Service Manual Index
LWT / Ausgabe / Edition / Edition / 03.2010
0.1.00 Index Section Title
Date of issue
0.1.00 Index
03.2010
1.0.00 Sub group index "General" 1.1.00 Foreword and explanation 1.2.00 Safety regulations Charts 1.3.01 Tightening torques 1.3.02 Conversion tables 1.3.03 Tapping holes 1.4.00 Conservation guidelines 1.5.00 Material weights
01.2008 01.2008 05.2008 05.2008 01.2009 01.2008 02.2010 03.2009
2.0.00 2.1.00 2.2.00 2.3.00
Sub group index "Tools and work instructions" Special tools Repair welding Installation instructions
01.2008 03.2010 03.2010 03.2010
3.0.00 3.1.40 3.1.60 3.2.00 3.3.00 3.4.40 3.4.60 3.5.00
Sub group index "Technical data and maintenance guidelines" Technical data Technical data Maintenance and inspection schedule Maintenance and inspection instructions Adjustment checklist Adjustment checklist Test and adjustment tasks
01.2008 06.2008 06.2008 03.2010 03.2009 03.2010 03.2010 03.2010
4.0.00 4.1.40 4.1.60 4.2.00
Sub group index "Engine" Data page Data page Fan and cylinder arrangement
01.2008 01.2008 05.2008 05.2008
5.0.00 5.1.00 5.2.40 5.2.60 5.3.40 5.3.60 5.4.40 5.4.60
Sub group index "Coupling and splitterbox" Data page Coupling Coupling Pump distributor gear Pump distributor gear Coupling Pump output Coupling Pump output
01.2008 05.2008 05.2008 05.2008 01.2008 05.2008 05.2008 06.2008
6.0.00 6.1.00 6.2.40 6.2.60 6.3.40 6.3.60 6.4.00 6.5.40 6.5.60
Sub group index "Travel hydraulic" Data page Design Design Function Function Repair work and troubleshooting Component arrangement Component arrangement
01.2008 05.2008 06.2008 06.2008 01.2009 01.2009 05.2008 01.2008 05.2008
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Service Manual Index
7.0.00 7.1.00 7.2.00 7.3.00 7.4.00 7.5.40 7.5.60 8.0.00 8.1.40 8.1.60 8.2.40 8.2.60 8.3.00 8.4.40 8.4.60 8.5.40 8.5.60 8.6.00 8.7.00 8.8.00 8.9.00 8.10.00 9.0.00 9.1.40 9.1.41 9.1.60 9.1.61 9.2.00 9.3.40 9.3.60 9.4.00 9.5.00
Sub group index "Working hydraulic" Data page Design Function Repair work and troubleshooting Component arrangement Component arrangement
01.2008 05.2008 05.2008 02.2010 05.2008 01.2008 05.2008
Sub group index "Hydraulic components" Var. displacement pump Var. displacement pump Var. displacement motor Var. displacement motor Regulating pump – Working hydraulic Double gear pump – replenishing / fan drive Double gear pump – replenishing Gear motor – fan drive Gear motor – fan drive Pilot control – working hydraulic Control valve block Valves Hydraulic cylinder Control motor hoist gear – winch
01.2008 01.2008 01.2009 01.2008 05.2008 05.2008 05.2008 05.2008 05.2008 05.2008 01.2008 05.2008 02.2009 05.2008 05.2008
Sub group index "Electrical system – Diagrams and components" Wiring diagram, component description, function list Wiring diagram, component description, function list Wiring diagram, component description, function list Wiring diagram, component description, function list Instrument panel Component arrangement Component arrangement Joystick Inching- / brake pedal
05.2008 01.2010 01.2010 01.2010 01.2010 05.2008 02.2010 02.2010 02.2010 02.2009
10.0.00 Sub group index "Electrical system - descriptions" 10.1.00 Diagnostics software LinDiag 10.2.00 Software PDL – Diesel particle filter
01.2009 01.2010 01.2010
11.0.00 11.1.40 11.1.60 11.2.40 11.2.60 11.3.40 11.3.60
01.2008 05.2008 05.2008 01.2008 05.2008 01.2008 01.2009
Sub group index "Final drive" Data page Data page Design and Function Design and Function Sectional view - final drive Sectional view - final drive
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Date of issue
Section Title
Service Manual Index
Date of issue
Section Title
LWT / Ausgabe / Edition / Edition / 03.2010
12.0.00 12.1.00 12.2.00 12.3.00 12.3.01 12.4.40 12.4.60 12.5.00 12.6.00 12.7.40 12.7.60
Sub group index "Track components" Data page Design, function, wear and evaluation Test report Wear chart Track roller frame and idler unit Track roller frame and idler unit Track roller Carrier roller Tension unit Tension unit
01.2008 05.2008 01.2008 01.2010 01.2009 05.2008 03.2010 01.2008 01.2008 06.2008 06.2008
13.0.00 Sub group index "Working attachment – front side"
01.2008
14.0.00 Sub group index "Working attachment" 14.1.00 Hoist gear 14.2.00 Rope winch
01.2008 05.2008 02.2009
15.0.00 15.1.40 15.1.60 15.2.40 15.2.60 15.3.40 15.3.60
Sub group index "Main frame – Components" Cooler arrangement Cooler arrangement Equalizer bar Equalizer bar Engine mounting Engine mounting
01.2008 01.2008 05.2008 01.2008 05.2008 01.2008 05.2008
16.0.00 16.1.40 16.1.60 16.2.40 16.2.60 16.3.40 16.3.60
Sub group index "Tank arrangements" Hydraulic tank Hydraulic tank Fuel tank Fuel tank Battery compartment Battery compartment
01.2008 05.2008 05.2008 01.2008 05.2008 01.2008 02.2009
17.0.00 17.1.00 17.2.00 17.3.00 17.4.00 17.5.00
Sub group index "Operator’s platform, heater, air conditioning system" Operator’s platform Heater with blower Air conditioning system Operator’s seat – air cushioned Throttle control
01.2008 01.2008 01.2008 01.2008 01.2008 05.2008
18.0.00 Sub group index "Special equipment" 18.1.00 Refueling pump 18.3.00 Add-on installations – Pipe chamfering device and welding generator
01.2009 03.2009 01.2009
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Service Manual Index
Date of issue
Section Title Sub group index "Additional documentation" Schematic – Travel hydraulic Schematics – Travel hydraulic Schematic – Working hydraulic Schematic – Working hydraulic Wiring diagram, component description, function list Wiring diagram, component description, function list Wiring diagram, component description, function list Wiring diagram, component description, function list
01.2008 05.2008 05.2008 02.2010 02.2010 01.2010 01.2010 01.2010 01.2010
LWT / Ausgabe / Edition / Edition / 03.2010
19.0.00 6.3.40 6.3.60 7.3.40 7.3.60 9.1.40 9.1.41 9.1.60 9.1.61
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General Sub group index - General
1 General 1.0.00 Sub group index - General Foreword and explanations ......................................................................... 1.1 Safety regulations ......................................................................................... 1.2 Charts ............................................................................................................. 1.3 Tightening torques ............................................................................................................1.3.01 Conversion tables ............................................................................................................. 1.3.02 Tapping holes ................................................................................................................... 1.3.03
Conservation guidelines ............................................................................... 1.4
LWT / Ausgabe / Edition / Edition / 01.2008
Material weights............................................................................................. 1.5
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Service Manual
General Foreword and explanation
1.1.00 Foreword and explanation 1
For information This manual contains technical data, design and functional descriptions, work and adjustment instructions as well as numerous drawings, functional views and illustrations for the LIEBHERR – Pipe layers (RL) of Series 4. This manual should simplify competent customer service of our products, however, it does not replace expert and qualified user training and attendance of our factory training classes. Generally valid technical basic information is not listed. Refer to separate documentation for operational and spare parts information. The manual will be updated and expanded as necessary when changes occur in series. For all tasks on the machine, accident prevention guidelines and safety guidelines must be strictly observed. This manual is solely for the own use of the registered owner and may not be duplicated or copied, complete or in part, nor passed on to a third person and remains the 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 illustrations in this manual.
LWT / Ausgabe / Edition / Edition / 01.2008
Written and published by LIEBHERR-Werk Telfs GmbH., Technical Documentation Dept.
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General
Service Manual
Foreword and explanation
2
Explanation of layout To simplify finding certain information and filing of updates, we set up the following layout: Main group
Type group Structure based on information content or machine size
Component (item) groups according to register Sub group
Page number
Structure of main group according to sub group index
Continuous No. and complete number of pages within the type group
It is possible that other continuous numbers are listed after the continuous number, for example 9.4.20 - 13/15 - 02. This number is for supplements, especially for electrical schematics, where only one page is supplemented. Changes are supplied with the same number, but with a later date, supplements are assigned a new number. If only one page is valid for a certain machine group, then this is noted in the header. Note! This symbol is used in the manual for very important safety notes. This symbol identifies a standard listing. This symbol signifies the following: “The prerequisite must be met”. The maintenance personnel must first fulfil the precondition described, i.e. the machine must be brought into a particular work position in order to be able to carry out the actions subsequently described. This symbol identifies an action. The maintenance personnel should be active at this location and carry out the action described. This symbol identifies a result. The maintenance personnel is notified that a result will occur after a working step, for example, after the test knob is pressed, the LED light lights up.
We hope that with the supplied information we have taken yet another step to improve service on the LIEBHERR crawler dozers, crawler loaders, pipe layers and telescopic handlers.
LIEBHERR-Werk Telfs GmbH. Technical documentation
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This note shows that a detail view of an illustration is shown rotated by a given angle, as compared to the actual installation position. (In this case 180°)
Service Manual
General Safety guidelines
1.2.00 Safety guidelines 1
Introduction Prior and during the performance of tests / inspections, adjustments and repairs, it is imperative that the following safety guidelines are observed: Any type of work may only be carried out by qualified expert personnel or under their guidance and supervision. Qualified expert personnel are persons, who, based on their specialized training and experience, have sufficient knowledge in the area of earthmoving equipment and the specific technology of our machines in particular and who are familiar with all applicable laws and general work protection regulations, accident prevention guidelines, regulations, guidelines and generally approved rules concerning technology so that they are able to evaluate if the earthmoving equipment is safe to operate and if the necessary work can be performed without endangering themselves or third persons. Machines with raised operator’s platform may not be driven! The machine may only be operated from a lowered and secured operator’s platform! Always adhere to the adjustment values noted in the LIEBHERR documentation when performing adjustment work. At the delivery of a machine, the operating personnel must be trained using the current operating instructions. The safety guidelines noted in the instructions must be particularly observed. These safety guidelines must also be observed during inspection, adjustment or repair work. However, there are special repair and / or inspection work which require qualified personnel to follow another procedure than that noted in the safety guidelines. In such cases, qualified personnel or individuals performing the 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. The decision to carry out this measure can only be made by qualified expertly trained personnel. Such items of repair and/ or inspection work include, but are not limited to the following: Opening the side doors while the Diesel engine running to carry out tests and / or adjustments. In these cases, care should be taken that the side engine compartment doors are properly secured during the entire duration of the work to prevent them from closing unexpectedly and / or inadvertently. Care should 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. Wear only tightly fitted clothing (no scarves, no tie, no wide sleeves, etc.) Starting the Diesel engine with tilted operator’s platform, as well as actuating the travel drive with properly raised machine for adjustment, repair or diagnostics purposes. In these cases, before starting the engine, the support of the operator’s platform support as well as the support for the machine and the required ground clearance for the track chains must be checked again.
