Page 1

       

 

    

 

    

   

 



     

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

     

                                 

 



   

     


Service Manual Index

LWT / Ausgabe / Edition / Edition / 03.2010

0.1.00 Index Section Title

Date of issue

0.1.00 Index

03.2010

1.0.00 Sub group index "General" 1.1.00 Foreword and explanation 1.2.00 Safety regulations Charts 1.3.01 Tightening torques 1.3.02 Conversion tables 1.3.03 Tapping holes 1.4.00 Conservation guidelines 1.5.00 Material weights

01.2008 01.2008 05.2008 05.2008 01.2009 01.2008 02.2010 03.2009

2.0.00 2.1.00 2.2.00 2.3.00

Sub group index "Tools and work instructions" Special tools Repair welding Installation instructions

01.2008 03.2010 03.2010 03.2010

3.0.00 3.1.40 3.1.60 3.2.00 3.3.00 3.4.40 3.4.60 3.5.00

Sub group index "Technical data and maintenance guidelines" Technical data Technical data Maintenance and inspection schedule Maintenance and inspection instructions Adjustment checklist Adjustment checklist Test and adjustment tasks

01.2008 06.2008 06.2008 03.2010 03.2009 03.2010 03.2010 03.2010

4.0.00 4.1.40 4.1.60 4.2.00

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

01.2008 01.2008 05.2008 05.2008

5.0.00 5.1.00 5.2.40 5.2.60 5.3.40 5.3.60 5.4.40 5.4.60

Sub group index "Coupling and splitterbox" Data page Coupling Coupling Pump distributor gear Pump distributor gear Coupling Pump output Coupling Pump output

01.2008 05.2008 05.2008 05.2008 01.2008 05.2008 05.2008 06.2008

6.0.00 6.1.00 6.2.40 6.2.60 6.3.40 6.3.60 6.4.00 6.5.40 6.5.60

Sub group index "Travel hydraulic" Data page Design Design Function Function Repair work and troubleshooting Component arrangement Component arrangement

01.2008 05.2008 06.2008 06.2008 01.2009 01.2009 05.2008 01.2008 05.2008

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Service Manual Index

7.0.00 7.1.00 7.2.00 7.3.00 7.4.00 7.5.40 7.5.60 8.0.00 8.1.40 8.1.60 8.2.40 8.2.60 8.3.00 8.4.40 8.4.60 8.5.40 8.5.60 8.6.00 8.7.00 8.8.00 8.9.00 8.10.00 9.0.00 9.1.40 9.1.41 9.1.60 9.1.61 9.2.00 9.3.40 9.3.60 9.4.00 9.5.00

Sub group index "Working hydraulic" Data page Design Function Repair work and troubleshooting Component arrangement Component arrangement

01.2008 05.2008 05.2008 02.2010 05.2008 01.2008 05.2008

Sub group index "Hydraulic components" Var. displacement pump Var. displacement pump Var. displacement motor Var. displacement motor Regulating pump – Working hydraulic Double gear pump – replenishing / fan drive Double gear pump – replenishing Gear motor – fan drive Gear motor – fan drive Pilot control – working hydraulic Control valve block Valves Hydraulic cylinder Control motor hoist gear – winch

01.2008 01.2008 01.2009 01.2008 05.2008 05.2008 05.2008 05.2008 05.2008 05.2008 01.2008 05.2008 02.2009 05.2008 05.2008

Sub group index "Electrical system – Diagrams and components" Wiring diagram, component description, function list Wiring diagram, component description, function list Wiring diagram, component description, function list Wiring diagram, component description, function list Instrument panel Component arrangement Component arrangement Joystick Inching- / brake pedal

05.2008 01.2010 01.2010 01.2010 01.2010 05.2008 02.2010 02.2010 02.2010 02.2009

10.0.00 Sub group index "Electrical system - descriptions" 10.1.00 Diagnostics software LinDiag 10.2.00 Software PDL – Diesel particle filter

01.2009 01.2010 01.2010

11.0.00 11.1.40 11.1.60 11.2.40 11.2.60 11.3.40 11.3.60

01.2008 05.2008 05.2008 01.2008 05.2008 01.2008 01.2009

Sub group index "Final drive" Data page Data page Design and Function Design and Function Sectional view - final drive Sectional view - final drive

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Date of issue

Section Title


Service Manual Index

Date of issue

Section Title

LWT / Ausgabe / Edition / Edition / 03.2010

12.0.00 12.1.00 12.2.00 12.3.00 12.3.01 12.4.40 12.4.60 12.5.00 12.6.00 12.7.40 12.7.60

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

01.2008 05.2008 01.2008 01.2010 01.2009 05.2008 03.2010 01.2008 01.2008 06.2008 06.2008

13.0.00 Sub group index "Working attachment – front side"

01.2008

14.0.00 Sub group index "Working attachment" 14.1.00 Hoist gear 14.2.00 Rope winch

01.2008 05.2008 02.2009

15.0.00 15.1.40 15.1.60 15.2.40 15.2.60 15.3.40 15.3.60

Sub group index "Main frame – Components" Cooler arrangement Cooler arrangement Equalizer bar Equalizer bar Engine mounting Engine mounting

01.2008 01.2008 05.2008 01.2008 05.2008 01.2008 05.2008

16.0.00 16.1.40 16.1.60 16.2.40 16.2.60 16.3.40 16.3.60

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

01.2008 05.2008 05.2008 01.2008 05.2008 01.2008 02.2009

17.0.00 17.1.00 17.2.00 17.3.00 17.4.00 17.5.00

Sub group index "Operator’s platform, heater, air conditioning system" Operator’s platform Heater with blower Air conditioning system Operator’s seat – air cushioned Throttle control

01.2008 01.2008 01.2008 01.2008 01.2008 05.2008

18.0.00 Sub group index "Special equipment" 18.1.00 Refueling pump 18.3.00 Add-on installations – Pipe chamfering device and welding generator

01.2009 03.2009 01.2009

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Service Manual Index

Date of issue

Section Title Sub group index "Additional documentation" Schematic – Travel hydraulic Schematics – Travel hydraulic Schematic – Working hydraulic Schematic – Working hydraulic Wiring diagram, component description, function list Wiring diagram, component description, function list Wiring diagram, component description, function list Wiring diagram, component description, function list

01.2008 05.2008 05.2008 02.2010 02.2010 01.2010 01.2010 01.2010 01.2010

LWT / Ausgabe / Edition / Edition / 03.2010

19.0.00 6.3.40 6.3.60 7.3.40 7.3.60 9.1.40 9.1.41 9.1.60 9.1.61

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Service Manual

General Sub group index - General

1 General 1.0.00 Sub group index - General Foreword and explanations ......................................................................... 1.1 Safety regulations ......................................................................................... 1.2 Charts ............................................................................................................. 1.3 Tightening torques ............................................................................................................1.3.01 Conversion tables ............................................................................................................. 1.3.02 Tapping holes ................................................................................................................... 1.3.03

Conservation guidelines ............................................................................... 1.4

LWT / Ausgabe / Edition / Edition / 01.2008

Material weights............................................................................................. 1.5

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Service Manual

General Foreword and explanation

1.1.00 Foreword and explanation 1

For information This manual contains technical data, design and functional descriptions, work and adjustment instructions as well as numerous drawings, functional views and illustrations for the LIEBHERR – Pipe layers (RL) of Series 4. This manual should simplify competent customer service of our products, however, it does not replace expert and qualified user training and attendance of our factory training classes. Generally valid technical basic information is not listed. Refer to separate documentation for operational and spare parts information. The manual will be updated and expanded as necessary when changes occur in series. For all tasks on the machine, accident prevention guidelines and safety guidelines must be strictly observed. This manual is solely for the own use of the registered owner and may not be duplicated or copied, complete or in part, nor passed on to a third person and remains the property of LIEBHERR-Werk Telfs GmbH. All rights reserved. – Printed in Austria. We reserve the right to make changes of technical details on the machine in comparison to the information and illustrations in this manual.

LWT / Ausgabe / Edition / Edition / 01.2008

Written and published by LIEBHERR-Werk Telfs GmbH., Technical Documentation Dept.

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General

Service Manual

Foreword and explanation

2

Explanation of layout To simplify finding certain information and filing of updates, we set up the following layout: Main group

Type group Structure based on information content or machine size

Component (item) groups according to register Sub group

Page number

Structure of main group according to sub group index

Continuous No. and complete number of pages within the type group

It is possible that other continuous numbers are listed after the continuous number, for example 9.4.20 - 13/15 - 02. This number is for supplements, especially for electrical schematics, where only one page is supplemented. Changes are supplied with the same number, but with a later date, supplements are assigned a new number. If only one page is valid for a certain machine group, then this is noted in the header. Note! This symbol is used in the manual for very important safety notes. This symbol identifies a standard listing. This symbol signifies the following: “The prerequisite must be met”. The maintenance personnel must first fulfil the precondition described, i.e. the machine must be brought into a particular work position in order to be able to carry out the actions subsequently described. This symbol identifies an action. The maintenance personnel should be active at this location and carry out the action described. This symbol identifies a result. The maintenance personnel is notified that a result will occur after a working step, for example, after the test knob is pressed, the LED light lights up.

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

LIEBHERR-Werk Telfs GmbH. Technical documentation

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LWT / Ausgabe / Edition / Edition / 01.2008

This note shows that a detail view of an illustration is shown rotated by a given angle, as compared to the actual installation position. (In this case 180°)


Service Manual

General Safety guidelines

1.2.00 Safety guidelines 1

Introduction Prior and during the performance of tests / inspections, adjustments and repairs, it is imperative that the following safety guidelines are observed: Any type of work may only be carried out by qualified expert personnel or under their guidance and supervision. Qualified expert personnel are persons, who, based on their specialized training and experience, have sufficient knowledge in the area of earthmoving equipment and the specific technology of our machines in particular and who are familiar with all applicable laws and general work protection regulations, accident prevention guidelines, regulations, guidelines and generally approved rules concerning technology so that they are able to evaluate if the earthmoving equipment is safe to operate and if the necessary work can be performed without endangering themselves or third persons. Machines with raised operator’s platform may not be driven! The machine may only be operated from a lowered and secured operator’s platform! Always adhere to the adjustment values noted in the LIEBHERR documentation when performing adjustment work. At the delivery of a machine, the operating personnel must be trained using the current operating instructions. The safety guidelines noted in the instructions must be particularly observed. These safety guidelines must also be observed during inspection, adjustment or repair work. However, there are special repair and / or inspection work which require qualified personnel to follow another procedure than that noted in the safety guidelines. In such cases, qualified personnel or individuals performing the work under the supervision of such personnel should assure that additional safety precautions necessary to insure the safety of those involved in the repair are taken. The decision to carry out this measure can only be made by qualified expertly trained personnel. Such items of repair and/ or inspection work include, but are not limited to the following: Opening the side doors while the Diesel engine running to carry out tests and / or adjustments. In these cases, care should be taken that the side engine compartment doors are properly secured during the entire duration of the work to prevent them from closing unexpectedly and / or inadvertently. Care should be exercised to assure that there will be no inadvertent or unintended contact of any part of the body with any moving and / or heated parts of the engine. Wear only tightly fitted clothing (no scarves, no tie, no wide sleeves, etc.) Starting the Diesel engine with tilted operator’s platform, as well as actuating the travel drive with properly raised machine for adjustment, repair or diagnostics purposes. In these cases, before starting the engine, the support of the operator’s platform support as well as the support for the machine and the required ground clearance for the track chains must be checked again.

