Liebherr a316 li ind litronic wheel excavator service repair manual sn2001 an up

en

Service Manual Hydraulic Excavator A 309 - R 317 Litronic

General

1

Tools

2

Technical data / maintenance instructions

3

Drive motor

4

Coupling / pump distribution gear

5

Hydraulic system

6

Hydraulic components

7

Electrical system

8

Slewing gear mechanism

9

Slewing ring

10

Transmission

11

Axles

12

Steering

13

Oscillating axle support

14

Brake system

15

Special equipment / accessory kits

16

Operator's cab / heating and air-conditioning

17

Undercarriage / uppercarriage / attachments

18

Tank arrangement

19

Service Manual

SUBGROUP - INDEX Section

Group

Type

Modification of series

1.02.1

A 309 LI - R 317 LI

Safety instructions

1.10.1

A 309 LI - R 317 LI

Tightening torques WN 4037

1.20.1

A 309 LI - R 317 LI

Tightening torques for screw connections

1.21.1

A 309 LI - R 317 LI

Assembly instruction for cylinder (WN 4121B)

1.22.1

A 309 LI - R 317 LI

Assembly instruction for cylinder (WN 4122B)

1.24.1

A 309 LI - R 317 LI

Fuels, lubricants and other consumables

1.50.1

A 309 LI -R 317 LI

Lubricant list TE-ML 05

1.55.1

A 309 LI -R 317 LI

Lubricant list TE-ML 07

1.56.1

A 309 LI -R 317 LI

1.1 MJFCIFSS

Service Manual

1.2 MJFCIFSS

Service Manual

Modification of series

Modification of series Item (a)

Type of modification Modified actuation of the pressure-relief valves for slewing gear Joint control line Xab replaced by separate control lines Xa / Xb for each valve

Affected models A 314 Li: 11147 A 316 Li: 11152 A 316 Li industrial: 11178

Additional orifice 126 in connection P of valve 125 Modified measuring connections Measuring connections 137 / 138 are moved from the side to the top (b)

Modified spool

A 314 Li: 11820

Spool for slewing gear (change in design from restricted to blocked outlet)

A 316 Li: 11822 A 316 Li industrial: 11823

Spool for chassis (change in design from restricted to open outlet) (c)

Modified pressure balance 244 for stick cylinder

A 314 Li: 12814 A 316 Li: 12741

Change from pressure balance without shock absorption to pressure balance with 0.4mm shock absorption

A 316 Li industrial: 11846

Additional control line from control valve block connection MLS to pressure balance 244 at spring side connection LSE Modified shuttle valves 227 (a3 /b3) for boom cylinder spool Change from Ă˜ 0.8 mm to Ă˜ 0.6 mm (d)

(e)

Modified fan cycle

A 312 Li: 13289

Installation of coarse filter 15 in the pressure line to oil motor / radiator fan

A 314 Li: 13104

Various modifications to control valve block

A 312 Li: 16275

A 316 Li: 13105

A 314 Li: 16215 Tuning improved. Pressure balance 224 pilotcontrolled. Shuttle valve 107 integrated into control block. Central nozzle 109 screwed in.

New slewing gear module (check valve 123 before spool 120).

A 316 Li: 16141 A 316 Li industrial: 16286

Modified TC valve 125 Integrated restrictor 126 and bypass line with restrictor 129

1.02.1 MJFCIFSS

Modification of series

Item (f)

Service Manual

Type of modification Pressure-relief valve in the gear pump / steering

Affected models A 312 - A 316 Li: 20241

Gear pump of steering system with integrated pressure control (g)

Modified electrical system Modifications: K392 (industrial shut-off) omitted, S5 with 3 push buttons, S382 modified, S263 modified, S422 added

(h)

New pilot control unit for travel working movement:

A 312 Li: 20330 A 314 Li: 20334 A 316 Li: 20340 A 316 Li in.: 20340

R 317 Li: 21205

The two individual pilot control units 2x are replaced by one pilot control unit 4x (i)

Optimised control of control valve block Regulating cylinder spool modified; control of spool of combined boom / slewing gear with shuttle valves Restrictor check valve 171 for stick cylinder is omitted

(k)

Optimisation of fine control Spool of the boom and regulating cylinder and the summary pistons modified. Installation of priority circuit "Total of boom before total of stick" with decoupling.

Actuation of boom and stick spools with additional shuttle valves.

A 309 Li: 23503 A 311 Li: 23504

A 309 Li: 27110 A 311 Li: 27112

See also service information 07-11-37/2005 (l)

Speed reduction when working at 1950 rpm Omission of solenoid valve Y330 for zero boom switching from P2 during travel

A 309 Li: 27110 A 311 Li: 27112

The solenoid valve Y330 at the control oil unit is omitted.

See service information 07-11-37/2005 (m)

Hydraulic slewing ring locking mechanism A hydraulically operated cylinder (via pilot control system) with a locking bolt is installed in the uppercarriage. It is used for the locking of the uppercarriage during parking and transport of the machine.

(n)

Changeover to travel operation By changing over to the 2 HL 270/290 transmission, the travel motor has also been upgraded to a DMVA 165 motor.

A 309 Li: 26392 A 311 Li: 26396 A 312 Li: 29898 A 316 Li: 28061 A 316 Li ind.: 28061 A 316 Li: 28061 A 316 Li ind.: 28061

1.02A 309 LI 20221-A 311 LI 20222-A 312 LI 12363-A 314 LI 2001-A 316 LI 2001-A 316 LI-IND 2001-R 317 LI 18161-

1.02.2 MJFCIFSS

Service Manual

Safety instructions Proper use

Safety instructions Working with the machine holds dangers to which you as the owner, machine operator or maintenance expert could be exposed. If you regularly read and observe the safety information, you can guard against dangers and accidents. This applies especially to persons, who are working on the machine only occasionally, such as for maintenance work. The following information comprises safety regulations which, if followed conscientiously, will guarantee your safety and that of other persons, as well as avoid damage to the machine.

Following these regulations does not release you from the responsibility to follow all safety regulations and guidelines valid for the jobsite, as required by law or issued by trade associations.

For EU countries, guideline 89/655/EEC contains the minimum safety information applicable to the operator.

1

Proper use – The hydraulic excavator is a machine with attachments (such as backhoe, grapple, bucket ) designed to loosen, take on, transport and dump soil, rocks and other materials, where the load is predominantly transported without moving the machine. Moving the machine when it is carrying a load must be carried out by observing the appropriate safety measures (see section "Notes for machine operating safety").

– Machines used for load-lifting work are subject to specific conditions and must be equipped with the stipulated safety devices (see section “Load-lifting work”).

– Other or additional usage, such as for demolition or material handling work, requires special equipment and may also require special safety devices. These attachments (e.g. log grapple, demolition hammer, concrete cutter etc.) may only be attached and used with approval and in accordance with the basic machine manufacturer.

– Transporting persons is not deemed to be intended use. The manufacturer is not liable for damage resulting from this action. The risk must be assumed solely by the user.

– Observing the operating instructions and the inspection / maintenance instructions is also deemed to be appropriate and destined use in accordance with regulations.

2

General Safety instructions – Please familiarize yourself with the operating instructions before starting the machine.

– Please verify that you have supplemental instructions and have read and understood these (this may concern special options for the machine).

– Only explicitly authorized personnel may operate, maintain or repair the machine. The legal minimum age must be observed.

– Use only trained or instructed personnel. Clearly define who is responsible for the operation or set up, maintenance and repair. Allow personnel to refuse unsafe instructions given by a third person. This also applies to traffic regulations. Reject unsafe instructions by third parties and/or allow your personnel to reject these. This also applies in regards to traffic regulations.

– Any person still in training should only operate or work on the machine under the constant supervision and guidance of an experienced person.

– Check and observe any person working or operating the machine at least periodically if they observe safety instructions and guidelines given in the Operating manual.

– Wear proper work clothing when operating or working on the machine. Avoid wearing rings, watches, ties, scarves, open jackets or loose clothing. There is a danger of injury, as these items could get caught or be pulled in.The following are mandatory for certain tasks: Safety glasses, safety shoes, safety helmet, work gloves, reflecting vest, hearing protection, ...

1.10.1 copyright by

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Safety instructions

Service Manual

Crushing and burn prevention – For certain tasks, safety glasses, hard hats, safety boots, work gloves, reflective vests, ear protection etc. are required.

– Consult the supervisor at the job site for special safety instructions and regulations.

– Always raise the safety lever before leaving the operator’s seat.

– When entering or leaving the cab, do not use the steering column, the control panel or the joysticks as handholds. Inadvertent movements, which could cause accidents, should be touched off.

– Never jump off the machine, always use the steps, ladders, rails and handles provided to climb off or on the machine.

– Use both hands to hold on, facing the machine.

– Familiarize yourself with the emergency exit through the front window.

– Proceed as described in the operating instructions, if no other instructions are available for maintenance and repairs: • Place the machine on a solid and level ground and lower the work equipment to the ground.

• Depressurize the hydraulic system.

• Move all control levers to the neutral position.

• Move the safety levers up prior to leaving the machine.

• Remove the ignition key.

– You must also reduce the pressure in the hydraulic system and the interior pressure of the tank prior to any operation on the hydraulic system as described in these operating instructions.

– Secure all loose parts on the machine.

– Never start a machine before completing a thorough inspection and check, if safety tags are missing or are illegible.

– Do not complete any modifications, attachments or retrofits on the machine, which could inhibit safety, without the prior consent of the manufacturer. This also applies to the installation and adjustment of safety devices and safety valves as well as to any welding on load carrying parts.

3

Crushing and burn prevention – Never work underneath the attachment as long as it is not safely resting on the ground or properly supported.

– Do not use any damaged or insufficiently supporting load carrying devices, such as ropes or chains.

– Always wear work gloves when handling wire ropes.

– When working on the attachment, never align bores with your fingers, always use a suitable alignment tool.

– Please verify that no objects enter the fan while the Diesel engine is running. Rotating fans will swirl and throw out objects, which can damage the fan.

– At or near operating temperature, the engine cooling system is hot and under pressure. Avoid contact with any components containing coolant. Danger of severe burns.

– Check the coolant level only after the radiator cap on the expansion tank is cool enough to touch.

Turn the cap carefully to relieve the pressure.

– At or near operating temperature, the engine and the hydraulic oil are hot. Do not allow your skin to come into contact with hot oil or components containing hot oil.

– Always wear safety glasses and protective gloves when handling batteries. Avoid sparks and open flames.

– Never permit anyone to guide the grapple by hand.

– When working on the engine area, make sure that the side doors are properly secured with the appropriate supports to prevent them from closing inadvertently.

– Never work underneath the machine if it is raised with the attachment, without being properly supported from below with hardwood beams.

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Service Manual

Safety instructions Fire and explosion prevention

4

Fire and explosion prevention – Switch off the Diesel engine prior to filling the tank.

– Routinely check the electrical system.

– Have skilled personnel immediately repair all defects, such as loose connections, blown fuses and burned out light bulbs, burned or frayed cables.

– Do not smoke and avoid open flames when filling the tank or loading the batteries.

– Always start the Diesel engine according to the regulations in the operating instructions.

– Never store flammable fluids on the machine except in appropriate storage tanks.

– Regularly inspect all lines, hoses and fittings for leaks and damage.

– Repair any leaks immediately and replace damaged components.

– Any oil escaping from leaks can easily cause a fire.

– Be certain that all clamps, guards and heat shields are properly installed to prevent vibration, rubbing and heat build up.

– Do not use cold start aids (ether) near heat sources or open flames or in insufficiently ventilated areas.

– Do not use ether containing starting aids to start Diesel engines with preheat system or flame glow systems. DANGER OF EXPLOSION! – Familiarize yourself with the location and use of fire extinguishers on the machine as well as the local fire reporting procedures and fire fighting possibilities.

5

Transporting the machine safely – Due to the space restrictions during transport, use only suitable transporting and lifting devices with sufficient capacity – Park the machine on a level surface and chock the chains and/or wheels.

– If necessary, remove parts of the attachment during transport.

– The ramp to drive onto the transporting vehicle should not exceed an inclination of 30° and be provided with a wood covering to prevent sliding.

– Clean the undercarriage. The undercarriage must be swept clean, meaning, the chains / wheels must be free of snow, ice and sludge prior to driving onto the ramp.

– Align the machine precisely with the loading ramp.

– Attach the manual lever for sensitive driving (crawler excavator) to the driving pedals.

– Note that a guide gives the necessary signals to the machine driver.

– Drop the equipment in and drive it onto the loading ramp. Keep the equipment tight over the loading surface and drive it carefully onto the ramp and further into the transporting vehicle.

– The superstructure must be secured with the undercarriage by using locking bolts (only for Aequipment), after loading the machine onto the low loader.

– Secure the machine and the remaining equipment parts with chains and chocks against shifting according to national regulations for loading and transporting.

– Release all pressure lines (as described in these operating instructions), pull the ignition key and pull the safety lever up prior to leaving the machine.

– Close all cab and panel doors.

– Verify that no one is located on the machine during the transport.

– Investigate the travel route, specifically in reference to limits for width, height and weight prior to the transport.

– Pay special attention when driving under electrical lines and bridges and when passing through tunnels.

– Use the same care for unloading as for loading.

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Safety instructions

Service Manual

Bringing the machine safely into service

6

Bringing the machine safely into service – – – – – – – – – – – –

7

Before starting the machine, perform a thorough walk around inspection.

Visually check the machine for loose bolts, cracks, wear, leaks and damage.

Never start or operate a damaged machine.

Make sure to correct any problems immediately.

Verify that all hoods, covers and doors are closed, however, the locks should remain unlocked.

Verify that all safety tags are available.

Make sure that all windows, as well as the inside and outside mirrors are clean. Secure all doors and windows to prevent unintentional movement.

Be certain that no one works on or under the machine and warn any personnel in the surrounding area with the horn before starting the machine.

Before operating the machine, adjust the operator’s seat, the mirror, the arm rests and the other items to ensure comfortable and safe working conditions.

The noise protection devices on the machine must be in functional protective position during operation.

Follow the regulations effective for the relevant site.

Never start the machine without the driver’s cab.

Starting the machine safely – Before start up, check all indicator lights and instruments for proper function, bring all controls into neutral position and raise the safety lever.

– Honk the horn briefly prior to starting the Diesel engine, in order to warn persons located near the machine.

– Only start the machine from the driver’s seat.

– Start the Diesel engine according to the regulations in the operating instructions, if you have not received any other instructions.

– Lower the safety lever and check all indicators, gauges, warning devices and controls for their proper indication.

– Only operate the Diesel engine in a well ventilated area, if the area is enclosed. Open doors and windows to ensure sufficient fresh air supply, if necessary.

– Bring the engine and hydraulic oil to operating temperature. Low oil temperatures cause a slow reaction of the controls.

– Check that all attachment functions are operating properly.

– Carefully take the machine to an open area and check all safety-related functions.

8

Shutting down the machine safely – Only place the machine on a level and solid ground. The machine must be secured with chocks, wenn setting it on a slope, to secrure it against rolling away.

– Lower the working equipment and anchor it lightly into the ground.

– Move all control elements into the neutral position. Set the parking and slewing gear brake.

– Switch off the Diesel engine according to the operating instructions and move the safety lever up, prior to leaving the driver’s seat.

– Lock the machine, as well as all hoods, covers and doors; pull out all keys and secure the machine against any unauthorized use.

1.10.4 copyright by

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Service Manual

Safety instructions Towing the machine safely

9

Towing the machine safely – Always observe the correct procedure: See chapter “Towing the machine” in this operating manual.

– The machine may only be towed in exceptional circumstances, e.g. in order to move the machine away from a dangerous place.

– Before pulling or towing the machine, check all cables, hooks and couplers for safety and stability.

– Towing equipment must have sufficient tensile strength and must be attached to the undercarriage at the provided stops.

Be aware that any damage or accidents caused by towing the machine are never covered by the manufacturer's warranty.

– Never allow anyone to remain in the area of the towing devices.

– During the towing procedure, keep within the required transport position, the permissible speed and distance.

– After the towing procedure is completed, return the machine to its previous state.

– Proceed as outlined in the operation manual when putting the machine back into service.

10

Working with the machine safely – Before starting to work, familiarize yourself with the peculiarities of the job site, the special regulations and warning signals. Part of the surrounding area includes, for example, the obstacles in the working or movement area, the load carrying capacity of the ground and required safeguards for the job site to shield it from public highway traffic.

– Always keep an adequate safety distance to overhangs, edges, embankments and an unsecured substrate.

– Be particularly cautious in conditions of reduced visibility and changing ground conditions.

– Familiarize yourself with the location of power lines on the job site and work particularly careful in their vicinity. If necessary, inform the responsible authorities.

– Maintain a safe distance from electrical overhead lines. Do not approach the line with the equipment when working near electrical overhead lines. Danger of fatal injury! Inform yourself about required safety distances.

– In case of a flashover, proceed as follows: • do not move the machine or its attachment, • do not leave the operator’s platform, • warn people in the vicinity not to approach or touch the machine, • have the power turned off.

– Before moving the machine, always ensure that the attachments are safely secured.

– When travelling on public roads, paths or squares, observe the valid traffic regulations and, if necessary, first bring the machine into proper condition to meet federal and local highway standards.

– Always turn on the lights in conditions of poor visibility or darkness.

– Do not permit any passengers on the machine (except on two way excavators).

– Operate the machine only when seated and with the seat belt fastened.

– Report any problems or needed repairs and make sure that all required repairs are carried out immediately.

– Personally make sure that no one is endangered by moving the machine.

– Before starting to work, always check the brake system as outlined in the operating manual.

– Never leave the operator’s seat as long as the machine is still moving.

– Never leave the machine unattended while the Diesel engine is running.

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Safety instructions

Service Manual

Working with the machine safely – The machine must be utilized, driven and operated in such way that the stability is ensured and that there is no danger of tipping over. Only known loads may be moved with the attachments, especially in grapple operation.

– The maximum approved passable incline / traverse slope of the machine depends on the attached equipment as well as the substrate.

– For travel, move the uppercarriage in lengthwise direction and hold the load as close as possible to the ground.

EXCEPTION: see WHEN LOADING AND UNLOADING – Adjust the travel speed to suit local conditions.

– Avoid working movements which could cause the machine to tip over.

– If possible, always work downhill or uphill, never sideways on a slope.

– Only travel downhill at the permitted speed or you could loose control over the machine.

– Only drive downhill at a low driving speed, since you may otherwise loose control of the machine.

The Diesel engine must run in the upper revolution range and be reduced by selecting the low driving speed range / the lowest gear.

– Before travelling downhill, always shift to a lower gear. When doing this, the Diesel engine must run at maximum RPM and the speed may only be reduced using the accelerator pedals.

– When loading a truck, make sure that the truck driver leaves the cab, even if a rock protection is present.

– Always use the safety devices intended for their specific use for demolition work, clearings, hoisting operations, etc.

– For terrain which is difficult to gain an overview of and whenever necessary, ask for assistance of a guide. Have only one person signal you.

– Only permit experienced personnel to secure loads and signal the machine operator. The guide must position himself within view of the operator or be in voice contact with him.

– Depending on the attachment combination, there can be a danger of collision between the working tool and the operator’s cab, the cab protection or the boom cylinders. To avoid damage, utmost attention is required when the bucket teeth enter this range.

10.1

Safe application in material handling operation (especially when handling timber) – Particularly when working with a grapple it can be necessary to move the machine with a raised attachment and picked up load, for example when handling wood or timber.

– This will shift the center of gravity of the machine upward in vertical direction. The travel behaviour of the machine will be strongly influenced, for example reduction of dynamic stability.

For that reason, the following rules must be strictly observed: • Match your travel behaviour to the changed machine characteristics and surrounding conditions.

• Reduce the travel speed to avoid sudden braking or steering manoeuvres.

• Avoid sudden speed changes, such as braking, acceleration, changes in travel direction.

• Turn the uppercarriage only if the undercarriage is stationary.

• Turn the uppercarriage only after taking on the load.

• Move the machine only after you have taken on the load, lifted it and turned the uppercarriage in travel position.

• If the attachment is raised, there is a danger due to possible oscillating movements and falling of the picked up load.

• A protective screen (FOPS) according to ISO 10262 must be attached on the front on the cab.

• The protective screen (FOPS) according to ISO 10262 must be installed if there is a danger of falling objects from overhead.

• Only the maximum permissible load may be picked up with the grapple.

1.10.6 copyright by

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Service Manual

Safety instructions Working with the machine safely

– NOTE: The weight of absorbent material, such as wooden logs, depends on the length, the diameter and the specific weight. The existing influencing factors for a natural product, such as moisture, must be considered.

– The working sequences when working with machines with grapples require special instruction and training of the machine operator.

– The work application is only permitted after the machine operator has received sufficient training and practical experience.

10.2

Safe application of machines with tower elevation – Due to the tower elevation, the center of gravity of the machine will shift upward in vertical direction. The travel and work behaviour of the machine will thereby be strongly influenced, for example reduction of dynamic stability.

– Due to the elevated center of gravity, the machine must be aligned in horizontal direction before starting to work. In horizontal direction, the center of gravity of the uppercarriage is above the center of the undercarriage, which reduces the danger of tipping over.

– The machine can rock despite leveling and tip over!

For that reason, the following rules must be strictly observed: When driving the machine: • Swing the uppercarriage parallel to the undercarriage (transport position).

• Pull the attachment as close as possible to the machine.

• Only then may the outriggers be retracted and the machine be driven.

• Driving with loads is not permitted.

• Check the roadway to ensure the ground is solid and even! Pot holes and uneven road surfaces endanger the stability of the machine.

• Match your travel behaviour to the changed machine characteristics (higher center of gravity) and surrounding conditions.

• Reduce the travel speed to avoid sudden braking or steering manoeuvres.

• Avoid sudden speed changes, such as braking, acceleration, changes in travel direction.

• Drive uphill and over obstacles only in lengthwise direction, to avoid impermissible transverse slopes of the machine.

• Special care must be taken when driving through narrow passages – drive slowly!

In material handling operation: • Before moving (turning) the uppercarriage from transport position, the machine must be supported and horizontally aligned.

• Make sure to check the placement surface of the outriggers (load carrying capacity of ground).

Sinking of an outrigger below ground level would result in devastating consequences!

• Carry out all movements with increased caution.

• To turn a load, move the attachment as close as possible to the machine (Caution! Oscillating grapple), while holding the load as close as possible to the undercarriage and above the ground.

• Avoid abrupt slow down or acceleration of the attachment or uppercarriage.

• Never lift a heavier load than stated in the load chart.

10.3

Additional notes for machines with fixed operator’s cab elevation – To enter and exit the machine, park the machine on ground, which is level in lengthwise and horizontal direction. Position the uppercarriage to the undercarriage in such a way that the steps and ladders are aligned.

– Keep steps, ladders and handholds (handles) in proper condition. Make especially sure that they are free of dirt, oil, ice and snow.

NOTE: To ensure that the doors open in all weather conditions, lubricate the weather strips at least every two month, or more often, if necessary, with talcum powder or silicon. Lubricate the door hinges and locks regularly.

1.10.7 copyright by

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Safety instructions

Service Manual

Working with the machine safely – When entering or leaving the machine, always face the machine and use the three point support, i.e. always have two hands and one foot or two feet and one hand in contact with the entry system.

– When you can reach the door handle with the free hand, open the door first before climbing higher.

External influences, such as wind, can make it more difficult to open the door. For that reason, always guide the door by hand when opening the door. Make sure that the door is engaged when it is open, to prevent it from banging open or closed.

– Continue to climb up and immediately sit on the operator’s seat in the cab. Then close the door and fasten the safety belt.

– Proceed with the same care when exiting and climbing down as when entering and climbing up the machine.

– Park the machine only on firm and level ground. Position the uppercarriage to the undercarriage in such a way that the steps and ladders are aligned.

– Release the safety belt. When exiting, face the machine and use the three point support. Climb down until you can close the door safely. Always guide the door by hand when closing the door.

– Finally climb down to the ground.

10.4

Protection from vibrations – The vibration impact on mobile construction machinery is usually the result of the manner of utilization. Especially the following parameters have a significant influence: • Terrain conditions: Unevenness and potholes; • Operating techniques: Speed, steering, braking, control of operating elements of the machine during travel as well as working.

– The machine operator determines the vibration impact to a great part, since he himself selects the speed, the gear ratio, the working manner and the travel route.

This results in a wide range of various vibration impacts for the same machine type.

The full body vibration impact for the machine operator can be reduced if the following recommendations are observed: – Select the appropriate machine, equipment parts and auxiliary devices for the corresponding tasks.

– Use a machine equipped with the appropriate seat (i.e. for earth moving machines, for example hydraulic excavators, a seat which meets EN ISO 7096).

– Keep the seat in good order and adjust it as follows: • The seat adjustment and the suspension should be made according to the weight and the size of the operator.

• Check the suspension and the adjustment mechanism regularly and make sure that the characteristics of the seat remain as specified by the seat manufacturer.

– Check the maintenance condition of the machine, especially regarding: Tire pressure, brakes, steering, mechanical connections, etc.

– Do not steer, brake, accelerate and shift or move and load the attachment of the machine in a jerky manner.

– Match the machine speed to the travel route to avoid vibration impacts.

• Decrease the speed when driving on pathless terrain; • Drive around obstacles and avoid very impassable terrain.

– Keep the quality of the terrain where the machine is working and travelling in good order: • Remove large rocks and obstacles; • Fill furrows and holes; • To establish and retain suitable terrain conditions, keep machines available and allow for sufficient time.

– Travel longer distances (i.e. on public roads) with suitable (medium) speed.

– For machines, which are frequently used for travel, utilize special auxiliary systems for travel (if installed), which reduce the vibration for this application.

If such auxiliary systems are not available, regulate the speed to keep the machine from "rocking".

1.10.8 copyright by

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Service Manual

Safety instructions Safe installation and removal of attachment parts

11

Safe installation and removal of attachment parts – Equipment and attachment parts made by other manufacturers or those which do not have LIEBHERR’s general approval for installation may not be installed on the machine without prior written approval by LIEBHERR. LIEBHERR must be provided with the required technical documentation necessary for this purpose.

– When installing attachment parts, which are supplied via the machine's hydraulics system, such as an attachment with cylinder movement, it must be ensured that different types of oil are not mixed together.

Mixing environmentally friendly hydraulic oils made by different manufacturers as well as mixing them with mineral oils must be avoided.

– Set the machine on a level and stable ground prior to any attachment and removal of equipment parts.

– Lock the uppercarriage with the locking pin to the undercarriage.

– Do not work under the equipment as long as it does not contact the ground or prior to being supported.

– Never lie under the machine, if it is lifted by the work equipment without properly propping the machine.

– Before releasing a line or bolt, you must reduce the pressure in the hydraulic system as described in these operating instructions.

– Do not attempt to lift heavy parts. Use suitable lifting devices with sufficient load carrying capacity.

– Do not use damaged or insufficiently sized ropes or cables. Always wear work gloves when handling wire cables.

– When working on the equipment: Switch off the Diesel engine and turn the safety lever upward.

Never align the holes with your fingers; use a suitable mandrel.

– During repairs: Make sure that the hydraulic lines are properly attached and that all fittings and connections are properly tightened.

– As soon as an attachment part is removed and supported, close off the openings in the hydraulic circuit to prevent dirt infiltration. Permit only authorized persons near the machine or the lifting device.

11.1

Safe removal and installation of attachment pins – If possible, always use a hydraulic pin pulling device to push out the pins on the attachment.

– If pins must be removed with a sledge hammer, use a punch and a guide tube held by another person.

– To drive out a pin, install the impact screw from the tool box in the threaded bore of the pin and hit the screw only.

– For the installation of a pin retained with castle nut and cotter pin, drive the pin in first to the stop, then install the castle nut by hand until contact and tighten it only to the point where the cotter pin can be installed.

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Safety instructions

Service Manual

Safe maintenance of the machine

12 12.1

Safe maintenance of the machine General safety instructions – All maintenance and repair work must be carried out by suitably trained specialist technicians.

– Always adhere to the prescribed testing and inspection schedule and the relevant intervals laid down in the operating manual. To properly maintain the machine, the operator must have access to a suitably equipped workshop.

– The inspection and maintenance schedule clearly defines the tasks and who is authorised to carry them out.

Certain work may be carried out by the machine operator (or staff of the company who owns the machine), while other tasks must be completed by specialist technicians who have been specifically trained for this type of work.

– All spare parts must conform to the technical specifications laid down by the manufacturer.

Original spare parts always meet these requirements.

– When carrying out maintenance work, wear suitable protective clothing. Always wear suitable personal protective equipment. For certain work, you must also wear a hard hat, safety footwear, goggles and protective gloves.

– During maintenance work, keep unauthorised personnel away from the machine.

– If necessary, cordon off the work area.

– Before starting any maintenance work or other special work on the machine, inform the operating personnel. Appoint a supervisor.

– Unless stated otherwise in the operating manual, all maintenance work must be carried out after the attachment is lowered, the diesel engine is shut down while the machine is parked on level and firm ground.

– While carrying out maintenance work, and especially when working under the machine, attach a warning sign "Do not start" to the ignition. Remove the ignition key and set the battery main switch to position "0".

– Always retighten all screwed connections that have been loosened for maintenance and repair purposes.

– If safety devices must be removed, these devices must be mounted and tested immediately after the work is completed.

12.2

Cleaning – Prior to any maintenance and repair work, clean the machine and especially all connections and screws that might be contaminated with oil, fuel or other cleaning products.

Use only mild detergents and lint-free cloths.

– During the first two months after commissioning (or repainting), do not clean the machine with aggressive detergents or a steam cleaner.

– Do not clean the machine with flammable liquids.

– Before cleaning the machine with water, steam (pressure cleaner) or other detergents: • Lubricate the slewing ring as well as all bearings and pin connections to prevent water or steam from penetrating the bearing positions.

• Seal all openings where penetrating water, steam or detergent might cause damage or lead to malfunctions.

Especially at risk are electric motors, electronic components, switch cabinets, plug connections and air filters.

– When cleaning the engine compartment, ensure that the temperature sensor of the fire alarm and extinguishing systems are not accidentally brought into contact with the hot cleaning solution, as this could trigger an alarm and activate the extinguishing system.

– After completion of the cleaning work:

1.10.10 copyright by

MJFCIFSS

Service Manual

Safety instructions Safe maintenance of the machine • Remove all temporary covers.

• Check all fuel, engine oil and hydraulic lines for leakage, loose connections, chaffing and damage.

• Repair all detected defects.

• Lubricate slewing ring as well as all bearings and pin connections to eliminate water or detergent that might have penetrated these assemblies.

12.3

Crack detection – The machines are subject to various loads and stresses, depending on the actual application, location of operation, operating hours and the ambient conditions. The various load scenarios result in service lives of the machine components that might differ from each other. This might lead to cracks or loose connections, especially on load-bearing parts. This applies in particular to machines used for loading or industrial purposes, or to machines equipped with optional equipment, such as demolition excavators. To maintain the operational safety of the machine, it must be regularly inspected for cracks, loose connections and other visible damage.

– To be able to inspect the machine for cracks, it must be kept clean.

– The inspections must be carried out as described in the inspection and maintenance schedule: • every 250 operating hours, by the maintenance personnel of the machine operator • every 500 operating hours by authorised specialist technicians.

– We strongly recommend to carry out these inspections after the machine has been placed on a firm and level surface, and by applying various different loads in longitudinal and transverse direction by moving the attachment. Always comply with the applicable workplace safety and accident prevention regulations.

– Particular care is required for the inspection of load-bearing components, in particular: • The steel structure of the undercarriage with axle and gearbox bearings, the support system, the lower slewing ring support, the tower and the slewing ring.

• The steel structure of the uppercarriage with bearing block for booms and boom cylinders, the upper slewing ring support, the cab bearing, and the securing devices of the slewing gear and ballasts.

• The steel components of the attachments, e.g. booms, members, quick change adapters, digging buckets and grapples.

• Hydraulic cylinders, axles, steering components, bolts and pin connections, ladders, steps and securing devices.

– The crack inspection is a visual inspection. To improve the reliability of the inspection, check areas where you suspect cracks or areas that are not easily accessible (e.g. at the slewing ring support) with a dye penetration test.

– Immediately eliminate any detected damage. Welding work on load-bearing parts of earth moving machines, handling and transport equipment must be carried out by specialist welding technicians and according to best welding practice. If in doubt, contact the LIEBHERR customer service department to discuss the envisaged measures.

12.4

Welding work – Welding, torch-cutting and grinding work on the machine is only permitted with the explicit consent of the manufacturer. Before carrying out such work, clean the machine and remove any dust and flammable material around the equipment.

Ensure that the working areas is properly ventilated. Risk of fire and/or explosion!

– Before carrying out arc welding work, or work on the electric components of the machine, disconnect the battery.

First disconnect the negative pole, then disconnect the positive pole. To reconnect the battery, first connect the positive pole, then the negative pole.

– For arc welding work, position the earth contact point at the machine as close as possible to the welding area.

