Liebherr r 974 c hydraulic excavator service repair manual sn：15259 and up

Service Manual Hydraulic excavator R964C - R974C

issue:

03 / 2008

Valid for:

R964C - R974C

Machine:

R964C - R974C

Type no.:

R 964C : 448 / 1008 / 1009 / 1126 R 974C : 449 / 1010 / 1011 / 1057 / 1058 / 1059 / 1060 / 1084 / 1120 / 1124 / 1037

Service Manual

INDEX 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 / Two speed gear box

12

Track components / Axles

13 14

Centralized lubrication

15 16

Special attachments / Additional installations

17

Cab / Heater / Air conditioning system

18

Undercarriage / Uppercarriage attachments

R 964 C / R 974 C

INDEX

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.

R 964 C / R 974 C

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.

R 964 C / R 974 C

Service Manual

Group 1: General Information

Safety instructions .................................................................................................................1.10 1 2 3 4 5

Meaning of the symbols in this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10.1 Use in accordance with the regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10.2 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10.2 Bringing the machine safely into service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10.4 Servicing the machine safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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

Lubricants and operating fluids............................................................................................1.55

LFR / en / Edition: 05.2009

R 964 C from serial number 22 612 R 974 C from serial number 22 515 1 Lubricants and operating fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.55.1 1.1 General information on changing lubricants and operating fluids . . . . . . . . . . . . . . . . . . . . . . . 1.55.1 2 Lubricants and operating fluids specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.55.2 2.1 Diesel fuel specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.55.2 2.2 Diesel fuels with the LIEBHERR Particles filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.55.3 2.3 Lubricating oil for the Diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.55.3 2.4 Coolant for the diesel engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.55.4 2.5 Hydraulic liquids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.55.8 2.6 Transmission oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.55.12 2.7 Lubricating grease and other lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.55.12

R 964 C / R 974C

1.00.1 copyright by

MJFCIFSS

LFR / en / Edition: 05.2009

Service Manual

R 964 C / R 974C

1.00.2 copyright by

MJFCIFSS

Service Manual

Safety instructions Meaning of the symbols in this manual

Group 1: General Information 1.10: Safety instructions Working with the machine holds dangers to which you as the owne r, 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.

LFR / en / Edition: 05.2009

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.

X This symbol identifies an action.

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

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

R 964 C / R 974C

1.10.1 copyright by

MJFCIFSS

Safety instructions

Service Manual

Use in accordance with the regulations 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

Use in accordance with the regulations – The hydraulic excavator is a machine with work equipment (eg. hoe type bucket, grab, bucket attachment) designed to detach, lift, transport and shake off earth, stones and other materials, while the transportation of the l oad itself usually takes place without moving the machine. Moving the machine when it is car rying a load must be carried out wh ile observing the appropriate safety measures (see section "Notes for safe working").

– Machines used for hoisting are subject to specific conditions and must be fitted with the stipulated safety devices (see section “Hoisting work”).

– Other or additional usage, eg. for demolition work or transfer work, requires special equipment and may also require special safety devices. These devices (eg. tree grab, demolition hammer, concrete cutter etc.) may only be attached and used with approval and in accordance with the original manufacturer of the device.

– Transporting persons is not deemed to be in accordance with regulations. The manufacturer is not liable for damage resulting from this action. The user is solely responsible for the risk incurred.

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

3

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.

– 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.

R 964 C / R 974C

1.10.2 copyright by

MJFCIFSS

LFR / en / Edition: 05.2009

General safety instructions

Service Manual

Safety instructions Safety Instructions

– 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 dir ections 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 b e 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 – – – – – – –

LFR / en / Edition: 05.2009

– – – – –

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 coo lant when the sealing cap of the expansion container has cooled to a p oint 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.

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.

R 964 C / R 974C

1.10.3 copyright by

MJFCIFSS

Safety instructions

Service Manual

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

4

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 vici nity of he at 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 mac hine, this will facilitate fighting a possibly upcoming fire.

Bringing the machine safely into service – – – – –

Carry out a careful inspection tour around the machine each time before starting it.

Check the machine for loose bolts, cracks, wear, leakage and damage.

Never attempt to operate a damaged machine.

Ensure that any damage is immediately rectified.

Ensure that all hoods and covers are closed, but that lock s are unlocked, to facilitate the fight against fire in case of.

– Ensure that all warning signs are present.

– Keep windows and interior and exterior mirrors clean. Secure doors and windows against unintended movement.

– Ensure that no one is working on or under the machine and warn personnel in the vicinity of the machine that it is about to start by sounding the horn.

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

– When getting up or down, position the machine on even, horizontal ground. The upper structure should be positioned with the undercarriage in such a way that the steps and ladders are aligned with each other.

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

NOTE: To ensure that the doors open properly in all weather conditions, the door seals must be dusted with talc or silicon at least every two months or more often if required. The door hinges and locks should be greased regularly.

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

– If you are able to reach the door handle with your free hand, open the doors before you climb any higher. External influences, such as wind , can make it mor e difficult to open doors. Because of this, always use your hand for control when opening doors. Ensure that the door is latched open to prevent it slamming open and shut.

R 964 C / R 974C

1.10.4 copyright by

MJFCIFSS

LFR / en / Edition: 05.2009

Safely getting up

Service Manual

Safety instructions Bringing the machine safely into service

– In case of bad weather conditions, be particulary vigilant to realise the climbing and descent from the cab with the best safety conditions, and do or give the instuctions to the execution of prior preparations to be accomplished, as enunciated above, in order to displace yourself safely.

– Be particulary vigilant with those prerequisites conditions.

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

– Close the doors and fasten the safety belt (if available), unlock the door, using the planned lever, and close it immediately using the door handle, befor tilting down the safety lever, and start the machine.

– If you wish to work with the door open, it is necessary to fasten your safety belt. If unavailable, let it be instaled before working with the door open.

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

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

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

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

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

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

LFR / en / Edition: 05.2009

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.

– 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 stopp ed on an i ncline, 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.

R 964 C / R 974C

1.10.5 copyright by

MJFCIFSS

Safety instructions

Service Manual

Bringing the machine safely into service – – – –

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 ac cordance 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.

– 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.

– 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 th e operating instructions.

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

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

R 964 C / R 974C

1.10.6 copyright by

MJFCIFSS

LFR / en / Edition: 05.2009

Working safely with the machine

Service Manual

Safety instructions

LFR / en / Edition: 05.2009

Bringing the machine safely into service – 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 equi pment combination, there is a ris k 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 fr om the machine before the storm breaks out. Otherwise, you must stop the excavator, turn off the radio and keep inside the closed cab until the end of the storm.

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

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

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

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

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

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

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

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

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

R 964 C / R 974C

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Safety instructions

Service Manual

Bringing the machine safely into service – Do not lift th e 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 fo rbidden 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 th e 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

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

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

The following instructions are therefore to be observed at all times: • Adjust vehicle ha ndling to suit the a ltered ma chine char acteristics and en vironmental con ditions.

• 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 ther e is a risk of objects falling from above.

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

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

R 964 C / R 974C

1.10.8 copyright by

MJFCIFSS

LFR / en / Edition: 05.2009

Safe use when loading and unloading (particularly when loading and unloading wood)

Service Manual

Safety instructions Bringing the machine safely into service

– Working procedures when using machines with grabs re quire t he m achine operator to r eceive 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!

