Professional Documents
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Service Manual
Table of contents
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9.0.00 1 2 Sub group index "Electrical system – Plans and components" 03.2007
9.1.20 1 6 Code letter explanations 02.2010
9.1.30 1 8 Code letter explanations 02.2010
9.1.60 1 6 Code letter explanations 02.2009
9.2.20 1 2 Function list 02.2007
9.2.30 1 2 Function list 02.2007
9.2.40 1 2 Function list 03.2008
9.2.60 1 2 Function list 02.2009
9.3.20 1 2 Fuses, cross points, notes 02.2007
9.3.30 1 2 Fuses, cross points, notes 03.2007
9.3.40 1 2 Fuses, cross points, notes 03.2008
9.3.60 1 2 Fuses, cross points, notes 02.2007
9.4.20 1 16 Current flow diagram 02.2007
9.4.20 1/02 Current flow diagram Addendum 02.2007
9.4.20 2/02 Current flow diagram Addendum 02.2007
9.4.20 3/02 Current flow diagram Addendum 02.2007
9.4.20 15/02 Current flow diagram Addendum 02.2007
9.4.21 1 62 Current flow diagram 03.2008
9.4.22 1 76 Current flow diagram 03.2009
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17.0.00 1 2 Sub group index "Operator’s platform, heater, air conditioner" 03.2007
17.1.00 1 6 Operator’s platform 01.2008
17.2.00 1 4 Heater and blower 01.2007
17.3.00 1 10 Air conditioning system 01.2009
17.4.00 1 2 Operator’s seat – air cushioned 03.2006
17.5.20 1 4 Throttle control 01.2007
17.5.21 1 2 Throttle control 01.2007
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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.
We reserve the right to make changes of technical details on the machine in comparison to the information and
drawings in this manual.
6.3.10 - 01/02
main group according sub group of main group division based on continuous running
to manual index according to sub group information content or number and complete
index machine model group 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.
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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.
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A. Prior and during the performance of tests, adjustments, and repairs, the following
guidelines must be followed:
Any type of work may only be performed by qualified personnel or under the supervision of such personnel.
Qualified personnel are persons who - based on specialized training and experience - have sufficient
knowledge in the general area of earthmoving 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 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 to the LIEBHERR adjustment values when performing 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. in such event, qualified personnel or
individuals performing said work under the supervision of such personnel, should assure that additional safety
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 doors are fully secured from
unexpected and/or unintended closing during the diagnostic and/or adjustment work effort. Care should
also be exercised to assure that there will be no inadvertent or 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 avoided.
- It may be necessary for purposes of performing repairs, adjustments 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 reserves the
right to update any Operation Manual, including but not limited to the revision or addition of safety guidelines. It
is, therefore, strongly recommended to also consult the latest Operation Manual of the machine involved.
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Working with earth moving machinery can be dangerous, it could result in injury or death if proper 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.
Important safety notes are used throughout this manual, such as DANGER, CAUTION, WARNING or NOTE.
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.
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Always place the safety lever up before leaving the 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
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 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.
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Regularly check all components, lines, tubes, and hoses for oil and fuel leaks and / or damage. Replace 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! Never use cold 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; make sure 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.
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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, etc.
Always have another person guide you if visibility is restricted. Always take signals from one person only.
Utilize only experienced personnel to attach loads and direct operators. The person giving signals must be
visible to the operator or equipped with two way radios.
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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 down the ramp.
- Hold the attachment as close as possible above the ground.
- Use a guide to signal you.
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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 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 and repair work, make sure that all screw connections or fittings, which had to be
loosened, are retightened.
If it becomes 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 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, fuel or service fluids from connections and 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 during cleaning, the temperature sensors of the fire warning and sprinkler system do not
come in contact with the hot cleaning fluid or the sprinkler system could be activated.
- After the clearing procedure, remove all covers and tape.
- After cleaning the machine, check all fuel, engine oil, and hydraulic lines for leaks, loose connections and
for chafed and damaged areas.
- All problems must be remedied immediately.
Adhere to product safety instructions issued for handling oils, greases and other chemical 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 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 lifting devices with sufficient carrying capacity.
Procedure:
- To lift spare parts and component assemblies for replacement on the machine, they must be securely
mounted and secured onto the lifting devices, to prevent accidents.
- Use only suitable and technically flawless lifting devices as well as tackle with sufficient load lifting capacity.
- Do not allow anyone to work or remain underneath the lifted load!
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Do not use damaged or insufficient wire ropes. Always wear gloves when handling wire ropes and cables.
Only experienced 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 on any machine parts or components to get closer to the working
area. Always wear safety harnesses or similar safety equipment when working 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. The machine and / or
its attachment must always be properly blocked and supported with wooden blocks or beams.
Always block the machine in such a way that any change in the center of gravity will not endanger its stability.
Never use metal on metal supports!
Only authorized, specially trained 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 when checking for leaks. A thin stream of fluid escaping from a 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, 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 component 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.
Use only Original fuses with the same amperage. In case of problems in the electrical power supply, turn the
machine off immediately.
Inspect / check the electronic 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.
If any work is necessary on energized, voltage carrying parts, a second person must be utilized to 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 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.
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Service Items
Notes for the disposition of service fluids and filter:
- Service fluids may not be discharged into the ground, drainage system or waterways.
- Different service fluids and filters should be collected and disposed of in separate containers.
- Do not use containers, which previously held food items or drinks - to 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.
- Do not use old or incorrectly stored service fluids and filters, dispose of them properly.
Note: For older machines / Diesel engines, if still in use, engine oils according to the lower 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.
For the operation in extreme climate zones, such as in arctic regions, special guidelines apply and are
available from the manufacturer.
Oil quality:
Oil quality:
Applications
CF-4, CG-4, CH-4,
E3 (D5), E4, E5,
CI-4, E2 (D4))
Ambient Sulfur content
Change interval Change interval
temperature in fuel
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 fluid. This concentration protects the system to approx. -37°C / -34°F.
Antifreeze protection chart
Protection to
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!
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 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 given parts outside the cooling circuit in a suitable, clean
container first.
