Service manual Crawler dozer Document ID Order number: Issued Versio! Author: Product ID Manufacturer: Valid for: Conformity: Contact 12203101 01.02.2021 12 LWT / Technical Documentation Department Liebherr-Werk Telfs GmbH PR 776-1296 CE Liebherr-Werk Telfs GmbH Hans Liebherr-StraRe 35 A—6410 TelfsPRI76-1296i Foreword Notes for the user This Service manual is intended for trained specialist staff in the Liebherr organiza- tion and its dealers, The Service manual provides specific knowledge for the maintenance of Liebherr construction machinery. Basic technical knowledge of electrics, hydraulics, ‘mechanics and Diesel engine technology are not detailed in this Service manual. A subject-based, qualified training is therefore necessary. Liebherr recommends Participation on the Liebherr Training program for construction machinery, In this Service manual you find information about: = Special tools = Technical data — Maintenance intervals and maintenance tasks = Adjustment procedure = Design and functional descriptions — Removal and installation tasks = Wiring diagrams, hydraulic schematics and technical drawings For information relating to control and operation refer to the operator's manual. For information relating to spare parts refer to the Spare parts catalog. Observe the locally applicable accident prevention regulations. This document - even in part - may only be reproduced with approval from Liebherr, ‘Subject to technical changes. Designation of safety advice of injury. Follow all measures, which are marked A This is a warning sign. Warns of possible danger with this warning sign to avoid injuries or death, ‘The warning sign always appears in connection with the signal words DANGER WARNING CAUTION DANGER __|indicates an immediate dangerous situation which will lead to death or serious bodily injury ifit is not prevented. WARNING __ [indicates a dangerous situation which could result in fatal or serious bodily injury if tis not prevented. LIEBHERR 3Foreword Service manual |CAUTION indicates a dangerous situation, which could result in slight or medium-grade bodily injuries if it is not prevented. NOTICE indicates a dangerous situation which could result in material damage if itis not prevented. Structure of warning notes Warning notes in this document are structured as follows: WARNING Here you find information about the type and source of the danger. Here you are information about possible consequences, if you ignore the warning note. > Here you are asked to take measures to avoid the dangerous situation. nal designations Symbol [Meaning ®@ Note indicates useful information and tips. > io > [This symbol means: perform task This symbol means: prerequisite must be met This symbol means: result of a task [This symbol identifies a listing. ‘Symbols Colour legend for the hydraulic schematics Line thickness Name Thick or thin High pressure Thick Tank line Thin Leak oil line Thin [Supply pressure or pilot pressure to the pilot control — unit ae 4 LIEBHERR PRI76-1296i Service manual Foreword Colour Line thickness. Name Thin Control pressure or pilot eet pressure from the pilot control unit | | Thick Enclosed oil [| Thick Operating pressure || Thin Load sensing pressure PR775-1298Foreword Service manual PRI76-1296010 Introduction Contents 010.1 010.2 Safety instructions 00.1.1 General safety instructions 010.1.2 Safety instructions for crushing and burn prevention 010.1.3 Safety guidelines for fire and explosion prevention 010.1.4 Safety instructions for machine start up 010.1.5 Safety instruction for start up 010.1.6 Safety guidelines for working 010.1.7 Safety instructions for parking the machine 010,1.8 Safety instructions for transporting