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Technical documentation

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Technical documentation Hydraulic excavator R 900 C-Li - R 904 C-Li

Document identification Order number:

10069965

Issue:

01 / 2008

Valid for:

R 900 C-Li from serial number 13860 R 904 C-Li from serial number 23072

Author:

LFR - Technical documentation department

Product identification Manufacturer:

LIEBHERR France S.A.S.

Type:

971 / 981 / 982 for R 900 C-Li 983 / 984 / 985 / 993 / 1017 / 1018 for R 904 C-Li

Conformity:

CE

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Service Manual

1

General information

2

Tools

3

Technical data / Maintenance guidelines

4

Engine

5

Coupling / Splitterbox

6

Hydraulic system

7

Hydraulic components

8

Electrical system

9

Swing gear

10

Swing ring

11

Travel gear

12

Track components

13 14 15 16

Options

17

Cab / Heater / Air conditioning system

18

Central lubrication

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Service Manual

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Service Manual

Introduction This manual contains technical data, design and functional descriptions, as well as service and set up instructions. The documents include numbers of drawings, functional diagrams, as well as detailed views of units and assemblies of LIEBHERR hydraulic excavators. This manual has been created in order to assist the customer support services, but does of course replace neither proper technical training and qualification of the user nor participation in LIEBHERR operator training courses. General basic technical information is not included in this manual. For operating instructions and information on spare parts, please refer to the separate documentation. For maintenance and reparation of the machine, follow conscientiously the safety instructions and warnings.

Symbols used in this manual In this manual the description of tasks and procedures that are associated with specific dangers are accompanied by safety instructions mentioning the danger related to described work. The safety instructions are graded according to the severity of the risk, and are identified with the symbols «Danger» and «Caution», which have the following significances: These terms are identified by symbols in the operating instructions and : 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 machine damages, unless the prescribed safety measures are taken. The symbol «Note» is destined to attract the attention of the persons having to intervene on the machine upon observations and comments concerning the procedure to be followed for operating as well for maintenance or repair works. Note! Comments and advices which will, if adhered to, help you to keep your excavator operating, to insure longlife to your machine and to facilitate certain procedures.

Signification of specific punctuation marks in descriptions – This mark introduces «an entry in a list». • This mark introduces «an entry in a sublist». This mark indicates «a requirement that must be fulfilled», before going on with the procedure below. This mark identifies «an injunction to perform the mentioned action». This mark indicates «the normally expected result of a carried out action».

About the contain of this Service Handbuchs This manual may not be replicated or made available to third parties without the explicit written consent of LIEBHERR, who retains all rights in this documents. All rights reserved - Printed in France.

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Service Manual This 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. This manual might be complemented by additional service information sheets issued by LIEBHERR. This manual has been compiled and published by the Technical Documentation Department of LIEBHERR-FRANCE SAS 68005 Colmar cedex. We hope that the information in this documentation, aimed at improving the service of LIEBHERR excavators, is useful to you.

Structuration of our Service Manuals In order to make it easy for users to find a specific sheet or information on a certain group, and to file amended and additional pages, each page is identified as follows: .

7.

12.

Main Group

Example 7. = Main Group «Hydraulic components»

Sub Group

12. = Sub Group «Variable Flow Hydraulic Pump - Type LPVD»

Number of the Page in Sub Group

14. = Page «Adjustment for Variable Flow Hydraulic Pump LPVD»

14

The main groups are listed in the table of contents at the beginning of the book. The subgroups are listed on a subgroup index, on the first page of each main group section. This subgroup index also includes the indication of machines modells, types and serial number to which the subgroup is relevant.

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Technical documentation

Group 1: General Information

Safety instructions .................................................................................................................1.10 1 2 3

Use in accordance with the regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10.1 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10.1 Servicing the machine safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10.11

Tightening torques .................................................................................................................1.20 1 2 3 4

Tightening torques for screws with metric coarse and fine thread (Liebherr Standard WN 4037) . . . 1.20.1 Tightening torques of screw-in studs (Ermeto) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.20.3 Tightening torques of swivelling connections (Ermeto) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.20.4 Tightening torques of screw-in studs (Ermeto) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.20.5

Assembly instruction for pistons and piston nuts (hydraulic cylinders) .........................1.22 1 2 3

Scope of application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.22.1 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.22.1 2.1 Definitions : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.22.1 Tightening torques for factory standard (04.08.2004) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.22.2

Assembly instruction for piston rod bearings with external threads (hydraulic cylinders) .. 1.24 1 2

Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.24.1 1.1 Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.24.1 Tightening torques for factory standard (02.07.2008) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.24.3

Tightening torques of screws with LH-washer 340HV........................................................1.25 1

Identification of the tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.25.1

Preloads and tightening torques (Din 13) ............................................................................1.26 1 2

Preloads and tightening torques table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.26.1 Angle tightening process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.26.3 2.1 Retightening angle depending on the clamping lenght - Preloads 50 Nm. . . . . . . . . . . . . . . . . 1.26.4 2.2 Retightening angle depending on the clamping lenght - Preloads - 100 Nm . . . . . . . . . . . . . . 1.26.5 2.3 Retightening angle depending on the clamping lenght - Preloads 400 Nm. . . . . . . . . . . . . . . . 1.26.6

Fuel and Lubricants ...............................................................................................................1.50 1 2 3 4 5 6

General specifications for the replacement of fuels and lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50.1 Lubricant Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50.1 Fuel and Lubricants Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50.2 Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50.4 Hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50.5 Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50.8

1.00.1

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Technical documentation

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Technical documentation

Safety instructions Use in accordance with the regulations

Group 1: General Information 1.10: 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 note the safety information, however, you can prevent danger and accidents. This is particularly true for those who are only occasionally in contact with the machine, eg. 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 avoiding damage to the machine. Following these precautions does not release you from the responsibility to take note of safety regulations which apply on site or of guidelines given by legal bodies or professional associations. For EU countries, guideline 89 / 655 / EEC contains the minimum safety information applicable to the owner.

1

Use in accordance with the regulations – The hydraulic excavator is a machine with work equipment (eg. hoe type bucket, grab, bucket attachment) designed to detach, lift, transport and shake off earth, stones and other materials, while the transportation of the load itself usually takes place without moving the machine. Moving the machine when it is carrying a load must be carried out while observing the appropriate safety measures (see section "Notes for safe working"). – Machines used for hoisting are subject to specific conditions and must be fitted with the stipulated safety devices (see section “Hoisting work”). – Other or additional usage, eg. for demolition work or transfer work, requires special equipment and may also require special safety devices. These devices (eg. tree grab, demolition hammer, concrete cutter etc.) may only be attached and used with approval and in accordance with the original manufacturer of the device. – Transporting persons is not deemed to be in accordance with regulations. The manufacturer is not liable for damage resulting from this action. The user is solely responsible for the risk incurred. – Observing the operating instructions and the inspection / maintenance instructions is also deemed to be appropriate use in accordance with regulations.

2

Safety Instructions General safety instructions – Please familiarize yourself with the operating instructions before starting up the machine. – Ensure that you have obtained, read and understood any additional instructions relating to special accessories for the machine. – Only specifically authorized persons may operate, maintain or repair the machine. The legal minimum age is to be adhered to. – Only employ trained or appropriately instructed personnel. Clearly establish which personnel are responsible for operating, setting up, maintaining and repairing the machine. Give personnel the power to refuse to carry out unsafe instructions by third parties. This also applies in relation to traffic regulations. – Only permit apprentices and personnel who are in training or who have only general training to operate on the machine under the constant supervision of an experienced member of staff. – As far as possible, monitor personnel to ensure that they are adhering to safe working practices, are aware of risks and are observing the operating instructions.

1.10.1

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Safety instructions

Technical documentation

Safety Instructions – Always wear safe work clothes when you are working on or with the machine. Avoid wearing rings, wrist watches, ties, scarves, open jackets, baggy clothing etc... There is a risk of injury from, for example, getting caught up or being drawn in. – For specific jobs wear individual protective equipment (protective goggles, safety helmets, safety shoes and gloves, reflective vests and ear protection etc...).. – Ensure that you obtain information on any special safety regulations for the job site from the site foreman. – Always tilt up the safety lever before leaving the operator’s seat. – When getting in and out, do not hold on to the steering column, control panel or joystick. Doing this could cause unintentional movement, which could result in an accident. – Never jump from the machine; use the steps, ladders, gangplanks and supporting straps provided for this purpose. – Face the machine when getting in or out and always use three-point support, i.e. two hands and one foot or two feet and one hand must always be in contact with the access system at the same time. – Familiarize yourself with the location of the emergency exit out of the cab. – In the absence of any other instructions, proceed as follows for all maintenance and repair work: • switch off the machine on firm, level ground • align the uppercarriage with the undercarriage so that the sprockets locate at the back-end • anchor the grab in the ground. • place all operating levers into neutral and tilt the safety lever up. • switch off the engine and remove the start key. – Before touching any parts of the hydraulic circuits, you must also operate all pilot control devices (joystick and pedals) in all directions with the start key in contact position and with the security lever lowered, in order to reduce the actuating and dynamic pressures in the work circuits. You must then reduce the internal tank pressure as described in these operating instructions. – Secure all loose parts on the machine. – Never operate a machine before carrying out a careful inspection tour and checking whether any warning signs are missing or illegible. – Respect all danger and safety instructions. – For special applications the machine must be equiped with specific safety equipments. Work only if they are mounted and functional. – Do not carry out any modifications, alterations or conversions to the machine which may affect safety without the express permission of the manufacturer. This also applies for the installation of safety devices and valves and for welding work on load-bearing parts. – It is forbiden to repair the structure of the cab. – Not original equipment and component parts or such kind, wich has generaly not been validated by LIEBHERR for installation or extension, has not to be installed or added onto the excavator without previous written agreement of LIEBHERR. Wherefore the necessary technical documentations has to be at LIEBHERR’s disposal.

Avoidance of crushing and burns – – – –

Do not work beneath the equipment if it is not safely positioned on the ground or supported. Do not use any damaged or insufficient load-bearing take-up materials, such as ropes or chains. Wear work gloves when working with wire cables. When working on the equipment, never use your fingers to locate bores; use the correct punch for the procedure. – Ensure that no objects enter the fan when the engine is on. The fan will eject or destroy these objects and will itself be damaged. – The engine cooling system is hot and pressurized when near operating temperature. Avoid coming into contact with coolant carrying parts. There is a risk of sustaining burns. – Only check the coolant when the sealing cap of the expansion container has cooled to a point where it is possible to touch it. Then turn the cap carefully to let off the overpressure.

1.10.2

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Technical documentation

Safety instructions Safety Instructions

– Engine and hydraulic oil, as well the engine exhaust system are hot when near operating temperature. Avoid coming into contact with hot oil or oil-bearing parts and with parts of the exhaust system. – Wear protective goggles and gloves when working on the battery. Avoid sparks and naked flames. – Never permit the grab to be guided by hand by auxiliary personnel. – When reaching into the engine compartment, always secure the side doors against unintentional closing by positioning the supports provided for this purpose. – Never lay under the machine if it is raised with work equipment and has not been correctly and securely supported with hardwood beams.

Avoidance of fire and explosions – – – – – – – – – – – – –

–

Switch off the engine when refuelling. Do not smoke or use a naked flame when refuelling and charging the batteries. Always start the engine in accordance with the operating instructions. Check the electrical system regularly. Have all faults, such as loose connections, blown fuses and lamps and clogged or abraded cables rectified by personnel. Do not transport any combustible liquids anywhere on the machine other than in the tanks provided for this purpose. Check all lines, hoses and screwed joints regularly for leakage and damage. Rectify leakages immediately and replace damaged components. Oil spraying out of leaking areas can easily cause a fire. Ensure that all holds and shields are correctly installed to guard against vibration, abrasion and heat accumulation. Do not use cold start materials (ether) in the vicinity of heat sources, naked flames or in inadequately ventilated areas. Do not use any starting aids containing ether to start diesel engines with preheating or flame glow systems. There is a risk of EXPLOSION. Familiarize yourself with the location and operation of fire extinguishers on the machine and with local fire warning and fire abatement options. The driver’s cab of the machine is provided with a fixing possibility for an extinguisher. Unlock all hoods and side doors locks before operating the machine, this will facilitate fighting a possibly upcoming fire.

Bringing the machine safely into service – – – – –

Carry out a careful inspection tour around the machine each time before starting it. Check the machine for loose bolts, cracks, wear, leakage and damage. Never attempt to operate a damaged machine. Ensure that any damage is immediately rectified. Ensure that all hoods and covers are closed, but that locks are unlocked, to facilitate the fight against fire in case of. – Ensure that all warning signs are present. – Keep windows and interior and exterior mirrors clean. Secure doors and windows against unintended movement. – Ensure that no one is working on or under the machine and warn personnel in the vicinity of the machine that it is about to start by sounding the horn.

Safely getting up – Proceed with the the same precautions to climb up or down onto the machine, as to instal yourself.

1.10.3

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Safety instructions

Technical documentation

Safety Instructions – When getting up or down, position the machine on even, horizontal ground. The upper structure should be positioned with the undercarriage in such a way that the steps and ladders are aligned with each other. – Ensure that steps, ladders and hand-rails (grips) are in good condition. In particular, you should ensure that they are free of dirt, oil, ice and snow. NOTE: To ensure that the doors open properly in all weather conditions, the door seals must be dusted with talc or silicon at least every two months or more often if required. The door hinges and locks should be greased regularly. – Face the machine when getting in or out and always use three-point support, i.e. two hands and one foot or two feet and one hand must always be in contact with the access system at the same time. – If you are able to reach the door handle with your free hand, open the doors before you climb any higher. External influences, such as wind, can make it more difficult to open doors. Because of this, always use your hand for control when opening doors. Ensure that the door is latched open to prevent it slamming open and shut. – In case of bad weather conditions, be particulary vigilant to realise the climbing and descent from the cab with the best safety conditions, and do or give the instuctions to the execution of prior preparations to be accomplished, as enunciated above, in order to displace yourself safely. – Be particulary vigilant with those prerequisites conditions. – Now continue to climb up, still using the three-point support and sit down in the operator’s seat as soon as you enter the cab. – Close the doors and fasten the safety belt (if available), unlock the door, using the planned lever, and close it immediately using the door handle, befor tilting down the safety lever, and start the machine. – If you wish to work with the door open, it is necessary to fasten your safety belt. If unavailable, let it be instaled before working with the door open. Adjusting the operator’s standing position – Before starting the machine, adjust the seat, mirrors, armrests and operator’s controls in such a way that you are able to work comfortably and safely. – Acoustic insulation devices on the machine must be set to the insulation position throughout operation. Protection from vibration - seat adjusting – Keep the seat in good condition and adjust it as follows: • The seat and its damping action should be adjusted depending on the weight and height of the operator. • Check the seat’s damping action and adjustment mechanisms regularly and ensure that these seat characteristics remain as per the seat manufacturer’s instructions. Utilisation in confined spaces – Only operate combustion engines and fuel-operated heaters in adequately ventilated spaces. Before starting in closed areas, ensure adequate ventilation. Follow the regulations which apply for the particular area of use.