Deutz Kühlschutzmittel 0101 1490 DEUTZ Service International GmbH, Köln / BRD
Glycoshell N Shell
Glysantin (G 48-00) BASF AG, Ludwigshafen / BRD
Presently approved anti corrosion / antifreeze fluids / 50:50 Premix (as of December 2003):
(50 % water : 50 % corrosion/antifreeze fluids)
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).
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 DCA 4 - water filter
Liter Container approx.0.5 liter appr. liter Id. No.
24-39 3 oder 1,5 7367 045
40-59 4 oder 2,0 7381 493
60-79 5 oder 2,5 7367 052
80-115 8 oder 4 7367 052
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
1.3.2 Coolant - special filling - with anti corrosion fluids, without 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 water-
soluble 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".
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
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.
5. Grease
6. Miscellaneous
Always observe all guidelines issued in the Operation and Maintenance manuals, repair manuals and on
drawings.
Service Items
see operation and maintenance manual.
The preload and tightening torques listed in the chart are from VDI guidelines 2230 of July 1986.
Installation preload FM and tightening torques MA 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 socket head screws DIN EN ISO 4762 (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)
Preload forces and tightening torques for screws with standard metric thread according
to factory standard WN 4037 I
Wrench size
Preload values FM based on Tightening torques MA are (x) = per DIN931, for
screw grades and are given based on screw grades and
Standard Hex head
in N are given in Nm Socket head
metric thread
screws screws
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
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Preload forces and tightening torques for screws with fine metric thread according to
factory standard WN 4037 I
Wrench size
Preload values FM based on Tightening torques MA are (x) = per DIN931, for
screw grades and are given based on screw grades and
Fine metric
in N are given in Nm Socket head
thread
Hex head screws screws
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 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
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Tightening torques for cutting edges, end bits and bolt- on adapters
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To obtain To
Unit of Measure Multiply by by
Multiply obtain
Length 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
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Dimensions are in mm
mm x 0,03937 = inches
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PR Litronic Serie 4
LR Litronic Serie 4 MJFCIFSS! 1.5.00 - 1 / 6
RL Litronic Serie 4
General Service Manual
Conservation guidelines
Note!
Despite completed conservations measures, the machine must still be inspected in certain
intervals and touched up, if necessary. This is within left to the discretion of the operator, but
these inspections should be carried out regularly (monthly), especially in aggravated
conditions (cold, heat, near the coast, etc.).
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PR Litronic Serie 4
1.5.00 - 2 / 6 Mjfcifss! LR Litronic Serie 4
RL Litronic Serie 4
Service Manual General
Conservation guidelines
Apply a thick layer of conservation wax „Waxoyl 120-4“ to cover ball joints, 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 and add distilled water, if necessary. Always store the batteries
in a cool and dry area. Check the load current regularly every 6 weeks and recharge, if
necessary.
Close the exhaust outlet with an air and watertight cover.
Pay attention to any additional guidelines for special components or special local conditions.
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PR Litronic Serie 4
LR Litronic Serie 4 MJFCIFSS! 1.5.00 - 3 / 6
RL Litronic Serie 4
General Service Manual
Conservation guidelines
4 Return to operation
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PR Litronic Serie 4
1.5.00 - 4 / 6 Mjfcifss! LR Litronic Serie 4
RL Litronic Serie 4
Service Manual General
Conservation guidelines
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PR Litronic Serie 4
LR Litronic Serie 4 MJFCIFSS! 1.5.00 - 5 / 6
RL Litronic Serie 4
General Service Manual
Conservation guidelines
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PR Litronic Serie 4
1.5.00 - 6 / 6 Mjfcifss! LR Litronic Serie 4
RL Litronic Serie 4
Service-Manual General Information
Weight of materials
Weight of materials
1) Varies with moisture content, grain size, degree of compaction, etc.. Test must be made to determine exact
material characterics.
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PR Litronic Serie 4
LR Litronic Serie 4 MJFCIFSS! 2.1.00 - 1 / 20
RL Litronic Serie 4
Tools and work instructions Service Manual
Special tools
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PR Litronic Serie 4
2.1.00 - 2 / 20 Mjfcifss! LR Litronic Serie 4
RL Litronic Serie 4
Service Manual Tools and work instructions
Special tools
Turning device
to check / adjust the
valve play
Pos. 1 0524045 LR Series 4 To be installed on
the flywheel
RL Series 4 housing instead of
PR Series 4 the cover
except
Pos. 2 10490350 PR 764 S/Nxxx- To be installed on
9506 the V-belt -
10116805 RL 64 crankshaft
(can also be
used for
PR 724 F/Nxxx-
9200
PR 734 F/Nxxx-
8220
PR 744
PR 754
LR 624
LR 634
RL 44 )
Hand pump with 10454803 PR Series 4 For optional Diesel
pressure gauge LR Series 4 particle filter.
RL Series 4 Can be used for
leak tests of
counter-pressure
line
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PR Litronic Serie 4
LR Litronic Serie 4 MJFCIFSS! 2.1.00 - 3 / 20
RL Litronic Serie 4
Tools and work instructions Service Manual
Special tools
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PR Litronic Serie 4
2.1.00 - 4 / 20 Mjfcifss! LR Litronic Serie 4
RL Litronic Serie 4
Service Manual Tools and work instructions
Special tools
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Tools and work instructions Service Manual
Special tools
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RL Litronic Serie 4
Service Manual Tools and work instructions
Special tools
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Tools and work instructions Service Manual
Special tools
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Service Manual Tools and work instructions
Special tools
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Tools and work instructions Service Manual
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RL Litronic Serie 4
Service Manual Tools and work instructions
Special tools
2 each required
Note!
The Id. Numbers for the following tools are listed in the spare parts list for the hydraulic
cylinders.
For tightening
torques, see
section 8 Hydraulic
cylinders
For tightening
torques, see
section 8 Hydraulic
cylinders
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Tools and work instructions Service Manual
Special tools
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Service Manual Tools and work instructions
Special tools
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Tools and work instructions Service Manual
Special tools
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Service Manual Tools and work instructions
Special tools
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Tools and work instructions Service Manual
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RL Litronic Serie 4
Service Manual Tools and work instructions
Special tools
Type Machine A B C D E F G H I
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RL Litronic Serie 4
Tools and work instructions Service Manual
Special tools
3.2 Mandrels
For the installation of the radial shaft seal rings into the hoist cylinder bearing.
