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Introduction Service manual 010.3 010.4 010.2.1 010.2.2 010.2.3 010.2.4 010.2.5 010.26 010.27 010.28 Standards and specifications Tools - Hydraulic system 010-22 Tools - Hydraulic cylinder 010-27 Tools - Electrical system 010-28 Tools - Travel gearbox 010-30 Tools - Undercarriage 010-32 Tools - Oscillating axle frame 010-36 Tools, operator's platform 0103.1 Preload values and tightening torques for screws with standard and fine metric thread according to DIN ISO 26% 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 010-46 010.32 Installation specifications 010-47 010.3.2.1. Duo cone slipring seals 010-47 010.33 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 010.34 Conversion tables Conservation guidelines 010-55 010.41 General 010-55 010.42 Taking the machine out of service for an unknown duration 010-55 010.43 Shut down of the machine 010-56 010.4.3.1. 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. 010.44 _Retum to operation 010.4.4.1 010.4.4.2 After a shut down of 2 months After a shut down of 12 months 010-58 010-2 EBHERR PRI76-1296Service manual Introduction 010.4.4.3 010.5 Repair welding 0105.1 0105.1 0105.1 0105.1 0105.4 0105.1 After shut down of longer than 12 months Preparation of cracked part Preparation of a weld Treatment of electrodes Welding technique Reinforcement of welding seam General use of reinforcement sheeting 010.5.1.1 010.5.1.1 010.5.1.1 010.5.1.1 010.5.1.1 010.5.1.1 010.5.1.2 010.5.1.2 010.5.1.2 010.6 Hydraulic symbols 010.7. Electrical symbols 010.8 Material weights Form of sheeting Thickness of sheeting Material quality of sheeting Application of reinforcement sheeting Welding the reinforcement sheeting Selection of correct welding electrodes Electrode selection Steel chart Welding additives chart 010-60 010-60 010-61 010-61 010-61 10-62 010-63, 010-63, 010-63, 010-64 010-64 010-65, 010-66 010-84 PR775-1298 010-3Introduction Service manual 010.1 010.1.1 Safety instructions General safety instructions 1 " 12 13. 14. 16. 16. 17. 18. 19. Please familiarize yourself with operator's manual before putting machine into service. Make sure that you have obtained, read and understand any additional instruc- tions relating to special accessories for machine. ‘Only explicitly authorized personnel may operate, maintain or repair machine, Observe the permissible minimum legal age limit! Use only trained or instructed personnel, clearly determine the responsibility of the personnel for operation, set up, maintenance and repairs, Determine machine operator responsibilty (also in regards to traffic tions) and allow him to refuse unsafe instructions from third persons. the regula. Do not allow any person either stil to be trained or already in training to ‘operate or work on machine unless under constant supervision and. of an experienced instructor or operator. Check and observe any person working or operating machine at leas guidance st period! cally if they observe safety instructions and guidelines given in operator's manual. Always wear proper work clothing when operating or working on ma‘ chine. ‘Avoid wearing rings, watches, ties, scarves, open jackets, loose clothing, etc. ‘There is a danger of injury, as they can get stuck or be pulled in. Prescribed for specific tasks: safety glasses, safety shoes, safety helmet, work gloves, reflective vest, ear protection, Consult supervisor at jobsite for special safety instructions and regul When entering and exiting the machine, maintain three-point contact When entering or exiting, never use joysticks as handholds. lations. . This could trigger inadvertent movement of machine and cause serious acci- dents. Never jump off the machine. When climbing on or off machine, use i steps, ladders and catwalks and handles. Use both hands for support and face machine, Keep steps, ladders and handles free of oil, grease, mud, snow and ice. These precautions will minimize the danger of slipping, stumbling or falling Make yourself familiar with emergency exit, If no other instructions are given, proceed as follows for maintenanc repair work, Procedure: + Park the machine on solid and level ground. + Bring all control levers to neutral position. + Switch parking switch to park position, ‘+ Tum engine off and pull ignition key. + Actuate control levers several times to relieve pressure in servo li + Bring all control levers to neutral position. Before working on hydraulic circuit, with engine turned off and with ignition key in contact position, move all pilot controls (joysticks and pedals) in b tions to relieve servo pressure and remaining back pressures in work circuits. Then release internal hydraulic tank pressure. intended "2 and lines. th direc- king Before leaving operator's seat, switch parking switch to Park position. ‘Secure al loose parts on machine. Never operate a machine without a complete walk around inspection. Check if all warning signs are on the machine and if they are all legible. Observe all signs with danger and safety instructions. 010-4 PRI76-1296i Service manual Introduction 010.1.2 010.1.3 20. For special applications, this machine must be equipped with specific safety devices. In this case, use the machine only if they are installed and func- tioning, 21. Never make any changes or additions and modifications on machine, which could affect safety, without obtaining explicit approval from manufacturer / supplier, This also applies to installation and adjustment of safety devices and safely valves as well as to any welding on load carrying parts. 22. Avoid staying near running Diesel engine. Persons with a pacemaker may not stay near a running Diesel engine (minimum distance 50 cm). 23. Do not touch current carrying components on electrical connection of solenoid valve controlled injection pumps (Unit Pumps) when Diesel engine is running, Safety instructions for crushing and burn prevention 1. Never work underneath attachment as long as itis not safely resting on ground or properly supported. 2. Never use damaged or insufficient tackle (such as cables, chains, .). ‘Always wear work gloves when handling wire cables. 3. When working on attachment, never align bores with your fingers, always use a suitable alignment tool 4. When engine is running, make sure that no objects touch fan. Any objects falling or protruding into fan will be thrown out or destroyed and can damage fan ‘Avoid skin contact with hot surfaces and fluids. There is a danger of bums. 6. Check coolant level only after cap of expansion tank is cool enough to touch, Tum cap carefully to relieve pressure 7. Ator near operating temperature, engine and hydraulic oil are hot. Do not allow hot oil or oil-bearing parts to touch skin. 8. Always wear safety glasses and work gloves when handling batteries. Avoid ‘sparks and open flames. Never permit anyone to hand guide attachment into proper position, 10. Check if open door position of engine compartment door is ensured by gas, cylinder. If function is not ensured, then problem must be remedied immediately. 11. Before operating machine, close and lock all engine compartment doors and covers. 12, Never lay underneath machine unless machine is properly and safely ‘supported. Safety guidelines for fire and explosion prevention 1. Engine must be tumed off when refueling, In addition, heater must also be turned off before refueling, 2. Do not smoke and avoid open flames when refueling and where batteries are charged Always start engine as described in “operator's manual 4. Check electrical system. Correct any defects, such as loose connections, chafed wiring or burnt out fuses and bulbs immediately. 5. Never store flammable fluids on machine except in appropriate storage tanks. 6. Regularly inspect all ines, hoses and fittings for leaks and damage. Repair any leaks immediately and replace damaged components. Any oil escaping from leaks can easily cause a fire. 7. Be certain that all clamps and protective guards are properly installed to prevent vibration, rubbing and heat build up. PR775-1298 LIEBHERR 010-5Introduction Service manual 8. Starter fluid (ether) is especially flammable! Never use cold start ether near heat sources, open flames (for example cigarettes) or in insufficiently venti- lated areas. 9. Never use flame glow system or preheat systems when using cold start ether! (Danger of explosion) 10. Know location of fire extinguishers, make sure you know how to use them properly and check out location of where to report a fire and inform yourself about fire fighting capabilities before you start to work. 010.1.4 Safety instructions for machine start up Before starting the machine, always perform a thorough walk-around inspec- tion. 2. Visually check the machine for loose bolts, cracks, wear, leaks and intentional damage. Never start or operate a damaged machine. Make sure to correct any problems immediately. Make sure that all hoods and covers are closed and locked. Check if all warning and reference signs are on the machine. 6. Clean all windows and mirrors, secure all doors and windows to prevent inad- vertent movements. 7. Always enter and leave the machine using the ascending aids provided, 8. Make sure that no one works on or under the machine. Warn all persons in the surrounding area before operating the machine. 9. After entering the cab, adjust the operator's seat, the mirrors, the arm rests and the safety belt so that you can work comfortably. 10. The noise protection devices on the machine must be in protective position during operation. 11. Never operate the machine without the operator's cab or canopy. vee 010.1.5 Safety instruction for start up 1. Before starting machine, check all indicator lights and instrument for proper function. Bring al control levers into neutral positon, 2. Before starting engine, alert any nearby personnel that machine is being started by sounding hom. 3. Start machine only from operator's seat 4. If no other instructions were issued, start engine according to guidelines in operator's manual. 5. Start engine and check all indicators, gauges, instruments and contrals. 6. When operating in enclosed spaces, run engine only if there is sufficient vent lation. If necessary, open doors and windows to ensure sufficient fresh air supply 7. Bring engine and hydraulic oil to operating temperature, low oil temperatures cause controls to be sluggish. 8. Check that control fr attachment functions propery 9. Move machine carefully into an open area and check all travel functions, check travel brake, steering function as well as turn signals and lights. 