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Service Manual Hydraulic Excavator A 934 C Litronic A 944 C-HD Litronic A 954 C-HD Litronic

Last update:

Types:

11 / 2010

A 934 C Litronic / A 944 C-HD Litronic / A 954 C-HD Litronic


Service Manual

Introduction Symbols used in this manual

Introduction This manual contains technical data, design and functional descriptions, as well as instructions as regards the operation and the adjustment of machine settings. The document includes a number of drawings, functional schematics, as well as detailed views of units and assemblies of LIEBHERR hydraulic excavators. The documentation has been designed to support customer support services, but does of course not replace proper technical training and qualification of the user, and participation in LIEBHERR operator training courses. General basic technical information is not included in the manual. For operating instructions and information on spare parts, please refer to the separate documentation. During all work on the machine, strictly adhere to the relevant accident prevention and safety regulations.

1

Symbols used in this manual Tasks and procedures that are associated with specific dangers are accompanied by safety instructions. The safety instructions are graded according to the severity of the risk and are identified with the terms DANGER, CAUTION and NOTE and the respective danger symbol: These terms are used in combination with the following symbols: Danger Warning referring to a danger where there is a high probability of death or serious injury to operators, unless the prescribed safety measures are taken.

Caution Warning relating to dangers that might lead to injury or damage to the machine, unless the prescribed safety measures are taken.

Note This symbol accompanies instructions and tips regarding the operation, maintenance and repair of the equipment. If adhered to, the service life of the machine can be prolonged and/or procedures are made easier. – This symbol precedes entries in a list. • This symbol precedes entries in a sub-list. This symbol identifies "Pre-condition MUST be fulfilled" This symbol indicates a single procedure in a sequence of procedures. This symbol indicates a result of an action. This manual has been exclusively compiled for internal use by the registered machine owner. It may not be reproduced or made available to third parties without the explicit written consent of LIEBHERR, who retains all rights in this document. This publication remains the property of LIEBHERR-HYDRAULIKBAGGER GMBH. All rights reserved – printed in Germany. This service manual shall be amended without prior notice to reflect new technical developments and machine series. LIEBHERR reserves the right to make minor technical amendments to the machines that might not be reflected in the accompanying documentation.

1.00.1


Introduction

Service Manual

Symbols used in this manual Depending on the series development, the service manual shall be revised in electronic format. Changes and amendments are listed in group 1.02. This manual might be complemented by additional service information sheets issued by LIEBHERR. Compiled by the Technical Documentation Department. Published by Customer Service Centre Training Group of LIEBHERR-HYDRAULIKBAGGER GMBH 88457 Kirchdorf / lller, Germany. We hope that the information in this documentation aimed at improving the service of LIEBHERR excavators is of use to you.

1.1

Explanation In order to make it easy for users to find specific information regarding revised or amended documents, each page is identified as follows:

A

Page number

D

Drive motor

B

Subgroup

E

Diesel engine

C

Main group

F

Page

The main groups are listed in the main group directory. The subgroups are listed on the first page of each main group section. The subgroup list also includes the machines and serial numbers to which the subgroup is relevant. In the event of minor changes, we will send you the amended page showing the current date. If an existing subgroup is completely revised and re-edited, the new version will be assigned a new subgroup number.

1.00.2


General Information

1

Tools

2

Technical Data / Maintenance Guidelines

3

Engine

4

Clutch / Splitterbox

5

Hydraulic System

6

Hydraulic Components

7

Electrical System

8

Swing Gear

9

Swing ring

10

Two Speed Gear Box

11

Axles / Gear Box

12

Steering

13

Oscillating Axle Stabilizer

14

Brake system

15

Special Attachments / Accessory Kits

16

Cab Heater / Air Conditioning System

17

Undercarriage / Uppercarriage / Attachments

18


Service Manual

SUBGROUP - INDEX Section

Group

Type

Changes and modifications to series

1.02.1

A 934 C-LI 25436A 944 C-LI 24475A 954 C-LI 21416-

Safety instructions

1.10.1

A 934 C-LI A 944 C-LI A 954 C-LI

Tightening torques (WN 4037 K)

1.20.1

A 934 C-LI A 944 C-LI A 954 C-LI

Tightening torques

1.21.1

A 934 C-LI A 944 C-LI A 954 C-LI

Assembly instruction for hydraulilc cylinder WN 4121 C

1.22.1

A 934 C-LI A 944 C-LI A 954 C-LI

Assembly instruction for hydraulic cylinder WN 4122 B

1.24.1

A 934 C-LI A 944 C-LI A 954 C-LI

Tightening torques for piston rod bearing screws

1.25.1

A 934 C-LI A 944 C-LI A 954 C-LI

Angle-controlled screw tightening

1.30.1

A 934 C-LI A 944 C-LI A 954 C-LI

Fuels, lubricants and process chemicals

1.51.1

A 934 C-LI A 944 C-LI A 954 C-LI

1.1 MJFCIFSS


Service Manual

1.2 MJFCIFSS


Service Manual

Changes and modifications to series Last updated: 11 / 2010

Changes and modifications to series 1 Change mark

Last updated: 11 / 2010

Change to group

Type of modification

Affected models

revised

3.05

Technical data

A 934 C type 1006

revised

3.07

Technical data

A 934 C type 1007

revised

3.09

Technical data

A 934 C type 1053

revised

3.11

Technical data

A 944 C type 194

revised

3.13

Technical data

A 944 C type 196

new

3.60

Adjustment protocol version 4.8.1

A 954 C type 450 from 51610

new

4.25

Liebherr diesel particle filter accessory kit

A 934 C type 1006/1007/1053 A 944 C type 194/196

new

4.40

Data logger version 02.03.00

A 934 C type 1006/1007/1053 A 944 C type 194/196

new

4.41

Data logger version 2.3.09

A 934 C type 1006/1007/1053 A 944 C type 194/196

new (a, b, c, d)

6.71

Hydraulic schematic with Bucher pipe fracture safety valve

A 934 C 1006/1007

new (a, b, c, d)

6.73

Hydraulic schematic with Bucher pipe fracture safety valve

A 934 C type 1053

new (a, b, c, d)

6.76

Hydraulic schematic with Bucher pipe fracture safety valve

A 944 C type 194

new (a, b, c, d)

6.78

Hydraulic schematic with Bucher pipe fracture safety valve

A 944 C type 196

new

7.60

M8 control valve block

A 934 C type 1006/1007/1053

new

7.62

M8 control valve block

A 944 C type 194

new

7.64

M8 control valve block

A 944 C type 196

revised

7.73

Rotary connection

A 934 C type 1006/1007/1053 A 944 C type 196

new

8.01

Overview of electrical symbols

A 934 C type 1006/1007/1053 A 944 C type 194/196 A 954 C type 450

new

8.02

Notes regarding the electrical system

A 934 C type 1006/1007/1053 A 944 C type 194/196 A 954 C type 450

new

8.50

BST excavator control system

A 934 C type 1006/1007/1053 A 944 C type 194/196 A 954 C type 450

new

8.55

Menu structure version 4.8 / 4.8.1

A 934 C type 1006/10071053 from 47120 A 944C type 194/196 from 47120 A 954 C type 450 from 47120

1.02.1 copyright by

MJFCIFSS


Changes and modifications to series

Service Manual

Last updated: 11 / 2010 Change mark

Change to group

Type of modification

Affected models

new

8.82

Slip ring contact

A 934 C type 1006/1007/1053 A 944 C type 194/196 A 954 C type 450

revised

12.01

Tyres

A 934 C type 1006/1007/1053 A 944 C type 194/196 A 954 C type 450

new

16.16

Pipe-fracture safety valve of hoist cylinder

A 934 C type 1006/1007/1053 A 944 C type 194/196

new

16.18

Pipe fracture safety valve of stick cylinder

A 934 C type 1006/1007/1053 A 944 C type 194/196

Updated 06/2010 revised

1.51

Fuels, lubricants and process chemicals

all types

revised

2.06

Special tools for electrical equipment

all types

revised

6.70

Hydraulic schematic

A 934 C type 1006/1007

revised

6.72

Hydraulic schematic

A 934 C type 1053

NEW

7.42 replaced 7.55

Pilot control unit 1x

A 934 C type 1006/1007/1053 A 944 C type 194/196 A 954 C type 450

revised

7.45

Control and regulating unit

A 934 C type 1006/1007/1053 A 944 C type 194/196 A 954 C type 450

new

8.107

Stick cylinder shut-down / potentiometer

A 934 C type 1006/1007/1053 A 944 C type 194/196 A 954 C type 450

new

8.122

Stick cylinder shut-down / Hall sensor

A 934 C type 1006/1007/1053 A 944 C type 194/196 A 954 C type 450

revised

13.10

Hydraulic steering system

A 934 C type 1006/1007

new

13.12

Hydraulic steering system

A 934 C type 1053

new

13.14

Hydraulic steering system

A 944 C type 196

new

13.16

Hydraulic steering system

A 944 C type 194 A 954 C type 450

new

13.18

Joystick steering

A 934 C type 1006/1007/1053 A 944 C type 194/196 A 954 C type 450

new

15.05

Operating pressures of the brake system

A 934 C type 1006/1007/1053 A 944 C type 194/196 A 954 C type 450

new

15.08

Hydraulic brake system

A 934 C type 1006/1007/1053

new

15.10

Hydraulic brake system

A 944 C type 194/196

revised

15.12

Hydraulic brake system

A 954 C type 450

revised

15.20

Compact brake block

A 934 C type 1006/1007/1053 A 944 C type 194/196 A 954 C type 450

1.02.2 copyright by

MJFCIFSS


Service Manual

Changes and modifications to series Last updated: 11 / 2010

Change mark

Change to group

Type of modification

Affected models

new

16.80

Hydraulic operator's cab elevation system

A 934 C type 1006/1007/1053 A 944 C type 194/196 A 954 C type 450

new

16.82

Stick cylinder shut-down with proximity switch

A 934 C type 1006/1007/1053 A 944 C type 194/196 A 954 C type 450

new

16.84

Electronic stick cylinder shut-down

A 934 C type 1006/1007/1053 A 944 C type 194/196 A 954 C type 450

new

17.40

Inspection and repair instructions for heating and air-conditioning system

A 934 C type 1006/1007/1053 A 944 C type 194/196 A 954 C type 450

new

17.50

Heating and air-conditioning system

A 934 C type 1006/1007/1053 A 944 C type 194/196 A 954 C type 450

new

18.01

Fixture of operator's cab

A 934 C type 1006/1007/1053 A 944 C type 194/196 A 954 C type 450

new

18.50

Repair instructions for lubrication hoses

all types

Update 12/2009 revised

2.06.

Special tools for electrical equipment

all types

revised

2.07.

Special tools for slewing gear mechanism

A 934 C type 1006/1007/1053 A 944 C type 194/196 A 954 C type 450

new

3.52.

Adjustment protocol V 4.7

A 944 C type 194 from 39086

new

3.53.

Adjustment protocol V 4.5

A 944 C type 196 from 33765 to 39086

new

3.54.

Adjustment protocol V 4.7

A 944 C type 196 from 39086

new

6.77.

Hydraulic schematic

A 944 C type 196 from 29225

revised

12.01.

Tyres

A 934 C type 1006/1007/1053 A 944 C type 194/196 A 954 C type 450

revised

12.07.

Steering drive axle LT 71

A 934 C type 1006 from 28016

revised

12.08.

Rigid axle D 71

A 934 C type 1006 from 28016

revised

12.16.

Steering drive axle LT 81

A 934 C type 1007/1053 from 25436

revised

12.18.

Rigid axle D 81

A 934 C type 1007/1053 from 25436

revised

12.35.

Steering drive axle LT 102

A 954 C type 450 from 21416

revised

12.36.

Rigid axle D 102

A 954 C type 450 from 21416

revised

16.86.

Generator drive accessory kit

A 954 C type 450 from 21416

Update 07/2009 revised

3.45. 3.47.

Adjustment protocol V 4.2

A 934 C type 1006/1007 from 25436 39076

new

3.46 3.48

Adjustment protocol V 4.7

A 934 C type 1006/1007 from 39077

1.02.3 copyright by

MJFCIFSS


Changes and modifications to series

Service Manual

Last updated: 11 / 2010 Change mark

Change to group

Type of modification

Affected models

revised

3.49

Adjustment protocol V 4.5 and V 4.7

A 934 C type 1053 from 39077

new

3.70.

Testing and adjustment tasks V4.7

A 934 C type 100671007 from 39077

revised (a)

6.70.

Control connections 11 and 12 at control valve block confused

A 934 C type 1006/1007 from 25436

new

7.07.

DPVP 108 double variable-displacement pump

A 934 C type 1006/10071053 from 25436

new

8.02.

Notes regarding the electrical system

A 934 C type 1006/10071053 from 25436 A 944 C type 194/196 from 24475 A 954 C type 450 from 21416

revised

8.10.

Arrangement of components

A 934 C type 1006/10071053 from 25436

new

8.44.

Operating symbols on operator's platform

A 934 C type 1006/10071053 from 25436 A 944 C type 194/196 from 24475 A 954 C type 450 from 21416

new

8.79

Keyboard

A 934 C type 1006/10071053 from 25436 A 944 C type 194/196 from 24475 A 954 C type 450 from 21416

new

8.80

Error code list

A 934 C type 1006/10071053 from 25436 A 944 C type 194/196 from 24475 A 954 C type 450 from 21416

new

12.10.

Steering drive axle LT 71

A 934 C type 1006 from 28016

new

12.12.

Rigid axle D 71

A 934 C type 1006 from 28016

new

12.16.

Steering drive axle LT 81

A 934 C type 1007/1053 from 25436

new

12.18.

Rigid axle D 81

A 934 C type 1007/1053 from 25436

new

16.88.

Generator drive accessory kit

A 934 C type 1006/1007 from 25436 A 944 C type 194 from 24475

new

16.90.

Generator conversion kit for LIKUFIX

A 934 C type 1006/1007 from 25436 A 944 C type 194 from 24475

1.02.4 copyright by

MJFCIFSS


Service Manual

Safety instructions Proper use

Safety instructions Working with the machine holds dangers to which you as the owner, machine operator or maintenance expert could be exposed. If you regularly read and observe the safety information, you can guard against dangers and accidents. This applies especially to persons, who are working on the machine only occasionally, such as for maintenance work. The following information comprises safety regulations which, if followed conscientiously, will guarantee your safety and that of other persons, as well as avoid damage to the machine. Following these regulations does not release you from the responsibility to follow all safety regulations and guidelines valid for the jobsite, as required by law or issued by trade associations. For EU countries, guideline 89/655/EEC contains the minimum safety information applicable to the operator.

1

Proper use – The hydraulic excavator is a machine with attachments (such as backhoe, grapple, bucket ) designed to loosen, take on, transport and dump soil, rocks and other materials, where the load is predominantly transported without moving the machine. Moving the machine when it is carrying a load must be carried out by observing the appropriate safety measures (see section "Notes for machine operating safety"). – Machines used for load-lifting work are subject to specific conditions and must be equipped with the stipulated safety devices (see section “Load-lifting work”). – Other or additional usage, such as for demolition or material handling work, requires special equipment and may also require special safety devices. These attachments (e.g. log grapple, demolition hammer, concrete cutter etc.) may only be attached and used with approval and in accordance with the basic machine manufacturer. – Transporting persons is not deemed to be intended use. The manufacturer is not liable for damage resulting from this action. The risk must be assumed solely by the user. – Observing the operating instructions and the inspection / maintenance instructions is also deemed to be appropriate and destined use in accordance with regulations.

2

General Safety instructions – Please familiarize yourself with the operating instructions before starting the machine. – Please verify that you have read and understood supplemental instructions (this may concern special options for the machine). – Only explicitly authorized personnel may operate, maintain or repair the machine. The legal minimum age must be observed. – Use only trained or instructed personnel. Clearly define who is responsible for the operation or set up, maintenance and repair. Reject unsafe instructions by third parties and/or allow your personnel to reject these. This also applies in regards to traffic regulations. – Any person still in training should only operate or work on the machine under the constant supervision and guidance of an experienced person. – Check and observe all persons working or operating the machine at least periodically to ensure that they observe safety instructions and guidelines given in the operating manual. – Wear proper work clothing when operating or working on the machine. Avoid wearing rings, watches, ties, scarves, open jackets or loose clothing. There is a danger of injury, as these items could get caught or be pulled in. Wear task-appropriate personal protective equipment at all times. – Consult the supervisor for any special safety procedures applicable to your job site. – Always raise the safety lever before leaving the operator’s seat.

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Safety instructions

Service Manual

Crushing and burn prevention – Keep steps, ladders and handholds (handles) in proper condition. Make especially sure that they are free of dirt, oil, ice and snow. NOTE: To ensure that the doors open in all weather conditions, lubricate the weather strips at least every two months, or more often, if necessary, with talcum powder or silicon. Lubricate the door hinges and locks regularly. – When entering or leaving the cab, do not use the steering column, the control panel or the joysticks as handholds. – Never jump off the machine, always use the steps, ladders, rails and handles provided to climb off or on the machine. – Always face towards the machine when climbing on and off it, and always use the three points of contact with the machine (all times either two hands and one foot, or two feet and one hand are in contact with the access system). – Familiarize yourself with the emergency exit. – Proceed as described in the operating manual, if no other instructions are available for maintenance and repairs: • Place the machine on a solid and level ground and lower the working attachment to the ground. • Depressurize the hydraulic system. • Move all control levers to the neutral position. • Move the safety levers up prior to leaving the machine. • Remove the ignition key. – Before servicing the hydraulic system you must reduce the pressure in the hydraulic system and tank, as described in this operating manual. – Secure all loose parts on the machine. – Never start a machine before completing a thorough walkaround inspection. Insure that all required safety signs are in place and legible. – Do not modify, alter or otherwise change any safety-related systems of components without the specific approval of LIEBHERR.

3

Crushing and burn prevention – Never work underneath the attachment as long as it is not safely resting on the ground or properly supported. – Insure that all load supporting systems are in good repair and rated for the required load. – Always wear work gloves when handling wire ropes. – When working on the attachment, never align bores with your fingers, always use a suitable alignment tool. – Keep hands, tools and any other objects away from contact with the cooling fan. The cooling fan can cause severe injury, objects can be catapulted away or destroyed, and the fan can be damaged by the objects. – At or near operating temperature, the engine cooling system is hot and under pressure. Avoid contact with any components containing coolant. Danger of severe burns. – Check the coolant level only after the radiator cap on the expansion tank is cool enough to touch. Turn the cap carefully to relieve the pressure. – At or near operating temperature, the engine and the hydraulic oil are hot. Do not allow your skin to come into contact with hot oil or components containing hot oil. – Always wear safety glasses and protective gloves when handling batteries. Avoid sparks and naked flames. – Do not let any assisting personnel hold the attachment, bucket or grapple to assist in any operation. – When working on the engine area, make sure that the side doors are properly secured to remain open during the service operation.

1.10.2 copyright by

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Service Manual

Safety instructions Fire and explosion prevention

4

Fire and explosion prevention – Switch off the diesel engine prior to filling the tank. – Have skilled personnel immediately repair all defects, such as loose connections, blown fuses and burned out light bulbs, burned or frayed cables. – Do not smoke and avoid naked flames when filling the tank or loading the batteries. – Always start the diesel engine according to the operating instructions. – Never store flammable fluids on the machine except in appropriate storage tanks. – Regularly inspect all lines, hoses and fittings for leaks and damage. – Repair any leaks immediately and replace damaged components. – Be certain that all clamps, guards and heat shields are properly installed to prevent vibration, rubbing and heat build up. – Do not use cold start aids (ether) near heat sources or naked flames or in insufficiently ventilated areas. – Do not use ether containing starting aids to start diesel engines with pre-heat system or flame glow systems. – Familiarize yourself with the location and use of fire extinguishers on the machine as well as the local fire reporting procedures and fire fighting possibilities.

5

Transport – Insure that the transporting vehicle or truck trailer is rated for the intended machine weight and size. – Park the machine on a level surface and chock the track chains and/or wheels. – During transport, remove parts of the attachment that create an over width or length condition, if necessary. – Clean the undercarriage. The undercarriage must be swept clean, meaning, the chains / wheels must be free of snow, ice and sludge prior to driving onto the transporting vehicle. – Align the machine precisely with the loading ramp. – Attach the manual lever for sensitive driving (crawler excavator) to the driving pedals. – Have another person guide and signal the operator. – On wheel models equipped with an uppercarriage locking mechanism, the uppercarriage must be secured to the undercarriage with the locking pin after loading onto the trailer. – Secure the machine and any loose components with tiedowns in accordance with any applicable national regulations. – Release all pressure lines (as described in this operating manual), remove the ignition key and pull the safety lever up prior to leaving the machine. – Close all cab and panel doors. – Verify that no one remains on the machine during the transport. – Investigate the travel route, specifically in reference to limits for width, height and weight prior to the transport. – Pay special attention when driving under electrical lines and bridges and when passing through tunnels. – Use the same care for unloading as for loading.

6

Bringing the machine into service – Before starting the machine, perform a thorough walkaround inspection. – Visually check the machine for loose bolts, cracks, wear, leaks and damage. – Never start or operate a damaged machine.

1.10.3 copyright by

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Safety instructions

Service Manual

Starting the machine – – – –

Make sure to correct any problems immediately. Verify that all hoods, covers and doors are closed, however, the locks should remain unlocked. Verify that all safety signs are in place. Make sure that all windows, as well as the inside and outside mirrors are clean. Secure all doors and windows to prevent unintentional movement. – Before operating the machine, adjust the operator’s seat, the mirror, the armrests and the other items to ensure comfortable and safe working conditions. – The noise protection devices on the machine must be in working order. – Never operate the machine without the cab.

7

Starting the machine – Before start up, check all indicator lights and instruments for proper function, bring all controls into neutral position and insure that the safety lever is in the raised position. – Blow the horn briefly prior to starting the diesel engine, in order to warn persons located near the machine. – Only start the machine from the driver’s seat. – Start the diesel engine according to the regulations in the operating instructions, if you have not received any other instructions. – Lower the safety lever and check all indicators, gauges, warning devices and controls for their proper indication. – Only operate the diesel engine in a well-ventilated area, if the area is enclosed. If necessary, open doors and windows in the building to provide ample fresh air. – Bring the engine and hydraulic oil to operating temperature. Low oil temperatures cause a slow reaction of the controls. – Check that all attachment functions are operating properly. – Carefully take the machine to an open area and check all control functions.

8

Shutting down the machine – Park the machine on level and stable ground whenever possible. Otherwise, chock or block wheels when parking on a slope. – Lower the attachment so that it rests on the ground. – Move all control elements into the neutral position. Set the parking and slewing gear brake. – Switch off the diesel engine according to the operating instructions and move the safety lever up, prior to leaving the driver’s seat. – Lock the machine, as well as all hoods, covers and doors; remove all keys and secure the machine against any unauthorized use.

9

Towing the machine – Always observe the correct procedure: See chapter “Towing the machine” in this operating manual. – The machine may only be towed in exceptional circumstances, such as moving a disabled machine from a hazardous location. – Before pulling or towing the machine, check all cables, hooks and couplers for safety and stability. – Towing equipment must have sufficient tensile strength and must be attached to the undercarriage at the designated tiedown attachment points. – Never allow anyone to remain in the area of the towing devices. – During the towing procedure, keep within the required transport position, the permissible speed

1.10.4 copyright by

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Service Manual

Safety instructions Working with the machine

and distance. – Proceed as outlined in the operating manual when putting the machine back into service.

10

Working with the machine – Before starting to work, familiarize yourself with the specific conditions of the job site and any local regulations. These include: the obstacles in the working or movement area, the load carrying capacity of the ground and required safeguards for the job site to protect machines and personnel from public highway traffic. – Always keep an adequate safety distance to overhangs, edges, embankments and an unsecured substrate. – Be particularly cautious in conditions of reduced visibility and changing ground conditions. – Always locate any underground utilities before you dig. Observe the required clearance distances to any underground utilities. – Familiarize yourself with the location of power lines and use caution when working near them. Observe the required clearance distances to any power lines. – In the case of contact with a power line: • do not move the machine or its attachment, • do not leave the operator’s platform, • warn people in the vicinity not to approach or touch the machine, • have the power turned off. – Before moving the machine, always ensure that the attachments are safely secured. – When traveling on public roads, observe all traffic regulations, insure that your equipment has all required lighting and marking, and observe any applicable load limitations. – Always turn on the lights in conditions of poor visibility or darkness. – Do not permit any passengers on the machine (except on two way excavators). – Operate the machine only when seated and with the seat belt fastened. – Report any problems or needed repairs and make sure that all required repairs are carried out immediately. – Insure that the intended work area is clear of all personnel before beginning work. – Before starting to work, always check the brake system as outlined in the operating manual. – Never leave the operator’s seat as long as the machine is still moving. – Never leave the machine unattended while the diesel engine is running. – Know the loads to be handled and be aware of any stability limitations these loads may create. – The maximum approved passable incline / traverse slope of the machine depends on the attached equipment as well as the substrate. – For travel, move the uppercarriage parallel to the undercarriage and hold the load as close as possible to the ground. EXCEPTION: see WHEN LOADING AND UNLOADING – Adjust the travel speed to suit local conditions. – Avoid working movements which could cause the machine to tip over. – If possible, always work downhill or uphill, never sideways on a slope. – Travel downhill at the permitted speed or you could lose control over the machine. – Travel down grades at the appropriate speed to maintain control of the machine. Shift to a lower gear to allow the engine to control the maximum speed of the machine. – When loading a truck, make sure that the truck driver leaves the cab, even if a rock protection is present. – Always use the safety devices intended for their specific use for demolition work, clearings, hoisting operations, etc. – 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. – Only permit experienced personnel to secure loads and signal the machine operator. The guide

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Safety instructions

Service Manual

Working with the machine must position himself within view of the operator or be in voice contact with him. – Depending on the attachment combination, there can be a danger of collision between the working tool and the operator’s cab, the cab protection or the boom cylinders. To avoid damage, utmost attention is required when the bucket teeth enter this range.

