Replace oil in hydraulic system (refill via filter) - at least every 4 years - when using an environmentally friendly hydraulic medium, request / observe special guidelines

OI OI

Remar ks


Service Manual

Maintenance and inspection schedule

Maintenance / inspection at operating hours




SM Service manual

Reference see:

For correct fill quantities, use test marksfor procedure and quantities, see OI For quality and viscosity guidelines, see “Service “Service fluids”, OI See data in SM

SPLITTERBOX Check oil level

OI

Replace gear oil - at least every 2 years

OI

ELECTRICAL SYSTEM Check the function of the system incl. displays and instruments Check battery electrolyte level - at least 1x a year Clean / check / grease battery connections

OI OI OI

Check cable routing and connections

OI / SM

Check / adjust control system of travel drive according to adjustment check list Check battery charge condition - before start of cold season Check machine software version - update older version with the latest software version

OI / SM SM SM

HEATER / VENTILATION / AIR AIR CONDITIONING SYSTEM Turn the air conditioning system on regularly - at least 1x every 14 days Check water drain valve of air cond. system, clean as necessary Check the system for function and leaks Check the condenser for contamination - blow out if necessary Clean air circulation and fresh fresh air filter, replace as necessary. In dusty conditions, shorten maintenance interval Check mounting screws and drive belt of compressor Check dryer unit (moisture, fill, condition) - if necessary, replace - evacuate the system and refill Clean water drain valve of air conditioning system

OI OI OI OI OI OI OI OI

Check evaporator unit, clean if necessary

OI

Check electrical lines for chafing and plug connections for tight seating Have air conditioning system checked / inspected by HVAC technician - 1x a year

OI

TRAVEL GEAR Check oil level for seal area - at least 1x year - or if indicator light lights up Check gear oil level – clean magnetic plug Check fittings for tight seating 1) Replace gear oil – clean magnetic plug - at least every 4 years Seal area – replace lube oil / flush seal area - at least every 4 years Take oil sample from gear before oil change and send in for analysis

OI OI OI / SM OI OI OI

Remark s

Service Manual

Technical Data and Maintenance guidelines Maintenance and inspection schedule





SM Service manual

Reference see:

For correct fill quantities, use test marksfor procedure and quantities, see OI For quality and viscosity guidelines, see “Service fluids”, OI See data in SM

TRACK COMPONENTS Check mounting screws and nuts of track components, especially track pad and spr ocket Segment bolts for tight seating Lubricate equalizer bar bearing - shorten interval if necessary

OI OI

Check oil level of support axle bearing (only PR 724, PR 734 and PR 744)

OI

Check all track components for leaks

OI

Check / adjust idler guides, replace parts if necessary

OI

Check front side axle bearing screws for tight seating (only PR 754)

OI

Adjust chain tension to suit application - as necessary / when changing applications Clean track - as necessary Check track wear - as necessary

OI / SM OI SM

WORKING ATTACHMENT Check cutting edges, bucket and ripper tooth tooth tips for wear - Make sure attachments are suited to application Check blade center position and attachment of bracket - and at every installation Check all bearing points for play / wear

OI OI OI / SM

Check screws, nuts and bolt retainers for tight seating

OI

Check attachments for intentional damage

OI

GENERAL Lubricate all lube points according to lubrication schedule - Shorten intervals as necessary Check complete machine for correct maintenance and proper condition Explain machine documentation, especially operating instructions / safety guidelines to operating personnel

OI OI OI

Remar ks

Technical data and Maintenance guidelines Maintenance and inspection schedule

Service Manual

Service Manual


Company:..................................................Machine type..............S/N.........-............Hrs................Date............ Maintenance / inspection at operating hours




SM Service Manual

Reference see:

For correct fill quantities, use test marksfor procedure and quantities, see OI For quality and viscosity guidelines, see “Service i tems” OI See data in SM

DIESEL ENGINE Check oil level and coolant level

OI

Check / clean Diesel engine, coolant assembly and belly pan for contamination Check fuel water separator on pre-filter / empty as necessary -immediately if indicator light lights up Drain fuel tank, condensation and sediments - but at least 1x week 1) Change engine oil - Specification: CI-4, CH-4

OI

1)

OI OI

Change engine oil - Specification: E4, E5, E6, E7 - Shorten interval in case of aggravating circumstances - but at least 1 x a year 1) Change lube oil filter - but at least 1 x a year

