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   

    



   

 

 

 

     

    

  

  



  

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 

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  

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  



     



 

 



    

   



 



 


Service Manual Table of contents

0.1.00 Table of contents Page No. 0.1.00

Pages from to 1 4

Table of contents

Date of issue 2.2010

Title

1.0.00 1.1.00 1.2.00 1.3.00 1.4.01 1.4.02 1.4.03 1.5.00 1.6.01

1 1 1 1 1 1 1 1 1

2 2 4 2 4 2 2 4 2

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

3.2007 3.2007 5.2008 3.2007 5.2008 1.2009 3.2007 2.2010 3.2009

2.0.00 2.1.00 2.2.00 2.3.00

1 1 1 1

2 20 8 4

Sub group index "Tools and application remarks" Special tools Repair welding Installation notes for slipring seals

2.2008 1.2010 1.2009 4.2008

3.0.00 3.1.20 3.1.30 3.1.31 3.2.20 3.3.20 3.4.20 3.5.20 3.5.30 3.5.31

1 1 1 1 1 1 1 1 1 1

2 2 2 2 4 8 6 4 4 4

Sub group index "Technical data and Maintenance guidelines" Technical Data Technical Data Technical Data Maintenance and inspection schedule Maintenance and Inspection guidelines Quick reference for machine adjustment Adjustment check list Adjustment check list Adjustment check list

3.2007 3.2007 2.2009 2.2009 2.2010 3.2009 3.2009 5.2008 3.2009 3.2009

4.0.00 4.1.20 4.1.30 4.2.20 4.3.00 4.4.00

1 1 1 1 1 1

2 2 2 2 12 4

Sub group index "Engine" Data page Data page Fan and cylinder arrangement Installation kit- Diesel particle filter Installation and test list for Diesel particle filter

2.2008 1.2009 3.2008 1.2009 1.2009 5.2008

5.0.00 5.1.20 5.2.20 5.3.20 5.3.30 5.4.20

1 1 1 1 1 1

2 2 2 4 4 2

Sub group index "Coupling and splitterbox" Data page Coupling Splitterbox Splitterbox Coupling – pump output

4.2008 1.2009 4.2008 4.2008 4.2008 4.2008

6.0.00 6.1.20 6.1.30 6.2.20 6.2.21 6.2.30 6.2.31 6.3.20 6.3.21

1 1 1 1 1 1 1 1 1

2 2 2 10 10 10 10 8 8

Sub group index "Travel hydraulic" Data page Data page Design Design Design Design Function Function

3.2007 1.2009 3.2008 5.2008 5.2008 5.2008 5.2008 1.2009 1.2009

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Page No. 6.3.30 6.3.31 6.3.32 6.3.33 6.4.00 6.5.20 6.5.21 6.5.30 6.5.31

Pages from to 1 8 1 8 1 8 1 8 1 10 1 2 1 2 1 2 1 2

Function Function Function Function Test and adjustment Component arrangement Component arrangement Component arrangement Component arrangement

Date of issue 1.2009 1.2009 1.2009 1.2009 2.2010 2.2008 2.2008 2.2008 3.2008

Title

7.0.00 7.1.20 7.1.30 7.2.20 7.3.20 7.3.30 7.4.00 7.5.20

1 1 1 1 1 1 1 1

2 2 2 6 10 10 10 2

Sub group index "Working hydraulic" Data page Data page Design Function Function Test and adjustment Component arrangement

3.2007 1.2009 1.2009 2.2008 1.2008 1.2008 3.2009 1.2009

8.0.00 8.1.20 8.1.30 8.2.20 8.2.30 8.2.31 8.3.20 8.4.20 8.4.25 8.4.35 8.5.20 8.5.25 8.6.20 8.7.00 8.8.00

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

2 6 6 6 6 6 10 4 4 4 8 6 6 12 8

Sub group index "Hydraulic components" Variable displacement pump Variable displacement pump Variable displacement motor Variable displacement motor Variable displacement motor Regulator pump – Working hydraulic Double gear pump – Replenishing / Fan drive Fan motor Fan motor Pilot control – Working hydraulic Pilot control – Auxiliary equipment Control valve block Valves Hydraulic cylinder

2.2009 3.2007 6.2006 3.2007 2.2008 2.2008 2.2008 4.2008 3.2008 4.2008 3.2009 1.2009 3.2007 2.2009 3.2007

9.0.00 9.1.30 9.2.30 9.2.31 9.3.30 9.4.20 9.4.21 9.4.30 9.4.31 9.4.32 9.5.20 9.6.20 9.6.30 9.6.31 9.7.20 9.7.25 9.8.20

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

2 6 2 2 2 76 80 16 16 76 2 18 14 18 4 4 4

Sub group index "Electrical system – Schematics and components" Component description Function list Function list Fuses, cross points, notes Current flow diagram Current flow diagram Current flow diagram Current flow diagram Current flow diagram Instrument panel Component arrangement – Electrical system Component arrangement – Electrical system Component arrangement – Electrical system Travel joystick V- joystick Speed reduction pedal

3.2009 2.2010 1.2010 1.2010 1.2008 3.2009 3.2009 1.2008 1.2008 1.2008 1.2010 2.2010 2.2010 2.2010 2.2010 2.2010 1.2008

Sub group index "Electrical system descriptions" Application Software – travel drive Software PDL – Diesel particle filter

3.2008 1.2010 1.2010

10.0.00 10.1.00 10.2.00

1 2 1 70 1 20

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Page No. 11.0.00 11.1.20 11.1.30 11.2.20 11.2.30 11.3.20 11.3.30

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

Sub group index "Final drive" Data page Data page Design and function Design and function Sectional view Sectional view

Date of issue 3.2007 3.2007 6.2006 3.2007 3.2007 3.2007 3.2007

Sub group index "Track components" Data page Design, function, wear and evaluation Inspection checklist Wear chart Track roller frame and idler unit Track roller Carrier roller Tension unit

3.2007 2.2010 3.2008 1.2010 1.2009 2.2008 3.2007 3.2007 5.2008

Title

12.0.00 12.1.00 12.2.00 12.3.00 12.3.01 12.4.20 12.5.20 12.6.20 12.8.00

1 1 1 1 1 1 1 1 1

13.0.00 13.1.20 13.2.20

1 2 1 6 1 4

Sub group index "Attachments - front" 4 in 1 Bucket Bucket arm

3.2007 3.2007 3.2009

14.0.00 14.1.20 14.1.21

1 2 1 6 1 6

Sub group index "Attachments - rear" Ripper Ripper

3.2007 3.2007 3.2007

15.0.00 15.1.20 15.1.30 15.2.20 15.3.20 15.3.30 15.4.20

1 1 1 1 1 1 1

2 2 2 2 2 4 2

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

3.2007 3.2007 3.2008 3.2007 3.2007 3.2007 1.2008

16.0.00 16.1.20 16.1.30 16.2.20 16.2.30 16.3.20

1 1 1 1 1 1

2 6 4 2 2 4

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

3.2007 2.2010 1.2008 3.2009 1.2008 1.2008

17.0.00 17.1.00 17.2.00 17.3.00 17.4.20 17.5.20

1 1 1 1 1 1

2 4 4 10 2 2

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

3.2007 1.2009 1.2009 1.2009 3.2007 5.2008

18.0.00 18.2.20 18.3.20 18.3.30 18.3.31 18.4.00

1 1 1 1 1 1

2 4 6 6 6 6

Sub group index "Special equipment" Refueling pump Reversible fan Reversible fan Reversible fan Rope winch

5.2008 1.2008 2.2010 3.2008 2.2010 1.2009

2 2 26 4 4 6 2 2 10

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Page No. 19.0.00 6.3.20 6.3.21 6.3.30 6.3.31 6.3.32 6.3.33 7.3.20 7.3.30 9.4.20 9.4.21 9.4.30

9.4.31 9.4.32

Pages from to 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 1 1 1 1 76 1 80 1 16 13,16 6 1 16 1 76

Date of issue 3.2009 1.2009 1.2009 1.2009 1.2009 1.2009 1.2009 1.2008 1.2008 3.2009 3.2009 2.2007 3.2007 1.2008 1.2008 2.2009

Title Sub group index "Additional documentation" Schematics Travel Hydraulic Schematics Travel Hydraulic Schematics Travel Hydraulic Schematics Travel Hydraulic Schematics Travel Hydraulic Schematics Travel Hydraulic Schematic Working Hydraulic Schematic Working Hydraulic Current Flow Diagram Current Flow Diagram Current Flow Diagram

Current Flow Diagram Current Flow Diagram

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General Sub group index General

1 General 1.0.00 Sub group index General Foreword and Explanation ........................................................................... 1.1 Safety Guidelines .......................................................................................... 1.2 Service fluids ................................................................................................. 1.3 Table charts ................................................................................................... 1.4 Tightening torques ............................................................................................................1.4.01 Conversion charts............................................................................................................. 1.4.02 Tapping holes ...................................................................................................................1.4.03

Conservation guidelines............................................................................... 1.5 Material weights............................................................................................. 1.6

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General Foreword and explanation

1.1.00 Foreword and explanation 1

For information This manual contains technical data, descriptions of design and function, repair and adjustment instructions as well as numerous drawings, functional views and illustrations of LIEBHERR – crawler loaders (LR) in Series 4. This manual should simplify competent customer service of our product, however, it does not replace expert and qualified training and attendance at our factory training classes. Information which is in the trade considered to be basic knowledge is not included. Operation and spare parts information can be found in separate documentation. The manual will be updated and expanded as necessary, when changes occur in series. During all activities on the machine, accident prevention regulations and safety guidelines must be strictly observed. The manual is intended for the exclusive use of the registered owners and may not be reproduced complete or in part or passed on to a third person without our written permission and remains property of LIEBHERR-Werk Telfs GmbH. All rights reserved - Printed in Austria. We reserve the right to make changes of technical details on the machine in comparison to the information and drawings in this manual. Printed and published by LIEBHERR-Werk Telfs GmbH., Technical Documentation Dept.