10.1

Use in material handling applications, specifically when travelling with raised loads and attachments – Material handling applications, especially using a grapple, may require travel with suspended loads. Doing this will shift the machine centre of gravity and reduce stability. The following practices and precautions should be observed: • Match your travel behaviour to the changed machine characteristics and surrounding conditions. • Reduce the travel speed to avoid sudden braking or steering manoeuvres. • Avoid sudden speed changes, such as braking, acceleration, changes in travel direction. • Turn the uppercarriage only if the undercarriage is not travelling. • Turn the uppercarriage only after taking on the load. • Move the machine only after you have taken on the load, lifted it and turned the uppercarriage in travel position. • If so required to the job site conditions, ensure, that you have appropriate windscreen protection. The protective screen (FOPS) must be installed if there is a danger of falling objects from overhead. • Do not exceed the grapple rated load. Know the density and weight of materials being handled. – The working sequences when working with machines with grapples require a properly instructed and trained operator. – The work application is only permitted after the machine operator has received sufficient training and practical experience.

10.2

Application of machines with tower elevation – Due to the tower elevation, the centre of gravity of the machine will shift upward in vertical direction. The travel and work behaviour of the machine will thereby be strongly influenced, for example reduction of dynamic stability. – Due to the elevated centre of gravity, the machine must be aligned in horizontal direction before starting to work. In horizontal direction, the centre of gravity of the uppercarriage is above the centre of the undercarriage, which improves stability. – The machine can rock despite levelling and tip over! For that reason, the following rules must be strictly observed: When driving the machine: • Driving with loads is not permitted. • Swing the uppercarriage parallel to the undercarriage (transport position). • Pull the attachment as close as possible to the machine. • Only then may the outriggers be retracted and the machine be driven. • Check the roadway to ensure that the ground is solid and even! Potholes and uneven road surfaces endanger the stability of the machine. • Match your travel behaviour to the changed machine characteristics (higher centre of gravity) and surrounding conditions. • Reduce the travel speed to avoid sudden braking or steering manoeuvres. • Avoid sudden speed changes, such as braking, acceleration, changes in travel direction. • Travel up or down grades perpendicular (at right angles) to the slope. • Special care must be taken when driving through narrow passages - drive slowly! In material handling operation: • Wheel model: Before moving (turning) the uppercarriage from transport position, the machine must be supported on outriggers and horizontally aligned.

1.10.6 copyright by

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Service Manual

Safety instructions Working with the machine • Make sure to check the placement surface of the outriggers (load carrying capacity of ground). Sinking of an outrigger below ground level would result in devastating consequences! • Carry out all movements with increased caution. • When swinging a load, first bring the attachment as low and close to the machine as practical. Note: be aware of the hazard of grapple swing when moving a load toward the operator cab. • Avoid abrupt slow down or acceleration of the attachment or uppercarriage. • Never lift a heavier load than stated in the load chart.

10.3

Additional notes for machines with fixed cab raiser – To enter and exit the machine, park the machine on level ground. Position the uppercarriage to the undercarriage in such a way that the steps and ladders are aligned. – When entering or leaving the machine, always face the machine and use the three points of contact with the machine. – When you can reach the door handle with your free hand, open the door first before climbing higher. Note that factors such as wind, can make it more difficult to open the door. For that reason, always guide the door by hand when opening the door. Make sure that the door is properly latched open. – Continue to climb up and immediately sit on the operator’s seat in the cab. Then close the door and fasten the safety belt. – Proceed with the same care when exiting and climbing down as when entering and climbing up the machine. – Park the machine only on firm and level ground. Position the uppercarriage to the undercarriage in such a way that the steps and ladders are aligned. – Release the safety belt. When exiting, face the machine and use the three-point support. Climb down until you can close the door safely. Always guide the door by hand when closing the door. – Finally climb down to the ground.

10.4

Protection from vibrations – The vibration impact on mobile construction machinery is usually the result of the manner of utilization. Especially the following parameters have a significant influence: • Terrain conditions: Unevenness and potholes; • Operating techniques: Speed, steering, braking, control of operating elements of the machine during travel as well as working. – The machine operator determines the vibration impact to a great part, since he himself selects the speed, the gear ratio, the working manner and the travel route. This results in a wide range of various vibration impacts for the same machine type. The full body vibration impact for the machine operator can be reduced if the following recommendations are observed: – Select the appropriate machine, equipment parts and auxiliary devices for the corresponding tasks. – Keep the seat in good order and adjust it as follows: • The seat adjustment and the suspension should be made according to the weight and the size of the operator. • Check the suspension and the adjustment mechanism regularly and make sure that the characteristics of the seat remain as specified by the seat manufacturer. – Check the maintenance condition of the machine, especially regarding: Tire pressure, brakes, steering, mechanical connections, etc. – Do not steer, brake, accelerate and shift or move and load the attachment of the machine in a jerky manner. – Match the machine speed to the travel route to avoid vibration impacts. • Decrease the speed when driving on pathless terrain;

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Safety instructions

Service Manual

Installation and removal of attachment parts • Drive around obstacles and avoid very impassable terrain. – Keep the quality of the terrain where the 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 (i.e. on public roads) with suitable (medium) speed. – For machines, which are frequently used for travel, consider use of auxiliary ride control systems, and also monitor speed to minimize buildup of "pitching" vehicle movement.

11

Installation and removal of attachment parts – Equipment and attachment parts made by other manufacturers or those which do not have LIEBHERR’s general approval for installation may not be installed on the machine without prior written approval by LIEBHERR. LIEBHERR must be provided with the required technical documentation necessary for this purpose. – Set the machine on a level and stable ground prior to any work with attachments. – Lock the uppercarriage with the locking pin to the undercarriage. – Do not position yourself under a raised attachment that has not been adequately and securely supported. – Never place yourself under a machine while it is elevated. – Remove hydraulic system pressure before working on any attachments (as described in this operating manual). – Do not attempt to lift heavy parts. Use suitable lifting devices with sufficient load carrying capacity. – Insure any lifting system or lifting device that is used is in good repair and adequately rated for the component or machine to be supported. Always wear work gloves when handling wire cables. – When working on the equipment: Switch off the diesel engine, remove the key and turn the safety lever upward. – During repairs: Make sure that the hydraulic lines are properly attached and that all fittings and connections are properly tightened. – As soon as an attachment part is removed and supported, cover or cap the openings in the hydraulic circuit to prevent dirt infiltration. Permit only authorized persons near the machine or the lifting device.

11.1

Removal and installation of attachment pins – Never use your fingers to align pin bores. If possible, always use a hydraulic pin pulling device to push out the pins on the attachment. – If pins must be removed with a sledge hammer, use a punch and a guide tube held by another person. – To drive out a pin, install the impact screw from the tool box in the threaded bore of the pin and hit the screw only. – For the installation of a pin retained with castle nut and cotter pin, drive the pin in first to the stop, then install the castle nut by hand until contact and tighten it only to the point where the cotter pin can be installed.

1.10.8 copyright by

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Service Manual

Safety instructions Maintenance

12 12.1

Maintenance General safety instructions – Maintenance and repairs may only be carried out by trained expert technicians. – Always note the frequency intervals for inspections as contained in this operating manual. – Insure that an adequately equipped workshop is available to perform these tasks, and note the designated qualifications of the personnel responsible for each inspection. – The maintenance and inspection schedule sets out precisely who should, or is allowed to carry out which jobs. The machine operator (and his staff) are allowed to carry out certain jobs, but other jobs must be carried out only by qualified and trained staff. – Spare parts must meet the technical requirements set forth by the manufacturer. This is always ensured with original spare parts. – Wear task-appropriate personal protective equipment at all times. Example: In addition to a protective helmet and safety boots, for certain jobs protective goggles and gloves are also necessary. – Keep unauthorized personnel away from the machine during maintenance. – Secure a wide-ranging area for maintenance, as necessary. – Inform the operator before starting to carry out special tasks and maintenance work. Make sure he knows the person who is in charge of the work. – Perform all maintenance operations on the machine on a level and stable ground with the working equipment lowered and the diesel engine turned off, unless described otherwise in the operating manual. – Hang a well visible warning label “do not switch on“ onto the ignition during maintenance operations, especially when working under the machine. Remove the ignition key and set the main battery switch to position 0. – Re-torque all bolts at the completion of the maintenance procedure to the required torque specification. – If the dismantling of safety equipment is necessary, the safety equipment must be re-attached and inspected directly upon conclusion of the operations.

12.2

Checking for cracks – Machines are subject to different loads, depending on application, job site, duration of use and conditions of use. The different load conditions result in different service lives for various machines components. This could lead to cracks and loose connections, particularly on load-bearing parts. This applies particularly to machines used in material handling or industrial applications or for machines with special equipment, such as demolition excavators. To ensure that operating safety is maintained, the machine must be checked regularly for cracks, loose connections or other visible damage. – To check for cracks, it is necessary to keep the machine clean and to clean it regularly. – The inspection must be carried out according to the inspection and maintenance schedule. – It is advisable to carry out these inspections with the machine supported, on firm and level ground. – Specific attention should be given to the following: • The steel structure undercarriage with axle and gear mounting, support, lower slewing ring seating with tower and slewing ring. • The steel structure uppercarriage with bearing block for boom and boom cylinder, upper slewing ring seating, cab bearing, mounting of slewing gear and counterweight. • Steel structure of working attachments, e. g. boom, stick, quick change adapter, digging tool and grapple. • Hydraulic cylinder, axles, steering, pins and pin connections, steps, ladders and mounting elements. – Check for cracks visually. If a crack is suspected or is in areas which are not easily visible, such

1.10.9 copyright by

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Safety instructions

Service Manual

Maintenance as the slewing ring seating, then the dye penetration procedure should be used to check for cracks. – Any damage found must be fixed immediately. Welding on load-bearing parts of earth moving machines, material handling and transport units may only be made by certified welders in accordance with acceptable welding practices. Contact LIEBHERR Service to discuss suitable measures.

12.3

Welding – Welding, cutting and grinding should only be done with the specific approval of LIEBHERR. Prior to any welding, cutting or grinding, clean the machine and surrounding area to remove dust and flammable materials. – Insure adequate ventilation.

12.4

Fuels, lubricants and process chemicals – When handling oils, greases and other chemical substances, always observe the applicable safety regulations for the corresponding product. – Ensure safe and environmentally friendly disposal of operating and service fluids as well as exchange parts. – Handle hot operating and service fluids carefully (danger of burning and scalding).

12.5

Repair – Do not attempt to lift heavy parts. Use lifting devices with sufficient load carrying capacity. When replacing parts or large sub-assemblies, use appropriate and functioning lifting devices and adequate load carrying capacity to insure safe movement during installation. Never stand or work under suspended loads. – Always wear work gloves when handling wire ropes. – Only permit experienced personnel to secure loads and signal the crane operator. The guide must position himself within view of the operator or be in voice contact with him. – When working overhead, use appropriate safe access ladders and working platforms. Do not use parts of the machine as climbing devices, if they are not designed for this purpose. Wear a harness when working at great heights. Keep handles, steps, railings, platforms, and ladders free of dirt, ice and snow. – When working on the attachment (for example when replacing teeth), make sure the machine is properly supported. Never use metal-on-metal support. – Never stand underneath a machine that has been raised with the aid of work equipment unless it has been properly and securely supported. – Always support the machine in such a ways that any shifting weight will not endanger the stability of the machine and avoid metal to metal contact. – Work on travel gears, brake and steering systems may only be carried out by specially trained expert personnel. – If the machine must be repaired on an incline, block the track chains with chocks and secure the uppercarriage to the undercarriage with the locking pin. – Only qualified, specially trained personnel may work on the hydraulic system. – Do not check for hydraulic leaks with your hand. Use cardboard or similar material to detect leaks. Wear work gloves. – Do not loosen any lines or bolts before lowering the equipment, turning off the diesel engine and relieving the hydraulic system. After the diesel engine has been turned off, you must move all pilot controls (right handed joystick and pedals) into all directions to reduce the control pressure and the dynamic pressure in the work cycles. Then release the pressure in the tank, as described in this operating manual.

1.10.10 copyright by

MJFCIFSS


Service Manual

Safety instructions Maintenance

12.6

Electrical system – Check the electrical system regularly. All defects, such as loose connections, burnt out fuses and bulbs, burnt or damaged wires or cables must be repaired immediately by an electrician or specially trained personnel. – Only use original fuses with the correct amperage. – Only qualified technicians should attempt troubleshooting or repairs on high voltage systems. – DO NOT work on energized attachments. – When working on mid and high voltage components, shut off the voltage and connect the supply cable to the ground to discharge any stored energy. – Check all disconnected parts if they are truly free of current, ground them and short circuit them. Insulate adjacent, current carrying parts. – Disconnect the battery before working on the electrical system or before carrying out any arc welding work on the machine.

12.7

Pressure accumulator – Pressure accumulators contain stored energy and operate at high pressures. Only specially trained personnel may work on pressure accumulators. – Do not operate damaged pressure accumulators. – You must reduce the pressure in the hydraulic system as described in this operating manual prior to working on a hydraulic accumulator. – Do not weld or solder on the pressure accumulator and do not carry out any mechanical work on them. – Fill the pressure accumulator only with nitrogen. – The accumulator housing can become hot during operation, there is a danger of burning. – New pressure accumulators must be charged to the required pressure for the application before use. – The operating data (minimum and maximum pressure) is marked permanently on the pressure accumulators. Make sure that the marking remains visible.

12.8

Hydraulic hoses and lines – Hydraulic lines and hoses may never be repaired! – All hoses, lines and fittings must be checked every two weeks for leaks and visible damage. Damaged parts must be replaced immediately. Remember that escaping high pressure oil can penetrate skin. Escaping oil can also cause fires. – Even if hoses are properly stored and used, they undergo a natural aging process. For that reason, their service life is limited. • Improper storage, mechanical damage and impermissible use are the most frequent causes of failure. • Using hoses and lines close to the limit ranges of permitted use can shorten the service life (for example in high temperatures, frequent work cycles, extremely high impulse frequencies, multi shift operation). – Hoses and lines must be replaced when the following conditions are found during inspection: • Damage to the outer layer as far as the intermediate layer (e.g. chafing, cuts and cracks); • Brittleness of the outer layer (hose material cracking); • Deformations, which differ from the natural shape of the hose or hose line, when under pressure or not under pressure, or in bends (e.g. separation of layers, blisters or bubbles); • Leaks; • Failure to follow installation instructions; • Damage or deformation of hose fittings, which reduce the strength of the fitting or the hose / fitting connection; • Hose slipping out of the fitting;

1.10.11 copyright by

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Safety instructions

Service Manual

Maintenance • Corrosion on the fittings, which reduces function and strength; – When replacing hoses and lines, observe the following: • Use only original spare parts. • Route and install hoses and lines properly, observe correct connection points. • Always ensure that the hoses and lines are free of torsion when routing. On high pressure hoses, always attach the screws of half clamps or full flange on both ends of hose first and then tighten. • When using high pressure hoses and lines with a bent fitting, always tighten the end with the bent fitting first when tightening the flanges, then the end with the straight fitting. • Any existing mounting clamps in the centre of the hose may only be installed and tightened thereafter. • Check daily to ensure that all clamps, covers and protective devices are properly mounted. This prevents vibration and damage during operation. • Route the hoses and lines in such a way that chafing with other hoses or other structures is prevented. • A minimum distance of approximately ½ of the outer hose diameter to the other parts is recommended. The distance should not be less than 10 to 15 mm (1/2 inch). • When replacing hoses and lines on movable parts (e.g. from boom to stick), check for hose interference and kinking over the complete range of motion.

12.9

Cab protection (FOPS) For certain machine applications LIEBHERR offers optional cab protection systems of various designs. These systems consist of a full length FOPS (falling objects protective structure) or a top guard and front guard to protect the operator's cab and windscreen area from falling objects (for example rocks or debris). The full length FOPS wraps around the operator's cab, is mounted to the uppercarriage and is a stand-alone system. The top and front guards are either bolted individually or in combination to the cab structure. In that case the operator's cab is also part of the cab protection system and is subject to the following instructions. – Never operate a machine if one of these protections is damaged in any way. – Damages may occur due to: • structural modifications or repairs (for example welding, cutting or drilling) • deformation after an accident • falling objects – Structural modifications or repairs of any kind are prohibited without the expressed, written approval of LIEBHERR.

1.10.12 copyright by

MJFCIFSS


Product code

Standard

Version

10409969 001 WN 4037 K

PRELOADS AND TIGHTENING TORQUES FOR SCREWS WITH METRIC COARSE AND FINE THREADS ACCORDING TO DIN ISO 261 The preloads and torques included in the table are based on the VDI regulations 2230 of July 1986. (The values of the edition from February 2003 have not been included in the table, as this would not be justified according to our experience.) Assembly preloads FM and tightening torques MA at v = 0.9 for headless screws with metric coarse or fine threads according to DIN ISO 262 (and DIN ISO 965-2); Head dimensions of hex head screws according to DIN EN ISO 4014 to 4018, screws with hexalobular external driving heads according to DIN 34800 or Allen head screws according to DIN EN ISO 4762 and "centre" bores according to DIN EN 20273 Metric coarse thread Surface finish: black-chrome finish or phosphatised electro-galvanised flZn = zinc flake coating (LH standard 10021432, DAC) Assembly Thread Class preloads FM in N

oiled

for mean friction factor

M4

M5

M6

M7

M8

8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9

4 050 6 000 7 000 6 600 9 700 11 400 9 400 13 700 16 100 13 700 20 100 23 500 17 200 25 000 29 500

Tightening torques MA in Nm

Metric fine thread Surface finish: black-chrome finish or phosphatised electro-galvanised flZn = zinc flake coating (LH standard 10021432, DAC) Assembly Thread Class preloads FM in N

µG= 0.12

2,8 4,1 4,8 5,5 8,1 9,5 9,5 14,0 16,5 15,5 23,0 27 23 34 40

8.8 10.9 12.9

27 500 40 000 47 000

46 68 79

M8x1

M10x1

M10x1,25

M12

8.8 10.9 12.9

40 000 59 000 69 000

79 117 135

M12x1,25

M12x1,5

M14

M16

.04.08 Date

8.8 10.9 12.9 8.8 10.9 12.9

LHB Plant

55 000 80 000 94 000 75 000 111 000 130 000

125 185 215 195 280 330

Wimbauer Alois Created

Tightening torques MA in Nm

for mean friction factor

M9x1

M10

oiled

M14x1,5

M16x1,5

8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9

Examined

This document may not be copied or otherwise reproduced without the prior consent of LIEBHERR. This document has been created by electronic means and is valid without signature.

µG= 0.12

18 800 27 500 32 500 24 800 36 500 42 500 31 500 46 500 54 000 29 500 43 000 51 000 45 000 66 000 77 000 42 500 62 000 73 000 61 000 89 000 104 000 82 000 121 000 141 000

24,5 36 43 36 53 62 52 76 89 49 72 84 87 125 150 83 122 145 135 200 235 205 300 360

owatzky Dirk Released

1.20.1


Product code

Standard Metric coarse thread Surface finish: black-chrome finish or phosphatised electro-galvanised flZn = zinc flake coating (LH standard 10021432, DAC) Assembly Thread Class preloads FM in N

oiled

for mean friction factor

M18

8.8 10.9 12.9

94 000 135 000 157 000

Version

Tightening torques MA in Nm

Metric fine thread Surface finish: black-chrome finish or phosphatised electro-galvanised flZn = zinc flake coating (LH standard 10021432, DAC) Assembly Thread Class preloads FM in N

µG= 0.12

280 390 460

M22

M24

8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9

121 000 173 000 202 000 152 000 216 000 250 000 175 000 249 000 290 000

390 560 650 530 750 880 670 960 1120

M18x1,5

M20x1,5

M22x1,5

M24x1,5

M24x2

M27

8.8 10.9 12.9

230 000 330 000 385 000

1000 1400 1650

M27x1,5

M27x2

M30

8.8 10.9 12.9

280 000 400 000 465 000

1350 1900 2250

M30x1,5

M30x2

M33

8.8 10.9 12.9

350 000 495 000 580 000

1850 2600 3000

M33x1,5

M33x2

M36

8.8 10.9 12.9

410 000 580 000 680 000

2350 3300 3900

M36x1,5

M36x3

M39

8.8 10.9 12.9

490 000 700 000 820 000

3000 4300 5100

oiled

Tightening torques MA in Nm

for mean friction factor

M18x2

M20

10409969 001

M39x1,5

M39x3

8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9

110 000 157 000 184 000 102 000 146 000 170 000 139 000 199 000 232 000 171 000 245 000 285 000 207 000 295 000 346 000 196 000 280 000 325 000 267 000 381 000 445 000 255 000 365 000 425 000 335 000 477 000 558 000 321 000 457 000 534 000 410 000 584 000 683 000 395 000 560 000 660 000 492 000 701 000 820 000 440 000 630 000 740 000 582 000 830 000 971 000 530 000 750 000 880 000

µG= 0.12

310 440 520 290 420 490 430 620 720 580 820 960 760 1090 1270 730 1040 1220 1110 1580 1850 1070 1500 1800 1540 2190 2560 1490 2120 2480 2050 2920 3420 2000 2800 3300 2680 3820 4470 2500 3500 4100 3430 4890 5720 3200 4600 5300

Notes:  Torques indicated in drawings have precedence over those specified in the factory standards and must at all times be adhered to.  For important screw connections, we recommend using a torque angle gauge. For such connections, the required tightening torques (assembly torque, angle of rotation) must be determined individually by the technical department. .

1.20.2


Standard ď‚–

.

Product code Version

10409969 001

When tightening in aluminum, with or without Helicoil-Inserts, the values for category 8.8 must be used. However, tightening torques indicated on drawings are binding, to be treated with priority and must be adhered to.

1.20.3


Service Manual

Tightening torques of screw-in studs (Ermeto)

Tightening torques 1 1.1

of screw-in studs (Ermeto) mating material: steel (Grease well before inserting!) Type with sealing edge Thread M or G

Type

Type with EOLASTIC seal Tightening torques in Nm

Thread M or G

Type

Light-duty series L

Tightening torques in Nm

Light-duty series L

GE 06 LM A 3 C

M 10x1

18

GE 06 LM ED A 3 C

M 10x1

18

GE 06 LR A 3 C

G 1/8 A

18

GE 06 LR ED A 3 C

G 1/8 A

18

GE 08 LM A 3 C

M 12x1.5

30

GE 08 LM ED A 3 C

M 12x1.5

25

GE 08 LR A 3 C

G 1/4 A

35

GE 08 LR ED A 3 C

G 1/4 A

35

GE 10 LM A 3 C

M 14x1.5

45

GE 10 LM ED A 3 C

M 14x1.5

45

GE 10 LR A 3 C

G 1/4 A

35

GE 10 LR ED A 3 C

G 1/4 A

35

GE 12 LM A 3 C

M 16x1.5

65

GE 12 LM ED A 3 C

M 16x1.5

55

GE 12 LR A 3 C

G 3/8 A

70

GE 12 LR ED A 3 C

G 3/8 A

70

GE 15 LM A 3 C

M 18x1.5

80

GE 15 LM ED A 3 C

M 18x1.5

70

GE 15 LR A 3 C

G 1/2 A

140

GE 15 LR ED A 3 C

G 1/2 A

90

GE 18 LM A 3 C

M 22x1.5

140

GE 18 LM ED A 3 C

M 22x1.5

125

GE 18 LR A 3 C

G 1/2 A

100

GE 18 LR ED A 3 C

G 1/2 A

90

GE 22 Lm A 3 C

M 22x1.5

140

GE 22 Lm Ed A 3 C

M 26x1.5

180

GE 22 Lr A 3 C

G 3/4

180

GE 22 Lr Ed A 3 C

G 3/4 A

180

GE 28 Lm A 3 C

M 33x2.0

340

GE 28 Lm Ed A 3 C

M 33x2.0

310

GE 28 Lr A 3 C

G1A

330

GE 28 Lr Ed A 3 C

G1A

310

GE 35 Lm A 3 C

M 42x2.0

500

GE 35 Lm Ed A 3 C

M 42x2.0

450

GE 35 Lr A 3 C

G 1 1/4 A

540

GE 35 Lr Ed A 3 C

G 1 1/4 A

450

GE 42 Lm A 3 C

M 48x2.0

630

GE 42 Lm Ed A 3 C

M 48x2.0

540

GE 42 Lr A 3 C

G 1 1/2 A

630

GE 42 Lr Ed A 3 C

G 1 1/2 A

540

Heavy-duty series S

Heavy-duty series S

GE 06 SM A 3 C

M 12x1.5

35

GE 06 SM ED A 3 C

M 12x1.5

35

GE 06 SR A 3 C

G 1/4 A

55

GE 06 SR ED A 3 C

G 1/4 A

55

GE 08 SM A 3 C

M 14x1.5

55

GE 08 SM ED A 3 C

M 14x1.5

55

GE 08 SR A 3 C

G 1/4 A

55

GE 08 SR ED A 3 C

G 1/4 A

55

GE 10 SM A 3 C

M 16x1.5

70

GE 10 SM ED A 3 C

M 16x1.5

70

GE 10 SR A 3 C

G 3/8 A

90

GE 10 SR ED A 3 C

G 3/8 A

80

GE 12 SM A 3 C

M 18x1.5

110

GE 12 SM ED A 3 C

M 18x1.5

90

GE 12 SR A 3 C

G 3/8 A

90

GE 12 SR ED A 3 C

G 3/8 A

80

GE 14 SM A 3 C

M 20x1.5

150

GE 14 SM ED A 3 C

M 20x1.5

125

GE 14 SR A 3 C

G 1/2 A

150

GE 14 SR ED A 3 C

G 1/2 A

115

1.21.1 copyright by

MJFCIFSS


Tightening torques

Service Manual

of swivelling connections (Ermeto) Type with sealing edge Thread M or G

Type

Type with EOLASTIC seal Tightening torques in Nm

Type

Thread M or G

Tightening torques in Nm

GE 16 SM A 3 C

M 22x1.5

170

GE 16 SM ED A 3 C

M 22x1.5

135

GE 16 SR A 3 C

G 1/2 A

130

GE 16 SR ED A 3 C

G 1/2 A

115

GE 20 SM A 3 C

M 27x2.0

270

GE 20 SM ED A 3 C

M 27x2.0

180

GE 20 SR A 3 C

G 3/4 A

270

GE 20 SR ED A 3 C

G 3/4 A

180

GE 25 SM A 3 C

M 33x2.0

410

GE 25 SM ED A 3 C

M 33x2.0

310

GE 25 SR A 3 C

G1A

340

GE 25 SR ED A 3 C

G1A

310

GE 30 SM A 3 C

M 42x2.0

540

GE 30 SM ED A 3 C

M 42x2.0

450

GE 30 SR A 3 C

G 1 1/4 A

540

GE 30 SR ED A 3 C

G 1 1/4 A

450

GE 38 SM A 3 C

M 48x2.0

700

GE 38 SM ED A 3 C

M 48x2.0

540

GE 38 SR A 3 C

G 1 1/2 A

700

GE 28 SR ED A 3 C

M 1 1/2 A

540

Tab. 1

Tightening torques of screw-in studs

GE = Straight screw-in connection (with metric thread M or pipe thread G)