010.1.6 Safety guidelines for working 1. Before starting to work, familiarize yourself with the peculiarities of the job site, as well as the special regulations and warning signals. Part of the surrounding area includes, for example, the obstacles in the working or traffic area, the load bearing capacity of the ground and special protection required to secure the job site from public highway traffic. 010-6 LIEBHERR PR776-1296i Service manual Introduction 10. 1" 12, 13, 14, 15. 16. 17 18, 19. 20. 24 22. 23, 24, 25. 26. Always keep a safe distance to overhangs, edges, embankments and unstable ground, Be particularly cautious of changing ground conditions, unfavourable visibility and changing weather. Familiarize yourself with location of power lines on jobsite and work particularly careful in their vicinity. If necessary, inform the responsible authorities. Maintain a safe distance from electrical overhead lines. When working near electrical overhead lines, do not allow attachment too come close to wires. Risk of fatal injury! Inform yourself about required safety distances. Ifyou do touch a high voltage power line, proceed as follows: + Do not leave the machine! + Ifpossible, move the machine a sufficient distance away from the danger zone. + Wam all personnel in the surrounding area not to come close to the machine and not to touch the machine. + Instruct someone to tur the electric power off. + Do not leave machine until you are assured that electric wire, which has been touched or damaged is no longer energized and power has been turned off! Before moving machine or working with machine, always make sure that ‘equipment is safely secured ‘When travelling on public roads, highways or properties, always observe valid traffic regulations and, if necessary, first bring machine into proper condition to meet federal and local highway standards. ‘Always tur on lights if visibility is poor or as dusk approaches. Itis strictly prohibited for anyone to ride along on machine. Operate machine only when seated and with safety belt fastened. In-even that machine should tip over, remain seated with seatbelt secured, Experience has shown that itis safer to remain in cab in event of an overturn. Report any functional problems or defects, make sure that all necessary repairs are completed immediately. Personally make sure that no one is endangered by moving the machine. Never leave the operator's seat as long as the machine is still moving. Never leave machine unattended while engine is running, ‘When moving loads, keep load as close as possible to ground. Maximum permissible incline and side slope of machine depends on installed attachment as well as on ground conditions! Avoid any working movements which could cause machine to tip over. However, if machine does begin to tip or slide, lower attachment immediately and tun machine downhill. If possible, always work downhill or uphill, never sideways on a slope. Always move slowly and carefully on rocky or slippery ground or on a slope. ‘Always adapt the travel speed to the working conditions, Never travel on slopes which exceed the maximum permissible gradeability. Travel downhill only at low travel speed, maximum 4 km/h, to prevent loss of control over machine, Engine must run at high idle speed and speed must be reduced by selecting lower speed range. Never switch into lower travel speed range while already driving downhill, always switch before approaching slope. For terrain which is difficult to gain an overview of and whenever necessary, ask for assistance of a guide. Have only one person signal you. Danger of accidents due to restriction of vision for large machines! Take sult- able measures to ensure a safe working application of machine on construc- tion site, Exclusively permit experienced personnel to secure loads and signal crane ‘operator, Signaller must position himself within view of operator or be in voice contact with him. PR775-1298 LIEBHERR 010-7Introduction Service manual 010.1.7 010.1.8 010.1.9 Safety instructions for parking the machine 1, Park machine only on firm and level ground. If it becomes necessary to park the machine on a grade, it must be properly blocked and secured with wedges to prevent any unintentional movement. Lower working attachment and lightly anchor working attachment on ground, Bring all control levers to neutral position, switch parking switch to park posi- tion and turn engine off according to Operating instructions before leaving operator's seat. 4, Lock the machine, remove all keys and secure the machine to prevent unau- thorized use and vandalism. Never park machine in such a way as to block access to entrances, dock ladders, fire hydrants, ete. Safety instructions for transporting machine 1. Use only suitable transport devices and lifting devices with sufficient load carrying capacity. 2. Park the machine on level ground and block the chains or wheels with wedges, 3. Ifnecessary, remove parts of working attachment for duration of transport 4, When loading a machine on a transport vehicle, be sure that the stipulated ramp incline angle is not exceeded and the ramp is covered with wooden planks to prevent slipping 5. Before moving onto ramp, clean chains or wheels of machine, remove any snow, ice or mud, Align machine with loading ramp. 7. Use a guide to signal machine operator. Drive onto ramp and onto transport vehicle very carefully. 8. Secure machine and remaining parts with chains and wedges to prevent them from slipping. 9. Relieve pressure from hydraulic lines and hoses, remove ignition key, lock cab and all covers before leaving machine. 10. Carefully check out transport route beforehand, especially in regards to width, height and weight limitations. 11. Check that there is enough clearance underneath all electrical lines, bridges, underpasses and in tunnels. 12. During unloading procedure, proceed with same caution as during loading procedure. Procedure’ + Remove all chains and wedges. Start engine as outlined in operator's manual. + Carefully drive off loading platform down ramp. + Have another person guide and signal you. Safety instructions for towing machine 1. Always follow the correct procedure according to the instructions in the opera- tor's manual, refer to section “Towing the machine’, 2. The machine may only be towed in exceptional circumstances, for example to move the machine from a dangerous area for repall. 3, If the sun gears are removed, the machine starts to roll by itself from an incline of 2°. Before removing and installing the sun gears, secure the machine to prevent it from rolling of. 4, Ifthe sun gears are removed, the service brake and parking brake are without function. 010-8 LIEBHERR PRI76-1296i Service manual Introduction 010.1.10 5. Before pulling or towing, check all towing and pull devices for safety and stability 6, The rod, which is used to tow the machine must be adequate to pull the machine and must be connected to the appropriate bores and towing devices. Damage or accidents which occur when towing machine cannot be covered by manufacturer's guarantee under any circumstances. 7. During towing procedure, keep within required transport position, permissible speed and distance. 8 When returning machine to operation, proceed only as outlined in operator's manual 9. After the towing procedure, re-establish the series condition of the machine. Safety instructions for maintenance 1. Never perform any maintenance or repairs for which you are not qualified or you do not understand. 2. Observe stated intervals or time periods for repeat checks and inspections as outlined in operator's manual. Always use appropriate tools to carry out main- tenance work 3. Chart in this operator's manual defines exactly who must or can carry out which type of work. Operator can exclusively carry out work marked in mainte- nance and inspection schedule with by “maintenance staff’. Remaining tasks can exclusively be carried out by specialist staff with appropriate training, 4. Spare parts must meet technical requirements set forth by manufacturer. This is always ensured by using original spare parts. Spare parts, which do not meet technical requirements of manufacturer can impact safety and function of machine. 5. Always wear safe work clothing when performing maintenance. For certain work, safety glasses and work gloves are required, in addition to a hard hat, and safety shoes. Keep unauthorized personnel away from machine during maintenance. Secure a wide-ranging area for service, as necessary, Inform operator before carrying out any special task or maintenance work. Appoint one supervisory person, 9. Ifnot otherwise noted in this operator's manual, carry out all maintenance work ‘on machine on firm and level ground, with engine tured off. 10. Operator's platform can exclusively be tilted when machine is at a standstill and engine is turned off! When tiling operator's platform forward or backward, there can be no personnel within tit range. Work under tilted operator's plat- form may only be carried out if machine is at a standstill and after placing safely support bar. Machine can NOT be started or driven with a tilted opera- tor’s platform. Leave parking switch in park position! 11, During maintenance and repairs, make sure you always tighten any loosened ‘screw connections, 12. Ifit becomes necessary to remove any safety devices during set up, mainte- nance and repairs, safety devices which were removed must be reinstalled immediately after completion of maintenance and repair work and then be inspected for proper function 13, Before any maintenance and repair work, especially when working under machine, attach an easily visible “DO NOT TURN ON” waning sign to ignition ‘switch. Pull ignition key off. 14, Before any maintenance and repairs, clean machine, especially connections and fittings to remove oll, fuel or cleaning substances. Never use aggressive cleaning substances. Use exclusively lint-free cleaning cloths. 15. To clean machine, never use flammable cleaning fluids, 16. Before any welding, cutting and grinding, clean machine and surrounding area of dust and flammable substances and assure adequate ventilation. PR775-1298 LIEBHERR 010-9Introduction Service manual + Otherwise there is a DANGER OF EXPLOSION! 17. Before cleaning machine with water, steam (high pressure cleaner) or other cleaning fluids, cover / tape off all openings whose safety and function could be affected by infiltration of water, steam or cleaning fluid. Electric motors, switch boxes and battery compartments are especially endan- gered. Further procedure: + Make sure that temperature sensor of fire warning system and fire extin- guisher do not come in contact with hot cleaning fluids when cleaning oper- ator’s cab. Otherwise they could trigger fire extinguishing system. + After cleaning, completely remove covers and tapes. + After cleaning machine, check all fuel, engine oil, hydraulic oil lines for leaks, loose connections, chafing and damage, + Fix any defects immediately. 