Fault Codes Xeroxةنتها

 
    
  


 
   

    
   
     
  
  
  
  

  
    
  
  
     
  
    
  
  

  
  
      
  
Service Manual
Index
0.1.00 Index
Date of
Section Title
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
LWT / Ausgabe / Edition / Edition / 03.2010
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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RL Litronic Serie 4 MJFCIFSS! 0.1.00 - 1 / 4

Service Manual
Index
Date of
Section Title
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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0.1.00 - 2 / 4 Mjfcifss! RL Litronic Serie 4

Service Manual
Index
Date of
Section Title
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
Date of
Section Title
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
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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RL Litronic Series 4 MJFCIFSS! 1.0.00 - 1 / 2

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.
copyright by

General Service Manual
Foreword and explanation
2 Explanation of layout
To simplify finding certain information and filing of updates, we set up the following layout:
Main group Type group
Component (item) groups Structure based on
according to register information content or
machine size
Sub group Page number
Structure of main group Continuous No. and
according to sub group index 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
copyright by
1.1.00 - 2 / 2 Mjfcifss! RL Litronic Series 4

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
Metric Preload value Fm based Tightening torques Wrench size (x) = according to DIN931,
standard on grades in N Ma based on for
thread grades in Nm
Hex head screw Socket head
screw
8.8 10.9 12.9 8.8 10.9 12.9 mm Inch mm Inch

M4 x 0.7 4050 6000 7000 2,8 4,1 4,8 7 9/32 3 --
M5 x 0.8 6600 9700 11400 5,5 8,1 9,5 8 5/16 4 5/32
M6 x1 9400 13700 16100 9,5 14 16,5 10 -- 5 --
M7 x1 13700 20100 23500 15,5 23 27 11 -- -- --
M8 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 x2 55000 80000 94000 125 185 215 (22) 21 (7/8) - - 12 --
M 16 x2 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 x3 175000 249000 290000 670 960 1120 36 1-7/16 19 3/4
M 27 x3 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 x4 410000 580000 680000 2350 3300 3900 55 2-3/16 27 1-1/16
M 39 x4 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
Metric Preload value Fm based Tightening torques Wrench size (x) = according to DIN931,
standard on grades in N Ma based on for
thread grades in Nm
Hex head screw Socket head
screw
8.8 10.9 12.9 8.8 10.9 12.9 mm Inch mm Inch

M8 x1 18800 27500 32500 24,5 36 43 13 1/2 6 --
M9 x1 24800 36500 42500 36 53 62 -- -- -- --
M 10 x1 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 x2 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 x2 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 x2 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 x2 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 x2 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 x3 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 x3 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
Screw size
nominal size Flat flange without Flange with
Half flange
reinforcement rim reinforcement rim
½" M8 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" M8 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

to unit
Size from unit Multiplier Multiplier to unit
from
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
2
Ground pressure kg/cm² 14,223 lbs.inch 0,0703 kg/cm²
2
kg/m² 0,205 lbs. ft. 4,878 kg/m²
3
Density g/cm³ 0,036 lbs. inch 27,78 g/cm³
3
kg/m³ 0,062 lbs. 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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Conversion chart
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Tapping holes
1.3.03 Tapping holes

1 Tapping holes for metric ISO standard threads
Hole diameter Ø
Diameter
Thread Drill bit Ø
dimensions
max. min.
M1 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
M2 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
M3 2,599 2,459 2,5
M 3,5 3,010 2,850 2,9
M4 3,422 3,242 3,3
M 4,5 3,878 3,688 3,7
M5 4,334 4,134 4,2
M6 5,153 4,917 5
M7 6,153 5,917 6
M8 6,912 6,647 6,8
M9 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

Hole Ø diameter limits Hole Ø diameter limits
Thread size Drill bit Ø Thread size Drill bit Ø
max. min. max. min.
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
M8x1 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
M9x1 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
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 4 MJFCIFSS! 1.4.00 - 1 / 6
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 See section To check the battery
tester 2.1 condition and the
antifreeze in the
coolant
WAXOYL 120-4 8504472 Spray can 500ml

Anti corrosion wax Long term protection
for up to 2 years
Ballistol Spray 10025514 Application area:
Corrosion protection Door locks
Dehumidification 10013313 Prevents infiltration
capsule 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
1.4.00 - 2 / 6 Mjfcifss! LR Litronic Serie 4
RL Litronic Serie 4
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
RL Litronic Serie 4
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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PR Litronic Serie 4
RL Litronic Serie 4
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
Material A B C D
Weathered rock
2790 42 0,70 1960
75% rock, 25% soil
Weathered rock
2280 33 0,75 1720
50% rock, 50% Soil
Weathered rock
1960 24 0,80 1570
25% rock, 75% Soil
The actual values depend on the moisture content, the grain size and the compression. Testing
is required to determine more exact values.
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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
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 Diagnostics
software - accessory software for
maintenance and
consisting of: adjustment of
Sculi License with 10450054 LR Series 4 Diesel engine.
USB Dongle RL Series 4 For ordering, a
for engine Service PR 724 F/Nxxx- Liebherr form
Level 9200 from Liebherr
(LH ECU UPCR-, PR 734 F/Nxxx- Bulle must be
DC4-, DC5- engine 8220 filled out.
control units and PR 744 F/Nxxx-
Master 4 controls) 7356 Download the
PR 754 F/Nxxx- current software
6924 version with the
PR 764 F/Nxxx- aid of the Lidos
6888 DVD.
Communication cable 10035410 LR Series 4
for LH-ECU-UPCR RL Series 4
control units
PR 724 F/Nxxx-
9200
PR 734 F/Nxxx-
8220
PR 744 F/Nxxx-
7356 Use of Sculi
PR 754 F/Nxxx- software also
6924 possible with the
PR 764 F/Nxxx- previous DC-Desk
9506 Dongle.
Communication cable 10035411 PR 764 F/Nxxx-
for DC4 / DC5 6888 9505
control units
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PR Litronic Series 4
LR Litronic Series 4 MJFCIFSS! 2.1.00 - 1 / 22
RL Litronic Series 4
Special tools

Digital rpm gauge 7364284 PR Series 4 To measure the
„Shimpo“ LR Series 4 rpm with the
RL Series 4 reflective strip
Test range: 6-8300
rpm ±1 rpm
Reflective strip 614063201
Digital rpm gauge 10286429 PR 724 F/Nxxx- To measure the

„Piezzo A2106“ 6600 9199 engine rpm via
PR 734 F/Nxxx- impulse frequency
6200 8219 of the injection line
PR 764 F/Nxxx-
6888 9505
DCA 4 Test Kit 5608459 PR 724 F/Nxxx- To check the DCA

„CC2602M“ 6600 9199 4 concentration in
Consisting of: PR 734 F/Nxxx- the coolant
Container 6200 8219
50 Test strips PR 764 F/Nxxx-
Clear plastic container 6888 9505
Pipette
Hand pump [1] 8145666 PR Series 4 To take oil