2 2.1

of swivelling connections (Ermeto) mating material: steel (Grease well before inserting!) Tightening torques

Tightening torques

Type

Type Thread

Nm

Thread

Light-duty series

Nm

Light-duty series

WH / TH 06 LR KDS A 3 C

G 1/8 A

18

WH / TH 06 LM KDS A 3 C

M 10 X 1

18

WH / TH 08 LR KDS A 3 C

G 1/4 A

45

WH / TH 08 LM KDS A 3 C

M 12 X 1.5

45

WH / TH 10 LR KDS A 3 C

G 3/8 A

45

WH / TH 10 LM KDS A 3 C

M 14 X 1.5

55

WH / TH 12 LR KDS A 3 C

G 1/2 A

70

WH / TH 12 LM KDS A 3 C

M 16 X 1.5

80

WH / TH 15 LR KDS A 3 C

G 3/4 A

120

WH / TH 15 LM KDS A 3 C

M 18 X 1.5

100

WH / TH 18 LR KDS A 3 C

G1A

120

WH / TH 18 LM KDS A 3 C

M 22 X 1.5

140

WH / TH 22 LR KDS A 3 C

G 1 1/4 A

230

WH / TH 22 LM KDS A 3 C

M 27 X 2.0

320

WH / TH 28 LR KDS A 3 C

G 1 1/4 A

320

WH / TH 28 LM KDS A 3 C

M 33 X 2.0

360

WH / TH 35 LR KDS A 3 C

G 1 1/4 A

540

WH / TH 35 LM KDS A 3 C

M 42 X 2.0

540

WH / TH 42 LR KDS A 3 C

G 1 1/2 A

700

WH / TH 42 LM KDS A 3 C

M 48 X 2.0

700

Heavy-duty series

Heavy-duty series

WH / TH 06 SR KDS A 3 C

G 1/4 A

45

WH / TH 06 SM KDS A 3 C

M 12 X 1.5

45

WH / TH 08 SR KDS A 3 C

G 1/4 A

45

WH / TH 08 SM KDS A 3 C

M 14 X 1.5

55

WH / TH 10 SR KDS A 3 C

G 3/8 A

70

WH / TH 10 SM KDS A 3 C

M 16 X 1.5

80

WH / TH 12 SR KDS A 3 C

G 3/8 A

70

WH / TH 12 SM KDS A 3 C

M 18 X 1.5

100

WH / TH 16 SR KDS A 3 C

G 1/2 A

120

WH / TH 14 SM KDS A 3 C

M 20 X 1.5

125

WH / TH 20 SR KDS A 3 C

G 3/4 A

230

WH / TH 16 SM KDS A 3 C

M 22 X 1.5

135

WH / TH 25 SR KDS A 3 C

G1A

320

WH / TH 20 SM KDS A 3 C

M 27 X 2.0

320

1.21.2 copyright by

MJFCIFSS


Service Manual

Tightening torques of screw-in studs (Ermeto) Tightening torques

Tightening torques

Type

Type Thread

Nm

Thread

Nm

WH / TH 30 SR KDS A 3 C

G 1 1/4 A

540

WH / TH 25 SM KDS A 3 C

M 33 X 2.0

360

WH / TH 38 SR KDS A 3 C

G 1/4 A

700

WH / TH 30 SM KDS A 3 C

M 42 X 2.0

540

WH / TH 38 SM KDS A 3 C

M 48 X 2.0

700

Tab. 2

3 3.1

Tightening torques of swivelling connections

of screw-in studs (Ermeto) mating material: steel (Grease well before inserting!)

Type VSTI

Screw-in thread M

Tightening torques Nm

Type VSTI

Screw-in thread G

Tightening torques Nm

VSTI 10X1 ED A3C

M 10 X 1

12

VSTI 1/8 ED A3C

G 1/8 A

13

VSTI 12X1.5 ED A3C

M 12 X 1.5

25

VSTI 1/4 ED A3C

G 1/4 A

30

VSTI 14X1.5 ED A3C

M 14 X 1.5

35

VSTI 3/8 ED A3C

G 3/8 A

60

VSTI 16X1.5 ED A3C

M 16 X 1.5

55

VSTI 1/2 ED A3C

G 1/2 A

80

VSTI 18X1.5 ED A3C

M 18 X 1.5

65

VSTI 3/4 ED A3C

G 3/4 A

140

VSTI 20X1.5 ED A3C

M 20 X 1.5

80

VSTI 1 ED A3C

G1A

200

VSTI 22X1.5 ED A3C

M 22 X 1.5

90

VSTI 1 1/4 ED A3C

G 1 1/4 A

450

VSTI 26X1.5 ED A3C

M 26 X 1.5

120

VSTI 1 1/2 ED A3C

G 1 1/2 A

450

VSTI 27X2 ED A3C

M 27 X 2.0

135

VSTI 33X2 ED A3C

M 33 X 2.0

225

VSTI 42X2 ED A3C

M 42 X 2.0

360

VSTI 48X2 ED A3C

M 48 X 2.0

360

Tab. 3

Tightening torques of screw-in studs

VSTI = Hexagon socket plug

1.21.3 copyright by

MJFCIFSS


Tightening torques

Service Manual

of screw-in studs (Ermeto)

1.21.4 copyright by

MJFCIFSS


Standard

Product code Version

10334184 000 WN 4121 C

Installations for pistons and piston nuts by hydraulic cylinders 1. Application and purpose This Liebherr standard applies only to hydraulic cylinders, and in particular to the mounting of pistons and piston nuts on piston rods from a thread diameter of M42 and greater. This standard describes the tightening procedure with turning distance and angle. For threads with diameters smaller than M42, the applicable tightening torque is indicated in the drawings. The values in the drawings are always binding.

2. Requirements / description of procedure For the valid torque value number, refer to the drawing. The standard may not be adopted or transferred to apparently similar geometries. Use this number to find the applicable turning distance and angle in the torque table (see item 4). The torque values have been determined empirically and are subject to changes. This standard differentiates between two tightening procedures, which are identified with 3-digit and 4-digit numbers respectively (see chapters 2.1 and 2.2).

1.22.1 1/7


Product code

Standard

Version

10334184 000

2.1. Tightening with assembly wrench This tightening procedure applies to 3-digit tightening numbers. Preparation: Clean the contact surfaces (threads contact faces between piston rod, piston and piston nut) and apply a thin layer of Gleitmo high-performance lubricating grease (ID no. 8300 004, 40 g tube) to both sides.

Definitions: Pretightening torque (Mv): The piston (A) is secured with a torque wrench (B) applied to the square/hexagon head of the assembly wrench (C). The position of the torque wrench must be carefully noted (see figure 1). Turning distance (4): Radian measure [mm] travelled as a result of the tightening of the piston, or piston nut along the outer thread diameter, after application of the pretightening torque (see figure 2). Turning angle (5): Angle ° travelled by the piston or piston nut respectively, after application of the pretightening torque (see figure 2).

A Mv

B

C

Figure 1 When applying the pretightening torque (Mv), the torque wrench (B) must point in the same direction as the assembly wrench (C). Proceed in the same way to tighten the piston nut, using a suitable assembly wrench.

.

1.22.2


10334184 000

Product code

Standard

Version

5 4 1

2

3

5 4 6

2

7

Figure 2 1: Markings on the piston and the piston rod thread after application of the pretightening torque 2: Markings on the piston rod thread 3: Markings on the piston after tightening 4: Turning distance 5: Turning angle 6: Markings on the piston nut and the piston rod thread after application of the pretightening torque 7: Markings on the piston nut after tightening

.

1.22.3


Product code

Standard

Version

10334184 000

2.2. Tightening with hydraulic assembly device This tightening procedure applies to 4-digit tightening numbers. Preparation: Clean the contact surfaces (threads contact faces between piston rod, piston and piston nut) and apply a thin layer of Gleitmo high-performance lubricating grease (ID no. 8300 004, 40 g tube) to both sides.

Definitions: Pretightening torque: Torque applied on the piston or piston nut with the torque wrench (A) via the hexagon head (B) of the torque converter (C) (see figure 1). Turning angle: Angle ° travelled by the piston or piston nut respectively, after application of the pretightening torque (see figure 3).

C

A

B

Figure 1 A: Torque wrench B: Hexagon head C : Torque converter

.

1.22.4


Product code

Standard

Version

10334184 000

Operation of the assembly device: See separate operating manual of the assembly device (H). For suitable adapters for the piston rod, piston and piston nut, refer to the piston parts list (see figure 2).

A D F

H B C E

G

Figure 2 A: Piston rod B: Piston C : Adapter for piston D: Adapter for piston rod E: Piston nut F: Adapter for piston nut G: Torque converter H: Assembly device

.

1.22.5


Standard

Product code Version

10334184 000

C

A

B

Figure 3 A: Dial B: Adjusting screw C : Angle scale Before tightening, set the dial (A) with the adjusting screw (B) to position 0° on the angle scale (C). The angle scale indicates the turning angle. If the opening angle of the assembly device is not sufficient to achieve the prescribed turning angle, mount the device again for a second tightening process. Note the previously completed angle. Before continuing the tightening process, set the dial to the last achieved angle value. Repeat this process as often as necessary to achieve the prescribed turning angle.

.

1.22.6


Standard

Product code Version

10334184 000

3. Modifications 4. Other applicable documents Torque table Drawing with reference to this Liebherr Standard and the torque number.

.

1.22.7


 

  

    

                                                         

                                                                 

                                                         

                                                         

                                                         

                                                         

                                                           

1.22.8


 

  

 

                          

                                  

                          

                          

                          

                          

                            

  

             

                 

             

               

               

1.22.9


Bezeichnung Description / DĂŠnomination

Mjfcifss!

Assembly instruction for piston rod bearings with external threads (hydraulic cylinders)

1

Blatt/Page/Feuille: bestehend aus consisting of composĂŠ

4

Blatt Pages Feuille

WN 4122 B

Contents 1.

Scope of application

2.

Description

3.

Referenced documents (torque table)

1.

Scope of application This factory standard applies exclusively to the assembly of hydraulic cylinders. For the valid factory standard number, refer to the drawing. The standard may not be adopted or transferred to apparently similar geometries. The torques have been determined empirically and are subject to changes. The revision and release dates indicate the latest version of the factory standard.

1.24.1


2.

Description

Preparation: Clean the threads and apply a thin layer of Gleitmo high-performance lubricating grease (ID no. 8300 004, 40 g tube) on both sides.

Definitions: Pretightening torque: The piston rod bearing is secured with a torque wrench applied to the square of the assembly wrench. The position of the torque wrench must be carefully noted (see figure 1).

Figure 1 A B C

Bearing head Assembly wrench Torque wrench

When applying the pretightening torque, the torque wrench must point in the same direction as the assembly wrench.

1.24.2


Turning distance: Radian measure [mm] between the bearing head outer diameter and the cylinder tube, travelled after application of the pretightening torque (see figure 2).

Turning angle: Angle ° travelled by the bearing head after application of the pretightening torque (see figure 2).

Figure 2 A B C D E F G

Marks on the cylinder tube and the auter diameter of the bearing head after application of the pretightening torque Mark on the cylinder tube Turning angle Turning distance Mark on the bearing head after tightening Cylinder Tube Bearing head

After the bearing head and the cylinder tube have been tightened, apply a notch mark at the rod side oil connection level, using a flat chisel.

1.24.3


3.

List of tightening torques for factory standard 4122 (Assembly instructions for piston and piston nut)

The date indicates the latest version of this table. This document is not covered by the revision service.

NU 4122... 001 011 016 017 026 027 031 036 037 039 041 046 047 051 052 053 061 151

Preload Torque Mv [Nm]

Edition: 14.09.2007

Piston rod bearing Turning distance Turning angle [mm] ~ [°]

50 100 100 100 100 100 100 100

7 +1 10 +1 10 +1 9 +1 10 +1 8 +1 8 +1 10 +1

10 12 12 10 11 8 9 9

150 200

9 +1 12 +1

7 10

200 200 400

25 +1 10 +1 14 +1

18 7 6

1.24.4


Standard

Product code Version

10409554 000

Tightening torques for piston rod bearing screws with LH 320HV washers 1. Application and purpose This Liebherr Standard applies exclusively to the mounting screws of the piston rod bearing of hydraulic cylinders.

2. Other applicable documents Drawing with reference to this Liebherr Standard. RIBE-Blauheft no. 30, 4. edition 2003.

3. Screw coating Black screw see table chapter 4.1 DACROMET screw (silver-colour zinc flake coating)

see table chapter 4.2

1.25.1


Product code

Standard

Version

10409554 000

4. Table of tightening torques 4.1. Black screw + LH washer The tightening torques apply to grease-free black screws used in conjunction with LH 320HV washers (FLZN anti-corrosion protection according to Liebherr Standard 10021432). Tightening torques MA determined according to RIBE-Blauheft. Friction coefficients: For thread friction torque MG: µG = 0.14 Head friction torque MK: µK = 0.11

Thread Wrench size

M10 WS 16 M12 WS 18 M14 WS 21 M16 WS 24 M18 WS 27 M20 WS 30 M22 WS 34 M24 WS 36 M27 WS 41

MG

MK

MA

Nm

Nm

Nm

8.8

28

21

50

10.9

41

30

70

12.9

48

35

85

8.8

49

35

85

10.9

71

51

120

12.9

84

60

145

8.8

78

56

135

10.9

114

82

195

12.9

133

96

230

8.8

119

87

205

10.9

175

128

305

12.9

204

150

355

8.8

166

121

285

10.9

243

177

420

12.9

285

207

490

8.8

232

172

405

10.9

341

252

595

12.9

399

295

695

8.8

314

237

550

10.9

462

348

810

12.9

540

408

950

8.8

401

293

695

10.9

590

430

1020

12.9

690

504

1195

8.8

583

438

1020

10.9

857

644

1500

12.9

1003

753

1755

Strength class

LH washer 320HV ID no. dxDxh 99 18 225

10.5x18.0x3.0

99 18 226

12.5x21.0x3.5

95 86 491

14.5x25.0x3.5

99 18 228

16.5x28.0x4.0

95 86 492

18.5x31.0x5.0

99 18 229

20.5x34.0x5.0

92 82 976

22.5x38.0x5.0

99 18 230

24.5x40.0x5.0

95 86 495

27.5x45.0x6.0

1.25.2


Product code

Standard M30 WS 46 M33 WS 50 M36 WS 55 M39 WS 60 M42 WS 65 M42x3 WS 65

Version

8.8

794

594

1390

10.9

1166

872

2040

12.9

1364

1021

2385

8.8

1073

805

1880

10.9

1576

1182

2760

12.9

1844

1383

3225

8.8

1383

1031

2415

10.9

2031

1515

3545

12.9

2377

1773

4150

8.8

1779

1343

3120

10.9

2613

1973

4585

12.9

3058

2309

5365

8.8

2208

1654

3860

10.9

3243

2429

5670

12.9

3795

2842

6635

8.8

2315

1809

4125

10.9

3401

2657

6060

12.9

3979

3109

7090

10409554 000

99 18 231

31.0x52.0x6.0

95 86 496

34.0x56.0x7.0

99 18 232

37.0x60.0x7.0

96 02 352

40.0x66.0x8.0

96 02 353

43.0x72.0x10.0

96 02 353

43.0x72.0x10.0

1.25.3


Product code

Standard

Version

10409554 000

4.2. DACROMET screw + LH washer The tightening torques apply to grease-free DACROMET screws used in conjunction with LH 320HV washers (FLZN anti-corrosion protection according to Liebherr Standard 10021432). Tightening torques MA according to Liebherr Standard10409969 (WN 4037). (see internal memo from H. Wimbauer of the 19.10.01)

M10 WS 16 M12 WS 18 M14 WS 21 M16 WS 24 M18 WS 27 M20 WS 30 M22 WS 34 M24 WS 36 M27 WS 41 M30 WS 46

8.8

46

10.9

68

12.9

79

8.8

79

10.9

117

12.9

135

8.8

125

10.9

185

12.9

215

8.8

195

10.9

280

12.9

330

8.8

280

10.9

390

12.9

460

8.8

390

10.9

560

12.9

650

8.8

530

10.9

750

12.9

880

8.8

670

10.9

960

12.9

1120

8.8

1000

10.9

1400

12.9

1650

8.8

1350

10.9

1900

99 18 225

10.5x18.0x3.0

99 18 226

12.5x21.0x3.5

95 86 491

14.5x25.0x3.5

99 18 228

16.5x28.0x4.0

95 86 492

18.5x31.0x5.0

99 18 229

20.5x34.0x5.0

92 82 976

22.5x38.0x5.0

99 18 230

24.5x40.0x5.0

95 86 495

27.5x45.0x6.0

99 18 231

31.0x52.0x6.0

1.25.4


Product code

Standard M30 WS 46

M33 WS 50

M36 WS 55

M39 WS 60

Version

8.8

1350

10.9

1900

12.9

2250

8.8

1850

10.9

2600

12.9

3000

8.8

2350

10.9

3300

12.9

3900

8.8

3000

10.9

4300

12.9

5100

10409554 000

99 18 231

31.0x52.0x6.0

95 86 496

34.0x56.0x7.0

99 18 232

37.0x60.0x7.0

96 02 352

40.0x66.0x8.0

5. Revision log

1.25.5


Standard

Product code Version

10650522 000

Angle-controlled screw tightenning method 1. Application and purpose This Liebherr Standard has been devised to provide the production department at LHB with details of screw parameters for the angle-controlled tightening of screw connections. This standard is only valid for screw connections that are specially marked in the drawing at LHB and to which one of the screwdriving conditions listed in the "Table of tightening torques" applies (see also section 2). The standard also contains information on two possible tightening methods.

2. Other applicable documents  

Table of tightening torques Drawing with reference to this Liebherr Standard and the screwdriving condition number

3. Requirements / description of procedure With the torque-controlled tightening method, the prestressing force is applied exclusively by means of a specific torque. With the angle-controlled tightening method, the prestressing force is applied through a combination of torque and tightening angle. The screw connection is thereby tightened in 2 steps: 1st step:

Pre-torque MAF [Nm]

In a first step, the screw is tightened with a preset torque, similar to the torque-controlled tightening method. This torque is known as the pre-torque MAF and is considerably lower than the torque applied with the torque-controlled tightening method (approx. 15% to 30% of the tightening torque according to LH standard 10409969). By pre-tightening with the pre-torque in this first step, the screw connection is properly defined and any dirt particles, burrs and other protrusions in the joints are eliminated. 2nd step:

Additional angle of rotation

[°]

In the second step, the remaining prestressing force is applied by means of the additional angle of rotation . The additional angle of rotation results in an elongation of the screw and thus the desired prestress, depending on the pitch of the thread. Advantages of the angle-controlled tightening method: 

With this method, the greater part of the prestressing force is applied to the screw connection through the angle of rotation, and friction factors (head contact friction and thread friction) play only a minor role. In contrast with the torque-controlled tightening method, this results in a significantly reduced dispersion of the prestressing forces. The angle-controlled tightening method is an overelastic tightening method. This means that, during tightening, the screw is stressed just beyond its breaking point. This results in significantly higher screw utilization and higher prestressing forces than are achievable with the torque-controlled tightening method.

1.30.1


Product code

Standard

Version

10650522 000

Screws that have been tightened once with an angle-controlled method must not be used again!

4.

Identification in drawing

The tightening values for the angle-controlled tightening method (pre-torque MAF and additional angle of rotation ) depend on the geometry of the individual screw (thread diameter, pitch, grip length, thread, length, etc.) It is thus not possible to provide generally applicable values. In this standard, the respective screw connection geometries are assigned a screwdriving condition number. For the valid screwdriving condition number, you must refer to the drawing. The respective values may not be adopted for or transferred to apparently similar geometries! For the applicable screw parameters, refer to the respective screwdriving condition number in the "Table of tightening torques" (see section 2). Identification in the drawing:

MOUNTING INSTRUCTION ACCORDING TO LH STANDARD 1065 0522 - 0000 Screwdriving condition number

5.

Tightening method

There are various ways in which a screw connection can be tightened according to the angle-controlled tightening method. In the sections below, tightening by hand with a torque wrench and tightening with a torque-controlled electric or hydraulic wrench are described. The preferred method is tightening with a controlled electric of hydraulic wrench.

5.1.

Preparation

All contact surfaces, and in particular the contact surfaces of the screw head and the nut must be cleaned. Ensure that the contact surfaces are free of tinder, burrs and weld splashes. If necessary, remove weld splashes with a scraper. Remove excess grease along the thread length. This applies in particular to flat-bottom holes. All surfaces of components that are to be placed against each other with the screw connection must be cleaned and degreased.

1.30.2


Product code

Standard 5.2.

Version

10650522 000

Tightening with torque wrench

1. Using a torque wrench, apply the pre-torque MAF as specified in the "Table of tightening torques" for the respective screwdriving condition. 2. Apply a mark on the screw head that is aligned with a mark applied on the component (see figure 4). 3. Apply a third mark on the component, which indicates the additional angle of rotation the "Table of tightening torques" for the screwdriving condition marked in the drawing.

specified in

4. Using a suitable wrench (torque or standard wrench), turn the screw so that mark 1 and mark 3 are aligned (see figure 5). Figure 4

Marks on screw and component after application of pre-torque

Figure 5

Marks on screw and component turning by additional angle of rotation

Direction of rotation

5.3. Tightening with electric or hydraulic wrench 1. In the control program of the electric or hydraulic wrench, enter the values for pre-torque MAF, additional angle of rotation and the tolerance window for the additional angle of rotation and the final tightening torque. The values are indicated for each screwdriving condition in the "Table of tightening torques". 2. Turn the screws by hand or with a pneumatic wrench. When using a pneumatic wrench, ensure that the skews are only turned, i.e. that the torque of the pneumatic wrench is smaller than the pretorque! 3. Place the electric or hydraulic wrench on the screw head. Ensure that the reaction arm is suitably positioned. 4. Start the 2-step tightening procedure. 5. Check the achieved result (screw connection OK or NOK), indicated at the wrench tool. 6. Record the values of the achieved tightening torque and the additional angle of rotation. 7. After tightening of all screw connections, test a number of screws using the tightening torque according to LH standard 10409969. The number of screws to be tested depends on the total number of screw connections and is normally between 1 and 3 (see also section 6).

6.

Checking during routine maintenance 1.30.3


Standard

Product code Version

10650522 000

Screw connections must normally be checked by service personnel at predefined intervals for proper fixture. For screw connections established with the angle-controlled tightening method, observe the following: The connections can only be checked as regards the correct tightening torque. To do this, use a torque wrench and apply the tightening torque specified in LH standard 10409969 to the screw connection.

7. Revision log First issue

1.30.4


MJFCIFSS

2. Torque table for LH standard 10650522

Status: 31.01.2011

(Turning angle controlled tightening procedure)

Tightening case No.

0001 0002 0003 0004 0005 0006 0007 0008 0009 0010 0011 0012 0013 0014 0015 0016 0017 0018 0019 0020 0021 0022 0023 0024 0025 0026 0027 0028 0029 0030 0031 0032 0033 0034 0035 0036

Property Class

10.9 10.9 10.9 10.9 10.9 10.9 10.9 10.9 10.9 10.9 10.9 10.9 10.9 10.9 10.9 10.9 10.9 10.9 10.9 10.9 10.9 10.9 10.9 10.9 12.9 10.9 10.9 12.9 12.9 10.9 10.9 12.9 10.9 10.9 10.9 12.9

Thread

Pitch

Nominal Length

Threaded Length

Claming Length

d [mm] M16 M16 M20 M20 M20 M20 M20 M20 M20 M24 M24 M27 M27 M27 M27 M36 M30 M30 M30 M36 M42 M24 M24 M30 M56 M30 M30 M30 M30 M20 M20 M20 M16 M16 M16 M16

p [mm] 2 2 2,5 2,5 2,5 2,5 2,5 2,5 2,5 3 3 3 3 3 3 4 3,5 3,5 3,5 4 4,5 3 3 3,5 5,5 3,5 3,5 3,5 3,5 2,5 2,5 2,5 2 2 2 2

L [mm] 55 80 70 80 70 90 90 70 105 100 125 110 150 140 150 265 190 200 190 200 300 96,5 96,5 119,4 220 150 150 150 150 50 60 110 50 45 70 110

Lg [mm] 49 38 66 46 66 46 46 66 46 56 56 66 66 66 66 100 72 72 72 84 109 96,5 96,5 119,4 137 72 72 72 72 46 55 55 45 40 65 105

Lk [mm] 34 52 47 53 45 53 63 44 77 65 97 77 116 95 134 208 141,5 136,5 134 157 265 50,2 53,2 57,6 125 106 101 112 101 24 29 87 19 18 39 43,5

The date indicates the latest status of the table. This document is not subject to revision!