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General

Service Manual

Foreword and explanation

2

Explanation of set up In order to find specific information and to simplify the addition of supplements, the following system is used: Main group

Model group

Component (item) groups according to index

Division based on information content or machine size

Sub group

Page No.

Sub group of main group according to sub group index

Continuous running No. and complete number of pages within the model group

It is possible that there is an additional running number behind the continuous number, for example 9.4.20 - 13/15 - 02. This number stands for updates, especially on electrical schematics, where only one page is updated. Changes will be issued with the same number, but with updated date. Updates will be given new numbers. If one page applies only for a certain machine group, then this is noted in the heading. Note! This sign marks special important notes in the manual. This symbol notes a standard listing. This symbol means:“ The prerequisite must be met“. The maintenance personnel must first fulfill the described prerequisites, for example, to bring the machine in working position, to be able to carry out the steps described thereafter as. This symbol marks an activity step. The maintenance personnel is to become active on this point and carry out the described activity. This symbol denotes a result. The maintenance personnel is alerted to the fact that a result will occur after a work step, for example, after the test button is pushed, the LED light lights up.

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

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

LIEBHERR-Werk Telfs GmbH. Technical Documentation

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General Safety guidelines

1.2.00 Safety guidelines 1

Introduction 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.

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General

Service Manual

Safety guidelines

2

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.

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General Safety guidelines

3

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

Introduction

2

Proper and intended use

3

Signs on the machine

4

Safety regulations

4.1

General safety guidelines

4.2

Crushing and burn prevention

4.3

Fire and explosion prevention

4.4

Machine start up safety

4.5

Engine start up safety

4.6

Machine operating safety

4.7

Machine parking safety

4.8

Machine transporting safety

4.9

Machine towing safety

4.10 Machine maintenance safety 4.11 Machine welding safety 4.12 Safety guidelines to be observed when working on the attachment 4.13 Safety guidelines to be observed when loading the machine with a crane 4.14 Safe maintenance of hydraulic hoses and lines 4.15 Safety guidelines for maintenance work on the machine with hydro accumulators 4.16 Roll over protection (ROPS) and falling object protection (FOPS) 4.17 Attachments and components 4.18 Protection from vibration

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Safety guidelines

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General Service fluids

1.3.00 Service fluids Note! See Operating instructions

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Service Manual

Service fluids

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General Tightening torques

1.4.01 Tightening torques 1

General information The preload values and tightening torques noted in the chart have been taken from the VDI guidelines 2230 of July 1986. Installation preload values FM and tightening torques MA for shoulder studs with standard metric or fine thread per DIN ISO 262 and DIN ISO 965 T2 (replacement for DIN 13 part 13) and wrench sizes for hex head screws with shaft DIN EN 24014 (replacement for DIN 931 part 1) or socket head screws DIN EN ISO 4762 (replacement for DIN 912) The chart values are valid for screws with surface: -

black or phosphated – lubricated

-

zinc plated – lubricated

-

flZn per LH-Norm 10021432 - dry (replaces DACROMET 500).

Medium friction value

G

= 0,12

Note! Any tightening torque values and/ or tightening procedures noted in drawings / parts lists, instructions or component descriptions must be adhered to and given preference over factory standards. Beginning with grade 10.9, the use of lock washers does no longer provide any safety action. Always use correctly sized torque wrenches – the torque value according to the chart should be within the upper third of the existing range. when using impact werenches, care must be taken so that the torque values are not exceeded – Check before and intermediately with a torque wrench. Note! The tightening torques for the following components are listed in the corresponding sections in detail: Hydraulic cylinder – see section 8.8. Track chain pad and sprocket screws, see 12.1

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General

Service Manual

Tightening torques

2 Standard metric thread

Preload values and tightening torques with standard metric thread according to WN 4037 I Preload Values Fm based on screw grades and are given in N

Tightening torques Ma are based on screw grades and are given in Nm

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

Socket head screws

8.8

10.9

12.9

8.8

10.9

12.9

mm

Zoll

mm

Zoll

M4

x 0,7

4050

6000

7000

2,8

4,1

4,8

7

9/32

3

--

M5

x 0,8

6600

9700

11400

5,5

8,1

9,5

8

5/16

4

5/32

M6

x1

9400

13700

16100

9,5

14

16,5

10

--

5

--

M7

x1

13700

20100

23500

15,5

23

27

11

--

--

--

M8

x 1,25

17200

25000

29500

23

34

40

13

1/2

6

--

M 10

x 1,5

27500

40000

47000

46

68

79

(17) 16

(11/16)--

8

5/16

M 12

x 1,75

40000

59000

69000

79

117

135

(19) 18

(3/4) - -

10

--

M 14

x2

55000

80000

94000

125

185

215

(22) 21

(7/8) - -

12

--

M 16

x2

75000

111000

130000

195

280

330

24

--

14

9/16

M 18

x 2,5

94000

135000

157000

280

390

460

27

1-1/16

14

9/16

M 20

x 2,5

121000

173000

202000

390

560

650

30

1-3/16

17

--

M 22

x 2,5

152000

216000

250000

530

750

880

(32) 34

--

17

--

M 24

x3

175000

249000

290000

670

960

1120

36

1-7/16

19

3/4

M 27

x3

230000

330000

385000

1000

1400

1650

41

1-5/8

19

3/4

M 30

x 3,5

280000

400000

465000

1350

1900

2250

46

1-13/16

22

7/8

M 33

x 3,5

350000

495000

580000

1850

2600

3000

50

2

24

--

M 36

x4

410000

580000

680000

2350

3300

3900

55

2-3/16

27

1-1/16

M 39

x4

490000

700000

820000

3000

4300

5100

60

2-3/8

27

1-1/16

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General Tightening torques

3 Fine metric thread

Preload values and tightening torques for screws with fine metric thread according to WN 4037 I Preload Values Fm based on screw grades and are given in N

Tightening torques Ma are based on screw grades and are given in Nm

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

Socket head screws

8.8

10.9

12.9

8.8

10.9

12.9

mm

Zoll

mm

Zoll

M8

x1

18800

27500

32500

24,5

36

43

13

1/2

6

--

M9

x1

24800

36500

42500

36

53

62

--

--

--

--

M 10

x1

31500

46500

54000

52

76

89

17

11/16

8

5/16

M 10

x 1,25

29500

43000

51000

49

72

84

17

11/16

8

5/16

M 12

x 1,25

45000

66000

77000

87

125

150

19

3/4

10

--

M 12

x 1,5

42500

62000

73000

83

122

145

19

3/4

10

--

M 14

x 1,5

61000

89000

104000

135

200

235

22

7/8

12

--

M 16

x 1,5

82000

121000

141000

205

300

360

24

--

14

9/16

M 18

x 1,5

110000

157000

184000

310

440

520

27

1-1/16

14

9/16

M 18

x2

102000

146000

170000

290

420

490

27

1-1/16

14

9/16

M 20

x 1,5

139000

199000

232000

430

620

720

30

1-3/16

17

--

M 22

x 1,5

171000

245000

285000

580

820

960

32

--

17

--

M 24

x 1,5

207000

295000

346000

760

1090

1270

36

1-7/16

19

3/4

M 24

x2

196000

280000

325000

730

1040

1220

36

1-7/16

19

3/4

M 27

x 1,5

267000

381000

445000

1110

1580

1850

41

1-5/8

19

3/4

M 27

x2

255000

365000

425000

1070

1500

1800

41

1-5/8

19

3/4

M 30

x 1,5

335000

477000

558000

1540

2190

2560

46

1-13/16

22

7/8

M 30

x2

321000

457000

534000

1490

2120

2480

46

1-13/16

22

7/8

M 33

x 1,5

410000

584000

683000

2050

2920

3420

50

2

24

--

M 33

x2

395000

560000

660000

2000

2800

3300

50

2

24

--

M 36

x 1,5

492000

701000

820000

2680

3820

4470

55

2-3/16

27

1-1/16

M 36

x3

440000

630000

740000

2500

3500

4100

55

2-3/16

27

1-1/16

M 39

x 1,5

582000

830000

971000

3430

4890

5720

60

2-3/8

27

1-1/16

M 39

x3

530000

750000

880000

3200

4600

5300

60

2-3/8

27

1-1/16

4

Tightening torques for cutting edges, end bits and bolt- on adapters inch 5/8" 3/4" 7/8" 1" 1-1/4"

mm 16 19 22 25 32

Tightening torque [Nm] ±40

270 475±60 750±90 1125±150 1850±300

Tightening torque [ft. lbs.] 200±30 350±45 550±65 825±110 1350±220

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Tightening torques

5

Tightening torque for screws to mount SAE flange Note! Not part of WN 4037 I Listing according to LFR – Quality service 2QA 6 051 00 as of Oct. 2001

