service repair manual

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2. Service Manual
Table of contents
LR Litronic Serie 4 MJFCIFSS! 0.1.00 - 1 / 4
0.1.00 Table of contents
Page No.
Pages
from to
Title
Date of
issue
0.1.00 1 4 Table of contents 2.2010
1.0.00 1 2 Sub group index "General" 3.2007
1.1.00 1 2 Foreword and explanation 3.2007
1.2.00 1 4 Safety guidelines 5.2008
1.3.00 1 2 Service fluids 3.2007
1.4.01 1 4 Tightening torques 5.2008
1.4.02 1 2 Conversion chart 1.2009
1.4.03 1 2 Tapping holes 3.2007
1.5.00 1 4 Conservation guidelines 2.2010
1.6.01 1 2 Material weights 3.2009
2.0.00 1 2 Sub group index "Tools and application remarks" 2.2008
2.1.00 1 20 Special tools 1.2010
2.2.00 1 8 Repair welding 1.2009
2.3.00 1 4 Installation notes for slipring seals 4.2008
3.0.00 1 2 Sub group index "Technical data and Maintenance guidelines" 3.2007
3.1.20 1 2 Technical Data 3.2007
3.1.30 1 2 Technical Data 2.2009
3.1.31 1 2 Technical Data 2.2009
3.2.20 1 4 Maintenance and inspection schedule 2.2010
3.3.20 1 8 Maintenance and Inspection guidelines 3.2009
3.4.20 1 6 Quick reference for machine adjustment 3.2009
3.5.20 1 4 Adjustment check list 5.2008
3.5.30 1 4 Adjustment check list 3.2009
3.5.31 1 4 Adjustment check list 3.2009
4.0.00 1 2 Sub group index "Engine" 2.2008
4.1.20 1 2 Data page 1.2009
4.1.30 1 2 Data page 3.2008
4.2.20 1 2 Fan and cylinder arrangement 1.2009
4.3.00 1 12 Installation kit- Diesel particle filter 1.2009
4.4.00 1 4 Installation and test list for Diesel particle filter 5.2008
5.0.00 1 2 Sub group index "Coupling and splitterbox" 4.2008
5.1.20 1 2 Data page 1.2009
5.2.20 1 2 Coupling 4.2008
5.3.20 1 4 Splitterbox 4.2008
5.3.30 1 4 Splitterbox 4.2008
5.4.20 1 2 Coupling – pump output 4.2008
6.0.00 1 2 Sub group index "Travel hydraulic" 3.2007
6.1.20 1 2 Data page 1.2009
6.1.30 1 2 Data page 3.2008
6.2.20 1 10 Design 5.2008
6.2.21 1 10 Design 5.2008
6.2.30 1 10 Design 5.2008
6.2.31 1 10 Design 5.2008
6.3.20 1 8 Function 1.2009
6.3.21 1 8 Function 1.2009
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3. Service Manual
Table of contents
LR Litronic Serie 4
0.1.00 - 2 / 4 Mjfcifss!
Page No.
Pages
from to
Title
Date of
issue
6.3.30 1 8 Function 1.2009
6.3.31 1 8 Function 1.2009
6.3.32 1 8 Function 1.2009
6.3.33 1 8 Function 1.2009
6.4.00 1 10 Test and adjustment 2.2010
6.5.20 1 2 Component arrangement 2.2008
6.5.21 1 2 Component arrangement 2.2008
6.5.30 1 2 Component arrangement 2.2008
6.5.31 1 2 Component arrangement 3.2008
7.0.00 1 2 Sub group index "Working hydraulic" 3.2007
7.1.20 1 2 Data page 1.2009
7.1.30 1 2 Data page 1.2009
7.2.20 1 6 Design 2.2008
7.3.20 1 10 Function 1.2008
7.3.30 1 10 Function 1.2008
7.4.00 1 10 Test and adjustment 3.2009
7.5.20 1 2 Component arrangement 1.2009
8.0.00 1 2 Sub group index "Hydraulic components" 2.2009
8.1.20 1 6 Variable displacement pump 3.2007
8.1.30 1 6 Variable displacement pump 6.2006
8.2.20 1 6 Variable displacement motor 3.2007
8.2.30 1 6 Variable displacement motor 2.2008
8.2.31 1 6 Variable displacement motor 2.2008
8.3.20 1 10 Regulator pump – Working hydraulic 2.2008
8.4.20 1 4 Double gear pump – Replenishing / Fan drive 4.2008
8.4.25 1 4 Fan motor 3.2008
8.4.35 1 4 Fan motor 4.2008
8.5.20 1 8 Pilot control – Working hydraulic 3.2009