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Service Manual Tools and work instructions
Special tools
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Tools and work instructions Service Manual
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RL Litronic Serie 4
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. Preparation of a 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.
2. Preparation of a 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. Storing Electrodes
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.
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4. Welding Technique
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.
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After the welding is completed, clean the welding seam as necessary. Grind the run out between reinforcement
plate and basic material.
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Installation instructions
Note!
On Series 4 machines, due to design reasons, only seals toward the outside are used.
2. Installation
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, the seal half can incline and/ or the O-ring can twist.
These improper installations as well as damage to the sealing surfaces cause leaks.
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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 offset by 120°. Check the
sealing surfaces again for absolute cleanliness and apply a thin film of oil or grease.
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For removal, use the installation sleeve 10 on the housing side marked OUT. Set the 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.
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C. Safety lever
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 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.
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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
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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 new hex head screws with washers 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 bar bearing on the travel gear frame 1.
Then tighten the hex head screws 10 crosswise according to WN4307.
Repeat the installation procedure on the second travel gear side.
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SPLITTER BOX
Type 351 B 366
Construction 1 stage spur gear
Ratio i 0,784
Oil quantity l 3,2
Oil specification see lube oil - group 1.3
HYDRAULIC SYSTEM
Travel pumps type 2 x HPV 105
max. flow - Qmax l/min 2 x 233
max. operating pressure (M1 / M2) - pmax bar 420
Tandem gear pump - replenishing - coolant circuit / fan drive model 56 / 19
max. flow replenishing - Qmax l/min 124
max. operating pressure (SP) - pmax bar 20
max. flow fan drive - Qmax l/min 42
max. operating pressure (electronic regulated) - pmax bar 150+10
Gear motor fan drive model 16
operation RPM 1/min 1850+100
Travel motors type 2 x BMV 186
ELECTRIC SYSTEM
Voltage V 24
Battery 2 x 12 V, 110 Ah (in series)
Alternator 28 V, 55 A
Starter kW 5,4
Automatic circuit breaker A 35
Fuses A see operation and maintenance manual
/..
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TRACK COMPONENTS
Track chain pitch mm / inch 190 / 7,5
Track chain length links 42 46
Track pad width ( single grouser) mm 508 / 560 / 610 / 660 711/ 812/ 864/ 914
Track pad bolts thread. size ¾“ UNF
Track rollers - single flange (s) qty.4
Track rollers - double flange (d) qty.3 4
Track roller location s-d-s-d-s-d-s s-d-s-d-d-s-d-s
Carrier rollers each side qty. 2
Max. roller frame oscillation ± 3°
ATTACHMENT
GENERAL DATA
Travel speed normal range - III km/h 0 11,0
reduced range - II km/h 0 6,5 reverse 0 7,8
reduced range - I km/h 0 4,0 reverse 0 4,8
Operating weight with Semi-U- / Straight blade (track pad 610 mm) kg 16400/16530/16660 17010/17150/17295 17740/18025/18310
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SPLITTER BOX
Type 351 B 366
Construction 1 stage spur gear
Ratio i 0,784
Oil quantity l 3,2
Oil specification see lube oil - group 1.3
HYDRAULIC SYSTEM
Travel pumps type 2 x HPV 105
max. flow - Qmax l/min 2 x 233
max. operating pressure (M1 / M2) - pmax bar 420
Tandem gear pump - replenishing - coolant circuit / fan drive model 56 / 19
max. flow replenishing - Qmax l/min 124
max. operating pressure (SP) - pmax bar 20
max. flow fan drive - Qmax l/min 42
max. operating pressure (electronic regulated) - pmax bar 150+10
Gear motor fan drive model 16
operation RPM 1/min 1850+100
Travel motors type 2 x HMV 210
ELECTRIC SYSTEM
Voltage V 24
Battery 2 x 12 V, 110 Ah (in series)
Alternator 28 V, 55 A
Starter kW 5,4
Automatic circuit breaker A 35
Fuses A see operation and maintenance manual
/..
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TRACK COMPONENTS
Track chain pitch mm / inch 190 / 7,5
Track chain length links 42 46
Track pad width ( single grouser) mm 508 / 560 / 610 / 660 711/ 812/ 864/ 914
Track pad bolts thread. size ¾“ UNF
Track rollers - single flange (s) qty.4
Track rollers - double flange (d) qty.3 4
Track roller location s-d-s-d-s-d-s s-d-s-d-d-s-d-s
Carrier rollers each side qty. 2
Max. roller frame oscillation ± 3°
ATTACHMENT
GENERAL DATA
Travel speed normal range - III km/h 0 11,0
reduced range - II km/h 0 6,5 reverse 0 7,8
reduced range - I km/h 0 4,0 reverse 0 4,8
Operating weight with Semi-U- / Straight blade (track pad 610 mm) kg 16400/16530/16660 17010/17150/17295 17740/18025/18310
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SPLITTERBOX
Type 300 B 344
Version Spur gear drive – 1-rodge
Ratio i 0,788
Oil quantity l 3
Oil quality / viscosity see Service fluids, section 1.3
HYDRAULIC SYSTEM
Variable / travel pumps – travel hydraulic Type 2 x HPV 105 - 2
Flow - Qmax l/min 2 x240
Operating pressure (M1 / M2) pmax bar 420
Tandem gear pumps - Replenishing – cooling circuit / fan drive Type / size 55 + 19 / 56 + 16
Flow replenishing - Qmax l/min 117
Operating pressure (SP) pmax bar 20
Flow fan drive - Qmax l/min 43
Operating pressure (electronically regulated) - pmax bar 185±5
Gear motor Fan drive Type / size 16
Operating RPM 1/min 2150+100
Variable travel motors – travel hydraulic Type 2 x HMV 210 - 02
ELECTRICAL SYSTEM
Operating voltage V 24
Batteries 2 x 12 V, 170 Ah (in Series)
Alternator 28 V, 80 A
Starter kW 6,6
Central fuse A 45
Individual fuses A See Operating instructions
/..
