Liebherr pr752 series 2 litronic crawler dozer service repair manual by 163757

     

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 

  

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           

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



   

Sub Group Index Foreword and explanation

1.1

Safety guidelines Hand signals

1.2.01 1.2.02

Service items

1.3.01

Table - charts

1.4

Conversion table

1.4.01

Tightening torques standard screws

1.4.02

Tightening torques SAE screws

1.4.03

Hole diameter before tapping

1.4.04

Couplings

1.4.05

ISO - tolerances

1.4.06

Code letters + terminal designations electric

Benennung Description DĂŠnomination

1.5

Typ/ab Type/from Type/ a partir de

Mjfcifss!

PR Litronic LR Litronic RL Litronic

Datum Edition Date

01 01

General information

Blatt Page Feuille

1.0.00.01

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

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

main group

sub group

page No.

model group

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

sub group of main group according to sub group index

division based on information content or machine model group

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

Updated pages retain the same page number, but receive a more recent date when mailed. Supplements have a new number. If the page is only valid for a certain machine model group, it will so be indicated on the page. We hope that with the enclosed information we have taken yet another step to improve the service on the LIEBHERR - crawler dozers, crawler loaders and pipelayers.

LIEBHERR-Werk Telfs GmbH. Service-Training Dept.

Benennung Description DĂŠnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

PR Litronic LR Litronic RL Litronic

Foreword and explanation Datum Edition Date

01 03

General Information

Blatt Page Feuille

1.1.00.01

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

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

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

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

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

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

Benennung Description Dénomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

PR Litronic LR Litronic RL Litronic

Datum Edition Date

01 04

Service Items

Blatt Page Feuille

01.3.01.01

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

Sulfur content in fuel

Oil quality:

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

E3 (D5), E4, E5,

Change interval

above -10°C

to 0,5%

250 hrs.

500 hrs.

(Normal temperature)

above 0,5%

125 hrs.

250 hrs.

below -10°C

to 0,5%

125 hrs.

250 hrs.

Continuous temperature

above 0,5%

60 hrs.

125 hrs.

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

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

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

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

Ambient temperature °C

% Fuel

% Additive

0 to -10

100

-10 to -15

50*

100

-15 to -20

100

Summer Diesel fuel

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

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

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

Percentage of antifreeze (%)

Note:

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

Benennung Description Dénomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

PR Litronic LR Litronic RL Litronic

Datum Edition Date

01 04

Service Items

Blatt Page Feuille

01.3.01.02

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

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

- with DCA4

Sum of alkaline earths (water hardness):

: 0,6 to 3,6 mmol/l (3 to 20°d)

0,6 to 2,7 mmol/l (3 to 15°d)

Ph - value at 20° C

: 6,5 to 8,5

6,5 to 8,0

Chloride / ion content

: max. 80 mg/l

max. 80 mg/l

Sulfate / ion content

: max. 100 mg/l

max. 80 mg/l

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

Manufacturer

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

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

BP Antifrost X 2270 A BP Napgel C 2270/1

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

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

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

Deutz Kühlschutzmittel 0101 1490

DEUTZ Service International GmbH, Köln / BRD

Esso Kühlerfrostschutz

Esso AG, Hamburg / BRD

Fricofin Frostschutz Motorex (G48-00) Frostschutz 500

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

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

Total Shell Shell BASF AG, Ludwigshafen / BRD

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

ARTECO Chevron Texaco

Igol Antigel Type DB

Igol France, Paris / Frankreich

Labo FP 100

Labo Industrie, Nanterre / Frankreich

Motul Anti-freeze

Motul SA, Aubervilliers Cedex / Frankreich

OMV-Kühlerfrostschutzmittel Organifreeze OZO Frostschutz S

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

Total Antigel S-MB 486 Total Frostfrei

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

Veedol Antifreeze O

Deutsche Veedol GmbH, Hamburg / BRD

Wintershall Kühlerschutz

Wintershall Mineralöl GmbH, Düsseldorf / BRD

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

Brand name

Manufacturer

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

LIEBHERR Caltex Chevron Texaco ARTECO Chevron Texaco Total

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

Manufacturer

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

LIEBHERR

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

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

Benennung Description Dénomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

PR Litronic LR Litronic RL Litronic

Datum Edition Date

01 04

Service Items

Blatt Page Feuille

01.3.01.03

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

Container approx.0.5 liter

appr. liter

DCA 4 - water filter Id. No.

24-39

oder

1,5

7367 045

40-59

oder

2,0

7381 493

60-79

oder

2,5

7367 052

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

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

Manufacturer

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

Fleetguard Caltex Chevron Texaco ARTECO Total

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

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

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

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

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

Single grade oils

Multi grade oils

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

Typ/ab Type/from Type/ a partir de

Mjfcifss!

PR Litronic LR Litronic RL Litronic

Datum Edition Date

01 04

Service Items

Blatt Page Feuille

01.3.01.04

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

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

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

API - classification ACEA (CCMC) - classification

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

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

: 10W : VG 32

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

Unit of Measure Length

Multiply

To obtain Multiply

To obtain

0,039

inch

25,4

3,281

feet

0,305

1,093

yard

0,914

0,621

mile

1,609

cm²

0,155

sq. inch

6,452

cm²

m²

10,764

sq. feet

0,093

m²

1,196

sq. yard

0,0863

m²

km²

0,386

sq. mile

2,59

km²

cm³

0,061

cu. inch

16,387

cm³

m³

35,314

cu. feet

0,028

m³

1,308

cu. yard

0,764

m³

61,025

cu. inch

0,016

0,035

cu. feet

28,316

0,264

gallon

3,785

1,057

quart

0,946

0,035

oz.

28,349

2,204

lbs.

0,453

1,102

short t

0,907

0,225

lbs.

4,449

224,732

lbs.

0,0044

Torque

0,737

ft. lbs.

1,356

Power

1,342

0,745

0,736

1,358

0,986

1,014

Pressure

bar

14,5

PSI

0,069

bar

(hydraulic)

kpa

0,145

PSI

6,896

kpa

Ground pressure

kg/cm²

14,223

lbs. sq. inch

kg/m²

0,205

g/cm³

Area

Volume

Weight

Force

Compression

Speed

Temperature

0,0703

kg/cm²

lbs. sq. ft.

4,878

kg/m²

0,036

lbs. cu. inch

27,78

g/cm³

kg/m³

0,062

lbs. cu. ft.

16,13

kg/m³

km/h

0,621

mph

1,609

km/h

m/min

3,281

ft. / min

0,305

m/min

°C

(°Cx1,8) + 32

°F

(°F-32)/1,8

°C

°C+273

°K

°K-273

°C

Benennung Description Dénomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

PR Litronic LR Litronic RL Litronic

Datum Edition Date

01 01

Conversion table

Blatt Page Feuille

1.4.01.01

The preload and tightening torques listed in the chart are from VDI guidelines 2230 of July 1986. Installation preload FM and tightening torques MA for shaft screws with metric standard or fine thread per DIN ISO 262 and DIN ISO 965 T2 (replacement for DIN 13 part 13) and screw head dimension of hex head screws with shaft DIN EN 24014 (replacement for DIN 931 part 1) or socket head screws DIN EN ISO 4762 (replacement for DIN 912). The chart values are valid for lubricated screws, surface black treated, phosphated or galvanic zinc plated and for dry screws, surface according to flZn - LH-Norm 10021432 (replaces DACROMET 500) Medium friction ÂľG = 0,12. Always observe the tightening torques and/ or procedures listed in drawings / parts lists, instructions of component descriptions, if noted, they override the factory standards listed in the torque charts. Never use a standard lock washer with 10.9 or 12.9 screws. If a washer is necessary, use only "heavy duty" washers, made from hardened material. Always use torque wrenches with the correct range - the upper third of the range should include the listed torque value according to the chart. When using impact screws, make sure that the given tightening torque is observed - should be checked before and during the tightening procedure with torque wrench (Nm x 0,7375 = ft.lbs.)!