Starting the machine safely – Before starting, check all control lamps and instruments for correct function, place all operator’s controls in Neutral and tilt the safety lever up. – Before starting, sound the horn briefly to alert people in the vicinity of the machine. – Only start the machine from the driver’s seat. – In the absence of any other instructions, start the engine in accordance with the regulations given in the operating instructions. – Tilt the safety lever down and then test all display and checking devices.

1.10.4

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Technical documentation

Safety instructions Safety Instructions

– In enclosed spaces, only allow the engine to run when there is adequate ventilation. If necessary, open doors and windows to ensure sufficient fresh air supplies. – Bring the engine and hydraulic oil to operating temperature. Low oil temperatures make the control unit react sluggishly. – Check that the equipment is operating correctly. – Move the machine carefully to an open area and then check the function of the running and slewing gear brakes, the steering and the signaling and lighting devices.

Stopping the machine safely – Only stop the machine on level, firm ground. – If the machine has to be stopped on an incline, chocks should be used to secure it from rolling away. – Before stopping the machine, each time it is possible, align the uppercarriage with the undercarriage so that the sprockets locate at the back-end. This is the only one position which enables a secured access to every maintenance locations on the uppercarriage. – Use the stop bolts to secure the upper structure facing the undercarriage, if available. – Lower the equipment and anchor the grab lightly in the ground. – Position every control lever into neutral position and depress the parking and slewing brakes. – Stop the engine in accordance with the operating instructions and tilt the safety lever up before leaving the cab. – Lock the machine, included hoods and compartments, retire every keys and secure the machine against unpermited use and vandalis.

Safely getting down – Proceed with the the same precautions to climb up or down onto the machine, as to instal yourself. – Stop the machine on level, horizontal ground. The upper structure should be positioned with the undercarriage in such a way that the steps and ladders are aligned with each other. – Open and lock the door. Be sure of it’s locking. Take care of weather conditions ! Unfasten the safety belt. – Position yourself with your face toward the machine when getting out and use three-point support, i.e. two hands and one foot or two feet and one hand must always be in contact with the access system at the same time. Climb down until you can close the doors safely. Always use your hand for control when closing the doors. Lock the door. – Now climb down to the ground.

Working safely with the machine – Before you start working, acquaint yourself with the special features of the job site and any special precautions and warning signals. Examples of particular work environments would be on-site or traffic obstructions, the load-carrying capacity of the ground and any requirements to make the job site safe from public use. – Always maintain a safe distance from overhangs, edges, slopes and unsafe ground. – Be particularly careful in conditions of reduced visibility and changeable ground conditions. – Familiarize yourself with the location of power lines on the job site and take particular care when working near them. If necessary, inform the responsible authorities. – Maintain a safe distance from electrical aerial lines. Do not allow the equipment to come near cables when working near electrical aerial lines. Risk of fatality! Inform yourself about required safety distances.

1.10.5

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Safety instructions

Technical documentation

Safety Instructions – The following actions must be carried out in the event of any transfer of electricity: • do not move the machine or its equipment, • do not leave the driver’s cab, • warn any personnel in the vicinity not to come close to the excavator and not to touch it, • instruct or initiate that someone turns off the voltage. • move the machine, if possible, from the danger zone to a sufficient distance, • Do not leave the machine until you are absolutely sure that voltage in the line, which had been touched or damaged, has been turned off ! – Before moving the machine, always ensure that any attachments are safely secured. – When driving onto public roads, paths and squares, observe current traffic regulations and if necessary, ensure that the machine has been made safe as per regulations beforehand. – Always turn on the lights in conditions of poor visibility or darkness. – Do not permit any passengers in the machine. – Only work when seated properly and with the safety belt securely fastened (if available). – Report all function faults and ensure that all necessary repairs are carried out immediately. – Assure yourself that no one is endangered when you start the machine moving. – Before you start working, test the brake system in accordance with the regulations given in the operating instructions. – Never leave the driver’s seat while the machine is moving. – Never leave the machine unattended while the engine is running. – The machine must be positioned, moved and operated in such a way that it is stable and that there is no danger of overturning. Only known loads may be moved with the equipment; this applies particularly when using the grab. – Position the upper structure in the longitudinal direction when moving and hold the load as close to the ground as possible. EXCEPTION: “Safe use when loading and unloading (particularly when loading and unloading wood)” on page 8. – Adjust your driving speed to suit local conditions. – Avoid any working movements which may tip the machine. Should the machine start to tip or slide sideways, however, turn the upper structure to face downhill and lower the equipment at the same time. – As far as possible, work downhill or uphill and not side on to the slope. – Drive safely on stony, sleepery or inclined ground – Only drive downhill at the permitted speed or you could lose control of the machine. – Always shift down to a lower running step before a slope. When doing this, the diesel engine must run at maximal speed and the speed may only be reduced using the accelerator pedals. – Load an occupied truck only if all safety requirements are fulfilled, notably in order to protect the truck operator. – For demolition work, digging and crane operations etc., always use protective devices specifically designed for the purpose. – For terrain which is difficult to gain an overview of and whenever necessary, ask for the assistance of a spotter. Only permit one person to give you signals. – Only permit experienced personnel to attach loads and give signals to the machine operator. The spotter must be positioned within the visual range of the operator or be in voice contact with him. – Depending on the equipment combination, there is a risk of collision between the work tool and the cab, the cab protection or the boom cylinders. The greatest degree of care must be taken to avoid damage when the hoe teeth come within this area. – Depending on the equipment combination, there is a risk of collision between the lift ring of the attachment and the cab or the cab protection. Before operating, ensure that there is no risk of collision, especially on excavator with cab elevation. If necessary remove the lift ring.

1.10.6

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Technical documentation

Safety instructions Safety Instructions

– In case of a thunderstorm : • lower the attachment to the ground and if possible anchor the digging tool into the soil. • leave the cab and move away from the machine before the storm breaks out. Otherwise, you must stop the excavator, turn off the radio and keep inside the closed cab until the end of the storm. – Auxiliary control units can have various functions. Always check their functions when starting up the machine. – Stop the swinging motion of the uppercarriage when lowering the attachment into a ditch without striking the attachment on the ditch walls. – Inspect the machine for damage if the attachment has been swung into a wall or any other obstacles. – Applications in which the attachment is to be used to strike the material being extracted are not permitted, even when working in a longitudinal direction. – Repeated strikes against an object leads to damage to the steel structures and machine components. – Please refer to your LIEBHERR dealer if special teeth for heavy-duty or special applications are required. – Do not attach too large bucket or bucket with side cutters or that are during operations with rocky material. This would prolong the work cycles and may lead to damage to the bucket as well as further machine components. – With the 2x45° offset articulation, the offset position may only be employed if the working tool or the attachment does not touch the material. – Operation of the offset articulation to drill into the material is not permitted. – Do not lift the machine during operation. Should this happen, lower the machine slowly back to the ground. – Do not let the machine fall heavily on the ground and do not hold it back with the hydraulics. This would damage the machine. – During operation with the attachment it is forbidden to raise the machine with the dozing blade (e.g. carving at the ceiling when tunnelling).

Safe use with a hydraulic hammer – The hydraulic hammer must be selected with particular care. When using a hydraulic hammer not permitted by LIEBHERR, steel structures or the other machine components can become damaged. – Before beginning breaking tasks, position the machine on firm and level ground. – Use a hydraulic hammer designed exclusively for breaking stone, concrete and other breakable materials. – Only operate the hydraulic hammer in the longitudinal direction of the machine and with the windshield closed or with a front protective grid. – Ensure during hammer operation that no cylinder is entirely extended or retracted and that the stick is not in the vertical position. – In order to avoid damages to the machine, try not to break stone or concrete while performing retraction and extension motions of the hydraulic hammer. – Do not apply the hydraulic hammer uninterrupted for more than 15 secs. at a time to the same place. Change the breaking point. Too long uninterrupted operation of the hydraulic hammer leads to an unnecessary overheating of the hydraulic oil. – Do not use the drop force of the hydraulic hammer to break stone or other materials. Do not move obstacles with the hydraulic hammer. Misuse of this nature would damage both the hammer and the machine. – Do not use the hydraulic hammer to lift objects

1.10.7

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Safety instructions

Technical documentation

Safety Instructions

Safe use when loading and unloading (particularly when loading and unloading wood) – According to use, it can be necessary when working with a grab to move with the equipment raised and the load lifted up; this applies, for example, when loading and unloading wood. – Here, the centre of gravity of the machine will be displaced upwards in the vertical direction. The driving characteristics of the machine will thus be influenced persistently, e.g. through reduction of the dynamic stability. The following instructions are therefore to be observed at all times: • Adjust vehicle handling to suit the altered machine characteristics and environmental conditions. • Reduce your speed to prevent the need for sudden braking and steering manoeuvres. • Avoid sudden speed changes, such as braking, accelerating and changing direction. • Only rotate the upper structure when the undercarriage is stationary. • Only rotate the upper structure after you have picked up the load. • Only move the machine when you have picked up and lifted the load and rotated the upper structure to the driving position. • There is a danger of possible swinging movement and dropping of the load when the equipment is raised. • A protective grid (FOPS) in accordance with ISO 10262 must be attached to the cab. • A protective roof (FOPS) in accordance with ISO 10262 must be attached if there is a risk of objects falling from above. • Only the maximum permissible load may be taken up using the grab. – NOTE: The weight of absorbent materials, such as logs, is dependent on length, diameter and specific weight. The influencing variables present in a natural product, such as moisture, must be noted. – Working procedures when using machines with grabs require the machine operator to receive special instruction and training. – Use as part of the work process is only permitted when the machine operator has sufficient training and practical experience.

Safe use of machines with tower elevation – Due to the tower elevation, the centre of gravity of the machine will be displaced upwards in the vertical direction. The driving and work characteristics of the machine will thus be influenced persistently, e.g. through reduction of the dynamic stability. – Due to the heightened centre of gravity, the machine must be aligned horizontally before use. In horizontal alignment, the centre of gravity of the upper structure is over the centre of the undercarriage, which reduces the risk of tilting. – The machine can still sway and tilt despite being aligned! The following instructions are therefore to be observed at all times: When moving the machine: • Rotate the upper structure parallel to the undercarriage undercarriage (transport position). • Draw the equipment as close as possible to the machine. • Only at this point may the support feet be retracted and the machine moved. • Moving with loads is not permitted. • Check the terrain to be covered to ensure that the ground is solid and even. Potholes and uneven surfaces jeopardize the stability of the machine. • Adjust vehicle handling to suit the altered machine characteristics (high centre of gravity) and environmental conditions. • Reduce your speed to prevent the need for sudden braking and steering manoeuvres. • Avoid sudden speed changes, such as braking, accelerating and changing direction. • Ascending gradients and obstacles may only be approached in the longitudinal direction in order to prevent unacceptable banking of the machine. • Special care should be taken when driving through narrow passages - drive slowly!

1.10.8

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Technical documentation

Safety instructions Safety Instructions

When loading and unloading: • The machine must be supported and aligned horizontally before moving (slewing) the upper structure out of the transport position. • It is imperative that you check the contact surface of the support (load carrying capacity of the substrate). A support subsiding would have disastrous consequences! • Carry out all movements with increased care. • To slew the load, move the equipment as close as possible to the machine (Caution! swinging grab)and hold the load close to the undercarriage and above the substrate. • Avoid braking or accelerating the equipment or upper structure abruptly. • Do not lift any loads which are heavier than those given in the load chart.

Protection from vibration – Vibrational loads on mobile building machinery are mainly the result of the type and method of use. The following parameters in particular are decisive influences: • Terrain conditions: Uneven areas and potholes; • Operational techniques: Speed, steering, brakes, controlling the machine’s control elements when driving and working. – To a large extent, the machine operator determines the vibrational loads since he selects the speed, gearbox ratio, working method and route himself. This means that there is a wide range of different vibrational loads for the same machine type. Whole-body vibrational load for the machine operator can be reduced if the following recommendations are observed: – Select suitable machines, equipment parts and auxiliary devices for each part of the job. – Use a machine that has a suitable seat (i.e. for earth-moving machinery such as hydraulic excavators, this should be a seat which corresponds with EN ISO 7096). – Keep the seat in good condition and adjust it as follows: • The seat and its damping action should be adjusted depending on the weight and height of the operator. • Check the seat’s damping action and adjustment mechanisms regularly and ensure that these seat characteristics remain as per the seat manufacturer’s instructions. – Check the maintenance status of the machine, particularly with respect to: tyre pressure, brakes, steering, mechanical connections etc. – Do not steer, brake, accelerate, shift gears, move or load the machine’s equipment jerkily. – To reduce vibrational load, adjust the machine speed to suit the route as follows: • Reduce speed when driving on difficult terrain; • Drive around obstacles and avoid driving on very difficult terrain. – Keep the terrain on which the machine is working and driving in good condition: • Remove large stones and obstacles; • Fill in ruts and holes; • Have machines ready to prepare and maintain suitable ground conditions and calculate in sufficient time to carry out any work required. – Drive longer distances (e.g. on public roads) at an appropriate (medium) speed. – Use special auxiliary systems (if available) which reduce vibration for machines that are driven frequently. If such auxiliary systems are not available, regulate speed to avoid "oscillating" the machine.