18. Adhere to product safety instructions issued for handling of oils, greases and other chemical substances, 19. Ensure safe and environmentally friendly disposal of operating and service fluids as well as exchange parts. 20. Be very careful when handling any hot components or service fluids on machine as there is a danger of burns and scalding 21. Operate combustion engines and fuel operated heaters exclusively in suffi- ciently ventilated areas, Before starting machine in a closed area, make sure ventilation is sufficient, Always follow all regulations valid for current job site. 22. Perform any welding, cutting or grinding work on machine exclusively if this work has been explicitly authorized, as there can be a danger of fire or explo- sion 23. Operator's cab windows are made of safety glass. Damaged operator's cab windows must always be replaced immediately. + Exclusively safety glass can be used for operator's cab windows. + Use exclusively Original Liebherr spare parts. 24, Do not attempt to lift heavy parts. Use suitable lifing devices with sufficient load carrying capacity Procedure’ + When replacing individual parts and larger components, attach and secure them carefully to lifting devices to avoid any danger. + Use exclusively suitable and technically sound lifting devices as well as load tackle with sufficient load carrying capacity. + Do not allow anyone to work or remain underneath suspended loads. 25. Do not use damaged or insufficiently sized ropes or cables. Always wear work gloves when handling wire cables. 26. Exclusively permit experienced personnel to secure loads and signal crane operator, Guide must position himself within view of operator or be in voice contact with him. 27. When working overhead during installation work, use appropriate safe access ladders and working platforms. Never use machine parts as access aids, Wear a harness / anti-fall guards when working in great heights. Keep all handles, steps, railings, platforms, ladders free of dir, ice and snow. 28, When working on attachment, make sure itis safely supported, Never use ‘metal on metal support. 29. Never lay underneath machine unless machine is properly and safely supported with wooden beams. 30. Always support machine in such a way that any shifting weight will not endanger stability of machine and avoid metal to metal contact. 31. Exclusively specially trained specialist staff can work on travel gears, brake and steering system, 010-10 LIEBHERR PRI76-1296i Service manual Introduction 010.1.11 010.1.12 32. If machine must be repaired while parked on a slope, track chains or wheels must be blocked with chocks to prevent any movement. Bring working attach- ment into maintenance position. 33, Exclusively authorized personnel with specialized training and experience in hydraulics can work on hydraulic system. 34, Wear protective gloves when checking for leaks. Fluid escaping from a small hole can have enough pressure to penetrate skin. 35. Never loosen any hydraulic oil ines or fittings before attachment has been lowered and engine has been turned off. Then, with ignition key in contact position and parking switch in operating position, actuate all pilot controls, (oysticks and pedals) in both directions to relieve servo pressure and back pressures in working circuits, and relieve internal tank pressure by releasing breather screw. 36. Regularly inspect all hydraulic oil ines, hoses and fitings for leaks and exter- nally visible damage. Fix any defects immediately, Oil spray can lead to inju- ries and fires. 37. Before starting repair work, depressurise system sections and pressure lines to be opened (hydraulics, compressed air) in accordance with assembly descriptions. 38. Route and install hydraulic hoses and air pressure lines properly. Do not mix up connections. All fittings, including length and quality of hose lines must match specified requirements. Use exclusively Liebherr replacement parts. 39. Replace hydraulic hoses and lines in regular intervals, as stated, even if no safely relevant defects can be seen 40. Exclusively qualified electricians or trained personnel under guidance and ‘supervision of a licensed electrician can work on electrical equipment of machine, according to electro-technical rules and regulations. 41. Exclusively use Original fuses with correct amperage. In case of problems in electric energy supply, turn machine off immediately. 42. Inspect and check electronic equipment on machine regularly. Correct any defects, such as loose connections, burnt or chafed wiring or burnt out fuses. and bulbs immediately, 43. If any work is necessary on energized, voltage carrying parts, a second person must be utilized to disconnect emergency off or master switch in case a problem arises. Rope off work area off with a red and white safety chain and a warning sign. Use exclusively insulated tools. 44. When working on high voltage carrying components, turn off power supply, then connect supply cable to ground and use a grounding rod to ground these parts, such as condensers, 45. Check all disconnected parts frst if they are really free of voltage, ground them and then short circuit them. Insulate adjacent, voltage carrying parts. Safety guidelines for welding work on machine 1, Adhere to following procedure for welding work on machine: + Switch off ignition, + Tum battery master switch off (if present). + Attach earth of welding unit as close as possible to welding location + Only authorized expert personnel is permitted to carry out welding work. Safety guidelines for working on attachment 1. Never work underneath attachment as long as itis not safely resting on ground or properly supported. PR775-1298 LIEBHERR 010-11Introduction Service manual 010.1.13 010.1.14 2. When replacing or changing any part of attachment (such as blade, cutting edges, teeth etc.) never use metal on metal support 3. Do not attempt to lift heavy parts. Use suitable lifing devices with sufficient load carrying capacity When working with wire cables, always wear gloves! Never loosen any hydraulic oil lines or fittings before attachment has been lowered and engine has been turned off. Then, with ignition key in contact position and parking switch in operating position, actuate all pilot controls (joysticks and pedals) in both directions to relieve servo pressure and back pressures in working circuits, and relieve internal tank pressure by releasing breather screw. 6. After completion of all maintenance and repair work, make sure that all lines, hoses and fittings are properly connected and retightened. 7. Removing and installing tempered steel bolts and pins can be dangerous, metal chips can cause severe injuries. Always wear gloves and safety glasses. If possible, use special tools (such as mandrels, pin pullers, etc.) on Safety guidelines for loading machine with a crane Remove boom and counterweight or bring into transport position. Bring all control levers into neutral position. Tur engine off as outlined in operating instructions and switch parking switch to park position before leaving operator's seat 4, Close all doors, covers and hoods on machine properly, 5. Exclusively permit experienced personnel to secure loads and signal crane operator. Signaller must position himself within view of operator or be in voice contact with him. 6. Install shackles and hooks for suspension to appropriate and designated brackets or bore holes on machine. Make sure suspension is of sufficient length. Carefully lift machine. Do not allow anyone to work or remain underneath suspended loads. 10. When returning machine to operation, proceed only as outlined in operator's manual. Safety notes for maintenance of hydraulic hoses and hose lines Hydraulic lines and hoses may never be repaired! This is strictly prohibited! 2. All hoses, hose lines and fitings must be checked regularly, but at least 1 x per year for leaks and any externally visible damage! Any damaged parts must be replaced immediately. Oil spray can lead to injuries and fires. 3. Even if hoses and hose lines are properly stored and used, they undergo a natural aging process. For that reason, their service life is limited. 4, Improper storage, mechanical damage and improper use are most frequent causes of hose failures, 5. Service life of a hose line may not exceed six years, including a storage period of a maximum of two years (always check manufacturer's date on hoses). 6. Using hoses and lines close to limit ranges of permitted use can shorten service life (for example at high temperatures, frequent working cycles, extremely high impulse frequencies, mutt shift operation). 7. Hoses and lines must be replaced if any of following conditions are found during an inspection: 010-12 LIEBHERR PRI76-1296i Service manual Introduction 010.1.15 010.1.16 010.1.16.1 Criteria: + Damage to outer layer as far as intermediate layer (e.g. chafing, cuts and cracks). + Brittleness of outer layer (hose material cracking); + Deformations, which differ from natural shape of hose or hose line, when Under pressure or not under pressure, or in bends, e.g, separation of layers, blisters or bubble formation; + Leaks; + Failure to follow installation instructions; + Damage or deformation in hose fitings, which reduce stability of fitting or connection from hose to fitting; + Hose slipping out of fitting + Corrosion of fiting, which reduces function and strength; + Storage time or service life has been exceeded. 8 When replacing hoses and hose lines, use only Original spare parts. 9. Route and install hoses and hose lines properly. Do not mix up connections. Safety guidelines for maintenance work on mac! with hydro accumulators Only especially trained expert personnel may work on hydro accumulators. Improper mounting and handling of hydro accumulators can cause severe accidents, 3. Do not operate damaged hydro accumulators, 4, Before working on hydro accumulators, relieve pressure in hydraulic system (hydraulic system including hydraulic tank), as described in these operating instructions. 5. Do not weld or solder on hydro accumulator and do not carry out any mechan- ical work, Hydro accumulator can be damaged due to heat exposure and can rupture due to mechanical treatment. THERE IS A DANGER OF EXPLOSION! 6. Fill hyrdo accumulator only with nitrogen. When using oxygen or air, there is a DANGER OF EXPLOSION! 