1.10.11 copyright by

MJFCIFSS

Safety instructions

Service Manual

Safe maintenance of the machine

12.5

Fuels and lubricants – When handling oil, grease or other chemical products, always comply with the respective safety instructions provided by the supplier.

– All fuels, lubricants and replaced parts must be disposed of in a safe and environmentally friendly manner.

– Handle hot fuels and lubricants with particular care to prevent injury.

12.6

Repairs – Do not attempt to lift heavy parts by hand but use suitable lifting gear with appropriate load-bearing capacity. To replace component parts and assemblies, attach and secure them carefully to suitable lifting tackle and ensure that they cannot cause damage or injury while being transported.

Use only lifting tackle that is in proper working order and has the necessary load-bearing capacity.

Do not stand under suspended loads.

– Never use chaffed or damaged lifting tackle or gear that does not have the necessary load-bearing capacity.

When working with wire cables, always wear protective gloves.

– Only experienced personnel may attach loads and guide crane operators. The signaller must be positioned within the sight of the machine operator. Alternatively, the signaller and the operator might be in contact through walkie-talkies or similar devices.

– When working above head height, use safe ladders and platforms.

Never use machine parts as climbing aids, unless they are designed for this purpose.

When working at great height, wear suitable safety gear.

Keep all handles, steps, railings, platforms and ladders free of dirt, snow and ice.

– When working at the attachment (e.g. replacement of teeth), ensure that it is properly supported.

Avoid metal supports (metal-to-metal contact).

– Never stand below a machine propped up by means of the attachment, unless the machine has been properly secured with supports.

– Jack up the machine in such a way that shifting weights cannot impair its stability. Avoid metal-tometal contact.

– All work on the chassis, brake and steering systems must be carried out by suitably trained specialists technicians.

– If the machine is to be repaired while standing on a slope, the chains must be secured with sprags and the uppercarriage must be locked onto the undercarriage with the locking bolt.

– All work on the hydraulic equipment must be carried out by specialist technicians who are trained and experienced in the field of hydraulics.

– When searching for leaks, always wear protective gloves, as high-pressure liquid might penetrate the skin and cause damage.

– Before loosening or disconnecting any lines of screwed connections, lower the attachment to the ground, shut down the diesel engine and release the pressure from the hydraulic system. After the diesel engine has been shut down, insert the ignition key and turn it to its ON position, then move all control devices (joystick and pedals) of the pilot control units in all directions in order to release the control pressure and backpressures in the circuits. Continue with releasing the tank pressure as described in this manual.

12.7

Electrical system – Regularly inspect the electrical system.

Ensure that any detected faults such as loose connections, blown fuses and light bulbs, scorched or chafed cables are eliminated without delay by specialist technicians.

– Use only original fuses of the prescribed amperage.

1.10.12 copyright by

MJFCIFSS

Service Manual

Safety instructions Safe maintenance of the machine

– For machines equipped with electrical medium-voltage and high-voltage lines: • In the event of a disruption in the power supply, immediately shut down the machine.

– All work on the electrical equipment of the machine must be carried out by a trained electrician or specialist technician under the supervision of an electrician and in accordance with the relevant electro-technical regulations and guidelines.

– When working on powered parts, always employ a second person with access to the emergencystop or main switch to shut down the system in the event of an emergency. Cordon off the work area, using red and white chain and a suitable warning sign. Always use insulated tools.

– When working on medium-voltage and high-voltage assemblies, first disconnect them from the power supply, and then short-circuit the supply line and the assemblies (e.g. condensers) using an earthing rod.

– Check all parts for voltage, then earth them and short-circuit them. Insulate adjacent parts that remain powered.

– Before carrying out arc welding work, or work on the electric components of the machine, disconnect the battery.

First disconnect the negative pole, then disconnect the positive pole. To reconnect the battery, first connect the positive pole, then the negative pole.

12.8

Hydraulic accumulators – – – – –

– – – –

12.9

All work on hydraulic accumulators must be carried out by specialist technicians.

Improper installation and handling of hydraulic accumulators can lead to serious injury.

Never use hydraulic accumulators that are damaged.

Before carrying out any work on a hydraulic accumulator, release the pressure from the hydraulic system as described in this operating manual.

Do not carry out any welding or soldering work on the hydraulic accumulator and protect it from mechanical impact.

The hydraulic accumulator might become damaged or ruptured if exposed to heat arising from mechanical impact. RISK OF EXPLOSION! Fill the hydraulic accumulator only with nitrogen. Do not use oxygen or air! RISK OF EXPLOSION! During operation, the storage body might become hot, so that there is a risk of injury.

New hydraulic accumulators must be pressurised to the level required for the actual purpose before they are commissioned.

The operating data (minimum and maximum pressure) are permanently attached to the hydraulic accumulators. Ensure that this identification is legible at all times.

Hydraulic and other hoses – The repair of hydraulic and other hoses is prohibited!

– All hoses and fittings must be inspected every 2 weeks for damage. If any damage is suspected, immediately check the respective line for leakage and visible damage!

Always replace damaged parts without delay! Escaping oil can lead to serious injury or fire!

– Even if stored and used properly, hoses tend to age, so that their service life is limited.

• Improper storage, mechanical damage and inadmissible loads are however the most common causes of failure.

• As regards the permissible period of use, observe the applicable standards, regulations and rules for hoses and hose lines.

• Use of the hose with near limit loads and stresses (e.g. at high temperature, frequent movement, extremely high pulse frequencies, multiple shift operation) may shorten its service life.

– Replace hoses, if the inspection reveals any of the following: • Damage at the outer jacket exposing the ply (e.g. caused by chafing, wear, cuts or cracks) • Embrittlement of the outer jacket (formation of cracks in the hose material)

1.10.13 copyright by

MJFCIFSS

Safety instructions

Service Manual

Safe maintenance of the machine • Deformation of the hose when pressurised, depressurised, or at bends, resulting in separation of the layers, bubbles, etc.

• Leakage • Non-compliance with installation requirements • Damage or deformation of the hose fittings, which might impair the fitting strength of the connection between fitting and hose • Disconnection of the hose from the fittings • Corrosion at the fittings, impairing its function and strength – Always replace hoses and hose connections with original spare parts.

– Ensure that all hoses and lines are installed and connected properly. Do not confuse connections.

– When replacing hoses and hose lines: • Ensure that the hoses are installed without torsion. For high-pressure hoses first insert the screws at the pipe clips or full flanges at both ends, and then tighten them.

• For high-pressure hoses and lines with angled fittings, first tighten the flange at the angled fitting and then the one at the straight fitting.

• Pipe clamps at other point of the hose may not be attached and tightened, when the hose ends are properly secured.

• Daily inspect all hose clips, covers and protective devices to ensure that they are properly secured and tightened. Avoid vibration and damage during operation.

• To prevent chafing, install hoses and lines in such a way that they are not in contact with other hoses, lines or machine parts.

• We recommend keeping a minimum distance of 1/2 the outer hose diameter between the hose and any other parts. The distance should in any case not be less than 10 to 15 mm.

• When replacing hoses and hose lines connected to moving parts (e.g. from the boom to the stick), first check that they are not rubbing on any other parts when the machine is operated.

12.10

Cab protection (FOPS) For certain machine applications LIEBHERR offers optional cab protection systems of various designs. These systems consist of a full length FOPS (falling objects protective structure) or a top guard and front guard to protect the operator's cab and windscreen area from falling objects (for example rocks or debris).

The full length FOPS wraps around the operator's cab, is mounted to the uppercarriage and is a stand-alone system.

The top and front guards are either bolted individually or in combination to the cab structure. In that case the operator's cab is also part of the cab protection system and is subject to the following instructions.

– Never operate a machine if one of these protections is damaged in any way.

– Damages may occur due to: • structural modifications or repairs (for example welding, cutting or drilling) • deformation after an accident • falling objects – Structural modifications or repairs of any kind are prohibited without the expressed, written approval of LIEBHERR.

1.10.14 copyright by

MJFCIFSS

Bezeichnung Description / Dénomination

Mjfcifss!

1

Blatt/Page/Feuille: bestehend aus consisting of composé

Preloads and tightening torques for screws with metric coarse and fine threads according to DIN 13, sheet 12

6

Blatt Pages Feuille

WN 4037 I

The preload forces and tightening torques compiled in the table are based on the VDI 2230, 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 (replaces DIN 13, part 13) and head dimensions of hexagon head bolts according to DIN EN 24014 (replaces DIN 931, part 1) or hexagon socket head cap screws according to DIN EN ISO 4762 (replaces DIN 912)

Metric coarse thread Surface finish: black-chrome finished or phosphatised oiled electro-galvanized flZn according to LH standard 10021432 dry Tightening Thread Class Assembly preload torque FM in N MA in Nm for mean friction factor

M4

M5

M6

M7

M8

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

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

Metric fine thread Surface finish: black-chrome finished or phosphatised oiled electro-galvanized flZn according to LH standard 10021432 dry Tightening Thread Class Assembly preload torque FM in N MA in Nm

µG= 0.12

2.8 4.1 4.8 5.5 8.1 9.5 9.5 14.0 16.5 15.5 23.0 27 23 34 40

for mean friction factor

M8x1

M9x1

M10

8.8 10.9 12.9

27 500 40 000 47 000

46 68 79

M10x1

M10x1.25

M12

8.8 10.9 12.9

40 000 59 000 69 000

79 117 135

M12x1.25

M12x1.5

M14

M16

01/2005

8.8 10.9 12.9 8.8 10.9 12.9

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

125 185 215 195 280 330

M14x1.5

M16x1.5

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

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

µG= 0.12

24.5 36 43 36 53 62 52 76 89 49 72 84 87 125 150 83 122 145 135 200 235 205 300 360

1.20.1

Metric coarse thread Surface finish: black-chrome finished or phosphatised oiled electro-galvanized flZn according to LH standard 10021432 dry Tightening Thread Class Assembly preload torque FM in N MA in Nm for mean friction factor

M18

8.8 10.9 12.9

94 000 135 000 157 000

Metric fine thread Surface finish: black-chrome finished or phosphatised oiled electro-galvanized flZn according to LH standard 10021432 dry Tightening Thread Class Assembly preload torque FM in N MA in Nm

ÂľG= 0.12

280 390 460

for mean friction factor

M18x1.5

M18x2

M20

M22

M24

8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9

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

390 560 650 530 750 880 670 960 1120

M20x1.5

M22x1.5

M24x1.5

M24x2

M27

8.8 10.9 12.9

230 000 330 000 385 000

1000 1400 1650

M27x1.5

M27x2

M30

8.8 10.9 12.9

280 000 400 000 465 000

1350 1900 2250

M30x1.5

M30x2

M33

8.8 10.9 12.9

350 000 495 000 580 000

1850 2600 3000

M33x1.5

M33x2

M36

8.8 10.9 12.9

410 000 580 000 680 000

2350 3300 3900

M36x1.5

M36x3

M39

8.8 10.9 12.9

490 000 700 000 820 000

3000 4300 5100

M39x1.5

M39x3

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

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

ÂľG= 0.12

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

Notes: Torques indicated in drawings have precedence over those specified in the factory standards and must at all times be adhered to.

For very important screw connections, we recommend applying the angle tightening method.

Alternatively determine the total friction factor by carrying out a series of tests and refer to VDI 2230 or consult the technical department for the relevant tightening torques.

1.20.2

01/2005

Appendix:

Angle tightening method With the angle tightening method, the bolt is turned by a defined angle , which is based on the flexible elongation of the bolt and compression of the screwed plates. Depending on the bolt size, it is preloaded by a given torque before it is inserted into the parts to be secured, so that the zero point of the angle measurement can be determined. From this zero angle o = 0, the bolt can be preloaded - irrespective of the friction factor of the thread and the contact surface by turning it by the retightening angle .

Example 1: Bolt: M14 – 10.9, grip length Lk=80mm; According to table (strength class 10.9): Pretightening torque MA = 50Nm; retightening angle

45°

Example 2: Bolt: M24 – 12.9, grip length Lk=100mm; According to table (strength class 12.9): Pretightening torque MA = 160Nm; retightening angle

01/2005

57°

1.20.3

1.20.4

01/2005

01/2005

1.20.5

1.20.6

01/2005

Service Manual

Tightening torques of screw-in studs (Ermeto)

Tightening torques 1 1.1

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

Type with sealing edge Thread M or G

Type

Type with EOLASTIC seal Tightening torques in Nm

Thread M or G

Type

Light-duty series L

Tightening torques in Nm

Light-duty series L

GE 06 LM A 3 C

M 10x1

18

GE 06 LM ED A 3 C

M 10x1

18

GE 06 LR A 3 C

G 1/8 A

18

GE 06 LR ED A 3 C

G 1/8 A

18

GE 08 LM A 3 C

M 12x1.5

30

GE 08 LM ED A 3 C

M 12x1.5

25

GE 08 LR A 3 C

G 1/4 A

35

GE 08 LR ED A 3 C

G 1/4 A

35

GE 10 LM A 3 C

M 14x1.5

45

GE 10 LM ED A 3 C

M 14x1.5

45

GE 10 LR A 3 C

G 1/4 A

35

GE 10 LR ED A 3 C

G 1/4 A

35

GE 12 LM A 3 C

M 16x1.5

65

GE 12 LM ED A 3 C

M 16x1.5

55

GE 12 LR A 3 C

G 3/8 A

70

GE 12 LR ED A 3 C

G 3/8 A

70

GE 15 LM A 3 C

M 18x1.5

80

GE 15 LM ED A 3 C

M 18x1.5

70

GE 15 LR A 3 C

G 1/2 A

140

GE 15 LR ED A 3 C

G 1/2 A

90

GE 18 LM A 3 C

M 22x1.5

140

GE 18 LM ED A 3 C

M 22x1.5

125

GE 18 LR A 3 C

G 1/2 A

100

GE 18 LR ED A 3 C

G 1/2 A

90

GE 22 Lm A 3 C

M 22x1.5

140

GE 22 Lm Ed A 3 C

M 26x1.5

180

GE 22 Lr A 3 C

G 3/4

180

GE 22 Lr Ed A 3 C

G 3/4 A

180

GE 28 Lm A 3 C

M 33x2.0

340

GE 28 Lm Ed A 3 C

M 33x2.0

310

GE 28 Lr A 3 C

G1A

330

GE 28 Lr Ed A 3 C

G1A

310

GE 35 Lm A 3 C

M 42x2.0

500

GE 35 Lm Ed A 3 C

M 42x2.0

450

GE 35 Lr A 3 C

G 1 1/4 A

540

GE 35 Lr Ed A 3 C

G 1 1/4 A

450

GE 42 Lm A 3 C

M 48x2.0

630

GE 42 Lm Ed A 3 C

M 48x2.0

540

GE 42 Lr A 3 C

G 1 1/2 A

630

GE 42 Lr Ed A 3 C

G 1 1/2 A

540

Heavy-duty series S

Heavy-duty series S

GE 06 SM A 3 C

M 12x1.5

35

GE 06 SM ED A 3 C

M 12x1.5

35

GE 06 SR A 3 C

G 1/4 A

55

GE 06 SR ED A 3 C

G 1/4 A

55

GE 08 SM A 3 C

M 14x1.5

55

GE 08 SM ED A 3 C

M 14x1.5

55

GE 08 SR A 3 C

G 1/4 A

55

GE 08 SR ED A 3 C

G 1/4 A

55

GE 10 SM A 3 C

M 16x1.5

70

GE 10 SM ED A 3 C

M 16x1.5

70

GE 10 SR A 3 C

G 3/8 A

90

GE 10 SR ED A 3 C

G 3/8 A

80

GE 12 SM A 3 C

M 18x1.5

110

GE 12 SM ED A 3 C

M 18x1.5

90

GE 12 SR A 3 C

G 3/8 A

90

GE 12 SR ED A 3 C

G 3/8 A

80

GE 14 SM A 3 C

M 20x1.5

150

GE 14 SM ED A 3 C

M 20x1.5

125

GE 14 SR A 3 C

G 1/2 A

150

GE 14 SR ED A 3 C

G 1/2 A

115

MJFCIFSS

1.21. 1

Tightening torques

Service Manual

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

Type

Type with EOLASTIC seal Tightening torques in Nm

Type

Thread M or G

Tightening torques in Nm

GE 16 SM A 3 C

M 22x1.5

170

GE 16 SM ED A 3 C

M 22x1.5

135

GE 16 SR A 3 C

G 1/2 A

130

GE 16 SR ED A 3 C

G 1/2 A

115

GE 20 SM A 3 C

M 27x2.0

270

GE 20 SM ED A 3 C

M 27x2.0

180

GE 20 SR A 3 C

G 3/4 A

270

GE 20 SR ED A 3 C

G 3/4 A

180

GE 25 SM A 3 C

M 33x2.0

410

GE 25 SM ED A 3 C

M 33x2.0

310

GE 25 SR A 3 C

G1A

340

GE 25 SR ED A 3 C

G1A

310

GE 30 SM A 3 C

M 42x2.0

540

GE 30 SM ED A 3 C

M 42x2.0

450

GE 30 SR A 3 C

G 1 1/4 A

540

GE 30 SR ED A 3 C

G 1 1/4 A

450

GE 38 SM A 3 C

M 48x2.0

700

GE 38 SM ED A 3 C

M 48x2.0

540

GE 38 SR A 3 C

G 1 1/2 A

700

GE 28 SR ED A 3 C

M 1 1/2 A

540

Tab. 2

Tightening torques of screw-in studs

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

2 2.1

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

Tightening torques

Tightening torques

Type

Type Thread

Nm

Thread

Light-duty series

Nm

Light-duty series

WH / TH 06 LR KDS A 3 C

G 1/8 A

18

WH / TH 06 LM KDS A 3 C

M 10 X 1

18

WH / TH 08 LR KDS A 3 C

G 1/4 A

45

WH / TH 08 LM KDS A 3 C

M 12 X 1.5

45

WH / TH 10 LR KDS A 3 C

G 3/8 A

45

WH / TH 10 LM KDS A 3 C

M 14 X 1.5

55

WH / TH 12 LR KDS A 3 C

G 1/2 A

70

WH / TH 12 LM KDS A 3 C

M 16 X 1.5

80

WH / TH 15 LR KDS A 3 C

G 3/4 A

120

WH / TH 15 LM KDS A 3 C

M 18 X 1.5

100

WH / TH 18 LR KDS A 3 C

G1A

120

WH / TH 18 LM KDS A 3 C

M 22 X 1.5

140

WH / TH 22 LR KDS A 3 C

G 1 1/4 A

230

WH / TH 22 LM KDS A 3 C

M 27 X 2.0

320

WH / TH 28 LR KDS A 3 C

G 1 1/4 A

320

WH / TH 28 LM KDS A 3 C

M 33 X 2.0

360

WH / TH 35 LR KDS A 3 C

G 1 1/4 A

540

WH / TH 35 LM KDS A 3 C

M 42 X 2.0

540

WH / TH 42 LR KDS A 3 C

G 1 1/2 A

700

WH / TH 42 LM KDS A 3 C

M 48 X 2.0

700

Heavy-duty series

Heavy-duty series

WH / TH 06 SR KDS A 3 C

G 1/4 A

45

WH / TH 06 SM KDS A 3 C

M 12 X 1.5

45

WH / TH 08 SR KDS A 3 C

G 1/4 A

45

WH / TH 08 SM KDS A 3 C

M 14 X 1.5

55

WH / TH 10 SR KDS A 3 C

G 3/8 A

70

WH / TH 10 SM KDS A 3 C

M 16 X 1.5

80

WH / TH 12 SR KDS A 3 C

G 3/8 A

70

WH / TH 12 SM KDS A 3 C

M 18 X 1.5

100

WH / TH 16 SR KDS A 3 C

G 1/2 A

120

WH / TH 14 SM KDS A 3 C

M 20 X 1.5

125

WH / TH 20 SR KDS A 3 C

G 3/4 A

230

WH / TH 16 SM KDS A 3 C

M 22 X 1.5

135

1.21. 2

MJFCIFSS

Service Manual

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

Tightening torques

Type

Type Thread

Nm

Thread

Nm

WH / TH 25 SR KDS A 3 C

G1A

320

WH / TH 20 SM KDS A 3 C

M 27 X 2.0

320

WH / TH 30 SR KDS A 3 C

G 1 1/4 A

540

WH / TH 25 SM KDS A 3 C

M 33 X 2.0

360

WH / TH 38 SR KDS A 3 C

G 1/4 A

700

WH / TH 30 SM KDS A 3 C

M 42 X 2.0

540

WH / TH 38 SM KDS A 3 C

M 48 X 2.0

700

Tab. 2

3 3.1

Tightening torques of swivelling connections

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

Type VSTI

Screw-in thread M

Tightening torques Nm

Type VSTI

Screw-in thread G

Tightening torques Nm

VSTI 10X1 ED A3C

M 10 X 1

12

VSTI 1/8 ED A3C

G 1/8 A

13

VSTI 12X1.5 ED A3C

M 12 X 1.5

25

VSTI 1/4 ED A3C

G 1/4 A

30

VSTI 14X1.5 ED A3C

M 14 X 1.5

35

VSTI 3/8 ED A3C

G 3/8 A

60

VSTI 16X1.5 ED A3C

M 16 X 1.5

55

VSTI 1/2 ED A3C

G 1/2 A

80

VSTI 18X1.5 ED A3C

M 18 X 1.5

65

VSTI 3/4 ED A3C

G 3/4 A

140

VSTI 20X1.5 ED A3C

M 20 X 1.5

80

VSTI 1 ED A3C

G1A

200

VSTI 22X1.5 ED A3C

M 22 X 1.5

90

VSTI 1 1/4 ED A3C

G 1 1/4 A

450

VSTI 26X1.5 ED A3C

M 26 X 1.5

120

VSTI 1 1/2 ED A3C

G 1 1/2 A

450

VSTI 27X2 ED A3C

M 27 X 2.0

135

VSTI 33X2 ED A3C

M 33 X 2.0

225

VSTI 42X2 ED A3C

M 42 X 2.0

360

VSTI 48X2 ED A3C

M 48 X 2.0

360

Tab. 2

Tightening torques of screw-in studs

VSTI = Hexagon socket plug

MJFCIFSS

1.21. 3

Tightening torques

Service Manual

of screw-in studs (Ermeto)

1.21. 4

MJFCIFSS

Bezeichnung Description / DĂŠnomination

Mjfcifss!

Assembly instruction for pistons and piston nuts (hydraulic cylinders)

1

Blatt/Page/Feuille: bestehend aus consisting of composĂŠ

6

Blatt Pages Feuille

WN 4121 B

Contents 1.

Scope of application

2.

Description

3.

Referenced documents (torque table)

1.

Scope of application This factory standard applies exclusively to the assembly of hydraulic cylinders 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.

09 / 2005

1.22.1

2.

Description

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

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 (see figure 1).

Figure 1 A B C

Piston Assembly wrench Torque wrench

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

Proceed in the same way to tighten the piston nut, using a suitable assembly wrench.

1.22.2

09 / 2005

Turning distance: Radian measure [mm] travelled as a result of the tightening of the piston, or piston nut along the outer thread diameter, after application of the pretightening torque (see figures 2 and 3).

Turning angle: Angle ďƒ…Â°ďƒƒ travelled by the piston or piston nut respectively, after application of the pretightening torque (see figures 2 and 3).

Figure 2 A Marks on the piston and piston rod thread after application of the pretightening torque B Mark on the piston rod thread C Turning angle D Turning distance E Mark on the piston after tightening

Figure 3 A Marks on the piston nut and piston rod thread after application of the pretightening torque B Mark on the piston rod thread C Turning angle D Turning distance E Mark on the piston nut after tightening 09 / 2005

1.22.3

1.22.4

09 / 2005

3.

List of tightening torques for factory standard 4121 (Assembly instructions for piston and piston nur)

The date indicates the latest version of this table.

This document is not covered by the revision service.

FS

Preload

4121...

071 072 073 075 079 080 091 092 093 095 096 097 098 099 111 112 113 114 115 121 123 126 127 151 152 153 171 173 174 175 176 177 179 180 181 183 201 202 203 204 205 206 207 208 209 231 232

Torque Mv [Nm] 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 150 200 200 200 200 200 200 200 200 200 200 200 200

09 / 2005

Piston

Edition: 11.04.2005

Piston nut

Turn.distance

Turning angle

Turns distance

Turning angle

[mm] 11 +1 21 +1 18 +1 19 +1 11 +1 18 +1 13 +1 25 +1 24 +1 13 +1 10 +1 17 +1 17 +1 24 +1 16 +1 17 +1 18 +1 19 +1 18 +1 15 +1 17 +1 14 +1 22 +1 15 +1 20 +1 20 +1 12 +2 19 +2 25 +2 25 +2 19 +2 19 +2 11 +2 20 +2 20 +2 17 +2 26 +2 27 +2 27 +2 13 +2 25 +2 23 +2 15 +2 30 +2 8 +2 17 +2

~ [°] 30 57 49 52 30 49 30 57 55 30 23 39 39 55 33 35 37 39 37 29 32 27 42 27 35 35 20 32 42 42 32 32 19 34 34 26 39 41 41 20 38 35 22 45 11 23

[mm] 21 +1 21 +1 19 +1 21 +1 21 +1 19 +1 19 +1 19 +1 19 +1 9 +1 19 +1 19 +1 18 +1 18 +1 18 +1 19 +1 19 +1 19 +1 19 +1 18 +1 18 +1 18 +1 18 +1 18 +1 18 +1 18 +1 18 +1 40 +2 16 +1 16 +1 16 +1 16 +1 25 +1 16 +1 16 +1

~ [°] 57 57 52 57 57 44 44 44 44 21 44 44 37 37 37 36 36 34 34 30 30 30 30 30 30 30 30 67 24 24 24 24 38 22 22

Thread M [mm] 42x1,5 42x1,5 42x1,5 42x1,5 42x1,5 42x1,5 50x2 50x2 50x2 50x2 50x2/SW65 50x2 50x2 50x2 56x2 56x2 56x2 56x2 56x2 60x2 60x2 60x2 60x2 65x2 65x2 65x2 68x2 68x2 68x2 68x2 68x2 68x2 68x2 68x2 68x2 68x2 76x2 76x2 76x2 76x2 76x2 76x2 76x2 76x2 76x2 85x3 85x3 1.22.5

FS

Preload

4121...

234 261 281 282 301 302 303 304 305 306 307 331 332 333 334 335 501 531

Torque Mv [Nm] 200 250 250 250 300 300 300 300 300 300 300 400 400 400 400 400 200 500

1.22.6

Piston

Piston nut

Turn.distance

Turning angle

Turns distance

Turning angle

[mm] 22 +2 20 +2 20 +2 25 +2 21 +3 18 +3 20 +3 23 +3 9 +3 24 +3 27 +3 23 +3 11 +3 27 +3 20 +3 30 +3 21 +2 34 +3

~ [°] 30 25 23 29 22 19 21 24 9 25 28 22 11 26 19 29 30 28

[mm] 10 +1 13 +1 20 +2 20 +2 20 +2 20 +2 20 +2 20 +2 -

~ [°] 12 15 21 21 21 21 19 19 -

Thread M [mm] 85x3 95x3 100x3 100x3 110x3 110x3 110x3 110x3 110x3 110x3 110x3 120x3 120x3 120x3 120x3 120x3 80x2 140x3

09 / 2005

Bezeichnung Description / DĂŠnomination

Mjfcifss!

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

1

Blatt/Page/Feuille: bestehend aus consisting of composĂŠ

4

Blatt Pages Feuille

WN 4122 B

Contents 1.

Scope of application

2.

Description

3.

Referenced documents (torque table)

1.

Scope of application This factory standard applies exclusively to the assembly of hydraulic cylinders. For the valid factory standard number, refer to the drawing. The standard may not be adopted or transferred to apparently similar geometries.

The torques have been determined empirically and are subject to changes. The revision and release dates indicate the latest version of the factory standard.

09 / 2005

1.24.1

2.

Description

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

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

Figure 1 A B C

Bearing head Assembly wrench Torque wrench

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

1.24.2

09 / 2005

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

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

Figure 2 A B C D E F G

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

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

09 / 2005

1.24.3

3.

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

The date indicates the latest version of this table.

This document is not covered by the revision service. .

NU 4122...

001 011 016 017 026 027 031 036 039 041 046 047 051 052 151

1.24.4

Preload

Piston rod bearing Turning distance

Turning angle

[mm]

~ [°]

50 100 100 100 100 100 100

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

10 12 12 10 11 8 9

400

14 +1

6

Torque Mv [Nm]

Edition: 24.01.2005

09 / 2005

Service Manual

Fuels, lubricants and other consumables General instructions regarding the change of fuel, hydraulic oils, lubricants, etc.

Fuels, lubricants and other consumables 1

General instructions regarding the change of fuel, hydraulic oils, lubricants, etc.

Note!

The fill volumes specified in the fuel and lubricant table in the operator manual, and in the documentation of the assemblies, as well as in the lubrication schedule in the operator's cab are only approximate values.

After each oil change or refilling, check the fill level in the respective tank or unit.

Note!

Compliance with the instructions regarding lubrication, fill level checks and oil changes improve the reliability and prolong the service life of the machine. It is very important that the prescribed intervals for oil change are adhered to and that only products of the prescribed quality and grade are used.

Note!

Cleanliness during the oil change is of crucial importance.

Always clean all fill screws, lids and drain plugs and the area around fill openings.

When draining oil, ensure that the oil is at operating temperature.

Carefully collect the old oil and dispose of it in an environmentally friendly manner. This also applies to the oil filter cartridges.

Danger!

When checking and/or changing lubricants and fuels: If not instructed otherwise, ensure that the machine is standing on level and firm ground and that the engine is shut down.

When working inside the engine compartment, always secure the cover and doors against inadvertent closing.

Before refuelling the machine, switch off the engine. Do not smoke or use naked flames.

MJFCIFSS

1.50. 1

Fuels, lubricants and other consumables

Service Manual

General instructions regarding the change of fuel, hydraulic oils, lubricants, etc.

1.1

1.50. 2

Lubricant table Description

Medium

Symbol

Diesel engine

Engine oil

Refer to the instructions of the engine manufacturer (see Deutz manual)

Hydraulic tank

Engine oil

API-CD, APICD+SF, CCMC-D4, CCMC-D5, ACEA-E1, ACEA-E3

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

Slewing gear mechanism (as stop brake)

Gear oil

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

SAE 80W90 or SAE 90

Slewing gear mechanism (as positioning slewing brake)

Gear oil

API - GL -5 MIL-L 2105 B

SAE 90 LS

Steering axle

Gear oil

API - GL -5 MIL-L 2105 B ZF TE-ML 05

SAE 90 LS

Rigid axle with multi-disc brake

Gear oil

API - GL -5 MIL-L 2105 B ZF TE-ML 05

SAE 90 LS

Rigid axle with drum brake

Gear oil

API - GL -5 MIL-L 2105 B ZF TE-ML 05

SAE 90 LS

Wheel hubs in steering and rigid axles with multi-disc and drum brakes

Gear oil

API - GL -5 MIL-L 2105 B ZF TE-ML 05

SAE 90 LS

Transmission

Gear oil

ZF TE-ML 07

SAE 10 W 30 SAE 10 W 20

Travel gear

Gear oil

API - GL -5 MIL-L 2105 B ZF TE-ML 05

SAE 80W90 or SAE 90

MJFCIFSS

Classification

Viscosity

Service Manual

Fuels, lubricants and other consumables General instructions regarding the change of fuel, hydraulic oils, lubricants, etc.

Description

Medium

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

Grease

Hinges, joints, locks

Engine oil

Sealing rubber on doors and covering sections

Silicone spray or talcum powder

Tab. 1 *BI

1.1.1

Symbol

Classification

Viscosity

High-pressure grease KP2k or EP2

Consiste ncy 2 NLGI grade with lithium complex Tab. 8

MPG-A

-

-

-

-

-

-

-

-

Lubricant table =

Lubricant for building machinery and vehicles recommended by the Federation of the German Construction Industry (Hauptverband der Deutschen Bauindustrie e. V.), see brochure published by Bauverlag GmbH, Wiesbaden and Berlin regarding the use of lubricant and fuel tables.

