LIEBHERR RL64 PIPE LAYER SERIES 4 LITRONIC Service Repair Manual

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  
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    

Service Manual
Index
RL Litronic Serie 4 MJFCIFSS! 0.1.00 - 1 / 4
LWT/Ausgabe/Edition/Edition/03.2010
0.1.00 Index
Section Title
Date of
issue
0.1.00 Index 03.2010
1.0.00 Sub group index "General" 01.2008
1.1.00 Foreword and explanation 01.2008
1.2.00 Safety regulations 05.2008
Charts
1.3.01 Tightening torques 05.2008
1.3.02 Conversion tables 01.2009
1.3.03 Tapping holes 01.2008
1.4.00 Conservation guidelines 02.2010
1.5.00 Material weights 03.2009
2.0.00 Sub group index "Tools and work instructions" 01.2008
2.1.00 Special tools 03.2010
2.2.00 Repair welding 03.2010
2.3.00 Installation instructions 03.2010
3.0.00 Sub group index "Technical data and maintenance guidelines" 01.2008
3.1.40 Technical data 06.2008
3.1.60 Technical data 06.2008
3.2.00 Maintenance and inspection schedule 03.2010
3.3.00 Maintenance and inspection instructions 03.2009
3.4.40 Adjustment checklist 03.2010
3.4.60 Adjustment checklist 03.2010
3.5.00 Test and adjustment tasks 03.2010
4.0.00 Sub group index "Engine" 01.2008
4.1.40 Data page 01.2008
4.1.60 Data page 05.2008
4.2.00 Fan and cylinder arrangement 05.2008
5.0.00 Sub group index "Coupling and splitterbox" 01.2008
5.1.00 Data page 05.2008
5.2.40 Coupling 05.2008
5.2.60 Coupling 05.2008
5.3.40 Pump distributor gear 01.2008
5.3.60 Pump distributor gear 05.2008
5.4.40 Coupling Pump output 05.2008
5.4.60 Coupling Pump output 06.2008
6.0.00 Sub group index "Travel hydraulic" 01.2008
6.1.00 Data page 05.2008
6.2.40 Design 06.2008
6.2.60 Design 06.2008
6.3.40 Function 01.2009
6.3.60 Function 01.2009
6.4.00 Repair work and troubleshooting 05.2008
6.5.40 Component arrangement 01.2008
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Service Manual
Index
RL Litronic Serie 40.1.00 - 2 / 4 Mjfcifss!
Section Title
Date of
issue
7.0.00 Sub group index "Working hydraulic" 01.2008
7.1.00 Data page 05.2008
7.2.00 Design 05.2008
7.3.00 Function 02.2010
7.4.00 Repair work and troubleshooting 05.2008
8.0.00 Sub group index "Hydraulic components" 01.2008
8.1.40 Var. displacement pump 01.2008
8.1.60 Var. displacement pump 01.2009
8.2.40 Var. displacement motor 01.2008
8.2.60 Var. displacement motor 05.2008
8.3.00 Regulating pump – Working hydraulic 05.2008
8.4.40 Double gear pump – replenishing / fan drive 05.2008
8.4.60 Double gear pump – replenishing 05.2008
8.5.40 Gear motor – fan drive 05.2008
8.5.60 Gear motor – fan drive 05.2008
8.6.00 Pilot control – working hydraulic 01.2008
8.7.00 Control valve block 05.2008
8.8.00 Valves 02.2009
8.9.00 Hydraulic cylinder 05.2008
8.10.00 Control motor hoist gear – winch 05.2008
9.0.00 Sub group index "Electrical system – Diagrams and components" 05.2008
9.1.40 Wiring diagram, component description, function list 01.2010
9.2.00 Instrument panel 05.2008
9.4.00 Joystick 02.2010
9.5.00 Inching- / brake pedal 02.2009
10.0.00 Sub group index "Electrical system - descriptions" 01.2009
10.1.00 Diagnostics software LinDiag 01.2010
10.2.00 Software PDL – Diesel particle filter 01.2010
11.0.00 Sub group index "Final drive" 01.2008
11.1.40 Data page 05.2008
11.1.60 Data page 05.2008
11.2.40 Design and Function 01.2008
11.2.60 Design and Function 05.2008
11.3.40 Sectional view - final drive 01.2008
11.3.60 Sectional view - final drive 01.2009
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Service Manual
Index
RL Litronic Serie 4 MJFCIFSS! 0.1.00 - 3 / 4
Section Title
Date of
issue
12.0.00 Sub group index "Track components" 01.2008
12.1.00 Data page 05.2008
12.2.00 Design, function, wear and evaluation 01.2008
12.3.00 Test report 01.2010
12.3.01 Wear chart 01.2009
12.4.40 Track roller frame and idler unit 05.2008
12.4.60 Track roller frame and idler unit 03.2010
12.5.00 Track roller 01.2008
12.6.00 Carrier roller 01.2008
12.7.40 Tension unit 06.2008
12.7.60 Tension unit 06.2008
13.0.00 Sub group index "Working attachment – front side" 01.2008
14.0.00 Sub group index "Working attachment" 01.2008
14.1.00 Hoist gear 05.2008
14.2.00 Rope winch 02.2009
15.0.00 Sub group index "Main frame – Components" 01.2008
15.1.40 Cooler arrangement 01.2008
15.1.60 Cooler arrangement 05.2008
15.2.40 Equalizer bar 01.2008
15.2.60 Equalizer bar 05.2008
15.3.40 Engine mounting 01.2008
15.3.60 Engine mounting 05.2008
16.0.00 Sub group index "Tank arrangements" 01.2008
16.1.40 Hydraulic tank 05.2008
16.1.60 Hydraulic tank 05.2008
16.2.40 Fuel tank 01.2008
16.2.60 Fuel tank 05.2008
16.3.40 Battery compartment 01.2008
16.3.60 Battery compartment 02.2009
17.0.00 Sub group index "Operator’s platform, heater, air conditioning system" 01.2008
17.1.00 Operator’s platform 01.2008
17.2.00 Heater with blower 01.2008
17.3.00 Air conditioning system 01.2008
17.4.00 Operator’s seat – air cushioned 01.2008
17.5.00 Throttle control 05.2008
18.0.00 Sub group index "Special equipment" 01.2009
18.1.00 Refueling pump 03.2009
18.3.00 Add-on installations – Pipe chamfering device and welding generator 01.2009
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Service Manual
Index
Section Title
Date of
issue
19.0.00 Sub group index "Additional documentation" 01.2008
6.3.40 Schematic – Travel hydraulic 05.2008
6.3.60 Schematics – Travel hydraulic 05.2008
7.3.40 Schematic – Working hydraulic 02.2010
7.3.60 Schematic – Working hydraulic 02.2010
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Service Manual General
Sub group index - General
RL Litronic Series 4 MJFCIFSS! 1.0.00 - 1 / 2
1 General
1.0.00 Sub group index - General
Foreword and explanations ......................................................................... 1.1
Safety regulations ......................................................................................... 1.2
Charts............................................................................................................. 1.3
Tightening torques............................................................................................................1.3.01
Conversion tables.............................................................................................................1.3.02
Tapping holes ...................................................................................................................1.3.03
Conservation guidelines............................................................................... 1.4
Material weights............................................................................................. 1.5
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Foreword and explanation
1.1.00 Foreword and explanation
1 For information
This manual contains technical data, design and functional descriptions, work and adjustment
instructions as well as numerous drawings, functional views and illustrations for the
LIEBHERR – Pipe layers (RL) of Series 4.
This manual should simplify competent customer service of our products, however, it does not
replace expert and qualified user training and attendance of our factory training classes.
Generally valid technical basic information is not listed. Refer to separate documentation for
operational and spare parts information.
The manual will be updated and expanded as necessary when changes occur in series.
For all tasks on the machine, accident prevention guidelines and safety guidelines must be
strictly observed.
This manual is solely for the own use of the registered owner and may not be duplicated or
copied, complete or in part, nor passed on to a third person and remains the property of
LIEBHERR-Werk Telfs GmbH.
All rights reserved. – Printed in Austria.
We reserve the right to make changes of technical details on the machine in comparison to the
information and illustrations in this manual.
Written and published by
LIEBHERR-Werk Telfs GmbH., Technical Documentation Dept.
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General Service Manual
Foreword and explanation
RL Litronic Series 41.1.00 - 2 / 2 Mjfcifss!
2 Explanation of layout
To simplify finding certain information and filing of updates, we set up the following layout:
Main group
Component (item) groups
according to register
Type group
Structure based on
information content or
machine size
Sub group
Structure of main group
according to sub group index
Page number
Continuous No. and
complete number of
pages within the type
group
It is possible that other continuous numbers are listed after the continuous number, for example
9.4.20 - 13/15 - 02. This number is for supplements, especially for electrical schematics, where
only one page is supplemented.
Changes are supplied with the same number, but with a later date, supplements are assigned a
new number. If only one page is valid for a certain machine group, then this is noted in the
header.
Note!
This symbol is used in the manual for very important safety notes.
This symbol identifies a standard listing.
This symbol signifies the following: “The prerequisite must be met”.
The maintenance personnel must first fulfil the precondition described, i.e. the machine must
be brought into a particular work position in order to be able to carry out the actions
subsequently described.
This symbol identifies an action.
The maintenance personnel should be active at this location and carry out the action
described.
This symbol identifies a result.
The maintenance personnel is notified that a result will occur after a working step, for
example, after the test knob is pressed, the LED light lights up.
This note shows that a detail view of an illustration is shown
rotated by a given angle, as compared to the actual installation
position. (In this case 180°)
We hope that with the supplied information we have taken yet another step to improve service
on the LIEBHERR crawler dozers, crawler loaders, pipe layers and telescopic handlers.
LIEBHERR-Werk Telfs GmbH.
Technical documentation
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Safety guidelines
1.2.00 Safety guidelines
1 Introduction
Prior and during the performance of tests / inspections, adjustments and repairs, it is
imperative that the following safety guidelines are observed:
Any type of work may only be carried out by qualified expert personnel or under their guidance
and supervision.
Qualified expert personnel are persons, who, based on their specialized training and experience,
have sufficient knowledge in the area of earthmoving equipment and the specific technology of
our machines in particular and who are familiar with all applicable laws and general work
protection regulations, accident prevention guidelines, regulations, guidelines and generally
approved rules concerning technology so that they are able to evaluate if the earthmoving
equipment is safe to operate and if the necessary work can be performed without endangering
themselves or third persons.
Machines with raised operator’s platform may not be driven! The machine may only be operated
from a lowered and secured operator’s platform!
Always adhere to the adjustment values noted in the LIEBHERR documentation when
performing adjustment work.
At the delivery of a machine, the operating personnel must be trained using the current operating
instructions. The safety guidelines noted in the instructions must be particularly observed.
These safety guidelines must also be observed during inspection, adjustment or repair work.
However, there are special repair and / or inspection work which require qualified personnel to
follow another procedure than that noted in the safety guidelines. In such cases, qualified
personnel or individuals performing the work under the supervision of such personnel should
assure that additional safety precautions necessary to insure the safety of those involved in the
repair are taken. The decision to carry out this measure can only be made by qualified expertly
trained personnel. Such items of repair and/ or inspection work include, but are not limited to the
following:
- Opening the side doors while the Diesel engine running to carry out tests and / or
adjustments.
