Service Manual Table of contents
Section
Pages from to
Title
Date of issue
0.1.00
1 8
Index
02.2010
1.0.00
1 2
Sub group index "General Information"
03.2007
1.1.00
1 2
Foreword and explanations
03.2007
1.2.00
1 14
Safety guidelines
01.2007
1.3.01
1 10
Service items
03.2006
1.3.02
1 2
Service items
01.2009
1.4.01
1 4
Tightening torques
05.2008
1.4.03
1 2
Conversion chart
01.2009
1.4.04
1 2
Tapping holes
01.2004
1.5.00
1 6
Storage guidelines
02.2010
1.6.00
1 2
Weights of Material
03.2009
2.0.00
1 2
Sub group index "Special Tools, Application Guidelines"
02.2008
2.1.00
1 20
Special tools
01.2010
2.2.00
1 6
Repair welding
02.2007
2.3.00
1 6
Installation instructions – slip ring seals
02.2010
3.0.00
1 2
Sub group index "Technical data - maintenance guidelines"
03.2007
3.1.20
1 2
Technical data
03.2006
3.1.21
1 2
Technical data
01.2007
3.1.22
1 4
Technical data
03.2009
3.1.23
1 4
Technical data
03.2009
3.1.30
1 2
Technical data
03.2006
3.1.31
1 4
Technical data
01.2009
3.1.40
1 2
Technical data
01.2008
3.1.50
1 2
Technical data
02.2008
3.1.60
1 2
Technical data
01.2009
3.1.61
1 2
Technical data
02.2009
3.2.20
1 2
Maintenance and inspection schedule
01.2009
3.2.21
1 4
Maintenance and inspection schedule
02.2010
3.2.60
1 4
Maintenance and inspection schedule
02.2010
3.3.20
1 8
Maintenance and inspection guidelines
03.2007
3.3.21
1 10
Maintenance and inspection guidelines
01.2010
3.4.00
1 6
Quick reference for machine adjustment
02.2009
3.5.20
1
4
Adjustment check list
01.2009
3.5.21
1 6
Adjustment check list
01.2009
3.5.30
1 6
Adjustment check list
01.2009
3.5.40
1 6
Adjustment check list
01.2009
3.5.50
1 6
Adjustment check list
01.2009
3.5.60
1 6
Adjustment check list
01.2009
3.5.61
1 6
Adjustment check list
01.2009
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Service Manual Table of contents
4.0.00
1 2
Sub group index "Engine"
03.2007
4.1.00
1 6
Data page
03.2007
4.2.00
1 4
Fan and cylinder configuration
03.2007
4.3.00
1 10
Installation kit Liebherr – Diesel particle filter
01.2009
4.4.00
1 4
Installation and check list for Diesel particle filter
05.2008
5.0.00
1 2
Sub group index "Coupling and splitterbox"
03.2007
5.1.00
1 2
Data page
02.2009
5.2.20
1 2
Coupling
01.2006
5.2.40
1 2
Coupling
02.2006
5.3.20
1 4
Splitterbox
01.2007
5.3.30
1 4
Splitterbox
01.2006
5.3.40
1 4
Splitterbox
02.2006
5.4.00
1 4
Couplings pump output
04.2008
6.0.00
1 2
Sub group index "Travel hydraulic"
03.2007
6.1.20
1 2
Data page
01.2009
6.1.30
1 2
Data page
01.2009
6.1.40
1 2
Data page
01.2008
6.2.20
1 6
Description
01.2006
6.2.21
1 6
Description
04.2008
6.2.22
1 6
Description
04.2008
6.2.30
1 6
Description
04.2008
6.2.40
1 8
Description
01.2009
6.2.50
1 8
Description
04.2008
6.2.60
1 8
Description
01.2009
6.2.61
1 8
Description
01.2009
6.3.20
1 8
Function
01.2008
6.3.21
1 8
Function
01.2009
6.3.22
1 8
Function
01.2009
6.3.30
1 8
Function
01.2008
6.3.31
1 8
Function
01.2008
6.3.32
1 8
Function
01.2009
6.3.40
1 10
Function
01.2009
6.3.50
1 10
Function
01.2009
6.3.60
1 10
Function
01.2009
6.4.20
1 12
Test and adjustment
05.2008
6.4.21
1 18
Test and adjustment
01.2009
6.4.60
1 18
Test and adjustment
05.2008
6.5.20
1 2
Component location
01.2006
6.5.21
1 2
Component location
01.2007
6.5.22
1 2
Component location
01.2007
6.5.30
1 2
Component location
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Service Manual Table of contents
6.5.40
1 2
Component location
02.2006
6.5.50
1 2
Component location
02.2006
6.5.60
1 2
Component location
01.2009
6.5.61
1 2
Component location
01.2009
7.0.00
1 2
Sub group index "Working hydraulic"
03.2007
7.1.20
1 2
Data page
03.2009
7.1.30
1 2
Data page
03.2009
7.1.40
1 2
Data page
03.2009
7.2.20
1 4
Description
01.2007
7.2.21
1 4
Description
03.2009
7.2.30
1 4
Description
02.2008
7.2.40
1 4
Description
02.2008
7.2.50
1 4
Description
02.2008
7.2.60
1 4
Description
03.2006
7.2.61
1 4
Description
03.2007
7.3.20
1 10
Function
01.2008
7.3.21
1 10
Function
01.2008
7.3.22
1 10
Function
01.2008
7.3.30
1 10
Function
01.2008
7.3.31
1 10
Function
01.2008
7.3.40
1 12
Function
01.2008
7.3.50
1 10
Function
01.2008
7.3.60
1 10
Function
01.2008
7.3.61
1 10
Function
01.2009
7.4.20
1 8
Test and adjustment
05.2008
7.4.30
1 8
Test and adjustment
05.2008
7.4.40
1 10
Test and adjustment
05.2008
7.5.20
1 2
Component location
01.2006
7.5.21
1 2
Component location
01.2007
7.5.22
1 2
Component location
03.2009
7.5.23
1 2
Component location
03.2009
7.5.30
1 2
Component location
01.2006
7.5.40
1 2
Component location
02.2006
7.5.50
1 2
Component location
02.2006
7.5.60
1
2
Component location
03.2006
7.5.61
1 2
Component location
03.2006
8.0.00
1 2
Sub group index "Hydraulic components"
03.2007
8.1.20
1 8
Variable pump
03.2006
8.1.40
1 6
Variable pump
01.2009
8.2.20
1 4
Variable motor
01.2005
8.2.21
1 6
Variable motor
02.2008
8.2.22
1 6
Variable motor
02.2008
8.2.30
1 4
Variable motor
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Service Manual Table of contents
8.2.31
1 6
Variable motor
03.2009
8.2.40
1 6
Variable motor
03.2007
8.2.50
1 6
Variable motor
02.2008
8.2.51
1 6
Variable motor
02.2008
8.3.20
1 8
Regulating pump
03.2009
8.3.21
1 6
Regulating pump
03.2009
8.3.30
1 6
Regulating pump
03.2006
8.3.31
1 10
Regulating pump
02.2009
8.3.60
1 6
Regulating pump
03.2006
8.4.20
1 4
Double gear pump– fan drive
03.2006
8.4.25
1 4
Gear motor – fan drive
03.2008
8.4.26
1 4
Gear motor – fan drive
03.2008
8.4.40
1 4
Double gear pump – Replenishing
02.2006
8.4.45
1 4
Axial piston fixed displacement motor – fan drive
02.2006
8.4.50
1 4
Double gear pump – Replenishing
02.2006
8.4.55
1 4
Gear motor – fan drive external oil cooler
02.2006
8.5.20
1 8
Pilot control valve
01.2008
8.5.21
1 8
Pilot control valve
01.2008
8.6.20
1 6
Control valve block
02.2006
8.6.21
1 6
Control valve block
01.2007
8.6.22
1 6
Control valve block
01.2007
8.6.40
1 6
Control valve block
03.2006
8.6.41
1 6
Control valve block
03.2006
8.7.00
1 12
Valves
02.2009
8.8.00
1 12
Hydraulic cylinder
01.2010
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
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Service Manual Table of contents
9.4.23
1 76
Current flow diagram
03.2009
9.4.30
1 22
Current flow diagram
02.2007
9.4.31
1 62
Current flow diagram
03.2008
9.4.40
1 18
Current flow diagram
03.2008
9.4.50
1 80
Current flow diagram
02.2010
9.4.51
1 80
Current flow diagram
02.2010
9.4.60
1 18
Current flow diagram
03.2006
9.4.61
1 80
Current flow diagram
02.2009
9.5.20
1 2
Instrument panel
01.2007
9.5.21
1 2
Instrument panel
03.2007
9.6.20
1 16
Component arrangement
05.2008
9.6.21
1 16
Component arrangement
05.2008
9.6.22
1 18
Component arrangement
02.2010
9.6.30
1 18
Component arrangement
02.2010
9.6.40
1 14
Component arrangement
02.2010
9.6.41
1 16
Component arrangement
02.2010
9.6.50
1 14
Component arrangement
02.2010
9.6.60
1 16
Component arrangement
05.2008
9.6.61
1 18
Component arrangement
02.2010
9.7.00
1 4
Travel joystick
02.2010
9.7.25
1 4
Inching - brake pedal
03.2007
9.7.26
1 4
Inching - brake pedal
04.2008
10.0.00
1 2
Sub group index "Electrical system descriptions"
01.2008
10.1.00
1 70
Application Software – travel drive
01.2010
10.2.00
1 20
Software PDL – Diesel particle filter
01.2010
11.0.00
1 2
Sub group index "Final drive"
03.2007
11.1.20
1 2
Data page
01.2010
11.1.30
1 2
Data page
01.2007
11.1.40
1 2
Data page
02.2008
11.1.50
1 2
Data page
01.2008
11.2.20
1 4
Design and function
03.2006
11.2.21
1 4
Design and function
01.2007
11.2.22
1 6
Design and function
02.2008
11.2.40
1 4
Design and function
03.2007
11.2.41
1 4
Design and function
03.2007
11.2.50
1 4
Design and function
04.2008
11.2.51
1 4
Design and function
05.2008
11.2.60
1 6
Design and function
03.2006
11.2.61
1 6
Design and function
02.2008
11.3.20
1 4
Sectional view
01.2006
11.3.21
1 4
Sectional view
03.2007
11.3.40
1 4
Sectional view
01.2009
11.3.41
1 4
Sectional view
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Service Manual Table of contents
11.3.42
1 4
Sectional view
01.2009
11.3.50
1 4
Sectional view
01.2009
11.3.51
1 4
Sectional view
01.2009
11.3.60
1 4
Sectional view
01.2009
11.3.61
1 4
Sectional view
01.2009
12.0.00
1 2
Sub group index "Track components"
03.2007
12.1.00
1 2
Data page
02.2010
12.2.00
1 26
Description, function, wear and evaluation
03.2008
12.3.00
1 4
Inspection checklist
01.2010
12.3.01
1 6
Wear chart
01.2009
12.4.20
1 8
Track roller frame and idler unit
03.2009
12.4.50
1 8
Track roller frame and idler unit
02.2010
12.5.00
1 2
Track roller
01.2006
12.6.00
1 2
Carrier roller
02.2007
12.8.50
1 6
Tension unit
02.2007
12.8.60
1 6
Tension unit
03.2007
13.0.00
1 2
Sub group index "Working Attachments - front"
03.2007
13.1.00
1
6
Straight blade
02.2007
13.2.20
1
6
6 way blade
01.2008
13.4.40
1
6
Hydraulic cutting angle adjustment
01.2008
13.4.50
1
8
Hydraulic cutting angle adjustment
02.2008
13.4.60
1
6
Hydraulic cutting angle adjustment
01.2008
14.0.00
1
2
Sub group index "Attachments - rear"
03.2007
14.1.20
1
4
Ripper
01.2006
14.1.21
1
8
Ripper
02.2007
14.1.40
1 14
Ripper
01.2008
14.1.60
1 12
Ripper
01.2008
15.0.00
1
2
Sub group index "Main frame components"
03.2007
15.1.20
1
2
Cooler arrangement
01.2006
15.1.21
1
2
Cooler arrangement
01.2007
15.1.22
1
2
Cooler arrangement
01.2007
15.1.30
1
2
Cooler arrangement
03.2008
15.1.40
1 2
Cooler arrangement
02.2006
15.1.50
1 2
Cooler arrangement
03.2006
15.1.60
1
2
Cooler arrangement
01.2009
15.1.61
1
2
Cooler arrangement
01.2009
15.2.00
1
2
Hoist cylinder suspension
02.2006
15.3.20
1
2
Equalizer bar
01.2006
15.3.40
1
2
Equalizer bar
01.2006
15.3.50
1
2
Equalizer bar
02.2006
15.3.60
1
2
Equalizer bar
01.2010
15.4.20
1
2
Engine mount
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Service Manual Table of contents
15.4.21
1 2
Engine mount
01.2007
15.4.30
1 2
Engine mount
01.2006
15.4.40
1 2
Engine mount
02.2006
15.4.60
1 2
Engine mount
02.2010
16.0.00
1 2
Sub group index "Tank arrangement"
03.2007
16.1.20
1 4
Hydraulic tank
05.2008
16.1.21
1 4
Hydraulic tank
05.2008
16.1.30
1 4
Hydraulic tank
05.2008
16.1.40
1 4
Hydraulic tank
05.2008
16.1.50
1 4
Hydraulic tank
05.2008
16.1.60
1 4
Hydraulic tank
05.2008
16.2.20
1 2
Fuel tank
01.2007
16.2.30
1 2
Fuel tank
01.2007
16.2.40
1 2
Fuel tank
02.2006
16.2.50
1 2
Fuel tank
03.2006
16.2.60
1 2
Fuel tank
03.2007
16.2.61
1 2
Fuel tank
03.2007
16.3.20
1 2
Battery box
01.2007
16.3.21
1 2
Battery box
03.2008
16.3.22
1 2
Battery box
03.2008
16.3.30
1 2
Battery box
03.2008
16.3.31
1 2
Battery box
03.2008
16.3.40
1 2
Battery box
01.2006
16.3.50
1 2
Battery box
02.2006
16.3.60
1 2
Battery box
03.2007
16.3.61
1 2
Battery box
03.2007
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
18.0.00
1 2
Sub group index "Special equipment"
01.2009
18.2.00
1 4
Refueling pump
02.2007
18.3.20
1 4
Reversible fan
02.2008
18.3.21
1 4
Reversible fan
02.2008
18.3.30
1 4
Reversible fan
02.2008
18.3.31
1 4
Reversible fan
02.2008
18.3.32
1 4
Reversible fan
02.2008
18.3.40
1 4
Reversible fan
02.2008
18.3.50
1 4
Reversible fan
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Service Manual Table of contents
18.3.60
1 4
Reversible fan
02.2008
18.3.61
1 4
Reversible fan
02.2008
18.4.20
1 12
Cable winch
01.2009
19.0.00
1 2
Sub group index "Additional documentation"
03.2008
6.3.20
1 1
Schematic Travel hydraulic
01.2008
6.3.21
1 1
Schematic Travel hydraulic
01.2009
6.3.22
1 1
Schematic Travel hydraulic
01.2009
6.3.30
1 1
Schematic Travel hydraulic
03.2006
6.3.31
1 1
Schematic Travel hydraulic
03.2006
6.3.32
1 1
Schematic Travel hydraulic
01.2009
6.3.40
1 2
Schematic Travel hydraulic
01.2009
6.3.50
1 2
Schematic Travel hydraulic
01.2009
6.3.60
1 3
Schematic Travel hydraulic
01.2009
7.3.20
1 1
Schematic Working hydraulic
03.2006
7.3.21
1 1
Schematic Working hydraulic
01.2007
7.3.22
1 1
Schematic Working hydraulic
01.2008
7.3.30
1 1
Schematic Working hydraulic
03.2006
7.3.31
1 1
Schematic Working hydraulic
01.2008
7.3.40
1 2
Schematic Working hydraulic
01.2008
7.3.50
1 1
Schematic Working hydraulic
01.2008
7.3.60
1 1
Schematic Working hydraulic
03.2006
7.3.61
1 1
Schematic Working hydraulic
01.2008
9.4.20
1 16
Current flow diagram
02.2007
9.4.21
1 61
Current flow diagram
03.2008
9.4.22
1 76
Current flow diagram
03.2009
9.4.23
1 76
Current flow diagram
03.2009
9.4.30
1 21
Current flow diagram
02.2007
9.4.31
1 61
Current flow diagram
03.2008
9.4.40
1 18
Current flow diagram
03.2008
9.4.50
1 80
Current flow diagram
02.2010
9.4.51
1 80
Current flow diagram
02.2010
9.4.60
1 17
Current flow diagram
03.2006
9.4.61
1 80
Current flow diagram
02.2009
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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
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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 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. 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 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.
