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Benennung Description Dénomination Typ/ab Type/from Type/ a partir de
Mjfcifss! LR 614 F/N xxx-6358
Datum Edition Date
02 10 Table of contents Blatt
Page
Feuille
0.1.00.01
Page No.
Pages
from to
Title
Date of
issue
0.1.00 1 4 Index 02.2010
1.0.00 1 2 Sub group index "General" 02.2007
1.1.00 1 2 Foreword and explanation 02.2007
1.2.01 1 4 Safety guidelines 04.2008
1.3.10 1 8 Service fluids 01.2009
1.3.11 1 2 Service fluids 01.2009
1.4.01 1 4 Tightening torques 02.2007
1.4.02 1 2 Conversion chart 04.2008
1.4.03 1 2 Tapping holes 02.2007
1.5.01 1 2 Material weights 01.2009
2.0.00 1 2 Sub group index "Tools and Working instructions" 02.2007
2.1.10 1 10 Special tools 01.2009
2.2.01 1 6 Repair welding 02.2010
2.3.01 1 4 Installation instruction for duo cone seals 01.2009
3.0.00 1 2 Sub group index "Technical data and maintenance guidelines" 02.2007
3.1.10 1 2 Technical data 04.2008
3.1.11 1 2 Technical data 01.2010
3.2.10 1 4 Maintenance and inspection schedule 04.2008
3.2.11 1 2 Maintenance and inspection schedule 01.2009
3.3.10 1 8 Maintenance and Inspection instructions 01.2009
3.4.10 1 4 Quick reference for Machine adjustment 01.2010
3.5.10 1 2 Adjustment check list 01.2010
3.5.11 1 4 Adjustment check list 01.2010
4.0.00 1 2 Sub group index "Engine" 02.2007
4.1.10 1 2 Data page 04.2008
4.2.10 1 2 Fan and cylinder arrangement 04.2008
5.0.00 1 2 Sub group index "Coupling and splitter box" 02.2007
5.1.10 1 2 Data page 04.2008
5.2.10 1 2 Coupling 02.2007
5.3.10 1 4 Splitter box 02.2007
6.0.00 1 2 Sub group index "Travel hydraulic" 02.2007
6.1.10 1 2 Data page 04.2008
6.2.10 1 6 Design 04.2008
6.2.11 1 8 Design 04.2008
6.3.10 1 6 Function 04.2008
6.3.10 1 1 Schematic Travel hydraulic 04.2008
6.3.11 1 6 Function 01.2009
6.3.11 1 2 Schematic Travel hydraulic 01.2009
6.5.10 1 2 Component arrangement 04.2008
6.5.11 1 2 Component arrangement 04.2008
Page No.
Pages
from to
Title
Date of
issue
7.0.00 1 2 Sub group index "Working hydraulic" 02.2007
7.1.10 1 2 Data page 02.2007
7.2.10 1 6 Design 04.2008
7.2.11 1 4 Design 04.2008
7.3.10 1 8 Function 04.2008
7.3.10 1 1 Schematic Working hydraulic 04.2008
7.3.11 1 8 Function 04.2008
7.3.11 1 1 Schematic Working hydraulic 04.2008
7.5.10 1 4 Component arrangement 04.2008
7.5.11 1 2 Component arrangement 04.2008
8.0.00 1 2 Sub group index "Hydraulic components" 04.2008
8.1.10 1 4 Variable displacement pump 02.2007
8.2.10 1 4 Variable displacement motor 02.2007
8.4.10 1 4 Gear pump working hydraulic 04.2008
8.4.15 1 4 Gear pump Fan drive 04.2008
8.4.20 1 4 Gear motor 04.2008
8.4.21 1 4 Gear motor 04.2008
8.5.10 1 8 Pilot control working hydraulic 04.2008
8.5.11 1 8 Pilot control working hydraulic 04.2008
8.6.10 1 6 Control valve block 04.2008
8.6.11 1 6 Control valve block 04.2008
8.7.10 1 26 Valves 02.2007
8.8.10 1 8 Hydraulic cylinder 04.2008
9.0.00 1 2 Sub group index "Electrical system – Schematics and components" 04.2008
9.1.10 1 12 Item list- wiring diagram 04.2008
9.1.11 1 21 Current flow diagram, code letter explanations, function list 04.2008
9.1.12 1 21 Current flow diagram, code letter explanations, function list 04.2008
9.2.10 1 4 Instrument panel 04.2008
9.2.11 1 4 Instrument panel 04.2008
9.3.10 1 6 Electronic component arrangement 04.2008
9.3.11 1 6 Electronic component arrangement 04.2008
9.4.10 1 2 Travel joystick 04.2008
10.0.00 1 2 Sub group index "Electrical system descriptions" 02.2007
10.1.01 1 2 Application software- Introduction 04.2008
10.1.02 1 16 Application software 02.2007
10.1.03 1 2 Application software- Diagram 01.2010
10.1.04 1 4 Application software description 02.2007
10.1.05 1 8 Error chart 02.2007
12.0.00 1 2 Sub group index "Track arrangement" 02.2007
12.1.10 1 2 Data page 02.2010
12.2.10 1 22 Design, Function, wear evaluation 02.2007
12.3.01 1 2 Appraisal report 02.2007
12.3.10 1 2 Wear chart 04.2008
12.5.10 1 2 Track roller 02.2007
12.6.10 1 2 Carrier roller 02.2007
13.0.00 1 2 Sub group index "Attachments - front" 02.2007
13.1.10 1 4 Mechanical stops- bucket attachments 04.2008
13.2.10 1 6 4 in 1 bucket 04.2008
14.0.00 1 2 Sub group index "Attachments - rear" 02.2007
14.1.10 1 4 Multi tooth ripper- Design, function, item list 04.2008
Benennung Description Dénomination Typ/ab Type/from Type/ a partir de
Mjfcifss! LR 614 F/N xxx-6358
Datum Edition Date
02 10 Table of contents Blatt
Page
Feuille
0.1.00.02
15.0.00 1 2 Sub group index " Main frame – Add on components " 02.2007
15.1.10 1 2 Cooler arrangement 04.2008
15.1.11 1 2 Cooler arrangement 04.2008
15.2.10 1 2 Hoist and tilt cylinder mount 01.2009
15.3.10 1 2 Engine mount 04.2008
15.3.11 1 2 Engine mount 04.2008
16.0.00 1 2 Sub group index "Tank arrangement" 02.2007
16.1.10 1 4 Hydraulic tank 04.2008
16.1.11 1 4 Hydraulic tank 01.2009
16.2.10 1 2 Fuel tank 04.2008
16.2.11 1 2 Fuel tank 04.2008
16.3.10 1 2 Battery box 04.2008
16.3.11 1 2 Battery box 04.2008
17.0.00 1 2 Sub group index "Operators platform, heater, air conditioner" 02.2007
17.1.10 1 8 Operator’s platform 04.2008
17.2.10 1 4 Heater and Blower 04.2008
17.3.10 1 10 Air conditioning system 04.2008
17.4.10 1 2 Operator’s seat – air cushioned 04.2008
17.5.10 1 2 Engine RPM adjustment 02.2007
Benennung Description Dénomination Typ/ab Type/from Type/ a partir de
Mjfcifss! LR 614 F/N xxx-6358
Datum Edition Date
02 07 General Blatt
Page
Feuille
1.0.00.01
Sub group index
General
Forword and explanations 1.1
Safety guidelines 1.2
Service items 1.3
Charts 1.4
Tightening torques for standard screws 1.4.01
Conversion chart 1.4.02
Tapping holes 1.4.03
Material weights 1.5.
Benennung Description Dénomination Typ/ab Type/from Type/ a partir de
Mjfcifss!
Foreword and explanation LR 614 F/N xxx-6358
Datum Edition Date
02 07 General Information Blatt
Page
Feuille 1.1.00.01
For your information
This manual contains technical data, descriptions of design and function, repair and adjustment guidelines as well
as numerous drawings, functional views and illustrations
LIEBHERR - crawler dozers (PR), crawler loaders (LR) or pipelayers (RL).
This manual should simplify competent customer service of our products, does however, not replace expert and
qualified training and an attendance of our factory schools.
Information which is in trade considered basic knowledge is not included. Operation and spare parts information can
be found in separate manuals.
The manual will be updated as necessary when changes occur in series.
During the activities on the machine, accident prevention regulations and safety guidelines must be strictly
observed.
This manual is intended for the exclusive use of the registered owner and may not be reproduced complete or in
part or passed on a third person without written permission.
This manual is still on property of LIEBHERR-Werk Telfs GmbH.
All rights reserved - Printed in Austria.
We reserve the right to make changes of technical details on the machine in comparison to the information and
drawings in this manual.
Printed and published by
LIEBHERR-Werk Telfs GmbH., Service -Training Department.
Explanation of structure (page numbers)
In order to find specific information and add supplements more easily, the following numbering system is being
used:
We hope that with the enclosed information we have taken yet another step to improve the service on the
LIEBHERR - crawler dozers, crawler loaders and pipelayers.
LIEBHERR-Werk Telfs GmbH.
Technical Documentation
Note!
This sign marks special important notes in the manual.
6. 3. 10 01
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 within the model
group, illustrations or
parts list with .00 may be
added at the beginning or
end of each group.
division based on
information content or
machine model group
Benennung Description Dénomination Typ/ab Type/from Type/ a partir de
Mjfcifss!
Safety guidelines LR 614 F/N xxx-6358
Datum Edition Date
04 08 General Information Blatt
Page
Feuille 1.2.01.01
Safety guidelines
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.
1. 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.
Benennung Description Dénomination Typ/ab Type/from Type/ a partir de
Mjfcifss!
Safety guidelines LR 614 F/N xxx-6358
Datum Edition Date
04 08 General Information Blatt
Page
Feuille 1.2.01.02
2. 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 General safety guidelines
2 Crushing and burn prevention
3 Fire and explosion prevention
4 Machine start up safety
5 Engine start up safety
6 Machine operating safety
7 Machine parking safety
8 Machine transporting safety
9 Machine towing safety
10 Machine maintenance safety
11 Machine welding safety
12 Safety guidelines to be observed when working on the attachment
13 Safety guidelines to be observed when loading the machine with a crane
14 Safe maintenance of hydraulic hoses and lines
15 Safety guidelines for maintenance work on the machine with hydro accumulators
16 Roll over protection (ROPS) and falling object protection (FOPS)
17 Attachments and components
18 Protection from vibration
Benennung Description Dénomination Typ/ab Type/from Type/ a partir de
Mjfcifss!
LR 614 F/N xxx-6358 10719
Datum Edition Date
01 09 Service Items Blatt
Page
Feuille 01.3.10.01
Service Items
Notes for the disposition of service fluids and filter:
- Service fluids may not be discharged into the ground, drainage system or waterways.
- Different service fluids and filters should be collected and disposed of in separate containers.
- Do not use containers, which previously held food items or drinks - to prevent danger of mix-ups.
- Dispose of these items in an environmentally friendly manner according to applicable guidelines and
regulations. Observe all state, local and national regulations.
- Do not use old or incorrectly stored service fluids and filters, dispose of them properly.
1. Service fluids for Diesel engines with turbo chargers
1.1. Engine lube oil
Engine lube oils must meet a certain quality and a certain viscosity, depending on their use and ambient
temperatures. Problem-free operation can only be ensured only if the requirements for both areas are met.
1.1.1 Oil quality
To meet the technical demands, only highly alloyed lube oils are used in modern Diesel engines. They
consists of high-quality base oils, mixed with additives. These additives provide the required properties for
these oils.
For LIEBHERR Diesel engines with turbo chargers, oils of the following specifications are approved, the higher
quality oils are preferred:
API - classification : CF-4, CG-4, CH-4, CI-4,
(American Petroleum Institute)
ACEA (CCMC) - classification : E2 (D4), E3 (D5), E4, E5
(Association des Constructeurs Européens de l´Automobile)
Note: For older machines / Diesel engines, if still in use, engine oils according to the lower specification as
noted in the original operation manuals may be used. However, we recommend the use of these new
oils, since the service life of the engine can be extended significantly by using these higher quality
oils. The originally noted oil and filter change intervals may be extended.
1.1.2 Oil viscosity
Z In addition to the quality, the oil must also provide a certain viscosity the selection is made according to the
SAE - classification (Society of Automotive Engineers).
The determining factor for the correct selection of the SAE classification is the ambient temperature. In most
regions, SAE 10W-40 is recommended (see chart below).
If the viscosity is too high, starting problems can occur, if it is too low, the lubrication efficiency can be
endangered, both factors can lead to increased engine wear.
The temperature ranges shown in the following chart are guidelines and may be exceeded or fallen below for a
short time.
For the operation in extreme climate zones, such as in arctic regions, special guidelines apply and are
available from the manufacturer.
1.1.3 Oil change intervals
The oil change intervals noted in the Maintenance and Inspection schedules always apply to "normal operating
conditions". They apply for normal, central European temperatures, annual operation of approx. 1000
operating hours, use of oils of the required minimum quality and fuels with a sulfur content of less than 0.5%.
When using higher quality oils, the operating hours per interval may be doubled - see the following chart.
However, the 500 hour interval may not be exceeded.
Engine oil and filters must be changed at least once a year, even if the given change interval has not yet been
reached.
In difficult circumstances, such as repeated cold start, higher sulfur content (above 05.%) in the fuel, more
severe climatic conditions (for example continuous temperatures below -10°C) etc., the intervals must be cut in
half. This means, for each difficulty, the permitted operating hours per interval must be multiplied by a factor of
0.5.
Permissible oil change intervals in operating hours:
Applications
Oil quality:
CF-4, CG-4, CH-4,
CI-4, E2 (D4))
Oil quality:
E3 (D5), E4, E5,
Ambient
temperature
Sulfur content
in fuel
Change interval Change interval
to 0,5% 250 hrs. 500 hrs.above -10°C
(Normal
temperature) above 0,5% 125 hrs. 250 hrs.
to 0,5% 125 hrs. 250 hrs.below -10°C
Continuous
temperature above 0,5% 60 hrs. 125 hrs.
1.2. Diesel fuels
Diesel fuels must meet the minimum requirements of the following specifications.
The sulfur content may not exceed 0.5%. A higher sulfur content has negative effects on oil change intervals
and engine service life. A higher sulfur content above 1% is not permitted.
Fuels with low sulfur content (for example, according to European regulations <0.05 %) must contain additives
to retain the lubrication efficiency according to HFRR(60°)-Test <400 m - . Insufficient lubrication causes
premature wear of the injection system components, especially distributor injection pumps. The additives should
be added by the fuel supplier, as he is responsible for the quality of the fuel. We do not recommend addition of
secondary lubrication additives by the user.
Approved fuel specifications:
DIN EN 590 + HFRR(60°)-Test <400 m
ASTM D 975 - 89a 1D and 2D + HFRR(60°)-Test <400 m + cetane rating >45 (recommendation: >50)
Benennung Description Dénomination Typ/ab Type/from Type/ a partir de
Mjfcifss!
LR 614 F/N xxx-6358 10719
Datum Edition Date
01 09 Service Items Blatt
Page
Feuille 01.3.10.02
Diesel fuels in very low temperatures
At ambient temperatures below freezing (0 C), the flow properties of warm temperature Diesel fuel can become
insufficient due to paraffin excretion. The same applies to cold temperature Diesel fuels in temperatures below.
-15 C.
In order to prevent operating problems in even lower temperatures, Diesel fuel with an additive is sometimes
available, for use in temperatures to -20 C.
In order to prevent operating problems in even lower temperatures, mix Diesel fuel with normal gasoline or
petroleum. Addition of normal gasoline is a makeshift measure and may not exceed 30% per volume. Do not
use Super gasoline for mixing.
Mixing fuel can diminish engine performance, for that reason, keep the added fuel as low as possible,
depending on the ambient temperatures.
For safety reasons, mix fuel only in the fuel tank. When refueling, add the lighter additive before the Diesel fuel.
Then let the engine run for a short time until the mixture has been distributed throughout the fuel system.
Diesel fuels - Mixing ratio ( Vol.-%)
Summer Diesel fuel
Winter Diesel fuel
to -15°C
Winter Diesel fuel
to -20°C
Ambient
temperature
°C % Fuel % Additive % Fuel % Additive % Fuel % Additive
0 to -10 70 30 100 -- 100 --
-10 to -15 50 50* 100 -- 100 --
-15 to -20 -- -- 70 30 100 --
-20 to -25 -- -- 50 50* 70 30
* = If an addition of more than 50% is required, use only petroleum (no regular gasoline). The Diesel fuel part
may never be more than 50% .
Additives to Diesel fuel (flow improvers)
Commercially available flow improvers can also improve Diesel fuel properties in cold temperatures. Always
read and observe the manufacturers user guidelines and quantities.
1.3. Coolant
Coolants, containing unsuitable anti corrosion / antifreeze fluids or wrong mixed coolants could damage the
engine or its parts, caused by cavitation or corrosion. Additionally heat isolating deposits could be created on
heat transferring parts, which overheat and lead to the damage of the engine.
For a long term, fault free operation, the coolant must be filled year round with a mixture of at least 50%
anticorrosion/antifreeze fluid. This concentration protects the system to approx. -37°C / -34°F.
Note: Do not use more than 60% anti-corrosion / antifreeze fluids, a higher percentage would actually
reduce the cooling and antifreeze protection and causes gel formation in the coolant fluid. Danger of
engine damage!
Protection to
Percentage of antifreeze (%)
Antifreeze protection chart
Coolant filters are used on some engine series, which filter the coolant in the auxiliary flow and in addition, a
chemical additive in the filter (DCA 4) reinforces the protection against cavitation, corrosion, scale deposits and
foam formation. The DCA4 concentration must be between 0.3 and 0.8 units per liter of coolant. See the
following chapter ”Coolant with DCA4”. This results in a mixing ration of approx. 48.5 % water, 48.5 % anti
corrosion /antifreeze fluid and 3 % DCA4.
Check the mixing ratio regularly during maintenance work. See instructions in section 3.4.
If coolant must be replaced, make sure that the given mixing ratios are retained. Do not fall below this ratios nor
exceed it.
Due to the natural aging process of the coolant, it must be replaced at least once every 2 years. Use only
suitable coolant, free of contaminants. Clean contaminated cooling systems. Note the following regulations.
To replace or add coolant in larger quantities, mix the given parts outside the cooling circuit in a suitable, clean
container first.
Fresh water guidelines:
To mix coolant fluid, use clean, clear water, which is not too hard. Often, but not always, regular tap water may
be used.
Seawater, brine, brackish water, or industrial waste water is not suitable.
Approved fresh water quality (as of 2001) for use with anti corrosion / antifreeze fluid -
- without DCA4 - with DCA4
Sum of alkaline earths (water hardness): : 0,6 to 3,6 mmol/l 0,6 to 2,7 mmol/l
(3 to 20°d) (3 to 15°d)
Ph - value at 20° C : 6,5 to 8,5 6,5 to 8,0
Chloride / ion content : max. 80 mg/l max. 80 mg/l
Sulfate / ion content : max. 100 mg/l max. 80 mg/l
Presently approved anti corrosion / antifreeze fluids (as of December 2003):
Brand name Manufacturer
Agip Antifreeze Plus Agip Petroli S.p.A, Rom / Italien
Agip Langzeit-Frostschutz Autol-Werke GmbH., Würzburg / BRD
Antigel DB 486 Sotragal SA, St. Priest / Frankreich
Aral Kühler-Frostschutz A Aral AG, Bochum / BRD
AVIA Frostschutz APN (G48-00) Deutsche AVIA-Mineralöl GmbH, München / BRD
BP Antifrost X 2270 A Deutsche BP AG, Hamburg / BRD
BP Napgel C 2270/1 BP Chemicals Ltd., London / England
Caltex Engine Coolant DB Caltex (UK) ltd., London / England
Caltex Extended Life Coolant Caltex
Castrol Anti-Freeze O Deutsche Castrol Vertriebs-GmbH, Hamburg /BRD
Century F.L. Antifreeze Century Oils, Hanley, Stoke-on-Trent / England
Chevron DEX-COOL Extended Life Anti-Freeze/Coolant Chevron Texaco
Deutz Kühlschutzmittel 0101 1490 DEUTZ Service International GmbH, Köln / BRD
Esso Kühlerfrostschutz Esso AG, Hamburg / BRD
Fricofin Fuchs Mineraloelwerke GmbH, Mannheim / BRD
Frostschutz Motorex (G48-00) Bucher+Cie, Langenthal / Schweiz
Frostschutz 500 Mobil Oil AG, Hamburg / BRD
Glacelf Auto Supra Total
Glycoshell AF 405 Shell
Glycoshell N Shell
Glysantin (G 48-00) BASF AG, Ludwigshafen / BRD
Havoline XLC ARTECO
Havoline DEX-COOL Extended Life Anti-Freece/Coolant Chevron Texaco
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Datum Edition Date
01 09 Service Items Blatt
Page
Feuille 01.3.10.03
Igol Antigel Type DB Igol France, Paris / Frankreich
Labo FP 100 Labo Industrie, Nanterre / Frankreich
Motul Anti-freeze Motul SA, Aubervilliers Cedex / Frankreich
OMV-Kühlerfrostschutzmittel OMV AG, Schwechat / Österreich
Organifreeze Total
OZO Frostschutz S Total Deutschland GmbH, Düsseldorf / BRD
Total Antigel S-MB 486 Total Deutschland GmbH, Düsseldorf / BRD
Total Frostfrei Total Deutschland GmbH, Düsseldorf / BRD
Veedol Antifreeze O Deutsche Veedol GmbH, Hamburg / BRD
Wintershall Kühlerschutz Wintershall Mineralöl GmbH, Düsseldorf / BRD
Presently approved anti corrosion / antifreeze fluids / 50:50 Premix (as of December 2003):
(50 % water : 50 % corrosion/antifreeze fluids)
Brand name Manufacturer
Liebherr Anti-Freeze APN mix Id.Nr. 8611 045 - 20 l bundle LIEBHERR
Caltex Extended Life Coolant Pre-Mixed 50/50 (ready-to-use-version) Caltex
Chevron DEX-COOL Extended Life Prediluted 50/50 Antifreeze coolant Chevron Texaco
Havoline XLC, 50/50 ARTECO
Havoline DEX-COOL Extended Prediluted 50/50 Antifreece coolant Chevron Texaco
Organicool 50/50 Total
Presently approved anti corrosion / antifreeze fluids with DCA4 - ready to use (as of December 2003):
Brand name Manufacturer
Liebherr Anti-Freeze "pret a l'emploi" Id.Nr. 10 005 347 - 20 l bundle LIEBHERR
The given anti corrosion / antifreeze fluids are approved for all Liebherr Diesel engines (with and without coolant
filter / DCA4).
1.3.1 Coolant with DCA4 (DCA = Diesel Coolant Additive)
The additive DCA4 is "used up" during use. The DCA4 concentration in the filter compensates for this loss
accordingly, if there is no loss of coolant and the correct filter is used at the given change interval.
The DCA4 concentration must be between 0.3 and 0.8 units per liter of coolant. To check, refer to the
"Maintenance and inspection guidelines", section 3.4.
For change intervals for filter and coolant, see ”Maintenance and inspection schedule” , section 3.2.
If the cooling system is filled initially or refilled after repairs, then DCA 4 in liquid form must be added to the
50% anticorrosion / antifreeze and 50% water mixture. The mixture should be mixed outside the cooling
system. Note the safety guidelines issued by the additive manufacturer.
This results in a coolant mixture ration of approx. 48.5 % water, 48.5 % anticorrosion / antifreeze fluid and 3%
DCA4.
In addition, use a new coolant filter, according to the filling quantity. The correct Id. No. of the filter can be
found in the Parts Manual or the Operation and Maintenance manual of the machine.
Overview chart DCA4 and filter requirements (as of 2001)
Coolant system contents Required quantity of liquid DCA 4 DCA 4 - water filter
Liter Container approx.0.5 liter appr. liter Id. No.
24-39 3 oder 1,5 7367 045
40-59 4 oder 2,0 7381 493
60-79 5 oder 2,5 7367 052
80-115 8 oder 4 7367 052
Container liquid DCA4 at approx. 0.5 l -Id. No. 7363 898
Liebherr coolant (ready to use, 20 liter, above mixing ratio) - Id. No. 10 005 347
1.3.2 Coolant - special filling - with anti corrosion fluids, without antifreeze fluids
In exceptional cases and if ambient temperatures are constantly above the freezing point, for example in
tropical regional, where no anticorrosion / antifreeze fluids is proofed available, fresh water and water-soluble
anticorrosion fluids (Inhibitors) may be used as coolant.
Do not use coolant refiners (anticorrosion oils) with emulsifying capacity. If necessary, flush the cooling system
before refilling.
