en
Service Manual Hydraulic Excavator A 934 C Litronic A 944 C-HD Litronic A 954 C-HD Litronic
Last update:
Types:
11 / 2010
A 934 C Litronic / A 944 C-HD Litronic / A 954 C-HD Litronic
Service Manual
Introduction Symbols used in this manual
Introduction This manual contains technical data, design and functional descriptions, as well as instructions as regards the operation and the adjustment of machine settings. The document includes a number of drawings, functional schematics, as well as detailed views of units and assemblies of LIEBHERR hydraulic excavators. The documentation has been designed to support customer support services, but does of course not replace proper technical training and qualification of the user, and participation in LIEBHERR operator training courses. General basic technical information is not included in the manual. For operating instructions and information on spare parts, please refer to the separate documentation. During all work on the machine, strictly adhere to the relevant accident prevention and safety regulations.
1
Symbols used in this manual Tasks and procedures that are associated with specific dangers are accompanied by safety instructions. The safety instructions are graded according to the severity of the risk and are identified with the terms DANGER, CAUTION and NOTE and the respective danger symbol: These terms are used in combination with the following symbols: Danger Warning referring to a danger where there is a high probability of death or serious injury to operators, unless the prescribed safety measures are taken.
Caution Warning relating to dangers that might lead to injury or damage to the machine, unless the prescribed safety measures are taken.
Note This symbol accompanies instructions and tips regarding the operation, maintenance and repair of the equipment. If adhered to, the service life of the machine can be prolonged and/or procedures are made easier. This symbol precedes entries in a list. This symbol precedes entries in a sub-list. This symbol identifies "Pre-condition MUST be fulfilled" This symbol indicates a single procedure in a sequence of procedures. This symbol indicates a result of an action. This manual has been exclusively compiled for internal use by the registered machine owner. It may not be reproduced or made available to third parties without the explicit written consent of LIEBHERR, who retains all rights in this document. This publication remains the property of LIEBHERR-HYDRAULIKBAGGER GMBH. All rights reserved printed in Germany. This service manual shall be amended without prior notice to reflect new technical developments and machine series. LIEBHERR reserves the right to make minor technical amendments to the machines that might not be reflected in the accompanying documentation.
1.00.1
Introduction
Service Manual
Symbols used in this manual Depending on the series development, the service manual shall be revised in electronic format. Changes and amendments are listed in group 1.02. This manual might be complemented by additional service information sheets issued by LIEBHERR. Compiled by the Technical Documentation Department. Published by Customer Service Centre Training Group of LIEBHERR-HYDRAULIKBAGGER GMBH 88457 Kirchdorf / lller, Germany. We hope that the information in this documentation aimed at improving the service of LIEBHERR excavators is of use to you.
1.1
Explanation In order to make it easy for users to find specific information regarding revised or amended documents, each page is identified as follows:
A
Page number
D
Drive motor
B
Subgroup
E
Diesel engine
C
Main group
F
Page
The main groups are listed in the main group directory. The subgroups are listed on the first page of each main group section. The subgroup list also includes the machines and serial numbers to which the subgroup is relevant. In the event of minor changes, we will send you the amended page showing the current date. If an existing subgroup is completely revised and re-edited, the new version will be assigned a new subgroup number.
1.00.2
General Information
1
Tools
2
Technical Data / Maintenance Guidelines
3
Engine
4
Clutch / Splitterbox
5
Hydraulic System
6
Hydraulic Components
7
Electrical System
8
Swing Gear
9
Swing ring
10
Two Speed Gear Box
11
Axles / Gear Box
12
Steering
13
Oscillating Axle Stabilizer
14
Brake system
15
Special Attachments / Accessory Kits
16
Cab Heater / Air Conditioning System
17
Undercarriage / Uppercarriage / Attachments
18
Service Manual
SUBGROUP - INDEX Section
Group
Type
Changes and modifications to series
1.02.1
A 934 C-LI 25436A 944 C-LI 24475A 954 C-LI 21416-
Safety instructions
1.10.1
A 934 C-LI A 944 C-LI A 954 C-LI
Tightening torques (WN 4037 K)
1.20.1
A 934 C-LI A 944 C-LI A 954 C-LI
Tightening torques
1.21.1
A 934 C-LI A 944 C-LI A 954 C-LI
Assembly instruction for hydraulilc cylinder WN 4121 C
1.22.1
A 934 C-LI A 944 C-LI A 954 C-LI
Assembly instruction for hydraulic cylinder WN 4122 B
1.24.1
A 934 C-LI A 944 C-LI A 954 C-LI
Tightening torques for piston rod bearing screws
1.25.1
A 934 C-LI A 944 C-LI A 954 C-LI
Angle-controlled screw tightening
1.30.1
A 934 C-LI A 944 C-LI A 954 C-LI
Fuels, lubricants and process chemicals
1.51.1
A 934 C-LI A 944 C-LI A 954 C-LI
1.1 MJFCIFSS
Service Manual
1.2 MJFCIFSS
Service Manual
Changes and modifications to series Last updated: 11 / 2010
Changes and modifications to series 1 Change mark
Last updated: 11 / 2010
Change to group
Type of modification
Affected models
revised
3.05
Technical data
A 934 C type 1006
revised
3.07
Technical data
A 934 C type 1007
revised
3.09
Technical data
A 934 C type 1053
revised
3.11
Technical data
A 944 C type 194
revised
3.13
Technical data
A 944 C type 196
new
3.60
Adjustment protocol version 4.8.1
A 954 C type 450 from 51610
new
4.25
Liebherr diesel particle filter accessory kit
A 934 C type 1006/1007/1053 A 944 C type 194/196
new
4.40
Data logger version 02.03.00
A 934 C type 1006/1007/1053 A 944 C type 194/196
new
4.41
Data logger version 2.3.09
A 934 C type 1006/1007/1053 A 944 C type 194/196
new (a, b, c, d)
6.71
Hydraulic schematic with Bucher pipe fracture safety valve
A 934 C 1006/1007
new (a, b, c, d)
6.73
Hydraulic schematic with Bucher pipe fracture safety valve
A 934 C type 1053
new (a, b, c, d)
6.76
Hydraulic schematic with Bucher pipe fracture safety valve
A 944 C type 194
new (a, b, c, d)
6.78
Hydraulic schematic with Bucher pipe fracture safety valve
A 944 C type 196
new
7.60
M8 control valve block
A 934 C type 1006/1007/1053
new
7.62
M8 control valve block
A 944 C type 194
new
7.64
M8 control valve block
A 944 C type 196
revised
7.73
Rotary connection
A 934 C type 1006/1007/1053 A 944 C type 196
new
8.01
Overview of electrical symbols
A 934 C type 1006/1007/1053 A 944 C type 194/196 A 954 C type 450
new
8.02
Notes regarding the electrical system
A 934 C type 1006/1007/1053 A 944 C type 194/196 A 954 C type 450
new
8.50
BST excavator control system
A 934 C type 1006/1007/1053 A 944 C type 194/196 A 954 C type 450
new
8.55
Menu structure version 4.8 / 4.8.1
A 934 C type 1006/10071053 from 47120 A 944C type 194/196 from 47120 A 954 C type 450 from 47120
1.02.1 copyright by
MJFCIFSS
Changes and modifications to series
Service Manual
Last updated: 11 / 2010 Change mark
Change to group
Type of modification
Affected models
new
8.82
Slip ring contact
A 934 C type 1006/1007/1053 A 944 C type 194/196 A 954 C type 450
revised
12.01
Tyres
A 934 C type 1006/1007/1053 A 944 C type 194/196 A 954 C type 450
new
16.16
Pipe-fracture safety valve of hoist cylinder
A 934 C type 1006/1007/1053 A 944 C type 194/196
new
16.18
Pipe fracture safety valve of stick cylinder
A 934 C type 1006/1007/1053 A 944 C type 194/196
Updated 06/2010 revised
1.51
Fuels, lubricants and process chemicals
all types
revised
2.06
Special tools for electrical equipment
all types
revised
6.70
Hydraulic schematic
A 934 C type 1006/1007
revised
6.72
Hydraulic schematic
A 934 C type 1053
NEW
7.42 replaced 7.55
Pilot control unit 1x
A 934 C type 1006/1007/1053 A 944 C type 194/196 A 954 C type 450
revised
7.45
Control and regulating unit
A 934 C type 1006/1007/1053 A 944 C type 194/196 A 954 C type 450
new
8.107
Stick cylinder shut-down / potentiometer
A 934 C type 1006/1007/1053 A 944 C type 194/196 A 954 C type 450
new
8.122
Stick cylinder shut-down / Hall sensor
A 934 C type 1006/1007/1053 A 944 C type 194/196 A 954 C type 450
revised
13.10
Hydraulic steering system
A 934 C type 1006/1007
new
13.12
Hydraulic steering system
A 934 C type 1053
new
13.14
Hydraulic steering system
A 944 C type 196
new
13.16
Hydraulic steering system
A 944 C type 194 A 954 C type 450
new
13.18
Joystick steering
A 934 C type 1006/1007/1053 A 944 C type 194/196 A 954 C type 450
new
15.05
Operating pressures of the brake system
A 934 C type 1006/1007/1053 A 944 C type 194/196 A 954 C type 450
new
15.08
Hydraulic brake system
A 934 C type 1006/1007/1053
new
15.10
Hydraulic brake system
A 944 C type 194/196
revised
15.12
Hydraulic brake system
A 954 C type 450
revised
15.20
Compact brake block
A 934 C type 1006/1007/1053 A 944 C type 194/196 A 954 C type 450
1.02.2 copyright by
MJFCIFSS
Service Manual
Changes and modifications to series Last updated: 11 / 2010
Change mark
Change to group
Type of modification
Affected models
new
16.80
Hydraulic operator's cab elevation system
A 934 C type 1006/1007/1053 A 944 C type 194/196 A 954 C type 450
new
16.82
Stick cylinder shut-down with proximity switch
A 934 C type 1006/1007/1053 A 944 C type 194/196 A 954 C type 450
new
16.84
Electronic stick cylinder shut-down
A 934 C type 1006/1007/1053 A 944 C type 194/196 A 954 C type 450
new
17.40
Inspection and repair instructions for heating and air-conditioning system
A 934 C type 1006/1007/1053 A 944 C type 194/196 A 954 C type 450
new
17.50
Heating and air-conditioning system
A 934 C type 1006/1007/1053 A 944 C type 194/196 A 954 C type 450
new
18.01
Fixture of operator's cab
A 934 C type 1006/1007/1053 A 944 C type 194/196 A 954 C type 450
new
18.50
Repair instructions for lubrication hoses
all types
Update 12/2009 revised
2.06.
Special tools for electrical equipment
all types
revised
2.07.
Special tools for slewing gear mechanism
A 934 C type 1006/1007/1053 A 944 C type 194/196 A 954 C type 450
new
3.52.
Adjustment protocol V 4.7
A 944 C type 194 from 39086
new
3.53.
Adjustment protocol V 4.5
A 944 C type 196 from 33765 to 39086
new
3.54.
Adjustment protocol V 4.7
A 944 C type 196 from 39086
new
6.77.
Hydraulic schematic
A 944 C type 196 from 29225
revised
12.01.
Tyres
A 934 C type 1006/1007/1053 A 944 C type 194/196 A 954 C type 450
revised
12.07.
Steering drive axle LT 71
A 934 C type 1006 from 28016
revised
12.08.
Rigid axle D 71
A 934 C type 1006 from 28016
revised
12.16.
Steering drive axle LT 81
A 934 C type 1007/1053 from 25436
revised
12.18.
Rigid axle D 81
A 934 C type 1007/1053 from 25436
revised
12.35.
Steering drive axle LT 102
A 954 C type 450 from 21416
revised
12.36.
Rigid axle D 102
A 954 C type 450 from 21416
revised
16.86.
Generator drive accessory kit
A 954 C type 450 from 21416
Update 07/2009 revised
3.45. 3.47.
Adjustment protocol V 4.2
A 934 C type 1006/1007 from 25436 39076
new
3.46 3.48
Adjustment protocol V 4.7
A 934 C type 1006/1007 from 39077
1.02.3 copyright by
MJFCIFSS
Changes and modifications to series
Service Manual
Last updated: 11 / 2010 Change mark
Change to group
Type of modification
Affected models
revised
3.49
Adjustment protocol V 4.5 and V 4.7
A 934 C type 1053 from 39077
new
3.70.
Testing and adjustment tasks V4.7
A 934 C type 100671007 from 39077
revised (a)
6.70.
Control connections 11 and 12 at control valve block confused
A 934 C type 1006/1007 from 25436
new
7.07.
DPVP 108 double variable-displacement pump
A 934 C type 1006/10071053 from 25436
new
8.02.
Notes regarding the electrical system
A 934 C type 1006/10071053 from 25436 A 944 C type 194/196 from 24475 A 954 C type 450 from 21416
revised
8.10.
Arrangement of components
A 934 C type 1006/10071053 from 25436
new
8.44.
Operating symbols on operator's platform
A 934 C type 1006/10071053 from 25436 A 944 C type 194/196 from 24475 A 954 C type 450 from 21416
new
8.79
Keyboard
A 934 C type 1006/10071053 from 25436 A 944 C type 194/196 from 24475 A 954 C type 450 from 21416
new
8.80
Error code list
A 934 C type 1006/10071053 from 25436 A 944 C type 194/196 from 24475 A 954 C type 450 from 21416
new
12.10.
Steering drive axle LT 71
A 934 C type 1006 from 28016
new
12.12.
Rigid axle D 71
A 934 C type 1006 from 28016
new
12.16.
Steering drive axle LT 81
A 934 C type 1007/1053 from 25436
new
12.18.
Rigid axle D 81
A 934 C type 1007/1053 from 25436
new
16.88.
Generator drive accessory kit
A 934 C type 1006/1007 from 25436 A 944 C type 194 from 24475
new
16.90.
Generator conversion kit for LIKUFIX
A 934 C type 1006/1007 from 25436 A 944 C type 194 from 24475
1.02.4 copyright by
MJFCIFSS
Service Manual
Safety instructions Proper use
Safety instructions Working with the machine holds dangers to which you as the owner, machine operator or maintenance expert could be exposed. If you regularly read and observe the safety information, you can guard against dangers and accidents. This applies especially to persons, who are working on the machine only occasionally, such as for maintenance work. The following information comprises safety regulations which, if followed conscientiously, will guarantee your safety and that of other persons, as well as avoid damage to the machine. Following these regulations does not release you from the responsibility to follow all safety regulations and guidelines valid for the jobsite, as required by law or issued by trade associations. For EU countries, guideline 89/655/EEC contains the minimum safety information applicable to the operator.
1
Proper use The hydraulic excavator is a machine with attachments (such as backhoe, grapple, bucket ) designed to loosen, take on, transport and dump soil, rocks and other materials, where the load is predominantly transported without moving the machine. Moving the machine when it is carrying a load must be carried out by observing the appropriate safety measures (see section "Notes for machine operating safety"). Machines used for load-lifting work are subject to specific conditions and must be equipped with the stipulated safety devices (see section Load-lifting work ). Other or additional usage, such as for demolition or material handling work, requires special equipment and may also require special safety devices. These attachments (e.g. log grapple, demolition hammer, concrete cutter etc.) may only be attached and used with approval and in accordance with the basic machine manufacturer. Transporting persons is not deemed to be intended use. The manufacturer is not liable for damage resulting from this action. The risk must be assumed solely by the user. Observing the operating instructions and the inspection / maintenance instructions is also deemed to be appropriate and destined use in accordance with regulations.
2
General Safety instructions Please familiarize yourself with the operating instructions before starting the machine. Please verify that you have read and understood supplemental instructions (this may concern special options for the machine). Only explicitly authorized personnel may operate, maintain or repair the machine. The legal minimum age must be observed. Use only trained or instructed personnel. Clearly define who is responsible for the operation or set up, maintenance and repair. Reject unsafe instructions by third parties and/or allow your personnel to reject these. This also applies in regards to traffic regulations. Any person still in training should only operate or work on the machine under the constant supervision and guidance of an experienced person. Check and observe all persons working or operating the machine at least periodically to ensure that they observe safety instructions and guidelines given in the operating manual. Wear proper work clothing when operating or working on the machine. Avoid wearing rings, watches, ties, scarves, open jackets or loose clothing. There is a danger of injury, as these items could get caught or be pulled in. Wear task-appropriate personal protective equipment at all times. Consult the supervisor for any special safety procedures applicable to your job site. Always raise the safety lever before leaving the operator s seat.
1.10.1 copyright by
MJFCIFSS
Safety instructions
Service Manual
Crushing and burn prevention Keep steps, ladders and handholds (handles) in proper condition. Make especially sure that they are free of dirt, oil, ice and snow. NOTE: To ensure that the doors open in all weather conditions, lubricate the weather strips at least every two months, or more often, if necessary, with talcum powder or silicon. Lubricate the door hinges and locks regularly. When entering or leaving the cab, do not use the steering column, the control panel or the joysticks as handholds. Never jump off the machine, always use the steps, ladders, rails and handles provided to climb off or on the machine. Always face towards the machine when climbing on and off it, and always use the three points of contact with the machine (all times either two hands and one foot, or two feet and one hand are in contact with the access system). Familiarize yourself with the emergency exit. Proceed as described in the operating manual, if no other instructions are available for maintenance and repairs: Place the machine on a solid and level ground and lower the working attachment to the ground. Depressurize the hydraulic system. Move all control levers to the neutral position. Move the safety levers up prior to leaving the machine. Remove the ignition key. Before servicing the hydraulic system you must reduce the pressure in the hydraulic system and tank, as described in this operating manual. Secure all loose parts on the machine. Never start a machine before completing a thorough walkaround inspection. Insure that all required safety signs are in place and legible. Do not modify, alter or otherwise change any safety-related systems of components without the specific approval of LIEBHERR.
3
Crushing and burn prevention Never work underneath the attachment as long as it is not safely resting on the ground or properly supported. Insure that all load supporting systems are in good repair and rated for the required load. Always wear work gloves when handling wire ropes. When working on the attachment, never align bores with your fingers, always use a suitable alignment tool. Keep hands, tools and any other objects away from contact with the cooling fan. The cooling fan can cause severe injury, objects can be catapulted away or destroyed, and the fan can be damaged by the objects. At or near operating temperature, the engine cooling system is hot and under pressure. Avoid contact with any components containing coolant. Danger of severe burns. Check the coolant level only after the radiator cap on the expansion tank is cool enough to touch. Turn the cap carefully to relieve the pressure. At or near operating temperature, the engine and the hydraulic oil are hot. Do not allow your skin to come into contact with hot oil or components containing hot oil. Always wear safety glasses and protective gloves when handling batteries. Avoid sparks and naked flames. Do not let any assisting personnel hold the attachment, bucket or grapple to assist in any operation. When working on the engine area, make sure that the side doors are properly secured to remain open during the service operation.
1.10.2 copyright by
MJFCIFSS
Service Manual
Safety instructions Fire and explosion prevention
4
Fire and explosion prevention Switch off the diesel engine prior to filling the tank. Have skilled personnel immediately repair all defects, such as loose connections, blown fuses and burned out light bulbs, burned or frayed cables. Do not smoke and avoid naked flames when filling the tank or loading the batteries. Always start the diesel engine according to the operating instructions. Never store flammable fluids on the machine except in appropriate storage tanks. Regularly inspect all lines, hoses and fittings for leaks and damage. Repair any leaks immediately and replace damaged components. Be certain that all clamps, guards and heat shields are properly installed to prevent vibration, rubbing and heat build up. Do not use cold start aids (ether) near heat sources or naked flames or in insufficiently ventilated areas. Do not use ether containing starting aids to start diesel engines with pre-heat system or flame glow systems. Familiarize yourself with the location and use of fire extinguishers on the machine as well as the local fire reporting procedures and fire fighting possibilities.
5
Transport Insure that the transporting vehicle or truck trailer is rated for the intended machine weight and size. Park the machine on a level surface and chock the track chains and/or wheels. During transport, remove parts of the attachment that create an over width or length condition, if necessary. Clean the undercarriage. The undercarriage must be swept clean, meaning, the chains / wheels must be free of snow, ice and sludge prior to driving onto the transporting vehicle. Align the machine precisely with the loading ramp. Attach the manual lever for sensitive driving (crawler excavator) to the driving pedals. Have another person guide and signal the operator. On wheel models equipped with an uppercarriage locking mechanism, the uppercarriage must be secured to the undercarriage with the locking pin after loading onto the trailer. Secure the machine and any loose components with tiedowns in accordance with any applicable national regulations. Release all pressure lines (as described in this operating manual), remove the ignition key and pull the safety lever up prior to leaving the machine. Close all cab and panel doors. Verify that no one remains on the machine during the transport. Investigate the travel route, specifically in reference to limits for width, height and weight prior to the transport. Pay special attention when driving under electrical lines and bridges and when passing through tunnels. Use the same care for unloading as for loading.
6
Bringing the machine into service Before starting the machine, perform a thorough walkaround inspection. Visually check the machine for loose bolts, cracks, wear, leaks and damage. Never start or operate a damaged machine.
1.10.3 copyright by
MJFCIFSS
Safety instructions
Service Manual
Starting the machine
Make sure to correct any problems immediately. Verify that all hoods, covers and doors are closed, however, the locks should remain unlocked. Verify that all safety signs are in place. Make sure that all windows, as well as the inside and outside mirrors are clean. Secure all doors and windows to prevent unintentional movement. Before operating the machine, adjust the operator s seat, the mirror, the armrests and the other items to ensure comfortable and safe working conditions. The noise protection devices on the machine must be in working order. Never operate the machine without the cab.
7
Starting the machine Before start up, check all indicator lights and instruments for proper function, bring all controls into neutral position and insure that the safety lever is in the raised position. Blow the horn briefly prior to starting the diesel engine, in order to warn persons located near the machine. Only start the machine from the driver s seat. Start the diesel engine according to the regulations in the operating instructions, if you have not received any other instructions. Lower the safety lever and check all indicators, gauges, warning devices and controls for their proper indication. Only operate the diesel engine in a well-ventilated area, if the area is enclosed. If necessary, open doors and windows in the building to provide ample fresh air. Bring the engine and hydraulic oil to operating temperature. Low oil temperatures cause a slow reaction of the controls. Check that all attachment functions are operating properly. Carefully take the machine to an open area and check all control functions.
8
Shutting down the machine Park the machine on level and stable ground whenever possible. Otherwise, chock or block wheels when parking on a slope. Lower the attachment so that it rests on the ground. Move all control elements into the neutral position. Set the parking and slewing gear brake. Switch off the diesel engine according to the operating instructions and move the safety lever up, prior to leaving the driver s seat. Lock the machine, as well as all hoods, covers and doors; remove all keys and secure the machine against any unauthorized use.
9
Towing the machine Always observe the correct procedure: See chapter Towing the machine in this operating manual. The machine may only be towed in exceptional circumstances, such as moving a disabled machine from a hazardous location. Before pulling or towing the machine, check all cables, hooks and couplers for safety and stability. Towing equipment must have sufficient tensile strength and must be attached to the undercarriage at the designated tiedown attachment points. Never allow anyone to remain in the area of the towing devices. During the towing procedure, keep within the required transport position, the permissible speed
1.10.4 copyright by
MJFCIFSS
Service Manual
Safety instructions Working with the machine
and distance. Proceed as outlined in the operating manual when putting the machine back into service.
10
Working with the machine Before starting to work, familiarize yourself with the specific conditions of the job site and any local regulations. These include: the obstacles in the working or movement area, the load carrying capacity of the ground and required safeguards for the job site to protect machines and personnel from public highway traffic. Always keep an adequate safety distance to overhangs, edges, embankments and an unsecured substrate. Be particularly cautious in conditions of reduced visibility and changing ground conditions. Always locate any underground utilities before you dig. Observe the required clearance distances to any underground utilities. Familiarize yourself with the location of power lines and use caution when working near them. Observe the required clearance distances to any power lines. In the case of contact with a power line: do not move the machine or its attachment, do not leave the operator s platform, warn people in the vicinity not to approach or touch the machine, have the power turned off. Before moving the machine, always ensure that the attachments are safely secured. When traveling on public roads, observe all traffic regulations, insure that your equipment has all required lighting and marking, and observe any applicable load limitations. Always turn on the lights in conditions of poor visibility or darkness. Do not permit any passengers on the machine (except on two way excavators). Operate the machine only when seated and with the seat belt fastened. Report any problems or needed repairs and make sure that all required repairs are carried out immediately. Insure that the intended work area is clear of all personnel before beginning work. Before starting to work, always check the brake system as outlined in the operating manual. Never leave the operator s seat as long as the machine is still moving. Never leave the machine unattended while the diesel engine is running. Know the loads to be handled and be aware of any stability limitations these loads may create. The maximum approved passable incline / traverse slope of the machine depends on the attached equipment as well as the substrate. For travel, move the uppercarriage parallel to the undercarriage and hold the load as close as possible to the ground. EXCEPTION: see WHEN LOADING AND UNLOADING Adjust the travel speed to suit local conditions. Avoid working movements which could cause the machine to tip over. If possible, always work downhill or uphill, never sideways on a slope. Travel downhill at the permitted speed or you could lose control over the machine. Travel down grades at the appropriate speed to maintain control of the machine. Shift to a lower gear to allow the engine to control the maximum speed of the machine. When loading a truck, make sure that the truck driver leaves the cab, even if a rock protection is present. Always use the safety devices intended for their specific use for demolition work, clearings, hoisting operations, etc. For terrain which is difficult to gain an overview of and whenever necessary, ask for assistance of a guide. Have only one person signal you. Only permit experienced personnel to secure loads and signal the machine operator. The guide
1.10.5 copyright by
MJFCIFSS
Safety instructions
Service Manual
Working with the machine must position himself within view of the operator or be in voice contact with him. Depending on the attachment combination, there can be a danger of collision between the working tool and the operator s cab, the cab protection or the boom cylinders. To avoid damage, utmost attention is required when the bucket teeth enter this range.