7. Accumulator housing can become hot during operation, there is a danger of burning, 8. New hydro accumulators must be charged to required pressure for application before use. 9. Operating data (minimum and maximum pressure) is marked permanently on hydro accumulators. Make sure that marks remain visible. Roll over protection (ROPS) and falling object protec- tion (FOPS) Machine is equipped with an operator's cab, which provides overroll (ROPS) and falling objects (FOPS) protection for machine operator. Avoid accidents Dangerous situations can occur depending on application and method of operation, even with intact protective devices. Avoid all unsafe methods of operation. PR775-1298 EBHERR 010-13Introduction Service manual 010.1.16.2 010.1.17 010.1.18 Note Overall weight of machine! > At installation of attached tools and attachments make sure that overall weight of machine is below weight for which overroll protection was certified, Protective function of overroll protection is not longer ensured if maximum permissible overall weight of machine is exceeded (see Data tag). Following changes on machine can cause maximum permissible overall weight to be exceeded: — Use of attached tools which are too heavy — Change of working attachment — Additions or modifications on machine Amachine with a damaged cab protective system (ROPS, FOPS) may not be placed into operation, Damage on operator's cab can be caused by following work and occurrences: Welding, cutting or driling of holes Attaching fittings Deformation after an accident Falling objects Structural changes or repair of any kind are prohibited. Avoid injuries Overroll protection of operator's cab protects operator only when he is wearing seatbelt. Any changes in interior of operator's cab, for example as a result of installation of accessories, may not restrict working area of operator. Any objects carried in operator's cab may not protrude into working area of oper- ator. Loose objects must be stored safely. Equipment and attachment parts 1. Equipment and attachment parts made by other manufacturers or those which were not approved by Liebherr for installation or attachment may not be installed on machine without prior written approval by Liebherr. 2. Liebherr must be provided with required technical documentation necessary for this purpose. Protection from vibrations 1. Vibration impact on mobile construction machinery is usually result of manner of utilization. Especially following parameters have a significant influence: Terrain conditions: unevenness and potholes; Operating techniques: speed, steering, braking, control of operating elements of machine during travel as well as working 2. Machine operator determines vibration impact to a large extent, as he himself selects speed, gear ratio, working manner and travel route. This results in a wide range of various vibration impacts for same machine type. 3. Full body vibration impact for machine operator can be reduced if following recommendations are observed: Select appropriate machine, equipment parts and auxiliary devices for corre- sponding tasks. 010-14 LIEBHERR PRI76-1296i Service manual Introduction 010.1.19 010.1,19.2 Use a machine equipped with appropriate seat (Le. for earth moving machines, for example hydraulic excavators, a seat which meets EN ISO 7096). 4. Keep seat in good order and adjust it as follows: Seat adjustment and suspension should be made according to weight and size of operator, Check suspension and adjustment mechanism regularly and make sure that characteristics of seat remains as specified by seat manufacturer. 5. Check maintenance condition of machine, particularly with regard to: tyre pres- sure, brakes, steering, mechanical connections, etc. 6. Do not steer, brake, accelerate and shift or move and load attachment of machine in a jerky manner. 7. Match machine speed to travel route to avoid vibration impacts. Decrease speed when driving on pathless terrain. Drive around obstacles and avoid very impassable terrain. 8. Keep quality of terrain where machine is working and travelling in good order: Remove large rocks and obstacles; Fill furrows and holes. To establish and retain suitable terrain conditions, keep machines available and allow for sufficient time, ‘Travel longer distances (j.e. on public roads) with suitable (medium) speed. 10. For machines, which are frequently used for travel, utllize special auxiliary ‘systems for travel (if installed), which reduce vibration for this application. If such auxiliary systems are not available, regulate speed to keep machine from “rocking’. See and be seen You as the machine operator perceive the most information for your work visually. Only if there is sufficient visibility while travelling and working can you minimize possible dangers for you and others, Since there is no direct view onto all areas in the surroundings, visual aids (such as mirrors and cameras) are installed on the machine. These visual aids are to be utilized for the areas around the machine which are not directly visible. WARNING. Restricted view due to some installations and equipment! Danger of accidents. > Pay attention to restrictions in the visibility leld and to blind spots. > Ifnecessary, work with a guide, Observe national regulations regarding visibility in the operator's cab. For countries within the European Economic Area, the Standard ISO 5006 describes the test and evaluation methods for the visibility field of the machine operator. Visibilty field is tested in this case with standard equipment. Changes to the machine, such as installation or modification of components may not impact the visibility field, When changes impact the visibility field, then a test according to ISO 5006 or the regula- tions valid on the job site must be carried out. Appropriate measures are to be taken, depending on the test result. The machine operator must be informed about the changes. Field of vision ‘The field of vision describes the visible range the operator can see from the opera- tor’s seat. PR775-1298 LIEBHERR 010-15Introduction Service manual The field of vision is determined according to ISO 5006. The figure below illustrates the field of vision in the near field and in the 12. m radius of the driver from the operator's seat. Not all areas of machine are located in the direct field of view. The hatched areas in the figure indicate the area that cannot be seen from the operator's workstation. g Fig. 1: Field of vision 1 Machine without rear equip-. == x_—-Radius: 12 m ment 2 Machine with rear equipment y Near field: 1 m The following obscured areas cannot be seen from the operator's workstation: (Obscured view in the area A due to front equipment. Obscured view in area B and C due to B-pillars, Obscured view in area D and E due to C-pillars. (Obscured view in the area F due to rear equipment, WARNING Restricted field of vision! Severe injuries, death D> Adjust the mirror. > When working attachments are used that limit the field of view, measures must be taken to ensure that the machine is operated safely. > Remove any obstacles in the work area. > Make sure that no persons are within the danger zone. The machine operator and construction site management must take measures to ensure that the obscured field of vision does not cause a safety hazard during operation. 010-16 LIEBHERR PR776-1296i Service manual Introduction 010.1.19.3 010.1.20 Measures before and during operation 1. Make sure that persons establish contact with the machine operator before they approach the machine. 2. Check visibilty aids for function, cleanliness and correct adjustment. 3. Adjust visibility aids in such a way that the best possible all around visibility is ensured. 4. Clean visibilty aids and windows in the operator's cab immediately if dirt affects the visibility Have defective visibiliy aids repaired or replaced immediately. Do not use sun visors if they limit visibility ‘Always monitor the surroundings to recognize potential dangers in time. Prefer direct visibility: plan the work in such a way that the visibility onto the work area is not limited by obstacles. 9. Asarule, always work with a guide for tasks with limited visibility or defective visual aids. Agree on hand signals, for difficult tasks use additional voice contact (for example via radio). 410. Use lights in bad visibilty conditions and according to the valid regulations. 11. Restriction and securing of work area 12. Observation of safety instructions, Safety notes for Diesel engines with electronic control units Start Diesel engine only with tightly connected batteries, Do not disconnect batteries when Diesel engine is running. Start Diesel engine only with a connected control unit ‘To start Diesel engine, do not use a quick charger, Starting aid only with sepa- rate batteries. 5. To quick charge batteries, battery terminals must be removed. Pay attention to ‘operating instructions of quick charger, 6. For electric welding work, batteries must be disconnected and both cables (plus and minus) must be tightly connected. Connection to engine electronic must be interrupted with interface plugs, 7. Connections of control units may only be pulled off or plugged in when elec- trical system is turned off. Tighten mounting screw of interface plugs with ‘specified tightening torque, 8. Incorrect polarization of control units - supply voltage (such as incorrect polari- zation of batteries) can destroy control units. Tighten connections on injection system with specified tightening torque. 10. If temperatures above 80 *C are expected (e.g. drying oven), control units must be removed. 11, For measurements on plug connections use only compatible test lines. 12. Sensors and actuators may not be connected individually or between external power sources, neither for checking nor for testing purposes, but only in connection with electronic control unit, otherwise there is a danger of destruc- tion or erroneous function of Diese! engine. 13. Electronic control unit is sufficiently protected from dust and water only when mating plug is installed and plugged in, If mating plug is not plugged in, then control unit must be protected sufficiently from dust and water. 