The fresh water quality must meet use with DCA4 - see chart ”Approved fresh water quality”.
The coolant must be changed once a year.
Use of DCA4
To provide sufficient protection against corrosion, approximately twice the amount of DCA4 must be used as
compared to the above mixing ration, when using anticorrosion / antifreeze fluids and DCA4 - see above
"overview chart and filter requirements".
The DCA4 concentration must be between 0.6 and 1.06 units. It must be checked during maintenance work or
when the coolant filter is changed, and corrected, as necessary.
This results in a mixing ratio of
max. 94 % fresh water and
min. 6 % DCA4 additive
Use of products from Caltex / Chevron Texaco / Havoline / Total
To provide sufficient protection against corrosion with these products, a mixture of 92,5 vol.% coolant and 7,5
vol.% anti corrosion fluid must be kept.
The mixture ratio must be checked during maintenance work and corrected, as necessary. The concentration
of the anti corrosion fluid must not fall below 5 vol.% nor exceed 10 vol.%.
Presently approved anti corrosion fluids (as of December 2003):
Brand name Manufacturer
DCA4 Diesel Coolant Additives Fleetguard
Caltex CL Corrosion Inhibitor Concentrate Caltex
Chevron Texaco Heavy Duty Extended Life Corrosion Inhibitor Nitrite Free Chevron Texaco
Havoline Extended Life Corrosion Inhibitor (XLI) ARTECO
Total WT Supra Total
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LR 614 F/N xxx-6358 10719
Datum Edition Date
01 09 Service Items Blatt
Page
Feuille 01.3.10.04
2. Oil for hydraulic system
In the hydraulic system, use only Diesel engine lube oils or special approved oils.
2.1. Oil quality
2.1.1 Approved engine oil classifications
API - classification : CF-4, CG-4, CH-4, CI-4,
(American Petroleum Institute)
ACEA (CCMC) - classification : E2 (D4), E3 (D5), E4, E5,
(Association des Constructeurs Européens de l´Automobile)
Note: The API classifications CC, CD, CE and CF are now obsolete, however, in quality, they had been
approved for use in the hydraulic system.
2.1.2 Special oils
Approval is given for each machine type separately. Special guidelines are issued with the release.
The following product presently considered to be an environmentally friendly hydraulic fluid:
Panolin - HLP Synth - VG 46
2.2. Oil viscosity
In addition to the quality, the oil must also provide a certain viscosity, the selection is made according to the
SAE classification (Society of Automotive Engineers).
The determining factor for the correct selection of SAE classification is the ambient temperature, single grade
oils are preferred.
If the viscosity is too high, it can cause cavitations, if it is too low, the lubrication efficiency may be endangered.
Both can cause failure of hydraulic components.
The temperature ranges shown in the following chart are guidelines. When operating the machine within the
black temperature range, the following warm up procedure should be carried out.
Viscosity for environmentally friendly hydraulic fluids according to ISO: VG 46
(covers SAE 10W and SAE 20W-20 or SAE 10W-30)
For operation in extreme climate zones, such as arctic regions, special guidelines are available from the
manufacturer.
Warm up procedure:
a) In temperatures up to 10° C below the given limit (black range)
After starting, run the Diesel engine at medium speed. Warm up the hydraulic system by carefully actuating
the hydraulic cylinders. Extend and retract the hydraulic cylinders fully for short periods. After 5 minutes,
carefully engage the travel hydraulic as well. Total warm up period is approximately 10 minutes.
b) At even lower temperatures:
Before starting the Diesel engine, preheat the oil in the hydraulic tank, then proceed as described in paragraph
a).
Single grade oils
Multi grade oils
3. Gear oil
The lube oil specification for gears is based on API and SAE classification. The oil chamber in travel gears for
double lifetime seal is filled with oil from the hydraulic system - see section 2.
3.1. Oil quality
As a general rule, only oils meeting API - classification GL-5 may be used.
3.2. Oil viscosity
The following oils must be used in travel gears, and are highly recommended for use in splitter boxes:
Viscosity classification SAE 85 W - 140 EP
For splitter boxes, oils of Viscosity classification SAE 90 EP or SAE 80 W - 90 EP may also be used.
For the operation in extreme climatic conditions, such as in arctic regions or in extreme temperatures ranges, such
as in slag applications, special oils may be approved if the prevailing ambient temperatures are known operations.
3.3. Lube oil for final drive - sealing chamber
For oil quality and viscosity see section 2, Oil for hydraulic system, but do not use special oils.
4. Lube oil for support shaft bearing
For oil quality and viscosity see section 2, Oil for hydraulic system, but do not use special oils.
5. Hoist gear oil - pipe layers
As a general rule, the guidelines noted in the Operation and Maintenance manual and the winch manufacturer
should be observed.
For lubrication technical reasons, we recommend the use of Diesel lube oil, which meets at least one of the
following quality and viscosity classifications.
5.1. Oil quality
according to API - classification : CF, CF-4, CG-4, CH-4, CI-4,
ACEA (CCMC) - classification : E2 (D4), E3 (D5), E4, E5,
5.2. Oil viscosity
according to SAE - classification : 10W
ISO - classification : VG 32
6. Grease
6.1. General lubrication points and track tensioner
The grease must meet specification KP 2 k - consistency 2 according to NL GI - class and DIN 51818 and DIN
51825 or EP 2 according to NF-T-60 132 .
The grease must also be lithium based, with a VKA value of at least 2300 N according to DIN 51350 or ASTM D
2596.
6.2. Long term grease / grease to protect against corrosion
For the lifetime lubrication of bearing points of lift cylinder suspensions and to protect against corrosion at the
initial installation of dry bearing points, to protect exposed piston rods, to prevent rust formation, etc., a special
calcic, acid free grease should be used.
We recommend LIEBHERR's special paste CTK - Id. No. 8613 313 01
For general conservation - see section 19, Conservation guidelines - other acid free anticorrosion grease may
be used.
7. Miscellaneous
Always observe all guidelines issued in the Operation and Maintenance manuals, repair manuals and on
drawings.
7.1. Rubber seals on doors and covers
Use silicon spray or Talcum powder.
7.2. Hydraulic cylinder installation
Lubricant for threads of pistons, piston nuts and piston rod bearings -
Liebherr High performance lubricant Id. No. 8300 004
Special protection against corrosion for installation of sealing elements -
Liebherr Special anticorrosion grease Id. No. 8300 005
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LR 614 F/N xxx-10720
Datum Edition Date
01 09 Service Items Blatt
Page
Feuille 01.3.11.01
Service Items
see operation and maintenance manual.
Benennung Description Dénomination Typ/ab Type/from Type/ a partir de
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Standard screws LR 614 F/N xxx- 6358
Datum Edition Date
02 07
Tightening Torques
Factory standard WN 4037 I
Blatt
Page
Feuille
1.4.01.01
The preload and tightening torques listed in the chart are from VDI guidelines 2230 of July 1986.
Installation preload FM and tightening torques MA for shaft screws with metric standard or fine thread per DIN ISO
262 and DIN ISO 965 T2 (replacement for DIN 13 part 13) and screw head dimension of hex head screws with shaft
DIN EN 24014 (replacement for DIN 931 part 1) or socket head screws DIN EN ISO 4762 (replacement for DIN
912).
The chart values are valid for lubricated screws, surface black treated, phosphated or galvanic zinc plated and for
dry screws, surface according to flZn - LH-Norm 10021432 (replaces DACROMET 500)
Medium friction G = 0,12.
Always observe the tightening torques and/ or procedures listed in drawings / parts lists, instructions of
component descriptions, if noted, they override the factory standards listed in the torque charts.
Never use a standard lock washer with 10.9 or 12.9 screws. If a washer is necessary, use only "heavy duty"
washers, made from hardened material.
Always use torque wrenches with the correct range - the upper third of the range should include the listed torque
value according to the chart.
When using impact screws, make sure that the given tightening torque is observed - should be checked before and
during the tightening procedure with torque wrench (Nm x 0,7375 = ft.lbs.)!
Preload forces and tightening torques for screws with standard metric thread according
to factory standard WN 4037 I
Wrench size
(x) = per DIN931, forPreload values FM based on
screw grades and are given
in N
Tightening torques MA are
based on screw grades and
are given in Nm Hex head
screws
Socket head
screws
Standard
metric thread
8.8 10.9 12.9 8.8 10.9 12.9 mm Inch mm Inch
M 4 x 0,7 4 050 6 000 7 000 2,8 4,1 4,8 7 9/32 3 --
M 5 x 0,8 6 600 9 700 11 400 5,5 8,1 9,5 8 5/16 4 5/32
M 6 x 1 9 400 13 700 16 100 9,5 14,0 16,5 10 -- 5 --
M 7 x 1 13 700 20 100 23 500 15,5 23,0 27,0 11 -- -- --
M 8 x 1,25 17 200 25 000 29 500 23 34 40 13 1/2 6 --
M 10 x 1,5 27 500 40 000 47 000 46 68 79 (17) 16 (11/16) -- 8 5/16
M 12 x 1,75 40 000 59 000 69 000 79 117 135 (19) 18 (3/4) -- 10 --
M 14 x 2 55 000 80 000 94 000 125 185 215 (22) 21 (7/8) -- 12 --
M 16 x 2 75 000 111 000 130 000 195 280 330 24 -- 14 9/16
M 18 x 2,5 94 000 135 000 157 000 280 390 460 27 1-1/16 14 9/16
M 20 x 2,5 121 000 173 000 202 000 390 560 650 30 1-3/16 17 --
M 22 x 2,5 152 000 216 000 250 000 530 750 880 (32) 34 -- 17 --
M 24 x 3 175 000 249 000 290 000 670 960 1120 36 1-7/16 19 3/4
M 27 x 3 230 000 330 000 385 000 1000 1400 1650 41 1-5/8 19 3/4
M 30 x 3,5 280 000 400 000 465 000 1350 1900 2250 46 1-13/16 22 7/8
M 33 x 3,5 350 000 495 000 580 000 1850 2600 3000 50 2 24 --
M 36 x 4 410 000 580 000 680 000 2350 3300 3900 55 2-3/16 27 1-1/16
M 39 x 4 490 000 700 000 820 000 3000 4300 5100 60 2-3/8 27 1-1/16
Preload forces and tightening torques for screws with fine metric thread according to
factory standard WN 4037 I
Note: Observe notes on front page!
Wrench size
(x) = per DIN931, forPreload values FM based on
screw grades and are given
in N
Tightening torques MA are
based on screw grades and
are given in Nm
Hex head screws
Socket head
screws
Fine metric
thread
8.8 10.9 12.9 8.8 10.9 12.9 mm Inch mm Inch
M 8 x 1 18 800 27 500 32 500 24,5 36 43 13 1/2 6 --
M 9 x 1 24 800 36 500 42 500 36 53 62 -- -- -- --
M 10 x 1 31 500 46 500 54 000 52 76 89 17 11/16 8 5/16
M 10 x 1,25 29 500 43 000 51 000 49 72 84 17 11/16 8 5/16
M 12 x 1,25 45 000 66 000 77 000 87 125 150 19 3/4 10 --
M 12 x 1,5 42 500 62 000 73 000 83 122 145 19 3/4 10 --
M 14 x 1,5 61 000 89 000 104 000 135 200 235 22 7/8 12 --
M 16 x 1,5 82 000 121 000 141 000 205 300 360 24 -- 14 9/16
M 18 x 1,5 110 000 157 000 184 000 310 440 520 27 1-1/16 14 9/16
M 18 x 2 102 000 146 000 170 000 290 420 490 27 1-1/16 14 9/16
M 20 x 1,5 139 000 199 000 232 000 430 620 720 30 1-3/16 17 --
M 22 x 1,5 171 000 245 000 285 000 580 820 960 32 -- 17 --
M 24 x 1,5 207 000 295 000 346 000 760 1090 1270 36 1-7/16 19 3/4
M 24 x 2 196 000 280 000 325 000 730 1040 1220 36 1-7/16 19 3/4
M 27 x 1,5 267 000 381 000 445 000 1110 1580 1850 41 1-5/8 19 3/4
M 27 x 2 255 000 365 000 425 000 1070 1500 1800 41 1-5/8 19 3/4
M 30 x 1,5 335 000 477 000 558 000 1540 2190 2560 46 1-13/16 22 7/8
M 30 x 2 321 000 457 000 534 000 1490 2120 2480 46 1-13/16 22 7/8
M 33 x 1,5 410 000 584 000 683 000 2050 2920 3420 50 2 24 --
M 33 x 2 395 000 560 000 660 000 2000 2800 3300 50 2 24 --
M 36 x 1,5 492 000 701 000 820 000 2680 3820 4470 55 2-3/16 27 1-1/16
M 36 x 3 440 000 630 000 740 000 2500 3500 4100 55 2-3/16 27 1-1/16
M 39 x 1,5 582 000 830 000 971 000 3430 4890 5720 60 2-3/8 27 1-1/16
M 39 x 3 530 000 750 000 880 000 3200 4600 5300 60 2-3/8 27 1-1/16
Benennung Description Dénomination Typ/ab Type/from Type/ a partir de
Mjfcifss!
Standard screws LR 614 F/N xxx- 6358
Datum Edition Date
02 07
Tightening Torques
Factory standard WN 4037 I
Blatt
Page
Feuille
1.4.01.02
Tightening torques for screws for SAE split flange installation
Not part of factory standard WN 4037 I
Listing per LFR - Quality service 2QA 6 051 00 as of Oct. 2001
1. Flange and half flange for high pressure (Norm 62)
2. Half flange for low pressure (Norm 61)
Tightening torques for oil drain plugs at travel gears
Not part of factory standard WN 4037 I
Listing per LBC - Quality service as of Oct. 2003
Oil drain plug
thread size
Tightening torque
in Nm
M 14x1,5 40
M 16x1,5 40
M 18x1,5 40
M 22x1,5 80
M 33x1,5 160
Tightening torques in Nm for screw grade 10.9
Flange nominal size Screw size
Half flange
flat flange without
reinforcement
Flange with
reinforcement
½" M 8 31 -- --
¾" M 10 62 45 65
1" M 12 108 70 110
1 ¼" M 14 172 120 180
1 ½" M 16 264 170 250
2" M 20 350 250 450
Tightening torques in Nm for
Flange nominal size Screw size
Screw grade 8.8 Screw grade 10.9
½" M 8 22 31
¾" M 10 44 62
1" M 10 44 62
1 ¼" M 10 44 62
1 ½" M 12 76 108
2" M 12 76 108
2 ½" M 12 76 108
3" M 14 122 172
3 ½" M 16 187 264
4" M 16 187 264
5" M 16 187 264
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Datum Edition Date
04 08 Conversion table Blatt
Page
Feuille
1.4.02.01
Unit of Measure Multiply by
To obtain
Multiply
by
To
obtain
Length mm 0,039 inch 25,4 mm
m 3,281 feet 0,305 m
m 1,093 yard 0,914 m
km 0,621 mile 1,609 km
Area cm² 0,155 sq. inch 6,452 cm²
m² 10,764 sq. feet 0,093 m²
m² 1,196 sq. yard 0,836 m²
km² 0,386 sq. mile 2,59 km²
Volume cm³ 0,061 cu. inch 16,387 cm³
m³ 35,314 cu. feet 0,028 m³
m³ 1,308 cu. yard 0,764 m³
l 61,025 cu. inch 0,016 l
l 0,035 cu. feet 28,316 l
l 0,264 gallon 3,785 l
l 1,057 quart 0,946 l
Weight g 0,035 oz. 28,349 g
kg 2,204 lbs. 0,453 kg
t 1,102 short t 0,907 t
Force N 0,225 lbs. 4,449 N
kN 224,732 lbs. 0,0044 kN
Torque Nm 0,737 ft. lbs. 1,356 Nm
Power kW 1,342 HP 0,745 kW
PS 0,736 kW 1,358 PS
PS 0,986 HP 1,014 PS
Pressure bar 14,5 PSI 0,069 bar
(hydraulic) kpa 0,145 PSI 6,896 kpa
Ground pressure kg/cm² 14,223 lbs. sq. inch 0,0703 kg/cm²
kg/m² 0,205 lbs. sq. ft. 4,878 kg/m²
Compression g/cm³ 0,036 lbs. cu. inch 27,78 g/cm³
kg/m³ 0,062 lbs. cu. ft. 16,13 kg/m³
Speed km/h 0,621 mph 1,609 km/h
m/min 3,281 ft. / min 0,305 m/min
Temperature °C (°Cx1,8) + 32 °F (°F-32)/1,8 °C
°C °C+273 °K °K-273 °C
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Datum Edition Date
02 07 Hole diameter before tapping Blatt
Page
Feuille 01.4.03.01
1. Hole diameter for tapping ISO standard Metric (internal) thread
Thread
size
Hole diameter
limits
max. min.
Drill bit Ø
M 1 0,785 0,729 0,75
M 1,1 0,885 0,829 0,85
M 1,2 0,985 0,929 0,95
M 1,4 1,160 1,075 1,1
M 1,6 1,321 1,221 1,25
M 1,7 1,346 1,258 1,30
M 1,8 1,521 1,421 1,45
M 2 1,679 1,567 1,6
M 2,2 1,838 1,713 1,75
M 2,3 1,920 1,795 1,9
M 2,5 2,138 2,013 2,05
M 2,6 2,176 2,036 2,10
M 3 2,599 2,459 2,5
M 3,5 3,010 2,850 2,9
M 4 3,422 3,242 3,3
M 4,5 3,878 3,688 3,7
M 5 4,334 4,134 4,2
M 6 5,153 4,917 5
M 7 6,153 5,917 6
M 8 6,912 6,647 6,8
M 9 7,912 7,647 7,8
M 10 8,676 8,376 8,5
M 11 9,676 9,376 9,6
M 12 10,441 10,106 10,2
M 14 12,210 11,835 12
M 16 14,210 13,835 14
M 18 15,744 15,294 15,5
M 20 17,744 17,294 17,5
M 22 19,744 19,294 19,5
M 24 21,252 20,752 21
M 27 24,252 23,752 24
M 30 26,771 26,211 26,5
M 33 29,771 29,211 29,5
M 36 32,270 31,650 32
M 39 35,270 34,670 35
M 42 37,799 39,129 37,5
M 45 40,799 40,129 40,5
M 48 43,297 42,587 43,0
M 52 47,297 46,587 47,0
M 56 50,796 50,046 50,5
M 60 54,796 54,046 54,1
M 64 58,305 57,505 57,6
M 68 62,305 61,505 61,6
Dimensions are in mm
mm x 0,03937 = inches
2. Hole diameter for tapping ISO fine Metric (internal) thread
Thread size
Hole diameter
limits
max. min.
Drill bit Ø
M 1 x 0,2 0,821 0,783 0,8
M 1,1 x 0,2 0,921 0,833 0,9
M 1,2 x 0,2 1,021 0,983 1
M 1,4 x 0,2 1,221 1,183 1,2
M 1,4 x 0,25 1,185 1,129 1,15
M 1,6 x 0,2 1,421 1,383 1,4
M 1,8 x 0,2 1,621 1,583 1,6
M 2 x 0,25 1,785 1,729 1,75
M 2,2 x 0,25 1,985 1,929 1,95
M 2,5 x 0,35 2,201 1,121 2,15
M 3 x 0,35 2,721 2,621 2,65
M 3,5 x 0,35 3,221 3,121 3,15
M 4 x 0,5 3,599 3,459 3,5
M 4,5 x 0,5 4,099 3,959 4
M 5 x 0,5 4,599 4,459 4,5
M 5,5 x 0,5 5,099 4,959 5
M 6 x 0,75 5,378 5,188 5,2
M 7 x 0,75 6,378 6,188 6,2
M 8 x 0,75 7,378 7,188 7,2
M 8 x 1 7,153 6,917 7
M 9 x 0,75 8,378 8,188 8,2
M 9 x 1 8,153 7,917 8
M 10 x 0,75 9,378 9,188 9,2
M 10 x 1 9,153 8,917 9
M 10 x 1,25 8,912 8,647 8,8
M 11 x 0,75 10,378 10,188 10,2
M 11 x 1 10,153 9,917 10
M 12 x 1 11,153 10,917 11,1
M 12 x 1,25 10,912 10,647 10,8
M 12 x 1,5 10,676 10,376 10,5
M 14 x 1 13,153 12,917 13
M 14 x 1,25 12,912 112,647 12,8
M 14 x 1,5 12,676 12,376 12,5
M 15 x 1 14,153 13,917 14
M 15 x 1,5 13,676 13,376 13,5
M 16 x 1 15,153 14,917 15
M 16 x 1,5 14,676 14,376 14,5
M 17 x 1 16,153 15,917 16
M 17 x 1,5 15,676 15,376 15,5
M 18 x 1 17,153 16,917 17
M 18 x 1,5 16,676 16,376 16,5
M 18 x 2 16,210 15,835 16
M 20 x 1 19,153 18,917 19
M 20 x 1,5 18,676 18,376 18,5
M 20 x 2 18,210 17,835 18
M 22 x 1 21,153 20,917 21
M 22 x 1,5 20,676 20,376 20,5
M 22 x 2 20,210 19,835 20
M 24 x 1 23,153 22,917 23
M 24 x 1,5 22,676 22,376 22,5
M 24 x 2 22,210 21,835 22
Thread size
Hole diameter
limits
max. min.
Drill bit Ø
M 25 x 1 24,153 23,917 24
M 25 x 1,5 23,676 23,376 23,5
M 25 x 2 23,210 22,835 23
M 26 x 1,5 24,676 24,376 24,5
M 27 x 1 26,153 25,917 26
M 27 x 1,5 25,676 25,376 25,5
M 27 x 2 25,210 24,835 25
M 28 x 1 27,153 26,917 27
M 28 x 1,5 26,676 26,376 26,5
M 28 x 2 26,210 25,835 26
M 30 x 1 29,153 28,917 29
M 30 x 1,5 28,676 28,376 28,5
M 30 x 2 28,210 27,835 28
M 30 x 3 27,252 26,752 27
M 32 x 1,5 30,676 30,376 30,5
M 32 x 2 30,210 29,835 30
M 33 x 1,5 31,676 31,376 31,5
M 33 x 2 31,210 30,835 31
M 33 x 3 30,252 29,752 30
M 35 x 1,5 33,676 33,376 33,5
M 36 x 1,5 34,676 34,376 34,5
M 36 x 2 34,210 33,835 34
M 36 x 3 33,252 32,752 33
M 38 x 1,5 36,676 36,376 36,5
M 39 x 1,5 37,676 37,376 37,5
M 39 x 2 37,210 36,835 37
M 39 x 3 36,252 35,752 36
M 40 x 1,5 38,676 38,376 38,5
M 40 x 2 38,210 37,835 38
M 40 x 3 37,252 36,752 37
M 42 x 1,5 40,676 40,376 40,5
M 42 x 2 40,210 39,835 40
M 42 x 3 39,252 38,752 39
M 42 x 4 38,270 37,670 38
M 45 x 1,5 43,676 43,376 43,5
M 43 x 2 43,210 42,835 43
M 45 x 3 42,252 41,752 42
M 45 x 4 41,270 40,670 41
M 48 x 1,5 46,676 46,376 46,5
M 48 x 2 46,210 45,835 46
M 48 x 3 45,252 44,752 45
M 48 x 4 44,270 43,670 44
M 50 x 1,5 48,676 48,376 48,5
M 50 x 2 48,210 47,835 48
M 50 x 3 47,252 46,752 47
M 52 x 1,5 50,676 50,376 50,5
M 52 x 2 50,210 49,835 50
M 52 x 3 49,252 48,752 49
M 52 x 4 48,270 47,670 48
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Mjfcifss! LR 614 F/N xxx-6358
Datum Edition Date
01 09 Material weights Blatt
Page
Feuille
1.5.01.01
Material weights
A Spec. weight
1)
in kg/m
3
solid
B Loosening in %
C Loosening factor
D Spec. weight kg/m
3
loose
Material A B C D
Anthracite coal - raw 1600 35 0,74 1190
- washed - 35 0,74 1100
Ash bituminous coal 590 - 890 8 0,93 550 - 830
Basalt 2970 52 0,66 1960
Bauxite, Kaolin 1900 33 0,75 1420
Bituminous coal - raw 1280 35 0,74 950
- washed - 35 0,74 830
Carnotite, Uranium ore 2200 35 0,74 1630
Soil - dry hardened 1900 26 0,79 1510
- wet loosened 2020 26 0,79 1600
- clay 1540 23 0,81 1250
Gypsum - broken 3170 75 0,57 1810
- ground 2790 75 0,57 1660
Granite - broken 2730 64 0,61 1660
Hematite, iron ore 2130 - 2900 18 0,85 1810 - 2450
Limestone - broken 2610 69 0,59 1540
- ground - - - 1540
Gravel - damp 2170 12 0,89 1930
- dry 1690 12 0,89 1510
- dry 6-50mm 1900 12 0,89 1690
- wet 6-50mm 2260 12 0,89 2020
Coke 860 54 0,65 1560
Loam, clay - seasoned 2020 22 0,82 1660
- dry 1840 24 0,80 1480
- wet 2080 24 0,80 1660
Clay with gravel - dry 1660 17 0,86 1420
- wet 1840 19 0,84 2540
Magnetite, iron ore 3260 17 0,86 2790
Topsoil 1370 44 0,69 950
Natural stone - ground 2670 67 0,60 1600
Pyrite, iron ore 3030 18 0,85 2580
Sand - dry, lose 1600 12 0,89 1420
- damp 1900 12 0,89 1690
- wet 2080 13 0,88 1840
Sand with clay - lose 2020 26 0,79 1600
- compressed - - - 2400
Sand with gravel - dry 1930 12 0,89 1720
- wet 2230 10 0,91 2020
Sandstone 2520 67 0,60 1510
Slate 1660 33 0,75 1250
Slag - broken 2940 68 0,59 1750
Snow - dry - - - 130
- wet - - - 520
Trapp rock - broken 2610 49 0,67 1750
The actual values depend on the moisture content, the grain size and the compression.
