Liebherr PR744 Crawler Dozer Service Repair Manual

1.  
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 
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 
 
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 
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  

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 

2. Service Manual
Table of contents
PR Litronic Series 4 Mjfcifss! 0.1.00 - 1 / 8
Section Pages Title Date of issue
from to
0.1.00 1 8 Index 02.2010
1.0.00 1 2 Sub group index "General Information" 03.2007
1.1.00 1 2 Foreword and explanations 03.2007
1.2.00 1 14 Safety guidelines 01.2007
1.3.01 1 10 Service items 03.2006
1.3.02 1 2 Service items 01.2009
1.4.01 1 4 Tightening torques 05.2008
1.4.03 1 2 Conversion chart 01.2009
1.4.04 1 2 Tapping holes 01.2004
1.5.00 1 6 Storage guidelines 02.2010
1.6.00 1 2 Weights of Material 03.2009
2.0.00 1 2 Sub group index "Special Tools, Application Guidelines" 02.2008
2.1.00 1 20 Special tools 01.2010
2.2.00 1 6 Repair welding 02.2007
2.3.00 1 6 Installation instructions – slip ring seals 02.2010
3.0.00 1 2 Sub group index "Technical data - maintenance guidelines" 03.2007
3.1.20 1 2 Technical data 03.2006
3.1.21 1 2 Technical data 01.2007
3.1.22 1 4 Technical data 03.2009
3.1.23 1 4 Technical data 03.2009
3.1.30 1 2 Technical data 03.2006
3.1.31 1 4 Technical data 01.2009
3.1.40 1 2 Technical data 01.2008
3.1.50 1 2 Technical data 02.2008
3.1.60 1 2 Technical data 01.2009
3.1.61 1 2 Technical data 02.2009
3.2.20 1 2 Maintenance and inspection schedule 01.2009
3.2.21 1 4 Maintenance and inspection schedule 02.2010
3.2.60 1 4 Maintenance and inspection schedule 02.2010
3.3.20 1 8 Maintenance and inspection guidelines 03.2007
3.3.21 1 10 Maintenance and inspection guidelines 01.2010
3.4.00 1 6 Quick reference for machine adjustment 02.2009
3.5.20 1 4 Adjustment check list 01.2009
3.5.21 1 6 Adjustment check list 01.2009
3.5.30 1 6 Adjustment check list 01.2009
3.5.40 1 6 Adjustment check list 01.2009
3.5.50 1 6 Adjustment check list 01.2009
3.5.60 1 6 Adjustment check list 01.2009
3.5.61 1 6 Adjustment check list 01.2009
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3. Service Manual
Table of contents
PR Litronic Serie 40.1.00 - 2 / 8 Mjfcifss!
4.0.00 1 2 Sub group index "Engine" 03.2007
4.1.00 1 6 Data page 03.2007
4.2.00 1 4 Fan and cylinder configuration 03.2007
4.3.00 1 10 Installation kit Liebherr – Diesel particle filter 01.2009
4.4.00 1 4 Installation and check list for Diesel particle filter 05.2008
5.0.00 1 2 Sub group index "Coupling and splitterbox" 03.2007
5.1.00 1 2 Data page 02.2009
5.2.20 1 2 Coupling 01.2006
5.2.40 1 2 Coupling 02.2006
5.3.20 1 4 Splitterbox 01.2007
5.3.30 1 4 Splitterbox 01.2006
5.3.40 1 4 Splitterbox 02.2006
5.4.00 1 4 Couplings pump output 04.2008
6.0.00 1 2 Sub group index "Travel hydraulic" 03.2007
6.1.20 1 2 Data page 01.2009
6.1.30 1 2 Data page 01.2009
6.1.40 1 2 Data page 01.2008
6.2.20 1 6 Description 01.2006
6.2.21 1 6 Description 04.2008
6.2.22 1 6 Description 04.2008
6.2.30 1 6 Description 04.2008
6.2.40 1 8 Description 01.2009
6.2.50 1 8 Description 04.2008