14, Telephones and radio units, which are not connected on an external antenna ‘can cause function problems on vehicle electronic and therefore endanger operating safety of Diesel engine. PR775-1298 LIEBHERR 010-17Introduction Service manual 010.1.21 Safety notes for working on Common Rail System of Diesel engines 1 When diesel engine is running, fuel lines are constantly under fuel pressure of up to 2200 bar, + When Diesel engine is running, never release fitings for fuel high pressure side on Common Rall System. Fuel emerging under pressure can penetrate skin and cause severe injuries. ‘There is a danger of fires due to fuel mist. After stopping Diesel engine, wait at least one minute until pressure in fuel lines has been relieved. Avoid staying near running Diesel engine. Persons with a pacemaker must remain at a distance of at least 20 cm from diesel engine when it is running, Do not touch energized parts on electrical connection of injectors when Diesel engine is running Modern components of Diesel injection consist of highly precise parts, which are subjected to extreme loads. Due to this high precision technology, ensure utmost cleanliness for all work on fuel system. Dirt particles above 0.2 mm can cause failure of components. Before starting to work, itis imperative that following described measures be observed: + Before working on clean side of fuel system, clean Diesel engine and Diesel engine compartment (steam jets), fuel system must hereby remain closed. + Carry out a visual inspection for leaks or damage on fuel system. + Do not spray directly on electrical parts with steam jet, cover them first + Bring Diesel engine into a clean area in workshop, where no work is carried ‘out which can disperse dust (grinding, welding work, brake repairs, brake: and performance tests, etc.) + Avoid air movements (possible dispersing dust caused by starting Diesel engines, workshop ventilation or heaters, drafts, etc.) + Clean and dry area of still closed fuel system with pressurized air. + Remove loose dust particles, such a paint chips and insulation material with a suitable suction device (industrial vacuum cleaner). + Cover areas of Diesel engine compartment, from which dirt particles could be released, with a new and clean protective sheeting, + Clean tools and work equipment before starting to work. + Use only tools, which are not damaged (cracked chrome coating). + Before starting disassembly work, wash your hands and put on clean work clothing, While working, itis imperative that following described measures be observed: + After opening clean side of fuel system, do not use pressurized air for cleaning + Remove loose dirt during installation work with a suitable suction device (industrial vacuum cleaner). + Use only lint-ree cleaning cloths on fuel system. + When removing and installing components, do not use materials such as rags, cartons or wood, since they could secrete particles and fibers. + If paint chips are created when releasing connections (due to possible ‘excess paint application), then remove these paint chips carefully before releasing fittings all way. + Close off all removed parts on clean side of fuel system immediately on their connection ports with suitable caps. Capping material must be packed dust-free until used and must be disposed after one-time use. + Store removed parts carefully in a clean, closed off container. 010-18 LIEBHERR PRI76-1296Service manual Introduction + Never use previously used cleaning or test fluids for removed parts. + Remove new parts from their original packaging just immediately before use. + Carry out work on removed components only on a workstation which is ‘equipped for this purpose. + To ship removed parts, always use original packaging of new part. i PR776-1298 LIEBHERR 010-19Introduction Service manual 010.2 Special tools for maintenance and repair work 010.2.1 Tools - Diesel engine Name ID no. Use ‘Comment / image Diagnostics software for maintenance and adjustment of diesel engine LIDIA service software | Orderform |PR-/LR with USB Dongle required [Series 6 3 For the maintenance and adjustment ofthe diesel engine using LIDIA service software CAN Fox adapter cable | 12206369, PROILR Series 6 For measuring the rpm via reflection strips, Digital tachometer raea284 [PR IIR A rs, Ss : ws : For measuring the pm PR-/LR CK» Reflection strip er4oea201 [ERR For taking oll samples for the oil analysis PR-/LR Hand pump erases [BRIER —_ 010-20 EBHERR PR776-1296i Service manual Introduction Name 1D no, Use ‘Comment image Oil analysis set - mineral ol (een 814se60 |PR/RL Series coven), single sat ‘Analysis at WEAR CHECK Germany Oil analysis set - mineral oil (green 10029626 |PRYRL Series cover) 4-way set Oil analysis set = ; mineral ol (green 7018368 |PRIRL Series 6 cover) 6-way set Oil analysis set - mineral ol (green 7orea69 |PRURE Series cover) 12-way set Oil analysis set - bio oll ‘Analysis at WEAR CHECK Germany (yellow cover), single | 7026817 |PR/RL Series set Oil analysis set - Bio of (yellow cover), way | 7026088 |PRYRL Series set a For diesel particle fiter option. Optional, for leak testing of back pressure line Hand pump with pres- PRILR 5 For checking the battery condition and the antifreeze in coolant Optical charge tester PRILRIRL (refractometer) 11690210 | series 6 To continue turning the diesel engine when checking and adjusting the valve clearance Spinning device valve | s1a7e649 lpRaz6 clearance B PR775-1298 EBHERR 010-24Introduction Service manual Name 1D no. Use ‘Comment/ Slinging gear for removalinstallation of diesel engine Diesel engine slinging | sogssago_ |pR776 gear Tab. 1 010.2.2 Tools - Hydraulic system Name IDno. [Use ‘Comment image Diagnostics software for maintenance and adjustment of travel hydraulics Order form required Sculi Master 4 Cantact license with USB PRLIRL Series 6 Denole Liebherr at customer service : For adjusting the travel hydraulics or checking the elec- tics and options. Data cable - diag- nosis 1.5m 10225579 |PRIRL Series 6 (ethernet) For writing to the compact flash card CF card reader via use PRUIRL Series 6 G6.0 ‘Compact flash card emply. As data carrier for application software Compact flash 10223095 |PR-IRL Series 6 G6.0 card EBHERR PRI76-1296 010-22Service manual Introduction 230V/120V consisting of: MultisHandy 2045 gauge 2 pressure sensors 0 bar to 600 bar 2 Mini test connec- tions. 2 test cables (12 m long) Vehicle connector cable Data cable Power unit Name IDne. [Use ‘Comment / image Vacuum pump, 7408148 For faster bleeding of the hydraulic system, a slight complete, with excess pressure (approx. 0.4 bar) can be produced by accessory consists enclosing the PVC hose. Connection point for vacuum of pump on machine is breather screw on hydraulic tank [Vacuum pump with electrical 7407987 cable Hose fitting 7407985 Hose fitting 10301165 Fitting SM 7404619 |PRIRL Series 6 Fitting LER 4901110 PVC hose 7360127 Terminal clamp, | 9938447 positive Terminal clamp, | sgo3eaq5 negative 2-pin plug connec- | 74ng154 tion For measuring the surface temperature Thermometer 10024185 |PRIRL Series 6 Differential pres- For measuring pressure, pressure peaks and pressure sure testing set | 14999678 difference, and suitable for data transfer to PC. PRARL Series 6 PR775-1298 LIEBHERR 010-23Introduction Service manual Name 1Dno, [Use ‘Comment image Scale pressure For checking the hydraulic pressures Seat 5002865 Scale pressure eae 7361289 Scale pressure [gauge 0-40 7361288 \ Scale pressure i ea 0 5002867 Scale pressure Jgauge 0-100 5802903 = PRIRL Series 6 Scale pressure gauge 0-160 7361286 Scale pressure [gauge 0-250 7361285 Scale pressure ]gauge 0-400 7500002 Scale pressure beemacieen 7361294 Scale pressure ]gauge 0-1000 4601115 Measuring neck 188 (in combina- | 7499903 |pR776 ton with meas- uring neck G16S) Measuring neck Meas 7202096 |prrrs ty ‘A square sealing ring, item code 7409794, must be used for sealing during pressure tests —_ Pressure gauge | 7992436 |PRIRL Series 6 connection R 010-24 LIEBHERR PRI76-1296i Service manual Introduction Name Dro, [Use ‘Comment image Measuring neck | 7aoggag Union nut and compression ring are permanently cpl. ROL installed on measuring neck Measuring neck TOL 7406864 PRIRL Series 6 Measuring neck ee 7409918 A i Sew counna M | a issz4 For connection to additional test points on the machine Screw coupling | senaago 0x1 Serew couning M | sao7a71 [pRuRL Series 6 ‘Serew coupling M 3 Sere 7406865 Seow counina | yace720 For connection of shorter test lines or for connection between test connection and pressure sensor Bulkhead screw | 7407070 |PRIRL Series 6 y coupling M 16x2 a Testhose NW2, | 799497 ‘Shorter test hoses are preferred for Keeping loss of pres 1000 mm sure as low as possible during tests, Test hose NW2, Tesiose 7002475 os PRIRL Series 6 fest hose NW2, aay ee 7009134 Test hose NW 2, s 5000 mm 7368732 5 Dummy plates for | aa7q999 For closing off high pressure connections, Material SAE flange 2" ‘Spring stee! (ground), taper rounded plate end. Round edges simpliy assembly and prevent damage to seal Dummy plates for Bae nage: OT | 7370098 ring, In-house manufacture possible. PRIRL Series 6 aonb Dummy plates for | 7379994 SAE flange 1%" PR775-1298 EBHERR 010-25Introduction Service manual 1Dno. [Use ‘Comment/ Dummy plates for SAE flange 1% 9327334 PR776 For closing off high pressure hoses s Dummy plates for SAE flange 1%" ‘with sealing ring 9465987 PR776 For closing off hydraulic components A Oil analysis set - mineral ol (green cover), single set 8145660 PRUIRL Series 6 Oil analysis set - mineral oil (green cover) 4-way set 10029626 PRUIRL Series 6 Oil analysis set - mineral oil (green cover) 6-way set 7018368, PRLIRL Series 6 Oil analysis set - mineral oil (green cover) 12.way set 7018369 PRURL Series 6 Analysis at WEAR CHECK Germany E Oil analysis set - Bio oil (yellow cover), single set 7026817 PRIRL Series 6 Oil analysis set - Bio oil (yellow cover), 6-way set 7026088 PR.IRL Series 6 ‘Analysis at WEAR CHECK Germany E Bolted chain, high- pressure test connections on variable displace- ment motors Position 1: 7410508 Position 2: 5607605 RL46: Unlocking tool for air hose quick coupling 11839557 PR776_1296_4F_05 Tab. 2 010-26 PRI76-1296Service manual Introduction 010.2.3. Tools - Hydraulic cylinder Name 1D no. [Use ‘Comment / image For installation of O-ring and stepseal ring on hydraulic cylinder pistons Assembly See spare_|PRILR/RL Series sleeve parts list |6 / TL4Xx.7 5 For installation of O-fing and stepseal ring on hydraulic cylinder pistons Spreader See spare_|PRILRIRL Series ZA >» sleeve partslist_ |6 / TL4XX.7 For tightening the pistons of hydraulic cylinders — Tightening torques (0.20 — Technical data) Piston installa. | See spare |PRILRIRL Series A tion wrench parts list |6 / TL4Xx-7 6A a = g 5 For tightening the piston nuts of hydraulic cylinders — Tight- ening torques (0.20 — Technical data) aria See spare_|PRILR/RL Series parts list |6 / TL4Xx-7 wrench Tab. 3: Tools - Hydraulic cylinder i PR775-1298 010-27Introduction Service manual 010.2.4 Tools - Electrical system Name. IDno, [Use ‘Comment / image For measuring voltage, current, resistance and frequency Digital multimeter 10018500 | PRIRL Series 6 XK i For checking the battery condition and the antifreeze in coolant