5.1

5.2

Flanges and half flanges for high pressure (Norm 62) Tightening torque in Nm for screws grade 10.9

Flange – Nominal size

Screw size

½" ¾" 1" 1 ¼" 1 ½" 2"

M8 M 10 M 12 M 14 M 16 M 20

Flat flange without Flange with reinforcement rim reinforcement rim

Half flange 31 62 108 172 264 350

-45 70 120 170 250

-65 110 180 250 450

Half flanges 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 torque 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

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General Conversion chart

1.4.02 Conversion chart Unit of measure

Multiply

by

to obtain – Multiply inch

by

to obtain

25,4

mm

feet

0,305

m

1,093

yard

0,914

m

km

0,621

mile

1,609

km

cm²

0,155

sq. inch

6,452

cm²

10,764

sq. feet

0,093

1,196

sq. yard

0,863

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

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

Pressure

bar

14,5

PSI

0,069

bar

(hydraulic)

kpa

0,145

PSI

6,896

kpa

0,0703

kg/cm²

Length

Area

Volume

Weight

Force

Ground pressure Compression Speed Temperature

mm

0,039

m

3,281

m

kg/cm²

14,223

lbs.inch

2

2

l

kg/m²

0,205

lbs. ft.

4,878

kg/m²

g/cm³

0,036

lbs. inch3

27,78

g/cm³

3

kg/m³

0,062

lbs. ft.

16,13

kg/m³

km/h

0,621

Mph

1,609

km/h

m/min

3,281

ft. / min

0,305

m/min

°C

(°Cx1,8) + 32

°F

(°F-32)/1,8

°C

°C

°C+273

°K

°K-273

°C

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Conversion chart

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Service Manual

General Tapping holes

1.4.03 Tapping holes 1

Hole diameter for tapping ISO standard metric threads 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 Ă˜ 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˜ 0,75 0,85 0,95 1,1 1,25 1,30 1,45 1,6 1,75 1,9 2,05 2,10 2,5 2,9 3,3 3,7 4,2 5 6 6,8 7,8 8,5 9,6 10,2 12 14 15,5 17,5 19,5 21 24 26,5 29,5 32 35 37,5 40,5 43,0 47,0 50,5 54,1 57,6 61,6

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Service Manual

Tapping holes

2

Hole diameter for tapping ISO metric fine 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

Hole diameter Ø 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

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

Thread size M 25 x 1 M 25 x 1,5 M 25 x 2 M 26 x 1,5 M 27 x 1 M 27 x 1,5 M 27 x 2 M 28 x 1 M 28 x 1,5 M 28 x 2 M 30 x 1 M 30 x 1,5 M 30 x 2 M 30 x 3 M 32 x 1,5 M 32 x 2 M 33 x 1,5 M 33 x 2 M 33 x 3 M 35 x 1,5 M 36 x 1,5 M 36 x 2 M 36 x 3 M 38 x 1,5 M 39 x 1,5 M 39 x 2 M 39 x 3 M 40 x 1,5 M 40 x 2 M 40 x 3 M 42 x 1,5 M 42 x 2 M 42 x 3 M 42 x 4 M 45 x 1,5 M 43 x 2 M 45 x 3 M 45 x 4 M 48 x 1,5 M 48 x 2 M 48 x 3 M 48 x 4 M 50 x 1,5 M 50 x 2 M 50 x 3 M 52 x 1,5 M 52 x 2 M 52 x 3 M 52 x 4 M 24 x 1,5 M 24 x 2

Hole diameter Ø 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 22,676 22,376 22,210 21,835

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Drill bit Ø 24 23,5 23 24,5 26 25,5 25 27 26,5 26 29 28,5 28 27 30,5 30 31,5 31 30 33,5 34,5 34 33 36,5 37,5 37 36 38,5 38 37 40,5 40 39 38 43,5 43 42 41 46,5 46 45 44 48,5 48 47 50,5 50 49 48 22,5 22


Service Manual

General Conservation guidelines

1.5.00 Conservation guidelines 1

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

2

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

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Conservation guidelines

3

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

3.1

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

Id. No. See section 2.1

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

WAXOYL 120-4 Anti corrosion wax

8504472

Ballistol Spray Corrosion protection Dehumidification capsule

10025514

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

10013313

Display

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

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General Conservation guidelines

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

3.2

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

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Conservation guidelines

3.3

Shut down for longer than 12 months Carry out all measures according to paragraph 3.1 and 3.2. In addition, the following is required: Note! If a shut down for longer than 12 months is scheduled, then contact the Service Dept. of the Diesel engine manufacturer. Close off all openings, such as air filter, exhaust pipe, vent openings on components, etc. airtight. The vent for the fuel tank (if present) must remain open for safety reasons! Rub the rubber seal of the cab and containers with talcum powder, close the doors. If the cab is not installed, cover the operator’s platform properly. If necessary, remove the operator’s seat. Cover the instrument panel and protect it.

4 4.1

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

4.2

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

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General Conservation guidelines

4.3

After shut down of longer than 12 months Complete all items outlined in paragraph 4.2 and 4.1. Note! After a scheduled shut down of longer than 12 months contact the Service Dept. of the Diesel engine manufacturer. Remove all covers and closures, which were installed for conservation measures. Turn the Diesel engine manually a few turns (use the turning device - flywheel – see Special tools). Start the machine and bring it to operating temperature. After the machine was brought to operating temperature, change all lube and service fluids as well as filters according to the Operating instructions Check the entire machine for function and for leaks. If necessary, carry out any time limited maintenance work at this time.

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General Material weights

1.6.01 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

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

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Material weights

Material Weathered rock 75% rock, 25% soil Weathered rock 50% rock, 50% Soil Weathered rock 25% rock, 75% Soil

A

B

C

D

2790

42

0,70

1960

2280

33

0,75

1720

1960

24

0,80

1570

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

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Tools and application remarks Sub group index Tools and application remarks

2 Tools and application remarks 2.0.00 Sub group index Tools and application remarks Special Tools ................................................................................................. 2.1 Repair welding ............................................................................................... 2.2 Installation instructions ................................................................................ 2.3

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Sub group index Tools and application remarks

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Tools and work instructions Special tools

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

1 1.1

Special tools - maintenance Diesel engine

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

Communication cable for LH-ECU-UPCR – control units

Communication cable for DC4 / DC5 – control units

Id. No.

10450054

M-Type

Remarks

LR Series 4 RL Series 4 PR 724 S/Nxxx9200 PR 734 S/Nxxx8220 PR 744 S/Nxxx7356 PR 754 S/Nxxx6924 PR 764 S/Nxxx6888

10035410

10035411

LR Series 4 RL Series 4 PR 724 S/Nxxx9200 PR 734 S/Nxxx8220 PR 744 S/Nxxx7356 PR 754 S/Nxxx6924 PR 764 S/Nxxx9506 PR 764 S/Nxxx6888 9505

Illustration

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

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

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Tools and work instructions

Service Manual

Special tools

Description Digital RPM gauge „Shimpo“

Id. No. 7364284

M-Type

Remarks

Illustration

PR Series 4 LR Series 4 RL Series 4

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

Reflexion strip

614063201

Digital RPM gauge „Piezzo A2106“

10286429

PR 724 S/Nxxx6600 9199 PR 734 S/Nxxx6200 8219 PR 764 S/Nxxx6888 9505

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

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

5608459

PR 724 S/Nxxx6600 9199 PR 734 S/Nxxx6200 8219 PR 764 S/Nxxx6888 9505

To check the DCA4 concentration in the coolant

Hand pump [1]

8145666

PR Series 4 LR Series 4 RL Series 4

To take oil samples for oil analysis

Oil sample valve for oil samples [2]

7019068

PR Series 4 LR Series 4 RL Series 4

Analysis at WEAR CHECK Germany

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

8145660 10029626 7018368 7018369

7026817 7026088

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Service Manual

Tools and work instructions Special tools

Description

Id. No.

