Liebherr r924 compact tier ⅲ hydraulic excavator service repair manual sn：20472

Technical documentation

En

Technical documentation Hydraulic excavator

R 924 Compact Tier III

Issue:

01/2011

Valid for:

R 924 Compact Tier III

Manufacturer:

LIEBHERR France S.A.S.

Type:

1055 / 1056 1083 Tunnel

Conformity:

CE

R 924 Compact Tier III copyright by

MJFCIFSS

Service Manual

1

General information

2

Tools

3

Technical data / Maintenance guidelines

4

Engine

5

Coupling / Splitterbox

6

Hydraulic system

7

Hydraulic components

8

Electrical system

9

Swing gear

10

Swing ring

11

Travel gear

12

Track components

13 14 15 16

Options

17

Cab / Heater / Air conditioning system

18

Central lubrication

copyright by

MJFCIFSS

Service Manual

Introduction This manual contains technical data, design and functional descriptions, as well as service and set up instructions. The documents include numbers of drawings, functional diagrams, as well as detailed views of units and assemblies of LIEBHERR hydraulic excavators.

This manual has been created in order to assist the customer support services, but does of course replace neither proper technical training and qualification of the user nor participation in LIEBHERR operator training courses.

General basic technical information is not included in this manual. For operating instructions and information on spare parts, please refer to the separate documentation.

For maintenance and reparation of the machine, follow conscientiously the safety instructions and warnings.

Symbols used in this manual In this manual the description of tasks and procedures that are associated with specific dangers are accompanied by safety instructions mentioning the danger related to described work. The safety instructions are graded according to the severity of the risk, and are identified with the symbols «Danger» and «Caution», which have the following significances: These terms are identified by symbols in the operating instructions and : Danger!

Warning referring to a danger where there is a high probability of death or serious injury to operators, unless the prescribed safety measures are taken.

Caution!

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

The symbol «Note» is destined to attract the attention of the persons having to intervene on the machine upon observations and comments concerning the procedure to be followed for operating as well for maintenance or repair works.

Note!

Comments and advices which will, if adhered to, help you to keep your excavator operating, to insure longlife to your machine and to facilitate certain procedures.

Signification of specific punctuation marks in descriptions – This mark introduces «an entry in a list».

• This mark introduces «an entry in a sublist».

This mark indicates «a requirement that must be fulfilled», before going on with the procedure below.

This mark identifies «an injunction to perform the mentioned action».

This mark indicates «the normally expected result of a carried out action».

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

All rights reserved - Printed in France.

MJFCIFSS

Service Manual

This manual shall be amended without prior notice to reflect new technical developments and machine series. LIEBHERR reserves the right to make minor technical amendments to the machines that might not be reflected in the accompanying documentation.

This manual might be complemented by additional service information sheets issued by LIEBHERR. This manual has been compiled and published by the Technical Documentation Department of LIEBHERR-FRANCE SAS 68005 Colmar cedex.

We hope that the information in this documentation, aimed at improving the service of LIEBHERR excavators, is useful to you.

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

7.

12.

Main Group

Example 7. = Main Group «Hydraulic components»

Sub Group

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

Number of the Page in Sub Group

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

14

The main groups are listed in the table of contents at the beginning of the book.

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

MJFCIFSS

Technical documentation

Group 1: General Information

Safety instructions, Signs on the machine ..........................................................................1.10 1 2 3 4

Meaning of the symbols in this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10.1 Bestimmungsgemäße Verwendung. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10.2 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10.2 Sichere Wartung der Maschine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10.12

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

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

Installations for pistons and piston nuts by hydraulic cylinders ......................................1.22 1 2

3

Application and purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.22.1 Requirements / description of procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.22.1 2.1 Tightening with assembly wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.22.2 2.2 Tightening with hydraulic assembly device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.22.4 Torque table - Status 02.06.2010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.22.7 3.1 Tightening with assembly wrench (siehe Kap. 2.1, ”Tightening with assembly wrench” auf Seite 2) .

1.22.7 3.2 Tightening with hydraulic assembly device (siehe Kap. 2.2, ”Tightening with hydraulic assembly device” auf Seite 4)1.22.9

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

1.24 1 2

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

Lubricants and operating fluids............................................................................................1.51 1 2 3 4

5

General information on changing lubricants and operating fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.51.1 Lubricant chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.51.1 Fuels, lubricants and process chemicals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.51.2 Diesel fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.51.3 4.1 Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.51.3 4.2 Sulphur content of diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.51.3 4.3 Diesel fuels for operation at low temperatures (winter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.51.4 4.4 Diesel fuels with the LIEBHERR Particles filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.51.4 Lubricating oil for the diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.51.4 5.1 Viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.51.4 5.2 Lubricating oil change intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.51.5

1.00.1

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Technical documentation

6

Coolant for the diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.51.6 6.1 General recommandations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.51.6 6.2 Water quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.51.6 6.3 Mixting ratio for coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.51.7 6.4 Permitted corrosion inhibitors / antifreeze agent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.51.7 6.5 Permitted premixed coolants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.51.8 6.6 Permitted corrosion inhibitors without antifreeze agent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.51.8 7 Hydraulic liquids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.51.9 7.1 Hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.51.9 7.2 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.51.10 7.3 Warm-up instruction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.51.11 7.4 Biodegradable hydraulic oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.51.11 7.5 Monitoring, filter change and oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.51.12 7.6 Instructions for the reduction of the contamination of the hydraulic oil in machines used for dust intensive applications1.51.13 8 Lubricating grease and other lubricants. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.51.14

1.00.2

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Technical documentation

Safety instructions, Signs on the machine Meaning of the symbols in this manual

Group 1: General Information 1.10: Safety instructions, Signs on the machine Working with the machine holds dangers to which you as the owner, machine operator or maintenance expert could be exposed. If you regularly read and note the safety information, however, you can prevent danger and accidents. This is particularly true for those who are only occasionally in contact with the machine, eg. for maintenance work. The following information comprises safety regulations which, if followed conscientiously, will guarantee your safety and that of other persons, as well as avoiding damage to the machine.

Following these precautions does not release you from the responsibility to take note of safety regulations which apply on site or of guidelines given by legal bodies or professional associations.

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

1

Meaning of the symbols in this manual Work processes and actions that could cause danger are accompanied by safety informations in these operating instructions. These safety informations describe various dangers which are emphasized by the terms Danger, Caution and Note.

These terms are identified by symbols in the operating instructions and have the following meaning: Danger!

Warning relating to a danger that carries with it a high risk of death or serious injury if the appropriate preventative measures are not taken.

Caution!

Warning relating to dangers that could result in physical injury and/or damage to the machine if the appropriate preventative measures are not taken.

Note!

This symbol identifies user tips and operating and maintenance procedures whose use will guarantee a high degree of user-friendliness and longevity to the machine or which will considerably simplify working procedures.

– This symbol identifies a listing.

• This symbol identifies a sub-listing.

This symbol signifies the following: “The precondition must be fulfilled”.

The machine operator or the maintenance personnel must first fulfil the precondition described, i e. the machine must be brought into a particular work position in order to be able to carry out the actions subsequently described.

This symbol identifies an action.

The machine operator or the maintenance personnel should be active at this location and carry out the action described.

This symbol means “Carry out an activity".

If the machine operator or maintenance personnel have carried out the activities described in an action, the result of this action will be described here.

1.10.1

R 924 Compact Tier III copyright by

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Safety instructions, Signs on the machine

Technical documentation

Bestimmungsgemäße Verwendung Following these notes does not relieve you of responsibility for following additional rules and guidelines!

Additional points that should be noted are: – the safety regulations which apply on site, – statutory road traffic regulations, – the guidelines provided by professional associations.

2

Bestimmungsgemäße Verwendung – Der Hydraulikbagger ist eine Maschine mit Arbeitseinrichtung (z. B. Tieflöffel, Greifer, Ladeschaufel) zum Lösen, Aufnehmen, Transportieren und Abschütten von Erdreich, Gestein und anderen Materialien, wobei der Transport des Ladeguts vorwiegend ohne Verfahren der Maschine erfolgt. Das Verfahren der Maschine mit Ladegut hat unter Beachtung der sicherheitstechnischen Maßgaben (siehe Abschnitt “Hinweise für ein sicheres Arbeiten”) zu erfolgen.

– Maschinen im Hebezeugeinsatz unterliegen besonderen Bedingungen und müssen mit den vorgeschriebenen Sicherheitseinrichtungen versehen sein (siehe Abschnitt “Hebezeugeinsatz“).

– Maschinen im Untertageeinsatz (Untertagebergbau und Tunnelbau) in nicht explosionsgefährdeter Umgebung müssen mit Technologien zur Abgasreduzierung (z.B. Dieselpartikelfilter) ausgestattet sein. Einzelstaatliche Anforderungen sind hierbei zu beachten.

– Besondere Einsätze erfordern spezielle Ausrüstungen und eventuell spezielle Sicherheitseinrichtungen. Diese Ausrüstungen dürfen nur nach Genehmigung und den Maßgaben des Grundgeräteherstellers angebaut und benutzt werden.

– Eine andere oder darüber hinausgehende Benutzung wie z.B. der Transport von Personen oder das Arbeiten in explosionsgefährdeter sowie kontaminierter Umgebung gilt als nicht bestimmungsgemäß. Für hieraus resultierende Schäden haftet der Hersteller nicht. Das Risiko trägt allein der Anwender.

– Die Beachtung der Betriebsanleitung und die Einhaltung der Inspektions- und Wartungsanleitungen gehört ebenfalls zur bestimmungsgemäßen Verwendung.

3

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

– Ensure that you have obtained, read and understood any additional instructions relating to special accessories for the machine.

– Only specifically authorized persons may operate, maintain or repair the machine. The legal minimum age is to be adhered to.

– Only employ trained or appropriately instructed personnel. Clearly establish which personnel are responsible for operating, setting up, maintaining and repairing the machine. Give personnel the power to refuse to carry out unsafe instructions by third parties. This also applies in relation to traffic regulations.

– Only permit apprentices and personnel who are in training or who have only general training to operate on the machine under the constant supervision of an experienced member of staff.

– As far as possible, monitor personnel to ensure that they are adhering to safe working practices, are aware of risks and are observing the operating instructions.

– Always wear safe work clothes when you are working on or with the machine. Avoid wearing rings, wrist watches, ties, scarves, open jackets, baggy clothing etc... There is a risk of injury from, for example, getting caught up or being drawn in.

– For specific jobs wear individual protective equipment (protective goggles, safety helmets, safety shoes and gloves, reflective vests and ear protection etc...)..

– Ensure that you obtain information on any special safety regulations for the job site from the site foreman.

1.10.2

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Technical documentation

Safety instructions, Signs on the machine Safety Instructions

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

– When getting in and out, do not hold on to the steering column, control panel or joystick. Doing this could cause unintentional movement, which could result in an accident.

– Never jump from the machine; use the steps, ladders, gangplanks and supporting straps provided for this purpose.

– Face the machine when getting in or out and always use three-point support, i.e. two hands and one foot or two feet and one hand must always be in contact with the access system at the same time.

– Familiarize yourself with the location of the emergency exit out of the cab.

– In the absence of any other instructions, proceed as follows for all maintenance and repair work: • switch off the machine on firm, level ground • align the uppercarriage with the undercarriage so that the sprockets locate at the back-end • anchor the grab in the ground.

• place all operating levers into neutral and tilt the safety lever up.

• switch off the engine and remove the start key.

– Before touching any parts of the hydraulic circuits, you must also operate all pilot control devices (joystick and pedals) in all directions with the start key in contact position and with the security lever lowered, in order to reduce the actuating and dynamic pressures in the work circuits. You must then reduce the internal tank pressure as described in these operating instructions.

– Secure all loose parts on the machine.

– Never operate a machine before carrying out a careful inspection tour and checking whether any warning signs are missing or illegible.

– Respect all danger and safety instructions.

– For special applications the machine must be equiped with specific safety equipments. Work only if they are mounted and functional.

– Do not carry out any modifications, alterations or conversions to the machine which may affect safety without the express permission of the manufacturer. This also applies for the installation of safety devices and valves and for welding work on load-bearing parts.

– It is forbiden to repair the structure of the cab.

– Not original equipment and component parts or such kind, wich has generaly not been validated

by LIEBHERR for installation or extension, has not to be installed or added onto the excavator without previous written agreement of LIEBHERR. Wherefore the necessary technical documentations has to be at LIEBHERR’s disposal.

Avoidance of crushing and burns – – – – – – – –

– – –

Do not work beneath the equipment if it is not safely positioned on the ground or supported.

Do not use any damaged or insufficient load-bearing take-up materials, such as ropes or chains.

Wear work gloves when working with wire cables.

When working on the equipment, never use your fingers to locate bores; use the correct punch for the procedure.

Ensure that no objects enter the fan when the engine is on. The fan will eject or destroy these objects and will itself be damaged.

The engine cooling system is hot and pressurized when near operating temperature. Avoid coming into contact with coolant carrying parts. There is a risk of sustaining burns.

Only check the coolant when the sealing cap of the expansion container has cooled to a point where it is possible to touch it. Then turn the cap carefully to let off the overpressure.

Engine and hydraulic oil, as well the engine exhaust system are hot when near operating temperature. Avoid coming into contact with hot oil or oil-bearing parts and with parts of the exhaust system.

Wear protective goggles and gloves when working on the battery. Avoid sparks and naked flames.

Never permit the grab to be guided by hand by auxiliary personnel.

When reaching into the engine compartment, always secure the side doors against unintentional closing by positioning the supports provided for this purpose.

1.10.3

R 924 Compact Tier III copyright by

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Safety instructions, Signs on the machine

Technical documentation

Safety Instructions – Never lay under the machine if it is raised with work equipment and has not been correctly and securely supported with hardwood beams.

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

–

Switch off the engine when refuelling.

Do not smoke or use a naked flame when refuelling and charging the batteries.

Always start the engine in accordance with the operating instructions.

Check the electrical system regularly.

Have all faults, such as loose connections, blown fuses and lamps and clogged or abraded cables rectified by personnel.

Do not transport any combustible liquids anywhere on the machine other than in the tanks provided for this purpose.

Check all lines, hoses and screwed joints regularly for leakage and damage.

Rectify leakages immediately and replace damaged components.

Oil spraying out of leaking areas can easily cause a fire.

Ensure that all holds and shields are correctly installed to guard against vibration, abrasion and heat accumulation.

Do not use cold start materials (ether) in the vicinity of heat sources, naked flames or in inadequately ventilated areas.

Do not use any starting aids containing ether to start diesel engines with preheating or flame glow systems. There is a risk of EXPLOSION. Familiarize yourself with the location and operation of fire extinguishers on the machine and with local fire warning and fire abatement options.

The driver’s cab of the machine is provided with a fixing possibility for an extinguisher.

Unlock all hoods and side doors locks before operating the machine, this will facilitate fighting a possibly upcoming fire.

Sichere Inbetriebnahme der Maschine – Machen Sie vor jeder Inbetriebnahme einen gründlichen Inspektionsrundgang um die Maschine.

– Vergewissern Sie sich, dass niemand, außer zu Ihnen Anschlagtätigkeit Beaufträgter, sich im Arbeits- und Bewegungsbereich der Maschine findet.

– Kontrollieren Sie die Maschine auf lose Bolzen, Risse, Verschleiß, Undichtigkeiten und mutwillige Beschädigungen.

– Nehmen Sie niemals eine schadhafte Maschine in Betrieb.

– Sorgen Sie dafür, dass Schäden sofort beseitigt werden.

– Vergewissern Sie sich, dass alle Hauben und Deckel geschlossen sind, die Schlösser jedoch nicht abgesperrt werden, um im Falle eines Brandes, die Feuerbekämpfung zu erleichtern.

– Vergewissern Sie sich, dass alle Warnschilder vorhanden sind.

– Sorgen Sie für saubere Fensterscheiben und Innen- und Außenspiegel. Sichern Sie Türen und Fenster gegen ungewollte Bewegungen.

– Vergewissern Sie sich, dass niemand auf oder unter der Maschine arbeitet und warnen Sie die umstehenden Personen vor der Inbetriebnahme der Maschine durch Betätigen der Hupe.

Safely getting up – Before getting up or down to the cab of the machine, position the machine on even, horizontal ground. Position the upper structure with the undercarriage in such a way that the steps and ladders are aligned with each other.

– Ensure that steps, ladders and hand-rails (grips) are in good condition. In particular, ensure that they are free of dirt, oil, ice and snow.

1.10.4

R 924 Compact Tier III copyright by

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Technical documentation

Safety instructions, Signs on the machine Safety Instructions

– To assure that the cab door opens easily in all weather conditions, the door seals must be dusted with talc or silicon at least every two months or more often if required. The door hinges and locks should be greased regularly.

– Face the machine when getting up or down and always adopt three-point support method, i.e. two hands and one foot or two feet and one hand must always be in contact with the access system at the same time.

– As soon as you can reach the door handle with your free hand, unlock the door as necessary and open it, while paying attention to remain out of its swing radius before you climb any higher. External influences, such as wind, can make it more difficult to open doors.

Because of this, always lead along the door with your hand during the whole opening motion. Ensure that the door locks in place when reaching its open position, so to prevent it can slam open and shut.

– Now continue to climb up, still using the three-point support and sit down in the operator’s seat as soon as you enter the cab.

– Close the door and fasten the safety belt, unlock the door using the destined lever, Close the door thereafter using the both handholds mounted to the inner face of the door frame.

Only after it tilt down the safety lever, and start the machine.

– It is essential to fasten your safety belt if you wish to work with the door open.

– For the excavators mounted on a special support or employed as a component of a larger installation (uppercarriage used on a pontoon, on a gantry crane,...), also consider the safety instructions in to the operator’s manual of the complete machine relating to a safe getting up.

Adjusting the operator’s standing position – Before starting the machine, adjust the seat, mirrors, armrests and operator’s controls in such a way that you are able to work comfortably and safely.

– Acoustic insulation devices on the machine must be set to the insulation position throughout operation.

Protection from vibration - seat adjusting – Keep the seat in good condition and adjust it as follows: • The seat and its damping action should be adjusted depending on the weight and height of the operator.

• Check the seat’s damping action and adjustment mechanisms regularly and ensure that these seat characteristics remain as per the seat manufacturer’s instructions.

Utilisation in confined spaces – Only operate combustion engines and fuel-operated heaters in adequately ventilated spaces. Before starting in closed areas, ensure adequate ventilation.

Follow the regulations which apply for the particular area of use.

Starting the machine safely – Before starting, check all control lamps and instruments for correct function, place all operator’s controls in Neutral and tilt the safety lever up.