LWT / Ausgabe / Edition / Edition / 05.2008

-

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General

Service Manual

Safety guidelines

2

Danger notes in this manual For description of work, which can pose a danger for man or machine, the required safety precautions are described in this manual. They are marked by the following notes:

Danger! Warns that certain working procedures without appropriate precautionary measures can result in fatal injuries. Warning! Warns that certain working procedures without appropriate precautionary measures can result in severe bodily injuries. Caution! Warns that certain working procedures without appropriate precautionary measures can result in bodily injuries or damage to the machine. Following these notes does not relieve you of the responsibility for following additional rules and guidelines! Additional points that should be noted are: the safety regulations which apply on the jobsite,

LWT / Ausgabe / Edition / Edition / 05.2008

statutory “road traffic regulations�, the guidelines provided by professional associations.

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Service Manual

General Safety guidelines

3

Safety guidelines in the operating instructions The detailed descriptions for the following safety guidelines are noted in the operating instructions of the machine and must be strictly observed. 2.1

Introduction

2.2

Designated use

2.3

Signs on the machine

2.4

Safety guidelines General safety guidelines

2.4.2

Crushing and burn prevention

2.4.3

Fire and explosion prevention

2.4.4

Safety guidelines for machine start up

2.4.5

Engine start up safety

2.4.6

Machine operating safety

2.4.7

Safety guidelines for working with the machine

2.4.8

Working in the vicinity of electrical overhead lines

2.4.9

Machine parking safety

2.4.10

Machine transporting safety

2.4.11

Machine towing safety

2.4.12

Machine maintenance safety

2.4.13

Safety guidelines for welding work on the machine

2.4.14

Safety guidelines for working on the attachment

2.4.15

Safety guidelines when loading the machine with a crane

2.4.16

Safe maintenance of hydraulic hoses and hose lines

2.4.17

Safety guidelines for maintenance work on machines with hydro accumulators

2.4.18

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

2.4.19

Equipment and attachment parts

2.4.20

Protection from vibrations

LWT / Ausgabe / Edition / Edition / 05.2008

2.4.1

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Service Manual

General Tightening torques

1.3.01 Tightening torques 1

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

black or phosphated – oiled

-

zinc plated – oiled

-

flZn according to LH standard 10021432 - dry (replaces DACROMET 500).

Medium friction value

G

= 0.12

Note! Any tightening torque values and/ or tightening procedures noted in drawings / parts lists, instructions or component descriptions must be adhered to and given preference over factory standards. Beginning with grade 10.9, no additional safety effect is provided when using lock washers Always use correctly sized torque wrenches – the torque value according to the chart should be within the upper third of the existing range. When using impact wrenches, care must be taken so that the torque values are not exceeded. Check before and intermediately with a torque wrench.

LWT / Ausgabe / Edition / Edition / 05.2008

Note! The tightening torques for the following components are noted in the following sections in detail: Hydraulic cylinder – see section 8.9. Track pad and sprocket segment screws – see section 12.1. Rope winch – see section 14.2.

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General

Service Manual

Tightening torques

2

Metric standard thread

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

Preload value Fm based on grades in N

Tightening torques Ma based on grades in Nm

Wrench size (x) = according to DIN931, for Hex head screw

Socket head screw

8.8

10.9

12.9

8.8

10.9

12.9

mm

Inch

mm

Inch

x 0.7

4050

6000

7000

2,8

4,1

4,8

7

9/32

3

--

M5

x 0.8

6600

9700

11400

5,5

8,1

9,5

8

5/16

4

5/32

M6

x1

9400

13700

16100

9,5

14

16,5

10

--

5

--

M7

x1

13700

20100

23500

15,5

23

27

11

--

--

--

M8

x 1.25

17200

25000

29500

23

34

40

13

1/2

6

--

M 10

x 1.5

27500

40000

47000

46

68

79

(17) 16

(11/16)--

8

5/16

M 12

x 1.75

40000

59000

69000

79

117

135

(19) 18

(3/4) - -

10

--

M 14

x2

55000

80000

94000

125

185

215

(22) 21

(7/8) - -

12

--

M 16

x2

75000

111000

130000

195

280

330

24

--

14

9/16

M 18

x 2.5

94000

135000

157000

280

390

460

27

1-1/16

14

9/16

M 20

x 2.5

121000

173000

202000

390

560

650

30

1-3/16

17

--

M 22

x 2.5

152000

216000

250000

530

750

880

(32) 34

--

17

--

M 24

x3

175000

249000

290000

670

960

1120

36

1-7/16

19

3/4

M 27

x3

230000

330000

385000

1000

1400

1650

41

1-5/8

19

3/4

M 30

x 3.5

280000

400000

465000

1350

1900

2250

46

1-13/16

22

7/8

M 33

x 3.5

350000

495000

580000

1850

2600

3000

50

2

24

--

M 36

x4

410000

580000

680000

2350

3300

3900

55

2-3/16

27

1-1/16

M 39

x4

490000

700000

820000

3000

4300

5100

60

2-3/8

27

1-1/16

LWT / Ausgabe / Edition / Edition / 05.2008

M4

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Service Manual

General Tightening torques

3

Metric standard thread

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

Preload value Fm based on grades in N

Tightening torques Ma based on grades in Nm

Wrench size (x) = according to DIN931, for

LWT / Ausgabe / Edition / Edition / 05.2008

Hex head screw

Socket head screw

8.8

10.9

12.9

8.8

10.9

12.9

mm

Inch

mm

Inch

M8

x1

18800

27500

32500

24,5

36

43

13

1/2

6

--

M9

x1

24800

36500

42500

36

53

62

--

--

--

--

M 10

x1

31500

46500

54000

52

76

89

17

11/16

8

5/16

M 10

x 1.25

29500

43000

51000

49

72

84

17

11/16

8

5/16

M 12

x 1.25

45000

66000

77000

87

125

150

19

3/4

10

--

M 12

x 1.5

42500

62000

73000

83

122

145

19

3/4

10

--

M 14

x 1.5

61000

89000

104000

135

200

235

22

7/8

12

--

M 16

x 1.5

82000

121000

141000

205

300

360

24

--

14

9/16

M 18

x 1.5

110000

157000

184000

310

440

520

27

1-1/16

14

9/16

M 18

x2

102000

146000

170000

290

420

490

27

1-1/16

14

9/16

M 20

x 1.5

139000

199000

232000

430

620

720

30

1-3/16

17

--

M 22

x 1.5

171000

245000

285000

580

820

960

32

--

17

--

M 24

x 1.5

207000

295000

346000

760

1090

1270

36

1-7/16

19

3/4

M 24

x2

196000

280000

325000

730

1040

1220

36

1-7/16

19

3/4

M 27

x 1.5

267000

381000

445000

1110

1580

1850

41

1-5/8

19

3/4

M 27

x2

255000

365000

425000

1070

1500

1800

41

1-5/8

19

3/4

M 30

x 1.5

335000

477000

558000

1540

2190

2560

46

1-13/16

22

7/8

M 30

x2

321000

457000

534000

1490

2120

2480

46

1-13/16

22

7/8

M 33

x 1.5

410000

584000

683000

2050

2920

3420

50

2

24

--

M 33

x2

395000

560000

660000

2000

2800

3300

50

2

24

--

M 36

x 1.5

492000

701000

820000

2680

3820

4470

55

2-3/16

27

1-1/16

M 36

x3

440000

630000

740000

2500

3500

4100

55

2-3/16

27

1-1/16

M 39

x 1.5

582000

830000

971000

3430

4890

5720

60

2-3/8

27

1-1/16

M 39

x3

530000

750000

880000

3200

4600

5300

60

2-3/8

27

1-1/16

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General

Service Manual

Tightening torques

4

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

4.1

4.2

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

Flange nominal size

Screw size

½" ¾" 1" 1 ¼" 1 ½" 2"

M8 M 10 M 12 M 14 M 16 M 20

Flat flange without Flange with reinforcement rim reinforcement rim

Half flange 31 62 108 172 264 350

-45 70 120 170 250

-65 110 180 250 450

Half flange for low pressure (Norm 61) Flange nominal size

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

Screw grade 8.8 22 44 44 44 76 76 76 122 187 187 187

Screw grade 10.9 31 62 62 62 108 108 108 172 264 264 264

LWT / Ausgabe / Edition / Edition / 05.2008

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

Tightening torques in Nm for

Screw size

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Service Manual

General Conversion chart

1.3.02 Conversion chart Size Length

0,039

m

3,281

m

Multiplier

Multiplier

to unit

25,4

mm

feet

0,305

m

1,093

yard

0,914

m

km

0,621

mile

1,609

km

cm²

0,155

sq. inch

6,452

cm²

10,764

sq. feet

0,093

1,196

sq. yard

0,863

km²

0,386

sq. mile

2,59

km²

cm³

0,061

cu. inch

16,387

cm³

35,314

cu. feet

0,028

1,308

cu. yard

0,764

l

61,025

cu. inch

l

0,035

cu. feet

28,316

l

l

0,264

gallon

3,785

l

l

1,057

quart

0,946

l

g

0,035

oz.

28,349

g

kg

2,204

lbs.

0,453

kg

t

1,102

short t

0,907

t

N

0,225

lbs.

4,449

N

kN

224,732

lbs.

0,0044

kN

Torque

Nm

0,737

ft. lbs.

1,356

Nm

Performance

kW

1,342

HP

0,745

kW

PS

0,736

kW

1,358

PS

Pressure

bar

14,5

PSI

0,069

bar

(hydraulic)

kpa

0,145

PSI

6,896

kpa

0,0703

kg/cm²

4,878

kg/m²

27,78

g/cm³

16,13

kg/m³

Area

Volume

Mass

Force

Ground pressure Density LWT / Ausgabe / Edition / Edition / 01.2009

mm

to unit from inch

from unit

Speed Temperature

kg/cm²

14,223

l

2

lbs.inch 2

kg/m²

0,205

lbs. ft.

g/cm³

0,036

lbs. inch 3

3

kg/m³

0,062

lbs. ft.

km/h

0,621

Mph

1,609

km/h

m/min

3,281

ft. / min

0,305

m/min

°C

(°Cx1,8) + 32

°F

(°F-32)/1,8

°C

°C

°C+273

°K

°K-273

°C

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General

Service Manual

LWT / Ausgabe / Edition / Edition / 01.2009

Conversion chart

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Service Manual

General Tapping holes

1.3.03 Tapping holes 1

Tapping holes for metric ISO standard threads Thread

LWT / Ausgabe / Edition / Edition / 01.2008

M1 M 1,1 M 1,2 M 1,4 M 1,6 M 1,7 M 1,8 M2 M 2,2 M 2,3 M 2,5 M 2,6 M3 M 3,5 M4 M 4,5 M5 M6 M7 M8 M9 M 10 M 11 M 12 M 14 M 16 M 18 M 20 M 22 M 24 M 27 M 30 M 33 M 36 M 39 M 42 M 45 M 48 M 52 M 56 M 60 M 64 M 68

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

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

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General

Service Manual

Tapping holes

Tapping holes for metric ISO fine threads

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

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

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

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

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

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

LWT / Ausgabe / Edition / Edition / 01.2008

2


Service Manual

General Conservation guidelines

1.4.00 Conservation guidelines 1

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

2

Taking the machine out of service – for an unknown duration If a machine is taken out of service for a longer period of time without conservation, then it must be operated in intervals not to exceed 14 days, to prevent abnormal corrosion and its effects.

