Sie sind auf Seite 1von 1426

en

Service Manual (20


Crawler Dozers

ints)

PR 712 - 752
(10

1 General Information 2 Special Tools, Application Guidelines 3 Technical Data - Maintenance Guidelines

Service Manual
Property of Liebherr-Werk Telfs GmbH

4 Engine

I
5 Coupling and Splitter Box 6 Travel Hydraulic 7 Working Hydraulic

Crawler Dozers
SERIES

Table of Contents
Issue 01/2004
8 Hydraulic Components

II

9 Electrical System 10 Electronic Control 11 Travel Gear 12 Track Components 13 Attachments - front 14 Attachments - rear

III
15 Main Frame - Add On Components 16 Tank Installation's
Book No.:

17 Operators Platform, Heater, Air Conditioner 18 Special Attachments 19 Miscellaneous Informations

Name of Manual Owner:

Sub Group Index


Foreword and explanation Safety guidelines Hand signals Service items Table - charts
Conversion table Tightening torques standard screws Tightening torques SAE screws Hole diameter before tapping Couplings ISO - tolerances

1.1 1.2.01 1.2.02 1.3.01 1.4


1.4.01 1.4.02 1.4.03 1.4.04 1.4.05 1.4.06

Code letters + terminal designations electric

1.5

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!
Datum Edition Date

PR Litronic LR Litronic RL Litronic

01 01

General information

Blatt Page Feuille

1.0.00.01

For your information


This manual contains technical data, descriptions of design and function, repair and adjustment guidelines as well as numerous drawings, functional views and illustrations LIEBHERR - crawler dozers (PR), crawler loaders (LR) or pipelayers (RL). This manual should simplify competent customer service of our products, does however, not replace expert and qualified training and an attendance of our factory schools. Information which is in trade considered basic knowledge is not included. Operation and spare parts information can be found in separate manuals. The manual will be updated as necessary when changes occur in series. This symbol is used in the manual for very important notes. During the activities on the machine, accident prevention regulations and safety guidelines must be strictly observed. This manual is intended for the exclusive use of the registered owner and may not be reproduced complete or in part or passed on a third person without written permission. This manual is still on property of LIEBHERR-Werk Telfs GmbH. All rights reserved - Printed in Austria. We reserve the right to make changes of technical details on the machine in comparison to the information and drawings in this manual. Printed and published by LIEBHERR-Werk Telfs GmbH., Service -Training Department.

Explanation of structure (page numbers)


In order to find specific information and add supplements more easily, the following numbering system is being used:

main group

sub group

model group

page No.

6. 3. 10 01
main group according to manual index sub group of main group according to sub group index division based on information content or machine model group continuous running number within the model group, illustrations or parts list with .00 may be added at the beginning or end of each group.

Updated pages retain the same page number, but receive a more recent date when mailed. Supplements have a new number. If the page is only valid for a certain machine model group, it will so be indicated on the page. We hope that with the enclosed information we have taken yet another step to improve the service on the LIEBHERR - crawler dozers, crawler loaders and pipelayers.

LIEBHERR-Werk Telfs GmbH. Service-Training Dept.

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Foreword and explanation


Datum Edition Date

PR Litronic LR Litronic RL Litronic


Blatt Page Feuille

01 03

General Information

1.1.00.01

Service Items
Notes for the disposition of service fluids and filter: Service fluids may not be discharged into the ground, drainage system or waterways. Different service fluids and filters should be collected and disposed of in separate containers. Do not use containers, which previously held food items or drinks - to prevent danger of mix-ups. Dispose of these items in an environmentally friendly manner according to applicable guidelines and regulations. Observe all state, local and national regulations. Do not use old or incorrectly stored service fluids and filters, dispose of them properly. 1. Service fluids for Diesel engines with turbo chargers 1.1. Engine lube oil Engine lube oils must meet a certain quality and a certain viscosity, depending on their use and ambient temperatures. Problem-free operation can only be ensured only if the requirements for both areas are met. 1.1.1 Oil quality To meet the technical demands, only highly alloyed lube oils are used in modern Diesel engines. They consists of high-quality base oils, mixed with additives. These additives provide the required properties for these oils. For LIEBHERR Diesel engines with turbo chargers, oils of the following specifications are approved, the higher quality oils are preferred: API - classification (American Petroleum Institute) : CF-4, CG-4, CH-4, CI-4,

ACEA (CCMC) - classification : E2 (D4), E3 (D5), E4, E5 (Association des Constructeurs Europens de lAutomobile) Note: For older machines / Diesel engines, if still in use, engine oils according to the lower specification as noted in the original operation manuals may be used. However, we recommend the use of these new oils, since the service life of the engine can be extended significantly by using these higher quality oils. The originally noted oil and filter change intervals may be extended.

1.1.2 Oil viscosity Z In addition to the quality, the oil must also provide a certain viscosity the selection is made according to the SAE - classification (Society of Automotive Engineers). The determining factor for the correct selection of the SAE classification is the ambient temperature. In most regions, SAE 10W-40 is recommended (see chart below). If the viscosity is too high, starting problems can occur, if it is too low, the lubrication efficiency can be endangered, both factors can lead to increased engine wear. The temperature ranges shown in the following chart are guidelines and may be exceeded or fallen below for a short time.

For the operation in extreme climate zones, such as in arctic regions, special guidelines apply and are available from the manufacturer.

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!
Datum Edition Date

PR Litronic LR Litronic RL Litronic

01 04

Service Items

Blatt Page Feuille

01.3.01.01

1.1.3 Oil change intervals The oil change intervals noted in the Maintenance and Inspection schedules always apply to "normal operating conditions". They apply for normal, central European temperatures, annual operation of approx. 1000 operating hours, use of oils of the required minimum quality and fuels with a sulfur content of less than 0.5%. When using higher quality oils, the operating hours per interval may be doubled - see the following chart. However, the 500 hour interval may not be exceeded. Engine oil and filters must be changed at least once a year, even if the given change interval has not yet been reached. In difficult circumstances, such as repeated cold start, higher sulfur content (above 05.%) in the fuel, more severe climatic conditions (for example continuous temperatures below -10C) etc., the intervals must be cut in half. This means, for each difficulty, the permitted operating hours per interval must be multiplied by a factor of 0.5. Permissible oil change intervals in operating hours: Oil quality: Applications Ambient temperature above -10C (Normal temperature) below -10C Continuous temperature Sulfur content in fuel to 0,5% above 0,5% to 0,5% above 0,5% CF-4, CG-4, CH-4, CI-4, E2 (D4)) Change interval 250 hrs. 125 hrs. 125 hrs. 60 hrs. Oil quality: E3 (D5), E4, E5, Change interval 500 hrs. 250 hrs. 250 hrs. 125 hrs.

1.2. Diesel fuels Diesel fuels must meet the minimum requirements of the following specifications. The sulfur content may not exceed 0.5%. A higher sulfur content has negative effects on oil change intervals and engine service life. A higher sulfur content above 1% is not permitted. Fuels with low sulfur content (for example, according to European regulations <0.05 %) must contain additives to retain the lubrication efficiency according to HFRR(60)-Test <400m - . Insufficient lubrication causes premature wear of the injection system components, especially distributor injection pumps. The additives should be added by the fuel supplier, as he is responsible for the quality of the fuel. We do not recommend addition of secondary lubrication additives by the user. Approved fuel specifications: DIN EN 590 + HFRR(60)-Test <400m ASTM D 975 - 89a 1D and 2D + HFRR(60)-Test <400m + cetane rating >45 (recommendation: >50)

Diesel fuels in very low temperatures At ambient temperatures below freezing (0 C), the flow properties of warm temperature Diesel fuel can become insufficient due to paraffin excretion. The same applies to cold temperature Diesel fuels in temperatures below. -15 C. In order to prevent operating problems in even lower temperatures, Diesel fuel with an additive is sometimes available, for use in temperatures to -20 C. In order to prevent operating problems in even lower temperatures, mix Diesel fuel with normal gasoline or petroleum. Addition of normal gasoline is a makeshift measure and may not exceed 30% per volume. Do not use Super gasoline for mixing. Mixing fuel can diminish engine performance, for that reason, keep the added fuel as low as possible, depending on the ambient temperatures. For safety reasons, mix fuel only in the fuel tank. When refueling, add the lighter additive before the Diesel fuel. Then let the engine run for a short time until the mixture has been distributed throughout the fuel system. Diesel fuels - Mixing ratio ( Vol.-%) Ambient temperature C 0 to -10 -10 to -15 -15 to -20 Summer Diesel fuel % Fuel 70 50 -% Additive 30 50* -Winter Diesel fuel to -15C % Fuel % Additive 100 100 70 --30 Winter Diesel fuel to -20C % Fuel % Additive 100 100 100 ----

-20 to -25 --50 50* 70 30 * = If an addition of more than 50% is required, use only petroleum (no regular gasoline). The Diesel fuel part may never be more than 50% .

Additives to Diesel fuel (flow improvers) Commercially available flow improvers can also improve Diesel fuel properties in cold temperatures. Always read and observe the manufacturers user guidelines and quantities.

1.3. Coolant Coolants, containing unsuitable anti corrosion / antifreeze fluids or wrong mixed coolants could damage the engine or its parts, caused by cavitation or corrosion. Additionally heat isolating deposits could be created on heat transferring parts, which overheat and lead to the damage of the engine. For a long term, fault free operation, the coolant must be filled year round with a mixture of at least 50% anticorrosion/antifreeze fluid. This concentration protects the system to approx. -37C / -34F. Antifreeze protection chart Protection to

Percentage of antifreeze (%)

Note:

Do not use more than 60% anti-corrosion / antifreeze fluids, a higher percentage would actually reduce the cooling and antifreeze protection and causes gel formation in the coolant fluid. Danger of engine damage!

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!
Datum Edition Date

PR Litronic LR Litronic RL Litronic

01 04

Service Items

Blatt Page Feuille

01.3.01.02

Coolant filters are used on some engine series, which filter the coolant in the auxiliary flow and in addition, a chemical additive in the filter (DCA 4) reinforces the protection against cavitation, corrosion, scale deposits and foam formation. The DCA4 concentration must be between 0.3 and 0.8 units per liter of coolant. See the following chapter Coolant with DCA4. This results in a mixing ration of approx. 48.5 % water, 48.5 % anti corrosion /antifreeze fluid and 3 % DCA4. Check the mixing ratio regularly during maintenance work. See instructions in section 3.4. If coolant must be replaced, make sure that the given mixing ratios are retained. Do not fall below this ratios nor exceed it. Due to the natural aging process of the coolant, it must be replaced at least once every 2 years. Use only suitable coolant, free of contaminants. Clean contaminated cooling systems. Note the following regulations. To replace or add coolant in larger quantities, mix the given parts outside the cooling circuit in a suitable, clean container first. Fresh water guidelines: To mix coolant fluid, use clean, clear water, which is not too hard. Often, but not always, regular tap water may be used. Seawater, brine, brackish water, or industrial waste water is not suitable. Approved fresh water quality (as of 2001) for use with anti corrosion / antifreeze fluid - without DCA4 Sum of alkaline earths (water hardness): Ph - value at 20 C Chloride / ion content Sulfate / ion content : 0,6 to 3,6 mmol/l (3 to 20d) : 6,5 to 8,5 : max. 80 mg/l : max. 100 mg/l - with DCA4 0,6 to 2,7 mmol/l (3 to 15d) 6,5 to 8,0 max. 80 mg/l max. 80 mg/l

Presently approved anti corrosion / antifreeze fluids (as of December 2003): Brand name Agip Antifreeze Plus Agip Langzeit-Frostschutz Antigel DB 486 Aral Khler-Frostschutz A AVIA Frostschutz APN (G48-00) BP Antifrost X 2270 A BP Napgel C 2270/1 Caltex Engine Coolant DB Caltex Extended Life Coolant Castrol Anti-Freeze O Century F.L. Antifreeze Chevron DEX-COOL Extended Life Anti-Freeze/Coolant Deutz Khlschutzmittel 0101 1490 Esso Khlerfrostschutz Fricofin Frostschutz Motorex (G48-00) Frostschutz 500 Glacelf Auto Supra Glycoshell AF 405 Glycoshell N Glysantin (G 48-00) Havoline XLC Havoline DEX-COOL Extended Life Anti-Freece/Coolant Manufacturer Agip Petroli S.p.A, Rom / Italien Autol-Werke GmbH., Wrzburg / BRD Sotragal SA, St. Priest / Frankreich Aral AG, Bochum / BRD Deutsche AVIA-Minerall GmbH, Mnchen / BRD Deutsche BP AG, Hamburg / BRD BP Chemicals Ltd., London / England Caltex (UK) ltd., London / England Caltex Deutsche Castrol Vertriebs-GmbH, Hamburg /BRD Century Oils, Hanley, Stoke-on-Trent / England Chevron Texaco DEUTZ Service International GmbH, Kln / BRD Esso AG, Hamburg / BRD Fuchs Mineraloelwerke GmbH, Mannheim / BRD Bucher+Cie, Langenthal / Schweiz Mobil Oil AG, Hamburg / BRD Total Shell Shell BASF AG, Ludwigshafen / BRD ARTECO Chevron Texaco

Igol Antigel Type DB Labo FP 100 Motul Anti-freeze OMV-Khlerfrostschutzmittel Organifreeze OZO Frostschutz S Total Antigel S-MB 486 Total Frostfrei Veedol Antifreeze O Wintershall Khlerschutz

Igol France, Paris / Frankreich Labo Industrie, Nanterre / Frankreich Motul SA, Aubervilliers Cedex / Frankreich OMV AG, Schwechat / sterreich Total Total Deutschland GmbH, Dsseldorf / BRD Total Deutschland GmbH, Dsseldorf / BRD Total Deutschland GmbH, Dsseldorf / BRD Deutsche Veedol GmbH, Hamburg / BRD Wintershall Minerall GmbH, Dsseldorf / BRD

Presently approved anti corrosion / antifreeze fluids / 50:50 Premix (as of December 2003):
(50 % water : 50 % corrosion/antifreeze fluids)

Brand name Liebherr Anti-Freeze APN mix Id.Nr. 8611 045 - 20 l bundle Caltex Extended Life Coolant Pre-Mixed 50/50 (ready-to-use-version) Chevron DEX-COOL Extended Life Prediluted 50/50 Antifreeze coolant Havoline XLC, 50/50 Havoline DEX-COOL Extended Prediluted 50/50 Antifreece coolant Organicool 50/50

Manufacturer LIEBHERR Caltex Chevron Texaco ARTECO Chevron Texaco Total

Presently approved anti corrosion / antifreeze fluids with DCA4 - ready to use (as of December 2003): Brand name Liebherr Anti-Freeze "pret a l'emploi" Id.Nr. 10 005 347 - 20 l bundle Manufacturer LIEBHERR

The given anti corrosion / antifreeze fluids are approved for all Liebherr Diesel engines (with and without coolant filter / DCA4).

1.3.1 Coolant with DCA4 (DCA = Diesel Coolant Additive) The additive DCA4 is "used up" during use. The DCA4 concentration in the filter compensates for this loss accordingly, if there is no loss of coolant and the correct filter is used at the given change interval. The DCA4 concentration must be between 0.3 and 0.8 units per liter of coolant. To check, refer to the "Maintenance and inspection guidelines", section 3.4. For change intervals for filter and coolant, see Maintenance and inspection schedule , section 3.2. If the cooling system is filled initially or refilled after repairs, then DCA 4 in liquid form must be added to the 50% anticorrosion / antifreeze and 50% water mixture. The mixture should be mixed outside the cooling system. Note the safety guidelines issued by the additive manufacturer.

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!
Datum Edition Date

PR Litronic LR Litronic RL Litronic

01 04

Service Items

Blatt Page Feuille

01.3.01.03

This results in a coolant mixture ration of approx. 48.5 % water, 48.5 % anticorrosion / antifreeze fluid and 3% DCA4. In addition, use a new coolant filter, according to the filling quantity. The correct Id. No. of the filter can be found in the Parts Manual or the Operation and Maintenance manual of the machine. Overview chart DCA4 and filter requirements (as of 2001) Coolant system contents Required quantity of liquid DCA 4 Liter 24-39 40-59 60-79 Container approx.0.5 liter 3 4 5 oder oder oder appr. liter 1,5 2,0 2,5 DCA 4 - water filter Id. No. 7367 045 7381 493 7367 052

80-115 8 oder 4 7367 052 Container liquid DCA4 at approx. 0.5 l -Id. No. 7363 898 Liebherr coolant (ready to use, 20 liter, above mixing ratio) - Id. No. 10 005 347 1.3.2 Coolant - special filling - with anti corrosion fluids, without antifreeze fluids In exceptional cases and if ambient temperatures are constantly above the freezing point, for example in tropical regional, where no anticorrosion / antifreeze fluids is proofed available, fresh water and water-soluble anticorrosion fluids (Inhibitors) may be used as coolant. Do not use coolant refiners (anticorrosion oils) with emulsifying capacity. If necessary, flush the cooling system before refilling. The fresh water quality must meet use with DCA4 - see chart Approved fresh water quality. The coolant must be changed once a year. Use of DCA4 To provide sufficient protection against corrosion, approximately twice the amount of DCA4 must be used as compared to the above mixing ration, when using anticorrosion / antifreeze fluids and DCA4 - see above "overview chart and filter requirements". The DCA4 concentration must be between 0.6 and 1.06 units. It must be checked during maintenance work or when the coolant filter is changed, and corrected, as necessary. This results in a mixing ratio of max. 94 % fresh water and min. 6 % DCA4 additive Use of products from Caltex / Chevron Texaco / Havoline / Total To provide sufficient protection against corrosion with these products, a mixture of 92,5 vol.% coolant and 7,5 vol.% anti corrosion fluid must be kept. The mixture ratio must be checked during maintenance work and corrected, as necessary. The concentration of the anti corrosion fluid must not fall below 5 vol.% nor exceed 10 vol.%. Presently approved anti corrosion fluids (as of December 2003): Brand name DCA4 Diesel Coolant Additives Caltex CL Corrosion Inhibitor Concentrate Chevron Texaco Heavy Duty Extended Life Corrosion Inhibitor Nitrite Free Havoline Extended Life Corrosion Inhibitor (XLI) Total WT Supra Manufacturer Fleetguard Caltex Chevron Texaco ARTECO Total

2. Oil for hydraulic system In the hydraulic system, use only Diesel engine lube oils or special approved oils. 2.1. Oil quality 2.1.1 Approved engine oil classifications API - classification (American Petroleum Institute) : CF-4, CG-4, CH-4, CI-4,

ACEA (CCMC) - classification : E2 (D4), E3 (D5), E4, E5, (Association des Constructeurs Europens de lAutomobile) Note: The API classifications CC, CD, CE and CF are now obsolete, however, in quality, they had been approved for use in the hydraulic system.

2.1.2 Special oils Approval is given for each machine type separately. Special guidelines are issued with the release. The following product presently considered to be an environmentally friendly hydraulic fluid: Panolin - HLP Synth - VG 46 2.2. Oil viscosity In addition to the quality, the oil must also provide a certain viscosity, the selection is made according to the SAE classification (Society of Automotive Engineers). The determining factor for the correct selection of SAE classification is the ambient temperature, single grade oils are preferred. If the viscosity is too high, it can cause cavitations, if it is too low, the lubrication efficiency may be endangered. Both can cause failure of hydraulic components. The temperature ranges shown in the following chart are guidelines. When operating the machine within the black temperature range, the following warm up procedure should be carried out.

Single grade oils

Multi grade oils

Viscosity for environmentally friendly hydraulic fluids according to ISO: VG 46 (covers SAE 10W and SAE 20W-20 or SAE 10W-30) For operation in extreme climate zones, such as arctic regions, special guidelines are available from the manufacturer. Warm up procedure: a) In temperatures up to 10 C below the given limit (black range) After starting, run the Diesel engine at medium speed. Warm up the hydraulic system by carefully actuating the hydraulic cylinders. Extend and retract the hydraulic cylinders fully for short periods. After 5 minutes, carefully engage the travel hydraulic as well. Total warm up period is approximately 10 minutes. b) At even lower temperatures: Before starting the Diesel engine, preheat the oil in the hydraulic tank, then proceed as described in paragraph a).
Benennung Description Dnomination Typ/ab Type/from Type/ a partir de

Mjfcifss!
Datum Edition Date

PR Litronic LR Litronic RL Litronic

01 04

Service Items

Blatt Page Feuille

01.3.01.04

3. Gear oil The lube oil specification for gears is based on API and SAE classification. The oil chamber in travel gears for double lifetime seal is filled with oil from the hydraulic system - see section 2. 3.1. Oil quality As a general rule, only oils meeting API - classification GL-5 may be used. 3.2. Oil viscosity The following oils must be used in travel gears, and are highly recommended for use in splitter boxes: Viscosity classification SAE 85 W - 140 EP For splitter boxes, oils of Viscosity classification SAE 90 EP or SAE 80 W - 90 EP may also be used. For the operation in extreme climatic conditions, such as in arctic regions or in extreme temperatures ranges, such as in slag applications, special oils may be approved if the prevailing ambient temperatures are known operations. 3.3. Lube oil for final drive - sealing chamber For oil quality and viscosity see section 2, Oil for hydraulic system, but do not use special oils. 4. Lube oil for support shaft bearing For oil quality and viscosity see section 2, Oil for hydraulic system, but do not use special oils. 5. Hoist gear oil - pipe layers As a general rule, the guidelines noted in the Operation and Maintenance manual and the winch manufacturer should be observed. For lubrication technical reasons, we recommend the use of Diesel lube oil, which meets at least one of the following quality and viscosity classifications. 5.1. Oil quality according to 5.2. Oil viscosity according to SAE - classification ISO - classification 6. Grease 6.1. General lubrication points and track tensioner The grease must meet specification KP 2 k - consistency 2 according to NL GI - class and DIN 51818 and DIN 51825 or EP 2 according to NF-T-60 132 . The grease must also be lithium based, with a VKA value of at least 2300 N according to DIN 51350 or ASTM D 2596. 6.2. Long term grease / grease to protect against corrosion For the lifetime lubrication of bearing points of lift cylinder suspensions and to protect against corrosion at the initial installation of dry bearing points, to protect exposed piston rods, to prevent rust formation, etc., a special calcic, acid free grease should be used. We recommend LIEBHERR's special paste CTK - Id. No. 8613 313 01 For general conservation - see section 19, Conservation guidelines - other acid free anticorrosion grease may be used. 7. Miscellaneous Always observe all guidelines issued in the Operation and Maintenance manuals, repair manuals and on drawings. 7.1. Rubber seals on doors and covers Use silicon spray or Talcum powder. 7.2. Hydraulic cylinder installation Lubricant for threads of pistons, piston nuts and piston rod bearings Liebherr High performance lubricant Id. No. 8300 004 Special protection against corrosion for installation of sealing elements Liebherr Special anticorrosion grease Id. No. 8300 005 : 10W : VG 32 API - classification ACEA (CCMC) - classification : CF, CF-4, CG-4, CH-4, CI-4, : E2 (D4), E3 (D5), E4, E5,

Unit of Measure Length

Multiply mm m m km

by 0,039 3,281 1,093 0,621 0,155 10,764 1,196 0,386 0,061 35,314 1,308 61,025 0,035 0,264 1,057 0,035 2,204 1,102 0,225 224,732 0,737 1,342 0,736 0,986 14,5 0,145 14,223 0,205 0,036 0,062 0,621 3,281 (Cx1,8) + 32 C+273

To obtain Multiply inch feet yard mile sq. inch sq. feet sq. yard sq. mile cu. inch cu. feet cu. yard cu. inch cu. feet gallon quart oz. lbs. short t lbs. lbs. ft. lbs. HP kW HP PSI PSI lbs. sq. inch lbs. sq. ft. lbs. cu. inch lbs. cu. ft. mph ft. / min F K

by 25,4 0,305 0,914 1,609 6,452 0,093 0,0863 2,59 16,387 0,028 0,764 0,016 28,316 3,785 0,946 28,349 0,453 0,907 4,449 0,0044 1,356 0,745 1,358 1,014 0,069 6,896 0,0703 4,878 27,78 16,13 1,609 0,305 (F-32)/1,8 K-273

To obtain mm m m km cm m m km cm m m l l l l g kg t N kN Nm kW PS PS bar kpa kg/cm kg/m g/cm kg/m km/h m/min C C

Area

cm m m km

Volume

cm m m l l l l

Weight

g kg t

Force

N kN

Torque Power

Nm kW PS PS

Pressure (hydraulic) Ground pressure

bar kpa kg/cm kg/m

Compression

g/cm kg/m

Speed

km/h m/min

Temperature

C C

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!
Datum Edition Date

PR Litronic LR Litronic RL Litronic

01 01

Conversion table

Blatt Page Feuille

1.4.01.01

The preload and tightening torques listed in the chart are from VDI guidelines 2230 of July 1986. Installation preload FM and tightening torques MA for shaft screws with metric standard or fine thread per DIN ISO 262 and DIN ISO 965 T2 (replacement for DIN 13 part 13) and screw head dimension of hex head screws with shaft DIN EN 24014 (replacement for DIN 931 part 1) or socket head screws DIN EN ISO 4762 (replacement for DIN 912). The chart values are valid for lubricated screws, surface black treated, phosphated or galvanic zinc plated and for dry screws, surface according to flZn - LH-Norm 10021432 (replaces DACROMET 500) Medium friction G = 0,12. Always observe the tightening torques and/ or procedures listed in drawings / parts lists, instructions of component descriptions, if noted, they override the factory standards listed in the torque charts. Never use a standard lock washer with 10.9 or 12.9 screws. If a washer is necessary, use only "heavy duty" washers, made from hardened material. Always use torque wrenches with the correct range - the upper third of the range should include the listed torque value according to the chart. When using impact screws, make sure that the given tightening torque is observed - should be checked before and during the tightening procedure with torque wrench (Nm x 0,7375 = ft.lbs.)!

Preload forces and tightening torques for screws with standard metric thread according to factory standard WN 4037 I
Preload values FM based on Tightening torques MA are screw grades and are given based on screw grades and in N are given in Nm Wrench size (x) = per DIN931, for Hex head screws Socket head screws

Standard metric thread

8.8
M M M M M 4 x 0,7 5 x 0,8 6 x1 7 x1 8 x 1,25
4 050 6 600 9 400 13 700 17 200 27 500 40 000 55 000 75 000 94 000 121 000 152 000 175 000 230 000 280 000 350 000 410 000 490 000

10.9
6 000 9 700 13 700 20 100 25 000 40 000 59 000 80 000 111 000 135 000 173 000 216 000 249 000 330 000 400 000 495 000 580 000 700 000

12.9
7 000 11 400 16 100 23 500 29 500 47 000 69 000 94 000 130 000 157 000 202 000 250 000 290 000 385 000 465 000 580 000 680 000 820 000

8.8
2,8 5,5 9,5 15,5 23 46 79 125 195 280 390 530 670 1000 1350 1850 2350 3000

10.9
4,1 8,1 14,0 23,0 34 68 117 185 280 390 560 750 960 1400 1900 2600 3300 4300

12.9
4,8 9,5 16,5 27,0 40 79 135 215 330 460 650 880 1120 1650 2250 3000 3900 5100

mm
7 8 10 11 13 (17) 16 (19) 18 (22) 21 24 27 30 (32) 34 36 41 46 50 55 60

Inch
9/32 5/16 --1/2 (11/16) -(3/4) -(7/8) --1-1/16 1-3/16 -1-7/16 1-5/8 1-13/16 2 2-3/16 2-3/8

mm
3 4 5 -6 8 10 12 14 14 17 17 19 19 22 24 27 27

Inch
-5/32 ---5/16 --9/16 9/16 --3/4 3/4 7/8 -1-1/16 1-1/16

M 10 x 1,5 M 12 x 1,75 M 14 x 2 M 16 x 2 M 18 x 2,5 M 20 x 2,5 M 22 x 2,5 M 24 x 3 M 27 x 3 M 30 x 3,5 M 33 x 3,5 M 36 x 4 M 39 x 4

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Standard screws
Datum Edition Date

PR Litronic LR Litronic RL Litronic


Blatt Page Feuille

01 04

Tightening Torques
Factory standard WN 4037 I

1.4.02.01

Preload forces and tightening torques for screws with fine metric thread according to factory standard WN 4037 I
Preload values FM based on Tightening torques MA are screw grades and are given based on screw grades and in N are given in Nm Wrench size (x) = per DIN931, for Hex head screws Socket head screws

Fine metric thread

8.8
M M 8 x1 9 x1
18 800 24 800 31 500 29 500 45 000 42 500 61 000 82 000 110 000 102 000 139 000 171 000 207 000 196 000 267 000 255 000 335 000 321 000 410 000 395 000 492 000 440 000 582 000 530 000

10.9
27 500 36 500 46 500 43 000 66 000 62 000 89 000 121 000 157 000 146 000 199 000 245 000 295 000 280 000 381 000 365 000 477 000 457 000 584 000 560 000 701 000 630 000 830 000 750 000

12.9
32 500 42 500 54 000 51 000 77 000 73 000 104 000 141 000 184 000 170 000 232 000 285 000 346 000 325 000 445 000 425 000 558 000 534 000 683 000 660 000 820 000 740 000 971 000 880 000

8.8
24,5 36 52 49 87 83 135 205 310 290 430 580 760 730 1110 1070 1540 1490 2050 2000 2680 2500 3430 3200

10.9
36 53 76 72 125 122 200 300 440 420 620 820 1090 1040 1580 1500 2190 2120 2920 2800 3820 3500 4890 4600

12.9
43 62 89 84 150 145 235 360 520 490 720 960 1270 1220 1850 1800 2560 2480 3420 3300 4470 4100 5720 5300

mm
13 -17 17 19 19 22 24 27 27 30 32 36 36 41 41 46 46 50 50 55 55 60 60

Inch
1/2 -11/16 11/16 3/4 3/4 7/8 -1-1/16 1-1/16 1-3/16 -1-7/16 1-7/16 1-5/8 1-5/8 1-13/16 1-13/16 2 2 2-3/16 2-3/16 2-3/8 2-3/8

mm
6 -8 8 10 10 12 14 14 14 17 17 19 19 19 19 22 22 24 24 27 27 27 27

Inch
--5/16 5/16 ---9/16 9/16 9/16 --3/4 3/4 3/4 3/4 7/8 7/8 --1-1/16 1-1/16 1-1/16 1-1/16

M 10 x 1 M 10 x 1,25 M 12 x 1,25 M 12 x 1,5 M 14 x 1,5 M 16 x 1,5 M 18 x 1,5 M 18 x 2 M 20 x 1,5 M 22 x 1,5 M 24 x 1,5 M 24 x 2 M 27 x 1,5 M 27 x 2 M 30 x 1,5 M 30 x 2 M 33 x 1,5 M 33 x 2 M 36 x 1,5 M 36 x 3 M 39 x 1,5 M 39 x 3

Note: Observe notes on front page!

Tightening torques for screws for SAE split flange installation


Not part of factory standard WN 4037 I Listing per LFR - Quality service 2QA 6 051 00 as of Oct. 2001
1. Flange and half flange for high pressure (Norm 62) Tightening torques in Nm for screw grade 10.9 flat flange without Flange with Half flange reinforcement reinforcement 31 62 108 172 264 350 -45 70 120 170 250 -65 110 180 250 450

Flange nominal size " " 1" 1 " 1 " 2"

Screw size M8 M 10 M 12 M 14 M 16 M 20

2. Half flange for low pressure (Norm 61) Tightening torques in Nm for Screw grade 8.8 Screw grade 10.9 22 44 44 44 76 76 76 122 187 187 187 31 62 62 62 108 108 108 172 264 264 264

Flange nominal size " " 1" 1 " 1 " 2" 2 " 3" 3 " 4" 5"

Screw size M8 M 10 M 10 M 10 M 12 M 12 M 12 M 14 M 16 M 16 M 16

Tightening torques for oil drain plugs at travel gears


Not part of factory standard WN 4037 I Listing per LBC - Quality service as of Oct. 2003
Oil drain plug Tightening torque thread size in Nm M 14x1,5 40 M 16x1,5 40 M 18x1,5 40 M 22x1,5 80 M 33x1,5 160

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Standard screws
Datum Edition Date

PR Litronic LR Litronic RL Litronic


Blatt Page Feuille

01 04

Tightening Torques
Factory standard WN 4037 I

1.4.02.02

1. Hole diameter for tapping ISO standard Metric (internal) thread Thread size M1 M 1,1 M 1,2 M 1,4 M 1,6 M 1,7 M 1,8 M2 M 2,2 M 2,3 M 2,5 M 2,6 M3 M 3,5 M4 M 4,5 M5 M6 M7 M8 M9 M 10 M 11 M 12 M 14 M 16 M 18 M 20 M 22 M 24 M 27 M 30 M 33 M 36 M 39 M 42 M 45 M 48 M 52 M 56 M 60 M 64 M 68 Hole diameter limits max. min. 0,785 0,729 0,885 0,829 0,985 0,929 1,160 1,075 1,321 1,221 1,346 1,258 1,521 1,421 1,679 1,567 1,838 1,713 1,920 1,795 2,138 2,013 2,176 2,036 2,599 2,459 3,010 2,850 3,422 3,242 3,878 3,688 4,334 4,134 5,153 4,917 6,153 5,917 6,912 6,647 7,912 7,647 8,676 8,376 9,676 9,376 10,441 10,106 12,210 11,835 14,210 13,835 15,744 15,294 17,744 17,294 19,744 19,294 21,252 20,752 24,252 23,752 26,771 26,211 29,771 29,211 32,270 31,650 35,270 34,670 37,799 39,129 40,799 40,129 43,297 42,587 47,297 46,587 50,796 50,046 54,796 54,046 58,305 57,505 62,305 61,505 Drill bit 0,75 0,85 0,95 1,1 1,25 1,30 1,45 1,6 1,75 1,9 2,05 2,10 2,5 2,9 3,3 3,7 4,2 5 6 6,8 7,8 8,5 9,6 10,2 12 14 15,5 17,5 19,5 21 24 26,5 29,5 32 35 37,5 40,5 43,0 47,0 50,5 54,1 57,6 61,6

Dimensions are in mm mm x 0,03937 = inches

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!
Datum Edition Date

PR Litronic LR Litronic RL Litronic

01 04

Hole diameter before tapping

Blatt Page Feuille

01.4.04.01

2. Hole diameter for tapping ISO fine Metric (internal) thread

Thread size M 1 x 0,2 M 1,1 x 0,2 M 1,2 x 0,2 M 1,4 x 0,2 M 1,4 x 0,25 M 1,6 x 0,2 M 1,8 x 0,2 M 2 x 0,25 M 2,2 x 0,25 M 2,5 x 0,35 M 3 x 0,35 M 3,5 x 0,35 M 4 x 0,5 M 4,5 x 0,5 M 5 x 0,5 M 5,5 x 0,5 M 6 x 0,75 M 7 x 0,75 M 8 x 0,75 M8x1 M 9 x 0,75 M9x1 M 10 x 0,75 M 10 x 1 M 10 x 1,25 M 11 x 0,75 M 11 x 1 M 12 x 1 M 12 x 1,25 M 12 x 1,5 M 14 x 1 M 14 x 1,25 M 14 x 1,5 M 15 x 1 M 15 x 1,5 M 16 x 1 M 16 x 1,5 M 17 x 1 M 17 x 1,5 M 18 x 1 M 18 x 1,5 M 18 x 2 M 20 x 1 M 20 x 1,5 M 20 x 2 M 22 x 1 M 22 x 1,5 M 22 x 2 M 24 x 1 M 24 x 1,5 M 24 x 2

Hole diameter limits max. min. 0,821 0,783 0,921 0,833 1,021 0,983 1,221 1,183 1,185 1,129 1,421 1,383 1,621 1,583 1,785 1,729 1,985 1,929 2,201 1,121 2,721 2,621 3,221 3,121 3,599 3,459 4,099 3,959 4,599 4,459 5,099 4,959 5,378 5,188 6,378 6,188 7,378 7,188 7,153 6,917 8,378 8,188 8,153 7,917 9,378 9,188 9,153 8,917 8,912 8,647 10,378 10,188 10,153 9,917 11,153 10,917 10,912 10,647 10,676 10,376 13,153 12,917 12,912 112,647 12,676 12,376 14,153 13,917 13,676 13,376 15,153 14,917 14,676 14,376 16,153 15,917 15,676 15,376 17,153 16,917 16,676 16,376 16,210 15,835 19,153 18,917 18,676 18,376 18,210 17,835 21,153 20,917 20,676 20,376 20,210 19,835 23,153 22,917 22,676 22,376 22,210 21,835

Drill bit 0,8 0,9 1 1,2 1,15 1,4 1,6 1,75 1,95 2,15 2,65 3,15 3,5 4 4,5 5 5,2 6,2 7,2 7 8,2 8 9,2 9 8,8 10,2 10 11,1 10,8 10,5 13 12,8 12,5 14 13,5 15 14,5 16 15,5 17 16,5 16 19 18,5 18 21 20,5 20 23 22,5 22

Thread size M 25 x 1 M 25 x 1,5 M 25 x 2 M 26 x 1,5 M 27 x 1 M 27 x 1,5 M 27 x 2 M 28 x 1 M 28 x 1,5 M 28 x 2 M 30 x 1 M 30 x 1,5 M 30 x 2 M 30 x 3 M 32 x 1,5 M 32 x 2 M 33 x 1,5 M 33 x 2 M 33 x 3 M 35 x 1,5 M 36 x 1,5 M 36 x 2 M 36 x 3 M 38 x 1,5 M 39 x 1,5 M 39 x 2 M 39 x 3 M 40 x 1,5 M 40 x 2 M 40 x 3 M 42 x 1,5 M 42 x 2 M 42 x 3 M 42 x 4 M 45 x 1,5 M 43 x 2 M 45 x 3 M 45 x 4 M 48 x 1,5 M 48 x 2 M 48 x 3 M 48 x 4 M 50 x 1,5 M 50 x 2 M 50 x 3 M 52 x 1,5 M 52 x 2 M 52 x 3 M 52 x 4

Hole diameter limits max. min. 24,153 23,917 23,676 23,376 23,210 22,835 24,676 24,376 26,153 25,917 25,676 25,376 25,210 24,835 27,153 26,917 26,676 26,376 26,210 25,835 29,153 28,917 28,676 28,376 28,210 27,835 27,252 26,752 30,676 30,376 30,210 29,835 31,676 31,376 31,210 30,835 30,252 29,752 33,676 33,376 34,676 34,376 34,210 33,835 33,252 32,752 36,676 36,376 37,676 37,376 37,210 36,835 36,252 35,752 38,676 38,376 38,210 37,835 37,252 36,752 40,676 40,376 40,210 39,835 39,252 38,752 38,270 37,670 43,676 43,376 43,210 42,835 42,252 41,752 41,270 40,670 46,676 46,376 46,210 45,835 45,252 44,752 44,270 43,670 48,676 48,376 48,210 47,835 47,252 46,752 50,676 50,376 50,210 49,835 49,252 48,752 48,270 47,670

Drill bit 24 23,5 23 24,5 26 25,5 25 27 26,5 26 29 28,5 28 27 30,5 30 31,5 31 30 33,5 34,5 34 33 36,5 37,5 37 36 38,5 38 37 40,5 40 39 38 43,5 43 42 41 46,5 46 45 44 48,5 48 47 50,5 50 49 48

Sub Group Index


Special tools
Special tools Liebherr Diesel engine Special tools general hydraulic repair Special tools hydraulic pressure testing Special tools hydraulic cylinder Special tools general - electric repair Special tools wiring harness Special tools mech. components

2.1
2.1.10 2.1.20 2.1.21 2.1.22 2.1.30 2.1.31 2.1.40

Repair welding Installation guidelines


Installation guidelines Duo-Cone-Seals Wiring installation guidelines ITT-Cannon plug Wiring installation guidelines Harting plug Wiring installation guidelines AMP plug

2.2.00 2.3.01
2.3.01 2.3.02 2.3.03 2.3.04

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Special tools
Datum Edition Date

PR Litronic LR Litronic RL Litronic


Blatt Page Feuille

01 01

Application guidelines

2.0.00.01

Description Digital Electronic Impulse Tachometer all engines

Id.No. 7009 538

Remarks test range: 400-6000 RPM accuracy 1 RPM

Illustration

Tachometer - mechanical

5003 069

test range: 100-3000 RPM accuracy: 1 RPM

Tachometer cable D904 TB / 904 T

5003 070

to be used with Id.No. 5003 069

Tachometer cable extension D904 TB / 904 T

8122 902

to be used with Id.No. 5003 070

Battery charge / coolant condition tester

7408 922

to test the condition of the battery charge and the percentage of antifreeze in the engine coolant.

Description Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Diesel engine
Datum Edition Date

PR Litronic LR Litronic RL Litronic


Blatt Page Feuille

01 04

Special tools

2.1.10.01

Illustration

Description DCA4 Test kit CC2602M includes: test strip container 50 test strips plastic container eye dropper Compression tester

Id.No. 5608 459

Remarks to test the DCA4 concentration in coolant. all engines

8008 782

to check the engines compression pressure. all engines

Test adapter for compression tester

0524 044

to be used in place of injector when checking compression all engines

Injector tester

7361 236

to check injector opening pressure all engines

High pressure hand pump with accessories, complete

7009 318

to check the injection pump timing. all engines

Description Slide hammer

Id.No. 0524 072

Remarks to remove injectors all engines

Illustration

Adapter

0524 029

to be used with Id.No. 0524 072 all engines

Angle method torque fixture

0524 062

to torque screws cylinder head main bearings rod bearings all engines

Engine turning fixture

0524 045

mounted on the flywheel housing all engines (not useable at D 9406 TI - PR 752, RL 52, use Id.No. 9183 785)

Dial gauge Pos.1 Dial fixture Pos.2

7022 418 7022 420

to control the delivery begin from the distribution injection pump all engines with distribution injection pump

Description Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Diesel engine
Datum Edition Date

PR Litronic LR Litronic RL Litronic


Blatt Page Feuille

01 04

Special tools

2.1.10.02

Illustration

Description V - Belt Measuring Tool Krikit2

Id.No. 8042 829

Remarks to measure V - Belt tension All engines

Holding fixture

0527 462

to eliminate starting fuel quantity when adjusting the delivery begin motors with MW injection pumps D914/916 D924/926 D9306/9308 D9406/9408

Sampling pump pos. 1 1 Sampling valve for oil samples pos. 2

8145 666

used for taking oil samples for the oil analysis.

7019 068

2 Oil analysis set German 6 samples 12 samples analysis at WEAR CHECK Germany, analysis report in German language.

7018 368 7018 369

Oil analysis set French 6 samples

8503 561

Analysis at WEAR CHECK Belgium, analysis report in French language

Engine turning fixture with " square head drive

9183 785

to turn the Diesel engine D 9406 TI - PR 752, RL 52, for adjustments fits on the fan side end of crankshaft

Description Vacuum pump, complete with the following accessories: Vacuum pump with electr. cord Hose assembly Hose assembly Fitting S8M Fitting L6R PVC hose Terminal clamp - pos. Terminal clamp - neg. Plug - 2 connectors Temperature gauge

Id. No. 7408 148

Remarks for faster bleeding of the hydraulic system the vacuum pump can produce low pressure (appr. 0.4 bar) by reversing the PVC hose. The connecting point for the machine is the bleeder screw on the hydraulic tank.

Illustration

7407 987 7407 985 7407 986 7404 619 4901 110 7360 127 7408 149 7408 150 7408 151 7020372

accuracy: 2%/2 test range: -18C - +260C

Adjustment tool for BPV 50, 70, 100 Tool to loosen / counter Item.1 12 point socket Adjustment tool Item.2 Hex head screw handle Item.3 socket wrench Hook wrench 58 - 62 mm

commercially available

to adjust pump end position via eccentric screw Note: The 12 point socket stub should have an outer diameter of 18 mm over a length of approx. 35 mm

SW 13 x 85

SW 4 x 200 SW13 x 120 7900 282 to loosen / tighten when adjusting the regulating range of BPV pumps

Adjustment tool for slotted nut at HPV 130

9792 711

to loosen / tighten lock nut when adjusting pump end stop - Qmax (also usable when adjusting regulating range at BPV) use together with hook wrench Id. No. 7900 282

Description Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

General hydraulic repair


Datum Edition Date

PR Litronic LR Litronic RL Litronic


Blatt Page Feuille

01 01

Special tools

2.1.20.01

Illustration

Description Adjustment tool for mechanical neutral position slotted nut HPV 135-02

Id. No. 9749 025

Remarks to loosen / tighten lock nut when adjusting mechanical neutral position.

Clamping tool for clamping spring at BPV BPV 35 - 200

6427 521

to tighten the spring and remove ball socket trumpet tube when changing swash plate bearing

Pin puller for pump BPV 35 - 100

6427 516

used to remove the pin for the swash plate bearing cage retainer clip

Punch for stud BPV 70 - 100 Swash plate Housing 7413 894 4713 895

to punch the studs change of needle bearing segment

Installation sleeve for radial shaft seal BPV 35 70 BPV 100 HPV 135-02 BPV 200 7404 289 7404 298 7404 567

for correct mounting the radial shaft seal on the pump drive shaft Note: install seal rings with Loctite 270

Description Measuring device for differential pressure contents - 230V 230V

Id. No.

Remarks to measure pressure, differential pressure and used for Data transfers to the PC contents of:
measuring device M - H 2045 2 pressure sensors 0-600 bar 2 test fittings 2 test hoses MK 12m connecting wire - board circuit adapter wire - data transfer power supply unit

Illustration

7025 376

Measuring device for differential pressure contents 120V Pressure gauge 0-10 0-25 0-40 0-60 0-100 0-160 0-250 0-400 0-600 0-1000 Digital pressure gauge 0 - 100 0 - 500 Lithium battery for digital pressure gauge

7025 755

5002 865 7361 289 7361 288 5002 867 5602 903 7361 286 7361 285 7500 002 7361 294 4601 115

accuracy: 1% of end value all pressure gauges are glycerin filled

resolution 0,1% of end value 7412 643 7412 644 6002 780 accuracy: 0,2% of end value gauge range - static: up to max. 50 % above the listed end value to seal the coupling during pressure tests, a seal ring, Id. No. 7409 794, must be installed. to avoid loss of pressure during tests, use the shortest possible test hose

Gauge - coupling R 7002 436

Test hose NW 2 1000 mm 1500 mm 4000 mm 5000 mm 7002 437 7002 475 7009 134 7363 732

Test fitting , complete R6L R 10 L R 12 L 7409 916 7406 864 7409 918

union nut and ferrule mounted on test fitting.

Description Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Hydraulic pressure testing


Datum Edition Date

PR Litronic LR Litronic RL Litronic


Blatt Page Feuille

01 04

Special tools

2.1.21.01

Illustration

Description Screw coupling M 8x1 M 10x1 M 12x1,5 M 14x1,5 R Schott screw coupling M 16x2

Id. No.

Remarks to connect to additional machine measuring points

7615 321 5608 462 7409 783 7406 865 7409 720

7407 070

to connect shorter test lines or connection between test connection and pressure sensor

Test plate A for SAE-flange


Size (in mm) A 90 B 40 C,r 5

7370 092

to close high pressure ports when checking system pressures material: ground resilient steel taper rounded plate ends, round off edges (simplifies installation, prevents damage to O ring)

Test plate B for SAE - flange 1


Size (in mm) A 90 B 44 C,r 5

7370 093

Test plate C for SAE flange 1


Size (in mm) A 90 B 52 C,r 5

7370 094 or to be made in house

Flange, complete ( 2 each with O - rings and screws) for support shaft PR712/722 LR622 RL(4)22 PR732/742 LR632 RL(4)42 Fitting pos.1 stopper pos.2 union nut pos 3 elbow fitting pos 4 reducer fitting pos 5 fitting 9787 796

to close high pressure ports when checking system pressures and when shaft flange is removed also to protect front surface when removing support shaft bearings. to close off control lines for adjustment of hydr. motors on the PR 752

9787 798

2 x 4900 038 2 x 4774 001 2 x 7403 569 2 x 7404 259 2 x 7410 458

Description Diagnostic box with adapter and connecting cables, complete


(consists of following parts marked with *)

Id.No. 9796 653

Remarks required for checking/ adjusting travel drive all machine types with electronic control system/ E-Box Version CEP for application guidelines, see group 10.4.

Illustration

* Diagnostic box without adapter/connecting cables

7409 318

Time delay fuse - 6.3 A (spare fuse) *Adapter CET-14/05

6002 702

7413 106

adapts diagnostic box for all machine types with E box Version CEP

*Adapter cable - straight 55-connectors

9814 970

required for all tests

*Y - Adapter cable

9747 733

additional cable for special checks in travel operation

Accessory Protective cap-male plug Protective cap- female socket *Power supply cable complete, consists of: Instrument panel plug Plug - 3 connectors Shrink wrapping for instrument panel plug Shrink wrapping - for 3pole plug cable Accessory Protective cap for plug - 3 connectors

6002 655 6002 654 6002 697 7409 682 7409 676 7409 681 7409 679 6000 738 instrument panel plug: contact middle: + contact lateral: power supply cable plug 3 - connections A: + B: C: free

7409 677

Description Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Electric system - general


Datum Edition Date

PR Litronic LR Litronic RL Litronic


Blatt Page Feuille

01 03

Special tools

2.1.30.01

Illustration

Description E-box evaluation kit consists of Pos. 1 floppy disk with software CEP 12 adapter cable

Id.No. 9812 435

Remarks to read E-box memory for use on CEP 12/08C, CEP 12/20 and CEP 12/22

7415 329 9812 434

Pos. 2

Pedal tester

7414 235

required for PR-2-Litronic: test/adjustment inch/brake pedal LR-2 Litronic: test/adjustment steering and brake pedal

LIKOM - Service Set consists of: LIKOM-Software pos. 1 Interface cable pos. 2 Instructions - not shown

9793 970 9758 760 01 9794 550

required for checking/adjusting travel drive - all machine types with electronic control system / E-Box version RST for application guidelines, see group 10.5

Accessories Note Book Voltage transformer 24/230 V Digital multimeter complete with harness and case

6140 645 01 6004 217 6001 231

for voltage (V)amperage (A)resistance ()and frequency(Hz)tests

Battery charge / coolant condition tester

7408 922

to test the condition of the battery charge and the percentage of antifreeze in the engine coolant

Socket wrench for adjustable sensor motor / gear

9797 973 or remachined12 point socket wrench size27 mm

rework as shown in drawing: shaded areas must be ground out.

Description Hand crimp tool - Cannon M 22 5 20/1-01

Id.No. 7367 086

Remarks to produce flawless crimp connections. application, see group 02.3.02.

Illustration

Crimp insert - Cannon CT 120090-20 TH 452 7409 779 7367 084

used with hand crimp tool Id.No. 7367 086 application, see group 02.3.02. to check the hand crimp tool Id.No. 7367 086 application, see group 02.3.02.

Reference gauge M 22 5 20/3-1 7409 718

Insertion tool for CA - B Crimp contacts CIT-F80-KIT complete consisting of: 1 Handle 1 Insert CIT 20 1 Insert CIT 16 1 Insert CIT 12 1 Insert CIT 8 1 Insert CIT 4 1 Insert CIT 0 Extraction tools for CA - B crimp contacts CET-F80-KIT complete consisting of: 1 Handle 1 Insert CET 20 1 Insert CET 16 1 Insert CET 12 1 Insert CET 8 1 Insert CET 4 1 Insert CET 0 Insertion tool for KPSE crimp contacts MS 24256 A16 MS 24256 A20 7409 708 7409 709 7409 700 7409 701 7409 702 7409 703 7409 704 7409 705 7409 706 7409 707 7409 721 7409 693 7409 694 7409 695 7409 696 7409 697 7409 698 7409 699

to insert wired crimp contacts into the plug connectors.

application, see group 02.3.02.

to remove wired crimp contacts from the plug connectors. depending if socket or pin contacts are removed, the corresponding side of the tool insert should be used. application, see group 02.3.02.

application, see group 02.3.02.

Description Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Electric system - wiring harness


Datum Edition Date

PR Litronic LR Litronic RL Litronic


Blatt Page Feuille

01 04

Special tools

2.1.31.01

Illustration

Description Extraction tool for KPSE crimp contacts MS 24256 R16 MS 24256 R20

Id.No.

Remarks application, see group 02.3.02.

7409 710 7409 711

Insertion tool for SURE SEAL crimp contacts, complete CITG-SS-1 Insertion tip CIT-SS-1-TIP Contact holder CT 317-8666-005 Extraction tools for SURE SEAL crimp contacts, complete CET-SS-P CET-SS-S Extraction tips CET-SS-P-TIP CET-SS-S-TIP Guiding pin - Cannon for: CA-B Crimp contacts Size 15S, 16S, 15, 16: 226-1017-000 Size 25, 12 226-1018-000 SURE SEAL crimp contacts CT 317-8588-000 Auxiliary tool - Cannon for SURE SEAL CIEF-SS-5-6-7

application, see group 02.3.02. 7367 023 7409 712 7409 713 P - valid for extraction of socket contacts. S - valid for extraction 7367 020 7367 022 application, see group 02.3.02.

7409 714 7409 715 when installing socket contacts, guiding pins must be used. 7409 716 7409 717 7409 745 protection against damage. application, see group 02.3.02. device for holding connectors during insertion and extraction of crimped contacts.

7367 085

4 notch hand crimp tool Buchanan pos1 - Crimp pliers pos2 - Positioning sleeve 8123 551 8123 552

for creating perfect crimp connections on Harting plug connectors

Test gauge 0,5-1 und 2,5 mm 1,5 mm 8123 553 8123 554

for inspecting crimp depth in Harting" connector

Extraction tool for Harting crimp contacts

8123 556

for extraction of crimp contacts from the Harting - connector

Description Insertion tool for Harting crimp contacts

Id.No. 8123 555

Remarks for insertion of connected crimp contacts into the Harting connector

Illustration

Crimp tool for MATE-N-LOK crimp contacts for 1,5 mm for 2,5 mm Extraction tool AMP for MATE-N-LOK crimp contacts substitute insert 7367 025 7366 314

to crimp contacts of MATE - N - LOK connectors

7366 655 7015 180

extraction tool to push a crimped contact of the MATE - N - LOK connectors

Insertion tool AMP for MATE-N-LOK Crimp contacts

8145 432

to insert pin and socket contacts in connectors type MATE - N - LOCK

Hand crimp tool - Cannon for DEUTSCH Connectors crimp turret

8503 647

to crimp correct contacts of connectors type DEUTSCH

7409 779

Extraction tool Cannon for crimp contacts DEUTSCH AWG 4 AWG 8 AWG 12 AWG 16 AWG 20 Crimp tool AMP AMP Certi-Lock

8503 633 8503 632 10 114 733 885 563 714 10 114 732 7415 333

extraction tool to push pin contacts and socket contacts of theDEUTSCH connectors

to crimp the JUNIOR POWER TIMER contacts

Description Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Electric system - wiring harness


Datum Edition Date

PR Litronic LR Litronic RL Litronic


Blatt Page Feuille

01 04

Special tools

2.1.31.02

Illustration

Description Extraction tool AMP

Id.No. 7370 373

Remarks extraction tool to remove contact of the JUNIOR POWER TIMER housing

Crimp tool CSA 0760

7409 781

to crimp insulated wire contacts 0,75 - 6,0 mm Example: isolated connectors

Crimp tool CRB 0560

7409 782

to crimp non insulated wire contacts 0,5 - 6,0 mm Example: connection to wiper motor see picture group 9

Wire stripper complete Type 5011-26 Spare blades 7409 777 7409 778

to remove the insulation on individual wires on the electronic wire harness. 0,75 mm

Blade inserts to strip metric wires with the following wire diameters 1,5 - 6,0 mm 0,15 - 2,5 mm 7409 788 7409 789

to be installed in wire stripper Id.No. 7409 777

Description track component measuring tool

Id.No. 7402 603

Remarks application, see group 12.2.

Illustration

R = ring wrench and E = adjustment template for PR 712 (B) FAT 400/523 R/E 400C563 R E 400P553 R E PR 722 (B) FAT 450/514 R/E 450C564 R E PR +LR 622 450P554 R +RL (4)22 E PR 732 (B) FAT 500/525 R/E 500C565 R E PR +LR 632 500P555 R E

to adjust bearing play of cross roller bearings 9054 282* 9790 992 8123 439 9790 992 8123 438 9054 281* 9790 996 8123 440 9790 996 8123 440 9054 280** 9790 999 8123 442 9790 999 8123 441 9054 279** 9791 003 8123 444 9791 003 8123 443 to loosen and tighten the ring nut on the support shaft 9054 840
1) 1)

*= with new adjustment R = template bearings **= with new adjustment template and new pin, can also be used for newer gear types see Service information 11-3-5/94 Litronic)

E=

= 8123 445 substitution - carrier / bolt = 8123 445 for wrench bolt = 8123 446 = 8123 446 for wrench bolt for wrench bolt IdNr. 9790 992 and IdNr. 9790 996 IdNr. 9790 995 IdNr. 9790 999 IdNr. 8123 445 IdNr. 9791 003 IdNr. 8123 446

1)

PR 742 (B) FAT 550/516 R/E 550C566 R E 550P556 R E special wrench - support shaft PR 712/722 LR 622 RL(4)22 PR +RL 42

1)

9785 922 PR732/742 LR 632 RL 42

Description Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Mech. components
Datum Edition Date

PR Litronic LR Litronic RL Litronic


Blatt Page Feuille

01 04

Special tools

2.1.40.01

Illustration

Description socket wrench - size 22 mm for cable fittings on axle flange PR 732 / LR 632 PR 742 RL 42

Id.No 9745 376

Remarks to release / tighten the cable fittings on the support axle

clamping tool for parking brakes FAT - Type P/D all types except PR 752 / RL 52

9814 884

to dissemble and assemble of the parking brake at FAT type - P/D measurements for manufacturing the clamping tool see page 2.1.40.02 for installation of radial shaft seal in hoist cylinder support. see chapter 15.2. A = fr Pos.12 B = fr Pos.11 for dimensions to manufacture the punch see page 2.1.40.02

press - in punch Pos.1 installation flange PR712/722 PR732 PR742/752 Pos.2 screw in handle for all installation flanges puller Pos.1 with counter support Pos.2 for the following dimensions (in mm) A B A B A B 9786 683 9786 684 9786 685 9786 687 9786 686 9786 687 9786 688 commercially available toll cut open bushings, pos. 3 from 120mm

to pull out bushings Pos.3 ad Pos.4 from hoist cylinder bearing support

A B C D

PR712 PR722 90 70 247,5 90

PR732 PR742 PR752 110 90 273 96 120 90 273 94 120 90 280 120

tension tool track adjuster unit Pos. 1 - installation flange Pos. 2 - bar Pos. 3 - hex head screw (6 pieces.) M16x310mm - 10.9 9798 353 9798 352 4601 217

to install and remove the spring in the track roller frame on the PR 752. absolutely requires

application, see group 12.5.50

Description Mounting sleeve

Id.No. 9817 062

Remarks for installation of outside bearings at the equalizer bar PR 752

Illustration

Dimensions to self - manufacture from special tools


1. For disassembly and assembly of the brake housing travel gear FAT - type A / C (without Id. No.)

Dim (mm) A B C D E F G H I

PR 712 PR 722 PR 732 PR 742 FAT 400/523 FAT 450/514 FAT 500/525 FAT 550/516 FAT 400 C 563 FAT 450 C 564 FAT 500 C 565 FAT 550 C 566 315 380 22 M20 x 2,5 130 30 16 21 36 340 400 22 M20 x 2,5 150 30 16 21 36 360 420 22 M20 x 2,5 170 30 16 21 36 395 460 26 M24 x 3 190 36 18 25 44

Dimensions on drawing are valid for all travel gears FAT 400 to 550. 2. For disassembly and assembly of the brake housing travel gear FAT - type P / D (Id. No. see page 2.1.40.01)

Pos. 1 2 3 4 5

Description washer with nut M20 (welded on) washer for machine size X32, X42 washer for machine size X12, X22 screw M20 x 110 10.9 A3C washer A3C

160 mm 160 mm 130 mm

Id.No. 9814 883 9814 881 9814 882 4600 161 4600 222

Description Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Mech. components
Datum Edition Date

PR Litronic LR Litronic RL Litronic


Blatt Page Feuille

01 04

Special tools

2.1.40.02

3. Mandrel for radial seal ring in lift cylinder bearing see crawler dozers service manual, chapter 15.2.(Id. No. see page 2.1.40.01) 3.1. Screw type handle page 2.1.40.01 - item 2, fits for following installation flanges all dimensions in mm

3.2. Installation flange page 2.1.40.01 - item 1 A for Pos.12, B for Pos.11 from group 15.2.
Id.No. PR 712 / 722 PR 732 PR 742/752 A B A B A B 9786 683 9786 684 9786 685 9786 687 9786 686 9786 687 Ma A 119 71 89 89
-0,3 -0,3 -0,3

Ma B 89 57 69 69
0,1 0,1 0,1

Ma C 12 8 14 10 14 10

DIM D 23 18 23 18 23 18 *edges rounded

139 149

109 119

-0,3 -0,3

0,1 0,1

-0,3

0,1

4. Intermediate flange travel pump to regulating pump, see 8.1.01.02 PR712(B) - PR732(B), LR622/LR632, RL(4)22 B With pulling device, IdNo.0524 072 - section 02.1.10.02., or with screw M10x100 all dimensions in mm

Prior to beginning any welding on earthmoving equipment, the battery cables and the wires on connection B+ and D- on the alternator must be disconnected and the electronic control box must be removed. In addition, the ground cable of the welding unit must be connected directly to the bare metal of the part to be welded. 1. Preparation of a crack The crack must be free of paint, grease and dirt. To prevent the crack from extending during the preparation or the welding process, the end of the cracks should be drilled with a hole of at least 0.32" (8mm) in diameter. The crack should now be ground, chiseled, torch cut or arced out at a 60 angle. Be certain the edges are clean and extend through the full cross section of the material, without exceeding the 0.04" (1 mm) space in the lower part. On larger grooves, a welding safety should be installed.

Certain materials must be preheated to 300F (150C) prior to welding. Special preparations are necessary when preparing a crack in manganese steel. Due to its hardness, mechanical preparation, such as a chisel or hobbing machine is not possible. We suggest that the crack is prepared with a slow running and water cooled grinding wheel to prevent overheating. Other possibilities for preparing cracks or removing high alloy welding seams are the use of cutting electrodes of the type UTP 82 AS. 2. Preparation of a weld The area to be welded must be free of paint, grease, oil, moisture and dirt. During rain, the area to be welded must be covered. Materials with a thickness above 0.60" (15 mm), high carbon steel or steel which is difficult to weld, the material must be preheated to approximately 176- 392F (80- 200C). Pre-heating is also necessary when the ambient or component temperature is below 40F (5C) or when the construction of the component prevent the welding stress to be released. 3. Storing Electrodes Use only dry and undamaged electrodes. Electrodes which are rusty or damaged should not be used. Electrodes should be stored in a dry room with a minimum temperature of 59F (15C). Open packages should be carefully closed and stored after the welding work is completed.

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!
Datum Edition Date

PR Litronic LR Litronic RL Litronic

01 04

Repar Welding

Blatt Page Feuille

2.2.00.01

4. Welding Technique The welding of material with the necessary electrodes (see table under paragraph 7) is in accordance with DIN 1912. The adjustment of the welding machine - dictated by the different thicknesses of the electrodes - can be taken from the table of the electrode package. Beginning with a material thickness of 1/4" (8 mm), butt welds must be made in several layers. The weld is applied in several beads. Wide butt welds are filled with several side by side beads, with the last layer covering the center. The electrode should melt evenly without creating burrs and peaks. The valley or crater, which is created when changing electrodes must be filled in and overlapped with the next electrode. To prevent cracks in those craters, care must betaken that they are properly filled. If the crack extends towards the outer edge of the material, slag may be trapped or burn holes may be created. To prevent this, the following aid may be used: Tack a piece of sheet metal to the outer edge of the material. The welding seam begins now at the sheet metal in the direction of the arrow. After the welding is completed, the sheet metal is removed and the edge of the material is ground smooth.

The weld must cool off slowly and should therefore be protected from rain and wind. 5. Reinforcement of the welding seam If the crack of the material is due to an overload or abuse, a reinforcement plate should be welded over the crack. The selection of the correct reinforcement plate is based on the construction and load factors of the component to be repaired. For this reason, only general recommendations can be made as to the size and shape of the reinforcement plates. 6. General application of reinforcement plates 6.1. Shape of reinforcement plates The crossover or connection between the reinforced and not reinforced part should be as gradual as possible. This means that the size of the plate should be selected in such a way that new or unacceptable high stress in the repaired parts are avoided. Plates with sharp corners (such as a rectangular plate) should not be used.

Suitable reinforcement plate with high tensile strength.

Suitable reinforcement plate against bending and alternating loads.

6.2. Plate Thickness The thickness of the reinforcement plate should be up to 2/3 (66%) of the thickness of the material to be reinforced. 6.3. Plate Quality The yield and tensile strength of the reinforcement plate should be equal to the material to be reinforced. 6.4. Plate Installation The welded area of the crack should be ground so it is smooth and level. The size of the plate must be selected in such a way that the longer sides of the plate extend into the connecting construction of the material to be reinforced. The plate should also overlap the crack on each side by at least 1" (20 mm). The correct position and fit of the reinforcement plate is achieved through clamping and spot welding. 6.5. Plate Welding The reinforcement plate should be welded on by running a welding bead alternately on both sides. The welding should always start in the middle of the plate and run towards the outside. Be certain to observe that each welding seam has proper run out.

Direction of weld Use formula: a=0,5 k

Direction of weld

The size of the welding run "a" is figured out in reference to the thickness "k" of the reinforcement plate. Up to a welding run "a" of approx. 1/8" (3 mm) a single run can be made, however, as a general rule, a double run should be preferred. Above a welding run "a" of 1/8"(3 mm), the first run provides excellent penetration between the reinforcement plate and the basic material. Subsequent runs are added on top of the first run.

After the welding is completed, clean the welding seam as necessary. Grind the run out between reinforcement plate and basic material.

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!
Datum Edition Date

PR Litronic LR Litronic RL Litronic

01 04

Repar Welding

Blatt Page Feuille

2.2.00.02

7. Selecting the correct electrodes For repair welding, only lime based {Kb} electrodes should be used, and as a rule, the electrodes {additional material} should be "softer" than the basic material. Exceptions to this rule should be observed. Important: To reach the theoretical welding quality, the work must not only be performed in a professional manner, the electrode manufacturer's guidelines must absolutely be observed as well. Welding of vertical-down welds on steel components is not permissible! 7.1. Electrode Selection Welding area BASIC MACHINE Roller frame - Main frame Material St 52 - 3 QStE 380 N LH 690 preheat to app. 100-150C (210-300F) ATTACHMENT Blade Bucket Push frame Bucket arm RL-Boom Q St E 380 N HARDOX 400 St 52 - 3 Electrode norm description according to EN 499: E42 5 B 4 2 H5 according to AWS A5.1-91: E7018-1 H4 R according to EN 757: E 69 6 Mn2NiCrMo B 4 2 H5 according to AWS A5.5-96: E 11018-G according to EN 499: E42 5 B 4 2 H5 according to AWS A5.1-91: E7018-1 H4 R according to EN 499: E42 5 B 4 2 H5 according to AWS A5.1-91: E7018-1 H4 R according to EN 757: E 69 6 Mn2NiCrMo B 4 2 H5 according to AWS A5.5-96: E 11018-G according to EN 499: E42 5 B 4 2 H5 according to AWS A5.1-91: E7018-1 H4 R Root runs according to EN 499: E42 5 B 4 2 H5 according to AWS A5.1-91: E7018-1 H4 R Cover layers with high-strength electrode according to EN 1600: E 18 8 Mn B 2 2 according to AWS A5.4-92: E 307-15 Protective gas welding wire norm description according to EN 440: G4Si1 according to AWS A5.18-93: ER 70 S-6 according to EN 12534: G3CrNi1Mo according to AWS A5.28-96: ER110S-G according to EN 440: G4Si1 according to AWS A5.18-93: ER 70 S-6 according to EN 440: G4Si1 according to AWS A5.18-93: ER 70 S-6 according to EN 12534: G3CrNi1Mo according to AWS A5.28-96: ER110S-G according to EN 440: G4Si1 according to AWS A5.18-93: ER 70 S-6 Root runs according to EN 440: G4Si1 according to AWS A5.18-93: ER 70 S-6 Cover layers with high-strength electrode according to EN 12072: G 18 8 Mn according to AWS A5.9-93: ER307

Ripper

LH 690 preheat to app. 100-150C (210-300F) St 52 - 3 Q St E 380 N HARDOX 400

WEAR ITEMS Adapter, Tooth adapter Ripper

Special steel

7.2. Steel Table Description HARDOX 400 Explanation Analysis Si 0,7% Cr 1,4%

Weldable, low alloy special steel highly C 0,27% wear resistant, tensile strength 1250 N/mm Mn 1,6% yield strength 1000 N/mm Mo 0,6% Structural steel poured at low turbulence with a guaranteed minimum tensile strength of 500 - 640 N/mm and minimum yield strength of 380 N/mm Highly abrasion resistant steel with a tensile strength of 1720 N/mm C 0,18% Si 0,5% Mn 1,6% C = 0,3% Si = 0,5% Mo = 0,3% C 0,22%

Q St E 380 N

Special steel St 52 - 3 S355J2G3 LH 690

Mn = 0,7% Cu = 0,65% V = 0,05%

Structural steel poured at low turbulence with a guaranteed minimum tensile strength of 510 N/mm Heat treated fine grain structural steel with C 0,18% Si 0,50% a tensile strength of 770 - 940 N/mm and Mn 1,5% Mo 0,5 % yield strength of 690 N/mm Ni 1,5 % lightly alloyed with V, AI and Cu

7.3. Welding addition chart 7.3.1 For arc welding

Description according to EN 499: E42 5 B 4 2 H5

Explanation E = Arc welding, Rod electrode 42 = 500-640 N/mm Tensile strength 5 = Value for resistance to impact e.g. Bhler B = Shielded metal arc FOX EV 50 4 = Reference number for run out and type of flow 2 = Reference number for welding positions H5 = maximum hydrogen content according to EN 757: E = Arc welding, Rod electrode E 69 6 Mn2NiCrMo B 4 2 H5 69 = 760-960 N/mm Tensile strength 6 = Value for resistance to impact e.g. Bhler Mn2NiCrMo = Chemical composition FOX EV 85 B = Shielded metal arc 4 = Reference number for run out and type of flow 2 = Reference number for welding positions H5 = maximum hydrogen content according to EN 1600: E 18 8 Mn B 2 2 e.g. Bhler FOX A 7 E = Arc welding, Rod electrode 18 = 620-770 N/mm Tensile strength 8 = Value for resistance to impact Mn = Chemical composition B = Shielded metal arc 2 = Reference number for run out and type of flow 2 = Reference number for welding positions

Analysis - Value in % / Use C = 0,07, Si = 0,5, Mn = 1,1 For connection and application welding, especially for steel with low purity and higher carbon content. Weldable with direct current, electrode connected to plus terminal (+). No vertical seams C = 0,05, Si = 0,4, Mn = 1,5, Cr = 0,4, Ni = 2,0, Mo = 0,5 For welding, which require high viscosity and crack resistance. Use for high tensile refined fine-grained steel. Very low hydrogen content in weld metal. Weldable with direct current, electrode connected to plus terminal (+). No vertical seams C = 0,1, Si = 0,7, Mn = 6,5, Cr = 18,8, Ni = 8,8 For connections between various alloyed and steel which is difficult to weld. Weldable with direct current, electrode connected to plus terminal (+). No vertical seams

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!
Datum Edition Date

PR Litronic LR Litronic RL Litronic

01 04

Repar Welding

Blatt Page Feuille

2.2.00.03

7.3.2 For MIG welding with solid electrodes:

Description according to EN 440: G4Si1 e.g. Bhler EMK 8

Explanation G = MIG welding with solid electrodes 4 = 500-640 N/mm Tensile strength Si = Chemical composition 1 = Reference number for run out and type of flow

Analysis - Value in % / Use C = 0,1, Si = 1,0, Mn = 1,7 For connection and application welding, especially for steel with low purity and higher carbon content. Weldable with direct current, electrode connected to plus terminal (+). Protective gases: Argon + 15-20% CO2 or 100% CO2 No vertical seams C = 0,1, Si = 0,6, Mn = 1,6, Cr = 0,25, Ni = 1,3, Mo = 0,25, V = 0,1 For welding, which require high viscosity and crack resistance. Use for high tensile refined fine-grained steel. Weldable with direct current, electrode connected to plus terminal (+). Protective gases: Argon + 15-20% CO2 or 100% CO2 No vertical seams C = 0,08, Si = 0,9, Mn = 7,0, Cr = 19,2, Ni = 9,0 For connections between various alloyed and steel which is difficult to weld. Weldable with direct current, electrode connected to plus terminal (+). Protective gases: Argon+max. 2,5% CO2 No vertical seams

according to EN 12534: G3CrNi1Mo e.g. Bhler X 70 - IG

G = MIG welding with solid electrodes 3 = 900 N/mm Tensile strength CrNi1Mo = Chemical composition

according to EN 12072: G 18 8 Mn e.g. Bhler A7 IG

G = MIG welding with solid electrodes 18 = 580-730 N/mm Tensile strength 8 = Value for resistance to impact Mn = Chemical composition

Duo-cone seal design for:

sealing against outside,

sealing against inside

1 Retainer 2 O-ring 3 Metal ring 4 Sealing surface


Note: At the present time, for design reasons, we only use seals protecting against the outside.

Duo-cone seals are precision components made out of chilled cast iron. They are manufactured in pairs and should never be mixed whether they are new or used. Avoid shocks and beats as the sealing surfaces of the metal seal rings can get damaged. Eliminate sharp edges on the seal-retainers. Before installation the Duo-Cone-Seals and the retainers must be clean and free of grease. The toric or O-rings may not be oiled. Installation: Push the seal rings (with toric ring) with an installation tool into the seal seat. Even pressure must be exerted on the toric ring around the complete circumference to push the toric ring past the seal retaining lip. A standard installation tool, as shown on the reverse side, is folded over the seal ring and transfers even pressure directly onto the toric ring. If no suitable installation aid is available, place a round rubber cord or coil spring (as shown below) to provide a distance between the seal ring and the O-ring and hold it so that the O-ring cannot roll up on the conical seal ring surface when each half of the seal ring is pressed in.

1 2 3 5 6

Retainer O-ring Metal ring Installation tool Installation aid, such as coil spring, rubber cord or rope, etc.

If no installation tool is used, the toric O-ring can roll up on the conical seal seat surface. If pressure is exerted only on one side, the seal may not be positioned vertically and / or the O-ring can be distorted. These installation problems can cause leaks as well as damage to the sealing surfaces. Installation position: incorrect incorrect -

correct

O-ring distorted

Seal is not vertical

Before the components are assembled, check if the seal rings protrude evenly. Measure the distance from the seal seat to the seal rings on at least 3 locations, 120 apart. Check the sealing surfaces again to ensure they are clean and lightly lubricated.
Benennung Description Dnomination Typ/ab Type/from Type/ a partir de

Mjfcifss!

Installation guidelines
Datum Edition Date

PR Litronic LR Litronic RL Litronic


Blatt Page Feuille

01 02

Duo-Cone-Seals

2.3.01.01

Listing of available installation tools for travel gear - Duo-Cone seals:

The tools may be ordered by the spare parts dept. from Liebherr Werk Telfs GmbH. - under the description of "Duo-Cone-Seal installation tool" and the corresponding Id. No.

Gear Type FAT 400 / 523 FAT 450 / 514 FAT 500 / 525 FAT 550 / 516 FAT 400 C 563 FAT 450 C 564 FAT 500 C 565 FAT 550 C 566

Gear Machine Ident-No. Type PR/LR/RL 9443 850 9443 090 9443 100 9443 105 9443 410 9443 430 9443 450 9443 470 712 722 732 742 712 722 732 742 x32 x42

Duo cone seal Ident-No. 7610 242 7610 243 7610 244 7610 245 7610 544 7610 545 7610 543 7610 546 7610 244 7610 249 7610 245 7610 548 7610 242 7610 243 7610 244 7610 245 7610 244 7610 242 7610 245 7610 243 7610 237 7610 244 7610 548 7610 245 7610 241 7610 245

Installation tool tool number Ident-No. 07590 39022 1001 7428 07590 38886 1001 7430 07590 38891 1001 7436 07590 39023 1001 7433 07590 39022 07590 38886 07590 38891 07590 39023 07590 38891 00100 07500 07590 39023 07590 41339 07590 39022 07590 38886 07590 38891 07590 39023 07590 38891 07590 39022 07590 39023 07590 38886 07590 41338 07590 38891 07590 41339 07590 39023 00100 01300 07590 39023 1001 7428 1001 7430 1001 7436 1001 7433 1001 7436 1001 8934 1001 7433 1001 7456 1001 7428 1001 7430 1001 7436 1001 7433 1001 7436 1001 7428 1001 7433 1001 7430 1001 7468 1001 7436 1001 7456 1001 7433 1001 7472 1001 7433

FAT 500 P 595 D 9444 380 FAT 550 P 596 D 9444 390

FAT 400 P 553 FAT 450 P 554 FAT 500 P 555 FAT 550 P 556 FAT 400 D 583 FAT 450 D 584 FAT 500 D 585 FAT 550 D 586

9443 340 9443 270 9443 310 9443 390 9444 305 9444 315 9444 260 9444 325

x12 x22 x32 x42 x12 x22 x32 x42

FAT 650 / 508

9443 830

x52

1 2 3 4 5 6

General repair guidelines Crimp tool and use Installation guidelines - CA - B / CA - COM - B cable connector Installation guidelines - KPSE cable connector Installation guidelines - SURE SEAL cable connector Installation guidelines - DEUTSCH cable connector

1. General Repair Guidelines When working with cable connectors, the following must be observed: Keep hands, work place and connectors clean, dry and free of grease. Always use the special installation tool - see paragraph 3.1.31 - for installation. For CA - COM - B connectors use the same special tool as for CA - B connectors. Check tools for wear before use - a wrong or defective tool as well as improper handling can damage the cable connector components. When cutting cables to proper length, make sure they are the same length and the cutting edge is straight. Do not compress or squeeze the cable. For 90 cable routing, cut the cable to proper length when in angled position. The cable covering must reach under the crimp joint. Check installation guidelines for correct length to be stripped. When stripping the cable, make sure that the individual wires are not damaged, kinked, bent or soiled. Before installation, check crimp connections of all contacts: - Individual wires must be visible in the inspection hole of the contact. - All wires must be tightly caught in the crimp connection. - The wire insulation must reach the contact. When removing and reinstalling contacts, make sure to check the flow direction and use isopropyl alcohol (rubbing alcohol) as a lubricant, do not twist contacts and tool. Do not reuse damaged parts. Contacts in size 60/100, 160 and 500 can only be crimped hydraulically. If these contacts are damaged, the complete wire must be replaced. Make sure all parts are positioned correctly, check charts!. On straight cable feeds, insert the contacts from the center to the outside. On 90 cable feeds, insert them in a row from the bottom to the top. Even contacts, which are not wired, need to be installed. Close off any empty chambers with a plug. Visually check if all mating ends of the contacts are at the same level. Route the wires free of tension and fasten them.

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Wiring installation guidelines


Datum Edition Date

PR Litronic LR Litronic RL Litronic


Blatt Page Feuille

01 04

ITT-Cannon plug

2.3.02.01

2. Use of crimp tool 2.1. Adjust the manual crimp tool - M 22 520 / 01 - 01

Set the selector dial on the handle to the appropriate diameter, see installation guidelines on wiring chart.

2.2. To adjust turret head TH 452 and CT 1200 90 - 20 Install the proper turret head with a 9/64 Allen wrench. Push switch 1. Adjust color coded crimp position on knob 2 according to the wiring chart. Push knob 2 in to the stop and push the tool once more.

2.3. Use Before crimping, strip the wire endings to the length noted in the installation guidelines, using the appropriate tool - see paragraph 2.1.31. Insert the stripped wires into the contact crimp sleeve as far as possible until they are visible in the inspection port Insert contact and wire into the preset crimp tool. Push the tool handles together all the way.

Note: The locking mechanism will not allow you to open the tool until the crimping operation has been completed. Pull the crimped contact with wire from tool. Check the crimp, see paragraph 1.

2.4. Check crimp tool wear. Check the crimping die for wear with a M 22 520 / 3 - 1 gauge (see paragraph 2.1.31.02), without the crimping head in place. Set the dial on the handles of the crimp tool to No. 4. Turret both sides of the gauge into the crimp opening of the tool. The GREEN - side (good) must fit easily between the crimp dies, or the adjustment of the tool and the crimp die must be checked. The RED - side (oversize) may not fit, or the tool are not closed all the way or the crimp dies are worn and must be replaced.

Caution: Do not operate the crimp tool when the gauge is inserted!

3. Installation Guidelines for CA - B / CA - COM - B Cable Connectors

3.1. Description A = Plug B = Socket Components 1 2 3 3.1 4 5 5.1 6 7 Grommet Insulator Cylinder barrel Seal ring End bell with nut Bayonet coupling nut Spring washer (on CA-COM-B) Socket contacts Pin contacts

Tightening torque for end bell: Size: 10 SL 14S/14 20 32 max. 3 Nm max. 5 Nm max. 9 Nm max. 15 Nm

CA CA

3106 06COM

E E

3232-

8SB 03 8SB 03 LH Other specifications Size Classification Type of housing Model

3.2. Overview table Plug Description Number / Type of Contact - Size S=Socket, P=Pins
CA 3106 E 32-8SB-03 CA 06 COM-E 32-8SB03-LH Socket (30 pole) on main wiring harness - large

Insertion Tool
Removal: CET-F80-16 Installation: CIT-F80-16 Removal: CET-F80-12 Installation: CIT-F80-12 Removal: CET-F80-16 Installation: CIT-F80-16 Removal: CET-F80-12 Installation: CIT-F80-12 Removal: CET-F80-16 Installation: CIT-F80-16 Removal: CET-F80-12 Installation: CIT-F80-12 Removal: CET-F80-8 Tool:

Crimp Tool
M 22520/1-01 TH 452 M 22520/1-01 TH 452 M 22520/1-01 TH 452 M 22520/1-01 TH 452 M 22520/1-01 TH 452 M 22520/1-01 TH 452

Notes Contact size 15 metric Contact size 25 metric Contact size 15 metric Contact size 25 metric Contact size 15 metric Contact size 25 metric
If these crimp contacts are damaged, replace small instrument cable kit

24 / S - 15 6 / S - 25 24 / P - 15 6 / P - 25 16 / S - 15

Turret: Tool: Turret: Tool: Turret: Tool: Turret: Tool: Turret: Tool: Turret:

CA 3106 E 32-8SB-04 Plug (30 pole) in instrument panel for main wiring harness large

CA 3106 E 32-6SB-03 CA 06 COM-E 32-6SB03-LH Socket (23 pole) on main wiring harness small

2 / S - 25 3 / S - 60 2 / S - 160

Installation: CIT-F80-8 Removal: CET-F80-4

Hydraulic crimp tool and hand pump

Installation: CIT-F80-4

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Wiring installation guidelines


Datum Edition Date

PR Litronic LR Litronic RL Litronic


Blatt Page Feuille

01 04

ITT-Cannon plug

2.3.02.02

Plug Description

Number / Type of Contact - Size S=Socket, P=Pins 16 / P - 15 2 / P - 25 3 / P - 60 2 / P - 160

Insertion Tool
Removal: CET-F80-16 Installation: CIT-F80-16 Removal: CET-F80-12 Installation: CIT-F80-12 Removal: CET-F80-8 Tool:

Crimp Tool
M 22520/1-01 TH 452 M 22520/1-01 TH 452

Notes Contact size 15 metric Contact size 25 metric


If these crimp contacts are damaged, replace small instrument cable kit

Turret: Tool: Turret:

CA 3106 E 32-6PB-04 Plug (23 pole) in instrument panel for main wiring harness small

Installation: CIT-F80-8 Removal: CET-F80-4

Hydraulic crimp tool and hand pump

Installation: CIT-F80-4

CA 3102 E 20-27 SB-03A176 CA 06 COM-E 20-27 SB03-LH Socket (14 pole) on electronic wiring harness for joystick CA 3106 E 14S-6 SB-03A176 CA 06 COM-E 14S-6 SB03-LH Socket (6 pole) on electronic wiring harness for engine speed sensing potentiometer and outrigger wiring harness right / left CA 3106 E 10SL-3SB-03 CA 06 COM-E 10 SL3SB-03-LH Plug (6 pole) on outrigger wiring harness right / left for electronic wiring harness CA 3106 E 10SL-3SB-03 CA 06 COM-E 10 SL3SB-03-LH Socket (3pole) on electronic and variable motor wiring harness - left / right for solenoid valves

14 / S - 15

Removal: CET-F80-16 Installation: CIT-F80-16

Tool: Turret:

M 22520/1-01 TH 452

Contact size 15 metric

6 / S - 15 S

Removal: CET-F80-16 Installation: CIT-F80-16

Tool: Turret:

M 22520/1-01 TH 452

Contact size 15S metric

6 / P - 15 S

Removal: CET-F80-16 Installation: CIT-F80-16

Tool: Turret:

M 22520/1-01 TH 452

Contact size 15S metric

Removal: CET-F80-16

3 / S - 15 S

Tool: Turret:

M 22520/1-01 TH 452

Installation: F80-16

CIT-

Contact size 15S metric

For guide pins and various additional tools , see paragraph 2.1.31

3.3. Removal of Contacts Note general guidelines in paragraph 1.

Carefully lift the plastic insulation (see manufacturer s guidelines), slit it carefully and remove. Caution: Do not damage the insulation and wires inside the cover insulation!

Unscrew the housing from the cylinder and push the seal over the wires.

Push out the contacts with appropriate tool out of the insulator - see paragraph 3.2 by applying even and continuous pressure towards the connector, keep the tool parallel to the axis of the plug connector. Stop when the shoulder of the tool touches the front of the insulator. Carefully pull the tool from the insulator. Remove all contacts in the same way, make sure to note different versions / tools. Important: The tool must fit properly into or over the contacts.

The housing and seal normally stay on the wiring. If necessary, pull the wires and contacts carefully from the seal, remove the housing from the wires.

3.4. To wire the Contacts Wire diameter Adjustment - Crimp tool Contact Stripping type Color length S=Socket Metric AWG Dial No. mm AWG Crimping (mm) P=Pin insert P 5 blue +0,5 1,0 18 6,0 5 green S 15S 16S P 6 blue 1,5 16 6,0+0,5 S 6 green P 5 green 1,0 18 6,0+0,5 5 red S 15 16 P 6 green +0,5 1,5 16 6,0 S 6 red P 8 red +0,5 25 12 2,5 12 6,0 S 8 red Strip the wire as noted on chart and crimp - see paragraph 2.1 to 2.3 3.5. Insertion of Contacts Note general guidelines in paragraph 1. Push the plastic insulation over the housing onto the wires. If housing and sealer were removed, push on housing, dip seal into isopropyl alcohol and guide contact with cable from the side marked with letter. Use the appropriate insertion tool. The seal housing must align with the insulator housing! Contact size

Important:

Note the installation position of the wire as noted on number coding plan. Insert contacts into the guide tool, push the insertion tool to the top of the connector tip. On socket type contacts, insert guide pin. Dip in isopropyl alcohol and insert straight into insulator until it snaps into position. Make sure to check number coding chart.

Important:

Remove guide pin and insertion tool. Slightly pull the wire to check proper seating of the contact, plug chambers with empty contacts.

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Wiring installation guidelines


Datum Edition Date

PR Litronic LR Litronic RL Litronic


Blatt Page Feuille

01 04

ITT-Cannon plug

2.3.02.03

Push sealer and housing into cylinder housing, carefully tighten nut. If necessary, use the counter part of the connector as a retainer. To retain all parts, loosen nut by 1/4 turn and retighten properly, secure with adhesive. On electronic wiring harness, insert heat seal (Ray-blocker) on end of insulation and adhere during the following shrinking procedure.

Pull shrink fit sleeve over housing and evenly heat with hot air blower until all parts are tightly covered. Do not pull the wires during the shrink fit procedure. Do not apply heat above 125 C (257 F).

Caution:

4. Installation Guidelines KPSE plug Connector

4.1. Design A = Socket B = plug Item listing 1 Insulator 1.1 Contact retainer (integrated in insulator) 2 Barrel 2.1 Seal ring 3 Cone ring 4 Housing 5 Bayonet coupling nut 6 Socket type contact with crimped wire 7 Pin type contact with crimped wire Tightening torque for end bell: Size: 8, 10 12,14,16 18, 20, 22, 24 max. 4 Nm max. 6 Nm max. 10 Nm

KPSE

06

22-

21PB DN Other specifications Size Classification Type of housing Model

4.2. Chart Number / Type of contact size S=Socket, P=Pins


KPSE 06E22-21PB-DN Plug (21 pole) on wiring harness - Cab KPSE 07E22-21SB Socket (21 pole) in instrument panel for Wiring harness - Cab KPSE 06E22-55SB-DN Socket (55 pole) on electronic wiring harness for electronic box KPSE 06E8-3A SB-DN Plug (3 pole) on var. motor wiring harness left / right for RPM sensor Removal: MS24256 R16

Plug description

Insertion tool

Crimp tool

Notes

21 / P - 16

Tool: Insert: Tool: Insert: Tool: Insert: Tool: Insert:

M 22520/1-01 CT120090-20 M 22520/1-01 CT120090-20 M 22520/1-01 CT120090-20 M 22520/1-01 CT120090-20

Installation: A16

MS24256

Contact size 16 per AWG Contact size 16 per AWG Contact size 20 per AWG Contact size 20 per AWG

Removal: MS24256 R16

21 / S - 16

Installation: A16

MS24256

Removal: MS24256 R20

55 / S - 20

Installation: A20

MS24256

Removal: MS24256 R20

3 / S - 20

Installation: A20

MS24256

4.3. Removal of contacts Note general guidelines in paragraph 1 . Carefully cut and remove shrink fit sleeve per manufacturers guidelines. Important: Do not damage insulator and inside wires. Remove housing, loosen cone ring, housing cone and push nut over the wires. Select proper removal tool for contact size per paragraph 4.2. Check and apply tool first while empty, check the ejector point and hollow needle for damage. Improper or damaged tools can damage plug parts. On pin contacts set tool above the pin until mark 1 straight on the insulator. On jack contacts, insert tool over socket until mark 2 into the insulator.

Applying even pressure to tool, move ejector with thumb and forefinger forward and push contact from retainer clip. Carefully remove tool from insulator and pull contact by the wire from the socket. Remove all contacts the same way. Remove all connector components from wire harness.

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Wiring installation guidelines


Datum Edition Date

PR Litronic LR Litronic RL Litronic


Blatt Page Feuille

01 04

ITT-Cannon plug

2.3.02.04

4.4. Wiring of contacts Wire diameter Adjustment - Crimp Tool Contact Insulator type Color Length S=Jack AWG Dial No. mm AWG Crimping (mm) P=Pins Insert P 20 0,96 18 5,0 5 red S P 16 1,5 16 6,5 6 blue S Insulate wire as noted on chart and crimp - see paragraph 2.1 to 2.3 Contact size

4.5. Installation of Contacts Note general guidelines in paragraph 1..

Push the shrink fit sleeve and nut in proper sequence over the wires. Insert contact (see chart) by hand into reverse side of plug, until the top of the contact is no more than 3 mm from the insulator.