LWT / Ausgabe / Edition / Edition / 05.2008
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General
Service Manual
Safety guidelines
2
Danger notes in this manual For description of work, which can pose a danger for man or machine, the required safety precautions are described in this manual. They are marked by the following notes:
Danger! Warns that certain working procedures without appropriate precautionary measures can result in fatal injuries. Warning! Warns that certain working procedures without appropriate precautionary measures can result in severe bodily injuries. Caution! Warns that certain working procedures without appropriate precautionary measures can result in bodily injuries or damage to the machine. Following these notes does not relieve you of the responsibility for following additional rules and guidelines! Additional points that should be noted are: the safety regulations which apply on the jobsite,
LWT / Ausgabe / Edition / Edition / 05.2008
statutory “road traffic regulations�, the guidelines provided by professional associations.
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General Safety guidelines
3
Safety guidelines in the operating instructions The detailed descriptions for the following safety guidelines are noted in the operating instructions of the machine and must be strictly observed. 2.1
Introduction
2.2
Designated use
2.3
Signs on the machine
2.4
Safety guidelines General safety guidelines
2.4.2
Crushing and burn prevention
2.4.3
Fire and explosion prevention
2.4.4
Safety guidelines for machine start up
2.4.5
Engine start up safety
2.4.6
Machine operating safety
2.4.7
Safety guidelines for working with the machine
2.4.8
Working in the vicinity of electrical overhead lines
2.4.9
Machine parking safety
2.4.10
Machine transporting safety
2.4.11
Machine towing safety
2.4.12
Machine maintenance safety
2.4.13
Safety guidelines for welding work on the machine
2.4.14
Safety guidelines for working on the attachment
2.4.15
Safety guidelines when loading the machine with a crane
2.4.16
Safe maintenance of hydraulic hoses and hose lines
2.4.17
Safety guidelines for maintenance work on machines with hydro accumulators
2.4.18
Roll over protection (ROPS) and falling object protection (FOPS)
2.4.19
Equipment and attachment parts
2.4.20
Protection from vibrations
LWT / Ausgabe / Edition / Edition / 05.2008
2.4.1
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Service Manual
General Tightening torques
1.3.01 Tightening torques 1
General information The preload values and the tightening torques noted in the chart have been taken from the VDI (Association of German Engineers) guidelines 2230 of July 1986. Installation preload values FM and tightening torques MA for shoulder studs with standard metric or fine thread per DIN ISO 262 and DIN ISO 965 T2 (replacement for DIN 13 part 13) and wrench sizes for 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 screws with surface: -
black or phosphated oiled
-
zinc plated oiled
-
flZn according to LH standard 10021432 - dry (replaces DACROMET 500).
Medium friction value
G
= 0.12
Note! Any tightening torque values and/ or tightening procedures noted in drawings / parts lists, instructions or component descriptions must be adhered to and given preference over factory standards. Beginning with grade 10.9, no additional safety effect is provided when using lock washers Always use correctly sized torque wrenches the torque value according to the chart should be within the upper third of the existing range. When using impact wrenches, care must be taken so that the torque values are not exceeded. Check before and intermediately with a torque wrench.
LWT / Ausgabe / Edition / Edition / 05.2008
Note! The tightening torques for the following components are noted in the following sections in detail: Hydraulic cylinder – see section 8.9. Track pad and sprocket segment screws – see section 12.1. Rope winch – see section 14.2.
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General
Service Manual
Tightening torques
2
Metric standard thread
Preload values and tightening torques for screws with standard metric thread according to factory standard WN 4037 I
Preload value Fm based on grades in N
Tightening torques Ma based on grades in Nm
Wrench size (x) = according to DIN931, for Hex head screw
Socket head screw
8.8
10.9
12.9
8.8
10.9
12.9
mm
Inch
mm
Inch
x 0.7
4050
6000
7000
2,8
4,1
4,8
7
9/32
3
--
M5
x 0.8
6600
9700
11400
5,5
8,1
9,5
8
5/16
4
5/32
M6
x1
9400
13700
16100
9,5
14
16,5
10
--
5
--
M7
x1
13700
20100
23500
15,5
23
27
11
--
--
--
M8
x 1.25
17200
25000
29500
23
34
40
13
1/2
6
--
M 10
x 1.5
27500
40000
47000
46
68
79
(17) 16
(11/16)--
8
5/16
M 12
x 1.75
40000
59000
69000
79
117
135
(19) 18
(3/4) - -
10
--
M 14
x2
55000
80000
94000
125
185
215
(22) 21
(7/8) - -
12
--
M 16
x2
75000
111000
130000
195
280
330
24
--
14
9/16
M 18
x 2.5
94000
135000
157000
280
390
460
27
1-1/16
14
9/16
M 20
x 2.5
121000
173000
202000
390
560
650
30
1-3/16
17
--
M 22
x 2.5
152000
216000
250000
530
750
880
(32) 34
--
17
--
M 24
x3
175000
249000
290000
670
960
1120
36
1-7/16
19
3/4
M 27
x3
230000
330000
385000
1000
1400
1650
41
1-5/8
19
3/4
M 30
x 3.5
280000
400000
465000
1350
1900
2250
46
1-13/16
22
7/8
M 33
x 3.5
350000
495000
580000
1850
2600
3000
50
2
24
--
M 36
x4
410000
580000
680000
2350
3300
3900
55
2-3/16
27
1-1/16
M 39
x4
490000
700000
820000
3000
4300
5100
60
2-3/8
27
1-1/16
LWT / Ausgabe / Edition / Edition / 05.2008
M4
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General Tightening torques
3
Metric standard thread
Preload values and tightening torques for screws with fine metric thread according to factory standard WN 4037 I
Preload value Fm based on grades in N
Tightening torques Ma based on grades in Nm
Wrench size (x) = according to DIN931, for
LWT / Ausgabe / Edition / Edition / 05.2008
Hex head screw
Socket head screw
8.8
10.9
12.9
8.8
10.9
12.9
mm
Inch
mm
Inch
M8
x1
18800
27500
32500
24,5
36
43
13
1/2
6
--
M9
x1
24800
36500
42500
36
53
62
--
--
--
--
M 10
x1
31500
46500
54000
52
76
89
17
11/16
8
5/16
M 10
x 1.25
29500
43000
51000
49
72
84
17
11/16
8
5/16
M 12
x 1.25
45000
66000
77000
87
125
150
19
3/4
10
--
M 12
x 1.5
42500
62000
73000
83
122
145
19
3/4
10
--
M 14
x 1.5
61000
89000
104000
135
200
235
22
7/8
12
--
M 16
x 1.5
82000
121000
141000
205
300
360
24
--
14
9/16
M 18
x 1.5
110000
157000
184000
310
440
520
27
1-1/16
14
9/16
M 18
x2
102000
146000
170000
290
420
490
27
1-1/16
14
9/16
M 20
x 1.5
139000
199000
232000
430
620
720
30
1-3/16
17
--
M 22
x 1.5
171000
245000
285000
580
820
960
32
--
17
--
M 24
x 1.5
207000
295000
346000
760
1090
1270
36
1-7/16
19
3/4
M 24
x2
196000
280000
325000
730
1040
1220
36
1-7/16
19
3/4
M 27
x 1.5
267000
381000
445000
1110
1580
1850
41
1-5/8
19
3/4
M 27
x2
255000
365000
425000
1070
1500
1800
41
1-5/8
19
3/4
M 30
x 1.5
335000
477000
558000
1540
2190
2560
46
1-13/16
22
7/8
M 30
x2
321000
457000
534000
1490
2120
2480
46
1-13/16
22
7/8
M 33
x 1.5
410000
584000
683000
2050
2920
3420
50
2
24
--
M 33
x2
395000
560000
660000
2000
2800
3300
50
2
24
--
M 36
x 1.5
492000
701000
820000
2680
3820
4470
55
2-3/16
27
1-1/16
M 36
x3
440000
630000
740000
2500
3500
4100
55
2-3/16
27
1-1/16
M 39
x 1.5
582000
830000
971000
3430
4890
5720
60
2-3/8
27
1-1/16
M 39
x3
530000
750000
880000
3200
4600
5300
60
2-3/8
27
1-1/16
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General
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Tightening torques
4
Tightening torques for screws to mount SAE flange Note! Not part of factory standard WN 4037 I Listing according to LFR Quality service 2QA 6 051 00 as of Oct. 2001
4.1
4.2
Flanges and half flanges for high pressure (Norm 62) Tightening torques in Nm for screw grade 10.9
Flange nominal size
Screw size
½" ¾" 1" 1 ¼" 1 ½" 2"
M8 M 10 M 12 M 14 M 16 M 20
Flat flange without Flange with reinforcement rim reinforcement rim
Half flange 31 62 108 172 264 350
-45 70 120 170 250
-65 110 180 250 450
Half flange for low pressure (Norm 61) Flange nominal size
M8 M 10 M 10 M 10 M 12 M 12 M 12 M 14 M 16 M 16 M 16
Screw grade 8.8 22 44 44 44 76 76 76 122 187 187 187
Screw grade 10.9 31 62 62 62 108 108 108 172 264 264 264
LWT / Ausgabe / Edition / Edition / 05.2008
½" ¾" 1" 1 ¼" 1 ½" 2" 2 ½" 3" 3 ½" 4" 5"
Tightening torques in Nm for
Screw size
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General Conversion chart
1.3.02 Conversion chart Size Length
0,039
m
3,281
m
Multiplier
Multiplier
to unit
25,4
mm
feet
0,305
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
Performance
kW
1,342
HP
0,745
kW
PS
0,736
kW
1,358
PS
Pressure
bar
14,5
PSI
0,069
bar
(hydraulic)
kpa
0,145
PSI
6,896
kpa
0,0703
kg/cm²
4,878
kg/m²
27,78
g/cm³
16,13
kg/m³
Area
Volume
Mass
Force
Ground pressure Density LWT / Ausgabe / Edition / Edition / 01.2009
mm
to unit from inch
from unit
Speed Temperature
kg/cm²
14,223
l
2
lbs.inch 2
kg/m²
0,205
lbs. ft.
g/cm³
0,036
lbs. inch 3
3
kg/m³
0,062
lbs. ft.