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

Standard metric thread

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

8.8

10.9

12.9

8.8

10.9

12.9

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

Socket head screws

Inch

4 x 0,7

4 050

6 000

7 000

2,8

4,1

4,8

9/32

5 x 0,8

6 600

9 700

11 400

5,5

8,1

9,5

5/16

5/32

6 x1

9 400

13 700

16 100

9,5

14,0

16,5

7 x1

13 700

20 100

23 500

15,5

23,0

27,0

8 x 1,25

17 200

25 000

29 500

1/2

M 10 x 1,5

27 500

40 000

47 000

(17) 16

(11/16) --

5/16

M 12 x 1,75

40 000

59 000

69 000

117

135

(19) 18

(3/4) --

M 14 x 2

55 000

80 000

94 000

125

185

215

(22) 21

(7/8) --

M 16 x 2

75 000

111 000

130 000

195

280

330

9/16

M 18 x 2,5

94 000

135 000

157 000

280

390

460

1-1/16

9/16

M 20 x 2,5

121 000

173 000

202 000

390

560

650

1-3/16

M 22 x 2,5

152 000

216 000

250 000

530

750

880

(32) 34

M 24 x 3

175 000

249 000

290 000

670

960

1120

1-7/16

3/4

M 27 x 3

230 000

330 000

385 000

1000

1400

1650

1-5/8

3/4

M 30 x 3,5

280 000

400 000

465 000

1350

1900

2250

1-13/16

7/8

M 33 x 3,5

350 000

495 000

580 000

1850

2600

3000

M 36 x 4

410 000

580 000

680 000

2350

3300

3900

2-3/16

1-1/16

M 39 x 4

490 000

700 000

820 000

3000

4300

5100

2-3/8

1-1/16

Benennung Description DĂŠnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

PR Litronic LR Litronic RL Litronic

Standard screws Datum Edition Date

01 04

Tightening Torques Factory standard WN 4037 I

Blatt Page Feuille

1.4.02.01

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

Fine metric thread

Wrench size (x) = per DIN931, for

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

Hex head screws

8.8

10.9

12.9

8.8

Socket head screws

10.9

12.9

Inch

8 x1

18 800

27 500

32 500

24,5

1/2

9 x1

24 800

36 500

42 500

M 10 x 1

31 500

46 500

54 000

11/16

5/16

M 10 x 1,25

29 500

43 000

51 000

11/16

5/16

M 12 x 1,25

45 000

66 000

77 000

125

150

3/4

M 12 x 1,5

42 500

62 000

73 000

122

145

3/4

M 14 x 1,5

61 000

89 000

104 000

135

200

235

7/8

M 16 x 1,5

82 000

121 000

141 000

205

300

360

9/16

M 18 x 1,5

110 000

157 000

184 000

310

440

520

1-1/16

9/16

M 18 x 2

102 000

146 000

170 000

290

420

490

1-1/16

9/16

M 20 x 1,5

139 000

199 000

232 000

430

620

720

1-3/16

M 22 x 1,5

171 000

245 000

285 000

580

820

960

M 24 x 1,5

207 000

295 000

346 000

760

1090

1270

1-7/16

3/4

M 24 x 2

196 000

280 000

325 000

730

1040

1220

1-7/16

3/4

M 27 x 1,5

267 000

381 000

445 000

1110

1580

1850

1-5/8

3/4

M 27 x 2

255 000

365 000

425 000

1070

1500

1800

1-5/8

3/4

M 30 x 1,5

335 000

477 000

558 000

1540

2190

2560

1-13/16

7/8

M 30 x 2

321 000

457 000

534 000

1490

2120

2480

1-13/16

7/8

M 33 x 1,5

410 000

584 000

683 000

2050

2920

3420

M 33 x 2

395 000

560 000

660 000

2000

2800

3300

M 36 x 1,5

492 000

701 000

820 000

2680

3820

4470

2-3/16

1-1/16

M 36 x 3

440 000

630 000

740 000

2500

3500

4100

2-3/16

1-1/16

M 39 x 1,5

582 000

830 000

971 000

3430

4890

5720

2-3/8

1-1/16

M 39 x 3

530 000

750 000

880 000

3200

4600

5300

2-3/8

1-1/16

Note: Observe notes on front page!

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

Flange nominal size

Screw size

½" ¾" 1" 1 ¼" 1 ½" 2"

M8 M 10 M 12 M 14 M 16 M 20

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

-45 70 120 170 250

-65 110 180 250 450

2. Half flange for low pressure (Norm 61)

Flange nominal size

Screw size

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

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

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

31 62 62 62 108 108 108 172 264 264 264

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

Benennung Description Dénomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

PR Litronic LR Litronic RL Litronic

Standard screws Datum Edition Date

01 04

Tightening Torques Factory standard WN 4037 I

Blatt Page Feuille

1.4.02.02

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

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

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

Dimensions are in mm mm x 0,03937 = inches

Benennung Description DĂŠnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

PR Litronic LR Litronic RL Litronic

Datum Edition Date

01 04

Hole diameter before tapping

Blatt Page Feuille

01.4.04.01

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

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

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

Drill bit Ă&#x2DC;

Thread size

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

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

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

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

Sub Group Index Special tools

2.1

Special tools Liebherr Diesel engine

2.1.10

Special tools general hydraulic repair

2.1.20

Special tools hydraulic pressure testing

2.1.21

Special tools hydraulic cylinder

2.1.22

Special tools general - electric repair

2.1.30

Special tools wiring harness

2.1.31

Special tools mech. components

2.1.40

Repair welding

2.2.00

Installation guidelines

2.3.01

Installation guidelines Duo-Cone-Seals

2.3.01

Wiring installation guidelines ITT-Cannon plug

2.3.02

Wiring installation guidelines Harting plug

2.3.03

Wiring installation guidelines AMP plug

2.3.04

Benennung Description DĂŠnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

PR Litronic LR Litronic RL Litronic

Special tools Datum Edition Date

01 01

Application guidelines

Blatt Page Feuille

2.0.00.01

Description

Id.No.

Digital Electronic Impulse Tachometer

Remarks

7009 538

test range: 400-6000 RPM accuracy 1 RPM

Tachometer - mechanical

5003 069

test range: 100-3000 RPM accuracy: 1 RPM

Tachometer cable

5003 070

to be used with Id.No. 5003 069

8122 902

to be used with Id.No. 5003 070

7408 922

to test the condition of the battery charge and the percentage of antifreeze in the engine coolant.

all engines

Illustration

D904 TB / 904 T

Tachometer cable extension D904 TB / 904 T

Battery charge / coolant condition tester

Description Description DĂŠnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

PR Litronic LR Litronic RL Litronic

Diesel engine Datum Edition Date

01 04

Special tools

Blatt Page Feuille

2.1.10.01

Illustration

Description DCA4 Test kit â&#x20AC;&#x17E;CC2602Mâ&#x20AC;&#x153;

Id.No. 5608 459

includes: test strip container 50 test strips plastic container eye dropper Compression tester

Remarks to test the DCA4 concentration in coolant. all engines

8008 782

to check the engineÂ&#x2019;s compression pressure. all engines

Test adapter for compression tester

0524 044

to be used in place of injector when checking compression all engines

Injector tester

7361 236

to check injector opening pressure all engines

High pressure hand pump with accessories, complete

7009 318

to check the injection pump timing. all engines

Description

Id.No.

Slide hammer

0524 072

Remarks

Illustration

to remove injectors all engines

Adapter

0524 029

to be used with Id.No. 0524 072

all engines

Angle method torque fixture

0524 062

to torque screws cylinder head main bearings rod bearings all engines

Engine turning fixture

0524 045

mounted on the flywheel housing all engines (not useable at D 9406 TI - PR 752, RL 52, use Id.No. 9183 785)

Dial gauge Pos.1

7022 418

Dial fixture Pos.2

7022 420

to control the delivery begin from the distribution injection pump all engines with distribution injection pump

Description Description DĂŠnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

PR Litronic LR Litronic RL Litronic

Diesel engine Datum Edition Date

01 04

Special tools

Blatt Page Feuille

2.1.10.02

Illustration

Description V - Belt Measuring Tool „Krikit2“

Id.No. 8042 829

Remarks to measure V - Belt tension All engines

Holding fixture

0527 462

to eliminate starting fuel quantity when adjusting the delivery begin motors with MW injection pumps D914/916 D924/926 D9306/9308 D9406/9408

Sampling pump pos. 1

8145 666

Sampling valve for oil samples pos. 2

7019 068

Oil analysis set German 6 samples 12 samples

7018 368 7018 369

analysis at WEAR CHECK Germany, analysis report in German language.

8503 561

Analysis at WEAR CHECK Belgium, analysis report in French language

used for taking oil samples for the oil analysis.

Oil analysis set French 6 samples

Engine turning fixture with ¾" square head drive

9183 785

to turn the Diesel engine D 9406 TI - PR 752, RL 52, for adjustments fits on the fan side end of crankshaft

Description

Id. No.

Remarks

Vacuum pump, complete with the following accessories:

7408 148

for faster bleeding of the hydraulic system the vacuum pump can produce low pressure (appr. 0.4 bar) by reversing the PVC hose. The connecting point for the machine is the bleeder screw on the hydraulic tank.