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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.
LIEBHERR-Werk Telfs GmbH. Technical Documentation Dept.
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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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B. General safety information (Abstract of the Operation Manual Issue 10/2003) 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. 0.1. Proper and destined use With the standard dozer attachment, the machine may only be used to loosen, 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, driving piles, transporting personnel, etc. are considered to be improper and unsafe use. Neither the 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 equipped 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. copyright by
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1. Decals on the machine 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 safety regulations Study the Operation Manual before operating the machine. - Make sure that you have additional information for special attachments on your machine, that you have read it and that you understand it. Allow only trained and authorized personnel to operate the machine, to maintain, service or repair it. - Be aware of the minimum age requirements for machine operators. Allow only trained and authorized personnel to operate, set up, maintain and repair the machine, make sure 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 to supervise personnel still in 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, bracelets and loose clothing such as ties, scarves, unbuttoned or unzipped shirts or jackets are dangerous and could cause serious injury! - Utilize proper safety equipment for certain tasks: safety glasses, hard hat, gloves, reflector vest, ear protection or respirator, .... Consult your employer or site supervisor for specific safety equipment requirements and safety regulations on the jobsite. When entering or leaving the 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 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 on firm and level ground and lower the attachment to the ground. - Bring all control levers into neutral position. - Turn the engine off, leave the starter key in contact position. - Actuate the control levers several times to 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.
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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. 3. Crushing and burn prevention 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, 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 will 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 temperature, the engine cooling system is hot and under pressure. Avoid contact with components 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 temperature, the engine and hydraulic oil is hot. Do not allow your skin to come into contact with hot oil or components containing hot oil. Always wear safety glasses and gloves when handling batteries. Keep sparks and open flames 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 function is not ensured, find the problem and remedy it 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 if it is raised with the attachment, the machine must always be properly blocked and supported. 4. Fire and explosion prevention Always shut the engine off before refueling. - In addition, the heater must also be 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 engine starting procedure, as described in the "Operating Manual". Check the electrical system 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. 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. 5. Machine start up safety Before starting the machine, perform a thorough walk-around inspection. Check the machine for loose bolts, cracks, wear, leaks and any evidence of 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 through the left door. Use the right door only in emergencies. Make sure that no one is on or under the machine. Warn all personnel in the surrounding area on the job site before operating the machine. After entering the operator's cab, adjust the operator's seat, the mirrors, the arm rests and the seat belt so you can work comfortably. All noise level protection devices on the machine must be operational when operating the machine. Never operate the machine without a cab or canopy. 6. Engine start up safety 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 surrounding 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 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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7. Machine operating safety Before starting to work, make sure that you area aware of any special conditions at the jobsite, as well as special regulations, federal, state and local safety requirements and warning signals. The work environment includes any obstacles in the working and traffic area, the load carrying capacity of the ground, and any necessary guard rails to protect the jobsite from close-by traffic. Always keep sufficient and safe distance to overhangs, walls, drop offs 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. - There is a DANGER OF LOSS OF LIFE! - You must inform yourself of proper distances to assure your safety while working. If you do touch a high voltage wire: - Do not leave the machine! - If possible, move the machine a sufficient distance away from the danger area. - Warn all personnel in the surrounding area not to come too close to the machine and / or touch the machine. - Instruct somebody to turn the electrical power off. - Do not leave the machine until you are assured that the electrical line, which has been touched 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 light if visibility is poor or as dusk approaches. Never allow another person to ride along on the machine. Always work while seated in the operator's seat and with the seatbelt secured. In the event the machine should tip, remain in the operator's seat with the seatbelt securely fastened. Experience has shown 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 / side slope of the machine depends on the installed attachment as well as the ground conditions! Avoid any working movements, which could cause the machine to tip or slide or slip on a grade. 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 on rocky, rough or slippery ground or on a slope. Always adapt the travel speed to the working 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, 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. 8. Machine parking 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 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, etc. 9. Machine transporting 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 with the ramp. Use another person as a guide to signal you, the operator. Move very slowly 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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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. 10.Machine towing safety Always follow the correct procedure as noted in the "Operating Manual", see "Towing the machine". Tow the machine only in exceptional cases, such as removing the machine from a dangerous area to have 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 cable tight, do not 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 speed and route. When returning the machine to operation, proceed as noted in the Operating Manual. After towing the machine, and before continuing operation, be certain to return the machine to a 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 / inspection should be performed in the intervals noted in the Operating Manual. To perform any repairs, you must have the proper tools. Maintenance work should be performed according to the chart in this Operating 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 conform to the technical requirements set forth by the manufacturer. This is only assured by using original spare parts. Always wear proper and safe work clothing. For certain jobs, in addition to hard hats and safety 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 work is required. Appoint one supervisory person to assure that this work has been done 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 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. 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 the negative (-minus) terminal first, and 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 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 of all maintenance and repairs, make sure that all lines and hoses and fittings are 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, such as pin pullers, punches, etc.). 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. 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 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 appropriate and 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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15.Safe maintenance of hydraulic hoses and lines Hydraulic hoses and lines may never be repaired! All hoses, lines and fittings must be checked regularly, but at least once a year for leaks and 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 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, multi-shift or around the clock operation). Hoses and lines must be replaced if any of the following points are found during an inspection: Criteria: - Damage on the external layer into the inner layer (such as chafing, cuts and rips ); - Brittle outer layers (crack formation 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 of installation requirements; - Damage or deformation of hose fittings, which might reduce the strength of the fitting or the connection between the hose and the fitting; - Any movement of the hose away from the fitting; - Corrosion on the fittings, which might reduce the function or the strength of 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 fire extinguishers, first aid kits, floodlights or similar objects to these protective structures. - Welding points or drilling of holes could weaken the structure. For similar work, always consult with your LIEBHERR dealer. Any changes, which have not been explicitly approved by LIEBHERR would invalidate the roll over or falling object protection permit. - Damage to the structure can also be caused by a roll over accident or falling objects, etc. 17.Attachments and installations Attachments and installations from other sources or parts which 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 is generally the result of the way they are used. Especially the following parameters have a significant influence: - Environmental conditions Unevenness and potholes; - Operating techniques: speed, steering, brakes, control of operating elements of the machine while driving as well as when working. The machine operator himself affects the actual vibration exposure to a great degree himself, since he selects the speed, the gear ratio, the working 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 are observed: Select the correct machine, attachment parts and auxiliary 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 of the seat and its suspension should be matched to the weight and size of the 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 connections, etc. Do not steer, brake, accelerate and shift as well as move and load the working attachments of the machine abruptly. Match the machine speed to the travel route, to reduce vibration exposure: - Decrease the speed when driving 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 and holes. - Have machines available to establish and keep suitable terrain conditions and leave enough time to do this. Drive longer distances (for example on public roads) with suitable (medium) speed. For machines, which are predominately used for driving, use special auxiliary systems (if available), which make it possible to reduce vibration exposure for this type of application. If such auxiliary systems are not available, regulate the speed, to avoid “build up� of the machine.
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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. 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. 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 are approved, the higher quality oils are preferred: API - classification (American Petroleum Institute)
: CF-4, CG-4, CH-4, CI-4,
ACEA (CCMC) - classification : E2 (D4), E3 (D5), E4, E5 (Association des Constructeurs EuropÊens de l´Automobile) 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.
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 (see chart 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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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. 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 efficiency according to HFRR(60°)-Test <400 m - . Insufficient lubrication 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°)-Test <400 m ASTM D 975 - 89a 1D and 2D + HFRR(60°)-Test <400 m + cetane rating >45 (recommendation: >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 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 has been distributed throughout the fuel system. Diesel fuels - Mixing ratio ( Vol.-%) Winter Diesel fuel to -15°C % Fuel % Additive
Winter Diesel fuel to -20°C % Fuel % Additive
Ambient temperature °C
% Fuel
% Additive
0 to -10
70
30
100
--
100
--
-10 to -15
50
50*
100
--
100
--
-15 to -20
--
--
70
30
100
--
Summer Diesel fuel
-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 fluid. This concentration protects the system to approx. -37°C / -34°F. Antifreeze protection chart Protection to
Percentage of antifreeze (%)
Note:
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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!
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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.
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
Agip Antifreeze Plus Agip Langzeit-Frostschutz Antigel DB 486 Aral Kühler-Frostschutz A AVIA Frostschutz APN (G48-00)
Agip Petroli S.p.A, Rom / Italien Autol-Werke GmbH., Würzburg / BRD Sotragal SA, St. Priest / Frankreich Aral AG, Bochum / BRD Deutsche AVIA-Mineralöl GmbH, 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
Caltex (UK) ltd., London / England Caltex Deutsche Castrol Vertriebs-GmbH, Hamburg /BRD Century Oils, Hanley, Stoke-on-Trent / England Chevron Texaco
Deutz Kühlschutzmittel 0101 1490
DEUTZ Service International GmbH, Köln / BRD
Esso Kühlerfrostschutz
Esso AG, Hamburg / BRD
Fricofin Frostschutz Motorex (G48-00) Frostschutz 500
Fuchs Mineraloelwerke GmbH, Mannheim / BRD Bucher+Cie, Langenthal / Schweiz Mobil Oil AG, Hamburg / BRD
Glacelf Auto Supra Glycoshell AF 405
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Glycoshell N Glysantin (G 48-00)
Shell BASF AG, Ludwigshafen / BRD
Havoline XLC Havoline DEX-COOL Extended Life Anti-Freece/Coolant
ARTECO Chevron Texaco
Igol Antigel Type DB
Igol France, Paris / Frankreich
Labo FP 100
Labo Industrie, Nanterre / Frankreich
Motul Anti-freeze
Motul SA, Aubervilliers Cedex / Frankreich
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 O
Deutsche Veedol GmbH, Hamburg / BRD
Wintershall 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) Chevron DEX-COOL Extended Life Prediluted 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 , 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.
