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Page No. 0.1.00

Pages from to 1 4

Index

Date of issue 02.2010

Title

1.0.00 1.1.00 1.2.01 1.3.10 1.3.11 1.4.01 1.4.02 1.4.03 1.5.01

1 1 1 1 1 1 1 1 1

2 2 4 8 2 4 2 2 2

Sub group index "General" Foreword and explanation Safety guidelines Service fluids Service fluids Tightening torques Conversion chart Tapping holes Material weights

02.2007 02.2007 04.2008 01.2009 01.2009 02.2007 04.2008 02.2007 01.2009

2.0.00 2.1.10 2.2.01 2.3.01

1 1 1 1

2 10 6 4

Sub group index "Tools and Working instructions" Special tools Repair welding Installation instruction for duo cone seals

02.2007 01.2009 02.2010 01.2009

3.0.00 3.1.10 3.1.11 3.2.10 3.2.11 3.3.10 3.4.10 3.5.10 3.5.11

1 1 1 1 1 1 1 1 1

2 2 2 4 2 8 4 2 4

Sub group index "Technical data and maintenance guidelines" Technical data Technical data Maintenance and inspection schedule Maintenance and inspection schedule Maintenance and Inspection instructions Quick reference for Machine adjustment Adjustment check list Adjustment check list

02.2007 04.2008 01.2010 04.2008 01.2009 01.2009 01.2010 01.2010 01.2010

4.0.00 4.1.10 4.2.10

1 2 1 2 1 2

Sub group index "Engine" Data page Fan and cylinder arrangement

02.2007 04.2008 04.2008

5.0.00 5.1.10 5.2.10 5.3.10

1 1 1 1

2 2 2 4

Sub group index "Coupling and splitter box" Data page Coupling Splitter box

02.2007 04.2008 02.2007 02.2007

6.0.00 6.1.10 6.2.10 6.2.11 6.3.10 6.3.10 6.3.11 6.3.11 6.5.10 6.5.11

1 1 1 1 1 1 1 1 1 1

2 2 6 8 6 1 6 2 2 2

Sub group index "Travel hydraulic" Data page Design Design Function Schematic Travel hydraulic Function Schematic Travel hydraulic Component arrangement Component arrangement

02.2007 04.2008 04.2008 04.2008 04.2008 04.2008 01.2009 01.2009 04.2008 04.2008

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Typ/ab Type/from Type/ a partir de

LR 614 F/N xxx-6358

Datum Edition Date

02 10

Table of contents

Blatt Page Feuille

0.1.00.01


Page No. 7.0.00 7.1.10 7.2.10 7.2.11 7.3.10 7.3.10 7.3.11 7.3.11 7.5.10 7.5.11

Pages from to 1 2 1 2 1 6 1 4 1 8 1 1 1 8 1 1 1 4 1 2

Sub group index "Working hydraulic" Data page Design Design Function Schematic Working hydraulic Function Schematic Working hydraulic Component arrangement Component arrangement

Date of issue 02.2007 02.2007 04.2008 04.2008 04.2008 04.2008 04.2008 04.2008 04.2008 04.2008

Title

8.0.00 8.1.10 8.2.10 8.4.10 8.4.15 8.4.20 8.4.21 8.5.10 8.5.11 8.6.10 8.6.11 8.7.10 8.8.10

1 1 1 1 1 1 1 1 1 1 1 1 1

2 4 4 4 4 4 4 8 8 6 6 26 8

Sub group index "Hydraulic components" Variable displacement pump Variable displacement motor Gear pump working hydraulic Gear pump Fan drive Gear motor Gear motor Pilot control working hydraulic Pilot control working hydraulic Control valve block Control valve block Valves Hydraulic cylinder

04.2008 02.2007 02.2007 04.2008 04.2008 04.2008 04.2008 04.2008 04.2008 04.2008 04.2008 02.2007 04.2008

9.0.00 9.1.10 9.1.11 9.1.12 9.2.10 9.2.11 9.3.10 9.3.11 9.4.10

1 1 1 1 1 1 1 1 1

2 12 21 21 4 4 6 6 2

Sub group index "Electrical system – Schematics and components" Item list- wiring diagram Current flow diagram, code letter explanations, function list Current flow diagram, code letter explanations, function list Instrument panel Instrument panel Electronic component arrangement Electronic component arrangement Travel joystick

04.2008 04.2008 04.2008 04.2008 04.2008 04.2008 04.2008 04.2008 04.2008

10.0.00 10.1.01 10.1.02 10.1.03 10.1.04 10.1.05

1 1 1 1 1 1

2 2 16 2 4 8

Sub group index "Electrical system descriptions" Application software- Introduction Application software Application software- Diagram Application software description Error chart

02.2007 04.2008 02.2007 01.2010 02.2007 02.2007

12.0.00 12.1.10 12.2.10 12.3.01 12.3.10 12.5.10 12.6.10

1 1 1 1 1 1 1

2 2 22 2 2 2 2

Sub group index "Track arrangement" Data page Design, Function, wear evaluation Appraisal report Wear chart Track roller Carrier roller

02.2007 02.2010 02.2007 02.2007 04.2008 02.2007 02.2007

13.0.00 13.1.10 13.2.10

1 2 1 4 1 6

Sub group index "Attachments - front" Mechanical stops- bucket attachments 4 in 1 bucket

02.2007 04.2008 04.2008

14.0.00 14.1.10

1 2 1 4

Sub group index "Attachments - rear" Multi tooth ripper- Design, function, item list

02.2007 04.2008


15.0.00 15.1.10 15.1.11 15.2.10 15.3.10 15.3.11

1 1 1 1 1 1

2 2 2 2 2 2

Sub group index " Main frame – Add on components " Cooler arrangement Cooler arrangement Hoist and tilt cylinder mount Engine mount Engine mount

02.2007 04.2008 04.2008 01.2009 04.2008 04.2008

16.0.00 16.1.10 16.1.11 16.2.10 16.2.11 16.3.10 16.3.11

1 1 1 1 1 1 1

2 4 4 2 2 2 2

Sub group index "Tank arrangement" Hydraulic tank Hydraulic tank Fuel tank Fuel tank Battery box Battery box

02.2007 04.2008 01.2009 04.2008 04.2008 04.2008 04.2008

17.0.00 17.1.10 17.2.10 17.3.10 17.4.10 17.5.10

1 1 1 1 1 1

2 8 4 10 2 2

Sub group index "Operators platform, heater, air conditioner" Operator’s platform Heater and Blower Air conditioning system Operator’s seat – air cushioned Engine RPM adjustment

02.2007 04.2008 04.2008 04.2008 04.2008 02.2007

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Typ/ab Type/from Type/ a partir de

LR 614 F/N xxx-6358

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02 10

Table of contents

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Sub group index General

Forword and explanations

1.1

Safety guidelines

1.2

Service items

1.3

Charts

1.4

Tightening torques for standard screws

1.4.01

Conversion chart

1.4.02

Tapping holes

1.4.03

Material weights

1.5.

Benennung Description DĂŠnomination

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LR 614

F/N xxx-6358

Blatt Page Feuille

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Datum Edition Date

02 07

General


For your information This manual contains technical data, descriptions of design and function, repair and adjustment guidelines as well as numerous drawings, functional views and illustrations LIEBHERR - crawler dozers (PR), crawler loaders (LR) or pipelayers (RL). This manual should simplify competent customer service of our products, does however, not replace expert and qualified training and an attendance of our factory schools. Information which is in trade considered basic knowledge is not included. Operation and spare parts information can be found in separate manuals. The manual will be updated as necessary when changes occur in series. Note! This sign marks special important notes in the manual. During the activities on the machine, accident prevention regulations and safety guidelines must be strictly observed. This manual is intended for the exclusive use of the registered owner and may not be reproduced complete or in part or passed on a third person without written permission. This manual is still on property of LIEBHERR-Werk Telfs GmbH. All rights reserved - Printed in Austria. We reserve the right to make changes of technical details on the machine in comparison to the information and drawings in this manual. Printed and published by LIEBHERR-Werk Telfs GmbH., Service -Training Department.

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

main group

sub group

model group

page No.

6. 3. 10 01 main group according to manual index

sub group of main group according to sub group index

division based on information content or machine model group

continuous running number within the model group, illustrations or parts list with .00 may be added at the beginning or end of each group.