LR Series 4 samples for the oil
RL Series 4 analysis
Oil sample vale for oil 7019068

samples [2]
Oil analysis set– PR Series 4 Analysis at WEAR

mineral oil (green LR Series 4 CHECK Germany
cover) RL Series 4
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
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2.1.00 - 2 / 22 Mjfcifss! LR Litronic Series 4
Special tools

V-belt test unit 8042829 PR Series 4 To check the V-belt
„Krikit2“ LR Series 4 tension
RL Series 4
Optical battery tester 7408922 PR Series 4 To check the

LR Series 4 battery charge and
RL Series 4 the antifreeze in
the coolant
Turning device for

valve clearance /
check / adjust
Pos. 1 0524045 LR Series 4 To be installed on
the flywheel
RL Series 4 housing instead of
PR Series 4 the cover
except
Pos. 2 10490350 PR 764 To be installed on
F/Nxxx-9506 the V-belt -
10116805 RL 64 crankshaft
(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 )
Hand pump with 10454803 PR Series 4 For optional Diesel
pressure gauge LR Series 4 particle filter. Can
RL Series 4 also be used for
leak test of
counterpressure
line
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Special tools
1.2 Hydraulic system

Vacuum pump cpl. 7408148 PR Series 4 For faster bleeding
with accessory LR Series 4 of hydraulic
RL Series 4 system, by
Consisting of:
enclosing the PVC
Vacuum pump with 7407987 hose, a slight
electrical cable excess pressure
Hose fitting 7407985 (ca.0.4 bar) can be
Hose fitting 10301165 produced.
Fitting S8M 7404619 Connection point
Fitting L6R 4901110 for the vacuum
PVC hose 7360127 pump on the
Terminal clamp, 10038447 machine is the
positive breather screw on
Terminal clamp, 10038448 the hydraulic tank
negative
Plug 2-pin 7408151
Temperature gauge 10024185 PR Series 4 Accuracy:
LR Series 4 2% / 2°
RL Series 4
Test range:
-18°C to +260°C
Difference pressure – 10288229 PR Series 4 To measure

Mess-Set 230V/120V LR Series 4 pressure, pressure
RL Series 4 peaks and
Consisting of: pressure difference
Test unit Multi-Handy and suitable for
2045 data transfer to PC
2 Pressure sensors 0-
600 bar
2 Mini test connections
2 Test cable 12m long
KFZ Connector cable
Data cable
Power unit
Scale pressure gauge PR Series 4 Accuracy:
LR Series 4 1% of the scale
0-10 5002865 RL Series 4 end value
0-25 7361289
0-40 7361288 All pressure
0-60 5002867 gauges are
0-100 5602903 glycerin filled
0-160 7361286
0-250 7361285
0-400 7500002
0-600 7361294
0-1000 4601115
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Special tools

Pressure gauge 7002436 PR Series 4 To seal at pressure
connection LR Series 4 tests, a square
R½ RL Series 4 seal ring,
Id.No. 7409794
must be used
Test fitting cpl. PR Series 4 Union nut and

LR Series 4 compression ring
R6L 7409916 RL Series 4 are affixed on the
R 10 L 7406864 test fitting
R 12 L 7409918
Screw coupling PR Series 4 To connect to

LR Series 4 additional test
M 8x1 7615321 RL Series 4 points in the
M 10x1 5608462 machines
M 12x1,5 7407071
M 14x1,5 7406865
R¼ 7409720
Screw coupling PR Series 4 To connect shorter

LR Series 4 test lines or for
M 16x2 7407070 RL Series 4 connection
between test
connection and
pressure sensor
Test hose NW 2 PR Series 4 To keep loss of

LR Series 4 pressure during
1000 mm 7002437 RL Series 4 tests to a
1500 mm 7002475 minimum, shorter
4000 mm 7009134 test hoses are
5000 mm 7363732 preferable
Hook wrench PR Series 4 To loosen / counter

LR Series 4 when adjusting the
58 - 62 mm 7900282 RL Series 4 pump regulating
range
Socket wrench 9792711 PR Series 4 To loosen / counter

For grooved nut LR Series 4 when adjusting the
variable pump HPV RL Series 4 pump end stop.
Use with hook
wrench
Id. Nr. 7900282
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Special tools

Socket wrench for 0- 9749025 PR Series 4 To loosen / counter
position grooved nut LR Series 4 the grooved nut
Variable pump HPV RL Series 4 when adjusting the
hydraulic zero
position
Test plates PR Series 4 To close off high

LR Series 4 pressure
For SAE-flange ¾ 7370092 RL Series 4 connections
A 90mm
B 40mm Material:
C,r 5mm Ground spring
For SAE-flange 1 7370093 steel
A 90mm
Round off end of
B 44mm
the plate
C,r 5mm
(simplifies
For SAE-flange 1¼ 7370094
installation, avoids
A 90mm damage to the seal
B 52mm ring)
C,r 5mm
Or to be made in-
house
Open ended wrench 8006305 PR 724 F/Nxxx- Open ended
SW 30/32 6600 9199 wrench to check or
PR 734 F/Nxxx- replace the return
6200 8219 filters. Can also be
PR 764 F/Nxxx- used for other
6888 9505 connections.
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1.3 Electrical system

LinDiag Diagnostics 9413782 PR 724 F/Nxxx- To adjust the travel
KIT 6600 9199 hydraulic, read out
PR 734 F/Nxxx- the Service Codes
Consisting of: 6200 8219 and for trouble-
PR 764 F/Nxxx- shooting on Series
Data carrier with latest 9410472
6888 9505
software version + 4 machines of
Dongle exhaust stage
Tier2
Adapter cable 9932747
LinDiag Diagnostics 9413763 LR Series 4 To adjust the travel

KIT RL Series 4 hydraulic, read out
PR 724 F/Nxxx-
the Service Codes
Consisting of: and for trouble-
9200
Data carrier with latest 9410472 PR 734 F/Nxxx- shooting on Series
software version + 8220 4 machines of
Dongle PR 744 F/Nxxx- exhaust stage
Adapter cable 10035410 7356 Tier3
PR 754 F/Nxxx-
6924
PR 764 F/Nxxx-
9506
USB – Adapter 693190714 PR Series 4 Intermediate

LR Series 4 adapter from serial
RL Series 4 interface to USB
Digital multi meter 10018500 PR Series 4 For

cpl. with cable and bag LR Series 4 Voltage (V)-
RL Series 4
Amperage (A)-
Resistance ( )-
Frequency (Hz)-
tests
Optical charge tester see Pt. 1.1 PR Series 4 To check the

Diesel engine LR Series 4 battery condition

RL Series 4 and the antifreeze
in the coolant
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1.4 Mechanical component groups

Test tool Travel gear 7402603 PR Series 4 To measure travel
LR Series 4 gear wear
RL Series 4
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.