machine 00.1.9 Safety instructions for towing machine 010.1.10 Safety instructions for maintenance 010,1.11 Safety guidelines for welding work on machine 010.1.12 Safety guidelines for working on attachment 010.1.13 Safety guidelines for loading machine with a crane 010-12 010.1.14 Safety notes for maintenance of hydraulic hoses and hose lines 010-12 010.1.15 Safety guidelines for maintenance work on machines with hydro accumulators 010.1.16 Roll aver protection (ROPS) and falling abject protection (FOPS) 010.1.16.1 Avoid accidents 010.1.16.2 Avoid injuries 010.1.17 Equipment and attachment parts 010-14 010.1.18 Protection from vibrations 010-14 010.1.19 See and be seen 010-15 010.1.19.2 Field of vision 010-45, 010.1.19.3 Measures before and during operation 010-47 010.1.20 Safety notes for Diesel engines with electronic control units 010-17 010.1.21 Safety notes for working on Common Rail System of Diesel engines)10-18 Special tools for maintenance and repair work 010-20 010.2.1 Tools - Diesel engine PR775-1298Contents Service manual 010.3 010.4 010.2.2 Tools - Hydraulic system o10-22 010.2.3 Tools - Hydraulic cylinder 010-27 010.2.4 Tools - Electrical system 010-28 010.2.5 Tools - Travel gearbox 010-30 010.26 Tools - Undercarriage 010-32 010.2.7 Tools - Oscillating axle frame 010-36 010.2.8 Tools, operator's platform 010-36 Standards and specifications 010-39 010.3.1 reload values and tightening torques for screws with standard and fine metric thread according to DIN ISO 261 010-39 010.3.1.1 Scope of application and purpose 010-39 010.3.1.2 Further applicable documentation 010-39 010.3.1.3 Changes and descriptions 010-40, 010.3.1.4 Tightening values 010-40 010.3.1.5 Flanges and half flanges for high pressure (standard 62) 010-46 010.3.1.6 Half flange for low pressure (standard 61) 010-46 010.3.1.7 Tightening torques for cutting edges, end bits and adapters 010-46 010.3.2 Installation specifications 010-47 010.3.2.1 Duo cone slipring seals 010-47 00.3.3 Tapping bores 010-49 010.3.3.1 Tapping bores of metric ISO standard threads 010-49 010.3.3.2 Tapping bores of metric ISO fine threads 010-61 010.34 Conversion tables 010-54 Conservation guidelines 010-55 0104.1 General 010-55 010.4.2 Taking the machine out of service for an unknown duration 010-55 010.4.3 Shut down of the machine 010-66 010.4.3.1 Shut down for up to 2 months 010-56 010.4.3.2. Shut down for up to 12 months 010-57 010.4.3.3 Shut down for longer than 12 months 010-68 010.4.4 Return to operation 010.4.4.1 010.4.4.2 010.4.4,3 After a shut down of 2 months ‘After a shut down of 12 months ‘After shut down of longer than 12 months 010-59 EBHERR PRI76-1296Service manual Contents 020 010.5 Repair welding 010.5.1 010-60 Preparation of cracked part 0105.1 0105.1 0105.1 0105.1 0105.1 Preparation of a weld 010-61 010-61 Treatment of electrodes Welding technique 010-61 Reinforcement of welding seam 010-62 General use of reinforcement sheeting 10-62 010.5.1.1 Form of sheeting 010.5.1.1 Thickness of sheeting 010.5.1.1 Material quality of sheeting 010-63, 0105.11 Application of reinforcement sheeting 010.5.1.1 Welding the reinforcement sheeting 010-63, 010.5.1.1 Selection of correct welding electrodes. 010-64 010-64 010.5.1.2 Electrode selection 010.5.1.2 Steel chart 010-65 010.5.1.2 Welding additives chart 010-66 010.8 Hydraulic symbols 010-70 010.7. Electrical symbols 010.8 Material weights Technical data 020-4 020.1 Complete machine 020-3, 020.1.1 Complete machine - Overview PR776-1296/12589-; 020-3 020.2. Drive group 020-6 020.2.1 Diesel engine PR776-1296/12589.; 020-6 020,2.2 Clutch PR776-1296/12589-; 020-7 0202.3 Splitter box PR776-1296/12589-; 020-7 020.3 Cooling system 020-9 020.3.1 Regulator pump for coolant circuit PR776-1296/12589-; 020-9 0203.2 Fan drive gear motors of hydraulic oil cooler PR776-1296/12589. 