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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
appr. liter
DCA 4 - water filter 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 watersoluble 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 Â&#x201D;Approved fresh water qualityÂ&#x201D;. 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 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
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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 API - classification (American Petroleum Institute)
: CF-4, CG-4, CH-4, CI-4,
ACEA (CCMC) - classification : E2 (D4), E3 (D5), E4, E5, (Association des Constructeurs Européens de l´Automobile) Note:
The API classifications CC, CD, CE and CF are now obsolete, however, in quality, they had been approved for use in the hydraulic system.
2.1.2 Special oils Approval is given for each machine type separately. Special guidelines are issued with the release. The following product presently considered to be an 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). 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 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 fluids according to 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: Before starting the Diesel engine, preheat the oil in the hydraulic tank, then proceed as described in paragraph a). PR 724 PR 734 PR 764
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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 rule, only oils 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 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 noted in the Operation and Maintenance manual and the winch 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
: E2 (D4), E3 (D5), 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.
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6. Miscellaneous Always observe all guidelines issued in the Operation and 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
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Service Items see operation and maintenance manual.
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General Information Tightening Torques
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) Medium friction
= 0,12.
G
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 wrenches with the correct range - the upper third of the range should include the listed 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 in Nm
8.8
10.9
12.9
8.8
10.9
12.9
Wrench size (x) = per DIN931, for Hex head screws
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
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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
Preload values FM based on Tightening torques MA are screw grades and are given based on screw grades and in N are 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!
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General Information Tightening Torques
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 half flange for high pressure (Norm 62)
Flange nominal size
Screw size
½" ¾" 1" 1 ¼" 1 ½" 2"
M8 M 10 M 12 M 14 M 16 M 20
Tightening torques in Nm for screw grade 10.9 flat flange without Flange with Half flange reinforcement reinforcement 31 62 108 172 264 350
-45 70 120 170 250
-65 110 180 250 450
2. Half flange for low pressure (Norm 61)
Flange nominal size
Screw size
½" ¾" 1" 1 ¼" 1 ½" 2" 2 ½" 3" 3 ½" 4" 5"
M8 M 10 M 10 M 10 M 12 M 12 M 12 M 14 M 16 M 16 M 16
Tightening torques in Nm for Screw grade 8.8 Screw grade 10.9 22 44 44 44 76 76 76 122 187 187 187
31 62 62 62 108 108 108 172 264 264 264
Tightening torques for cutting edges, end bits and bolt- on adapters inch
mm
Tightening torque [Nm]
Tightening torque [ft. lbs.]
5/8" 3/4" 7/8" 1" 1-1/4"
16 19 22 25 32
270±40 475±60 750±90 1125±150 1850±300
200±30 350±45 550±65 825±110 1350±220
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Tightening Torques
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General Information Conversion table
Unit of Measure Length
Multiply
To obtain Multiply
by
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
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
Ground pressure
kg/cm²
14,223
lbs. sq. inch
0,0703
kg/cm²
kg/m²
0,205
lbs. sq. ft.
4,878
kg/m²
g/cm³
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
Area
Volume
Weight
Force
Compression
Speed
Temperature
l
°C
(°Cx1,8) + 32
°F
(°F-32)/1,8
°C
°C
°C+273
°K
°K-273
°C
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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
Drill bit Ă&#x2DC; 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
Dimensions are in mm mm x 0,03937 = inches
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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
Thread size
Drill bit Ă&#x2DC; 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
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
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Drill bit Ă&#x2DC; 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 be compared to wear. However, the effects of corrosion can greatly exceed that of mechanical wear and shorten the service life of the affected parts significantly. For that reason, for longer shut down, the machines and its components must be preserved according to certain guidelines. In general, these guidelines are tiered according to the following times: Taking the machine out of service â&#x20AC;&#x201C; 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 time frames. The conservation 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 â&#x20AC;&#x201C; 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 maintenance work before putting the machine back 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 of the travel, working hydraulic as well as functions of 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. 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 and remove them and recharge them, if necessary. Check the electrical contact points and grease them, if necessary.
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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 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.).
3.1
Shut down for up to 2 months Required tools / Service items Description Optical charge tester
Id. No. See section 2.1
Description To check the battery condition and the antifreeze in the coolant
WAXOYL 120-4 Anti corrosion 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
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 â&#x20AC;&#x17E;Waxoyl 120-4â&#x20AC;&#x153;.
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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.
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 available Diesel fuel to the fuel tank until it is completely 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, 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 at 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 the tension cylinder (see Operating instructions). Check the machine monthly and reapply conservation protective measures if necessary.
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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, cover the operator’s platform properly. If necessary, remove the 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 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 of the travel, working hydraulic as well as functions of 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 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 tension to suit the application (see Operating instructions).
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General Conservation guidelines
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 shut down of longer than 12 months contact the Service Dept. of the Diesel engine manufacturer. Remove all covers and closures, which were installed for conservation measures. Turn the Diesel engine manually a few turns (use the turning device - flywheel â&#x20AC;&#x201C; see Special tools). Start the machine and bring it to operating temperature. After the machine was brought to operating temperature, change all lube and service fluids as well as filters 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.
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General Information Weight of materials
Weight of materials 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
Bank1) kg/m3 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 kg/m3 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 content, grain size, degree of compaction, etc.. Test must be made to determine exact material characterics.
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Tools and work instructions Sub group index
Sub group index â&#x20AC;&#x201C; Tools and work instructions Special tools
2.1
Repair welding
2.2
Installation instructions
2.3
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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. 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 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
Id. No.
10450054
M-Type
Remarks
LR Series 4 RL Series 4 PR 724 S/Nxxx9200 PR 734 S/Nxxx8220 PR 744 S/Nxxx7356 PR 754 S/Nxxx6924 PR 764 S/Nxxx6888
10035410
10035411
LR Series 4 RL Series 4 PR 724 S/Nxxx9200 PR 734 S/Nxxx8220 PR 744 S/Nxxx7356 PR 754 S/Nxxx6924 PR 764 S/Nxxx9506 PR 764 S/Nxxx6888 9505
Illustration
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.
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Service Manual
Special tools
Description Digital RPM gauge „Shimpo“
Id. No. 7364284
M-Type
Remarks
Illustration
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/Nxxx6600 9199 PR 734 S/Nxxx6200 8219 PR 764 S/Nxxx6888 9505
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
PR 724 S/Nxxx6600 9199 PR 734 S/Nxxx6200 8219 PR 764 S/Nxxx6888 9505
To check the DCA4 concentration in the coolant
Hand pump [1]
8145666
PR Series 4 LR Series 4 RL Series 4
To take oil samples for oil analysis
Oil sample valve for oil samples [2]
7019068
PR Series 4 LR Series 4 RL Series 4
Analysis at 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
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Service Manual
Tools and work instructions Special tools
Description
Id. No.
M-Type
Remarks
V-belt tester â&#x20AC;&#x17E;Krikit2â&#x20AC;&#x153;
8042829
PR Series 4 LR Series 4 RL Series 4
To check the Vbelt tension
Optical battery charge tester
7408922
PR Series 4 LR Series 4 RL Series 4
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
Illustration
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/Nxxx9506 RL 64 (can also be used for PR 724 F/Nxxx9200 PR 734 F/Nxxx8220 PR 744 PR 754 LR 624 LR 634 RL 44 )
To be installed on the V-belt crankshaft
PR Series 4 LR Series 4 RL Series 4
For optional Diesel particle filter. Can be used for leak tests of counter-pressure line
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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
PR Series 4 LR Series 4 RL Series 4
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
PR Series 4 LR Series 4 RL Series 4
Accuracy: 2% / 2°
7407987 7407985 10301165 7404619 4901110 7360127 10038447 10038448 7408151 10024185
Illustration
Test range: -18°C to +260°C
Difference pressure test kit 230V/120V
10288229
Consists of: Test unit Multi-Handy 2045 2 Pressure sensors 0600 bar 2 Mini test 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
PR Series 4 LR Series 4 RL Series 4
To measure pressure, pressure peaks and pressure difference and suitable for data transfer to PC
PR Series 4 LR Series 4 RL Series 4
Accuracy: 1% of scale limit value All pressure gauges are glycerin filled
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Service Manual
Tools and work instructions Special tools
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 RÂź
7615321 5608462 7407071 7406865 7409720
Bulkhead screw coupling M 16x2
Remarks
PR Series 4 LR Series 4 RL Series 4
To seal at pressure checks, a square seal ring Id.No. 7409794 must be inserted
PR Series 4 LR Series 4 RL Series 4
Union nut and cutting ring are permanently installed on the test fitting
PR Series 4 LR Series 4 RL Series 4
To connect to additional test points on the machine
PR Series 4 LR Series 4 RL Series 4
To connect shorter test lines or for connections between test connection and pressure sensor
PR Series 4 LR Series 4 RL Series 4
To keep the loss of pressure to a minimum during tests, use shorter test hoses, if possible
PR Series 4 LR Series 4 RL Series 4
To loosen / counter when setting the pump regulating range
PR Series 4 LR Series 4 RL Series 4
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
Illustration
Use with hook wrench Id. No. 7900282
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Service Manual
Special tools
Description Socket wrench for 0-position grooved nut - variable displacement pump HPV
Id. No. 9749025
Test plates For SAE-flange ž A 90mm B 40mm C,r 5mm For SAE-flange 1 A 90mm B 44mm C,r 5mm For SAE-flange 1Ÿ A 90mm B 52mm C,r 5mm Line wrench SW 30/32
7370092
M-Type
Remarks
PR Series 4 LR Series 4 RL Series 4
To loosen / counter the grooved nut when setting the 0position
PR Series 4 LR Series 4 RL Series 4
To close off high pressure connections Material: Spring steel (ground), taper rounded off plate end (simplifies installation, prevents damage to the seal ring)
PR 724 S/Nxxx6600 9199 PR 734 S/Nxxx6200 8219 PR 764 S/Nxxx6888 9505
Line wrench to check or replace the return filters. Can also be used for other connections.
7370093
7370094
Or make in-house 8006305
Illustration
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Service Manual
Tools and work instructions Special tools
1.3
Electrical system
Description LinDiag Diagnostics KIT
Id. No. 9413782
Consists of: Data carrier with current software version + Dongle Adapter cable
9410472
LinDiag Diagnostics KIT
9413763
M-Type
Remarks
PR 724 S/Nxxx6600 9199 PR 734 S/Nxxx6200 8219 PR 764 S/Nxxx6888 9505
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
Consists of: Data carrier with current software version + Dongle Adapter cable
10035410
USB â&#x20AC;&#x201C; adapter
693190714
PR Series 4 LR Series 4 RL Series 4
Intermediate adapter from serial interface to USB
Digital multi meter complete with cable and bag
10018500
PR Series 4 LR Series 4 RL Series 4
for Voltage (V)Amperage (A)Resistance ( )Frequency (Hz)tests
see Pt. 1.1 Diesel engine
PR Series 4 LR Series 4 RL Series 4
To check the battery charge and the antifreeze in the coolant
Optical charge tester
9410472
PR 724 S/Nxxx9200 PR 734 S/Nxxx8220 PR 744 S/Nxxx7356 PR 754 S/Nxxx6924 PR 764 S/Nxxx9506
Illustration
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Tools and work instructions
Service Manual
Special tools
1.4
Mechanical components
Description
Id. No.
Test tool for tracks
7402603
M-Type
Remarks
Illustration
PR Series 4 LR Series 4 RL Series 4
To measure track wear For 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 â&#x20AC;&#x201C; 3 Slits
10430260
Valve â&#x20AC;&#x201C; 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/Nxxx7697 PR 734 S/Nxxx8220 PR 744 S/Nxxx7356 PR 754 S/Nxxx6924 PR 764 S/Nxxx6888
PR Series 4 LR Series 4 RL Series 4
Illustration
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
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Service Manual
Tools and work instructions Special tools
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
Mandrel [1] and protective sleeve [2] for shaft seal ring
Remarks
Illustration
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
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
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Tools and work instructions
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
PR Series 4 LR Series 4 RL Series 4
Remarks
Illustration
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
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Service Manual
Tools and work instructions Special tools
Description
Id. No.
Centering device for swash plate mount
10324937
M-Type
Remarks
PR Series 4 LR Series 4 RL Series 4
For repairs of var. displ. pump HPV or var. displ. motor HMV
Illustration
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 sleeve
See spare parts list
To install the Oring and step seal ring on pistons of hydraulic cylinders
Spreader sleeve
See spare parts list
To install the Oring and step seal ring on pistons of hydraulic cylinders
Installation wrench Piston
See spare parts list
To tighten the pistons of hydraulic cylinders For tightening torques, see section 8 Hydraulic cylinders
Installation wrench Piston nut
See spare parts list
To tighten the piston nut of hydraulic cylinders For tightening torques, see section 8 Hydraulic cylinders
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Tools and work instructions
Service Manual
Special tools
2.3
Electrical system
Description
Id. No.