Vacuum pump with electr. cord Hose assembly Hose assembly Fitting S8M Fitting L6R PVC hose Terminal clamp - pos. Terminal clamp - neg. Plug - 2 connectors Temperature gauge

7407 987 7407 985 7407 986 7404 619 4901 110 7360 127 7408 149 7408 150 7408 151 7020372

Adjustment tool for BPV 50, 70, 100

commercially available

Illustration

accuracy: 2%/2° test range: -18°C - +260°C

to adjust pump end position via eccentric screw

Tool to loosen / counter Item.1 12 point socket ½“

SW 13 x 85

Adjustment tool Item.2 Hex head screw handle

Note: The 12 point socket ½“ stub should have an outer diameter of 18 mm over a length of approx. 35 mm

SW 4 x 200

Item.3 socket wrench Hook wrench 58 - 62 mm

SW13 x 120 7900 282

Adjustment tool for slotted nut at HPV 130

9792 711

to loosen / tighten when adjusting the regulating range of BPV pumps

to loosen / tighten lock nut when adjusting pump end stop - Qmax (also usable when adjusting regulating range at BPV) use together with hook wrench Id. No. 7900 282

Description Description Dénomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

PR Litronic LR Litronic RL Litronic

General hydraulic repair Datum Edition Date

01 09

Special tools

Blatt Page Feuille

2.1.20.01

Illustration

Description

Id. No.

Adjustment tool for mechanical neutral position slotted nut HPV 135-02

9749 025

to loosen / tighten lock nut when adjusting mechanical neutral position.

Clamping tool for clamping spring at BPV BPV 35 - 200

6427 521

to tighten the spring and remove ball socket trumpet tube when changing swash plate bearing

Pin puller for pump BPV 35 - 100

6427 516

used to remove the pin for the swash plate bearing cage retainer clip

Punch for stud BPV 70 - 100

Remarks

to punch the studs change of needle bearing segment

Swash plate

7413 894

Housing

4713 895

for correct mounting the radial shaft seal on the pump drive shaft

Installation sleeve for radial shaft seal BPV 35 â&#x20AC;&#x201C; 70

7404 289

BPV 100

7404 298

BPV 200

7404 567

Note: install seal rings with Loctite 270

Description

Id. No.

Measuring device for differential pressure contents - 230V 230V

7025 376

Remarks

Illustration

to measure pressure, differential pressure and used for Data transfers to the PC contents of:

Measuring device for differential pressure contents 120V

7025 755

Pressure gauge 0-10 0-25 0-40 0-60 0-100 0-160 0-250 0-400 0-600 0-1000

5002 865 7361 289 7361 288 5002 867 5602 903 7361 286 7361 285 7500 002 7361 294 4601 115

Digital pressure gauge 7412 643

0 - 500

7412 644

Lithium battery for digital pressure gauge

6002 780

Gauge - coupling 7002 436

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

7002 437 7002 475 7009 134 7363 732

Test fitting , complete R6L R 10 L R 12 L

accuracy: 1% of end value all pressure gauges are glycerin filled

resolution 0,1% of end value

0 - 100

R½

measuring device M - H 2045 2 pressure sensors 0-600 bar 2 test fittings 2 test hoses MK 12m connecting wire - board circuit adapter wire - data transfer power supply unit

accuracy: 0,2% of end value gauge range - static: up to max. 50 % above the listed end value to seal the coupling during pressure tests, a seal ring, Id. No. 7409 794, must be installed. to avoid loss of pressure during tests, use the shortest possible test hose

union nut and ferrule mounted on test fitting. 7409 916 7406 864 7409 918

Description Description Dénomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

PR Litronic LR Litronic RL Litronic

Hydraulic pressure testing Datum Edition Date

01 04

Special tools

Blatt Page Feuille

2.1.21.01

Illustration

Description

Id. No.

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

7615 321 5608 462 7409 783 7406 865 7409 720

Schott screw coupling M 16x2

7407 070

Test plate A for SAE-flange ¾

7370 092

Size (in mm) A 90 B 40 C,r 5

Test plate B for SAE - flange 1

7370 093

Size (in mm) A 90 B 44 C,r 5

Test plate C for SAE flange 1¼ Size (in mm) A 90 B 52 C,r 5

7370 094

Remarks to connect to additional machine measuring points

to connect shorter test lines or connection between test connection and pressure sensor

to close high pressure ports when checking system pressures material: ground resilient steel taper rounded plate ends, round off edges (simplifies installation, prevents damage to O ring)

or to be made in house

Flange, complete ( 2 each with O - rings and screws) for support shaft PR712/722 LR622 RL(4)22

9787 796

to close high pressure ports when checking system pressures and when shaft flange is removed

PR732/742 LR632 RL(4)42 Fitting

9787 798

also to protect front surface when removing support shaft bearings.

pos.1 stopper pos.2 union nut pos 3 elbow fitting pos 4 reducer fitting pos 5 fitting

2 x 4900 038 2 x 4774 001 2 x 7403 569 2 x 7404 259 2 x 7410 458

to close off control lines for adjustment of hydr. motors on the PR 752

Description

Id. No.

Remarks

10305903

Required to check / adjust the travel drive - for all machine models with electronic control / EBox Version CEP

* Diagnostics unit

10470376

For application of diagnostics unit, see section 10.4.

* Adapter cable 55-pin

9814970

Diagnostics unit CET 08/05 With adapter cable (consists of the following parts marked with *)

Adapter CET-14/05 for old Diagnostics unit 08/03 (box)

7413 106

Adapts the diagnostics unit for all machine models with E-Box Version CEP

Adapter cable

9814 970

Necessary for all tests

55-pin

Illustration

Use for diagnostics units CET 08/03 and CET 08/05.

Adapter cable - Y for old diagnostics unit 08/03 (Box)

9747 733

Accessories Protective cap for plug Protective cap for socket

6002 655 6002 654

Power supply cable cpl. for old diagnostics unit 08/03 (Box)

6002 697

consists of: Panel plug Plug 3-pin Shrink tubing for panel plug Shrink tubing for plug 3-pin Cable

Auxiliary cable for special tests in travel drive

Use for diagnostics unit CET 08/03 Power supply cable: Plug 3-pin A: + B: C: free

7409 682 7409 676 7409 681 7409 679 6000 738

Accessories Protective cap for plug 3-pin 7409 677

Panel plug Center contact: + Side contact: Use for diagnostics unit CET 08/03

Benennung Description Dénomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

PR Litronic LR Litronic RL Litronic

Electric - General Datum Edition Date

01 08

Special tools

Blatt Page Feuille

2.1.30.01

Illustration

Description E-Box Evaluation kit Consists of Pos.1

Pos. 2

Id. No.

Remarks

9812 435

To read out error stack - EBox CEP 12/08C, CEP 12/20 and CEP 1/22

Disk with Software CEP 12

7415 329

Adapter cable

9812 434

Pedal test unit

7414 235

Required for PR-2-Litronic: Check / adjustment of inching / brake pedal LR-2 Litronic: Check / adjustment of steering and brake pedals

LIKOM - Service Set Consists of: LIKOM Software Pos. 1 Interface cable Pos. 2 Application description Â&#x2013; not shown

Application accessories: Note Book Transformer 24/230 V Digital multi meter cpl. with cable and bag

9793 970 9758 760 01 9794 550

Required to check / adjust the travel drive - for all machine models with electronic control / EBox Version RST For application of diagnostics unit, see section 10.5.

6140 645 01 6004 217 6001 231

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

Optical charge tester

7408 922

Socket wrench for sensor Â&#x2013; control motor / gear

9797 973 or 12 pt. Socket wrench SW 27 reworked

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

Rework according to drawing: Notched surfaces must be ground out.

Description

Id.No.

Hand crimp tool - Cannon

7367 086

Remarks

Illustration

to produce flawless crimp connections.

M 22 5 20/1-01 application, see group 02.3.02.

Crimp insert - Cannon CT 120090-20

7409 779

TH 452

7367 084

Reference gauge M 22 5 20/3-1

7409 718

used with hand crimp tool Id.No. 7367 086 application, see group 02.3.02. to check the hand crimp tool Id.No. 7367 086 application, see group 02.3.02. to insert wired crimp contacts into the plug connectors.

