Liebherr TL441 - 1234 Telescopic Handler Service Repair Workshop Manual

en Service manual Telescopic handler TL 441-1234 7 13652 Document ID Order number: 93517084 Issued: 09-2015 Version: 00 Author: LWT / Technical Documentation Department Product ID Manufacturer: Liebherr-Werk Telfs GmbH Valid for: TL 441-1234 7 13652 Conformity: Contact Liebherr-Werk Telfs GmbH Hans Liebherr-Straße 35 A – 6410 Telfs

LWT/93517084/00/215-20150903.1047/en Contents 010 Introduction 010-1 010.1 Safety guidelines 010-4 010.1.1 General safety instructions 010-4 010.1.2 Safety guidelines for crushing and burn prevention 010-5 010.1.3 Safety guidelines for machine start up 010-5 010.1.4 Safety guidelines for start up 010-6 010.1.5 Safety guidelines for working 010-6 010.1.6 Safety guidelines for turning the machine off 010-8 010.1.7 Safety guidelines for transporting the machine 010-8 010.1.8 Working in the vicinity of electrical overhead lines 010-9 010.1.9 Safety guidelines for towing the machine 010-9 010.1.10 Safety guidelines for maintenance 010-10 010.1.11 Safety guidelines for welding work on the machine 010-12 010.1.12 Safety guidelines for working on the working attachment 010-13 010.1.13 Safety guidelines for loading the machine with a crane 010-13 010.1.14 Roll over protection (ROPS) and falling object protection (FOPS) 010-13 010.1.15 Equipment and attachment parts 010-14 010.1.16 Safety guidelines for machine application in material handling operation 010-14 010.1.17 Safety guidelines for machine application with quick coupler 010-15 010.2 Special tools for maintenance and repair work 010-16 010.2.1 Tools Diesel engine 010-16 010.2.2 Tools - Hydraulic system 010-17 010.2.3 Tools Hydraulic cylinder 010-19 010.2.4 Tools - Electrical system 010-19 010.2.5 Tools Counterweight 010-21 010.2.6 Tools - Telescopic boom 010-21 010.3 Standards and specifications 010-22 010.3.1 Tightening torques 010-22 010.3.1.1 General information 010-22 TL441-1234 7 /13652 copyright © Liebherr-Werk Telfs GmbH 2015 3

Contents Service manual LWT/93517084/00/215-20150903.1047/en 010.3.1.1 Flanges and half flanges for high pressure (Norm 62) 010-24 010.3.1.1 Half flange for low pressure (Norm 61) 010-24 010.3.1.1 Tightening torques for cutting edges, end bits and adapters 010-25 010.3.2 Tapping bores 010-25 010.3.2.1 Tapping bores of metric ISO standard threads 010-25 010.3.2.2 Tapping bores of metric ISO fine threads 010-27 010.3.3 Conversion tables 010-30 010.4 Conservation guidelines 010-31 010.4.1 General 010-31 010.4.2 Taking the machine out of service for an unknown duration 010-31 010.4.3 Shut down of the machine 010-32 010.4.3.1 Shut down for up to 2 months 010-32 010.4.3.2 Shut down for up to 12 months 010-33 010.4.3.3 Shut down for longer than 12 months 010-34 010.4.4 Return to operation 010-34 010.4.4.1 After a shut down of 2 months 010-34 010.4.4.2 After a shut down of 12 months 010-34 010.4.4.3 After shut down of longer than 12 months 010-35 010.5 Repair welding 010-36 010.5.1 Preparation of cracked part 010-36 010.5.1 Preparation of a weld 010-37 010.5.1 Treatment of electrodes 010-37 010.5.1 Welding technique 010-37 010.5.1 Reinforcement of welding seam 010-38 010.5.1 General use of reinforcement sheeting 010-38 010.5.1.1 Form of sheeting 010-38 010.5.1.1 Thickness of sheeting 010-38 010.5.1.1 Material quality of sheeting 010-39 010.5.1.1 Application of reinforcement sheeting 010-39 010.5.1.1 Welding the reinforcement sheeting 010-39 010.5.1.1 Selection of correct welding electrodes 010-40 010.5.1.2 Electrode selection 010-40 010.5.1.2 Steel chart 010-41 010.5.1.2 Welding additives chart 010-42 4 copyright © Liebherr-Werk Telfs GmbH 2015 TL441-1234 7 / 13652