LWT / Ausgabe / Edition / Edition / 02.2010

Before putting the machine back into service, check all oil levels and correct them, if necessary. Always carry out the specified daily maintenance work before putting the machine back into service. In addition, carry out the time limited maintenance work according to the inspection schedule and additional Diesel engine Operating instructions no later than the specified intervals. Put the machine into operation according to the Operating instructions and operate it until the Diesel engine and the hydraulic system has reached the specified operating temperature in the hydraulic tank and in the coolant circuit. Actuate all functions of the travel, working hydraulic as well as functions of additionally installed hydraulic components and alternately operate them over a period of approx. 20 minutes. The hydraulic cylinders must be extended and retracted over their full stroke length. When turning the machine off, retract all hydraulic cylinders fully, if possible, and fill the fuel tank. If the machine is parked on soft ground, park the machine on wooden planks or similar and secure it to prevent it from rolling off. Check the batteries and remove them and recharge them, if necessary. Check the electrical contact points and grease them, if necessary.

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Conservation guidelines

3

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

3.1

Shut down for up to 2 months Required tools / Service items Id. No. See section 2.1

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

WAXOYL 120-4 Anti corrosion wax

8504472

Ballistol Spray Corrosion protection Dehumidification capsule

10025514

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

10013313

Display

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

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Description Optical charge tester


Service Manual

General Conservation guidelines

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

3.2

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

LWT / Ausgabe / Edition / Edition / 02.2010

Release the chain tension by relieving the tension cylinder (see Operating instructions). Check the machine monthly and reapply conservation protective measures if necessary.

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Conservation guidelines

3.3

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

4 4.1

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

4.2

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

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Carry out the items according to paragraph 4.1.


Service Manual

General Conservation guidelines

4.3

After shut down of longer than 12 months Complete all items outlined in paragraph 4.2 and 4.1.

LWT / Ausgabe / Edition / Edition / 02.2010

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

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Service Manual

LWT / Ausgabe / Edition / Edition / 02.2010

Conservation guidelines

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General Material weights

1.5.00 Material weights A B

spec. weight 1) in kg/m3 solid Loosening in %

C D

Loosening facttor spec. weight kg/m3 loose

Material - raw - washed Ash bituminous coal Basalt Bauxite, Kaolin Bituminous coal - raw - washed Carnotite, Uranium ore Soil - dry hardened - wet loosened - clay Gypsum - broken - ground Granite - broken Hematite, iron ore Limestone - broken - ground Gravel - damp - dry - dry 6-50mm - wet 6-50mm Coke Loam, clay - seasoned - dry - wet Clay with gravel - dry - wet Magnetite, iron ore Topsoil Natural stone - ground Pyrite, iron ore Sand - dry, lose - damp - wet Sand with clay - lose - compressed Sand with gravel - dry - wet Sandstone Slate Slag - broken Snow - dry - wet Trapp rock - broken

LWT / Ausgabe / Edition / Edition / 03.2009

Anthracite coal

A

B

C

D

1600 590 - 890 2970 1900 1280 2200 1900 2020 1540 3170 2790 2730 2130 - 2900 2610 2170 1690 1900 2260 860 2020 1840 2080 1660 1840 3260 1370 2670 3030 1600 1900 2080 2020 1930 2230 2520 1660 2940 2610

35 35 8 52 33 35 35 35 26 26 23 75 75 64 18 69 12 12 12 12 54 22 24 24 17 19 17 44 67 18 12 12 13 26 12 10 67 33 68 49

0,74 0,74 0,93 0,66 0,75 0,74 0,74 0,74 0,79 0,79 0,81 0,57 0,57 0,61 0,85 0,59 0,89 0,89 0,89 0,89 0,65 0,82 0,80 0,80 0,86 0,84 0,86 0,69 0,60 0,85 0,89 0,89 0,88 0,79 0,89 0,91 0,60 0,75 0,59 0,67

1190 1100 550 - 830 1960 1420 950 830 1630 1510 1600 1250 1810 1660 1660 1810 - 2450 1540 1540 1930 1510 1690 2020 1560 1660 1480 1660 1420 2540 2790 950 1600 2580 1420 1690 1840 1600 2400 1720 2020 1510 1250 1750 130 520 1750

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Material weights

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

A

B

C

D

2790

42

0,70

1960

2280

33

0,75

1720

1960

24

0,80

1570

LWT / Ausgabe / Edition / Edition / 03.2009

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

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Service Manual

Tools and work instructions Sub group index -Tools and work instructions

2 Tools and work instructions 2.0.00 Sub group index -Tools and work instructions Special tools .................................................................................................. 2.1 Repair welding ............................................................................................... 2.2

LWT / Ausgabe / Edition / Edition / 01.2008

Installation instructions ............................................................................... 2.3

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Tools and work instructions

Service Manual

LWT / Ausgabe / Edition / Edition / 01.2008

Sub group index -Tools and work instructions

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Tools and work instructions Special tools

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

1 1.1

Special tools Maintenance Diesel engine

Description

Id. No.

M-Type

Remarks

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

LWT / Ausgabe / Edition / Edition / 03.2010

Communication cable for LH-ECU-UPCR – control units

Communication cable for DC4 / DC5 – control units

10450054

LR Series 4 RL Series 4 PR 724 9200 PR 734 8220 PR 744 7356 PR 754 6924 PR 764 6888

10035410

10035411

F/NxxxF/Nxxx-

Illustration

Diagnostics software for maintenance and adjustment of Diesel engine. For ordering, a Liebherr form from Liebherr Bulle must be filled out.

F/NxxxF/NxxxF/Nxxx-

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

Download the current software version with the aid of the Lidos DVD.

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

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Tools and work instructions

Service Manual

Special tools

Description Digital rpm gauge „Shimpo“

Id. No. 7364284

M-Type

Remarks

Illustration

PR Series 4 LR Series 4 RL Series 4

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

614063201

Digital rpm gauge „Piezzo A2106“

10286429

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

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

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

5608459

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

To check the DCA 4 concentration in the coolant

Hand pump [1]

8145666

PR Series 4 LR Series 4 RL Series 4

To take oil samples for the oil analysis

Oil sample vale for oil samples [2]

7019068

PR Series 4 LR Series 4 RL Series 4

Analysis at WEAR CHECK Germany

Oil analysis set– mineral oil (green cover) Individual set 4 sets 6 sets 12 sets Oil analysis set – Bio oil (yellow cover) Individual set 6 sets

LWT / Ausgabe / Edition / Edition / 03.2010

Reflective strip

8145660 10029626 7018368 7018369

7026817 7026088

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Service Manual

Tools and work instructions Special tools

Description

Id. No.

M-Type

Remarks

V-belt test unit „Krikit2“

8042829

PR Series 4 LR Series 4 RL Series 4

To check the V-belt tension

Optical battery tester

7408922

PR Series 4 LR Series 4 RL Series 4

To check the battery charge and the antifreeze in the coolant

Turning device for valve clearance / check / adjust Pos. 1

0524045

LR Series 4

To be installed on the flywheel housing instead of the cover

RL Series 4 PR Series 4 except Pos. 2

10490350 10116805

10454803

To be installed on the V-belt crankshaft

PR Series 4 LR Series 4 RL Series 4

For optional Diesel particle filter. Can also be used for leak test of counterpressure line

LWT / Ausgabe / Edition / Edition / 03.2010

Hand pump with pressure gauge

PR 764 F/Nxxx-9506 RL 64 (can be used alternatively also on PR 724 F/Nxxx-9200 PR 734 F/Nxxx-8220 PR 744 PR 754 LR 624 LR 634 RL 44 )

Illustration

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Tools and work instructions

Service Manual

Special tools

1.2

Hydraulic system

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

Id. No. 7408148

M-Type

Remarks

PR Series 4 LR Series 4 RL Series 4

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

PR Series 4 LR Series 4 RL Series 4

Accuracy: 2% / 2°

7407987 7407985 10301165 7404619 4901110 7360127 10038447 10038448 7408151 10024185

Illustration

Difference pressure – Mess-Set 230V/120V

10288229

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

5002865 7361289 7361288 5002867 5602903 7361286 7361285 7500002 7361294 4601115

PR Series 4 LR Series 4 RL Series 4

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

PR Series 4 LR Series 4 RL Series 4

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

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Test range: -18°C to +260°C


Service Manual

Tools and work instructions Special tools

Description Pressure gauge connection R½

Id. No. 7002436

Test fitting cpl. R6L R 10 L R 12 L

7409916 7406864 7409918

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

7615321 5608462 7407071 7406865 7409720

Screw coupling M 16x2

7407070

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

7002437 7002475 7009134 7363732

LWT / Ausgabe / Edition / Edition / 03.2010

Hook wrench 58 - 62 mm

7900282

Socket wrench For grooved nut variable pump HPV

9792711

M-Type

Remarks

PR Series 4 LR Series 4 RL Series 4

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

PR Series 4 LR Series 4 RL Series 4

Union nut and compression ring are affixed on the test fitting

PR Series 4 LR Series 4 RL Series 4

To connect to additional test points in the machines

PR Series 4 LR Series 4 RL Series 4

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

PR Series 4 LR Series 4 RL Series 4

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

PR Series 4 LR Series 4 RL Series 4

To loosen / counter when adjusting the pump regulating range

PR Series 4 LR Series 4 RL Series 4

To loosen / counter when adjusting the pump end stop. Use with hook wrench Id. Nr. 7900282

Illustration

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Tools and work instructions

Service Manual

Special tools

Description Socket wrench for 0position grooved nut Variable pump HPV

Id. No. 9749025

Test plates For SAE-flange ž A 90mm B 40mm C,r 5mm For SAE-flange 1 A 90mm B 44mm C,r 5mm For SAE-flange 1Ÿ A 90mm B 52mm C,r 5mm

Remarks

PR Series 4 LR Series 4 RL Series 4

To loosen / counter the grooved nut when adjusting the hydraulic zero position

PR Series 4 LR Series 4 RL Series 4

To close off high pressure connections Material: Ground spring steel

7370093

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

7370094

Or to be made inhouse 8006305

Illustration

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

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

LWT / Ausgabe / Edition / Edition / 03.2010

Open ended wrench SW 30/32

7370092

M-Type

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Service Manual

Tools and work instructions Special tools

1.3

Electrical system

Description LinDiag Diagnostics KIT

Id. No. 9413782

Consisting of: Data carrier with latest software version + Dongle

9410472

Adapter cable

9932747

LinDiag Diagnostics KIT

9413763

Consisting of:

LWT / Ausgabe / Edition / Edition / 03.2010

Data carrier with latest software version + Dongle Adapter cable

9410472

10035410

M-Type

Remarks

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

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

LR Series 4 RL Series 4

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

PR 724 9200 PR 734 8220 PR 744 7356 PR 754 6924 PR 764 9506

F/NxxxF/NxxxF/Nxxx-

Illustration

F/NxxxF/Nxxx-

USB – Adapter

693190714

PR Series 4 LR Series 4 RL Series 4

Intermediate adapter from serial interface to USB

Digital multi meter cpl. with cable and bag

10018500

PR Series 4 LR Series 4 RL Series 4

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

Optical charge tester

see Pt. 1.1 Diesel engine

PR Series 4 LR Series 4 RL Series 4

To check the battery condition and the antifreeze in the coolant

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Tools and work instructions

Service Manual

Special tools

1.4

Mechanical component groups

Description

Id. No.