Optical charge tester —_| 11690210 | PRIRL Series 6 Crimper for MATE-N- For making proper crimp connections on MATE-N-LOK LOK Crimp contacts for | 7367025 plug connections 4.5 mm? PRURL Series 6 Crimper for MATE-N- LOK Crimp contacts for | 7366314 2.5 mm? ‘ For removing crimp contacts from plug connector| Removal tool AMP for MATE-N-LOK Crimp 7366655 |PRIRL Series 6 contacts For inserting the pin and bushing contacts in MATE-N- LOK plug connectors Installation tool AMP for MATE-N-LOK Crimp 8145432 |PRURL Series 6 contacts, —_ 010-28 LIEBHERR PRI76-1296i Service manual Introduction Name 1Dno, [Use ‘Comment image For making proper crimp connections Crimping plies for Deutsch’ plug connec- | 8503647 |PR-RL Series 6 tors 5 Gannon extraction tool For removing pin and bushing contacts in “Deutsch” for ‘Deutsch" AWG 12 | 10114733, plug connectors crimp contacts Cannon extraction tool for "Deutsch" AWG 16 /885563714/PRIRL Series 6 crimp contacts Cannon extraction tool for "Deutsch" AWG 20 | 10114732 3 crimp contacts 3 Cannon extraction tool For removing pin and bushing contacts in “Deutsch” for ‘Deutsch’ (alterna- plug connectors (alternative) tive) AWG 12 crimp sraser4 contacts Cannon extraction tool for ‘Deutsch (alterna — reyane 76 cine 8145673 |PRIRL Series 6 contacts g Cannon extraction tool ‘ for ‘Deutsch’ (alterna tive) AWG 20 crimp 8503680 contacts For erimping the “JUNIOR POWER TIMER” contacts Crimper AMP Certi-Lock | 7415333 |PRURL Series 6 ——— For removal of contacts from the “JUNIOR POWER TIME! Extraction tool AMP 726 PR-/LR Series, 503-1 7026268 |e) TLaXxX-7 i For removal of contacts from the “JUNIOR POWER TIMER’ housing Extraction tool AMP 726 | 7997449 [PR-/LR Series 534-1 16 / TL4Xx-7 PR775-1298 EBHERR 010-29Introduction Service manual Name 1Dno, [Use ‘Comment / image Crimper ESA 0760 7409781 For crimping insulated cable shoes 0.5 - 6.0 mm?, e.g cable connectors, CRB 0560 also windscreen wiper motor PR-IRL Series 6 Crimper CRB 0560 7409782 =e. ITT-Cannon - contact removal tool (APD 4-9In) | sgaaavaa |PRI76 Hor high power jam nut 2- — way z ITT-Cannon - contact removal tol (APD 7-0in) | so>4q8g8 |PRIT6 Hor high power jam nut 2- — way z “Tyco pin removal too! for control unit plug connection ‘A700 (ECU) [Tyco pin removal too! Deon 11114828 | PR776 G6.0_02 ~ : PR series 6 66.0/ LR series | TYCO pin removal too! for control unit, plug eonneston Tyco pin removal tool 6.6.0/RL 45mm 12206714 | series 6 G5.0 —e: and PR776 3 66.0_02 Tab. 4 010.2.5 Tools - Travel gearbox Name Ino. [Use ‘Comment / image Installation device for {travel gearbox slipring seal FAT 800 F 538 PR776 ; Slipring seal item code For proper assembly of duo cone (slipring) seals on travel gearboxes. Device number: 761023703 outside 10190049 0759049617 761024303 inside 10190047 (0759046823 010-30 LIEBHERR PRI76-1296i Service manual Introduction Name Dro, [Use ‘Comment image For flushing the duo cone (slipring) area of the travel gearbox Flushing line 9415306 |PR776 5 Travel gearbox For loosening and tightening the adjustment nut in the travel mounting device cpl gearbox consisting of. Item codes 12259631, 12259633, 12250635. | 12269637 [PR776 and 12244852 See also the following three special tools. 5 Far loosening and tightening the adjustment nut in the travel gearbox Press-t ing bearing | 12259631 |PR776 and tightening the adjustment nut in the travel Grooved ring and brace gearbox in conjunction with a Bae power wrench. 12259633 + ll \ Power wrench is not | 12259635 |PR776 , included in the scope of delivery! Jolt r22aaas2 |PR776 For measuring the bearing pretension Ferque converter 11601078 [PR 776 bearing PR775-1298 EBHERR 010-34Introduction Service manual Name 1D no. [Use ‘Comment / image For measuring the bearing pretension Spring balance 11601080 |PR 776 ii | For installing and removing the travel gearbox and undercar- riage PR776 Lifting device 13341609 |onoo 02 Device for installation and removal of the sun gear, the internal gear and the planetary carrier Device 12220156 |PR 776 Tab. 5 010.2.6 Tools - Undercarriage Name 1D no. Use ‘Comment / image For measuring undercarriage wear Testing tool- Undercar- | 7yqy6q3 | PRILRIRL riage components Series 6 = A 010-32 EBHERR PRI76-1296Service manual Introduction 2x Pos.2 (idler unit retainer) Name 1D no. ‘Comment / image ‘Too! set for disassembly/assembly of pins with bearings for double pendulum track rollers Roller bearing tool set PR776/ g Transport retainers for Post: | PR756 ‘Transport retainer for fastening the undercarriage each undercarriage: 12480929 pendulum and the idler unit 3x Pos.1 (undercarriage | Pos.2 Pendulum 1 to 3 /left) 12429656 3x Pos4 (undercarriage | _ Pos.3 pendulum 1 to 3/right) | 93505329 2x Pos.3 (for the last Pos.4: Undercarriage pendulum) | 12480930 PR775-1298 EBHERR 010-33Introduction Service manual Dn. coupling ‘Comment / image Transport retainers for Post: [PR776 Transport retainer for fastening the undercarriage Jeach undercarriage: 93505329 pendulum and the idler unit 8x Pos.t (undercarriage | Pos.2. pendulum 1 to4/left and | 93501483 Fight) 1x Pos.2 (idler unit retainer) Hydraulic cylinder for pressing the pendulum bearing in and out Enerpac cylinder RCS PRI776/ 201 11081098 | pR756 g For pressing out the support axles Enerpac cylinder RCS soos 12281319 |PR776 Hydraulic hose and hydraulic coupling for connecting the hydraulic pump to the hydraulic cylinder Enerpac hydraulic hose 10430200, |PR776/ He” 7206, hydraulic 886120808 |PR756 010-34 LIEBHERR PRI76-1296i Service manual Introduction Name 1D no. ‘Comment / image Pressure gauge with connector for pressure monitoring ge 2) Enerpac pressure gauge | 11081099, |PR776/ we : GF-230B, Enerpac GA-2 | 10430202 /PR756 . Hydraulic pump for pressing the pendulum bearing in and out Enerpac hydraulic pump PR776/ P80 10430198 oR 766 z ‘Special tool for mounting rubber plugs on the track bolt for Intertrac tracks Installation tool 12264280 | PR776 Lifting device for installing and removing the undercar- riage and for general ting tasks PR776/ C-frame sosaziat [ERS For installing and removing the travel gearbox and undercarriage PR776 Lifting device 19341608 [oo oeo2 Tab. 6 PR775-1298 EBHERR 010-35Introduction 010.2.7 Tools - Oscillating axle frame Service manual Name ID no, Use [Comment Mounting sleeve for oscillating axle frame bearing In-house manufacture only | PR 776 For mounting oscillating axle frame bearing Tab. 7 In-house manufacture of mounting sleeve For mounting oscillating axle frame bearing Fig, 84 Bearing [9A |oB [c PR776 [Inner bearing | 147 mm| 188 mm|75 mm PR776 [Outer bearing | 145 mm| 166 mm|75 mm Tab. 8 010.2.8 Tools, operator's platform Name ID no. Use ‘Comment / image For installation and removal of elastic bearing of operator's PR series 6 platform Extraction tool - eeoreR operator's cab rasti002 [series & bearing ooo series 6 G6.0 2 010-36 EBHERR PRI76-1296i Service manual Introduction Name ID no. Use ‘Comment / image For installation and removal of elastic bearing of operator's platform Enerpac hollow piston cylinder 3 RCH1211 and gootorsog [PRIZE g coupling sleeve cRé00 go For installation and removal of elastic bearing of operator's platform Enerpac hydraulic 8 hose HC- 7206, | gatiognns |PR776 hydraulic coupling For installation and removal of elastic bearing of operator's platform Pressure gauge with connector for pressure monitoring Enerpac pressure gauge GF-230B, \esozos, |PR776 2 Enerpac GA-2 3 > , For insiallation and removal of elastic bearing of operator's platform Enerpac hydraulic pum PD 10430198 |PR776 z PR776-1298 EBHERR 010-37Introduction Service manual Name 1D no. [Use ‘Comment / image For raising the operator's cab with cab support Cab support 12939234 |PR776 Tab. 9: Tools, operator's platform 010-38 PRI76-1296Service manual Introduction 010.3 010.3.1 010.3.1.1 010,3.1.2 Standards and specifications Preload values and tightening torques for screws with standard and fine metric thread according to DIN ISO 261 Item code: 10409969 Version: 005 Scope of application and purpose ‘Screw connections should be mounted so that there is sufficient clamping force under operating loads to ensure that no shearing forces (FQ) act transversely to the screw axis. Ifthe transverse forces are greater than the clamping force, this will lead to loosening and eventual failure of the connection, The respective required clamping effect is achieved during assembly by tightening the threaded parts. Further applicable documentation Standards [Description DIN ISO 261 (11/1999) _|ISO general purpose metric screw threads - General plan (ISO 261:1998) DINISO 262 (11/1998) [ISO general purpose metric screw threads - Selected sizes for screws, bolts and nuts (ISO 262:1998) DIN ISO 965-2 (11/1999) |ISO general purpose metric screw threads - Tole lances - Part 2: Limits of sizes for general purpose lexternal and internal screw threads - Medium quality (ISO 965-2:1998) DIN ENISO 4014 Hexagon head screws with shank - Product grades A (06/2011) land B (ISO 4014:2011); German version EN ISO }4014:2011 DIN ENISO 4016 Hexagon head screws with shank - Product grade C (08/2011) SO 4016:2011); German version EN ISO 4016:2011 DIN EN ISO 4017 Fasteners - Hexagon head screws with thread up to (05/2015) head - Product grades A and B (ISO 4017:2014) |German version EN ISO 4017:2014 DIN EN ISO 4018 Hexagon head screws with thread up to head - (07/2011) Product grade C (ISO 4018:2011); German version EN Iso 4018:2011 DIN ENISO 4762 Hexagon socket head cap screws (ISO 4762-2004) (08/2004) |German version EN ISO 4762:2004 DIN EN 20273 (02/1992) |Fasteners; clearance holes for bolts and screws (ISO 1273:1979); German version EN 20273:1991 DIN 34800 (11/2016) | Bolts and screws with external hexalobular driving feature with small flange VDI 2230 Sheett [Systematic calculation of high stressed bolted joints - (02/2003) Joints with one cylindrical bolt PR775-1298 010-39Introduction Service manual 010.3.1.3 010.3.1.4 ®@ Standards Description LH 10215295-002 LN 252-8 Corrosion protection for low-value standard (08/2015) arts (C parts) salt spray mist test > 480 hours LH 10021432-010 Delivery specifications for steel fasteners with zinc (08/2015) coating (FiZn) Tab. 10: Further applicable documentation Changes and descriptions The prestressing forces and the tightening torques noted in the chart have been taken from the VDI (Association of German Engineers) guidelines 2230 of February 2003 Assembly prestressing forces F,, and tightening torques M, at 90% utilisation of the yield strength for shank bolts with standard or fine metric threads as per DIN ISO 262 (and DIN ISO 965-2); wrench sizes for hex head screw in accordance with DIN EN ISO 4014 to 4018, screws with external hexalobular driving feature according to DIN 34800 or socket head bolts according to DIN EN ISO 4762 and hole “middle” according to DIN EN 20273. Note: — Any tightening values noted in Liebherr service documentation drawings or documents must be adhered to and given preference over factory standards. — For important screw connections, angle-controlled tightening can be advanta- geous. In this case, the necessary tightening values (joining moment, angle) must be determined by the technical customer service department for the indi- vidual case. — When tightening in aluminium, with or without Helicoil insert and for weld nuts, the values for class 8.8 must be used. Any tightening values noted in Liebherr service documentation drawings or documents are binding, paramount and must be adhered to, Tightening values Note If tightening values are specified in Liebherr design drawings or documents in the iebherr service documentation, they must be given priority. 