Service manual Contents LWT/93517084/00/215-20150903.1047/en 010.6 Hydraulic symbols 010-46 010.7 Electrical symbols 010-56 010.8 Material weights 010-60 020 Technical data 020-1 020.1 Overall machine 020-3 020.1.1 Overall machine - Overview 020-3 020.2 Drive group 020-4 020.2.1 Diesel engine 020-4 020.2.2 Alternator 020-5 020.2.3 Fuel tank 020-5 020.3 Cooling system 020-6 020.3.1 Double gear pump 020-6 020.3.2 High pressure gear motor 020-6 020.4 Working hydraulic 020-7 020.4.1 Double gear pump 020-7 020.4.2 Proportional control valve block 020-7 020.4.3 Lift cylinder 020-8 020.4.4 Tilt cylinder 020-8 020.4.5 Balancing cylinder 020-8 020.4.6 Telescopic cylinder 020-8 020.5 Travel hydraulic 020-9 020.5.1 Axial piston variable displacement pump 020-9 020.5.2 Variable displacement motor 020-9 020.6 Hydraulic components 020-11 020.6.1 Hydraulic tank 020-11 020.7 Electrical system 020-12 020.7.1 Batteries 020-12 020.7.2 Fuses 020-12 020.8 Axles, tires, gear shafts, travel gear 020-13 020.8.1 Front axle 020-13 020.8.1 Rear axle 020-13 020.9 Steel components Basic machine 020-14 020.9.1 Counterweight 020-14 020.10 Working attachments 020-15 TL441-1234 7 /13652 copyright © Liebherr-Werk Telfs GmbH 2015 5

Contents Service manual LWT/93517084/00/215-20150903.1047/en 020.10.1 Working attachments 020-15 030 Maintenance 030-1 030.1 Maintenance and inspection schedule 030-5 030.2 Fill quantities, lubrication schedule 030-10 030.2.1 Recommended lubricants 030-10 030.2.2 Recommended service items 030-10 030.2.3 Lubrication schedule 030-11 030.3 Lubricants and service items 030-16 030.3.1 General Specifications 030-16 030.3.3 Lubricating oils for Diesel engines 030-16 030.3.3.1 Lube oil quality 030-16 030.3.3.2 Lube oil viscosity 030-16 030.3.3.3 Aggravating factors have an influence on the oil change 030-17 030.3.6 Lube oils for axles 030-17 030.3.6.1 Quality 030-18 030.3.6.2 Viscosity 030-18 030.3.7 Oil for the brake system 030-18 030.3.7.1 Quality 030-18 030.3.8 Grease for the telescopic boom 030-19 030.3.9 Grease and other lubricants 030-19 030.4 Maintenance tasks 030-22 030.4.1 Safety measures 030-22 030.4.2 Overall machine 030-23 030.4.2.1 Check the machine for external damage 030-23 030.4.2.2 Check the window wiper 030-23 030.4.3 Drive group 030-24 030.4.3.1 Diesel engine: Check the oil level 030-24 030.4.3.2 Diesel engine: Change the oil 030-26 030.4.3.3 Diesel engine: Change the lube oil filter 030-27 030.4.3.4 Check and clean the engine compartment 030-28 030.4.3.5 Diesel engine: Check and change the V-belt 030-28 030.4.3.6 Check the Diesel engine arrangement for leaks and condition 030-30 6 copyright © Liebherr-Werk Telfs GmbH 2015 TL441-1234 7 / 13652