Crimper for MATE-N-LOK Crimp contacts
M-Type
Remarks
Illustration
PR Series 4 LR Series 4 RL Series 4
To make proper crimp connections on MATE-N-LOK plug connections
PR Series 4 LR Series 4 RL Series 4
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
PR Series 4 LR Series 4 RL Series 4
To insert pin and bushing contacts into the MATE-N-LOK plug connectors
Hand crimper for plug connector „Deutsch“
8503647
PR Series 4 LR Series 4 RL Series 4
To make proper crimp connections
PR Series 4 LR Series 4 RL Series 4
To remove pin and bushing contacts in „Deutsch“ plug connectors
PR Series 4 LR Series 4 RL Series 4
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) AWG 12 AWG 16 AWG 20
8145674 8145673 8503630
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Tools and work instructions Special tools
Description Crimper AMP AMP Certi-Lock
Id. No. 7415333
Removal tool AMP AMP 726 503-1 AMP 726 534-1
7026266 7027340
Crimper ESA 0760 CRB 0560
7409781 7409782
M-Type
Remarks
PR Series 4 LR Series 4 RL Series 4
To crimp the contacts „JUNIOR POWER TIMER“
PR Series 4 LR Series 4 RL Series 4
To remove contacts from „JUNIOR POWER TIMER“ housing
PR Series 4 LR Series 4 RL Series 4
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
Illustration
In case of defective inching / brake pedal for continued operation of the machine. See section 9. Inching / brake pedal
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Tools and work instructions
Service Manual
Special tools
2.4
Mechanical components
Description
Id. No.
M-Type
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
Illustration
To properly install the slip ring seals on travel gears
Installation device for slip ring seal â&#x20AC;&#x201C; travel gear FAT 400 E 511 Slip ring seal Id.No. 7361 197 outside 7109 24901 inside
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.
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Service Manual
Tools and work instructions Special tools
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
PR Series 4 LR Series 4 RL Series 4
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
Illustration
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 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
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Service Manual
Special tools
Description
Id. No.
M-Type
Remarks To remove / install the tension unit – chain tensioner is required!
Installation tool Tension unit Pos.1 Installation flange Pos.2 Bar Pos.3 Hex head screw 6 each M16x310 mm 10.9
9798353 9798352 4601217
PR 754 RL 64
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
Illustration
For application, see section 12 Tension unit To remove / install the tension unit – chain tensioner is required!
Installation tool Tension unit
For application, see section 12 Tension unit
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 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
Piston surface
71,2 cm3
Operating pressure max.700ba
Oil volume
1131cm3
Lever force max.
47.0kg
Weight
10.9kg
Weight Overall height Retracted Extended outside
23,1kg
9,5 x 1800mm
Pressure range 0-700bar
282mm 441mm 127mm
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Tools and work instructions Special tools
Description Installation sleeve Equalizer bar
Id. No.
M-Type
Remarks
Illustration
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 Â&#x2013; 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
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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.
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
Punch
PR724
A B A B A B A B A B
PR734 PR744 PR754 PR764
Dimensions D Ø119-0,3 -0,3 Ø71 Ø139-0,3 Ø89-0,3 Ø149-0,3 Ø94-0,3 Ø149-0,3 Ø94-0,3 Ø149-0,3 Ø94-0,3
E Ø89±0,1 ±0,1 Ø57 Ø109±0,1 Ø69±0,1 Ø119±0,1 Ø74±0,1 Ø119±0,1 Ø74±0,1 Ø119±0,1 Ø74±0,1
F 13 9 14 11 14 12 14 12 14 12
G 23 18 23 18 23 18 23 18 23 18
* Edges rounded off All dimensions in [mm]
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Service Manual
Tools and work instructions Special tools
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
Dimensions of removal tool
1 Threaded rod M30 2 Sleeve 3 Washer
3.4
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
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Special tools
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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.
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. 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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Special Tools, Application Guidelines
Service-Manual
Repair welding
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. 5. Reinforcement of the welding 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 application of reinforcement plates 6.1. Shape of reinforcement 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.
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Special Tools, Application Guidelines Repair welding
6.2. Plate Thickness 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 The yield and tensile strength of the reinforcement plate should be equal to the material to be reinforced. 6.4. Plate Installation The 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 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 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 plate and the basic material. Subsequent runs are added on top of the first run.
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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Special Tools, Application Guidelines
Service-Manual
Repair welding
7. Selecting the correct electrodes 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, 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. Electrode Selection Welding area
Material
BASIC MACHINE Roller frame - Main frame
St 52 - 3 QStE 380 N
LH 690 preheat to app. 100-150째C (210-300째F) ATTACHMENT Blade Bucket
Push frame Bucket arm RL-Boom
Ripper
WEAR ITEMS Adapter, Tooth adapter Ripper
Q St E 380 N HARDOX 400
St 52 - 3
LH 690 preheat to app. 100-150째C (210-300째F) 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
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Special Tools, Application Guidelines Repair welding
7.2. Steel Table Description
Explanation
HARDOX 400
Weldable, low alloy special steel highly C 0,27% wear resistant, tensile strength 1250 N/mm² 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 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 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 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
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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 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, electrode connected to plus terminal (+). Protective gases: Argon + 15-20% CO2 or 100% CO2 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, electrode connected to plus terminal (+). Protective gases: Argon + 15-20% CO2 or 100% CO2 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, electrode connected to plus terminal (+). Protective gases: Argon+max. 2,5% CO 2 No vertical seams
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Service Manual
Tools and work instructions Installation instructions
Installation instructions A. 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 of the seals are made as a pair. For that reason, they may only be used in the original pairing, in new as well as in used condition. Avoid shock and impact, since this could damage the sealing surfaces of the hard cast 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, 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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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 the slip ring 3 and transfers the pressure 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 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 offset by 120°. Check the sealing surfaces again for absolute cleanliness and apply a thin film of oil or grease.
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Service Manual
Tools and work instructions Installation instructions
B. Removal / installation of the equalizer bar (only PR 754) For replacement of the equalizer bar, the entire bearing must be replaced. The equalizer bar and be 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 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 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.
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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 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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Tools and work instructions Installation instructions
D. 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 the carrier frame. Align the equalizer bar in horizontal (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 Installation screws 7, M24x80, 10.9 PR 764 S/N xxx-6888 Installation screws 7, M24x100, 10.9 Tighten the axle bearing cover crosswise with four installation screws with washers 7 according to factory standards WN 4037 (see detail B).
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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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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
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Sub Group Index
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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
7696
DIESEL ENGINE Type Construction Rating to ISO 9249 Rated RPM Low idle RPM High idle RPM Displacement Oil quantity incl. filter Oil specification Max. machine inclination - all directions Valve clearance - cold Firing order Coolant capacity / DCA 4 Fuel tank capacity Fuel consumption
kW 1/min 1/min 1/min l l
intake / exhaust l l app. l/h
D 924 TI - E A2 4 cylinder in-line - intercooled 118 (160 HP) 1800 +100 780 +100 1860 6,6 19 see lube oil - group 1.3 45° = 100% 0,25 / 0,30 1-3-4-2 30 / 1,4 365 15 - 30
SPLITTER BOX Type Construction Ratio Oil quantity Oil specification
351 B 366 1 stage spur gear i 0,784 l 3,2 see lube oil - group 1.3
HYDRAULIC SYSTEM Travel pumps max. flow - Qmax max. operating pressure (M1 / M2) - pmax Tandem gear pump - replenishing - coolant circuit / fan drive max. flow replenishing - Qmax max. operating pressure (SP) - pmax max. flow fan drive - Qmax max. operating pressure (electronic regulated) - pmax Gear motor fan drive operation RPM Travel motors Variable flow working hydraulic pump max. flow - Qmax stand by pressure(HD) max. operating pressure (HD) - pmax Servo - operating pressure - working hydraulic (ND) Hydraulic tank capacity + circuit capacity Oil specification
type l/min bar model l/min bar l/min bar model 1/min type
l/min bar bar bar
2 x HPV 105 2 x 233 420 56 / 19 124 20 42 150+10 16 1850+100 2 x BMV 186 A 10 V 085 188 20 200 20+4
l 144 l 70 see lube oil - group 1.3
ELECTRIC SYSTEM Voltage Battery Alternator Starter Automatic circuit breaker Fuses
V 24 2 x 12 V, 110 Ah (in series) 28 V, 55 A kW 5,4 A 35 A see operation and maintenance manual
/..
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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 Oil quantity Oil specification
2 x FAT 450 E 504 spur + planetary gear, each 1 stage disk brake i total 41,4 : 1 l 2 x 18,5 see lube oil - group 1.3
2 x FAT 450 E 505
2 x 24,0
TRACK COMPONENTS Track chain pitch Track chain length Track pad width ( single grouser) Track pad bolts Track rollers - single flange (s) Track rollers - double flange (d) Track roller location Carrier rollers each side Max. roller frame oscillation
mm / inch links mm 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
6-way-blade cyl. Ø / rod Ø / stroke Straight blade cyl. Ø / rod Ø / stroke
mm 90 / 50 / 900 mm 90 / 50 / 1140
Tilt cylinder
6-way-blade cyl. Ø / rod Ø / stroke 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
Lift cylinder
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
km/h 0 km/h 0 km/h 0
Drawbar pull max. due to ground condition Mud depth max. measured horizontally - app. Basic machine:
height over cab mm overall length w/o attachment (transport dimension) mm overall length with straight blade mm track gauge mm Width over trunnions mm ground clearance mm
Semi-U- / Straight blade: blade width blade capacity weight - attachment complete ground pressure (varies due to pad width). length add.(lowered) length add.(raised) weight slope angle (with short tooth length)
reverse 0 reverse 0
7,8 4,8
kN 227 mm 1000
Operating weight with Semi-U- / Straight blade (track pad 610 mm)
Ripper(3):
11,0 6,5 4,0
3197 4170 5369 1800 2648 475
kg 16400/16530/16660 mm 3 m kg kg/cm2 mm mm kg °
3204 3,17 2790 0,57 / 0,52 / 0,48
5670
5624 2084 3248
17010/17150/17295
17740/18025/18310
0,52 / 0,48 / 0,44
3790 3,39 2740 0,39 / 0,35 / 0,31
1428 1071 1500 33
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Service-Manual
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PR 724
L - F/N 753-
XL - F/N 754-
LGP - F/N 755-
7697
7697
7697
DIESEL ENGINE Type Construction Rating to ISO 9249 Rated RPM Low idle RPM High idle RPM Displacement Oil quantity incl. filter Oil specification Max. machine inclination - all directions Valve clearance - cold Firing order Coolant capacity / DCA 4 Fuel tank capacity Fuel consumption
kW 1/min 1/min 1/min l l
intake / exhaust l l app. l/h
D 924 TI - E A2 4 cylinder in-line - intercooled 118 (160 HP) 1800 +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 quantity Oil specification
351 B 366 1 stage spur gear i 0,784 l 3,2 see lube oil - group 1.3
HYDRAULIC SYSTEM Travel pumps max. flow - Qmax max. operating pressure (M1 / M2) - pmax Tandem gear pump - replenishing - coolant circuit / fan drive max. flow replenishing - Qmax max. operating pressure (SP) - pmax max. flow fan drive - Qmax max. operating pressure (electronic regulated) - pmax Gear motor fan drive operation RPM Travel motors Variable flow working hydraulic pump max. flow - Qmax stand by pressure(HD) max. operating pressure (HD) - pmax Servo - operating pressure - working hydraulic (ND) Hydraulic tank capacity + circuit capacity Oil specification
type l/min bar model l/min bar l/min bar model 1/min type
l/min bar bar bar
2 x HPV 105 2 x 233 420 56 / 19 124 20 42 150+10 16 1850+100 2 x HMV 210 A 10 V 085 188 20 200 20+4
l 144 l 70 see lube oil - group 1.3
ELECTRIC SYSTEM Voltage Battery Alternator Starter Automatic circuit breaker Fuses
V 24 2 x 12 V, 110 Ah (in series) 28 V, 55 A kW 5,4 A 35 A see operation and maintenance manual
/..