10.1
Use in material handling applications, specifically when travelling with raised loads and attachments Material handling applications, especially using a grapple, may require travel with suspended loads. Doing this will shift the machine centre of gravity and reduce stability. The following practices and precautions should be observed: Match your travel behaviour to the changed machine characteristics and surrounding conditions. Reduce the travel speed to avoid sudden braking or steering manoeuvres. Avoid sudden speed changes, such as braking, acceleration, changes in travel direction. Turn the uppercarriage only if the undercarriage is not travelling. Turn the uppercarriage only after taking on the load. Move the machine only after you have taken on the load, lifted it and turned the uppercarriage in travel position. If so required to the job site conditions, ensure, that you have appropriate windscreen protection. The protective screen (FOPS) must be installed if there is a danger of falling objects from overhead. Do not exceed the grapple rated load. Know the density and weight of materials being handled. The working sequences when working with machines with grapples require a properly instructed and trained operator. The work application is only permitted after the machine operator has received sufficient training and practical experience.
10.2
Application of machines with tower elevation Due to the tower elevation, the centre of gravity of the machine will shift upward in vertical direction. The travel and work behaviour of the machine will thereby be strongly influenced, for example reduction of dynamic stability. Due to the elevated centre of gravity, the machine must be aligned in horizontal direction before starting to work. In horizontal direction, the centre of gravity of the uppercarriage is above the centre of the undercarriage, which improves stability. The machine can rock despite levelling and tip over! For that reason, the following rules must be strictly observed: When driving the machine: Driving with loads is not permitted. Swing the uppercarriage parallel to the undercarriage (transport position). Pull the attachment as close as possible to the machine. Only then may the outriggers be retracted and the machine be driven. Check the roadway to ensure that the ground is solid and even! Potholes and uneven road surfaces endanger the stability of the machine. Match your travel behaviour to the changed machine characteristics (higher centre of gravity) and surrounding conditions. Reduce the travel speed to avoid sudden braking or steering manoeuvres. Avoid sudden speed changes, such as braking, acceleration, changes in travel direction. Travel up or down grades perpendicular (at right angles) to the slope. Special care must be taken when driving through narrow passages - drive slowly! In material handling operation: Wheel model: Before moving (turning) the uppercarriage from transport position, the machine must be supported on outriggers and horizontally aligned.
1.10.6 copyright by
MJFCIFSS
Service Manual
Safety instructions Working with the machine Make sure to check the placement surface of the outriggers (load carrying capacity of ground). Sinking of an outrigger below ground level would result in devastating consequences! Carry out all movements with increased caution. When swinging a load, first bring the attachment as low and close to the machine as practical. Note: be aware of the hazard of grapple swing when moving a load toward the operator cab. Avoid abrupt slow down or acceleration of the attachment or uppercarriage. Never lift a heavier load than stated in the load chart.
10.3
Additional notes for machines with fixed cab raiser To enter and exit the machine, park the machine on level ground. Position the uppercarriage to the undercarriage in such a way that the steps and ladders are aligned. When entering or leaving the machine, always face the machine and use the three points of contact with the machine. When you can reach the door handle with your free hand, open the door first before climbing higher. Note that factors such as wind, can make it more difficult to open the door. For that reason, always guide the door by hand when opening the door. Make sure that the door is properly latched open. Continue to climb up and immediately sit on the operator s seat in the cab. Then close the door and fasten the safety belt. Proceed with the same care when exiting and climbing down as when entering and climbing up the machine. Park the machine only on firm and level ground. Position the uppercarriage to the undercarriage in such a way that the steps and ladders are aligned. Release the safety belt. When exiting, face the machine and use the three-point support. Climb down until you can close the door safely. Always guide the door by hand when closing the door. Finally climb down to the ground.
10.4
Protection from vibrations The vibration impact on mobile construction machinery is usually the result of the manner of utilization. Especially the following parameters have a significant influence: Terrain conditions: Unevenness and potholes; Operating techniques: Speed, steering, braking, control of operating elements of the machine during travel as well as working. The machine operator determines the vibration impact to a great part, since he himself selects the speed, the gear ratio, the working manner and the travel route. This results in a wide range of various vibration impacts for the same machine type. The full body vibration impact for the machine operator can be reduced if the following recommendations are observed: Select the appropriate machine, equipment parts and auxiliary devices for the corresponding tasks. Keep the seat in good order and adjust it as follows: The seat adjustment and the suspension should be made according to the weight and the size of the operator. Check the suspension and the adjustment mechanism regularly and make sure that the characteristics of the seat remain as specified by the seat manufacturer. Check the maintenance condition of the machine, especially regarding: Tire pressure, brakes, steering, mechanical connections, etc. Do not steer, brake, accelerate and shift or move and load the attachment of the machine in a jerky manner. Match the machine speed to the travel route to avoid vibration impacts. Decrease the speed when driving on pathless terrain;
1.10.7 copyright by
MJFCIFSS
Safety instructions
Service Manual
Installation and removal of attachment parts Drive around obstacles and avoid very impassable terrain. Keep the quality of the terrain where the machine is working and travelling in good order: Remove large rocks and obstacles; Fill furrows and holes; To establish and retain suitable terrain conditions, keep machines available and allow for sufficient time. Travel longer distances (i.e. on public roads) with suitable (medium) speed. For machines, which are frequently used for travel, consider use of auxiliary ride control systems, and also monitor speed to minimize buildup of "pitching" vehicle movement.
11
Installation and removal of attachment parts Equipment and attachment parts made by other manufacturers or those which do not have LIEBHERR s general approval for installation may not be installed on the machine without prior written approval by LIEBHERR. LIEBHERR must be provided with the required technical documentation necessary for this purpose. Set the machine on a level and stable ground prior to any work with attachments. Lock the uppercarriage with the locking pin to the undercarriage. Do not position yourself under a raised attachment that has not been adequately and securely supported. Never place yourself under a machine while it is elevated. Remove hydraulic system pressure before working on any attachments (as described in this operating manual). Do not attempt to lift heavy parts. Use suitable lifting devices with sufficient load carrying capacity. Insure any lifting system or lifting device that is used is in good repair and adequately rated for the component or machine to be supported. Always wear work gloves when handling wire cables. When working on the equipment: Switch off the diesel engine, remove the key and turn the safety lever upward. During repairs: Make sure that the hydraulic lines are properly attached and that all fittings and connections are properly tightened. As soon as an attachment part is removed and supported, cover or cap the openings in the hydraulic circuit to prevent dirt infiltration. Permit only authorized persons near the machine or the lifting device.
11.1
Removal and installation of attachment pins Never use your fingers to align pin bores. If possible, always use a hydraulic pin pulling device to push out the pins on the attachment. If pins must be removed with a sledge hammer, use a punch and a guide tube held by another person. To drive out a pin, install the impact screw from the tool box in the threaded bore of the pin and hit the screw only. For the installation of a pin retained with castle nut and cotter pin, drive the pin in first to the stop, then install the castle nut by hand until contact and tighten it only to the point where the cotter pin can be installed.
1.10.8 copyright by
MJFCIFSS
Service Manual
Safety instructions Maintenance
12 12.1
Maintenance General safety instructions Maintenance and repairs may only be carried out by trained expert technicians. Always note the frequency intervals for inspections as contained in this operating manual. Insure that an adequately equipped workshop is available to perform these tasks, and note the designated qualifications of the personnel responsible for each inspection. The maintenance and inspection schedule sets out precisely who should, or is allowed to carry out which jobs. The machine operator (and his staff) are allowed to carry out certain jobs, but other jobs must be carried out only by qualified and trained staff. Spare parts must meet the technical requirements set forth by the manufacturer. This is always ensured with original spare parts. Wear task-appropriate personal protective equipment at all times. Example: In addition to a protective helmet and safety boots, for certain jobs protective goggles and gloves are also necessary. Keep unauthorized personnel away from the machine during maintenance. Secure a wide-ranging area for maintenance, as necessary. Inform the operator before starting to carry out special tasks and maintenance work. Make sure he knows the person who is in charge of the work. Perform all maintenance operations on the machine on a level and stable ground with the working equipment lowered and the diesel engine turned off, unless described otherwise in the operating manual. Hang a well visible warning label do not switch on onto the ignition during maintenance operations, especially when working under the machine. Remove the ignition key and set the main battery switch to position 0. Re-torque all bolts at the completion of the maintenance procedure to the required torque specification. If the dismantling of safety equipment is necessary, the safety equipment must be re-attached and inspected directly upon conclusion of the operations.
12.2
Checking for cracks Machines are subject to different loads, depending on application, job site, duration of use and conditions of use. The different load conditions result in different service lives for various machines components. This could lead to cracks and loose connections, particularly on load-bearing parts. This applies particularly to machines used in material handling or industrial applications or for machines with special equipment, such as demolition excavators. To ensure that operating safety is maintained, the machine must be checked regularly for cracks, loose connections or other visible damage. To check for cracks, it is necessary to keep the machine clean and to clean it regularly. The inspection must be carried out according to the inspection and maintenance schedule. It is advisable to carry out these inspections with the machine supported, on firm and level ground. Specific attention should be given to the following: The steel structure undercarriage with axle and gear mounting, support, lower slewing ring seating with tower and slewing ring. The steel structure uppercarriage with bearing block for boom and boom cylinder, upper slewing ring seating, cab bearing, mounting of slewing gear and counterweight. Steel structure of working attachments, e. g. boom, stick, quick change adapter, digging tool and grapple. Hydraulic cylinder, axles, steering, pins and pin connections, steps, ladders and mounting elements. Check for cracks visually. If a crack is suspected or is in areas which are not easily visible, such
1.10.9 copyright by
MJFCIFSS
Safety instructions
Service Manual
Maintenance as the slewing ring seating, then the dye penetration procedure should be used to check for cracks. Any damage found must be fixed immediately. Welding on load-bearing parts of earth moving machines, material handling and transport units may only be made by certified welders in accordance with acceptable welding practices. Contact LIEBHERR Service to discuss suitable measures.
12.3
Welding Welding, cutting and grinding should only be done with the specific approval of LIEBHERR. Prior to any welding, cutting or grinding, clean the machine and surrounding area to remove dust and flammable materials. Insure adequate ventilation.
12.4
Fuels, lubricants and process chemicals When handling oils, greases and other chemical substances, always observe the applicable safety regulations for the corresponding product. Ensure safe and environmentally friendly disposal of operating and service fluids as well as exchange parts. Handle hot operating and service fluids carefully (danger of burning and scalding).
12.5
Repair Do not attempt to lift heavy parts. Use lifting devices with sufficient load carrying capacity. When replacing parts or large sub-assemblies, use appropriate and functioning lifting devices and adequate load carrying capacity to insure safe movement during installation. Never stand or work under suspended loads. Always wear work gloves when handling wire ropes. Only permit experienced personnel to secure loads and signal the crane operator. The guide must position himself within view of the operator or be in voice contact with him. When working overhead, use appropriate safe access ladders and working platforms. Do not use parts of the machine as climbing devices, if they are not designed for this purpose. Wear a harness when working at great heights. Keep handles, steps, railings, platforms, and ladders free of dirt, ice and snow. When working on the attachment (for example when replacing teeth), make sure the machine is properly supported. Never use metal-on-metal support. Never stand underneath a machine that has been raised with the aid of work equipment unless it has been properly and securely supported. Always support the machine in such a ways that any shifting weight will not endanger the stability of the machine and avoid metal to metal contact. Work on travel gears, brake and steering systems may only be carried out by specially trained expert personnel. If the machine must be repaired on an incline, block the track chains with chocks and secure the uppercarriage to the undercarriage with the locking pin. Only qualified, specially trained personnel may work on the hydraulic system. Do not check for hydraulic leaks with your hand. Use cardboard or similar material to detect leaks. Wear work gloves. Do not loosen any lines or bolts before lowering the equipment, turning off the diesel engine and relieving the hydraulic system. After the diesel engine has been turned off, you must move all pilot controls (right handed joystick and pedals) into all directions to reduce the control pressure and the dynamic pressure in the work cycles. Then release the pressure in the tank, as described in this operating manual.
1.10.10 copyright by
MJFCIFSS
Service Manual
Safety instructions Maintenance
12.6
Electrical system Check the electrical system regularly. All defects, such as loose connections, burnt out fuses and bulbs, burnt or damaged wires or cables must be repaired immediately by an electrician or specially trained personnel. Only use original fuses with the correct amperage. Only qualified technicians should attempt troubleshooting or repairs on high voltage systems. DO NOT work on energized attachments. When working on mid and high voltage components, shut off the voltage and connect the supply cable to the ground to discharge any stored energy. Check all disconnected parts if they are truly free of current, ground them and short circuit them. Insulate adjacent, current carrying parts. Disconnect the battery before working on the electrical system or before carrying out any arc welding work on the machine.
12.7
Pressure accumulator Pressure accumulators contain stored energy and operate at high pressures. Only specially trained personnel may work on pressure accumulators. Do not operate damaged pressure accumulators. You must reduce the pressure in the hydraulic system as described in this operating manual prior to working on a hydraulic accumulator. Do not weld or solder on the pressure accumulator and do not carry out any mechanical work on them. Fill the pressure accumulator only with nitrogen. The accumulator housing can become hot during operation, there is a danger of burning. New pressure accumulators must be charged to the required pressure for the application before use. The operating data (minimum and maximum pressure) is marked permanently on the pressure accumulators. Make sure that the marking remains visible.
12.8
Hydraulic hoses and lines Hydraulic lines and hoses may never be repaired! All hoses, lines and fittings must be checked every two weeks for leaks and visible damage. Damaged parts must be replaced immediately. Remember that escaping high pressure oil can penetrate skin. Escaping oil can also cause fires. Even if hoses are properly stored and used, they undergo a natural aging process. For that reason, their service life is limited. Improper storage, mechanical damage and impermissible use are the most frequent causes of failure. Using hoses and lines close to the limit ranges of permitted use can shorten the service life (for example in high temperatures, frequent work cycles, extremely high impulse frequencies, multi shift operation). Hoses and lines must be replaced when the following conditions are found during inspection: Damage to the outer layer as far as the intermediate layer (e.g. chafing, cuts and cracks); Brittleness of the outer layer (hose material cracking); Deformations, which differ from the natural shape of the hose or hose line, when under pressure or not under pressure, or in bends (e.g. separation of layers, blisters or bubbles); Leaks; Failure to follow installation instructions; Damage or deformation of hose fittings, which reduce the strength of the fitting or the hose / fitting connection; Hose slipping out of the fitting;
1.10.11 copyright by
MJFCIFSS
Safety instructions
Service Manual
Maintenance Corrosion on the fittings, which reduces function and strength; When replacing hoses and lines, observe the following: Use only original spare parts. Route and install hoses and lines properly, observe correct connection points. Always ensure that the hoses and lines are free of torsion when routing. On high pressure hoses, always attach the screws of half clamps or full flange on both ends of hose first and then tighten. When using high pressure hoses and lines with a bent fitting, always tighten the end with the bent fitting first when tightening the flanges, then the end with the straight fitting. Any existing mounting clamps in the centre of the hose may only be installed and tightened thereafter. Check daily to ensure that all clamps, covers and protective devices are properly mounted. This prevents vibration and damage during operation. Route the hoses and lines in such a way that chafing with other hoses or other structures is prevented. A minimum distance of approximately ½ of the outer hose diameter to the other parts is recommended. The distance should not be less than 10 to 15 mm (1/2 inch). When replacing hoses and lines on movable parts (e.g. from boom to stick), check for hose interference and kinking over the complete range of motion.
12.9
Cab protection (FOPS) For certain machine applications LIEBHERR offers optional cab protection systems of various designs. These systems consist of a full length FOPS (falling objects protective structure) or a top guard and front guard to protect the operator's cab and windscreen area from falling objects (for example rocks or debris). The full length FOPS wraps around the operator's cab, is mounted to the uppercarriage and is a stand-alone system. The top and front guards are either bolted individually or in combination to the cab structure. In that case the operator's cab is also part of the cab protection system and is subject to the following instructions. Never operate a machine if one of these protections is damaged in any way. Damages may occur due to: structural modifications or repairs (for example welding, cutting or drilling) deformation after an accident falling objects Structural modifications or repairs of any kind are prohibited without the expressed, written approval of LIEBHERR.
1.10.12 copyright by
MJFCIFSS
Product code
Standard
Version
10409969 001 WN 4037 K
PRELOADS AND TIGHTENING TORQUES FOR SCREWS WITH METRIC COARSE AND FINE THREADS ACCORDING TO DIN ISO 261 The preloads and torques included in the table are based on the VDI regulations 2230 of July 1986. (The values of the edition from February 2003 have not been included in the table, as this would not be justified according to our experience.) Assembly preloads FM and tightening torques MA at v = 0.9 for headless screws with metric coarse or fine threads according to DIN ISO 262 (and DIN ISO 965-2); Head dimensions of hex head screws according to DIN EN ISO 4014 to 4018, screws with hexalobular external driving heads according to DIN 34800 or Allen head screws according to DIN EN ISO 4762 and "centre" bores according to DIN EN 20273 Metric coarse thread Surface finish: black-chrome finish or phosphatised electro-galvanised flZn = zinc flake coating (LH standard 10021432, DAC) Assembly Thread Class preloads FM in N
oiled
for mean friction factor
M4
M5
M6
M7
M8
8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9
4 050 6 000 7 000 6 600 9 700 11 400 9 400 13 700 16 100 13 700 20 100 23 500 17 200 25 000 29 500
Tightening torques MA in Nm
Metric fine thread Surface finish: black-chrome finish or phosphatised electro-galvanised flZn = zinc flake coating (LH standard 10021432, DAC) Assembly Thread Class preloads FM in N
µG= 0.12
2,8 4,1 4,8 5,5 8,1 9,5 9,5 14,0 16,5 15,5 23,0 27 23 34 40
8.8 10.9 12.9
27 500 40 000 47 000
46 68 79
M8x1
M10x1
M10x1,25
M12
8.8 10.9 12.9
40 000 59 000 69 000
79 117 135
M12x1,25
M12x1,5
M14
M16
.04.08 Date
8.8 10.9 12.9 8.8 10.9 12.9
LHB Plant
55 000 80 000 94 000 75 000 111 000 130 000
125 185 215 195 280 330
Wimbauer Alois Created
Tightening torques MA in Nm
for mean friction factor
M9x1
M10
oiled
M14x1,5
M16x1,5
8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9
Examined
This document may not be copied or otherwise reproduced without the prior consent of LIEBHERR. This document has been created by electronic means and is valid without signature.
µG= 0.12
18 800 27 500 32 500 24 800 36 500 42 500 31 500 46 500 54 000 29 500 43 000 51 000 45 000 66 000 77 000 42 500 62 000 73 000 61 000 89 000 104 000 82 000 121 000 141 000
24,5 36 43 36 53 62 52 76 89 49 72 84 87 125 150 83 122 145 135 200 235 205 300 360
owatzky Dirk Released
1.20.1
Product code
Standard Metric coarse thread Surface finish: black-chrome finish or phosphatised electro-galvanised flZn = zinc flake coating (LH standard 10021432, DAC) Assembly Thread Class preloads FM in N
oiled
for mean friction factor
M18
8.8 10.9 12.9
94 000 135 000 157 000
Version
Tightening torques MA in Nm
Metric fine thread Surface finish: black-chrome finish or phosphatised electro-galvanised flZn = zinc flake coating (LH standard 10021432, DAC) Assembly Thread Class preloads FM in N
µG= 0.12
280 390 460
M22
M24
8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9
121 000 173 000 202 000 152 000 216 000 250 000 175 000 249 000 290 000
390 560 650 530 750 880 670 960 1120
M18x1,5
M20x1,5
M22x1,5
M24x1,5
M24x2
M27
8.8 10.9 12.9
230 000 330 000 385 000
1000 1400 1650
M27x1,5
M27x2
M30
8.8 10.9 12.9
280 000 400 000 465 000
1350 1900 2250
M30x1,5
M30x2
M33
8.8 10.9 12.9
350 000 495 000 580 000
1850 2600 3000
M33x1,5
M33x2
M36
8.8 10.9 12.9
410 000 580 000 680 000
2350 3300 3900
M36x1,5
M36x3
M39
8.8 10.9 12.9
490 000 700 000 820 000
3000 4300 5100
oiled
Tightening torques MA in Nm
for mean friction factor
M18x2
M20
10409969 001
M39x1,5
M39x3
8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9 8.8 10.9 12.9
110 000 157 000 184 000 102 000 146 000 170 000 139 000 199 000 232 000 171 000 245 000 285 000 207 000 295 000 346 000 196 000 280 000 325 000 267 000 381 000 445 000 255 000 365 000 425 000 335 000 477 000 558 000 321 000 457 000 534 000 410 000 584 000 683 000 395 000 560 000 660 000 492 000 701 000 820 000 440 000 630 000 740 000 582 000 830 000 971 000 530 000 750 000 880 000
µG= 0.12
310 440 520 290 420 490 430 620 720 580 820 960 760 1090 1270 730 1040 1220 1110 1580 1850 1070 1500 1800 1540 2190 2560 1490 2120 2480 2050 2920 3420 2000 2800 3300 2680 3820 4470 2500 3500 4100 3430 4890 5720 3200 4600 5300
Notes: Torques indicated in drawings have precedence over those specified in the factory standards and must at all times be adhered to. For important screw connections, we recommend using a torque angle gauge. For such connections, the required tightening torques (assembly torque, angle of rotation) must be determined individually by the technical department. .
1.20.2
Standard ď‚–
.
Product code Version
10409969 001
When tightening in aluminum, with or without Helicoil-Inserts, the values for category 8.8 must be used. However, tightening torques indicated on drawings are binding, to be treated with priority and must be adhered to.
1.20.3
Service Manual
Tightening torques of screw-in studs (Ermeto)
Tightening torques 1 1.1
of screw-in studs (Ermeto) mating material: steel (Grease well before inserting!) Type with sealing edge Thread M or G
Type
Type with EOLASTIC seal Tightening torques in Nm
Thread M or G
Type
Light-duty series L
Tightening torques in Nm
Light-duty series L
GE 06 LM A 3 C
M 10x1
18
GE 06 LM ED A 3 C
M 10x1
18
GE 06 LR A 3 C
G 1/8 A
18
GE 06 LR ED A 3 C
G 1/8 A
18
GE 08 LM A 3 C
M 12x1.5
30
GE 08 LM ED A 3 C
M 12x1.5
25
GE 08 LR A 3 C
G 1/4 A
35
GE 08 LR ED A 3 C
G 1/4 A
35
GE 10 LM A 3 C
M 14x1.5
45
GE 10 LM ED A 3 C
M 14x1.5
45
GE 10 LR A 3 C
G 1/4 A
35
GE 10 LR ED A 3 C
G 1/4 A
35
GE 12 LM A 3 C
M 16x1.5
65
GE 12 LM ED A 3 C
M 16x1.5
55
GE 12 LR A 3 C
G 3/8 A
70
GE 12 LR ED A 3 C
G 3/8 A
70
GE 15 LM A 3 C
M 18x1.5
80
GE 15 LM ED A 3 C
M 18x1.5
70
GE 15 LR A 3 C
G 1/2 A
140
GE 15 LR ED A 3 C
G 1/2 A
90
GE 18 LM A 3 C
M 22x1.5
140
GE 18 LM ED A 3 C
M 22x1.5
125
GE 18 LR A 3 C
G 1/2 A
100
GE 18 LR ED A 3 C
G 1/2 A
90
GE 22 Lm A 3 C
M 22x1.5
140
GE 22 Lm Ed A 3 C
M 26x1.5
180
GE 22 Lr A 3 C
G 3/4
180
GE 22 Lr Ed A 3 C
G 3/4 A
180
GE 28 Lm A 3 C
M 33x2.0
340
GE 28 Lm Ed A 3 C
M 33x2.0
310
GE 28 Lr A 3 C
G1A
330
GE 28 Lr Ed A 3 C
G1A
310
GE 35 Lm A 3 C
M 42x2.0
500
GE 35 Lm Ed A 3 C
M 42x2.0
450
GE 35 Lr A 3 C
G 1 1/4 A
540
GE 35 Lr Ed A 3 C
G 1 1/4 A
450
GE 42 Lm A 3 C
M 48x2.0
630
GE 42 Lm Ed A 3 C
M 48x2.0
540
GE 42 Lr A 3 C
G 1 1/2 A
630
GE 42 Lr Ed A 3 C
G 1 1/2 A
540
Heavy-duty series S
Heavy-duty series S
GE 06 SM A 3 C
M 12x1.5
35
GE 06 SM ED A 3 C
M 12x1.5
35
GE 06 SR A 3 C
G 1/4 A
55
GE 06 SR ED A 3 C
G 1/4 A
55
GE 08 SM A 3 C
M 14x1.5
55
GE 08 SM ED A 3 C
M 14x1.5
55
GE 08 SR A 3 C
G 1/4 A
55
GE 08 SR ED A 3 C
G 1/4 A
55
GE 10 SM A 3 C
M 16x1.5
70
GE 10 SM ED A 3 C
M 16x1.5
70
GE 10 SR A 3 C
G 3/8 A
90
GE 10 SR ED A 3 C
G 3/8 A
80
GE 12 SM A 3 C
M 18x1.5
110
GE 12 SM ED A 3 C
M 18x1.5
90
GE 12 SR A 3 C
G 3/8 A
90
GE 12 SR ED A 3 C
G 3/8 A
80
GE 14 SM A 3 C
M 20x1.5
150
GE 14 SM ED A 3 C
M 20x1.5
125
GE 14 SR A 3 C
G 1/2 A
150
GE 14 SR ED A 3 C
G 1/2 A
115
1.21.1 copyright by
MJFCIFSS
Tightening torques
Service Manual
of swivelling connections (Ermeto) Type with sealing edge Thread M or G
Type
Type with EOLASTIC seal Tightening torques in Nm
Type
Thread M or G
Tightening torques in Nm
GE 16 SM A 3 C
M 22x1.5
170
GE 16 SM ED A 3 C
M 22x1.5
135
GE 16 SR A 3 C
G 1/2 A
130
GE 16 SR ED A 3 C
G 1/2 A
115
GE 20 SM A 3 C
M 27x2.0
270
GE 20 SM ED A 3 C
M 27x2.0
180
GE 20 SR A 3 C
G 3/4 A
270
GE 20 SR ED A 3 C
G 3/4 A
180
GE 25 SM A 3 C
M 33x2.0
410
GE 25 SM ED A 3 C
M 33x2.0
310
GE 25 SR A 3 C
G1A
340
GE 25 SR ED A 3 C
G1A
310
GE 30 SM A 3 C
M 42x2.0
540
GE 30 SM ED A 3 C
M 42x2.0
450
GE 30 SR A 3 C
G 1 1/4 A
540
GE 30 SR ED A 3 C
G 1 1/4 A
450
GE 38 SM A 3 C
M 48x2.0
700
GE 38 SM ED A 3 C
M 48x2.0
540
GE 38 SR A 3 C
G 1 1/2 A
700
GE 28 SR ED A 3 C
M 1 1/2 A
540
Tab. 1
Tightening torques of screw-in studs
GE = Straight screw-in connection (with metric thread M or pipe thread G)
2 2.1
of swivelling connections (Ermeto) mating material: steel (Grease well before inserting!) Tightening torques
Tightening torques
Type
Type Thread
Nm
Thread
Light-duty series
Nm
Light-duty series
WH / TH 06 LR KDS A 3 C
G 1/8 A
18
WH / TH 06 LM KDS A 3 C
M 10 X 1
18
WH / TH 08 LR KDS A 3 C
G 1/4 A
45
WH / TH 08 LM KDS A 3 C
M 12 X 1.5
45
WH / TH 10 LR KDS A 3 C
G 3/8 A
45
WH / TH 10 LM KDS A 3 C
M 14 X 1.5
55
WH / TH 12 LR KDS A 3 C
G 1/2 A
70
WH / TH 12 LM KDS A 3 C
M 16 X 1.5
80
WH / TH 15 LR KDS A 3 C
G 3/4 A
120
WH / TH 15 LM KDS A 3 C
M 18 X 1.5
100
WH / TH 18 LR KDS A 3 C
G1A
120
WH / TH 18 LM KDS A 3 C
M 22 X 1.5
140
WH / TH 22 LR KDS A 3 C
G 1 1/4 A
230
WH / TH 22 LM KDS A 3 C
M 27 X 2.0
320
WH / TH 28 LR KDS A 3 C
G 1 1/4 A
320
WH / TH 28 LM KDS A 3 C
M 33 X 2.0
360
WH / TH 35 LR KDS A 3 C
G 1 1/4 A
540
WH / TH 35 LM KDS A 3 C
M 42 X 2.0
540
WH / TH 42 LR KDS A 3 C
G 1 1/2 A
700
WH / TH 42 LM KDS A 3 C
M 48 X 2.0
700
Heavy-duty series
Heavy-duty series
WH / TH 06 SR KDS A 3 C
G 1/4 A
45
WH / TH 06 SM KDS A 3 C
M 12 X 1.5
45
WH / TH 08 SR KDS A 3 C
G 1/4 A
45
WH / TH 08 SM KDS A 3 C
M 14 X 1.5
55
WH / TH 10 SR KDS A 3 C
G 3/8 A
70
WH / TH 10 SM KDS A 3 C
M 16 X 1.5
80
WH / TH 12 SR KDS A 3 C
G 3/8 A
70
WH / TH 12 SM KDS A 3 C
M 18 X 1.5
100
WH / TH 16 SR KDS A 3 C
G 1/2 A
120
WH / TH 14 SM KDS A 3 C
M 20 X 1.5
125
WH / TH 20 SR KDS A 3 C
G 3/4 A
230
WH / TH 16 SM KDS A 3 C
M 22 X 1.5
135
WH / TH 25 SR KDS A 3 C
G1A
320
WH / TH 20 SM KDS A 3 C
M 27 X 2.0
320
1.21.2 copyright by
MJFCIFSS
Service Manual
Tightening torques of screw-in studs (Ermeto) Tightening torques
Tightening torques
Type
Type Thread
Nm
Thread
Nm
WH / TH 30 SR KDS A 3 C
G 1 1/4 A
540
WH / TH 25 SM KDS A 3 C
M 33 X 2.0
360
WH / TH 38 SR KDS A 3 C
G 1/4 A
700
WH / TH 30 SM KDS A 3 C
M 42 X 2.0
540
WH / TH 38 SM KDS A 3 C
M 48 X 2.0
700
Tab. 2
3 3.1
Tightening torques of swivelling connections
of screw-in studs (Ermeto) mating material: steel (Grease well before inserting!)