– Before starting, sound the horn briefly to alert people in the vicinity of the machine.

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

– In the absence of any other instructions, start the engine in accordance with the regulations given in the operating instructions.

– Tilt the safety lever down and then test all display and checking devices.

– In enclosed spaces, only allow the engine to run when there is adequate ventilation. If necessary, open doors and windows to ensure sufficient fresh air supplies.

– Bring the engine and hydraulic oil to operating temperature. Low oil temperatures make the control unit react sluggishly.

– Check that the equipment is operating correctly.

1.10.5

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Safety instructions, Signs on the machine

Technical documentation

Safety Instructions – Move the machine carefully to an open area and then check the function of the running and slewing gear brakes, the steering and the signaling and lighting devices.

Stopping the machine safely – Only stop the machine on level, firm ground.

– If the machine has to be stopped on an incline, chocks should be used to secure it from rolling away.

– Before stopping the machine, each time it is possible, align the uppercarriage with the undercarriage so that the sprockets locate at the back-end. This is the only one position which enables a secured access to every maintenance locations on the uppercarriage.

– Use the stop bolts to secure the upper structure facing the undercarriage, if available.

– Lower the equipment and anchor the grab lightly in the ground.

– Position every control lever into neutral position and depress the parking and slewing brakes.

– Stop the engine in accordance with the operating instructions and tilt the safety lever up before leaving the cab.

– Lock the machine, included hoods and compartments, retire every keys and secure the machine against unpermited use and vandalis.

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

– Stop the machine on level, horizontal ground. The upper structure should be positioned with the undercarriage in such a way that the steps and ladders are aligned with each other.

– Open and lock the door. Be sure of it’s locking. Take care of weather conditions ! Unfasten the safety belt.

– Position yourself with your face toward the machine when getting out and use three-point support, i.e. two hands and one foot or two feet and one hand must always be in contact with the access system at the same time. Climb down until you can close the doors safely. Always use your hand for control when closing the doors. Lock the door.

– Now climb down to the ground.

Working safely with the machine – Before you start working, acquaint yourself with the special features of the job site and any special precautions and warning signals. Examples of particular work environments would be on-site or traffic obstructions, the load-carrying capacity of the ground and any requirements to make the job site safe from public use.

– Always maintain a safe distance from overhangs, edges, slopes and unsafe ground.

– Be particularly careful in conditions of reduced visibility and changeable ground conditions.

– Familiarize yourself with the location of power lines on the job site and take particular care when working near them. If necessary, inform the responsible authorities.

– Maintain a safe distance from electrical aerial lines. Do not allow the equipment to come near cables when working near electrical aerial lines. Risk of fatality! Inform yourself about required safety distances.

– The following actions must be carried out in the event of any transfer of electricity: • do not move the machine or its equipment, • do not leave the driver’s cab, • warn any personnel in the vicinity not to come close to the excavator and not to touch it, • instruct or initiate that someone turns off the voltage.

• move the machine, if possible, from the danger zone to a sufficient distance, • Do not leave the machine until you are absolutely sure that voltage in the line, which had been touched or damaged, has been turned off !

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

1.10.6

R 924 Compact Tier III copyright by

MJFCIFSS

Technical documentation

Safety instructions, Signs on the machine Safety Instructions

– When driving onto public roads, paths and squares, observe current traffic regulations and if necessary, ensure that the machine has been made safe as per regulations beforehand.

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

– Do not permit any passengers in the machine.

– Only work when seated properly and with the safety belt securely fastened (if available).

– Report all function faults and ensure that all necessary repairs are carried out immediately.

– Assure yourself that no one is endangered when you start the machine moving.

– Before you start working, test the brake system in accordance with the regulations given in the operating instructions.

– Never leave the driver’s seat while the machine is moving.

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

– The machine must be positioned, moved and operated in such a way that it is stable and that there is no danger of overturning. Only known loads may be moved with the equipment; this applies particularly when using the grab.

– Position the upper structure in the longitudinal direction when moving and hold the load as close to the ground as possible.

EXCEPTION: “Safe use when loading and unloading (particularly when loading and unloading wood)” on page 8.

– Adjust your driving speed to suit local conditions.

– Avoid any working movements which may tip the machine. Should the machine start to tip or slide sideways, however, turn the upper structure to face downhill and lower the equipment at the same time.

– As far as possible, work downhill or uphill and not side on to the slope.

– Drive safely on stony, sleepery or inclined ground – Only drive downhill at the permitted speed or you could lose control of the machine.

– Always shift down to a lower running step before a slope. When doing this, the diesel engine must run at maximal speed and the speed may only be reduced using the accelerator pedals.

– Load an occupied truck only if all safety requirements are fulfilled, notably in order to protect the truck operator.

– For demolition work, digging and crane operations etc., always use protective devices specifically designed for the purpose.

– For terrain which is difficult to gain an overview of and whenever necessary, ask for the assistance of a spotter. Only permit one person to give you signals.

– Only permit experienced personnel to attach loads and give signals to the machine operator. The spotter must be positioned within the visual range of the operator or be in voice contact with him.

– Depending on the equipment combination, there is a risk of collision between the work tool and the cab, the cab protection or the boom cylinders. The greatest degree of care must be taken to avoid damage when the hoe teeth come within this area.

– Depending on the equipment combination, there is a risk of collision between the lift ring of the attachment and the cab or the cab protection. Before operating, ensure that there is no risk of collision, especially on excavator with cab elevation. If necessary remove the lift ring.

– In case of a thunderstorm : • lower the attachment to the ground and if possible anchor the digging tool into the soil.

• leave the cab and move away from the machine before the storm breaks out. Otherwise, you must stop the excavator, turn off the radio and keep inside the closed cab until the end of the storm.

– Auxiliary control units can have various functions. Always check their functions when starting up the machine.

– Stop the swinging motion of the uppercarriage when lowering the attachment into a ditch without striking the attachment on the ditch walls.

– Inspect the machine for damage if the attachment has been swung into a wall or any other obstacles.

– Applications in which the attachment is to be used to strike the material being extracted are not permitted, even when working in a longitudinal direction.

1.10.7

R 924 Compact Tier III copyright by

MJFCIFSS

Safety instructions, Signs on the machine

Technical documentation

Safety Instructions – Repeated strikes against an object leads to damage to the steel structures and machine components.

– Please refer to your LIEBHERR dealer if special teeth for heavy-duty or special applications are required.

– Do not attach too large bucket or bucket with side cutters or that are during operations with rocky material. This would prolong the work cycles and may lead to damage to the bucket as well as further machine components.

– With the 2x45° offset articulation, the offset position may only be employed if the working tool or the attachment does not touch the material.

– Operation of the offset articulation to drill into the material is not permitted.

– Do not lift the machine during operation. Should this happen, lower the machine slowly back to the ground.

– Do not let the machine fall heavily on the ground and do not hold it back with the hydraulics. This would damage the machine.

– During operation with the attachment it is forbidden to raise the machine with the dozing blade (e.g. carving at the ceiling when tunnelling).

Safe use with a hydraulic hammer – The hydraulic hammer must be selected with particular care. When using a hydraulic hammer not permitted by LIEBHERR, steel structures or the other machine components can become damaged.

– Before beginning breaking tasks, position the machine on firm and level ground.

– Use a hydraulic hammer designed exclusively for breaking stone, concrete and other breakable materials.

– Only operate the hydraulic hammer in the longitudinal direction of the machine and with the windshield closed or with a front protective grid.

– Ensure during hammer operation that no cylinder is entirely extended or retracted and that the stick is not in the vertical position.

– In order to avoid damages to the machine, try not to break stone or concrete while performing retraction and extension motions of the hydraulic hammer.

– Do not apply the hydraulic hammer uninterrupted for more than 15 secs. at a time to the same place. Change the breaking point. Too long uninterrupted operation of the hydraulic hammer leads to an unnecessary overheating of the hydraulic oil.

– Do not use the drop force of the hydraulic hammer to break stone or other materials. Do not move obstacles with the hydraulic hammer. Misuse of this nature would damage both the hammer and the machine.

– Do not use the hydraulic hammer to lift objects

Safe use when loading and unloading (particularly when loading and unloading wood) – According to use, it can be necessary when working with a grab to move with the equipment raised and the load lifted up; this applies, for example, when loading and unloading wood.

1.10.8

R 924 Compact Tier III copyright by

MJFCIFSS

Technical documentation

Safety instructions, Signs on the machine Safety Instructions

– Here, the centre of gravity of the machine will be displaced upwards in the vertical direction. The driving characteristics of the machine will thus be influenced persistently, e.g. through reduction of the dynamic stability.

The following instructions are therefore to be observed at all times: • Adjust vehicle handling to suit the altered machine characteristics and environmental conditions.

• Reduce your speed to prevent the need for sudden braking and steering manoeuvres.

• Avoid sudden speed changes, such as braking, accelerating and changing direction.

• Only rotate the upper structure when the undercarriage is stationary.

• Only rotate the upper structure after you have picked up the load.

• Only move the machine when you have picked up and lifted the load and rotated the upper structure to the driving position.

• There is a danger of possible swinging movement and dropping of the load when the equipment is raised.

• A protective grid (FOPS) in accordance with ISO 10262 must be attached to the cab.

• A protective roof (FOPS) in accordance with ISO 10262 must be attached if there is a risk of objects falling from above.

• Only the maximum permissible load may be taken up using the grab.

– NOTE: The weight of absorbent materials, such as logs, is dependent on length, diameter and specific weight. The influencing variables present in a natural product, such as moisture, must be noted.

– Working procedures when using machines with grabs require the machine operator to receive special instruction and training.

– Use as part of the work process is only permitted when the machine operator has sufficient training and practical experience.

Safe use of machines with tower elevation – Due to the tower elevation, the centre of gravity of the machine will be displaced upwards in the vertical direction. The driving and work characteristics of the machine will thus be influenced persistently, e.g. through reduction of the dynamic stability.

– Due to the heightened centre of gravity, the machine must be aligned horizontally before use. In horizontal alignment, the centre of gravity of the upper structure is over the centre of the undercarriage, which reduces the risk of tilting.

– The machine can still sway and tilt despite being aligned!

The following instructions are therefore to be observed at all times: When moving the machine: • Rotate the upper structure parallel to the undercarriage undercarriage (transport position).

• Draw the equipment as close as possible to the machine.

• Only at this point may the support feet be retracted and the machine moved.

• Moving with loads is not permitted.

• Check the terrain to be covered to ensure that the ground is solid and even. Potholes and uneven surfaces jeopardize the stability of the machine.

• Adjust vehicle handling to suit the altered machine characteristics (high centre of gravity) and environmental conditions.

• Reduce your speed to prevent the need for sudden braking and steering manoeuvres.

• Avoid sudden speed changes, such as braking, accelerating and changing direction.

• Ascending gradients and obstacles may only be approached in the longitudinal direction in order to prevent unacceptable banking of the machine.

• Special care should be taken when driving through narrow passages - drive slowly!

1.10.9

R 924 Compact Tier III copyright by

MJFCIFSS

Safety instructions, Signs on the machine

Technical documentation

Safety Instructions When loading and unloading: • The machine must be supported and aligned horizontally before moving (slewing) the upper structure out of the transport position.

• It is imperative that you check the contact surface of the support (load carrying capacity of the substrate). A support subsiding would have disastrous consequences!

• Carry out all movements with increased care.

• To slew the load, move the equipment as close as possible to the machine (Caution! swinging grab)and hold the load close to the undercarriage and above the substrate.

• Avoid braking or accelerating the equipment or upper structure abruptly.

• Do not lift any loads which are heavier than those given in the load chart.

Protection from vibration – Vibrational loads on mobile building machinery are mainly the result of the type and method of use. The following parameters in particular are decisive influences: • Terrain conditions: Uneven areas and potholes; • Operational techniques: Speed, steering, brakes, controlling the machine’s control elements when driving and working.

– To a large extent, the machine operator determines the vibrational loads since he selects the speed, gearbox ratio, working method and route himself.

This means that there is a wide range of different vibrational loads for the same machine type.

Whole-body vibrational load for the machine operator can be reduced if the following recommendations are observed: – Select suitable machines, equipment parts and auxiliary devices for each part of the job.

– Use a machine that has a suitable seat (i.e. for earth-moving machinery such as hydraulic excavators, this should be a seat which corresponds with EN ISO 7096).

– Keep the seat in good condition and adjust it as follows: • The seat and its damping action should be adjusted depending on the weight and height of the operator.

• Check the seat’s damping action and adjustment mechanisms regularly and ensure that these seat characteristics remain as per the seat manufacturer’s instructions.

– Check the maintenance status of the machine, particularly with respect to: tyre pressure, brakes, steering, mechanical connections etc.

– Do not steer, brake, accelerate, shift gears, move or load the machine’s equipment jerkily.

– To reduce vibrational load, adjust the machine speed to suit the route as follows: • Reduce speed when driving on difficult terrain; • Drive around obstacles and avoid driving on very difficult terrain.

– Keep the terrain on which the machine is working and driving in good condition: • Remove large stones and obstacles; • Fill in ruts and holes; • Have machines ready to prepare and maintain suitable ground conditions and calculate in sufficient time to carry out any work required.

– Drive longer distances (e.g. on public roads) at an appropriate (medium) speed.

– Use special auxiliary systems (if available) which reduce vibration for machines that are driven frequently.

If such auxiliary systems are not available, regulate speed to avoid "oscillating" the machine.

Towing the machine safely – Always follow the correct procedure: see chapter “Towing the machine” in these operating instructions.

– The machine may only be towed in exceptional circumstances, e.g. in order to move the machine away from an area where it is at risk.

– Before towing, check all attachments and towing devices for safety and stability.

1.10.10

R 924 Compact Tier III copyright by

MJFCIFSS

Technical documentation

Safety instructions, Signs on the machine Safety Instructions

– Towing devices such as bars, cables or ropes must have adequate tensile strength and should be secured around the undercarriage tower or the towing hook provided on the undercarriage.

Any damage or accidents which occur while towing the machine are not covered by the manufacturer’s guarantee.

– Ensure that there is no one in the vicinity of the towing devices when towing.

– Stretch safely and hold the towing devices. Avoid kinks on cables or ropes.

– When towing, maintain the correct transport position, permitted speed and route, and avoid lurching.

– After towing, return the machine to correct operational status.

– When restarting the machine, be sure only to proceed in accordance with the operating instructions.

Attaching and removing equipment parts safely – Equipment or attachments made by other manufacturers or those which do not have general approval from LIEBHERR for installation or attachment may not be installed or attached to the machine without LIEBHERR’s prior written consent.

LIEBHERR must be provided with the appropriate technical documentation necessary for this purpose.

– Before carrying out any major repair work on the equipment, position the machine on level, firm ground.

– Do not work beneath the equipment if it is not safely positioned on the ground or supported with wooden blocks.

– Before loosening lines or unscrewing bolts, you must store the equipment, switch off the engine and press the start key to the contact position and both joysticks and the pushbuttons to “Turn grab” in order to reduce the pressure in the hydraulic system.

– Do not attempt to lift heavy parts. Use devices which are suitable for this purpose and which have sufficient load carrying capacity.

– Do not use cable which is damaged or does not have sufficient load carrying capacity. Wear work gloves when working with wire cables.

– When working on the equipment: switch off the engine and keep the safety lever tilted up. Never use your fingers to locate bores; use the correct punch for the procedure.

– During repair work: ensure that the hydraulic lines are secured correctly and that all bolts and connections are tight.

– When you have removed and chocked an equipment part, close open areas of the hydraulic circuit to stop dirt entering. Only allow authorized persons in the vicinity of the machine or the lifting device used.

Removing and installing equipment bolts safely – If possible, always use a hydraulic bolt press to press out the equipment’s bolts.

– If you have to remove a bolt using a sledge-hammer, a driving punch and a bore hole conductor held by another person must be used.

– To drive in a bolt, screw the drive screws provided in the toolbox into the bolt's threaded hole and only hammer these screws.

– When installing bolts locked by means of castle nuts and cotter pins, first drive the bolt to the stop, then screw the castle nut by hand until contact and then only pull it far enough to push in the cotter pin.

Transporting the machine safely – Due to transport restrictions, use only suitable means of transport and lifting devices with sufficient load-carrying capacity.

– Park the machine on a flat surface and wedge the crawler or wheels securely.

– If required, detach a part of the machine’s working equipment during transportation.

1.10.11

R 924 Compact Tier III copyright by

MJFCIFSS

Safety instructions, Signs on the machine

Technical documentation

Sichere Wartung der Maschine – The ramp used to drive the machine up onto the flatbed trailer should not exceed an inclination of 30° and should have a wooden cover to prevent sliding back.

– The undercarriage undercarriage should be swept clean, i.e. before driving up the ramp, clean any snow, ice and mud from the crawler / wheels of the machine.

– Align the machine precisely with the loading ramp.

– Attach the hand lever for fine-tune driving (crawler excavator) onto the accelerator pedals.

– Ensure that a spotter gives the machine operator the required signal.

– Prepare the placing block to ensure against rolling back when the machine is driving up onto the flatbed.

– Tilt the equipment up and drive up the loading ramp. While doing this, always hold the equipment securely over the loading area, drive very carefully up the ramp and onto the transportation vehicle.

– Rotate the upper structure carefully to the rear and lower the equipment. Due to restrictions during transport on hoe equipment, tilt the arm in and dismantle the bucket during transportation.

– After loading the machine onto the flatbed trailer, the upper structure must be secured facing the undercarriage using the stop bolts (only A devices).

– Secure the undercarriage and the remaining individual parts using chains and blocks to prevent slipping.

– Before you leave the machine, reduce pressure on all pressure lines, remove the ignition key and tilt up the safety lever.

– Lock all cab and panel doors.

– Before transportation, find out all details about the route to be travelled, particularly as they relate to width, height and weight restrictions.

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

– When unloading the machine, take the same amount of care as was taken when it was loaded.

Remove all chains and blocks. Start the engine as per the operating instructions. Drive carefully off the trailer’s loading area and down the ramp. Hold the working equipment as securely as possible over the ground while doing this. Have a spotter guide you.

4

Sichere Wartung der Maschine Allgemeine Sicherheitshinweise - Wartung – Wartungs- und Reparaturarbeiten dürfen nur durch ausgebildetes Fachpersonal durchgeführt werden.

– Halten Sie vorgeschriebene oder in der Betriebsanleitung angegebene Fristen für wiederkehrende Prüfungen / Inspektionen ein. Zur Durchführung von Instandhaltungsmaßnahmen ist eine der Arbeit angemessene Werkstattausrüstung unbedingt notwendig.