In these cases, care should be taken that the side engine compartment doors are properly
secured during the entire duration of the work to prevent them from closing unexpectedly
and / or inadvertently. Care should be exercised to assure that there will be no inadvertent
or unintended contact of any part of the body with any moving and / or heated parts of the
engine. Wear only tightly fitted clothing (no scarves, no tie, no wide sleeves, etc.)
- Starting the Diesel engine with tilted operator’s platform, as well as actuating the travel
drive with properly raised machine for adjustment, repair or diagnostics purposes. In these
cases, before starting the engine, the support of the operator’s platform support as well as
the support for the machine and the required ground clearance for the track chains must
be checked again.
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Safety guidelines
2 Danger notes in this manual
For description of work, which can pose a danger for man or machine, the required safety
precautions are described in this manual.
They are marked by the following notes:
Danger!
Warns that certain working procedures without appropriate precautionary measures can result
in fatal injuries.
Warning!
in severe bodily injuries.
Caution!
in bodily injuries or damage to the machine.
Following these notes does not relieve you of the responsibility for following additional
rules and guidelines!
Additional points that should be noted are:
the safety regulations which apply on the jobsite,
statutory “road traffic regulations”,
the guidelines provided by professional associations.
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Safety guidelines
3 Safety guidelines in the operating instructions
The detailed descriptions for the following safety guidelines are noted in the operating
instructions of the machine and must be strictly observed.
2.1 Introduction
2.2 Designated use
2.3 Signs on the machine
2.4 Safety guidelines
2.4.1 General safety guidelines
2.4.2 Crushing and burn prevention
2.4.3 Fire and explosion prevention
2.4.4 Safety guidelines for machine start up
2.4.5 Engine start up safety
2.4.6 Machine operating safety
2.4.7 Safety guidelines for working with the machine
2.4.8 Working in the vicinity of electrical overhead lines
2.4.9 Machine parking safety
2.4.10 Machine transporting safety
2.4.11 Machine towing safety
2.4.12 Machine maintenance safety
2.4.13 Safety guidelines for welding work on the machine
2.4.14 Safety guidelines for working on the attachment
2.4.15 Safety guidelines when loading the machine with a crane
2.4.16 Safe maintenance of hydraulic hoses and hose lines
2.4.17 Safety guidelines for maintenance work on machines with hydro accumulators
2.4.18 Roll over protection (ROPS) and falling object protection (FOPS)
2.4.19 Equipment and attachment parts
2.4.20 Protection from vibrations
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Tightening torques
1.3.01 Tightening torques
1 General information
The preload values and the tightening torques noted in the chart have been taken from the VDI
(Association of German Engineers) guidelines 2230 of July 1986.
Installation preload values FM and tightening torques MA for shoulder studs with standard metric
or fine thread per DIN ISO 262 and DIN ISO 965 T2 (replacement for DIN 13 part 13) and
wrench sizes for hex head screws with shaft DIN EN 24014 (replacement for DIN 931 part 1) or
socket head screws DIN EN ISO 4762 (replacement for DIN 912)
The chart values are valid for screws with surface:
- black or phosphated – oiled
- zinc plated – oiled
- flZn according to LH standard 10021432 - dry (replaces DACROMET 500).
Medium friction value G = 0.12
Note!
Any tightening torque values and/ or tightening procedures noted in drawings / parts
lists, instructions or component descriptions must be adhered to and given preference
over factory standards.
Beginning with grade 10.9, no additional safety effect is provided when using lock washers
Always use correctly sized torque wrenches – the torque value according to the chart should be
within the upper third of the existing range.
When using impact wrenches, care must be taken so that the torque values are not exceeded.
Check before and intermediately with a torque wrench.
Note!
The tightening torques for the following components are noted in the following
sections in detail:
Hydraulic cylinder – see section 8.9.
Track pad and sprocket segment screws – see section 12.1.
Rope winch – see section 14.2.
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Tightening torques
2 Preload values and tightening torques for screws with standard
metric thread according to factory standard WN 4037 I
Wrench size (x) = according to DIN931,
for
Preload value Fm based
on grades in N
Tightening torques
Ma based on
grades in Nm
Hex head screw Socket head
screw
Metric
standard
thread
8.8 10.9 12.9 8.8 10.9 12.9 mm Inch mm Inch
M 4 x 0.7 4050 6000 7000 2,8 4,1 4,8 7 9/32 3 - -
M 5 x 0.8 6600 9700 11400 5,5 8,1 9,5 8 5/16 4 5/32
M 6 x 1 9400 13700 16100 9,5 14 16,5 10 - - 5 - -
M 7 x 1 13700 20100 23500 15,5 23 27 11 - - - - - -
M 8 x 1.25 17200 25000 29500 23 34 40 13 1/2 6 - -
M 10 x 1.5 27500 40000 47000 46 68 79 (17) 16 (11/16)-- 8 5/16
M 12 x 1.75 40000 59000 69000 79 117 135 (19) 18 (3/4) - - 10 - -
M 14 x 2 55000 80000 94000 125 185 215 (22) 21 (7/8) - - 12 - -
M 16 x 2 75000 111000 130000 195 280 330 24 - - 14 9/16
M 18 x 2.5 94000 135000 157000 280 390 460 27 1-1/16 14 9/16
M 20 x 2.5 121000 173000 202000 390 560 650 30 1-3/16 17 - -
M 22 x 2.5 152000 216000 250000 530 750 880 (32) 34 - - 17 - -
M 24 x 3 175000 249000 290000 670 960 1120 36 1-7/16 19 3/4
M 27 x 3 230000 330000 385000 1000 1400 1650 41 1-5/8 19 3/4
M 30 x 3.5 280000 400000 465000 1350 1900 2250 46 1-13/16 22 7/8
M 33 x 3.5 350000 495000 580000 1850 2600 3000 50 2 24 - -
M 36 x 4 410000 580000 680000 2350 3300 3900 55 2-3/16 27 1-1/16
M 39 x 4 490000 700000 820000 3000 4300 5100 60 2-3/8 27 1-1/16
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Tightening torques
3 Preload values and tightening torques for screws with fine
metric thread according to factory standard WN 4037 I
Wrench size (x) = according to DIN931,
for
Preload value Fm based
on grades in N
Tightening torques
Ma based on
grades in Nm
Hex head screw Socket head
screw
Metric
standard
thread
8.8 10.9 12.9 8.8 10.9 12.9 mm Inch mm Inch
M 8 x 1 18800 27500 32500 24,5 36 43 13 1/2 6 - -
M 9 x 1 24800 36500 42500 36 53 62 - - - - - - - -
M 10 x 1 31500 46500 54000 52 76 89 17 11/16 8 5/16
M 10 x 1.25 29500 43000 51000 49 72 84 17 11/16 8 5/16
M 12 x 1.25 45000 66000 77000 87 125 150 19 3/4 10 - -
M 12 x 1.5 42500 62000 73000 83 122 145 19 3/4 10 - -
M 14 x 1.5 61000 89000 104000 135 200 235 22 7/8 12 - -
M 16 x 1.5 82000 121000 141000 205 300 360 24 - - 14 9/16
M 18 x 1.5 110000 157000 184000 310 440 520 27 1-1/16 14 9/16
M 18 x 2 102000 146000 170000 290 420 490 27 1-1/16 14 9/16
M 20 x 1.5 139000 199000 232000 430 620 720 30 1-3/16 17 - -
M 22 x 1.5 171000 245000 285000 580 820 960 32 - - 17 - -
M 24 x 1.5 207000 295000 346000 760 1090 1270 36 1-7/16 19 3/4
M 24 x 2 196000 280000 325000 730 1040 1220 36 1-7/16 19 3/4
M 27 x 1.5 267000 381000 445000 1110 1580 1850 41 1-5/8 19 3/4
M 27 x 2 255000 365000 425000 1070 1500 1800 41 1-5/8 19 3/4
M 30 x 1.5 335000 477000 558000 1540 2190 2560 46 1-13/16 22 7/8
M 30 x 2 321000 457000 534000 1490 2120 2480 46 1-13/16 22 7/8
M 33 x 1.5 410000 584000 683000 2050 2920 3420 50 2 24 - -
M 33 x 2 395000 560000 660000 2000 2800 3300 50 2 24 - -
M 36 x 1.5 492000 701000 820000 2680 3820 4470 55 2-3/16 27 1-1/16
M 36 x 3 440000 630000 740000 2500 3500 4100 55 2-3/16 27 1-1/16
M 39 x 1.5 582000 830000 971000 3430 4890 5720 60 2-3/8 27 1-1/16
M 39 x 3 530000 750000 880000 3200 4600 5300 60 2-3/8 27 1-1/16
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Tightening torques
4 Tightening torques for screws to mount SAE flange
Note!
Not part of factory standard WN 4037 I
Listing according to LFR – Quality service 2QA 6 051 00 as of Oct. 2001
4.1 Flanges and half flanges for high pressure (Norm 62)
Tightening torques in Nm for screw grade 10.9
Flange
nominal size
Screw size
Half flange
Flat flange without
reinforcement rim
Flange with
reinforcement rim
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
4.2 Half flange for low pressure (Norm 61)
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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Conversion chart
1.3.02 Conversion chart
Size from unit Multiplier
to unit
from
Multiplier to unit
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 0,863 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 l
l 0,035 cu. feet 28,316 l
l 0,264 gallon 3,785 l
l 1,057 quart 0,946 l
Mass 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
Performance kW 1,342 HP 0,745 kW
PS 0,736 kW 1,358 PS
Pressure bar 14,5 PSI 0,069 bar
(hydraulic) kpa 0,145 PSI 6,896 kpa
Ground pressure kg/cm² 14,223 lbs.inch2
0,0703 kg/cm²
kg/m² 0,205 lbs. ft.2
4,878 kg/m²
Density g/cm³ 0,036 lbs. inch
3
27,78 g/cm³
kg/m³ 0,062 lbs. ft.3
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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Conversion chart
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Tapping holes
1.3.03 Tapping holes
1 Tapping holes for metric ISO standard threads
Thread
Hole diameter Ø
Diameter
dimensions
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
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Tapping holes
2 Tapping holes for metric ISO fine threads
Thread size
Hole Ø diameter limits
max. min.
Drill bit Ø Thread size
Hole Ø diameter limits
max. min.