Head Bearing Surface dw [mm] 24 24 30 30 30 30 30 30 30 36 36 41 41 41 41 55 46 46 46 55 65 36 36 46 85 46 46 46 46 30 30 30 24 24 24 24

Clearance Component Hole Size dh [mm] 17 17,5 21 22 21 22 22 21 22 26 26 29 30 29 30 37,5 32 32 33 38 45 26 26 33 62 33 32 33 32 21 22 21 17,5 17,5 17,5 17,5

DA [mm] 45 36 45 40 45 40 40 45 60 63 70 65 70 50 65 70 105 125 75 80 110 36 36 46 110 66 55 66 55 50 46 150 90 60 130 116

Seating Torque MAF [Nm] 113 113 191 192 191 192 192 191 192 332 332 484 487 484 487 1142 659 659 663 1145 1842 332 332 663 5186 663 659 775 771 191 192 223 113 113 113 133

Further Turning Angle [°] 50 +5 46 +5 61 +5 49 +5 58 +5 42 +5 54 +5 57 +5 54 +5 45 +5 59 +5 59 +5 72 +5 65 +5 91 +5 94 +5 62 +5 52 +5 60 +5 74 +5 104 +5 68 +5 72 +5 68 +5 67 +5 60 +5 60 +5 77 +5 71 +5 33 +5 39 +5 77 +5 30 +5 29 +5 56 +5 75 +5

Torque Range (Quality Control for Assembly) Min. Max. [Nm] [Nm] 226 416 227 418 441 810 445 818 441 810 445 818 445 818 441 810 445 818 766 1409 766 1409 1113 2071 1120 2086 1113 2071 1120 2086 2627 4887 1517 2811 1517 2811 1526 2829 2633 4900 4230 7901 766 1409 766 1409 1526 2829 11878 22360 1526 2829 1517 2811 1786 3310 1776 3289 441 810 445 818 516 948 227 418 227 418 227 418 266 489

Page 1 of 2


MJFCIFSS

2. Torque table for LH standard 10650522

Status: 31.01.2011

(Turning angle controlled tightening procedure)

Tightening case No.

0037 0038 0039 0040 0041 0042 0043 0044 0045 0046 0047 0048 0049 0050 0051 0052 0053 0054 0055 0056 0057 0058 0059 0060 0061 0062 0063 0064 0065 0066 0067 0068 0069 0070 0071 0072

Property Class

10.9 10.9 10.9 12.9 12.9 10.9 10.9 12.9 12.9 10.9 10.9 10.9 12.9 10.9 10.9 10.9 10.9 10.9 12.9 12.9 12.9 12.9 12.9 10.9 10.9

Thread

Pitch

Nominal Length

Threaded Length

Claming Length

d [mm] M30 M30 M42 M24 M24 M30 M30 M20 M20 M30 M30 M30 M12 M56 M20 M30 M30 M30 M16 M20 M20 M20 M16 M30 M30

p [mm] 3,5 3,5 4,5 3 3 3,5 3,5 2,5 2,5 3,5 3,5 3,5 1,75 5,5 2,5 3,5 3,5 3,5 2 2,5 2,5 2,5 2 3,5 3,5

L [mm] 100 200 320 130 100 230 200 90 100 250 200 180 65 420 120 95,8 140 110 70 90 110 80 120 160 140

Lg [mm] 95 72 109 60 54 85 72 85 95 66 72 72 36 137 46 95,8 135 105 48 58 58 58 115 135 105

Lk [mm] 68,2 156 250 91 65 178 156 54,9 66,3 198 145 133 47 324 101 52,8 107 53,5 42,4 69,8 82,8 41,4 83 114,5 58,5

The date indicates the latest status of the table. This document is not subject to revision!

Head Bearing Surface dw [mm] 46 46 65 36 36 46 46 29 29 46 46 46 18 85 30 46 46 46 24 30 30 30 24 46 46

Clearance Component Hole Size dh [mm] 33 33 45 26 26 33 33 21 21 32 32 33 13,5 62 22 33 32 32 17,5 21 21 21 17 32 32

DA [mm] 85 66 100 86 44 75 70 57 57 55 125 75 20 244 40 51 100 100 130 40 40 40 34 100 100

Seating Torque MAF [Nm] 663 663 1842 388 388 663 663 221 221 659 659 663 54 4432 192 663 659 659 133 223 223 223 132 659 659

Further Turning Angle [°] 63 +5 75 +5 89 +5 61 +5 58 +5 82 +5 74 +5 82 +5 98 +5 89 +5 59 +5 64 +5 73 +5 86 +5 77 +5 59 +5 93 +5 50 +5 55 +5 83 +5 84 +5 51 +5 148 +5 89 +5 39 +5

Torque Range (Quality Control for Assembly) Min. Max. [Nm] [Nm] 1526 2829 1526 2829 4230 7901 896 1648 896 1648 1526 2829 1526 2829 511 939 511 939 1517 2811 1517 2811 1526 2829 110 198 10150 19108 445 818 1526 2829 1517 2811 1517 2811 266 489 516 948 516 948 516 948 265 486 1517 2811 1517 2811

Page 2 of 2


Service Manual

Fuels, lubricants and process chemicals General information

Fuels, lubricants and process chemicals 1

General information Observe the instructions for lubricants and process chemicals. Lubricate the machine and change the oils at the prescribed intervals. For more information, see lubrication chart and inspection and maintenance schedule. Keep workplaces for these activities clean. This enhances the service life and reliability of the machine. All work on the machine must be carried out while it is standing on firm and level ground. Shut down the diesel engine, remove the ignition key and set the battery main switch to position 0 (OFF). Clean lubricating nipples before adding grease. Clean all filling points and the area around them before opening the caps and screws. The oil should be changed while it is at operating temperature. After each oil change or refilling, check the fill level in the respective unit (the specified fill levels are guide values). Collect used oil and chemicals in suitable containers and dispose of them according to the applicable statutory regulations.

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Fuels, lubricants and process chemicals

Service Manual

Recommended lubricants

2

3

Recommended lubricants Designation

Recommended lubricant

Diesel engine

Liebherr Motoroil 10W-40 Liebherr Motoroil 10W-40 low ash Liebherr Motoroil 5W-30

Hydraulic system (system capacity / oil change volume / tank capacity)

Liebherr Hydraulic Basic 68 Liebherr Hydraulic Basic 100 Liebherr Hydraulic HVI Liebherr Hydraulic Plus Liebherr Hydraulic Plus Arctic

Slewing gear mechanism

Liebherr Gear Basic 90 LS

Transmission

Liebherr Motoroil 10W-40

Rigid axle

Liebherr Gear Basic 90 LS

Wheel hubs of the rigid axle

Liebherr Gear Basic 90 LS

Steering axle

Liebherr Gear Basic 90 LS

Wheel hubs of the steering axle

Liebherr Gear Basic 90 LS

Tracks and gearing of the slewing ring, bearing of the equipment

Liebherr Universalfett 9900

Hinges, joints, locks

Engine oil

Symbol

-

Recommended fuels and chemicals

Designation

Recommended fuel

Fuel tank

Conventional diesel fuel

Coolant

Liebherr Antifreeze Mix Liebherr Antifreeze Concentrate

Windscreen washer system

Conventional windscreen cleaning agent or denatured alcohol

1.51.2 copyright by

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Symbol

-


Service Manual

Fuels, lubricants and process chemicals Specifications for fuels, lubricants and process chemicals

4 4.1 4.1.1

Specifications for fuels, lubricants and process chemicals Diesel fuels Specification The diesel fuels must meet the minimum requirements of the fuel specifications outlined below. Approved specifications: – DIN EN 590 – ASTM D 975 (89a) - 1D and 2D The fuel supplier must submit a fuel certificate (fuel specification, sulphur content, lubricity, cetane number)

4.1.2

Sulphur content, lubricity The following restrictions apply: – Do not use fuels with a sulphur content of more than 1 % (10,000 mg/kg). – When using engine oils conforming to specification E6 and standard oil change intervals (every 500 operating hours): Do not use fuels with a sulphur content of more than 0.005 % (50 mg/kg). – When using exhaust gas purification units (particle filters): Do not use fuels with a sulphur content of more than 0.005 % (50 mg/kg). – Diesel engines with external exhaust gas return system: We recommend using fuels with a sulphur content of less than 0.005 % (50 mg/kg). Additional information: see oil change intervals for operation under adverse conditions. According to DIN EN 590, diesel fuels must have a lubricity determined by HFRR test (corrected wear scar diameter [wsd 1.4] at 60 °C) of maximum 460 µm The ASTM D 975 fuel standard does not specify that the fuels must undergo a fuel lubricity test. The required additives should be added by the supplier, who is responsible for the quality of the fuel.

4.1.3

Cetane number ASTM D 975 fuels must have a cetane number of minimum 45. A cetane number of more than 50 is preferable, especially at temperatures below 0 °C (32 °F).

4.1.4

Low temperature operation At low temperatures, paraffin crystals are formed in the diesel fuel. They increase the flow stress in the fuel filter so that the diesel engine might not be supplied with sufficient fuel. Caution! The use of an unsuitable fuel can cause damage to the diesel engine. Adding petroleum, normal car petrol or other substances damages the injection system. Never add petroleum, car petrol or other additives to the diesel fuel. At ambient temperatures of below -20 °C: use start-up aid (e.g. fuel filter heater). For operation of the machine under arctic conditions: use special diesel fuels that offer adequate viscosity.

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Fuels, lubricants and process chemicals

Service Manual

Specifications for fuels, lubricants and process chemicals

4.2 4.2.1

Lubricating oil for the diesel engine Quality Modern diesel engines must be lubricated with high-performance oils. They consist of a basic oil with special additives. The lubricating oil requirements for LIEBHERR diesel engines are based on the following standards and regulations: Designation

Specification

ACEA classification (Association des Constructeurs Européens de l'Automobile)

E4, E6, E7 Caution: particle filter only permitted with E6

API classification (American Petroleum Institute)

CH-4, CI-4 Caution: observe shorter oil change intervals

Tab. 1

Lubricating oil specifications

If LIEBHERR oils are not available locally, use an oil that conforms to the specifications (before choosing an oil, contact our customer service department).

4.2.2

Viscosity The choice of the lubricating oil viscosity is based on the SAE classification (Society of Automotive Engineers). The SAE classification does not provide any indication as regards the quality of a lubricating oil. The relevant factor for the correct choice of SAE class is the ambient temperature. Excessively high viscosity might lead to start-up problems. If the viscosity is too low, the oil's lubrication might not be sufficiently efficient. The temperature ranges shown in the diagram are approximate ranges that might temporarily be exceeded.

Fig. 1

Temperature-based selection of the SAE class

For ambient temperatures of -20 °C (-4 °F) to +45 °C (+113 °F), we recommend the following diesel engine oils: Liebherr Motoroil 10W-40, specification ACEA E4 Liebherr Motoroil 10W-40 low ash, specification ACEA E6 For ambient temperatures of -30 °C (-22 °F) to +30 °C (+86 °F), we recommend the following diesel engine oils: Liebherr Motoroil 10W-30, specification ACEA E4

4.2.3

Adverse operating conditions affecting the oil change intervals Oil change intervals: see chapter "Inspection and maintenance schedule".

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Service Manual

Fuels, lubricants and process chemicals Coolant for the diesel engine

Subsequent oil changes depend on the climate, the sulphur content of the fuel and the oil grade. For details, see the table below. If the specified operating hours (h) per year are not reached, the diesel engine oil and the filter must be changed at least once every year. A number of adverse factors (unfavourable operating conditions) affect the length of the maintenance interval. Possible adverse factors: – Frequent cold starts – Sulphur content of fuel – Operating temperature If such factors apply, the oil and filter must be changed according to the table below. Adverse factor

Oil quality CH-4, CI-4

E4 / E7*

Operating conditions

Sulphur content of fuel

Interval

Normal climate, to -10 °C

to 0.5 %

250 h

500 h

between 0.5 % and 1 %

125 h

250 h

below -10 °C

to 0.5 %

125 h

250 h

between 0.5 % and 1 %

not permissible

125 h

Adverse factor

Oil quality E6

Operating conditions

Sulphur content of fuel

Normal climate, to -10 °C

to 0.005 %

500 h

between 0.005 % and 0.05 %

250 h

below -10 °C

Interval

between 0.0501 % and 0.1 %

125 h

to 0.005 %

250 h

between 0.005 % and 0.05 %

125 h

between 0.0501 % and 0.1 %

not permissible

h= operating hours * TBN minimum 13 mg KOH/g

5 5.1

Coolant for the diesel engine General recommendations The radiator system works only properly when pressurised. It is therefore imperative that it is kept clean and sealed at all times, that the radiator sealing and operating valves work properly and that the required coolant level is maintained. Corrosion inhibitors/antifreeze agents approved by LIEBHERR ensure proper protection against frost, corrosion and cavitation without causing damage to seals and hoses and without foaming. Coolants that contain unsuitable corrosion inhibitors or antifreeze agents or that have been prepared incorrectly might cause failure of assemblies and component parts in the coolant circuit due to cavitation or corrosion. Heat-insulating deposits on components that conduct heat might result in overheating and consequently failure of the engine.

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Fuels, lubricants and process chemicals

Service Manual

Coolant for the diesel engine

5.2

Water (fresh water) Clear and clean water free of particles that meets the following chemical requirements is suitable for use as a coolant. Do not use sea water, brackish water, brine or industrial wastewater. Designation

Value / unit

Total alkaline earth metals (water hardness)

0.6 to 3.6 mmol/l (3 to 20 °dH)

pH at 20 °C

6.5 to 8.5

Chloride ion concentration

max. 80 mg/l

Sulphate ion concentration

max. 100 mg/l

Tab. 2

Fresh water quality

Designation

Value / unit

Total alkaline earth metals (water hardness)

0.6 to 2.7 mmol/l (3 to 15 °dH)

pH at 20 °C

6.5 to 8.0

Chloride ion concentration

max. 80 mg/l

Sulphate ion concentration

max. 80 mg/l

Tab. 3

Fresh water quality with use of DCA 4*

* = Diesel Coolant Additives

Water analysis results are available from the local authorities.

5.3

Mixing ratio for coolant The coolant must contain min. 50% corrosion inhibitor and antifreeze agent at all times of the year. Mixing ratio Outdoor temperature to Water %

Corrosion inhibitor/antifreeze agent %

-37 °C

50 %

50 %

-50 °C

40 %

60 %

Tab. 4

Permissible mixing ratio (for all seasons)

Fig. 2

Temperature-based mixing ratio of water + corrosion inhibitor / antifreeze agent

A Ambient temperature B Corrosion inhibitor/antifreeze agent concentration in coolant

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Service Manual

Fuels, lubricants and process chemicals Coolant for the diesel engine

5.4

Permissible corrosion inhibitors/antifreeze agent Note! Improper mixing of different products might negatively affect the properties of the coolant and cause damage to the cooling system. Use only approved products. Do not mix different products. Never mix products containing silicone with silicone-free products. If the recommended LIEBHERR product is not available locally: contact the LIEBHERR customer service department; choose a product conforming to the "Coolant specifications for LIEBHERR diesel engines". Concentrate Product name

Manufacturer

Liebherr Antifreeze Concentrate

Liebherr

Ready-mixed corrosion inhibitor/antifreeze agent (premix) Product name

Manufacturer

Liebherr Antifreeze Mix

Liebherr

Premix = ready-mixed product (50 % water and 50 % corrosion inhibitor/antifreeze agent)

5.5

Approved corrosion inhibitors without antifreeze agent Note! Improper mixing of different products might negatively affect the properties of the coolant and cause damage to the cooling system. Use only approved products. Do not mix different products. Never mix products containing silicone with silicone-free products. If the recommended LIEBHERR product is not available locally: contact the LIEBHERR customer service department; choose product conforming to the "Coolant specifications for LIEBHERR diesel engines".

In exceptional circumstances and at ambient temperatures that are always above the freezing point, e.g. during use in tropical regions where there are no corrosion inhibitors/antifreeze agents available, the following inhibitors must be added to the coolant: – DCA 4 (Diesel Coolant Additives 4) – Caltex / Chevron / Havoline / Total product In this case, the coolant must be changed annually. As part of routine maintenance work, check the concentration and correct it, if necessary. Product name

Manufacturer

DCA 4 Diesel Coolant Additives

Fleetguard / Cummins Filtration

Caltex CL Corrosion Inhibitor Concentrate

Chevron Texaco

Chevron Heavy Duty Extended Life Corrosion Inhibitor Nitrite Free (ELC)

Chevron Texaco

Havoline Extended Life Corrosion Inhibitor (XLI)

Chevron Texaco

Total WT Supra

Total, Paris

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Fuels, lubricants and process chemicals

Service Manual

Hydraulic oil

6

Hydraulic oil Hydraulic oils must meet the requirements outlined below. Maximum water content of hydraulic oil: < 0.1 %

6.1

Hydraulic oil LIEBHERR recommends using the following hydraulic oils in its machines (depending on temperature range):

Fig. 3

Hydraulic oil for use as hydraulic fluid (ISO classes)*

A Ambient temperature B Cold-start range with warm-up C Operating range * temperature-based selection of the ISO class

Liebherr Hydraulic Plus and Liebherr Hydraulic Plus Arctic are suitable for both bio and longterm use. If LIEBHERR oils are not available locally, use one of the engine oils listed in the section below (before choosing an oil, contact the respective customer service department). Use only LIEBHERR hydraulic oils. The use of other oils is not permitted.

6.2

Engine oil used as hydraulic fluid When using engine oil (third-party products) as hydraulic fluids, we advise customers to request a certificate from the oil manufacturer, confirming that the product meets the following specifications. Engine oils that are to be used as hydraulic fluids must conform to the following specifications: Single grade oils (1):

API - CD / ACEA - E1 (MB 226.0 and 227.0)

Multigrade oils (2):

API - CD, CE, CF / ACEA - E2, E3, E4 (MB 227.5, 228.1, 228.3 and 228.5)

Tab. 5

Engine oils for use as hydraulic fluids

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Service Manual

Fuels, lubricants and process chemicals Hydraulic oil

Fig. 4 A

Ambient temperature

1

Single grade oils

B

Cold-start range with warm-up

2

Multigrade oils

C

Operating range

*

6.3

Engine oil for use as hydraulic fluid (SAE classes)*

temperature-based selection of the SAE class; for deviating viscosity grade, consult LIEBHERR customer service.

Warm-up instruction The black bar B indicates ambient temperatures that are up to 20 °C below the operating range C. For cold starting at an ambient temperature below range B, the following warm-up instruction for hydraulic oil applies: 1.: Start the diesel engine and run it at approx. 1 / 2 rated speed. Carefully activate the working hydraulics. Operate the hydraulic cylinders and move them to the stop. After approx. 5 minutes, start the travel hydraulics. Warm-up time: approx. 10 minutes. For cold starting at even lower ambient temperatures, follow the warm-up instruction below: 2.: Before starting the engine, warm up the hydraulic oil tank. Then proceed according to the warm-up instruction in 1.

6.4

Biodegradable hydraulic oils Caution! Do not mix bio hydraulic oils with mineral oils! When mixing ester-based biodegradable hydraulic oils with mineral oils, aggressive chemical reactions might occur, causing damage to the hydraulic equipment. Therefore never mix biodegradable hydraulic fluids from different producers, and never mix bio hydraulic oils with mineral oils! LIEBHERR recommends using the following hydraulic oils in its machines (depending on the temperature range): Liebherr Hydraulic Plus or Liebherr Hydraulic Plus Arctic These products are polyalphaolefins (HEPR) conforming to CEC-L-33-A-93, and are biodegradable.

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Fuels, lubricants and process chemicals

Service Manual

Hydraulic oil When using these hydraulic oils, bypass filtration might be omitted. If these oils are not available locally, use a fully saturated hydraulic environmental ester synthetic (HEES fluid) (before choosing an oil, contact the respective customer service department). When using synthetic ester-based fluids, bypass filtration is mandatory. When using such fluids, we recommend replacing the hydraulic hoses every 4000 operating hours or latest every 4 years. Do not use vegetable oils, as they do not possess the necessary thermal stability. The use of polyglycols is not permissible, as they cause damage to paintwork. When using third-party products, we advise customers to request a certificate from the oil manufacturer, confirming that the product meets the above specifications.

6.5

Monitoring, filter change and oil change Symbol

Description Filter change for hydraulic oil

Oil sampling

Tab. 6

Key to diagrams

Hydraulic oil in normal use:

Fig. 5

Oil sampling and filter change in normal use

h

Operating hours

1

First oil sample

a

Mineral oil

2

Second oil sample

b

Biodegradable hydraulic oil

3

Subsequent oil samples: every 500 operating hours

Interval for the change of the hydraulic oil return filter (20 / 5 Âľm): first change after 500 and 1000 operating hours, then every 1000 operating hours and after each hydraulic oil change. Interval for mineral oil change: every 2000 operating hours, or when indicated by the lab report or analyses. Oil change intervals for mineral oils may only be extended, if an oil analysis has been carried out. The first analysis must be performed after 1500 operating hours, subsequent analyses must be carried out every 500 operating hours. The oil change intervals for bio oils are determined solely by oil analyses and lab reports.

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Service Manual

Fuels, lubricants and process chemicals Hydraulic oil

For bio oils, a first analysis must be carried out after a change of oil type* and subsequently every 500 operating hours. *

Change of oil type = change from mineral oil to biodegradable hydraulic oil

Hydraulic fluid used in dust intensive applications:

Fig. 6

Oil sampling and filter change intervals for machines used for dust-intensive applications

h

Operating hours

1

First oil sample

a

Mineral oil

2

Second oil sample

b

Biodegradable hydraulic oil

3

Subsequent oil samples: every 250 operating hours

Interval for the change of the hydraulic oil return filter (10 µm): first change after 500 operating hours, then every 500 operating hours and after each hydraulic oil change. Interval for mineral oil change: every 500 operating hours, or when indicated by the lab report or analyses. The oil change intervals for bio oils are determined solely by oil analyses and lab reports. For bio oils, a first analysis must be carried out after a change of oil type* and subsequently at least every 500 operating hours. *

6.6

Change of oil type = change from mineral oil to biodegradable hydraulic oil

Recommendations for oil analyses For oil analyses, LIEBHERR recommends contracting WEAR-CHECK* and changing the oil when indicated by the test results in the lab report. For more information, see customer service and product information. *

6.7

Yellow kit for biodegradable hydraulic oils Green kit for mineral oils

Tips for the reduction of contamination of the hydraulic oil in machines used for dust-intensive applications If the machine is frequently operated with a hydraulic hammer or under similar conditions (high dust production), the hydraulic oil might become more heavily contaminated than under normal working conditions. To prevent premature wear of the hydraulic components, shorten the oil change intervals (or oil sampling intervals respectively) and observe the following instructions: – The filter cartridge(s) in the return filter must be replaced every 500 operating hours and after every hydraulic oil change. – Use 10-µm filter cartridges instead of the standard 20 / 5-µm cartridges.

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Fuels, lubricants and process chemicals

Service Manual

Lubricants for axles and gearboxes – The 2-µm breather filter must be replaced every 500 operating hours and after every hydraulic oil change. Note! Machines delivered with hydraulic hammer attachment and retrofitted hydraulic hammer kits are already fitted with 10-µm filter cartridges in the return filter.

7 7.1

Lubricants for axles and gearboxes Quality Recommended lubricant

Specification

Liebherr Gear Basic 90 LS

API: GL-5 MIL-L: 2105 B

Liebherr Gear Plus 20W-40

API: from GL4 ZF: TE-ML 05F, 06K, 17E

Liebherr Gear Hypoid 90 EP

API: GL5 MIL-L: 2105 B, C, D

Liebherr Hypoid 85W-140 EP

API: GL-5 MIL-L: 2105 D, PRF-2105 E

Liebherr Hydraulic-Gear ATF

GM: Dexron II D ZF: TE-ML 03D, 04D, 11A, 14A, 17C

Liebherr Syntogear Plus 75W-90

API: GL-4, GL-5, MT-1 MIL-L: 2105 D, PRF-2105 E

Tab. 7

Lubricating oil specifications

If LIEBHERR oils are not available locally, use an oil that conforms to the specifications (before choosing an oil, contact our customer service department).

1.51.12 copyright by

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Service Manual

Fuels, lubricants and process chemicals Lubricating oil for transmission

7.2

Viscosity

Fig. 7

Temperature-based selection of the SAE class

A

Ambient temperature

1

Use in gearboxes

2

Use in automatic transmissions

3

Use in axles

4

Use in pump distributor gear systems

*

If the pump distributor gear is equipped with an oil cooler, the oil is not suitable for the marked temperature range (shaded area).

The choice of the lubricating oil viscosity is based on the SAE classification (Society of Automotive Engineers). The SAE classification does not provide any indication as regards the quality of a lubricating oil. The relevant factor for the correct choice of SAE class is the ambient temperature. Incorrect viscosity can impair the operation of axles and gearboxes. The temperature ranges shown in the diagram are approximate ranges that might temporarily be exceeded.

8

Lubricating oil for transmission Recommended lubricant

Specification

Liebherr Motoroil 10W-40

API: CF

If LIEBHERR oils are not available locally, use an oil that conforms to the specifications (before choosing an oil, contact our customer service department).

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Fuels, lubricants and process chemicals

Service Manual

Grease

9 9.1

Grease Quality Recommended lubricant

Specification

Liebherr Universalfett 9900

Soap-base grease (lithium complex) KPF 2 N - 25 (DIN 51502) NLGI grade: 2 (DIN 51818) VKA welding force: > 6000 N (DIN 51350 / 4)

Liebherr Universalfett Arctic (for low-temperature operation)

Soap-base grease (lithium complex) KPFHC 1 N - 60 (DIN 51502) NLGI grade: 1 (DIN 51818) VKA welding force: > 5500 N (DIN 51350 / 4)

The grease is used for both automatic and manual machine lubrication. it is supplied by the central lubrication system or through lubrication nipples to the respective lube points. Examples: – – – –

9.2

Slewing ring bearings Crown gears, geared wheels Bolts, axles and screws Attachments

Operating temperature

Fig. 8

10

Operating temperature for Liebherr greases

A

Grease temperature

*

The grease is not suitable for the temperature range (shaded), if used in a central lubrication nipple.

**

The grease may only be within the temperature range (shaded) for short periods of time. Peak temperatures of max. 200 °C (392 °F) are possible.