020.3.3 Axial piston motor fan drive of water cooler and intercooler PR776-1296/1258: PR775-1298Contents Service manual 020.4 Working hydra 020.5 020.6 020.7 020.8 020.9 020.4.1 020.4.2 020.4.3 020.44 s Working hydraulics regulating pump PR776-1296/12589-; Front equipment, proportional control valve block PR776-1296/1258: Lift eylinder PR776-1296/12589- Tilt cylinder PR776-1296/12589-; Travel hydraulics 020.5.1 020.5.2 020.5.3 Variable displacement pump PR776-1296/12589-; Variable displacement motor PR776-1296/12589-; Double gear pump replenishing and pilot control working hydraulic PR776-1296/1258: Hydraulic components 020.6.1 Hydraulic tank PR776-1296/1258: Electrical system 020.7.1 Batteries - Installation PR776-1296/12589- Travel gearbox 020.8.1 020.8.2 Travel gearbox PR776-1296/1258: Brake system PR776-1296/12589-; Travel gear, axles, tyres, drive shafts 020.9.1 020.9.2 020.9.3 020.9.4 020.95 0209.6 020.9.7 Travel gear frame PR776-1296/1258: Idler PR776-1296/12589-; Tension unit PR776-1296/1258: Track roller PR776-1296/12589-; Carrier roller (Optional) PR776-1296/1258: Track chain PR776-1296/12589-; Sprocket PR776-1296/1258 020.10 Working attachment 020-10 020-10 020-40 020-11 020-12 020-42 020-43, 020-43, 020-14 020-14 020-15 020-16 020-47 020-47 020-17 020-17 020-18 020-48 020-20 40 PRI76-1296Service manual Contents 020.10.1 Semi U-blade PR776-1296/12589-; 020-20 020.10.2 Cutting angle adjustment for blade PR776-1296/12589-; 020-21 020.10.3 Cutting angle adjustment cylinder PR776-1296/12589-; 020-21 020.10.4 Rear equipment, proportional control valve block PR776-1296/1258: 020,10.5 Ripper with cutting angle adjustment PR776-1296/12589-; 020-22 030 Maintenance 030-1 030.1 Maintenance and inspection schedule 030-8 030.2 Fill quantities and lubrication chart 030-14 030.21 Recommended lubricants PR776-1296/12589-; 030-14 030.2.2 Recommended fuel and operating fluids PR776-1296/12589. 030-15, 030.2.3 Lubrication schedule PR776-1296, 030-45 030.3 Lubricants and fuels 030-18 030.3.1 General information about lubricants and fuels 030-18 030.3.1.1 General Information 030-18 030.3.1.2 General questions 030-18 030.3.1.3 Safety data sheets 030-48 030,3.1.4 Technical data sheets 0303.15 Specific Liebherr standards 030.3.2 Diesel fuels PR776-1296/12589-; 030,3.2.1 030.3.2.2 030.3.2.3 030,3.2.4 030.3.2.5 Specification ‘Sulfur content in Diesel fuel Diesel fuel - Lubricity Ignitabilty Diesel fuels at low temperatures (winter operation) 030.3.3 Lubricating oils for Diesel engines PR776-1296/1258: 030-19 030-19 030-19 030-19 030-19 030.3.3.1 Lube oil quality 030-20 030.3.3.2 Lube oil viscosity 030-20 030.3.3.3 Lube oil change intervals 030-21 PR776-1298 "Contents Service manual 030.3.4 030.35 030.3.6 030.3.7 030.3.8 030,3.9 030.3.10 030.3.11 Coolant for Diesel engines PR776-1296/12589-; 030-21 030.3.4,1 General recommendations 030-21 030.3.4.2 Water (Fresh water) 030-22 030.3.4.3 Coolant mixing ratio 030-22 030.3.4.4 Approved anti-freeze and corrosion protection agent 030-23 030.3.4.5 Approved premixed anti-freeze and corrosion protec- tion agent 034 030.3.4.8 Approved corrosion inhibitors without antifreeze protection 030-24 Hydraulic oil PR776-1296, 030-24 030.3.5.1 Liebherr Hydraulic oil 030-24 030.3.5.2 Engine oll as hydraulic oil 030-25 030.3.5.3 Warm up specification 030-26 030.3.5.4 Biodegradable hydraulic oils 034 030.3.5.5 Oil change, oil analysis, filter change 034 Lube oils for splitterboxes PR776-1296; 030-29 0303.61 Quality 030-29 030.3.6.2 Viscosity 030-30 Lube oils for travel gearbox PR776-1296/12589-; 030.3.7.1 