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.

LFR / en / Edition: 05.2009

Protection from vibration – Vibrational loads on mob ile 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, brak es, controlling th e machine’s control elements when driving and working.

– To a lar ge e xtent, the machine op erator determines the vi brational load s since he sele cts th e 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).

R 964 C / R 974C

1.10.9 copyright by

MJFCIFSS

Safety instructions

Service Manual

Bringing the machine safely into service – 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.

– 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.

– 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.

R 964 C / R 974C

1.10.10 copyright by

MJFCIFSS

LFR / en / Edition: 05.2009

Attaching and removing equipment parts safely

Service Manual

Safety instructions Bringing the machine safely into service

– 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.

LFR / en / Edition: 05.2009

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.

– 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.

R 964 C / R 974C

1.10.11 copyright by

MJFCIFSS

Safety instructions

Service Manual

Servicing the machine safely – When unloading the machine, take the same amount of care as was taken when it was loa ded.

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.

5

Servicing the machine safely

– Maintenance and repair work may only be carried out by specially trained personnel.

– Observe statutory timetables or intervals given in the operating instructions for repeat tests / inspections. It is imperative that a suitably equipped workshop is available in order to carry out maintenance work.

– The inspection and maintenance schedule given at the end of these operating instructions defines precisely who is required / permitted to carry out what work.

Jobs listed as daily / weekly work may be carried out by the machine's driver or maintenance personnel when they have received appropriate instruction.

The remaining work may only be carried out by specialist personnel with appropriate training.

– Replacement parts must correspond to the technical requirements determined by the manufacturer. Original replacement parts are always guaranteed to meet these criteria.

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

Protective goggles, safety helmets, safety shoes and gloves, reflective vests and ear protection etc. are required for specific jobs.

– Do not remain in direct proximity of the diesel engine while the diesel engine is running.

Persons with pacemakers should not approach within 20 cm of the running diesel engine.

Do not touch voltage-carrying parts on the electrical connection of the individual solenoid injection pumps (Unit Pumps UP) while the diesel engine is running.

– Do not permit unauthorised persons to approach the machine during maintenance work.

– Cordon off a wide maintenance area if required.

– Inform operational personnel before starting to carry out any special work and repair work. Designate persons in charge of supervision.

– In the absence of an y other information in the operating instructions, carry out all maintenance work on the machine on level, firm ground with the working equipment set aside and the engine switched off.

– For some machines, the only one position which enables a secured access to every maintenance locations on the uppercarriage, is when the uppercarriage is aligned with the undercarriage so that the sprockets locate at the back-end.

The ladder situated on the undercarriage only corresponds with the uppercarriage’s access when the excavator is in this configuration.

– Pull out the ignition key and shut off the main battery switch.

– Always tighten any loose screw connections during maintenance and repair work.

– The mounting bolts of the main components, of the hydraulic hoses and of the counterweight must be replaced after every removal.

– If safety devices have to be dismantled during set-up, maintenance and repair work, they must be immediately reinstalled and checked at the end of the work.

– When carrying out repair work, particularly when working under the machine, hang a “Do not start” warning sign in a clearly visible position on the starting lock. Pull out the start key and shut off the main battery switch.

– Operate combustion motors and fuel operated heaters only in well ventilated areas. Before operating these units, check ventilation.

– In addition, always follow applicable local regulations.

R 964 C / R 974C

1.10.12 copyright by

MJFCIFSS

LFR / en / Edition: 05.2009

General safety instructions

Service Manual

Safety instructions Servicing the machine safely

Cleaning – Clean oil, fue l or care products off the machine before starting maintenance or repair work and pay particular attention to connections and screw fittings.

Do not use aggressive cleaning products and use lint-free cleaning cloths.

– Do not use aggressive cleaning products or steam jet devices to clean the machine for the first two months after initial set-up of the machine (or after repainting).

– Do not use combustible liquids to clean the machine.

– Before cleaning the machine with water or steam jets (high pressure cleaner) or other cleaning materials: • lubricate all bearing points, bolt connections and the rim bearing to prevent water or steam entering the bearing points.

• cover or glue shut all openings into which for safety or functional reasons water or steam may not be permitted to enter.

Electric motors, electrical components, control boxes, plug connections and air filters are particularly at risk.

– Ensure that the fire warning systems and fire extinguishers of the engine compartment’s temperature sensor do not come into contact with hot cleaning products during cleaning work.

The fire extinguisher could start.

– If you use a high pressure cleaner with steam or hot water to clean the machine, observe following recommendations : • the distance between the nozzle and the surface to be cleaned must be no lower than 20 inches • the water temperature should not exceed 60°c (140°F) • limit the water pressure to 80 bar maximum (11500 PSI) • if you employ cleaning fluid, only use neutral cleaning agents such as customary car shampoos diluted to 2 or 3 percent maximum – After cleaning: • remove all covers completely.

• check all fu el, engine oil and hydraulic lines for leakage, loosened connections, ch afing and damage.

• rectify any defects found immediately.

• lubricate all bearing points, bolt connections and the rim bearing to displace any water or cleaning products that may have entered.

LFR / en / Edition: 05.2009

Crack testing – Even when the machine is operated carefully, there is a possibility of individual cases of overloading occurring, which could lead to cracks or loose connections. The machine should therefore be checked regularly for cracks, loose connections or other visible damage to maintain operational safety.

– In order to be able to check for cracks, it is essential that the machine is kept clean and cleaned regularly.

– The tests should be carried out in accordance with the monitoring and maintenance plan: • every 250 operating hours by the machine owner’s maintenance personnel.

• every 500 operating hours by authorised specialist personnel.

– It is advisable to carry out these tests: supported, on firm, horizontal substrate, with the equipment in longitudinal and cross direction for variable loads. Current accident prevention regulations must be adhered to.

– Special care must be taken when testing load-bearing components, particularly: • the steel chassis members and axle a nd transmission mountings, the support, the lo wer rim bearing support and tower and ball rim bearing.

• the steel upper structure members and bearing block for boom and boom cylinder, the upper rim bearing support, the cab mount and the mount for swing gear and ballast.

• the steel components of the working equipment, e. g. the boom, stay, quick change adaptor, and bucket.

• hydraulic cylinders, axles, steering, bolts and bolt connections, steps, ladders and mounting elements.

R 964 C / R 974C

1.10.13 copyright by

MJFCIFSS

Safety instructions

Service Manual

Servicing the machine safely – The crack test should be carried out visually. If a crack is suspected, the dye pe netration test should be carried out as a crack test on areas which do not have good v isibility, such as the rim bearing support, in order to increase testing safety.

– Any da mage fo und mu st be r ectified im mediately. We lding wo rk on load -bearing par ts o f the earth-moving machinery, loading devices and transport devices may only be carried out by trained specialist personnel and only in accor dance with the accepted rules of we lding engineering. In case of doubt, contact the LIEBHERR customer support service to discuss suitable remedies.

Welding, drilling, firing and grinding work – Any welding on structural parts (as undercarriage, uppercarriage, equipment parts,…) may only be done the manufacturer, or authorized official dealer. If this ru le is ne glected, the warranty is voided.

– Only carry out welding, drilling, firing and grinding work on the machine with express authorization.