010-40 LIEBHERR PRI76-1296Service manual Introduction Metric standard thread and fine thread ‘Metric standard thread and fine thread At least one element of the screwed connection (screws, washers, nuts, ...) with following surface: fiZn = zinc coating (LH standard 10021432, LH ‘standard 10215295 fizZnnc-480h-L valid 2M6) ;crewed connection (screws, with following surface: black oxide or phosphated zinc plated (LH standard 10215295 Fel! ZnNi(12)S//Cn/IT2) 4: Zine coating 4: Black oxide, phosphated, burnished 2: Thick film passivation 3: Yellow chromated 4: Zinc plated Fe//ZnNi(12)5//Cni/T2 Tab. 11: Screw types Metric standard thread and fine thread Metric standard thread and fine thread ‘At least one element of the screwed connection | All elements of the screwed connection (screws, (screws, washers, nuts, ...) with following surface: washers, nuts, ...) with following surface: fIZn = zinc coating (LH standard 10021432, LH black oxide or phosphated ‘standard 10215295 fiZnne-480h-L valid 2M6) zinc plated (LH standard 10215295 Fel! ZnNi(12)5//Cn/IT2) Minimum total coefficient of friction y.= 0.08 ‘Minimum total coefficient of friction w,= 0.11 Thread Grade [Assembly _|Tightening Thread Grade [Assembly | Tightening prestressing |torques M, prestressing |torques M, in forces Fin |Nm_ forces F, in |Nm kN kN M4 88 45 29 108 66 43 129 17 5.0 M5 88 73 57 108 107 84 12.9 126 98 Mé 88 106 86" M6 88 103 9.9) 10.9 155 126" 109 152 145 129 182 147" 129 77 169 PR775-1298 010-44Introduction Service manual ‘standard thread and fine thread ‘Metric standard thread and fine thread ment of the screwed connection (screws, washers, nuts, ..) with following surface: flZn = zinc coating (LH standard 10021432, LH ‘standard 10215295 flZnnc-480h-L valid 2M6) All elements of the screwed connection (screws, washers, nuts, ...) with following surface: black oxide or phosphated zinc plated (LH standard 10215295 Fel! ZnNi(12)S//Cn/IT2) Minimum total coefficient of friction y,= 0.08 Minimum total coefficient of friction y.= 0.11 Thread Grade [Assembly _ Tightening Thread Grade [Assembly | Tightening prestressing | torques M, in prestrossing | torques M, in forces Fin |Nm forces Fy in |Nm KN kN M7 88 15.3 13.9" M7 88 15.0 16.1 108 225 20.4" 109 220 236 129 26 23.9" 129 26 28 MB 88 19.3 20.6" Ms 88 18.9 238 109 28 30° 109 28 35 129 3 3st 12.9 32 at Mext | 88 21.0 27" Mext | 68 208 28 109 34 3 109 30 a7 129 36 ar 12.9 36 43 Mext | 88 27 at Moxt | 68 27 36 109 40 4st 109 39 53 129 47 53° 129 46 62 M10 88 4 40 M10 38 30 a7 109 45 59 109 44 68 128 53 69 129 52 80 mioxi | 88 35 “4 mioxi | 88 34 51 109 51 64 109 50 7% 128 60 75 129 58 88 M10x125| 88 33 42 M10x125 | 68 2 48 10.9 48 62 109 47 2 129 56 72 129 55 84 Mi2 88 45 Cy Miz 88 44 80 10.9 66 102 109 64 118 129 7 119 129 75 140 Mi2x125| 88 50 74 M12x125 | 88 48 86 108 73 109 10.9 nm 125 129 85 125 129 84 150 Mi2x15 | 88 a 72 Mi2x15 | 88 46 83 109 69 105 109 68 122 129 81 123 129 78 145 010-42 PRI76-1296Service manual Introduction Metric standard thread and fine thread Metric standard thread and fine thread ‘Atleast one element of the screwed connection | All elements of the screwed connection (screws, (screws, washers, nuts, ...) with following surfa washers, nuts, ...) with following surface: fIZn = zinc coating (LH standard 10021432, LH black oxide or phosphated ‘standard 10215295 fizZnnc-480h-L valid 2M6) zinc plated (LH standard 10215295 Fel! ZnNi(12)//Cn/IT2) Minimum total coefficient of friction y,= 0.08 ‘Minimum total coefficient of friction y,= 0.11 Thread Grade [Assembly _|Tightening Thread Grade [Assembly | Tightening [prestressing |torques M, in prestressing | torques M, in forces F, in [Nm forces Fy in |Nm kN kN M14 88 61 110 M14 88 60 125 10.9 90 160 109 88 185 12.9 105 190 129 103 220 Mi4x15 | 88 67 17 Mi4x15 | 88 66 135 10.9 99 170 109 96 200 129 18 200 129 113 235 M16 88 84 170 M16 88 82 195 10.9 123 250 109 120 290 129 145 290 129 140 340 Miexts | 88 a4 175 Miexts | 88 89 205 10.9 135 260 109 130 300 129 155 300 129 150 360 M18 88 702 238 M18 88 400 270 10.9 150 350 109 145 400 129 175 410 128 170 470 Misxt5 | 88 17 260 Miexi5 | 68 118 300 10.9 175 380 109 170 440 129 200 440 129 200 520 Miex2 | 88 110 245 Misx2 | 88 107 290 10.9 160 360 109 160 420 129 190 420 129 185 490 M20 88 130 330 M20 88 130 380 10.9 190 490 109 190 560 129 225 570 129 220 660 M20x15 | 88 150 360 M20x15 | 88 145 420 10.9 218 520 109 215 610 129 250 610 129 250 720 M22 88 165 450 M22 88 160 520 10.9 240 660 108 235 770 129 280 770 129 270 900 PR775-1298 010-43Introduction Service manual ‘standard thread and fine thread ‘Metric standard thread and fine thread ment of the screwed connection (screws, washers, nuts, ..) with following surface: flZn = zinc coating (LH standard 10021432, LH ‘standard 10215295 flZnnc-480h-L valid 2M6) All elements of the screwed connection (screws, washers, nuts, ...) with following surface: black oxide or phosphated zinc plated (LH standard 10215295 Fel! ZnNi(12)S//Cn/IT2) Minimum total coefficient of friction y,= 0.08 Minimum total coefficient of friction y.= 0.11 Thread Grade [Assembly _ Tightening Thread Grade [Assembly | Tightening prestressing | torques M, in prestrossing | torques M, in forces Fin |Nm forces Fy in |Nm KN kN M22x15 | 88 180 480 M22x15 | 88 180 570 108 270 700 109 260 830 129 310 820 129 310 970 M24 88 190 570 M24 88 185 660 109 280 840 109 270 970 129 320 980 12.9 320 1140 M24x15 | 88 220 620 M24x15 | 88 215 730 109 320 910 109 320 1080 12.9 380 1070 12.9 370 1250 M2ax2 | 88 210 600 M2ax2 | 88 205 710 109 310 890 109 300 1040 129 360 1040 129 350 1220 M27 88 245 830 M27 38 240 970 109 360 1230 109 360 1450 128 420 1450 129 420 1650 Ma7x15 | 88 280 900 Ma7x15 | 68 280 1080 109 410 1300 109 410 1550 128 480 1550 129 480 1850 Ma7x2 | 88 270 80 Ma7x2 | 88 260 1030 10.9 400 1300 10.9 390 1500 129 460 1500 129 460 1800 M30 88 300 1140 M30 88 280 1300 10.9 440 1650 109 430 1950 129 520 1950 129 510 2250 M30x15 | 88 350 1240 M30x15 | 88 350 1450 10.9 520 1800 109 510 2150 129 610 2180 129 590 2500 m30x2 | 88 340 1220 ma0x2 | 88 330 1450 109 500 1800 109 490 2100 129 580 2100 129 570 2450 010-44 PRI76-1296Service manual Introduction Metric standard thread and fine thread Metric standard thread and fine thread ‘Atleast one element of the screwed connection | All elements of the screwed connection (screws, (screws, washers, nuts, ...) with following surfa washers, nuts, ...) with following surface: fIZn = zinc coating (LH standard 10021432, LH black oxide or phosphated ‘standard 10215295 fizZnnc-480h-L valid 2M6) zinc plated (LH standard 10215295 Fel! ZnNi(12)//Cn/IT2) Minimum total coefficient of friction y,= 0.08 ‘Minimum total coefficient of friction y,= 0.11 Thread Grade [Assembly _|Tightening Thread Grade [Assembly | Tightening [prestressing |torques M, in prestressing | torques M, in forces F, in [Nm forces Fy in |Nm kN kN M33 88 370 1550 M33 88 370 1800 10.9 550 250 109 540 2600 12.9 640 2600 129 630 3100 Ma3xt5 | 88 430 1650 M33x15 | 88 420 1950 10.9 630 2450 109 620 2900 129 740 2800 129 730 3400 masx2 | 68 420 1600 Masx2 | 88 410 71900 10.9 610 2400 109 600 2800 129 720 2800 129 700 3300 M36 88 440 1950 M36 88 430 2300 10.9 650 2900 109 630 3400 129 760 3400 129 740 3900 M3ext5 | 86 520 2150 Msex15 | 88 510 2600 10.9 760 3200 109 750 3800 129 890 3700 128 870 4400 masx3 | 88 470 2050 Masx3 | 88 460 2400 10.9 690 3000 109 680 3500 129 810 3500 129 790 4100 M39 88 530 2500 M39 88 520 3000 10.9 770 3700 109 760 4400 129 910 4400 129 890 5100 Maox15 | 88 610 2800 M3ox15 | 88 600 3300 10.9 900 4000 109 880 4800 129 1050 4700 129 1030 5600 ma9x3 | 88 560 2600 Ma9x3 | 88 550 3100 10.9 820 3900 109 810 4500 129 960 4500 129 940 5300 Tab. 12: Prestressing forces and tightening torques for screws “The tightening torques for fIZn screws See note, Installation General installation notes — The sliprings of seals are manufactured as pairs. For that reason, new as well as used seals may only be installed as original pairs. = Avoid impacts and blows which could damage the sealing surfaces of chilled cast sliprings. ~ Round off sharp edges on the seal mounts. = Slipring seals and their receptacles must be absolutely clean and free of grease and oil for installation, — O-rings must not be lubricated with oil. PR775-1298 EBHERR 010-47Introduction Service manual Note Slipring seals should be installed generally with the aid of an installation device (see Special tools)! > Install slipring seals with installation devices. NOTICE If the installation device is not used, the O-ring can roll up on the conical slipring surface! In case of one-sided installation pressure, the seal half and / or the O-ring may twist. These installation defects and damages of the slipring surfaces cause leaks. D> Use the installation device Fig. 97: Installation position O-ring 1 Installation position O-ring correct 3 _ Installation position incorrect / seal half O-ring is inclined. 2 Installation position incorrect / O- ring twisted Installation of slipring seal Fig. 98: Installation of slipring seal 4 Seal mount 5 Installation device 2 O-ing 6 — Round rubber string aid 3 Slipring A split installation device § is used as installation aid, it is folded over the slipring 3, transferring the pressure at installation directly to the O-ring 2. 