km/h
0,621
Mph
1,609
km/h
m/min
3,281
ft. / min
0,305
m/min
°C
(°Cx1,8) + 32
°F
(°F-32)/1,8
°C
°C
°C+273
°K
°K-273
°C
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General
Service Manual
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Conversion chart
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General Tapping holes
1.3.03 Tapping holes 1
Tapping holes for metric ISO standard threads Thread
LWT / Ausgabe / Edition / Edition / 01.2008
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 Ă˜ Diameter dimensions 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˜ 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
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Tapping holes
Tapping holes for metric ISO fine threads
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 Ø diameter limits max. min. 0,821 0,783 0,921 0,833 1,021 0,983 1,221 1,183 1,185 1,129 1,421 1,383 1,621 1,583 1,785 1,729 1,985 1,929 2,201 1,121 2,721 2,621 3,221 3,121 3,599 3,459 4,099 3,959 4,599 4,459 5,099 4,959 5,378 5,188 6,378 6,188 7,378 7,188 7,153 6,917 8,378 8,188 8,153 7,917 9,378 9,188 9,153 8,917 8,912 8,647 10,378 10,188 10,153 9,917 11,153 10,917 10,912 10,647 10,676 10,376 13,153 12,917 12,912 112,647 12,676 12,376 14,153 13,917 13,676 13,376 15,153 14,917 14,676 14,376 16,153 15,917 15,676 15,376 17,153 16,917 16,676 16,376 16,210 15,835 19,153 18,917 18,676 18,376 18,210 17,835 21,153 20,917 20,676 20,376 20,210 19,835 23,153 22,917 22,676 22,376 22,210 21,835
Drill bit Ø 0,8 0,9 1 1,2 1,15 1,4 1,6 1,75 1,95 2,15 2,65 3,15 3,5 4 4,5 5 5,2 6,2 7,2 7 8,2 8 9,2 9 8,8 10,2 10 11,1 10,8 10,5 13 12,8 12,5 14 13,5 15 14,5 16 15,5 17 16,5 16 19 18,5 18 21 20,5 20 23 22,5 22
Thread size M 25 x 1 M 25 x 1,5 M 25 x 2 M 26 x 1,5 M 27 x 1 M 27 x 1,5 M 27 x 2 M 28 x 1 M 28 x 1,5 M 28 x 2 M 30 x 1 M 30 x 1,5 M 30 x 2 M 30 x 3 M 32 x 1,5 M 32 x 2 M 33 x 1,5 M 33 x 2 M 33 x 3 M 35 x 1,5 M 36 x 1,5 M 36 x 2 M 36 x 3 M 38 x 1,5 M 39 x 1,5 M 39 x 2 M 39 x 3 M 40 x 1,5 M 40 x 2 M 40 x 3 M 42 x 1,5 M 42 x 2 M 42 x 3 M 42 x 4 M 45 x 1,5 M 43 x 2 M 45 x 3 M 45 x 4 M 48 x 1,5 M 48 x 2 M 48 x 3 M 48 x 4 M 50 x 1,5 M 50 x 2 M 50 x 3 M 52 x 1,5 M 52 x 2 M 52 x 3 M 52 x 4
Hole Ø 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 Ø 24 23,5 23 24,5 26 25,5 25 27 26,5 26 29 28,5 28 27 30,5 30 31,5 31 30 33,5 34,5 34 33 36,5 37,5 37 36 38,5 38 37 40,5 40 39 38 43,5 43 42 41 46,5 46 45 44 48,5 48 47 50,5 50 49 48
LWT / Ausgabe / Edition / Edition / 01.2008
2
Service Manual
General Conservation guidelines
1.4.00 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 – 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 – 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.
LWT / Ausgabe / Edition / Edition / 02.2010
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 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 „Waxoyl 120-4“.
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Description Optical charge tester
Service Manual
General Conservation guidelines
Apply a thick layer of conservation wax „Waxoyl 120-4“ to cover ball joints, hinges, blank parts and exposed piston rods. (Do not protect ball bearings with Waxoyl!) Place a dehumidification capsule into the central electric box. Protect all door and container locks with „Ballistol Spray“. Set the battery master switch (if present) to position „0“ and then remove the batteries. Check the battery acid level and add distilled water, if necessary. Always store the batteries in a cool and dry area. Check the load current regularly every 6 weeks and recharge, if necessary. Close the exhaust outlet with an air and watertight cover. Pay attention to any additional guidelines for special components or special local conditions.
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, track / 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.
LWT / Ausgabe / Edition / Edition / 02.2010
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 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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Carry out the items according to paragraph 4.1.
Service Manual
General Conservation guidelines
4.3
After shut down of longer than 12 months Complete all items outlined in paragraph 4.2 and 4.1.
LWT / Ausgabe / Edition / Edition / 02.2010
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 – 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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Conservation guidelines
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General Material weights
1.5.00 Material weights A B
spec. weight 1) in kg/m3 solid Loosening in %
C D
Loosening facttor spec. weight kg/m3 loose
Material - raw - washed Ash bituminous coal Basalt Bauxite, Kaolin Bituminous coal - raw - washed Carnotite, Uranium ore Soil - dry hardened - wet loosened - clay Gypsum - broken - ground Granite - broken Hematite, iron ore Limestone - broken - ground Gravel - damp - dry - dry 6-50mm - wet 6-50mm Coke Loam, clay - seasoned - dry - wet Clay with gravel - dry - wet Magnetite, iron ore Topsoil Natural stone - ground Pyrite, iron ore Sand - dry, lose - damp - wet Sand with clay - lose - compressed Sand with gravel - dry - wet Sandstone Slate Slag - broken Snow - dry - wet Trapp rock - broken
LWT / Ausgabe / Edition / Edition / 03.2009
Anthracite coal
A
B
C
D
1600 590 - 890 2970 1900 1280 2200 1900 2020 1540 3170 2790 2730 2130 - 2900 2610 2170 1690 1900 2260 860 2020 1840 2080 1660 1840 3260 1370 2670 3030 1600 1900 2080 2020 1930 2230 2520 1660 2940 2610
35 35 8 52 33 35 35 35 26 26 23 75 75 64 18 69 12 12 12 12 54 22 24 24 17 19 17 44 67 18 12 12 13 26 12 10 67 33 68 49
0,74 0,74 0,93 0,66 0,75 0,74 0,74 0,74 0,79 0,79 0,81 0,57 0,57 0,61 0,85 0,59 0,89 0,89 0,89 0,89 0,65 0,82 0,80 0,80 0,86 0,84 0,86 0,69 0,60 0,85 0,89 0,89 0,88 0,79 0,89 0,91 0,60 0,75 0,59 0,67
1190 1100 550 - 830 1960 1420 950 830 1630 1510 1600 1250 1810 1660 1660 1810 - 2450 1540 1540 1930 1510 1690 2020 1560 1660 1480 1660 1420 2540 2790 950 1600 2580 1420 1690 1840 1600 2400 1720 2020 1510 1250 1750 130 520 1750
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Material weights
Material Weathered rock 75% rock, 25% soil Weathered rock 50% rock, 50% Soil Weathered rock 25% rock, 75% Soil
A
B
C
D
2790
42
0,70
1960
2280
33
0,75
1720
1960
24
0,80
1570
LWT / Ausgabe / Edition / Edition / 03.2009
The actual values depend on the moisture content, the grain size and the compression. Testing is required to determine more exact values.
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Tools and work instructions Sub group index -Tools and work instructions
2 Tools and work instructions 2.0.00 Sub group index -Tools and work instructions Special tools .................................................................................................. 2.1 Repair welding ............................................................................................... 2.2
LWT / Ausgabe / Edition / Edition / 01.2008
Installation instructions ............................................................................... 2.3
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Sub group index -Tools and work instructions
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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
Id. No.
M-Type
Remarks
Sculi – Diagnostics software - accessory consisting of: Sculi License with USB Dongle for engine Service Level (LH ECU UPCR-, DC4-, DC5- engine control units and Master 4 controls)
LWT / Ausgabe / Edition / Edition / 03.2010
Communication cable for LH-ECU-UPCR control units
Communication cable for DC4 / DC5 control units
10450054
LR Series 4 RL Series 4 PR 724 9200 PR 734 8220 PR 744 7356 PR 754 6924 PR 764 6888
10035410
10035411
F/NxxxF/Nxxx-
Illustration
Diagnostics software for maintenance and adjustment of Diesel engine. For ordering, a Liebherr form from Liebherr Bulle must be filled out.
F/NxxxF/NxxxF/Nxxx-
LR Series 4 RL Series 4 PR 724 F/Nxxx9200 PR 734 F/Nxxx8220 PR 744 F/Nxxx7356 PR 754 F/Nxxx6924 PR 764 F/Nxxx9506 PR 764 F/Nxxx6888 9505
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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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 the reflective strip Test range: 6-8300 rpm ±1 rpm
614063201
Digital rpm gauge „Piezzo A2106“
10286429
PR 724 F/Nxxx6600 9199 PR 734 F/Nxxx6200 8219 PR 764 F/Nxxx6888 9505
To measure the engine rpm via impulse frequency of the injection line
DCA 4 Test Kit „CC2602M“ Consisting of: Container 50 Test strips Clear plastic container Pipette
5608459
PR 724 F/Nxxx6600 9199 PR 734 F/Nxxx6200 8219 PR 764 F/Nxxx6888 9505
To check the DCA 4 concentration in the coolant
Hand pump [1]
8145666
PR Series 4 LR Series 4 RL Series 4
To take oil samples for the oil analysis
Oil sample vale 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 cover) Individual set 4 sets 6 sets 12 sets Oil analysis set – Bio oil (yellow cover) Individual set 6 sets
LWT / Ausgabe / Edition / Edition / 03.2010
Reflective strip
8145660 10029626 7018368 7018369
7026817 7026088
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Tools and work instructions Special tools
Description
Id. No.