Clean dust and combustible materials off the machine and its surrounding areas before welding, drilling, firing or grinding.

Ensure adequate ventilation. Risk of fire or explosion.

– Before welding repairs on other parts, always disconnect the battery. Always remove the negative terminal first and reconnect it last.

– Nevertheless if welding repair should be done on components which may contain inflammable gases (welded counterweight, hydraulic tank, fuel tank, …), these components must be previously and sufficiently ventilated with pressurized air to avoid all fire or explosion hazard – Before welding, connect the ground cable as close as possible to the welding point, so the welding current will not run through the swing ring, joints, gears, bushings, rubber parts and seals

Process materials – When working with oils, greases and other chemical substances, observe the appropriate current safety regulations for the product.

– Ensure that process materials and replacement parts are disposed of in a safe and environmentally acceptable manner.

– Take care when handling hot process materials (Risk of burning and scalding).

– Do not attempt to lift heavy parts. Use devices which are suitable for this purpose and which have sufficient load capacity. When replacing single parts and larger subassemblies, carefully secure them on liftin g devices them so th at they do not present a risk. Only use su itable and correctly functioning lifting devices and load take-up devices with adequate load capacity.

Do not stand or work under swinging loads.

– Do not use lifting devices which are damaged or do not have sufficient load carrying capacity.

Wear work gloves when working with wire cables.

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

– When working above body height, use safe climbing devices and working platforms which are appropriate for the job.

Do not use machine parts as climbing devices if they are not designed for this purpose.

When working at height, wear a harness to prevent falling.

Ensure that all grips, steps, rails, platforms and ladders are free of dirt, snow and ice.

– Pneumatic cylinders do not have to be used as handles. Open doors and covers carefully, so that pneumatic cylinders do not hit their stops, because this could cause mechanical dammages.

– Be sure to support yourself safely when working on the equipment (e.g. replacing teeth). Prevent metal touching metal when doing this.

– For sa fety reasons, ne ver o pen a nd remove a tra ck cha in u nless ha ving previously totally r eleased the pretension of the chain tensioning unit.

R 964 C / R 974C

1.10.14 copyright by

MJFCIFSS

LFR / en / Edition: 05.2009

Repair work

Service Manual

Safety instructions Servicing the machine safely

– Never lay under the machine if it is ra ised with work equipment and has not been securely supported with wooden beams.

– Always jack the machine up in such a way that any weight displacement does not jeopardize stability and prevent metal touching metal while doing this.

– Work on the suspension, brake and steering systems may only be carried out by trained specialist personnel.

– If the machine has to be repaired on a slope, secure the crawler with chocks and connect the upper structure to the chassis using stop bolts.

– Only personnel with special training and experience may work on hydraulic equipment.

– When searching for leakage, wear protective gloves. A fine jet of liquid under pressure can penetrate the skin.

– Do not unscrew any lines or connections before you have set aside the equipment, switched off the engine and depressurized the hydraulic system. After switching off the engine, with the start key in contact position and with the safety lever down into its lowest position, you must operate all pilot control devices (joystick and pedals) in all directions in order to reduce the actuating and dynamic pr essures in the wor k circuits. You must t hen re duce the internal tank p ressure a s described in these operating instructions.

Electrical system – Check the electrical system regularly.

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

– Only use original fuses with approved current strength.

– For machines with electrical neutral and high tension leads: • switch the machine off immediately in the event of malfunctions in the power supply.

– Work on the machine’s electrical equipment may only be carried out by skilled electrical personnel or by trained personnel under the supervision of an electrician in accordance with electrical regulations.

– When working on live parts, ensure that a second person is available to operate the emergencyoff or the main switch and overvoltage release. Cordon off the working area with a red and white safety chain and a warning sign. Only use insulated tools.

– When working on neutral and high tension subassemblies, after releasing the voltage, briefly disconnect the supply cable at earth and electronic devices such as capacitors using an earthing rod.

– First test the released parts to make sure that they are off circuit, earth them and then disconnect them briefly. Insulate adjacent live parts.

– Disconnect the battery before working on the ele ctrical system or carrying out any electric arc welding on the machine.

First disconnect the negative, then the positive pole. When reconnecting, proceed in the reverse order.

LFR / en / Edition: 05.2009

Hydraulic accumulator – – – –

All work on the hydraulic accumulators must be carried out by trained specialist personnel.

Inexpert assembly and handling of hydraulic accumulators can cause serious accidents.

Do not operate damaged hydraulic accumulators.

Before working on a hydraulic accumulator, you must reduce the pressure in the hydraulic system (hydraulic system including hydraulic tank), as described in these operating instructions.

– Do not carry out welding or soldering or do any mechanical work on the hydraulic accumulator.

The hydraulic accumulator can be damaged by heat penetration and can be made to rupture by mechanical working. RISK OF EXPLOSION! – Only charge the hydraulic accumulator with nitrogen. There is a RISK OF EXPLOSION if oxygen or air is used.

– The accumulator body can become hot during operation; there is a risk of burning.

R 964 C / R 974C

1.10.15 copyright by

MJFCIFSS

Safety instructions

Service Manual

Servicing the machine safely – New hydraulic accumulators must be charged with the pressure required for the purpose of use before installation.

– The operating data (minimum and maximum pressure) are marked permanently on hydraulic accumulators. Ensure that this marking remains visible.

– It is forbidden to carry out repair work on hydraulic hoses and sheathed cables!

– All hoses, sheathed cables and bolt connections must be checked re gularly every 2 weeks for externally visible damage and any possible damage must be immediately checked for leakage.

– Never check for leaks with your bare hands, use a sheet of paper or something else.

– Any damaged parts must be removed immediately! Spurting oil can lead to injury and burns.

– Even with correct storage and permitted load, hoses and sheathed cables are subject to the natural aging process. This restricts their duration of use.

• Incorrect storage, mechanical damage and unauthorized load are the most common causes of failure.

• In relation to duration of use, current norms, regulations and guidelines pertaining to hoses and sheathed cables at place of use must be adhered to.

• Use at the limit range of permissible load can shorten duration of use (e.g. high temperatures, frequent movement cycles, extremely high pulse frequencies, multiple shift usage).

– Hoses and sheathed cables should be replaced if the following are found during inspection: • Damage to the outer sheath as far as the liner (e.g. chafing, cuts and cracks); • Brittleness of the outer sheath (fracture formation in hose material); • Deformations which do not correspond to the natural form of the hose or sheathed cable, whether in a unpressurized or pressurized state or on bends e.g. sheath separation, blistering; • Unsealed areas; • Non-adherence to requirements during installation; • Damage or deformations to the hose fittings which reduce the tightness of the fittings or the hose / fitting connection; • Hoses working themselves out of the fittings; • Corrosion of the fittings which reduces function and tightness; – When replacing hoses and sheathed cables, use only original replacement parts.

– Install and mount hoses and sheathed cables correctly. Do not mix up the connections.

– The following is to be noted when replacing hoses and sheathed cables: • Always ensure that the hoses and sheathed cables are installed free of torsion. For high-pressure hoses, the screws from the half-clamps or full flange must always be attached to both hose ends and should only be tightened afterwards.

• When tightening the flange on high-pressure hoses and sheathed cables with bent fittings, the side with the bent fitting must always be tightened first and then the side with the straight fitting tightened afterwards.