– Anhand des Inspektions- und Wartungsplanes am Ende dieser Betriebsanleitung ist genau definiert, wer welche Arbeiten durchführen muss bzw. darf.

Nach einer Einweisung dürfen die unter täglich / wöchentlich aufgelisteten Arbeiten vom Maschinenfahrer oder Wartungspersonal durchgeführt werden.

Die restlichen Arbeiten dürfen nur durch Fachpersonal mit entsprechender Ausbildung ausgeführt werden.

– Ersatzteile müssen den vom Hersteller festgelegten technischen Anforderungen entsprechen.

Dies ist bei Originalersatzteilen immer gewährleistet.

– Tragen Sie bei der Wartung eine sichere Arbeitskleidung. Vermeiden Sie das Tragen von Ringen, Armbanduhren, Krawatten, Schals, offenen Jacken, nicht anliegenden Kleidern usw.. Es besteht Verletzungsgefahr z.B. durch Hängenbleiben oder Einziehen.

Für bestimmte Arbeiten sind Schutzbrillen, Schutzhelm, Sicherheitsschuhe, Schutzhandschuhe, reflektierende Weste, Gehörschutz usw. notwendig.

1.10.12

R 924 Compact Tier III copyright by

MJFCIFSS

Technical documentation

Safety instructions, Signs on the machine Sichere Wartung der Maschine

– Vermeiden Sie den Aufenthalt in der Nähe des laufenden Dieselmotors.

Menschen mit Herzschrittmacher dürfen sich nicht näher als 20 cm dem laufenden Dieselmotor nähern.

Spannungsführende Teile am elektrischen Anschluss der magnetventilgesteuerten Einzeleinspritzpumpen (Unit Pumps UP) bei laufendem Dieselmotor nicht berühren.

– Halten Sie während der Wartung unbefugte Personen von der Maschine fern.

– Sichern Sie den Instandhaltungsbereich, soweit erforderlich, weiträumig ab.

– Informieren Sie das Bedienungspersonal vor Beginn der Durchführung von Sonder- und Instandhaltungsarbeiten. Benennen Sie die Aufsichtsführenden.

– Führen Sie, wenn in der Betriebsanleitung nicht anders angegeben, alle Wartungsarbeiten an der Maschine auf ebenem, festem Grund mit abgelegter Arbeitsausrüstung und abgestelltem Motor durch.

– Bei bestimmten Geräten ist ein sicherer Zugang zu den Wartungsstellen des Oberwagens (Motorraum, Tanks, ...) gewährleistet nur wenn der Oberwagen in Längsrichtung des Unterwagens und mit den Antriebsrädern nach hinten zeigend steht.

Nur in dieser Stellung stimmt die Lage der Aufstiegsleitern an der Unterwagenstruktur mit den Zutrittstellen am Oberwagen überein.

– Ziehen Sie den Zündschlüssel ab und schließen Sie den Batteriehauptschalter.

– Ziehen Sie bei Wartungs- und Instandsetzungsarbeiten gelöste Schraubenverbindungen stets fest.

– Die Halteschrauben der Haupteile, der Schlaüche und des Gegengewichts müssen nach jeder Demontage ersetzt werden.

– Ist die Demontage von Sicherheitseinrichtungen beim Rüsten, Warten und Reparieren erforderlich, müssen unmittelbar nach Abschluss der Arbeiten die Sicherheitseinrichtungen wieder angebaut und überprüft werden.

– Hängen Sie bei Wartungsarbeiten, besonders bei Arbeit unter der Maschine, ein Warnschild “Nicht einschalten” gut sichtbar an das Startschloss. Ziehen Sie den Startschlüssel ab und schließen Sie den Batteriehauptschalter.

– Betreiben Sie Verbrennungsmotoren und kraftstoffbetriebene Heizungen nur in ausreichend belüfteten Räumen. Achten Sie vor dem Starten in geschlossenem Raum auf ausreichende Belüftung.

– Befolgen Sie die für den jeweiligen Einsatzort geltenden Vorschriften.

Reinigung – Reinigen Sie die Maschine zu Beginn einer Wartung oder Reparatur, und hier insbesondere Anschlüsse und Verschraubungen, von Öl, Kraftstoff oder Pflegemitteln.

Verwenden Sie keine aggressiven Reinigungsmittel und benutzen Sie faserfreie Putztücher.

– Verwenden Sie zum Reinigen der Maschine keine aggressiven Reinigungsmittel oder Dampfstrahlgeräte in den ersten zwei Monaten nach Inbetriebnahme (oder nach Neulackierung).

– Verwenden Sie zum Reinigen der Maschine keine brennbaren Flüssigkeiten.

– Vor dem Reinigen der Maschine mit Wasser oder Dampfstrahl (Hochdruckreiniger) oder anderen Reinigungsmitteln, • schmieren Sie alle Lagerstellen, Bolzenverbindungen und den Drehkranz, um das Eindringen von Wasser und Wasserdampf in die Lagerstellen zu vermeiden.

• decken Sie alle Öffnungen ab bzw. kleben Sie diese zu, in die aus Sicherheits- und / oder Funktionsgründen kein Wasser, Dampf oder Reinigungsmittel eindringen darf.

Besonders gefährdet sind Elektromotoren, Elektrobauteile, Schaltschränke, Steckverbindungen und Luftfilter.

– Achten Sie darauf, dass bei Reinigungsarbeiten des Motorraums Temperaturfühler der Feuerwarn- und Löschanlagen nicht mit heißem Reinigungsmittel in Berührung kommen.

Die Löschanlage könnte ansprechen.

1.10.13

R 924 Compact Tier III copyright by

MJFCIFSS

Safety instructions, Signs on the machine

Technical documentation

Sichere Wartung der Maschine – Wenn Sie zum Reinigen der Maschine ein Dampf- und Heißwasserstrahlgerät verwenden, so sind folgende Vorschriften einzuhalten: • Der Lanzenabstand zur zu reinigenden Fläche muss mindestens 50 cm betragen.

• Die Wassertemperatur darf 60°C nicht überschreiten.

• Der Wasserdruck darf maximal 80 bar sein.

• Verwenden Sie als Waschmittel handelsübliche Auto-Shampoos (Neutral- Reiniger), 2 bis 3 % ig zudosiert.

– Nach dem Reingen, • entfernen Sie die Abdeckungen vollständig.

• untersuchen Sie alle Kraftstoff-, Motoröl- und Hydraulikleitungen auf Undichtigkeiten, gelockerte Verbindungen, Scheuerstellen und Beschädigungen.

• beheben Sie festgestellte Mängel sofort.

• schmieren Sie alle Lagerstellen, Bolzenverbindungen und den Drehkranz, um evtl. eingedrungenes Wasser bzw. Reinigungsmittel zu verdrängen.

Sichtfeld – Spiegel die für den Transport eventuell abgebaut wurden, müssen unvermeidbar vor Geräte-Inbetriebnahme wieder angebaut und richtig eingestellt werden.

– Überprüfen Sie regelmässig die richtige Einstellung der Innen- und Aussenspiegel.

– Überwachen Sie die Umgebung, und besonders den Nahbereich rund um die Maschine, während dem Betrieb oder Fahren.

– Aussenspiegel sind an der Maschine angebracht: • Links an der Kabine zur Überwachung der linken Maschinenseite.

• Vorne-links an der Kabine zur Überwachung der Vorderseite der Grundmaschine.

• Rechts am Oberwagen zur Überwachung der rechten Maschinenseite.

• Über dem Ballastgewicht zur Überwachung der hinteren Maschinenseite; dieser Spiegel ist auf einigen Geräten durch eine Kamera ersetzt bzw. ergänzt.

– Bei jedem An-, Auf- bzw. Umbau an der Maschine muss gewährleistet bleiben, dass die Sichtverhältnisse beibehalten werden. Wird dies nicht gewährleistet, so müssen die Sichtverhältnisse gemäss ISO 5006 überprüft werden.

– Reinigen Sie mindestens täglich alle Spiegel.

– Beschädigte Spiegel sind umgehend zu erneuern.

– Die Baustelle ist so zu organisieren, dass die Gefährdungen durch eingeschränkte Sichtverhältnisse minimiert werden. Dies gilt besonders für Geräte mit einem Dienstgewicht von über 40 Tonnen.

Rissprüfung – Auch bei sorgsamem Umgang mit der Maschine sind in Einzelfällen Überbelastungen nicht auszuschließen, die zu Rissen oder losen Verbindungen führen können. Zur Erhaltung der Betriebssicherheit ist die Maschine daher regelmäßig auf Risse, lose Verbindungen oder andere sichtbare Schäden zu prüfen.

– Zur Prüfung auf Risse ist es zwingend erforderlich, dass die Maschine sauber gehalten und regelmäßig gereinigt wird.

– Die Prüfungen sind gemäß Kontroll- und Wartungsplan durchzuführen, • vom Wartungspersonal des Maschinenbetreibers alle 250 Betriebsstunden.

• vom autorisierten Fachpersonal alle 500 Betriebsstunden.

– Es ist zweckmäßig, solche Prüfungen abgestützt, auf festem und waagerechtem Untergrund, bei wechselnder Belastung mittels Ausrüstung in Längs- und Querrichtung durchzuführen. Die jeweils gültigen Unfallverhütungsvorschriften müssen eingehalten werden.

1.10.14

R 924 Compact Tier III copyright by

MJFCIFSS

Technical documentation

Safety instructions, Signs on the machine Sichere Wartung der Maschine

– Besondere Sorgfalt muss hierbei für die Prüfung der tragenden Bauteile gelten, insbesondere: • Stahlbau Unterwagen mit Achs- und Getriebelagerung, Abstützung, untere Drehkranzauflage mit Turm und Kugeldrehkranz.

• Stahlbau Oberwagen mit Lagerbock für Ausleger und Hubzylinder, obere Drehkranzauflage, Kabinenlagerung, Befestigung von Drehwerksgetriebe und Ballastgewicht.

• Stahlbauteile der Arbeitsausrüstungen, z. B. Ausleger, Stiel, Schnellwechseladapter, Grabgefäße und Greifer.

• Hydraulikzylinder, Achsen, Lenkung, Bolzen und Bolzenverbindungen, Aufstiege, Leitern und Befestigungselemente.

– Die Rissprüfung ist optisch durchzuführen. Um die Prüfsicherheit zu erhöhen, ist bei Rissverdacht oder an schlecht einsehbaren Stellen wie beispielsweise der Drehkranzauflage als Rissprüfung das Farbeindringverfahren anzuwenden.

– Festgestellte Schäden sind umgehend zu beseitigen. Schweißarbeiten an tragenden Teilen von Erdbaumaschinen, Umschlaggeräten und Transportgeräten sind nur durch ausgebildetes Fachpersonal und nur nach den anerkannten Regeln der Schweißtechnik durchzuführen. Im Zweifelsfall sollte Rücksprache mit dem LIEBHERR-Kundendienst gehalten werden, um geeignete Maßnahmen abzusprechen.

Schweißungen, Bohr-, Brenn- und Schleifarbeiten – An allen der Kräfteübertragung dienenden Hauptbauteilen (wie Unterwagenrahmen, Drehbühne, Ausrüstungsteile, ...) darf nur vom Hersteller, oder von einer autorisierten Vertragswerkstatt geschweißt, gebohrt, gebrennt oder geschleift werden. Bei Nichtachtung dieser Vorschrift entfällt die Garantie – Führen Sie Schweiß-, Bohr-, Brenn- und Schleifarbeiten an der Maschine nur durch, wenn dies ausdrücklich genehmigt ist und reinigen Sie vor dem Schweißen, Bohren, Brennen und Schleifen die Maschine und deren Umgebung von Staub und brennbaren Stoffen.

Sorgen Sie für ausreichende Belüftung. Es besteht Brand- und / oder Explosionsgefahr.

– Vor jeder Lichtbogenschweißung am Gerät muss die Batterie abgeklemmt werden. Den Minuspol immer zuerst abklemmen und zuletzt wieder anschließen.

– Bei der Durchführung von Schweissarbeiten an Komponenten die entzündbare Gase enthalten können (Ballastgewicht in geschweisster Konstruktion, Kraftstofftank, Hydrauliktank,...), müssen diese vorher ausreichend mit Druckluft belüftet werden um jede Brenn- oder Explosionsgefahr auszuschliessen.

– Das Massekabel des Schweißgerätes ist so nahe wie möglich an der Schweißstelle anzubringen, damit der Schweißstrom nicht über Teile wie Drehkranz, Gelenke, Lager, Büchsen, Gummielemente oder Dichtungen fließen kann

Betriebs- und Hilfsstoffe – Beachten Sie beim Umgang mit Ölen, Fetten und anderen chemischen Substanzen die für das jeweilige Produkt geltenden Sicherheitsvorschriften.

– Sorgen Sie für sichere und umweltschonende Entsorgung von Betriebs- und Hilfsstoffen sowie Austauschteilen.

– Gehen Sie mit heißen Betriebs- und Hilfsstoffen vorsichtig um (Verbrennungs- und Verbrühungsgefahr).

Reparatur – Versuchen Sie nicht, schwere Teile anzuheben. Verwenden Sie dafür geeignete Hilfsmittel mit ausreichender Tragkraft. Befestigen und sichern Sie Einzelteile und größere Baugruppen beim Austausch sorgfältig an Hebezeugen, so dass von ihnen keine Gefahr ausgehen kann. Verwenden Sie nur geeignete und technisch einwandfreie Hebezeuge sowie Lastaufnahmemittel mit ausreichender Tragkraft.

Halten Sie sich nicht unter schwebenden Lasten auf bzw. arbeiten Sie nicht darunter.

– Verwenden Sie keine beschädigten oder in der Tragfähigkeit nicht ausreichende Hebezeuge.

Tragen Sie Schutzhandschuhe beim Umgang mit Drahtseilen.

1.10.15

R 924 Compact Tier III copyright by

MJFCIFSS

Safety instructions, Signs on the machine

Technical documentation

Sichere Wartung der Maschine – Beauftragen Sie nur erfahrene Personen mit dem Anschlagen von Lasten und Einweisen von Kranführern. Der Einweiser muss sich in Sichtweite des Bedieners aufhalten oder mit ihm in Sprechkontakt stehen.

– Verwenden Sie bei Arbeiten über Körperhöhe dafür vorgesehene, sicherheitsgerechte Aufstiegshilfen und Arbeitsbühnen.

Maschinenteile nicht als Aufstiegshilfen benutzen, wenn diese nicht dafür vorgesehen sind.

Tragen Sie Absturzsicherungen bei Arbeiten in großer Höhe.

Halten Sie alle Griffe, Tritte, Geländer, Podeste, Bühnen und Leitern frei von Verschmutzung, Schnee und Eis. – Gasfedern dürfen nicht als Haltegriffe verwendet werden. Achten Sie darauf dass beim öffnen der Türen und Hauben die Gasfedern nicht auf Anschlag stossen, dadurch können mechanische Beschädigungen der Gasfedern entstehen – Achten Sie auf eine sichere Abstützung bevor Sie an der Ausrüstung Arbeiten (z. B. Auswechseln von Zähnen). Vermeiden Sie dabei Metall auf Metall.

– Öffnen und montieren Sie aus Sicherheitsgründen niemals eine Kette ab, ohne vorher die Feder der Spanneinheit entspannt zu haben.

– Legen Sie sich niemals unter die Maschine, wenn diese mit Hilfe der Arbeitsausrüstung angehoben ist, ohne dass der Unterwagen mit Holzbalken oder anderen geeigneten Auflagen standsicher unterbaut ist.

– Bocken Sie die Maschine immer so auf, dass eventuelle Gewichtsverlagerungen die Standsicherheit nicht gefährden und vermeiden Sie dabei den Kontakt von Metall auf Metall.

– Arbeiten an Fahrwerken, Brems- und Lenkanlagen dürfen nur von hierfür ausgebildetem Fachpersonal durchgeführt werden.

– Muss die Maschine am Hang repariert werden, sind die Ketten mit Hemmklötzen zu sichern, der Oberwagen richtung Bergab zu drehen, und das Arbeitswerkzeug auf dem Boden zu legen. Der Oberwagen ist mittels Arretierbolzen mit dem Unterwagen zu verbinden, wenn vorhanden.

– An hydraulischen Einrichtungen darf nur Personal mit speziellen Kenntnissen und Erfahrungen arbeiten.

– Tragen Sie Schutzhandschuhe bei der Suche nach Leckagen. Ein feiner Flüssigkeitsstrahl unter Druck kann die Haut durchdringen.

– Lösen Sie keine Leitung oder Verschraubung, bevor sie die Ausrüstung abgelegt, den Motor abgestellt und das Hydrauliksystem entlastet haben. Nach dem Abstellen des Motors müssen Sie, mit dem Zündschlüssel in Kontaktstellung und nach unten geklapptem Sicherheitshebel, alle Vorsteuergeräte (Kreuzschalthebel und Pedale) in allen Richtungen bewegen, um den Steuerdruck und die Staudrücke in den Arbeitskreisen abzubauen. Anschließend müssen Sie den Tankinnendruck, wie in dieser Betriebsanleitung beschrieben, abbauen.

Elektroanlage – Prüfen Sie regelmäßig die elektrische Anlage.

Lassen Sie sofort alle Fehler, wie lose Verbindungen, durchgebrannte Sicherungen und Glühlampen, angeschmorte oder durchgescheuerte Kabel, von Fachpersonal beheben.

– Verwenden Sie nur Original-Sicherungen mit vorgeschriebener Stromstärke.

– Bei Maschinen mit elektrischen Mittel- und Hochspannungsleitungen: • bei Störungen in der elektrischen Energieversorgung schalten Sie die Maschine sofort ab.

– Arbeiten an elektrischen Ausrüstungen der Maschine dürfen nur von einer Elektrofachkraft oder von unterwiesenen Personen unter Leitung und Aufsicht einer Elektrofachkraft gemäß den elektrotechnischen Vorschriften vorgenommen werden.

– Ziehen Sie bei Arbeiten an spannungsführenden Teilen eine zweite Person hinzu, die im Notfall den Not-Aus bzw. den Hauptschalter mit Spannungsauslösung betätigt. Sperren Sie den Arbeitsbereich mit einer rotweißen Sicherungskette und einem Warnschild ab. Benutzen Sie nur spannungsisoliertes Werkzeug.

– Bei Arbeiten an Mittel- und Hochspannungsbaugruppen, nach dem Freischalten der Spannung, schließen Sie das Versorgungskabel an Masse und die Bauteile, z. B. Kondensatoren, mit einem Erdungsstab kurz.

1.10.16

R 924 Compact Tier III copyright by

MJFCIFSS

Technical documentation

Safety instructions, Signs on the machine Sichere Wartung der Maschine

– Prüfen Sie die freigeschalteten Teile zuerst auf Spannungsfreiheit, erden und schließen Sie diese dann kurz. Isolieren Sie benachbarte, unter Spannung stehende Teile.