Insertion tool for CA - B Crimp contacts CIT-F80-KIT complete consisting of: 1 Handle 1 Insert CIT 20 1 Insert CIT 16 1 Insert CIT 12 1 Insert CIT 8 1 Insert CIT 4 1 Insert CIT 0

7409 721 7409 693 7409 694 7409 695 7409 696 7409 697 7409 698 7409 699

Extraction tools for CA - B crimp contacts CET-F80-KIT complete consisting of: 1 Handle 1 Insert CET 20 1 Insert CET 16 1 Insert CET 12 1 Insert CET 8 1 Insert CET 4 1 Insert CET 0

7409 700 7409 701 7409 702 7409 703 7409 704 7409 705 7409 706 7409 707

Insertion tool for KPSE crimp contacts

application, see group 02.3.02.

to remove wired crimp contacts from the plug connectors. depending if socket or pin contacts are removed, the corresponding side of the tool insert should be used. application, see group 02.3.02.

application, see group 02.3.02.

MS 24256 A16

7409 708

MS 24256 A20

7409 709

Description Description Dénomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

PR Litronic LR Litronic RL Litronic

Electric system - wiring harness Datum Edition Date

01 04

Special tools

Blatt Page Feuille

2.1.31.01

Illustration

Description

Id.No.

application, see group 02.3.02.

Extraction tool for KPSE crimp contacts MS 24256 R16

7409 710

MS 24256 R20

7409 711

Insertion tool for SURE SEAL crimp contacts, complete CITG-SS-1 Insertion tip CIT-SS-1-TIP Contact holder CT 317-8666-005 Extraction tools for SURE SEAL crimp contacts, complete CET-SS-P CET-SS-S Extraction tips CET-SS-P-TIP CET-SS-S-TIP Guiding pin - Cannon for: CA-B Crimp contacts Size 15S, 16S, 15, 16: 226-1017-000 Size 25, 12 226-1018-000 SURE SEAL crimp contacts CT 317-8588-000

application, see group 02.3.02. 7367 023 7409 712 7409 713 P - valid for extraction of socket contacts. S - valid for extraction 7367 020 7367 022

when installing socket contacts, guiding pins must be used. 7409 716 7409 717 7409 745

7367 085

4 notch hand crimp tool „Buchanan“ pos1 - Crimp pliers pos2 - Positioning sleeve

application, see group 02.3.02.

7409 714 7409 715

Auxiliary tool - Cannon for SURE SEAL CIEF-SS-5-6-7

Remarks

8123 551 8123 552

Test gauge 0,5-1 und 2,5 mm 1,5 mm

8123 553 8123 554

Extraction tool for Harting crimp contacts

8123 556

protection against damage. application, see group 02.3.02. device for holding connectors during insertion and extraction of crimped contacts.

for creating perfect crimp connections on Harting plug connectors

for inspecting crimp depth in Harting" connector

for extraction of crimp contacts from the Harting - connector

Description

Id.No.

Insertion tool for “Harting” crimp contacts

8123 555

Crimp tool for MATE-N-LOK crimp contacts for 1,5 mm² for 2,5 mm²

Remarks for insertion of connected crimp contacts into the Harting connector

to crimp contacts of MATE - N - LOK connectors 7367 025 7366 314

Extraction tool AMP for MATE-N-LOK crimp contacts

7366 655

substitute insert

7015 180

Insertion tool AMP for MATE-N-LOK Crimp contacts

8145 432

to insert pin and socket contacts in connectors type MATE - N - LOCK

Hand crimp tool - Cannon for „DEUTSCH“ Connectors

8503 647

to crimp correct contacts of connectors type DEUTSCH

crimp turret

7409 779

Extraction tool Cannon for crimp contacts DEUTSCH AWG 4 AWG 8 AWG 12 AWG 16 AWG 20 Crimp tool AMP AMP Certi-Lock

Illustration

8503 633 8503 632 10 114 733 885 563 714 10 114 732 7415 333

extraction tool to push a crimped contact of the MATE - N - LOK connectors

extraction tool to push pin contacts and socket contacts of the DEUTSCH connectors

to crimp the JUNIOR POWER TIMER contacts

Description Description Dénomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

PR Litronic LR Litronic RL Litronic

Electric system - wiring harness Datum Edition Date

01 04

Special tools

Blatt Page Feuille

2.1.31.02

Illustration

Description

Id.No.

Remarks

Extraction tool AMP

7370 373

extraction tool to remove contact of the JUNIOR POWER TIMER housing

Crimp tool CSA 0760

7409 781

to crimp insulated wire contacts 0,75 - 6,0 mm² Example: isolated connectors

Crimp tool CRB 0560

7409 782

to crimp non insulated wire contacts 0,5 - 6,0 mm² Example: connection to wiper motor see picture group 9

Wire stripper complete Type 5011-26

7409 777

Spare blades

7409 778

Blade inserts to strip metric wires with the following wire diameters

to remove the insulation on individual wires on the electronic wire harness. 0,75 mm²

to be installed in wire stripper Id.No. 7409 777

1,5 - 6,0 mm²

7409 788

0,15 - 2,5 mm²

7409 789

Description

Id.No.

track component measuring tool

7402 603

R = ring wrench and E = adjustment template for PR 712 (B) FAT 400/523 R/E

9054 282*

400C563 R E

9790 992 8123 439

400P553 R E

9790 992 8123 438

PR 722 (B) FAT 450/514 R/E

9054 281*

450C564 R E

9790 996 8123 440

PR +LR 622 450P554 R +RL (4)22 E

9790 996 8123 440

PR 732 (B) FAT 500/525 R/E

Remarks

Illustration

application, see group 12.2.

to adjust bearing play of cross roller bearings

9054 280**

500C565 R E

9790 999 8123 442

500P555 R E

9790 999 8123 441

*= with new adjustment R = template bearings

**= with new adjustment template and new pin, can also be used for newer gear types see Service information 11-3-5/94 Litronic) E=

= 8123 445

substitution - carrier / bolt for wrench

PR +LR 632

PR 742 (B) FAT 550/516 R/E

9054 279**

550C566 R E

9791 003 8123 444

550P556 R E special wrench - support shaft

9791 003 8123 443

PR +RL 42

bolt

IdNr. 9790 992 and IdNr. 9790 996 IdNr. 9790 995

= 8123 446

for wrench bolt

IdNr. 9790 999 IdNr. 8123 445

= 8123 446

for wrench bolt

IdNr. 9791 003 IdNr. 8123 446

to loosen and tighten the ring nut on the support shaft 9054 840

PR 712/722 LR 622 RL(4)22 9785 922 PR732/742 LR 632 RL 42

Description Description DĂŠnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

PR Litronic LR Litronic RL Litronic

Mech. components Datum Edition Date

01 09

Special tools

Blatt Page Feuille

2.1.40.01

Illustration

Description

Id.No

Remarks

socket wrench - size 22 mm for cable fittings on axle flange

9745 376

to release / tighten the cable fittings on the support axle

9814 884

to dissemble and assemble of the parking brake at FAT type - P/D

PR 732 / LR 632 PR 742 RL 42

clamping tool for parking brakes FAT - Type P/D all types except PR 752 / RL 52

measurements for manufacturing the clamping tool see page 2.1.40.02

press - in punch

for installation of radial shaft seal in hoist cylinder support. see chapter 15.2. A = für Pos.12 B = für Pos.11

Pos.1 installation flange PR712/722

A B

9786 683 9786 684

PR732

A B

9786 685 9786 687

PR742/752

A B

9786 686 9786 687

Pos.2 screw in handle for all installation flanges puller Pos.1 with counter support Pos.2 for the following dimensions (in mm)

A B C D

PR712 PR722 90 70 247,5 90

9786 688 commercially available toll cut open bushings, pos. 3 from Ø 120mm

for dimensions to manufacture the punch see page 2.1.40.02

to pull out bushings Pos.3 ad Pos.4 from hoist cylinder bearing support

PR732 PR742 PR752 110 90 273 96

120 90 273 94

120 90 280 120

tension tool track adjuster unit Pos. 1 - installation flange

9798 353

Pos. 2 - bar

9798 352

Pos. 3 - hex head screw (6 pieces.) M16x310mm - 10.9

4601 217

to install and remove the spring in the track roller frame on the PR 752. absolutely requires

application, see „group 12.5.50“

Description

Id.No.

Remarks

Installation wrench Tension unit

9416915

Special hook wrench to loosen and attach the ring nut

Installation tool Tension unit

9416922

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

Mounting sleeve

9817 062

for installation of outside bearings at the equalizer bar PR 752

Illustration

Dimensions to self - manufacture from special tools 1. For disassembly and assembly of the brake housing travel gear FAT - type A / C (without Id. No.)

Dim (mm)

PR 712 PR 722 PR 732 PR 742 FAT 400/523 FAT 450/514 FAT 500/525 FAT 550/516 FAT 400 C 563 FAT 450 C 564 FAT 500 C 565 FAT 550 C 566

315

340

360

395

380

400

420

460

ØC

M20 x 2,5

M24 x 3

130

150

170

190

ØH

ØI

Dimensions on drawing are valid for all travel gears FAT 400 to 550.