Testing is required to determine more exact values.
Material A B C D
Weathered rock
75% rock, 25% soil
2790 42 0,70 1960
Weathered rock
50% rock, 50% Soil
2280 33 0,75 1720
Weathered rock
25% rock, 75% Soil
1960 24 0,80 1570
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Mjfcifss!
Tools and LR 614 F/N xxx-6358
Datum Edition Date
02 07 Work instructions Blatt
Page
Feuille
2.0.00.01
Sub group index
Tools and work instructions
Special tools 2.1.
Repair welding 2.2.
Installation instruction 2.3
Installation instruction for duo cone (slipring) seals 2.3.01
Benennung Description Dénomination Typ/ab Type/from Type/ a partir de
Mjfcifss!
Special tools
LR 614 F/N xxx-6358
Datum Edition Date
01 09 Tools and work instructions Blatt
Page
Feuille
2.1.10.01
Special tools
A. Special tools - Diesel engine
Description Id. No. Remarks Illustration
Digital RPM gauge
„shimpo“
Reflexion strip
7364284
614063201
To measure the RPM via
reflexion strips
Test range: 6-8300 Rpm ±1
Rpm
Use with „Shimpo“ Rpm
gauge
Optical charge tester 7408922 To check the battery charge
condition and the antifreeze
in the coolant
V-belt test unit „Krikit2“ 8042829 To check the V-belt tension
Description Id. No. Remarks Illustration
Hand pump [1]
Removal valve for oil
samples [2]
8145666
7019068
To take oil samples for the oil
analysis
Oil analysis set –
Mineral oil
(green cover)
Individual set
4 each set
6 each set
12 each set
Oil analysis set – Bio oil
(yellow cover)
Individual set
6 each set
8145660
10029626
7018368
7018369
7026817
7026088
Analysis at WEAR CHECK
Germany
Compression test kit
JT01674
7090894 To check the cylinder
compression pressure. Use
the adapter and the pressure
gauge / hose components of
the kit.
Benennung Description Dénomination Typ/ab Type/from Type/ a partir de
Mjfcifss!
Special tools
LR 614 F/N xxx-6358
Datum Edition Date
01 09 Tools and work instructions Blatt
Page
Feuille
2.1.10.02
Description Id. No. Remarks Illustration
Flywheel turning tool
JDE83
for LR 614 F/N xxx-
6358 10719
7090362 To turn the flywheel.
Is required for valve
clearance adjustment
Flywheel turning tool
JDG820
for LR 614 F/N xxx-
10720
7090361 To turn the flywheel.
Is required for valve
clearance adjustment
Adjustment pin
JDG1571
7090360 To hold the flywheel on OT to
adjust the injection pump.
Is required along with the
JDE 83 or JDG 820 for valve
clearance adjustment.
Screw tap
½-13 UNC-2A
JDG680
10490109 To recut threaded bores in
the cylinder block
Square cut insert for
plug
JDG782A
10490111 To install and remove the oil
channel plug in the cylinder
block
B. Special tools – Hydraulic system
Description Id. No. Remarks Illustration
Vacuum pump cpl.
with accessories
Consists 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
7408148
7407987
7407985
10301165
7404619
4901110
7360127
10038447
10038448
7408151
For faster bleeding of
hydraulic system, by
enclosing the PVC hose, a
slight excess pressure
(approx. 0.4 bar) can be
produced.
The connection point for
vacuum pump on the
machine is the breather
screw on the hydraulic tank.
Connector fitting 10303657 For use with vacuum pump
cpl. with accessories
Temperature gauge 10024185 Accuracy: 2%/2°
Test range: -18°C - +260°C
Differential pressure
Test set 230V/120V
Consists of:
Test unit Multi-Handy
2045
2 pressure sensors 0-600
bar
2 Mini test connections
2 test cables 12m long
KFZ connector cable
Data cable
Power unit
10288229
To measure pressure,
pressure peaks and pressure
difference and suitable for
data transfer to PC
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Mjfcifss!
Special tools
LR 614 F/N xxx-6358
Datum Edition Date
01 09 Tools and work instructions Blatt
Page
Feuille
2.1.10.03
Description Id. No. Remarks Illustration
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
Accuracy:
1% of the scale end value
All pressure gauges are
„glycerine filled“
Pressure gauge
connection
R ½
7002436
To seal at pressure tests, a
square seal ring,
Id. No. 7409794
must be used.
Test hose NW 2
1,000 mm
1,500 mm
4,000 mm
5,000 mm
7002437
7002475
7009134
7363732
To keep loss of pressure
during tests to a minimum,
shorter test hoses are
preferable
Test fitting, cpl.
R 6 L
R 10 L
R 12 L
7409916
7406864
7409918
Union nut and compression
ring are affixed on the test
fitting
Screw coupling
M 8x1
M 10x1
M 12x1.5
M 14x1.5
R ¼
7615321
5608462
7409783
7406865
7409720
To connect to additional test
points on the machine
Screw coupling
M 16x2 7407070
To connect shorter test lines
or for connection between
test connection and pressure
sensor
Description Id. No. Remarks Illustration
Brake vent adapter 9401975 Adapter for air pressure
cartridge (included in tool
box)
Air pressure cartridge 10045498 CO2 cartridge to vent the
parking brake for towing
operation
Test plate A
for SAE flange 3/4
Dimensions (in mm)
A 90
B 40
C,r 5
Test plate B
for SAE flange 1
Dimensions (in mm)
A 90
B 44
C,r 5
Test plate C
for SAE flange 1 1/4
Dimensions (in mm)
A 90
B 52
C,r 5
7370 092
7370 093
7370 094
or made in
house
To close off high pressure
connections
Material:
Ground spring steel
Round off end of the plate
Round off edges
(simplifies installation, avoids
damage to the seal ring)
Benennung Description Dénomination Typ/ab Type/from Type/ a partir de
Mjfcifss!
Special tools
LR 614 F/N xxx-6358
Datum Edition Date
01 09 Tools and work instructions Blatt
Page
Feuille
2.1.10.04
Note!
The Id. No. for the following tools are in the spare parts list of the hydraulic cylinders.
Assembly sleeve See Spare Parts
List
For installation of
the O-ring and
stepseal ring on
the pistons of
hydraulic cylinders
Spreader sleeve See Spare Parts
List
For installation of
the O-ring and
stepseal ring on
the pistons of
hydraulic cylinders
Installation wrench
Piston
See Spare Parts
List
To tighten the
pistons of hydraulic
cylinders
For tightening
torques, see
section 8 Hydraulic
cylinder
Installation wrench
Piston nut
See Spare Parts
List
To tighten the
piston nut of
hydraulic cylinders
For tightening
torques, see
section 8 Hydraulic
cylinder
C. Special tools – Electrical system
Description Id. No. Remarks Illustration
Digital multi meter
cpl. with cable and bag
10018500 for
Voltage (V)
Amperage (A)
Resistance ( )
and
Frequency (Hz)
tests
Optical charge tester 7408922 To check the battery charge
condition and the antifreeze
in the coolant
Hand crimper
for „DEUTSCH“ plug
connectors
8503647 To make proper crimp
connections
Removal tool Cannon
For crimp contacts
„DEUTSCH“
AWG 12
AWG 16
AWG 20
10114733
885563714
10114732
To remove pin and bushing
contacts in „DEUTSCH“ plug
connectors
Crimper AMP
AMP Certi-Lock
7415333 To crimp the „JUNIOR
POWER TIMER“ contacts
Removal tool AMP
AMP 726 503-1
AMP 726,534-1
7370373
7027340
To remove contacts from the
„JUNIOR POWER TIMER“
housing
Benennung Description Dénomination Typ/ab Type/from Type/ a partir de
Mjfcifss!
Special tools
LR 614 F/N xxx-6358
Datum Edition Date
01 09 Tools and work instructions Blatt
Page
Feuille
2.1.10.05
Description Id. No. Remarks Illustration
Crimper
ESA 0760
7409781 To crimp insulated cable
shoes
0.5 -6.0 mm²
For example cable
connectors
Crimper
CRB 0560
7409782 To crimp non-insulated cable
shoes
0.5 -6.0 mm²
For example plug connectors
on windshield wiper motor
D. Special tools – Mechanical component groups
Description Id. No. Remarks Illustration
Test tool
Track
7402603 For use, see
section 12.2.
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Mjfcifss!
Repair welding LR 614 F/N xxx-6358
Datum Edition Date
02 10 Tools and instructions Blatt
Page
Feuille 2.2.01.01
Repair welding
Before starting any welding work on PR Series 4 machines, 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 a crack
The crack must be free of paint, grease and dirt.
To prevent the crack from extending during the preparation or the welding process, the end of the cracks should
be drilled with a hole of at least 0.32" (8mm) in diameter.
The crack should now be ground, chiseled, torch cut or arced out at a 60° angle. Be certain the edges are clean
and extend through the full cross section of the material, without exceeding the 0.04" (1 mm) space in the lower
part. On larger grooves, a welding safety should be installed.
Certain materials must be preheated to 300°F (150°C) prior to welding.
Special preparations are necessary when preparing a crack in manganese steel. Due to its hardness,
mechanical preparation, such as a chisel or hobbing machine is not possible. We suggest that the crack is
prepared with a slow running and water cooled grinding wheel to prevent overheating.
Other possibilities for preparing cracks or removing high alloy welding seams are the use of cutting electrodes of
the type UTP 82 AS.
2. Preparation of a weld
The area to be welded must be free of paint, grease, oil, moisture and dirt. During rain, the area to be welded
must be covered. Materials with a thickness above 0.60" (15 mm), high carbon steel or steel which is difficult to
weld, the material must be preheated to approximately 176°- 392°F (80°- 200°C).
Pre-heating is also necessary when the ambient or component temperature is below 40°F (5°C) or when the
construction of the component prevent the welding stress to be released.
3. Storing Electrodes
Use only dry and undamaged electrodes. Electrodes which are rusty or damaged should not be used. Electrodes
should be stored in a dry room with a minimum temperature of 59°F (15°C). Open packages should be carefully
closed and stored after the welding work is completed.
4. Welding Technique
The welding of material with the necessary electrodes (see table under paragraph 7) is in accordance with DIN
1912.
The adjustment of the welding machine - dictated by the different thicknesses of the electrodes - can be taken
from the table of the electrode package.
Beginning with a material thickness of 1/4" (8 mm), butt welds must be made in several layers. The weld is
applied in several beads. Wide butt welds are filled with several side by side beads, with the last layer covering
the center. The electrode should melt evenly without creating burrs and peaks. The valley or crater, which is
created when changing electrodes must be filled in and overlapped with the next electrode. To prevent cracks in
those craters, care must betaken that they are properly filled.
If the crack extends towards the outer edge of the material, slag may be trapped or burn holes may be created.
To prevent this, the following aid may be used: Tack a piece of sheet metal to the outer edge of the material. The
welding seam begins now at the sheet metal in the direction of the arrow. After the welding is completed, the
sheet metal is removed and the edge of the material is ground smooth.
The weld must cool off slowly and should therefore be protected from rain and wind.
5. Reinforcement of the welding seam
If the crack of the material is due to an overload or abuse, a reinforcement plate should be welded over the
crack. The selection of the correct reinforcement plate is based on the construction and load factors of the
component to be repaired.
For this reason, only general recommendations can be made as to the size and shape of the reinforcement
plates.
6. General application of reinforcement plates
6.1. Shape of reinforcement plates
The crossover or connection between the reinforced and not reinforced part should be as gradual as possible.
This means that the size of the plate should be selected in such a way that new or unacceptable high stress in
the repaired parts are avoided. Plates with sharp corners (such as a rectangular plate) should not be used.
Suitable reinforcement plate with Suitable reinforcement plate against
high tensile strength. bending and alternating loads.
Benennung Description Dénomination Typ/ab Type/from Type/ a partir de
Mjfcifss!
Repair welding LR 614 F/N xxx-6358
Datum Edition Date
02 10 Tools and instructions Blatt
Page
Feuille 2.2.01.02
6.2. Plate Thickness
The thickness of the reinforcement plate should be up to 2/3 (66%) of the thickness of the material to be
reinforced.
6.3. Plate Quality
The yield and tensile strength of the reinforcement plate should be equal to the material to be reinforced.
6.4. Plate Installation
The welded area of the crack should be ground so it is smooth and level.
The size of the plate must be selected in such a way that the longer sides of the plate extend into the
connecting construction of the material to be reinforced. The plate should also overlap the crack on each side
by at least 1" (20 mm). The correct position and fit of the reinforcement plate is achieved through clamping and
spot welding.
6.5. Plate Welding
The reinforcement plate should be welded on by running a welding bead alternately on both sides. The welding
should always start in the middle of the plate and run towards the outside. Be certain to observe that each
welding seam has proper run out.
Direction of weld Direction of weld
The size of the welding run "a" is figured out in reference to the thickness "k" of the reinforcement plate.
Use formula: a=0,5 k
Up to a welding run "a" of approx. 1/8" (3 mm) a single run can be made, however, as a general rule, a double
run should be preferred.
Above a welding run "a" of 1/8"(3 mm), the first run provides excellent penetration between the reinforcement
plate and the basic material. Subsequent runs are added on top of the first run.
After the welding is completed, clean the welding seam as necessary. Grind the run out between reinforcement
plate and basic material.
7. Selecting the correct electrodes
For repair welding, only lime based {Kb} electrodes should be used, and as a rule, the electrodes {additional
material} should be "softer" than the basic material. Exceptions to this rule should be observed.
Important: To reach the theoretical welding quality, the work must not only be performed in a
professional manner, the electrode manufacturer's guidelines must absolutely be observed as
well.
Welding of vertical-down welds on steel components is not permissible!
7.1. Electrode Selection
Welding area Material
Electrode -
norm description
Protective gas welding wire
norm description
BASIC MACHINE
Roller frame - Main
frame
St 52 - 3
QStE 380 N
according to EN 499:
E42 5 B 4 2 H5
according to AWS A5.1-91:
E7018-1 H4 R
according to EN 440:
G4Si1
according to AWS A5.18-93:
ER 70 S-6
LH 690
preheat to app.
100-150°C
(210-300°F)
according to EN 757:
E 69 6 Mn2NiCrMo B 4 2 H5
according to AWS A5.5-96:
E 11018-G
according to EN 12534:
G3CrNi1Mo
according to AWS A5.28-96:
ER110S-G
Roller frame - Main
frame/ bottom plates
HARDOX 400 according to AWS A5.1-91:
E7018-1 H4 R
according to AWS A5.18-93:
ER 70 S-6
ATTACHMENT
Blade
Bucket
Q St E 380 N
HARDOX 400
according to EN 499:
E42 5 B 4 2 H5
according to AWS A5.1-91:
E7018-1 H4 R
according to EN 440:
G4Si1
according to AWS A5.18-93:
ER 70 S-6
St 52 - 3 according to EN 499:
E42 5 B 4 2 H5
according to AWS A5.1-91:
E7018-1 H4 R
according to EN 440:
G4Si1
according to AWS A5.18-93:
ER 70 S-6
Push frame
Bucket arm
RL-Boom
LH 690
preheat to app.
100-150°C
(210-300°F)
according to EN 757:
E 69 6 Mn2NiCrMo B 4 2 H5
according to AWS A5.5-96:
E 11018-G
according to EN 12534:
G3CrNi1Mo
according to AWS A5.28-96:
ER110S-G
Ripper St 52 - 3
Q St E 380 N
HARDOX 400
according to EN 499:
E42 5 B 4 2 H5
according to AWS A5.1-91:
E7018-1 H4 R
according to EN 440:
G4Si1
according to AWS A5.18-93:
ER 70 S-6
WEAR ITEMS
Root runs
according to EN 499:
E42 5 B 4 2 H5
according to AWS A5.1-91:
E7018-1 H4 R
Root runs
according to EN 440:
G4Si1
according to AWS A5.18-93:
ER 70 S-6
Adapter, Tooth adapter
Ripper
Special steel
Cover layers with
high-strength electrode
according to EN 1600:
E 18 8 Mn B 2 2
according to AWS A5.4-92:
E 307-15
Cover layers with
high-strength electrode
according to EN 12072:
G 18 8 Mn
according to AWS A5.9-93:
ER307
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Repair welding LR 614 F/N xxx-6358
Datum Edition Date
02 10 Tools and instructions Blatt
Page
Feuille 2.2.01.03
7.2. Steel Table
Description Explanation Analysis
HARDOX 400 Weldable, low alloy special steel highly
wear resistant, tensile strength 1250 N/mm²
yield strength 1000 N/mm²
C 0,27% Si 0,7%
Mn 1,6% Cr 1,4%
Mo 0,6%
Q St E 380 N Structural steel poured at low turbulence
with a guaranteed minimum tensile strength
of 500 - 640 N/mm² and minimum yield
strength of 380 N/mm²
C 0,18%
Si 0,5%
Mn 1,6%
Special steel Highly abrasion resistant steel with a tensile
strength of 1720 N/mm²
C = 0,3% Mn = 0,7%
Si = 0,5% Cu = 0,65%
Mo = 0,3% V = 0,05%
St 52 - 3
S355J2G3
Structural steel poured at low turbulence
with a guaranteed minimum tensile strength
of 510 N/mm²
C 0,22%
LH 690 Heat treated fine grain structural steel with
a tensile strength of 770 - 940 N/mm² and
yield strength of 690 N/mm²
C 0,18% Si 0,50%
Mn 1,5% Mo 0,5 %
Ni 1,5 %
lightly alloyed with V, AI and Cu
7.3. Welding addition chart
7.3.1 For arc welding
Description Explanation Analysis - Value in % / Use
according to EN 499:
E42 5 B 4 2 H5
e.g. Böhler
FOX EV 50
E = Arc welding, Rod electrode
42 = 500-640 N/mm² Tensile strength
5 = Value for resistance to impact
B = Shielded metal arc
4 = Reference number for run out and
type of flow
2 = Reference number for welding
positions
H5 = maximum hydrogen content
C = 0,07, Si = 0,5, Mn = 1,1
For connection and application
welding, especially for steel with low
purity and higher carbon content.
Weldable with direct current, electrode
connected to plus terminal (+).
No vertical seams
according to EN 757:
E 69 6 Mn2NiCrMo B 4 2 H5
e.g. Böhler
FOX EV 85
E = Arc welding, Rod electrode
69 = 760-960 N/mm² Tensile strength
6 = Value for resistance to impact
Mn2NiCrMo = Chemical composition
B = Shielded metal arc
4 = Reference number for run out and
type of flow
2 = Reference number for welding
positions
H5 = maximum hydrogen content
C = 0,05, Si = 0,4, Mn = 1,5,
Cr = 0,4, Ni = 2,0, Mo = 0,5
For welding, which require high
viscosity and crack resistance. Use for
high tensile refined fine-grained steel.
Very low hydrogen content in weld
metal.
Weldable with direct current, electrode
connected to plus terminal (+).
No vertical seams
according to EN 1600:
E 18 8 Mn B 2 2
e.g. Böhler
FOX A 7
E = Arc welding, Rod electrode
18 = 620-770 N/mm² Tensile strength
8 = Value for resistance to impact
Mn = Chemical composition
B = Shielded metal arc
2 = Reference number for run out and
type of flow
2 = Reference number for welding
positions
C = 0,1, Si = 0,7, Mn = 6,5,
Cr = 18,8, Ni = 8,8
For connections between various
alloyed and steel which is difficult to
weld.
Weldable with direct current, electrode
connected to plus terminal (+).
No vertical seams
7.3.2 For MIG welding with solid electrodes:
Description Explanation Analysis - Value in % / Use
according to EN 440:
G4Si1
e.g. Böhler
EMK 8
G = MIG welding with solid electrodes
4 = 500-640 N/mm² Tensile strength
Si = Chemical composition
1 = Reference number for run out and
type of flow
C = 0,1, Si = 1,0, Mn = 1,7
For connection and application welding,
especially for steel with low purity and
higher carbon content.
Weldable with direct current, electrode
connected to plus terminal (+).
Protective gases: Argon + 15-20% CO2
or 100% CO2
No vertical seams
according to EN 12534:
G3CrNi1Mo
e.g. Böhler
X 70 - IG
G = MIG welding with solid electrodes
3 = 900 N/mm² Tensile strength
CrNi1Mo = Chemical composition
C = 0,1, Si = 0,6, Mn = 1,6, Cr = 0,25,
Ni = 1,3, Mo = 0,25, V = 0,1
For welding, which require high viscosity
and crack resistance. Use for high
tensile refined fine-grained steel.
Weldable with direct current, electrode
connected to plus terminal (+).
Protective gases: Argon + 15-20% CO2
or 100% CO2
No vertical seams
according to EN 12072:
G 18 8 Mn
e.g. Böhler
A7 IG
G = MIG welding with solid electrodes
18 = 580-730 N/mm² Tensile strength
8 = Value for resistance to impact
Mn = Chemical composition
C = 0,08, Si = 0,9, Mn = 7,0,
Cr = 19,2, Ni = 9,0
For connections between various
alloyed and steel which is difficult to
weld.
Weldable with direct current, electrode
connected to plus terminal (+).
Protective gases: Argon+max. 2,5% CO2
No vertical seams
1. Installation instructions
1.1. Slipring seals
1.1.1 Design and Function
Due to the pretension of the O-rings 2, the two duo cone seals (sliprings) 3 are pressed together and therefore
seal of the bearing point via the gliding surface 4.
Seal variations:
- Seal toward the outside - Seal toward the inside
1 Seal mount
2 O-ring
3 Slipring
4 Gliding surface
Note!
Only seals toward the outside are used in the machines of Series 4, because of design
reasons.
1.1.2 Installation
1.1.2.1. General installation notes
The sliprings of the seals are manufactured as pairs. For that reason, new as well as used seals may only
be installed as original pairs.
Avoid impacts and blows, which could damage the sealing surfaces of the chilled cast sliprings.
Round off sharp edges on the seal mounts.
Slipring seals and their receptacles must be absolutely clean and free of grease and oil for installation.
O-rings may not be lubricated with oil.
Caution!
If the installation device is not used, the O-ring can roll up on the conical slipring surface. In
case of one-sided installation pressure, the seal half and / or the O-ring can twist. These
types of installation problems cause leaks as well as damage to the gliding surfaces.
Benennung Description Dénomination Typ/ab Type/from Type/ a partir de
LR 614 F/N xxx-6358
Mjfcifss!
Datum Edition Date
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Installation instructions
Blatt
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Installation position correct Installation position incorrect Installation position incorrect
O-ring twisted Seal half is crooked
1.1.3 Installation of the slipring seal
allation aid, it is folded over slipring 3, transferring the pressure at installation
with the appropriate installation aid into the seal mount 1. The required pressure must
tring 6 can be inserted between the slipring 3 and
1 Seal mount 5 Installation device
string
Before the two seal mounts are assembled, check if the sliprings protrude evenly. Measure the distance from
ase film.
A split device 5 is used as inst
directly to O-ring 2.
Press the seal halves
be exerted evenly onto the full circumference of the O-ring.
If no suitable installation device is available, a round rubber s
the O-ring 2 as a makeshift spacer and affixed by hand, so that the O-ring cannot roll up on the conical slipring
surface when the seal half is pressed in.
2 O-ring 6 Aid – round rubber
3 Slipring
the seal mount to the slipring on at least 3 locations around the circumference, 120° apart.