Test tool Travel gear

7402603

M-Type

Remarks

Illustration

PR Series 4 LR Series 4 RL Series 4

To measure travel gear wear For use, see section 12.2

2 2.1

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

Hydraulic system

Description Pressurized air cartridge

Brake vent adapter

Id. No. 10045498

9401975

Socket wrench Valve sleeve Valve – 3 slits

10430260

Valve – 2 slits

10491131

M-Type

Remarks

LR Series 4 RL Series 4

CO2 cartridge to vent the parking brake for towing operation.

PR 724 7697 PR 734 8220 PR 744 7356 PR 754 6924 PR 764 6888

F/Nxxx-

Illustration

F/NxxxF/NxxxF/NxxxF/Nxxx-

PR Series 4 LR Series 4 RL Series 4

Adapter for pressurized air cartridge (part of tool kit)

For repair of variable motor HMV To remove and install the valve sleeve of the directional valve See section 8.2 Position 73

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2.2


Service Manual

Tools and work instructions Special tools

Description

Id. No.

M-Type

Mandrel Thrust ring HPV 105

10472254

HPV 135

10472255

HPV 210

10472257

HMV 165

10472261

HMV 210

10472266

HPV 280

10472269

HMV 280

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

LWT / Ausgabe / Edition / Edition / 03.2010

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

Remarks

Illustration

For repair of var. pump HPV or var. motor HMV For the installation of the hot thrust ring on the drive shaft. See chapter 8.1 or 8.2, Position 11

For repair of var. pump HPV or var. motor HMV

HPV 105 HPV 105

1 2

10472303 10411001

PR 724 LR 624

HPV 135 HPV 135

1 2

10472310 10411002

HMV 165 HMV 165

1 2

10472316 10410291

PR 734 LR 634 RL 44 PR 744 LR 624

HMV 210

1

10472317

HPV 210

1

HMV 210

2

HPV 210

2

HMV 280

1

HPV 280

1

HMV 280

2

HPV 280

2

10410295

10472318

10411003

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

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

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Tools and work instructions

Service Manual

Special tools

Description

Id. No.

M-Type

Installation aid for seal ring on oil guide pipes

Remarks

Illustration

For repair of var. pump HPV or var. motor HMV

Pos.1 HPV + HMV

10472322

Pos.2 HPV 105

10472321

Spindle device for swash plate mount

10324938

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

PR Series 4 LR Series 4 RL Series 4

The tool is used to install the O-rings on the oil guide pipes See section 8.1 Position 46 or section 8.2. Position 45 For repair of var. pump HPV

With this device, the swash plate mount can be lowered targeted onto the pump housing at installation.

For repair of var. pump HPV or var. motor HMV

M12

HPV

10472319

M14

HPV

10472320

M14

HMV

M16

HPV

M16

HMV

10347066

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

The guide pins are used to guide the swash plate mount at assembly with the pump housing. minimum 2 each maximum 4 each required LWT / Ausgabe / Edition / Edition / 03.2010

Centering pins for swash plate mount

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Service Manual

Tools and work instructions Special tools

Description

Id. No.

Centering device for swash plate mount

10324937

M-Type

Remarks

PR Series 4 LR Series 4 RL Series 4

For repair of var. pump HPV or var. motor HMV

Illustration

Device to affix the oil guide pipes at installation of swash plate mount 2 each required

Note! The Id. numbers for the following tools are in the spare parts list for the hydraulic cylinders.

Assembly sleeve

see spare parts list

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

Spreader sleeve

see spare parts list

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

Installation wrench Piston

see spare parts list

To tighten the pistons of hydraulic cylinders

LWT / Ausgabe / Edition / Edition / 03.2010

For tightening torque, see section 8 Hydraulic cylinder Installation wrench Piston nut

To tighten the piston nuts of hydraulic cylinders

see spare parts list

For tightening torque, see section 8 Hydraulic cylinder

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Tools and work instructions

Service Manual

Special tools

Electrical system

Description

Id. No.

Crimper for MATE-N-LOK Crimp contacts

M-Type

Remarks

Illustration

PR Series 4 LR Series 4 RL Series 4

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

PR Series 4 LR Series 4 RL Series 4

To remove crimp contacts from plug connector

For 1.5 mm² For 2.5 mm²

7367025 7366314

Removal tool AMP for MATE-N-LOK Crimp contacts

7366655

Spare insert

7015180

Installation tool AMP for MATE-N-LOK Crimp contacts

8145432

PR Series 4 LR Series 4 RL Series 4

To insert the pin and bushing contacts in MATEN-LOK plug connectors

Hand crimper for „Deutsch“ plug connector

8503647

PR Series 4 LR Series 4 RL Series 4

To make proper crimp connections

PR Series 4 LR Series 4 RL Series 4

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

PR Series 4 LR Series 4 RL Series 4

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

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

10114733 885563714 10114732

Removal tool Cannon for „Deutsch“ crimp contacts (alternate) AWG 12 AWG 16 AWG 20

8145674 8145673 8503630

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2.3


Service Manual

Tools and work instructions Special tools

Description Crimper AMP AMP Certi-Lock

Id. No. 7415333

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

7026266 7027340

Crimper ESA 0760 CRB 0560

7409781 7409782

M-Type

Remarks

PR Series 4 LR Series 4 RL Series 4

To crimp the „JUNIOR POWER TIMER“ contacts

PR Series 4 LR Series 4 RL Series 4

To remove contacts from the „JUNIOR POWER TIMER“ housing

PR Series 4 LR Series 4 RL Series 4

To crimp insulated 0.5 -6.0 mm² cable shoes, for example cable connectors CRB 0560 also windshield wiper motor

Coding plug Inching / brake pedal 9813111

X46.1

9413850

PR Series 4 RL Series 4 LR Series 4

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

LWT / Ausgabe / Edition / Edition / 03.2010

X46

Illustration

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Tools and work instructions

Service Manual

Special tools

Mechanical component groups

Description

Id. No.

M-Type

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

LR 624 Device No.: 07590 45459 07590 45458

10467795 10467796 PR 724 LR 634

Device No.: 07590 38616 07590 43327

10219780 10219779 PR 734 RL 44

Device No.: 07590 39022 07590 43326

10017428 10219781 PR 744

Device No.: 07590 38891 07590 38472

10017436 10303340 PR 754 RL 64 10017433 10017472

B

Pos.2 Screw in handle for all installation flanges

Device No.: 07590 39023 00100 01300

PR 764 Device No.: 07590 41338 07590 38886

10017468 10017430

Mandrel Pos.1 Installation flange A

Illustration

To properly install the slip ring seals on travel gears

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

Remarks

9786683 9786685 9786686

9786684 9786687 9411074

9786688

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

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

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2.4


Service Manual

Tools and work instructions Special tools

Description

Id. No.

Inside puller

Commercially available tool

M-Type

Remarks

PR Series 4

To pull the bushings, Pos. 3 and Pos.4 from the hoist cylinder bearing

PR Series 4 LR Series 4 RL Series 4

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

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

A B C D

PR 724

PR 734

90 70 247 89,5

90 70 273 96

Pull tool Elastic bearing – operator’s platform

Installation sleeve Equalizer bar bearing

PR744 PR754 PR764 120 90 273 114

9404645

9415227

In-house manufacture

LWT / Ausgabe / Edition / Edition / 03.2010

Installation wrench Tension unit

Installation tool Tension unit

Illustration

9416915

PR 764

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

9416913

PR 764

9416922

PR 754 RL 64

9416921

PR 764

For dimensions for in-house manufacture of mandrel, see Pt. 3. To install the outer um equalizer bar bearing For dimensions for in-house manufacture of assembly sleeves, see Pt. 33.

Special hook wrench to release and attach the ring nut

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

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Tools and work instructions

Service Manual

Special tools

Description

Id. No.

M-Type

Remarks For removal / installation of tension unit – chain tensioner is required!

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

9798353 9798352 4601217

PR 754 RL 64

Installation tool cpl.

9415198

PR 764

Mechanical device (without hydraulic components)

10303939

LR Series 4

10307625

RL 44

Hydraulic components For Installation tool

10303852

LR Series 4 RL 44

Illustration

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

Installation tool Tension unit

For use, see section 12 Tension unit

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

Hand pump

Hydraulic hose

Pressure gauge

Enerpac RC 506 (50 t single acting)

Enerpac P80 (two stage hand pump)

Enerpac HC-7206

Enerpac GF-50B

71.2 cm2

Operating pressure max.700ba

Oil volume

1131cm3

Lever force max.

47,0kg

Weight

10,9kg

Weight

23,1kg

9.5 x 1800mm

Pressure range 0-700bar

LWT / Ausgabe / Edition / Edition / 03.2010

Piston surface

Installation height retracted 282mm extended 441mm outside 127mm

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Service Manual

Tools and work instructions Special tools

Description Installation sleeve Equalizer bar

Installation tool set Double oscillating track roller

Id. No.

M-Type

Remarks

10306449

PR 754

To press the equalizer bar in with oscillating track rollers.

10318790

PR 764

Pos.1 Threaded rod M30x360 (2 each) Pos.2 Plate

For dimensions for in-house manufacture of mandrel, see Pt. 3. For removal / installation of pins with bearing for double oscillating track rollers.

Pos.3 Washer M30 (2 each) Pos.4 Hex nut M30 (4 each)

For dimensions for in-house manufacture of plate (Pos.2) see Pt. 3.

Installation tool Double oscillating track roller Hydraulic components for Installation tool

For use, see section 2.3 For removal / installation of pins with bearing for double oscillating track rollers.

PR764

Consisting of: Hydraulic cylinder Enerpac RCS 201

11081098

Hydraulic hose Enerpac HC- 7206

10430200

Pressure gauge Enerpac GF- 230B Intermediate section Enerpac GA-2 Hand pump Enerpac P39

11081099

Illustration

For use, see section 2.3

10430202

LWT / Ausgabe / Edition / Edition / 03.2010

886120508

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Tools and work instructions

Service Manual

Special tools

Technical data – Hydraulic components Hydraulic cylinder

Hand pump

Hydraulic hose

Pressure gauge

Enerpac RCS 201 (20 t single acting)

Enerpac P39 (two stage hand pump)

Enerpac HC-7206

Enerpac GF-230B

2

Piston surface

28,7cm

Operating pressure max.700ba

Oil volume

129cm3

Lever force max.

