Liebherr PR712 PR712B PR722 PR722B PR732 PR732B PR742 PR742B PR752 Series 2 Litronic Crawler Dozer Service Repair Factory Manual

Operating manual Crawler dozer PR 712 B Litronic PR 722 B Litronic Document identification Id. No.: 9084102 Issue: 05/2003 Valid for: PR 712B / BM / BL from S/N 6200 PR 722B / BM / BL from S/N 6200 Author: LWT / Technical Documentation Dept. Product identification Manufacturer: LIEBHERR Werk Telfs GMBH Product group: Crawler dozer Type: PR 712B, PR 722B Address Address: LIEBHERR Werk Telfs GMBH Hans LIEBHERR - Straße 35, A - 6410 TELFS Austria

Machine data We recommend that you fill in the following information in the space provided as soon as you receive your machine: This information will also be helpful when ordering parts. Machine S/N: .................. * Year: .......... CE * Delivery date: ../../.. * This information is found on the data tag of your machine, on the left front of the main frame. Noise level Sound pressure level LpA PR712B max. 80 dB(A) at the work station according to ISO 6396 PR722B max. 80 dB(A) at the work station according to ISO 6396 Sound emission level LWA PR712B max. 108 dB(A) emitted to the surrounding area, according to EU guide line 2000 / 14 / EG PR722B max. 109 dB(A) emitted to the surrounding area, according to EU guide line 2000 / 14 / EG

0 -1 Foreword This operating manual has been written for the operator and for the maintenance personnel of this machine. This manual contains descriptions for: – Technical Data – Safety information – Operating instructions and guidelines – Maintenance – Instructions for special / optional equipment This operating manual should be given to the operator and the maintenance personnel and any other person who works on the machine, who should read it carefully at regular intervals and before operating or servicing the machine. Work with or on the machine is, for example: – Operation, including set up, trouble shooting during operation, removal of debris, service, removal of oil, lubricants, fuels and operating fluids. – Maintenance, including inspection, upkeep and or repair. – Transportation or loading the machine. Reading this manual will familiarize the operator with the machine and prevent problems due to improper operation. Following the operation and maintenance guidelines by maintenance personnel will: – increase reliable service, – increase the service life expectancy of your machine, – reduce repair costs and downtime. The Operation and Maintenance Manual is part of the machine. Keep a copy of this manual in the glove compartment in the operator's cab to assure that it can be consulted and referred to at any time. Any existing federal, state and local safety requirements governing accident prevention and environmental safety must be added to this Op- eration and Maintenance Manual, in addition to safety and accident prevention regulations applicable to the country and job site you operate in, including any technical rules and regulations to assure safe and proper operation must be followed. This operation and Maintenance Manual includes the necessary information to operate and maintain your machine. – Some illustrations in this manual might show details and machines which differ from your machine. – For some illustrations, covers and protective devices were removed to provide a better view. – Continuing improvements on our machines might result in changes, which are not reflected in this Operation and Maintenance Manual. Foreword Englisch LWT - TD 16/5/2003

0 -2 If you need any additional information and / or clarification, please don't hesitate to contact LIEBHERR's Technical Documentation Department, Customer Service School or Service Department. We hope you understand that LIEBHERR cannot honor warranty claims resulting from improper operation, inadequate maintenance, use of wrong and unauthorized oils, lubricants, fuels and operating fluids and / or from disregard of safety information and guidelines. LIEBHERR reserves the right to reject any warranty claims, service contracts or agreements established by LIEBHERR and / or any of its dealers without prior notice if any other than Original LIEBHERR parts or parts sold by LIEBHERR are being or have been used for maintenance and repair. Under extreme conditions, it might be necessary to increase maintenance intervals as compared to those listed in the inspection schedule. Changes, conditions, copyright: – We reserve the right to make changes of technical details on the machine which differ from the wording and illustrations in this manual. – No part of this manual, technical or otherwise, may be reproduced nor copied in any form or used for competitive purposes in the market place. All rights reserved. – Above and the following remarks will not expand LIEBHERR's general business conditions regarding warranties and liability. Foreword