Fuel and consumables Description

Medium

Fuel tank

Conventional diesel fuel with <= 0.5 % sulphur content

Coolant

Anticorrosion and antifreeze agent

Windscreen washer system

Conventional windscreen cleaning agent or denatured alcohol

-

Coolant of airconditioning system

R 134 a

-

Refrigeration oil in SD 7H15 a/c compressor

PLANETELF PAG SP 20 ID no. 8504414 (0.25 litre) or. 7620633 (1.0 litre)

-

Tab. 2

Symbol

Fuel and consumables

MJFCIFSS

1.50. 3

Fuels, lubricants and other consumables

Service Manual

Specifications for fuels, lubricants and consumables

2 2.1

Specifications for fuels, lubricants and consumables Lubricating oil for the diesel engine Refer to the instructions of the engine manufacturer (see Deutz manual): Classification

Specification

API classification (American Petrol Institute)

CG-4, CF-4, CH-4

ACEA (CCMC) classification (Association des Constructeurs Européens de l´Automobile)

E2-96 (D4), E3-96 (D5), E4-98

Tab. 3

2.1.1

Lubricating oil for the diesel engine

Oil change intervals for turbocharged engines Oil change interval depending on oil quality: Operating conditions

Sulphur content of fuel

CH-4 CG-4 CF-4 E2-96 (D4)

E3-96 (D5) E4-98 E5-99

Temperature normally not dropping below -10°C

max. 0.5 % higher than 0.5 %

250 h 125 h

500 h 250 h

below -10 °C

max. 0.5 % higher than 0.5 %

125 h -

250 h 125 h

Tab. 4

Oil change intervals

The oil change intervals of the diesel engine are based on the following criteria: First oil and filter change after 500 operating hours, if the oil of the first filling was an oil of E3-96 grade Subsequent filter changes after 500 operating hours Subsequent oil changes depending on the climate, sulphur content of the fuel and oil grade, Tab. 4.

If the above number of operating hours is not reached within 12 months, change the engine oil and the oil filter at least once every year.

2.2

Fuel Diesel fuels should meet the minimum requirements of the fuel specifications named below.

The sulphur content should not exceed 0.5 mass %. A higher sulphur content affects the oil change intervals and the service life of the engine.

2.2.1

Lubricity By reducing the sulphur content in diesel, the issue of lubricity has come to the fore. It has been shown that diesel fuels with the sulphur levels of maximum 0.05 %, which corresponds to the limit in the European Union, can lead to wear in the injection system (especially in distributor fuel injection pumps).

1.50. 4

MJFCIFSS

Service Manual

Fuels, lubricants and other consumables Specifications for fuels, lubricants and consumables

Branded fuels in Germany and elsewhere therefore contain lubricating additives. The lubricity of the fuel must be < 400 µm in a HFFR test (60°).

The additives should be added by the supplier, who is responsible for the quality of the fuel. We advise machine operators not to add any secondary lubricity additives to the fuel.

2.2.2

Improvement of fluidity by adding petrol At outdoor temperatures below approx. 0 °C, the fluidity of summer diesel might not be sufficient, due to the separation of paraffin.

This also applies to winter diesel at temperatures below approx. -15 °C. There is however diesel fuel on the market, containing additives that make it suitable for use at temperatures to -20 °C. In order to avoid malfunction at low temperatures, diesel must be mixed with normal petrol or petroleum.

This approach must be considered an emergency measure and the petrol content may never exceed 30 % (volume).

Do not use premium petrol for this mixture. Please note that the engine output might be reduced due to the addition of petrol. The addition of petrol should therefore be based on the actual outdoor temperature and kept as low as possible.

Danger!

For safety reasons, the diesel-petrol mix must be produced in the fuel tank.

Note!

When filling tank, first fill in the lighter additional fuel (petrol) and than add the diesel. Run the motor until the entire fuel system is filled with the fuel mix (see Tab. 6, page 6).

Approved fuel specifications DIN EN 590 ASTM D 975 (89 a) 1D and 2D DIN EN 590 with max. 5 volume % FAME* according to draft standard prEN 14214 (formerly: DIN 51606)

MJFCIFSS

1.50. 5

Fuels, lubricants and other consumables

Service Manual

Specifications for fuels, lubricants and consumables

Diesel fuel petrol mixing ratio Outdoor temperature °C

Summer diesel fuel %

Addition of petrol %

0 to -10

70

30

-10 to -15

50

50*

-15 to -20

-

-

-20 to -25

-

-

Tab. 5

Summer diesel fuel petrol mixing ratio Winter diesel fuel %

Addition of petrol %

Grade -15 °C

Grade -20 °C

Grade -15 °C

Grade -20 °C

0 to -10

100

100

-

-

-10 to -15

100

100

-

-

-15 to -20

70

100

30

-

-20 to -25

50

70

50*

30

Outdoor temperature °C

Tab. 6

Winter diesel fuel petrol mixing ratio

* If an additive content of 50 % is required, use only petroleum (not standard petrol).

2.2.3

Diesel fuel additives (fluidity improvers) Fluidity improvers are widely available and help improve the fluidity of diesel at low temperatures.

When using such additives, always adhere to the dosing and handling instructions of the manufacturers.

2.3 2.3.1

Hydraulic oil Mineral oil Use only motor oils that conform to the specifications and requirements below: Single grade engine oils:

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

Multigrade engine oil:

API - CD + SF / CCMC - D5 / ACEA - E3 Mercedes-Benz specifications, sheet no. 227.5 and 228.3

Tab. 7

Engine oils to be used as hydraulic oils

Select the engine oil for use as hydraulic oil according to the following diagram.

1.50. 6

MJFCIFSS

Service Manual

Fuels, lubricants and other consumables Specifications for fuels, lubricants and consumables

Fig. 1

Engine oil for use as hydraulic oil

Warm-up instruction At temperatures to 10 °C below the indicted limit (black bar), the oil must be warmed up as follows: Start diesel engine and run it at approx. 1 / 2 the rated speed. Operate the hydraulic cylinders and motors, but do not move the cylinders to their stops. Warm-up time: approx. 10 minutes At lower temperatures: Before starting the engine, warm up the oil tank.

2.3.2

Environmentally friendly hydraulic oils Note!

Do not mix different brands of environmentally friendly hydraulic oils or such oils with mineral oils (see customer service information)!

LIEBHERR will fill the system before delivery, based on a list of approved oils. Before using environmentally friendly oils, you must consult LIEBHERR. The list of products recommended by LIEBHERR contains only ester-based synthetic oils with a viscosity according to ISO VG 46.

Do not use vegetable oils, as they do not possess the necessary thermal stability.

2.3.3

Monitoring of hydraulic oil Note!

Environmentally friendly hydraulic oils must be regularly tested by means of an oil analysis. For mineral oils, we recommend carrying out oil analyses at regular intervals. LIEBHERR recommends contracting WEAR-CHECK with these analyses, and to change the oil when indicated by the test results (see also customer service and product information).

Machines in normal use: at least every 500 operating hours Machines used for dust intensive applications: at least every 250 operating hours

2.3.4

Monitoring of hydraulic oil in normal use

Fig. 2

Oil sampling from machines in normal use

MJFCIFSS

1.50. 7

Fuels, lubricants and other consumables

Service Manual

Specifications for fuels, lubricants and consumables h 1

Operating hours First oil sample

2 3

Second oil sample Subsequent oil samples: every 500 operating hours

Oil change based on analysis and lab report.

Interval for the change of the hydraulic oil return filter (20/5 µm): first change after 500 operating hours, then every 1000 operating hours.

2.3.5

Oil sampling from machines used for dust intensive applications:

Fig. 3 h 1

Oil sampling from machines used for dust intensive applications

Operating hours First oil sample

2 3

Second oil sample Subsequent oil samples: every 250 operating hours

Oil change based on analysis and lab report.

Interval for the change of the hydraulic oil return filter (10 µm): first change after 500 operating hours, then every 500 operating hours.

2.3.6

Instructions for the reduction of the contamination of the hydraulic oil in machine used for dust intensive applications If the machine is normally operated with a hydraulic hammer or under similar conditions (considerable dust generation), the hydraulic oil might become more contaminated than under normal working conditions.

In order to prevent premature wear of the hydraulic components, shorten the intervals between the oil changes (or oil samples respectively) and observe the following instructions: Every 500 operating hours, replace the filter cartridge(s) in the return filter.

Use 10-µm filter cartridges instead of the standard 20 / 5-µm cartridges.

Replace the breather filter on the hydraulic tank with a 2-µm fine filter (mesh size of series filters: 7 µm).

Replace the 2-µm breather at each change of the hydraulic oil (i.e. every 500 operating hours).

Note!

Machines that are delivered with a fully installed AHS 11 or AHS12 accessory kit, and machines with retrofitted kits are already equipped with 10-µm filter cartridges 2-µm breather filters.

All machines produced after approx. September 2005 have been equipped with 2-µm breather filters.

2.4

Gear oil Gear oils must conform to the following specifications: API-GL-5 and MIL-L-2105 B, C or D respectively for viscosity grade SAE 90 Engine oils used in gearboxes must conform to the following specifications: API-CG-4, CF-4, CF for viscosity grade SAE 20

1.50. 8

MJFCIFSS

Service Manual

Fuels, lubricants and other consumables Specifications for fuels, lubricants and consumables

For viscosity grades SAE 80 and SAE 90 according to MIL-L-2105 D, you may use an oil of viscosity grade SAE 80W90.

2.4.1

Grease and other process chemicals Process chemicals

Description / manufacturer

Grease for slewing ring / general lube points

The grease must conform to specification KP2k, consistency grade 2, NLGI grade according to DIN 51818 and DIN 51825 or EP 2 according to NF-T-60 132.

The grease must consist of a lithium complex with a VKA value of minimum 2300 N according to DIN 51350 or ASTM D 2596 respectively.

Contact spray for slip rings

Cramolin ID no. 7024145

Lubricant for pistons, piston nuts, also used for the mounting of piston rod bearings and cushioning sleeves to hydraulic cylinders

Gleitmo 800 ID no. 8300004 (40g tube)

Anti-friction varnish and lubricant for LIKUFIX coupling system

Gleitmo 900 ID no. 8610227 (400 ml spray can)

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

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

Other grease: Lubricant used for the mounting of pumps to prevent fretting corrosion on spline meshes

LIEBHERR CTK special lubricant ID no. 861331301 (400g cartridge)

Coolant for air-conditioning system

R 134 A Drain and fill the system according to the instructions in this manual (air-conditioning assembly).

Refrigeration oil for a/c compressor

The SD5H14 / SD7H15 a/c compressors are factory-filled with Planetelf PAG SP 20.

ID no. 8504414 (0.25 litre can) ID no. 7620633 (1.0 litre can) The compressor supplier does not permit the use of any other refrigeration oil.

Tab. 8

2.5

Grease and other process chemicals

Coolant In order to improve the quality of the cooling water, LIEBHERR diesel engines are equipped with water filter installations for Deutz engines.

This ensures that the coolant is also filtered in the bypass flow where dirt and rust particles that might lead to leakage in the cooling pump are removed.

MJFCIFSS

1.50. 9

Fuels, lubricants and other consumables

Service Manual

Specifications for fuels, lubricants and consumables

Outdoor temperature to

Water content in %

Content of corrosion inhibitors/antifreeze agents in %

-37 °C / -34 °F

50

50

-50 °C / -58 °F

40

60

Tab. 9

Mixing ratio water : corrosion inhibitor / antifreeze agent

The coolant must contain at least 50 volume % of corrosion inhibitor and antifreeze agent during all seasons. This protected the coolant against freezing to a temperature of -37 °C and ensures adequate protection against corrosion. In the event of loss of coolant, ensure that the additive concentration does not drop below 50 volume %.

Note!

Do not exceed a corrosion inhibitor and antifreeze agent concentration of 60 %! Higher concentrations tend to result in poor cooling and antifreeze protection.

As part of the regular maintenance, check the mixing ratio.

Note!

Change the coolant every 2 years.

Before refilling the cooling system with new coolant, ensure that it is clean and rinse it, if required.

2.5.1

Requirements regarding the fresh water quality To prepare the coolant, use clean water with as little limestone content as possible. In most cases, the local drinking water meets these requirements. Do not use sea water, brackish water, brine or industrial wastewater.

Requirements regarding the fresh water quality for coolants with corrosion inhibitors and antifreeze agents Substance

Volume

Total of alkaline earths (water hardness)

0.6 to 3.6 mmol / l (3 to 20 °d)

pH at 20 °C

6.5 to 8.5

Chloride ion content

max. 80 mg / l

Total chloride and sulphate

max. 100 mg / l

Tab. 10

1.50. 10

Max. concentration of water contaminations for use with corrosion inhibitors and antifreeze agents

MJFCIFSS

Service Manual

Fuels, lubricants and other consumables Specifications for fuels, lubricants and consumables

F

Fig. 4

Mixing ratio water : corrosion inhibitor / antifreeze agent

A % of corrosion inhibitor and antifreeze agent B Antifreeze agent to indicated temperature, according to value A

2.5.2

Approved corrosion inhibitors and antifreeze agents Concentrates

Brand

Producer

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

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., The Hague

NL

Glycoshell AF 405

Shell Deutschland GmbH, Hamburg

D

Glycoshell N

Shell Deutschland GmbH, Hamburg

D

MJFCIFSS

1.50. 11

Fuels, lubricants and other consumables

Service Manual

Specifications for fuels, lubricants and consumables Brand

Producer

Country

Glysantin (G48-00)

BASF AG, Ludwigshafen

D

Havoline XLC

Arteco, Ghent

B

Chevron 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

Castrol Anti-Freeze O

Total Deutschland GmbH, Düsseldorf

D

Wintershall Kühlerschutz

Wintershall Mineralöl GmbH, Düsseldorf

D

Tab. 11

Approved corrosion inhibitors and antifreeze agents

50:50 premixed products (water: corrosion inhibitor / antifreeze agent) Product

Producer

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, Ghent

B

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

Chevron Texaco, San Ramon, CA

USA

Organicool 50/50

Total Deutschland GmbH, Düsseldorf

D

Tab. 12

1.50. 12

Approved corrosion inhibitors / antifreeze agents / 50:50 premix

MJFCIFSS

Off-Road Driveline Technology and Axle Systems

Axles for off-road vehicles

List of lubricants TE-ML 05 Lubricant classes for service fills (1)

Product groups

without

with

wet multi-disc brakes and / or multi-disk limited-slip differentials 1. Axles (exception see section 2-5) Differentialsx Wheel hubsx Stub shafts 2. Axles with hypoid drive (AP 420R; AV230; MT-C 2025; MT-C2035; MT-C2075)

ZF-Powerfluidx 05A / 05B / 05C / 05D / 05E / 05F / 05G

ZF-Powerfluidx 05C / 05D / 05E / 05F / 05G

05A / 05B / 05C / 05D

05C / 05D

---

ZF-Powerfluid 05E / 05F / 05G

ZF-Powerfluid 05A / 05B / 05C / 05D 05E / 05F / 05G

ZF-Powerfluid 05E / 05F / 05G

05A / 05B / 05C / 05D

---

3. MT-D 3105 (only oil circuit brake) MT-L 3000 (with sintered brake linings) 4. MS-T 3025, MS-T 3035, MS-T 3045, MS-T 3055, MS-T 3060x MT-T 3025, MT-T 3035, MT-T 3045 MT 2075 (old: AP 2075), MT 2085 (old: AP 2085) 5. ZF-half-shafts (planetary final drives) for tractor transmissions T-7000

(1) Refer to the following pages for approved commercial products.

A lithium saponified multipurpose grease of NLGI class 2 which is mixable with mineral oil is to be used at greasing points (grease code KP2K-30 in acc. with DIN 51825 or ISO-L-XCCHB2 in accordance with ISO 6743-9).

Additives of any kind added later to the oil change the oil in a manner that is unpredictable, and they are therefore not permitted. No liability of any kind will be accepted by ZF for any damage resulting from the use of such additives.

The list of lubricants TE-ML 05, Edition 01.04.2005 replaces all previous editions. The current list can be requested from any ZF after-sales service center or accessed on the Internet under www.zf.com.

09 / 2005

ZF Passau GmbH ZF Friedrichshafen AG D-94030 Passau D-88038 Friedrichshafen phone: + 49 7541 77 3505 fax: + 49 7541 77 7319

1.55.1

Continued

ZF Friedrichshafen AG / List of lubricants TE-ML 05, edition 01.04.2005

Oil change intervals Lubricant class

05A, 05B, 05C, 05D, 05E, 05F

Load class

ZF Powerfluid 05G

Oil change interval

1

1500 h

2000 h

2

1000 h

1500 h

3

500 h

1000 h

Load classes Load class 1

1.55.2

Examples of applications - Dumper - Mobile excavator with low driving-mode share (<25%)x - Wheel loader with hydrostatic drivex - Other axles without wet brakes

2

- Mobile excavator with increased driving-mode share (>25%) - Wheel loader, grader, backhoe, telescopic handlerx - T 7000 half shafts

3

- Wheel loader operated under extreme braking conditions - Mobile excavator, material-handling areasx - At ambient temperatures > 40°C

09 / 2005

Continue

ZF Friedrichshafen AG / List of lubricants TE-ML 05, edition 01.04.2005

Lubricant class 05A Gear oilx Viscosity grades: SAE 75W-90 / 75W-140 / 80W-90 / 80W-140 / 85W-90 / 85W-140 / 90 Manufacturer (05A)

Trade name (05A)

ADDINOL LUBE OIL GMBH, LEUNA/D ADDINOL LUBE OIL GMBH, LEUNA/D ADDINOL LUBE OIL GMBH, LEUNA/D AGIP SCHMIERTECHNIK GMBH, WÜRZBURG/D ARAL AG, BOCHUM/D ARAL AG, BOCHUM/D ARAL AG, BOCHUM/D ARMORINE S.A., LANESTER CEDEX/F AVIA MINERALÖL-AG, MÜNCHEN/D AVIA MINERALÖL-AG, MÜNCHEN/D BAYWA AG, MÜNCHEN/D BAYWA AG, MÜNCHEN/D BEIJING TONGYI PETROLEUM CH. CO. LTD., BEIJING/CN BLASER SWISSLUBE AG, HASLE-RÜEGSAU/CH BLASER SWISSLUBE AG, HASLE-RÜEGSAU/CH BLASER SWISSLUBE AG, HASLE-RÜEGSAU/CH BP INTERNATIONAL, PANGBOURNE, READING/GB BP INTERNATIONAL, PANGBOURNE, READING/GB BP INTERNATIONAL, PANGBOURNE, READING/GB BP INTERNATIONAL, PANGBOURNE, READING/GB BP INTERNATIONAL, PANGBOURNE, READING/GB BP INTERNATIONAL, PANGBOURNE, READING/GB BP INTERNATIONAL, PANGBOURNE, READING/GB BP INTERNATIONAL, PANGBOURNE, READING/GB BP INTERNATIONAL, PANGBOURNE, READING/GB BUCHER AG LANGENTHAL, LANGENTHAL/CH BUCHER AG LANGENTHAL, LANGENTHAL/CH CALPAM MINERALÖL-GMBH, ASCHAFFENBURG/D CALPAM MINERALÖL-GMBH, ASCHAFFENBURG/D CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL INTERNATIONAL, PANGBOURNE READING/GB CEPSA LUBRICANTS S.A., MADRID/E CEPSA LUBRICANTS S.A., MADRID/E CEPSA LUBRICANTS S.A., MADRID/E CEPSA LUBRICANTS S.A., MADRID/E CEPSA LUBRICANTS S.A., MADRID/E CEPSA LUBRICANTS S.A., MADRID/E CHEVRONTEXACO GLOBAL LUBRICANTS, SAN RAMON/USA CHEVRONTEXACO GLOBAL LUBRICANTS, SAN RAMON/USA CHEVRONTEXACO, GHENT/B CHEVRONTEXACO, GHENT/B CHEVRONTEXACO, GHENT/B CHEVRONTEXACO, SYDNEY/AUS CHEVRONTEXACO, SYDNEY/AUS CONDAT LUBRIFIANTS, CHASSE SUR RHONE/F CONDAT LUBRIFIANTS, CHASSE SUR RHONE/F DE OLIEBRON B.V., ZWIJNDRECHT/NL ENI S.P.A. REFINING & MARKETING DIVISION, ROME/I ENI S.P.A. REFINING & MARKETING DIVISION, ROME/I ENI S.P.A. REFINING & MARKETING DIVISION, ROME/I ENI S.P.A. REFINING & MARKETING DIVISION, ROME/I EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA FALCON OIL COMPANY LTD., SHARJAH/UAE FALCON OIL COMPANY LTD., SHARJAH/UAE FL SELENIA S.P.A., VILLASTELLONE/I FL SELENIA S.P.A., VILLASTELLONE/I FL SELENIA S.P.A., VILLASTELLONE/I

ADDINOL GETRIEBEÖL GH 80W-90 ADDINOL GETRIEBEÖL GH 85W-90 ADDINOL GETRIEBEÖL GX 80 W 90 ML AUTOL HYPOID-GETRIEBEÖL SAE 80W-90 ARAL GETRIEBEOL EP PLUS 80W-90 ARAL GETRIEBEOL HYP 85W-90 ARAL GETRIEBEÖL HYP SAE 85W-140 PM 90 AVIA HYPOID 90 EP AVIA SYNTOGEAR FE 80W-90 BAYWA HYPOID GETRIEBEÖL 85W-90 BAYWA SUPER 8090 MC XIECHENG 85W-90 GEAR OIL HYPOID-GETRIEBEÖL 80W90 HYPOID-GETRIEBEÖL 85W140 HYPOID-GETRIEBEÖL 90 BP ENERGEAR DL 80W-90 BP ENERGEAR HT 80W-90 BP ENERGEAR HYPO 80W-90 BP ENERGEAR HYPO 85W-140 BP ENERGEAR HYPO 90 ENERGEAR HT 85W140 FRONTOL GETRIEBEÖL FE SAE 80W-90 FRONTOL HYPOID GETRIEBEÖL B SAE 85W-140 FRONTOL HYPOID GETRIEBEÖL B SAE 90 MOTOREX GEAR OIL UNIVERSAL 80W/90 MOTOREX GEAR OIL UNIVERSAL 85W/140 CALPAM MULTI GEAR OIL FE 80W90 CALPAM SUPER GEAR OIL 85W90 GL 5 CASTROL AF-STO 85W140 CASTROL AGRI GEAR GL5 90 CASTROL AGRI GEAR ULTRA CASTROL DYNADRIVE 80W-90 CASTROL EPX 85W-140 CASTROL EPX 90 CASTROL EPX M 90 CASTROL MULTIDRIVE 80W90 CEPSA TRANSMISIONES EP 90 CEPSA TRANSMISIONES EP MULTIG. 85W-140 CEPSA TRANSMISIONES EP MULTIGRADO 80W-90 ERTOIL EP CAMBIOS Y DIFERENCIALES SAE 90 ERTOIL EP MULT. CAMBIOS Y DIFERENCIALES 80W-90 ERTOIL EP MULT. CAMBIOS Y DIFERENCIALES 85W-140 CHEVRON RPM UNIVERSAL GEAR LUBRICANT SAE 80W-90 CHEVRON RPM UNIVERSAL GEAR LUBRICANT SAE 85W-140 GEARTEX EP-B 85W-90 GEARTEX EP-C 85W-140 MULTIGEAR 80W-90 CALTEX HYPOID LD SAE 85W-90 CALTEX HYPOID LD SAE 90 GEAR S 80W90 GEAR S 85W140 TOR SUPER GEAR OIL 80W90 AGIP ROTRA MP 85W-140 AGIP ROTRA TRUCK GEAR 85W-140 ROTRA MP 80W-90 ROTRA TRUCK GEAR 80W-90 ESSO GEAR OIL GX-D 85W-90 ESSO GEAR OIL TDL 80W-90 MOBILUBE HD-A 85W-90 MOBILUBE S 80W-90 FALCON SUPER MP GEAR OIL 85W/140 GL-5 FALCON SUPER MP GEAR OIL 80W/90 GL-5 AKCELA GEAR 135H EP (SAE 80W90) AKCELA GEAR 135H EP (SAE 85W140) AKROS EP 90 SAE 80W90

09 / 2005

1.55.3

Continued

FL SELENIA S.P.A., VILLASTELLONE/I FL SELENIA S.P.A., VILLASTELLONE/I FL SELENIA S.P.A., VILLASTELLONE/I FL SELENIA S.P.A., VILLASTELLONE/I FL SELENIA S.P.A., VILLASTELLONE/I FL SELENIA S.P.A., VILLASTELLONE/I FUCHS PETROLUB AG, MANNHEIM/D FUCHS PETROLUB AG, MANNHEIM/D GENOL GMBH & CO., WIEN/A GENOL GMBH & CO., WIEN/A GINOUVES GEORGES SA, LA FARLEDE/F GINOUVES GEORGES SA, LA FARLEDE/F GREAT WALL LUBE OIL CO., BEIJING/CHINA GRUPA LOTOS SA, GDANSK/PL GULF OIL INTERNATIONAL, PITTSBURG/USA HAFA, PARIS/F HANDEL MIJ NOVIOL B.V., NIJMEGEN/NL HUILES BERLIET S.A., SAINT PRIEST/F HUILES BERLIET S.A., SAINT PRIEST/F HUILES BERLIET S.A., SAINT PRIEST/F IGOL FRANCE SA, AMIENS/F IGOL FRANCE SA, AMIENS/F JOHN DEERE, WATERLOO/USA JOHN DEERE, WATERLOO/USA KOMPRESSOL-OEL VERKAUFS GMBH, KÖLN/D KRAFFT S.A., ANDOAIN/E KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL LIQUI MOLY GMBH, ULM/D LIQUI MOLY GMBH, ULM/D LIQUI MOLY GMBH, ULM/D LIQUI MOLY GMBH, ULM/D LIQUI MOLY GMBH, ULM/D MAROIL S.R.L. CONC. BARDAHL MANU. CO.,ALTOPASCIO/I MAZIVA ZAGREB D.O.O, ZAGREB/HR MAZIVA ZAGREB D.O.O, ZAGREB/HR MAZIVA ZAGREB D.O.O, ZAGREB/HR MAZIVA ZAGREB D.O.O, ZAGREB/HR MEGUIN GMBH & CO. KG MINERALOELWERKE, SAARLOUIS/D MEGUIN GMBH & CO. KG MINERALOELWERKE, SAARLOUIS/D MEGUIN GMBH & CO. KG MINERALOELWERKE, SAARLOUIS/D MEGUIN GMBH & CO. KG MINERALOELWERKE, SAARLOUIS/D MILLERS OILS LIMITED, BRIGHOUSE/GB MINERALÖL-RAFFIN. DOLLBERGEN, UETZE-DOLLBERGEN/D MINERALÖL-RAFFIN. DOLLBERGEN, UETZE-DOLLBERGEN/D MINERALÖL-RAFFIN. DOLLBERGEN, UETZE-DOLLBERGEN/D MINERALÖL-RAFFIN. DOLLBERGEN, UETZE-DOLLBERGEN/D MINERALÖL-RAFFIN. DOLLBERGEN, UETZE-DOLLBERGEN/D MINERALÖL-RAFFIN. DOLLBERGEN, UETZE-DOLLBERGEN/D MODRICA OIL REFINERY, MODRICA/BIH MODRICA OIL REFINERY, MODRICA/BIH MOL-LUB LTD., ALMASFUZITO/H MOL-LUB LTD., ALMASFUZITO/H MORRIS LUBRICANTS, SHREWSBURY/GB MORRIS LUBRICANTS, SHREWSBURY/GB MOTUL SA, AUBERVILLIERS CEDEX/F NEW PROCESS AG, TÜBACH/CH NOVA STILMOIL SPA, MODENA/I OEL-BRACK AG, HUNZENSCHWIL/CH OEL-BRACK AG, HUNZENSCHWIL/CH OEST, GEORG MINERALÖLWERK, FREUDENSTADT/D OEST, GEORG MINERALÖLWERK, FREUDENSTADT/D OEST, GEORG MINERALÖLWERK, FREUDENSTADT/D OMV AG, SCHWECHAT/A OMV AG, SCHWECHAT/A OMV AG, SCHWECHAT/A ORLY INTERNATIONAL G.I.E., VIEUX-THANN/F

1.55.4

ZF Friedrichshafen AG / List of lubricants TE-ML 05, edition 01.04.2005

AMBRA HYPOIDE 140 SAE 85W140 AMBRA HYPOIDE 90 SAE 80W90 ARBOR TRW 140 (SAE 85W140) ARBOR TRW 90 (SAE 80W90) TUTELA W140/M-DA SAE 85W140 TUTELA W90/M-DA SAE 80W90 TITAN GEAR HYP SAE 90 TITAN SUPERGEAR MC 80W-90 GENOL GEAR-SYN 80W-90 GENOL HYPOLUBE 80W-90 YORK 793 SAE 80W90 YORK 793 SAE 85W140 GREATWALL 85W/90 GL-5 LOTOS TITANIS GL-5 SAE 80W/90 GULF GEAR DB 85W 90 HYPOID PL SAE 80W-90 KENDALL NS-MP GEAR LUBE SAE 80W-90 RTO HD 80W-90 RTO LONGEVIA P ECO 80W-140 RTO LONGEVIA P ECO 80W-90 GEAR M 80W90 HYPOID B SAE85W90 GL-5 GEAR LUBRICANT (80W90) GL-5 GEAR LUBRICANT (85W140) KOMPRESSOL-HYPOID EW SAE 80W-90 HIDROIL EP SAE 80W-90 Q8 AUTO 12 SAE 80W-90 Q8 AXLE OIL XG SAE 80W-140 Q8 GEAR OIL XG SAE 80W-90 Q8 T 55 SAE 80W-90 Q8 T 55 SAE 85W-140 Q8 T 55 SAE 90 Q8 T 65 SAE 75W-90 Q8 TRANS XGS SAE 75W-90 HYPOID GETRIEBEÖL GL 5 SAE 80W-90 HYPOID GETRIEBEÖL GL 5 SAE 85W-140 HYPOID GETRIEBEÖL GL 5 SAE 85W-90 HYPOID GETRIEBEÖL GL 5 SAE 90W HYPOID GETRIEBEÖL TDL SAE 80W-90 BARDAHL T&D OIL 80W 90 INA HIPENOL GTL DB 90 INA HIPENOL GTL HD 80W-90 INA HIPENOL GTL HD 85W-140 INA HIPENOL TDL 80W-90 MEGOL HYPOID-GETRIEBEOEL GL 5 SAE 80W-90 MEGOL HYPOID-GETRIEBEOEL GL 5 SAE 85W-140 MEGOL HYPOID-GETRIEBEOEL GL 5 SAE 85W-90 MEGOL HYPOID-GETRIEBEOEL TDL SAE 80W-90 SYNTRAN II/MILLERS TRX 80W/90 PENNASOL HYPOID-GETRIEBEOEL GL 5 SAE 80W90 PENNASOL HYPOID-GETRIEBEOEL GL 5 SAE 85W90 PENNASOL HYPOID-GETRIEBEOEL GL 5 SAE 90 PENNASOL LONGLIFE GEAR GL 5 SAE 80W90 PENNASOL LONGLIFE GEAR GL 5 SAE 85W90 PENNASOL LONGLIFE GEAR GL 5 SAE 90 HIPOIDNO ULJE B SAE 80W90 HIPOIDNO ULJE B SAE 90 MOL HYKOMOL K 85W-90 MOL HYKOMOL KZ 80W-90 MORRIS EP 80W/90 MORRIS EP 85W/140 MOTUL TRANS MB 85W-90 HD GEAROIL SAE 90 GEARING PLUS 80W90 MIDLAND SUPER M 5 80W-90 MIDLAND SUPER M 5 85W90 OEST MEHRZWECK-GETRIEBEÖL FE SAE 80W-90 OEST MEHRZWECK-GETRIEBEÖL SPEZIAL SAE 85W-140 OEST MEHRZWECK-GETRIEBEÖL SPEZIAL SAE 85W-90 OMV GEAR OIL B SAE 85W-90 OMV GEAR OIL XD-5 SAE 80W-90 OMV UNIGEAR SAE 80W-90 ORLY AURIGA EP SAE 85W140

09 / 2005

Continued

ZF Friedrichshafen AG / List of lubricants TE-ML 05, edition 01.04.2005

ORLY INTERNATIONAL G.I.E., VIEUX-THANN/F PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PANOLIN AG, MADETSWIL/CH PANOLIN AG, MADETSWIL/CH PANOLIN AG, MADETSWIL/CH PANOLIN AG, MADETSWIL/CH PETRO-CANADA LUBRICANTS, MISSISSAUGA/CDN PETRO-CANADA LUBRICANTS, MISSISSAUGA/CDN PETROGAL S.A., LISBOA/P PETROGAL S.A., LISBOA/P PETROGAL S.A., LISBOA/P PETROL OFISI A.S, MASLAK-ISTANBUL-TURKEY/TR PRISTA OIL AD, ROUSSE/BG PRISTA OIL AD, ROUSSE/BG PT PERTAMINA (PERSERO), JAKARTA/RI PT PERTAMINA (PERSERO), JAKARTA/RI PT PERTAMINA (PERSERO), JAKARTA/RI RAFINERIA NAFTY JEDLICZE SA, JEDLICZE/PL RAFINERIA NAFTY JEDLICZE SA, JEDLICZE/PL RAFINERIA NAFTY JEDLICZE SA, JEDLICZE/PL RAVENSBERGER SCHMIERSTOFFVERTRIEB GMBH, WERTHER/D RAVENSBERGER SCHMIERSTOFFVERTRIEB GMBH, WERTHER/D RAVENSBERGER SCHMIERSTOFFVERTRIEB GMBH, WERTHER/D RAVENSBERGER SCHMIERSTOFFVERTRIEB GMBH, WERTHER/D REPSOL LUBRICANTES, MADRID/E REPSOL LUBRICANTES, MADRID/E S.A.E.L., MADRID/E SHARJAH NATIONAL LUBE OIL CO. LTD., SHARJAH/UAE SHARJAH NATIONAL LUBE OIL CO. LTD., SHARJAH/UAE SHELL ASEOL AG, BERN 5/CH SHELL ASEOL AG, BERN 5/CH SHELL ASEOL AG, BERN 5/CH SHELL ASEOL AG, BERN 5/CH SHELL BRASIL, BARRA DA TIJUCA - RIO DE JANEIRO/BR SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D STATOIL LUBRICANTS, STOCKHOLM/S STATOIL LUBRICANTS, STOCKHOLM/S STRUB + CO AG, REIDEN/CH SUOMEN PETROOLI OY, HAMINA/FIN SYNECO SPA, SAN GIULIANO MILANESE/I SYNECO SPA, SAN GIULIANO MILANESE/I TEDEX PRODUCTION SP.Z.O.O., TOMASZOW MAZOWIECKI/PL TEXACO BRASIL S.A., RIO DE JANEIRO/BR TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F