50kg

Weight

5,9kg

Weight

5kg

Pressure range 0-700bar

9,5 x 1800mm

Installation height retracted 98mm extended 143mm outside 92mm

3 3.1

Special tools for in-house manufacture Assembly sleeve for equalizer bar bearing, outside To install the outer equalizer bar bearing – see section 15.3.

Fig. 1 Dimensions of installation sleeves

Machine

1

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

2 3

A

B

C

D

E

F

G

H

100

130

75

---

---

---

---

---

---

120

150

100

---

---

---

---

---

---

81,5

137

120

91

115

35

7

13

129

83

149

120

101

135

---

7,5

12,8

---

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I

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Type


Service Manual

Tools and work instructions Special tools

3.2

Mandrel For installation of radial shaft seal rings in hoist cylinder bearing.

Fig.2 Dimensions of mandrel – screw in handle and mandrel

See also section 15.2 Hoist cylinder suspension. Mandrel A ..........For Pos.10 Mandrel B ..........For Pos.7

M-Type

Mandrel

PR724

A B A B A B A B A B

PR734 PR744 PR754 LWT / Ausgabe / Edition / Edition / 03.2010

PR764

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

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

F 13 9 14 11 14 12 14 12 14 12

G 23 18 23 18 23 18 23 18 23 18

* edges rounded off All dimensions in [mm]

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Tools and work instructions

Service Manual

Special tools

3.3

Pull tool – operator’s cab bearing For installation and removal of elastic bearing of operator’s platform. See section 17.1 Position 11 and 22.

Fig. 3

Dimensions of pull tool

1 Threaded rod M30 2 Sleeve 3 Washer

3.4

4 Washer 5 Shim M30 6 Nut M30

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

LWT / Ausgabe / Edition / Edition / 03.2010

Fig. 4 Dimensions installation sleeve for equalizer bar

Continuous fillet weld 4mm

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Service Manual

Tools and work instructions Special tools

3.5

Plate – Double oscillating track rollers (PR764) For removal / installation of the pins with bearings on double oscillating track rollers. See section 2.3 Installation notes.

LWT / Ausgabe / Edition / Edition / 03.2010

Fig. 5 Dimension of plate for double oscillating track rollers

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Tools and work instructions

Service Manual

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Special tools

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Service Manual

Tools and work instructions Repair welding

2.2.00 Repair welding Before starting any welding work on the machine, various electronic parts and components must be unplugged to prevent damage to the machine. Note! See operating instructions: Preparations for maintenance In addition, for arc welding, the ground terminal of the welding unit should be connected in the immediate vicinity of the blank work piece which is to be welded.

1

Preparation of cracked part Clean the cracked area to remove paint, grease and any dirt. To prevent the crack from extending during the preparation and welding process, the end of the cracks should be drilled out with a drill (at least 8 mm Ø). Then the crack should be ground, chiselled, or arched out to an angle of approx. 60° . Be certain that the edges are clean and extend through the full cross section of the material, without exceeding the space of 1 mm in the lower part. On larger grooves, a welding safety should be installed.

Fig. 1 Ground out / drilled out crack

Easy to harden materials must be preheated to approx. 150°C before welding. Special preparations are necessary when preparing a crack in manganese steel. This material cannot be prepared with a smoothing planer. Mechanical work cannot be carried out due to its hardness and peen hardening. We suggest that the crack is prepared with a slow running and water-cooled grinding wheel to prevent overheating.

LWT / Ausgabe / Edition / Edition / 03.2010

Note! Another possibility to make groves for repair welding of cracks and remove high alloy welding seams by using cutting electrodes of the type UTP 82 AS.

2

Preparation of a weld The welding area must be free of grease, paint, oil, moisture and dirt. During rain, the area to be welded must be covered sufficiently. Materials with a thickness above 15 mm and high carbon steel (carbon content more than 0.22 %) and difficult to weld steel, the material must be preheated to approx. 80°- 200° C. Preheating is also necessary when the component temperature at the start of the welding work is below +5°C and when the construction of the repair part prevents the welding stress to be released.

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Repair welding

3

Treatment of electrodes Use only dry electrodes for welding. Electrodes with damaged coating and rusted electrodes may not be used any longer. Electrodes must be stored in a dry room with a minimum temperature of 15°C. Open electrode packages must be carefully closed and stored after the welding work is complete.

4

Welding technique The welding of material with the required electrodes (see chart under paragraph 7) is carried out Per DIN 1912. The adjustment of the welding current – dictated by the different thicknesses of the electrodes – can be taken from the chart of the electrode package. Beginning with material thickness of 8 mm, butt welds must be made in several layers. The weld is applied in several beads. Wide butt welds are filled with several side by side beads, with the last layer covering the center. The electrode should melt evenly without creating burrs and peaks. The valley or crater, which is created when changing electrodes must be filled in and overlapped with the next electrode. To prevent cracks in those craters, care must be taken that they are properly filled in. If the crack extends towards the outer edge of the material, slap may be trapped or burn holes may be created. To prevent this, the following aid may be used: Tack a piece of sheet metal to the outer edge of the material. The welding seam begins now at the sheet metal in the direction of the arrow toward the inside. After the welding is completed, the sheet metal is removed and the edge of the material is ground smooth. The welding seam must be cooled off slowly and should therefore be protected from rain and wind.

LWT / Ausgabe / Edition / Edition / 03.2010

Fig. 2 Crack running to the outer edge of the material / Prepared crack

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Tools and work instructions Repair welding

5

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

5.1

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

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

5.2

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

5.3

Material quality of plate The material properties (yield and tensile strength, etc.) of the reinforcement plate should be equal to the material to be reinforced.

5.4

Installation of reinforcement plate The welded area of the crack should be ground so it is smooth and level.

LWT / Ausgabe / Edition / Edition / 03.2010

The size of the plate must be selected in such a way that the longer sides of the plate extend into the connecting construction of the material to be reinforced. The plate should also overlap the crack on each side by at least 20 mm. The correct position and fit of the reinforcement plate is achieved by clamping and spot welding.

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5.5

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

Fig. 4 Welding directions

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

Fig. 5 Three or one layer welding seam

LWT / Ausgabe / Edition / Edition / 03.2010

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

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Tools and work instructions Repair welding

6

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

6.1 Electrode selection Material

BASIC MACHINE Track Main frame

St 52 - 3 QStE 380 N

Track Main frame/ bottom plates ATTACHMENT Dozer blade Bucket

Per EN 499: E42 5 B 4 2 H5 per AWS A5.1-91: E7018-1 H4 R LH 690 Per EN 757: Preheat to approx. E 69 6 Mn2NiCrMo B 4 2 H5 100-150°C. per AWS A5.5-96: E 11018-G HARDOX 400 per AWS A5.1-91: E7018-1 H4 R

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

Q St E 380 N HARDOX 400

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

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

Special steel

Root layers Per EN 440: G4Si1 per AWS A5.18-93: ER 70 S-6

Push frame Bucket arm Pipe layer boom

LWT / Ausgabe / Edition / Edition / 03.2010

Ripper

WEAR PARTS Adapter Tooth retainer Ripper

Electrode norm description

Shielding gas weld welding wire – norm description

Welding area

Root layers Per EN 499: E42 5 B 4 2 H5 per AWS A5.1-91: E7018-1 H4 R

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Cover runs with high tensile welding wire per EN 12072: G 18 8 Mn per AWS A5.9-93: ER307

LWT / Ausgabe / Edition / Edition / 03.2010

Cover runs with high tensile electrode per EN 1600: E 18 8 Mn B 2 2 per AWS A5.4-92: E 307-15

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6.2 Steel chart Item

Description

Analysis

HARDOX 400

Weldable, low alloy special steel with high wear resistance, a tensile strength of 1250

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

²

Q St E 380 N

Sonderstahl

St 52 - 3 S355J2G3 LH 690

N/mm and a yield strength limit of 1000 N/mm² Fine grain structural steel poured at special low turbulence with a guaranteed minimum tensile strength of 500 - 640 N/mm² and minimum yield strength limit of 380 N/mm² Highly abrasion resistant steel with a tensile strength of 1720 N/mm²

C 0,18% Si 0,5% Mn 1,6% C = 0,3% Mn = 0,7% Si = 0,5% Cu = 0,65% Mo = 0,3% V = 0,05% C 0,22%

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

6.3 Welding additive chart for arc welding Item

Description

Analysis values in % / Application

Per EN 499: E42 5 B 4 2 H5

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

C = 0,07, Si = 0,5, Mn = 1,1

for example Böhler FOX EV 50

Per EN 757: E 69 6 Mn2NiCrMo B 4 2 H5

LWT / Ausgabe / Edition / Edition / 03.2010

for example Böhler FOX EV 85

nach EN 1600: E 18 8 Mn B 2 2 z.B. Böhler FOX A 7

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

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

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6.4

Welding additive chart for metal inert gas weld with solid wire electrodes

Item

Description

Analysis values in % / Application

per EN 440: G4Si1

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

C = 0,1, Si = 1,0, Mn = 1,7

for example Böhler EMK 8

per EN 12072: G 18 8 Mn

For connections between different alloyed and difficult to weld steel Weldable with DC current, Electrode on Plus terminal (+). Shielding gas: Argon + max. 2.5% CO2 No vertical seams

LWT / Ausgabe / Edition / Edition / 03.2010

for example Böhler A7 IG

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

For connection and applied welds, especially for steels with low purity and higher carbon content. Weldable with DC current, Electrode on Plus terminal (+). Shielding gas: Argon + 15-20% CO2 or 100% CO2 No vertical seams C = 0,08, Si = 0,9, Mn = 7,0, Cr = 19,2, Ni = 9,0

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Tools and work instructions Installation instructions

2.3.00 Installation instructions 1 1.1

Duo cone (slip ring) seals Design and function Due to the pretension of the O-rings 2, the two slip rings 3 are pushed against each other and thereby seal the bearing point via the sliding surface 4. Seal variations: - Seal toward the outside

- Seal toward the inside

Fig.1 Seal variations

1 2 3 4

Seal mount O-ring Slip ring Sliding surface

Note! On Series 4 machines, due to design reasons, only seals toward the outside are used.

1.2 1.2.1

Installation General installation notes

LWT / Ausgabe / Edition / Edition / 03.2010

The slip rings of the seals are made as a pair. For that reason, they may only be used in the original pairing, in new as well as in used condition. Avoid shock and impact, since this could damage the sealing surfaces of the hard cast duo cone slip rings. Round off any sharp edges on the sealing mounts. Slip rings seals and their mounts must be absolutely clean and free of grease at installation. O-rings may not be lubricated with oil. Slip ring seals should generally be installed with the aid of an installation device, see Special tools, section 2.1.