030.3.7.2 030.3.7.3 Quality Viscosity Oil change 030-31 Oil for duo cone (slipring) seal Travel gear PR776-1296; Grease and other lubricants PR776-1296/12589-; Oil for hinges and joints PR776-1296, Oil for axle bearing PR776-1296; 030.4 Maintenance tasks 030.4.1 030.4.2 Safety instructions for maintenance PR776-1296, Maintenance — Preparatory activities 0304.21 Maintenance position PR776-1296/1258: 030-32 030-32 030-34 030-35 030-36 12 PRI76-1296Service manual Contents 030.4.2.2 Turn the electrical system off PR776-1296; 030-38 030.4.2.3 Lift the operator's cab PR776-1296/1 2589 030-39 030.4.2.4 Lower the operator's cab PR776-1296/1 2589. 030-42 030.43 Complete machine 030-44 030.4.3,1 Checking the machine for external damage, correct maintenance and proper condition PR776-1296; 030-44 030.4.3.2 Lubricating the machine PR776-1296; 030-44 030,4.3,3 Central lubrication system (optional): Check the fill level of the grease container PR776-1296/1 258 030-44 030.4.3.4 Checking the window wiper PR776-1296/1258! 030-46 030.4.3.6 Oil samples and oil analysis PR776-1296/12589. 030-47 030.4.3.6 Wet cleaning the machine PR776-1296/1258: 030.4.3.7 Protecting the piston rods PR776-1296/1 258 030-52 030,4.3,8 Taking the machine out of service PRT76-1296; 030-53, 030.44 Drive group 030-53, 030.4.4.1 Diesel engine: checking oil level PR776-1296/12589. 030,4.4,2 Changing engine oil PR776-1296/1 2585 030-54 030.4.4.3 Changing lube oil fers PR776-1296/1 258: 030-58 030.4.4.4 Checking the diesel engine configuration and the belly pans for contamination and cleaning them PR776-1296/12585 030-59 030.4.4.8 Checking and changing ribbed V-belt PR776-1296/12589. 030-60 030.4.4.6 Check the Diesel engine arrangement for leaks and condition PR776-1296/1258: 031 030.4.4,.7 Check the intake and exhaust lines for mounting and leaks PR776-1296/1258: 030-62 030.4.4.8 Check the electrical system of the Diesel engine PR776-1296/12589. 030-63, PR775-1298 13Contents Service manual 030.45, 030.4.6 030.4.7 030.4.4.9 Changing oil separator filter cartridge PR776-1296/1258: 030.4.4.10 Checking and changing heater flange PR776-1296/1258: 030.4.4.11 Notes for work on the fuel system PR776-1296/12589-; 030.4.4.12 Fuel preliminary fiter: Drain the condensation PR776-1296/12589. 030.4.4,13 Fuel tank: Drain condensation and sediments PR776-1296/1258: 030.4.4.14 Changing fuel pre-fiter cartridge PR776-1296/1 258: 030.4.4.15 Changing fuel fine fier PR776-1296/12589. 030,4.4,16 Empty and clean the fuel tank PR776-1296/12589-; 030.4.4.17 Venting fuel system PR776-1296/1258 030.4.4.18 Replacing the air filter PR776-1296/12589.; 030,4.4,19 Splitterbox: Check the oil level PR776-1296/12589; 030.4.4.20 Splitter box: Changing the oil PR776-1296/1258 Cooling system 030,4.5.1 Check the coolant level and refill PR776-1296/12589; 030.4.5.2 Check the cooling system for contamination and clean it PR776-1296/1258: 030.4.5.3 Checking the cooling system PR776-1296/12589.; 030.4.5.4 Check the antifreeze concentration in the coolant. PR776-1296; 030.4.5.5 Changing the coolant PR776-1296/12589. Travel hydraulics 030.4.6.1 Change the replenishing circuit filter PR776-1296/1 258: Hydraulic components 030,4.7.1 Checking the oil level in the hydraulic tank and topping up oil PR776-1296/1258: 030.4.7.2 Clean the magnetic rod on the hydraulic tank PR776-1296/1258: 030-64 030-85 030-66 030-66 030-67 030-68 030-70 030-71 030-74 030-76 030-83, 030-87 030-87 030-89 030-91 030-94 030-101 030-102 030-102 030-106 030-106 030-109 14 EBHERR PRI76-1296Service manual Contents 030.4.7.3 Checking the hydraulic system for function and leaks PR776-1296/1258 030-110 030.4.7.4 Clean the oil cooler PR776-1296/1 2589 030-111 030.4.7.5 Changing hydraulic oll PR776-1296/1 2589. 