Towing the machine safely – Always follow the correct procedure: see chapter “Towing the machine” in these operating instructions. – The machine may only be towed in exceptional circumstances, e.g. in order to move the machine away from an area where it is at risk. – Before towing, check all attachments and towing devices for safety and stability.

1.10.9

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Safety instructions

Technical documentation

Safety Instructions – Towing devices such as bars, cables or ropes must have adequate tensile strength and should be secured around the undercarriage tower or the towing hook provided on the undercarriage. Any damage or accidents which occur while towing the machine are not covered by the manufacturer’s guarantee. – Ensure that there is no one in the vicinity of the towing devices when towing. – Stretch safely and hold the towing devices. Avoid kinks on cables or ropes. – When towing, maintain the correct transport position, permitted speed and route, and avoid lurching. – After towing, return the machine to correct operational status. – When restarting the machine, be sure only to proceed in accordance with the operating instructions.

Attaching and removing equipment parts safely – Equipment or attachments made by other manufacturers or those which do not have general approval from LIEBHERR for installation or attachment may not be installed or attached to the machine without LIEBHERR’s prior written consent. – LIEBHERR must be provided with the appropriate technical documentation necessary for this purpose. – Before carrying out any major repair work on the equipment, position the machine on level, firm ground. – Do not work beneath the equipment if it is not safely positioned on the ground or supported with wooden blocks. – Before loosening lines or unscrewing bolts, you must store the equipment, switch off the engine and press the start key to the contact position and both joysticks and the pushbuttons to “Turn grab” in order to reduce the pressure in the hydraulic system. – Do not attempt to lift heavy parts. Use devices which are suitable for this purpose and which have sufficient load carrying capacity. – Do not use cable which is damaged or does not have sufficient load carrying capacity. Wear work gloves when working with wire cables. – When working on the equipment: switch off the engine and keep the safety lever tilted up. Never use your fingers to locate bores; use the correct punch for the procedure. – During repair work: ensure that the hydraulic lines are secured correctly and that all bolts and connections are tight. – When you have removed and chocked an equipment part, close open areas of the hydraulic circuit to stop dirt entering. Only allow authorized persons in the vicinity of the machine or the lifting device used.

Removing and installing equipment bolts safely – If possible, always use a hydraulic bolt press to press out the equipment’s bolts. – If you have to remove a bolt using a sledge-hammer, a driving punch and a bore hole conductor held by another person must be used. – To drive in a bolt, screw the drive screws provided in the toolbox into the bolt's threaded hole and only hammer these screws. – When installing bolts locked by means of castle nuts and cotter pins, first drive the bolt to the stop, then screw the castle nut by hand until contact and then only pull it far enough to push in the cotter pin.

Transporting the machine safely – Due to transport restrictions, use only suitable means of transport and lifting devices with sufficient load-carrying capacity. – Park the machine on a flat surface and wedge the crawler or wheels securely. – If required, detach a part of the machine’s working equipment during transportation.

1.10.10

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Technical documentation

Safety instructions Servicing the machine safely

– The ramp used to drive the machine up onto the flatbed trailer should not exceed an inclination of 30° and should have a wooden cover to prevent sliding back. – The undercarriage undercarriage should be swept clean, i.e. before driving up the ramp, clean any snow, ice and mud from the crawler / wheels of the machine. – Align the machine precisely with the loading ramp. – Attach the hand lever for fine-tune driving (crawler excavator) onto the accelerator pedals. – Ensure that a spotter gives the machine operator the required signal. – Prepare the placing block to ensure against rolling back when the machine is driving up onto the flatbed. – Tilt the equipment up and drive up the loading ramp. While doing this, always hold the equipment securely over the loading area, drive very carefully up the ramp and onto the transportation vehicle. – Rotate the upper structure carefully to the rear and lower the equipment. Due to restrictions during transport on hoe equipment, tilt the arm in and dismantle the bucket during transportation. – After loading the machine onto the flatbed trailer, the upper structure must be secured facing the undercarriage using the stop bolts (only A devices). – Secure the undercarriage and the remaining individual parts using chains and blocks to prevent slipping. – Before you leave the machine, reduce pressure on all pressure lines, remove the ignition key and tilt up the safety lever. – Lock all cab and panel doors. – Before transportation, find out all details about the route to be travelled, particularly as they relate to width, height and weight restrictions. – Pay particular attention when driving under electrical lines and bridges and through tunnels. – When unloading the machine, take the same amount of care as was taken when it was loaded. Remove all chains and blocks. Start the engine as per the operating instructions. Drive carefully off the trailer’s loading area and down the ramp. Hold the working equipment as securely as possible over the ground while doing this. Have a spotter guide you.

3

Servicing the machine safely General safety instructions – Maintenance and repair work may only be carried out by specially trained personnel. – Observe statutory timetables or intervals given in the operating instructions for repeat tests / inspections. It is imperative that a suitably equipped workshop is available in order to carry out maintenance work. – The inspection and maintenance schedule given at the end of these operating instructions defines precisely who is required / permitted to carry out what work. Jobs listed as daily / weekly work may be carried out by the machine's driver or maintenance personnel when they have received appropriate instruction. The remaining work may only be carried out by specialist personnel with appropriate training. – Replacement parts must correspond to the technical requirements determined by the manufacturer. Original replacement parts are always guaranteed to meet these criteria. – Always wear safe work clothes when carrying out maintenance work. Avoid the wearing of rings, wrist watches, ties, scarves, open jackets, baggy clothing etc... There is a risk of injury from, for example, getting caught up or being drawn in. Protective goggles, safety helmets, safety shoes and gloves, reflective vests and ear protection etc. are required for specific jobs. – Do not remain in direct proximity of the diesel engine while the diesel engine is running. Persons with pacemakers should not approach within 20 cm of the running diesel engine. Do not touch voltage-carrying parts on the electrical connection of the individual solenoid injection pumps (Unit Pumps UP) while the diesel engine is running. – Do not permit unauthorised persons to approach the machine during maintenance work.

1.10.11

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Safety instructions

Technical documentation

Servicing the machine safely – Cordon off a wide maintenance area if required. – Inform operational personnel before starting to carry out any special work and repair work. Designate persons in charge of supervision. – In the absence of any other information in the operating instructions, carry out all maintenance work on the machine on level, firm ground with the working equipment set aside and the engine switched off. – For some machines, the only one position which enables a secured access to every maintenance locations on the uppercarriage, is when the uppercarriage is aligned with the undercarriage so that the sprockets locate at the back-end. The ladder situated on the undercarriage only corresponds with the uppercarriage’s access when the excavator is in this configuration. – Pull out the ignition key and shut off the main battery switch. – Always tighten any loose screw connections during maintenance and repair work. – The mounting bolts of the main components, of the hydraulic hoses and of the counterweight must be replaced after every removal. – If safety devices have to be dismantled during set-up, maintenance and repair work, they must be immediately reinstalled and checked at the end of the work. – When carrying out repair work, particularly when working under the machine, hang a “Do not start” warning sign in a clearly visible position on the starting lock. Pull out the start key and shut off the main battery switch. – Operate combustion motors and fuel operated heaters only in well ventilated areas. Before operating these units, check ventilation. – In addition, always follow applicable local regulations.

Cleaning – Clean oil, fuel or care products off the machine before starting maintenance or repair work and pay particular attention to connections and screw fittings. Do not use aggressive cleaning products and use lint-free cleaning cloths. – Do not use aggressive cleaning products or steam jet devices to clean the machine for the first two months after initial set-up of the machine (or after repainting). – Do not use combustible liquids to clean the machine. – Before cleaning the machine with water or steam jets (high pressure cleaner) or other cleaning materials: • lubricate all bearing points, bolt connections and the rim bearing to prevent water or steam entering the bearing points. • cover or glue shut all openings into which for safety or functional reasons water or steam may not be permitted to enter. Electric motors, electrical components, control boxes, plug connections and air filters are particularly at risk. – Ensure that the fire warning systems and fire extinguishers of the engine compartment’s temperature sensor do not come into contact with hot cleaning products during cleaning work. The fire extinguisher could start. – If you use a high pressure cleaner with steam or hot water to clean the machine, observe following recommendations : • the distance between the nozzle and the surface to be cleaned must be no lower than 20 inches • the water temperature should not exceed 60°c (140°F) • limit the water pressure to 80 bar maximum (11500 PSI) • if you employ cleaning fluid, only use neutral cleaning agents such as customary car shampoos diluted to 2 or 3 percent maximum

1.10.12

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Technical documentation

Safety instructions Servicing the machine safely

– After cleaning: • remove all covers completely. • check all fuel, engine oil and hydraulic lines for leakage, loosened connections, chafing and damage. • rectify any defects found immediately. • lubricate all bearing points, bolt connections and the rim bearing to displace any water or cleaning products that may have entered.

Crack testing – Even when the machine is operated carefully, there is a possibility of individual cases of overloading occurring, which could lead to cracks or loose connections. The machine should therefore be checked regularly for cracks, loose connections or other visible damage to maintain operational safety. – In order to be able to check for cracks, it is essential that the machine is kept clean and cleaned regularly. – The tests should be carried out in accordance with the monitoring and maintenance plan: • every 250 operating hours by the machine owner’s maintenance personnel. • every 500 operating hours by authorised specialist personnel. – It is advisable to carry out these tests: supported, on firm, horizontal substrate, with the equipment in longitudinal and cross direction for variable loads. Current accident prevention regulations must be adhered to. – Special care must be taken when testing load-bearing components, particularly: • the steel chassis members and axle and transmission mountings, the support, the lower rim bearing support and tower and ball rim bearing. • the steel upper structure members and bearing block for boom and boom cylinder, the upper rim bearing support, the cab mount and the mount for swing gear and ballast. • the steel components of the working equipment, e. g. the boom, stay, quick change adaptor, and bucket. • hydraulic cylinders, axles, steering, bolts and bolt connections, steps, ladders and mounting elements. – The crack test should be carried out visually. If a crack is suspected, the dye penetration test should be carried out as a crack test on areas which do not have good visibility, such as the rim bearing support, in order to increase testing safety. – Any damage found must be rectified immediately. Welding work on load-bearing parts of the earth-moving machinery, loading devices and transport devices may only be carried out by trained specialist personnel and only in accordance with the accepted rules of welding engineering. In case of doubt, contact the LIEBHERR customer support service to discuss suitable remedies.

Welding, drilling, firing and grinding work – Any welding on structural parts (as undercarriage, uppercarriage, equipment parts,…) may only be done the manufacturer, or authorized official dealer. If this rule is neglected, the warranty is voided. – Only carry out welding, drilling, firing and grinding work on the machine with express authorization. Clean dust and combustible materials off the machine and its surrounding areas before welding, drilling, firing or grinding. Ensure adequate ventilation. Risk of fire or explosion. – Before welding repairs on other parts, always disconnect the battery. Always remove the negative terminal first and reconnect it last. – Nevertheless if welding repair should be done on components which may contain inflammable gases (welded counterweight, hydraulic tank, fuel tank, …), these components must be previously and sufficiently ventilated with pressurized air to avoid all fire or explosion hazard – Before welding, connect the ground cable as close as possible to the welding point, so the welding current will not run through the swing ring, joints, gears, bushings, rubber parts and seals

1.10.13

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Safety instructions

Technical documentation

Servicing the machine safely

Process materials – When working with oils, greases and other chemical substances, observe the appropriate current safety regulations for the product. – Ensure that process materials and replacement parts are disposed of in a safe and environmentally acceptable manner. – Take care when handling hot process materials (Risk of burning and scalding).

Repair work – Do not attempt to lift heavy parts. Use devices which are suitable for this purpose and which have sufficient load capacity. When replacing single parts and larger subassemblies, carefully secure them on lifting devices them so that they do not present a risk. Only use suitable and correctly functioning lifting devices and load take-up devices with adequate load capacity. Do not stand or work under swinging loads. – Do not use lifting devices which are damaged or do not have sufficient load carrying capacity. Wear work gloves when working with wire cables. – Only permit experienced personnel to attach loads and give signals to the crane operator. The spotter must be positioned within the visual range of the operator or be in voice contact with him. – When working above body height, use safe climbing devices and working platforms which are appropriate for the job. Do not use machine parts as climbing devices if they are not designed for this purpose. When working at height, wear a harness to prevent falling. Ensure that all grips, steps, rails, platforms and ladders are free of dirt, snow and ice. – Pneumatic cylinders do not have to be used as handles. Open doors and covers carefully, so that pneumatic cylinders do not hit their stops, because this could cause mechanical dammages. – Be sure to support yourself safely when working on the equipment (e.g. replacing teeth). Prevent metal touching metal when doing this. – For safety reasons, never open and remove a track chain unless having previously totally released the pretension of the chain tensioning unit. – Never lay under the machine if it is raised with work equipment and has not been securely supported with wooden beams. – Always jack the machine up in such a way that any weight displacement does not jeopardize stability and prevent metal touching metal while doing this. – Work on the suspension, brake and steering systems may only be carried out by trained specialist personnel. – If the machine has to be repaired on a slope, secure the crawler with chocks and connect the upper structure to the chassis using stop bolts. – Only personnel with special training and experience may work on hydraulic equipment. – When searching for leakage, wear protective gloves. A fine jet of liquid under pressure can penetrate the skin. – Do not unscrew any lines or connections before you have set aside the equipment, switched off the engine and depressurized the hydraulic system. After switching off the engine, with the start key in contact position and with the safety lever down into its lowest position, you must operate all pilot control devices (joystick and pedals) in all directions in order to reduce the actuating and dynamic pressures in the work circuits. You must then reduce the internal tank pressure as described in these operating instructions.

Electrical system – Check the electrical system regularly. Have all faults, such as loose connections, blown fuses and lamps and clogged or abraded cables rectified by personnel. – Only use original fuses with approved current strength.