Caution! Without the aid of the installation device, the O-ring can roll up on the conical slip ring surface. If the pressure at installation is one-sided, the seal half can move sideways and/ or the O-ring can twist. These improper installations as well as damage to the sealing surfaces cause leaks.

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Installation position correct

Installation position incorrect O-ring twisted

Installation position incorrect Seal half is inclined

Fig.2 O-ring installation positions

1.2.2

Installation of the slip ring seal A split device 5 is used as an installation aid, which is folded over the slip ring 3 and transfers the pressure at installation directly to the O-ring 2. Push the seal halves with the appropriate installation aid into the seal mount 1. The required pressure must be exerted evenly over the entire circumference of the O-ring.

Fig.3 Installation slip ring seal

1 2 3

Seal mount O-ring Slip ring

5 6

Installation device Aid round rubber string

Before assembly of the two seal mounts, check if the slip rings project evenly. To do so, measure the distance of the seal mount to the slip ring on at least 3 locations of the circumference, always offset by 120°. Check the sealing surfaces again for absolute cleanliness and apply a thin film of oil or grease.

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If no matching installation aid is available, then a round rubber string 6 can be inserted as a makeshift spacer between the slip ring 3 and the O-ring 2 and affixed by hand, so that the Oring cannot roll up on the conical slip ring surface when the seal halves are pushed in.


Service Manual

Tools and work instructions Installation instructions

2

Safety lever

Fig.4 Installation notes for safety lever

Adjust the Allen screw on the limit switch. Tighten the hex nut to a tightening torque of 8 Nm and open by 1 1/4 turns. Insert the hex nut with Loctite. Tighten the hex nut to the tightening torque (see section 1.3) and then open by 1.5 to 2 turns.

LWT / Ausgabe / Edition / Edition / 03.2010

Note! 1. 2. 3. 4.

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3

Assembly instructions for track Note! The assembly instructions for the track are valid only for the following machine: RL 64 F/N xxx-10598

Fig. 5 Instructions for track installation

1 2 3 4 5

Track frame Final drive Idler unit Axle bearing housing Axle bearing cover

6 7 8 9 10

Track axle Installation screw with washer Hex head screw with washer Axle cover Hex head screw

Install the track axle 6 into the carrier frame. Align the equalizer bar in horizontal (center) position. Lubricate the rubber elements of the track axle 6 and the corresponding counter surfaces of the axle bearing with linseed oil (see detail A) Lift the track onto the track axle 6 which was installed in the carrier frame. Place the axle bearing cover 5 onto the axle bearing housing 4. Note! The installation screws may only be used for the assembly process. RL 64 F/N xxx-10598 installation screws 7, M24x80, 10.9 Tighten the axle bearing cover crosswise with four installation screws with washers 7 according to factory standard WN 4037 (see detail B).

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LWT / Ausgabe / Edition / Edition / 03.2010

For the assembly of the complete track on the machine, observe the following points:


Service Manual

Tools and work instructions Installation instructions

Check the installation of the axle bearing cover 5 on the axle bearing housing 4. The gap between the two components must be evenly closed. Install all remaining hex head screws with washers 8 and tighten crosswise according to WN 4037. Remove the installation screws 7 (see detail C) Note! The installation screws may only be used for the assembly process. Instead of the installation screws 7, install four new hex head screws with washers 8 and tighten according to WN 4037. Then check all hex head screws 8 for the specified tightening torque (see detail D) Attach the equalizer bar bearing on the Track frame 1. Then install the axle cover 9 with the hex head screws 10 and tighten them crosswise according to WN 4307.

LWT / Ausgabe / Edition / Edition / 03.2010

Repeat the installation procedure on the second track side.

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4

Assembly instructions for mounting the axle cover on idler and track roller (RL64)

For installation of axle covers for the track roller A or idler B, observe the following procedure:

Tighten the hex head screw marked „1“ or „tighten first“ according to the tightening torque, see chart. Tighten all remaining hex head screws in sequence (2-3-4) crosswise according to the tightening torque, see chart. Screw mounting with friction number G = 0,10

Tightening torque Ma according to grade in Nm

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

10.9

10.9

mm

Inch

M 24

249000

800

36

1-7/16

M 30

400000

1600

46

1-13/16

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Thread

Pretension force Fm according to grade in N


Service Manual

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

3 Technical data and maintenance guidelines 3.0.00 Sub group index - Technical data and maintenance guidelines Technical data................................................................................................ 3.1 Maintenance and inspection schedule ........................................................ 3.2 Maintenance and inspection instructions ................................................... 3.3 Adjustment checklist .................................................................................... 3.4

LWT / Ausgabe / Edition / Edition / 01.2008

Test and adjustment tasks .......................................................................... 3.5

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Sub group index - Technical data and maintenance guidelines

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Service Manual

Technical data and maintenance guidelines Technical data

3.1.40 Technical data Diesel engine Type Version Rating according to ISO 9249 Nominal RPM Low idle (ULL) High idle (OLL) Displacement Oil quality / viscosity Max. permissible machine incline – all directions Valve clearance – cold Firing order

kW RPM RPM RPM l

On/ off

D 936-L A6 6 cyl. Inline – charge air cooled 175 (238 PS) 1800 900+50 1900+50 10,52 See operating instructions 45° = 100% See data tag / Diesel engine 1–5–3–6–2–4

Splitterbox Type Version Ratio Oil quantity / oil quality / viscosity

351 B 374 Spur gear – 1-stage 0,86 See operating instructions

Hydraulic system Var. displacement pump Type Flow quantity - Qmax l/min Operating pressure (M1 / M2) - pmax bar Tandem gear pump – replenishing Flow quantity - Qmax l/min Operating pressure (SP) - pmax bar Tandem gear pump – fan drive Flow quantity - Qmax l/min Operating pressure (LA) - pmax bar Gear motor – fan drive Operating RPM RPM Var. displacement motors Type Discharge bar Regulating pump Type Working Flow quantity - Qmax l/min hydraulic Stand-by pressure (HD) bar Operating pressure (HD) - pmax bar Servo pressure – operating pressure (ND) bar Hydraulic tank capacity l - Circuit - additionally l Oil quality / viscosity

LWT / Ausgabe / Edition / Edition / 06.2008

Travel hydraulic

2 x HPV 135 2 x 282 420+30/-10 Size 55 117 23+5 Size 19 33 220±10 Size 16 1800±100 2 x HMV 280 14 A 10 V O140 284 25+2 280±5 23+4 126 164 See operating instructions

Electrical system Operating voltage Batteries Alternator Starter Central fuse

V 24 2 x 12V, 170Ah (in Series) 28V, 80A kW 7,8 A 45

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Technical data

Final drive Type

FAT 500 E 517/518 Spur gear + planetary gear, each 1 stage Disk brake i ges 41,4 : 1 l See section 11.1 Data page See operating instructions

Version Parking brake, integrated Ratio Oil quantity Oil quality / viscosity Track Chain pitch Chain length

left mm (inch) 215,9 (8,5) Links 43

Track pad width (2 grouser)

mm (inch)

Track pad bolts Track rollers – single flange per side (e) Track rollers – double flange per side (d) Track roller arrangement Carrier rollers per side Track oscillation Ground placement surface

right

914 (36)

610 (24) 710 (28)

Thread size 7⁄8“ UNF Each 4 Each 4 e–d–e–d–d–e–d–e Each 2 Fixed m2 5,39

Working attachment Boom length Working range (ISO 8813) Boom cylinder Counterweight - cylinder Counterweight – total Fixed installed Removable (10 pieces)

Cyl. Cyl.

/ rod / rod

/ Stroke / Stroke

Total / piece/ piece

mm mm mm mm kg kg kg

6000 7320 1180 6000 1240 7150 170 / 90 / 1260 100 / 60 / 610 7222 2192 5030 / 5x 619 / 5x 387

Hoist winch hydraulic mm 254 mm 279,4 mm 609,6 mm mm Strands m / min t

20 65000 4 0 23.6 stepless 28,4 Freefall control See operating instructions

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Drive Drum - Diameter - Length - Flanged wheel diameter Rope - Diameter - Length Hook block Hook speed in 1. rope layer lift / lower Load capacity max. (according to ISO 8813) Safety devices Oil quantity / oil quality / viscosity


Service Manual

Technical data and maintenance guidelines Technical data

General Travel speed Normal range – III Reduced range – II Reduced range – I

km/h km/h km/h

forward 0 10,5 0 6,5 0 4,0

reverse 0 10,5 0 7,8 0 4,5

Boom length (mm) 6000 7320 Tractive power, max., depends on ground composition kN 283 Operating weight kg 35059 Ground load (calculated comparison value) kg/cm2 0,65

mm mm mm mm mm mm mm mm

5295 3316 3475 2997 2075 6999

8319

3298 461

LWT / Ausgabe / Edition / Edition / 06.2008

Dimensions – basic machine Total length Wheel base Transport width (with retracted counterweight) Transport width (with removed counterweight) Track width Total height max. Transport height Ground clearance

35321 0,66

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Technical data

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Technical data and maintenance guidelines Technical data

3.1.60 Technical data Diesel engine Type Engine version Performance according to ISO 9249 Nominal RPM Low idle RPM (ULL) High idle RPM (OLL) Displacement Oil quality / viscosity Max. permissible machine incline - all directions Valve play - cold Firing order

kW RPM RPM RPM l

In / out

D 946-L A6 6 cyl. in-line - charge air cooled 275 (374 PS) 1800 900+50 1900+50 11,95 See Operating instructions 45° = 100% See data tag / Diesel engine 1–5–3–6–2–4

Splitterbox Type Version Gear ratio Oil fill quantity / oil quality / viscosity

351 B 364 Spur gear 1-stage 0,86 See Operating instructions

Hydraulic system Travel hydraulic

LWT / Ausgabe / Edition / Edition / 06.2008

Working hydraulic

Var. displ. pumps Type Flow quantity – Qmax l/min Operating pressure (M1 / M2) – pmax bar Tandem gear pump – Replenishing Flow quantity – Qmax l/min Operating pressure (SP) – pmax bar Axial piston pump – Fan drive Type Flow quantity – Qmax l/min Stand by pressure LA bar Operating pressure bar Axial piston motor – Combi cooler Operating RPM 1/min Gear motor – Oil cooler Operating RPM 1/min Var. displ. motor Type Discharge bar Regulating pump Type Flow quantity – Qmax l/min Stand by pressure (HD) bar Operating pressure (HD) – pmax bar Servo pressure – Operating pressure (ND) bar

Tank capacity - Circuit – additional Oil quality / viscosity

2 x HPV 280-02 2 x 518 420+30/-10 Size 55 + 38 174 23+5 A 10 V 28 57 30+5 205±5 Size 28/52 1500±100 Size 19 ±100 1800 4 x HMV 210 14 A 10 V O140 284 +2 25 280±5 23+4

l 215 l 181 See Operating instructions

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Technical data

Electrical system Operating voltage Batteries Alternator Starter Central fuse

V 24 2 x 12V, 225Ah (in Series) 28V, 80A kW 7,8 A 45

Final drive Type

FAT 650 E 519 Spur gear 1-stage + Planetary gear 2-stage Disk brake i ges 54,32 : 1 l see section 11.1 Data page See Operating instructions

Version Parking brake integrated Ratio Oil quantity Oil quality / viscosity Track

left right 215,9 (8,5) 48 914 (36) 762 (30) M 24 x 1,5 9 d–d–d–d–d–d–d–d–d each 2 fixed m2 6,05

Chain pitch Chain length Track pad width (2 grouser) Track pad screws Track rollers – double flange per side (d) Track roller arrangement Carrier rollers per side Track oscillation Ground surface area

mm (inch) links mm (inch) Thread size each

Working attachment

cyl. cyl.