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

LIEBHERR-Werk Telfs GmbH. Technical Documentation

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Foreword and explanation

LR 614

F/N xxx-6358

Blatt Page Feuille

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Datum Edition Date

02 07

General Information


Safety guidelines Prior to and during the performance of tests, adjustments and repairs, the following safety guidelines must be followed:

Any type of work may only be performed by qualified trained personnel or under the supervision and responsibility of such personnel. Qualified trained personnel are persons, who – based on specialized training and experience – have sufficient knowledge in the general area of earthmoving machinery and the specific technology of our machines. They must also have knowledge of all applicable laws and general work protection regulations, guidelines and generally approved rules concerning technology and be able to evaluate if earthmoving equipment is safe to operate and if the necessary work can be performed without endangering themselves or third persons. Never operate a machine with a raised cab/ operator’s platform! The machine may only be operated with a lowered and secured cab / operator’s platform! Always adhere to the adjustment values noted in LIEBHERR documentation when performing adjustment work. When delivering the machine, the operating personnel must be trained using the currently valid operating manual. The safety guidelines in that manual must be particularly observed. These safety guidelines must also be observed when performing testing, adjustment or repair work. However, there are special repair and/ or inspection tasks, which require different procedures than specified 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 and/ or third parties are taken. The decision to carry out this measures can only be made by qualified expert personnel. Such examples of repair and/ or maintenance include, but are not limited to the following: -

Opening of the side engine compartment doors with the Diesel engine running to carry out tests and / or adjustments. In these cases, it should be assured that the side doors are properly secured for the complete duration of the work to prevent them from closing unexpectedly and / or inadvertently. Avoid body contact with turning and / or heated parts! Wear only tight clothing (for example no scarves, no ties, no wide sleeves, etc.)

-

Starting the Diesel engine with the cab tilted, as well as actuating the travel drive with properly raised machine for adjustment, repair and diagnostics purposes. In these cases, before starting the engine, it must be ensured that the cab support as well as the support under the machine and the required ground clearance of the track chains has been checked.

Benennung Description Dénomination

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Mjfcifss!

Safety guidelines

LR 614 F/N xxx-6358

Datum Edition Date

04 08

General Information

Blatt Page Feuille

1.2.01.01


1. Safety notes in this manual In the description of tasks, which can pose a danger to man or machine, the following safety precautions are described in this manual.

They are defined with the following notes:

Danger! Warns that certain working procedures could result in death or serious injury if proper precautions are not taken. Warning! Warns that certain working procedures could result in serious injury if certain precautions are not taken. Caution! Warns that certain working procedures could result in personal injury or damage to the machine if certain precautions are not taken. In addition to these instructions, you must follow additional safety regulations and guidelines! In addition, the following must be observed: the safety regulations applicable at the jobsite. federal, state and local laws governing „travel on public roads“. any guidelines issued by trade and professional associations.


2. Safety guidelines in this operating manual

The detailed descriptions to the following safety guidelines are noted in the operating instructions of your machine and must be strictly observed.

1

General safety guidelines

2

Crushing and burn prevention

3

Fire and explosion prevention

4

Machine start up safety

5

Engine start up safety

6

Machine operating safety

7

Machine parking safety

8

Machine transporting safety

9

Machine towing safety

10

Machine maintenance safety

11

Machine welding safety

12

Safety guidelines to be observed when working on the attachment

13

Safety guidelines to be observed when loading the machine with a crane

14

Safe maintenance of hydraulic hoses and lines

15

Safety guidelines for maintenance work on the machine with hydro accumulators

16

Roll over protection (ROPS) and falling object protection (FOPS)

17

Attachments and components

18

Protection from vibration

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Mjfcifss!

Safety guidelines

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General Information

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Service Items Notes for the disposition of service fluids and filter: Service fluids may not be discharged into the ground, drainage system or waterways. Different service fluids and filters should be collected and disposed of in separate containers. Do not use containers, which previously held food items or drinks - to prevent danger of mix-ups. Dispose of these items in an environmentally friendly manner according to applicable guidelines and regulations. Observe all state, local and national regulations. Do not use old or incorrectly stored service fluids and filters, dispose of them properly. 1. Service fluids for Diesel engines with turbo chargers 1.1. Engine lube oil Engine lube oils must meet a certain quality and a certain viscosity, depending on their use and ambient temperatures. Problem-free operation can only be ensured only if the requirements for both areas are met. 1.1.1 Oil quality To meet the technical demands, only highly alloyed lube oils are used in modern Diesel engines. They consists of high-quality base oils, mixed with additives. These additives provide the required properties for these oils. For LIEBHERR Diesel engines with turbo chargers, oils of the following specifications are approved, the higher quality oils are preferred: API - classification (American Petroleum Institute)

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

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

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

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

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

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Service Items

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

Sulfur content in fuel

Oil quality:

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

E3 (D5), E4, E5,

Change interval

Change interval

above -10°C

to 0,5%

250 hrs.

500 hrs.

(Normal temperature)

above 0,5%

125 hrs.

250 hrs.

below -10°C

to 0,5%

125 hrs.

250 hrs.

Continuous temperature

above 0,5%

60 hrs.

125 hrs.

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

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


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

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

Ambient temperature °C

% Fuel

% Additive

0 to -10

70

30

100

--

100

--

-10 to -15

50

50*

100

--

100

--

-15 to -20

--

--

70

30

100

--

Summer Diesel fuel

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

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

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

Percentage of antifreeze (%)

Note:

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

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Service Items

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

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

- with DCA4

Sum of alkaline earths (water hardness):

: 0,6 to 3,6 mmol/l (3 to 20°d)

0,6 to 2,7 mmol/l (3 to 15°d)

Ph - value at 20° C

: 6,5 to 8,5

6,5 to 8,0

Chloride / ion content

: max. 80 mg/l

max. 80 mg/l

Sulfate / ion content

: max. 100 mg/l

max. 80 mg/l

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

Manufacturer

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

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

BP Antifrost X 2270 A BP Napgel C 2270/1

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

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

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

Deutz Kühlschutzmittel 0101 1490

DEUTZ Service International GmbH, Köln / BRD

Esso Kühlerfrostschutz

Esso AG, Hamburg / BRD

Fricofin Frostschutz Motorex (G48-00) Frostschutz 500

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

Glacelf Auto Supra Glycoshell AF 405 Glycoshell N Glysantin (G 48-00)

Total Shell Shell BASF AG, Ludwigshafen / BRD

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

ARTECO Chevron Texaco


Igol Antigel Type DB

Igol France, Paris / Frankreich

Labo FP 100

Labo Industrie, Nanterre / Frankreich

Motul Anti-freeze

Motul SA, Aubervilliers Cedex / Frankreich

OMV-Kühlerfrostschutzmittel Organifreeze OZO Frostschutz S

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

Total Antigel S-MB 486 Total Frostfrei

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

Veedol Antifreeze O

Deutsche Veedol GmbH, Hamburg / BRD

Wintershall Kühlerschutz

Wintershall Mineralöl GmbH, Düsseldorf / BRD

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

Brand name

Manufacturer

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

LIEBHERR Caltex Chevron Texaco ARTECO Chevron Texaco Total

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

Manufacturer

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

LIEBHERR

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

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

Benennung Description Dénomination

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Mjfcifss! LR 614 F/N xxx-6358 10719 Datum Edition Date

01 09

Service Items

Blatt Page Feuille

01.3.10.03


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

Container approx.0.5 liter

appr. liter

DCA 4 - water filter Id. No.

24-39

3

oder

1,5

7367 045

40-59

4

oder

2,0

7381 493

60-79

5

oder

2,5

7367 052

80-115 8 oder 4 7367 052 Container liquid DCA4 at approx. 0.5 l -Id. No. 7363 898 Liebherr coolant (ready to use, 20 liter, above mixing ratio) - Id. No. 10 005 347 1.3.2 Coolant - special filling - with anti corrosion fluids, without antifreeze fluids In exceptional cases and if ambient temperatures are constantly above the freezing point, for example in tropical regional, where no anticorrosion / antifreeze fluids is proofed available, fresh water and water-soluble anticorrosion fluids (Inhibitors) may be used as coolant. Do not use coolant refiners (anticorrosion oils) with emulsifying capacity. If necessary, flush the cooling system before refilling. The fresh water quality must meet use with DCA4 - see chart Â&#x201D;Approved fresh water qualityÂ&#x201D;. The coolant must be changed once a year. Use of DCA4 To provide sufficient protection against corrosion, approximately twice the amount of DCA4 must be used as compared to the above mixing ration, when using anticorrosion / antifreeze fluids and DCA4 - see above "overview chart and filter requirements". The DCA4 concentration must be between 0.6 and 1.06 units. It must be checked during maintenance work or when the coolant filter is changed, and corrected, as necessary. This results in a mixing ratio of max. 94 % fresh water and min. 6 % DCA4 additive Use of products from Caltex / Chevron Texaco / Havoline / Total To provide sufficient protection against corrosion with these products, a mixture of 92,5 vol.% coolant and 7,5 vol.% anti corrosion fluid must be kept. The mixture ratio must be checked during maintenance work and corrected, as necessary. The concentration of the anti corrosion fluid must not fall below 5 vol.% nor exceed 10 vol.%.