Lubricants and care products for electrical and mechanical components Medium, purpose

Product (manufacturer)

Contact spray for slip rings

Cramolin

Lubricant for pistons, piston nuts and for the mounting of piston rod bearings at hydraulic cylinders

Gleitmo 800

Special corrosion inhibitor for mounting recesses of sealing elements at hydraulic cylinders

Rostilo Tarp CFX

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Service Manual

Fuels, lubricants and process chemicals Lubricants and care products for electrical and mechanical components

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Fuels, lubricants and process chemicals

Service Manual

Lubricants and care products for electrical and mechanical components

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Service Manual

SUBGROUP - INDEX Section

Group

Type

Special tools - general information

2.01.1

A 934 C-LI 25436A 944 C-LI 24475A 954 C-LI 21416-

Special tools for diesel engines

2.02.1

A 934 C-LI 25436A 944 C-LI 24475A 954 C-LI 21416-

Special tools for hydraulic unit

2.05.1

A 934 C-LI 25436A 944 C-LI 24475A 954 C-LI 21416-

Special tools for electrical equipment

2.06.1

A 934 C-LI 25436A 944 C-LI 24475A 954 C-LI 21416-

Special tools for slewing gear mechanism

2.07.1

A 934 C-LI 25436A 944 C-LI 24475A 954 C-LI 21416-

Special tools for axles (Kessler)

2.09.1

A 934 C-LI 25436A 944 C-LI 24475A 954 C-LI 21416-

Stroke measuring device for control block

2.10.1

A 934 C-LI 25436A 944 C-LI 24475A 954 C-LI 21416-

Assembly tools for hydraulic cylinders

2.12.1

A 934 C-LI 25436A 944 C-LI A 954 C-LI 21416-

Mounting device for piston rod bearings

2.13.1

A 934 C-LI 25436A 944 C-LI 24475A 954 C-LI 21416-

Slotted nut wrench for slewing gear

2.14.1

A 934 C-LI 25436A 944 C-LI 24475A 954 C-LI 21416-

2.1 MJFCIFSS


Service Manual

Mounting device for multi-disc brake

2.15.1

2.2 MJFCIFSS

A 934 C-LI 25436A 944 C-LI 24475A 954 C-LI 21416-


Service Manual

Special tools - general information

Special tools - general information for maintenance and repair Representation

no.

Designation

1 2

Mach.

Size

ID no.

Measuring neck

NW 8 NW 10 NW 12

7019906 7002404 7008688

all types

4

Pressure gauge connection

R 1/2"

7002436

all types

5

Pressure gauge direct connection

R 1/2"

7002435

all types

7

High-pressure hose length

1,000 mm

7002437

all types

1,500 mm

7002475

5,000 mm

7363732

M10X1 M12X1.5 M14X1.5 M16X1.5 R 1/4"

5005180 7402580 5004002 7361345 7362579

8

10 11 12 13 14

Screw coupling assembly, complete

Application

Connection of the pressure gauges to all measuring points (measuring neck no.1/2 and screw couplings 10-14)

all types

2.01.1 copyright by

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Special tools - general information

Representation

Service Manual

no.

Designation

15

Pressure gauge

Mach.

Application

all types

8042578

Measuring of operating pressures of one or more hydraulic circuits.

5002865

* glycerine dampened

Size

ID no.

0-1.6 bar

8042577

0-1.6 bar * 0-10 bar * 0-40 bar * 0-60 bar * 0-250 bar *

21

0-400 bar *

7500002

22

0-600 bar *

5002866

16 17 18 19 20

30

Differential pressure measuring kit, consisting of:

7361288 5002867 7361285

10288229

30.1

all types

Measuring of difference p between the pump and the LS pressure.

10288155 1 manual measuring device 3010

30.2

10288152 1 data cable

30.3

10288154 2 Measuring cables

30.4

0-600 bar

2 Pressure sensor 30.5

10288153

10288151 1 power adapter

30.6

7025273

30.7 30.8

Vehicle connecting cable not included in delivery! Pressure sensor Pressure sensor

6140626 01 6140647 01

33

Fitting

4901372

34

Measuring neck with metal cap

7002404

35

Union nut

4774002

36

Cutting ring

4774001

44

Measuring adapter

8504231

2.01.2 copyright by

MJFCIFSS

see sensors on Page 6

all types

Pressure compensation in connection with tool no. 30

all types

Measuring of current at pump regulation


Service Manual

Representation

Special tools - general information

no.

Designation

Mach.

Application

45

Adapter

9956422

all types

Measuring of the inductive pickup B12 from 3-pin (LH) to 2-pin (Deutz), in conjunction with tool no. 44

46

Measuring cables

9956436

all types

Measuring and testing of solenoid valves

60

Piezzo speed counter

A 2106

10286429

all types

Measuring of engine speed via pulse frequency of injection line

Terminal sensor Terminal sensor Terminal sensor

5.0 mm 7.0 mm 8.0 mm

10492920 10492922 10492925

62

Ornel speed meter

HT 460

7006974

all types

Measuring of speed with reflective strips

63

Shimpo speed meter

DT 205

7364284

Size

ID no.

Strips 64

65

614063201

Multimeter with digital display

Chauvin Arnoux

10018500

with no. 63

all types

Measuring of voltage, current and resistance in electric components and valves

2.01.3 copyright by

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Special tools - general information

Representation

Service Manual

no.

Designation

70

Thermometer non-contact (infrared)

72

Thermometer with probe and sensor (magnetic)

80

Hand pump

8145666

82

Sampling valve for oil samples, alternative to hand pump 80

7019068

84

Oil analysis kit *

85

Oil analysis kit *

Size

ID no. 10024185

GTH 1150

no. 1

Mach.

Application

all types

Monitoring of temperature of a medium / outside temperature of a unit

all types

Sampling of oil for analysis

all types

6 oil samples

7020372

7018368

8145660

1 oil sample

*Analyses carried out by WAER CHECK Germany, lab report in German

88

Bio oil analysis kit *

89

Bio oil analysis kit *

no. 1

7026817

all types

7026088

1 oil sample

6 oil samples

*Analyses carried out by WAER CHECK Germany, lab report in German 90

REFCO vacuum pump

RD-4

2.01.4 copyright by

MJFCIFSS

7027552

all types

Maintenance and repair of a/c system


Service Manual

Representation

Special tools - general information

no.

Designation

91

Mach.

Application

all types

See item 90

all types

See item 90

7027558

all types

Maintenance and repair of a/c system

M37X1 M42X1.5 M48X1.5

9583459 9583521 9583522

all types

Dismantling of grapple bolts

M42X1.5 M48X1.5 M58X1.5

9584738

all types

Removal of Passfix bolts

Size

ID no.

ITE filling hose, blue

1,500 mm

7027553

92

ITE filling hose, yellow

1,500 mm

7027554

93

ITE filling hose, red

1,500 mm

7027555

94

ITE HGV coupling

253a

7027556

95

ITE HGV coupling

254 a

7027557

96

4-valve test fittings

M4WS5 C

100 101 102

Dismantling tool

105

Universal Passfix puller

2.01.5 copyright by

MJFCIFSS


Special tools - general information

Representation

Service Manual

no.

Designation

120

Diagnostic instrument

5010474

121

Adapter cable / data

9614382

Connection to cable harness in right bracket

122

Adapter cable / data

10025620

Direct plugging to the heating device

130

Testing tool for cooling system

7029179

all types

Pressurisation of engine cooling system (leakage test)

140

Torque wrench

10045464

all types

Tightening the hose clamps

150

B20 pressure switch conversion kit consisting of: screw-in stud T-connection fitting Measuring piece Screw nozzle

9645488

all types

Testing of switching pressure (dropping) of B20 pressure switch

Hand pump with pressure gauge

10454803

all types

Leakage test of backpressure line at particle filter installation

151 152 153 154

160

Size

4-20 Nm

ID no.

Mach.

Application

all types

Diagnostics of D5 WS auxiliary heating

7617216 7405617 7409919 7368150

Scope of delivery of the Litronic measuring system Depending on the requirements, there might be a need for various additional adapters and cables, which must be ordered separately. Item

Sensors

ID no.

2

OEM pressure sensor, measuring range 0 - 1000 bar, output 0 - 20 mA

3

OEM pressure sensor, measuring range 0 - 600 bar, output 0 - 20 mA

6*

6140 624 01

4

OEM pressure sensor, measuring range 0 - 60 bar, output 0 - 20 mA

3*

6140 625 01

2.01.6 copyright by

MJFCIFSS

1001 8329


Service Manual

Special tools - general information

Item

Sensors

ID no.

5

OEM pressure sensor, measuring range 0 - 10 bar, output 0 - 20 mA

1002 7591

6

OEM pressure sensor, measuring range -1 to +6 bar, output 4 - 20 mA (LWE)

5718 886 08

7

MINIMESS direct connection pressure sensor, 1620 screws

6*

6140 626 01

8

MINIMESS direct connection pressure sensor, 1620 screws, angled by 90°

3*

6140 647 01

9

Pt 100 temperature sensor, measuring range -50 °C to +200 °C

1*

6140 627 01

10

MINIMESS p / t coupling, screw series 1620, G 1/4"

1*

6140 628 01

11

MINIMESS P / T coupling, screw coupling 1620, M10 x 1.5

1*

1004 1274

12

RE 4 – 10 measuring turbine, measuring range 1 to 10 l/min

1*

5010 031

13

RE 3 – 75 measuring turbine, measuring range 7.5 to 75 l/min

1*

6410 629 01

14

RE 3 – 300 measuring turbine, measuring range 15 to 300 l/min

0*

6140 630 01

15

RE 3 – 600 measuring turbine, measuring range 25 to 600 l/min

2*

5009 492

16

DS 03 speed sensor, measuring range 1 to 9999 rpm

1*

6140 631 01

17

Spare reflector foil kit

1*

6140 632 01

18

Magnet holder, for DS 03 speed sensor

1*

6140 633 01

19

Inductive sensor for speed measurement

1*

6140 634 01

Item

Accessory

20

Transport case for RE 3 measuring turbine

1*

6140 635 01

21

MK 12 measuring cable for the connection of the sensors, length 12 m

12*

6140 636 01

22

MK 12 measuring cable for the connection of the sensors, length 12 m

4*

6140 637 01

23

MK 12 measuring cable for the connection of the sensors, length 12 m

1*

6140 638 01

24

Power supply cable for connection to the on-board power system, length 6 m

1*

6140 639 01

25

Power supply cable for connection to the on-board power system, length 12 m

0*

6140 640 01

26

DPU 411 thermal printer with power adapter

0*

6140 641 01

27

Thermal paper rolls for DPU 411

0*

6140 642 01

28

Centronics data cable, length 2 m (for DPU 411)

0*

6140 643 01

29

RS 232 data cable, length 2 m (for connection to PC)

1*

9684 327

30

AK 12 adapter cable (for speed measurement with GLR testing instrument)

1*

6140 648 01

31

Litronic Service Program, German version (for DOS operating system)

0*

6140 646 01

32

Evaluation software (d / e / f) on CD-ROM (for Windows, 16 bit)

1*

6004 401

33

Evaluation software (d / e / f) on CD-ROM (for Windows, 32 bit)

34

Measuring adapter for current measurement A 309 - R 317 Litronic

1*

8504 231

36

Y-adapter for current measuring Junior Timer plug

1*

9956 436

37

3-to-2 pin plug adapter

1*

9956 422

ID no.

* number of units for recommended basic equipment

2.01.7 copyright by

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Special tools - general information

Service Manual

2.01.8 copyright by

MJFCIFSS


Service Manual

Special tools for diesel engines

Special tools for diesel engines Maintenance and setting instructions for Liebherr diesel engines Representation

Machi ne

Application

all types

Measurement of compression pressure

0524044

all types

Insert at the position of the injection valve

Nozzle tester

7361236

all types

Testing of injection nozzles

4

High-pressure hand pump with accessories

7009318

all types

Checking and adjustment of start of delivery of the injection pump

10

Measuring device

7022420

all types

Checking and adjustment of start of delivery of the injection pump

No.

Designation

Size

1a

Compression pressure tester

1b

Diagram sheets for item 1a

2

Connecting piece for compression pressure tester

3

ID no. 8008782

100 Units

10012817

2.02.1 copyright by

MJFCIFSS


Special tools for diesel engines

Representation

Service Manual

Size

Designation

12

Dial gauge

7022418

13

Spacer

7022419

18

Removal tool for injection nozzles

0524072

19

Adapter for removal tool

0524029

30

Rotating device / attachment to flywheel housing

0524045

all types

Turning of diesel engine by means of the flywheel

35

V-belt measuring instrument

8042829

all types

Measuring of V-belt tension

36

Communication cable for LH-ECU-UP/CR control units

10035410

D 934 LA 6 / D 936 LA 6

Reading of error memory, fault analysis, processing of measurements, calibration

Krikit

ID no.

Machi ne

No.

2.02.2 copyright by

MJFCIFSS

Application

all types

Testing and adjustment of start of delivery in conjunction with no. 10

all types

Removal of injection nozzles To be used together with the removal tool


Service Manual

Representation

Special tools for diesel engines

No.

Designation

Size

37

Diagnostic software DC-DESK 2000 for LH-ECU-UP/CR DC4 and DC5 control units

ID no. 10118924

Machi ne

Application

D 934 LA 6 / D 936 LA 6

Reading error memory, analyse faults, edit measurements and carry out calibrations.

Note! The software is supplied together with each dongle!

38

USB dongle

40

Nozzle gauge

10410078

all types

Measuring and checking of nozzle bores and small drilled holes

50

Connecting piece

10297211

D 934 LA 6 / D 936 LA 6

Measuring of compression pressure

60

Outrigger

10117612

D 934 LA 6 / D 936 LA 6

Measuring of compression pressure

2.02.3 copyright by

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Special tools for diesel engines

Service Manual

2.02.4 copyright by

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Service Manual

Special tools for hydraulic unit

Special tools for hydraulic unit the maintenance, repair and adjustment of the hydraulic unit Picture

No.

Description

Size

ID no.

Machine

Application

10

Special spanner for pressure-relief valves

WS 17

9359414

all types

Adjustment of the primary and secondary valves in the control valve block

WS 19

9210371

all types

Securing of adjusting screws at hydraulic units

11

20

Safety cap

WS 10

7009315

21 22 23 24 25

short long short long

WS 13 WS 13 l WS 17 WS 19 WS 19 l

7023492 7615515 7380629 7009316 7009317

30

Mounting sleeve

see group 2.12

all types

Mounting of O-rings and Stepseal rings onto pistons of hydraulic cylinders and control pistons of variabledisplacement pumps and regulating motors

40

Expanding sleeve

see group 2.12

all types

See tool no. 40

50

Piston wrench

see group 2.12

all types

Diagram of manufacture, see sheet 2.12-01

2.05.1 copyright by

MJFCIFSS


Special tools for hydraulic unit

Picture

Service Manual

No.

Description

Size

ID no.

60

Piston wrench

WS

0541333

Machine

Application

all types

Loosening and tightening of piston nut

61 see group 2.12 62 63 64 70

Socket wrench for threaded bushing

WS 41

9245656

all types

Dismantling and mounting of damping plugs for two-side end-of-travel cushioning of hydraulic cylinders

80

Removal tool for piston rod bearing

M16

9951120

all types

Removal of piston rod bearings at hydraulic cylinders

M20

9959261

M24

9959262

W 24x 1-1/4" 3.0m

8145359

all types

Checking and filling of gas accumulator as well as piston and membrane accumulator

Ø 20 mm

10017281

all types

Clamping of spools during dismantling and mounting of piston elements

Ø 25 mm

10017282

Ø 32 mm

10017283

Ø 25 mm Ø 22 mm Ø 45 mm Ø 25 mm

9951457

all types

Mounting of Turcon-Glyd rings and scraper rings on the plunger piston of LIKUFIX couplings

90

Filling device, complete with adapter and hose

W 32x 1-1/4“ 3.0m

140

160 161 162 163

Clamping device for spool

Mounting sleeve

9951508 9966421 9951458

2.05.2 copyright by

MJFCIFSS


Service Manual

Picture

Special tools for hydraulic unit

No.

Description

Size

ID no.

Machine

Application

180

Vacuum pump, complete consisting of: Pump no. 180, vacuum control valve no. 181 with sealing, hose with filter no. 187.

00A7. 300

7405073

all types

Retension of hydraulic tank content

181

10097130 Vacuum control valve, complete

184 185 186

Connecting piece to tank, consisting of: Screw-in stud Cone RED connection 16/8S Straight nipple

7002240 7407155 7024875

200

Mounting sleeve

see group 2.12

all types

Calibration of the seal rings during the installation of the piston in the cylinder (tool no. 950 in the Lidos)

210

Mounting sleeve

see group 2.12

all types

Installation of the piston rod bearing on specially shaped piston rods (tool no. 960 in the Lidos)

2.05.3 copyright by

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Special tools for hydraulic unit

Service Manual

2.05.4 copyright by

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Service Manual

Special tools for electrical equipment

Special tools for electrical equipment Maintenance and repair of electric plug connectors

Picture

Fig. 1

Mate-N-LOK and DT plugs

Fig. 2

Juniortimer and JPT plugs

Size

ID no.

Machi ne

No.

Designation

10

Used to crimp the contacts for 1.5 mm2 wires for MATE-N-LOK plug connectors

7367025

all types

12

Used to crimp the contacts for 2.5 mm2 wires for MATE-N-LOK plug connectors

7366314

all types

15

Used to remove the crimp contacts from MATE-N-LOK plug connectors

7015179

all types

Application

2.06.1 copyright by

MJFCIFSS


Special tools for electrical equipment

Picture

Service Manual

Designation

20

Socket contact for 1.5 mm2 wires of MATE-N-LOCK plug connectors

6202619

21

Pin contact for 1.5 mm2 wires of MATE-N-LOCK plug connectors

6202620

22

Socket contact for 2.5 mm2 wires of MATE-N-LOCK plug connectors

6202591

23

Pin contact for 2.5 mm2 wires of MATE-N-LOCK plug connectors

6202592

28

Hand crimp tool (according to MILC5015, VG 95234, VG 955342)

7367086

29

Crimping insert for the crimping of DEUTSCH plug connectors with no. 28 pliers

7409779

30

Hand crimp tool for the crimping of contacts for DEUTSCH plug connectors

8503647

all types

31

Pulling tool

7026267

all types

32

Tool for the removal of wired crimp contacts at DEUTSCH plug connectors

Size 4

8503633

all types

Size 8 “ 12 “ 16 “ 20

8503632 8145674 8145673 8503630

33 34 35 36

Size

ID no.

Machi ne

No.

2.06.2 copyright by

MJFCIFSS

Application

all types

all types

all types

Used for the disassembly of DEUTSCH plugs.


Service Manual

Picture

Special tools for electrical equipment

No.

Designation

Size

ID no.

37

Pin contact for wires of DT plug connectors

Ø 0.81.0 Ø 1.02.0 Ø 2.03.0

7368251

Ø 0.81.0 Ø 1.02.0 Ø 2.03.0

7368252

38

Socket contact for wires of DT plug connectors

Machi ne all types

7368406 6905271

7368405 6905272

39

Plug

7368253

40

Used to crimp the punched contacts of SURE-SEAL plug connectors

7367025

all types

41

Mounting tool for the insertion of wired crimp contacts into SURESEAL CT 31 plug connectors

7367023

all types

42

A: Removal tool for pin contacts in SURE-SEAL plug connectors

7367020

all types

B: Removal tool for socket contacts

7367022

all types

43

Installation tubes for tool no. 42

7022464

all types

45

Auxiliary tool used to hold the SURE-SEAL 2, 3 and 4-pin plug connectors during installation and removal of the crimped contacts

7367021

all types

46

Similar to tool no. 324, for 5, 6 and 7-pin contacts

7367085

CT 31

Application

2.06.3 copyright by

MJFCIFSS


Special tools for electrical equipment

Picture

Service Manual

Designation

48

Repair kit containing special tools no. 40, 41, 42, 45 and 46, including operating manual and lubricant

7015073

all types

50

Socket contact for 1.5 mm2 wires of SURE-SEAL plug connectors

6202434

all types

51

Size

Pin contact for 1.5 mm2 wires of SURE-SEAL plug connectors

ID no.

Machi ne

No.

Application

6202444

52

Removal tool for contacts of MICROTIMER plug connectors

7026266

all types

55

Unlocking tool for WAGO plug elements

7022773

all types

60

Dismantling and mounting tool

10356764

all types

Used to dismantle and mount EPROMs

65

Mounting sleeve

9629620

all types

Used to install O-rings in Likufix signal contacts

777-310

2.06.4 copyright by

MJFCIFSS


Service Manual

Picture

Special tools for electrical equipment

No.

Designation

Size

70

Ergocrimp hand tool

ID no. 6004391

Ergocrimp matrix 72

0.5-2.5 mm2

10016253

0.2-2.5 mm2

10016255

0.5-2.5 mm2

10016256

Machi ne

Application

all types

Used to crimp the contacts for JPT (Tyco) plug connectors

all types

Used to crimp the contacts for Junior Power Timer no. 927777-3 / 927779-3 / 927846-2

73

Junior power Timer/EDS no. 929938-3/doublespring contact no. 9299403

74

flat adapters no. 963745-1 / 963746-1 80

Removal tool

7415334

all types

Used to remove the wired crimp contacts from JPT (Tyco) plug connectors

90

Crimp tool

10016251

all types

Used to crimp the Littlefuse contacts for JPT (Tyco) plug connectors, see also no. 92.

92

Ergocrimp matrix

10016252

all types

Used to crimp the contacts in conjunction with no. 90

0.5-5.37 mm2

Pin bushing no. 913053 / 913065 / 913066 / 913067 / 913069 / 913079 Double-spring contact no. 913071 / 913072

2.06.5 copyright by

MJFCIFSS


Special tools for electrical equipment

Picture

Service Manual

Machi ne

Application

10011168

all types

Used to crimp wire end ferules

0.25-16 mm2

8033014

all types

Used to crimp wire end ferules

Crimp tool

0.5-6.0 mm2

8004713

all types

Used to crimp insulated fork terminals

Crimp tool with compression insert R 10

10-70 mm2

all types

Used to crimp uninsulated fork terminals

No.

Designation

Size

ID no.

95

Crimp tool

0.08-10 mm2

96

Crimp tool

98

100

Inserts for tool no. 100

all types

101 102 103 104 105

R 16 R 25 R 35 R 50 R 70

108

Crimp tool

0.5-6 mm2

8033015

all types

Used to crimp uninsulated plug connectors

109

Crimp tool

0.5-2.5 mm2

6003491

all types

Used to crimp uninsulated plug connectors

110

Crimp tool

0.5-2.5 mm2

all types

Used to crimp uninsulated plug connectors

2.06.6 copyright by

MJFCIFSS


Service Manual

Picture

Special tools for electrical equipment

No.

Designation

Size

111

Crimp tool

0.03-0.6 mm2

112

Pin remover for D-Sub contacts

ID no.

Machi ne

Application

all types

Used to crimp D-Sub contacts

all types

2.06.7 copyright by

MJFCIFSS


Special tools for electrical equipment

Service Manual

2.06.8 copyright by

MJFCIFSS


Service Manual

Special tools for slewing gear mechanism

Special tools for slewing gear mechanism Maintenance and repair of slewing gear mechanism and slewing gear motor Diagram

No.

Designation

Size

ID no.

Machi ne

10

Slotted nut wrench for slewing gear mechanism

SAT 275

9202821

A 934C

11

SAT 325

9202823

A 944C

12

SAT 350

9202824

A 954C

SAT 275

9202826

A 934C

21

SAT 325

9202828

A 944C

22

SAT 350

9202829

A 954C

FMF 64

10127252

A 934C

20

30

Mounting device of slewing gear mechanisms

Special wrench for speed sensor

FMF 90

A 944C

FMF 100

A 954C

Application For releasing and tightening of slotted nuts in drive/ slewing gear mechanisms (SAT drawing, see page 2.14-01)

For dismantling and assembly of brake housing/ multi-disc brake for SAT slewing gear mechanisms, see SAT drawing, page 2.15-01.

For dismantling and assembly of the speed sensor at the slewing gear motor.

2.07.1 copyright by

MJFCIFSS


Special tools for slewing gear mechanism

Service Manual

2.07.2 copyright by

MJFCIFSS


Service Manual

Special tools for axles (Kessler)

Special tools for axles (Kessler) for the maintenance and repair of axles (Kessler) Representation

no.

Designation

ID no.

Axle type

Machine

Application

10

Insertion tool for slip seal ring

7027696

LT/D 71

Mounting of slip seal ring

LT/D 81

A 924 C-HD A 934 C A 934 C-HD

10046704

LT/D 101

A 954 C-HD

10455408

LT/D 41 LT/D 71

A 900 C-ZW A 924 C-HD A 934 C

21

10424371

LT/D 81

A 934 C-HD

22

10424498

LT/D 91

A 944 C-HD

23

10424380

LT/D 101

A 954 C-HD

10492637

LT/D 41 LT/D 71

A 900 C-ZE A 924 C-HD A 934 C

7026040

LT/D 71

A 924 C-HD A 934 C

Removal tool for steering knuckle bolts (mechanical)

10424373

LT 41 LT 71

A 900 C-ZW A 924 C-HD A 934 C A 934 C-HD

Removal of steering knuckle bolt

Removal tool for steering knuckle bolts (hydraulic)

10424374

Removal of steering knuckle bolt by means of a hydraulic pump*

LT 81

A 900 C-ZW A 924 C-HD A 934 C A 934 C-HD

11

20

30

Spanner for wheel nut / shaft nut

Spanner for lock nut

31

40

50

LT 81

LT 41 LT 71

Loosening and tightening of shaft nut

Loosening and tightening of lock nut at planetary gear box

51

10424381

LT 91 LT 101

A 944 C-HD A 954 C-HD

(Removal thread M27X2 from December 2006)

52

10424382

LT 91 LT 101

A 944 C-HD A 954 C-HD

(Removal thread M24 until November 2006)

2.09.1 copyright by

MJFCIFSS


Special tools for axles (Kessler)

Representation

Service Manual

no.

Designation

ID no.

Axle type

Machine

Application

60

Push-in tool for steering knuckle bolts (hydraulic)

10046711

LT 41 LT 71 LT 81

A 900 C-ZW A 924 C-HD A 934 C A 934 C-HD

Hydraulic pushing in of steering knuckle bolt by means of a hydraulic pump*

10424383

LT 91 LT 101

A 944 C-HD A 954 C-HD

10046715

LT 41 LT 71

A 900 C-ZW A 924 C-HD A 934 C A 934 C-HD A 944 C-HD A 954 C-HD

Insertion of steering knuckle bolt

Insertion of steering knuckle bushing into axle housing

LT 81

A 900 C-ZW A 924 C-HD A 934 C A 934 C-HD

10492635

LT 41 (AGS)

A 900 C-ZW

Removal of needle bearing and bearing bushing from axle housing

10424375

LT 71 LT 81 LT 91 (ASS) LT 101 (ASS)

A 924 C-HD A 934 C A 934 C-HD A 944 C-HD A 954 C-HD

LT 91 (AGS) LT 101 (AGS)

A 944 C-HD A 954 C-HD

61

70

Insertion pin for steering knuckle bolt

LT 81 LT 91 LT 101

80

90

91

92

Mounting tool for steering knuckle bushings

Removing tool for double joint drive shaft bearing

7028268

10424384

LT 47 LT 71

2.09.2 copyright by

MJFCIFSS


Service Manual

Representation

Special tools for axles (Kessler)

no.