Pressurized air 10045498 LR Series 4 CO2 cartridge to
cartridge RL Series 4 vent the parking
PR 724 F/Nxxx- brake for towing
7697 operation.
PR 734 F/Nxxx-
8220
PR 744 F/Nxxx-
7356
Brake vent adapter 9401975 PR 754 F/Nxxx- Adapter for
6924 pressurized air
PR 764 F/Nxxx- cartridge (part of
6888 tool kit)
Socket wrench PR Series 4 For repair of

Valve sleeve LR Series 4 variable motor
RL Series 4 HMV
Valve – 3 slits 10430260
To remove and
Valve – 2 slits 10491131 install the valve
sleeve of the
directional valve
See section 8.2

Position 73
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Mandrel Thrust ring For repair of var.
pump HPV or var.
HPV 105 10472254 PR 724 motor HMV
LR 624
HPV 135 10472255 PR 734 For the installation
LR 634 of the hot thrust
RL 44 ring on the drive
HPV 210 10472257 PR 744 shaft.
PR 764
HMV 165 10472261 PR 744 See chapter 8.1 or
LR 624 8.2, Position 11
HMV 210 10472266 PR 724
PR 754
LR 634
RL 64
HPV 280 10472269 PR 754
RL 64
HMV 280 PR 734
PR 764
RL 44
Mandrel [1] and For repair of var.
protective sleeve [2] pump HPV or var.
for shaft seal ring motor HMV
HPV 105 1 10472303 PR 724 For pressing in the

HPV 105 2 10411001 LR 624 radial shaft seal
ring to push over
HPV 135 1 10472310 PR 734 the drive shaft (in
HPV 135 2 10411002 LR 634 connection with the
RL 44 corresponding
HMV 165 1 10472316 PR 744 protective sleeve)
HMV 165 2 10410291 LR 624
See section 8.1 or
HMV 210 1 10472317 PR 724 8.2, Position 12
PR 754
LR 634
RL 64
HPV 210 1 PR 744
PR 764
HMV 210 2 10410295 PR 724
PR 754
LR 634
RL 64
HPV 210 2 PR 744
PR 764
HMV 280 1 10472318 PR 734
PR 764
RL 44
HPV 280 1 PR 754
RL 64
HMV 280 2 10411003 PR 734
PR 764
RL 44
HPV 280 2 PR 754
RL 64
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Installation aid for For repair of var.
seal ring on oil guide pump HPV or var.
pipes motor HMV
Pos.1 10472322 RL Series 4 The tool is used to

HPV + HMV LR Series 4 install the O-rings
PR Series 4 on the oil guide
except pipes
Pos.2 10472321 PR 724
HPV 105 LR 624 See section 8.1
Position 46 or
section 8.2.
Position 45
Spindle device for 10324938 PR Series 4 For repair of var.
swash plate mount LR Series 4 pump HPV
RL Series 4
With this device,

the swash plate
mount can be
lowered targeted
onto the pump
housing at
installation.
Centering pins for For repair of var.

swash plate mount pump HPV or var.
motor HMV
M12 HPV 10472319 PR 724
LR 624 The guide pins are
M14 HPV 10472320 PR 734 used to guide the
PR 744 swash plate mount
PR 764 at assembly with
LR 634 the pump housing.
RL 44
M14 HMV PR 724 minimum 2 each
PR 744 maximum 4 each
PR 754 required
LR 624
LR 634
RL 64
M16 HPV 10347066 PR 754
RL 64
M16 HMV PR 734
PR 764
RL 44
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Centering device for 10324937 PR Series 4 For repair of var.
swash plate mount LR Series 4 pump HPV or var.
RL Series 4 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 For installation of

list O-ring and
stepseal ring on
pistons of hydraulic
cylinders
Spreader sleeve see spare parts For installation of

list O-ring and
stepseal ring on
pistons of hydraulic
cylinders
Installation wrench see spare parts To tighten the

Piston list pistons of hydraulic
cylinders
For tightening
torque, see section
8 Hydraulic
cylinder
Installation wrench see spare parts To tighten the

Piston nut list piston nuts of
hydraulic cylinders
For tightening
torque, see section
8 Hydraulic
cylinder
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Crimper PR Series 4 To make proper
for LR Series 4 crimp connection
MATE-N-LOK Crimp RL Series 4 on MATE-N-LOK
contacts plug connections
For 1.5 mm² 7367025

For 2.5 mm² 7366314
Removal tool AMP 7366655 PR Series 4 To remove crimp
for LR Series 4 contacts from plug
MATE-N-LOK Crimp RL Series 4 connector
contacts
Spare insert 7015180
Installation tool AMP 8145432 PR Series 4 To insert the pin

for LR Series 4 and bushing
MATE-N-LOK Crimp RL Series 4 contacts in MATE-
contacts N-LOK plug
connectors
Hand crimper 8503647 PR Series 4 To make proper

for „Deutsch“ plug LR Series 4 crimp connections
connector RL Series 4
Removal tool Cannon PR Series 4 To remove pin and

for „Deutsch“ LR Series 4 bushing contacts in
crimp contacts RL Series 4 „Deutsch“ plug
connectors
AWG 12 10114733
AWG 16 885563714
AWG 20 10114732
Removal tool Cannon PR Series 4 To remove pin and

for „Deutsch“ crimp LR Series 4 bushing contacts in
contacts RL Series 4 „Deutsch“ plug
(alternate) connectors
(alternate)
AWG 12 8145674
AWG 16 8145673
AWG 20 8503630
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Crimper AMP 7415333 PR Series 4 To crimp the
AMP Certi-Lock LR Series 4 „JUNIOR POWER
RL Series 4 TIMER“ contacts
Removal tool AMP PR Series 4 To remove

LR Series 4 contacts from the
AMP 726 503-1 7026266 RL Series 4 „JUNIOR POWER
AMP 726 534-1 7027340 TIMER“ housing
Crimper PR Series 4 To crimp insulated

LR Series 4 0.5 -6.0 mm² cable
ESA 0760 7409781 RL Series 4 shoes, for example
CRB 0560 7409782 cable connectors
CRB 0560 also
windshield wiper
motor
Coding plug In case of

Inching / brake pedal defective inching /
brake pedal for
X46 9813111 PR Series 4 continued
RL Series 4 operation of the
X46.1 9413850 LR Series 4 machine.
See section 9.
Inching / brake
pedal
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2.4 Mechanical component groups

Installation device for To properly install
slip ring seal – travel the slip ring seals
gear on travel gears
FAT 400 E 511 LR 624

Slip ring seal Id.No. Device No.:
7361 197 outside 10467795 07590 45459
7109 24901 inside 10467796 07590 45458
FAT 450 E 504/505 PR 724

FAT 450 E 510 LR 634
Slipring seal Id.No. Device No.:
7109 25201 outside 10219780 07590 38616
7109 26301 inside 10219779 07590 43327
FAT 500 E 502/503 PR 734

FAT 500 E 517/518 RL 44
7610 242 outside 10017428 07590 39022
7361 197 inside 10219781 07590 43326
FAT 600 E 506 PR 744

7610 244 outside 10017436 07590 38891
7610 240 inside 10303340 07590 38472
FAT 650 E 508 PR 754

Slipring seal Id.No. RL 64 Device No.:
7610 245 outside 10017433 07590 39023
7610 241 inside 10017472 00100 01300
FAT 700 E 501 PR 764