Push appropriate guide tool over the contact connector and hold it vertical to the front the insulator. Contact size 16 and 12 are inside the tool, the tool pushed against the top of the contact. On contacts, size 20, the side pushes against the end of the contact, therefore the contact is farther outside the tool. Dip all parts in isopropyl alcohol and push evenly into insulator until you hear the contact click in.

Remove the tool and check if the contact is seated properly by a slight pull on the wires. Close off empty chambers with plug. Push cone ring as far as possible over the insulator. Apply isopropyl alcohol to lubricate contact surfaces. Push housing, on sockets also nut, onto cylinder housing and tighten carefully. If necessary, use plug connector part as holder. To set the parts, loosen the housing by 1/4 turn, retighten and secure with adhesive.

Pull shrink fit sleeve over housing and evenly heat with heater fan until all parts are tightly covered.

Caution:

Do not pull the wires during the shrink fit procedure. Do no apply heat above 125 C (257 F).

5. Installation Guidelines SURE SEAL Plug Connector 5.1. Design A = Plug B= Socket 1 Housing 2 Pin type contact 3 Socket type contact 4 Seal

5.2. Chart Number / Type of contact S=Jack, P=Pin


SURE SEAL SS 5 P plug (5 pole) on electronic wiring harness SURE SEAL SS 5 R plug (5 pole) on var. motor wiring harness - left/ right

Plug description

Insertion Tool

Crimp Tool

Notes P valid only for removal of socket S valid only for removal of pin type contacts

2-P 3-S 3-P 2-S

Removal: CET-SS-P/S Installation: CITG-SS-1 Removal: CET-SS-P/S Installation: CITG-SS-1

Tool: Insert: Tool: Insert:

M 22520/1-01 CT120090-20 M 22520/1-01 CT120090-20

5.3. Removal of contacts Note general guidelines in paragraph 1. Remove the plug, loosen connection. Remove shrink fit sleeve as described by manufacturer, or carefully slit open and remove.

Caution:

Do not damage the insulation or wires inside the cable!

Use proper extraction tool - see paragraph 5.2 - insert from contact side parallel to the plug axis into the socket or over the pin contact. Apply even pressure and push contacts out in direction of the cable. Carefully pull extraction tool from plug, clean wire. 5.4. To wire contacts Contact size AWG SS10 Contact type S=Socket P=Pin P S Wire diameter mm 0,96 AWG 18 Stripping length (mm) 6,0+0,3 Adjustment - crimp tool Dial. No 5 5 Color Crimp insert gray gray

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Wiring installation guidelines


Datum Edition Date

PR Litronic LR Litronic RL Litronic


Blatt Page Feuille

01 04

ITT-Cannon plug

2.3.02.05

Depending on the number of poles, the minimum stripping length must be adhered to on covered cables. No. of Min. stripping poles length (mm) 2, 3, 4 40 5, 6, 7 45 8, 9, 10 50 Strip the wire to the length shown on chart and crimp - see paragraph 2.1 to 2.3 5.5. To install contacts Note general guidelines described in paragraph 1. Push shrink fit sleeve onto wires. Insert plug into installation tool, see paragraph 2.1.31 to facilitate this process. Insert wired contact into the insertion tool, see paragraph 5.2, keeping contact 1, cable 2 and tool 3 in a straight line and push until tool shoulder touches contact.. On socket type contacts, add guide pin. Dip parts into isopropyl alcohol and push into plug, see chart, applying even pressure parallel to the length axis until it snaps in place. Remove guide pin, pull tool carefully from plug and check if wire is seated properly, by pulling slightly.. Remove plug from installation tool. Check seating and position of contacts again. On the end of the cover, insert seal (Ray-Block), and push shrink fit sleeve over plug. Evenly heat is with hot air fan until the Ray-Block is melted and the components are covered tightly. Caution: Do not pull on the wires during the shrink fit procedure. Do not overheat the connector..

6. Installation Guidelines DEUTSCH Plug Connector General: In machines, plug connections type Deutsch DT and Deutsch HDP Series are used - see the following overview chart. Plug Connector series DT A = Socket B = Plug Item listing: 1 2 3 4 5 6 7 Housing Grommet Locking wedge socket Locking wedge plug Seal plug Pin Socket

Plug Connector series HDP A = Socket B = Plug

Item listing: 1 2 3 4 Socket housing with pin Plug housing with socket Grommet Union nut

6.1. Overview chart Number / Type of contact - size S=Socket, P=Pins


Deutsch plug (2 pole) Deutsch Plug (3 pole) Deutsch Plug (4 pole) Deutsch Plug (6 pole) Deutsch Plug (8 pole) Deutsch Plug (12 pole)

Plug description

Plug series

Crimp tool

Notes
for designations see group. 09

2-S 2-P 3-S 3-P 4-S 4-P 6-S 6-P 8-S 8-P 12 - S 12 - P 18 - S 18 - P

DT

Tool: Insert: Tool: Insert: Tool: Insert: Tool: Insert: Tool: Turret: Tool: Insert:

M 22520/1-01 CT120090-20 M 22520/1-01 CT120090-20 M 22520/1-01 CT120090-20 M 22520/1-01 CT120090-20 M 22520/1-01 CT120090-20 M 22520/1-01 CT120090-20

Y14 B5, B6, X34(S2) X69, X70, X71, X72, X77 X6, X7 X6, X/ X65, X73

DT

DT

DT

DT

DT

Deutsch plug (18 pole)

HDP

Tool: Insert:

M 22520/1-01 CT120090-20

X64

6.2. Wiring of contacts contact Wire diameter Adjustment - Crimp tool Insulator type Length color crimping S=Jack AWG Dial No.. mm AWG (mm) insert P=pin P 20 0,75 20 5,0 4 red S P 18 1,0 18 5,0 5 red S P 16 1,5 16 6,0 6 blue S P 12 2,5 12 6,0 8 gray S In case of repairs, crimp contacts >2,5 mm must be soldered on the central cable harness. contact size
Benennung Description Dnomination Typ/ab Type/from Type/ a partir de

Mjfcifss!

Wiring installation guidelines


Datum Edition Date

PR Litronic LR Litronic RL Litronic


Blatt Page Feuille

01 04

ITT-Cannon plug

2.3.02.06

6.3. Crimping of contacts See installation instructions, point 1 to 2.4 6.4. Installation of contacts DT Series: Contacts must engage properly at installation (click). Installation is made without tools. Inserted Engaged

After positioning the contacts, the locking wedge must be inserted, see illustration DT-Series. Note: Insert the contacts straight, do not kink. Use Isopropyl alcohol (rubbing alcohol) . 6.5. Removal of contacts DT Series: Remove the locking wedge and use a small screw driver to loosen the pin or bushing lock and pull the contact with the cable from the housing . 6.6. Installation of contacts HDP Series: Installation is made without tools. Contacts must engage properly (click). Inserted Engaged

Note: Insert the contacts straight, do not kink. Use Isopropyl alcohol (rubbing alcohol) .

6.7. Removal of contacts HDP Series: To remove the contacts, use special tool, see section 02.1.31.

Select tool according to cable diameter and push over cable and pin or bushing contact. Push the lock in to loosen and pull out the cable together with contact and tool.

Loosen the lock

Pull out

Directions for use of Four Notch Hand Crimping Tool


1. General: Protect the pliers from contamination. Do not open with force. When crimping, push the tool together all the way before opening it again. Use positioning sleeve for HAN D contacts, see section 02.1.31. 2. Four notch hand crimping tool, see section 02.1.31. Parts list: 1 2 3 4 5 6 Pliers Positioning sleeve Locking bar Lock screw Adjustment scale Adjustment screw

2.1. Attach the positioning sleeve Loosen the lock screw 4 on the locking bar, pull the bar 3 back and insert the sleeve 2, close the bar and retighten the lock screw 4. Set the crimping depth. Determine the diameter of the conductor and select the corresponding pin = crimping depth. For pin Id. No., see section 2.1.31. Conductor mm AWG 0,50 20 0,75 18 1,00 18 1,38 16 1,50 16 2,10 14 2.50 14 Pin HAN D 1,55 1,55 1,55 1,60 1,80 1,45 1,55

Open and close the crimping tool several times and then hold in open position. Turn the adjustment screw, pos.6 until the edge of the indicator bar aligns with the line of the selected pin diameter. Close the tool and check the setting with the pin. If set correctly, the pin * must fit without a clearance into the existing tool opening. Caution: When the pin is inserted, do not open or close the tool - danger of breaking correct incorrect

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Wiring installation guidelines


Datum Edition Date

PR Litronic LR Litronic RL Litronic


Blatt Page Feuille

01 01

Harting plug

2.3.03.01

2.2. Crimping Before crimping, insulate the ends of the wire with a suitable tool - see section 02.1.31. 8 mm on 0.75 1.50 mm contacts 6 mm on 2.50 mm contacts Note: The cable wires must be visible in the control bore. All cable wires must be caught in the crimping point. The insulation must reach the contact.

Insert the cable with the contact into the pre-set tool. Push the tool together, quickly and all the way. Pull the cable with the crimped contact from the tool and check the crimping. Note: The tool can only be opened when the cable is crimped completely.

2.3. Installation of pin contacts - plug section on instrument panel

Set the plug section, pos.1 into the instrument panel. Set the pin contacts, pos.3 in to the contact base, pos.2. Screw the base with the plug section, pos.1.

2.4. Installation of bushing contacts / plug section central wiring harness Push the shrink fit sleeve or shrink fit part over the cable before installation of the contact base . Push the clamping section, pos.5, rubber seal with washers, pos.4, screw fitting, pos.3 and plug housing, pos.1 over the cable. For installation of contacts, use insertion tool, see section 02.1.31. Insert the bushing contacts into the contact base, pos. 2, screw the base together with the housing, pos. 1. Caution: The cables can be stuck / damaged when connecting. Screw the screw fitting, pos. 3 into the plug housing and tighten. Insert the rubber seal with washers and attach wiring harness with clamping section on the plug housing, pos. 1. Note: Do not use damaged parts. Make sure all parts are positioned correctly, check corresponding plug illustrations (see section 9.2). Visually check the installation position of the contacts, route the cable free of tension. 2.5. Sealing Push the shrink fit sleeve over the clamping section, pos.5 and push in the screw fitting, pos.3 and use a hot air blower to heat evenly until the sleeve is shrunk in place. Note: Do not heat the components of the screw connection above 125C ( 257F). 2.6. Removal of pin and bushing contacts For removal, use removal tool, see section 02.1.31. Push the removal tool over the pin or bushing and loosen the lock, push the contacts out.

Installation guidelines for MATE-N-LOK and JUNIOR POWER TIMER plug connectors
1. MATE-N-LOK Design: Plug with contact pin Socket with contact bushings

1.1. Use of hand crimping tool Profile 1 Pos.2 Wire diameter 0.5 1.3 mm Profile 2 Pos.3 Wire diameter 1.3 2.1 mm

Open the pliers, pos.1 all the way to insert the contact, which is to be crimped (note the correct profile) and slowly push the pliers together until the contact is lightly clamped on the crimping sleeve. Insert the wire, which is to be insulated (insulation length 5 mm). Push the pliers all the way together. Pull the crimped contact from the pliers and check the crimping.

Contact pin with crimped wire

Contact bushing with crimped wire

* = Contact notch

1.2. Installation of contacts Installation is made without tools. Note: Check contact notches before installation for damage or breaks. Contacts must audibly click when engaging in the housing. 1.3. Removal of contacts To remove the contacts, use special tool, see section 02.1.31. Use: Push the tool, pos.2 over the pin or bushing contact and push the contact notches together, pull the contact on the cable from housing, pos. 1 .

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Wiring installation guidelines


Datum Edition Date

PR Litronic LR Litronic RL Litronic


Blatt Page Feuille

01 01

AMP plug

2.3.04.01

2. JUNIOR POWER TIMER Design: Plug with contact pins Socket with contact bushings

2.1. Use of hand crimping tool

Mark: Red Blue Yellow for cable diameter 0.25 - 1.60 mm for cable diameter 1.00 - 2.60 mm for cable diameter 2.70 - 6.60 mm

Open the pliers all the way to insert the contact, which is to be crimped with the seal and slowly push the pliers together until the contact is lightly clamped on the crimping sleeve. Insert the wire, which is to be insulated (insulation length 5 mm). Push the pliers all the way together.

Pull the crimped contact 1 from the pliers. Check the crimping with seal 2.

2.2. Installation of contacts Installation is made without tools. Note: Check contact notches before installation for damage or breaks. Contacts must audibly click when engaging in the housing. 2.3. Removal of contacts To remove the contacts, use special tool, see section 02.1.31. Use:

Push the tool, pos.2 over the pin or bushing contact and push the contact notches together, pull the contact on the cable from housing, pos. 1.

Sub Group Index


Technical data
PR 712 PR 712B PR 712B PR 712B PR 712B PR 722 PR 722B PR 722B PR 722B PR 722B PR 732 PR 732B PR 732B PR 732B PR 732B PR 742 PR 742B PR 742B PR 742B PR 742B PR 742B PR 752 PR 752 PR 752 F/N xxx-01030500 F/N xxx-05012999 F/N xxx-30003083 F/N xxx-30845599 F/N xxx-5600 F/N xxx-01031000 F/N xxx-10013000 F/N xxx-30013170 F/N xxx-31715599 F/N xxx-5600 F/N xxx-20032500 F/N xxx-25012999 F/N xxx-30003135 F/N xxx-31365599 F/N xxx-5600 F/N xxx-20012500 F/N xxx-25012999 F/N xxx-30003088 F/N xxx-30895233 F/N xxx-52345599 F/N xxx-5600 F/N xxx-20025599 F/N xxx-56006199 F/N xxx-6200

3.1
3.1.10 3.1.11 3.1.12 3.1.13 3.1.14 3.1.20 3.1.21 3.1.22 3.1.23 3.1.24 3.1.30 3.1.31 3.1.32 3.1.33 3.1.34 3.1.40 3.1.41 3.1.42 3.1.43 3.1.44 3.1.45 3.1.50 3.1.51 3.1.52

Maintenance and inspection guidelines


PR 712 PR 722 PR 732 PR 742 PR 712B PR 722B PR 732B PR 742B PR 712B PR 722B PR 732B PR 742B PR 752 PR 712B PR 722B PR 732B PR 742B PR 752 F/N xxx-01010500 F/N xxx-01011000 F/N xxx-20012500 F/N xxx-20012500 F/N xxx-05012999 F/N xxx-10012999 F/N xxx-25012999 F/N xxx-25012999 F/N xxx- 3000 F/N xxx- 3000 F/N xxx-30003039 F/N xxx-30003024 F/N xxx-20022008 F/N xxx-30013083 F/N xxx-30013170 F/N xxx-30403135 F/N xxx-30253088 F/N xxx-20092059
Benennung Description Dnomination

3.2
3.2.10

3.2.11

3.2.12

3.2.13

Typ/ab Type/from Type/ a partir de

Mjfcifss!

PR Litronic

Technical Data Datum Edition Date

01 03

Maintenance Guidelines

Blatt Page Feuille

3.0.00.01

PR 712B PR 722B PR 732B PR 742B PR 752 PR 712B PR 722B PR 732B PR 742B PR 752

F/N xxx-30845599 F/N xxx-31715599 F/N xxx-31365599 F/N xxx-30895599 F/N xxx-20605599 F/N xxx-5600 F/N xxx-5600 F/N xxx-5600 F/N xxx-5600 F/N xxx-5600

3.2.14

3.2.15

Maintenance and inspection instructions Adjustment checklist and quick reference


PR 712 PR 722 PR 732 PR 742 F/N xxx-01030384 F/N xxx-01030563 F/N xxx-20032500 F/N xxx-20012500

3.4 3.5
3.5.00

PR 712(B) F/N xxx-03855599 PR 722(B) F/N xxx-05645599 PR 732B F/N xxx-25015599 PR 742B F/N xxx-25015599 PR 712B PR 722B PR 732B PR 742B PR 712B PR 722B PR 732B PR 742B PR 752 PR 752 PR 752 F/N xxx-56006199 F/N xxx-56006199 F/N xxx-56006199 F/N xxx-56006199 F/N xxx-6200 F/N xxx-6200 F/N xxx-6200 F/N xxx-6200 F/N xxx-20025599 F/N xxx-56006199 F/N xxx-6200

3.5.01

3.5.02

3.5.03

3.5.50 3.5.51 3.5.52

PR 712 Type No.


DIESEL ENGINE Type Engine version Rating to DIN 6271 Rated RPM Low idle RPM High idle RPM Displacement Oil quantity incl. filter Oil specifications Max. machine inclination > all directions Valve clearance > cold intake/ / exhaust Firing order Coolant capacity Fuel tank capacity Fuel consumption

> 103 348

L > 103 415

M>103 349

kW 1/min 1/min 1/min l (cu. in) l (qt)

mm l (gal) l (gal) appr. l/h (gal/h)

D 904 TB LIEBHERR in line 4 > mildly turbocharged 74 (98.6 HP) 2000 800 2100+80 5.6 (342) 18 (19) see lube oil > group 1.3 45 = 100 % 0.20 / 0.25 1>3>4>2 52 (13) 310 (82) 11 > 18 (2.9 > 4.75)

SPLITTER BOX Type Gear version Ratio Oil quantity Oil specifications 250 B 266 1 stage spur gear 0,803 2.5 (2.65) see lube oil group 1.3

i l (qt)

HYDRAULIC SYSTEM Travel pumps max. flow> Q max. max. operating pressure Gear pump > repl. circuit max. flow Q max. max. operating pressure (Sp) Travel motors Variable flow working hydraulic pump > max. flow > Q max. stand by pressure (HD) max. operating pressure (HD) Servo > operating pressure > working hydraulic (ND) Hydr. tank capacity > + circuit capacity Oil specifications type l/min (gal/min) bar type l/min (gal/min) bar type type l/min (gal/min) bar bar bar l (gal) l (gal) 2BPV 50 2 125 (33) 420 BOSCH 0510 79 (21) 16+4 2BMV 105 A 10 V 045 112 (29.6) 20 160 18 max. 25 178 / 157 * (47 / 41 *) 53 (14) see lube oil > group 1.3

ELECTRICAL SYSTEM Voltage Batteries Alternator Starter Automatic circuit breaker Fuses V 24 212 V 110 Ah (in series) 28 V 55 A 5.4 60 see Operation and Maintenance Manual

kW A A

TRAVEL GEAR Type Gear version Parking brake (integrated) 2FAT 400 / 523 2 stage planetary gear disk brake /.. Typ/ab Type/from Type/a partir de

Benennung Description Dnomination

PR 712
Datum Edition Date

F/N xxx> 0103 0500

01 01

Technical Data
Blatt Page Feuille

3.1.10.01

PR 712 Type No.


TRAVEL GEAR Gear ratio Oil quantity Oil specifications i total l (qt)

>103 348

L > 103 415

M > 103 349

46,5 24.5 (4,8) see lube oil > group 1.3

TRACK COMPONENTS Track chain pitch Track chain length Track pad width (single grouser) Track pad bolts Track rollers > single flange (s) Track rollers > double flange (d) Track roller location Carrier rollers each side Max. roller frame oscillation mm (inch) links mm thread. size qty. qty. 171.5 (6.7) 42 457 / 560 5/8 UNF 4 2 s>d>s>s>d>s 1 +/> 2.5 171.5 (6.7) 44 457/560/610/711 5/8UNF 4 3 s>d>s>d>s>d>s 2 +/> 2.5 171.5 (6.7) 44 610/711/762/864 5/8 UNF 4 3 s>d>s>d>s>d>s 2 +/> 2.5

ATTACHMENT Lift cylinder bearing > lube oil quantity Oil specifications Lift cylinder straight blade cyl. a / rod a / stroke 6>way blade cyl. a / rod a / stroke Tilt cylinder straight blade cyl. a / rod a / stroke 6 > way blade cyl. a / rod a / stroke Angle cylinder 6 > way blade cyl. a / rod a / stroke Ripper cylinder > cyl. a / rod a / stroke l (qt) 0.50 (0.52) see lube oil > group1.3 90 / 50 / 1100 90 / 50 / 850 90/50/1100 120 / 60 / 90 110 / 50 / 150 110 / 50 / 275 140 / 70 / 450

mm mm mm mm mm mm

90/50/850

GENERAL DATA Travel speed Basic machine: normal speed range km/h (mp/h) reduced speed range km/h (mp/h) height over cab mm overall length w/o attachment (transport dimension) mm overall length with straight blade mm overall length with 6>way blade (straight) mm overall length with 6>way blade (angled) mm track gauge (+1width of 1 pad=total width) mm ground clearance mm kg kg mm m3 kg kg/cm2 mm mm m3 kg kg/cm2 mm mm kg mm kg mm mm kN (t) m/min mm m 0 > 11 (0 > 6.8) 0 > 4,6 (0 > 2.8) 3100 3675 4475 4665 4810 4835 5255 5335 1630 1750 370 370 11550 / 11800/12000/ 11750 12100/12300 11500 / >>>>> 11850/12050/>>>>> 2750 3000 1,96 2,14 1200 1270 0,51 /0,43 0.49/0.41/0.38/0.33 2650 2950 2440 2750 1,78 2,42 1160 1270 0.51 / >>>> 0.50/0.42/>>>> 1185 925 850 31 635 800 25 1130 515 228 (23,2) 0 > 78 infinitely variable 19 70

Operating weight w. straight blade (varies due to pad width ) Operating weight w. 6>way blade (varies due to pad width) Straight blade: blade width blade capacity weight > attachment complete ground pressure (varies due to pad width) 6>way blade: blade width width (angled) blade capacity weight > attachment complete ground pressure (varies due to pad width) Ripper: add. length ripper lowered add. length ripper raised weight > ripper complete max. slope angle Winch: additional length weight max. slope angle height cable exit height drawbar pull max. line pull max. line speed cable size a max. length *) PR 712 / 103 > 113, M/103>109

4645 4810 5360 1930 370 >>>>>>/12450/ 12600/12800 12200/12300/12500 3350 2,08 1300 >>>/0.33/0.32/0.28 3235 3000 2,20 1250 0.38/0.33/0.31

PR 712
DIESEL ENGINE Type Engine version Rating to ISO 9249 Rated RPM Low idle RPM High idle RPM Displacement Oil quantity incl. filter Oil specifications Max. machine inclination > all directions Valve clearance > cold intake/exhaust Firing order Coolant capacity Fuel tank > capacity Fuel consumption

B >F/N 348 >


05012999

B L >F/N 415 >


05012999

B M >F/N 349 >


05012999

kW 1/min 1/min 1/min l (cu.in) l (qt)

mm l (gal) l (gal) appr. l/h (gal/h)

D 904 TB LIEBHERR in line 4 > mildly turbocharged 77 (103 HP) 2000 800 2100+80 5,6 (342) 18 (19) see lube oil > group 1.3 45 = 100 % 0.20 / 0.25 1>3>4>2 42 (11,1) 310 ( 81,8) 11 > 18 (2.9 > 4.7)

SPLITTERBOX Type Gear version Ratio Oil quantity Oil specifications 250 B 266 1 stage spur gear 0,803 2,5 (2.65) see lube oil > group 1.3

i l (qt)

HYDRAULIC SYSTEM Travel pumps max. flow > Q max. max. operating pressure > p max. Gear pump > repl. circuit max. flow > Q max. max. operating pressure (Sp) > p max. Travel motors Variable flow working hydraulic pump max. flow > Q max. standby pressure (HD) max. operating pressure (HD) > p max. Servo > operating pressure > working hydraulic (ND) Hydr. tank capacity > + circuit capacity Oil specifications type l/min (gal/min) bar type l/min (gal/min) bar type type l /min (gal/min) bar bar bar l (gal) l (gal) 2BPV 50 2125 (33) 420 BOSCH 0510 79 (20,8) 16+4 2BMV 105 A10V045 112 (29,5) 20 160 18 max. 25 178 (47) 53 (14) see lube oil > group 1.3

ELECTRICAL SYSTEM Voltage Batteries Alternator Starter Automatic circuit breaker Fuses V 24 212 V 110 Ah (in series) 28 V 55 A 5.4 35 see Operation and Maintenance Manual

kW A A

TRAVEL GEAR Type Gear version Parking brake (integrated) 2FAT 400 P 553 2 stage planetary gear disk brake /.. Benennung Description Dnomination Typ/ab Type/from Type/a partir de

PR 712 B F/N xxx> 0501 2999

Datum Edition Date

01 01

Technical Data
Blatt Page Feuille

3.1.11.01

PR 712
TRAVEL GEAR Gear ratio Oil quantity Oil specifications i total l (qt)

B >F/N 348 >


05012999

B L >F/N 415 >


05012999

B M >F/N 349 >


05012999

45.4 :1 210 (10.6) see lube oil > group 1.3

TRACK COMPONENTS Track chain pitch Track chain length Track pad width (single grouser) Track pad bolts Track rollers > single flange (s) Track rollers > double flange (d) Track roller location Carrier rollers each side Max. roller frame oscillation mm (inch) links mm thread. size qty. qty. 171,5 ( 6,7) 42 457/560 5/8 UNF 4 2 s>d>s>s>d>s 1 +/> 2.5 171,5 ( 6,7) 44 457/560/610/711 5/8UNF 4 3 s>d>s>d>s>d>s 2 +/> 2.5 171,5 ( 6,7) 44 762/864 5/8 UNF 4 3 s>d>s>d>s>d>s 2 +/> 2.5

ATTACHMENT Lift cylinder straight blade cyl. a / rod a / stroke 6>way blade cyl. a / rod a / stroke Tilt cylinder straight blade cyl. a / rod a / stroke 6 > way blade cyl. a / rod a / stroke Angle cylinder 6 > way blade cyl. a / rod a / stroke Ripper cylinder > cyl. a / rod a / stroke mm mm mm mm mm mm 90 / 50 / 1100 90 / 50 / 850 120 / 60 / 90 110 / 50 / 150 110 / 50 / 275 140 / 70 / 450

90/50/1100

90/50/850

GENERAL DATA Travel speed Drawbar pull max. Mud depth max. Basic machine: normal speed range reduced speed range due to ground condition measured horizontally km/h (mp/h) km/h (mp/h) kN mm mm mm mm mm mm mm mm kg kg mm m3 kg kg/cm2 mm mm m3 kg kg/cm2 mm mm kg mm kg mm kN (t) m/min mm m 0 > 11 (0 > 6.8) 0 > 4.6 (0 > 2.8) 146 740 3100 3675 4485

height over cab overall length w/o attachment (transport dimension) overall length with straight blade overall length with 6>way blade (straight) overall length with 6>way blade (angled) track gauge (+1width of 1 pad=total width) ground clearance

Operating weight w. straight blade (varies due to pad width ) Operating weight w. 6>way blade (varies due to pad width) Straight blade: blade width blade capacity weight > attachment complete ground pressure (varies due to pad width) blade width width (angled) blade capacity weight > attachment complete ground pressure (varies due to pad width) add. length ripper lowered add. length ripper raised weight > ripper complete max. slope angle additional length weight height drawbar pull max. line pull max. line speed cable size a max. length

4665 4835 5335 1630 1750 370 370 11550 / 11750 11800/12000/ 12100/12300 11850/12050/>>>>> 2750 2.18 1200 0,51 /0,43 3000 2.14 1270 0.49/0.41/0.38/0.33 2950 2750 2.42 1270 0.50/0.42/>>>>>

4645 4810 5360 1930 370 12600/12800 12300/12500 3350 2.15 1300 0.32/0.28 3235 3000 2.20 1250 0.33/0.31

6>way blade:

Ripper (3):

Winch:

1185 925 850 31 635 1200 525 227 (23.1) 0 > 105 infinitely variable 19 70

PR 712
DIESEL ENGINE Type Engine version Rating to ISO 9249 Rated RPM Low idle RPM High idle RPM Displacement Oil quantity incl. filter Oil specifications Max. machine inclination > all directions Valve clearance > cold intake/exhaust Firing order Coolant capacity /DCA 4 Fuel tank > capacity Fuel consumption

B >F/N 348 >


30013083

B L >F/N 415 >


30013083

B M >F/N 349 >


30013083

kW 1/min 1/min 1/min l (cu.in) l (qt)

mm l (gal) l (gal) appr. l/h (gal/h)

D 924 T>E A1 in line 4 > turbo charged 77 (103 HP) 2000 800 2100+80 6,64 (405,2) 18 (19) see lube oil > group 1.3 45 = 100 % 0.25 / 0.30 1>3>4>2 52 (13.7)/2 (0.5) 310 (81,8) 10 > 17 (2.6 > 4.5)

SPLITTERBOX Type Gear version Ratio Oil quantity Oil specifications 250 B 266 1 stage spur gear 0,803 2.5 (2.65) see lube oil > group 1.3

i l (qt)

HYDRAULIC SYSTEM Travel pumps max. flow > Q max. max. operating pressure > p max. Gear pump > repl. circuit max. flow > Q max. max. operating pressure (Sp) > p max. Travel motors Variable flow working hydraulic pump max. flow > Q max. standby pressure (HD) max. operating pressure (HD) > p max. Servo > operating pressure > working hydraulic (ND) Hydr. tank capacity > + circuit capacity Oil specifications type l/min (gal/min) bar type l/min (gal/min) bar type type l/min (gal/min) bar bar bar l (gal) l (gal) 2BPV 50 2125 (33) 420 BOSCH 0510 79 (20,8) 16+4 2BMV 105 A10V045 112 (29,5) 20 160 18 max. 25 178 (47) 53 (14) see lube oil > group 1.3

ELECTRICAL SYSTEM Voltage Batteries Alternator Starter Automatic circuit breaker Fuses V 24 212 V 110 Ah (in series) 28 V 55 A 5,4 35 see Operation and Maintenance Manual

kW A A

TRAVEL GEAR Type Gear version Parking brake (integrated) 2FAT 400 P 553 2 stage planetary gear disk brake /.. Benennung Description Dnomination Typ/ab Type/from Type/a partir de

PR 712 B F/N xxx>30013083

Datum Edition Date

01 01

Technical Data
Blatt Page Feuille

3.1.12.01

PR 712
TRAVEL GEAR Gear ratio Oil quantity Oil specifications i total l (qt)

B >F/N 348 >


30013083

B L >F/N 415 >


30013083

B M >F/N 349 >


30013083

45,4 :1 2 10 (2.75) see lube oil > group 1.3

TRACK COMPONENTS Track chain pitch Track chain length Track pad width (single grouser) Track pad bolts Track rollers > single flange (s) Track rollers > double flange (d) Track roller location Carrier rollers each side Max. roller frame oscillation mm (inch) links mm thread. size qty. qty. 171.5 ( 6.7) 42 457 / 560 5/8 UNF 4 2 s>d>s>s>d>s 1 +/> 2.5 171.5 ( 6.7) 44 457/560/610/660 5/8UNF 4 3 s>d>s>d>s>d>s 2 +/> 2.5 171.5 ( 6.7) 44 762/864 5/8 UNF 4 3 s>d>s>d>s>d>s 2 +/> 2.5

ATTACHMENT Lift cylinder straight blade cyl. a / rod a / stroke 6>way blade cyl. a / rod a / stroke Tilt cylinder straight blade cyl. a / rod a / stroke 6 > way blade cyl. a / rod a / stroke Angle cylinder 6 > way blade cyl. a / rod a / stroke Ripper cylinder > cyl. a / rod a / stroke mm mm mm mm mm mm 90 / 50 / 1100 90 / 50 / 850 120 / 60 / 90 110 / 50 / 150 110 / 50 / 275 140 / 70 / 450

90/50/1100

90/50/850

GENERAL DATA Travel speed Drawbar pull max. Mud depth max. Basic machine: normal speed range reduced speed range due to ground condition measured horizontally km/h (mp/h) km/h (mp/h) kN mm mm mm mm mm mm mm mm kg kg mm m3 kg kg/cm2 mm mm m3 kg kg/cm2 mm mm kg mm kg mm kN (t) m/min mm m 0 > 11 ( 0> 6.8) 0 > 4.6 (0> 2.8) 146 740 3100 3675 4485

height over cab overall length w/o attachment (transport dimension) overall length with straight blade overall length with 6>way blade (straight) overall length with 6>way blade (angled) track gauge (+1width of 1 pad=total width) ground clearance

1630 370

4665 4835 5335 1750 370

4645 4810 5360 1930 370 12600/12800 12300/12500 3350 2.15 1300 0.32/0.28 3235 3000 2,20 1250 0.33/0.31

Operating weight w. straight blade (varies due to pad width ) Operating weight w. 6>way blade (varies due to pad width) Straight blade: blade width blade capacity weight > attachment complete ground pressure (varies due to pad width) blade width width (angled) blade capacity weight > attachment complete ground pressure (varies due to pad width) add. length ripper lowered add. length ripper raised weight > ripper complete max. slope angle additional length weight height drawbar pull max. line pull max. line speed cable size a max. length

11550 / 11750 11800/12000/ 12100/12300 11850/12050/>>>>> 2750 2.18 1200 0.51 /0.43 3000 2.14 1270 0.49/0.41/0.38/0.33 2950 2750 2,42 1270 0.50/0.42/>>>>>

6>way blade:

Ripper (3):

Winch:

1185 925 850 31 635 1200 525 227 (23,1) 0 > 105 infinitely variable 19 70

PR 712
DIESEL ENGINE Type Construction Rating to ISO 9249 Rated RPM Low idle RPM High idle RPM Displacement Oil quantity incl. filter Oil specification Max. machine inclination - all directions Valve clearance - cold intake / exhaust Firing order Coolant capacity / DCA 4 Fuel tank capacity Fuel consumption

B - F/N 348 30845599

BL - F/N 415 30845599

BM - F/N 349 30845599

kW 1/min 1/min 1/min l (cu. in) l (qt)

mm l (gal) l (gal) appr. l/h (gal/h)

D 924 T - E A1 4 cylinder in line - turbocharged 77 (103 HP) 2000 800 +80 2100 6,64 (405,2) 18 (19) see lube oil - group 1.3 45 = 100% 0,25 / 0,30 1-3-4-2 52 / 2 (13,7 / 0,5) 310 (81,8) 10 - 17 (2,6 - 4,5)

SPLITTER BOX Type Construction Ratio Oil quantity Oil specification 250 B 266 1 stage spur gear i 0,803 l (qt) 2,5 (2,65) see lube oil - group 1.3

HYDRAULIC SYSTEM Travel pumps max. flow - Qmax max. operating pressure (M1 / M2) pmax Gear pump - repl. circuit max flow Qmax max operating pressure (SP) pmax Travel motors Variable flow working hydraulic pump max. flow - Qmax stand by pressure(HD) max. operating pressure (HD) pmax Servo - operating pressure - working hydraulic (ND) Hydr. tank capacity + circuit capacity Oil specification type l/min (gal/min) bar type l/min (gal/min) bar type type l/min (gal/min) bar bar bar 2 x BPV 50 2 x 125 (33) 420 BOSCH 0510 79 (20,8) +4 16 2 x BMV 105 A 10 V 045 112 (29,5) 20 160 18 max. 25

l (gal) 178 (47) l (gal) 53 (14) see lube oil - group 1.3

ELECTRIC SYSTEM Voltage Battery Alternator Starter Automatic circuit breaker Fuses V 24 2 x 12 V, 110 Ah (in series) 28 V 55 A kW 5,4 A 35 A see operation and maintenance manual

TRAVEL GEAR Type Construction Parking brake (integrated) Ratio 2 x FAT 450 D 583 2 stage planetary gear disk brake i total 45,4 : 1 /.. Benennung Description Dnomination Typ/ab Type/from Type/ a partir de

Mjfcifss!
Datum Edition Date

PR 712 B F/N xxx-3084 5599

01 03

Technical Data

Blatt Page Feuille

3.1.13.01

PR 712
TRAVEL GEAR Oil quantity Oil specification

B - F/N 348 30845599

BL - F/N 415 30845599

BM - F/N 349 30845599

l (qt) 2 x 5,5 (5,8) see lube oil - group 1.3

TRACK COMPONENTS Track chain pitch Track chain length Track pad width ( single grouser) Track pad bolts Track rollers - single flange (s) Track rollers - double flange (d) Track roller location Carrier rollers each side Max. roller frame oscillation mm / inch links mm thread. size qty. qty. 171,5 / 6,7 42 457 / 560 5/8 UNF 4 2 s-d-s-s-d-s 1 2,5 44 457 /560 /610 /660

762 / 864

3 s-d-s-d- s-d-s 2

ATTACHMENT Lift cylinder straight blade cyl. / rod / stroke 6-way-blade cyl. / rod / stroke Tilt cylinder straight blade cyl. / rod / stroke 6-way-blade cyl. / rod / stroke Angle cylinder 6-way blade cyl. / rod / stroke Ripper cylinder - cyl. / rod / stroke mm 90 / 50 / 1100 mm 90 / 50 / 850 mm 120 / 60 / 90 mm 110 / 50 / 150 mm 110 / 50 / 275 mm 140 / 70 / 450

90 / 50 / 1100

90 / 50 / 850

GENERAL DATA Travel speed normal speed range reduced speed range due to ground condition measured horizontally km/h (mp/h) 0 - 11 (0 - 6,8) km/h (mp/h) 0 - 4,6 (0 - 2,8) kN 146 mm 740 3100 3675 4485

Drawbar pull max. Mud depth max. Basic machine:

height over cab mm overall length w/o attachment (transport dimension) mm overall length with straight blade mm overall length with 6-way-blade (straight) mm overall length with 6-way-blade (angled) mm track gauge (+ 1 width of 1 pad = total width) mm ground clearance mm

1630 370

4665 4835 5335 1750

4645 4810 5360 1930

Operating weight w. straight blade ( varies due to pad width) Operating weight w. 6-way-blade ( varies due to pad width) Straight blade: blade width blade capacity weight - attachment complete ground pressure (varies due to pad width). blade width width (angled) blade capacity weight - attachment complete ground pressure (varies due to pad width). length add.(lowered) length add.(raised) weight slope angle additional length weight height drawbar pull max. line pull max. line speed cable size max. length

kg 11550 / 11750 kg mm 3 m kg 2 kg/cm mm mm 3 m kg 2 kg/cm mm mm kg mm kg mm kN m/min mm m 2750 2,18 1200 0,51 / 0,43

11800 / 12000 / 12100 / 12300 11850 / 12050 / --3000 2,14 1270 0,49/0,41/0,38/0,33 2950 2750 2,42 1270 0,50 / 0,42 / ---

12600 / 12800 12300 / 12500 3350 2,15 1300 0,32 / 0,28 3235 3000 2,20 1250 0,33 / 0,31

6-way-blade:

Ripper(3):

Winch

1185 925 850 31 635 1200 525 227 (23,1t) 0-105 infinitely variable 19 70

PR 712
DIESEL ENGINE Type Construction Rating to ISO 9249 Rated RPM Low idle RPM High idle RPM Displacement Oil quantity incl. filter Oil specification Max. machine inclination - all directions Valve clearance - cold intake / exhaust Firing order Coolant capacity / DCA 4 Fuel tank capacity Fuel consumption SPLITTER BOX Type Construction Ratio Oil quantity Oil specification HYDRAULIC SYSTEM Travel pumps max. flow - Qmax max. operating pressure (M1 / M2) pmax Tandem gear pump - replenishing / fan drive max. flow replenishing - Qmax max. operating pressure (SP) pmax max. flow fan drive - Qmax max. operating pressure (electronic regulated) pmax Gear motor - fan drive operation RPM Travel motors Variable flow working hydraulic pump max. flow - Qmax stand by pressure(HD) max. operating pressure (HD) pmax Servo - operating pressure - working hydraulic (ND) Hydr. tank capacity + circuit capacity Oil specification type l/min (gal/min) bar type l/min (gal/min) bar l/min (gal/min) bar type 1/min type type l/min (gal/min) bar bar bar

B - F/N 348 5600

BL - F/N 415 5600

BM - F/N 349 5600

kW 1/min 1/min 1/min l (cu. in) l (qt)

mm l (gal) l (gal) appr. l/h (gal/h)

D 924 T - E A1 4 cylinder in line - turbocharged 77 (103 HP) 2000 800 +80 2100 6,64 (405,2) 22,5 (23,7) see lube oil - group 1.3 45 = 100% 0,25 / 0,30 1-3-4-2 52 / 2 (13,7 - 0,5) 310 (81,8) 10 - 17 (2,6 - 4,5)

250 B 266 1 stage spur gear i 0,803 l (qt) 2,5 (2,65) see lube oil - group 1.3

2 x BPV 50 2 x 125 (33) 420 32 ZP + 16 ZP 79 (20,8) +4 16 39 (10,3) +10 110 ZM 0511 +100 1850 2 x BMV 105 A 10 V 045 112 (29,5) 20 160 18 max. 25

l (gal) 178 (47) l (gal) 53 (14) see lube oil - group 1.3

ELECTRIC SYSTEM Voltage Battery Alternator Starter Automatic circuit breaker Fuses V 24 2 x 12 V, 110 Ah (in series) 28 V 55 A kW 5,4 A 35 A see operation and maintenance manual

TRAVEL GEAR Type Construction 2 x FAT 450 D 583 2 stage planetary gear /.. Benennung Description Dnomination Typ/ab Type/from Type/ a partir de

Mjfcifss!
Datum Edition Date

PR 712 B F/N xxx-5600

01 03

Technical Data

Blatt Page Feuille

3.1.14.01

PR 712
TRAVEL GEAR Parking brake (integrated) Ratio Oil quantity Oil specification TRACK COMPONENTS Track chain pitch Track chain length Track pad width ( single grouser) Track pad bolts Track rollers - single flange (s) Track rollers - double flange (d) Track roller location Carrier rollers each side Max. roller frame oscillation ATTACHMENT Lift cylinder straight blade cyl. / rod / stroke 6-way-blade cyl. / rod / stroke Tilt cylinder straight blade cyl. / rod / stroke 6-way-blade cyl. / rod / stroke Angle cylinder 6-way blade cyl. / rod / stroke Ripper cylinder - cyl. / rod / stroke mm / inch links mm thread. size qty. qty.

B - F/N 348 5600

BL - F/N 415 5600

BM - F/N 349 5600

disk brake i total 45,4 : 1 l (qt) 2 x 5,5 (5,8) see lube oil - group 1.3

171,5 / 6,7 42 457 / 560 5/8 UNF 4 2 s-d-s-s-d-s 1 2,5

44 457 /560 /610 /660

762 / 864

3 s-d-s-d- s-d-s 2

mm 90 / 50 / 1100 mm 90 / 50 / 850 mm 120 / 60 / 90 mm 110 / 50 / 150 mm 110 / 50 / 275 mm 140 / 70 / 450

90 / 50 / 1100

90 / 50 / 850

GENERAL DATA Travel speed normal speed range reduced speed range due to ground condition measured horizontally km/h (mp/h) 0 - 11 (0 - 6.8) km/h (mp/h) 0 - 4,6 (0 - 2.8) kN 146 mm 740 3100 3675 4485

Drawbar pull max. Mud depth max. Basic machine:

height over cab mm overall length w/o attachment (transport dimension) mm overall length with straight blade mm overall length with 6-way-blade (straight) mm overall length with 6-way-blade (angled) mm track gauge (+ 1 width of 1 pad = total width) mm ground clearance mm

1630 370

4665 4835 5335 1750

4645 4810 5360 1930

Operating weight w. straight blade ( varies due to pad width) Operating weight w. 6-way-blade ( varies due to pad width) Straight blade: blade width blade capacity weight - attachment complete ground pressure (varies due to pad width). blade width width (angled) blade capacity weight - attachment complete ground pressure (varies due to pad width). length add.(lowered) length add.(raised) weight slope angle additional length weight height drawbar pull max. line pull max. line speed cable size max. length

kg 11550 / 11750 kg mm 3 m kg 2 kg/cm mm mm 3 m kg 2 kg/cm mm mm kg mm kg mm kN m/min mm m 2750 2,18 1200 0,51 / 0,43

11800 / 12000 / 12100 / 12300 11850 / 12050 / --3000 2,14 1270 0,49/0,41/0,38/0,33 2950 2750 2,42 1270 0,50 / 0,42 / ---

12600 / 12800 12300 / 12500 3350 2,15 1300 0,32 / 0,28 3235 3000 2,20 1250 0,33 / 0,31

6-way-blade:

Ripper(3):

Winch

1185 925 850 31 635 1200 525 227 (23,1t) 0-105 infinitely variable 19 70

PR 722 Type No.


DIESEL ENGINE Type Engine version Rating to DIN 6271 Rated RPM Low idle RPM High idle RPM Displacement Oil quantity incl. filter Oil specifications Max. machine inclination > all directions Valve clearance > cold intake / exhaust Firing order Coolant capacity Fuel tank capacity Fuel consumption

> 103 281

L>101 397

M > 103 347

kW 1/min 1/min 1/min l (cu. in) l (qt)

mm l (gal) l (gal) appr. l/h (gal/h)

D 904 T LIEBHERR in line 4 > turbocharged 94 (126 HP) 2000 800 2100+80 5.6 (342) 18 (19) see lube oil > group 1.3 45 = 100 % 0.20 / 0.25 1>3>4>2 52 (13) 310 (82) 14 > 22 (3.7 > 5.8)

SPLITTER BOX Type Gear version Ratio Oil quantity Oil specifications 250 B 265 1 stage spur gear 0,914 2.5 (2.65) see lube oil group. 1.3

i l (qt)

HYDRAULIC SYSTEM Travel pumps max. flow > Q max. max. operating pressure Gear pump > repl. circuit max. flow Q max. max. operating pressure (Sp) Travel motors Variable flow working hydraulic pump > max. flow > Q max. stand by pressure (HD) max. operating pressure (HD) Servo > operating pressure > working hydraulic (ND) Hydr. tank capacity > +circuit capacity Oil specifications type l /min (gal/min) bar type l /min (gal/min) bar type type l/min (gal/min) bar bar bar l (gal) l (gal) 2BPV 70 2154 (40) 420 BOSCH 0510 83 (22) 16+4 2BMV 135 A10V071 156 (41.2) 20 160 18 max. 25 178/ 157* (47/ 41*) 53 (14) see lube oil > group 1.3

ELECTRICAL SYSTEM Voltage Batteries Alternator Starter Automatic circuit breaker Fuses V 24 212 V 110 AH (in series) 28 V 55 A 5.4 60 see Operation and Maintenance Manual

kW A A

TRAVEL GEAR Type Gear version Parking brake (integrated) 2FAT 450 / 514 2 stage planetary gear disk brake /.. Typ/ab Type/from Type/a partir de

Benennung Description Dnomination

PR 722
Datum Edition Date

F/N xxx> 0103 1000

01 01

Technical Data
Blatt Page Feuille

3.1.20.01

PR 722 Type No.


TRAVEL GEAR Gear ratio Oil quantity Oil specifications i total l (qt)

>103 281

L>101 397

M > 103 347

42,9 26 (6,4) see lube oil > group 1.3

TRACK COMPONENTS Track chain pitch Track chain length Track pad width (single grouser) Track pad bolts Track rollers > single flange (s) Track rollers > double flange (d) Track roller location Carrier rollers each side Max. roller frame oscillation ATTACHMENT Lift cylinder bearing > lube oil quantity Oil specifications Lift cylinder straight blade cyl. a / rod a / stroke 6>way blade cyl. a / rod a / stroke Tilt cylinder straight blade cyl. a / rod a / stroke 6>way blade cyl. a / rod a / stroke Angle cylinder 6>way blade cyl. Ripper cylinder > cyl.
a / rod a / stroke

mm(inch) links mm thread. size qty. qty.

175,5 (6,9) 43 508 / 610 5/8 UNF 4 3 s>d>s>d>s>d>s 1 +/> 2.5

175,5 (6,9) 47 508 / 610 5/8 UNF 4 4 s>d>s>d>d>s>d>s 2 +/>2.5

175,5 (6,9) 47 711 / 812 / 914 5/8 UNF 4 4 s>d>s>d>d>s>d>s 2 +/> 2.5

l (qt)

0.50 (0.52) see lube oil > group. 1.3 90 / 50 / 1140 90 / 50 / 850 140 / 70 / 100 120 / 60 / 170 120 / 60 / 325 140 / 70 / 450 90 / 50 / 1030 90 / 50 / 1030

mm mm mm mm mm mm

a / rod a / stroke

GENERAL DATA normal speed range km/h (mp/h) reduced speed range km/h (mp/h) Basic machine: height over cab mm overall length w/o attachment (transport dimension) mm overall length with straight blade mm overall length with 6>way blade (straight) mm overall length with 6>way blade (angled) mm track gauge (+1 width of 1 pad = total width) mm ground clearance mm Operating weight w. straight blade (varies due to pad width) kg Operating weight w. 6>way blade (varies due to pad width) kg Straight blade: blade width mm blade capacity m3 weight > attachment complete kg ground pressure (varies due to pad width) kg/cm2 6>way blade: blade width mm width (angled) mm blade capacity m3 weight > attachment complete kg ground pressure (varies due to pad width) kg/cm2 Ripper: add. length ripper lowered mm add. length ripper raised mm weight > ripper complete kg max. slope angle Winch: additional length mm weight kg max. slope angle height cable exit height drawbar pull mm max. line pull kN (t) max. line speed m/min mm cable size a max. length m *) PR 722/103>108, M/103>112 Travel speed 0 > 11 (0 > 6.8) 0 > 4,6 (0 > 2.8) 3105 3890 3910 4695 5045 4890 5190 5480 5780 1800 1800 365 365 13350 / 13550 13740 / 13980 13350 / 13550 13795 / 14035 3000 3000 2.85 2.85 1650 1650 0.51 / 0.43 0.46 / 0.39 3200 3200 2950 2950 2,59 2,59 1575 1575 0.51 / 0.43 0.46 / 0.39 1235 945 1100 30 635 900 25 1135 520 283 (28,3) 0 > 88 infinitely variable 22 65

3910 5045 5190 5895 2084 365 14400 /14600 /14850 14300 /14550 /14800 3600 3.13 1800 0.35 / 0.31 / 0.28 3790 3490 3,11 1770 0.34 / 0.31 / 0.28

PR 722
DIESEL ENGINE Type Engine version Rating to ISO 9249 Rated RPM Low idle RPM High idle RPM Displacement Oil quantity incl. filter Oil specifications Max. machine inclination > all directions Valve clearance > cold intake / exhaust Firing order Coolant capacity Fuel tank capacity Fuel consumption

B >F/N 281 >


10013000

B L >F/N 397 >


10013000

B M >F/N 347
10013000

kW 1/min 1/min 1/min l (cu. in) l (qt)

mm l (gal) l (gal) appr. l/h (gal/h)

D 904 T LIEBHERR in line 4 > turbocharged 97 (130 HP) 2000 800 2100+80 5,6 (342) 18 (19) see lube oil > group 1.3 45 = 100 % 0.20 / 0.25 1>3>4>2 42 (11) 310 (82) 14 > 22 (3.7 > 5.8)

SPLITTER BOX Type Gear version Ratio Oil quantity Oil specifications 250 B 265 1 stage spur gear 0,914 2.5 (2.65) see lube oil group. 1.3

i l (qt)

HYDRAULIC SYSTEM Travel pumps max. flow > Q max. max. operating pressure Gear pump > repl. circuit max. flow Q max. max. operating pressure (Sp) Travel motors Variable flow working hydraulic pump > max. flow > Q max. stand by pressure (HD) max. operating pressure (HD) Servo > operating pressure > working hydraulic (ND) Hydr. tank capacity > +circuit capacity Oil specifications type l/min (gal/min) bar type l/min (gal/min) bar type type l/min (gal/min) bar bar bar l (gal) l (gal) 2BPV 70 2154 (40) 420 BOSCH 0510 83 (22) 16+4 2BMV 135 A10V071 156 (40.2) 20 160 18 max. 25 178 (47) 53 (14) see lube oil > group 1.3

ELECTRICAL SYSTEM Voltage Batteries Alternator Starter Automatic circuit breaker Fuses V 24 212 V 110 Ah (in series) 28 V 55 A 5.4 35 see Operation and Maintenance Manual

kW A A

TRAVEL GEAR Type Gear version Parking brake (integrated) 2FAT 450 P 554 2 stage planetary gear disk brake /.. Typ/ab Type/from Type/a partir de

Benennung Description Dnomination

PR 722 B F/N xxx> 1001 3000


Datum Edition Date

01 01

Technical Data
Blatt Page Feuille

3.1.21.01

PR 722
TRAVEL GEAR Gear ratio Oil quantity Oil specifications i total l (qt)

B >F/N 281 >


10013000

B L >F/N 397 >


10013000

B M >F/N 347>
10013000

41.7 :1 213 (13.7) see lube oil > group 1.3

TRACK COMPONENTS Track chain pitch Track chain length Track pad width (single grouser) Track pad bolts Track rollers > single flange (s) Track rollers > double flange (d) Track roller location Carrier rollers each side Max. roller frame oscillation mm (inch) links mm thread. size qty. qty. 175,5 ( 6,9) 43 508 / 610 5/8 UNF 4 3 s>d>s>d>s>d>s 1 +/> 2.5 175,5 ( 6,9) 47 508 / 610 5/8 UNF 4 4 s>d>s>d>d>s>d>s 2 +/>2.5 175,5 (6,9) 47 711 / 812 / 914 5/8 UNF 4 4 s>d>s>d>d>s>d>s 2 +/> 2.5

ATTACHMENT Lift cylinder straight blade cyl. a / rod a / stroke 6>way blade cyl. a / rod a / stroke Tilt cylinder straight blade cyl. a / rod a / stroke 6>way blade cyl. a / rod a / stroke Angle cylinder 6>way blade cyl. Ripper cylinder > cyl.
a / rod a / stroke

mm mm mm mm mm mm

90 / 50 / 1140 90 / 50 / 850 140 / 70 / 100 120 / 60 / 170 120 / 60 / 325 140 / 70 / 450

90 / 50 / 1030

90 / 50 / 1030

a / rod a / stroke

GENERAL DATA Travel speed Drawbar pull max. Mud depth max. Basic machine: normal speed range reduced speed range due to ground condition measured horizontally km/h (mp/h) km/h (mp/h) kN mm mm mm mm mm mm mm mm kg kg mm m3 kg kg/cm2 mm mm m3 kg kg/cm2 mm mm kg mm kg mm kN (t) m/min mm m 0 > 11 (0 > 6.8) 0 > 4.6 (0 > 2.8) 171 750 3105 3890 4695

height over cab overall length w/o attachment (transport dimension) overall length with straight blade overall length with 6>way blade (straight) overall length with 6>way blade (angled) track gauge (+1width of 1 pad = total width) ground clearance

1800 370 13350 / 13550 13350 / 13550 3000 2,85 1650 0.51 / 0.43

3910 5045 5220 5805 1800 370 13740 /14000 13795 / 14035 3000 2,85 1650 0.46 / 0.39 3200 3490 2,59 1575 0.46 / 0.39

3910 5045 5190 5895 2084 370 14400 /14600 /14850 14300 /14550 /14800 3600 3,13 1800 0.35 / 0.31 / 0.28 3790 3490 3,11 1770 0.34 / 0.31 / 0.28

Operating weight w. straight blade (varies due to pad width) Operating weight w. 6>way blade (varies due to pad width) Straight blade: blade width blade capacity weight > attachment complete ground pressure (varies due to pad width) blade width width (angled) blade capacity weight > attachment complete ground pressure (varies due to pad width) add. length ripper lowered add. length ripper raised weight > ripper complete max. slope angle additional length weight height drawbar pull max. line pull max. line speed cable size a max. length

6>way blade:

Ripper (3):

Winch:

1235 945 1100 30 635 1200 530 300 (30,6) 0 > 96 infinitely variable 22 50

PR 722
DIESEL ENGINE Type Engine version Rating to ISO 9249 Rated RPM Low idle RPM High idle RPM Displacement Oil quantity incl. filter Oil specifications Max. machine inclination > all directions Valve clearance > cold intake / exhaust Firing order Coolant capacity /DCA 4 Fuel tank capacity Fuel consumption

B >F/N 281 >


30013170

B L >F/N 397 >


30013170

B M >F/N 347
30013170

kW 1/min 1/min 1/min l (cu. in) l (qt)

mm l (gal) l (gal) appr. l/h (gal/h)

D 924 T>E A1 in line 4 > turbocharged 97 (130 HP) 2000 800 2100+80 6.64 (405.2 ) 18 (19) see lube oil > group 1.3 45 = 100 % 0,25 / 0,30 1>3>4>2 52/2 (13.7/0.5) 310 (82) 12 > 21 (3.2 > 5.5)

SPLITTER BOX Type Gear version Ratio Oil quantity Oil specifications 250 B 265 1 stage spur gear 0,914 2.5 (2.65) see lube oil group. 1.3

i l (qt)

HYDRAULIC SYSTEM Travel pumps max. flow > Q max. max. operating pressure Gear pump > repl. circuit max. flow Q max. max. operating pressure (Sp) Travel motors Variable flow working hydraulic pump > max. flow > Q max. stand by pressure (HD) max. operating pressure (HD) Servo > operating pressure > working hydraulic (ND) Hydr. tank capacity > +circuit capacity Oil specifications type l/min (gal/min) bar type l/min (gal/min) bar type type l/min (gal/min) bar bar bar l (gal) l (gal) 2BPV 70 2154 (40) 420 BOSCH 0510 83 (22) 16+4 2BMV 135 A10V071 156 (41.2) 20 160 18 max. 25 178 (47) 53 (14) see lube oil > group 1.3

ELECTRICAL SYSTEM Voltage Batteries Alternator Starter Automatic circuit breaker Fuses V 24 212 V 110 Ah (in series) 28 V 55 A 5,4 35 see Operation and Maintenance Manual

kW A A

TRAVEL GEAR Type Gear version Parking brake (integrated) 2FAT 450 P 554 2 stage planetary gear disk brake /.. Typ/ab Type/from Type/a partir de

Benennung Description Dnomination

PR 722 B F/N xxx>30013170


Datum Edition Date

01 01

Technical Data
Blatt Page Feuille

3.1.22.01

PR 722
TRAVEL GEAR Gear ratio Oil quantity Oil specifications i total l (qt)

B >F/N 281 >


30013170

B L >F/N 397 >


30013170

B M >F/N 347>
30013170

41.7 :1 213 (13.75) see lube oil > group 1.3

TRACK COMPONENTS Track chain pitch Track chain length Track pad width (single grouser) Track pad bolts Track rollers > single flange (s) Track rollers > double flange (d) Track roller location Carrier rollers each side Max. roller frame oscillation mm (inch) links mm thread. size qty. qty. 175.5 (6.9) 43 508 / 610 5/8 UNF 4 3 s>d>s>d>s>d>s 1 +/> 2.5 175.5 (6.9) 47 508 / 610 5/8 UNF 4 4 s>d>s>d>d>s>d>s 2 +/>2.5 175.5 (6.9) 47 711 / 812 / 914 5/8 UNF 4 4 s>d>s>d>d>s>d>s 2 +/> 2.5

ATTACHMENT Lift cylinder straight blade cyl. a / rod a / stroke 6>way blade cyl. a / rod a / stroke Tilt cylinder straight blade cyl. a / rod a / stroke 6>way blade cyl. a / rod a / stroke Angle cylinder 6>way blade cyl. Ripper cylinder > cyl.
a / rod a / stroke

mm mm mm mm mm mm

90 / 50 / 1140 90 / 50 / 850 140 / 70 / 100 120 / 60 / 170 120 / 60 / 325 140 / 70 / 450

90 / 50 / 1030

90 / 50 / 1030

a / rod a / stroke

GENERAL DATA Travel speed Drawbar pull max. Mud depth max. Basic machine: normal speed range reduced speed range due to ground condition measured horizontally km/h (mp/h) km/h (mp/h) kN mm mm mm mm mm mm mm mm kg kg mm m3 kg kg/cm2 mm mm m3 kg kg/cm2 mm mm kg mm kg mm kN (t) m/min mm m 0 > 11 (0 > 6.8) 0 > 4.6 (0 > 2.8) 171 750 3105 3890 4695

height over cab overall length w/o attachment (transport dimension) overall length with straight blade overall length with 6>way blade (straight) overall length with 6>way blade (angled) track gauge (+1width of 1 pad = total width) ground clearance

1800 370 13350 / 13550 13350 / 13550 3000 2.85 1650 0.51 / 0.43

3910 5045 5220 5805 1800 370 13740 /14000 13795 / 14035 3000 2.85 1650 0.46 / 0.39 3200 3490 2,59 1575 0.46 / 0.39

3910 5045 5190 5895 2084 370 14400 /14600 /14850 14300 /14550 /14800 3600 3.13 1800 0.35 / 0.31 / 0.28 3790 3490 3,11 1770 0.34 / 0.31 / 0.28

Operating weight w. straight blade (varies due to pad width) Operating weight w. 6>way blade (varies due to pad width) Straight blade: blade width blade capacity weight > attachment complete ground pressure (varies due to pad width) blade width width (angled) blade capacity weight > attachment complete ground pressure (varies due to pad width) add. length ripper lowered add. length ripper raised weight > ripper complete max. slope angle additional length weight height drawbar pull max. line pull max. line speed cable size a max. length

6>way blade:

Ripper (3):

Winch:

1235 945 1100 30 635 1200 530 300 (30,6) 0 > 96 infinitely variable 22 50

PR 722
DIESEL ENGINE Type Construction Rating to ISO 9249 Rated RPM Low idle RPM High idle RPM Displacement Oil quantity incl. filter Oil specification Max. machine inclination - all directions Valve clearance - cold intake / exhaust Firing order Coolant capacity / DCA 4 Fuel tank capacity Fuel consumption

B - F/N 281 31715599

BL - F/N 397 31715599

BM - F/N 347 31715599

kW 1/min 1/min 1/min l (cu. in) l (qt)

mm l (gal) l (gal) appr. l/h (gal/h)

D 924 T - E A1 4 cylinder in line - turbocharged 97 (130 HP) 2000 800 +80 2100 6,64 (405,2) 18 (19) see lube oil - group 1.3 45 = 100% 0,25 / 0,30 1-3-4-2 52 / 2 (13,7 / 0,5) 310 (82) 12 - 21 (3,2 - 5,5)

SPLITTER BOX Type Construction Ratio Oil quantity Oil specification 250 B 265 1 stage spur gear i 0,914 l (qt) 2,5 (2,65) see lube oil - group 1.3

HYDRAULIC SYSTEM Travel pumps max. flow - Qmax max. operating pressure (M1 / M2) pmax Gear pump - repl. circuit max flow Qmax max operating pressure (SP) pmax Travel motors Variable flow working hydraulic pump max. flow - Qmax stand by pressure(HD) max. operating pressure (HD) pmax Servo - operating pressure - working hydraulic (ND) Hydr. tank capacity + circuit capacity Oil specification type l/min (gal/min) bar type l/min (gal/min) bar type type l/min (gal/min) bar bar bar 2 x BPV 70 2 x 154 (40) 420 BOSCH 0510 83 (22) +4 16 2 x BMV 135 A 10 V 071 156 (41,2) 20 160 18 max. 25

l (gal) 178 (47) l (gal) 53 (14) see lube oil - group 1.3

ELECTRIC SYSTEM Voltage Battery Alternator Starter Automatic circuit breaker Fuses V 24 2 x 12 V, 110 Ah (in series) 28 V 55 A kW 5,4 A 35 A see operation and maintenance manual

TRAVEL GEAR Type Construction Parking brake (integrated) Ratio 2 x FAT 450 D 584 2 stage planetary gear disk brake i total 41,7 : 1 /.. Benennung Description Dnomination Typ/ab Type/from Type/ a partir de

Mjfcifss!
Datum Edition Date

PR 722 B F/N xxx-3171 5599

01 03

Technical Data

Blatt Page Feuille

3.1.23.01

PR 722
TRAVEL GEAR Oil quantity Oil specification

B - F/N 281 31715599

BL - F/N 397 31715599

BM - F/N 347 31715599

l (qt) 2 x 8,5 (8,9) see lube oil - group 1.3

TRACK COMPONENTS Track chain pitch Track chain length Track pad width ( single grouser) Track pad bolts Track rollers - single flange (s) Track rollers - double flange (d) Track roller location Carrier rollers each side Max. roller frame oscillation mm / inch links mm thread. size qty. qty. 175,5 / 6,9 43 508 / 610 5/8 UNF 4 3 s-d-s-d-s-d-s 1 2,5 47 711 / 812 / 914

4 s-d-s-d-d-s-d-s 2

ATTACHMENT Lift cylinder straight blade cyl. / rod / stroke 6-way-blade cyl. / rod / stroke Tilt cylinder straight blade cyl. / rod / stroke 6-way-blade cyl. / rod / stroke Angle cylinder 6-way blade cyl. / rod / stroke Ripper cylinder - cyl. / rod / stroke mm 90 / 50 / 1140 mm 90 / 50 / 850 mm 140 / 70 / 100 mm 120 / 60 / 170 mm 120 / 60 / 325 mm 140 / 70 / 450 90 / 50 / 1030

GENERAL DATA Travel speed normal speed range reduced speed range due to ground condition measured horizontally km/h (mp/h) 0 - 11 (0 - 6,8) km/h (mp/h) 0 - 4,6 (0 - 2,8) kN 171 mm 750 3105 3890 4695

Drawbar pull max. Mud depth max. Basic machine:

height over cab mm overall length w/o attachment (transport dimension) mm overall length with straight blade mm overall length with 6-way-blade (straight) mm overall length with 6-way-blade (angled) mm track gauge (+ 1 width of 1 pad = total width) mm ground clearance mm

3910 5045 5220 5805

1800 370 13740 / 14000 13795 / 14035

5190 5895 2084

Operating weight w. straight blade ( varies due to pad width) Operating weight w. 6-way-blade ( varies due to pad width) Straight blade: blade width blade capacity weight - attachment complete ground pressure (varies due to pad width). blade width width (angled) blade capacity weight - attachment complete ground pressure (varies due to pad width). length add.(lowered) length add.(raised) weight slope angle additional length weight height drawbar pull max. line pull max. line speed cable size max. length

kg 13350 / 13550 kg 13350 / 13550 mm 3 m kg 2 kg/cm mm mm m3 kg 2 kg/cm mm mm kg mm kg mm kN m/min mm m 3000 2,85 1650 0,51 / 0,43

14400/14600/14850 14300/14550/14800 3600 3,13 1800 0,35 / 0,31 / 0,28 3790 3490 3,11 1770 0,34 / 0,31 / 0,28

6-way-blade:

0,46 / 0,39 3200 3490 2,59 1575 0,46 / 0,39

Ripper(3):

Winch

1235 945 1100 30 635 1200 530 300 (30,6t) 0-96 infinitely variable 22 50

PR 722
DIESEL ENGINE Type Construction Rating to ISO 9249 Rated RPM Low idle RPM High idle RPM Displacement Oil quantity incl. filter Oil specification Max. machine inclination - all directions Valve clearance - cold intake / exhaust Firing order Coolant capacity / DCA 4 Fuel tank capacity Fuel consumption SPLITTER BOX Type Construction Ratio Oil quantity Oil specification HYDRAULIC SYSTEM Travel pumps max. flow - Qmax max. operating pressure (M1 / M2) pmax Tandem gear pump - replenishing / fan drive max. flow replenishing - Qmax max. operating pressure (SP) pmax max. flow fan drive - Qmax max. operating pressure (electronic regulated) pmax Gear motor - fan drive operation RPM Travel motors Variable flow working hydraulic pump max. flow - Qmax stand by pressure(HD) max. operating pressure (HD) pmax Servo - operating pressure - working hydraulic (ND) Hydr. tank capacity + circuit capacity Oil specification type l/min (gal/min) bar type l/min (gal/min) bar l/min (gal/min) bar type 1/min type type l/min (gal/min) bar bar bar

B - F/N 281 5600

BL - F/N 397 5600

BM - F/N 347 5600

kW 1/min 1/min 1/min l (cu. in) l (qt)

mm l (gal) l (gal) appr. l/h (gal/h)

D 924 T - E A1 4 cylinder in line - turbocharged 97 (130 HP) 2000 800 +80 2100 6,64 (405,2) 22,5 (23,7) see lube oil - group 1.3 45 = 100% 0,25 / 0,30 1-3-4-2 52 / 2 (13,7 / 0,5) 310 (82) 12 - 21 (3,2 - 5,5)

250 B 265 1 stage spur gear i 0,914 l (qt) 2,5 (2,65) see lube oil - group 1.3

2 x BPV 70 2 x 154 (40) 420 38 ZP + 16 ZP 83 (22) +4 16 35 (9,2) +10 130 ZM 0511 +100 1990 2 x BMV 135 A 10 V 071 156 (41,2) 20 160 18 max. 25

l (gal) 178 (47) l (gal) 53 (14) see lube oil - group 1.3

ELECTRIC SYSTEM Voltage Battery Alternator Starter Automatic circuit breaker Fuses V 24 2 x 12 V, 110 Ah (in series) 28 V 55 A kW 5,4 A 35 A see operation and maintenance manual

TRAVEL GEAR Type Construction 2 x FAT 450 D 584 2 stage planetary gear /.. Benennung Description Dnomination Typ/ab Type/from Type/ a partir de

Mjfcifss!
Datum Edition Date

PR 722 B F/N xxx-5600

01 03

Technical Data

Blatt Page Feuille

3.1.24.01

PR 722
TRAVEL GEAR Parking brake (integrated) Ratio Oil quantity Oil specification TRACK COMPONENTS Track chain pitch Track chain length Track pad width ( single grouser) Track pad bolts Track rollers - single flange (s) Track rollers - double flange (d) Track roller location Carrier rollers each side Max. roller frame oscillation mm / inch links mm thread. size qty. qty.

B - F/N 281 5600

BL - F/N 397 5600

BM - F/N 347 5600

disk brake i total 41,7 : 1 l (qt) 2 x 8,5 (8,9) see lube oil - group 1.3

175,5 / 6,9 43 508 / 610 5/8 UNF 4 3 s-d-s-d-s-d-s 1 2,5

47 711 / 812 / 914

4 s-d-s-d-d-s-d-s 2

ATTACHMENT Lift cylinder straight blade cyl. / rod / stroke 6-way-blade cyl. / rod / stroke Tilt cylinder straight blade cyl. / rod / stroke 6-way-blade cyl. / rod / stroke Angle cylinder 6-way blade cyl. / rod / stroke Ripper cylinder - cyl. / rod / stroke mm 90 / 50 / 1140 mm 90 / 50 / 850 mm 140 / 70 / 100 mm 120 / 60 / 170 mm 120 / 60 / 325 mm 140 / 70 / 450 90 / 50 / 1030

GENERAL DATA Travel speed normal speed range reduced speed range due to ground condition measured horizontally km/h (mp/h) 0 - 11 (0 - 6.8) km/h (mp/h) 0 - 4,6 (0 - 2.8) kN 171 mm 750 3105 3890 4695

Drawbar pull max. Mud depth max. Basic machine:

height over cab mm overall length w/o attachment (transport dimension) mm overall length with straight blade mm overall length with 6-way-blade (straight) mm overall length with 6-way-blade (angled) mm track gauge (+ 1 width of 1 pad = total width) mm ground clearance mm

3910 5045 5220 5805

1800 370 13740 / 14000 13795 / 14035

5190 5895 2084

Operating weight w. straight blade ( varies due to pad width) Operating weight w. 6-way-blade ( varies due to pad width) Straight blade: blade width blade capacity weight - attachment complete ground pressure (varies due to pad width). blade width width (angled) blade capacity weight - attachment complete ground pressure (varies due to pad width). length add.(lowered) length add.(raised) weight slope angle additional length weight height drawbar pull max. line pull max. line speed cable size max. length

kg 13350 / 13550 kg 13350 / 13550 mm 3 m kg kg/cm2 mm mm 3 m kg 2 kg/cm mm mm kg mm kg mm kN m/min mm m 3000 2,85 1650 0,51 / 0,43

14400/14600/14850 14300/14550/14800 3600 3,13 1800 0,35 / 0,31 / 0,28 3790 3490 3,11 1770 0,34 / 0,31 / 0,28

6-way-blade:

0,46 / 0,39 3200 3490 2,59 1575 0,46 / 0,39

Ripper(3):

Winch

1235 945 1100 30 635 1200 530 300 (30,6t) 0-96 infinitely variable 22 50

PR 732 Type No.


DIESEL ENGINE Type Engine version Rating to DIN 6271 Rated RPM Low idle RPM High idle RPM Displacement Oil quantity incl. filter Oil specifications Max. machine inclination > all directions Valve clearance > cold intake / exhaust Firing order Coolant capacity Fuel tank capacity Fuel consumption

> 2003 350

L>2003 412

M > 2003 351

kW 1/min 1/min 1/min l (cu. in) l (qt)

mm l (gal) l (gal) appr. l/h (gal/h)

D 9306 TB LIEBHERR 6 Cyl. V 132 ( 180 HP) 1800 800+50 1900+60 12,0 (732) 25.5 (27) see lube oil > group 1.3 45 = 100 % 0,25 / 0,30 1>6>3>5>2>4 59 (15.5) 375 (98.7) 17 > 27 (4.5 > 7.1)

SPLITTER BOX Type Gear version Ratio Oil quantity Oil specifications 350 B 375 1 stage spur gear 0,860 3 (3.2) see lube oil group. 1.3

i l (qt)

HYDRAULIC SYSTEM Travel pumps max. flow > Q max. max. operating pressure Gear pump > repl. circuit max. flow Q max. max. operating pressure (Sp) Travel motors Variable flow working hydraulic pump > max. flow > Q max. stand by pressure (HD) max. operating pressure (HD) Servo > operating pressure > working hydraulic (ND) Hydr. tank capacity > +circuit capacity Oil specifications type l/min (gal/min) bar type l/min (gal/min) bar type type l/min (gal/min) bar bar bar l (gal) l (gal) 2BPV 100 2209 (55) 420 BOSCH 0510 83 (22) 16+4 2BMV 186 A10V100 209 (55) 20 160 18 max. 25 178 (47) 87 (23) see lube oil > group 1.3

ELECTRICAL SYSTEM Voltage Batteries Alternator Starter Automatic circuit breaker Fuses V 24 212 V 143 AH (in series) 28 V 55 A 6,6 60 see Operation and Maintenance Manual

kW A A

TRAVEL GEAR Type Gear version Parking brake (integrated) 2FAT 500 / 515 2 stage planetary gear disk brake /.. Typ/ab Type/from Type/a partir de

Benennung Description Dnomination

PR 732
Datum Edition Date

F/N xxx> 2003 2500

01 01

Technical Data
Blatt Page Feuille

3.1.30.01

PR 732 Type No.


TRAVEL GEAR Gear ratio Oil quantity Oil specifications i total l (qt)

>2003 350

L>2003 412

M > 2003 351

46,5 27.5 (7.6) see lube oil > group 1.3

TRACK COMPONENTS Track chain pitch Track chain length Track pad width (single grouser) Track pad bolts Track rollers > single flange (s) Track rollers > double flange (d) Track roller location Carrier rollers each side Max. roller frame oscillation mm (inch) links mm thread. size qty. qty. 203,2 ( 8,0) 39 508 / 610 3/4 UNF 4 2 s>d>s>s>d>s 1 +/> 3 203,2 ( 8,0) 43 508 / 610 3/4 UNF 4 4 s>d>s>d>d>s>d>s 2 +/>3 203,2 ( 8,0) 43 711 / 812 3/4 UNF 4 4 s>d>s>d>d>s>d>s 2 +/> 3

ATTACHMENT Lift cylinder bearing > lube oil quantity Oil specifications Lift cylinder straight blade cyl. a / rod a / stroke 6>way blade cyl. a / rod a / stroke Tilt cylinder straight blade cyl. a / rod a / stroke 6>way blade cyl. a / rod a / stroke Angle cylinder 6>way blade cyl. Ripper cylinder > cyl.
a / rod a / stroke

l (qt)

0.65 (0.68) see lube oil > group. 1.3 100 / 50 / 1300

mm mm mm mm mm mm

150 / 70 / 140

a / rod a / stroke

160 / 80 / 530

GENERAL DATA normal speed range km/h (mp/h) reduced speed range km/h (mp/h) Basic machine: height over cab mm overall length w/o attachment (transport dimension) mm overall length with straight blade mm overall length with 6>way blade (straight) mm overall length with 6>way blade (angled) mm track gauge (+1width of 1 pad = total width) mm ground clearance mm Operating weight w. straight blade (varies due to pad width) kg Operating weight w. 6>way blade (varies due to pad width) kg Straight blade: blade width mm blade capacity m3 weight > attachment complete kg ground pressure (varies due to pad width) kg/cm2 6>way blade: blade width mm width (angled) mm blade capacity m3 weight > attachment complete kg ground pressure (varies due to pad width) kg/cm2 Ripper: add. length ripper lowered mm add. length ripper raised mm weight > ripper complete kg max. slope angle Winch: additional length mm weight kg max. slope angle height cable exit height drawbar pull mm max. line pull kN (t) max. line speed m/min mm cable size a max. length m Travel speed 0 > 11 (0 > 6.8) 0 > 4,6 (0 > 2.8) 3240 4090 5110

4140 5395

4140 5395

1880 415 17150 / 17400 3200 4.49 2425 0.63 / 0.53

1880 415 17900 / 18100 3200 4.49 2425 0.57 / 0.48

2180 415 18730 / 19150 3900 4.34 2452 0.37 / 0.32

1385 1055 1820 31,5 795 1400 1315 500 390 (39) 0 > 92 infinitely variable 26 70

PR 732
DIESEL ENGINE Type Engine version Rating to ISO 9249 Rated RPM Low idle RPM High idle RPM Displacement Oil quantity incl. filter Oil specification Max. machine inclination - all directions Valve clearance - cold intake / exhaust Firing order Coolant capacity Fuel tank capacity Fuel consumption Visco fan - at rated RPM SPLITTER BOX Type Gear version Ratio Oil quantity Oil specifications

B - F/N 350 25012999

BL - F/N 412 25012999

BM - F/N 351 25012999

kW 1/min 1/min 1/min l (cu. in) l (qt)

mm l (gal) l (gal) appr. l/h (gal/h)

D 916 T LIEBHERR 6 cylinder in line - turbocharged 132 (180 HP) 1800 +50 800 +80 1900 9,16 (558,78) 22 (23,25) see lube oil - group 1.3 45 = 100% 0,20 / 0,25 1-5-3-6-2-4 56 (14,7) 375 (99,1) 17 - 27 (4,5 - 7,1)
50

1/min 1630

350 B 375 1 stage spur gear i 0,860 l (qt) 3 (3,2) see lube oil - group 1.3

HYDRAULIC SYSTEM Travel pumps max. flow - Qmax max. operating pressure (M1 / M2) pmax Gear pump - repl. circuit max flow Qmax max operating pressure (SP) pmax Travel motors Variable flow working hydraulic pump max. flow - Qmax stand by pressure(HD) max. operating pressure (HD) pmax Servo - operating pressure - working hydraulic (ND) Hydr. tank capacity + circuit capacity Oil specifications type l/min (gal/min) bar type l/min (gal/min) bar type type l/min (gal/min) bar bar bar 2 x BPV 100 2 x 209 (55) 420 BOSCH 0510 83 (22) +4 16 2 x BMV 186 A 10 V 100 209 (55) 25 160 18 max. 25

l (gal) 178 (47) l (gal) 87 (23) see lube oil - group 1.3

ELECTRIC SYSTEM Voltage Battery Alternator Starter Automatic circuit breaker Fuses V 24 2 x 12 V, 143 Ah (in series) 28 V 55 A kW 6,6 A 35 A see operation and maintenance manual

TRAVEL GEAR Type Gear version Parking brake (integrated) Gear ratio 2 x FAT 500 P 555 2 stage planetary gear disk brake i total 46,5 : 1 /.. Benennung Description Dnomination Typ/ab Type/from Type/ a partir de

Mjfcifss!
PR 732 B F/N xxx-2501 2999
Datum Edition Date

01 03

Technical Data

Blatt Page Feuille

3.1.31.01

PR 732
TRAVEL GEAR Oil quantity Oil specifications

B - F/N 350 25012999

BL - F/N 412 25012999

BM - F/N 351 25012999

l (qt) 2 x 18 (19) see lube oil - group 1.3

TRACK COMPONENTS Track chain pitch Track chain length Track pad width ( single grouser) Track pad bolts Track rollers - single flange (s) Track rollers - double flange (d) Track roller location Carrier rollers each side Max. roller frame oscillation mm / inch links mm thread. size qty. qty. 203,2 / 8,0 39 508 / 610 UNF 4 2 e-d-e-e-d-e 1 3 43 812 / 965

4 e-d-e-d-d-e-d-e 2

ATTACHMENT Lift cylinder straight blade cyl. / rod / stroke 6-way-blade cyl. / rod / stroke Tilt cylinder straight blade cyl. / rod / stroke 6-way-blade cyl. / rod / stroke Angle cylinder 6-way blade cyl. / rod / stroke Ripper cylinder - cyl. / rod / stroke mm 100 / 50 / 1300 mm 100 / 50 / 1300 mm 150 / 70 / 140 mm 150 / 70 / 680 mm 150 / 70 / 785 mm 160 / 80 / 530

GENERAL DATA Travel speed normal speed range reduced speed range due to ground condition measured horizontally km/h (mp/h) 0 - 11 (0 - 6.8) km/h (mp/h) 0 - 4,6 (0 - 2.8) kN 234 mm 800 mm mm mm mm mm mm mm 3240 4090 5110 5560 6120 1880 474

Drawbar pull max. Mud depth max.

Basic machine: height over cab overall length w/o attachment (transport dimension) overall length with straight blade overall length with 6-way-blade (straight) overall length with 6-way-blade (angled) track gauge (+ 1 width of 1 pad = total width) ground clearance Operating weight w. straight blade ( varies due to pad width) Operating weight w. 6-way-blade ( varies due to pad width) Straight blade: blade width blade capacity weight - attachment complete ground pressure (varies due to pad width). blade width width (angled) blade capacity weight - attachment complete ground pressure (varies due to pad width). length add.(lowered) length add.(raised) weight slope angle additional length weight height drawbar pull max. line pull max. line speed cable size max. length

4140 5395 5885 6445 2180

kg 17150 / 17400 kg 20000 / 20250 mm 3 m kg 2 kg/cm mm mm 3 m kg 2 kg/cm mm mm kg mm kg mm kN m/min mm m

17900 / 18100 20650 / 20950

18730 / 19150

6-way-blade:

Ripper(3):

Winch

3200 4,49 2425 0,63 / 0,53 0,57 / 0,48 3600 3390 4,13 3120 0,74 / 0,62 0,66 / 0,56 1385 1055 1720 31 / 36,5 795 1400 500 390 (39t) 0-92 infinitely variable 26 70

3900 4,34 2452 0,37 / 0,32

PR 732
DIESEL ENGINE Type Engine version Rating to ISO 9249 Rated RPM Low idle RPM High idle RPM Displacement Oil quantity incl. filter Oil specification Max. machine inclination - all directions Valve clearance - cold intake / exhaust Firing order Coolant capacity / DCA 4 Fuel tank capacity Fuel consumption Visco fan - at rated RPM SPLITTER BOX Type Gear version Ratio Oil quantity Oil specifications

B - F/N 350 30003135

BL - F/N 412 30003135

BM - F/N 351 30003135

kW 1/min 1/min 1/min l (cu. in) l (qt)

mm l (gal) l (gal) appr. l/h (gal/h)

D 926 T - E A2 6 cylinder in line - turbocharged 132 (180 HP) 1800 +50 800 +80 1900 9,96 (607,8) 20 (21,1) see lube oil - group 1.3 45 = 100% 0,25 / 0,30 1-5-3-6-2-4 59 / 1,9 (15,5 / 0,5) 375 (99,1) 16 - 28 (4,2 - 7,4)
50

1/min 1630

350 B 375 1 stage spur gear i 0,860 l (qt) 3 (3,2) see lube oil - group 1.3

HYDRAULIC SYSTEM Travel pumps max. flow - Qmax max. operating pressure (M1 / M2) pmax Gear pump - repl. circuit max flow Qmax max operating pressure (SP) pmax Travel motors Variable flow working hydraulic pump max. flow - Qmax stand by pressure(HD) max. operating pressure (HD) pmax Servo - operating pressure - working hydraulic (ND) Hydr. tank capacity + circuit capacity Oil specifications type l/min (gal/min) bar type l/min (gal/min) bar type type l/min (gal/min) bar bar bar 2 x BPV 100 2 x 209 (55) 420 BOSCH 0510 83 (22) +4 16 2 x BMV 186 A 10 V 100 209 (55) 25 160 18 max. 25

l (gal) 178 (47) l (gal) 87 (23) see lube oil - group 1.3

ELECTRIC SYSTEM Voltage Battery Alternator Starter Automatic circuit breaker Fuses V 24 2 x 12 V, 143 Ah (in series) 28 V 55 A kW 6,6 A 35 A see operation and maintenance manual

TRAVEL GEAR Type Gear version Parking brake (integrated) Gear ratio 2 x FAT 500 P 555 2 stage planetary gear disk brake i total 46,5 : 1 /.. Benennung Description Dnomination Typ/ab Type/from Type/ a partir de

Mjfcifss!
PR 732 B F/N xxx-3000 3135
Datum Edition Date

01 03

Technical Data

Blatt Page Feuille

3.1.32.01

PR 732
TRAVEL GEAR Oil quantity Oil specifications

B - F/N 350 30003135

BL - F/N 412 30003135

BM - F/N 351 30003135

l (qt) 2 x 18 (19) see lube oil - group 1.3

TRACK COMPONENTS Track chain pitch Track chain length Track pad width ( single grouser) Track pad bolts Track rollers - single flange (s) Track rollers - double flange (d) Track roller location Carrier rollers each side Max. roller frame oscillation mm / inch links mm thread. size qty. qty. 203,2 / 8,0 39 508 / 610 UNF 4 2 e-d-e-e-d-e 1 3 43 812 / 965

4 e-d-e-d-d-e-d-e 2

ATTACHMENT Lift cylinder straight blade cyl. / rod / stroke 6-way-blade cyl. / rod / stroke Tilt cylinder straight blade cyl. / rod / stroke 6-way-blade cyl. / rod / stroke Angle cylinder 6-way blade cyl. / rod / stroke Ripper cylinder - cyl. / rod / stroke mm 100 / 50 / 1300 mm 100 / 50 / 1300 mm 150 / 70 / 140 mm 150 / 70 / 680 mm 150 / 70 / 785 mm 160 / 80 / 530

GENERAL DATA Travel speed normal speed range reduced speed range due to ground condition measured horizontally km/h (mp/h) 0 - 11 (0 - 6.8) km/h (mp/h) 0 - 4,6 (0 - 2.8) kN 234 mm 800 mm mm mm mm mm mm mm 3240 4090 5110 5560 6120 1880 474

Drawbar pull max. Mud depth max.