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TRACK COMPONENTS
Chain pitch mm / inch 190 / 7,5
Chain length links 42 46
Chain pad width (1 grouser) mm 508/560/610/660 711/812/864/914
Track pad bolts Thread size 3/4“ UNF
Track rollers – single flange, per side (e) Qty. 4 4 4
Track rollers – double flange, per side (d) Qty. 3 4 4
Track roller arrangement e-d-e-d-e-d-e e-d-e-d-d-e-d-e e-d-e-d-d-e-d-e
Track rollers per side 2
Track frame oscillation, max. ± 3°
Tilt cylinder Straight and Semi-U-blade Cyl. Ø / Rod Ø / Strokemm140 / 70 / 100 140 / 70 / 100 140 / 70 / 100
Tilt blade Cyl. Ø / Rod Ø / Stroke mm 140 / 70 / 130 140 / 70 / 130 ----
6 – way blade Inside Cyl. Ø / Rod Ø / Stroke mm 120 / 60 / 170 120 / 60 / 170 120 / 60 / 170
6 – way blade outside Cyl. Ø / Rod Ø / Stroke mm 120 / 60 / 170 120 / 60 / 170 ----
Swing cylinder 6 – way blade inside Cyl. Ø / Rod Ø / Stroke mm 120 / 60 / 325 120 / 60 / 325 120 / 60 / 325
Lift cylinder Three tooth ripper Cyl. Ø / Rod Ø / Stroke mm 140 / 70 / 490
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Ground pressure² kg (for chain pad width mm) See Operating instructions „Technical data“
² Lubricants/ service fluids, Semi-U-blade/straight blade/6-way blade ,
GENERAL
Travel speed Normal range - III km/h 0 11 reverse 0 11
Reduced range - II km/h 0 6,5 reverse 0 7,8
Reduced range - I km/h 0 4,0 reverse 0 4,8
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SPLITTERBOX
Type 300 B 344
Version Spur gear drive – 1-rodge
Ratio i 0,788
Oil quantity l 3
Oil quality / viscosity see Service fluids, section 1.3
HYDRAULIC SYSTEM
Variable / travel pumps – travel hydraulic Type 2 x HPV 105 - 2
Flow - Qmax l/min 2 x240
Operating pressure (M1 / M2) pmax bar 420
Tandem gear pumps - Replenishing – cooling circuit / fan drive Type / size 55 + 19 / 56 + 16
Flow replenishing - Qmax l/min 117
Operating pressure (SP) pmax bar 20
Flow fan drive - Qmax l/min 43
Operating pressure (electronically regulated) - pmax bar 185±5
Gear motor Fan drive Type / size 16
Operating RPM 1/min 2150+100
Variable travel motors – travel hydraulic Type 2 x HMV 210 - 02
ELECTRICAL SYSTEM
Operating voltage V 24
Batteries 2 x 12 V, 170 Ah (in Series)
Alternator 28 V, 80 A
Starter kW 6,6
Central fuse A 45
Individual fuses A See Operating instructions
/..
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TRACK COMPONENTS
Chain pitch mm / inch 190 / 7,5
Chain length links 42 46
Chain pad width (1 grouser) mm 508/560/610/660 711/812/864/914
Track pad bolts Thread size 3/4“ UNF
Track rollers – single flange, per side (e) Qty. 4 4 4
Track rollers – double flange, per side (d) Qty. 3 4 4
Track roller arrangement e-d-e-d-e-d-e e-d-e-d-d-e-d-e e-d-e-d-d-e-d-e
Track rollers per side 2
Track frame oscillation, max. ± 3°
Tilt cylinder Straight and Semi-U-blade Cyl. Ø / Rod Ø / Strokemm140 / 70 / 100 140 / 70 / 100 140 / 70 / 100
Tilt blade Cyl. Ø / Rod Ø / Stroke mm 140 / 70 / 130 140 / 70 / 130 ----
6 – way blade Inside Cyl. Ø / Rod Ø / Stroke mm 120 / 60 / 170 120 / 60 / 170 120 / 60 / 170
6 – way blade outside Cyl. Ø / Rod Ø / Stroke mm 120 / 60 / 170 120 / 60 / 170 ----
Swing cylinder 6 – way blade inside Cyl. Ø / Rod Ø / Stroke mm 120 / 60 / 325 120 / 60 / 325 120 / 60 / 325
Lift cylinder Three tooth ripper Cyl. Ø / Rod Ø / Stroke mm 140 / 70 / 490
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Ground pressure² kg (for chain pad width mm) See Operating instructions „Technical data“
² Lubricants/ service fluids, Semi-U-blade/straight blade/6-way blade ,
GENERAL
Travel speed Normal range - III km/h 0 11 reverse 0 11
Reduced range - II km/h 0 6,5 reverse 0 7,8
Reduced range - I km/h 0 4,0 reverse 0 4,8
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SPLITTER BOX
Type 350 B 374
Construction 1 stage spur gear
Ratio i 0,86
Oil quantity l 3
Oil specification see lube oil - group 1.3
HYDRAULIC SYSTEM
Travel pumps type 2 x HPV 135
max. flow - Qmax l/min 2 x 282
max. operating pressure (M1 / M2) - pmax bar 420
Tandem gear pump - replenishing - coolant circuit / fan drive model 56 / 19
max. flow replenishing - Qmax l/min 117
max. operating pressure (SP) - pmax bar 20
max. flow fan drive - Qmax l/min 33
max. operating pressure (electronic regulated) - pmax bar 210+10
Gear motor fan drive model 16
operation RPM 1/min 1730+100
Travel motors type 2 x BMV 260
ELECTRIC SYSTEM
Voltage V 24
Battery 2 x 12 V, 143 Ah (in series)
Alternator 28 V, 55 A
Starter kW 6,6
Automatic circuit breaker A 35
Fuses A see operation and maintenance manual
/..