M-Type

Remarks

V-belt tester „Krikit2“

8042829

PR Series 4 LR Series 4 RL Series 4

To check the Vbelt tension

Optical battery charge tester

7408922

PR Series 4 LR Series 4 RL Series 4

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

0524045

LR Series 4

To be installed on the flywheel housing instead of the cover

Illustration

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

RL Series 4 PR Series 4 except Pos. 2

10490350 10116805

Hand pump with pressure gauge

10454803

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

To be installed on the V-belt crankshaft

PR Series 4 LR Series 4 RL Series 4

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

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Special tools

1.2

Hydraulic system

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

Id. No. 7408148

M-Type

Remarks

PR Series 4 LR Series 4 RL Series 4

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

PR Series 4 LR Series 4 RL Series 4

Accuracy: 2% / 2°

7407987 7407985 10301165 7404619 4901110 7360127 10038447 10038448 7408151 10024185

Illustration

Test range: -18°C to +260°C

Difference pressure test kit 230V/120V

10288229

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

5002865 7361289 7361288 5002867 5602903 7361286 7361285 7500002 7361294 4601115

PR Series 4 LR Series 4 RL Series 4

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

PR Series 4 LR Series 4 RL Series 4

Accuracy: 1% of scale limit value All pressure gauges are „glycerin filled“

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Service Manual

Tools and work instructions Special tools

Description Pressure gauge connection R½

Id. No. 7002436

Test fitting cpl. R6L R 10 L R 12 L

7409916 7406864 7409918

Screw coupling M 8x1 M 10x1 M 12x1,5 M 14x1,5 RÂź

7615321 5608462 7407071 7406865 7409720

Bulkhead screw coupling M 16x2

Remarks

PR Series 4 LR Series 4 RL Series 4

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

PR Series 4 LR Series 4 RL Series 4

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

PR Series 4 LR Series 4 RL Series 4

To connect to additional test points on the machine

PR Series 4 LR Series 4 RL Series 4

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

PR Series 4 LR Series 4 RL Series 4

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

PR Series 4 LR Series 4 RL Series 4

To loosen / counter when setting the pump regulating range

PR Series 4 LR Series 4 RL Series 4

To loosen / counter when adjusting the pump limit stop

7407070

Test hose NW 2 1000 mm 1500 mm 4000 mm 5000 mm

M-Type

7002437 7002475 7009134 7363732

Hook wrench 58 - 62 mm

7900282

Socket wrench for grooved nut variable displacement pump HPV

9792711

Illustration

Use with hook wrench Id. No. 7900282

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Service Manual

Special tools

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

Id. No. 9749025

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

7370092

M-Type

Remarks

PR Series 4 LR Series 4 RL Series 4

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

PR Series 4 LR Series 4 RL Series 4

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

PR 724 S/Nxxx6600 9199 PR 734 S/Nxxx6200 8219 PR 764 S/Nxxx6888 9505

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

7370093

7370094

Or make in-house 8006305

Illustration

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Service Manual

Tools and work instructions Special tools

1.3

Electrical system

Description LinDiag Diagnostics KIT

Id. No. 9413782

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

9410472

LinDiag Diagnostics KIT

9413763

M-Type

Remarks

PR 724 S/Nxxx6600 9199 PR 734 S/Nxxx6200 8219 PR 764 S/Nxxx6888 9505

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

LR Series 4 RL Series 4

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

9932747

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

10035410

USB – adapter

693190714

PR Series 4 LR Series 4 RL Series 4

Intermediate adapter from serial interface to USB

Digital multi meter complete with cable and bag

10018500

PR Series 4 LR Series 4 RL Series 4

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

see Pt. 1.1 Diesel engine

PR Series 4 LR Series 4 RL Series 4

To check the battery charge and the antifreeze in the coolant

Optical charge tester

9410472

PR 724 S/Nxxx9200 PR 734 S/Nxxx8220 PR 744 S/Nxxx7356 PR 754 S/Nxxx6924 PR 764 S/Nxxx9506

Illustration

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Tools and work instructions

Service Manual

Special tools

1.4

Mechanical components

Description

Id. No.

Test tool for tracks

7402603

M-Type

Remarks

Illustration

PR Series 4 LR Series 4 RL Series 4

To measure track wear For applications, see section 12.2

2 2.1

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

2.2

Hydraulic system

Description Pressurized air cartridge

Brake vent adapter

Id. No. 10045498

9401975

Socket wrench Valve sleeve Valve – 3 Slits

10430260

Valve – 2 Slits

10491131

M-Type

Remarks

LR Series 4 RL Series 4

CO2 cartridge to vent the parking brake for towing operation.

PR 724 S/Nxxx7697 PR 734 S/Nxxx8220 PR 744 S/Nxxx7356 PR 754 S/Nxxx6924 PR 764 S/Nxxx6888

PR Series 4 LR Series 4 RL Series 4

Illustration

Adapter for pressurized air cartridge (part of tool kit)

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

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Service Manual

Tools and work instructions Special tools

Description

Id. No.

M-Type

Mandrel Thrust ring HPV 105

10472254

HPV 135

10472255

HPV 210

10472257

HMV 165

10472261

HMV 210

10472266

HPV 280

10472269

HMV 280

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

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

Remarks

Illustration

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

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

HPV 105 HPV 105

1 2

10472303 10411001

PR 724 LR 624

HPV 135 HPV 135

1 2

10472310 10411002

HMV 165 HMV 165

1 2

10472316 10410291

PR 734 LR 634 RL 44 PR 744 LR 624

HMV 210

1

10472317

HPV 210

1

HMV 210

2

HPV 210

2

HMV 280

1

HPV 280

1

HMV 280

2

HPV 280

2

10410295

10472318

10411003

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

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

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Tools and work instructions

Service Manual

Special tools

Description

Id. No.

M-Type

Installation aid seal ring on oil guide tubes Pos.1 HPV + HMV

10472322

Pos.2 HPV 105

10472321

Spindle device for swash plate mount

10324938

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

PR Series 4 LR Series 4 RL Series 4

Remarks

Illustration

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

With this device, the swash plate mount can be aligned and lowered properly onto the pump housing at installation. Centering pins for swash plate mount M12

HPV

10472319

M14

HPV

10472320

M14

HMV

M16

HPV

M16

HMV

10347066

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

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

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Service Manual

Tools and work instructions Special tools

Description

Id. No.

Centering device for swash plate mount

10324937

M-Type

Remarks

PR Series 4 LR Series 4 RL Series 4

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

Illustration

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

See spare parts list

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

Spreader sleeve

See spare parts list

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

Installation wrench Piston

See spare parts list

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

Installation wrench Piston nut

See spare parts list

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

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Tools and work instructions

Service Manual

Special tools

2.3

Electrical system

Description

Id. No.

Crimper for MATE-N-LOK Crimp contacts

M-Type

Remarks

Illustration

PR Series 4 LR Series 4 RL Series 4

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

PR Series 4 LR Series 4 RL Series 4

To remove crimp contacts from plug connector

For 1.5 mm² For 2.5 mm²

7367025 7366314

Removal tool AMP for MATE-N-LOK Crimp contacts

7366655

Spare insert

7015180

Installation tool AMP for MATE-N-LOK Crimp contacts

8145432

PR Series 4 LR Series 4 RL Series 4

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

Hand crimper for plug connector „Deutsch“

8503647

PR Series 4 LR Series 4 RL Series 4

To make proper crimp connections

PR Series 4 LR Series 4 RL Series 4

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

PR Series 4 LR Series 4 RL Series 4

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

Removal tool Cannon for Crimp contacts „Deutsch“ AWG 12 AWG 16 AWG 20

10114733 885563714 10114732

Removal tool Cannon for Crimp contacts „Deutsch“ (Alternative) AWG 12 AWG 16 AWG 20

8145674 8145673 8503630

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Service Manual

Tools and work instructions Special tools

Description Crimper AMP AMP Certi-Lock

Id. No. 7415333

Removal tool AMP AMP 726 503-1 AMP 726 534-1

7026266 7027340

Crimper ESA 0760 CRB 0560

7409781 7409782

M-Type

Remarks

PR Series 4 LR Series 4 RL Series 4

To crimp the contacts „JUNIOR POWER TIMER“

PR Series 4 LR Series 4 RL Series 4

To remove contacts from „JUNIOR POWER TIMER“ housing

PR Series 4 LR Series 4 RL Series 4

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

Coding plug Inching / brake pedal X46

9813111

X46.1

9413850

PR Series 4 RL Series 4 LR Series 4

Illustration

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

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Tools and work instructions

Service Manual

Special tools

2.4

Mechanical components

Description

Id. No.

M-Type

FAT 450 E 504/505 FAT 450 E 510 Slip ring seal Id.No. 7109 25201 outside 7109 26301 inside FAT 500 E 502/503 FAT 500 E 517/518 Slip ring seal Id.No. 7610 242 outside 7361 197 inside FAT 600 E 506 Slip ring seal Id.No. 7610 244 outside 7610 240 inside FAT 650 E 508 Slip ring seal Id.No. 7610 245 outside 7610 241 inside FAT 700 E 501 Slip ring seal Id.No. 7610 237 outside 7610 243 inside

LR 624 Device No.: 07590 45459 07590 45458

10467795 10467796 PR 724 LR 634

Device No.: 07590 38616 07590 43327

10219780 10219779 PR 734 RL 44

Device No.: 07590 39022 07590 43326

10017428 10219781 PR 744

Device No.: 07590 38891 07590 38472

10017436 10303340 PR 754 RL 64 10017433 10017472

B

Pos.2 Screw in handle for all installation flanges

Device No.: 07590 39023 00100 01300

PR 764 Device No.: 07590 41338 07590 38886

10017468 10017430

Mandrel Pos.1 Installation flange A

Illustration

To properly install the slip ring seals on travel gears

Installation device for slip ring seal – travel gear FAT 400 E 511 Slip ring seal Id.No. 7361 197 outside 7109 24901 inside

Remarks

9786683 9786685 9786686

9786684 9786687 9411074

9786688

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

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

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Service Manual

Tools and work instructions Special tools

Description

Id. No.