OI

Check corrosions inhibitor / antifreeze concentration in coolant

OI

Check V-belt condition

OI

Check control unit mounting, sensory and cable connections for condition

OI

Check oil, coolant and fuel system for leaks and condition

OI

OI

Check intake and exhaust system – mounting and leaks

OI

Check engine mount and oil pan for tight seating Change fuel pre-filter and fine filter - Observe bleeding instructions - check pre-filter in case of insufficie nt power Check / adjust valve clearance - with cold engine

OI OI SM

Check exhaust return flap

OI

Check engine RPM

SM

Grease ring gear on flywheel

SM

Take oil sample before oil change and send it in for analysis Change / replace oil separator - but at least 1 x a year Check heater flanges – before start of cold season

OI

Change heater flanges – 10000 hrs. Replace air filter inserts - as necessary, once a year Replace coolant with antifreeze - 3000 hrs. - must be replaced once every 2 years

OI SM OI OI OI

HYDRAULIC SYSTEM Check oil level in hydraulic tank Clean magnetic rod (also after repairs) - up to 50 hrs. daily Check / clean oil cooler for contamination

OI OI

Replace pressure filter for replenishing

OI

Replace main return filter or immediately after indicator light lights up Check working and travel hydraulic system for function and leaks, check hose routing for chafing Check / adjust all hydraulic pressures according to adjustment check list

OI

OI

OI / SM SM

Check mountings and fittings for tight seating

OI

Take oil sample (before oil change) and send it in for analysis Replace oil in hydraulic system system (add oil via filter) - at least every 4 years - when using an environmentally friendly hydraulic medium, request / observe special guidelines

OI OI

Remar ks


Service Manual

Maintenance and inspection schedule





SM Service Manual

Reference see:

For correct fill quantities, use test marksfor procedure and quantities, see OI For quality and viscosity guidelines, see “Service items” OI See data in SM

SPLITTERBOX Check oil level

OI

Replace gear oil - but at least every 2 years

OI

ELECTRICAL SYSTEM Check function of system, incl. displays and instruments Check battery electrolyte level - at least 1x a year Clean / check / grease battery connections

OI OI OI

Check cable routing and connections

OI

Check / adjust control system of travel drive according to adjustment check list Check battery charge condition - before start of cold season Check machine software version - update older version with the latest software version

SM SM SM

HEATER / VENTILATION / AIR CONDITIONING SYSTEM SYSTEM Turn the air conditioning system on regularly - at least 1x every 14 days Check water drain valve or air cond. system, clean if necessary Check the system for function and leaks Check the condenser for contamination - blow out if necessary Clean air circulation and fresh fresh air filter, replace as necessary. In dusty conditions, shorten maintenance interval Check mounting screws and drive belt pulley of compressor Check dryer unit (moisture, fill, condition) - replace if necessary - evacuate the system and refill Clean water drain valve of air conditioning system

OI OI OI OI OI OI OI OI

Check evaporator unit, clean if necessary

OI

Check electrical lines for chafing and plug connections for tight seating Have air conditioning system checked / inspected by HVAC technician - 1x a year

OI

TRAVEL GEAR Check oil level for seal area - at least 1x year - or if indicator light lights up Check gear oil level – clean magnetic plug Check fittings for tight seating 1) Replace gear oil – clean magnetic plug - at least every 4 years Seal area – replace lube oil / flush seal area - at least every 4 years Take oil sample from gear and send in for analysis

OI OI OI / SM OI OI OI

Remark s

Service Manual






SM Service Manual

Reference see:

For correct fill quantities, use test marksfor procedure and quantities, see OI For quality and viscosity guidelines, see “Service i tems” OI See data in SM

TRACK COMPONENTS Check mounting screws and nuts of track components, especially track pad and sprock et segment screws for tight seating Lubricate equalizer bar bearing - shorten interval if necessary

OI OI

Check all track components for leaks

OI

Check / adjust idler guides, replace parts, if necessary

OI

Check front axle bearing screws for tight seating

OI

Adjust chain tension to suit application - as necessary / when changing applications Clean track - as necessary Check for track wear - as necessary

OI / SM OI SM

WORKING ATTACHMENT Check cutting edges, bucket and ripper tooth tips for wear Make sure attachments are suited to application Check blade center position and mounting of bracket - and at every installation Check all bearing points for play / wear