Service manual Contents LWT/93517084/00/215-20150903.1047/en 030.4.3.7 Diesel engine: Check intake and exhaust system for condition, mounting and leaks 030-31 030.4.3.8 Diesel engine: Check the electrical system 030-32 030.4.3.9 Diesel engine: Check the engine mounting, mounting of oil pan and bracket 030-33 030.4.3.10 Notes for work on the fuel system 030-33 030.4.3.11 Fuel preliminary filter: drain the condensation 030-34 030.4.3.12 Fuel tank: Drain condensation and sediments 030-34 030.4.3.13 Fuel: replace the filter cartridges 030-35 030.4.3.14 Vent the fuel system 030-37 030.4.3.16 Air filter system: Clean and change the air filter 030-37 030.4.3.17 Air filter: Clean the service cover and dust discharge valve 030-40 030.4.4 Cooling system 030-41 030.4.4.1 Cooling system: Check the coolant level 030-41 030.4.4.2 Clean the cooling system 030-43 030.4.4.3 Check the cooling system 030-43 030.4.4.4 Cooling system: Check the antifreeze concentration in the coolant 030-44 030.4.4.5 Cooling system: Change the coolant 030-47 030.4.5 Travel hydraulic 030-49 030.4.5.1 Change the replenishing circuit filter 030-49 030.4.6 Hydraulic components 030-50 030.4.6.1 Check the oil level in the hydraulic tank and add oil 030-50 030.4.6.2 Change the tank vent filer on the hydraulic tank 030-51 030.4.6.3 Hydraulic system: Check function and for leaks 030-52 030.4.6.4 Check the oil cooler for contamination and clean it 030-52 030.4.6.5 Change the hydraulic oil 030-52 030.4.6.6 Clean the hydraulic tank 030-54 030.4.6.7 Change the return filter insert 030-55 030.4.7 Steering system 030-57 030.4.7.1 Check the function of the steering system 030-57 030.4.8 Brake system 030-58 030.4.8.1 Service brake and parking brake: Check function and effectiveness 030-58 030.4.8.2 Brake system: Check the oil level in the expansion tank 030-60 TL441-1234 7 /13652 copyright © Liebherr-Werk Telfs GmbH 2015 7

Contents Service manual LWT/93517084/00/215-20150903.1047/en 030.4.8.3 Brake system: Check the brake linings for wear 030-61 030.4.9 Electrical system 030-65 030.4.9.1 Electrical system: Check the function of the load torque limitation 030-65 030.4.9.2 Check the display unit and lighting 030-68 030.4.10 Axles, tires, gear shafts, travel gear 030-68 030.4.10.1 Wheels: Check the mounting of the wheel lugs 030-68 030.4.10.2 Tires: Check and adjust the air pressure 030-69 030.4.10.3 Axles: Check the oil levels 030-71 030.4.10.4 Change the oil in the axles 030-73 030.4.10.5 Axles: Lubricate 030-75 030.4.10.6 Axles: Check the tightening torque of the axle mounting screws 030-75 030.4.11 Steel components Basic machine 030-76 030.4.11.1 Telescopic boom: Check the glide elements 030-76 030.4.11.2 Lubricate the telescopic boom 030-78 030.4.11.3 Lubricate the hydraulic cylinders 030-80 030.4.11.4 Lubricate the telescopic boom 030-81 030.4.12 Working attachments 030-82 030.4.12.1 Working attachment and the telescopic boom: Check for damage and wear 030-82 030.4.12.2 Working attachment and the telescopic boom: Lubri- cate 030-83 030.4.13 Driver's cab, heater, climate control system 030-83 030.4.13.1 Heater and air conditioning system: Check the function 030-83 030.4.13.2 Clean and change the heater - fresh air filter 030-84 030.4.13.3 Check the air conditioning system (optional) 030-85 030.5 Testing and adjustment checklist 030-87 030.5.1 Inspection and adjustment check list 030-87 030.6 Testing and adjustment tasks 030-101 030.6.1 Safety measures 030-101 030.6.2 Overall machine 030-102 030.6.2.1 Preparations for inspection and adjustment tasks 030-102 030.6.2.2 Visual inspection and maintenance 030-104 030.6.2.3 Bring the machine to operating temperature 030-105 030.6.3 Working hydraulic 030-107 8 copyright © Liebherr-Werk Telfs GmbH 2015 TL441-1234 7 / 13652