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TRACK COMPONENTS
Track chain pitch mm / inch 203,2 / 8,0
Track chain length links 40 44
Track pad width ( single grouser) mm 508 / 560 / 610 712/ 812/ 914/ 965
Track pad bolts thread. size 3/4“ UNF
Track rollers - single flange (s) qty. 4
Track rollers - double flange (d) qty. 3 4
Track roller location s-d-s-d-s-d-s s-d-s-d-d-s-d-s
Carrier rollers each side qty. 2
Max. roller frame oscillation ± 3°
ATTACHMENT
Lift cylinder straight blade cyl. Ø / rod Ø / stroke mm 100 / 60 / 1300 100 / 60 / 1165
GENERAL DATA
Travel speed normal range - III km/h 0 11,0
reduced range - II km/h 0 6,5 reverse 0 7,8
reduced range - I km/h 0 4,0 reverse 0 4,8
Operating weight with Semi-U- / Straight blade (track pad 610 mm) kg 20 878 21 503 22 237
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SPLITTER BOX
Type 351 B 374
Construction 1 stage spur gear
Ratio i 0,86
Oil quantity l min. 2,6 – max. 3,0
Oil specification see lube oil - group 1.3
HYDRAULIC SYSTEM
Travel pumps type 2 x HPV 135
max. flow - Qmax l/min 2 x 282
max. operating pressure (M1 / M2) - pmax bar 420
Tandem gear pump - replenishing - coolant circuit / fan drive model 55 + 19 / 56 + 16
max. flow replenishing - Qmax l/min 117
max. operating pressure (SP) - pmax bar 20
max. flow fan drive - Qmax l/min 33
max. operating pressure (electronic regulated) - pmax bar 220±5
Gear motor - fan drive model 16
operation RPM 1/min 1800+100
Travel motors type 2 x HMV 280
ELECTRIC SYSTEM
Voltage V 24
Battery 2 x 12 V, 170 Ah (in series)
Alternator 28 V, 80 A
Starter kW 7,8
Automatic circuit breaker A 45
Fuses A see operation and maintenance manual
/..
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Mjfcifss! 3.1.31 - 1 / 4
PR 734 F/N xxx-8220
Technical Data - Maintenance Guidelines Service-Manual
Technical data
TRACK COMPONENTS
Track chain pitch mm / inch 203,2 / 8,5
Track chain length links 40 44 44
Track pad width ( single grouser) mm 508 / 560 / 610 710/812/914/965
Track pad bolts thread. size 3/4“ UNF
Track rollers - single flange (s) qty. 4 4 4
Track rollers - double flange (d) qty. 3 4 4
Track roller location s-d-s-d-s-d-s s-d-s-d-d-s-d-s s-d-s-d-d-s-d-s
Carrier rollers each side qty. 2
Max. roller frame oscillation ± 3°
ATTACHMENT - cylinder
Lift cylinder straight- and Semi-U-blade cyl. Ø / rod Ø / stroke mm 100 / 60 / 1230 100 / 60 / 1230
angle cylinder cyl. Ø / rod Ø / stroke mm 100 / 60 / 1300 100 / 60 / 1230
Tilt cylinder straight- and Semi-U-blade cyl. Ø / rod Ø / stroke mm 160 / 80 / 0120
angle blade - cyl. Ø / rod Ø / stroke mm 180 / 80 / 0200
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
Operating weight with straight blade kg (track pad in mm) 20481/20605/2072 20993/21131/21267 21902/22176
Operating weight with straight blade kg (track pad in mm) 2813/20937/21061 21325/21463/21599
/..
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3.1.31 - 2 / 4 Mjfcifss!
PR 734 F/N xxx-8220
Service-Manual Technical Data - Maintenance Guidelines
Technical data
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PR 734 F/N xxx-8220
Technical Data - Maintenance Guidelines Service-Manual
Technical data
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3.1.31 - 4 / 4 Mjfcifss!
PR 734 F/N xxx-8220
Service-Manual Technical Data - Maintenance Guidelines
Technical data
SPLITTER BOX
Type 351 B 355
Construction 1 stage spur gear
Ratio i 0,861
Oil quantity l 6,4
Oil specification see lube oil - group 1.3
HYDRAULIC SYSTEM
Travel pumps type 2 x HPV 210-02
max. flow - Qmax l/min 2 x 380
+30/-10
max. operating pressure (M1 / M2) - pmax bar 420
Axial piston pump – cooling circuit A 10 V 28
Flow quantity replenishing - Qmax l/min 57
+/-5
Operating pressure (LA electronically regulated) pmax bar 205
+5
Stand by pressure LA (at cold machine) bar 30
Tandem gear pumps – replenishing – servo control WH model 45 + 38
Flow quantity - Qmax –ges (Qmax –ges =Q1 + Q2) l/min 150
+4
Operating pressure (SP) pmax bar 20
ELECTRICAL SYSTEM
Voltage V 24
Battery 2 x 12 V, 170 Ah (in series)
Alternator 28 V, 80 A
Starter kW 7,8
Automatic circuit breaker A 45
Fuses A see Operation and maintenance manual
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TRACK COMPONENTS
Track chain pitch mm / inch 215,9 / 8,5
Track chain length links 40 44
Track pad width ( single grouser) mm 508 / 560 / 610 / 710 812/ 914
Track pad bolts thread. size 7/8“ UNF
Track rollers - single flange (s) qty.4 4
Track rollers - double flange (d) qty.3 4
Track roller location s-d-s-d-s-d-s s-d-s-d-d-s-d-s
Carrier rollers each side qty. 2
Max. roller frame oscillation ± 3°
ATTACHMENT
GENERAL DATA
Travel speed normal range - III km/h 0 11,0 reverse 0 11
reduced range - II km/h 0 6,5 reverse 0 8
reduced range - I km/h 0 4,0 reverse 0 4,5
Operating weight with Semi-U- / Straight blade kg (track pad in mm) 25620 (560) 27000 (914)
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PR 754
DIESEL ENGINE
Type D 946-L A6
Design 6 cyl. in line – charge air cooled
Rated to ISO 9249 kW 250 (340 PS)
Rated RPM RPM 1600
Low idle RPM RPM 900+50
High idle RPM RPM 1700+50
Displacement l 12
Oil specification / viscosity See Service items, section 1.3
Max. machine inclination - all directions 45° = 100%
Valve clearance - cold intake / exhaust See Data tag / engine
Firing order 1-5-3-6-2-4
SPLITTERBOX
Type 351 B 364
Design Spur gear 1-stage
Ratio i 0,86
Oil quantity l Min. 5 – Max. 5,5
Oil specification / viscosity See Service items section 1.3
HYDRAULIC SYSTEM
Variable pumps – travel hydraulic Type 2 x HPV 280-02
Flow - Qmax l/min 2 x 518