Type VSTI
Screw-in thread M
Tightening torques Nm
Type VSTI
Screw-in thread G
Tightening torques Nm
VSTI 10X1 ED A3C
M 10 X 1
12
VSTI 1/8 ED A3C
G 1/8 A
13
VSTI 12X1.5 ED A3C
M 12 X 1.5
25
VSTI 1/4 ED A3C
G 1/4 A
30
VSTI 14X1.5 ED A3C
M 14 X 1.5
35
VSTI 3/8 ED A3C
G 3/8 A
60
VSTI 16X1.5 ED A3C
M 16 X 1.5
55
VSTI 1/2 ED A3C
G 1/2 A
80
VSTI 18X1.5 ED A3C
M 18 X 1.5
65
VSTI 3/4 ED A3C
G 3/4 A
140
VSTI 20X1.5 ED A3C
M 20 X 1.5
80
VSTI 1 ED A3C
G1A
200
VSTI 22X1.5 ED A3C
M 22 X 1.5
90
VSTI 1 1/4 ED A3C
G 1 1/4 A
450
VSTI 26X1.5 ED A3C
M 26 X 1.5
120
VSTI 1 1/2 ED A3C
G 1 1/2 A
450
VSTI 27X2 ED A3C
M 27 X 2.0
135
VSTI 33X2 ED A3C
M 33 X 2.0
225
VSTI 42X2 ED A3C
M 42 X 2.0
360
VSTI 48X2 ED A3C
M 48 X 2.0
360
Tab. 3
Tightening torques of screw-in studs
VSTI = Hexagon socket plug
1.21.3 copyright by
MJFCIFSS
Tightening torques
Service Manual
of screw-in studs (Ermeto)
1.21.4 copyright by
MJFCIFSS
Standard
Product code Version
10334184 000 WN 4121 C
Installations for pistons and piston nuts by hydraulic cylinders 1. Application and purpose This Liebherr standard applies only to hydraulic cylinders, and in particular to the mounting of pistons and piston nuts on piston rods from a thread diameter of M42 and greater. This standard describes the tightening procedure with turning distance and angle. For threads with diameters smaller than M42, the applicable tightening torque is indicated in the drawings. The values in the drawings are always binding.
2. Requirements / description of procedure For the valid torque value number, refer to the drawing. The standard may not be adopted or transferred to apparently similar geometries. Use this number to find the applicable turning distance and angle in the torque table (see item 4). The torque values have been determined empirically and are subject to changes. This standard differentiates between two tightening procedures, which are identified with 3-digit and 4-digit numbers respectively (see chapters 2.1 and 2.2).
1.22.1 1/7
Product code
Standard
Version
10334184 000
2.1. Tightening with assembly wrench This tightening procedure applies to 3-digit tightening numbers. Preparation: Clean the contact surfaces (threads contact faces between piston rod, piston and piston nut) and apply a thin layer of Gleitmo high-performance lubricating grease (ID no. 8300 004, 40 g tube) to both sides.
Definitions: Pretightening torque (Mv): The piston (A) is secured with a torque wrench (B) applied to the square/hexagon head of the assembly wrench (C). The position of the torque wrench must be carefully noted (see figure 1). Turning distance (4): Radian measure [mm] travelled as a result of the tightening of the piston, or piston nut along the outer thread diameter, after application of the pretightening torque (see figure 2). Turning angle (5): Angle ° travelled by the piston or piston nut respectively, after application of the pretightening torque (see figure 2).
A Mv
B
C
Figure 1 When applying the pretightening torque (Mv), the torque wrench (B) must point in the same direction as the assembly wrench (C). Proceed in the same way to tighten the piston nut, using a suitable assembly wrench.
.
1.22.2
10334184 000
Product code
Standard
Version
5 4 1
2
3
5 4 6
2
7
Figure 2 1: Markings on the piston and the piston rod thread after application of the pretightening torque 2: Markings on the piston rod thread 3: Markings on the piston after tightening 4: Turning distance 5: Turning angle 6: Markings on the piston nut and the piston rod thread after application of the pretightening torque 7: Markings on the piston nut after tightening
.
1.22.3
Product code
Standard
Version
10334184 000
2.2. Tightening with hydraulic assembly device This tightening procedure applies to 4-digit tightening numbers. Preparation: Clean the contact surfaces (threads contact faces between piston rod, piston and piston nut) and apply a thin layer of Gleitmo high-performance lubricating grease (ID no. 8300 004, 40 g tube) to both sides.
Definitions: Pretightening torque: Torque applied on the piston or piston nut with the torque wrench (A) via the hexagon head (B) of the torque converter (C) (see figure 1). Turning angle: Angle ° travelled by the piston or piston nut respectively, after application of the pretightening torque (see figure 3).
C
A
B
Figure 1 A: Torque wrench B: Hexagon head C : Torque converter
.
1.22.4
Product code
Standard
Version
10334184 000
Operation of the assembly device: See separate operating manual of the assembly device (H). For suitable adapters for the piston rod, piston and piston nut, refer to the piston parts list (see figure 2).
A D F
H B C E
G
Figure 2 A: Piston rod B: Piston C : Adapter for piston D: Adapter for piston rod E: Piston nut F: Adapter for piston nut G: Torque converter H: Assembly device
.
1.22.5
Standard
Product code Version
10334184 000
C
A
B
Figure 3 A: Dial B: Adjusting screw C : Angle scale Before tightening, set the dial (A) with the adjusting screw (B) to position 0° on the angle scale (C). The angle scale indicates the turning angle. If the opening angle of the assembly device is not sufficient to achieve the prescribed turning angle, mount the device again for a second tightening process. Note the previously completed angle. Before continuing the tightening process, set the dial to the last achieved angle value. Repeat this process as often as necessary to achieve the prescribed turning angle.
.
1.22.6
Standard
Product code Version
10334184 000
3. Modifications 4. Other applicable documents Torque table Drawing with reference to this Liebherr Standard and the torque number.
.
1.22.7
1.22.8
1.22.9
Bezeichnung Description / DĂŠnomination
Mjfcifss!
Assembly instruction for piston rod bearings with external threads (hydraulic cylinders)
1
Blatt/Page/Feuille: bestehend aus consisting of composĂŠ
4
Blatt Pages Feuille
WN 4122 B
Contents 1.
Scope of application
2.
Description
3.
Referenced documents (torque table)
1.
Scope of application This factory standard applies exclusively to the assembly of hydraulic cylinders. For the valid factory standard number, refer to the drawing. The standard may not be adopted or transferred to apparently similar geometries. The torques have been determined empirically and are subject to changes. The revision and release dates indicate the latest version of the factory standard.
1.24.1
2.
Description
Preparation: Clean the threads and apply a thin layer of Gleitmo high-performance lubricating grease (ID no. 8300 004, 40 g tube) on both sides.
Definitions: Pretightening torque: The piston rod bearing is secured with a torque wrench applied to the square of the assembly wrench. The position of the torque wrench must be carefully noted (see figure 1).
Figure 1 A B C
Bearing head Assembly wrench Torque wrench
When applying the pretightening torque, the torque wrench must point in the same direction as the assembly wrench.
1.24.2
Turning distance: Radian measure [mm] between the bearing head outer diameter and the cylinder tube, travelled after application of the pretightening torque (see figure 2).
Turning angle: Angle ° travelled by the bearing head after application of the pretightening torque (see figure 2).
Figure 2 A B C D E F G
Marks on the cylinder tube and the auter diameter of the bearing head after application of the pretightening torque Mark on the cylinder tube Turning angle Turning distance Mark on the bearing head after tightening Cylinder Tube Bearing head
After the bearing head and the cylinder tube have been tightened, apply a notch mark at the rod side oil connection level, using a flat chisel.
1.24.3
3.
List of tightening torques for factory standard 4122 (Assembly instructions for piston and piston nut)
The date indicates the latest version of this table. This document is not covered by the revision service.
NU 4122... 001 011 016 017 026 027 031 036 037 039 041 046 047 051 052 053 061 151
Preload Torque Mv [Nm]
Edition: 14.09.2007
Piston rod bearing Turning distance Turning angle [mm] ~ [°]
50 100 100 100 100 100 100 100
7 +1 10 +1 10 +1 9 +1 10 +1 8 +1 8 +1 10 +1
10 12 12 10 11 8 9 9
150 200
9 +1 12 +1
7 10
200 200 400
25 +1 10 +1 14 +1
18 7 6
1.24.4
Standard
Product code Version
10409554 000
Tightening torques for piston rod bearing screws with LH 320HV washers 1. Application and purpose This Liebherr Standard applies exclusively to the mounting screws of the piston rod bearing of hydraulic cylinders.
2. Other applicable documents Drawing with reference to this Liebherr Standard. RIBE-Blauheft no. 30, 4. edition 2003.
3. Screw coating Black screw see table chapter 4.1 DACROMET screw (silver-colour zinc flake coating)
see table chapter 4.2
1.25.1
Product code
Standard
Version
10409554 000
4. Table of tightening torques 4.1. Black screw + LH washer The tightening torques apply to grease-free black screws used in conjunction with LH 320HV washers (FLZN anti-corrosion protection according to Liebherr Standard 10021432). Tightening torques MA determined according to RIBE-Blauheft. Friction coefficients: For thread friction torque MG: µG = 0.14 Head friction torque MK: µK = 0.11
Thread Wrench size
M10 WS 16 M12 WS 18 M14 WS 21 M16 WS 24 M18 WS 27 M20 WS 30 M22 WS 34 M24 WS 36 M27 WS 41
MG
MK
MA
Nm
Nm
Nm
8.8
28
21
50
10.9
41
30
70
12.9
48
35
85
8.8
49
35
85
10.9
71
51
120
12.9
84
60
145
8.8
78
56
135
10.9
114
82
195
12.9
133
96
230
8.8
119
87
205
10.9
175
128
305
12.9
204
150
355
8.8
166
121
285
10.9
243
177
420
12.9
285
207
490
8.8
232
172
405
10.9
341
252
595
12.9
399
295
695
8.8
314
237
550
10.9
462
348
810
12.9
540
408
950
8.8
401
293
695
10.9
590
430
1020
12.9
690
504
1195
8.8
583
438
1020
10.9
857
644
1500
12.9
1003
753
1755
Strength class
LH washer 320HV ID no. dxDxh 99 18 225
10.5x18.0x3.0
99 18 226
12.5x21.0x3.5
95 86 491
14.5x25.0x3.5
99 18 228
16.5x28.0x4.0
95 86 492
18.5x31.0x5.0
99 18 229
20.5x34.0x5.0
92 82 976
22.5x38.0x5.0
99 18 230
24.5x40.0x5.0
95 86 495
27.5x45.0x6.0
1.25.2
Product code
Standard M30 WS 46 M33 WS 50 M36 WS 55 M39 WS 60 M42 WS 65 M42x3 WS 65
Version
8.8
794
594
1390
10.9
1166
872
2040
12.9
1364
1021
2385
8.8
1073
805
1880
10.9
1576
1182
2760
12.9
1844
1383
3225
8.8
1383
1031
2415
10.9
2031
1515
3545
12.9
2377
1773
4150
8.8
1779
1343
3120
10.9
2613
1973
4585
12.9
3058
2309
5365
8.8
2208
1654
3860
10.9
3243
2429
5670
12.9
3795
2842
6635
8.8
2315
1809
4125
10.9
3401
2657
6060
12.9
3979
3109
7090
10409554 000
99 18 231
31.0x52.0x6.0
95 86 496
34.0x56.0x7.0
99 18 232
37.0x60.0x7.0
96 02 352
40.0x66.0x8.0
96 02 353
43.0x72.0x10.0
96 02 353
43.0x72.0x10.0
1.25.3
Product code
Standard
Version
10409554 000
4.2. DACROMET screw + LH washer The tightening torques apply to grease-free DACROMET screws used in conjunction with LH 320HV washers (FLZN anti-corrosion protection according to Liebherr Standard 10021432). Tightening torques MA according to Liebherr Standard10409969 (WN 4037). (see internal memo from H. Wimbauer of the 19.10.01)
M10 WS 16 M12 WS 18 M14 WS 21 M16 WS 24 M18 WS 27 M20 WS 30 M22 WS 34 M24 WS 36 M27 WS 41 M30 WS 46
8.8
46
10.9
68
12.9
79
8.8
79
10.9
117
12.9
135
8.8
125
10.9
185
12.9
215
8.8
195
10.9
280
12.9
330
8.8
280
10.9
390
12.9
460
8.8
390
10.9
560
12.9
650
8.8
530
10.9
750
12.9
880
8.8
670
10.9
960
12.9
1120
8.8
1000
10.9
1400
12.9
1650
8.8
1350
10.9
1900
99 18 225
10.5x18.0x3.0
99 18 226
12.5x21.0x3.5
95 86 491
14.5x25.0x3.5
99 18 228
16.5x28.0x4.0
95 86 492
18.5x31.0x5.0
99 18 229
20.5x34.0x5.0
92 82 976
22.5x38.0x5.0
99 18 230
24.5x40.0x5.0
95 86 495
27.5x45.0x6.0
99 18 231
31.0x52.0x6.0
1.25.4
Product code
Standard M30 WS 46
M33 WS 50
M36 WS 55
M39 WS 60
Version
8.8
1350
10.9
1900
12.9
2250
8.8
1850
10.9
2600
12.9
3000
8.8
2350
10.9
3300
12.9
3900
8.8
3000
10.9
4300
12.9
5100
10409554 000
99 18 231
31.0x52.0x6.0
95 86 496
34.0x56.0x7.0
99 18 232
37.0x60.0x7.0
96 02 352
40.0x66.0x8.0
5. Revision log
1.25.5
Standard
Product code Version
10650522 000
Angle-controlled screw tightenning method 1. Application and purpose This Liebherr Standard has been devised to provide the production department at LHB with details of screw parameters for the angle-controlled tightening of screw connections. This standard is only valid for screw connections that are specially marked in the drawing at LHB and to which one of the screwdriving conditions listed in the "Table of tightening torques" applies (see also section 2). The standard also contains information on two possible tightening methods.
2. Other applicable documents
Table of tightening torques Drawing with reference to this Liebherr Standard and the screwdriving condition number
3. Requirements / description of procedure With the torque-controlled tightening method, the prestressing force is applied exclusively by means of a specific torque. With the angle-controlled tightening method, the prestressing force is applied through a combination of torque and tightening angle. The screw connection is thereby tightened in 2 steps: 1st step:
Pre-torque MAF [Nm]
In a first step, the screw is tightened with a preset torque, similar to the torque-controlled tightening method. This torque is known as the pre-torque MAF and is considerably lower than the torque applied with the torque-controlled tightening method (approx. 15% to 30% of the tightening torque according to LH standard 10409969). By pre-tightening with the pre-torque in this first step, the screw connection is properly defined and any dirt particles, burrs and other protrusions in the joints are eliminated. 2nd step:
Additional angle of rotation
[°]
In the second step, the remaining prestressing force is applied by means of the additional angle of rotation . The additional angle of rotation results in an elongation of the screw and thus the desired prestress, depending on the pitch of the thread. Advantages of the angle-controlled tightening method:
With this method, the greater part of the prestressing force is applied to the screw connection through the angle of rotation, and friction factors (head contact friction and thread friction) play only a minor role. In contrast with the torque-controlled tightening method, this results in a significantly reduced dispersion of the prestressing forces. The angle-controlled tightening method is an overelastic tightening method. This means that, during tightening, the screw is stressed just beyond its breaking point. This results in significantly higher screw utilization and higher prestressing forces than are achievable with the torque-controlled tightening method.
1.30.1
Product code
Standard
Version
10650522 000
Screws that have been tightened once with an angle-controlled method must not be used again!
4.
Identification in drawing
The tightening values for the angle-controlled tightening method (pre-torque MAF and additional angle of rotation ) depend on the geometry of the individual screw (thread diameter, pitch, grip length, thread, length, etc.) It is thus not possible to provide generally applicable values. In this standard, the respective screw connection geometries are assigned a screwdriving condition number. For the valid screwdriving condition number, you must refer to the drawing. The respective values may not be adopted for or transferred to apparently similar geometries! For the applicable screw parameters, refer to the respective screwdriving condition number in the "Table of tightening torques" (see section 2). Identification in the drawing:
MOUNTING INSTRUCTION ACCORDING TO LH STANDARD 1065 0522 - 0000 Screwdriving condition number
5.
Tightening method
There are various ways in which a screw connection can be tightened according to the angle-controlled tightening method. In the sections below, tightening by hand with a torque wrench and tightening with a torque-controlled electric or hydraulic wrench are described. The preferred method is tightening with a controlled electric of hydraulic wrench.
5.1.
Preparation
All contact surfaces, and in particular the contact surfaces of the screw head and the nut must be cleaned. Ensure that the contact surfaces are free of tinder, burrs and weld splashes. If necessary, remove weld splashes with a scraper. Remove excess grease along the thread length. This applies in particular to flat-bottom holes. All surfaces of components that are to be placed against each other with the screw connection must be cleaned and degreased.
1.30.2
Product code
Standard 5.2.
Version
10650522 000
Tightening with torque wrench
1. Using a torque wrench, apply the pre-torque MAF as specified in the "Table of tightening torques" for the respective screwdriving condition. 2. Apply a mark on the screw head that is aligned with a mark applied on the component (see figure 4). 3. Apply a third mark on the component, which indicates the additional angle of rotation the "Table of tightening torques" for the screwdriving condition marked in the drawing.
specified in
4. Using a suitable wrench (torque or standard wrench), turn the screw so that mark 1 and mark 3 are aligned (see figure 5). Figure 4
Marks on screw and component after application of pre-torque
Figure 5
Marks on screw and component turning by additional angle of rotation
Direction of rotation
5.3. Tightening with electric or hydraulic wrench 1. In the control program of the electric or hydraulic wrench, enter the values for pre-torque MAF, additional angle of rotation and the tolerance window for the additional angle of rotation and the final tightening torque. The values are indicated for each screwdriving condition in the "Table of tightening torques". 2. Turn the screws by hand or with a pneumatic wrench. When using a pneumatic wrench, ensure that the skews are only turned, i.e. that the torque of the pneumatic wrench is smaller than the pretorque! 3. Place the electric or hydraulic wrench on the screw head. Ensure that the reaction arm is suitably positioned. 4. Start the 2-step tightening procedure. 5. Check the achieved result (screw connection OK or NOK), indicated at the wrench tool. 6. Record the values of the achieved tightening torque and the additional angle of rotation. 7. After tightening of all screw connections, test a number of screws using the tightening torque according to LH standard 10409969. The number of screws to be tested depends on the total number of screw connections and is normally between 1 and 3 (see also section 6).
6.
Checking during routine maintenance 1.30.3
Standard
Product code Version
10650522 000
Screw connections must normally be checked by service personnel at predefined intervals for proper fixture. For screw connections established with the angle-controlled tightening method, observe the following: The connections can only be checked as regards the correct tightening torque. To do this, use a torque wrench and apply the tightening torque specified in LH standard 10409969 to the screw connection.
7. Revision log First issue
1.30.4
MJFCIFSS
2. Torque table for LH standard 10650522
Status: 31.01.2011
(Turning angle controlled tightening procedure)
Tightening case No.
0001 0002 0003 0004 0005 0006 0007 0008 0009 0010 0011 0012 0013 0014 0015 0016 0017 0018 0019 0020 0021 0022 0023 0024 0025 0026 0027 0028 0029 0030 0031 0032 0033 0034 0035 0036
Property Class
10.9 10.9 10.9 10.9 10.9 10.9 10.9 10.9 10.9 10.9 10.9 10.9 10.9 10.9 10.9 10.9 10.9 10.9 10.9 10.9 10.9 10.9 10.9 10.9 12.9 10.9 10.9 12.9 12.9 10.9 10.9 12.9 10.9 10.9 10.9 12.9
Thread
Pitch
Nominal Length
Threaded Length
Claming Length
d [mm] M16 M16 M20 M20 M20 M20 M20 M20 M20 M24 M24 M27 M27 M27 M27 M36 M30 M30 M30 M36 M42 M24 M24 M30 M56 M30 M30 M30 M30 M20 M20 M20 M16 M16 M16 M16
p [mm] 2 2 2,5 2,5 2,5 2,5 2,5 2,5 2,5 3 3 3 3 3 3 4 3,5 3,5 3,5 4 4,5 3 3 3,5 5,5 3,5 3,5 3,5 3,5 2,5 2,5 2,5 2 2 2 2
L [mm] 55 80 70 80 70 90 90 70 105 100 125 110 150 140 150 265 190 200 190 200 300 96,5 96,5 119,4 220 150 150 150 150 50 60 110 50 45 70 110
Lg [mm] 49 38 66 46 66 46 46 66 46 56 56 66 66 66 66 100 72 72 72 84 109 96,5 96,5 119,4 137 72 72 72 72 46 55 55 45 40 65 105
Lk [mm] 34 52 47 53 45 53 63 44 77 65 97 77 116 95 134 208 141,5 136,5 134 157 265 50,2 53,2 57,6 125 106 101 112 101 24 29 87 19 18 39 43,5
The date indicates the latest status of the table. This document is not subject to revision!
Head Bearing Surface dw [mm] 24 24 30 30 30 30 30 30 30 36 36 41 41 41 41 55 46 46 46 55 65 36 36 46 85 46 46 46 46 30 30 30 24 24 24 24
Clearance Component Hole Size dh [mm] 17 17,5 21 22 21 22 22 21 22 26 26 29 30 29 30 37,5 32 32 33 38 45 26 26 33 62 33 32 33 32 21 22 21 17,5 17,5 17,5 17,5
DA [mm] 45 36 45 40 45 40 40 45 60 63 70 65 70 50 65 70 105 125 75 80 110 36 36 46 110 66 55 66 55 50 46 150 90 60 130 116
Seating Torque MAF [Nm] 113 113 191 192 191 192 192 191 192 332 332 484 487 484 487 1142 659 659 663 1145 1842 332 332 663 5186 663 659 775 771 191 192 223 113 113 113 133
Further Turning Angle [°] 50 +5 46 +5 61 +5 49 +5 58 +5 42 +5 54 +5 57 +5 54 +5 45 +5 59 +5 59 +5 72 +5 65 +5 91 +5 94 +5 62 +5 52 +5 60 +5 74 +5 104 +5 68 +5 72 +5 68 +5 67 +5 60 +5 60 +5 77 +5 71 +5 33 +5 39 +5 77 +5 30 +5 29 +5 56 +5 75 +5
Torque Range (Quality Control for Assembly) Min. Max. [Nm] [Nm] 226 416 227 418 441 810 445 818 441 810 445 818 445 818 441 810 445 818 766 1409 766 1409 1113 2071 1120 2086 1113 2071 1120 2086 2627 4887 1517 2811 1517 2811 1526 2829 2633 4900 4230 7901 766 1409 766 1409 1526 2829 11878 22360 1526 2829 1517 2811 1786 3310 1776 3289 441 810 445 818 516 948 227 418 227 418 227 418 266 489
Page 1 of 2
MJFCIFSS
2. Torque table for LH standard 10650522
Status: 31.01.2011
(Turning angle controlled tightening procedure)
Tightening case No.