Presently approved anti corrosion fluids (as of December 2003): Brand name

Manufacturer

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

Fleetguard Caltex Chevron Texaco ARTECO Total


2. Oil for hydraulic system In the hydraulic system, use only Diesel engine lube oils or special approved oils. 2.1. Oil quality 2.1.1 Approved engine oil classifications API - classification (American Petroleum Institute)

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

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

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

2.1.2 Special oils Approval is given for each machine type separately. Special guidelines are issued with the release. The following product presently considered to be an environmentally friendly hydraulic fluid: Panolin - HLP Synth - VG 46 2.2. Oil viscosity In addition to the quality, the oil must also provide a certain viscosity, the selection is made according to the SAE classification (Society of Automotive Engineers). The determining factor for the correct selection of SAE classification is the ambient temperature, single grade oils are preferred. If the viscosity is too high, it can cause cavitations, if it is too low, the lubrication efficiency may be endangered. Both can cause failure of hydraulic components. The temperature ranges shown in the following chart are guidelines. When operating the machine within the black temperature range, the following warm up procedure should be carried out.

Single grade oils

Multi grade oils

Viscosity for environmentally friendly hydraulic fluids according to ISO: VG 46 (covers SAE 10W and SAE 20W-20 or SAE 10W-30) For operation in extreme climate zones, such as arctic regions, special guidelines are available from the manufacturer. Warm up procedure: a) In temperatures up to 10° C below the given limit (black range) After starting, run the Diesel engine at medium speed. Warm up the hydraulic system by carefully actuating the hydraulic cylinders. Extend and retract the hydraulic cylinders fully for short periods. After 5 minutes, carefully engage the travel hydraulic as well. Total warm up period is approximately 10 minutes. b) At even lower temperatures: Before starting the Diesel engine, preheat the oil in the hydraulic tank, then proceed as described in paragraph a). Benennung Description Dénomination

Typ/ab Type/from Type/ a partir de

Mjfcifss! LR 614 F/N xxx-6358 10719 Datum Edition Date

01 09

Service Items

Blatt Page Feuille

01.3.10.04


3. Gear oil The lube oil specification for gears is based on API and SAE classification. The oil chamber in travel gears for double lifetime seal is filled with oil from the hydraulic system - see section 2. 3.1. Oil quality As a general rule, only oils meeting API - classification GL-5 may be used. 3.2. Oil viscosity The following oils must be used in travel gears, and are highly recommended for use in splitter boxes: Viscosity classification SAE 85 W - 140 EP For splitter boxes, oils of

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

For the operation in extreme climatic conditions, such as in arctic regions or in extreme temperatures ranges, such as in slag applications, special oils may be approved if the prevailing ambient temperatures are known operations. 3.3. Lube oil for final drive - sealing chamber For oil quality and viscosity see section 2, Oil for hydraulic system, but do not use special oils. 4. Lube oil for support shaft bearing For oil quality and viscosity see section 2, Oil for hydraulic system, but do not use special oils. 5. Hoist gear oil - pipe layers As a general rule, the guidelines noted in the Operation and Maintenance manual and the winch manufacturer should be observed. For lubrication technical reasons, we recommend the use of Diesel lube oil, which meets at least one of the following quality and viscosity classifications. 5.1. Oil quality according to

API - classification ACEA (CCMC) - classification

: CF, CF-4, CG-4, CH-4, CI-4, : E2 (D4), E3 (D5), E4, E5,

5.2. Oil viscosity according to SAE - classification ISO - classification

: 10W : VG 32

6. Grease 6.1. General lubrication points and track tensioner The grease must meet specification KP 2 k - consistency 2 according to NL GI - class and DIN 51818 and DIN 51825 or EP 2 according to NF-T-60 132 . The grease must also be lithium based, with a VKA value of at least 2300 N according to DIN 51350 or ASTM D 2596. 6.2. Long term grease / grease to protect against corrosion For the lifetime lubrication of bearing points of lift cylinder suspensions and to protect against corrosion at the initial installation of dry bearing points, to protect exposed piston rods, to prevent rust formation, etc., a special calcic, acid free grease should be used. We recommend LIEBHERR's special paste CTK - Id. No. 8613 313 01 For general conservation - see section 19, Conservation guidelines - other acid free anticorrosion grease may be used. 7. Miscellaneous Always observe all guidelines issued in the Operation and Maintenance manuals, repair manuals and on drawings. 7.1. Rubber seals on doors and covers Use silicon spray or Talcum powder. 7.2. Hydraulic cylinder installation Lubricant for threads of pistons, piston nuts and piston rod bearings Liebherr High performance lubricant Id. No. 8300 004 Special protection against corrosion for installation of sealing elements Liebherr Special anticorrosion grease Id. No. 8300 005


Service Items see operation and maintenance manual.

Benennung Description DĂŠnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss! LR 614 F/N xxx-10720 Datum Edition Date

01 09

Service Items

Blatt Page Feuille

01.3.11.01


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

G

= 0,12.

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

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

Standard metric thread

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

8.8

10.9

12.9

8.8

10.9

12.9

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

Socket head screws

mm

Inch

mm

Inch

M

4 x 0,7

4 050

6 000

7 000

2,8

4,1

4,8

7

9/32

3

--

M

5 x 0,8

6 600

9 700

11 400

5,5

8,1

9,5

8

5/16

4

5/32

M

6 x1

9 400

13 700

16 100

9,5

14,0

16,5

10

--

5

--

M

7 x1

13 700

20 100

23 500

15,5

23,0

27,0

11

--

--

--

M

8 x 1,25

17 200

25 000

29 500

23

34

40

13

1/2

6

--

M 10 x 1,5

27 500

40 000

47 000

46

68

79

(17) 16

(11/16) --

8

5/16

M 12 x 1,75

40 000

59 000

69 000

79

117

135

(19) 18

(3/4) --

10

--

M 14 x 2

55 000

80 000

94 000

125

185

215

(22) 21

(7/8) --

12

--

M 16 x 2

75 000

111 000

130 000

195

280

330

24

--

14

9/16

M 18 x 2,5

94 000

135 000

157 000

280

390

460

27

1-1/16

14

9/16

M 20 x 2,5

121 000

173 000

202 000

390

560

650

30

1-3/16

17

--

M 22 x 2,5

152 000

216 000

250 000

530

750

880

(32) 34

--

17

--

M 24 x 3

175 000

249 000

290 000

670

960

1120

36

1-7/16

19

3/4

M 27 x 3

230 000

330 000

385 000

1000

1400

1650

41

1-5/8

19

3/4

M 30 x 3,5

280 000

400 000

465 000

1350

1900

2250

46

1-13/16

22

7/8

M 33 x 3,5

350 000

495 000

580 000

1850

2600

3000

50

2

24

--

M 36 x 4

410 000

580 000

680 000

2350

3300

3900

55

2-3/16

27

1-1/16

M 39 x 4

490 000

700 000

820 000

3000

4300

5100

60

2-3/8

27

1-1/16

Benennung Description DĂŠnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Standard screws

LR 614

F/N xxx- 6358

Blatt Page Feuille

1.4.01.01

Datum Edition Date

02 07

Tightening Torques Factory standard WN 4037 I


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

Fine metric thread

Wrench size (x) = per DIN931, for

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

Hex head screws

8.8

10.9

12.9

8.8

Socket head screws

10.9

12.9

mm

Inch

mm

Inch

M

8 x1

18 800

27 500

32 500

24,5

36

43

13

1/2

6

--

M

9 x1

24 800

36 500

42 500

36

53

62

--

--

--

--

M 10 x 1

31 500

46 500

54 000

52

76

89

17

11/16

8

5/16

M 10 x 1,25

29 500

43 000

51 000

49

72

84

17

11/16

8

5/16

M 12 x 1,25

45 000

66 000

77 000

87

125

150

19

3/4

10

--

M 12 x 1,5

42 500

62 000

73 000

83

122

145

19

3/4

10

--

M 14 x 1,5

61 000

89 000

104 000

135

200

235

22

7/8

12

--

M 16 x 1,5

82 000

121 000

141 000

205

300

360

24

--

14

9/16

M 18 x 1,5

110 000

157 000

184 000

310

440

520

27

1-1/16

14

9/16

M 18 x 2

102 000

146 000

170 000

290

420

490

27

1-1/16

14

9/16

M 20 x 1,5

139 000

199 000

232 000

430

620

720

30

1-3/16

17

--

M 22 x 1,5

171 000

245 000

285 000

580

820

960

32

--

17

--

M 24 x 1,5

207 000

295 000

346 000

760

1090

1270

36

1-7/16

19

3/4

M 24 x 2

196 000

280 000

325 000

730

1040

1220

36

1-7/16

19

3/4

M 27 x 1,5

267 000

381 000

445 000

1110

1580

1850

41

1-5/8

19

3/4

M 27 x 2

255 000

365 000

425 000

1070

1500

1800

41

1-5/8

19

3/4

M 30 x 1,5

335 000

477 000

558 000

1540

2190

2560

46

1-13/16

22

7/8

M 30 x 2

321 000

457 000

534 000

1490

2120

2480

46

1-13/16

22

7/8

M 33 x 1,5

410 000

584 000

683 000

2050

2920

3420

50

2

24

--

M 33 x 2

395 000

560 000

660 000

2000

2800

3300

50

2

24

--

M 36 x 1,5

492 000

701 000

820 000

2680

3820

4470

55

2-3/16

27

1-1/16

M 36 x 3

440 000

630 000

740 000

2500

3500

4100

55

2-3/16

27

1-1/16

M 39 x 1,5

582 000

830 000

971 000

3430

4890

5720

60

2-3/8

27

1-1/16

M 39 x 3

530 000

750 000

880 000

3200

4600

5300

60

2-3/8

27

1-1/16

Note: Observe notes on front page!


