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Technical documentation

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Technical documentation

Hydraulic excavator

R 924 Compact Tier III

Issue: 01/2011
Valid for: R 924 Compact Tier III

Manufacturer: LIEBHERR France S.A.S.


Type: 1055 / 1056
1083 Tunnel
Conformity: CE

R 924 Compact Tier III


copyright by

MJFCIFSS
Service Manual

1 General information

2 Tools

3 Technical data / Maintenance guidelines

4 Engine

5 Coupling / Splitterbox

6 Hydraulic system

7 Hydraulic components

8 Electrical system

9 Swing gear

10 Swing ring

11 Travel gear

12 Track components

13

14

15

16 Options

17 Cab / Heater / Air conditioning system

18 Central lubrication

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MJFCIFSS
Service Manual

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

Symbols used in this manual


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

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

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

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

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

Signification of specific punctuation marks in descriptions


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

About the contain of this Service Handbuchs


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

MJFCIFSS
Service Manual

This manual shall be amended without prior notice to reflect new technical developments and
machine series. LIEBHERR reserves the right to make minor technical amendments to the machines
that might not be reflected in the accompanying documentation.
This manual might be complemented by additional service information sheets issued by LIEBHERR.
This manual has been compiled and published by the Technical Documentation Department of
LIEBHERR-FRANCE SAS 68005 Colmar cedex.
We hope that the information in this documentation, aimed at improving the service of LIEBHERR
excavators, is useful to you.

Structuration of our Service Manuals


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

Example
7. = Main Group «Hydraulic com-
Main Group ponents»
12. = Sub Group «Variable Flow
Sub Group Hydraulic Pump - Type LPVD»
14. = Page «Adjustment for Varia-
Number of the Page in Sub Group ble Flow Hydraulic Pump LPVD»

7. 12. 14
The main groups are listed in the table of contents at the beginning of the book.
The subgroups are listed on a subgroup index, on the first page of each main group section. This
subgroup index also includes the indication of machines modells, types and serial number to which
the subgroup is relevant.

MJFCIFSS
Technical documentation

Group 1: General Information

Safety instructions, Signs on the machine ..........................................................................1.10


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

Tightening torques .................................................................................................................1.20


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

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


1 Application and purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.22.1
2 Requirements / description of procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.22.1
2.1 Tightening with assembly wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.22.2
2.2 Tightening with hydraulic assembly device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.22.4
3 Torque table - Status 02.06.2010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.22.7
3.1 Tightening with assembly wrench (siehe Kap. 2.1, ”Tightening with assembly wrench” auf Seite 2) .
1.22.7
3.2 Tightening with hydraulic assembly device (siehe Kap. 2.2, ”Tightening with hydraulic assembly de-
vice” auf Seite 4)1.22.9

Assembly instruction for piston rod bearings with external threads (hydraulic cylinders) ..
1.24
1 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.24.1
1.1 Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.24.1
2 Tightening torques for factory standard (02.07.2008) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.24.3

Lubricants and operating fluids............................................................................................1.51


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

R 924 Compact Tier III 1.00.1


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MJFCIFSS
Technical documentation

6Coolant for the diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.51.6


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

1.00.2 R 924 Compact Tier III


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

Group 1: General Information

1.10: Safety instructions, Signs on the machine


Working with the machine holds dangers to which you as the owner, machine operator or mainte-
nance expert could be exposed. If you regularly read and note the safety information, however, you
can prevent danger and accidents. This is particularly true for those who are only occasionally in con-
tact with the machine, eg. for maintenance work. The following information comprises safety regula-
tions which, if followed conscientiously, will guarantee your safety and that of other persons, as well
as avoiding damage to the machine.
Following these precautions does not release you from the responsibility to take note of safety regu-
lations which apply on site or of guidelines given by legal bodies or professional associations.
For EU countries, guideline 89 / 655 / EEC contains the minimum safety information applicable to the
owner.

1 Meaning of the symbols in this manual


Work processes and actions that could cause danger are accompanied by safety informations in
these operating instructions. These safety informations describe various dangers which are
emphasized by the terms Danger, Caution and Note.
These terms are identified by symbols in the operating instructions and have the following meaning:

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

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

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

– This symbol identifies a listing.


• This symbol identifies a sub-listing.

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


The machine operator or the maintenance personnel must first fulfil the precondition described,
i e. the machine must be brought into a particular work position in order to be able to carry out the
actions subsequently described.
This symbol identifies an action.
The machine operator or the maintenance personnel should be active at this location and carry
out the action described.
This symbol means “Carry out an activity".
If the machine operator or maintenance personnel have carried out the activities described in an
action, the result of this action will be described here.