0037 0038 0039 0040 0041 0042 0043 0044 0045 0046 0047 0048 0049 0050 0051 0052 0053 0054 0055 0056 0057 0058 0059 0060 0061 0062 0063 0064 0065 0066 0067 0068 0069 0070 0071 0072
Property Class
10.9 10.9 10.9 12.9 12.9 10.9 10.9 12.9 12.9 10.9 10.9 10.9 12.9 10.9 10.9 10.9 10.9 10.9 12.9 12.9 12.9 12.9 12.9 10.9 10.9
Thread
Pitch
Nominal Length
Threaded Length
Claming Length
d [mm] M30 M30 M42 M24 M24 M30 M30 M20 M20 M30 M30 M30 M12 M56 M20 M30 M30 M30 M16 M20 M20 M20 M16 M30 M30
p [mm] 3,5 3,5 4,5 3 3 3,5 3,5 2,5 2,5 3,5 3,5 3,5 1,75 5,5 2,5 3,5 3,5 3,5 2 2,5 2,5 2,5 2 3,5 3,5
L [mm] 100 200 320 130 100 230 200 90 100 250 200 180 65 420 120 95,8 140 110 70 90 110 80 120 160 140
Lg [mm] 95 72 109 60 54 85 72 85 95 66 72 72 36 137 46 95,8 135 105 48 58 58 58 115 135 105
Lk [mm] 68,2 156 250 91 65 178 156 54,9 66,3 198 145 133 47 324 101 52,8 107 53,5 42,4 69,8 82,8 41,4 83 114,5 58,5
The date indicates the latest status of the table. This document is not subject to revision!
Head Bearing Surface dw [mm] 46 46 65 36 36 46 46 29 29 46 46 46 18 85 30 46 46 46 24 30 30 30 24 46 46
Clearance Component Hole Size dh [mm] 33 33 45 26 26 33 33 21 21 32 32 33 13,5 62 22 33 32 32 17,5 21 21 21 17 32 32
DA [mm] 85 66 100 86 44 75 70 57 57 55 125 75 20 244 40 51 100 100 130 40 40 40 34 100 100
Seating Torque MAF [Nm] 663 663 1842 388 388 663 663 221 221 659 659 663 54 4432 192 663 659 659 133 223 223 223 132 659 659
Further Turning Angle [°] 63 +5 75 +5 89 +5 61 +5 58 +5 82 +5 74 +5 82 +5 98 +5 89 +5 59 +5 64 +5 73 +5 86 +5 77 +5 59 +5 93 +5 50 +5 55 +5 83 +5 84 +5 51 +5 148 +5 89 +5 39 +5
Torque Range (Quality Control for Assembly) Min. Max. [Nm] [Nm] 1526 2829 1526 2829 4230 7901 896 1648 896 1648 1526 2829 1526 2829 511 939 511 939 1517 2811 1517 2811 1526 2829 110 198 10150 19108 445 818 1526 2829 1517 2811 1517 2811 266 489 516 948 516 948 516 948 265 486 1517 2811 1517 2811
Page 2 of 2
Service Manual
Fuels, lubricants and process chemicals General information
Fuels, lubricants and process chemicals 1
General information Observe the instructions for lubricants and process chemicals. Lubricate the machine and change the oils at the prescribed intervals. For more information, see lubrication chart and inspection and maintenance schedule. Keep workplaces for these activities clean. This enhances the service life and reliability of the machine. All work on the machine must be carried out while it is standing on firm and level ground. Shut down the diesel engine, remove the ignition key and set the battery main switch to position 0 (OFF). Clean lubricating nipples before adding grease. Clean all filling points and the area around them before opening the caps and screws. The oil should be changed while it is at operating temperature. After each oil change or refilling, check the fill level in the respective unit (the specified fill levels are guide values). Collect used oil and chemicals in suitable containers and dispose of them according to the applicable statutory regulations.
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Fuels, lubricants and process chemicals
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Recommended lubricants
2
3
Recommended lubricants Designation
Recommended lubricant
Diesel engine
Liebherr Motoroil 10W-40 Liebherr Motoroil 10W-40 low ash Liebherr Motoroil 5W-30
Hydraulic system (system capacity / oil change volume / tank capacity)
Liebherr Hydraulic Basic 68 Liebherr Hydraulic Basic 100 Liebherr Hydraulic HVI Liebherr Hydraulic Plus Liebherr Hydraulic Plus Arctic
Slewing gear mechanism
Liebherr Gear Basic 90 LS
Transmission
Liebherr Motoroil 10W-40
Rigid axle
Liebherr Gear Basic 90 LS
Wheel hubs of the rigid axle
Liebherr Gear Basic 90 LS
Steering axle
Liebherr Gear Basic 90 LS
Wheel hubs of the steering axle
Liebherr Gear Basic 90 LS
Tracks and gearing of the slewing ring, bearing of the equipment
Liebherr Universalfett 9900
Hinges, joints, locks
Engine oil
Symbol
-
Recommended fuels and chemicals
Designation
Recommended fuel
Fuel tank
Conventional diesel fuel
Coolant
Liebherr Antifreeze Mix Liebherr Antifreeze Concentrate
Windscreen washer system
Conventional windscreen cleaning agent or denatured alcohol
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Symbol
-
Service Manual
Fuels, lubricants and process chemicals Specifications for fuels, lubricants and process chemicals
4 4.1 4.1.1
Specifications for fuels, lubricants and process chemicals Diesel fuels Specification The diesel fuels must meet the minimum requirements of the fuel specifications outlined below. Approved specifications: DIN EN 590 ASTM D 975 (89a) - 1D and 2D The fuel supplier must submit a fuel certificate (fuel specification, sulphur content, lubricity, cetane number)
4.1.2
Sulphur content, lubricity The following restrictions apply: Do not use fuels with a sulphur content of more than 1 % (10,000 mg/kg). When using engine oils conforming to specification E6 and standard oil change intervals (every 500 operating hours): Do not use fuels with a sulphur content of more than 0.005 % (50 mg/kg). When using exhaust gas purification units (particle filters): Do not use fuels with a sulphur content of more than 0.005 % (50 mg/kg). Diesel engines with external exhaust gas return system: We recommend using fuels with a sulphur content of less than 0.005 % (50 mg/kg). Additional information: see oil change intervals for operation under adverse conditions. According to DIN EN 590, diesel fuels must have a lubricity determined by HFRR test (corrected wear scar diameter [wsd 1.4] at 60 °C) of maximum 460 µm The ASTM D 975 fuel standard does not specify that the fuels must undergo a fuel lubricity test. The required additives should be added by the supplier, who is responsible for the quality of the fuel.
4.1.3
Cetane number ASTM D 975 fuels must have a cetane number of minimum 45. A cetane number of more than 50 is preferable, especially at temperatures below 0 °C (32 °F).
4.1.4
Low temperature operation At low temperatures, paraffin crystals are formed in the diesel fuel. They increase the flow stress in the fuel filter so that the diesel engine might not be supplied with sufficient fuel. Caution! The use of an unsuitable fuel can cause damage to the diesel engine. Adding petroleum, normal car petrol or other substances damages the injection system. Never add petroleum, car petrol or other additives to the diesel fuel. At ambient temperatures of below -20 °C: use start-up aid (e.g. fuel filter heater). For operation of the machine under arctic conditions: use special diesel fuels that offer adequate viscosity.
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Specifications for fuels, lubricants and process chemicals
4.2 4.2.1
Lubricating oil for the diesel engine Quality Modern diesel engines must be lubricated with high-performance oils. They consist of a basic oil with special additives. The lubricating oil requirements for LIEBHERR diesel engines are based on the following standards and regulations: Designation
Specification
ACEA classification (Association des Constructeurs Européens de l'Automobile)
E4, E6, E7 Caution: particle filter only permitted with E6
API classification (American Petroleum Institute)
CH-4, CI-4 Caution: observe shorter oil change intervals
Tab. 1
Lubricating oil specifications
If LIEBHERR oils are not available locally, use an oil that conforms to the specifications (before choosing an oil, contact our customer service department).
4.2.2
Viscosity The choice of the lubricating oil viscosity is based on the SAE classification (Society of Automotive Engineers). The SAE classification does not provide any indication as regards the quality of a lubricating oil. The relevant factor for the correct choice of SAE class is the ambient temperature. Excessively high viscosity might lead to start-up problems. If the viscosity is too low, the oil's lubrication might not be sufficiently efficient. The temperature ranges shown in the diagram are approximate ranges that might temporarily be exceeded.
Fig. 1
Temperature-based selection of the SAE class
For ambient temperatures of -20 °C (-4 °F) to +45 °C (+113 °F), we recommend the following diesel engine oils: Liebherr Motoroil 10W-40, specification ACEA E4 Liebherr Motoroil 10W-40 low ash, specification ACEA E6 For ambient temperatures of -30 °C (-22 °F) to +30 °C (+86 °F), we recommend the following diesel engine oils: Liebherr Motoroil 10W-30, specification ACEA E4
4.2.3
Adverse operating conditions affecting the oil change intervals Oil change intervals: see chapter "Inspection and maintenance schedule".
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Service Manual
Fuels, lubricants and process chemicals Coolant for the diesel engine
Subsequent oil changes depend on the climate, the sulphur content of the fuel and the oil grade. For details, see the table below. If the specified operating hours (h) per year are not reached, the diesel engine oil and the filter must be changed at least once every year. A number of adverse factors (unfavourable operating conditions) affect the length of the maintenance interval. Possible adverse factors: Frequent cold starts Sulphur content of fuel Operating temperature If such factors apply, the oil and filter must be changed according to the table below. Adverse factor
Oil quality CH-4, CI-4
E4 / E7*
Operating conditions
Sulphur content of fuel
Interval
Normal climate, to -10 °C
to 0.5 %
250 h
500 h
between 0.5 % and 1 %
125 h
250 h
below -10 °C
to 0.5 %
125 h
250 h
between 0.5 % and 1 %
not permissible
125 h
Adverse factor
Oil quality E6
Operating conditions
Sulphur content of fuel
Normal climate, to -10 °C
to 0.005 %
500 h
between 0.005 % and 0.05 %
250 h
below -10 °C
Interval
between 0.0501 % and 0.1 %
125 h
to 0.005 %
250 h
between 0.005 % and 0.05 %
125 h
between 0.0501 % and 0.1 %
not permissible
h= operating hours * TBN minimum 13 mg KOH/g
5 5.1
Coolant for the diesel engine General recommendations The radiator system works only properly when pressurised. It is therefore imperative that it is kept clean and sealed at all times, that the radiator sealing and operating valves work properly and that the required coolant level is maintained. Corrosion inhibitors/antifreeze agents approved by LIEBHERR ensure proper protection against frost, corrosion and cavitation without causing damage to seals and hoses and without foaming. Coolants that contain unsuitable corrosion inhibitors or antifreeze agents or that have been prepared incorrectly might cause failure of assemblies and component parts in the coolant circuit due to cavitation or corrosion. Heat-insulating deposits on components that conduct heat might result in overheating and consequently failure of the engine.
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Coolant for the diesel engine
5.2
Water (fresh water) Clear and clean water free of particles that meets the following chemical requirements is suitable for use as a coolant. Do not use sea water, brackish water, brine or industrial wastewater. Designation
Value / unit
Total alkaline earth metals (water hardness)
0.6 to 3.6 mmol/l (3 to 20 °dH)
pH at 20 °C
6.5 to 8.5
Chloride ion concentration
max. 80 mg/l
Sulphate ion concentration
max. 100 mg/l
Tab. 2
Fresh water quality
Designation
Value / unit
Total alkaline earth metals (water hardness)
0.6 to 2.7 mmol/l (3 to 15 °dH)
pH at 20 °C
6.5 to 8.0
Chloride ion concentration
max. 80 mg/l
Sulphate ion concentration
max. 80 mg/l
Tab. 3
Fresh water quality with use of DCA 4*
* = Diesel Coolant Additives
Water analysis results are available from the local authorities.
5.3
Mixing ratio for coolant The coolant must contain min. 50% corrosion inhibitor and antifreeze agent at all times of the year. Mixing ratio Outdoor temperature to Water %
Corrosion inhibitor/antifreeze agent %
-37 °C
50 %
50 %
-50 °C
40 %
60 %
Tab. 4
Permissible mixing ratio (for all seasons)
Fig. 2
Temperature-based mixing ratio of water + corrosion inhibitor / antifreeze agent
A Ambient temperature B Corrosion inhibitor/antifreeze agent concentration in coolant
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Fuels, lubricants and process chemicals Coolant for the diesel engine
5.4
Permissible corrosion inhibitors/antifreeze agent Note! Improper mixing of different products might negatively affect the properties of the coolant and cause damage to the cooling system. Use only approved products. Do not mix different products. Never mix products containing silicone with silicone-free products. If the recommended LIEBHERR product is not available locally: contact the LIEBHERR customer service department; choose a product conforming to the "Coolant specifications for LIEBHERR diesel engines". Concentrate Product name
Manufacturer
Liebherr Antifreeze Concentrate
Liebherr
Ready-mixed corrosion inhibitor/antifreeze agent (premix) Product name
Manufacturer
Liebherr Antifreeze Mix
Liebherr
Premix = ready-mixed product (50 % water and 50 % corrosion inhibitor/antifreeze agent)
5.5
Approved corrosion inhibitors without antifreeze agent Note! Improper mixing of different products might negatively affect the properties of the coolant and cause damage to the cooling system. Use only approved products. Do not mix different products. Never mix products containing silicone with silicone-free products. If the recommended LIEBHERR product is not available locally: contact the LIEBHERR customer service department; choose product conforming to the "Coolant specifications for LIEBHERR diesel engines".
In exceptional circumstances and at ambient temperatures that are always above the freezing point, e.g. during use in tropical regions where there are no corrosion inhibitors/antifreeze agents available, the following inhibitors must be added to the coolant: – DCA 4 (Diesel Coolant Additives 4) – Caltex / Chevron / Havoline / Total product In this case, the coolant must be changed annually. As part of routine maintenance work, check the concentration and correct it, if necessary. Product name
Manufacturer
DCA 4 Diesel Coolant Additives
Fleetguard / Cummins Filtration
Caltex CL Corrosion Inhibitor Concentrate
Chevron Texaco
Chevron Heavy Duty Extended Life Corrosion Inhibitor Nitrite Free (ELC)
Chevron Texaco
Havoline Extended Life Corrosion Inhibitor (XLI)
Chevron Texaco
Total WT Supra
Total, Paris
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Service Manual
Hydraulic oil
6
Hydraulic oil Hydraulic oils must meet the requirements outlined below. Maximum water content of hydraulic oil: < 0.1 %
6.1
Hydraulic oil LIEBHERR recommends using the following hydraulic oils in its machines (depending on temperature range):
Fig. 3
Hydraulic oil for use as hydraulic fluid (ISO classes)*
A Ambient temperature B Cold-start range with warm-up C Operating range * temperature-based selection of the ISO class
Liebherr Hydraulic Plus and Liebherr Hydraulic Plus Arctic are suitable for both bio and longterm use. If LIEBHERR oils are not available locally, use one of the engine oils listed in the section below (before choosing an oil, contact the respective customer service department). Use only LIEBHERR hydraulic oils. The use of other oils is not permitted.
6.2
Engine oil used as hydraulic fluid When using engine oil (third-party products) as hydraulic fluids, we advise customers to request a certificate from the oil manufacturer, confirming that the product meets the following specifications. Engine oils that are to be used as hydraulic fluids must conform to the following specifications: Single grade oils (1):
API - CD / ACEA - E1 (MB 226.0 and 227.0)
Multigrade oils (2):
API - CD, CE, CF / ACEA - E2, E3, E4 (MB 227.5, 228.1, 228.3 and 228.5)
Tab. 5
Engine oils for use as hydraulic fluids
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Fuels, lubricants and process chemicals Hydraulic oil
Fig. 4 A
Ambient temperature
1
Single grade oils
B
Cold-start range with warm-up
2
Multigrade oils
C
Operating range
*
6.3
Engine oil for use as hydraulic fluid (SAE classes)*
temperature-based selection of the SAE class; for deviating viscosity grade, consult LIEBHERR customer service.
Warm-up instruction The black bar B indicates ambient temperatures that are up to 20 °C below the operating range C. For cold starting at an ambient temperature below range B, the following warm-up instruction for hydraulic oil applies: 1.: Start the diesel engine and run it at approx. 1 / 2 rated speed. Carefully activate the working hydraulics. Operate the hydraulic cylinders and move them to the stop. After approx. 5 minutes, start the travel hydraulics. Warm-up time: approx. 10 minutes. For cold starting at even lower ambient temperatures, follow the warm-up instruction below: 2.: Before starting the engine, warm up the hydraulic oil tank. Then proceed according to the warm-up instruction in 1.
6.4
Biodegradable hydraulic oils Caution! Do not mix bio hydraulic oils with mineral oils! When mixing ester-based biodegradable hydraulic oils with mineral oils, aggressive chemical reactions might occur, causing damage to the hydraulic equipment. Therefore never mix biodegradable hydraulic fluids from different producers, and never mix bio hydraulic oils with mineral oils! LIEBHERR recommends using the following hydraulic oils in its machines (depending on the temperature range): Liebherr Hydraulic Plus or Liebherr Hydraulic Plus Arctic These products are polyalphaolefins (HEPR) conforming to CEC-L-33-A-93, and are biodegradable.
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Hydraulic oil When using these hydraulic oils, bypass filtration might be omitted. If these oils are not available locally, use a fully saturated hydraulic environmental ester synthetic (HEES fluid) (before choosing an oil, contact the respective customer service department). When using synthetic ester-based fluids, bypass filtration is mandatory. When using such fluids, we recommend replacing the hydraulic hoses every 4000 operating hours or latest every 4 years. Do not use vegetable oils, as they do not possess the necessary thermal stability. The use of polyglycols is not permissible, as they cause damage to paintwork. When using third-party products, we advise customers to request a certificate from the oil manufacturer, confirming that the product meets the above specifications.
6.5
Monitoring, filter change and oil change Symbol
Description Filter change for hydraulic oil
Oil sampling
Tab. 6
Key to diagrams
Hydraulic oil in normal use:
Fig. 5
Oil sampling and filter change in normal use
h
Operating hours
1
First oil sample
a
Mineral oil
2
Second oil sample
b
Biodegradable hydraulic oil
3
Subsequent oil samples: every 500 operating hours
Interval for the change of the hydraulic oil return filter (20 / 5 Âľm): first change after 500 and 1000 operating hours, then every 1000 operating hours and after each hydraulic oil change. Interval for mineral oil change: every 2000 operating hours, or when indicated by the lab report or analyses. Oil change intervals for mineral oils may only be extended, if an oil analysis has been carried out. The first analysis must be performed after 1500 operating hours, subsequent analyses must be carried out every 500 operating hours. The oil change intervals for bio oils are determined solely by oil analyses and lab reports.
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Fuels, lubricants and process chemicals Hydraulic oil
For bio oils, a first analysis must be carried out after a change of oil type* and subsequently every 500 operating hours. *
Change of oil type = change from mineral oil to biodegradable hydraulic oil
Hydraulic fluid used in dust intensive applications:
Fig. 6
Oil sampling and filter change intervals for machines used for dust-intensive applications
h
Operating hours
1
First oil sample
a
Mineral oil
2
Second oil sample
b
Biodegradable hydraulic oil
3
Subsequent oil samples: every 250 operating hours
Interval for the change of the hydraulic oil return filter (10 µm): first change after 500 operating hours, then every 500 operating hours and after each hydraulic oil change. Interval for mineral oil change: every 500 operating hours, or when indicated by the lab report or analyses. The oil change intervals for bio oils are determined solely by oil analyses and lab reports. For bio oils, a first analysis must be carried out after a change of oil type* and subsequently at least every 500 operating hours. *
6.6
Change of oil type = change from mineral oil to biodegradable hydraulic oil
Recommendations for oil analyses For oil analyses, LIEBHERR recommends contracting WEAR-CHECK* and changing the oil when indicated by the test results in the lab report. For more information, see customer service and product information. *
6.7
Yellow kit for biodegradable hydraulic oils Green kit for mineral oils
Tips for the reduction of contamination of the hydraulic oil in machines used for dust-intensive applications If the machine is frequently operated with a hydraulic hammer or under similar conditions (high dust production), the hydraulic oil might become more heavily contaminated than under normal working conditions. To prevent premature wear of the hydraulic components, shorten the oil change intervals (or oil sampling intervals respectively) and observe the following instructions: The filter cartridge(s) in the return filter must be replaced every 500 operating hours and after every hydraulic oil change. Use 10-µm filter cartridges instead of the standard 20 / 5-µm cartridges.
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Lubricants for axles and gearboxes The 2-µm breather filter must be replaced every 500 operating hours and after every hydraulic oil change. Note! Machines delivered with hydraulic hammer attachment and retrofitted hydraulic hammer kits are already fitted with 10-µm filter cartridges in the return filter.
7 7.1
Lubricants for axles and gearboxes Quality Recommended lubricant
Specification
Liebherr Gear Basic 90 LS
API: GL-5 MIL-L: 2105 B
Liebherr Gear Plus 20W-40
API: from GL4 ZF: TE-ML 05F, 06K, 17E
Liebherr Gear Hypoid 90 EP
API: GL5 MIL-L: 2105 B, C, D
Liebherr Hypoid 85W-140 EP
API: GL-5 MIL-L: 2105 D, PRF-2105 E
Liebherr Hydraulic-Gear ATF
GM: Dexron II D ZF: TE-ML 03D, 04D, 11A, 14A, 17C
Liebherr Syntogear Plus 75W-90
API: GL-4, GL-5, MT-1 MIL-L: 2105 D, PRF-2105 E
Tab. 7
Lubricating oil specifications
If LIEBHERR oils are not available locally, use an oil that conforms to the specifications (before choosing an oil, contact our customer service department).
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Service Manual
Fuels, lubricants and process chemicals Lubricating oil for transmission
7.2
Viscosity
Fig. 7
Temperature-based selection of the SAE class
A
Ambient temperature
1
Use in gearboxes
2
Use in automatic transmissions
3
Use in axles
4
Use in pump distributor gear systems
*
If the pump distributor gear is equipped with an oil cooler, the oil is not suitable for the marked temperature range (shaded area).
The choice of the lubricating oil viscosity is based on the SAE classification (Society of Automotive Engineers). The SAE classification does not provide any indication as regards the quality of a lubricating oil. The relevant factor for the correct choice of SAE class is the ambient temperature. Incorrect viscosity can impair the operation of axles and gearboxes. The temperature ranges shown in the diagram are approximate ranges that might temporarily be exceeded.
8
Lubricating oil for transmission Recommended lubricant
Specification
Liebherr Motoroil 10W-40
API: CF
If LIEBHERR oils are not available locally, use an oil that conforms to the specifications (before choosing an oil, contact our customer service department).
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Grease
9 9.1
Grease Quality Recommended lubricant
Specification
Liebherr Universalfett 9900
Soap-base grease (lithium complex) KPF 2 N - 25 (DIN 51502) NLGI grade: 2 (DIN 51818) VKA welding force: > 6000 N (DIN 51350 / 4)
Liebherr Universalfett Arctic (for low-temperature operation)
Soap-base grease (lithium complex) KPFHC 1 N - 60 (DIN 51502) NLGI grade: 1 (DIN 51818) VKA welding force: > 5500 N (DIN 51350 / 4)
The grease is used for both automatic and manual machine lubrication. it is supplied by the central lubrication system or through lubrication nipples to the respective lube points. Examples:
9.2
Slewing ring bearings Crown gears, geared wheels Bolts, axles and screws Attachments
Operating temperature
Fig. 8
10
Operating temperature for Liebherr greases
A
Grease temperature
*
The grease is not suitable for the temperature range (shaded), if used in a central lubrication nipple.
**
The grease may only be within the temperature range (shaded) for short periods of time. Peak temperatures of max. 200 °C (392 °F) are possible.
Lubricants and care products for electrical and mechanical components Medium, purpose
Product (manufacturer)
Contact spray for slip rings
Cramolin
Lubricant for pistons, piston nuts and for the mounting of piston rod bearings at hydraulic cylinders
Gleitmo 800
Special corrosion inhibitor for mounting recesses of sealing elements at hydraulic cylinders
Rostilo Tarp CFX
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Fuels, lubricants and process chemicals Lubricants and care products for electrical and mechanical components
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Fuels, lubricants and process chemicals
Service Manual
Lubricants and care products for electrical and mechanical components
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Service Manual
SUBGROUP - INDEX Section
Group
Type
Special tools - general information
2.01.1
A 934 C-LI 25436A 944 C-LI 24475A 954 C-LI 21416-
Special tools for diesel engines
2.02.1
A 934 C-LI 25436A 944 C-LI 24475A 954 C-LI 21416-
Special tools for hydraulic unit
2.05.1
A 934 C-LI 25436A 944 C-LI 24475A 954 C-LI 21416-
Special tools for electrical equipment
2.06.1
A 934 C-LI 25436A 944 C-LI 24475A 954 C-LI 21416-
Special tools for slewing gear mechanism
2.07.1
A 934 C-LI 25436A 944 C-LI 24475A 954 C-LI 21416-
Special tools for axles (Kessler)
2.09.1
A 934 C-LI 25436A 944 C-LI 24475A 954 C-LI 21416-
Stroke measuring device for control block
2.10.1
A 934 C-LI 25436A 944 C-LI 24475A 954 C-LI 21416-
Assembly tools for hydraulic cylinders
2.12.1
A 934 C-LI 25436A 944 C-LI A 954 C-LI 21416-
Mounting device for piston rod bearings
2.13.1
A 934 C-LI 25436A 944 C-LI 24475A 954 C-LI 21416-
Slotted nut wrench for slewing gear
2.14.1
A 934 C-LI 25436A 944 C-LI 24475A 954 C-LI 21416-
2.1 MJFCIFSS
Service Manual
Mounting device for multi-disc brake
2.15.1
2.2 MJFCIFSS
A 934 C-LI 25436A 944 C-LI 24475A 954 C-LI 21416-
Service Manual
Special tools - general information
Special tools - general information for maintenance and repair Representation
no.