Basic machine: height over cab overall length w/o attachment (transport dimension) overall length with straight blade overall length with 6-way-blade (straight) overall length with 6-way-blade (angled) track gauge (+ 1 width of 1 pad = total width) ground clearance Operating weight w. straight blade ( varies due to pad width) Operating weight w. 6-way-blade ( varies due to pad width) Straight blade: blade width blade capacity weight - attachment complete ground pressure (varies due to pad width). blade width width (angled) blade capacity weight - attachment complete ground pressure (varies due to pad width). length add.(lowered) length add.(raised) weight slope angle additional length weight height drawbar pull max. line pull max. line speed cable size max. length

4140 5395 5885 6445 2180

kg 17150 / 17400 kg 20000 / 20250 mm 3 m kg 2 kg/cm mm mm 3 m kg 2 kg/cm mm mm kg mm kg mm kN m/min mm m

17900 / 18100 20650 / 20950

18730 / 19150

6-way-blade:

Ripper(3):

Winch

3200 4,49 2425 0,63 / 0,53 0,57 / 0,48 3600 3390 4,13 3120 0,74 / 0,62 0,66 / 0,56 1385 1055 1720 31 / 36,5 795 1400 500 390 (39t) 0-92 infinitely variable 26 70

3900 4,34 2452 0,37 / 0,32

PR 732
DIESEL ENGINE Type Engine version Rating to ISO 9249 Rated RPM Low idle RPM High idle RPM Displacement Oil quantity incl. filter Oil specification Max. machine inclination - all directions Valve clearance - cold intake / exhaust Firing order Coolant capacity / DCA 4 Fuel tank capacity Fuel consumption Visco fan - at rated RPM SPLITTER BOX Type Gear version Ratio Oil quantity Oil specifications

B - F/N 350 31365599

BL - F/N 412 31365599

BM - F/N 351 31365599

kW 1/min 1/min 1/min l (cu. in) l (qt)

mm l (gal) l (gal) appr. l/h (gal/h)

D 926 T - E A2 6 cylinder in line - turbocharged 132 (180 HP) 1800 +50 800 +80 1900 9,96 (607,8) 20 (21,1) see lube oil - group 1.3 45 = 100% 0,25 / 0,30 1-5-3-6-2-4 59 / 1,9 (15,5 / 0,5) 375 (99,1) 16 - 28 (4,2 - 7,4)
50

1/min 1630

350 B 375 1 stage spur gear i 0,860 l (qt) 3 (3,2) see lube oil - group 1.3

HYDRAULIC SYSTEM Travel pumps max. flow - Qmax max. operating pressure (M1 / M2) pmax Gear pump - repl. circuit max flow Qmax max operating pressure (SP) pmax Travel motors Variable flow working hydraulic pump max. flow - Qmax stand by pressure(HD) max. operating pressure (HD) pmax Servo - operating pressure - working hydraulic (ND) Hydr. tank capacity + circuit capacity Oil specifications type l/min (gal/min) bar type l/min (gal/min) bar type type l/min (gal/min) bar bar bar 2 x BPV 100 2 x 209 (55) 420 BOSCH 0510 83 (22) +4 16 2 x BMV 186 A 10 V 100 209 (55) 25 160 18 max. 25

l (gal) 178 (47) l (gal) 87 (23) see lube oil - group 1.3

ELECTRIC SYSTEM Voltage Battery Alternator Starter Automatic circuit breaker Fuses V 24 2 x 12 V, 143 Ah (in series) 28 V 55 A kW 6,6 A 35 A see operation and maintenance manual

TRAVEL GEAR Type Gear version Parking brake (integrated) Gear ratio 2 x FAT 500 D 585 2 stage planetary gear disk brake i total 46,5 : 1 /.. Benennung Description Dnomination Typ/ab Type/from Type/ a partir de

Mjfcifss!
PR 732 B F/N xxx-3136 5599
Datum Edition Date

01 03

Technical Data

Blatt Page Feuille

3.1.33.01

PR 732
TRAVEL GEAR Oil quantity Oil specifications

B - F/N 350 31365599

BL - F/N 412 31365599

BM - F/N 351 31365599

l (qt) 2 x 11 (11,6) see lube oil - group 1.3

TRACK COMPONENTS Track chain pitch Track chain length Track pad width ( single grouser) Track pad bolts Track rollers - single flange (s) Track rollers - double flange (d) Track roller location Carrier rollers each side Max. roller frame oscillation mm / inch links mm thread. size qty. qty. 203,2 / 8,0 39 508 / 610 UNF 4 2 s-d-s-s-d-s 1 3 43 812 / 965

4 s-d-s-d-d-s-d-s 2

ATTACHMENT Lift cylinder straight blade cyl. / rod / stroke 6-way-blade cyl. / rod / stroke Tilt cylinder straight blade cyl. / rod / stroke 6-way-blade cyl. / rod / stroke Angle cylinder 6-way blade cyl. / rod / stroke Ripper cylinder - cyl. / rod / stroke mm 100 / 50 / 1300 mm 100 / 50 / 1300 mm 150 / 70 / 140 mm 150 / 70 / 680 mm 150 / 70 / 785 mm 160 / 80 / 530

GENERAL DATA Travel speed normal speed range reduced speed range due to ground condition measured horizontally km/h (mp/h) 0 - 11 (0 - 6.8) km/h (mp/h) 0 - 4,6 (0 - 2.8) kN 234 mm 800 3240 4090 5110 5560 6120 1880 474

Drawbar pull max. Mud depth max. Basic machine:

height over cab mm overall length w/o attachment (transport dimension) mm overall length with straight blade mm overall length with 6-way-blade (straight) mm overall length with 6-way-blade (angled) mm track gauge (+ 1 width of 1 pad = total width) mm ground clearance mm

4140 5395 5885 6445 2180

Operating weight w. straight blade ( varies due to pad width) Operating weight w. 6-way-blade ( varies due to pad width) Straight blade: blade width blade capacity weight - attachment complete ground pressure (varies due to pad width). blade width width (angled) blade capacity weight - attachment complete ground pressure (varies due to pad width). length add.(lowered) length add.(raised) weight slope angle additional length weight height drawbar pull max. line pull max. line speed cable size max. length

kg 17150 / 17400 kg 20000 / 20250 mm 3 m kg 2 kg/cm mm mm 3 m kg 2 kg/cm mm mm kg mm kg mm kN m/min mm m

17900 / 18100 20650 / 20950

18730 / 19150

6-way-blade:

Ripper(3):

Winch

3200 4,49 2425 0,63 / 0,53 0,57 / 0,48 3600 3390 4,13 3120 0,74 / 0,62 0,66 / 0,56 1385 1055 1720 31 / 36,5 795 1400 500 390 (39t) 0-92 infinitely variable 26 70

3900 4,34 2452 0,37 / 0,32

PR 732
DIESEL ENGINE Type Construction Rating to ISO 9249 Rated RPM Low idle RPM High idle RPM Displacement Oil quantity incl. filter Oil specification Max. machine inclination - all directions Valve clearance - cold intake / exhaust Firing order Coolant capacity / DCA 4 Fuel tank capacity Fuel consumption SPLITTER BOX Type Construction Ratio Oil quantity Oil specification HYDRAULIC SYSTEM Travel pumps max. flow - Qmax max. operating pressure (M1 / M2) pmax Tandem gear pump - replenishing / fan drive max. flow replenishing - Qmax max. operating pressure (SP) pmax max. flow fan drive - Qmax max. operating pressure (electronic regulated) pmax Axial piston motor - fan drive operation RPM Travel motors Variable flow working hydraulic pump max. flow - Qmax stand by pressure(HD) max. operating pressure (HD) pmax Servo - operating pressure - working hydraulic (ND) Hydr. tank capacity + circuit capacity Oil specification type l/min (gal/min) bar type l/min (gal/min) bar l/min (gal/min) bar type 1/min type type l/min (gal/min) bar bar bar

B - F/N 350 5600

BL - F/N 412 5600

BM - F/N 351 5600

kW 1/min 1/min 1/min l (cu. in) l (qt)

mm l (gal) l (gal) appr. l/h (gal/h)

D 926 T - E A2 6 cylinder in line - turbocharged 127 (172 HP) 1800 +50 800 +80 1900 9,96 (607,8) 20 (21,1) see lube oil - group 1.3 45 = 100% 0,25 / 0,30 1-5-3-6-2-4 59 / 1,9 (15,5 / 0,5) 375 (99,1) 16 - 28 (4,2 - 7,4)

350 B 375 1 stage spur gear i 0,860 l (qt) 3 (3,2) see lube oil - group 1.3

2 x BPV 100 2 x 209 (55) 420 45 ZP + 19 ZP 94 (99,36) 25 38 (40,17) +10 150 A 10 FSM +100 1700 2 x BMV 186 A 10 V 100 209 (55) 25 160 18 max. 25

l (gal) 178 (47) l (gal) 87 (23) see lube oil - group 1.3

ELECTRIC SYSTEM Voltage Battery Alternator Starter Automatic circuit breaker Fuses TRAVEL GEAR Type Construction Parking brake (integrated) 2 x FAT 500 D 585 2 stage planetary gear disk brake /.. Benennung Description Dnomination Typ/ab Type/from Type/ a partir de V 24 2 x 12 V, 143 Ah (in series) 28 V 55 A kW 6,6 A 35 A see operation and maintenance manual

Mjfcifss!
PR 732 B F/N xxx-5600
Datum Edition Date

01 03

Technical Data

Blatt Page Feuille

3.1.34.01

PR 732
TRAVEL GEAR Ratio Oil quantity Oil specification TRACK COMPONENTS Track chain pitch Track chain length Track pad width ( single grouser) Track pad bolts Track rollers - single flange (s) Track rollers - double flange (d) Track roller location Carrier rollers each side Max. roller frame oscillation ATTACHMENT Lift cylinder straight blade cyl. / rod / stroke 6-way-blade cyl. / rod / stroke Tilt cylinder straight blade cyl. / rod / stroke 6-way-blade cyl. / rod / stroke Angle cylinder 6-way blade cyl. / rod / stroke Ripper cylinder - cyl. / rod / stroke GENERAL DATA Travel speed normal range reduced range normal range = III reduced range - II reduced range - I due to ground condition measured horizontally mm / inch links mm thread. size qty. qty.

B - F/N 350 5600

BL - F/N 412 5600

BM - F/N 351 5600

i total 46,5 : 1 l (qt) 2 x 11 (11,6) see lube oil - group 1.3

203,2 / 8,0 39 508 / 610 UNF 4 2 s-d-s-s-d-s 1 3

43 812 / 965

4 s-d-s-d-d-s-d-s 2

mm 100 / 50 / 1300 mm 100 / 50 / 1300 mm 150 / 70 / 140 mm 150 / 70 / 680 mm 150 / 70 / 785 mm 160 / 80 / 530

km/h (mph) 0 11,0 (0 6,8) km/h (mph) 0 4,6 (0 2,8) km/h (mph) 0 11,0 (0 6,8) km/h (mph) 0 6,5 (0 4,0) km/h (mph) 0 4,0 (0 2,4) kN 234 mm 800 3240 4090 5110 5560 6120 1880 474

Travel speed

Drawbar pull max. Mud depth max. Basic machine:

height over cab mm overall length w/o attachment (transport dimension) mm overall length with straight blade mm overall length with 6-way-blade (straight) mm overall length with 6-way-blade (angled) mm track gauge (+ 1 width of 1 pad = total width) mm ground clearance mm

4140 5395 5885 6445 2180

Operating weight w. straight blade ( varies due to pad width) Operating weight w. 6-way-blade ( varies due to pad width) Straight blade: blade width blade capacity weight - attachment complete ground pressure (varies due to pad width). blade width width (angled) blade capacity weight - attachment complete ground pressure (varies due to pad width). length add.(lowered) length add.(raised) weight slope angle additional length weight height drawbar pull max. line pull max. line speed cable size max. length

kg 17150 / 17400 kg 20000 / 20250 mm 3 m kg 2 kg/cm mm mm 3 m kg 2 kg/cm mm mm kg mm kg mm kN m/min mm m

17900 / 18100 20650 / 20950

18730 / 19150

6-way-blade:

Ripper(3):

Winch

3200 4,49 2425 0,63 / 0,53 0,57 / 0,48 3600 3390 4,13 3120 0,74 / 0,62 0,66 / 0,56 1385 1055 1720 31 / 36,5 795 1400 500 390 (39t) 0-92 infinitely variable 26 70

3900 4,34 2452 0,37 / 0,32

PR 742 Type No.


DIESEL ENGINE Type Engine version Rating to DIN 6271 Rated RPM Low idle RPM High idle RPM Displacement Oil quantity incl. filter Oil specifications Max. machine inclination > all directions Valve clearance > cold intake / exhaust Firing order Coolant capacity Fuel tank capacity Fuel consumption SPLITTER BOX Type Gear version Ratio Oil quantity Oil specifications

> 2001 352


D 9306 T LIEBHERR 6 Cyl. V 172 (234 HP) 1800 800+50 1900+60 12,0 (732) 25.5 (27) see lube oil > group 1.3 45 = 100 % 0.25 / 0.30 1>6>3>5>2>4 69 (18.2) 460 (121.5) 35>40 (9.2 > 10.5)

M > 2001 353

kW 1/min 1/min 1/min l (cu. in) l (qt)

mm l (gal) l (gal) appr. l/h (gal/h)

i l (qt)

350 B 376 1 stage spur gear 0,860 3 (3.2) see lube oil > group. 1.3

HYDRAULIC SYSTEM Travel pumps max. flow > Q max. max. operating pressure Gear pump > replenishing / coolant circuit max. flow Q max. max. operating pressure (Sp) Gear pump > pump control / replenishing max. flow Q max. max. operting pressure (St) Travel motors Variable flow working hydraulic pump > max. flow > Q max. stand by pressure (HD) max. operating pressure (HD) Servo > operating pressure > working hydraulic (ND) Hydr. tank capacity > +circuit capacity Oil specifications ELECTRICAL SYSTEM Voltage Batteries Alternator Starter Automatic circuit breaker Fuses V 24 212 V 143 AH (in series) 28 V 55 A 6.6 60 see Operation and Maintenance Manual type l/min (gal/min) bar type l/min (gal/min) bar type l/min (gal/min) bar type type l/min (gal/min) bar bar bar l (gal) l (gal) 2HPV 130 2272 (72) 420 BOSCH ZP 56 117 (30.9) 25 BOSCH ZP 16 33 (8.7) 50 2BMV 260 HPR 130 272 (72) 30+5 160 25 189 (50) 77 (20.3) see lube oil>group 1.3

kW A A

TRAVEL GEAR Type Gear version Parking brake (integrated) Benennung Description Dnomination 2FAT 550 / 516 2 stage planetary gear disk brake /.. Typ/ab Type/from

Type/a partir de

Datum Edition Date

01 01

Technical Data

PR 742
Blatt Page Feuille

F/N xxx> 2001 2500

3.1.40.01

PR 742 Type No.


TRAVEL GEAR Gear ratio Oil quantity Oil specifications i total l (qt)

>2001 352
42.9 11 (11.6) see lube oil > group 1.3

M > 2001 353

TRACK COMPONENTS Track chain pitch Track chain length Track pad width (single grouser) Track pad bolts Track rollers > single flange (s) Track rollers > double flange (d) Track roller location Carrier rollers each side Max. roller frame oscillation mm(inch) links mm thread. size qty. qty. 215.9 ( 8.5) 40 508 / 610 / 710 3/4 UNF 4 3 s>d>s>d>s>d>s 2 +/>3 215.9 (8.5) 43 812 / 914 3/4 UNF 4 4 s>d>s>d>d>s>d>s 2 +/>3

ATTACHMENT Lift cylinder bearing > lube oil quantity Oil specifications Lift cylinder straight blade cyl. a / rod a / stroke 6>way blade cyl. a / rod a / stroke Tilt cylinder straight blade cyl. a / rod a / stroke 6>way blade cyl. a / rod a / stroke Angle cylinder 6>way blade cyl. Ripper cylinder > cyl.
a / rod a / stroke

l (qt)

0.65 (0.68) see lube oil > group. 1.3 110 / 60 / 1345

mm mm mm mm mm mm

180 / 80 / 170

a / rod a / stroke

180 / 80 / 530

GENERAL DATA normal speed range km/h (mp/h) reduced speed range km/h (mp/h) Basic machine: height over cab mm overall length w/o attachment (transport dimension) mm overall length with straight blade mm overall length with 6>way blade (straight) mm overall length with 6>way blade (angled) mm track gauge (+1width of 1 pad = total width) mm ground clearance mm Operating weight w. straight blade (varies due to pad width) kg Operating weight w. 6>way blade (varies due to pad width) Straight blade: blade width blade capacity weight > attachment complete ground pressure (varies due to pad width) 6>way blade: blade width width (angled) blade capacity weight > attachment complete ground pressure (varies due to pad width) Ripper: add. length ripper lowered add. length ripper raised weight > ripper complete max. slope angle Winch: additional length weight max. slope angle height cable exit height drawbar pull max. line pull max. line speed cable size a max. length kg mm m3 kg kg/cm2 mm mm m3 kg kg/cm2 mm mm kg mm kg Travel speed 0 > 11 (0 > 6.8) 0 > 4.6 (0 > 2.8) 3305 4300 5460

5770

1980 410 21600 / 21900 / 22200 3860 6.53 3715 0.72 / 0.61 / 0.53

2180 410 23000 / 23300

4500 6.23 3805 0.43 / 0.39

1675 1130 2600 29 740 2250 1325 510 520 (53) 0 > 80 infinitely variable 28 60

mm kN (t) m/min mm m

PR 742
DIESEL ENGINE Type Engine version Rating to ISO 9249 Rated RPM Low idle RPM High idle RPM Displacement Oil quantity incl. filter Oil specification Max. machine inclination - all directions Valve clearance - cold intake / exhaust Firing order Coolant capacity Fuel tank capacity Fuel consumption Visco fan - at rated RPM SPLITTER BOX Type Gear version Ratio Oil quantity Oil specifications HYDRAULIC SYSTEM Travel pumps type max. flow - Qmax l/min (gal/min) max. operating pressure (M1 / M2) pmax bar Tandem gear pump - repl.- / cool.- / pump contr. circuit type replenishing / coolant circuit - max. flow Qmax l/min (gal/min) max. operating pressure (SP) pmax bar pump control / replenishing - max. flow Qmax l/min (gal/min) max. operating pressure (St) pmax bar Travel motors type Variable flow working hydraulic pump max. flow - Qmax stand by pressure(HD) max. operating pressure (HD) pmax Servo - operating pressure - working hydraulic (ND) Hydr. tank capacity + circuit capacity Oil specifications type l/min (gal/min) bar bar bar

B - F/N 352 25012999

BL - F/N 581 25012999

BM - F/N 353 25012999

kW 1/min 1/min 1/min l (cu. in) l (qt)

mm l (gal) l (gal) appr. l/h (gal/h)

D 926 TI LIEBHERR 6 cylinder in line - intercooled 172 (234 HP) 1800 +50 800 +80 1900 9,96 (607.9) 22 (23.2) see lube oil - group 1.3 45 = 100% 0,20 / 0,25 1-5-3-6-2-4 62 (16.4) 450 ( 118.9) 32 - 37 (8.4 - 9.8)
50

1/min 1560

350 B 376 1 stage spur gear i 0,860 l (qt) 3 (3.2) see lube oil - group 1.3

2 x HPV 130 2 x 272 (2 x 72) 420 PRN 55 + 17S SC37 G 117 (31) 25 33 (8.7) 50 2 x BMV 260 A 10 V 140 292 (77.1) 25 160 25

l (gal) 178 (47) l (gal) 88 (23.2) see lube oil - group 1.3

ELECTRIC SYSTEM Voltage Battery Alternator Starter Automatic circuit breaker Fuses V 24 2 x 12 V, 143 Ah (in series) 28 V 55 A kW 6,6 A 35 A see operation and maintenance manual

TRAVEL GEAR Type Gear version Parking brake (integrated) 2 x FAT 550 P 556 2 stage planetary gear disk brake /.. Benennung Description Dnomination Typ/ab Type/from Type/ a partir de

Mjfcifss!
Datum Edition Date

PR 742 B F/N xxx-2501 2999

01 03

Technical Data

Blatt Page Feuille

3.1.41.01

PR 742
TRAVEL GEAR Gear ratio Oil quantity Oil specifications

B - F/N 352 25012999

BL - F/N 581 25012999

BM - F/N 353 25012999

i total 43,9 : 1 l (qt) 2 x 23 (24,3) see lube oil - group 1.3

TRACK COMPONENTS Track chain pitch Track chain length Track pad width ( single grouser) Track pad bolts Track rollers - single flange (s) Track rollers - double flange (d) Track roller location Carrier rollers each side Max. roller frame oscillation mm / inch links mm thread. size qty. qty. 215,9 / 8,5 39 508 / 610 / 710 UNF 4 3 s-d-s-d-s-d-s 2 3 43 812 / 914

4 s-d-s-d-d-s-d-s

ATTACHMENT Lift cylinder straight blade cyl. / rod / stroke Tilt cylinder straight blade cyl. / rod / stroke Ripper cylinder - cyl. / rod / stroke mm 110 / 60 / 1345 mm 180 / 80 / 170 mm 180 / 80 / 530

GENERAL DATA Travel speed normal speed range reduced speed range due to ground condition measured horizontally km/h (mp/h) 0 - 11 (0 - 6.8) km/h (mp/h) 0 - 4,6 (0 - 2.8) kN 285 mm 850 3305 4300 5460 1980 482 22150 / 22450 / 22750 3990 6,37 3540 0,73 / 0,62 / 0,54 1675 1130 2600 29 / 36,5 740 2550 510 520 (53t) 0-80 infinitely variable 28 60 22925 / 23225 23525

Drawbar pull max. Mud depth max. Basic machine:

height over cab mm overall length w/o attachment (transport dimension) mm overall length with straight blade mm track gauge (+ 1 width of 1 pad = total width) mm ground clearance mm kg mm 3 m kg 2 kg/cm mm mm kg mm kg mm kN (t) m/min mm m

5770 2180

Operating weight w. straight blade ( varies due to pad width) Straight blade: blade width blade capacity weight - attachment complete ground pressure (varies due to pad width). length add.(lowered) length add.(raised) weight slope angle additional length weight height drawbar pull max. line pull max. line speed cable size max. length

23550 / 23850 4500 6,27 3610 0,44 / 0,40

0,69 / 0,58 / 0,50

Ripper(3):

Winch

PR 742
DIESEL ENGINE Type Engine version Rating to ISO 9249 Rated RPM Low idle RPM High idle RPM Displacement Oil quantity incl. filter Oil specification Max. machine inclination - all directions Valve clearance - cold intake / exhaust Firing order Coolant capacity / DCA 4 Fuel tank capacity Fuel consumption Visco fan - at rated RPM SPLITTER BOX Type Gear version Ratio Oil quantity Oil specifications HYDRAULIC SYSTEM Travel pumps type max. flow - Qmax l/min (gal/min) max. operating pressure (M1 / M2) pmax bar Tandem gear pump - repl.- / cool.- / pump contr. circuit type replenishing / coolant circuit - max. flow Qmax l/min (gal/min) max. operating pressure (SP) pmax bar pump control / replenishing - max. flow Qmax l/min (gal/min) max. operating pressure (St) pmax bar Travel motors type Variable flow working hydraulic pump max. flow - Qmax stand by pressure(HD) max. operating pressure (HD) pmax Servo - operating pressure - working hydraulic (ND) Hydr. tank capacity + circuit capacity Oil specifications type l/min (gal/min) bar bar bar

B - F/N 352 30003088

BL - F/N 581 30003088

BM - F/N 353 30003088

kW 1/min 1/min 1/min l (cu. in) l (qt)

mm l (gal) l (gal) appr. l/h (gal/h)

D 926 TI - E A2 6 cylinder in line - intercooled 172 (234 HP) 1800 +50 800 +80 1900 9,96 (607.9) 25,5 (27) see lube oil - group 1.3 45 = 100% 0,25 / 0,30 1-5-3-6-2-4 62 / 2,4 (16.4 / 0.66) 450 ( 118.9) 20 - 35
50

1/min 1560

350 B 376 1 stage spur gear i 0,860 l (qt) 3 (3.2) see lube oil - group 1.3

2 x HPV 130 2 x 272 (2 x 72) 420 PRN 55 + 17S SC37 G 117 (31) 25 33 (8.7) 50 2 x BMV 260 A 10 V 140 292 (77.1) 25 160 25

l (gal) 178 (47) l (gal) 88 (23.2) see lube oil - group 1.3

ELECTRIC SYSTEM Voltage Battery Alternator Starter Automatic circuit breaker Fuses V 24 2 x 12 V, 143 Ah (in series) 28 V 55 A kW 6,6 A 35 A see operation and maintenance manual

TRAVEL GEAR Type Gear version Parking brake (integrated) 2 x FAT 550 P 556 2 stage planetary gear disk brake /.. Benennung Description Dnomination Typ/ab Type/from Type/ a partir de

Mjfcifss!
Datum Edition Date

PR 742 B F/N xxx-3000 3088

01 03

Technical Data

Blatt Page Feuille

3.1.42.01

PR 742
TRAVEL GEAR Gear ratio Oil quantity Oil specifications

B - F/N 352 30003088

BL - F/N 581 30003088

BM - F/N 353 30003088

i total 43,9 : 1 l (qt) 2 x 23 (24,3) see lube oil - group 1.3

TRACK COMPONENTS Track chain pitch Track chain length Track pad width ( single grouser) Track pad bolts Track rollers - single flange (s) Track rollers - double flange (d) Track roller location Carrier rollers each side Max. roller frame oscillation mm / inch links mm thread. size qty. qty. 215,9 / 8,5 39 508 / 610 / 710 UNF 4 3 s-d-s-d-s-d-s 2 3 43 812 / 914

4 s-d-s-d-d-s-d-s

ATTACHMENT Lift cylinder straight blade cyl. / rod / stroke Tilt cylinder straight blade cyl. / rod / stroke Ripper cylinder - cyl. / rod / stroke mm 110 / 60 / 1345 mm 180 / 80 / 170 mm 180 / 80 / 530

GENERAL DATA Travel speed normal speed range reduced speed range due to ground condition measured horizontally km/h (mp/h) 0 - 11 (0 - 6.8) km/h (mp/h) 0 - 4,6 (0 - 2.8) kN 285 mm 850 3305 4300 5460 1980 482 22150 / 22450 / 22750 3990 6,37 3540 0,73 / 0,62 / 0,54 1675 1130 2600 29 / 36,5 740 2550 510 520 (53t) 0-80 infinitely variable 28 60 22925 / 23225 23525

Drawbar pull max. Mud depth max. Basic machine:

height over cab mm overall length w/o attachment (transport dimension) mm overall length with straight blade mm track gauge (+ 1 width of 1 pad = total width) mm ground clearance mm kg mm 3 m kg 2 kg/cm mm mm kg mm kg mm kN (t) m/min mm m

5770 2180

Operating weight w. straight blade ( varies due to pad width) Straight blade: blade width blade capacity weight - attachment complete ground pressure (varies due to pad width). length add.(lowered) length add.(raised) weight slope angle additional length weight height drawbar pull max. line pull max. line speed cable size max. length

23550 / 23850 4500 6,27 3610 0,44 / 0,40

0,69 / 0,58 / 0,50

Ripper(3):

Winch

PR 742
DIESEL ENGINE Type Engine version Rating to ISO 9249 Rated RPM Low idle RPM High idle RPM Displacement Oil quantity incl. filter Oil specification Max. machine inclination - all directions Valve clearance - cold intake / exhaust Firing order Coolant capacity / DCA 4 Fuel tank capacity Fuel consumption Visco fan - at rated RPM SPLITTER BOX Type Gear version Ratio Oil quantity Oil specifications HYDRAULIC SYSTEM Travel pumps type max. flow - Qmax l/min (gal/min) max. operating pressure (M1 / M2) pmax bar Tandem gear pump - repl.- / cool.- / pump contr. circuit type replenishing / coolant circuit - max. flow Qmax l/min (gal/min) max. operating pressure (SP) pmax bar pump control / replenishing - max. flow Qmax l/min (gal/min) max. operating pressure (St) pmax bar Travel motors type Variable flow working hydraulic pump max. flow - Qmax stand by pressure(HD) max. operating pressure (HD) pmax Servo - operating pressure - working hydraulic (ND) Hydr. tank capacity + circuit capacity Oil specifications type l/min (gal/min) bar bar bar

B - F/N 352 30895233

BL - F/N 581 30895233

BM - F/N 353 30895233

kW 1/min 1/min 1/min l (cu. in) l (qt)

mm l (gal) l (gal) appr. l/h (gal/h)

D 926 TI - E A2 6 cylinder in line - intercooled 172 (234 HP) 1800 +50 800 +80 1900 9,96 (607.9) 25,5 (27) see lube oil - group 1.3 45 = 100% 0,25 / 0,30 1-5-3-6-2-4 62 / 2,4 (16.4 / 0.66) 450 ( 118.9) 20 - 35 (5.3 - 9.2)
50

1/min 1560

350 B 376 1 stage spur gear i 0,860 l (qt) 3 (3.2) see lube oil - group 1.3

2 x HPV 130 2 x 272 (2 x 72) 420 PRN 55 + 17S SC37 G 117 (31) 25 33 (8.7) 50 2 x BMV 260 A 10 V 140 292 (77.1) 25 160 25

l (gal) 178 (47) l (gal) 88 (23.2) see lube oil - group 1.3

ELECTRIC SYSTEM Voltage Battery Alternator Starter Automatic circuit breaker Fuses V 24 2 x 12 V, 143 Ah (in series) 28 V 55 A kW 6,6 A 35 A see operation and maintenance manual

TRAVEL GEAR Type Gear version Parking brake (integrated) 2 x FAT 550 D 586 2 stage planetary gear disk brake /.. Benennung Description Dnomination Typ/ab Type/from Type/ a partir de

Mjfcifss!
Datum Edition Date

PR 742 B F/N xxx-3089 5233

01 03

Technical Data

Blatt Page Feuille

3.1.43.01

PR 742
TRAVEL GEAR Gear ratio Oil quantity Oil specifications

B - F/N 352 30895233

BL - F/N 581 30895233

BM - F/N 353 30895233

i total 43,9 : 1 l (qt) 2 x 14,5 (15,3) see lube oil - group 1.3

TRACK COMPONENTS Track chain pitch Track chain length Track pad width ( single grouser) Track pad bolts Track rollers - single flange (s) Track rollers - double flange (d) Track roller location Carrier rollers each side Max. roller frame oscillation mm / inch links mm thread. size qty. qty. 215,9 / 8,5 39 508 / 610 / 710 UNF 4 3 s-d-s-d-s-d-s 2 3 43 812 / 914

4 s-d-s-d-d-s-d-s

ATTACHMENT Lift cylinder straight blade cyl. / rod / stroke Tilt cylinder straight blade cyl. / rod / stroke Ripper cylinder - cyl. / rod / stroke mm 110 / 60 / 1345 mm 180 / 80 / 170 mm 180 / 80 / 530

GENERAL DATA Travel speed normal speed range reduced speed range due to ground condition measured horizontally km/h (mp/h) 0 - 11 (0 - 6.8) km/h (mp/h) 0 - 4,6 (0 - 2.8) kN 285 mm 850 3305 4300 5460 1980 482 22950 / 23350 / 23750 3990 6,37 3540 0,76 / 0,65 / 0,57 1675 1130 2600 29 / 36,5 740 2550 510 520 (53t) 0-80 infinitely variable 28 60 23700 / 24100 24450

Drawbar pull max. Mud depth max. Basic machine:

height over cab mm overall length w/o attachment (transport dimension) mm overall length with straight blade mm track gauge (+ 1 width of 1 pad = total width) mm ground clearance mm kg mm 3 m kg 2 kg/cm mm mm kg mm kg mm kN (t) m/min mm m

5770 2180

Operating weight w. straight blade ( varies due to pad width) Straight blade: blade width blade capacity weight - attachment complete ground pressure (varies due to pad width). length add.(lowered) length add.(raised) weight slope angle additional length weight height drawbar pull max. line pull max. line speed cable size max. length

24600 / 24950 4500 6,27 3610 0,46 / 0,42

0,72 / 0,59 / 0,53

Ripper(3):

Winch

PR 742
DIESEL ENGINE Type Engine version Rating to ISO 9249 Rated RPM Low idle RPM High idle RPM Displacement Oil quantity incl. filter Oil specification Max. machine inclination - all directions Valve clearance - cold intake / exhaust Firing order Coolant capacity / DCA 4 Fuel tank capacity Fuel consumption Visco fan - at rated RPM SPLITTER BOX Type Gear version Ratio Oil quantity Oil specifications

B - F/N 352 52345599

BL - F/N 581 52345599

BM - F/N 353 52345599

kW 1/min 1/min 1/min l (cu. in) l (qt)

mm l (gal) l (gal) appr. l/h (gal/h)

D 926 TI - E A2 6 cylinder in line - intercooled 172 (234 HP) 1800 +50 800 +80 1900 9,96 (607,9) 25,5 (27) see lube oil - group 1.3 45 = 100% 0,25 / 0,30 1-5-3-6-2-4 62 / 2,4 (16,4 / 0,66) 450 ( 118,9) 20 - 35 (5,3 - 9,2)
50

1/min 1560

350 B 374 1 stage spur gear i 0,860 l (qt) 3 (3,2) see lube oil - group 1.3

HYDRAULIC SYSTEM Travel pumps type 2 x HPV 135 max. flow - Qmax l/min (gal/min) 2 x 282 (2 x 75) max. operating pressure (M1 / M2) pmax bar 420 Tandem gear pump - replenishing - coolant circuit / fan drive type PRN 55 + 17S SC37 G max. flow - Qmax total(Q1+Q2) l/min (gal/min) 150 (39,6) max. operating pressure (SP) pmax bar 25 Travel motors type 2 x BMV 260 Variable flow working hydraulic pump max. flow - Qmax stand by pressure(HD) max. operating pressure (HD) pmax Servo - operating pressure - working hydraulic (ND) Hydr. tank capacity + circuit capacity Oil specifications type l/min (gal/min) bar bar bar A 10 V 140 292 (77,1) 25 160 25

l (gal) 178 (47) l (gal) 88 (23,2) see lube oil - group 1.3

ELECTRIC SYSTEM Voltage Battery Alternator Starter Automatic circuit breaker Fuses V 24 2 x 12 V, 143 Ah (in series) 28 V 55 A kW 6,6 A 35 A see operation and maintenance manual

TRAVEL GEAR Type Gear version Parking brake (integrated) Gear ratio 2 x FAT 550 D 586 2 stage planetary gear disk brake i total 43,9 : 1 /.. Benennung Description Dnomination Typ/ab Type/from Type/ a partir de

Mjfcifss!
Datum Edition Date

PR 742 B F/N xxx-5234 5599

01 03

Technical Data

Blatt Page Feuille

3.1.44.01

PR 742
TRAVEL GEAR Oil quantity Oil specifications

B - F/N 352 52345599

BL - F/N 581 52345599

BM - F/N 353 52345599

l (qt) 2 x 14,5 (15,3) see lube oil - group 1.3

TRACK COMPONENTS Track chain pitch Track chain length Track pad width ( single grouser) Track pad bolts Track rollers - single flange (s) Track rollers - double flange (d) Track roller location Carrier rollers each side Max. roller frame oscillation mm / inch links mm thread. size qty. qty. 215,9 / 8,5 39 508 / 610 / 710 UNF 4 3 s-d-s-d-s-d-s qty 2 3 43 812 / 914

4 s-d-s-d-d-s-d-s

ATTACHMENT Lift cylinder straight blade cyl. / rod / stroke Tilt cylinder straight blade cyl. / rod / stroke Ripper cylinder - cyl. / rod / stroke mm 110 / 60 / 1345 mm 180 / 80 / 170 mm 180 / 80 / 530

GENERAL DATA Travel speed normal speed range reduced speed range due to ground condition measured horizontally km/h (mp/h) 0 - 11 (0 - 6.8) km/h (mp/h) 0 - 4,6 (0 - 2.8) kN 285 mm 850 3305 4300 5460 1980 482 22950 / 23350 / 23750 3990 6,37 3540 0,76 / 0,65 / 0,57 1675 1130 2600 29 / 36,5 740 2550 510 520 (53t) 0-80 infinitely variable 28 60 23700 / 24100 24450

Drawbar pull max. Mud depth max. Basic machine:

height over cab mm overall length w/o attachment (transport dimension) mm overall length with straight blade mm track gauge (+ 1 width of 1 pad = total width) mm ground clearance mm kg mm 3 m kg 2 kg/cm mm mm kg mm kg mm kN m/min mm m

5770 2180

Operating weight w. straight blade ( varies due to pad width) Straight blade: blade width blade capacity weight - attachment complete ground pressure (varies due to pad width). length add.(lowered) length add.(raised) weight slope angle additional length weight height drawbar pull max. line pull max. line speed cable size max. length

24600 / 24950 4500 6,27 3610 0,46 / 0,42

0,72 / 0,59 / 0,53

Ripper(3):

Winch

PR 742
DIESEL ENGINE Type Engine version Rating to ISO 9249 Rated RPM Low idle RPM High idle RPM Displacement Oil quantity incl. filter Oil specification Max. machine inclination - all directions Valve clearance - cold intake / exhaust Firing order Coolant capacity / DCA 4 Fuel tank capacity Fuel consumption

B - F/N 352 5600

BL - F/N 581 5600

BM - F/N 353 5600

kW 1/min 1/min 1/min l (cu. in) l (qt)

mm l (gal) l (gal) appr. l/h (gal/h)

D 926 TI - E A2 6 cylinder in line - intercooled 172 (234 HP) 1800 +50 800 +80 1900 9,96 (607.9) 25,5 (27) see lube oil - group 1.3 45 = 100% 0,25 / 0,30 1-5-3-6-2-4 62 / 2,4 (16.4 / 0.66) 450 ( 118.9) 20 - 35 (5.3 - 9.2)

SPLITTER BOX Type Gear version Ratio Oil quantity Oil specifications 350 B 374 1 stage spur gear i 0,860 l (qt) 3 (3,2) see lube oil - group 1.3

HYDRAULIC SYSTEM Travel pumps type 2 x HPV 135 max. flow - Qmax l/min (gal/min) 2 x 282 (2x 75) max. operating pressure (M1 / M2) pmax bar 420 Tandem gear pump - replenishing - coolant circuit / fan drive type PRN 55 + 17S SC37 G max. flow replenishing - Qmax l/min (gal/min) 117 (30,8) max. operating pressure (SP) pmax bar 25 max. flow fan drive - Qmax l/min (gal/min) 33 (8,7) +10 max. operating pressure (electronic regulated) pmax bar 210 Axial piston motor - fan drive type A 10 FSM +100 operation RPM 1/min 1475 Travel motors type 2 x BMV 260 Variable flow working hydraulic pump max. flow - Qmax stand by pressure(HD) max. operating pressure (HD) pmax Servo - operating pressure - working hydraulic (ND) Hydr. tank capacity + circuit capacity Oil specifications type l/min (gal/min) bar bar bar A 10 V 140 292 (77,1) 25 160 25

l (gal) 178 (47) l (gal) 88 (23,2) see lube oil - group 1.3

ELECTRIC SYSTEM Voltage Battery Alternator Starter Automatic circuit breaker Fuses V 24 2 x 12 V, 143 Ah (in series) 28 V 55 A kW 6,6 A 35 A see operation and maintenance manual

/..

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!
Datum Edition Date

PR 742 B F/N xxx-5600

01 03

Technical Data

Blatt Page Feuille

3.1.45.01

PR 742
TRAVEL GEAR Type Gear version Parking brake (integrated) Gear ratio Oil quantity Oil specifications

B - F/N 352 5600

BL - F/N 581 5600

BM - F/N 353 5600

2 x FAT 550 D 586 2 stage planetary gear disk brake i total 43,9 : 1 l (qt) 2 x 14,5 (15,3) see lube oil - group 1.3

TRACK COMPONENTS Track chain pitch Track chain length Track pad width ( single grouser) Track pad bolts Track rollers - single flange (s) Track rollers - double flange (d) Track roller location Carrier rollers each side Max. roller frame oscillation mm / inch links mm thread. size qty. qty. 215,9 / 8,5 39 508 / 610 / 710 UNF 4 3 e-d-e-d-e-d-e qty. 2 3 43 812 / 914

4 e-d-e-d-d-e-d-e

ATTACHMENT Lift cylinder straight blade cyl. / rod / stroke Tilt cylinder straight blade cyl. / rod / stroke Ripper cylinder - cyl. / rod / stroke mm 110 / 60 / 1345 mm 180 / 80 / 170 mm 180 / 80 / 530

GENERAL DATA Travel speed normal range = III reduced range - II reduced range - I due to ground condition measured horizontally km/h (mph) 0 11,0 (0 6,8) km/h (mph) 0 6,5 (0 4,0) from F/N xxx-6200 reverse 0 7,8 (0 4,8) km/h (mph) 0 4,0 (0 2,4) from F/N xxx-6200 reverse 0 4,8 (0 3,0) kN 285 mm 850 3305 4300 5460 1980 482 22950 / 23350 / 23750 3990 6,37 3540 0,76 / 0,65 / 0,57 1675 1130 2600 29 / 36,5 740 2550 510 520 (53t) 0-80 infinitely variable 28 60 23700 / 24100 24450

Drawbar pull max. Mud depth max. Basic machine:

height over cab mm overall length w/o attachment (transport dimension) mm overall length with straight blade mm track gauge (+ 1 width of 1 pad = total width) mm ground clearance mm kg mm 3 m kg 2 kg/cm mm mm kg mm kg mm kN m/min mm m

5770 2180

Operating weight w. straight blade ( varies due to pad width) Straight blade: blade width blade capacity weight - attachment complete ground pressure (varies due to pad width). length add.(lowered) length add.(raised) weight slope angle additional length weight height drawbar pull max. line pull max. line speed cable size max. length

24600 / 24950 4500 6,27 3610 0,46 / 0,42

0,72 / 0,59 / 0,53

Ripper(3):

Winch

PR 752
DIESEL ENGINE Type Construction Rating to ISO 9249 Rated RPM Low idle RPM High idle RPM Displacement Oil quantity incl. filter Oil specification Max. machine inclination - all directions Valve clearance -cold Firing order Coolant capacity / DCA 4 Fuel tank capacity Fuel consumption

F/N 32422005599 D 9406 TI-E A3 6 cyl. V - intercooled 243 (326 HP) 1800 +50 800 +60 1900 12,88 (786) 24 (25,4) see lube oil - group 1.3 45 = 100% 0,25 / 0,30 1-6-3-5-2-4 68 / 2,5 (17,9 / 0,66) 610 (161) 29 - 50 (7,6 - 13,2)

kW 1/min 1/min 1/min l (cu. in) l (qt)

intake/exhaust

mm

l (gal) l (gal) appr. l/h (gal/h)

SPLITTERBOX Type Construction Ratio Oil quantity Oil specification 350 B 365 1 stage spur gear i 0,83 l (qt) 6 (6,3) see lube oil - group 1.3

HYDRAULIC SYSTEM Travel pumps max. flow - Qmax max. operating pressure (M1 / M2) pmax Tandem gear pumps - replenishing/coolant circuit max. flow - Qmax total (Q1+Q2) max. operating pressure (SP) pmax Travel motors

type 2xBPV 200 L-EH l/min (gal/min) 2x425 (2x112,3) bar 420 HY/ZGGS11/45+38 L (F/N -20022006 = PRR 44+32 SC, type F/N -20072027 = HY/ZGGS11/45+32L) l/min (gal/min) 180 (47,6) (162 (42,8)) bar 25 type 4xBMV 186 HF A10V28 58 (15,3) 160 30 AA10FM28 1300 (350) SNM2/19 CO 02 1900 (500) HPR 160 336 (88,7) 30 200

Variable flow pump - fan drive max. flow - Qmax l/min (gal/min) max. operating pressure (LA) pmax bar stand by pressure (LA) (when machine is cold) bar Axial piston-constant motor (fan - water cooler) type operation RPM nmax (nmin) 1/min Gear motor (fan - hydraulic oil cooler) type operation RPM nmax (nmin) 1/min Variable flow working hydraulic pump max. flow - Qmax stand by pressure (HD) max. operating pressure (HD) pmax Control valve block - working hydraulic Servo - operating pressure - working hydraulic (ND) Hydr. tank capacity - +circuit capacity Oil specification type l/min (gal/min) bar bar

type M7-3022 bar 25 l (gal) 210 (55,4) l (gal) 170 (44,8) see lube oil - group 1.3

ELECTRICAL SYSTEM Voltage Batteries Alternator Starter Automatic circuit breaker Fuses V 24 2x12V 170Ah (in series) 28V 55A kW 9 A 45 A see Operation and Maintenance Manual /.. Benennung Description Dnomination Typ/ab Type/from Type/ a partir de

Mjfcifss!
Datum Edition Date

PR 752

01 03

Technical Data

F/N 324-20025599

Blatt Page Feuille

3.1.50.01

PR 752
TRAVEL GEAR Type Construction Parking brake (integrated) Ratio Oil quantity - gear area Oil quantity - sealed area Oil specification

F/N 32420025599 2xFAT 650 / 508 spur- + 2 stage planetary gear 4x disk brake i total 54,3 : 1 l (qt) 2x21 (22,2) l (qt) 9,4 (9,9) see lube oil - group 1.3

TRACK COMPONENTS Track chain pitch Track chain length Track pad width ( single grouser) Track pad bolts Track rollers - single flange (s) Track rollers - double flange (d) Track roller location Carrier rollers each side Max. roller frame oscillation

mm (inch) links mm thread. size qty. qty.

215,9 (8,5) 44 560 / 610 / 711 7/8 UNF 4 3 s-d-s-d-s-d-s qty. 2 3

ATTACHMENT Semi-U-Blade Lift cylinder Tilt cylinder Cutting angle cylinder Ripper 1 tooth / 3 teeth Lift cylinder Ripping angle cylinder piston / rod / stroke piston / rod / stroke piston / rod / stroke mm 120 / 070 / 1490 mm 200 / 090 / 0195 mm 220 / 090 / 0145

piston / rod / stroke piston / rod / stroke

mm 180 / 100 / 0480 mm 180 / 100 / 0480

GENERAL DATA Travel speed - 2 ranges normal range reduced range normal range = III reduced range - II reduced range - I due to ground condition measured horizontally height over cab overall length (transport dimension) length with semi-U blade track gauge (+1 width of 1 pad = total width) ground clearance km/h (mph) 0 11,0 (0 6,8) km/h (mph) 0 4,6 (0 2,8) km/h (mph) 0 11,0 (0 6,8) km/h (mph) 0 6,5 (0 4,0) km/h (mph) 0 4,0 (0 2,4) kN 460 mm 1123 mm mm mm mm mm 3640 4885 6515 2180 625

Travel speed - 3 ranges

Drawbar pull max. Mud depth max. Basic machine

Operating weight with semi-U blade (varies due to pad width) Ground pressure with semi-U blade (varies due to pad width) Semi-U blade blade width blade capacity weight blade complete add. length ripper lowered add. length ripper raised weight - ripper complete max. penetration max. slope angle weight - ripper complete max. penetration max. slope angle

kg 34200 / 34400 / 34800 kg/cm 0,96 / 0,89 / 0,77 mm 4200 m 9,54 kg 6350 mm mm kg mm 2390 1880 4200 1200 33 kg 4900 mm 855 29

Ripper 1 tooth

3 teeth

PR 752
DIESEL ENGINE Type Construction Rating to ISO 9249 Rated RPM Low idle RPM High idle RPM Displacement Oil quantity incl. filter Oil specification Max. machine inclination - all directions Valve clearance -cold Firing order Coolant capacity / DCA 4 Fuel tank capacity Fuel consumption

F/N 32456006199 D 9406 TI-E A3 6 cyl. V - intercooled 243 (326 HP) 1800 +60 750 +60 1900 12,88 (786) 26 (27,5) see lube oil - group 1.3 45 = 100% 0,25 / 0,30 1-6-3-5-2-4 68 / 2,5 (17,9 / 0,66) 610 (161) 29 - 50 (7,6 - 13,2)

kW 1/min 1/min 1/min l (cu. in) l (qt)

intake/exhaust

mm

l (gal) l (gal) appr. l/h (gal/h)

SPLITTERBOX Type Construction Ratio Oil quantity Oil specification 350 B 365 1 stage spur gear i 0,83 l (qt) 6 (6,3) see lube oil - group 1.3

HYDRAULIC SYSTEM Travel pumps max. flow - Qmax max. operating pressure (M1 / M2) pmax Tandem gear pumps - replenishing/coolant circuit max. flow - Qmax total (Q1+Q2) max. operating pressure (SP) pmax Travel motors

type l/min (gal/min) bar type l/min (gal/min) bar type

2xBPV 200 L-EH 2x425 (2x112,3) 420 HY/ZGGS11/45+38 L 180 (47,6) 25 4xBMV 186 HF A10V28 58 (15,3) 160 30 AA10FM28 1300 (350) SNM2/19 CO 02 1900 (550) HPR 160 336 (88,7) 30 200

Variable flow pump - fan drive max. flow - Qmax l/min (gal/min) max. operating pressure (LA) (electronic regulated) pmax bar stand by pressure (LA) (when machine is cold) bar Axial piston-constant motor (fan - water cooler) type operation RPM nmax (nmin) 1/min Gear motor (fan - hydraulic oil cooler) type operation RPM nmax (nmin) 1/min Variable flow working hydraulic pump max. flow - Qmax stand by pressure (HD) max. operating pressure (HD) pmax Control valve block - working hydraulic Servo - operating pressure - working hydraulic (ND) Hydr. tank capacity - +circuit capacity Oil specification type l/min (gal/min) bar bar

type M7-3022 bar 25 l (gal) 230 (60,7) l (gal) 170 (44,8) see lube oil - group 1.3

ELECTRICAL SYSTEM Voltage Batteries Alternator Starter Automatic circuit breaker Fuses V 24 2x12V 170Ah (in series) 28V 80A kW 9 A 45 A see Operation and Maintenance Manual

/.. Benennung Description Dnomination Typ/ab Type/from Type/ a partir de

Mjfcifss!
Datum Edition Date

01 03

Technical Data

PR 752
Blatt Page Feuille

F/N 324-56006199

3.1.51.01

PR 752
TRAVEL GEAR Type Construction Parking brake (integrated) Ratio Oil quantity - gear area Oil quantity - sealed area Oil specification

F/N 32456006199 2xFAT 650 / 508 spur- + 2 stage planetary gear 4x disk brake i total 54,3 : 1 l (qt) 2x21 (22,2) l (qt) 9,4 (9,9) see lube oil - group 1.3

TRACK COMPONENTS Track chain pitch Track chain length Track pad width ( single grouser) Track pad bolts Track rollers - single flange (s) Track rollers - double flange (d) Track roller location Carrier rollers each side Max. roller frame oscillation

mm (inch) links mm thread. size qty. qty.

215,9 (8,5) 44 560 / 610 / 711 7/8 UNF 4 3 s-d-s-d-s-d-s qty. 2 3

ATTACHMENT Semi-U-Blade Lift cylinder Tilt cylinder Cutting angle cylinder Ripper 1 tooth / 3 teeth Lift cylinder Ripping angle cylinder piston / rod / stroke piston / rod / stroke piston / rod / stroke mm 120 / 070 / 1490 mm 200 / 090 / 0195 mm 220 / 090 / 0145

piston / rod / stroke piston / rod / stroke

mm 180 / 100 / 0480 mm 180 / 100 / 0480

GENERAL DATA Travel speed - 2 ranges normal range reduced range normal range = III reduced range - II reduced range - I due to ground condition measured horizontally height over cab overall length (transport dimension) length with semi-U blade track gauge (+1 width of 1 pad = total width) ground clearance km/h (mph) 0 11,0 (0 6,8) km/h (mph) 0 4,6 (0 2,8) km/h (mph) 0 11,0 (0 6,8) km/h (mph) 0 6,5 (0 4,0) km/h (mph) 0 4,0 (0 2,4) kN 460 mm 1123 mm mm mm mm mm 3640 4885 6515 2180 625

Travel speed - 3 ranges

Drawbar pull max. Mud depth max. Basic machine

Operating weight with semi-U blade (varies due to pad width) Ground pressure with semi-U blade (varies due to pad width) Semi-U blade blade width blade capacity weight blade complete add. length ripper lowered add. length ripper raised weight - ripper complete max. penetration max. slope angle weight - ripper complete max. penetration max. slope angle

kg 34200 / 34400 / 34800 kg/cm 0,96 / 0,89 / 0,77 mm 4200 m 9,54 kg 6350 mm mm kg mm 2390 1880 4200 1200 33 kg 4900 mm 855 29

Ripper 1 tooth

3 teeth

PR 752
DIESEL ENGINE Type Construction Rating to ISO 9249 Rated RPM Low idle RPM High idle RPM Displacement Oil quantity incl. filter Oil specification Max. machine inclination - all directions Valve clearance -cold Firing order Coolant capacity / DCA 4 Fuel tank capacity Fuel consumption

F/N 3246200 D 9406 TI-E A3 6 cyl. V - intercooled 243 (326 HP) 1800 +60 750 +60 1900 12,88 (786) 26 (27,5) see lube oil - group 1.3 45 = 100% 0,25 / 0,30 1-6-3-5-2-4 68 / 2,5 (17,9 / 0,66) 610 (161) 29 - 50 (7,6 - 13,2)

kW 1/min 1/min 1/min l (cu. in) l (qt)

intake/exhaust

mm

l (gal) l (gal) appr. l/h (gal/h)

SPLITTERBOX Type Construction Ratio Oil quantity Oil specification 350 B 365 1 stage spur gear i 0,83 l (qt) 6 (6,3) see lube oil - group 1.3

HYDRAULIC SYSTEM Travel pumps max. flow - Qmax max. operating pressure (M1 / M2) pmax Tandem gear pumps - replenishing/coolant circuit max. flow - Qmax total (Q1+Q2) max. operating pressure (SP) pmax Travel motors

type l/min (gal/min) bar type l/min (gal/min) bar type

2xBPV 200 L-EH 2x425 (2x112,3) 420 HY/ZGGS11/45+38 L 180 (47,6) 25 4xBMV 186 HF A10V28 58 (15,3) 190 30 AA10FM28 1530 (350) SNM2/19 CO 02 2200 (550) HPR 160 336 (88,7) 30 200

Variable flow pump - fan drive max. flow - Qmax l/min (gal/min) max. operating pressure (LA) (electronic regulated) pmax bar stand by pressure (LA) (when machine is cold) bar Axial piston-constant motor (fan - water cooler) type operation RPM nmax (nmin) 1/min Gear motor (fan - hydraulic oil cooler) type operation RPM nmax (nmin) 1/min Variable flow working hydraulic pump max. flow - Qmax stand by pressure (HD) max. operating pressure (HD) pmax Control valve block - working hydraulic Servo - operating pressure - working hydraulic (ND) Hydr. tank capacity - +circuit capacity Oil specification type l/min (gal/min) bar bar

type M6-1149 bar 25 l (gal) 230 (60,7) l (gal) 170 (44,8) see lube oil - group 1.3

ELECTRICAL SYSTEM Voltage Batteries Alternator Starter Automatic circuit breaker Fuses V 24 2x12V 170Ah (in series) 28V 80A kW 9 A 45 A see Operation and Maintenance Manual

/.. Benennung Description Dnomination Typ/ab Type/from Type/ a partir de

Mjfcifss!
Datum Edition Date

01 03

Technical Data

PR 752
Blatt Page Feuille

F/N 324-6200

3.1.52.01

PR 752
TRAVEL GEAR Type Construction Parking brake (integrated) Ratio Oil quantity - gear area Oil quantity - sealed area Oil specification

F/N 3246200 2xFAT 650 / 508 spur- + 2 stage planetary gear 4x disk brake i total 54,3 : 1 l (qt) 2x21 (22,2) l (qt) 9,4 (9,9) see lube oil - group 1.3

TRACK COMPONENTS Track chain pitch Track chain length Track pad width ( single grouser) Track pad bolts Track rollers - single flange (s) Track rollers - double flange (d) Track roller location Carrier rollers each side Max. roller frame oscillation

mm (inch) links mm thread. size qty. qty.

215,9 (8,5) 44 560 / 610 / 711 7/8 UNF 4 3 s-d-s-d-s-d-s qty. 2 3

ATTACHMENT Semi-U-Blade Lift cylinder Tilt cylinder Cutting angle cylinder Ripper 1 tooth / 3 teeth Lift cylinder Ripping angle cylinder piston / rod / stroke piston / rod / stroke piston / rod / stroke mm 120 / 070 / 1490 mm 200 / 090 / 0195 mm 220 / 090 / 0145

piston / rod / stroke piston / rod / stroke

mm 180 / 100 / 0480 mm 180 / 100 / 0480

Travel speed

GENERAL DATA normal range = III reduced range - II reduced range - I due to ground condition measured horizontally height over cab overall length (transport dimension) length with semi-U blade track gauge (+1 width of 1 pad = total width) ground clearance

km/h (mph) 0 11,0 (0 6,8) km/h (mph) 0 6,5 (0 4,0) km/h (mph) 0 4,0 (0 2,4) kN 460 mm 1123 mm mm mm mm mm 3640 4885 6515 2180 625

reverse 0 7,8 (0 4,8) reverse 0 4,8 (0 3,0)

Drawbar pull max. Mud depth max. Basic machine

Operating weight with semi-U blade (varies due to pad width) Ground pressure with semi-U blade (varies due to pad width) Semi-U blade blade width blade capacity weight blade complete add. length ripper lowered add. length ripper raised weight - ripper complete max. penetration max. slope angle weight - ripper complete max. penetration max. slope angle

kg 34200 / 34400 / 34800 kg/cm 0,96 / 0,89 / 0,77 mm 4200 m 9,54 kg 6350 mm mm kg mm 2390 1880 4200 1200 33 kg 4900 mm 855 29

Ripper 1 tooth

3 teeth

Customer:.................................................Mach.-Type..............F/N.........-..............Hours...............Date.............
Maintenance by operating hours

WORK TO BE CARRIED OUT {


by maintenance personnel first and only maintenance interval repeat maintenance interval by authorized trained personnel OM operation/maintenance manual SM service manual

every 8 - 10

every 1000

every 2000

at delivery

every 250

every 500

at 10 - 50

cFor correct oil level, use dipstick marks - for procedure and quantities, see OM d For quality and viscosity guidelines see Service Fluids, SM - section 1.3 e For adjustment values, see data page entries in SM

Reference

Notes

DIESEL ENGINE { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { {
Check engine oil level and pressure Check coolant level Check radiator cap and fan Replace coolant filter, check antifreece / DCA4 percentage in coolant Check fuel filter water seperator - drain if necessary Replace engine oil Replace lube oil filter PR 712B / 722B - Replace fuel finefilter element - stage 2 Check condition and tension of V-belt Check engine, radiator and oil pan for dirt - clean if necessary Check oil, cooling and fuel system for leaks and condition Check air intake and exhaust system for tightness and leaks Check oil pan and engine mounts for condition and tightness Check engine RPM - adjust if necessary Check and adjust valve clearance - with cold engine OM OM OM OM SM (before cold season) OM OM OM OM SM SM SM SM - every 2 years - every 2 years - every 2 years / 3000 hrs. - if necessary or at least every 3000 operating hours - if necessary or at least once a year SM Check and service injection pump and potentiometer linkage Drain fuel tank condensation and sediments PR 732B / 742B / 752 - Check fuel prefilter element - clean if necessary PR 732B / 742B / 752 - Replace fuel filter cartridge Grease flywheel teeth Check preheater system PR 712B / 722B - Replace fuel prefilter element - stage 1 Replace air filter elements Replace oil separator Replace coolant / corrosion inhibitor and DCA4 Check / adjust fuel injectors Check coolant pump (at PR 752 not necessary) - at least once a year - at least once a year OM OM OM OM OM OM OM OM OM OM OM OM OM SM SM SM SM SM SM SM SM SM SM

c c cd cd

e e

cd e e c

HYDRAULIC SYSTEM { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { {
Check oil level in hydraulic tank Clean magnetic rod - daily up to 250 operating hours Replace return oil filter element in hydraulic tank, check all case drain filter inserts for deposits / contamination Replace pressure filter (element) of the repl. circuit Check attachment and travel hydraulic system for function and leaks, check hydraulic hose routing / for chafing Drain hydraulic tank condensation and sediments (at least every 6 months) Check hydraulic oil cooler - clean if necessary + check fan at PR 752 Check all hydraulic pressures according setting prescription, adjust as necessary Check allscrews, nuts connections for tightness Replace hydraulic oil (refill via tank filter) - al least every 4 years - Whenever environmentally safe hydraulic fluids are used request / observe any special guidelines from manufacturer OM OM OM OM OM OM OM OM OM SM SM SM SM SM

e cd

Benennung Description Dnomination

Typ/ab

Type/from

Type/a partir de

Mjfcifss!
Datum Edition Date

Maintenance and

01 00

Inspection Guidelines

PR 712 B PR 722 B PR 732 B PR 742 B PR 752


Blatt Page Feuille

F/N xxx- 3000 F/N xxx- 3000 F/N xxx-3000 3039 F/N xxx-3000 3024 F/N xxx-2002 2008

3.2.12.01

Maintenance by operating hours

WORK TO BE CARRIED OUT {


by maintenance personnel first and only maintenance interval repeat maintenance interval by authorized trained personnel OM operation/maintenance manual SM service manual Durchfhrungshinweis Bemerkungen

every 8 - 10

every 1000

every 2000

at delivery

every 250

every 500

at 10 - 50

cFor correct oil level, use dipstick marks - for procedure and quantities, see OM d For quality and viscosity guidelines see Service Fluids, SM - section 1.3 e For adjustment values, see data page entries in SM

SPLITTERBOX { { { { { { { {
Check oil level Replace gear oil - at least once a years OM OM

c cd

ELECTRICAL SYSTEM { { { { { { { { { { { { { { { { { { { { {
Check system function incl. indicators and gauges Check battery electrolyte level Check, clean and grease battery terminals Check wire routing and connections Check control system according to adjustment checklist - adjust as necessary Check battery acid concentration / charge (before cold season) OM OM OM OM SM SM SM SM SM

e e

HEATER / FRESH AIR SYSTEM { { { {


Check system for function and leaks Replace air filter - as necessary OM OM SM

TRAVEL GEAR { { { { { { { { {
Check oil level - clean magnetic plugs / magnetic rods Check screws and nuts for tightness Replace gear oil - clean magnetic plugs / magnetic rods - at least every 4 years OM OM OM SM

c cd

TRACK COMPONENTS { { { { { { { { { { { { { {
Check all bolts and nuts of track components, in particular at track pads and sprocket segments for tightness Check track and carrier rollers, idlers for leaks PR 752 - grease outer bearings of equalizer bar Check idler guides / adjust, replace parts as necessary PR 752 - check screws at the outher rings of support shafts for tight seating Adjust chain tension to suit application Clean track components Check track components for wear - as necessary - as necessary - as necessary - shorten interval as necessary OM OM OM OM OM OM OM SM SM SM SM SM

e e

ATTACHMENTS { { { { { { { { { { { { { { { { { { { { { { { {
Check blade adjustment / centered to main frame - after every installation OM OM OM OM OM OM SM Check bolts, nuts and pin safeties for tightness Check all cutting edges, corner shanks and ripper teeth for wear, check if attachments are suited to application Check attachments for damage Check all attachment bearings for play / wear Grease all bearings including lift cylinder forks according to the lubrication chart - shorten interval as necessary

e d

GENERAL { { { {
Check entire machine for proper maintenance and condition PR 752 - Grease door hinges on battery and oil cooler room - as necessary OM OM SM

Customer:...............................................Mach.-Type...........F/N.........-.............Hours..............Date............
Maintenance by operating hours

WORK TO BE CARRIED OUT {


by maintenance personnel first and only maintenance interval repeat maintenance interval by authorized trained personnel OM operation/maintenance manual SM service manual

every 8 - 10

every 1000

every 2000

at delivery

every 250

every 500

every 50

cFor correct oil level, use dipstick marks - for procedure and quantities, see OM d For quality and viscosity guidelines see Service Fluids, SM - section 1.3 e For adjustment values, see data page entries in SM

Reference

Notes

DIESEL ENGINE { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { {
Check engine oil level and pressure Check coolant level Check engine, radiator and oil pan for dirt - clean if necessary Check fuel filter water seperator - drain if necessary Drain fuel tank condensation and sediments Replace engine oil Replace lube oil filter ( = as soon as after 30 operating hours) ( = as soon as after 30 operating hours) - al least once a week - at least once a year - at least once a year OM OM OM OM OM OM OM / SM OM / SM OM / SM OM / SM OM / SM OM / SM OM / SM SM SM OM / SM OM OM OM SM (before cold season) - if necessary or at least once a year - every 2 years - every 2 years - if necessary or at least every 3000 operating hours SM OM OM / SM OM / SM SM

c c

cd

Check radiator cap and fan Replace coolant filter, check antifreece / DCA4 percentage in coolant Check condition and tension of V-belt Check oil, cooling and fuel system for leaks and condition Check air intake and exhaust system for tightness and leaks Check oil pan and engine mounts for condition and tightness Check engine RPM - adjust if necessary Check and adjust valve clearance - with cold engine Check and service injection pump and potentiometer linkage PR 712B / 722B - Replace fuel filter(s) (prefilter and fine filter elements) - stage 1 and 2 PR 732B / 742B / 752 - Check fuel prefilter element - clean if necessary PR 732B / 742B / 752 - Replace fuel filter cartridge Grease flywheel teeth Check preheater system Replace air filter elements Replace oil separator Replace coolant / corrosion inhibitor and DCA4 Check / adjust fuel injectors

cd

{ {

e e

cd e

HYDRAULIC SYSTEM { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { {
Check oil level in hydraulic tank Clean magnetic rod - daily up to 250 operating hours Replace return oil filter element in hydraulic tank, check all case drain filter inserts for deposits / contamination Replace pressure filter (element) of the repl. circuit Check attachment and travel hydraulic system for function and leaks, check hydraulic hose routing / for chafing Drain hydraulic tank condensation and sediments (at least every 6 months) Check hydraulic oil cooler - clean if necessary + PR 752 - fan for condition Check all hydraulic pressures according setting prescription, adjust as necessary Check allscrews, nuts connections for tightness Replace hydraulic oil (refill via tank filter) - al least every 4 years - Whenever environmentally safe hydraulic fluids are used request / observe any special guidelines from manufacturer OM OM / SM OM / SM OM OM / SM OM OM SM OM / SM OM

e cd

Benennung Description Dnomination

Typ/ab

Type/from

Type/a partir de

Mjfcifss!
Datum Edition Date

Maintenance and

01 00

Inspection Guidelines

PR 712 B PR 722 B PR 732 B PR 742 B PR 752


Blatt Page Feuille

F/N xxx-3001 3083 F/N xxx-3001 3170 F/N xxx-3040 3135 F/N xxx-3025 3088 F/N xxx-2009 2059

3.2.13.01

Maintenance by operating hours

WORK TO BE CARRIED OUT {


by maintenance personnel first and only maintenance interval repeat maintenance interval by authorized trained personnel OM operation/maintenance manual SM service manual

every 8 - 10

every 1000

every 2000

at delivery

every 250

every 500

every 50

cFor correct oil level, use dipstick marks - for procedure and quantities, see OM d For quality and viscosity guidelines see Service Fluids, SM - section 1.3 e For adjustment values, see data page entries in SM

Reference

Notes

SPLITTERBOX { { { { { { { {
Check oil level Replace gear oil - at least every 2 years OM OM

c cd

ELECTRICAL SYSTEM { { { { { { { { { { { { { { { { { { { { {
Check system function incl. indicators and gauges Check battery electrolyte level Check, clean and grease battery terminals Check wire routing and connections Check control system according to adjustment checklist - adjust as necessary Check battery acid concentration / charge (before cold season) OM / SM OM OM / SM OM / SM SM SM

e e

HEATER / FRESH AIR SYSTEM { { { {


Check system for function and leaks Replace air filter - as necessary OM / SM OM

TRAVEL GEAR { { { { { { { { { { {
Check oil level - clean magnetic plugs / magnetic rods Check screws and nuts for tightness Replace gear oil - clean magnetic plugs / magnetic rods PR 752 - replace lube oil from cone seal area - at least every 4 years - at least every 4 years OM OM / SM OM OM

c cd cd

TRACK COMPONENTS { { { { { { { { { { { { { {
Check all bolts and nuts of track components, in particular at track pads and sprocket segments for tightness Check track and carrier rollers, idlers for leaks PR 752 - grease outer bearings of equalizer bar Check idler guides / adjust, replace parts as necessary PR 752 - check screws at the outher rings of support shafts for tight seating Adjust chain tension to suit application Clean track components Check track components for wear - as necessary - as necessary - as necessary - shorten interval as necessary OM / SM OM OM OM / SM OM / SM OM / SM OM SM

e e

ATTACHMENTS { { { { { { { { { { { { { { { { { { { { { { { { {
Check all cutting edges, corner shanks and ripper teeth for wear, check if attachments are suited to application Grease all bearings including lift cylinder forks according to the lubrication chart - shorten interval as necessary Check all attachment bearings for play / wear Check blade adjustment / centered to main frame Check bolts, nuts and pin safeties for tightness Check attachments for damage - after every installation OM OM OM / SM OM OM OM

d e

GENERAL { { { { {
Check entire machine for proper maintenance and condition PR 752 - Grease door hinges on battery and oil cooler room - as necessary Explain machine literature and/or special instructions / safety guidelines to operating personnel OM / SM

OM

Customer:............................................Mach.-Type...........F/N(PIN).........-..............Sm.-hours............Date............
Maintenance/Inspection by Operating Hours

WORK TO BE CARRIED OUT {


by maintenance personnel first and only maintenance interval repeat maintenance interval by authorized trained personnel OM Operation Manual SM Service Manual

every 8 - 10

every 1000

every 2000

at delivery

every 250

every 500

every 50

cfor correct oil level, use dipstick marks - for procedure and quantities, see OM d for quality and viscosity guidelines see "Service fluids", SM - section 1.3 e for adjustment values, see data page entries in SM

Reference

Notes

DIESEL ENGINE { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { {
Check engine oil level and pressure Check coolant level Check engine, radiator and belly pan for dirt - clean if necessary Check fuel filter water separator / drain if necessary Drain fuel tank condensation and sediments Replace engine oil Replace lube oil filter Check radiator cap and fan Replace coolant filter, check antifreeze / DCA4 percentage in coolant Check condition and tension of V-belt Check oil, cooling and fuel system for leaks and condition Check air intake and exhaust system for tightness and leaks Check oil pan and engine mounts for condition and tightness Check engine RPM - adjust if necessary Check and adjust valve clearance - with cold engine OM OM OM SM (before start of cold season) - if necessary or at least once a year - every 2 years - every 2 years - if necessary or at least every 3000 operating hours OM OM OM SM SM SM SM Check and service injection pump and potentiometer linkage PR 712B / 722B - Replace fuel pre- and fine filter elements - stage 1 and 2 PR 732B / 742B / 752 - Check fuel prefilter strainer / clean if necessary PR 732B / 742B / 752 - Replace fuel filter cartridge Grease flywheel teeth Check flame glow plug system Replace air filter elements Replace oil separator Replace coolant with antifreeze and DCA4 Check / adjust fuel injectors - at least once a week - at least once a year - at least once a year OM OM OM OM OM OM OM OM OM OM OM OM OM SM SM SM SM SM SM SM SM SM SM

c c

cd

cd

{ {

e e

cd e

HYDRAULIC SYSTEM { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { {
Check oil level in hydraulic tank Clean magnetic rod - daily up to 250 operating hours Replace return oil filter element in hydraulic tank, check all case drain filter inserts for deposits / contamination Replace pressure filter (element) of the repl. circuit Check attachment and travel hydraulic system for function and leaks, check hydraulic hose routing for chafing Drain hydraulic tank condensation and sediments (at least every 6 month) Check hydraulic oil cooler for dirt / clean if necessary, check fan for condition Check / adjust all hydraulic pressures according to adjustment checklist Check mountings and fittings for tight seating Replace hydraulic oil (refill via tank filter) - at least every 4 years - whenever environmentally safe hydraulic fluids are used request / observe any special guidelines from manufacturer OM OM OM OM OM OM OM OM OM SM SM SM SM SM

e cd

Benennung Description Dnomination

Typ/ab

Type/from

Type/a partir de

Mjfcifss!
Datum Edition Date

Maintenance and

01 00

Inspection Guidelines

PR 712 B PR 722 B PR 732 B PR 742 B PR 752


Blatt Page Feuille

F/N xxx-3084 5599 F/N xxx-3171 5599 F/N xxx-3136 5599 F/N xxx-3089 5599 F/N xxx-2060 5599

3.2.14.01

Maintenance/Inspection by Operating Hours

WORK TO BE CARRIED OUT {


by maintenance personnel first and only maintenance interval repeat maintenance interval by authorized trained personnel OM Operation Manual SM Service Manual

every 8 - 10

every 1000

every 2000

at delivery

every 250

every 500

every 50

cfor correct oil level, use dipstick marks - for procedure and quantities, see OM d for quality and viscosity guidelines see "Service fluids", SM - section 1.3 e for adjustment values, see data page entries in SM

Reference

Notes

SPLITTERBOX { { { { { { { {
Check oil level Replace gear oil - at least every 2 years OM OM

c cd

ELECTRICAL SYSTEM { { { { { { { { { { { { { { { { { { { { {
Check system functions incl. indicators and gauges Check battery electrolyte level Check, clean and grease battery terminals Check wire routing and connections Check control system according to adjustment checklist / adjust as necessary Check battery acid concentration / charge (before start of cold season) OM OM OM OM SM SM SM SM SM

e e

HEATER / FRESH AIR SYSTEM { { { {


Check system for function and leaks Replace fresh air filter - as necessary OM OM SM

TRAVEL GEAR { { { { { { { { { { {
Check oil level - clean magnetic plugs / magnetic rods Check bolts and nuts for tightness Replace gear oil - clean magnetic plugs / magnetic rods Replace lube oil from cone seal area - at least every 4 years - at least every 4 years OM OM OM OM SM

c cd cd

TRACK COMPONENTS { { { { { { { { { { { { { {
Check all bolts and nuts of track components, in particular at track pads and sprocket segments for tightness Check carrier rollers, track rollers and idlers for leaks PR 752 - grease outer bearings of equalizer bar Check idler guides / adjust, replace parts as necessary PR 752 - check screws at the outer rings of support shafts for tight seating Adjust chain tension to suit application Clean track components Check track components for wear - as necessary - as necessary - as necessary - shorten interval as necessary OM OM OM OM OM OM OM SM SM SM SM SM

e e

ATTACHMENTS { { { { { { { { { { { { { { { { { { { { { { { { {
Check all cutting edges, corner shanks and ripper teeth for wear, check if attachments are suited to application Grease all bearings including lift cylinder forks according to the lubrication chart - shorten interval as necessary Check all attachment bearings for play / wear Check blade adjustment / centered to main frame Check bolts, nuts and pin safeties for tightness Check attachments for damage - after every installation OM OM OM OM OM OM SM

d e

GENERAL { { { { {
Check entire machine for proper maintenance and condition PR 752 - Grease door hinges on battery and oil cooler room - as necessary Explain machine literature, in specially Operation Manual-safety guidelines to the operating personnel OM OM OM SM

Customer:............................................Mach.-Type...........F/N(PIN).........-..............Sm.-hours............Date............
Maintenance/Inspection by Operating Hours

WORK TO BE CARRIED OUT {


by maintenance personnel first and only maintenance interval repeat maintenance interval by authorized trained personnel OM Operation Manual SM Service Manual

every 8 - 10

every 1000

every 2000

at delivery

every 250

every 500

every 50

cfor correct oil level, use dipstick marks - for procedure and quantities, see OM d for quality and viscosity guidelines see "Service fluids", SM - section 1.3 e for adjustment values, see data page entries in SM

Reference

Notes

DIESEL ENGINE { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { {
Check engine oil level and pressure Check coolant level Check engine, radiator and belly pan for dirt - clean if necessary Check fuel filter water separator / drain if necessary Drain fuel tank condensation and sediments Replace engine oil Replace lube oil filter Check radiator cap and fan Replace coolant filter, check antifreeze / DCA4 percentage in coolant Check condition and tension of V-belt Check oil, cooling and fuel system for leaks and condition Check air intake and exhaust system for tightness and leaks Check oil pan and engine mounts for condition and tightness Check engine RPM - adjust if necessary Replace fuel prefilter - filter element Check and adjust valve clearance Replace fuel fine filter cartridge Grease flywheel teeth Check flame glow plug system Replace air filter elements Replace oil separator Replace coolant with antifreeze and DCA4 Check / adjust fuel injectors (before start of cold season) - if necessary or at least once a year - every 2 years - every 2 years - if necessary or at least every 3000 operating hours OM OM OM SM SM SM - with cold engine OM OM SM SM Check and service injection pump and potentiometer linkage OM SM SM - at least once a week - at least once a year - at least once a year OM OM OM OM OM OM OM OM OM OM OM OM OM SM SM SM SM SM SM SM SM

c c

cd

cd

{ {

e e

cd e

HYDRAULIC SYSTEM { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { { {
Check oil level in hydraulic tank Clean magnetic rod - daily up to 250 operating hours Replace return oil filter element in hydraulic tank, check all case drain filter inserts for deposits / contamination Replace pressure filter (element) of the replenishing circuit Check attachment and travel hydraulic system for function and leaks, check hydraulic hose routing for chafing Drain hydraulic tank condensation and sediments (at least every 6 month) - whenever environmentally safe hydraulic fluids are used drain once a week Check hydraulic oil cooler for dirt / clean if necessary, check fan for condition Check / adjust all hydraulic pressures according to adjustment checklist Check mountings and fittings for tight seating Replace hydraulic oil (refill via tank filter) - at least every 4 years - whenever environmentally safe hydraulic fluids are used request / observe any special guidelines from manufacturer OM OM OM OM OM OM OM OM OM SM SM SM SM SM

e cd

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Maintenance and
Datum Edition Date

PR 712B PR 722B PR 732B PR 742B PR 752


Blatt Page Feuille

01 03

Inspection Guidelines

F/N xxx-5600 F/N xxx-5600 F/N xxx-5600 F/N xxx-5600 F/N xxx-5600

3.2.15.01

Maintenance/Inspection by Operating Hours

WORK TO BE CARRIED OUT {


by maintenance personnel first and only maintenance interval repeat maintenance interval by authorized trained personnel OM Operation Manual SM Service Manual

every 8 - 10

every 1000

every 2000

at delivery

every 250

every 500

every 50

cfor correct oil level, use dipstick marks - for procedure and quantities, see OM d for quality and viscosity guidelines see "Service fluids", SM - section 1.3 e for adjustment values, see data page entries in SM

Reference

Notes

SPLITTERBOX { { { { { { { {
Check oil level Replace gear oil - at least every 2 years OM OM

c cd

ELECTRICAL SYSTEM { { { { { { { { { { { { { { { { { { { { {
Check system functions incl. indicators and gauges Check battery electrolyte level Check, clean and grease battery terminals Check wire routing and connections Check control system according to adjustment checklist / adjust as necessary Check battery acid concentration / charge (before start of cold season) OM OM OM OM SM SM SM SM SM

e e

HEATER / FRESH AIR SYSTEM { { { {


Check system for function and leaks Replace fresh air filter - as necessary OM OM SM

TRAVEL GEAR { { { { { { { { { { {
Check oil level - clean magnetic plugs / magnetic rods Check bolts and nuts for tightness Replace gear oil - clean magnetic plugs / magnetic rods Replace lube oil from cone seal area / flush cone seal area - at least every 4 years - at least every 4 years OM OM OM OM SM

c cd cd

TRACK COMPONENTS { { { { { { { { { { { { { {
Check all bolts and nuts of track components, in particular at track pads and sprocket segments for tightness Check carrier rollers, track rollers and idlers for leaks PR 752 - grease outer bearings of equalizer bar Check idler guides / adjust, replace parts as necessary PR 752 - check screws at the outer rings of support shafts for tight seating Adjust chain tension to suit application Clean track components Check track components for wear - as necessary - as necessary - as necessary - shorten interval as necessary OM OM OM OM OM OM OM SM SM SM SM SM

e e

ATTACHMENTS { { { { { { { { { { { { { { { { { { { { { { { { {
Check all cutting edges, corner shanks and ripper teeth for wear, check if attachments are suited to application Grease all bearings including lift cylinder forks according to the lubrication chart - shorten interval as necessary Check all attachment bearings for play / wear Check blade adjustment / centered to main frame Check bolts, nuts and pin safeties for tightness Check attachments for damage - after every installation OM OM OM OM OM OM SM

d e

GENERAL { { { { {
Check entire machine for proper maintenance and condition PR 752 - Grease door hinges on battery and oil cooler room - as necessary Explain machine literature, in specially Operation Manual-safety guidelines to the operating personnel OM OM OM SM

1. General Guidelines 1.1. Documentation of work to be performed All maintenance work is noted in the Maintenance and Inspection Guidelines for the subject machine model, see group 3.2. A detailed record of completed work can be made by checking off all completed items on a report form and comparison with this list. Record the values obtained during adjustment checks on the adjustment check list form for the corresponding machine model, see group 3.5. In addition, confirm the completion of the inspection / delivery in the machines inspection notebook, send the appropriate service check to the applicable LIEBHERR representative. Remove the old sticker and attach the next inspection sticker, which is also in the notebook, in a clearly visible location in the operators cab of the machine. Explain the set-up and contents of the machine literature to the operator. Emphasize the safety guidelines and regulations and all necessary maintenance work to be carried out between inspections. 1.2. Safety Guidelines When performing any maintenance, inspection or repair work, observe all appropriate safety guidelines as outlined in group 1.2.01 and in the Operation and Maintenance Manual. In addition, observe all regional labors laws and regulations, accident prevention regulations and all applicable local, state and national laws and regulations. 1.3. Intervals Never exceed the given maintenance and inspection intervals; they can be shortened, if necessary. For example: replace the filters and drain the sediment in the fuel tank in case of contamination, clean the radiator in case of contamination, replace the filters and change the oil during and after repairs, etc. 1.4. Oil samples Any required oil samples must be taken directly from the component before changing the oil. Before taking the oil sample, operate the machine to circulate the oil to distribute any existing concentration of particles and to prevent incorrect test results due to deposits. To determine any residual contamination after the repair is completed, take another sample shortly after putting the machine back in service. Use the hand pump and take an oil sample from the center of the oil tank, do not overfill the oil sample container. Replace the suction hose on the hand pump after taking an oil sample. Fill out all forms to be submitted with the oil sample correctly and completely. Incorrect information can lead to unnecessary measures or to the elimination of necessary procedures and cause unnecessary charges. For further details, refer to the oil sample documentation. 1.5. Oils, filters and miscellaneous If possible, always drain the oil at operating temperature. For that reason complete all work, which has to be performed when the machine is cold first, such as adjusting the valves on the Diesel engine. Change the oil filters after draining the oil and before adding new oil. Before restarting the machine, bleed the system, as necessary. Turn the starter for 10 - 15 seconds before starting the Diesel engine. When possible, cut open the replaced filter cartridges and check them for abnormal deposits. The type and amount of deposits can give clues about the condition of the system and / or future problems. Dispose of used oil, filters and other waste products in an environmentally safe manner !

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Maintenance and Inspection


Datum Edition Date

PR Litronic LR Litronic RL Litronic


Blatt Page Feuille

01 04

Instructions

3.4.10.01

Use only original LIEBHERR spare part and supplies for all maintenance, inspection and repair work. If the operator insists on the installation of other parts, inform the operator that this could cause potential loss of warranty coverage; make sure to note this request and installation on the inspection report. For tightening torques, refer to page 1.4.02. For torque instructions for track pad and sprocket segment screws, refer to page 12.1.00.

2. Maintenance guidelines 2.1. Diesel engine maintenance On new machines, make sure to observe the first oil and filter change interval, because corrosion inhibitors have been added to the engine oil at the factory.

2.1.1 Change the lube oil filter Loosen the filter cartridges with a filter band and unscrew them by hand. Refer to the Operation and Maintenance Manual for installation position. Standing filters can also be removed with a suitable tool on the top of the cartridges. The filters are designed to retain the oil in the filters! 'Hand-tighten' (30 Nm) the filter cartridges.

2.1.2 Check the radiator cap and fan Radiator cap - Check the seal and function of the pressure relief valve. Replace the radiator cap, if necessary. Note: Insufficient pressure in the cooling system increases formation of vapors and can damage the engine. Check the fan for damage and make sure the distance between the fan and the radiator guard is the same on all sides. Adjust the guard, if necessary.

2.1.3 Check / replace the coolant / antifreeze mixture / corrosion inhibitor - in cooling systems without coolant filter Check the required percentage of antifreeze or corrosion inhibitor with an optical densimeter - see Special Tools, page 2.1.30.01. The test procedure is independent of the coolant temperature. A line between light and dark on the right scale of the sight gauge shows the protection value. When using antifreeze / corrosion inhibitor, the lowest temperature for which antifreeze protection is provided will be shown ( minus values above the 0 C mark, protection should be provided to - 37 C). Refer to the user instructions given by the manufacturer for further details. If in certain exceptional cases, the system is filled only with corrosion inhibitors, use the same scale to read the protection. Each -1C corresponds to 1% by volume of corrosion inhibitor (nominal value = 1%). Replace the coolant containing antifreeze every 2 years. Replace all special mixtures once a year. To drain the coolant from radiator and engine block, refer to instructions given in the Operation and Maintenance Manual. See also group 1.3.01 - Service items, paragraph 1.3 - Coolant. If required, check the coolant pump before refilling, see paragraph 2.1.11. 2.1.4 Check / replace coolant - antifreeze and DCA4 concentration - in cooling systems with a coolant filter Check the DCA4 concentration before changing the coolant filter. Check for possible gel formation. Use the DCA4 test kit CC2602M, see Special Tools, group 2.1 to check the system. The kit contains multilanguage test instructions and maintenance guidelines, which must be observed. Check the expiration date of the test kit (example: "Use before Nov.1999").

If gel build up is found, drain the coolant and clean the system. Before refilling, check coolant / antifreeze quality and specification. The antifreeze may not be out of date nor emit silicates. Note: To prepare the coolant mixture, mix water first with the correct ratio of DCA4. Then add the required quantity of antifreeze to the water - DCA4 mixture and mix thoroughly. Replace the coolant with antifreeze and DCA4 every 2 years. Replace special coolant fluids every year. For details on draining the coolant from radiator and engine block, refer to the Operation and Maintenance Manual. See also group 1.3.01 - Service items, paragraph 1.3 - Coolant. If necessary, check the coolant pump before refilling, see 2.1.11. 2.1.5 V-belt - Check condition and tension Check the belt tension manually, as outlined in the "Operation and Maintenance Manual". To check the V-belt tension with the Krikit test unit, (Id. No. 8122560), refer to the Diesel Engine Manual. Replace worn or brittle V-belts. For details on adjusting and changing the belt, refer to the "Operation and Maintenance Manual".

2.1.6 Check the oil, cooling and fuel systems as well as the intake and exhaust systems Check the systems for leaks, damage and chafed hoses. Repair leaks immediately, tighten loose connections, fittings and hose clamps. Replace chafed hoses or lines. Make sure they are routed properly to prevent chafing and kinks. Check the radiator mounts, change the radiator mounts, if necessary. Check the air filter housing and filter elements in the housing to ensure they are seated tightly. If applicable, replace damaged parts, seals and elements. 2.1.7 Checking the oil pan and engine mounts for tightness Check the screws on the oil pan and engine mounts, retighten if necessary. For torque values, see group 1.4. Check engine mounts, change engine mounts, if necessary. For torque values, see page 15.3. Check other fittings and components, such as fuel injectors, to ensure they are tight. 2.1.8 Check / adjust engine RPM - Service mechanical linkage to injection pump and potentiometer Check the RPMs when you check the electronic control system. See Adjustment checklist, group 3.5. If the required high / low idle RPMs are not reached, adjust the stop screws on the engine throttle control in the cab, adjust the routing / adjustment of the shut off and throttle control cable, check the neutral functions of hydraulic systems, and - if necessary - check the adjustment of the injection pump - see group 17.4. The engine RPMs can also be checked with an impulse tachometer (connect to a clear injection line), see Special Tools, page 2.1.10. Check the mechanical linkage to the injection pump and potentiometer for damage, check the ball joints for wear. Replace any damaged or worn parts.

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Maintenance and Inspection


Datum Edition Date

PR Litronic LR Litronic RL Litronic


Blatt Page Feuille

01 04

Instructions

3.4.10.02

2.1.9 Check / adjust valve clearance Check and adjust valve clearance when the engine is cold (ambient temperature). For valve clearance, firing order and cylinder location, see page 4.3.10.01. For further details and adjustment instructions, refer to the Diesel Engine Manual. Install the engine turning fixture, see Special Tools page 2.1.10 (see point 2.1.10) in place of the cover on the flywheel housing. 2.1.10 Check / grease the flywheel teeth Remove the cover from the flywheel housing and check the flywheel teeth. Apply about 1 cm of grease in the visible tooth cavity. Reinstall the cover. Note: Whenever possible, use non-metallic based greases. High metal or graphite content as well as too much grease combined with metallic friction, can cause problems with the RPM sensor signal.

2.1.11 Check the flame glow plug system - Replace the oil seperator - Check / test the fuel injectors - Check the coolant pump A defective flame glow plug system can impair the starting performance of the Diesel engine. For that reason, check the system before the start of the cold season. The diaphragm of the oil separator can leak due to aging or external damage and cause contamination damage to the engine. Check the service time and replace old or damaged oil separators. Check / test fuel injectors if there is any decrease in performance, if the engine runs rough, if you hear the engine knocking, or if the exhaust is black. If required, remove the cover on the coolant pump and check the axial play of the pump shaft with a dial indicator. If the axial play 0.1 mm, change the coolant pump. For further details, refer to the Diesel Engine Manual.

2.2. Inspect the hydraulic system 2.2.1 Clean the magnetic rod in the hydraulic tank Check and clean the magnetic rod daily on new machines and after repairs until you find only a minute amount of particles. Check the magnetic rod at regular intervals. Any increase in particles indicate abnormal wear. 2.2.2 Check / replace the return filter elements Replace the main return filter elements installed in the hydraulic tank. Check all case drain filters on travel pumps, motors and attachment pump for contamination. If any deposits are found, determine their origin and cause. Repair or replace components, as necessary. Replace case drain filters. 2.2.3 Check the working and the travel hydraulic system for function and leaks / check hose routing and check hoses for chafting, check mountings and fittings for tightness Actuate all travel and working functions, check for problems. Check the actuating disc, plunger and universal joint of the working hydraulic joysticks for wear, lubricate lightly and adjust, as necessary. For details, refer to page 8.5.01.02. Proceed the same way for pilot controls for added attachments. To check the accumulator (safety control) for the working hydraulic (except for on RL machines), start the Diesel engine and raise the front attachment. Shut off the engine (turn ignition key again to position 1) and leave the safety lever in raised position. Actuate the ' attachment down' function quickly and several times. If the attachment can be lowered less than 4 times, the accumulator is defective or there is excessive leakage in the system.

Check hoses and lines for leaks, make sure there are no kinks. Check for chafing. Replace chafed, sweaty (brittle) and old hoses! See safety guidelines, page 1.2.01.07. Do not route control, leak oil and tank lines and hoses together with high pressure hoses, do not route them over sharp corners, edges or hose fittings. Check connections for leaks and replace seal rings, as necessary. Check piston rods for damage, check piston rod bearings for leaks. Repair, as necessary. Check mounting screws on hydraulic components (pumps, motors, tank, etc.) as well as flange connections for tightness. Retighten, if necessary. 2.2.4 Check / adjust all hydraulic pressures Carry out pressure checks / adjustments according to adjustment checklist for the corresponding machine model - see group 3.5 - and record the results. For further details, data and instructions, refer to the quick reference for the adjustment checklist or the appropriate section in the Service Manual.

2.3. Inspect the electrical system 2.3.1 Check the function of the system including indicators and gauges Turn on all electrical functions and test all indicators and gauges on the instrument panel, as outlined in the "Operation and Maintenance Manual". In case of problems, check fuses and / or cables. Refer to the corresponding schematics in group 9.. 2.3.2 Clean / check / grease the battery connections, check the cable routing and connections Check the battery terminals and cable clamps for corrosion and tightness. Clean and grease the clamps and terminals at regular intervals. Check the batteries for external damage and leaks. Check the battery cable harness for chafing, check connections for corrosion. If chafed areas have been found, wrap them with electrical tape, reroute them and shrink fit the cable harness to prevent moisture infiltration.

2.3.3 Check / adjust the electronic control system On machines with electronic crawler control / E-box version CEP, use the test box to check and adjust the system, as outlined in group 10.4.. On machines with electronic crawler control / E-box version RST , use a notebook computer and the LIKOM Service Set, as outlined in group 10.5. Perform all checks / adjustments according to the adjustment checklist for the corresponding machine model - see group 3.5 - and record the results. For special tools, refer to page 2.1.30.01.

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Maintenance and Inspection


Datum Edition Date

PR Litronic LR Litronic RL Litronic


Blatt Page Feuille

01 04

Instructions

3.4.10.03

2.3.4 Check the battery electrolyte level (charge condition) Use an optical battery charge tester to check the electrolyte level, see Special Tools, page 2.1.30.01. The tester displays a line between light and dark on the left scale of the window, which means: GOOD FAIR RECHARGE = battery charged = battery half charged = battery discharged

Check the battery acid before adding water. Perform a separate test for each battery cell. If test values are the same for all cells, below 1200, the battery must be re- charged with an external battery charger. If the test values vary (difference is greater than 0.02), or if they are below 1.100, the battery must be replaced. Note: Disconnect the negative ( - ) terminal first, then disconnect the positive terminal ( +) ; connect the positive + terminal first, then connect the negative terminal ( - ).

For further details on the use of the battery charge tester or on the charging procedure, refer to the manufacturers instructions. Caution : Battery acid is highly corrosive! Handle the battery very carefully, always wear safety glasses and gloves. There is a danger of explosion in case of sparks! Make sure to strictly observe all safety guidelines!

2.4. Inspect the heater, ventilation and air conditioner 2.4.1 Check the system for function and for leaks Check all heater and fresh air functions and/or cooling function, if an air conditioner is installed. For further details, see Operation and Maintenance Manual. In case of heater problems, check the connections of the input and return lines, check for leaks. See group 17.3. For maintenance / malfunctions on air conditioners, call an air conditioning technician. For details, see group 17.5 and/or "Operation and Maintenance Manual".

2.5. Inspect the travel gear 2.5.1 Check screws for tightness Check all mounting screws for tightness, torque as necessary. For tightening torques, see page 1.4.02.01. Note: If the oil level is too high, the disk brake or travel motor seals may be leaking. On gears with two (2) life time seals, check the oil level (oil volume) in the seal chamber, open gears if necessary and check the inner life time seal (seal chamber is filled with hydraulic oil SAE 20, see Operation and Maintenance Manual).

Remove the gear cover and check hoses and flange connections for leaks.

2.6. Inspect the track components 2.6.1 Check screws and nuts for tightness This inspection is especially important on new track components. Loose track pad screws can also be detected by offset nuts.. Replace loose screws and retorque them. For safety reasons , retorque similar screw connections on the affected part as well. For torque specifications on track pad and sprocket segment screws, refer to page 12.1.00.01. For all other screws, use tightening torques given in section 1.4.