Drill bit Ø
M 1 x 0,2 0,821 0,783 0,8 M 25 x 1 24,153 23,917 24
M 1,1 x 0,2 0,921 0,833 0,9 M 25 x 1,5 23,676 23,376 23,5
M 1,2 x 0,2 1,021 0,983 1 M 25 x 2 23,210 22,835 23
M 1,4 x 0,2 1,221 1,183 1,2 M 26 x 1,5 24,676 24,376 24,5
M 1,4 x 0,25 1,185 1,129 1,15 M 27 x 1 26,153 25,917 26
M 1,6 x 0,2 1,421 1,383 1,4 M 27 x 1,5 25,676 25,376 25,5
M 1,8 x 0,2 1,621 1,583 1,6 M 27 x 2 25,210 24,835 25
M 2 x 0,25 1,785 1,729 1,75 M 28 x 1 27,153 26,917 27
M 2,2 x 0,25 1,985 1,929 1,95 M 28 x 1,5 26,676 26,376 26,5
M 2,5 x 0,35 2,201 1,121 2,15 M 28 x 2 26,210 25,835 26
M 3 x 0,35 2,721 2,621 2,65 M 30 x 1 29,153 28,917 29
M 3,5 x 0,35 3,221 3,121 3,15 M 30 x 1,5 28,676 28,376 28,5
M 4 x 0,5 3,599 3,459 3,5 M 30 x 2 28,210 27,835 28
M 4,5 x 0,5 4,099 3,959 4 M 30 x 3 27,252 26,752 27
M 5 x 0,5 4,599 4,459 4,5 M 32 x 1,5 30,676 30,376 30,5
M 5,5 x 0,5 5,099 4,959 5 M 32 x 2 30,210 29,835 30
M 6 x 0,75 5,378 5,188 5,2 M 33 x 1,5 31,676 31,376 31,5
M 7 x 0,75 6,378 6,188 6,2 M 33 x 2 31,210 30,835 31
M 8 x 0,75 7,378 7,188 7,2 M 33 x 3 30,252 29,752 30
M 8 x 1 7,153 6,917 7 M 35 x 1,5 33,676 33,376 33,5
M 9 x 0,75 8,378 8,188 8,2 M 36 x 1,5 34,676 34,376 34,5
M 9 x 1 8,153 7,917 8 M 36 x 2 34,210 33,835 34
M 10 x 0,75 9,378 9,188 9,2 M 36 x 3 33,252 32,752 33
M 10 x 1 9,153 8,917 9 M 38 x 1,5 36,676 36,376 36,5
M 10 x 1,25 8,912 8,647 8,8 M 39 x 1,5 37,676 37,376 37,5
M 11 x 0,75 10,378 10,188 10,2 M 39 x 2 37,210 36,835 37
M 11 x 1 10,153 9,917 10 M 39 x 3 36,252 35,752 36
M 12 x 1 11,153 10,917 11,1 M 40 x 1,5 38,676 38,376 38,5
M 12 x 1,25 10,912 10,647 10,8 M 40 x 2 38,210 37,835 38
M 12 x 1,5 10,676 10,376 10,5 M 40 x 3 37,252 36,752 37
M 14 x 1 13,153 12,917 13 M 42 x 1,5 40,676 40,376 40,5
M 14 x 1,25 12,912 112,647 12,8 M 42 x 2 40,210 39,835 40
M 14 x 1,5 12,676 12,376 12,5 M 42 x 3 39,252 38,752 39
M 15 x 1 14,153 13,917 14 M 42 x 4 38,270 37,670 38
M 15 x 1,5 13,676 13,376 13,5 M 45 x 1,5 43,676 43,376 43,5
M 16 x 1 15,153 14,917 15 M 43 x 2 43,210 42,835 43
M 16 x 1,5 14,676 14,376 14,5 M 45 x 3 42,252 41,752 42
M 17 x 1 16,153 15,917 16 M 45 x 4 41,270 40,670 41
M 17 x 1,5 15,676 15,376 15,5 M 48 x 1,5 46,676 46,376 46,5
M 18 x 1 17,153 16,917 17 M 48 x 2 46,210 45,835 46
M 18 x 1,5 16,676 16,376 16,5 M 48 x 3 45,252 44,752 45
M 18 x 2 16,210 15,835 16 M 48 x 4 44,270 43,670 44
M 20 x 1 19,153 18,917 19 M 50 x 1,5 48,676 48,376 48,5
M 20 x 1,5 18,676 18,376 18,5 M 50 x 2 48,210 47,835 48
M 20 x 2 18,210 17,835 18 M 50 x 3 47,252 46,752 47
M 22 x 1 21,153 20,917 21 M 52 x 1,5 50,676 50,376 50,5
M 22 x 1,5 20,676 20,376 20,5 M 52 x 2 50,210 49,835 50
M 22 x 2 20,210 19,835 20 M 52 x 3 49,252 48,752 49
M 24 x 1 23,153 22,917 23 M 52 x 4 48,270 47,670 48
M 24 x 1,5 22,676 22,376 22,5
M 24 x 2 22,210 21,835 22
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Conservation guidelines
PR Litronic Serie 4
LR Litronic Serie 4
RL Litronic Serie 4
MJFCIFSS! 1.4.00 - 1 / 6
1.4.00 Conservation guidelines
1 General
All parts of a construction machine are exposed to corrosion, especially when the machine is
taken out of service. Corrosion can be compared to wear. However, the effects of corrosion can
greatly exceed that of mechanical wear and shorten the service life of the affected parts
significantly. For that reason, for longer shut down, the machines and its components must be
preserved according to certain guidelines.
In general, these guidelines are tiered according to the following times:
Taking the machine out of service – for an unknown duration
Shut down of the machine
Shut down for up to 2 months
Shut down for up to 12 months
Shut down for longer than 12 months
Return to operation
The required measures are graduated depending on the different time frames. The
conservation measures cannot be strictly standardized and they must be shorted or lengthened
depending on the assessment of necessity (such as environmental influences).
Such influences are, for example:
Placement location of machine (for example in unprotected surrounding, in
closed areas, protected by a roof, temperate surrounding)
Type of climate (for example extreme temperatures, location in water / near the
coast, etc.)
Note!
For conservation for sea transport, special guidelines must be observed, which are not
included in these instructions. Refer to the special operating instructions.
2 Taking the machine out of service – for an unknown duration
If a machine is taken out of service for a longer period of time without conservation, then it must
be operated in intervals not to exceed 14 days, to prevent abnormal corrosion and its effects.
Before putting the machine back into service, check all oil levels and correct them, if
necessary.
Always carry out the specified daily maintenance work before putting the machine back into
service. In addition, carry out the time limited maintenance work according to the inspection
schedule and additional Diesel engine Operating instructions no later than the specified
intervals.
Put the machine into operation according to the Operating instructions and operate it until the
Diesel engine and the hydraulic system has reached the specified operating temperature in
the hydraulic tank and in the coolant circuit.
Actuate all functions of the travel, working hydraulic as well as functions of additionally
installed hydraulic components and alternately operate them over a period of approx. 20
minutes. The hydraulic cylinders must be extended and retracted over their full stroke length.
When turning the machine off, retract all hydraulic cylinders fully, if possible, and fill the fuel
tank. If the machine is parked on soft ground, park the machine on wooden planks or similar
and secure it to prevent it from rolling off.
Check the batteries and remove them and recharge them, if necessary. Check the electrical
contact points and grease them, if necessary.
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PR Litronic Serie 4
LR Litronic Serie 41.4.00 - 2 / 6 Mjfcifss!
RL Litronic Serie 4
3 Shut down of the machine
Preparations for shut down
Park the machine on horizontal, dry and solid ground and secure it to prevent it from rolling
off. Lower the working attachment to the ground level so that there is no longer any residual
pressure of the hydraulic.
Clean the machine diligently according to the procedure outlined in the Operating
instructions.
The machine must be completely dry before starting the conservation measures. Dry
electronic components and damp areas on the machine with pressurized air.
If freezing temperatures are expected for the intended duration of shut down, then the fuel
tank must be filled with winter fuel. Then start the Diesel engine and let it run for some time to
bring the winter fuel into the fuel circuit. Then add enough fuel to the fuel tank until it is full.
Note!
When a conserved machine is moved for loading or transport, then the conservation
protection on the piston rods of the cylinders will most often be removed by the scraper ring.
For that reason, if the machine is transported, the conservation of the piston rods must be
rechecked after loading and carried out again, if necessary.
Note!
Despite completed conservations measures, the machine must still be inspected in certain
intervals and touched up, if necessary. This is within left to the discretion of the operator, but
these inspections should be carried out regularly (monthly), especially in aggravated
conditions (cold, heat, near the coast, etc.).
3.1 Shut down for up to 2 months
Required tools / Service items
Description Id. No. Description Display
Optical charge
tester
See section
2.1
To check the battery
condition and the
antifreeze in the
coolant
WAXOYL 120-4
Anti corrosion wax
8504472 Spray can 500ml
Long term protection
for up to 2 years
Ballistol Spray
Corrosion protection
10025514 Application area:
Door locks
Dehumidification
capsule
10013313 Prevents infiltration
of moisture over an
extended period of
time
Check the entire machine for damage and remedy, if necessary.
Check the machine for paint damage and remedy, if necessary.
Take care of any maintenance work which would fall within the timeframe of the planned shut
down.
Due to the UV exposure of the components, synthetic materials, such as plastic parts, hoses,
rubber etc. must be covered with suitable aids.
Electrical components, contact points and plug connections which are not sealed must be
sealed with conservation wax „Waxoyl 120-4“.
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PR Litronic Serie 4
LR Litronic Serie 4
RL Litronic Serie 4
MJFCIFSS! 1.4.00 - 3 / 6
Apply a thick layer of conservation wax „Waxoyl 120-4“ to cover ball joints, hinges, blank
parts and exposed piston rods. (Do not protect ball bearings with Waxoyl!)
Place a dehumidification capsule into the central electric box.
Protect all door and container locks with „Ballistol Spray“.
Set the battery master switch (if present) to position „0“ and then remove the batteries.
Check the battery acid level and add distilled water, if necessary. Always store the batteries
in a cool and dry area. Check the load current regularly every 6 weeks and recharge, if
necessary.
Close the exhaust outlet with an air and watertight cover.
Pay attention to any additional guidelines for special components or special local conditions.
3.2 Shut down for up to 12 months
Carry out all measures according to paragraph 3.1. In addition, the following is required:
Clean the Diesel engine externally.
Drain water from the fuel tank or condensation of the Diesel engine prefilter (see Operating
instructions).
Add commercially available Diesel fuel to the fuel tank until it is completely full. If the shut
down is during the cold time of the year, fill the fuel dank with winter Diesel fuel (Winter
Diesel fuel is suitable up to a temperature of -22°C / -7.6°F). Then start the Diesel engine and
let it run for some time to bring the winter fuel into the fuel circuit. Then add enough fuel to
the fuel tank until it is full.
Check the coolant to ensure it has sufficient corrosion and antifreeze protection - at least
50% corrosion inhibitor antifreeze fluid (for guidelines refer to the Operating instructions).
Seal the entire machine (Diesel engine, hydraulic aggregates, main frame, tank, track / axles,
equalizer bar, working attachments, etc.) with preservation wax „Waxoyl 120-4“. (Amount of
preservative agent: An area of approx. 5m² can be treated with one liter Waxoyl)
Note!
The following points must be observed when applying the corrosion inhibitor wax:
Observe a drying time of 3 hours.
Ambient temperature at least +15°C / 59°F.
Use protective equipment (breathing protection, safety glasses, respirator, etc.).
The solvents of the anti corrosion wax are flammable! (Do not smoke and avoid open
flames!)
Cold resistant to a temperature of -40°C / -40°F.
Release the chain tension by relieving the tension cylinder (see Operating instructions).
Check the machine monthly and reapply conservation protective measures if necessary.