M-Type
Remarks
V-belt test unit „Krikit2“
8042829
PR Series 4 LR Series 4 RL Series 4
To check the V-belt tension
Optical battery tester
7408922
PR Series 4 LR Series 4 RL Series 4
To check the battery charge and the antifreeze in the coolant
Turning device for valve clearance / check / adjust Pos. 1
0524045
LR Series 4
To be installed on the flywheel housing instead of the cover
RL Series 4 PR Series 4 except Pos. 2
10490350 10116805
10454803
To be installed on the V-belt crankshaft
PR Series 4 LR Series 4 RL Series 4
For optional Diesel particle filter. Can also be used for leak test of counterpressure line
LWT / Ausgabe / Edition / Edition / 03.2010
Hand pump with pressure gauge
PR 764 F/Nxxx-9506 RL 64 (can be used alternatively also on PR 724 F/Nxxx-9200 PR 734 F/Nxxx-8220 PR 744 PR 754 LR 624 LR 634 RL 44 )
Illustration
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Special tools
1.2
Hydraulic system
Description Vacuum pump cpl. with accessory Consisting 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
For faster bleeding of hydraulic system, by enclosing the PVC hose, a slight excess pressure (ca.0.4 bar) can be produced. 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
Difference pressure – Mess-Set 230V/120V
10288229
Consisting 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 the scale end value All pressure gauges are glycerin filled
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Test range: -18°C to +260°C
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
Screw coupling M 16x2
7407070
Test hose NW 2 1000 mm 1500 mm 4000 mm 5000 mm
7002437 7002475 7009134 7363732
LWT / Ausgabe / Edition / Edition / 03.2010
Hook wrench 58 - 62 mm
7900282
Socket wrench For grooved nut variable pump HPV
9792711
M-Type
Remarks
PR Series 4 LR Series 4 RL Series 4
To seal at pressure tests, a square seal ring, Id.No. 7409794 must be used
PR Series 4 LR Series 4 RL Series 4
Union nut and compression ring are affixed on the test fitting
PR Series 4 LR Series 4 RL Series 4
To connect to additional test points in the machines
PR Series 4 LR Series 4 RL Series 4
To connect shorter test lines or for connection between test connection and pressure sensor
PR Series 4 LR Series 4 RL Series 4
To keep loss of pressure during tests to a minimum, shorter test hoses are preferable
PR Series 4 LR Series 4 RL Series 4
To loosen / counter when adjusting the pump regulating range
PR Series 4 LR Series 4 RL Series 4
To loosen / counter when adjusting the pump end stop. Use with hook wrench Id. Nr. 7900282
Illustration
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Special tools
Description Socket wrench for 0position grooved nut Variable 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
Remarks
PR Series 4 LR Series 4 RL Series 4
To loosen / counter the grooved nut when adjusting the hydraulic zero position
PR Series 4 LR Series 4 RL Series 4
To close off high pressure connections Material: Ground spring steel
7370093
Round off end of the plate (simplifies installation, avoids damage to the seal ring)
7370094
Or to be made inhouse 8006305
Illustration
PR 724 F/Nxxx6600 9199 PR 734 F/Nxxx6200 8219 PR 764 F/Nxxx6888 9505
Open ended wrench to check or replace the return filters. Can also be used for other connections.
LWT / Ausgabe / Edition / Edition / 03.2010
Open ended wrench SW 30/32
7370092
M-Type
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Service Manual
Tools and work instructions Special tools
1.3
Electrical system
Description LinDiag Diagnostics KIT
Id. No. 9413782
Consisting of: Data carrier with latest software version + Dongle
9410472
Adapter cable
9932747
LinDiag Diagnostics KIT
9413763
Consisting of:
LWT / Ausgabe / Edition / Edition / 03.2010
Data carrier with latest software version + Dongle Adapter cable
9410472
10035410
M-Type
Remarks
PR 724 F/Nxxx6600 9199 PR 734 F/Nxxx6200 8219 PR 764 F/Nxxx6888 9505
To adjust the travel hydraulic, read out the Service Codes and for troubleshooting on Series 4 machines of exhaust stage Tier2
LR Series 4 RL Series 4
To adjust the travel hydraulic, read out the Service Codes and for troubleshooting on Series 4 machines of exhaust stage Tier3
PR 724 9200 PR 734 8220 PR 744 7356 PR 754 6924 PR 764 9506
F/NxxxF/NxxxF/Nxxx-
Illustration
F/NxxxF/Nxxx-
USB – Adapter
693190714
PR Series 4 LR Series 4 RL Series 4
Intermediate adapter from serial interface to USB
Digital multi meter cpl. with cable and bag
10018500
PR Series 4 LR Series 4 RL Series 4
For Voltage (V)Amperage (A)Resistance ( )Frequency (Hz)tests
Optical charge tester
see Pt. 1.1 Diesel engine
PR Series 4 LR Series 4 RL Series 4
To check the battery condition and the antifreeze in the coolant
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Service Manual
Special tools
1.4
Mechanical component groups
Description
Id. No.
Test tool Travel gear
7402603
M-Type
Remarks
Illustration
PR Series 4 LR Series 4 RL Series 4
To measure travel gear wear For use, see section 12.2
2 2.1
Special tools Repair Diesel engine Note! The special tools for Diesel engine repair are listed in the Diesel engine workshop manual.
Hydraulic system
Description Pressurized air cartridge
Brake vent adapter
Id. No. 10045498
9401975
Socket wrench Valve sleeve Valve – 3 slits
10430260
Valve – 2 slits
10491131
M-Type
Remarks
LR Series 4 RL Series 4
CO2 cartridge to vent the parking brake for towing operation.
PR 724 7697 PR 734 8220 PR 744 7356 PR 754 6924 PR 764 6888
F/Nxxx-
Illustration
F/NxxxF/NxxxF/NxxxF/Nxxx-
PR Series 4 LR Series 4 RL Series 4
Adapter for pressurized air cartridge (part of tool kit)
For repair of variable motor HMV To remove and install the valve sleeve of the directional valve See section 8.2 Position 73
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2.2
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
LWT / Ausgabe / Edition / Edition / 03.2010
Mandrel [1] and protective sleeve [2] for shaft seal ring
Remarks
Illustration
For repair of var. pump HPV or var. motor HMV For the installation of the hot thrust ring on the drive shaft. See chapter 8.1 or 8.2, Position 11
For repair of var. pump HPV or var. 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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Service Manual
Special tools
Description
Id. No.
M-Type
Installation aid for seal ring on oil guide pipes
Remarks
Illustration
For repair of var. pump HPV or var. motor HMV
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
The tool is used to install the O-rings on the oil guide pipes See section 8.1 Position 46 or section 8.2. Position 45 For repair of var. pump HPV
With this device, the swash plate mount can be lowered targeted onto the pump housing at installation.
For repair of var. pump HPV or var. motor HMV
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
The guide pins are used to guide the swash plate mount at assembly with the pump housing. minimum 2 each maximum 4 each required LWT / Ausgabe / Edition / Edition / 03.2010
Centering pins for swash plate mount
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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 repair of var. pump HPV or var. motor HMV
Illustration
Device to affix the oil guide pipes at installation of swash plate mount 2 each required
Note! The Id. numbers for the following tools are in the spare parts list for the hydraulic cylinders.
Assembly sleeve
see spare parts list
For installation of O-ring and stepseal ring on pistons of hydraulic cylinders
Spreader sleeve
see spare parts list
For installation of O-ring and stepseal ring on pistons of hydraulic cylinders
Installation wrench Piston
see spare parts list
To tighten the pistons of hydraulic cylinders
LWT / Ausgabe / Edition / Edition / 03.2010
For tightening torque, see section 8 Hydraulic cylinder Installation wrench Piston nut
To tighten the piston nuts of hydraulic cylinders
see spare parts list
For tightening torque, see section 8 Hydraulic cylinder
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Service Manual
Special tools
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 connection 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 the pin and bushing contacts in MATEN-LOK plug connectors
Hand crimper for „Deutsch“ plug connector
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 (alternate)
Removal tool Cannon for „Deutsch“ crimp contacts AWG 12 AWG 16 AWG 20
10114733 885563714 10114732
Removal tool Cannon for „Deutsch“ crimp contacts (alternate) AWG 12 AWG 16 AWG 20
8145674 8145673 8503630
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2.3
Service Manual
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 „JUNIOR POWER TIMER“ contacts
PR Series 4 LR Series 4 RL Series 4
To remove contacts from the „JUNIOR POWER TIMER“ housing
PR Series 4 LR Series 4 RL Series 4
To crimp insulated 0.5 -6.0 mm² cable shoes, for example cable connectors CRB 0560 also windshield wiper motor
Coding plug Inching / brake pedal 9813111
X46.1
9413850
PR Series 4 RL Series 4 LR Series 4
In case of defective inching / brake pedal for continued operation of the machine. See section 9. Inching / brake pedal
LWT / Ausgabe / Edition / Edition / 03.2010
X46
Illustration
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Tools and work instructions
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Special tools
Mechanical component groups
Description
Id. No.
M-Type
FAT 450 E 504/505 FAT 450 E 510 Slipring seal Id.No. 7109 25201 outside 7109 26301 inside FAT 500 E 502/503 FAT 500 E 517/518 Slipring seal Id.No. 7610 242 outside 7361 197 inside FAT 600 E 506 Slipring seal Id.No. 7610 244 outside 7610 240 inside FAT 650 E 508 Slipring seal Id.No. 7610 245 outside 7610 241 inside FAT 700 E 501 Slipring 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 – 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
For installation of 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 of mandrel, see Pt. 3.
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2.4
Service Manual
Tools and work instructions Special tools
Description
Id. No.
Inside puller
Commercially available tool
M-Type
Remarks
PR Series 4
To pull the bushings, Pos. 3 and 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 counter 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
Pull tool Elastic bearing operator s platform
Installation sleeve Equalizer bar bearing
PR744 PR754 PR764 120 90 273 114
9404645
9415227
In-house manufacture
LWT / Ausgabe / Edition / Edition / 03.2010
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 of mandrel, see Pt. 3. To install the outer um equalizer bar bearing For dimensions for in-house manufacture of assembly sleeves, see Pt. 33.
Special hook wrench to release and attach the ring nut
Sleeve to push on the ring nut prevents twisting of ring nut
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Tools and work instructions
Service Manual
Special tools
Description
Id. No.
M-Type
Remarks For removal / installation of 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 use, see section 12 Tension unit To remove / install the tension unit – chain tensioner is required!
Installation tool Tension unit
For use, see section 12 Tension unit
Consisting 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 single acting)
Enerpac P80 (two stage hand pump)
Enerpac HC-7206
Enerpac GF-50B
71.2 cm2
Operating pressure max.700ba
Oil volume
1131cm3
Lever force max.
47,0kg
Weight
10,9kg
Weight
23,1kg
9.5 x 1800mm
Pressure range 0-700bar
LWT / Ausgabe / Edition / Edition / 03.2010
Piston surface
Installation height retracted 282mm extended 441mm outside 127mm
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Tools and work instructions Special tools
Description Installation sleeve Equalizer bar
Installation tool set Double oscillating track roller
Id. No.
M-Type
Remarks
10306449
PR 754
To press the equalizer bar in with oscillating track rollers.
10318790
PR 764
Pos.1 Threaded rod M30x360 (2 each) Pos.2 Plate
For dimensions for in-house manufacture of mandrel, see Pt. 3. For removal / installation of pins with bearing for double oscillating track rollers.
Pos.3 Washer M30 (2 each) Pos.4 Hex nut M30 (4 each)
For dimensions for in-house manufacture of plate (Pos.2) see Pt. 3.
Installation tool Double oscillating track roller Hydraulic components for Installation tool
For use, see section 2.3 For removal / installation of pins with bearing for double oscillating track rollers.