030-112 030.4.7.6 Drain water and sediments in the hydraulic tank PR776-1296/1258! 030-117 030.4.7.7 Change the retum fiter insert PR776-1296/1258 030-118 030.48 Electrical system 030-119 030.4.8.1 Check the display unit and lighting PR776-1296/12589.; 030-119 030.4.8.2 Check the batteries PR776-1296/12589. 030-120 030.4.8.3 Change the light bulbs PR776-1296/1 2585 030-124 030.4.9 Travel gearbox 030-124 030.4.9.1 Travel gearbox: checking the condition PRT76-1296, 030-124 030.4.9.2 Check the oil level PR776-1296/12589-; 030-124 030.4.9.3 Changing the oil PR776-1296/1 2585 030-125 030,4.9.4 Check the oil level in the duo cone (slipring) area PR776-1296/1258 030-128 030.4.9.5 Change oil in brake chamber PR776-1296/1 2589; 030-129 030.4.9.6 Change the oil in the duo cone (slip ring) area PR776-1296/12589. 030-130 030.4.10 Travel gear, axles, tyres, drive shafts 030-135 030.4.10.1 Checking that the nuts and bolts of the travel gear components are firmly seated PR776-1296/12589. 030-135 030.4.10.2 Check the seal on the carrier rollers, track rollers, idlers and undercarriage carriers for leaks PR776-1296/1258 030-136 030.4.10.3 Checking and adjusting the track tension, PR776-1296/1258: 030-137, 030.4.10.4 Change the track PR776-1296/12589. 030-141 030.4.10.8 Checking travel gear guides PR776-1296/1 258 030-144 030.4.10.6 Checking the oil fil of the axle bearings PR776-1296/1258 030-147, PR775-1298 15Contents Service manual 030.4.10.7 Greasing equaliser bar bearing PR776-1296/1258: 030-148 030.4.10.8 Check the rubber stop of the equalizer bar PR776-1296/1258: 030-149, 030.4.10.9 Check the oil level of the track carriers, PR776-1296/12589-; 030-149 030.4.10.10 Checking the chain guides for wear PR776-1296/12589. 030-151 030,4.10,11 Checking idler spacing and adjusting it, f necessary PR776-1296/1258: 030-152 030.4.11 Working attachment 030-154 030.4.11.1 Checking the cutting edges, comers and ripper teeth for wear PR776-1296/12589. 030-154 030.4.11.2 Lubricate the working attachment and hoist cylinder bearing PR776-1296/1258: 030-155 030.4.11.3 Check the working equipment PR776-1296/12589. 030-155 030.4.11.4 Checking the bearing points of the working attach- ment for play and wear PR776-1296/1258: 030-156 030.4.11.5 Checking the mounting screws and pin retainers of the working attachment for tight seating PR776-1296; 030-159, 030.4.11.6 Removing and installing the ripper tooth tips PR776-1296/1258: 030-160, 030,4.12 Operator's cab, heating, air conditioning 030-163 030.4.12.1 Checking the heating for function and leaks PR776-1296/1258: 030-163 030.4.12.2 Clean and replace the heater fresh air filter and air circulation filter PR776-1296/12589.; 030-164 030.4.12.3 Inspection of the air conditioning system by HVAC. specialist staff PR776-1296/12589.; 030-166 030.4.12.4 Check the compressor mounting PR776-1296/12589; 030-167 030.4.12.5 To check the capacitor PR776-1296/1258: 030-167 § 030.5 Adjustment checklist PR776-1296/1 258: 030-168 030.5.1 Adjustment checklist 030-168 0305.2 Travel gear check list 030-180 0305.21 Test report 030-180 16 PRI76-1296Service manual Contents 030.5.2.2 Wear data 030-184 030.5.2.3 Track inner wear measurement (Intertrac) 030-187 030.8 Adjustment procedure 030-189 030.6.1 Safety instructions PR776-1296, 030-189, 030.6.2 Complete machine 030-190 030.6.2.1 Preparations for check and adjustment tasks PR776-1296/12589. 