Designation

ID no.

Axle type

Machine

Application

100

Mounting tool for double joint drive shaft bearing

10492639

LT 41

A 900 C-ZW

Insertion of needle bearing and bearing bushing from axle housing

101

10492640

LT 41

A 900 C-ZW

102

10424499

LT 71 LT 81 LT 91 (ASS) LT 101 (ASS)

A 924 C-HD A 934 C A 934 C-HD A 944 C-HD A 954 C-HD

10424385

LT 91 (AGS) LT 101 (AGS)

A 944 C-HD A 954 C-HD

10492636

LT 41

A 900C-ZW

111

10492653

LT 41

A 900 C-ZW

112

10424376

LT 71

A 924 C-HD A 934 C A 934 C-HD A 944 C-HD A 954 C-HD

103 110

Seal ring mounting tool for double joint drive shaft bearing

LT 81 LT 91 (ASS) LT 101 (ASS) 113

10424377

114

120

Seal ring mounting tool for axle drive

LT 71 LT 81 LT 91 (ASS) LT 101 (ASS)

A 924 C-HD A 934 C A 934 C-HD A 944 C-HD A 954 C-HD

10424385

LT 91 (AGS) LT 101 (AGS)

A 944 C-HD A 954 C-HD

Insertion of radial seal ring in axle housing

10424378

LT/D 41 LT/D 71

A 900 C-ZW A 924 C-HD A 934 C A 934 C-HD A 944 C-HD

Insertion of radial seal ring in axle drive

LT/D 81 LT/D 91 121

10046716

LT/D 71 LT/D 81 LT/D 91

130

Spanner for threaded ring

10492634

LT 41 LT 71 LT 81 LT 91

131

Insertion of radial seal ring in steering knuckle

10492638

LT 71 LT 81 LT 91 LT 101

A 924 C-HD A 934 C A 934 C-HD A 944 C-HD

A 900 C-ZW A 924 C-HD A 934 C A 934 C-HD A 944 C-HD

Loosening and removal of adjusting ring in axle drive

A 924 C-HD A 934 C A 934 C-HD A 944 C-HD A 954 C-HD

2.09.3 copyright by

MJFCIFSS


Special tools for axles (Kessler)

Representation

Service Manual

no.

Designation

ID no.

Axle type

Machine

Application

140

Slotted nut wrench for lock nut in auxiliary transmission (lock nut installed from June 2006)

10412169

D 91 D 101

A 944 C-HD A 954 C-HD

Loosening and tightening of lock nut in auxiliary transmission

150

Centring device for discs

10424386

LT/D 101

A 954 C-HD

Mounting of brake discs

* = hydraulic hand pump not included with the respective tool ASS = steering knuckle side AGS = axle housing side

2.09.4 copyright by

MJFCIFSS


Service Manual

Stroke measuring device for control block Device for the measuring of the spool stroke

Stroke measuring device for control block 1

Device for the measuring of the spool stroke Stroke length at NG 25= 14 mm Stroke length at NG 32= 15 mm Stroke length at NG 40= 20 mm

Fig. 1

Stroke measuring device

1

Stroke measuring device

3

Lid of control valve block

2

Seal

4

Spool

ID no. 8007363

Parts drawing on reverse side!

2.10.1 copyright by

MJFCIFSS


Stroke measuring device for control block

Service Manual

Device for the measuring of the spool stroke

Fig. 2

Spare Parts for storke measuring

2.10.2 copyright by

MJFCIFSS


Service Manual

Assembly tools for hydraulic cylinders Assembly wrenches for pistons of hydraulic cylinders WN 4121

Assembly tools for hydraulic cylinders 1

Assembly wrenches for pistons of hydraulic cylinders WN 4121

Fig. 1

Assembly tool (bore for mounting bolt a)

a

b

c

d

e

f

g

h

i

Squar e

9131359

52

38

75

200

10

8

8

15

60

1/2“

9131362

60

44

85

200

14

10

10

15

65

1/2“

9231993

68

52

100

220

14

10

10

15

70

1/2“

8007364*

75

54

110

220

14

12

10

20

84

3/4“

8007364*

80

54

110

220

14

12

10

20

84

3/4“

7364036 8007365

88

63

120

250

14

12

10

20

90

3/4“

8007366

100

78

135

260

14

14

10

20

95

3/4“

9919856

115

88

150

300

14

14

10

20

105

3/4“

9196978#

125

97

170

320

14

14

10

25

110

3/4“

9196978#

130

97

170

320

14

18

15

25

110

3/4“

8007367

145

113

185

380

14

18

15

25

120

3/4“

9925117

160

125

200

420

14

18

15

25

130

3/4“

9131373

175

135

215

450

14

20

19

25

135

3/4“

9131376

220

156

280

500

14

30

28

40

158

3/4“

0541380

85

72

110

210

11

8

8

15

210

1/2“

0542336

120

100

140

240

12

8

9

152

240

1/2“

0540947

124

100

150

240

12

8

9

15

240

1/2“

0541379

145

125

170

280

11

8

9

15

280

3/4“

0540966

160

135

185

280

12

10

9

20

280

3/4“

0529897

165

140

190

280

12

10

9

20

280

3/4“

ID no.

Tab. 1

List of assembly wrenches (all dimensions in mm)

2.12.1 copyright by

MJFCIFSS


Assembly tools for hydraulic cylinders

Service Manual

Assembly wrenches for piston nuts

Note! The dimensions of the pistons and assembly wrenches and the ID numbers can be looked up in Lidos (* and # correspond to one wrench each)!

2

Assembly wrenches for piston nuts

Fig. 2

Assembly wrenches for piston nuts

size for piston nut ID no.

*WS hexagon

*WS2 flat

Slotted nut Ø

Square

ID no.

M30X1.5 - 7006469

44

**

M32X1.5 - 7010262

50

**

M33 X1.5 - 9226916 M36X1.5 - 9875702

41 50

M42X1.5 - 7010163 M42X1.5 - 9970088

9921132

1/2“

9211967

62 60

M42X1.5 - 9113734 M50X2 - 4129202

1/2“

55 70

M50X2 - 9166795

65

** 1/2“

9211967

1/2“

9921132

1/2“

9921123

1/2“

9921123

M56X2 - 9921260

80

1/2“

9921124

M60X2 - 4129203

80

1/2“

9921124

M65X2 - 9247441

85

1/2“

9921133

M68X2 - 9129554

90

1/2“

9921124

M76X2 - 9970448

100

3/4“

9921125

M85X3 - 9142472

110

3/4“

9921125

M95X3 - 9101411

120

3/4“

9921126

M100X3 - 9950036

130

3/4“

9951123

M110X3 - 9129653 / 9112934

149

3/4“

9921127

M120X3 - 9143685

165

3/4“

9921128

M130X3 - 9125066

180

3/4“

9921129

M150X3 - 9144654

210

3/4“

9921131

2.12.2 copyright by

MJFCIFSS


Service Manual

Assembly tools for hydraulic cylinders Assembly wrenches for WN 4122 piston rod bearings

size for piston nut ID no.

*WS hexagon

*WS2 flat

M170X3 - 5008571 Tab. 2

Slotted nut Ø

230

Square

ID no.

3/4“

9921134

List of piston nuts

* spanner size / ** conventional grooved socket spanner

3

Assembly wrenches for WN 4122 piston rod bearings

Fig. 3

Assembly wrenches for piston rod bearings

ID no.

a

b

c

d

e

f

g

h

i

Squar e

0541665

76

62

95

210

9

6

7

15

70

1/2“

0541666

87,5

72

110

210

10

8

8

15

70

1/2“

0541063

92

75

115

210

12

8

8

15

75

1/2“

0541064

100

80

120

210

12

10

10

15

80

1/2“

0529893

110

90

130

240

12

10

10

15

90

1/2“

0542005

115

95

135

240

12

8

10

15

95

1/2“

0541667

125

98

150

240

12

10

9

15

98

1/2“

0529894

135

110

160

260

12

8

8

15

105

1/2“

0540948

140

120

160

260

12

8

8

15

110

1/2“

0541661

145

120

170

280

12

10

9

15

110

1/2“

0529895

145

120

170

280

12

12

13

15

120

1/2“

0540949

150

130

170

280

12

12

12

20

110

3/4“

0529896

170

140

200

300

12

14

13

20

110

3/4“

0541378

180

160

200

300

12

10

9

20

120

3/4“

Tab. 3

List of assembly wrenches

2.12.3 copyright by

MJFCIFSS


Assembly tools for hydraulic cylinders

Service Manual

Assembly wrenches for version 5100 pistons

4

Assembly wrenches for version 5100 pistons

Fig. 4

Assembly wrenches for version 5100 pistons

size for piston nut

*WS hexagon

Øa for mounting bolts

WS square

ID no.

M 110X3

150

180

3/4“

9281614

M 120X3

175

220

3/4“

9584641

M 110X3

190

240

3/4“

9581705

Tab. 4

4.1

List of assembly wrenches / * spanner width

Assembly wrenches for pistons

Fig. 5

Assembly wrenches for pistons

ID no.

a

b

c

d

e

f

g

h

i

Squar e

9249886

250

204

310

600

14

30

28

30

175

3/4“

9249741

260

176

330

600

19

36

35

40

180

3/4“

9243215

280

206

354

650

19

36

35

40

190

3/4“

2.12.4 copyright by

MJFCIFSS


Service Manual

Assembly tools for hydraulic cylinders Mounting and expanding sleeves

Tab. 5

4.2

List of assembly wrenches

Assembly wrench for pistons with hexagon piece

Fig. 6

Assembly wrench for pistons with hexagon piece mm

mm

mm

*WS hexagon

mm Piston Max. Ø

mm

mm

mm

l

mm Piston Min. Ø

Square

a

b

c

9600751

80

3/4“

170

Ø110

Ø140

Ø160

525

15

9602239

85

3/4“

170

Ø115

Ø140

Ø160

525

15

9600418

90

3/4“

170

Ø120

Ø150

Ø160

525

15

9597668

100

3/4“

170

Ø130

Ø160

Ø180

525

15

9600928

110

3/4“

170

Ø160

Ø190

Ø200

525

15

9600769

120

3/4“

174

Ø170

Ø200

Ø200

525

15

ID no.

Tab. 6

List of assembly wrenches

* spanner width

5

Mounting and expanding sleeves Piston Ø

990 mounting sleeve ID no.

991 expanding sleeve ID no.

25

9951457

9951458

32

9136418

9136416

32

9113100

9113099

38

9143279

9143280

40

9196902

9136417

40

9580414

9580413

45

9136419

9136417

50

9288953

9288954

63

9170510

9170512

65

9177541

9177540

2.12.5 copyright by

MJFCIFSS


Assembly tools for hydraulic cylinders

Service Manual

Mounting and expanding sleeves

Piston Ă&#x2DC;

990 mounting sleeve ID no.

991 expanding sleeve ID no.

70

9110556

9110402

80

9227165

9227166

85

9998618

9110404

85

9115710

9115708

90

9227161

9227162

98

9289130

9289131

100

9998626

9110405

105

9951984

9951983

106

9583670

9583671

110

9170509

9170511

110

9960483

9960502

115

9998625

9110406

120

9998778

9110407

125

9227163

9227164

125

9960484

9960503

130

9998624

9110408

135

9285578

9285579

140

9998623

9110409

150

9998622

9110410

160

9998621

9110411

170

9107931

9110412

180

9998619

9110413

180

9107932

9110413

190

9907684

9907701

190

9280862

9280863

200

9107933

9110414

210

9192854

9192853

220

9113008

9113009

230

9144914

9144912

240

9903977

9903978

300

9135351

9135350

Tab. 7

List of mounting and expanding sleeves

Piston Ă&#x2DC;

992 mounting sleeve ID no.

993 mounting sleeve ID no.

25

9966421

9951508

Tab. 8

List of 992 and 993 mounting sleeves

Note! The mounting sleeves 992 and 993 are required for the installation of the piston and the scraper ring in the plunger cylinder with the LIKUFIX accessory kit.

2.12.6 copyright by

MJFCIFSS


Service Manual

Assembly tools for hydraulic cylinders Mounting and expanding sleeves

Mounting sleeves used to insert pistons into cylinders Piston Ă&#x2DC;

950 mounting sleeve ID no.

65

9177543

80

9231749

90

9248893

90

9248894

100

9248895

110

9248897

120

9248898

130

9248899

140

9177542

140

9952180

160

9248909

190

9281241

210

9281240

250

9951147

260

9284918

Tab. 9

950 mounting sleeves

Note! The mounting sleeve 950 is required to restore the shape of the expanded sealing elements to suit the inside diameter of the cylinder (calibration). Mounting sleeves used to mount the piston rod bearings on the piston rods Piston rod Ă&#x2DC;

960 mounting sleeve ID no.

90

9282761

100

9638789

105

9287177

140

9926806

Tab. 10

960 mounting sleeves

Note! The 960 mounting sleeve is required in order to prevent damage to sealing and guide elements.

2.12.7 copyright by

MJFCIFSS


Assembly tools for hydraulic cylinders

Service Manual

Mounting and expanding sleeves

2.12.8 copyright by

MJFCIFSS


Service Manual

Mounting device for piston rod bearings Tool used to dismantle piston rod bearings in hydraulic cylinders

Mounting device for piston rod bearings 1

Tool used to dismantle piston rod bearings in hydraulic cylinders

Fig. 1

Mounting device

Thread in flange ring

Thread in bearing head M1

Thread of mounting driver M2

Length of mounting driver L

ID -no.

M12

M16

M10

250

9951120

M16

M20

M12

270

9959261

M20

M24X2

M16

290

9959262

Tab. 1

Mounting device sizes for various flange ring threads

2.13.1 copyright by

MJFCIFSS


Mounting device for piston rod bearings

Service Manual

Tool used to dismantle piston rod bearings in hydraulic cylinders

2.13.2 copyright by

MJFCIFSS


Service Manual

Slotted nut wrench for slewing gear Tool used to remove the slotted nut in the slewing gear mechanism

Slotted nut wrench for slewing gear 1

Tool used to remove the slotted nut in the slewing gear mechanism

Fig. 1

Slotted nut wrench for Sat 225 / 250 / 275 / 300 Gearbox type

ID number

SAT 275

9202821

SAT 325

9202823

SAT 350

9202824

2.14.1 copyright by

MJFCIFSS


Slotted nut wrench for slewing gear

Service Manual

Tool used to remove the slotted nut in the slewing gear mechanism

Fig. 2 SAT 275 325 350

A 110 132 137

B 55 55 55 Tab. 1

Technical drawing of slotted nut wrench C 46 46 46

D

E +0.2

F

G

H

J

K

L

M

N

O

P

70

92.2

95

120

105

3.8

90

35

30

50

70

7.8

80

115+0.2

119.5

150

117

3.8

94

35

30

55

78

7.8

50

125+0.2

126.2

160

113

3.8

92

35

30

55

78

7.8

Dimensions

Material: 42 CrMo 4 hardened to 800 - 950 N/mm2

2.14.2 copyright by

MJFCIFSS


Service Manual

Mounting device for multi-disc brake

Mounting device for multi-disc brake Tool used to dismantle and mount the multi-disc brake of the slewing gear mechanism SAT 275 / 325 / 350

Fig. 1

Tab. 1

Mounting device of slewing gear mechanisms Size

SAT 275

SAT 325

SAT 350

A

326

390

410

B

40

50

50

C

12

20

20

D

10

15

15

E

10

15

15

F

18

22

22

G

120

142

154

H

143

170

180

ID no.

9202826

9202828

9202829

List of mounting device sizes

2.15.1 copyright by

MJFCIFSS


Mounting device for multi-disc brake

Service Manual

2.15.2 copyright by

MJFCIFSS


Service Manual

SUBGROUP - INDEX Section

Group

Type

Technical data A 934 C LI

3.05.1

A 934 C-LI 28016-

Technical data A 934 C HD LI

3.07.1

A 934 C-LI 25436-

Technical dataA 934 C HD LI Log Loader

3.09.1

A 934 C-LI 31793-

Technical data

3.11.1

A 944 C-LI 24475-

Technical data

3.13.1

A 944 C-LI 29225-

Technical data

3.15.1

A 954 C-LI 21416-

Maintenance and inspection schedule

3.17.1

A 934 C-LI 28016-

Maintenance and inspection schedule

3.19.1

A 934 C-LI 25436-

Maintenance and inspection schedule

3.21.1

A 934 C-LI 31793-

Maintenance and inspection schedule

3.23.1

A 944 C-LI 24475-

Maintenance and inspection schedule

3.25.1

A 944 C-LI 29225-

Maintenance and inspection schedule

3.27.1

A 954 C-LI 21416-

Lubrication schedule for A 934 C Litronic Type 1006

3.29.1

A 934 C-LI 28016-

Lubrication schedule for A 934 C-HD Litronic Type 1007

3.31.1

A 934 C-LI 25436-

Lubrication Schedule A 934 C-HD Litronic log loader Type 1053

3.33.1

A 934 C-LI 31793-

Lubrication schedule for A 944 C-HD Litronic Type 194

3.35.1

A 944 C-LI 24475-

Lubrication schedule A 944 C - HD Litronic log loader type 196

3.37.1

A 944 C-LI 29225-

Lubrication schedule for A 954 C-HD Litronic Type 450

3.39.1

A 954 C-LI 21416-

3.1 MJFCIFSS


Service Manual

Adjustment protocol A 934 C Li

3.45.1

A 934 C-LI 28016-

Adjustment protocol A 934 C LI

3.46.1

A 934 C-LI 39077-

Adjustment protocol A 934 C HD LI

3.47.1

A 934 C-LI 25436-

Adjustment protocol A 934 C HD LI

3.48.1

A 934 C-LI 39077-

Adjustment protocol A 934 C HD LI log loader

3.49.1

A 934 C-LI 31793-

Adjustment protocol A 944 C HD LI

3.51.1

A 944 C-LI 24475-

Adjustment protocol A 944 C HD LI

3.52.1

A 944 C-LI 39086-

Adjustment protocol A 944 C HD LI log loader

3.53.1

A 944 C-LI 33765-39085

Adjustment protocol A 944 C HD LI log loader

3.54.1

A 944 C-LI 39086-

Adjustment protocol A 954 C HD LI

3.55.1

A 954 C-LI 21416-

Adjustment guidelines for the hydraulic system 3.69.1

A 934 C-LI 25436-

Checking and adjusting tasks V4.7

3.70.1

A 934 C-LI 39077-

Adjustment guidelines for hydraulic system

3.71.1

A 934 C-LI 31793-

Adjustment guidelines for hydraulic system

3.73.1

A 944 C-LI 24475-

Adjustment guidelines for hydraulic system

3.77.1

A 954 C-LI 21416-

3.2 MJFCIFSS


Service Manual

Technical data A 934 C LI Type 1006

Technical data A 934 C LI 1

Type 1006 starting 28016

General Weight of basic machineapprox.

t

28.7

Weight of basic machine with attachment, without grappleapprox.

t

35.5

Overall length (basic machine without attachment)

mm

5906

Overall width

mm

3000

Overall height without attachment (operator's cab elevation 1200)

mm

3598

Rear reach from centre/slewing radius

mm

3096

Ground clearance

mm

254

Diesel engine

Type

D 934 L A6

Power at rated speed according to DIN ISO 9249

kW

150 (204 PS)

Rated speed

rpm

1800

Max. torque

Nm

920 at 1400 rpm

Drive motor

Oil volume in engine (filling quantity at oil change with filter)

l

Oil quality/oil viscosity and oil change intervals

29 see groups 1.50 and 3.80

Cooling liquid including coolant

l

40

Type

DPVP 108

Hydraulic system Hydraulic pump Design

Axial piston swash plate pump

Input speed

rpm

1800

Max. flow rate

l/min

2 x 240

Oil volume in pump distribution gear

l

3.1

Flow rate / hydraulic pump - pump distribution gear

l/min

13.3

Hydraulic oil volume (oil change with filter)

l

approx. 350

Hydraulic oil and filter change intervals

see groups 1.50 and 3.80

Control valve block

Type

Slewing gear circuit

NG 22 Closed circuit

Slewing gear pump

Type

Slewing gear pump / type

A4V 71 DWD Swash-plate axial-piston pump with attached feeder pump

Pump performance

kW

80 (108 PS)

Max. flow rate

l/min

148

Feeder pump flow rate

l/min

41

3.05.1 copyright by

MJFCIFSS


Technical data A 934 C LI

Service Manual

Type 1006 Hydraulic system Feed pressure

bar

16

Hydraulic pump / pilot control

Type

Gear pump

Max. flow / pilot control

l/min

45.5

Pressure limitation pilot control

bar

32+2

Pilot control unit / working attachment / slewing gear

Type

4TH 87 X 70-10

Pilot control unit / travel drive

Type

VG - 7 - 1 / 1

Pilot control unit / support

Type

VG - 5 - 2

Additional information

see group 6.10

Hydraulic pump / fan

Type

A 10 V 28 ED

Max. flow rate

l/min

62

Hydraulic motor / fan

Type

A 10 FE 28

Hydraulic pump / accessory kit

Type

Gear pump

Max. flow rate

l/min

24.7

Rotary connection 7 x

Type

DDF 720

Rotary connection 6 x

Type

815.006 B

Hydraulic cylinder

see group 7.30

Electrical system Operating voltage

V

24

Battery capacity

Ah

2 x 170 (in series)

Alternator voltage / current

A

28V / 80A

Starter

kW

24V / 6.6 kW

Gearbox

Type

SAT 275 / 255

Oil motor

Type

FMF 64

Max. slewing speed

rpm

8.2

Oil volume in gearbox

l

7.0

Slewing gear mechanism

Oil quality /oil viscosity and oil change intervals

see groups 1.50 and 3.80

Slewing gear brake

Type

Wet multi-disc brake (negative)

Max. release pressure

bar

20

Additional information

see group 9.10

Axles Steering axle

Type

LT 71 PL 478 NLB

Rigid axle

Type

D 71 PL 478 NLB

Oil volume in steering axle housing

l

26.5

Oil volume in rigid axle housing

l

19.0

Oil volume in steering axle / rigid axle wheel hub

l

3.0

Oil quality /oil viscosity and oil change intervals

see groups 1.50 and 3.80

Working brake

Type

Tyres

Wet multi-disc brake (positive) 11.00 - 20 / 12.00 - 20

3.05.2 copyright by

MJFCIFSS


Service Manual

Technical data A 934 C LI Type 1006

Transmission Gearbox

Type

2 HL 290

Oil motor

Type

DMVA 165

Travel speed at creeper speed off-road/on-road

kph

2.4 / 10

Travel speed in working gear / on-road gear

kph

4.6 / 20

Oil volume in gearbox

l

3.3

Oil quality, oil viscosity and oil change intervals

see groups 1.50 and 3.80

Parking brake

Type

Additional information

Wet multi-disc brake (negative) see group 11

Steering Hydraulic pump

Type

Gear pump

Flow rate

l/min

61

Steering valve

Type

7030176

First primary protection

bar

220+5

Second primary protection

bar

180+5

Secondary protection

bar

240+5

Hydraulic pump

Type

Gear pump

Max. flow rate

l/min

2.7

Max. charging pressure

bar

200

Max. brake pressure / working brake

bar

75+10

cm3

approx. 30

Brake system

Central lubrication system Volume of grease per working hour Number of cycles / grease processes with automatic greasing (optional)

see group 18.50

3.05.3 copyright by

MJFCIFSS


Technical data A 934 C LI

Service Manual

Type 1006

3.05.4 copyright by

MJFCIFSS


Service Manual

Technical data A 934 C HD LI Type 1007

Technical data A 934 C HD LI 1

Type 1007 starting 25436

General Weight of basic machineapprox.

t

30.9

Weight of basic machine with attachment, without grappleapprox.

t

37.8

Overall length (basic machine without attachment)

mm

6296

Overall width

mm

3000

Overall height without attachment (operator's cab elevation 1200)

mm

4807

Rear reach from centre/slewing radius

mm

3161

Ground clearance

mm

391

Diesel engine

Type

D 934 L A6

Power at rated speed according to DIN ISO 9249

kW

150 (204 PS)

Rated speed

rpm

1800

Max. torque

Nm

920 at 1400 rpm

Drive motor

Oil volume in engine (filling quantity at oil change with filter)

l

Oil quality/oil viscosity and oil change intervals

29 see groups 1.50 and 3.83

Cooling liquid including coolant

l

40

Type

DPVP 108

Hydraulic system Hydraulic pump Design

Axial piston swash plate pump

Hydr. drive power at max. motor output

kW

147 (200 PS)

Input speed

rpm

1800

Max. flow rate

l/min

2 x 240

Oil volume in pump distribution gear

l

3.1

Flow rate / hydraulic pump - pump distribution gear

l/min

13.3

Hydraulic oil volume (oil change with filter)

l

approx. 350

Hydraulic oil and filter change intervals

see groups 1.50 and 3.83

Control valve block

Type

Slewing gear circuit

NG 22 Closed circuit

Slewing gear pump

Type

Slewing gear pump / type

A4V 71 DWD Swash-plate axial-piston pump with attached feeder pump

Pump performance

kW

80 (108 PS)

Max. flow rate

l/min

148

3.07.1 copyright by

MJFCIFSS


Technical data A 934 C HD LI

Service Manual

Type 1007 Hydraulic system Feeder pump flow rate

l/min

41

Feed pressure

bar

16+2

Hydraulic pump / pilot control

Type

Gear pump

Max. flow / pilot control

l/min

45.5

Pressure limitation pilot control

bar

32+2

Pilot control unit / working attachment / slewing gear

Type

4TH 87 X 70-10

Pilot control unit / travel drive

Type

VG - 7 - 1 / 1

Pilot control unit / support

Type

VG - 5 - 2

Additional information

see group 6.11

Hydraulic pump / fan

Type

A 10 V 28 ED

Max. flow rate

l/min

62

Hydraulic motor / fan

Type

A 10 FE 28

Hydraulic pump / accessory kit

Type

Gear pump

Max. flow rate

l/min

24.7

Rotary connection 7 x

Type

DDF 720

Rotary connection 6 x

Type

815.006 B

Hydraulic cylinder

see group 7.30

Electrical system Operating voltage

V

24

Battery capacity

Ah

2 x 170 (in series)