OI OI OI / SM

Check screws, nuts and pin retainers for tight seating

OI

Check attachment for intentional damage

OI

GENERAL Lubricate all lube points according to lubrication schedule - Shorten intervals as necessary Check complete machine for correct maintenance and proper condition Explain machine literature, especially Operating instructions / safety guidelines to operating personnel

OI OI OI

Remar ks


Service Manual

Service Manual

Technical Data - Maintenance Guidelines Maintenance and inspection guidelines

Maintenance and inspection guidelines 1. Gene General ral guid guideli eline nes s 1.1. Documentation Documentation for work to be be carried out For work to be performed, refer to the Maintenance and inspection schedule for your particular machine model  see section 3.2. Check off completed inspections or work by making a check mark on a copy of the form and have the completed form countersigned. The determined test values for the adjustment checks should be documented on an adjustment check list  list  corresponding to the machine model, see paragraph 3.5. In addition, confirm the performance of the inspection / delivery in the machines inspection booklet and booklet and send the appropriate appropriate Service ticket to the appropriate appropriate LIEBHERR company. After removing the old sticker, attach the new inspection sticker, which can also be found in the inspection booklet, clearly clearly visible in the cab. Explain the set up and the contents of the machine documentation to the machine operator. Special emphasis should be given to safety regulations and maintenance task to be performed between inspections. 1.2. Safety Safety guidelines guidelines During all maintenance, inspection or repair work, the applicable safety guidelines according guidelines according to section 1.2. and the operating instructions for the machine must be observed. In addition, all applicable Federal, state and local safety requirements, accident prevention regulations and local laws must be observed. 1.3. Interva Intervals ls The given Maintenance and inspection intervals may not be exceeded, if necessary, necessary, they should be shorted, shorted , for example: Changing filters, draining condensation and sediments in case of dirty fuel; cleaning the radiator in case of contamination; changing filters and oils during or after repairs, etc. 1.4. Taking Taking oil samples samples 1.5. Taking Taking oil samples samples Any required required oil samples must samples must be taken directly from the component before the oil is changed . Run the machine to distribute the oil before taking the oil sample to evenly distribute any existing particle concentration evenly and to prevent prevent incorrect test test results due to deposits. deposits. To determine determine the initial situation situation after repairs repairs (residual contamination), take another sample shortly after reuse. Take the sample from the center area of the oil volume with a manual suction pump, do not overfill the sample container, replace the suction hose every time a sample is taken. Fill out accompanying paperwork correctly and completely. completely . Wrong information can result in unnecessary service or can lead to omissions of necessary service or repair, resulting in unnecessary unnecessary high costs. Also refer to documentation documentation in the oil oil analysis kits. 1.6. Oils, filter filter and other If possible, oils should be drained when drained when warm warm. . Any work which must be done when the machine is cold, for example adjusting the Diesel engine valves, should be completed before. Oil filters should filters should be changed after the oil has been drained and before the oil is refilled. Before reusing the machine, bleed the systems as necessary. necessa ry. Turn the starter about 10-15 seconds before starting the Diesel engine. If possible, cut removed filter cartridges and cartridges and elements open to check for abnormal deposits. deposits . The type and amount of deposits can be helpful to draw conclusions about the condition of the system or the start of any problems. Dispose of Dispose of old oils, filters and other throw away items properly! properly !


Service Manual


For all maintenance, inspection and repair work, use only Original LIEBHERR replacement parts or maintenance items. items . If the customer insists on the installation of other will fit parts, inform the customer about a possible loss of warranty, and make a note to this effect on the inspection report. For general screw tightening torques, see page 1.4., for tightening guidelines for track pad and sprocket segment screws, see page 12.1.

2. Performa Performance nce guideline guidelines s 2.1. Inspection work on the Diesel engine

2.1.1 Change the lube oil filter Loosen filter cartridges with a filter wrench and remove by hand. For installation position, see Operating and maintenance instructions. The standing filters can also be loosened with a suitable tool via the studs on the cartridges. The filters remain filled due to leak safe guards! Tighten the filter cartridges only hand tight (30 Nm).

2.1.2 Check the radiator cap and fan Radiator cap  cap  Check the seal and function of the pressure relief valve. If necessary, replace the cap. Note: If the pressure in the cooling system is too low, steam bubbles formation is increased, which can cause engine problems. Check the fan the fan for damage and make sure the distance to the cooler hood is even. If necessary, realign the hood.