030-190 030.6.2.2 Visual inspection and maintenance PR776-1296/1258: 030-192 030.623 Bringing the machine to operating temperature PR776-1296/12589-; 030-193, 0306.23 Various procedures can be selected for reaching the operating temperature: PR776-1296/1258: 030-193 030,6.3 Drive group 030-194 030.6.3.1 Engine speed controller of diesel engine — deter- mining adjustment range PR776-1296/12589.; 030-194 030,6.4 Cooling system 030-197 030.6.4.1 Checking the stand-by pressure for the fan control PR776-1296/1 2585 030.8.4.2 Checking pressure relief valve — fan motor and fan control PR776-1296/12589-; 030-200 030.6.5 Working hydraulics 030-206 030.8.5.1 Checking the standby pressure PR776-1296/1258: 030-206 030.6.5.2 Checking the primary pressure relief valve on the control valve block PR776-1296/1258 030-207 030.6.5.3 Checking the secondary pressure relief valve on the control valve block PR776-1296/1258: 030-208 5, 0306.54 Checking pressure cut-off valves 2 PR776-1296/1258: 030-210 3 030655 Checking the pressure difference HD-LS 5 PR776-1296/12589-; 030-212 5 030.6.8.6 Checking the nitrogen fill n the hydro accumulator a PR776-1296/12589. 030-213 030.6.6 Travel hydraulics 030.6.6.1 Checking supply pressure of variable displacement pump PR776-1296/12589-; 030-213, PR775-1298 7Contents Service manual 030.6.6.2 Checking and adjusting the pressure limitation for high pressure PR776-1296/1258 030-214 0306.7 Electrical system 030.217 030.67.1 Calibrating the hydrostat PR776-1296/12589. 030-217 030.6.7.2 Checking travel joystick PR776-1296/1258 030-228 030.6.7.3Callbrating inching brake pedal PR776-1296/1258 030-241 030.6.7.4 Brake test PR776-1296/12589: 030-248 030.6.7.5 Overspeed safety test PR776-1296/12589. 030-252 030.6.7.6 Parameter adjustment options PR776-1296/1258 030254 030.6.7.7 Addressing CAN modules PR776-1296/1258 030-256 030.6.7,8 _LiDAT: Establishing the connection with the LiDAT module PR776-1296 030.260 030.6.7.9_LIDAT: LIDAT module software update PR776-1296; 030-263 030,6.7.10 _LiDAT: Creating a report and snapshot PR776-1296; 030-265 040 Drive group 040-1 040.1 Diesel engine 040-2 0404.1 Diesel engine = full overview PR776-1296/12589- 040-2 040.1.2 Fuel system 040-6 040.4.2.1 Fuel system PR776-1296/1258 040-7 0401.22 Fuel quantity sensor PR776-1296/1258 o40-8 £ 040.1.2.3 Fuel pre-filter and fuel fine filter g PR776-1296/12589- 040-9 3 0401.24 Fuel tank PR776-1296/12589. oat 040.4.3Airfiter system 040-14 040.1.3.1 Airfiter system PR776-1296/1258 040-15 0401.32 Airfiter PR776-1296/12589-; 040-17 EBHERR PRI76-1296 18Service manual Contents 040.1.4 Exhaust system 040.141 Exhaust system - full overview PR776-1296/1258: 040-18 040.1.5 Diesel engine mounting PR776-1296/12589-; 040-19 040.2 Clutch PR776-1296/12589. 040-20 040.3. Splitter box PR776-1296/12589-; 049-22 050 Cooling system 050-1 050.1 Complete cooling system PR776-1296/1258: 050-2 050.2 Cooler arrangement 050-5 050.21 Combi cooler PR776-1296/12589-; 050-6 050.3. Hydraulic 050-14 050,3.1 Gear motor - fan oil cooler PR776-1296/12589-; 050.3.2 Axial piston fixed displ. motor - fan drive PR7T76-1296/12589; 050-15 060 Working hydraulics 060-1 060.1 Working hydraulics - Full overview PR776-1296/12585 060-2 060.2 Regulating pump 060-14 060.21 Regulating pump - full overview PR7T76-1296/12589.; 060-14 060.3. Proportional control valve block 060.3.1 Proportional control valve block - working attachment front - full overview PR776-1296/12589.; 060-20 060.4 Working hydraulic pilot control unit 060-23 60.4.1 Pilot control Full overview PR776-1296/12589; 060-23 060.5 Hydraulic cylinder 060.51 Lifteylinder PR776-1296/12589-; 080-29 060.5,.2 Tilt cylinder PR776-1296/12589-; 060-30 PR775-1298 19Contents Service manual 070 080 100 110 Travel hydraulics 0704 070.1 Complete travel hydraulics PR776-1296/12589-; 070-2 070.2 Regulating pump PR776-1296/12589:; o70-14 070.3. Variable displacement pump PR776-1296/1258 070.4 Variable displacement motors 