0 -3 Table of contents 1. Product description 1-1 1.1 Technical Data 1-2 1.1.1 Air conditioning system 1-3 1.2 Tightening torques 1-5 1.2.1 Preload values and tightening torques for screws with standard metric threads according to 1-6 1.2.2 Preload force and tightening torque for screws with fine metric thread according to factor 1-7 2. Safety guidelines, decals 2-1 2.1 Introduction 2-1 2.2 Proper and intended use 2-1 2.3 Decals on the machine 2-2 2.3.1 Safety decals 2-2 2.3.2 Reference decals 2-5 2.3.3 Data tags 2-9 2.4 Safety guidelines 2 - 10 2.4.1 General Safety Guidelines 2 - 10 2.4.2 Crushing and burn prevention 2 - 11 2.4.3 Fire and explosion prevention 2 - 12 2.4.4 Machine start up safety 2 - 13 2.4.5 Engine start up safety 2 - 13 2.4.6 Machine operating safety 2 - 13 2.4.7 Machine parking safety 2 - 15 2.4.8 Machine transporting safety 2 - 15 2.4.9 Machine towing safety 2 - 16 2.4.10 Machine maintenance safety 2 - 16 2.4.11 Safety guidelines to be observed when welding on the machine 2 - 20 2.4.12 Safety guidelines to be observed when working on the attachment 2 - 20 2.4.13 Safety guidelines to be observed when loading the machine with a crane 2 - 20 2.4.14 Safe maintenance of hydraulic hoses and lines 2 - 21 2.4.15 Roll over protection (ROPS) and falling object protection (FOPS) 2 - 21 2.4.16 Attachments and installations 2 - 22 3. Control, instrumentation 3-1 3.1 Location of controls and instrumentation 3-1 3.1.1 Operator's cab 3-1 3.1.2 Controls and instrumentation on the instrument panel 3-3 3.1.3 Controls on the instrument panel 3-6 3.1.4 Controls and indicators in the roof console 3-8 3.2 Operation 3-9 3.2.1 Entry 3-9 Table of contents Englisch LWT - TD 16/5/2003

0 -4 3.2.2 Emergency exit 3 - 10 3.2.3 Door lock 3 - 11 3.2.4 Operator's seat 3 - 12 3.2.5 Operator's seat - air cushioned 3 - 15 3.2.6 Arm rests 3 - 18 3.2.7 Seat belt 3 - 18 3.2.8 Heater, ventilation 3 - 20 3.2.9 Air conditioning system 3 - 22 3.2.10 Sliding window 3 - 24 3.2.11 Sun shade 3 - 24 3.2.12 Cab interior lighting 3 - 24 3.2.13 Rear view mirror 3 - 25 3.2.14 Electric windshield wiper and washer system 3 - 25 3.2.15 Reservoir for windshield washer fluid 3 - 26 3.2.16 Compartment for machine documentation 3 - 27 3.2.17 Back up alarm 3 - 27 3.2.18 Fire extinguisher 3 - 28 3.2.19 Beacon 3 - 28 3.3 Operation 3 - 29 3.3.1 Daily operation 3 - 29 3.3.2 Machine operation in low ambient temperatures 3 - 31 3.3.3 Start the Diesel engine 3 - 31 3.3.4 Travel operation 3 - 37 3.3.5 Travel 3 - 39 3.3.6 Brakes 3 - 41 3.3.7 Machine shut down 3 - 43 3.3.8 Guidelines for working in water 3 - 46 3.3.9 Working with the attachment 3 - 47 3.3.10 Working with optional attachments 3 - 53 3.4 General operating methods 3 - 55 3.4.1 Dozing 3 - 55 3.4.2 Fine grading 3 - 56 3.4.3 Operating several machines 3 - 56 3.4.4 Establishing or cutting trenches 3 - 57 3.4.5 Land clearing operation 3 - 58 3.4.6 Ripper application 3 - 60 3.4.7 Transporting the machine 3 - 61 3.4.8 Loading the machine with a crane 3 - 67 3.5 Installation guidelines to be observed for removal and installation of attachments 3 - 68 3.5.1 Installation and removal of straight blade with outside push frame 3 - 69 3.5.2 Installation and removal of 6-way blade 3 - 72 3.5.3 Installation and removal of 3- shank ripper 3 - 76 3.6 Emergency operation 3 - 77 3.6.1 Towing the machine 3 - 78 Table of contents