– Klemmen Sie die Batterie ab, bevor Sie an der Elektroanlage arbeiten oder Lichtbogenschweißungen an der Maschine vornehmen.

Lösen Sie zuerst den Minuspol, dann den Pluspol. Verfahren Sie beim Anklemmen in umgekehrter Reihenfolge.

Hydrospeicher – Alle Arbeiten an den Hydrospeichern dürfen nur von dafür ausgebildetem Fachpersonal ausgeführt werden.

– Unsachgemäßes Montieren und Handhaben von Hydrospeichern kann schwere Unfälle verursachen.

– Nehmen Sie keine beschädigten Hydrospeicher in Betrieb.

– Vor Arbeiten an einem Hydrospeicher müssen Sie den Druck im Hydrauliksystem (Hydraulikanlage einschließlich Hydrauliktank) wie in dieser Betriebsanleitung beschrieben abbauen.

– Schweißen oder löten Sie nicht am Hydrospeicher und führen Sie daran keine mechanischen Arbeiten durch.

Der Hydrospeicher kann durch Hitzeeinwirkung beschädigt sowie durch mechanische Bearbeitung zum Bersten gebracht werden. ES BESTEHT EXPLOSIONSGEFAHR! – Befüllen Sie Hydrospeicher nur mit Stickstoff. Bei Verwendung von Sauerstoff oder Luft besteht EXPLOSIONSGEFAHR! – Der Speicherkörper kann im Betrieb heiß werden, es besteht Verbrennungsgefahr.

– Neue Hydrospeicher müssen vor Inbetriebnahme mit dem für den Einsatzzweck notwendigen Druck gefüllt sein.

– Die Betriebsdaten (minimaler und maximaler Druck) sind auf Hydrospeichern dauerhaft gekennzeichnet. Sorgen Sie dafür, dass die Kennzeichnung sichtbar erhalten bleibt.

Hydraulikschläuche und Schlauchleitungen – Reparaturen an Hydraulikschläuchen und Schlauchleitungen sind verboten!

– Alle Schläuche, Schlauchleitungen und Verschraubungen sind regelmäßig alle 2 Wochen, bei mutmaßlichen Beschädigungen sofort auf Undichtigkeiten und äußerlich erkennbare Beschädigungen zu überprüfen!

Suchen Sie eventuelle Leckstellen nicht mit nackten Händen, verwenden Sie dazu ein Blatt Papier oder ähnliches Material.

Beseitigen Sie umgehend beschädigte Teile! Herausspritzendes Öl kann zu Verletzungen und Bränden führen.

– Auch bei sachgemäßer Lagerung und zulässiger Beanspruchung unterliegen Schläuche und Schlauchleitungen einer natürlichen Alterung. Dadurch ist ihre Verwendungsdauer begrenzt.

• Unsachgemäße Lagerung, mechanische Beschädigungen und unzulässige Beanspruchung sind die häufigsten Ausfallursachen.

• Im Bezug auf die Verwendungsdauer sind die am Einsatzort gültigen Normen, Regeln und Richtlinien über Schläuche und Schlauchleitungen zu beachten.

• Der Einsatz im Grenzbereich der zulässigen Beanspruchung kann die Verwendungsdauer verkürzen (z. B. hohe Temperaturen, häufige Bewegungsspiele, extrem hohe Impulsfrequenzen, Mehrschichtbetrieb).

1.10.17

R 924 Compact Tier III copyright by

MJFCIFSS

Safety instructions, Signs on the machine

Technical documentation

Sichere Wartung der Maschine – Schläuche und Schlauchleitungen sind zu ersetzen, wenn bei der Inspektion folgende Zustände festgestellt werden: • Beschädigungen an der Außenschicht bis zur Einlage (z. B. Scheuerstellen, Schnitte und Risse); • Versprödung der Außenschicht (Rissbildung des Schlauchmaterials); • Verformungen, die der natürlichen Form des Schlauches oder der Schlauchleitung nicht entsprechen, sowohl im drucklosen wie auch im druckbeaufschlagten Zustand oder bei Biegungen, z. B. Schichtentrennung, Blasenbildung, Knick- oder Quetschstellen; • Undichte Stellen; • Nichtbeachtung der Anforderungen an den Einbau; • Beschädigungen oder Deformationen der Schlaucharmatur, welche die Festigkeit der Armatur oder der Verbindung Schlauch / Armatur mindern; • Herauswandern des Schlauches aus der Armatur; • Korrosion der Armatur, welche die Funktion und Festigkeit mindern; – Verwenden Sie beim Austausch von Schläuchen und Schlauchleitungen nur Original-Ersatzteile.

– Verlegen und montieren Sie Schläuche und Schlauchleitungen fachgerecht. Verwechseln Sie Anschlüsse nicht.

– Beim Austausch von Schläuchen und Schlauchleitungen ist zu beachten: • Achten Sie immer auf eine torsionsfreie Verlegung der Schläuche und Schlauchleitungen. Bei Hochdruckschläuchen sind immer die Schrauben der Halbschellen bzw. Vollflansche an beiden Schlauchenden anzubringen und erst danach anzuziehen.

• Bei Hochdruckschläuche und Schlauchleitungen mit gebogener Armatur muss beim Anziehen der Flansche immer zuerst die Seite mit der gebogenen Armatur und erst danach die Seite mit der geraden Armatur angezogen werden.

• Eventuell vorhandene Befestigungsschellen in der Schlauchmitte dürfen erst anschließend angebracht und angezogen werden.

• Prüfen Sie täglich, dass alle Schellen, Abdeckungen und Schutzeinrichtungen richtig befestigt sind. Dadurch werden während des Betriebs Vibrationen und Beschädigungen vermieden.

• Verlegen Sie die Schläuche und Schlauchleitungen so, dass ein Scheuern mit anderen Schläuchen und Schlauchleitungen oder sonstigen Teilen ausgeschlossen ist.

• Ein Mindestabstand zu den restlichen Teilen von ca. 1/2 des Außendurchmessers des Schlauches wird empfohlen. Der Abstand sollte jedoch 10 bis 15 mm nicht unterschreiten.

• Prüfen Sie beim Austausch von Schläuchen und Schlauchleitungen an beweglichen Teilen (z.

B. vom Ausleger zum Stiel) vor der Erstinbetriebnahme, dass über den gesamten Bewegungsbereich keine Scheuerstellen vorhanden sind.

1.10.18

R 924 Compact Tier III copyright by

MJFCIFSS

Technical documentation

Tightening torques

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

1.20: Tightening torques 1

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

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

Metric coarse thread

Thread

Class

Assembly preloads FM in N

Metric fine thread Tightening torques MA in Nm

M4

8.8 10.9 12.9

4050 6000 7000

2,8 4,1 4,8

M5

8.8 10.9 12.9

6600 9700 11400

5,5 8,1 9,5

M6

8.8 10.9 12.9

9400 13700 16100

9,5 14,0 16,5

M7

8.8 10.9 12.9

13700 20100 23500

15,5 23,0 27,0

M8

8.8 10.9 12.9

17200 25000 29500

23,0 34,0 40,0

M10

M12

M14

8.8 10.9 12.9

8.8 10.9 12.9

8.8 10.9 12.9

27500 40000 47000

40000 59000 69000

55000 80000 94000

46,0 68,0 79,0

79,0 117,0 135,0

125,0 185,0 215,0

Thread

Class

Assembly preloads FM in N

Tightening torques MA in Nm

M8×1

8.8 10.9 12.9

18800 27500 32500

24,5 36 43

M9×1

8.8 10.9 12.9

24800 36500 42500

36 53 62

M10×1

8.8 10.9 12.9

31500 46500 54000

52 76 89

M10×1,25

8.8 10.9 12.9

29500 43000 51000

49 72 84

M12×1,25

8.8 10.9 12.9

45000 66000 73000

87 125 150

M12×1,5

8.8 10.9 12.9

42500 62000 73000

83 122 145

M14×1,5

8.8 10.9 12.9

61000 89000 104000

135 200 235

1.20.1

R 924 Compact Tier III copyright by

MJFCIFSS

Tightening torques

Technical documentation

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

Metric fine thread

8.8 10.9 12.9

75000 111000 130000

195,0 280,0 330,0

8,8 10,9 12,9

94000 135000 157000

280 390 460

8.8 10.9 12.9

82000 121000 141000

205 300 360

M18×1,5

8,8 10,9 12,9

110000 157000 184000

310 440 520

M18×2

8,8 10,9 12,9

102000 146000 170000

290 420 490

M16×1,5

M20

8,8 10,9 12,9

121000 173000 202000

390 560 650

M20×1,5

8,8 10,9 12,9

139000 199000 232000

430 620 720

M22

8,8 10,9 12,9

152000 216000 250000

530 750 880

M22×1,5

8,8 10,9 12,9

171000 245000 285000

580 820 960

M24

8,8 10,9 12,9

175000 249000 290000

670 960 1120

M24×1,5

8,8 10,9 12,9

207000 295000 346000

760 1090 1270

M24×2

8,8 10,9 12,9

196000 280000 325000

730 1040 1220

M27×1,5

8,8 10,9 12,9

267000 381000 445000

1110 1580 1850

M27×2

8,8 10,9 12,9

255000 365000 425000

1070 1500 1800

M30×1,5

8,8 10,9 12,9

335000 477000 558000

1540 2190 2560

M30×2

8,8 10,9 12,9

321000 457000 534000

1490 2120 2480

M33×1,5

8,8 10,9 12,9

410000 584000 683000

2050 2920 3420

M33×2

8,8 10,9 12,9

395000 560000 660000

2000 2800 3300

M36×1,5

8,8 10,9 12,9

492000 701000 820000

2680 3820 4470

M36×3

8,8 10,9 12,9

440000 630000 740000

2500 3500 4100

M39×1,5

8,8 10,9 12,9

582000 830000 971000

3430 4890 5720

M39×3

8,8 10,9 12,9

530000 750000 880000

3200 4600 5300

M27

M30

M33

M36

M39

8,8 10,9 12,9

8,8 10,9 12,9

8,8 10,9 12,9

8,8 10,9 12,9

8,8 10,9 12,9

230000 330000 385000

280000 400000 465000

350000 495000 580000

410000 580000 680000

490000 700000 820000

1000 1400 1650

1350 1900 2250

1850 2600 3000

2350 3300 3900

3000 4300 5100

1.20.2

R 924 Compact Tier III copyright by

MJFCIFSS

Technical documentation

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

2

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

Type with sealing edge Type

Thread M or G

Type with EOLASTIC seal Tightening torques (Nm)

Type

Thread M or G

Tightening torques (Nm)

Light-duty series L GE 06 LM A 3 C

M 10×1

18

GE 06 LM ED A 3 C

M 10×1

18

GE 06 LR A 3 C

G 1/8 A

18

GE 06 LR ED A 3 C

G 1/8 A

18

GE 08 LM A 3 C

M 12×1,5

30

GE 08 LM ED A 3 C

M 12×1,5

25

GE 08 LR A 3 C

G 1/4 A

35

GE 08 LR ED A 3 C

G 1/4 A

35

GE 10 LM A 3 C

M 14×1,5

45

GE 10 LM ED A 3 C

M 14×1,5

45

GE 10 LR A 3 C

G 1/4 A

35

GE 10 LR ED A 3 C

G 1/4 A

35

GE 12 LM A 3 C

M 16×1,5

65

GE 12 LM ED A 3 C

M 16×1,5

55

GE 12 LR A 3 C

G 3/8 A

70

GE 12 LR ED A 3 C

G 3/8 A

70

GE 15 LM A 3 C

M 18×1,5

80

GE 15 LM ED A 3 C

M 18×1,5

70

GE 15 LR A 3 C

G 1/2 A

140

GE 15 LR ED A 3 C

G 1/2 A

90

GE 18 LM A 3 C

M 22×1,5

140

GE 18 LM ED A 3 C

M 22×1,5

125

GE 18 LM A 3 C

M 22×1,5

140

GE 18 LM ED A 3 C

M 22×1,5

125

GE 18 LR A 3 C

G 1/2 A

100

GE 18 LR ED A 3 C

G 1/2 A

GE 22 LM A 3 C

M 22×1,5

140

GE 22 LM ED A 3 C

M 26×1,5

180

GE 22 LR A 3 C

G 3/4 A

180

GE 22 LR ED A 3 C

G 3/4 A

180

GE 28 LM A 3 C

M 33×2,0

340

GE 28 LM ED A 3 C

M 33 x 2,0

310

GE 28 LR A 3 C

G1A

330

GE 28 LR ED A 3 C

G1A

310

GE 35 LM A 3 C

M 42×2,0

500

GE 35 LM ED A 3 C

M 42×2,0

450

GE 35 LR A 3 C

G 1 1/4 A

540

GE 35 LR ED A 3 C

G 1 1/4 A

450

GE 42 LM A 3 C

M 48×2,0

630

GE 42 LM ED A 3 C

M 48×2,0

540

GE 42 LR A 3 C

G 1 1/2 A

630

GE 42 LR ED A 3 C

G 1 1/2 A

540

90

Heavy-duty series S GE 06 SM A 3 C

M 12×1,5

35

GE 06 SM ED A 3 C

M 12×1,5

35

GE 06 SR A 3 C

G 1/4 A

55

GE 06 SR ED A 3 C

G 1/4 A

55

GE 08 SM A 3 C

M 14×1,5

55

GE 08 SM ED A 3 C

M 14×1,5

55

GE 08 SR A 3 C

G 1/4 A

55

GE 08 SR ED A 3 C

G 1/4 A

55

GE 10 SM A 3 C

M 16×1,5

70

GE 10 SM ED A 3 C

M 16×1,5

70

GE 10 SR A 3 C

G 3/8 A

90

GE 10 SR ED A 3 C

G 3/8 A

80

GE 12 SM A 3 C

M 18×1,5

110

GE 12 SM ED A 3 C

M 18×1,5

90

GE 12 SR A 3 C

G 3/8 A

90

GE 12 SR ED A 3 C

G 3/8 A

80

GE 14 SM A 3 C

M 20×1,5

150

GE 14 SM ED A 3 C

M 20×1,5

125

GE 14 SR A 3 C

G 1/2 A

150

GE 14 SR ED A 3 C

G 1/2 A

115

GE 16 SM A 3 C

M 22×1,5

170

GE 16 SM ED A 3 C

M 22×1,5

135

GE 16 SR A 3 C

G 1/2 A

130

GE 16 SR ED A 3 C

G 1/2 A

115

GE 20 SM A 3 C

M 27×2,0

270

GE 20 SM ED A 3 C

M 27×2,0

180

GE 20 SR A 3 C

G 3/4 A

270

GE 20 SR ED A 3 C

G 3/4 A

180

GE 25 SM A 3 C

M 33×2,0

410

GE 25 SM ED A 3 C

M 33×2,0

310

GE 25 SR A 3 C

G1A

340

GE 25 SR ED A 3 C

G1A

310

1.20.3

R 924 Compact Tier III copyright by

MJFCIFSS

Tightening torques

Technical documentation

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

M 42×2,0

540

GE 30 SM ED A 3 C

M 42×2,0

450

GE 30 SR A 3 C

G 1 1/4 A

GE 38 SM A 3 C

M 48×2,0

540

GE 30 SR ED A 3 C

G 1 1/4 A

450

700

GE 38 SM ED A 3 C

M 48×2,0

540

GE 38 SR A 3 C

G 1 1/2 A

700

GE 38 SR ED A 3 C

G 1 1/2 A

540

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

3

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

Type

Thread

Tightening torque (Nm)

Type

Thread

Tightening torque (Nm)

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

G 1/8 A

18

WH / TH 06 LM KDS A3C

M 10×1

18

WH / TH 08 LR KDS A 3C

G 1/4 A

45

WH / TH 08 LM KDS A3C

M 12×1,5

45

WH / TH 10 LR KDS A 3C

G 3/8 A

45

WH / TH 10 LM KDS A3C

M 14×1,5

55

WH / TH 12 LR KDS A 3C

G1/2 A

70

WH / TH 12 LM KDS A3C

M 16×1,5

80

WH / TH 15 LR KDS A 3C

G3/4 A

120

WH / TH 15 LM KDS A3C

M 18×1,5

100

WH / TH 18 LR KDS A 3C

G1 A

120

WH / TH 18 LM KDS A3C

M 22×1,5

140

WH / TH 22 LR KDS A 3C

G 1 1/4 A

230

WH / TH 22 LM KDS A3C

M 27×2,0

320

WH / TH 28 LR KDS A 3C

G 1 1/4 A

320

WH / TH 28 LM KDS A3C

M 33 x 2,0

360

WH / TH 35 LR KDS A 3C

G 1 1/4 A

540

WH / TH 35 LM KDS A3C

M 42×2,0

540

WH / TH 42 LR KDS A 3C

R 1 1/2 A

700

WH / TH 42 LM KDS A3C

M 48×2,0

700

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

G 1/4 A

45

WH / TH 06 SM KDS A3C

M 12×1,5

45

WH / TH 08 SR KDS A3C

G 1/4 A

45

WH / TH 08 SM KDS A3C

M 14×1,5

55

WH / TH 10 SR KDS A3C

G 3/8 A

70

WH / TH 10 SM KDS A3C

M 16×1,5

80

WH / TH 12 SR KDS A3C

G 3/8 A

70

WH / TH 12 SM KDS A3C

M 18×1,5

100

WH / TH 16 SR KDS A3C

G 1/2 A

120

WH / TH 14 SM KDS A3C

M 20×1,5

125

WH / TH 20 SR KDS A3C

G 3/4 A

230

WH / TH 16 SM KDS A3C

M 22×1,5

135

WH / TH 25 SR KDS A3C

G1A

320

WH / TH 20 SM KDS A3C

M 27×2,0

320

WH / TH 30 SR KDS A3C

G 1 1/4 A

540

WH / TH 25 SM KDS A3C

M 33×2,0

360

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Technical documentation

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

WH / TH 38SR KDS A 3C

4

G 1/4 A

700

WH / TH 30 SM KDS A3C

M 42×2,0

540

WH / TH 38 SM KDS A3C

M 48×2,0

700

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

Gewinde

Anziehdreh momente (Nm)

M 10×1

12

VSTI 1/8 ED A3C

G 1/8 A

13

VSTI 12×1,5 ED A3C

M 12×1,5

25

VSTI 1/4 ED A3C

G 1/4 A

30

VSTI 14×1,5 ED A3C

M 14×1,5

35

VSTI 3/8 ED A3C

G 3/8 A

60

VSTI 16×1,5 ED A3C

M 16×1,5

55

VSTI 1/2 ED A3C

G 1/2 A

80

VSTI 18×1,5 ED A3C

M 18×1,5

65

VSTI 3/4 ED A3C

G 3/4 A

140

VSTI 20×1,5 ED A3C

M 20×1,5

80

VSTI 1 ED A3C

G1A

200

VSTI 22×1,5 ED A3C

M 22×1,5

90

VSTI 1 1/4 ED A3C

G 1 1/4 A

450

VSTI 1 1/2 ED A3C

G 1 1/2 A

450

Type VSTI 10×1 ED A3C

VSTI 26×1,5 ED A3C

M 26×1,5

120

VSTI 27×2 ED A3C

M 27×2,0

135

VSTI 33×2 ED A3C

M 33×2,0

225

VSTI 42×2 ED A3C

M 42×2,0

360

VSTI 48×2 ED A3C

M 48×2,0

380

Type

Gewinde

Anziehdreh momente (Nm)

VSTI = Hexagon socket plug

1.20.5

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Tightening torques

Technical documentation

Tightening torques of screw-in studs (Ermeto)

1.20.6

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Technical documentation

Installations for pistons and piston nuts by hydraulic Application and purpose

1.22: Installations for pistons and piston nuts by hydraulic cylinders According to standard 4121 C (06/2008)

1

Application and purpose This Liebherr standard applies only to hydraulic cylinders, and in particular to the mounting of pistons and piston nuts on piston rods from a thread diameter of M42 and greater.