Operating pressure (M1 / M2) pmax bar 420+30/-10
Axial piston pump – cooling circuit A 10 V 28
Flow quantity replenishing - Qmax l/min 57
Operating pressure (LA electronically regulated) pmax bar 205+/-5
Stand by pressure LA (with cold machine) bar 30+5
Tandem gear pumps - Replenishing – Pilot control WH Size 55 + 38
Flow quantity - Qmax –ges (Qmax –ges =Q1 + Q2) l/min 174
Operating pressure (SP) pmax bar 20+4
ELECTRICAL SYSTEM
Operating voltage V 24
Batteries 2 x 12 V, 225 Ah (in Series)
Alternator 28 V, 80 A
Starter kW 7,8
Central fuse A 45
Individual fuses A See Operating instructions
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PR 754
FINAL DRIVE
Type 2 x FAT 650 E 508
Design Spur gear 1-stage + Planetary gear – 2 stage
Parking brake integrated Disk brake
Ratio Total 54,3 : 1
Oil quantity l 2 x 18,5 -
Oil specification / viscosity See Service items section 1.3
WORKING ATTACHMENT
Operating weight with Semi-U-blade kg ( for track pad width 610 mm) 35225 36120
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PR 764
DIESEL ENGINE
Type D 9408 TI – E A4
Design V8 engine – charge air cooled
Rated to ISO 9249 kW 310 ( 422 PS )
Rated RPM RPM 1800
Low idle RPM RPM 900 +50
High idle RPM RPM 1700 +50
Displacement l 17,18
Oil specification / viscosity see Service items section 1.3
Max. machine inclination - all directions 45° = 100%
Valve clearance - cold intake / exhaust See Data tag / engine
Firing order 1–8–4–2–7–3–6–5
SPLITTERBOX
Type PVG 351 B 355
Design Spur gear 1-stage
Ratio i 0,8653
Oil quantity l 6,3
Oil specification / viscosity see Service items section 1.3
HYDRAULIC SYSTEM
Variable pumps – travel hydraulic Type 2 x THPV 210
Flow - Qmax l/min 4 x 437
Operating pressure (M1 / M2) pmax bar 420+30/-10
Axial piston pump – cooling circuit A 10 V 28
Flow quantity replenishing - Qmax l/min 57
Operating pressure (LA electronically regulated) pmax bar 280+/-5
Ground by pressure LA (with cold machine) bar 30+5
Tandem gear pumps - Replenishing – Pilot control WH Size 55 + 55
Flow quantity - Qmax –ges (Qmax –ges =Q1 + Q2) l/min 232
Operating pressure (SP) pmax bar 20+4
ELECTRICAL SYSTEM
Operating voltage V 24
Batteries 2 x 12 V, 170 Ah (in Series)
Alternator 28 V, 80 A
Starter kW 9
Central fuse A 35
Individual fuses A See Operating instructions
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Mjfcifss! 3.1.60 - 1 / 2
PR 764 F/N xxx-6888 9505
Technical data and Maintenance guidelines Service Manual
Technical data
PR 764
FINAL DRIVE
Type 700 E 501
Design Spur gear 1-stage + Planetary gear – 2 stage
Parking brake integrated Disk brake
Ratio Total 54,31 : 1
Oil quantity l 22,5 + 7,5
Oil specification / viscosity See Service items section 1.3
WORKING ATTACHMENT
Operating weight with Semi-U-blade kg ( for track pad width 610 mm) 44720 45220 45620
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3.1.60 - 2 / 2 Mjfcifss!
PR 764 F/N xxx-6888 9505
Service Manual Technical data and Maintenance guidelines
Technical data
PR 764
DIESEL ENGINE
Type D 9508 A7
Version 8 cylinder V-engine
Performance according to ISO 9249 kW 310 ( 422 PS )
Nominal RPM 1/min 1600
Low idle RPM 1/min 900 +50
High idle RPM 1/min 1700 +50
Displacement l 16,2
Oil quality / viscosity see Service items– Operating instructions
Max. permissible machine incline – all directions 45° = 100%
Valve clearance - cold intake / exhaust See data tag / engine
Firing order 1–5–7–2–6–3–4–8
SPLITTERBOX
Type PVG 351 B 355
Version Spur gear 1-stufig
Ratio i 0,8653
Oil quantity l 6,4
Oil quality / viscosity see Service items– Operating instructions
HYDRAULIC SYSTEM
Variable / travel pumps – travel hydraulic Type 4 x HPV 210
Flow - Qmax l/min 4 x 388
Operating pressure (M1 / M2) pmax bar 420+30/-10
Axial piston pump – Cooling circuit A 10 V 28
Flow replenishing - Qmax l/min 52
Operating pressure (LA electronically regulated) pmax bar 250+/-5
Stand by pressure LA (at cold machine) bar 30+5
Tandem gear pumps - replenishing – Servo control WH Size 56+ 56
Flow - Qmax –ges (Qmax –ges =Q1 + Q2) l/min 208
Operating pressure (SP) pmax bar 23+5
ELECTRICAL SYSTEM
Operating voltage V 24
Batteries 2 x 12 V, 225 Ah
Alternator 28 V, 80 A
Starter kW 7,8
Central fuse A 45
Individual fuses A see Operating instructions
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PR 764
FINAL DRIVE
Type 700 E 501
Version Spur gear + Planetary gear, each 2-stage
Parking brake, integrated Disk brake
Ratio i ges 54,31 : 1
Oil quantity l See Service items – Operating instructions
Oil quality / viscosity See Service items – Operating instructions
Fixed and simple oscillating track
TRACK COMPONENTS Double oscillating track rollers
rollers
Chain pitch mm / 240 / 9,45
Chain length 44
Chain pad width (1 grouser) 610 – 660 – 710 – 760
Track pad bolts Thread 1“ – 14 UNF
Track rollers – single flange, per side (e) Each 4
Track rollers – double flange, per side (d) Each 3
Track roller arrangement (from back to front) e–d–e–d–e–d–e e–e–d–d–e–d–e
Track rollers per side Each 2
Track frame oscillation, max. ± 3°
Sprocket segments per side Each 3
WORKING ATTACHMENT
Lift cylinder U – and Semi-U-blade cyl. Ø / rod Ø / stroke mm 120 / 70 / 1490
Tilt cylinder U – and Semi-U-blade cyl. Ø / rod Ø / stroke mm 200 / 90 / 215
Cutting angle cylinder U – und Semi-U-blade cyl. Ø / rod Ø / stroke mm 220 / 90 / 165
Operating weight with Semi-U-blade kg ( for 610mm plate width) 44720 45220 45620
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Customer:.................................................Mach.-Type..............F/N..…..-....….....Sm.hours..........Date........….