0 -5 3.6.2 Auxiliary starting procedure 3 - 83 4. Operating problems 4-1 4.1 Problems and remedy 4-2 4.2 Problem remedy 4-5 4.2.1 Change fuse 4-5 5. Maintenance 5-1 5.1 Maintenance and inspection schedule 5-2 5.2 Lubrication chart 5-6 5.3 Lubricants and service fluids 5-8 5.3.1 Handling lubricants and service fluids 5-8 5.3.2 Lubricants and service fluid specification, quantities 5-8 5.3.3 Change from mineral oil to environmentally hydraulic fluids 5 - 15 5.3.4 Proper oil diagnostics analysis 5 - 15 5.4 Preparations for maintenance 5 - 19 5.4.1 Maintenance position 5 - 19 5.4.2 Electrical system 5 - 22 5.5 Diesel engine 5 - 22 5.5.1 Check the engine oil level 5 - 23 5.5.2 Check the engine oil pressure 5 - 23 5.5.3 Engine compartment 5 - 24 5.5.4 Change the engine oil 5 - 24 5.5.5 Change the lube oil filter 5 - 26 5.5.6 Check / change the V-belt 5 - 27 5.5.7 Check the Diesel engine area for leaks and condition 5 - 28 5.5.8 Check the mounting of intake and exhaust lines 5 - 28 5.5.9 Oil separator 5 - 29 5.6 Cooling system 5 - 29 5.6.1 Check the coolant level 5 - 30 5.6.2 Clean the cooling system 5 - 31 5.6.3 Check the cooling system for leaks 5 - 32 5.6.4 Change the coolant filter 5 - 33 5.6.5 Check the antifreeze and DCA-4 concentration in the coolant 5 - 33 5.6.6 Change the coolant 5 - 34 5.7 Fuel system 5 - 36 5.7.1 Drain the fuel separator condensation 5 - 36 5.7.2 Drain water and contaminants in the fuel tank 5 - 37 5.7.3 Empty the fuel tank 5 - 38 5.7.4 Change the fuel filter elements 5 - 39 5.7.5 Bleed the fuel system 5 - 41 5.8 Air filter system 5 - 42 5.8.1 Clean / change the air filter 5 - 42 5.9 Hydraulic system 5 - 44 5.9.1 Oil level in hydraulic tank 5 - 45 Table of contents Englisch LWT - TD 16/5/2003

0 -6 5.9.2 Clean the magnetic rod on the hydraulic tank. 5 - 47 5.9.3 Change the return filter insert 5 - 48 5.9.4 Change the replenishing oil filter 5 - 50 5.9.5 Check the hydraulic system for function and leaks 5 - 50 5.9.6 Clean the oil cooler 5 - 51 5.9.7 Change the hydraulic oil 5 - 52 5.10 Splitterbox 5 - 53 5.10.1 Check oil level 5 - 53 5.10.2 Change the gear oil 5 - 54 5.11 Electrical system 5 - 55 5.11.1 Check indicator lights and illumination 5 - 56 5.11.2 Batteries 5 - 57 5.11.3 Change bulbs 5 - 58 5.12 Heating and fresh air system, air conditioning system 5 - 60 5.12.1 Check the heater for function and for leaks 5 - 60 5.12.2 Heater - fresh air filter 5 - 61 5.12.3 Air conditioning system 5 - 62 5.13 Travel gear 5 - 65 5.13.1 Check the condition of the travel gear 5 - 65 5.13.2 Check oil level 5 - 66 5.13.3 Change the gear oil 5 - 66 5.13.4 Travel gear - lifetime seal area 5 - 67 5.14 Track components 5 - 73 5.14.1 Check the screws on nuts on the track components for tight seating 5 - 73 5.14.2 Check the seal on the carrier rollers, track rollers and idlers 5 - 74 5.14.3 Idler guide 5 - 74 5.14.4 Chain tension 5 - 77 5.14.5 Changing the chain 5 - 79 5.14.6 Clean the tracks 5 - 86 5.14.7 Check track wear 5 - 87 5.15 Working attachment 5 - 87 5.15.1 Check the attachment 5 - 87 5.15.2 Lift cylinder bearing 5 - 87 5.15.3 Replace the ripper teeth 5 - 88 5.15.4 Check the bearing play 5 - 89 5.16 Total machine 5 - 89 5.16.1 Check the machine for external damage 5 - 89 5.16.2 Windshield wiper 5 - 90 5.16.3 Piston rod preservation 5 - 90 5.16.4 Taking the machine out of service 5 - 91 5.17 Cab - tilting device 5 - 91 5.17.1 Raise the cab 5 - 91 5.17.2 Lower the cab 5 - 93 Table of contents

1 -1 1. Product description Design - Overview This paragraph shows an overview of the machine with description of the displayed components. Complete machine - right view 1 Dozer blade 2 Push frame 3 Travel gear 4 Hydraulic tank 5 Fuel tank 6 Operator's cab 7 Battery box 8 Cover 9 Diesel engine with pump as- sembly 10 Lift cylinder 1. Product description Englisch LWT - TD 16/5/2003

1 -2 1.1 Technical Data The most important technical data can be found in the enclosed technical description. 1. Product description

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Liebherr PR712 PR712B PR722 PR722B PR732 PR732B PR742 PR742B PR752 Series 2 Litronic Crawler Dozer Service Repair Factory Manual

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