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

Flange nominal size

Screw size

½" ¾" 1" 1 ¼" 1 ½" 2"

M8 M 10 M 12 M 14 M 16 M 20

Tightening torques in Nm for screw grade 10.9 flat flange without Flange with Half flange reinforcement reinforcement 31 62 108 172 264 350

-45 70 120 170 250

-65 110 180 250 450

2. Half flange for low pressure (Norm 61)

Flange nominal size

Screw size

½" ¾" 1" 1 ¼" 1 ½" 2" 2 ½" 3" 3 ½" 4" 5"

M8 M 10 M 10 M 10 M 12 M 12 M 12 M 14 M 16 M 16 M 16

Tightening torques in Nm for Screw grade 8.8 Screw grade 10.9 22 44 44 44 76 76 76 122 187 187 187

31 62 62 62 108 108 108 172 264 264 264

Tightening torques for oil drain plugs at travel gears Not part of factory standard WN 4037 I Listing per LBC - Quality service as of Oct. 2003 Oil drain plug Tightening torque thread size in Nm M 14x1,5 40 M 16x1,5 40 M 18x1,5 40 M 22x1,5 80 M 33x1,5 160

Benennung Description Dénomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Standard screws

LR 614

F/N xxx- 6358

Blatt Page Feuille

1.4.01.02

Datum Edition Date

02 07

Tightening Torques Factory standard WN 4037 I


Unit of Measure Length

Multiply

by

To obtain Multiply

To obtain

by

mm

0,039

inch

25,4

mm

m

3,281

feet

0,305

m

m

1,093

yard

0,914

m

km

0,621

mile

1,609

km

cm²

0,155

sq. inch

6,452

cm²

10,764

sq. feet

0,093

1,196

sq. yard

0,836

km²

0,386

sq. mile

2,59

km²

cm³

0,061

cu. inch

16,387

cm³

35,314

cu. feet

0,028

1,308

cu. yard

0,764

l

61,025

cu. inch

0,016

l

l

0,035

cu. feet

28,316

l

l

0,264

gallon

3,785

l

l

1,057

quart

0,946

l

g

0,035

oz.

28,349

g

kg

2,204

lbs.

0,453

kg

t

1,102

short t

0,907

t

N

0,225

lbs.

4,449

N

kN

224,732

lbs.

0,0044

kN

Torque

Nm

0,737

ft. lbs.

1,356

Nm

Power

kW

1,342

HP

0,745

kW

PS

0,736

kW

1,358

PS

PS

0,986

HP

1,014

PS

Pressure

bar

14,5

PSI

0,069

bar

(hydraulic)

kpa

0,145

PSI

6,896

kpa

Ground pressure

kg/cm²

14,223

lbs. sq. inch

0,0703

kg/cm²

kg/m²

0,205

lbs. sq. ft.

4,878

kg/m²

g/cm³

0,036

lbs. cu. inch

27,78

g/cm³

kg/m³

0,062

lbs. cu. ft.

16,13

kg/m³

km/h

0,621

mph

1,609

km/h

m/min

3,281

ft. / min

0,305

m/min

Area

Volume

Weight

Force

Compression

Speed

Temperature

°C

(°Cx1,8) + 32

°F

(°F-32)/1,8

°C

°C

°C+273

°K

°K-273

°C

Benennung Description Dénomination

Typ/ab Type/from Type/ a partir de

Mjfcifss! LR 614

F/N xxx- 6358

Blatt Page Feuille

1.4.02.01

Datum Edition Date

04 08

Conversion table


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

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

Drill bit Ă&#x2DC; 0,75 0,85 0,95 1,1 1,25 1,30 1,45 1,6 1,75 1,9 2,05 2,10 2,5 2,9 3,3 3,7 4,2 5 6 6,8 7,8 8,5 9,6 10,2 12 14 15,5 17,5 19,5 21 24 26,5 29,5 32 35 37,5 40,5 43,0 47,0 50,5 54,1 57,6 61,6

Dimensions are in mm mm x 0,03937 = inches

Benennung Description DĂŠnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss! LR 614

F/N xxx-6358

Datum Edition Date

02 07

Hole diameter before tapping

Blatt Page Feuille

01.4.03.01


2. Hole diameter for tapping ISO fine Metric (internal) thread

Thread size M 1 x 0,2 M 1,1 x 0,2 M 1,2 x 0,2 M 1,4 x 0,2 M 1,4 x 0,25 M 1,6 x 0,2 M 1,8 x 0,2 M 2 x 0,25 M 2,2 x 0,25 M 2,5 x 0,35 M 3 x 0,35 M 3,5 x 0,35 M 4 x 0,5 M 4,5 x 0,5 M 5 x 0,5 M 5,5 x 0,5 M 6 x 0,75 M 7 x 0,75 M 8 x 0,75 M8x1 M 9 x 0,75 M9x1 M 10 x 0,75 M 10 x 1 M 10 x 1,25 M 11 x 0,75 M 11 x 1 M 12 x 1 M 12 x 1,25 M 12 x 1,5 M 14 x 1 M 14 x 1,25 M 14 x 1,5 M 15 x 1 M 15 x 1,5 M 16 x 1 M 16 x 1,5 M 17 x 1 M 17 x 1,5 M 18 x 1 M 18 x 1,5 M 18 x 2 M 20 x 1 M 20 x 1,5 M 20 x 2 M 22 x 1 M 22 x 1,5 M 22 x 2 M 24 x 1 M 24 x 1,5 M 24 x 2

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

Drill bit Ă&#x2DC;

Thread size

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

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

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

Drill bit Ă&#x2DC; 24 23,5 23 24,5 26 25,5 25 27 26,5 26 29 28,5 28 27 30,5 30 31,5 31 30 33,5 34,5 34 33 36,5 37,5 37 36 38,5 38 37 40,5 40 39 38 43,5 43 42 41 46,5 46 45 44 48,5 48 47 50,5 50 49 48


Material weights A Spec. weight1) in kg/m3 solid B Loosening in % C Loosening factor D Spec. weight kg/m3 loose Material Anthracite coal - 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

A 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

Benennung Description DĂŠnomination

Mjfcifss!

B 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

C 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

D 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

Typ/ab Type/from Type/ a partir de

LR 614 F/N xxx-6358

Datum Edition Date

01 09

Material weights

Blatt Page Feuille

1.5.01.01


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

The actual values depend on the moisture content, the grain size and the compression. Testing is required to determine more exact values.


Sub group index Tools and work instructions

Special tools

2.1.

Repair welding

2.2.

Installation instruction

2.3

Installation instruction for duo cone (slipring) seals

2.3.01

Benennung Description DĂŠnomination

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Mjfcifss!

Tools and

LR 614

F/N xxx-6358

Blatt Page Feuille

2.0.00.01

Datum Edition Date

02 07

Work instructions


Special tools A. Special tools - Diesel engine

Description

Id. No.

Digital RPM gauge „shimpo“

7364284

Remarks

Illustration

To measure the RPM via reflexion strips Test range: 6-8300 Rpm ±1 Rpm

Reflexion strip

614063201

Use with „Shimpo“ Rpm gauge

Optical charge tester

7408922

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

V-belt test unit „Krikit2“

8042829

To check the V-belt tension

Benennung Description Dénomination

Mjfcifss!

Typ/ab Type/from Type/ a partir de

LR 614 F/N xxx-6358

Special tools Datum Edition Date

01 09

Tools and work instructions

Blatt Page Feuille

2.1.10.01


Description Hand pump [1]

Removal valve for oil samples [2]

Oil analysis set â&#x20AC;&#x201C; Mineral oil (green cover) Individual set 4 each set 6 each set

Id. No.

Remarks

8145666 To take oil samples for the oil analysis 7019068

8145660

Analysis at WEAR CHECK Germany

10029626 7018368 7018369

12 each set Oil analysis set â&#x20AC;&#x201C; Bio oil (yellow cover) Individual set

7026817 7026088

6 each set Compression test kit JT01674

7090894

To check the cylinder compression pressure. Use the adapter and the pressure gauge / hose components of the kit.

Illustration


Description

Id. No.

Flywheel turning tool JDE83

7090362

7090361

To turn the flywheel.

To turn the flywheel. Is required for valve clearance adjustment

for LR 614 F/N xxx10720

Adjustment pin JDG1571

Illustration

Is required for valve clearance adjustment

for LR 614 F/N xxx6358 10719

Flywheel turning tool JDG820

Remarks

7090360

To hold the flywheel on OT to adjust the injection pump. Is required along with the JDE 83 or JDG 820 for valve clearance adjustment.