7610 237 outside 10017468 07590 41338
7610 243 inside 10017430 07590 38886
Mandrel For installation of

radial shaft seal
Pos.1 Installation flange rings into the hoist
A 9786683 PR 724 cylinder bearing.
9786685 PR 734 See section 15.2
9786686 PR 744 A= For Pos.10

PR 754 B= For Pos.7
PR 764
B 9786684 PR 724 For dimensions for
9786687 PR 734 in-house
9411074 PR 744 manufacture of
PR 754 mandrel, see Pt. 3.
PR 764
Pos.2 Screw in handle 9786688 PR Series 4
for all installation
flanges
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Inside puller Commercially PR Series 4 To pull the
available tool bushings, Pos. 3
Pos.1 with counter and Pos.4 from the
support hoist cylinder
Pos.2 For the following bearing
dimensions (in mm)
PR 724 PR 734 PR744

PR754
PR764
A 90 90 120
B 70 70 90
C 247 273 273
D 89,5 96 114
Pull tool Elastic 9404645 PR Series 4 To install and
bearing operators LR Series 4 remove the elastic
platform RL Series 4 bearing of the
operators platform
For dimensions for

in-house
manufacture of
mandrel, see Pt. 3.
Installation sleeve 9415227 PR 764 To install the outer
Equalizer bar bearing um equalizer bar
bearing
In-house LR Series 4 For dimensions for
manufacture RL Series 4 in-house
PR 724 manufacture of
PR 734 assembly sleeves,
PR 744 see Pt. 33.
PR 754
PR 764
Installation wrench 9416915 PR 754 Special hook
Tension unit RL 64 wrench to release
and attach the ring
9416913 PR 764 nut
Installation tool 9416922 PR 754 Sleeve to push on

Tension unit RL 64 the ring nut
prevents twisting of
9416921 PR 764 ring nut
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Installation tool For removal /
Tension unit installation of
tension unit –
Pos.1 Installation flange 9798353 PR 754 chain tensioner is
Pos.2 Bar 9798352 RL 64 required!
Pos.3 hex head screw 4601217
6 each
M16x310 mm 10.9
For use, see
Installation tool cpl. 9415198 PR 764 section 12 Tension
unit
Installation tool To remove /
Tension unit install the tension
unit – chain
Mechanical device 10303939 LR Series 4 tensioner is
(without hydraulic required!
components)
10307625 RL 44
Hydraulic components 10303852 LR Series 4 For use, see

For Installation tool RL 44 section 12 Tension
unit
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
Technical data – Hydraulic components
Hydraulic cylinder Hand pump Hydraulic hose Pressure gauge

Enerpac RC 506 Enerpac P80 Enerpac HC-7206 Enerpac GF-50B
(50 t single acting) (two stage hand pump)
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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Installation sleeve 10306449 PR 754 To press the
Equalizer bar equalizer bar in
with oscillating
track rollers.
For dimensions for

in-house
manufacture of
mandrel, see Pt. 3.
Installation tool set 10318790 PR 764 For removal /
Double oscillating track installation of pins
roller with bearing for
double oscillating
Pos.1 Threaded rod track rollers.
M30x360 (2 each)
Pos.2 Plate For dimensions for
Pos.3 Washer M30 in-house
(2 each) manufacture of
Pos.4 Hex nut M30 (4 plate (Pos.2) see
each) Pt. 3.
For use, see

section 2.3
Installation tool PR764 For removal /
Double oscillating track installation of pins
roller with bearing for
Hydraulic components double oscillating
for Installation tool track rollers.
Consisting of:
For use, see
section 2.3
Hydraulic cylinder 11081098
Enerpac RCS 201
Hydraulic hose Enerpac 10430200
HC- 7206
Pressure gauge 11081099
Enerpac
GF- 230B
Intermediate section 10430202
Enerpac
GA-2
Hand pump Enerpac 886120508
P39
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Technical data – Hydraulic components
Hydraulic cylinder Hand pump Hydraulic hose Pressure gauge

Enerpac RCS 201 Enerpac P39 Enerpac HC-7206 Enerpac GF-230B
(20 t single acting) (two stage hand pump)
2
Piston surface 28,7cm 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
1 PR 724 100 130 75 --- --- --- --- --- ---

LR 624
PR 734 120 150 100 --- --- --- --- --- ---
LR 634
2 PR 744 81,5 137 120 91 115 35 7 13 129

PR 754
RL 44
RL 64
3 PR 764 83 149 120 101 135 --- 7,5 12,8 ---
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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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3.3 Pull tool – operator’s cab bearing

For installation and removal of elastic bearing of operators platform.
See section 17.1 Position 11 and 22.
Fig. 3 Dimensions of pull tool

1 Threaded rod M30 4 Washer
2 Sleeve 5 Shim M30
3 Washer 6 Nut M30
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
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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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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 manufacturers guidelines must be strictly observed as well.
Caution!
Welding of vertical-down welds is not permitted for steel components!
6.1 Electrode selection

Shielding gas weld welding
Welding area Material Electrode norm description
wire – norm description
BASIC MACHINE
Track St 52 - 3 Per EN 499: Per EN 440:
Main frame QStE 380 N E42 5 B 4 2 H5 G4Si1
per AWS A5.1-91: per AWS A5.18-93:
E7018-1 H4 R ER 70 S-6
LH 690 Per EN 757: Per EN 12534:
Preheat to approx. E 69 6 Mn2NiCrMo B 4 2 H5 G3CrNi1Mo
100-150°C. per AWS A5.5-96: per AWS A5.28-96:
E 11018-G ER110S-G
Track HARDOX 400 per AWS A5.1-91: per AWS A5.18-93:
Main frame/ E7018-1 H4 R ER 70 S-6
bottom plates
ATTACHMENT
Dozer blade Q St E 380 N Per EN 499: Per EN 440:
Bucket HARDOX 400 E42 5 B 4 2 H5 G4Si1
E7018-1 H4 R ER 70 S-6
Push frame St 52 - 3 Per EN 499: Per EN 440:
Bucket arm E42 5 B 4 2 H5 G4Si1
Pipe layer boom per AWS A5.1-91: per AWS A5.18-93:
E7018-1 H4 R ER 70 S-6
LH 690 Per EN 757: Per EN 12534:
Preheat to approx. E 69 6 Mn2NiCrMo B 4 2 H5 G3CrNi1Mo
100-150°C. per AWS A5.5-96: per AWS A5.28-96:
E 11018-G ER110S-G
Ripper St 52 - 3 Per EN 499: Per EN 440:
Q St E 380 N E42 5 B 4 2 H5 G4Si1
HARDOX 400 per AWS A5.1-91: per AWS A5.18-93:
E7018-1 H4 R ER 70 S-6
WEAR PARTS
Adapter Special steel Root layers Root layers
Tooth retainer Per EN 499: Per EN 440:
Ripper E42 5 B 4 2 H5 G4Si1
E7018-1 H4 R ER 70 S-6
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Repair welding
Cover runs with high tensile Cover runs with high tensile
electrode welding wire
per EN 1600: per EN 12072:
E 18 8 Mn B 2 2 G 18 8 Mn
E 307-15 ER307
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Repair welding
6.2 Steel chart
Item Description Analysis