Designation
1 2
Mach.
Size
ID no.
Measuring neck
NW 8 NW 10 NW 12
7019906 7002404 7008688
all types
4
Pressure gauge connection
R 1/2"
7002436
all types
5
Pressure gauge direct connection
R 1/2"
7002435
all types
7
High-pressure hose length
1,000 mm
7002437
all types
1,500 mm
7002475
5,000 mm
7363732
M10X1 M12X1.5 M14X1.5 M16X1.5 R 1/4"
5005180 7402580 5004002 7361345 7362579
8
10 11 12 13 14
Screw coupling assembly, complete
Application
Connection of the pressure gauges to all measuring points (measuring neck no.1/2 and screw couplings 10-14)
all types
2.01.1 copyright by
MJFCIFSS
Special tools - general information
Representation
Service Manual
no.
Designation
15
Pressure gauge
Mach.
Application
all types
8042578
Measuring of operating pressures of one or more hydraulic circuits.
5002865
* glycerine dampened
Size
ID no.
0-1.6 bar
8042577
0-1.6 bar * 0-10 bar * 0-40 bar * 0-60 bar * 0-250 bar *
21
0-400 bar *
7500002
22
0-600 bar *
5002866
16 17 18 19 20
30
Differential pressure measuring kit, consisting of:
7361288 5002867 7361285
10288229
30.1
all types
Measuring of difference p between the pump and the LS pressure.
10288155 1 manual measuring device 3010
30.2
10288152 1 data cable
30.3
10288154 2 Measuring cables
30.4
0-600 bar
2 Pressure sensor 30.5
10288153
10288151 1 power adapter
30.6
7025273
30.7 30.8
Vehicle connecting cable not included in delivery! Pressure sensor Pressure sensor
6140626 01 6140647 01
33
Fitting
4901372
34
Measuring neck with metal cap
7002404
35
Union nut
4774002
36
Cutting ring
4774001
44
Measuring adapter
8504231
2.01.2 copyright by
MJFCIFSS
see sensors on Page 6
all types
Pressure compensation in connection with tool no. 30
all types
Measuring of current at pump regulation
Service Manual
Representation
Special tools - general information
no.
Designation
Mach.
Application
45
Adapter
9956422
all types
Measuring of the inductive pickup B12 from 3-pin (LH) to 2-pin (Deutz), in conjunction with tool no. 44
46
Measuring cables
9956436
all types
Measuring and testing of solenoid valves
60
Piezzo speed counter
A 2106
10286429
all types
Measuring of engine speed via pulse frequency of injection line
Terminal sensor Terminal sensor Terminal sensor
5.0 mm 7.0 mm 8.0 mm
10492920 10492922 10492925
62
Ornel speed meter
HT 460
7006974
all types
Measuring of speed with reflective strips
63
Shimpo speed meter
DT 205
7364284
Size
ID no.
Strips 64
65
614063201
Multimeter with digital display
Chauvin Arnoux
10018500
with no. 63
all types
Measuring of voltage, current and resistance in electric components and valves
2.01.3 copyright by
MJFCIFSS
Special tools - general information
Representation
Service Manual
no.
Designation
70
Thermometer non-contact (infrared)
72
Thermometer with probe and sensor (magnetic)
80
Hand pump
8145666
82
Sampling valve for oil samples, alternative to hand pump 80
7019068
84
Oil analysis kit *
85
Oil analysis kit *
Size
ID no. 10024185
GTH 1150
no. 1
Mach.
Application
all types
Monitoring of temperature of a medium / outside temperature of a unit
all types
Sampling of oil for analysis
all types
6 oil samples
7020372
7018368
8145660
1 oil sample
*Analyses carried out by WAER CHECK Germany, lab report in German
88
Bio oil analysis kit *
89
Bio oil analysis kit *
no. 1
7026817
all types
7026088
1 oil sample
6 oil samples
*Analyses carried out by WAER CHECK Germany, lab report in German 90
REFCO vacuum pump
RD-4
2.01.4 copyright by
MJFCIFSS
7027552
all types
Maintenance and repair of a/c system
Service Manual
Representation
Special tools - general information
no.
Designation
91
Mach.
Application
all types
See item 90
all types
See item 90
7027558
all types
Maintenance and repair of a/c system
M37X1 M42X1.5 M48X1.5
9583459 9583521 9583522
all types
Dismantling of grapple bolts
M42X1.5 M48X1.5 M58X1.5
9584738
all types
Removal of Passfix bolts
Size
ID no.
ITE filling hose, blue
1,500 mm
7027553
92
ITE filling hose, yellow
1,500 mm
7027554
93
ITE filling hose, red
1,500 mm
7027555
94
ITE HGV coupling
253a
7027556
95
ITE HGV coupling
254 a
7027557
96
4-valve test fittings
M4WS5 C
100 101 102
Dismantling tool
105
Universal Passfix puller
2.01.5 copyright by
MJFCIFSS
Special tools - general information
Representation
Service Manual
no.
Designation
120
Diagnostic instrument
5010474
121
Adapter cable / data
9614382
Connection to cable harness in right bracket
122
Adapter cable / data
10025620
Direct plugging to the heating device
130
Testing tool for cooling system
7029179
all types
Pressurisation of engine cooling system (leakage test)
140
Torque wrench
10045464
all types
Tightening the hose clamps
150
B20 pressure switch conversion kit consisting of: screw-in stud T-connection fitting Measuring piece Screw nozzle
9645488
all types
Testing of switching pressure (dropping) of B20 pressure switch
Hand pump with pressure gauge
10454803
all types
Leakage test of backpressure line at particle filter installation
151 152 153 154
160
Size
4-20 Nm
ID no.
Mach.
Application
all types
Diagnostics of D5 WS auxiliary heating
7617216 7405617 7409919 7368150
Scope of delivery of the Litronic measuring system Depending on the requirements, there might be a need for various additional adapters and cables, which must be ordered separately. Item
Sensors
ID no.
2
OEM pressure sensor, measuring range 0 - 1000 bar, output 0 - 20 mA
3
OEM pressure sensor, measuring range 0 - 600 bar, output 0 - 20 mA
6*
6140 624 01
4
OEM pressure sensor, measuring range 0 - 60 bar, output 0 - 20 mA
3*
6140 625 01
2.01.6 copyright by
MJFCIFSS
1001 8329
Service Manual
Special tools - general information
Item
Sensors
ID no.
5
OEM pressure sensor, measuring range 0 - 10 bar, output 0 - 20 mA
1002 7591
6
OEM pressure sensor, measuring range -1 to +6 bar, output 4 - 20 mA (LWE)
5718 886 08
7
MINIMESS direct connection pressure sensor, 1620 screws
6*
6140 626 01
8
MINIMESS direct connection pressure sensor, 1620 screws, angled by 90°
3*
6140 647 01
9
Pt 100 temperature sensor, measuring range -50 °C to +200 °C
1*
6140 627 01
10
MINIMESS p / t coupling, screw series 1620, G 1/4"
1*
6140 628 01
11
MINIMESS P / T coupling, screw coupling 1620, M10 x 1.5
1*
1004 1274
12
RE 4 10 measuring turbine, measuring range 1 to 10 l/min
1*
5010 031
13
RE 3 75 measuring turbine, measuring range 7.5 to 75 l/min
1*
6410 629 01
14
RE 3 300 measuring turbine, measuring range 15 to 300 l/min
0*
6140 630 01
15
RE 3 600 measuring turbine, measuring range 25 to 600 l/min
2*
5009 492
16
DS 03 speed sensor, measuring range 1 to 9999 rpm
1*
6140 631 01
17
Spare reflector foil kit
1*
6140 632 01
18
Magnet holder, for DS 03 speed sensor
1*
6140 633 01
19
Inductive sensor for speed measurement
1*
6140 634 01
Item
Accessory
20
Transport case for RE 3 measuring turbine
1*
6140 635 01
21
MK 12 measuring cable for the connection of the sensors, length 12 m
12*
6140 636 01
22
MK 12 measuring cable for the connection of the sensors, length 12 m
4*
6140 637 01
23
MK 12 measuring cable for the connection of the sensors, length 12 m
1*
6140 638 01
24
Power supply cable for connection to the on-board power system, length 6 m
1*
6140 639 01
25
Power supply cable for connection to the on-board power system, length 12 m
0*
6140 640 01
26
DPU 411 thermal printer with power adapter
0*
6140 641 01
27
Thermal paper rolls for DPU 411
0*
6140 642 01
28
Centronics data cable, length 2 m (for DPU 411)
0*
6140 643 01
29
RS 232 data cable, length 2 m (for connection to PC)
1*
9684 327
30
AK 12 adapter cable (for speed measurement with GLR testing instrument)
1*
6140 648 01
31
Litronic Service Program, German version (for DOS operating system)
0*
6140 646 01
32
Evaluation software (d / e / f) on CD-ROM (for Windows, 16 bit)
1*
6004 401
33
Evaluation software (d / e / f) on CD-ROM (for Windows, 32 bit)
34
Measuring adapter for current measurement A 309 - R 317 Litronic
1*
8504 231
36
Y-adapter for current measuring Junior Timer plug
1*
9956 436
37
3-to-2 pin plug adapter
1*
9956 422
ID no.
* number of units for recommended basic equipment
2.01.7 copyright by
MJFCIFSS
Special tools - general information
Service Manual
2.01.8 copyright by
MJFCIFSS
Service Manual
Special tools for diesel engines
Special tools for diesel engines Maintenance and setting instructions for Liebherr diesel engines Representation
Machi ne
Application
all types
Measurement of compression pressure
0524044
all types
Insert at the position of the injection valve
Nozzle tester
7361236
all types
Testing of injection nozzles
4
High-pressure hand pump with accessories
7009318
all types
Checking and adjustment of start of delivery of the injection pump
10
Measuring device
7022420
all types
Checking and adjustment of start of delivery of the injection pump
No.
Designation
Size
1a
Compression pressure tester
1b
Diagram sheets for item 1a
2
Connecting piece for compression pressure tester
3
ID no. 8008782
100 Units
10012817
2.02.1 copyright by
MJFCIFSS
Special tools for diesel engines
Representation
Service Manual
Size
Designation
12
Dial gauge
7022418
13
Spacer
7022419
18
Removal tool for injection nozzles
0524072
19
Adapter for removal tool
0524029
30
Rotating device / attachment to flywheel housing
0524045
all types
Turning of diesel engine by means of the flywheel
35
V-belt measuring instrument
8042829
all types
Measuring of V-belt tension
36
Communication cable for LH-ECU-UP/CR control units
10035410
D 934 LA 6 / D 936 LA 6
Reading of error memory, fault analysis, processing of measurements, calibration
Krikit
ID no.
Machi ne
No.
2.02.2 copyright by
MJFCIFSS
Application
all types
Testing and adjustment of start of delivery in conjunction with no. 10
all types
Removal of injection nozzles To be used together with the removal tool
Service Manual
Representation
Special tools for diesel engines
No.
Designation
Size
37
Diagnostic software DC-DESK 2000 for LH-ECU-UP/CR DC4 and DC5 control units
ID no. 10118924
Machi ne
Application
D 934 LA 6 / D 936 LA 6
Reading error memory, analyse faults, edit measurements and carry out calibrations.
Note! The software is supplied together with each dongle!
38
USB dongle
40
Nozzle gauge
10410078
all types
Measuring and checking of nozzle bores and small drilled holes
50
Connecting piece
10297211
D 934 LA 6 / D 936 LA 6
Measuring of compression pressure
60
Outrigger
10117612
D 934 LA 6 / D 936 LA 6
Measuring of compression pressure
2.02.3 copyright by
MJFCIFSS
Special tools for diesel engines
Service Manual
2.02.4 copyright by
MJFCIFSS
Service Manual
Special tools for hydraulic unit
Special tools for hydraulic unit the maintenance, repair and adjustment of the hydraulic unit Picture
No.
Description
Size
ID no.
Machine
Application
10
Special spanner for pressure-relief valves
WS 17
9359414
all types
Adjustment of the primary and secondary valves in the control valve block
WS 19
9210371
all types
Securing of adjusting screws at hydraulic units
11
20
Safety cap
WS 10
7009315
21 22 23 24 25
short long short long
WS 13 WS 13 l WS 17 WS 19 WS 19 l
7023492 7615515 7380629 7009316 7009317
30
Mounting sleeve
see group 2.12
all types
Mounting of O-rings and Stepseal rings onto pistons of hydraulic cylinders and control pistons of variabledisplacement pumps and regulating motors
40
Expanding sleeve
see group 2.12
all types
See tool no. 40
50
Piston wrench
see group 2.12
all types
Diagram of manufacture, see sheet 2.12-01
2.05.1 copyright by
MJFCIFSS
Special tools for hydraulic unit
Picture
Service Manual
No.
Description
Size
ID no.
60
Piston wrench
WS
0541333
Machine
Application
all types
Loosening and tightening of piston nut
61 see group 2.12 62 63 64 70
Socket wrench for threaded bushing
WS 41
9245656
all types
Dismantling and mounting of damping plugs for two-side end-of-travel cushioning of hydraulic cylinders
80
Removal tool for piston rod bearing
M16
9951120
all types
Removal of piston rod bearings at hydraulic cylinders
M20
9959261
M24
9959262
W 24x 1-1/4" 3.0m
8145359
all types
Checking and filling of gas accumulator as well as piston and membrane accumulator
Ø 20 mm
10017281
all types
Clamping of spools during dismantling and mounting of piston elements
Ø 25 mm
10017282
Ø 32 mm
10017283
Ø 25 mm Ø 22 mm Ø 45 mm Ø 25 mm
9951457
all types
Mounting of Turcon-Glyd rings and scraper rings on the plunger piston of LIKUFIX couplings
90
Filling device, complete with adapter and hose
W 32x 1-1/4 3.0m
140
160 161 162 163
Clamping device for spool
Mounting sleeve
9951508 9966421 9951458
2.05.2 copyright by
MJFCIFSS
Service Manual
Picture
Special tools for hydraulic unit
No.
Description
Size
ID no.
Machine
Application
180
Vacuum pump, complete consisting of: Pump no. 180, vacuum control valve no. 181 with sealing, hose with filter no. 187.
00A7. 300
7405073
all types
Retension of hydraulic tank content
181
10097130 Vacuum control valve, complete
184 185 186
Connecting piece to tank, consisting of: Screw-in stud Cone RED connection 16/8S Straight nipple
7002240 7407155 7024875
200
Mounting sleeve
see group 2.12
all types
Calibration of the seal rings during the installation of the piston in the cylinder (tool no. 950 in the Lidos)
210
Mounting sleeve
see group 2.12
all types
Installation of the piston rod bearing on specially shaped piston rods (tool no. 960 in the Lidos)
2.05.3 copyright by
MJFCIFSS
Special tools for hydraulic unit
Service Manual
2.05.4 copyright by
MJFCIFSS
Service Manual
Special tools for electrical equipment
Special tools for electrical equipment Maintenance and repair of electric plug connectors
Picture
Fig. 1
Mate-N-LOK and DT plugs
Fig. 2
Juniortimer and JPT plugs
Size
ID no.
Machi ne
No.
Designation
10
Used to crimp the contacts for 1.5 mm2 wires for MATE-N-LOK plug connectors
7367025
all types
12
Used to crimp the contacts for 2.5 mm2 wires for MATE-N-LOK plug connectors
7366314
all types
15
Used to remove the crimp contacts from MATE-N-LOK plug connectors
7015179
all types
Application
2.06.1 copyright by
MJFCIFSS
Special tools for electrical equipment
Picture
Service Manual
Designation
20
Socket contact for 1.5 mm2 wires of MATE-N-LOCK plug connectors
6202619
21
Pin contact for 1.5 mm2 wires of MATE-N-LOCK plug connectors
6202620
22
Socket contact for 2.5 mm2 wires of MATE-N-LOCK plug connectors
6202591
23
Pin contact for 2.5 mm2 wires of MATE-N-LOCK plug connectors
6202592
28
Hand crimp tool (according to MILC5015, VG 95234, VG 955342)
7367086
29
Crimping insert for the crimping of DEUTSCH plug connectors with no. 28 pliers
7409779
30
Hand crimp tool for the crimping of contacts for DEUTSCH plug connectors
8503647
all types
31
Pulling tool
7026267
all types
32
Tool for the removal of wired crimp contacts at DEUTSCH plug connectors
Size 4
8503633
all types
Size 8 12 16 20
8503632 8145674 8145673 8503630
33 34 35 36
Size
ID no.
Machi ne
No.
2.06.2 copyright by
MJFCIFSS
Application
all types
all types
all types
Used for the disassembly of DEUTSCH plugs.
Service Manual
Picture
Special tools for electrical equipment
No.
Designation
Size
ID no.
37
Pin contact for wires of DT plug connectors
Ø 0.81.0 Ø 1.02.0 Ø 2.03.0
7368251
Ø 0.81.0 Ø 1.02.0 Ø 2.03.0
7368252
38
Socket contact for wires of DT plug connectors
Machi ne all types
7368406 6905271
7368405 6905272
39
Plug
7368253
40
Used to crimp the punched contacts of SURE-SEAL plug connectors
7367025
all types
41
Mounting tool for the insertion of wired crimp contacts into SURESEAL CT 31 plug connectors
7367023
all types
42
A: Removal tool for pin contacts in SURE-SEAL plug connectors
7367020
all types
B: Removal tool for socket contacts
7367022
all types
43
Installation tubes for tool no. 42
7022464
all types
45
Auxiliary tool used to hold the SURE-SEAL 2, 3 and 4-pin plug connectors during installation and removal of the crimped contacts
7367021
all types
46
Similar to tool no. 324, for 5, 6 and 7-pin contacts
7367085
CT 31
Application
2.06.3 copyright by
MJFCIFSS
Special tools for electrical equipment
Picture
Service Manual
Designation
48
Repair kit containing special tools no. 40, 41, 42, 45 and 46, including operating manual and lubricant
7015073
all types
50
Socket contact for 1.5 mm2 wires of SURE-SEAL plug connectors
6202434
all types
51
Size
Pin contact for 1.5 mm2 wires of SURE-SEAL plug connectors
ID no.
Machi ne
No.
Application
6202444
52
Removal tool for contacts of MICROTIMER plug connectors
7026266
all types
55
Unlocking tool for WAGO plug elements
7022773
all types
60
Dismantling and mounting tool
10356764
all types
Used to dismantle and mount EPROMs
65
Mounting sleeve
9629620
all types
Used to install O-rings in Likufix signal contacts
777-310
2.06.4 copyright by
MJFCIFSS
Service Manual
Picture
Special tools for electrical equipment
No.
Designation
Size
70
Ergocrimp hand tool
ID no. 6004391
Ergocrimp matrix 72
0.5-2.5 mm2
10016253
0.2-2.5 mm2
10016255
0.5-2.5 mm2
10016256
Machi ne
Application
all types
Used to crimp the contacts for JPT (Tyco) plug connectors
all types
Used to crimp the contacts for Junior Power Timer no. 927777-3 / 927779-3 / 927846-2
73
Junior power Timer/EDS no. 929938-3/doublespring contact no. 9299403
74
flat adapters no. 963745-1 / 963746-1 80
Removal tool
7415334
all types
Used to remove the wired crimp contacts from JPT (Tyco) plug connectors
90
Crimp tool
10016251
all types
Used to crimp the Littlefuse contacts for JPT (Tyco) plug connectors, see also no. 92.
92
Ergocrimp matrix
10016252
all types
Used to crimp the contacts in conjunction with no. 90
0.5-5.37 mm2
Pin bushing no. 913053 / 913065 / 913066 / 913067 / 913069 / 913079 Double-spring contact no. 913071 / 913072
2.06.5 copyright by
MJFCIFSS
Special tools for electrical equipment
Picture
Service Manual
Machi ne
Application
10011168
all types
Used to crimp wire end ferules
0.25-16 mm2
8033014
all types
Used to crimp wire end ferules
Crimp tool
0.5-6.0 mm2
8004713
all types
Used to crimp insulated fork terminals
Crimp tool with compression insert R 10
10-70 mm2
all types
Used to crimp uninsulated fork terminals
No.
Designation
Size
ID no.
95
Crimp tool
0.08-10 mm2
96
Crimp tool
98
100
Inserts for tool no. 100
all types
101 102 103 104 105
R 16 R 25 R 35 R 50 R 70
108
Crimp tool
0.5-6 mm2
8033015
all types
Used to crimp uninsulated plug connectors
109
Crimp tool
0.5-2.5 mm2
6003491
all types
Used to crimp uninsulated plug connectors
110
Crimp tool
0.5-2.5 mm2
all types
Used to crimp uninsulated plug connectors
2.06.6 copyright by
MJFCIFSS
Service Manual
Picture
Special tools for electrical equipment
No.
Designation
Size
111
Crimp tool
0.03-0.6 mm2
112
Pin remover for D-Sub contacts
ID no.
Machi ne
Application
all types
Used to crimp D-Sub contacts
all types
2.06.7 copyright by
MJFCIFSS
Special tools for electrical equipment
Service Manual
2.06.8 copyright by
MJFCIFSS
Service Manual
Special tools for slewing gear mechanism
Special tools for slewing gear mechanism Maintenance and repair of slewing gear mechanism and slewing gear motor Diagram
No.
Designation
Size
ID no.
Machi ne
10
Slotted nut wrench for slewing gear mechanism
SAT 275
9202821
A 934C
11
SAT 325
9202823
A 944C
12
SAT 350
9202824
A 954C
SAT 275
9202826
A 934C
21
SAT 325
9202828
A 944C
22
SAT 350
9202829
A 954C
FMF 64
10127252
A 934C
20
30
Mounting device of slewing gear mechanisms
Special wrench for speed sensor
FMF 90
A 944C
FMF 100
A 954C
Application For releasing and tightening of slotted nuts in drive/ slewing gear mechanisms (SAT drawing, see page 2.14-01)
For dismantling and assembly of brake housing/ multi-disc brake for SAT slewing gear mechanisms, see SAT drawing, page 2.15-01.
For dismantling and assembly of the speed sensor at the slewing gear motor.
2.07.1 copyright by
MJFCIFSS
Special tools for slewing gear mechanism
Service Manual
2.07.2 copyright by
MJFCIFSS
Service Manual
Special tools for axles (Kessler)
Special tools for axles (Kessler) for the maintenance and repair of axles (Kessler) Representation
no.
Designation
ID no.
Axle type
Machine
Application
10
Insertion tool for slip seal ring
7027696
LT/D 71
Mounting of slip seal ring
LT/D 81
A 924 C-HD A 934 C A 934 C-HD
10046704
LT/D 101
A 954 C-HD
10455408
LT/D 41 LT/D 71
A 900 C-ZW A 924 C-HD A 934 C
21
10424371
LT/D 81
A 934 C-HD
22
10424498
LT/D 91
A 944 C-HD
23
10424380
LT/D 101
A 954 C-HD
10492637
LT/D 41 LT/D 71
A 900 C-ZE A 924 C-HD A 934 C
7026040
LT/D 71
A 924 C-HD A 934 C
Removal tool for steering knuckle bolts (mechanical)
10424373
LT 41 LT 71
A 900 C-ZW A 924 C-HD A 934 C A 934 C-HD
Removal of steering knuckle bolt
Removal tool for steering knuckle bolts (hydraulic)
10424374
Removal of steering knuckle bolt by means of a hydraulic pump*
LT 81
A 900 C-ZW A 924 C-HD A 934 C A 934 C-HD
11
20
30
Spanner for wheel nut / shaft nut
Spanner for lock nut
31
40
50
LT 81
LT 41 LT 71
Loosening and tightening of shaft nut
Loosening and tightening of lock nut at planetary gear box
51
10424381
LT 91 LT 101
A 944 C-HD A 954 C-HD
(Removal thread M27X2 from December 2006)
52
10424382
LT 91 LT 101
A 944 C-HD A 954 C-HD
(Removal thread M24 until November 2006)
2.09.1 copyright by
MJFCIFSS
Special tools for axles (Kessler)
Representation
Service Manual
no.
Designation
ID no.
Axle type
Machine
Application
60
Push-in tool for steering knuckle bolts (hydraulic)
10046711
LT 41 LT 71 LT 81
A 900 C-ZW A 924 C-HD A 934 C A 934 C-HD
Hydraulic pushing in of steering knuckle bolt by means of a hydraulic pump*
10424383
LT 91 LT 101
A 944 C-HD A 954 C-HD
10046715
LT 41 LT 71
A 900 C-ZW A 924 C-HD A 934 C A 934 C-HD A 944 C-HD A 954 C-HD
Insertion of steering knuckle bolt
Insertion of steering knuckle bushing into axle housing
LT 81
A 900 C-ZW A 924 C-HD A 934 C A 934 C-HD
10492635
LT 41 (AGS)
A 900 C-ZW
Removal of needle bearing and bearing bushing from axle housing
10424375
LT 71 LT 81 LT 91 (ASS) LT 101 (ASS)
A 924 C-HD A 934 C A 934 C-HD A 944 C-HD A 954 C-HD
LT 91 (AGS) LT 101 (AGS)
A 944 C-HD A 954 C-HD
61
70
Insertion pin for steering knuckle bolt
LT 81 LT 91 LT 101
80
90
91
92
Mounting tool for steering knuckle bushings
Removing tool for double joint drive shaft bearing
7028268
10424384
LT 47 LT 71
2.09.2 copyright by
MJFCIFSS
Service Manual
Representation
Special tools for axles (Kessler)
no.
Designation
ID no.