Puller

Commercially available tool

M-Type

Remarks

PR Series 4

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

PR Series 4 LR Series 4 RL Series 4

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

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

A B C D

PR 724

PR 734

90 70 247 89,5

90 70 273 96

Puller Elastic bearing – operator’s platform

Installation sleeve Equalizer bar bearing

PR744 PR754 PR764 120 90 273 114

9404645

9415227

In-house manufacture

Installation wrench Tension unit

Installation tool Tension unit

Illustration

9416915

PR 764

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

9416913

PR 764

9416922

PR 754 RL 64

9416921

PR 764

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

Special hook wrench to loosen and attach the ring nut

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

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Tools and work instructions

Service Manual

Special tools

Description

Id. No.

M-Type

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

Installation tool Tension unit Pos.1 Installation flange Pos.2 Bar Pos.3 Hex head screw 6 each M16x310 mm – 10.9

9798353 9798352 4601217

PR 754 RL 64

Installation tool cpl.

9415198

PR 764

Mechanical device (without hydraulic components)

10303939

LR Series 4

10307625

RL 44

Hydraulic components for installation tool

10303852

LR Series 4 RL 44

Illustration

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

Installation tool Tension unit

For application, see section 12 Tension unit

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

Hand pump

Hydraulic hose

Pressure gauge

Enerpac RC 506 (50 t simple acting)

Enerpac P80 (two stage hand pump)

Enerpac HC-7206

Enerpac GF-50B

Piston surface

71,2 cm3

Operating pressure max.700ba

Oil volume

1131cm3

Lever force max.

47.0kg

Weight

10.9kg

Weight Overall height Retracted Extended outside

23,1kg

9,5 x 1800mm

Pressure range 0-700bar

282mm 441mm 127mm

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Service Manual

Tools and work instructions Special tools

Description Installation sleeve Equalizer bar

Id. No.

M-Type

Remarks

Illustration

10306449

PR 754

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

3 3.1

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

Fig. 1 Dimensions of installation sleeves

Type

Machine

1

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

2 3

A

B

C

D

E

F

G

H

100

130

75

---

---

---

---

---

---

120

150

100

---

---

---

---

---

---

81,5

137

120

91

115

35

7

13

129

83

149

120

101

135

---

7,5

12,8

---

I

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Tools and work instructions

Service Manual

Special tools

3.2

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

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

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

M-Type

Punch

PR724

A B A B A B A B A B

PR734 PR744 PR754 PR764

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

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

F 13 9 14 11 14 12 14 12 14 12

G 23 18 23 18 23 18 23 18 23 18

* Edges rounded off All dimensions in [mm]

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Service Manual

Tools and work instructions Special tools

3.3

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

Fig. 3

Dimensions of removal tool

1 Threaded rod M30 2 Sleeve 3 Washer

3.4

4 Washer 5 Shim M30 6 Nut M30

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

Fig. 4 Dimensions of installation sleeve for equalizer bar

Continuous fillet weld 4mm

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Service Manual

Special tools

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Service Manual

Tools and application remarks Repair welding

2.2.00 Repair welding Before starting any welding work on LR 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 crack The crack must be free of paint, grease and any kind of dirt. To prevent the crack from extending duing the preparation and the welding procedure, the end of the cracks should be drilled with a hole (of at least 8 mm Ø). Then the crack must be ground out, torch cut or arced to an approx. 60° angle. Be certain that the edges are cleanand extend through the full cross section of the material, without exceeding the 1mm space in the lower part. For larger grooves, a welding safety should be installed.

Fig. 1

Ground / drilled crack

Certain materials must be preheated to approx. 150°C prior to welding. Special preparation is 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 an water cooled grinding wheel ot prevent overheating. Note! Another possiblity to prepare cracks or remove high alloy welding seems is 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 ara to be welded must be sufficiently covered. Material with a thickness above 15 mm and high cabon steel (carbon content more than 0.22 %) and steel which is difficult to weld must be preheated to approx. 80°- 200°C. Preheating is also necessary when the component temperature is less than+5°C or when the construction of the component prevents the welding stress to be released.

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Tools and application remarks

Service Manual

Repair welding

3

Treatment of electrodes Use only dry electrodes for welding. Electrodes which are rusty or damaged should not be used. Electrodes should be stored in a dry room with a minimum temperature of 15°C. Open packages should be carefully closed and stored immediately after welding work is completed.

4

Welding technique The welding of material with the necessary electrodes (see chart, paragraph 7) is in accordance with DIN 1912. The adjustment of the welding machines – dictated by different diameters of electrodes – can be taken from the chart of the electorde package. Beginning with a material thickness of 8 mm, butt welds must be made in several layers. The weld is applied in several beads. Wide butt welds are filled with several side by side beads, with the last layer covering the center. The electrode should melt evenly without creating burrs and peaks. The valley or crater, which is creates when chaing electrodes must be filled in and overlapped with the next electrode. To prevent cracks in those craters, care must be taken that they are properly filled. If the crack extends towards the outer edge of the material, slap may be trapped or burn holes may be created. To prevent this, the following aid must 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 welding seam must cool off slowly and should therefore be protectd from rain and wind.

Fig. 2

Crack running towards to outer edge of the material / Prepared crack

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Tools and application remarks Repair welding

5

Reinforcement of welding seam If the crack of the material is due to on overload or abuse, a reinforcement plate should be welded over the crack. The selection of the correct reinforcement plate is based on the construction and load factors of the component to be repaird. For that rason, only genral recommendations can be made as to the size and shape of the reinforcement plates.

5.1

Shape of plate The crossover or connection between the reinforced and not reinforced part should be as gradual as possible, this means that the size of the plate should be selected in such a way that new or unacceptable high stress in the repaired part is avoided. Plates with sharp corners (such as a rectangular plate) should not be used.

Fig. 3 Reinforcement plate against clean pulling / bending and alternating loads

5.2

Plate thickness The thickness of the reinforcement plate should be up to 2/3 of the thickness of the material to be reinforced.

5.3

Plate quality The yield and tensile strength of the reinforcement plate should be equal to the material to be reinforced.

5.4

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 o fthe material to be reinforced. The plate should also overlap the crack on each side by at least 20 mm. The corect position and fit of the reinforcement plate is achieved by clamping and spot welding.

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5.5

Plate welding The reinforcement plate should be welded on by runnign a welding bead alternately on both sides. The welding should always start in the middle of the plate and run towards the outside. Be certain to observe that each welding seam has proper run out. Welding direction

Fig. 4

Welding directions

The size of the welding run "a" is figured out in reference to the thickness "k" of the reinforcement plate. Use formula: a=0.5 k Up to a welding run "a" of approx. 3 mmm, a single run can be made, however, as a general rule, a double run should be preferred. Above a welding run "a" = 3 mm, the first run provides excellent penetration between the reinforcement plate and the basic material. Subsequent runs are added on top of the first run.

Fig. 5

3- or 1- run welding seam

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

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6

Selection of correct welding electrodes For repair welding, only lime based (Kb) electrodes should be used, and as a rule, the electrodes (additonal material) should be "softer" than the basic material. Exceptions to this ruse should be observed. Note! To reach the theoretical welding quality, the work must not only be performed in a professional manner, the electrode manufacturer’s guidelines must be strictly observed as well. Caution! Welding of vertical-down welds is not permitted for steel components!

