Liebherr Tractor PR 721C Operation & Maintenance Manual - PDF DOWNLOAD

OPERATION AND MAINTENANCE MANUAL

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FOREWORD This manual is primarily for the operator and the maintenance crew and contains information which is vital to the correct and secure operation and proper maintenance of the LIEBHERR PR 721 C crawler dozer.

If you follow these instructions, your LIEBHERR PR 721 C crawler dozer will give you constant and reliable service with excellent performance.

This manual should be given to the OPERATOR, who should read it carefully before operating the crawler dozer and thereafter at regular intervals.

Please take notice that we cannot honor any claim which could arise due to careless handling, improper operation, or inadequate maintenance.

We reserve the right to modify the technical details of the machine as compared with the information and illustrations contained in these Operating instructions.

PR 721 C LH-Motor

from 1524

PR 721 CM LH-Motor from 1529

Ed. 11.89, Id. No. 9082380, engl.

1111111 Mllilll

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TABLE OF CONTENTS INTRODUCTION

1

MACHINE DESCRIPTION

1.1 1.2 1.3 1.4 1.5 1.6 1.7

Diesel Engine ............................................................... .

Splitter Box ................................................................. .

Hydraulic System ........................................................... .

Main Frame, Steel Structure, Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Undercarriage ............................................................... 2 Operator's Platform, Cab and Canopy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Attachments ................................................................. 3

2

TECHNICAL DATA PR 721 C . . . . .. .. . . .. .. . . . . . . . . . . . . . . . . . . . . .. .

Dimensions- Basic Machine

1

5

................................................... 5

3

TRANSPORT DIMENSIONS AND WEIGHTS

3.1 3.2 3.3 3.4 3.5 3.5.1 3.5.2 3.6 3.6.1 3.7 3.7.1 3.8 3.9 3.10 3.11

Basic Machine ................................................................ 6 Operator's Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Canopy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Track Guard (1 piece) ......................................................... 6 Straight Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Push Arm - left with Hydr. Ti It Cylinder and Brace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Push Arm - right with Braces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Angle Blade w. Braces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 "C" Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Power Angle and Tilt Blade ................................................... 7 "C" Frame with Adaptor Plate ................................................. 7 Multi Shank Ripper .......................................................... 7 Winch ...................................................................... 7 Swinging Drawbar ........................................................... 7 Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

.....................

4

GENERAL TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1 4.1.1 4.1.2 4.1.3 4.1.4 4.1.5 4.1.6 4.2 4.2.1 4.2.2 4.2.3 4.2.4 4.2.5

Engine Installation ........................................................... 8 Engine Data ......................................... . .......... . ............ 8 Air Cleaner .................................................................. 8 Coupling - Engine to Splitter box ................... . ........................... 8 Cooling System/Capacity ...................................................... 8 Fuel System/ Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Splitter box/Capacity ........................................ . ................ 8 Hydraulic System ............................................................. 8 Closed Loop Hydrostatic Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Attachment Hydraulics ....................................................... 8 Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Pilot (servo) Control Valve ..................................................... 8 Servo Pump .................................................................. 9

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6-7

8-10

4.2.6 4.2.7 4.2.8

4.6.4

Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Hydraulic Oil Cooler ....... . .......... . ........... . ....... . .... . .......... . . . . 9 Hydraulic Oil Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Undercarriage ........ . ... ... . . .. . .. .... ... . .. ..... .......... . ........ . .. . .. . 9 Travel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Cab Heater/Fresh Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Blade Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Blade Tilt Cylinder(Straight Blade} . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Ripper Cylinder . . ........ . . .. ........ .. ...... . ................ ... ....... .. . . 10 Blade Tilt Cylinder (Angle Blade} . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

5

CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

6

V-BELTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

7

COLD START DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

8

FILTER ELEMENTS/0-RINGS .. .. .. . .. . .. .. .. . .. .. . .. .. . .. . .. .. ..

12

8.1 8.2 8.3 8.4

EngineFilters . .......... . ......... .. ......................... . .. . ....... . ... 12 Hydraulic Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Cab Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 O-Rings ..... . ........................ .. ........ . ........................... 12

9 9.1 9.2

SAFETY INFORMATION

........................................