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PR Litronic Serie 4
RL Litronic Serie 4
3.3 Shut down for longer than 12 months
Carry out all measures according to paragraph 3.1 and 3.2. In addition, the following is required:
Note!
If a shut down for longer than 12 months is scheduled, then contact the Service Dept. of the
Diesel engine manufacturer.
Close off all openings, such as air filter, exhaust pipe, vent openings on components, etc.
airtight.
The vent for the fuel tank (if present) must remain open for safety reasons!
Rub the rubber seal of the cab and containers with talcum powder, close the doors. If the cab
is not installed, cover the operator’s platform properly. If necessary, remove the operator’s
seat. Cover the instrument panel and protect it.
4 Return to operation
4.1 After a shut down of 2 months
Remove the dehumidification capsule from the electronic box.
Check the fill levels and lubricate the machine according to the Operating instructions.
Install the batteries and clean / grease the battery terminals.
Open the exhaust outlet.
Drain water from the fuel tank or drain any condensation of the Diesel engine prefilter (see
Operating instructions).
Clean anti corrosion wax from ball joints, hinges, blank parts and exposed piston rods.
Put the machine back into service as outlined in the Operating instructions.
Before working with the machine, check all functions of the machine and remedy and defects
immediately. Carry out a thorough visual inspection on the machine.
Actuate all functions of the travel, working hydraulic as well as functions of additionally
installed hydraulic components and alternately operate them over a period of approx. 20
minutes. The hydraulic cylinders must be extended and retracted over their full stroke length.
Observe any additional guidelines for special components or special local conditions.
4.2 After a shut down of 12 months
Carry out the items according to paragraph 4.1.
Take an oil sample of the hydraulic oil and send it in for analysis.
Carry out the scheduled maintenance and inspection work on the machine before putting it
back into service.
On the Diesel engine, mechanically actuate the AGR flap (exhaust return) and the engine
brake flap and check for easy movement.
Grease the V-belts!
Use a high pressure cleaner with steam (at least 120°C) as well as 5% additive of solvent
(such as petroleum) to clean the anti corrosion wax from the machine and aggregates.
(Caution when walking on surfaces, there is a danger of slipping due to the wax residue.)
Check the V-belt of the Diesel engine and replace it if necessary.
Carry out a Diesel engine test run: Increase the Diesel engine rpm only slowly to ¾ of the
high idle rpm until the operating temperature is reached.
Check the oil pressure display immediately after starting the Diesel engine.
Check the vacuum display of the air filter.
Adjust the chain tension to suit the application (see Operating instructions).
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PR Litronic Serie 4
LR Litronic Serie 4
RL Litronic Serie 4
MJFCIFSS! 1.4.00 - 5 / 6
4.3 After shut down of longer than 12 months
Complete all items outlined in paragraph 4.2 and 4.1.
Note!
After a scheduled shut down of longer than 12 months contact the Service Dept. of the Diesel
engine manufacturer.
Remove all covers and closures, which were installed for conservation measures.
Turn the Diesel engine manually a few turns (use the turning device - flywheel – see Special
tools).
Start the machine and bring it to operating temperature.
After the machine was brought to operating temperature, change all lube and service fluids
as well as filters according to the Operating instructions
Check the entire machine for function and for leaks.
If necessary, carry out any time limited maintenance work at this time.
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PR Litronic Serie 4
RL Litronic Serie 4
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Material weights
1.5.00 Material weights
A spec. weight 1)
in kg/m3
solid
B Loosening in %
C Loosening facttor
D spec. weight kg/m3
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
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Material weights
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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Service Manual Tools and work instructions
Sub group index -Tools and work instructions
2 Tools and work instructions
2.0.00 Sub group index -Tools and work instructions
Special tools .................................................................................................. 2.1
Repair welding............................................................................................... 2.2
Installation instructions ............................................................................... 2.3
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Tools and work instructions Service Manual
Sub group index -Tools and work instructions
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Special tools
PR Litronic Series 4
LR Litronic Series 4
RL Litronic Series 4
MJFCIFSS! 2.1.00 - 1 / 22
2.1.00 Special tools
General
The following section is divided into three sections:
1 Special tools - Maintenance
2 Special tools - Repairs
3 Special tools for in-house manufacture
Special tools for maintenance are a must-have to carry out the maintenance and inspection
schedule. In addition, some tools are necessary aids for troubleshooting.
Special tools for repairs are only required in case of a repair of the affected components.
Special tools for in-house manufacture can be made in-house as necessary. The drawings to
make them are made available by the manufacturer.
1 Special tools Maintenance
1.1 Diesel engine
Description Id. No. M-Type Remarks Illustration
Sculi – Diagnostics
software - accessory
consisting of:
LR Series 4
RL Series 4
PR 724 F/Nxxx-
9200
PR 734 F/Nxxx-
8220
PR 744 F/Nxxx-
7356
PR 754 F/Nxxx-
6924
Sculi License with
USB Dongle
for engine Service
Level
(LH ECU UPCR-,
DC4-, DC5- engine
control units and
Master 4 – controls)
10450054
PR 764 F/Nxxx-
6888
LR Series 4
RL Series 4
PR 724 F/Nxxx-
9200
PR 734 F/Nxxx-
8220
PR 744 F/Nxxx-
7356
PR 754 F/Nxxx-
6924
Communication cable
for LH-ECU-UPCR –
control units
10035410
PR 764 F/Nxxx-
9506
Communication cable
for DC4 / DC5 –
control units
10035411 PR 764 F/Nxxx-
6888 9505
Diagnostics
software for
maintenance and
adjustment of
Diesel engine.
For ordering, a
Liebherr form
from Liebherr
Bulle must be
filled out.
Download the
current software
version with the
aid of the Lidos
DVD.
Use of Sculi
software also
possible with the
previous DC-Desk
Dongle.
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Special tools
LR Litronic Series 42.1.00 - 2 / 22 Mjfcifss!
Digital rpm gauge
„Shimpo“
7364284
Reflective strip 614063201
PR Series 4
LR Series 4
RL Series 4
To measure the
rpm with the
reflective strip
Test range: 6-8300
rpm ±1 rpm
PR 724 F/Nxxx-
6600 9199
PR 734 F/Nxxx-
6200 8219
Digital rpm gauge
„Piezzo A2106“
10286429
PR 764 F/Nxxx-
6888 9505
To measure the
engine rpm via
impulse frequency
of the injection line
PR 724 F/Nxxx-
6600 9199
PR 734 F/Nxxx-
6200 8219
DCA 4 Test Kit
„CC2602M“
Consisting of:
Container
50 Test strips
Clear plastic container
Pipette
5608459
PR 764 F/Nxxx-
6888 9505
To check the DCA
4 concentration in
the coolant
Hand pump [1] 8145666
Oil sample vale for oil
samples [2]
7019068
PR Series 4
LR Series 4
RL Series 4
To take oil
samples for the oil
analysis
Oil analysis set–
mineral oil (green
cover)
Individual set 8145660
4 sets 10029626
6 sets 7018368
12 sets 7018369
Oil analysis set – Bio
oil (yellow cover)
Individual set 7026817
6 sets 7026088
PR Series 4
LR Series 4
RL Series 4
Analysis at WEAR
CHECK Germany
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Special tools
MJFCIFSS! 2.1.00 - 3 / 22
V-belt test unit
„Krikit2“
8042829 PR Series 4
LR Series 4
RL Series 4
To check the V-belt
tension
Optical battery tester 7408922 PR Series 4
LR Series 4
RL Series 4
To check the
battery charge and
the antifreeze in
the coolant
Turning device for
valve clearance /
check / adjust
Pos. 1 0524045 LR Series 4
RL Series 4
PR Series 4
except
To be installed on
the flywheel
housing instead of
the cover
10490350 PR 764
F/Nxxx-9506
Pos. 2
10116805 RL 64
(can be used
alternatively
also on
PR 724
F/Nxxx-9200
PR 734
F/Nxxx-8220
PR 744
PR 754
LR 624
LR 634
RL 44 )
To be installed on
the V-belt -
crankshaft
Hand pump with
pressure gauge
10454803 PR Series 4
LR Series 4
RL Series 4
For optional Diesel
particle filter. Can
also be used for
leak test of
counterpressure
line
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Special tools
1.2 Hydraulic system
Vacuum pump cpl.
with accessory
7408148
Consisting of:
Vacuum pump with
electrical cable
7407987
Hose fitting 7407985
Hose fitting 10301165
Fitting S8M 7404619
Fitting L6R 4901110
PVC hose 7360127
Terminal clamp,
positive
10038447
Terminal clamp,
negative
10038448
Plug 2-pin 7408151
PR Series 4
LR Series 4
RL Series 4
For faster bleeding
of hydraulic
system, by
enclosing the PVC
hose, a slight
excess pressure
(ca.0.4 bar) can be
produced.
Connection point
for the vacuum
pump on the
machine is the
breather screw on
the hydraulic tank
Temperature gauge 10024185 PR Series 4
LR Series 4
RL Series 4
Accuracy:
2% / 2°
Test range:
-18°C to +260°C
Difference pressure –
Mess-Set 230V/120V
Consisting of:
Test unit Multi-Handy
2045
2 Pressure sensors 0-
600 bar
2 Mini test connections
2 Test cable 12m long
KFZ Connector cable
Data cable
Power unit
LR Series 4
RL Series 4
To measure
pressure, pressure
peaks and
pressure difference
and suitable for
data transfer to PC
Scale pressure gauge
0-10 5002865
0-25 7361289
0-40 7361288
0-60 5002867
0-100 5602903
0-160 7361286
0-250 7361285
0-400 7500002
0-600 7361294
0-1000 4601115
PR Series 4
LR Series 4
RL Series 4
Accuracy:
1% of the scale
end value
All pressure
gauges are
„glycerin filled“
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Special tools
MJFCIFSS! 2.1.00 - 5 / 22
Pressure gauge
connection
R ½
7002436 PR Series 4
LR Series 4
RL Series 4
To seal at pressure
tests, a square
seal ring,
Id.No. 7409794
must be used
Test fitting cpl.
R 6 L 7409916
R 10 L 7406864
R 12 L 7409918
PR Series 4
LR Series 4
RL Series 4
Union nut and
compression ring
are affixed on the
test fitting
Screw coupling
M 8x1 7615321
M 10x1 5608462
M 12x1,5 7407071
M 14x1,5 7406865
R ¼ 7409720
PR Series 4
LR Series 4
RL Series 4
To connect to
additional test
points in the
machines
Screw coupling
M 16x2 7407070
PR Series 4
LR Series 4
RL Series 4
To connect shorter
test lines or for
connection
between test
connection and
pressure sensor
Test hose NW 2
1000 mm 7002437
1500 mm 7002475
4000 mm 7009134
5000 mm 7363732
PR Series 4
LR Series 4
RL Series 4
To keep loss of
pressure during
tests to a
minimum, shorter
test hoses are
preferable
Hook wrench
58 - 62 mm 7900282
PR Series 4
LR Series 4
RL Series 4
To loosen / counter
when adjusting the
pump regulating
range
Socket wrench
For grooved nut
variable pump HPV
9792711 PR Series 4
LR Series 4
RL Series 4
To loosen / counter
when adjusting the
pump end stop.