This standard describes the tightening procedure with turning distance and angle.

For threads with diameters smaller than M42, the applicable tightening torque is indicated in the drawings. The values in the drawings are always binding.

2

Requirements / description of procedure For the valid torque value number, refer to the drawing. The standard may not be adopted or transferred to apparently similar geometries.

Use this number to find the applicable turning distance and angle in the torque table (siehe Kap. 3, �Torque table - Status 02.06.2010� auf Seite 7).

The torque values have been determined empirically and are subject to changes. This standard differentiates between two tightening procedures, which are identified with 3-digit and 4-digit numbers respectively (see chapters 2.1 and 2.2).

1.22.1

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Installations for pistons and piston nuts by hydraulic

Technical documentation

Requirements / description of procedure

2.1

Tightening with assembly wrench This tightening procedure applies to 3-digit tightening numbers.

2.1.1

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

2.1.2

Definitions Pretightening torque (Mv) The piston (A) is secured with a torque wrench (B) applied to the square/hexagon head of the assembly wrench (C). The position of the torque wrench must be carefully noted (see Fig. 1 on page2).

Turning distance (4) Radian measure [mm] travelled as a result of the tightening of the piston, or piston nut along the outer thread diameter, after application of the pretightening torque (see Fig. 2 on page3).

Turning angle (5) Angle [°] travelled by the piston or piston nut respectively, after application of the pretightening torque (see Fig. 2 on page3).

Fig. 1

Torque wrench A B

Piston Torque wrench

C

Assembly wrench

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

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Technical documentation

Installations for pistons and piston nuts by hydraulic Requirements / description of procedure

Fig. 2

Markings, turning distance, turning angle 1 2 3 4 5 6 7

Markings on the piston and the piston rod thread after application of the pretightening torque Markings on the piston rod thread Markings on the piston after tightening Turning distance Turning angle Markings on the piston nut and the piston rod thread after application of the pretightening torque Markings on the piston nut after tightening

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Installations for pistons and piston nuts by hydraulic

Technical documentation

Requirements / description of procedure

2.2

Tightening with hydraulic assembly device This tightening procedure applies to 4-digit tightening numbers.

2.2.1

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

2.2.2

Definitions Pretightening torque Torque applied on the piston or piston nut with the torque wrench (A) via the hexagon head (B) of the torque converter (C) (see Fig. 3 on page4).

Turning angle Angle [°] travelled by the piston or piston nut respectively, after application of the pretightening torque (see Fig. 5 on page6).

Fig. 3

Torque wrench A Torque wrench B Hexagon head C Torque converter

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Technical documentation

Installations for pistons and piston nuts by hydraulic Requirements / description of procedure

2.2.3

Operation of the assembly device See separate operating manual of the assembly device (H).

For suitable adapters for the piston rod, piston and piston nut, refer to the piston parts list (see Fig. 4 on page5).

Fig. 4

Operation of the assembly device A Piston rod B Piston C D E F G H

Adapter for piston Adapter for piston rod Piston nut Adapter for piston nut Torque converter Assembly device

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Installations for pistons and piston nuts by hydraulic

Technical documentation

Requirements / description of procedure

Fig. 5

Angle scale A Dial B Adjusting screw C Angle scale

Before tightening, set the dial (A) with the adjusting screw (B) to position 0° on the angle scale (C).

The angle scale indicates the turning angle.

If the opening angle of the assembly device is not sufficient to achieve the prescribed turning angle, mount the device again for a second tightening process. Note the previously completed angle.

Before continuing the tightening process, set the dial to the last achieved angle value.

Repeat this process as often as necessary to achieve the prescribed turning angle.

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Technical documentation

Installations for pistons and piston nuts by hydraulic Torque table - Status 02.06.2010

3 3.1

Torque table - Status 02.06.2010 Tightening with assembly wrench (siehe Kap. 2.1, ”Tightening with assembly wrench” auf Seite 2) Piston

Piston nut

WN 4121 No

Pretightening torque [N.m]

Turning distance [mm]

Turning angle ~ [°]

Turning distance [mm]

Turning angle ~ [°]

Thread M [mm]

071

100

11 +1

30

21 +1

57

42x1,5

072

100

21 +1

57

21 +1

57

42x1,5

073

100

18 +1

49

19 +1

52

42x1,5

074

100

16 +1

44

-

-

42x1,5

075

100

19 +1

52

21 +1

57

42x1,5

078

100

20 +1

55

14 +1

38

42x1,5

079

100

11 +1

30

21 +1

57

42x1,5

080

100

18 +1

49

-

-

42x1,5

091

100

13 +1

30

19 +1

44

50x2

092

100

25 +1

57

19 +1

44

50x2

093

100

24 +1

55

19 +1

44

50x2

095

100

13 +1

30

19 +1

44

50x2

096

100

10 +1

23

9 +1

21

50x2/SW65

097

100

17 +1

39

19 +1

44

50x2

098

100

17 +1

39

-

-

50x2

099

100

24 +1

55

19 +1

44

50x2

103

100

9 +1

21

-

-

50x2

111

100

16 +1

33

18 +1

37

56x2

112

100

17 +1

35

18 +1

37

56x2

113

100

18 +1

37

18 +1

37

56x2

114

100

19 +1

39

-

-

56x2

115

100

18 +1

37

-

-

56x2

116

100

19 +1

39

-

-

56x2

121

150

15 +1

29

19 +1

36

60x2

123

150

17 +1

32

19 +1

36

60x2

126

150

14 +1

27

-

-

60x2

127

150

22 +1

42

-

-

60x2

129

150

7 +1

13

8 +1

15

60x2

151

150

15 +1

27

19 +1

34

65x2

152

150

20 +1

35

19 +1

34

65x2

153

150

20 +1

35

-

-

65x2

171

150

12 +2

20

18 +1

30

68x2

172

150

21 +2

35

18 +1

30

68x2

173

150

19 +2

32

18 +1

30

68x2

174

150

25 +2

42

18 +1

30

68x2

175

150

25 +2

42

18 +1

30

68x2

176

150

19 +2

32

18 +1

30

68x2

177

150

19 +2

32

18 +1

30

68x2

1.22.7

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Installations for pistons and piston nuts by hydraulic

Technical documentation

Torque table - Status 02.06.2010 Piston

Piston nut

WN 4121 No

Pretightening torque [N.m]

Turning distance [mm]

Turning angle ~ [°]

Turning distance [mm]

Turning angle ~ [°]

179

150

11 +2

19

18 +1

30

68x2

180

150

20 +2

34

18 +1

30

68x2

181

150

20 +2

34

-

-

68x2

183

200

-

-

40 +2

67

68x2

201

200

17 +2

26

16 +1

24

76x2

202

200

26 +2

39

16 +1

24

76x2

203

200

27 +2

41

16 +1

24

76x2

204

200

27 +2

41

16 +1

24

76x2

205

200

13 +2

20

-

-

76x2

206

200

25 +2

38

25 +1

38

76x2

207

200

23 +2

35

-

-

76x2

208

200

15 +2

22

-

-

76x2

209

200

30 +2

45

-

-

76x2

231

200

8 +2

11

16 +1

22

85x3

232

200

17 +2

23

16 +1

22

85x3

234

200

22 +2

30

-

-

85x3

236

200

15 +2

20

-

-

85x3

237

200

19 +2

26

-

-

85x3

261

250

20 +2

25

10 +1

12

95x3

265

250

24 +2

29

10 +1

12

95x3

267

250

24 +2

29

-

-

95x3

281

250

20 +2

23

13 +1

15

100x3

282

250

25 +2

29

-

-

100x3

283

250

25 +2

29

21 +1

24

100x3

284

250

9 +1

10

-

-

100x3

285

250

18 +1

20

-

-

100x3

301

300

21 +3

22

20 +2

21

110x3

302

300

18 +3

19

20 +2

21

110x3

303

300

20 +3

21

20 +2

21

110x3

304

300

23 +3

24

20 +2

21

110x3

305

300

9 +3

9

-

-

110x3

306

300

24 +3

25

-

-

110x3

307

300

27 +3

28

-

-

110x3

331

400

23 +3

22

20 +2

19

120x3

332

400

11 +3

11

-

-

120x3

333

400

27 +3

26

-

-

120x3

334

400

20 +3

19

20 +2

19

120x3

335

400

30 +3

29

-

-

120x3

336

400

29 +3

28

-

-

120x3

501

200

21 +2

30

-

-

80x2

531

500

34 +3

28

-

-

140x3

561

100

10 +1

25

-

-

45x1,5

1.22.8

Thread M [mm]

R 924 Compact Tier III copyright by

MJFCIFSS

Technical documentation

Installations for pistons and piston nuts by hydraulic Torque table - Status 02.06.2010

3.2

Tightening with hydraulic assembly device (siehe Kap. 2.2, ”Tightening with hydraulic assembly device” auf Seite 4) Piston

Piston nut

WN 4121 No

Pretightening torque Mv [N.m]

Turning angle ~ [°]

Turning angle ~ [°]

1000

300

27+1

8+1

240x4

1001

300

18+1

8+1

200x4

1002

300

18+1

8+1

150x4

1003

300

23+1

8+1

170x4

1004

300

21+1

8+1

140x4

1005

300

18+1

8+1

180x4

1006

300

39+1

8+1

150x3

1007

300

27+1

3+1

160x4

1008

300

31+1

5+1

180x4

1009

300

20 +1

-

200x4

1010

300

27 +1

5 +1

180x4

1011

300

18 +1

-

260x4

1012

300

33 +1

-

200x4

Thread M [mm]

1.22.9

R 924 Compact Tier III copyright by

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Installations for pistons and piston nuts by hydraulic

Technical documentation

Torque table - Status 02.06.2010

1.22.10

R 924 Compact Tier III copyright by

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Technical documentation

Assembly instruction for piston rod bearings with exDescription

1.24: Assembly instruction for piston rod bearings with external threads (hydraulic cylinders) According to standard 4122 B (01/2005) Scope of application This factory standard applies exclusively to the assembly of hydraulic cylinders.

For the valid factory standard number, refer to the drawing. The standard may not be adopted or transferred to apparently similar geometries.

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

1

Description Preparation: Clean the thread and apply a thin layer of Gleitmo high-performance lubricating grease (ID no.

8300 004, 40 g tube) on both sides.

1.1

Definitions Pretightening torque: The piston rod bearing is secured with a torque wrench applied to the square of the assembly wrench.

The position of the torque wrench must be carefully noted.

Fig. 1

Torque wrench A B

Piston Torque wrench

C

Assembly wrench

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

Turning distance: Radian measure [mm] between the bearing head outer diameter and the cylinder tube, tavelled after application of the pretightening torque.

Turning angle: Angle [°] travelled by the bearing head after application of the pretightening torque.

1.24.1

R 924 Compact Tier III copyright by

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Assembly instruction for piston rod bearings with ex-

Technical documentation

Description

Fig. 2

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

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

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

1.24.2

R 924 Compact Tier III copyright by

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Technical documentation

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

2

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

Preload (N.m)

Turning distance (mm)

Turning angle (< °)

001 011

50

7 +1

10

016

100

10 +1

12

017

100

10 +1

12

026

100

9 +1

10

027

100

10 +1

11

031

100

8 +1

8

036

100

11 +1

10

037

100

10 +1

9

039 041

150

9 +1

7

046

200

12 +1

10

053

200

25 +1

18

061

200

10 +1

7

091

300

10 +1

5,5

111

300

12 +1

6

151

400

14 +1

6

047 051 052

1.24.3

R 924 Compact Tier III copyright by

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Assembly instruction for piston rod bearings with ex-

Technical documentation

Tightening torques for factory standard (02.07.2008)

1.24.4

R 924 Compact Tier III copyright by

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Technical documentation

Lubricants and operating fluids General information on changing lubricants and operating fluids

1.51: Lubricants and operating fluids 1

General information on changing lubricants and operating fluids Note The quantities given in the lubrication and operating material chart and on the lubrication chart in the cab are only guide values.

After each oil change or refill, check the level in the relevant unit.

Note!

Adhering to regulations for lubrication, level checks and operating material changes guarantees a high degree of reliability and a long service life for the machine.

It is particularly important to adhere to the oil change intervals and use the specified type of lubricant.

Observe the following when using and checking lubricants and operating fluids: â&#x20AC;&#x201C; see "Lubricants and operating fluids" â&#x20AC;&#x201C; see "Inspection and maintenance schedule"

Note!

Cleanliness is of the utmost importance when changing oil.

Clean all filler plugs, filler covers and drain plugs and their surroundings before opening.

For preference, drain off oil when it is at operating temperature.

Ensure that old oils are collected and disposed of in an environmentally acceptable manner using the removable oil filter cartridges.

Danger!

When checking and changing lubrication and operating materials, ensure that the following precautions are adhered to: Unless otherwise indicated, carry out all work on the machine on level, solid ground and with the engine switched off.

Whenever you reach into the engine compartment, always secure the cover and side doors against accidentally falling back or closing.

Only refuel the machine when the engine is switched off, do not smoke and avoid naked flame.

Turn the main battery switch to position 0 (off) and remove the ignition key.

2

Lubricant chart Designation

Medium

Diesel engine

Engine oil

Symbol

Classification

Viscosity

API-CI-4, CH-4, ACEA E4, E6, E7

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

1.51.1

R 924 Compact Tier III copyright by

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Lubricants and operating fluids

Technical documentation

Fuels, lubricants and process chemicals Designation

Medium

Hydraulic tank

Engine oil

Symbol

Classification

Viscosity

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

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

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

DIN 51524 T2/T3 ISO11158 HM/HV ASTM D6158 HM/HV

ISO VG 32 ISO VG 46 ISO VG 68 ISO VG 100

LAV < 10 min (air separation charcteristics at 50°C, DIN 51381) KLR < 15% (viscosity drop after 20 h at 100°C, DIN 51350-6, CEC L 45-A-99)

3

Swing gear (as parking brake)

Transmission oil

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

SAE 80W-90 or SAE 90 LS

Swing gear (as positioning swing brake)

Transmission oil

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

SAE 90 LS

Travel gear

Transmission oil

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

SAE 90 SAE 80W-90

Splitterbox

Transmission oil

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

SAE 90

Tracks and corresponding gearing of swing ring, equipment mounting

Lubricating grease

High pressure grease KP2k or EP2

Consistency 2 NLGI Class

Hinges, joints, locks

Engine oil

-

-

Rubber seal on doors and trim panels

Silicon spray or talc

-

-

Fuels, lubricants and process chemicals Designation

Medium

Symbol

Fuel tank

Commercially available diesel fuel with sulphur content between 0,05 % and 0.5 %

1.51.2

R 924 Compact Tier III copyright by

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Technical documentation

Lubricants and operating fluids Diesel fuels

Designation

Medium

Coolant

Corrosion inhibitor and antifreeze agent

Windscreen washing system

Conventional windscreen cleaning agent or denatured alcohol

Air conditioning system refrigerant

R 134 a

Refrigerant oil in A/C compressor

PLANETELF PAG SP 20

Tab. 1

Symbol

* = Guide values

4

Diesel fuels

4.1

Specification The diesel fuels must meet the minimum requirements of the fuel specifications outlined below.

Approved fuel specifications: – DIN EN 590 – ASTM D 975 (89a) 1D and 2D The use of fuels with other specifications is only permitted with the explicit consent of the LIEBHERR.

4.2

Sulphur content of diesel fuel Fuel that meets the DIN EN 590 standard may contain maximum 50 mg/kg (maximum 0,005 weight percent) of sulphur.

The reduction of sulphur content has raised the problem of diesel fuel lubrication characteristics. It has been shown that diesel fuels containing the maximum permitted European sulphur limit of 0.05 weight per cent can cause the fuel injection system to wear (particularly applicable to distributortype injection pumps).

"Low-sulphur" diesel fuels with a sulphur content of less than 0,05% are only suitable after addition of a lubrication additive. According to HFRR (60) test, the lubricity of the diesel fuel may not exceed 460 µm (lubricity-corrected wear scar diameter [1.4] at 60 °C).

When using diesel fuels with a sulphur content of more than 0,5 weight percent, the oil change intervals must be halved.

Do not use fuels with a sulphur content of more than 1 %.

Note!

The ASTM D 975 fuel standard does not specify that the fuels must undergo a fuel lubricity test.

A written confirmation of compliance from fuel supplier must be submitted. 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 ASTM D 975 fuels must have a cetane number of minimum 45. A cetane number of more than 50 is preferable, especially at temperatures below 0 °C (32 °F).

1.51.3

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Lubricants and operating fluids

Technical documentation

Lubricating oil for the diesel engine

4.3

Diesel fuels for operation at low temperatures (winter) At low temperatures, paraffin crystals are formed in the diesel fuel. They increase the flow reduction in the fuel filter, so that the diesel engine might not be supplied with sufficient fuel.

Caution!

For technical and reasons, it is forbidden to add petroleum fuel to the diesel.

For arctic climates, use special diesel fuels developed for such extreme conditions.

In the case of insufficient fluidity of th diesel fuel or températures below -20 °C: use a start-up aid, such as a fuel filter heater.

4.4

Diesel fuels with the LIEBHERR Particles filter Caution!