Screw tap

10490109

To recut threaded bores in the cylinder block

10490111

To install and remove the oil channel plug in the cylinder block

½-13 UNC-2A JDG680

Square cut insert for plug JDG782A

Benennung Description Dénomination

Mjfcifss!

Typ/ab Type/from Type/ a partir de

LR 614 F/N xxx-6358

Special tools Datum Edition Date

01 09

Tools and work instructions

Blatt Page Feuille

2.1.10.02


B. Special tools – Hydraulic system Description Vacuum pump cpl. with accessories Consists of:

Id. No.

Remarks

7408148 For faster bleeding of hydraulic system, by enclosing the PVC hose, a slight excess pressure (approx. 0.4 bar) can be produced. The connection point for vacuum pump on the machine is the breather screw on the hydraulic tank.

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

7407987 7407985 10301165 7404619 4901110 7360127 10038447 10038448 7408151

Connector fitting

10303657

For use with vacuum pump cpl. with accessories

Temperature gauge

10024185

Accuracy:

2%/2°

Test range: -18°C - +260°C

Differential pressure Test set 230V/120V Consists of: Test unit Multi-Handy 2045 2 pressure sensors 0-600 bar 2 Mini test connections 2 test cables 12m long KFZ connector cable Data cable Power unit

10288229

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

Illustration


Description

Id. No.

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

Pressure gauge connection 7002436 R½

Test hose NW 2 1,000 mm 1,500 mm 4,000 mm 5,000 mm

7002437 7002475 7009134 7363732

Test fitting, cpl. R6L R 10 L R 12 L

7409916 7406864 7409918

Screw coupling M 8x1 M 10x1 M 12x1.5 M 14x1.5 R¼

Illustration

Accuracy: 1% of the scale end value All pressure gauges are „glycerine filled“

To seal at pressure tests, a square seal ring, Id. No. 7409794 must be used.

To keep loss of pressure during tests to a minimum, shorter test hoses are preferable

Union nut and compression ring are affixed on the test fitting

To connect to additional test points on the machine 7615321 5608462 7409783 7406865 7409720

Screw coupling M 16x2

Remarks

7407070

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

Benennung Description Dénomination

Mjfcifss!

Typ/ab Type/from Type/ a partir de

LR 614 F/N xxx-6358

Special tools Datum Edition Date

01 09

Tools and work instructions

Blatt Page Feuille

2.1.10.03


Description

Id. No.

Remarks

Brake vent adapter

9401975

Adapter for air pressure cartridge (included in tool box)

Air pressure cartridge

10045498

CO2 cartridge to vent the parking brake for towing operation

Test plate A for SAE flange 3/4 Dimensions (in mm) A 90 B 40 C,r 5 Test plate B for SAE flange 1 Dimensions (in mm) A 90 B 44 C,r 5 Test plate C for SAE flange 1 1/4 Dimensions (in mm) A 90 B 52 C,r 5

7370 092

To close off high pressure connections Material: Ground spring steel

7370 093

7370 094

or made in house

Round off end of the plate Round off edges (simplifies installation, avoids damage to the seal ring)

Illustration


Note! The Id. No. for the following tools are in the spare parts list of the hydraulic cylinders.

Assembly sleeve

See Spare Parts List

For installation of the O-ring and stepseal ring on the pistons of hydraulic cylinders

Spreader sleeve

See Spare Parts List

For installation of the O-ring and stepseal ring on the pistons of hydraulic cylinders

Installation wrench Piston

See Spare Parts List

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

Installation wrench Piston nut

See Spare Parts List

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

Benennung Description DĂŠnomination

Mjfcifss!

Typ/ab Type/from Type/ a partir de

LR 614 F/N xxx-6358

Special tools Datum Edition Date

01 09

Tools and work instructions

Blatt Page Feuille

2.1.10.04


C. Special tools – Electrical system Description Digital multi meter cpl. with cable and bag

Id. No. 10018500

Remarks for Voltage (V) Amperage (A) Resistance ( ) and Frequency (Hz) tests

Optical charge tester

7408922

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

Hand crimper for „DEUTSCH“ plug connectors

8503647

To make proper crimp connections

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

Removal tool Cannon For crimp contacts „DEUTSCH“ AWG 12 AWG 16 AWG 20 Crimper AMP AMP Certi-Lock

10114733 885563714 10114732 7415333

Removal tool AMP AMP 726 503-1

7370373

AMP 726,534-1

7027340

To crimp the „JUNIOR POWER TIMER“ contacts

To remove contacts from the „JUNIOR POWER TIMER“ housing

Illustration


Description

Id. No.

Remarks

Crimper ESA 0760

7409781

To crimp insulated cable shoes 0.5 -6.0 mm² For example cable connectors

Crimper CRB 0560

7409782

To crimp non-insulated cable shoes 0.5 -6.0 mm² For example plug connectors on windshield wiper motor

Illustration

D. Special tools – Mechanical component groups Description Test tool Track

Id. No. 7402603

Remarks

Illustration

For use, see section 12.2.

Benennung Description Dénomination

Mjfcifss!

Typ/ab Type/from Type/ a partir de

LR 614 F/N xxx-6358

Special tools Datum Edition Date

01 09

Tools and work instructions

Blatt Page Feuille

2.1.10.05


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

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

Benennung Description Dénomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Repair welding

LR 614

F/N xxx-6358

Blatt Page Feuille

2.2.01.01

Datum Edition Date

02 10

Tools and instructions


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

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

Suitable reinforcement plate with high tensile strength.

Suitable reinforcement plate against bending and alternating loads.


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

Direction of weld

Direction of weld

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

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

Benennung Description DĂŠnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Repair welding

LR 614

F/N xxx-6358

Blatt Page Feuille

2.2.01.02

Datum Edition Date

02 10

Tools and instructions


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

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

7.1. Electrode Selection Welding area

Material

BASIC MACHINE Roller frame - Main frame

St 52 - 3 QStE 380 N

Roller frame - Main frame/ bottom plates ATTACHMENT Blade Bucket

Push frame Bucket arm RL-Boom

Ripper

WEAR ITEMS Adapter, Tooth adapter Ripper

LH 690 preheat to app. 100-150째C (210-300째F) HARDOX 400

Q St E 380 N HARDOX 400

St 52 - 3

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

Special steel

Electrode norm description

Protective gas welding wire norm description

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

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

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

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

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

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


7.2. Steel Table Description

Explanation

HARDOX 400

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

Q St E 380 N

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

Special steel

St 52 - 3 S355J2G3 LH 690

Analysis Si 0,7% Cr 1,4%

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

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

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

7.3. Welding addition chart 7.3.1 For arc welding

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

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

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

Benennung Description Dénomination

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

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Repair welding

LR 614

F/N xxx-6358

Blatt Page Feuille

2.2.01.03

Datum Edition Date

02 10

Tools and instructions


7.3.2 For MIG welding with solid electrodes:

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

according to EN 12534: G3CrNi1Mo

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

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

e.g. Böhler X 70 - IG

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

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

Analysis - Value in % / Use C = 0,1, Si = 1,0, Mn = 1,7 For connection and application welding, especially for steel with low purity and higher carbon content. Weldable with direct current, electrode connected to plus terminal (+). Protective gases: Argon + 15-20% CO2 or 100% CO2 No vertical seams C = 0,1, Si = 0,6, Mn = 1,6, Cr = 0,25, Ni = 1,3, Mo = 0,25, V = 0,1 For welding, which require high viscosity and crack resistance. Use for high tensile refined fine-grained steel. Weldable with direct current, electrode connected to plus terminal (+). Protective gases: Argon + 15-20% CO2 or 100% CO2 No vertical seams C = 0,08, Si = 0,9, Mn = 7,0, Cr = 19,2, Ni = 9,0 For connections between various alloyed and steel which is difficult to weld. Weldable with direct current, electrode connected to plus terminal (+). Protective gases: Argon+max. 2,5% CO 2 No vertical seams


1. Installation instructions 1.1. Slipring seals 1.1.1 Design and Function Due to the pretension of the O-rings 2, the two duo cone seals (sliprings) 3 are pressed together and therefore seal of the bearing point via the gliding surface 4. Seal variations: - Seal toward the outside

- Seal toward the inside

1 Seal mount 2 O-ring 3 Slipring 4 Gliding surface Note! Only seals toward the outside are used in the machines of Series 4, because of design reasons. 1.1.2 Installation 1.1.2.1. General installation notes The sliprings of the seals are manufactured as pairs. For that reason, new as well as used seals may only be installed as original pairs. Avoid impacts and blows, which could damage the sealing surfaces of the chilled cast sliprings. Round off sharp edges on the seal mounts. Slipring seals and their receptacles must be absolutely clean and free of grease and oil for installation. O-rings may not be lubricated with oil.

Caution! If the installation device is not used, the O-ring can roll up on the conical slipring surface. In case of one-sided installation pressure, the seal half and / or the O-ring can twist. These types of installation problems cause leaks as well as damage to the gliding surfaces.