6.1 Electrode selection Electrode Norm description

Shielding gas weld welding wire Norm description

Welding area

Material

BASIC MACHINE Track Main frame

St 52 - 3 QStE 380 N

per EN 499: E42 5 B 4 2 H5 per AWS A5.1-91: E7018-1 H4 R LH 690 per EN 757: Preheat to approx. E 69 6 Mn2NiCrMo B 4 2 H5 100-150°C . per AWS A5.5-96: E 11018-G

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

ATTACHMENT Dozer blade Bucket

Q St E 380 N HARDOX 400

per EN 499: E42 5 B 4 2 H5 per AWS A5.1-91: E7018-1 H4 R St 52 - 3 per EN 499: E42 5 B 4 2 H5 per AWS A5.1-91: E7018-1 H4 R LH 690 per EN 757: auf ca. 100-150°C E 69 6 Mn2NiCrMo B 4 2 H5 vorwärmen. per AWS A5.5-96: E 11018-G St 52 - 3 per EN 499: Q St E 380 N E42 5 B 4 2 H5 HARDOX 400 per AWS A5.1-91: E7018-1 H4 R

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

Special steel

Root runs per EN 440: G4Si1 per AWS A5.18-93: ER 70 S-6 Cover runs with high tensile welding wire per EN 12072: G 18 8 Mn per AWS A5.9-93: ER307

Push frame Bucket arm RL-boom

Ripper

WEAR ITEMS Adapter Tooth adapter Ripper

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

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6.2 Steel chart Item

Description

Analysis

HARDOX 400

Weldable, low alloy special steel with high wear resistancan, tensile strength of 1250 N/mm² and a yiel strength limit of 1000 N/mm²

C 0,27% Si 0,7% Mn 1,6% Cr 1,4% Mo 0,6%

Q St E 380 N

Fine grain structural steel poured at special low turbulence with a guaranteed miniumum tensile strenght of 500 - 640 N/mm² and minimum yield strength limit of 380 N/mm² Highly abrasion restiant steel with a tensile strength of 1720 N/mm²

C 0,18% Si 0,5% Mn 1,6%

Special steel

St 52 - 3 S355J2G3 LH 690

C = 0,3% Mn = 0,7% Si = 0,5% Cu = 0,65% Mo = 0,3% V = 0,05% C 0,22%

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

6.3 Welding chart for arc welding Item per EN 499: E42 5 B 4 2 H5 such as Böhler FOX EV 50

per EN 757: E 69 6 Mn2NiCrMo B 4 2 H5 such as Böhler FOX EV 85

per EN 1600: E 18 8 Mn B 2 2 such as Böhler FOX A 7

Description E = Arc welding 42 = 500-640 N/mm² Tensile strength 5 = Value for notch impact strength B = basic shielded 4 = Value for run out and type of curent 2 = Value for welding positions H5 = maximum hydrogen content E = Arc welding 69 = 760-960 N/mm² Tensile strength 6 = Value for notch impact strength Mn2NiCrMo = Chemical properties B = basic shielded 4 = Value for run out and type of current 2 = Value for welding positions H5 = maximum hydrogen content

E = Arc welding 18 = 620-770 N/mm² Tensile strength 8 = Value for notch impact strength Mn = Chemical properties B = basic shielded 2 = Value for run out and type of current 2 = Value for welding positions

Analysis values in % / Application C = 0,07, Si = 0,5, Mn = 1,1 For connection and applied welds, especially for steels with low purity and higher carbon content. Weldable with DC current, Electrode on Plus terminal (+). No vertical seams C = 0,05, Si = 0,4, Mn = 1,5, Cr = 0,4, Ni = 2,0, Mo = 0,5 For welds, which require high tenacity and crack resistance, use for highly alloyed fine grain steel. Very low hydrogen content in welding material. Weldable with DC current, Electrode on Plus terminal (+). No vertical seams C = 0,1, Si = 0,7, Mn = 6,5, Cr = 18,8, Ni = 8,8 For connections between different alloyed and difficult to weld steel Weldable with DC current, Electrode on Plus terminal (+). No vertical seams

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Tools and application remarks Repair welding

6.4 Welding chart for metal inert gas weld with solid wire electrodes Item per EN 440: G4Si1 such as Böhler EMK 8

per EN 12534: G3CrNi1Mo such as Böhler X 70 - IG

per EN 12072: G 18 8 Mn such as Böhler A7 IG

Description G = Metal inert gas weld with solid wire electrodes 4 = 500-640 N/mm² Tensile strength Si = Chemical properties 1 = Value for run out and type of current

G = Metal inert gas weld with solid wire electrodes 3 = 900 N/mm² Tensile strength CrNi1Mo = Chemical properties

G = Metal inert gas weld with solid wire electrodes 18 = 580-730 N/mm² Tensile strength 8 = Value for notch impact strength Mn = Chemical properties

Analysis values in % / Application C = 0,1, Si = 1,0, Mn = 1,7 For connection and applied welds, especially for steels with low purity and higher carbon content. Weldable with DC current, Electrode on Plus terminal (+). Shielding gas: Argon + 15-20% CO2 or 100% CO2 No vertical seams C = 0,1, Si = 0,6, Mn = 1,6, Cr = 0,25, Ni = 1,3, Mo = 0,25, V = 0,1 For welds, which require high tenacity and crack resistance, use for highly alloyed fine grain steel. Weldable with DC current, Electrode on Plus terminal (+). Shielding gas: Argon + 15-20% CO2 or 100% CO2 No vertical seams C = 0,08, Si = 0,9, Mn = 7,0, Cr = 19,2, Ni = 9,0 For connections between different alloyed an difficult to weld steel Weldable with DC current, Electrode on Plus terminal (+). Shielding gas: Argon + max. 2,5% CO2 No vertical seams

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Tools and installation instructions Installation instructions

2.3.00 Installation instructions 1 1.1

Slipring seals Design and function Due to the pretension of the O-rings 2, the two 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

Fig. 1

1 2 3 4

Seal variations

Seal mount O-ring Slipring Gliding surface

Note! Only seals toward the outside are used in the machines of the Series 4, because of design reasons.

1.2 1.2.1

Installation 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. Slipring seals should be installed generally with the aid of an installation device, see Special Tools, section 2.1

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.

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Installation instructions

Installation position correct

Installation position incorrect O-ring twisted

Fig. 2

1.3

Installation position incorrect Seal half is crooked

O-ring installation positions

Installation of 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.

Fig. 3

1 2 3

Seal mount O-ring Slipring

Installation slipring seal

5 6

Installation device Aid – round rubber string

Before the components are assembled, check if the seal rings protrude evenly. Measure the distance from the seal seat to the seal ring on at least 3 locations, 120° apart. Check the sealing surfaces again to ensure they are clean and lightly lubricated.

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Tools and installation instructions Installation instructions

2

Safety lever

Fig. 4

1 2 3

Safety lever Hex nut Allen screw

Installation of safety lever

4 5

Hex nut Limit switch

To ensure a safe and error free function of the safety lever, the following must be observed at installation: When the safety lever is in the down position, adjust the Allen screw 3 on the limit switch 5. Tighten the hex nut 2 to the tightening torque (see section 1.4) and then open by 1.5 to 2 turns. Tighten the hex nut 4 to the tightening torque (see section 1.4) and then open by 0.5 turn.

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Technical data and maintenance guidelines Sub group index Technical data and maintenance guidelines

3 Technical data and maintenance guidelines 3.0.00 Sub group index Technical data and maintenance guidelines Technical data................................................................................................ 3.1 Maintenance and inspection schedule ........................................................ 3.2 Maintenance and inspection guidelines...................................................... 3.3 Quick reference for machine adjustment .................................................... 3.4 Adjustment check list ................................................................................... 3.5

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Technical data and Maintenance guidelines Technical data

3.1.20 Technical data LR 624 DIESEL ENGINE Type Version Performance Nominal RPM Low idle RPM High idle RPM Displacement Oil quantity / incl. filter Oil quality / viscosity Max. permissible machine incline – all directions Valve clearance - cold Firing order Coolant Fuel tank contents

D934 S A6 4 – Cylinder in-line engine, charge air cooled kW 105 1/min 1800 1/min 800 +30/-30 1/min 1918 +30/-30 l 6,4 See Operating Instructions: See Operating Instructions: 45 = 100% on / off 0,3 / 0,4 1–3–4–2 See Operating Instructions: See Operating Instructions:

SPLITTERBOX Type Version Ratio Oil quantity Oil quality / viscosity

i

300 B 344 Spur gear 1- stage 0,788 See Operating Instructions: See Operating Instructions:

HYDRAULIC SYSTEM Variable / travel pumps – travel hydraulic Flow - Qmax Operating pressure (M1 / M2) pmax Tandem gear pumps – replenishing – cooling circuit / fan drive Flow replenishing - Qmax Operating pressure (SP) pmax Flow fan drive - Qmax Operating pressure (electronically regulated) - pmax Gear motor fan drive Operating RPM Variable motors – travel hydraulic

Type l/min bar Size l/min bar l/min bar Size 1/min Type

2 x HPV 105 2 x 240 420 56 + 19 128 20 43 185 16 1950 2 x HMV 165

Regulating pump - Working hydraulic Flow - Qmax Stand by pressure (HD) Operating pressure (HD) - pmax Servo control - Working hydraulic Operating pressure (ND)

Type l/min bar bar bar

P-A10V071 162 ±2 20 260 20

Oil capacity – Tank capacity - additional circuit capacity Oil quality / viscosity

See Operating Instructions: See Operating Instructions: See Operating Instructions:

ELECTRICAL SYSTEM Operating voltage Batteries Alternator Starter Central fuse Individual fuses

V

kW A A

24 2 x 12V 170Ah 28V 80A 5,4 45 See Operating Instructions

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Technical data

LR 624 FINAL DRIVE Type Version Parking brake integrated Ratio Oil quantity Oil quality / viscosity

i ges

2 x 400 E511 Spur gear + single state planetary gear Disk brake 44.86 See Operating Instructions: See Operating Instructions:

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

mm /Inch links mm Thread size Qty. Qty. Qty.