R 924 Compact Tier III 1.10.1


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MJFCIFSS
Safety instructions, Signs on the machine Technical documentation
Bestimmungsgemäße Verwendung

Following these notes does not relieve you of responsibility for following additional rules and
guidelines!
Additional points that should be noted are:
– the safety regulations which apply on site,
– statutory road traffic regulations,
– the guidelines provided by professional associations.

2 Bestimmungsgemäße Verwendung
– Der Hydraulikbagger ist eine Maschine mit Arbeitseinrichtung (z. B. Tieflöffel, Greifer, Lade-
schaufel) zum Lösen, Aufnehmen, Transportieren und Abschütten von Erdreich, Gestein und an-
deren Materialien, wobei der Transport des Ladeguts vorwiegend ohne Verfahren der Maschine
erfolgt. Das Verfahren der Maschine mit Ladegut hat unter Beachtung der sicherheitstechnischen
Maßgaben (siehe Abschnitt “Hinweise für ein sicheres Arbeiten”) zu erfolgen.
– Maschinen im Hebezeugeinsatz unterliegen besonderen Bedingungen und müssen mit den vor-
geschriebenen Sicherheitseinrichtungen versehen sein (siehe Abschnitt “Hebezeugeinsatz“).
– Maschinen im Untertageeinsatz (Untertagebergbau und Tunnelbau) in nicht explosionsgefährde-
ter Umgebung müssen mit Technologien zur Abgasreduzierung (z.B. Dieselpartikelfilter) ausges-
tattet sein. Einzelstaatliche Anforderungen sind hierbei zu beachten.
– Besondere Einsätze erfordern spezielle Ausrüstungen und eventuell spezielle Sicherheitseinrich-
tungen. Diese Ausrüstungen dürfen nur nach Genehmigung und den Maßgaben des Grundg-
eräteherstellers angebaut und benutzt werden.
– Eine andere oder darüber hinausgehende Benutzung wie z.B. der Transport von Personen oder
das Arbeiten in explosionsgefährdeter sowie kontaminierter Umgebung gilt als nicht bestim-
mungsgemäß. Für hieraus resultierende Schäden haftet der Hersteller nicht. Das Risiko trägt al-
lein der Anwender.
– Die Beachtung der Betriebsanleitung und die Einhaltung der Inspektions- und Wartungsanleitun-
gen gehört ebenfalls zur bestimmungsgemäßen Verwendung.

3 Safety Instructions

General safety instructions


– Please familiarize yourself with the operating instructions before starting up the machine.
– Ensure that you have obtained, read and understood any additional instructions relating to special
accessories for the machine.
– Only specifically authorized persons may operate, maintain or repair the machine. The legal min-
imum age is to be adhered to.
– Only employ trained or appropriately instructed personnel. Clearly establish which personnel are
responsible for operating, setting up, maintaining and repairing the machine. Give personnel the
power to refuse to carry out unsafe instructions by third parties. This also applies in relation to traf-
fic regulations.
– Only permit apprentices and personnel who are in training or who have only general training to
operate on the machine under the constant supervision of an experienced member of staff.
– As far as possible, monitor personnel to ensure that they are adhering to safe working practices,
are aware of risks and are observing the operating instructions.
– Always wear safe work clothes when you are working on or with the machine. Avoid wearing rings,
wrist watches, ties, scarves, open jackets, baggy clothing etc... There is a risk of injury from, for
example, getting caught up or being drawn in.
– For specific jobs wear individual protective equipment (protective goggles, safety helmets, safety
shoes and gloves, reflective vests and ear protection etc...)..
– Ensure that you obtain information on any special safety regulations for the job site from the site
foreman.

1.10.2 R 924 Compact Tier III


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MJFCIFSS
Technical documentation Safety instructions, Signs on the machine
Safety Instructions

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

Avoidance of crushing and burns


– Do not work beneath the equipment if it is not safely positioned on the ground or supported.
– Do not use any damaged or insufficient load-bearing take-up materials, such as ropes or chains.
– Wear work gloves when working with wire cables.
– When working on the equipment, never use your fingers to locate bores; use the correct punch for
the procedure.
– Ensure that no objects enter the fan when the engine is on. The fan will eject or destroy these
objects and will itself be damaged.
– The engine cooling system is hot and pressurized when near operating temperature. Avoid com-
ing into contact with coolant carrying parts. There is a risk of sustaining burns.
– Only check the coolant when the sealing cap of the expansion container has cooled to a point
where it is possible to touch it. Then turn the cap carefully to let off the overpressure.
– Engine and hydraulic oil, as well the engine exhaust system are hot when near operating temper-
ature. Avoid coming into contact with hot oil or oil-bearing parts and with parts of the exhaust sys-
tem.
– Wear protective goggles and gloves when working on the battery. Avoid sparks and naked flames.
– Never permit the grab to be guided by hand by auxiliary personnel.
– When reaching into the engine compartment, always secure the side doors against unintentional
closing by positioning the supports provided for this purpose.