1.10.14

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Technical documentation

Safety instructions Servicing the machine safely

– For machines with electrical neutral and high tension leads: • switch the machine off immediately in the event of malfunctions in the power supply. – Work on the machine’s electrical equipment may only be carried out by skilled electrical personnel or by trained personnel under the supervision of an electrician in accordance with electrical regulations. – When working on live parts, ensure that a second person is available to operate the emergencyoff or the main switch and overvoltage release. Cordon off the working area with a red and white safety chain and a warning sign. Only use insulated tools. – When working on neutral and high tension subassemblies, after releasing the voltage, briefly disconnect the supply cable at earth and electronic devices such as capacitors using an earthing rod. – First test the released parts to make sure that they are off circuit, earth them and then disconnect them briefly. Insulate adjacent live parts. – Disconnect the battery before working on the electrical system or carrying out any electric arc welding on the machine. First disconnect the negative, then the positive pole. When reconnecting, proceed in the reverse order.

Hydraulic accumulator – – – – –

– – – –

All work on the hydraulic accumulators must be carried out by trained specialist personnel. Inexpert assembly and handling of hydraulic accumulators can cause serious accidents. Do not operate damaged hydraulic accumulators. Before working on a hydraulic accumulator, you must reduce the pressure in the hydraulic system (hydraulic system including hydraulic tank), as described in these operating instructions. Do not carry out welding or soldering or do any mechanical work on the hydraulic accumulator. The hydraulic accumulator can be damaged by heat penetration and can be made to rupture by mechanical working. RISK OF EXPLOSION! Only charge the hydraulic accumulator with nitrogen. There is a RISK OF EXPLOSION if oxygen or air is used. The accumulator body can become hot during operation; there is a risk of burning. New hydraulic accumulators must be charged with the pressure required for the purpose of use before installation. The operating data (minimum and maximum pressure) are marked permanently on hydraulic accumulators. Ensure that this marking remains visible.

Hydraulic hoses and sheathed cables. – It is forbidden to carry out repair work on hydraulic hoses and sheathed cables! – All hoses, sheathed cables and bolt connections must be checked regularly every 2 weeks for externally visible damage and any possible damage must be immediately checked for leakage. – Never check for leaks with your bare hands, use a sheet of paper or something else. – Any damaged parts must be removed immediately! Spurting oil can lead to injury and burns. – Even with correct storage and permitted load, hoses and sheathed cables are subject to the natural aging process. This restricts their duration of use. • Incorrect storage, mechanical damage and unauthorized load are the most common causes of failure. • In relation to duration of use, current norms, regulations and guidelines pertaining to hoses and sheathed cables at place of use must be adhered to. • Use at the limit range of permissible load can shorten duration of use (e.g. high temperatures, frequent movement cycles, extremely high pulse frequencies, multiple shift usage).

1.10.15

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Safety instructions

Technical documentation

Servicing the machine safely – Hoses and sheathed cables should be replaced if the following are found during inspection: • Damage to the outer sheath as far as the liner (e.g. chafing, cuts and cracks); • Brittleness of the outer sheath (fracture formation in hose material); • Deformations which do not correspond to the natural form of the hose or sheathed cable, whether in a unpressurized or pressurized state or on bends e.g. sheath separation, blistering; • Unsealed areas; • Non-adherence to requirements during installation; • Damage or deformations to the hose fittings which reduce the tightness of the fittings or the hose / fitting connection; • Hoses working themselves out of the fittings; • Corrosion of the fittings which reduces function and tightness; – When replacing hoses and sheathed cables, use only original replacement parts. – Install and mount hoses and sheathed cables correctly. Do not mix up the connections. – The following is to be noted when replacing hoses and sheathed cables: • Always ensure that the hoses and sheathed cables are installed free of torsion. For high-pressure hoses, the screws from the half-clamps or full flange must always be attached to both hose ends and should only be tightened afterwards. • When tightening the flange on high-pressure hoses and sheathed cables with bent fittings, the side with the bent fitting must always be tightened first and then the side with the straight fitting tightened afterwards. • Any mounting clamps which are located in the centre of the hose may only be attached and tightened subsequently. • Check daily to ensure that all clamps, covers and protective devices are properly fastened. Doing this will prevent vibration and damage during operation. • Install the hoses and sheathed cables in such a way that they cannot chafe on other hoses, sheathed cables or parts. • A minimum distance from other parts of approx. half the exterior diameter of the hose is recommended. The distance should not, however, be less than 10 to 15 mm. • When replacing the hoses or sheathed cables on moving parts (e.g. from the boom to the stay), check before initial start-up that there are no chafing areas in the entire area of movement.

1.10.16

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Technical documentation

Tightening torques

Tightening torques for screws with metric coarse and fine thread (Liebherr Standard WN 4037)

1.20: Tightening torques 1

Tightening torques for screws with metric coarse and fine thread (Liebherr Standard WN 4037) The assembly preloads FM given in the table, show a 90% utilisation of the screw extension limit 0 2 . The tightening torques MA are calculated from FM. Involved screws are those with the following surface finish: – – – –

black-chrome finished or phosphatised galvanized DAKROMET 500 Screws and nut without rework or surface treatment and ungreased, for mean friction factor µ=0,12. Metric coarse thread

Thread

Class

Assembly preloads FM in N

Metric fine thread Tightening torques MA in Nm

M4

8.8 10.9 12.9

4050 6000 7000

2,8 4,1 4,8

M5

8.8 10.9 12.9

6600 9700 11400

5,5 8,1 9,5

M6

8.8 10.9 12.9

9400 13700 16100

9,5 14,0 16,5

M7

8.8 10.9 12.9

13700 20100 23500

15,5 23,0 27,0

M8

8.8 10.9 12.9

17200 25000 29500

23,0 34,0 40,0

M10

M12

M14

8.8 10.9 12.9

8.8 10.9 12.9

8.8 10.9 12.9

27500 40000 47000

40000 59000 69000

55000 80000 94000

46,0 68,0 79,0

79,0 117,0 135,0

125,0 185,0 215,0

Thread

Class

Assembly preloads FM in N

Tightening torques MA in Nm

M8×1

8.8 10.9 12.9

18800 27500 32500

24,5 36 43

M9×1

8.8 10.9 12.9

24800 36500 42500

36 53 62

M10×1

8.8 10.9 12.9

31500 46500 54000

52 76 89

M10×1,25

8.8 10.9 12.9

29500 43000 51000

49 72 84

M12×1,25

8.8 10.9 12.9

45000 66000 73000

87 125 150

M12×1,5

8.8 10.9 12.9

42500 62000 73000

83 122 145

M14×1,5

8.8 10.9 12.9

61000 89000 104000

135 200 235

1.20.1

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Tightening torques

Technical documentation

Tightening torques for screws with metric coarse and fine thread (Liebherr Standard WN 4037) Metric coarse thread M16 M18

Metric fine thread

8.8 10.9 12.9

75000 111000 130000

195,0 280,0 330,0

8,8 10,9 12,9

94000 135000 157000

280 390 460

8.8 10.9 12.9

82000 121000 141000

205 300 360

M18×1,5

8,8 10,9 12,9

110000 157000 184000

310 440 520

M18×2

8,8 10,9 12,9

102000 146000 170000

290 420 490

M16×1,5

M20

8,8 10,9 12,9

121000 173000 202000

390 560 650

M20×1,5

8,8 10,9 12,9

139000 199000 232000

430 620 720

M22

8,8 10,9 12,9

152000 216000 250000

530 750 880

M22×1,5

8,8 10,9 12,9

171000 245000 285000

580 820 960

M24

8,8 10,9 12,9

175000 249000 290000

670 960 1120

M24×1,5

8,8 10,9 12,9

207000 295000 346000

760 1090 1270

M24×2

8,8 10,9 12,9

196000 280000 325000

730 1040 1220

M27×1,5

8,8 10,9 12,9

267000 381000 445000

1110 1580 1850

M27×2

8,8 10,9 12,9

255000 365000 425000

1070 1500 1800

M30×1,5

8,8 10,9 12,9

335000 477000 558000

1540 2190 2560

M30×2

8,8 10,9 12,9

321000 457000 534000

1490 2120 2480

M33×1,5

8,8 10,9 12,9

410000 584000 683000

2050 2920 3420

M33×2

8,8 10,9 12,9

395000 560000 660000

2000 2800 3300

M36×1,5

8,8 10,9 12,9

492000 701000 820000

2680 3820 4470

M36×3

8,8 10,9 12,9

440000 630000 740000

2500 3500 4100

M39×1,5

8,8 10,9 12,9

582000 830000 971000

3430 4890 5720

M39×3

8,8 10,9 12,9

530000 750000 880000

3200 4600 5300

M27

M30

M33

M36

M39

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

230000 330000 385000

280000 400000 465000

350000 495000 580000

410000 580000 680000

490000 700000 820000

1000 1400 1650

1350 1900 2250

1850 2600 3000

2350 3300 3900

3000 4300 5100

1.20.2

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Technical documentation

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

2

Tightening torques of screw-in studs (Ermeto) Mating material: steel (grease well before inserting!) Type with sealing edge Type

Thread M or G

Type with EOLASTIC seal Tightening torques (Nm)

Type

Thread M or G

Tightening torques (Nm)

Light-duty series L GE 06 LM A 3 C

M 10×1

18

GE 06 LM ED A 3 C

M 10×1

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 12×1,5

30

GE 08 LM ED A 3 C

M 12×1,5

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 14×1,5

45

GE 10 LM ED A 3 C

M 14×1,5

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 16×1,5

65

GE 12 LM ED A 3 C

M 16×1,5

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 18×1,5

80

GE 15 LM ED A 3 C

M 18×1,5

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 22×1,5

140

GE 18 LM ED A 3 C

M 22×1,5

125

GE 18 LM A 3 C

M 22×1,5

140

GE 18 LM ED A 3 C

M 22×1,5

125

GE 18 LR A 3 C

G 1/2 A

100

GE 18 LR ED A 3 C

G 1/2 A

GE 22 LM A 3 C

M 22×1,5

140

GE 22 LM ED A 3 C

M 26×1,5

180

GE 22 LR A 3 C

G 3/4 A

180

GE 22 LR ED A 3 C

G 3/4 A

180

GE 28 LM A 3 C

M 33×2,0

340

GE 28 LM ED A 3 C

M 33 x 2,0

310

90

GE 28 LR A 3 C

G1A

330

GE 28 LR ED A 3 C

G1A

310

GE 35 LM A 3 C

M 42×2,0

500

GE 35 LM ED A 3 C

M 42×2,0

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 48×2,0

630

GE 42 LM ED A 3 C

M 48×2,0

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 GE 06 SM A 3 C

M 12×1,5

35

GE 06 SM ED A 3 C

M 12×1,5

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 14×1,5

55

GE 08 SM ED A 3 C

M 14×1,5

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 16×1,5

70

GE 10 SM ED A 3 C

M 16×1,5

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 18×1,5

110

GE 12 SM ED A 3 C

M 18×1,5

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 20×1,5

150

GE 14 SM ED A 3 C

M 20×1,5

125

GE 14 SR A 3 C

G 1/2 A

150

GE 14 SR ED A 3 C

G 1/2 A

115

GE 16 SM A 3 C

M 22×1,5

170

GE 16 SM ED A 3 C

M 22×1,5

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 27×2,0

270

GE 20 SM ED A 3 C

M 27×2,0

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 33×2,0

410

GE 25 SM ED A 3 C

M 33×2,0

310

GE 25 SR A 3 C

G1A

340

GE 25 SR ED A 3 C

G1A

310

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Tightening torques

Technical documentation

Tightening torques of swivelling connections (Ermeto) GE 30 SM A 3 C

M 42×2,0

540

GE 30 SM ED A 3 C

M 42×2,0

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 48×2,0

700

GE 38 SM ED A 3 C

M 48×2,0

540

GE 38 SR A 3 C

G 1 1/2 A

700

GE 38 SR ED A 3 C

G 1 1/2 A

540

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

3

Tightening torques of swivelling connections (Ermeto) Mating material : steel (grease well before inserting!) Type

Thread

Tightening torque (Nm)

Type

Thread

Tightening torque (Nm)

Light-duty series L WH / TH 06 LR KDS A 3C

G 1/8 A

18

WH / TH 06 LM KDS A3C

M 10×1

18

WH / TH 08 LR KDS A 3C

G 1/4 A

45

WH / TH 08 LM KDS A3C

M 12×1,5

45

WH / TH 10 LR KDS A 3C

G 3/8 A

45

WH / TH 10 LM KDS A3C

M 14×1,5

55

WH / TH 12 LR KDS A 3C

G1/2 A

70

WH / TH 12 LM KDS A3C

M 16×1,5

80

WH / TH 15 LR KDS A 3C

G3/4 A

120

WH / TH 15 LM KDS A3C

M 18×1,5

100

WH / TH 18 LR KDS A 3C

G1 A

120

WH / TH 18 LM KDS A3C

M 22×1,5

140

WH / TH 22 LR KDS A 3C

G 1 1/4 A

230

WH / TH 22 LM KDS A3C

M 27×2,0

320

WH / TH 28 LR KDS A 3C

G 1 1/4 A

320

WH / TH 28 LM KDS A3C

M 33 x 2,0

360

WH / TH 35 LR KDS A 3C

G 1 1/4 A

540

WH / TH 35 LM KDS A3C

M 42×2,0

540

WH / TH 42 LR KDS A 3C

R 1 1/2 A

700

WH / TH 42 LM KDS A3C

M 48×2,0

700

Heavy-duty series S WH / TH 06 SR KDS A3C

G 1/4 A

45

WH / TH 06 SM KDS A3C

M 12×1,5

45

WH / TH 08 SR KDS A3C

G 1/4 A

45

WH / TH 08 SM KDS A3C

M 14×1,5

55

WH / TH 10 SR KDS A3C

G 3/8 A

70

WH / TH 10 SM KDS A3C

M 16×1,5

80

WH / TH 12 SR KDS A3C

G 3/8 A

70

WH / TH 12 SM KDS A3C

M 18×1,5

100

WH / TH 16 SR KDS A3C

G 1/2 A

120

WH / TH 14 SM KDS A3C

M 20×1,5

125

WH / TH 20 SR KDS A3C

G 3/4 A

230

WH / TH 16 SM KDS A3C

M 22×1,5

135

WH / TH 25 SR KDS A3C

G1A

320

WH / TH 20 SM KDS A3C

M 27×2,0

320

WH / TH 30 SR KDS A3C

G 1 1/4 A

540

WH / TH 25 SM KDS A3C

M 33×2,0

360

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Technical documentation

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

WH / TH 38SR KDS A 3C

4

G 1/4 A

700

WH / TH 30 SM KDS A3C

M 42×2,0

540

WH / TH 38 SM KDS A3C

M 48×2,0

700

Tightening torques of screw-in studs (Ermeto) Mating material : steel (grease well before inserting!) Gewinde