8.5.25 1 6 Pilot control – Auxiliary equipment 1.2009
8.6.20 1 6 Control valve block 3.2007
8.7.00 1 12 Valves 2.2009
8.8.00 1 8 Hydraulic cylinder 3.2007
9.0.00 1 2 Sub group index "Electrical system – Schematics and components" 3.2009
9.1.30 1 6 Component description 2.2010
9.2.30 1 2 Function list 1.2010
9.2.31 1 2 Function list 1.2010
9.3.30 1 2 Fuses, cross points, notes 1.2008
9.4.20 1 76 Current flow diagram 3.2009
9.4.21 1 80 Current flow diagram 3.2009
9.4.30 1 16 Current flow diagram 1.2008
9.4.31 1 16 Current flow diagram 1.2008
9.4.32 1 76 Current flow diagram 1.2008
9.5.20 1 2 Instrument panel 1.2010
9.6.20 1 18 Component arrangement – Electrical system 2.2010
9.6.30 1 14 Component arrangement – Electrical system 2.2010
9.6.31 1 18 Component arrangement – Electrical system 2.2010
9.7.20 1 4 Travel joystick 2.2010
9.7.25 1 4 V- joystick 2.2010
9.8.20 1 4 Speed reduction pedal 1.2008
10.0.00 1 2 Sub group index "Electrical system descriptions" 3.2008
10.1.00 1 70 Application Software – travel drive 1.2010
10.2.00 1 20 Software PDL – Diesel particle filter 1.2010
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4. Service Manual
Table of contents
LR Litronic Serie 4 MJFCIFSS! 0.1.00 - 3 / 4
Page No.
Pages
from to
Title
Date of
issue
11.0.00 1 2 Sub group index "Final drive" 3.2007
11.1.20 1 2 Data page 3.2007
11.1.30 1 2 Data page 6.2006
11.2.20 1 6 Design and function 3.2007
11.2.30 1 6 Design and function 3.2007
11.3.20 1 4 Sectional view 3.2007
11.3.30 1 4 Sectional view 3.2007
12.0.00 1 2 Sub group index "Track components" 3.2007
12.1.00 1 2 Data page 2.2010
12.2.00 1 26 Design, function, wear and evaluation 3.2008
12.3.00 1 4 Inspection checklist 1.2010
12.3.01 1 4 Wear chart 1.2009
12.4.20 1 6 Track roller frame and idler unit 2.2008
12.5.20 1 2 Track roller 3.2007
12.6.20 1 2 Carrier roller 3.2007
12.8.00 1 10 Tension unit 5.2008
13.0.00 1 2 Sub group index "Attachments - front" 3.2007
13.1.20 1 6 4 in 1 Bucket 3.2007
13.2.20 1 4 Bucket arm 3.2009
14.0.00 1 2 Sub group index "Attachments - rear" 3.2007
14.1.20 1 6 Ripper 3.2007
14.1.21 1 6 Ripper 3.2007
15.0.00 1 2 Sub group index " Main frame – Add on components " 3.2007
15.1.20 1 2 Cooler arrangement 3.2007
15.1.30 1 2 Cooler arrangement 3.2008
15.2.20 1 2 Hoist and tilt cylinder mount 3.2007
15.3.20 1 2 Equalizer bar 3.2007
15.3.30 1 4 Equalizer bar 3.2007
15.4.20 1 2 Engine mount 1.2008
16.0.00 1 2 Sub group index "Tank arrangement" 3.2007
16.1.20 1 6 Hydraulic tank 2.2010
16.1.30 1 4 Hydraulic tank 1.2008
16.2.20 1 2 Fuel tank 3.2009
16.2.30 1 2 Fuel tank 1.2008
16.3.20 1 4 Battery compartment 1.2008
17.0.00 1 2 Sub group index "Operators platform, heater, air conditioner" 3.2007
17.1.00 1 4 Operators platform 1.2009
17.2.00 1 4 Heater and Blower 1.2009
17.3.00 1 10 Air conditioning system 1.2009
17.4.20 1 2 Operator’s seat – air cushioned 3.2007
17.5.20 1 2 Engine RPM adjustment 5.2008
18.0.00 1 2 Sub group index "Special equipment" 5.2008
18.2.20 1 4 Refueling pump 1.2008
18.3.20 1 6 Reversible fan 2.2010
18.3.30 1 6 Reversible fan 3.2008
18.3.31 1 6 Reversible fan 2.2010
18.4.00 1 6 Rope winch 1.2009
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5. Service Manual
Table of contents
LR Litronic Serie 4
0.1.00 - 4 / 4 Mjfcifss!