09 / 2005

ORLY LYRA EP PAKELO GEAR OIL EP GL-5 SAE 80W/90 PAKELO GEAR OIL EP GL-5 SAE 85W/140 PAKELO GLOBAL GEAR CBS SAE 75W/90 PAKELO GLOBAL GEAR DLS SAE 85W/140 PAKELO GLOBAL GEAR DLS SAE 85W/90 PAKELO GLOBAL GEAR SA SAE 80W/90 PAKELO GLOBAL GEAR SA SAE 85W/140 PAKELO GLOBAL GEAR SA SAE 85W/90 PAKELO GLOBAL MULTIGEAR CBS PAKELO GLOBAL MULTIGEAR CBS DLS PAKELO GLOBAL MULTIGEAR SA SAE 80W/140 PANOLIN SUPER DUTY 80W/90 PANOLIN SUPER DUTY 85W/140 PANOLIN SUPER DUTY 90 PANOLIN TOPGEAR 80W/90 TRAXON 80W-90 TRAXON 85W-140 GALP TRANSOIL HP 80W90 GALP TRANSOIL HP 85W140 GALP TRANSVEX TDL 85W140 PO UNI. KEBAN EP MAN 80W/90 PRISTA EP 85W140 PRISTA EP 90 RORED HD-A SAE80W-90 RORED HD-A SAE85W-140 RORED HD-A SAE90 HIPOL EXTRA GL-5 80W-90 HIPOL SUPER GL-5 80W-90 HIPOL SUPER GL-5 85W-90 RAVENOL HYP. EPX GETR.ÖL 85W-140 GL5 RAVENOL HYPOID EPX GETR.-OEL 80W-90 GL 5 RAVENOL HYPOID EPX GETRIEBE-OEL SAE 90 GL-5 RAVENOL SLG SPEC. LKW GETR.ÖL 80W90 CARTAGO EP SAE 90 CARTAGO EP SAE 80W90 GULF MULTIPURPOSE GEAR LUBRICANT 85W-90 SHARLU MP GEAR LUBE 80W/90 (GL-5) SHARLU MP GEAR LUBE 85W/140(GL-5) ASEOL TOPRESS 320 ASEOL TOPRESS 80W-90 ASEOL TOPRESS 85W-140 ASEOL TOPRESS 85W-90 SHELL SPIRAX A 90 SHELL SPIRAX AX 80W-90 SHELL SPIRAX AX 85W-140 SHELL SPIRAX AX 90 SHELL SPIRAX MB 90 SHELL SPIRAX MX 80W-90 SHELL SPIRAX ST 80W-140 WINTERSHALL GETRIEBEFLUID SML 80W-90 WINTERSHALL WIOLIN HYPOID-GETRIEBEÖL 80W-90 WINTERSHALL WIOLIN HYPOID-GETRIEBEÖL 85W-140 WINTERSHALL WIOLIN HYPOID-GETRIEBEÖL 90 GEARWAY G5 80W-90 GEARWAY G5 85W-140 STRUB MULTIGEAR SGO 80W-90 TEBOIL HYPOID SAE 80W-140 AMPLEX 80W90 AMPLEX 85W140 TEDEX SUPER GEAR OIL (3343ML) SAE 80W90 MULTIGEAR EP SAE 90 ANTAR EPR 90 ANTAR EPR 80W-90 ANTAR UNIVERSAL FE 80W-140 ANTAR UNIVERSAL FE 80W-90 FINA PONTONIC A 80W-140 FINA PONTONIC MDL 80W-90 FINA PONTONIC MP 80W-90 FINA PONTONIC MP 85W-140 FINA PONTONIC MP 85W-90 TOTAL EP B 80W-90 TOTAL EP B 85W-90

1.55.5

Continued

TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F UNIL S.A., SAUMUR CEDEX/F VALVOLINE EUROPE, DORDRECHT/NL VALVOLINE EUROPE, DORDRECHT/NL VALVOLINE EUROPE, DORDRECHT/NL VEEDOL INTERNATIONAL, PANGBOURNE READING/GB VEEDOL INTERNATIONAL, PANGBOURNE READING/GB YACCO, ST PIERRE LES ELBEUF/F ZELLER + GMELIN GMBH & CO., EISLINGEN/D ZELLER + GMELIN GMBH & CO., EISLINGEN/D ZELLER + GMELIN GMBH & CO., EISLINGEN/D ZEPPELIN BAUMASCHINEN GMBH, GARCHING/D ZF FRIEDRICHSHAFEN AG, FRIEDRICHSHAFEN/D

1.55.6

ZF Friedrichshafen AG / List of lubricants TE-ML 05, edition 01.04.2005

TOTAL EP-B 85W-140 TOTAL TRANSMISSION MDL 80W-90 TOTAL TRANSMISSION RS FE 80W-140 TOTAL TRANSMISSION RS FE 80W-90 TRANSELF TYPE B 80W-90 TRANSELF TYPE B 90 TRANSELF UNIVERSAL FE 80W-140 TRANSELF UNIVERSAL FE 80W-90 UNIL OPAL GEAR ZF 80W90 HIGH PERFORMANCE GEAR OIL GL-5 90 VALVOLINE STX GEAR OIL GL-5 80W-140 VALVOLINE STX GEAR OIL GL-5 80W-90 VEEDOL MULTIGEAR B SAE 90 VEEDOL MULTIGEAR C SAE 85W-140 BVX C 100 80W-90 DIVINOL GEAR OIL STO SAE 80W-90 DIVINOL HYPOID-GETRIEBEÖL SAE 85W-140 DIVINOL SYNTHOGEAR SAE 75W-90 ZEPPELIN SPEZIALGETRIEBEÖL GL-4/GL-5 80W-90 ZF-ECOFLUID X

09 / 2005

Continued

ZF Friedrichshafen AG / List of lubricants TE-ML 05, edition 01.04.2005

Lubricant class 05B Gear oilx Viscosity grades: SAE 75W-90 / 75W-140x Manufacturer (05B)

Trade name (05B)

AGIP SCHMIERTECHNIK GMBH, WÜRZBURG/D AGIP SCHMIERTECHNIK GMBH, WÜRZBURG/D AVIA MINERALÖL-AG, MÜNCHEN/D BP INTERNATIONAL, PANGBOURNE, READING/GB BP INTERNATIONAL, PANGBOURNE, READING/GB BUCHER AG LANGENTHAL, LANGENTHAL/CH CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL INTERNATIONAL, PANGBOURNE READING/GB CEPSA LUBRICANTS S.A., MADRID/E CHEVRONTEXACO, GHENT/B DE OLIEBRON B.V., ZWIJNDRECHT/NL ENI S.P.A. REFINING & MARKETING DIVISION, ROME/I EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA FUCHS PETROLUB AG, MANNHEIM/D GINOUVES GEORGES SA, LA FARLEDE/F HAFA, PARIS/F HUILES BERLIET S.A., SAINT PRIEST/F IGOL FRANCE SA, AMIENS/F MEGUIN GMBH & CO. KG MINERALOELWERKE, SAARLOUIS/D MILLERS OILS LIMITED, BRIGHOUSE/GB MOTUL SA, AUBERVILLIERS CEDEX/F NEW PROCESS AG, TÜBACH/CH OEST, GEORG MINERALÖLWERK, FREUDENSTADT/D OMV AG, SCHWECHAT/A PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PANOLIN AG, MADETSWIL/CH PETROGAL S.A., LISBOA/P S.A.E.L., MADRID/E SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D STRUB + CO AG, REIDEN/CH SUOMEN PETROOLI OY, HAMINA/FIN SUOMEN PETROOLI OY, HAMINA/FIN TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F VALVOLINE EUROPE, DORDRECHT/NL VALVOLINE EUROPE, DORDRECHT/NL VALVOLINE EUROPE, DORDRECHT/NL VEEDOL INTERNATIONAL, PANGBOURNE READING/GB YACCO, ST PIERRE LES ELBEUF/F

AGIP HLX, SAE 75W-90 AGIP ROTRA TRUCK GEAR S, SAE 75W-90 AVIA SYNTOGEAR FE 75W-90 EP BP ENERGEAR SHX 75W90 ENERGEAR SHX-M SAE 75W-90 MOTOREX UNISYNT TX CASTROL DYNADRIVE PLUS 75W90 CASTROL SAF-XO SAE 75W-90 SAF-XT CEPSA TRANSMISIONES EP FE+LD 75W-90 MULTIGEAR S 75W-90 TOR UNIGEAR 75W90 LD ROTRA LSX 75W-90 ESSO GEAR OIL TDL 75W-90 MOBILUBE 1 SHC 75W-90 TITAN CYTRAC HSY SAE 75W-90 YORK 896 EUROGEAR SAE 75W-90 RTO LONGEVIA PXD ECO 75W-90 SYNTHEGEAR SAE75W90 MEGOL GETRIEBEOEL TRUCK-SYNTH SAE 75W-90 SYNTRAN FE/MILLERS TRX SYNTH 75W/90 MOTUL GEAR SYNT TDL 75W-90 GEAROIL SYNTH OEST SYNTH GETRIEBEÖL SAE 75W-90 OMV UNIGEAR S SAE 75W-90 PAKELO GLOBAL MULTIGEAR TS SAE 75W/90 PANOLIN SUPER DUTY SYNTH 75W/90 GALP TRANSVEX TDL 75W90 GULF SYTHETIC GEAR LUBRICANT 75W-90 SHELL SPIRAX ASX 75W-90 WINTERSHALL GETRIEBEFLUID BOS VULCOGEAR SYNT SGX 75W-90 TEBOIL HYPOID SAE 75W-140 TEBOIL HYPOID SAE 75W-90 ANTAR EPS 75W-90 FINA PONTONIC FDL 75W-90 TOTAL TRANSMISSION SYN FE 75W-90 TRANSELF SYNTHESE FE 75W-90 SYNPOWER GEAR OIL TDL 75W-90 VALVOLINE SYNPOWER STX GL-5 75W-140 VALVOLINE SYNPOWER STX GL-5 75W-90 VEEDOL SAF 66 BVX 1000

09 / 2005

1.55.7

Continued

ZF Friedrichshafen AG / List of lubricants TE-ML 05, edition 01.04.2005

Lubricant class 05C Gear oil with limited-slip-additivesx Viscosity grades: SAE 80W-90 / 80W-140 / 85W-90 / 85W-140 / 90x Manufacturer (05C)

Trade name (05C)

ADDINOL LUBE OIL GMBH, LEUNA/D ADDINOL LUBE OIL GMBH, LEUNA/D ARAL AG, BOCHUM/D AVIA MINERALÖL-AG, MÜNCHEN/D AVIA MINERALÖL-AG, MÜNCHEN/D BAYWA AG, MÜNCHEN/D BLASER SWISSLUBE AG, HASLE-RÜEGSAU/CH BP INTERNATIONAL, PANGBOURNE, READING/GB BP INTERNATIONAL, PANGBOURNE, READING/GB BUCHER AG LANGENTHAL, LANGENTHAL/CH CALPAM MINERALÖL-GMBH, ASCHAFFENBURG/D CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL INTERNATIONAL, PANGBOURNE READING/GB CHEVRONTEXACO, GHENT/B CHEVRONTEXACO, GHENT/B CHEVRONTEXACO, SYDNEY/AUS CHEVRONTEXACO, SYDNEY/AUS CHEVRONTEXACO, SYDNEY/AUS CONDAT LUBRIFIANTS, CHASSE SUR RHONE/F CONDAT LUBRIFIANTS, CHASSE SUR RHONE/F DE OLIEBRON B.V., ZWIJNDRECHT/NL ENGEN PETROLEUM LTD., CAPE TOWN/ZA ENI S.P.A. REFINING & MARKETING DIVISION, ROME/I EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA FL SELENIA S.P.A., VILLASTELLONE/I FL SELENIA S.P.A., VILLASTELLONE/I FL SELENIA S.P.A., VILLASTELLONE/I FUCHS PETROLUB AG, MANNHEIM/D HAFA, PARIS/F HUILES BERLIET S.A., SAINT PRIEST/F IGOL FRANCE SA, AMIENS/F JOHN DEERE, WATERLOO/USA KOMPRESSOL-OEL VERKAUFS GMBH, KÖLN/D KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL LIQUI MOLY GMBH, ULM/D MAZIVA ZAGREB D.O.O, ZAGREB/HR MEGUIN GMBH & CO. KG MINERALOELWERKE, SAARLOUIS/D MINERALÖL-RAFFIN. DOLLBERGEN, UETZE-DOLLBERGEN/D MOL-LUB LTD., ALMASFUZITO/H NOVA STILMOIL SPA, MODENA/I OEST, GEORG MINERALÖLWERK, FREUDENSTADT/D OMV AG, SCHWECHAT/A ORLY INTERNATIONAL G.I.E., VIEUX-THANN/F PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PANOLIN AG, MADETSWIL/CH PETROGAL S.A., LISBOA/P RAVENSBERGER SCHMIERSTOFFVERTRIEB GMBH, WERTHER/D REPSOL LUBRICANTES, MADRID/E S.A.E.L., MADRID/E SHELL ASEOL AG, BERN 5/CH SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D TEXACO BRASIL S.A., RIO DE JANEIRO/BR TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F UNIL S.A., SAUMUR CEDEX/F VEEDOL INTERNATIONAL, PANGBOURNE READING/GB YACCO, ST PIERRE LES ELBEUF/F ZEPPELIN BAUMASCHINEN GMBH, GARCHING/D

ADDINOL GETRIEBEÖL GH 80W-90 LS ADDINOL GETRIEBEÖL GH 85W-90 LS ARAL GETRIEBEOL HYP LS 90 AVIA HYPOID 90 LS AVIA HYPOID 90 LS, 85W-90 BAYWA GETRIEBEÖL HYPOID LS 90 GETRIEBEÖL LS 85W90 BP ENERGEAR LIMSLIP 90 FRONTOL GETRIEBEÖL LS 90 MOTOREX GEAR OIL UNIVERSAL LS 80W/90 CALPAM GEAR OIL LS 90 CASTROL HYPOY LS 90 CASTROL LSX GEARTEX LS 80W-90 GEARTEX LS 85W-90 CALTEX GEAR OIL ZF SAE 80W-90 CALTEX GEAR OIL ZF SAE 85W-140 CALTEX GEAR OIL ZF SAE 90 GEAR T ( 90 ) GEAR T (80W90) TOR SUPER GEAR OIL LS 80W90 ENGEN GEARLUBE EP 90 LS - SAE 80W-90 AGIP ROTRA MP/S 85W-90 ESSO GEAR OIL LSA 85W-90 MOBILUBE LS 85W-90 AKCELA AXLEPOWER (80W90) AMBRA AXF 80W90 AMBRA STF (80W90) TITAN GEAR LS 90 HYPOID PA SAE 80W-90 RTO EP 90 GL HYPOID BPA SAE90 GL-5 GEAR LUBRICANT WITH LS ADDITIVE (85W140) KOMPRESSOL-HYPOID LS SAE 90 Q8 T 45 SAE 90 HYPOID GETRIEBEÖL GL 5 SAE 85W-90 LS INA HIPENOL GTL LS 90 MEGOL HYPOID-GETRIEBEOEL GL 5 SAE 85W-90 LS PENNASOL SPERRDIFFERENTIAL HYPOID GETRIEBEOEL LS90 MOL HYKOMOL LS 85W-90 GEARING WONDER LS SAE 85W90 OEST GETRIEBEÖL HYPOID LS 90 OMV GEAR OIL LS SAE 85W-90 ORLY TUCANA LS PAKELO UNIVERSAL GEAR EP/LS SAE 85W/140 PAKELO UNIVERSAL GEAR EP/LS SAE 80W/90 PANOLIN SUPER DUTY LS 90 GALP LS 90 RAVENOL SPERRDIFF.-GETR.-OEL LS 90 CS EP AUTOBLOCANTE SAE 85W140 GULF LS REAR AXLE OIL 80W-90 ASEOL TOPRESS LS 85W-90 SHELL SPIRAX A LS 85W-140 SHELL SPIRAX A LS 90 WINTERSHALL WIOLIN RSH GEARTEX LS 85W140 ANTAR BLS 90 FINA PONTONIC LS 80W-90 TOTAL TRANSMISSION DA 80W-90 TRANSELF BLS 90 UNIL OPAL GEAR AB-EP SAE 85W90 VEEDOL MULTIGEAR LS SAE 90 BVX LS 200 ZEPPELIN SPEZIALGETRIEBEÖL GL-5 LS 90

1.55.8

09 / 2005

Continued

ZF Friedrichshafen AG / List of lubricants TE-ML 05, edition 01.04.2005

Lubricant class 05D Gear oil with limited-slip-additives Viscosity grades: SAE 75W-90 / 75W-140 Manufacturer (05D)

Trade name (05D)

AGIP SCHMIERTECHNIK GMBH, WÃ&#x153;RZBURG/D BP INTERNATIONAL, PANGBOURNE, READING/GB BP INTERNATIONAL, PANGBOURNE, READING/GB CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL INTERNATIONAL, PANGBOURNE READING/GB EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F VEEDOL INTERNATIONAL, PANGBOURNE READING/GB VEEDOL INTERNATIONAL, PANGBOURNE READING/GB

AGIP HLZ, SAE 75W-140 BP ENERGEAR SHX S 75W140 BP ENERGEAR SHX-ZR 75W-140 CASTROL SAF-X SAE 75W-140 CASTROL SAF-XJ SAE 75W-140 CASTROL SAF-XLS SAE 75W-90 MOBIL GEARLUBE VS 500 WINTERSHALL GETRIEBEFLUID BMS PLUS FINA PONTONIC MLX 75W-140 TOTAL TRANSMISSION LS 75W-140 VEEDOL SAF 22 VEEDOL SAF 44

09 / 2005

1.55.9

Continued

ZF Friedrichshafen AG / List of lubricants TE-ML 05, edition 01.04.2005

Lubricant class 05E Universal Tractor Transmission Oil (UTTO) Viscosity grades: SAE 20W-40 / 80W-140 Manufacturer (05E)

Trade name (05E)

CASTROL INTERNATIONAL, PANGBOURNE READING/GB CNH, BURR RIDGE/USA EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA FUCHS PETROLUB AG, MANNHEIM/D MAZIVA ZAGREB D.O.O, ZAGREB/HR OMV AG, SCHWECHAT/A PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I STRUB + CO AG, REIDEN/CH

KOMATSU WBL 20W40 CASE TRANSAXLE FLUID, SAE 80W-140 MOBILFLUID 2040 TITAN UTTO ZF SAE 20W-40 INA TRANSHIDROL ZF 20W-40 OMV AUSTROMATIC ZF SAE 20W-40 PAKELO UTTO FLUID 4D SAE 20W/40 VULCOTRAC UTTO SAE 20W-40

1.55.10

09 / 2005

Continued

ZF Friedrichshafen AG / List of lubricants TE-ML 05, edition 01.04.2005

Lubricant class 05F Universal Tractor Transmission Oil (UTTO) Manufacturer (05F)

Trade name (05F)

76 LUBRICANTS (CONOCOPHILLIPS COMP.), HOUSTON/USA ARAL AG, BOCHUM/D AVIA MINERALÖL-AG, MÜNCHEN/D BP INTERNATIONAL, PANGBOURNE, READING/GB BP INTERNATIONAL, PANGBOURNE, READING/GB BP INTERNATIONAL, PANGBOURNE, READING/GB BP INTERNATIONAL, PANGBOURNE, READING/GB BUCHER AG LANGENTHAL, LANGENTHAL/CH CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL INTERNATIONAL, PANGBOURNE READING/GB CHEVRONTEXACO, GHENT/B CHEVRONTEXACO, GHENT/B ENGEN PETROLEUM LTD., CAPE TOWN/ZA EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA FL SELENIA S.P.A., VILLASTELLONE/I FUCHS PETROLUB AG, MANNHEIM/D GINOUVES GEORGES SA, LA FARLEDE/F IGOL FRANCE SA, AMIENS/F KENDALL MOTOR OIL (CONOCOPHILLIPS C.), HOUSTON/USA KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL OEL-BRACK AG, HUNZENSCHWIL/CH OMV AG, SCHWECHAT/A PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PANOLIN AG, MADETSWIL/CH PETROGAL S.A., LISBOA/P RAVENSBERGER SCHMIERSTOFFVERTRIEB GMBH, WERTHER/D REPSOL LUBRICANTES, MADRID/E SHELL ASEOL AG, BERN 5/CH SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D

76 HYDRAULIC/TRACTOR FLUID ARAL FLUID HGS 10W-30 AVIA HYDROFLUID DLZ BP OLEX GO 4926 BP TERRAC SUPER TRANSMISSION 10W-30 BP TERRAC SUPER TRANSMISSION CVT 10W-30 BP TRACTRAN TF 10 MOTOREX POLYFARM 304 CASTROL AGRI TRANS PLUS 10W-30 CASTROL AGRI TRANS PLUS CVT 10W-30 CASTROL KOMATSU UTTO 10W-30 TEXTRAN TDH TEXTRAN TDH PREMIUM ENGEN AGRIFLUID ESSO TORQUE FLUID 56 MOBIL AGRIFLUID 424 MOBILFLUID 424 MOBILFLUID 426 AMBRA MULTI G TITAN UTTO J20C YORK 676 SAE 10W30 TICMA FLUID MU SAE80W KENDALL HYKEN 052 Q8 T 2000 Q8 T 2200 MIDLAND TOU OMV AUSTROMATIC IGB SAE 10W-30 PAKELO UTTO FLUID 4D SAE 10W/30 PANOLIN JD 303 GALP TRALUB 807S RAVENOL UTTO AGRO ORION SAE 10W30 ASEOL MULTITRAC 85W SHELL DONAX TD 10W-30 SHELL DONAX TD 5W-30 WINTERSHALL HYDROFLUID N

09 / 2005

1.55.11

Continued

ZF Friedrichshafen AG / List of lubricants TE-ML 05, edition 01.04.2005

Lubricant class 05G Universal construction-machinery oil Manufacturer (05G)

Trade name (05G)

CATERPILLAR INC., PEORIA/USA JOHN DEERE, MANNHEIM/D ZF FRIEDRICHSHAFEN AG, FRIEDRICHSHAFEN/D

CATERPILLAR MULTIPURPOSE TRACTOR OIL (MTO) 10W-30 JOHN DEERE HY-GARD ZF-POWERFLUID

1.55.12

09 / 2005

Off-Road Driveline Technology and Axle Systems

Hydrostatic and mechanical drives and electric drive systems Product groups

List of lubricants TE-ML 07 Lubricant classes for service fills (1)

Alternative lubricant classes for service fills (1)

07B / 07D / 07E

---

07C / 07E

07D

07A / 07C / 07E

07D

Powershift transmissions AVG (2) HL Mobile mixer drives Common oil circuit for transmissionx and hydrostatic systemx P3200 PLM 7, PLM 9 Mobile mixer drives Separate oil circuits for transmissionx and hydrostatic systemx P3301, P4300, P5300, P6300, P7300 PK5300, PK6500, PK7500 Transmissions for lifting equipment RME, RMT Swing drives DR

07A / 07E --07D / 07E Mineral oil-based Hydraulic oil: - DIN 51524-02 (HLP) and - ISO VG 46 / 68

---

(1) Refer to the following pages for approved commercial products and low temperature limits.

(2) For AVGs directly mounted on ZF axles, use gear oils in accordance with TE-ML 05 for the common oil circuit of the transmission and axle

A lithium saponified multipurpose grease of NLGI class 2 which is mixable with mineral oil is to be used at greasing points (grease code KP2K-30 in acc. with DIN 51825 or ISO-L-XCCHB2 in accordance with ISO 6743-9).

Additives of any kind added later to the oil change the oil in a manner that is unpredictable, and they are therefore not permitted. No liability of any kind will be accepted by ZF for any damage resulting from the use of such additives.

Note low-temperature limits on page 2!

The list of lubricants TE-ML 07, Edition 01.04.2005 replaces all previous editions. The current list can be requested from any ZF after-sales service center or accessed on the Internet under www.zf.com.

09 / 2005

ZF Passau GmbH ZF Friedrichshafen AG D-94030 Passau D-88038 Friedrichshafenx phone: + 49 7541 77 7181 fax: + 49 7541 77 7319

1.56.1

Continued

ZF Friedrichshafen AG / List of lubricants TE-ML 07, edition 01.041

Low temperatures limits Use at outside temperatures above Lubricant classes

07A

viscosity grades

Powershift transmissions; Mobile mixer drives with common oil circuit;x (with pump)

- SAE 75W-90, 75W-140 - SAE 80W-85, 80W-90, 80W-140

(3)

Mobile mixer drives with separate oil circuit; Transmissions for lifting equipment; Swing drives; (without pump) -40°C

---

- SAE 85W-90, 85W-140, 90

-26°C -12°C

07C, 07D

- SAE 5W-30, 5W-40

-35°C

-40°C

07E

- SAE 75W-80, ISO VG 46 (only 07E)

-35°C

-40°C

07B, 07C, 07D

- SAE 10W-30, 10W-40

-30°C

-35°C

07B, 07C, 07D

- SAE 15W-30, 15W-40

-25°C

-30°C

07D

- SAE 20W-20

-20°C

-25°C

07B

- SAE 20W-40

-20°C

---

07D

- SAE 30

-5°C

-10°C

Hydraulic oil

- ISO VG 46

---

-10°C

- ISO VG 68

---

-5°C

(3) An even warm-up phase is needed in order to reach the minimum oil temperature required for starting the drive unit (mentioned low temperature limit). At outside temperatures below -5°C, a warm-up phase of at least 10 minutes is required, irrespective of the viscosity grade used.

1.56.2

09 / 2005

Continued

ZF Friedrichshafen AG / List of lubricants TE-ML 07, edition 01.04.2005

Lubricant class 07A Gear oil Viscosity grades: SAE 75W-90 / 75W-140 / 80W-85 / 80W-90 / 80W-140 / 85W-90 / 85W-140 / 90 Note: Other gear oils may be used in addition to those listed, if they satisfy the following specifications: - SAE 80W-85 / 80W-90 / 80W-140 / 85W-90 / 85W-140 / 90 - API GL-5 and MIL-L-2105 D or - MIL-PRF-2105E or - SAE J 2360 Manufacturer (07A)

Trade name (07A)

ADDINOL LUBE OIL GMBH, LEUNA/D ADDINOL LUBE OIL GMBH, LEUNA/D ADDINOL LUBE OIL GMBH, LEUNA/D AGIP SCHMIERTECHNIK GMBH, WÜRZBURG/D AGIP SCHMIERTECHNIK GMBH, WÜRZBURG/D ARAL AG, BOCHUM/D ARAL AG, BOCHUM/D ARAL AG, BOCHUM/D ARAL AG, BOCHUM/D ARMORINE S.A., LANESTER CEDEX/F AVIA MINERALÖL-AG, MÜNCHEN/D AVIA MINERALÖL-AG, MÜNCHEN/D AVIA MINERALÖL-AG, MÜNCHEN/D BAYWA AG, MÜNCHEN/D BAYWA AG, MÜNCHEN/D BEIJING TONGYI PETROLEUM CH. CO. LTD., BEIJING/CN BLASER SWISSLUBE AG, HASLE-RÜEGSAU/CH BLASER SWISSLUBE AG, HASLE-RÜEGSAU/CH BLASER SWISSLUBE AG, HASLE-RÜEGSAU/CH BP INTERNATIONAL, PANGBOURNE, READING/GB BP INTERNATIONAL, PANGBOURNE, READING/GB BP INTERNATIONAL, PANGBOURNE, READING/GB BP INTERNATIONAL, PANGBOURNE, READING/GB BP INTERNATIONAL, PANGBOURNE, READING/GB BP INTERNATIONAL, PANGBOURNE, READING/GB BP INTERNATIONAL, PANGBOURNE, READING/GB BP INTERNATIONAL, PANGBOURNE, READING/GB BP INTERNATIONAL, PANGBOURNE, READING/GB BP INTERNATIONAL, PANGBOURNE, READING/GB BUCHER AG LANGENTHAL, LANGENTHAL/CH BUCHER AG LANGENTHAL, LANGENTHAL/CH BUCHER AG LANGENTHAL, LANGENTHAL/CH BUCHER AG LANGENTHAL, LANGENTHAL/CH CALPAM MINERALÖL-GMBH, ASCHAFFENBURG/D CALPAM MINERALÖL-GMBH, ASCHAFFENBURG/D CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL INTERNATIONAL, PANGBOURNE READING/GB CEPSA LUBRICANTS S.A., MADRID/E CEPSA LUBRICANTS S.A., MADRID/E CEPSA LUBRICANTS S.A., MADRID/E CEPSA LUBRICANTS S.A., MADRID/E CEPSA LUBRICANTS S.A., MADRID/E CEPSA LUBRICANTS S.A., MADRID/E CEPSA LUBRICANTS S.A., MADRID/E CHEVRONTEXACO GLOBAL LUBRICANTS, SAN RAMON/USA CHEVRONTEXACO GLOBAL LUBRICANTS, SAN RAMON/USA CHEVRONTEXACO, GHENT/B

ADDINOL GETRIEBEÖL GH 80W-90 ADDINOL GETRIEBEÖL GH 85W-90 ADDINOL GETRIEBEÖL GX 80 W 90 ML AGIP ROTRA TRUCK GEAR S, SAE 75W-90 AUTOL HYPOID-GETRIEBEÖL SAE 80W-90 ARAL GETRIEBEOL EP PLUS 80W-90 ARAL GETRIEBEOL HYP 85W-90 ARAL GETRIEBEÖL HYP SAE 85W-140 ARAL GETRIEBEÖL SNA-C SAE 75W-90 PM 90 AVIA HYPOID 90 EP AVIA SYNTOGEAR FE 75W-90 EP AVIA SYNTOGEAR FE 80W-90 BAYWA HYPOID GETRIEBEÖL 85W-90 BAYWA SUPER 8090 MC XIECHENG 85W-90 GEAR OIL HYPOID-GETRIEBEÖL 80W90 HYPOID-GETRIEBEÖL 85W140 HYPOID-GETRIEBEÖL 90 BP ENERGEAR DL 80W-90 BP ENERGEAR HT 80W-90 BP ENERGEAR HYPO 80W-90 BP ENERGEAR HYPO 85W-140 BP ENERGEAR HYPO 90 ENERGEAR HT 85W140 ENERGEAR SHX-M SAE 75W-90 FRONTOL GETRIEBEÖL FE SAE 80W-90 FRONTOL HYPOID GETRIEBEÖL B SAE 85W-140 FRONTOL HYPOID GETRIEBEÖL B SAE 90 MOTOREX GEAR OIL UNIVERSAL 80W/90 MOTOREX GEAR OIL UNIVERSAL 85W/140 MOTOREX PENTA TL MOTOREX UNISYNT TX CALPAM MULTI GEAR OIL FE 80W90 CALPAM SUPER GEAR OIL 85W90 GL 5 CASTROL AF-STO 85W140 CASTROL AGRI GEAR GL5 90 CASTROL AGRI GEAR ULTRA CASTROL DYNADRIVE 80W-90 CASTROL DYNADRIVE PLUS 75W90 CASTROL EPX 85W-140 CASTROL EPX 90 CASTROL EPX M 90 CASTROL MULTIDRIVE 80W90 CEPSA TRANSMISIONES EP 90 CEPSA TRANSMISIONES EP FE+LD 75W-90 CEPSA TRANSMISIONES EP MULTIG. 85W-140 CEPSA TRANSMISIONES EP MULTIGRADO 80W-90 ERTOIL EP CAMBIOS Y DIFERENCIALES SAE 90 ERTOIL EP MULT. CAMBIOS Y DIFERENCIALES 80W-90 ERTOIL EP MULT. CAMBIOS Y DIFERENCIALES 85W-140 CHEVRON RPM UNIVERSAL GEAR LUBRICANT SAE 80W-90 CHEVRON RPM UNIVERSAL GEAR LUBRICANT SAE 85W-140 GEARTEX EP-B 85W-90