2.1.3 Check / replace the coolant  antifreeze / corrosion inhibitor  inhibitor  Cooling systems systems without without coolant coolant filter Check the required part of antifreeze or corrosion inhibitor with an optical charge tester  see Special tools, page 2.1. The testing procedure is independent of the coolant temperature. The display is shown by a line between light and dark on the right scale of the sight gauge. When using corrosion inhibitor / antifreeze fluid, the temperature is shown to which freeze protection protection is provided (minus values above the 0°C - mark, nominal value at least -37°C). For details, follow the directions of the manufacturer. If in exceptional cases only corrosion inhibitor is used (special fill), then the the ratio can be read on the same scale. In this case, the display corresponds to each -1°C of 1% of corrosion inhibitor (nominal value = 1%). Replace coolant with antifreeze every 2 years. Replace special special fill coolant every every year. To drain the coolant from the cooler and engine block, refer to the machines operating instructions. See also section 1.3. - Service fluids, chapter 1.3- Coolant. If required, check the coolant pump before refilling  see paragraph 2.1.

Service Manual


2.1.4 Check / replace the coolant  antifreeze protection and DCA4 part  cooling systems with coolant with coolant filter Before replacing the coolant filter, check the DCA4 concentration, watch for possible gel formation. The test must be made with DCA4-Test kit CC2602M  see Special tools, section 2.1. Included in the kit is a test instruction with maintenance guidelines guidelines in several languages, which must be strictly observed. Note the expiration date of the test kit = "Use before" for example "Jun. 2005". In case of gel formation, the coolant must be drained and the system must be cleaned. Before preparing the refill, check the quality / specification of water and antifreeze. The antifreeze fluids may not be outdated nor precipitate silicates. Note: To prepare the coolant, mix water first with DCA4 in the required ration. Then add the required antifreeze fluid to the water / DCA4 mixture and mix well. Replace the Replace the coolant with antifreeze and DCA4 every 2 years. Replace the the special coolant fill annually. To drain the coolant from cooler and engine block, refer to machines operating instructions. See also section 1.3.  Service fluids, chapter 1.3 - coolant. If required, check the coolant pump before refilling  see paragraph 2.1. 2.1.5 Check the V-belt condition and tension Check by hand, see Operating instructions. Check with Krikit test kit, see Special Special tools, page 2.1. Replace worn or brittle V-belts. For procedure to adjust or change the belt, see Operating instructions.

2.1.6 Check oil, coolant and fuel system as system as well as Intake and exhaust system Check systems for leaks, damage and chafing. Fix leaks properly, retighten loose mountings and hose clamps. Replace chafed hoses or lines, make sure they are routed properly to prevent kinks and chafing.

428044

Check the radiator mount, replace Megi bearings if necessary. Check air filter housing and filter inserts in the housing for tight seating. If necessary, replace damaged parts, seals and elements. 2.1.7 Check mounting of oil pan and engine consoles for tight seating Check the screws on the oil pan and engine console and retighten, if necessary. For tighten torques, see section 1.4. Check the engine mount, replace Megi bearings if necessary. Check other screw fittings, such as the injector retainers retainers for tight seating. 2.1.8 Check / adjust engine RPM  Service the mechanical actuator actuato r to to the injection pump and potentiometer

The RPM can RPM can be be checked on the display in the machine. For values, see adjustment check list, section 3.5. If the required low idle RPM values are not reached, adjust the stop screws on the engine control in the cab, correct the routing / adjustment of the shut off and RPM control, neutral function of hydraulic systems and, if necessary, also the adjustment of the injection pump  see section 17.4. If necessary, the RPM can also be checked with an electronic RPM gauge (connection on a blank injection line). For RPM gauge  see Special tools, page 2.1. Check the mechanical actuation to the injection pump and potentiometer for damage, as well as the ball joints for war. Replace damaged or worn parts.


Service Manual


2.1.9 Check / adjust valve clearance Check and adjust clearance with cold (= cold (= warm to the touch) engine. engine. For valve clearance, firing order and cylinder configuration, see page 4.2. For further details and adjustment procedure, see Service Manual  Diesel engines. Install engine cranking tool  tool  see Special tools. page 2.1.  instead of cover on flywheel housing  see paragraph 2.1. 2.1.10 Grease flywheel teeth Remove the cover from the timing case and check the gear. Distribute about 3 1 cm of grease in the visible tooth gaps. Reinstall cover.