Maintenance / inspection WORK TO BE CARRIED OUT
at operating hours
by maintenance personnel by authorized trained personnel
first and only interval first and only interval
Repeat interval Repeat interval
DIESEL ENGINE
Check engine oil level and pressure OM
Check coolant level OM
Check engine, radiator and belly pan for dirt - clean if necessary OM
Check fuel filter water separator / drain if necessary OM
Drain fuel tank condensation and sediments - at least once a week OM
Take oil sample before changing oil and prepare it for analyze OM SM
Replace engine oil - at least once a year OM
Replace lube oil filter - at least once a year OM SM
Check radiator cap and fan OM SM
Replace coolant filter, check antifreeze / DCA4 percentage in coolant OM SM
Check oil, cooling and fuel system for leaks and condition OM SM
Fuel pre-filter - replace filter element OM
V-belt - check condition OM SM
Check air intake and exhaust system for tightness and leaks OM SM
Check engine mounts for condition and tightness OM SM
Check engine RPM - adjust if necessary SM
Check and adjust valve clearance - with cold engine SM
Check and service injection pump linkage OM SM
Replace fuel fine filter cartridge OM
Grease flywheel teeth SM
Check flame glow plug system (before start of cold season) SM
Replace air filter elements - if necessary or at least once a year OM
Replace oil separator - every 2 years OM SM
Replace coolant with antifreeze and DCA4 - every 2 years OM SM
Check / adjust fuel injectors - if necessary or at least every 3000 operating hours SM
HYDRAULIC SYSTEM
Check oil level in hydraulic tank OM
Clean magnetic rod (also after repairs) - daily up to 50 operating hours OM SM
Check hydraulic oil cooler for dirt / clean if necessary OM
Replace pressure filter element of the replenishing circuit OM
Check attachment and travel hydraulic system for function and leaks,
OM SM
check hydraulic hose routing for chafing
Replace main return flow filter element - immediately if indicator light lights up OM
Check / adjust all hydraulic pressures according to adjustment checklist SM
Check mountings and fittings for tight seating OM SM
Check all case drain filter inserts for deposits / contamination SM
Take oil sample (before changing oil) and prepare it for analyze OM SM
Replace hydraulic oil (refill via tank filter) - at least every 4 years
- whenever “environmentally safe hydraulic fluids” are used OM
request / observe any special guidelines from manufacturer
SPLITTERBOX
Check oil level OM
Replace gear oil - at least every 2 years OM
ELECTRICAL SYSTEM
Check system functions incl. indicators and gauges OM SM
Check battery electrolyte level - at least once a year OM
Check, clean and grease battery terminals OM SM
Check wire routing and connections OM SM
Check / adjust travel drive control system according to adjustment checklist SM
Check battery acid concentration / charge (before start of cold season) SM
FINAL DRIVE
Check oil level for sealing area - at least once a year OM
Check oil level at gear - clean magnetic plugs - at least once a year OM
Check bolts and nuts for tightness OM SM
Take oil sample before changing oil and prepare it for analyze OM SM
Replace gear oil - clean magnetic plugs - at least every 4 years OM
Replace lube oil from sealing area / flush area - at least every 4 years OM
TRACK COMPONENTS
Check all bolts and nuts of track components,
OM SM
in particular at track pads and sprocket segments for tightness
Check carrier rollers, track rollers and idlers for leaks OM
Check oil level for support shaft bearing OM
Grease middle bearing of equalizer bar - shorten interval as necessary OM
Check idler guides / adjust, replace parts as necessary OM SM
Adjust chain tension to suit application - as necessary OM SM
Clean track components - as necessary OM
Check track components for wear - as necessary SM
ATTACHMENTS
Check cutting edges, end bits and ripper teeth for wear -
OM
check if attachments are suited to application
Check blade adjustment / centered to main frame and link connection - after every installation OM
Check bolts, nuts and pin safeties for tightness OM
Check all attachment bearings for play / wear OM SM
Check attachments for damage OM
GENERAL
Grease all grease points according to the lubrication chart - shorten interval as necessary OM
Check entire machine for proper maintenance and condition OM SM
Explain machine literature, in specially Operation Manual-safety guidelines
OM
to the operating personnel
Company:....................................................Mach.-Type..............S/N....................Hrs................Date............