09 / 2005

1.56.3

Continued

CHEVRONTEXACO, GHENT/B CHEVRONTEXACO, GHENT/B CHEVRONTEXACO, GHENT/B CHEVRONTEXACO, SYDNEY/AUS CHEVRONTEXACO, SYDNEY/AUS COGNIS DEUTSCHLAND GMBH, DÜSSELDORF/D CONDAT LUBRIFIANTS, CHASSE SUR RHONE/F CONDAT LUBRIFIANTS, CHASSE SUR RHONE/F DE OLIEBRON B.V., ZWIJNDRECHT/NL DE OLIEBRON B.V., ZWIJNDRECHT/NL ENI S.P.A. REFINING & MARKETING DIVISION, ROME/I ENI S.P.A. REFINING & MARKETING DIVISION, ROME/I ENI S.P.A. REFINING & MARKETING DIVISION, ROME/I ENI S.P.A. REFINING & MARKETING DIVISION, ROME/I ENI S.P.A. REFINING & MARKETING DIVISION, ROME/I EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA FALCON OIL COMPANY LTD., SHARJAH/UAE FALCON OIL COMPANY LTD., SHARJAH/UAE FL SELENIA S.P.A., VILLASTELLONE/I FL SELENIA S.P.A., VILLASTELLONE/I FL SELENIA S.P.A., VILLASTELLONE/I FL SELENIA S.P.A., VILLASTELLONE/I FL SELENIA S.P.A., VILLASTELLONE/I FL SELENIA S.P.A., VILLASTELLONE/I FL SELENIA S.P.A., VILLASTELLONE/I FL SELENIA S.P.A., VILLASTELLONE/I FL SELENIA S.P.A., VILLASTELLONE/I FUCHS PETROLUB AG, MANNHEIM/D FUCHS PETROLUB AG, MANNHEIM/D FUCHS PETROLUB AG, MANNHEIM/D FUCHS PETROLUB AG, MANNHEIM/D GENOL GMBH & CO., WIEN/A GENOL GMBH & CO., WIEN/A GINOUVES GEORGES SA, LA FARLEDE/F GINOUVES GEORGES SA, LA FARLEDE/F GINOUVES GEORGES SA, LA FARLEDE/F GREAT WALL LUBE OIL CO., BEIJING/CHINA GRUPA LOTOS SA, GDANSK/PL GULF OIL INTERNATIONAL, PITTSBURG/USA HAFA, PARIS/F HAFA, PARIS/F HANDEL MIJ NOVIOL B.V., NIJMEGEN/NL HUILES BERLIET S.A., SAINT PRIEST/F HUILES BERLIET S.A., SAINT PRIEST/F HUILES BERLIET S.A., SAINT PRIEST/F HUILES BERLIET S.A., SAINT PRIEST/F IGOL FRANCE SA, AMIENS/F IGOL FRANCE SA, AMIENS/F IGOL FRANCE SA, AMIENS/F JOHN DEERE, WATERLOO/USA JOHN DEERE, WATERLOO/USA KOMPRESSOL-OEL VERKAUFS GMBH, KÖLN/D KRAFFT S.A., ANDOAIN/E KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL LIQUI MOLY GMBH, ULM/D LIQUI MOLY GMBH, ULM/D LIQUI MOLY GMBH, ULM/D LIQUI MOLY GMBH, ULM/D LIQUI MOLY GMBH, ULM/D MAROIL S.R.L. CONC. BARDAHL MANU. CO.,ALTOPASCIO/I MAZIVA ZAGREB D.O.O, ZAGREB/HR

1.56.4

ZF Friedrichshafen AG / List of lubricants TE-ML 07, edition 01.04.2005

GEARTEX EP-C 85W-140 MULTIGEAR 80W-90 MULTIGEAR S 75W-90 CALTEX HYPOID LD SAE 85W-90 CALTEX HYPOID LD SAE 90 COGNIS EMGARD UAF 4209, SAE 75W-90 GEAR S 80W90 GEAR S 85W140 TOR SUPER GEAR OIL 80W90 TOR UNIGEAR 75W90 LD AGIP ROTRA MP 85W-140 AGIP ROTRA TRUCK GEAR 85W-140 ROTRA LSX 75W-90 ROTRA MP 80W-90 ROTRA TRUCK GEAR 80W-90 ESSO GEAR OIL GX-D 85W-90 ESSO GEAR OIL TDL 75W-90 ESSO GEAR OIL TDL 80W-90 MOBILUBE 1 SHC 75W-90 MOBILUBE HD-A 85W-90 MOBILUBE S 80W-90 FALCON SUPER MP GEAR OIL 85W/140 GL-5 FALCON SUPER MP GEAR OIL 80W/90 GL-5 AKCELA GEAR 135H EP (SAE 80W90) AKCELA GEAR 135H EP (SAE 85W140) AKROS EP 90 SAE 80W90 AMBRA HYPOIDE 140 SAE 85W140 AMBRA HYPOIDE 90 SAE 80W90 ARBOR TRW 140 (SAE 85W140) ARBOR TRW 90 (SAE 80W90) TUTELA W140/M-DA SAE 85W140 TUTELA W90/M-DA SAE 80W90 FUCHS TITAN CYTRAC SL SAE 75W-90 TITAN CYTRAC HSY SAE 75W-90 TITAN GEAR HYP SAE 90 TITAN SUPERGEAR MC 80W-90 GENOL GEAR-SYN 80W-90 GENOL HYPOLUBE 80W-90 YORK 793 SAE 80W90 YORK 793 SAE 85W140 YORK 896 GREATWALL 85W/90 GL-5 LOTOS TITANIS GL-5 SAE 80W/90 GULF GEAR DB 85W 90 EUROGEAR SAE 75W-90 HYPOID PL SAE 80W-90 KENDALL NS-MP GEAR LUBE SAE 80W-90 RTO HD 80W-90 RTO LONGEVIA P ECO 80W-140 RTO LONGEVIA P ECO 80W-90 RTO LONGEVIA PXD ECO 75W-90 GEAR M 80W90 HYPOID B SAE85W90 SYNTHEGEAR SAE75W90 GL-5 GEAR LUBRICANT (80W90) GL-5 GEAR LUBRICANT (85W140) KOMPRESSOL-HYPOID EW SAE 80W-90 HIDROIL EP SAE 80W-90 Q8 AUTO 12 SAE 80W-90 Q8 AXLE OIL XG SAE 80W-140 Q8 GEAR OIL XG SAE 80W-90 Q8 T 55 SAE 80W-90 Q8 T 55 SAE 85W-140 Q8 T 55 SAE 90 Q8 T 65 SAE 75W-90 Q8 TRANS XGS SAE 75W-90 HYPOID GETRIEBEÖL GL 5 SAE 80W-90 HYPOID GETRIEBEÖL GL 5 SAE 85W-140 HYPOID GETRIEBEÖL GL 5 SAE 85W-90 HYPOID GETRIEBEÖL GL 5 SAE 90W HYPOID GETRIEBEÖL TDL SAE 80W-90 BARDAHL T&D OIL 80W 90 INA HIPENOL GTL DB 90

09 / 2005

Continued

ZF Friedrichshafen AG / List of lubricants TE-ML 07, edition 01.04.2005

MAZIVA ZAGREB D.O.O, ZAGREB/HR MAZIVA ZAGREB D.O.O, ZAGREB/HR MAZIVA ZAGREB D.O.O, ZAGREB/HR MEGUIN GMBH & CO. KG MINERALOELWERKE, SAARLOUIS/D MEGUIN GMBH & CO. KG MINERALOELWERKE, SAARLOUIS/D MEGUIN GMBH & CO. KG MINERALOELWERKE, SAARLOUIS/D MEGUIN GMBH & CO. KG MINERALOELWERKE, SAARLOUIS/D MEGUIN GMBH & CO. KG MINERALOELWERKE, SAARLOUIS/D MILLERS OILS LIMITED, BRIGHOUSE/GB MILLERS OILS LIMITED, BRIGHOUSE/GB MINERALÖL-RAFFIN. DOLLBERGEN, UETZE-DOLLBERGEN/D MINERALÖL-RAFFIN. DOLLBERGEN, UETZE-DOLLBERGEN/D MINERALÖL-RAFFIN. DOLLBERGEN, UETZE-DOLLBERGEN/D MINERALÖL-RAFFIN. DOLLBERGEN, UETZE-DOLLBERGEN/D MINERALÖL-RAFFIN. DOLLBERGEN, UETZE-DOLLBERGEN/D MINERALÖL-RAFFIN. DOLLBERGEN, UETZE-DOLLBERGEN/D MODRICA OIL REFINERY, MODRICA/BIH MODRICA OIL REFINERY, MODRICA/BIH MOL-LUB LTD., ALMASFUZITO/H MOL-LUB LTD., ALMASFUZITO/H MORRIS LUBRICANTS, SHREWSBURY/GB MORRIS LUBRICANTS, SHREWSBURY/GB MOTUL SA, AUBERVILLIERS CEDEX/F MOTUL SA, AUBERVILLIERS CEDEX/F NEW PROCESS AG, TÜBACH/CH NEW PROCESS AG, TÜBACH/CH NOVA STILMOIL SPA, MODENA/I OEL-BRACK AG, HUNZENSCHWIL/CH OEL-BRACK AG, HUNZENSCHWIL/CH OEST, GEORG MINERALÖLWERK, FREUDENSTADT/D OEST, GEORG MINERALÖLWERK, FREUDENSTADT/D OEST, GEORG MINERALÖLWERK, FREUDENSTADT/D OEST, GEORG MINERALÖLWERK, FREUDENSTADT/D OMV AG, SCHWECHAT/A OMV AG, SCHWECHAT/A OMV AG, SCHWECHAT/A OMV AG, SCHWECHAT/A OMV AG, SCHWECHAT/A ORLY INTERNATIONAL G.I.E., VIEUX-THANN/F ORLY INTERNATIONAL G.I.E., VIEUX-THANN/F PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PANOLIN AG, MADETSWIL/CH PANOLIN AG, MADETSWIL/CH PANOLIN AG, MADETSWIL/CH PANOLIN AG, MADETSWIL/CH PANOLIN AG, MADETSWIL/CH PETRO-CANADA LUBRICANTS, MISSISSAUGA/CDN PETRO-CANADA LUBRICANTS, MISSISSAUGA/CDN PETROGAL S.A., LISBOA/P PETROGAL S.A., LISBOA/P PETROGAL S.A., LISBOA/P PETROGAL S.A., LISBOA/P PETROL OFISI A.S, MASLAK-ISTANBUL-TURKEY/TR PRISTA OIL AD, ROUSSE/BG PRISTA OIL AD, ROUSSE/BG PT PERTAMINA (PERSERO), JAKARTA/RI PT PERTAMINA (PERSERO), JAKARTA/RI PT PERTAMINA (PERSERO), JAKARTA/RI RAFINERIA NAFTY JEDLICZE SA, JEDLICZE/PL RAFINERIA NAFTY JEDLICZE SA, JEDLICZE/PL RAFINERIA NAFTY JEDLICZE SA, JEDLICZE/PL RAVENSBERGER SCHMIERSTOFFVERTRIEB GMBH, WERTHER/D

09 / 2005

INA HIPENOL GTL HD 80W-90 INA HIPENOL GTL HD 85W-140 INA HIPENOL TDL 80W-90 MEGOL GETRIEBEOEL TRUCK-SYNTH SAE 75W-90 MEGOL HYPOID-GETRIEBEOEL GL 5 SAE 80W-90 MEGOL HYPOID-GETRIEBEOEL GL 5 SAE 85W-140 MEGOL HYPOID-GETRIEBEOEL GL 5 SAE 85W-90 MEGOL HYPOID-GETRIEBEOEL TDL SAE 80W-90 SYNTRAN FE/MILLERS TRX SYNTH 75W/90 SYNTRAN II/MILLERS TRX 80W/90 PENNASOL HYPOID-GETRIEBEOEL GL 5 SAE 80W90 PENNASOL HYPOID-GETRIEBEOEL GL 5 SAE 85W90 PENNASOL HYPOID-GETRIEBEOEL GL 5 SAE 90 PENNASOL LONGLIFE GEAR GL 5 SAE 80W90 PENNASOL LONGLIFE GEAR GL 5 SAE 85W90 PENNASOL LONGLIFE GEAR GL 5 SAE 90 HIPOIDNO ULJE B SAE 80W90 HIPOIDNO ULJE B SAE 90 MOL HYKOMOL K 85W-90 MOL HYKOMOL KZ 80W-90 MORRIS EP 80W/90 MORRIS EP 85W/140 MOTUL GEAR SYNT TDL 75W-90 MOTUL TRANS MB 85W-90 GEAROIL SYNTH HD GEAROIL SAE 90 GEARING PLUS 80W90 MIDLAND SUPER M 5 80W-90 MIDLAND SUPER M 5 85W90 OEST MEHRZWECK-GETRIEBEÖL FE SAE 80W-90 OEST MEHRZWECK-GETRIEBEÖL SPEZIAL SAE 85W-140 OEST MEHRZWECK-GETRIEBEÖL SPEZIAL SAE 85W-90 OEST SYNTH GETRIEBEÖL SAE 75W-90 OMV GEAR OIL B SAE 85W-90 OMV GEAR OIL BSX SAE 75W-90 OMV GEAR OIL XD-5 SAE 80W-90 OMV UNIGEAR S SAE 75W-90 OMV UNIGEAR SAE 80W-90 ORLY AURIGA EP SAE 85W140 ORLY LYRA EP PAKELO GEAR OIL EP GL-5 SAE 80W/90 PAKELO GEAR OIL EP GL-5 SAE 85W/140 PAKELO GLOBAL GEAR CBS SAE 75W/90 PAKELO GLOBAL GEAR DLS SAE 85W/140 PAKELO GLOBAL GEAR DLS SAE 85W/90 PAKELO GLOBAL GEAR SA SAE 80W/90 PAKELO GLOBAL GEAR SA SAE 85W/140 PAKELO GLOBAL GEAR SA SAE 85W/90 PAKELO GLOBAL MULTIGEAR CBS PAKELO GLOBAL MULTIGEAR CBS DLS PAKELO GLOBAL MULTIGEAR SA SAE 80W/140 PAKELO GLOBAL MULTIGEAR TS SAE 75W/90 PANOLIN SUPER DUTY 80W/90 PANOLIN SUPER DUTY 85W/140 PANOLIN SUPER DUTY 90 PANOLIN SUPER DUTY SYNTH 75W/90 PANOLIN TOPGEAR 80W/90 TRAXON 80W-90 TRAXON 85W-140 GALP TRANSOIL HP 80W90 GALP TRANSOIL HP 85W140 GALP TRANSVEX TDL 75W90 GALP TRANSVEX TDL 85W140 PO UNI. KEBAN EP MAN 80W/90 PRISTA EP 85W140 PRISTA EP 90 RORED HD-A SAE80W-90 RORED HD-A SAE85W-140 RORED HD-A SAE90 HIPOL EXTRA GL-5 80W-90 HIPOL SUPER GL-5 80W-90 HIPOL SUPER GL-5 85W-90 RAVENOL GETR.OEL 75W-90 VSG VOLLSYNTH.

1.56.5

Continued

RAVENSBERGER SCHMIERSTOFFVERTRIEB GMBH, WERTHER/D RAVENSBERGER SCHMIERSTOFFVERTRIEB GMBH, WERTHER/D RAVENSBERGER SCHMIERSTOFFVERTRIEB GMBH, WERTHER/D RAVENSBERGER SCHMIERSTOFFVERTRIEB GMBH, WERTHER/D REPSOL LUBRICANTES, MADRID/E S.A.E.L., MADRID/E S.A.E.L., MADRID/E SHARJAH NATIONAL LUBE OIL CO. LTD., SHARJAH/UAE SHARJAH NATIONAL LUBE OIL CO. LTD., SHARJAH/UAE SHELL ASEOL AG, BERN 5/CH SHELL ASEOL AG, BERN 5/CH SHELL ASEOL AG, BERN 5/CH SHELL ASEOL AG, BERN 5/CH SHELL BRASIL, BARRA DA TIJUCA - RIO DE JANEIRO/BR SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D STATOIL LUBRICANTS, STOCKHOLM/S STATOIL LUBRICANTS, STOCKHOLM/S STRUB + CO AG, REIDEN/CH STRUB + CO AG, REIDEN/CH SUOMEN PETROOLI OY, HAMINA/FIN SUOMEN PETROOLI OY, HAMINA/FIN SUOMEN PETROOLI OY, HAMINA/FIN SYNECO SPA, SAN GIULIANO MILANESE/I SYNECO SPA, SAN GIULIANO MILANESE/I TEDEX PRODUCTION SP.Z.O.O., TOMASZOW MAZOWIECKI/PL TEXACO BRASIL S.A., RIO DE JANEIRO/BR TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F UNIL S.A., SAUMUR CEDEX/F VALVOLINE EUROPE, DORDRECHT/NL VALVOLINE EUROPE, DORDRECHT/NL VALVOLINE EUROPE, DORDRECHT/NL VALVOLINE EUROPE, DORDRECHT/NL VALVOLINE EUROPE, DORDRECHT/NL VALVOLINE EUROPE, DORDRECHT/NL VEEDOL INTERNATIONAL, PANGBOURNE READING/GB VEEDOL INTERNATIONAL, PANGBOURNE READING/GB YACCO, ST PIERRE LES ELBEUF/F YACCO, ST PIERRE LES ELBEUF/F

1.56.6

ZF Friedrichshafen AG / List of lubricants TE-ML 07, edition 01.04.2005

RAVENOL HYP. EPX GETR.ÖL 85W-140 GL5 RAVENOL HYPOID EPX GETR.-OEL 80W-90 GL 5 RAVENOL HYPOID EPX GETRIEBE-OEL SAE 90 GL-5 RAVENOL SLG SPEC. LKW GETR.ÖL 80W90 CARTAGO EP SAE 90 GULF MULTIPURPOSE GEAR LUBRICANT 85W-90 GULF SYTHETIC GEAR LUBRICANT 75W-90 SHARLU MP GEAR LUBE 80W/90 (GL-5) SHARLU MP GEAR LUBE 85W/140(GL-5) ASEOL TOPRESS 320 ASEOL TOPRESS 80W-90 ASEOL TOPRESS 85W-140 ASEOL TOPRESS 85W-90 SHELL SPIRAX A 90 SHELL SPIRAX ASX 75W-90 SHELL SPIRAX AX 80W-90 SHELL SPIRAX AX 85W-140 SHELL SPIRAX AX 90 SHELL SPIRAX MB 90 SHELL SPIRAX MX 80W-90 SHELL SPIRAX ST 80W-140 WINTERSHALL GETRIEBEFLUID AFS WINTERSHALL GETRIEBEFLUID SML 80W-90 WINTERSHALL WIOLIN HYPOID-GETRIEBEÖL 80W-90 WINTERSHALL WIOLIN HYPOID-GETRIEBEÖL 85W-140 WINTERSHALL WIOLIN HYPOID-GETRIEBEÖL 90 GEARWAY G5 80W-90 GEARWAY G5 85W-140 STRUB MULTIGEAR SGO 80W-90 VULCOGEAR SYNT SGX 75W-90 TEBOIL HYPOID SAE 75W-140 TEBOIL HYPOID SAE 75W-90 TEBOIL HYPOID SAE 80W-140 AMPLEX 80W90 AMPLEX 85W140 TEDEX SUPER GEAR OIL (3343ML) SAE 80W90 MULTIGEAR EP SAE 90 ANTAR EPR 90 ANTAR EPR 80W-90 ANTAR EPS 75W-90 ANTAR UNIVERSAL FE 80W-140 ANTAR UNIVERSAL FE 80W-90 FINA PONTONIC A 80W-140 FINA PONTONIC FDL 75W-90 FINA PONTONIC MDL 80W-90 FINA PONTONIC MP 80W-90 FINA PONTONIC MP 85W-140 FINA PONTONIC MP 85W-90 TOTAL EP B 80W-90 TOTAL EP B 85W-90 TOTAL EP-B 85W-140 TOTAL TRANSMISSION BM 75W-90 TOTAL TRANSMISSION MDL 80W-90 TOTAL TRANSMISSION RS FE 80W-140 TOTAL TRANSMISSION RS FE 80W-90 TOTAL TRANSMISSION SYN FE 75W-90 TRANSELF BM 75W-90 TRANSELF SYNTHESE FE 75W-90 TRANSELF TYPE B 80W-90 TRANSELF TYPE B 90 TRANSELF UNIVERSAL FE 80W-140 TRANSELF UNIVERSAL FE 80W-90 UNIL OPAL GEAR ZF 80W90 HIGH PERFORMANCE GEAR OIL GL-5 90 SYNPOWER GEAR OIL TDL 75W-90 VALVOLINE STX GEAR OIL GL-5 80W-140 VALVOLINE STX GEAR OIL GL-5 80W-90 VALVOLINE SYNPOWER STX GL-5 75W-140 VALVOLINE SYNPOWER STX GL-5 75W-90 VEEDOL MULTIGEAR B SAE 90 VEEDOL MULTIGEAR C SAE 85W-140 BVX 1000 BVX C 100 80W-90

09 / 2005

Continued

ZELLER + GMELIN GMBH & CO., EISLINGEN/D ZELLER + GMELIN GMBH & CO., EISLINGEN/D ZELLER + GMELIN GMBH & CO., EISLINGEN/D ZEPPELIN BAUMASCHINEN GMBH, GARCHING/D ZF FRIEDRICHSHAFEN AG, FRIEDRICHSHAFEN/D

09 / 2005

ZF Friedrichshafen AG / List of lubricants TE-ML 07, edition 01.04.2005

DIVINOL GEAR OIL STO SAE 80W-90 DIVINOL HYPOID-GETRIEBEÖL SAE 85W-140 DIVINOL SYNTHOGEAR SAE 75W-90 ZEPPELIN SPEZIALGETRIEBEÖL GL-4/GL-5 80W-90 ZF-ECOFLUID X

1.56.7

Continued

ZF Friedrichshafen AG / List of lubricants TE-ML 07, edition 01.04.2005

Lubricant class 07B Super tractor oil (STOU) Viscosity grades: SAE 10W-30 / 10W-40 / 15W-30 / 15W-40 / 20W-40 Manufacturer (07B)

Trade name (07B)

ADDINOL LUBE OIL GMBH, LEUNA/D AGIP SCHMIERTECHNIK GMBH, WÜRZBURG/D ARAL AG, BOCHUM/D ARAL AG, BOCHUM/D AVIA MINERALÖL-AG, MÜNCHEN/D AVIA MINERALÖL-AG, MÜNCHEN/D BAYWA AG, MÜNCHEN/D BAYWA AG, MÜNCHEN/D BLASER SWISSLUBE AG, HASLE-RÜEGSAU/CH BP INTERNATIONAL, PANGBOURNE, READING/GB BP INTERNATIONAL, PANGBOURNE, READING/GB BP INTERNATIONAL, PANGBOURNE, READING/GB BUCHER AG LANGENTHAL, LANGENTHAL/CH CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL INTERNATIONAL, PANGBOURNE READING/GB CEPSA LUBRICANTS S.A., MADRID/E CEPSA LUBRICANTS S.A., MADRID/E CHEVRONTEXACO, GHENT/B CHEVRONTEXACO, GHENT/B CHEVRONTEXACO, SYDNEY/AUS CHEVRONTEXACO, SYDNEY/AUS CONDAT LUBRIFIANTS, CHASSE SUR RHONE/F CONDAT LUBRIFIANTS, CHASSE SUR RHONE/F DE OLIEBRON B.V., ZWIJNDRECHT/NL EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA FL SELENIA S.P.A., VILLASTELLONE/I FL SELENIA S.P.A., VILLASTELLONE/I FL SELENIA S.P.A., VILLASTELLONE/I FL SELENIA S.P.A., VILLASTELLONE/I FL SELENIA S.P.A., VILLASTELLONE/I FL SELENIA S.P.A., VILLASTELLONE/I FL SELENIA S.P.A., VILLASTELLONE/I FL SELENIA S.P.A., VILLASTELLONE/I FL SELENIA S.P.A., VILLASTELLONE/I FL SELENIA S.P.A., VILLASTELLONE/I FUCHS PETROLUB AG, MANNHEIM/D FUCHS PETROLUB AG, MANNHEIM/D GENOL GMBH & CO., WIEN/A GINOUVES GEORGES SA, LA FARLEDE/F HAFA, PARIS/F HAFA, PARIS/F HANDEL MIJ NOVIOL B.V., NIJMEGEN/NL IGOL FRANCE SA, AMIENS/F INA MAZIVA RIJEKA, RIJEKA/HR KRAFFT S.A., ANDOAIN/E KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL MAGNA INDUSTRIAL CO. LIMITED, HONG KONG/HK MEGUIN GMBH & CO. KG MINERALOELWERKE, SAARLOUIS/D MINERALÖL-RAFFIN. DOLLBERGEN, UETZE-DOLLBERGEN/D MINERALÖL-RAFFIN. DOLLBERGEN, UETZE-DOLLBERGEN/D MORRIS LUBRICANTS, SHREWSBURY/GB NOVA STILMOIL SPA, MODENA/I OEL-BRACK AG, HUNZENSCHWIL/CH OMV AG, SCHWECHAT/A ORLY INTERNATIONAL G.I.E., VIEUX-THANN/F ORLY INTERNATIONAL G.I.E., VIEUX-THANN/F PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I

ADDINOL SUPER TRAKTOR MU 1045 SAE 10W-40 AUTOL AGROTECH SAE 10W-30 ARAL SUPER TRAKTORAL 10W-40 ARAL SUPER TRAKTORAL SAE 10W-30 TRACTAVIA FE 10W-40 TRACTAVIA SPEZIAL 10W-30 BAYWA SUPER 2000 CD-MC 10W-30 BAYWA SUPER MULTISYN SL 10W-40 BLASOL STOU 10W40 BP TERRAC SUPER UNIVERSAL 10W-40 BP TERRAC UNIVERSAL 15W-30 BP TERRAC UNIVERSAL 15W-40 MOTOREX FARMER TRAC CASTROL AGRI MP 15W-30 CASTROL AGRI MP 15W-40 CASTROL AGRI MP PLUS 10W-30 CASTROL AGRI MP PLUS 10W-40 CEPSA AGRO PLUS 15W-40 ERTOIL MULTI AGRO 15W-40 MULTITEX PREMIUM 10W-40 SUPER UNIVERSAL TRACTOR OIL PREMIUM 10W-30 CALTEX SUPER TRACTOR SAE 15W-40 CALTEX SUPER TRACTOR SAE 20W-40 MAXITRACT 15W40 VICAM TP 10W40 MULTITRAC 15W30 ESSO UNIFARM 10W-30 ESSO UNIFARM 15W-40 MOBIL AGRI EXTRA 10W-40 MOBIL AGRI SUPER 10W-30 MOBIL AGRI SUPER 15W-40 AKCELA MULTI TRACTOR (SAE 10W40) AKCELA SUPER UNIVERSAL (SAE 10W30) AKCELA SUPER UNIVERSAL (SAE 15W40) AKROS MULTI VT SAE 10W30 AKROS UNIVERSAL SAE 10W30 AKROS UNIVERSAL SAE 15W40 AMBRA UNIVERSAL SAE 10W30 AMBRA UNIVERSAL SAE 15W40 AMBRA VT SPECIAL (10W40) ARBOR UNIVERSAL (SAE 15W40) TITAN HYDRAMOT 10W-40 MC TITAN HYDRAMOT MC 10W-30 GENOL TRAC-SYN 1040 YORK 743 10W40 POLYMAT SAE 10W-40 SUPER TUT SAE 15W-40 KENDALL MULTIFARM SAE 15W-30 AGRI MU SUPER 10W40 INA AGRINA 15W-30 STOU 15W40 Q8 T 1000 D SAE 10W-30 Q8 T 1000 D SAE 15W-30 Q8 T 1000 SAE 10W-30 Q8 T 1000 SAE 15W-30 OMEGA 603 SAE15W40 MEGOL SUPER TRAKTORENOEL STOU SAE 10W-30 PENNASOL SUPER TRACTOR UNIVERSALOEL STOU 10W30 PENNASOL SUPER TRACTOR UNIVERSALOEL STOU 15W30 SUPER VERSITRAC MF LUBE+ AGRILUBE UNIVERSAL 10W30 MIDLAND STOU OMV AUSTROTRAC SAE 10W-40 ORLY APOLLO SAE 15W-40 ORLY STOU LUNA PAKELO STOU FLUID SAE 15W/40

1.56.8

09 / 2005

Continued

ZF Friedrichshafen AG / List of lubricants TE-ML 07, edition 01.04.2005

PANOLIN AG, MADETSWIL/CH PANOLIN AG, MADETSWIL/CH PETROGAL S.A., LISBOA/P RAVENSBERGER SCHMIERSTOFFVERTRIEB GMBH, WERTHER/D REPSOL LUBRICANTES, MADRID/E SHELL ASEOL AG, BERN 5/CH SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D STRUB + CO AG, REIDEN/CH SYNECO SPA, SAN GIULIANO MILANESE/I TAMOIL PETROLI S.P.A., MILANO/I TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F UNIL S.A., SAUMUR CEDEX/F VALVOLINE EUROPE, DORDRECHT/NL VALVOLINE EUROPE, DORDRECHT/NL VALVOLINE EUROPE, DORDRECHT/NL

09 / 2005

PANOLIN STOU 10W/30 PANOLIN STOU 15W/30 GALP UNIAGRO RAVENOL SUTO SAE 15W-30 AGRO CERES STOU SAE 15W40 ASEOL MULTITRAC SUPER 10W-30 SHELL HARVELLA T 10W-30 SHELL HARVELLA T 15W-40 SHELL HARVELLA TX 10W-40 WINTERSHALL PRIMANOL 10W-30 WINTERSHALL PRIMANOL 10W-40 SUPER TRACTOROEL UNI.10W-30 (STOU) MULTITRACTOR STOU 15W40 SUPER TRACTOR SAE 15W/40 ANTAR AGRIA GR4 SAE 10W-40 ANTAR AGRIA SUPER FM SAE 15W-40 FINA SUPER UNIVERSAL OIL MF SAE 10W-40 FINA SUPER UNIVERSAL OIL SAE 15W-30 FINA SUPER UNIVERSAL OIL SAE 15W-40 TOTAL MULTAGRI MAX SAE 10W-40 TOTAL MULTAGRI MS SAE 15W-40 TOTAL MULTAGRI SUPER 10W-30 TOTAL MULTAGRI SUPER 15W-40 TOTAL MULTAGRI SUPER SAE 15W-30 TRACTORELF ST3 SAE 15W-30 TRACTORELF ST3 SAE 15W-40 TRACTORELF ST4 SAE 10W-40 XANTHOS 10W40 VALVOLINE STOU 10W-30 VALVOLINE STOU 15W-30 VALVOLINE STOU 15W-40

1.56.9

Continued

ZF Friedrichshafen AG / List of lubricants TE-ML 07, edition 01.04.2005

Lubricant class 07C Engine oil Viscosity grades: SAE 5W-30 / 5W-40 / 10W-30 / 10W-40 / 15W-30 / 15W-40 Manufacturer (07C)

Trade name (07C)

ADDINOL LUBE OIL GMBH, LEUNA/D ARAL AG, BOCHUM/D AVIA MINERALÖL-AG, MÜNCHEN/D AVIA MINERALÖL-AG, MÜNCHEN/D BLASER SWISSLUBE AG, HASLE-RÜEGSAU/CH BLASER SWISSLUBE AG, HASLE-RÜEGSAU/CH BP INTERNATIONAL, PANGBOURNE, READING/GB BP INTERNATIONAL, PANGBOURNE, READING/GB CEPSA LUBRICANTS S.A., MADRID/E CEPSA LUBRICANTS S.A., MADRID/E CEPSA LUBRICANTS S.A., MADRID/E CHEVRONTEXACO GLOBAL LUBRICANTS, SAN RAMON/USA GINOUVES GEORGES SA, LA FARLEDE/F GINOUVES GEORGES SA, LA FARLEDE/F KOMPRESSOL-OEL VERKAUFS GMBH, KÖLN/D KRAFFT S.A., ANDOAIN/E KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL LIQUI MOLY GMBH, ULM/D MEGUIN GMBH & CO. KG MINERALOELWERKE, SAARLOUIS/D NOVA STILMOIL SPA, MODENA/I PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I RAVENSBERGER SCHMIERSTOFFVERTRIEB GMBH, WERTHER/D RAVENSBERGER SCHMIERSTOFFVERTRIEB GMBH, WERTHER/D REPSOL LUBRICANTES, MADRID/E SHELL ASEOL AG, BERN 5/CH SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D STRUB + CO AG, REIDEN/CH SUN OIL COMPANY (BELGIUM) N.V., AARTSELAAR/B VEEDOL INTERNATIONAL, PANGBOURNE READING/GB

ADDINOL SUPER STAR MX 1547 SAE 15W-40 ARAL MULTITURBORAL SAE 15W-40 AVIA MULTI CFE PLUS 10W-40 AVILUB MULTI HDC-B 15W40 BLASOL MHP 10W40 BLASOL MHP 15W40 BP VANELLUS C6 GLOBAL PLUS SAE 10W-40 ECONO VERITAS HDE SAE 10W-40 CEPSA DIESEL TURBO SHPD 15W-40 CEPSA SUPER MULTIGRADO SHPD 15W-40 CEPSA ULTRA SHPD 15W-40 CHEVRON DELO 400 MULTIGRADE SAE 15W-40 YORK 645 SAE 15W40 YORK 740 SAE 15W40 KOMPRESSOL-ULTRALUB C SAE 15W-40 SUPERMULTIGRADO D 15W40 Q8 T 500 SAE 15W-40 Q8 T 710 SAE 15W-40 TOURING HIGH TECH DIESELSPEZIALOIL SAE 15W-40 MEGOL MOTORENOEL HD-C3 SAE 15W-40 ORION SUPER PLUS 15W40 PAKELO GOLDEN D/G SAE 15W/40 PAKELO PKO HD SUPER 4 SAE 15W/40 RAVENOL FORMEL DIESEL SUPER 15W-40 RAVENOL TURBO-C HD-C 15W-40 SUPERTURBO DIESEL SAE 15W40 ASEOL PERLA 15W-40 SHELL RIMULA X 15W-40 WINTERSHALL MULTI REKORD 15W-40 WINTERSHALL MULTI REKORD TOP, SAE 15W-40 SUPER MULTI TURBO 15W-40 FORZA SAE 15W40 VEEDOL DIESELSTAR

1.56.10

09 / 2005

Continued

ZF Friedrichshafen AG / List of lubricants TE-ML 07, edition 01.04.2005

Lubricant class 07D Engine oil (API CD/CE/CF-4/CF/CG-4/CH-4/CI-4/SF/SG/SH/SJ/SL or ACEA-categories A/B/E) Product groups in accordance with page 1

SAE viscosity grades

Powershift transmissions Swing drives

20W-20 / 30 / 5W-30 / 5W-40 / 10W-30 / 10W-40 / 15W-30 / 15W-40

Mobile mixer drives

10W-40 / 15W-40

Note: All mineral oil-based gear oils which satisfy the above specifications may be used.