Note: If possible, use non-metallic based grease. High metal or graphite content as well as large amounts of grease in connection with metallic abraded particles can cause problems for the engine RPM sensor signal.

2.1.11 Check the flame glow system system  replace oil separator separator  check / adjust fuel injectors injectors  check water pump pump A defective flame glow system greatly system greatly influences the starting behavior of the Diesel engine. For that reason, make sure to check the system before the start of the cold season. Due to age or external damage, the membrane of the oil separator can can leak, which can cause engine damage due to dust ingestion. For that reason, make sure to check the service date and replace replace old or damaged oil separators. If there is a drop in engine performance, if the engine runs unevenly or a knocking sound can be heard coming from the engine, or if exhaust fumes are dark, check and adjust the fuel injectors ( nozzles ). ). If noted for inspection, remove the cover to the coolant pump and pump and check the axial play of the pump shaft with a test gauge. If the axial play is

0,1 mm, replace the coolant pump.

For details, see "Service Manual  Diesel engines. 2.2. Inspection / maintenance maintenance work on the hydraulic hydraulic system 2.2.1 Clean the magnetic rod On new machines and after repairs, check and clean the magnetic rod daily until only minute deposits are found. After that, use normal maintenance intervals. Increasing deposits point to abnormal wear. 2.2.2 Check / replace return filter inserts Replace the main return filter insert in the hydraulic tank. Check the strainer inserts on variable displacement pumps and motors and check the regulating pumps replenishing replenishing circuit filter for deposits. If any deposits are found, determine determine the origin and find the cause. cause. If necessary, repair the component component or replace it. Replace the strainer insert. 2.2.3 Check the working and travel hydraulic hydraulic system for function and leaks, hose routing for chafing, mountings and fittings for tight seating Run through all travel and working movements and movements and check for abnormal function. Check the actuator plate, plunger and universal joint of the working hydraulic pilot control valve for wear, grease lightly and adjust, if necessary. The same applies for pilot controls for auxiliary equipment. To check the pressure accumulator - Safety control  working hydraulic, start the Diesel engine and raise

Service Manual


the attachment on the front. Turn the engine off (bring starter key again to position 1) and leave the safety lever in the down position. Quickly actuate the function function down several several times. If the attachment can be lowered less than four times, then the pressure accumulator is defective or there is excessive leakage in the system. Check the hose lines for lines for leaks and make sure they are routed without kinks. Check for chafed areas. Replace chafed sweating and old hoses. See safety guideliens, page 1.2. Do not route servo, leak oil and tank line hoses together with the high pressure hoses in one bundle. Do not route them around sharp corners, edges or fittings. Check connections for leaks and replace seal rings, if necessary. Check piston Check piston rods for rods for damage as well as piston rod bearings bearings for for leaks. Correct any problems, if necessary. Check mounting screws of screws of hydraulic components (pumps, motors, tank etc. as well as flange connection for tight seating. seating. Retighten, ifif necessary. necessary. 2.2.4 Check / adjust all hydraulic pressures Carry out pressure tests / adjustments according to the Adjustment check list for list for the corresponding machine  see section 3.5  and enter enter the results. results. For detailed description, data and instructions, see adjustment check list or corresponding sub group in Service Manual.

2.3. Inspection work on electrical electrical system system 2.3.1 Check function of system, incl. displays and instruments Turn on all electrical operating functions individually, check correct function and display on instrument panel. See "Operating instructions". In case of problems, check fuses or wiring. See corresponding corresponding schematics in section 9. 2.3.2 Clean / check / grease battery connections, check cable routing and connections connections

Check battery heads and terminals and terminals for for oxidation and tight seating. Clean heads and terminal regularly and cover with grease. Check batteries for external damage and leaks. Check cable harnesses for chafing and connections for oxidation. Re-insulate any chafing, optimize the routing and protect the cable harness with a shrink-fit hose to prevent moisture infiltration.

2.3.3 Check / adjust control system On Series 4 machines, the test / adjustment is made with a Notebook and the L-Diag Diagnostics software set according set according to instructions, section 10.1. Carry out tests / adjustments according to the adjustment check list for list for the corresponding machine model  see section 3.5  and enter the results. For special tools, see page 2.1.

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