PR764
Consisting of: Hydraulic cylinder Enerpac RCS 201
11081098
Hydraulic hose Enerpac HC- 7206
10430200
Pressure gauge Enerpac GF- 230B Intermediate section Enerpac GA-2 Hand pump Enerpac P39
11081099
Illustration
For use, see section 2.3
10430202
LWT / Ausgabe / Edition / Edition / 03.2010
886120508
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Tools and work instructions
Service Manual
Special tools
Technical data – Hydraulic components Hydraulic cylinder
Hand pump
Hydraulic hose
Pressure gauge
Enerpac RCS 201 (20 t single acting)
Enerpac P39 (two stage hand pump)
Enerpac HC-7206
Enerpac GF-230B
2
Piston surface
28,7cm
Operating pressure max.700ba
Oil volume
129cm3
Lever force max.
50kg
Weight
5,9kg
Weight
5kg
Pressure range 0-700bar
9,5 x 1800mm
Installation height retracted 98mm extended 143mm outside 92mm
3 3.1
Special tools for in-house manufacture Assembly sleeve for equalizer bar bearing, outside To install the outer equalizer bar bearing – see section 15.3.
Fig. 1 Dimensions of installation sleeves
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
---
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LWT / Ausgabe / Edition / Edition / 03.2010
Type
Service Manual
Tools and work instructions Special tools
3.2
Mandrel For installation of radial shaft seal rings in hoist cylinder bearing.
Fig.2 Dimensions of mandrel – screw in handle and mandrel
See also section 15.2 Hoist cylinder suspension. Mandrel A ..........For Pos.10 Mandrel B ..........For Pos.7
M-Type
Mandrel
PR724
A B A B A B A B A B
PR734 PR744 PR754 LWT / Ausgabe / Edition / Edition / 03.2010
PR764
Dimensions D Ø119-0,3 Ø71-0,3 Ø139-0,3 Ø89-0,3 Ø149-0,3 Ø94-0,3 Ø149-0,3 Ø94-0,3 Ø149-0,3 Ø94-0,3
E Ø89±0,1 Ø57±0,1 Ø109±0,1 Ø69±0,1 Ø119±0,1 Ø74±0,1 Ø119±0,1 Ø74±0,1 Ø119±0,1 Ø74±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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Special tools
3.3
Pull tool – operator’s cab bearing For installation and removal of elastic bearing of operator s platform. See section 17.1 Position 11 and 22.
Fig. 3
Dimensions of pull 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 with oscillating track rollers. See section 2.3 Installation notes.
LWT / Ausgabe / Edition / Edition / 03.2010
Fig. 4 Dimensions installation sleeve for equalizer bar
Continuous fillet weld 4mm
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3.5
Plate – Double oscillating track rollers (PR764) For removal / installation of the pins with bearings on double oscillating track rollers. See section 2.3 Installation notes.
LWT / Ausgabe / Edition / Edition / 03.2010
Fig. 5 Dimension of plate for double oscillating track rollers
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Special tools
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Tools and work instructions Repair welding
2.2.00 Repair welding Before starting any welding work on the machine, 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 cracked part Clean the cracked area to remove paint, grease and any dirt. To prevent the crack from extending during the preparation and welding process, the end of the cracks should be drilled out with a drill (at least 8 mm Ø). Then the crack should be ground, chiselled, or arched out to an angle of approx. 60° . Be certain that the edges are clean and extend through the full cross section of the material, without exceeding the space of 1 mm in the lower part. On larger grooves, a welding safety should be installed.
Fig. 1 Ground out / drilled out crack
Easy to harden materials must be preheated to approx. 150°C before welding. Special preparations are necessary when preparing a crack in manganese steel. This material cannot be prepared with a smoothing planer. Mechanical work cannot be carried out due to its hardness and peen hardening. We suggest that the crack is prepared with a slow running and water-cooled grinding wheel to prevent overheating.
LWT / Ausgabe / Edition / Edition / 03.2010
Note! Another possibility to make groves for repair welding of cracks and remove high alloy welding seams by using cutting electrodes of the type UTP 82 AS.
2
Preparation of a weld The welding area must be free of grease, paint, oil, moisture and dirt. During rain, the area to be welded must be covered sufficiently. Materials with a thickness above 15 mm and high carbon steel (carbon content more than 0.22 %) and difficult to weld steel, the material must be preheated to approx. 80°- 200° C. Preheating is also necessary when the component temperature at the start of the welding work is below +5°C and when the construction of the repair part prevents the welding stress to be released.
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Repair welding
3
Treatment of electrodes Use only dry electrodes for welding. Electrodes with damaged coating and rusted electrodes may not be used any longer. Electrodes must be stored in a dry room with a minimum temperature of 15°C. Open electrode packages must be carefully closed and stored after the welding work is complete.
4
Welding technique The welding of material with the required electrodes (see chart under paragraph 7) is carried out Per DIN 1912. The adjustment of the welding current dictated by the different thicknesses of the electrodes can be taken from the chart of the electrode package. Beginning with material thickness of 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 be taken that they are properly filled in. If the crack extends towards the outer edge of the material, slap 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 toward the inside. After the welding is completed, the sheet metal is removed and the edge of the material is ground smooth. The welding seam must be cooled off slowly and should therefore be protected from rain and wind.
LWT / Ausgabe / Edition / Edition / 03.2010
Fig. 2 Crack running to the outer edge of the material / Prepared crack
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Tools and work instructions Repair welding
5
Reinforcement of welding seam If the crack of the material is due to on 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 that reason, only general recommendations can be made as to the size and shape of the reinforcement plates.
5.1
Shape of plate 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 part is avoided. Plates with sharp corners (such as a rectangular plate) should not be used.
Fig. 3 Reinforcement plate against clean pulling / bending and alternating loads
5.2
Plate thickness The thickness of the reinforcement plate should be up to 2/3 of the thickness of the material to be reinforced.
5.3
Material quality of plate The material properties (yield and tensile strength, etc.) of the reinforcement plate should be equal to the material to be reinforced.
5.4
Installation of reinforcement plate The welded area of the crack should be ground so it is smooth and level.
LWT / Ausgabe / Edition / Edition / 03.2010
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 20 mm. The correct position and fit of the reinforcement plate is achieved by clamping and spot welding.
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Repair welding
5.5
Welding the reinforcement plate 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. Welding direction
Fig. 4 Welding directions
The size of the welding run "a" is figured out in reference to the thickness "k" of the repair plate. Use formula: a=0.5 k Up to a welding run "a" of approx. 3 mm, a single run can be made, however, as a general rule, a double run should be preferred. Above a welding run "a" = 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.
Fig. 5 Three or one layer welding seam
LWT / Ausgabe / Edition / Edition / 03.2010
After the welding is completed, clean the welding seam as necessary and grind out the run between the reinforcement plate and the basic material,
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Tools and work instructions Repair welding
6
Selection of correct welding 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 should be observed. Note! To reach the theoretical welding quality, the work must not only be performed in a professional manner, the electrode manufacturer s guidelines must be strictly observed as well. Caution! Welding of vertical-down welds is not permitted for steel components!
6.1 Electrode selection Material
BASIC MACHINE Track Main frame
St 52 - 3 QStE 380 N
Track Main frame/ bottom plates ATTACHMENT Dozer blade Bucket
Per EN 499: E42 5 B 4 2 H5 per AWS A5.1-91: E7018-1 H4 R LH 690 Per EN 757: Preheat to approx. E 69 6 Mn2NiCrMo B 4 2 H5 100-150°C. per AWS A5.5-96: E 11018-G HARDOX 400 per AWS A5.1-91: E7018-1 H4 R
Per EN 440: G4Si1 per AWS A5.18-93: ER 70 S-6 Per EN 12534: G3CrNi1Mo per AWS A5.28-96: ER110S-G per AWS A5.18-93: ER 70 S-6
Q St E 380 N HARDOX 400
Per EN 499: E42 5 B 4 2 H5 per AWS A5.1-91: E7018-1 H4 R St 52 - 3 Per EN 499: E42 5 B 4 2 H5 per AWS A5.1-91: E7018-1 H4 R LH 690 Per EN 757: Preheat to approx. E 69 6 Mn2NiCrMo B 4 2 H5 100-150°C. per AWS A5.5-96: E 11018-G St 52 - 3 Per EN 499: Q St E 380 N E42 5 B 4 2 H5 HARDOX 400 per AWS A5.1-91: E7018-1 H4 R
Per EN 440: G4Si1 per AWS A5.18-93: ER 70 S-6 Per EN 440: G4Si1 per AWS A5.18-93: ER 70 S-6 Per EN 12534: G3CrNi1Mo per AWS A5.28-96: ER110S-G Per EN 440: G4Si1 per AWS A5.18-93: ER 70 S-6
Special steel
Root layers Per EN 440: G4Si1 per AWS A5.18-93: ER 70 S-6
Push frame Bucket arm Pipe layer boom
LWT / Ausgabe / Edition / Edition / 03.2010
Ripper
WEAR PARTS Adapter Tooth retainer Ripper
Electrode norm description
Shielding gas weld welding wire – norm description
Welding area
Root layers Per EN 499: E42 5 B 4 2 H5 per AWS A5.1-91: E7018-1 H4 R
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Cover runs with high tensile welding wire per EN 12072: G 18 8 Mn per AWS A5.9-93: ER307
LWT / Ausgabe / Edition / Edition / 03.2010
Cover runs with high tensile electrode per EN 1600: E 18 8 Mn B 2 2 per AWS A5.4-92: E 307-15
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Tools and work instructions Repair welding
6.2 Steel chart Item
Description
Analysis
HARDOX 400
Weldable, low alloy special steel with high wear resistance, a tensile strength of 1250
C 0,27% Si 0,7% Mn 1,6% Cr 1,4% Mo 0,6%
²
Q St E 380 N
Sonderstahl
St 52 - 3 S355J2G3 LH 690
N/mm and a yield strength limit of 1000 N/mm² Fine grain structural steel poured at special low turbulence with a guaranteed minimum tensile strength of 500 - 640 N/mm² and minimum yield strength limit of 380 N/mm² Highly abrasion resistant steel with a tensile strength of 1720 N/mm²
C 0,18% Si 0,5% Mn 1,6% C = 0,3% Mn = 0,7% Si = 0,5% Cu = 0,65% Mo = 0,3% V = 0,05% C 0,22%
Structural steel poured at low turbulence with a guaranteed minimum tensile strength of 510 N/mm² Tempered fine grade structural steel with a C 0,18% Si 0,50% tensile strength 770 - 940 N/mm² and a Mn 1,5% Mo 0,5 % yield strength limit of 690 N/mm² Ni 1,5 % leicht legiert mit V, AI und Cu
6.3 Welding additive chart for arc welding Item
Description
Analysis values in % / Application
Per EN 499: E42 5 B 4 2 H5
E = Arc welding 42 = 500-640 N/mm² tensile strength 5 = Value for notch impact strength B = basic shielded 4 = Value for run out and type of current 2 = Value for welding positions H5 = maximum hydrogen content E = Arc welding 69 = 760-960 N/mm² tensile strength 6 = Value for notch impact strength Mn2NiCrMo = Chemical composition B = basic shielded 4 = Value for run out and type of current 2 = Value for welding positions H5 = maximum hydrogen content
C = 0,07, Si = 0,5, Mn = 1,1
for example Böhler FOX EV 50
Per EN 757: E 69 6 Mn2NiCrMo B 4 2 H5
LWT / Ausgabe / Edition / Edition / 03.2010
for example Böhler FOX EV 85
nach EN 1600: E 18 8 Mn B 2 2 z.B. Böhler FOX A 7
E = Arc welding 18 = 620-770 N/mm² tensile strength 8 = Value for notch impact strength Mn = Chemical composition B = basic shielded 2 = Value for run out and type of current 2 = Value for welding positions
For connection and applied welds, especially for steels with low purity and higher carbon content. Weldable with DC current, Electrode on Plus terminal (+). No vertical seams. C = 0,05, Si = 0,4, Mn = 1,5, Cr = 0,4, Ni = 2,0, Mo = 0,5 For welds, which require high tenacity and crack resistance, use for highly alloyed fine grain steel. Very low hydrogen content in welding material. Weldable with DC current, Electrode on Plus terminal (+). No vertical seams. C = 0,1, Si = 0,7, Mn = 6,5, Cr = 18,8, Ni = 8,8 For connections between different alloyed and difficult to weld steel Weldable with DC current, Electrode on Plus terminal (+). No vertical seams
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6.4
Welding additive chart for metal inert gas weld with solid wire electrodes
Item
Description
Analysis values in % / Application
per EN 440: G4Si1
G = Metal inert gas weld with solid wire electrodes 4 = 500-640 N/mm² tensile strength Si = Chemical properties 1 = Value for run out and type of current
C = 0,1, Si = 1,0, Mn = 1,7
for example Böhler EMK 8
per EN 12072: G 18 8 Mn
For connections between different alloyed and difficult to weld steel Weldable with DC current, Electrode on Plus terminal (+). Shielding gas: Argon + max. 2.5% CO2 No vertical seams
LWT / Ausgabe / Edition / Edition / 03.2010
for example Böhler A7 IG
G = Metal inert gas weld with solid wire electrodes 18 = 580-730 N/mm² tensile strength 8 = Value for notch impact strength Mn = Chemical composition
For connection and applied welds, especially for steels with low purity and higher carbon content. Weldable with DC current, Electrode on Plus terminal (+). Shielding gas: 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
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Tools and work instructions Installation instructions
2.3.00 Installation instructions 1 1.1
Duo cone (slip ring) seals 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. Seal variations: - Seal toward the outside
- Seal toward the inside
Fig.1 Seal variations
1 2 3 4
Seal mount O-ring Slip ring Sliding surface
Note! On Series 4 machines, due to design reasons, only seals toward the outside are used.