/ rod / rod

/ stroke / stroke

total / each

mm mm mm mm kg kg kg

8500 1400 8440 230 / 115 / 2230 120 / 70 / 1420 15035,5 3905,5 11130 / 14x 795

10500 1480 10260

LWT / Ausgabe / Edition / Edition / 06.2008

Boom length Working range (ISO 8813) Boom cylinder Counterweight - cylinder Counterweight - total Fixed installed Removable (14 each)

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Service Manual

Technical data and maintenance guidelines Technical data

Hoist winch Drive Drum - Diameter - Length - Pulley diameter Rope - Diameter - Length Hook block Hook speed in 1.Seillage up / down Load capacity max. (according to ISO 8813) Safety device Oil quantity / oil quality / viscosity

hydraulic mm 254 mm 279,4 mm 609,6 mm mm Strands m/min t

20 100000 8 0 11,6 stepless 48,3 Freefall control See Operating instructions

General Travel speed normal range – III reduced Range II reduced Range I

km/h km/h km/h

forward 0 10,5 0 6,5 0 4,0

rerverse 0 10,5 0 7,8 0 4,5

Boom length (mm) 8500 10500 Tractive power max. depends on ground conditions Operating weight Ground load (calculated comparison value)

mm mm mm mm mm mm mm mm

59257 1,01

5760 3605 4835 3495 2510 9515

11515

3630 630

LWT / Ausgabe / Edition / Edition / 06.2008

Dimensions of basic machine Overall length Wheel base Transport width (with retracted counterweight) Transport width (with removed counterweight) Track gauge Overall height max. Transport height Ground clearance

kN 520 kg 57719 kg/cm2 1,00

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Technical data

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Technical data and maintenance guidelines Maintenance and inspection schedule

3.2.00 Maintenance and inspection schedule Company:

Machine: S/N:

-

Operating hours: Inspector: Application type:

From company:

Application location:

Date:

Maintenance / Inspection at operating hours

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

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

OI Operating instructions SM Service Manual

Remar ks

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

DIESEL ENGINE

LWT / Ausgabe / Edition / Edition / 03.2010

Check oil level and coolant level Check / clean Diesel engine, coolant assembly and belly pan for contamination Drain condensation in fuel separator Fuel tank, drain condensation and sediments - but at least 1x a week Change engine oil -1) - shorten interval in case of aggravating circumstances - but at least 1x a year Change lube oil filter 1) - but at least 1x a year Check corrosion inhibitor / antifreeze concentration in coolant Check V-belt condition Check control unit mounting, sensory and cable connections for condition Change / replace oil separator filter insert Check oil, coolant and fuel system for leaks and condition Check intake and exhaust system - mounting and leaks Check engine mount Check engine rpm Change fuel pre-filter and fine filter - Observe bleeding instructions Check / adjust valve clearance - with cold Diesel engine Grease gear ring on flywheel Take oil sample and send it in for analysis Check vibration damper for leaks and distortion - 3000 hrs. Check heater flange - before start of cold season Change heater flange - 10000 hrs. Replace air filter inserts - as necessary / a year Replace coolant with antifreeze - 3000 hrs. - but at least every 2 years

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

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Technical data and maintenance guidelines

Service manual

Maintenance and inspection schedule

Maintenance / Inspection at operating hours

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

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

OI Operating instructions SM Service Manual

Remar ks

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

HYDRAULIC SYSTEM Check oil level in hydraulic tank Check oil cooler for contamination and clean Replace pressure filter for replenishing Replace main return filter or immediately after indicator light lights up Check working and travel hydraulic system for function and leaks, check hose routing for chafing Check and adjust all hydraulic pressures according to adjustment check list Check mountings and fittings for tight seating Clean magnetic rod (also after repairs) - up to 50 hrs daily Take oil sample (before oil change) and send it in for analysis Replace third party mineral oil product in hydraulic system (add oil via filter) - at least every 4 years - when using an environmentally friendly hydraulic medium, request / observe special guidelines Replace Liebherr Hydraulic oil in hydraulic system (add oil via filter) - at least every 4 years - or 3000 hrs.

OI OI OI OI OI / SM SM OI OI OI OI

SPLITTERBOX Check oil level

OI

Replace gear oil

OI

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

OI OI OI OI / SM SM SM SM

HEATER / VENTILATION / AIR CONDITIONING SYSTEM

Check electrical lines for chafing and plug connections for tight seating Air conditioning system – have it checked / inspected by HVAC technician - 1x a year Check condenser for contamination - as necessary

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OI OI OI OI OI OI OI OI SM OI

LWT / Ausgabe / Edition / Edition / 03.2010

Turn the air conditioning system on regularly - at least 1x every 14 days Check water drain valves for air cond. system, clean if necessary Check system for function and leaks Clean air circulation and fresh air filter, replace as necessary, in dusty conditions, shorted maintenance interval Check mounting screws and drive belt of air conditioner compressor Check dryer unit (moisture, fill, condition) - replace if necessary, evacuate system and refill Clean water drain valves for air cond. system


Service manual

Technical data and maintenance guidelines Maintenance and inspection schedule

Maintenance / Inspection at operating hours

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

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

OI Operating instructions SM Service Manual

Remar ks

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

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

OI OI OI / SM OI OI OI

TRACK COMPONENTS Check mounting screws and nuts of track components, especially track pad and sprocket segment screws for tight seating Check oil level in support axle bearing (only RL 44)

OI OI

Check all track components for leaks

OI

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

OI OI / SM OI SM

WORKING ATTACHMENT

LWT / Ausgabe / Edition / Edition / 03.2010

Check screws, nuts and pin retainers for tight seating Winch rope – check entire length for damage and grease, if necessary See Operating instructions of rope manufacturer Check attachment for intentional damage Check all bearing points for play / wear Hoist – rope winch (2 separate oil chambers) - but at least every 3 months or if leaks are found Check function of freefall device - always after extended downtime Check function of hoist limit switch - always after extended downtime Check rope pulleys and load hook for wear - always after extended downtime - Shorten interval if necessary / if instructed to do so Maintain and check load moment limiter with display function according to manufacturer’s instructions Take oil sample on hoist winch and send it in for analysis (2 separate oil chambers) - but at least every 6 months Change hoist – rope winch oil(s) - Clean breather screw - but at least 1 x a year Rope winch – removal and inspection of all wear parts according to ANSI - Specification B30.5c 1987 and API RP2D, section 3 - if necessary, but at least every 6 years or 10000 hrs.

OI OI OI OI OI OI OI OI Manufacturer OI OI OI

OI

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RL Litronic Series 4

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Technical data and maintenance guidelines

Service manual

Maintenance and inspection schedule

Maintenance / Inspection at operating hours

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

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

OI Operating instructions SM Service Manual

Remar ks

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

GENERAL Special OI OI OI OI

LWT / Ausgabe / Edition / Edition / 03.2010

Determine and carry out maintenance and inspection requirements of all special / optional equipment included in the scope of delivery according to separate OI / manufacturer’s instructions Lubricate all lube points according to lubrication schedule - Shorten intervals as necessary Check complete machine for correct maintenance and proper condition Explain machine literature, especially Operating instructions / safety guidelines to operating personnel

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Service Manual

Technical data and maintenance guidelines Maintenance and inspection instructions

3.3.00 Maintenance and inspection instructions 1 1.1

General guidelines Documentation of work to be carried out Note! For work to be performed, refer to the Maintenance and inspection schedule for your particular machine model – see section 3.2. For detailed proof of completion, heck off completed inspections or work by making a check mark on a copy of the form and have the completed form countersigned The determined test values for the adjustment checks should be documented on an adjustment check list – corresponding to the machine model, see paragraph 3.4. In addition, confirm the performance of the inspection / delivery in the machine’s inspection booklet and send the appropriate Service ticket to the appropriate LIEBHERR organization. After removing the old sticker, attach the new inspection sticker, which can also be found in the inspection booklet, clearly visible in the cab. Explain the set up and the contents of the machine documentation to the machine operator. Special emphasis should be given to safety regulations and maintenance task to be performed between inspections.

1.2

Safety guidelines During all maintenance, inspection or repair work, the applicable safety guidelines according to the operating instructions for the machine must be observed. In addition, all applicable Federal, state and local safety requirements, accident prevention regulations and local laws must be observed.

1.3

Intervals The given maintenance and inspection intervals may not be exceeded, if necessary, they should be shorted. For example for: changing filters, draining condensation and sediments in case of dirty fuel; cleaning the cooler in case of contamination; changing filters and oils during or after repairs, etc. Dispose of used oil, filters and other waste products properly!

1.4

General

LWT / Ausgabe / Edition / Edition / 03.2009

For all maintenance, inspection and repair work, use only LIEBHERR Original spare and maintenance parts. If the operator requests the use of other, provided parts at installation, then this should be noted in the inspection report after notifying him about a possible loss of warranty. For general screw tightening torques see section 1.3, for tightening guidelines for track pad and sprocket segment bolts, see section 12.1.

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Technical data and maintenance guidelines

Service Manual

Maintenance and inspection instructions

2 2.1 2.1.1

Maintenance and inspection work Diesel engine Check the Diesel engine RPM Start the Diesel engine. Read the RPM on the display or via the evaluation software LinDiag. Compare the speed with the nominal RPM (see section 3.1. Data page). If the RPM does not match the nominal RPM, then the throttle control must be adjusted. To do so, see section 17.5 Throttle control.

2.1.2

Check / adjust valve clearance Preparation for test Ensure that: The machine is in maintenance position. The main battery switch S43 is turned off (Position „0“). The Diesel engine is cold. Special tool “Turning device for flywheel” is available. New seals for the cylinder head covers are available. Check only when the Diesel engine is cold, for adjustment values, see “Diesel engine data tag”.

Fig. 1 Installation of Diesel engine turning device

Install the special tool (see section 2.1) „Turning device - flywheel (RL44) or Turning device V-belt (RL64)“. Remove the valve cover of the Diesel engine. Turn the crankshaft in direction of rotation until the cylinders to be adjusted overlap the opposite valves.

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LWT / Ausgabe / Edition / Edition / 03.2009

Note! - Cylinder 1 is on the flywheel side of the Diesel engine. - The direction of rotation is to the left, when viewed on the flywheel. - The drain valve of the respective cylinder is located on the flywheel side.