Alternator voltage / current

A

28 V / 80

Starter

kW

24 V / 6.6

Gearbox

Type

SAT 275 / 255

Oil motor

Type

FMF 64

Max. slewing speed

rpm

8.2

Oil volume in gearbox

l

7.0

Slewing gear mechanism

Oil quality /oil viscosity and oil change intervals

see groups 1.50 and 3.83

Slewing gear brake

Type

Wet multi-disc brake (negative)

Max. release pressure

bar

20

Additional information

see group 9.10

Axles Steering axle

Type

LT 81 PL 488 NLB

Rigid axle

Type

D 81 PL 488 NLB

Oil volume in steering axle housing

l

30.5

Oil volume in rigid axle housing

l

22

Oil volume in steering axle / rigid axle wheel hub

l

4.0

Oil quality /oil viscosity and oil change intervals

see groups 1.50 and 3.83

Working brake

Type

3.07.2 copyright by

MJFCIFSS

Wet multi-disc brake (positive)


Service Manual

Technical data A 934 C HD LI Type 1007

Axles Tyres

16.00 - 25 / 20.50 - 25

Transmission Gearbox

Type

2 HL 290

Oil motor

Type

DMVA 165

Travel speed at creeper speed off road/on road

kph

2.4 / 10

Travel speed in working gear / on-road gear

kph

4.6 / 20

Oil volume in gearbox

l

3.3

Oil quality, oil viscosity and oil change intervals

see groups 1.50 and 3.83

Parking brake

Type

Additional information

Wet multi-disc brake (negative) see group 11

Steering Hydraulic pump

Type

Gear pump

Flow rate

l/min

61

Steering valve

Type

7030176

First primary protection

bar

220+5

Second primary protection

bar

180+5

Secondary protection

bar

240+5

Hydraulic pump

Type

Gear pump

Max. flow rate

l/min

2.7

Max. charging pressure

bar

200

Max. brake pressure / working brake

bar

75+10

cm3

approx. 30

Brake system

Central lubrication system Volume of grease per working hour Number of cycles / grease processes with automatic greasing (optional)

see group 18.50

3.07.3 copyright by

MJFCIFSS


Technical data A 934 C HD LI

Service Manual

Type 1007

3.07.4 copyright by

MJFCIFSS


Service Manual

Technical dataA 934 C HD LI Log Loader Type 1053

Technical dataA 934 C HD LI Log Loader 1

Type 1053 starting 31793 T

General Weight of basic machines (blade rear), without attachment appr.

t

28,67

Weight of basic machines (blade rear), without attachment without grapple appr.

t

34,35

Weight of basic machine (blade rear and front), without attachment appr.

t

29,96

Weight of basic machine (blade rear and front), with attachmen, without grapple appr.

t

35,64

Length overall ( basic machine without attachment )

mm

6147

Width overall

mm

3412

Heigth overall without attachment (cab elevation 800)

mm

4350

Tail radius from center / swing radius

mm

3074

Ground clearance

mm

349

Diesel engine

Type

D 934 L A6

Performance at rated rpm according to DIN IDSO 9249

KW

150 (204 Hp)

Rated rpm

rpm

1800

max. torque

Nm

920 at 1400 rpm

Oil quantity in engine (filling quantity for oil change with filter)

l

29

Drive train

Oil quality / - viscosity and oil change interval

see group 1.50 and 3.83

Coolant quantity including radiator

l

40

Type

DPVP 108

Hydraulic system Hydraulic pump Design

Axial piston swash plate pump

Input rpm

min-1

1800

Max. flow

l/min

2 x 240

Oil quantity in pump distributor gear

l

3,1

Flow / hydraulic pump - pump distributor gear

l/min

13,3

Hydraulic oil quantity (oil change with filter)

l

appr. 350

Hydraulic oil- and filter change interval

see group 1.50 and 3.83

Control valve block

Type

Swing circuit

NG 22 closed circuit

Swing pump

Type

A4V 71 DWD

3.09.1 copyright by

MJFCIFSS


Technical dataA 934 C HD LI Log Loader

Service Manual

Type 1053 Hydraulic system Swing pump / design

Axial piston swash plate pump with attached replenishing pump

Pump performance

KW

80 (108 Hp)

Max. flow

l/min.

148

Replenishing pump flow

l/min.

41

Replenishing pressure

bar

16+2

Hydraulic pump / pilot pressure

Type

gear pump

Max.flow / pilot control

l/min.

45,5

Pressure limitation pilot control

bar

32+1

Pilot valves / attachment / swing circuit

Type

4TH 87 X 70-10

Pilot valve / travel circuit

Type

VG - 7 - 1 / 1

Pilot valve / outrigger

Typ

VG - 5 - 2

further specifications

see group 6.11

Hydraulic pump / fan drive

Type

A 10 VO 28 ED

Max. flow

l/min.

62

Hydraulic motor / fan

Type

A 10 FE 28

Hydraulic pump / opional installation

Type

gear pump

Max. flow

l/min.

24,7

Rotary connection 7-way

Type

DDF 720

Rotary connection 6-way

Type

815.006 B

Hydraulic cylinder

refer to group 7.30

Electrical system Operating voltage

V

24

Battery - capacity

Ah

2 x 170 ( in series )

Alternator voltage / current

A

28V / 80

Starter motor

KW

24V / 6,6

Gearbox

Type

SAT 275 / 255

Oil motor

Type

FMF 64

Swing speed max.

rpm

8,2

Oil quantity in gear box

l

7,0

Swing gear

Oil quality / -viscosity and oil change interval

refer to group 1.50 and 3.83

Swing brake

Typw

wet disk brake (negativ)

Opening pressure max.

bar

20

Further specifications

refer to group 9.10

Axles Oscillating axle

Type

LT 81 PL 488 NLB

Rigid Axle

Type

LT 81 PL 488 NLB

Oil quantity in axle housing of oscillating axle

l

39

3.09.2 copyright by

MJFCIFSS


Service Manual

Technical dataA 934 C HD LI Log Loader Type 1053

Axles Oil quantity in axle housing of rigid axle

l

39

Oil quantity in wheel hub steering axle / rigid axle

l

4,0

Oil quality / -viscosity and oil change interval

refer to group 1.50 and 3.83

Operating brake

Type

Tires

wet disk brake positiv 17.50-25

Transmission Gear box

Type

2 HL 290

Oil motor

Type

DMVA 165

Travel speed in creeper mode 1. gear / 2. gear

Km/h

2,4 / 10

Travel speed in 1. gear / 2. gear

Km/h

4,6 / 20

Oil quantity in gear box

l

3,3

Oil quality, oil viscosity and oil change interval

refer to group 1.50 and 3.83

Parking brake

Type

Further specifications

wet disk brake negativ refer to group 11

Steering Hydraulic pump

Type

gear pump

Flow

l/min

61

Steering valve

Type

7030176

First primary relief valve

bar

220+5

Second primary relief valve

bar

180+5

Secondary relief valve

bar

240+5

Hydraulic pump

Type

gear pump

Flow max.

l/min

2,7

Charge pressure max.

bar

200

Brake pressure max. / operating brake

bar

75+10

cm3

appr. 30

Brake system

Central lubricating system Grease quantity / working hour Cycles / lubrication during automatic greasing (option)

refer to group 18.50

3.09.3 copyright by

MJFCIFSS


Technical dataA 934 C HD LI Log Loader

Service Manual

Type 1053

3.09.4 copyright by

MJFCIFSS


Service Manual

Technical data A 944 C-HD Litronic, 24 475

Technical data 1

A 944 C-HD Litronic, 24 475 Type 194

General Weight of basic machineapprox.

t

46

Weight of basic machine with attachment, without grappleapprox.

t

56

Overall length (basic machine without attachment)

mm

6846

Overall width

mm

3502

Overall height without attachment (operator's cab elevation 1200)

mm

5073

Rear reach from centre/slewing radius

mm

3521

Ground clearance

mm

455

Diesel engine

Type

D 936 L

Power at rated speed according to DIN ISO 9249

kW

190 (255 PS)

Rated speed

rpm

1800

Max. torque

Nm

1200 at 1500 rpm

Drive motor

Oil volume in engine (filling quantity at oil change with filter)

l

40

Pump distribution gear

Type

PVG 351 B 382

Oil volume in pump distribution gear

l

2.5

Flow rate / hydraulic pump - pump distribution gear

l/min

10.5

Oil quality/oil viscosity and oil change intervals

see groups 1.50 and 3.85

Cooling liquid including coolant

l

81

Type

LPVD 150

Hydraulic system Hydraulic pump Design

Axial piston swash plate pump

Hydr. drive power at max. motor output

kW

186 (250 PS)

Input speed

rpm

2025

Max. flow rate

l/min

2 x 303

Hydraulic oil volume (oil change with filter)

l

approx. 460

Hydraulic oil and filter change intervals

see groups 1.50 and 3.85

Control valve block

Type

Slewing gear circuit

NG 22 Closed circuit

Slewing gear pump

Type

Slewing gear pump / type

A4V 71 DWD Swash-plate axial-piston pump with attached feeder pump

Pump performance

kW

112 (150 PS)

3.11.1 copyright by

MJFCIFSS


Technical data

Service Manual

A 944 C-HD Litronic, 24 475 Hydraulic system Max. flow rate

l/min

185

Feeder pump flow rate

l/min

46

Feed pressure

bar

16

Hydraulic pump / pilot control

Type

Gear pump

3

Hydraulic pump / pilot control flow volume

cm

11

Max. flow / pilot control

l/min

31.8

Pressure limitation pilot control

bar

35+2

Pilot control unit / working attachment / slewing gear

Type

4TH 87 Z 70-10

Pilot control unit / travel drive

Type

VG - 7 - 1 / 1

Pilot control unit / support

Type

VG - 5 - 2

Additional information

see group 6.15

Hydraulic pump / fan

Type

A 10 V 28 ED

Max. flow rate

l/min

62

Hydraulic motor / fan

Type

A 10 FE 28

Hydraulic pump / accessory kit

Type

Gear pump

Max. flow rate

l/min

24

Rotary connection 9 x

Type

A 431

Rotary connection 6 x

Type

815.006 B

Hydraulic cylinder

see group 7.30

Electrical system Operating voltage

V

24

Battery capacity

Ah

2 x 170 (in series)

Alternator voltage / current

A

28 V / 80

Starter

kW

24 V / 7.8

Gearbox

Type

SAT 325 / 254

Oil motor

Type

FMF 90

Max. slewing speed

rpm

7.2

Oil volume in gearbox

l

11.0

Slewing gear mechanism

Oil quality /oil viscosity and oil change intervals

see groups 1.50 and 3.85

Slewing gear brake

Type

Wet multi-disc brake (negative)

Max. release pressure

bar

20

Additional information

see group 9.10

Parking brake Parking brake

Type

Wet multi-disc brake (negative)

Max. release pressure

bar

35

Oil quality /oil viscosity and oil change intervals

see groups 1.50 and 3.85

Oil volume in gearbox

l

3.11.2 copyright by

MJFCIFSS

0.25


Service Manual

Technical data A 944 C-HD Litronic, 24 475

Axle gear Oil motor

Type

A 6 VM 200

Travel speed in working gear

kph

11

Travel speed in creeper gear

kph

5

Oil quality /oil viscosity and oil change intervals

see groups 1.50 and 3.85

Axles Steering axle

Type

LT 91 VPL 488

Rigid axle

Type

D 91 VPL 488

Oil volume in steering axle housing

l

43

Oil volume in rigid axle housing

l

38

Oil volume in steering axle / rigid axle wheel hub

l

3.6

Oil quality /oil viscosity and oil change intervals

see groups 1.50 and 3.85

Working brake

Type

Tyres

Disc brake Ă&#x2DC;1500 x 520 wide / solid tyres

Steering Hydraulic pump

Type

Gear pump

Flow rate

l/min

61

Steering valve

Type

7030176

First primary protection

bar

220+5

Second primary protection

bar

180+5

Secondary protection

bar

240+5

Hydraulic pump

Type

Gear pump

Max. flow rate

l/min

2.7

Max. charging pressure

bar

200

Max. brake pressure / working brake

bar

135+10

cm3

approx. 30

Brake system

Central lubrication system Volume of grease per working hour Number of cycles / grease processes with automatic greasing (optional)

see group 18.50

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Technical data

Service Manual

A 944 C-HD Litronic, 24 475

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Service Manual

Technical data A 944 C - HD Litronic, from 29 225 – log loader

Technical data 1

A 944 C - HD Litronic, from 29 225 – log loader Type 196

General Weight of basic machine approx.

t

36

Weight of basic machine with attachment, without grapple approx.

t

43

Overall length (basic machine without attachment)

mm

6835

Overall width

mm

3502

Overall height without attachment (operator's cab elevation 800)

mm

4702

Rear reach from centre/slewing radius

mm

3346

Ground clearance

mm

519

Diesel engine

Type

D 936 L A6

Power at rated speed according to DIN ISO 9249

kW

190 (255 PS)

Rated speed

rpm

1800

Max. torque

Nm

at 1200 rpm

Drive motor

Oil volume in engine (filling quantity at oil change with filter)

l

40

Pump distributor gear

Type

PVG 351 B 382

Oil volume in pump distributor gear

l

2,5

Pump volume / hydraulic pump – pump distributor gear

l/min

10,5

Oil quality/oil viscosity and oil change intervals

see groups 1.50 and 3.88

Cooling liquid including coolant

l

81

Type

LPVD 150

Hydraulic system Hydraulic pump Design

Axial piston swash plate pump

Hydraulic drive output at maximum motor power

kW

186 (250 PS)

Input speed

rpm

2025

Max. flow rate

l/min

2 x 303

Hydraulic oil volume (oil change with filter)

l

approx. 460

Hydraulic oil and filter change intervals

see groups 1.50 and 3.88

Control valve block

Type

Slewing gear circuit

NG 22 Closed circuit

Slewing gear pump

Type

Slewing gear pump / design

A4VG 71 DWD Swash plate axial piston pump with attached feed pump

Pump performance

kW

112 (150 PS)

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Technical data

Service Manual

A 944 C - HD Litronic, from 29 225 Â&#x2013; log loader Hydraulic system Max. flow

l/min. 3

185

Feed pump flow volume

cm

19.6

Feed pump flow rate

l/min.

46

Feed pressure

bar

16

Hydraulic pump / pilot control

Type

Gear pump

3

Hydraulic pump / pilot control flow volume

cm

11

Max. flow / pilot control

l/min.

31.8

Pilot control pressure control

bar

35+2

Pilot control unit / working attachment / slewing gear

Type

4TH 87 Z 70-10

Pilot control unit / travel drive

Type

VG - 7 - 1 / 1

Pilot control unit / support

Type

VG - 5 - 2

Additional information

see group 6.15

Hydraulic pump / fan

Type

A 10 V 28 ED

Max. flow rate

l/min.

62

Hydraulic motor / fan

Type

A 10 FE 28

Hydraulic pump / accessory kit

Type

Gear pump

Max. flow

l/min.

24

Rotary connection 6 x

Type

DDF 720

Rotary connection 6 x

Type

815.006 C

Hydraulic cylinder

see group 7.30

Electrical system Operating voltage

V

24

Battery capacity

Ah

2 x 170 (in series)

Alternator voltage / current

A

28 V / 80

Starter

kW

24 V / 7.8

Gearbox

Type

SAT 325 / 254

Oil motor

Type

FMF 90

Max. slewing speed

rpm

7.2

Oil volume in gearbox

l

11.0

Slewing gear

Oil quality /oil viscosity and oil change intervals

see groups 1.50 and 3.88

Slewing gear brake

Type

Wet multi-disc brake (negative)

Max. opening pressure

bar

20

Additional information

see group 9.10

Transmission Gearbox

Type

2 HL 290

Oil motor

Type

DMVA 165

Travel speed at creeper speed off-road/on-road

kph

3 / 12

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Service Manual

Technical data A 944 C - HD Litronic, from 29 225 Â&#x2013; log loader

Transmission Travel speed in working gear / on-road gear

kph

6 / 18

Oil volume in gearbox

l

3,3

Oil quality, oil viscosity and oil change intervals

see groups 1.50 and 3.88

Parking brake

Type

Additional information

Wet multi-disc brake (negative) see group 11

Axles Oscillating axle

Type

LT 91 VPL 488

Rigid axle

Type

LT 91 VPL 488

Oil volume in oscillating axle housing

l

47

Oil volume in rigid axle housing

l

50,6

Oil volume in oscillating / rigid axle wheel hub

l

3.6

Oil quality /oil viscosity and oil change intervals

see groups 1.50 and 3.88

Working brake

Type

Tyres

Disc brake 18.00 - 25

Ă&#x2DC;1672 x 512

Steering Hydraulic pump

Type

Gear pump

Flow rate

l/min

61

Steering valve

Type

7030176

First primary protection

bar

220+5

Second primary protection

bar

180+5

Secondary protection

bar

240+5

Hydraulic pump

Type

Gear pump

Max. flow rate

l/min

2.7

Max. charging pressure

bar

200

Max. brake pressure / working brake

bar

135+10

cm3

approx. 30

Brake system

Central lubrication system Volume of grease per working hour Number of cycles / grease processes with automatic greasing (optional)

see group 18.50

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Technical data

Service Manual

A 944 C - HD Litronic, from 29 225 Â&#x2013; log loader

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Service Manual

Technical data A 954 C-HD Litronic from 21 416

Technical data 1

A 954 C-HD Litronic from 21 416 Type 450

General Weight of basic machine

approx.

t

59.5

t

73.5

Overall length (basic machine without attachment)

mm

7323

Overall width

mm

3800

Overall height without attachment

mm

5231

Rear reach from centre/slewing radius

mm

3823

Ground clearance

mm

500

Type

D 936 L A 6

Power at rated speed according to DIN ISO 9249

kW

240 (320 PS)

Rated speed

rpm

1800

Max. torque

Nm

2495 at 1000 rpm

l

40

Type

PVG 351 C 391

l

6.5

l/min

10.5

Weight of basic machine with attachment, without grapple approx.

Drive motor Diesel engine

Oil volume in engine (filling quantity at oil change with filter) Pump distribution gear Oil volume in pump distribution gear Flow rate / hydraulic pump - pump distribution gear Oil quality/oil viscosity and oil change intervals

see groups 1.50 and 3.90

Cooling liquid including coolant

l

81

Hydraulic system Hydraulic pump

Type

Design

2 x LPV 165 Axial piston swash plate pump

Hydr. drive power at max. motor output

kW

235 (315 PS)

Input speed

rpm

2169

Max. flow rate

l/min

2 x 357

Hydraulic oil volume (oil change with filter)

l

Hydraulic oil and filter change intervals

approx. 450 see groups 1.50 and 3.90

Control valve block

Type

Slewing gear circuit

NG 32 Closed circuit

Slewing gear pump

Type

Slewing gear pump / type

A4VG 71 DWD swash-plate axial-piston pump with attached feeder pump

Pump performance

kW

142 (190 PS)

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Technical data

Service Manual

A 954 C-HD Litronic from 21 416 Hydraulic system Max. geomtr. flow volume

cm3

71

Max. flow rate

l/min.

211

3

Feeder pump flow volume

cm

Feeder pump flow rate

l/min.

46

Feed pressure

bar

16

Hydraulic pump / pilot control

Type

Gear pump

Hydraulic pump / pilot controlflow volume

cm3

11

Max. flow / pilot control

l/min.

30

Pressure limitation pilot control

bar

Pilot control unit / working attachment / slewing gear

Type

4TH 87 Z 70-10

Pilot control unit / travel drive

Type

VG - 7 - 1 / 1

Pilot control unit / support

Type

VG - 5 - 2

Additional information

19.6

35+2

see group 6.11

Hydraulic pump / fan

Type

A 10 V 28 ED

Max. flow rate

l/min.

62

Hydraulic motor / fan

Type

A 10 FE 28

Hydraulic pump / accessory kit

Type

Gear pump

Max. flow rate

l/min.

24

Rotary connection 9 x

Type

A 431

Rotary connection 6 x

Type

815.006 B

Hydraulic cylinder

see group 7.30

Electrical system Operating voltage

V

24

Battery capacity

Ah

2 x 170 (in series)

Alternator voltage / current

A

28 V / 80

Starter

kW

24 V / 7.8

Slewing gear mechanism Gearbox

Type

SAT 350 / 252

Oil motor

Type

FMF 100

Max. slewing speed

rpm

7

Oil volume in gearbox

l

11

Oil quality /oil viscosity and oil change intervals

see groups 1.50 and 3.90

Slewing gear brake

Type

Max. release pressure

bar

Additional information

Wet multi-disc brake (negative) 20 see group 9.10

Parking brake Parking brake

Type

Max. release pressure

bar

Oil quality /oil viscosity and oil change intervals

Wet multi-disc brake (negative) 35 see groups 1.50 and 3.90

3.15.2 copyright by

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Service Manual

Technical data A 954 C-HD Litronic from 21 416

Oil volume in gearbox

l

0.25

Axle gear Oil motor

Type

A 6 VM 200 HA 1 T

Travel speed working gear / creeper gear

km/h

10 / 5

Oil quality /oil viscosity and oil change intervals

see axles

Axles Steering axle

Type

LT 102 VPL 341 / 528 NLB

Rigid axle

Type

D 102 VPL 341 / 528 NLB

Oil volume in steering axle housing

l

55

Oil volume in rigid axle housing

l

45

Oil volume in steering axle / rigid axle wheel hub

l

9.5

Oil quality /oil viscosity and oil change intervals

see groups 1.50 and 3.90

Working brake

Type

Tyres

Multi-disc brake Ă&#x2DC;1600 x 600 wide / solid tyres

Steering Hydraulic pump

Type

Gear pump

Flow rate

l/min

61

Steering / Servostat

Type

ZF / 2

First primary protection

bar

220+5

Second primary protection

bar

180+5

Secondary protection

bar

240+5

Brake system Hydraulic pump

Type

Gear pump

Max. flow rate

l/min

2.7

Max. charging pressure

bar

200

Max. brake pressure / working brake

bar

135+10

cm3

approx. 30

Central lubrication system Volume of grease per working hour Number of cycles / grease processes with automatic greasing (optional)

see group 18.50

3.15.3 copyright by

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Technical data

Service Manual

A 954 C-HD Litronic from 21 416

3.15.4 copyright by

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Service Manual

Maintenance and inspection schedule A 934 C Litronic from 28 016

Maintenance and inspection schedule 1

A 934 C Litronic from 28 016 Type 1006 Customer:

Serial no.:

Date:

Machine type:

Operating hours:

Caution! Careful maintenance is only possible, if the machine is clean. Especially visual inspections, e.g. for cracks, can be carried out properly only with a machine that has been cleaned recently. Therefore clean the machine thoroughly before starting any maintenance work (see also chapter "Safe maintenance of machine", subchapters "Cleaning" and "Crack inspection").

Note! The daily maintenance tasks of the machine operator include a functional test of the brakes (slewing gear brake, working brake, parking brake), steering, electrical and hydraulic systems. Also to be carried out is a daily visual inspection of the motor, hydraulic system, gearbox and axles for leakage.