Maintenance / inspection WORK TO BE CARRIED OUT
at operating hours
by maintenance personnel by authorized trained personnel
First and only interval First and only interval
Repeat interval Repeat interval
Reference Remar
see: ks
OI Operating instructions SM Service manual
For correct fill quantities, use test marks-
for 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
SPLITTERBOX
Check oil level OI
Replace gear oil
OI
- at least every 2 years
ELECTRICAL SYSTEM
Check the function of the system incl. displays and instruments OI
Check battery electrolyte level
OI
- at least 1x a year
Clean / check / grease battery connections OI
Check cable routing and connections OI / SM
Check / adjust control system of travel drive according to adjustment check list OI / SM
Check battery charge condition
SM
- before start of cold season
Check machine software version
SM
- update older version with the latest software version
HEATER / VENTILATION / AIR CONDITIONING SYSTEM
Turn the air conditioning system on regularly
OI
- at least 1x every 14 days
Check water drain valve of air cond. system, clean as necessary OI
Check the system for function and leaks OI
Check the condenser for contamination
OI
- blow out if necessary
Clean air circulation and fresh air filter, replace as necessary. In dusty conditions, shorten
OI
maintenance interval
Check mounting screws and drive belt of compressor OI
Check dryer unit (moisture, fill, condition)
- if necessary, replace OI
- evacuate the system and refill
Clean water drain valve of air conditioning system OI
Check evaporator unit, clean if necessary OI
Check electrical lines for chafing and plug connections for tight seating OI
Have air conditioning system checked / inspected by HVAC technician
- 1x a year
TRAVEL GEAR
Check oil level for seal area
- at least 1x year OI
- or if indicator light lights up
Check gear oil level – clean magnetic plug OI
Check fittings for tight seating OI / SM
Replace gear oil 1) – clean magnetic plug
OI
- at least every 4 years
Seal area – replace lube oil / flush seal area
OI
- at least every 4 years
Take oil sample from gear before oil change and send in for analysis OI
TRACK COMPONENTS
Check mounting screws and nuts of track components, especially track pad and sprocket
OI
Segment bolts for tight seating
Lubricate equalizer bar bearing
OI
- shorten interval if necessary
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
OI / SM
- as necessary / when changing applications
Clean track
OI
- as necessary
Check track wear
SM
- as necessary
WORKING ATTACHMENT
Check cutting edges, bucket and ripper tooth tips for wear - Make sure attachments are suited
OI
to application
Check blade center position and attachment of bracket
OI
- and at every installation
Check all bearing points for play / wear 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
OI
- Shorten intervals as necessary
Check complete machine for correct maintenance and proper condition OI
Explain machine documentation, especially operating instructions /
OI
safety guidelines to operating personnel
Company:..................................................Machine type..............S/N.........-............Hrs................Date............
Maintenance / inspection WORK TO BE CARRIED OUT
at operating hours
by maintenance personnel by authorized trained personnel
First and only interval First and only interval
Repeat interval Repeat interval
Reference Remar
see: ks
OI Operating instructions SM Service Manual
For correct fill quantities, use test marks-
for procedure and quantities, see OI
For quality and viscosity guidelines, see “Service items” 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
OI
-immediately if indicator light lights up
Drain fuel tank, condensation and sediments
OI
- but at least 1x week
Change engine oil -1) Specification: CI-4, CH-4
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SPLITTERBOX
Check oil level OI
Replace gear oil
OI
- but at least every 2 years
ELECTRICAL SYSTEM
Check function of system, incl. displays and instruments OI
Check battery electrolyte level
OI
- at least 1x a year
Clean / check / grease battery connections OI
Check cable routing and connections OI
Check / adjust control system of travel drive according to adjustment check list SM
Check battery charge condition
SM
- before start of cold season
Check machine software version
SM
- update older version with the latest software version
HEATER / VENTILATION / AIR CONDITIONING SYSTEM
Turn the air conditioning system on regularly
OI
- at least 1x every 14 days
Check water drain valve or air cond. system, clean if necessary OI
Check the system for function and leaks OI
Check the condenser for contamination
OI
- blow out if necessary
Clean air circulation and fresh air filter, replace as necessary. In dusty conditions, shorten
OI
maintenance interval
Check mounting screws and drive belt pulley of compressor OI
Check dryer unit (moisture, fill, condition)
- replace if necessary OI
- evacuate the system and refill
Clean water drain valve of air conditioning system OI
Check evaporator unit, clean if necessary OI
Check electrical lines for chafing and plug connections for tight seating OI
Have air conditioning system checked / inspected by HVAC technician
- 1x a year
TRAVEL GEAR
Check oil level for seal area
- at least 1x year OI
- or if indicator light lights up
Check gear oil level – clean magnetic plug OI
Check fittings for tight seating OI / SM
Replace gear oil 1) – clean magnetic plug
OI
- at least every 4 years
Seal area – replace lube oil / flush seal area
OI
- at least every 4 years
Take oil sample from gear and send in for analysis OI
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TRACK COMPONENTS
Check mounting screws and nuts of track components, especially track pad and sprocket
OI
segment screws for tight seating
Lubricate equalizer bar bearing
OI
- shorten interval if necessary
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
OI / SM
- as necessary / when changing applications
Clean track
OI
- as necessary
Check for track wear
SM
- as necessary
WORKING ATTACHMENT
Check cutting edges, bucket and ripper tooth tips for wear -
OI
Make sure attachments are suited to application
Check blade center position and mounting of bracket
OI
- and at every installation
Check all bearing points for play / wear 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
OI
- Shorten intervals as necessary
Check complete machine for correct maintenance and proper condition OI
Explain machine literature, especially Operating instructions / safety guidelines
OI
to operating personnel
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1.3. Intervals
The given Maintenance and inspection intervals may not be exceeded, if necessary, they should be
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.
For all maintenance, inspection and repair work, use only Original LIEBHERR replacement parts or
maintenance 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. Performance guidelines
2.1.3 Check / replace the coolant antifreeze / corrosion inhibitor Cooling systems without 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 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 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 fill coolant every
year. To drain the coolant from the cooler and engine block, refer to the machines
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.
2.1.4 Check / replace the coolant antifreeze protection and DCA4 part cooling systems 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 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 coolant with antifreeze and DCA4 every 2 years. Replace the special coolant fill annually. To
drain the coolant from cooler and engine block, refer to machines 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.
2.1.6 Check oil, coolant and fuel system as well as Intake and exhaust system
Check systems for leaks, damage and chafing. Fix leaks properly, 428044
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 for tight seating.
2.1.8 Check / adjust engine RPM Service the mechanical actuator to the injection pump and potentiometer
The RPM can 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.
2.1.11 Check the flame glow system replace oil separator check / adjust fuel injectors check water pump
A defective flame glow 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 leak, which can cause engine
damage due to dust ingestion. For that reason, make sure to check the service date and 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 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.
2.2.3 Check the working and travel hydraulic system for function and leaks, hose routing for chafing, mountings and
fittings for tight seating
Run through all travel and working 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
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 down 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 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 rods for damage as well as piston rod bearings for leaks. Correct any problems, if
necessary.
Check mounting screws of hydraulic components (pumps, motors, tank etc. as well as flange connection for
tight seating. Retighten, if necessary.
2.3.2 Clean / check / grease battery connections, check cable routing and connections
Check battery heads and terminals 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.