09 / 2005

1.56.11

Continued

ZF Friedrichshafen AG / List of lubricants TE-ML 07, edition 01.04.2005

Lubricant class 07E Biodegradable lubricant in accordance to Environmental labels RAL-UZ 79 (Blauer Engel), VAMIL-regeling Viscosity grade: SAE 75W-80 Manufacturer (07E)

Trade name (07E)

PANOLIN AG, MADETSWIL/CH

PANOLIN BIOFLUID ZFH

Only swing drives: Biodegradable lubricant in accordance to Environmental labels RAL-UZ 79 (Blauer Engel), VAMIL-regeling, Swedish standard 15 54 34 Viscosity grade: ISO VG 46x Manufacturer

Trade name

PANOLIN AG, MADETSWIL/CH

PANOLIN HLP SYNTH 46

Instructions on the use of biodegradable lubricants: The oil manufacturer`s change-over directives included in the product description are to be observed when change-over to biodegradable lubricants is effected.

1.56.12

09 / 2005

Service Manual

SUBGROUP - INDEX Section

Group

Type

Special tools general

2.01.1

A 309 LI 20221A 311 LI 20222A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001R 313 LI 27752R 317 LI 18161-

Special tools for diesel engines

2.03.1

A 309 LI 20221A 311 LI 20222A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001R 313 LI 27752R 317 LI 18161-

Special tools for hydraulic systems

2.05.1

A 309 LI 20221A 311 LI 20222A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001R 313 LI 27752R 317 LI 18161-

Special tools for electric systems

2.06.1

A 309 LI 20221A 311 LI 20222A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001R 313 LI 27752R 317 LI 18161-

Special tools for gears

2.07.1

A 309 LI 20221A 311 LI 20222A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 20012.1

MJFCIFSS

Service Manual

R 313 LI 27752R 317 LI 18161Special tools for axles

2.08.1

A 309 LI 20221A 311 LI 20222A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-

Assembly tools for hydraulic cylinders

2.12.1

A 309 LI 20221A 311 LI 20222A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001R 313 LI 27752R 317 LI 18161-

Mounting device for piston rod bearings

2.13.1

A 309 LI 20221A 311 LI 20222A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001R 313 LI 27752R 317 LI 18161-

Slotted nut wrench for slewing gear

2.14.1

A 309 LI 20221A 311 LI 20222A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001R 313 LI 27752R 317 LI 18161-

Mounting device for slewing gear

2.15.1

A 309 LI 20221A 311 LI 20222A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001R 313 LI 27752R 317 LI 18161-

Mounting device for travel gear

2.16.1

R 313 LI 27752R 317 LI 18161-

2.2 MJFCIFSS

Service Manual

Special tools general

Special tools general for maintenance and repair Picture

No.

Designation

Size

ID no.

Machi ne

1 2

Measuring neck

NW 10 NW 12

7002404 7008688

all types

4

Pressure gauge connection

R 1/2"

7002436

all types

5

Pressure gauge direct connection

R 1/2"

7002435

all types

7

High-pressure hose length

1,000 mm

7002437

all types

1,500 mm

7002475

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

5005180 7402580 5004002 7361345 7362579

8

10 11 12 13 14

Screw coupling assembly, complete

Application

Connection of the pressure gauges to all measuring points (measuring neck no.

1/2 and screw couplings 10-14)

all types

2.01.1 copyright by

MJFCIFSS

Special tools general

Picture

Service Manual

No.

15

Designation

Size

Pressure gauge

ID no.

Machi ne

0-1.6 bar

8042577 8042578

17

0-1.6 bar * 0-10 bar *

Measuring of operating pressures of one or more hydraulic circuits.

5002865

* glycerine dampened

18

0-40 bar *

7361288

19

0-60 bar *

5002867

20

0-250 bar *

7361285

21

0-400 bar *

7500002

22

0-600 bar *

5002866

16

30

Differential pressure measuring kit, consisting of:

10288229

30.1

all types

Application

all types

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

10288155 1 manual measuring device 3010

30.2

10288152 1 data cable

30.3

10288154 2 measuring cables

30.4

0-600 bar

2 pressure sensors 30.5

10288153

10288151 1 power adapter

30.6

7025273

30.7 30.8

Vehicle connecting cable not included in delivery!

Pressure sensor Pressure sensor

6140626 01 6140647 01

33

Fitting

4901372

34

Measuring neck with metal cap

7002404

35

Union nut

4774002

36

Cutting ring

4774001

2.01.2 copyright by

MJFCIFSS

see sensors on page 7

all types

Pressure compensation in connection with tool no. 30

Service Manual

Picture

Special tools general

No.

Designation

Size

ID no.

Machi ne

Application

44

Measuring adapter

8504231

all types

Measuring of current at pump regulation

45

Adapter

9956422

all types

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

44

46

Measuring cable

9956436

all types

Measuring and testing of solenoid valves

60

Piezzo speed

A 2106

10286429

all types

Measuring of engine speed via pulse frequency of injection line

62

Ornel speed meter

HT 460

7006974

all types

Measuring of speed with reflective strips

63

Shimpo speed meter

DT 205

7364284

Strips 64

614063201

with no. 63

2.01.3 copyright by

MJFCIFSS

Special tools general

Picture

Service Manual

No.

Designation

Size Chauvin Arnoux

ID no.

65

Multimeter with digital display

70

Thermometer non-contact (infrared)

72

Thermometer with probe and sensor (magnetic)

80

Hand pump

8145666

82

Sampling valve for oil samples, alternative to hand pump 80

7019068

84

Mineral oil analysis kit *

GTH 1150

no. 1

Machi ne

Application

10018500

all types

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

10024185

all types

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

all types

Sampling of oil for analysis

all types

1 oil sample

7020372

8145660

85

10029626

4 oil samples

86

7018368

6 oil samples

87

7018369

12 oil samples

*Analyses carried out by WAER CHECK Germany, lab report in German 88

Bio oil analysis kit *

no. 3

89

7026817

7026088 *Analyses carried out by WAER CHECK Germany, lab report in German

2.01.4 copyright by

MJFCIFSS

all types

1 oil sample

6 oil samples

Service Manual

Picture

Special tools general

No.

Designation

Size

ID no.

Machi ne

Application

90

REFCO vacuum pump

RD-4

7027552

all types

Maintenance and repair of a/c system

91

ITE filling hose, blue

1,500 mm

7027553

all types

See item 90

92

ITE filling hose, yellow

1,500 mm

7027554

93

ITE filling hose, red

1,500 mm

7027555

94

ITE HGV coupling

253a

7027556

all types

See item 90

95

ITE HGV coupling

254 a

7027557

96

4-valve test fittings

M4WS5 C

7027558

all types

Maintenance and repair of a/c system

100 101 102

Dismantling tool

M37X1 M42X1.5 M48X1.5

9583459 9583521 9583522

all types

Dismantling of grapple bolts

2.01.5 copyright by

MJFCIFSS

Special tools general

Picture

Service Manual

No.

Designation

105

Universal Passfix puller

120

Size M42X1.5 M48X1.5 M58X1.5

ID no.

Machi ne

Application

9584738

all types

Removal of Passfix bolts

Diagnostic instrument

5010474

all types

Diagnostics of D5 WS auxiliary heating

121

Adapter cable

9614382

For connection to cable harness in right bracket

122

Adapter cable

10025620

For direct plugging to the heating device

130

Testing tool for cooling system

7029179

all types

Pressurisation of engine cooling system (leakage test)

140

Torque wrench

10045464

all types

For tightening the hose clamps

150

Hand pump with pressure gauge

10454803

all types

For leakage test of backpressure line at particle filter installation

4-20 Nm

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

Item

Sensors

ID no.

2

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

3

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

6*

6140 624 01

4

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

3*

6140 625 01

2.01.6 copyright by

MJFCIFSS

1001 8329

Service Manual

Special tools general

Item

Sensors

ID no.

5

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

6

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

7

MINIMESS direct connection pressure sensor, 1620 screws

6*

6140 626 01

8

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

3*

6140 647 01

9

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

1*

6140 627 01

10

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

1*

6140 628 01

11

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

1*

1004 1274

12

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

1*

5010 031

13

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

1*

6410 629 01

14

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

0*

6140 630 01

15

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

2*

5009 492

16

DS 03 speed sensor, measuring range 1 to 9999 rpm

1*

6140 631 01

17

Spare reflector foil kit

1*

6140 632 01

18

Magnet holder, for DS 03 speed sensor

1*

6140 633 01

19

Inductive sensor for speed measurement

1*

6140 634 01

Item

Accessory

20

Transport case for RE 3 measuring turbine

1*

6140 635 01

21

MK 12 measuring cable for the connection of the sensors, length 6 m

12*

6140 636 01

22

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

4*

6140 637 01

23

MK 12 measuring cable for the connection of the sensors, length 18 m

1*

6140 638 01

24

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

1*

6140 639 01

25

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

0*

6140 640 01

26

DPU 411 thermal printer with power adapter

0*

6140 641 01

27

Thermal paper rolls for DPU 411

0*

6140 642 01

28

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

0*

6140 643 01

29

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

1*

9684 327

30

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

1*

6140 648 01

31

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

0*

6140 646 01

32

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

1*

6004 401

33

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

34

Measuring adapter for current measurement A 309 - R 317 Litronic

1*

8504 231

36

Y-adapter for current measuring Junior Timer plug

1*

9956 436

37

3-to-2 pin plug adapter

1*

9956 422

1002 7591 5718 886 08

ID no.

* number of units for recommended basic equipment

2.01.7 copyright by

MJFCIFSS

Special tools general

Service Manual

2.01.8 copyright by

MJFCIFSS

Service Manual

Special tools for diesel engines

Special tools for diesel engines for the maintenance and adjustment of DEUTZ diesel engines Picture

no.

Designation

Size

1a

Compression pressure tester

1b

Diagram sheets for item 1a

2

Connecting piece for compression pressure tester

3

Nozzle tester

10

V-belt measuring instrument

14

Torx too kit

ID no.

8008782

100 Units

Krikit

Machi ne

Application

all types

Measurement of compression pressure

7019856

all types

Insert at the position of the injection valve

7361236

all types

Testing of injection nozzles

7019872

all types

for measurement of V-belt tension

7014716

all types

10012817

2.03.1 copyright by

MJFCIFSS

Special tools for diesel engines

Picture

no.

22

Service Manual

Designation

Size

Torx insert key kits for (long design)

ID no.

Machi ne

E 14

7019851

all types

23

E 18

7021668

24

E 20

7019852

WS 15

7019853

all types

25

Socket for injection nozzle (long design) (union nut)

30

Torque wrench

7019854

all types

32

Insert key 1/4Â&#x201C;

7019855

A 312 R 317

35

Turning key

7021680

A 312 R 317

2.03.2 copyright by

MJFCIFSS

Application

Service Manual

Picture

Special tools for diesel engines

no.

Designation

Size

ID no.

Machi ne

40

Mounting device for regulating rod

7021677

all types

50

Mounting tool for coolant thermostat

7019861

A 312 R 317

54

Piston ring mounting pliers

7009319

all types

60

Dismantling tool (hooks) for crank shaft seals (front and rear)

7019858

A 312 R 317

64

Mounting tool for crank shaft seals, front (fan side)

7021676

A 312 R 317

Application

2.03.3 copyright by

MJFCIFSS

Special tools for diesel engines

Picture

no.

Service Manual

Designation

Size

ID no.

Machi ne

66

Mounting tool for crank shaft seal, rear (flywheel side)

7021675

A 312 R 317

68

Mounting tool for crank shaft seal (rear)

7019859

A 309 / A 311/ R 313

70

Mounting tool for crank shaft seal (front)

10294728

A 309 / A 311 / R 313

75

Claw wrench for injection lines

10294729

A 309 / A 311 / R 313

80

Valve seal clamp

10294730

all types

WS 17

2.03.4 copyright by

MJFCIFSS

Application

Service Manual

Picture

Special tools for diesel engines

no.

Designation

Size

ID no.

Machi ne

85

Turning key (multitooth) for injection pump

10294731

A 309 / A 311/ R 313

90

Wheelspin device

10294732

A 309 / A 311 / R 313

95

Wheelspin device

10294733

A 309 / A 311 / R 313

100

Adjusting bolt for MAG shafts

10294734

A 309 / A 311 / R 313

105

Removing tool for injection nozzle, in conjunction with tool no.

115

10294735

A 309 / A 311 / R 313

Application

2.03.5 copyright by

MJFCIFSS

Special tools for diesel engines

Picture

no.

Service Manual

Designation

Size

ID no.

Machi ne

110

Special key for injection line

10294736

A 309 / A 311 / R 313

115

Removal tool for injection nozzle

8008803

all types

120

Indicator for dial disc

8008789

all types

2.03.6 copyright by

MJFCIFSS

Application

Service Manual

Special tools for hydraulic systems

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

No.

Order no.

Model

SW 17

9359414

all types

SW 19 WS 19

9210371

To adjust primary and secondary pressure-relief valves in the control valve block

7009315

all types

To secure the adjusting screws on the hydraulik aggregates

short long

SW 10 WS 10 SW 13 SW 13 l SW 17 SW 19 SW 19 l

30

Mounting sleeve

See chapter 2.12

all types

To assemble the O-ring and stepseal ring on hydraulic cylinder pistons, variable-displacement pump pistons and variable dispacement motor regulating pistons

40

Expanding sleeve

See chapter 2.12

all types

for application, see also tool no. 40

50

Piston wrench

See chapter 2.12

all types

10

Desciption

Size

Special wrench for pressure -relief valves

11

20

Safety cap short long

7023492 7615515 7380629 7009316 7009317

Application

21 22 23 24 25

Details for manufact. see page 2.12-01

2.05.1

A 309 LI - R 317 LI copyright by

MJFCIFSS

Special tools for hydraulic systems

Picture

No. 60

Service Manual

Desciption

Size

Piston wrench

Order no.

Model

0541333

all types

To remove and tighten piston nuts

9245656

all types

To remove and install damper pins on hydraulic cylinders with damper on piston/rod side.

M16

9951120

all types

M20

9959261

To dismantle the piston rod bearing from the hydraulic cylinder

M24

9959262

SW WS

Application

61 See chapter 2.12 62 63 64 70

Socket wrench for threaded bushing

SW 41 WS 41

80

Mounting tool for piston rod bearings

90

Filling device, complete with adapter and filling hose

W24,3 2x1/14Â&#x201C; 3,0m W24.3 2x1/14Â&#x201D; 3.0m

8145359

all types

To check and refill diaphragm and piston type accumulators

110

Rod

M6

9288234

A 900C A 904C

Used to remove and install piston of pressure balance on LSC - control valve block

120

Allen key

9922975

all types

To remove and install the check valves in connection K (with radiator bypass valve)

2.05.2

A 309 LI - R 317 LI copyright by

MJFCIFSS

Service Manual

Picture

Special tools for hydraulic systems

No.

Desciption

Size

Order no.

Model

Application

135

Wrench

Ø 10 mm

10114826

A 900C A 904C

To remove the check valve 123 (LUDV system)

140

Clamping device for spool

Ø 20 mm

10017281

all types

To clamp the spool during disassembly/reassembly

Ø 25 mm

10017282

Ø 32 mm

10017283

Ø 25 mm Ø 22 mm Ø 45 mm Ø 25 mm

9951457

all types

To assemble the Glyd-ring and scraper ring on the plunger piston of the hydraulic LIKUFIX coupling

00A7.

300

7405073

all types

To retain content of hydraulic tank during repair work on the hydraulic system

160

Montagehülse

161 162 163

180

Vacuum pump complete, consisting of: pump no. 180, vacuum regulation valve no.

181 with seal, hose with filter no. 187

181

Vacuum regulation valve complete:

184 185 186

9951508 9966421 951458

10097130

Tank fitting, consisting of: GE 165 fitting Cone reducing coupling 16/85 Straight nipple

7002240 7407155 7024875

2.05.3

A 309 LI - R 317 LI copyright by

MJFCIFSS

Special tools for hydraulic systems

Service Manual

2.05.4

A 309 LI - R 317 LI copyright by

MJFCIFSS

Service Manual

Special tools for electric systems

Special tools for electric systems for the maintenance and repair of electrical plug-type connectors

Fig. 1

Mate-N-LOK and DT plugs

Fig. 2

Juniortimer and JPC plugs

2.06.1 copyright by

MJFCIFSS

Special tools for electric systems

Picture

No.

Service Manual

Desciption

Size

Order no.

Model

10

To crimp contacts for MATE-NLOK 1.5mm2 leads

7367025

all types

12

To crimp contacts for MATE-NLOK 2.5mm2 connectors

7366314

all types

15

Extraction tool to remove crimped contacts from MATE-N-LOK connectors

7366655

all types

20

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

6202619

all types

21

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

6202620

22

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

6202591

23

Pin contact for 2.5 mm2 wires fo MATE-N-LOCK connectors

6202592

28

Hand-held tool to crimp contacts (according to MIL-C5015, VG952234, VG 955342)

7367086

29

Crimp turret to crimp contacts DEUTSCH-type connectors with special tool no. 28

7409779

30

Tool to crimp contacts of DEUTSCH - type connectors

8503647

2.06.2 copyright by

MJFCIFSS

all types

all types

all types

Application

Service Manual

Picture

Special tools for electric systems

No. 32

Desciption

Size

Extraction tool to remove crimped contacts from DEUTSCHtype connectors

33 34 35 36 37

38

Pin contact for wires of DT connectors

Socket contact for wires of DT connectors

39

Stopfen / Plug / Bouchon

55

Extraction tool for WAGO connectors

60

Order no.

Model

Size 4

8503633

all types

Size 8 Size 12 Size 16 Size 20

8503632 8145674 8145673 8503630

Ø 0,81,0 Ø 1,02,0 Ø 2,03,0

7368251

Ø 0,81,0 Ø 1,02,0 Ø 2,03,0

7368252

Application

all types

7368406 6905271

7368405 6905272

7368253 777-310

7022773

all types

IC extraction tool

8042630

all types

61

IC mounting tool

8042629

70

Ergocrimp pliers

6004391

all types

To crimp contacts for wires of JPT (Tyco) connectors

2.06.3 copyright by

MJFCIFSS

Special tools for electric systems

Picture

No.

Service Manual

Desciption

Size

Order no.

Ergocrimp matrix

Model all types

Application To crimp contacts for leads

72

0.5-2.5 mm2

10016253

Junior Power Timer Nr./no.

927777-3 / 927779-3 / 927846-2

73

0.5-2.5 mm2

10016255

Junior power Timer/EDS Nr./no. 929938-3 double spring contact no.

929940-3

74

0.5-2.5 mm2

10016256 flat adapter no. 963745-1 / 963746-1

80

Extraction tool

7415334

all types

To remove crimped contacts from JPT (Tyco) connectors

90

Crimp plier

10016251

all types

To crimp littlefuse contacts for leads of JPT (Tyco) connectors, see also no.

92.

92

Ergocrimp matrix

10016252

all types

In connection with no. 90 and used to crimp contacts for leads

0.5 mm2 -3.32 mm2

receptacle no. 913053/ 913065 / 913066 / 913067 / 913069 / 913079 Double spring contact no.

913071 / 913072

2.06.4 copyright by

MJFCIFSS

Service Manual

Special tools for gears

Special tools for gears for the maintenance and repair of gear systems Picture

No.

Equip ment

Description

Size

ID no.

Application

10

Slotted nut wrench for slewing gear mechanism

SAT 225

9202820

all types

Releasing and tightening of slotted nuts in drive/slewing gear mechanisms (SAT drawing, see page 2.1401)

20

Mounting device

SAT 225

9202825

A 309 R 317

Dismantling and assembly of brake housing/multi-disc brake for SAT slewing gear mechanisms (SAT drawing, see page 2.15-01)

30

Mounting device

FAT 350/022 FAT 350/032

9981445

Rmachines

Tool used to dismantle and mount the multi-disc brake of the FAT slewing gear mechanism (drawing, see page 2.16-01)

35

Mounting device for slide ring seals

FAT 350/022 FAT 350/032

8503594

Rmachines

For the mounting of slip ring seals in FAT travel gear systems

2.07.1 copyright by

MJFCIFSS

Special tools for gears

Service Manual

2.07.2 copyright by

MJFCIFSS

Service Manual

Special tools for axles

Special tools for axles for the maintenance and repair of axles Picture

no.

10

Designation

Size

Collet chuck for axles Chuck tip

11

ID no.

7009536

Machin e

Application

all types

Used to top in and top out the snap ring into/from the planetary gear of the axles

Used to loosen and tighten slotted nuts in planetary gears / axles.

5 mm

8145768

6 mm

8145769

AP/APL 745/ 755

7013102

A 314 / A 316

21

AP 745 TR* AP 755 TR*

7021789

A 314 / A 316

22

AP 755 HD APL 755 HD

7014452

A 316 Industry

AP/APL 745 APL 755

7013101

A 314 / A 316

31

AP 745 TR* AP 755 TR*

7029469

A 314 / A 316

32

AP/APL 755 HD

7013920

AP/APL 745 TR* APL 755

7024975

A 316 Industry A 314 / A 316

Chuck tip 12

20

30

35

Slotted nut wrench for axles

Centring disc

Centring ring

In conjunction with tool no.

20-22

In conjunction with tool no.

30

2.08.1 copyright by

MJFCIFSS

Special tools for axles

Picture

Service Manual

no.

40

Designation

Size

Mounting tool

AP/APL 745 AP 745 TR*

ID no.

7024127

Machin e A 314

Application Used to insert the cassette seal ring in the hub / axles.

A 314

APL 755 42

AP 755 TR*

7024974

A 316

44

APL 755 HD

7024973

46

AP 755 HD

7029525

A 316 Industry A 316 Industry

AP/APL 745 APL 755

7019632

AP/APL 755 HD

7024131

A 316 Industry

M 16 x 1.5

7019556

A 314 / A 316

Used to measure the pad wear at the ZP axles.

A 309 / A 312

Used to measure the pad wear at the multi-disc brake

A 316

Used to loosen and tighten the slotted nuts in the planetary housing / hub carrier

50

Slip bushing, 2-part

51

60

Measuring screw for pad wear

65

Measuring tool for pad wear

70

Slotted nut wrench for axles

MS-E 3060 MT-E 3060

A 314 A 316

10346444

2.08.2 copyright by

MJFCIFSS

Used to mount the brake piston into the hollow wheel.

Service Manual

Picture

Special tools for axles

no.

Designation

Size

ID no.

Machin e

Application

75

Gripping piece

MS-E 3060

10354109

A 316

Used to remove the inner bearing race from the joint housing.

In conjunction with tool no.

78

78

Removal insert

MS-E 3060

7011520

A 316

80

Removing tool

MS-E 3060

7026311

A 316

Used to remove the outer bearing race from the joint housing.

In conjunction with tool no.

90

85

Removing tool

MS-E 3060

10353377

A 316

Used to pull the shaft seal ring and the bushing from the axle housing and the joint housing.

In conjunction with tool no.

90

90

Counter piece

MS-E 3060

7026310

A 316

2.08.3 copyright by

MJFCIFSS

Special tools for axles

Picture

Service Manual

no.

Designation

Size

ID no.

Machin e

Application

95

Mounting tool

MS-E 3060

7011527

A 316

Used to insert the outer bearing race in the joint housing.

100

Mounting tool

MS-E 3060

10353378

A 316

103

Handle

MS-E 3060

7011518

Used to insert shaft seal rings / bushings in the axle housing and the joint housing.

In conjunction with tool no.

103

* = Drum brake

2.08.4 copyright by

MJFCIFSS

Service Manual

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

Assembly tools for hydraulic cylinders 1

Assembly wrenches for pistons of hydraulic cylinders WN 4121

Fig. 1

Assembly tool (bore for mounting bolt a)

ID no.

a

b

c

d

e

f

g

h

i

Square

9131359

52

38

75

200

10

8

8

15

60

1/2

9131362

60

44

85

200

14

10

10

15

65

1/2

9231993

68

52

100

220

14

10

10

15

70

1/2

8007364*

75

54

110

220

14

12

10

20

84

3/4

8007364*

80

54

110

220

14

12

10

20

84

3/4

8007365

88

63

120

250

14

12

10

20

90

3/4

8007366

100

78

135

260

14

14

10

20

95

3/4

9919856

115

88

150

300

14

14

10

20

105

3/4

9196978#

125

97

170

320

14

14

10

25

110

3/4

9196978#

130

97

170

320

14

18

15

25

110

3/4

8007367

145

113

185

380

14

18

15

25

120

3/4

9925117

160

125

200

420

14

18

15

25

130

3/4

9131373

175

135

215

450

14

20

19

25

135

3/4

9131376

220

156

280

500

14

30

28

40

158

3/4

0541380

85

72

110

210

11

8

8

15

210

1/2

0542336

120

100

140

240

12

8

9

152

240

1/2

0540947

124

100

150

240

12

8

9

15

240

1/2

0541379

145

125

170

280

11

8

9

15

280

3/4

0540966

160

135

185

280

12

10

9

20

280

3/4

0529897

165

140

190

280

12

10

9

20

280

3/4

Tab. 1

List of assembly wrenches (all dimensions in mm)

Note!

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

2.12.1 copyright by

MJFCIFSS

Assembly tools for hydraulic cylinders

Service Manual

Assembly wrenches for piston nuts

2

Assembly wrenches for piston nuts

Fig. 2

Assembly wrenches for piston nuts

Size of piston nut ID no.

*WS hex.

WS paral.

Slotted nut Ø

Square

ID no.

M30X1.5 - 7006469

44

**

M32X1.5 - 7010262

50

**

M33 X1.5 - 9226916 M36X1.5 - 9875702

41 50

M42X1.5 - 7010163 M42X1.5 - 9970088

9921132

1/2

9211967

62 60

M42X1.5 - 9113734 M50X2 - 4129202

1/2

55 70

M50X2 - 9166795

65

** 1/2

9211967

1/2

9921132

1/2

9921123

1/2

9921123

M56X2 - 9921260

80

1/2

9921124

M60X2 - 4129203

80

1/2

9921124

M65X2 - 9247441

85

1/2

9921133

M68X2 - 9129554

90

1/2

9921124

M76X2 - 9970448

100

3/4

9921125

M85X3 - 9142472

110

3/4

9921125

M95X3 - 9101411

120

3/4

9921126

M100X3 - 9950036

130

3/4

9951123

M110X3 - 9129653 / 9112934

149

3/4

9921127

M120X3 - 9143685

165

3/4

9921128

M130X3 - 9125066

180

3/4

9921129

M150X3 - 9144654

210

3/4

9921131

M170X3 - 5008571

230

3/4

9921134

Tab. 2

List of piston nuts

* width over flats / ** conventional grooved socket spanner

2.12.2 copyright by

MJFCIFSS

Service Manual

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

3

Assembly wrenches for WN 4122 piston rod bearings

Fig. 3

Assembly wrenches for piston rod bearings

ID no.

a

b

c

d

e

f

g

h

i

Square

0541665

76

62

95

210

9

6

7

15

70

1/2

0541666

87,5

72

110

210

10

8

8

15

70

1/2

0541063

92

75

115

210

12

8

8

15

75

1/2

0541064

100

80

120

210

12

10

10

15

80

1/2

0529893

110

90

130

240

12

10

10

15

90

1/2

0542005

115

95

135

240

12

8

10

15

95

1/2

0541667

125

98

150

240

12

10

9

15

98

1/2

0529894

135

110

160

260

12

8

8

15

105

1/2

0540948

140

120

160

260

12

8

8

15

110

1/2

0541661

145

120

170

280

12

10

9

15

110

1/2

0529895

145

120

170

280

12

12

13

15

120

1/2

0540949

150

130

170

280

12

12

12

20

110

3/4

0529896

170

140

200

300

12

14

13

20

110

3/4

0541378

180

160

200

300

12

10

9

20

120

3/4

Tab. 3

List of assembly wrenches

2.12.3 copyright by

MJFCIFSS

Assembly tools for hydraulic cylinders

Service Manual

Assembly wrenches for version 5100 pistons

4

Assembly wrenches for version 5100 pistons

Fig. 4

Assembly wrenches for version 5100 pistons

Size of piston nut

*WS hex.

Øa for mounting bolts

M120X3

175

220

3/4

9584641

M140X3

190

240

3/4

9581705

Tab. 4

WS square

ID no.

List of assembly wrenches

* width over flats

4.1

Assembly wrenches for pistons

Fig. 5 ID no.

Assembly wrenches for pistons a

b

c

d

e

f

g

h

i

Square

9249886

250

204

310

600

14

30

28

30

175

3/4

9249741

260

176

330

600

19

36

35

40

180

3/4

9243215

280

206

354

650

19

36

35

40

190

3/4

Tab. 5

List of assembly wrenches

2.12.4 copyright by

MJFCIFSS

Service Manual

Assembly tools for hydraulic cylinders Mounting and expanding sleeves

4.2

Assembly wrenches with hex nut for pistons

Fig. 6

Assembly wrenches with hex nut for pistons

mm

mm

mm

mm Piston largest Ø

mm

mm

mm

l

mm Piston smallest Ø

*SW 6-KT

4-KT

a

b

c

9600751

80

3/4

170

Ø110

Ø140

Ø160

525

15

9602239

85

3/4

170

Ø115

Ø140

Ø160

525

15

9600418

90

3/4

170

Ø120

Ø150

Ø160

525

15

9597668

100

3/4

170

Ø130

Ø160

Ø180

525

15

9600928

110

3/4

170

Ø160

Ø190

Ø200

525

15

9600769

120

3/4

174

Ø170

Ø200

Ø200

525

15

ID no.

Tab. 6

List of assembly wrenches

* width over flats

5

Mounting and expanding sleeves

Piston Ø

990 mounting sleeve ID no.

991 expanding sleeve ID no.

32

9136418

9136416

32

9113100

9113099

38

9143279

9143280

40

9196902

9136417

40

9580414

9580413

45

9136419

9136417

50

9288953

9288954

63

9170510

9170512

65

9177541

9177540

70

9110556

9110402

80

9227165

9227166

2.12.5 copyright by

MJFCIFSS

Assembly tools for hydraulic cylinders

Service Manual

Mounting and expanding sleeves

Tab. 7

Piston Ã&#x2DC;

990 mounting sleeve ID no.

991 expanding sleeve ID no.

85

9998618

9110404

85

9115710

9115708

90

9227161

9227162

98

9289130

9289131

100

9998626

9110405

105

9951984

9951983

106

9583670

9583671

110

9170509

9170511

110

9960483

9960502

115

9998625

9110406

120

9998778

9110407

125

9227163

9227164

125

9960484

9960503

130

9998624

9110408

135

9285578

9285579

140

9998623

9110409

150

9998622

9110410

160

9998621

9110411

170

9107931

9110412

180

9998619

9110413

180

9107932

9110413

190

9907684

9907701

190

9280862

9280863

200

9107933

9110414

List of mounting and expanding sleeves

2.12.6 copyright by

MJFCIFSS

Service Manual

Assembly tools for hydraulic cylinders Mounting and expanding sleeves

Mounting sleeves used to insert pistons into cylinders

Tab. 8

Piston Ă&#x2DC;

950 mounting sleeve ID no.