1.2 1.2.1
Installation General installation notes
LWT / Ausgabe / Edition / Edition / 03.2010
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 Special tools, section 2.1.
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 move sideways 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
Fig.2 O-ring installation positions
1.2.2
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.
Fig.3 Installation slip ring seal
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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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 Oring cannot roll up on the conical slip ring surface when the seal halves are pushed in.
Service Manual
Tools and work instructions Installation instructions
2
Safety lever
Fig.4 Installation notes for safety lever
Adjust the Allen screw on the limit switch. Tighten the hex nut to a tightening torque of 8 Nm and open by 1 1/4 turns. Insert the hex nut with Loctite. Tighten the hex nut to the tightening torque (see section 1.3) and then open by 1.5 to 2 turns.
LWT / Ausgabe / Edition / Edition / 03.2010
Note! 1. 2. 3. 4.
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Assembly instructions for track Note! The assembly instructions for the track are valid only for the following machine: RL 64 F/N xxx-10598
Fig. 5 Instructions for track installation
1 2 3 4 5
Track frame Final drive Idler unit Axle bearing housing Axle bearing cover
6 7 8 9 10
Track axle Installation screw with washer Hex head screw with washer Axle cover Hex head screw
Install the track axle 6 into the carrier frame. Align the equalizer bar in horizontal (center) position. Lubricate the rubber elements of the track axle 6 and the corresponding counter surfaces of the axle bearing with linseed oil (see detail A) Lift the track onto the track 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. RL 64 F/N xxx-10598 installation screws 7, M24x80, 10.9 Tighten the axle bearing cover crosswise with four installation screws with washers 7 according to factory standard WN 4037 (see detail B).
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For the assembly of the complete track on the machine, observe the following points:
Service Manual
Tools and work instructions Installation instructions
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 Track frame 1. Then install the axle cover 9 with the hex head screws 10 and tighten them crosswise according to WN 4307.
LWT / Ausgabe / Edition / Edition / 03.2010
Repeat the installation procedure on the second track side.
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4
Assembly instructions for mounting the axle cover on idler and track roller (RL64)
For installation of axle covers for the track roller A or idler B, observe the following procedure:
Tighten the hex head screw marked 1 or tighten first according to the tightening torque, see chart. Tighten all remaining hex head screws in sequence (2-3-4) crosswise according to the tightening torque, see chart. Screw mounting with friction number G = 0,10
Tightening torque Ma according to grade in Nm
Wrench size (x) = per DIN931, for Hex head screw
10.9
10.9
mm
Inch
M 24
249000
800
36
1-7/16
M 30
400000
1600
46
1-13/16
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Thread
Pretension force Fm according to grade in N
Service Manual
Technical data and maintenance guidelines Sub group index - Technical data and maintenance guidelines
3 Technical data and maintenance guidelines 3.0.00 Sub group index - Technical data and maintenance guidelines Technical data................................................................................................ 3.1 Maintenance and inspection schedule ........................................................ 3.2 Maintenance and inspection instructions ................................................... 3.3 Adjustment checklist .................................................................................... 3.4
LWT / Ausgabe / Edition / Edition / 01.2008
Test and adjustment tasks .......................................................................... 3.5
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Sub group index - Technical data and maintenance guidelines
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Technical data and maintenance guidelines Technical data
3.1.40 Technical data Diesel engine Type Version Rating according to ISO 9249 Nominal RPM Low idle (ULL) High idle (OLL) Displacement Oil quality / viscosity Max. permissible machine incline all directions Valve clearance cold Firing order
kW RPM RPM RPM l
On/ off
D 936-L A6 6 cyl. Inline charge air cooled 175 (238 PS) 1800 900+50 1900+50 10,52 See operating instructions 45° = 100% See data tag / Diesel engine 1 5 3 6 2 4
Splitterbox Type Version Ratio Oil quantity / oil quality / viscosity
351 B 374 Spur gear 1-stage 0,86 See operating instructions
Hydraulic system Var. displacement pump Type Flow quantity - Qmax l/min Operating pressure (M1 / M2) - pmax bar Tandem gear pump – replenishing Flow quantity - Qmax l/min Operating pressure (SP) - pmax bar Tandem gear pump – fan drive Flow quantity - Qmax l/min Operating pressure (LA) - pmax bar Gear motor – fan drive Operating RPM RPM Var. displacement motors Type Discharge bar Regulating pump Type Working Flow quantity - Qmax l/min hydraulic Stand-by pressure (HD) bar Operating pressure (HD) - pmax bar Servo pressure operating pressure (ND) bar Hydraulic tank capacity l - Circuit - additionally l Oil quality / viscosity
LWT / Ausgabe / Edition / Edition / 06.2008
Travel hydraulic
2 x HPV 135 2 x 282 420+30/-10 Size 55 117 23+5 Size 19 33 220±10 Size 16 1800±100 2 x HMV 280 14 A 10 V O140 284 25+2 280±5 23+4 126 164 See operating instructions
Electrical system Operating voltage Batteries Alternator Starter Central fuse
V 24 2 x 12V, 170Ah (in Series) 28V, 80A kW 7,8 A 45
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Final drive Type
FAT 500 E 517/518 Spur gear + planetary gear, each 1 stage Disk brake i ges 41,4 : 1 l See section 11.1 Data page See operating instructions
Version Parking brake, integrated Ratio Oil quantity Oil quality / viscosity Track Chain pitch Chain length
left mm (inch) 215,9 (8,5) Links 43
Track pad width (2 grouser)
mm (inch)
Track pad bolts Track rollers single flange per side (e) Track rollers double flange per side (d) Track roller arrangement Carrier rollers per side Track oscillation Ground placement surface
right
914 (36)
610 (24) 710 (28)
Thread size 7⁄8 UNF Each 4 Each 4 e d e d d e d e Each 2 Fixed m2 5,39
Working attachment Boom length Working range (ISO 8813) Boom cylinder Counterweight - cylinder Counterweight total Fixed installed Removable (10 pieces)
Cyl. Cyl.