• Any mounting clamps which are located in the centre of the hose may only be attached and tightened subsequently.

• Check daily to ensure that all clamps, covers and protective devices are properly fastened. Doing this will prevent vibration and damage during operation.

• Install the hoses an d sheathed cables in such a way th at they cannot chafe on oth er hoses, sheathed cables or parts.

• A minimum distance from other parts of approx. half the exterior diameter of the hose is recommended. The distance should not, however, be less than 10 to 15 mm.

• When replacing the hoses or sheathed cables on moving parts (e.g. from the boom to the stay), check before initial start-up that there are no chafing areas in the entire area of movement.

R 964 C / R 974C

1.10.16 copyright by

MJFCIFSS

LFR / en / Edition: 05.2009

Hydraulic hoses and sheathed cables.

Service Manual

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 σ ( 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 an d nu t withou t r ework or sur face trea tment a nd u ngreased, fo r me an fr iction fa ctor µ=0,12.

Metric coarse thread

Thread

Assembly preloads FM in N

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

LFR / en / Edition: 05.2009

Class

Metric fine thread

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

R 964 C / R 974C

1.20.1 copyright by

MJFCIFSS

Tightening torques

Service Manual

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

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

M16×1,5 M18×1,5

M18×2

M20

M22

M24

8,8 10,9 12,9

121000 173000 202000

390 560 650

8,8 10,9 12,9

152000 216000 250000

530 750 880

8,8 10,9 12,9

175000 249000 290000

670 960 1120

M20×1,5

M22×1,5

M24×1,5

M24×2

M27

8,8 10,9 12,9

230000 330000 385000

1000 1400 1650

M27×1,5

M27×2

M30

8,8 10,9 12,9

280000 400000 465000

1350 1900 2250

M30×1,5

M30×2

M33

8,8 10,9 12,9

350000 495000 580000

1850 2600 3000

M33×1,5

M33×2

M36

8,8 10,9 12,9

410000 580000 680000

2350 3300 3900

M36×1,5

M36×3

M39

8,8 10,9 12,9

490000 700000 820000

3000 4300 5100

M39×1,5

M39×3

8.8 10.9 12.9

82000 121000 141000

205 300 360

8,8 10,9 12,9

110000 157000 184000

310 440 520

8,8 10,9 12,9

102000 146000 170000

290 420 490

8,8 10,9 12,9

139000 199000 232000

430 620 720

8,8 10,9 12,9

171000 245000 285000

580 820 960

8,8 10,9 12,9

207000 295000 346000

760 1090 1270

8,8 10,9 12,9

196000 280000 325000

730 1040 1220

8,8 10,9 12,9

267000 381000 445000

1110 1580 1850

8,8 10,9 12,9

255000 365000 425000

1070 1500 1800

8,8 10,9 12,9

335000 477000 558000

1540 2190 2560

8,8 10,9 12,9

321000 457000 534000

1490 2120 2480

8,8 10,9 12,9

410000 584000 683000

2050 2920 3420

8,8 10,9 12,9

395000 560000 660000

2000 2800 3300

8,8 10,9 12,9

492000 701000 820000

2680 3820 4470

8,8 10,9 12,9

440000 630000 740000

2500 3500 4100

8,8 10,9 12,9

582000 830000 971000

3430 4890 5720

8,8 10,9 12,9

530000 750000 880000

3200 4600 5300 R 964 C / R 974C

1.20.2 copyright by

MJFCIFSS

LFR / en / Edition: 05.2009

Metric coarse thread

Service Manual

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

90

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

LFR / en / Edition: 05.2009

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

R 964 C / R 974C

1.20.3 copyright by

MJFCIFSS

Tightening torques

Service Manual

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

M 42×2,0

540

GE 30 SM ED A 3 C

M 42×2,0

450

GE 30 SR A 3 C

G 1 1/4 A

540

GE 30 SR ED A 3 C

G 1 1/4 A

450

GE 38 SM A 3 C

M 48×2,0

700

GE 38 SM ED A 3 C

M 48×2,0

540

GE 38 SR A 3 C

G 1 1/2 A

700

GE 38 SR ED A 3 C

G 1 1/2 A

540

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

3

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

Type

Thread

Tightening torque (Nm)

Type

Thread

Tightening torque (Nm)

Light-duty series L WH / TH06 LR KDS A 3C

G 1/8 A

18

WH / TH 06 LM KDS A3C

M 10×1

18

WH / TH08 LR KDS A 3C

G 1/4 A

45

WH / TH 08 LM KDS A3C

M 12×1,5

45

WH / TH10 LR KDS A 3C

G 3/8 A

45

WH / TH 10 LM KDS A3C

M 14×1,5

55

WH / TH12 LR KDS A 3C

G1/2 A

70

WH / TH 12 LM KDS A3C

M 16×1,5

80

WH / TH15 LR KDS A 3C

G3/4 A

120

WH / TH 15 LM KDS A3C

M 18×1,5

100

WH / TH18 LR KDS A 3C

G1 A

120

WH / TH 18 LM KDS A3C

M 22×1,5

140

WH / TH22 LR KDS A 3C

G 1 1/4 A

230

WH / TH 22 LM KDS A3C

M 27×2,0

320

WH / TH28 LR KDS A 3C

G 1 1/4 A

320

WH / TH 28 LM KDS A3C

M 33 x 2,0

360

WH / TH35 LR KDS A 3C

G 1 1/4 A

540

WH / TH 35 LM KDS A3C

M 42×2,0

540

WH / TH42 LR KDS A 3C

R 1 1/2 A

700

WH / TH 42 LM KDS A3C

M 48×2,0

700

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

R 964 C / R 974C

1.20.4 copyright by

MJFCIFSS

LFR / en / Edition: 05.2009

Heavy-duty series S

Service Manual

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

WH / TH 38SR KDS A 3C

4

G 1/4 A

700

WH / TH 30 SM KDS A3C

M 42×2,0

540

WH / TH 38 SM KDS A3C

M 48×2,0

700

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

Gewinde

Anziehdreh momente (Nm)

M 10×1

12

VSTI 1/8 ED A3C

G 1/8 A

13

VSTI 12×1,5 ED A3C

M 12×1,5

25

VSTI 1/4 ED A3C

G 1/4 A

30

VSTI 14×1,5 ED A3C

M 14×1,5

35

VSTI 3/8 ED A3C

G 3/8 A

60

VSTI 16×1,5 ED A3C

M 16×1,5

55

VSTI 1/2 ED A3C

G 1/2 A

80

VSTI 18×1,5 ED A3C

M 18×1,5

65

VSTI 3/4 ED A3C

G 3/4 A

140

VSTI 20×1,5 ED A3C

M 20×1,5

80

VSTI 1 ED A3C

G1A

200

VSTI 22×1,5 ED A3C

M 22×1,5

90

VSTI 1 1/4 ED A3C

G 1 1/4 A

450

VSTI 26×1,5 ED A3C

M 26×1,5

120

VSTI 1 1/2 ED A3C

G 1 1/2 A

450

VSTI 27×2 ED A3C

M 27×2,0

135

VSTI 33×2 ED A3C

M 33×2,0

225

VSTI 42×2 ED A3C

M 42×2,0

360

VSTI 48×2 ED A3C

M 48×2,0

380

Type VSTI 10×1 ED A3C

Type

Gewinde

Anziehdreh momente (Nm)

LFR / en / Edition: 05.2009

VSTI = Hexagon socket plug

R 964 C / R 974C

1.20.5 copyright by

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Tightening torques

Service Manual

LFR / en / Edition: 05.2009

Tightening torques of screw-in studs (Ermeto)

R 964 C / R 974C

1.20.6 copyright by

MJFCIFSS

Service Manual

Lubricants and operating fluids Lubricants and operating fluids

1.55: Lubricants and operating fluids R 964 C from serial number 22 612 R 974 C from serial number 22 515

1 1.1

Lubricants and operating fluids 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.