Description Description Dénomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

PR Litronic LR Litronic RL Litronic

Mech. components Datum Edition Date

01 09

Special tools

Blatt Page Feuille

2.1.40.02

2. For disassembly and assembly of the brake housing travel gear FAT - type P / D (Id. No. see page 2.1.40.01)

Pos.

Description

Id.No.

washer with nut M20 (welded on)

160 mm

9814 883

washer for machine size X32, X42

160 mm

9814 881

washer for machine size X12, X22

130 mm

9814 882

screw M20 x 110 10.9 A3C

4600 161

washer A3C

4600 222

3. Mandrel for radial seal ring in lift cylinder bearing see crawler dozers service manual, chapter 15.2.(Id. No. see page 2.1.40.01) 3.1. Screw type handle page 2.1.40.01 - item 2, fits for following installation flanges

all dimensions in mm

3.2. Installation flange page 2.1.40.01 - item 1 A for Pos.12, B for Pos.11 from group 15.2.

PR 712 / 722 PR 732 PR 742/752

Id.No.

Maß A

Maß B

Maß C

DIM D

9786 683

Ø119-0,3

Ø89±0,1

Ø57

Ø139-0,3

Ø109±0,1

9786 687

Ø89-0,3

Ø69±0,1

9786 686

Ø149-0,3

Ø119±0,1

Ø69±0,1

9786 684

Ø71

9786 685

B A B

9786 687

Ø89

-0,3

±0,1

4. Intermediate flange travel pump to regulating pump, see 8.1.01.02 PR712(B) - PR732(B), LR622/LR632, RL(4)22 B With pulling device, IdNo.0524 072 - section 02.1.10.02., or with screw M10x100

all dimensions in mm

*edges rounded

Prior to beginning any welding on earthmoving equipment, the battery cables and the wires on connection B+ and D- on the alternator must be disconnected and the electronic control box must be removed. In addition, the ground cable of the welding unit must be connected directly to the bare metal of the part to be welded. 1. Preparation of a crack The crack must be free of paint, grease and dirt. To prevent the crack from extending during the preparation or the welding process, the end of the cracks should be drilled with a hole of at least 0.32" (8mm) in diameter. The crack should now be ground, chiseled, torch cut or arced out at a 60° angle. Be certain the edges are clean and extend through the full cross section of the material, without exceeding the 0.04" (1 mm) space in the lower part. On larger grooves, a welding safety should be installed.

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

Benennung Description Dénomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

PR Litronic LR Litronic RL Litronic

Datum Edition Date

01 04

Repar Welding

Blatt Page Feuille

2.2.00.01

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

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

Suitable reinforcement plate with high tensile strength.

Suitable reinforcement plate against bending and alternating loads.

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

Direction of weld

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

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

Benennung Description DĂŠnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

PR Litronic LR Litronic RL Litronic

Datum Edition Date

01 04

Repar Welding

Blatt Page Feuille

2.2.00.02

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

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

7.1. Electrode Selection Welding area

Material

BASIC MACHINE Roller frame - Main frame

St 52 - 3 QStE 380 N

LH 690 preheat to app. 100-150째C (210-300째F) ATTACHMENT Blade Bucket

Push frame Bucket arm RL-Boom

Ripper

WEAR ITEMS Adapter, Tooth adapter Ripper

Q St E 380 N HARDOX 400

St 52 - 3

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

Special steel

Electrode norm description

Protective gas welding wire norm description

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

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

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

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

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

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

7.2. Steel Table Description

Explanation

HARDOX 400

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

Q St E 380 N

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

Special steel

St 52 - 3 S355J2G3 LH 690

Analysis Si 0,7% Cr 1,4%

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

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

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

7.3. Welding addition chart 7.3.1 For arc welding

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

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

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

Benennung Description Dénomination

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

Typ/ab Type/from Type/ a partir de

Mjfcifss!

PR Litronic LR Litronic RL Litronic

Datum Edition Date

01 04

Repar Welding

Blatt Page Feuille

2.2.00.03

7.3.2 For MIG welding with solid electrodes:

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

according to EN 12534: G3CrNi1Mo

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

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

e.g. Böhler X 70 - IG

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

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

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

Duo-cone seal design for:

sealing against outside,

sealing against inside

1 Retainer 2 O-ring 3 Metal ring 4 Sealing surface Note: At the present time, for design reasons, we only use seals protecting against the outside.

Duo-cone seals are precision components made out of chilled cast iron. They are manufactured in pairs and should never be mixed whether they are new or used. Avoid shocks and beats as the sealing surfaces of the metal seal rings can get damaged. Eliminate sharp edges on the seal-retainers. Before installation the Duo-Cone-Seals and the retainers must be clean and free of grease. The toric or O-rings may not be oiled. Installation: Push the seal rings (with toric ring) with an installation tool into the seal seat. Even pressure must be exerted on the toric ring around the complete circumference to push the toric ring past the seal retaining lip. A standard installation tool, as shown on the reverse side, is folded over the seal ring and transfers even pressure directly onto the toric ring. If no suitable installation aid is available, place a round rubber cord or coil spring (as shown below) to provide a distance between the seal ring and the O-ring and hold it so that the O-ring cannot roll up on the conical seal ring surface when each half of the seal ring is pressed in.

1 2 3 5 6

Retainer O-ring Metal ring Installation tool Installation aid, such as coil spring, rubber cord or rope, etc.

If no installation tool is used, the toric O-ring can roll up on the conical seal seat surface. If pressure is exerted only on one side, the seal may not be positioned vertically and / or the O-ring can be distorted. These installation problems can cause leaks as well as damage to the sealing surfaces. Installation position:

incorrect -

correct

O-ring distorted

Seal is not vertical

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

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Installation guidelines Datum Edition Date

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Duo-Cone-Seals

Blatt Page Feuille

2.3.01.01

Listing of available installation tools for travel gear - Duo-Cone seals:

The tools may be ordered by the spare parts dept. from Liebherr Werk Telfs GmbH. - under the description of "Duo-Cone-Seal installation tool" and the corresponding Id. No.

FAT 400 / 523 FAT 450 / 514 FAT 500 / 525 FAT 550 / 516

9443 850 9443 090 9443 100 9443 105

712 722 732 742

7610 242 7610 243 7610 244 7610 245

Installation tool tool number Ident-No. 07590 39022 1001 7428 07590 38886 1001 7430 07590 38891 1001 7436 07590 39023 1001 7433

FAT 400 C 563 FAT 450 C 564 FAT 500 C 565 FAT 550 C 566

9443 410 9443 430 9443 450 9443 470

712 722 732 742

7610 544 7610 545 7610 543 7610 546

07590 39022 07590 38886 07590 38891 07590 39023

1001 7428 1001 7430 1001 7436 1001 7433

FAT 500 P 595 D 9444 380

x32

FAT 550 P 596 D 9444 390

x42

7610 244 7610 249 7610 245 7610 548

07590 38891 00100 07500 07590 39023 07590 41339

1001 7436 1001 8934 1001 7433 1001 7456

Gear Type

Gear Machine Ident-No. Type PR/LR/RL

Duo cone seal Ident-No.

FAT 400 P 553 FAT 450 P 554 FAT 500 P 555 FAT 550 P 556

9443 340 9443 270 9443 310 9443 390

x12 x22 x32 x42

7610 242 7610 243 7610 244 7610 245

07590 39022 07590 38886 07590 38891 07590 39023

1001 7428 1001 7430 1001 7436 1001 7433

FAT 400 D 583

9444 305

x12

FAT 450 D 584

9444 315

x22

FAT 500 D 585

9444 260

x32

FAT 550 D 586

9444 325

x42

7610 244 7610 242 7610 245 7610 243 7610 237 7610 244 7610 548 7610 245

07590 38891 07590 39022 07590 39023 07590 38886 07590 41338 07590 38891 07590 41339 07590 39023

1001 7436 1001 7428 1001 7433 1001 7430 1001 7468 1001 7436 1001 7456 1001 7433

FAT 650 / 508

9443 830

x52

7610 241 7610 245

00100 01300 07590 39023

1001 7472 1001 7433

1 2 3 4 5 6

General repair guidelines Crimp tool and use Installation guidelines - CA - B / CA - COM - B cable connector Installation guidelines - KPSE cable connector Installation guidelines - SURE SEAL cable connector Installation guidelines - DEUTSCH cable connector