Check the gliding surface again to ensure it is clean and lightly lubricated with a thin oil or gre
1.2. Safety lever
1 Safety lever
2 Hex nut
3 Hex nut
4 Limit switch
To ensure a safe and error free function of the safety lever, observe the following for installation:
Tighten the hex nut 2 to the tightening torque (see section 1.4) and then open by 1 to 1.5
turns.
Tighten the hex nut 3 to the tightening torque (see section 1.4) and then open by 0.5 turn.
1.3. Tilt cylinder suspension
When installing the tilt cylinders 5, make sure that the hex head screw 6 at the suspension of the change over lever
4 is tightened with a tightening torque of 670 ± 20Nm.
1 Main frame
2 Bucket
3 Bucket arm
4 Change over lever
5 Tilt cylinder
6 Hex head screw
Benennung Description Dénomination Typ/ab Type/from Type/ a partir de
LR 614 F/N xxx-6358
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Datum Edition Date
01 09
Installation instructions
Blatt
Page
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Benennung Description Dénomination Typ/ab Type/from Type/ a partir de
Mjfcifss!
Technical data and LR 614 F/N xxx-6358
Datum Edition Date
02 07 Maintenance guidelines Blatt
Page
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3.0.00.01
Sub group index
Technical data and maintenance guidelines
Technical data 3.1
Maintenance and inspection schedule 3.2
Maintenance and inspection guidelines 3.3
Adjustment check list – short instructions 3.4
Adjustment check list 3.5
LR 614 F/N xxx-6358 10719
DIESEL ENGINE
Type D504 T (CD4045TF 277)
version 4 cyl. in-line
Performance per ISO 9249 kW 72 (98PS)
Nominal RPM 1/min 2200
Low idle RPM 1/min 850
High idle RPM 1/min 2370
Displacement l 4,5
Oil quantity incl. filter l 14,7
Oil quality / viscosity See service fluids section 1.3
Max. machine incline - max. permissible all directions 35° = 78% / 30° constancy
Valve clearance - cold On/off mm 0,36 / 0,46
Firing order 1-3-4-2
Coolant l 24
Fuel tank content l 180
SPLITTERBOX
Type 250 B 270
Version 1-stage spur gear
Ratio i 0,9107
Oil quantity l 1,75
Oil specifications / viscosity See Service fluids, section 1.3
HYDRAULIC SYSTEM
Travel pumps – Travel hydraulic Type 2 x 90 L0 75
Max. flow - Q max. l/min 181,2
Max. operating pressure - p max bar 415
Gear pump - Replenishing circuit (2 pieces) Type SNP2 / 11
Max. flow - Q max./ piece l/min 48,3
Max. operating pressure (SP) - p max bar 28
Travel motors – Travel hydraulic Type 51 VO 80
Regulating pump – Working hydraulic Type CPB 30
Max. flow - Q max. l/min 115 at 2400 U/min
Control valve block - Working hydraulic Type 08401604 SX14
Max. operating pressure (HD) p max. bar 230
Servo control - working hydraulic - operating pressure (ND) bar 28
Hydr. tank capacity l 126
Oil specifications/ viscosity See Service fluids, section 1.3
ELECTRICAL SYSTEM
Operating voltage V 24
Batteries 2 x 12V 2 x 88Ah
Alternator 45A
Starter kW 4
Central fuse A 35
Individual fuses A See Operating Instructions
TRAVEL GEAR
Type left: AT 320547 / right: AT320548
Version 3-stage spur gear
Parking brake integrated Disk brake
Ratio i ges 52,127 : 1
Oil quantity l 2 x 8,75
Oil specifications/ viscosity See Service fluids, section 1.3
LR 614 F/N xxx-6358 10719
Typ/ab Type/from Type/a partir de
Datum Edition Date
04 08 Blatt
Page
Feuille
Benennung Description Dénomination
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Technical Data
Mjfcifss!
LR 614 F/N xxx-6358 10719
TRACK COMPONENTS
Chain pitch mm (inch) 170 (6.692)
Chain length Links 38
Track pad width (2 grouser) mm 457 / 508 (with and without dirt hole)
Track pad bolts Thread size 5/8“ UNF
Track rollers, single flange, per side (s) Qty. 3
Track rollers, double flange, per side (d) Qty. 3
Track roller location s-d-s-d-d-s
Track rollers per side Qty. 1
Track frame oscillation, max. Fixed
WORKING ATTACHMENTS
Lift cylinder Cyl. / Rod / Stroke mm 110 / 60 / 680
Tilt cylinder Cyl. / Rod / Stroke mm 130 / 70 / 385
Flap cylinder (4 in 1) Cyl. / Rod / Stroke mm 80 / 50 / 260
GENERAL
Travel speed - full speed range km/h 0 9,6
Reduced speed range km/h 0 5,3
Basic machine: Height over cab mm 2998
Total length without attachment mm 3859
Track gauge (+1 x pad width = total width) mm 1600
Ground clearance mm 408
Fording depth max., measured horizontally mm 920
Operating weight with Standard bucket (depending on track pad widths)kg 11028
Ground pressure (according to track pad widths) kg/cm² 0,55
Operating weight with 4 in 1 Bucket (depending on track pad widths) kg 11590
Ground pressure (depending on track pad widths) kg/cm² 0,58
Standard bucket: Contents heaped (ISO 7546) m³ 1,20
Width mm 2300
Digging depth mm 130
Ripping force kN 100
Static tipping load kg 7088
Dumping height at45° mm 2679
Reach at45° mm 890
Weight kg 744,2 (with cat teeth installed)
Total length of machine (without teeth) mm 5500 (with teeth)
4 in 1 Bucket: Contents heaped (ISO 7546) m³ 1,20
Width mm 2300
Digging depth mm 140
Ripping force kN 95
Static tipping load kg 7024
Dumping height at45° (Bucket) mm 2647
Reach at45° (Bucket) mm 908
Weight kg 1115 (with cat teeth installed)
Total length of machine mm 5593
LR 614 F/N xxx-10720
DIESEL ENGINE
Type D504 TI (CD4045HF 289)
version 4 cyl. in-line
Performance per ISO 9249 kW 72 (98 HP)
Nominal RPM 1/min 2200
Low idle RPM 1/min 1090
High idle RPM 1/min 2370
Displacement l 4,5
Oil quantity incl. filter l 12
Oil quality / viscosity See service fluids section 1.3
Max. machine incline - max. permissible all directions 35° = 78% / 30° constancy
Valve clearance - cold On/off mm 0,36 / 0,46
Firing order 1-3-4-2
Coolant l 24
Fuel tank content l 210
SPLITTERBOX
Type 250 B 270
Version 1-stage spur gear
Ratio i 0,9107
Oil quantity l 1,75
Oil specifications / viscosity See Service fluids, section 1.3
HYDRAULIC SYSTEM
Travel pumps – Travel hydraulic Type 2 x 90 L0 75
Max. flow - Q max. l/min 181,2
Max. operating pressure - p max bar 415
Gear pump - Replenishing circuit (2 pieces) Type SNP2 / 11
Max. flow - Q max./ piece l/min 48,3
Max. operating pressure (SP) - p max bar 28
Travel motors – Travel hydraulic Type 51 VO 80
Regulating pump – Working hydraulic Type CPB 30
Max. flow - Q max. l/min 115 at 2400 U/min
Control valve block - Working hydraulic Type 08401604 SX14
Max. operating pressure (HD) p max. bar 230
Servo control - working hydraulic - operating pressure (ND) bar 28
Hydr. tank capacity l 102
Oil specifications/ viscosity See Service fluids, section 1.3
ELECTRICAL SYSTEM
Operating voltage V 24
Batteries 2 x 12V 2 x 100Ah
Alternator A 55
Starter kW 7
Central fuse A 35
Individual fuses A See Operating Instructions
TRAVEL GEAR
Type left: AT 320547 / right: AT320548
Version 3-stage spur gear
Parking brake integrated Disk brake
Ratio i ges 52,127 : 1
Oil quantity l 2 x 8,75
Oil specifications/ viscosity See Service fluids, section 1.3
LR 614 F/N xxx-10720
Typ/ab Type/from Type/a partir de
Datum Edition Date
01 10 Blatt
Page
Feuille
Benennung Description Dénomination
3.1.11.01
Technical Data
Mjfcifss!
LR 614 F/N xxx-10720
TRACK COMPONENTS
Chain pitch mm (inch) 170 (6.692)
Chain length Links 38
Track pad width (2 grouser) mm 457 / 508 (with and without dirt hole)
Track pad bolts Thread size 5/8“ UNF
Track rollers, single flange, per side (s) Qty. 3
Track rollers, double flange, per side (d) Qty. 3
Track roller location s-d-s-d-d-s
Track rollers per side Qty. 1
Track frame oscillation, max. Fixed
WORKING ATTACHMENTS
Lift cylinder Cyl. / Rod / Stroke mm 110 / 60 / 680
Tilt cylinder Cyl. / Rod / Stroke mm 130 / 70 / 385
Flap cylinder (4 in 1) Cyl. / Rod / Stroke mm 80 / 50 / 260
GENERAL
Travel speed - full speed range km/h 0 10
Reduced speed range km/h 0 6,5
Basic machine: Height over cab mm 2998
Total length without attachment mm 3859
Track gauge (+1 x pad width = total width) mm 1600
Ground clearance mm 408
Fording depth max., measured horizontally mm 920
Operating weight with Standard bucket (depending on track pad widths)kg 11100
Ground pressure (according to track pad widths) kg/cm² 0,56
Operating weight with 4 in 1 Bucket (depending on track pad widths) kg 11475
Ground pressure (depending on track pad widths) kg/cm² 0,58
Standard bucket: Contents heaped (ISO 7546) m³ 1,20
Width mm 2300
Digging depth mm 130
Ripping force kN 100
Static tipping load kg 7517
Dumping height at45° mm 2679
Reach at45° mm 890
Weight kg 744,2 (with cat teeth installed)
Total length of machine (without teeth) mm 5585 (with teeth)
4 in 1 Bucket: Contents heaped (ISO 7546) m³ 1,20
Width mm 2300
Digging depth mm 140
Ripping force kN 95
Static tipping load kg 6988
Dumping height at 45° (Bucket) mm 2647
Reach at 45° (Bucket) mm 908
Weight kg 1115 (with cat teeth installed)
Total length of machine mm 5653
Customer:.............................................Machine-Type..............PIN.........-..............Hours...............Date............
Maintenance/Inspection
at operating hours
WORK TO BE CARRIED OUT
by maintenance personnel by authorized trained personnel
First and only interval First and only interval
Repeat interval Repeat interval
OM Operating instructions SM Service Manual
For correct oil level, use test marks –
for procedure and quantities, see OM
For quality and viscosity guidelines, see “Service fluids” OM
For adjustment values, see data page entries in SM Reference Notes
DIESEL ENGINE
Check oil level and oil pressure OM
Check coolant level OM
Check engine / cooling system and engine compartment for contamination / clean if necessary OM
Check fuel water separator / empty if necessary OM
Check / clean air filter service cover and dust discharge valve OM
Change engine oil / first and only time before 100 hrs. - at least 1 x a year
(regular interval 250 or 500 hrs. depending on oil specification)
OM
Change engine oil filter / first and only time at 100 hrs. - at least 1 x a year OM
Check antifreeze ratio of coolant OM
Check V/belt condition and tension OM
Check oil, cooling and fuel system for leaks and condition OM
Check intake and exhaust system - mounting and leaks OM
Check engine mount
Change fuel pre- and fine filter element OM
Check engine RPM OM
Replace coolant with antifreeze OM
Check / adjust engine valve clearance – with cold engine SM
Drain condensation and sediments from fuel tank - as necessary OM
Replace air filter inserts - as necessary /once a year OM
Clean air filter pre-separator - as necessary /once a year OM
Replace oil separator - every 2 years OM
HYDRAULIC SYSTEM
Check oil level in hydraulic tank OM
Clean magnetic ring (also after repairs) - up to 50 hrs. daily OM
Replace main return filter inserts -
or as soon as the indicator light lights up
OM
Replace pressure filter- replenishing circuit -
or as soon as the indicator light lights up
OM
Check / clean oil cooler for contamination OM
Check working and travel hydraulic system for function and leaks,
check hose routing for chafing or damage
OM SM
Check / adjust all hydraulic pressures according to adjustment check list SM
Check mountings and fittings for tight seating OM SM
Replace oil in hydraulic system (add oil via filter) - at least every 4 years
when using „environmentally friendly hydraulic oils“, request / observe
special guidelines
OM
SPLITTERBOX
Check oil level OM
Replace gear oil - at least every 2 years OM
LR 614 F/N xxx-6358 10719
Typ/ab Type/from Type/a partir de
Datum Edition Date
04 08 Blatt
Page
Feuille
Benennung Description Dénomination
3.2.10.01
Maintenance and
Inspection schedule
Mjfcifss!
Maintenance/Inspection
at operating hours ff
WORK TO BE CARRIED OUT
by maintenance personnel mit autorisiertem Fachpersonal
First and only interval First and only interval
Repeat interval Repeat interval
OM Operating instructions SM Service Manual
For correct oil level, use test marks –
for procedure and quantities, see OM
For quality and viscosity guidelines, see “Service fluids” OM
For adjustment values, see data page entries in SM
Reference Notes
ELECRICAL SYSTEM
Check function of system, incl. displays and instruments OM
Check battery electrolyte level - at least 1 x a year OM
Clean / check / grease battery terminals OM SM
Check cable routing and connections OM SM
Check /adjust all control system according to adjustment check list SM
Check battery charge (before start of cold season) SM
HEATER / VENTILATION / AIR CONDITIONING SYSTEM
Check system for function and leaks OM
Check air conditioning system antifreeze level and moisture indicator OM
Replace fresh air filter and air circulation filter - as necessary OM
Air conditioning system – inspection by expert HVAC personnel 1x a year
TRAVEL GEAR
Check oil level OM
Check fittings for tight seating OM SM
Replace gear oil OM
TRACK COMPONENTS
Check mounting screws and nuts of track components,
especially track pad and sprocket segment screws for tight seating
OM
Check carrier rollers, track rollers, idlers for leaks OM
Check / adjust idler guides, replace parts as necessary OM
Adjust track tension to suit application - as necessary OM SM
Clean travel gear - as necessary OM
Check travel gear for wear - as necessary SM
Working attachment
Check cutting edges, bucket and ripper teeth for wear -
make sure attachments are suited to application
OM
Check bucket attachment – stops and adjustment of limit switches OM
Check screws, nuts and pin retainers for tight seating OM
Check all bearing points for play / wear OM SM
Check attachment for damage OM
GENERAL
Lubricate all bearing points according to lubrication chart Shorten interval as necessary OM
Check complete machine for proper maintenance and condition OM SM
Lubricate door hinges on operator’s cab - as necessary OM
Explain machine documentation, especially operating instructions / safety guidelines to
operating personnel
OM
Company:.................................................Machine Type..............S/N.........-..............Hrs................Date............
Maintenance / Inspection
At operating hours
WORK TO BE CARRIED OUT
by maintenance personnel by authorized expert personnel
first and only task first and only task
Repeat interval Repeat interval
OI Operating instructions SM Service manual
For fill quantities, use the test marks -
For instructions and quantities, see OI
For quality and viscosity guidelines, see “Service items” OI
See data in SM Instructions
see:
Remark
s
DIESEL ENGINE
Check oil level and oil pressure OI
Check coolant level OI
Check the engine, cooler arrangement and engine compartment for contamination / clean OI
Check the fuel water separator / empty if necessary OI
Check the air filter service cover and dust discharge valve / clean OI
Change the engine oil / first and only time before 100 hrs.
- at least 1 x a year
(Regular interval 250 or 500 hrs. depending on oil specification)
OI
Change the engine oil filter / first and only time before 100 hrs.
- at least 1 x a year
OI
Check the crankcase breather system OI
Check the electrical ground connection for the engine OI
Check the corrosion inhibitor – antifreeze concentration in the coolant OI
Check the V-belt condition and tension OI
Check the oil, coolant and fuel system for leaks and condition OI
Check the air intake and exhaust system – mounting and leaks OI
Check the engine mounting
Change the fuel pre- and fine filter cartridge OI
Check the engine RPM OI
Replace the coolant with antifreeze OI
Check / adjust engine valve clearance - with cold engine SM
Fuel tank, drain condensation and sediments - as necessary OI
Replace air filter inserts - as necessary / annually OI
Clean air filter pre-separator - as necessary / annually OI
HYDRAULIC SYSTEM
Check oil level in hydraulic tank OI
Replace main flow return filter or immediately if the indicator light lights up OI
Replace pressure filter replenishing circuit – or immediately if the indicator light lights up OI
Check oil cooler for contamination / clean OI
Check working and travel hydraulic system for function and leaks,
check hose routing for chafing
OI SM
Check / adjust all hydraulic pressures according to adjustment check list SM
Check mountings and fittings for tight seating OI SM
Replace oil in hydraulic system - at least every 4 years
- If using an “environmentally friendly hydraulic medium”
request / observe special guidelines
OI
SPLITTERBOX
Check oil level OI
Replace gear oil - at least every 2 years OI
LR 614 F/N xxx-10720
Typ/ab Type/from Type/a partir de
Datum Edition Date
01 09 Blatt
Page
Feuille
Benennung Description Dénomination
3.2.11.01
Maintenance and
Inspection schedule
Mjfcifss!
Maintenance / Inspection
At operating hours ff
WORK TO BE CARRIED OUT
by maintenance personnel by authorized expert personnel
first and only task first and only task
Repeat interval Repeat interval
OI Operating instructions SM Service manual
For fill quantities, use the test marks -
For instructions and quantities, see OI
For quality and viscosity guidelines, see “Service items” OI
See data in SMfff Instructions
see:
Remark
s
ELECTRICAL SYSTEM
Check function of system incl. displays and instruments OI
Check battery acid level - at least 1x annually OI
Clean / check / grease battery connections OI SM
Check cable routing and connections OI SM
Check / adjust control system according to adjustment check list SM
Check battery charge condition (before start of cold season) SM
HEATER / VENTILATION / AIR CONDITIONING SYSTEM
Turn the air conditioning system on regularly - at least 1x in 14 days OI
Check water discharge valve of air cond. system, clean as necessary OI
Check system for function and leaks OI
Check condenser for contamination - blow out as necessary OI
Clean air circulation fresh air filter, replace as necessary, in dusty conditions, shorten
maintenance interval
OI
Check mounting screws and drive belt of air cond. compressor OI
Check dryer unit (moisture, fill, condition)
- replace dyer unit and moisture indicator as necessary, evacuate system and refill
OI
Clean water drain valve of air conditioning system OI
Check evaporator unit, clean as necessary OI
Check electrical lines for chafing and plug connections for tight seating OI
Air conditioning system – have inspected by HVAC technician - 1x annually
TRAVEL GEAR
Check oil level OI
Check fittings for tight seating OI SM
Replace gear oil OI
TRACK COMPONENTS
Check mounting screws and nuts of track components,
espec. track pad and sprocket segment screws for tight seating
OI
Check all track components for leaks OI
Check / adjust idler guides, replace parts as necessary OI
Adjust chain tension to suit working application - as necessary OI SM
Clean tracks - as necessary OI
Check track wear - as necessary SM
WORKING ATTACHMENTS
Check cutting edges, end bits and ripper tooth tips for wear -
make sure attachments are suited for application
OI
Check screws, nuts and pin retainers for tight seating OI
Check bucket stops OI
Check all bearing points for play / wear OI SM
Check attachment for intentional damage OI
GENERAL
Lubricate all bearing points according to lubrication schedule - shorten interval as necessary OI
Check entire machine for correct maintenance and proper condition OI SM
Explain machine literature, especially the Operating instructions / Safety guidelines to
operating personnel
OI
Lubricate operator’s cab – door hinges - as necessary
Benennung Description Dénomination Typ/ab Type/from Type/ a partir de
Mjfcifss!
Maintenance and
LR 614 F/N xxx-6358
Datum Edition Date
01 09 Inspection guidelines Blatt
Page
Feuille
3.3.10.01
1. General guidelines
1.1. Documentation for work to be carried out
For work to be performed, refer to the Maintenance and inspection schedule for your particular machine
model – see section 3.2.
Check 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 3.5.
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 company. 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 section 1.2
and 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: Changing filters, draining condensation and sediments in case of dirty fuel; cleaning the
radiator in case of contamination; changing filters and oils during or after repairs, etc.
Dispose of oil oils, filters and other waste products properly!
1.4. General
Use only LIEBHERR Original spare and maintenance parts for all maintenance, inspection and repair work.
If the operator requests other on hand parts for installation, then this must be noted separately on the inspection
check lists by noting possible loss of warranty.
For general screw tightening torques, see section 1.4. For tightening guidelines for track chain pads and
sprocket segment bolts, see section 12.1.
2. Maintenance and inspection guidelines
2.1. Inspection work on the Diesel engine
2.1.1 Check / adjust valve clearance
Preparation for test
Make sure that:
The machine is in maintenance position.
The battery master switch (optional) is turned off or the negative cable is disconnected from the
battery.
The Diesel engine is cold.
Special tools are available (turning tool – flywheel, adjustment pin, see section 2.1.)
If necessary, have new gaskets for the cylinder head covers ready for use.
Procedure:
Remove the rocker lever cover and the crankcase vent pipe.
Note!
Visually inspect the contact surfaces of the valve tips, valve bridges and rocker lever wear
surfaces. Check all parts for excessive wear, breakage and cracks. Replace any parts which
show visible damage.
Rocker levers, which show excessive valve clearance should be checked closely to determine
damaged parts.
Replace valves, seats, springs and retainers in pair per cylinder if they are damaged. In
addition, replace the bridge if one of these parts is being replaced.
Remove the plastic plug or the cover plate from the engine adjustment / rotary opening (A) and the
adjustment pin opening (B) on the flywheel side.
With the special tool “Turning device – flywheel“ turn the engine flywheel in direction of rotation (when
viewed from the front, turn it in clockwise direction until the cylinder No. 1 is on the top dead center (TDC) of
the compression stroke.
Insert the special tool „adjustment pin“ into the flywheel.
Benennung Description Dénomination Typ/ab Type/from Type/ a partir de
Mjfcifss!
Maintenance and
LR 614 F/N xxx-6358
Datum Edition Date
01 09 Inspection guidelines Blatt
Page
Feuille
3.3.10.02
Note!
If the rocker levers of cylinder No. 1 can be moved, then the engine is on the TDC of No. 1 in
the compression stroke.
If the rocker levers of cylinder No. 1 cannot be moved, turn the engine a complete rotation
(360°) to the TDC No. 1 of the compression stroke.
When the engine is held with the adjustment pin on the TDC of the compression stroke of piston No. 1,
check the valve clearance according to the following specification.
Adjust valve clearance
Note!
If the valves must be adjusted, release the counter nut (A) on the rocker lever adjustment
screw. Prevent the adjustment screw from turning with a screw driver and tighten the counter
nut according to specifications. After tightening the counter nut, check the clearance again.
Readjust the clearance, if necessary.
A = Outlet valve
E = Intake valve
Specifications
Test dimension
Adjustment
dimension
Intake valve clearance (rocker lever to valve
bridge)
[engine cold] – clearance
0.31 – 0.38 mm 0.36 mm
Exhaust valve clearance (rocker lever to valve
bridge)
[engine cold] – clearance
0.41 – 0.48 mm 0.46 mm
Counter nut of rocker lever adjustment screw
Torque
27 Nm
Four cylinder engine:
Note!
The firing order is 1-3-4-2.
Piston No. 1 on the top dead center (TDC) of the compression stroke:
Hold the piston No. 1 with the adjustment pin on the TDC of the compression stroke.
Adjust the valve clearance on the exhaust valves No. 1 and 3.
Adjust the valve clearance on the intake valves No. 1 and 2.
Piston No. 4 on the top dead center (TDC) of the compression stroke:
Turn the crankcase by 360°.
Hold the piston No. 4 on the TDC of the compression stroke.
Adjust the valve clearance on the exhaust valves No. 2 and 4.
Adjust the valve clearance on the intake valves No. 3 and 4.
Attach the rocker lever cover and the crankcase vent pipe.
Benennung Description Dénomination Typ/ab Type/from Type/ a partir de
Mjfcifss!
Maintenance and
LR 614 F/N xxx-6358
Datum Edition Date
01 09 Inspection guidelines Blatt
Page
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3.3.10.03
2.2. Inspection work on the hydraulic system
2.2.2 Check the working and travel hydraulic system for function and leaks, check hose routing for chafing, check
mountings and fittings for tight seating
Carry out all travel and working movements and check for malfunction.
Check the actuator plate, plunger and universal joint of the working hydraulic pilot control for wear, grease
lightly and adjust, if necessary. The same applies for pilot control for auxiliary equipment.