Anziehdreh momente (Nm)

M 10×1

12

VSTI 1/8 ED A3C

G 1/8 A

13

VSTI 12×1,5 ED A3C

M 12×1,5

25

VSTI 1/4 ED A3C

G 1/4 A

30

VSTI 14×1,5 ED A3C

M 14×1,5

35

VSTI 3/8 ED A3C

G 3/8 A

60

VSTI 16×1,5 ED A3C

M 16×1,5

55

VSTI 1/2 ED A3C

G 1/2 A

80

VSTI 18×1,5 ED A3C

M 18×1,5

65

VSTI 3/4 ED A3C

G 3/4 A

140

VSTI 20×1,5 ED A3C

M 20×1,5

80

VSTI 1 ED A3C

G1A

200

VSTI 22×1,5 ED A3C

M 22×1,5

90

VSTI 1 1/4 ED A3C

G 1 1/4 A

450

VSTI 26×1,5 ED A3C

M 26×1,5

120

VSTI 1 1/2 ED A3C

G 1 1/2 A

450

VSTI 27×2 ED A3C

M 27×2,0

135

VSTI 33×2 ED A3C

M 33×2,0

225

VSTI 42×2 ED A3C

M 42×2,0

360

VSTI 48×2 ED A3C

M 48×2,0

380

Type VSTI 10×1 ED A3C

Type

Gewinde

Anziehdreh momente (Nm)

VSTI = Hexagon socket plug

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Tightening torques

Technical documentation

Tightening torques of screw-in studs (Ermeto)

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Technical documentation

Assembly instruction for pistons and piston nuts (hyScope of application

1.22: Assembly instruction for pistons and piston nuts (hydraulic cylinders) According to standard WN 4121 B (04/2005)

1

Scope of application This factory standard applies exclusively to the assembly of hydraulic cylinders with a thread diameter of M42 and greater. 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. For threads with diameters smaller than M42, the applicable tightening torques are indicated in the drawings. The values in the drawings are always binding.

2

Description Preparation : Clean the contact surfaces (threads contact faces between piston rod, piston and piton nut) and apply a thin layer of Gleitmo high-performance lubricating grease (ID no. 8300 004, 40 g tube) on both sides.

2.1

Definitions : Pretightening torque : The piston is secured with a torque wrench applied to the square / hexagon head of the assembly wrench. The position of the torque wrench must be carefully noted.

Fig. 1

Torque wrench A B

Piston Torque wrench

C

Assembly wrench

When applying the pretightening torque, the torque wrench must point in the same direction as the assembly wrench. Proceed in the same w<ay to tighten the piston nut, using a suitable assembly wrench.

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Assembly instruction for pistons and piston nuts (hy-

Technical documentation

Tightening torques for factory standard (04.08.2004) Turning distance: Radian measure [mm] travelled as a result of the tightning of the piston, or piston nut along the outer thread diameter, after application of the pretightening torque. Turning angle : Angle [°] travelled by the piston or piston nut respectively, after application of the pretightening torque.

Fig. 2

Marks, turning distance and turning angle on the piston

Fig. 3

Marks, turning distance and turning angle on the piston nut c d e

3

Marks on the piston and piston rod thread after application of the pretightening torque Marks on the piston rod thread Mark on the piston after tightening Turning angle Turning distance

Tightening torques for factory standard (04.08.2004) Piston

Piston nut Thread M (mm)

WN 4121 No.

Preload (N.m)

Turning distance (mm)

Turning angle (< °)

Turning distance (mm)

Turning angle (< °)

071

100

11 +1

30

21 +1

57

42x1,5

072

100

21 +1

57

21 +1

57

42x1,5

073

100

18 +1

49

19 +1

52

42x1,5

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Technical documentation

Assembly instruction for pistons and piston nuts (hyTightening torques for factory standard (04.08.2004) Piston

Piston nut Thread M (mm)

WN 4121 No.

Preload (N.m)

Turning distance (mm)

Turning angle (< °)

Turning distance (mm)

Turning angle (< °)

075

100

19 +1

52

21 +1

57

42x1,5

079

100

11 +1

30

21 +1

57

42x1,5

080

100

18 +1

49

-

-

42x1,5

091

100

13 +1

30

19 +1

44

50x2

092

100

25 +1

57

19 +1

44

50x2

093

100

24 +1

55

19 +1

44

50x2

095

100

13 +1

30

19 +1

44

50x2

096

100

10 +1

23

9 +1

21

50x2/SW65

097

100

17 +1

39

19 +1

44

50x2

098

100

17 +1

39

-

-

50x2

099

100

24 +1

55

19 +1

44

50x2

111

100

16 +1

33

18 +1

37

56x2

112

100

17 +1

35

18 +1

37

56x2

113

100

18 +1

37

18 +1

37

56x2

114

100

19 +1

39

-

-

56x2

115

100

18 +1

37

-

-

56x2

121

150

15 +1

29

19 +1

36

60x2

123

150

17 +1

32

19 +1

36

60x2

126

150

14 +1

27

-

-

60x2

127

150

22 +1

42

-

-

60x2

151

150

15 +1

27

19 +1

34

65x2

152

150

20 +1

35

19 +1

34

65x2

153

150

20 +1

35

-

-

65x2

171

150

12 +2

20

18 +1

30

68x2

173

150

19 +2

32

18 +1

30

68x2

174

150

25 +2

42

18 +1

30

68x2

175

150

25 +2

42

18 +1

30

68x2

176

150

19 +2

32

18 +1

30

68x2

177

150

19 +2

32

18 +1

30

68x2

179

150

11 +2

19

18 +1

30

68x2

180

150

20 +2

34

18 +1

30

68x2

181

150

20 +2

34

-

-

68x2

183

200

-

-

40 +2

67

68x2

201

200

17 +2

26

16 +1

24

76x2

202

200

26 +2

39

16 +1

24

76x2

203

200

27 +2

41

16 +1

24

76x2

204

200

27 +2

41

16 +1

24

76x2

205

200

13 +2

20

-

-

76x2

206

200

25 +2

38

25 +1

38

76x2

207

200

23 +2

35

-

-

76x2

208

200

15 +2

22

-

-

76x2

209

200

30 +2

45

-

-

76x2

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Assembly instruction for pistons and piston nuts (hy-

Technical documentation

Tightening torques for factory standard (04.08.2004) Piston

Piston nut Thread M (mm)

WN 4121 No.

Preload (N.m)

Turning distance (mm)

Turning angle (< °)

Turning distance (mm)

Turning angle (< °)

231

200

8 +2

11

16 +1

22

85x3

232

200

17 +2

23

16 +1

22

85x3

234

200

22 +2

30

-

-

85x3

261

250

20 +2

25

10 +1

12

95x3

281

250

20 +2

23

13 +1

15

100x3

282

250

25 +2

29

-

-

100x3

301

300

21 +3

22

20 +2

21

110x3

302

300

18 +3

19

20 +2

21

110x3

303

300

20 +3

21

20 +2

21

110x3

304

300

23 +3

24

20 +2

21

110x3

305

300

9 +3

9

-

-

110x3

306

300

24 +3

25

-

-

110x3

307

300

27 +3

28

-

-

110x3

331

400

23 +3

22

20 +2

19

120x3

332

400

11 +3

11

-

-

120x3

333

400

27 +3

26

-

-

120x3

334

400

20 +3

19

20 +2

19

120x3

335

400

30 +3

29

-

-

120x3

501

200

21 +2

30

-

-

80x2

531

500

34 +3

28

-

-

140x3

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Technical documentation

Assembly instruction for piston rod bearings with exDescription

1.24: Assembly instruction for piston rod bearings with external threads (hydraulic cylinders) According to standard 4122 B (01/2005) 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

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

1.1

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.

Fig. 1

Torque wrench A B

Piston Torque wrench

C

Assembly wrench

When applying the pretightening torque, the torque wrench must point in the same direction as the assembly wrench. Turning distance: Radian measure [mm] between the bearing head outer diameter and the cylinder tube, tavelled after application of the pretightening torque. Turning angle: Angle [°] travelled by the bearing head after application of the pretightening torque.

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Assembly instruction for piston rod bearings with ex-

Technical documentation

Description

Fig. 2

Marks, turning angle and distance on the piston rod bearing c d e g h

Marks on piston and piston rod thread after application of the pretightening torque Mark on the cylinder tube Mark on the bearing head after tightning Cylinder tube Bearing head Turning angle Turning distance

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

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Technical documentation

Assembly instruction for piston rod bearings with exTightening torques for factory standard (02.07.2008)

2

Tightening torques for factory standard (02.07.2008) Piston WN 4122 No.

Preload (N.m)

Turning distance (mm)

Turning angle (< °)

001 011

50

7 +1

10

016

100

10 +1

12

017

100

10 +1

12

026

100

9 +1

10

027

100

10 +1

11

031

100

8 +1

8

036

100

11 +1

10

037

100

10 +1

9

039 041

150

9 +1

7

046

200

12 +1

10

053

200

25 +1

18

061

200

10 +1

7

091

300

10 +1

5,5

111

300

12 +1

6

151

400

14 +1

6

047 051 052

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Assembly instruction for piston rod bearings with ex-

Technical documentation

Tightening torques for factory standard (02.07.2008)

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Technical documentation

Tightening torques of screws with LH-washer 340HV Identification of the tightening torques

1.25: Tightening torques of screws with LH-washer 340HV According to LIEBHERR standard KR 0015A

1

Identification of the tightening torques Mounting screws of piston rod bearing according to ISO 4014, ISO 4017 and ISO 4762. • black-chrome finished or phosphatised • LH washer 340 HV - A3C • DACROMET Friction values: • in the thread µG = 0,14 • under the head µK = 0,11 (Values out of the RIBE - Blauheft)

Filetage

Class

MG (Nm)

Mk (Nm)

MA (Nm)

M10

10.9

38 +

31 =

70

SW16

12.9

44 +

36 =

80

M12

10.9

65 +

52 =

120

SW18

12.9

76 +

61 =

140

M16

10.9

161 +

127 =

SW24

12.9

189 +

M20

10.9

SW30

12.9

M24

MA for A3C screws with total friction = 0,10 (Nm) *

Ident. No.

Dxh

60

9918225

18 x 3,0

70

9918225

18 x 3,0

105

9918226

21 x 3,5

125

9918226

21 x 3,5

290

9918228

28 x 4,0

148 =

340

9918228

28 x 4,0

315 +

250 =

565

9918229

34 x 5,0

369 +

292 =

660

9918229

34 x 5,0

10.9

544 +

427 =

970

9918230

40 x 5,0

SW36

12.9

637 +

500 =

1130

9918230

40 x 5,0

M27

10.9

794 +

642 =

1440

SW41

12.9

M30

10.9

1080 +

870 =

SW45

12.9

1260 +

1020 =

M36

10.9

1880 +

1500 =

3400

9918232

60 x 7,0

SW55

12.9

2200 +

1760 =

3900

9918232

60 x 7,0

9586495

45 x 6,0

9586495

45 x 6,0

1950

9918231

52 x 6,0

2250

9918231

52 x 6,0

* rounded value out of the RIBE - Blauheft

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Tightening torques of screws with LH-washer 340HV

Technical documentation

Identification of the tightening torques

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Technical documentation

Preloads and tightening torques (Din 13) Preloads and tightening torques table

1.26: Preloads and tightening torques (Din 13) for screws with metric coarse and fine threads according to DIN 13, page 12 According to Standard WN 4037 I

1

Preloads and tightening torques table The preloads and torques included in the table are based on the VDI regulations 2230 of july 1986. Assembly preloads FM and tightening torques MA for headless screws with metric coarse or fine threads according to DIN ISO 262 and DIN ISO 965 T2 (DIN 13 part 13 replacement); Head dimensions of hex head srews according to DIN EN 24014 (DIN 931 part 1 replacement) or Allen head screws according to DIN EN ISO 4762 (DIN 912 replacement)

Metric coarse thread

Metric fine thread

Surface finish : - black-chrome finish or phosphatised oiled - electro-galvanised oiled - flZn = zinc flakecoating oiled (LH Standard 10021432, DAC)

Surface finish : - black-chrome finish or phosphatised oiled - electro-galvanised oiled - flZn = zinc flakecoating oiled (LH Standard 10021432, DAC)

Thread

Class

Assembly preloads FM in N

Tightening torques MA in N

Thread

Class

for mean friction factor Âľg = 0.12 M4

8.8 10.9 12.9

4050 6000 7000

2.8 4.1 4.8

M5

8.8 10.9 12.9

6600 9700 11400

5.5 8.1 9.5

M6

8.8 10.9 12.9

9400 13700 16100

9.5 14.0 16.5

M7

8.8 10.9 12.9

13700 20100 23500

15.5 23.0 27

M8

8.8 10.9 12.9

17200 25000 29500

23 34 40

M10

M12

8.8 10.9 12.9

8.8 10.9 12.9

27500 40000 47000

40000 59000 69000

46 68 79

79 117 135

Assembly preloads FM in N

Tightening torques MA in N

for mean friction factor Âľg = 0,12

M8x1

8.8 10.9 12.9

18800 27500 32500

24,5 36 43

M9x1

8.8 10.9 12.9

24800 36500 42500

36 53 62

M10x1

8.8 10.9 12.9

31500 46500 54000

52 76 89

M10x1,25

8.8 10.9 12.9

29500 43000 51000

49 72 84

M12x1,25

8.8 10.9 12.9

45000 66000 77000

87 125 150

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Preloads and tightening torques (Din 13)

Technical documentation

Preloads and tightening torques table Metric coarse thread

Metric fine thread

Surface finish : - black-chrome finish or phosphatised oiled - electro-galvanised oiled - flZn = zinc flakecoating oiled (LH Standard 10021432, DAC)