1. General Repair Guidelines When working with cable connectors, the following must be observed:

Keep hands, work place and connectors clean, dry and free of grease. Always use the special installation tool - see paragraph 3.1.31 - for installation. For CA - COM - B connectors use the same special tool as for CA - B connectors. Check tools for wear before use - a wrong or defective tool as well as improper handling can damage the cable connector components. When cutting cables to proper length, make sure they are the same length and the cutting edge is straight. Do not compress or squeeze the cable. For 90 ° cable routing, cut the cable to proper length when in angled position. The cable covering must reach under the crimp joint. Check installation guidelines for correct length to be stripped. When stripping the cable, make sure that the individual wires are not damaged, kinked, bent or soiled. Before installation, check crimp connections of all contacts: - Individual wires must be visible in the inspection hole of the contact. - All wires must be tightly caught in the crimp connection. - The wire insulation must reach the contact. When removing and reinstalling contacts, make sure to check the flow direction and use isopropyl alcohol (rubbing alcohol) as a lubricant, do not twist contacts and tool. Do not reuse damaged parts. Contacts in size 60/100, 160 and 500 can only be crimped hydraulically. If these contacts are damaged, the complete wire must be replaced. Make sure all parts are positioned correctly, check charts!. On straight cable feeds, insert the contacts from the center to the outside. On 90° cable feeds, insert them in a row from the bottom to the top. Even contacts, which are not wired, need to be installed. Close off any empty chambers with a plug. Visually check if all mating ends of the contacts are at the same level. Route the wires free of tension and fasten them.

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ITT-Cannon plug

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2. Use of crimp tool 2.1. Adjust the manual crimp tool - M 22 520 / 01 - 01

Set the selector dial on the handle to the appropriate diameter, see installation guidelines on wiring chart.

2.2. To adjust turret head TH 452 and CT 1200 90 - 20 Install the proper turret head with a 9/64 Allen wrench. Push switch 1. Adjust color coded crimp position on knob 2 according to the wiring chart. Push knob 2 in to the stop and push the tool once more.

2.3. Use

Before crimping, strip the wire endings to the length noted in the installation guidelines, using the appropriate tool - see paragraph 2.1.31. Insert the stripped wires into the contact crimp sleeve as far as possible until they are visible in the inspection port Insert contact and wire into the preset crimp tool. Push the tool handles together all the way.

Note: The locking mechanism will not allow you to open the tool until the crimping operation has been completed. Pull the crimped contact with wire from tool. Check the crimp, see paragraph 1.

2.4. Check crimp tool wear. Check the crimping die for wear with a M 22 520 / 3 - 1 gauge (see paragraph 2.1.31.02), without the crimping head in place. Set the dial on the handles of the crimp tool to No. 4. Turret both sides of the gauge into the crimp opening of the tool. The GREEN - side ( good ) must fit easily between the crimp dies, or the adjustment of the tool and the crimp die must be checked. The RED - side ( oversize ) may not fit, or the tool are not closed all the way or the crimp dies are worn and must be replaced.

Caution: Do not operate the crimp tool when the gauge is inserted!

3. Installation Guidelines for CA - B / CA - COM - B Cable Connectors

3.1. Description A = Plug B = Socket Components 1 2 3 3.1 4 5 5.1 6 7

Grommet Insulator Cylinder barrel Seal ring End bell with nut Bayonet coupling nut Spring washer (on CA-COM-B) Socket contacts Pin contacts

Tightening torque for end bell:

3106

32-

8SB – 03

Size:

06COM

32-

8SB – 03 – LH

10 SL

max. 3 Nm

Other specifications

14S/14

max. 5 Nm

Size

max. 9 Nm

Classification

max. 15 Nm

Type of housing Model

3.2. Overview table Plug Description

Number / Type of Contact - Size

Insertion Tool

Crimp Tool

Notes

S=Socket, P=Pins CA 3106 E 32-8SB-03 CA 06 COM-E 32-8SB03-LH Socket (30 pole) on main wiring harness - large

CA 3106 E 32-8SB-04 Plug (30 pole) in instrument panel for main wiring harness large

24 / S - 15 6 / S - 25 24 / P - 15 6 / P - 25 16 / S - 15

CA 3106 E 32-6SB-03 CA 06 COM-E 32-6SB03-LH Socket (23 pole) on main wiring harness small

2 / S - 25 3 / S - 60 2 / S - 160

Removal: CET-F80-16

Tool:

M 22520/1-01

Installation: CIT-F80-16

Turret:

TH 452

Removal: CET-F80-12

Tool:

M 22520/1-01

Installation: CIT-F80-12

Turret:

TH 452

Removal: CET-F80-16

Tool:

M 22520/1-01

Installation: CIT-F80-16

Turret:

TH 452

Removal: CET-F80-12

Tool:

M 22520/1-01

Installation: CIT-F80-12

Turret:

TH 452

Removal: CET-F80-16

Tool:

M 22520/1-01

Installation: CIT-F80-16

Turret:

TH 452

Removal: CET-F80-12

Tool:

M 22520/1-01

Installation: CIT-F80-12

Turret:

TH 452

Removal:

CET-F80-4

Hydraulic crimp tool and hand pump

Contact size 15 metric Contact size 25 metric Contact size 15 metric Contact size 25 metric

If these crimp contacts are damaged, replace small instrument cable kit

Installation: CIT-F80-4

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Contact size 25 metric

CET-F80-8

Installation: CIT-F80-8 Removal:

Contact size 15 metric

ITT-Cannon plug

Blatt Page Feuille

2.3.02.02

Plug Description

Number / Type of Contact - Size

Insertion Tool

Crimp Tool

Notes

S=Socket, P=Pins 16 / P - 15

CA 3106 E 32-6PB-04 Plug (23 pole) in instrument panel for main wiring harness small

2 / P - 25 3 / P - 60 2 / P - 160

CA 3102 E 20-27 SB-03A176 CA 06 COM-E 20-27 SB03-LH Socket (14 pole) on electronic wiring harness for joystick

14 / S - 15

CA 3106 E 14S-6 SB-03A176 CA 06 COM-E 14S-6 SB03-LH Socket (6 pole) on electronic wiring harness for engine speed sensing potentiometer and outrigger wiring harness right / left

6 / S - 15 S

CA 3106 E 10SL-3SB-03 CA 06 COM-E 10 SL3SB-03-LH Plug (6 pole) on outrigger wiring harness right / left for electronic wiring harness

6 / P - 15 S

CA 3106 E 10SL-3SB-03 CA 06 COM-E 10 SL3SB-03-LH Socket (3pole) on electronic and variable motor wiring harness - left / right for solenoid valves

3 / S - 15 S

Removal: CET-F80-16

Tool:

M 22520/1-01

Installation: CIT-F80-16

Turret:

TH 452

Removal: CET-F80-12

Tool:

M 22520/1-01

Installation: CIT-F80-12

Turret:

TH 452

Removal:

Contact size 25 metric

CET-F80-8

Installation: CIT-F80-8 Removal:

Contact size 15 metric

CET-F80-4

Hydraulic crimp tool and hand pump

If these crimp contacts are damaged, replace small instrument cable kit

Installation: CIT-F80-4

Removal: CET-F80-16

Tool:

Installation: CIT-F80-16

Turret:

Removal: CET-F80-16

Tool:

Installation: CIT-F80-16

Turret:

Removal: CET-F80-16

Tool:

Installation: CIT-F80-16

Turret:

Removal: CET-F80-16 Installation: F80-16

CIT-

Tool: Turret:

M 22520/1-01 TH 452

Contact size 15 metric

Contact size 15S metric

For guide pins and various additional tools , see paragraph 2.1.31

3.3. Removal of Contacts Note general guidelines in paragraph 1.

Carefully lift the plastic insulation (see manufacturer Â&#x2019;s guidelines), slit it carefully and remove. Caution:

Do not damage the insulation and wires inside the cover insulation!

Unscrew the housing from the cylinder and push the seal over the wires.

Push out the contacts with appropriate tool out of the insulator - see paragraph 3.2 by applying even and continuous pressure towards the connector, keep the tool parallel to the axis of the plug connector. Stop when the shoulder of the tool touches the front of the insulator. Carefully pull the tool from the insulator. Remove all contacts in the same way, make sure to note different versions / tools. Important:

The tool must fit properly into or over the contacts.

The housing and seal normally stay on the wiring. If necessary, pull the wires and contacts carefully from the seal, remove the housing from the wires.