To inspect the pressure accumulator – safety control – working hydraulic, start the Diesel engine and raise
the front attachment. Turn the engine off (return the ignition key again to position 1) and leave the safety lever
in the down position. Actuate the function “down” several times jerkily. If the attachment moves down less
than four times, then the accumulator is defective or there is excessive
leakage in the system.
Check the hose lines for leaks and kink-free routing. Watch for chafe
marks. Replace chafed, “sweating” or aging hoses. Refer to the Safety
guidelines, Section 1.2.
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. Retighten, if necessary.
2.2.3 Check / adjust all hydraulic pressures
Carry out tests / adjustments according to the adjustment check list for the respective machine type – see
section 3.5 – and enter the results.
For detailed descriptions, data and instructions, see adjustment check list or corresponding sub group in the
Service Manual.
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LIEBHERR LR 614 LR614 CRAWLER LOADER SERIES 4 LITRONIC Service Repair Manual

  • 1.                                                                                        
  • 2. Benennung Description Dénomination Typ/ab Type/from Type/ a partir de Mjfcifss! LR 614 F/N xxx-6358 Datum Edition Date 02 10 Table of contents Blatt Page Feuille 0.1.00.01 Page No. Pages from to Title Date of issue 0.1.00 1 4 Index 02.2010 1.0.00 1 2 Sub group index "General" 02.2007 1.1.00 1 2 Foreword and explanation 02.2007 1.2.01 1 4 Safety guidelines 04.2008 1.3.10 1 8 Service fluids 01.2009 1.3.11 1 2 Service fluids 01.2009 1.4.01 1 4 Tightening torques 02.2007 1.4.02 1 2 Conversion chart 04.2008 1.4.03 1 2 Tapping holes 02.2007 1.5.01 1 2 Material weights 01.2009 2.0.00 1 2 Sub group index "Tools and Working instructions" 02.2007 2.1.10 1 10 Special tools 01.2009 2.2.01 1 6 Repair welding 02.2010 2.3.01 1 4 Installation instruction for duo cone seals 01.2009 3.0.00 1 2 Sub group index "Technical data and maintenance guidelines" 02.2007 3.1.10 1 2 Technical data 04.2008 3.1.11 1 2 Technical data 01.2010 3.2.10 1 4 Maintenance and inspection schedule 04.2008 3.2.11 1 2 Maintenance and inspection schedule 01.2009 3.3.10 1 8 Maintenance and Inspection instructions 01.2009 3.4.10 1 4 Quick reference for Machine adjustment 01.2010 3.5.10 1 2 Adjustment check list 01.2010 3.5.11 1 4 Adjustment check list 01.2010 4.0.00 1 2 Sub group index "Engine" 02.2007 4.1.10 1 2 Data page 04.2008 4.2.10 1 2 Fan and cylinder arrangement 04.2008 5.0.00 1 2 Sub group index "Coupling and splitter box" 02.2007 5.1.10 1 2 Data page 04.2008 5.2.10 1 2 Coupling 02.2007 5.3.10 1 4 Splitter box 02.2007 6.0.00 1 2 Sub group index "Travel hydraulic" 02.2007 6.1.10 1 2 Data page 04.2008 6.2.10 1 6 Design 04.2008 6.2.11 1 8 Design 04.2008 6.3.10 1 6 Function 04.2008 6.3.10 1 1 Schematic Travel hydraulic 04.2008 6.3.11 1 6 Function 01.2009 6.3.11 1 2 Schematic Travel hydraulic 01.2009 6.5.10 1 2 Component arrangement 04.2008 6.5.11 1 2 Component arrangement 04.2008
  • 3. Page No. Pages from to Title Date of issue 7.0.00 1 2 Sub group index "Working hydraulic" 02.2007 7.1.10 1 2 Data page 02.2007 7.2.10 1 6 Design 04.2008 7.2.11 1 4 Design 04.2008 7.3.10 1 8 Function 04.2008 7.3.10 1 1 Schematic Working hydraulic 04.2008 7.3.11 1 8 Function 04.2008 7.3.11 1 1 Schematic Working hydraulic 04.2008 7.5.10 1 4 Component arrangement 04.2008 7.5.11 1 2 Component arrangement 04.2008 8.0.00 1 2 Sub group index "Hydraulic components" 04.2008 8.1.10 1 4 Variable displacement pump 02.2007 8.2.10 1 4 Variable displacement motor 02.2007 8.4.10 1 4 Gear pump working hydraulic 04.2008 8.4.15 1 4 Gear pump Fan drive 04.2008 8.4.20 1 4 Gear motor 04.2008 8.4.21 1 4 Gear motor 04.2008 8.5.10 1 8 Pilot control working hydraulic 04.2008 8.5.11 1 8 Pilot control working hydraulic 04.2008 8.6.10 1 6 Control valve block 04.2008 8.6.11 1 6 Control valve block 04.2008 8.7.10 1 26 Valves 02.2007 8.8.10 1 8 Hydraulic cylinder 04.2008 9.0.00 1 2 Sub group index "Electrical system – Schematics and components" 04.2008 9.1.10 1 12 Item list- wiring diagram 04.2008 9.1.11 1 21 Current flow diagram, code letter explanations, function list 04.2008 9.1.12 1 21 Current flow diagram, code letter explanations, function list 04.2008 9.2.10 1 4 Instrument panel 04.2008 9.2.11 1 4 Instrument panel 04.2008 9.3.10 1 6 Electronic component arrangement 04.2008 9.3.11 1 6 Electronic component arrangement 04.2008 9.4.10 1 2 Travel joystick 04.2008 10.0.00 1 2 Sub group index "Electrical system descriptions" 02.2007 10.1.01 1 2 Application software- Introduction 04.2008 10.1.02 1 16 Application software 02.2007 10.1.03 1 2 Application software- Diagram 01.2010 10.1.04 1 4 Application software description 02.2007 10.1.05 1 8 Error chart 02.2007 12.0.00 1 2 Sub group index "Track arrangement" 02.2007 12.1.10 1 2 Data page 02.2010 12.2.10 1 22 Design, Function, wear evaluation 02.2007 12.3.01 1 2 Appraisal report 02.2007 12.3.10 1 2 Wear chart 04.2008 12.5.10 1 2 Track roller 02.2007 12.6.10 1 2 Carrier roller 02.2007 13.0.00 1 2 Sub group index "Attachments - front" 02.2007 13.1.10 1 4 Mechanical stops- bucket attachments 04.2008 13.2.10 1 6 4 in 1 bucket 04.2008 14.0.00 1 2 Sub group index "Attachments - rear" 02.2007 14.1.10 1 4 Multi tooth ripper- Design, function, item list 04.2008
  • 4. Benennung Description Dénomination Typ/ab Type/from Type/ a partir de Mjfcifss! LR 614 F/N xxx-6358 Datum Edition Date 02 10 Table of contents Blatt Page Feuille 0.1.00.02 15.0.00 1 2 Sub group index " Main frame – Add on components " 02.2007 15.1.10 1 2 Cooler arrangement 04.2008 15.1.11 1 2 Cooler arrangement 04.2008 15.2.10 1 2 Hoist and tilt cylinder mount 01.2009 15.3.10 1 2 Engine mount 04.2008 15.3.11 1 2 Engine mount 04.2008 16.0.00 1 2 Sub group index "Tank arrangement" 02.2007 16.1.10 1 4 Hydraulic tank 04.2008 16.1.11 1 4 Hydraulic tank 01.2009 16.2.10 1 2 Fuel tank 04.2008 16.2.11 1 2 Fuel tank 04.2008 16.3.10 1 2 Battery box 04.2008 16.3.11 1 2 Battery box 04.2008 17.0.00 1 2 Sub group index "Operators platform, heater, air conditioner" 02.2007 17.1.10 1 8 Operator’s platform 04.2008 17.2.10 1 4 Heater and Blower 04.2008 17.3.10 1 10 Air conditioning system 04.2008 17.4.10 1 2 Operator’s seat – air cushioned 04.2008 17.5.10 1 2 Engine RPM adjustment 02.2007
  • 5. Benennung Description Dénomination Typ/ab Type/from Type/ a partir de Mjfcifss! LR 614 F/N xxx-6358 Datum Edition Date 02 07 General Blatt Page Feuille 1.0.00.01 Sub group index General Forword and explanations 1.1 Safety guidelines 1.2 Service items 1.3 Charts 1.4 Tightening torques for standard screws 1.4.01 Conversion chart 1.4.02 Tapping holes 1.4.03 Material weights 1.5.
  • 6. Benennung Description Dénomination Typ/ab Type/from Type/ a partir de Mjfcifss! Foreword and explanation LR 614 F/N xxx-6358 Datum Edition Date 02 07 General Information Blatt Page Feuille 1.1.00.01 For your information This manual contains technical data, descriptions of design and function, repair and adjustment guidelines as well as numerous drawings, functional views and illustrations LIEBHERR - crawler dozers (PR), crawler loaders (LR) or pipelayers (RL). This manual should simplify competent customer service of our products, does however, not replace expert and qualified training and an attendance of our factory schools. Information which is in trade considered basic knowledge is not included. Operation and spare parts information can be found in separate manuals. The manual will be updated as necessary when changes occur in series. During the activities on the machine, accident prevention regulations and safety guidelines must be strictly observed. This manual is intended for the exclusive use of the registered owner and may not be reproduced complete or in part or passed on a third person without written permission. This manual is still on property of LIEBHERR-Werk Telfs GmbH. All rights reserved - Printed in Austria. We reserve the right to make changes of technical details on the machine in comparison to the information and drawings in this manual. Printed and published by LIEBHERR-Werk Telfs GmbH., Service -Training Department. Explanation of structure (page numbers) In order to find specific information and add supplements more easily, the following numbering system is being used: We hope that with the enclosed information we have taken yet another step to improve the service on the LIEBHERR - crawler dozers, crawler loaders and pipelayers. LIEBHERR-Werk Telfs GmbH. Technical Documentation Note! This sign marks special important notes in the manual. 6. 3. 10 01 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 within the model group, illustrations or parts list with .00 may be added at the beginning or end of each group. division based on information content or machine model group
  • 7. Benennung Description Dénomination Typ/ab Type/from Type/ a partir de Mjfcifss! Safety guidelines LR 614 F/N xxx-6358 Datum Edition Date 04 08 General Information Blatt Page Feuille 1.2.01.01 Safety guidelines 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.
  • 8. 1. 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.
  • 9. Benennung Description Dénomination Typ/ab Type/from Type/ a partir de Mjfcifss! Safety guidelines LR 614 F/N xxx-6358 Datum Edition Date 04 08 General Information Blatt Page Feuille 1.2.01.02 2. 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 General safety guidelines 2 Crushing and burn prevention 3 Fire and explosion prevention 4 Machine start up safety 5 Engine start up safety 6 Machine operating safety 7 Machine parking safety 8 Machine transporting safety 9 Machine towing safety 10 Machine maintenance safety 11 Machine welding safety 12 Safety guidelines to be observed when working on the attachment 13 Safety guidelines to be observed when loading the machine with a crane 14 Safe maintenance of hydraulic hoses and lines 15 Safety guidelines for maintenance work on the machine with hydro accumulators 16 Roll over protection (ROPS) and falling object protection (FOPS) 17 Attachments and components 18 Protection from vibration
  • 10. Benennung Description Dénomination Typ/ab Type/from Type/ a partir de Mjfcifss! LR 614 F/N xxx-6358 10719 Datum Edition Date 01 09 Service Items Blatt Page Feuille 01.3.10.01 Service Items Notes for the disposition of service fluids and filter: - Service fluids may not be discharged into the ground, drainage system or waterways. - Different service fluids and filters should be collected and disposed of in separate containers. - Do not use containers, which previously held food items or drinks - to prevent danger of mix-ups. - Dispose of these items in an environmentally friendly manner according to applicable guidelines and regulations. Observe all state, local and national regulations. - Do not use old or incorrectly stored service fluids and filters, dispose of them properly. 1. Service fluids for Diesel engines with turbo chargers 1.1. Engine lube oil Engine lube oils must meet a certain quality and a certain viscosity, depending on their use and ambient temperatures. Problem-free operation can only be ensured only if the requirements for both areas are met. 1.1.1 Oil quality To meet the technical demands, only highly alloyed lube oils are used in modern Diesel engines. They consists of high-quality base oils, mixed with additives. These additives provide the required properties for these oils. For LIEBHERR Diesel engines with turbo chargers, oils of the following specifications are approved, the higher quality oils are preferred: API - classification : CF-4, CG-4, CH-4, CI-4, (American Petroleum Institute) ACEA (CCMC) - classification : E2 (D4), E3 (D5), E4, E5 (Association des Constructeurs Européens de l´Automobile) Note: For older machines / Diesel engines, if still in use, engine oils according to the lower specification as noted in the original operation manuals may be used. However, we recommend the use of these new oils, since the service life of the engine can be extended significantly by using these higher quality oils. The originally noted oil and filter change intervals may be extended. 1.1.2 Oil viscosity Z In addition to the quality, the oil must also provide a certain viscosity the selection is made according to the SAE - classification (Society of Automotive Engineers). The determining factor for the correct selection of the SAE classification is the ambient temperature. In most regions, SAE 10W-40 is recommended (see chart below). If the viscosity is too high, starting problems can occur, if it is too low, the lubrication efficiency can be endangered, both factors can lead to increased engine wear. The temperature ranges shown in the following chart are guidelines and may be exceeded or fallen below for a short time. For the operation in extreme climate zones, such as in arctic regions, special guidelines apply and are available from the manufacturer.
  • 11. 1.1.3 Oil change intervals The oil change intervals noted in the Maintenance and Inspection schedules always apply to "normal operating conditions". They apply for normal, central European temperatures, annual operation of approx. 1000 operating hours, use of oils of the required minimum quality and fuels with a sulfur content of less than 0.5%. When using higher quality oils, the operating hours per interval may be doubled - see the following chart. However, the 500 hour interval may not be exceeded. Engine oil and filters must be changed at least once a year, even if the given change interval has not yet been reached. In difficult circumstances, such as repeated cold start, higher sulfur content (above 05.%) in the fuel, more severe climatic conditions (for example continuous temperatures below -10°C) etc., the intervals must be cut in half. This means, for each difficulty, the permitted operating hours per interval must be multiplied by a factor of 0.5. Permissible oil change intervals in operating hours: Applications Oil quality: CF-4, CG-4, CH-4, CI-4, E2 (D4)) Oil quality: E3 (D5), E4, E5, Ambient temperature Sulfur content in fuel Change interval Change interval to 0,5% 250 hrs. 500 hrs.above -10°C (Normal temperature) above 0,5% 125 hrs. 250 hrs. to 0,5% 125 hrs. 250 hrs.below -10°C Continuous temperature above 0,5% 60 hrs. 125 hrs. 1.2. Diesel fuels Diesel fuels must meet the minimum requirements of the following specifications. The sulfur content may not exceed 0.5%. A higher sulfur content has negative effects on oil change intervals and engine service life. A higher sulfur content above 1% is not permitted. Fuels with low sulfur content (for example, according to European regulations <0.05 %) must contain additives to retain the lubrication efficiency according to HFRR(60°)-Test <400 m - . Insufficient lubrication causes premature wear of the injection system components, especially distributor injection pumps. The additives should be added by the fuel supplier, as he is responsible for the quality of the fuel. We do not recommend addition of secondary lubrication additives by the user. Approved fuel specifications: DIN EN 590 + HFRR(60°)-Test <400 m ASTM D 975 - 89a 1D and 2D + HFRR(60°)-Test <400 m + cetane rating >45 (recommendation: >50)
  • 12. Benennung Description Dénomination Typ/ab Type/from Type/ a partir de Mjfcifss! LR 614 F/N xxx-6358 10719 Datum Edition Date 01 09 Service Items Blatt Page Feuille 01.3.10.02 Diesel fuels in very low temperatures At ambient temperatures below freezing (0 C), the flow properties of warm temperature Diesel fuel can become insufficient due to paraffin excretion. The same applies to cold temperature Diesel fuels in temperatures below. -15 C. In order to prevent operating problems in even lower temperatures, Diesel fuel with an additive is sometimes available, for use in temperatures to -20 C. In order to prevent operating problems in even lower temperatures, mix Diesel fuel with normal gasoline or petroleum. Addition of normal gasoline is a makeshift measure and may not exceed 30% per volume. Do not use Super gasoline for mixing. Mixing fuel can diminish engine performance, for that reason, keep the added fuel as low as possible, depending on the ambient temperatures. For safety reasons, mix fuel only in the fuel tank. When refueling, add the lighter additive before the Diesel fuel. Then let the engine run for a short time until the mixture has been distributed throughout the fuel system. Diesel fuels - Mixing ratio ( Vol.-%) Summer Diesel fuel Winter Diesel fuel to -15°C Winter Diesel fuel to -20°C Ambient temperature °C % Fuel % Additive % Fuel % Additive % Fuel % Additive 0 to -10 70 30 100 -- 100 -- -10 to -15 50 50* 100 -- 100 -- -15 to -20 -- -- 70 30 100 -- -20 to -25 -- -- 50 50* 70 30 * = If an addition of more than 50% is required, use only petroleum (no regular gasoline). The Diesel fuel part may never be more than 50% . Additives to Diesel fuel (flow improvers) Commercially available flow improvers can also improve Diesel fuel properties in cold temperatures. Always read and observe the manufacturers user guidelines and quantities. 1.3. Coolant Coolants, containing unsuitable anti corrosion / antifreeze fluids or wrong mixed coolants could damage the engine or its parts, caused by cavitation or corrosion. Additionally heat isolating deposits could be created on heat transferring parts, which overheat and lead to the damage of the engine. For a long term, fault free operation, the coolant must be filled year round with a mixture of at least 50% anticorrosion/antifreeze fluid. This concentration protects the system to approx. -37°C / -34°F. Note: Do not use more than 60% anti-corrosion / antifreeze fluids, a higher percentage would actually reduce the cooling and antifreeze protection and causes gel formation in the coolant fluid. Danger of engine damage! Protection to Percentage of antifreeze (%) Antifreeze protection chart
  • 13. Coolant filters are used on some engine series, which filter the coolant in the auxiliary flow and in addition, a chemical additive in the filter (DCA 4) reinforces the protection against cavitation, corrosion, scale deposits and foam formation. The DCA4 concentration must be between 0.3 and 0.8 units per liter of coolant. See the following chapter ”Coolant with DCA4”. This results in a mixing ration of approx. 48.5 % water, 48.5 % anti corrosion /antifreeze fluid and 3 % DCA4. Check the mixing ratio regularly during maintenance work. See instructions in section 3.4. If coolant must be replaced, make sure that the given mixing ratios are retained. Do not fall below this ratios nor exceed it. Due to the natural aging process of the coolant, it must be replaced at least once every 2 years. Use only suitable coolant, free of contaminants. Clean contaminated cooling systems. Note the following regulations. To replace or add coolant in larger quantities, mix the given parts outside the cooling circuit in a suitable, clean container first. Fresh water guidelines: To mix coolant fluid, use clean, clear water, which is not too hard. Often, but not always, regular tap water may be used. Seawater, brine, brackish water, or industrial waste water is not suitable. Approved fresh water quality (as of 2001) for use with anti corrosion / antifreeze fluid - - without DCA4 - with DCA4 Sum of alkaline earths (water hardness): : 0,6 to 3,6 mmol/l 0,6 to 2,7 mmol/l (3 to 20°d) (3 to 15°d) Ph - value at 20° C : 6,5 to 8,5 6,5 to 8,0 Chloride / ion content : max. 80 mg/l max. 80 mg/l Sulfate / ion content : max. 100 mg/l max. 80 mg/l Presently approved anti corrosion / antifreeze fluids (as of December 2003): Brand name Manufacturer Agip Antifreeze Plus Agip Petroli S.p.A, Rom / Italien Agip Langzeit-Frostschutz Autol-Werke GmbH., Würzburg / BRD Antigel DB 486 Sotragal SA, St. Priest / Frankreich Aral Kühler-Frostschutz A Aral AG, Bochum / BRD AVIA Frostschutz APN (G48-00) Deutsche AVIA-Mineralöl GmbH, München / BRD BP Antifrost X 2270 A Deutsche BP AG, Hamburg / BRD BP Napgel C 2270/1 BP Chemicals Ltd., London / England Caltex Engine Coolant DB Caltex (UK) ltd., London / England Caltex Extended Life Coolant Caltex Castrol Anti-Freeze O Deutsche Castrol Vertriebs-GmbH, Hamburg /BRD Century F.L. Antifreeze Century Oils, Hanley, Stoke-on-Trent / England Chevron DEX-COOL Extended Life Anti-Freeze/Coolant Chevron Texaco Deutz Kühlschutzmittel 0101 1490 DEUTZ Service International GmbH, Köln / BRD Esso Kühlerfrostschutz Esso AG, Hamburg / BRD Fricofin Fuchs Mineraloelwerke GmbH, Mannheim / BRD Frostschutz Motorex (G48-00) Bucher+Cie, Langenthal / Schweiz Frostschutz 500 Mobil Oil AG, Hamburg / BRD Glacelf Auto Supra Total Glycoshell AF 405 Shell Glycoshell N Shell Glysantin (G 48-00) BASF AG, Ludwigshafen / BRD Havoline XLC ARTECO Havoline DEX-COOL Extended Life Anti-Freece/Coolant Chevron Texaco
  • 14. Benennung Description Dénomination Typ/ab Type/from Type/ a partir de Mjfcifss! LR 614 F/N xxx-6358 10719 Datum Edition Date 01 09 Service Items Blatt Page Feuille 01.3.10.03 Igol Antigel Type DB Igol France, Paris / Frankreich Labo FP 100 Labo Industrie, Nanterre / Frankreich Motul Anti-freeze Motul SA, Aubervilliers Cedex / Frankreich OMV-Kühlerfrostschutzmittel OMV AG, Schwechat / Österreich Organifreeze Total OZO Frostschutz S Total Deutschland GmbH, Düsseldorf / BRD Total Antigel S-MB 486 Total Deutschland GmbH, Düsseldorf / BRD Total Frostfrei Total Deutschland GmbH, Düsseldorf / BRD Veedol Antifreeze O Deutsche Veedol GmbH, Hamburg / BRD Wintershall Kühlerschutz Wintershall Mineralöl GmbH, Düsseldorf / BRD Presently approved anti corrosion / antifreeze fluids / 50:50 Premix (as of December 2003): (50 % water : 50 % corrosion/antifreeze fluids) Brand name Manufacturer Liebherr Anti-Freeze APN mix Id.Nr. 8611 045 - 20 l bundle LIEBHERR Caltex Extended Life Coolant Pre-Mixed 50/50 (ready-to-use-version) Caltex Chevron DEX-COOL Extended Life Prediluted 50/50 Antifreeze coolant Chevron Texaco Havoline XLC, 50/50 ARTECO Havoline DEX-COOL Extended Prediluted 50/50 Antifreece coolant Chevron Texaco Organicool 50/50 Total Presently approved anti corrosion / antifreeze fluids with DCA4 - ready to use (as of December 2003): Brand name Manufacturer Liebherr Anti-Freeze "pret a l'emploi" Id.Nr. 10 005 347 - 20 l bundle LIEBHERR The given anti corrosion / antifreeze fluids are approved for all Liebherr Diesel engines (with and without coolant filter / DCA4). 1.3.1 Coolant with DCA4 (DCA = Diesel Coolant Additive) The additive DCA4 is "used up" during use. The DCA4 concentration in the filter compensates for this loss accordingly, if there is no loss of coolant and the correct filter is used at the given change interval. The DCA4 concentration must be between 0.3 and 0.8 units per liter of coolant. To check, refer to the "Maintenance and inspection guidelines", section 3.4. For change intervals for filter and coolant, see ”Maintenance and inspection schedule” , section 3.2. If the cooling system is filled initially or refilled after repairs, then DCA 4 in liquid form must be added to the 50% anticorrosion / antifreeze and 50% water mixture. The mixture should be mixed outside the cooling system. Note the safety guidelines issued by the additive manufacturer.