HARDOX 400 Weldable, low alloy special steel with high C 0,27% Si 0,7%
wear resistance, a tensile strength of 1250 Mn 1,6% Cr 1,4%
Mo 0,6%
²
N/mm and a yield strength limit of 1000
N/mm²
Q St E 380 N Fine grain structural steel poured at special C 0,18%
low turbulence with a guaranteed minimum Si 0,5%
tensile strength of 500 - 640 N/mm² and Mn 1,6%
minimum yield strength limit of 380 N/mm²
Sonderstahl Highly abrasion resistant steel with a tensile C = 0,3% Mn = 0,7%
strength of 1720 N/mm² Si = 0,5% Cu = 0,65%
Mo = 0,3% V = 0,05%
St 52 - 3 Structural steel poured at low turbulence C 0,22%
S355J2G3 with a guaranteed minimum tensile strength
of 510 N/mm²
LH 690 Tempered fine grade structural steel with a C 0,18% Si 0,50%
tensile strength 770 - 940 N/mm² and a Mn 1,5% Mo 0,5 %
yield strength limit of 690 N/mm² 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: E = Arc welding C = 0,07, Si = 0,5, Mn = 1,1
E42 5 B 4 2 H5 42 = 500-640 N/mm² tensile strength
5 = Value for notch impact strength For connection and applied welds,
for example Böhler B = basic shielded especially for steels with low purity
FOX EV 50 4 = Value for run out and type of and higher carbon content.
current Weldable with DC current, Electrode
2 = Value for welding positions on Plus terminal (+).
H5 = maximum hydrogen content No vertical seams.
Per EN 757: E = Arc welding C = 0,05, Si = 0,4, Mn = 1,5,
E 69 6 Mn2NiCrMo B 69 = 760-960 N/mm² tensile strength Cr = 0,4, Ni = 2,0, Mo = 0,5
4 2 H5 6 = Value for notch impact strength
Mn2NiCrMo = Chemical composition For welds, which require high tenacity
for example Böhler B = basic shielded and crack resistance, use for highly
FOX EV 85 4 = Value for run out and type of alloyed fine grain steel.
current Very low hydrogen content in welding
2 = Value for welding positions material.
H5 = maximum hydrogen content Weldable with DC current, Electrode
on Plus terminal (+).
No vertical seams.
nach EN 1600: E = Arc welding C = 0,1, Si = 0,7, Mn = 6,5,
E 18 8 Mn B 2 2 18 = 620-770 N/mm² tensile strength Cr = 18,8, Ni = 8,8
8 = Value for notch impact strength
z.B. Böhler Mn = Chemical composition For connections between different
FOX A 7 B = basic shielded alloyed and difficult to weld steel
2 = Value for run out and type of Weldable with DC current, Electrode
current on Plus terminal (+).
2 = Value for welding positions 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: G = Metal inert gas weld with solid wire C = 0,1, Si = 1,0, Mn = 1,7
G4Si1 electrodes
4 = 500-640 N/mm² tensile strength For connection and applied welds,
for example Böhler Si = Chemical properties especially for steels with low purity
EMK 8 1 = Value for run out and type of and higher carbon content.
current Weldable with DC current, Electrode
Shielding gas: Argon + 15-20% CO2
or 100% CO2
No vertical seams
per EN 12072: G = Metal inert gas weld with solid wire C = 0,08, Si = 0,9, Mn = 7,0,
G 18 8 Mn electrodes Cr = 19,2, Ni = 9,0
18 = 580-730 N/mm² tensile strength
for example Böhler 8 = Value for notch impact strength For connections between different
A7 IG Mn = Chemical composition alloyed and difficult to weld steel
Weldable with DC current, Electrode
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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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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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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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
Pretension force Fm Tightening torque Wrench size (x) = per DIN931, for
according to grade in N Ma according to
Thread grade in Nm Hex head screw
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
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 153624
Splitterbox
Type 351 B 374
Version Spur gear 1-stage
Ratio 0,86
Oil quantity / oil quality / viscosity See operating instructions
Hydraulic system
Travel Var. displacement pump Type 2 x HPV 135
hydraulic 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
Flow quantity - Qmax l/min 33
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
Discharge bar 14
Working Regulating pump Type A 10 V O140
hydraulic Flow quantity - Qmax l/min 284
Stand-by pressure (HD) bar 25+2
Operating pressure (HD) - pmax bar 280±5
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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RL 44 F/N xxx-10000
MJFCIFSS! 3.1.40 - 1 / 4
Technical data
Final drive
Type FAT 500 E 517/518
Spur gear + planetary gear, each 1
Version
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
610 (24)
Track pad width (2 grouser) mm (inch) 914 (36)
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 ededdede
Carrier rollers per side Each 2
Track oscillation Fixed
Ground placement surface m2 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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RL 44 F/N xxx-10000
3.1.40 - 2 / 4 Mjfcifss!
Technical data
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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RL 44 F/N xxx-10000
MJFCIFSS! 3.1.40 - 3 / 4
Technical data
copyright by
RL 44 F/N xxx-10000
3.1.40 - 4 / 4 Mjfcifss!
Technical data
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 153624
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
Travel Var. displ. pumps Type 2 x HPV 280-02
hydraulic 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
Flow quantity Qmax l/min 57
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
±100
Operating RPM 1/min 1800
Var. displ. motor Type 4 x HMV 210
Discharge bar 14
Working Regulating pump Type A 10 V O140
hydraulic Flow quantity Qmax l/min 284
+2
Stand by pressure (HD) bar 25
Operating pressure (HD) pmax bar 280±5

Servo pressure Operating pressure (ND)
bar 23+4
Tank capacity l 215

- Circuit additional l 181
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RL 64 F/N xxx-10598 MJFCIFSS! 3.1.60 - 1 / 4

Technical data
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
Spur gear 1-stage +
Version
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 ddddddddd
Carrier rollers per side each 2
Track oscillation fixed
Ground surface area m2 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 LWT / Ausgabe / Edition / Edition / 06.2008
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3.1.60 - 2 / 4 Mjfcifss! RL 64 F/N xxx-10598

Technical data
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/cm2 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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RL 64 F/N xxx-10598 MJFCIFSS! 3.1.60 - 3 / 4

Technical data
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3.1.60 - 4 / 4 Mjfcifss! RL 64 F/N xxx-10598

Service manual Technical data and maintenance guidelines
Maintenance and inspection schedule
3.2.00 Maintenance and inspection schedule