6.2.60 1 8 Description 01.2009
6.2.61 1 8 Description 01.2009
6.3.20 1 8 Function 01.2008
6.3.21 1 8 Function 01.2009
6.3.22 1 8 Function 01.2009
6.3.30 1 8 Function 01.2008
6.3.31 1 8 Function 01.2008
6.3.32 1 8 Function 01.2009
6.3.40 1 10 Function 01.2009
6.3.50 1 10 Function 01.2009
6.3.60 1 10 Function 01.2009
6.4.20 1 12 Test and adjustment 05.2008
6.4.21 1 18 Test and adjustment 01.2009
6.4.60 1 18 Test and adjustment 05.2008
6.5.20 1 2 Component location 01.2006
6.5.21 1 2 Component location 01.2007
6.5.22 1 2 Component location 01.2007
6.5.30 1 2 Component location 03.2008
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4. Service Manual
Table of contents
PR Litronic Series 4 Mjfcifss! 0.1.00 - 3 / 8
6.5.40 1 2 Component location 02.2006
6.5.50 1 2 Component location 02.2006
6.5.60 1 2 Component location 01.2009
6.5.61 1 2 Component location 01.2009
7.0.00 1 2 Sub group index "Working hydraulic" 03.2007
7.1.20 1 2 Data page 03.2009
7.1.30 1 2 Data page 03.2009
7.1.40 1 2 Data page 03.2009
7.2.20 1 4 Description 01.2007
7.2.21 1 4 Description 03.2009
7.2.30 1 4 Description 02.2008
7.2.40 1 4 Description 02.2008
7.2.50 1 4 Description 02.2008
7.2.60 1 4 Description 03.2006
7.2.61 1 4 Description 03.2007
7.3.20 1 10 Function 01.2008
7.3.21 1 10 Function 01.2008
7.3.22 1 10 Function 01.2008
7.3.30 1 10 Function 01.2008
7.3.31 1 10 Function 01.2008
7.3.40 1 12 Function 01.2008
7.3.50 1 10 Function 01.2008
7.3.60 1 10 Function 01.2008
7.3.61 1 10 Function 01.2009
7.4.20 1 8 Test and adjustment 05.2008
7.4.30 1 8 Test and adjustment 05.2008
7.4.40 1 10 Test and adjustment 05.2008
7.5.20 1 2 Component location 01.2006
7.5.21 1 2 Component location 01.2007
7.5.22 1 2 Component location 03.2009
7.5.23 1 2 Component location 03.2009
7.5.30 1 2 Component location 01.2006
7.5.40 1 2 Component location 02.2006
7.5.50 1 2 Component location 02.2006
7.5.60 1 2 Component location 03.2006
7.5.61 1 2 Component location 03.2006
8.0.00 1 2 Sub group index "Hydraulic components" 03.2007
8.1.20 1 8 Variable pump 03.2006
8.1.40 1 6 Variable pump 01.2009
8.2.20 1 4 Variable motor 01.2005
8.2.21 1 6 Variable motor 02.2008
8.2.22 1 6 Variable motor 02.2008
8.2.30 1 4 Variable motor 01.2006
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5. Service Manual
Table of contents
PR Litronic Serie 40.1.00 - 4 / 8 Mjfcifss!
8.2.31 1 6 Variable motor 03.2009
8.2.40 1 6 Variable motor 03.2007
8.2.50 1 6 Variable motor 02.2008
8.2.51 1 6 Variable motor 02.2008
8.3.20 1 8 Regulating pump 03.2009
8.3.21 1 6 Regulating pump 03.2009
8.3.30 1 6 Regulating pump 03.2006
8.3.31 1 10 Regulating pump 02.2009
8.3.60 1 6 Regulating pump 03.2006
8.4.20 1 4 Double gear pump– fan drive 03.2006
8.4.25 1 4 Gear motor – fan drive 03.2008
8.4.26 1 4 Gear motor – fan drive 03.2008
8.4.40 1 4 Double gear pump – Replenishing 02.2006
8.4.45 1 4 Axial piston fixed displacement motor – fan drive 02.2006
8.4.50 1 4 Double gear pump – Replenishing 02.2006
8.4.55 1 4 Gear motor – fan drive external oil cooler 02.2006
8.5.20 1 8 Pilot control valve 01.2008
8.5.21 1 8 Pilot control valve 01.2008