Use with hook
wrench
Id. Nr. 7900282
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Special tools
Socket wrench for 0-
position grooved nut
Variable pump HPV
9749025 PR Series 4
LR Series 4
RL Series 4
To loosen / counter
the grooved nut
when adjusting the
hydraulic zero
position
Test plates
For SAE-flange ¾
A 90mm
B 40mm
C,r 5mm
7370092
For SAE-flange 1
A 90mm
B 44mm
C,r 5mm
7370093
For SAE-flange 1¼
A 90mm
B 52mm
C,r 5mm
7370094
Or to be made in-
house
PR Series 4
LR Series 4
RL Series 4
To close off high
pressure
connections
Material:
Ground spring
steel
Round off end of
the plate
(simplifies
installation, avoids
damage to the seal
ring)
PR 724 F/Nxxx-
6600 9199
PR 734 F/Nxxx-
6200 8219
Open ended wrench
SW 30/32
8006305
PR 764 F/Nxxx-
6888 9505
Open ended
wrench to check or
replace the return
filters. Can also be
used for other
connections.
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Special tools
MJFCIFSS! 2.1.00 - 7 / 22
1.3 Electrical system
LinDiag Diagnostics
KIT
9413782
Consisting of:
Data carrier with latest
software version +
Dongle
9410472
Adapter cable 9932747
PR 724 F/Nxxx-
6600 9199
PR 734 F/Nxxx-
6200 8219
PR 764 F/Nxxx-
6888 9505
To adjust the travel
hydraulic, read out
the Service Codes
and for trouble-
shooting on Series
4 machines of
exhaust stage
Tier2
LinDiag Diagnostics
KIT
9413763
Consisting of:
Data carrier with latest
software version +
Dongle
9410472
Adapter cable 10035410
LR Series 4
RL Series 4
PR 724 F/Nxxx-
9200
PR 734 F/Nxxx-
8220
PR 744 F/Nxxx-
7356
PR 754 F/Nxxx-
6924
PR 764 F/Nxxx-
9506
To adjust the travel
hydraulic, read out
the Service Codes
and for trouble-
shooting on Series
4 machines of
exhaust stage
Tier3
USB – Adapter 693190714 PR Series 4
LR Series 4
RL Series 4
Intermediate
adapter from serial
interface to USB
Digital multi meter
cpl. with cable and bag
LR Series 4
RL Series 4
For
Voltage (V)-
Amperage (A)-
Resistance ( )-
Frequency (Hz)-
tests
Optical charge tester see Pt. 1.1
Diesel engine
PR Series 4
LR Series 4
RL Series 4
To check the
battery condition
and the antifreeze
in the coolant
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Special tools
1.4 Mechanical component groups
Test tool Travel gear 7402603 PR Series 4
LR Series 4
RL Series 4
To measure travel
gear wear
For use, see
section 12.2
2 Special tools Repair
2.1 Diesel engine
Note!
The special tools for Diesel engine repair are listed in the Diesel engine workshop manual.
2.2 Hydraulic system
Pressurized air
cartridge
10045498 CO2 cartridge to
vent the parking
brake for towing
operation.
Brake vent adapter 9401975
LR Series 4
RL Series 4
PR 724 F/Nxxx-
7697
PR 734 F/Nxxx-
8220
PR 744 F/Nxxx-
7356
PR 754 F/Nxxx-
6924
PR 764 F/Nxxx-
6888
Adapter for
pressurized air
cartridge (part of
tool kit)
Socket wrench
Valve sleeve
Valve – 3 slits 10430260
Valve – 2 slits 10491131
PR Series 4
LR Series 4
RL Series 4
For repair of
variable motor
HMV
To remove and
install the valve
sleeve of the
directional valve
See section 8.2
Position 73
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Special tools
MJFCIFSS! 2.1.00 - 9 / 22
Mandrel Thrust ring
HPV 105 10472254 PR 724
LR 624
HPV 135 10472255 PR 734
LR 634
RL 44
HPV 210 10472257 PR 744
PR 764
HMV 165 10472261 PR 744
LR 624
HMV 210 10472266 PR 724
PR 754
LR 634
RL 64
HPV 280 PR 754
RL 64
HMV 280
10472269
PR 734
PR 764
RL 44
For repair of var.
pump HPV or var.
motor HMV
For the installation
of the hot thrust
ring on the drive
shaft.
See chapter 8.1 or
8.2, Position 11
Mandrel [1] and
protective sleeve [2]
for shaft seal ring
HPV 105 1 10472303
HPV 105 2 10411001
PR 724
LR 624
HPV 135 1 10472310
HPV 135 2 10411002
PR 734
LR 634
RL 44
HMV 165 1 10472316
HMV 165 2 10410291
PR 744
LR 624
HMV 210 1 PR 724
PR 754
LR 634
RL 64
HPV 210 1
10472317
PR 744
PR 764
HMV 210 2 PR 724
PR 754
LR 634
RL 64
HPV 210 2
10410295
PR 744
PR 764
HMV 280 1 PR 734
PR 764
RL 44
HPV 280 1
10472318
PR 754
RL 64
HMV 280 2 PR 734
PR 764
RL 44
HPV 280 2
10411003
PR 754
RL 64
For repair of var.
pump HPV or var.
motor HMV
For pressing in the
radial shaft seal
ring to push over
the drive shaft (in
connection with the
corresponding
protective sleeve)
See section 8.1 or
8.2, Position 12
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Special tools
Installation aid for
seal ring on oil guide
pipes
Pos.1
HPV + HMV
10472322 RL Series 4
LR Series 4
PR Series 4
except
Pos.2
HPV 105
10472321 PR 724
LR 624
For repair of var.
pump HPV or var.
motor HMV
The tool is used to
install the O-rings
on the oil guide
pipes
See section 8.1
Position 46 or
section 8.2.
Position 45
Spindle device for
swash plate mount
LR Series 4
RL Series 4
For repair of var.
pump HPV
With this device,
the swash plate
mount can be
lowered targeted
onto the pump
housing at
installation.
Centering pins for
swash plate mount
M12 HPV 10472319 PR 724
LR 624
M14 HPV PR 734
PR 744
PR 764
LR 634
RL 44
M14 HMV
10472320
PR 724
PR 744
PR 754
LR 624
LR 634
RL 64
M16 HPV PR 754
RL 64
M16 HMV
10347066
PR 734
PR 764
RL 44
For repair of var.
pump HPV or var.
motor HMV
The guide pins are
used to guide the
swash plate mount
at assembly with
the pump housing.
minimum 2 each
maximum 4 each
required
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Special tools
MJFCIFSS! 2.1.00 - 11 / 22
Centering device for
swash plate mount
LR Series 4
RL Series 4
For repair of var.
pump HPV or var.
motor HMV
Device to affix the
oil guide pipes at
installation of
swash plate mount
2 each required
Note!
The Id. numbers for the following tools are in the spare parts list for the hydraulic cylinders.
Assembly sleeve see spare parts
list
For installation of
O-ring and
stepseal ring on
pistons of hydraulic
cylinders
Spreader sleeve see spare parts
list
For installation of
O-ring and
stepseal ring on
cylinders
Installation wrench
Piston
see spare parts
list
To tighten the
cylinders
For tightening
torque, see section
8 Hydraulic
cylinder
Installation wrench
Piston nut
see spare parts
list
To tighten the
piston nuts of
hydraulic cylinders
For tightening
torque, see section
8 Hydraulic
cylinder
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Special tools
2.3 Electrical system
Crimper
for
MATE-N-LOK Crimp
contacts
For 1.5 mm² 7367025
For 2.5 mm² 7366314
PR Series 4
LR Series 4
RL Series 4
To make proper
crimp connection
on MATE-N-LOK
plug connections
Removal tool AMP
for
MATE-N-LOK Crimp
contacts
7366655
Spare insert 7015180
PR Series 4
LR Series 4
RL Series 4
To remove crimp
contacts from plug
connector
Installation tool AMP
for
MATE-N-LOK Crimp
contacts
8145432 PR Series 4
LR Series 4
RL Series 4
To insert the pin
and bushing
contacts in MATE-
N-LOK plug
connectors
Hand crimper
for „Deutsch“ plug
connector
8503647 PR Series 4
LR Series 4
RL Series 4
To make proper
crimp connections
Removal tool Cannon
for „Deutsch“
crimp contacts
AWG 12 10114733
AWG 16 885563714
AWG 20 10114732
PR Series 4
LR Series 4
RL Series 4
To remove pin and
bushing contacts in
„Deutsch“ plug
connectors
Removal tool Cannon
for „Deutsch“ crimp
contacts
(alternate)
AWG 12 8145674
AWG 16 8145673
AWG 20 8503630
PR Series 4
LR Series 4
RL Series 4
To remove pin and
bushing contacts in
„Deutsch“ plug
connectors
(alternate)
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Special tools
MJFCIFSS! 2.1.00 - 13 / 22
Crimper AMP
AMP Certi-Lock
7415333 PR Series 4
LR Series 4
RL Series 4
To crimp the
„JUNIOR POWER
TIMER“ contacts
Removal tool AMP
AMP 726 503-1 7026266
AMP 726 534-1 7027340
PR Series 4
LR Series 4
RL Series 4
To remove
contacts from the
„JUNIOR POWER
TIMER“ housing
Crimper
ESA 0760 7409781
CRB 0560 7409782
PR Series 4
LR Series 4
RL Series 4
To crimp insulated
0.5 -6.0 mm² cable
shoes, for example
cable connectors
CRB 0560 also
windshield wiper
motor
Coding plug
Inching / brake pedal
X46 9813111 PR Series 4
RL Series 4
X46.1 9413850 LR Series 4
In case of
defective inching /
brake pedal for
continued
operation of the
machine.
See section 9.
Inching / brake
pedal
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Special tools
2.4 Mechanical component groups
Installation device for
slip ring seal – travel
gear
To properly install
the slip ring seals
on travel gears
FAT 400 E 511
Slip ring seal Id.No. Device No.:
7361 197 outside 10467795 07590 45459
7109 24901 inside 10467796
LR 624
07590 45458
FAT 450 E 504/505
FAT 450 E 510
Slipring seal Id.No. Device No.:
7109 25201 outside 10219780 07590 38616
7109 26301 inside 10219779
PR 724
LR 634
07590 43327
FAT 500 E 502/503
FAT 500 E 517/518
7610 242 outside 10017428 07590 39022
7361 197 inside 10219781
PR 734
RL 44
07590 43326
FAT 600 E 506
7610 244 outside 10017436 07590 38891
7610 240 inside 10303340
PR 744
07590 38472
FAT 650 E 508
7610 245 outside 10017433 07590 39023
7610 241 inside 10017472
PR 754
RL 64
00100 01300
FAT 700 E 501
7610 237 outside 10017468 07590 41338
7610 243 inside 10017430
PR 764
07590 38886
Mandrel
Pos.1 Installation flange
9786683 PR 724
9786685 PR 734
A
9786686 PR 744
PR 754
PR 764
9786684 PR 724
9786687 PR 734
B
9411074 PR 744
PR 754
PR 764
Pos.2 Screw in handle
for all installation
flanges
9786688 PR Series 4
For installation of
radial shaft seal
rings into the hoist
cylinder bearing.