Service Manual

Technical data and maintenance guidelines Maintenance and inspection instructions

Cylinder and valve arrangement on the Diesel engine

Fig. 2 Cylinder and valve arrangement

= Inlet

D936 L A6 D946 L A6

= Outlet

overlap

6

2

4

1

5

3

adjust

1

5

3

6

2

4

Note! The valve clearance V is noted on the Diesel engine data tag.

Fig. 3 Diesel engine data tag

LWT / Ausgabe / Edition / Edition / 03.2009

Slide a feeler gauge between the valve bridge and the rocker lever.

Fig. 4 Check the valve clearance

Check the valve clearance.

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Technical data and maintenance guidelines

Service Manual

Maintenance and inspection instructions

If the value of the valve clearance does not match the nominal value, then the valve clearance must be re-adjusted.

Fig. 5 Adjust the valve clearance

Loosen the lock nut on the adjustment screw of the respective rocker lever and correct the adjustment. Tighten the lock nut (40Nm). Carry out a recheck. After checking and adjusting all valves, install the cylinder head covers with new gaskets. Remove the turning device from the flywheel housing.

2.1.3

Grease the gear ring on the flywheel Note! If possible use grease on non-metallic basis. High metal or graphite ratios as well as excessive amounts of grease in connection with metallic wear debris can cause problems for the RPM sensor signal.

Fig. 6 Position of maintenance cover

The Diesel engine must be in maintenance position. Remove maintenance cover 1 from the flywheel housing 4. Caution! Danger of damage! Grease only the starter gear ring 2. The sensor gear ring 3 must be free of grease. Grease the starter gear ring 2. Install maintenance cover 1.

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LWT / Ausgabe / Edition / Edition / 03.2009

The maintenance cover 1 is on the right side of the Diesel engine on the flywheel housing 4.


Service Manual

Technical data and maintenance guidelines Maintenance and inspection instructions

2.1.4

Check the heat flange The machine must be in the maintenance position. Turn the master battery switch off (see section 16.3) and disconnect the negative cable of the battery. Disconnect the electric connector cable on the heat flange. Connect an ohmmeter or multi-meter to the terminals and check the resistance. If no resistance value of 250 mOhm +/– 10% at 20 °C is obtained, then the heat flange must be replaced. Connect the electric connector cable as well as the negative cable to the battery.

Fig. 7 Heat flange

2.2 2.2.5

Hydraulic system Check working and travel hydraulic system for function and leaks, check hose routing for chafing Actuate all travel and working movements. Check for erroneous functions and remedy them immediately.

Pilot control – working hydraulic Check the actuator plate, plunger and joint of the working hydraulic pilot control for wear. If necessary, lubricate lightly and adjust. See section 8.6, Pilot controls. The same applies for pilot control for auxiliary equipment.

Accumulator – Safety control

LWT / Ausgabe / Edition / Edition / 03.2009

Start the Diesel engine. Lift the hoist gear and lower the counterweight. Turn the Diesel engine off (return the ignition key again to position 1 – Ignition on) and leave the safety lever in the down position. Actuate the function “hoist gear down” several times, jerkily and momentarily. If the attachment moves down less than four times, then the accumulator is defective or there is excessive leakage in the system.

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Technical data and maintenance guidelines

Service Manual

Maintenance and inspection instructions

Hose lines Check hose lines for leaks and kink-free routing. Watch for chafe marks. Replace chafed, “sweating” or aging hoses. See Safety guidelines in the Operating instructions. Do not route control, leak oil and tank line hoses with the HP hose lines in one strand, and do not route them over sharp corners, edges or hose fittings. Check connections for leaks and replace seal rings, if necessary. Check the piston rods for damage as well as the piston rod bearings for leaks. Fix, if necessary. Check the mounting screws of hydraulic components (pumps, motors, hydraulic tank etc. ) as well as the flange connections for tight seating. If necessary, tighten to the proper tightening torque.

2.2.6

Check / adjust all hydraulic pressure according to adjustment check list Carry out pressure tests / adjustments according to the adjustment check list for the respective machine type – see section 3.4 Adjustment check list – and enter the results. For details, data and instructions, see section 3.5. Test and adjustment tasks.

2.3 2.3.7

Electrical system Check cable routing and connections Check terminal posts and terminal clamps of batteries for oxidation and tight seating. Clean terminal posts and clamps regularly and apply terminal grease. Check batteries for external damage and leaks. Check cable strands of electronic components for chafe marks and connections for oxidation. Insulate any chafe marks, optimize the routing and protect the cable strand with heat shrink tubing to prevent moisture infiltration.

2.3.8

Check / adjust the control system of the travel drive according to the adjustment check list Carry out with the aid of the notebook and the LinDiag Diagnostics software (For software description, see section 10.1).

For software - LinDiag Diagnostics KIT see section 2.1 Special tools.

2.3.9

Check battery charge condition Warning! Batteries emit explosive gases. Battery acid has strong caustic properties. Do not smoke and avoid open flames when handling batteries as well as during battery maintenance and charging. Check the battery acid concentration with an optical battery charge tester - see Special tools Section 2.1.

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Carry out tests / adjustments according to the adjustment check list for the respective machine type – see section 3.4 Adjustment check list – and enter the results.


Service Manual

Technical data and maintenance guidelines Maintenance and inspection instructions

Note! To disconnect battery: Disconnect the negative „– ” terminal first, then the positive „+ ” terminal. To connect battery: Connect the positive „+ ” terminal first, then the negative „- ” terminal . The display is made by a line between light and dark on the left scale of the indicator window. The indicator ranges are: GOOD

= Battery charged

FAIR

= Battery half charged

RECHARGE

= Battery discharged

The battery acid must be checked before adding water. Check each battery cell separately. If the test values of all cells are evenly below a density level of 1,200, then the battery must be recharged with an external battery charger. If the values differ (difference 0,02) or if they are below 1,100, then the battery must be replaced. For details about the use of a battery charge tester or to charge the battery, refer to the manufacturer’s operating instructions.

Fig. 8

2.3.10

Display

Check the machine software version On Series 4 machines, check the software version with the software programs LinDiag Diagnostics software set for the travel drive. If you don’t have the most current software version, then the software must be updated. For software update, see software description, section 10.1. The current software version is described in these instructions. In addition to the software update, an adjustment of the corresponding components must be carried out as described in section 3.4 - Adjustment check list.

2.4 2.4.11

Heater / ventilation / air conditioning system Check the heater and air conditioning system For instructions regarding function and general maintenance points, see section 17.2. Heater and 17.3 Air conditioning system. If access into the coolant circuit is required in case of problems or repairs of damaged components, then it is imperative that a HVAC trained technician is called in.

LWT / Ausgabe / Edition / Edition / 03.2009

2.5 2.5.12

Travel gear Check fittings for tight seating and oil level Check all mounting screws on both final drives for tight seating, retighten, if necessary. For screw tightening torques, see section 1.3. Check gear oil level and oil level in seal area. Note! If an increased oil level is found in the travel gear, then the seal of the disk brake and the oil motor must be checked. If necessary, open the gear and check the inner slipring seal (seal gap is filled with hydraulic oil according to the Operating instructions).

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Technical data and maintenance guidelines

Service Manual

Maintenance and inspection instructions

2.6 2.6.13

Inspection work on the tracks Check screws and nuts for tight seating The inspection of screws and nuts is especially important for new track components. Loose track pad screws can also be recognized by misaligned nuts. Loosen screws and retighten them. For safety reason, retighten all screw connections on the affected components at the same time. For tightening torque guidelines of track pad and sprocket segment screws, see section 12.1 Data page. For all other screws, refer to the standard tightening torques according to section 1.3.

2.6.14

Adjust chain tension to suit application, check track wear Note! The track chain tension must be adjusted by taking the working conditions into account, since different ground or soil conditions cause different material build-up, and the track chain sag should always be the same. Too much tension causes significantly increased track component wear. After machine standstill for forward travel on level ground, the chain sag between the idler and the carrier roller or the carrier roller and the sprocket should be 30 to 40 mm, depending on the track type. See “Operating Instructions”, The scope of the track roller guard must also be matched to the given application conditions – see section 12.2. The procedure for wear check, evaluation of test data and evaluation of wear pictures and their causes, see description in section 12.2.

LWT / Ausgabe / Edition / Edition / 03.2009

During the inspection of the track components, the condition of the elastic bearings on the equalizer bar should also be inspected visually.

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Service Manual

Technical data and maintenance guidelines Adjustment checklist

3.4.40 Adjustment checklist Company:

Machine: S/N:

-

Hrs.: Inspector: Application type:

From Co.:

Application location:

Date:

1

Preparation for hydraulic test

No. Test

Defects at inspection

Defects remedied

1.1 Visual inspection Before visual inspection, carry out scheduled maintenance and inspection work 1.1.1 Visual inspection and maintenance Service media and filters, mechanical components, travel joysticks and dust covers, cable harness and plug connections, leaks on hydraulic system, component mounting tightness

Remarks:

No. Task

1.2

LinDiag Software

Remarks

LinDiag Diagnostics software – save report

1.2.1 Reports saved

Print out report acc. to software instructions before hydraulic tests and add to check list

LWT / Ausgabe / Edition / Edition / 03.2010

1.2.2 Service Codes available

Note! The checklist sequence is according to system requirements, for instructions which are matched to the task of the adjustment checklist, see section 3.5.

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Technical data and maintenance guidelines

Service Manual

Adjustment checklist

2

Test with standard testing devices

Test points

Battery box

Engine compartment left

Travel hydraulic LA SP MR1 MR2 ML1 ML2

System pressure - fan drive Replenishing pressure High pressure travel forward right High pressure travel reverse right High pressure travel forward left High pressure travel reverse left

Working hydraulic LS HD ND

Load pressure – Load Sensing High pressure Low pressure - pilot control

Measure with preselected Diesel engine RPM = 1200+50 rpm or as noted. No.

2.1

Test Remark

Unit

Nomina l value

bar

220±10

°C

70

Test value at Test

Test value after adjustment

Adjust ment loc.

Test point

System Fan drive

2.1.2 Pressure limitation fan drive Diesel engine on nmax, at least one temperature sensor unplugged.

LA

Only test, no adjustment possible. In case of pressure deviation, replace proportional solenoid valve Y48.

2.1.3 Hydraulic oil temperature Bring machine to operating temperature. Temperature must remain constant for all adjustments

2.2

±10

P5 or LinDiag

Travel hydraulic

2.2.1 Replenishing pressure No adjustment possible

+5

bar

23

SP

bar

M1=M2

±1

bar

M2=M1

±1

MR2

bar

M1=M2±1

ML1

bar

M2=M1±1

ML2

LWT / Ausgabe / Edition / Edition / 03.2010

Diesel engine RPM from 1000 RPM to high idle 2.2.2 Hydraulic neutral position Pump right Pump left

1

MR1

2.2.3 Pressure limitation – High pressure (only as necessary / troubleshooting) Pressure limitations in connection with Pt. 3.3.2 [Test BS / Y13] Test Brake solenoid – check LinDiag. Travel forward Travel reverse

bar

420

+30/-10

ML1

bar

420+30/-10

MR1

bar

420+30/-10

ML2

bar

420+30/-10

MR2

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