Surface finish : - black-chrome finish or phosphatised oiled - electro-galvanised oiled - flZn = zinc flakecoating oiled (LH Standard 10021432, DAC)

Thread

Class

Assembly preloads FM in N

Tightening torques MA in N

Thread

Class

for mean friction factor Âľg = 0.12

Assembly preloads FM in N

Tightening torques MA in N

for mean friction factor Âľg = 0,12 M12x1,5

8.8 10.9 12.9

42500 62000 73000

83 122 145

M14

8.8 10.9 12.9

55000 80000 94000

125 185 215

M14x1,5

8.8 10.9 12.9

61000 89000 104000

135 200 235

M16

8.8 10.9 12.9

75000 111000 130000

195 280 330

M16x1,5

8.8 10.9 12.9

82000 121000 141000

205 300 360

M18

8.8 10.9 12.9

94000 135000 157000

280 390 460

M18x1,5

8.8 10.9 12.9

110000 157000 184000

310 440 520

M18x2

8.8 10.9 12.9

102000 146000 170000

290 420 490

M20

8.8 10.9 12.9

121000 173000 202000

390 560 650

M20x1,5

8.8 10.9 12.9

139000 199000 232000

430 620 720

M22

8.8 10.9 12.9

152000 216000 250000

530 750 880

M22x1,5

8.8 10.9 12.9

171000 245000 285000

580 820 960

M24

8.8 10.9 12.9

175000 249000 290000

670 960 1120

M24x1,5

8.8 10.9 12.9

207000 295000 346000

760 1090 1270

M24x2

8.8 10.9 12.9

196000 280000 325000

730 1040 1220

M27x1,5

8.8 10.9 12.9

267000 381000 445000

1110 1580 1850

M27x2

8.8 10.9 12.9

255000 365000 425000

1070 1500 1800

M30x1,5

8.8 10.9 12.9

335000 477000 558000

1540 2190 2560

M30x2

8.8 10.9 12.9

321000 457000 534000

1490 2120 2480

M33x1,5

8.8 10.9 12.9

410000 584000 683000

2050 2920 3420

M33x2

8.8 10.9 12.9

395000 560000 660000

2000 2800 3300

M27

M30

M33

8.8 10.9 12.9

8.8 10.9 12.9

8.8 10.9 12.9

230000 330000 385000

280000 400000 465000

350000 495000 580000

1000 1400 1650

1350 1900 2250

1850 2600 3000

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Technical documentation

Preloads and tightening torques (Din 13) Angle tightening process

Metric coarse thread

Metric fine thread

Surface finish : - black-chrome finish or phosphatised oiled - electro-galvanised oiled - flZn = zinc flakecoating oiled (LH Standard 10021432, DAC)

Surface finish : - black-chrome finish or phosphatised oiled - electro-galvanised oiled - flZn = zinc flakecoating oiled (LH Standard 10021432, DAC)

Thread

Class

Assembly preloads FM in N

Tightening torques MA in N

Thread

Class

for mean friction factor µg = 0.12 8.8 10.9 12.9

M36

8.8 10.9 12.9

M39

2

410000 580000 680000

490000 700000 820000

2350 3300 3900

3000 4300 5100

Assembly preloads FM in N

Tightening torques MA in N

for mean friction factor µg = 0,12 M36x1,5

8.8 10.9 12.9

492000 701000 820000

2680 3820 4470

M36x3

8.8 10.9 12.9

440000 630000 740000

2500 3500 4100

M39x1,5

8.8 10.9 12.9

582000 830000 971000

3430 4890 5720

M39x3

8.8 10.9 12.9

530000 750000 880000

3200 4600 5300

Angle tightening process The angle tightening process constists in rotating the screw from a defined angle in order to enable the screw elastic lenghtening and the plates tightening. A tightening torque predetermined according to the screw size, will bring this screw on block against the parts to tighten, in order to determine the beginning of the tightening angle mesure. From this value 0=0, the preload force is set up regardless of the thread friction coefficient or of the bearing surface, simply by rotating the screw by retightening angle . Example 1 : Screw M14 - 10.9, clamping lenght Lk = 80mm; According to the table, for the 10.9 class: Preloads MA = 50Nm; Retightening angle

~ 45°

Example 2 : Screw M24 - 12.9, clamping lenght Lk = 100mm; According to the table, for the 12.9 class: Preloads MA = 160Nm; Retightening angle

~ 57°

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Preloads and tightening torques (Din 13)

Technical documentation

Angle tightening process

2.1

Retightening angle depending on the clamping lenght - Preloads 50 Nm

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Preloads and tightening torques (Din 13) Angle tightening process

2.2

Retightening angle depending on the clamping lenght - Preloads - 100 Nm

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Technical documentation

Angle tightening process

2.3

Retightening angle depending on the clamping lenght - Preloads 400 Nm

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Technical documentation

Fuel and Lubricants General specifications for the replacement of fuels and lubricants

1.50: Fuel and Lubricants 1

General specifications for the replacement of fuels and lubricants Note! The filling amounts specified in the fuel and lubricants chart, as well as in the lubrication chart, are reference values only. After performing an oil-change or top-up, always check the level in the respective aggregate. Note! Conscientious adherence of the guidelines for lubrication, checking levels and replacing fuels will guarantee increased reliability and life-expectancy of the machine. Particular attention must be paid to the intervals for oil-changes and it is imperative that the stipulated lubricant qualities are adhered to. Note! Cleanliness is extremely important when carrying out oil-changes. Clean all filling screws, filler caps and drain plugs, including their immediate surroundings before opening them. Always ensure that the oil is at operating temperature before draining. Ensure that used oils are collected and disposed of in an environmentally-friendly manner along with the removed oil filter cartridges. Danger! It is imperative that the following guidelines are observed when inspecting or changing fuels and lubricants: Unless otherwise specified, carry out the respective work on the machine on firm, level ground with the engine switched off. Always secure the cover against falling or closing before leaning into the engine room. Refuelling may only be carried out with the engine switched off, never smoke and avoid naked flames.

2

Lubricant Chart Description

Medium

Diesel engine

Hydraulic oil tank

Symbol

Classification

Viscosity

BI *

Engine oil

API-CG-4, CF4 or CH-4, ACEA-E2-96, E3-96 or E4-98

SAE 5W40 SAE 10W30 SAE 10W40 SAE 15W30 SAE 15W40

EO 0540 EO 1030 EO 1040 EO 1540

Engine oil

API-CD, APICD+SF, ACEA-E4,

SAE 10W SAE 10W-30 SAE 10W-40 SAE 15W-40 SAE 20W-20 SAE 30W

EO 10 EO 1030 EO 1040 EO 1540 EO 20 EO 30

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Fuel and Lubricants

Technical documentation

Fuel and Lubricants Chart Description

Medium

Swing gear (as holding brake)

Classification

Viscosity

BI *

Gear oil

API-GL-5 MIL-L 2105 B, C or D

SAE 80W90 or SAE 90

GO 90

Swing gear (as positioning swing brake)

Gear oil

API-GL-5 MIL-L 2105 B

SAE 90 LS

GO 90 LS

Travel gear

Gear oil

API-GL-5 MIL-L 2105 B, C or D

SAE 80W90 SAE 90

GO 90

Raceways and toothing of swing ring, bearing of attachment

Lubricating grease

High-pressure grease KP2k or EP2

Consistency 2 NLGI class with lithium complex Tab. 6

MPG-A

Hinges, articulations, locks

Engine oil

-

-

-

-

Rubber seals on doors and panelling

Silicon spray or talcum

-

-

-

-

Tab. 1 *BI

3

Symbol

Lubricant Chart =

Standardised lubricants for construction machinery and vehicles of the Federation of the German Construction Industry (see brochure from Bauverlag GmbH - Wiesbaden and Berlin, information regarding the fuels and lubricants chart).

Fuel and Lubricants Chart Description

Medium

Fuel tank

Commercially-approved diesel fuel with a sulphur content of <= 0.5 %

Coolant

Anticorrosive and antifreeze Filling with DCA 4 BI = SP-C

Windshield washing system

Commercially-approved windshield washing agent or denatured alcohol

-

Refrigerant for air-conditioning system

R 134 a

-

Refrigerating oil in the air-conditioning compressor SD 7 H15

PLANETELF PAG SP 10 ID no. 10017679 (0.25 litres)

-

Tab. 2

Symbol

Fuel and Lubricants Chart

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Technical documentation

Fuel and Lubricants Fuel and Lubricants Chart

3.0.1

Fuel and lubricant specifications Lube oil for the diesel engine The lube oil guideline for diesel engines is based on the following classifications: Classification

Specification

API-classification (American Petrol Insti- CG-4, CF-4, CH-4 tute) ACEA (CCMC) - classification (Associa- E2-96 (D4), E3-96 (D5), E4-98 tion des Constructeurs Européens de l´Automobile) Tab. 3

Lube oil for the diesel engine

The engine oil for the diesel engine can be selected in accordance with the following chart.

Fig. 1

Engine oil for utilisation as lube oil for the diesel engine

Oil-change intervals for the turbo engine Conditions of use

Sulphur content in the fuel

Oil-change interval dependent on oil quality: CH-4 CG-4 CF-4 E2-96 (D4)

E3-96 (D5) E4-98

Climate normal to -10 °C

up to 0.5 % more than 0.5 %

250 h 125 h

500 h 250 h

below -10 °C

up to 0.5 % more than 0.5 %

125 h -

250 h 125 h

Tab. 4

Oil-change intervals

The oil-change intervals for the diesel engine are arranged in accordance with the following criteria: – First oil and filter change at 500 operating hours when using initial fill oil of quality E3-96 – Subsequent filter change every 500 operating hours – Subsequent oil-change depending on climate zone, sulphur content in fuel and oil quality E3-96 (D5), E4-98 (see Tab. 4). – Wherever the stipulated number of operating hours has not been reached in any given year, the engine oil and the oil filter must be changed at least once a year

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Fuel and Lubricants

Technical documentation

Fuel

4

Fuel Diesel fuels should comply with the minimum requirements of the permissible fuel specifications stipulated below.

4.0.1

Lubricity / sulphur content In DIN EN 590 a max. 350 mg/kg = max. 0.035 wt% sulphur content permissible. „Low-sulphur“ diesel fuels with a sulphur content below / less than 0.05% are only permissible if a lubricity can be guaranteed with the addition of additives. The diesel fuel lubricity must be 460 µm in accordance with HFRR (60) Testmax. [lubricity amended „wear scar diameter“ (1.4) at 60 °C]. For diesel fuels with a sulphur content above / more than 0.5 wt%, the oil-change intervals are to be halved.Diesel fuels with a sulphur content above / more than 1% are not permissible. Note! An approval can be granted in correspondence with the quality of the diesel engine lube oil! Fuel standard ASTM D 975 does not stipulate that the fuels must pass a fuel lubricity test. A written confirmation from the fuel suppliers must be acquired. The additives must be added by the supplier in his capacity as sole responsible agent for quality of the fuel. The addition of secondary lubricity additives by the customer is not recommended. – A cetane number of at least 45 is required for fuels in accordance with ASTM D 975. A cetane number above 50 is recommended, particularly when working in temperatures below 0 °C or 32 °F.

4.0.2

Permissible fuel specifications DIN EN 590 ASTM D 975 - 89a 1 D and 2 D Further fuel specifications can be obtained upon consultation with LIEBHERR's diesel engine development department.

4.0.3

Diesel fuel at low temperatures (winter operation) Paraffin crystals become separated in the diesel fuel as ambient temperatures fall. This causes a subsequent flow resistance in the fuel filter and a sufficient supply of fuel to the diesel engine can no longer be guaranteed. In moderate climates, optimum flow flexibility can be guaranteed up to: 0 °C from 15.04. to 30.09. -10 °C from 01.10. to 15.11. and from 1.3. to 14.04. -20 °C from 16.11. to 29.02. in accordance with DIN EN 590. We recommend using a fuel filter heater wherever flow flexibility of the diesel fuel proves inadequate, or when working in ambient temperatures below -20 °C. Other approved diesel fuels: Diesel fuel in compliance with DIN EN 590 with up to 5% Vol. FAME. Caution! Improving flow of the diesel fuel by adding petroleum or regular benzine, or flow improvers from alternate manufacturers which can be readily purchased in stores, even in insignificant quantities, is absolutely prohibited. Such an addition is not compatible with the high-pressure injection system of your diesel engine and would lead to ruination of the diesel engine as a direct result of inadequate lubrication.

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Technical documentation

Fuel and Lubricants Hydraulic oil

5 5.0.1

Hydraulic oil Mineral oil Engine oils are stipulated in accordance with the following specifications and guidelines: Single-grade oils:

API - CD / CCMC - D4 / ACEA - E1 Mercedes-Benz Guidelines, page no. 226.0 and 227.0

Multi-grade oils:

API - CD + SF / CCMC - D5 / ACEA - E3 Mercedes-Benz Guidelines, page no. 227.5, 228.1 and 228.3

Tab. 5

Prescribed engine oils for utilisation as hydraulic oil

Engine oil for utilisation as hydraulic oil can be selected in accordance with the following chart.

Fig. 2

Engine oil for utilisation as hydraulic oil

Warm-up directive The following warm-up directive applies for temperatures up to 10 °C below the stipulated limit (black bar): Following start-up, regulate the diesel engine to approx. 1 / 2 the nominal speed. Actuate hydraulic cylinders and hydraulic motors, do not allow the cylinders to run at full load. Warm-up period approx. 10 minutes. In even lower temperatures: Preheat the oil reservoir before starting up the engine.

5.0.2

Environmentally-friendly hydraulic fluids Note! Mixing environmentally-friendly hydraulic oils from different manufacturers, as well as mixing with mineral oils is strictly forbidden (see also information from after-sales services)! All environmentally-friendly hydraulic oils recommended by LIEBHERR are restricted to oils featuring synthetic ester base and a viscosity in compliance with ISO VG 46. Initial filling is carried out at the factory in accordance with a list of approved suppliers. It is essential that the utilisation of environmentally-friendly hydraulic oils is first agreed with the LIEBHERR company. Plant-based oils are not to be used due to their poor temperature resistance. The utilisation of partial flow filters is absolutely essential.