X 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.

X Observe the following when using and checking lubricants and operating fluids: – see "Lubricants and operating fluids" – see "Inspection and maintenance schedule" Note!

Cleanliness is of the utmost importance when changing oil.

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

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

X 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: X Unless otherwise indicated, carry out all work on the machine on level, solid ground and with the engine switched off.

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

LFR / en / Edition: 05.2009

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

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

R 964 C / R 974C

1.55.1 copyright by

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Lubricants and operating fluids

Service Manual

Lubricants and operating fluids specification

2 2.1

Lubricants and operating fluids specification Diesel fuel specification The Diesel fu els mu st meet th e m inimum 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.

2.1.1

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 fue l lubrication characteristics. It has be en sh own tha t d iesel fue ls con taining the m aximum p ermitted Eu ropean s ulphur 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).

2.1.2

Diesel fuels for operation at low temperatures (winter)

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.

X 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.

R 964 C / R 974C

1.55.2 copyright by

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LFR / en / Edition: 05.2009

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.

Service Manual

Lubricants and operating fluids Lubricants and operating fluids specification

2.2

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).

2.3

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: 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) Tab. 1

E4, E6, E7

Lubricating oil for the Diesel engine - specifications Caution !

Particle filter only permitted with oil E6.

2.3.1

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.

LFR / en / Edition: 05.2009

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

Fig. 1

Temperature-based selection of the SAE class

R 964 C / R 974C

1.55.3 copyright by

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Lubricants and operating fluids

Service Manual

Lubricants and operating fluids specification 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

2.3.2

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: Oil change interval dependent on oil quality:

Operating conditions

CH-4, CI-4

E4, E6, E7

Operating conditions

Sulphur content of fuel

Interval

Climate normal to -10 °C

up to 0.5 %

250 h

500 h

above 0.5 %

125 h

250 h

up to 0.5 %

125 h

250 h

above 0.5 %

not permissible

125 h

below -10 °C

Tab. 2

Oil change intervals for the Diesel engine

h = operating hours

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.

2.4.1

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.

R 964 C / R 974C

1.55.4 copyright by

MJFCIFSS

LFR / en / Edition: 05.2009

2.4

Service Manual

Lubricants and operating fluids Lubricants and operating fluids specification

Corrosion in hibitors/antifreeze a gents approved by LIEBHERR ensur e p roper pr otection ag ainst 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.

2.4.2

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.

Contents

Quantity

Total earth alkaline content (water hardness)

0.6 to 3.6 mmol / l (3 to 20 °d)

pH value at 20 °C

6.5 to 8.5

Chloride ion content

max. 80 mg / l

Sulphate ion content

max. 100 mg / l

Tab. 3

Fresh water quality

Fresh water quality when using coolant with DCA 4 Contents

Quantity

Total earth alkaline content (water hardness)

0.6 bis 2.7 mmol/l (3 to 15 °d)

ph value at 20 °C

6.5 to 8.0

Chloride-ion content

max. 80 mg / l

Sulphate ion content

max. 80 mg / l

Tab. 4

Fresh water quality with use of DCA 4

Water analysis results are available from the local authorities.

2.4.3

Mixting ratio for coolant

LFR / en / Edition: 05.2009

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. 5

Mixture ratio (for all seasons)

R 964 C / R 974C

1.55.5 copyright by

MJFCIFSS

Lubricants and operating fluids

Service Manual

Lubricants and operating fluids specification

Fig. 2

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

A Corrosion inhibitor/antifreeze agent content in coolant

2.4.4

Permitted corrosion inhibitors / antifreeze agent Note!

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

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

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

*

LFR / en / Edition: 05.2009

X Do not mix different products.

R 964 C / R 974C

1.55.6 copyright by

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Service Manual

Lubricants and operating fluids Lubricants and operating fluids specification

Product description

Manufacturer

Country

Havoline XLC

Arteco

B

Motorex Antifreeze Protect G48

Bucher AG, Langenthal

CH

Motul Inugel Optimal Ultra

Motul SA, Aubervilliers Cedex

F

OMV KĂźhlerfrostschutz / Coolant Plus

OMV Refining & Marketing GmbH, Vienna

A

* = global / worldwide

2.4.5

Permitted premixed coolants Note!

The combination of different coolants might impair their properties.

X 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

2.4.6

Permitted corrosion inhibitors without antifreeze agent In exceptional circumstances and at ambient temperatures that are always above freezing points, e.g. du ring use in tro pical 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) Caltex / Chevron / Havoline / Total

LFR / en / Edition: 05.2009

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.

X Do not mix different products.

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

R 964 C / R 974C

1.55.7 copyright by

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Lubricants and operating fluids

Service Manual

Lubricants and operating fluids specification 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

2.5

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%.

2.5.1

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

Fig. 3

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

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 2.5.2(before choosing an oil, contact our customer service department).

R 964 C / R 974C

1.55.8 copyright by

MJFCIFSS

LFR / en / Edition: 05.2009

A Ambient temperature

Service Manual

Lubricants and operating fluids Lubricants and operating fluids specification

2.5.2

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: 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

Tab. 6

Engine oils for use as hydraulic oil

Fig. 4

Engine oils for use as hydraulic oil (SAE classes)* A Ambient temperature

1

Single grade engine oil

B Cold-start range with warm-up instruction

2

Multigrade oils

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

2.5.3

Warm-up instruction The black bar B indicates that the ambient temperatures are maximum 20 °C below the operating range C.

LFR / en / Edition: 05.2009

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: X 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: X 2. Before starting the engine, warm up the hydraulic oil tank. Then proceed according to the warmup instructions in 1.

R 964 C / R 974C

1.55.9 copyright by

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Lubricants and operating fluids

Service Manual

Lubricants and operating fluids specification

2.5.4

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.

X 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).

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.

2.5.5

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 r ecommends conta cting WEAR-CHECK** with th ese ana lysis,and to change the oil when indicated by the test results in the lab report (see also customer service and product information).

Symbol

LFR / en / Edition: 05.2009

* 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

Signification Filter change for hydraulic oil

Oil sampling

Tab. 7

Key to figures

R 964 C / R 974C

1.55.10 copyright by

MJFCIFSS

Service Manual

Lubricants and operating fluids Lubricants and operating fluids specification

Hydraulic oil in normal use

Fig. 5

Oil sampling and filters change in normal use h

Operating hours

1

First oil sample

a

Mineral oil

2

Second oil sample

h

Biodegradable hydraulic oil

3

Subsequent oil samples every 500 operating hours

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

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

Hydraulic oil used in dust intensive applications

Fig. 6

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

Operating hours

1

First oil sample

a

Mineral oil

2

Second oil sample

h

Biodegradable hydraulic oil

3

Subsequent oil samples: every 250 operating hours

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

LFR / en / Edition: 05.2009

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

2.5.6

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: â&#x20AC;&#x201C; The filter cartridge(s) in the return filter must be replaced every 500 operating hours and after every hydraulic oil change.