2.6.2 Check / adjust idler guides For check and adjustment details, refer to the Operation and Maintenance Manual. Incorrectly adjusted idler guides will lead to idler damage! If the idler guide can no longer be properly adjusted due to excessive wear, replace worn parts. Wear strips for vertical play are attached to the inside of the roller frame and on the claws of the idler guide by tack welding or with screws. If new wear strips are installed and shims are intended to be installed, replace missing shims under the screw heads / covers for subsequent adjustments. If there are no more shims for the lateral play adjustment, replace or recondition the guide plates and add new shims, if the design calls for them, for subsequent adjustments. For details about idler guides for various machine types, refer to the Operation and Maintenance Manual or group 12.4. 2.6.3 PR 752 - Check screws of the support shaft mounting for tightness Demount wire guard1. Tighten the screws2 of the support shaft crosswise up to the required torque- see section 1.4.02. Note: It is possible that the ring doesnt run in smooth. So repeat this action at least twice with different begins to reach the required screw torque for a long time.

2.6.4 Adjust the track chain tension to the job application, check the track components for wear Chain tension must be adjusted to suit the actual job application, since different ground conditions result in different material accumulation, but the slack should always be the same. If chains are tightened too much, track wear is significantly increased. Stop the machine in forward direction on level ground. The track chain tension is correct when the slack between the carrier roller and the idler or carrier roller and sprocket is approx. 40 to 60 mm, depending on track design. The track guards must be selected according to the working conditions, see page 12.2.00.04, paragraph 3.3.

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Maintenance and Inspection


Datum Edition Date

PR Litronic LR Litronic RL Litronic


Blatt Page Feuille

01 04

Instructions

3.4.10.04

For track wear inspection, measuring guidelines, wear data (wear chart) and evaluation of wear patterns and causes, see group 12.2. When checking the track components, always visually inspect the elastic bearings on support shafts and the equalizer bar.

2.7. Inspect the attachment 2.7.1 Check all bearings for play / wear To check the bearing play at the trunion, apply pressure upward or downward to one side and check the play with a feeler gauge or similar tool on the opposite site. A minimum play must be present, as soon as the maximum wear limit is reached, replace worn parts. Permissible play = min.0.5 mm max. 4.0 mm Check the crawler's center bearing on the push frame to ensure it is correctly mounted and adjusted, see page 13.2.10.01 and/or the Operation and Maintenance Manual, chapter Blade installation.

To check the radial play on cylindrical pin bushings, move the attachment vertically to the bolt axis and measure the play with a ruler. Replace excessively worn parts. Measure the axial play with feeler gauge or similar tool. If play is excessive, add shims. Pull or push the pipe layer reverse roller bearing at one point and check the play on the opposite side with feeler gauge or similar tool. Replace worn parts. Permissible radial play = max. 2.0 mm, Permissible axial play = max. 3.0 mm, Note: Cylindrical mounted hydraulic cylinders must be able to move freely in axial direction up to approx. 5 mm. Do not add shims.

Crawler loaders - Check oil filled bucket pin bearings for leaks, correct mounting and possible wear. Replace leaking or worn bucket pin bearings. Permissible radial play without leakage and/or dry = up to max. 2.0 mm.

When necessary, point out proper attachment selection to match application, i.e. on crawler dozers: on crawler loaders: straight corners for precision dozing, HP cutting edge for severe applications, side cutters, correct ripper tooth configuration, etc. bucket type (rock or standard bucket), proper bucket and ripper tooth configuration, etc.

2.7.2 Crawler loaders - bucket stops and limit switch adjustment With the bucket fully tilted in and in its lowest position, there must be a min. of 5 mm distance between the bucket and the linkage, and the bucket must touch the stops on both sides evenly. With the bucket fully raised (limit switch disabled) and fully tilted out, the linkage must touch the stop, the back of the bucket may touch the stops (bucket unloaded). Replace worn stops as outlined in group 13.2. Hoist and bucket limit switches must be adjusted to suit application and to aid the operator. See "Operation and Maintenance Manual".

2.7.3 Pipe layer - hoist gear - cable winch For further details on maintenance and inspection as well as important safety recommendations, refer to group 14, the winch manufacturers instructions and the "Operation and Maintenance Manual".

2.7.4 Pipe layer - function free fall device Caution: Secure machine and working area. The free fall area of the load has to be free. Observe safety guidelines.

Lift a suitable test load with a weight of appr. 1500 kg with the hoist gear and actuate the free fall device. The load has to drop down faster than normal lowering. Note: for attaching loads and actuating the free fall device, observe all guidelines of the machine reflected operation manuals.

2.8. General inspection procedures If any maintenance problems have been found, discuss the correct procedures with maintenance personnel. If possible, check for possible operational errors and advise the machine operator, as necessary. If additional measures, maintenance or inspections for special attachments are required, make sure to carry them out and record them on the inspection report. Determine any spare parts requirements or any expected repairs, discuss with and inform the appropriate personnel.

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Maintenance and Inspection


Datum Edition Date

PR Litronic LR Litronic RL Litronic


Blatt Page Feuille

01 04

Instructions

3.4.10.05

Customer - Name and address:

Machine type: Job application/ location:

PIN:

Sm-hrs.:

Date:

Checked by: from company:

A. Tests with standard test instruments - test with Diesel engine RPM at n-max
Test No. 1. 2. 3. 4. 5. Test Test points Nominal value Remarks Test value actual value adjusted value o.k. remarks o.k. remarks fluids, filters, mech. components, etc.

Visual tests and maintenance Operatingtemperature Cold start valve replenishing circuit Servo pressure Stand by pressure

Hydraulic system hydraulic tank SD (ND) ND working hydr. HD 70 C theoretic 1 25 bar


10

18+ bar
7

C C checked: changed: yes no yes no bar -bar bar bar bar bar bar bar bar bar bar bar bar bar bar M1 M2 M1 M2 re li re li bar bar bar bar bar bar bar bar bar bar bar bar bar bar bar bar

must remain constant during all tests at PR 712 to PR 732 - only if necessary for test / adjustment see guidelines working hydraulic

20 bar 1 25+ bar +5 30 bar 210 bar 5 190 bar 5 160 bar bar bar bar
5

+1

bar PR 712 to 732 (A10V-without stand-by valve) bar PR 732 (A10V-with stand-by valve) bar PR 742 (HPR 130) bar bar bar bar bar bar bar bar lift cylinder circuit max. working pressure pressure settings for optional hydraulic functions in fine control range/PR 742(HPR) adjust when spool is fully shifted possible actuation after engine is turned off PR 712 to PR 732 PR 742 PR 742 only pump right pump left check only if necessary use test flanges! max. engine RPM is 1400 Upm

6.

Pressure limitation 6.1 Sec. pressure 6.2 Prim. pressure 6.3 Pressure cut off 6.4 6.5 6.6 Pressure difference = p Accumulator Replenishing pressure Control pressure Hydr. neutral pos. travel hydraulic

working hydr. HD

7. 8. 9. 10. 11.

working hydr. HD to LD test SP travel hydr. ST shaft right M1 + M2 shaft left M1 + M2 M1 right M1 left M2 right M2 left

14+ bar <13 bar min. 4x +4 16 bar 3 25 bar


6

12.

Max. pressure travel forward Max. pressure travel reverse

50 bar M1 = M2 1 bar M1 = M2 1 bar +30/-10 420 bar +30/-10 420 bar


5

B. Test with test box CET 08/03 H (see SM - section 10.4) and adapter CET 14/03 or CET 14/05
- mark LED which lights up or note position of analog indicator (space No. = at test box, A = at adapter) - test with Diesel engine RPM at max. RPM or as noted LED - color: = green = yellow = red indicators = Test No. 1. 2. 3. 4. 5. 6. 7. Test Space No. A/6 8 9 9 9 4 11
Inl.6

During test Diesel engine is not running

After adjustment / repair

Remarks

Identification Battery Indicator light electron. fault ind. Signal red. speed. Signal counter rot. Travel joystick Proportional solenoids

V6/Inl.4

752/X.....

Inl.6

V6/Inl.4

752/X..... record denomination of LED

o.k. light at panel on:

undervolt. yes no

o.k. light at panel on:

undervolt. yes no

after approx. 10 sec. of actuation light at panel = on instrument panel of machine ("reduced speed" light lights together) select reduced travel speed range press button and deflect joystick in all directions = analogic display of sections after approx. 10 sec. of actuation

no signal signal error good defect

no signal signal error good defect

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!
Datum Edition Date

PR 712 PR 722 PR 732 PR 742

F/N xxx-0103 0384 F/N xxx-0103 0563 F/N xxx-2003 2500 F/N xxx-2001 2500

01 01

Adjustment Checklist

Blatt Page Feuille

3.5.00.01

Test No. 8. 9. 10.

Test

Space No. 8 A 2

During test Diesel engine running

After adjustment / repair

Remarks

Alternator RPM sensor Diesel engine RPM Diesel engine Potentiometer nominal RPM Brake release RPM sensor oil motors Basic adjustment left track - only if required at PR 742 pos. 3 before pos. 2

overv. low min:

o.k. o.k.

underv. high max:

overv. low min:

o.k. o.k.

underv. Diesel engine approx. 1500 RPM / test for 10 sec. high max: must be green from nmin up to nmax
+50

...............- Rpm -................. 3 14 {max.-.....Rpm {min.+.....Rpm light at panel: 14 forward 2 forward 3 reverse 2 reverse 3 forward 4 forward 5 reverse 4 reverse 5 Test forward 1 forward 2 forward 3 reverse 1 reverse 2 reverse 3 forward 4 forward 5 reverse 4 reverse 5 (440 )
20

min: 800 Rpm max: PR 712 / 722 ...............- Rpm -................. PR 732 / 742 good defect on off right left

2100 Rpm +60 1900 Rpm


+20

+80

11. 12.

good defect on off right left

{max.-.....Rpm {min.+.....Rpm light at panel:

should be green at nmax -30 RPM and +20 nmin +30 RPM / = indication at part. range must be functioning for all remaining tests machine must be raised off the ground = no indication / must be "ok" for further tests pump regulating range forward pump end of regulating forward pump regulating range reverse pump end of regulating reverse motor regulating range forward control tests values are resulting from previous adjustments

Tracks running 13. 14. 13

forward 2 forward 3 reverse 2 reverse 3 forward 4 forward 5 reverse 4 reverse 5 Adjust Adjust yes no forward 1 yes forward 2 forward 3 yes no reverse 1 yes reverse 2 reverse 3 forward 4 forward 5 reverse 4 reverse 5 mA mA mA

15.

Straight run compare track right to track left at PR 742 pos. 3 before pos. 2

14

note position of rotary switch no travel begin forward - tracks start to turn pump regulating range forward pump end of regulating forward no travel begin reverse - tracks start to turn pump regulating range reverse pump end of regulating reverse motor regulating range forward control tests values are resulting from previous adjustments throttle lever must be at max. RPM position initial current jump 50 50 PR 712 - 1000 mA, PR 722 - 990 mA PR 732 - 980 mA, PR 742 - 960 mA 70 70 PR 712 - 1450 mA, PR 722 - 1445 mA
50 50

Special tests - travel operation 16. Current supply 16.1 Diesel engine not running 2 max.
in reduced speed range

max.
in normal speed range

(1180 16.2 Diesel engine running 17. Straight run compare track right to track left 14 +2

60

mA mA mA | | | | mA mA mA mA

PR 732 - 1410 mA, PR 742 - 1380 mA reduced value when steering left
70 70

(440 )
20 30

initial current jump minimum current at maximum load (RPM drop) forward with approx. 550 mA reverse with approx. 550 mA forward with approx. 950 mA reverse with approx. 950 mA

(590 ) | | | | mA mA mA mA

Remarks:

Adjustment guidelines - quick reference and explanations


Complete the test procedure according to the checklist, even for a partial check. Use pressure gauges appropriate for the test ranges. To test the track speed / straight run, raise the machine off the ground and support it properly, so that the chains can turn freely without danger. Make sure to observe all safety guidelines - see group 1.2.01! Use only the correct tools (test instruments). The Diesel engine RPMs must be as noted. Perform all required maintenance work before adjustment. In case of questions, make sure to use the detailed instructions: for the adjustment of the travel hydraulic, see section 6.5.00, for the adjustment of the working hydraulic, see section 7.5.10 and for the use of the test box CET 08/03, see section 10.4.00 When putting the machine into service, proceed according to the guidelines given in the Operation and Maintenance Manual. Check all indicators and gauges to ensure they are functioning correctly. Defects must be repaired immediately or as soon as possible, depending on the type of problem .

A. Tests with standard test instruments


All pressure tests must be performed at max. engine RPM unless noted otherwise. 1. Visual tests and maintenance Insufficient maintenance and mechanical component defects often point to the cause of the problem. Check oil levels, filters, coolant level, mechanical components and their mounting, cables and wiring harnesses, etc. Repair any detected defects immediately or as soon as possible, depending on the type of problem. 2. Operating temperature If the operating temperature is reached only for a short time, cover the cooler (air flow) partially for the test / adjustment. With the oil at operating temperature, before performing additional tests, actuate all hydraulic functions and monitor the temperature constantly. For additional information about bringing the hydraulic system to operating temperature, see group 6.5 or 7.5. 3. Cold start valve (travel hydraulic) Needs to be checked only for troubleshooting (example: in case of temperature problems). Valve should be closed, with the oil at operating temperature (also valid for by-pass valve on PR 742). Check adjustment, see group 6.5, p. 3. 4. Servo pressure (working hydraulic) Not adjustable - is a result of SP pressure. In case of problems, for example Quick drop, see Adjustment Working hydraulic, group 7.5.10. 5. Stand-by pressure (working hydraulic) This pressure is the basis for the proper function of the entire working hydraulic system. Note: - Only the new A10V100 pumps in PR732 are equipped with the stand-by valve (which is installed between the regulator and the pump housing). The adjustment on all A10V-pumps is made on the LS regulator. - The test value on PR 742 with regulating pump HPR 130 depends significantly on the temperature, the adjustment must be made via the Qmin stop on the pump. 6. Pressure limitation (working hydraulic) 6.1. Secondary pressure To check, raise the pressure cut off and primary pressure setting. For the blade down function, block the line. Note the secondary pressure relief setting for additional attachments separately on the checklist.
Benennung Description Dnomination Typ/ab Type/from Type/ a partir de

Mjfcifss!

Quick Reference
Datum Edition Date

PR 712 PR 722 PR 732 PR 742


Blatt Page Feuille

F/N xxx-0103 0384 F/N xxx-0103 0563 F/N xxx-2003 2500 F/N xxx-2001 2500

01 01

Adjustment Checklist

3.5.00.02

6.2. Primary pressure To check, raise the pressure cut off setting. Check the pressure via the tilt circuit or additional attachments. 6.3. Pressure cut off The pressure cut off limits the maximum working pressure, primary and secondary pressure relief valves are installed for system safety. Check the pressure with the primary pressure via the tilt circuit or additional attachment circuit. 6.4. Blank line for pressure setting of additional attachment (enter description/test points) 6.5. Blank line for pressure setting of additional attachment (enter description/test points) 6.6. Blank line for pressure setting of additional attachment (enter description/test points) 7. Pressure difference -p HD to LD (working hydraulic) The p pressure in the fine control range is obtained on the machines with regulating pump A10V = PR 712, PR 722, PR 732 from the setting of the stand-by pressure. On machines with HPR 130 regulating pumps = PR742, the LS-regulator must be adjusted separately. The drop of p with the control valve spools fully opened is necessary to obtain the shortest working cycles. 8. Accumulator (working hydraulic) For safety reasons, it must be possible to actuate a function (blade down) several times (within 3 minutes) after the Diesel engine is turned off. 9. Replenishing pressure ( travel hydraulic) If the pressure is too low, find and remedy the problem before continuing machine operation. 10. Control pressure (travel hydraulic PR 742) The existing pressure value depends on the valve adjustment and the replenishing pressure, see schematic, group 6. 11. Hydraulic neutral position (travel hydraulic - travel pumps) Leave the safety lever in the down position. Check first with 0-600 bar pressure gauge, for final check / adjustment, use a 0- 40 / 0-60 bar pressure gauge. The normal pressure reading should correspond to the replenishing pressure. The permissible pressure difference between M1 and M2 may be no more than 1.0 bar. 12. Pressure limitation of maximum system pressure (travel hydraulic) Not adjustable. Check only if needed. Check O-rings on blind flanges. Determine location of test points M1/M2 , depending on the type of travel gear. All work must be performed clean and carefully. Actuate the pumps carefully and hold the maximum pressure only for a short time. Bleed the system after tests.

B. Tests with test box CET 08 / 03


Before carrying out tests / adjustments, check the operational readiness and function of the LED on the test box and its adapter- see 10.4. LED = light emitting diode 1. Identification For identification, the indicators on the adapter and the test box have to be combined. In case of incorrect identification, check the operating condition of test box first - for example: check the rotary switch position and the cable configuration, then check the machine wire harness connections. 2. Battery If the battery is always at undervoltage, check the position of the safety lever and the emergency shut off button first, then continue to check the power supply.

3. Indicator lights - electronic fault indicator- H12 If there is a problem in the system, the time the indicator light lights up can give an initial hint to the problem area. Along with the electronic monitoring indicator light, the 'reduced speed range' indicator light H11 lights up as well. If these lights do not light up during the test, check the bulbs, wiring and relays. 4. Signal - preselection "reduced speed range" If the LED does not light up during the test, check the switch and wiring. 5. Signal - counter rotation If the LED does not light up during the test, or if it turns off during joystick deflection, check the wiring as well as the switch and cable in the joystick. 6. Travel joystick The pointers in the test box must follow the joystick deflection evenly. Erratic movement or lack of movement indicates an error and should be noted as such on the checklist. In the four main directions, at full joystick deflection, the corresponding green LED must light up. In diagonal deflection, most of the time both directional LEDs light up, a jump", however, is within the permitted tolerance range. The red error" diode may not light up in any joystick position. 7. Proportional solenoids Push the push button for about 15 seconds. If an error is shown, swap the connectors at the proportional solenoids and check again to find the problem - cable or solenoid. 8. Alternator In case of constant low voltage, always check the position of the safety lever and the emergency shut off button, then continue to check the power supply. Push the push button for about 15 seconds. If the green LED turns off and the red one lights up, check the alternator or V-belt. 9. RPM sensor - Diesel engine Readings at the test box adapter are valid. In case of error indication, remove the sensor and check it visually and/or clean. Check the harness and adjust required distance to the top of the flywheel tooth. Repeat the test. 10. Diesel engine RPM Readings at the test box are valid. If values are too low, check function and routing of shut off cable, even check the neutral functions of the hydraulic system. Make adjustments on the stop screws of the engine operation in the cab and when necessary check adjustment of the injection pump - see chapter 17.4. If engine RPM is changed via a lever, the springs may not be fully compressed in any position. 11. Potentiometer The pointer in the test box must follow the throttle position evenly. Jerky movement or lack of movement indicates a defect and should be noted as such on the checklist. Approach test values of potentiometer adjustment from the medium RPM range of the Diesel engine. Determine the difference between the high and low idle (step 10) to those engine speeds and record the RPM where the corresponding LED just lights up (not flicker). If necessary, repeat the test several times. The nominal value should be within 30 RPM each.

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Quick Reference
Datum Edition Date

PR 712 PR 722 PR 732 PR 742


Blatt Page Feuille

F/N xxx-0103 0384 F/N xxx-0103 0563 F/N xxx-2003 2500 F/N xxx-2001 2500

01 01

Adjustment Checklist

3.5.00.03

12. Release the brake When the LED lights up on the test box, the indicator light H4 on the panel must turn off. LED does not light up electrical defect Indicator light does not turn off hydraulic / mechanical defect Caution: If step A-11 was not carried out at all or carried out incorrectly, the chains may already begin to turn. 13. RPM sensor - hydraulic motors Test read out usually starts in speed range 3, however, perform the test always in stage 5 (higher signal number). Before changing from left right", stop the track run, switch over and run again. No indication Red diode Problem due to electrical circuit interruption, possible total sensor failure Mark appropriate square on check list Sensor sends error signal

14. Basic adjustment - left track The speed of the left track is shown in relation to the stored values in the test box. Carry out the required adjustment corrections until the analog indicator is in the green - center" range, even after several checks. Beachte: - The pump control / adjustment depends on the type of travel gear installed. - If surging" occurs in a speed range, set the corresponding regulating range (= adjustment stage 4, or stage 2 and 4, or stage 2) to the end of the left (slower) green range. - If an existing adjustment is changed, change the adjustment to the required direction until indication is in the red range during the next test run. Then return the adjustment to the required green range. - Always make adjustment changes after the chain stops turning. 15. Straight run, right chain compared to the left chain The speed of the right chain is shown in relation to the speed of the left chain, measured via the speed sensors of the travel motors. If no basic adjustment of the left track was made as noted in par. 14, only minor corrections may be made. But in all speed ranges the faster chain has to be matched to the slower chain. If the basic adjustment of the left track was made as noted in par. 14, the right track is matched to the left track. A normal test run can be carried out in the switch position Test". For adjustments, every test run must be made in the switch position Adjust". Correct adjustments until the analog indicator is in the green - center" range, even after several test runs. Note: - If an existing adjustment is changed, change the adjustment to the required direction until the indication is in the red range during the test run. Then return the adjustment to the required green range. - For the simulation of the required engine load, see paragraph 10.4. 16. Current supply (Special test during normal travel - test box with Y-cable) This test is only required when troubleshooting. Only the current supply on the right track is measured. Additional indications are due to the switch design and have no meaning. Notes: - If the maximum values are not reached, check the position of the throttle control lever. - For the simulation of the required engine load, see paragraph 10.4. 17. Straight run, right chain to left chain (Special test during normal travel - test box with Y-cable) Perform this test only if the machine cannot be raised off the ground and properly supported. During normal travel operation, the current supply to the right drive side and the speed of the right track in relation to the speed of the left track is shown. Due to external influences, despite a wide tolerance range, large deviations (fluctuating) exist. Additional indications are due to the switch design and have no meaning.

Customer - Name and address:

Machine type: Job application/ location:

PIN:

Sm-hrs.:

Date:

Checked by: from company:

A Tests with standard test instruments - test with Diesel engine RPM at 1000 RPM
Test No. 1. 2. 3. 4. 5. Test Test points Nominal value Remarks Test value actual value adjusted value o.k. remarks o.k. remarks fluids, filters, mech. components, etc..

Visual test and maintenance Operating temperature Cold start valve replenishing circuit Servo pressure Stand by pressure

Hydraulic system hydraulic tank SD (ND) ND working hydr HD 70 C theoretic 1 25 bar


10

must remain constant during all tests

18+ bar
7

checked: changed: at PR 712 to PR 732B - only if necessary yes no yes no for test / adjustment see guidelines bar -working hydraulic bar bar bar PR 712 to 732 (A10V-without stand-by valve) bar PR 732 (A10V-with stand-by valve)

20 bar 1 25+ bar

+1

6.

Pressure limitation 6.1 Prim. pressure 6.2 Sec. pressure 6.3 Pressure cut off 6.4 6.5 6.6 Pressure difference = p Accumulator Replenishing pressure Control pressure Hydr. neutral pos. travel hydraulic

working hydr. HD

220 bar 5 210 bar 5 160 bar bar bar bar


5

7. 8. 9. 10. 11.

working hydr HD to LD test SP travel hydr. ST Shaft right M1 + M2 Shaft left M1 + M2 M1 right M1 left M2 right M2 left

14+ bar <13 bar min. 4x +4 16 bar 3 25 bar


6

bar bar bar bar bar bar bar bar bar bar M1 M2 M1 M2 ri le ri le bar bar bar bar bar bar bar bar bar

bar bar bar bar bar bar bar bar

lift cylinder circuit max. working pressure pressure settings for optional hydraulic functions in fine control range (check only if necessary) when spool is fully shifted possible actuation after engine is turned off PR 712 to PR 732B PR 742B PR 742B up to F/Nxxx-5233 only

12.

Max. pressure travel forward Max. pressure travel reverse

50 bar M1 = M2 1 bar M1 = M2 1 bar +30/-10 420 bar +30/-10 420 bar


5

bar bar bar bar bar bar bar bar

pump right pump left check only if necessary use test flanges!

B. Test with test box CET 08/03 H (see SM - section 10.4) and adapter CET 14/03 or CET 14/05
- mark LED which lights up or note position of analog indicator (space No. = at test box, A = at adapter) - test with Diesel engine RPM at max. RPM or as noted LED - color: = green = yellow = red indicators = Test No. 1. 2. 3. 4. Test Space No. A/6 8 9 9
Inl.6

During test Diesel engine is not running

After adjustment / repair.

Remarks

Identification Battery Indicator light electron. fault ind. Signal


travel speed range selection

V6/Inl.4

752/X.....

Inl.6

V6/Inl.4

752/X.....

record denomination of LED after approx. 10 sec. of actuation light at panel = on instrument panel of machine ("reduced speed" light lights together) 2-ranges -normal range 3-ranges - select "red. speed range"

o.k. light at panel on:

undervolt. yes no

o.k. light at panel on:

undervolt. yes no

no signal no signal no signal

no signal no signal no signal signal error good defect

normal = III

--

- red. speed range II - red. speed range I

5. 6. 7.

Signal counter rot. Travel joystick Proportional solenoids

9 4 11

signal error good defect

press button and deflect joystick in all directions = analogic display of sections after approx. 10 sec. of actuation

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!
Datum Edition Date

PR 712(B) F/N xxx-0385 5599 PR 722(B) F/N xxx-0564 5599 PR 732 B F/N xxx-2501 5599 PR 742 B F/N xxx-2501 5599

01 03

Adjustment Checklist

Blatt Page Feuille

3.5.01.01

Test. No. 8. 9. 10.

Test

Space No. 8 A 2

During test Diesel engine running

After adjustment / repair

Remarks

Alternator RPM sensor Diesel engine RPM Diesel engine Potentiometer nominal RPM Brake release

overv. low min:

o.k. o.k.

underv. high max:

overv. low min:

o.k. o.k.

underv. Diesel engine approx. 1500 RPM / test for 10 sec. high max: must be green from nmin up to nmax
+50

min: 800 RPM max: PR 712 / 722 ...............- RPM -................. ...............- RPM -................. PR 732 / 742 good defect on off right left forward 2 forward 3 reverse 2 reverse 3 forward 4 forward 5 reverse 4 reverse 5 Adjust Adjust yes no forward 1 yes forward 2 forward 3 yes no reverse 1 yes reverse 2 reverse 3 forward 4 forward 5 reverse 4 reverse 5 mA mA {max.-.....RPM {min.+.....RPM light at panel: good defect on off right left

2100 RPM +80 1900 RPM


+20

+80

11. 12.

3 14

{max.-.....RPM {min.+.....RPM light at panel:

should be green at nmax -30 RPM and +20 nmin +30 RPM / = indication at part. range must be functioning for all remaining tests machine must be raised off the ground  = no indication / must be "ok" for further tests pump regulating range forward pump end of regulating forward pump regulating range reverse pump end of regulating reverse motor regulating range forward control tests values are resulting from previous adjustments

Tracks running 13. 14. RPM sensor oil motors Basic adjustment left track - only if required at PR 742 up to F/Nxxx-5233 pos. 3 before pos. 2 13 14 forward 2 forward 3 reverse 2 reverse 3 forward 4 forward 5 reverse 4 reverse 5 Test forward 1 forward 2 forward 3 reverse 1 reverse 2 reverse 3 forward 4 forward 5 reverse 4 reverse 5 (440 ) max.
20

15.

Straight run compare track right to track left at PR 742 up to F/Nxxx-5233 pos. 3 before pos. 2

14

note position of rotary switch no travel begin forward - tracks start to turn pump regulating range forward pump end of regulating forward no travel begin reverse - tracks start to turn pump regulating range reverse pump end of regulating reverse motor regulating range forward control tests values are resulting from previous adjustments throttle lever must be at max. RPM position initial current jump
2-ranges mA, PR 712 - 1450+70 PR 722 - 1445+70 mA +70 PR 732 - 1410 70 mA, PR 742 - 1380+ mA mA PR 712 - 100050 PR 722 - 99050 mA 50 PR 732 - 980 50 mA PR 742 - 960 mA 3-ranges mA PR 712 - 1450+70 PR 722 - 1445+70 mA +70 PR 732 - 1410 mA PR 742 - 1380+70 mA mA PR 712 - 1240+50 PR 722 - 1235+50 mA +50 PR 732 - 1230 mA PR 742 - 1200+50 mA PR 712 - 910+50 mA PR 722 - 900+50 mA +50 PR 732 - 890 mA PR 742 - 880+50 mA

Special tests - travel operation 16. Current supply 16.1 Diesel engine not running 2

in normal speed range (switch position III)

max.
in reduced speed range (switch position II)

mA

max.
in reduced speed range (switch position I)

mA

--

(1180 )
80

mA mA mA | | | | mA mA mA mA

reduced value when steering left (normal range) initial current jump minimum current at maximum load (RPM drop) forward with approx. 550 mA reverse with approx. 550 mA forward with approx. 950 mA reverse with approx. 950 mA

16.2 Diesel engine running 17. Straight run compare track right to track left 14 +2

(440 | | | |

20

) )

(500+

100

mA mA mA mA

If installed:

C. Pedal-tests with tester CET 03/08 (see Service Manual section 10.6/chapter "fine adjustment") - Diesel engine not running
T.No.

Test Inch/brake pedal

During test adjustments according to guidelines yes no

After adjustment / repair adjustments according to guidelines yes no

Remarks observe display - "Inchpedal ext" etc. LED "Voltage" must be always green

1.

Remarks:

Adjustment guidelines - quick reference and explanations


Complete the test procedure according to the checklist, even for a partial check. Use pressure gauges appropriate for the test ranges. To test the track speed / straight run, raise the machine off the ground and support it properly, so that the chains can turn freely without danger. Make sure to observe all safety guidelines - see group 1.2.01! Use only the correct tools (test instruments). The Diesel engine RPMs must be as noted. Perform all required maintenance work before adjustment. In case of questions, make sure to use the detailed instructions: for the adjustment of the travel hydraulic, see section 6.5.00, for the adjustment of the working hydraulic, see section 7.5.10 ,for the use of the test box CET 08/03, see section 10.4.00. and for the use of the pedal control tester, see section 10.6.00. When putting the machine into service, proceed according to the guidelines given in the Operation and Maintenance Manual. Check all indicators and gauges to ensure they are functioning correctly. Defects must be repaired immediately or as soon as possible, depending on the type of problem.

A. Tests with standard test instruments


All pressure tests must be performed at 1000 RPM (without engine load) unless noted otherwise. 1. Visual tests and maintenance Insufficient maintenance and mechanical component defects often point to the cause of the problem. Check oil levels, filters, coolant level, mechanical components and their mounting, cables and wiring harnesses, etc. Repair any detected defects immediately or as soon as possible, depending on the type of problem. 2. Operating temperature If the operating temperature is reached only for a short time, cover the cooler (air flow) partially for the test / adjustment. With the oil at operating temperature, before performing additional tests, actuate all hydraulic functions and monitor the temperature constantly. For additional information about bringing the hydraulic system to operating temperature, see group 6.5 or 7.5. 3. Cold start valve (travel hydraulic) Needs to be checked only for troubleshooting (example: in case of temperature problems). Valve should be closed, with the oil at operating temperature (also valid for by-pass valve on PR 742B). Check adjustment, see group 6.5, p. 3. 4. Servo pressure (working hydraulic) Not adjustable - is a result of SP pressure. In case of problems, for example Quick drop, see Adjustment Working hydraulic, group 7.5.10. 5. Stand-by pressure (working hydraulic) This pressure is the basis for the proper function of the entire working hydraulic system. Note: Only the new A10V100 pumps in PR732 and all A10V140 pumps in PR 742B machines, are equipped with the stand-by valve (which is installed between the regulator and the pump housing). The adjustment on all A10V-pumps is made on the LS regulator.

6. Pressure limitation (working hydraulic) 6.1. Primary pressure To check, raise the pressure cut off setting. Check the pressure via the tilt circuit or additional attachments without secondary relief.

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Quick Reference
Datum Edition Date

PR 712(B) F/N xxx-0385 5599 PR 722(B) F/N xxx-0564 5599 PR 732 B F/N xxx-2501 5599 PR 742 B F/N xxx-2501 5599
Blatt Page Feuille

01 03

Adjustment Checklist

3.5.01.02

6.2. Secondary pressure To check, raise the pressure cut off and primary pressure setting. For the blade down function, block the line or proceed as outlined in group 7.5. Note the secondary pressure relief setting for additional attachments separately on the checklist. 6.3. Pressure cut off The pressure cut off limits the maximum working pressure. Primary and secondary pressure relief valves are only installed for system safety. Check the pressure as the primary pressure via the tilt circuit or additional attachment circuit without secondary relief. 6.4. Blank line for pressure setting of additional attachment (enter test point / description) 6.5. Blank line for pressure setting of additional attachment (enter test point / description) 6.6. Blank line for pressure setting of additional attachment (enter test point / description) 7. Pressure difference -p HD to LD (working hydraulic) The p pressure in the fine control range is obtained on the machines with regulating pump A10V = PR 712(B), PR 722(B), PR 732B und PR 742B from the setting of the stand-by pressure. The drop of p with the control valve spools fully opened is necessary to obtain the shortest working cycles. 8. Accumulator (working hydraulic) For safety reasons, it must be possible to actuate a function (blade down) several times (within 3 minutes) after the Diesel engine is turned off. 9. Replenishing pressure ( travel hydraulic) If the pressure is too low, find and remedy the problem before continuing machine operation. 10. Control pressure (travel hydraulic PR 742(B) to F/N xxx-5233) The existing pressure value depends on the valve adjustment and the replenishing pressure, see schematic, group 6. 11.Hydraulic neutral position (travel hydraulic - travel pumps) Leave the safety lever in the down position. Check first with 0-600 bar pressure gauge, for final check / adjustment, use a 0- 40 / 0-60 bar pressure gauge. The normal pressure reading should correspond to the replenishing pressure. The permissible pressure difference between M1 and M2 may be no more than 1.0 bar. 12.Pressure limitation of maximum system pressure (travel hydraulic) Not adjustable. Check only if needed. Check O-rings on blind flanges. Determine location of test points M1/M2 , depending on the type of travel gear. All work must be performed clean and carefully. Actuate the pumps carefully and hold the maximum pressure only for a short time. Bleed the system after tests.

B. Tests with test box CET 08 / 03


Before carrying out tests / adjustments, check the operational readiness and function of the LED on the test box and its adapter- see 10.4. 1. Identification For identification, the indicators on the adapter and the test box have to be combined. In case of incorrect identification, check the operating condition of test box first - for example: check the rotary switch position and the cable configuration, then check the machine wire harness connections. 2. Battery If the battery is always at undervoltage, check the position of the safety lever and the emergency shut off button first, then continue to check the power supply. 3. Indicator lights - electronic fault indicator- H12 If there is a problem in the system, the time the indicator light lights up can give an initial hint to the problem area. Along with the electronic monitoring indicator light, the 'reduced speed range' indicator light H11 lights up as well. If these lights do not light up during the test, check the bulbs, wiring and relays. 4. Signal - preselection "reduced speed range" 4.1. Reduced travel speed range with push button switch S12 on the panel (0 4,6 km/h) If the LED does not light up during the test, check the switch and wiring. 4.2. Reduced travel speed range with rocker switch S29 on the travel control joystick Rocker switch in position I (04 km/h) = diode must be on Rocker switch in position II (06,5 km/h) = diode must switch off Rocker switch in position III (011 km/h) = diode must be on If the test result is not correct, check the switch and the wiring harness. 5. Signal - counter rotation" If the LED does not light up during the test, or if it turns off during joystick deflection, check the wiring as well as the switch and cable in the joystick. 6. Travel joystick The pointers in the test box must follow the joystick deflection evenly. Erratic movement or lack of movement indicates an error and should be noted as such on the checklist. In the four main directions, at full joystick deflection, the corresponding green LED must light up. In diagonal deflection, most of the time both directional LEDs light up, a jump", however, is within the permitted tolerance range. The red error" diode may not light up in any joystick position. Notes: Do not actuate the push button switch counter rotation while testing the travel joystick - this can cause wrong Error - indications.

7. Proportional solenoids Push the push button for about 15 seconds. If an error is shown, swap the connectors at the proportional solenoids and check again to find the problem - cable or solenoid.

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Quick Reference
Datum Edition Date

PR 712(B) F/N xxx-0385 5599 PR 722(B) F/N xxx-0564 5599 PR 732 B F/N xxx-2501 5599 PR 742 B F/N xxx-2501 5599
Blatt Page Feuille

01 03

Adjustment Checklist

3.5.01.03

8. Alternator In case of constant low voltage, always check the position of the safety lever and the emergency shut off button, then continue to check the power supply. Push the push button for about 15 seconds. If the green LED turns off and the red one lights up, check the alternator or V-belt. 9. RPM sensor - Diesel engine Readings at the test box adapter are valid. In case of error indication, remove the sensor and check it visually and/or clean. Check the harness and required distance to the top of the flywheel tooth. Repeat the test. 10.Diesel engine RPM Readings at the test box are valid. If values are too low, check function and routing of shut off cable, even check the neutral functions of the hydraulic system. Make adjustments on the stop screws of the engine operation in the cab and when necessary check adjustment of the injection pump - see chapter 17.4. If engine RPM is changed via a lever, the springs may not be fully compressed in any position. 11.Potentiometer The pointer in the test box must follow the throttle position evenly. Jerky movement or lack of movement indicates a defect and should be noted as such on the checklist. Approach test values of potentiometer adjustment from the medium RPM range of the Diesel engine. Determine the difference between the high and low idle (step 10) to those engine speeds and record the RPM where the corresponding LED just lights up (not flicker). If necessary, repeat the test several times. The nominal value should be within 30+20 RPM each. 12. Release the brake When the LED lights up on the test box, the indicator light on the panel must turn off. LED does not light up electrical defect Indicator light does not turn off hydraulic / mechanical defect Caution: If step A-11 was not carried out at all or carried out incorrectly, the chains may already begin to turn. 13. RPM sensor - hydraulic motors Test read out usually starts in speed range 3, however, perform the test always in stage 5 (higher signal number). Before changing from left right", stop the track run, switch over and run again. No indication Red diode Problem due to electrical circuit interruption, possible total sensor failure Mark appropriate square on check list Sensor sends error signal

14.Basic adjustment - left track The speed of the left track is shown in relation to the stored values in the test box. Carry out the required adjustment corrections until the analog indicator is in the green - center" range, even after several checks. Note: - The pump control / adjustment depends on the type of travel gear installed. - If surging" occurs in a speed range, set the corresponding regulating range (= adjustment stage 4, or stage 2 and 4, or stage 2) to the end of the left (slower) green range. - If an existing adjustment is changed, change the adjustment to the required direction until indication is in the red range during the next test run. Then return the adjustment to the required green range. - Always make adjustment changes after the chain stops turning.

15.Straight run, right chain compared to the left chain The speed of the right chain is shown in relation to the speed of the left chain, measured via the speed sensors of the travel motors. If no basic adjustment of the left track was made as noted in par. 14, only minor corrections may be made. But in all speed ranges the faster chain has to be matched to the slower chain. If the basic adjustment of the left track was made as noted in par. 14, the right track is matched to the left track. A normal test run can be carried out in the switch position Test". For adjustments, every test run must be made in the switch position Adjust". Correct adjustments until the analog indicator is in the green - center" range, even after several test runs. Note: - If an existing adjustment is changed, change the adjustment to the required direction until the indication is in the red range during the test run. Then return the adjustment to the required green range. - Always make adjustment changes after the chain stops turning. 16. Current supply (Special test during normal travel - test box with Y-cable) This test is only required when troubleshooting. Only the current supply on the right track is measured. Additional indications are due to the switch design and have no meaning. When selecting the travel speed range via push button switch S12 on the panel = use values of column "2ranges", when selecting the travel speed range via rocker switch S29 on the travel control joystick = use values of column "3-ranges". Notes - If the maximum values are not reached, check the position of the throttle control lever. - For the simulation of the required engine load, see paragraph 10.4. 17.Straight run, right chain to left chain (Special test during normal travel - test box with Y-cable) Perform this test only if the machine cannot be raised off the ground and properly supported. During normal travel operation, the current supply to the right drive side and the speed of the right track in relation to the speed of the left track is shown. Due to external influences, despite a wide tolerance range, large deviations (fluctuating) exist. Additional indications are due to the switch design and have no meaning.

C. Pedal-tests with tester CET 03/08


1. Inch/brake pedal If there is an Inch / brake pedal installed, always perform the check of the adjustments when the electronic box is connected = connect all cables of the tester. Guidelines for the test and further notes see chapter 10.6, section B -1.

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Quick Reference
Datum Edition Date

PR 712(B) F/N xxx-0385 5599 PR 722(B) F/N xxx-0564 5599 PR 732 B F/N xxx-2501 5599 PR 742 B F/N xxx-2501 5599
Blatt Page Feuille

01 03

Adjustment Checklist

3.5.01.04

Customer - Name and address:

Machine type: Job application/ location:

PIN:

Sm-hrs.:

Date:

Checked by: from company:

A Tests with standard test instruments - test with Diesel engine RPM at 1000 RPM or as outlined
Test No. 1. 2. 3. Test Test points Nominal value Remarks Test value actual value adjusted value o.k. remarks o.k. remarks fluids, filters, mech. components, etc.. at PR 712 to PR 732 - only if necessary for test / adjustment see guidelines PR 712 Diesel engine at nmax, PR 722 at least one sensor unplugged. PR 732 PR 742 must remain constant during all tests working hydraulic bar PR 712, PR 722 (A10V-without stand-by valve) bar PR 732, PR 742 (A10V-with stand-by valve) bar bar bar bar bar bar bar

Visual test and maintenance Cold start valve replenishing circuit Pressure limitation fan drive

SD LA

Hydraulic system checked: changed: theoretic 1 25 bar yes no yes no +10 110 bar bar -+10 130 bar bar -+10 150 bar bar -+10 bar -210 bar 70 C
10 7

4. 5. 6. 7.

Operating temperature Servo pressure Stand by pressure Pressure limitation 7.1 Prim. pressure 7.2 Sec. pressure 7.3 Pressure cut off 7.4 7.5 Pressure difference = p Accumulator Replenishing pressure Hydr. neutral pos. travel hydraulic

hydraulic tank ND working hydr HD working hydr. HD

C bar bar bar bar bar bar bar bar bar bar bar bar bar bar bar bar bar bar bar bar --

18+ bar 20 bar 1 25+ bar 220 bar 5 210 bar 5 160 bar bar bar
5 +1

lift cylinder circuit max. working pressure pressure settings for optional hydraulic functions in fine control range (check only if necessary) when spool is fully shifted possible actuation after engine is turned off PR 712 to PR 732 PR 742 pump right pump left check only if necessary use test flanges!

8. 9. 10. 11.

working hydr HD to LD test SP travel hydr. Shaft right M1 + M2 Shaft left M1 + M2 M1 right M1 left M2 right M2 left

12.

Max. pressure travel forward Max. pressure travel reverse

14+ bar <13 bar min. 4x +4 16 bar 3 25 bar M1 = M2 1 bar M1 = M2 1 bar +30/-10 420 bar +30/-10 420 bar
6

M1 M2 M1 M2 ri le ri le

bar bar bar bar bar bar bar bar

B. Test with test box CET 08/03 H (see SM - section 10.4) and adapter CET 14/03 or CET 14/05
- mark LED which lights up or note position of analog indicator (space No. = at test box, A = at adapter) - test with Diesel engine RPM at max. RPM or as noted - with e-box CEP12/08C, CEP12/20 first observe section D LED - color: = green = yellow = red indicators = Test No. 1. 2. 3. 4. Test Space No. A/6 8 9 9
Inl.6

During test Diesel engine is not running

After adjustment / repair.

Remarks

Identification Battery Indicator light electron. fault ind. Signal


travel speed range selection

V6/Inl.4

752/X.....

Inl.6

V6/Inl.4

752/X.....

record denomination of LED after approx. 10 sec. of actuation light at panel = on instrument panel of machine ("reduced speed" light lights together) 2-ranges -normal range 3-ranges - normal = III - select "red. speed range" - red. speed range II -- red. speed range I press button and deflect joystick in all directions = analogic display of sections after approx. 10 sec. of actuation

o.k. light at panel on:

undervolt. yes no

o.k. light at panel on:

undervolt. yes no

no signal no signal no signal signal error good defect

no signal no signal no signal signal error good defect

5. 6. 7.

Signal counter rot. Travel joystick Proportional solenoids

9 4 11

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!
Datum Edition Date

PR 712 B PR 722 B PR 732 B PR 742 B

F/N xxx-5600 6199 F/N xxx-5600 6199 F/N xxx-5600 6199 F/N xxx-5600 6199

01 03

Adjustment Checklist

Blatt Page Feuille

3.5.02.01

Test. No. 8. 9. 10.

Test

Space No. 8 A 2

During test Diesel engine running

After adjustment / repair

Remarks

Alternator RPM sensor Diesel engine RPM Diesel engine Potentiometer nominal RPM Brake release

overv. low min:

o.k. o.k.

underv. high max:

overv. low min:

o.k. o.k.

underv. Diesel engine approx. 1500 RPM / test for 10 sec. high max: must be green from nmin up to nmax
+50

min: 800 RPM max: PR 712 / 722 ...............- RPM -................. ...............- RPM -................. PR 732 / 742 good defect on off right left forward 2 forward 3 reverse 2 reverse 3 forward 4 forward 5 reverse 4 reverse 5 Adjust Adjust yes no forward 1 yes forward 2 forward 3 yes no reverse 1 yes reverse 2 reverse 3 forward 4 forward 5 reverse 4 reverse 5 mA mA {max.-.....RPM {min.+.....RPM light at panel: good defect on off right left

2100 RPM +80 1900 RPM


+20

+80

11. 12.

3 14

{max.-.....RPM {min.+.....RPM light at panel:

should be green at nmax -30 RPM and +20 nmin +30 RPM / = indication at part. range must be functioning for all remaining tests machine must be raised off the ground  = no indication / must be "ok" for further tests pump regulating range forward pump end of regulating forward pump regulating range reverse pump end of regulating reverse motor regulating range forward control tests values are resulting from previous adjustments

Tracks running 13. 14. RPM sensor oil motors Basic adjustment left track - only if required 13 14 forward 2 forward 3 reverse 2 reverse 3 forward 4 forward 5 reverse 4 reverse 5 Test forward 1 forward 2 forward 3 reverse 1 reverse 2 reverse 3 forward 4 forward 5 reverse 4 reverse 5 (440 ) max.
in normal speed range (switch position III)
20

15.

Straight run compare track right to track left

14

note position of rotary switch no travel begin forward - tracks start to turn pump regulating range forward pump end of regulating forward no travel begin reverse - tracks start to turn pump regulating range reverse pump end of regulating reverse motor regulating range forward control tests values are resulting from previous adjustments throttle lever must be at max. RPM position initial current jump
2-ranges mA, PR 712 - 1450+70 PR 722 - 1445+70 mA PR 732 - 1410+70 mA, mA PR 712 - 100050 mA PR 722 - 99050 PR 732 - 98050 mA 3-ranges mA PR 712 - 1450+70 PR 722 - 1445+70 mA PR 732 - 1410+70 mA PR 742 - 1380+70 mA mA PR 712 - 1240+50 mA PR 722 - 1235+50 PR 732 - 1230+50 mA PR 742 - 1200+50 mA PR 712 - 910+50 mA mA PR 722 - 900+50 PR 732 - 890+50 mA PR 742 - 880+50 mA

Special tests - travel operation 16. Current supply 16.1 Diesel engine not running 2

max.
in reduced speed range (switch position II)

mA

max.
in reduced speed range (switch position I)

mA

--

(1180 )
80

mA mA mA

reduced value when steering left (normal range) initial current jump minimum current at maximum load (RPM drop)

16.2 Diesel engine running If installed:

(440

20

) )

(500+

100

C. Pedal-tests with tester CET 03/08 (see Service Manual section 10.6/chapter "fine adjustment") - Diesel engine not running
T.No.

Test Inch/brake pedal

During test adjustments according to guidelines yes no

After adjustment / repair adjustments according to guidelines yes no

Remarks observe display - "Inchpedal ext" etc. LED "Voltage" must be always green

1.

D. Edit error memory with E-Box Evaluation Kit (with e-box CEP12/08C, CEP12/20) - following the software instructions
T.No.

1. 1.1

Test Read memory Record codes

Before checklist step B/C memory available: yes no

After checklist step B/C memory deleted: yes no

Remarks Print out memory following the software instructions and add the adjustment checklist, or record here in saved order.

Remarks:

Adjustment guidelines - quick reference and explanations


Complete the test procedure according to the checklist, even for a partial check. Use pressure gauges appropriate for the test ranges. To test the track speed / straight run, raise the machine off the ground and support it properly, so that the chains can turn freely without danger. Make sure to observe all safety guidelines - see group 1.2.01! Use only the correct tools (test instruments). The Diesel engine RPMs must be as noted. Perform all required maintenance work before adjustment. In case of questions, make sure to use the detailed instructions: for the adjustment of the travel hydraulic, see section 6.5.00, for the adjustment of the working hydraulic, see section 7.5.10 ,for the use of the test box CET 08/03, see section 10.4.00. and for the use of the pedal control tester, see section 10.6.00. When putting the machine into service, proceed according to the guidelines given in the Operation and Maintenance Manual. Check all indicators and gauges to ensure they are functioning correctly. Defects must be repaired immediately or as soon as possible, depending on the type of problem.

A. Tests with standard test instruments


All pressure tests must be performed at 1000 RPM (without engine load) unless noted otherwise. 1. Visual tests and maintenance Insufficient maintenance and mechanical component defects often point to the cause of the problem. Check oil levels, filters, coolant level, mechanical components and their mounting, cables and wiring harnesses, etc. Repair any detected defects immediately or as soon as possible, depending on the type of problem. 2. Cold start valve (travel hydraulic) Needs to be checked only for troubleshooting (example: in case of temperature problems). Valve should be closed, with the oil at operating temperature (also valid for by-pass valve on PR 742B). Check adjustment, see group 6.5, p. 3. 3. Pressure limitation (fan drive) When the sensor is unplugged and the Diesel engine is on high idle, the postulated maximum pressure has to be reached. The proportional - pressure relief valve is not adjustable and is regulated by the electronic. When overheating in spite of right pressure and clean radiator, in every case check the fan RPM. This RPM doesn't depends only on pressure (also on air supply, turning resistance, damages, and suchlike). for RPM see technical data 3.1, Instructions see chapter 6.5. 4. Operating temperature If the operating temperature is reached only for a short time, cover the cooler (air flow) partially for the test / adjustment. With the oil at operating temperature, before performing additional tests, actuate all hydraulic functions and monitor the temperature constantly. For additional information about bringing the hydraulic system to operating temperature, see group 6.5 or 7.5. 5. Servo pressure (working hydraulic) Not adjustable - is a result of SP pressure. In case of problems, for example Quick drop, see Adjustment Working hydraulic, group 7.5.10. 6. Stand-by pressure (working hydraulic) This pressure is the basis for the proper function of the entire working hydraulic system. Note: Only the A10V100 pumps in PR732 and the A10V140 pumps in PR 742B machines, are equipped with the stand-by valve (which is installed between the regulator and the pump housing). The adjustment on all A10V-pumps is made on the LS regulator.
Benennung Description Dnomination Typ/ab Type/from Type/ a partir de

Mjfcifss!

Quick Reference
Datum Edition Date

PR 712 B PR 722 B PR 732 B PR 742 B


Blatt Page Feuille

F/N xxx-5600 6199 F/N xxx-5600 6199 F/N xxx-5600 6199 F/N xxx-5600 6199

01 03

Adjustment Checklist

3.5.02.02

7. Pressure limitation (working hydraulic) 7.1. Primary pressure To check, raise the pressure cut off setting. Check the pressure via the tilt circuit or additional attachments without secondary relief. 7.2. Secondary pressure To check, raise the pressure cut off and primary pressure setting. For the blade down function, block the line or proceed as outlined in group 7.5. Note the secondary pressure relief setting for additional attachments separately on the checklist. 7.3. Pressure cut off The pressure cut off limits the maximum working pressure. Primary and secondary pressure relief valves are only installed for system safety. Check the pressure as the primary pressure via the tilt circuit or additional attachment circuit without secondary relief. 7.4. Blank line for pressure setting of additional attachment (enter test point / description) 7.5. Blank line for pressure setting of additional attachment (enter test point / description) 8. Pressure difference -p HD to LD (working hydraulic) The p pressure in the fine control range is obtained on the machines with regulating pump A10V = PR 712 B, PR 722 B, PR 732 B und PR 742 B from the setting of the stand-by pressure. The drop of p with the control valve spools fully opened is necessary to obtain the shortest working cycles. 9. Accumulator (working hydraulic) For safety reasons, it must be possible to actuate a function (blade down) several times (within 3 minutes) after the Diesel engine is turned off. 10. Replenishing pressure ( travel hydraulic) If the pressure is too low, find and remedy the problem before continuing machine operation. 11.Hydraulic neutral position (travel hydraulic - travel pumps) Leave the safety lever in the down position. Check first with 0-600 bar pressure gauge, for final check / adjustment, use a 0- 40 / 0-60 bar pressure gauge. The normal pressure reading should correspond to the replenishing pressure. The permissible pressure difference between M1 and M2 may be no more than 1.0 bar. 12.Pressure limitation of maximum system pressure (travel hydraulic) Not adjustable. Check only if needed. Check O-rings on blind flanges. Determine location of test points M1/M2 , depending on the type of travel gear. All work must be performed clean and carefully. Actuate the pumps carefully and hold the maximum pressure only for a short time. Bleed the system after tests.

Caution: Before carrying out tests/adjustments following section B, check the version of the electronic box. If there is a CEP 12/08C, CEP 12/20 or higher electronic box installed, observe section D = evaluate memory.

B. Tests with test box CET 08 / 03


Before carrying out tests / adjustments, check the operational readiness and function of the LED on the test box and its adapter- see 10.4. 1. Identification For identification, the indicators on the adapter and the test box have to be combined. In case of incorrect identification, check the operating condition of test box first - for example: check the rotary switch position and the cable configuration, then check the machine wire harness connections. 2. Battery If the battery is always at undervoltage, check the position of the safety lever and the emergency shut off button first, then continue to check the power supply. 3. Indicator lights - electronic fault indicator- H12 If there is a problem in the system, the time the indicator light lights up can give an initial hint to the problem area. Along with the electronic monitoring indicator light, the 'reduced speed range' indicator light H11 lights up as well. If these lights do not light up during the test, check the bulbs, wiring and relays. 4. Signal - preselection "reduced speed range" 4.1. Reduced travel speed range with push button switch S12 on the panel (0 4,6 km/h) If the LED does not light up during the test, check the switch and wiring. 4.2. Reduced travel speed range with rocker switch S29 on the travel control joystick Rocker switch in position I (04 km/h) = diode must be on Rocker switch in position II (06,5 km/h) = diode must switch off Rocker switch in position III (011 km/h) = diode must be on If the test result is not correct, check the switch and the wiring harness. 5. Signal - counter rotation" If the LED does not light up during the test, or if it turns off during joystick deflection, check the wiring as well as the switch and cable in the joystick. 6. Travel joystick The pointers in the test box must follow the joystick deflection evenly. Erratic movement or lack of movement indicates an error and should be noted as such on the checklist. In the four main directions, at full joystick deflection, the corresponding green LED must light up. In diagonal deflection, most of the time both directional LEDs light up, a jump", however, is within the permitted tolerance range. The red error" diode may not light up in any joystick position. Notes: Do not actuate the push button switch counter rotation while testing the travel joystick - this can cause wrong Error - indications.

7. Proportional solenoids Push the push button for about 15 seconds. If an error is shown, swap the connectors at the proportional solenoids and check again to find the problem - cable or solenoid.

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Quick Reference
Datum Edition Date

PR 712 B PR 722 B PR 732 B PR 742 B


Blatt Page Feuille

F/N xxx-5600 6199 F/N xxx-5600 6199 F/N xxx-5600 6199 F/N xxx-5600 6199

01 03

Adjustment Checklist

3.5.02.03

8. Alternator In case of constant low voltage, always check the position of the safety lever and the emergency shut off button, then continue to check the power supply. Push the push button for about 15 seconds. If the green LED turns off and the red one lights up, check the alternator or V-belt. 9. RPM sensor - Diesel engine Readings at the test box adapter are valid. In case of error indication, remove the sensor and check it visually and/or clean. Check the harness and required distance to the top of the flywheel tooth. Repeat the test. 10.Diesel engine RPM Readings at the test box are valid. If values are too low, check the neutral functions of the hydraulic system. Make adjustments on the stop screws of the engine operation in the cab and when necessary check adjustment of the injection pump - see chapter 17.4. If engine RPM is changed via a lever, the springs may not be fully compressed in any position. 11.Potentiometer The pointer in the test box must follow the throttle position evenly. Jerky movement or lack of movement indicates a defect and should be noted as such on the checklist. Approach test values of potentiometer adjustment from the medium RPM range of the Diesel engine. Determine the difference between the high and low idle (step 10) to those engine speeds and record the RPM where the corresponding LED just lights up (not flicker). If necessary, repeat the test several times. The nominal value should be within 30+20 RPM each. 12. Release the brake When the LED lights up on the test box, the indicator light on the panel must turn off. LED does not light up electrical defect Indicator light does not turn off hydraulic / mechanical defect Caution: If step A-11 was not carried out at all or carried out incorrectly, the chains may already begin to turn. 13. RPM sensor - hydraulic motors Test read out usually starts in speed range 3, however, perform the test as possible in stage 5 (higher signal number). Before changing from left right", stop the track run, switch over and run again. No indication Red diode Problem due to electrical circuit interruption (wiring), possible total sensor failure Mark appropriate square on adjustment check list Sensor sends error signal

14.Basic adjustment - left track The speed of the left track is shown in relation to the stored values in the test box. Carry out the required adjustment corrections until the analog indicator is in the green - center" range, even after several checks. Note: - If an existing adjustment is changed, change the adjustment to the required direction until indication is in the red range during the next test run. Then return the adjustment to the required green range - Always make adjustment changes after the chain stops turning

15.Straight run, right chain compared to the left chain The speed of the right chain is shown in relation to the speed of the left chain, measured via the speed sensors of the travel motors. If no basic adjustment of the left track was made as noted in par. 14, only minor corrections may be made. But in all speed ranges the faster chain has to be matched to the slower chain. If the basic adjustment of the left track was made as noted in par. 14, the right track is matched to the left track. A normal test run can be carried out in the switch position Test". For adjustments, every test run must be made in the switch position Adjust". Correct adjustments until the analog indicator is in the green - center" range, even after several test runs. Note: - If an existing adjustment is changed, change the adjustment to the required direction until the indication is in the red range during the test run. Then return the adjustment to the required green range. - Always make adjustment changes after the chain stops turning. 16. Current supply (Special test during normal travel - test box with Y-cable) This test is only required when troubleshooting. Only the current supply on the right track is measured. Additional indications are due to the switch design and have no meaning. When selecting the travel speed range via push button switch S12 on the panel = use values of column "2ranges", when selecting the travel speed range via rocker switch S29 on the travel control joystick = use values of column "3-ranges". Notes - If the maximum values are not reached, check the position of the throttle control lever. - For the simulation of the required engine load, see paragraph 10.4. 17.Straight run, right chain to left chain (Special test during normal travel - test box with Y-cable) Notes: This test can still be carried out. Caused by the rarely use, this test isn't on the checklist any more. Record the result under section "Remarks".

Perform this test only if the machine cannot be raised off the ground and properly supported. During normal travel operation, the current supply to the right drive side and the speed of the right track in relation to the speed of the left track is shown. Due to external influences, despite a wide tolerance range, large deviations (fluctuating) exist. Additional indications are due to the switch design and have no meaning.

C. Pedal-tests with tester CET 03/08


1. Inch/brake pedal If there is an Inch / brake pedal installed, always perform the check of the adjustments when the electronic box is connected = connect all cables of the tester. Guidelines for the test and further notes see chapter 10.6, section B -1.

D. Edit error memory with E-Box Evaluation Kit


Can only be used for electronic box version CEP12/08C, CEP12/20 and higher. 1. Read error memory Before carrying out tests / adjustments following section B, evaluate the memory, save it on the notebook, print it out or record the codes in the saved order in the adjustment checklist. Repair existing defects. After adjustments, check the memory once again, delete the error memory! Notes: If the program displays "Error" from the beginning, check if the right interface COM1,2,3 or 4 is chosen, check plugs/wiring, check the power supply 24V from the instrument panel.

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Quick Reference
Datum Edition Date

PR 712 B PR 722 B PR 732 B PR 742 B


Blatt Page Feuille

F/N xxx-5600 6199 F/N xxx-5600 6199 F/N xxx-5600 6199 F/N xxx-5600 6199

01 03

Adjustment Checklist

3.5.02.04

Customer - Name and address:

Machine type: Job application/ location:

PIN:

Sm-hrs.:

Date:

Checked by: from company:

A Tests with standard test instruments - test with Diesel engine RPM at 1000 RPM or as outlined
Test No. 1. 2. 3. Test Test points Nominal value Remarks Test value actual value adjusted value o.k. remarks o.k. remarks fluids, filters, mech. components, etc.. at PR 712 to PR 732 - only if necessary for test / adjustment see guidelines PR 712 Diesel engine at nmax, PR 722 at least one sensor unplugged. PR 732 PR 742 must remain constant during all tests working hydraulic bar PR 712, PR 722 (A10V-without stand-by valve) bar PR 732, PR 742 (A10V-with stand-by valve) bar bar bar bar bar bar bar

Visual test and maintenance Cold start valve replenishing circuit Pressure limitation fan drive

SD LA

Hydraulic system checked: changed: theoretic 1 25 bar yes no yes no +10 110 bar bar -+10 130 bar bar -+10 150 bar bar -+10 bar -210 bar 70 C
10 7

4. 5. 6. 7.

Operating temperature Servo pressure Stand by pressure Pressure limitation 7.1 Prim. pressure 7.2 Sec. pressure 7.3 Pressure cut off 7.4 7.5 Pressure difference = p Accumulator Replenishing pressure Hydr. neutral pos. travel hydraulic

hydraulic tank ND working hydr HD working hydr. HD

C bar bar bar bar bar bar bar bar bar bar bar bar bar bar bar bar bar bar bar bar --

18+ bar 20 bar 1 25+ bar 220 bar 5 210 bar 5 160 bar bar bar
5 +1

lift cylinder circuit max. working pressure pressure settings for optional hydraulic functions in fine control range (check only if necessary) when spool is fully shifted possible actuation after engine is turned off PR 712 to PR 732 PR 742 pump right pump left check only if necessary use test flanges!

8. 9. 10. 11.

working hydr HD to LD test SP travel hydr. Shaft right M1 + M2 Shaft left M1 + M2 M1 right M1 left M2 right M2 left

12.

Max. pressure travel forward Max. pressure travel reverse

14+ bar <13 bar min. 4x +4 16 bar 3 25 bar M1 = M2 1 bar M1 = M2 1 bar +30/-10 420 bar +30/-10 420 bar
6

M1 M2 M1 M2 ri le ri le

bar bar bar bar bar bar bar bar

B. Edit error memory with E-Box Evaluation Kit - following the software instructions
T.No.

1. 1.1

Test Read memory Record codes

Before checklist step C/D memory available: yes no

After checklist step C/D memory deleted: yes no

Remarks Print out memory following the software instructions and add the adjustment checklist, or record here in saved order.

C. Pedal-tests with tester CET 03/08 (see Service Manual section 10.6/chapter "fine adjustment") - Diesel engine not running
Pedal installed
T.No.

yes Test

no During test adjustments according to guidelines yes no After adjustment / repair adjustments according to guidelines yes no Remarks observe display - "Inchpedal ext" etc. LED "Voltage" must be always green

1.

Inch/brake pedal

Remarks to A - B - C:

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!
Datum Edition Date

PR 712 B PR 722 B PR 732 B PR 742 B

F/N xxx-6200 F/N xxx-6200 F/N xxx-6200 F/N xxx-6200

01 03

Adjustment Checklist

Blatt Page Feuille

3.5.03.01

D. Test with test box CET 08/03 H (see SM - section 10.4) and adapter CET 14/03 or CET 14/05
- mark LED which lights up or note position of analog indicator (space No. = at test box, A = at adapter) - test with Diesel engine RPM at max. RPM or as noted - after all adjustments are done check and delete E-Box memory - see step B. LED - color: = green = yellow = red indicators = Test No. 1. 2. 3. 4. Test Space No. A/6 8 9 9
Inl.6

During test Diesel engine is not running

After adjustment / repair.

Remarks

Identification Battery Indicator light electron. fault ind. Signal


travel speed range selection

V6/Inl.4

752/X.....

Inl.6

V6/Inl.4

752/X.....

record denomination of LED after approx. 10 sec. of actuation light at panel = on instrument panel of machine ("reduced speed" light lights together) 3-ranges - normal = III - red. speed range II - red. speed range I press button and deflect joystick in all directions = analogic display of sections after approx. 10 sec. of actuation

o.k. light at panel on:

undervolt. yes no

o.k. light at panel on:

undervolt. yes no

no signal no signal no signal signal error good defect

no signal no signal no signal signal error good defect

5. 6. 7.

Signal counterrot." Travel joystick Proportional solenoids

9 4 11

Diesel engine running 8. 9. 10. Alternator RPM sensor Diesel engine RPM Diesel engine Potentiometer nominal RPM Brake release 8 A 2 overv. low min: o.k. o.k. underv. high max: overv. low min: o.k. o.k. underv. Diesel engine approx. 1500 RPM / test for 10 sec. high max: must be green from nmin up to nmax
+50

min: 800 RPM max: PR 712 / 722 ...............- RPM -................. ...............- RPM -................. PR 732 / 742 good defect on off right left forward 2 forward 3 reverse 2 reverse 3 forward 4 forward 5 reverse 4 reverse 5 Adjust Adjust yes no forward 1 yes forward 2 forward 3 yes no reverse 1 yes reverse 2 reverse 3 forward 4 forward 5 reverse 4 reverse 5 mA mA {max.-.....RPM {min.+.....RPM light at panel: good defect on off right left

2100 RPM +80 1900 RPM


+20

+80

11. 12.

3 14

{max.-.....RPM {min.+.....RPM light at panel:

should be green at nmax -30 RPM and +20 nmin +30 RPM / = indication at part. range must be functioning for all remaining tests machine must be raised off the ground  = no indication / must be "ok" for further tests pump regulating range forward pump end of regulating forward pump regulating range reverse pump end of regulating reverse motor regulating range forward control tests values are resulting from previous adjustments

Tracks running 13. 14. RPM sensor oil motors Basic adjustment left track - only if required 13 14 forward 2 forward 3 reverse 2 reverse 3 forward 4 forward 5 reverse 4 reverse 5 Test forward 1 forward 2 forward 3 reverse 1 reverse 2 reverse 3 forward 4 forward 5 reverse 4 reverse 5 (440 ) max.
20

15.

Straight run compare track right to track left

14

note position of rotary switch no travel begin forward - tracks start to turn pump regulating range forward pump end of regulating forward no travel begin reverse - tracks start to turn pump regulating range reverse pump end of regulating reverse motor regulating range forward control tests values are resulting from previous adjustments throttle lever must be at max. RPM position initial current jump
PR 712 - 1450+70 mA PR 722 - 1445+70 mA +70 PR 732 - 1410 mA PR 742 - 1380+70 mA PR 712 - 1240+50 mA PR 722 - 1235+50 mA +50 PR 732 - 1230 mA PR 742 - 1160+50 mA forward / 1230+50 mA reverse PR 712 - 910+50 mA PR 722 - 900+50 mA +50 PR 732 - 890 mA PR 742 - 890+50 mA forward / 1000+50 mA reverse

Special tests - travel operation 16. Current supply 16.1 Diesel engine not running 2

in normal speed range (switch position III)

max. f.

/r.

mA

in reduced speed range (switch position II)

forward: reverse: forward: reverse:

max. f.

/r.

mA

in reduced speed range (switch position I)

16.2 Diesel engine running

(1180 ) 20 (440 )
80

mA mA

reduced value when steering left (normal range) initial current jump

Remarks:

Adjustment guidelines - quick reference and explanations


Complete the test procedure according to the checklist, even for a partial check. Use pressure gauges appropriate for the test ranges. To test the track speed / straight run, raise the machine off the ground and support it properly, so that the chains can turn freely without danger. Make sure to observe all safety guidelines - see group 1.2.01! Use only the correct tools (test instruments). The Diesel engine RPMs must be as noted. Perform all required maintenance work before adjustment. In case of questions, make sure to use the detailed instructions: for the adjustment of the travel hydraulic, see section 6.5.00, for the adjustment of the working hydraulic, see section 7.5.10 ,for the use of the test box CET 08/03, see section 10.4.00. and for the use of the pedal control tester, see section 10.6.00. When putting the machine into service, proceed according to the guidelines given in the Operation and Maintenance Manual. Check all indicators and gauges to ensure they are functioning correctly. Defects must be repaired immediately or as soon as possible, depending on the type of problem.

A. Tests with standard test instruments


All pressure tests must be performed at 1000 RPM (without engine load) unless noted otherwise. 1. Visual tests and maintenance Insufficient maintenance and mechanical component defects often point to the cause of the problem. Check oil levels, filters, coolant level, mechanical components and their mounting, cables and wiring harnesses, etc. Repair any detected defects immediately or as soon as possible, depending on the type of problem. 2. Cold start valve (travel hydraulic) Needs to be checked only for troubleshooting (example: in case of temperature problems). Valve should be closed, with the oil at operating temperature (also valid for by-pass valve on PR 742B). Check adjustment, see group 6.5, p. 3. 3. Pressure limitation (fan drive) When the sensor is unplugged and the Diesel engine is on high idle, the postulated maximum pressure has to be reached. The proportional - pressure relief valve is not adjustable and is regulated by the electronic. When overheating in spite of right pressure and clean radiator, in every case check the fan RPM. This RPM doesn't depends only on pressure (also on air supply, turning resistance, damages, and suchlike). for RPM see technical data 3.1, Instructions see chapter 6.5. 4. Operating temperature If the operating temperature is reached only for a short time, cover the cooler (air flow) partially for the test / adjustment. With the oil at operating temperature, before performing additional tests, actuate all hydraulic functions and monitor the temperature constantly. For additional information about bringing the hydraulic system to operating temperature, see group 6.5 or 7.5. 5. Servo pressure (working hydraulic) Not adjustable - is a result of SP pressure. In case of problems, for example Quick drop, see Adjustment Working hydraulic, group 7.5.10. 6. Stand-by pressure (working hydraulic) This pressure is the basis for the proper function of the entire working hydraulic system. Note: Only the A10V100 pumps in PR732 and the A10V140 pumps in PR 742B machines, are equipped with the stand-by valve (which is installed between the regulator and the pump housing). The adjustment on all A10V-pumps is made on the LS regulator.
Benennung Description Dnomination Typ/ab Type/from Type/ a partir de

Mjfcifss!

Quick Reference
Datum Edition Date

PR 712 B PR 722 B PR 732 B PR 742 B


Blatt Page Feuille

F/N xxx-6200 F/N xxx-6200 F/N xxx-6200 F/N xxx-6200

01 03

Adjustment Checklist

3.5.03.02

7. Pressure limitation (working hydraulic) 7.1. Primary pressure To check, raise the pressure cut off setting. Check the pressure via the tilt circuit or additional attachments without secondary relief. 7.2. Secondary pressure To check, raise the pressure cut off and primary pressure setting. For the blade down function, block the line or proceed as outlined in group 7.5. Note the secondary pressure relief setting for additional attachments separately on the checklist. 7.3. Pressure cut off The pressure cut off limits the maximum working pressure. Primary and secondary pressure relief valves are only installed for system safety. Check the pressure as the primary pressure via the tilt circuit or additional attachment circuit without secondary relief. 7.4. Blank line for pressure setting of additional attachment (enter test point / description) 7.5. Blank line for pressure setting of additional attachment (enter test point / description) 8. Pressure difference -p HD to LD (working hydraulic) The p pressure in the fine control range is obtained on the machines with regulating pump A10V = PR 712 B, PR 722 B, PR 732 B und PR 742 B from the setting of the stand-by pressure. The drop of p with the control valve spools fully opened is necessary to obtain the shortest working cycles. 9. Accumulator (working hydraulic) For safety reasons, it must be possible to actuate a function (blade down) several times (within 3 minutes) after the Diesel engine is turned off. 10. Replenishing pressure (travel hydraulic) If the pressure is too low, find and remedy the problem before continuing machine operation. 11.Hydraulic neutral position (travel hydraulic - travel pumps) Leave the safety lever in the down position. Check first with 0-600 bar pressure gauge, for final check / adjustment, use a 0- 40 / 0-60 bar pressure gauge. The normal pressure reading should correspond to the replenishing pressure. The permissible pressure difference between M1 and M2 may be no more than 1.0 bar. 12.Pressure limitation of maximum system pressure (travel hydraulic) Not adjustable. Check only if needed. Check O-rings on blind flanges. Determine location of test points M1/M2, depending on the type of travel gear. All work must be performed clean and carefully. Actuate the pumps carefully and hold the maximum pressure only for a short time. Bleed the system after tests.

B. Edit error memory with E-Box Evaluation Kit


1. Read error memory Before carrying out tests / adjustments following section C/D, evaluate the memory, save it on the notebook, print it out or record the codes in the saved order in the adjustment checklist. Repair existing defects. After adjustments according to checklist step C and D, check the memory once again, delete the error memory! Notes: If the program displays "Error" from the beginning, check if the right interface COM1,2,3 or 4 is chosen, check plugs/wiring, check the power supply 24V from the instrument panel.

C. Pedal-tests with tester CET 03/08


1. Inch/brake pedal If there is an Inch / brake pedal installed, always perform the check of the adjustments when the electronic box is connected = connect all cables of the tester. Guidelines for the test and further notes see chapter 10.6, section B -1.

D. Tests with test box CET 08/03


Before carrying out tests / adjustments, check the operational readiness and function of the LED on the test box and its adapter- see 10.4. 1. Identification For identification, the indicators on the adapter and the test box have to be combined. In case of incorrect identification, check the operating condition of test box first - for example: check the rotary switch position and the cable configuration, then check the machine wire harness connections. 2. Battery If the battery is always at undervoltage, check the position of the safety lever and the emergency shut off button first, then continue to check the power supply. 3. Indicator lights - electronic fault indicator- H12 If there is a problem in the system, the time the indicator light lights up can give an initial hint to the problem area. Along with the electronic monitoring indicator light, the 'reduced speed range' indicator light H11 lights up as well. If these lights do not light up during the test, check the bulbs, wiring and relays. 4. Signal - preselection "reduced speed range" with rocker switch S29 on the travel control joystick Rocker switch in position I (04 km/h) = diode must be on Rocker switch in position II (06,5 km/h) = diode must switch off Rocker switch in position III (011 km/h) = diode must be on If the test result is not correct, check the switch and the wiring harness. 5. Signal - counter rotation" If the LED does not light up during the test, or if it turns off during joystick deflection, check the wiring as well as the switch and cable in the joystick. 6. Travel joystick The pointers in the test box must follow the joystick deflection evenly. Erratic movement or lack of movement indicates an error and should be noted as such on the checklist. In the four main directions, at full joystick deflection, the corresponding green LED must light up. In diagonal deflection, most of the time both directional LEDs light up, a jump", however, is within the permitted tolerance range. The red error" diode may not light up in any joystick position. Notes: Do not actuate the push button switch counter rotation while testing the travel joystick - this can cause wrong Error - indications.

7. Proportional solenoids Push the push button for about 15 seconds. If an error is shown, swap the connectors at the proportional solenoids and check again to find the problem - cable or solenoid.

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Quick Reference
Datum Edition Date

PR 712 B PR 722 B PR 732 B PR 742 B


Blatt Page Feuille

F/N xxx-6200 F/N xxx-6200 F/N xxx-6200 F/N xxx-6200

01 03

Adjustment Checklist

3.5.03.03

8. Alternator In case of constant low voltage, always check the position of the safety lever and the emergency shut off button, then continue to check the power supply. Push the push button for about 15 seconds. If the green LED turns off and the red one lights up, check the alternator or V-belt. 9. RPM sensor - Diesel engine Readings at the test box adapter are valid. In case of error indication, remove the sensor and check it visually and/or clean. Check the harness and required distance to the top of the flywheel tooth. Repeat the test. 10.Diesel engine RPM Readings at the test box are valid. If values are too low, check also the neutral functions of the hydraulic system. Make adjustments on the stop screws of the engine operation in the cab and when necessary check adjustment of the injection pump - see chapter 17.4. If engine RPM is changed via a lever, the springs may not be fully compressed in any position. 11.Potentiometer The pointer in the test box must follow the throttle position evenly. Jerky movement or lack of movement indicates a defect and should be noted as such on the checklist. Approach test values of potentiometer adjustment from the medium RPM range of the Diesel engine. Determine the difference between the high and low idle (step 10) to those engine speeds and record the RPM where the corresponding LED just lights up (not flicker). If necessary, repeat the test several times. The nominal value should be within 30+20 RPM each. 12. Release the brake When the LED lights up on the test box, the indicator light on the panel must turn off. LED does not light up electrical defect Indicator light does not turn off hydraulic / mechanical defect Caution: If step A-11 was not carried out at all or carried out incorrectly, the chains may already begin to turn. 13. RPM sensor - hydraulic motors Test read out usually starts in speed range 3, however, perform the test as possible in stage 5 (higher signal number). Before changing from left right", stop the track run, switch over and run again. No indication Red diode Problem due to electrical circuit interruption (wiring), possible total sensor failure Mark appropriate square on adjustment check list Sensor sends error signal

14.Basic adjustment - left track The speed of the left track is shown in relation to the stored values in the test box. Carry out the required adjustment corrections until the analog indicator is in the green - center" range, even after several checks. Note: - If an existing adjustment is changed, change the adjustment to the required direction until indication is in the red range during the next test run. Then return the adjustment to the required green range - Always make adjustment changes after the chain stops turning

15.Straight run, right chain compared to the left chain The speed of the right chain is shown in relation to the speed of the left chain, measured via the speed sensors of the travel motors. If no basic adjustment of the left track was made as noted in par. 14, only minor corrections may be made. But in all speed ranges the faster chain has to be matched to the slower chain. If the basic adjustment of the left track was made as noted in par. 14, the right track is matched to the left track. A normal test run can be carried out in the switch position Test". For adjustments, every test run must be made in the switch position Adjust". Correct adjustments until the analog indicator is in the green - center" range, even after several test runs. Note: - If an existing adjustment is changed, change the adjustment to the required direction until the indication is in the red range during the test run. Then return the adjustment to the required green range. - Always make adjustment changes after the chain stops turning. 16. Current supply (Special test during normal travel - test box with Y-cable) This test is only required when troubleshooting. Only the current supply on the right track is measured. Additional indications are due to the switch design and have no meaning. Notes: - If the maximum values are not reached, check the position of the throttle control lever.

17.Straight run, right chain to left chain (Special test during normal travel - test box with Y-cable) Notes: This test can still be carried out. Caused by the rarely use, this test isn't on the checklist any more. Record the result under section "Remarks".

Perform this test only if the machine cannot be raised off the ground and properly supported. During normal travel operation, the current supply to the right drive side and the speed of the right track in relation to the speed of the left track is shown. Due to external influences, despite a wide tolerance range, large deviations (fluctuating) exist. Additional indications are due to the switch design and have no meaning.

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Quick Reference
Datum Edition Date

PR 712 B PR 722 B PR 732 B PR 742 B


Blatt Page Feuille

F/N xxx-6200 F/N xxx-6200 F/N xxx-6200 F/N xxx-6200

01 03

Adjustment Checklist

3.5.03.04

Customer - Name and address:

Machine type:

PIN:

Sm-hrs.:

Date:

Job application/ location: Checked by: from company:

A. Tests with standard test instruments - test with Diesel engine RPM at 1000 RPM or as outlined
Test No. 1. 2. 3. 4. 5. 6. 7. 8. 9. Test Test points Remarks Test value actual value adjusted value o.k. remarks o.k. remarks fluids, filters, mech. components, etc. Hydraulic system 30+
10 3

Nominal value

Visual tests and maintenance Stand by pressure Operating temperature Pressure limitation Cold start valve replenishing circuit Servo pressure Pressure difference = p Stand by pressure Pressure limitation 9.1 Prim. pressure 9.2 Sec. pressure 9.3 Pressure cut off 9.4 9.5 Accumulator Repl. pressure Hydr. neutral pos. travel hydraulic

fan drive. - LA Hydraulic tank LA travel hydr. SD ND working hydr. HD to LS HD working hydr. HD

bar C bar

bar A10V - check when machine is cold must remain constant during all tests C bar fan drive - A10V/Diesel engine at max RPM

70 C 160 theoretic 28+2 bar


3

25+ bar
3

- check only if necessary changed: checked: no - for test / adjustment see guidelines yes no yes bar -working hydraulic bar bar bar bar bar bar bar bar bar bar bar bar bar bar bar bar bar bar bar in fine control range - adjust at HPR-pump bar when spool is fully shifted bar working hydraulic - adjust at HPR-pump bar bar bar bar bar bar

15 bar <13 bar 30+ bar


5

+6

10. 11. 12.

test SP right M1 + M2 left M1 + M2 M1 rights M1 left M2 right M2 left

13.

Max. pressure travel forward Max. pressure travel reverse

270 bar 5 250 bar 5 250 bar 5 200 bar bar bar min. 4x +7 20 bar M1 = M2 1 bar M1 = M2 1 bar +30/-10 420 bar +30/-10 420 bar
5

lift cylinder circuit - piston bottom side = A1 lift cylinder circuit - piston rod side = B1 max. working pressure pressure settings for optional hydraulic functions possible actuation after engine is turned off travel hydraulic

M1 M2 M1 M2 ri le ri le

bar bar bar bar bar bar bar bar

pump right pump left check only if necessary use test plates!

B. Test with test box CET 08/03 H (see SM - section 10.4) and adapter CET 14/05
- mark LED which lights up or note position of analog indicator (space No. = at test box, A = at adapter) - test with Diesel engine RPM at max. RPM or as noted LED - color: = green = yellow = red indicators = Test. No. 1. 2. 3. 4. Test Space No. A/6 8 9 9
Inl.6

During test Diesel engine is not running

After adjustment / repair.

Remarks

Identification Battery Indicator light electron. fault ind. Signal


travel speed range selection

V6/Inl.4

752/X.....

Inl.6

V6/Inl.4

752/X.....

record denomination of LED after approx. 10 sec. of actuation light at panel = on instrument panel of machine ("reduced speed" light lights together) 2-ranges -normal range 3-ranges - normal = III - select "red. speed range" - red. speed range II -- red. speed range I press button and deflect joystick in all directions = analogic display of sections after approx. 10 sec. of actuation

o.k. light at panel on:

undervolt. yes no

o.k. light at panel on:

undervolt. yes no

no signal no signal no signal signal error good defect

no signal no signal no signal signal error good defect

5. 6. 7.

Signal counter rot. Travel joystick Proportional solenoids

9 4 11

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!
Datum Edition Date

01 03

Adjustment Checklist

PR 752 F/N xxx- 2002 5599


Blatt Page Feuille

3.5.50.01

Test. No.

Test

Space No.

During test Diesel engine running

After adjustment / repair

Remarks

8. 9. 10. 11. 12. 13.

Alternator RPM sensor Diesel engine RPM Diesel engine Potentiometer nominal RPM Overspeeding protection / D-engine Brake release

8 A A 3 A 14

overv. low

o.k. o.k.

underv. high

overv. low

o.k. o.k.

underv. Diesel engine approx. 1500 RPM / test for 10 sec. high must be green from nmin up to nmax
+50

min: max: min: max: min: 800 RPM +60 ...............- RPM -................. ...............- RPM -................. max: 1900 RPM {max.-......RPM good {min.+......RPM defect Function available: {max.-......RPM good {min.+......RPM defect should be green at nmax -30 RPM and +20 nmin +30 RPM / = indication at part. range
+20

yes Function available: no Light at panel:

yes press button RPM drop at engine working hydraulic - HD = max. no on off right left must be functioning for all remaining tests machine must be raised off the ground

Light at on panel: off Tracks running right left

14.

RPM sensor travel gear

13

= no Indication/ must be ok for further tests

Disconnect servo lines from pump-connection X to travel motor - see instructions 15.1. basic adjustment forward 2 forward 2 Pump regulating range forward 14 left track forward 3 forward 3 Pump end of regulation forward reverse 2 reverse 2 Pump regulating range reverse reverse 3 reverse 3 Pump end of regulation reverse note position of rotary switch 14 16.1 Straight run Test" "Adjust Adjust compare track right forward 1 yes no forward 1 yes no travel begin forward - tracks starts to turn to track left forward 2 forward 2 Pump regulating range forward forward 3 reverse 1 reverse 2 reverse 3 15.2 16.2 yes forward 3 no reverse 1 reverse 2 reverse 3 yes Pump end of regulation forward no travel begin reverse - tracks starts to turn Pump regulating range reverse Pump end of regulation reverse

Servo lines from pump-connection X connected to one travel motor on each side - see instruction Basic adjustment forward 4 forward 4 left motor regulating range forward 14 left track reverse 4 reverse 4 control test Straight run 14 forward 4 forward 4 right motor regulating range forward right track reverse 4 reverse 4 control test Servo lines from pump-connection X connected to all travel motors - see instruction basic adjustment 14 forward 4 forward 4 left motor regulating range forward left track forward 5 forward 5 left motor - mech. end stop - Qmin control test - values are resulting from previous reverse 4 reverse 4 adjustments reverse 5 reverse 5 Straight run compare track right to track left 14 forward 4 forward 4 forward 5 forward 5 reverse 4 reverse 4 reverse 5 reverse 5 Special tests - travel operation (440 ) max.
20

15.3

16.3

right motor regulating range forward right motor - mech. end stop - Qmin control test - values are resulting from previous adjustments throttle lever must be at max. RPM position initial current jump 2-ranges 70 1350+ mA +50 950 mA -3-ranges 70 1350+ mA (Switch pos. III) 50 1170+ mA (Switch pos. II) 870+ mA
50

17.

current supply 17.1 Diesel engine not running

mA mA mA mA

in normal speed range

max.
in reduced speed range

max.
in reduced speed range

(Switch pos. I)

(1180 )
80

mA mA mA | | | | mA mA mA mA

reduced value when steering left (normal speed) initial current jump minimum current at maximum load (RPM drop) forward with approx. 550 mA reverse with approx. 550 mA forward with approx. 950 mA reverse with approx. 950 mA

17.2 Diesel engine running 18. Straight run compare right to track left

2 14 +2

(440 | | | |

20

) )

(500+

100

mA mA mA mA

If installed:

C. Pedal-tests with tester CET 03/08 (see Service Manual section 10.6/chapter "fine adjustment") - Diesel engine not running
T.No. 1. Test Inch/brake pedal During test adjustments according to guidelines yes no After adjustment /repair adjustments according to guidelines yes no Remarks observe display - "Inchpedal ext" etc. LED "Voltage" must be always green

Remarks:

Adjustment guidelines - quick reference and explanations


Complete the test procedure according to the checklist, even for a partial check. Use pressure gauges appropriate for the test ranges. To test the track speed / straight run, raise the machine off the ground and support it properly, so that the chains can turn freely without danger. Make sure to observe all safety guidelines see group 1.2.01! Use only the correct tools(test instruments). The Diesel engine RPMs must be as noted. Perform all required maintenance work before adjustment. In case of questions, make sure to use the detailed instructions: for the adjustment of the travel hydraulic, see section 6.5.00, for the adjustment of the working hydraulic, see section 7.5.10 ,for the use of the test box CET 08/03, see section 10.4.00. and for the use of the pedal control tester, see section 10.6.00. When putting the machine into service, proceed according to the guidelines given in the Operation and Maintenance Manual. Check all indicators and gauges to ensure they are functioning correctly. Defects must be repaired immediately or as soon as possible, depending on the type of problem.

A. Tests with standard test instruments


All pressure tests must be performed at 1000 RPM (without an engine load), unless noted otherwise. 1. Visual tests and maintenance Insufficient maintenance and mechanical component defects often point to the cause of the problem. Check oil levels, filters, coolant level, mechanical components and their mounting, cables and wiring harnesses, etc. Repair any detected defects immediately or as soon as possible, depending on the type of problem. 2. Standby pressure - fan drive The pressure determines the minimum RPM for the fan drive motors. Incorrect adjustments can cause failure of the hydraulic motors. Check / adjust with the machine cold. For instructions, refer to group 6.5. When the operating temperature is reached in one of the systems - hydraulic system, Diesel engine coolant circuit or charge air system - the fan drive is automatically changed over from stand by function to working function. 3. Operating temperature If the operating temperature is reached only for a short time, cover the cooler (air flow) partially for the test / adjustment. With the oil at operating temperature, before performing additional tests, actuate all hydraulic functions and monitor the temperature constantly. For additional information about bringing the hydraulic system to operating temperature, see group 6.5 or 7.5 4. Pressure limitation - fan drive The pressure determines the required working (minimum) RPM of the fan drive motors. For details, see group 6.5. 5. Cold start valve (travel hydraulic) Needs to be checked only for troubleshooting. With the oil at operating temperature, only a minimum amount of leak oil should emerge from the valve, otherwise, check the adjustment, see group 6.5, p. 3. 6. Servo pressure (working hydraulic) Not adjustable - is a result of SP pressure. In case of problems, for example Quick drop, see Adjustment working hydraulic, group 7.5.10.

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Quick Reference
Datum Edition Date

PR 752

01 03

Adjustment Checklist

F/N xxx-2002 5599

Blatt Page Feuille

3.5.50.02

7. Pressure difference - p HD to LD (working hydraulic) The correct adjustment of the LS regulator (p) is important for machine performance and simplifies the adjustment of the stand by pressure. The drop of p with the control valve spools fully opened is necessary to obtain the shortest working cycles. 8. Stand-by pressure (working hydraulic) This pressure is the basis for the proper function of the entire working hydraulic system. The adjustment is made via the Qmin stop of the pump. Important: The test value depends very much on the temperature. 9. Pressure limitation (working hydraulic) 9.1. Primary pressure To check, raise the pressure cut off setting. Check the pressure via the tilt circuit or additional attachments without secondary relief. Leave the pressure cut off valve adjustment for the secondary pressure check as is. 9.2. Secondary pressure To check, block pressure lines on lift cylinders - see group 7.5. (Pressure cut off raised from primary pressure check) lift circuit - piston bottom side =A1= lift circuit - piston rod side =B1= blade down blade up

Also check the secondary relief of additional attachments / list on checklist, No. 9.4 / 9.5. 9.3. Pressure cut off The pressure cut off limits the maximum working pressure. Primary and secondary pressure relief valves are only installed for system safety. Check the pressure as the primary pressure via the tilt circuit or additional attachment circuit without secondary relief. 9.4. Blank line for pressure setting of additional attachment (enter description / test points) 9.5. Blank line for pressure setting of additional attachment (enter description / test points) 10. Accumulator (working hydraulic) For safety reasons, it must be possible to actuate a function (blade down) several times (within 3 minutes) after the Diesel engine is turned off. 11. Replenishing pressure (travel hydraulic) If the pressure is too low, find and remedy the problem before continuing machine operation. 12.Hydraulic neutral position (travel hydraulic - travel pumps) Leave the safety lever in the down position. Check first with 0-600 bar pressure gauge, for final check / adjustment, use a 0-60 bar pressure gauge. The normal pressure reading should correspond to the replenishing pressure. The permissible pressure difference between M1 and M2 may be no more than 1.0 bar. 13.Pressure limitation of maximum system pressure (travel hydraulic) Not adjustable. Check only if needed. Check O-rings on blind flanges. To check, close off HD lines on travel motors with blind flanges - see special tools, page 2.1.21.01 and screws M12x50-10.9. For location of test points and details, refer to group 6.5. All work must be performed clean and carefully. Actuate the pumps carefully and hold the maximum pressure only for a short time. Bleed the system after tests.