8.6.20 1 6 Control valve block 02.2006
8.6.21 1 6 Control valve block 01.2007
8.6.22 1 6 Control valve block 01.2007
8.6.40 1 6 Control valve block 03.2006
8.6.41 1 6 Control valve block 03.2006
8.7.00 1 12 Valves 02.2009
8.8.00 1 12 Hydraulic cylinder 01.2010
9.0.00 1 2 Sub group index "Electrical system – Plans and components" 03.2007
9.1.20 1 6 Code letter explanations 02.2010
9.1.30 1 8 Code letter explanations 02.2010
9.1.60 1 6 Code letter explanations 02.2009
9.2.20 1 2 Function list 02.2007
9.2.30 1 2 Function list 02.2007
9.2.40 1 2 Function list 03.2008
9.2.60 1 2 Function list 02.2009
9.3.20 1 2 Fuses, cross points, notes 02.2007
9.3.30 1 2 Fuses, cross points, notes 03.2007
9.3.40 1 2 Fuses, cross points, notes 03.2008
9.3.60 1 2 Fuses, cross points, notes 02.2007
9.4.20 1 16 Current flow diagram 02.2007
9.4.20 1/02 Current flow diagram Addendum 02.2007
9.4.20 2/02 Current flow diagram Addendum 02.2007
9.4.20 3/02 Current flow diagram Addendum 02.2007
9.4.20 15/02 Current flow diagram Addendum 02.2007
9.4.21 1 62 Current flow diagram 03.2008
9.4.22 1 76 Current flow diagram 03.2009
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6. Service Manual
Table of contents
PR Litronic Series 4 Mjfcifss! 0.1.00 - 5 / 8
9.4.23 1 76 Current flow diagram 03.2009
9.4.30 1 22 Current flow diagram 02.2007
9.4.31 1 62 Current flow diagram 03.2008
9.4.40 1 18 Current flow diagram 03.2008
9.4.50 1 80 Current flow diagram 02.2010
9.4.51 1 80 Current flow diagram 02.2010
9.4.60 1 18 Current flow diagram 03.2006
9.4.61 1 80 Current flow diagram 02.2009
9.5.20 1 2 Instrument panel 01.2007
9.5.21 1 2 Instrument panel 03.2007
9.6.20 1 16 Component arrangement 05.2008
9.6.21 1 16 Component arrangement 05.2008
9.6.22 1 18 Component arrangement 02.2010
9.6.30 1 18 Component arrangement 02.2010
9.6.40 1 14 Component arrangement 02.2010
9.6.41 1 16 Component arrangement 02.2010
9.6.50 1 14 Component arrangement 02.2010
9.6.60 1 16 Component arrangement 05.2008
9.6.61 1 18 Component arrangement 02.2010
9.7.00 1 4 Travel joystick 02.2010
9.7.25 1 4 Inching - brake pedal 03.2007
9.7.26 1 4 Inching - brake pedal 04.2008
10.0.00 1 2 Sub group index "Electrical system descriptions" 01.2008
10.1.00 1 70 Application Software – travel drive 01.2010
10.2.00 1 20 Software PDL – Diesel particle filter 01.2010
11.0.00 1 2 Sub group index "Final drive" 03.2007
11.1.20 1 2 Data page 01.2010
11.1.30 1 2 Data page 01.2007
11.1.40 1 2 Data page 02.2008
11.1.50 1 2 Data page 01.2008
11.2.20 1 4 Design and function 03.2006
11.2.21 1 4 Design and function 01.2007
11.2.22 1 6 Design and function 02.2008
11.2.40 1 4 Design and function 03.2007
11.2.41 1 4 Design and function 03.2007
11.2.50 1 4 Design and function 04.2008
11.2.51 1 4 Design and function 05.2008
11.2.60 1 6 Design and function 03.2006
11.2.61 1 6 Design and function 02.2008
11.3.20 1 4 Sectional view 01.2006
11.3.21 1 4 Sectional view 03.2007
11.3.40 1 4 Sectional view 01.2009
11.3.41 1 4 Sectional view 01.2009
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7. Service Manual
Table of contents
PR Litronic Serie 40.1.00 - 6 / 8 Mjfcifss!