190 / 7,48 39 508 / 560 ¾“ UNF 4 2 e-d–e–e–d–e 1 ± 1,5°

WORKING ATTACHMENTS - Cylinders Lift cylinder Cyl. Ø / Rod Ø / Stroke

mm

120 / 70 / 750

Tilt cylinder Cyl. Ø / Rod Ø / Stroke

mm

140 / 80 / 455

Lift cylinder- ripper Cyl. Ø / Rod Ø / Stroke

mm

100 / 60 / 415

Flap cylinder (4 in 1) Cyl. Ø / Rod Ø / Stroke

mm

90 / 50 / 315

GENERAL Travel speed

Normal speed range Reduced speed range

km/h 0 km/h 0

Basic machine:

Height over operator’s cab Total length without attachment Track width (+1 x track pad width = total width) Ground clearance

Operating weight with Standard bucket (dep. on pad widths) [*] Ground pressure (dep. on pad widths) [*] Operating weight with 4 in 1 bucket (dep. on pad widths) [*] Ground pressure (dep. on pad widths) [*] [*] with bolted teeth

mm mm mm mm kg kg/cm² kg kg/cm²

10 6,5

3150 4600 1740 430 17006 (508mm) 0,67 (508mm) 17614 (508mm) 0,70 (508mm)

Buckets Bucket / contents heaped (ISO 7546) Standard bucket / 1.70 m3 Standard bucket / 1.80 m3 3 Standard bucket / 1.80 m 3 4 in 1Schaufel / 1.50 m 4 in 1Schaufel / 1.60 m3 4 in 1Schaufel / 1.60 m3

Width [mm] 2450 2444 2420 2450 2448 2420

with welded teeth with bolted teeth with bottom screw-on cutting edges with welded teeth with bolted teeth with bottom screw-on cutting edges

Weight [kg] 1126 1238 1140 1671 1782 1685

Total length of machine [mm] 6246 6337 6337 6384 6474 6474

Three tooth ripper Length, additional Weight Slope angle

mm kg °

706 919 20

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Technical Data and Maintenance guidelines Technical Data

3.1.30 Technical Data LR 634 DIESEL ENGINE Type Version Output Nominal RPM Low idle RPM Hgh idle RPM Displacement Oil quantity incl.filter Oil specfication / viscosity Max. inclination – all directions Valve play - cold Firing order Coolant Fuel tank capacity

D934 L A6 4 – cylinder in line engine mildly turbocharged kW 135 1/min 1800 1/min 910 1/min 1895 l 7 See Operating Instructions: See Operating Instructions: 45 = 100% In / out 0,3 / 0,4 1–3–4–2 See Operating Instructions: See Operating Instructions:

SPLITTERBOX Type Version Ratio Oil quantity Oil specification / viscosity

i

350 B 374 Spur gear 1- stage 0,86 See Operating Instructions: See Operating Instructions:

HYDRAULIC SYSTEM Var. displ. pumps – Travel hydraulic Max. flow - Qmax Operating pressure (M1 / M2) pmax Tandem gear pumps – replenishing – coolant cirucit / fan drive Max. flow replenishing - Qmax Operating pressure (SP) pmax Max. flow fan drive - Qmax Operating pressure (electronically regulated) - pmax Gear motor – Fan drive Operating RPM Var. displ. motors – Travel hydraulic

Type l/min bar Size l/min bar l/min bar Size 1/min Type

2 x HPV 135 2 x 282 420 56 + 19 117 20 33 170 16 1700 2 x HMV 210

Regulating pump – Working hydraulic Max. flow - Qmax Standby pressure (HD) Operating pressure (HD) - pmax Servo working hydraulic Operating pressure (ND)

Type l/min bar bar bar

P-A10V0100 209 ±2 20 260 20

Oil quantity – Tank capacity - circuit – additional Oil specification / viscosity

See Operating Instructions: See Operating Instructions: See Operating Instructions:

ELECTRICAL SYSTEM Operating voltage Batteries Alternator Starter Central fuse Individual fuses

V

kW A A

24 2 x 12V 170Ah 28V 80A 5,4 30 See Operating Instructions

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Technical Data

LR 634 FINAL DRIVE Type Version Parking brake, integrated Gear ratio Oil quantity Oil specification / viscosity

total

2 x 450 E510 Spur gear + 1-stage planetary gear Disk brake 48,58 See Operating Instructions: See Operating Instructions:

TRACK Chain pitch Chain length Track pad width (1 grouser) Track pad bolts Track rollers – single flange, per side (e) Track rollers – double flange, per side (d) Track roller location Carrier rollers per side Track oscillation, max.

mm /inch Links mm Thread size Each Each Each

203,2 / 8,5 38 508 / 560 / 610 ¾“ UNF 4 2 e-d–e–e–d–e 1 ± 1°

WORKING ATTACHMENT - cylinder Lift cylinder Cyl. Ø / Rod Ø / Stroke

mm

130 / 90 / 485

Tilt cylinder Cyl. Ø / Rod Ø / Stroke

mm

170 / 90 / 485

Lift cylinder- Ripper Cyl. Ø / Rod Ø / Stroke

mm

120 / 70 / 460

Bucket cylinder (4 in 1) Zyl. Ø / Rod Ø / Stroke

mm

100 / 50 / 320

GENERAL Travel speed

normal speed range Reduced speed range

Basic machine:

Height over cab Total length without attachment Track gauge (+1 x width of pad = total width) Ground clearance measured horizontally

Forlding depth max.

km/h km/h mm mm mm mm mm

Operating weight with standard bucket (varies due to pad width) Ground pressure (varies due to pad width) Operating weight with 4 in 1 bucket (varies due to pad width) Ground pressure (varies due to pad width)

kg kg/cm² kg kg/cm²

0 0

10,3 6,5

3310 4850 1800 458 1200 20680 (508mm) - 20828 (560mm) – 20976 (610mm) 0.794 (508mm) – 0,725 (560mm) – 0,671 (610mm) 21342 (508mm) - 21490 (560mm) – 21638 (610mm) 0,819 (508mm) – 0,748 (560mm) – 0,692 (610mm)

BUCKETS Bucket / contents heaped (ISO 7546) Standard bucket / 2,30m3 Standard bucket / 2,30m3 3 Standard bucket / 2,40m Standard bucket / 2,40m3 4 in 1Bucket / 1,90m3 4 in 1Bucket / 2,00m3 4 in 1Bucket / 2,00m3

Width [mm] 2500 2500 2500 2500 2500 2500 2500

with welded teeth with bolted on teeth with bolted on teeth with cutter with bolted on teeth with bolted on teeth with cutter

Weight [kg] 1557 1615 1730 1578 2157 2273 2127

Total length of machine [mm] 6729 6690 6690 6522 6751 6751 6583

TRIPLE TOOTH RIPPER Length additional Weight Counterweight (not applicable) Slope angle

mm kg kg °

780 1034 505 20

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Technical Data and Maintenance guidelines Technical Data

3.1.31 Technical Data LR 634 DIESEL ENGINE Type Version Output Nominal RPM Low idle RPM Hgh idle RPM Displacement Oil quantity incl.filter Oil specfication / viscosity Max. inclination – all directions Valve play - cold Firing order Coolant Fuel tank capacity

D934 L A6 4 – cylinder in line engine mildly turbocharged kW 135 1/min 1800 1/min 910 1/min 1895 l 7 See Operating Instructions: See Operating Instructions: 45 = 100% In / out 0,3 / 0,4 1–3–4–2 See Operating Instructions: See Operating Instructions:

SPLITTERBOX Type Version Ratio Oil quantity Oil specification / viscosity

i

350 B 374 Spur gear 1- stage 0,86 See Operating Instructions: See Operating Instructions:

HYDRAULIC SYSTEM Var. displ. pumps – Travel hydraulic Max. flow - Qmax Operating pressure (M1 / M2) pmax Tandem gear pumps – replenishing – coolant cirucit / fan drive Max. flow replenishing - Qmax Operating pressure (SP) pmax Max. flow fan drive - Qmax Operating pressure (electronically regulated) - pmax Gear motor – Fan drive Operating RPM Var. displ. motors – Travel hydraulic

Type l/min bar Size l/min bar l/min bar Size 1/min Type

2 x HPV 135 2 x 282 420 56 + 19 117 20 33 155 16 1550 2 x HMV 210

Regulating pump – Working hydraulic Max. flow - Qmax Standby pressure (HD) Operating pressure (HD) - pmax Servo working hydraulic Operating pressure (ND)

Type l/min bar bar bar

P-A10V0100 209 ±2 20 260 20

Oil quantity – Tank capacity - circuit – additional Oil specification / viscosity

See Operating Instructions: See Operating Instructions: See Operating Instructions:

ELECTRICAL SYSTEM Operating voltage Batteries Alternator Starter Central fuse Individual fuses

V

kW A A

24 2 x 12V 170Ah 28V 80A 5,4 30 See Operating Instructions

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Technical Data and Maintenance guidelines

Service Manual

Technical Data

LR 634 FINAL DRIVE Type Version Parking brake, integrated Gear ratio Oil quantity Oil specification / viscosity

total

2 x 450 E510 Spur gear + 1-stage planetary gear Disk brake 48,58 See Operating Instructions: See Operating Instructions:

TRACK Chain pitch Chain length Track pad width (1 grouser) Track pad bolts Track rollers – single flange, per side (e) Track rollers – double flange, per side (d) Track roller location Carrier rollers per side Track oscillation, max.

mm /inch Links mm Thread size Each Each Each

203,2 / 8,5 38 508 / 560 / 610 ¾“ UNF 4 2 e-d–e–e–d–e 1 ± 1°

WORKING ATTACHMENT - cylinder Lift cylinder Cyl. Ø / Rod Ø / Stroke

mm

130 / 90 / 485

Tilt cylinder Cyl. Ø / Rod Ø / Stroke

mm

170 / 90 / 485

Lift cylinder- Ripper Cyl. Ø / Rod Ø / Stroke

mm

120 / 70 / 460

Bucket cylinder (4 in 1) Zyl. Ø / Rod Ø / Stroke

mm

100 / 50 / 320

GENERAL Travel speed

normal speed range Reduced speed range

Basic machine:

Height over cab Total length without attachment Track gauge (+1 x width of pad = total width) Ground clearance measured horizontally

Forlding depth max.

km/h km/h mm mm mm mm mm

Operating weight with standard bucket (varies due to pad width) Ground pressure (varies due to pad width) Operating weight with 4 in 1 bucket (varies due to pad width) Ground pressure (varies due to pad width)

kg kg/cm² kg kg/cm²

0 0

10,3 6,5

3310 4850 1800 458 1200 20680 (508mm) - 20828 (560mm) – 20976 (610mm) 0.794 (508mm) – 0,725 (560mm) – 0,671 (610mm) 21342 (508mm) - 21490 (560mm) – 21638 (610mm) 0,819 (508mm) – 0,748 (560mm) – 0,692 (610mm)

BUCKETS Bucket / contents heaped (ISO 7546) Standard bucket / 2,30m3 Standard bucket / 2,30m3 3 Standard bucket / 2,40m Standard bucket / 2,40m3 4 in 1Bucket / 1,90m3 4 in 1Bucket / 2,00m3 4 in 1Bucket / 2,00m3

Width [mm] 2500 2500 2500 2500 2500 2500 2500

with welded teeth with bolted on teeth with bolted on teeth with cutter with bolted on teeth with bolted on teeth with cutter

Weight [kg] 1557 1615 1730 1578 2157 2273 2127

Total length of machine [mm] 6729 6690 6690 6522 6751 6751 6583

TRIPLE TOOTH RIPPER Length additional Weight Counterweight (not applicable) Slope angle

mm kg kg °

780 1034 505 20

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Technical data and Maintenance guidelines Maintenance and inspection schedule

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

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

by authorized trained personnel First and only interval Repeat interval Reference see:

OI Operating instructions SM Service manual

Remar ks

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

DIESEL ENGINE Check oil level and coolant level Check / clean Diesel engine, coolant assembly and belly pan for contamination Check fuel water separator on pre-filter / empty as necessary -immediately if indicator light lights up Drain fuel tank, condensation and sediments - but at least 1x week Clean air filter – Service cover and dust discharge valve (LR624) 1) Change engine oil - Specification: CI-4, CH-4 Change engine oil -1) Specification: E4, E5, E6, E7 - Shorten interval in case of aggravating circumstances - but at least 1 x a year Change lube oil filter 1) - but at least 1 x a year Check corrosions inhibitor / antifreeze concentration in coolant Check V-belt condition Check control unit mounting, sensory and cable connections for condition Change / replace oil separator filter insert Check oil, cooler and fuel system for leaks and condition Check intake and exhaust system – mounting and leaks Check engine mount Check engine RPM Change fuel pre-filter and fine filter - Observe bleeding instructions Check / adjust valve clearance - with cold Diesel engine Grease gear ring on flywheel Take oil sample and send it in for analysis Check vibration damper for leaks and distortion - 3000 hrs. Check heater flange - before start of cold season Replace air filter inserts - as necessary, once a year Replace coolant with antifreeze - every 2 years

OI OI OI OI OI OI

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

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Technical data and Maintenance guidelines

Service Manual

Maintenance and inspection schedule

Maintenance / inspection at operating hours

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

by authorized trained personnel First and only interval Repeat interval Reference see:

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

HYDRAULIC SYSTEM Check oil level in hydraulic tank Check / clean oil cooler for contamination Replace pressure filter for replenishing Replace main return filter or immediately after indicator light lights up Check working and travel hydraulic system for function and leaks, check hose routing for chafing Check / adjust all hydraulic pressures according to adjustment check list Check mountings and fittings for tight seating Take oil sample (before oil change) and send it in for analysis Clean magnetic plug (also after repairs) - up to 50 hrs. daily Replace oil in hydraulic system - at least every 4 years - when using an environmentally friendly hydraulic medium, request / observe special guidelines

OI OI OI OI OI / SM SM OI OI

OI

SPLITTERBOX Check oil level Replace gear oil - at least every 2 years

OI OI

ELECTRICAL SYSTEM Check the function of the system incl. displays and instruments Check battery electrolyte level - at least 1x a year Clean / check / grease battery connections Check cable routing and connections Check / adjust control system of travel drive according to adjustment check list Check battery charge condition - before start of cold season Check machine software version - update older version with the latest software version

OI OI OI OI / SM SM SM SM

HEATER / VENTILATION / AIR CONDITIONING SYSTEM Turn the air conditioning system on regularly - at least 1x every 14 days Check water drain valve of air cond. system, clean if necessary Check the system for function and leaks Check the condenser for contamination - blow out if necessary Clean air circulation and fresh air filter, replace as necessary. In dusty conditions, shorten maintenance interval Check mounting screws and drive belt of compressor Check dryer unit (moisture, fill, condition) - if necessary, replace dryer unit and moisture indicator, evacuate the system and refill Clean water drain valve of air conditioning system Check evaporator unit, clean if necessary Check electrical lines for chafing and plug connections for tight seating Have air conditioning system checked / inspected by HVAC technician - 1x a year

OI OI OI OI OI OI OI OI OI OI

copyright by

3.2.20 - 2 / 4

Mjfcifss!

LR624 LR634

F/N xxx-8957 F/N xxx-8397

Remar ks


Service Manual

Technical data and Maintenance guidelines Maintenance and inspection schedule

Maintenance / inspection at operating hours

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

by authorized trained personnel First and only interval Repeat interval Reference see:

OI Operating instructions SM Service manual

Remar ks

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

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

OI OI OI / SM OI OI OI

TRACK COMPONENTS Check mounting screws and nuts of track components, especially track pad and sprocket segment bolts for tight seating Lubricate equalizer bar bearing - shorten interval if necessary Check oil level of support axle bearing

OI OI OI

Check all track components for leaks

OI

Check / adjust idler guide, replace parts if necessary Adjust chain tension to suit application - as necessary / when changing applications Clean track - as necessary Check for track wear - as necessary

OI OI / SM OI SM

WORKING ATTACHMENT Check cutting edges, bucket and ripper tooth tips for wear Make sure attachments are suited to application Check all bearing points for play / wear Check screws, nuts and bolt retainers for tight seating Check attachment for intentional damage

OI OI OI OI

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

OI OI OI

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Technical data and Maintenance guidelines

Service Manual

Maintenance and inspection schedule

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LR624 LR634

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Service Manual

Technical data and Maintenance guidelines Maintenance and inspection guidelines

3.3.20 Maintenance and inspection guidelines 1 1.1

General guidelines Documentation for work to be carried out Note! For work to be performed, refer to the Maintenance and inspection schedule for your particular machine model – see section 3.2. 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 old oil, filters and other waste products properly!

1.4

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

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Technical data and Maintenance guidelines

Service Manual

Maintenance and inspection guidelines

2 2.1 2.1.1

Maintenance and inspection guidelines Inspection work on the Diesel engine Check the engine RPM Start the Diesel engine. Read out the engine RPM via the display or the evaluation software LinDiag. Compare the engine RPM with the nominal RPM (see section 3.1 Data page). If the engine RPM does not correspond to the nominal RPM, the engine speed control must be adjusted. See section 17.5 Engine speed control.

2.1.2

Check / adjust the valve clearance Preparation to check and adjust the valve clearance: Make sure that: the machine is in maintenance position. the main battery switch S43 is turned off (Position „0“). the Diesel engine is cold. the special tool - Diesel engine „Turning device for flywheel“ is available. new seals for the cylinder head screws are available. Check only when the Diesel engine is cold. For adjustment values, see „Diesel engine Data tag“. Note! - Cylinder 1 is on the flywheel side of the Diesel engine. - Direction of rotation of the Diesel engine is to the left, when viewed onto the flywheel. - The discharge valve of the corresponding cylinder is on the flywheel side.

Fig. 1

Installation of Diesel engine turning device

Install the special tool „Turning device for flywheel“on the Diesel engine flywheel housing, as shown in fig. 1. Remove the cylinder head screws. Turn the crankshaft in direction of rotation until the valves opposite the cylinder to be adjusted overlap.

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LR624 LR634

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