/ rod / rod
/ Stroke / Stroke
Total / piece/ piece
mm mm mm mm kg kg kg
6000 7320 1180 6000 1240 7150 170 / 90 / 1260 100 / 60 / 610 7222 2192 5030 / 5x 619 / 5x 387
Hoist winch hydraulic mm 254 mm 279,4 mm 609,6 mm mm Strands m / min t
20 65000 4 0 23.6 stepless 28,4 Freefall control See operating instructions
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Drive Drum - Diameter - Length - Flanged wheel diameter Rope - Diameter - Length Hook block Hook speed in 1. rope layer lift / lower Load capacity max. (according to ISO 8813) Safety devices Oil quantity / oil quality / viscosity
Service Manual
Technical data and maintenance guidelines Technical data
General Travel speed Normal range III Reduced range II Reduced range I
km/h km/h km/h
forward 0 10,5 0 6,5 0 4,0
reverse 0 10,5 0 7,8 0 4,5
Boom length (mm) 6000 7320 Tractive power, max., depends on ground composition kN 283 Operating weight kg 35059 Ground load (calculated comparison value) kg/cm2 0,65
mm mm mm mm mm mm mm mm
5295 3316 3475 2997 2075 6999
8319
3298 461
LWT / Ausgabe / Edition / Edition / 06.2008
Dimensions – basic machine Total length Wheel base Transport width (with retracted counterweight) Transport width (with removed counterweight) Track width Total height max. Transport height Ground clearance
35321 0,66
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Technical data
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Technical data and maintenance guidelines Technical data
3.1.60 Technical data Diesel engine Type Engine version Performance according to ISO 9249 Nominal RPM Low idle RPM (ULL) High idle RPM (OLL) Displacement Oil quality / viscosity Max. permissible machine incline - all directions Valve play - cold Firing order
kW RPM RPM RPM l
In / out
D 946-L A6 6 cyl. in-line - charge air cooled 275 (374 PS) 1800 900+50 1900+50 11,95 See Operating instructions 45° = 100% See data tag / Diesel engine 1 5 3 6 2 4
Splitterbox Type Version Gear ratio Oil fill quantity / oil quality / viscosity
351 B 364 Spur gear 1-stage 0,86 See Operating instructions
Hydraulic system Travel hydraulic
LWT / Ausgabe / Edition / Edition / 06.2008
Working hydraulic
Var. displ. pumps Type Flow quantity Qmax l/min Operating pressure (M1 / M2) pmax bar Tandem gear pump – Replenishing Flow quantity Qmax l/min Operating pressure (SP) pmax bar Axial piston pump – Fan drive Type Flow quantity Qmax l/min Stand by pressure LA bar Operating pressure bar Axial piston motor – Combi cooler Operating RPM 1/min Gear motor – Oil cooler Operating RPM 1/min Var. displ. motor Type Discharge bar Regulating pump Type Flow quantity Qmax l/min Stand by pressure (HD) bar Operating pressure (HD) pmax bar Servo pressure Operating pressure (ND) bar
Tank capacity - Circuit additional Oil quality / viscosity
2 x HPV 280-02 2 x 518 420+30/-10 Size 55 + 38 174 23+5 A 10 V 28 57 30+5 205±5 Size 28/52 1500±100 Size 19 ±100 1800 4 x HMV 210 14 A 10 V O140 284 +2 25 280±5 23+4
l 215 l 181 See Operating instructions
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Technical data
Electrical system Operating voltage Batteries Alternator Starter Central fuse
V 24 2 x 12V, 225Ah (in Series) 28V, 80A kW 7,8 A 45
Final drive Type
FAT 650 E 519 Spur gear 1-stage + Planetary gear 2-stage Disk brake i ges 54,32 : 1 l see section 11.1 Data page See Operating instructions
Version Parking brake integrated Ratio Oil quantity Oil quality / viscosity Track
left right 215,9 (8,5) 48 914 (36) 762 (30) M 24 x 1,5 9 d d d d d d d d d each 2 fixed m2 6,05
Chain pitch Chain length Track pad width (2 grouser) Track pad screws Track rollers double flange per side (d) Track roller arrangement Carrier rollers per side Track oscillation Ground surface area
mm (inch) links mm (inch) Thread size each
Working attachment
cyl. cyl.
/ rod / rod
/ stroke / stroke
total / each
mm mm mm mm kg kg kg
8500 1400 8440 230 / 115 / 2230 120 / 70 / 1420 15035,5 3905,5 11130 / 14x 795
10500 1480 10260
LWT / Ausgabe / Edition / Edition / 06.2008
Boom length Working range (ISO 8813) Boom cylinder Counterweight - cylinder Counterweight - total Fixed installed Removable (14 each)
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Technical data and maintenance guidelines Technical data
Hoist winch Drive Drum - Diameter - Length - Pulley diameter Rope - Diameter - Length Hook block Hook speed in 1.Seillage up / down Load capacity max. (according to ISO 8813) Safety device Oil quantity / oil quality / viscosity
hydraulic mm 254 mm 279,4 mm 609,6 mm mm Strands m/min t
20 100000 8 0 11,6 stepless 48,3 Freefall control See Operating instructions
General Travel speed normal range – III reduced Range II reduced Range I
km/h km/h km/h
forward 0 10,5 0 6,5 0 4,0
rerverse 0 10,5 0 7,8 0 4,5
Boom length (mm) 8500 10500 Tractive power max. depends on ground conditions Operating weight Ground load (calculated comparison value)
mm mm mm mm mm mm mm mm
59257 1,01
5760 3605 4835 3495 2510 9515
11515
3630 630
LWT / Ausgabe / Edition / Edition / 06.2008
Dimensions of basic machine Overall length Wheel base Transport width (with retracted counterweight) Transport width (with removed counterweight) Track gauge Overall height max. Transport height Ground clearance
kN 520 kg 57719 kg/cm2 1,00
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Technical data and maintenance guidelines Maintenance and inspection schedule
3.2.00 Maintenance and inspection schedule Company:
Machine: S/N:
-
Operating hours: Inspector: Application type:
From company:
Application location:
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 Reference see:
OI Operating instructions SM Service Manual
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
LWT / Ausgabe / Edition / Edition / 03.2010
Check oil level and coolant level Check / clean Diesel engine, coolant assembly and belly pan for contamination Drain condensation in fuel separator Fuel tank, drain condensation and sediments - but at least 1x a week Change engine oil -1) - shorten interval in case of aggravating circumstances - but at least 1x a year Change lube oil filter 1) - but at least 1x 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, coolant 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 clearance - with cold Diesel engine Grease gear ring on flywheel Take oil sample 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 / a year Replace coolant with antifreeze - 3000 hrs. - but at least every 2 years
OI OI OI OI OI OI OI OI OI OI OI OI OI SM OI SM SM OI OI SM SM OI OI
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Maintenance and inspection schedule
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 Reference see:
OI Operating instructions SM Service Manual
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
HYDRAULIC SYSTEM Check oil level in hydraulic tank Check oil cooler for contamination and clean 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 and adjust all hydraulic pressures according to adjustment check list Check mountings and fittings for tight seating Clean magnetic rod (also after repairs) - up to 50 hrs daily Take oil sample (before oil change) and send it in for analysis Replace third party mineral oil product in hydraulic system (add oil via filter) - at least every 4 years - when using an environmentally friendly hydraulic medium, request / observe special guidelines Replace Liebherr Hydraulic oil in hydraulic system (add oil via filter) - at least every 4 years - or 3000 hrs.
OI OI OI OI OI / SM SM OI OI OI OI
SPLITTERBOX Check oil level
OI
Replace gear oil
OI
ELECTRICAL SYSTEM Check function of system incl. displays, indicator lights and lighting Check battery electrolyte level - at least 1x a year Clean / check / grease battery connections Check cable routing and connections Check and 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 SM
HEATER / VENTILATION / AIR CONDITIONING SYSTEM
Check electrical lines for chafing and plug connections for tight seating Air conditioning system – have it checked / inspected by HVAC technician - 1x a year Check condenser for contamination - as necessary
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LWT / Ausgabe / Edition / Edition / 03.2010
Turn the air conditioning system on regularly - at least 1x every 14 days Check water drain valves for air cond. system, clean if necessary Check system for function and leaks Clean air circulation and fresh air filter, replace as necessary, in dusty conditions, shorted maintenance interval Check mounting screws and drive belt of air conditioner compressor Check dryer unit (moisture, fill, condition) - replace if necessary, evacuate system and refill Clean water drain valves for air cond. system
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
by authorized trained personnel first and only interval Repeat interval Reference see:
OI Operating instructions SM Service Manual
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
TRAVEL GEAR Check condition of travel gear Check oil level for seal area - at least 1x a year - or if indicator light lights up Check gear oil level – clean magnetic plug Check fittings for tight seating 1) Replace gear oil – clean magnetic plug - but at least every 4 years Replace lube oil in seal area / flush seal area - but at least every 4 years Take oil sample from gear before oil change and send it in for analysis
OI OI OI / SM OI OI OI
TRACK COMPONENTS Check mounting screws and nuts of track components, especially track pad and sprocket segment screws for tight seating Check oil level in support axle bearing (only RL 44)
OI OI
Check all track components for leaks
OI
Check / adjust idler guides, replace parts, if necessary 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
LWT / Ausgabe / Edition / Edition / 03.2010
Check screws, nuts and pin retainers for tight seating Winch rope – check entire length for damage and grease, if necessary See Operating instructions of rope manufacturer Check attachment for intentional damage Check all bearing points for play / wear Hoist – rope winch (2 separate oil chambers) - but at least every 3 months or if leaks are found Check function of freefall device - always after extended downtime Check function of hoist limit switch - always after extended downtime Check rope pulleys and load hook for wear - always after extended downtime - Shorten interval if necessary / if instructed to do so Maintain and check load moment limiter with display function according to manufacturer’s instructions Take oil sample on hoist winch and send it in for analysis (2 separate oil chambers) - but at least every 6 months Change hoist – rope winch oil(s) - Clean breather screw - but at least 1 x a year Rope winch – removal and inspection of all wear parts according to ANSI - Specification B30.5c 1987 and API RP2D, section 3 - if necessary, but at least every 6 years or 10000 hrs.
OI OI OI OI OI OI OI OI Manufacturer OI OI OI
OI
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Maintenance and inspection schedule
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 Reference see:
OI Operating instructions SM Service Manual
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
GENERAL Special OI OI OI OI
LWT / Ausgabe / Edition / Edition / 03.2010
Determine and carry out maintenance and inspection requirements of all special / optional equipment included in the scope of delivery according to separate OI / manufacturer’s instructions 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
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Technical data and maintenance guidelines Maintenance and inspection instructions
3.3.00 Maintenance and inspection instructions 1 1.1
General guidelines Documentation of work to be carried out Note! For work to be performed, refer to the Maintenance and inspection schedule for your particular machine model see section 3.2. For detailed proof of completion, heck 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 3.4. 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 organization. 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 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 for: changing filters, draining condensation and sediments in case of dirty fuel; cleaning the cooler in case of contamination; changing filters and oils during or after repairs, etc. Dispose of used oil, filters and other waste products properly!
1.4
General
LWT / Ausgabe / Edition / Edition / 03.2009
For all maintenance, inspection and repair work, use only LIEBHERR Original spare and maintenance parts. If the operator requests the use of other, provided parts at installation, then this should be noted in the inspection report after notifying him about a possible loss of warranty. For general screw tightening torques see section 1.3, for tightening guidelines for track pad and sprocket segment bolts, see section 12.1.
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2 2.1 2.1.1
Maintenance and inspection work Diesel engine Check the Diesel engine RPM Start the Diesel engine. Read the RPM on the display or via the evaluation software LinDiag. Compare the speed with the nominal RPM (see section 3.1. Data page). If the RPM does not match the nominal RPM, then the throttle control must be adjusted. To do so, see section 17.5 Throttle control.
2.1.2
Check / adjust valve clearance Preparation for test Ensure that: The machine is in maintenance position. The main battery switch S43 is turned off (Position 0 ). The Diesel engine is cold. Special tool Turning device for flywheel is available. New seals for the cylinder head covers are available. Check only when the Diesel engine is cold, for adjustment values, see Diesel engine data tag .
Fig. 1 Installation of Diesel engine turning device
Install the special tool (see section 2.1) Turning device - flywheel (RL44) or Turning device V-belt (RL64) . Remove the valve cover of the Diesel engine. Turn the crankshaft in direction of rotation until the cylinders to be adjusted overlap the opposite valves.