See section 15.2
A= For Pos.10
B= For Pos.7
For dimensions for
in-house
manufacture of
mandrel, see Pt. 3.
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MJFCIFSS! 2.1.00 - 15 / 22
Inside puller
Pos.1 with counter
support
Pos.2 For the following
dimensions (in mm)
Commercially
available tool
PR 724 PR 734 PR744
PR754
PR764
A 90 90 120
B 70 70 90
C 247 273 273
D 89,5 96 114
PR Series 4 To pull the
bushings, Pos. 3
and Pos.4 from the
hoist cylinder
bearing
Pull tool Elastic
bearing – operator’s
platform
9404645 PR Series 4
LR Series 4
RL Series 4
To install and
remove the elastic
bearing of the
operator’s platform
For dimensions for
in-house
manufacture of
mandrel, see Pt. 3.
9415227 PR 764 To install the outer
um equalizer bar
bearing
Installation sleeve
Equalizer bar bearing
In-house
manufacture
LR Series 4
RL Series 4
PR 724
PR 734
PR 744
PR 754
PR 764
For dimensions for
in-house
manufacture of
assembly sleeves,
see Pt. 33.
9416915 PR 754
RL 64
Installation wrench
Tension unit
9416913 PR 764
Special hook
wrench to release
and attach the ring
nut
9416922 PR 754
RL 64
Installation tool
Tension unit
9416921 PR 764
Sleeve to push on
the ring nut –
prevents twisting of
ring nut
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Special tools
Installation tool
Tension unit
Pos.1 Installation flange 9798353
Pos.2 Bar 9798352
Pos.3 hex head screw
6 each
M16x310 mm – 10.9
4601217
PR 754
RL 64
Installation tool cpl. 9415198 PR 764
For removal /
installation of
tension unit –
chain tensioner is
required!
For use, see
section 12 Tension
unit
Installation tool
Tension unit
10303939 LR Series 4Mechanical device
(without hydraulic
components)
10307625 RL 44
Hydraulic components
For Installation tool
Consisting of:
Hydraulic cylinder
Enerpac RC 506
Hydraulic hose
Enerpac HC- 7206
Pressure gauge
Enerpac GF- 50B
Intermediate section
Enerpac GA-2
Hand pump Enerpac
P80
10303852 LR Series 4
RL 44
To remove /
install the tension
unit – chain
tensioner is
required!
For use, see
section 12 Tension
unit
Technical data – Hydraulic components
Hydraulic cylinder Hand pump Hydraulic hose Pressure gauge
Enerpac RC 506
(50 t single acting)
Enerpac P80
(two stage hand pump)
Enerpac HC-7206 Enerpac GF-50B
Piston surface 71.2 cm2
Operating pressure max.700ba 9.5 x 1800mm Pressure range 0-700bar
Oil volume 1131cm3
Lever force max. 47,0kg
Weight 23,1kg Weight 10,9kg
Installation height -
retracted 282mm
extended 441mm
outside 127mm
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MJFCIFSS! 2.1.00 - 17 / 22
Installation sleeve
Equalizer bar
10306449 PR 754 To press the
equalizer bar in
with oscillating
track rollers.
For dimensions for
in-house
manufacture of
mandrel, see Pt. 3.
Installation tool set
Double oscillating track
roller
Pos.1 Threaded rod
M30x360 (2 each)
Pos.2 Plate
Pos.3 Washer M30
(2 each)
Pos.4 Hex nut M30 (4
each)
10318790 PR 764 For removal /
installation of pins
with bearing for
double oscillating
track rollers.
For dimensions for
in-house
manufacture of
plate (Pos.2) see
Pt. 3.
For use, see
section 2.3
Installation tool
Double oscillating track
roller
Hydraulic components
for Installation tool
Consisting of:
Hydraulic cylinder
Enerpac RCS 201
11081098
Hydraulic hose Enerpac
HC- 7206
10430200
Pressure gauge
Enerpac
GF- 230B
11081099
Intermediate section
Enerpac
GA-2
10430202
Hand pump Enerpac
P39
886120508
PR764 For removal /
installation of pins
with bearing for
double oscillating
track rollers.
For use, see
section 2.3
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Special tools
Technical data – Hydraulic components
Hydraulic cylinder Hand pump Hydraulic hose Pressure gauge
Enerpac RCS 201
(20 t single acting)
Enerpac P39
(two stage hand pump)
Enerpac HC-7206 Enerpac GF-230B
Piston surface 28,7cm
2
Operating pressure max.700ba 9,5 x 1800mm Pressure range 0-700bar
Oil volume 129cm3
Lever force max. 50kg
Weight 5kg Weight 5,9kg
Installation height -
retracted 98mm
extended 143mm
outside 92mm
3 Special tools for in-house manufacture
3.1 Assembly sleeve for equalizer bar bearing, outside
To install the outer equalizer bar bearing – see section 15.3.
Fig. 1 Dimensions of installation sleeves
Type Machine A B C D E F G H I
PR 724
LR 624
100 130 75 - - - - - - - - - - - - - - - - - -1
PR 734
LR 634
120 150 100 - - - - - - - - - - - - - - - - - -
2 PR 744
PR 754
RL 44
RL 64
81,5 137 120 91 115 35 7 13 129
3 PR 764 83 149 120 101 135 - - - 7,5 12,8 - - -
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Special tools
MJFCIFSS! 2.1.00 - 19 / 22
3.2 Mandrel
For installation of radial shaft seal rings in hoist cylinder bearing.
Fig.2 Dimensions of mandrel – screw in handle and mandrel
See also section 15.2 Hoist cylinder suspension.
Mandrel A ..........For Pos.10
Mandrel B ..........For Pos.7
M-Type Mandrel Dimensions
D E F G
PR724 A Ø119-0,3
Ø89±0,1
13 23
B Ø71-0,3
Ø57±0,1
9 18
PR734 A Ø139-0,3
Ø109±0,1
14 23
B Ø89-0,3
Ø69±0,1
11 18
PR744 A Ø149-0,3
Ø119±0,1
14 23
B Ø94-0,3
Ø74±0,1
12 18
PR754 A Ø149-0,3
Ø119±0,1
14 23
B Ø94-0,3
Ø74±0,1
12 18
PR764 A Ø149-0,3
Ø119±0,1
14 23
B Ø94-0,3
Ø74±0,1
12 18
* edges rounded off
All dimensions in [mm]
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Special tools
3.3 Pull tool – operator’s cab bearing
For installation and removal of elastic bearing of operator’s platform.
See section 17.1 Position 11 and 22.
Fig. 3 Dimensions of pull tool
3.4 Installation sleeve – equalizer bar
To press the equalizer bar in or out with oscillating track rollers.
See section 2.3 Installation notes.
Fig. 4 Dimensions installation sleeve for equalizer bar
Continuous fillet weld 4mm
1 Threaded rod M30 4 Washer
2 Sleeve 5 Shim M30
3 Washer 6 Nut M30
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Special tools
MJFCIFSS! 2.1.00 - 21 / 22
3.5 Plate – Double oscillating track rollers (PR764)
For removal / installation of the pins with bearings on double oscillating track rollers.
See section 2.3 Installation notes.
Fig. 5 Dimension of plate for double oscillating track rollers
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Special tools
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Repair welding
2.2.00 Repair welding
Before starting any welding work on the machine, various electronic parts and components must
be unplugged to prevent damage to the machine.
Note!
See operating instructions: Preparations for maintenance
In addition, for arc welding, the ground terminal of the welding unit should be connected in the
immediate vicinity of the blank work piece which is to be welded.
1 Preparation of cracked part
Clean the cracked area to remove paint, grease and any dirt.
To prevent the crack from extending during the preparation and welding process, the end of the
cracks should be drilled out with a drill (at least 8 mm Ø).
Then the crack should be ground, chiselled, or arched out to an angle of approx. 60° .
Be certain that the edges are clean and extend through the full cross section of the material,
without exceeding the space of 1 mm in the lower part. On larger grooves, a welding safety
should be installed.
Fig. 1 Ground out / drilled out crack
Easy to harden materials must be preheated to approx. 150°C before welding.
Special preparations are necessary when preparing a crack in manganese steel. This material
cannot be prepared with a smoothing planer. Mechanical work cannot be carried out due to its
hardness and peen hardening. We suggest that the crack is prepared with a slow running and
water-cooled grinding wheel to prevent overheating.
Note!
Another possibility to make groves for repair welding of cracks and remove high alloy welding
seams by using cutting electrodes of the type UTP 82 AS.
2 Preparation of a weld
The welding area must be free of grease, paint, oil, moisture and dirt. During rain, the area to
be welded must be covered sufficiently.
Materials with a thickness above 15 mm and high carbon steel (carbon content more than 0.22
%) and difficult to weld steel, the material must be preheated to approx. 80°- 200° C.
Preheating is also necessary when the component temperature at the start of the welding work
is below +5°C and when the construction of the repair part prevents the welding stress to be
released.
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Repair welding
3 Treatment of electrodes
Use only dry electrodes for welding. Electrodes with damaged coating and rusted electrodes
may not be used any longer.
Electrodes must be stored in a dry room with a minimum temperature of 15°C. Open electrode
packages must be carefully closed and stored after the welding work is complete.
4 Welding technique
The welding of material with the required electrodes (see chart under paragraph 7) is carried out
Per DIN 1912.
The adjustment of the welding current – dictated by the different thicknesses of the electrodes –
can be taken from the chart of the electrode package.
Beginning with material thickness of 8 mm, butt welds must be made in several layers. The weld
is applied in several beads. Wide butt welds are filled with several side by side beads, with the
last layer covering the center.
The electrode should melt evenly without creating burrs and peaks.
The valley or crater, which is created when changing electrodes must be filled in and
overlapped with the next electrode. To prevent cracks in those craters, care must be taken that
they are properly filled in.
If the crack extends towards the outer edge of the material, slap may be trapped or burn holes
may be created. To prevent this, the following aid may be used: Tack a piece of sheet metal to
the outer edge of the material. The welding seam begins now at the sheet metal in the direction
of the arrow toward the inside. After the welding is completed, the sheet metal is removed and
the edge of the material is ground smooth.
The welding seam must be cooled off slowly and should therefore be protected from rain and
wind.
Fig. 2 Crack running to the outer edge of the material / Prepared crack
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Repair welding
5 Reinforcement of welding seam
If the crack of the material is due to on overload or abuse, a reinforcement plate should be
welded over the crack. The selection of the correct reinforcement plate is based on the
construction and load factors of the component to be repaired.
For that reason, only general recommendations can be made as to the size and shape of the
reinforcement plates.
5.1 Shape of plate
The crossover or connection between the reinforced and not reinforced part should be as
gradual as possible, this means that the size of the plate should be selected in such a way that
new or unacceptable high stress in the repaired part is avoided. Plates with sharp corners
(such as a rectangular plate) should not be used.
Fig. 3 Reinforcement plate against clean pulling / bending and alternating loads
5.2 Plate thickness
The thickness of the reinforcement plate should be up to 2/3 of the thickness of the material to
be reinforced.