If the Liebherr particle filter is installed on the excavator, only use white diesel fuels (EN 590).

5

Lubricating oil for the diesel engine Modern diesel engines must be lubricated with high-performance oils. They consist of a basic oil with special additives.

The lubricating oil requirements for LIEBHERR diesel engines are based on the following standards and regulations:

Tab. 2

Classification

Specification

API classification (American Petrol Institute)

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

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

E4, E6, E7

Lubricating oil for the diesel engine - specifications

Caution !

Particle filter only permitted with oil E6.

5.1

Viscosity The choice of the lubricating oil viscosity is done according to the SAE classification (Society of Automotive Engineers).

The relevant factor for the right choice of the SAE class is the ambient temperature.

The SAE classification does not provide any indication as regards the quality of a lubricating oil.

Excessively high viscosity might lead to start-up problems. If the viscosity is too low, the oil's lubrication might not be sufficiently efficient.

The temperature ranges shown in the diagram are approximate ranges that might temporarily be exceeded.

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Technical documentation

Lubricants and operating fluids Lubricating oil for the diesel engine

Fig. 1

Temperature-based selection of the SAE class

For ambiant temperatures of -20 °C (- 4 °F) to +45 ° C (+113 ° F), we recommand the following diesel engine oils: Liebherr Motoroil 10W-40, specification ACEA E4 Liebherr Motoroil 10W-40 low ash, specification ACEA E6 For ambiant temperatures of -30 °C (-22 °F) to +30 °C (+86 °F), we recommand the following diesel engine oils: Liebherr Motoroil 5W-30, specification ACEA E4

5.2

Lubricating oil change intervals Change intervals: see chapter "Maintenance and inspection schedule".

Subsequent oil changes depend on the climate, sulphur content of the fuel and oil grade. For details, see the table below.

If the specified operating hours (h) per year are not reached, the diesel engine oil and filter must be changed at least once every year.

A number of adverse factors (unfavorable operating conditions) affect the length of the change interval.

Such adverse factors include: – Frequent cold starts – Sulphur content in fuel greter than 0,5 % – Ambiant temperature below -10° C If such a factory apply, the oil and filter must be changed according to th table below: Operating conditions

Oil change interval dependent on oil quality: CH-4, CI-4

Tab. 3

E4, E6, E7

Operating conditions

Sulphur content of fuel

Interval

Climate normal to -10 °C

up to 0.5 %

250 h

above 0.5 %

125 h

250 h

below -10 °C

up to 0.5 %

125 h

250 h

above 0.5 %

not permissible

125 h

500 h

Oil change intervals for the diesel engine

h = operating hours

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Lubricants and operating fluids

Technical documentation

Coolant for the diesel engine

6

Coolant for the diesel engine The coolant consists of an aqueous solution containing a corrosion inhibitor and an antifreeze agent.

It can be mixed by the operator using the products named below. Alternatively, it can be purchased as a premixed solution.

6.1

General recommandations The radiator works only properly when pressurised. It is therefore imperative that it is kept clean and sealed at all times, that the radiator plug and working valves work properly and that the required coolant level is maintained.

Corrosion inhibitors/antifreeze agents approved by LIEBHERR ensure proper protection against frost, corrosion and cavitation without causing damage to seals and hoses and without foaming.

Coolants that contain unsuitable corrosion inhibitors or antifreeze agents or that have been prepared incorrectly might cause failure of assemblies and component parts in the coolant circuit due to cavitation or corrosion. Heat-insulating deposits on components that conduct heat might result in overheating and consequently failure of the engine.

Note!

The use of emulsifiable corrosion inhibitor oils is not permitted.

6.2

Water quality Clear and clean water free of particles that meets the following chemical requirements is suitable as coolant.

Do not use sea water, brackish water, brine or industrial wastewater.

Tab. 4

Contents

Quantity

Total earth alkaline content (water hardness)

0.6 to 3.6 mmol / l (3 to 20 째d)

pH value at 20 째C

6.5 to 8.5

Chloride ion content

max. 80 mg / l

Sulphate ion content

max. 100 mg / l

Fresh water quality

Fresh water quality when using coolant with DCA 4

Tab. 5

Contents

Quantity

Total earth alkaline content (water hardness)

0.6 bis 2.7 mmol/l (3 to 15 째d)

ph value at 20 째C

6.5 to 8.0

Chloride-ion content

max. 80 mg / l

Sulphate ion content

max. 80 mg / l

Fresh water quality with use of DCA 4

Water analysis results are available from the local authorities.

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Technical documentation

Lubricants and operating fluids Coolant for the diesel engine

6.3

Mixting ratio for coolant The coolant must contain min 50% corrosion inhibitor and antifreeze agent at all times of the year.

Outside temperature up to

Mixing ratio

°C

°F

Water %

A%

-37

-34

50

50

-50

-58

40

60

Tab. 6

Mixture ratio (for all seasons)

Fig. 2

Temperature-based mixing ratio of water + corrosion inhibitor and anti-freeze agent

A Corrosion inhibitor/antifreeze agent content in coolant

6.4

Permitted corrosion inhibitors / antifreeze agent Note!

The mixture of certain corrosion inhibitors and antifreeze agents might negatively affect the properties of the coolant.

Do not mix different products.

Product description

Manufacturer

Country

Liebherr Antifreeze Concentrate

Liebherr

D

Addinol Antifreeze Super

Addinol Lube Oil GmbH, Leuna

D

Agip Antifreeze Plus

Aral AG, BochumEni S.p.A., Rome

I

Agip Langzeit-Frostschutz

Eni S.p.A., Würzburg

D

Antigel DB 486

Sotragal S.A., St. Priest

F

Aral Antifreeze Extra

Aral AG, Hambourg

D

Avia Antifreeze APN G48

Avia Mineralöl AG, Hambourg

D

BP Isocool

BP p.l.c., Londres

GB

Caltex Extended Life Coolant

Chevron Texaco

*

Castrol Antifreeze NF

Castrol, London

GB

Chevron Extended Life Coolant

Chevron Texaco

*

DEUTZ Kühlerschutzmittel 0101 1490

Deutz Service International GmbH, Cologne

D

ESA Frostschutz G48

ESA Burgdorf

CH

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Lubricants and operating fluids

Technical documentation

Coolant for the diesel engine Product description

Manufacturer

Country

Fuchs Fircofin Kühlerfrostschutz

Fuchs Petrolub AG, Mannheim

D

Glacelf Auto Supra (antifreeze)

Total, Paris

F

GlycoShell Longlife

Shell International Petroleum Company, London

GB

Glycoshell N

Shell International Petroleum Company, London

GB

Glysantin G 48

BASF AG, Ludwigshafen

D

Havoline Extend Life Antifreeze / réfrigérent

Chevron Texaco

*

Havoline XLC

Arteco

B

Motorex Antifreeze Protect G48

Bucher AG, Langenthal

CH

Motul Inugel Optimal Ultra

Motul SA, Aubervilliers Cedex

F

OMV Kühlerfrostschutz / Coolant Plus

OMV Refining & Marketing GmbH, Vienna

A

* = global / worldwide

6.5

Permitted premixed coolants Note!

The combination of different coolants might impair their properties.

Do not mix different products.

Product description

Manufacturer

Country

Liebherr Antifreeze Mix

Liebherr

D

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

Chevron Texaco

*

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

Chevron Texaco

*

Coolelf Auto Supra -37 °C

Total, Paris

F

Havoline XLC, 50/50

Arteco

B

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

Chevron Texaco

*

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

6.6

Permitted corrosion inhibitors without antifreeze agent In exceptional circumstances and at ambient temperatures that are always above freezing points, e.g. during use in tropical areas where there are no corrosion inhibitors/antifreeze agents available, the following inhibitors must be added to the coolant: DCA 4 (Diesel Coolant Additives 4)

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Technical documentation

Lubricants and operating fluids Hydraulic liquids

Caltex / Chevron / Havoline / Total In this case, the coolant must be changed annually.

As part of regular maintenance work, check the concentration and correct it, if necessary.

Note!

The admixture of certain corrosion inhibitors might negatively affect the properties of the coolant.

Do not mix different products.

Drain off a coolant before changing from a corrosion inhibitor with antifreeze agent to a standard corrosion inhibitor and vice versa.

Product description

Manufacturer

Country

DCA 4 Diesel Coolant Additives

Fleetguard / Cummins Filtration

*

Caltex CL Corrosion Inhibitor Concentrate

Chevron Texaco

*

Chevron Texaco Heavy Duty Extended Life Corrosion Inhibitor Nitrite Free

Chevron Texaco

*

Havoline Extended Life Corrosion Inhibitor (XLI)

Chevron Texaco

*

Total WT Supra

Total, Paris

F

* = global

7

Hydraulic liquids Hydraulic oils must meet the requirement outlined below.

Non-compliance with these requirements shall void all warranty and liability by LIEBHERR. Maximum water content of hydraulic oil: < 0,1%.

7.1

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

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Lubricants and operating fluids

Technical documentation

Hydraulic liquids

Fig. 3

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

A Ambient temperature B Cold-start range with warm-up instruction C Operating range

* Temperature-based selection of the ISO class

Liebherr Hydraulic Plus and Liebherr Hydraulic Plus Arctic are suitable for both biological as well as prolonged operation.

Use only LIEBHERR hydraulic oils. The use of other oils is not permitted.If LIEBHERR oils are not available locally, use one of the motor oils listed in the following chapter see 7.2(before choosing an oil, contact our customer service department).

7.2

Engine oil If you wish to use other products, it is your responsibility to obtain a warranty declaration from the oil supplier.

Engine oils that are to be used as hydraulic oils must conform to the following specifications:

Tab. 7

Single-grade oils (1):

API - CD / ACEA - E1 Mercedes-Benz regulations, sheet no. 226.0 and 227.0

Multigrade oils (2):

API - CD, CE, CF / ACEA - E2, E3, E4 Mercedes-Benz regulations, sheet no. 227.5, 228.1, 228.3 et 228.5

Engine oils for use as hydraulic oil

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Technical documentation

Lubricants and operating fluids Hydraulic liquids

Fig. 4

Engine oils for use as hydraulic oil (SAE classes)* A Ambient temperature B Cold-start range with warm-up instruction C Operating range

1 2

Single grade engine oil Multigrade oils

*temperature-based selection of the SAE class ** for deviating viscosity grade: consult the LIEBHERR customer service department

7.3

Warm-up instruction The black bar B indicates that the ambient temperatures are maximum 20 °C below the operating range C. In the event of a cold start at an ambient temperature included in range B, the following warm-up instruction applies to the hydraulic oil: 1. Start the diesel engine and run it at approx. 1/2 rated speed. Carefully activate the working hydraulic circuits. Operate a hydraulic cylinder (Stick- for example) and move them to the stop quickly and many times. After approx. 5 minutes, start the travel hydraulic circuits.

Warm-up duration: approx 10 minutes At even lower temperature: 2. Before starting the engine, warm up the hydraulic oil tank. Then proceed according to the warmup instructions in 1.

7.4

Biodegradable hydraulic oils Note!

Risk of damage to the hydraulic unit!

When mixing ester-based biodegradable hydraulic oils with mineral oils, there is a risk of aggressive chemical reactions, which can damage the hydraulic equipment.

Do not mix biodegradable hydraulic oils from different suppliers, and never mix with mineral oils.

The use of a partial flow filters is mandatory.

Depending on the temperature range, LIEBHERR recommands its poly-alpaha-olefin (PAO, HEPR) oils that are environmentally-friendly according to CEC-L-33-A-93: Liebherr Hydraulic Plus or Liebherr Hydraulic Plus Arctic If these oils are not available locally, use one of the following oils (before choosing an oil, contact our customer service departement).

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Lubricants and operating fluids

Technical documentation

Hydraulic liquids Fully saturated synthetic ester-based oils, HEES Before using biodegradable hydraulic oil, you must consult LIEBHERR. Do not use vegetable oils, as they do not possess the necessary thermal stability.

If you wish to use other products, it is your responsibility to obtain a warranty declaration from the oil supplier.

7.5

Monitoring, filter change and oil change Note!

Biodegradable hydraulic oils must be checked regularly by means of an oil analysis.

– Normal operation after change of oil* an then at least every 500 operating hours – Dust intensive application: after change of oil* an then at least every 250 operating hours For mineral oils, an oil analysis is only required if the oil change interval is to be extended.

– Normal operation first time after 1500 operating hours, then every 500 operating hours – Dust intensive application: at least every 250 operating hours LIEBHERR recommends contacting WEAR-CHECK** with these analysis,and to change the oil when indicated by the test results in the lab report (see also customer service and product information). * Change of oil = change from mineral oil to environmentally-friendly hydraulic oil ** Yellow kit for machines with environmentally-friendly oil filling (HEPR and HEES) Green kit for machines with mineral oil filling

Symbol

Signification Filter change for hydraulic oil

Oil sampling

Tab. 8

Key to figures

Hydraulic oil in normal use

Fig. 5

Oil sampling and filters change in normal use h

Operating hours

1

First oil sample

a h

Mineral oil Biodegradable hydraulic oil

2 3

Second oil sample Subsequent oil samples every 500 operating hours

Oil change after 2000 operating hours, or when indicated by the lab report of the

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Technical documentation

Lubricants and operating fluids Hydraulic liquids

analysis.

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

Hydraulic oil used in dust intensive applications

Fig. 6

Taking oil samples and changing return filters in heavy dust environments h a h

Operating hours Mineral oil Biodegradable hydraulic oil

1 2 3

First oil sample Second oil sample Subsequent oil samples: every 250 operating hours

Oil change after 500 operating hours, or when indicated by the lab report of the analysis.

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

7.6

Instructions for the reduction of the contamination of the hydraulic oil in machines 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: – The filter cartridge(s) in the return filter must be replaced every 500 operating hours and after every hydraulic oil change.

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

– The 2-µm breather filter must be replaced every 500 operating hours and after every hydraulic oil change.

Note!

Machines delivered with hydraulic hammer attachment and retrofitted hydraulic hammer kits are already fitted with 10-µm filter cartridges in the return filter.

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Lubricants and operating fluids

Technical documentation

Lubricating grease and other lubricants

8

Lubricating grease and other lubricants Lubricant

Description / manufacturer

Grease for swing ring and general lubrication points

The grease must correspond with the specification KP2k, consistency 2 or NLGI grade in accordance with DIN 51818 and DIN 51825 or EP 2 in accordance with NF-T-60 132.

The grease must consist of a lithium complex and have a four ball tester value of at least 2300 N in accordance with DIN 51350 and ASTM D 2596.

For use in central lubrication systems • for the temperature range +60° C to -10° C ( 140° F to -50° F) LIEBHERR recommends: Multi service grease RPL LIEBHERR order nb: 8501565 (1 pack with 5 cartridges of 400 grams).

• if ambient temperatures are expected to remain under -10° C, it is recommended to make an early change of the grease type to a specific "LOW TEMPERATURE" grade This grease must have the necessary pumpability and "WORKED PENETRATION" consistency between 265 - 295 at -10° C temperature.

Tab. 9

Contact spray for slip rings

Cramolin

Lubricant for pistons, piston nuts and piston bearing installations on the hydraulic cylinders

Gleitmo 800

Special anti-corrosive material for installation areas of sealingelements on hydraulic cylinders

Castrol-Tarp

Anti-corrosion grease for open piston rods (cylinders that do not move often or transportation)

Liebherr special grease CTK

Grease and other process chemicals

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Technical documentation

Group 2: Tools

Special tools for maintenance and repair ............................................................................2.01 Special tools for Liebherr Diesel engines D 934 / D 936.....................................................2.02 Special tool for the hydraulik system...................................................................................2.03 Special tools for electrical connectors.................................................................................2.06 Special tools for gears ...........................................................................................................2.07 Common tools ........................................................................................................................2.08 Measuring tool for spool travel .............................................................................................2.10 Mounting tools for hydraulic cylinders ................................................................................2.12 1 2 3

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

Wrench for the slotted nut on the swing gear SAT .............................................................2.14 Compression device for brake piston of gear SAT .............................................................2.15 Compression device for brake piston of gear FAT .............................................................2.16 Tools for installing the slipring seals ...................................................................................2.19 Special tools for the lifting of the uppercarriage.................................................................2.30

2.00.1

R 924 Compact Tier III copyright by

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Technical documentation

Special tools for maintenance and repair

Group 2: Tools 2.01: Special tools for maintenance and repair Representation

Size / Quantity

No. Designation 1

Pipe Adapter

2

Ident. No. MachineApplication

NW 10

7002404

NW 12

7008688

all types

13 Pipe Adapter

M22x1,5

5607671

14

M14x1,5

5607616

all types K Forme From – LH673-02

15

M16x1,5

5607605

16

M18x1,5

5607617

17

M20x1,5

7409922

18

M24x1,5

7409923

25 BSP coupling

R 1/2 “

7002436

all types

30 Direct gauge coupling

R 1/2 “

7002435

all types

2.01.1

R 924 Compact Tier III copyright by

MJFCIFSS

Special tools for maintenance and repair

Representation

Technical documentation

Size / Quantity

No. Designation

Ident. No. MachineApplication

35 High pressure hose 36 (Lenght)

1000 mm

7002437

1500 mm

7002475

37

5000 mm

7363732

all types To connect pressure gauge on all test points (pipe adaptor no 1/2 and gauge coupling 10-14)

all types

40 Gauge coupling

M10X1

5005180

41

M12X1,5

7402580

42

M14X1,5

5004002

43

M16X1,5

7361345

44

R 1/4â&#x20AC;&#x2122;â&#x20AC;&#x2122;

7362579

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

8042577 8042578 7361292 7361291 5002865 7361289 7361288 5002867 7361286 7361285 7500002 7361294

Used to check system pressure in one or more hydraulik system

11000678

all types To perform adjustment checks

45 Hydraulic pressure gauge 46 47 48 49 50 51 52 53 54 55 56

75 Measuring set complete, in carrying case, containing: - Measuring device MH 3020

10814168

- Pressure sensor (2 units) 0 - 600 bar, 0 - 20 mA

10288153

- Measuring wire, 12 meters (2 units)

10288154

- Power supply unit 110 / 220 V

7025279

- Data transfer cable

10814169

- Connector 1620

614062601

- Carrying case

10664392

78 Power supply cable / cigar lighter

7025273

82 Pressure sensor

7025751

0-600 bar

83 Adapter for pressure sensor 84 Measuring cable MK12

* dampened with glycerin

With tool no. 75 all types

7025752 12 m

2.01.2

7025753

R 924 Compact Tier III copyright by

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Technical documentation

Representation

Special tools for maintenance and repair

Size / Quantity

No. Designation

Ident. No. MachineApplication

90 Adapter for test point

4901372

91 Test point with metalic cap

7002404

all types For pressure balancing.