65

9177543

80

9231749

90

9248893

90

9248894

100

9248895

110

9248897

120

9248898

130

9248899

140

9177541

140

9952180

160

9248909

190

9281241

210

9281240

250

9951147

260

9284918

950 mounting sleeves

Note!

The mounting sleeve 950 is required to restore the shape of the expanded sealing elements to suit the inside diameter of the cylinder (calibration).

Mounting sleeves used to mount the piston rod bearings on the piston rods

Tab. 9

Piston rod Ă&#x2DC;

960 mounting sleeve ID no.

90

9282761

105

9287177

140

9926806

960 mounting sleeves

Note!

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

2.12.7 copyright by

MJFCIFSS

Assembly tools for hydraulic cylinders

Service Manual

Mounting and expanding sleeves

2.12.8 copyright by

MJFCIFSS

Service Manual

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

Mounting device for piston rod bearings 1

Tool used to dismantle piston rod bearings in hydraulic cylinders

Fig. 1

Mounting device

Thread in flange ring

Thread in bearing head M1

Thread of mounting driver M2

Length of mounting driver L

ID -no.

M12

M16

M10

250

9951120

M16

M20

M12

270

9959261

M20

M24X2

M16

290

9959262

Tab. 1

Mounting devices sizes for various flange ring threads

2.13.1 copyright by

MJFCIFSS

Mounting device for piston rod bearings

Service Manual

Tool used to dismantle piston rod bearings in hydraulic cylinders

2.13.2 copyright by

MJFCIFSS

Service Manual

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

Slotted nut wrench for slewing gear 1

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

Fig. 1

Tab. 1

Slotted nut wrench for Sat 225

Slewing gear type

ID number

SAT 225

9202820

ID numbers of slottet nut wrenches

2.14.1 copyright by

MJFCIFSS

Slotted nut wrench for slewing gear

Service Manual

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

Fig. 2

Technical drawing of slotted nut wrench

SAT

A

B

C

D

E

F

G

H

J

K

L

M

N

O

P

225

90

40

30

55

71.5+0.2

77

100

95

3.8

80

35

30

40

56

7.8

Tab. 2

Dimensions

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

2.14.2 copyright by

MJFCIFSS

Service Manual

Mounting device for slewing gear

Mounting device for slewing gear Tool used to dismantle and mount the multi-disc brake of the slewing gear mechanism SAT 225

Fig. 1

Mounting device of slewing gear mechanisms

Size

SAT 225

A

268

B

40

C

12

D

10

E

10

F

16

G

100

H

117

ID no.

9202825

Tab. 1

List of mounting device sizes

2.15.1 copyright by

MJFCIFSS

Mounting device for slewing gear

Service Manual

2.15.2 copyright by

MJFCIFSS

Service Manual

Mounting device for travel gear

Mounting device for travel gear Tool used to dismantle and mount the multi-disc brake of the FAT 350 travel gear mechanism

Fig. 1

Tab. 1

Technical drawing of mounting device

Size

FAT 350 022 / 032

A

238

B

205

C

100

D

108

E

40

F

18

G

Ă&#x2DC;16

H

15

ID no.

9981445

Dimensions of mounting device (in mm)

2.16.1 copyright by

MJFCIFSS

Mounting device for travel gear

Service Manual

2.16.2 copyright by

MJFCIFSS

Service Manual

SUBGROUP - INDEX Section

Group

Type

Technical data

3.09.1

A 309 LI 20221-

Technical data

3.11.1

A 311 LI 20222-

Technical data

3.12.1

A 312 LI 12363-

Technical data

3.13.1

R 313 LI 27752-

Technical data

3.14.1

A 314 LI 2001-

Technical data

3.16.1

A 316 LI 2001A 316 LI-IND 2001-

Technical data

3.17.1

R 317 LI 18161-

Inspection and maintenance schedule

3.29.1

A 309 LI 20221A 311 LI 20222-

Inspection and maintenance schedule

3.32.1

A 312 LI 12363A 314 LI 2001A 316 LI 2001A 316 LI-IND 2001-

Inspection and maintenance schedule

3.38.1

R 313 LI 27752R 317 LI 18161-

3.1 MJFCIFSS

Service Manual

3.2 MJFCIFSS

Service Manual

Technical data A 309 Litronic

Technical data 1 A 309 Litronic Type 717 Typ Valid from serial number

717 20221

717 29269

General

20221

29269

Weight of basic machine with 2-point support

t

9,05

=

Weight of backhoe bucket attachment (2-point support)

t

10,82

=

Overall length (with blade support)

mm

4230

=

Overall width

mm

2550

=

Overall height without attacment

mm

3110

=

Rear reach from centre/slewing radius

mm

1600 / 1600

=

Ground clearance

mm

320

=

Break-out force at tooth

KN

44,8 / 68,5

=

Max. drawing pull (in offroad gear and max. operating pressure)

KN

71,1

Drive motor Type Power at rated speed according to DIN ISO 9249

KW

Rated speed

min-1

Max. torque

Nm

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

l

Oil quality/oil viscosity and oil change intervals Fuel tank capacity

l

Additional information Hydraulic system Hydraulic pump

Typ

Design

20221

29269

BF 4 M 1012

=

63 (86 PS)

=

2000

=

352 Âą 10 bei1300-1500 min-1

=

15,5

=

see groups 1.50 and 3.29

=

215

=

see group 4.02

=

20221

29269

A 8 VO 55

=

axial piston swash plate double pump

=

Drive power of pump with power control (min. power)

KW

53

=

Max. flow

l/min

212

=

Hydraulic oil volume (oil change with filter)

l

ca.200

=

see groups 1.50 and 3.29

=

Hydraulic oil and filter change intervals Control valve block

Typ

M8/NG 20

=

Rotary connection 7 x

Typ

DDF 720

=

3.09.1

A 309 LI 20221copyright by

MJFCIFSS

Technical data

Service Manual

A 309 Litronic Hydraulic system

20221

29269

Rotary connection 6 x

Typ

815.006

=

Boom cylinder (adjustable and gooseneck equipment) Ø piston / rod

mm

115 / 70

=

Stick cylinder with adjustable attachment Ø piston / rod

mm

90 / 60

=

Bucket cylinder Ø piston / rod

mm

80 / 50

=

Swivel cylinder

mm

90 / 50

=

Support cylinder with outrigger - blade support Ø piston / rod

mm

110 / 50

=

Regulating cylinder with boom attachment Ø piston / rod

mm

125 / 70

=

see group 7.31

=

Additional cylinder Hydraulic pump / pilot control

Typ

Gear pump

=

Max. flow / pilot control

l/min

22

=

Hydraulic pump / brake system - swivel bearing and AS1

Typ

Gear pump

=

max. flow rate through flow distributor

l/min

53

=

Constant current for brake I residual current for swivel bearing and AS1

l/min

2

Hydraulic pump / fan drive (cooling)

Typ

Gear pump

=

Max. flow / fan drive (cooling)

l/min

50

=

Pilot control unit / working attachment / slewing gear

Typ

VG - 7 - 4

=

Pilot control unit / travel drive

VG - 7 - 1

=

Pilot control unit / support

VG - 7 - 2

=

see group 6. / 7.

=

20221

29269

Additional information Elektrical system

51

=

Operating voltage

V

24

=

Battery capacity

Ah

2 x 92 (in series)

=

Alternator voltage / current

V/A

28 / 55

=

Starter

V / KW

24 / 4,0

=

20221

29269

Slewing gear mechanism Gearbox

Typ

SAT 225 / 220

=

Oil motor

Typ

FMF 45

=

Max. slewing speed

min-1

9,0

=

Oil volume in gearbox

l

4,4

=

see groups 1.50 and 3.29

=

wet multi-disc brake (negative)

=

see group 9.10

=

20221

29269

Oil quality/oil viscosity and oil change intervals Slewing gear brake

Typ

Additional information Transmission Gearbox

Typ

2 HL 70

2 HL 270

Oil motor

Typ

DMVA 108

=

3.09.2

A 309 LI 20221copyright by

MJFCIFSS

Service Manual

Technical data A 309 Litronic

Transmission Travel speed in creeper / offroad / on-road gear

km/h

Oil volume in gearbox

l

Oil quality/oil viscosity and oil change intervals Parking brake

Typ

Additional information Axles

20221

29269

2,5 / 5,0 / 20,0

=

3,3

3,0

1.50 u. 3.29

=

wet multi-disc brake (negative)

=

see group 11.08

group 11.20

20221

29269

Steering axle

Typ

212

=

Rigid axle

Typ

112

=

Oil volume in steering axle housing

l

7,3

=

Oil volume in steering axle wheel hub

l

2 x 0,8

=

Oil volume in rigid axle housing

l

8,0

=

Oil volume in rigid axle wheel hub

l

2 x 2,1

=

Oil volume in axle housing of steered rigid axle (4-wheel steering)

l

7,3

=

Oil volume in wheel hub of steered rigid axle (4-wheel steering)

l

2 x 2,0

=

see groups 1.50 and 3.29

=

Oil quality/oil viscosity and oil change intervals Steering axle working brake

Typ

disc brake

=

Rigid axle working brake

Typ

disc brake

=

(positive)

=

see groups 12.02 / 12.03 / 12.05

=

9.00 - 20 500 / 45 - 20

=

see group 12.54

=

20221

29269

Brake type Additional information Tyres

Zoll

Additional information Steering Hydraulic pump

Typ

Gear pump

=

Flow

l/min

39

=

Steering / steering valve

Typ

Servostat 2 / LAGS 200

LAGS 200

see group 13.20/ 13.22

see group 13.22

20221

29269

Additional information

Brake system Hydraulic pump

Typ

Gear pump

=

Max. flow

l/min

2,0

=

see group 15.05

=

Additional information

3.09.3

A 309 LI 20221copyright by

MJFCIFSS

Technical data

Service Manual

A 309 Litronic

3.09.4

A 309 LI 20221copyright by

MJFCIFSS

Service Manual

Technical data A 311 Litronic

Technical data 1 A 311 Litronic Type 718 Typ Valid from serial number

718 20222

718 29170

General

20222

29170

Weight of basic machine with 2-point support

t

10,03

=

Weight of backhoe bucket attachment (2-point support)

t

11,99

=

Overall length (with blade support)

mm

4370

=

Overall width

mm

2550

=

Overall height without attacment

mm

3110

=

Rear reach from centre/slewing radius

mm

1750 / 1750

=

Ground clearance

mm

320

=

Break-out force at tooth

KN

49,9 / 77,5

=

Max. drawing pull (in offroad gear and max. operating pressure)

KN

71,1

Drive motor Type Power at rated speed according to DIN ISO 9249

KW

Rated speed

min-1

Max. torque

Nm

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

l

Oil quality/oil viscosity and oil change intervals Fuel tank capacity

l

Additional information Hydraulic system Hydraulic pump

Typ

Design

20222

29170

BF 4 M 1012

=

67 (91 PS)

=

2000

=

371 Âą 10 at 1300-1500 min-1

=

15,5

=

see groups 1.50 and 3.29

=

215

=

see group 4.02

=

20222

29170

A 8 VO 55

=

axial piston swash plate double pump

=

Drive power of pump with power control (min. power)

KW

57

=

Max. flow

l/min

212

=

Hydraulic oil volume (oil change with filter)

l

ca.200

=

see groups 1.50 and 3.29

=

Hydraulic oil and filter change intervals Control valve block

Typ

M8/NG 20

=

Rotary connection 7 x

Typ

DDF 720

=

3.11.1

A 311 LI 20222copyright by

MJFCIFSS

Technical data

Service Manual

A 311 Litronic Hydraulic system

20222

29170

Rotary connection 6 x

Typ

815.006

=

Boom cylinder (adjustable and gooseneck equipment) Ø piston / rod

mm

125 / 70

=

Stick cylinder with adjustable attachment Ø piston / rod

mm

100 / 70

=

Bucket cylinder Ø piston / rod

mm

90 / 60

=

Swivel cylinder

mm

90 / 50

=

Support cylinder with outrigger - blade support Ø piston / rod

mm

110 / 50

=

Regulating cylinder with boom attachment Ø piston / rod

mm

125 / 70

=

see group 7.33

=

Additional cylinder Hydraulic pump / pilot control

Typ

Gear pump

=

Max. flow / pilot control

l/min

22

=

Hydraulic pump / brake system - swivel bearing and AS1

Typ

Gear pump

=

max. flow rate through flow distributor

l/min

53

=

Constant current for brake I residual current for swivel bearing and AS1

l/min

2

Hydraulic pump / fan drive (cooling)

Typ

Gear pump

=

Max. flow / fan drive (cooling)

l/min

50

=

Pilot control unit / working attachment / slewing gear

Typ

VG - 7 - 4

=

Pilot control unit / travel drive

VG - 7 - 1

=

Pilot control unit / support

VG - 7 - 2

=

see group 6. / 7.

=

20222

29170

Additional information Elektrical system

51

=

Operating voltage

V

24

=

Battery capacity

Ah

2 x 92 (in series)

=

Alternator voltage / current

V/A

28 / 55

=

Starter

V / KW

24 / 4,0

=

20222

29170

Slewing gear mechanism Gearbox

Typ

SAT 225 / 220

=

Oil motor

Typ

FMF 45

=

Max. slewing speed

min-1

9,0

=

Oil volume in gearbox

l

4,4

=

see groups 1.50 and 3.29

=

wet multi-disc brake (negative)

=

see group 9.10

=

20222

29170

Oil quality/oil viscosity and oil change intervals Slewing gear brake

Typ

Additional information Transmission Gearbox

Typ

2 HL 70

2 HL 270

Oil motor

Typ

DMVA 108

=

3.11.2

A 311 LI 20222copyright by

MJFCIFSS

Service Manual

Technical data A 311 Litronic

Transmission Travel speed in creeper / offroad / on-road gear

km/h

Oil volume in gearbox

l

Oil quality/oil viscosity and oil change intervals Parking brake

Typ

Additional information Axles

20222

29170

2,5 / 5,0 / 20,0

=

3,3

3,0

1.50 and 3.29

=

wet multi-disc brake (negative)

=

see group 11.08

group 11.20

20222

29170

Steering axle

Typ

262 LD

=

Rigid axle

Typ

162 LD

=

Oil volume in steering axle housing

l

7,3

=

Oil volume in steering axle wheel hub

l

2 x 0,8

=

Oil volume in rigid axle housing

l

8,0

=

Oil volume in rigid axle wheel hub

l

2 x 2,1

=

Oil volume in axle housing of steered rigid axle (4-wheel steering)

l

7,3

=

Oil volume in wheel hub of steered rigid axle (4-wheel steering)

l

2 x 2,0

=

see groups 1.50 and 3.29

=

Oil quality/oil viscosity and oil change intervals Steering axle working brake

Typ

disc brake

=

Rigid axle working brake

Typ

disc brake

=

(positive)

=

see groups 12.05 / 12.10 / 12.11

=

9.00 - 20 500 / 45 - 20

=

see group 12.54

=

20222

29170

Brake type Additional information Tyres

Zoll

Additional information Steering Hydraulic pump

Typ

Gear pump

=

Flow

l/min

39

=

Steering / steering valve

Typ

Servostat 2 / LAGS 200

LAGS 200

see group 13.20/ 13.22

see group 13.22

20222

29170

Additional information

Brake system Hydraulic pump

Typ

Gear pump

=

Max. flow

l/min

2,0

=

see group 15.05

=

Additional information

3.11.3

A 311 LI 20222copyright by

MJFCIFSS

Technical data

Service Manual

A 311 Litronic

3.11.4

A 311 LI 20222copyright by

MJFCIFSS

Service Manual

Technical data A 312 Litronic

Technical data 1 A 312 Litronic Type 719 Typ Valid from serial number

719 12363

719 29898

General

12363

29898

Weight of basic machine with 2-point support

t

13,0

=

Weight of backhoe bucket attachment (2-point support)

t

12,5 - 13,5

=

Overall length (with blade support)

mm

4150

=

Overall width

mm

2500

=

Overall height without attacment

mm

3100

=

Rear reach from centre/slewing radius

mm

1900 / 1900

=

Ground clearance

mm

360

=

Break-out force at tooth

KN

64,5 / 79,1

=

Max. drawing pull (in offroad gear and max. operating pressure)

KN

87

Drive motor Type Power at rated speed according to DIN ISO 9249

KW

Rated speed

min-1

Max. torque

Nm

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

l

Oil quality/oil viscosity and oil change intervals Fuel tank capacity

l

Additional information Hydraulic system Hydraulic pump

Typ

Design Max. flow

l/min

Hydraulic oil volume (oil change with filter)

l

Hydraulic oil and filter change intervals

12363

29898

BF 4 M 1013 E

=

74 (100 PS)

=

1800

=

422 Âą 10 at 1400 min-1

=

15,5

=

see groups 1.50 and 3.32

=

215

=

see group 4.04

=

12363

29898

LMV 130

=

axial piston swash plate pump

=

234

=

ca.300

=

see groups 1.50 and 3.32

=

Control valve block

Typ

M7/NG 20

=

Rotary connection 7 x

Typ

DDF 720

=

Rotary connection 6 x

Typ

815.006

=

3.12.1

A 312 LI 12363copyright by

MJFCIFSS

Technical data

Service Manual

A 312 Litronic Hydraulic system

12363

29898

Boom cylinder (adjustable and gooseneck equipment) Ø piston / rod

mm

100 / 70

=

Stick cylinder with adjustable attachment Ø piston / rod

mm

110 / 70

=

Bucket cylinder Ø piston / rod

mm

90 / 70

=

Support cylinder with outrigger - blade support Ø piston / rod

mm

120 / 70 - 90 / 50

=

Regulating cylinder with boom attachment Ø piston / rod

mm

140 / 80

=

see group 7.34

=

Additional cylinder Hydraulic pump / Brake system - Servo control

Typ

Gear pump

=

Max. flow / pilot control

l/min

32

=

Flow devider K (Brake) / R (Servo control)

2

30

Hydraulic pump

Typ

Gear pump

=

Hydraulic pump / fan drive (cooling)

Typ

Gear pump

=

Max. flow / fan drive (cooling)

l/min

50

=

Pilot control unit / working attachment / slewing gear

Typ

VG - 7 - 4

=

Pilot control unit / travel drive

VG - 7 - 1

=

Pilot control unit / support

VG - 7 - 2

=

see group 6. / 7.

=

12363

29898

Additional information Elektrical system Operating voltage

V

24

=

Battery capacity

Ah

2 x 92 (in series)

=

Alternator voltage / current

V/A

28 / 55

=

Starter

V / KW

24 / 4,8

=

12363

29898

Slewing gear mechanism Gearbox

Typ

SAT 225 / 228

=

Oil motor

Typ

FMF 45

=

Max. slewing speed

min-1

9,0

=

Oil volume in gearbox

l

4,5

=

see groups 1.50 and 3.32

=

wet multi-disc brake (negative)

=

see group 9.10

=

12363

29898

Oil quality/oil viscosity and oil change intervals Slewing gear brake

Typ

Additional information Transmission Gearbox

Typ

2 HL 70

2 HL 270

Oil motor

Typ

DMVA 108

=

Travel speed in creeper / offroad / on-road gear

km/h

2,5 / 5,0 / 20,0

=

Oil volume in gearbox

l

3,3

3,0

1.50 and 3.32

=

Oil quality/oil viscosity and oil change intervals

3.12.2

A 312 LI 12363copyright by

MJFCIFSS

Service Manual

Technical data A 312 Litronic

Transmission Parking brake

Typ

Additional information Axles

12363

29898

wet multi-disc brake (negative)

=

see group 11.08

group 11.20

12363

29898

Steering axle

Typ

262 / 51

=

Rigid axle

Typ

162 / 51

=

Oil volume in steering axle housing

l

8,2

=

Oil volume in steering axle wheel hub

l

2 x 3,0

=

Oil volume in rigid axle housing

l

10,5 (at disc brake)

=

Oil volume in rigid axle wheel hub

l

2 x 0,7 (2,0 l at disc brake)

=

see groups 1.50 and 3.32

=

Oil quality/oil viscosity and oil change intervals Steering axle working brake

Typ

disc brake

=

Rigid axle working brake

Typ

drum brake (option disc brake)

=

(positive)

=

see groups 12.20 / 12.21 / 12.23

=

10.00 - 20 18.00 - 19,5 600 / 40 - 22,5

=

see group 12.54

=

12363

29898

Brake type Additional information Tyres

Zoll

Additional information Steering Hydraulic pump

Typ

Gear pump

=

Flow

l/min

44

=

Steering / steering valve

Typ

Servostat 2 / LAGS 200

LAGS 200

see group 13.20/ 13.22

see group 13.22

12363

29898

Additional information

Brake system Hydraulic pump

Typ

Gear pump

=

Max. flow

l/min

2,0

=

see group 15.05

=

Additional information

3.12.3

A 312 LI 12363copyright by

MJFCIFSS

Technical data

Service Manual

A 312 Litronic

3.12.4

A 312 LI 12363copyright by

MJFCIFSS

Service Manual

Technical data R 313 Litronic

Technical data 1

R 313 Litronic Type 636 Valid from serial number 27752 R 313 Litronic Type 636

General Weight of backhoe bucket attachment and 600 mm base plates

t

15.3 (16.4*)

Overall length

mm

4095

Overall width (500-750 mm base plates)

mm

2500-2750

Overall height without attachment

mm

2925

Rear reach from centre/slewing radius

mm

2215

Ground clearance

mm

435

Max. break-out force at tooth

kN

111.3 / 79.2

Max. drawing pull (in off-road gear and max. operating pressure)

kN

151

Drive motor

R 313 Litronic Type 636

Type

BF 4 M 2012 C

Power at rated speed according to DIN ISO 9249

kW

73 (99 HP)

Rated speed

rpm

1800

Max. torque

Nm

422 Âą 10 at 1500 rpm

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

l

Oil quality/oil viscosity and oil change intervals Total tank capacity

14,0 see groups 1.50 and 3.38

l

approx. 230

Additional information

see group 4.03

Hydraulic system

R 313 Litronic Type 636

Hydraulic pump

Type

Design

DPVO 165 Axial piston swash plate pump

Drive power of pump with power control (min. power)

kW

29

Drive power of pump with power control (max. power)

kW

73

Max. flow

l/min

297

Hydraulic oil volume (oil change with filter)

l

Hydraulic oil and filter change intervals

approx. 350 see groups 1.50 and 3.38

3.13.1

R 313 LI 27752copyright by

MJFCIFSS

Technical data

Service Manual

R 313 Litronic Hydraulic system

R 313 Litronic Type 636

Control valve block

Type

M7/NG 20-16

Rotary connection 5x

Type

DDF 520

Rotary connection 1x

Type

815.001

Boom cylinder (adjustable and gooseneck equipment) Ø piston / rod

mm

110 / 70

Stick cylinder with adjustable attachment Ø piston / rod

mm

115 / 70

Bucket cylinder Ø piston / rod

mm

90 / 60

Cylinder with blade support Ø piston / rod

mm

130 / 90

Regulating cylinder with boom attachment Ø piston / rod

mm

140 / 80

Hydraulic pump / pilot control

Type

Gear pump

Max. flow / pilot control

l/min

36

Hydraulic pump / fan drive (cooling)

Type

Gear pump

Max. flow / fan drive (cooling)

l/min

39

Pilot control unit / working attachment / slewing gear

Type

VG - 7 - 4

Pilot control unit / travel drive

Type

5 TH 6 NR

Additional information

see group 6

Electrical system

R 313 Li Type 636

Operating voltage

V

24

Battery capacity

Ah

2 x 92 (in series)

Alternator voltage / current

V/A

28 / 55

Starter

V / kW

24 / 4.8

Slewing gear mechanism

R 313 Li Type 636

Gearbox

Type

SAT 225 / 218

Oil motor

Type

FMF 45

Max. slewing speed

rpm

9.0

Oil volume in gearbox

l

5.2

Oil quality/oil viscosity and oil change intervals Slewing gear brake

see groups 1.50 and 3.38 Type

Additional information

Wet multi-disc brake (negative) see group 9.10

3.13.2

R 313 LI 27752copyright by

MJFCIFSS

Service Manual

Technical data R 313 Litronic

Travel gear

R 313 Litronic Type 636

Gearbox

Type

FAT 350

Oil motor

Type

A6 VE 55

Travel speed in standard / fast travel mode

km/h

2.4 / 5.0

Oil volume in gearbox

l

Oil quality/oil viscosity and oil change intervals Travel brake

3.0 see groups 1.50 and 3.38

Type

Additional information

Multi-disc brake see group 11.62 or 11.67

Drive

R 313 Litronic Type 636

Drive

bar

Running rollers

Type/ number of rollers

D4 L / 2 X 7

Support rollers

Type/ number of rollers

D4 L / 2 X 2

Number of base plates / chains

Units

46

Base plate width

mm

500/ 600/ 750

Specific pressure on ground (max.)

N/cm2

Additional information

D4 L

4.6(4.9*) / 3.9(4.2*)/ 3.2(3.4*) see group 12

* in machines with blade

3.13.3

R 313 LI 27752copyright by

MJFCIFSS

Technical data

Service Manual

R 313 Litronic

3.13.4

R 313 LI 27752copyright by

MJFCIFSS

Service Manual

Technical data A 314 Litronic

Technical data 1 A 314 Litronic Type 635 Typ Valid from serial number

635 2001

General

2001

Weight of basic machine with 2-point support

t

11,4

Weight of backhoe bucket attachment (2-point support)

t

13,4 - 15,2

Overall length (with blade support)

mm

4235

Overall width

mm

2500

Overall height without attacment

mm

3107

Rear reach from centre/slewing radius

mm

2030 / 2030

Ground clearance

mm

348

Break-out force at tooth

KN

66,1 / 72,9

Max. drawing pull (in offroad gear and max. operating pressure)

KN

87

Drive motor

2001

Type

BF 4 M 1013 EC

Power at rated speed according to DIN ISO 9249

KW

Rated speed

min-1

Max. torque

Nm

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

l

Oil quality/oil viscosity and oil change intervals

80 (109 PS) 1800 460 Âą 10 at 1400 min-1 15,5 see groups 1.50 and 3.32

Fuel tank capacity

l

Additional information

290 see group 4.05

Hydraulic system

2001

Hydraulic pump

Typ

Design

LMV 130 axial piston swash plate pump

Max. flow

l/min

Hydraulic oil volume (oil change with filter)

l

Hydraulic oil and filter change intervals

234 ca.250 see groups 1.50 and 3.32

Control valve block

Typ

M7/NG 20

Rotary connection 7 x

Typ

DDF 720

Rotary connection 6 x

Typ

815.006

3.14.1

A 314 LI 2001copyright by

MJFCIFSS

Technical data

Service Manual

A 314 Litronic Hydraulic system

2001

Boom cylinder (adjustable and gooseneck equipment) Ø piston / rod

mm

110 / 70

Stick cylinder with adjustable attachment Ø piston / rod

mm

115 / 75

Bucket cylinder Ø piston / rod

mm

100 / 70

Support cylinder with outrigger - blade support Ø piston / rod

mm

120 / 70 - 90 / 50

Regulating cylinder with boom attachment Ø piston / rod

mm

140 / 80

Additional cylinder

see group 7.35

Hydraulic pump / Brake system - Servo control

Typ

Gear pump

Max. flow / pilot control

l/min

32

Flow devider K (Brake) / R (Servo control)

2

30

Hydraulic pump

Typ

Gear pump

Hydraulic pump / fan drive (cooling)

Typ

Gear pump

Max. flow / fan drive (cooling)

l/min

45

Pilot control unit / working attachment / slewing gear

Typ

VG - 7 - 4

Pilot control unit / travel drive

VG - 7 - 1

Pilot control unit / support

VG - 7 - 2

Additional information

see group 6. / 7.

Elektrical system

2001

Operating voltage

V

24

Battery capacity

Ah

2 x 92 (in series)

Alternator voltage / current

V/A

28 / 55

Starter

V / KW

24 / 4,8

Slewing gear mechanism

2001

Gearbox

Typ

SAT 225 / 218

Oil motor

Typ

FMF 45

Max. slewing speed

min-1

9,0

Oil volume in gearbox

l

4,4

Oil quality/oil viscosity and oil change intervals

see groups 1.50 and 3.32

Slewing gear brake

Typ

Additional information

wet multi-disc brake (negative) see group 9.10

Transmission

2001

Gearbox

Typ

2 HL 100

Oil motor

Typ

LMV 108

Travel speed in creeper / offroad / on-road gear

km/h

2,5 / 5,0 / 20,0

Oil volume in gearbox

l

Oil quality/oil viscosity and oil change intervals

3,3 1.50 and 3.32

3.14.2

A 314 LI 2001copyright by

MJFCIFSS

Service Manual

Technical data A 314 Litronic

Transmission

2001

Parking brake

Typ

Additional information

wet multi-disc brake (negative) see group 11.10

Axles

2001

Steering axle

Typ

APL - B 745

Rigid axle

Typ

AP - B 745 TR

Oil volume in steering axle housing

l

7,5

Oil volume in steering axle wheel hub

l

2 x 0,7

Oil volume in rigid axle housing

l

9,0 ( 10,0 l at disc brake)

Oil volume in rigid axle wheel hub

l

2 x 0,7 (2,0 l at disc brake)

Oil quality/oil viscosity and oil change intervals

see groups 1.50 and 3.32

Steering axle working brake

Typ

disc brake

Rigid axle working brake

Typ

drum brake (option disc brake)

Brake type

(positive)

Additional information

see groups 12.28 / 12.29 / 12.31

Tyres

Zoll

Additional information

10.00 - 20 18.00 - 19,5 600 / 40 - 22,5 see group 12.54

Steering

2001

Hydraulic pump

Typ

Gear pump

Flow

l/min

44

Steering / steering valve

Typ

Servostat 2 / LAGS 200

Additional information

see group 13.20/ 13.22

Brake system

2001

Hydraulic pump

Typ

Gear pump

Max. flow

l/min

2,0

Additional information

see group 15.05

3.14.3

A 314 LI 2001copyright by

MJFCIFSS

Technical data

Service Manual

A 314 Litronic

3.14.4

A 314 LI 2001copyright by

MJFCIFSS

Service Manual

Technical data A 316 Litronic

Technical data 1 A 316 Litronic Type 715 / 716 Typ Valid from serial number

715 2001

716 2001

715 28061

716 28062

General

2001

2001

28061

28062

Weight of basic machine with 2-point support

t

12,4

14,9

12,4

14,9

Weight of backhoe bucket attachment (2-point support)

t

15,0 16,7

18,9 21,0

15,0 16,7

18,9 21,0

Overall length (with blade support)

mm

4235

=

Overall width

mm

2500

=

Overall height without attacment

mm

3125

=

Rear reach from centre/slewing radius

mm

2230 / 2230

=

Ground clearance

mm

390

=

Break-out force at tooth

KN

66,8 / 90

=

Max. drawing pull (in offroad gear and max. operating pressure)

KN

90

=

Drive motor

2001

Type

BF 4 M 1013 EC

=

86 (115 PS)

=

1800

=

497 Âą 10 at 1350 min-1

=

15,5

=

see groups 1.50 and 3.32

=

290

=

Additional information

see group 4.05

=

Hydraulic system

2001

Power at rated speed according to DIN ISO 9249

KW

Rated speed

min-1

Max. torque

Nm

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

l

Oil quality/oil viscosity and oil change intervals Fuel tank capacity

l

Hydraulic pump

Typ

Design

2001

2001

28061

28062

28062

LMV 150 axial piston swash plate pump

Max. flow

l/min

Hydraulic oil volume (oil change with filter)

l

Hydraulic oil and filter change intervals

270 ca.290 see groups 1.50 and 3.32

Control valve block

Typ

M7/NG 20

Rotary connection 7 x

Typ

DDF 720

A 316 LI 2001A 316 LI-IND 2001-

28061

3.16.1 copyright by

MJFCIFSS

Technical data

Service Manual

A 316 Litronic Hydraulic system

2001

2001

28061

28062

Rotary connection 6 x

Typ

815.006

=

Boom cylinder (adjustable and gooseneck equipment) Ø piston / rod

mm

120 / 70

=

Stick cylinder with adjustable attachment Ø piston / rod

mm

Bucket cylinder Ø piston / rod

mm

100 / 70

=

Support cylinder with outrigger - blade support Ø piston / rod

mm

120 / 70 - 90 / 50

=

Regulating cylinder with boom attachment Ø piston / rod

mm

140 / 80

=

see group 7.36

=

Additional cylinder

120 / 80

110 / 70

120 / 80

110 / 70

Hydraulic pump / Brake system - Servo control

Typ

Gear pump

=

Max. flow / pilot control

l/min

32

=

Flow devider K (Brake) / R (Servo control)

2

30

=

Hydraulic pump / fan drive (cooling)

Typ

Gear pump

=

Max. flow / fan drive (cooling)

l/min

45

=

Pilot control unit / working attachment / slewing gear

Typ

VG - 7 - 4

=

Pilot control unit / travel drive

VG - 7 - 1

=

Pilot control unit / support

VG - 7 - 2

=

see group 6. / 7.