R 964 C / R 974C

1.55.11 copyright by

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Lubricants and operating fluids

Service Manual

Lubricants and operating fluids specification – 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.

2.6

Transmission oil Transmission oils must correspond to the specifications – API-GL-5 and MIL-L-2105 B or C or D for viscosity class SAE 90.

For viscosity classes SAE 80 and SAE 90 in accordance with MIL-L-2105 D, an oil of viscosity class SAE 80W90 can be used.

2.7

Lubricating grease and other lubricants Lubricant

Description / manufacturer

Grease for swing ring bearing races and general lubrication points

The grease must correspo nd with the spe cification 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

Grease for swing ring teeth

This grease must comply with following recommendations : – be of consistency classification 2 in NL-GI viscosity per DIN 51818, – have a VKA value of a least 5500N per DIN 51350 or ASTM D 2596, – show a water resistance of 1-90 per DIN 51807.

LIEBHERR recommends the use of : Grease CRL

Liebherr order n°: 8503279

1 pack 5 cartridges of 400 grams each Contact spray for slip rings

Cramolin

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

Gleitmo 800

R 964 C / R 974C

1.55.12 copyright by

MJFCIFSS

LFR / en / Edition: 05.2009

• 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 speci fic "LOW TEMPERATURE" grade This grease must have the necessary pumpability and "WORKED PENETRATION" consistency between 265 - 295 at -10° C temperature.

Service Manual

Lubricants and operating fluids Lubricants and operating fluids specification

Lubricant

Description / manufacturer

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

Lubricating grease and other lubricants

LFR / en / Edition: 05.2009

Tab. 8

R 964 C / R 974C

1.55.13 copyright by

MJFCIFSS

Lubricants and operating fluids

Service Manual

LFR / en / Edition: 05.2009

Lubricants and operating fluids specification

R 964 C / R 974C

1.55.14 copyright by

MJFCIFSS

Service Manual

Group 2: Tools

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

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

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

2.00.1

R 964 C / R 974C copyright by

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Service Manual

2.00.2

R 964 C / R 974C copyright by

MJFCIFSS

Service Manual

Special tools for maintenance and repair

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

Nr. No. N°

Benennung Desciption Dénomination

Größe Size Grand.

Ident. Nr. Order no N°code

Gerät Model Type

1

Messstutzen Pipe adaptator Embout

NW 10

7002404

alle Typen

NW 12

7008688

2

13 14 15 16 17 18

Messstutzen Pipe adaptator Embout

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

5607671 5607616 5607605 5607617 7409922 7409923

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

25

Manometeranschluss BSP coupling Raccord

R 1/2 “

7002436

alle Typen

30

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

R 1/2 “

7002435

alle Typen

Anwendung Application Application

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

2.01.1

R 964 C / R 974C copyright by

MJFCIFSS

Special tools for maintenance and repair

Darstellung Representation Dessin

Service Manual

Nr. No. N°

Benennung Desciption Dénomination

Größe Size Grand.

Ident. Nr. Order no N°code

Gerät Model Type

Anwendung Application Application

35

Hochdruckschlauch Länge High pressure hose Length Flexible haute pres.

Long

1000 mm

7002437

alle Typen

1500 mm

7002475

5000 mm

7363732

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

36

37

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

40

Schraubkupplung kpl.

Gauge coupling Raccord complet

41 42 43 44

45

46 47 48 49 50 51 52 53 54 55 56

Manometer Hydraulic pressure gauge Mano. à bain de glycérine

M10X1

5005180

M12X1,5 M14X1,5 M16X1,5 R 1/4“

7402580 5004002 7361345 7362579

0-1,6 bar

8042577

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

8042578 7361292 7361291 5002865 7361289 7361288 5002867 7361286 7361285 7500002 7361294

2.01.2

alle Typen

alle Typen

Zur Überprüfung der Betriebsdrücke eines bzw. mehrerer Hydraulikkreise.

Used to check system pressure in one or more hydraulik systems.

Pour le contrôle des pressions d’un ou de plusieurs cicuits hydraulique * glyceringedämpft * dampened with glycerin * à bain de glycérine

R 964 C / R 974C copyright by

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Service Manual

Darstellung Representation Dessin

Special tools for maintenance and repair

Nr. No. N°

Benennung Desciption Dénomination

75

Größe Size Grand.

Ident. Nr. Order no N°code

Gerät Model Type

Anwendung Application Application

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

10288229

alle Typen

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

76

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

10288155

77

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

10288152

78

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

10288154

79

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

7025279

80

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

7025273

81

-Transportkoffer -Tavel box Coffret der transport

614063501

82

-Adapterkabel / Daten-übertrag.

-Adapter wire - data transfert -Càble pour transfert de données

7025275

83

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

7026910

To measure the differential pressure p between pump- and LS pressure.

Pour mesurer la différence de pression p entre pression de pompe et pression LS.

2.01.3

R 964 C / R 974C copyright by

MJFCIFSS

Special tools for maintenance and repair

Darstellung Representation Dessin

Service Manual

Nr. No. N°

Benennung Desciption Dénomination

Größe Size Grand.

Ident. Nr. Order no N°code

Gerät Model Type

84

-Druckaufnehmer -Pressure sensor -Capteur de pression Hydrotechnik

0-600 bar

614062401

alle Typen

85

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

86

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

100

Stutzen Pipe adaptator Embout de prise de pression

4901372

101

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

7002404

102

Überwurfmutter Cap nut Ecrou de raccord

4774002

103

Schneidring Cutting ring Bague de sertissage

4774001

109

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

9684328

Anwendung Application Application

614062601 614064701

12 m

614063701

alle Typen

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

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

2.01.4

R 964 C / R 974C copyright by

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Service Manual

Darstellung Representation Dessin

Special tools for maintenance and repair

Nr. No. N°

Benennung Desciption Dénomination

Größe Size Grand.

110

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

Trageriemen

Ident. Nr. Order no N°code 614062001

Gerät Model Type

Anwendung Application Application

alle Typen

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

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

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

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

111

115

Sensoren und Zubehör Sensors and Extras Capteurs et Accessoires

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

(siehe “Lieferumfang Litronic Messsystem” auf Seite 11)

Messadapter Measuring adapter Boîtier de mesure

8504231

alle Typen

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

120

Messkabel Measuring wire Càble de mesure

9956436

alle Typen

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

2.01.5

R 964 C / R 974C copyright by

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Special tools for maintenance and repair

Darstellung Representation Dessin

Service Manual

Nr. No. N°

Benennung Desciption Dénomination

Größe Size Grand.