B. Tests with test box CET 08/03


Before carrying out tests / adjustments, check the operational readiness and function of the LED on the test box and its adapter- see 10.4. LED = light emitting diode 1. Identification For identification, the indicators on the adapter and the test box have to be combined. In case of incorrect identification, check the operating condition of test box first - for example: check the rotary switch position and the cable configuration, then check the wire harness connections. 2. Battery If the battery is always at low voltage, check the position of the safety lever and the emergency shut off button first, then continue to check the power supply. 3. Indicator lights - electronic fault indicator - H12 If there is a problem in the system, the time the indicator light lights up can give an initial hint to the problem area. Along with the electronic monitoring indicator light, the 'reduced travel speed range' indicator light H11 lights up as well. If these lights do not light up during the test, check the bulbs, wiring and relays. 4. Signal - preselection "reduced speed range" 4.1. Reduced travel speed range with push button switch S12 on the panel (0 4,6 km/h) If the LED does not light up during the test, check the switch and wiring. 4.2. Reduced travel speed range with rocker switch S29 on the travel control joystick Rocker switch in position I (04 km/h) = diode must be on Rocker switch in position II (06,5 km/h) = diode must switch off Rocker switch in position III (011 km/h) = diode must be on If the test result is not correct, check the switch and the wiring harness.

5. Signal - counter rotation" If the LED does not light up during the test, or if it turns off during joystick deflection, check the wiring as well as the switch and cable in the joystick. 6. Travel joystick The pointers in the test box must follow the joystick deflection evenly. Erratic movement or lack of movement indicates an error and should be noted as such on the checklist. In the four main directions, at full joystick deflection, the corresponding green LED must light up. In diagonal deflection, most of the time both directional LEDs light up, a jump", however, is within the permitted tolerance range. The red error" diode may not light up in any joystick position. Notes: Do not actuate the push button switch counter rotation while testing the travel joystick - this can cause wrong Error - indications.

7. Proportional solenoids Push the push button for about 15 seconds. If an error is shown, swap the connectors at the proportional solenoids and check again to find the problem - cable or solenoid.

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Quick Reference
Datum Edition Date

PR 752

01 03

Adjustment Checklist

F/N xxx-2002 5599

Blatt Page Feuille

3.5.50.03

8. Alternator In case of constant low voltage, always check the position of the safety lever and the emergency shut off button, then continue to check the power supply. Push the push button for about 15 seconds. If the green LED turns off and the red one lights up, check the alternator or V-belt. 9. RPM sensor - Diesel engine Readings at the test box adapter are valid. In case of error indication, remove the sensor and check it visually and/or clean. Check the harness and required distance to the top of the flywheel tooth. Repeat the test. 10.Diesel engine RPM Readings at the test box adapter are valid. If values are too low, check function and routing of throttle control. Make adjustments primary on the control lever stops on the operators platform (tilt cab). 11.Potentiometer The pointer in the test box must follow the throttle position evenly. Jerky movement or lack of movement indicates a defect and should be noted as such on the checklist. Approach test values of potentiometer adjustment from the medium RPM range of the Diesel engine. Determine the difference between the high and low idle (step 10) to those engine speeds and record the RPM where the corresponding LED just lights up (not flicker). If necessary, repeat the test several times. The nominal value should be within 30+20 RPM each. 12.Overspeed safety - Diesel engine If the Diesel engine speed is not reduced significantly during the test and the pressure on the working hydraulic test point HD will not overcome primary setting, check the function of the solenoid valve and the pump regulator. See schematic, group 7.3. 13. Release the brake When the LED lights up on the test box, the indicator light H4 on the panel must turn off. LED does not light up electrical defect Indicator light does not turn off hydraulic / mechanical defect Caution: If step A-12 was not carried out at all or carried out incorrectly, the chains may already begin to turn. 14.RPM sensor - travel gear Test read out usually starts in speed range 3, however, perform the test always in stage 5 (higher signal number). Before changing from left right", stop the track run, switch over and run again. No indication Red diode problem due to electrical circuit interruption, possible total sensor failure mark appropriate square on check list sensor sends error signal.

15. / 16.Basic adjustment - left track / Straight run, right chain compared to the left chain A pre-check can be made during an inspection without closing off the control lines, limited to the following checklist points (right switch on test box to position "TEST"): 16.1 - forward 1 - forward 2 - reverse 1 - reverse 2 Note: 16.3 - forward 4 - forward 5 - reverse 4

If the indication is outside the "green center" range for one of these tests, then all tests / adjustment steps must be made according to the check list (right switch on test box in straight run adjustment position "ADJUST"). If one of the stages 3 are selected, the chains are running at full speed.

Attention:

Test steps for par. 15 "basic adjustment - left track " show the speed of the left chain in relation to the values stored in the test box. Adjustments are made on the left travel drive side. Test steps for par. 16 "straight run, right chain compared to left chain " show the speed of the right chain in relation to the speed of the left chain. Adjustments are made on the right travel drive side. Basic adjustments and straight run must be made in 3 groups, since the travel motors are hydraulically controlled by the pumps and there are 2 motors for each side. Group 15.1 / 16.1= Check / adjustment of pumps. Close of servo lines to motors on pump outlets (motors remain on Qmax). analog indicator "green center" Check / adjustment of motor per side. Servo lines to motors on pump outlets are reconnected, close off servo lines to one motor per side (motors remain on Qmax). Analog indicator exactly over the dividing line between the red indicator field SLOW and the green indicator field. "Center green" may not be exceeded. Analog indicator "Green center"

Correct adjustment for both groups: Group 15.2 / 16.2 =

Correct adjustment for group 15.2:

Correct adjustment for group 16.2: Group 15.3 / 16.3 =

Check / adjustment of one motor per side. Servo lines to all motors are reconnected. analog indicator "green center", for 15.3, the red indicator field "FAST" may never be reached.

Correct adjustment for both groups: Note:

- If an existing adjustment is changed, change it in the corresponding direction past the required indication value. Then reset it to the required value - see above. - Always make adjustments only after the chain stops turning. - Correct adjustments until the analog indicator remains in the required range, even after several rechecks. - If an adjustment must be made in stage 5 / mech. Qmin stop (group 15.3 / 16.3), determine the dimension of adjustment screw on both travel motors for the side to be adjusted. Chain too quick Chain too slow on travel motor with larger screw overlap, turn the adjustment screw in clockwise direction. on travel motor with smaller screw overlap, turn the adjustment screw in counterclockwise direction.

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Quick Reference
Datum Edition Date

PR 752

01 03

Adjustment Checklist

F/N xxx-2002 5599

Blatt Page Feuille

3.5.50.04

17.Current supply (special tests during normal travel - test box with Y-cable) This test is only required when troubleshooting. Only the current supply on the right track is measured. Additional indications are due to the switch design and have no meaning. When selecting the travel speed range via push button switch S12 on the panel = use values of column "2ranges", when selecting the travel speed range via rocker switch S29 on the travel control joystick = use values of column "3-ranges". Notes - if the maximum values are not reached, check the position of the throttle control lever. - for the simulation of the required engine load, see paragraph 10.4. 18.Straight run, right chain to left chain (special test during normal travel - test box with Y-cable) Perform this test only if the machine cannot be raised off the ground and properly supported. During normal travel operation, the current supply to the right drive side and the speed of the right track in relation to the speed of the left track is shown. Due to external influences, despite a wide tolerance range, large deviations (fluctuating)exist Additional indications are due to the switch design and have no meaning

C. Pedal-tests with tester CET 03/08


1. Inch/brake pedal If there is an Inch / brake pedal installed, always perform the check of the adjustments when the electronic box is connected = connect all cables of the tester. Guidelines for the test and further notes see chapter 10.6, section B -1.

Customer - Name and address:

Machine type:

PIN:

Sm-hrs.:

Date:

Job application/ location: Checked by: from company:

A. Tests with standard test instruments - test with Diesel engine RPM at 1000 RPM or as outlined
Test No. 1. 2. 3. Test Test points Test value Remarks actual value adjusted value o.k. remarks o.k. remarks fluids, filters, mech. components, etc. Hydraulic system 30
5

Nominal value

Visual tests and maintenance Stand by pressure Pressure cut off fan drive - ex factory 3.1 spare pump Operating temperature Cold start valve replenishing circuit Servo pressure Pressure difference = p Stand by pressure Pressure limitation 9.1 Prim. pressure 9.2 Sec. pressure 9.3 Pressure cut off 9.4 9.5 Accumulator Repl. pressure Hydr. neutral pos. travel hydraulic

fan drive. - LA LA

bar bar bar C yes

bar check w. cold machine/Diesel engine to nmax fuse F9 opened/Diesel engine at max RPM bar Caution: varied adjustments with special equipments - see page 2 bar must remain constant during all tests C

177+5 5 205 70 C theoretic 28+2 bar 25+ bar 15 bar <13 bar 30+ bar 270 bar 5 250 bar 5 250 bar 5 200 bar bar bar min. 4x +7 20 bar M1 = M2 1 bar M1 = M2 1 bar +30/-10 420 bar +30/-10 420 bar
5 5 +6 3 10

4. 5. 6. 7. 8. 9.

Hydraulic tank travel hydr. SD ND working hydr. HD to LS HD working hydr. HD

checked: changed: - check only if necessary no yes no - for test / adjustment see guidelines bar -working hydraulic bar bar bar bar bar bar bar bar bar bar bar bar bar bar bar bar bar bar bar in fine control range - adjust at HPR-pump bar when spool is fully shifted bar working hydraulic - adjust at HPR-pump bar bar bar bar bar bar

lift cylinder circuit - piston bottom side = A1 lift cylinder circuit - piston rod side = B1 max. working pressure pressure settings for optional hydraulic functions possible actuation after engine is turned off travel hydraulic

10. 11. 12.

test SP right M1 + M2 left M1 + M2 M1 rights M1 left M2 right M2 left

13.

Max. pressure travel forward Max. pressure travel reverse

M1 M2 M1 M2 ri le ri le

bar bar bar bar bar bar bar bar

pump right pump left check only if necessary use test plates!

B. Test with test box CET 08/03 H (see SM - section 10.4) and adapter CET 14/05
- mark LED which lights up or note position of analog indicator (space No. = at test box, A = at adapter) - test with Diesel engine RPM at max. RPM or as noted - with e-box CEP12/08C, CEP12/20 first observe section D LED - color: = green = yellow = red indicators = Test. No. 1. 2. 3. 4. Test Space No. A/6 8 9 9
Inl.6

During test Diesel engine is not running

After adjustment / repair.

Remarks

Identification Battery Indicator light electron. fault ind. Signal


travel speed range selection

V6/Inl.4

752/X.....

Inl.6

V6/Inl.4

752/X.....

record denomination of LED after approx. 10 sec. of actuation light at panel = on instrument panel of machine ("reduced speed" light lights together) 3-ranges normal = III - red. speed range II - red. speed range I

o.k. light at panel on:

undervolt. yes no

o.k. light at panel on:

undervolt. yes no

no signal no signal no signal signal error good defect

no signal no signal no signal signal error good defect

5. 6. 7.

Signal counter rot. Travel joystick Proportional solenoids

9 4 11

press button and deflect joystick in all directions = analogic display of sections after approx. 10 sec. of actuation

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!
Datum Edition Date

PR 752 F/N xxx-5600 6199

01 04

Adjustment Checklist

Blatt Page Feuille

3.5.51.01

Test. No.

Test

Space No.

During test Diesel engine running

After adjustment / repair

Remarks

8. 9. 10. 11. 12. 13.

Alternator RPM sensor Diesel engine RPM Diesel engine Potentiometer nominal RPM Overspeeding protection / D-engine Brake release

8 A A 3 A 14

overv. low

o.k. o.k.

underv. high

overv. low

o.k. o.k.

underv. Diesel engine approx. 1500 RPM / test for 10 sec. high must be green from nmin up to nmax
+60

min: max: min: max: min: 750 RPM +60 ...............- RPM -................. ...............- RPM -................. max: 1900 RPM {max.-......RPM good {min.+......RPM defect Function available: {max.-......RPM good {min.+......RPM defect should be green at nmax -30 RPM and +20 nmin +30 RPM / = indication at part. range
+20

yes Function available: no Light at panel:

yes press button RPM drop at engine working hydraulic - HD = max. no on off right left must be functioning for all remaining tests machine must be raised off the ground = no Indication/ must be ok for further tests

Light at on panel: off Tracks running right left

14.

RPM sensor travel gear

13

Disconnect servo lines from pump-connection X to travel motor - see instructions 15.1. basic adjustment forward 2 forward 2 Pump regulating range forward 14 left track forward 3 forward 3 Pump end of regulation forward reverse 2 reverse 2 Pump regulating range reverse reverse 3 reverse 3 Pump end of regulation reverse note position of rotary switch 16.1 Straight run Test" "Adjust Adjust 14 compare track right forward 1 yes no forward 1 yes no travel begin forward - tracks starts to turn to track left forward 2 forward 2 Pump regulating range forward forward 3 reverse 1 reverse 2 reverse 3 15.2 16.2 yes forward 3 no reverse 1 reverse 2 reverse 3 yes Pump end of regulation forward no travel begin reverse - tracks starts to turn Pump regulating range reverse Pump end of regulation reverse

Servo lines from pump-connection X connected to one travel motor on each side - see instruction Basic adjustment 14 forward 4 forward 4 left motor regulating range forward left track reverse 4 reverse 4 control test Straight run 14 forward 4 forward 4 right motor regulating range forward right track reverse 4 reverse 4 control test Servo lines from pump-connection X connected to all travel motors - see instruction basic adjustment 14 forward 4 forward 4 left motor regulating range forward left track forward 5 forward 5 left motor - mech. end stop - Qmin control test - values are resulting from previous reverse 4 reverse 4 adjustments reverse 5 reverse 5 Straight run compare track right to track left 14 forward 4 forward 4 forward 5 forward 5 reverse 4 reverse 4 reverse 5 reverse 5 Special tests - travel operation (440 ) max.
in normal speed range
20

15.3

16.3

right motor regulating range forward right motor - mech. end stop - Qmin control test - values are resulting from previous adjustments throttle lever must be at max. RPM position initial current jump 3-ranges 70 1350+ mA (Switch pos. III) 50 1170+ mA (Switch pos. II) 870+ mA (Switch pos. I) reduced value when steering left (normal speed) initial current jump minimum current at maximum load (RPM drop)
50

17.

current supply 17.1 Diesel engine not running

mA mA mA mA

max.
in reduced speed range

max.
in reduced speed range

(1180 ) 17.2 Diesel engine running 2 (440


20

80

mA mA mA

) )

(500+

100

C. Pedal-tests with tester CET 03/08 (see Service Manual section 10.6/chapter "fine adjustment") - Diesel engine not running
T.No.

Test Inch/brake pedal

During test adjustments according to guidelines yes no

After adjustment /repair adjustments according to guidelines yes no

Remarks observe display - "Inchpedal ext" etc. LED "Voltage" must be always green

1.

D. Edit error memory with E-Box Evaluation Kit (with e-box CEP12/08C, CEP12/20) - following the software instructions
T.No.

1. 1.1

Test Read memory Record codes

Before checklist step B/C memory available: yes no

After checklist step B/C memory deleted: yes no

Remarks Print out memory following the software instructions and add the adjustment checklist, or record here in saved order.

Remarks:

Adjustment guidelines - quick reference and explanations


Complete the test procedure according to the checklist, even for a partial check. Use pressure gauges appropriate for the test ranges. To test the track speed / straight run, raise the machine off the ground and support it properly, so that the chains can turn freely without danger. Make sure to observe all safety guidelines see group 1.2.01! Use only the correct tools( test instruments). The Diesel engine RPMs must be as noted. Perform all required maintenance work before adjustment. In case of questions, make sure to use the detailed instructions: for the adjustment of the travel hydraulic, see section 6.5.00, for the adjustment of the working hydraulic, see section 7.5.10 ,for the use of the test box CET 08/03, see section 10.4.00. and for the use of the pedal control tester, see section 10.6.00. When putting the machine into service, proceed according to the guidelines given in the Operation and Maintenance Manual. Check all indicators and gauges to ensure they are functioning correctly. Defects must be repaired immediately or as soon as possible, depending on the type of problem.

A. Tests with standard test instruments


All pressure tests must be performed at 1000 RPM (without an engine load), unless noted otherwise. 1. Visual tests and maintenance Insufficient maintenance and mechanical component defects often point to the cause of the problem. Check oil levels, filters, coolant level, mechanical components and their mounting, cables and wiring harnesses, etc. Repair any detected defects immediately or as soon as possible, depending on the type of problem. 2. Standby pressure - fan drive The pressure determines the minimum RPM for the fan drive motors. Incorrect adjustments can cause failure of the hydraulic motors. Check / adjust with the machine cold. For instructions, refer to group 6.5. Caution: When the temperature in the systems hydraulic oil, Diesel engine coolant or charge air is raising, the electronic control raises the pressure of the fan drive/fan RPM. When changing the standby pressure, the adjustments of the pressure limitation are also changing, according point 3. Both values have to be in the allowed tolerances.

3. Pressure cut off - fan drive For tests/adjustments, the power supply for the electronic control has to be interrupted - open fuse F9 (indicator light H7 is on) - the fan drive works with the maximum values (fail-save system) = adjustment-/test values see table "pmax" (fan RPM - main radiator front = n1, - oil cooler = n2). For details, see group 6.5.
Machine equipment = standard fans - standard ex factory spare pump fans - reversible ex factory spare pump 217 bar 1380 min +100 -1 1990 min
+100 -1 +5

Machine equipment = "waste kit" fans - standard 225 bar


-1 +5

fans - reversible 275 bar


+3

pmax
n1 n2

177+5 bar
1380 min +100 -1 1990 min
+100 -1

2055 bar
1530 min +100 -1 2200 min
+100 -1

255 bar 1520 min +100 -1 2180 min


+100

+5

1580 min +100 -1 2280 min

+100

-1

1560 min +100 -1 2240 min

+100

-1

Notes:

When changing the adjustments of the pressure limitation, the adjustments of the standby pressure are also changing, according point 2. Both values have to be in the allowed tolerances. If the temperature in one of the systems, which have to be cooled - hydraulic system, Diesel engine coolant circuit and charge air system - is too high, the indicator light H7 is flashing and the system regulates to maximum pressure. This pressure value is lower by the p of the regulation than the adjustment value. When overheating in spite of right pressure and clean radiator, in every case check the fan RPM. This RPM doesn't depends only on pressure (also on air supply, turning resistance, damages, and suchlike). Instructions see chapter 6.5.
Benennung Description Dnomination Typ/ab Type/from Type/ a partir de

Mjfcifss!

Quick Reference
Datum Edition Date

PR 752

F/N xxx-5600 6199

01 04

Adjustment Checklist

Blatt Page Feuille

3.5.51.02

4. Operating temperature If the operating temperature is reached only for a short time, cover the cooler (air flow) partially for the test / adjustment. With the oil at operating temperature, before performing additional tests, actuate all hydraulic functions and monitor the temperature constantly. For additional information about bringing the hydraulic system to operating temperature, see group 6.5 or 7.5 5. Cold start valve (travel hydraulic) Needs to be checked only for troubleshooting. With the oil at operating temperature, only a minimum amount of leak oil should emerge from the valve, otherwise, check the adjustment, see group 6.5, p. 3. 6. Servo pressure (working hydraulic) Not adjustable - is a result of SP pressure. In case of problems, for example Quick drop, see Adjustment working hydraulic, group 7.5.10. 7. Pressure difference - p HD to LD ( working hydraulic ) The correct adjustment of the LS regulator (p) is important for machine performance and simplifies the adjustment of the stand by pressure. The drop of p with the control valve spools fully opened is necessary to obtain the shortest working cycles. 8. Stand-by pressure (working hydraulic) This pressure is the basis for the proper function of the entire working hydraulic system. The adjustment is made via the Qmin stop of the pump. Important: The test value depends very much on the temperature. 9. Pressure limitation ( working hydraulic ) 9.1. Primary pressure To check, raise the pressure cut off setting. Check the pressure via the tilt circuit or additional attachments without secondary relief. Leave the pressure cut off valve adjustment for the secondary pressure check as is. 9.2. Secondary pressure To check, block pressure lines on lift cylinders - see group 7.5. (Pressure cut off raised from primary pressure check) lift circuit - piston bottom side =A1= lift circuit - piston rod side =B1= blade down blade up

Also check the secondary relief of additional attachments / list on checklist, No. 9.4 / 9.5. 9.3. Pressure cut off The pressure cut off limits the maximum working pressure. Primary and secondary pressure relief valves are only installed for system safety. Check the pressure as the primary pressure via the tilt circuit or additional attachment circuit without secondary relief. 9.4. Blank line for pressure setting of additional attachment (enter description / test points) 9.5. Blank line for pressure setting of additional attachment (enter description / test points) 10.Accumulator (working hydraulic) For safety reasons, it must be possible to actuate a function (blade down) several times (within 3 minutes) after the Diesel engine is turned off. 11.Replenishing pressure (travel hydraulic ) If the pressure is too low, find and remedy the problem before continuing machine operation. 12.Hydraulic neutral position (travel hydraulic - travel pumps) Leave the safety lever in the down position. Check first with 0-600 bar pressure gauge, for final check / adjustment, use a 0-60 bar pressure gauge. The normal pressure reading should correspond to the replenishing pressure. The permissible pressure difference between M1 and M2 may be no more than 1.0 bar.

13.Pressure limitation of maximum system pressure (travel hydraulic) Not adjustable. Check only if needed. Check O-rings on blind flanges. To check, close off HD lines on travel motors with blind flanges - see special tools, page 2.1.21.01 and screws M12x50-10.9. For location of test points and details, refer to group 6.5. All work must be performed clean and carefully. Actuate the pumps carefully and hold the maximum pressure only for a short time. Bleed the system after tests.

Caution: Before carrying out tests/adjustments following section B, check the version of the electronic box. If there is a CEP 12/08C, CEP 12/20 or higher electronic box installed, observe section D = evaluate memory.

B. Tests with test box CET 08 / 03


Before carrying out tests / adjustments, check the operational readiness and function of the LED on the test box and its adapter- see 10.4. LED = light emitting diode 1. Identification For identification, the indicators on the adapter and the test box have to be combined. In case of incorrect identification, check the operating condition of test box first - for example: check the rotary switch position and the cable configuration, then check the wire harness connections. 2. Battery If the battery is always at low voltage, check the position of the safety lever and the emergency shut off button first, then continue to check the power supply. 3. Indicator lights - electronic fault indicator - H12 If there is a problem in the system, the time the indicator light lights up can give an initial hint to the problem area. Along with the electronic monitoring indicator light, the 'reduced travel speed range' indicator light H11 lights up as well. If these lights do not light up during the test, check the bulbs, wiring and relays. 4. Signal - preselection "reduced speed range" - rocker switch S29 on the travel control joystick Rocker switch in position I (04 km/h) = diode must be on Rocker switch in position II (06,5 km/h) = diode must switch off Rocker switch in position III (011 km/h) = diode must be on If the test result is not correct, check the switch and the wiring harness. 5. Signal - counter rotation" If the LED does not light up during the test, or if it turns off during joystick deflection, check the wiring as well as the switch and cable in the joystick. 6. Travel joystick The pointers in the test box must follow the joystick deflection evenly. Erratic movement or lack of movement indicates an error and should be noted as such on the checklist. In the four main directions, at full joystick deflection, the corresponding green LED must light up. In diagonal deflection, most of the time both directional LEDs light up, a jump", however, is within the permitted tolerance range.

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Quick Reference
Datum Edition Date

PR 752

F/N xxx-5600 6199

01 04

Adjustment Checklist

Blatt Page Feuille

3.5.51.03

The red error" diode may not light up in any joystick position. Notes: Do not actuate the push button switch counter rotation while testing the travel joystick - this can cause wrong Error - indications.

7. Proportional solenoids Push the push button for about 15 seconds. If an error is shown, swap the connectors at the proportional solenoids and check again to find the problem - cable or solenoid. 8. Alternator In case of constant low voltage, always check the position of the safety lever and the emergency shut off button, then continue to check the power supply. Push the push button for about 15 seconds. If the green LED turns off and the red one lights up, check the alternator or V-belt. 9. RPM sensor - Diesel engine Readings at the test box adapter are valid. In case of error indication, remove the sensor and check it visually and/or clean. Check the harness and required distance to the top of the flywheel tooth. Repeat the test. 10.Diesel engine RPM Readings at the test box adapter are valid. If values are too low, check function and routing of throttle control. Make adjustments primary on the control lever stops on the operators platform (tilt cab). 11.Potentiometer The pointer in the test box must follow the throttle position evenly. Jerky movement or lack of movement indicates a defect and should be noted as such on the checklist. Approach test values of potentiometer adjustment from the medium RPM range of the Diesel engine. Determine the difference between the high and low idle (step 10) to those engine speeds and record the RPM where the corresponding LED just lights up (not flicker). If necessary, repeat the test several times. The nominal value should be within 30+20 RPM each. 12.Overspeed safety - Diesel engine If the Diesel engine speed is not reduced significantly during the test and the pressure on the working hydraulic test point HD will not overcome primary setting, check the function of the solenoid valve and the pump regulator. See schematic, group 7.3. 13. Release the brake When the LED lights up on the test box, the indicator light H4 on the panel must turn off. LED does not light up electrical defect Indicator light does not turn off hydraulic / mechanical defect Caution: If step A-12 was not carried out at all or carried out incorrectly, the chains may already begin to turn. 14.RPM sensor - travel gear Test read out usually starts in speed range 3, however, perform the test as possible in stage 5 (higher signal number). Before changing from left right", stop the track run, switch over and run again. No indication Red diode Problem due to electrical circuit interruption (wiring), possible total sensor failure Mark appropriate square on adjustment check list Sensor sends error signal

15. / 16.Basic adjustment - left track / Straight run, right chain compared to the left chain A pre-check can be made during an inspection without closing off the control lines, limited to the following checklist points (right switch on test box to position "TEST"): 16.1 - forward 1 - forward 2 - reverse 1 - reverse 2 Note: 16.3 - forward 4 - forward 5 - reverse 4

If the indication is outside the "green center" range for one of these tests, then all tests / adjustment steps must be made according to the check list (right switch on test box in straight run adjustment position "ADJUST"). If one of the stages 3 are selected, the chains are running at full speed.

Attention:

Test steps for par. 15 "basic adjustment - left track " show the speed of the left chain in relation to the values stored in the test box. Adjustments are made on the left travel drive side. Test steps for par. 16 "straight run, right chain compared to left chain " show the speed of the right chain in relation to the speed of the left chain. Adjustments are made on the right travel drive side. Basic adjustments and straight run must be made in 3 groups, since the travel motors are hydraulically controlled by the pumps and there are 2 motors for each side. Group 15.1 / 16.1= Check / adjustment of pumps. Close of servo lines to motors on pump outlets (motors remain on Qmax). analog indicator "green center" Check / adjustment of motor per side. Servo lines to motors on pump outlets are reconnected, close off servo lines to one motor per side (motors remain on Qmax). Analog indicator exactly over the dividing line between the red indicator field SLOW and the green indicator field. "Center green" may not be exceeded. Analog indicator "Green center" analog indicator "green center", for 15.3, the red indicator field "FAST" may never be reached.

Correct adjustment for both groups: Group 15.2 / 16.2 =

Correct adjustment for group 15.2:

Correct adjustment for group 16.2: Group 15.3 / 16.3 = Correct adjustment for both groups: Note:

Check / adjustment of one motor per side. Servo lines to all motors are reconnected.

- If an existing adjustment is changed, change it in the corresponding direction past the required indication value. Then reset it to the required value - see above. - Always make adjustments only after the chain stops turning. - Correct adjustments until the analog indicator remains in the required range, even after several rechecks. - If an adjustment must be made in stage 5 / mech. Qmin stop (group 15.3 / 16.3), determine the dimension of adjustment screw on both travel motors for the side to be adjusted. Chain too quick Chain too slow on travel motor with larger screw overlap, turn the adjustment screw in clockwise direction. on travel motor with smaller screw overlap, turn the adjustment screw in counterclockwise direction.

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Quick Reference
Datum Edition Date

PR 752

F/N xxx-5600 6199

01 04

Adjustment Checklist

Blatt Page Feuille

3.5.51.04

17.Current supply (special tests during normal travel - test box with Y-cable) This test is only required when troubleshooting. Only the current supply on the right track is measured. Additional indications are due to the switch design and have no meaning. Select the travel speed range via rocker switch S29 on the travel control joystick. Notes - if the maximum values are not reached, check the position of the throttle control lever. - for the simulation of the required engine load, see paragraph 10.4. 18.Straight run, right chain to left chain (special test during normal travel - test box with Y-cable) Notes: This test can still be carried out. Caused by the rarely use, this test isn't on the checklist any more. Record the result under section "Remarks".

Perform this test only if the machine cannot be raised off the ground and properly supported. During normal travel operation, the current supply to the right drive side and the speed of the right track in relation to the speed of the left track is shown. Due to external influences, despite a wide tolerance range, large deviations (fluctuating)exist Additional indications are due to the switch design and have no meaning

C. Pedal-tests with tester CET 03/08


1. Inch/brake pedal Always perform the check of the adjustments of the Inch/brake pedal when the electronic box is connected = connect all cables of the tester. Guidelines for the test and further notes see chapter 10.6, section B -1.

D. Edit error memory with E-Box Evaluation Kit


Can only be used for electronic box version CEP12/08C, CEP12/20 and higher. 1. Read error memory Before carrying out tests / adjustments following section B, evaluate the memory, save it on the notebook, print it out or record the codes in saved order in the adjustment checklist. Repair existing defects. After adjustments, check the memory once again, delete the error memory! Notes: If the program displays "Error" from the beginning, check if the right interface COM1,2,3 or 4 is chosen, check plugs/wiring, check the power supply 24V from the instrument panel.

Customer - Name and address:

Machine type:

PIN:

Sm-hrs.:

Date:

Job application/ location: Checked by: from company:

A. Tests with standard test instruments - test with Diesel engine RPM at 1000 RPM or as outlined
Test No. 1. 2. 3. Test Test points Test value Remarks actual value adjusted value o.k. remarks o.k. remarks fluids, filters, mech. components, etc. Hydraulic system 30
5

Nominal value

Visual tests and maintenance Stand by pressure Pressure cut off fan drive Operating temperature Cold start valve replenishing circuit Servo pressure Pressure difference = p Stand by pressure Pressure limitation 9.1 Prim. pressure 9.2 Sec. pressure 9.3 Pressure cut off 9.4 9.5 Accumulator Repl. pressure Hydr. neutral pos. travel hydraulic

fan drive. - LA LA

bar bar

bar check w. cold machine/Diesel engine to nmax fuse F9 opened/Diesel engine at max RPM bar Caution: varied adjustments with special equipments - see page 2 must remain constant during all tests C

205

4. 5. 6. 7. 8. 9.

Hydraulic tank travel hydr. SD ND working hydr. HD to LS HD working hydr. HD

70 C theoretic 28+2 bar 25+ bar 15 bar <13 bar 30+ bar 270 bar 5 250 bar 5 250 bar 5 200 bar bar bar min. 4x +7 20 bar M1 = M2 1 bar M1 = M2 1 bar +30/-10 420 bar +30/-10 420 bar
5 5 +6 3

10

C yes

checked: changed: - check only if necessary no yes no - for test / adjustment see guidelines bar -working hydraulic bar bar bar bar bar bar bar bar bar bar bar bar bar bar bar bar bar bar bar in fine control range - adjust at HPR-pump bar when spool is fully shifted bar working hydraulic - adjust at HPR-pump bar bar bar bar bar bar

lift cylinder circuit - piston bottom side = A1 lift cylinder circuit - piston rod side = B1 max. working pressure pressure settings for optional hydraulic functions possible actuation after engine is turned off travel hydraulic

10. 11. 12.

test SP right M1 + M2 left M1 + M2 M1 rights M1 left M2 right M2 left

13.

Max. pressure travel forward Max. pressure travel reverse

M1 M2 M1 M2 ri le ri le

bar bar bar bar bar bar bar bar

pump right pump left check only if necessary use test plates!

B. Edit error memory with E-Box Evaluation Kit - following the software instructions
T.No.

1. 1.1

Test Read memory Record codes

Before checklist step C/D memory available: yes no

After checklist step C/D memory deleted: yes no

Remarks Print out memory following the software instructions and add the adjustment checklist, or record here in saved order.

C. Pedal-tests with tester CET 03/08 (see Service Manual section 10.6/chapter "fine adjustment") - Diesel engine not running
T.No.

Test Inch/brake pedal

During test adjustments according to guidelines yes no

After adjustment /repair adjustments according to guidelines yes no

Remarks observe display - "Inchpedal ext" etc. LED "Voltage" must be always green

1.

D. Test with test box CET 08/03 H (see SM - section 10.4) and adapter CET 14/05
- mark LED which lights up or note position of analog indicator (space = space No. at test box, A = at adapter) - test with Diesel engine RPM at max. RPM or as noted - after all adjustments are done check and delete E-Box memory - see step B. LED - color: = green = yellow = red indicators = No. 1. 2. 3. Test Identification Battery Indicator light electron. fault ind. Space A/6 8 9
Inl.6

During test Diesel engine is not running


V6/Inl.4 752/X.....

After adjustment / repair.


Inl.6 V6/Inl.4

Remarks

752/X..... record denomination of LED

o.k. light at panel on:

undervolt. yes no

o.k. light at panel on:

undervolt. yes no

after approx. 10 sec. of actuation light at panel = on instrument panel of machine ("reduced speed" light lights together) Typ/ab Type/from Type/ a partir de

Benennung Description Dnomination

Mjfcifss!
Datum Edition Date

PR 752 F/N xxx-6200

01 04

Adjustment Checklist

Blatt Page Feuille

3.5.52.01

No. 4.

Test Signal
travel speed range selection

Space 9

During test no signal no signal no signal signal error good defect

After adjustment / repair. no signal no signal no signal signal error good defect 3-ranges -

Remarks normal = III - red. speed range II - red. speed range I

5. 6. 7.

Signal counter rot. Travel joystick Proportional solenoids

9 4 11

press button and deflect joystick in all directions = analogic display of sections after approx. 10 sec. of actuation

Diesel engine running 8. 9. 10. 11. 12. 13. Alternator RPM sensor Diesel engine RPM Diesel engine Potentiometer nominal RPM Overspeeding protection / D-engine Brake release 8 A A 3 A 14 overv. low o.k. o.k. underv. high overv. low o.k. o.k. underv. Diesel engine approx. 1500 RPM / test for 10 sec. high must be green from nmin up to nmax
+60

min: max: min: max: min: 750 RPM +60 ...............- RPM -................. ...............- RPM -................. max: 1900 RPM {max.-......RPM good {min.+......RPM defect Function available: {max.-......RPM good {min.+......RPM defect should be green at nmax -30 RPM and +20 nmin +30 RPM / = indication at part. range
+20

yes Function available: no Light at panel:

yes press button RPM drop at engine no working hydraulic - HD = max. on off right left must be functioning for all remaining tests machine must be raised off the ground = no Indication/ must be ok for further tests

Light at on panel: off Tracks running right left

14.

RPM sensor travel gear

13

Disconnect servo lines from pump-connection X to travel motor - see instructions 15.1. basic adjustment forward 2 forward 2 Pump regulating range forward 14 left track forward 3 forward 3 Pump end of regulation forward reverse 2 reverse 2 Pump regulating range reverse reverse 3 reverse 3 Pump end of regulation reverse note position of rotary switch 16.1 Straight run Test" "Adjust Adjust 14 compare track right forward 1 yes no forward 1 yes no travel begin forward - tracks starts to turn to track left forward 2 forward 2 Pump regulating range forward forward 3 reverse 1 reverse 2 reverse 3 15.2 16.2 yes forward 3 no reverse 1 reverse 2 reverse 3 yes Pump end of regulation forward no travel begin reverse - tracks starts to turn Pump regulating range reverse Pump end of regulation reverse

Servo lines from pump-connection X connected to one travel motor on each side - see instruction Basic adjustment 14 forward 4 forward 4 left motor regulating range forward left track reverse 4 reverse 4 control test Straight run 14 forward 4 forward 4 right motor regulating range forward right track reverse 4 reverse 4 control test Servo lines from pump-connection X connected to all travel motors - see instruction basic adjustment 14 forward 4 forward 4 left motor regulating range forward left track forward 5 forward 5 left motor - mech. end stop - Qmin control test - values are resulting from previous reverse 4 reverse 4 adjustments reverse 5 reverse 5 Straight run compare track right to track left 14 forward 4 forward 4 forward 5 forward 5 reverse 4 reverse 4 reverse 5 reverse 5 Special tests - travel operation (440 ) max.
in normal speed range
20

15.3

16.3

right motor regulating range forward right motor - mech. end stop - Qmin control test - values are resulting from previous adjustments throttle lever must be at max. RPM position initial current jump 3-ranges 70 1390+ mA (Switch pos. III) 50 +50 1150 mA forward / 1220+ mA reverse
(Switch pos. II)

17.

current supply 17.1 Diesel engine not running

mA mA /r. /r. mA mA mA mA
forward: reverse: forward: reverse:

max. f. max. f. (1340+50)

in reduced speed range in reduced speed range

880+ mA forward / 990+ mA reverse


(Switch pos. I)

50

50

reduced value when steering left (normal speed) initial current jump

17.2 Diesel engine running

(440 )

20

Remarks:

Adjustment guidelines - quick reference and explanations


Complete the test procedure according to the checklist, even for a partial check. Use pressure gauges appropriate for the test ranges. To test the track speed / straight run, raise the machine off the ground and support it properly, so that the chains can turn freely without danger. Make sure to observe all safety guidelines see group 1.2.01! Use only the correct tools( test instruments). The Diesel engine RPMs must be as noted. Perform all required maintenance work before adjustment. In case of questions, make sure to use the detailed instructions: for the adjustment of the travel hydraulic, see section 6.5.00, for the adjustment of the working hydraulic, see section 7.5.10 ,for the use of the test box CET 08/03, see section 10.4.00. and for the use of the pedal control tester, see section 10.6.00. When putting the machine into service, proceed according to the guidelines given in the Operation and Maintenance Manual. Check all indicators and gauges to ensure they are functioning correctly. Defects must be repaired immediately or as soon as possible, depending on the type of problem.

A. Tests with standard test instruments


All pressure tests must be performed at 1000 RPM (without an engine load), unless noted otherwise. 1. Visual tests and maintenance Insufficient maintenance and mechanical component defects often point to the cause of the problem. Check oil levels, filters, coolant level, mechanical components and their mounting, cables and wiring harnesses, etc. Repair any detected defects immediately or as soon as possible, depending on the type of problem. 2. Standby pressure - fan drive The pressure determines the minimum RPM for the fan drive motors. Incorrect adjustments can cause failure of the hydraulic motors. Check / adjust with the machine cold. For instructions, refer to group 6.5. Caution: When the temperature in the systems hydraulic oil, Diesel engine coolant or charge air is raising, the electronic control raises the pressure of the fan drive/fan RPM. When changing the standby pressure, the adjustments of the pressure limitation are also changing, according point 3. Both values have to be in the allowed tolerances.

3. Pressure cut off - fan drive For tests/adjustments, the power supply for the electronic control has to be interrupted - open fuse (automatic circuit breaker) F9 (indicator light H7 is on) - the fan drive works with the maximum values (fail-save system) = adjustment-/test values see table "pmax" (fan RPM - main radiator front = n1, - oil cooler = n2). For details, see group 6.5.
Machine equipment = standard fans - standard Machine equipment = "waste kit" fans - reversible 275 bar
-1 +3

fans - reversible fans - standard 255 bar 1520 min +100 -1 2180 min
+100 -1 +5

pmax
n1 n2

2055 bar
1530 min +100 -1 2200 min
+100 -1

225 bar 1580 min +100 -1 2280 min


+100

+5

1560 min +100 -1 2240 min

+100

-1

Notes:

When changing the adjustments of the pressure limitation, the adjustments of the standby pressure are also changing, according point 2. Both values have to be in the allowed tolerances. If the temperature in one of the systems, which have to be cooled - hydraulic system, Diesel engine coolant circuit and charge air system - is too high, the indicator light H7 is flashing and the system regulates to maximum pressure. This pressure value is lower by the p of the regulation than the adjustment value. When overheating in spite of right pressure and clean radiator, in every case check the fan RPM. This RPM doesn't depends only on pressure (also on air supply, turning resistance, damages, and suchlike). Instructions see chapter 6.5.
Benennung Description Dnomination Typ/ab Type/from Type/ a partir de

Mjfcifss!

Quick Reference
Datum Edition Date

PR 752

F/N xxx-6200

01 04

Adjustment Checklist

Blatt Page Feuille

3.5.52.02

4. Operating temperature If the operating temperature is reached only for a short time, cover the cooler (air flow) partially for the test / adjustment. With the oil at operating temperature, before performing additional tests, actuate all hydraulic functions and monitor the temperature constantly. For additional information about bringing the hydraulic system to operating temperature, see group 6.5 or 7.5 5. Cold start valve (travel hydraulic) Needs to be checked only for troubleshooting. With the oil at operating temperature, only a minimum amount of leak oil should emerge from the valve, otherwise, check the adjustment, see group 6.5, p. 3. 6. Servo pressure (working hydraulic) Not adjustable - is a result of SP pressure. In case of problems, for example Quick drop, see Adjustment working hydraulic, group 7.5.10. 7. Pressure difference - p HD to LD ( working hydraulic ) The correct adjustment of the LS regulator (p) is important for machine performance and simplifies the adjustment of the stand by pressure. The drop of p with the control valve spools fully opened is necessary to obtain the shortest working cycles. 8. Stand-by pressure (working hydraulic) This pressure is the basis for the proper function of the entire working hydraulic system. The adjustment is made via the Qmin stop of the pump. Important: The test value depends very much on the temperature. 9. Pressure limitation ( working hydraulic ) 9.1. Primary pressure To check, raise the pressure cut off setting. Check the pressure via the tilt circuit or additional attachments without secondary relief. Leave the pressure cut off valve adjustment for the secondary pressure check as is. 9.2. Secondary pressure To check, block pressure lines on lift cylinders - see group 7.5. (Pressure cut off raised from primary pressure check) lift circuit - piston bottom side =A1= lift circuit - piston rod side =B1= blade down blade up

Also check the secondary relief of additional attachments / list on checklist, No. 9.4 / 9.5. 9.3. Pressure cut off The pressure cut off limits the maximum working pressure. Primary and secondary pressure relief valves are only installed for system safety. Check the pressure as the primary pressure via the tilt circuit or additional attachment circuit without secondary relief. 9.4. Blank line for pressure setting of additional attachment (enter description / test points) 9.5. Blank line for pressure setting of additional attachment (enter description / test points) 10.Accumulator (working hydraulic) For safety reasons, it must be possible to actuate a function (blade down) several times (within 3 minutes) after the Diesel engine is turned off. 11.Replenishing pressure (travel hydraulic ) If the pressure is too low, find and remedy the problem before continuing machine operation. 12.Hydraulic neutral position (travel hydraulic - travel pumps) Leave the safety lever in the down position. Check first with 0-600 bar pressure gauge, for final check / adjustment, use a 0-60 bar pressure gauge. The normal pressure reading should correspond to the replenishing pressure. The permissible pressure difference between M1 and M2 may be no more than 1.0 bar.

13.Pressure limitation of maximum system pressure (travel hydraulic) Not adjustable. Check only if needed. Check O-rings on blind flanges. To check, close off HD lines on travel motors with blind flanges - see special tools, page 2.1.21.01 and screws M12x50-10.9. For location of test points and details, refer to group 6.5. All work must be performed clean and carefully. Actuate the pumps carefully and hold the maximum pressure only for a short time. Bleed the system after tests.

B. Edit error memory with E-Box Evaluation Kit


1. Read error memory Before carrying out tests / adjustments following section C/D, evaluate the memory, save it on the notebook, print it out or record the codes in saved order in the adjustment checklist. Repair existing defects. After adjustments according to checklist step C and D, check the memory once again, delete the error memory! Notes: If the program displays "Error" from the beginning, check if the right interface COM1,2,3 or 4 is chosen, check plugs/wiring, check the power supply 24V from the instrument panel.

C. Pedal-tests with tester CET 03/08


1. Inch/brake pedal Always perform the check of the adjustments of the Inch/brake pedal when the electronic box is connected = connect all cables of the tester. Guidelines for the test and further notes see chapter 10.6, section B -1.

D. Tests with test box CET 08/03


Before carrying out tests / adjustments, check the operational readiness and function of the LED on the test box and its adapter- see 10.4. LED = light emitting diode 1. Identification For identification, the indicators on the adapter and the test box have to be combined. In case of incorrect identification, check the operating condition of test box first - for example: check the rotary switch position and the cable configuration, then check the wire harness connections. 2. Battery If the battery is always at low voltage, check the position of the safety lever and the emergency shut off button first, then continue to check the power supply. 3. Indicator lights - electronic fault indicator - H12 If there is a problem in the system, the time the indicator light lights up can give an initial hint to the problem area. Along with the electronic monitoring indicator light, the 'reduced travel speed range' indicator light H11 lights up as well. If these lights do not light up during the test, check the bulbs, wiring and relays. 4. Signal - preselection "reduced speed range" - rocker switch S29 on the travel control joystick Rocker switch in position I (04 km/h) = diode must be on Rocker switch in position II (06,5 km/h) = diode must switch off Rocker switch in position III (011 km/h) = diode must be on If the test result is not correct, check the switch and the wiring harness.

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Quick Reference
Datum Edition Date

PR 752

F/N xxx-6200

01 04

Adjustment Checklist

Blatt Page Feuille

3.5.52.03

5. Signal - counter rotation" If the LED does not light up during the test, or if it turns off during joystick deflection, check the wiring as well as the switch and cable in the joystick. 6. Travel joystick The pointers in the test box must follow the joystick deflection evenly. Erratic movement or lack of movement indicates an error and should be noted as such on the checklist. In the four main directions, at full joystick deflection, the corresponding green LED must light up. In diagonal deflection, most of the time both directional LEDs light up, a jump", however, is within the permitted tolerance range. The red error" diode may not light up in any joystick position. Notes: Do not actuate the push button switch counter rotation while testing the travel joystick - this can cause wrong Error - indications.

7. Proportional solenoids Push the push button for about 15 seconds. If an error is shown, swap the connectors at the proportional solenoids and check again to find the problem - cable or solenoid. 8. Alternator In case of constant low voltage, always check the position of the safety lever and the emergency shut off button, then continue to check the power supply. Push the push button for about 15 seconds. If the green LED turns off and the red one lights up, check the alternator or V-belt. 9. RPM sensor - Diesel engine Readings at the test box adapter are valid. In case of error indication, remove the sensor and check it visually and/or clean. Check the harness and required distance to the top of the flywheel tooth. Repeat the test. 10.Diesel engine RPM Readings at the test box adapter are valid. If values are too low, check function and routing of throttle control. Make adjustments primary on the control lever stops on the operators platform (tilt cab). 11.Potentiometer The pointer in the test box must follow the throttle position evenly. Jerky movement or lack of movement indicates a defect and should be noted as such on the checklist. Approach test values of potentiometer adjustment from the medium RPM range of the Diesel engine. Determine the difference between the high and low idle (step 10) to those engine speeds and record the RPM where the corresponding LED just lights up (not flicker). If necessary, repeat the test several times. The nominal value should be within 30+20 RPM each. 12.Overspeed safety - Diesel engine If the Diesel engine speed is not reduced significantly during the test and the pressure on the working hydraulic test point HD will not overcome primary setting, check the function of the solenoid valve and the pump regulator. See schematic, group 7.3. 13. Release the brake When the LED lights up on the test box, the indicator light H4 on the panel must turn off. LED does not light up electrical defect Indicator light does not turn off hydraulic / mechanical defect Caution: If step A-12 was not carried out at all or carried out incorrectly, the chains may already begin to turn.

14.RPM sensor - travel gear Test read out usually starts in speed range 3, however, perform the test as possible in stage 5 (higher signal number). Before changing from left right", stop the track run, switch over and run again. No indication Red diode Problem due to electrical circuit interruption (wiring), possible total sensor failure Mark appropriate square on adjustment check list Sensor sends error signal

15./ 16.Basic adjustment - left track / Straight run, right chain compared to the left chain A pre-check can be made during an inspection without closing off the control lines, limited to the following checklist points (right switch on test box to position "TEST"): 16.1 - forward 1 - forward 2 - reverse 1 - reverse 2 Note: 16.3 - forward 4 - forward 5 - reverse 4

If the indication is outside the "green center" range for one of these tests, then all tests / adjustment steps must be made according to the check list (right switch on test box in straight run adjustment position "ADJUST"). If one of the stages 3 are selected, the chains are running at full speed.

Attention:

Test steps for par. 15 "basic adjustment - left track " show the speed of the left chain in relation to the values stored in the test box. Adjustments are made on the left travel drive side. Test steps for par. 16 "straight run, right chain compared to left chain " show the speed of the right chain in relation to the speed of the left chain. Adjustments are made on the right travel drive side. Basic adjustments and straight run must be made in 3 groups, since the travel motors are hydraulically controlled by the pumps and there are 2 motors for each side. Group 15.1 / 16.1= Check / adjustment of pumps. Close of servo lines to motors on pump outlets (motors remain on Qmax). analog indicator "green center" Check / adjustment of motor per side. Servo lines to motors on pump outlets are reconnected, close off servo lines to one motor per side (motors remain on Qmax). Analog indicator exactly over the dividing line between the red indicator field SLOW and the green indicator field. "Center green" may not be exceeded. Analog indicator "Green center" analog indicator "green center", for 15.3, the red indicator field "FAST" may never be reached.

Correct adjustment for both groups: Group 15.2 / 16.2 =

Correct adjustment for group 15.2:

Correct adjustment for group 16.2: Group 15.3 / 16.3 = Correct adjustment for both groups: Note:

Check / adjustment of one motor per side. Servo lines to all motors are reconnected.

- If an existing adjustment is changed, change it in the corresponding direction past the required indication value. Then reset it to the required value - see above. - Always make adjustments only after the chain stops turning. - Correct adjustments until the analog indicator remains in the required range, even after several rechecks.

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Quick Reference
Datum Edition Date

PR 752

F/N xxx-6200

01 04

Adjustment Checklist

Blatt Page Feuille

3.5.52.04

- If an adjustment must be made in stage 5 / mech. Qmin stop (group 15.3 / 16.3), determine the dimension of adjustment screw on both travel motors for the side to be adjusted. Chain too quick Chain too slow on travel motor with larger screw overlap, turn the adjustment screw in clockwise direction. on travel motor with smaller screw overlap, turn the adjustment screw in counterclockwise direction.

17.Current supply (special tests during normal travel - test box with Y-cable) This test is only required when troubleshooting. Only the current supply on the right track is measured. Additional indications are due to the switch design and have no meaning. Select the travel speed range via rocker switch S29 on the travel control joystick. Notes - if the maximum values are not reached, check the position of the throttle control lever.

18.Straight run, right chain to left chain (special test during normal travel - test box with Y-cable) Notes: This test can still be carried out. Caused by the rarely use, this test isn't on the checklist any more. Record the result under section "Remarks".

Perform this test only if the machine cannot be raised off the ground and properly supported. During normal travel operation, the current supply to the right drive side and the speed of the right track in relation to the speed of the left track is shown. Due to external influences, despite a wide tolerance range, large deviations (fluctuating)exist Additional indications are due to the switch design and have no meaning

Sub Group Index


Technical data LH engine
LH - engine in line D 904 TB D 904 T D 916 T D 916 TI LH - engine in line E D 924 T-E A1 D 926 T-E A2 D 926 TI-E A2 LH - engine V-type D 9306 TB D 9306 T D 9406 TI-E A3

4.1
4.1.10

4.1.11

4.1.30

Power, torque LH engine


PR 712 PR 722 PR 732 PR 742 PR 712B PR 722B PR 732B PR 742B PR 752 F/N xxx-01012999 F/N xxx-01012999 F/N xxx-20012999 F/N xxx-20012999 F/N xxx-3000 F/N xxx-3000 F/N xxx-3000 F/N xxx-3000 F/N xxx-2002

4.2
4.2.10

4.2.11

Fan and cylinder configuration LH - Diesel engine Remove and install engine fan

4.3 4.4

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!
Datum Edition Date

PR Litronic

01 02

Engine

Blatt Page Feuille

4.0.00.01

Technical Data, Wear Limits, Torques


Type Cylinder bore Piston stroke Displacement, total Direction of rotation Diesel engine - on flywheel Direction of rotation fan - on flywheel Fan drive - up to F/N xxx-5599 Fan RPM rating at Fan drive - from F/N xxx-5600 Fan RPM rating at Fuel consumption at rated RPM Lube oil consumption - in relation to fuel consumption Firing order Overlap Firing sequence Injection pump timing Compression ratio Compression pressure min. / max. Deviation between cylinders max. Engine oil pressure min. (warmed-up) - low idle RPM - high idle RPM mm (inch) mm (inch) l (cu. in)

appr. 1/min

D 924 T-E A1 4 - in line 122 (4,803) 142 (5,590) 6,64 (405) left right direct 1850 hydr. - regulated see group 3.1

D 926 T-E A2 6 - in line

D 926 TI-E A2*

9,96 (607)

viscous 50 1630 see reverse side

1560

50

g/kWh 217 appr. % 0,8

210

205

1-3-4-2 1-5-3-6-2-4 4-2-1-3 6-2-4-1-5-3 CS 180 120 for details see engine type - plate 17,2 : 1 bar 20 - 28 bar 4 bar 1,5 bar 3,5 0,7 1,1 79 (174) 8 (0,314) Bosch VE 225 +8 217 23 20
+8

Cooling system - excess pressure bar - minimum pressure at coolant pump outlet (rated RPM) bar Thermostats - setting C (F) - stroke mm (inch) Fuel injection pump Governor Injectors Screw - injector holder Fuel supply line nuts Valve clearance - inl. / ex. Valve seat angle - inl. / ex. Cylinder head screws tightening torque (soft gasket) type type bar bar Nm Nm

0,8

Bosch MW Bosch RSV

Bosch P 3000

- injector opening pressure - new - operating pressure tightening torque tightening torque

mm 0,25 / 0,30 30 / 45 30 Nm + 30+30+60+60=180 90 30 Nm - 90 Nm + 70+70+70+70=280 -1,5 -0,06 161 (6,338 ) 162,5 (6,397)

Cylinder head screws retorque (soft gasket) Cylinder head screws tightening torque (metallic elastomer gasket) Cylinder head screws length mm (inch) Cylinder head screws length - limit max. mm (inch) Cam stroke Turbocharger

inl. / ex. mm (inch) 8,5 / 9 (0,334 / 0,354) - axial play max. mm (inch) 0,16 (0,006) - radial play max. mm (inch) 0,43 (0,016) tightening torque Nm 110

Oil drain valve - oil sump

For additional data or updates, refer to the Diesel Engine Service Manual For performance data - see machine specific data in groups 3.1 and 4.2

* = at PR 742 installed from F/N xxx-3000 to F/N xxx-5599 and


at RL 42 installed from F/N xxx-3002

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Technical Data
Datum Edition Date

PR Litronic LR Litronic RL Litronic


Blatt Page Feuille

01 03

LH-engine (in line) E

4.1.11.01

Technical Data, Wear Limits, Torques


Emission limit values in accordance with Nominal values (maximum) according to engine type plate power RPM Operating (nominal) values power RPM Type Cylinder bore Piston stroke Displacement, total Direction of rotation Diesel engine - on flywheel Direction of rotation fan - on flywheel Fan drive Fan RPM rating at Fuel consumption at rated RPM Lube oil consumption - in relation to fuel consumption Firing order Overlap Firing sequence Injection pump timing Compression ratio Compression pressure min. / max. Deviation between cylinders max. Engine oil pressure min. (warmed-up) - low idle RPM - high idle RPM kW 1/min kW 1/min

D 926 TI-E A2 D 926 TI-E A2* 97/68/EG (stage2) and EPA/CARB (Tier 2) 135 180 2100 2000 132 172 1800 1800

6 - in line mm (inch) 122 (4,803) mm (inch) 142 (5,590) l (cu. in) 9,96 (607) left right hydraulic - regulated appr. 1/min 1680 1475 g/kWh 210 appr. % 0,8 204

1-5-3-6-2-4 6-2-4-1-5-3 KW 120 for details see engine type - plate 17,2 : 1 bar 20 - 28 bar 4 bar 1,5 bar 3,5 0,6 1,1 79 (174) 8 (0,314) Bosch P 3000 Bosch RSV +8 225 +8 217 23 20 0,8

Cooling system - excess pressure bar minimum pressure at coolant pump outlet (rated RPM) bar Thermostats - setting C (F) - stroke mm (inch) Fuel injection pump Governor Injectors Screw - injector holder Fuel supply line nuts Valve clearance - inl. / ex. Valve seat angle - inl. / ex. Cylinder head screws tightening torque Cylinder head screws length Cylinder head screws length Cam stroke - inl. / ex. Turbocharger type type bar bar Nm Nm

- injector opening pressure - new - operating pressure tightening torque tightening torque

mm 0,25 / 0,30 30 / 45 30 Nm - 90 Nm + 70+70+70+70=280 -1,5 -0,06 mm (inch) 161 (6,338 ) - limit max. mm (inch) 162,5 (6,397) mm (inch) 8,5 / 9 (0,334 / 0,354) - axial play max. mm (inch) 0,16 (0,006) - radial play max. mm (inch) 0,43 (0,016) tightening torque Nm 110

Oil drain valve - oil sump

For additional data or updates, refer to the Diesel Engine Service Manual For performance data - see machine specific data in groups 3.1 and 4.2

* = at PR 742 installed from F/N xxx-5600


#

= at LR 632 installed from F/N xxx-6200

Technical Data, Wear Limits, Torques


Type Cylinder bore Piston stroke Displacement, total Direction of rotation Diesel engine - on flywheel Direction of rotation fan - on flywheel Fan drive Fan RPM rating at Fuel consumption at rated RPM Lube oil consumption - in relation to fuel consumption Firing order Overlap Firing sequence Injection pump timing Compression ratio Compression pressure min. / max. Deviation between cylinders max. Engine oil pressure min. (warmed-up) - low idle RPM - high idle RPM mm (inch) mm (inch) l (cu. in)

appr. 1/min

D 9306 TB V6 130 (5,118) 150 (5,905) 12 (732) left left direct 1530

D 9306 T

D 9406 TI-E A3* 135 (5,314) 12,88 (786) right hydraulic 1300

g/kWh 234 appr. % 0,8

222

206

1-6-3-5-2-4 5-2-4-1-6-3 CS 150-90-150-90-150-90 for details see engine type - plate 17 : 1 bar 20 - 28 bar 4 bar 1,5 bar 3,5 0,6 1,5 80 (175) 10 - 12,5 (0,393 - 0,492) Bosch P 3000 Bosch RSV +8 225 +8 217 23 20 15,5 : 1 18 - 26

120

17,2 : 1 20 - 28

Cooling system - excess pressure bar - minimum pressure at coolant pump outlet (rated RPM) bar Thermostats - setting C (F) - stroke mm (inch) Fuel injection pump Governor Injectors Screw - injector holder Fuel supply line nuts Valve clearance - inl. / ex. Valve seat angle - inl. / ex. Cylinder head screws tightening torque Cylinder head screws retorque Cylinder head screws length Cylinder head screws length Cam stroke Turbocharger type type bar bar Nm Nm

0,7

Bosch P 7800

- injector opening pressure - new - operating pressure tightening torque tightening torque

mm 0,25 / 0,30 30 / 30 30 Nm - 90 Nm + 60+60+60+60=240 mm (inch) 170 (6,692 - limit max. mm (inch) 171,5 (6,751)
90
-1,5 -0,06

30 / 45

inl. / ex. mm (inch) 8,5 / 9 (0,334 / 0,354) - axial play max. mm (inch) 0,16 (0,006) - radial play max. mm (inch) 0,43 (0,016) tightening torque Nm 110

Oil drain valve - oil sump

For additional data or updates, refer to the Diesel Engine Service Manual For performance data - see machine specific data in groups 3.1 and 4.2

* = at PR 752 installed from F/N xxx-2002 to F/N xxx-5599 and


at RL 52 installed from F/N xxx-2002

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Technical Data
Datum Edition Date

01 04

LH - engine (V-type)

PR 732 PR 732 PR 742 PR 752 RL 52


Blatt Page Feuille

F/N xxx-2001 2500 F/N xxx-2001 2500 F/N xxx-2001 2500 F/N xxx-2002 F/N 739-2001

4.1.30.01

Technical Data, Wear Limits, Torques


Emission limit values in accordance with Nominal values (maximum) according to engine type plate power RPM Operating (nominal) values power RPM Type Cylinder bore Piston stroke Displacement, total Direction of rotation Diesel engine - on flywheel Direction of rotation fan - on flywheel Fan drive Fan RPM rating at Fuel consumption at rated RPM Lube oil consumption - in relation to fuel consumption Firing order Overlap Firing sequence Injection pump timing Compression ratio Compression pressure min. / max. Deviation between cylinders max. Engine oil pressure min. (warmed-up) - low idle RPM - high idle RPM kW 1/min kW 1/min

D 9406 TI-E A3* 97/68/EG (stage2) and EPA/CARB (Tier 2) 258 2100 243 1800

V6 mm (inch) 135 (5,314) mm (inch) 150 (5,905) l (cu. in) 12,88 (786) left right hydraulic - regulated appr. 1/min 1300 from F/N xxx-6200 appr. 1500 g/kWh 210 appr. % 0,8 1-6-3-5-2-4 5-2-4-1-6-3 KW 120 for details see engine type - plate 17,2 : 1 bar 20 - 28 bar 4 bar 1,5 bar 3,5 0,7 1,5 80 (175) 10 - 12,5 (0,393 - 0,492) Bosch P 7800 Bosch RSV +8 225 +8 217 23 20

Cooling system - excess pressure bar minimum pressure at coolant pump outlet (rated RPM) bar Thermostats - setting C (F) - stroke mm (inch) Fuel injection pump Governor Injectors Screw - injector holder Fuel supply line nuts Valve clearance - inl. / ex. Valve seat angle - inl. / ex. Cylinder head screws tightening torque Cylinder head screws retorque Cylinder head screws length Cylinder head screws length Cam stroke Turbocharger type type bar bar Nm Nm

- injector opening pressure - new - operating pressure tightening torque tightening torque

mm 0,25 / 0,30 30 / 45 30 Nm - 90 Nm + 60+60+60+60=240 mm (inch) 170 (6,692 - limit max. mm (inch) 171,5 (6,751)
90
-1,5 -0,06

inl. / ex. mm (inch) 8,5 / 9 (0,334 / 0,354) - axial play max. mm (inch) 0,16 (0,006) - radial play max. mm (inch) 0,43 (0,016) tightening torque Nm 110

Oil drain valve - oil sump

For additional data or updates, refer to the Diesel Engine Service Manual For performance data - see machine specific data in groups 3.1 and 4.2

* = at PR 752 installed from F/N xxx-5600

PR 712B F/N xxx-3000

PR 722B F/N xxx-3000

PR 732B F/N xxx-3000

PR 742B F/N xxx-30005599

Power P Torque Md

- kW - Nm

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Power, Torque
Datum Edition Date

PR 712 B PR 722 B PR 732 B PR 742 B PR 752


Blatt Page Feuille

01 02

LH-Engine "E"

F/N xxx-3000 F/N xxx-3000 F/N xxx-3000 F/N xxx-3000 F/N xxx-2002

4.2.11.01

PR 742B F/N xxx-5600

PR 752 F/N xxx-20025599

PR 752 F/N xxx-5600

Power P Torque Md

- kW - Nm

LH - 4/6 cylinder - In line engine Fan - push type = serial version MUL -viewed in air flow direction "running clockwise" Fan - suction type EDUL - viewed in air flow direction "running anti-clockwise"

= intake valve = exhaust valve

Firing order 4-cylinder engines:

firing overlap firing overlap

1 4 1 6

3 2 5 2

4 1 3 4

2 3 6 1 2 5 4 3

Firing order 6-cylinder engines

Valve clearance - adjust when the engine is cold: Emission optimised "E"-engines previous types intake/exhaust intake/exhaust 0,25/0,30 mm 0,20/0,25 mm

To adjust the valve clearance, see "Workshop Manual - Engine"

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Fan and Cylinder Configuration


Datum Edition Date

PR Litronic LR Litronic RL Litronic


Blatt Page Feuille

01 03

LH-Diesel Engine

4.3.10.01

LH - 4/6 cylinder - In line engine / LH - 6/8 Cylinder - V-type engine Fan - push type = serial version MUL - viewed in air flow direction "running clockwise" with hydraulic fan drive motor

LH - 6/8 Cylinder - V-type engine Fan - push type = serial version EDUL - viewed in air flow direction "running anti-clockwise" Fan suction type MUL - viewed in air flow direction "running clockwise"

= intake valve = exhaust valve Firing order 6-cylinder V-type engines: firing overlap firing overlap intake/exhaust 1 5 1 7 6 2 8 3 3 4 4 6 5 1 2 5 2 6 7 1 4 3 3 8 6 4 5 2

Firing order 8-cylinder V-type engines:

Valve clearance -adjust when engine is cold

0,25/0,30 mm

To adjust the valve clearance, see "Workshop Manual - Engine"

Sub Group Index


Technical data coupling and splitter box Coupling
PR 712 PR 722 PR 732 PR 742 PR 752 F/N xxx-0103 F/N xxx-0103 F/N xxx-2003 F/N xxx-2001 F/N xxx-2002

5.1 5.2
5.2.10

5.2.30

5.2.50

Splitter box
PR 712 PR 722 PR 732 PR 742 PR 752 PR 752 F/N xxx-0103 F/N xxx-0103 F/N xxx-2003 F/N xxx-2001 F/N xxx-20025303 F/N xxx-5304

5.3
5.3.10

5.3.30

5.3.50 5.3.51

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Coupling and
Datum Edition Date

PR Litronic

01 01

Splitter box

Blatt Page Feuille

5.0.00.01

Description

PR 712

PR 722

PR 732

PR 742 350 B 376 350 B 374* 3 50 43 0,86 0,40 1,00 0,016-0,039 0 -218 / 8,58 10 / 0,39

PR 752

Splitter box

type

250 B 266 2,5 61 49

250 B 265 2,5 58 53 0,914 0,40 1,00 0,016-0,039 0 -163 / 6,42 10 / 0,39

350 B 375 3 50 43 0,86 0,40 1,00 0,016-0,039 0 -218 / 8,58 10 / 0,39

350 B 365 6 53 44 0,83 0,40 1,00 0,016-0,039 0 0,40 1,00# 0,016-0,039# 299 / 11,66 10 / 0,39

Oil quantity (for specification see group 1.3) l shaft I No. of teeth shaft II Gear ratio I,II shaft I roller bearing shaft II ball bearing shaft II roller bearing dim. A dim. B mm/inch mm/inch i

0,803 0,40 1,00 0,016-0,039 0 -163 / 6,42 10 / 0,39

Bearing play - axial min. max. mm inches

Oil level - control dimensions

Note:

* = installed at PR 742B F/N xxx-5234 (new travel hydraulic pumps) # = installed at PR 752 F/N xxx-5304 F/N xxx-5303 = bearings will be changed from ball to rollers at repair.

Description Coupling size Rated torque Max. torque Max. allowable. RPM Allowable. temperature range set. screw, item 8 Tightening torque screws, item 9/14 screws, item 7 Nm Nm min-1 C Nm Nm Nm

PR 712 H - 50 - 1 800 2100 4000 - 40 to + 150 120 220 --

PR 722 H - 50 - 1 800 2100 4000 - 40 to + 150 120 220 --

PR 732 K - 150 D 2400 6000 4000 - 40 to + 150 120 79 --

PR 742 K - 150 D 2400 6000 4000 - 40 to + 150 120 79 --

PR 752 H - 400 - 1 4000 10000 2500 - 40 to + 150 200 500 120

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Technical Data
Datum Edition Date

PR Litronic

01 01

Coupling and Splitter Box

Blatt Page Feuille

5.1.00.01

1. Construction, function Main components Pos. 6 hub Pos. 10 bushing- axial - with resilient elements Pos. 13 Elements - radial

The axial bushings are screwed onto the flywheel of the engine at fixed positions = torque input The hub is fixed at the input shaft of the splitter box with set screws and at that way also secured against axial and radial movement = torque output. The torque transfer from input to output is done by the plug-in type resilient elements = free of axial forces. 2. Maintenance The coupling is maintenance free and requires no lubrication. The material is oil and grease resistant. If a knocking noise is heard in the area of the coupling when shutting off the engine, maybe the cause is given by worn out resilient elements. Check the coupling as soon as possible and change all worn or damaged parts. 3. Disassembly / assembly Secure components with suitable lifting devices. Disconnect the splitter box 2 from the flywheel housing. Move it in axial direction to make it possible to disassemble parts of the coupling. It is not necessary to disassemble any other parts to change worn out resilient elements. To disassemble the complete coupling loosen set screws 8 in the hub and screw out socket head screws 9 from the bushings. Remove all parts. Assemble in reverse order. Due to cut outs in the flywheel the bushings 10 are centered. Slide the hub 6 together with the screwed on parts on the input shaft of the splitter box until the hub contacts the end of the spline. To secure the hub tighten and torque the set screws 8 correct. Note: The screws 9 and 14 may only be used once (1x) since the adhesive looses its properties after repeated use. Use only original screws of the quality "Inbus Plus". Prior to the installation, lubricate the friction surface on the heads of the screws lightly with grease. The curing process of the adhesive at 20C ambient temperature, after the screws have been tightened with the listed torque, is approx. 4 to 5 hours. The machine should therefore not be operated within this time frame. Tightening torque's of screws 7, 8, 9 and 14 are listed at data sheet 5.1.00.01. After the bushings 10 are bolted, slide on the resilient elements and slide in the hub together with the screwed on elements 13 to check the correct mounting position. The parts must be easily movable in axial direction.

4. Pre-assemble of a disassembled coupling (see also above notes) Combine inner and outer hub together, according to the drawing. screw in socket head screws 7 and tighten it with the correct torque. Assemble radial elements according to the drawing and fix it with screws 14. Fix the elements with a suitable tool against twisting (turning) and tighten the screws with the correct torque. Note: If hub and radial elements are not 100% in line, the coupling will be damaged after a short time. Slide in resilient elements between the radial elements the check there position. The elements must be easily movable in axial direction.

Benennung Description Dnomination

Typ/ab

Type/from

Type/a partir de

Mjfcifss!
Datum Edition Date

01 01

Coupling

PR 752 RL 52
Blatt Page Feuille

F/N xxx-2002 F/N 739-2001

5.2.50.01

1 2 3 4

Diesel engine Splitter box Hex head screw with washer Coupling complete

6 7 8 9 10 11 12 13 14

Inner hub Socket head screw M12x20 Set screw Socket head screw M20x70 Bushing- axial Resilient element Outer hub Radial element Socket head screw M20x50

Notes
Reference dimension for oil level A, B see page 5.1.00.01

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!
Datum Edition Date

01 01

Splitter box

PR 752 F/N xxx- 2002 5303 RL 52 F/N xxx- 2001 5303


Blatt Page Feuille

5.3.50.01

1 housing 2 dipstick 3 tube 4 guide tube 5 oil filler neck 6 fitting - oil filler 7 oil drain valve complete .1 poppet .2 seal ring .3 piston .4 spring .5 valve cap 8 seal ring 10 11 12 13 14 15 16 20 21 22 23 24 25 input shaft roller bearing roller bearing shaft seal bearing flange O-ring socket head screw spur gear roller bearing bearing flange O-ring grooved ball bearing socket head screw

26 stud with hex nut and washer 27 O-ring 30 31 32 33 34 35 spur gear roller bearing bearing flange O-ring grooved ball bearing socket head screw

36 stud with hex nut and washer 37 O-ring 40 identification plate install with Loctite 242 or comparable product install with Omnivisc 1050 or comparable product

* space between sealing lips filled with appr. ca. 30%


grease

Repositioned - sectional view

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!
Datum Edition Date

01 01

Splitter box

PR 752 F/N xxx- 2002 5303 RL 52 F/N xxx- 2001 5303


Blatt Page Feuille

5.3.50.02

Notes
Reference dimension for oil level A, B see page 5.1.00.01

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!
Datum Edition Date

01 01

Splitter box

PR 752 F/N xxx- 5304 RL 52 F/N xxx- 5304


Blatt Page Feuille

5.3.51.01

1 housing 2 dipstick 3 tube 4 guide tube 5 oil filler neck 6 fitting - oil filler 7 oil drain valve complete .1 poppet .2 seal ring .3 piston .4 spring .5 valve cap 8 seal ring 10 11 12 13 14 15 16 20 21 22 23 24 25 input shaft roller bearing roller bearing shaft seal bearing flange O-ring socket head screw spur gear roller bearing bearing flange O-ring roller bearing socket head screw

26 stud with hex nut and washer 27 O-ring 30 31 32 33 34 35 spur gear roller bearing bearing flange O-ring roller bearing socket head screw

36 stud with hex nut and washer 37 O-ring 40 identification plate install with Loctite 242 or comparable product install with Omnivisc 1050 or comparable product

* space between sealing lips filled with appr. ca. 30%


grease

Repositioned - sectional view

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!
Datum Edition Date

01 01

Splitter box

PR 752 F/N xxx- 5304 RL 52 F/N xxx- 5304


Blatt Page Feuille

5.3.51.02

Sub Group Index


Technical data Description
PR 712(B) F/N xxx-0103 PR 722(B) F/N xxx-0103 PR 732(B) F/N xxx-2003 PR 742(B) F/N xxx-2003 PR 752 F/N xxx-2002

6.1 6.2
6.2.10

6.2.50

Function
PR 712 PR 722 F/N xxx-01030421 F/N xxx-01030606

6.3
6.3.10 6.3.11 6.3.12 6.3.30 6.3.31 6.3.32 6.3.33 6.3.40 6.3.41 6.3.42 6.3.50 6.3.51 6.3.52 6.3.53

PR 712(B) F/N xxx-04225599 PR 722(B) F/N xxx-06075599 PR 712B F/N xxx-5600 PR 722B F/N xxx-5600 PR 732 PR 732 F/N xxx-20032207 F/N xxx-22082500

PR 732B F/N xxx-25015599 PR 732B F/N xxx-5600 PR 742(B) F/N xxx-20015233 PR 742B F/N xxx-52345599 PR 742B F/N xxx-5600 PR 752 PR 752 PR 752 PR 752 F/N xxx-20022062 F/N xxx-20635071 F/N xxx-50725599 F/N xxx-5600

Hydraulic hose routing


Installation guidelines travel motor - high pressure hoses Hydraulic hose routing PR 712 F/N xxx-01030421 PR 722 F/N xxx-01030606 PR 732 F/N xxx-20032207

6.4
6.4.01 6.4.10 6.4.30 6.4.40

PR 742(B) F/N xxx-20015233

Test and adjustment


Benennung Description Dnomination

6.5
Typ/ab Type/from Type/ a partir de

Mjfcifss!
Datum Edition Date

PR Litronic

01 01

Travel hydraulic

Blatt Page Feuille

6.0.00.01

Description Gear pump(s) - replenishing oil flow Qmax pressure relief valve - replenishing pressure SP pressure relief valve - cold start SD to protect cooler and gear pump one way valve - oil cooler bypass Accumulator - replenishing system Gear pump - pump control circuit oil flow Qmax pressure relief valve - control pressure (measured value) Regulating pump - fan drive oil flow Qmax stand-by pressure working pressure flushing flow Variable pump - travel drive - oil flow Qmax hydraulic regulating pressure - servo control cylinder pressure relief valve - replenishing quantity protection pressure relief valves - max. high pressure - closed circuit left/right - travel forward/reverse flushing flow

PR 712(B) PR 722(B) PR 732(B) PR 742(B) PR 752 01035599 01035599 20035599 20015599 20025599 l/min bar bar 79 16+4 251 83 16+4 251 83 16+4 251 117* 150# 253 -180 20+7 28+2

bar bar

---

---

---

3 15* --#

---

l/min bar

---

---

---

33 505

---

l/min bar bar l/min

-----

-----

-----

----272* 282# 2-8 -420+30/-10 10 - 15* 15 - 20#

58 30+3 1603 2-5

l bar bar bar l/min

125 2-8 -420+30/-10 10 - 15

154 2-8 -420+30/-10 10 - 15

209 2-8 -420+30/-10 10 - 15

425 2-8 16+2 420+30/-10 10 - 15

Variable motor - travel drive - pressure relief valve - flushing hydraulic regulating pressure - at pilot piston flushing flow

bar bar l/min

10 - 10 - 15

10 - 10 - 15

10 - 10 - 15

10 - 10 - 15

10 8 - 15 10 - 15

Note:

* = PR 742(B) F/N xxx- 5233 # = PR 742B F/N xxx-52345599


Benennung Description Dnomination Typ/ab Type/from Type/ a partir de

Mjfcifss!

Technical data
Datum Edition Date

PR Litronic

01 03

Travel hydraulic

Blatt Page Feuille

6.1.00.01

Description Gear pump(s) - replenishing oil flow Qmax pressure relief valve - replenishing pressure SP pressure relief valve - cold start SD to protect cooler and gear pump one way valve - oil cooler bypass Gear pump - fan drive oil flow Qmax

PR 712B PR 722B PR 732B PR 742B PR 752 5600 5600 5600 5600 5600 l/min bar bar 79 16+4 251 83 16+4 251 83 16+4 251 117 20+7 -180 20+7 28+2

bar

--

--

--

--

l/min

39 110+10

35 130+10

38 150+10

33 210+10

---

Proportional solenoid valve - electronic regulated - maximum pressure pmax bar Regulating pump - fan drive oil flow Qmax stand-by pressure

l/min bar

-----

-----

-----

-----

58 30+3 160+10 190+10 2-5

working pressure - standard (not adjustm. value) F/N xxx- 6199 max. bar F/N xxx-6200 max. bar flushing flow Variable pump - travel drive - oil flow Qmax hydraulic regulating pressure - servo control cylinder pressure relief valve - replenishing quantity protection pressure relief valves - max. high pressure - closed circuit left/right - travel forward/reverse flushing flow Variable motor - travel drive - pressure relief valve - flushing hydraulic regulating pressure - at pilot piston flushing flow Pressure limitation brake release (towing) l/min

l bar bar bar l/min

125 2-8 -420+30/-10 10 - 15

154 2-8 -420+30/-10 10 - 15

209 2-8 -420+30/-10 10 - 15

282 2-8 -420+30/-10 15 - 20

425 2-8 16+2 420+30/-10 10 - 15

bar bar l/min

10 - 10 - 15

10 - 10 - 15

10 - 10 - 15

10 - 10 - 15

10 8 - 15 10 - 15

bar

351

351

351

351

351

1. Description The travel hydraulic system consists primarily of two independent hydrostatic circuits. A variable flow pump and variable flow motors for each drive operate in a closed loop circuit and each drive a travel gear / track . The drives are always connected and also serve as the service brake. All travel and steering movements of the machine, from straight travel to counterrotation are infinitely variable by moving the travel lever. Control and regulation of the travel hydraulic system is handled by the electronic control system. The stepless regulation also makes maximum utilization of the existing Diesel engine power possible, since the result of force speed can be held at a constant level . The pressure between travel pumps and motors depends on the travel resistance, the transferred torque on the angle of the variable flow motors. The oil cooling system and hydraulic tank are also utilized for the working hydraulics of the machine. 2. Main components of drive train Diesel engine 7Splitter box 8Swash plate type variable flow pump, right & left 9Bent axis type variable flow motor 102 x right, 2 x left x5- Swash plate type - regulating pump (fan drive) 6- Gear pumps - replenishing 1234Axial piston fixed displ. motor / engine cooling fan Gear motor/ hydraulic oil cooling fan Hydr. oil cooler Hydraulic tank Travel gear with parking brake (not shown)

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Description
Datum Edition Date

01 01

Travel Hydraulic

PR 752 RL 52
Blatt Page Feuille

F/N xxx-2002 F/N xxx-2001

6.2.50.01

2.1. Basic function of main components 2.1.1 Diesel engine - Splitter box - pump configuration The Diesel engine drives the splitter box via an elastic coupling at preselected RPM. The splitter box transfers the input RPM via two output shafts to the travel pumps, mounted on the splitter box. Mounted on the right output shaft are the right travel pump, the variable flow pump for the fan drive as well as the replenishing (tandem) gear pumps. Mounted on the left output shaft is the left travel pump as well as the variable flow working hydraulic pump.

2.1.2 Travel pumps - travel motors (closed loop circuit) The closed loop circuit consists of a variable flow travel pump which is connected to the variable flow travel motor with four high pressure hoses.

The travel pumps are regulated via two proportional solenoid valves per pump. They determine the direction (= travel direction ) and flow (= speed range). The intake volume of the travel motors (= higher speed) is regulated via pressure lines, also by the pump proportional solenoid valves. The change-over from pump to motor regulating range is stepless. The total speed range (= regulating range) ranges from 0 to 6.8 mph ( 0 to 11 km/h) The maximum speed can be limited to 2.8 mph ( 4.6 km/h ) via a switch in the electronic control.

This type of regulation with the same Diesel engine output results in:: a) small travel joystick deflection on travel pumps - small pump angle - small displacement = small flow on travel motors - large angle = large consumption slow speed - high torque b) large travel joystick deflection on travel pumps - large pump angle = large flow on travel motors - small angle = small consumption high speed - reduced torque c) in every intermediate position of the infinite joystick deflection a corresponding relation between speed and power, depending on the joystick deflection.

a)

b)

The hydraulic pressure created in the closed loop circuit is limited to maximum 420 bar by pressure relief valves integrated in the travel pumps. The required oil to shift the hydraulic pumps and motors is taken from the (tandem) gear pumps - replenishing circuit. Part of the oil in the closed loop circuit is discharged to the tank via valves in the travel motors. This oil as well as leak oil losses are replenished with cooled and filtered oil via the replenishing function in the travel pumps. The travel motors are inserted directly into the travel gears and are accessible from the outside via the rear main frame cover.

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Description
Datum Edition Date

01 01

Travel Hydraulic

PR 752 RL 52
Blatt Page Feuille

F/N xxx-2002 F/N xxx-2001

6.2.50.02

2.1.3 Tandem gear pumps - replenishing function The gear pumps deliver oil from the hydraulic tank via a valve block, the filter bracket and the pressure filter to the travel pumps to replenish the closed circuits, for flushing the housing, for the pump control and to build up regulating pressure for pumps and motors. to the travel motors to control the motor angle. to the distributor block with solenoid valves for the oil pressure supply for the servo control of the working hydraulic and to release the parking brakes.

The resulting pressure in the system is limited by two pressure relief valves, which are installed in the valve block. Oil not needed in the system flows via these valves and the oil cooler back to tank. The valve block is mounted on the right hand side of the machine in the main frame. This valve block also holds the thermostat switch for the fan control. When the oil is cold and sluggish, part of the oil is displaced directly to the tank, via a pressure relief valve, which also is installed in the right hand side of the main frame. This prevents increased back pressure and the oil will heat up quicker to the required operating temperature. 2.1.4 Regulating pump- fan drive/ hydraulic fixed displacement motors The pump is an axial piston pump with swash plate design and load sensing control. Due to the load sensing control, the axial piston unit draws just enough oil from the hydraulic tank as is presently required to maintain the function (load sensing). When the machine is cold, the load sensing signal from the working circuit is directed via a solenoid valve to tank. The load sensing control regulates the axial piston unit in such a way, that the system pressure required to maintain the minimum speed for the fixed hydraulic motors / fan drive is always maintained. The electric fan drive control monitors the hydraulic oil temperature as well as the temperature for engine coolant and turbocharger. As soon as one item reaches the required operating temperature, the oil flow of the load sensing signal to the tank is blocked by the solenoid valve and the pressurized oil is redirected to the pump. The system pressure required for maximum RPM of the fixed hydraulic motors / fan drive is maintained, in the normal working RPM range of the Diesel engine. This control makes it possible for the oil to heat up quickly, even in cold ambient temperatures, and also makes it possible to maintain a constant operating temperature, even with changing loads. 2.1.5 Hydraulic tank The hydraulic tank is mounted on the left rear of the machine, it contains a return oil filter and serves as a reservoir for the complete hydraulic system of the machine. 2.1.6 Travel gears and disk brakes The travel gears, bolted to the main frame, transfer the output power of the travel motors to the track chains. The integrated parking brakes are always vented during travel operation.

1. Neutralfunction 1.1. Gear pump 15 - Replenishing

Functional schematic, see 6.3.11.00

As soon as the engine is started, the gear pump 15 draws oil from the hydraulic tank 80 via the shut off valve 81 and supplies it to the oil cooler 16 and to the distributor block 50. From distributor block 50 to solenoid valve 51 (parking brake) blocked. check valve 54, accumulator 55 and solenoid valve 53 blocked (servo cut off - working hydraulic) test point ND blocked.

The pressure relief valve in the distributor block limits the possible back up pressure in front of the oil cooler to max. 25+3 bar. After raising the safety lever, the solenoid valve 53 clears the path to the servo control for the working hydraulic. From oil cooler 16 to pressure relief valve 17 pressure filter 18 F-travel pump 2 (right) internal. test connection SP. F-travel pump 2 (left) internal. pressure switch 19. restrictor 6 ( pump housing tank) replenishing function relief valve 4 closed loop circuit - M1(2) replenishing function relief valve 5 closed loop circuit - M2(1) proportional solenoid valve 10 and 11 blocked. pilot piston 8 orifice 12 pump control cylinder 9.

In F-travel pump 2 left / right to

Approx. ~1,5 l/min of oil flows through restrictors 6, through the pump housing and through the filter 85 into the hydraulic tank 80. The oil not needed in the pressure area of the system flows via the pressure relief valve 17, through the return filter 82 into the tank. The paths of pilot pistons 8 to control pistons 9 are severely restricted. All control cylinders are equally actuated with pressurized oil, keeping the swash plate for pumps 3 in neutral position = 0 pump angle. 1.2. Travel pumps 2 and travel motors 20 - closed loop circuit With the pumps in neutral, the oil in the closed loop circuit does not circulate. Because the swash plates of the travel pumps 2 are in the neutral position, the pistons in the barrels do not stroke, meaning there is no flow, even though the rotary group is turning. However, the closed loop circuit is being pressurized with approx. 16+4 bar by the replenishing circuit (via check valves integrated into the high pressure relief valves 4 and 5 (see paragraph 1.1). The 7/2 directional valves 26 (= 7 connections/ 2 positions) in the travel motors 20 are in an end position, its side is not defined. Approx. 10 l/min oil is discharged from one side of the closed loop circuit, M1 or M2, from the opposite side the oil flows to the spring side of the control piston 22 and the axial piston unit 21 is held in neutral position = maximum (displacement) angle. Replenishing oil flows from M1/M2 to directional valve 26 pressure reducing valve 27 directional valve 26 pressure relief valve 24 orifice 28 motor housing (flushing) screen filter 30 support shaft 40 tank 80. directional valve 26 pressure reducing valve 27 directional valve 26 pilot piston 23 control piston 22 - spring side.

Control pressure moves from M1 /M2 to

The pressure reducing valves 27 are actuated on both sides with equal pressure, and therefore remain in neutral position = free flow. The piston bottom side of the control piston 22 is open towards the motor housing/ tank via the servo control piston 23 and orifice 29.

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

PR 712(B) F/N xxx-0422 5599 PR 722B F/N xxx-0607 5599

Function
Datum Edition Date

01 02

Travel hydraulic

Blatt Page Feuille

6.3.11.01

2. Operating functions - travel The various travel functions are controlled by the electronic system via the proportional solenoid valves, which are installed on the pump covers and the travel motor remote control. The current and therefore the regulating pressure build-up is in proportion to the lever deflection. See also Description - Travel Hydraulic - section 6.2.10 and Functional Description - Electronic Control - section 10.3. Note: The pump control depends on the type of travel gear installed - see "Notes" on the parts listing or sub group 11. The direction is selected in travel operation on the travel pumps 2, with travel gear type "A" or "C", for: Travel forward Travel reverse Electronic control: on solenoid valve 10 on solenoid valve 11 Regulating pressure build -up: at connection Z at connection Y Oil flow output: on P(top) on S(bottom)

The direction is selected in travel operation on the travel pumps 2, with travel gear type "P", for: Travel forward Travel reverse Electronic control: on solenoid valve 11 on solenoid valve 10 Regulating pressure build -up: at connection Y at connection Z Oil flow output: on S(bottom) on P(top)

The solenoid valves for the travel motors are always energized during travel operation, but they only regulate from a certain current value. When turning, the solenoid valve on the side to which the machine is turning receives less current, as a result the intake volume of the motor is increased or the flow volume from the pump is reduced and the travel speed on this side is reduced. The solenoid valve 51 is energized during the complete travel operation. The valve shifts to diagonal path, the switch 52 is actuated by the oil pressure, flows via support axle 40 to the travel gears 35 and vents (releases) the disk brakes 36. Depending on the travel resistance (= rotary resistance of travel motors), high pressure is created in the pump flow = high pressure side of closed loop circuits. In the return flow from the travel motors, the pressure is SPpressure = low pressure side of closed loop circuits. High pressure side - travel forward = System section - test point M1 High pressure side - travel reverse = System section - test point M2 2.1. Regulation - travel pumps 2 starting from neutral function, as described in section 1. The valve is opened when the proportional solenoid valves 10/11 are energized, the pressurized oil flows to one side of the regulating cylinder 7 and builds up a magnetic force in proportion to the hydraulic pressure. The piston of the regulating cylinder 7 is moved by hydraulic pressure to the opposite regulating spring assembly, until the forces are balanced again. The servo control piston 8 is also moved via a mechanical connection. It opens the oil port to the side opposite of the control direction of the piston 8 of swash plate control cylinder 9 and allows the oil to flow from the opposite side into the pump housing. The swash plate pump 3 is changed to flow direction against Qmax . low current small flow volume high current large flow volume flow direction, see chart, section 2 As the swash place is moved, the housing of servo control piston 8 is mechanically moved along until the bores in the housing and the servo control piston are again positively overlapped = neutral position. Both sides of the swash plate control cylinder 9 are actuated again with pressurized oil and the swash plate is held hydraulically on the actuated pump angle. As current increases, it moves further in direction Qmax until the mechanical regulating stop of the travel pump is reached. If current is decreased, the swash plate pump 3 is moved in direction Qmin / neutral position, regulation / control sequence is as described above. 2.2. Regulation - travel motors 20 starting from neutral function, as described in section 1. Due to current going to the proportional solenoids, the servo control piston 23 is moved against the regulating spring and return spring to shift position parallel path. When starting to travel, the 7/2 directional valve 26 is actuated on one side with low pressure, on the other side with high pressure from the closed loop circuit and is moved depending on the forces against the low pressure side.