Maintenance/inspection at operating hours

WORK TO BE CARRIED OUT A 934 C Litronic, type 1006 by maintenance personnel (machine operator) Initial and single interval Repeat interval Annually, at the start of the cold season when required

with authorised specialist technician Initial and single interval Repeat interval

DIESEL ENGINE Check the oil level Visual inspection (leakage, dirt, damage) Check oil level in pump distributor gear Replace gear oil in pump distribution gear Check flap of diesel engine brake 1)

Change diesel engine oil (at least once a year) Change oil filter insert (at least once a year) Check batteries and cable connections

3.17.1 copyright by

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Maintenance and inspection schedule

Service Manual

A 934 C Litronic from 28 016 Maintenance/inspection at operating hours

WORK TO BE CARRIED OUT A 934 C Litronic, type 1006 by maintenance personnel (machine operator) Initial and single interval Repeat interval Annually, at the start of the cold season when required

with authorised specialist technician Initial and single interval Repeat interval

Belt drive: check belt; replace, if necessary / V-ribbed belt: check tension; adjust, if necessary Check intake and exhaust systems for general condition, fixture and leakage Grease the flywheel ring gear Replace filter insert at the crankcase ventilation Check oil pan, engine bearings and diesel engine support for proper fixture Check / readjust valve play Check heating flange 3000

Check vibration dampers for deformation RADIATOR Check the coolant level Check cooling and heating systems for general condition and leakage Check corrosion inhibitor and antifreeze agent concentration in coolant

3000

Change coolant (at least every 2 years) FUEL SYSTEM Check water separator at the fuel pre-filter and drain off water, if necessary Drain water and deposit from fuel tank

4)

Check fuel system for leakage and general state

4)

Change fuel pre-filter

4)

Change fuel fine filter Bleed fuel system AIR FILTER Check underpressure indicator of the air filter Clean dust removal valve of the air filter Change main element of the dry air filter (according to maintenance indication / annually)

3.17.2 copyright by

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Service Manual

Maintenance and inspection schedule A 934 C Litronic from 28 016

Maintenance/inspection at operating hours

WORK TO BE CARRIED OUT A 934 C Litronic, type 1006 by maintenance personnel (machine operator) Initial and single interval Repeat interval Annually, at the start of the cold season when required

with authorised specialist technician Initial and single interval Repeat interval

Change safety element of the dry air filter (at every third main element change / annually) - do not clean or reuse! ELECTRICAL SYSTEM OF THE DIESEL ENGINE Check control device bearing for general condition Check sensor devices and cable connections HYDRAULIC SYSTEM Check oil level in hydraulic tank Clean magnetic rod in return filter (daily during first 300 operating hours) 2)

Replace filter element in bypass filter (optional equipment) (in machines used in dusty environments: every 250 operating hours)

2)

Replace filter insert in return filter Replace filter cartridge in control oil unit Replace feed oil filter on slewing gear pump Check components for proper mounting Check the hydraulic oil cooler for dirt; clean it, if necessary Drain water from hydraulic tank (max. permissible water content for environmentally friendly fluids: 0.1 %; insert bypass filter, take oil sample) Check hydraulic system for leakage; complete functional test Check / readjust servo, primary and secondary pressures

2), 3) 2)

Change hydraulic oil in tank (optimise interval by carrying out oil analyses) Change breather filter on hydraulic tank ELECTRICAL SYSTEM Check indicator lights and indicating devices upon start-up Check lighting Check acid density and level, wire terminals and terminal ports of the batteries Spray slip rings of the slewing gear connection with Cramolin contact spray Carry out functional tests of entire unit and all components

3.17.3 copyright by

MJFCIFSS


Maintenance and inspection schedule

Service Manual

A 934 C Litronic from 28 016 Maintenance/inspection at operating hours

WORK TO BE CARRIED OUT A 934 C Litronic, type 1006 by maintenance personnel (machine operator) Initial and single interval Repeat interval Annually, at the start of the cold season when required

with authorised specialist technician Initial and single interval Repeat interval

SLEWING GEAR MECHANISM Check oil level; check system for leakage Carry out functional test of slewing gear brake Check gearbox and oil motor for proper mounting Change gear oil SLEWING RING Check mounting bolts for press fit; slewing gear pining meshing AXLES Lubricate steering knuckle bearing and oscillating bolts (weekly or monthly, depending on use) Check oil level; check system for leakage Check axles, gears, oil motor, oscillating axle bearing and wheel lugs for proper mounting and retighten, if necessary Change oil in axle housing (front and rear) Change oil in planetary drive (front and rear) Check multi-disc brake for wear (once a year; shorten interval, if necessary) TRANSMISSION Check oil level; check system for leakage Carry out functional test of power shift mechanism and parking brake Check gearbox, oil motor and joint shafts for proper mounting Change gear oil STEERING Check system for leakage; complete functional test Check components and steering system parts for proper mounting

3.17.4 copyright by

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Service Manual

Maintenance and inspection schedule A 934 C Litronic from 28 016

Maintenance/inspection at operating hours

WORK TO BE CARRIED OUT A 934 C Litronic, type 1006 by maintenance personnel (machine operator) Initial and single interval Repeat interval Annually, at the start of the cold season when required

with authorised specialist technician Initial and single interval Repeat interval

OSCILLATING AXLE SUPPORT Check system for leakage; complete functional test Check cylinders for proper mounting BRAKE SYSTEM Check system for leakage; check accumulator and brake pressure as well as check switch Carry out functional test OPERATOR'S CAB + HEATING Check / add detergent solution in windscreen washer tank Treat rubber seals of the operatorÂ&#x2019;s cabin with silicone or talcum Treat rubber seals of the access doors on the uppercarriage with silicone or talcum Check function of heating Check heating system for leakage Check door and window hinges as well as locks Check water inlet valve for contamination, and clean, if necessary; carry out functional test of valve AIR-CONDITIONING SYSTEM Regularly switch on air-conditioning system (at least 1x every 14 days) Check condenser for contamination; blow clean, if necessary Clean re-circulated air / fresh air filter; replace, if necessary; shorten interval if there is excessive generation of dust Check compressor mounting bolts and drive belts Check dryer-collector unit (humidity, fill level); replace, if necessary Check evaporator unit; clean, if necessary Check electrical lines for chafe marks; check plug connections Complete functional test of excess pressure switch

3.17.5 copyright by

MJFCIFSS


Maintenance and inspection schedule

Service Manual

A 934 C Litronic from 28 016 Maintenance/inspection at operating hours

WORK TO BE CARRIED OUT A 934 C Litronic, type 1006 by maintenance personnel (machine operator) Initial and single interval Repeat interval Annually, at the start of the cold season when required

with authorised specialist technician Initial and single interval Repeat interval

Check cooling performance Replace dryer-collector unit every 12 months; also check cooling circuit for leakage and change coolant and refrigeration oil Every 12 months, contract a refrigeration technician to carry out a functional test of the air flaps and the defrost thermostat UNDERCARRIAGE + UPPERCARRIAGE + WORKING ATTACHMENTS Lubricate bearing points, using the semi-automatic central lubrication system; exception: not required in units with fully automatic central lubrication system (optional equipment) Lubricate bearing positions (undercarriage and working attachments) Lubricate daily when required due to type of use and/or shift operation Inspect teeth for wear 250

Check parts for cracks

250

Check counter weight and tank for proper mounting Check lines and screwed connections for proper fit Check panelling hinges, quick fasteners and gas pressure springs of the caps Instruct operators in the proper use of the equipment Instruct the operator on how the machine must be lubricated according to the lubricating chart and make him aware of potential operator errors

HYDRAULIC QUICK CHANGE ADAPTER Carry out a functional test of the visual and acoustic warning systems Carry out a visual inspection of the extended locking bolts Check hydraulic hoses and wire harness Lubricate locking bolts Clean mesh filter MECHANICAL QUICK CHANGE ADAPTER Carry out a visual inspection of the extended locking bolts Lubricate locking bolts

3.17.6 copyright by

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Service Manual

Maintenance and inspection schedule A 934 C Litronic from 28 016

Maintenance/inspection at operating hours

WORK TO BE CARRIED OUT A 934 C Litronic, type 1006 by maintenance personnel (machine operator) Initial and single interval Repeat interval Annually, at the start of the cold season when required

with authorised specialist technician Initial and single interval Repeat interval

Check entire machine for proper maintenance and orderly condition. Explain machine literature (especially operatorÂ&#x2019;s manual, safety instructions) to the operators. Tab. 1 1 2 3 4

Inspection- and maintenance schedule

The intervals for the change of the motor oil might have to be shortened, depending on the actual temperature, fuel and oil quality. In the case of applications with excessive dust generation, observe shortened maintenance intervals. For environmentally friendly hydraulic fluids, adjust the maintenance interval on the basis of regular analyses. The maintenance intervals might have to be shortened, depending on the operating conditions (e.g. generation of dust, barrel fuelling).

Comments / defects

Date:

Mechanic:

Customer:

3.17.7 copyright by

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Maintenance and inspection schedule

Service Manual

A 934 C Litronic from 28 016

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Service Manual

Maintenance and inspection schedule A 934 C-HD Litronic, 25 436

Maintenance and inspection schedule 1

A 934 C-HD Litronic, 25 436 Type 1007 Customer:

Serial no.:

Date:

Machine type:

Operating hours:

Caution! Careful maintenance is only possible, if the machine is clean. Especially visual inspections, e.g. for cracks, can be carried out properly only with a machine that has been cleaned recently. Therefore clean the machine thoroughly before starting any maintenance work (see also chapter "Safe maintenance of machine", subchapters "Cleaning" and "Crack inspection").

Note! The daily maintenance tasks of the machine operator include a functional test of the brakes (slewing gear brake, working brake, parking brake), steering, electrical and hydraulic systems. Also to be carried out is a daily visual inspection of the motor, hydraulic system, gearbox and axles for leakage.

Maintenance/inspection at operating hours

WORK TO BE CARRIED OUT A 934 C Litronic, type 1007 by maintenance personnel (machine operator) Initial and single interval Repeat interval Annually, at the start of the cold season when required

with authorised specialist technician Initial and single interval Repeat interval

DIESEL ENGINE Check the oil level Visual inspection (leakage, dirt, damage) Check oil level in pump distributor gear Replace gear oil in pump distribution gear Check flap of diesel engine brake 1)

Change diesel engine oil (at least once a year) Change oil filter insert (at least once a year) Check batteries and cable connections

3.19.1 copyright by

MJFCIFSS


Maintenance and inspection schedule

Service Manual

A 934 C-HD Litronic, 25 436 Maintenance/inspection at operating hours

WORK TO BE CARRIED OUT A 934 C Litronic, type 1007 by maintenance personnel (machine operator) Initial and single interval Repeat interval Annually, at the start of the cold season when required

with authorised specialist technician Initial and single interval Repeat interval

Belt drive: check belt; replace, if necessary / V-ribbed belt: check tension; adjust, if necessary Check intake and exhaust systems for general condition, fixture and leakage Grease the flywheel ring gear Replace filter insert at the crankcase ventilation Check oil pan, engine bearings and diesel engine support for proper fixture Check / readjust valve play Check heating flange 3000

Check vibration dampers for deformation RADIATOR Check the coolant level Check cooling and heating systems for general condition and leakage Check corrosion inhibitor and antifreeze agent concentration in coolant

3000

Change coolant (at least every 2 years) FUEL SYSTEM Check water separator at the fuel pre-filter and drain off water, if necessary Drain water and deposit from fuel tank

4)

Check fuel system for leakage and general state

4)

Change fuel pre-filter

4)

Change fuel fine filter Bleed fuel system AIR FILTER Check underpressure indicator of the air filter Clean dust removal valve of the air filter Change main element of the dry air filter (according to maintenance indication / annually)

3.19.2 copyright by

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Service Manual

Maintenance and inspection schedule A 934 C-HD Litronic, 25 436

Maintenance/inspection at operating hours

WORK TO BE CARRIED OUT A 934 C Litronic, type 1007 by maintenance personnel (machine operator) Initial and single interval Repeat interval Annually, at the start of the cold season when required

with authorised specialist technician Initial and single interval Repeat interval

Change safety element of the dry air filter (at every third main element change / annually) - do not clean or reuse! ELECTRICAL SYSTEM OF THE DIESEL ENGINE Check control device bearing for general condition Check sensor devices and cable connections HYDRAULIC SYSTEM Check oil level in hydraulic tank Clean magnetic rod in return filter (daily during first 300 operating hours) 2)

Replace filter element in bypass filter (optional equipment) (in machines used in dusty environments: every 250 operating hours)

2)

Replace filter insert in return filter Replace filter cartridge in control oil unit Replace feed oil filter on slewing gear pump Check components for proper mounting Check the hydraulic oil cooler for dirt; clean it, if necessary Drain water from hydraulic tank (max. permissible water content for environmentally friendly fluids: 0.1 %; insert bypass filter, take oil sample) Check hydraulic system for leakage; complete functional test Check / readjust servo, primary and secondary pressures

2), 3) 2)

Change hydraulic oil in tank (optimise interval by carrying out oil analyses) Change breather filter on hydraulic tank ELECTRICAL SYSTEM Check indicator lights and indicating devices upon start-up Check lighting Check acid density and level, wire terminals and terminal ports of the batteries Spray slip rings of the slewing gear connection with Cramolin contact spray Carry out functional tests of entire unit and all components

3.19.3 copyright by

MJFCIFSS


Maintenance and inspection schedule

Service Manual

A 934 C-HD Litronic, 25 436 Maintenance/inspection at operating hours

WORK TO BE CARRIED OUT A 934 C Litronic, type 1007 by maintenance personnel (machine operator) Initial and single interval Repeat interval Annually, at the start of the cold season when required

with authorised specialist technician Initial and single interval Repeat interval

SLEWING GEAR MECHANISM Check oil level; check system for leakage Carry out functional test of slewing gear brake Check gearbox and oil motor for proper mounting Change gear oil SLEWING RING Check mounting bolts for press fit; slewing gear pining meshing AXLES Lubricate steering knuckle bearing and oscillating bolts (weekly or monthly, depending on use) Check oil level; check system for leakage Check axles, gears, oil motor, oscillating axle bearing and wheel lugs for proper mounting and retighten, if necessary Change oil in axle housing (front and rear) Change oil in planetary drive (front and rear) Check multi-disc brake for wear (once a year; shorten interval, if necessary) TRANSMISSION Check oil level; check system for leakage Carry out functional test of power shift mechanism and parking brake Check gearbox, oil motor and joint shafts for proper mounting Change gear oil STEERING Check system for leakage; complete functional test Check components and steering system parts for proper mounting

3.19.4 copyright by

MJFCIFSS


Service Manual

Maintenance and inspection schedule A 934 C-HD Litronic, 25 436

Maintenance/inspection at operating hours

WORK TO BE CARRIED OUT A 934 C Litronic, type 1007 by maintenance personnel (machine operator) Initial and single interval Repeat interval Annually, at the start of the cold season when required

with authorised specialist technician Initial and single interval Repeat interval

OSCILLATING AXLE SUPPORT Check system for leakage; complete functional test Check cylinders for proper mounting BRAKE SYSTEM Check system for leakage; check accumulator and brake pressure as well as check switch Carry out functional test OPERATOR'S CAB + HEATING Check / add detergent solution in windscreen washer tank Treat rubber seals of the operatorÂ&#x2019;s cabin with silicone or talcum Treat rubber seals of the access doors on the uppercarriage with silicone or talcum Check function of heating Check heating system for leakage Check door and window hinges as well as locks Check water inlet valve for contamination, and clean, if necessary; carry out functional test of valve AIR-CONDITIONING SYSTEM Regularly switch on air-conditioning system (at least 1x every 14 days) Check condenser for contamination; blow clean, if necessary Clean re-circulated air / fresh air filter; replace, if necessary; shorten interval if there is excessive generation of dust Check compressor mounting bolts and drive belts Check dryer-collector unit (humidity, fill level); replace, if necessary Check evaporator unit; clean, if necessary Check electrical lines for chafe marks; check plug connections Complete functional test of excess pressure switch

3.19.5 copyright by

MJFCIFSS


Maintenance and inspection schedule

Service Manual

A 934 C-HD Litronic, 25 436 Maintenance/inspection at operating hours

WORK TO BE CARRIED OUT A 934 C Litronic, type 1007 by maintenance personnel (machine operator) Initial and single interval Repeat interval Annually, at the start of the cold season when required

with authorised specialist technician Initial and single interval Repeat interval

Check cooling performance Replace dryer-collector unit every 12 months; also check cooling circuit for leakage and change coolant and refrigeration oil Every 12 months, contract a refrigeration technician to carry out a functional test of the air flaps and the defrost thermostat UNDERCARRIAGE + UPPERCARRIAGE + WORKING ATTACHMENTS Lubricate bearing points, using the semi-automatic central lubrication system; exception: not required in units with fully automatic central lubrication system (optional equipment) Lubricate bearing positions (undercarriage and working attachments) Lubricate daily when required due to type of use and/or shift operation Inspect teeth for wear 250

Check parts for cracks

250

Check counter weight and tank for proper mounting Check lines and screwed connections for proper fit Check panelling hinges, quick fasteners and gas pressure springs of the caps Instruct operators in the proper use of the equipment Instruct the operator on how the machine must be lubricated according to the lubricating chart and make him aware of potential operator errors HYDRAULIC QUICK CHANGE ADAPTER Carry out a functional test of the visual and acoustic warning systems Carry out a visual inspection of the extended locking bolts Check hydraulic hoses and wire harness Lubricate locking bolts Clean mesh filter

MECHANICAL QUICK CHANGE ADAPTER Carry out a visual inspection of the extended locking bolts Lubricate locking bolts

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Service Manual

Maintenance and inspection schedule A 934 C-HD Litronic, 25 436

Maintenance/inspection at operating hours

WORK TO BE CARRIED OUT A 934 C Litronic, type 1007 by maintenance personnel (machine operator) Initial and single interval Repeat interval Annually, at the start of the cold season when required

with authorised specialist technician Initial and single interval Repeat interval

Check entire machine for proper maintenance and orderly condition. Explain machine literature (especially operatorÂ&#x2019;s manual, safety instructions) to the operators. Tab. 1 1 2 3 4

Inspection- and maintenance schedule

The intervals for the change of the motor oil might have to be shortened, depending on the actual temperature, fuel and oil quality. In the case of applications with excessive dust generation, observe shortened maintenance intervals. For environmentally friendly hydraulic fluids, adjust the maintenance interval on the basis of regular analyses. The maintenance intervals might have to be shortened, depending on the operating conditions (e.g. generation of dust, barrel fuelling).

Comments / defects

Date:

Mechanic:

Customer:

3.19.7 copyright by

MJFCIFSS


Maintenance and inspection schedule

Service Manual

A 934 C-HD Litronic, 25 436

3.19.8 copyright by

MJFCIFSS


Service Manual

Maintenance and inspection schedule A 934 C-HD Litronic, 31793 - log loader

Maintenance and inspection schedule 1

A 934 C-HD Litronic, 31793 - log loader Type 1053 Customer:

Serial no.:

Date:

Machine type:

Operating hours:

Caution! Careful maintenance is only possible, if the machine is clean. Especially visual inspections, e.g. for cracks, can be carried out properly only with a machine that has been cleaned recently. Therefore clean the machine thoroughly before starting any maintenance work (see also chapter "Safe maintenance of machine", subchapters "Cleaning" and "Crack inspection").

Note! The daily maintenance tasks of the machine operator include a functional test of the brakes (slewing gear brake, working brake, parking brake), steering, electrical and hydraulic systems. Also to be carried out is a daily visual inspection of the motor, hydraulic system, gearbox and axles for leakage.

Maintenance/inspection at operating hours

WORK TO BE CARRIED OUT A 934 C-HD Litronic, type 1053 by maintenance personnel (machine operator)

with authorised specialist technician

Initial and single interval Repeat interval Annually, at the start of the cold season when required

Initial and single interval Repeat interval

DIESEL ENGINE Check oil level Visual inspection (leakage, dirt, damage) Check oil level in pump distributor gear Replace gear oil in pump distribution gear Check flap of diesel engine brake 1)

Change diesel engine oil (at least once a year) Change oil filter insert (at least once a year) Check batteries and cable connections

3.21.1 copyright by

MJFCIFSS


Maintenance and inspection schedule

Service Manual

A 934 C-HD Litronic, 31793 - log loader Maintenance/inspection at operating hours

WORK TO BE CARRIED OUT A 934 C-HD Litronic, type 1053 by maintenance personnel (machine operator) Initial and single interval Repeat interval Annually, at the start of the cold season when required

with authorised specialist technician Initial and single interval Repeat interval

Belt drive: Check belt; replace, if necessary / V-ribbed belt: check tension; adjust, if necessary Check intake and exhaust systems for general condition, fixture and leakage Grease the flywheel ring gear Replace filter insert at the crankcase ventilation Check oil pan, engine bearings and diesel engine support for proper fixture Check / readjust valve play Check heating flange 3000

Check vibration dampers for deformation RADIATOR Checking the coolant level Check cooling and heating systems for general condition and leakage Check corrosion inhibitor and antifreeze agent concentration in coolant

3000

Change coolant (at least every 2 years) FUEL SYSTEM Check water separator at the fuel pre-filter and drain off water, if necessary Drain water and deposit from fuel tank

4)

Check fuel system for leakage and general state

4)

Change fuel pre-filter

4)

Change fuel fine filter Bleed fuel system AIR FILTER Check underpressure indicator of the air filter Clean dust removal valve of the air filter Change main element of the dry air filter (according to maintenance indication / annually)

3.21.2 copyright by

MJFCIFSS


Service Manual

Maintenance and inspection schedule A 934 C-HD Litronic, 31793 - log loader

Maintenance/inspection at operating hours

WORK TO BE CARRIED OUT A 934 C-HD Litronic, type 1053 by maintenance personnel (machine operator)

with authorised specialist technician

Initial and single interval Repeat interval Annually, at the start of the cold season when required

Initial and single interval Repeat interval

Change safety element of the dry air filter (at every third main element change / annually) - do not clean or reuse! ELECTRICAL SYSTEM OF THE DIESEL ENGINE Check control device bearing for general condition Check sensor devices and cable connections HYDRAULIC SYSTEM Check oil level in hydraulic tank Clean magnetic rod in return filter (daily during first 300 operating hours) 2)

Replace filter element in bypass filter (optional equipment) (in machines used in dusty environments: every 250 operating hours)

2)

Replace filter insert in return filter Replace filter cartridge in control oil unit Replace feed oil filter on slewing gear pump Check components for proper mounting Check the hydraulic oil cooler for dirt; clean it, if necessary Drain water from hydraulic tank (max. permissible water content for environmentally friendly fluids: 0.1 %; insert bypass filter, take oil sample) Check hydraulic system for leakage; complete functional test Check / readjust servo, primary and secondary pressures

2), 3) 2)

Change hydraulic oil in tank (optimise interval by carrying out oil analyses) Change breather filter on hydraulic tank ELECTRICAL SYSTEM Check indicator lights and indicating devices upon start-up Check lighting Check acid density and level, wire terminals and terminal ports of the batteries Spray slip rings of the slewing gear connection with Cramolin contact spray Carry out functional tests of entire unit and all components

3.21.3 copyright by

MJFCIFSS


Maintenance and inspection schedule

Service Manual

A 934 C-HD Litronic, 31793 - log loader Maintenance/inspection at operating hours

WORK TO BE CARRIED OUT A 934 C-HD Litronic, type 1053 by maintenance personnel (machine operator)

with authorised specialist technician

Initial and single interval Repeat interval Annually, at the start of the cold season when required

Initial and single interval Repeat interval

SLEWING GEAR MECHANISM Check oil level; check system for leakage Carry out functional test of slewing gear brake Check gearbox and oil motor for proper mounting Change gear oil SLEWING RING Check mounting bolts for press fit; slewing gear pining meshing AXLES Lubricate steering knuckle bearing and oscillating bolts (weekly or monthly, depending on use) Check oil level; check system for leakage Check wheel lugs for proper fit (uniquely at 50, 100 and 250 working hours Â&#x2013; and after every wheel change or loosening of the wheel lugs) Check fixture of the axles and oscillating axle bearing Change oil in axle housing (front and rear) Change oil in planetary drive (front and rear) Check multi-disc brake for wear (once a year; shorten interval, if necessary) TRANSMISSION Check oil level; check system for leakage Carry out functional test of power shift mechanism and parking brake Check gearbox, oil motor and joint shafts for proper mounting Change gear oil STEERING Check system for leakage; complete functional test Check components and steering system parts for proper mounting

3.21.4 copyright by

MJFCIFSS


Service Manual

Maintenance and inspection schedule A 934 C-HD Litronic, 31793 - log loader

Maintenance/inspection at operating hours

WORK TO BE CARRIED OUT A 934 C-HD Litronic, type 1053 by maintenance personnel (machine operator)

with authorised specialist technician

Initial and single interval Repeat interval Annually, at the start of the cold season when required

Initial and single interval Repeat interval

OSCILLATING AXLE SUPPORT Check system for leakage; complete functional test Check cylinders for proper mounting BRAKE SYSTEM Check system for leakage; check accumulator and brake pressure as well as check switch Carry out functional test OPERATOR'S CAB + HEATING Check / add detergent solution in windscreen washer tank Treat rubber seals of the operatorÂ&#x2019;s cabin with silicone or talcum Treat rubber seals of the access doors on the uppercarriage with silicone or talcum Check function of heating Check heating system for leakage Check door and window hinges as well as locks Treat rubber seals of the operatorÂ&#x2019;s cab with silicone or talcum Treat rubber seals of the covers on the uppercarriage with silicone or talcum Check water inlet valve for contamination, and clean, if necessary; carry out functional test of valve AIR-CONDITIONING SYSTEM Regularly switch on air-conditioning system (at least 1x every 14 days) Check condenser for contamination; blow clean, if necessary Clean re-circulated air / fresh air filter; replace, if necessary; shorten interval if there is excessive generation of dust Check compressor mounting bolts and drive belts Check dryer-collector unit (humidity, fill level); replace, if necessary Check evaporator unit; clean, if necessary

3.21.5 copyright by

MJFCIFSS


Maintenance and inspection schedule

Service Manual

A 934 C-HD Litronic, 31793 - log loader Maintenance/inspection at operating hours

WORK TO BE CARRIED OUT A 934 C-HD Litronic, type 1053 by maintenance personnel (machine operator) Initial and single interval Repeat interval Annually, at the start of the cold season when required

with authorised specialist technician Initial and single interval Repeat interval

Check electrical lines for chafe marks; check plug connections Complete functional test of excess pressure switch Check cooling performance Replace dryer-collector unit every 12 months; also check cooling circuit for leakage and change coolant and refrigeration oil Every 12 months, contract a refrigeration technician to carry out a functional test of the air flaps and the defrost thermostat UNDERCARRIAGE + UPPERCARRIAGE + WORKING ATTACHMENTS Lubricate bearing points, using the semi-automatic central lubrication system; exception: not required in units with fully automatic central lubrication system (optional equipment) Lubricate bearing positions (undercarriage and working attachments) Lubricate daily when required due to type of use and/or shift operation Inspect teeth for wear 250

Check parts for cracks

250

Check counter weight and tank for proper mounting Check lines and screwed connections for proper fit Check panelling hinges, quick fasteners and gas pressure springs of the caps Instruct operators in the proper use of the equipment Instruct the operator on how the machine must be lubricated according to the lubricating chart and make him aware of potential operator errors HYDRAULIC QUICK CHANGE ADAPTER Carry out a functional test of the visual and acoustic warning systems Carry out a visual inspection of the extended locking bolts Check hydraulic hoses and wire harness Lubricate locking bolts Clean mesh filter MECHANICAL QUICK CHANGE ADAPTER Carry out a visual inspection of the extended locking bolts

3.21.6 copyright by

MJFCIFSS


Service Manual

Maintenance and inspection schedule A 934 C-HD Litronic, 31793 - log loader

Maintenance/inspection at operating hours

WORK TO BE CARRIED OUT A 934 C-HD Litronic, type 1053 by maintenance personnel (machine operator) Initial and single interval Repeat interval Annually, at the start of the cold season when required

with authorised specialist technician Initial and single interval Repeat interval

Lubricate locking bolts

Check entire machine for proper maintenance and orderly condition. Explain machine literature (especially operatorÂ&#x2019;s manual, safety instructions) to the operators. Tab. 1 1 2 3 4

Inspection and maintenance schedule

The intervals for the change of the motor oil might have to be shortened, depending on the actual temperature, fuel and oil quality. In the case of applications with excessive dust generation, observe shortened maintenance intervals. For environmentally friendly hydraulic fluids, adjust the maintenance interval on the basis of regular analyses. The maintenance intervals might have to be shortened, depending on the operating conditions (e.g. generation of dust, barrel fuelling).

Comments / defects

Date:

Mechanic:

Customer:

3.21.7 copyright by

MJFCIFSS


Maintenance and inspection schedule

Service Manual

A 934 C-HD Litronic, 31793 - log loader

3.21.8 copyright by

MJFCIFSS


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