  • 15. This results in a coolant mixture ration of approx. 48.5 % water, 48.5 % anticorrosion / antifreeze fluid and 3% DCA4. In addition, use a new coolant filter, according to the filling quantity. The correct Id. No. of the filter can be found in the Parts Manual or the Operation and Maintenance manual of the machine. Overview chart DCA4 and filter requirements (as of 2001) Coolant system contents Required quantity of liquid DCA 4 DCA 4 - water filter Liter Container approx.0.5 liter appr. liter Id. No. 24-39 3 oder 1,5 7367 045 40-59 4 oder 2,0 7381 493 60-79 5 oder 2,5 7367 052 80-115 8 oder 4 7367 052 Container liquid DCA4 at approx. 0.5 l -Id. No. 7363 898 Liebherr coolant (ready to use, 20 liter, above mixing ratio) - Id. No. 10 005 347 1.3.2 Coolant - special filling - with anti corrosion fluids, without antifreeze fluids In exceptional cases and if ambient temperatures are constantly above the freezing point, for example in tropical regional, where no anticorrosion / antifreeze fluids is proofed available, fresh water and water-soluble anticorrosion fluids (Inhibitors) may be used as coolant. Do not use coolant refiners (anticorrosion oils) with emulsifying capacity. If necessary, flush the cooling system before refilling. The fresh water quality must meet use with DCA4 - see chart ”Approved fresh water quality”. The coolant must be changed once a year. Use of DCA4 To provide sufficient protection against corrosion, approximately twice the amount of DCA4 must be used as compared to the above mixing ration, when using anticorrosion / antifreeze fluids and DCA4 - see above "overview chart and filter requirements". The DCA4 concentration must be between 0.6 and 1.06 units. It must be checked during maintenance work or when the coolant filter is changed, and corrected, as necessary. This results in a mixing ratio of max. 94 % fresh water and min. 6 % DCA4 additive Use of products from Caltex / Chevron Texaco / Havoline / Total To provide sufficient protection against corrosion with these products, a mixture of 92,5 vol.% coolant and 7,5 vol.% anti corrosion fluid must be kept. The mixture ratio must be checked during maintenance work and corrected, as necessary. The concentration of the anti corrosion fluid must not fall below 5 vol.% nor exceed 10 vol.%. Presently approved anti corrosion fluids (as of December 2003): Brand name Manufacturer DCA4 Diesel Coolant Additives Fleetguard Caltex CL Corrosion Inhibitor Concentrate Caltex Chevron Texaco Heavy Duty Extended Life Corrosion Inhibitor Nitrite Free Chevron Texaco Havoline Extended Life Corrosion Inhibitor (XLI) ARTECO Total WT Supra Total
  • 16. Benennung Description Dénomination Typ/ab Type/from Type/ a partir de Mjfcifss! LR 614 F/N xxx-6358 10719 Datum Edition Date 01 09 Service Items Blatt Page Feuille 01.3.10.04 2. Oil for hydraulic system In the hydraulic system, use only Diesel engine lube oils or special approved oils. 2.1. Oil quality 2.1.1 Approved engine oil classifications API - classification : CF-4, CG-4, CH-4, CI-4, (American Petroleum Institute) ACEA (CCMC) - classification : E2 (D4), E3 (D5), E4, E5, (Association des Constructeurs Européens de l´Automobile) Note: The API classifications CC, CD, CE and CF are now obsolete, however, in quality, they had been approved for use in the hydraulic system. 2.1.2 Special oils Approval is given for each machine type separately. Special guidelines are issued with the release. The following product presently considered to be an environmentally friendly hydraulic fluid: Panolin - HLP Synth - VG 46 2.2. Oil viscosity In addition to the quality, the oil must also provide a certain viscosity, the selection is made according to the SAE classification (Society of Automotive Engineers). The determining factor for the correct selection of SAE classification is the ambient temperature, single grade oils are preferred. If the viscosity is too high, it can cause cavitations, if it is too low, the lubrication efficiency may be endangered. Both can cause failure of hydraulic components. The temperature ranges shown in the following chart are guidelines. When operating the machine within the black temperature range, the following warm up procedure should be carried out. Viscosity for environmentally friendly hydraulic fluids according to ISO: VG 46 (covers SAE 10W and SAE 20W-20 or SAE 10W-30) For operation in extreme climate zones, such as arctic regions, special guidelines are available from the manufacturer. Warm up procedure: a) In temperatures up to 10° C below the given limit (black range) After starting, run the Diesel engine at medium speed. Warm up the hydraulic system by carefully actuating the hydraulic cylinders. Extend and retract the hydraulic cylinders fully for short periods. After 5 minutes, carefully engage the travel hydraulic as well. Total warm up period is approximately 10 minutes. b) At even lower temperatures: Before starting the Diesel engine, preheat the oil in the hydraulic tank, then proceed as described in paragraph a). Single grade oils Multi grade oils
  • 17. 3. Gear oil The lube oil specification for gears is based on API and SAE classification. The oil chamber in travel gears for double lifetime seal is filled with oil from the hydraulic system - see section 2. 3.1. Oil quality As a general rule, only oils meeting API - classification GL-5 may be used. 3.2. Oil viscosity The following oils must be used in travel gears, and are highly recommended for use in splitter boxes: Viscosity classification SAE 85 W - 140 EP For splitter boxes, oils of Viscosity classification SAE 90 EP or SAE 80 W - 90 EP may also be used. For the operation in extreme climatic conditions, such as in arctic regions or in extreme temperatures ranges, such as in slag applications, special oils may be approved if the prevailing ambient temperatures are known operations. 3.3. Lube oil for final drive - sealing chamber For oil quality and viscosity see section 2, Oil for hydraulic system, but do not use special oils. 4. Lube oil for support shaft bearing For oil quality and viscosity see section 2, Oil for hydraulic system, but do not use special oils. 5. Hoist gear oil - pipe layers As a general rule, the guidelines noted in the Operation and Maintenance manual and the winch manufacturer should be observed. For lubrication technical reasons, we recommend the use of Diesel lube oil, which meets at least one of the following quality and viscosity classifications. 5.1. Oil quality according to API - classification : CF, CF-4, CG-4, CH-4, CI-4, ACEA (CCMC) - classification : E2 (D4), E3 (D5), E4, E5, 5.2. Oil viscosity according to SAE - classification : 10W ISO - classification : VG 32 6. Grease 6.1. General lubrication points and track tensioner The grease must meet specification KP 2 k - consistency 2 according to NL GI - class and DIN 51818 and DIN 51825 or EP 2 according to NF-T-60 132 . The grease must also be lithium based, with a VKA value of at least 2300 N according to DIN 51350 or ASTM D 2596. 6.2. Long term grease / grease to protect against corrosion For the lifetime lubrication of bearing points of lift cylinder suspensions and to protect against corrosion at the initial installation of dry bearing points, to protect exposed piston rods, to prevent rust formation, etc., a special calcic, acid free grease should be used. We recommend LIEBHERR's special paste CTK - Id. No. 8613 313 01 For general conservation - see section 19, Conservation guidelines - other acid free anticorrosion grease may be used. 7. Miscellaneous Always observe all guidelines issued in the Operation and Maintenance manuals, repair manuals and on drawings. 7.1. Rubber seals on doors and covers Use silicon spray or Talcum powder. 7.2. Hydraulic cylinder installation Lubricant for threads of pistons, piston nuts and piston rod bearings - Liebherr High performance lubricant Id. No. 8300 004 Special protection against corrosion for installation of sealing elements - Liebherr Special anticorrosion grease Id. No. 8300 005
  • 18. Benennung Description Dénomination Typ/ab Type/from Type/ a partir de Mjfcifss! LR 614 F/N xxx-10720 Datum Edition Date 01 09 Service Items Blatt Page Feuille 01.3.11.01 Service Items see operation and maintenance manual.
  • 19. Benennung Description Dénomination Typ/ab Type/from Type/ a partir de Mjfcifss! Standard screws LR 614 F/N xxx- 6358 Datum Edition Date 02 07 Tightening Torques Factory standard WN 4037 I Blatt Page Feuille 1.4.01.01 The preload and tightening torques listed in the chart are from VDI guidelines 2230 of July 1986. Installation preload FM and tightening torques MA for shaft screws with metric standard or fine thread per DIN ISO 262 and DIN ISO 965 T2 (replacement for DIN 13 part 13) and screw head dimension of hex head screws with shaft DIN EN 24014 (replacement for DIN 931 part 1) or socket head screws DIN EN ISO 4762 (replacement for DIN 912). The chart values are valid for lubricated screws, surface black treated, phosphated or galvanic zinc plated and for dry screws, surface according to flZn - LH-Norm 10021432 (replaces DACROMET 500) Medium friction G = 0,12. Always observe the tightening torques and/ or procedures listed in drawings / parts lists, instructions of component descriptions, if noted, they override the factory standards listed in the torque charts. Never use a standard lock washer with 10.9 or 12.9 screws. If a washer is necessary, use only "heavy duty" washers, made from hardened material. Always use torque wrenches with the correct range - the upper third of the range should include the listed torque value according to the chart. When using impact screws, make sure that the given tightening torque is observed - should be checked before and during the tightening procedure with torque wrench (Nm x 0,7375 = ft.lbs.)! Preload forces and tightening torques for screws with standard metric thread according to factory standard WN 4037 I Wrench size (x) = per DIN931, forPreload values FM based on screw grades and are given in N Tightening torques MA are based on screw grades and are given in Nm Hex head screws Socket head screws Standard metric thread 8.8 10.9 12.9 8.8 10.9 12.9 mm Inch mm Inch M 4 x 0,7 4 050 6 000 7 000 2,8 4,1 4,8 7 9/32 3 -- M 5 x 0,8 6 600 9 700 11 400 5,5 8,1 9,5 8 5/16 4 5/32 M 6 x 1 9 400 13 700 16 100 9,5 14,0 16,5 10 -- 5 -- M 7 x 1 13 700 20 100 23 500 15,5 23,0 27,0 11 -- -- -- M 8 x 1,25 17 200 25 000 29 500 23 34 40 13 1/2 6 -- M 10 x 1,5 27 500 40 000 47 000 46 68 79 (17) 16 (11/16) -- 8 5/16 M 12 x 1,75 40 000 59 000 69 000 79 117 135 (19) 18 (3/4) -- 10 -- M 14 x 2 55 000 80 000 94 000 125 185 215 (22) 21 (7/8) -- 12 -- M 16 x 2 75 000 111 000 130 000 195 280 330 24 -- 14 9/16 M 18 x 2,5 94 000 135 000 157 000 280 390 460 27 1-1/16 14 9/16 M 20 x 2,5 121 000 173 000 202 000 390 560 650 30 1-3/16 17 -- M 22 x 2,5 152 000 216 000 250 000 530 750 880 (32) 34 -- 17 -- M 24 x 3 175 000 249 000 290 000 670 960 1120 36 1-7/16 19 3/4 M 27 x 3 230 000 330 000 385 000 1000 1400 1650 41 1-5/8 19 3/4 M 30 x 3,5 280 000 400 000 465 000 1350 1900 2250 46 1-13/16 22 7/8 M 33 x 3,5 350 000 495 000 580 000 1850 2600 3000 50 2 24 -- M 36 x 4 410 000 580 000 680 000 2350 3300 3900 55 2-3/16 27 1-1/16 M 39 x 4 490 000 700 000 820 000 3000 4300 5100 60 2-3/8 27 1-1/16
  • 20. Preload forces and tightening torques for screws with fine metric thread according to factory standard WN 4037 I Note: Observe notes on front page! Wrench size (x) = per DIN931, forPreload values FM based on screw grades and are given in N Tightening torques MA are based on screw grades and are given in Nm Hex head screws Socket head screws Fine metric thread 8.8 10.9 12.9 8.8 10.9 12.9 mm Inch mm Inch M 8 x 1 18 800 27 500 32 500 24,5 36 43 13 1/2 6 -- M 9 x 1 24 800 36 500 42 500 36 53 62 -- -- -- -- M 10 x 1 31 500 46 500 54 000 52 76 89 17 11/16 8 5/16 M 10 x 1,25 29 500 43 000 51 000 49 72 84 17 11/16 8 5/16 M 12 x 1,25 45 000 66 000 77 000 87 125 150 19 3/4 10 -- M 12 x 1,5 42 500 62 000 73 000 83 122 145 19 3/4 10 -- M 14 x 1,5 61 000 89 000 104 000 135 200 235 22 7/8 12 -- M 16 x 1,5 82 000 121 000 141 000 205 300 360 24 -- 14 9/16 M 18 x 1,5 110 000 157 000 184 000 310 440 520 27 1-1/16 14 9/16 M 18 x 2 102 000 146 000 170 000 290 420 490 27 1-1/16 14 9/16 M 20 x 1,5 139 000 199 000 232 000 430 620 720 30 1-3/16 17 -- M 22 x 1,5 171 000 245 000 285 000 580 820 960 32 -- 17 -- M 24 x 1,5 207 000 295 000 346 000 760 1090 1270 36 1-7/16 19 3/4 M 24 x 2 196 000 280 000 325 000 730 1040 1220 36 1-7/16 19 3/4 M 27 x 1,5 267 000 381 000 445 000 1110 1580 1850 41 1-5/8 19 3/4 M 27 x 2 255 000 365 000 425 000 1070 1500 1800 41 1-5/8 19 3/4 M 30 x 1,5 335 000 477 000 558 000 1540 2190 2560 46 1-13/16 22 7/8 M 30 x 2 321 000 457 000 534 000 1490 2120 2480 46 1-13/16 22 7/8 M 33 x 1,5 410 000 584 000 683 000 2050 2920 3420 50 2 24 -- M 33 x 2 395 000 560 000 660 000 2000 2800 3300 50 2 24 -- M 36 x 1,5 492 000 701 000 820 000 2680 3820 4470 55 2-3/16 27 1-1/16 M 36 x 3 440 000 630 000 740 000 2500 3500 4100 55 2-3/16 27 1-1/16 M 39 x 1,5 582 000 830 000 971 000 3430 4890 5720 60 2-3/8 27 1-1/16 M 39 x 3 530 000 750 000 880 000 3200 4600 5300 60 2-3/8 27 1-1/16
  • 21. Benennung Description Dénomination Typ/ab Type/from Type/ a partir de Mjfcifss! Standard screws LR 614 F/N xxx- 6358 Datum Edition Date 02 07 Tightening Torques Factory standard WN 4037 I Blatt Page Feuille 1.4.01.02 Tightening torques for screws for SAE split flange installation Not part of factory standard WN 4037 I Listing per LFR - Quality service 2QA 6 051 00 as of Oct. 2001 1. Flange and half flange for high pressure (Norm 62) 2. Half flange for low pressure (Norm 61) Tightening torques for oil drain plugs at travel gears Not part of factory standard WN 4037 I Listing per LBC - Quality service as of Oct. 2003 Oil drain plug thread size Tightening torque in Nm M 14x1,5 40 M 16x1,5 40 M 18x1,5 40 M 22x1,5 80 M 33x1,5 160 Tightening torques in Nm for screw grade 10.9 Flange nominal size Screw size Half flange flat flange without reinforcement Flange with reinforcement ½" M 8 31 -- -- ¾" M 10 62 45 65 1" M 12 108 70 110 1 ¼" M 14 172 120 180 1 ½" M 16 264 170 250 2" M 20 350 250 450 Tightening torques in Nm for Flange nominal size Screw size Screw grade 8.8 Screw grade 10.9 ½" M 8 22 31 ¾" M 10 44 62 1" M 10 44 62 1 ¼" M 10 44 62 1 ½" M 12 76 108 2" M 12 76 108 2 ½" M 12 76 108 3" M 14 122 172 3 ½" M 16 187 264 4" M 16 187 264 5" M 16 187 264
  • 22. Benennung Description Dénomination Typ/ab Type/from Type/ a partir de Mjfcifss! LR 614 F/N xxx- 6358 Datum Edition Date 04 08 Conversion table Blatt Page Feuille 1.4.02.01 Unit of Measure Multiply by To obtain Multiply by To obtain Length mm 0,039 inch 25,4 mm m 3,281 feet 0,305 m m 1,093 yard 0,914 m km 0,621 mile 1,609 km Area cm² 0,155 sq. inch 6,452 cm² m² 10,764 sq. feet 0,093 m² m² 1,196 sq. yard 0,836 m² km² 0,386 sq. mile 2,59 km² Volume cm³ 0,061 cu. inch 16,387 cm³ m³ 35,314 cu. feet 0,028 m³ m³ 1,308 cu. yard 0,764 m³ l 61,025 cu. inch 0,016 l l 0,035 cu. feet 28,316 l l 0,264 gallon 3,785 l l 1,057 quart 0,946 l Weight g 0,035 oz. 28,349 g kg 2,204 lbs. 0,453 kg t 1,102 short t 0,907 t Force N 0,225 lbs. 4,449 N kN 224,732 lbs. 0,0044 kN Torque Nm 0,737 ft. lbs. 1,356 Nm Power kW 1,342 HP 0,745 kW PS 0,736 kW 1,358 PS PS 0,986 HP 1,014 PS Pressure bar 14,5 PSI 0,069 bar (hydraulic) kpa 0,145 PSI 6,896 kpa Ground pressure kg/cm² 14,223 lbs. sq. inch 0,0703 kg/cm² kg/m² 0,205 lbs. sq. ft. 4,878 kg/m² Compression g/cm³ 0,036 lbs. cu. inch 27,78 g/cm³ kg/m³ 0,062 lbs. cu. ft. 16,13 kg/m³ Speed km/h 0,621 mph 1,609 km/h m/min 3,281 ft. / min 0,305 m/min Temperature °C (°Cx1,8) + 32 °F (°F-32)/1,8 °C °C °C+273 °K °K-273 °C
  • 23. Benennung Description Dénomination Typ/ab Type/from Type/ a partir de Mjfcifss! LR 614 F/N xxx-6358 Datum Edition Date 02 07 Hole diameter before tapping Blatt Page Feuille 01.4.03.01 1. Hole diameter for tapping ISO standard Metric (internal) thread Thread size Hole diameter limits max. min. Drill bit Ø M 1 0,785 0,729 0,75 M 1,1 0,885 0,829 0,85 M 1,2 0,985 0,929 0,95 M 1,4 1,160 1,075 1,1 M 1,6 1,321 1,221 1,25 M 1,7 1,346 1,258 1,30 M 1,8 1,521 1,421 1,45 M 2 1,679 1,567 1,6 M 2,2 1,838 1,713 1,75 M 2,3 1,920 1,795 1,9 M 2,5 2,138 2,013 2,05 M 2,6 2,176 2,036 2,10 M 3 2,599 2,459 2,5 M 3,5 3,010 2,850 2,9 M 4 3,422 3,242 3,3 M 4,5 3,878 3,688 3,7 M 5 4,334 4,134 4,2 M 6 5,153 4,917 5 M 7 6,153 5,917 6 M 8 6,912 6,647 6,8 M 9 7,912 7,647 7,8 M 10 8,676 8,376 8,5 M 11 9,676 9,376 9,6 M 12 10,441 10,106 10,2 M 14 12,210 11,835 12 M 16 14,210 13,835 14 M 18 15,744 15,294 15,5 M 20 17,744 17,294 17,5 M 22 19,744 19,294 19,5 M 24 21,252 20,752 21 M 27 24,252 23,752 24 M 30 26,771 26,211 26,5 M 33 29,771 29,211 29,5 M 36 32,270 31,650 32 M 39 35,270 34,670 35 M 42 37,799 39,129 37,5 M 45 40,799 40,129 40,5 M 48 43,297 42,587 43,0 M 52 47,297 46,587 47,0 M 56 50,796 50,046 50,5 M 60 54,796 54,046 54,1 M 64 58,305 57,505 57,6 M 68 62,305 61,505 61,6 Dimensions are in mm mm x 0,03937 = inches
  • 24. 2. Hole diameter for tapping ISO fine Metric (internal) thread Thread size Hole diameter limits max. min. Drill bit Ø M 1 x 0,2 0,821 0,783 0,8 M 1,1 x 0,2 0,921 0,833 0,9 M 1,2 x 0,2 1,021 0,983 1 M 1,4 x 0,2 1,221 1,183 1,2 M 1,4 x 0,25 1,185 1,129 1,15 M 1,6 x 0,2 1,421 1,383 1,4 M 1,8 x 0,2 1,621 1,583 1,6 M 2 x 0,25 1,785 1,729 1,75 M 2,2 x 0,25 1,985 1,929 1,95 M 2,5 x 0,35 2,201 1,121 2,15 M 3 x 0,35 2,721 2,621 2,65 M 3,5 x 0,35 3,221 3,121 3,15 M 4 x 0,5 3,599 3,459 3,5 M 4,5 x 0,5 4,099 3,959 4 M 5 x 0,5 4,599 4,459 4,5 M 5,5 x 0,5 5,099 4,959 5 M 6 x 0,75 5,378 5,188 5,2 M 7 x 0,75 6,378 6,188 6,2 M 8 x 0,75 7,378 7,188 7,2 M 8 x 1 7,153 6,917 7 M 9 x 0,75 8,378 8,188 8,2 M 9 x 1 8,153 7,917 8 M 10 x 0,75 9,378 9,188 9,2 M 10 x 1 9,153 8,917 9 M 10 x 1,25 8,912 8,647 8,8 M 11 x 0,75 10,378 10,188 10,2 M 11 x 1 10,153 9,917 10 M 12 x 1 11,153 10,917 11,1 M 12 x 1,25 10,912 10,647 10,8 M 12 x 1,5 10,676 10,376 10,5 M 14 x 1 13,153 12,917 13 M 14 x 1,25 12,912 112,647 12,8 M 14 x 1,5 12,676 12,376 12,5 M 15 x 1 14,153 13,917 14 M 15 x 1,5 13,676 13,376 13,5 M 16 x 1 15,153 14,917 15 M 16 x 1,5 14,676 14,376 14,5 M 17 x 1 16,153 15,917 16 M 17 x 1,5 15,676 15,376 15,5 M 18 x 1 17,153 16,917 17 M 18 x 1,5 16,676 16,376 16,5 M 18 x 2 16,210 15,835 16 M 20 x 1 19,153 18,917 19 M 20 x 1,5 18,676 18,376 18,5 M 20 x 2 18,210 17,835 18 M 22 x 1 21,153 20,917 21 M 22 x 1,5 20,676 20,376 20,5 M 22 x 2 20,210 19,835 20 M 24 x 1 23,153 22,917 23 M 24 x 1,5 22,676 22,376 22,5 M 24 x 2 22,210 21,835 22 Thread size Hole diameter limits max. min. Drill bit Ø M 25 x 1 24,153 23,917 24 M 25 x 1,5 23,676 23,376 23,5 M 25 x 2 23,210 22,835 23 M 26 x 1,5 24,676 24,376 24,5 M 27 x 1 26,153 25,917 26 M 27 x 1,5 25,676 25,376 25,5 M 27 x 2 25,210 24,835 25 M 28 x 1 27,153 26,917 27 M 28 x 1,5 26,676 26,376 26,5 M 28 x 2 26,210 25,835 26 M 30 x 1 29,153 28,917 29 M 30 x 1,5 28,676 28,376 28,5 M 30 x 2 28,210 27,835 28 M 30 x 3 27,252 26,752 27 M 32 x 1,5 30,676 30,376 30,5 M 32 x 2 30,210 29,835 30 M 33 x 1,5 31,676 31,376 31,5 M 33 x 2 31,210 30,835 31 M 33 x 3 30,252 29,752 30 M 35 x 1,5 33,676 33,376 33,5 M 36 x 1,5 34,676 34,376 34,5 M 36 x 2 34,210 33,835 34 M 36 x 3 33,252 32,752 33 M 38 x 1,5 36,676 36,376 36,5 M 39 x 1,5 37,676 37,376 37,5 M 39 x 2 37,210 36,835 37 M 39 x 3 36,252 35,752 36 M 40 x 1,5 38,676 38,376 38,5 M 40 x 2 38,210 37,835 38 M 40 x 3 37,252 36,752 37 M 42 x 1,5 40,676 40,376 40,5 M 42 x 2 40,210 39,835 40 M 42 x 3 39,252 38,752 39 M 42 x 4 38,270 37,670 38 M 45 x 1,5 43,676 43,376 43,5 M 43 x 2 43,210 42,835 43 M 45 x 3 42,252 41,752 42 M 45 x 4 41,270 40,670 41 M 48 x 1,5 46,676 46,376 46,5 M 48 x 2 46,210 45,835 46 M 48 x 3 45,252 44,752 45 M 48 x 4 44,270 43,670 44 M 50 x 1,5 48,676 48,376 48,5 M 50 x 2 48,210 47,835 48 M 50 x 3 47,252 46,752 47 M 52 x 1,5 50,676 50,376 50,5 M 52 x 2 50,210 49,835 50 M 52 x 3 49,252 48,752 49 M 52 x 4 48,270 47,670 48
  • 25. Benennung Description Dénomination Typ/ab Type/from Type/ a partir de Mjfcifss! LR 614 F/N xxx-6358 Datum Edition Date 01 09 Material weights Blatt Page Feuille 1.5.01.01 Material weights A Spec. weight 1) in kg/m 3 solid B Loosening in % C Loosening factor D Spec. weight kg/m 3 loose Material A B C D Anthracite coal - raw 1600 35 0,74 1190 - washed - 35 0,74 1100 Ash bituminous coal 590 - 890 8 0,93 550 - 830 Basalt 2970 52 0,66 1960 Bauxite, Kaolin 1900 33 0,75 1420 Bituminous coal - raw 1280 35 0,74 950 - washed - 35 0,74 830 Carnotite, Uranium ore 2200 35 0,74 1630 Soil - dry hardened 1900 26 0,79 1510 - wet loosened 2020 26 0,79 1600 - clay 1540 23 0,81 1250 Gypsum - broken 3170 75 0,57 1810 - ground 2790 75 0,57 1660 Granite - broken 2730 64 0,61 1660 Hematite, iron ore 2130 - 2900 18 0,85 1810 - 2450 Limestone - broken 2610 69 0,59 1540 - ground - - - 1540 Gravel - damp 2170 12 0,89 1930 - dry 1690 12 0,89 1510 - dry 6-50mm 1900 12 0,89 1690 - wet 6-50mm 2260 12 0,89 2020 Coke 860 54 0,65 1560 Loam, clay - seasoned 2020 22 0,82 1660 - dry 1840 24 0,80 1480 - wet 2080 24 0,80 1660 Clay with gravel - dry 1660 17 0,86 1420 - wet 1840 19 0,84 2540 Magnetite, iron ore 3260 17 0,86 2790 Topsoil 1370 44 0,69 950 Natural stone - ground 2670 67 0,60 1600 Pyrite, iron ore 3030 18 0,85 2580 Sand - dry, lose 1600 12 0,89 1420 - damp 1900 12 0,89 1690 - wet 2080 13 0,88 1840 Sand with clay - lose 2020 26 0,79 1600 - compressed - - - 2400 Sand with gravel - dry 1930 12 0,89 1720 - wet 2230 10 0,91 2020 Sandstone 2520 67 0,60 1510 Slate 1660 33 0,75 1250 Slag - broken 2940 68 0,59 1750 Snow - dry - - - 130 - wet - - - 520 Trapp rock - broken 2610 49 0,67 1750
  • 26. The actual values depend on the moisture content, the grain size and the compression. Testing is required to determine more exact values. Material A B C D Weathered rock 75% rock, 25% soil 2790 42 0,70 1960 Weathered rock 50% rock, 50% Soil 2280 33 0,75 1720 Weathered rock 25% rock, 75% Soil 1960 24 0,80 1570
  • 27. Benennung Description Dénomination Typ/ab Type/from Type/ a partir de Mjfcifss! Tools and LR 614 F/N xxx-6358 Datum Edition Date 02 07 Work instructions Blatt Page Feuille 2.0.00.01 Sub group index Tools and work instructions Special tools 2.1. Repair welding 2.2. Installation instruction 2.3 Installation instruction for duo cone (slipring) seals 2.3.01
  • 28. Benennung Description Dénomination Typ/ab Type/from Type/ a partir de Mjfcifss! Special tools LR 614 F/N xxx-6358 Datum Edition Date 01 09 Tools and work instructions Blatt Page Feuille 2.1.10.01 Special tools A. Special tools - Diesel engine Description Id. No. Remarks Illustration Digital RPM gauge „shimpo“ Reflexion strip 7364284 614063201 To measure the RPM via reflexion strips Test range: 6-8300 Rpm ±1 Rpm Use with „Shimpo“ Rpm gauge Optical charge tester 7408922 To check the battery charge condition and the antifreeze in the coolant V-belt test unit „Krikit2“ 8042829 To check the V-belt tension
  • 29. Description Id. No. Remarks Illustration Hand pump [1] Removal valve for oil samples [2] 8145666 7019068 To take oil samples for the oil analysis Oil analysis set – Mineral oil (green cover) Individual set 4 each set 6 each set 12 each set Oil analysis set – Bio oil (yellow cover) Individual set 6 each set 8145660 10029626 7018368 7018369 7026817 7026088 Analysis at WEAR CHECK Germany Compression test kit JT01674 7090894 To check the cylinder compression pressure. Use the adapter and the pressure gauge / hose components of the kit.