Benennung Description DĂŠnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss! LR 614 F/N xxx-6358 Datum Edition Date

01 09

Installation instructions Blatt Page Feuille

2.3.01.01


Installation position correct

Installation position incorrect O-ring twisted

Installation position incorrect Seal half is crooked

1.1.3 Installation of the slipring seal A split device 5 is used as installation aid, it is folded over slipring 3, transferring the pressure at installation directly to O-ring 2. Press the seal halves with the appropriate installation aid into the seal mount 1. The required pressure must be exerted evenly onto the full circumference of the O-ring. If no suitable installation device is available, a round rubber string 6 can be inserted between the slipring 3 and the O-ring 2 as a makeshift spacer and affixed by hand, so that the O-ring cannot roll up on the conical slipring surface when the seal half is pressed in.

1 2 3

Seal mount O-ring Slipring

5 6

Installation device Aid â&#x20AC;&#x201C; round rubber string

Before the two seal mounts are assembled, check if the sliprings protrude evenly. Measure the distance from the seal mount to the slipring on at least 3 locations around the circumference, 120° apart. Check the gliding surface again to ensure it is clean and lightly lubricated with a thin oil or grease film.


1.2. Safety lever

1 2 3 4

Safety lever Hex nut Hex nut Limit switch

To ensure a safe and error free function of the safety lever, observe the following for installation: Tighten the hex nut 2 to the tightening torque (see section 1.4) and then open by 1 to 1.5 turns. Tighten the hex nut 3 to the tightening torque (see section 1.4) and then open by 0.5 turn. 1.3. Tilt cylinder suspension When installing the tilt cylinders 5, make sure that the hex head screw 6 at the suspension of the change over lever 4 is tightened with a tightening torque of 670 Âą 20Nm.

1 2 3 4 5 6

Main frame Bucket Bucket arm Change over lever Tilt cylinder Hex head screw

Benennung Description DĂŠnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss! LR 614 F/N xxx-6358 Datum Edition Date

01 09

Installation instructions Blatt Page Feuille

2.3.01.02


Sub group index Technical data and maintenance guidelines

Technical data

3.1

Maintenance and inspection schedule

3.2

Maintenance and inspection guidelines

3.3

Adjustment check list â&#x20AC;&#x201C; short instructions

3.4

Adjustment check list

3.5

Benennung Description DĂŠnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Technical data and

LR 614

F/N xxx-6358

Blatt Page Feuille

3.0.00.01

Datum Edition Date

02 07

Maintenance guidelines


LR 614

F/N xxx-6358 10719

DIESEL ENGINE Type version Performance per ISO 9249 Nominal RPM Low idle RPM High idle RPM Displacement Oil quantity incl. filter Oil quality / viscosity Max. machine incline - max. permissible all directions Valve clearance - cold On/off Firing order Coolant Fuel tank content

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

mm l l

D504 T (CD4045TF 277) 4 cyl. in-line 72 (98PS) 2200 850 2370 4,5 14,7 See service fluids section 1.3 35° = 78% / 30° constancy 0,36 / 0,46 1-3-4-2 24 180

SPLITTERBOX Type Version Ratio Oil quantity Oil specifications / viscosity

i l

250 B 270 1-stage spur gear 0,9107 1,75 See Service fluids, section 1.3

HYDRAULIC SYSTEM Travel pumps – Travel hydraulic Max. flow - Q max. Max. operating pressure - p max Gear pump - Replenishing circuit (2 pieces) Max. flow - Q max./ piece Max. operating pressure (SP) - p max Travel motors – Travel hydraulic

Type l/min bar Type l/min bar Type

2 x 90 L0 75 181,2 415 SNP2 / 11 48,3 28 51 VO 80

Regulating pump – Working hydraulic Max. flow - Q max. Control valve block - Working hydraulic Max. operating pressure (HD) p max. Servo control - working hydraulic - operating pressure (ND)

Type l/min Type bar bar

CPB 30 115 at 2400 U/min 08401604 SX14 230 28

Hydr. tank capacity Oil specifications/ viscosity

l

126 See Service fluids, section 1.3

ELECTRICAL SYSTEM Operating voltage Batteries Alternator Starter Central fuse Individual fuses

V

kW A A

24 2 x 12V 2 x 88Ah 45A 4 35 See Operating Instructions

TRAVEL GEAR Type Version Parking brake integrated Ratio Oil quantity Oil specifications/ viscosity

i ges l

left: AT 320547 / right: AT320548 3-stage spur gear Disk brake 52,127 : 1 2 x 8,75 See Service fluids, section 1.3

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LR 614 F/N xxx-6358 10719

Datum Edition Date

04 08

Technical Data

Blatt Page Feuille

3.1.10.01


LR 614

F/N xxx-6358 10719

TRACK COMPONENTS Chain pitch Chain length Track pad width (2 grouser) Track pad bolts Track rollers, single flange, per side (s) Track rollers, double flange, per side (d) Track roller location Track rollers per side Track frame oscillation, max.

mm (inch) Links mm Thread size Qty. Qty. Qty.

170 (6.692) 38 457 / 508 (with and without dirt hole) 5/8“ UNF 3 3 s-d-s-d-d-s 1 Fixed

WORKING ATTACHMENTS Lift cylinder

Cyl.

/ Rod

/ Stroke

mm

110 / 60 / 680

Tilt cylinder

Cyl.

/ Rod

/ Stroke

mm

130 / 70 / 385

Flap cylinder (4 in 1)

Cyl.

/ Rod

/ Stroke

mm

80 / 50 / 260

GENERAL Travel speed -

full speed range

km/h

0

9,6

Reduced speed range

km/h

0

5,3

Basic machine:

Height over cab Total length without attachment Track gauge (+1 x pad width = total width) Ground clearance Fording depth max., measured horizontally

mm mm mm mm mm

Operating weight with Standard bucket (depending on track pad widths) kg Ground pressure (according to track pad widths) kg/cm² Operating weight with 4 in 1 Bucket (depending on track pad widths) kg Ground pressure (depending on track pad widths) kg/cm² Standard bucket: Contents heaped (ISO 7546) Width Digging depth Ripping force Static tipping load Dumping height at45° Reach at45° Weight Total length of machine (without teeth) 4 in 1 Bucket: Contents heaped (ISO 7546) Width Digging depth Ripping force Static tipping load Dumping height at45° (Bucket) Reach at45° (Bucket) Weight Total length of machine

m³ mm mm kN kg mm mm kg mm m³ mm mm kN kg mm mm kg mm

2998 3859 1600 408 920 11028 0,55 11590 0,58 1,20 2300 130 100 7088 2679 890 744,2 (with cat teeth installed) 5500 (with teeth) 1,20 2300 140 95 7024 2647 908 1115 (with cat teeth installed) 5593


LR 614

F/N xxx-10720

DIESEL ENGINE Type version Performance per ISO 9249 Nominal RPM Low idle RPM High idle RPM Displacement Oil quantity incl. filter Oil quality / viscosity Max. machine incline - max. permissible all directions Valve clearance - cold On/off Firing order Coolant Fuel tank content

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

mm l l

D504 TI (CD4045HF 289) 4 cyl. in-line 72 (98 HP) 2200 1090 2370 4,5 12 See service fluids section 1.3 35° = 78% / 30° constancy 0,36 / 0,46 1-3-4-2 24 210

SPLITTERBOX Type Version Ratio Oil quantity Oil specifications / viscosity

i l

250 B 270 1-stage spur gear 0,9107 1,75 See Service fluids, section 1.3

HYDRAULIC SYSTEM Travel pumps – Travel hydraulic Max. flow - Q max. Max. operating pressure - p max Gear pump - Replenishing circuit (2 pieces) Max. flow - Q max./ piece Max. operating pressure (SP) - p max Travel motors – Travel hydraulic

Type l/min bar Type l/min bar Type

2 x 90 L0 75 181,2 415 SNP2 / 11 48,3 28 51 VO 80

Regulating pump – Working hydraulic Max. flow - Q max. Control valve block - Working hydraulic Max. operating pressure (HD) p max. Servo control - working hydraulic - operating pressure (ND)

Type l/min Type bar bar

CPB 30 115 at 2400 U/min 08401604 SX14 230 28

Hydr. tank capacity Oil specifications/ viscosity

l

102 See Service fluids, section 1.3

ELECTRICAL SYSTEM Operating voltage Batteries Alternator Starter Central fuse Individual fuses

V A kW A A

24 2 x 12V 2 x 100Ah 55 7 35 See Operating Instructions

TRAVEL GEAR Type Version Parking brake integrated Ratio Oil quantity Oil specifications/ viscosity

i ges l

left: AT 320547 / right: AT320548 3-stage spur gear Disk brake 52,127 : 1 2 x 8,75 See Service fluids, section 1.3

Benennung Description Dénomination

Mjfcifss!