13 Accident Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 General Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

9.3

Crushing and Burn Prevention

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

9.4

Fire and Explosion Prevention

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

9.5

Machine Start-up Safety

4.3 4.3.1 4.4 4.5 4.6

4.6.1 4.6.2

4.6.3

............... .. .......... . ............ . ............ 16

9.6

Engine Start-up and Operation Safety ............................ ............. 17

9.7

Machine Operating Safety

9.9

.......... . ............. ... ........................ 17 Machine Towing and Pulling Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Machine Parking Safety .. .. . ........ .. ............................ ........... 19

9.10

Machine Transportation Safety ............................ ... .. .......... . ... 19

10

BEFORE STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.1 10.2 10.3 10.4 10.5 10.6 10. 7

Check Engine Oil Level .. ... ............................ ..... ..... .......... . . 20 Check Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Check Electrical System/Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Check Fuel System/ Fuel Level . . ..... ... . . . . ...... .. ... . . . .... . ... . .... .. .. .. . 21 Check Air FilterNacuum Indicator ............................ . ... . .. ....... . .. 21 Check Hydraulic Oil Level . ............ .. ............................ ......... 21 Check Splitter Box Oi I Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

9.8

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20

11

CONTROLS AND INSTRUMENTATION

11 .1 11.2 11.3

Operator's Cab .. . .. .... . . .. . . .. .... . ... ....... ... .... . . ... . . . ... .. . .. . . .. ... 22 Operator's Seat . .... . .. .... . .. . . . . ..................... . . . . . ............... . 24 Cab Heater/Fresh Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

22-23

12

OPERATION

12.1 12.1.1 12.1.2 12.1.3 12.1.4 12.2 12.2.1 12.2.2 12.2.3 12.2.4 12.2.5 12.2.6 12.2.7 12.3 12.3.1 12.3.2 12.3.3 12.3.4 12.3.5 12.3.6 12.3.7 12.3.8 12.3.9 12.4 12.4.1 12.4.2

Start-up Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Start-up Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Starting the Engine with Flame Glow Plug . . . . ... . . . ... .. .. . .. . .. .. ... . ..... ... 26 Low Idle Automatic - Ecomat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Stopping/Parking the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Travel Functions ...... .... ... . . . .. .................... . ............. . ...... . . 27 Straight Travel ......... . ..... ... ...................... .. .. . ....... . ........ . 27 Counter Rotation ............ . . . ..................... . . . ................... . 27 Turning left/right in forward or reverse .......... . .. . . ... .................. . ... 27 Turning - Power Turn ........ . . ... ............ . .. . . ..... ........ . ........... . 28 Brake Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Hi/Low Travel Speed Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Towing . . . . ....... . . . .... . . . . . . .. .. ... . . . . .. ... .. . ... . .. ... . .. . .. . . . ... .. . . . 28 Attachment Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Blade - Raise/Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Blade - Float Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Hydraulic Blade Tilt (Straight and Angle Blade) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Blade Pitch Adjustment (Straight Blade) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Manual Adjustment of Angle Blade .. .. ................. . ............ . ... . .. .. 30 Manual Tilt Adjustment of Angle Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Power Angle and Ti It Blade - Operate blade angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Power Angle and Tilt Blade- Operate blade tilt . ... . .. ... . .. . . .. .. ... . . . . .. ..... 31 Ripper Attachment Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Tilting the Cab/Canopy . . . . .. . .. .. ...................... . .. . ........... . . . . . . 32 Raise (tilt) Cab ................... . ................ . ......................... 32 Lower Cab .............. .. . .. ...................... . ..................... .. 32

13

MAINTENANCE

13.1 13.2 13.2.1 13.2.2 13.2.3 13.2.4 13.2.5 13.2.6 13.3 13.3.1 13.4 13.4.1 13.4.2 13.4.3 13.4.4 13.4.5

Diesel Engine ... . .. ... . . . .... . . . . .. . .. . .... . ... . .. .. . . . .. . . . . . ... . . ....... .. 33 Engine Air Intake System . . .. . ... . .. . ... . .... .... ... .. .... .. . ..... . . .. . ... . . . . 33 Servicing the Air Cleaner . ... . .. . ..... . .... . . . . . . . .... . .. .... . . ... .. . .. ... .. .. 33 Dry Cleaning ... . ... . . . .. . .. . . ... ....... . . . .......... . .. . . .. .. . . . ........... 34 Wet Cleaning ........................................ . ...................... 34 Primary Element Inspection ....... ....... . ......... .. . ... ... . ........... ..... 35 Primary Element Installation .. .... .................. ... ..................... . 35 Inspection of the Air Intake and Pre-Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Fuel Tank/Hydraulic Tank .. . ......... . ........ . .. .. ... . . ... . .. .... . ...... . ... 36 Fuel Filter/Water Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Hydraulic System .. . ... .. .. . . . . . . . .... . ... . ... . . .. . . .. . . . . . . . . . . . . . ... . . .. .. . 36 Check and Clean the Magnetic Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Replace Hydr. Tank Filter ...... .. ... .. .......... . .... . ... .. ............. . ..... 37 Replace Servo Oil Filter .. . . . . . . . .. . .............. . . . ... . ..................... 37 Replace Replenishing Oil (Spin on) and In Line Filters on the Travel Pumps . . . . . . . . 37 Splitterbox .................. . . . ................... .... ... . ................. 37