Company: Machine:
S/N: -
Operating
hours:
Inspector:
Application From
type: company:
Application Date:
location:
Maintenance /
Inspection WORK TO BE CARRIED OUT
at operating hours by maintenance personnel by authorized trained personnel
first and only interval first and only interval
Repeat interval Repeat interval
Reference Remar
see: ks
OI Operating instructions
SM Service Manual
For correct fill quantities, use test marks-
for procedure and quantities, see OI
For quality and viscosity guidelines, see “Service items” OI
See data in SM
DIESEL ENGINE
Check oil level and coolant level OI
Check / clean Diesel engine, coolant assembly and belly pan for contamination OI
Drain condensation in fuel separator OI
Fuel tank, drain condensation and sediments
OI
- but at least 1x a week
Change engine oil -1)
- shorten interval in case of aggravating circumstances OI
- but at least 1x a year
Change lube oil filter 1)
OI
- but at least 1x a year
Check corrosion inhibitor / antifreeze concentration in coolant OI
Check V-belt condition OI
Check control unit mounting, sensory and cable connections for condition OI
Change / replace oil separator filter insert OI
Check oil, coolant and fuel system for leaks and condition OI
Check intake and exhaust system - mounting and leaks OI
Check engine mount OI
Check engine rpm SM
Change fuel pre-filter and fine filter
OI
- Observe bleeding instructions
Check / adjust valve clearance
SM
- with cold Diesel engine
Grease gear ring on flywheel SM

Take oil sample and send it in for analysis OI
Check vibration damper for leaks and distortion
OI
- 3000 hrs.
Check heater flange
SM
- before start of cold season
Change heater flange
SM
- 10000 hrs.
Replace air filter inserts
OI
- as necessary / a year
Replace coolant with antifreeze
- 3000 hrs. OI
- but at least every 2 years
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Technical data and maintenance guidelines Service manual
Maintenance /
Reference Remar
OI Operating instructions see: ks
SM Service Manual
See data in SM
HYDRAULIC SYSTEM
Check oil level in hydraulic tank OI
Check oil cooler for contamination and clean OI
Replace pressure filter for replenishing OI
Replace main return filter or immediately after indicator light lights up OI
Check working and travel hydraulic system for function and leaks,
OI / SM
check hose routing for chafing
Check and adjust all hydraulic pressures according to adjustment check list SM
Check mountings and fittings for tight seating OI
Clean magnetic rod (also after repairs)
OI
- up to 50 hrs daily
Take oil sample (before oil change) and send it in for analysis OI
Replace third party mineral oil product in hydraulic system (add oil via filter)
- at least every 4 years
OI
- when using an environmentally friendly hydraulic medium, request / observe special
guidelines
Replace Liebherr Hydraulic oil in hydraulic system (add oil via filter)
- at least every 4 years
- or 3000 hrs.
SPLITTERBOX
Check oil level OI
Replace gear oil OI
ELECTRICAL SYSTEM
Check function of system incl. displays, indicator lights and lighting OI
Check battery electrolyte level
OI
- at least 1x a year
Clean / check / grease battery connections OI
Check cable routing and connections OI / SM
Check and adjust control system of travel drive according to adjustment check list SM
Check battery charge condition
SM
- before start of cold season
Check machine software version
SM
- update older version with the latest software version
HEATER / VENTILATION / AIR CONDITIONING SYSTEM
Turn the air conditioning system on regularly
OI
- at least 1x every 14 days
Check water drain valves for air cond. system, clean if necessary OI
Check system for function and leaks OI

Clean air circulation and fresh air filter, replace as necessary, in dusty conditions, shorted
OI
maintenance interval
Check mounting screws and drive belt of air conditioner compressor OI
Check dryer unit (moisture, fill, condition)
OI
- replace if necessary, evacuate system and refill
Clean water drain valves for air cond. system OI
Check electrical lines for chafing and plug connections for tight seating OI
Air conditioning system – have it checked / inspected by HVAC technician
SM
- 1x a year
Check condenser for contamination
OI
- as necessary
copyright by

Service manual Technical data and maintenance guidelines
Maintenance /
Reference Remar
see: ks
SM Service Manual

See data in SM
TRAVEL GEAR
Check condition of travel gear
Check oil level for seal area
- at least 1x a year OI
- or if indicator light lights up
Check gear oil level – clean magnetic plug OI
Check fittings for tight seating OI / SM
1)
Replace gear oil – clean magnetic plug
OI
Replace lube oil in seal area / flush seal area
OI
Take oil sample from gear before oil change and send it in for analysis OI
TRACK COMPONENTS
Check mounting screws and nuts of track components,
OI
especially track pad and sprocket segment screws for tight seating
Check oil level in support axle bearing (only RL 44) OI
Check all track components for leaks OI
Check / adjust idler guides, replace parts, if necessary OI
Adjust chain tension to suit application
OI / SM
- as necessary / when changing applications
Clean track
OI
- as necessary
Check for track wear
SM
- as necessary
WORKING ATTACHMENT
Check screws, nuts and pin retainers for tight seating OI
Winch rope – check entire length for damage and grease, if necessary
OI
See Operating instructions of rope manufacturer
Check attachment for intentional damage OI
Check all bearing points for play / wear OI
Hoist – rope winch (2 separate oil chambers)
OI
- but at least every 3 months or if leaks are found
Check function of freefall device
OI
- always after extended downtime
Check function of hoist limit switch
OI
- always after extended downtime
Check rope pulleys and load hook for wear
- always after extended downtime OI

- Shorten interval if necessary / if instructed to do so
Maintain and check load moment limiter with display function according to manufacturer’s Manufacturer
instructions OI
Take oil sample on hoist winch and send it in for analysis (2 separate oil chambers)
OI
- but at least every 6 months
Change hoist – rope winch oil(s)
- Clean breather screw OI
- but at least 1 x a year
Rope winch – removal and inspection of all wear parts according to ANSI
- Specification B30.5c 1987 and API RP2D, section 3 OI
- if necessary, but at least every 6 years or 10000 hrs.
copyright by

Technical data and maintenance guidelines Service manual
Maintenance /
Reference Remar
see: ks
SM Service Manual
See data in SM
GENERAL
Determine and carry out maintenance and inspection requirements of all special / optional
Special
equipment included in the scope of delivery according to separate OI / manufacturer’s
OI
instructions
Lubricate all lube points according to lubrication schedule
OI
- Shorten intervals as necessary
Check complete machine for correct maintenance and proper condition OI
Explain machine literature, especially Operating instructions / safety guidelines
OI
to operating personnel
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Maintenance and inspection instructions
3.3.00 Maintenance and inspection instructions

1 General guidelines
1.1 Documentation of work to be carried out

Note!
For work to be performed, refer to the Maintenance and inspection schedule for your particular
machine model see section 3.2.
For detailed proof of completion, heck 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 3.4.
In addition, confirm the performance of the inspection / delivery in the machines inspection
booklet and send the appropriate Service ticket to the appropriate LIEBHERR organization.
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
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 for: changing filters, draining condensation and sediments in
case of dirty fuel; cleaning the cooler in case of contamination; changing filters and oils during or
after repairs, etc.
Dispose of used oil, filters and other waste products properly!
1.4 General
For all maintenance, inspection and repair work, use only LIEBHERR Original spare and
maintenance parts. If the operator requests the use of other, provided parts at installation, then
this should be noted in the inspection report after notifying him about a possible loss of
warranty.
For general screw tightening torques see section 1.3, for tightening guidelines for track pad and
sprocket segment bolts, see section 12.1.
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2 Maintenance and inspection work
2.1 Diesel engine
2.1.1 Check the Diesel engine RPM