This results in the following oil pressure flow, in addition to the closed loop circuit: Low pressure sidedirectional valve 26 1.pressure reducing valve 27-spring side. (SP-pressure) 1.pressure reducing valve 27-piston side/pathdirectional valve 26 2. pressure reducing valve 27 -spring side. pressure relief valve 24 orifice 28 motor housing (flushing) screen filter 30 support shaft 40 tank 80. The sum of spring force + SP-pressure on the piston of pressure reducing valves 27 results in a pressure value of ~40 bar. High pressure side directional valve 26 blocked. pressure reducing valve 27 - path/piston side directional valve 26 pilot piston 23 control piston 22 - piston bottom side. When the pressure on the piston bottom side of the pressure reducing valve 27 reaches a pressure of ~40 bar, the piston is moved against the spring + SP-pressure and the path is restricted, so that the pressure cannot continue to increase (control pressure on piston 22 40 bar). The spring side of the control piston 22 is relieved via the servo control piston 23 and orifice 29 to the motor housing / tank, the axial piston unit 21 is moved to a smaller angle = in direction Qmin. Due to this change in direction Qmin, the return spring pushes the servo control piston 23 increasingly against the force of the proportional solenoid. When the spring force is the same as the magnetic force, the servo control piston 23 is held in center position, the ports to the control piston 22 are closed and the axial piston unit is held on the selected angle. As current is increased, it continues to move in direction Qmin. The maximum possible current is limited by the electronic control. As current is decreased, the axial piston unit 21 is moved again in direction Qmax = neutral position, the control pressure is moved the same way as in neutral function via the servo control piston 23- diagonal path to the spring side of the control piston 22 and the piston bottom side is relieved. Intermediate positions for equal force of solenoid to spring are held as described. 2.3. Closed loop circuits starting from neutral function, as described in section 1.1 The swash plate pump flow 3 is moved via a line connection and through the support axle 40 to a connection side of travel motor 20/ axial piston unit 21, it actuates its piston and sets the unit in rotation. Due to the output rotation, the oil is transported to the opposite connector side and flows via a second line connection through the support axle back to the suction side of the travel pump 2- swash plate pump 3. The expelled oil in the travel motor 20 - see previous description - is taken in again into the travel pump 2, also on the low pressure side = suction side via the replenishing function of the pressure relief valve 4 or 5 - see neutral function, section 1.1. On the high pressure side = delivery side, the replenishing function is held closed by high pressure and the maximum pressure of the pressure relief valve is limited to 420+30/-10 bar. If the pressure increases above this value, the pressure relief valve opens and lets the oil flow off to the replenishing - low pressure side. The second closed loop circuit works the same way. The pressures in the closed loop circuits can also be measured on test points M1 and M2 (support axles 40 test connections are installed inside, can also be connected to outer flanges) with suitable pressure gauges. See special tools, section 2.1.21. Observe safety guidelines - see section 1.2.

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

PR 712(B) F/N xxx-0422 5599 PR 722B F/N xxx-0607 5599

Function
Datum Edition Date

01 02

Travel hydraulic

Blatt Page Feuille

6.3.11.02

1. Neutralfunction 1.1. Gear pump 15 - Replenishing

Functional schematic, see 6.3.12.00

As soon as the engine is started, the gear pump 15 draws oil from the hydraulic tank 80 via the shut off valve 81 and supplies it to the oil cooler 17 and to the distributor block 45. From distributor block 45 to solenoid valve Y13 (parking brake) blocked. check valve 51, accumulator 55 and solenoid valve Y4 blocked (servo cut off - working hydraulic) test point SD blocked.

The pressure relief valve in the distributor block limits the possible back up pressure in front of the oil cooler to max. 25+3 bar. After raising the safety lever, the solenoid valve Y4 clears the path to the servo control for the working hydraulic. From oil cooler 17 to pressure relief valve 18 pressure filter 19 F-travel pump 3 (right) internal. test connection SP. F-travel pump 2 (left) internal. pressure switch B6. restrictor 11 ( pump housing tank) replenishing function relief valve 5 closed loop circuit - M1 replenishing function relief valve 6 closed loop circuit - M2 proportional solenoid valve Y9/Y10 or Y11/Y12 blocked. pilot piston 8 orifice 10 pump control cylinder 9.

In F-travel pump 2/3 left / right to

Approx. ~1,5 l/min of oil flows through restrictors 11, through the pump housing and through the filter 85 into the hydraulic tank 80. The oil not needed in the pressure area of the system flows via the pressure relief valve 18, through the return filter 82 into the tank. The paths of pilot pistons 8 to control pistons 9 are severely restricted. All control cylinders are equally actuated with pressurized oil, keeping the swash plate for pumps 4 in neutral position = 0 pump angle. 1.2. Travel pumps 2/3 and travel motors 20 - closed loop circuit With the pumps in neutral, the oil in the closed loop circuit does not circulate. Because the swash plates of the travel pumps 2/3 are in the neutral position, the pistons in the barrels do not stroke, meaning there is no flow, even though the rotary group is turning. However, the closed loop circuit is being pressurized with approx. 16+4 bar by the replenishing circuit (via check valves integrated into the high pressure relief valves 5 and 6 (see paragraph 1.1). The 7/2 directional valves 26 (= 7 connections/ 2 positions) in the travel motors 20 are in an end position, its side is not defined. Approx. 10 l/min oil is discharged from one side of the closed loop circuit, M1 or M2, from the opposite side the oil flows to the spring side of the control piston 22 and the axial piston unit 21 is held in neutral position = maximum (displacement) angle. Replenishing oil flows from M1/M2 to directional valve 26 pressure reducing valve 27 directional valve 26 pressure relief valve 24 orifice 28 motor housing (flushing) screen filter 41 support shaft 40 tank 80. directional valve 26 pressure reducing valve 27 directional valve 26 pilot piston 23 control piston 22 - spring side.

Control pressure moves from M1 /M2 to

The pressure reducing valves 27 are actuated on both sides with equal pressure, and therefore remain in neutral position = free flow. The piston bottom side of the control piston 22 is open towards the motor housing/ tank via the servo control piston 23 and orifice 29.

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

PR 712B F/N xxx-5600 PR 722B F/N xxx-5600

Function
Datum Edition Date

01 03

Travel hydraulic

Blatt Page Feuille

6.3.12.01

1.3. Gear pump 16 - fan drive With the Diesel engine running, the gear pump 16 draws oil from the hydraulic tank 80, via shut off valve 81 and supplies it via the filter 72 to the fixed displacement motor 70 and solenoid valve Y64. The motor 70 / fan begins to turn and the pressure regulating valve of the proportional solenoid valve Y64 opens when the regulated pressure level is reached = flow is divided. The oil flows together with the replenishing oil via the filter 82 to the tank 80. Test point LA (pressure build up in the fan drive) connected to outlet P of pump 16 . Regulation: With the starter switch S1 in operating position, the electronic fan control A18 is energized, among other items. A18 regulates the electrical power of the proportional solenoid valve Y64 depending on the signal values of temperature sensors B38 to 39 and limits the pressure build up in the hydraulic fan drive = the fan speed. S1 K4 F6 A18 B38 - coolant temperature B39 - hydraulic oil temperature Y64 - proportional solenoid valve - fan drive When the machine is cold, Y64 is energized with the maximum value and regulates the possible pressure build up in the hydraulic fan drive - pump 16 motor 70 - to the minimum value (fan turns at minimum speed or is stationary). At increasing temperatures, the current from Y64 is reduced proportionally and as a result, the hydraulic pressure value is increased proportionally = the fan speed increases. When one of the temperatures reaches the operating temperature, Y64 is fully shifted without current by A18. Without current, also in case of a system failure, Y64 regulates to the set maximum pressure = maximum fan speed (fail-save system) - pmax = 110+10 bar (PR 712), 130+10 bar (PR 722) For wiring see section 9 - Electrical System. 2. Operating functions - travel The various travel functions are controlled by the electronic system via the proportional solenoid valves, which are installed on the pump covers and the travel motor remote control. The current and therefore the regulating pressure build-up is in proportion to the lever deflection. See also Description - Travel Hydraulic - section 6.2.10 and Functional Description - Electronic Control - section 10.3. The direction is selected in travel operation on the travel pumps 2/3 for: Travel forward Travel reverse Electronic control: on solenoid valve Y9/Y11 on solenoid valve Y10/Y12 Regulating pressure build -up: at connection Y at connection Z Oil flow output: on S(bottom) on P(top)

The solenoid valves for the travel motors are always energized during travel operation, but they only regulate from a certain current value. When turning, the solenoid valve on the side to which the machine is turning receives less current, as a result the intake volume of the motor is increased or the flow volume from the pump is reduced and the travel speed on this side is reduced. The solenoid valve Y13 is energized during the complete travel operation. The valve shifts to diagonal path, the pressurized oil flows via outlet B to test center 65-BB to distributor block 75, actuates pressure switch B5 and pressure relief valve 76. support shafts 40 travel gear 35 and vents (releases) the disk brakes 36. Depending on the travel resistance (= rotary resistance of travel motors), high pressure is created in the pump flow = high pressure side of closed loop circuits. In the return flow from the travel motors, the pressure is SPpressure = low pressure side of closed loop circuits. High pressure side - travel forward = System section - test point M1 High pressure side - travel reverse = System section - test point M2

2.4. Regulation - travel pumps 2/3 starting from neutral function, as described in section 1. The valve is opened when the proportional solenoid valves Y9/Y10 or Y11/Y12 are energized, the pressurized oil flows to one side of the regulating cylinder 7 and builds up a magnetic force in proportion to the hydraulic pressure. The piston of the regulating cylinder 7 is moved by hydraulic pressure to the opposite regulating spring assembly, until the forces are balanced again. The servo control piston 8 is also moved via a mechanical connection. It opens the oil port to the side opposite of the control direction of the piston 8 of swash plate control cylinder 9 and allows the oil to flow from the opposite side into the pump housing. The swash plate pump 4 is changed to flow direction against Qmax . low current small flow volume high current large flow volume flow direction, see chart, section 2 As the swash place is moved, the housing of servo control piston 8 is mechanically moved along until the bores in the housing and the servo control piston are again positively overlapped = neutral position. Both sides of the swash plate control cylinder 9 are actuated again with pressurized oil and the swash plate is held hydraulically on the actuated pump angle. As current increases, it moves further in direction Qmax until the mechanical regulating stop of the travel pump is reached. If current is decreased, the swash plate pump 3 is moved in direction Qmin / neutral position, regulation / control sequence is as described above. 2.5. Regulation - travel motors 20 starting from neutral function, as described in section 1. Due to current going to the proportional solenoids, the servo control piston 23 is moved against the regulating spring and return spring to shift position parallel path. When starting to travel, the 7/2 directional valve 26 is actuated on one side with low pressure, on the other side with high pressure from the closed loop circuit and is moved depending on the forces against the low pressure side. This results in the following oil pressure flow, in addition to the closed loop circuit: Low pressure sidedirectional valve 26 1.pressure reducing valve 27-spring side. (SP-pressure) 1.pressure reducing valve 27-piston side/pathdirectional valve 26 2. pressure reducing valve 27 -spring side. pressure relief valve 24 orifice 28 motor housing (flushing) screen filter 41 support shaft 40 tank 80. The sum of spring force + SP-pressure on the piston of pressure reducing valves 27 results in a pressure value of ~40 bar. High pressure side directional valve 26 blocked. pressure reducing valve 27 - path/piston side directional valve 26 pilot piston 23 control piston 22 - piston bottom side. When the pressure on the piston bottom side of the pressure reducing valve 27 reaches a pressure of ~40 bar, the piston is moved against the spring + SP-pressure and the path is restricted, so that the pressure cannot continue to increase (control pressure on piston 22 40 bar). The spring side of the control piston 22 is relieved via the servo control piston 23 and orifice 29 to the motor housing / tank, the axial piston unit 21 is moved to a smaller angle = in direction Qmin. Due to this change in direction Qmin, the return spring pushes the servo control piston 23 increasingly against the force of the proportional solenoid. When the spring force is the same as the magnetic force, the servo control piston 23 is held in center position, the ports to the control piston 22 are closed and the axial piston unit is held on the selected angle.

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

PR 712B F/N xxx-5600 PR 722B F/N xxx-5600

Function
Datum Edition Date

01 03

Travel hydraulic

Blatt Page Feuille

6.3.12.02

As current is increased, it continues to move in direction Qmin. The maximum possible current is limited by the electronic control. As current is decreased, the axial piston unit 21 is moved again in direction Qmax = neutral position, the control pressure is moved the same way as in neutral function via the servo control piston 23- diagonal path to the spring side of the control piston 22 and the piston bottom side is relieved. Intermediate positions for equal force of solenoid to spring are held as described. 2.6. Closed loop circuits starting from neutral function, as described in section 1.1 The swash plate pump flow 4 is moved via a line connection and through the support axle 40 to a connection side of travel motor 20/ axial piston unit 21, it actuates its piston and sets the unit in rotation. Due to the output rotation, the oil is transported to the opposite connector side and flows via a second line connection through the support axle back to the suction side of the travel pump 2/3- swash plate pump 4. The expelled oil in the travel motor 20 - see previous description - is taken in again into the travel pump 2/3, also on the low pressure side = suction side via the replenishing function of the pressure relief valve 5 or 6 - see neutral function, section 1.1. On the high pressure side = delivery side, the replenishing function is held closed by high pressure and the maximum pressure of the pressure relief valve is limited to 420+30/-10 bar. If the pressure increases above this value, the pressure relief valve opens and lets the oil flow off to the replenishing - low pressure side. The second closed loop circuit works the same way. The pressures in the closed loop circuits can also be measured on test points M1 and M2 located on the test center 65 with suitable pressure gauges. See special tools, section 2.1.21. Observe safety guidelines - see section 1.2. 3. Special function - brake actuating when towing If any traveling function of the machine fails, the break function (operating brake) of the hydrostatic travel drive and the mechanic parking brake can be released manually/hydraulically. Observe all guidelines of the operation manual and all safety guidelines. 3.1. Brake release Connect hose from connection "BB" to connection "BS" and close "BB"(all connections on the test center 65). connect M1RM2R and M1LM2L on the test center 65 with hoses (delivered with the machine-tools) = hydrostatic drive - brake function is not in function anymore. set accumulator 77 by multiple actuating of the hand pump for tilting operators cab (see section 17.2.10) under sufficient pressure. bring starter switch, emergency OFF switch and safety lever in operating position = solenoid valve Y63 is currented/switched and the brakes 36 are released via path PB by the stored pressurized oil. When necessary, the brakes can be released directly by the hand pump, when the solenoid valve is switched.

The pressure relief valve 76 prevents the brake of too high pressure. The releasing of the brake is indicated on the instrument panel via pressure switch B5. While towing, the displaced oil by the variable motors circulates in the closed loop circuit via connection M1M2. 3.2. Emergency braking when towing Interrupt currenting to solenoid valve Y63 by - pressing the emergency OFF switch, or - lower the safety lever, or - turn starter switch to 0 position. The solenoid valve Y63 returns to neutral position, the pressure to the parking brake gets via path BT to tank and the brakes closes. The size of the accumulator 77 allows a recent releasing (twice is possible) of the parking brake.

Notes

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

PR 712B F/N xxx-5600 PR 722B F/N xxx-5600

Parts list
Datum Edition Date

02 02

Travel Hydraulic

Blatt Page Feuille

6.3.12.00

1 splitter box 2 3 4 5 6 7 8 9 10 11 travel pump left travel pump right swash plate pump pressure relief valve - HP forward / M1 - with replenishing valve pressure relief valve - HP reverse / M2 - with replenishing valve servo control piston pilot piston pump control cylinder orifice restrictor 70 axial piston fixed displacement motor (fan - combinated cooler) 72 strainer 75 distributor block 76 pressure relief valve - parking brake 77 accumulator - safety device towing 80 81 82 83 85 90 91 92 93 95 hydraulic tank shut off valve return filter bypass valve strainer to regulating pump 100 - working hydraulic to control valve block - working hydraulic to pilot (servo) control valve - working hydraulic return line - working hydraulic to /from hand pump - cab tilt

15 gear pump - replenishing / coolant circuit 16 gear pump - fan drive 17 oil cooler 18 pressure relief valve - repl. oil pressure SP 19 filter - replenishing 20 21 22 23 24 25 26 27 28 29 travel motor complete left /right axial piston unit control piston pilot piston pressure relief valve - flushing valve unit directional valve pressure reducing valve (40 bar) orifice orifice

100 regulating pump - working hydraulic

B5 B6 B18 B39 Y4 Y7 Y8 Y9

pressure switch - parking brake (15 bar) pressure switch - repl. oil pressure (8 bar) pressure switch - filter monitoring (2,5 bar) temperature sensor - fan drive solenoid valve - servo cut off proportional solenoid valve - travel motor left proportional solenoid valve - travel motor right

35 travel gear complete left /right 36 ring piston - parking brake 40 support shaft complete left /right 41 strainer 45 valve block / pressure relief valve - cold start 51 check valve 55 accumulator - working hydraulic 60 test center - test points SP = repl. oil pressure ND = control pressure - working hydraulic 65 test center - test points / connections M1L = high pressure travel forward - left side M2L = high pressure travel reverse - left side M1R = high pressure travel forward - right side M2R = high pressure travel reverse - right side hose connection BB = parking brake - operating position BS = parking brake - towing position M = test point - bleeding

proportional solenoid valve - travel pump left travel forward Y10 proportional solenoid valve - travel pump left travel reverse Y11 proportional solenoid valve - travel pump right travel forward Y12 proportional solenoid valve - travel pump right travel reverse Y13 solenoid valve - parking brake Y63 solenoid valve - safety device towing Y64 proportional solenoid valve pressure relief - fan drive

test points in the machine SD = back-up pressure - cold start (pump 15)

Benennung Description Dnomination

Typ/ab Type/from Type/a partir de

liebherr
Datum Edition Date

F/N xxx - 5600 F/N xxx - 5600

02 02

Blatt Page Feuille

00

Notes
Note: Pump control and position of test points M1, M2 depends on the type of travel gear installed > see sub
group 11

Pos.

for FAT > Type AorC > Control / travel forward > Control / travel reverse > upper test point > lower test point

for FAT > Type P > Control / travel reverse > Control / travel forward > lower test point >upper test point

10 11 M1 M2

Benennung Description Dnomination

Typ/ab

Type/from

Type/a partir de

Datum Edition Date

Parts List

PR 732

F/N xxx > 2208 2500

01 00

Travel Hydraulic

Blatt Page Feuille

6.3.31.00

1 2 3 4 5 6 7 8 9 10 11 12

Splitterbox Travel pump, complete > right / left Swash plate pump Pressure relief valve > HP with replenishing valve Pressure relief valve > HP with replenishing valve Restrictor Servo control piston Servo piston Pump control piston Proportional solenoid valve (travel > primary regulation) Proportional solenoid valve (travel > primary regulation) Orifice Gear pump > Replenishing pressure Oil cooler Pressure relief valve > Replenishing pressure Pressure filter > Replenishing pressure Oil pressure switch > Replenishing pressure> Indicator light Travel motor, complete > right / left Axial piston unit Control piston Servo piston with proportional solenoid (secondary regulation) Pressure relief valve > flushing circuit Valve unit Directional valve Pressure reducing valves (integrated) 40 bar Orifice Orifice Filter Travel gear, complete > right / left Ring piston > disk brake Support axle > right / left Distributor block with pressure relief valve > cold start Solenoid valve > disk brake Oil pressure switch > brake indicator light

53 54 55 60 80 81 82 83 85 90 91 92 93 94 95 100

Solenoid valve > Safety control working hydraulic Check valve Accumulator Test center Hydraulic tank Shut off valve Return filter Bypass valve Filter Suction line > working pump to control valve block WH to servo control WH Leak oil line (from regulating pump to hydraulic tank) Return lines WH to / from hand pump Regulating pump / working hydraulic

15 16 17 18 19

20 21 22 23 24 25 26 27 28 29 30 35 36 40

Test points SP ND M1 M2 Replenishing pressure Cold start pressure / control pressure working hydraulic High pressure > travel forward High pressure > travel reverse

WH = working hydraulic

50

51 52

1. Neutralfunction 1.1. Gear pump 15 - Replenishing

Functional schematic, see 6.3.32.00

As soon as the engine is started, the gear pump 15 draws oil from the hydraulic tank 80 via the shut off valve 81 and supplies it to the oil cooler 16 and to the distributor block 50. From distributor block 50 to solenoid valve 51 (parking brake) blocked. check valve 53, accumulator 54 and solenoid valve 55 blocked (servo cut off - working hydraulic)

The pressure relief valve in the distributor block limits the possible back up pressure in front of the oil cooler to max. 25+3 bar. After raising the safety lever, the solenoid valve 55 clears the path to the servo control for the working hydraulic and test point ND. From oil cooler 16 to pressure relief valve 17 pressure filter 18 F-travel pump 2 (right) internal. test connection SP. F-travel pump 2 (left) internal. pressure switch 19. restrictor 6 ( pump housing tank) replenishing function relief valve 4 closed loop circuit - M2 replenishing function relief valve 5 closed loop circuit - M1 proportional solenoid valve 10 and 11 blocked. pilot piston 8 orifice 12 pump control cylinder 9.

In F-travel pump 2 left / right to

Approx. ~1,5 l/min of oil flows through restrictors 6, through the pump housing and through the filter 85 into the hydraulic tank 80. The oil not needed in the pressure area of the system flows via the pressure relief valve 17, through the return filter 82 into the tank. The paths of pilot pistons 8 to control pistons 9 are severely restricted. All control cylinders are equally actuated with pressurized oil, keeping the swash plate for pumps 3 in neutral position = 0 pump angle. 1.2. Travel pumps 2/3 and travel motors 20 - closed loop circuit With the pumps in neutral, the oil in the closed loop circuit does not circulate. Because the swash plates of the travel pumps 2 are in the neutral position, the pistons in the barrels do not stroke, meaning there is no flow, even though the rotary group is turning. However, the closed loop circuit is being pressurized with approx. 16+4 bar by the replenishing circuit (via check valves integrated into the high pressure relief valves 4 and 5 (see paragraph 1.1). The 7/2 directional valves 26 (= 7 connections/ 2 positions) in the travel motors 20 are in an end position, its side is not defined. Approx. 10 l/min oil is discharged from one side of the closed loop circuit, M1 or M2, from the opposite side the oil flows to the spring side of the control piston 22 and the axial piston unit 21 is held in neutral position = maximum (displacement) angle. Replenishing oil flows from M1/M2 to directional valve 26 pressure reducing valve 27 directional valve 26 pressure relief valve 24 orifice 28 motor housing (flushing) screen filter 30 support shaft 40 tank 80. directional valve 26 pressure reducing valve 27 directional valve 26 pilot piston 23 control piston 22 - spring side.

Control pressure moves from M1 /M2 to

The pressure reducing valves 27 are actuated on both sides with equal pressure, and therefore remain in neutral position = free flow. The piston bottom side of the control piston 22 is open towards the motor housing/ tank via the servo control piston 23 and orifice 29.

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Function
Datum Edition Date

PR 732B F/N xxx-2501 5599

01 02

Travel hydraulic

Blatt Page Feuille

6.3.32.01

2. Operating functions - travel The various travel functions are controlled by the electronic system via the proportional solenoid valves, which are installed on the pump covers and the travel motor remote control. The current and therefore the regulating pressure build-up is in proportion to the lever deflection. See also Description - Travel Hydraulic - section 6.2.10 and Functional Description - Electronic Control - section 10.3. The direction is selected in travel operation on the travel pumps 2 for: Travel forward Travel reverse Electronic control: on solenoid valve 11 on solenoid valve 10 Regulating pressure build -up: at connection Y at connection Z Oil flow output: on S(bottom) on P(top)

The solenoid valves for the travel motors are always energized during travel operation, but they only regulate from a certain current value. When turning, the solenoid valve on the side to which the machine is turning receives less current, as a result the intake volume of the motor is increased or the flow volume from the pump is reduced and the travel speed on this side is reduced. The solenoid valve 51 is energized during the complete travel operation. The valve shifts to diagonal path, the switch 52 is actuated by the oil pressure, flows via support axle 40 to the travel gears 35 and vents (releases) the disk brakes 36. Depending on the travel resistance (= rotary resistance of travel motors), high pressure is created in the pump flow = high pressure side of closed loop circuits. In the return flow from the travel motors, the pressure is SPpressure = low pressure side of closed loop circuits. High pressure side - travel forward = System section - test point M1 High pressure side - travel reverse = System section - test point M2 2.1. Regulation - travel pumps 2 starting from neutral function, as described in section 1. The valve is opened when the proportional solenoid valves 10/11 are energized, the pressurized oil flows to one side of the regulating cylinder 7 and builds up a magnetic force in proportion to the hydraulic pressure. The piston of the regulating cylinder 7 is moved by hydraulic pressure to the opposite regulating spring assembly, until the forces are balanced again. The servo control piston 8 is also moved via a mechanical connection. It opens the oil port to the side opposite of the control direction of the piston 8 of swash plate control cylinder 9 and allows the oil to flow from the opposite side into the pump housing. The swash plate pump 3 is changed to flow direction against Qmax . low current small flow volume high current large flow volume flow direction, see chart, section 2 As the swash place is moved, the housing of servo control piston 8 is mechanically moved along until the bores in the housing and the servo control piston are again positively overlapped = neutral position. Both sides of the swash plate control cylinder 9 are actuated again with pressurized oil and the swash plate is held hydraulically on the actuated pump angle. As current increases, it moves further in direction Qmax until the mechanical regulating stop of the travel pump is reached. If current is decreased, the swash plate pump 3 is moved in direction Qmin / neutral position, regulation / control sequence is as described above. 2.2. Regulation - travel motors 20 starting from neutral function, as described in section 1. Due to current going to the proportional solenoids, the servo control piston 23 is moved against the regulating spring and return spring to shift position parallel path. When starting to travel, the 7/2 directional valve 26 is actuated on one side with low pressure, on the other side with high pressure from the closed loop circuit and is moved depending on the forces against the low pressure side.

This results in the following oil pressure flow, in addition to the closed loop circuit: Low pressure sidedirectional valve 26 1.pressure reducing valve 27-spring side. (SP-pressure) 1.pressure reducing valve 27-piston side/pathdirectional valve 26 2. pressure reducing valve 27 -spring side. pressure relief valve 24 orifice 28 motor housing (flushing) screen filter 30 support shaft 40 tank 80. The sum of spring force + SP-pressure on the piston of pressure reducing valves 27 results in a pressure value of ~40 bar. High pressure side directional valve 26 blocked. pressure reducing valve 27 - path/piston side directional valve 26 pilot piston 23 control piston 22 - piston bottom side. When the pressure on the piston bottom side of the pressure reducing valve 27 reaches a pressure of ~40 bar, the piston is moved against the spring + SP-pressure and the path is restricted, so that the pressure cannot continue to increase (control pressure on piston 22 40 bar). The spring side of the control piston 22 is relieved via the servo control piston 23 and orifice 29 to the motor housing / tank, the axial piston unit 21 is moved to a smaller angle = in direction Qmin. Due to this change in direction Qmin, the return spring pushes the servo control piston 23 increasingly against the force of the proportional solenoid. When the spring force is the same as the magnetic force, the servo control piston 23 is held in center position, the ports to the control piston 22 are closed and the axial piston unit is held on the selected angle. As current is increased, it continues to move in direction Qmin. The maximum possible current is limited by the electronic control. As current is decreased, the axial piston unit 21 is moved again in direction Qmax = neutral position, the control pressure is moved the same way as in neutral function via the servo control piston 23- diagonal path to the spring side of the control piston 22 and the piston bottom side is relieved. Intermediate positions for equal force of solenoid to spring are held as described. 2.3. Closed loop circuits starting from neutral function, as described in section 1.1 The swash plate pump flow 3 is moved via a line connection and through the support axle 40 to a connection side of travel motor 20/ axial piston unit 21, it actuates its piston and sets the unit in rotation. Due to the output rotation, the oil is transported to the opposite connector side and flows via a second line connection through the support axle back to the suction side of the travel pump 2- swash plate pump 3. The expelled oil in the travel motor 20 - see previous description - is taken in again into the travel pump 2, also on the low pressure side = suction side via the replenishing function of the pressure relief valve 4 or 5 - see neutral function, section 1.1. On the high pressure side = delivery side, the replenishing function is held closed by high pressure and the maximum pressure of the pressure relief valve is limited to 420+30/-10 bar. If the pressure increases above this value, the pressure relief valve opens and lets the oil flow off to the replenishing - low pressure side. The second closed loop circuit works the same way. The pressures in the closed loop circuits can also be measured on test points M1 and M2 (support axles 40 test connections are installed inside, can also be connected to outer flanges) with suitable pressure gauges. See special tools, section 2.1.21. Observe safety guidelines - see section 1.2.

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Function
Datum Edition Date

PR 732B F/N xxx-2501 5599

01 02

Travel hydraulic

Blatt Page Feuille

6.3.32.02

Notes

Benennung Description Dnomination

Typ/ab

Type/from

Type/a partir de

Datum Edition Date

Parts List

PR 732 B F/N xxx> 25015599


Blatt Page Feuille

01 00

Travel Hydraulic

6.3.32.00

1 2 3 4 5 6 7 8 9 10 11 12 15 16 17 18 19

Splitterbox Travel pump, complete > right / left Swash plate pump Pressure relief valve > HP> reverse with replenishing valve Pressure relief valve > HP > forward with replenishing valve Restrictor Servo control piston Servo piston Pump control piston Proportional solenoid valve (travel reverse > primary regulation) Proportional solenoid valve (travel forward > primary regulation) Orifice Gear pump > Replenishing pressure Oil cooler Pressure relief valve > Replenishing pressure Pressure filter > Replenishing pressure Oil pressure switch > Replenishing pressure> Indicator light Travel motor, complete > right / left Axial piston unit Control piston Servo piston with proportional solenoid (secondary regulation) Pressure relief valve > flushing circuit Valve unit Directional valve Pressure reducing valves (integrated) 40 bar Orifice Orifice Filter Travel gear, complete > right / left Ring piston > disk brake Support axle > right / left Distributor block with pressure relief valve > cold start Solenoid valve > disk brake Oil pressure switch > brake indicator light

53 54 55

Check valve Accumulator Solenoid valve > Safety control working hydraulic Test center Hydraulic tank Shut off valve Return filter > tank Bypass valve > tank Filter > tank Oil pressure switch > return filter monitor Suction line > working pump to control valve WH to servo control WH Leak oil line (from WH pump to hydraulic tank) Return lines WH to / from hand pump Pump / working hydraulic

60 80 81 82 83 85 86 90 91 92 93 94 95 100

20 21 22 23 24 25 26 27 28 29 30 35 36 40 50

Test points SP ND M1 M2 Replenishing pressure Cold start pressure / control pressure working hydraulic High pressure > travel forward High pressure > travel reverse

WH = working hydraulic

51 52

1. Neutralfunction 1.1. Gear pump 15 - Replenishing

Functional schematic, see 6.3.33.00

As soon as the engine is started, the gear pump 15 draws oil from the hydraulic tank 80 via the shut off valve 81 and supplies it to the oil cooler 17 and to the distributor block 45. From distributor block 45 to check valve 52 solenoid valve Y13 (parking brake) blocked. check valve 51, accumulator 55 and solenoid valve Y4 blocked (servo cut off - working hydraulic) test point SD blocked.

The pressure relief valve in the distributor block limits the possible back up pressure in front of the oil cooler to max. 25+3 bar. After raising the safety lever, the solenoid valve Y4 clears the path to the servo control for the working hydraulic. From oil cooler 17 to pressure relief valve 18 pressure filter 19 F-travel pump 3 (right) internal. test connection SP. F-travel pump 2 (left) internal. pressure switch B6. restrictor 11 ( pump housing tank) replenishing function relief valve 5 closed loop circuit - M1 replenishing function relief valve 6 closed loop circuit - M2 proportional solenoid valve Y9/Y10 or Y11/Y12 blocked. pilot piston 8 orifice 10 pump control cylinder 9.

In F-travel pump 2/3 left / right to

Approx. ~1,5 l/min of oil flows through restrictors 11, through the pump housing and through the filter 85 into the hydraulic tank 80. The oil not needed in the pressure area of the system flows via the pressure relief valve 18, through the return filter 82 into the tank. The paths of pilot pistons 8 to control pistons 9 are severely restricted. All control cylinders are equally actuated with pressurized oil, keeping the swash plate for pumps 4 in neutral position = 0 pump angle. 1.2. Travel pumps 2/3 and travel motors 20 - closed loop circuit With the pumps in neutral, the oil in the closed loop circuit does not circulate. Because the swash plates of the travel pumps 2/3 are in the neutral position, the pistons in the barrels do not stroke, meaning there is no flow, even though the rotary group is turning. However, the closed loop circuit is being pressurized with approx. 16+4 bar by the replenishing circuit (via check valves integrated into the high pressure relief valves 5 and 6 (see paragraph 1.1). The 7/2 directional valves 26 (= 7 connections/ 2 positions) in the travel motors 20 are in an end position, its side is not defined. Approx. 10 l/min oil is discharged from one side of the closed loop circuit, M1 or M2, from the opposite side the oil flows to the spring side of the control piston 22 and the axial piston unit 21 is held in neutral position = maximum (displacement) angle. Replenishing oil flows from M1/M2 to directional valve 26 pressure reducing valve 27 directional valve 26 pressure relief valve 24 orifice 28 motor housing (flushing) screen filter 41 support shaft 40 tank 80. directional valve 26 pressure reducing valve 27 directional valve 26 pilot piston 23 control piston 22 - spring side.

Control pressure moves from M1 /M2 to

The pressure reducing valves 27 are actuated on both sides with equal pressure, and therefore remain in neutral position = free flow. The piston bottom side of the control piston 22 is open towards the motor housing/ tank via the servo control piston 23 and orifice 29.

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Function
Datum Edition Date

PR 732B F/N xxx-5600

01 03

Travel hydraulic

Blatt Page Feuille

6.3.33.01

1.3. Gear pump 16 - fan drive With the Diesel engine running, the gear pump 16 draws oil from the hydraulic tank 80, via shut off valve 81 and supplies it via the filter 72 to the fixed displacement motor 70 and solenoid valve Y64. The motor 70 / fan begins to turn and the pressure regulating valve of the proportional solenoid valve Y64 opens when the regulated pressure level is reached = flow is divided. The oil flows together with the replenishing oil via the filter 82 to the tank 80. Test point LA (pressure build up in the fan drive) connected to outlet P of pump 16 . Regulation: With the starter switch S1 in operating position, the electronic fan control A18 is energized, among other items. A18 regulates the electrical power of the proportional solenoid valve Y64 depending on the signal values of temperature sensors B38 to 39 and limits the pressure build up in the hydraulic fan drive = the fan speed. S1 K4 F6 A18 B38 - coolant temperature B39 - hydraulic oil temperature Y64 - proportional solenoid valve - fan drive When the machine is cold, Y64 is energized with the maximum value and regulates the possible pressure build up in the hydraulic fan drive - pump 16 motor 70 - to the minimum value (fan turns at minimum speed or is stationary). At increasing temperatures, the current from Y64 is reduced proportionally and as a result, the hydraulic pressure value is increased proportionally = the fan speed increases. When one of the temperatures reaches the operating temperature, Y64 is fully shifted without current by A18. Without current, also in case of a system failure, Y64 regulates to the set maximum pressure = maximum fan speed (fail-save system) - pmax = 150+10 bar For wiring see section 9 - Electrical System. 2. Operating functions - travel The various travel functions are controlled by the electronic system via the proportional solenoid valves, which are installed on the pump covers and the travel motor remote control. The current and therefore the regulating pressure build-up is in proportion to the lever deflection. See also Description - Travel Hydraulic - section 6.2.10 and Functional Description - Electronic Control - section 10.3. The direction is selected in travel operation on the travel pumps 2/3 for: Travel forward Travel reverse Electronic control: on solenoid valve Y9/Y11 on solenoid valve Y10/Y12 Regulating pressure build -up: at connection Y at connection Z Oil flow output: on S(bottom) on P(top)

The solenoid valves for the travel motors are always energized during travel operation, but they only regulate from a certain current value. When turning, the solenoid valve on the side to which the machine is turning receives less current, as a result the intake volume of the motor is increased or the flow volume from the pump is reduced and the travel speed on this side is reduced. The solenoid valve Y13 is energized during the complete travel operation. The valve shifts to diagonal path, the pressurized oil flows via outlet B to test center 65-BB to distributor block 75, actuates pressure switch B5 and pressure relief valve 76. support shafts 40 travel gear 35 and vents (releases) the disk brakes 36. Depending on the travel resistance (= rotary resistance of travel motors), high pressure is created in the pump flow = high pressure side of closed loop circuits. In the return flow from the travel motors, the pressure is SPpressure = low pressure side of closed loop circuits. High pressure side - travel forward = System section - test point M1 High pressure side - travel reverse = System section - test point M2

2.4. Regulation - travel pumps 2/3 starting from neutral function, as described in section 1. The valve is opened when the proportional solenoid valves Y9/Y10 or Y11/Y12 are energized, the pressurized oil flows to one side of the regulating cylinder 7 and builds up a magnetic force in proportion to the hydraulic pressure. The piston of the regulating cylinder 7 is moved by hydraulic pressure to the opposite regulating spring assembly, until the forces are balanced again. The servo control piston 8 is also moved via a mechanical connection. It opens the oil port to the side opposite of the control direction of the piston 8 of swash plate control cylinder 9 and allows the oil to flow from the opposite side into the pump housing. The swash plate pump 4 is changed to flow direction against Qmax . low current small flow volume high current large flow volume flow direction, see chart, section 2 As the swash place is moved, the housing of servo control piston 8 is mechanically moved along until the bores in the housing and the servo control piston are again positively overlapped = neutral position. Both sides of the swash plate control cylinder 9 are actuated again with pressurized oil and the swash plate is held hydraulically on the actuated pump angle. As current increases, it moves further in direction Qmax until the mechanical regulating stop of the travel pump is reached. If current is decreased, the swash plate pump 3 is moved in direction Qmin / neutral position, regulation / control sequence is as described above. 2.5. Regulation - travel motors 20 starting from neutral function, as described in section 1. Due to current going to the proportional solenoids, the servo control piston 23 is moved against the regulating spring and return spring to shift position parallel path. When starting to travel, the 7/2 directional valve 26 is actuated on one side with low pressure, on the other side with high pressure from the closed loop circuit and is moved depending on the forces against the low pressure side. This results in the following oil pressure flow, in addition to the closed loop circuit: Low pressure sidedirectional valve 26 1.pressure reducing valve 27-spring side. (SP-pressure) 1.pressure reducing valve 27-piston side/pathdirectional valve 26 2. pressure reducing valve 27 -spring side. pressure relief valve 24 orifice 28 motor housing (flushing) screen filter 41 support shaft 40 tank 80. The sum of spring force + SP-pressure on the piston of pressure reducing valves 27 results in a pressure value of ~40 bar. High pressure side directional valve 26 blocked. pressure reducing valve 27 - path/piston side directional valve 26 pilot piston 23 control piston 22 - piston bottom side. When the pressure on the piston bottom side of the pressure reducing valve 27 reaches a pressure of ~40 bar, the piston is moved against the spring + SP-pressure and the path is restricted, so that the pressure cannot continue to increase (control pressure on piston 22 40 bar). The spring side of the control piston 22 is relieved via the servo control piston 23 and orifice 29 to the motor housing / tank, the axial piston unit 21 is moved to a smaller angle = in direction Qmin. Due to this change in direction Qmin, the return spring pushes the servo control piston 23 increasingly against the force of the proportional solenoid. When the spring force is the same as the magnetic force, the servo control piston 23 is held in center position, the ports to the control piston 22 are closed and the axial piston unit is held on the selected angle.

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Function
Datum Edition Date

PR 732B F/N xxx-5600

01 03

Travel hydraulic

Blatt Page Feuille

6.3.33.02

As current is increased, it continues to move in direction Qmin. The maximum possible current is limited by the electronic control. As current is decreased, the axial piston unit 21 is moved again in direction Qmax = neutral position, the control pressure is moved the same way as in neutral function via the servo control piston 23- diagonal path to the spring side of the control piston 22 and the piston bottom side is relieved. Intermediate positions for equal force of solenoid to spring are held as described. 2.6. Closed loop circuits starting from neutral function, as described in section 1.1 The swash plate pump flow 4 is moved via a line connection and through the support axle 40 to a connection side of travel motor 20/ axial piston unit 21, it actuates its piston and sets the unit in rotation. Due to the output rotation, the oil is transported to the opposite connector side and flows via a second line connection through the support axle back to the suction side of the travel pump 2/3- swash plate pump 4. The expelled oil in the travel motor 20 - see previous description - is taken in again into the travel pump 2/3, also on the low pressure side = suction side via the replenishing function of the pressure relief valve 5 or 6 - see neutral function, section 1.1. On the high pressure side = delivery side, the replenishing function is held closed by high pressure and the maximum pressure of the pressure relief valve is limited to 420+30/-10 bar. If the pressure increases above this value, the pressure relief valve opens and lets the oil flow off to the replenishing - low pressure side. The second closed loop circuit works the same way. The pressures in the closed loop circuits can also be measured on test points M1 and M2 located on the test center 65 with suitable pressure gauges. See special tools, section 2.1.21. Observe safety guidelines - see section 1.2. 3. Special function - brake actuating when towing If any traveling function of the machine fails, the break function (operating brake) of the hydrostatic travel drive and the mechanic parking brake can be released manually/hydraulically. Observe all guidelines of the operation manual and all safety guidelines. 3.1. Brake release Connect hose from connection "BB" to connection "BS" and close "BB"(all connections on the test center 65). connect M1RM2R and M1LM2L on the test center 65 with hoses (delivered with the machine-tools) = hydrostatic drive - brake function is not in function anymore. set accumulator 77 by multiple actuating of the hand pump for tilting operators cab (see section 17.2.10) under sufficient pressure. bring starter switch, emergency OFF switch and safety lever in operating position = solenoid valve Y63 is currented/switched and the brakes 36 are released via path PB by the stored pressurized oil. When necessary, the brakes can be released directly by the hand pump, when the solenoid valve is switched.

The pressure relief valve 76 prevents the brake of too high pressure. The releasing of the brake is indicated on the instrument panel via pressure switch B5. While towing, the displaced oil by the variable motors circulates in the closed loop circuit via connection M1M2. 3.2. Emergency braking when towing Interrupt currenting to solenoid valve Y63 by - pressing the emergency OFF switch, or - lower the safety lever, or - turn starter switch to 0 position. The solenoid valve Y63 returns to neutral position, the pressure to the parking brake gets via path BT to tank and the brakes closes. The size of the accumulator 77 allows a recent releasing (twice is possible) of the parking brake.

Notes

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Parts list
Datum Edition Date

PR 732B F/N xxx-5600

02 02

Travel Hydraulic

Blatt Page Feuille

6.3.33.00

1 splitter box 2 3 4 5 6 7 8 9 10 11 travel pump left travel pump right swash plate pump pressure relief valve - HP forward / M1 - with replenishing valve pressure relief valve - HP reverse / M2 - with replenishing valve servo control piston pilot piston pump control cylinder orifice restrictor 70 axial piston fixed displacement motor (fan - combinated cooler) 72 strainer 75 distributor block 76 pressure relief valve - parking brake 77 accumulator - safety device towing 80 81 82 83 85 90 91 92 93 95 hydraulic tank shut off valve return filter bypass valve strainer to regulating pump 100 - working hydraulic to control valve block - working hydraulic to pilot (servo) control valve - working hydraulic return line - working hydraulic to /from hand pump - cab tilt

15 gear pump - replenishing / coolant circuit 16 gear pump - fan drive 17 oil cooler 18 pressure relief valve - repl. oil pressure SP 19 filter - replenishing 20 21 22 23 24 25 26 27 28 29 travel motor complete left /right axial piston unit control piston pilot piston pressure relief valve - flushing valve unit directional valve pressure reducing valve (40 bar) orifice orifice

100 regulating pump - working hydraulic

B5 B6 B18 B39 Y4 Y7 Y8 Y9

pressure switch - parking brake (15 bar) pressure switch - repl. oil pressure (8 bar) pressure switch - filter monitoring (2,5 bar) temperature sensor - fan drive solenoid valve - servo cut off proportional solenoid valve - travel motor left proportional solenoid valve - travel motor right

35 travel gear complete left /right 36 ring piston - parking brake 40 support shaft complete left /right 41 strainer 45 valve block / pressure relief valve - cold start 51 check valve 52 check valve 55 accumulator - working hydraulic 60 test center - test points SP = repl. oil pressure ND = control pressure - working hydraulic 65 test center - test points / connections M1L = high pressure travel forward - left side M2L = high pressure travel reverse - left side M1R = high pressure travel forward - right side M2R = high pressure travel reverse - right side hose connection BB = parking brake - operating position BS = parking brake - towing position M = test point - bleeding

proportional solenoid valve - travel pump left travel forward Y10 proportional solenoid valve - travel pump left travel reverse Y11 proportional solenoid valve - travel pump right travel forward Y12 proportional solenoid valve - travel pump right travel reverse Y13 solenoid valve - parking brake Y63 solenoid valve - safety device towing Y64 proportional solenoid valve pressure relief -fan drive - max. 150 bar test points in the machine SD = back-up pressure - cold start (pump 15)

Benennung Description Dnomination

Typ/ab Type/from Type/a partir de

liebherr
F/N xxx - 5600
Datum Edition Date

02 02

Blatt Page Feuille

00

Notes
Note: Pump control and position of test points M1, M2 depends on the type of travel gear installed > see sub
group 11 Pos. for FAT > Type AorC > Control / travel forward > Control / travel reverse > upper test point > lower test point for FAT > Type P > Control / travel reverse > Control / travel forward > lower test point >upper test point

10 11 M1 M2

Benennung Description Dnomination

Typ/ab

Type/from

Type/a partir de

Datum Edition Date

Parts List

PR 742(B) F/N xxx- 20015233


Blatt Page Feuille

01 01

Travel Hydraulic

6.3.40.00

1 Splitter box 2 Travel pump, complete > L/R 3 Travel pump > rotary group 4 Pressure relief valve > HP with replenishing valve 5 Pressure relief valve > HP with replenishing valve 6 Pump control piston 7 Orifice 8 Spool valve > pump control 9 Servo control piston 10 Proportional solenoid valve > conn. z. > (travel > primary regulation) 11 Proportional solenoid valve > conn. y > (travel > primary regulation) 12 Check valve > Replenishing 13 Orifice 15 Gear pump > Replenishing / Cooling circuit 16 Gear pump > Pump control / Replenishing 18 Oil cooler 19 Check valve > Bypass (3 bar) 40 Support shaft, complete > L/R 41 Flange 42 Flange 43 Filter 45 Travel gear, complete > L/R 46 Piston > Travel brake 51 Solenoid valve > Travel brake 52 Pressure switch > Brake indicator 53 Check valve 54 Accumulator W.H. 55 Solenoid valve > servo cut off > W.H. 60 Test center 80 Hydraulic tank 81 Shut off valve > tank 82 Hydraulic oil filter 83 Check valve 85 Filter screen

20 Travel motor, complete > L/R 90 Suction line > W.H. 21 Travel motor, rotary group 91 to Control valve 130 > W.H. 22 Motor control piston 92 to Pilot (servo) control valve 115 > W.H. 23 Motor regulator valve w. proportional solenoid 93 from Variable pump to Hydraulic tank (secondary regulation) 94 Return lines W.H. 24 Motor relief valve > flushing 95 to / from hand pump 25 Motor control valve > complete 26 Directional valve 100 Variable pump > W.H. 27 Pressure reducing valve > 40 bar (integrated) 28 Orifice Test points 29 Orifice SP Replenishing pump pressure 30 Valve block ND Servo pressure > W.H. 31 Replenishing pressure relief valve 32 Control pressure relief valve M1 Travel pressure > forward > L/R M2 Travel pressure > reverse > L/R 35 Filter block 36 Filter assembly > Replenishing ST Control pressure 37 Filter assembly > Control 38 Accumulator 39 Pressure switch > Replenishing oil Note: L = Left R = Right T.R. = Travel hydraulic W.H. = Working hydraulic Repl. = Replenishing

Notes
Note: travel pump - for sectional drawing see group 8.1.41

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Parts list
Datum Edition Date

PR 742B F/N xxx-5234 5599


Blatt Page Feuille

07 01

Travel Hydraulic

6.3.41.00

1 splitter box 2 3 4 5 6 7 8 9 travel pump left travel pump right swash plate pump pressure relief valve - HP forward / M1 - with replenishing valve pressure relief valve - HP reverse / M2 - with replenishing valve servo control piston pilot piston pump control cylinder 80 81 82 83 85 90 91 92 93 95 hydraulic tank shut off valve return filter bypass valve strainer to regulating pump 100 - working hydraulic to control valve block - working hydraulic to pilot (servo) control valve - working hydraulic return line - working hydraulic to /from hand pump - cab tilt

15 gear pump - replenishing / coolant circuit 16 gear pump - replenishing / coolant circuit 18 oil cooler 19 bypass valve (3 bar) 20 21 22 23 24 25 26 27 28 29 travel motor complete left /right axial piston unit control piston pilot piston pressure relief valve - flushing valve unit directional valve pressure reducing valve (40 bar) orifice orifice

100 regulating pump - working hydraulic

B5 pressure switch - parking brake (15 bar) B6 pressure switch - repl. oil pressure (8 bar) B18 pressure switch - filter monitoring (2,5 bar) Y4 Y7 Y8 Y9 solenoid valve - servo cut off proportional solenoid valve - travel motor left proportional solenoid valve - travel motor right

proportional solenoid valve - travel pump left travel forward Y10 proportional solenoid valve - travel pump left travel reverse Y11 proportional solenoid valve - travel pump right travel forward Y12 proportional solenoid valve - travel pump right travel reverse Y13 solenoid valve - parking brake

30 valve block 31 pressure relief valves - repl. oil pressure SP 35 filter block 36 filter - replenishing 40 support shaft complete left /right 41 strainer 45 travel gear complete left /right 46 ring piston - parking brake 51 orifice 52 check valve 55 accumulator - working hydraulic 60 test center - test points SP = repl. oil pressure ND = control pressure - working hydraulic 65 test center - test points M1L = high pressure travel forward - left side M2L = high pressure travel reverse - left side M1R = high pressure travel forward - right side M2R = high pressure travel reverse - right side

Benennung Description Dnomination

Typ/ab Type/from Type/a partir de

liebherr
Datum Edition Date

F/N xxx - 5234


Blatt Page Feuille

5599

07 01

00

Functional schematic, see 6.3.42.00 1. Neutralfunction 1.1. Gear pump 15 - Replenishing With the Diesel engine running, the gear pump 15 draws oil from the hydraulic tank 80, via shut off valve 81 to the valve block 30-P2 pressure relief valves 31. In the distributor block 30 the temperature sensor B39 determines the oil temperature and sends the value to the electronic box of the fan drive. From distributor block 30 to -F F-filter block 35/filter 36 -SP check valve 52 accumulator 55 (blocked) solenoid valve Y4 (servo cut off WH) blocked. solenoid valve Y13 (parking brake) blocked.

After raising the safety lever, the solenoid valve Y4 clears the path to outlet B servo control for the working hydraulic and test point ND. The oil not needed in the pressure area of the system flows via the pressure relief valve 31/ valve block 30-T hydraulic oil cooler 18 return filter 82 back to the hydraulic tank 80. Even with the oil at operating temperature, a back pressure of approx. 5 bar is created in the flow via the oil cooler, lines and filter, which is applied on the spring side of the pressure relief valves 31 (pressure adjustment 20+2 bar). This results in an operating pressure of approx. 25+2 bar in the system in front of the PR valves = test point SP (and M on valve block 30). If the oil is cold, part of the oil is directed parallel to the oil cooler, via check valve 19 (p 3 bar) to the filter tank. The system pressure increases proportionally if the oil is cold, depending on the viscosity.

Splitting of the oil flow- filter block35/filter 36 -FR F-travel pump2 right and test point SP. -FL F-travel pump2 left and pressure switch B6. -B, -PM, -X blocked. In travel pump 2 right/left from F to replenishing function relief valve 6 replenishing - closed loop circuit - M2 replenishing function relief valve 5 replenishing - closed loop circuit - M1 pilot piston 8 control cylinder 9. proportional solenoid valves Y9/Y10 or Y11/Y12 blocked. The paths of pilot pistons 8 to control pistons 9 are severely restricted. All control cylinders are equally actuated with pressurized oil, keeping the swash plate for pumps 4 in neutral position = 0 pump angle. Leak oil in the travel pumps 2 flushes, cools and lubricates the parts of the rotary group and flows via housing connections L and T strainer 85 into the tank 80. 1.2. Travel pumps 2 and travel motors 20 - closed loop circuit With the pumps in neutral, the oil in the closed loop circuit does not circulate. Because the swash plates of the travel pumps 2 are in the neutral position, the pistons in the barrels do not stroke, meaning there is no flow, even though the rotary group is turning. However, the closed loop circuit is being pressurized with approx. 25+2 bar by the replenishing circuit (via check valves integrated into the high pressure relief valves 5 and 6 (see paragraph 1.1). The 7/2 directional valves 26 (= 7 connections/ 2 positions) in the travel motors 20 are in an end position, its side is not defined. Approx. 10 l/min oil is discharged from one side of the closed loop circuit, M1 or M2, from the opposite side the oil flows to the spring side of the control piston 22 and the axial piston unit 21 is held in neutral position = maximum (displacement) angle. Replenishing oil flows from M1/M2 to directional valve 26 pressure reducing valve 27 directional valve 26 pressure relief valve 24 orifice 28 motor housing (flushing) screen filter 41 support shaft 40 tank 80.

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Function
Datum Edition Date

PR 742B F/N xxx-5600


Blatt Page Feuille

01 02

Travel Hydraulic

6.3.42.01

Control pressure moves from M1 /M2 to

directional valve 26 pressure reducing valve 27 directional valve 26 pilot piston 23 control piston 22 - spring side.

The pressure reducing valves 27 are actuated on both sides with equal pressure, and therefore remain in neutral position = free flow. The piston bottom side of the control piston 22 is open towards the motor housing/ tank via the servo control piston 23 and orifice 29. 1.3. Gear pump 16 - fan drive With the Diesel engine running, the gear pump 16 draws oil from the hydraulic tank 80, via shut off valve 81 and supplies it via the filter 72 to the fixed displacement motor 70 and solenoid valve Y45. The motor 70 / fan begins to turn and the pressure regulating valve of the proportional solenoid valve Y45 opens when the regulated pressure level is reached = flow is divided. The oil flows together with the replenishing oil via the oil cooler 18 filter 82 to the tank 80. Test point LA (pressure build up in the fan drive) connected to outlet P of pump 16 . Regulation: With the starter switch S1 in operating position, the electronic fan control A11 is energized, among other items. A11 regulates the electrical power of the proportional solenoid valve Y45 depending on the signal values of temperature sensors B38 to 40and limits the pressure build up in the hydraulic fan drive = the fan speed. S1 K4 F6 A11 B38 - coolant temperature B39 - hydraulic oil temperature B40 - turbo charge air temperature Y45 - proportional solenoid valve - fan drive When the machine is cold, Y45 is energized with the maximum value and regulates the possible pressure build up in the hydraulic fan drive - pump 16 motor 70 - to the minimum value (fan turns at minimum speed or is stationary). At increasing temperatures, the current from Y45 is reduced proportionally and as a result, the hydraulic pressure value is increased proportionally = the fan speed increases. When one of the temperatures reaches the operating temperature, Y45 is fully shifted without current by A11. Without current, also in case of a system failure, Y45 regulates to the set maximum pressure = maximum fan speed (fail-save system) - pmax = 210+10 bar For wiring see section 9 - Electrical System. 2. Operating functions - travel The various travel functions are controlled by the electronic system via the proportional solenoid valves Y7 to Y12, which are installed on the pump covers and the travel motor remote control. The current and therefore the regulating pressure build-up is in proportion to the lever deflection. See also Description - Travel Hydraulic section 6.2 and Functional Description - Electronic Control - section 10.3., Sectional drawing of the pump/ oil flow outlets - section 8.1.41. The direction is selected in travel operation on the travel pumps 2 for: Travel forward Travel reverse Electronic control: on solenoid valve Y9/Y11 on solenoid valve Y10/Y12 Regulating pressure build -up: at connection Z at connection Y Oil flow output: on P(left) on S(right)

The proportional solenoid valves for the travel motors are always energized during travel operation, but they only regulate from a certain current value. When turning, the solenoid valve on the side to which the machine is turning receives less current, as a result the intake volume of the motor is increased or the flow volume from the pump is reduced and the travel speed on this side is reduced. The solenoid valve Y13 is energized during the complete travel operation. The valve shifts to diagonal path, the pressurized oil flows via outlet B to test center 65-BB to distributor block 75, actuates pressure switch B5 and pressure relief valve 76. support shafts 40 travel gear 45 and vents (releases) the disk brakes 46. Depending on the travel resistance (= rotary resistance of travel motors), high pressure is created in the pump flow = high pressure side of closed loop circuits. In the return flow from the travel motors, the pressure is SPpressure = low pressure side of closed loop circuits. High pressure side - travel forward = System section - test point M1 High pressure side - travel reverse = System section - test point M2

2.1. Regulation - travel pumps 2 starting from neutral function, as described in section 1. The valve is opened when the proportional solenoid valves Y9/Y10 or Y11/Y12 are energized, the pressurized oil from the "replenishing" section of the system flows to one side of the servo control cylinders 7 and builds up a hydraulic regulating pressure in proportion to the magnetic force. The piston of the servo control cylinder 7 is moved by regulating pressure against the opposite regulating spring assembly, until the forces are balanced again. Via a mechanical connection, the piston 8 is moved into the opposite direction. The piston opens the oil flow to the swash plate - control cylinder 9, where the pressure build up occurred and allows the oil to flow into the pump housing from the opposite side of the swash plate - control cylinder 9. The swash plate pump 4 is changed to flow direction against Qmax . low current small flow volume high current large flow volume flow direction, see chart, section 2 With the shifting of the swash plate, the pilot piston 8 in the housing is returned to the neutral position (positive overlap) via a mechanical connection. Both sides of the swash plate control cylinder 9 are actuated again with pressurized oil and the swash plate is held hydraulically on the actuated pump angle. As current increases, it moves further in direction of Qmax until the mechanical regulating stop of the travel pump is reached. If current is decreased, the swash plate of pump 4 is moved in direction Qmin / neutral position, regulation / control sequence is as described above. 2.2. Regulation - travel motors 20 starting from neutral position, as described in section 1. Due to current going to the proportional solenoids Y7 or Y8, the servo control piston 23 is moved against the regulating spring and return spring to shift position parallel path. When starting to travel, the 7/2 directional valve 26 is actuated on one side with low pressure, on the other side with high pressure from the closed loop circuit and is moved depending on the forces against the low pressure side. This results in the following oil pressure flow, in addition to the closed loop circuit: Low pressure sidedirectional valve 26 1.pressure reducing valve 27-spring side. (SP-pressure) 1.pressure reducing valve 27-piston side/pathdirectional valve 26 2. pressure reducing valve 27 -spring side. pressure relief valve 24 orifice 28 motor housing (flushing) screen filter 41 support shaft 40 tank 80. The sum of spring force+SP-pressure on the piston of pressure reducing valves 27 results in a pressure value of ~40 bar. High pressure side directional valve 26 blocked. pressure reducing valve 27 - path/piston side directional valve 26 pilot piston 23 control piston 22 - piston bottom side. When the pressure on the piston bottom side of the pressure reducing valve 27 reaches a pressure of ~40 bar, the piston is moved against the spring+SP-pressure and the path is restricted, so that the pressure cannot continue to increase (control pressure on piston 22 40 bar). The spring side of the control piston 22 is relieved via the servo control piston 23 and orifice 29 to the motor housing / tank, the axial piston unit 21 is moved to a smaller angle = in direction Qmin. Due to this change in Qmin direction, the return springs push the pilot pistons 23 more and more against the force of the proportional solenoid. When the spring force is the same as the solenoid force, the pilot pistons 23 are held in center position, the ports to the control piston 22 are closed and the axial piston unit is held on the selected angle / intake volume. As current is increased, the pressure continues to increase towards Qmin. The maximum possible current/ regulation is limited by the electronic control.
Benennung Description Dnomination Typ/ab Type/from Type/ a partir de

Mjfcifss!

Function
Datum Edition Date

PR 742B F/N xxx-5600


Blatt Page Feuille

01 02

Travel Hydraulic

6.3.42.02

As current is decreased, the axial piston units 21 are moved again in direction of Qmax =neutral position, the control pressure is directed the same way as in neutral function: via the pilot piston 23- diagonal path to the spring side of the control piston 22 and the piston bottom side is vented. Intermediate positions are held as described before in case of equal force between solenoid and spring. 2.3. Closed loop circuits starting from neutral function, as described in section 1.1 The swash plate pump flow 4 is moved via a line connection and through the support axle 40 to a connection side of travel motor 20/ axial piston unit 21, it actuates its piston and sets the unit in rotation. Due to the output rotation, the oil is transported to the opposite connector side and flows via a second line connection through the support axle back to the suction side of the travel pump 2 - swash plate pump 4. The expelled oil in the travel motor 20 - see previous description - is taken in again into the travel pump 2, also on the low pressure side = suction side via the replenishing function of the pressure relief valve 5 or 6 - see neutral function, section 1.1. On the high pressure side = delivery side, the replenishing function is held closed by high pressure and the maximum pressure of the pressure relief valve is limited to 420+30/-10 bar. If the pressure increases above this value, the pressure relief valve opens and directs the oil flow to the replenishing side / low pressure side. The second closed loop circuit works the same way. The pressures in the closed loop circuits can also be measured on test points M1 and M2 located on the test center 65 with suitable pressure gauges. See special tools, section 2.1.21. Observe safety guidelines - see section 1.2. 3. Special function - brake actuating when towing If any traveling function of the machine fails, the break function (operating brake) of the hydrostatic travel drive and the mechanic parking brake can be released manually/hydraulically. Observe all guidelines of the operation manual and all safety guidelines. 3.1. Brake release Connect hose from connection "BB" to connection "BS" and close "BB"(all connections on the test center 65). connect M1RM2R and M1LM2L on the test center 65 with hoses (delivered with the machine-tools) = hydrostatic drive - brake function is not in function anymore. set accumulator 77 by multiple actuating of the hand pump for tilting operators cab (see section 17.2.10) under sufficient pressure. bring starter switch, emergency OFF switch and safety lever in operating position = solenoid valve Y43 is currented/switched and the brakes 46 are released via path PB by the stored pressurized oil. When necessary, the brakes can be released directly by the hand pump, when the solenoid valve is switched.

The pressure relief valve 76 prevents the brake of too high pressure. The releasing of the brake is indicated on the instrument panel via pressure switch B5. While towing, the displaced oil by the variable motors circulates in the closed loop circuit via connection M1M2. 3.2. Emergency braking when towing Interrupt currenting to solenoid valve Y43 by - pressing the emergency OFF switch, or - lower the safety lever, or - turn starter switch to 0 position. The solenoid valve returns to neutral position, the pressure to the parking brake gets via path BT to tank and the brakes closes. The size of the accumulator 77 allows a recent releasing (twice is possible) of the parking brake.

Notes
Note: travel pump - for sectional drawing see group 8.1.41

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Parts list
Datum Edition Date

PR 742B F/N xxx-5600


Blatt Page Feuille

02 02

Travel Hydraulic

6.3.42.00

1 splitter box 2 travel pump right /left 4 swash plate pump 5 pressure relief valve - HP forward / M1 - with replenishing valve 6 pressure relief valve - HP reverse / M2 - with replenishing valve 7 servo control piston 8 pilot piston 9 pump control cylinder 15 gear pump - replenishing / coolant circuit 16 gear pump - fan drive 18 oil cooler 19 bypass valve (3 bar) 20 21 22 23 24 25 26 27 28 29 travel motor complete left /right axial piston unit control piston pilot piston pressure relief valve - flushing valve unit directional valve pressure reducing valve (40 bar) orifice 2,5 mm orifice 70 axial piston fixed displacement motor (fan - combinated cooler) 72 strainer 75 distributor block 76 pressure relief valve - parking brake 77 accumulator - safety device towing 80 81 82 83 85 90 91 92 93 95 hydraulic tank shut off valve return filter bypass valve strainer to regulating pump 100 - working hydraulic to control valve block - working hydraulic to pilot (servo) control valve - working hydraulic return line - working hydraulic to /from hand pump - cab tilt

100 regulating pump - working hydraulic

B5 B6 B18 B39 Y4 Y7 Y8 Y9

pressure switch - parking brake (17 bar) pressure switch - repl. oil pressure (8 bar) pressure switch - filter monitoring (2,5 bar) temperature sensor - fan drive solenoid valve - servo cut off proportional solenoid valve - travel motor left proportional solenoid valve - travel motor right

30 valve block 31 pressure relief valve - repl. oil pressure SP 35 filter block 36 filter - replenishing 40 support shaft complete left /right 41 strainer 45 travel gear complete left /right 46 ring piston - parking brake 52 check valve 55 accumulator - working hydraulic 60 test center - test points SP = repl. oil pressure ND = control pressure - working hydraulic LA = system pressure - fan drive 65 test center - test points /hose connection M1L = high pressure travel forward - left side M2L = high pressure travel reverse - left side M1R = high pressure travel forward - right side M2R = high pressure travel reverse - right side hose connection: BB = parking brake - operating position BS = parking brake - towing position M = test point - bleeding

proportional solenoid valve - travel pump left travel forward Y10 proportional solenoid valve - travel pump left travel reverse Y11 proportional solenoid valve - travel pump right travel forward Y12 proportional solenoid valve - travel pump right travel reverse Y13 solenoid valve - parking brake Y43 solenoid valve - safety device towing Y45 proportional solenoid valve pressure relief -fan drive - max. 210 bar test points in the machine M = test point at pos. 30 (SP)

Benennung Description Dnomination

Typ/ab T ype/from Type/a partir de

liebherr
Datum Edition Date

F/N xxx - 5600


Blatt Page Feuille

02 02

00

1. Neutral function

Functional schematic, see 6.3.50.00

1.1. Tandem gear pumps 15 - Replenishing function As soon as the engine is started, the gear pump 15 draws oil from the hydraulic tank 80 via the shut off valve 82 and supplies it to the distributor block 16/P1+P2. From the distributor block 16/ K P-valve block 19 F F-filter bracket 18

Oil not needed in the system flows via the pressure relief valve 17 hydraulic oil cooler 66 return filter 83 to hydraulic tank 80. When the oil is at operating temperature, a certain resistance (appr. 5 bar) is created in the return oil flow by the oil cooler, lines and filter, which is applied on the spring side of the pressure relief valves 17 (adjusted to 20+2 bar). This results in an operating pressure of appr. 25+2 bar in the section in front of the pressure relief valves = test point SP (and SD). When the oil is cold, part of the oil is directed via the pressure relief valve in block 19 directly to tank and the system pressure is thereby limited to max. 28+2 bar (cold start pressure) = test point SD. Distribution of the oil flow - filter bracket18 /B check valve 52 distributor block50 solenoid valveY13 (parking brake) blocked. accumulator 55 and solenoid valve Y4 blocked. (servo cut off WH) /FR F-travel pump2 right and pressure switch B6. /FL F-travel pump2 left and test connection SP. /PM P-travel motor20 right pilot piston23 spring side control piston22. /PM P - travel motor20 leftpilot piston23spring side control piston22.

The solenoid valve Y4 is actuated, after raising off the safety lever, and permits passage to outlet GP servo control working hydraulic. In travel pump 2 right / left to (oil flow) check valve 6 replenishing - closed loop circuit - M1 channel pressure relief valve 4 (blocked). proportional solenoid valves Y9/Y10 or Y11/Y12 blocked. pilot piston 9 control cylinder 10. orifice11 pressure relief valve12 pump housing screen filter 85 tank. channel pressure relief valve 5 (blocked). check valve 7 replenishing - closed loop circuit - M2.

The passages of pilot pistons 9 to control cylinders 10 are severely restricted. All control cylinders are equally pressurized with oil, keeping the swash plates of pumps 3 in neutral position =0 pump angle. The pressure relief valves 12 are opened by the system pressure. The orifices 11 limit the oil flow Q to ~ 8l/min. The oil flow flushes, cools and lubricates the drive sections of the travel pumps 2. If the system pressure drops below 16 bar, due to a problem, the pressure relief valves 12 close. The flushing circuit is interrupted and the entire oil flow is directed to the closed loop circuit and the control. The pump housing remains filled with oil via the tank lines. The control lines for the travel pumps and motors are vented to the pump housing/ tank via the proportional solenoid valves Y9 to Y12.

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Function
Datum Edition Date

PR 752

F/N xxx-2002 2062

01 04

Travel Hydraulic

Blatt Page Feuille

6.3.50.01

1.2. Travel pumps 3 and travel motors 20 - closed loop circuits With the pumps in neutral, the oil in the closed loop circuit does not circulate. Because the swash plates of the travel pumps 3 are in the neutral position, no piston stroke is created and therefore no oil flow, despite the rotation of the axial piston unit and pistons. However, the closed loop circuit is filled with pressurized oil of approx. 23+2 bar through the replenishing circuit (via check valves 6 and 7 (see paragraph 1.1)). In every travel motor 20, the pressurized oil from the closed loop circuit is directed on both sides to the directional valve 24 and blocked. The axial piston unit 21 is held by the spring and the pressurized oil on the springside of the control piston 22 (see paragraph 1.1) at maximum angle = Q max = neutral position. The piston bottom side of the control piston 22 is vented via the pilot piston 23 to the motor housing / tank.

1.3. Regulating pump 30 - fan drive When the Diesel engine is not running, the axial piston unit 31 of the pump 30 is at maximum angle = Qmax. As soon as the Diesel engine is running, the pump 30 starts deliver oil, the system pressure increases and the fan motors start to turn. If the starter switch S1 is in operating position and if the safety lever is raised (switch S2), the thermo switches for the fan drive control are energized. S1 S1 S1 F6 B28 - Coolant temperature - Diesel engine (closes at 90C opens at 85C) F10 B29 - Hydraulic oil temperature (closes at 65C opens at 60C) F15 B30 - Turbo charge air temperature - Diesel engine (closes at 55C opens at 50C).

If one of these media reaches the corresponding temperature, the contact of the thermo switch closes and energizes the solenoid valve Y52. For more information see group 9 - Electrical System. When the engine is cold, the solenoid valve Y52 is not energized and remains in neutral position and relieves the servo oil connection X of pump 30 to tank. The Load Sensing regulator 35 is displaced against its spring with a system pressure of 25+1 bar and pressurized oil is directed via the pressure cut off valve 34 to the control cylinder 32. Due to the given surface ratio, the control cylinder 32 moves the axial piston unit 31 against the return cylinder 33 to min. angle=Qmin. The angle/oil flow is regulated by the LS-regulator 35 and the return force of cylinder 33 in such a way, that a constant stand-by pressure of 30+1 bar (LA) is created in the system. This pressure determines the minimum RPM of the motors / fan - see page 3.1.50.01. When the machine is at operating temperature, the solenoid valve Y52 is energized and actuated via at least one thermo switch B28/B29/B30. The connection to tank is blocked, the servo oil connection X is pressurized with system pressure, which keeps the LS-regulator in neutral position. The control cylinder 32 is without pressure, the return cylinder 33 moves the axial piston unit 31 to max. angle = Qmax the system pressure exceeds the stand-by pressure. If the system pressure exceeds the spring value of the pressure cut off valve 34, the valve is shifted against the spring and pressurized oil flows to the control cylinder 32. Due to the given surface ratio, the control cylinder 32 moves the axial piston unit 31 against the return cylinder 33 to a smaller angle. The angle / oil flow is regulated by the pressure cut off valve 34 and the return force of the cylinder 33 in such a way, that at normal Diesel engine RPM range a constant operating pressure of 1603 bar (LA) is retained in the system. This pressure determines the maximum RPM of the motors / fan - see page 3.1.50.01. The displaced amount of oil which flows off via restrictor 36 when the pump is regulated is pressure dependent and is used to mute the signal and to flush the housing. The system pressure is measured on test point LA, just before the restrictor 53.

The check valves 39 and 41 are necessary to supply the oil for coasting of the fan / motors after the engine is shut down. Oil flow - working circuit: Hydraulic tank80 axial piston unit31 axial piston - fixed displacement motor38 gear motor40 oil cooler66 return filter83 tank80. Check valves 39 and 41 are kept closed by pressurized oil. Servo oil flow - when machine is cold: Axial piston unit31 restrictor53 LP-valve block50 P-solenoid valve Y52-A valve block50-T tank80.

(pump 30 - internal) return cylinder33. pressure cut off valve34 Load Sensing regulator35 pressure cut off valve34 control cylinder32. ( restrictor36 housing L screen filter85 tank80.) Servo oil flow - when machine is at operating temperature: Axial piston unit31 restrictor53 LP-valve block50 P-solenoid valve Y52 (blocked). regulating pump30 spring side LS-regulator35.

(pump30 internal) return cylinder33. pressure cut off valve34 Load Sensing regulator35 (blocked). pressure cut off valve34 control cylinder32. ( restrictor36 housing L screen filter85 tank80.) 2. Operating functions - travel The various travel functions are regulated by the electronic control via the proportional solenoid valves Y9 to Y12, which are installed on the travel pump covers. The lever deflection is in relation to the current flow of the solenoid valves and therefore the regulating pressure build-up. See also description - Travel Hydraulic - section 6.2. and Functional description - Electronic Control - section 10.3. The travel direction during travel operation is selected on the travel pumps 2 as follows: Travel forward Travel reverse electronic control: regulating pressure built up: on solenoid valves Y9 / Y11 at connection Y on solenoid valves Y10 / Y12 at connection Z oil flow output: on S (bottom) on P (top)

The travel speed depends on the joystick deflection = current =regulating pressure and can be infinitely regulated. Pump control: Motor control: flow volume zero Qmax intake volume Qmax Qmin =regulating pressure appr. 2 to 8 bar =regulating pressure appr. 8 to 15 bar

The regulation begin for the travel motors is approx. 0.3 bar before the end of regulation of the pumps, which means there is a slight overlap of pump / motor control in the regulating range of 8 bar. The regulating pressure for the travel motors is supplied from the travel pumps via a two way check valve 13 connection X. When turning, the solenoid valve on the side into which the machine is turning receives less current, as a result the intake volume of the motor is increased or the flow volume from the pump is reduced, which in turn reduces the travel speed on this side.

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Function
Datum Edition Date

PR 752

F/N xxx-2002 2062

01 04

Travel Hydraulic

Blatt Page Feuille

6.3.50.02

The solenoid valve Y13 is energized during every travel operation. The valve shifts to diagonal path, the pressurized oil flows via distributor block 50 to the pressure switch B5 and via outlet B to the travel gears 45 and vents (releases) the disk brakes 46. Depending on the travel resistance (=rotary resistance of travel motors), hydraulic pressure is created in the pump flow = high pressure side of closed loop circuits. In the return flow from the travel motors, the replenishing pressure ( SP- pressure) is present = low pressure side of closed loop circuits. High pressure side - travel forward = system - test point M1 High pressure side - travel reverse = system - test point M2

2.1. Regulation - travel pumps 2 starting from neutral position, as described in section 1. The valve is opened when the proportional solenoid valves Y9/Y10 or Y11/Y12 are energized, the pressurized oil from the "replenishing" section of the system flows to one side of the servo control cylinders 8 and builds up a hydraulic regulating pressure in proportion to the magnetic force. The piston of the servo control cylinder 8 is moved by regulating pressure against the opposite regulating spring assembly, until the forces are balanced again. The pilot piston 9 is also moved via a mechanical connection. It opens the oil port to the side opposite of the control direction of the piston 9 of swash plate control cylinder 10 and allows the oil to flow from the opposite side into the pump housing. The swash plate pump 3 is shifted in the direction towards Qmax . For flow direction and volume, refer to par. 2. As the swash plate is moved, the housing of servo control piston 8 is mechanically moved along until the bores in the housing and the servo control piston are again posetively overlapped =neutral position. Both sides of the swash plate control cylinder 10 are actuated again with pressurized oil and the swash plate is held hydraulically at the actuated pump angle. As current increases, it moves further in direction of Qmax until the mechanical regulating stop of the travel pump is reached. If current is decreased, the swash plate of pump 3 is moved in direction Qmin / neutral position, regulation / control sequence is as described above.

2.2. Regulation - travel motors 20 starting from neutral position, as described in section 1. Regulating pressure flow: Travel pump2 left - proportional solenoid valve Y9 or Y10 servo control cylinder8 two way check valve13-X X-travel motors20 left pilot piston23. Travel pump2 right - proportional solenoid valve Y11 or Y12 servo control cylinder8 two way check valve13-X X-travel motors20 right pilot piston23. If the regulating pressure increases by energizing of one of the proportional solenoid valves Y9/Y10 or Y11/Y12 on the travel pump 2 and exceeds the regulating begin of the travel motors 20, the pilot pistons 23 will be shifted against the regulating and return spring to "parallel passage" position . The spring side of the control piston 22 is relieved to the housing / tank, the pressurized oil from the "replenishing" section of the system is directed to the piston bottom side of the control piston 22 and the axial piston units 21 are moved to a smaller angle = in direction of Qmin. Due to this change in Qmin direction, the return springs push the pilot pistons 23 more and more against the force of the regulating pressure. When the spring force is the same as the pressure force, the pilot pistons 23 are held in center position, the ports to the control piston 22 are closed and the axial piston unit is held on the selected angle / intake volume.

As current is increased, the pressure continues to increase towards Qmin. The maximum possible current/ regulation is limited by the electronic control. The axial piston units 21 do not reach the mechanical Qmin. stop = smallest angle. As current is decreased, the axial piston units 21 are moved again in direction of Qmax =neutral position, the control pressure is directed the same way as in neutral function: via the pilot piston 23- diagonal path to the spring side of the control piston 22 and the piston bottom side is vented. Intermediate positions are held as described before in case of equal force between regulating pressure to spring.

2.3. Closed loop circuits starting from neutral function, as described in section 1.1 Pump flow from swash plate pump3 pump outlet - distributor block travel motor20-front/axial piston unit21 travel motor20-rear/axial piston unit21 distributor block-pump inlet swash plate pump3 The resulting high pressure in the travel motor intake actuates the piston of the axial piston unit 21 and starts to turn the unit. With this turning movement, the oil is directed to the opposite (low pressure) side . When the machine starts to travel, the directional valves 24 in the travel motors are actuated on one side with low pressure, on the opposite side with high pressure from the closed loop circuit, and they are moved towards the low pressure side and the port is opened. Pressurized oil (SP pressure)- low pressure sidedirectional valve 24restrictor 25pressure relief valve 26 (opens) motor housing U (flushing)screen filter 28 tank 80. Oil flow - restrictor 25 - each travel motor appr. 10 l/min = discharge If the pressure on the low pressure side drops below 10 bar, due to a problem, the pressure relief valves 26 will close. The discharge is stopped and cavitation in the closed loop circuit is prevented. The discharged oil from the travel motors 20 flows to the travel pump 2 via the check valve (7 or 6) on the low pressure side = suction side; see neutral function, section 1.1. On the high pressure side = delivery side, the check valve (6 or 7) is held in the closed position by high pressure and the maximum pressure is limited to 420+30/-10 bar by the pressure relief valve (4 or 5) . If the pressure increases above this value, the pressure relief valve opens and directs the oil flow to the replenishing side / low pressure side. The second closed loop circuit works the same way. The pressures in the closed loop circuits can be measured on test points M1 and M2 (each on the distributor block - pump outlet) with suitable pressure gauges. See special tools, section 2.1.21. Observe safety guidelines - see section 1.2.

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Function
Datum Edition Date

PR 752

F/N xxx-2002 2062

01 04

Travel Hydraulic

Blatt Page Feuille

6.3.50.03

Notes

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Parts list
Datum Edition Date

01 01

Travel Hydraulic

PR 752
Blatt Page Feuille

F/N xxx-2002 2062

6.3.50.00

1 splitter box 2 travel pump cpl. - right / left 3 swash plate pump 4 pressure relief valve - HP forward - M1 5 pressure relief valve - HP reverse - M2 6 check valve - replenishing M1 7 check valve - replenishing M2 8 servo control piston 9 pilot piston 10 pump control cylinder 11 orifice 12 pressure relief valve - repl. circuit 13 two way check valve block 15 tandem gear pumps - replenishing 16 valve block 17 pressure relief valves - repl. oil pressure SP 18 filter assembly / filter - replenishing 19 valve block / pressure relief valve - cold start 20 travel motor cpl. - 2x left / 2x right 21 axial piston unit 22 control piston 23 pilot piston 24 directional valve - flushing 25 orifice 26 pressure relief valve - flushing 28 strainer

52 check valve 53 restrictor 55 accumulator WH. 60 test center - test points SP repl. oil pressure LA fan drive - system pressure 65 water cooler 66 hydraulic oil cooler 80 hydraulic tank 81 shut off valve 82 shut off valve 83 return filter 84 bypass valve 85 strainer 100 regulating pump working hydraulic

B5 B6

pressure switch - brake indicator light pressure switch - replenishing pressure indicator light B22 pressure switch - return filter monitor B29 thermo switch - fan drive Y4 Y9 Y10 Y11 Y12 Y13 Y45 Y52 Y53 solenoid valve - servo cut off WH. proportional solenoid valve - le. travel forward proportional solenoid valve - le. travel reverse proportional solenoid valve - ri. travel forward proportional solenoid valve - ri. travel reverse solenoid valve - parking brake solenoid valve - special attachment - WH. solenoid valve - fan drive solenoid valve - Diesel engine RPM safety - WH.

30 regulating pump cpl. - fan drive 31 axial piston unit 32 control cylinder (Qmin) 33 return cylinder (Qmax) 34 pressure cut off valve 35 load sensing regulator 36 restrictor 38 axial piston fixed displacement motor (fan - water cooler) 39 check valve 40 gear motor (fan - hydraulic oil cooler) 41 check valve 45 travel gear cpl. left / right 46 ring piston - parking brake 50 distributor block 51 orifice GP to pilot (servo) control valve - P / WH. UP to regulating pump - X / WH.

M1 M2 SD

test points in the machine high pressure travel forward high pressure travel reverse back-up pressure - cold start (pumps 15)

unnamed line outlets on the hydraulic tank - suction line working hydraulic pump - return line working hydraulic - connection to hand pump - cab tilt

01 00

2062

1. Neutral function

Functional schematic, see 6.3.51.00

1.1. Tandem gear pumps 15 - Replenishing function As soon as the engine is started, the gear pump 15 draws oil from the hydraulic tank 80 via the shut off valve 82 and supplies it to the distributor block 16/P1+P2. From the distributor block 16/ K P-valve block 19 F F-filter bracket 18

Oil not needed in the system flows via the pressure relief valve 17 hydraulic oil cooler 66 return filter 83 to hydraulic tank 80. When the oil is at operating temperature, a certain resistance (appr. 5 bar) is created in the return oil flow by the oil cooler, lines and filter, which is applied on the spring side of the pressure relief valves 17 (adjusted to 20+2 bar). This results in an operating pressure of appr. 25+2 bar in the section in front of the pressure relief valves = test point SP (and SD). When the oil is cold, part of the oil is directed via the pressure relief valve in block 19 directly to tank and the system pressure is thereby limited to max. 28+2 bar (cold start pressure) = test point SD. Distribution of the oil flow - filter bracket18 /B check valve 52 distributor block50 solenoid valveY13 (parking brake) blocked. accumulator 55 and solenoid valve Y4 blocked. (servo cut off WH) /FR F-travel pump2 right and pressure switch B6. /FL F-travel pump2 left and test connection SP. /PM P-travel motor20 right pilot piston23 spring side control piston22. /PM P - travel motor20 leftpilot piston23spring side control piston22.

The solenoid valve Y4 is actuated, after raising off the safety lever, and permits passage to outlet GP servo control working hydraulic. In travel pump 2 right / left to (oil flow) check valve 6 replenishing - closed loop circuit - M1 channel pressure relief valve 4 (blocked). proportional solenoid valves Y9/Y10 or Y11/Y12 blocked. pilot piston 9 control cylinder 10. orifice11 pressure relief valve12 pump housing screen filter 85 tank. channel pressure relief valve 5 (blocked). check valve 7 replenishing - closed loop circuit - M2.

The passages of pilot pistons 9 to control cylinders 10 are severely restricted. All control cylinders are equally pressurized with oil, keeping the swash plates of pumps 3 in neutral position =0 pump angle. The pressure relief valves 12 are opened by the system pressure. The orifices 11 limit the oil flow Q to ~ 8l/min. The oil flow flushes, cools and lubricates the drive sections of the travel pumps 2. If the system pressure drops below 16 bar, due to a problem, the pressure relief valves 12 close. The flushing circuit is interrupted and the entire oil flow is directed to the closed loop circuit and the control. The pump housing remains filled with oil via the tank lines. The control lines for the travel pumps and motors are vented to the pump housing/ tank via the proportional solenoid valves Y9 to Y12.

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Function
Datum Edition Date

PR 752

F/N xxx-2063 5071

01 04

Travel Hydraulic

Blatt Page Feuille

6.3.51.01

1.2. Travel pumps 3 and travel motors 20 - closed loop circuits With the pumps in neutral, the oil in the closed loop circuit does not circulate. Because the swash plates of the travel pumps 3 are in the neutral position, no piston stroke is created and therefore no oil flow, despite the rotation of the axial piston unit and pistons. However, the closed loop circuit is filled with pressurized oil of approx. 23+2 bar through the replenishing circuit (via check valves 6 and 7 (see paragraph 1.1)). In every travel motor 20, the pressurized oil from the closed loop circuit is directed on both sides to the directional valve 24 and blocked. The axial piston unit 21 is held by the spring and the pressurized oil on the springside of the control piston 22 (see paragraph 1.1) at maximum angle = Q max = neutral position. The piston bottom side of the control piston 22 is vented via the pilot piston 23 to the motor housing / tank.

1.3. Regulating pump 30 - fan drive When the Diesel engine is not running, the axial piston unit 31 of the pump 30 is at maximum angle = Qmax. As soon as the Diesel engine is running, the pump 30 starts deliver oil, the system pressure increases and the fan motors start to turn. In operating position of the starter switch S1, the solenoid valve Y25 gets currented via thermo switch of the fan control (closed in neutral position). S1 K4 F10 B25 - Turbo charge air temperature Diesel engine (closes at 55C opens at 50C) B24 - Hydraulic oil temperature (closes at 65C opens at 60C) B23 - Coolant temperature - Diesel engine (closes at 90C opens at 85C) Y25 solenoid valve - fan drive control. If one of these media reaches the corresponding temperature, the contact of the thermo switch opens and the currenting of the solenoid valve Y25 is interrupted. For more information see group 9 - Electrical System. When the engine is cold, the solenoid valve Y52 is energized and remains in actuated position and relieves the servo oil connection X of pump 30 to tank. The Load Sensing regulator 35 is displaced against its spring with a system pressure of 25+1 bar and pressurized oil is directed via the pressure cut off valve 34 to the control cylinder 32. Due to the given surface ratio, the control cylinder 32 moves the axial piston unit 31 against the return cylinder 33 to min. angle=Qmin. The angle/oil flow is regulated by the LS-regulator 35 and the return force of cylinder 33 in such a way, that a constant stand-by pressure of 30+1 bar (LA) is created in the system. This pressure determines the minimum RPM of the motors / fan - see page 3.1.50.01. When the machine is at operating temperature, the currenting of the solenoid valve Y25 is interrupted by at least one thermo switch B23/B24/B25, the solenoid valve is in neutral position. The connection to tank is blocked, the servo oil connection X is pressurized with system pressure, which keeps the LS-regulator in neutral position. The control cylinder 32 is without pressure, the return cylinder 33 moves the axial piston unit 31 to max. angle = Qmax the system pressure exceeds the stand-by pressure. If the system pressure exceeds the spring value of the pressure cut off valve 34, the valve is shifted against the spring and pressurized oil flows to the control cylinder 32. Due to the given surface ratio, the control cylinder 32 moves the axial piston unit 31 against the return cylinder 33 to a smaller angle. The angle / oil flow is regulated by the pressure cut off valve 34 and the return force of the cylinder 33 in such a way, that at normal Diesel engine RPM range a constant operating pressure of 1603 bar (LA) is retained in the system. This pressure determines the maximum RPM of the motors / fan - see page 3.1.50.01. The displaced amount of oil which flows off via restrictor 36 when the pump is regulated is pressure dependent and is used to mute the signal and to flush the housing. The system pressure is measured on test point LA, just before the restrictor 53.

The check valves 39 and 41 are necessary to supply the oil for coasting of the fan / motors after the engine is shut down. Oil flow - working circuit: Hydraulic tank80 axial piston unit31 axial piston - fixed displacement motor38 gear motor40 oil cooler66 return filter83 tank80. Check valves 39 and 41 are kept closed by pressurized oil. Servo oil flow - when machine is cold: Axial piston unit31 restrictor53 LP-valve block50 P-solenoid valve Y25-A valve block50-T tank80.

(pump 30 - internal) return cylinder33. pressure cut off valve34 Load Sensing regulator35 pressure cut off valve34 control cylinder32. ( restrictor36 housing L screen filter85 tank80.) Servo oil flow - when machine is at operating temperature: Axial piston unit31 restrictor53 LP-valve block50 P-solenoid valve Y25 (blocked). regulating pump30 spring side LS-regulator35.

(pump30 internal) return cylinder33. pressure cut off valve34 Load Sensing regulator35 (blocked). pressure cut off valve34 control cylinder32. ( restrictor36 housing L screen filter85 tank80.) 2. Operating functions - travel The various travel functions are regulated by the electronic control via the proportional solenoid valves Y9 to Y12, which are installed on the travel pump covers. The lever deflection is in relation to the current flow of the solenoid valves and therefore the regulating pressure build-up. See also description - Travel Hydraulic - section 6.2. and Functional description - Electronic Control - section 10.3. The travel direction during travel operation is selected on the travel pumps 2 as follows: Travel forward Travel reverse electronic control: regulating pressure built up: on solenoid valves Y9 / Y11 at connection Y on solenoid valves Y10 / Y12 at connection Z oil flow output: on S (bottom) on P (top)

The travel speed depends on the joystick deflection = current =regulating pressure and can be infinitely regulated. Pump control: Motor control: flow volume zero Qmax intake volume Qmax Qmin =regulating pressure appr. 2 to 8 bar =regulating pressure appr. 8 to 15 bar

The regulation begin for the travel motors is approx. 0.3 bar before the end of regulation of the pumps, which means there is a slight overlap of pump / motor control in the regulating range of 8 bar. The regulating pressure for the travel motors is supplied from the travel pumps via a two way check valve 13 connection X. When turning, the solenoid valve on the side into which the machine is turning receives less current, as a result the intake volume of the motor is increased or the flow volume from the pump is reduced, which in turn reduces the travel speed on this side.