Typ/ab

Type/from

Type/a partir de

LR 614 F/N xxx-10720

Datum Edition Date

01 10

Technical Data

Blatt Page Feuille

3.1.11.01


LR 614

F/N xxx-10720

TRACK COMPONENTS Chain pitch Chain length Track pad width (2 grouser) Track pad bolts Track rollers, single flange, per side (s) Track rollers, double flange, per side (d) Track roller location Track rollers per side Track frame oscillation, max.

mm (inch) Links mm Thread size Qty. Qty. Qty.

170 (6.692) 38 457 / 508 (with and without dirt hole) 5/8“ UNF 3 3 s-d-s-d-d-s 1 Fixed

WORKING ATTACHMENTS Lift cylinder

Cyl.

/ Rod

/ Stroke

mm

110 / 60 / 680

Tilt cylinder

Cyl.

/ Rod

/ Stroke

mm

130 / 70 / 385

Flap cylinder (4 in 1)

Cyl.

/ Rod

/ Stroke

mm

80 / 50 / 260

GENERAL Travel speed -

full speed range

km/h

0

10

Reduced speed range

km/h

0

6,5

Basic machine:

Height over cab Total length without attachment Track gauge (+1 x pad width = total width) Ground clearance Fording depth max., measured horizontally

mm mm mm mm mm

Operating weight with Standard bucket (depending on track pad widths)kg Ground pressure (according to track pad widths) kg/cm² Operating weight with 4 in 1 Bucket (depending on track pad widths) kg Ground pressure (depending on track pad widths) kg/cm² Standard bucket: Contents heaped (ISO 7546) Width Digging depth Ripping force Static tipping load Dumping height at45° Reach at45° Weight Total length of machine (without teeth) 4 in 1 Bucket: Contents heaped (ISO 7546) Width Digging depth Ripping force Static tipping load Dumping height at 45° (Bucket) Reach at 45° (Bucket) Weight Total length of machine

m³ mm mm kN kg mm mm kg mm m³ mm mm kN kg mm mm kg mm

2998 3859 1600 408 920 11100 0,56 11475 0,58 1,20 2300 130 100 7517 2679 890 744,2 (with cat teeth installed) 5585 (with teeth) 1,20 2300 140 95 6988 2647 908 1115 (with cat teeth installed) 5653


Customer:.............................................Machine-Type..............PIN.........-..............Hours...............Date............ Maintenance/Inspection at operating hours

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

by authorized trained personnel First and only interval Repeat interval

OM Operating instructions

SM Service Manual

For correct oil level, use test marks – for procedure and quantities, see OM For quality and viscosity guidelines, see “Service fluids” OM For adjustment values, see data page entries in SM

Reference

Notes

DIESEL ENGINE Check oil level and oil pressure Check coolant level Check engine / cooling system and engine compartment for contamination / clean if necessary Check fuel water separator / empty if necessary Check / clean air filter service cover and dust discharge valve Change engine oil / first and only time before 100 hrs. - at least 1 x a year (regular interval 250 or 500 hrs. depending on oil specification) Change engine oil filter / first and only time at 100 hrs. - at least 1 x a year Check antifreeze ratio of coolant Check V/belt condition and tension Check oil, cooling and fuel system for leaks and condition Check intake and exhaust system - mounting and leaks Check engine mount Change fuel pre- and fine filter element Check engine RPM Replace coolant with antifreeze Check / adjust engine valve clearance – with cold engine Drain condensation and sediments from fuel tank - as necessary Replace air filter inserts - as necessary /once a year Clean air filter pre-separator - as necessary /once a year Replace oil separator - every 2 years

OM OM OM OM OM OM OM OM OM OM OM OM OM OM SM OM OM OM OM

HYDRAULIC SYSTEM Check oil level in hydraulic tank Clean magnetic ring (also after repairs) - up to 50 hrs. daily Replace main return filter inserts or as soon as the indicator light lights up Replace pressure filter- replenishing circuit or as soon as the indicator light lights up Check / clean oil cooler for contamination Check working and travel hydraulic system for function and leaks, check hose routing for chafing or damage Check / adjust all hydraulic pressures according to adjustment check list Check mountings and fittings for tight seating Replace oil in hydraulic system (add oil via filter) - at least every 4 years when using „environmentally friendly hydraulic oils“, request / observe special guidelines

OM OM OM OM OM OM

SM

OM

SM SM

OM

SPLITTERBOX Check oil level Replace gear oil

- at least every 2 years

Benennung Description Dénomination

Mjfcifss! Datum Edition Date

04 08

Typ/ab

Type/from

OM OM

Type/a partir de

LR 614 F/N xxx-6358 10719

Maintenance and

Inspection schedule

Blatt Page Feuille

3.2.10.01


Maintenance/Inspection at operating hours

WORK TO BE CARRIED OUT by maintenance personnel First and only interval Repeat interval OM Operating instructions

ff

mit autorisiertem Fachpersonal First and only interval Repeat interval SM Service Manual

For correct oil level, use test marks – for procedure and quantities, see OM For quality and viscosity guidelines, see “Service fluids” OM For adjustment values, see data page entries in SM

Reference

ELECRICAL SYSTEM Check function of system, incl. displays and instruments Check battery electrolyte level - at least 1 x a year Clean / check / grease battery terminals Check cable routing and connections Check /adjust all control system according to adjustment check list Check battery charge (before start of cold season)

OM OM OM OM

SM SM SM SM

HEATER / VENTILATION / AIR CONDITIONING SYSTEM Check system for function and leaks Check air conditioning system antifreeze level and moisture indicator Replace fresh air filter and air circulation filter Air conditioning system – inspection by expert HVAC personnel

- as necessary 1x a year

OM OM OM

TRAVEL GEAR Check oil level Check fittings for tight seating Replace gear oil

OM OM OM

SM

TRACK COMPONENTS Check mounting screws and nuts of track components, especially track pad and sprocket segment screws for tight seating Check carrier rollers, track rollers, idlers for leaks Check / adjust idler guides, replace parts as necessary Adjust track tension to suit application - as necessary Clean travel gear - as necessary Check travel gear for wear - as necessary

OM OM OM OM OM

SM SM

Working attachment Check cutting edges, bucket and ripper teeth for wear make sure attachments are suited to application Check bucket attachment – stops and adjustment of limit switches Check screws, nuts and pin retainers for tight seating Check all bearing points for play / wear Check attachment for damage

OM OM OM OM OM

SM

GENERAL Lubricate all bearing points according to lubrication chart Shorten interval as necessary Check complete machine for proper maintenance and condition Lubricate door hinges on operator’s cab - as necessary Explain machine documentation, especially operating instructions / safety guidelines to operating personnel

OM OM OM OM

SM

Notes


Company:.................................................Machine Type..............S/N.........-..............Hrs................Date............ Maintenance / Inspection At operating hours

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

by authorized expert personnel first and only task Repeat interval

Operating instructions

SM Service manual

For fill quantities, use the test marks For instructions and quantities, see OI For quality and viscosity guidelines, see “Service items” OI See data in SM

Instructions see:

Remark s

DIESEL ENGINE Check oil level and oil pressure Check coolant level Check the engine, cooler arrangement and engine compartment for contamination / clean Check the fuel water separator / empty if necessary Check the air filter service cover and dust discharge valve / clean Change the engine oil / first and only time before 100 hrs. - at least 1 x a year (Regular interval 250 or 500 hrs. depending on oil specification) Change the engine oil filter / first and only time before 100 hrs. - at least 1 x a year Check the crankcase breather system Check the electrical ground connection for the engine Check the corrosion inhibitor – antifreeze concentration in the coolant Check the V-belt condition and tension Check the oil, coolant and fuel system for leaks and condition Check the air intake and exhaust system – mounting and leaks Check the engine mounting Change the fuel pre- and fine filter cartridge Check the engine RPM Replace the coolant with antifreeze Check / adjust engine valve clearance - with cold engine Fuel tank, drain condensation and sediments - as necessary Replace air filter inserts - as necessary / annually Clean air filter pre-separator - as necessary / annually

OI OI OI OI OI OI OI OI OI OI OI OI OI OI OI OI SM OI OI OI

HYDRAULIC SYSTEM Check oil level in hydraulic tank Replace main flow return filter or immediately if the indicator light lights up Replace pressure filter replenishing circuit – or immediately if the indicator light lights up Check oil cooler for contamination / clean Check working and travel hydraulic system for function and leaks, check hose routing for chafing Check / adjust all hydraulic pressures according to adjustment check list Check mountings and fittings for tight seating Replace oil in hydraulic system - at least every 4 years - If using an “environmentally friendly hydraulic medium” request / observe special guidelines

OI OI OI OI OI

SM

OI

SM SM

OI

SPLITTERBOX Check oil level Replace gear oil

- at least every 2 years

Benennung Description Dénomination

Mjfcifss! Datum Edition Date

01 09

Typ/ab

LR 614

Type/from

OI OI

Type/a partir de

F/N xxx-10720

Maintenance and

Inspection schedule

Blatt Page Feuille

3.2.11.01


Maintenance / Inspection At operating hours

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

ff

by authorized expert personnel first and only task Repeat interval

Operating instructions

SM Service manual

For fill quantities, use the test marks For instructions and quantities, see OI For quality and viscosity guidelines, see “Service items” OI See data in SMfff