70.4.1. Variable displacement motors - Full overview PR776-1296/12589-; 070.5 Distributor block 070.5.1 Distributor blocks PR776-1296/12589- 070-27 070-27 070-36 Hydraulic components 80-1 080.1 Hydraulic cylinder 080-2 080.11 Ripper cylinder PR776-1296/1258: 080-2 080.2 Valves PR776-1296/12589-; 080-4 080.3. Hydraulic tank 080-17 080.31 Hydraulic tank PR776-1296/12589-; 080-17 0803.2 Return filter PR776-1296/12589-; Brake system 100-1 100.1 Inching brake pedal 10.1.1 Speed reduction pedal PR776-1296/1258: Electrical system 100-2 110-4 110.1 Electrical system - Full overview PR776-1296, 110.2._Lighting system PR776-1296/1258: 110.3 Circuit diagrams PR776-1296/12589; 110.4 Electrical components of operator's cab 1104.1 Cab electrical components - Full overview PR776-1296/1258: 110-4 110-7 110-10 110-11 20 PRI76-1296Service manual Contents 110.4.2 Central control - Master (A100) PR776-1296/12589-; 110-18 110.43 Travel sensor PR776-1296/12589-; 110-24 110.44 Speed control PR776-1296/12589-; 110-26 110.5. Electrical components - Heatable exterior mirror (option) PR776-1296/1 258! 110.6 Electrical components - Diesel engine PR776-1296/1258 110-29 110.7 Electrical components - Main frame PR776-1296/1 2585 110-38 110.8 Electrical components Compartments 110-43 110.8.1 Battery compartment PR776-1296/12589-; 110-43 10.8.2 Fuel tank PR776-1296/12589-; 110-44 110.8.3 Central electrical system compartment PR776-1296/12589.; 110-45 110.84 Hydraulic tank PR776-1296/12589. 110.9 Display unit PR776-1296/1 2585 110.10 Electrical components LiDAT (option) PR776-1296/12589-17835; 110-53 110,11 Electrical components LiDAT (option) PR776-1296/17836-; 110-84 110.12 Electrical components LiTU2 (option) PR776-1296/1 2589. 110.13 Electrical components LiTU3 (option) PR776-1296/1 2585 110-56 110,14 Electrical components - Incline alarm (option) PRT76-1296/1 2585 110-58 110.15 Electrical components - Data interface (option) PR776-1296/1 2589 110-61 110.16 Electrical components - Input module A240 (option) PR776-1296/1 258 110.17 Electrical components - Output module A135 (option) PR776-1296/1258: 110-66 110.18 Electrical components - Travel hydraulics pressure cut-off PR776-1296/1258 110-68 110.19 Electrical components - Acoustic reversing warning device (option) PR776-1296/1 2589. 110-69 110.20 Electrical components - Disengageable reversing warning device (option) PR776-1296/1 258! 110-71 PR775-1298 2Contents Service manual 110.21 Electrical components - Optical reversing warning device (option) PR776-1296/1258: 110-74 110.22 Electrical components - Engine after-run_ PR776-1296/1258: 110-77 110.23 Electrical components - Access ladder PR776-1296/12589:; 110-78 110.24 Electrical components - Warm water heating device (option) PR776-1296/1258: a 110.25 Electrical components - Jump-start (option) PR776-1296/1258: 110-86 110.26 Electrical components - Reversible fan drive (option) PR776-1296/1258: 110-87 110.27 Electrical components - Working hydraulics cutting angle adjustment (option) PR776-1296/12589 110-89 110.28 Electrical components - 3-point belt with warning sound (option) PR776-1296/12589-; 110-92 110.29 Electrical components - Supply box for external users (option) PR776-1296/1258: 110-95 110.30 Electrical components - Coolant level check (option) PR776-1296/12589-; 110-98 110,31 Electrical components - External operating hour meter (option) PR776-1296/12569-; 110-100 110.32 Electrical components - Generator disconnecting switch (option) PR7T76-1296/1258: 110-101 110.33 Electrical components - Ripper headlight (option) PR776-1296/1258: 110-103, 110.34 Electrical components — Coolant preheating (option) PR776-1296/12589- 110-106 120 Travel gearbox 120-1 120.1 Travel gear, overall PR776-1296/12589. 