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Technical Data - Maintenance Guidelines
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 quantity Oil specification
2 x FAT 450 E 504 spur + planetary gear, each 1 stage disk brake i total 41,4 : 1 l 2 x 18,5 see lube oil - group 1.3
2 x FAT 450 E 505
2 x 24,0
TRACK COMPONENTS Track chain pitch Track chain length Track pad width ( single grouser) Track pad bolts Track rollers - single flange (s) Track rollers - double flange (d) Track roller location Carrier rollers each side Max. roller frame oscillation
mm / inch links mm 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
6-way-blade cyl. Ø / rod Ø / stroke Straight blade cyl. Ø / rod Ø / stroke
mm 90 / 50 / 900 mm 90 / 50 / 1140
Tilt cylinder
6-way-blade cyl. Ø / rod Ø / stroke 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
Lift cylinder
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
km/h 0 km/h 0 km/h 0
Drawbar pull max. due to ground condition Mud depth max. measured horizontally - app. Basic machine:
height over cab mm overall length w/o attachment (transport dimension) mm overall length with straight blade mm track gauge mm Width over trunnions mm ground clearance mm
Semi-U- / Straight blade: blade width blade capacity weight - attachment complete ground pressure (varies due to pad width). length add.(lowered) length add.(raised) weight slope angle (with short tooth length)
reverse 0 reverse 0
7,8 4,8
kN 227 mm 1000
Operating weight with Semi-U- / Straight blade (track pad 610 mm)
Ripper(3):
11,0 6,5 4,0
3197 4170 5369 1800 2648 475
kg 16400/16530/16660 mm 3 m kg kg/cm2 mm mm kg °
3204 3,17 2790 0,57 / 0,52 / 0,48
5670
5624 2084 3248
17010/17150/17295
17740/18025/18310
0,52 / 0,48 / 0,44
3790 3,39 2740 0,39 / 0,35 / 0,31
1428 1071 1500 33
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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
11222
DIESEL ENGINE Type Version Performance per ISO 9249 Nominal RPM Low idle RPM High idle RPM Displacement Oil quantity incl. filter Oil quality / viscosity Max. permissible machine incline – all directions Valve clearance - cold Firing order
kW 1/min 1/min 1/min l l
on/ off
D 934-L A6 4 cyl. In line – charge air cooled 120 (163 PS) 1800 830+30/-30 1920+30/-30 7,0 29 See Service fluids, section 1.3 45° = 100% See engine data tag 1-3-4-2
SPLITTERBOX Type Version Ratio Oil quantity Oil quality / viscosity
300 B 344 Spur gear drive – 1-rodge i 0,788 l 3 see Service fluids, section 1.3
HYDRAULIC SYSTEM Variable / travel pumps – travel hydraulic Flow - Qmax Operating pressure (M1 / M2) pmax Tandem gear pumps - Replenishing – cooling circuit / fan drive Flow replenishing - Qmax Operating pressure (SP) pmax Flow fan drive - Qmax Operating pressure (electronically regulated) - pmax Gear motor Fan drive Operating RPM Variable travel motors – travel hydraulic Regulating pump – working hydraulic Flow - Qmax Stand by pressure (HD) Operating pressure (HD) - pmax Servo control working hydraulic Operating pressure (ND) Hydraulic tank capacity - Additional circuit capacity Oil quality / viscosity
Type 2 x HPV 105 - 2 l/min bar Type / size l/min bar l/min bar Type / size 1/min Type
l/min bar bar bar
2 x240 420 55 + 19 / 56 + 16 117 20 43 185±5 16 2150+100 2 x HMV 210 - 02 A 10 V 085 194 20±2 200 20+4
l 144 l 70 see Service fluids, section 1.3
ELECTRICAL SYSTEM Operating voltage Batteries Alternator Starter Central fuse Individual fuses
V 24 2 x 12 V, 170 Ah (in Series) 28 V, 80 A kW 6,6 A 45 A See Operating instructions
/..
copyright by
PR 724
F/N xxx -9200
11222
Mjfcifss!
3.1.22 - 1 / 4
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 Oil quantity Oil quality / viscosity
2 x FAT 450 E 504 Spur gear + Planetary gear, per 1-stage Disk brake Total 38,23 : 1 l 2 x 18,5 see Service fluids, section 1.3
2 x FAT 450 E 505
2 x 24
TRACK COMPONENTS Chain pitch Chain length Chain pad width (1 grouser) Track pad bolts Track rollers – single flange, per side (e) Track rollers – double flange, per side (d) Track roller arrangement Track rollers per side Track frame oscillation, max.
mm / inch links mm 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 Lift cylinder
Straight and Semi-U-blade Cyl. Ø / Rod Ø / Strokemm 90 / 50 / 1140 Tilt blade Cyl. Ø / Rod Ø / Stroke mm 90 / 50 / 1140 6 – way blade inside Cyl. Ø / Rod Ø / Stroke mm 90 / 50 / 950 6 – way blade outside Cyl. Ø / Rod Ø / Stroke mm 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 / Strokemm140 / 70 / 100 Tilt blade Cyl. Ø / Rod Ø / Stroke mm 140 / 70 / 130 6 – way blade Inside Cyl. Ø / Rod Ø / Stroke mm 120 / 60 / 170 6 – way blade outside Cyl. Ø / Rod Ø / Stroke mm 120 / 60 / 170
140 / 70 / 100 140 / 70 / 130 120 / 60 / 170 120 / 60 / 170
140 / 70 / 100 ---120 / 60 / 170 ----
120 / 60 / 325
120 / 60 / 325
Swing cylinder
Lift cylinder
6 – way blade inside
Three tooth ripper
Cyl. Ø / Rod Ø / Stroke
Cyl. Ø / Rod Ø / Stroke
mm 120 / 60 / 325
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
kg ( for chain pad width mm) 16530 / 16664 / 16792
----
Operating weight with tilt blade
kg ( for chain pad width mm) 16842 / 16976 / 17104
Operating weight with 6 – way blade
kg ( for chain pad width mm) 16605 / 16739 / 16867
17000 / 17147 / 17287 / 17428 17301 / 17448 / 17588 / 17729 17140 / 17287 / 17427 / 17568
---17864 / 18156 / 18297 / 18437
Blade width
Straight blade Semi-U-blade Tilt blade 6 – way blade
mm mm mm mm
3000 3000 3900 3204
3000 3000 3900 3204
3600 ------3790
Blade capacity
Straight blade Semi-U-blade Tilt blade 6 – way blade
m3 m3 m3 m3
3,14 4,27 3,27 3,17
3,14 4,27 3,27 3,17
3,43 ------3,39
Weight of blades
Straight blade Semi-U-blade Tilt blade
kg 969 kg 1091 kg 1022
969 1091 1022
1143 -------
copyright by
3.1.22 - 2 / 4
Mjfcifss!
PR 724 F/N xxx-9200 11222
Service Manual
Technical data and Maintenance guidelines Technical data
PR 724 Three tooth ripper
6 – way blade Length additional (lowered) Length additional (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
11222
1060
See Operating instructions „Technical data“
GENERAL Travel speed
Normal range - III Reduced range - II Reduced range - I
km/h 0 km/h 0 km/h 0
Traction max. Fording depth max.
depending on ground conditions measured horizontally – approx.
kN 235 mm 1000
Basic machine:
Height over 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 clearance
mm mm mm mm mm mm mm mm mm
11 reverse 0 6,5 reverse 0 4,0 reverse 0
3197 4114 4941 5155 5376 5369 1800 2648 475
11 7,8 4,8
4173 5321 5535 5756 5501 1800 2648
4173 5316 ------5468 2084 3248
copyright by
PR 724
F/N xxx -9200
11222
Mjfcifss!
3.1.22 - 3 / 4
Technical data and Maintenance guidelines
Service Manual
Technical data
copyright by
3.1.22 - 4 / 4
Mjfcifss!
PR 724 F/N xxx-9200 11222
Service Manual
Technical data and Maintenance guidelines Technical data
PR 724
L - F/N 753-
XL - F/N 754-
LGP - F/N 755-
11223
11223
11223
DIESEL ENGINE Type Version Performance per ISO 9249 Nominal RPM Low idle RPM High idle RPM Displacement Oil quantity incl. filter Oil quality / viscosity Max. permissible machine incline – all directions Valve clearance - cold Firing order
kW 1/min 1/min 1/min l l
on/ off
D 934-L A6 4 cyl. In line – charge air cooled 120 (163 PS) 1800 830+30/-30 1920+30/-30 7,0 29 See Service fluids, section 1.3 45° = 100% See engine data tag 1-3-4-2
SPLITTERBOX Type Version Ratio Oil quantity Oil quality / viscosity
300 B 344 Spur gear drive – 1-rodge i 0,788 l 3 see Service fluids, section 1.3
HYDRAULIC SYSTEM Variable / travel pumps – travel hydraulic Flow - Qmax Operating pressure (M1 / M2) pmax Tandem gear pumps - Replenishing – cooling circuit / fan drive Flow replenishing - Qmax Operating pressure (SP) pmax Flow fan drive - Qmax Operating pressure (electronically regulated) - pmax Gear motor Fan drive Operating RPM Variable travel motors – travel hydraulic Regulating pump – working hydraulic Flow - Qmax Stand by pressure (HD) Operating pressure (HD) - pmax Servo control working hydraulic Operating pressure (ND) Hydraulic tank capacity - Additional circuit capacity Oil quality / viscosity
Type 2 x HPV 105 - 2 l/min bar Type / size l/min bar l/min bar Type / size 1/min Type
l/min bar bar bar
2 x240 420 55 + 19 / 56 + 16 117 20 43 185±5 16 2150+100 2 x HMV 210 - 02 A 10 V 074 169 20±2 200 20+4
l 144 l 70 see Service fluids, section 1.3
ELECTRICAL SYSTEM Operating voltage Batteries Alternator Starter Central fuse Individual fuses
V 24 2 x 12 V, 170 Ah (in Series) 28 V, 80 A kW 6,6 A 45 A See Operating instructions
/..
copyright by
PR 724
F/N xxx -11223
Mjfcifss!
3.1.23 - 1 / 4
Technical data and Maintenance guidelines
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 Oil quantity Oil quality / viscosity
2 x FAT 450 E 504 Spur gear + Planetary gear, per 1-stage Disk brake Total 38,23 : 1 l 2 x 18,5 see Service fluids, section 1.3
2 x FAT 450 E 505
2 x 24
TRACK COMPONENTS Chain pitch Chain length Chain pad width (1 grouser) Track pad bolts Track rollers – single flange, per side (e) Track rollers – double flange, per side (d) Track roller arrangement Track rollers per side Track frame oscillation, max.
mm / inch links mm 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 Lift cylinder
Straight and Semi-U-blade Cyl. Ø / Rod Ø / Strokemm 90 / 50 / 1140 Tilt blade Cyl. Ø / Rod Ø / Stroke mm 90 / 50 / 1140 6 – way blade inside Cyl. Ø / Rod Ø / Stroke mm 90 / 50 / 950 6 – way blade outside Cyl. Ø / Rod Ø / Stroke mm 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 / Strokemm140 / 70 / 100 Tilt blade Cyl. Ø / Rod Ø / Stroke mm 140 / 70 / 130 6 – way blade Inside Cyl. Ø / Rod Ø / Stroke mm 120 / 60 / 170 6 – way blade outside Cyl. Ø / Rod Ø / Stroke mm 120 / 60 / 170
140 / 70 / 100 140 / 70 / 130 120 / 60 / 170 120 / 60 / 170
140 / 70 / 100 ---120 / 60 / 170 ----
120 / 60 / 325
120 / 60 / 325
Swing cylinder
Lift cylinder
6 – way blade inside
Three tooth ripper
Cyl. Ø / Rod Ø / Stroke
Cyl. Ø / Rod Ø / Stroke
mm 120 / 60 / 325
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
kg ( for chain pad width mm) 16530 / 16664 / 16792
----
Operating weight with tilt blade
kg ( for chain pad width mm) 16842 / 16976 / 17104
Operating weight with 6 – way blade
kg ( for chain pad width mm) 16605 / 16739 / 16867
17000 / 17147 / 17287 / 17428 17301 / 17448 / 17588 / 17729 17140 / 17287 / 17427 / 17568
---17864 / 18156 / 18297 / 18437
Blade width
Straight blade Semi-U-blade Tilt blade 6 – way blade
mm mm mm mm
3000 3000 3900 3204
3000 3000 3900 3204
3600 ------3790
Blade capacity
Straight blade Semi-U-blade Tilt blade 6 – way blade
m3 m3 m3 m3
3,14 4,27 3,27 3,17
3,14 4,27 3,27 3,17
3,43 ------3,39
Weight of blades
Straight blade Semi-U-blade Tilt blade
kg 969 kg 1091 kg 1022
969 1091 1022
1143 -------
copyright by
3.1.23 - 2 / 4
Mjfcifss!
PR 724 F/N xxx-11223
Service Manual
Technical data and Maintenance guidelines Technical data
PR 724 Three tooth ripper
6 – way blade Length additional (lowered) Length additional (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
Normal range - III Reduced range - II Reduced range - I
km/h 0 km/h 0 km/h 0
Traction max. Fording depth max.
depending on ground conditions measured horizontally – approx.
kN 235 mm 1000
Basic machine:
Height over 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 clearance
mm mm mm mm mm mm mm mm mm
11 reverse 0 6,5 reverse 0 4,0 reverse 0
3197 4114 4941 5155 5376 5369 1800 2648 475
11 7,8 4,8
4173 5321 5535 5756 5501 1800 2648
4173 5316 ------5468 2084 3248
copyright by
PR 724
F/N xxx -11223
Mjfcifss!
3.1.23 - 3 / 4
Technical data and Maintenance guidelines
Service Manual
Technical data
copyright by
3.1.23 - 4 / 4
Mjfcifss!
PR 724 F/N xxx-11223
Service-Manual
Technical Data - Maintenance Guidelines Technical data
PR 734
L - F/N 724-
XL - F/N 725-
LGP - F/N 726-
6200
6200
6200
8219
8219
8219
DIESEL ENGINE Type Construction Rating to ISO 9249 Rated RPM Low idle RPM High idle RPM Displacement Oil quantity incl. filter Oil specification Max. machine inclination - all directions Valve clearance - cold Firing order Coolant capacity / DCA 4 Fuel tank capacity Fuel consumption
kW 1/min 1/min 1/min l l
intake / exhaust l l app. l/h
D 926 TI - E A2 6 cylinder in-line - intercooled 147 (200 HP) 1800 800+50 1900+80 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 Ratio Oil quantity Oil specification
350 B 374 1 stage spur gear i 0,86 l 3 see lube oil - group 1.3
HYDRAULIC SYSTEM Travel pumps max. flow - Qmax max. operating pressure (M1 / M2) - pmax Tandem gear pump - replenishing - coolant circuit / fan drive max. flow replenishing - Qmax max. operating pressure (SP) - pmax max. flow fan drive - Qmax max. operating pressure (electronic regulated) - pmax Gear motor fan drive operation RPM Travel motors Variable flow working hydraulic pump max. flow - Qmax stand by pressure(HD) max. operating pressure (HD) - pmax Servo - operating pressure - working hydraulic (ND) Hydraulic tank capacity + circuit capacity Oil specification
type l/min bar model l/min bar l/min bar model 1/min type
2 x HPV 135 2 x 282 420 56 / 19 117 20 33 210+10 16 1730+100 2 x BMV 260
l/min bar bar bar
A 10 V 0100 209 25 200 20+4
l 162 l 93 see lube oil - group 1.3
ELECTRIC SYSTEM Voltage Battery Alternator Starter Automatic circuit breaker Fuses
V 24 2 x 12 V, 143 Ah (in series) 28 V, 55 A kW 6,6 A 35 A see operation and maintenance manual
/..
copyright by
PR 734
F/N xxx-6200 8219
Mjfcifss!