25

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13.4.6 13.4.7

Hydraulic System Maintenance and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Hydraulic Cylinders ................... .. . ....... .. ....... .. ...... . ...... . .... 38 Travel Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 13.5 13.5.1 Travel Gear Maintenance . .. . ..... . . .. ... .. .. . .......... .. ... ... ... ... ... .. . . 39 13.5.2 Travel Gear Parking Brake ................... . .. .. ............... .. ...... .. ... 39 13.6 Track Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 13.6.1 To Tighten Track Tension ....... . ..... . . .... .. ... ....... . .. ........... .. .. ... 40 To Release Track Tension . ............... . .................. .................. 40 13.6.2 13.6.3 Check Tightness of Track Pads and Sprocket Segments . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Check and Adjust the Idler Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 13.6.4 13.6.5 Cleaning the Track Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 13.7 Replace Track Chain .. ... ..... ....... ... . ....... .... ............. .... ... . .. . . 42 13.7.1 Remove Sealed Track Chain ......... ..... . . . .... ..... .. . ................... . . 42 13.7.2 Install Sealed Track Chain ...... .. ....... .. ...... . ...... .. ....... . ....... .. 42-43 13.7.3 Remove SALT Chain ............ .. .. .. .. . ..... . . ....... ......... ... .. .. . . ... 43 13.7.4 Install SALT Chain .. ... ............. .. ......... .. ...... . ........ . ...... . . .. . 44 13.8 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 13.8.1 Battery Maintenance ...... . .. ........ ....... . .. . .............. . . ...... .. .... 45 13.8.2 To Replace Fuses ............... . ...... .. ....... .. ............ . .. . ........ . .. 45 · Heatingand Fresh Air System ............ . ................ .. .................. 46 13.9 13.10 Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 13. 10. 1 Cutting Edges and Corner Shanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 13.10.2 Blade Mounting, Push Arms and Braces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46-47 13.10.3 Ripper Shanks and Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 13.11 Replacement of Wear and Tear Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 13.12 Piston Rod Preservation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

14

MAINTENANCE GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14.1 14.2 14.3 14.4 14.5 14.6

Daily ... .. . ......... . ... . .. .. ..... ... ...... ... ............... . ... . ... .. ..... 49 Every 250 Operating Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-51 Every 500 Operating Hours ................... .... . ...... .. ................ 51-52 Every 2000 Operating Hours .......... ..... ...... . .. ... ..... ... . .. ....... . .... 52 Lubrication Chart ................... .. .. ........ . ............ . ........ . ..... 53 Lubrication Points ..... . ............... .. .................. .................. 54

15

TORQUE CHART

...........................................

55-60

16

ELECTRICAL SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

61-63

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49

1

MACHINE DESCRIPTION The PR 721 C is a crawler dozer with hydrostatic drive, easy and comfortable to operate and fast and easy to maintain. ·

1.1

DIESEL ENGINE The machine is powered by a front mounted, water cooled LIEBHERR - Diesel engine. Easy to reach maintenance items include cyclone precleaner, two stage dry air filter with vacuum indicator, radiator, engine oil dip stick, oil filter, fuel filter, and fuel filter/water separator.

1.2

SPLITTER BOX The splitter box, together with a centaflex coupling, connects the Diesel engine to the hydraulic system. Maintenance of the splitter box is limited to a daily visual oil level and leakage check, as well as scheduled oil changes. The drain plug is equipped with a check valve to make the oil change easier.

1.3

HYDRAULIC SYSTEM The travel hydraulic system includes a fully hydrostatic drive with closed loop circuit.

Each side (track} has its own independent circuit, whose main components consist of a variable displacement piston pump in swash plate design with integrated replenishing gear, pump and filter, and a variable flow axial piston motor.

All travel movements of the machine are hydraulically controlled with the single lever of a servo control valve. The movements go from normal forward or reverse to counter rotation. This type of travel system insures infinitely variable travel speed in all directions. The servo circuit with its single lever control and engine speed sensing horsepower control (S~HC} valve, insures utilization ofthe available horsepower at all times.

The working hydraulic system consists of a fixed flow gear pump, a servo operated control valve in an open loop circuit, as well as hand operated pilot (servo) valves for the various attachment functions.

The daily maintenance of the hydraulic system consists of visual oil level and leakage checks and checking the hydraulic oil cooler, mounted side by side to the radiator, for cleanliness. Other maintenance items such as hydraulic oi I filters are easily accessible.

1.4

MAIN FRAME, STEEL STRUCTURE, COVERS The main frame is a one piece torsion resistant structure. Due to this design, the underside is relatively flat and smooth. Strong belly pans which are hinged and access plates protect internal components and provide easy access. Cross members are added where necessary to add strength.

All covers and plates are made of heavy gauge material. Whenever practical or necessary, covers are hinged and/or fitted with sound insulation.

From the maintenance point of view, only a visual inspection, checking for damage, cracks and/or loose bolts is necessary.

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