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Fuel and Lubricants

Technical documentation

Hydraulic oil

5.0.3

Hydraulic oil monitoring Note! Environmentally-friendly hydraulic fluids are to undergo regular inspections via oil analysis . Oil analysis is recommended for mineral oils. Machines working in normal conditions: at least every 500 operating hours Machines working in extremely dusty conditions: at least every 250 operating hours LIEBHERR recommends that the oil analyses be undertaken by the WEAR-CHECK company, and that the oil-change is performed in accordance with the respective laboratory report (see also aftersales service information and product information).

5.0.4

Hydraulic oil monitoring in normal conditions

Fig. 3

Taking oil samples in normal conditions

--- Taking an oil sample - Filter change h Operating hours

1 2 3

First oil sample Second oil sample Additional oil samples every 500 operating hours

Oil-change in accordance with analysis and laboratory report. Change intervals for the hydraulic oil return-flow filters (20/5 Âľm): first after 500 operating hours with subsequent changes every 1000 operating hours.

5.0.5

Hydraulic oil monitoring in extremely dusty conditions

Fig. 4

Taking an oil sample in extremely dusty conditions

--- Taking an oil sample - Filter change h Operating hours

1 2 3

First oil sample Second oil sample Additional oil samples every 250 operating hours

Oil-change in accordance with analysis and laboratory report. Change intervals for the hydraulic oil return-flow filters (10 Âľm): first after 500 operating hours with subsequent changes every 500 operating hours.

5.0.6

Tips for reducing contamination of the hydraulic oil in extremely dusty conditions If the machine is being operated predominantly with hydraulic hammer or comparable applications (extremely dusty conditions), it is likely that the hydraulic oil will become more contaminated than usual.

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Technical documentation

Fuel and Lubricants Hydraulic oil

To avoid premature wear of the hydraulic components, the oil-change intervals (or the intervals separating the taking of oil samples) are to be reduced and the following guidelines are to be observed: – The filter cartridge(s) in the return-flow filter must be replaced every 500 operating hours – For the return-flow filter, 10-µm filter cartridges must be used instead of the regular 20 / 5-µm filter cartridges – The ventilation filter on the hydraulic oil tank is to be replaced with a 2 µm fine filter (refinement of the standard filter is 7 µm) – The 2-µm ventilation filter is to be replaced each time a hydraulic oil-change is performed (every 500 operating hours) Note! Machines which have been equipped with a hydraulic installation kit in the factory, as well as machines featuring a retrofitted kit for the hydraulic hammer, are already equipped with these 10-µm filter cartridges and 2-µm ventilation filter.

5.0.7

Gear oil Gear oils must comply with the specifications – API-GL-5 and MIL-L-2105 B or C or D for viscosity class SAE 90 For viscosity classes SAE 80 and SAE 90 in accordance with MIL-L-2105 D, oils of viscosity class SAE 80W90 may also be used. Lubricating grease and other lubricants Lubricants

Description / manufacturer

Lubricating grease for the swing ring / The grease must comply with specification KP2k, general lubrication points consistency 2 or NLGI class in accordance with DIN 51818 and DIN 51825 or EP 2 in accordance with NF-T-60 132. The grease must comprise a lithium complex and must indicate a VKA-value of at least 2300 N in accordance with DIN 51350 or ASTM D 2596. Contact spray for sliprings

Cramolin ID no. 7024145

Lubricant for pistons, piston nuts and Gleitmo 800 the mounting of piston rod bearings ID no. 8300004 (40g tube) and damping sleeves on hydraulic cyl- Gleitmo 900 inders ID no. 8610227 (400 ml spray can) Special anticorrosive for installation points on the hydraulic cylinders for sealing elements

Castrol-Tarp ID no. 8300005 (40g tube)

Other greases: Liebherr special paste CTK Lubricant for the assembly of pumps to ID no. 861331301 (400g cartridge) prevent fretting corrosion on the splined shaft toothing Refrigerant for the air-conditioning system

R 134 a Draining and filling of the system must be performed in accordance with the guidelines (see airconditioning system componentry).

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Fuel and Lubricants

Technical documentation

Coolant Tab. 6

6 6.0.1

Lubricating grease and other lubricants

Coolant Anticorrosive and antifreeze with DCA (ID no. 8503890 - 30 l drum) Water filter accessories are introduced to LIEBHERR diesel engines to improve quality of the cooling water. This allows a supplementary filtering of the coolant in the bypass flow where it is purified of dirt or rust particles which could cause leakages in the cooling pumps. Additionally, a chemical admixture in the filter (DCA 4) protects the cooling system, or parts which come into contact with the coolant such as coolant pumps, cylinder liners etc. against cavitation, corrosion, limescale and the build-up of foam. Four different water filter accessories have been implemented due to the diverse volumes of cooling water or diverse water accessories on engines or equipment.

6.0.2

Coolant with DCA 4 (DIESEL COOLANT ADDITIVES) Ambient temperatures up to

Percentage (%) of water

Percentage (%) of anticorrosive / antifreeze

-37 °C / -34 °F

50

50

-50 °C / -58 °F

40

60

Tab. 7

Mix ratio of water / anticorrosive / antifreeze

The coolant must comprise at least 50 vol-% of anticorrosive and antifreeze all year round. This corresponds with a freeze protection down to -37 °C and guarantees ample protection against corrosion. In the event that coolant is disappearing at an unusual rate, ensure that the minimum 50 vol-% is being adhered to when refilling. Note! Do not use more than 60 % anticorrosive and antifreeze! Cooling effect and freeze protection will be minimised if higher percentages are added. The mix ratio and the DCA 4 concentration must be checked when carrying out the maintenance tasks. Note! – The coolant is to be changed every 2 years. – The DCA 4 concentration must total between 0.3 and 0.8 units per litre. – Test kit CC 2602 M from Fleetguard is recommended for checking.

6.0.3

Anticorrosive In exceptional cases and if ambient temperatures are continuously above freezing point, e.g. in tropical regions, in which no approved anticorrosive /antifreeze is readily available, a mixture of water and water-based anticorrosive may be used as coolant. Utilisation of DCA 4 without anticorrosive / antifreeze To protect the cooling system from corrosion, approximately double the amount of DCA 4 must be added to achieve the same mix ratio of water and DCA 4 (see Tab. 7).

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Technical documentation

Fuel and Lubricants Coolant

Note! – The coolant is to be changed once a year. – The DCA 4 concentration must total between 0.6 and 1.6 units per litre. – Test kit CC 2602 M from Fleetguard is recommended for checking. Utilisation of other water-based anticorrosives Note! – The coolant is to be changed once a year. – The mix ratio must comprise 7.5 % anticorrosive and 92.5 % water. – Refractometer 2710 from the Gefo company is recommended for checking. Checking using a refractometer

Fig. 6-1

Gefo refractometer no. 2710.

Setting the refractometer: Adjusting screw for adjusting the 0–line (water line) Visual acuity is adjusted by turning the eyepiece. Measuring procedure: Clean cover and prism thoroughly Apply 1–2 drops of test fluid onto the prism. The fluid is distributed by closing the flap. Look at a bright background through the eyepiece and adjust so that the scale can be seen clearly. Read off the values on the blue dividing line. Determine the concentration using the conversion table.

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Fuel and Lubricants

Technical documentation

Coolant

Concentration (vol%) Fig. 5

Gefo refractometer no. 2710 - conversion table.

Summary of approved water-based anticorrosives Product description

Manufacturer

DCA 4 Diesel Coolant Additives

Fleetguard

Caltex CL Corrosion Inhibitor Concentrate

Caltex

Chevron Texaco Heavy Duty Extended Life Corrosion Inhibitor Nitrite Free

Chevron Texaco

Havoline Extended Life Corrosion Inhibitor (XLI)

Arteco

Total WT Supra

Total

Tab. 8

6.1.4

Water-based anticorrosive

Refilling the cooling system Before filling new coolant into the cooling system, ensure that it is clean and rinse as necessary When filling or refilling the cooling system following the carrying out of repair work, liquid DCA 4 must be added to the coolant to supplement the DCA 4 concentration in the water filters Cooling system content

Tab. 9

6.1.5

Required amount of liquid DCA 4

DCA 4 water filter

Litre

0.5 litre drum ID no. 7363898

or

Litre

24 - 39

3

or

1,4

WF 2071

7367045

40 - 59

4

or

1,9

WF 2072

7381493

60 - 79

5

or

2,4

WF 2073

7367052

80 - 115

8

or

3,8

WF 2073

7367052

Designation

ID no.

Filling amounts of coolant with DCA 4

Change intervals for the DCA 4 water filter The DCA 4 water filter must be replaced every 500 operating hours. If no loss of coolant has been determined in the cooling system, a sufficient DCA 4 concentration in the cooling system is assured for change intervals of 500 operating hours.

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Technical documentation

Fuel and Lubricants Coolant

6.1.6

Guideline for quality of fresh water Clean water which is not too hard should be used for the preparation of the coolant. Tap water usually, however, not always, fulfils this requirement. Sea water, brackish water, salt water and industrial waste water are not suitable. Fresh water quality when using anticorrosive and antifreeze Substance of content

Quantity

Total alkaline earths (water hardness)

0.6 to 3.6 mmol / l (3 to 20 °d)

pH-value at 20 °C

6.5 to 8.5

Chloride-Ion content

max. 80 mg / l

Total Chloride + Sulphate

max. 100 mg / l

Tab. 10

Water substance content with anticorrosive and antifreeze

Fresh water content when using coolant with DCA 4 Substance of content

Quantity

Total alkaline earths (water hardness)

0.6 to 2.7 mmol / l (3 to 15 °d)

pH-value at 20 °C

6.5 to 8.0

Chloride-Ion content

max. 80 mg / l

Total Chloride + Sulphate

max. 80 mg / l

Tab. 11

6.1.7

Water substance content for coolant with DCA 4

Approved anticorrosive and antifreeze Undiluted concentrate

Brand

Manufacturer

Country

Agip Antifreeze Plus

Agip Petrol S.p.A., Rome

I

Agip Langzeit-Frostschutz

Autol-Werke GmbH, Würzburg

D

Antigel DB 486

Sotragal SA, St. Priest

F

Aral Kühlerfrostschutz A

Aral AG, Bochum

D

Avia Frostschutz APN (G48-00)

Deutsche Avia-Mineralöl GmbH, Munich

D

BP Antifrost X 2270 A

Deutsche BP AG, Hamburg

D

BP Napgel C 2270 / 1

BP Chemicals LTD., London

GB

Caltex Engine Coolant DB

Caltex UK Ltd, London

GB

Caltex Extended Life Coolant

Caltex UK Ltd, London

GB

Castrol Anti-Freeze O

Deutsche Castrol Vertriebs GmbH, Hamburg

D

Century F.L. Anti-Freeze

Century Oils, Hanley, Stoke-on-Tent

GB

Chevron DEX-Cool Extended Life Anti-Freeze / Coolant

Chevron Texaco, San Ramon, CA

USA

DEUTZ Kühlschutzmittel 0101 1490

Deutz Service International GmbH, Cologne

D

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Fuel and Lubricants

Technical documentation

Coolant Brand

Manufacturer

Country

Esso Kühlerfrostschutz

Esso AG, Hamburg

D

Fircofin

Fuchs Mineralölwerke GmbH, Mannheim

D

Frostschutz Motorex (G48-00)

Bucher & Cie, Langenthal

CH

Frostschutz 500

Mobil Oil AG, Hamburg

D

Glacelf Auto Supra

Total Nederland N.V., Den Haag

NL

Glycoshell AF 405

Shell Deutschland GmbH, Hamburg

D

Glycoshell N

Shell Deutschland GmbH, Hamburg

D

Glysantin (G48-00)

BASF AG, Ludwigshafen

D

Havoline XLC

Arteco, Gent

B

Havoline DEX-Cool Extended Life Anti-Freeze / Coolant

Chevron Texaco, San Ramon, CA

USA

Igol Antigel Type DB

Igol France, Paris

F

Labo FP 100

Labo Industrie, Nanteree

F

Motul Anti-Freeze

Motul SA, Aubervilles

F

OMV Kühlerfrostschutzmittel

OMV AG, Schwechat

A

Organifreeze

Total Deutschland GmbH, Düsseldorf

D

OZO Frostschutz S

Total Deutschland GmbH, Düsseldorf

D

Total Antigel S-MB 486

Total Deutschland GmbH, Düsseldorf

D

Total Frostfrei

Total Deutschland GmbH, Düsseldorf

D

Veedol Anti-Freeze O

Deutsche Veedol GmbH, Düsseldorf

D

Wintershall Kühlerschutz

Wintershall Mineralöl GmbH, Düsseldorf

D

Tab. 12

Approved anticorrosive and antifreeze

50:50 Premix (water: anticorrosive / antifreeze) Product description

Manufacturer

Country

Liebherr Anti-Freeze APN Mix ID no. 8611045

LIEBHERR

D

Caltex Extended Life Coolant Pre-Mixed 50/50 (ready-to-use-version)

Caltex UK Ltd, London

GB

Chevron DEX-Cool Extended Life Prediluted 50/50 Anti-Freeze / Coolant

Chevron Texaco, San Ramon, CA

USA

Havoline XLC, 50/50

Arteco, Gent

B

Havoline DEX-Cool Extended Life Prediluted 50/50 Anti-Freeze / Coolant

Chevron Texaco, San Ramon, CA

USA

1.50.12

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Technical documentation

Fuel and Lubricants Coolant

Product description

Manufacturer

Country

Organicool 50/50

Total Deutschland GmbH, Düsseldorf

D

Tab. 13

Approved anticorrosive / antifreeze / 50:50 Premix

1.50.13

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Fuel and Lubricants

Technical documentation

Coolant

1.50.14

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Technical documentation

Group 2: Tools

Special tools for maintenance and repair ............................................................................2.01 Special tools for Liebherr Diesel engines ............................................................................2.02 Special tools for the hydraulic system.................................................................................2.03 Special tools for electrical connectors.................................................................................2.06 Special tools for gears ...........................................................................................................2.07 Common tools ........................................................................................................................2.08 Measuring tool for spool travel .............................................................................................2.10 Mounting tools for hydraulic cylinders ................................................................................2.12 1 2 3

Mounting wrench for hydraulic cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12.1 Piston nut wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12.2 Mounting and spreader sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12.3

Wrench for the slotted nut on the swing gear SAT .............................................................2.14 Compression device for brake piston of gear SAT .............................................................2.15 Compression device for brake piston of gear FAT .............................................................2.16 Mounting device for disk brake on travel gear ....................................................................2.17 Eichwerten LMS System / Valeurs de calibrage .................................................................2.19 Pump test kit ...........................................................................................................................2.21 Tools for installing the slipring seals ...................................................................................2.22

2.00.1

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Technical documentation

2.00.2

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Technical documentation

Special tools for maintenance and repair

Group 2: Tools 2.01: Special tools for maintenance and repair Spezialwerkzeuge zur Wartung und Reparatur Outillage spécial utilisé pour l’entretien et les réparations Darstellung Representation Dessin

Nr. No. N°

Benennung Desciption Dénomination

Größe Size Grand.