Service manual Contents LWT/93517084/00/215-20150903.1047/en 030.6.3.1 Check the primary pressure relief valve on the control valve block 030-107 030.6.3.2 Check the secondary pressure relief valve on the control valve block 030-108 030.6.4 Travel hydraulic 030-109 030.6.4.1 Check the replenishing pressure for var. displ. pump 030-109 030.6.4.2 Check the pressure limitation - High pressure 030-110 030.6.5 Steering system 030-111 030.6.5.1 Check the regulating pressure steering cylinder 030-111 030.6.6 Brake system 030-112 030.6.6.1 Check the pilot pressure of the brake hydraulic 030-112 030.6.6.2 Check the brake pressure of the parking brake 030-112 030.6.6.3 Check the brake pressure of the Service brake 030-112 030.6.7 Electrical system 030-113 030.6.7.1 Save parameters 030-113 030.6.7.2 High Pressure Test — 030-113 030.6.7.3 Boom Angle Sensor 030-115 030.6.7.4 Option Selection — Options 030-116 030.6.8 Axles, tires, gear shafts, travel gear 030-118 030.6.8.1 Check the tire pressure 030-118 040 Drive group 040-1 040.1 Diesel engine 040-2 040.1.1 Diesel engine - Full overview 040-2 040.1.2 Electrical components on the Diesel engine 040-7 040.1.2.1 Electrical components Diesel engine and engine compartment 040-8 040.1.3 Fuel system 040-11 040.1.3.1 Fuel system - Full overview 040-11 040.1.3.2 Fuel quantity sensor 040-14 040.1.3.3 Fuel preliminary filter 040-15 040.1.3.4 Fuel main filter (fine filter) 040-15 040.1.3.5 High pressure pump (injection pump) 040-17 040.1.3.6 Fuel tank 040-19 040.1.4 Air filter system 040-20 040.1.4.1 Air filter system - Full overview 040-20 TL441-1234 7 /13652 copyright © Liebherr-Werk Telfs GmbH 2015 9

Contents Service manual LWT/93517084/00/215-20150903.1047/en 040.1.5 Exhaust system 040-21 040.1.5.1 Exhaust system - Full overview 040-22 040.1.5.2 Diesel oxidation catalytic converter (DOC) 040-23 040.1.5.3 Exhaust gas return (EGR) 040-24 040.1.6 Engine mounting 040-27 040.2 Clutch 040-29 050 Cooling system 050-1 050.1 Cooling system - Full overview 050-2 050.2 Cooler arrangement 050-9 050.2.1 Combi cooler 050-9 060 Working hydraulic 060-1 060.1 Working hydraulics - Full overview 060-2 060.2 Proportional control valve block 060-15 060.2.1 Proportional control valve block 060-15 060.3 Pilot control Working hydraulic 060-21 060.3.1 Operating lever / joystick 060-21 060.4 Lowering brake valve 060-29 060.4.1 Lowering brake valve 060-29 060.5 Hydraulic cylinder 060-33 060.5.1 Hydraulic cylinder - Full overview 060-33 060.5.2 Tilt cylinder 060-35 060.5.3 Lift cylinder 060-36 060.5.4 Telescope cylinder 060-38 060.5.5 Balancing cylinder 060-39 060.6 Pressure relief Y76 060-41 070 Travel hydraulic 070-1 070.1 Travel hydraulic - Full overview 070-2 080 Hydraulic components 080-1 080.1 Axial piston variable displacement pump 080-2 080.2 Variable displacement motors - Full overview 080-19 080.3 Double gear pump 080-29 080.4 Gear motor – fan drive 080-32 10 copyright © Liebherr-Werk Telfs GmbH 2015 TL441-1234 7 / 13652

Liebherr TL441 - 1234 Telescopic Handler Service Repair Workshop Manual

You're Reading a Preview

Recently Viewed