  • 30. Benennung Description Dénomination Typ/ab Type/from Type/ a partir de Mjfcifss! Special tools LR 614 F/N xxx-6358 Datum Edition Date 01 09 Tools and work instructions Blatt Page Feuille 2.1.10.02 Description Id. No. Remarks Illustration Flywheel turning tool JDE83 for LR 614 F/N xxx- 6358 10719 7090362 To turn the flywheel. Is required for valve clearance adjustment Flywheel turning tool JDG820 for LR 614 F/N xxx- 10720 7090361 To turn the flywheel. Is required for valve clearance adjustment Adjustment pin JDG1571 7090360 To hold the flywheel on OT to adjust the injection pump. Is required along with the JDE 83 or JDG 820 for valve clearance adjustment. Screw tap ½-13 UNC-2A JDG680 10490109 To recut threaded bores in the cylinder block Square cut insert for plug JDG782A 10490111 To install and remove the oil channel plug in the cylinder block
  • 31. B. Special tools – Hydraulic system Description Id. No. Remarks Illustration Vacuum pump cpl. with accessories Consists 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 7408148 7407987 7407985 10301165 7404619 4901110 7360127 10038447 10038448 7408151 For faster bleeding of hydraulic system, by enclosing the PVC hose, a slight excess pressure (approx. 0.4 bar) can be produced. The connection point for vacuum pump on the machine is the breather screw on the hydraulic tank. Connector fitting 10303657 For use with vacuum pump cpl. with accessories Temperature gauge 10024185 Accuracy: 2%/2° Test range: -18°C - +260°C Differential pressure Test set 230V/120V Consists of: Test unit Multi-Handy 2045 2 pressure sensors 0-600 bar 2 Mini test connections 2 test cables 12m long KFZ connector cable Data cable Power unit 10288229 To measure pressure, pressure peaks and pressure difference and suitable for data transfer to PC
  • 32. Benennung Description Dénomination Typ/ab Type/from Type/ a partir de Mjfcifss! Special tools LR 614 F/N xxx-6358 Datum Edition Date 01 09 Tools and work instructions Blatt Page Feuille 2.1.10.03 Description Id. No. Remarks Illustration 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 Accuracy: 1% of the scale end value All pressure gauges are „glycerine filled“ Pressure gauge connection R ½ 7002436 To seal at pressure tests, a square seal ring, Id. No. 7409794 must be used. Test hose NW 2 1,000 mm 1,500 mm 4,000 mm 5,000 mm 7002437 7002475 7009134 7363732 To keep loss of pressure during tests to a minimum, shorter test hoses are preferable Test fitting, cpl. R 6 L R 10 L R 12 L 7409916 7406864 7409918 Union nut and compression ring are affixed on the test fitting Screw coupling M 8x1 M 10x1 M 12x1.5 M 14x1.5 R ¼ 7615321 5608462 7409783 7406865 7409720 To connect to additional test points on the machine Screw coupling M 16x2 7407070 To connect shorter test lines or for connection between test connection and pressure sensor
  • 33. Description Id. No. Remarks Illustration Brake vent adapter 9401975 Adapter for air pressure cartridge (included in tool box) Air pressure cartridge 10045498 CO2 cartridge to vent the parking brake for towing operation Test plate A for SAE flange 3/4 Dimensions (in mm) A 90 B 40 C,r 5 Test plate B for SAE flange 1 Dimensions (in mm) A 90 B 44 C,r 5 Test plate C for SAE flange 1 1/4 Dimensions (in mm) A 90 B 52 C,r 5 7370 092 7370 093 7370 094 or made in house To close off high pressure connections Material: Ground spring steel Round off end of the plate Round off edges (simplifies installation, avoids damage to the seal ring)
  • 34. Benennung Description Dénomination Typ/ab Type/from Type/ a partir de Mjfcifss! Special tools LR 614 F/N xxx-6358 Datum Edition Date 01 09 Tools and work instructions Blatt Page Feuille 2.1.10.04 Note! The Id. No. for the following tools are in the spare parts list of the hydraulic cylinders. Assembly sleeve See Spare Parts List For installation of the O-ring and stepseal ring on the pistons of hydraulic cylinders Spreader sleeve See Spare Parts List For installation of the O-ring and stepseal ring on the pistons of hydraulic cylinders Installation wrench Piston See Spare Parts List To tighten the pistons of hydraulic cylinders For tightening torques, see section 8 Hydraulic cylinder Installation wrench Piston nut See Spare Parts List To tighten the piston nut of hydraulic cylinders For tightening torques, see section 8 Hydraulic cylinder
  • 35. C. Special tools – Electrical system Description Id. No. Remarks Illustration Digital multi meter cpl. with cable and bag 10018500 for Voltage (V) Amperage (A) Resistance ( ) and Frequency (Hz) tests Optical charge tester 7408922 To check the battery charge condition and the antifreeze in the coolant Hand crimper for „DEUTSCH“ plug connectors 8503647 To make proper crimp connections Removal tool Cannon For crimp contacts „DEUTSCH“ AWG 12 AWG 16 AWG 20 10114733 885563714 10114732 To remove pin and bushing contacts in „DEUTSCH“ plug connectors Crimper AMP AMP Certi-Lock 7415333 To crimp the „JUNIOR POWER TIMER“ contacts Removal tool AMP AMP 726 503-1 AMP 726,534-1 7370373 7027340 To remove contacts from the „JUNIOR POWER TIMER“ housing
  • 36. Benennung Description Dénomination Typ/ab Type/from Type/ a partir de Mjfcifss! Special tools LR 614 F/N xxx-6358 Datum Edition Date 01 09 Tools and work instructions Blatt Page Feuille 2.1.10.05 Description Id. No. Remarks Illustration Crimper ESA 0760 7409781 To crimp insulated cable shoes 0.5 -6.0 mm² For example cable connectors Crimper CRB 0560 7409782 To crimp non-insulated cable shoes 0.5 -6.0 mm² For example plug connectors on windshield wiper motor D. Special tools – Mechanical component groups Description Id. No. Remarks Illustration Test tool Track 7402603 For use, see section 12.2.
  • 37. Benennung Description Dénomination Typ/ab Type/from Type/ a partir de Mjfcifss! Repair welding LR 614 F/N xxx-6358 Datum Edition Date 02 10 Tools and instructions Blatt Page Feuille 2.2.01.01 Repair welding Before starting any welding work on PR Series 4 machines, 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 a crack The crack must be free of paint, grease and dirt. To prevent the crack from extending during the preparation or the welding process, the end of the cracks should be drilled with a hole of at least 0.32" (8mm) in diameter. The crack should now be ground, chiseled, torch cut or arced out at a 60° angle. Be certain the edges are clean and extend through the full cross section of the material, without exceeding the 0.04" (1 mm) space in the lower part. On larger grooves, a welding safety should be installed. Certain materials must be preheated to 300°F (150°C) prior to welding. Special preparations are necessary when preparing a crack in manganese steel. Due to its hardness, mechanical preparation, such as a chisel or hobbing machine is not possible. We suggest that the crack is prepared with a slow running and water cooled grinding wheel to prevent overheating. Other possibilities for preparing cracks or removing high alloy welding seams are the use of cutting electrodes of the type UTP 82 AS. 2. Preparation of a weld The area to be welded must be free of paint, grease, oil, moisture and dirt. During rain, the area to be welded must be covered. Materials with a thickness above 0.60" (15 mm), high carbon steel or steel which is difficult to weld, the material must be preheated to approximately 176°- 392°F (80°- 200°C). Pre-heating is also necessary when the ambient or component temperature is below 40°F (5°C) or when the construction of the component prevent the welding stress to be released. 3. Storing Electrodes Use only dry and undamaged electrodes. Electrodes which are rusty or damaged should not be used. Electrodes should be stored in a dry room with a minimum temperature of 59°F (15°C). Open packages should be carefully closed and stored after the welding work is completed.
  • 38. 4. Welding Technique The welding of material with the necessary electrodes (see table under paragraph 7) is in accordance with DIN 1912. The adjustment of the welding machine - dictated by the different thicknesses of the electrodes - can be taken from the table of the electrode package. Beginning with a material thickness of 1/4" (8 mm), butt welds must be made in several layers. The weld is applied in several beads. Wide butt welds are filled with several side by side beads, with the last layer covering the center. The electrode should melt evenly without creating burrs and peaks. The valley or crater, which is created when changing electrodes must be filled in and overlapped with the next electrode. To prevent cracks in those craters, care must betaken that they are properly filled. If the crack extends towards the outer edge of the material, slag may be trapped or burn holes may be created. To prevent this, the following aid may be used: Tack a piece of sheet metal to the outer edge of the material. The welding seam begins now at the sheet metal in the direction of the arrow. After the welding is completed, the sheet metal is removed and the edge of the material is ground smooth. The weld must cool off slowly and should therefore be protected from rain and wind. 5. Reinforcement of the welding seam If the crack of the material is due to an overload or abuse, a reinforcement plate should be welded over the crack. The selection of the correct reinforcement plate is based on the construction and load factors of the component to be repaired. For this reason, only general recommendations can be made as to the size and shape of the reinforcement plates. 6. General application of reinforcement plates 6.1. Shape of reinforcement plates The crossover or connection between the reinforced and not reinforced part should be as gradual as possible. This means that the size of the plate should be selected in such a way that new or unacceptable high stress in the repaired parts are avoided. Plates with sharp corners (such as a rectangular plate) should not be used. Suitable reinforcement plate with Suitable reinforcement plate against high tensile strength. bending and alternating loads.
  • 39. Benennung Description Dénomination Typ/ab Type/from Type/ a partir de Mjfcifss! Repair welding LR 614 F/N xxx-6358 Datum Edition Date 02 10 Tools and instructions Blatt Page Feuille 2.2.01.02 6.2. Plate Thickness The thickness of the reinforcement plate should be up to 2/3 (66%) of the thickness of the material to be reinforced. 6.3. Plate Quality The yield and tensile strength of the reinforcement plate should be equal to the material to be reinforced. 6.4. Plate Installation The welded area of the crack should be ground so it is smooth and level. The size of the plate must be selected in such a way that the longer sides of the plate extend into the connecting construction of the material to be reinforced. The plate should also overlap the crack on each side by at least 1" (20 mm). The correct position and fit of the reinforcement plate is achieved through clamping and spot welding. 6.5. Plate Welding The reinforcement plate should be welded on by running a welding bead alternately on both sides. The welding should always start in the middle of the plate and run towards the outside. Be certain to observe that each welding seam has proper run out. Direction of weld Direction of weld The size of the welding run "a" is figured out in reference to the thickness "k" of the reinforcement plate. Use formula: a=0,5 k Up to a welding run "a" of approx. 1/8" (3 mm) a single run can be made, however, as a general rule, a double run should be preferred. Above a welding run "a" of 1/8"(3 mm), the first run provides excellent penetration between the reinforcement plate and the basic material. Subsequent runs are added on top of the first run. After the welding is completed, clean the welding seam as necessary. Grind the run out between reinforcement plate and basic material.
  • 40. 7. Selecting the correct electrodes For repair welding, only lime based {Kb} electrodes should be used, and as a rule, the electrodes {additional material} should be "softer" than the basic material. Exceptions to this rule should be observed. Important: To reach the theoretical welding quality, the work must not only be performed in a professional manner, the electrode manufacturer's guidelines must absolutely be observed as well. Welding of vertical-down welds on steel components is not permissible! 7.1. Electrode Selection Welding area Material Electrode - norm description Protective gas welding wire norm description BASIC MACHINE Roller frame - Main frame St 52 - 3 QStE 380 N according to EN 499: E42 5 B 4 2 H5 according to AWS A5.1-91: E7018-1 H4 R according to EN 440: G4Si1 according to AWS A5.18-93: ER 70 S-6 LH 690 preheat to app. 100-150°C (210-300°F) according to EN 757: E 69 6 Mn2NiCrMo B 4 2 H5 according to AWS A5.5-96: E 11018-G according to EN 12534: G3CrNi1Mo according to AWS A5.28-96: ER110S-G Roller frame - Main frame/ bottom plates HARDOX 400 according to AWS A5.1-91: E7018-1 H4 R according to AWS A5.18-93: ER 70 S-6 ATTACHMENT Blade Bucket Q St E 380 N HARDOX 400 according to EN 499: E42 5 B 4 2 H5 according to AWS A5.1-91: E7018-1 H4 R according to EN 440: G4Si1 according to AWS A5.18-93: ER 70 S-6 St 52 - 3 according to EN 499: E42 5 B 4 2 H5 according to AWS A5.1-91: E7018-1 H4 R according to EN 440: G4Si1 according to AWS A5.18-93: ER 70 S-6 Push frame Bucket arm RL-Boom LH 690 preheat to app. 100-150°C (210-300°F) according to EN 757: E 69 6 Mn2NiCrMo B 4 2 H5 according to AWS A5.5-96: E 11018-G according to EN 12534: G3CrNi1Mo according to AWS A5.28-96: ER110S-G Ripper St 52 - 3 Q St E 380 N HARDOX 400 according to EN 499: E42 5 B 4 2 H5 according to AWS A5.1-91: E7018-1 H4 R according to EN 440: G4Si1 according to AWS A5.18-93: ER 70 S-6 WEAR ITEMS Root runs according to EN 499: E42 5 B 4 2 H5 according to AWS A5.1-91: E7018-1 H4 R Root runs according to EN 440: G4Si1 according to AWS A5.18-93: ER 70 S-6 Adapter, Tooth adapter Ripper Special steel Cover layers with high-strength electrode according to EN 1600: E 18 8 Mn B 2 2 according to AWS A5.4-92: E 307-15 Cover layers with high-strength electrode according to EN 12072: G 18 8 Mn according to AWS A5.9-93: ER307
  • 41. Benennung Description Dénomination Typ/ab Type/from Type/ a partir de Mjfcifss! Repair welding LR 614 F/N xxx-6358 Datum Edition Date 02 10 Tools and instructions Blatt Page Feuille 2.2.01.03 7.2. Steel Table Description Explanation Analysis HARDOX 400 Weldable, low alloy special steel highly wear resistant, tensile strength 1250 N/mm² yield strength 1000 N/mm² C 0,27% Si 0,7% Mn 1,6% Cr 1,4% Mo 0,6% Q St E 380 N Structural steel poured at low turbulence with a guaranteed minimum tensile strength of 500 - 640 N/mm² and minimum yield strength of 380 N/mm² C 0,18% Si 0,5% Mn 1,6% Special steel Highly abrasion resistant steel with a tensile strength of 1720 N/mm² C = 0,3% Mn = 0,7% Si = 0,5% Cu = 0,65% Mo = 0,3% V = 0,05% St 52 - 3 S355J2G3 Structural steel poured at low turbulence with a guaranteed minimum tensile strength of 510 N/mm² C 0,22% LH 690 Heat treated fine grain structural steel with a tensile strength of 770 - 940 N/mm² and yield strength of 690 N/mm² C 0,18% Si 0,50% Mn 1,5% Mo 0,5 % Ni 1,5 % lightly alloyed with V, AI and Cu 7.3. Welding addition chart 7.3.1 For arc welding Description Explanation Analysis - Value in % / Use according to EN 499: E42 5 B 4 2 H5 e.g. Böhler FOX EV 50 E = Arc welding, Rod electrode 42 = 500-640 N/mm² Tensile strength 5 = Value for resistance to impact B = Shielded metal arc 4 = Reference number for run out and type of flow 2 = Reference number for welding positions H5 = maximum hydrogen content C = 0,07, Si = 0,5, Mn = 1,1 For connection and application welding, especially for steel with low purity and higher carbon content. Weldable with direct current, electrode connected to plus terminal (+). No vertical seams according to EN 757: E 69 6 Mn2NiCrMo B 4 2 H5 e.g. Böhler FOX EV 85 E = Arc welding, Rod electrode 69 = 760-960 N/mm² Tensile strength 6 = Value for resistance to impact Mn2NiCrMo = Chemical composition B = Shielded metal arc 4 = Reference number for run out and type of flow 2 = Reference number for welding positions H5 = maximum hydrogen content C = 0,05, Si = 0,4, Mn = 1,5, Cr = 0,4, Ni = 2,0, Mo = 0,5 For welding, which require high viscosity and crack resistance. Use for high tensile refined fine-grained steel. Very low hydrogen content in weld metal. Weldable with direct current, electrode connected to plus terminal (+). No vertical seams according to EN 1600: E 18 8 Mn B 2 2 e.g. Böhler FOX A 7 E = Arc welding, Rod electrode 18 = 620-770 N/mm² Tensile strength 8 = Value for resistance to impact Mn = Chemical composition B = Shielded metal arc 2 = Reference number for run out and type of flow 2 = Reference number for welding positions C = 0,1, Si = 0,7, Mn = 6,5, Cr = 18,8, Ni = 8,8 For connections between various alloyed and steel which is difficult to weld. Weldable with direct current, electrode connected to plus terminal (+). No vertical seams
  • 42. 7.3.2 For MIG welding with solid electrodes: Description Explanation Analysis - Value in % / Use according to EN 440: G4Si1 e.g. Böhler EMK 8 G = MIG welding with solid electrodes 4 = 500-640 N/mm² Tensile strength Si = Chemical composition 1 = Reference number for run out and type of flow C = 0,1, Si = 1,0, Mn = 1,7 For connection and application welding, especially for steel with low purity and higher carbon content. Weldable with direct current, electrode connected to plus terminal (+). Protective gases: Argon + 15-20% CO2 or 100% CO2 No vertical seams according to EN 12534: G3CrNi1Mo e.g. Böhler X 70 - IG G = MIG welding with solid electrodes 3 = 900 N/mm² Tensile strength CrNi1Mo = Chemical composition C = 0,1, Si = 0,6, Mn = 1,6, Cr = 0,25, Ni = 1,3, Mo = 0,25, V = 0,1 For welding, which require high viscosity and crack resistance. Use for high tensile refined fine-grained steel. Weldable with direct current, electrode connected to plus terminal (+). Protective gases: Argon + 15-20% CO2 or 100% CO2 No vertical seams according to EN 12072: G 18 8 Mn e.g. Böhler A7 IG G = MIG welding with solid electrodes 18 = 580-730 N/mm² Tensile strength 8 = Value for resistance to impact Mn = Chemical composition C = 0,08, Si = 0,9, Mn = 7,0, Cr = 19,2, Ni = 9,0 For connections between various alloyed and steel which is difficult to weld. Weldable with direct current, electrode connected to plus terminal (+). Protective gases: Argon+max. 2,5% CO2 No vertical seams
  • 43. 1. Installation instructions 1.1. Slipring seals 1.1.1 Design and Function Due to the pretension of the O-rings 2, the two duo cone seals (sliprings) 3 are pressed together and therefore seal of the bearing point via the gliding surface 4. Seal variations: - Seal toward the outside - Seal toward the inside 1 Seal mount 2 O-ring 3 Slipring 4 Gliding surface Note! Only seals toward the outside are used in the machines of Series 4, because of design reasons. 1.1.2 Installation 1.1.2.1. General installation notes The sliprings of the seals are manufactured as pairs. For that reason, new as well as used seals may only be installed as original pairs. Avoid impacts and blows, which could damage the sealing surfaces of the chilled cast sliprings. Round off sharp edges on the seal mounts. Slipring seals and their receptacles must be absolutely clean and free of grease and oil for installation. O-rings may not be lubricated with oil. Caution! If the installation device is not used, the O-ring can roll up on the conical slipring surface. In case of one-sided installation pressure, the seal half and / or the O-ring can twist. These types of installation problems cause leaks as well as damage to the gliding surfaces. Benennung Description Dénomination Typ/ab Type/from Type/ a partir de LR 614 F/N xxx-6358 Mjfcifss! Datum Edition Date 01 09 Installation instructions Blatt Page Feuille 2.3.01.01
  • 44. Installation position correct Installation position incorrect Installation position incorrect O-ring twisted Seal half is crooked 1.1.3 Installation of the slipring seal allation aid, it is folded over slipring 3, transferring the pressure at installation with the appropriate installation aid into the seal mount 1. The required pressure must tring 6 can be inserted between the slipring 3 and 1 Seal mount 5 Installation device string Before the two seal mounts are assembled, check if the sliprings protrude evenly. Measure the distance from ase film. A split device 5 is used as inst directly to O-ring 2. Press the seal halves be exerted evenly onto the full circumference of the O-ring. If no suitable installation device is available, a round rubber s the O-ring 2 as a makeshift spacer and affixed by hand, so that the O-ring cannot roll up on the conical slipring surface when the seal half is pressed in. 2 O-ring 6 Aid – round rubber 3 Slipring the seal mount to the slipring on at least 3 locations around the circumference, 120° apart. Check the gliding surface again to ensure it is clean and lightly lubricated with a thin oil or gre
  • 45. 1.2. Safety lever 1 Safety lever 2 Hex nut 3 Hex nut 4 Limit switch To ensure a safe and error free function of the safety lever, observe the following for installation: Tighten the hex nut 2 to the tightening torque (see section 1.4) and then open by 1 to 1.5 turns. Tighten the hex nut 3 to the tightening torque (see section 1.4) and then open by 0.5 turn. 1.3. Tilt cylinder suspension When installing the tilt cylinders 5, make sure that the hex head screw 6 at the suspension of the change over lever 4 is tightened with a tightening torque of 670 ± 20Nm. 1 Main frame 2 Bucket 3 Bucket arm 4 Change over lever 5 Tilt cylinder 6 Hex head screw Benennung Description Dénomination Typ/ab Type/from Type/ a partir de LR 614 F/N xxx-6358 Mjfcifss! Datum Edition Date 01 09 Installation instructions Blatt Page Feuille 2.3.01.02
  • 46. Benennung Description Dénomination Typ/ab Type/from Type/ a partir de Mjfcifss! Technical data and LR 614 F/N xxx-6358 Datum Edition Date 02 07 Maintenance guidelines Blatt Page Feuille 3.0.00.01 Sub group index Technical data and maintenance guidelines Technical data 3.1 Maintenance and inspection schedule 3.2 Maintenance and inspection guidelines 3.3 Adjustment check list – short instructions 3.4 Adjustment check list 3.5
  • 47. LR 614 F/N xxx-6358 10719 DIESEL ENGINE Type D504 T (CD4045TF 277) version 4 cyl. in-line Performance per ISO 9249 kW 72 (98PS) Nominal RPM 1/min 2200 Low idle RPM 1/min 850 High idle RPM 1/min 2370 Displacement l 4,5 Oil quantity incl. filter l 14,7 Oil quality / viscosity See service fluids section 1.3 Max. machine incline - max. permissible all directions 35° = 78% / 30° constancy Valve clearance - cold On/off mm 0,36 / 0,46 Firing order 1-3-4-2 Coolant l 24 Fuel tank content l 180 SPLITTERBOX Type 250 B 270 Version 1-stage spur gear Ratio i 0,9107 Oil quantity l 1,75 Oil specifications / viscosity See Service fluids, section 1.3 HYDRAULIC SYSTEM Travel pumps – Travel hydraulic Type 2 x 90 L0 75 Max. flow - Q max. l/min 181,2 Max. operating pressure - p max bar 415 Gear pump - Replenishing circuit (2 pieces) Type SNP2 / 11 Max. flow - Q max./ piece l/min 48,3 Max. operating pressure (SP) - p max bar 28 Travel motors – Travel hydraulic Type 51 VO 80 Regulating pump – Working hydraulic Type CPB 30 Max. flow - Q max. l/min 115 at 2400 U/min Control valve block - Working hydraulic Type 08401604 SX14 Max. operating pressure (HD) p max. bar 230 Servo control - working hydraulic - operating pressure (ND) bar 28 Hydr. tank capacity l 126 Oil specifications/ viscosity See Service fluids, section 1.3 ELECTRICAL SYSTEM Operating voltage V 24 Batteries 2 x 12V 2 x 88Ah Alternator 45A Starter kW 4 Central fuse A 35 Individual fuses A See Operating Instructions TRAVEL GEAR Type left: AT 320547 / right: AT320548 Version 3-stage spur gear Parking brake integrated Disk brake Ratio i ges 52,127 : 1 Oil quantity l 2 x 8,75 Oil specifications/ viscosity See Service fluids, section 1.3 LR 614 F/N xxx-6358 10719 Typ/ab Type/from Type/a partir de Datum Edition Date 04 08 Blatt Page Feuille Benennung Description Dénomination 3.1.10.01 Technical Data Mjfcifss!