Axle type
Machine
Application
100
Mounting tool for double joint drive shaft bearing
10492639
LT 41
A 900 C-ZW
Insertion of needle bearing and bearing bushing from axle housing
101
10492640
LT 41
A 900 C-ZW
102
10424499
LT 71 LT 81 LT 91 (ASS) LT 101 (ASS)
A 924 C-HD A 934 C A 934 C-HD A 944 C-HD A 954 C-HD
10424385
LT 91 (AGS) LT 101 (AGS)
A 944 C-HD A 954 C-HD
10492636
LT 41
A 900C-ZW
111
10492653
LT 41
A 900 C-ZW
112
10424376
LT 71
A 924 C-HD A 934 C A 934 C-HD A 944 C-HD A 954 C-HD
103 110
Seal ring mounting tool for double joint drive shaft bearing
LT 81 LT 91 (ASS) LT 101 (ASS) 113
10424377
114
120
Seal ring mounting tool for axle drive
LT 71 LT 81 LT 91 (ASS) LT 101 (ASS)
A 924 C-HD A 934 C A 934 C-HD A 944 C-HD A 954 C-HD
10424385
LT 91 (AGS) LT 101 (AGS)
A 944 C-HD A 954 C-HD
Insertion of radial seal ring in axle housing
10424378
LT/D 41 LT/D 71
A 900 C-ZW A 924 C-HD A 934 C A 934 C-HD A 944 C-HD
Insertion of radial seal ring in axle drive
LT/D 81 LT/D 91 121
10046716
LT/D 71 LT/D 81 LT/D 91
130
Spanner for threaded ring
10492634
LT 41 LT 71 LT 81 LT 91
131
Insertion of radial seal ring in steering knuckle
10492638
LT 71 LT 81 LT 91 LT 101
A 924 C-HD A 934 C A 934 C-HD A 944 C-HD
A 900 C-ZW A 924 C-HD A 934 C A 934 C-HD A 944 C-HD
Loosening and removal of adjusting ring in axle drive
A 924 C-HD A 934 C A 934 C-HD A 944 C-HD A 954 C-HD
2.09.3 copyright by
MJFCIFSS
Special tools for axles (Kessler)
Representation
Service Manual
no.
Designation
ID no.
Axle type
Machine
Application
140
Slotted nut wrench for lock nut in auxiliary transmission (lock nut installed from June 2006)
10412169
D 91 D 101
A 944 C-HD A 954 C-HD
Loosening and tightening of lock nut in auxiliary transmission
150
Centring device for discs
10424386
LT/D 101
A 954 C-HD
Mounting of brake discs
* = hydraulic hand pump not included with the respective tool ASS = steering knuckle side AGS = axle housing side
2.09.4 copyright by
MJFCIFSS
Service Manual
Stroke measuring device for control block Device for the measuring of the spool stroke
Stroke measuring device for control block 1
Device for the measuring of the spool stroke Stroke length at NG 25= 14 mm Stroke length at NG 32= 15 mm Stroke length at NG 40= 20 mm
Fig. 1
Stroke measuring device
1
Stroke measuring device
3
Lid of control valve block
2
Seal
4
Spool
ID no. 8007363
Parts drawing on reverse side!
2.10.1 copyright by
MJFCIFSS
Stroke measuring device for control block
Service Manual
Device for the measuring of the spool stroke
Fig. 2
Spare Parts for storke measuring
2.10.2 copyright by
MJFCIFSS
Service Manual
Assembly tools for hydraulic cylinders Assembly wrenches for pistons of hydraulic cylinders WN 4121
Assembly tools for hydraulic cylinders 1
Assembly wrenches for pistons of hydraulic cylinders WN 4121
Fig. 1
Assembly tool (bore for mounting bolt a)
a
b
c
d
e
f
g
h
i
Squar e
9131359
52
38
75
200
10
8
8
15
60
1/2
9131362
60
44
85
200
14
10
10
15
65
1/2
9231993
68
52
100
220
14
10
10
15
70
1/2
8007364*
75
54
110
220
14
12
10
20
84
3/4
8007364*
80
54
110
220
14
12
10
20
84
3/4
7364036 8007365
88
63
120
250
14
12
10
20
90
3/4
8007366
100
78
135
260
14
14
10
20
95
3/4
9919856
115
88
150
300
14
14
10
20
105
3/4
9196978#
125
97
170
320
14
14
10
25
110
3/4
9196978#
130
97
170
320
14
18
15
25
110
3/4
8007367
145
113
185
380
14
18
15
25
120
3/4
9925117
160
125
200
420
14
18
15
25
130
3/4
9131373
175
135
215
450
14
20
19
25
135
3/4
9131376
220
156
280
500
14
30
28
40
158
3/4
0541380
85
72
110
210
11
8
8
15
210
1/2
0542336
120
100
140
240
12
8
9
152
240
1/2
0540947
124
100
150
240
12
8
9
15
240
1/2
0541379
145
125
170
280
11
8
9
15
280
3/4
0540966
160
135
185
280
12
10
9
20
280
3/4
0529897
165
140
190
280
12
10
9
20
280
3/4
ID no.
Tab. 1
List of assembly wrenches (all dimensions in mm)
2.12.1 copyright by
MJFCIFSS
Assembly tools for hydraulic cylinders
Service Manual
Assembly wrenches for piston nuts
Note! The dimensions of the pistons and assembly wrenches and the ID numbers can be looked up in Lidos (* and # correspond to one wrench each)!
2
Assembly wrenches for piston nuts
Fig. 2
Assembly wrenches for piston nuts
size for piston nut ID no.
*WS hexagon
*WS2 flat
Slotted nut Ø
Square
ID no.
M30X1.5 - 7006469
44
**
M32X1.5 - 7010262
50
**
M33 X1.5 - 9226916 M36X1.5 - 9875702
41 50
M42X1.5 - 7010163 M42X1.5 - 9970088
9921132
1/2
9211967
62 60
M42X1.5 - 9113734 M50X2 - 4129202
1/2
55 70
M50X2 - 9166795
65
** 1/2
9211967
1/2
9921132
1/2
9921123
1/2
9921123
M56X2 - 9921260
80
1/2
9921124
M60X2 - 4129203
80
1/2
9921124
M65X2 - 9247441
85
1/2
9921133
M68X2 - 9129554
90
1/2
9921124
M76X2 - 9970448
100
3/4
9921125
M85X3 - 9142472
110
3/4
9921125
M95X3 - 9101411
120
3/4
9921126
M100X3 - 9950036
130
3/4
9951123
M110X3 - 9129653 / 9112934
149
3/4
9921127
M120X3 - 9143685
165
3/4
9921128
M130X3 - 9125066
180
3/4
9921129
M150X3 - 9144654
210
3/4
9921131
2.12.2 copyright by
MJFCIFSS
Service Manual
Assembly tools for hydraulic cylinders Assembly wrenches for WN 4122 piston rod bearings
size for piston nut ID no.
*WS hexagon
*WS2 flat
M170X3 - 5008571 Tab. 2
Slotted nut Ø
230
Square
ID no.
3/4
9921134
List of piston nuts
* spanner size / ** conventional grooved socket spanner
3
Assembly wrenches for WN 4122 piston rod bearings
Fig. 3
Assembly wrenches for piston rod bearings
ID no.
a
b
c
d
e
f
g
h
i
Squar e
0541665
76
62
95
210
9
6
7
15
70
1/2
0541666
87,5
72
110
210
10
8
8
15
70
1/2
0541063
92
75
115
210
12
8
8
15
75
1/2
0541064
100
80
120
210
12
10
10
15
80
1/2
0529893
110
90
130
240
12
10
10
15
90
1/2
0542005
115
95
135
240
12
8
10
15
95
1/2
0541667
125
98
150
240
12
10
9
15
98
1/2
0529894
135
110
160
260
12
8
8
15
105
1/2
0540948
140
120
160
260
12
8
8
15
110
1/2
0541661
145
120
170
280
12
10
9
15
110
1/2
0529895
145
120
170
280
12
12
13
15
120
1/2
0540949
150
130
170
280
12
12
12
20
110
3/4
0529896
170
140
200
300
12
14
13
20
110
3/4
0541378
180
160
200
300
12
10
9
20
120
3/4
Tab. 3
List of assembly wrenches
2.12.3 copyright by
MJFCIFSS
Assembly tools for hydraulic cylinders
Service Manual
Assembly wrenches for version 5100 pistons
4
Assembly wrenches for version 5100 pistons
Fig. 4
Assembly wrenches for version 5100 pistons
size for piston nut
*WS hexagon
Øa for mounting bolts
WS square
ID no.
M 110X3
150
180
3/4
9281614
M 120X3
175
220
3/4
9584641
M 110X3
190
240
3/4
9581705
Tab. 4
4.1
List of assembly wrenches / * spanner width
Assembly wrenches for pistons
Fig. 5
Assembly wrenches for pistons
ID no.
a
b
c
d
e
f
g
h
i
Squar e
9249886
250
204
310
600
14
30
28
30
175
3/4
9249741
260
176
330
600
19
36
35
40
180
3/4
9243215
280
206
354
650
19
36
35
40
190
3/4
2.12.4 copyright by
MJFCIFSS
Service Manual
Assembly tools for hydraulic cylinders Mounting and expanding sleeves
Tab. 5
4.2
List of assembly wrenches
Assembly wrench for pistons with hexagon piece
Fig. 6
Assembly wrench for pistons with hexagon piece mm
mm
mm
*WS hexagon
mm Piston Max. Ø
mm
mm
mm
l
mm Piston Min. Ø
Square
a
b
c
9600751
80
3/4
170
Ø110
Ø140
Ø160
525
15
9602239
85
3/4
170
Ø115
Ø140
Ø160
525
15
9600418
90
3/4
170
Ø120
Ø150
Ø160
525
15
9597668
100
3/4
170
Ø130
Ø160
Ø180
525
15
9600928
110
3/4
170
Ø160
Ø190
Ø200
525
15
9600769
120
3/4
174
Ø170
Ø200
Ø200
525
15
ID no.
Tab. 6
List of assembly wrenches
* spanner width
5
Mounting and expanding sleeves Piston Ø
990 mounting sleeve ID no.
991 expanding sleeve ID no.
25
9951457
9951458
32
9136418
9136416
32
9113100
9113099
38
9143279
9143280
40
9196902
9136417
40
9580414
9580413
45
9136419
9136417
50
9288953
9288954
63
9170510
9170512
65
9177541
9177540
2.12.5 copyright by
MJFCIFSS
Assembly tools for hydraulic cylinders
Service Manual
Mounting and expanding sleeves
Piston Ă&#x2DC;
990 mounting sleeve ID no.
991 expanding sleeve ID no.
70
9110556
9110402
80
9227165
9227166
85
9998618
9110404
85
9115710
9115708
90
9227161
9227162
98
9289130
9289131
100
9998626
9110405
105
9951984
9951983
106
9583670
9583671
110
9170509
9170511
110
9960483
9960502
115
9998625
9110406
120
9998778
9110407
125
9227163
9227164
125
9960484
9960503
130
9998624
9110408
135
9285578
9285579
140
9998623
9110409
150
9998622
9110410
160
9998621
9110411
170
9107931
9110412
180
9998619
9110413
180
9107932
9110413
190
9907684
9907701
190
9280862
9280863
200
9107933
9110414
210
9192854
9192853
220
9113008
9113009
230
9144914
9144912
240
9903977
9903978
300
9135351
9135350
Tab. 7
List of mounting and expanding sleeves
Piston Ă&#x2DC;
992 mounting sleeve ID no.
993 mounting sleeve ID no.
25
9966421
9951508
Tab. 8
List of 992 and 993 mounting sleeves
Note! The mounting sleeves 992 and 993 are required for the installation of the piston and the scraper ring in the plunger cylinder with the LIKUFIX accessory kit.
2.12.6 copyright by
MJFCIFSS
Service Manual
Assembly tools for hydraulic cylinders Mounting and expanding sleeves
Mounting sleeves used to insert pistons into cylinders Piston Ă&#x2DC;
950 mounting sleeve ID no.
65
9177543
80
9231749
90
9248893
90
9248894
100
9248895
110
9248897
120
9248898
130
9248899
140
9177542
140
9952180
160
9248909
190
9281241
210
9281240
250
9951147
260
9284918
Tab. 9
950 mounting sleeves
Note! The mounting sleeve 950 is required to restore the shape of the expanded sealing elements to suit the inside diameter of the cylinder (calibration). Mounting sleeves used to mount the piston rod bearings on the piston rods Piston rod Ă&#x2DC;
960 mounting sleeve ID no.
90
9282761
100
9638789
105
9287177
140
9926806
Tab. 10
960 mounting sleeves
Note! The 960 mounting sleeve is required in order to prevent damage to sealing and guide elements.
2.12.7 copyright by
MJFCIFSS
Assembly tools for hydraulic cylinders
Service Manual
Mounting and expanding sleeves
2.12.8 copyright by
MJFCIFSS
Service Manual
Mounting device for piston rod bearings Tool used to dismantle piston rod bearings in hydraulic cylinders
Mounting device for piston rod bearings 1
Tool used to dismantle piston rod bearings in hydraulic cylinders
Fig. 1
Mounting device
Thread in flange ring
Thread in bearing head M1
Thread of mounting driver M2
Length of mounting driver L
ID -no.
M12
M16
M10
250
9951120
M16
M20
M12
270
9959261
M20
M24X2
M16
290
9959262
Tab. 1
Mounting device sizes for various flange ring threads
2.13.1 copyright by
MJFCIFSS
Mounting device for piston rod bearings
Service Manual
Tool used to dismantle piston rod bearings in hydraulic cylinders
2.13.2 copyright by
MJFCIFSS
Service Manual
Slotted nut wrench for slewing gear Tool used to remove the slotted nut in the slewing gear mechanism
Slotted nut wrench for slewing gear 1
Tool used to remove the slotted nut in the slewing gear mechanism
Fig. 1
Slotted nut wrench for Sat 225 / 250 / 275 / 300 Gearbox type
ID number
SAT 275
9202821
SAT 325
9202823
SAT 350
9202824
2.14.1 copyright by
MJFCIFSS
Slotted nut wrench for slewing gear
Service Manual
Tool used to remove the slotted nut in the slewing gear mechanism
Fig. 2 SAT 275 325 350
A 110 132 137
B 55 55 55 Tab. 1
Technical drawing of slotted nut wrench C 46 46 46
D
E +0.2
F
G
H
J
K
L
M
N
O
P
70
92.2
95
120
105
3.8
90
35
30
50
70
7.8
80
115+0.2
119.5
150
117
3.8
94
35
30
55
78
7.8
50
125+0.2
126.2
160
113
3.8
92
35
30
55
78
7.8
Dimensions
Material: 42 CrMo 4 hardened to 800 - 950 N/mm2
2.14.2 copyright by
MJFCIFSS
Service Manual
Mounting device for multi-disc brake
Mounting device for multi-disc brake Tool used to dismantle and mount the multi-disc brake of the slewing gear mechanism SAT 275 / 325 / 350
Fig. 1
Tab. 1
Mounting device of slewing gear mechanisms Size
SAT 275
SAT 325
SAT 350
A
326
390
410
B
40
50
50
C
12
20
20
D
10
15
15
E
10
15
15
F
18
22
22
G
120
142
154
H
143
170
180
ID no.
9202826
9202828
9202829
List of mounting device sizes
2.15.1 copyright by
MJFCIFSS
Mounting device for multi-disc brake
Service Manual
2.15.2 copyright by
MJFCIFSS
Service Manual
SUBGROUP - INDEX Section
Group
Type
Technical data A 934 C LI
3.05.1
A 934 C-LI 28016-
Technical data A 934 C HD LI
3.07.1
A 934 C-LI 25436-
Technical dataA 934 C HD LI Log Loader
3.09.1
A 934 C-LI 31793-
Technical data
3.11.1
A 944 C-LI 24475-
Technical data
3.13.1
A 944 C-LI 29225-
Technical data
3.15.1
A 954 C-LI 21416-
Maintenance and inspection schedule
3.17.1
A 934 C-LI 28016-
Maintenance and inspection schedule
3.19.1
A 934 C-LI 25436-
Maintenance and inspection schedule
3.21.1
A 934 C-LI 31793-
Maintenance and inspection schedule
3.23.1
A 944 C-LI 24475-
Maintenance and inspection schedule
3.25.1
A 944 C-LI 29225-
Maintenance and inspection schedule
3.27.1
A 954 C-LI 21416-
Lubrication schedule for A 934 C Litronic Type 1006
3.29.1
A 934 C-LI 28016-
Lubrication schedule for A 934 C-HD Litronic Type 1007
3.31.1
A 934 C-LI 25436-
Lubrication Schedule A 934 C-HD Litronic log loader Type 1053
3.33.1
A 934 C-LI 31793-
Lubrication schedule for A 944 C-HD Litronic Type 194
3.35.1
A 944 C-LI 24475-
Lubrication schedule A 944 C - HD Litronic log loader type 196
3.37.1
A 944 C-LI 29225-
Lubrication schedule for A 954 C-HD Litronic Type 450
3.39.1
A 954 C-LI 21416-
3.1 MJFCIFSS
Service Manual
Adjustment protocol A 934 C Li
3.45.1
A 934 C-LI 28016-
Adjustment protocol A 934 C LI
3.46.1
A 934 C-LI 39077-
Adjustment protocol A 934 C HD LI
3.47.1
A 934 C-LI 25436-
Adjustment protocol A 934 C HD LI
3.48.1
A 934 C-LI 39077-
Adjustment protocol A 934 C HD LI log loader
3.49.1
A 934 C-LI 31793-
Adjustment protocol A 944 C HD LI
3.51.1
A 944 C-LI 24475-
Adjustment protocol A 944 C HD LI
3.52.1
A 944 C-LI 39086-
Adjustment protocol A 944 C HD LI log loader
3.53.1
A 944 C-LI 33765-39085
Adjustment protocol A 944 C HD LI log loader
3.54.1
A 944 C-LI 39086-
Adjustment protocol A 954 C HD LI
3.55.1
A 954 C-LI 21416-
Adjustment guidelines for the hydraulic system 3.69.1
A 934 C-LI 25436-
Checking and adjusting tasks V4.7
3.70.1
A 934 C-LI 39077-
Adjustment guidelines for hydraulic system
3.71.1
A 934 C-LI 31793-
Adjustment guidelines for hydraulic system
3.73.1
A 944 C-LI 24475-
Adjustment guidelines for hydraulic system
3.77.1
A 954 C-LI 21416-
3.2 MJFCIFSS
Service Manual
Technical data A 934 C LI Type 1006
Technical data A 934 C LI 1
Type 1006 starting 28016
General Weight of basic machineapprox.
t
28.7
Weight of basic machine with attachment, without grappleapprox.
t
35.5
Overall length (basic machine without attachment)
mm
5906
Overall width
mm
3000
Overall height without attachment (operator's cab elevation 1200)
mm
3598
Rear reach from centre/slewing radius
mm
3096
Ground clearance
mm
254
Diesel engine
Type
D 934 L A6
Power at rated speed according to DIN ISO 9249
kW
150 (204 PS)
Rated speed
rpm
1800
Max. torque
Nm
920 at 1400 rpm
Drive motor
Oil volume in engine (filling quantity at oil change with filter)
l
Oil quality/oil viscosity and oil change intervals
29 see groups 1.50 and 3.80
Cooling liquid including coolant
l
40
Type
DPVP 108
Hydraulic system Hydraulic pump Design
Axial piston swash plate pump
Input speed
rpm
1800
Max. flow rate
l/min
2 x 240
Oil volume in pump distribution gear
l
3.1
Flow rate / hydraulic pump - pump distribution gear
l/min
13.3
Hydraulic oil volume (oil change with filter)
l
approx. 350
Hydraulic oil and filter change intervals
see groups 1.50 and 3.80
Control valve block
Type
Slewing gear circuit
NG 22 Closed circuit
Slewing gear pump
Type
Slewing gear pump / type
A4V 71 DWD Swash-plate axial-piston pump with attached feeder pump
Pump performance
kW
80 (108 PS)
Max. flow rate
l/min
148
Feeder pump flow rate
l/min
41
3.05.1 copyright by
MJFCIFSS
Technical data A 934 C LI
Service Manual
Type 1006 Hydraulic system Feed pressure
bar
16
Hydraulic pump / pilot control
Type
Gear pump
Max. flow / pilot control
l/min
45.5
Pressure limitation pilot control
bar
32+2
Pilot control unit / working attachment / slewing gear
Type
4TH 87 X 70-10
Pilot control unit / travel drive
Type
VG - 7 - 1 / 1
Pilot control unit / support
Type
VG - 5 - 2
Additional information
see group 6.10
Hydraulic pump / fan
Type
A 10 V 28 ED
Max. flow rate
l/min
62
Hydraulic motor / fan
Type
A 10 FE 28
Hydraulic pump / accessory kit
Type
Gear pump
Max. flow rate
l/min
24.7
Rotary connection 7 x
Type
DDF 720
Rotary connection 6 x
Type
815.006 B
Hydraulic cylinder
see group 7.30
Electrical system Operating voltage
V
24
Battery capacity
Ah
2 x 170 (in series)
Alternator voltage / current
A
28V / 80A
Starter
kW
24V / 6.6 kW
Gearbox
Type
SAT 275 / 255
Oil motor
Type
FMF 64
Max. slewing speed
rpm
8.2
Oil volume in gearbox
l
7.0
Slewing gear mechanism
Oil quality /oil viscosity and oil change intervals
see groups 1.50 and 3.80
Slewing gear brake
Type
Wet multi-disc brake (negative)
Max. release pressure
bar
20
Additional information
see group 9.10
Axles Steering axle
Type
LT 71 PL 478 NLB
Rigid axle
Type
D 71 PL 478 NLB
Oil volume in steering axle housing
l
26.5
Oil volume in rigid axle housing
l
19.0
Oil volume in steering axle / rigid axle wheel hub
l
3.0
Oil quality /oil viscosity and oil change intervals
see groups 1.50 and 3.80
Working brake
Type
Tyres
Wet multi-disc brake (positive) 11.00 - 20 / 12.00 - 20
3.05.2 copyright by
MJFCIFSS
Service Manual
Technical data A 934 C LI Type 1006
Transmission Gearbox
Type
2 HL 290
Oil motor
Type
DMVA 165
Travel speed at creeper speed off-road/on-road
kph
2.4 / 10
Travel speed in working gear / on-road gear
kph
4.6 / 20
Oil volume in gearbox
l
3.3
Oil quality, oil viscosity and oil change intervals
see groups 1.50 and 3.80
Parking brake
Type
Additional information
Wet multi-disc brake (negative) see group 11
Steering Hydraulic pump
Type
Gear pump
Flow rate
l/min
61
Steering valve
Type
7030176
First primary protection
bar
220+5
Second primary protection
bar
180+5
Secondary protection
bar
240+5
Hydraulic pump
Type
Gear pump
Max. flow rate
l/min
2.7
Max. charging pressure
bar
200
Max. brake pressure / working brake
bar
75+10
cm3
approx. 30
Brake system
Central lubrication system Volume of grease per working hour Number of cycles / grease processes with automatic greasing (optional)
see group 18.50
3.05.3 copyright by
MJFCIFSS
Technical data A 934 C LI
Service Manual
Type 1006
3.05.4 copyright by
MJFCIFSS
Service Manual
Technical data A 934 C HD LI Type 1007
Technical data A 934 C HD LI 1
Type 1007 starting 25436
General Weight of basic machineapprox.
t
30.9
Weight of basic machine with attachment, without grappleapprox.
t
37.8
Overall length (basic machine without attachment)
mm
6296
Overall width
mm
3000
Overall height without attachment (operator's cab elevation 1200)
mm
4807
Rear reach from centre/slewing radius
mm
3161
Ground clearance
mm
391
Diesel engine
Type
D 934 L A6
Power at rated speed according to DIN ISO 9249
kW
150 (204 PS)
Rated speed
rpm
1800
Max. torque
Nm
920 at 1400 rpm
Drive motor
Oil volume in engine (filling quantity at oil change with filter)
l
Oil quality/oil viscosity and oil change intervals
29 see groups 1.50 and 3.83
Cooling liquid including coolant
l
40
Type
DPVP 108
Hydraulic system Hydraulic pump Design
Axial piston swash plate pump
Hydr. drive power at max. motor output
kW
147 (200 PS)
Input speed
rpm
1800
Max. flow rate
l/min
2 x 240
Oil volume in pump distribution gear
l
3.1
Flow rate / hydraulic pump - pump distribution gear
l/min
13.3
Hydraulic oil volume (oil change with filter)
l
approx. 350
Hydraulic oil and filter change intervals
see groups 1.50 and 3.83
Control valve block
Type
Slewing gear circuit
NG 22 Closed circuit
Slewing gear pump
Type
Slewing gear pump / type
A4V 71 DWD Swash-plate axial-piston pump with attached feeder pump
Pump performance
kW
80 (108 PS)
Max. flow rate
l/min
148
3.07.1 copyright by
MJFCIFSS
Technical data A 934 C HD LI
Service Manual
Type 1007 Hydraulic system Feeder pump flow rate
l/min
41
Feed pressure
bar
16+2
Hydraulic pump / pilot control
Type
Gear pump
Max. flow / pilot control
l/min
45.5
Pressure limitation pilot control
bar
32+2
Pilot control unit / working attachment / slewing gear
Type
4TH 87 X 70-10
Pilot control unit / travel drive
Type
VG - 7 - 1 / 1
Pilot control unit / support
Type
VG - 5 - 2
Additional information
see group 6.11
Hydraulic pump / fan
Type
A 10 V 28 ED
Max. flow rate
l/min
62
Hydraulic motor / fan
Type
A 10 FE 28
Hydraulic pump / accessory kit
Type
Gear pump
Max. flow rate
l/min
24.7
Rotary connection 7 x
Type
DDF 720
Rotary connection 6 x
Type
815.006 B
Hydraulic cylinder
see group 7.30
Electrical system Operating voltage
V
24
Battery capacity
Ah
2 x 170 (in series)
Alternator voltage / current
A
28 V / 80
Starter
kW
24 V / 6.6
Gearbox
Type
SAT 275 / 255
Oil motor
Type
FMF 64
Max. slewing speed
rpm
8.2
Oil volume in gearbox
l
7.0
Slewing gear mechanism
Oil quality /oil viscosity and oil change intervals
see groups 1.50 and 3.83
Slewing gear brake
Type
Wet multi-disc brake (negative)
Max. release pressure
bar
20
Additional information
see group 9.10
Axles Steering axle
Type
LT 81 PL 488 NLB
Rigid axle
Type
D 81 PL 488 NLB
Oil volume in steering axle housing
l
30.5
Oil volume in rigid axle housing
l
22
Oil volume in steering axle / rigid axle wheel hub
l
4.0
Oil quality /oil viscosity and oil change intervals
see groups 1.50 and 3.83
Working brake
Type
3.07.2 copyright by
MJFCIFSS
Wet multi-disc brake (positive)
Service Manual
Technical data A 934 C HD LI Type 1007
Axles Tyres
16.00 - 25 / 20.50 - 25
Transmission Gearbox
Type
2 HL 290
Oil motor
Type
DMVA 165
Travel speed at creeper speed off road/on road
kph
2.4 / 10
Travel speed in working gear / on-road gear
kph
4.6 / 20
Oil volume in gearbox
l
3.3
Oil quality, oil viscosity and oil change intervals
see groups 1.50 and 3.83
Parking brake
Type
Additional information
Wet multi-disc brake (negative) see group 11
Steering Hydraulic pump
Type
Gear pump
Flow rate
l/min
61
Steering valve
Type
7030176
First primary protection
bar
220+5
Second primary protection
bar
180+5
Secondary protection
bar
240+5
Hydraulic pump
Type
Gear pump
Max. flow rate
l/min
2.7
Max. charging pressure
bar
200
Max. brake pressure / working brake
bar
75+10
cm3
approx. 30
Brake system
Central lubrication system Volume of grease per working hour Number of cycles / grease processes with automatic greasing (optional)
see group 18.50
3.07.3 copyright by
MJFCIFSS
Technical data A 934 C HD LI
Service Manual
Type 1007
3.07.4 copyright by
MJFCIFSS
Service Manual
Technical dataA 934 C HD LI Log Loader Type 1053
Technical dataA 934 C HD LI Log Loader 1
Type 1053 starting 31793 T
General Weight of basic machines (blade rear), without attachment appr.
t
28,67
Weight of basic machines (blade rear), without attachment without grapple appr.
t
34,35
Weight of basic machine (blade rear and front), without attachment appr.
t
29,96
Weight of basic machine (blade rear and front), with attachmen, without grapple appr.
t
35,64
Length overall ( basic machine without attachment )
mm
6147
Width overall
mm
3412
Heigth overall without attachment (cab elevation 800)
mm
4350
Tail radius from center / swing radius
mm
3074
Ground clearance
mm
349
Diesel engine
Type
D 934 L A6
Performance at rated rpm according to DIN IDSO 9249
KW
150 (204 Hp)
Rated rpm
rpm
1800
max. torque
Nm
920 at 1400 rpm
Oil quantity in engine (filling quantity for oil change with filter)
l
29
Drive train
Oil quality / - viscosity and oil change interval
see group 1.50 and 3.83
Coolant quantity including radiator
l
40
Type
DPVP 108
Hydraulic system Hydraulic pump Design
Axial piston swash plate pump
Input rpm
min-1
1800
Max. flow
l/min
2 x 240
Oil quantity in pump distributor gear
l
3,1
Flow / hydraulic pump - pump distributor gear
l/min
13,3
Hydraulic oil quantity (oil change with filter)
l
appr. 350
Hydraulic oil- and filter change interval
see group 1.50 and 3.83
Control valve block
Type
Swing circuit
NG 22 closed circuit
Swing pump
Type
A4V 71 DWD
3.09.1 copyright by
MJFCIFSS
Technical dataA 934 C HD LI Log Loader
Service Manual
Type 1053 Hydraulic system Swing pump / design
Axial piston swash plate pump with attached replenishing pump
Pump performance
KW
80 (108 Hp)
Max. flow
l/min.