Page No.
Pages
from to
Title
Date of
issue
19.0.00 1 2 Sub group index "Additional documentation" 3.2009
6.3.20 1 2 Schematics Travel Hydraulic 1.2009
6.3.21 1 2 Schematics Travel Hydraulic 1.2009
6.3.30 1 2 Schematics Travel Hydraulic 1.2009
6.3.31 1 2 Schematics Travel Hydraulic 1.2009
6.3.32 1 2 Schematics Travel Hydraulic 1.2009
6.3.33 1 2 Schematics Travel Hydraulic 1.2009
7.3.20 1 1 Schematic Working Hydraulic 1.2008
7.3.30 1 1 Schematic Working Hydraulic 1.2008
9.4.20 1 76 Current Flow Diagram 3.2009
9.4.21 1 80 Current Flow Diagram 3.2009
1 16 Current Flow Diagram 2.2007
9.4.30
13,16 3.2007
6 1.2008
9.4.31 1 16 Current Flow Diagram 1.2008
9.4.32 1 76 Current Flow Diagram 2.2009
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6. Service Manual General
Sub group index General
LR Litronic Serie 4 MJFCIFSS! 1.0.00 - 1 / 2
1 General
1.0.00 Sub group index General
Foreword and Explanation ........................................................................... 1.1
Safety Guidelines .......................................................................................... 1.2
Service fluids ................................................................................................. 1.3
Table charts ................................................................................................... 1.4
Tightening torques............................................................................................................1.4.01
Conversion charts.............................................................................................................1.4.02
Tapping holes ...................................................................................................................1.4.03
Conservation guidelines............................................................................... 1.5
Material weights............................................................................................. 1.6
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7. Service Manual General
Foreword and explanation
LR Litronic Serie 4 MJFCIFSS! 1.1.00 - 1 / 2
1.1.00 Foreword and explanation
1 For information
This manual contains technical data, descriptions of design and function, repair and adjustment
instructions as well as numerous drawings, functional views and illustrations of
LIEBHERR – crawler loaders (LR) in Series 4.
This manual should simplify competent customer service of our product, however, it does not
replace expert and qualified training and attendance at our factory training classes.
Information which is in the trade considered to be basic knowledge is not included. Operation
and spare parts information can be found in separate documentation.
The manual will be updated and expanded as necessary, when changes occur in series.
During all activities on the machine, accident prevention regulations and safety guidelines must
be strictly observed.
The manual is intended for the exclusive use of the registered owners and may not be
reproduced complete or in part or passed on to a third person without our written permission
and remains property of LIEBHERR-Werk Telfs GmbH.
All rights reserved - Printed in Austria.
We reserve the right to make changes of technical details on the machine in comparison to the
information and drawings in this manual.
Printed and published by
LIEBHERR-Werk Telfs GmbH., Technical Documentation Dept.
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8. General Service Manual
Foreword and explanation
LR Litronic Serie 4
1.1.00 - 2 / 2 Mjfcifss!
2 Explanation of set up
In order to find specific information and to simplify the addition of supplements, the following
system is used:
Main group
Component (item) groups
according to index
Model group
Division based on
information content or
machine size
Sub group
Sub group of main group
according to sub group index
Page No.
Continuous running No.
and complete number of
pages within the model
group
It is possible that there is an additional running number behind the continuous number, for
example 9.4.20 - 13/15 - 02. This number stands for updates, especially on electrical
schematics, where only one page is updated.
Changes will be issued with the same number, but with updated date. Updates will be given
new numbers. If one page applies only for a certain machine group, then this is noted in the
heading.
Note!
This sign marks special important notes in the manual.
This symbol notes a standard listing.
This symbol means:“ The prerequisite must be met“.
The maintenance personnel must first fulfill the described prerequisites, for example, to bring
the machine in working position, to be able to carry out the steps described thereafter as.
This symbol marks an activity step.
The maintenance personnel is to become active on this point and carry out the described
activity.
This symbol denotes a result.
The maintenance personnel is alerted to the fact that a result will occur after a work step, for
example, after the test button is pushed, the LED light lights up.