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Note! - Cylinder 1 is on the flywheel side of the Diesel engine. - The direction of rotation is to the left, when viewed on the flywheel. - The drain valve of the respective cylinder is located on the flywheel side.
Service Manual
Technical data and maintenance guidelines Maintenance and inspection instructions
Cylinder and valve arrangement on the Diesel engine
Fig. 2 Cylinder and valve arrangement
= Inlet
D936 L A6 D946 L A6
= Outlet
overlap
6
2
4
1
5
3
adjust
1
5
3
6
2
4
Note! The valve clearance V is noted on the Diesel engine data tag.
Fig. 3 Diesel engine data tag
LWT / Ausgabe / Edition / Edition / 03.2009
Slide a feeler gauge between the valve bridge and the rocker lever.
Fig. 4 Check the valve clearance
Check the valve clearance.
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If the value of the valve clearance does not match the nominal value, then the valve clearance must be re-adjusted.
Fig. 5 Adjust the valve clearance
Loosen the lock nut on the adjustment screw of the respective rocker lever and correct the adjustment. Tighten the lock nut (40Nm). Carry out a recheck. After checking and adjusting all valves, install the cylinder head covers with new gaskets. Remove the turning device from the flywheel housing.
2.1.3
Grease the gear ring on the flywheel Note! If possible use grease on non-metallic basis. High metal or graphite ratios as well as excessive amounts of grease in connection with metallic wear debris can cause problems for the RPM sensor signal.
Fig. 6 Position of maintenance cover
The Diesel engine must be in maintenance position. Remove maintenance cover 1 from the flywheel housing 4. Caution! Danger of damage! Grease only the starter gear ring 2. The sensor gear ring 3 must be free of grease. Grease the starter gear ring 2. Install maintenance cover 1.
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The maintenance cover 1 is on the right side of the Diesel engine on the flywheel housing 4.
Service Manual
Technical data and maintenance guidelines Maintenance and inspection instructions
2.1.4
Check the heat flange The machine must be in the maintenance position. Turn the master battery switch off (see section 16.3) and disconnect the negative cable of the battery. Disconnect the electric connector cable on the heat flange. Connect an ohmmeter or multi-meter to the terminals and check the resistance. If no resistance value of 250 mOhm +/ 10% at 20 °C is obtained, then the heat flange must be replaced. Connect the electric connector cable as well as the negative cable to the battery.
Fig. 7 Heat flange
2.2 2.2.5
Hydraulic system Check working and travel hydraulic system for function and leaks, check hose routing for chafing Actuate all travel and working movements. Check for erroneous functions and remedy them immediately.
Pilot control – working hydraulic Check the actuator plate, plunger and joint of the working hydraulic pilot control for wear. If necessary, lubricate lightly and adjust. See section 8.6, Pilot controls. The same applies for pilot control for auxiliary equipment.
Accumulator – Safety control
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Start the Diesel engine. Lift the hoist gear and lower the counterweight. Turn the Diesel engine off (return the ignition key again to position 1 Ignition on) and leave the safety lever in the down position. Actuate the function hoist gear down several times, jerkily and momentarily. If the attachment moves down less than four times, then the accumulator is defective or there is excessive leakage in the system.
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Hose lines Check hose lines for leaks and kink-free routing. Watch for chafe marks. Replace chafed, sweating or aging hoses. See Safety guidelines in the Operating instructions. Do not route control, leak oil and tank line hoses with the HP hose lines in one strand, and do not route them over sharp corners, edges or hose fittings. Check connections for leaks and replace seal rings, if necessary. Check the piston rods for damage as well as the piston rod bearings for leaks. Fix, if necessary. Check the mounting screws of hydraulic components (pumps, motors, hydraulic tank etc. ) as well as the flange connections for tight seating. If necessary, tighten to the proper tightening torque.
2.2.6
Check / adjust all hydraulic pressure according to adjustment check list Carry out pressure tests / adjustments according to the adjustment check list for the respective machine type see section 3.4 Adjustment check list and enter the results. For details, data and instructions, see section 3.5. Test and adjustment tasks.
2.3 2.3.7
Electrical system Check cable routing and connections Check terminal posts and terminal clamps of batteries for oxidation and tight seating. Clean terminal posts and clamps regularly and apply terminal grease. Check batteries for external damage and leaks. Check cable strands of electronic components for chafe marks and connections for oxidation. Insulate any chafe marks, optimize the routing and protect the cable strand with heat shrink tubing to prevent moisture infiltration.
2.3.8
Check / adjust the control system of the travel drive according to the adjustment check list Carry out with the aid of the notebook and the LinDiag Diagnostics software (For software description, see section 10.1).
For software - LinDiag Diagnostics KIT see section 2.1 Special tools.
2.3.9
Check battery charge condition Warning! Batteries emit explosive gases. Battery acid has strong caustic properties. Do not smoke and avoid open flames when handling batteries as well as during battery maintenance and charging. Check the battery acid concentration with an optical battery charge tester - see Special tools Section 2.1.
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Carry out tests / adjustments according to the adjustment check list for the respective machine type see section 3.4 Adjustment check list and enter the results.
Service Manual
Technical data and maintenance guidelines Maintenance and inspection instructions
Note! To disconnect battery: Disconnect the negative terminal first, then the positive + terminal. To connect battery: Connect the positive + terminal first, then the negative - terminal . The display is made by a line between light and dark on the left scale of the indicator window. The indicator ranges are: GOOD
= Battery charged
FAIR
= Battery half charged
RECHARGE
= Battery discharged
The battery acid must be checked before adding water. Check each battery cell separately. If the test values of all cells are evenly below a density level of 1,200, then the battery must be recharged with an external battery charger. If the values differ (difference 0,02) or if they are below 1,100, then the battery must be replaced. For details about the use of a battery charge tester or to charge the battery, refer to the manufacturer s operating instructions.
Fig. 8
2.3.10
Display
Check the machine software version On Series 4 machines, check the software version with the software programs LinDiag Diagnostics software set for the travel drive. If you don t have the most current software version, then the software must be updated. For software update, see software description, section 10.1. The current software version is described in these instructions. In addition to the software update, an adjustment of the corresponding components must be carried out as described in section 3.4 - Adjustment check list.
2.4 2.4.11
Heater / ventilation / air conditioning system Check the heater and air conditioning system For instructions regarding function and general maintenance points, see section 17.2. Heater and 17.3 Air conditioning system. If access into the coolant circuit is required in case of problems or repairs of damaged components, then it is imperative that a HVAC trained technician is called in.
LWT / Ausgabe / Edition / Edition / 03.2009
2.5 2.5.12
Travel gear Check fittings for tight seating and oil level Check all mounting screws on both final drives for tight seating, retighten, if necessary. For screw tightening torques, see section 1.3. Check gear oil level and oil level in seal area. Note! If an increased oil level is found in the travel gear, then the seal of the disk brake and the oil motor must be checked. If necessary, open the gear and check the inner slipring seal (seal gap is filled with hydraulic oil according to the Operating instructions).
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2.6 2.6.13
Inspection work on the tracks Check screws and nuts for tight seating The inspection of screws and nuts is especially important for new track components. Loose track pad screws can also be recognized by misaligned nuts. Loosen screws and retighten them. For safety reason, retighten all screw connections on the affected components at the same time. For tightening torque guidelines of track pad and sprocket segment screws, see section 12.1 Data page. For all other screws, refer to the standard tightening torques according to section 1.3.
2.6.14
Adjust chain tension to suit application, check track wear Note! The track chain tension must be adjusted by taking the working conditions into account, since different ground or soil conditions cause different material build-up, and the track chain sag should always be the same. Too much tension causes significantly increased track component wear. After machine standstill for forward travel on level ground, the chain sag between the idler and the carrier roller or the carrier roller and the sprocket should be 30 to 40 mm, depending on the track type. See Operating Instructions , The scope of the track roller guard must also be matched to the given application conditions see section 12.2. The procedure for wear check, evaluation of test data and evaluation of wear pictures and their causes, see description in section 12.2.
LWT / Ausgabe / Edition / Edition / 03.2009
During the inspection of the track components, the condition of the elastic bearings on the equalizer bar should also be inspected visually.
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Technical data and maintenance guidelines Adjustment checklist
3.4.40 Adjustment checklist Company:
Machine: S/N:
-
Hrs.: Inspector: Application type:
From Co.:
Application location:
Date:
1
Preparation for hydraulic test
No. Test
Defects at inspection
Defects remedied
1.1 Visual inspection Before visual inspection, carry out scheduled maintenance and inspection work 1.1.1 Visual inspection and maintenance Service media and filters, mechanical components, travel joysticks and dust covers, cable harness and plug connections, leaks on hydraulic system, component mounting tightness
Remarks:
No. Task
1.2
LinDiag Software
Remarks
LinDiag Diagnostics software – save report
1.2.1 Reports saved
Print out report acc. to software instructions before hydraulic tests and add to check list
LWT / Ausgabe / Edition / Edition / 03.2010
1.2.2 Service Codes available
Note! The checklist sequence is according to system requirements, for instructions which are matched to the task of the adjustment checklist, see section 3.5.
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Adjustment checklist
2
Test with standard testing devices
Test points
Battery box
Engine compartment left
Travel hydraulic LA SP MR1 MR2 ML1 ML2
System pressure - fan drive Replenishing pressure High pressure travel forward right High pressure travel reverse right High pressure travel forward left High pressure travel reverse left
Working hydraulic LS HD ND
Load pressure Load Sensing High pressure Low pressure - pilot control
Measure with preselected Diesel engine RPM = 1200+50 rpm or as noted. No.
2.1
Test Remark
Unit
Nomina l value
bar
220±10
°C
70
Test value at Test
Test value after adjustment
Adjust ment loc.
Test point
System Fan drive
2.1.2 Pressure limitation fan drive Diesel engine on nmax, at least one temperature sensor unplugged.
LA
Only test, no adjustment possible. In case of pressure deviation, replace proportional solenoid valve Y48.
2.1.3 Hydraulic oil temperature Bring machine to operating temperature. Temperature must remain constant for all adjustments
2.2
±10
P5 or LinDiag
Travel hydraulic
2.2.1 Replenishing pressure No adjustment possible
+5
bar
23
SP
bar
M1=M2
±1
bar
M2=M1
±1
MR2
bar
M1=M2±1
ML1
bar
M2=M1±1
ML2
LWT / Ausgabe / Edition / Edition / 03.2010
Diesel engine RPM from 1000 RPM to high idle 2.2.2 Hydraulic neutral position Pump right Pump left
1
MR1
2.2.3 Pressure limitation High pressure (only as necessary / troubleshooting) Pressure limitations in connection with Pt. 3.3.2 [Test BS / Y13] Test Brake solenoid check LinDiag. Travel forward Travel reverse
bar
420
+30/-10
ML1
bar
420+30/-10
MR1
bar
420+30/-10
ML2
bar
420+30/-10
MR2
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