010-48 LIEBHERR PRI76-1296Service manual Introduction Press the seal halves using the appropriate installation aid into the seal mount 4. ‘The required pressure must be exerted evenly onto the full circumference of O- ring, If no suitable installation device is available, a round rubber string 6 can be inserted between the slipring 3 and O-ring 2 as a makeshift spacer and affixed by hand, so that the O-ring cannot roll up on the conical slipring surface when the seal half is pressed in. Before the components are assembled, check if the seal rings protrude evenly. To do so, measure the distance of seal mount 4 to slipring 3 on at least three points of circumference, always offset by 120°, Check the sealing surfaces again to ensure they are clean and lightly lubricated with a thin oil or grease film. Installation specification for spring-loaded hose clamps Due to large temperature differences on radiators, the outer diameters of mounting studs for the hose connections change significantly. These differences on the ‘mounting studs are equalized by using spring-loaded hose clamps. NOTICE Hose clamp is tightened too much! The spring assembly of hose clamps blocks and the required spring effect is no longer provided, > Loosen the hose clamp completely and tighten again with the specified tight- ening torque. To ensure proper function of spring-loaded hose clamps, note the following tight- ening torques: Hose clamp type [Band width mm|Tightening torque Nm PR775-1298 HKF 15.8 a HKF -K 14.3 75% Tab. 16 010.3.3 Tapping bores 010.3.3.1 Tapping bores of metric ISO standard threads rn Core diameter limit dimen- | 519 diameter sions maximum | _ minimum M1 0,785 0.729 0.75 Mata 0,885) 0.829 0.85 M12 0,985 0.928 0.95 M14 1,160 1.075 1.10 M16 1321 1.221 1.25 Maz 1,346 1.258 1.30 010-49Introduction Service manual 010-50 Thread size Gore diameter i Drill diameter maximum | minimum M18 1821 1421 145 M2 1679 1567 160 M22 7.838 1718 175 M23 7,920 1798 790 M25 2.138 2.078 2.08 M26 2,176 2.036 2.10 M3 2,590 2.459 2.50 Mas 3.070 2.650 2.90 Ma 3.422 3.242 3.30 mas 3.878 3.688 370 Ms 4.334 4134 420 Me 5.153 4917 5.00 M7 6.153 5917 6.00 Me 6.912 6.647 6.80 Me 7.912 7647 7.80 m0 3.676 8.376 3.50 Mati 9.676 0.576 9.60 maz 70.484 70.106 102 maa 72210 71.835 120 Ma6 74210 13.835 740 M18 15,744 15.294 155 20 7.744 17.294 178 M22 19,744 19.294 198 M24 24,252 20.752 210 M27 24,252 23.752 240 m0 26771 26.271 266 m3 29.71 e271 29.50 M36 32,270 31.650 32.0 mae 36,270 34670 35.0 a2 37,798 30.129 a7 mas 40,799 20.129 205 mae 43.207 42.587 20 52 47.207 46.587 470 56 50,796 50,046 505 moo 54,796 34.046 Baa mee 58,308 37.505 376 PRI76-1296Service manual Introduction Thread size Core diameter i Drill diameter maximum | minimum M68 62,305 61.505 616 Tab. 17 010.3.3.2 Tapping bores of metric ISO fine threads Thread | CO Samet En SME | Day ameter sions maximum M1x02 0,821 0.80 Mitxo2 0.924 080 Mi2x02 1.024 1.00 Mi4x02 1224 120 14x 025 7.185 1415 Mi6x02 1azt 140 Mi8x02 1621 160 M2x025 71,785 175 M22x025 7,985 195 M25x0.35 2201 2.16 M3x035 2721 2.65 M35x035 322 348 Max05 3,598 3.50 M45x05 4,099 4.00 M5x05 4,599 450 M55x05 5,099 5.00 MOx075 5,378 520 M7x075 6.378 620 Max075 7.378 7.20 Maxi 7.168 7.00 Mox075 3.378 8.20 Moxt 3,163 3.00 M10x075 9.378 920 Mi0x4 9,163 3.00 M40x125 3.912 3.80 M11x075 10.378 102 Miixt 10.183 70.0 Mi2xi 71,183 Wa M12 x128 10.912 108 PRI78-1208 010-51Introduction Service manual 010-52 Thread size Gore diameter i Drill diameter maximum | minimum M1215 10,676 10.376 105 Mtaxd 73,453 12.917 73 M14 1.25 72.912 12.647 128 Mtax15 12,676 12.376 125 M16x1 74,153 13.9017 14.0 M18x15 13,676 13.376 138 M16x1 75,153 14.917 15.0 M16x15 14,676 14.376 145 Mi7xi 16,183 15.917 76.0 Mi7xis 15.676 15.376 155 Miext 17.183 76917 170 Mtex45 16.676 16.376 165 M18x2 76210 15.895 16.0 M20x4 79,458 18.817 18.0 M20x15 18,676 18.376 185 M20x2 78210 17.835 78.0 M22x4 21.453 20.917 210 M22x15 20.676 20.376 205 M22x2 20.210 19.835 20.0 M2axi 23,153 22.917 23.0 M2ax15 22.676 22.376 25 M24 x2 22.210 21,895 22.0 M25x1 24,158 23.917 240 M25x15 23,676 23.376 235 M25x2 23.210 22.835 23 M26x15 24.676 24.376 245 M27x4 26,163 25.917 26.0 Ma7x15 25.676 25.376 255 M27 x2 25.210 24.895 25.0 M 28x14 27.458 26.917 270 M2ex15 26.676 26.376 265 M28x2 26.210 25.695 26.0 M 30x14 29,153 28.917 280 Ma0x15 28.676 28.376 285 M30x2 26,210 27.835 28.0 M30x3 2282 26.752 270 PRI76-1296Service manual Introduction Thread size Core diameter i Drill diameter maximum | minimum Ma2x 15 30,676 30.376 30.6 Ma2x2 30.210 29.835 30.0 M3ax15 31,676 31.376 318 M33x2 34.210 30.836 310 M35x3 30,252 20.752 30.0 M35x15 33,676 33.376 335 M36x15 34676 34.376 348 M36x2 34210 35.635 340 M36x3 33,252 32.752 330 Ma8x 15 36,676 36.376 365 M39x15 37,676 37.376 378 M39x2 a7210 36.835 37.0 M39x3 36,252 35.752 36.0 M40x15 38,676 38.376 385 M40x2 38210 37.835 380 m40x3 37.252 36.752 370 Maaxi5 40.676 20.376 405 Ma2x2 40.210 30.835 40.0 Ma2x3 39252 38.752 300 Maza 38270 37.670 38.0 MASK 15 43.676 43.576 435 M43 x2 43.210 42.635 430 M45 x3 42.282 41752 42.0 MAS x4 41,270 40.670 410 MaBx15 46.676 46.376 465 MAB x2 46.210 45.635 460 MabxS 45.252 44,752 450 Max 44.270 43.670 440 M 50x15 48.676 48.376 485 M50x2 48.210 47.835 480 M50x3 47.252 46.752 470 M52x15 50,676 30.376 505 M522 50,210 49.635 50.0 M523 49.252 48.752 490 Me2x4 48.270 47.670 480 Tab. 18 PRI78-1208 010-53,Introduction Service manual 010.3.4 Conversion tables Size From unit Multiplier et eee Multiplier To unit Length tr 0,038 a 25a mm m 3281 a 0308 m m 1,093 yd 0,914 m mn 0621 mle 7,609 em Surface om 0,185 7 6482 on = 70764 7 0098 = = 7.196 ve 0883 = ia? 0386 a mile 259 oP Vaume om 0061 9 763387 on oe 3518 we 0028 7 oP 7,308 e 0784 [7 1 31025 iw 1 1 0035 e 7a16 1 1 0264 cal 3785 1 1 1.087 quar 0.948 1 Cath a 0,088 @ 73,348 a kg 2,204 Ib 0,453 kg t 7.102 thom 0.907 t Force N 07225 1 wr N KN (224,732 Ib, 0.0044 kN Work Nn 0737 tb 7356 Nm Performance kW 1,342 HP 0,745 kW PS 0,736 kW 1,358 PS PS. 0,986 HP 1,014 PS Pressure bar 14.5 psi 0,069 bar (hydrautic) kPa 0,145 psi 6,896 kPa Ground pressure kg/cm? 14,223 Ibyin® 0.0703 kg/cm? kg/m? 0,205 Ibift? 4,878 kg/m? Densiy olor 0,086 wie 278 glen? gin? 09082 wie 7613 gine Speed rent O62 mph 7.609 ren nin 3281 tun 0308 nin Temperature c Coxt 8) +2 = (Fags ra c "+28 * 278 6 Tab 19 010-84 "LIEBHERR prrre-286Service manual Introduction i 010.4 010.4.1 010.4.2 Conservation guidelines General All parts of a construction machine are exposed to corrosion, especially when the machine is taken out of service. Corrosion can be compared to wear. However, the effects of corrosion can greatly exceed that of mechanical wear and shorten the service life of the affected parts significantly. For that reason, for longer shut down, the machines and its components must be conserved according to certain guide- lines. In general, these guidelines are tiered according to the following periods of time: = Taking the machine out of service for an unknown duration = Shut down of the machine + Shut down for up to 2 months + Shut down for up to 12 months + Shut down for longer than 12 months — Return to operation The required measures are grades according to the different time frames. The conservation measures cannot be strictly standardised and they must be shorted or lengthened depending on the assessment of necessity (such as environmental influences). ‘Such influences are, for example: = Placement location of machine (such as in unprotected surroundings, in enclosed areas, under a roof, in a temperature-controlled environment) — Type of climate (for example extreme temperatures, storage at sea / near the coast, etc.) Note For conservation for sea transport, special guidelines must be observed, which are not included in these instructions. > See special guidelines. Taking the machine out of service for an unknown duration Ia machine is taken out of service for a longer period of time without conservation, then it must be operated in maximum 14-day intervals to prevent abnormal corro- sion and its effects to a large extent. = Before putting the machine back into service, check all oil evels and correct them, if necessary. — Every time a machine is put back into service, carry out the daily maintenance tasks. In addition, carry out time limited maintenance work at least by the inter- vals given on the inspection check list and additional diesel engine operating instructions. = Put the machine back in service according to the operating instructions and operate it until the diesel engine and the hydraulic system have reached the required operating temperature in the hydraulic tank and in the coolant circuit. = Actuate all functions of the travel/working hydraulics as well as functions of additionally installed hydraulic components and alternately operate them over a period of approx. 20 minutes. The hydraulic cylinders must be extended and retracted over their full stroke length, PR775-1298 LIEBHERR 010-55Introduction Service manual 010.4.3 010.4.3.1 — When turing the machine off, retract all hydraulic cylinders fully if possible, and fil the fuel tank completely. if the machine is parked on soft ground, park the machine on wooden planks or similar and secure it to prevent it from rolling away. = Check the batteries, and if necessary remove and recharge them. Check the electrical contact points and grease them with terminal grease, if necessary. Shut down of the machine Preparations for shut down: — Park the machine on horizontal, dry and solid ground and secure it to prevent it from rolling away. Lower the working attachment to level ground so that there is. no more residual pressure in the hydraulic system. — Clean the machine diligently according to the procedure outlined in the Oper- ating instructions. — The machine must be completely dry before starting the conservation meas- ures. Dry electronic components and damp areas on the machine with compressed air. — freezing temperatures are expected for the intended duration of shut down, then the fuel tank must be filled with winter fuel, Then start the diesel engine and operate it for some time so that the winter fuel gets into the fuel circuit. ‘Then refill the fuel tank again completely. Note When a conserved machine is moved for loading or transport, then the conserva tion protection on the piston rods of the cylinders will most often be removed by the scraper ring, > When the machine is transported, the conservation ofthe piston rods must be checked again after loading, and replaced if necessary. Note Even if conservation measures have been carried out, the machine must still be inspected at certain intervals and touched up, if necessary. This is at the discretion of the operator. > Carry out this inspection regularly (monthly), especially under difficult conditions (cold, heat, near the coast, etc.) Shut down for up to 2 months Name ID number [Description Image Optical '7408922 [To check the acid charge tester Jdensity of the battery and the antifreeze in the coolant = WAXOYL [8504472 | Spray can 500 mi 120-4 Corro- Long term protec- sion protective tion for up to 2 wax years 010-56 LIEBHERR PRI76-1296