11.3.42 1 4 Sectional view 01.2009
11.3.50 1 4 Sectional view 01.2009
11.3.51 1 4 Sectional view 01.2009
11.3.60 1 4 Sectional view 01.2009
11.3.61 1 4 Sectional view 01.2009
12.0.00 1 2 Sub group index "Track components" 03.2007
12.1.00 1 2 Data page 02.2010
12.2.00 1 26 Description, function, wear and evaluation 03.2008
12.3.00 1 4 Inspection checklist 01.2010
12.3.01 1 6 Wear chart 01.2009
12.4.20 1 8 Track roller frame and idler unit 03.2009
12.4.50 1 8 Track roller frame and idler unit 02.2010
12.5.00 1 2 Track roller 01.2006
12.6.00 1 2 Carrier roller 02.2007
12.8.50 1 6 Tension unit 02.2007
12.8.60 1 6 Tension unit 03.2007
13.0.00 1 2 Sub group index "Working Attachments - front" 03.2007
13.1.00 1 6 Straight blade 02.2007
13.2.20 1 6 6 way blade 01.2008
13.4.40 1 6 Hydraulic cutting angle adjustment 01.2008
13.4.50 1 8 Hydraulic cutting angle adjustment 02.2008
13.4.60 1 6 Hydraulic cutting angle adjustment 01.2008
14.0.00 1 2 Sub group index "Attachments - rear" 03.2007
14.1.20 1 4 Ripper 01.2006
14.1.21 1 8 Ripper 02.2007
14.1.40 1 14 Ripper 01.2008
14.1.60 1 12 Ripper 01.2008
15.0.00 1 2 Sub group index "Main frame components" 03.2007
15.1.20 1 2 Cooler arrangement 01.2006
15.1.21 1 2 Cooler arrangement 01.2007
15.1.22 1 2 Cooler arrangement 01.2007
15.1.30 1 2 Cooler arrangement 03.2008
15.1.40 1 2 Cooler arrangement 02.2006
15.1.50 1 2 Cooler arrangement 03.2006
15.1.60 1 2 Cooler arrangement 01.2009
15.1.61 1 2 Cooler arrangement 01.2009
15.2.00 1 2 Hoist cylinder suspension 02.2006
15.3.20 1 2 Equalizer bar 01.2006
15.3.40 1 2 Equalizer bar 01.2006
15.3.50 1 2 Equalizer bar 02.2006
15.3.60 1 2 Equalizer bar 01.2010
15.4.20 1 2 Engine mount 01.2007
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9. Service Manual
Table of contents
PR Litronic Series 4 Mjfcifss! 0.1.00 - 7 / 8
15.4.21 1 2 Engine mount 01.2007
15.4.30 1 2 Engine mount 01.2006
15.4.40 1 2 Engine mount 02.2006
15.4.60 1 2 Engine mount 02.2010
16.0.00 1 2 Sub group index "Tank arrangement" 03.2007
16.1.20 1 4 Hydraulic tank 05.2008
16.1.21 1 4 Hydraulic tank 05.2008
16.1.30 1 4 Hydraulic tank 05.2008
16.1.40 1 4 Hydraulic tank 05.2008
16.1.50 1 4 Hydraulic tank 05.2008
16.1.60 1 4 Hydraulic tank 05.2008
16.2.20 1 2 Fuel tank 01.2007
16.2.30 1 2 Fuel tank 01.2007
16.2.40 1 2 Fuel tank 02.2006
16.2.50 1 2 Fuel tank 03.2006
16.2.60 1 2 Fuel tank 03.2007
16.2.61 1 2 Fuel tank 03.2007
16.3.20 1 2 Battery box 01.2007
16.3.21 1 2 Battery box 03.2008
16.3.22 1 2 Battery box 03.2008
16.3.30 1 2 Battery box 03.2008
16.3.31 1 2 Battery box 03.2008
16.3.40 1 2 Battery box 01.2006
16.3.50 1 2 Battery box 02.2006
16.3.60 1 2 Battery box 03.2007
16.3.61 1 2 Battery box 03.2007
17.0.00 1 2 Sub group index "Operator’s platform, heater, air conditioner" 03.2007
17.1.00 1 6 Operator’s platform 01.2008
17.2.00 1 4 Heater and blower 01.2007
17.3.00 1 10 Air conditioning system 01.2009
17.4.00 1 2 Operator’s seat – air cushioned 03.2006
17.5.20 1 4 Throttle control 01.2007
17.5.21 1 2 Throttle control 01.2007
18.0.00 1 2 Sub group index "Special equipment" 01.2009
18.2.00 1 4 Refueling pump 02.2007
18.3.20 1 4 Reversible fan 02.2008
18.3.21 1 4 Reversible fan 02.2008
18.3.30 1 4 Reversible fan 02.2008
18.3.31 1 4 Reversible fan 02.2008
18.3.32 1 4 Reversible fan 02.2008
18.3.40 1 4 Reversible fan 02.2008
18.3.50 1 4 Reversible fan 02.2008
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10. Service Manual
Table of contents
PR Litronic Serie 40.1.00 - 8 / 8 Mjfcifss!