5.3 Material quality of plate
The material properties (yield and tensile strength, etc.) of the reinforcement plate should be
equal to the material to be reinforced.
5.4 Installation of reinforcement plate
The welded area of the crack should be ground so it is smooth and level.
The size of the plate must be selected in such a way that the longer sides of the plate extend
into the connecting construction of the material to be reinforced. The plate should also overlap
the crack on each side by at least 20 mm. The correct position and fit of the reinforcement plate
is achieved by clamping and spot welding.
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Repair welding
5.5 Welding the reinforcement plate
The reinforcement plate should be welded on by running a welding bead alternately on both
sides. The welding should always start in the middle of the plate and run towards the outside.
Be certain to observe that each welding seam has proper run out.
Welding direction
Fig. 4 Welding directions
The size of the welding run "a" is figured out in reference to the thickness "k" of the repair plate.
Use formula: a=0.5 k
Up to a welding run "a" of approx. 3 mm, a single run can be made, however, as a general rule,
a double run should be preferred.
Above a welding run "a" = 3 mm, the first run provides excellent penetration between the
reinforcement plate and the basic material. Subsequent runs are added on top of the first run.
Fig. 5 Three or one layer welding seam
After the welding is completed, clean the welding seam as necessary and grind out the run
between the reinforcement plate and the basic material,
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Repair welding
6 Selection of correct welding electrodes
For repair welding, only lime based (Kb) electrodes should be used, and as a rule, the
electrodes (additional material) should be "softer" than the basic material. Exceptions should be
observed.
Note!
To reach the theoretical welding quality, the work must not only be performed in a professional
manner, the electrode manufacturer’s guidelines must be strictly observed as well.
Caution!
Welding of vertical-down welds is not permitted for steel components!
6.1 Electrode selection
Welding area Material Electrode norm description
Shielding gas weld welding
wire – norm description
BASIC MACHINE
St 52 - 3
QStE 380 N
Per EN 499:
E42 5 B 4 2 H5
per AWS A5.1-91:
E7018-1 H4 R
Per EN 440:
G4Si1
per AWS A5.18-93:
ER 70 S-6
Track
Main frame
LH 690
Preheat to approx.
100-150°C.
Per EN 757:
E 69 6 Mn2NiCrMo B 4 2 H5
per AWS A5.5-96:
E 11018-G
Per EN 12534:
G3CrNi1Mo
per AWS A5.28-96:
ER110S-G
Track
Main frame/
bottom plates
HARDOX 400 per AWS A5.1-91:
E7018-1 H4 R
per AWS A5.18-93:
ER 70 S-6
ATTACHMENT
Dozer blade
Bucket
Q St E 380 N
HARDOX 400
Per EN 499:
E42 5 B 4 2 H5
per AWS A5.1-91:
E7018-1 H4 R
Per EN 440:
G4Si1
per AWS A5.18-93:
ER 70 S-6
St 52 - 3 Per EN 499:
E42 5 B 4 2 H5
per AWS A5.1-91:
E7018-1 H4 R
Per EN 440:
G4Si1
per AWS A5.18-93:
ER 70 S-6
Push frame
Bucket arm
Pipe layer boom
LH 690
Preheat to approx.
100-150°C.
Per EN 757:
E 69 6 Mn2NiCrMo B 4 2 H5
per AWS A5.5-96:
E 11018-G
Per EN 12534:
G3CrNi1Mo
per AWS A5.28-96:
ER110S-G
Ripper St 52 - 3
Q St E 380 N
HARDOX 400
Per EN 499:
E42 5 B 4 2 H5
per AWS A5.1-91:
E7018-1 H4 R
Per EN 440:
G4Si1
per AWS A5.18-93:
ER 70 S-6
WEAR PARTS
Adapter
Tooth retainer
Ripper
Special steel Root layers
Per EN 499:
E42 5 B 4 2 H5
per AWS A5.1-91:
E7018-1 H4 R
Root layers
Per EN 440:
G4Si1
per AWS A5.18-93:
ER 70 S-6
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Repair welding
Cover runs with high tensile
electrode
per EN 1600:
E 18 8 Mn B 2 2
per AWS A5.4-92:
E 307-15
Cover runs with high tensile
welding wire
per EN 12072:
G 18 8 Mn
per AWS A5.9-93:
ER307
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Repair welding
6.2 Steel chart
Item Description Analysis
HARDOX 400 Weldable, low alloy special steel with high
wear resistance, a tensile strength of 1250
N/mm² and a yield strength limit of 1000
N/mm²
C 0,27% Si 0,7%
Mn 1,6% Cr 1,4%
Mo 0,6%
Q St E 380 N Fine grain structural steel poured at special
low turbulence with a guaranteed minimum
tensile strength of 500 - 640 N/mm² and
minimum yield strength limit of 380 N/mm²
C 0,18%
Si 0,5%
Mn 1,6%
Sonderstahl 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 Tempered fine grade structural steel with a
tensile strength 770 - 940 N/mm² and a
yield strength limit of 690 N/mm²
C 0,18% Si 0,50%
Mn 1,5% Mo 0,5 %
Ni 1,5 %
leicht legiert mit V, AI und Cu
6.3 Welding additive chart for arc welding
Item Description Analysis values in % / Application
Per EN 499:
E42 5 B 4 2 H5
for example Böhler
FOX EV 50
E = Arc welding
42 = 500-640 N/mm² tensile strength
5 = Value for notch impact strength
B = basic shielded
4 = Value for run out and type of
current
2 = Value for welding positions
H5 = maximum hydrogen content
C = 0,07, Si = 0,5, Mn = 1,1
For connection and applied welds,
especially for steels with low purity
and higher carbon content.
Weldable with DC current, Electrode
on Plus terminal (+).
No vertical seams.
Per EN 757:
E 69 6 Mn2NiCrMo B
4 2 H5
for example Böhler
FOX EV 85
E = Arc welding
Mn2NiCrMo = Chemical composition
B = basic shielded
current
H5 = maximum hydrogen content
C = 0,05, Si = 0,4, Mn = 1,5,
Cr = 0,4, Ni = 2,0, Mo = 0,5
For welds, which require high tenacity
and crack resistance, use for highly
alloyed fine grain steel.
Very low hydrogen content in welding
material.
No vertical seams.
nach EN 1600:
E 18 8 Mn B 2 2
z.B. Böhler
FOX A 7
E = Arc welding
Mn = Chemical composition
B = basic shielded
current
C = 0,1, Si = 0,7, Mn = 6,5,
Cr = 18,8, Ni = 8,8
For connections between different
alloyed and difficult to weld steel
No vertical seams
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Repair welding
6.4 Welding additive chart for metal inert gas weld with solid wire electrodes
Item Description Analysis values in % / Application
per EN 440:
G4Si1
for example Böhler
EMK 8
G = Metal inert gas weld with solid wire
electrodes
Si = Chemical properties
current
C = 0,1, Si = 1,0, Mn = 1,7
For connection and applied welds,
especially for steels with low purity
and higher carbon content.
Shielding gas: Argon + 15-20% CO2
or 100% CO2
No vertical seams
per EN 12072:
G 18 8 Mn
for example Böhler
A7 IG
G = Metal inert gas weld with solid wire
electrodes
Mn = Chemical composition
C = 0,08, Si = 0,9, Mn = 7,0,
Cr = 19,2, Ni = 9,0
For connections between different
alloyed and difficult to weld steel
Shielding gas: Argon + max. 2.5%
CO2
No vertical seams
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Installation instructions
2.3.00 Installation instructions
1 Duo cone (slip ring) seals
1.1 Design and function
Due to the pretension of the O-rings 2, the two slip rings 3 are pushed against each other and
thereby seal the bearing point via the sliding surface 4.
Seal variations:
- Seal toward the outside - Seal toward the inside
Fig.1 Seal variations
1 Seal mount
2 O-ring
3 Slip ring
4 Sliding surface
Note!
On Series 4 machines, due to design reasons, only seals toward the outside are used.
1.2 Installation
1.2.1 General installation notes
The slip rings of the seals are made as a pair. For that reason, they may only be used in the
original pairing, in new as well as in used condition.
Avoid shock and impact, since this could damage the sealing surfaces of the hard cast duo
cone slip rings.
Round off any sharp edges on the sealing mounts.
Slip rings seals and their mounts must be absolutely clean and free of grease at installation.
O-rings may not be lubricated with oil.
Slip ring seals should generally be installed with the aid of an installation device, see Special
tools, section 2.1.
Caution!
Without the aid of the installation device, the O-ring can roll up on the conical slip ring surface.
If the pressure at installation is one-sided, the seal half can move sideways and/ or the O-ring
can twist. These improper installations as well as damage to the sealing surfaces cause leaks.
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2.3.00 - 2 / 6 Mjfcifss!
Installation position correct Installation position incorrect Installation position incorrect
O-ring twisted Seal half is inclined
Fig.2 O-ring installation positions
1.2.2 Installation of the slip ring seal
A split device 5 is used as an installation aid, which is folded over the slip ring 3 and transfers
the pressure at installation directly to the O-ring 2.
Push the seal halves with the appropriate installation aid into the seal mount 1. The required
pressure must be exerted evenly over the entire circumference of the O-ring.
If no matching installation aid is available, then a round rubber string 6 can be inserted as a
makeshift spacer between the slip ring 3 and the O-ring 2 and affixed by hand, so that the O-
ring cannot roll up on the conical slip ring surface when the seal halves are pushed in.
Fig.3 Installation slip ring seal
1 Seal mount 5 Installation device
2 O-ring 6 Aid round rubber string
3 Slip ring
Before assembly of the two seal mounts, check if the slip rings project evenly. To do so,
measure the distance of the seal mount to the slip ring on at least 3 locations of the
circumference, always offset by 120°. Check the sealing surfaces again for absolute cleanliness
and apply a thin film of oil or grease.
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2 Safety lever
Fig.4 Installation notes for safety lever
Note!
1. Adjust the Allen screw on the limit switch.
2. Tighten the hex nut to a tightening torque of 8 Nm and open by 1 1/4 turns.
3. Insert the hex nut with Loctite.
4. Tighten the hex nut to the tightening torque (see section 1.3) and then open by 1.5 to
2 turns.
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2.3.00 - 4 / 6 Mjfcifss!
3 Assembly instructions for track
Note!
The assembly instructions for the track are valid only for the following machine:
RL 64 F/N xxx-10598
Fig. 5 Instructions for track installation
1 Track frame 6 Track axle
2 Final drive 7 Installation screw with washer
3 Idler unit 8 Hex head screw with washer
4 Axle bearing housing 9 Axle cover
5 Axle bearing cover 10 Hex head screw
For the assembly of the complete track on the machine, observe the following points:
Install the track axle 6 into the carrier frame.
Align the equalizer bar in horizontal (center) position.
Lubricate the rubber elements of the track axle 6 and the corresponding counter surfaces of the
axle bearing with linseed oil (see detail A)
Lift the track onto the track axle 6 which was installed in the carrier frame.
Place the axle bearing cover 5 onto the axle bearing housing 4.
Note!
The installation screws may only be used for the assembly process.
RL 64 F/N xxx-10598 installation screws 7, M24x80, 10.9
Tighten the axle bearing cover crosswise with four installation screws with washers 7 according
to factory standard WN 4037 (see detail B).