Instructions see:

ELECTRICAL SYSTEM Check function of system incl. displays and instruments Check battery acid level - at least 1x annually Clean / check / grease battery connections Check cable routing and connections Check / adjust control system according to adjustment check list Check battery charge condition (before start of cold season)

OI OI OI OI

SM SM SM SM

HEATER / VENTILATION / AIR CONDITIONING SYSTEM Turn the air conditioning system on regularly

- at least 1x in 14 days

Check water discharge valve of air cond. system, clean as necessary

OI OI

Check system for function and leaks

OI

Check condenser for contamination - blow out as necessary Clean air circulation fresh air filter, replace as necessary, in dusty conditions, shorten maintenance interval Check mounting screws and drive belt of air cond. compressor Check dryer unit (moisture, fill, condition) - replace dyer unit and moisture indicator as necessary, evacuate system and refill Clean water drain valve of air conditioning system

OI

Check evaporator unit, clean as necessary

OI

Check electrical lines for chafing and plug connections for tight seating Air conditioning system – have inspected by HVAC technician

OI OI OI OI OI

- 1x annually

TRAVEL GEAR Check oil level Check fittings for tight seating Replace gear oil

OI OI OI

SM

TRACK COMPONENTS Check mounting screws and nuts of track components, espec. track pad and sprocket segment screws for tight seating Check all track components for leaks Check / adjust idler guides, replace parts as necessary Adjust chain tension to suit working application - as necessary Clean tracks - as necessary Check track wear - as necessary

OI OI OI OI OI

SM SM

WORKING ATTACHMENTS Check cutting edges, end bits and ripper tooth tips for wear make sure attachments are suited for application Check screws, nuts and pin retainers for tight seating Check bucket stops Check all bearing points for play / wear Check attachment for intentional damage

OI OI OI OI OI

SM

GENERAL Lubricate all bearing points according to lubrication schedule - shorten interval as necessary Check entire machine for correct maintenance and proper condition Explain machine literature, especially the Operating instructions / Safety guidelines to operating personnel Lubricate operator’s cab – door hinges - as necessary

OI OI OI

SM

Remark s


1. General guidelines 1.1. Documentation for work to be carried out For work to be performed, refer to the Maintenance and inspection schedule for your particular machine model – see section 3.2. Check off completed inspections or work by making a check mark on a copy of the form and have the completed form countersigned. The determined test values for the adjustment checks should be documented on an adjustment check list – corresponding to the machine model, see paragraph 3.5. In addition, confirm the performance of the inspection / delivery in the machine’s inspection booklet and send the appropriate Service ticket to the appropriate LIEBHERR company. After removing the old sticker, attach the new inspection sticker, which can also be found in the inspection booklet, clearly visible in the cab. Explain the set up and the contents of the machine documentation to the machine operator. Special emphasis should be given to safety regulations and maintenance task to be performed between inspections. 1.2. Safety guidelines During all maintenance, inspection or repair work, the applicable safety guidelines according to section 1.2 and the operating instructions for the machine must be observed. In addition, all applicable Federal, state and local safety requirements, accident prevention regulations and local laws must be observed. 1.3. Intervals The given Maintenance and inspection intervals may not be exceeded, if necessary, they should be shorted, for example: Changing filters, draining condensation and sediments in case of dirty fuel; cleaning the radiator in case of contamination; changing filters and oils during or after repairs, etc. Dispose of oil oils, filters and other waste products properly! 1.4. General Use only LIEBHERR Original spare and maintenance parts for all maintenance, inspection and repair work. If the operator requests other on hand parts for installation, then this must be noted separately on the inspection check lists by noting possible loss of warranty. For general screw tightening torques, see section 1.4. For tightening guidelines for track chain pads and sprocket segment bolts, see section 12.1.

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Typ/ab Type/from Type/ a partir de

LR 614 F/N xxx-6358

Maintenance and Datum Edition Date

01 09

Inspection guidelines

Blatt Page Feuille

3.3.10.01


2. Maintenance and inspection guidelines 2.1. Inspection work on the Diesel engine 2.1.1 Check / adjust valve clearance Preparation for test Make sure that: The machine is in maintenance position. The battery master switch (optional) is turned off or the negative cable is disconnected from the battery. The Diesel engine is cold. Special tools are available (turning tool – flywheel, adjustment pin, see section 2.1.) If necessary, have new gaskets for the cylinder head covers ready for use.

Procedure: Remove the rocker lever cover and the crankcase vent pipe.

Note! Visually inspect the contact surfaces of the valve tips, valve bridges and rocker lever wear surfaces. Check all parts for excessive wear, breakage and cracks. Replace any parts which show visible damage. Rocker levers, which show excessive valve clearance should be checked closely to determine damaged parts. Replace valves, seats, springs and retainers in pair per cylinder if they are damaged. In addition, replace the bridge if one of these parts is being replaced. Remove the plastic plug or the cover plate from the engine adjustment / rotary opening (A) and the adjustment pin opening (B) on the flywheel side.

With the special tool “Turning device – flywheel“ turn the engine flywheel in direction of rotation (when viewed from the front, turn it in clockwise direction until the cylinder No. 1 is on the top dead center (TDC) of the compression stroke. Insert the special tool „adjustment pin“ into the flywheel.


Note! If the rocker levers of cylinder No. 1 can be moved, then the engine is on the TDC of No. 1 in the compression stroke. If the rocker levers of cylinder No. 1 cannot be moved, turn the engine a complete rotation (360°) to the TDC No. 1 of the compression stroke. When the engine is held with the adjustment pin on the TDC of the compression stroke of piston No. 1, check the valve clearance according to the following specification. Specifications Intake valve clearance (rocker lever to valve bridge) [engine cold] – clearance Exhaust valve clearance (rocker lever to valve bridge) [engine cold] – clearance Counter nut of rocker lever adjustment screw Torque

Test dimension 0.31 – 0.38 mm

Adjustment dimension 0.36 mm

0.41 – 0.48 mm

0.46 mm

27 Nm

Adjust valve clearance Note! If the valves must be adjusted, release the counter nut (A) on the rocker lever adjustment screw. Prevent the adjustment screw from turning with a screw driver and tighten the counter nut according to specifications. After tightening the counter nut, check the clearance again. Readjust the clearance, if necessary.

A = Outlet valve E = Intake valve

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LR 614 F/N xxx-6358

Maintenance and Datum Edition Date

01 09

Inspection guidelines

Blatt Page Feuille

3.3.10.02


Four cylinder engine: Note! The firing order is 1-3-4-2.

Piston No. 1 on the top dead center (TDC) of the compression stroke:

Hold the piston No. 1 with the adjustment pin on the TDC of the compression stroke. Adjust the valve clearance on the exhaust valves No. 1 and 3. Adjust the valve clearance on the intake valves No. 1 and 2.

Piston No. 4 on the top dead center (TDC) of the compression stroke:

Turn the crankcase by 360°. Hold the piston No. 4 on the TDC of the compression stroke. Adjust the valve clearance on the exhaust valves No. 2 and 4. Adjust the valve clearance on the intake valves No. 3 and 4.

Attach the rocker lever cover and the crankcase vent pipe.


2.2. Inspection work on the hydraulic system 2.2.2 Check the working and travel hydraulic system for function and leaks, check hose routing for chafing, check mountings and fittings for tight seating Carry out all travel and working movements and check for malfunction. Check the actuator plate, plunger and universal joint of the working hydraulic pilot control for wear, grease lightly and adjust, if necessary. The same applies for pilot control for auxiliary equipment. To inspect the pressure accumulator – safety control – working hydraulic, start the Diesel engine and raise the front attachment. Turn the engine off (return the ignition key again to position 1) and leave the safety lever in the down position. Actuate the function “down” several times jerkily. If the attachment moves down less than four times, then the accumulator is defective or there is excessive leakage in the system.

Check the hose lines for leaks and kink-free routing. Watch for chafe marks. Replace chafed, “sweating” or aging hoses. Refer to the Safety guidelines, Section 1.2. 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. Retighten, if necessary. 2.2.3 Check / adjust all hydraulic pressures Carry out tests / adjustments according to the adjustment check list for the respective machine type – see section 3.5 – and enter the results. For detailed descriptions, data and instructions, see adjustment check list or corresponding sub group in the Service Manual.

Benennung Description Dénomination

Mjfcifss!

Typ/ab Type/from Type/ a partir de

LR 614 F/N xxx-6358

Maintenance and Datum Edition Date

01 09

Inspection guidelines

Blatt Page Feuille

3.3.10.03


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Liebherr lr 614 lr614 crawler loader series 4 litronic service repair manual  
Liebherr lr 614 lr614 crawler loader series 4 litronic service repair manual  
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