Ident. Nr. Order no N°code

Gerät Model Type

Anwendung Application Application

125

Drehzahlmesser Piezzo

A 2106 450

10286429

alle Typen

Zum Messen der Motordrehzahl über Impulsfrequenz der Einspritzleitung

Revolution - Indicator Compte-tours Piezzo

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

130

Drehzahlmesser Ornel Revolution - Indicator Compte-tours Ornel

HT 460

7006974

alle Typen

Zum Messen der Drehzahl über ReflexionsStreifen To check the RPM via reflexions stripe

131

132

Drehzahlmesser Shimpo Revolution - Indicator Compte-tours Shimpo

DT 205

7364284

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

614063201 mit / with / avec / n° 130

Streifen / Stripes / Pastilles 145

Vielfachmessgerät mit Digitalanzeige

Chauvin Arnoux MAX 3000

10018500

Multimeter with digital display

alle Typen

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

Contrôleur universel à affichage digital

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

Zusatz - Messwerkzeuge Measuring tools kit Outillages optionnels de mesures

5616316

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

147

Meßkabelsatz Measuring cable set Lot de câbles de mesure

886125008

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

148

Bereitschaftstasche Carrying case Pochette de protection

6001128 In Verbindung mit / To be used with tool / A usiter avec l’ outillage / n° 145

2.01.6

R 964 C / R 974C copyright by

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Service Manual

Darstellung Representation Dessin

Special tools for maintenance and repair

Nr. No. N°

Benennung Desciption Dénomination

Größe Size Grand.

Ident. Nr. Order no N°code

Gerät Model Type

Anwendung Application Application

160

Thermometer berührungslos (Infrarot)

GMTL 1826

7020372

alle Typen

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

Thermometer Infrared Temperature sensor

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

Thermométre sans contact

162

Thermometer mit Sonde und Fühler (magnetisch.)

Thermometer with probe and sensor (magnetic.)

Thermométre avec sonde et capteur (magnetic.)

GTH 1150

170

Handpumpe Sampling pump Pompe manuelle

8145666

172

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

7019068

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

10024185

alle Typen

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

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

Öl Analysenset * Oil Analysis set *

180

Öl Analysenset * Oil Analysis set *

Nr. 1

7018368

alle Typen

6 Stck. Ölproben 6 samples 6 pièces

8145660

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

1 Stck. Ölprobe 1 sample 1 jeu

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

2.01.7

R 964 C / R 974C copyright by

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Special tools for maintenance and repair

Darstellung Representation Dessin

Service Manual

Nr. No. N°

Benennung Desciption Dénomination

Größe Size Grand.

Ident. Nr. Order no N°code

Gerät Model Type

Anwendung Application Application

190

Vakuumpumpe REFCO Evacuation pump REFCO Pompe à vide REFCO

RD-4

7027552

alle Typen

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

195

Füllschlauch ITE blau Filling hose ITE blue

1500 mm

7027553

1500 mm

7027554

alle Typen

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

alle Typen

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

alle Typen

Zur Wartung und Reparatur der Klimaanlage Konvekta

Flexible de remplissage ITE bleu 196

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

197

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

1500 mm

7027555

205

KFZ - Kupplung ITE Quick coupling ITE Attache rapide ITE

253a

7027556

210

KFZ - Kupplung ITE Quick coupling ITE Attache rapide ITE

254 a

7027557

215

4-Ventil - Prüfarmatur

M4WS5C

7027558

Test equipement with 4 valves

For servicing and repairing the air conditioning equipment Konvekta

Unité d’essai à 4 clapets

Pour l’entretien et la réparation du elimatiseur Konvekta

2.01.8

R 964 C / R 974C copyright by

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Service Manual

Darstellung Representation Dessin

Special tools for maintenance and repair

Nr. No. N°

Benennung Desciption Dénomination

Größe Size Grand.

Ident. Nr. Order no N°code

Gerät Model Type

Anwendung Application Application

220 221 222 223 224

Demontagewerkzeug

UTV-M20 UTV-M24 UTV-M30 UTV-M36 UTV-M42

7023304 7023305 7023306 7023307 7023308

alle Typen

Zur Demontage der Greiferbolzen

Disassembly tool

To dis assemble the pins of the grabble

Outillage de démontage

230 231 232 233 234 235

Demontagescheibe Disassembly tool Rondelle d'appui de démontage

Pour le démontage des pivots du grappin

M14 M20 M24 M30 M36 M42

7023309 7023310 7023311 7023312 7023313 7023314

alle Typen

Zur Demontage der Passfix - Bolzen For disassembly of passfix bolts Pour le démontage des axes à bague de serrage passfixe

240

Diagnosegerät Diagnostic tool Appareil diagnostique

5010474

alle Typen

Zur Fehlerdiagnose der Zusatz-Heizung D5 WS. For diagnostic purposes on the additional cab heater.

Pour diagnostiser des anomalies au chauffage supplémontaire

241

Adapterkabel Adapter harness Câble d’adaption

9960799 Zum Anschluß im Kabelbaum linke Konsole To connect to the wire harness in left control panel.

Pour brancher au faisceau dans le pupitre gauche

245

Diagnose - Kit (CD mit Software und Verbindungskabel)

10008427

alle Typen

Kommunikation- und Diagnostesoftware für BEKA-MAX Zentralschmierung

Diagnostic software (software on CD and connecting cable)

Communication and diagnostic software for BEKAMAX central lubrication

Ensemble de diagnostic (logiciel sur CD et cäble de raccordement)

Logiciel de communication et de diagnostic pour système de graissage centralisé BEKA-MAX.

2.01.9

R 964 C / R 974C copyright by

MJFCIFSS

Special tools for maintenance and repair

Darstellung Representation Dessin

Service Manual

Nr. No. N°

Benennung Desciption Dénomination

Größe Size Grand.

Ident. Nr. Order no N°code

Gerät Model Type

Anwendung Application Application

250

Drehmomenschlüssel

4-20 Nm

10045464

alle Typen

Zum Anziehen der Schlauchschellen

255

Handpumpe mit manometer

10454803

alle Typen

Zur Dichtheitsprüfung der Gegendruckleitung bei Partikelfilter Einbau

2.01.10

R 964 C / R 974C copyright by

MJFCIFSS

Service Manual

Special tools for maintenance and repair

Lieferumfang Litronic Messsystem Pos.

Bezeichnung Designation / Désignation

Ident-Nr.

1

LMS - Litronic Messsystem, bestehend aus: Measuring kpl. containing : Système de mesure comprenant :

1.1

Messgerät / Measuring tool / instrument de mesure

6140 621 01

1.2

Transportkoffer / carrying case / coffret de transport

6140 622 01

1.3

Trageriemen / straps / courroie d’épaule

6140 623 01

1*

6140 620 01

Zusätzlich werden, je nach Anforderung, verschiedene Aufnehmer und Kabel benötigt, welche gesondert bestellt werden müssen.

Besides, on request, several sensors and wires can be needed, wich have to be ordered in addition.

En outre, selon votre demande, divers capteurs et câbles sont nécessaires, devant être commandé en sus.

Grösse / Size / Dimensions

Pos.

Sensoren / Sensors / Capteurs

Ident-Nr.