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Check the installation of the axle bearing cover 5 on the axle bearing housing 4. The gap
between the two components must be evenly closed.
Install all remaining hex head screws with washers 8 and tighten crosswise according to WN
4037.
Remove the installation screws 7 (see detail C)
Note!
The installation screws may only be used for the assembly process.
Instead of the installation screws 7, install four new hex head screws with washers 8 and tighten
according to WN 4037.
Then check all hex head screws 8 for the specified tightening torque (see detail D)
Attach the equalizer bar bearing on the Track frame 1.
Then install the axle cover 9 with the hex head screws 10 and tighten them crosswise according
to WN 4307.
Repeat the installation procedure on the second track side.
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2.3.00 - 6 / 6 Mjfcifss!
4 Assembly instructions for mounting the axle cover on idler and
track roller (RL64)
For installation of axle covers for the track roller A or idler B, observe the following procedure:
Tighten the hex head screw marked „1“ or „tighten first“ according to the tightening torque, see
chart.
Tighten all remaining hex head screws in sequence (2-3-4) crosswise according to the
tightening torque, see chart.
Screw mounting with friction number G = 0,10
Wrench size (x) = per DIN931, forPretension force Fm
according to grade in N
Tightening torque
Ma according to
grade in Nm Hex head screwThread
10.9 10.9 mm Inch
M 24 249000 800 36 1-7/16
M 30 400000 1600 46 1-13/16
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Service Manual Technical data and maintenance guidelines
Sub group index - Technical data and maintenance guidelines
3 Technical data and maintenance
guidelines
3.0.00 Sub group index - Technical data and
maintenance guidelines
Technical data................................................................................................ 3.1
Maintenance and inspection schedule........................................................ 3.2
Maintenance and inspection instructions ................................................... 3.3
Adjustment checklist .................................................................................... 3.4
Test and adjustment tasks .......................................................................... 3.5
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Technical data and maintenance guidelines Service Manual
Sub group index - Technical data and maintenance guidelines
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Technical data
RL 44 F/N xxx-10000
MJFCIFSS! 3.1.40 - 1 / 4
3.1.40 Technical data
Diesel engine
Type D 936-L A6
Version 6 cyl. Inline – charge air cooled
Rating according to ISO 9249 kW 175 (238 PS)
Nominal RPM RPM 1800
Low idle (ULL) RPM 900+50
High idle (OLL) RPM 1900+50
Displacement l 10,52
Oil quality / viscosity See operating instructions
Max. permissible machine incline – all directions 45° = 100%
Valve clearance – cold On/ off See data tag / Diesel engine
Firing order 1 – 5 – 3 – 6 – 2 – 4
Splitterbox
Type 351 B 374
Version Spur gear – 1-stage
Ratio 0,86
Oil quantity / oil quality / viscosity See operating instructions
Hydraulic system
Var. displacement pump Type 2 x HPV 135
Flow quantity - Qmax l/min 2 x 282
Operating pressure (M1 / M2) - pmax bar 420+30/-10
Tandem gear pump – replenishing Size 55
Flow quantity - Qmax l/min 117
Operating pressure (SP) - pmax bar 23+5
Tandem gear pump – fan drive Size 19
Operating pressure (LA) - pmax bar 220±10
Gear motor – fan drive Size 16
Operating RPM RPM 1800±100
Var. displacement motors Type 2 x HMV 280
Travel
hydraulic
Discharge bar 14
Regulating pump Type A 10 V O140
Stand-by pressure (HD) bar 25+2
Operating pressure (HD) - pmax bar 280±5
Working
hydraulic
Servo pressure – operating pressure (ND)
bar 23+4
Hydraulic tank capacity l 126
- Circuit - additionally l 164
Electrical system
Operating voltage V 24
Batteries 2 x 12V, 170Ah (in Series)
Alternator 28V, 80A
Starter kW 7,8
Central fuse A 45
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Technical data
RL 44 F/N xxx-10000
3.1.40 - 2 / 4 Mjfcifss!
Final drive
Type FAT 500 E 517/518
Version
Spur gear + planetary gear, each 1
stage
Parking brake, integrated Disk brake
Ratio i ges 41,4 : 1
Oil quantity l See section 11.1 Data page
Track
left right
Chain pitch mm (inch) 215,9 (8,5)
Chain length Links 43
Track pad width (2 grouser) mm (inch) 914 (36)
610 (24)
710 (28)
Track pad bolts Thread size 7
⁄8“ UNF
Track rollers – single flange per side (e) Each 4
Track rollers – double flange per side (d) Each 4
Track roller arrangement e – d – e – d – d – e – d – e
Carrier rollers per side Each 2
Track oscillation Fixed
Ground placement surface m
2
5,39
Working attachment
Boom length mm 6000 7320
Working range (ISO 8813) mm 1180 6000 1240 7150
Boom cylinder Cyl. / rod / Stroke mm 170 / 90 / 1260
Counterweight - cylinder Cyl. / rod / Stroke mm 100 / 60 / 610
Counterweight – total kg 7222
Fixed installed kg 2192
Removable (10 pieces) Total / piece/ piece kg 5030 / 5x 619 / 5x 387
Hoist winch
Drive hydraulic
Drum
- Diameter mm 254
- Length mm 279,4
- Flanged wheel diameter mm 609,6
Rope
- Diameter mm 20
- Length mm 65000
Hook block Strands 4
Hook speed in 1. rope layer lift / lower m / min 0 23.6 stepless
Load capacity max. (according to ISO 8813) t 28,4
Safety devices Freefall control
Oil quantity / oil quality / viscosity See operating instructions
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Technical data
RL 44 F/N xxx-10000
MJFCIFSS! 3.1.40 - 3 / 4
General
Travel speed forward reverse
Normal range – III km/h 0 10,5 0 10,5
Reduced range – II km/h 0 6,5 0 7,8
Reduced range – I km/h 0 4,0 0 4,5
Boom length (mm)
6000 7320
Tractive power, max., depends on ground composition kN 283
Operating weight kg 35059 35321
Ground load (calculated comparison value) kg/cm2
0,65 0,66
Dimensions – basic machine
Total length mm 5295
Wheel base mm 3316
Transport width (with retracted counterweight) mm 3475
Transport width (with removed counterweight) mm 2997
Track width mm 2075
Total height max. mm 6999 8319
Transport height mm 3298
Ground clearance mm 461
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Technical data
RL 44 F/N xxx-10000
3.1.40 - 4 / 4 Mjfcifss!
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Technical data
RL 64 F/N xxx-10598 MJFCIFSS! 3.1.60 - 1 / 4
3.1.60 Technical data
Diesel engine
Type D 946-L A6
Engine version 6 cyl. in-line - charge air cooled
Performance according to ISO 9249 kW 275 (374 PS)
Nominal RPM RPM 1800
Low idle RPM (ULL) RPM 900+50
High idle RPM (OLL) RPM 1900+50
Displacement l 11,95
Oil quality / viscosity See Operating instructions
Max. permissible machine incline - all directions 45° = 100%
Valve play - cold In / out See data tag / Diesel engine
Firing order 1 – 5 – 3 – 6 – 2 – 4
Splitterbox
Type 351 B 364
Version Spur gear 1-stage
Gear ratio 0,86
Oil fill quantity / oil quality / viscosity See Operating instructions
Hydraulic system
Var. displ. pumps Type 2 x HPV 280-02
Flow quantity – Qmax l/min 2 x 518
Operating pressure (M1 / M2) – pmax bar 420+30/-10
Tandem gear pump – Replenishing Size 55 + 38
Flow quantity – Qmax l/min 174
Operating pressure (SP) – pmax bar 23+5
Axial piston pump – Fan drive Type A 10 V 28
Stand by pressure LA bar 30+5
Operating pressure bar 205±5
Axial piston motor – Combi cooler Size 28/52
Operating RPM 1/min 1500±100
Gear motor – Oil cooler Size 19
Operating RPM 1/min 1800
±100
Var. displ. motor Type 4 x HMV 210
Travel
hydraulic
Discharge bar 14
Regulating pump Type A 10 V O140
Stand by pressure (HD) bar 25
+2
Operating pressure (HD) – pmax bar 280±5
Working
hydraulic
Servo pressure – Operating pressure (ND)
bar 23+4
Tank capacity l 215
- Circuit – additional l 181
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Technical data
RL 64 F/N xxx-105983.1.60 - 2 / 4 Mjfcifss!
Electrical system
Operating voltage V 24
Batteries 2 x 12V, 225Ah (in Series)
Alternator 28V, 80A
Starter kW 7,8
Central fuse A 45
Final drive
Type FAT 650 E 519
Version
Spur gear 1-stage +
Planetary gear 2-stage
Parking brake integrated Disk brake
Ratio i ges 54,32 : 1
Oil quantity l see section 11.1 Data page
Track
left right
Chain pitch mm (inch) 215,9 (8,5)
Chain length links 48
Track pad width (2 grouser) mm (inch) 914 (36) 762 (30)
Track pad screws Thread size M 24 x 1,5
Track rollers – double flange per side (d) each 9
Track roller arrangement d – d – d – d – d – d – d – d – d
Carrier rollers per side each 2
Track oscillation fixed
Ground surface area m
2
6,05
Working attachment
Boom length mm 8500 10500
Working range (ISO 8813) mm 1400 8440 1480 10260
Boom cylinder cyl. / rod / stroke mm 230 / 115 / 2230
Counterweight - cylinder cyl. / rod / stroke mm 120 / 70 / 1420
Counterweight - total kg 15035,5
Fixed installed kg 3905,5
Removable (14 each) total / each kg 11130 / 14x 795
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Technical data
RL 64 F/N xxx-10598 MJFCIFSS! 3.1.60 - 3 / 4
Hoist winch
Drive hydraulic
Drum
- Diameter mm 254
- Length mm 279,4
- Pulley diameter mm 609,6
Rope
- Diameter mm 20
- Length mm 100000
Hook block Strands 8
Hook speed in 1.Seillage up / down m/min 0 11,6 stepless
Load capacity max. (according to ISO 8813) t 48,3
Safety device Freefall control
Oil quantity / oil quality / viscosity See Operating instructions
General
Travel speed forward rerverse
normal range – III km/h 0 10,5 0 10,5
reduced Range II km/h 0 6,5 0 7,8
reduced Range I km/h 0 4,0 0 4,5
Boom length (mm)
8500 10500
Tractive power max. depends on ground conditions kN 520
Operating weight kg 57719 59257
Ground load (calculated comparison value) kg/cm
2
1,00 1,01
Dimensions of basic machine
Overall length mm 5760
Wheel base mm 3605
Transport width (with retracted counterweight) mm 4835
Transport width (with removed counterweight) mm 3495
Track gauge mm 2510
Overall height max. mm 9515 11515
Transport height mm 3630
Ground clearance mm 630
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Technical data
RL 64 F/N xxx-105983.1.60 - 4 / 4 Mjfcifss!
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LIEBHERR RL64 PIPE LAYER SERIES 4 LITRONIC Service Repair Manual

LIEBHERR RL64 PIPE LAYER SERIES 4 LITRONIC Service Repair Manual

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