Start the Diesel engine.
Read the RPM on the display or via the evaluation software LinDiag.
Compare the speed with the nominal RPM (see section 3.1. Data page).
If the RPM does not match the nominal RPM, then the throttle control must be adjusted. To do
so, see section 17.5 Throttle control.
2.1.2 Check / adjust valve clearance
Preparation for test

Ensure that:
The machine is in maintenance position.
The main battery switch S43 is turned off (Position 0).
The Diesel engine is cold.
Special tool Turning device for flywheel is available.
New seals for the cylinder head covers are available.
Check only when the Diesel engine is cold, for adjustment values, see Diesel engine data tag.
Note!
- Cylinder 1 is on the flywheel side of the Diesel engine.
- The direction of rotation is to the left, when viewed on the flywheel.
- The drain valve of the respective cylinder is located on the flywheel side.
Fig. 1 Installation of Diesel engine turning device

Install the special tool (see section 2.1) Turning device - flywheel (RL44) or Turning device
V-belt (RL64).
Remove the valve cover of the Diesel engine.
Turn the crankshaft in direction of rotation until the cylinders to be adjusted overlap the
opposite valves.
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Cylinder and valve arrangement on the Diesel engine
Fig. 2 Cylinder and valve arrangement
D936 L A6 = Inlet
D946 L A6 = Outlet
overlap 6 2 4 1 5 3
adjust 1 5 3 6 2 4
Note!
The valve clearance V is noted on the Diesel engine data tag.
Fig. 3 Diesel engine data tag

Slide a feeler gauge between the valve bridge and the rocker lever.
Fig. 4 Check the valve clearance

Check the valve clearance.
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If the value of the valve clearance does not match the nominal value, then the valve clearance
must be re-adjusted.
Fig. 5 Adjust the valve clearance

Loosen the lock nut on the adjustment screw of the respective rocker lever and correct the
adjustment.
Tighten the lock nut (40Nm).
Carry out a recheck.
After checking and adjusting all valves, install the cylinder head covers with new gaskets.
Remove the turning device from the flywheel housing.
2.1.3 Grease the gear ring on the flywheel
Note!
If possible use grease on non-metallic basis. High metal or graphite ratios as well as
excessive amounts of grease in connection with metallic wear debris can cause problems for
the RPM sensor signal.
The maintenance cover 1 is on the right side of the Diesel engine on the flywheel housing 4.
Fig. 6 Position of maintenance cover

The Diesel engine must be in maintenance position.
Remove maintenance cover 1 from the flywheel housing 4.
Caution!
Danger of damage!
Grease only the starter gear ring 2. The sensor gear ring 3 must be free of grease.
Grease the starter gear ring 2.
Install maintenance cover 1.
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2.1.4 Check the heat flange

The machine must be in the maintenance position.
Turn the master battery switch off (see section 16.3) and disconnect the negative cable of the
battery.
Disconnect the electric connector cable on the heat flange.
Connect an ohmmeter or multi-meter to the terminals and check the resistance.
If no resistance value of 250 mOhm +/ 10% at 20 °C is obtained, then the heat flange must
be replaced.
Connect the electric connector cable as well as the negative cable to the battery.
Fig. 7 Heat flange
2.2.5 Check working and travel hydraulic system for function and leaks, check
hose routing for chafing
Actuate all travel and working movements.
Check for erroneous functions and remedy them immediately.
Pilot control – working hydraulic

Check the actuator plate, plunger and joint of the working hydraulic pilot control for wear.
If necessary, lubricate lightly and adjust. See section 8.6, Pilot controls.
The same applies for pilot control for auxiliary equipment.
Accumulator – Safety control

Start the Diesel engine.
Lift the hoist gear and lower the counterweight.
Turn the Diesel engine off (return the ignition key again to position 1 Ignition on) and leave
the safety lever in the down position.
Actuate the function hoist gear down several times, jerkily and momentarily.
If the attachment moves down less than four times, then the accumulator is defective or there is
excessive leakage in the system.
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Hose lines
Check hose lines for leaks and kink-free routing.
Watch for chafe marks.
Replace chafed, sweating or aging hoses. See Safety guidelines in the Operating
instructions.
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. If necessary, tighten to the proper tightening
torque.
2.2.6 Check / adjust all hydraulic pressure according to adjustment check list
Carry out pressure tests / adjustments according to the adjustment check list for the respective
machine type see section 3.4 Adjustment check list and enter the results.
For details, data and instructions, see section 3.5. Test and adjustment tasks.
2.3.7 Check cable routing and connections

Check terminal posts and terminal clamps of batteries for oxidation and tight seating.
Clean terminal posts and clamps regularly and apply terminal grease.
Check batteries for external damage and leaks.
Check cable strands of electronic components for chafe marks and connections for oxidation.
Insulate any chafe marks, optimize the routing and protect the cable strand with heat shrink
tubing to prevent moisture infiltration.
2.3.8 Check / adjust the control system of the travel drive according to the
adjustment check list
Carry out with the aid of the notebook and the LinDiag Diagnostics software (For software
description, see section 10.1).
Carry out tests / adjustments according to the adjustment check list for the respective machine
type see section 3.4 Adjustment check list and enter the results.
For software - LinDiag Diagnostics KIT see section 2.1 Special tools.
2.3.9 Check battery charge condition
Warning!
Batteries emit explosive gases. Battery acid has strong caustic properties. Do not smoke and
avoid open flames when handling batteries as well as during battery maintenance and
charging.
Check the battery acid concentration with an optical battery charge tester - see Special tools
Section 2.1.
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Note!
To disconnect battery: Disconnect the negative terminal first, then the positive +
terminal.
To connect battery: Connect the positive + terminal first, then the negative - terminal .
The display is made by a line between light and dark on the left scale of the indicator window.
The indicator ranges are:
GOOD = Battery charged
FAIR = Battery half charged
RECHARGE = Battery discharged
The battery acid must be checked before adding water. Check each
battery cell separately.
If the test values of all cells are evenly below a density level of 1,200,
then the battery must be recharged with an external battery charger. If
the values differ (difference 0,02) or if they are below 1,100, then the
battery must be replaced.
For details about the use of a battery charge tester or to charge the
battery, refer to the manufacturers operating instructions.
Fig. 8 Display
2.3.10 Check the machine software version

On Series 4 machines, check the software version with the software programs LinDiag
Diagnostics software set for the travel drive. If you dont have the most current software
version, then the software must be updated. For software update, see software description,
section 10.1. The current software version is described in these instructions.
In addition to the software update, an adjustment of the corresponding components must be
carried out as described in section 3.4 - Adjustment check list.
2.4 Heater / ventilation / air conditioning system
2.4.11 Check the heater and air conditioning system

For instructions regarding function and general maintenance points, see section 17.2. Heater
and 17.3 Air conditioning system.
If access into the coolant circuit is required in case of problems or repairs of damaged
components, then it is imperative that a HVAC trained technician is called in.
2.5 Travel gear

2.5.12 Check fittings for tight seating and oil level

Check all mounting screws on both final drives for tight seating, retighten, if necessary. For
screw tightening torques, see section 1.3.
Check gear oil level and oil level in seal area.
Note!
If an increased oil level is found in the travel gear, then the seal of the disk brake and the oil
motor must be checked.
If necessary, open the gear and check the inner slipring seal (seal gap is filled with hydraulic
oil according to the Operating instructions).
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2.6 Inspection work on the tracks
2.6.13 Check screws and nuts for tight seating