With tool no. 75

92 Cap nut

4774002

93 Cutting ring

4774001

100 Service plug (green)

9684328

all types To adjust the electronic conexcept trol circuit via the display of Ad- the excavator. vanced

101 RS232 crossover cable

9684327

all types To save the error codes conexcept tained in the BBT. Advanced

102 RS232 normal cable

10029996

all types Can be used as an extension with the other cables.

With tool no. 103

103 Adapter

10029999

all types

104 USB to RS232 converter

693190714 all types

110 PME cable

10035410

all types To establish the link between: - PC and engine - PC and machine (advanced)

2.01.3

R 924 Compact Tier III copyright by

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Special tools for maintenance and repair

Representation

Technical documentation

Size / Quantity

No. Designation 113 Compact flash card reader

Sculi software

Ident. No. MachineApplication 10223095

AdTo read the contents of the vanced compact flash card (see 2.04, advanced)

LIDOS

all types For the diagnosis of: - the Diesel engine - the machine (advanced)

Sculi - Engine diagnosis

all types For the diagnosis of the Diesel engine

115 - Marx Dongle with a sculi licence - en- 10450053 gine diagnosis «light» 116 - Marx Dongle with a sculi licence - en- 10450054 gine diagnosis «service» Sculi - Master 4 diagnosis 120 - Marx Dongle with a sculi licence - Mas-10333608 ter 4 diagnosis «service» including sculiengine diagnosis «light»

Advan- For the diagnosis of: ced - the Diesel engine - the machine (advanced)

121 - Marx Dongle with a sculi licence - Mas-10489591 ter 4 diagnosis «service» including sculiengine diagnosis «service» Upgrade (already beeing in possession with a Marx Dongle) 125 - Sculi licence - Diagnosis Master4 «ser-0010301 vice»

Advanced

126 - Sculi licence - Engine diagnosis «ser- 0010300 vice»

all types

131 Revolution indicator Shimpo

all types To check the RPM via reflexions stripe

DT 205

132 Stripes

7364284 614063201

140 Measuring adapter

8504231

2.01.4

all types To check regulation current on the pumps

R 924 Compact Tier III copyright by

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Technical documentation

Representation

Special tools for maintenance and repair

Size / Quantity

No. Designation 145 Multimeter with digital display

Chauvin Arnoux MAX 3000

146 Measuring tool kits

Ident. No. MachineApplication 10018500

all types For voltage, current and resistance measurements of electrical systems and of solenoid valves

5616316

With tool no. 145

147 Measuring cable set

886125008

With tool no. 145

149 Measuring cable set

6204166

With tool no. 145

160 Infrared thermometer

GMTL 1826

7020372

all types Used to monitor the temperatur of a liquid or the external temperature of a component

GTH 1150

10024185

all types

170 Hand pump

8145666

172 Sampling valve for oil samples alternative to the hand pump

7019068

all types Used to take samples for oil analysis

7018368

all types 6 samples

162 Thermometer with probe and sensor (magnetic)

175 Oil analysis set

No. 1

180 Oil analisys set

8145660

1 sample

181 Complete set for oil analysis ** ** Analysis by WAER CHECK society Analysis report in German

8503561

For 6 samples

188 Bio oil analysis set

7026817

No. 1

189 Bio Oil analisys set

7026088

all types 1 sample 6 samples

Complete set for oil analysis ** ** Analysis by WAER CHECK society Analysis report in German

2.01.5

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Special tools for maintenance and repair

Representation

Technical documentation

Size / Quantity

No. Designation 190 Evacuation pump REFCO

Ident. No. MachineApplication

RD-4

7027552

all types For servicing and repairing the air conditioning equipment

195 Filling hose ITE blue

1500 mm

7027553

all types With tool no. 190

196 Filling hose ITE yellow

1500 mm

7027554

197 Filling hose ITE red

1500 mm

7027555

205 Quick coupling ITE

253a

7027556

210 Quick coupling ITE

254 a

7027557

215 Test equipment with 4 valves

M4WS5C

7027558

all types For servicing and repairing the air conditioning equipment

220 Disassembly tool

UTV-M20

7023304

221

UTV-M24

7023305

all types To disassemble the pins of the grabble

222

UTV-M30

7023306

223

UTV-M36

7023307

224

UTV-M42

7023308

2.01.6

all types With tool no. 190

R 924 Compact Tier III copyright by

MJFCIFSS

Technical documentation

Representation

Special tools for maintenance and repair

Size / Quantity

No. Designation

Ident. No. MachineApplication

230 Disassembly washer

M14

7023309

231

M20

7023310

232

M24

7023311

233

M30

7023312

234

M36

7023313

235

M42

7023314

240 Removal tool for CMVE 108 motor

10385026

245 Diagnostic set (software on CD and connecting cable)

10008427

all types To disassemble passfix bolts

all types To remove the travel motor alone

all types Communication and diagnostic software for BEKA-MAX central lubrication

Associated products : Pos.

Sensors

Ident. no.

2

OEM - Pressure sensor

0 - 1000 bar 0 - 20 mA

1001 8329

3

OEM - Pressure sensor

0 - 60 bar 0 - 20 mA

6140 625 01

4

OEM - Pressure sensor

0 - 10 bar 0 - 20 mA

1002 7591

5

OEM - Pressure sensor

-1 / +6 bar 4 - 20 mA (LWE)

5718 886 08

6

OEM - Pressure sensor

-1 / +6 bar 0 - 20 mA (LWE)

1028 5368

7

Adapter for pressure sensor to MINIMESS

Serie 1620 - 0°

6140 626 01

8

Adapter for pressure sensor to MINIMESS

Serie 1620 - 90°

6140 647 01

9

Temperature sensor Pt 100

-50 °C / +200 °C

6140 627 01

10

P / T - Measuring coupling, MINIMESS

Serie 1620 G 1/4“

6140 628 01

11

P / T - Measuring coupling, MINIMESS

Serie 1620 M10 x 1,5

1004 1274

12

Measuring turbine

RE 4 - 10 1 - 10 l/min

5010 031

2.01.7

R 924 Compact Tier III copyright by

MJFCIFSS

Special tools for maintenance and repair

Technical documentation

Pos.

Sensors

Ident. no.

13

Measuring turbine

RE 4 - 75 2 - 75 l/min

6140 62901

14

Measuring turbine

RE 4 - 300 9 - 300 l/min

6140 630 01

15

Measuring turbine

RE 4 - 600 16 - 600 l/min

5009 492

15

Measuring turbine

RE 7 - 600 25 - 600 l/min

1100 2327

16

Tachometer

DS 03 1 - 9999 U/min

6140 631 01

17

Set of spare reflective foils

6140 632 01

18

Magnetic holder for tachometer DS 03

6140 633 01

19

Inductive sensor for tachometer

6140 634 01

Pos.

Options

20

Carrying case to carry the measuring turbine RE 3

21.1

Measuring cable to connect the sensors (7 on 6 poles) MK12

6 meters

1029 5330

21

Measuring cable to connect the sensors MK12

6 meters

6140 636 01

22

Measuring cable to connect the sensors MK12

12 meters

6140 637 01

23

Measuring cable to connect the sensors MK12

18 meters

6140 638 01

24

Power supply cable

6 meters

6140 639 01

25

Power supply cable

12 meters

6140 640 01

26

Network printer

DPU 411

6140 641 01

27

Exchange thermopaper roll

for DPU 411

6140 642 01

28

Centronics date transfer cable

2 meters for DPU 411

6140 643 01

29

Data transfer cable (to connect to PC)

RS 232 - 2 m.

9684 327

33

Exploitation transfer

CD-rom Windows 32 bit (d / e / f)

10287659

Size

2.01.8

Ident. no.

6140 635 01

R 924 Compact Tier III copyright by

MJFCIFSS

Technical documentation

Special tools for Liebherr Diesel engines D 934 /

2.02: Special tools for Liebherr Diesel engines D 934 / D 936 Representation

No.

Size / Ident. No. Quantity

Designation

Machine Application

Sculi special tools

see 2.01

all types

For the diagnosis of the Diesel engine and of the machine

20

Compressiometer

8008782

all types

To check the compression pressure

21

Diagramms

25

Connecting piece for the compressi- 10297211 ometer

all types

To insert instead of the injection valve

26

Claw

all types

To fasten the piece 25.

35

Extracting device for injection valve 0524072

all types

To remove injection valves

36

Adapter for extracting device

0524029

37

Adapter

10220689

100 pieces

10012817

10117612

Has to be used with the extracting device

all types

To remove injection valves Has to be used with the extracting device

2.02.1

R 924 Compact Tier III copyright by

MJFCIFSS

Special tools for Liebherr Diesel engines D 934 /

Representation

Technical documentation

Size / Ident. No. Quantity

No.

Designation

40

Turning gear on the flywheel hous- 0524045 ing

all types

To turn the Diesel engine over the flywheel

41

Turning gear

10116805

all types

To turn the Diesel engine

42

Turning gear on the air compressor 10117936

all types

To turn the Diesel engine

43

Turning gear for vibration damper

all types

To turn the Diesel engine

44

Rotation device

1/2’’ - An- 0524062 gle

all types

To drive the turning gear

45

Rotation device

3/4’’ - An- 10023839 gle

all types

To drive the turning gear

50

Pin

9078119

all types

To install and to dismantle the crankshaft

51

Mounting bolt

0528470

all types

To install and to dismantle the flywheel

52

Mounting bolt

0528472

all types

To install and to dismantle the aggregate carrier

10118801

2.02.2

Machine Application

R 924 Compact Tier III copyright by

MJFCIFSS

Technical documentation

Representation

Special tools for Liebherr Diesel engines D 934 /

Size / Ident. No. Quantity

No.

Designation

Machine Application

53

Mounting bolt

0524059

all types

To install and to dismantle the oil cooler housing with oil cooler

54

Stamp

0523639

all types

To install and to dismantle the regulating valve

60

Extractor

0526855

all types

To install and to dismantle the cylinder liner

61

Extractor

0528462

all types

To install and to dismantle the cylinder liner

62

Holding fixture

0528464

all types

To hold the cylinder liner in its position Zylinderlaufbuchsen in ihrer Lage halten

63

Dial gauge holder

10023885

all types

To hold the dial gauge

70

Hook

7019858

all types

Dismantling the crankshaft seal

71

Press-in device

10116249

all types

Installing the crankshaft seal

72

Press-in device

10116250

all types

Installing the crankshaft seal

75

Special spanner

10020852

all types

Installing and dismantling the injection lines

2.02.3

R 924 Compact Tier III copyright by

MJFCIFSS

Special tools for Liebherr Diesel engines D 934 /

Representation

Technical documentation

No.

Designation

Size / Ident. No. Quantity

76

Nozzle tester

10340104

all types

To test the nozzle

77

Suction device

10337931

all types

To test the nozzle

78

Adapter

10340119

all types

To test the nozzle

79

Nozzle cleaning tool

10340120

all types

To clean the nozzle

85

Testing device

10340121

all types

Concentric running test and wobble measurement

86

Dial gauge

8004064

all types

For wobble measurement

87

Dynamometer

10340124

all types

Dismantling and reassembling the injection nozzle

88

Force sensor

10340125

all types

Reassembling the injection nozzle

2.02.4

Machine Application

R 924 Compact Tier III copyright by

MJFCIFSS

Technical documentation

Representation

Special tools for Liebherr Diesel engines D 934 /

Size / Ident. No. Quantity

No.

Designation

Machine Application

89

Press-in device

10340126

all types

Reassembling the injection nozzle

90

Mounting collar

10289319

all types

Reassembling the injection nozzle

91

Mounting collar

10289320

all types

Reassembling the injection nozzle

2.02.5

R 924 Compact Tier III copyright by

MJFCIFSS

Technical documentation

Special tool for the hydraulik system

2.03: Special tool for the hydraulik system Representation

Size / Ident. No. Quantity

No.

Designation

10

Special wrench for relief SW 17 valves SW 19

9359414

11

20

Safety cap

SW 10

7009315

21

short

SW 13

7018734

22

long

SW 13l

7615515

SW 17

7380629

23

all types

To adjust primary and secondary relief valves on control valves

all types

To secure the adjusting screws on the hydraulic components

For assembly of the o-ring and stepseal-ring on the pistons of the hydraulic cylinders and on the positioning piston of the pump and of the variable displacement motor

9210371

24

short

SW 19

7009316

25

long

SW 19l

7009317

26

M6

7023491

27

M8

7023492

28

M10

7023493

M12

7023494

29

Machine Application

30

Mounting sleeve

see sub-group 2.12

all types

40

Spreader sleeve

see sub-group 2.12

all types

50

Piston wrench

see sub-group 2.12

all types

Voir sous-groupe 2.12

2.03.1

R 924 Compact Tier III copyright by

MJFCIFSS

Special tool for the hydraulik system

Representation

Technical documentation

No.

Designation

Size / Ident. No. Quantity

Machine Application

60

Piston wrench

SW

all types

To remove and to tighten the piston nuts

all types

Used to remove and install damper pin on hydraulic cylinders with damper on piston / piston rod side.

all types

To remove the piston rod bearing

61

0541333

see sub-group 2.12

62 63 64

70

80

Socket wrench for thread- SW 41 ed bushing SW 46

9247110

9245656

SW 50

9244173

Puller for piston rod bear- M16 ing M20

9951120

M24

9959262

W24x 1-1/4“ 3,0m

8145359

all types

To check and refill diaphragm and piston type accumulations

all types

For assembly of the Glyd-ring and scraper - ring on plunger piston of hydraulic coupling LIKUFIX.

90

Filling device complete with adapter and filling hose

95

Mounting sleeve

9959261

Ø 25

9951457

96

Ø 22

9951508

97

Ø 45

9966421

98

Ø 25

9951458

M6

4901114

106

Hexagon socket set screw

2.03.2

R 906 To stop the pressure which R 916 releases the travel brakes.

R 926 Classic Advanced

R 924 Compact Tier III copyright by

MJFCIFSS

Technical documentation

Representation

Special tool for the hydraulik system

Size / Ident. No. Quantity

No.

Designation

180

Vacuum pump, complete TF63/2consisting of: Pump no. 24V 180, vaccum control valve no. 181 with sealing, hose with filter no.

187.

181

Vacuum control valve, complete

10097130

182

Vacuum control valve

5006213

183

T coupling

7015042

7405073

Machine Application all types

Retension of hydraulic tank content

Connecting piece to tank, consisting of: 184

- screw-in stud

7002240

185

- Cone RED connection 16/8S

7407155

186

- straight nipple

7024875

2.03.3

R 924 Compact Tier III copyright by

MJFCIFSS

Technical documentation

Special tools for electrical connectors

2.06: Special tools for electrical connectors

Fig. 1

Deutsch connectors

Fig. 3

Lugs

Fig. 2

Mate-N-Lock connectors

Fig. 4

AMP connectors

2.06.1

R 924 Compact Tier III copyright by

MJFCIFSS

Special tools for electrical connectors

Representation

Technical documentation

Size / Ident. No. Quantity

No.

Designation

8

Transformet set 24 / 230 V

11006157

all types

10

Repearing kit for connector technol- 10359794 ogy, including four carrying cases with connector technology and one carrying case with speficic tools:

all types

1

- Deutsch connector technology

10359757

2

- Mate-N-Lock connector technology

10359758

3

- Lugs and fuses

10359759

4

- Deutsch and AMP connector tech- 10360599 nology

5

- Carrying case with tooling

15

Tool to crimp contacts of connectors 8503647 type Deutsch Included in the carrying case 5 (10360630)

all types

28

Tool to crimp contacts (from MILC5015, VG 95234, 955342)

all types

29

Crimp turret to crimp contact of con- 7409779 nectors type Deutsch (KPS - KPT PT) sizes with special tool no. 28

30

Crimp turret to crimp contact of con- 7367084 nectors type Deutsch (15S/16S 15/16 - 25/12) sizes with special tool no. 28

35

Pneumatic power crimp HDP 400 8504158 equipment to crimp inserts for connectors Deutsch

36

Tools (sockets and pins) Taille 4

8504159

37

Tools (sockets and pins) Taille 8

8504160

38

Tools (sockets and pins) Taille 12

8504161

39

Tools (sockets and pins) Taille 16

8504162

45

Extraction tool to push a crimped contact of the connectors Deutsch Included in the carrying case 1 (10359757)

Taille 4

8503633

Taille 8

8503632

Taille 12

8145674

Taille 16

8145673

Taille 20

8503630

46 47 48 49

Machine Application

Contains all the connectors and the associated tools

10360630

7367086

2.06.2

all types

all types

R 924 Compact Tier III copyright by

MJFCIFSS

Technical documentation

Representation

Special tools for electrical connectors

Size / Ident. No. Quantity

No.

Designation

Machine Application

55

Deutsch cable extractor Included in the carrying case 5 (10360630)

7026267

all types

60

Dynamometric screwdriver - 3 Nm Included in the carrying case 5 (10360630)

10800772

all types

61

Hexagonal drive socket for spanner (4 mm) Included in the carrying case 5 (10360630)

10801159

65

Insertion tool for CA-COM contact (15S - 16S)

7367017

all types

80

Test tip - red Included in the carrying case 1 (10359757)

884191214

all types

81

Test tip - black Included in the carrying case 1 (10359757)

884191114

all types

90

To crimp contacts for leads of MATE-N-LOK 1,5mm2 SURE-SEAL FASTON 0,5 - 2,1 mm² Junior Power Timer Mini timer Included in the carrying case 5 (10360630)

7367025

all types

100

Extraction tool to push a crimped contact out of to the MATE-N-LOK connectors Included in the carrying case 2 (10359758)

7366655

all types

105

Mini-timer extrator

7027340

all types

110

Mini-timer extrator Included in the carrying case 4 (10360599)

7026266

all types

120

Tool to crimp lugs Included in the carrying case 5 (10360630)

8502520

all types

121

Tool to crimp bushes Included in the carrying case 5 (10360630)

7367665

all types

2.06.3

R 924 Compact Tier III copyright by

MJFCIFSS

Special tools for electrical connectors

Representation

No.