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Function
Datum Edition Date

PR 752

F/N xxx-2063 5071

01 04

Travel Hydraulic

Blatt Page Feuille

6.3.51.02

The solenoid valve Y13 is energized during every travel operation. The valve shifts to diagonal path, the pressurized oil flows via distributor block 50 to the pressure switch B5 and via outlet B to the travel gears 45 and vents (releases) the disk brakes 46. Depending on the travel resistance (=rotary resistance of travel motors), hydraulic pressure is created in the pump flow = high pressure side of closed loop circuits. In the return flow from the travel motors, the replenishing pressure ( SP- pressure) is present = low pressure side of closed loop circuits. High pressure side - travel forward = system - test point M1 High pressure side - travel reverse = system - test point M2

2.1. Regulation - travel pumps 2 starting from neutral position, as described in section 1. The valve is opened when the proportional solenoid valves Y9/Y10 or Y11/Y12 are energized, the pressurized oil from the "replenishing" section of the system flows to one side of the servo control cylinders 8 and builds up a hydraulic regulating pressure in proportion to the magnetic force. The piston of the servo control cylinder 8 is moved by regulating pressure against the opposite regulating spring assembly, until the forces are balanced again. The pilot piston 9 is also moved via a mechanical connection. It opens the oil port to the side opposite of the control direction of the piston 9 of swash plate control cylinder 10 and allows the oil to flow from the opposite side into the pump housing. The swash plate pump 3 is shifted in the direction towards Qmax . For flow direction and volume, refer to par. 2. As the swash plate is moved, the housing of servo control piston 8 is mechanically moved along until the bores in the housing and the servo control piston are again positively overlapped =neutral position. Both sides of the swash plate control cylinder 10 are actuated again with pressurized oil and the swash plate is held hydraulically at the actuated pump angle. As current increases, it moves further in direction of Qmax until the mechanical regulating stop of the travel pump is reached. If current is decreased, the swash plate of pump 3 is moved in direction Qmin / neutral position, regulation / control sequence is as described above.

2.2. Regulation - travel motors 20 starting from neutral position, as described in section 1. Regulating pressure flow: Travel pump2 left - proportional solenoid valve Y9 or Y10 servo control cylinder8 two way check valve13-X X-travel motors20 left pilot piston23. Travel pump2 right - proportional solenoid valve Y11 or Y12 servo control cylinder8 two way check valve13-X X-travel motors20 right pilot piston23. If the regulating pressure increases by energizing of one of the proportional solenoid valves Y9/Y10 or Y11/Y12 on the travel pump 2 and exceeds the regulating begin of the travel motors 20, the pilot pistons 23 will be shifted against the regulating and return spring to "parallel passage" position . The spring side of the control piston 22 is relieved to the housing / tank, the pressurized oil from the "replenishing" section of the system is directed to the piston bottom side of the control piston 22 and the axial piston units 21 are moved to a smaller angle = in direction of Qmin. Due to this change in Qmin direction, the return springs push the pilot pistons 23 more and more against the force of the regulating pressure. When the spring force is the same as the pressure force, the pilot pistons 23 are held in center position, the ports to the control piston 22 are closed and the axial piston unit is held on the selected angle / intake volume.

As current is increased, the pressure continues to increase towards Qmin. The maximum possible current/ regulation is limited by the electronic control. The axial piston units 21 do not reach the mechanical Qmin. stop = smallest angle. As current is decreased, the axial piston units 21 are moved again in direction of Qmax =neutral position, the control pressure is directed the same way as in neutral function: via the pilot piston 23- diagonal path to the spring side of the control piston 22 and the piston bottom side is vented. Intermediate positions are held as described before in case of equal force between regulating pressure to spring.

2.3. Closed loop circuits starting from neutral function, as described in section 1.1 Pump flow from swash plate pump3 pump outlet - distributor block travel motor20-front/axial piston unit21 travel motor20-rear/axial piston unit21 distributor block-pump inlet swash plate pump3 The resulting high pressure in the travel motor intake actuates the piston of the axial piston unit 21 and starts to turn the unit. With this turning movement, the oil is directed to the opposite (low pressure) side. When the machine starts to travel, the directional valves 24 in the travel motors are actuated on one side with low pressure, on the opposite side with high pressure from the closed loop circuit, and they are moved towards the low pressure side and the port is opened. Pressurized oil (SP pressure)- low pressure sidedirectional valve 24restrictor 25pressure relief valve 26 (opens) motor housing U (flushing)screen filter 28 tank 80. Oil flow - restrictor 25 - each travel motor appr. 10 l/min = discharge If the pressure on the low pressure side drops below 10 bar, due to a problem, the pressure relief valves 26 will close. The discharge is stopped and cavitation in the closed loop circuit is prevented. The discharged oil from the travel motors 20 flows to the travel pump 2 via the check valve (7 or 6) on the low pressure side = suction side; see neutral function, section 1.1. On the high pressure side = delivery side, the check valve (6 or 7) is held in the closed position by high pressure and the maximum pressure is limited to 420+30/-10 bar by the pressure relief valve (4 or 5) . If the pressure increases above this value, the pressure relief valve opens and directs the oil flow to the replenishing side / low pressure side. The second closed loop circuit works the same way. The pressures in the closed loop circuits can be measured on test points M1 and M2 (each on the distributor block - pump outlet) with suitable pressure gauges. See special tools, section 2.1.21. Observe safety guidelines - see section 1.2.

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Function
Datum Edition Date

PR 752

F/N xxx-2063 5071

01 04

Travel Hydraulic

Blatt Page Feuille

6.3.51.03

Notes

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Parts list
Datum Edition Date

01 01

Travel Hydraulic

PR 752
Blatt Page Feuille

F/N xxx-2063 5071

6.3.51.00

1 splitter box 2 travel pump cpl. - right / left 3 swash plate pump 4 pressure relief valve - HP forward - M1 5 pressure relief valve - HP reverse - M2 6 check valve - replenishing M1 7 check valve - replenishing M2 8 servo control piston 9 pilot piston 10 pump control cylinder 11 orifice 12 pressure relief valve - repl. circuit 13 two way check valve block 15 tandem gear pumps - replenishing 16 valve block 17 pressure relief valves - repl. oil pressure SP 18 filter assembly / filter - replenishing 19 valve block / pressure relief valve - cold start 20 travel motor cpl. - 2x left / 2x right 21 axial piston unit 22 control piston 23 pilot piston 24 directional valve - flushing 25 orifice 26 pressure relief valve - flushing 28 strainer

52 check valve 53 restrictor 55 accumulator WH. 60 test center - test points SP repl. oil pressure LA fan drive - system pressure 65 water cooler 66 hydraulic oil cooler 80 hydraulic tank 81 shut off valve 82 shut off valve 83 return filter 84 bypass valve 85 strainer 100 regulating pump working hydraulic

B5 B6

pressure switch - brake indicator light pressure switch - replenishing pressure indicator light B18 pressure switch - return filter monitor B24 thermo switch - fan drive B26 temperature sending unit - indicator light hydraulic oil overheating Y4 Y9 Y10 Y11 Y12 solenoid valve - servo cut off WH. proportional solenoid valve - le. travel forward proportional solenoid valve - le. travel reverse proportional solenoid valve - ri. travel forward proportional solenoid valve - ri. travel reverse

30 regulating pump cpl. - fan drive 31 axial piston unit 32 control cylinder (Qmin) 33 return cylinder (Qmax) 34 pressure cut off valve 35 load sensing regulator 36 restrictor 38 axial piston fixed displacement motor (fan - water cooler) 39 check valve 40 gear motor (fan - hydraulic oil cooler) 41 check valve 45 travel gear cpl. left / right 46 ring piston - parking brake 50 distributor block 51 orifice GP to pilot (servo) control valve - P / WH. UP to regulating pump - X / WH.

Y13 solenoid valve - parking brake Y25 solenoid valve - fan drive Y28 solenoid valve - Diesel engine RPM safety - WH. Y29 solenoid valve - special attachment - WH. test points in the machine high pressure travel forward high pressure travel reverse back-up pressure - cold start (pumps 15)

M1 M2 SD

unnamed line outlets on the hydraulic tank - suction line working hydraulic pump - return line working hydraulic - connection to hand pump - cab tilt

Benennung Description Dnomination

Typ/ab Type/from Type/a partir de

liebherr
Datum Edition Date

01 01

Fahrhydraulik Travel Hydraulic Hydraulique de translation

PR 752
Blatt Page Feuille

F/N xxx- 2063

5071

6.3.51. 00

1. Neutral function

Functional schematic, see 6.3.52.00

1.1. Tandem gear pumps 15 - Replenishing function As soon as the engine is started, the gear pump 15 draws oil from the hydraulic tank 80 via the shut off valve 82 and supplies it to the distributor block 16/P1+P2. From the distributor block 16/ K P-valve block 19 F F-filter bracket 18

Oil not needed in the system flows via the pressure relief valve 17 hydraulic oil cooler 66 return filter 83 to hydraulic tank 80. When the oil is at operating temperature, a certain resistance (appr. 5 bar) is created in the return oil flow by the oil cooler, lines and filter, which is applied on the spring side of the pressure relief valves 17 (adjusted to 20+2 bar). This results in an operating pressure of appr. 25+2 bar in the section in front of the pressure relief valves = test point SP (and SD). When the oil is cold, part of the oil is directed via the pressure relief valve in block 19 directly to tank and the system pressure is thereby limited to max. 28+2 bar (cold start pressure) = test point SD. Distribution of the oil flow - filter bracket18 /B check valve 52 distributor block50 solenoid valveY13 (parking brake) blocked. accumulator 55 and solenoid valve Y4 blocked. (servo cut off WH) /FR F-travel pump2 right and pressure switch B6. /FL F-travel pump2 left and test connection SP. /PM P-travel motor20 right pilot piston23 spring side control piston22. /PM P - travel motor20 leftpilot piston23spring side control piston22.

The solenoid valve Y4 is actuated, after raising off the safety lever, and permits passage to outlet GP servo control working hydraulic. In travel pump 2 right / left to (oil flow) check valve 6 replenishing - closed loop circuit - M1 channel pressure relief valve 4 (blocked). proportional solenoid valves Y9/Y10 or Y11/Y12 blocked. pilot piston 9 control cylinder 10. orifice11 pressure relief valve12 pump housing screen filter 85 tank. channel pressure relief valve 5 (blocked). check valve 7 replenishing - closed loop circuit - M2.

The passages of pilot pistons 9 to control cylinders 10 are severely restricted. All control cylinders are equally pressurized with oil, keeping the swash plates of pumps 3 in neutral position =0 pump angle. The pressure relief valves 12 are opened by the system pressure. The orifices 11 limit the oil flow Q to ~ 8l/min. The oil flow flushes, cools and lubricates the drive sections of the travel pumps 2. If the system pressure drops below 16 bar, due to a problem, the pressure relief valves 12 close. The flushing circuit is interrupted and the entire oil flow is directed to the closed loop circuit and the control. The pump housing remains filled with oil via the tank lines. The control lines for the travel pumps and motors are vented to the pump housing/ tank via the proportional solenoid valves Y9 to Y12.

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Function
Datum Edition Date

PR 752

F/N xxx-5072 5599

01 04

Travel Hydraulic

Blatt Page Feuille

6.3.52.01

1.2. Travel pumps 3 and travel motors 20 - closed loop circuits With the pumps in neutral, the oil in the closed loop circuit does not circulate. Because the swash plates of the travel pumps 3 are in the neutral position, no piston stroke is created and therefore no oil flow, despite the rotation of the axial piston unit and pistons. However, the closed loop circuit is filled with pressurized oil of approx. 23+2 bar through the replenishing circuit (via check valves 6 and 7 (see paragraph 1.1)). In every travel motor 20, the pressurized oil from the closed loop circuit is directed on both sides to the directional valve 24 and blocked. The axial piston unit 21 is held by the spring and the pressurized oil on the springside of the control piston 22 (see paragraph 1.1) at maximum angle = Q max = neutral position. The piston bottom side of the control piston 22 is vented via the pilot piston 23 to the motor housing / tank.

1.3. Regulating pump 30 - fan drive When the Diesel engine is not running, the axial piston unit 31 of the pump 30 is at maximum angle = Qmax. As soon as the Diesel engine is running, the pump 30 starts deliver oil, the system pressure increases and the fan motors start to turn. In operating position of the starter switch S1, the solenoid valve Y25 gets currented via thermo switch of the fan control (closed in neutral position). S1 K4 F10 B25 - Turbo charge air temperature Diesel engine (closes at 55C opens at 50C) B24 - Hydraulic oil temperature (closes at 65C opens at 60C) B23 - Coolant temperature - Diesel engine (closes at 90C opens at 85C) Y25 solenoid valve - fan drive control. If one of these media reaches the corresponding temperature, the contact of the thermo switch opens and the currenting of the solenoid valve Y25 is interrupted. For more information see group 9 - Electrical System. When the engine is cold, the solenoid valve Y52 is energized and remains in actuated position and relieves the servo oil connection X of pump 30 to tank. The Load Sensing regulator 35 is displaced against its spring with a system pressure of 25+1 bar and pressurized oil is directed via the pressure cut off valve 34 to the control cylinder 32. Due to the given surface ratio, the control cylinder 32 moves the axial piston unit 31 against the return cylinder 33 to min. angle=Qmin. The angle/oil flow is regulated by the LS-regulator 35 and the return force of cylinder 33 in such a way, that a constant stand-by pressure of 30+1 bar (LA) is created in the system. This pressure determines the minimum RPM of the motors / fan - see page 3.1.50.01. When the machine is at operating temperature, the currenting of the solenoid valve Y25 is interrupted by at least one thermo switch B23/B24/B25, the solenoid valve is in neutral position. The connection to tank is blocked, the servo oil connection X is pressurized with system pressure, which keeps the LS-regulator in neutral position. The control cylinder 32 is without pressure, the return cylinder 33 moves the axial piston unit 31 to max. angle = Qmax the system pressure exceeds the stand-by pressure. If the system pressure exceeds the spring value of the pressure cut off valve 34, the valve is shifted against the spring and pressurized oil flows to the control cylinder 32. Due to the given surface ratio, the control cylinder 32 moves the axial piston unit 31 against the return cylinder 33 to a smaller angle. The angle / oil flow is regulated by the pressure cut off valve 34 and the return force of the cylinder 33 in such a way, that at normal Diesel engine RPM range a constant operating pressure of 1603 bar (LA) is retained in the system. This pressure determines the maximum RPM of the motors / fan - see page 3.1.50.01. The displaced amount of oil which flows off via restrictor 36 when the pump is regulated is pressure dependent and is used to mute the signal and to flush the housing. The system pressure is measured on test point LA, just before the restrictor 53.

The check valves 39 and 41 are necessary to supply the oil for coasting of the fan / motors after the engine is shut down. Oil flow - working circuit: Hydraulic tank80 axial piston unit31 axial piston - fixed displacement motor38 gear motor40 oil cooler66 return filter83 tank80. Check valves 39 and 41 are kept closed by pressurized oil. Servo oil flow - when machine is cold: Axial piston unit31 restrictor53 LP-valve block50 P-solenoid valve Y25-A valve block50-T tank80.

(pump 30 - internal) return cylinder33. pressure cut off valve34 Load Sensing regulator35 pressure cut off valve34 control cylinder32. ( restrictor36 housing L screen filter85 tank80.) Servo oil flow - when machine is at operating temperature: Axial piston unit31 restrictor53 LP-valve block50 P-solenoid valve Y25 (blocked). regulating pump30 spring side LS-regulator35.

(pump30 internal) return cylinder33. pressure cut off valve34 Load Sensing regulator35 (blocked). pressure cut off valve34 control cylinder32. ( restrictor36 housing L screen filter85 tank80.) 2. Operating functions - travel The various travel functions are regulated by the electronic control via the proportional solenoid valves Y9 to Y12, which are installed on the travel pump covers. The lever deflection is in relation to the current flow of the solenoid valves and therefore the regulating pressure build-up. See also description - Travel Hydraulic - section 6.2. and Functional description - Electronic Control - section 10.3. The travel direction during travel operation is selected on the travel pumps 2 as follows: Travel forward Travel reverse electronic control: regulating pressure built up: on solenoid valves Y9 / Y11 at connection Y on solenoid valves Y10 / Y12 at connection Z oil flow output: on S (bottom) on P (top)

The travel speed depends on the joystick deflection = current =regulating pressure and can be infinitely regulated. Pump control: Motor control: flow volume zero Qmax intake volume Qmax Qmin =regulating pressure appr. 2 to 8 bar =regulating pressure appr. 8 to 15 bar

The regulation begin for the travel motors is approx. 0.3 bar before the end of regulation of the pumps, which means there is a slight overlap of pump / motor control in the regulating range of 8 bar. The regulating pressure for the travel motors is supplied from the travel pumps via a two way check valve 13 connection X. When turning, the solenoid valve on the side into which the machine is turning receives less current, as a result the intake volume of the motor is increased or the flow volume from the pump is reduced, which in turn reduces the travel speed on this side.

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Function
Datum Edition Date

PR 752

F/N xxx-5072 5599

01 04

Travel Hydraulic

Blatt Page Feuille

6.3.52.02

The solenoid valve Y13 is energized during every travel operation. The valve shifts to diagonal path, the pressurized oil flows via distributor block 50 to the pressure switch B5 and via outlet B to the travel gears 45 and vents (releases) the disk brakes 46. Depending on the travel resistance (=rotary resistance of travel motors), hydraulic pressure is created in the pump flow = high pressure side of closed loop circuits. In the return flow from the travel motors, the replenishing pressure ( SP- pressure) is present = low pressure side of closed loop circuits. High pressure side - travel forward = system - test point M1 High pressure side - travel reverse = system - test point M2

2.4. Regulation - travel pumps 2 starting from neutral position, as described in section 1. The valve is opened when the proportional solenoid valves Y9/Y10 or Y11/Y12 are energized, the pressurized oil from the "replenishing" section of the system flows to one side of the servo control cylinders 8 and builds up a hydraulic regulating pressure in proportion to the magnetic force. The piston of the servo control cylinder 8 is moved by regulating pressure against the opposite regulating spring assembly, until the forces are balanced again. The pilot piston 9 is also moved via a mechanical connection. It opens the oil port to the side opposite of the control direction of the piston 9 of swash plate control cylinder 10 and allows the oil to flow from the opposite side into the pump housing. The swash plate pump 3 is shifted in the direction towards Qmax . For flow direction and volume, refer to par. 2. As the swash plate is moved, the housing of servo control piston 8 is mechanically moved along until the bores in the housing and the servo control piston are again positively overlapped =neutral position. Both sides of the swash plate control cylinder 10 are actuated again with pressurized oil and the swash plate is held hydraulically at the actuated pump angle. As current increases, it moves further in direction of Qmax until the mechanical regulating stop of the travel pump is reached. If current is decreased, the swash plate of pump 3 is moved in direction Qmin / neutral position, regulation / control sequence is as described above.

2.5. Regulation - travel motors 20 starting from neutral position, as described in section 1. Regulating pressure flow: Travel pump2 left - proportional solenoid valve Y9 or Y10 servo control cylinder8 two way check valve13-X X-travel motors20 left pilot piston23. Travel pump2 right - proportional solenoid valve Y11 or Y12 servo control cylinder8 two way check valve13-X X-travel motors20 right pilot piston23. If the regulating pressure increases by energizing of one of the proportional solenoid valves Y9/Y10 or Y11/Y12 on the travel pump 2 and exceeds the regulating begin of the travel motors 20, the pilot pistons 23 will be shifted against the regulating and return spring to "parallel passage" position . The spring side of the control piston 22 is relieved to the housing / tank, the pressurized oil from the "replenishing" section of the system is directed to the piston bottom side of the control piston 22 and the axial piston units 21 are moved to a smaller angle = in direction of Qmin. Due to this change in Qmin direction, the return springs push the pilot pistons 23 more and more against the force of the regulating pressure. When the spring force is the same as the pressure force, the pilot pistons 23 are held in center position, the ports to the control piston 22 are closed and the axial piston unit is held on the selected angle / intake volume.

As current is increased, the pressure continues to increase towards Qmin. The maximum possible current/ regulation is limited by the electronic control. The axial piston units 21 do not reach the mechanical Qmin. stop = smallest angle. As current is decreased, the axial piston units 21 are moved again in direction of Qmax =neutral position, the control pressure is directed the same way as in neutral function: via the pilot piston 23- diagonal path to the spring side of the control piston 22 and the piston bottom side is vented. Intermediate positions are held as described before in case of equal force between regulating pressure to spring.

2.6. Closed loop circuits starting from neutral function, as described in section 1.1 Pump flow from swash plate pump3 pump outlet - distributor block travel motor20-front/axial piston unit21 travel motor20-rear/axial piston unit21 distributor block-pump inlet swash plate pump3 The resulting high pressure in the travel motor intake actuates the piston of the axial piston unit 21 and starts to turn the unit. With this turning movement, the oil is directed to the opposite (low pressure) side . When the machine starts to travel, the directional valves 24 in the travel motors are actuated on one side with low pressure, on the opposite side with high pressure from the closed loop circuit, and they are moved towards the low pressure side and the port is opened. Pressurized oil (SP pressure)- low pressure sidedirectional valve 24restrictor 25pressure relief valve 26 (opens) motor housing U (flushing)screen filter 28 tank 80. Oil flow - restrictor 25 - each travel motor appr. 10 l/min = discharge If the pressure on the low pressure side drops below 10 bar, due to a problem, the pressure relief valves 26 will close. The discharge is stopped and cavitation in the closed loop circuit is prevented. The discharged oil from the travel motors 20 flows to the travel pump 2 via the check valve (7 or 6) on the low pressure side = suction side; see neutral function, section 1.1. On the high pressure side = delivery side, the check valve (6 or 7) is held in the closed position by high pressure and the maximum pressure is limited to 420+30/-10 bar by the pressure relief valve (4 or 5) . If the pressure increases above this value, the pressure relief valve opens and directs the oil flow to the replenishing side / low pressure side. The second closed loop circuit works the same way. The pressures in the closed loop circuits can be measured on test points M1 and M2 (each on the distributor block - pump outlet) with suitable pressure gauges. See special tools, section 2.1.21. Observe safety guidelines - see section 1.2. 3. Special function - brake actuating when towing If any traveling function of the machine fails, the break function (operating brake) of the hydrostatic travel drive and the mechanic parking brake can be released manually/hydraulically. Observe all guidelines of the operation manual and all safety guidelines.

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Function
Datum Edition Date

PR 752

F/N xxx-5072 5599

01 04

Travel Hydraulic

Blatt Page Feuille

6.3.52.03

3.1. Brake release Connect hose from connection "BB" to connection "BS" and close "BB"(all connections on the test center 60). connect M1RM2R and M1LM2L on the test center 60 with hoses (delivered with the machine-tools) = hydrostatic drive - brake function is not in function anymore. set accumulator 57 by multiple actuating of the hand pump for tilting operators cab (see section 17.2.10) under sufficient pressure. bring starter switch, emergency OFF switch and safety lever in operating position = solenoid valve Y43 is currented/switched and the brakes 46 are released via path PB by the stored pressurized oil. When necessary, the brakes can be released directly by the hand pump, when the solenoid valve is switched.

The pressure relief valve 58 prevents the brake of too high pressure. The releasing of the brake is indicated on the instrument panel via pressure switch B5. While towing, the displaced oil by the variable motors circulates in the closed loop circuit via connection M1M2. 3.2. Emergency braking when towing Interrupt currenting to solenoid valve Y43 by - pressing the emergency OFF switch, or - lower the safety lever, or - turn starter switch to 0 position. The solenoid valve returns to neutral position, the pressure to the parking brake gets via path BT to tank and the brakes closes. The size of the accumulator 57 allows a recent releasing (twice is possible) of the parking brake.

Notes

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Parts list
Datum Edition Date

01 01

Travel Hydraulic

PR 752
Blatt Page Feuille

F/N xxx-5072 5599

6.3.52.00

1 splitter box 2 travel pump cpl. - right / left 3 swash plate pump 4 pressure relief valve - HP forward - M1 5 pressure relief valve - HP reverse - M2 6 check valve - replenishing M1 7 check valve - replenishing M2 8 servo control piston 9 pilot piston 10 pump control cylinder 11 orifice 12 pressure relief valve - repl. circuit 13 two way check valve block 15 tandem gear pumps - replenishing 16 valve block 17 pressure relief valves - repl. oil pressure SP 18 filter assembly / filter - replenishing 19 valve block / pressure relief valve - cold start 20 travel motor cpl. - 2x left / 2x right 21 axial piston unit 22 control piston 23 pilot piston 24 directional valve - flushing 25 orifice 26 pressure relief valve - flushing 28 strainer

52 check valve 53 restrictor 55 accumulator WH. 57 accumulator - safety device towing 58 pressure relief valve - parking brake 60 test center - test points SP repl. oil pressure LA fan drive - system pressure M1R high pressure - travel forward - right M2R high pressure - travel reverse - right M1L high pressure - travel forward - left M2L high pressure - travel reverse - left hose connection BB parking brake - operating position BS parking brake - towing position 65 water cooler 66 hydraulic oil cooler 80 hydraulic tank 81 shut off valve 82 shut off valve 83 return filter 84 bypass valve 85 strainer 96 to /from hand pump - cab tilt 97 from safety device towing to hydraulic tank 100 regulating pump working hydraulic

30 regulating pump cpl. - fan drive 31 axial piston unit 32 control cylinder (Qmin) 33 return cylinder (Qmax) 34 pressure cut off valve 35 load sensing regulator 36 restrictor 38 axial piston fixed displacement motor (fan - water cooler) 39 check valve 40 gear motor (fan - hydraulic oil cooler) 41 check valve 45 travel gear cpl. left / right 46 ring piston - parking brake 50 distributor block 51 orifice GP to pilot (servo) control valve - P / WH. UP to regulating pump - X / WH.

B5 B6

pressure switch - brake indicator light pressure switch - replenishing pressure indicator light B18 pressure switch - return filter monitor B24 thermo switch - fan drive B26 temperature sending unit - indicator light hydraulic oil overheating Y4 Y9 Y10 Y11 Y12 solenoid valve - servo cut off WH. proportional solenoid valve - le. travel forward proportional solenoid valve - le. travel reverse proportional solenoid valve - ri. travel forward proportional solenoid valve - ri. travel reverse

Y13 solenoid valve - parking brake Y25 solenoid valve - fan drive Y28 solenoid valve - Diesel engine RPM safety - WH. Y29 solenoid valve - special attachment - WH. Y43 solenoid valve - safety device towing test points in the machine back-up pressure - cold start (pumps 15)

SD

unnamed line outlets on the hydraulic tank - suction line working hydraulic pump - return line working hydraulic - connection to hand pump - cab tilt

Benennung Description Dnomination

Typ/ab Type/from Type/a partir de

liebherr
Datum Edition Date

01 03

Fahrhydraulik Travel Hydraulic Hydraulique de translation

PR 752
Blatt Page Feuille

F/N xxx- 5072

5599

6.3.52. 00

1. Neutral function 1.1. Tandem gear pumps 15 - Replenishing function

Functional schematic, see 6.3.53.00

As soon as the engine is started, the gear pump 15 draws oil from the hydraulic tank 80 via the shut off valve 82 and supplies it to the distributor block 16/P1+P2. From the distributor block 16/ K P-valve block 19 F F-filter bracket 18

Oil not needed in the system flows via the pressure relief valve 17 hydraulic oil cooler 66 return filter 83 to hydraulic tank 80. When the oil is at operating temperature, a certain resistance (appr. 5 bar) is created in the return oil flow by the oil cooler, lines and filter, which is applied on the spring side of the pressure relief valves 17 (adjusted to 20+2 bar). This results in an operating pressure of appr. 25+2 bar in the section in front of the pressure relief valves = test point SP (and SD). When the oil is cold, part of the oil is directed via the pressure relief valve in block 19 directly to the hydraulic tank - connector flange of the suction line of the gear pumps 15 - and the system pressure is thereby limited to max. 28+2 bar (cold start pressure) = test point SD. Distribution of the oil flow - filter bracket18 /B check valve 52 distributor block50 solenoid valveY13 (parking brake) blocked. accumulator 55 and solenoid valve Y4 blocked. (servo cut off WH) /FR F-travel pump2 right and pressure switch B6. /FL F-travel pump2 left and test connection SP. /PM P-travel motor20 right pilot piston23 spring side control piston22. /PM P - travel motor20 leftpilot piston23spring side control piston22.

The solenoid valve Y4 is actuated, after raising off the safety lever, and permits passage to outlet GP servo control working hydraulic. In travel pump 2 right / left to check valve 6 replenishing - closed loop circuit - M1 (oil flow) channel pressure relief valve 4 (blocked). proportional solenoid valves Y9/Y10 or Y11/Y12 blocked. pilot piston 9 control cylinder 10. orifice11 pressure relief valve12 pump housing screen filter 85 tank. channel pressure relief valve 5 (blocked). check valve 7 replenishing - closed loop circuit - M2. The passages of pilot pistons 9 to control cylinders 10 are severely restricted. All control cylinders are equally pressurized with oil, keeping the swash plates of pumps 3 in neutral position =0 pump angle. The pressure relief valves 12 are opened by the system pressure. The orifices 11 limit the oil flow Q to ~ 8l/min. The oil flow flushes, cools and lubricates the drive sections of the travel pumps 2. If the system pressure drops below 16 bar, due to a problem, the pressure relief valves 12 close. The flushing circuit is interrupted and the entire oil flow is directed to the closed loop circuit and the control. The pump housing remains filled with oil via the tank lines. The control lines for the travel pumps and motors are vented to the pump housing/ tank via the proportional solenoid valves Y9 to Y12.

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Function
Datum Edition Date

PR 752

F/N xxx-5600

01 04

Travel Hydraulic

Blatt Page Feuille

6.3.53.01

1.2. Travel pumps 3 and travel motors 20 - closed loop circuits With the pumps in neutral, the oil in the closed loop circuit does not circulate. Because the swash plates of the travel pumps 3 are in the neutral position, no piston stroke is created and therefore no oil flow, despite the rotation of the axial piston unit and pistons. However, the closed loop circuit is filled with pressurized oil of approx. 23+2 bar through the replenishing circuit (via check valves 6 and 7 (see paragraph 1.1)). In every travel motor 20, the pressurized oil from the closed loop circuit is directed on both sides to the directional valve 24 and blocked. The axial piston unit 21 is held by the spring and the pressurized oil on the spring side of the control piston 22 (see paragraph 1.1) at maximum angle = Qmax = neutral position. The piston bottom side of the control piston 22 is vented via the pilot piston 23 to the motor housing / tank. 1.3. Regulating pump 30 - fan drive When the Diesel engine is not running, the axial piston unit 31 of the pump 30 is at maximum angle = Qmax. As soon as the Diesel engine is running, the pump 30 starts deliver oil, the system pressure increases and the fan motors start to turn. Electronic regulation: With the starter switch S1 in operating position, the electronic fan control A11 is supplied with current. Circuit board A11 regulates the current to the proportional valve Y45, depending on the signal values of the temperature sensors B38 to 40 and limits thereby the pressure built up in the hydraulic fan drive = the fan speed. S1 K4 F9 A11 B38 - coolant temperature B39 - hydraulic oil temperature

B40 - turbo charge air temperature Y45 - proportional solenoid valve - fan drive When the machine is cold, Y45 is supplied with maximum current from A11 and regulates the possible pressure build up in the hydraulic fan drive - pump 30 motors 38/40 - to the adjusted operating pressure (305 bar) (fans turn at minimum speed). With increasing operating temperature (hydraulic oil, Diesel engine coolant, charge air), the current to Y45 is proportionally reduced and as a result, the pressure in the fan drive ( fan speed ) is increased accordingly. When one of the temperatures reaches the operating temperature, Y45 ,supplied with minimum current from A11, is fully shifted and regulates the fan drive to normal operating pressure (approx. 160 bar) . If there is no current, for example in case of failure of fuse F9 or in case of a broken wire, Y45 regulates the pressure in the fan drive to the adjusted spring value of the pressure cut off valve mechanically / hydraulically (maximum fan speed / fail-save system) - p = 177+5 bar - see section 6.5, Check and Adjustment. For wiring, see sub group 9 - Electrical System, min/max fan speeds in normal operation, see page 3.1.51.01. Pump regulation: The pressure created in the system by the flow from pump 30 is applied against the spring on the load sensing regulator 35. On the proportional pressure cut off valve Y45, the magnetic force created by the winding (regulated by electronic box A11) and the pressure which is available via the restrictor bore 37 acts against the spring of the valve. If the sum of these forces exceeds the spring force, the valve Y45 opens and allows the pressurized oil to flow off into the housing / to the tank. The pressure remaining between the restrictor bore 37 and the pressure cut off valve Y45 ( = regulating pressure) supports the spring force on the LS regulator 35. If the force of the system pressure on the LS regulator 35 surpasses the sum of spring value and regulating pressure, the regulator is moved in direction of the spring and pressurized oil is directed to the control cylinder 32. Due to the given surface areas, the control cylinder 32 moves the piston unit 31 against the return force of cylinder 33 to a reduced angle = in the direction of Qmin. Via the LS regulator 35 and the force of cylinder 33 the pump angle / pump flow is adjusted based on the regulating forces to create a matching pressure. This pressure determines the speed (RPM) of the fan motor / drive. If the system pressure or the magnetic force, as determined by the electronic box A11, drops, the axial piston unit 31 is moved in reverse order in direction Qmax . The displaced amount of oil which flows off via restrictor 36 when the pump is regulated is pressure dependent and is used to mute the signal and to flush the housing. Test point LA (pressure build up in fan drive) is connected to the output side P of pump 30.

Oil flow - working circuit: Hydraulic tank80 axial piston unit31 axial piston - fixed displacement motor38 gear motor40 oil cooler66 return filter83 tank80. Check valves 39 and 41 are kept closed by pressurized oil. Oil flow - servo pressure (pump30 - internal): Axial piston unit 31 return cylinder33. restrictor 37 load sensing regulator35 proportional solenoid valve - pressure relief Y45 load sensing regluator35 control cylinder32. ( restrictor36 housing L screen filter85 tank80.)

2. Operating functions - travel The various travel functions are regulated by the electronic control via the proportional solenoid valves Y9 to Y12, which are installed on the travel pump covers. The lever deflection is in relation to the current flow of the solenoid valves and therefore the regulating pressure build-up. See also description - Travel Hydraulic - section 6.2. and Functional description - Electronic Control - section 10.3. The travel direction during travel operation is selected on the travel pumps 2 as follows: Travel forward Travel reverse electronic control: regulating pressure built up: on solenoid valves Y9 / Y11 at connection Y on solenoid valves Y10 / Y12 at connection Z oil flow output: on S (bottom) on P (top)

The travel speed depends on the joystick deflection = current =regulating pressure and can be infinitely regulated. Pump control: Motor control: flow volume zero Qmax intake volume Qmax Qmin =regulating pressure appr. 2 to 8 bar =regulating pressure appr. 8 to 15 bar

The regulation begin for the travel motors is approx. 0.3 bar before the end of regulation of the pumps, which means there is a slight overlap of pump / motor control in the regulating range of 8 bar. The regulating pressure for the travel motors is supplied from the travel pumps via a two way check valve 13 connection X. When turning, the solenoid valve on the side into which the machine is turning receives less current, as a result the intake volume of the motor is increased or the flow volume from the pump is reduced, which in turn reduces the travel speed on this side. The solenoid valve Y13 is energized during every travel operation. The valve shifts to diagonal path, the pressurized oil flows via distributor block 50 to the pressure switch B5 and via outlet B to the travel gears 45 and vents (releases) the disk brakes 46. Depending on the travel resistance (=rotary resistance of travel motors), hydraulic pressure is created in the pump flow = high pressure side of closed loop circuits. In the return flow from the travel motors, the replenishing pressure ( SP- pressure) is present = low pressure side of closed loop circuits. High pressure side - travel forward = system - test point M1 High pressure side - travel reverse = system - test point M2

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Function
Datum Edition Date

PR 752

F/N xxx-5600

01 04

Travel Hydraulic

Blatt Page Feuille

6.3.53.02

2.1. Regulation - travel pumps 2 starting from neutral position, as described in section 1. The valve is opened when the proportional solenoid valves Y9/Y10 or Y11/Y12 are energized, the pressurized oil from the "replenishing" section of the system flows to one side of the servo control cylinders 8 and builds up a hydraulic regulating pressure in proportion to the magnetic force. The piston of the servo control cylinder 8 is moved by regulating pressure against the opposite regulating spring assembly, until the forces are balanced again. The pilot piston 9 is also moved via a mechanical connection. It opens the oil port to the side opposite of the control direction of the piston 9 of swash plate control cylinder 10 and allows the oil to flow from the opposite side into the pump housing. The swash plate pump 3 is shifted in the direction towards Qmax . For flow direction and volume, refer to par. 2. As the swash plate is moved, the housing of servo control piston 8 is mechanically moved along until the bores in the housing and the servo control piston are again positively overlapped =neutral position. Both sides of the swash plate control cylinder 10 are actuated again with pressurized oil and the swash plate is held hydraulically at the actuated pump angle. As current increases, it moves further in direction of Qmax until the mechanical regulating stop of the travel pump is reached. If current is decreased, the swash plate of pump 3 is moved in direction Qmin / neutral position, regulation / control sequence is as described above. 2.2. Regulation - travel motors 20 starting from neutral position, as described in section 1. Regulating pressure flow: Travel pump2 left - proportional solenoid valve Y9 or Y10 servo control cylinder8 two way check valve13-X X-travel motors20 left pilot piston23. Travel pump2 right - proportional solenoid valve Y11 or Y12 servo control cylinder8 two way check valve13-X X-travel motors20 right pilot piston23. If the regulating pressure increases by energizing of one of the proportional solenoid valves Y9/Y10 or Y11/Y12 on the travel pump 2 and exceeds the regulating begin of the travel motors 20, the pilot pistons 23 will be shifted against the regulating and return spring to "parallel passage" position . The spring side of the control piston 22 is relieved to the housing / tank, the pressurized oil from the "replenishing" section of the system is directed to the piston bottom side of the control piston 22 and the axial piston units 21 are moved to a smaller angle = in direction of Qmin. Due to this change in Qmin direction, the return springs push the pilot pistons 23 more and more against the force of the regulating pressure. When the spring force is the same as the pressure force, the pilot pistons 23 are held in center position, the ports to the control piston 22 are closed and the axial piston unit is held on the selected angle / intake volume. As current is increased, the pressure continues to increase towards Qmin. The maximum possible current/ regulation is limited by the electronic control. The axial piston units 21 do not reach the mechanical Qmin. stop = smallest angle. As current is decreased, the axial piston units 21 are moved again in direction of Qmax =neutral position, the control pressure is directed the same way as in neutral function: via the pilot piston 23- diagonal path to the spring side of the control piston 22 and the piston bottom side is vented. Intermediate positions are held as described before in case of equal force between regulating pressure to spring.

2.3. Closed loop circuits starting from neutral function, as described in section 1.1 Pump flow from swash plate pump3 pump outlet - distributor block travel motor20-front/axial piston unit21 travel motor20-rear/axial piston unit21 distributor block-pump inlet swash plate pump3 The resulting high pressure in the travel motor intake actuates the piston of the axial piston unit 21 and starts to turn the unit. With this turning movement, the oil is directed to the opposite (low pressure) side . When the machine starts to travel, the directional valves 24 in the travel motors are actuated on one side with low pressure, on the opposite side with high pressure from the closed loop circuit, and they are moved towards the low pressure side and the port is opened. Pressurized oil (SP pressure)- low pressure sidedirectional valve 24restrictor 25pressure relief valve 26 (opens) motor housing U (flushing)screen filter 28 tank 80. Oil flow - restrictor 25 - each travel motor appr. 10 l/min = discharge If the pressure on the low pressure side drops below 10 bar, due to a problem, the pressure relief valves 26 will close. The discharge is stopped and cavitation in the closed loop circuit is prevented. The discharged oil from the travel motors 20 flows to the travel pump 2 via the check valve (7 or 6) on the low pressure side = suction side; see neutral function, section 1.1. On the high pressure side = delivery side, the check valve (6 or 7) is held in the closed position by high pressure and the maximum pressure is limited to 420+30/-10 bar by the pressure relief valve (4 or 5) . If the pressure increases above this value, the pressure relief valve opens and directs the oil flow to the replenishing side / low pressure side. The second closed loop circuit works the same way. The pressures in the closed loop circuits can be measured on test points M1 and M2 (each on the distributor block - pump outlet) with suitable pressure gauges. See special tools, section 2.1.21. Observe safety guidelines - see section 1.2. 3. Special function - brake actuating when towing If any traveling function of the machine fails, the break function (operating brake) of the hydrostatic travel drive and the mechanic parking brake can be released manually/hydraulically. Observe all guidelines of the operation manual and all safety guidelines. 3.1. Brake release Connect hose from connection "BB" to connection "BS" and close "BB"(all connections on the test center 60). connect M1RM2R and M1LM2L on the test center 60 with hoses (delivered with the machine-tools) = hydrostatic drive - brake function is not in function anymore. set accumulator 57 by multiple actuating of the hand pump for tilting operators cab (see section 17.2.10) under sufficient pressure. bring starter switch, emergency OFF switch and safety lever in operating position = solenoid valve Y43 is currented/switched and the brakes 46 are released via path PB by the stored pressurized oil. When necessary, the brakes can be released directly by the hand pump, when the solenoid valve is switched.

The pressure relief valve 58 prevents the brake of too high pressure. The releasing of the brake is indicated on the instrument panel via pressure switch B5. While towing, the displaced oil by the variable motors circulates in the closed loop circuit via connection M1M2.

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Function
Datum Edition Date

PR 752

F/N xxx-5600

01 04

Travel Hydraulic

Blatt Page Feuille

6.3.53.03

3.2. Emergency braking when towing Interrupt currenting to solenoid valve Y43 by - pressing the emergency OFF switch, or - lower the safety lever, or - turn starter switch to 0 position. The solenoid valve returns to neutral position, the pressure to the parking brake gets via path BT to tank and the brakes closes. The size of the accumulator 57 allows a recent releasing (twice is possible) of the parking brake.

Notes

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Parts list
Datum Edition Date

PR 752

01 03

Travel Hydraulic

F/N xxx-5600

Blatt Page Feuille

6.3.53.00

1 splitter box 2 travel pump cpl. - right / left 3 swash plate pump 4 pressure relief valve - HP forward - M1 5 pressure relief valve - HP reverse - M2 6 check valve - replenishing M1 7 check valve - replenishing M2 8 servo control piston 9 pilot piston 10 pump control cylinder 11 orifice 12 pressure relief valve - repl. circuit 13 two way check valve block 15 tandem gear pumps - replenishing 16 valve block 17 pressure relief valves - repl. oil pressure SP 18 filter assembly / filter - replenishing 19 valve block / pressure relief valve - cold start 20 travel motor cpl. - 2x left / 2x right 21 axial piston unit 22 control piston 23 pilot piston 24 directional valve - flushing 25 orifice 26 pressure relief valve - flushing 28 strainer 57 accumulator - safety device towing 58 pressure relief valve - parking brake 60 test center - test points /hose connection SP repl. oil pressure LA fan drive - system pressure M1R high pressure - travel forward - right M2R high pressure - travel reverse - right M1L high pressure - travel forward - left M2L high pressure - travel reverse - left hose connection: BB parking brake - operating position BS parking brake - towing position M = test point - bleeding 65 water cooler 66 hydraulic oil cooler 80 hydraulic tank 81 shut off valve 82 shut off valve 83 return filter 84 bypass valve 85 strainer 96 to /from hand pump - cab tilt 97 from safety device towing to hydraulic tank 100 regulating pump working hydraulic B5 B6 pressure switch - brake indicator light pressure switch - replenishing pressure indicator light B18 pressure switch - return filter monitor B26 temperature sending unit - indicator light hydraulic oil overheating B39 temperatur sensor - fan drive Y4 Y9 Y10 Y11 Y12 solenoid valve - servo cut off WH. proportional solenoid valve - le. travel forward proportional solenoid valve - le. travel reverse proportional solenoid valve - ri. travel forward proportional solenoid valve - ri. travel reverse

30 regulating pump cpl. - fan drive 31 axial piston unit 32 control cylinder (Qmin) 33 return cylinder (Qmax) 35 load sensing regulator 36 restrictor 37 restrictor 38 axial piston fixed displacement motor (fan - water cooler) 39 check valve 40 gear motor (fan - hydraulic oil cooler) 41 check valve 45 travel gear cpl. left / right 46 ring piston - parking brake 50 distributor block GP to pilot (servo) control valve - P / WH. UP to regulating pump - X / WH. 52 check valve 55 accumulator WH.

Y13 solenoid valve - parking brake Y28 solenoid valve - Diesel engine RPM safety - WH. Y29 solenoid valve - special attachment - WH. Y43 solenoid valve - safety device towing Y45 proportional solenoid valve - pressure relief fan drive test points in the machine back-up pressure - cold start (pumps 15)

SD

unnamed line outlets on the hydraulic tank - suction line working hydraulic pump - return line working hydraulic - connection to hand pump - cab tilt

Benennung Description Dnomination

Typ/ab Type/from Type/a partir de

liebherr
Datum Edition Date

02 02

Fahrhydraulik Travel Hydraulic Hydraulique de translation

PR 752
Blatt Page Feuille

F/N xxx- 5600

6.3.53. 00

Important information
The following adjustment instructions are intended for step by step machine adjustment; generally, only sections of the adjustments/instructions are required. However, it must be ensured that the required preconditions are met. Use only glycerin-filled pressure gauges with a reading accuracy of 1% or even more accurate test devices. The range of the pressure gauge should be approx. 30%, max. 100% above the test value to be adjusted. Use only the test box with adapter - see Special Tools, page 2.1.30.01. - to check the electronic system and the straight-run of the machine. For instructions, see group 10.4.00. When adjusting the straight run, just as in actual application, the track tension must be the same on the left and right track - see Operation Manual. Caution: To check / adjust the straight-run, park the machine on firm and level ground, raise it and securely support the machine to allow the chains to turn freely. Secure the danger zone. Observe all safety guidelines as outlined in group 1.2.01. If the operators cab is raised, the test box may only be used outside the machine and its danger zone. It is not permitted for persons to be on or near the crawler during these tests. When putting the machine into service, proceed according to the instructions given in the Operation Manual. Check the right origin of the indicator lights. Perform all tests and adjustments with Diesel-RPM, as indicated in the adjustment checklist and with the machine at operating temperature. (for exceptions see remarks) Any problems or defects detected during tests must be fixed immediately or as soon as possible, depending on the severity and type of problem. For tests / adjustments, use the corresponding Adjustment Checklist, page 3.5.xx.xx. The sequence of checks corresponds to system requirements, the following instructions have been matched to those requirements as much as possible. The nominal adjustment values are noted on the checklist.

A. Tests with standard measuring devices - adjustments


1. Visual tests and maintenance Perform scheduled maintenance and inspection work before checking the system visually. For intermediate tests / adjustments, observe the following points. 1.1 Service items and filters Check the coolant and oil level in the Diesel engine, splitter box and hydraulic tank. Add oil as necessary. Check the air filter for contamination, damage, correct installation and correct type. Add fuel as necessary, drain water and sediments from tank and separator. If there is any reduction of power, clean the screen filter and replace the pre / fine filters. If component failure is suspected, open / check the hydraulic oil filter for the affected part. In case of temperature problems, check the hydraulic oil cooler and fan for contamination / damage. 1.2 Mechanical components Diesel engine - check engine shut off, RPM adjustment and potentiometer linkage for mounting, function and wear.

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

PR Litronic

Test and Adjustment


Datum Edition Date

01 04

Travel Hydraulic

Blatt Page Feuille

6.5.00.01

Travel joystick - check rubber boots / covers for damage and correct installation. Wire harnesses - check for damage, chafing and defective plug connections. Leakage - check system functions and for leaks, check hose routing. Mounting tightness - check all items, such as potentiometer, sensors, consoles, etc. for tightness and condition. 2. Location of fixed hydraulic pressure test points 2.1 Machines up to F/N xxx-5599 PR 712742 - Battery compartment SP ND LD (LS) HD LA Test center - test points PR 752 - engine compartment, right

- Replenishing system pressure- TH - Servo pressure (repl.) - WH - Load sensing pressure - WH - High pressure (attachment) - WH - Operating pressure / fan drive - TH (only PR 752)

(Test points listed below in PR 752 starting with 5072) M1L High pressure travel forward, left - TH M1R High pressure travel forward, right - TH M2L High pressure travel reverse, left - TH M2R High pressure travel reverse, right - TH BB Operating pos. of hose to brake - TH BS Towing position of hose to brake - TH Test point SD - on valve block in main frame - right (tilt operators cab) PR 712 u.722 PR 732 PR 752 Test point ST - only PR 742 up to F/N xxx-5233 filter block in main frame right (tilt operators cab)

Test points M1 / M2 PR 712742 up to F/N xxx-5233 on inside of support shaft (tilt operators cab) PR 752 F/N xxx-20015071 variable pumps on top/below (tilt operators cab) PR 752 F/N xxx-5072 engine compartment right (see point Test center)

Additional installation possibilities on blind flanges (see page 2.1.21) and support shaft flanges available.

PR 742B F/N xxx-5234 engine compartment right

2.2 Machines from F/N xxx-5600 2.2.1 Test points on the test centers PR 712742 - Battery compartment PR 712732 engine compartment left PR 742 - engine compartment right

PR 752 - engine compartment right LA SP ND LD (LS) HD M1L M1R M2L M2R BB BS - Operating pressure / fan drive - Replenishing system pressure - Servo pressure - Load sensing pressure - High pressure High pressure travel forward, left High pressure travel forward, right High pressure travel reverse, left High pressure travel reverse, right Operating pos. of hose to brake Towing position of hose to brake with test point "M" (not marked) - TH - TH - WH - WH - WH - TH - TH - TH - TH - TH - TH

2.2.2 Test point SD - oil pressure at cold start - on valve block in main frame - right (tilt operators cab) PR 712, PR722 PR 732 PR 742,PR 752

SD

3. Cold start valve - replenishing / cooling circuit To protect components, the back pressure in front of the oil cooler when the oil is cold must be limited. When the hydraulic oil is at operating temperature no by-pass to the oil cooler may occur. Normally, this test must be made only for troubleshooting, i.e. if replenishing pressure is too low, the operating temperature is too high in spite of a clean oil cooler, or if excessive pressure values are suspected.. Do not block the existing oil circuit (replenishing), not even for tests! Otherwise the pumps/motors could be damaged by lack of oil.

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

PR Litronic

Test and Adjustment


Datum Edition Date

01 04

Travel Hydraulic

Blatt Page Feuille

6.5.00.02

3.1 Inspection PR 712 to PR 732 and PR 752 Perform a function check in the corresponding temperature range. Maximum pressure = cold oil = below +20C, shut off function = oil at operating temperature = above +60C. If valve adjustment is changed in one temperature range, then - for safety reasons - the function in the other temperature range must be rechecked.

Valve installation position for PR 712 to PR 732 and PR 752 The distributor block with valve is mounted on the right hand side of the main frame, below the cab. For valve design / function, see group 8.7. PR 712, PR 722 PR 732 PR 752

3.1.1 Checking when oil is cold - Pmax - PR 712 to PR 732 Check on test point SD with a 0-40 bar pressure gauge. On older machines, test point ND is connected instead of SD and has to be checked. Check / monitor the oil temperature in the hydraulic tank with a remote thermometer. Start the Diesel engine, slowly increase the engine speed and watch the pressure gauge. Pressure should remain constant shortly before reaching high idle = maximum pressure, value to appr. 30 bar admissible. Correct the valve adjustment, as necessary. Remove the protective cap, loosen the locknut, turn the adjustment screw counterclockwise to lower the pressure adjustment, or clockwise to raise the pressure. Tighten the lock nut, reinstall the cap, recheck the pressure setting. Check the shut off function with the oil at operating temperature Note: Oil temperature increases rapidly when the engine is running and makes it impossible to perform subsequent checks for a long period of time. For that reason, turn the engine off after every pressure check and before readjustment. At PR 752, there is normally no test required - the oil cooler is not in this part of the system.

3.1.2 Checking with the oil at operating temperature - PR 712 to PR 732 and PR 752 Hold the temperature in the hydraulic tank constant above 60C (140 F). Check/monitor the oil temperature in the hydraulic tank with a thermometer. Unscrew the tank line of the valve unit and close off the line. Start the Diesel engine, slowly increase the engine speed to maximum RPM, while monitoring the oil flow from the open tank connection on the valve unit. Only a slight amount of leak oil may emerge. If the leakage is high, correct the valve adjustment: - Remove the cap, loosen the locknut. - Turn the adjustment screw counterclockwise until the pressure on SD drops significantly. - Turn the adjustment screw in clockwise direction until the pressure on SD no longer increases. - Continue to turn the adjustment screw by turn in clockwise direction. - Tighten the lock nut, reinstall the cap. - Check the maximum pressure when the oil is cold. (except PR 752). If the shut off function is not reached, check the valve for damage / replace valve.

3.2 Checking the PR 742 Increased backup pressure is released via a check valve, see schematics, group 6.3 and valve description in group 8.7. The distributor block with valve is installed up to F/N xxx-5233 on the right hand side of the main frame, below the variable pump and starting with F/N xxx-5234 underneath the battery box. PR 742 up to F/N xxx-5233

3.2.1 Check opening function Disconnect the valve from the line connection on the block side and push the valve piston several times against the spring with a tool (pretension is approx. 3 bar) to check valve movement. Reinstall the valve, if the piston did not move freely, clean or replace the valve. 3.2.2 Check closing function Check the oil temperature in the hydraulic tank with a thermometer. Disconnect the return line to the tank from the valve and plug the line. Start the Diesel engine and raise the engine speed slowly to maximum engine RPM while checking the oil flow from the open end of the valve. Only a slight amount of leak oil may emerge. If oil leakage is high, clean / replace the valve. PR 742B from F/N xxx-5234

4. Stand by pressure - fan drive - only PR 752 Check the pressure on test point LA (test panel on right side of engine compartment) with a 0-40 bar pressure gauge. Carry out the test before the machine reaches operating temperature in any range, see description of function on page 6.3.5x. Connect the pressure gauge and check the pressure. This pressure determines the required minimum RPM for the fan motors, see page 3.1.5x. If the pressure does not correspond to the nominal value, correct the adjustment on the LS regulator of the pump (fan drive pump is mounted to the right travel pump, see schematics, group 6.3). PR 752 up to F/N xxx-5599 - remove the cap on the LS regulator and install the cap after the adjustment Remove the cap on the LS regulator, loosen the locknut and turn the adjustment screw until the nominal value is reached. To increase pressure, turn the screw clockwise, to reduce pressure, turn the screw counterclockwise. After adjustment, tighten the locknut, install the cap and recheck the pressure. Check the fan speed, if necessary - use a photo tach with a reflector strip. Note: At machines PR 752 F/N xxx-5600 with electronic regulating, the stand by pressure is changing with the maximum pressure check always both pressures and if necessary correct the adjustments. from F/N xxx-5600 up to F/N xxx-5599

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

PR Litronic

Test and Adjustment


Datum Edition Date

01 04

Travel Hydraulic

Blatt Page Feuille

6.5.00.03

5. Pressure limitation - fan drive - PR 712B to PR 742B - from F/N xxx-5600 and PR 752 Check the pressure on test point LA (see group 2. - test center) with a 0-250 bar pressure gauge (PR 752 - with "waste handling arrangement" and reversible fans 0-500 bar).Diesel engine RPM to nmax. - see description 6.3. The available pressure dictates the maximum RPM of the motors/fans. Note: Any time the system overheats, despite the correct system pressure and a clean cooler / radiator, the fan RPM must be checked. The fan RPM is not only dictated by the pressure, but by pump flow, air supply, turning resistance, component failure) by other conditions as well. For pressure values see adjustment checklist page 3.5.xx, fan RPM see technical data in group 3.1.

5.1 PR 712B to PR 742B - from F/N xxx-5600 Remove the plug from one of the temperature sensors. Connect a pressure gauge. Read the pressure and compare it with the nominal pressure. If the nominal pressure is not correct, determine the reason. Troubleshooting: If there is a temperature problem due to insufficient pressure on LA, unplug the proportional pressure relief valve: If the pressure does not increase to the nominal value, check the strainer and the gear pump, replace the proportional pressure relief valve, if necessary. If the pressure increases to the nominal value, check wiring and sensors. If there is no defect, replace the electronic box. If the pressure (RPM) is already obtained when the machine is cold, without unplugging a sensor or the valve, check the wiring (power supply to E-Box and E-Box to valve) and the sensors (resistance). If there is no other defect, replace the electronic box. For test values for temperature sensors see point 5.4. Proportional pressure relief valves with screen filter (= long fitting) - installed in the main frame:

PR 732 - engine compartment right, middle

PR 712, PR 722 - cross traverse rear PR 742 - engine compartment right

Temperature sensors: - Diesel engine coolant


front of Diesel engine

- Hydraulic oil
PR 712, PR 722 - SP pump outlet

- Hydraulic oil
PR 732 - SP pump outlet

- Hydraulic oil
PR 742 - SP valve block

- Diesel engine charge air


PR 742 - air intake pipe

5.2 PR 752 up to F/N xxx-5599 Test when machine is at operating temperature! Test on test point LA (test panel on right side of engine compartment) with a 0-250 bar pressure gauge. The machine must be at operating temperature, Diesel engine RPM to nmax - see description 6.3. Connect the pressure gauge and check the pressure. This pressure determines the required maximum speed of the fan motors, see page 3.1.5x. If the pressure does not correspond to the nominal value, correct the pressure adjustment on the pressure cut-off valve for the pump (mounted to the right travel pump, see schematics group 6.3). 5.3 PR 752 from F/N xxx-5600 Test when machine is cold! To check / adjust, interrupt the power supply to the electronic control - open fuse (automatic circuit breaker)F9 - the fan drive runs at maximum values = adjustment / test values (fail save system). Connect a pressure gauge, read the pressure and compare it with the nominal value. If the pressure does not correspond to the nominal value, correct the adjustment on the proportional pressure cut-off valve for the pump (mounted to the right travel pump, see schematics group 6.3.5x.). Remove the cap on the pressure cut-off valve, loosen the locknut and turn the adjustment screw until the nominal value is reached. To increase pressure, turn clockwise, to decrease, turn counterclockwise. After adjustment, tighten the locknut, install the cap and recheck the pressure setting. If necessary, check the fan speed - see data page, paragraph 3.1 - using a photo tach with reflector strip. Note: The maximum pressure also changes with the standby pressure counter check and possible correction of adjustments is necessary. To check the standby pressure when the machine is warm, 3 "Blind sensors" are required, otherwise the test can only be made when the machine is cold. Procedure: Disconnect all 3 temperature sensor and connect 3 spare sensor on the wire harness. Make sure the 3 sensors do not touch anything hot, reset the fuse F9 and proceed with the test. Adjustment values:: (the stand by pressure is generally) Stand by pressure:: 305 bar fan RPM - main radiator front = >350 RPM, Pressure cut off = pmax bar fan RPM - main radiator front = n1,
Machine equipment = standard fans - standard F/N xxx-6199 F/N xxx-6200 fans - reversible F/N xxx-6199 F/N xxx-6200 217 bar 1380 min +100 -1 1990 min
+100 -1 +5

- oil cooler = 550 - oil cooler = n2

+200

RPM

Machine equipment = "waste kit" fans - standard 225 bar


-1 +5

fans - reversible 275 bar


+3

pmax
n1 n2

177

+5

bar
-1

205 bar
1530 min +100 -1 2200 min
+100 -1

255 bar 1520 min +100 -1 2180 min


+100

+5

1380 min +100 -1 1990 min

+100

1580 min +100 -1 2280 min

+100

-1

1560 min +100 -1 2240 min

+100

-1

Note regarding function of indicator light H7 on the instrument panel: The indicator light lights up - during the starting procedure in case of temperature sensor failure in case of line interruption (for example broken wire, loose plug) in case of insufficient power supply to the electronic box The indicator light blinks if the temperature of the liquids is too high

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

PR Litronic

Test and Adjustment


Datum Edition Date

01 04

Travel Hydraulic

Blatt Page Feuille

6.5.00.04

Temperature sensors: - Diesel engine coolant


- front of Diesel engine

- Hydraulic oil
- SP valve block

- Diesel engine charge air


- air intake pipe

5.4 Test values for temperature sensors - resistance in Ohm: Sensor for coolant and hydraulic oil ID.No. 6290 186 and ID.No. 10 043 264 PR 712 PR 742 Temp. C 50 60 70 80 90 100 110 Ohm 1300 1350 1420 1480 1560 1620 1680 Sensor for charge air Id.No. 5802 148 PR 712 PR 742 Temp. C 0 10 20 30 40 50 60 70 80 90 Ohm 900 950 1000 1050 1100 1150 1200 1250 1310 1360 Sensor for coolant and hydraulic oil ID.No. 7414 002 and charge air Id.No. 7414 003 PR 752 Temp. C 0 10 20 30 40 50 60 70 80 90 Ohm 1640 1778 1924 2078 2239 2408 2584 2767 2959 3157

6. Operating temperature Check the oil temperature in the hydraulic tank with remote mounted thermometer, see special tools, group 2.1.20. With an external thermometer, test the temperature on several points of the tank surface and determine the average value. The pressure values in a hydraulic system may change due to oil viscosity. Viscosity, however, always changes depending on oil temperature. For that reason, always maintain a constant operating temperature, and monitor the temperature during the entire inspection and adjustment procedure. If necessary, the warm up procedure must be repeated or the oil cooler must be partially covered during inspection and adjustment procedures. The operating temperature can be reached in various ways: a. b. Move the machine into appropriate work application. Actuate the ripper or blade tilt" function all the way and slowly extend and retract the lift cylinders in fine control range, pressure at HD should be at 105 bar. The oil is warmed up via the restrictions of the spool valves. "Lower" the ripper and blade lift cylinder function all the way. The oil is heated via the lift cylinder piston check valves. Warm up the oil" in intervals of approx. 5 minutes, with a 1 minute break between intervals. The travel drive should also be actuated to full speed at the same time, continuously, provided the machine is raised off the ground and is properly supported. Caution: Do not actuate the blade quick drop function.

c.

d.

Fully actuate the "lift" and "blade tilt" function. The oil is heated by flowing via the check valves in the lift cylinder pistons. Warm up the oil" in intervals of approx. 5 minutes, with a 1 minute break between intervals. Set the adjustment value of the pressure cut-off valve on the working hydraulic pump to max. 5 bar above the adjustment value (nominal value) of the primary pressure relief valve and actuate the ripper or blade tilt" function all the way. Fully actuate in intervals of approx. 1 minute, return to neutral position for approx. 20 seconds, otherwise the relief valve can be damaged due to overheating. On PR 752 machines, actuate the function Engine overspeed safety" with the test box, see group 10.4. Actuate in intervals of approx. 1 minute, with a 20 second break between intervals, otherwise the relief valve can be damaged due to overheating.

e.

f.

For procedures b, c, d, e and f, the travel drive (track chain) must be also actuated repeatedly during and after the warm-up procedure to ensure that the entire hydraulic system warms up evenly. For this procedure, the machine must be raised off the ground or driven. 7. Replenishing pressure Check the pressure on test point SP (test panel in battery box or, on the PR 752, on the right side of the engine compartment), using a 0-40 bar pressure gauge. While testing, vary the Diesel engine RPM slowly between appr. 1000 RPM and high idle RPM and observe the replenishing pressure. It should change only slightly. If the nominal value is not reached, or if the pressure drops sharply when engine speed is reduced, find / eliminate the problem before continuing to operate the machine. Failure to do so can result in complete failure of travel pumps / motors. The pressure relief valves are preset by the manufacturer. For design/function of valves, see group 8.7. Pressure loss can be caused, for example, by a defective relief valve, see also par. 3, by gear pump wear or by excessive leakage in the variable flow pumps or motors. On older PR 712, PR 722 and PR 732 models, the pressure limitation was handled by a relief valve in the travel pumps. See function / schematics in group 6.3 or variable flow pump, group 8.1. On all other models, the relief valve (PR 742B F/N xxx-5234 and PR 752 = 2pcs.) is mounted in a distributor block on the inside of the main frame, on the right hand side next to the variable pumps. PR 742 up to F/N xxx-5233 PR 742B from F/N xxx-5234

PR 712, PR 722, PR 732

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

PR Litronic

Test and Adjustment


Datum Edition Date

01 04

Travel Hydraulic

Blatt Page Feuille

6.5.00.05

PR 752

8. Control pressure - only PR 742 up to F/N xxx-5233 Check the pressure with a 0-100 bar pressure gauge on test point ST (on the filter bracket in the main frame, on the right hand side) The existing pressure results from the SP pressure acting on the spring side of the valve and from the spring setting, which is preset by the manufacturer, see schematic, group 6.3. The valve is mounted into the valve block, just as the relief valve for SP pressure, on the right side of the main frame, below the variable pump. For valve design / function, see group 8.7.

9. Hydraulic neutral position of the variable pumps Check on test points M1 and M2. Safety lever and joystick must remain in the park position during this test. After starting the Diesel engine, the variable pumps are held hydraulically in the neutral position, which means they may not produce any oil flow. To check the hydraulic neutral position, check the pressure build-up in the closed circuits = test points M1 and M2 on the right and left support shaft, at PR 742B F/N xxx-5234 at the test center, on PR 752 directly on the travel pumps - see schematics in group 6.3. The pressure value (approximately SP pressure) on M1 and M2 must be the same on both sides. Tolerance max 1 bar. 9.1 Pre-check and basic adjustment After repairs to pumps and when in doubt, recheck the neutral position with a 0-600 bar pressure gauge. On PR 712, PR 722, PR 732 and PR 752 machine, also check the position of the mark () on the eccentric pin on the pump cover, which must point towards the proportional solenoids. If necessary, turn the eccentric pin to the correct position, with the Diesel engine shut off. Connect the pressure gauges to test point M1 and M2 on the right and then on the left hydrostatic drive, turn over the Diesel engine with the starter or start briefly and check the increase in pressure. Caution: Chains may already be turning. Adjust the neutral position - see point 9.3 - as necessary, until all four test points show approximately the same pressure. 9.2 Test Connect a 0-40 (0-60) bar pressure gauge one after the other to test points M1 and M2 on both support shafts. Start the Diesel engine, check the pressure values and compare for each side M1 with M2. Adjust the neutral position, if necessary, until nominal values are obtained.

9.3 Adjustment procedure Connect one 0-40 (0-60) bar pressure gauge each to test points M1 and M2 of the pump to be adjusted. Change the adjustment to slightly decrease the higher pressure and to increase the lower pressure on the opposite side. Check also the reference dimension at PR 742B F/N xxx-5234, see Point 9.3.2.2. Caution: Chains may already be turning. Adjust until the same pressure is shown on both sides, tighten lock nut and recheck with one pressure gauge.

9.3.1 Additional instructions for PR 712, PR 722, PR 732, PR 752 Hold the eccentric pin1 with an Allen wrench, loosen the locknut 2. Watch the pressure gauge and turn the eccentric pin carefully until the required adjustment is completed and the neutral position of the pump is reached. Hold the eccentric pin and tighten the locknut. Check the pressures again.

9.3.2 Additional instructions for PR 742 9.3.2.1. up to F/N xxx-5233 Remove the plug 65 and loosen the clamp screw 67. Watch the pressure gauge and turn the valve sleeve stop 66 with a suitable screwdriver until the required adjustment is completed and the neutral position of the pump is reached. Tighten the clamp screw. Recheck the pressures and reinstall the plug. 9.3.2.2. from F/N xxx-5234 Check distance A from valve housing C front face to the control housing (clean areas from varnish coat before measuring) Nominal value = 14,75 mm. If adjustment is not correct, loosen locknut B with special tool - see page 2.1.20.01 - and turn valve housing C with a socket wrench until the reference dimension is reached. Hold the valve housing and tighten the locknut. Check pressures at M1/M2. If a further adjustment necessary, loosen locknut again, watch the pressure gauge and turn the valve housing until the required adjustment is completed and the neutral position of the pump is reached. Hold the valve housing and tighten the locknut. Recheck the pressures.

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

PR Litronic

Test and Adjustment


Datum Edition Date

01 04

Travel Hydraulic

Blatt Page Feuille

6.5.00.06

10.Pressure limitation - maximum operating pressure of the closed circuits Check pressures on test points M1 and M2 with a 0-600 bar pressure gauge. This test is only needed when troubleshooting, for example in case of undesired steering movements under load, insufficient power or excessive loss of replenishing pressure. A precheck of the existing high pressure should be performed in every application where the problem occurs. Check the high and low pressure on both circuits at the same time as a comparison. At machines without test center - before starting the test, match the components to the test points. They depend on the type of travel gear (see also group 6.3 and 11.3): For PR 712 to PR 742 from the start of production and with travel gear Type C - travel forward - travel backward For PR712 to PR742 after change in series / with travel gear Type P/D and PR 752 , from start of series production - travel forward - travel backward - M1 - located on top - M2 - located below - M1 - located below - M2 - located on top

The position of the high pressure hoses to the pumps and travel motors corresponds to the location of the test points. For this test, close off the high pressure lines. See par. 10.1 resp. 10.2 Test preparation. Install pressure gauges on the left and right on test point M1 to check travel forward" or M2 to check travel reverse". Start the Diesel engine and run at approx. 1400 RPM. Slowly deflect the travel joystick to travel forward" or travel reverse" until the pressure reading on the pressure gauge remains constant. Leave the travel joystick in this position for a short period and reduce the engine speed gradually to approx. 1000 RPM. The pressure reading on the gauge should remain constant or decrease slightly. Caution: For safety reasons, carry out this test at the lowest possible oil flow = slightest possible joystick deflection. Hold the highest pressure for no longer than 5 to 10 seconds.

If the nominal value was not reached on one or several points, find and eliminate the cause. Possible causes are loose or damaged relief valves, damaged cylinder barrels or control plates, defective servo piston seal (pressure increases when RPM decreases) or general wear. If nominal values were reached during this test, but they were not reached during the prechecks in working application, then the problem is located in the travel motor. For example, it could be caused by a damaged cylinder barrel or control plate, a defective directional valve for the flushing function. Find and eliminate the cause. After completing the test, reinstall all components with new seals. For tightening torques, see page 1.4.02. Bleed the hydraulic circuits. Test run the travel circuit. 10.1 Test preparation - block HP lines - PR 712 to PR 742 Remove gear cover on both sides, clean the support shaft area as necessary. Disconnect the wire harnesses, loosen and unscrew grommets on support shaft flanges. Remove silicon from mounting grooves and remove harness from flange passage. Remove flange mounting screws, lift the flange from the support shafts. Close the ports on the flanges with plastic plugs. Install special test flanges - see special tools page 2.1.21.01 - on the support shafts and tighten with corresponding screws. Reconnect the wiring harnesses.

Important: Water or dirt in oil ports and cable connections can cause pump and motor damage or electrical malfunctions. Do not damage the wiring harnesses. Check the special flanges and their O-rings before installation. Install test fittings or blind plugs. After the test, remove the flanges and pressure gauges. Replace the seals on the support shaft flange. Reinstall the flange. Insert the wiring harnesses properly, install the grommets, cover the mounting groove with silicon.

10.2 Test preparation - block HP lines - PR 752 Prepare blind plates B (4 or 8 pieces required) - see special tools page 2.1.21.01 - and hex head screws M12 x 50 - 10.9, ID No. 4600 724 (16 or 32 pieces required) for installation. The blind plates are installed with the SAE flanges of the HP lines to the travel motors. The mounting area is accessible via the rear cover plate, the bottom maintenance cover and, if necessary, by tilting the cab. Caution: Do not block the oil flow at the pump outlets with the blind plates, because there is no O-ring seal at the pump side. There is danger of serious injury due to hot oil blowing out.

To install, loosen the SAE flange screws and push in the blind plates. Replace the original screws individually with the longer screws mentioned above and tighten. Caution: Check the blind plates before installation for damage. Do not damage or push out the seal rings during installation. Protect the lines and ports from water or contamination, this could damage the pumps and motors. To remove the plates, replace one by one the screws on the SAE flanges again with the original screws and tighten them just to the point where the seal ring touches. Pull out the plate and torque the screws in sequence. For torque values, see page 1.4.02. Notes: For this test, all 8 HP line connections should be closed off. This makes it possible to check all four areas of the system in one test procedure. If this is not possible, close off at least all 4 line connections for one drive direction. To check the other direction, change over the blind plates to the other connections. It is not permitted to check both travel directions with the plates installed in the same position. The pressure which occurs on both sides of the travel motors could damage the motors. In addition, there is no O-ring seal on the motor. This could cause serious injury due to oil blowing out. For safety reasons, it is not permitted to block only one travel drive (the track chain on the opposite side could start to turn). Notes for troubleshooting: Even for troubleshooting, it is not permitted to disconnect just one travel motor of one travel drive from the high pressure circuit. If only one motor is driven per side, it may be damaged due to overload. If a high pressure oil loss is discovered in the area of the motors, a comparison of the pressure in each housing can show in which of the two motors the problem occurred. The comparison test must be made at the same time when the high pressure loss occurs.

B. Track chain run - test with test box CET 08/03 H - adjustments
1. Preparations Before performing any of the tests, all the points outlined in section A as well as the tests and preparations outlined in test box use", group 10.4 and other adjustment guidelines in test sections A and B must have been performed up to/ including track chain run - RPM sensor". 2. Type of test / adjustment The extent and procedure for testing and adjustment can be selected based on the problem. The actual adjustment procedure for the individual components is independent of the problems and is always performed in the same manner.
Benennung Description Dnomination Typ/ab Type/from Type/ a partir de

Mjfcifss!

PR Litronic

Test and Adjustment


Datum Edition Date

01 04

Travel Hydraulic

Blatt Page Feuille

6.5.00.07

2.1 Checking straight run - minor corrections In this test, the check the speed of the right travel drive is compared to the speed of the left travel drive. For test instructions, see test box use" group 10.4, paragraph Checking straight run of tracks. Test steps according to paragraph in adjustment guidelines Straight run - right track to left track". If minor corrections/adjustments are made without checking the "basic adjustment / left track", always match the faster track to the slower one. On PR 752 machines, the hydraulic motor control must be disconnected when testing the end of pump regulation. See par. B2.3 2.2 Check / adjustment of speed and straight run = base adjustment Step 1 = Speed - The speed of the left track in relation to the nominal values in the test box is measured / adjusted. - For test instructions, see test box use" group 10.4, paragraph Base adjustment - left track speed. - Test steps according to the checklist in paragraph Basic adjustment - left track

Step 2 = Straight run - The speed of right track in relation to the speed of left track is measured / adjusted = matching to nominal speed. - For test instructions, see test box use" group 10.4, paragraph Checking track straight run. - Test steps according to the checklist in paragraph Straight run - right track to left track.

Notes: - Speed stages 1 and 5 as well as stage 4 in reverse are only used to double check the adjustment since they are results from adjusting stages 2, 3 and 4 forward. Exception: stage 5 forward on model PR 752 - see par. B-5. - If stop screws are installed in the spring housings of the pump covers they must be used for the adjustment. Additional eccentric pins in the pump cover have been added by the manufacturer as safety stops and may not be adjusted. If the spring housing is changed (regulating range adjustment), the end stop must also be readjusted. If only eccentric pins and spring housings without stop screws are installed, the regulating range and end stop can be adjusted independent of one another. - For travel pumps, type HPV 130 = PR 742 up to F/N xxx-5233, the regulating range must be readjusted after the end stop is adjusted. For that reason, check / adjust speed stage 3 before speed stage 2. - Pump control / adjustment of travel pumps depends on the type of travel gear installed. See previous point A-10 Maximum working pressure" and the following illustrations in par. 4. - For adjustments on the pumps, the operators cab must be raised, and for travel motor adjustments on machine models PR 712 to PR 742, the gear cover must be removed. For travel motor adjustments on model PR 752, remove rear cover plate. Observe all safety recommendations.

2.2.1 Additional preparations for machine models PR 752 The travel motors (2 per side) on the PR 752 are controlled hydraulically from the pump remote control and start regulating shortly before the end of pump regulation. For function / schematics, see group 6.3. Because of this overlap, the servo control of hydraulic motors must be disconnected when testing / adjusting the end of pump regulation. Because internal leakage can cause a build-up in pressure and, as a result, change the motor adjustment, servo lines must be connected to tank" and may not be closed off. Test / adjustment of pumps - travel speed and straight run: Remove the servo line to the hydraulic motors on pump port X and connect to free housing port J. Close off connection X with the plug Perform tests / adjustments as outlined in checklist section disconnected servo lines". Reinstall parts after adjustment.

Test / adjustment of hydraulic motors - travel speed and straight run: The four displacement motors must be tested / adjusted individually during the basic adjustment. Therefore it is a need, to have on each side only one variable motor connected to the servo line before you start with the next tests/adjustments. In travel direction forward the two motors in front are on the end of the servo line. Remove the plug from connection Y at the remote controls of this motors and install fittings as listed below (drawing shows left hand front motor, seen from the rear side of the machine = cover at the main frame). Disconnect the servo lines "motor to motor" from the rear motors connection X and connect the lines with the fittings at connection Y on the front motors. Close fittings at the rear motors with stopper and union nut. Required parts: 1 2 3 4 5 2 x IdNo. 4900 038 2 x IdNo. 4774 001 2 x IdNo. 7403 569 2 x IdNo. 7404 259 2 x IdNo. 7410 458 Stopper Union nut Elbow fitting Reducer fitting Fitting

At the front motors connection X is now open to "tank", the rear motors are still connected to the servo lines. Carry out tests/adjustments referring to the checklist step "servo lines connected to one motor on each side", If necessary, adjust the rear motors. Note: The base adjustment (speed) for the left motor must be set to the line between the red and green field on the SLOW" side of the straight run indicator on the test box, the straight run of the right motor is as usual adjusted to the center of the green section. See test box use", group 10.4.

Reinstall the servo lines and close off connections Y.


Benennung Description Dnomination Typ/ab Type/from Type/ a partir de

Mjfcifss!

PR Litronic

Test and Adjustment


Datum Edition Date

01 04

Travel Hydraulic

Blatt Page Feuille

6.5.00.08

Carry out tests/adjustments referring to the checklist step "servo lines connected to all travel motors". If necessary, adjust the front motors. Note: The additional Qmin - limit screw (minimum angle) has been preset by the manufacturer to a nominal value and may not be readjusted. The Qmin - screw serves as a safety stop and is normally not reached since the maximum speed limitation is regulated via the electronic control. When replacing / readjusting a variable motor, note point 5 - adjustment of variable motors mechanical Qmin -stop - PR752. 3. Adjustments For simplified illustration of parts as well as component related sequence of test/adjustment steps, see par. 4. For more precise design details, see sectional views in group 8.1 and 8. Note: - If the test result for an existing adjustment is shown in red area on the test box, change the adjustment first past the green range until it is in the other red area. Then reset the adjustment to the required green area. Exception: PR 752 - stage 4 and 5. - Adjustments to reach the green area may only be made when the chain is at a standstill. - Recheck the adjustments to ensure the indicated value several times within a certain time frame approx. 20 seconds. Between the test runs, actuate the travel in different speeds / directions. 3.1 Adjustments on variable pumps type BPV and "HPV 135" - PR 712, PR 722, PR 732, PR 742B F/N xxx-5234, PR 752 See also Notes under par. 2.2. 3.1.1 Regulating range (begin of regulation) = test box test forward stage 2" / reverse stage 2" Begin of regulation and flow in the regulating range depend on the regulating spring adjustment and for that reason, they cannot be adjusted separately. Loosen the nut, turn the spring housing - clockwise - counterclockwise to slow down the track speed to increase the track speed.

Tighten the nut, perform a test run. Repeat the procedure until the required adjustment is obtained. If installed, loosen the lock nut and turn the adjustment screw - end of pump regulation by the same amount as the spring housing, but in the opposite direction. Tighten the lock nut. Proceed to the next test position for the required fine adjustment. 3.1.2 End stop (maximum pump angle) = test box test forward stage 3" / reverse stage 3" Version adjustment pin in spring housing Loosen the lock nut, turn adjustment screw - clockwise - counterclockwise to slow down the track speed to increase the track speed

Tighten the nut, perform a test run. Repeat the procedure until the required adjustment is obtained. Version eccentric pin in pump cover Remove the plug, loosen the lock nut on the eccentric pin. For special tools, see sub group 2.1.20. Note: The necessary turning direction for the adjustment cannot be determined beforehand. It must be determined after the first adjustment via a test run.

Move the eccentric pin slightly in one direction and lock it in this position with the lock nut. Perform a test run. Repeat the procedure in the necessary turning direction until the required adjustment is obtained.

3.2 Adjustments on variable pumps type HPV 130 - PR 742 up to F/N xxx-5233 See also Notes under par. 2.2. 3.2.1 End stop (maximum pump angle) = test box test forward stage 3" / reverse stage 3" Loosen the lock nut, turn the spring housing - clockwise - counterclockwise to slow down the track speed to increase the track speed

Tighten the nut, perform a test run. Repeat the process until the required adjustment is obtained. Loosen the lock nut on adjustment screw, turn the screw the same amount as the spring housing but in the opposite direction. Tighten the nut. For the required fine adjustment, proceed to the next step = regulating range pumps. 3.2.2 Regulating range (begin of regulation) = test box test forward stage 2" / reverse stage 2" Begin of regulation and the flow in the regulating range depend on the regulating spring adjustment and for that reason, are not adjusted separately. Loosen the lock nut, turn the adjustment screw - clockwise - counterclockwise to slow down the track speed to increase the track speed

Tighten the nut, perform a test run. Repeat the procedure until the required adjustment is obtained. 3.3 Adjustment of variable motors regulating range (begin of regulation) = test box test forward stage 4" See also Notes" in par. 2.2 as well as par. 2.2.1 Preparations for machine models PR 752. Begin of regulation and the flow consumption in the regulating range depend on the regulating spring adjustment and for that reason, are not adjusted separately. The adjustment procedure is the same for all variable motor models "BMV". Loosen the lock nut, turn the adjustment screw - counterclockwise - clockwise to slow down the track speed to increase the track speed

Tighten the nut, perform a test run. Repeat the procedure until the required adjustment is obtained. Note: The Qmax limit screw (maximum motor angle) on the variable motors has been adjusted to a nominal value by the manufacturer and may not be readjusted. The Qmax screw determines oil consumption and torque transfer in the low speed range.

4. Sequence and location of adjustments The sequence of adjustments is given in steps 1 to 5 (6) and is valid for both base adjustment left track" = speed and straight run adjustment" =matching right track to left track. The sections are set up according to the type of travel gear installed (see group 11) and the type of end stops of the pumps. See also Notes" in par. 2.2 as well as par. 2.2.1 Preparations" for machine models PR 752. Parts are illustrated in simplified form; for more details refer to sectional views in group 8.1 and 8.2.

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

PR Litronic

Test and Adjustment


Datum Edition Date

01 04

Travel Hydraulic

Blatt Page Feuille

6.5.00.09

4.1 PR 712, PR 722, PR 732 - travel gear type C (A) Pump type BPV adjustment screw in spring housing eccentric pins in pump cover

Key to 4.1

c = test box - forward stage 2 = regulating range pump e = test box - reverse stage 2 = regulating range pump d = test box - forward stage 3 = end of pump regulation f = test box - reverse stage 3 = end of pump regulat. g = test box - forward stage 4 = regulating range motor
4.2 PR 712, PR 722, PR 732, PR 742B F/N xxx-5234, PR 752 - travel gear type P / type D and similar Pump type BPV adjustment screw in spring housing eccentric pins in pump cover

PR 752

d c
Key to 4.2

PR 742

f 3

c = test box - forward stage 2 = regulating range pump g = test box - forward stage 4 = regulating range motor d = test box - forward stage 3 = end of pump regulation f = test box - reverse stage 3 = end of pump regulation
(PR 752 - one hydraulic motor right/left)

e = test box - reverse stage 2 = regulating range pump h = test box - forward stage 4 = regulating range motor
(PR 752 - second hydraulic motor right/left)

4.3 PR 742 up to F/N xxx-5233 - pump type HPV 130 Travel gear type C (A) type P / type D

Key to 4.3

c = test box - forward stage 3 = end of pump regulation e = test box - reverse stage 3 = end of pump regulat. d = test box - forward stage 2 = regulating range pump f = test box - reverse stage 2 = regulating range pu. g = test box - forward stage 4 = regulating range motor

5. Adjustment of variable motors - mechanical Qmin -stop - PR 752 Note: When replacing a variable motor, the adjustment of the Qmin stop screw (=protrusion) on the new motor must be compared to the adjustment on the old, original motor. If necessary, change the adjustment on the new motor before installation. The protrusion should be about the same for all 4 motors. Servo lines to variable motors are connected normally. Check adjustments according to the adjustment checklist with the test box in speed stage 5 - forward. Note: The correct basic adjustment (speed) for the left motors and the straight run for the right motors is shown on the test box in the " green" area, as usual.

Adjustment procedure: If an adjustment must be made, determine the protrusion of the adjustment screw on both variable motors for the side to be adjusted. Chain too fast Chain too slow on the variable motor with the larger screw protrusion: loosen the lock nut, turn the, adjustment screw in clockwise direction. on the variable motor with the smaller screw protrusion: loosen the lock nut, turn the, adjustment screw in counterclockwise direction. Turn the adjustment screw only slightly. Do not change the adjustment past the green range on the straight run indicator into the red "FAST" area.

Note:

Tighten the lock nut, run through a test run. Repeat the procedure until the required adjustment is reached.

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

PR Litronic

Test and Adjustment


Datum Edition Date

01 04

Travel Hydraulic

Blatt Page Feuille

6.5.00.10

6. Actuate the parking brake - bleed system and check pressure setting - PR 712PR752 F/N xxx-5600 Perform only if necessary - but always after repairs on the system. For schematic, see group 6.3. 6.1 Operating system - bleed pressure line to brake PR 712PR742 - Loosen the fitting on the brake line on the left and right support shaft flange. PR 752 - Loosen the hose connection to the brake on the right rear and the left front. If possible, place a container underneath to catch the oil. . Connect the test box and prepare to check the "solenoid valve - brake" - see group 10.4, point 3.6. Start the machine as outlined in group 10.4 , press the switch "BRAKE RELEASE" on the test box until oil free of air bubbles emerges on the fittings. Turn the machine off. Remove the test box. Tighten the fittings and clean the machine (oil). 6.2 Actuate the brake to bleed the system for towing Connect a test hose on test point "M" at test console / hose connection "BS" and place hose into a suitable container. Test console, see point 2. Bring starter switch S1, safety lever and the emergency shut off switch into operating position - solenoid valve / towing shifts. Do not start the engine! Move the hand pump of the cab tilt device to "Lift". Actuate the pump until oil free of air bubbles emerges on connection "BS" / test hose. Note: After changing a hose, it may be necessary to actuate the hand pump 30 times. Bring the starter switch S1 and the safety lever to neutral position. 6.3 Check the system for towing and the pressure setting As outlined in the operating manual, the hose from "BB" to "BS" and close off "BB" . Install a 0-60 bar pressure gauge on test connection "M" at "BS". Bring the starter switch S1 and safety lever into operating position - solenoid valve -( towing) is actuated. Watch the pressure gauge and actuate the hand pump for the cab tilt device in position "Lift" until the pressure relief valve opens and the pressure remains constant. Nominal value 35+3 bar. Under no circumstances may it exceed 40 bar - danger of damage to the brake piston seal. If the pressure relief valve does not open in the required range, correct the adjustment. Move the safety lever to the down position or press the emergency shut off switch. The solenoid valve (towing) moves to the neutral position, the indicator light - brake release H4, which was turned off before, lights up again on the instrument panel. Bring the safety lever and the emergency shut off switch again into the operating position. The solenoid valve is actuated, the brake is released by the accumulated pressure in the accumulator. The indicator light - brake release H4 must turn off. If the indicator light H4 does not turn off, the whole process and system check must be repeated. If necessary, check the charge pressure in the accumulator. Move the starter switch S1 to 0 and the safety lever to the down position. Move the lever on the hand pump for the cab tilt to the "down" position. Remove the pressure gauge, reposition the hose from "BS" to "BB" and close off "BS" with plug and nut. Clean the area, as necessary. Pressure relief valve: (tilt cab) on PR 712PR742 in main frame - right on PR 752 in main frame - left

Sub Group Index


Technical data Description Function
PR 712 PR 722 PR 732 PR 712 PR 722 F/N xxx-01030384 F/N xxx-01030563 F/N xxx-20032500 F/N xxx-03850500 F/N xxx-05641000

7.1 7.2 7.3


7.3.10

7.3.11

PR 712B F/N xxx-0501 PR 722B F/N xxx-1001 PR 732B F/N xxx-25012627 PR 732B F/N xxx-2628 PR 742B F/N xxx-2501 PR 742 PR 752 PR 752 PR 752 F/N xxx-20012500 F/N xxx-20022062 F/N xxx-20636199 F/N xxx-6200

7.3.12

7.3.30

7.3.40 7.3.50 7.3.51 7.3.52

Hydraulic hose routing


Hydraulic hose routing PR 712 F/N xxx-01030384 PR 722 F/N xxx-01030563 PR 732 PR 742 F/N xxx-20032500 F/N xxx-20012500

7.4
7.4.10

7.4.30 7.4.40

Test and adjustment

7.5

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!
Datum Edition Date

PR Litronic

01 03

Working hydraulic

Blatt Page Feuille

7.0.00.01

Description Servo control pressure ND bar

PR 712(B) 18+7

PR 722(B) 18+7 0103 A10V071 156 20+1 1605 2-5

PR 732(B) 18+7

PR 742(B) 253

PR 752 25+7

Regulating pump F/N xxx-fromto 0103 type A10V045 oil flow l/min 112 stand-by pressure bar 20+1 pressure different p HD-LS bar pressure cut-off bar 1605 flushing flow l/min 2-5 Regulating pump type oil flow stand-by pressure pressure cut-off flushing flow Control valve type spool - regulating range spool - stroke primary pressure max. secondary pressure max. Control valve type 00 spool - regulating range spool - stroke - lift spool - stroke - tilt primary pressure max. secondary pressure max. Control valve type 10 Control valve type 10 spool - regulating range spool - stroke - lift spool - stroke - tilt primary pressure max. secondary pressure max. Accumulator - nitrogen pressure F/N xxx-fromto l/min bar bar l/min

20032627 20012500 2002 A10V100 HPR 130 HPR 160 209 272 336 +1 +5 20 30 30+5 +6 14 15+6 1605 1605 2005 2-5 2-5 2-5 2628 A10V100 209 25+1 1605 2-5 2500 A10V140 292 25+1 1605 2-5 --

F/N xxx-fromto 01030384 01030563 20032500 20012500 M5-1072/20 M5-1073/20 M5-1082/20 M5-1085/25 bar 5,2 - 15 5,2 - 15 5,2 - 15 5,3 - 15 mm 11 11 11 14 bar 1905 1905 1905 1905 bar 2105 2105 2105 2105

F/N xxx-fromto 03853084 05643175 25013206 25013095 20022077 M7-3001/22 M7-3001/22 M7-3004/22 M7-3004/22 M7-3022/22 bar 5 - 14 5 - 14 5 - 14 5 - 14 4,5 - 22 short cap A - mm 9 9 9 9 11 long cap B - mm 11 11 11 11 short cap A - mm 11 11 11 11 11 long cap B - mm 9 9 9 9 bar 2205 2205 2205 2205 2705 5 5 5 5 bar 210 210 210 210 2505 F/N xxx-fromto 3085 3176 3207 30966199 20786199 M7-3001/22 M7-3001/22 M7-3004/22 M7-3004/22 M7-3022/22 F/N xxx-fromto bar cap A - mm cap B - mm cap A - mm cap B - mm bar bar bar 5 - 14 9 11 11 9 2205 2105 12 5 - 14 9 11 11 9 2205 2105 12 5 - 14 9 11 11 9 2205 2105 12 6200 6200 M6-1149/22 M6-1149/22 5 - 14 4,5 - 22 9 11 11 11 11 9 2205 2705 5 210 2505 12 12

Note:

Certain equipments, such as winches and special attachments may require different pressure values.
Benennung Description Dnomination Typ/ab Type/from Type/ a partir de

Mjfcifss!