The inspection of screws and nuts is especially important for new track components. Loose
track pad screws can also be recognized by misaligned nuts.
Loosen screws and retighten them. For safety reason, retighten all screw connections on the
affected components at the same time.
For tightening torque guidelines of track pad and sprocket segment screws, see section 12.1
Data page. For all other screws, refer to the standard tightening torques according to section
1.3.
2.6.14 Adjust chain tension to suit application, check track wear
Note!
The track chain tension must be adjusted by taking the working conditions into account, since
different ground or soil conditions cause different material build-up, and the track chain sag
should always be the same. Too much tension causes significantly increased track component
wear.
After machine standstill for forward travel on level ground, the chain sag between the idler and
the carrier roller or the carrier roller and the sprocket should be 30 to 40 mm, depending on the
track type. See Operating Instructions,
The scope of the track roller guard must also be matched to the given application conditions
see section 12.2.
The procedure for wear check, evaluation of test data and evaluation of wear pictures and their
causes, see description in section 12.2.
During the inspection of the track components, the condition of the elastic bearings on the
equalizer bar should also be inspected visually.
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Adjustment checklist
3.4.40 Adjustment checklist

Company: Machine:
S/N: -
Hrs.:
Inspector:
Application From Co.:
type:
Application Date:
location:
1 Preparation for hydraulic test

No.
Test Defects at inspection Defects remedied
1.1 Visual inspection

Before visual inspection, carry out scheduled maintenance and
inspection work
1.1.1 Visual inspection and maintenance
Service media and filters, mechanical components, travel joysticks and

dust covers, cable harness and plug connections, leaks on hydraulic
system, component mounting tightness
Remarks:
No.
Task LinDiag Software Remarks
1.2 LinDiag Diagnostics software save report

1.2.1 Reports saved Print out report acc. to software
instructions before hydraulic tests and
add to check list
1.2.2 Service Codes available
Note!
The checklist sequence is according to system requirements, for instructions which are
matched to the task of the adjustment checklist, see section 3.5.
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RL 44 F/N xxx-10000
MJFCIFSS! 3.4.40 - 1 / 4
Adjustment checklist
2 Test with standard testing devices

Test points Battery box Engine compartment left
Travel hydraulic
LA System pressure - fan drive

SP Replenishing pressure
MR1 High pressure travel forward right
MR2 High pressure travel reverse right
ML1 High pressure travel forward left
ML2 High pressure travel reverse left
Working hydraulic
LS Load pressure Load Sensing

HD High pressure
ND Low pressure - pilot control
Measure with preselected Diesel engine RPM = 1200+50 rpm or as noted.

Test Test value Adjust Test
No. Test Nomina value after ment point
Remark Unit l value at Test adjustment loc.
2.1 System Fan drive

2.1.2 Pressure limitation fan drive
Diesel engine on nmax, at least one bar 220±10 LA
temperature sensor unplugged.
Only test, no adjustment possible.

In case of pressure deviation, replace
proportional solenoid valve Y48.
2.1.3 Hydraulic oil temperature

±10
Bring machine to operating °C 70 P5
temperature. or
Temperature must remain constant LinDiag
for all adjustments
2.2 Travel hydraulic

2.2.1 Replenishing pressure
+5
No adjustment possible bar 23 SP
Diesel engine RPM from 1000 RPM
to high idle
2.2.2 Hydraulic neutral position

±1
Pump right bar M1=M2 1 MR1
±1
bar M2=M1 MR2
Pump left bar M1=M2±1 ML1
bar M2=M1±1 ML2
2.2.3 Pressure limitation High pressure (only as necessary / troubleshooting)
Pressure limitations in connection with Pt. 3.3.2 [Test BS / Y13] Test Brake solenoid check LinDiag.
+30/-10
Travel forward bar 420 ML1
bar 420+30/-10 MR1
Travel reverse bar 420+30/-10 ML2
bar 420+30/-10 MR2
copyright by
RL 44 F/N xxx-10000
3.4.40 - 2 / 4 Mjfcifss!
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  

      

1.0.00 Sub group index "General" 01.2008

2.0.00 Sub group index "Tools and work instructions" 01.2008

4.0.00 Sub group index "Engine" 01.2008

5.0.00 Sub group index "Coupling and splitterbox" 01.2008

5.4.60 Coupling Pump output 06.2008

6.0.00 Sub group index "Travel hydraulic" 01.2008

RL Litronic Serie 4 MJFCIFSS! 0.1.00 - 1 / 4

7.0.00 Sub group index "Working hydraulic" 01.2008

8.0.00 Sub group index "Hydraulic components" 01.2008

10.0.00 Sub group index "Electrical system - descriptions" 01.2009

11.0.00 Sub group index "Final drive" 01.2008

11.1.60 Data page 05.2008

0.1.00 - 2 / 4 Mjfcifss! RL Litronic Serie 4

12.0.00 Sub group index "Track components" 01.2008

13.0.00 Sub group index "Working attachment – front side" 01.2008

14.0.00 Sub group index "Working attachment" 01.2008

15.0.00 Sub group index "Main frame – Components" 01.2008

16.0.00 Sub group index "Tank arrangements" 01.2008

18.0.00 Sub group index "Special equipment" 01.2009

RL Litronic Serie 4 MJFCIFSS! 0.1.00 - 3 / 4

19.0.00 Sub group index "Additional documentation" 01.2008

LWT / Ausgabe / Edition / Edition / 03.2010

0.1.00 - 4 / 4 Mjfcifss! RL Litronic Serie 4

Safety regulations ......................................................................................... 1.2

Charts ............................................................................................................. 1.3

Tightening torques ............................................................................................................1.3.01

Conservation guidelines ............................................................................... 1.4

Material weights............................................................................................. 1.5

RL Litronic Series 4 MJFCIFSS! 1.0.00 - 1 / 2

1.1.00 Foreword and explanation

Written and published by

RL Litronic Series 4 MJFCIFSS! 1.1.00 - 1 / 2

This symbol identifies a standard listing.

This note shows that a detail view of an illustration is shown

LIEBHERR-Werk Telfs GmbH.

1.1.00 - 2 / 2 Mjfcifss! RL Litronic Series 4

1.2.00 Safety guidelines

RL Litronic Series 4 MJFCIFSS! 1.2.00 - 1 / 4

2 Danger notes in this manual

LWT / Ausgabe / Edition / Edition / 05.2008

1.2.00 - 2 / 4 Mjfcifss! RL Litronic Serie 4

3 Safety guidelines in the operating instructions

RL Litronic Series 4 MJFCIFSS! 1.2.00 - 3 / 4

1.3.01 Tightening torques

RL Litronic Series 4 MJFCIFSS! 1.3.01 - 1 / 4

2 Preload values and tightening torques for screws with standard

8.8 10.9 12.9 8.8 10.9 12.9 mm Inch mm Inch

LWT / Ausgabe / Edition / Edition / 05.2008