3.4. To wire the Contacts Contact size

Contact Wire diameter Adjustment - Crimp tool Stripping type Color length S=Socket Metric AWG mmÂ˛ AWG Dial No. Crimping (mm) P=Pin insert P 5 blue +0,5 1,0 18 6,0 S 5 green 15S 16S P 6 blue 1,5 16 6,0+0,5 S 6 green P 5 green 1,0 18 6,0+0,5 S 5 red 15 16 P 6 green +0,5 1,5 16 6,0 S 6 red P 8 red +0,5 25 12 2,5 12 6,0 S 8 red Strip the wire as noted on chart and crimp - see paragraph 2.1 to 2.3 3.5. Insertion of Contacts Note general guidelines in paragraph 1. Push the plastic insulation over the housing onto the wires. If housing and sealer were removed, push on housing, dip seal into isopropyl alcohol and guide contact with cable from the side marked with letter. Use the appropriate insertion tool.

Important:

The seal housing must align with the insulator housing!

Note the installation position of the wire as noted on number coding plan.

Insert contacts into the guide tool, push the insertion tool to the top of the connector tip. On socket type contacts, insert guide pin. Dip in isopropyl alcohol and insert straight into insulator until it snaps into position.

Important:

Make sure to check number coding chart.

Remove guide pin and insertion tool. Slightly pull the wire to check proper seating of the contact, plug chambers with empty contacts.

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ITT-Cannon plug

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Push sealer and housing into cylinder housing, carefully tighten nut. If necessary, use the counter part of the connector as a retainer.

To retain all parts, loosen nut by 1/4 turn and retighten properly, secure with adhesive.

On electronic wiring harness, insert heat seal (Ray-blocker) on end of insulation and adhere during the following shrinking procedure.

Pull shrink fit sleeve over housing and evenly heat with hot air blower until all parts are tightly covered.

Caution:

Do not pull the wires during the shrink fit procedure. Do not apply heat above 125° C (257° F).

4. Installation Guidelines KPSE plug Connector

4.1. Design A = Socket B = plug Item listing 1 Insulator 1.1 Contact retainer (integrated in insulator) 2 Barrel 2.1 Seal ring 3 Cone ring 4 Housing 5 Bayonet coupling nut 6 Socket type contact with crimped wire 7 Pin type contact with crimped wire Tightening torque for end bell: Size:

KPSE

22-

21PB – DN Other specifications Size Classification Type of housing Model

8, 10

max. 4 Nm

12,14,16

max. 6 Nm

18, 20, 22, 24

max. 10 Nm

4.2. Chart Number / Type of contact size

Plug description

Insertion tool

Crimp tool

Notes

S=Socket, P=Pins Removal: MS24256 R16

KPSE 06E22-21PB-DN Plug (21 pole) on wiring harness - Cab

21 / P - 16

KPSE 07E22-21SB Socket (21 pole) in instrument panel for Wiring harness - Cab

21 / S - 16

Installation: A16

MS24256

Removal: MS24256 R16

KPSE 06E22-55SB-DN Socket (55 pole) on electronic wiring harness for electronic box

Installation: A16

MS24256

Removal: MS24256 R20

55 / S - 20

KPSE 06E8-3A SB-DN Plug (3 pole) on var. motor wiring harness left / right for RPM sensor

Installation: A20

MS24256

Removal: MS24256 R20

3 / S - 20

Installation: A20

MS24256

Tool:

M 22520/1-01

Insert:

CT120090-20

Tool:

M 22520/1-01

Insert:

CT120090-20

Tool:

M 22520/1-01

Insert:

CT120090-20

Tool:

M 22520/1-01

Insert:

CT120090-20

Contact size 16 per AWG Contact size 16 per AWG Contact size 20 per AWG Contact size 20 per AWG

4.3. Removal of contacts Note general guidelines in paragraph 1 . Carefully cut and remove shrink fit sleeve per manufacturerÂ&#x2019;s guidelines.

Important: Do not damage insulator and inside wires.

Remove housing, loosen cone ring, housing cone and push nut over the wires. Select proper removal tool for contact size per paragraph 4.2. Check and apply tool first while empty, check the ejector point and hollow needle for damage. Improper or damaged tools can damage plug parts. On pin contacts set tool above the pin until mark 1 straight on the insulator. On jack contacts, insert tool over socket until mark 2 into the insulator.

Applying even pressure to tool, move ejector with thumb and forefinger forward and push contact from retainer clip.

Carefully remove tool from insulator and pull contact by the wire from the socket.

Remove all contacts the same way. Remove all connector components from wire harness.

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ITT-Cannon plug

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4.4. Wiring of contacts Contact size

Contact Wire diameter Adjustment - Crimp Tool Insulator type Color Length S=Jack AWG mmÂ˛ AWG Dial No. Crimping (mm) P=Pins Insert P 20 0,96 18 5,0 5 red S P 16 1,5 16 6,5 6 blue S Insulate wire as noted on chart and crimp - see paragraph 2.1 to 2.3

4.5. Installation of Contacts Note general guidelines in paragraph 1..

Push the shrink fit sleeve and nut in proper sequence over the wires. Insert contact (see chart) by hand into reverse side of plug, until the top of the contact is no more than 3 mm from the insulator.

Push appropriate guide tool over the contact connector and hold it vertical to the front the insulator. Contact size 16 and 12 are inside the tool, the tool pushed against the top of the contact. On contacts, size 20, the side pushes against the end of the contact, therefore the contact is farther outside the tool.

Dip all parts in isopropyl alcohol and push evenly into insulator until you hear the contact click in.

Remove the tool and check if the contact is seated properly by a slight pull on the wires. Close off empty chambers with plug. Push cone ring as far as possible over the insulator. Apply isopropyl alcohol to lubricate contact surfaces. Push housing, on sockets also nut, onto cylinder housing and tighten carefully. If necessary, use plug connector part as holder. To set the parts, loosen the housing by 1/4 turn, retighten and secure with adhesive.

Pull shrink fit sleeve over housing and evenly heat with heater fan until all parts are tightly covered.

Caution:

Do not pull the wires during the shrink fit procedure. Do no apply heat above 125Â° C (257Â° F).

5. Installation Guidelines SURE SEAL Plug Connector 5.1. Design A = Plug B= Socket 1 Housing 2 Pin type contact 3 Socket type contact 4 Seal

5.2. Chart Number / Type of contact

Plug description

Insertion Tool

Crimp Tool

Notes

S=Jack, P=Pin SURE SEAL SS 5 P plug (5 pole) on electronic wiring harness

2-P 3-S

Removal: CET-SS-P/S Installation: CITG-SS-1

Tool: Insert:

M 22520/1-01 CT120090-20

P valid only for removal of socket

SURE SEAL SS 5 R plug (5 pole) on var. motor wiring harness - left/ right

3-P 2-S

Removal: CET-SS-P/S Installation: CITG-SS-1

Tool: Insert:

M 22520/1-01 CT120090-20

S valid only for removal of pin type contacts

5.3. Removal of contacts Note general guidelines in paragraph 1. Remove the plug, loosen connection. Remove shrink fit sleeve as described by manufacturer, or carefully slit open and remove.

Caution:

Do not damage the insulation or wires inside the cable!

Use proper extraction tool - see paragraph 5.2 - insert from contact side parallel to the plug axis into the socket or over the pin contact. Apply even pressure and push contacts out in direction of the cable. Carefully pull extraction tool from plug, clean wire. 5.4. To wire contacts Contact size AWG SS10

Contact type S=Socket P=Pin P S

Wire diameter mmÂ˛

AWG

Stripping length (mm)

0,96

6,0+0,3

Adjustment - crimp tool Dial. No

Color Crimp insert

5 5

gray gray

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Depending on the number of poles, the minimum stripping length must be adhered to on covered cables. No. of Min. stripping poles length (mm) 2, 3, 4 40 5, 6, 7 45 8, 9, 10 50 Strip the wire to the length shown on chart and crimp - see paragraph 2.1 to 2.3 5.5. To install contacts Note general guidelines described in paragraph 1. Push shrink fit sleeve onto wires. Insert plug into installation tool, see paragraph 2.1.31 to facilitate this process. Insert wired contact into the insertion tool, see paragraph 5.2, keeping contact 1, cable 2 and tool 3 in a straight line and push until tool shoulder touches contact.. On socket type contacts, add guide pin. Dip parts into isopropyl alcohol and push into plug, see chart, applying even pressure parallel to the length axis until it snaps in place. Remove guide pin, pull tool carefully from plug and check if wire is seated properly, by pulling slightly.. Remove plug from installation tool. Check seating and position of contacts again. On the end of the cover, insert seal (Ray-Block), and push shrink fit sleeve over plug. Evenly heat is with hot air fan until the Ray-Block is melted and the components are covered tightly. Caution:

Do not pull on the wires during the shrink fit procedure. Do not overheat the connector..