=

Additional information Elektrical system

2001

28061

28062

Operating voltage

V

24

=

=

Battery capacity

Ah

2 x 92 (in series)

=

=

Alternator voltage / current

V/A

28 / 55

=

=

Starter

V / KW

24 / 4,8

=

=

2001

28061

28062

28061

28062

Slewing gear mechanism Gearbox

Typ

SAT 225 / 218

Oil motor

Typ

FMF 45

Max. slewing speed

min-1

9,0

Oil volume in gearbox

l

4,4

Oil quality/oil viscosity and oil change intervals

see groups 1.50 and 3.32

Slewing gear brake

Typ

Additional information

wet multi-disc brake (negative) see group 9.10

Transmission

2001

2001

Gearbox

Typ

2 HL 100

2 HL 290

Oil motor

Typ

LMV 100

DMVA 108

Travel speed in creeper / offroad / on-road gear

km/h

2,5 / 5,0 / 20,0

=

Oil volume in gearbox

l

3,3

3,0

1.50 and 3.32

=

Oil quality/oil viscosity and oil change intervals

3.16.2 copyright by

MJFCIFSS

A 316 LI 2001A 316 LI-IND 2001-

Service Manual

Technical data A 316 Litronic

Transmission

2001

Parking brake

Typ

2001

28061

28062

wet multi-disc brake (negative)

=

Additional information

see group 11.10

group 11.20

Axles

2001

2001

28061

28062

Steering axle

Typ

APL-B 755

APL-B 755 HD

MS-E 3060

Rigid axle

Typ

AP-B 755 TR

AP-B 755 HD

MT-E 3060

Oil volume in steering axle housing

l

9,0

9,5

Oil volume in steering axle wheel hub

l

2 x 2,0

2,5

Oil volume in rigid axle housing

l

9,0 (10 l at disc brake)

10,0

12,5

Oil volume in rigid axle wheel hub

l

2 x 1,0 (2,0 l at disc brake)

2,0

2,5

Oil quality/oil viscosity and oil change intervals Steering axle working brake

Typ

Rigid axle working brake

Typ

Brake type

see groups 1.50 and 3.32

=

disc brake

=

drum brake (option disc brake)

disc brake

disc brake

(positive)

Additional information

see groups 12.36 / 12.37 / 12.39

Tyres

Zoll

see groups 12.41 / 12.42 / 12.44

= see groups 12.46 / 12.47 / 12.48

10.00 - 20 18.00 - 19,5 600 / 40 - 22,5

= =

Additional information

see group 12.54

= =

Steering

2001

2001

28061

28062

Hydraulic pump

Typ

Gear pump

=

Flow

l/min

44

=

Steering / steering valve

Typ

Servostat 2 / LAGZ 190

LAGZ 190

Additional information

see group 13.20/ 13.24

see group 13.24

Brake system

2001

28061

Hydraulic pump A 316 LI 2001A 316 LI-IND 2001-

Typ

2001

Gear pump

28062 =

3.16.3 copyright by

MJFCIFSS

Technical data

Service Manual

A 316 Litronic Brake system

2001

Max. flow

l/min

Additional information

3.16.4 copyright by

MJFCIFSS

2001

28061

28062

2,0

=

see group 15.05

=

A 316 LI 2001A 316 LI-IND 2001-

Service Manual

Technical data R 317 Litronic

Technical data 1

R 317 Litronic Type 970/ 362 Valid from serial number 18161

General

R 317 Li Type 970

R 317 Type 362

Weight of backhoe bucket attachment and 600 mm track pad

t

17,6

18,7

Overall length

mm

3975

5010

Overall width (500-750mm track pad)

mm

2500.2750

=

Overall height without attacment

mm

2995

=

Rear reach from centre/slewing radius

mm

2450

=

Ground clearance

mm

470

=

Break-out force at tooth

KN

100,6 / 125,7

=

Max. drawing pull (in offroad gear and max. operating pressure)

KN

151

=

R 317 Li Type 970

R 317 Type 362

BF 4 M 1013 EC

=

86 (115 HP)

=

1800

=

491 Âą 10 at 1400 min-1

=

15,5

=

see group 1.50 and 3.38

=

290

=

see group 4.05

=

R 317 Li Type 970

R 317 Type 362

DPVO 165

=

axial piston swash plate pump

=

Drive motor Type Power at rated speed according to DIN ISO 9249

kW

Rated speed

min-1

Max. torque

Nm

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

l

Oil quality/oil viscosity and oil change intervals Fuel tank capacity

l

Additional information Hydraulic system Hydraulic pump

Type

Design

Drive power of pump with power control (min. power)

kW

29

=

Drive power of pump with power control (max. power)

kW

73

=

Max. flow

l/min

297

=

Hydraulic oil volume (oil change with filter)

l

approx. 290

=

see group 1.50 and 3.38

=

M7/NG 20-16

=

Hydraulic oil and filter change intervals Control valve block

Type

3.17.1

R 317 LI 18161copyright by

MJFCIFSS

Technical data

Service Manual

R 317 Litronic Hydraulic system

R 317 Li Type 970

R 317 Type 362

Rotary connection 5-way

Type

DDF 520

=

Rotary connection 1-way

Type

815.001

=

Boom cylinder (adjustable and gooseneck equipment) Ø piston / rod

mm

125 / 70

=

Stick cylinder with adjustable attachment Ø piston / rod

mm

130 / 80

=

Bucket cylinder Ø piston / rod

mm

120 / 80

=

Regulating cylinder with boom attachment Ø piston / rod

mm

140 / 80

=

Hydraulic pump / pilot control

Type

Gear pump

=

Max. flow / pilot control

l/min

36

=

Hydraulic pump / fan drive (cooling)

Type

Gear pump

=

Max. flow / fan drive (cooling)

l/min

43

=

Pilot control unit / working attachment / slewing gear

Type

VG - 7 - 4

=

Pilot control unit / travel drive

Type

5 TH 6 NR

=

see group 6. / 7.

=

R 317 Li Type 970

R 317 Li Type 362

Additional information Electrical system Operating voltage

V

24

=

Battery capacity

Ah

2 x 92 (in series)

=

Alternator voltage / current

V/A

28 / 55

=

Starter

V / kW

24 / 4,8

=

R 317 Li Type 970

R 317 Li Type 362

Slewing gear mechanism Gearbox

Type

SAT 225 / 218

=

Oil motor

Type

FMF 45

=

Max. slewing speed

min-1

9.0

=

Oil volume in gearbox

l

4,4

=

see groups 1.50 and 3.38

=

Wet multi-disc brake (negative)

=

see group 9.10

=

R 317 Li Type 970

R 317 Li Type 362

Oil quality/oil viscosity and oil change intervals Slewing gear brake

Type

Additional information Travel gear Gearbox

Type

F40 / FAT 350

FAT 350

Oil motor

Type

A6 VE 55

=

Travel speed max on slow speed / on fast speed

km/h

1,8 / 6,0

=

Oil volume in gearbox

l

4,5

=

see groups 1.50 and 3.38

=

Oil quality/oil viscosity and oil change intervals

3.17.2

R 317 LI 18161copyright by

MJFCIFSS

Service Manual

Technical data R 317 Litronic

Travel gear Parking brake

Type

Additional information

Translation

R 317 Li Type 970

R 317 Li Type 362

multi-disc brake

=

see group 11.60 / 11.62 11.65 / 11.67

11.62 / 11.67

R 317 Li Type 970

R 317 Li Type 362

B 60 L

=

Track

bar

Track roller

Type/ Qty

B 60 L / 2 x 7

D6KL 2 x 9

Carier roller

Type/ Qty

B 60 L / 2 x 2

B 60 L / 2 x 3

Quantity of track pads

piece

44

55

Track pad width

mm

500 / 600 / 750 / 900 / 1000

600/ 900 / 1000

Ground pressure

n/cm2

5,0 / 4,3 / 3,5 / 2,7 / 2,4

3,5 / 2,4 / 2,1

see group 12

=

Additional information

3.17.3

R 317 LI 18161copyright by

MJFCIFSS

Technical data

Service Manual

R 317 Litronic

3.17.4

R 317 LI 18161copyright by

MJFCIFSS

Service Manual

Inspection and maintenance schedule A 309 Litronic / A 311 Litronic

Inspection and maintenance schedule

1

A 309 Litronic / A 311 Litronic A 309:Typ 717 from serial number 20221 A 311:Typ 718 from serial number. 20222

Customer:

................................

Serial no.:

................................

Type:

................................

Operating hours:

................................

Date:

.............................

Caution!

Careful maintenance can only be carried out when the machine is clean. In particular, visual inspections, such as for cracks, can only be made on a clean machine.

Clean the machine before starting any maintenance work (see also the chapter Maintaining the machine safely , subheadings Cleaning and Checking for cracks ).

Note!

The daily maintenance tasks, which the machine operator has to carry out, include a function check of the brakes (swing gear, operating and parking brake), steering and the electrical and hydraulic systems.

Additionally, a visual check must be made for leaks on the engine, hydraulic system, transmission and axles.

Maintenance / inspection at operating hours

WORK TO BE CARRIED OUT A 309 / A 311 Litronic By maintenance personnel (machine operator)

By authorized expert personnel

First and only interval Repeat interval Special interval every 250 hours

Note

First and only interval Repeat interval

DIESEL ENGINE Check oil level and oil pressure in engine Check coolant level and coolant temperature Check air filter via maintenance indicator Check and drain water separator on fuel filter Drain off water and sediment on fuel tank

3.29.1 copyright by

MJFCIFSS

Inspection and maintenance schedule

Service Manual

A 309 Litronic / A 311 Litronic Maintenance / inspection at operating hours

WORK TO BE CARRIED OUT A 309 / A 311 Litronic By maintenance personnel (machine operator) First and only interval Repeat interval Special interval every 250 hours

By authorized expert personnel

Note

First and only interval Repeat interval

Empty dust collector on air filter (shorten or extend interval as necessary) Check and clean cooler, pressure relief valve, coolant hose, fan Replace lube oil filter cartridge Replace engine oil

1)

Check oil, cooling and fuel system for leaks and condition Replace water filter cartridge (at least 1 x annually) Check and adjust throttle control Check anti-corrosion fluid / antifreeze in coolant (replace coolant every 2 years) Check condition and tension of the V-belt (using a testing device at operating temperature). (Replace every 2 years) Check / adjust valve clearance Check engine console and oil sump mounts, clamps etc.

Check flexible fuel leak oil line (change at least every 2 years) Check intake system and exhaust system for leaks and for condition Replace fuel fine filter cartridge (or as necessary)

4)

Replace fuel pre- filter cartridge (or as necessary)

4)

Replace main element of air filter (according to maintenance indicator / annually) Replace safety element of air filter (every third change of main element / annually)

Never clean!

Check clean air line (during filter maintenance) Check / adjust injection valves every 3000 hrs. (if performance diminishes) HYDRAULIC SYSTEM Check oil level in hydraulic tank Clean magnetic rod in return filter (daily during first 300 hrs.)

Replace filter element in return filter (first time at 500 hrs.)

Replace filter unit on servo oil unit Check mounting of components

3.29.2 copyright by

MJFCIFSS

2)

Service Manual

Inspection and maintenance schedule A 309 Litronic / A 311 Litronic

Maintenance / inspection at operating hours

WORK TO BE CARRIED OUT A 309 / A 311 Litronic By maintenance personnel (machine operator)

By authorized expert personnel

First and only interval Repeat interval Special interval every 250 hours

Note

First and only interval Repeat interval

Clean hydraulic oil cooler (and as necessary) Drain off water in hydraulic tank (when using environmentally friendly fluids, max. 0.1 % part of water permissible, insert bypass filter, take oil sample) Check hydraulic system for leaks and function Check / adjust servo, primary and secondary pressures Replace hydraulic oil in tank (or optimize interval with oil analysis)

2), 3)

Replace breather filters on hydraulic tank

2)

ELECTRICAL SYSTEM Check indicator lights and displays when turning on Check lighting Check acid concentration and level and cable terminals and pole ends on batteries as well as all plug connections Spray slip rings on rotary connection (if present) with Cramolin contact spray Check function of entire system and components SWING GEAR Check oil level and look for leaks Check function and action of swing gear brake Check mounting of gear and oil motor Replace gear oil (first time at 500 hrs.)

SWING RING Renew lubrication on gear Renew lubrication on swing race Check mounting screws for tight seating and entry of swing gear pinion TRANSMISSION Check oil level and look for leaks Check function of gear shift and parking brake

3.29.3 copyright by

MJFCIFSS

Inspection and maintenance schedule

Service Manual

A 309 Litronic / A 311 Litronic Maintenance / inspection at operating hours

WORK TO BE CARRIED OUT A 309 / A 311 Litronic By maintenance personnel (machine operator)

By authorized expert personnel

First and only interval Repeat interval Special interval every 250 hours

First and only interval Repeat interval

Check mounting of transmission, oil motor and drive shafts Replace gear oil (first time at 500 hrs.)

AXLES Check oil level and for leaks, check wheel lugs for tight seating.

Check mounting tightness of axles Lubricate steering knuckle bearing (weekly / monthly, depending on application) Replace oil of differential and planetary gear, front and rear (first time at 500 hrs.)

Check wear on multi-disk brake (1 x annually or as necessary) STEERING Check for leaks and function Check mounting tightness of components and steering parts OSCILLATING AXLE SUPPORT Check for leaks and function Check mounting tightness of cylinders BRAKE SYSTEM Check system for leaks Check function and action Check accumulator and brake pressure as well as control switch OPERATORÂ&#x2019;S CAB + HEATER Check / refill washing fluid in windshield washer system container Check function of heater (before start of winter) Check heating system for leaks Check door and window hinges as well as locks

3.29.4 copyright by

MJFCIFSS

Note

Service Manual

Inspection and maintenance schedule A 309 Litronic / A 311 Litronic

Maintenance / inspection at operating hours

WORK TO BE CARRIED OUT A 309 / A 311 Litronic By maintenance personnel (machine operator) First and only interval Repeat interval Special interval every 250 hours

By authorized expert personnel

Note

First and only interval Repeat interval

Check water inlet valve for function and dirt, clean if necessary AIR CONDITIONING SYSTEM Turn on air conditioning system regularly (at least 1 x every 14 days) Check condenser for contamination, blow out if necessary Check mounting screws and compressor drive belt Check dryer collector unit (moisture, fill and condition), replace if required (at least every 2 years) Clean fresh air filter (at least 1 x monthly, weekly for dust intensive use) Replace fresh air filter (shorten change interval for dust intensive use) Check mounting of air conditioning system, hose connections and electrical contacts (at least 1 x annually) UNDERCARRIAGE + UPPERCARRIAGE + ATTACHMENTS Lubricate bearing points on attachment Grease swing bearing Visually check wear condition of teeth Lubricate bearing points on undercarriage (depending on application, daily in mult-shift operation) Check parts for cracks Check mounting tightness of counterweight and tank Check tight seating of attachment pins

400 Nm

Check line and screw connections for tight seating Check cover hinges, quick connections and gas cylinders on hoods Point out appropriate use of attachment Have machine lubricated according to lubrication schedule by the machine operator and point out any operating errors.

HYDRAULIC QUICK CHANGE ADAPTER Check function of visual and acoustic warning devices Check extended position of locking pins visually

3.29.5 copyright by

MJFCIFSS

Inspection and maintenance schedule

Service Manual

A 309 Litronic / A 311 Litronic Maintenance / inspection at operating hours

WORK TO BE CARRIED OUT A 309 / A 311 Litronic By maintenance personnel (machine operator)

By authorized expert personnel

First and only interval Repeat interval Special interval every 250 hours

Note

First and only interval Repeat interval

Check condition of hydraulic hoses and of wiring harness Lubricate locking pins Clean strainer MECHANICAL QUICK CHANGE ADAPTER Check extended position of locking pins visually Lubricate locking pins Tab. 1-1 1 2 3 4

Inspection and maintenance schedule

Engine oil change intervals can be shortened depending on temperature, fuel and oil quality.

Observe shortened maintenance intervals in dust intensive application.

When using environmentally friendly hydraulic fluids, the maintenance interval is to be determined by regular analysis.

Shorten the maintenance interval depending on application (e.g. dust intensive application, barrel refuelling).

Comments / defects

Date:

...................................... ...

Mechanic:

.........................................

3.29.6 copyright by

MJFCIFSS

Customer:

.........................................

Service Manual

Inspection and maintenance schedule A 312 Litronic - A 316 Litronic

Inspection and maintenance schedule 1

A 312 Litronic - A 316 Litronic A 312: type 719, starting with serial no. 12363 A 314: type 635, starting with serial no. 2001 A 316: type 715 / 716, starting with serial no. 2001 Customer:

................................

Serial no.:

................................

Machine type:

................................

Operating hours:

................................

Date:

.............................

Caution!

Careful maintenance is only possible, if the machine is clean. Especially visual inspections, e.g. for cracks can only be carried out properly on a clean machine.

Therefore clean the machine thoroughly before starting any maintenance work (see also chapter 1.10 "Save maintenance of machine", subchapters "Cleaning" and "Crack inspection").

Note!

The daily maintenance tasks of the machine operator include a functional test of the brakes (slewing gear brake, working brake, parking brake), steering, electrical and hydraulic system.

Also to be carried out are a daily visual inspection of the motor, hydraulic system, gearbox and axles for leakage.

Maintenance/ inspection at operating hours

WORK TO BE CARRIED OUT A 312 - A 316 Litronic by maintenance personnel (machine operator)

by authorised specialist technician

Initial and single interval Repeat interval Special interval: every 250 hours

Note Initial and single interval Repeat interval

DIESEL ENGINE Check motor oil level and oil pressure Check coolant level and temperature Check air filter (maintenance indicator) Check and drain water separator at the fuel filter Drain water at fuel tank with bottom settlings Empty dust collecting container at air filter (shorten or extend interval, if necessary)

3.32.1 copyright by

MJFCIFSS

Inspection and maintenance schedule

Service Manual

A 312 Litronic - A 316 Litronic Maintenance/ inspection at operating hours

WORK TO BE CARRIED OUT A 312 - A 316 Litronic by maintenance personnel (machine operator)

by authorised specialist technician

Initial and single interval Repeat interval Special interval: every 250 hours

Note Initial and single interval Repeat interval

Check and clean cooler, pressure relief valve, coolant hose and fan Replace lubricating oil filter cartridge Change engine oil

1)

Check oil, coolant and fuel systems for leakage Replace water filter cartridge (at least 1 x every 12 months) Check and adjust speed adjustment Check corrosion inhibitor and antifreeze agent in coolant (change coolant every 2 years) Check condition and tension of V-belt; check at operating temperature; use gauge; replace every two years Check / adjust valve play (first time after 500 operating hours) Check motor brackets and oil pan, hose clips etc.

Check flexible fuel leak-oil line (replace latest every 2 years) Check intake and exhaust systems for general condition and leaks Clean or replace the cartridge of the fuel prefilter or Separ prefilter (depending on filter type); if necessary, clean or replace at shorter intervals

4)

Replace cartridge of the fuel fine filter (shorten interval, if necessary)

4)

Replace air filter main element (based on maintenance indicator / annually) Replace air filter safety element (at every 3rd replacement of the main element / annually)

Do not clean element!

Check clean air line (during maintenance of filters) Check / adjust injection nozzles (every 3000 operating hours or in the event of loss of performance) HYDRAULIC SYSTEM Check oil level in hydraulic tank Clean magnetic rod in return filter (daily during first 300 operating hours) Replace return filter cartridge (first time after 500 operating hours) Replace filter cartridge in control oil unit Check components for proper mounting

3.32.2 copyright by

MJFCIFSS

2)

Service Manual

Inspection and maintenance schedule A 312 Litronic - A 316 Litronic

Maintenance/ inspection at operating hours

WORK TO BE CARRIED OUT A 312 - A 316 Litronic by maintenance personnel (machine operator)

by authorised specialist technician

Initial and single interval Repeat interval Special interval: every 250 hours

Note Initial and single interval Repeat interval

Clean hydraulic oil cooler (shorten interval, if necessary) Drain water from hydraulic tank (max. permissible water content for environmentally friendly fluids: 0.1 %; insert bypass filter, take oil sample) Check hydraulic system for leakage; complete functional test Check / readjust servo and secondary pressures; check adjust pressure cut-off valve Change hydraulic oil in tank (optimise interval by carrying out oil analyses)

2), 3)

Replace breather filter on hydraulic tank

2)

ELECTRICAL SYSTEM Check indicator lights and indicating devices upon start-up Check lighting Check acid density and level, wire terminals and terminal ports of the batteries, and all the plug connections Spray slip rights of the slewing gear connection with Cramolin contact spray Carry out functional tests of entire unit and all components SLEWING GEAR MECHANISM Check oil level; check system for leakage Carry out functional test of slewing gear brake Check gearbox and oil motor for proper mounting Change gear oil (first time after 500 operating hours) SLEWING RING Replace lubricant of the gearing Replace lubricant of the ball race Check mounting bolts for press fit; slewing gear pining meshing TRANSMISSION Check oil level; check system for leakage

3.32.3 copyright by

MJFCIFSS

Inspection and maintenance schedule

Service Manual

A 312 Litronic - A 316 Litronic Maintenance/ inspection at operating hours

WORK TO BE CARRIED OUT A 312 - A 316 Litronic by maintenance personnel (machine operator)

by authorised specialist technician

Initial and single interval Repeat interval Special interval: every 250 hours

Note Initial and single interval Repeat interval

Carry out functional test of power shift mechanism and parking brake Check gearbox, oil motor and joint shafts for proper mounting Change gear oil (first time after 500 operating hours) AXLES Check oil level; check for leaks; check wheel lugs for proper fit Check axles for proper mounting Lubricate oscillating axle bearing (weekly or monthly, depending on use) Lubricate steering knuckle bearing (weekly or monthly, depending on use) Change oil in axle housing and planetary drives (front and rear) (first time after 500 operating hours) Check multi-disc brake for wear (1 x every 12 months; shorten interval, if necessary) STEERING Check system for leakage; complete functional test Check components and steering system parts for proper mounting OSCILLATING AXLE SUPPORT Check system for leakage; complete functional test Check cylinders for proper mounting BRAKE SYSTEM Check system for tightness Carry out functional test Check pressure of accumulator and brakes; check test switches OPERATOR'S CAB + HEATING Check / add detergent solution in windscreen washer tank Carry out functional test of heating system (before start of winter season)

3.32.4 copyright by

MJFCIFSS

Service Manual

Inspection and maintenance schedule A 312 Litronic - A 316 Litronic

Maintenance/ inspection at operating hours

WORK TO BE CARRIED OUT A 312 - A 316 Litronic by maintenance personnel (machine operator)

by authorised specialist technician

Initial and single interval Repeat interval Special interval: every 250 hours

Note Initial and single interval Repeat interval

Check heating system for leakage Check door and window hinges as well as locks Check water inlet valve for contamination, and clean, if necessary; carry out functional test of valve AIR-CONDITIONING SYSTEM Regularly switch on air-conditioning system (at least 1 x every 14 days) Check condenser for contamination; blow clean, if necessary Check compressor mounting bolts and drive belts Check dryer-collector unit (humidity, fill level, condition); replace, if necessary; replace at least every two years Clean fresh air filter; clean at least once every month; clean once every week when operation generates lots of dust Replace fresh air filter; where operation produces lots of dust, replace more often Check air condition: proper mounting, hose connections and electric contacts; check at least once every year UNDERCARRIAGE + UPPERCARRIAGE + WORKING ATTACHMENTS Lubricate bearing points of working attachments Inspect teeth for wear Lubricate bearing points on undercarriage Lubricate daily when required due to type of use and/or shift operation Check parts for cracks Check counter weight and tank for proper mounting Check lines and screwed connections for proper fit Check panelling hinges, quick fasteners and gas pressure springs of the caps Instruct operators in the proper use of the equipment Instruct the operator in how the machine must be lubricated according to the lubricating chart and make him aware of potential operator errors

3.32.5 copyright by

MJFCIFSS

Inspection and maintenance schedule

Service Manual

A 312 Litronic - A 316 Litronic Maintenance/ inspection at operating hours

WORK TO BE CARRIED OUT A 312 - A 316 Litronic by maintenance personnel (machine operator)

by authorised specialist technician Note

Initial and single interval Repeat interval Special interval: every 250 hours

Initial and single interval Repeat interval

HYDRAULIC QUICK CHANGE ADAPTER Carry out a functional test of the visual and acoustic warning systems Carry out a visual inspection of the extended locking bolts Check hydraulic hoses and wire harness Lubricate locking bolts Clean mesh filters inside the screwed connections of the hydraulic hoses MECHANICAL QUICK CHANGE ADAPTER Carry out a visual inspection of the extended locking bolts Lubricate locking bolts Tab. 1

Inspection and maintenance schedule

Note: 1 The intervals for the change of the motor oil might have to be shortened, depending on the actual temperature, fuel and oil quality.

2 In the case of applications with excessive dust generation, observe shortened maintenance intervals, see group 1.50.

3 For environmentally friendly hydraulic fluids, adjust the maintenance interval on the basis of regular analyses, see group 1.50.

4 The maintenance intervals might have to be shortened, depending on the operating conditions (e.g. generation of dust, barrel fuelling).

Comments / defects

Date:

.........................................

Mechanic:

.........................................

3.32.6 copyright by

MJFCIFSS

Customer:

.........................................

Service Manual

Inspection and maintenance schedule R 313 Litronic / R 317 Litronic

Inspection and maintenance schedule

1

R 313 Litronic / R 317 Litronic A 313:Typ 636 from serial number 27752 A 317:Typ 790 from serial number 18161

Customer:

................................

Serial no.:

................................

Type:

................................

Operating hours:

................................

Date:

.............................

Caution!

Careful maintenance can only be carried out when the machine is clean. In particular, visual inspections, such as for cracks, can only be made on a clean machine.

Clean the machine before starting any maintenance work (see also the chapter Maintaining the machine safely , subheadings Cleaning and Checking for cracks ).

Note!

The daily maintenance tasks, which the machine operator has to carry out, include a function check of the brakes (swing gear, operating and parking brake), electrical and hydraulic systems.

Additionally, a visual check must be made for leaks on the engine, hydraulic system, transmission and axles.

Maintenance / inspection at operating hours

WORK TO BE CARRIED OUT R 313 Litronic / R 317 Litronic By maintenance personnel (machine operator)

By authorized expert personnel

First and only interval Repeat interval Special interval every 250 hours

Note

First and only interval Repeat interval

DIESEL ENGINE Check oil level and oil pressure in engine Check coolant level and coolant temperature Check air filter via maintenance indicator Check and drain water separator on fuel filter Drain off water and sediment on fuel tank Empty dust collector on air filter (shorten or extend interval as necessary)

3.38.1 copyright by

MJFCIFSS

Inspection and maintenance schedule

Service Manual

R 313 Litronic / R 317 Litronic Maintenance / inspection at operating hours

WORK TO BE CARRIED OUT R 313 Litronic / R 317 Litronic By maintenance personnel (machine operator) First and only interval Repeat interval Special interval every 250 hours

By authorized expert personnel

Note

First and only interval Repeat interval

Check and clean cooler, pressure relief valve, coolant hose, fan Check condition of V-belt Replace lube oil filter cartridge Replace engine oil

1)

Check oil, cooling and fuel system for leaks and condition Replace water filter cartridge (at least 1 x annually) Check and adjust throttle control Check engine bracket, oil pan mounting and clamps Check anti-corrosion fluid / antifreeze in coolant (replace coolant every 2 years) Check / adjust valve clearance, Renew valve bonnet seal Check fuel leakage oil line (replace at least every 2 years) Check intake system and exhaust system for leaks and for condition Check glow plugs, change if necessary Replace fuel fine filter cartridge (or as necessary)

4)

Replace fuel pre- filter cartridge (or as necessary)

4)

Replace main element of air filter (according to maintenance indicator / annually) Replace safety element of air filter (every third change of main element / annually)

Never clean!

Check clean air line (during filter maintenance) Replace adjust injection valve (every 3000 operating hours) HYDRAULIC SYSTEM Check oil level in hydraulic tank Clean magnetic rod in return filter (daily during first 300 hrs.)

Replace filter element in return filter (first time at 500 hrs.)

Replace filter unit on servo oil unit Check mounting of components

3.38.2 copyright by

MJFCIFSS

2)

Service Manual

Inspection and maintenance schedule R 313 Litronic / R 317 Litronic

Maintenance / inspection at operating hours

WORK TO BE CARRIED OUT R 313 Litronic / R 317 Litronic By maintenance personnel (machine operator)

By authorized expert personnel

First and only interval Repeat interval Special interval every 250 hours

Note

First and only interval Repeat interval

Clean hydraulic oil cooler (and as necessary) Drain off water in hydraulic tank (when using environmentally friendly fluids, max. 0.1 % part of water permissible, insert bypass filter, take oil sample) Check hydraulic system for leaks and function Check / adjust servo, primary and secondary pressures Replace hydraulic oil in tank (or optimize interval with oil analysis)

2), 3)

Replace breather filters on hydraulic tank

2)

ELECTRICAL SYSTEM Check indicator lights and displays when turning on Check lighting Check acid concentration and level and wire terminals and pole ends on batteries and all plug connections Spray slip rings on rotary connection (if present) with Cramolin contact spray Check function of entire system and components SWING GEAR Check oil level and look for leaks Check function and action of swing gear brake Check mounting of gear and oil motor Replace gear oil (first time at 500 hrs.)

SWING RING Check mounting screws for tight seating and entry of swing gear pinion TRAVEL GEAR Check oil level and look for leaks Check function and effectiveness of travel brake Check mounting of gear and oil motor Replace gear oil (first time at 500 hrs.)

3.38.3 copyright by

MJFCIFSS

Inspection and maintenance schedule

Service Manual

R 313 Litronic / R 317 Litronic Maintenance / inspection at operating hours

WORK TO BE CARRIED OUT R 313 Litronic / R 317 Litronic By maintenance personnel (machine operator) First and only interval Repeat interval Special interval every 250 hours

By authorized expert personnel

First and only interval Repeat interval

TRACK COMPONENTS Check chain tension visually, retension if necessary Clean chain (after completion of work) Check mounting of track pads and sprockets Clean and grease sliding surfaces of tensioning device Check for leaks on idlers, carrier and track rollers OPERATORÂ&#x2019;S CAB + HEATER Check / refill washing fluid in windshield washer system container Check function of heater (before start of winter) Check heating system for leaks Check door and window hinges as well as locks Check water inlet valve for function and dirt, clean if necessary AIR CONDITIONING SYSTEM Turn on air conditioning system regularly (at least 1 x every 14 days) Check condenser for contamination, blow out if necessary Check mounting screws and compressor drive belt Check dryer collector unit (moisture, fill and condition), replace if required (at least every 2 years) Clean fresh air filter (at least 1 x monthly, weekly for dust intensive use) Replace fresh air filter (shorten change interval for dust intensive use) Check mounting of air conditioning system, hose connections and electrical contacts (at least 1 x annually) UNDERCARRIAGE + UPPERCARRIAGE + ATTACHMENTS Visually check wear condition of teeth Lubrication of bearing points (depending on application, daily in mult-shift operation) Check parts for cracks

3.38.4 copyright by

MJFCIFSS

Note

Service Manual

Inspection and maintenance schedule R 313 Litronic / R 317 Litronic

Maintenance / inspection at operating hours

WORK TO BE CARRIED OUT R 313 Litronic / R 317 Litronic By maintenance personnel (machine operator)

By authorized expert personnel

First and only interval Repeat interval Special interval every 250 hours

Note

First and only interval Repeat interval

Check mounting tightness of counterweight and tank Check line and screw connections for tight seating Check cover hinges, quick connections and gas cylinders on hoods Point out appropriate use of attachment Have machine lubricated according to lubrication schedule by the machine operator and point out any operating errors.

HYDRAULIC QUICK CHANGE ADAPTER Check function of visual and acoustic warning devices Check extended position of locking pins visually Check condition of hydraulic hoses and of wiring harness Lubricate locking pins Clean strainer MECHANICAL QUICK CHANGE ADAPTER Check extended position of locking pins visually Lubricate locking pins Tab. 1-1 1 2 3 4

Inspection and maintenance schedule

Engine oil change intervals can be shortened depending on temperature, fuel and oil quality.

Observe shortened maintenance intervals in dust intensive application.

When using environmentally friendly hydraulic fluids, the maintenance interval is to be determined by regular analysis.

Shorten the maintenance interval depending on application (e.g. dust intensive application, barrel refuelling).

Comments / defects

3.38.5 copyright by

MJFCIFSS

Thank you very much for your reading.

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