This note shows that the detail view of an illustration is turned by
the stated angle, as compared to the actual installation position.
(in this case 180°)
We hope that with the enclosed information we have taken yet another step to improve the
service on LIEBHERR crawler dozers, crawler loaders, pipe layers and telescopic handlers.
LIEBHERR-Werk Telfs GmbH.
Technical Documentation
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10. Service Manual General
Safety guidelines
LR Litronic Serie 4 MJFCIFSS! 1.2.00 - 1 / 4
1.2.00 Safety guidelines
1 Introduction
Prior to and during the performance of tests, adjustments and repairs, the following
safety guidelines must be followed:
Any type of work may only be performed by qualified trained personnel or under the
supervision and responsibility of such personnel.
Qualified trained personnel are persons, who – based on specialized training and experience –
have sufficient knowledge in the general area of earthmoving machinery and the specific
technology of our machines. They must also have knowledge of all applicable laws and general
work protection regulations, guidelines and generally approved rules concerning technology and
be able to evaluate if earthmoving equipment is safe to operate and if the necessary work can be
performed without endangering themselves or third persons.
Never operate a machine with a raised cab/ operator’s platform! The machine may only be
operated with a lowered and secured cab / operator’s platform!
Always adhere to the adjustment values noted in LIEBHERR documentation when performing
adjustment work.
When delivering the machine, the operating personnel must be trained using the currently valid
operating manual. The safety guidelines in that manual must be particularly observed.
These safety guidelines must also be observed when performing testing, adjustment or repair
work. However, there are special repair and/ or inspection tasks, which require different
procedures than specified in the safety guidelines. In such cases, qualified personnel or
individuals performing the work under the supervision of such personnel should assure that
additional safety precautions necessary to insure the safety of those involved in the repair and/
or third parties are taken. The decision to carry out this measures can only be made by qualified
expert personnel. Such examples of repair and/ or maintenance include, but are not limited to
the following:
- opening of the side engine compartment doors with the Diesel engine running to carry out
tests and / or adjustments.
In these cases, it should be assured that the side doors are properly secured for the
complete duration of the work to prevent them from closing unexpectedly and / or
inadvertently. Avoid body contact with turning and / or heated parts! Wear only tight
clothing (for example no scarves, no ties, no wide sleeves, etc.)
- starting the Diesel engine with the cab tilted, as well as actuating the travel drive with
properly raised machine for adjustment, repair and diagnostics purposes. In these cases,
before starting the engine, it must be ensured that the cab support as well as the support
under the machine and the required ground clearance of the track chains has been
checked.
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11. General Service Manual
Safety guidelines
LR Litronic Serie 4
1.2.00 - 2 / 4 Mjfcifss!
2 Safety notes in this manual
In the description of tasks, which can pose a danger to man or machine, the following safety
precautions are described in this manual.
They are defined with the following notes:
Danger!
Warns that certain working procedures could result in death or serious injury if proper
precautions are not taken.
Warning!
Warns that certain working procedures could result in serious injury if certain precautions are
not taken.
Caution!
Warns that certain working procedures could result in personal injury or damage to the
machine if certain precautions are not taken.
In addition to these instructions, you must follow additional safety regulations and
guidelines!
In addition, the following must be observed:
the safety regulations applicable at the jobsite.
federal, state and local laws governing „travel on public roads“.
any guidelines issued by trade and professional associations.
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12. Service Manual General
Safety guidelines
LR Litronic Serie 4 MJFCIFSS! 1.2.00 - 3 / 4
3 Safety guidelines in this operating manual
The detailed descriptions to the following safety guidelines are noted in the operating
instructions of your machine and must be strictly observed.
1 Introduction
2 Proper and intended use
3 Signs on the machine
4 Safety regulations
4.1 General safety guidelines
4.2 Crushing and burn prevention
4.3 Fire and explosion prevention
4.4 Machine start up safety
4.5 Engine start up safety
4.6 Machine operating safety
4.7 Machine parking safety
4.8 Machine transporting safety
4.9 Machine towing safety
4.10 Machine maintenance safety
4.11 Machine welding safety
4.12 Safety guidelines to be observed when working on the attachment
4.13 Safety guidelines to be observed when loading the machine with a crane
4.14 Safe maintenance of hydraulic hoses and lines
4.15 Safety guidelines for maintenance work on the machine with hydro accumulators
4.16 Roll over protection (ROPS) and falling object protection (FOPS)
4.17 Attachments and components
4.18 Protection from vibration
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