18.3.60 1 4 Reversible fan 02.2008
18.3.61 1 4 Reversible fan 02.2008
18.4.20 1 12 Cable winch 01.2009
19.0.00 1 2 Sub group index "Additional documentation" 03.2008
6.3.20 1 1 Schematic Travel hydraulic 01.2008
6.3.21 1 1 Schematic Travel hydraulic 01.2009
6.3.22 1 1 Schematic Travel hydraulic 01.2009
6.3.30 1 1 Schematic Travel hydraulic 03.2006
6.3.31 1 1 Schematic Travel hydraulic 03.2006
6.3.32 1 1 Schematic Travel hydraulic 01.2009
6.3.40 1 2 Schematic Travel hydraulic 01.2009
6.3.50 1 2 Schematic Travel hydraulic 01.2009
6.3.60 1 3 Schematic Travel hydraulic 01.2009
7.3.20 1 1 Schematic Working hydraulic 03.2006
7.3.21 1 1 Schematic Working hydraulic 01.2007
7.3.22 1 1 Schematic Working hydraulic 01.2008
7.3.30 1 1 Schematic Working hydraulic 03.2006
7.3.31 1 1 Schematic Working hydraulic 01.2008
7.3.40 1 2 Schematic Working hydraulic 01.2008
7.3.50 1 1 Schematic Working hydraulic 01.2008
7.3.60 1 1 Schematic Working hydraulic 03.2006
7.3.61 1 1 Schematic Working hydraulic 01.2008
9.4.20 1 16 Current flow diagram 02.2007
9.4.21 1 61 Current flow diagram 03.2008
9.4.22 1 76 Current flow diagram 03.2009
9.4.23 1 76 Current flow diagram 03.2009
9.4.30 1 21 Current flow diagram 02.2007
9.4.31 1 61 Current flow diagram 03.2008
9.4.40 1 18 Current flow diagram 03.2008
9.4.50 1 80 Current flow diagram 02.2010
9.4.51 1 80 Current flow diagram 02.2010
9.4.60 1 17 Current flow diagram 03.2006
9.4.61 1 80 Current flow diagram 02.2009
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11. Service-Manual General Information
Sub Group Index
PR Litronic Serie 4 Mjfcifss! 1.0.00 - 1 / 2
Sub Group Index - General Information
Foreword and explanation 1.1
Safety guidelines 1.2
Service Items 1.3
Table - charts 1.4
Tightening torques 1.4.01
Conversion table 1.4.03
Hole diameter before tapping 1.4.04
Storage (preservation) guidelines 1.5
Weight of materials 1.6
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12. Service-Manual General Information
Foreword and explanation
PR Litronic Serie 4 Mjfcifss! 1.1.00 - 1 / 2
For your information
This manual contains technical data, descriptions of design and function, repair and adjustment guidelines as well
as numerous drawings, functional views and illustrations
LIEBHERR - crawler dozers (PR) serial 4.
This manual should simplify competent customer service of our products, does however, not replace expert and
qualified training and an attendance of our factory schools.
Information which is in trade considered basic knowledge is not included. Operation and spare parts information can
be found in separate manuals.
The manual will be updated as necessary when changes occur in series.
This symbol is used in the manual for very important notes.
Note!
This sign marks special important notes in the manual.
During the activities on the machine, accident prevention regulations and safety guidelines must be strictly
observed.
This manual is intended for the exclusive use of the registered owner and may not be reproduced complete or in
part or passed on a third person without written permission.
This manual is still on property of LIEBHERR-Werk Telfs GmbH.
All rights reserved - Printed in Austria.
We reserve the right to make changes of technical details on the machine in comparison to the information and
drawings in this manual.
Printed and published by
LIEBHERR-Werk Telfs GmbH., Technical Documentation Department.
Explanation of structure (page numbers)
In order to find specific information and add supplements more easily, the following numbering system is being
used:
Sometimes there is a number behind the page number, e.g. 9.4.20 - 13/15 - 02. This number stands for
supplements, especially at current flow diagrams, when only one page is supplemented to the schematic.
Updated pages retain the same page number, but receive a more recent date when mailed. Supplements have a
new number. If the page is only valid for a certain machine model group, it will so be indicated on the page.
6.3.10 - 01/02
main group sub group model group page no.
main group according
to manual index
sub group of main group
according to sub group
index
continuous running
number and complete
number of pages within
the model group
division based on
information content or
machine model group
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13. General Information Service-Manual
Foreword and explanation
PR Litronic Serie 41.1.00 - 2 / 2 Mjfcifss!
This note shows that the detail view of an illustration is turned by the stated angle, as
compared to the actual installation position. (in this case 180°)
We hope that with the enclosed information we have taken yet another step to improve the service on the
LIEBHERR - crawler dozers, crawler loaders pipe layers and telescopic handlers.
LIEBHERR-Werk Telfs GmbH.
Technical Documentation Dept.
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