120-2 120.2 Brake system PR776-1296/1258: 120-7 120.3 Duo cone slipring seal PR776-1296/12589-; 120-9 5, 120.4 Extermal oll supply i PR776-1296/12589:; 120-10 3 130 Travel gear, axles, tyres, drive shafts 130-1 130.1 Undercarriage frame 130.1.1. Support frame PR776-1296/12589-; 130-2 22 PRI76-1296Service manual Contents 120.2 Idler PR776-1296/1258: 130-3 130.3. Tension unit PR776-1296/12589-17311, 130-4 130.4. Tension unit PR776-1296/17312:; 130-5 120.5. Track roller PR776-1296/12585 130.6. Carrier roller (Optional) PR776-1296/1258: 130-7 130.7 Function, wear and evaluation PR776-1296, 130-8 140 Steel components Basic machine 140-1 140.1 Lift oylinder suspension PR776-1296/12589-; 140-2 140.2. Oscillating axle frame PR776-1296/12589 140-3 140.3. Push frame PR776-1296/1258: 140-5 150 Working attachment 150-1 150.1. Semi U-blade PR776-1296/1258: 150-2 180.2 Hydraulic cutting angle adjustment PR776-1296/12589-; 150-4 150.3. Ripper PR776-1296; 10.3.1 Ripper proportional control valve block - Full overview PR776-1296/1258: 150.4 Cutting angle adjustment - Ripper PR776-1296/1258: 150-17 160 Operator's cab, heating, air conditioning 160-1 160.1 Operator's platform 160-2 160.1.1 Operator's platform installations PR7T76-1296/12589; 160-2 160.1.2 Operator's platform bearing PRIT76-1296/12589:; 160-3 160.1.3 Support eylinder PR776-1296/1258: 160.2 Operator's cab 160.21 Operators seat PRT76-1296/12589-; 160-10 PRIT6-1296 23Contents Service manual 160.2.2 Assembly of third party installations in the cab PR776-1296/12589-; 160-10 180.3. Heater and ventilation 160-13 1603.1 Warm water heater 160-13 160.3.1.1 Hose routing for warm water heating device PR776-1296/12589.; 160.4 Heating, ventilation, air conditioning 160.4.1_Heating and air conditioning unit 160.4.1.1 Heater, air conditioning system and ventilation PR776-1296/1258: 160-15, 190 Options 190-1 190.1 Reversible fan drive PR776-1296/1258: 190-2 200 Service codes, diagnosis 200-1 200.2 Test and adjustment software 200-2 200.2.1 Wizard test and adjustment software 200-2 2002.11 General 200-2 200.2.1.2 Symbols 200-3 200.2.1.3 Information window 200-80 EBHERR PRI76-1296 24010 Introduction Contents 010.1. Safety instructions 010-4 010.11 General safety instructions o10-8 010.1.2 Safety instructions for crushing and burn prevention 010-5 010.1.3 Safety guidelines for fire and explosion prevention o105 010.14 Safety instructions for machine start up 0108 010.1.5 Safety instruction for start up 010-6 010.1.6 Safety guidelines for working 0106 010.1.7 Safety instructions for parking the machine 0108 010.1.8 Safety instructions for transporting machine 010-8 010.1.9 Safety instructions for towing machine 010-8 010.1.10 Safety instructions for maintenance 010.1.11 Safety guidelines for welding work on machine 010.1.12 Safety guidelines for working on attachment 010.1.13. Safety guidelines for loading machine with a erane 010-12 010.1.14 Safety notes for maintenance of hydraulic hoses and hose lines 010-12 010.1.15 Safety guidelines for maintenance work an machines with hydro accumulators 010-13 010.1.16 Roll over protection (ROPS) and falling object protection (FOPS) 010-13 010.1.16.1 Avoid accidents 010-13 010.1162 Avoid injuries o10-14 010.1.17 Equipment and attachment parts o10-14 010.1.18 Protection from vibrations 10-14 010.1.19 See and be seen 010-15 010.1.19.2 Field of vision 010-15 010.1.19.3 Measures before and during operation 010-17 010.1.20 Safety notes for Diesel engines with electronic control units 010-17 010.1.21 Safety notes for working on Common Rail System of Diesel engines)10-18 010.2. Special tools for maintenance and repair work 010-20 PRI78-1208 010-1