3.1.30 - 1 / 2
Technical Data - Maintenance Guidelines
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 Type Construction Parking brake (integrated) Ratio Oil quantity Oil specification
2 x FAT 500 E 502 spur + planetary gear, each 1 stage disk brake i total 38,2 : 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 chain length Track pad width ( single grouser) Track pad bolts Track rollers - single flange (s) Track rollers - double flange (d) Track roller location Carrier rollers each side Max. roller frame oscillation
mm / inch links mm thread. size qty. qty.
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 straight blade cyl. Ø / rod Ø / stroke
mm 100 / 60 / 1300
Tilt cylinder straight blade cyl. Ø / rod Ø / stroke
mm 160 / 80 / 120
Ripper cylinder - cyl. Ø / rod Ø / stroke
mm 160 / 80 / 530
100 / 60 / 1165
GENERAL DATA Travel speed
normal range - III reduced range - II reduced range - I
km/h 0 km/h 0 km/h 0
11,0 6,5 4,0
Drawbar pull max. Mud depth max.
due to ground condition measured horizontally - app.
Basic machine:
height over cab mm 3266 overall length w/o attachment (transport dimension)mm4152 overall length with straight blade mm 5532 track gauge mm 1830 Width over trunnions mm 2724 ground clearance mm 500
7,8 4,8
kN 274 mm 1100
Operating weight with Semi-U- / Straight blade (track pad 610 mm) Semi-U- / Straight blade: blade width blade capacity weight - attachment complete ground pressure (varies due to pad width). Ripper(3):
reverse 0 reverse 0
length add.(lowered) length add.(raised) weight slope angle (with short tooth length)
kg 20 878 mm 3 m kg kg/cm2 mm mm kg °
3363 5,86 2790 0,60 (610)
4291 5950
5632 2180 3474
21 503
22 237
0,54 (610)
3995 4,1 2740 0,42 (812)
1531 1193 1915 33
copyright by
3.1.30 - 2 / 2
Mjfcifss!
PR 734
F/N xxx-6200 8219
Service-Manual
Technical Data - Maintenance Guidelines Technical data
PR 734
L - F/N 724-
L - F/N 725-
LGP - F/N 726-
8220
8220
8220
DIESEL ENGINE Type Construction Rating to ISO 9249 Rated RPM Low idle RPM High idle RPM Displacement Oil specification Max. machine inclination - all directions Valve clearance - cold Firing order
kW 1/min 1/min 1/min l
intake / exhaust
D 936 LA6 6 cylinder in-line - intercooled 150 (204 HP) 1800 900+50 1900+50 10,5 see lube oil - group 1.3 45° = 100% See data tag / engine 1-5-3-6-2-4
SPLITTER BOX Type Construction Ratio Oil quantity Oil specification
351 B 374 1 stage spur gear i 0,86 l min. 2,6 – max. 3,0 see lube oil - group 1.3
HYDRAULIC SYSTEM Travel pumps max. flow - Qmax max. operating pressure (M1 / M2) - pmax Tandem gear pump - replenishing - coolant circuit / fan drive max. flow replenishing - Qmax max. operating pressure (SP) - pmax max. flow fan drive - Qmax max. operating pressure (electronic regulated) - pmax Gear motor - fan drive operation RPM Travel motors Variable flow working hydraulic pump max. flow - Qmax stand by pressure(HD) max. operating pressure (HD) - pmax Servo - operating pressure - working hydraulic (NP) Hydraulic tank capacity + circuit capacity Oil specification
type l/min bar model l/min bar l/min bar model 1/min type
l/min bar bar bar
2 x HPV 135 2 x 282 420 55 + 19 / 56 + 16 117 20 33 220±5 16 1800+100 2 x HMV 280 A 10 V 0100 209 20+2 -2 200 20+4
l 144 l 93 see lube oil - group 1.3
ELECTRIC SYSTEM Voltage Battery Alternator Starter Automatic circuit breaker Fuses
V 24 2 x 12 V, 170 Ah (in series) 28 V, 80 A kW 7,8 A 45 A see operation and maintenance manual
/..
copyright by
Mjfcifss! PR 734
F/N xxx-8220
3.1.31 - 1 / 4
Technical Data - Maintenance Guidelines
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) Ratio Oil quantity Oil specification
2 x FAT 500 E 502 spur + planetary gear, each 1 stage disk brake i total 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) Track pad bolts Track rollers - single flange (s) Track rollers - double flange (d) Track roller location Carrier rollers each side Max. roller frame oscillation
mm / inch links mm 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. 2 ± 3°
44
44 710/812/914/965
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 cyl. Ø / rod Ø / stroke
mm 100 / 60 / 1230 mm 100 / 60 / 1300
Tilt cylinder
straight- and Semi-U-blade cyl. Ø / rod Ø / stroke angle blade cyl. Ø / rod Ø / stroke
mm 160 / 80 / 0120 mm 180 / 80 / 0200
Lift cylinder
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
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
Blade width
straight blade Semi-U-blade angle blade
mm 3397 mm 3372 mm 4240
3397 3372 4240
3995 3747
Schildkapazität
straight blade Semi-U-blade angle blade
m3 4,21 m3 5,56 m3 3,80
4,21 5,56 3,80
4,10 5,40
Weigth blade
straight blade Semi-U-blade angle blade
kg 1417 kg 1504 kg 1403
1417 1504 1403
1544
Ripper(1):
length add.(lowered) length add.(raised) weight slope angle
mm mm kg °
1961 1671 1530 19 / 23
Ripper(3):
length add.(lowered) length add.(raised) weight slope angle (with short tooth length)
mm mm kg °
1531 1199 1909 33,3 /..
copyright by
3.1.31 - 2 / 4
Mjfcifss! PR 734
F/N xxx-8220
Service-Manual
Technical Data - Maintenance Guidelines Technical data
PR 734
L - F/N 724-
L - F/N 725-
LGP - F/N 726-
8220
8220
8220
3258 8253 9804 5863 5093 3372 1400 2994 2724
3258 8521 10072 6133 5361 3372 1400 2994 2724
3258 9136 10687 5878 5361 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, with hydraulic quick hitch without blade Blade width Blade heigth Width hydraulic quick hitch1 width over ball trunnions
mm mm mm mm mm mm mm mm mm
Operation weight² kg 21351/21475/2159 21863/2201/22137 Ground 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
normal range - III reduced range - II reduced range - I
km/h 0 km/h 0 km/h 0
Drawbar pull max.
due to ground condition
Basic machine:
height over cab length over lift cylinder (transport dimension) length with straight blade length with Semi-U-blade length with angle blade track gauge width over ball trunnions ground clearance
11,0 6,5 4,0
reverse 0 reverse 0 reverse 0
11,0 7,8 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
copyright by
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F/N xxx-8220
3.1.31 - 3 / 4
Technical Data - Maintenance Guidelines
Service-Manual
Technical data
copyright by
3.1.31 - 4 / 4
Mjfcifss! PR 734
F/N xxx-8220
Service-Manual
Technical Data - Maintenance Guidelines Technical data
PR 744
L - F/N 940-
LGP - F/N 942-
7356
7356
DIESEL ENGINE Type Construction Rating to ISO 9249 Rated RPM Low idle RPM High idle RPM Displacement Oil specification Max. machine inclination - all directions Valve clearance - cold Firing order
kW 1/min 1/min 1/min l
intake / exhaust
D 936 LA6 6 cylinder in-line - intercooled 185 (252 HP) 1600 900+50 1700+50 10,5 see lube oil - group 1.3 45° = 100% See data tag / engine 1-5-3-6-2-4
SPLITTER BOX Type Construction Ratio Oil quantity Oil specification
351 B 355 1 stage spur gear i 0,861 l 6,4 see lube oil - group 1.3
HYDRAULIC SYSTEM Travel pumps max. flow - Qmax max. operating pressure (M1 / M2) - pmax Axial piston pump – cooling circuit Flow quantity replenishing - Qmax Operating pressure (LA electronically regulated) pmax Stand by pressure LA (at cold machine) Tandem gear pumps – replenishing – servo control WH Flow quantity - Qmax –ges (Qmax –ges =Q1 + Q2) Operating pressure (SP) pmax
type 2 x HPV 210-02 l/min 2 x 380 +30/-10 bar 420 A 10 V 28 l/min 57 +/-5 bar 205 +5 bar 30 model 45 + 38 l/min 150 +4 bar 20
Axial piston motor (fan – water cooler) Operating speed Gear motor (fan – hydraulic oil cooler) Operating speed
model 18 / 52 +100 RPM 1500 RPM 2350+100
Var. displ. motors – Travel hydraulic
Type 4 x HMV 165-02
Variable flow working hydraulic pump max. flow - Qmax stand by pressure(HD) max. operating pressure (HD) - pmax Servo - operating pressure - working hydraulic (NP)
l/min bar bar bar
Hydraulic tank capacity + circuit capacity Oil specification
A 10 V 140 260 20+2 260+5 20+4
l 167 l 136 See Service fluids, section 1.3
ELECTRICAL SYSTEM Voltage Battery Alternator Starter Automatic circuit breaker Fuses
V 24 2 x 12 V, 170 Ah (in series) 28 V, 80 A kW 7,8 A 45 A see Operation and maintenance manual
copyright by
PR 744
F/N xxx-7356
Mjfcifss!
3.1.40 - 1 / 2
Technical Data - Maintenance Guidelines
Service-Manual
Technical data
PR 744
L - F/N 940-
LGP - F/N 942-
7356
7356
FINAL DRIVE Type Construction Parking brake (integrated) Ratio Oil quantity Oil specification
2 x FAT 600 E 506 spur + planetary gear, each 2 stage disk brake i total 45,3 : 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 chain length Track pad width ( single grouser) Track pad bolts Track rollers - single flange (s) Track rollers - double flange (d) Track roller location Carrier rollers each side Max. roller frame oscillation
mm / inch links mm thread. size qty. qty.
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 straight blade cyl. Ø / rod Ø / stroke Tilt cylinder straight blade cyl. Ø / rod Ø / stroke Cutting angle cylinder straight blade - cyl. Ø / rod Ø / stroke
mm 100 / 60 / 1345 mm 160 / 80 / 170 mm 180 / 80 / 110
Lift cylinder ripper - cyl. Ø / rod Ø / stroke Ripping angle cylinder - cyl. Ø / rod Ø / stroke
mm 160 / 95 / 380 mm 160 / 95 / 380
GENERAL DATA Travel speed
normal range - III reduced range - II reduced range - I
Drawbar pull max.
due to ground condition
Basic machine:
height over cab mm overall length w/o attachment (transport dimension)m overall length with straight blade mm track gauge mm Width over trunnions mm ground clearance mm
Operating weight with Semi-U- / Straight blade
km/h 0 km/h 0 km/h 0
11,0 6,5 4,0
reverse 0 reverse 0 reverse 0
11 8 4,5
kN 360
3434 4657 6050 1980 3000 546
4692 5935 2180 3600
kg (track pad in mm) 25620 (560)
Semi-U- / Straight blade: blade width mm 3 blade capacity m weight - attachment complete kg ground pressure. kg/cm2 (varies due to pad width)
3690 7,2 3803 0,76 (560)
Ripper(3):
1937 1586 3304 28,5
length add.(lowered) length add.(raised) weight slope angle (with short tooth length)
mm mm kg °
27000 (914) 4520 6,0 3940 0,45 (914)
copyright by
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Mjfcifss!