6. Installation Guidelines DEUTSCH Plug Connector General: In machines, plug connections type Deutsch DT and Deutsch HDP Series are used - see the following overview chart. Plug Connector series DT

A = Socket B = Plug

Item listing: 1

Housing

Grommet

Locking wedge socket

Locking wedge plug

Seal plug

Socket

Plug Connector series HDP

A = Socket B = Plug

Item listing: 1

Socket housing with pin

Plug housing with socket

Grommet

Union nut

6.1. Overview chart

Plug description

Number / Type of contact - size

Plug series

Notes

Crimp tool

for designations see group. 09

S=Socket, P=Pins Deutsch plug (2 pole)

2-S 2-P

Tool: Insert:

M 22520/1-01 CT120090-20

Y14

Deutsch Plug (3 pole)

3-S 3-P

Tool: Insert:

M 22520/1-01 CT120090-20

B5, B6, X34(S2)

4-S 4-P

Tool: Insert:

M 22520/1-01 CT120090-20

X69, X70, X71, X72, X77

6-S 6-P

Tool: Insert:

M 22520/1-01 CT120090-20

X6, X7

8-S 8-P

Tool: Turret:

M 22520/1-01 CT120090-20

X6, X/

12 - S 12 - P

Tool: Insert:

M 22520/1-01 CT120090-20

X65, X73

18 - S 18 - P

HDP

Tool: Insert:

M 22520/1-01 CT120090-20

X64

Deutsch Plug (4 pole) Deutsch Plug (6 pole) Deutsch Plug (8 pole) Deutsch Plug (12 pole)

Deutsch plug (18 pole)

6.2. Wiring of contacts contact size

contact Wire diameter Adjustment - Crimp tool Insulator type Length color crimping S=Jack AWG mm² AWG Dial No.. (mm) insert P=pin P 20 0,75 20 5,0 4 red S P 18 1,0 18 5,0 5 red S P 16 1,5 16 6,0 6 blue S P 12 2,5 12 6,0 8 gray S In case of repairs, crimp contacts >2,5 mm² must be soldered on the central cable harness. Benennung Description Dénomination

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6.3. Crimping of contacts See installation instructions, point 1 to 2.4 6.4. Installation of contacts DT Series: Contacts must engage properly at installation (click). Installation is made without tools. Inserted

Engaged

After positioning the contacts, the locking wedge must be inserted, see illustration Â&#x201E;DT-SeriesÂ&#x201C;. Note: Insert the contacts straight, do not kink. Use Isopropyl alcohol (rubbing alcohol) . 6.5. Removal of contacts DT Series: Remove the locking wedge and use a small screw driver to loosen the pin or bushing lock and pull the contact with the cable from the housing . 6.6. Installation of contacts HDP Series: Installation is made without tools. Contacts must engage properly (click). Inserted

Engaged

Note: Insert the contacts straight, do not kink. Use Isopropyl alcohol (rubbing alcohol) .

6.7. Removal of contacts HDP Series: To remove the contacts, use special tool, see section 02.1.31.

Select tool according to cable diameter and push over cable and pin or bushing contact. Push the lock in to loosen and pull out the cable together with contact and tool.

Loosen the lock

Pull out

Directions for use of Four Notch Hand Crimping Tool 1. General: Protect the pliers from contamination. Do not open with force. When crimping, push the tool together all the way before opening it again. Use positioning sleeve for „HAN D“ contacts, see section 02.1.31. 2. Four notch hand crimping tool, see section 02.1.31. Parts list: 1 2 3 4 5 6

Pliers Positioning sleeve Locking bar Lock screw Adjustment scale Adjustment screw

2.1. Attach the positioning sleeve Loosen the lock screw 4 on the locking bar, pull the bar 3 back and insert the sleeve 2, close the bar and retighten the lock screw 4. Set the crimping depth. Determine the diameter of the conductor and select the corresponding pin = crimping depth. For pin Id. No., see section 2.1.31. Conductor ø mm² AWG 0,50 20 0,75 18 1,00 18 1,38 16 1,50 16 2,10 14 2.50 14

Pin ø HAN D 1,55 1,55 1,55 1,60 1,80 1,45 1,55

Open and close the crimping tool several times and then hold in open position. Turn the adjustment screw, pos.6 until the edge of the indicator bar aligns with the line of the selected pin diameter. Close the tool and check the setting with the pin. If set correctly, the pin * must fit without a clearance into the existing tool opening. Caution: When the pin is inserted, do not open or close the tool - danger of breaking correct

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2.2. Crimping Before crimping, insulate the ends of the wire with a suitable tool - see section 02.1.31. 8 mm on 0.75 – 1.50 mm contacts 6 mm on 2.50 mm contacts Note:

The cable wires must be visible in the control bore. All cable wires must be caught in the crimping point. The insulation must reach the contact.

Insert the cable with the contact into the pre-set tool. Push the tool together, quickly and all the way. Pull the cable with the crimped contact from the tool and check the crimping. Note:

The tool can only be opened when the cable is crimped completely.

2.3. Installation of pin contacts - plug section on instrument panel

Set the plug section, pos.1 into the instrument panel. Set the pin contacts, pos.3 in to the contact base, pos.2. Screw the base with the plug section, pos.1.

2.4. Installation of bushing contacts / plug section central wiring harness Push the shrink fit sleeve or shrink fit part over the cable before installation of the contact base . Push the clamping section, pos.5, rubber seal with washers, pos.4, screw fitting, pos.3 and plug housing, pos.1 over the cable. For installation of contacts, use insertion tool, see section 02.1.31. Insert the bushing contacts into the contact base, pos. 2, screw the base together with the housing, pos. 1. Caution: The cables can be stuck / damaged when connecting. Screw the screw fitting, pos. 3 into the plug housing and tighten. Insert the rubber seal with washers and attach wiring harness with clamping section on the plug housing, pos. 1. Note:

Do not use damaged parts. Make sure all parts are positioned correctly, check corresponding plug illustrations (see section 9.2). Visually check the installation position of the contacts, route the cable free of tension.

2.5. Sealing Push the shrink fit sleeve over the clamping section, pos.5 and push in the screw fitting, pos.3 and use a hot air blower to heat evenly until the sleeve is shrunk in place. Note: Do not heat the components of the screw connection above 125°C ( 257°F). 2.6. Removal of pin and bushing contacts For removal, use removal tool, see section 02.1.31. Push the removal tool over the pin or bushing and loosen the lock, push the contacts out.

Installation guidelines for MATE-N-LOK and JUNIOR POWER TIMER plug connectors 1. MATE-N-LOK Design: Plug with contact pin

Socket with contact bushings

1.1. Use of hand crimping tool Profile 1 Pos.2 Wire diameter 0.5 – 1.3 mm² Profile 2 Pos.3 Wire diameter 1.3 – 2.1 mm²

Open the pliers, pos.1 all the way to insert the contact, which is to be crimped (note the correct profile) and slowly push the pliers together until the contact is lightly clamped on the crimping sleeve. Insert the wire, which is to be insulated (insulation length 5 mm). Push the pliers all the way together. Pull the crimped contact from the pliers and check the crimping.

Contact pin with crimped wire

Contact bushing with crimped wire

* = Contact notch

1.2. Installation of contacts Installation is made without tools. Note: Check contact notches before installation for damage or breaks. Contacts must audibly click when engaging in the housing. 1.3. Removal of contacts To remove the contacts, use special tool, see section 02.1.31. Use: Push the tool, pos.2 over the pin or bushing contact and push the contact notches together, pull the contact on the cable from housing, pos. 1 .

Benennung Description Dénomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

PR Litronic LR Litronic RL Litronic

Wiring installation guidelines Datum Edition Date

01 01

AMP plug

Blatt Page Feuille

2.3.04.01

2. JUNIOR POWER TIMER Design: Plug with contact pins

Socket with contact bushings

2.1. Use of hand crimping tool

Mark: Red

for cable diameter 0.25 - 1.60 mm²

Blue

for cable diameter 1.00 - 2.60 mm²

Yellow

for cable diameter 2.70 - 6.60 mm²

Open the pliers all the way to insert the contact, which is to be crimped with the seal and slowly push the pliers together until the contact is lightly clamped on the crimping sleeve. Insert the wire, which is to be insulated (insulation length 5 mm). Push the pliers all the way together.

Pull the crimped contact 1 from the pliers. Check the crimping with seal 2.

2.2. Installation of contacts Installation is made without tools. Note: Check contact notches before installation for damage or breaks. Contacts must audibly click when engaging in the housing. 2.3. Removal of contacts To remove the contacts, use special tool, see section 02.1.31. Use:

Push the tool, pos.2 over the pin or bushing contact and push the contact notches together, pull the contact on the cable from housing, pos. 1.

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