  • 48. LR 614 F/N xxx-6358 10719 TRACK COMPONENTS Chain pitch mm (inch) 170 (6.692) Chain length Links 38 Track pad width (2 grouser) mm 457 / 508 (with and without dirt hole) Track pad bolts Thread size 5/8“ UNF Track rollers, single flange, per side (s) Qty. 3 Track rollers, double flange, per side (d) Qty. 3 Track roller location s-d-s-d-d-s Track rollers per side Qty. 1 Track frame oscillation, max. Fixed WORKING ATTACHMENTS Lift cylinder Cyl. / Rod / Stroke mm 110 / 60 / 680 Tilt cylinder Cyl. / Rod / Stroke mm 130 / 70 / 385 Flap cylinder (4 in 1) Cyl. / Rod / Stroke mm 80 / 50 / 260 GENERAL Travel speed - full speed range km/h 0 9,6 Reduced speed range km/h 0 5,3 Basic machine: Height over cab mm 2998 Total length without attachment mm 3859 Track gauge (+1 x pad width = total width) mm 1600 Ground clearance mm 408 Fording depth max., measured horizontally mm 920 Operating weight with Standard bucket (depending on track pad widths)kg 11028 Ground pressure (according to track pad widths) kg/cm² 0,55 Operating weight with 4 in 1 Bucket (depending on track pad widths) kg 11590 Ground pressure (depending on track pad widths) kg/cm² 0,58 Standard bucket: Contents heaped (ISO 7546) m³ 1,20 Width mm 2300 Digging depth mm 130 Ripping force kN 100 Static tipping load kg 7088 Dumping height at45° mm 2679 Reach at45° mm 890 Weight kg 744,2 (with cat teeth installed) Total length of machine (without teeth) mm 5500 (with teeth) 4 in 1 Bucket: Contents heaped (ISO 7546) m³ 1,20 Width mm 2300 Digging depth mm 140 Ripping force kN 95 Static tipping load kg 7024 Dumping height at45° (Bucket) mm 2647 Reach at45° (Bucket) mm 908 Weight kg 1115 (with cat teeth installed) Total length of machine mm 5593
  • 49. LR 614 F/N xxx-10720 DIESEL ENGINE Type D504 TI (CD4045HF 289) version 4 cyl. in-line Performance per ISO 9249 kW 72 (98 HP) Nominal RPM 1/min 2200 Low idle RPM 1/min 1090 High idle RPM 1/min 2370 Displacement l 4,5 Oil quantity incl. filter l 12 Oil quality / viscosity See service fluids section 1.3 Max. machine incline - max. permissible all directions 35° = 78% / 30° constancy Valve clearance - cold On/off mm 0,36 / 0,46 Firing order 1-3-4-2 Coolant l 24 Fuel tank content l 210 SPLITTERBOX Type 250 B 270 Version 1-stage spur gear Ratio i 0,9107 Oil quantity l 1,75 Oil specifications / viscosity See Service fluids, section 1.3 HYDRAULIC SYSTEM Travel pumps – Travel hydraulic Type 2 x 90 L0 75 Max. flow - Q max. l/min 181,2 Max. operating pressure - p max bar 415 Gear pump - Replenishing circuit (2 pieces) Type SNP2 / 11 Max. flow - Q max./ piece l/min 48,3 Max. operating pressure (SP) - p max bar 28 Travel motors – Travel hydraulic Type 51 VO 80 Regulating pump – Working hydraulic Type CPB 30 Max. flow - Q max. l/min 115 at 2400 U/min Control valve block - Working hydraulic Type 08401604 SX14 Max. operating pressure (HD) p max. bar 230 Servo control - working hydraulic - operating pressure (ND) bar 28 Hydr. tank capacity l 102 Oil specifications/ viscosity See Service fluids, section 1.3 ELECTRICAL SYSTEM Operating voltage V 24 Batteries 2 x 12V 2 x 100Ah Alternator A 55 Starter kW 7 Central fuse A 35 Individual fuses A See Operating Instructions TRAVEL GEAR Type left: AT 320547 / right: AT320548 Version 3-stage spur gear Parking brake integrated Disk brake Ratio i ges 52,127 : 1 Oil quantity l 2 x 8,75 Oil specifications/ viscosity See Service fluids, section 1.3 LR 614 F/N xxx-10720 Typ/ab Type/from Type/a partir de Datum Edition Date 01 10 Blatt Page Feuille Benennung Description Dénomination 3.1.11.01 Technical Data Mjfcifss!
  • 50. LR 614 F/N xxx-10720 TRACK COMPONENTS Chain pitch mm (inch) 170 (6.692) Chain length Links 38 Track pad width (2 grouser) mm 457 / 508 (with and without dirt hole) Track pad bolts Thread size 5/8“ UNF Track rollers, single flange, per side (s) Qty. 3 Track rollers, double flange, per side (d) Qty. 3 Track roller location s-d-s-d-d-s Track rollers per side Qty. 1 Track frame oscillation, max. Fixed WORKING ATTACHMENTS Lift cylinder Cyl. / Rod / Stroke mm 110 / 60 / 680 Tilt cylinder Cyl. / Rod / Stroke mm 130 / 70 / 385 Flap cylinder (4 in 1) Cyl. / Rod / Stroke mm 80 / 50 / 260 GENERAL Travel speed - full speed range km/h 0 10 Reduced speed range km/h 0 6,5 Basic machine: Height over cab mm 2998 Total length without attachment mm 3859 Track gauge (+1 x pad width = total width) mm 1600 Ground clearance mm 408 Fording depth max., measured horizontally mm 920 Operating weight with Standard bucket (depending on track pad widths)kg 11100 Ground pressure (according to track pad widths) kg/cm² 0,56 Operating weight with 4 in 1 Bucket (depending on track pad widths) kg 11475 Ground pressure (depending on track pad widths) kg/cm² 0,58 Standard bucket: Contents heaped (ISO 7546) m³ 1,20 Width mm 2300 Digging depth mm 130 Ripping force kN 100 Static tipping load kg 7517 Dumping height at45° mm 2679 Reach at45° mm 890 Weight kg 744,2 (with cat teeth installed) Total length of machine (without teeth) mm 5585 (with teeth) 4 in 1 Bucket: Contents heaped (ISO 7546) m³ 1,20 Width mm 2300 Digging depth mm 140 Ripping force kN 95 Static tipping load kg 6988 Dumping height at 45° (Bucket) mm 2647 Reach at 45° (Bucket) mm 908 Weight kg 1115 (with cat teeth installed) Total length of machine mm 5653
  • 51. Customer:.............................................Machine-Type..............PIN.........-..............Hours...............Date............ Maintenance/Inspection at operating hours WORK TO BE CARRIED OUT by maintenance personnel by authorized trained personnel First and only interval First and only interval Repeat interval Repeat interval OM Operating instructions SM Service Manual For correct oil level, use test marks – for procedure and quantities, see OM For quality and viscosity guidelines, see “Service fluids” OM For adjustment values, see data page entries in SM Reference Notes DIESEL ENGINE Check oil level and oil pressure OM Check coolant level OM Check engine / cooling system and engine compartment for contamination / clean if necessary OM Check fuel water separator / empty if necessary OM Check / clean air filter service cover and dust discharge valve OM Change engine oil / first and only time before 100 hrs. - at least 1 x a year (regular interval 250 or 500 hrs. depending on oil specification) OM Change engine oil filter / first and only time at 100 hrs. - at least 1 x a year OM Check antifreeze ratio of coolant OM Check V/belt condition and tension OM Check oil, cooling and fuel system for leaks and condition OM Check intake and exhaust system - mounting and leaks OM Check engine mount Change fuel pre- and fine filter element OM Check engine RPM OM Replace coolant with antifreeze OM Check / adjust engine valve clearance – with cold engine SM Drain condensation and sediments from fuel tank - as necessary OM Replace air filter inserts - as necessary /once a year OM Clean air filter pre-separator - as necessary /once a year OM Replace oil separator - every 2 years OM HYDRAULIC SYSTEM Check oil level in hydraulic tank OM Clean magnetic ring (also after repairs) - up to 50 hrs. daily OM Replace main return filter inserts - or as soon as the indicator light lights up OM Replace pressure filter- replenishing circuit - or as soon as the indicator light lights up OM Check / clean oil cooler for contamination OM Check working and travel hydraulic system for function and leaks, check hose routing for chafing or damage OM SM Check / adjust all hydraulic pressures according to adjustment check list SM Check mountings and fittings for tight seating OM SM Replace oil in hydraulic system (add oil via filter) - at least every 4 years when using „environmentally friendly hydraulic oils“, request / observe special guidelines OM SPLITTERBOX Check oil level OM Replace gear oil - at least every 2 years OM LR 614 F/N xxx-6358 10719 Typ/ab Type/from Type/a partir de Datum Edition Date 04 08 Blatt Page Feuille Benennung Description Dénomination 3.2.10.01 Maintenance and Inspection schedule Mjfcifss!
  • 52. Maintenance/Inspection at operating hours ff WORK TO BE CARRIED OUT by maintenance personnel mit autorisiertem Fachpersonal First and only interval First and only interval Repeat interval Repeat interval OM Operating instructions SM Service Manual For correct oil level, use test marks – for procedure and quantities, see OM For quality and viscosity guidelines, see “Service fluids” OM For adjustment values, see data page entries in SM Reference Notes ELECRICAL SYSTEM Check function of system, incl. displays and instruments OM Check battery electrolyte level - at least 1 x a year OM Clean / check / grease battery terminals OM SM Check cable routing and connections OM SM Check /adjust all control system according to adjustment check list SM Check battery charge (before start of cold season) SM HEATER / VENTILATION / AIR CONDITIONING SYSTEM Check system for function and leaks OM Check air conditioning system antifreeze level and moisture indicator OM Replace fresh air filter and air circulation filter - as necessary OM Air conditioning system – inspection by expert HVAC personnel 1x a year TRAVEL GEAR Check oil level OM Check fittings for tight seating OM SM Replace gear oil OM TRACK COMPONENTS Check mounting screws and nuts of track components, especially track pad and sprocket segment screws for tight seating OM Check carrier rollers, track rollers, idlers for leaks OM Check / adjust idler guides, replace parts as necessary OM Adjust track tension to suit application - as necessary OM SM Clean travel gear - as necessary OM Check travel gear for wear - as necessary SM Working attachment Check cutting edges, bucket and ripper teeth for wear - make sure attachments are suited to application OM Check bucket attachment – stops and adjustment of limit switches OM Check screws, nuts and pin retainers for tight seating OM Check all bearing points for play / wear OM SM Check attachment for damage OM GENERAL Lubricate all bearing points according to lubrication chart Shorten interval as necessary OM Check complete machine for proper maintenance and condition OM SM Lubricate door hinges on operator’s cab - as necessary OM Explain machine documentation, especially operating instructions / safety guidelines to operating personnel OM
  • 53. Company:.................................................Machine Type..............S/N.........-..............Hrs................Date............ Maintenance / Inspection At operating hours WORK TO BE CARRIED OUT by maintenance personnel by authorized expert personnel first and only task first and only task Repeat interval Repeat interval OI Operating instructions SM Service manual For fill quantities, use the test marks - For instructions and quantities, see OI For quality and viscosity guidelines, see “Service items” OI See data in SM Instructions see: Remark s DIESEL ENGINE Check oil level and oil pressure OI Check coolant level OI Check the engine, cooler arrangement and engine compartment for contamination / clean OI Check the fuel water separator / empty if necessary OI Check the air filter service cover and dust discharge valve / clean OI Change the engine oil / first and only time before 100 hrs. - at least 1 x a year (Regular interval 250 or 500 hrs. depending on oil specification) OI Change the engine oil filter / first and only time before 100 hrs. - at least 1 x a year OI Check the crankcase breather system OI Check the electrical ground connection for the engine OI Check the corrosion inhibitor – antifreeze concentration in the coolant OI Check the V-belt condition and tension OI Check the oil, coolant and fuel system for leaks and condition OI Check the air intake and exhaust system – mounting and leaks OI Check the engine mounting Change the fuel pre- and fine filter cartridge OI Check the engine RPM OI Replace the coolant with antifreeze OI Check / adjust engine valve clearance - with cold engine SM Fuel tank, drain condensation and sediments - as necessary OI Replace air filter inserts - as necessary / annually OI Clean air filter pre-separator - as necessary / annually OI HYDRAULIC SYSTEM Check oil level in hydraulic tank OI Replace main flow return filter or immediately if the indicator light lights up OI Replace pressure filter replenishing circuit – or immediately if the indicator light lights up OI Check oil cooler for contamination / clean OI Check working and travel hydraulic system for function and leaks, check hose routing for chafing OI SM Check / adjust all hydraulic pressures according to adjustment check list SM Check mountings and fittings for tight seating OI SM Replace oil in hydraulic system - at least every 4 years - If using an “environmentally friendly hydraulic medium” request / observe special guidelines OI SPLITTERBOX Check oil level OI Replace gear oil - at least every 2 years OI LR 614 F/N xxx-10720 Typ/ab Type/from Type/a partir de Datum Edition Date 01 09 Blatt Page Feuille Benennung Description Dénomination 3.2.11.01 Maintenance and Inspection schedule Mjfcifss!
  • 54. Maintenance / Inspection At operating hours ff WORK TO BE CARRIED OUT by maintenance personnel by authorized expert personnel first and only task first and only task Repeat interval Repeat interval OI Operating instructions SM Service manual For fill quantities, use the test marks - For instructions and quantities, see OI For quality and viscosity guidelines, see “Service items” OI See data in SMfff Instructions see: Remark s ELECTRICAL SYSTEM Check function of system incl. displays and instruments OI Check battery acid level - at least 1x annually OI Clean / check / grease battery connections OI SM Check cable routing and connections OI SM Check / adjust control system according to adjustment check list SM Check battery charge condition (before start of cold season) SM HEATER / VENTILATION / AIR CONDITIONING SYSTEM Turn the air conditioning system on regularly - at least 1x in 14 days OI Check water discharge valve of air cond. system, clean as necessary OI Check system for function and leaks OI Check condenser for contamination - blow out as necessary OI Clean air circulation fresh air filter, replace as necessary, in dusty conditions, shorten maintenance interval OI Check mounting screws and drive belt of air cond. compressor OI Check dryer unit (moisture, fill, condition) - replace dyer unit and moisture indicator as necessary, evacuate system and refill OI Clean water drain valve of air conditioning system OI Check evaporator unit, clean as necessary OI Check electrical lines for chafing and plug connections for tight seating OI Air conditioning system – have inspected by HVAC technician - 1x annually TRAVEL GEAR Check oil level OI Check fittings for tight seating OI SM Replace gear oil OI TRACK COMPONENTS Check mounting screws and nuts of track components, espec. track pad and sprocket segment screws for tight seating OI Check all track components for leaks OI Check / adjust idler guides, replace parts as necessary OI Adjust chain tension to suit working application - as necessary OI SM Clean tracks - as necessary OI Check track wear - as necessary SM WORKING ATTACHMENTS Check cutting edges, end bits and ripper tooth tips for wear - make sure attachments are suited for application OI Check screws, nuts and pin retainers for tight seating OI Check bucket stops OI Check all bearing points for play / wear OI SM Check attachment for intentional damage OI GENERAL Lubricate all bearing points according to lubrication schedule - shorten interval as necessary OI Check entire machine for correct maintenance and proper condition OI SM Explain machine literature, especially the Operating instructions / Safety guidelines to operating personnel OI Lubricate operator’s cab – door hinges - as necessary
  • 55. Benennung Description Dénomination Typ/ab Type/from Type/ a partir de Mjfcifss! Maintenance and LR 614 F/N xxx-6358 Datum Edition Date 01 09 Inspection guidelines Blatt Page Feuille 3.3.10.01 1. General guidelines 1.1. Documentation for work to be carried out For work to be performed, refer to the Maintenance and inspection schedule for your particular machine model – see section 3.2. Check 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 3.5. 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 company. 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 section 1.2 and 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: Changing filters, draining condensation and sediments in case of dirty fuel; cleaning the radiator in case of contamination; changing filters and oils during or after repairs, etc. Dispose of oil oils, filters and other waste products properly! 1.4. General Use only LIEBHERR Original spare and maintenance parts for all maintenance, inspection and repair work. If the operator requests other on hand parts for installation, then this must be noted separately on the inspection check lists by noting possible loss of warranty. For general screw tightening torques, see section 1.4. For tightening guidelines for track chain pads and sprocket segment bolts, see section 12.1.
  • 56. 2. Maintenance and inspection guidelines 2.1. Inspection work on the Diesel engine 2.1.1 Check / adjust valve clearance Preparation for test Make sure that: The machine is in maintenance position. The battery master switch (optional) is turned off or the negative cable is disconnected from the battery. The Diesel engine is cold. Special tools are available (turning tool – flywheel, adjustment pin, see section 2.1.) If necessary, have new gaskets for the cylinder head covers ready for use. Procedure: Remove the rocker lever cover and the crankcase vent pipe. Note! Visually inspect the contact surfaces of the valve tips, valve bridges and rocker lever wear surfaces. Check all parts for excessive wear, breakage and cracks. Replace any parts which show visible damage. Rocker levers, which show excessive valve clearance should be checked closely to determine damaged parts. Replace valves, seats, springs and retainers in pair per cylinder if they are damaged. In addition, replace the bridge if one of these parts is being replaced. Remove the plastic plug or the cover plate from the engine adjustment / rotary opening (A) and the adjustment pin opening (B) on the flywheel side. With the special tool “Turning device – flywheel“ turn the engine flywheel in direction of rotation (when viewed from the front, turn it in clockwise direction until the cylinder No. 1 is on the top dead center (TDC) of the compression stroke. Insert the special tool „adjustment pin“ into the flywheel.
  • 57. Benennung Description Dénomination Typ/ab Type/from Type/ a partir de Mjfcifss! Maintenance and LR 614 F/N xxx-6358 Datum Edition Date 01 09 Inspection guidelines Blatt Page Feuille 3.3.10.02 Note! If the rocker levers of cylinder No. 1 can be moved, then the engine is on the TDC of No. 1 in the compression stroke. If the rocker levers of cylinder No. 1 cannot be moved, turn the engine a complete rotation (360°) to the TDC No. 1 of the compression stroke. When the engine is held with the adjustment pin on the TDC of the compression stroke of piston No. 1, check the valve clearance according to the following specification. Adjust valve clearance Note! If the valves must be adjusted, release the counter nut (A) on the rocker lever adjustment screw. Prevent the adjustment screw from turning with a screw driver and tighten the counter nut according to specifications. After tightening the counter nut, check the clearance again. Readjust the clearance, if necessary. A = Outlet valve E = Intake valve Specifications Test dimension Adjustment dimension Intake valve clearance (rocker lever to valve bridge) [engine cold] – clearance 0.31 – 0.38 mm 0.36 mm Exhaust valve clearance (rocker lever to valve bridge) [engine cold] – clearance 0.41 – 0.48 mm 0.46 mm Counter nut of rocker lever adjustment screw Torque 27 Nm
  • 58. Four cylinder engine: Note! The firing order is 1-3-4-2. Piston No. 1 on the top dead center (TDC) of the compression stroke: Hold the piston No. 1 with the adjustment pin on the TDC of the compression stroke. Adjust the valve clearance on the exhaust valves No. 1 and 3. Adjust the valve clearance on the intake valves No. 1 and 2. Piston No. 4 on the top dead center (TDC) of the compression stroke: Turn the crankcase by 360°. Hold the piston No. 4 on the TDC of the compression stroke. Adjust the valve clearance on the exhaust valves No. 2 and 4. Adjust the valve clearance on the intake valves No. 3 and 4. Attach the rocker lever cover and the crankcase vent pipe.
  • 59. Benennung Description Dénomination Typ/ab Type/from Type/ a partir de Mjfcifss! Maintenance and LR 614 F/N xxx-6358 Datum Edition Date 01 09 Inspection guidelines Blatt Page Feuille 3.3.10.03 2.2. Inspection work on the hydraulic system 2.2.2 Check the working and travel hydraulic system for function and leaks, check hose routing for chafing, check mountings and fittings for tight seating Carry out all travel and working movements and check for malfunction. Check the actuator plate, plunger and universal joint of the working hydraulic pilot control for wear, grease lightly and adjust, if necessary. The same applies for pilot control for auxiliary equipment. To inspect the pressure accumulator – safety control – working hydraulic, start the Diesel engine and raise the front attachment. Turn the engine off (return the ignition key again to position 1) and leave the safety lever in the down position. Actuate the function “down” several times jerkily. If the attachment moves down less than four times, then the accumulator is defective or there is excessive leakage in the system. Check the hose lines for leaks and kink-free routing. Watch for chafe marks. Replace chafed, “sweating” or aging hoses. Refer to the Safety guidelines, Section 1.2. 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. Retighten, if necessary. 2.2.3 Check / adjust all hydraulic pressures Carry out tests / adjustments according to the adjustment check list for the respective machine type – see section 3.5 – and enter the results. For detailed descriptions, data and instructions, see adjustment check list or corresponding sub group in the Service Manual.
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