PR 744
F/N xxx-7356
Service Manual
Technical data and Maintenance guidelines Technical data
PR 754 DIESEL ENGINE Type Design Rated to ISO 9249 Rated RPM Low idle RPM High idle RPM Displacement Oil specification / viscosity Max. machine inclination - all directions Valve clearance - cold Firing order
kW RPM RPM RPM l
intake / exhaust
D 946-L A6 6 cyl. in line – charge air cooled 250 (340 PS) 1600 900+50 1700+50 12 See Service items, section 1.3 45° = 100% See Data tag / engine 1-5-3-6-2-4
SPLITTERBOX Type Design Ratio Oil quantity Oil specification / viscosity
351 B 364 Spur gear 1-stage i 0,86 l Min. 5 – Max. 5,5 See Service items section 1.3
HYDRAULIC SYSTEM Variable pumps – travel hydraulic Flow - Qmax Operating pressure (M1 / M2) pmax Axial piston pump – cooling circuit Flow quantity replenishing - Qmax Operating pressure (LA electronically regulated) pmax Stand by pressure LA (with cold machine) Tandem gear pumps - Replenishing – Pilot control WH Flow quantity - Qmax –ges (Qmax –ges =Q1 + Q2) Operating pressure (SP) pmax
Type 2 x HPV 280-02 l/min 2 x 518 bar 420+30/-10 A 10 V 28 l/min 57 bar 205+/-5 bar 30+5 Size 55 + 38 l/min 174 bar 20+4
Axial piston motor (fan – water cooler) Operating speed Gear motor (fan – hydraulic oil cooler) Operating speed
Size 1/min Size 1/min
Variable displ. motors - Travel hydraulic
Type 4 x HMV 210
Regulating pump – Working hydraulic Flow quantity - Qmax Stand by pressure (HD) Operating pressure (HD) - pmax Pilot control working hydraulic operating pressure (ND)
l/min bar bar bar
Oil tank capacity - circuit capacity - additional Oil specification / viscosity
18/52 1500+100 19 1800+100
A 10 V 140 260 20+2 260+5 20+4
l 240 ( sight gauge top) l 180 See Service items section 1.3
ELECTRICAL SYSTEM Operating voltage Batteries Alternator Starter Central fuse Individual fuses
V 24 2 x 12 V, 225 Ah (in Series) 28 V, 80 A kW 7,8 A 45 A See Operating instructions
copyright by
PR 754
F/N xxx-6924
Mjfcifss!
3.1.50 - 1 / 2
Technical data and Maintenance guidelines
Service Manual
Technical data
PR 754 FINAL DRIVE Type Design Parking brake integrated Ratio Oil quantity Oil specification / viscosity
2 x FAT 650 E 508 Spur gear 1-stage + Planetary gear – 2 stage Disk brake Total 54,3 : 1 l 2 x 18,5 See Service items section 1.3
TRACK COMPONENTS Track chain pitch Track chain length Track pad width (1 grouser) Track pad bolts Track rollers – single flange per side (e) Track rollers – double flange per side (d) Track roller arrangement Carrier rollers per side Max. roller frame oscillation
Fixed and single oscillating track rollers mm /inch Links mm 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 U – and Semi-U-blade 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 cylinder- ripper cyl. Ø / rod Ø / stroke Ripping angle cylinder- ripper cyl. Ø / rod Ø / stroke
mm 160 / 95 / 495 mm 160 / 95 / 495 Track with fixed track rollers
GENERAL Travel speed
normal range - III reduced range - II reduced range - I
Pull force max.
Depends on ground condition
Basic machine:
Height over cab Length over lift cylinder (Transport length) Length with straight blade Track gauge Width via trunion Ground clearance
Operating weight with Semi-U-blade Semi-U- / straight blade: Blade width Blade capacity Ground pressure Ripper(3):
km/h 0 km/h 0 km/h 0
11,0 6,5 4,0
kN mm mm mm mm mm mm
3630 4875 6448 2180 3145 630
kg ( for track pad width 610 mm) 35225 mm 4030 m3 8,9 2 kg/cm (for track pad width mm) 0,91
Length additional (lowered) Length additional ( raised) Weight Slope angle
Track with single oscillating track rollers reverse 0 11,0 reverse 0 8,0 reverse 0 4,5
mm mm kg °
36120
0,93
2374 1821 4725 31
copyright by
3.1.50 - 2 / 2
Mjfcifss!
PR 754
F/N xxx-6924
Service Manual
Technical data and Maintenance guidelines Technical data
PR 764 DIESEL ENGINE Type Design Rated to ISO 9249 Rated RPM Low idle RPM High idle RPM Displacement Oil specification / viscosity Max. machine inclination - all directions Valve clearance - cold Firing order
kW RPM RPM RPM l
intake / exhaust
D 9408 TI – E A4 V8 engine – charge air cooled 310 ( 422 PS ) 1800 900 +50 1700 +50 17,18 see Service items section 1.3 45° = 100% See Data tag / engine 1–8–4–2–7–3–6–5
SPLITTERBOX Type Design Ratio Oil quantity Oil specification / viscosity
PVG 351 B 355 Spur gear 1-stage i 0,8653 l 6,3 see Service items section 1.3
HYDRAULIC SYSTEM Variable pumps – travel hydraulic Flow - Qmax Operating pressure (M1 / M2) pmax Axial piston pump – cooling circuit Flow quantity replenishing - Qmax Operating pressure (LA electronically regulated) pmax Ground by pressure LA (with cold machine) Tandem gear pumps - Replenishing – Pilot control WH Flow quantity - Qmax –ges (Qmax –ges =Q1 + Q2) Operating pressure (SP) pmax
Type 2 x THPV 210 l/min 4 x 437 bar 420+30/-10 A 10 V 28 l/min 57 bar 280+/-5 bar 30+5 Size 55 + 55 l/min 232 bar 20+4
Axial piston motor (fan – water cooler) Operating speed Gear motor (fan – hydraulic oil cooler) Operating speed
Size 1/min Size 1/min
Variable displ. motors - Travel hydraulic
Type 4 x HMV 280
Regulating pump – Working hydraulic Flow quantity - Qmax Ground by pressure (HD) Operating pressure (HD) - pmax Pilot control working hydraulic operating pressure (ND)
l/min bar bar bar
Oil tank capacity - circuit capacity - additional Oil specification / viscosity
18/52 1380+100 19 2000+100
A11 VL 190 395 20+2 260+5 20+4
l 280 l 240 see Service items section 1.3
ELECTRICAL SYSTEM Operating voltage Batteries Alternator Starter Central fuse Individual fuses
V 24 2 x 12 V, 170 Ah (in Series) 28 V, 80 A kW 9 A 35 A See Operating instructions
copyright by
Mjfcifss! PR 764
F/N xxx-6888 9505
3.1.60 - 1 / 2
Technical data and Maintenance guidelines
Service Manual
Technical data
PR 764 FINAL DRIVE Type Design Parking brake integrated Ratio Oil quantity Oil specification / viscosity
700 E 501 Spur gear 1-stage + Planetary gear – 2 stage Disk brake Total 54,31 : 1 l 22,5 + 7,5 See Service items section 1.3
Fixed - and single oscillating track rollers
TRACK COMPONENTS Track chain pitch Track chain length Track pad width (1 grouser) Track pad bolts Track rollers – single flange per side (e) Track rollers – double flange per side (d) Track roller arrangement 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 size Qty. Qty.
e–e–d–d–e–d–e
WORKING ATTACHMENT Lift cylinder U – and Semi-U-blade 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 cylinder- ripper cyl. Ø / rod Ø / stroke Ripping angle cylinder- ripper cyl. Ø / rod Ø / stroke
mm 180 / 100 / 550 mm 180 / 100 / 550 Track with fixed track rollers
GENERAL Travel speed
normal range - III reduced range - II reduced range - I
km/h 0 km/h 0 km/h 0
Pull force max.
Depends on ground condition
Basic machine:
Height over cab Length over lift cylinder (Transport length) Length with straight blade Track gauge Width via trunion Ground clearance
Operating weight with Semi-U-blade
11,0 6,5 4,0
mm mm mm mm mm mm
7,8 4,8
3935 5280 7022 2240 3263 695
kg ( for track pad width 610 mm) 44720
Length additional (lowered) Length additional ( raised) Weight Slope angle (for short tooth length)
reverse 0 reverse 0
Track with double oscillating track roller
kN 610
Semi-U- / straight blade: Blade width mm 4370 3 Blade capacity m 14 Weight – attachment total kg 7806 Ground pressure kg/cm2 (for track pad width 610 mm) 1,04 Ripper(3):
Track with single oscillating track rollers
mm mm kg °
45220
45620
1,05
1,06
2494 1894 6160 31
copyright by
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 Version Performance according to ISO 9249 Nominal RPM Low idle RPM High idle RPM Displacement Oil quality / viscosity Max. permissible machine incline – all directions Valve clearance - cold Firing order
kW 1/min 1/min 1/min l
intake / exhaust
D 9508 A7 8 cylinder V-engine 310 ( 422 PS ) 1600 900 +50 1700 +50 16,2 see Service items– Operating instructions 45° = 100% See data tag / engine 1–5–7–2–6–3–4–8
SPLITTERBOX Type Version Ratio Oil quantity Oil quality / viscosity
PVG 351 B 355 Spur gear 1-stufig i 0,8653 l 6,4 see Service items– Operating instructions
HYDRAULIC SYSTEM Variable / travel pumps – travel hydraulic Flow - Qmax Operating pressure (M1 / M2) pmax Axial piston pump – Cooling circuit Flow replenishing - Qmax Operating pressure (LA electronically regulated) pmax Stand by pressure LA (at cold machine) Tandem gear pumps - replenishing – Servo control WH Flow - Qmax –ges (Qmax –ges =Q1 + Q2) Operating pressure (SP) pmax
Type 4 x HPV 210 l/min 4 x 388 bar 420+30/-10 A 10 V 28 l/min 52 bar 250+/-5 bar 30+5 Size 56+ 56 l/min 208 bar 23+5
Axial piston motor (fan – water cooler) Operating RPM Gear motor (fan – hydraulic oil cooler) Operating RPM
Size 1/min Size 1/min
Var. motors – Travel hydraulic
Type 4 x HMV 280
Regulating pump – Working hydraulic Flow - Qmax Stand by pressure (HD) Operating pressure (HD) - pmax Servo control - Working hydraulic Operating pressure (ND)
l/min bar bar bar
Oil capacity – tank capacity - additional circuit capacity Oil quality / viscosity
18/52 1350+100 19 2000+100
A11 VL 190 352 20+2 260+5 23+5
l 280 l 230 see Service items– Operating instructions
ELECTRICAL SYSTEM Operating voltage Batteries Alternator Starter Central fuse Individual fuses
V 24 2 x 12 V, 225 Ah 28 V, 80 A kW 7,8 A 45 A see Operating instructions
copyright by
PR 764
F/N xxx-9506
Mjfcifss!
3.1.61 - 1 / 2
Technical data and Maintenance guidelines
Service Manual
Technical data
PR 764 FINAL DRIVE Type Version Parking brake, integrated Ratio Oil quantity Oil quality / viscosity
700 E 501 Spur gear + Planetary gear, each 2-stage Disk brake i ges 54,31 : 1 l See Service items – Operating instructions See Service items – Operating instructions Fixed and simple oscillating track rollers
TRACK COMPONENTS Chain pitch Chain length Chain pad width (1 grouser) Track pad bolts Track rollers – single flange, per side (e) Track rollers – double flange, per side (d) Track roller arrangement (from back to front) Track rollers per side Track frame oscillation, max. Sprocket segments per side
Double oscillating track rollers
mm / 240 / 9,45 44 610 – 660 – 710 – 760 Thread 1“ – 14 UNF Each 4 Each 3 e–d–e–d–e–d–e Each 2 ± 3° Each 3
e–e–d–d–e–d–e
WORKING ATTACHMENT Lift cylinder U – and Semi-U-blade cyl. Ø / rod Ø / stroke Tilt cylinder U – and Semi-U-blade 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 cylinder- ripper cyl. Ø / rod Ø / stroke Ripper angle cylinder- ripper cyl. Ø / rod Ø / stroke
mm 180 / 100 / 550 mm 180 / 100 / 550 Track with fixed track rollers
GENERAL Travel speed
Normal range - III Reduced range - II Reduced range - I
Traction max.
depends on ground conditions
Basic machine:
Height over operator’s cab Length over lift cylinder (Transport length) Length with Semi-U-blade Track width Width over trunion Ground clearance
Operating weight with Semi-U-blade Semi-U-blade:
km/h 0 km/h 0 km/h 0
11,0 6,5 4,0
Track with single oscillating track rollers Reverse 0 Reverse 0 Reverse 0
Track with double oscillating track rollers
11,0 7,8 4,8
kN 610 mm mm mm mm mm mm
3935 5280 7022 2240 3263 695
kg ( for 610mm plate width) 44720
Blade width mm Blade capacity m3 Weight – attachment total kg Ground pressure kg/cm2 (for 610mm plate width)
4370 14 8100 1,04
Ripper 1 tooth:
Length additional(lowered) Length additional(raised) Weight Slope angle (for short tooth length)
mm mm kg °
2494 1894 4786 31
Ripper 3 tooth:
Length additional(lowered) Length additional(raised) Weight Slope angle (for short tooth length)
mm mm kg °
2494 1894 6160 31
45220
45620
1,05
1,06
copyright by
3.1.61 - 2 / 2
Mjfcifss!