Ident. Nr. Order no N°code

Gerät Model Type

1

Messstutzen Pipe adaptator Embout

NW 10

7002404

alle Typen

NW 12

7008688

2

13 14 15 16 17 18

Messstutzen Pipe adaptator Embout

M22x1,5 M14x1,5 M16x1,5 M18x1,5 M20x1,5 M24x1,5

5607671 5607616 5607605 5607617 7409922 7409923

914 alle alle 914/924 914/924 914/924

25

Manometeranschluss BSP coupling Raccord

R 1/2 “

7002436

alle Typen

30

Manometer Direktanschluss Direct gauge coupling Raccord (brancht. direct du manométre)

R 1/2 “

7002435

alle Typen

Anwendung Application Application

Form K K Form Forme K Nach / From / Selon – LH673-02

2.01.1

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Special tools for maintenance and repair

Darstellung Representation Dessin

Technical documentation

Nr. No. N°

Benennung Desciption Dénomination

Größe Size Grand.

Ident. Nr. Order no N°code

Gerät Model Type

Anwendung Application Application

35

Hochdruckschlauch Länge High pressure hose Length Flexible haute pres. Long

1000 mm

7002437

1500 mm

7002475

alle Typen

5000 mm

7363732

Zum Anschließen von Manometern an allen Messstellen (Messstutzen Nr. 1/2 und Schraubkupplungen 10-14)

36 37

To connect pressure gauges on all check points (pipe adapter no 1/ 2 and gauge coupling 10 14) Pour le branchement des manométres sur tous les embouts 1/2 es raccords complets 10-14.

40

Schraubkupplung kpl. Gauge coupling Raccord complet

41 42 43 44 45

46 47 48 49 50 51 52 53 54 55 56

Manometer Hydraulic pressure gauge Mano. à bain de glycérine

M10X1

5005180

M12X1,5 M14X1,5 M16X1,5 R 1/4“

7402580 5004002 7361345 7362579

0-1,6 bar

8042577

0-1,6 bar * 0-2,5 bar * 0-6 bar * 0-10 bar * 0-25 bar * 0-40 bar * 0-60 bar * 0-160 bar * 0-250 bar * 0-400 bar * 0-600 bar *

8042578 7361292 7361291 5002865 7361289 7361288 5002867 7361286 7361285 7500002 7361294

2.01.2

alle Typen

alle Typen

Zur Überprüfung der Betriebsdrücke eines bzw. mehrerer Hydraulikkreise. Used to check system pressure in one or more hydraulik systems. Pour le contrôle des pressions d’un ou de plusieurs cicuits hydraulique * glyceringedämpft * dampened with glycerin * à bain de glycérine

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Technical documentation

Darstellung Representation Dessin

Special tools for maintenance and repair

Nr. No. N°

Benennung Desciption Dénomination

75

Größe Size Grand.

Ident. Nr. Order no N°code

Gerät Model Type

Anwendung Application Application

DifferenzdruckMess-Set bestehend aus: Measuring device for differential pressures contents: Instrument de mesure pour pressions différentielles, comprenant:

10288229

alle Typen

Zum Messen des Differenzdruckes p zwischen Pumpen- und LS Druck.

76

-Messgerät MultiHandy 3010 -Measuring device M-H 3010 -Instrument de mesure M-H 3010

10288155

77

1 Stk. Datenkabel 1 wire data transfert 1 jeu de câble pour transfert de données

10288152

78

2 Stk. Messkabel 2 measuring wire 2 jeux de câble de mesure

10288154

79

-Steckernetzgerät 230 V -Power supply unit 230 V -Unité d’alimentation 230 V

7025279

80

-KFZ Anschlusskabel -Connecting wirebord circuit - Câble de brancht. au tableau

7025273

81

-Transportkoffer -Tavel box Coffret der transport

614063501

82

-Adapterkabel / Daten-übertrag. -Adapter wire - data transfert -Càble pour transfert de données

7025275

83

-Wechselakku für Nr. 76 -Replacement Battery for No. 76 -Aecu de rechange de No. 76

7026910

To measure the differential pressure p between pump- and LS pressure. Pour mesurer la différence de pression p entre pression de pompe et pression LS.

2.01.3

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Special tools for maintenance and repair

Darstellung Representation Dessin

Technical documentation

Nr. No. N°

Benennung Desciption Dénomination

Größe Size Grand.

Ident. Nr. Order no N°code

Gerät Model Type

84

-Druckaufnehmer -Pressure sensor -Capteur de pression Hydrotechnik

0-600 bar

614062401

alle Typen

85

-Direktanschluss für Druckaufnehmer -Connecting wire for pressure sensor -Raccord pour capteur de pression

86

-Messkabel MK 12 -Measuring wire MK 12 -Càble de mesure MK 12

100

Stutzen Pipe adaptator Embout de prise de pression

4901372

101

Messstutzen mit Metallkappe Pipe adaptator with metalic cap Prise de pression + embout métall

7002404

102

Überwurfmutter Cap nut Ecrou de raccord

4774002

103

Schneidring Cutting ring Bague de sertissage

4774001

109

Service Stecker (grün) Service plug (green) Connecteur de service (vert)

9684328

Anwendung Application Application

614062601 614064701

12 m

614063701

alle Typen

Zum Druckabgleich in Verbindung mit Werkzeug Nr. 75 / 85 For pressure equilibration in connection with tool no 75 / 85 Pour l’équilibrage en pression en utilisant l’outil n° 75 / 85

Für Kommunikation mit und Parametrieren des elektronischen Steuerkreis über Baggerdisplay For communicating with and adjusting the electronic control circuit via the display of the excavator Pour communication avec et paramétrage du circuit électronique de commande, via le display de la pelle Gültig für / Valid for / Valable pour : - Litronic 2

2.01.4

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Technical documentation

Darstellung Representation Dessin

Special tools for maintenance and repair

Nr. No. N°

Benennung Desciption Dénomination

Größe Size Grand.

110

LMS-LitronicMesssystem kpl. bestehend aus: Messgerät, Transportkoffer u. Trageriemen

Ident. Nr. Order no N°code 614062001

Gerät Model Type

Anwendung Application Application

alle Typen

Zum Messen und Abspeichern aller Drücke, Fördermengen, Drehzahlen, elektr. Ströme und Spannungen Used to measure and store hydr. pressures, pump flow, electrical current and voltage

LMS -Litronic-Measuring kpl. containing: measuring tool, carrying case and straps

Pour la mesure et la mémorisation de toutes les pressions, débits, régimes, tensions et courants électriques

Systéme de mesure Litronic-LMS comprenant: instruments de mesure, coffret de transport et courroie d’ épaule 111

115

Sensoren und Zubehör Sensors and Extras Capteurs et Accessoires

In Verbindung mit Werkzeug Nr. 110 On connexion with tool no. 110 En liaison avec l’outil n° 110

(see “Lieferumfang Litronic Messsystem” on page 11)

Messadapter Measuring adapter Boîtier de mesure

8504231

alle Typen

Für Strommessung an der Pumpenregelung To check current on pump regulation Mesure des courants de régulation sur les pompes

120

Messkabel Measuring wire Càble de mesure

9956436

alle Typen

Für Messung des Induktivgebers B 12 von 3-polig (LH) in Verbindung mit Werkzeug Nr. 115 To check of the RPMSensor B 12 from 3-pole (LH) in connection with tool no. 115 Mesure des capteur inductif B 12 3-bornes (LH) en utilisant l’ outil n° 115 Für Strommessung To check current Mesure des courants

2.01.5

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Special tools for maintenance and repair

Darstellung Representation Dessin

Technical documentation

Nr. No. N°

Benennung Desciption Dénomination

Größe Size Grand.

Ident. Nr. Order no N°code

Gerät Model Type

Anwendung Application Application

125

Drehzahlmesser Piezzo

A 2106 450

10286429

alle Typen

Zum Messen der Motordrehzahl über Impulsfrequenz der Einspritzleitung

Revolution - Indicator Compte-tours Piezzo

To check the engine RPM via impulse frequency of the injection line Mesure de régime du moteur thermique par rapport aux impulsions de la pompe à injection

130

131 132

Drehzahlmesser Ornel Revolution - Indicator Compte-tours Ornel Drehzahlmesser Shimpo Revolution - Indicator Compte-tours Shimpo

HT 460

7006974

alle Typen

To check the RPM via reflexions stripe DT 205

7364284

Mesure de régime par l’intermédiaire d’ une patille réflectrice

614063201

mit / with / avec / n° 130

Streifen / Stripes / Pastilles 145

Vielfachmessgerät mit Digitalanzeige Multimeter with digital display

Zum Messen der Drehzahl über ReflexionsStreifen

Chauvin Arnoux MAX 3000

10018500

alle Typen

Für Spannungs-, Stromund Widerstans-messungen von Elektroanlagen und Elektro - Ventilen For voltage, current and resistance measurements of electrical systems and electrical valves

Contrôleur universel à affichage digital

Mesure de la tension, de la résistance de circuits et clapets électriques 146

Zusatz - Messwerkzeuge Measuring tools kit Outillages optionnels de mesures

5616316

In Verbindung mit / To be used with tool / A usiter avec l’ outillage / n° 145

147

Meßkabelsatz Measuring cable set Lot de câbles de mesure

886125008

In Verbindung mit / To be used with tool / A usiter avec l’ outillage / n° 145

148

Bereitschaftstasche Carrying case Pochette de protection

6001128

2.01.6

In Verbindung mit / To be used with tool / A usiter avec l’ outillage / n° 145

R 900 C-Li - R 904 C-Li copyright by

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Technical documentation

Darstellung Representation Dessin

Special tools for maintenance and repair

Nr. No. N°

Benennung Desciption Dénomination

Größe Size Grand.

Ident. Nr. Order no N°code

Gerät Model Type

Anwendung Application Application

160

Thermometer berührungslos (Infrarot)

GMTL 1826

7020372

alle Typen

Zum Überwachen der Temperatur eines Mediums bzw. der AußenTemperatur eines Aggregates

Thermometer Infrared Temperature sensor

Used to monitor the temperatur of any liquid resp. the housing temp. of any component

Thermométre sans contact 162

Thermometer mit Sonde und Fühler (magnetisch.) Thermometer with probe and sensor (magnetic.) Thermométre avec sonde et capteur (magnetic.)

GTH 1150

170

Handpumpe Sampling pump Pompe manuelle

8145666

172

Entnahmeventil für Ölproben alternativ zur Handpumpe Sampling valve for oil samples alternative to the sampling pump no.

7019068

Pour mesurer la temp. d’un liquide ou la temp. extérieure d’un composant

10024185

alle Typen

Zur Entnahme einer Ölprobe für die Ölanalyse Used to taking samples for oil analysis Pour prélevement d’échantillon pour analyse d’huile

Vanne de soutirage d’échantillons d’huile utilisable au lieu de la pompe manuelle 175

Öl Analysenset * Oil Analysis set *

180

Öl Analysenset * Oil Analysis set *

Nr. 1

7018368 8145660

*Analysen bei WAER CHECK Deutschachland Laborbericht in deutscher Sprache *Analysis at WAER CHECK Germany Analysis report in German language

alle Typen

6 Stck. Ölproben 6 samples 6 pièces 1 Stck. Ölprobe 1 sample 1 jeu

Nécessaire pour anallyses d’huiles * Analyses par Sté WAER CHECK Belgique Rapport d’analyses en Francais

2.01.7

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Special tools for maintenance and repair

Darstellung Representation Dessin

Technical documentation

Nr. No. N°

Benennung Desciption Dénomination

Größe Size Grand.

Ident. Nr. Order no N°code

Gerät Model Type

Anwendung Application Application

190

Vakuumpumpe REFCO Evacuation pump REFCO Pompe à vide REFCO

RD-4

7027552

alle Typen

Zur Wartung und Reparatur der Klimaanlage Konvekta For sevicing and repairing the air conditioning equipement Konvekta Pour l’entretien et la réparation du elimatiseur Konvekta

195

Füllschlauch ITE blau Filling hose ITE blue

1500 mm

7027553

1500 mm

7027554

alle Typen

Siehe Pos. / See Pos. / Voir Pos. / 190

alle Typen

Siehe Pos. / See Pos. / Voir Pos. / 190

alle Typen

Zur Wartung und Reparatur der Klimaanlage Konvekta

Flexible de remplissage ITE bleu 196

Füllschlauch ITE gelb Filling hose ITE yellow Flexible de remplissage ITE jaune

197

Füllschlauch ITE rot Filling hose ITE red Flexible de remplissage ITE rouge

1500 mm

7027555

205

KFZ - Kupplung ITE Quick coupling ITE Attache rapide ITE

253a

7027556

210

KFZ - Kupplung ITE Quick coupling ITE Attache rapide ITE

254 a

7027557

215

4-Ventil - Prüfarmatur

M4WS5C

7027558

Test equipement with 4 valves

For servicing and repairing the air conditioning equipment Konvekta

Unité d’essai à 4 clapets

Pour l’entretien et la réparation du elimatiseur Konvekta

2.01.8

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Liebherr r904c litronic crawler excavator service repair manual sn23072  
Liebherr r904c litronic crawler excavator service repair manual sn23072  
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