Technical documentation

Size / Ident. No. Quantity

Designation

125A IC-Extraction tool

8042630

125B IC-Mouting tool

8042629

130

6204661

Solenoid tester

2.06.4

Machine Application all types

all types

R 924 Compact Tier III copyright by

MJFCIFSS

Technical documentation

Special tools for gears

2.07: Special tools for gears Designation

Nb

Designation

Size

Order no

Socket for wrench forslotted nut in swing gear SAT

SAT 225 250 275 300 325 350 400 450

9202820 9199665 9202821 9202822 9202823 9202824 9960374 9960410

Compression device

SAT 225 250 275 300 325 350 400 450

9202825 9199319 9202826 9202827 9202828 9202829 9393900 9393900

80

FAT 350 / 400

9196958

82

450 / 500

9199294

5 10 15 20 25 30 35 40 50 52 54 56 58 60 62

Compression device

Compression device 90 92

Installation tool for slipring seals

FAT 350/022 350/032 400/063 400/073

FAT 350/022 350/032 400/063 400/073 450/044 450/064 500/035 550P046 600P067

9981445 9392820

8503594 8503179

Model

Application To loosen and tighten the slotted nut at the roller bearing of the output shaft in the swing ring SAT. See details in subgroup 2.14.

For disassembly and assembly of the piston of the multidiscs brake in the swing gear SAT. See details in subgroup 2.15.

For disassembly and assembly of the piston of the multidiscs brake in the travel gear FAT. See details in subgroup 2.16.

For disassembly and assembly of the piston of the multidiscs brake in the travel gear FAT. See details in subgroup 2.16.

To install the slipring seals into the travel gears FAT. See details in subgroup 2.19.

8503181 8503181 10027892 10027891 10027894

2.07.1

R 924 Compact Tier III copyright by

MJFCIFSS

Technical documentation

Common tools

2.08: Common tools Representation

Size / Quantity

Ident. No. Machine Application

1-12 60-300 140-760 750-2000 1500-3000

8503599 8503048 7362441 8503600 8503601

all types

To tighten the bolt to the prescribed torque

25 30 35 40

Hydraulic wrench Hytorc 3 - XLT 5 - XLT 10 - XLT 30 - XLTC

7373023 8502890 8503882 8503881

all types

To tighten the bolt to the prescribed torque

45 46 47 48 49 50 51 52 53 54

Socket Hytorc

30 mm 32 mm 36 mm 41 mm 46 mm 50 mm 55 mm 65 mm 75 mm 85 mm

8589150 8565020 8589770 8502436 8502461 8502975 8589940 7362130 8503884 7373022

all types

Lifting eye

M12 M30 M42 M48 M56

4026006 400656 4001313 4900835 4901609

all types

No.

Designation

5 10 15 20 22

Torque wrench Size in Nm

For the lifting of different components of the excavator

2.08.1

R 924 Compact Tier III copyright by

MJFCIFSS

Technical documentation

Measuring tool for spool travel

2.10: Measuring tool for spool travel Messen des Hubes von servogesteuerten Steuerschiebern - Id. Nr 8007363 Measuring tool for spool travel - Id. Nr 8007363 Appareil de mesure de la course du tiroir du distributeur à servocommande - Id. Nr 8007363

Fig. 1

Messvorrichtung / Measuring tool / Appareil de mesure 1

Hubmessvorrichtung / Measuring tool / Appareil de mesure

2

Dichtung / Seal / Joint

3

Deckel des Steuerschiebers / Spool cover / Couvercle du tiroir

4

Schieberstange / Spool / Tiroir Hub bei grösse / Stroke for size / Course pour la taille

Tab. 1

NG 16

9 mm

NG 22

12 mm

NG 25

14 mm

NG 32

15 mm

NG 40

20 mm

Hub bei grösse / Stroke for size / Course pour la taille

2.10.1

R 924 Compact Tier III copyright by

MJFCIFSS

Measuring tool for spool travel

Fig. 2

Technical documentation

Technische Zeichnung / Technical drawing / dessin technique

Dimensionen sind in mm / Dimensions are in mm / Les dimensions sont en mm (mm x 0.03937 = inches)

2.10.2

R 924 Compact Tier III copyright by

MJFCIFSS

Technical documentation

Mounting tools for hydraulic cylinders Mounting wrench for hydraulic cylinders

2.12: Mounting tools for hydraulic cylinders 1

Mounting wrench for hydraulic cylinders Wrench with bores «A» for retaining bolts

Id.-Nr.

a

b

c

d

e

f

g

h

i

4-KT

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"

75

54

110

220

14

12

10

20

84

3/4"

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"

125

97

170

320

14

14

10

25

110

3/4"

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"

8007364 #

9196978 #

Tab. 1

Chart for mounting wrenches (with bores)

Notes!

• In this chart all size indications are in mm.

• The size for pistons and mounting wrenches and their respective identification numbers are to be found in the Lidos.

• # These wrenches can be used with two different pin distances, resp. pin sizes.

2.12.1

R 924 Compact Tier III copyright by

MJFCIFSS

Mounting tools for hydraulic cylinders

Technical documentation

Piston nut wrench Forked type piston wrench

Tab. 2

2

Ident-Nr.

a

b

c

d

e

f

g

h

i

4-KT

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“

Chart for mounting wrenches (forked type)

Piston nut wrench

Piston nut wrench Bauform Size - Identific. number.

SW 6-KT

SW 2-FL

Slotted round nut Ø

4-KT

Id.-Nr.

M30X1,5 - 7006469

44

*

M32X1,5 - 7010262

50

*

M33 X1,5 - 9226916 M36X1,5 - 9875702

41 50

M42X1,5 - 7010163 M42X1,5 - 9970088 M42X1,5 - 9113734

1/2“

9921132

1/2“

9211967

62 60 55

2.12.2

* 1/2“

9211967

1/2“

9921132

R 924 Compact Tier III copyright by

MJFCIFSS

Technical documentation

Mounting tools for hydraulic cylinders Mounting and spreader sleeve

Piston nut wrench Bauform Size - Identific. number.

SW 6-KT

M50X2 - 4129202

70

M50X2 - 9166795

SW 2-FL

Slotted round nut Ø

65

4-KT

Id.-Nr.

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

M200X4 - 5008563

260

3/4“

9921135

Tab. 3

Chart for piston nut mounting wrenches

* commercially available slotted nut wrench

3

Mounting and spreader sleeve Kolben Ø Piston Ø

Mounting sleeve 990 Identification number

Spreader sleeve 991 Identification number

32

9136418

9136416

32

9113100

9113099

38

9143279

9143280

40

9196902

9136417

45

9136419

9136417

50

9288953

9288954

63

9170510

9170512

65

9177541

9177540

70

9110556

9110402

80

9227165

9227166

85

9998618

9110404

85

9115710

9115708

90

9227161

9227162

100

9998626

9110405

105

9951984

9951983

110

9170509

9170511

110

9960483

9960502

2.12.3

R 924 Compact Tier III copyright by

MJFCIFSS

Mounting tools for hydraulic cylinders

Technical documentation

Mounting and spreader sleeve Kolben Ø Piston Ø

Mounting sleeve 990 Identification number

Spreader sleeve 991 Identification number

115

9998625

9110406

120

9998778

9110407

125

9227163

9227164

125

9960484

9960503

130

9998624

9110408

135

9285578

9285579

140

9998623

9110409

150

9998622

9110410

160

9998621

9110411

170

9107931

9110412

180

9998619

9110413

180

9107932

9110413

190

9907684

9907701

190

9280862

9280863

200

9107933

9110414

210

9192854

9192853

220

9113008

9113009

230

9144914

9144912

240

9903977

9903978

300

9135351

9135350

Tab. 4

Mounting and spreader sleeve chart

Mounting sleeve to insert the piston into the jack

Piston Ø

Mounting sleeve 950 Identification number

65

9177543

80

9231749

90

9248893

90

9248894

100

9248895

110

9248897

120

9248898

130

92487899

140

9177541

140

9952180

160

9248909

190

9281241

210

9281240

250

9951147

260

9284918

2.12.4

R 924 Compact Tier III copyright by

MJFCIFSS

Technical documentation

Mounting tools for hydraulic cylinders Mounting and spreader sleeve

Tab. 5

Piston mounting sleeves

Notice !

The mounting sleeve 950 are employed to narrow the sealing rings that have been streched during installation back to the cylinder diameter.

Mounting sleeve to insert the piston rod bearing on the piston rod

Tab. 6

Piston Ă&#x2DC;

Mounting sleeve 950 Identification number

90

9282761

105

9287177

140

9926806

Piston rod mounting sleeves

Notice !

The mounting sleeve 960 are destined to preserve the sealing and guiding elements from damage during the piston rod bearing installation.

2.12.5

R 924 Compact Tier III copyright by

MJFCIFSS

Technical documentation

Wrench for the slotted nut on the swing gear SAT

2.14: Wrench for the slotted nut on the swing gear SAT

Fig. 1

Tab. 1

Wrench socket for slotted nut Swing gear SAT Type

Identification number.

SAT 225

9202820

SAT 250

9199665

SAT 275

9202821

SAT 300

9202822

SAT 325

9202823

SAT 350

9202824

SAT 400

9960374

SAT 450

9960410

Identification numbers of the wrench sockets

2.14.1

R 924 Compact Tier III copyright by

MJFCIFSS

Wrench for the slotted nut on the swing gear SAT

Technical documentation

Material : 42 Cr Mo 4 V - Surface hardening : 800-1000 N/mm2

Fig. 2

Definition of dimensions of the sockets

SAT

A

B

C

D

E

F

G

H

J

K

L

M

N

O

225

90

40

30

55

71,5+0,2

77

100

95

3,8

80

35

30

40

7,8

250

100

55

46

60

81,5+0,2

86

110

105

3,8

90

35

30

50

7,8

275

110

55

46

70

92,2+0,2

95

120

105

3,8

90

35

30

50

7,8

300

125

55

46

80

106,5+0,2

110

140

120

3,8

105

35

30

50

7,8

325

126,5

55,5

46

50

115

115,5

150

115,5

3,8

94

35

30

55

7,8

350

137,5

55,5

46

50

125

126,2

160

113,5

3,8

92

35

30

55

7,8

400

173,5

60

46

60

144,3

146

189,5

145

6,7

117

35

30

85

19,7

450

179

50

30

0

164

166

198

127

6,5

107

35,47

33

76

20

Fig. 3

All the dimensions are indicated in mm (inches = mm x 0.03937).

2.14.2

R 924 Compact Tier III copyright by

MJFCIFSS

Technical documentation

Compression device for brake piston of gear SAT

2.15: Compression device for brake piston of gear SAT

Fig. 1

Definition of the dimensions of the compression devices

Swing Gear SAT / Type

Identificat. number

A

B

C

D

E

F

G

H

SAT 200

9206110

252

40

12

10

10

14

90

110

SAT 225

9202825

268

40

12

10

10

16

100

117

SAT 250

9199319

300

40

12

10

10

18

110

131

SAT 275

9202826

326

40

12

10

10

18

120

143

SAT 300

9202827

364

50

20

15

15

22

130

157

SAT 325 / 204

9202828

390

50

20

15

15

22

142

170

SAT 350 / 205

9202829

410

50

20

15

15

22

154

180

SAT 400 / 206 SAT 450 / 207

9393900

440

50

20

15

15

18

175

202.

5

Tab. 1

Compression devices / Identification numbers and dimensions in mm

2.15.1

R 924 Compact Tier III copyright by

MJFCIFSS

Technical documentation

Compression device for brake piston of gear FAT

2.16: Compression device for brake piston of gear FAT A) For travel gears FAT 350/..., 400/..., 450/... & 500/...

Fig. 1

Definition of the dimensions of the compression devices

Travel gears SAT Type

Identificat. number

A

B

C

D

E

F

G

FAT 350 / 400

9196958

350

318

284

16

33

50

10

FAT 450 / 500

9199294

400

360

340

20

30

47

20

Tab. 1

Compression devices / Identification numbers and dimensions in mm

2.16.1

R 924 Compact Tier III copyright by

MJFCIFSS

Compression device for brake piston of gear FAT

Technical documentation

B) For travel gears FAT 350 / 022 & 032, FAT 400 / 063 & 073

Fig. 2

Definition of the dimensions of the compression devices

Travel gears SAT Type

Identifica t. number

A

B

C

D

E

F

G

H

FAT 350 / 022 /032

9981445

238

205

100

108

40

18

Ø 16

15

FAT 400 / 063 / 073

9392820

280

245

123

125

40

Ø 21

Ø 16

Tab. 2

Compression devices / Identification numbers and dimensions in mm

2.16.2

R 924 Compact Tier III copyright by

MJFCIFSS

Technical documentation

Tools for installing the slipring seals

2.19: Tools for installing the slipring seals

Fig. 1

Definition of the dimensions of the mounting tool Slipring seal

Travel gear FAT

Ordering number

Type

Ø6

350 P 012 350 P 022

8503594

76.90 H - 28

350 / 012 355 P 076 355 P 077

8503178

400 / 023 400 / 043 400 / 063 400 / 073

Ø1

Ø2

Ø3

Ø4

Ø5

341

350

340

310

334

343

76.90 H - 30 A1 76.90 H - 30

375

384,1

372

325

369

377,5

8503179

76.90 H - 60

394

402

392

365

384

395

400 / 013

8503180

76.90 H - 70

415

424

414

390

405

417

450 / 064 450 / 044

8503181

76.90 H - 61

457

465

455

415

446

458

500 / 035

10027892

76.90 H - 65 A2

495

504

494

430

485

497

2.19.1

R 924 Compact Tier III copyright by

MJFCIFSS

Tools for installing the slipring seals

Technical documentation

Slipring seal

Travel gear FAT

Ordering number

Type

550 / 026 550 P 046

10027891

76.90 H - 74

600 / 047 600 P 067

10027894

76.90 H - 82

Tab. 1

Ø1

Ø2

Ø3

Ø4

Ø5

Ø6

Slipring seals installation tools / Ordering numbers and dimensions in mm

2.19.2

R 924 Compact Tier III copyright by

MJFCIFSS

Technical documentation

Special tools for the lifting of the uppercarriage

2.30: Special tools for the lifting of the uppercarriage For R 924 Compact types 911 / 198

Fig. 1

Definition of the dimensions of the standoff

2.30.1

R 924 Compact Tier III copyright by

MJFCIFSS

Special tools for the lifting of the uppercarriage

Technical documentation

For R 924 Compact Tier III types 1055 / 1056

Fig. 2

Definition of the dimensions of the standoff

2.30.2

R 924 Compact Tier III copyright by

MJFCIFSS

Technical documentation

Group 3: Technical Data / Maintenance guidelines

Technical data.........................................................................................................................3.12 R 924 Compact Tier III Type 1055 from serial number 20472 R 924 Compact Tier III Type 1056 from serial number 23772 R 924 Compact Tier III Type 1083 from serial number 21909

Control and maintenance chart.............................................................................................3.62 R 924 Compact Tier III Type 1055 from serial number 20472 R 924 Compact Tier III Type 1056 from serial number 23772

Control and maintenance chart.............................................................................................3.63 R 924 Compact Tier III Tunnel Type 1083 from serial number 21909

Lubrication chart ....................................................................................................................3.82 R 924 Compact Tier III Type 1055 from serial number 20472 R 924 Compact Tier III Type 1056 from serial number 23772

Lubrication chart ....................................................................................................................3.92 R 924 Compact Tier III Tunnel Type 1083 from serial number 21909

3.00.1

R 924 Compact Tier III copyright by

MJFCIFSS

Technical documentation

Technical data

Group 3: Technical Data / Maintenance guidelines 3.12: Technical data R 924 Compact Tier III Type 1055 from serial number 20472 R 924 Compact Tier III Type 1056 from serial number 23772 R 924 Compact Tier III Type 1083 from serial number 21909 Types 1055 / 1056 / 1083 Tunnel General

1055

1056

Operating weight

kg

Length

mm

Width

mm

3150

3000

Height of machine without attachment

mm

3140 / 3255

3151

Tail swing

mm

1690

1695

Ground clearance

mm

Digging force

kN

97 - 111

85

Breakout force

kN

117 - 141

135

Total drawbar max. (at compound speed and max. working pressure)

kN

264

260

Engine

25150 - 29050

1083 Tunnel

4555

5040

470

-

1055

1056

Type

-

1083 Tunnel

120 kW (163 PS)

Nominal speed

U / min

Max. torque

N.m

Oil quantity (fulling quantity on oil change with filter)

l

Oil quality / -viscosity and oil change intervall

1800 760 (at 1500 rpm) 29 see sub-group 1.50, 1.51 and 3.60

l

345

Further informations

see group 4

Hydraulic system Hydraulic pump

5070

D 934 S A6

Rating at nominal speed per DIN ISO 9249 KW

Fuel tank capacity

32440

1055

1056

Type

Design

1083 Tunnel

DPVP 108 Swash plate - axial pump piston

max. power of the working pumps

KW

max. volume

cm3

max. flow (theoretical)

l / min

87

87 (96 with milling cutter) 2 x 107,7 2 x 215

3.12.1

R 924 Compact Tier III copyright by

MJFCIFSS

Technical data

Technical documentation

Hydraulic system

1055

1056

max. flow (Qmax)

l / min

416

min. flow (Qmin)

l / min

137

Oil quantity (fulling quantity on oil change with filter)

l

Oil quality / -viscosity and oil change intervall

1083 Tunnel

174 in tank (360 in whole hydraulic circuit) see sub-group 1.50, 1.51 and 3.60

Control valve block

Type

M9-1039-00 / 7M9-25

1 way rotary connection

Type

1-way 815.001

-

-

5 ways rotary connection

Type

DDF 525

-

5-ways 815.005

7 ways rotary connection

Type

-

DDF 720

DDF 720

Boom cylinder Ø piston / rod

mm

(2x) 130 / 90

(2x) 140 / 85

Stick cylinder Ø piston / rod

mm

140 / 95

160 / 95

Bucket cylinder Ø piston / rod

mm

120 / 80

125 / 80

Swivel bearing cylinder Ø piston / rod

mm

-

140 / 80

Offset cylinder Ø piston / rod

mm

160 / 95

-

Hydraulic pump / servo control

Type

Gear pump

max. flow / servo control

l / min

46

Hydraulic pump / fan drive (cooling)

Type

Gear pump

max. flow / fan drive (cooling)

l / min

60

Further informations

M9-104700 / 9M9-25

see group 6

,

Electrical system

1055

1056

1083 Tunnel

Voltage

V

24 (2x 12 switched in series)

Battery capacity

Ah

135

Alternator voltage / max current

V/A

Starter power

V / KW

Swing gear

24 / 80

24 / 100 24 / 7,8

1055

1056

Gear

Type

Swing gear

Type

Motor oil

Type

Swing speed max.

U / min

12

Gear oil quantity

l

6

Oil quality / -viscosity and oil change intervals

1083 Tunnel

SAT 275 / 266 KUD 64 VJ 003-001

KUD 64 VJ 004-000

FMF 058

see sub-group 1.50, 1.51 and 3.60

3.12.2

R 924 Compact Tier III copyright by

MJFCIFSS

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