PR 764
F/N xxx-9506
Service-Manual
Technical Data - Maintenance Guidelines Maintenance and Inspection schedule
Customer:.................................................Mach.-Type..............F/N..…..-....….....Sm.hours..........Date........…. Maintenance / inspection at operating hours
WORK TO BE CARRIED OUT by maintenance personnel first and only interval Repeat interval
by authorized trained personnel first and only interval Repeat interval
OM Operating instructions
SM Service Manual
For control levels, use test marksFor procedure and quantities, see OM For quality and viscosity guidelines, see “Service Fluids” OM See data in SM
Reference see:
Notes
DIESEL ENGINE Check engine oil level and pressure Check coolant level Check engine, radiator and belly pan for dirt - clean if necessary
OM OM OM
Check fuel filter water separator / drain if necessary Drain fuel tank condensation and sediments - at least once a week Take oil sample before changing oil and prepare it for analyze Replace engine oil - at least once a year Replace lube oil filter - at least once a year Check radiator cap and fan Replace coolant filter, check antifreeze / DCA4 percentage in coolant Check oil, cooling and fuel system for leaks and condition Fuel pre-filter - replace filter element V-belt - check condition Check air intake and exhaust system for tightness and leaks Check engine mounts for condition and tightness Check engine RPM - adjust if necessary Check and adjust valve clearance - with cold engine Check and service injection pump linkage Replace fuel fine filter cartridge Grease flywheel teeth Check flame glow plug system (before start of cold season) Replace air filter elements - if necessary or at least once a year Replace oil separator - every 2 years Replace coolant with antifreeze and DCA4 - every 2 years Check / adjust fuel injectors - if necessary or at least every 3000 operating hours
OM OM OM OM OM OM OM OM OM OM OM OM
OM OM
SM SM SM SM SM SM SM SM SM SM SM SM SM
OM OM OM
SM SM SM
HYDRAULIC SYSTEM Check oil level in hydraulic tank Clean magnetic rod (also after repairs) - daily up to 50 operating hours Check hydraulic oil cooler for dirt / clean if necessary Replace pressure filter element of the replenishing circuit Check attachment and travel hydraulic system for function and leaks, check hydraulic hose routing for chafing Replace main return flow filter element immediately if indicator light lights up Check / adjust all hydraulic pressures according to adjustment checklist Check mountings and fittings for tight seating Check all case drain filter inserts for deposits / contamination Take oil sample (before changing oil) and prepare it for analyze Replace hydraulic oil (refill via tank filter) - at least every 4 years - whenever “environmentally safe hydraulic fluids” are used request / observe any special guidelines from manufacturer
OM OM OM OM OM
SM
SM
OM OM OM
SM SM SM SM
OM
SPLITTERBOX Check oil level Replace gear oil
PR 724 PR 734 PR 764
F/N xxx-6600 9199 F/N xxx-6200 8219 F/N xxx-6888 9505
- at least every 2 years
OM OM
copyright by
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3.2.20 - 1 / 2
Technical - Data and Maintenance Guidelines
Service Manual
Maintenance and Inspection schedule
Maintenance/Inspection by Operating Hours
WORK TO BE CARRIED OUT by maintenance personnel first and only interval Repeat interval
by authorized trained personnel first and only interval Repeat interval
OM Operating instructions
SM Service Manual
For control levels, use test marksFor procedure and quantities, see OM For quality and viscosity guidelines, see â&#x20AC;&#x153;Service Fluidsâ&#x20AC;? OM See data in SM
Reference see:
Notes
ELECTRICAL SYSTEM Check system functions incl. indicators and gauges Check battery electrolyte level - at least once a year Check, clean and grease battery terminals Check wire routing and connections Check / adjust travel drive control system according to adjustment checklist Check battery acid concentration / charge (before start of cold season)
OM OM OM OM
SM SM SM SM SM
HEATER / FRESH AIR SYSTEM / AIR CONDITIONER Check system for function and leaks Air conditioner - check refrigerant level and moisture indicator Replace fresh air filter and at air conditioner air circulation filter Air conditioner - check performed by trained A/C technician
- at least every 3 month - at least every 3 month - as necessary - once a year
OM OM OM OM
SM
- at least once a year - at least once a year
OM OM OM OM OM OM
SM SM
OM
SM
FINAL DRIVE Check oil level for sealing area Check oil level at gear - clean magnetic plugs Check bolts and nuts for tightness Take oil sample before changing oil and prepare it for analyze Replace gear oil - clean magnetic plugs Replace lube oil from sealing area / flush area
- at least every 4 years - at least every 4 years
TRACK COMPONENTS Check all bolts and nuts of track components, in particular at track pads and sprocket segments for tightness Check carrier rollers, track rollers and idlers for leaks Check oil level for support shaft bearing Grease middle bearing of equalizer bar - shorten interval as necessary Check idler guides / adjust, replace parts as necessary Adjust chain tension to suit application - as necessary Clean track components - as necessary Check track components for wear - as necessary
OM OM OM OM OM OM
SM SM SM
ATTACHMENTS Check cutting edges, end bits and ripper teeth for wear check if attachments are suited to application Check blade adjustment / centered to main frame and link connection - after every installation Check bolts, nuts and pin safeties for tightness Check all attachment bearings for play / wear Check attachments for damage
OM OM OM OM OM
SM
GENERAL Grease all grease points according to the lubrication chart - shorten interval as necessary Check entire machine for proper maintenance and condition Explain machine literature, in specially Operation Manual-safety guidelines to the operating personnel
copyright by
3.2.20 - 2 / 2
Mjfcifss!
PR 724 PR 734 PR 764
OM OM
SM
OM
F/N xxx-6600 9199 F/N xxx-6200 8219 F/N xxx-6888 9505
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:
Remar ks
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 Change engine oil -1) Specification: CI-4, CH-4
OI
Change engine oil -1) 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 Check V-belt condition Check control unit mounting, sensory and cable connections for condition Change / replace oil separator filter insert Check oil, cooling and fuel system for leaks and condition Check intake and exhaust system – mounting and leaks Check engine mount Check engine RPM Change fuel pre-filter and fine filter - Observe bleeding instructions Check / adjust valve play – with cold engine Grease gear ring on flywheel 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 Change heater flange – 10000 hrs. Replace air filter inserts - as necessary, once a year Replace coolant with antifreeze - every 2 years
OI
OI
OI OI OI OI OI OI OI OI SM OI SM SM OI 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 Replace pressure filter for replenishing 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 Check mountings and fittings for tight seating 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
PR 724 PR 734 PR 744 PR 754
F/N xxx-9200 F/N xxx-8220 F/N xxx-7356 F/N xxx-6924
OI OI OI OI OI OI / SM SM OI OI OI
copyright by
Mjfcifss!
3.2.21 - 1 / 4
Technical data and Maintenance guidelines
Service Manual
Maintenance and inspection schedule
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
SPLITTERBOX Check oil level Replace gear oil - at least every 2 years
OI 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 Check cable routing and connections 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 OI OI OI / SM OI / SM SM SM
HEATER / VENTILATION / 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 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 Check evaporator unit, clean if necessary Check electrical lines for chafing and plug connections for tight seating Have air conditioning system checked / inspected by HVAC technician - 1x a year
OI OI OI OI OI OI OI OI OI 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 Replace gear oil 1) – 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
copyright by
3.2.21 - 2 / 4
Mjfcifss!
OI OI OI / SM OI OI OI
PR 724 PR 734 PR 744 PR 754
F/N xxx-9200 F/N xxx-8220 F/N xxx-7356 F/N xxx-6924
Remark s
Service Manual
Technical Data and Maintenance guidelines Maintenance and inspection schedule
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:
Remar ks
For correct fill quantities, use test marksfor procedure and quantities, see OI For quality and viscosity guidelines, see â&#x20AC;&#x153;Service fluidsâ&#x20AC;?, OI See data in SM
TRACK COMPONENTS Check mounting screws and nuts of track components, especially track pad and sprocket Segment bolts for tight seating Lubricate equalizer bar bearing - shorten interval if necessary Check oil level of support axle bearing (only PR 724, PR 734 and PR 744)
OI OI 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) Adjust chain tension to suit application - as necessary / when changing applications Clean track - as necessary Check track wear - as necessary
OI 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 attachment of bracket - and at every installation Check all bearing points for play / wear Check screws, nuts and bolt retainers for tight seating Check attachments for intentional damage
OI OI OI / SM OI 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
PR 724 PR 734 PR 744 PR 754
F/N xxx-9200 F/N xxx-8220 F/N xxx-7356 F/N xxx-6924
OI OI OI
copyright by
Mjfcifss!
3.2.21 - 3 / 4
Technical data and Maintenance guidelines
Service Manual
Maintenance and inspection schedule
copyright by
3.2.21 - 4 / 4
Mjfcifss!
PR 724 PR 734 PR 744 PR 754
F/N xxx-9200 F/N xxx-8220 F/N xxx-7356 F/N xxx-6924
Service Manual
Technical data and Maintenance guidelines Maintenance and inspection schedule
Company:..................................................Machine 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:
Remar ks
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
DIESEL ENGINE Check oil level and coolant level 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 Change engine oil -1) Specification: CI-4, CH-4
OI OI
Change engine oil -1) 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 corrosions inhibitor / antifreeze concentration in coolant Check V-belt condition Check control unit mounting, sensory and cable connections for condition Check oil, coolant and fuel system for leaks and condition Check intake and exhaust system – mounting and leaks 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 insufficient power Check / adjust valve clearance - with cold engine Check exhaust return flap Check engine RPM Grease ring gear on flywheel 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 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
OI OI
OI OI OI OI OI OI OI OI SM OI SM SM OI 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 Replace pressure filter for replenishing 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 Check mountings and fittings for tight seating Take oil sample (before oil change) and send it in for analysis Replace oil in hydraulic system (add oil via filter) - at least every 4 years - when using an environmentally friendly hydraulic medium, request / observe special guidelines
OI OI OI OI OI OI / SM SM OI OI OI
copyright by
PR 764
F/N xxx-9506
Mjfcifss!
3.2.60 - 1 / 4
Technical data and Maintenance guidelines
Service Manual
Maintenance and inspection schedule
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 items” OI See data in SM
SPLITTERBOX Check oil level Replace gear oil - but at least every 2 years
OI 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 Check cable routing and connections 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 OI OI OI SM SM SM
HEATER / VENTILATION / AIR CONDITIONING 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 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 Check evaporator unit, clean if necessary Check electrical lines for chafing and plug connections for tight seating Have air conditioning system checked / inspected by HVAC technician - 1x a year
OI OI OI OI OI OI OI OI OI 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 Replace gear oil 1) – 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
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PR 764
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Service Manual
Technical data and Maintenance guidelines Maintenance and inspection schedule
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:
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For correct fill quantities, use test marksfor procedure and quantities, see OI For quality and viscosity guidelines, see â&#x20AC;&#x153;Service itemsâ&#x20AC;? OI See data in SM
TRACK COMPONENTS Check mounting screws and nuts of track components, especially track pad and sprocket segment screws for tight seating Lubricate equalizer bar bearing - shorten interval if necessary Check all track components for leaks
OI OI OI
Check / adjust idler guides, replace parts, if necessary
OI
Check front axle bearing screws for tight seating Adjust chain tension to suit application - as necessary / when changing applications Clean track - as necessary Check for track wear - as necessary
OI 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 Check screws, nuts and pin retainers for tight seating Check attachment for intentional damage
OI OI OI / SM OI 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
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Technical data and Maintenance guidelines
Service Manual
Maintenance and inspection schedule
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PR 764
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Service Manual
Technical Data - Maintenance Guidelines Maintenance and inspection guidelines
Maintenance and inspection guidelines 1. General guidelines 1.1. Documentation for work to 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 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 send the appropriate Service ticket to the appropriate LIEBHERR company. After removing the old sticker, attach the new inspection sticker, which can also be found in the inspection booklet, 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 guidelines During all maintenance, inspection or repair work, the applicable safety 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. 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. 1.4. Taking oil samples 1.5. Taking oil samples Any required oil 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 incorrect test results due to deposits. To determine the initial situation after 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. Wrong information can result in unnecessary service or can lead to omissions of necessary service or repair, resulting in unnecessary high costs. Also refer to documentation in the oil analysis kits. 1.6. Oils, filter and other If possible, oils should be drained when 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 be changed after the oil has been drained and before the oil is refilled. Before reusing the machine, bleed the systems as necessary. Turn the starter about 10-15 seconds before starting the Diesel engine. If possible, cut removed filter cartridges and elements open to check for abnormal 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 old oils, filters and other throw away items properly!
PR 724 PR 734 PR 764
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Technical Data - Maintenance Guidelines
Service Manual
Maintenance and inspection guidelines
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. 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 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 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 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 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.
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Service Manual
Technical Data - Maintenance Guidelines Maintenance and inspection guidelines
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 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 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 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.
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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 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.
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Technical Data - Maintenance Guidelines
Service Manual
Maintenance and inspection guidelines
2.1.9 Check / adjust valve clearance Check and adjust clearance with cold (= warm to the touch) 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 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 1 cm3 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 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. Inspection / maintenance work on the 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 circuit filter for deposits. If any deposits are found, determine the origin and find the cause. If necessary, repair the component or replace it. Replace the strainer insert. 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
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PR 724 PR 734 PR 764
F/N xxx-6600 9199 F/N xxx-6200 8219 F/N xxx-6888 9505
Service Manual
Technical Data - Maintenance Guidelines Maintenance and inspection guidelines
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. 2.2.4 Check / adjust all hydraulic pressures Carry out pressure tests / adjustments according to the Adjustment check list for the corresponding machine see section 3.5 and enter the results. For detailed description, data and instructions, see adjustment check list or corresponding sub group in Service Manual.
2.3. Inspection work on electrical 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 schematics in section 9. 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.
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 to instructions, section 10.1. Carry out tests / adjustments according to the adjustment check 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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F/N xxx-6600 9199 F/N xxx-6200 8219 F/N xxx-6888 9505
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