148
Replenishing pump flow
l/min.
41
Replenishing pressure
bar
16+2
Hydraulic pump / pilot pressure
Type
gear pump
Max.flow / pilot control
l/min.
45,5
Pressure limitation pilot control
bar
32+1
Pilot valves / attachment / swing circuit
Type
4TH 87 X 70-10
Pilot valve / travel circuit
Type
VG - 7 - 1 / 1
Pilot valve / outrigger
Typ
VG - 5 - 2
further specifications
see group 6.11
Hydraulic pump / fan drive
Type
A 10 VO 28 ED
Max. flow
l/min.
62
Hydraulic motor / fan
Type
A 10 FE 28
Hydraulic pump / opional installation
Type
gear pump
Max. flow
l/min.
24,7
Rotary connection 7-way
Type
DDF 720
Rotary connection 6-way
Type
815.006 B
Hydraulic cylinder
refer to group 7.30
Electrical system Operating voltage
V
24
Battery - capacity
Ah
2 x 170 ( in series )
Alternator voltage / current
A
28V / 80
Starter motor
KW
24V / 6,6
Gearbox
Type
SAT 275 / 255
Oil motor
Type
FMF 64
Swing speed max.
rpm
8,2
Oil quantity in gear box
l
7,0
Swing gear
Oil quality / -viscosity and oil change interval
refer to group 1.50 and 3.83
Swing brake
Typw
wet disk brake (negativ)
Opening pressure max.
bar
20
Further specifications
refer to group 9.10
Axles Oscillating axle
Type
LT 81 PL 488 NLB
Rigid Axle
Type
LT 81 PL 488 NLB
Oil quantity in axle housing of oscillating axle
l
39
3.09.2 copyright by
MJFCIFSS
Service Manual
Technical dataA 934 C HD LI Log Loader Type 1053
Axles Oil quantity in axle housing of rigid axle
l
39
Oil quantity in wheel hub steering axle / rigid axle
l
4,0
Oil quality / -viscosity and oil change interval
refer to group 1.50 and 3.83
Operating brake
Type
Tires
wet disk brake positiv 17.50-25
Transmission Gear box
Type
2 HL 290
Oil motor
Type
DMVA 165
Travel speed in creeper mode 1. gear / 2. gear
Km/h
2,4 / 10
Travel speed in 1. gear / 2. gear
Km/h
4,6 / 20
Oil quantity in gear box
l
3,3
Oil quality, oil viscosity and oil change interval
refer to group 1.50 and 3.83
Parking brake
Type
Further specifications
wet disk brake negativ refer to group 11
Steering Hydraulic pump
Type
gear pump
Flow
l/min
61
Steering valve
Type
7030176
First primary relief valve
bar
220+5
Second primary relief valve
bar
180+5
Secondary relief valve
bar
240+5
Hydraulic pump
Type
gear pump
Flow max.
l/min
2,7
Charge pressure max.
bar
200
Brake pressure max. / operating brake
bar
75+10
cm3
appr. 30
Brake system
Central lubricating system Grease quantity / working hour Cycles / lubrication during automatic greasing (option)
refer to group 18.50
3.09.3 copyright by
MJFCIFSS
Technical dataA 934 C HD LI Log Loader
Service Manual
Type 1053
3.09.4 copyright by
MJFCIFSS
Service Manual
Technical data A 944 C-HD Litronic, 24 475
Technical data 1
A 944 C-HD Litronic, 24 475 Type 194
General Weight of basic machineapprox.
t
46
Weight of basic machine with attachment, without grappleapprox.
t
56
Overall length (basic machine without attachment)
mm
6846
Overall width
mm
3502
Overall height without attachment (operator's cab elevation 1200)
mm
5073
Rear reach from centre/slewing radius
mm
3521
Ground clearance
mm
455
Diesel engine
Type
D 936 L
Power at rated speed according to DIN ISO 9249
kW
190 (255 PS)
Rated speed
rpm
1800
Max. torque
Nm
1200 at 1500 rpm
Drive motor
Oil volume in engine (filling quantity at oil change with filter)
l
40
Pump distribution gear
Type
PVG 351 B 382
Oil volume in pump distribution gear
l
2.5
Flow rate / hydraulic pump - pump distribution gear
l/min
10.5
Oil quality/oil viscosity and oil change intervals
see groups 1.50 and 3.85
Cooling liquid including coolant
l
81
Type
LPVD 150
Hydraulic system Hydraulic pump Design
Axial piston swash plate pump
Hydr. drive power at max. motor output
kW
186 (250 PS)
Input speed
rpm
2025
Max. flow rate
l/min
2 x 303
Hydraulic oil volume (oil change with filter)
l
approx. 460
Hydraulic oil and filter change intervals
see groups 1.50 and 3.85
Control valve block
Type
Slewing gear circuit
NG 22 Closed circuit
Slewing gear pump
Type
Slewing gear pump / type
A4V 71 DWD Swash-plate axial-piston pump with attached feeder pump
Pump performance
kW
112 (150 PS)
3.11.1 copyright by
MJFCIFSS
Technical data
Service Manual
A 944 C-HD Litronic, 24 475 Hydraulic system Max. flow rate
l/min
185
Feeder pump flow rate
l/min
46
Feed pressure
bar
16
Hydraulic pump / pilot control
Type
Gear pump
3
Hydraulic pump / pilot control flow volume
cm
11
Max. flow / pilot control
l/min
31.8
Pressure limitation pilot control
bar
35+2
Pilot control unit / working attachment / slewing gear
Type
4TH 87 Z 70-10
Pilot control unit / travel drive
Type
VG - 7 - 1 / 1
Pilot control unit / support
Type
VG - 5 - 2
Additional information
see group 6.15
Hydraulic pump / fan
Type
A 10 V 28 ED
Max. flow rate
l/min
62
Hydraulic motor / fan
Type
A 10 FE 28
Hydraulic pump / accessory kit
Type
Gear pump
Max. flow rate
l/min
24
Rotary connection 9 x
Type
A 431
Rotary connection 6 x
Type
815.006 B
Hydraulic cylinder
see group 7.30
Electrical system Operating voltage
V
24
Battery capacity
Ah
2 x 170 (in series)
Alternator voltage / current
A
28 V / 80
Starter
kW
24 V / 7.8
Gearbox
Type
SAT 325 / 254
Oil motor
Type
FMF 90
Max. slewing speed
rpm
7.2
Oil volume in gearbox
l
11.0
Slewing gear mechanism
Oil quality /oil viscosity and oil change intervals
see groups 1.50 and 3.85
Slewing gear brake
Type
Wet multi-disc brake (negative)
Max. release pressure
bar
20
Additional information
see group 9.10
Parking brake Parking brake
Type
Wet multi-disc brake (negative)
Max. release pressure
bar
35
Oil quality /oil viscosity and oil change intervals
see groups 1.50 and 3.85
Oil volume in gearbox
l
3.11.2 copyright by
MJFCIFSS
0.25
Service Manual
Technical data A 944 C-HD Litronic, 24 475
Axle gear Oil motor
Type
A 6 VM 200
Travel speed in working gear
kph
11
Travel speed in creeper gear
kph
5
Oil quality /oil viscosity and oil change intervals
see groups 1.50 and 3.85
Axles Steering axle
Type
LT 91 VPL 488
Rigid axle
Type
D 91 VPL 488
Oil volume in steering axle housing
l
43
Oil volume in rigid axle housing
l
38
Oil volume in steering axle / rigid axle wheel hub
l
3.6
Oil quality /oil viscosity and oil change intervals
see groups 1.50 and 3.85
Working brake
Type
Tyres
Disc brake Ă&#x2DC;1500 x 520 wide / solid tyres
Steering Hydraulic pump
Type
Gear pump
Flow rate
l/min
61
Steering valve
Type
7030176
First primary protection
bar
220+5
Second primary protection
bar
180+5
Secondary protection
bar
240+5
Hydraulic pump
Type
Gear pump
Max. flow rate
l/min
2.7
Max. charging pressure
bar
200
Max. brake pressure / working brake
bar
135+10
cm3
approx. 30
Brake system
Central lubrication system Volume of grease per working hour Number of cycles / grease processes with automatic greasing (optional)
see group 18.50
3.11.3 copyright by
MJFCIFSS
Technical data
Service Manual
A 944 C-HD Litronic, 24 475
3.11.4 copyright by
MJFCIFSS
Service Manual
Technical data A 944 C - HD Litronic, from 29 225 log loader
Technical data 1
A 944 C - HD Litronic, from 29 225 log loader Type 196
General Weight of basic machine approx.
t
36
Weight of basic machine with attachment, without grapple approx.
t
43
Overall length (basic machine without attachment)
mm
6835
Overall width
mm
3502
Overall height without attachment (operator's cab elevation 800)
mm
4702
Rear reach from centre/slewing radius
mm
3346
Ground clearance
mm
519
Diesel engine
Type
D 936 L A6
Power at rated speed according to DIN ISO 9249
kW
190 (255 PS)
Rated speed
rpm
1800
Max. torque
Nm
at 1200 rpm
Drive motor
Oil volume in engine (filling quantity at oil change with filter)
l
40
Pump distributor gear
Type
PVG 351 B 382
Oil volume in pump distributor gear
l
2,5
Pump volume / hydraulic pump pump distributor gear
l/min
10,5
Oil quality/oil viscosity and oil change intervals
see groups 1.50 and 3.88
Cooling liquid including coolant
l
81
Type
LPVD 150
Hydraulic system Hydraulic pump Design
Axial piston swash plate pump
Hydraulic drive output at maximum motor power
kW
186 (250 PS)
Input speed
rpm
2025
Max. flow rate
l/min
2 x 303
Hydraulic oil volume (oil change with filter)
l
approx. 460
Hydraulic oil and filter change intervals
see groups 1.50 and 3.88
Control valve block
Type
Slewing gear circuit
NG 22 Closed circuit
Slewing gear pump
Type
Slewing gear pump / design
A4VG 71 DWD Swash plate axial piston pump with attached feed pump
Pump performance
kW
112 (150 PS)
3.13.1 copyright by
MJFCIFSS
Technical data
Service Manual
A 944 C - HD Litronic, from 29 225 Â&#x2013; log loader Hydraulic system Max. flow
l/min. 3
185
Feed pump flow volume
cm
19.6
Feed pump flow rate
l/min.
46
Feed pressure
bar
16
Hydraulic pump / pilot control
Type
Gear pump
3
Hydraulic pump / pilot control flow volume
cm
11
Max. flow / pilot control
l/min.
31.8
Pilot control pressure control
bar
35+2
Pilot control unit / working attachment / slewing gear
Type
4TH 87 Z 70-10
Pilot control unit / travel drive
Type
VG - 7 - 1 / 1
Pilot control unit / support
Type
VG - 5 - 2
Additional information
see group 6.15
Hydraulic pump / fan
Type
A 10 V 28 ED
Max. flow rate
l/min.
62
Hydraulic motor / fan
Type
A 10 FE 28
Hydraulic pump / accessory kit
Type
Gear pump
Max. flow
l/min.
24
Rotary connection 6 x
Type
DDF 720
Rotary connection 6 x
Type
815.006 C
Hydraulic cylinder
see group 7.30
Electrical system Operating voltage
V
24
Battery capacity
Ah
2 x 170 (in series)
Alternator voltage / current
A
28 V / 80
Starter
kW
24 V / 7.8
Gearbox
Type
SAT 325 / 254
Oil motor
Type
FMF 90
Max. slewing speed
rpm
7.2
Oil volume in gearbox
l
11.0
Slewing gear
Oil quality /oil viscosity and oil change intervals
see groups 1.50 and 3.88
Slewing gear brake
Type
Wet multi-disc brake (negative)
Max. opening pressure
bar
20
Additional information
see group 9.10
Transmission Gearbox
Type
2 HL 290
Oil motor
Type
DMVA 165
Travel speed at creeper speed off-road/on-road
kph
3 / 12
3.13.2 copyright by
MJFCIFSS
Service Manual
Technical data A 944 C - HD Litronic, from 29 225 Â&#x2013; log loader
Transmission Travel speed in working gear / on-road gear
kph
6 / 18
Oil volume in gearbox
l
3,3
Oil quality, oil viscosity and oil change intervals
see groups 1.50 and 3.88
Parking brake
Type
Additional information
Wet multi-disc brake (negative) see group 11
Axles Oscillating axle
Type
LT 91 VPL 488
Rigid axle
Type
LT 91 VPL 488
Oil volume in oscillating axle housing
l
47
Oil volume in rigid axle housing
l
50,6
Oil volume in oscillating / rigid axle wheel hub
l
3.6
Oil quality /oil viscosity and oil change intervals
see groups 1.50 and 3.88
Working brake
Type
Tyres
Disc brake 18.00 - 25
Ă&#x2DC;1672 x 512
Steering Hydraulic pump
Type
Gear pump
Flow rate
l/min
61
Steering valve
Type
7030176
First primary protection
bar
220+5
Second primary protection
bar
180+5
Secondary protection
bar
240+5
Hydraulic pump
Type
Gear pump
Max. flow rate
l/min
2.7
Max. charging pressure
bar
200
Max. brake pressure / working brake
bar
135+10
cm3
approx. 30
Brake system
Central lubrication system Volume of grease per working hour Number of cycles / grease processes with automatic greasing (optional)
see group 18.50
3.13.3 copyright by
MJFCIFSS
Technical data
Service Manual
A 944 C - HD Litronic, from 29 225 Â&#x2013; log loader
3.13.4 copyright by
MJFCIFSS
Service Manual
Technical data A 954 C-HD Litronic from 21 416
Technical data 1
A 954 C-HD Litronic from 21 416 Type 450
General Weight of basic machine
approx.
t
59.5
t
73.5
Overall length (basic machine without attachment)
mm
7323
Overall width
mm
3800
Overall height without attachment
mm
5231
Rear reach from centre/slewing radius
mm
3823
Ground clearance
mm
500
Type
D 936 L A 6
Power at rated speed according to DIN ISO 9249
kW
240 (320 PS)
Rated speed
rpm
1800
Max. torque
Nm
2495 at 1000 rpm
l
40
Type
PVG 351 C 391
l
6.5
l/min
10.5
Weight of basic machine with attachment, without grapple approx.
Drive motor Diesel engine
Oil volume in engine (filling quantity at oil change with filter) Pump distribution gear Oil volume in pump distribution gear Flow rate / hydraulic pump - pump distribution gear Oil quality/oil viscosity and oil change intervals
see groups 1.50 and 3.90
Cooling liquid including coolant
l
81
Hydraulic system Hydraulic pump
Type
Design
2 x LPV 165 Axial piston swash plate pump
Hydr. drive power at max. motor output
kW
235 (315 PS)
Input speed
rpm
2169
Max. flow rate
l/min
2 x 357
Hydraulic oil volume (oil change with filter)
l
Hydraulic oil and filter change intervals
approx. 450 see groups 1.50 and 3.90
Control valve block
Type
Slewing gear circuit
NG 32 Closed circuit
Slewing gear pump
Type
Slewing gear pump / type
A4VG 71 DWD swash-plate axial-piston pump with attached feeder pump
Pump performance
kW
142 (190 PS)
3.15.1 copyright by
MJFCIFSS
Technical data
Service Manual
A 954 C-HD Litronic from 21 416 Hydraulic system Max. geomtr. flow volume
cm3
71
Max. flow rate
l/min.
211
3
Feeder pump flow volume
cm
Feeder pump flow rate
l/min.
46
Feed pressure
bar
16
Hydraulic pump / pilot control
Type
Gear pump
Hydraulic pump / pilot controlflow volume
cm3
11
Max. flow / pilot control
l/min.
30
Pressure limitation pilot control
bar
Pilot control unit / working attachment / slewing gear
Type
4TH 87 Z 70-10
Pilot control unit / travel drive
Type
VG - 7 - 1 / 1
Pilot control unit / support
Type
VG - 5 - 2
Additional information
19.6
35+2
see group 6.11
Hydraulic pump / fan
Type
A 10 V 28 ED
Max. flow rate
l/min.
62
Hydraulic motor / fan
Type
A 10 FE 28
Hydraulic pump / accessory kit
Type
Gear pump
Max. flow rate
l/min.
24
Rotary connection 9 x
Type
A 431
Rotary connection 6 x
Type
815.006 B
Hydraulic cylinder
see group 7.30
Electrical system Operating voltage
V
24
Battery capacity
Ah
2 x 170 (in series)
Alternator voltage / current
A
28 V / 80
Starter
kW
24 V / 7.8
Slewing gear mechanism Gearbox
Type
SAT 350 / 252
Oil motor
Type
FMF 100
Max. slewing speed
rpm
7
Oil volume in gearbox
l
11
Oil quality /oil viscosity and oil change intervals
see groups 1.50 and 3.90
Slewing gear brake
Type
Max. release pressure
bar
Additional information
Wet multi-disc brake (negative) 20 see group 9.10
Parking brake Parking brake
Type
Max. release pressure
bar
Oil quality /oil viscosity and oil change intervals
Wet multi-disc brake (negative) 35 see groups 1.50 and 3.90
3.15.2 copyright by
MJFCIFSS
Service Manual
Technical data A 954 C-HD Litronic from 21 416
Oil volume in gearbox
l
0.25
Axle gear Oil motor
Type
A 6 VM 200 HA 1 T
Travel speed working gear / creeper gear
km/h
10 / 5
Oil quality /oil viscosity and oil change intervals
see axles
Axles Steering axle
Type
LT 102 VPL 341 / 528 NLB
Rigid axle
Type
D 102 VPL 341 / 528 NLB
Oil volume in steering axle housing
l
55
Oil volume in rigid axle housing
l
45
Oil volume in steering axle / rigid axle wheel hub
l
9.5
Oil quality /oil viscosity and oil change intervals
see groups 1.50 and 3.90
Working brake
Type
Tyres
Multi-disc brake Ă&#x2DC;1600 x 600 wide / solid tyres
Steering Hydraulic pump
Type
Gear pump
Flow rate
l/min
61
Steering / Servostat
Type
ZF / 2
First primary protection
bar
220+5
Second primary protection
bar
180+5
Secondary protection
bar
240+5
Brake system Hydraulic pump
Type
Gear pump
Max. flow rate
l/min
2.7
Max. charging pressure
bar
200
Max. brake pressure / working brake
bar
135+10
cm3
approx. 30
Central lubrication system Volume of grease per working hour Number of cycles / grease processes with automatic greasing (optional)
see group 18.50
3.15.3 copyright by
MJFCIFSS
Technical data
Service Manual
A 954 C-HD Litronic from 21 416
3.15.4 copyright by
MJFCIFSS
Service Manual
Maintenance and inspection schedule A 934 C Litronic from 28 016
Maintenance and inspection schedule 1
A 934 C Litronic from 28 016 Type 1006 Customer:
Serial no.:
Date:
Machine type:
Operating hours:
Caution! Careful maintenance is only possible, if the machine is clean. Especially visual inspections, e.g. for cracks, can be carried out properly only with a machine that has been cleaned recently. Therefore clean the machine thoroughly before starting any maintenance work (see also chapter "Safe maintenance of machine", subchapters "Cleaning" and "Crack inspection").
Note! The daily maintenance tasks of the machine operator include a functional test of the brakes (slewing gear brake, working brake, parking brake), steering, electrical and hydraulic systems. Also to be carried out is a daily visual inspection of the motor, hydraulic system, gearbox and axles for leakage.