PR Litronic

Technical data
Datum Edition Date

01 03

Working hydraulic

Blatt Page Feuille

7.1.00.01

Cycle times (in seconds): Raise / lower from level ground to maximum height Description F/N xxx-fromto Straightblade raise lower quick drop tilt raise lower quick drop tilt angle function sec. sec. sec. sec. sec. sec. sec. sec. sec. PR 712 (B) 103384 3,8 5,2 2,0 0,8 2,8 3,8 1,2 0,9 2,6 PR 722(B) PR 732 (B) PR 742 (B) 103563 2,6 3,6 1,7 0,8 2,2 3,0 1,3 1,0 2,7 564 20032500 20012500 3,0 3,9 1,5 1,0 3,4 3,8 1,8 1,3 3,2 2501 3,2 2,2 1,4 1,0 1,9 1,2 1,0 0,9 2,5 3,0 3,7 1,9 1,7 -----2501 2,8 2,1 1,4 1,6 --------------2002 3,3 3,0 1,4 1,6 -----PR 752

6-way blade

F/N xxx-fromto 385 Straightblade


(PR 752 Semi-U blade)

raise lower quick drop tilt raise lower quick drop tilt angle function

sec. sec. sec. sec. sec. sec. sec. sec. sec.

3,3 2,7 1,7 0,7

6-way blade

Permissible leakage limits Measure on lift cylinder piston rods Bring machine to operating temperature Raise attachments to maximum lifting height

Description Blade attachment Ripper 1-tooth 3-tooth mm / 10 min mm / 10 min mm / 10 min

PR 712 (B) 25 -15

PR 722(B) PR 732 (B) PR 742 (B) 25 -15 20 15 12 18 10 10

PR 752 15 8 8

Notes

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Parts list
Datum Edition Date

PR 732B F/N xxx-2628 PR 742B F/N xxx-2501


Blatt Page Feuille

01 03

Working hydraulic

7.3.30.00

53 check valve 54 accumulator

60 test center - test points ND servo pressure - working hydraulic LD load sensing pressure HP high pressure - working hydraulic

80 hydraulic tank 81 shut off valve 82 return filter 83 bypass valve 85 strainer

130 control valve block cpl. 131 pressure relief valve - primary safety 140 spool - lift / lower 141 check valve 142 pressure relief valve - secondary safety lift cylinder bottom side 145 spool - tilt 146 check valve 148 two way check valve 155 end plate 162 check valve

170 lift cylinder 171 check valves - piston 172 block

92 from TH. - gear pump - replenishing (TH. - see chapter 6.3) 95 to / from hand pump 96 to TH. - gear pump - replenishing 97 from TH. - return line

173 block 175 tilt cylinder

100 regulating pump cpl. 101 axial piston unit 102 control cylinder (Qmin) 103 return cylinder (Qmax) 105 pressure cut off valve 106 pilot piston 107 restrictor 109 load sensing regulator 110 pilot piston 111 case drain filter 112 stand-by valve 113 valve piston 114 restrictor 115 pilot (servo) control valve 116 regulating piston - lower 117 regulating piston - lift 118 regulating piston - tilt left 119 regulating piston - tilt right

B11 pressure switch - quick drop (= B22 at PR 742B starting with F /N xxx-5600) B22 pressure switch - return filter monitor (= B18 at PR 742B starting with F /N xxx-5600) Y3 Y4 Y6 Y25 solenoid valve - float position (bottom side) solenoid valve - servo cut off solenoid valve - quick drop (return flow cut off) solenoid valve - float position (rod side)

220

01 03

1. Neutral function 1.1. Servo control

Functional schematic see 7.3.50.00

Pressurized oil flows from travel hydraulic replenishing" (see group 6.3 filter base 18/B) check valve 52 P-distributor block 50

accumulator 55. solenoid valveY4.

After raising the safety lever (solenoid valve Y4 energized) from solenoid valve Y4/distributor block 50-GP to P-servo control valve115 regulating piston 116 to119 blocked. test point ND. The servo lines from servo control valve (joystick) 115 - outlets 1 to 4 - are relieved via regulating pistons 116 to 119 and line connection T to the tank. 1.2. Working circuit - Attachment pump 100 In rest position, axial piston unit 101 of attachment pump 100 is at maximum pump angle. When the Diesel engine is started, the pump starts to deliver, LS regulator 109 is pushed immediately against the spring and axial piston unit 101 is set to the smallest pump angle = Qmin (flow) by the variable control cylinder 102. The system maintains stand-by pressure of 30 +5 bar. Oil flow: Tank 80 shut off valve 81 attachment pump 100/axial piston unit 101 internal return cylinder 103. intermediate plate 105 pressure cut off valve107. LS-regulator 109 107 105 variable control cylinder 102. housing X UP-distributor block 50 P-solenoid valve Y53-A blocked. external P-control block 130 relief valve 131 blocked. outlet MP test point HD.. spool 135 blocked. spool 140 blocked. end plate 155 blocked. Piston ratio cylinder 102 to 103 = approx. 2:1. Regulator connection X /test point LS (LS signal) is relieved via two way check valve 145 spool 135/140 end plate 155 to the tank. 1.3. Working circuit end user - secondary relief Lines to and from the end user - lift and tilt cylinders - are closed off. If necessary, these hydraulic system components are protected from pressure overloads due to external influences by secondary relief valves. Lift cylinder 170 - blocked by spool 135. Passage for pressure oil on solenoid valves Y3 and Y25 blocked. The piston 161 of the quick drop unit 160 is kept in neutral position (no passage). Secondary relief on piston bottom side (2505 bar) provided by pressure/suction valve 137, on piston rod side by pressure/suction valve 139. The oil suction for piston movement is assured by the pressure/suction valve on the opposite side. Tilt cylinder 175 - blocked by spool 140.

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Function
Datum Edition Date

01 01

Working Hydraulic

PR 752
Blatt Page Feuille

F/N xxx-2002 2062

7.3.50.01

2. Operational function of certain components remain identical based on neutral function according to par. 1. 2.1. Attachment pump 100 If a working function is actuated, the LS regulator 109 is actuated on one side with pressure in front of control piston (HD) and on the opposite side from the user side pressure (LS - connection X2) and the spring. The pressure ratio on the piston determines its position and thereby the pressure actuation of the control cylinder 102. The different forces of the control cylinders 102 and 103 that result from the pressure actuation and surface move the axial piston unit 101 constantly to the pump angle corresponding to the oil flow requirements (determined by valve spool opening) = on demand control. The pressure at test point HD is 15 +6 bar above the pressure on test point LS (HD-LS = p on the valve spool). At maximum pump flow = max. opening of a spool the p is (HD-LS) 13 bar. The pressure cut-off valve 107 is always actuated by the stand-by pressure on pump side. If the (load) pressure increases above the adjusted spring value = 2005 bar, then the piston is displaced toward the spring. The pressure oil supply from the LS regulator is closed off and the oil from the system is directed directly via valve107 to the control cylinder 102. The axial piston unit 101 is displaced toward Qmin until only the amount of oil which is required to maintain maximum operating pressure = pressure cut-off is supplied. HD=LS = p 0 bar The oil, bleeded at every setting from the pump control into the housing, along with the existing leakage oil, is used to flush the housing and flows via connection L filter 85 to the tank. 2.2. Servo control valve 115 The corresponding working function can be hydraulically controlled by deflecting the lever on the pilot control unit. The pressure build up in the control system and thus the working speed increases with the deflection angle of the lever. Maximum pilot control pressure = 25+3 bar, regulated control pressure build up via regulating pistons 116 to 119 = approx. 6.5 bar max. Tilt and lift cylinder functions can be actuated simultaneously by deflecting the lever diagonally. 2.3. Control valve block 130 Regulating range of spools 135 and 140 = approx. 4,5 - 22 bar 2.3.1 Spools 135 and 140, load check valves 136 and 141, two way check valve 145 When the spool is opened, load pressure on the user side is directed to the two way check valve 145. The higher pressure flows via the two way check valve to the LS regulator of pump 100 (which causes pump displacement toward Qmax). The path Puser is closed off by the check valve136/141 until the pressure induced by the end user is built up on the pump side (prevents load from sinking). The control spool travel and the opening for the input/outlet for the consumer (working speed) depends on servo pressure. 2.3.2 Pressure relief valve 131 - primary relief The valve protects the pump and the system from damage due to problems or incorrect adjustments of the pressure cut-off valve 107. Adjustment value 270 5 bar.

2.3.3 Solenoid valve-float function Y3/Y25 The available pressure oil flows via an orifice in the stage piston to the spring side of the piston and is blocked there by unenergized solenoids. Pressure and spring forces keep the valve closed. Tank pressure is applied constantly to the ring surface of the stage pistons and can lift them in case of low pressure in the control block channel A1 - A1 (Y3) or B1 - B1 (Y25) for suction. 2.3.4 Solenoid valve Y6 - Quick drop The oil returning from the end users via tank channel MT1 is slightly pressurized before the piston of the valve opens to the tank connection T. Oil reaching the spring chamber via the orifice in the piston flows through the open passage of the solenoid valve to connection T. 2.4. Quick drop unit 160 complete Oil in channel B - B1 - B1 flows around piston 161 and cannot act against the spring. The channel to connection P-solenoid valve Y50 is blocked on connection A. The pressurized hydraulic oil in channel A - A1 - A1 acts on the piston 161 and flows via a restrictor hole in the piston to its spring chamber. At the same time, the oil flow via the orifice 162 T-solenoid valve Y50-B also to the spring chamber. The piston is pressurized on both sides with the same pressure and is kept in neutral position by the higher force on the spring side (large surface x pressure) = passage A1 B1 remains blocked. 2.5. Lift cylinder 170 / check valves 171 When actuated with pressure, the pressure side check valves 171 open. However, the oil flow is blocked by the second check valves, which act in the opposite direction. When the pistons in the lift cylinders reach an end position, the previously blocked check valves are mechanically opened = the valve poppets contact the cylinder bottom/piston rod side, the cylinder pistons are moved further until the piston bottoms out, see group 8.8. The pressurized oil flows via the check valves to the opposite side, the system pressure does not increase further. 2.6. Solenoid valve - Diesel engine RPM safety Y53 If the Diesel engine overspeeds due to external influences, the electronic crawler control energizes the solenoid valve. The pressurized oil from the pump control cylinder 102 is directed via passage PB, valve block 50-T to the tank. The control cylinder 102 has no force, the return cylinder 103 shifts the axial piston unit 101, independent of the demand, to maximum flow. After the corresponding pressure build up, the increased flow is relieved to tank, via the primary pressure relief valve 131. The resulting higher power requirement acts as a brake force and prevents further increase of Diesel engine speed. 2.7. Oil pressure switch - return filter monitor B22 If the return filter element is not replaced in time, the back up pressure in the oil return line increases due to filter contamination. Just before the opening of the filter bypass valve 84, the electrical contact on the switch is closed (switching point 2.5 bar) and the indicator light on instrument panel lights up.

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Function
Datum Edition Date

01 01

Working Hydraulic

PR 752
Blatt Page Feuille

F/N xxx-2002 2062

7.3.50.02

3. Operating function - Working movement - starting from neutral position according to par. 1 and identical operating functions according to par. 2. 3.1. Blade up 3.1.1 Servo control Control pressure build up from regulating piston 117 to housing outlet 1 b1-control valve block 130 spool 135 - displacement toward a1. 3.1.2 Working circuit Pressurized oil moves from spool 135 to control valve block-outlet-B1 A-quick drop unit 160-A1/A1 B1-lift cylinder 170. pressure relief valve 139. solenoid valve Y25.

The piston/piston rod in the lift cylinders is pushed in and the blade is raised. Oil returns from lift cylinder/piston bottom side to B1/B1-quick drop unit 160-B A1-control block 130 spool 135 tank line/connection T return filter 82 tank 80. 3.2. Blade down 3.2.1 Servo control Control pressure build up from regulating piston 116 to housing outlet 3 pressure switch B22. a1-control valve block 130 spool 135 -displacement toward b1. 3.2.2 Working circuit Pressurized oil moves from spool 135 to control block-outlet A1 B-quick drop unit 160-B1/B1 A1-lift cylinder170. relief valve 137. one-way valve 138. solenoid valve Y3. The pistons/piston rods move outward on the lift cylinders, the blade is lowered. It moves downward to the ground level through its own weight load pressure build up in oil return, force from ground level on load pressure build up in oil supply. Oil returns from lift cylinders / piston rod side to A1/A1-quick drop unit 160-A B1-control block 130 spool 135 tank connection MT1 solenoid valve Y6 block connection T return filter83 tank 80. 3.3. Blade quick drop 3.3.1 Servo control Oil pressure builds up from regulating piston 116 as for blade down", point 3.2.1 but above 24 bar switch B22 / electr. contact closed solenoid valve Y6 and Y50 energized actuated. 3.3.2 Working circuit Oil supply from spool 135 as for blade down", point 3.2.2, however, in quick drop unit 160 channel B1 - B1 is connected with the spring chamber of piston 161 via P B-solenoid valve Y50. Pump 100 / spool 135 supply maximum flow to lift cylinder 170/piston bottom side. Oil return from lift cylinder/piston rod side to A1/A1-quick drop unit 160 orifice 162 T-solenoid valve Y50-A blocked. piston161 channel B1 - B1 A1-lift cylinder 170/piston bottom side. 160-outlet A B1-control block 130 spool 135 tank connection MT1 solenoid valve Y6 blocked one way valve 138 oil supply A1-lift cylinder 170/piston bottom side. Blade drops to ground level position at maximum speed.

3.4. Blade tilt - left 3.4.1 Servo control Oil pressure builds up from regulating piston 118 to housing outlet 2 WT-distributor block 50 T- solenoid valve Y45-B distributor block 50-WB a2-control block 130 spool140 -displacement toward b2. 3.4.2 Working circuit Oil pressure flows from spool 140 to control block-outlet A2 support shaft right 180-B block 173-B tilt cylinder 175. The piston and piston rod are pressed outward in the tilt cylinder, the left blade corner tilts down. Oil returns from tilt cylinder/piston rod side to A-block 173 A-support shaft right 180 B2-control block 130 spool140 tank connection MT1 solenoid valveY6 block connection T return filter 83 tank 80. By moving the blade, the piston/piston rod is pulled out on the left lift cylinder and pushed in on the right lift cylinder - and therefore in the hydraulic circuit of lift cylinder, an oil flow is mechanically created (spool 140 remains closed). Oil flow at intermediate position of lift cylinder pistons: Right lift cylinder/piston bottom side B1-quick drop unit 160-B1 left lift cylinder/piston bottom side. Left lift cylinder/piston rod side A1-quick drop unit 160-A1 right lift cylinder/piston rod side.. Oil flow at raised" end position: Right lift cylinder piston - blocked in bottom side end position, check valves are opened mechanically on one side. Left lift cylinder piston/movement toward piston rod side B1-pressure build up A1-quick drop unit 160-A1 B1-right lift cylinder/piston rod side check valves 171 piston bottom side-A1 B1-quick drop unit 160-B1 A1-left lift cylinder/piston bottom side. The missing oil volume (piston rod) is drawn in through the tank line via piston/solenoid valve Y3, one-way valve 138 or the suction function of pressure relief valve 137. Oil flow at lowered" end position Left lift cylinder piston - blocked in rod side end position, check valves opened mechanically on one side. Right lift cylinder piston/movement toward piston bottom side A1-pressure build up B1-quick drop unit 160-B1 A1-left lift cylinder/piston bottom side check valves 171 piston rod side-B1 A1-quick drop unit 160-A1 B1-right lift cylinder/piston rod side. Excess oil (piston rod) is relieved via the pressure relief valve 137 to the tank. The resulting pressure on the piston rod side, which occurs at immediately tilting in the opposite direction, is limited by the pressure/suction valve 139.

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Function
Datum Edition Date

01 01

Working Hydraulic

PR 752
Blatt Page Feuille

F/N xxx-2002 2062

7.3.50.03

3.5. Blade tilt - right 3.5.1 Servo Control Pressure build up from regulating piston 119 to housing outlet 4 WP-distributor block 50 P-solenoid valve Y45-A distributor block 50-WA b2-control block 130 spool 140 -displacement towards a2. 3.5.2 Working circuit Pressurized oil moves from spool 140 to control block-outlet B2 support shaft right 180-A block 173-A tilt cylinder 175. The piston and piston rod are pressed inward in tilt cylinder, the right blade corner tilts down. Oil returns from tilt cylinder/piston bottom side to B-block 173 B-support shaft right 180 A2-control block 130 spool 140 tank line/connection T return filter 83 tank 80. By moving the blade, the piston/piston rod is pulled out on the right lift cylinder and pushed in on the left lift cylinder - and therefore in the hydraulic circuit of the lift cylinder, an oil flow is created mechanically (spool 140 remains closed). Oil flow at intermediate position of lift cylinder pistons: Left lift cylinder/piston bottom side B1-quick drop unit 160-B1 right lift cylinder/piston bottom side.. Right lift cylinder/piston rod side A1-quick drop unit 160-A1 left lift cylinder/piston rod side..

Oil flow at raised end position: Left lift cylinder piston - blocked in bottom side end position, check valves opened mechanically on one side. Right lift cylinder piston/movement towards piston rod side B1-pressure build up A1-quick drop unit 160-A1 B1-left lift cylinder/piston rod side check valves 171 piston bottom side-A1 B1-quick drop unit 160-B1 A1-right lift cylinder/piston bottom side. The missing oil volume (piston rod) is drawn in from the tank line via solenoid valve Y3, one-way valve 138 or the suction function of pressure relief valve 137. Oil flow at lowered end position: Right lift cylinder piston - blocked in rod side end position, check valves opened mechanically on one side. Left lift cylinder piston/movement toward piston bottom side A1-pressure build up B1-quick drop unit 160-B1 A1-right lift cylinder/piston bottom side end stroke valve 171 piston rod side-B1 A1-quick drop unit 160-A1 B1-left lift cylinder/piston rod side. Excess oil (piston rod) is relieved via pressure relief valve 137 to the tank. The resulting pressure on the piston rod side, which occurs at immediately tilting in the opposite direction, is limited by the pressure/suction valve 139. 3.6. Blade float function For blade float function, the solenoid valves Y3 and Y25 are energized electrically to open port" position, the spring chamber of the piston is relieved to the tank. If the blade is raised or lowered due to ground conditions, the pressurized oil in the lift cylinder circuit lifts the piston and oil flows out into the tank channel. The oil required on the opposite side of the lift cylinder pistons is drawn from the tank channel via the second solenoid valve (piston bottom side also via the one-way valve 138 and the relief valve 137).

Notes

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Parts list
Datum Edition Date

01 01

Working Hydraulic

PR 752
Blatt Page Feuille

F/N xxx-2002 2062

7.3.50.00

50 distributor block 51 orifice P from filter assembly - replenishing / TH. B from parking brake / TH. LP to fan drive / TH. 52 check valve 55 accumulator 60 test center - test points ND servo pressure - working hydraulic LS load sensing pressure HP high pressure - working hydraulic 80 hydraulic tank 81 shut off valve 82 shut off valve 83 return filter 84 bypass valve 85 strainer 100 regulating pump cpl. 101 axial piston unit 102 control cylinder (Qmin) 103 return cylinder (Qmax) 105 intermediate plate 107 pressure cut off valve 109 load sensing regulator 115 pilot (servo) control valve 116 regulating piston - lower 117 regulating piston - lift 118 regulating piston - tilt left 119 regulating piston - tilt right 130 control valve block cpl. 131 pressure relief valve - primary safety 135 136 137 138 139 140 141 145 155 spool - lift / lower check valve pressure relief valve - secondary safety lift cylinder bottom side check valve pressure relief valve - secondary safety lift cylinder rod side spool - tilt check valve two way check valve end plate

160 quick drop unit cpl. 161 piston / built-in valve 162 orifice 163 intermediate plate 170 lift cylinder 171 check valves - piston 173 block 175 tilt cylinder 180 support shaft right B5 pressure switch / TH. B11 pressure switch - quick drop B22 pressure switch - return filter monitor Y3 Y4 Y6 Y13 Y25 Y45 Y50 Y52 Y53 solenoid valve - float position (bottom side) solenoid valve - servo cut off solenoid valve - quick drop (return flow cut off) solenoid valve - parking brake - travel hydraulic solenoid valve - float position (rod side) solenoid valve - special attachment solenoid valve - quick drop solenoid valve - fan drive - travel hydraulic solenoid valve - Diesel engine - RPM safety

unnamed line outlets on the hydraulic tank - suction line for fan drive und replenishing - return line travel hydraulic - connection to hand pump - cab tilt parts list remarks TH. see group 6, page 6.3.50.00

2062

01 01

1. Neutral function 1.1. Servo control

Functional schematic see 7.3.51.00

Pressurized oil flows from travel hydraulic replenishing" (see group 6.3 filter base 18/B) check valve 52 P-distributor block 50

accumulator 55. solenoid valveY4.

After raising the safety lever (solenoid valve Y4 energized) from solenoid valve Y4/distributor block 50-GP to P-servo control valve115 regulating piston 116 to119 blocked. test point ND. The servo lines from servo control valve (joystick) 115 - outlets 1 to 4 - are relieved via regulating pistons 116 to 119 and line connection T to the tank. 1.2. Working circuit - Attachment pump 100 In rest position, axial piston unit 101 of attachment pump 100 is at maximum pump angle. When the Diesel engine is started, the pump starts to deliver, LS regulator 109 is pushed immediately against the spring and axial piston unit 101 is set to the smallest pump angle = Qmin (flow) by the variable control cylinder 102. The system maintains stand-by pressure of 30+5 bar.

Oil flow: Tank 80 shut off valve 81 attachment pump 100/axial piston unit 101 internal return cylinder 103. intermediate plate 105 pressure cut off valve107. LS-regulator 109 107 105 variable control cylinder 102. housing X UP-distributor block 50 P-solenoid valve Y28-A blocked. external P-control block 130 relief valve 131 blocked. outlet MP test point HD.. spool 135 blocked. spool 140 blocked. end plate 155 blocked. Piston ratio cylinder 102 to 103 = approx. 2:1. Regulator connection X /test point LS (LS signal) is relieved via two way check valve 145 spool 135/140 end plate 155 to the tank. 1.3. Working circuit end user - secondary relief Lines to and from the end user - lift and tilt cylinders - are closed off. If necessary, these hydraulic system components are protected from pressure overloads due to external influences by secondary relief valves. Lift cylinder 170 - blocked by spool 135. Passage for pressure oil on solenoid valves Y3 and Y5 blocked. The piston 161 of the quick drop unit 160 is kept in neutral position (no passage). Secondary relief on piston bottom side (2505 bar) provided by pressure/suction valve 137, on piston rod side by pressure/suction valve 139. The oil suction for piston movement is assured by the pressure/suction valve on the opposite side. Tilt cylinder 175 - blocked by spool 140.

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Function
Datum Edition Date

PR 752

01 03

Working Hydraulic

F/N xxx-2063 6199

Blatt Page Feuille

7.3.51.01

2. Operational function of certain components remain identical based on neutral function according to par. 1. 2.1. Attachment pump 100 If a working function is actuated, the LS regulator 109 is actuated on one side with pressure in front of control piston (HD) and on the opposite side from the user side pressure (LS - connection X2) and the spring. The pressure ratio on the piston determines its position and thereby the pressure actuation of the control cylinder 102. The different forces of the control cylinders 102 and 103 that result from the pressure actuation and surface move the axial piston unit 101 constantly to the pump angle corresponding to the oil flow requirements (determined by valve spool opening) = on demand control. The pressure at test point HD is 15+6 bar above the pressure on test point LS (HD-LS = p on the valve spool). At maximum pump flow = max. opening of a spool the p is (HD-LS) 13 bar. The pressure cut-off valve 107 is always actuated by the stand-by pressure on pump side. If the (load) pressure increases above the adjusted spring value = 2005 bar, then the piston is displaced toward the spring. The pressure oil supply from the LS regulator is closed off and the oil from the system is directed directly via valve107 to the control cylinder 102. The axial piston unit 101 is displaced toward Qmin until only the amount of oil which is required to maintain maximum operating pressure = pressure cut-off is supplied. HD=LS = p 0 bar The oil, bleeded at every setting from the pump control into the housing, along with the existing leakage oil, is used to flush the housing and flows via connection L filter 85 to the tank. 2.2. Servo control valve 115 The corresponding working function can be hydraulically controlled by deflecting the lever on the pilot control unit.. The pressure build up in the control system and thus the working speed increases with the deflection angle of the lever. Maximum pilot control pressure = 25+3 bar, regulated control pressure build up via regulating pistons 116 to 119 = approx. 6.5 bar max. Tilt and lift cylinder functions can be actuated simultaneously by deflecting the lever diagonally. 2.3. Control valve block 130 Regulating range of spools 135 and 140 = approx. 4,5 - 22 bar 2.3.1 Spools 135 and 140, load check valves 136 and 141, two way check valve 145 When the spool is opened, load pressure on the user side is directed to the two way check valve 145. The higher pressure flows via the two way check valve to the LS regulator of pump 100 (which causes pump displacement toward Qmax). The path Puser is closed off by the check valve136/141 until the pressure induced by the end user is built up on the pump side (prevents load from sinking). The control spool travel and the opening for the input/outlet for the consumer (working speed) depends on servo pressure. 2.3.2 Pressure relief valve 131 - primary relief The valve protects the pump and the system from damage due to problems or incorrect adjustments of the pressure cut-off valve 107. Adjustment value 2705 bar.

2.3.3 Solenoid valve-float function Y3/Y5 The available pressure oil flows via an orifice in the stage piston to the spring side of the piston and is blocked there by unenergized solenoids. Pressure and spring forces keep the valve closed. Tank pressure is applied constantly to the ring surface of the stage pistons and can lift them in case of low pressure in the control block channel A1 - A1 (Y3) or B1 - B1 (Y5) for suction. 2.3.4 Solenoid valve Y24 - Quick drop The oil returning from the end users via tank channel MT1 is slightly pressurized before the piston of the valve opens to the tank connection T. Oil reaching the spring chamber via the orifice in the piston flows through the open passage of the solenoid valve to connection T. 2.4. Quick drop unit 160 complete Oil in channel B - B1 - B1 flows around piston 161 and cannot act against the spring. The channel to connection P-solenoid valve Y23 is blocked on connection A. The pressurized hydraulic oil in channel A - A1 - A1 acts on the piston 161 and flows via a restrictor hole in the piston to its spring chamber. At the same time, the oil flow via the orifice 162 T-solenoid valve Y23-B also to the spring chamber. The piston is pressurized on both sides with the same pressure and is kept in neutral position by the higher force on the spring side (large surface x pressure) = passage A1 B1 remains blocked. 2.5. Lift cylinder 170 / check valves 171 When actuated with pressure, the pressure side check valves 171 open. However, the oil flow is blocked by the second check valves, which act in the opposite direction. When the pistons in the lift cylinders reach an end position, the previously blocked check valves are mechanically opened = the valve poppets contact the cylinder bottom/piston rod side, the cylinder pistons are moved further until the piston bottoms out, see group 8.8. The pressurized oil flows via the check valves to the opposite side, the system pressure does not increase further. 2.6. Solenoid valve - Diesel engine RPM safety Y28 If the Diesel engine overspeeds due to external influences, the electronic crawler control energizes the solenoid valve. The pressurized oil from the pump control cylinder 102 is directed via passage PB, valve block 50-T to the tank. The control cylinder 102 has no force, the return cylinder 103 shifts the axial piston unit 101, independent of the demand, to maximum flow. After the corresponding pressure build up, the increased flow is relieved to tank, via the primary pressure relief valve 131. The resulting higher power requirement acts as a brake force and prevents further increase of Diesel engine speed. 2.7. Oil pressure switch - return filter monitor B18 If the return filter element is not replaced in time, the back up pressure in the oil return line increases due to filter contamination. Just before the opening of the filter bypass valve 84, the electrical contact on the switch is closed (switching point 2.5 bar) and the indicator light on instrument panel lights up.

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Function
Datum Edition Date

PR 752

01 03

Working Hydraulic

F/N xxx-2063 6199

Blatt Page Feuille

7.3.51.02

3. Operating function - Working movement - starting from neutral position according to par. 1 and identical operating functions according to par. 2. 3.1. Blade up 3.1.1 Servo control Control pressure build up from regulating piston 117 to housing outlet 1 b1-control valve block 130 spool 135 - displacement toward a1. 3.1.2 Working circuit Pressurized oil moves from spool 135 to control valve block-outlet-B1 A-quick drop unit 160-A1/A1 B1-lift cylinder 170. pressure relief valve 139. solenoid valve Y5.

The piston/piston rod in the lift cylinders is pushed in and the blade is raised. Oil returns from lift cylinder/piston bottom side to B1/B1-quick drop unit 160-B A1-control block 130 spool 135 tank line/connection T return filter 82 tank 80. 3.2. Blade down 3.2.1 Servo control Control pressure build up from regulating piston 116 to housing outlet 3 pressure switch B22. a1-control valve block 130 spool 135 -displacement toward b1. 3.2.2 Working circuit Pressurized oil moves from spool 135 to control block-outlet A1 B-quick drop unit 160-B1/B1 A1-lift cylinder170. relief valve 137. one-way valve 138. solenoid valve Y3. The pistons/piston rods move outward on the lift cylinders, the blade is lowered. It moves downward to the ground level through its own weight load pressure build up in oil return, force from ground level on load pressure build up in oil supply. Oil returns from lift cylinders / piston rod side to A1/A1-quick drop unit 160-A B1-control block 130 spool 135 tank connection MT1 solenoid valve Y24 block connection T return filter83 tank 80. 3.3. Blade quick drop 3.3.1 Servo control Oil pressure builds up from regulating piston 116 as for blade down", point 3.2.1 but above 24 bar switch B22 / electr. contact closed solenoid valve Y24 and Y23 energized actuated. 3.3.2 Working circuit Oil supply from spool 135 as for blade down", point 3.2.2, however, in quick drop unit 160 channel B1 - B1 is connected with the spring chamber of piston 161 via P B-solenoid valve Y23. Pump 100 / spool 135 supply maximum flow to lift cylinder 170/piston bottom side. Oil return from lift cylinder/piston rod side to A1/A1-quick drop unit 160 orifice 162 T-solenoid valve Y23-A blocked. piston161 channel B1 - B1 A1-lift cylinder 170/piston bottom side. 160-outlet A B1-control block 130 spool 135 tank connection MT1 solenoid valve Y24 blocked one way valve 138 oil supply A1-lift cylinder 170/piston bottom side. Blade drops to ground level position at maximum speed.

3.4. Blade tilt - left 3.4.1 Servo control Oil pressure builds up from regulating piston 118 to housing outlet 2 WT-distributor block 50 T- solenoid valve Y29-B distributor block 50-WB a2-control block 130 spool140 -displacement toward b2. 3.4.2 Working circuit Oil pressure flows from spool 140 to control block-outlet A2 support shaft right 180-B block 173-B tilt cylinder 175. The piston and piston rod are pressed outward in the tilt cylinder, the left blade corner tilts down. Oil returns from tilt cylinder/piston rod side to A-block 173 A-support shaft right 180 B2-control block 130 spool140 tank connection MT1 solenoid valveY24 block connection T return filter 83 tank 80. By moving the blade, the piston/piston rod is pulled out on the left lift cylinder and pushed in on the right lift cylinder - and therefore in the hydraulic circuit of lift cylinder, an oil flow is mechanically created (spool 140 remains closed).

Oil flow at intermediate position of lift cylinder pistons: Right lift cylinder/piston bottom side B1-quick drop unit 160-B1 left lift cylinder/piston bottom side. Left lift cylinder/piston rod side A1-quick drop unit 160-A1 right lift cylinder/piston rod side..

Oil flow at raised" end position: Right lift cylinder piston - blocked in bottom side end position, check valves are opened mechanically on one side. Left lift cylinder piston/movement toward piston rod side B1-pressure build up A1-quick drop unit 160-A1 B1-right lift cylinder/piston rod side check valves 171 piston bottom side-A1 B1-quick drop unit 160-B1 A1-left lift cylinder/piston bottom side. The missing oil volume (piston rod) is drawn in through the tank line via piston/solenoid valve Y3, one-way valve 138 or the suction function of pressure relief valve 137.

Oil flow at lowered" end position Left lift cylinder piston - blocked in rod side end position, check valves opened mechanically on one side. Right lift cylinder piston/movement toward piston bottom side A1-pressure build up B1-quick drop unit 160-B1 A1-left lift cylinder/piston bottom side check valves 171 piston rod side-B1 A1-quick drop unit 160-A1 B1-right lift cylinder/piston rod side. Excess oil (piston rod) is relieved via the pressure relief valve 137 to the tank. The resulting pressure on the piston rod side, which occurs at immediately tilting in the opposite direction, is limited by the pressure/suction valve 139.

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Function
Datum Edition Date

PR 752

01 03

Working Hydraulic

F/N xxx-2063 6199

Blatt Page Feuille

7.3.51.03

3.5. Blade tilt - right 3.5.1 Servo control Pressure build up from regulating piston 119 to housing outlet 4 WP-distributor block 50 P-solenoid valve Y29-A distributor block 50-WA b2-control block 130 spool 140 -displacement towards a2. 3.5.2 Working circuit Pressurized oil moves from spool 140 to control block-outlet B2 support shaft right 180-A block 173-A tilt cylinder 175. The piston and piston rod are pressed inward in tilt cylinder, the right blade corner tilts down. Oil returns from tilt cylinder/piston bottom side to B-block 173 B-support shaft right 180 A2-control block 130 spool 140 tank line/connection T return filter 83 tank 80. By moving the blade, the piston/piston rod is pulled out on the right lift cylinder and pushed in on the left lift cylinder - and therefore in the hydraulic circuit of the lift cylinder, an oil flow is created mechanically (spool 140 remains closed).

Oil flow at intermediate position of lift cylinder pistons: Left lift cylinder/piston bottom side B1-quick drop unit 160-B1 right lift cylinder/piston bottom side.. Right lift cylinder/piston rod side A1-quick drop unit 160-A1 left lift cylinder/piston rod side..

Oil flow at raised end position: Left lift cylinder piston - blocked in bottom side end position, check valves opened mechanically on one side. Right lift cylinder piston/movement towards piston rod side B1-pressure build up A1-quick drop unit 160-A1 B1-left lift cylinder/piston rod side check valves 171 piston bottom side-A1 B1-quick drop unit 160-B1 A1-right lift cylinder/piston bottom side. The missing oil volume (piston rod) is drawn in from the tank line via solenoid valve Y3, one-way valve 138 or the suction function of pressure relief valve 137.

Oil flow at lowered end position: Right lift cylinder piston - blocked in rod side end position, check valves opened mechanically on one side. Left lift cylinder piston/movement toward piston bottom side A1-pressure build up B1-quick drop unit 160-B1 A1-right lift cylinder/piston bottom side end stroke valve 171 piston rod side-B1 A1-quick drop unit 160-A1 B1-left lift cylinder/piston rod side. Excess oil (piston rod) is relieved via pressure relief valve 137 to the tank. The resulting pressure on the piston rod side, which occurs at immediately tilting in the opposite direction, is limited by the pressure/suction valve 139. 3.6. Blade float function For blade float function, the solenoid valves Y3 and Y5 are energized electrically to open port" position, the spring chamber of the piston is relieved to the tank. If the blade is raised or lowered due to ground conditions, the pressurized oil in the lift cylinder circuit lifts the piston and oil flows out into the tank channel. The oil required on the opposite side of the lift cylinder pistons is drawn from the tank channel via the second solenoid valve (piston bottom side also via the one-way valve 138 and the relief valve 137).

Notes

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Parts list
Datum Edition Date

PR 752

01 03

Working Hydraulic

F/N xxx-2063 6199

Blatt Page Feuille

7.3.51.00

50 distributor block 51 orifice P from filter assembly - replenishing / TH. B from parking brake / TH. LP to fan drive / TH. 52 check valve 55 accumulator 60 test center - test points ND servo pressure - working hydraulic LS load sensing pressure HP high pressure - working hydraulic 80 hydraulic tank 81 shut off valve 82 shut off valve 83 return filter 84 bypass valve 85 strainer 100 regulating pump cpl. 101 axial piston unit 102 control cylinder (Qmin) 103 return cylinder (Qmax) 105 intermediate plate 107 pressure cut off valve 109 load sensing regulator 115 pilot (servo) control valve 116 regulating piston - lower 117 regulating piston - lift 118 regulating piston - tilt left 119 regulating piston - tilt right 130 control valve block cpl. 131 pressure relief valve - primary safety 135 136 137 138 139 140 141 145 155 spool - lift / lower check valve pressure relief valve - secondary safety lift cylinder bottom side check valve pressure relief valve - secondary safety lift cylinder rod side spool - tilt check valve two way check valve end plate

160 quick drop unit cpl. 161 piston / built-in valve 162 orifice 163 intermediate plate 170 lift cylinder 171 check valves - piston 173 block 175 tilt cylinder 180 support shaft right B5 B18 B22 B26 pressure switch / TH. pressure switch - return filter monitor pressure switch - quick drop temperature sending unit - indicator light hydraulic oil overheating solenoid valve - float position (bottom side) solenoid valve - servo cut off solenoid valve - float position (rod side) solenoid valve - parking brake - travel hydraulic solenoid valve - quick drop (return flow cut off) solenoid valve - quick drop solenoid valve - fan drive - travel hydraulic solenoid valve - Diesel engine - RPM safety solenoid valve - special attachment

Y3 Y4 Y5 Y13 Y23 Y24 Y25 Y28 Y29

unnamed line outlets on the hydraulic tank - suction line for fan drive and replenishing - return line travel hydraulic - connection to hand pump - cab tilt

parts list remarks TH. see group 6, page 6.3.5x.00

Benennung Description Dnomination

Typ/ab Type/from Type/a partir de

liebherr
Datum Edition Date

01 03

Arbeitshydraulik Working Hydraulic Hydraulique de travail

PR 752
Blatt Page Feuille

F/N xxx- 2063

6199

7.3.51. 00

1. Neutral function 1.1. Servo control

Functional schematic see 7.3.52.00

Pressurized oil flows from travel hydraulic replenishing" (see group 6.3 filter base 18/B) check valve 52 P-distributor block 50

accumulator 55. solenoid valveY4.

After raising the safety lever (solenoid valve Y4 energized) from solenoid valve Y4/distributor block 50-GP to P-servo control valve115 regulating piston 116 to119 blocked. test point ND. The servo lines from servo control valve (joystick) 115 - outlets 1 to 4 - are relieved via regulating pistons 116 to 119 and line connection T to the tank. 1.2. Working circuit - Attachment pump 100 In rest position, axial piston unit 101 of attachment pump 100 is at maximum pump angle. When the Diesel engine is started, the pump starts to deliver, LS regulator 109 is pushed immediately against the spring and axial piston unit 101 is set to the smallest pump angle = Qmin (flow) by the variable control cylinder 102. The system maintains stand-by pressure of 30+5 bar.

Oil flow: Tank 80 shut off valve 81 attachment pump 100/axial piston unit 101 internal return cylinder 103. intermediate plate 105 pressure cut off valve107. LS-regulator 109 107 105 variable control cylinder 102. housing X UP-distributor block 50 P-solenoid valve Y28-A blocked. external P-control block 130 relief valve 131 blocked. outlet MP test point HD.. spool 135 blocked. spool 140 blocked. end plate 155 blocked. Piston ratio cylinder 102 to 103 = approx. 2:1. Regulator connection X /test point LS (LS signal) is relieved via two way check valve 145 spool 135/140 end plate 155 to the tank. 1.3. Working circuit end user - secondary relief Lines to and from the end user - lift and tilt cylinders - are closed off. If necessary, these hydraulic system components are protected from pressure overloads due to external influences by secondary relief valves. Lift cylinder 170 - blocked by spool 135. Passage for pressure oil on solenoid valves Y3 and Y5 blocked. The piston 161 of the quick drop unit 160 is kept in neutral position (no passage). Secondary relief on piston bottom side (2505 bar) provided by pressure/suction valve 137, on piston rod side by pressure/suction valve 139. The oil suction for piston movement is assured by the pressure/suction valve on the opposite side. Tilt cylinder 175 - blocked by spool 140.

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Function
Datum Edition Date

PR 752

01 03

Working Hydraulic

F/N xxx-6200

Blatt Page Feuille

7.3.52.01

2. Operational function of certain components remain identical based on neutral function according to par. 1. 2.1. Attachment pump 100 If a working function is actuated, the LS regulator 109 is actuated on one side with pressure in front of control piston (HD) and on the opposite side from the user side pressure (LS - connection X2) and the spring. The pressure ratio on the piston determines its position and thereby the pressure actuation of the control cylinder 102. The different forces of the control cylinders 102 and 103 that result from the pressure actuation and surface move the axial piston unit 101 constantly to the pump angle corresponding to the oil flow requirements (determined by valve spool opening) = on demand control. The pressure at test point HD is 15+6 bar above the pressure on test point LS (HD-LS = p on the valve spool). At maximum pump flow = max. opening of a spool the p is (HD-LS) 13 bar. The pressure cut-off valve 107 is always actuated by the stand-by pressure on pump side. If the (load) pressure increases above the adjusted spring value = 2005 bar, then the piston is displaced toward the spring. The pressure oil supply from the LS regulator is closed off and the oil from the system is directed directly via valve107 to the control cylinder 102. The axial piston unit 101 is displaced toward Qmin until only the amount of oil which is required to maintain maximum operating pressure = pressure cut-off is supplied. HD=LS = p 0 bar The oil, bleeded at every setting from the pump control into the housing, along with the existing leakage oil, is used to flush the housing and flows via connection L filter 85 to the tank. 2.2. Servo control valve 115 The corresponding working function can be hydraulically controlled by deflecting the lever on the pilot control unit.. The pressure build up in the control system and thus the working speed increases with the deflection angle of the lever. Maximum pilot control pressure = 25+3 bar, regulated control pressure build up via regulating pistons 116 to 119 = approx. 6.5 bar max. Tilt and lift cylinder functions can be actuated simultaneously by deflecting the lever diagonally. 2.3. Control valve block 130 Regulating range of spools 135 and 140 = approx. 4,5 - 22 bar 2.3.1 Spools 135 and 140, load check valves 136 and 141, two way check valve 145 When the spool is opened, load pressure on the user side is directed to the two way check valve 145. The higher pressure flows via the two way check valve to the LS regulator of pump 100 (which causes pump displacement toward Qmax). The path Puser is closed off by the check valve136/141 until the pressure induced by the end user is built up on the pump side (prevents load from sinking). The control spool travel and the opening for the input/outlet for the consumer (working speed) depends on servo pressure. 2.3.2 Pressure relief valve 131 - primary relief The valve protects the pump and the system from damage due to problems or incorrect adjustments of the pressure cut-off valve 107. Adjustment value 2705 bar.

2.3.3 Solenoid valve-float function Y3/Y5 The available pressure oil flows via an orifice in the stage piston to the spring side of the piston and is blocked there by unenergized solenoids. Pressure and spring forces keep the valve closed. Tank pressure is applied constantly to the ring surface of the stage pistons and can lift them in case of low pressure in the control block channel A1 - A1 (Y3) or B1 - B1 (Y5) for suction. 2.3.4 Solenoid valve Y24 - Quick drop The oil returning from the end users via tank channel MT1 is slightly pressurized before the piston of the valve opens to the tank connection T. Oil reaching the spring chamber via the orifice in the piston flows through the open passage of the solenoid valve to connection T. 2.4. Quick drop unit 160 complete Oil in channel B - B1 - B1 flows around piston 161 and cannot act against the spring. The channel to connection P-solenoid valve Y23 is blocked on connection A. The pressurized hydraulic oil in channel A - A1 - A1 acts on the piston 161 and flows via a restrictor hole in the piston to its spring chamber. At the same time, the oil flow via a channel from A-A1-A1 to T-solenoid valve Y23-B also to the spring chamber. The piston is pressurized on both sides with the same pressure and is kept in neutral position by the higher force on the spring side (large surface x pressure) = passage A1 B1 remains blocked. 2.5. Lift cylinder 170 / check valves 171 When actuated with pressure, the pressure side check valves 171 open. However, the oil flow is blocked by the second check valves, which act in the opposite direction. When the pistons in the lift cylinders reach an end position, the previously blocked check valves are mechanically opened = the valve poppets contact the cylinder bottom/piston rod side, the cylinder pistons are moved further until the piston bottoms out, see group 8.8. The pressurized oil flows via the check valves to the opposite side, the system pressure does not increase further. 2.6. Solenoid valve - Diesel engine RPM safety Y28 If the Diesel engine overspeeds due to external influences, the electronic crawler control energizes the solenoid valve. The pressurized oil from the pump control cylinder 102 is directed via passage PB, valve block 50-T to the tank. The control cylinder 102 has no force, the return cylinder 103 shifts the axial piston unit 101, independent of the demand, to maximum flow. After the corresponding pressure build up, the increased flow is relieved to tank, via the primary pressure relief valve 131. The resulting higher power requirement acts as a brake force and prevents further increase of Diesel engine speed. 2.7. Oil pressure switch - return filter monitor B18 If the return filter element is not replaced in time, the back up pressure in the oil return line increases due to filter contamination. Just before the opening of the filter bypass valve 84, the electrical contact on the switch is closed (switching point 2.5 bar) and the indicator light on instrument panel lights up.

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Function
Datum Edition Date

PR 752

01 03

Working Hydraulic

F/N xxx-6200

Blatt Page Feuille

7.3.52.02

3. Operating function - Working movement - starting from neutral position according to par. 1 and identical operating functions according to par. 2. 3.1. Blade up 3.1.1 Servo control Control pressure build up from regulating piston 117 to housing outlet 1 b1-control valve block 130 spool 135 - displacement toward a1. 3.1.2 Working circuit Pressurized oil moves from spool 135 to control valve block-outlet-B1 A-quick drop unit 160-A1/A1 B1-lift cylinder 170. pressure relief valve 139. solenoid valve Y5.

The piston/piston rod in the lift cylinders is pushed in and the blade is raised. Oil returns from lift cylinder/piston bottom side to B1/B1-quick drop unit 160-B A1-control block 130 spool 135 tank line/connection T return filter 82 tank 80. 3.2. Blade down 3.2.1 Servo control Control pressure build up from regulating piston 116 to housing outlet 3 pressure switch B22. a1-control valve block 130 spool 135 -displacement toward b1. 3.2.2 Working circuit Pressurized oil moves from spool 135 to control block-outlet A1 B-quick drop unit 160-B1/B1 A1-lift cylinder170. relief valve 137. one-way valve 138. solenoid valve Y3. The pistons/piston rods move outward on the lift cylinders, the blade is lowered. It moves downward to the ground level through its own weight load pressure build up in oil return, force from ground level on load pressure build up in oil supply. Oil returns from lift cylinders / piston rod side to A1/A1-quick drop unit 160-A B1-control block 130 spool 135 tank connection MT1 solenoid valve Y24 block connection T return filter83 tank 80. 3.3. Blade quick drop 3.3.1 Servo control Oil pressure builds up from regulating piston 116 as for blade down", point 3.2.1 but above 24 bar switch B22 / electr. contact closed solenoid valve Y24 and Y23 energized actuated. 3.3.2 Working circuit Oil supply from spool 135 as for blade down", point 3.2.2, however, in quick drop unit 160 channel B1 - B1 is connected with the spring chamber of piston 161 via P B-solenoid valve Y23. Pump 100 / spool 135 supply maximum flow to lift cylinder 170/piston bottom side. Oil return from lift cylinder/piston rod side to A1/A1-quick drop unit 160 T-solenoid valve Y23-A blocked. piston161 channel B1 - B1 A1-lift cylinder 170/piston bottom side. 160-outlet A B1-control block 130 spool 135 tank connection MT1 solenoid valve Y24 blocked one way valve 138 oil supply A1-lift cylinder 170/piston bottom side. Blade drops to ground level position at maximum speed.

3.4. Blade tilt - left 3.4.1 Servo control Oil pressure builds up from regulating piston 118 to housing outlet 2 WT-distributor block 50 T- solenoid valve Y29-B distributor block 50-WB a2-control block 130 spool140 -displacement toward b2. 3.4.2 Working circuit Oil pressure flows from spool 140 to control block-outlet A2 support shaft right 180-B block 173-B tilt cylinder 175. The piston and piston rod are pressed outward in the tilt cylinder, the left blade corner tilts down. Oil returns from tilt cylinder/piston rod side to A-block 173 A-support shaft right 180 B2-control block 130 spool140 tank connection MT1 solenoid valveY24 block connection T return filter 83 tank 80. By moving the blade, the piston/piston rod is pulled out on the left lift cylinder and pushed in on the right lift cylinder - and therefore in the hydraulic circuit of lift cylinder, an oil flow is mechanically created (spool 140 remains closed).

Oil flow at intermediate position of lift cylinder pistons: Right lift cylinder/piston bottom side B1-quick drop unit 160-B1 left lift cylinder/piston bottom side. Left lift cylinder/piston rod side A1-quick drop unit 160-A1 right lift cylinder/piston rod side..

Oil flow at raised" end position: Right lift cylinder piston - blocked in bottom side end position, check valves are opened mechanically on one side. Left lift cylinder piston/movement toward piston rod side B1-pressure build up A1-quick drop unit 160-A1 B1-right lift cylinder/piston rod side check valves 171 piston bottom side-A1 B1-quick drop unit 160-B1 A1-left lift cylinder/piston bottom side. The missing oil volume (piston rod) is drawn in through the tank line via piston/solenoid valve Y3, one-way valve 138 or the suction function of pressure relief valve 137.

Oil flow at lowered" end position Left lift cylinder piston - blocked in rod side end position, check valves opened mechanically on one side. Right lift cylinder piston/movement toward piston bottom side A1-pressure build up B1-quick drop unit 160-B1 A1-left lift cylinder/piston bottom side check valves 171 piston rod side-B1 A1-quick drop unit 160-A1 B1-right lift cylinder/piston rod side. Excess oil (piston rod) is relieved via the pressure relief valve 137 to the tank. The resulting pressure on the piston rod side, which occurs at immediately tilting in the opposite direction, is limited by the pressure/suction valve 139.

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Function
Datum Edition Date

PR 752

01 03

Working Hydraulic

F/N xxx-6200

Blatt Page Feuille

7.3.52.03

3.5. Blade tilt - right 3.5.1 Servo control Pressure build up from regulating piston 119 to housing outlet 4 WP-distributor block 50 P-solenoid valve Y29-A distributor block 50-WA b2-control block 130 spool 140 -displacement towards a2. 3.5.2 Working circuit Pressurized oil moves from spool 140 to control block-outlet B2 support shaft right 180-A block 173-A tilt cylinder 175. The piston and piston rod are pressed inward in tilt cylinder, the right blade corner tilts down. Oil returns from tilt cylinder/piston bottom side to B-block 173 B-support shaft right 180 A2-control block 130 spool 140 tank line/connection T return filter 83 tank 80. By moving the blade, the piston/piston rod is pulled out on the right lift cylinder and pushed in on the left lift cylinder - and therefore in the hydraulic circuit of the lift cylinder, an oil flow is created mechanically (spool 140 remains closed).

Oil flow at intermediate position of lift cylinder pistons: Left lift cylinder/piston bottom side B1-quick drop unit 160-B1 right lift cylinder/piston bottom side.. Right lift cylinder/piston rod side A1-quick drop unit 160-A1 left lift cylinder/piston rod side..

Oil flow at raised end position: Left lift cylinder piston - blocked in bottom side end position, check valves opened mechanically on one side. Right lift cylinder piston/movement towards piston rod side B1-pressure build up A1-quick drop unit 160-A1 B1-left lift cylinder/piston rod side check valves 171 piston bottom side-A1 B1-quick drop unit 160-B1 A1-right lift cylinder/piston bottom side. The missing oil volume (piston rod) is drawn in from the tank line via solenoid valve Y3, one-way valve 138 or the suction function of pressure relief valve 137.

Oil flow at lowered end position: Right lift cylinder piston - blocked in rod side end position, check valves opened mechanically on one side. Left lift cylinder piston/movement toward piston bottom side A1-pressure build up B1-quick drop unit 160-B1 A1-right lift cylinder/piston bottom side end stroke valve 171 piston rod side-B1 A1-quick drop unit 160-A1 B1-left lift cylinder/piston rod side. Excess oil (piston rod) is relieved via pressure relief valve 137 to the tank. The resulting pressure on the piston rod side, which occurs at immediately tilting in the opposite direction, is limited by the pressure/suction valve 139. 3.6. Blade float function For blade float function, the solenoid valves Y3 and Y5 are energized electrically to open port" position, the spring chamber of the piston is relieved to the tank. If the blade is raised or lowered due to ground conditions, the pressurized oil in the lift cylinder circuit lifts the piston and oil flows out into the tank channel. The oil required on the opposite side of the lift cylinder pistons is drawn from the tank channel via the second solenoid valve (piston bottom side also via the one-way valve 138 and the relief valve 137).

Notes

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Parts list
Datum Edition Date

PR 752

F/N xxx-6200

01 04

Working Hydraulic

Blatt Page Feuille

7.3.52.00

50 distributor block 51 orifice P from filter assembly - replenishing / TH. B from parking brake / TH. 52 check valve

160 quick drop unit cpl. 161 piston / built-in valve 163 intermediate plate 170 lift cylinder 171 check valves - piston 173 block

55 accumulator 175 tilt cylinder 60 test center - test points ND servo pressure - working hydraulic LS load sensing pressure HP high pressure - working hydraulic 80 hydraulic tank 81 shut off valve 82 shut off valve 83 return filter 84 bypass valve 85 strainer 100 regulating pump cpl. 101 axial piston unit 102 control cylinder (Qmin) 103 return cylinder (Qmax) 105 intermediate plate 107 pressure cut off valve 109 load sensing regulator 115 pilot (servo) control valve 116 regulating piston - lower 117 regulating piston - lift 118 regulating piston - tilt left 119 regulating piston - tilt right 130 control valve block cpl. 131 pressure relief valve - primary safety 135 136 137 138 139 140 141 145 155 spool - lift / lower check valve pressure relief valve - secondary safety lift cylinder bottom side check valve pressure relief valve - secondary safety lift cylinder rod side spool - tilt check valve two way check valve end plate 180 support shaft right B18 pressure switch - return filter monitor B22 pressure switch - quick drop B26 temperature sending unit - indicator light hydraulic oil overheating Y3 Y4 Y5 Y13 Y23 Y24 Y28 Y29 solenoid valve - float position (bottom side) solenoid valve - servo cut off solenoid valve - float position (rod side) solenoid valve - parking brake - travel hydraulic solenoid valve - quick drop (return flow cut off) solenoid valve - quick drop solenoid valve - Diesel engine - RPM safety solenoid valve - special attachment

unnamed line outlets on the hydraulic tank - suction line for fan drive and replenishing - return line travel hydraulic - connection to hand pump - cab tilt parts list remarks TH. see group 6, page 6.3.5x.00

Benennung Description Dnomination

Typ/ab Type/from Type/a partir de

liebherr
Datum Edition Date

01 04

Arbeitshydraulik Working Hydraulic Hydraulique de travail

PR 752
Blatt Page Feuille

F/N xxx- 6200

7.3.52. 00

Important information
For pressure tests, use only glycerin filled pressure gauges with a reading accuracy of 1 % or higher. The pressure gauge scale value should be approx. 30%, max. 100% above the test value to be checked. Caution: To check, adjust or repair a machine, observe all safety regulations and park the machine on solid, level ground, raise and support the machine and the attachment properly. Never move the machine with the cab in the raised position. Secure the danger zone. Observe all safety guidelines, as noted in group 1.2.01. When putting a machine into service, proceed according to the guidelines issued in the Operation Manual, check the correct function of the indicator lights and gauges. Carry out all checks and adjustments with the engine running at the engine speed as noted in the Adjustment Checklist and with the machine at operating temperature. If any defects are found during the inspection, they should be corrected immediately or as soon as possible. For inspection and adjustments, use the corresponding Adjustment check list, page 3.5.xx.xx. The check list sequence corresponds to system requirements, and the following procedure is tuned to this sequence. Refer to the check list for nominal adjustment values. Observe the following instructions accurately.

Test and adjustment

1. Visual inspections and maintenance Before the system inspection, carry out all necessary maintenance and inspections. For checks / adjustments in between, observe the following points. 1.1. Service fluids and filters Check the coolant level as well as the oil level in the Diesel engine, splitter box and hydraulic tank, add fluids, as necessary. Check the air filter for contamination, damage, correct installation and correct type. Add fuel if necessary. Drain water and sediments, corresponding to the machine design, from the tank and water separator. In case of reduced performance, clean the filter screen, replace the pre- and fine filter. In case of suspected component problems/wear, open/check the hydraulic oil filter on the affected component. In case of temperature problems, check the hydraulic oil cooler and fan for contamination / damage. 1.2. Mechanical components Check the Diesel engine shut off, throttle control and potentiometer linkage for installation position, function and wear. Check the working hydraulic joystick, adjustment and wear of the control plate and dust covers. Check wire harnesses for damage, chafing and defective plug connections. Check the systems for leaks and function as well as hose routing. Check the mounting tightness of components, such as cylinders mounts, brackets, etc., check for condition and tightness.

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

PR Litronic

Test and Adjustment


Datum Edition Date

01 03

Working Hydraulic

Blatt Page Feuille

7.5.10.01

2. Operating temperature Check the oil temperature in the hydraulic tank with remote mounted thermometer, see special tools, group 2.1.20. With an external thermometer, test the temperature on several points of the tank surface and determine the average value. The pressure values in a hydraulic system may change due to oil viscosity. Viscosity, however, always changes depending on oil temperature. For that reason, always maintain a constant operating temperature, and monitor the temperature during the entire inspection and adjustment procedure. If necessary, the warm up procedure must be repeated or the oil cooler must be partially covered during inspection and adjustment procedures.

Various procedures can be selected to obtain the operating temperature: a) Operate the machine to bring it to operating temperature. b) Fully actuate ripper or tilt blade and at the same time, slowly extend and retract the lift cylinder in fine control range, with the HP pressure at approx. 105 bar. Oil is warmed up via the spool valve edge. c) Bottom out ripper and blade lift cylinder. Oil is warmed up via the lift cylinder check valves. Heat up for approx. 5 minutes, then wait for 1 minute. If supported properly, the travel drive can be fully actuated at the same time. Note: Do not actuate the "quick drop" function.

d) Fully actuate lift cylinder blade up and tilt function. Oil is warmed up via the lift cylinder check valves. Heat up for approx. 5 minutes, then wait for 1 minute. e) Raise the adjustment of the pressure cut off valve on the attachment pump to maximum 5 bar above the adjustment value (nominal value) of the primary pressure relief valve and fully actuate the ripper or tilt function. Fully actuate for approx. 1 minute, then hold for 20 seconds in neutral position, or the pressure relief valve will be damaged due to localized overheating. f) On PR 752, actuate the function RPM safety - Diesel engine with the test box - see group 10.4. Fully actuate for approx. 1 minute, then hold for 20 seconds in neutral position, or the pressure relief valve will be damaged due to localized overheating.

For procedures b, c, d, e and f, actuate the travel drive (chain run) during and at the end of the warm up procedure, to ensure that the complete hydraulic system warms up evenly. To do so, raise or drive the machine. 3. Pressure check - fixed test points PR 712742 - Battery compartment Test center - test points PR 752 - engine compartment, right

SP - Replenishing system pressure - TH ND - Servo pressure - WH LD (LS) - Load sensing pressure - WH HD - High pressure - WH LA - Operating pressure fan drive - TH (only at PR 752 and PR 712PR 742 from 5600) (additional on test center only at PR 752 from 5072) M1L High pressure travel forward, left - TH M1R High pressure travel forward, right - TH M2L High pressure travel forward, left - TH M2R High pressure travel forward, right - TH BB Operating pos. of hose to brake - TH BS Towing position of hose to brake - TH

4. Check servo pressure Check on test point ND with 0-40 (0-60) bar pressure gauge. The pressure results from the SP pressure of the travel hydraulic and the flow restriction between components and the test points (see schematic, section 6.3). If the required pressure is not reached, check the components before (at oil flow direction) the test point connection. If the required pressure is reached and problems occur due to low servo pressure, check the components after the test point connection. Check components for flow problems (excessive restriction results in drop of pressure), as well as for leakage to tank connection (internal leaks). 5. Stand by pressure Check on test point HD with 0-40 bar or 0-100 bar pressure gauge. The initial check should always be made with a 0-100 bar (or higher) pressure gauge. To check, make sure no working function is actuated.

5.1. Adjustment of regulating pump - type A10V If the pressure does not correspond to the nominal value, remove the cap on the LS regulator, loosen the lock nut and turn the adjustment screw until the nominal value is reached. To increase pressure, turn in clockwise direction, to decrease pressure, turn counterclockwise. This adjustment also influences the p value (HD-LS) of LS regulation. After adjustment, tighten the lock nut, install the cap and recheck the pressure setting.

5.2. Adjustment of regulating pump - type HPR" If the pressure does not correspond to the nominal value, loosen the lock nut on the adjustment screw for Qmin flow limitation. If the pressure is too high, turn the screw approx. 360 counterclockwise. Remove the pressure gauge and actuate a WHfunction for a short period. Connect the pressure gauge and recheck the stand-by pressure. Repeat as necessary until the pressure has dropped below 30 bar. To increase pressure to the nominal value, slowly turn the screw in clockwise direction while constantly monitoring the pressure gauge reading. After adjustment, tighten the lock nut and recheck the pressure adjustment. Note: Stand-by pressure is easier to adjust when the pressure difference - p HD to LD (LS function) has first been set as outlined in paragraph 7.

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

PR Litronic

Test and Adjustment


Datum Edition Date

01 03

Working Hydraulic

Blatt Page Feuille

7.5.10.02

6. Pressure limitation Check on test point HD with 0-400 or 0-600 bar pressure gauge. For control valve type - see data page 7.1, for control valve design - see section 8.6, other valves design/ function - section 8.7, pump design - section 8.3. Control valve block - type M5 For all pressure checks/adjustments, except maximum working pressure, the adjustment of the pressure cut off valve on the pump regulator must be raised step by step until it is ensured that the primary pressure relief valve opens before the permissible secondary pressure. Then set the pressure cut off valve above the secondary setting and raise the primary relief valve adjustment until the secondary relief valve to be checked, opens or until its nominal value (including tolerance) has been exceeded by maximum 5 bar. If necessary, adjust the checked pressure relief valve to nominal value. Control valve block - type M7 and M6 Always adjust the primary relief valve first, then check/adjust the secondary relief valves. For all pressure checks/adjustments, except maximum working pressure, the adjustment of the pressure cut off valve on the pump regulator must be raised step by step until it is ensured that the valve to be checked opens or the nominal value (including tolerance) of the primary relief valve has been exceeded by maximum 5 bar. If necessary, adjust the checked pressure relief valve to nominal value. After the tests, readjust the valves with raised values back to nominal value. Valve adjustment procedure: - Remove the lead seal. Loosen the lock nut on the adjustment screw. - Turn the adjustment screw in clockwise direction = to increase pressure - Turn the adjustment screw in counterclockwise direction = to decrease pressure - Tighten the lock nut, attach new lead seal. To check/adjust corresponding functions, bottom out function, but do not actuate suddenly. Position of Pressure cut off valves Regulating pumps - type A10V Regulating pumps - type HPR

Position of Pressure relief valves Control valve block - type M5 Control valve block - type M7 and "M6"

1 2 3

Pressure relief valve - primary relief Pressure relief valve - secondary relief / lift cylinder piston bottom side Pressure relief valve - secondary relief / lift cylinder piston rod side = PR752 only

6.1. Test procedure on machines with control valve block - type M5 - see data page 7.1.00.01 6.1.1 Check/adjust secondary pressure, primary pressure and pressure cut off (inspection procedure) On both lift cylinders, loosen the screws on the SAE flange from connection B (line connections to piston bottom side) and install test plates. For required size, see special tools, page 2.1.21.01. Actuate the blade down function, check the pressure gauge reading. Raise pressure setting of cut off valve and primary pressure relief valve as described in paragraph 6. Adjust secondary pressure relief valve to nominal value primary pressure relief valve to nominal value pressure cut off valve to nominal value. Remove the test plates, replace the seal rings, if necessary, tighten flanges. If additional circuits with secondary relief valves are installed, actuate/set the corresponding functions / pressure relief valves before resetting the primary pressure relief valve. 6.1.2 Check/adjust only primary pressure and pressure cut off (for repairs, if necessary) Actuate the tilt blade or ripper function, monitor the pressure gauge, raise the setting of the pressure cut off valve as described in paragraph 6. Adjust primary pressure relief valve to nominal value, if necessary adjust pressure cut off valve to nominal value. 6.1.3 Check/adjust only pressure cut off (for repairs, if necessary) Actuate the tilt blade or ripper function, monitor the pressure gauge, adjust the pressure cut off valve to nominal value. 6.2. Test procedure on machines with control valve block - type M7 and M6 - see data page 7.1.00.01 6.2.1 Check/adjust primary pressure (inspection procedure) Actuate the tilt blade function or additional attachments without secondary relief, monitor the pressure gauge. Raise the setting of the pressure cut off valve as described in paragraph 6. Adjust primary pressure relief valve to nominal value, if necessary leave the pressure cut off valve adjustment for secondary pressure check. 6.2.2 Check/adjust secondary pressure and pressure cut off (inspection procedure) Adjustment of pressure cut off valve still raised from primary pressure check procedure. PR 712 to PR 742 (do not use for machine type PR 752) Lightly actuate the blade down function until the lift cylinder pistons bottom out, then continue to deflect the joystick lever past the pressure point to quick drop function and watch the pressure gauge. Set the secondary pressure relief valve to nominal value, if necessary set the pressure cut off valve to nominal value. PR 752 On both lift cylinders, loosen the screws on the SAE flange - connection A and B and install test plates. For size, see special tools, page 2.1.21.01. Actuate the blade down function and check the pressure setting of the secondary pressure relief valve, set to nominal value, if necessary. Actuate the blade up function and check the setting of the secondary pressure relief valve on the pressure gauge, set to nominal value if necessary set the pressure cut off valve to nominal value. If additional circuits with secondary valves are installed, actuate/set the corresponding functions/pressure relief valves before resetting the pressure cut off valve.
Benennung Description Dnomination Typ/ab Type/from Type/ a partir de

Mjfcifss!

PR Litronic

Test and Adjustment


Datum Edition Date

01 03

Working Hydraulic

Blatt Page Feuille

7.5.10.03

6.2.3 Check/adjust only pressure cut off (for repairs, if necessary) Actuate a function as in paragraph 6.2.1, monitor the pressure gauge, if necessary, set the pressure cut off valve to nominal value. 7. Pressure difference - p "HD" to "LD(LS)" ("high" pressure to "load" pressure/load sensing) Check at test point HD and LD (LS) with a 0-100 bar and/or 0-250 bar pressure gauge. The initial test should always be performed with a 0-250 bar (or higher) pressure gauge, to determine the more exact value, use a 0-100 bar pressure gauge. Place the blade in horizontal position and raise it all the way. Deflect the joystick about half way in blade up" direction (=fine control range) and hold it in this position. Read the pressure values of test points HD and LD (LS) and compare. The pressure difference HD to LD(LS)=p must decrease with corresponding lever movement from the upper tolerance limit down to 15 bar.

When spools are fully opened (= almost full lever deflection), p must decrease abruptly below 13 bar. If this range is not reached, then the pump is not regulating at maximum flow. This test should be performed with all working movements. Determine the pressure during the working movement on test point HD and LD (LS) at the same time. If the p 13 bar range is not reached, then the pump is not regulating at maximum flow. Possible causes for this problem are, for example: LS-regulator is stuck, axial piston unit of the pump or spool is not moved sufficiently, extreme pump wear, etc. 7.1. Adjustment of regulating pump - type A10V The regulating function pressure difference is part of the stand by pressure adjustment and cannot be adjusted separately. If there are problems, check the regulator function, for example: easy movement of the piston. 7.2. Adjustment of regulating pump - type HPR If the pressure difference in the fine control range does not match nominal value, release the lock nut from the adjustment screw on LS regulator. Turn the screw to approx. 90, depending on deviation, and check the pressure difference again. Repeat procedure until the nominal value is reached. Turn in clockwise direction Turn in counterclockwise direction to increase p / to raise HD pressure to decrease p / to decrease HD pressure the the the the

After the adjustment, tighten the lock nut and recheck. If p is not 13 bar, with spool fully open, see paragraph 7.

8. Check accumulator (emergency function) Let the Diesel engine run at high speed for a few minutes, raise the blade, turn the Diesel engine off. Leave the safety lever and the starter switch in operating position or return it to position 1. Actuate the blade down function a short distance several times - the blade must go down step by step (at least 4 times), or actuate the blade until the blade has dropped to the ground. If this requirement is not performed, check system and accumulator, renew defect parts.

9. Check quick drop function Normally, the quick drop function must only be checked in case of problems and therefore, it is not listed on the adjustment check list. If the function is actuated before the joystick reaches the pressure point, then the actuating point of the pressure switch is set too lowcheck/adjust function (replace switch). If the function does not actuate despite a fully deflected joystick, then the actuating point of pressure switch is set too high, the current supply from the switch to the solenoid valve is interrupted, or the solenoid valve is defective check electrical system / solenoid valve, check/adjust pressure switch function. For hydraulic functions, see group 7.3, for valve design, group 8.7, electrical system, group 9. 9.1. Check/adjust function of pressure switch Disconnect the oil pressure switch on connection 3 of the pilot control valve (joystick) and install a test fitting for a pressure gauge. Connect a 0-40 bar pressure gauge. Move the control lever towards blade down" to the pressure point. Watch the pressure gauge reading and continue to move the joystick past the pressure point. When the pressure point is passed, the pressure must star to increase. If the pressure does not increase or the readings are outside the norm values, check the pilot control / servo pressure, correct problem. On the switch, remove the color seal on the adjustment screw, remove the pressure gauge connection, install the switch and connect it with the currented wire. Check the power supply with a test lamp or voltage meter to determine the actuating point on the second electrical contact of the switch. Actuating point = voltage increase 0 24V. Deflect the joystick in blade down" direction, to the actuating point. The switch should not actuate, if necessary, raise the actuating point. Continue to deflect the joystick past the pressure point. The switch must actuate, otherwise lower the actuating point. Turn the adjustment screw on the switch in clockwise direction to raise the actuating point, turn it in counterclockwise direction to lower the actuating point. If the required actuating point cannot be reached, replace the switch.

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

PR Litronic

Test and Adjustment


Datum Edition Date

01 03

Working Hydraulic

Blatt Page Feuille

7.5.10.04

Sub Group Index


Variable pump travel hydraulic
Intermediate flange PR 712 F/N xxx-0103 PR 722 F/N xxx-0103 PR 732 F/N xxx-2003 Variable pump PR 712(B) F/N xxx-0103 PR 722(B) F/N xxx-0103 PR 732(B) F/N xxx-2003 Variable pump PR 742(B) F/N xxx-20015233 Variable pump PR 742B F/N xxx-5234 Variable pump PR 752 F/N xxx-2002

8.1
8.1.01

8.1.10

8.1.40 8.1.41 8.1.50

Variable motor travel hydraulic


Variable motor PR 712(B) F/N xxx-0103 PR 722(B) F/N xxx-0103 Variable motor PR 732(B) F/N xxx-2003 PR 742(B) F/N xxx-2003 Variable motor PR 752 F/N xxx-2002

8.2
8.2.10

8.2.30

8.2.50

Variable flow pump working hydraulic


Variable flow pump A10V PR 712(B) F/N xxx-0103 PR 722(B) F/N xxx-0103 PR 732(B) F/N xxx-2003 PR 752 F/N xxx-2002 Variable flow pump HPR PR 742B F/N xxx-20012500 PR 752 F/N xxx-2001

8.3
8.3.10

(fan drive) 8.3.40

Constant pumps and motors


Gear pump travel hydraulic Axial piston - constant motor fan drive PR 732 F/N xxx-5600 PR 742 F/N xxx-5600

8.4
8.4.01 8.4.02

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!
Datum Edition Date

PR Litronic

01 04

Hydraulic components

Blatt Page Feuille

8.0.00.01

Pilot control valve working hydraulic


Pilot control valve 2-way Pilot control valve 4-way PR 712(B) F/N xxx-0103 PR 722(B) F/N xxx-0103 PR 732(B) F/N xxx-2003 PR 742(B) F/N xxx-20016199 Pilot control valve 4-way PR 742B F/N xxx-6200 PR 752 F/N xxx-2001

8.5
8.5.03 8.5.10

8.5.40

Control valve block


PR 712 PR 722 PR 732 PR 742 F/N xxx-01030384 F/N xxx-01030563 F/N xxx-20032500 F/N xxx-20012500

8.6
8.6.10

PR 712(B) F/N xxx-03853084 PR 722(B) F/N xxx-05643175 PR 732B F/N xxx-25013206 PR 742B F/N xxx-25013095 PR 712B PR 722B PR 732B PR 742B PR 752 PR 752 F/N xxx-3085 F/N xxx-3176 F/N xxx-3207 F/N xxx-3096 F/N xxx-20022077 F/N xxx-2078

8.6.11

8.6.12

8.6.50 8.6.51

Valves
Overview Pressure valves Directional valves Shut off valves Other valves

8.7
8.7.00 8.7.01 8.7.02 8.7.03 8.7.04

Hydraulic cylinder

8.8

Intermediate flange variable pump BPV - regulating pump A10V


1 variable pump 1.1 drive shaft 1.2 tapered roller bearing 2 regulating pump - working hydraulic 2.1 drive shaft 3 4 5 6 7 8 9 10 11 12 13 14 15 16 intermediate flange centering flange connector sleeve hex head screw O-ring washer hex head nut socket head screw stud washer hex head nut O-ring O-ring O-ring

Intermediate flange variable pump BPV - constant pump


1.1st version: PR 712 F/Nxxx-0103 , PR 722 F/N xxx-0103 , PR 732 F/N xxx-2003 xxxx, RL 22 F/N xxx-1001 1 variable pump 1.1 drive shaft 1.2 tapered roller bearing 2 gear pump - replenishing 2.1 input shaft 3 intermediate flange 4 connector sleeve 5 spring 6 stud 7 washer 8 hex head nut 9 O-ring 10 O-ring 11 socket head screw 12 washer

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!

Variable pumps
Datum Edition Date

PR 712 PR 722 PR 732

F/N xxx-0103 F/N xxx-0103 F/N xxx-2003

01 04

Intermediate flange
Travel hydraulic

RL (4)22 F/N xxx-1001


Blatt Page Feuille

8.1.01.01

Intermediate flange Variable pump BPV - constant pump 2.2nd version: PR 732 F/N xxx-xxxx 7149

1 variable pump 1.1 drive shaft 1.2 tapered roller bearing 2 gear pump - replenishing 2.1 input shaft 3 intermediate flange 4 O-ring 5 O-ring 6 stud 7 washer 8 hex head nut 9 connector sleeve 10 lock ring 11 washer 12 spring 13 washer 14 socket head screw

3.3rd version: PR 732B F/N xxx-7150 1 variable pump 1.1 drive shaft 1.2 tapered roller bearing 2 gear pump - replenishing 2.1 input shaft 3 intermediate flange 4 O-ring 5 O-ring 6 stud 7 washer 8 hex head nut 9 connector sleeve 10 lock ring 11 sleeve 12 spring 13 washer 14 socket head screw

Notes

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!
Datum Edition Date

PR 712(B) F/N xxx-0103 PR 722(B) F/N xxx-0103 PR 732(B) F/N xxx-2003

01 01

Variable pump
Travel hydraulic

Blatt Page Feuille

8.1.10.01

1 housing 1.1 main housing 1.2 cover with electro-hydr. remote control 1.2.1 cover with remote control setscrew - end stop 1.2.2 cover with remote control eccentric pin - end stop 1.3 cover - mech. zero position 2 control plate mounting 3 flange 4 O-ring 5 swash plate 6 needle bearing - segment 7 retainer - guide 8 flange bolt 9 control cylinder 10 washer 11 control piston 12 seal 13 retainer plate 14 spacer 15 spacers 16 socket head screws 18 pilot valve, complete 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 ball end pin ball pin spring spacer pin O-ring drive shaft race cover socket head screws radial shaft seal tapered roller bearing spacers pin cylinder barrel piston with glide shoe return plate control plate support ring spring washer (retainer) shim lock ring tapered roller bearing for pumps with internal SP-pressure limitation: 44 pressure relief valve - replenishing 45 plug 46 adjustment shims 47 O-ring 48 spring 49 valve housing 50 piston

for pumps with external SP-pressure limitation: 44/1 intake restrictor 1,0 mm 47 O-ring 51 comp. pressure relief valve - high pressure with replenishing function 52 plug 53 O-ring 54 valve housing 55 O-ring 56 valve block 59 cylinder pin 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 90 91 92 93 94 95 96 spring cup spring spring cup roll pin bracket eccentric pin self sealing lock nut roll pin thrust washer roll pin hex head screw socket head screws eccentric pin - hydr. zero position O-ring hex nut O-ring lever piston - cylinder spring cup O-ring spring housing nut setscrew - end stop self sealing lock nut regulating spring regulating spring spring housing spring cup pressure relief valve proportional solenoid O-ring end stop plug hex nut eccentric pin lock ring

100 socket head screws 101 plug with O-ring

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!
Datum Edition Date

PR 712(B) F/N xxx-0103 PR 722(B) F/N xxx-0103 PR 732(B) F/N xxx-2003

01 01

Variable pump
Travel hydraulic

Blatt Page Feuille

8.1.10.02

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!
Datum Edition Date

PR 712(B) F/N xxx-0103 PR 722(B) F/N xxx-0103 PR 732(B) F/N xxx-2003

01 01

Variable pump
Travel hydraulic

Blatt Page Feuille

8.1.10.03

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!
Datum Edition Date

PR 712(B) F/N xxx-0103 PR 722(B) F/N xxx-0103 PR 732(B) F/N xxx-2003

01 01

Variable pump
Travel hydraulic

Blatt Page Feuille

8.1.10.04

Notes

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!
Datum Edition Date

07 01

Variable pump
Travel hydraulic

PR 742(B) F/N xxx-2001 5233 RL 42B F/N 683-2001


Blatt Page Feuille

8.1.40.01

1 1.1 1.2 1.3

housing main housing bearing housing regulator housing with remote control

2 control plate mounting 3 O-ring 4 socket head screw 5 6 7 8 9 10 11 12 13 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 drive shaft race snap ring radial shaft seal snap ring tapered roller bearing spacer shims tapered roller bearing swash plate needle bearing- segment cyl. pin - bearing shell lock bracket - bearing guide stud pin plug - pin lock return plate piston with glide shoe cylinder barrel complete return ball shims pin support ring spring support ring snap ring

70 71 72 73 74 75 76 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 101 102 103 104

spring cup spring pin pilot piston valve sleeve spring plug plug ball / socket lever pin with lock plate guide pin proportional solenoid regulation valve O-ring plug plug O-ring grooved nut spring spring cup threaded pin collar nut spring housing threaded pin with nut spring cup piston - cylinder O-ring plug dowel pin plug

32 control plate 33 pin 35 36 37 38 39 40 41 45 46 47 48 49 50 51 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 socket head screw pin dowel pin dowel pin O-ring O-ring socket head screw cover - control cylinder socket head screw plug nozzle O-ring O-ring O-ring control cylinder cylinder bushing piston piston seal ring piston rod with ball socket spring cup ball pin hex head nut spring spring plug valve sleeve stop socket head screw spring snap ring

106 segment 107 hex head screw with washer 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 valve block outlet socket head screw replenishing valve plug stud O-ring O-ring nozzle O-ring plug pressure relief valve - HP valve housing threaded pin - pressure adjustment collar nut O-ring O-ring

135 plug 136 O-ring 138 plug 140 pressure line 141 tank line 142 to cylinder F I X pressure connection - supply side connection - tank return side pressure connection - control pressure

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!
Datum Edition Date

07 01

Variable pump
Travel hydraulic

PR 742(B) F/N xxx-2001 5233 RL 42B F/N 683-2001


Blatt Page Feuille

8.1.40.02

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!
Datum Edition Date

07 01

Variable pump
Travel hydraulic

PR 742(B) F/N xxx-2001 5233 RL 42B F/N 683-2001


Blatt Page Feuille

8.1.40.03

Notes

Notes:

1) Following parts are just for its designated installation position - do not interchange them: 2 pcs. pos. 42 - spacer 2 pcs. pos. 46 - tube guide and 2 pcs. pos. 48 - shim 2) Following parts are suited to the given tolerances of the parts: pos. 17 - shim pos. 21 - shim pos. 29 - shim pos. 72 - spring cap pos. 87 - shim (with pos. 88 - snap ring) 3) Remark when exchanging: heat the race pos. 11 to maximum 150C and install with Loctite 648 or equivalent. install radial shaft seal pos. 12 with Loctite 648 or equivalent and fill space between sealing lips with appr. 50% grease. 4) The hydraulic zero-position of the pump is given by the position of the valve housing pos. 80. Preadjustment (as necessary): Distance between front area valve housing pos. 80 to housing pos. 60 = 14,75 mm 5) Tightening torque for pressure relief valve Pos. 50 = 170 Nm

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!
Datum Edition Date

PR 742B F/N xxx-5234

01 03

Variable pump
Travel hydraulic

Blatt Page Feuille

8.1.41.01

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 25 26 27 28 29 30 31 32 33 34

housing snap ring O-ring plug control plate mounting plug O-ring socket head screw plug (M14x1,5 mm) with O-ring drive shaft race radial shaft seal tapered roller bearing support ring spring washer (retainer) shim snap ring support ring tapered roller bearing shim swash plate bearing race pin retainer plate shim sleeve socket head screw piston with glide shoe return plate cylinder barrel complete

60 61 62 63 64 65 66 68 70 71 72 73 74 75 76 77 78 79

housing with bushings - pump control O-ring O-ring socket head screw sleeve plug plug plug piston end stop screw spring cup* spring spring cup spring housing O-ring nut setscrew - end stop self sealing lock nut

80 valve housing 81 O-ring 82 nut 83 spring 84 pilot piston 85 86 87 88 89 90 support lever shim snap ring socket head screw sleeve

91 pressure regulating valve - cartridge 35 control plate (ccw) 36 pin 40 41 42 43 44 45 control piston seal ring spacer* washer spring spring cup 95 proportional solenoid 96 O-ring 98 plug 99 O-ring

46 tube guide* 47 O-ring with support ring 48 shim* 50 pressure relief valve complete with replenishing function 51 O-ring 52 valve support 53 spring 54 guiding plate (fixed onto pos. 57) 55 snap ring 56 valve piston (one way valve) 57 valve piston (pressure relief valve) 58 spring 59 O-ring

F L MP P(S) S(P) T U Y (Y) Z (Z)

connection to filter (control pressure/replenishing) connection - housing to tank test point - to P/S connection - high pressure line connection - high pressure line connection / housing (bleeding) connection / housing servo control - flow in direction S(P) test point servo pressure at Y servo control - flow in direction P(S) test point servo pressure at Z

* = observe remarks on the front page accurately

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!
Datum Edition Date

PR 742B F/N xxx-5234

01 03

Variable pump
Travel hydraulic

Blatt Page Feuille

8.1.41.02

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!
Datum Edition Date

PR 742B F/N xxx-5234

01 03

Variable pump
Travel hydraulic

Blatt Page Feuille

8.1.41.03

Notes

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!
Datum Edition Date

07 01

Variable pump
Travel hydraulic

PR 752 RL 52
Blatt Page Feuille

F/N xxx-2002 F/N 739-2001

8.1.50.01

1 2 3 4 5 6 7 8

housing cover socket head screw radial shaft seal drive shaft race tapered roller bearing shim

9 pin with O-ring 10 11 12 13 14 15 16 17 18 19 20 swash plate needle bearing - segment retainer - bearing guide bolt with washer and cotter (bolt fixed with roll pin ) flange bolt control piston seal ring retainer plate spacer shims socket head screw

50 cover with cylinder pins electro-hydr. remote control 51 piston - servo control 52 spring cup 53 regulating spring 54 regulating spring 55 spring housing 56 O-ring 57 nut 58 setscrew - end stop 59 self sealing lock nut 60 lever 61 eccentric pin w. O-ring and counter nut (hydr. zero) 62 pressure regulating valve - cartridge 63 proportional solenoid 64 O-ring 65 shuttle valve block 66 valve seat 67 ball 68 hollow screw with O-ring 70 pilot valve complete (housing, spring, piston) 72 flange 73 O-ring 74 O-ring 75 76 77 78 79 80 81 82 83 84 85 86 87 90 91 92 93 94 95 96 97 98 99 check valve housing - replenishing piston spring spring retainer retainer ring pressure relief valve housing O-ring spring retainer shims spring valve socket valve body orifice 2,2 mm pressure relief valve housing - high pressure O-ring shims spring retainer spring spring spring retainer ring O-ring valve cartridge with poppet and closing ball

21 control cylinder 22 spacer 23 24 25 26 27 28 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 ball end pin ball pin spring spacer pin O-ring with steel ring O-ring cylinder barrel - complete piston with glide shoe return plate control plate (ccw) support ring spring washer (retainer) shim lock ring tapered roller bearing control plate mounting O-ring plug plug cover with cylinder pins - mech. zero position bar eccentric pin with self sealing lock nut spring cup with spring guide spring spring cup with roll pins

101 hex head screw 102 hex head screw 105 coupling sleeve

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!
Datum Edition Date

07 01

Variable pump
Travel hydraulic

PR 752 RL 52
Blatt Page Feuille

F/N xxx-2002 F/N 739-2001

8.1.50.02

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!
Datum Edition Date

07 01

Variable pump
Travel hydraulic

PR 752 RL 52
Blatt Page Feuille

F/N xxx-2002 F/N 739-2001

8.1.50.03

Notes

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!
Datum Edition Date

PR 712(B) F/N xxx-0103 PR 722(B) F/N xxx-0103

01 01

Variable motor
Travel hydraulic

LR 622 RL(4)22
Blatt Page Feuille

F/N 392-2030 F/N xxx-1001

8.2.10.01

1 housing complete 1.1 main housing 1.2 housing - control plate mounting 1.3 housing - remote control 1.4 cover 2 drive shaft bearing unit 2.1 drive shaft 2.2 flange 2.3 socket head screw 2.4 spacer 2.5 O-ring 2.6 radial shaft seal ring 2.7 nut 2.8 tapered roller bearing 2.9 bushing 2.10 socket head screw with washer 2.11 tapered roller bearing 4 retainer plate 5 socket head screw 6 piston with rod / retainer ring 7 cylinder bushing 8 cylinder barrel 9 center pin 10 lock ring 11 spring 12 retainer with spacers 13 lock ring 15 control plate 16 bushing 20 sensor (RPM) 21 O-ring 25 control piston 26 pin 27 threaded pin 28 spring 29 spring cup 30 pilot piston 31 spring cup 32 lock ring 33 spring 34 spring cup with washer 35 O-ring 36 cylinder pin 37 cylinder pin 38 39 40 41 42 socket head screw O-ring set screw self sealing lock nut O-ring

50 proportional solenoid 51 adjustment screw with nut 52 spring with washer 53 O-ring 54 bushing 55 plug 60 pressure relief valve (10 bar) 61 valve housing 62 O-ring 63 plug 64 shim 65 spring 66 ball 67 orifice 70 2/7 - directional valve with pressure reducing valves - valve version I and II 71 valve housing 72 plug - version I 73 spring 74 piston (pressure reducing valve) 75 plug 76 O-ring - version II 77 lock ring - version II 78 spring cup - version II 80 81 82 83 84 85 86 HD - channel HD - channel channel - control pressure channel - piston bottom side channel - spring chamber channel - flushing channel - tank

87 set screw - plug

45 O-ring 46 O-ring

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!
Datum Edition Date

PR 712(B) F/N xxx-0103 PR 722(B) F/N xxx-0103

01 01

Variable motor
Travel hydraulic

LR 622 RL(4)22
Blatt Page Feuille

F/N 392-2030 F/N xxx-1001

8.2.10.02

Valve Version II

Valve Version I

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!
Datum Edition Date

PR 712(B) F/N xxx-0103 PR 722(B) F/N xxx-0103

01 01

Variable motor
Travel hydraulic

LR 622 RL(4)22
Blatt Page Feuille

F/N 392-2030 F/N xxx-1001

8.2.10.03

Notes

Benennung Description Dnomination

Typ/ab Type/from Type/ a partir de

Mjfcifss!
Datum Edition Date

PR 732(B) F/N xxx-2003 PR 742(B) F/N xxx-2003 LR 632 F/N 393-2002 RL 42B F/N 683-3002
Blatt Page Feuille

01 04

Variable motor
Travel hydraulic

8.2.30.01

1 housing complete 1.1 main housing 1.2 housing - control plate mounting 1.3 housing - remote control 1.4 cover 2 drive shaft bearing BMV 186 - PR 732(B)/LR 632 2.1 drive shaft 2.2 flange 2.3 socket head screw 2.4 spacer 2.5 O-ring 2.6 radial shaft seal ring 2.7 nut 2.8 tapered roller bearing 2.9 bushing 2.10 socket head screw with washer 2.11 tapered roller bearing 3 drive shaft bearing BMV 260 - PR 742(B)/RL 42B 3.1 drive shaft 3.2 flange 3.3 socket head screw 3.4 spacers 3.5 spacer 3.6 O-ring 3.7 radial shaft seal ring 3.8 race 3.9 straight roller bearing 3.10 ring 3.11 spacer 3.12 bushing 3.13 comb. axial - radial straight roller bearing 3.14 socket head screw with seal ring 3.15 ball cup - center pin 4 retainer plate 5 socket head screw 6 piston with rod / retainer ring 6.1 piston with rod and ball cup 7 cylinder bushing 8 cylinder barrel 9 center pin 10 lock ring 11 spring 12 retainer with spacers 13 lock ring 15 control plate 16 bushing 20 sensor (RPM) 21 O-ring 22 spacers (only PR 742, RL 42B) 25 control piston 26 pin 27 threaded pin 28 spring 29 spring cup

30 pilot piston 31 spring cup 32 lock ring 33 spring 34 spring cup with washer 35 O-ring 36 cylinder pin 37 cylinder pin 38 39 40 41 42 socket head screw O-ring set screw self sealing lock nut O-ring

45 O-ring 50 proportional solenoid 51 adjustment screw with nut 52 spring with washer 53 O-ring 54 bushing 55 plug 60 pressure relief valve (10 bar) 61 valve housing 62 O-ring 63 plug 64 shim 65 spring 66 ball 67 orifice 70 2/7 - directional valve w. pressure reducing valves 71 valve housing 72 lock ring 73 spring cup 7