2

OEM - Drucksensor, Messbereich OEM - Pressure sensor OEM - Capteur de pression

0 - 1000 bar 0 - 20 mA

3

OEM - Drucksensor, Messbereich OEM - Pressure sensor OEM - Capteur de pression

0 - 600 bar 0 - 20 mA

6*

6140 624 01

4

OEM - Drucksensor, Messbereich OEM - Pressure sensor OEM - Capteur de pression

0 - 60 bar 0 - 20 mA

3*

6140 625 01

5

OEM - Drucksensor, Messbereich OEM - Pressure sensor OEM - Capteur de pression

0 - 10 bar 0 - 20 mA

1002 7591

6

OEM - Drucksensor, Messbereich OEM - Pressure sensor OEM - Capteur de pression

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

5718 886 08

7

Druckaufnehmer Direktanschluss nach MINIMESS Connection for pressure sensor to MINIMESS Adaptateur pour pressostat vers MINIMESS

Serie 1620 - 0°

6*

6140 626 01

8

Druckaufnehmer Direktanschluss nach MINIMESS Connection for pressure sensor to MINIMESS Adaptateur pour pressostat vers MINIMESS

Serie 1620 - 90°

3*

6140 647 01

9

Temperaturaufnehmer Pt 100 Temperature sensor Pt 100 Capteur de température Pt 100

-50 °C / +200 °C

1*

6140 627 01

10

P / T - Messkupplung, MINIMESS P / T - Measuring coupling, MINIMESS P / T - Adaptateur prise de mesure, MINIMESS

Serie 1620 G 1/4“

1*

6140 628 01

11

P / T - Messkupplung, MINIMESS P / T - Measuring coupling, MINIMESS P / T - Adaptateur prise de mesure, MINIMESS

Serie 1620 M10 x 1,5

1*

1004 1274

12

Messturbine Measuring turbineTurbine de mesure

RE 4 - 10 1 - 10 l/min

1*

5010 031

1001 8329

2.01.11

R 964 C / R 974C copyright by

MJFCIFSS

Special tools for maintenance and repair

Service Manual

Grösse / Size / Dimensions

Pos.

Sensoren / Sensors / Capteurs

Ident-Nr.

13

Messturbine Measuring turbine Turbine de mesure

RE 3 - 75 7,5 - 75 l/min

1*

6140 629 01

14

Messturbine Measuring turbine Turbine de mesure

RE 3 - 300 15 - 300 l/min

0*

6140 630 01

15

Messturbine Measuring turbine Turbine de mesure

RE 3 - 600 25 - 600 l/min

2*

5009 492

16

Drehzahlsensor Tachometer Tachymètre

DS 03 1 - 9999 U/min

1*

6140 631 01

17

Ersatzreflektionsfolien - Set Set of spare reflective foils Jeu de pastilles réflectives

1*

6140 632 01

18

Magnethalter, passend für Drehzahlsensor DS 03 Magnetic holder for tachometer DS 03 Support magnétique pour tachymètre DS 03

1*

6140 633 01

19

Induktivaufnehmer zur Drehzahlmessung Inductive sensor for tachometer Capteur inductif pour tachymètre

1*

6140 634 01

Pos.

Zubehör / Options / Options

20

Transportkoffer zur Aufbewahrung der Messturbinen RE 3 Carrying case to carry the measuring turbine RE 3 Coffret de transport pour préserver la turbine de mesure RE 3

21

Messkabel zum Anschluss der Sensoren, länge : Measuring cable to connect the sensors, length : Câble de mesure pour connecter les câbles. long. :

Grösse / Size / Dimensions

Ident-Nr. 1*

6140 635 01

MK 12 - 6 m.

12*

6140 636 01

22

MK 12 - 12 m.

4*

6140 637 01

23

MK 12 - 18 m.

1*

6140 638 01

6 m.

1*

6140 639 01

12 m.

0*

6140 640 01

24

Stromversorgungskabel zum Bordnetz Anschluss, länge : Power supply cable to connect to the system, length : Câble d’alimentation a connecter au réseau , longueur :

25 26

Thermodrucker mit Netzgerät Network printer Imprimante réseau

DPU 411

0*

6140 641 01

27

Ersatz-Thermopapierrollen Exchange thermopaper roll Rouleau de papier thermique de rechange

für / for / pour DPU 411

0*

6140 642 01

28

Datenübertragungskabel Centronics, länge : Centronics data transfer cabel, length : Câble de transfert de données Centronics, longueur :

2m. für / for / pour DPU 411

0*

6140 643 01

29

Datenübertragungskabel, (Anschluss an PC) Data transfer cabel, (to connect to PC) Câble de transfert de données (à connecter au PC)

RS 232 - 2 m.

1*

9684 327

2.01.12

R 964 C / R 974C copyright by

MJFCIFSS

Service Manual

Special tools for maintenance and repair

Grösse / Size / Dimensions

Pos.

Zubehör / Options / Options

Ident-Nr.

30

Adapterkabel (für Drehzahlmessung über Prüfgerät GLR) Adapter cabel (for tachometrical measuring using control apparel GLR) Câble adaptateur (pour mesure tachymétrique via appareil GLR)

AK 12

1*

6140 648 01

31

Litronic Service Programm (DOS Betriebssystem) Litronic Service Program (DOS system) Programme d’entretien Litronic (système d’exploitation DOS)

Deutsch German Allemand

0*

6140 646 01

32

Auswerte-Software Evaluation software Programme d’évaluation

CD-rom Windows 16 bit (d / e / f)

1*

6004 401

33

Auswerte-Software Evaluation software Programme d’évaluation

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

34

Messadapter für Strommessung Measuring adapter Boîtier de mesure

für / for / pour : - Litronic 2

1*

8504 231

36

Y-Adapter für Strommessung Junior Timer Stecker Y adapter to check current measuring Junior Timer plug Adaptateur en Y pour mesurer le courant clé Junior Timer

1*

9956 436

37

Adapter 3- auf 2-polig Stecker Adapter 3- on 2-pole Adapteur 3- sur 2-bornes

1*

9956 422

* Stückzahl für empfohlene Grundausstattung / Number of pieces for recommended basic equipment / Nombre de pièces pour l’équipement de base recommandé.

2.01.13

R 964 C / R 974C copyright by

MJFCIFSS

Special tools for maintenance and repair

Service Manual

2.01.14

R 964 C / R 974C copyright by

MJFCIFSS

Service Manual

Special tools for Liebherr Diesel engines

2.02: Special tools for Liebherr Diesel engines Spezialwerkzeuge für Liebherr Dieselmotoren Outillage spécial pour les moteurs Diesel Liebherr Darstellung Representation Dessin

Nr. No. N°

Benennung Desciption Dénomination

5

Kompressions-Druckprüfer CompressiometerCompressiométre

6

Größe Size Grand.

Diagrammblätter für Pos. 5 Diagramms for item 5

Ident. Nr. Order no N°code

Gerät Model Type

Anwendung Application Application

8008782

alle Typen

Zum Prüfen des Kompressionsdruckes To check compression

100 Stück

Pour le contrôle de la pression d’injection

10012817

100 pieces Diagramme pour pos.5 10

11

100 pièces

Anschlussstück für Kompressions-Druckprüfer Fitting of the recorder of compression pressure

0524044

all Typ except D 934 D 936

10297211

D 934 D 936

10117612

D 934 D 936

An Stelle des Einspritzventils einzusetzen Replaces injection valve A monter à la place de l’injecteur

Piéce de raccordement pour compressiométre

12

Pratze

Zum Befestigung des Anschlussstücks 11.

Claw To fasten the fitting 11.

Griffe Pour fixer la pièce 11.

15

Düsenprüfgerät Nozzle testing device Appareil de contrôle des injecteurs

7361236

alle Typen

Zum Prüfen der Einspritzventile To check injection valve Pour le contrôle des injecteurs

2.02.1

R 964 C / R 974C copyright by

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