Maintenance/inspection at operating hours
WORK TO BE CARRIED OUT A 934 C Litronic, type 1006 by maintenance personnel (machine operator) Initial and single interval Repeat interval Annually, at the start of the cold season when required
with authorised specialist technician Initial and single interval Repeat interval
DIESEL ENGINE Check the oil level Visual inspection (leakage, dirt, damage) Check oil level in pump distributor gear Replace gear oil in pump distribution gear Check flap of diesel engine brake 1)
Change diesel engine oil (at least once a year) Change oil filter insert (at least once a year) Check batteries and cable connections
3.17.1 copyright by
MJFCIFSS
Maintenance and inspection schedule
Service Manual
A 934 C Litronic from 28 016 Maintenance/inspection at operating hours
WORK TO BE CARRIED OUT A 934 C Litronic, type 1006 by maintenance personnel (machine operator) Initial and single interval Repeat interval Annually, at the start of the cold season when required
with authorised specialist technician Initial and single interval Repeat interval
Belt drive: check belt; replace, if necessary / V-ribbed belt: check tension; adjust, if necessary Check intake and exhaust systems for general condition, fixture and leakage Grease the flywheel ring gear Replace filter insert at the crankcase ventilation Check oil pan, engine bearings and diesel engine support for proper fixture Check / readjust valve play Check heating flange 3000
Check vibration dampers for deformation RADIATOR Check the coolant level Check cooling and heating systems for general condition and leakage Check corrosion inhibitor and antifreeze agent concentration in coolant
3000
Change coolant (at least every 2 years) FUEL SYSTEM Check water separator at the fuel pre-filter and drain off water, if necessary Drain water and deposit from fuel tank
4)
Check fuel system for leakage and general state
4)
Change fuel pre-filter
4)
Change fuel fine filter Bleed fuel system AIR FILTER Check underpressure indicator of the air filter Clean dust removal valve of the air filter Change main element of the dry air filter (according to maintenance indication / annually)
3.17.2 copyright by
MJFCIFSS
Service Manual
Maintenance and inspection schedule A 934 C Litronic from 28 016
Maintenance/inspection at operating hours
WORK TO BE CARRIED OUT A 934 C Litronic, type 1006 by maintenance personnel (machine operator) Initial and single interval Repeat interval Annually, at the start of the cold season when required
with authorised specialist technician Initial and single interval Repeat interval
Change safety element of the dry air filter (at every third main element change / annually) - do not clean or reuse! ELECTRICAL SYSTEM OF THE DIESEL ENGINE Check control device bearing for general condition Check sensor devices and cable connections HYDRAULIC SYSTEM Check oil level in hydraulic tank Clean magnetic rod in return filter (daily during first 300 operating hours) 2)
Replace filter element in bypass filter (optional equipment) (in machines used in dusty environments: every 250 operating hours)
2)
Replace filter insert in return filter Replace filter cartridge in control oil unit Replace feed oil filter on slewing gear pump Check components for proper mounting Check the hydraulic oil cooler for dirt; clean it, if necessary Drain water from hydraulic tank (max. permissible water content for environmentally friendly fluids: 0.1 %; insert bypass filter, take oil sample) Check hydraulic system for leakage; complete functional test Check / readjust servo, primary and secondary pressures
2), 3) 2)
Change hydraulic oil in tank (optimise interval by carrying out oil analyses) Change breather filter on hydraulic tank ELECTRICAL SYSTEM Check indicator lights and indicating devices upon start-up Check lighting Check acid density and level, wire terminals and terminal ports of the batteries Spray slip rings of the slewing gear connection with Cramolin contact spray Carry out functional tests of entire unit and all components
3.17.3 copyright by
MJFCIFSS
Maintenance and inspection schedule
Service Manual
A 934 C Litronic from 28 016 Maintenance/inspection at operating hours
WORK TO BE CARRIED OUT A 934 C Litronic, type 1006 by maintenance personnel (machine operator) Initial and single interval Repeat interval Annually, at the start of the cold season when required
with authorised specialist technician Initial and single interval Repeat interval
SLEWING GEAR MECHANISM Check oil level; check system for leakage Carry out functional test of slewing gear brake Check gearbox and oil motor for proper mounting Change gear oil SLEWING RING Check mounting bolts for press fit; slewing gear pining meshing AXLES Lubricate steering knuckle bearing and oscillating bolts (weekly or monthly, depending on use) Check oil level; check system for leakage Check axles, gears, oil motor, oscillating axle bearing and wheel lugs for proper mounting and retighten, if necessary Change oil in axle housing (front and rear) Change oil in planetary drive (front and rear) Check multi-disc brake for wear (once a year; shorten interval, if necessary) TRANSMISSION Check oil level; check system for leakage Carry out functional test of power shift mechanism and parking brake Check gearbox, oil motor and joint shafts for proper mounting Change gear oil STEERING Check system for leakage; complete functional test Check components and steering system parts for proper mounting
3.17.4 copyright by
MJFCIFSS
Service Manual
Maintenance and inspection schedule A 934 C Litronic from 28 016
Maintenance/inspection at operating hours
WORK TO BE CARRIED OUT A 934 C Litronic, type 1006 by maintenance personnel (machine operator) Initial and single interval Repeat interval Annually, at the start of the cold season when required
with authorised specialist technician Initial and single interval Repeat interval
OSCILLATING AXLE SUPPORT Check system for leakage; complete functional test Check cylinders for proper mounting BRAKE SYSTEM Check system for leakage; check accumulator and brake pressure as well as check switch Carry out functional test OPERATOR'S CAB + HEATING Check / add detergent solution in windscreen washer tank Treat rubber seals of the operatorÂ&#x2019;s cabin with silicone or talcum Treat rubber seals of the access doors on the uppercarriage with silicone or talcum Check function of heating Check heating system for leakage Check door and window hinges as well as locks Check water inlet valve for contamination, and clean, if necessary; carry out functional test of valve AIR-CONDITIONING SYSTEM Regularly switch on air-conditioning system (at least 1x every 14 days) Check condenser for contamination; blow clean, if necessary Clean re-circulated air / fresh air filter; replace, if necessary; shorten interval if there is excessive generation of dust Check compressor mounting bolts and drive belts Check dryer-collector unit (humidity, fill level); replace, if necessary Check evaporator unit; clean, if necessary Check electrical lines for chafe marks; check plug connections Complete functional test of excess pressure switch
3.17.5 copyright by
MJFCIFSS
Maintenance and inspection schedule
Service Manual
A 934 C Litronic from 28 016 Maintenance/inspection at operating hours
WORK TO BE CARRIED OUT A 934 C Litronic, type 1006 by maintenance personnel (machine operator) Initial and single interval Repeat interval Annually, at the start of the cold season when required
with authorised specialist technician Initial and single interval Repeat interval
Check cooling performance Replace dryer-collector unit every 12 months; also check cooling circuit for leakage and change coolant and refrigeration oil Every 12 months, contract a refrigeration technician to carry out a functional test of the air flaps and the defrost thermostat UNDERCARRIAGE + UPPERCARRIAGE + WORKING ATTACHMENTS Lubricate bearing points, using the semi-automatic central lubrication system; exception: not required in units with fully automatic central lubrication system (optional equipment) Lubricate bearing positions (undercarriage and working attachments) Lubricate daily when required due to type of use and/or shift operation Inspect teeth for wear 250
Check parts for cracks
250
Check counter weight and tank for proper mounting Check lines and screwed connections for proper fit Check panelling hinges, quick fasteners and gas pressure springs of the caps Instruct operators in the proper use of the equipment Instruct the operator on how the machine must be lubricated according to the lubricating chart and make him aware of potential operator errors
HYDRAULIC QUICK CHANGE ADAPTER Carry out a functional test of the visual and acoustic warning systems Carry out a visual inspection of the extended locking bolts Check hydraulic hoses and wire harness Lubricate locking bolts Clean mesh filter MECHANICAL QUICK CHANGE ADAPTER Carry out a visual inspection of the extended locking bolts Lubricate locking bolts
3.17.6 copyright by
MJFCIFSS
Service Manual
Maintenance and inspection schedule A 934 C Litronic from 28 016
Maintenance/inspection at operating hours
WORK TO BE CARRIED OUT A 934 C Litronic, type 1006 by maintenance personnel (machine operator) Initial and single interval Repeat interval Annually, at the start of the cold season when required
with authorised specialist technician Initial and single interval Repeat interval
Check entire machine for proper maintenance and orderly condition. Explain machine literature (especially operatorÂ&#x2019;s manual, safety instructions) to the operators. Tab. 1 1 2 3 4
Inspection- and maintenance schedule
The intervals for the change of the motor oil might have to be shortened, depending on the actual temperature, fuel and oil quality. In the case of applications with excessive dust generation, observe shortened maintenance intervals. For environmentally friendly hydraulic fluids, adjust the maintenance interval on the basis of regular analyses. The maintenance intervals might have to be shortened, depending on the operating conditions (e.g. generation of dust, barrel fuelling).
Comments / defects
Date:
Mechanic:
Customer:
3.17.7 copyright by
MJFCIFSS
Maintenance and inspection schedule
Service Manual
A 934 C Litronic from 28 016
3.17.8 copyright by
MJFCIFSS
Service Manual
Maintenance and inspection schedule A 934 C-HD Litronic, 25 436
Maintenance and inspection schedule 1
A 934 C-HD Litronic, 25 436 Type 1007 Customer:
Serial no.:
Date:
Machine type:
Operating hours:
Caution! Careful maintenance is only possible, if the machine is clean. Especially visual inspections, e.g. for cracks, can be carried out properly only with a machine that has been cleaned recently. Therefore clean the machine thoroughly before starting any maintenance work (see also chapter "Safe maintenance of machine", subchapters "Cleaning" and "Crack inspection").
Note! The daily maintenance tasks of the machine operator include a functional test of the brakes (slewing gear brake, working brake, parking brake), steering, electrical and hydraulic systems. Also to be carried out is a daily visual inspection of the motor, hydraulic system, gearbox and axles for leakage.
Maintenance/inspection at operating hours
WORK TO BE CARRIED OUT A 934 C Litronic, type 1007 by maintenance personnel (machine operator) Initial and single interval Repeat interval Annually, at the start of the cold season when required
with authorised specialist technician Initial and single interval Repeat interval
DIESEL ENGINE Check the oil level Visual inspection (leakage, dirt, damage) Check oil level in pump distributor gear Replace gear oil in pump distribution gear Check flap of diesel engine brake 1)
Change diesel engine oil (at least once a year) Change oil filter insert (at least once a year) Check batteries and cable connections
3.19.1 copyright by
MJFCIFSS
Maintenance and inspection schedule
Service Manual
A 934 C-HD Litronic, 25 436 Maintenance/inspection at operating hours
WORK TO BE CARRIED OUT A 934 C Litronic, type 1007 by maintenance personnel (machine operator) Initial and single interval Repeat interval Annually, at the start of the cold season when required
with authorised specialist technician Initial and single interval Repeat interval
Belt drive: check belt; replace, if necessary / V-ribbed belt: check tension; adjust, if necessary Check intake and exhaust systems for general condition, fixture and leakage Grease the flywheel ring gear Replace filter insert at the crankcase ventilation Check oil pan, engine bearings and diesel engine support for proper fixture Check / readjust valve play Check heating flange 3000
Check vibration dampers for deformation RADIATOR Check the coolant level Check cooling and heating systems for general condition and leakage Check corrosion inhibitor and antifreeze agent concentration in coolant
3000
Change coolant (at least every 2 years) FUEL SYSTEM Check water separator at the fuel pre-filter and drain off water, if necessary Drain water and deposit from fuel tank
4)
Check fuel system for leakage and general state
4)
Change fuel pre-filter
4)
Change fuel fine filter Bleed fuel system AIR FILTER Check underpressure indicator of the air filter Clean dust removal valve of the air filter Change main element of the dry air filter (according to maintenance indication / annually)
3.19.2 copyright by
MJFCIFSS
Service Manual
Maintenance and inspection schedule A 934 C-HD Litronic, 25 436
Maintenance/inspection at operating hours
WORK TO BE CARRIED OUT A 934 C Litronic, type 1007 by maintenance personnel (machine operator) Initial and single interval Repeat interval Annually, at the start of the cold season when required
with authorised specialist technician Initial and single interval Repeat interval
Change safety element of the dry air filter (at every third main element change / annually) - do not clean or reuse! ELECTRICAL SYSTEM OF THE DIESEL ENGINE Check control device bearing for general condition Check sensor devices and cable connections HYDRAULIC SYSTEM Check oil level in hydraulic tank Clean magnetic rod in return filter (daily during first 300 operating hours) 2)
Replace filter element in bypass filter (optional equipment) (in machines used in dusty environments: every 250 operating hours)
2)
Replace filter insert in return filter Replace filter cartridge in control oil unit Replace feed oil filter on slewing gear pump Check components for proper mounting Check the hydraulic oil cooler for dirt; clean it, if necessary Drain water from hydraulic tank (max. permissible water content for environmentally friendly fluids: 0.1 %; insert bypass filter, take oil sample) Check hydraulic system for leakage; complete functional test Check / readjust servo, primary and secondary pressures
2), 3) 2)
Change hydraulic oil in tank (optimise interval by carrying out oil analyses) Change breather filter on hydraulic tank ELECTRICAL SYSTEM Check indicator lights and indicating devices upon start-up Check lighting Check acid density and level, wire terminals and terminal ports of the batteries Spray slip rings of the slewing gear connection with Cramolin contact spray Carry out functional tests of entire unit and all components
3.19.3 copyright by
MJFCIFSS
Maintenance and inspection schedule
Service Manual
A 934 C-HD Litronic, 25 436 Maintenance/inspection at operating hours
WORK TO BE CARRIED OUT A 934 C Litronic, type 1007 by maintenance personnel (machine operator) Initial and single interval Repeat interval Annually, at the start of the cold season when required
with authorised specialist technician Initial and single interval Repeat interval
SLEWING GEAR MECHANISM Check oil level; check system for leakage Carry out functional test of slewing gear brake Check gearbox and oil motor for proper mounting Change gear oil SLEWING RING Check mounting bolts for press fit; slewing gear pining meshing AXLES Lubricate steering knuckle bearing and oscillating bolts (weekly or monthly, depending on use) Check oil level; check system for leakage Check axles, gears, oil motor, oscillating axle bearing and wheel lugs for proper mounting and retighten, if necessary Change oil in axle housing (front and rear) Change oil in planetary drive (front and rear) Check multi-disc brake for wear (once a year; shorten interval, if necessary) TRANSMISSION Check oil level; check system for leakage Carry out functional test of power shift mechanism and parking brake Check gearbox, oil motor and joint shafts for proper mounting Change gear oil STEERING Check system for leakage; complete functional test Check components and steering system parts for proper mounting
3.19.4 copyright by
MJFCIFSS
Service Manual
Maintenance and inspection schedule A 934 C-HD Litronic, 25 436
Maintenance/inspection at operating hours
WORK TO BE CARRIED OUT A 934 C Litronic, type 1007 by maintenance personnel (machine operator) Initial and single interval Repeat interval Annually, at the start of the cold season when required
with authorised specialist technician Initial and single interval Repeat interval
OSCILLATING AXLE SUPPORT Check system for leakage; complete functional test Check cylinders for proper mounting BRAKE SYSTEM Check system for leakage; check accumulator and brake pressure as well as check switch Carry out functional test OPERATOR'S CAB + HEATING Check / add detergent solution in windscreen washer tank Treat rubber seals of the operatorÂ&#x2019;s cabin with silicone or talcum Treat rubber seals of the access doors on the uppercarriage with silicone or talcum Check function of heating Check heating system for leakage Check door and window hinges as well as locks Check water inlet valve for contamination, and clean, if necessary; carry out functional test of valve AIR-CONDITIONING SYSTEM Regularly switch on air-conditioning system (at least 1x every 14 days) Check condenser for contamination; blow clean, if necessary Clean re-circulated air / fresh air filter; replace, if necessary; shorten interval if there is excessive generation of dust Check compressor mounting bolts and drive belts Check dryer-collector unit (humidity, fill level); replace, if necessary Check evaporator unit; clean, if necessary Check electrical lines for chafe marks; check plug connections Complete functional test of excess pressure switch
3.19.5 copyright by
MJFCIFSS
Maintenance and inspection schedule
Service Manual
A 934 C-HD Litronic, 25 436 Maintenance/inspection at operating hours
WORK TO BE CARRIED OUT A 934 C Litronic, type 1007 by maintenance personnel (machine operator) Initial and single interval Repeat interval Annually, at the start of the cold season when required
with authorised specialist technician Initial and single interval Repeat interval
Check cooling performance Replace dryer-collector unit every 12 months; also check cooling circuit for leakage and change coolant and refrigeration oil Every 12 months, contract a refrigeration technician to carry out a functional test of the air flaps and the defrost thermostat UNDERCARRIAGE + UPPERCARRIAGE + WORKING ATTACHMENTS Lubricate bearing points, using the semi-automatic central lubrication system; exception: not required in units with fully automatic central lubrication system (optional equipment) Lubricate bearing positions (undercarriage and working attachments) Lubricate daily when required due to type of use and/or shift operation Inspect teeth for wear 250
Check parts for cracks
250
Check counter weight and tank for proper mounting Check lines and screwed connections for proper fit Check panelling hinges, quick fasteners and gas pressure springs of the caps Instruct operators in the proper use of the equipment Instruct the operator on how the machine must be lubricated according to the lubricating chart and make him aware of potential operator errors HYDRAULIC QUICK CHANGE ADAPTER Carry out a functional test of the visual and acoustic warning systems Carry out a visual inspection of the extended locking bolts Check hydraulic hoses and wire harness Lubricate locking bolts Clean mesh filter
MECHANICAL QUICK CHANGE ADAPTER Carry out a visual inspection of the extended locking bolts Lubricate locking bolts
3.19.6 copyright by
MJFCIFSS
Service Manual
Maintenance and inspection schedule A 934 C-HD Litronic, 25 436
Maintenance/inspection at operating hours
WORK TO BE CARRIED OUT A 934 C Litronic, type 1007 by maintenance personnel (machine operator) Initial and single interval Repeat interval Annually, at the start of the cold season when required
with authorised specialist technician Initial and single interval Repeat interval
Check entire machine for proper maintenance and orderly condition. Explain machine literature (especially operatorÂ&#x2019;s manual, safety instructions) to the operators. Tab. 1 1 2 3 4
Inspection- and maintenance schedule
The intervals for the change of the motor oil might have to be shortened, depending on the actual temperature, fuel and oil quality. In the case of applications with excessive dust generation, observe shortened maintenance intervals. For environmentally friendly hydraulic fluids, adjust the maintenance interval on the basis of regular analyses. The maintenance intervals might have to be shortened, depending on the operating conditions (e.g. generation of dust, barrel fuelling).
Comments / defects
Date:
Mechanic:
Customer:
3.19.7 copyright by
MJFCIFSS
Maintenance and inspection schedule
Service Manual
A 934 C-HD Litronic, 25 436
3.19.8 copyright by
MJFCIFSS
Service Manual
Maintenance and inspection schedule A 934 C-HD Litronic, 31793 - log loader
Maintenance and inspection schedule 1
A 934 C-HD Litronic, 31793 - log loader Type 1053 Customer:
Serial no.:
Date:
Machine type:
Operating hours:
Caution! Careful maintenance is only possible, if the machine is clean. Especially visual inspections, e.g. for cracks, can be carried out properly only with a machine that has been cleaned recently. Therefore clean the machine thoroughly before starting any maintenance work (see also chapter "Safe maintenance of machine", subchapters "Cleaning" and "Crack inspection").
Note! The daily maintenance tasks of the machine operator include a functional test of the brakes (slewing gear brake, working brake, parking brake), steering, electrical and hydraulic systems. Also to be carried out is a daily visual inspection of the motor, hydraulic system, gearbox and axles for leakage.
Maintenance/inspection at operating hours
WORK TO BE CARRIED OUT A 934 C-HD Litronic, type 1053 by maintenance personnel (machine operator)
with authorised specialist technician
Initial and single interval Repeat interval Annually, at the start of the cold season when required
Initial and single interval Repeat interval
DIESEL ENGINE Check oil level Visual inspection (leakage, dirt, damage) Check oil level in pump distributor gear Replace gear oil in pump distribution gear Check flap of diesel engine brake 1)
Change diesel engine oil (at least once a year) Change oil filter insert (at least once a year) Check batteries and cable connections
3.21.1 copyright by
MJFCIFSS
Maintenance and inspection schedule
Service Manual
A 934 C-HD Litronic, 31793 - log loader Maintenance/inspection at operating hours
WORK TO BE CARRIED OUT A 934 C-HD Litronic, type 1053 by maintenance personnel (machine operator) Initial and single interval Repeat interval Annually, at the start of the cold season when required
with authorised specialist technician Initial and single interval Repeat interval
Belt drive: Check belt; replace, if necessary / V-ribbed belt: check tension; adjust, if necessary Check intake and exhaust systems for general condition, fixture and leakage Grease the flywheel ring gear Replace filter insert at the crankcase ventilation Check oil pan, engine bearings and diesel engine support for proper fixture Check / readjust valve play Check heating flange 3000
Check vibration dampers for deformation RADIATOR Checking the coolant level Check cooling and heating systems for general condition and leakage Check corrosion inhibitor and antifreeze agent concentration in coolant
3000
Change coolant (at least every 2 years) FUEL SYSTEM Check water separator at the fuel pre-filter and drain off water, if necessary Drain water and deposit from fuel tank
4)
Check fuel system for leakage and general state
4)
Change fuel pre-filter
4)
Change fuel fine filter Bleed fuel system AIR FILTER Check underpressure indicator of the air filter Clean dust removal valve of the air filter Change main element of the dry air filter (according to maintenance indication / annually)
3.21.2 copyright by
MJFCIFSS
Service Manual
Maintenance and inspection schedule A 934 C-HD Litronic, 31793 - log loader
Maintenance/inspection at operating hours
WORK TO BE CARRIED OUT A 934 C-HD Litronic, type 1053 by maintenance personnel (machine operator)
with authorised specialist technician
Initial and single interval Repeat interval Annually, at the start of the cold season when required
Initial and single interval Repeat interval
Change safety element of the dry air filter (at every third main element change / annually) - do not clean or reuse! ELECTRICAL SYSTEM OF THE DIESEL ENGINE Check control device bearing for general condition Check sensor devices and cable connections HYDRAULIC SYSTEM Check oil level in hydraulic tank Clean magnetic rod in return filter (daily during first 300 operating hours) 2)
Replace filter element in bypass filter (optional equipment) (in machines used in dusty environments: every 250 operating hours)
2)
Replace filter insert in return filter Replace filter cartridge in control oil unit Replace feed oil filter on slewing gear pump Check components for proper mounting Check the hydraulic oil cooler for dirt; clean it, if necessary Drain water from hydraulic tank (max. permissible water content for environmentally friendly fluids: 0.1 %; insert bypass filter, take oil sample) Check hydraulic system for leakage; complete functional test Check / readjust servo, primary and secondary pressures
2), 3) 2)
Change hydraulic oil in tank (optimise interval by carrying out oil analyses) Change breather filter on hydraulic tank ELECTRICAL SYSTEM Check indicator lights and indicating devices upon start-up Check lighting Check acid density and level, wire terminals and terminal ports of the batteries Spray slip rings of the slewing gear connection with Cramolin contact spray Carry out functional tests of entire unit and all components
3.21.3 copyright by
MJFCIFSS
Maintenance and inspection schedule
Service Manual
A 934 C-HD Litronic, 31793 - log loader Maintenance/inspection at operating hours
WORK TO BE CARRIED OUT A 934 C-HD Litronic, type 1053 by maintenance personnel (machine operator)
with authorised specialist technician
Initial and single interval Repeat interval Annually, at the start of the cold season when required
Initial and single interval Repeat interval
SLEWING GEAR MECHANISM Check oil level; check system for leakage Carry out functional test of slewing gear brake Check gearbox and oil motor for proper mounting Change gear oil SLEWING RING Check mounting bolts for press fit; slewing gear pining meshing AXLES Lubricate steering knuckle bearing and oscillating bolts (weekly or monthly, depending on use) Check oil level; check system for leakage Check wheel lugs for proper fit (uniquely at 50, 100 and 250 working hours Â&#x2013; and after every wheel change or loosening of the wheel lugs) Check fixture of the axles and oscillating axle bearing Change oil in axle housing (front and rear) Change oil in planetary drive (front and rear) Check multi-disc brake for wear (once a year; shorten interval, if necessary) TRANSMISSION Check oil level; check system for leakage Carry out functional test of power shift mechanism and parking brake Check gearbox, oil motor and joint shafts for proper mounting Change gear oil STEERING Check system for leakage; complete functional test Check components and steering system parts for proper mounting
3.21.4 copyright by
MJFCIFSS
Service Manual
Maintenance and inspection schedule A 934 C-HD Litronic, 31793 - log loader
Maintenance/inspection at operating hours
WORK TO BE CARRIED OUT A 934 C-HD Litronic, type 1053 by maintenance personnel (machine operator)
with authorised specialist technician
Initial and single interval Repeat interval Annually, at the start of the cold season when required
Initial and single interval Repeat interval
OSCILLATING AXLE SUPPORT Check system for leakage; complete functional test Check cylinders for proper mounting BRAKE SYSTEM Check system for leakage; check accumulator and brake pressure as well as check switch Carry out functional test OPERATOR'S CAB + HEATING Check / add detergent solution in windscreen washer tank Treat rubber seals of the operatorÂ&#x2019;s cabin with silicone or talcum Treat rubber seals of the access doors on the uppercarriage with silicone or talcum Check function of heating Check heating system for leakage Check door and window hinges as well as locks Treat rubber seals of the operatorÂ&#x2019;s cab with silicone or talcum Treat rubber seals of the covers on the uppercarriage with silicone or talcum Check water inlet valve for contamination, and clean, if necessary; carry out functional test of valve AIR-CONDITIONING SYSTEM Regularly switch on air-conditioning system (at least 1x every 14 days) Check condenser for contamination; blow clean, if necessary Clean re-circulated air / fresh air filter; replace, if necessary; shorten interval if there is excessive generation of dust Check compressor mounting bolts and drive belts Check dryer-collector unit (humidity, fill level); replace, if necessary Check evaporator unit; clean, if necessary
3.21.5 copyright by
MJFCIFSS
Maintenance and inspection schedule
Service Manual
A 934 C-HD Litronic, 31793 - log loader Maintenance/inspection at operating hours
WORK TO BE CARRIED OUT A 934 C-HD Litronic, type 1053 by maintenance personnel (machine operator) Initial and single interval Repeat interval Annually, at the start of the cold season when required
with authorised specialist technician Initial and single interval Repeat interval
Check electrical lines for chafe marks; check plug connections Complete functional test of excess pressure switch Check cooling performance Replace dryer-collector unit every 12 months; also check cooling circuit for leakage and change coolant and refrigeration oil Every 12 months, contract a refrigeration technician to carry out a functional test of the air flaps and the defrost thermostat UNDERCARRIAGE + UPPERCARRIAGE + WORKING ATTACHMENTS Lubricate bearing points, using the semi-automatic central lubrication system; exception: not required in units with fully automatic central lubrication system (optional equipment) Lubricate bearing positions (undercarriage and working attachments) Lubricate daily when required due to type of use and/or shift operation Inspect teeth for wear 250
Check parts for cracks
250
Check counter weight and tank for proper mounting Check lines and screwed connections for proper fit Check panelling hinges, quick fasteners and gas pressure springs of the caps Instruct operators in the proper use of the equipment Instruct the operator on how the machine must be lubricated according to the lubricating chart and make him aware of potential operator errors HYDRAULIC QUICK CHANGE ADAPTER Carry out a functional test of the visual and acoustic warning systems Carry out a visual inspection of the extended locking bolts Check hydraulic hoses and wire harness Lubricate locking bolts Clean mesh filter MECHANICAL QUICK CHANGE ADAPTER Carry out a visual inspection of the extended locking bolts
3.21.6 copyright by
MJFCIFSS
Service Manual
Maintenance and inspection schedule A 934 C-HD Litronic, 31793 - log loader
Maintenance/inspection at operating hours
WORK TO BE CARRIED OUT A 934 C-HD Litronic, type 1053 by maintenance personnel (machine operator) Initial and single interval Repeat interval Annually, at the start of the cold season when required
with authorised specialist technician Initial and single interval Repeat interval
Lubricate locking bolts
Check entire machine for proper maintenance and orderly condition. Explain machine literature (especially operatorÂ&#x2019;s manual, safety instructions) to the operators. Tab. 1 1 2 3 4
Inspection and maintenance schedule
The intervals for the change of the motor oil might have to be shortened, depending on the actual temperature, fuel and oil quality. In the case of applications with excessive dust generation, observe shortened maintenance intervals. For environmentally friendly hydraulic fluids, adjust the maintenance interval on the basis of regular analyses. The maintenance intervals might have to be shortened, depending on the operating conditions (e.g. generation of dust, barrel fuelling).
Comments / defects
Date:
Mechanic:
Customer:
3.21.7 copyright by
MJFCIFSS
Maintenance and inspection schedule
Service Manual
A 934 C-HD Litronic, 31793 - log loader
3.21.8 copyright by
MJFCIFSS
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