R 924 Compact Tier III 1.10.3


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MJFCIFSS
Safety instructions, Signs on the machine Technical documentation
Safety Instructions

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

Avoidance of fire and explosions


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

Sichere Inbetriebnahme der Maschine


– Machen Sie vor jeder Inbetriebnahme einen gründlichen Inspektionsrundgang um die Maschine.
– Vergewissern Sie sich, dass niemand, außer zu Ihnen Anschlagtätigkeit Beaufträgter, sich im Ar-
beits- und Bewegungsbereich der Maschine findet.
– Kontrollieren Sie die Maschine auf lose Bolzen, Risse, Verschleiß, Undichtigkeiten und mutwillige
Beschädigungen.
– Nehmen Sie niemals eine schadhafte Maschine in Betrieb.
– Sorgen Sie dafür, dass Schäden sofort beseitigt werden.
– Vergewissern Sie sich, dass alle Hauben und Deckel geschlossen sind, die Schlösser jedoch
nicht abgesperrt werden, um im Falle eines Brandes, die Feuerbekämpfung zu erleichtern.
– Vergewissern Sie sich, dass alle Warnschilder vorhanden sind.
– Sorgen Sie für saubere Fensterscheiben und Innen- und Außenspiegel. Sichern Sie Türen und
Fenster gegen ungewollte Bewegungen.
– Vergewissern Sie sich, dass niemand auf oder unter der Maschine arbeitet und warnen Sie die
umstehenden Personen vor der Inbetriebnahme der Maschine durch Betätigen der Hupe.

Safely getting up
– Before getting up or down to the cab of the machine, position the machine on even, horizontal
ground. Position the upper structure with the undercarriage in such a way that the steps and lad-
ders are aligned with each other.
– Ensure that steps, ladders and hand-rails (grips) are in good condition. In particular, ensure that
they are free of dirt, oil, ice and snow.

1.10.4 R 924 Compact Tier III


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MJFCIFSS
Technical documentation Safety instructions, Signs on the machine
Safety Instructions

– To assure that the cab door opens easily in all weather conditions, the door seals must be dusted
with talc or silicon at least every two months or more often if required. The door hinges and locks
should be greased regularly.
– Face the machine when getting up or down and always adopt three-point support method, i.e. two
hands and one foot or two feet and one hand must always be in contact with the access system
at the same time.
– As soon as you can reach the door handle with your free hand, unlock the door as necessary and
open it, while paying attention to remain out of its swing radius before you climb any higher. Ex-
ternal influences, such as wind, can make it more difficult to open doors.
Because of this, always lead along the door with your hand during the whole opening motion. En-
sure that the door locks in place when reaching its open position, so to prevent it can slam open
and shut.
– Now continue to climb up, still using the three-point support and sit down in the operator’s seat as
soon as you enter the cab.
– Close the door and fasten the safety belt, unlock the door using the destined lever,
Close the door thereafter using the both handholds mounted to the inner face of the door frame.
Only after it tilt down the safety lever, and start the machine.
– It is essential to fasten your safety belt if you wish to work with the door open.
– For the excavators mounted on a special support or employed as a component of a larger instal-
lation (uppercarriage used on a pontoon, on a gantry crane,...), also consider the safety instruc-
tions in to the operator’s manual of the complete machine relating to a safe getting up.

Adjusting the operator’s standing position


– Before starting the machine, adjust the seat, mirrors, armrests and operator’s controls in such a
way that you are able to work comfortably and safely.
– Acoustic insulation devices on the machine must be set to the insulation position throughout op-
eration.

Protection from vibration - seat adjusting


– Keep the seat in good condition and adjust it as follows:
• The seat and its damping action should be adjusted depending on the weight and height of the
operator.
• Check the seat’s damping action and adjustment mechanisms regularly and ensure that these
seat characteristics remain as per the seat manufacturer’s instructions.

Utilisation in confined spaces


– Only operate combustion engines and fuel-operated heaters in adequately ventilated spaces. Be-
fore starting in closed areas, ensure adequate ventilation.
Follow the regulations which apply for the particular area of use.

Starting the machine safely


– Before starting, check all control lamps and instruments for correct function, place all operator’s
controls in Neutral and tilt the safety lever up.
– Before starting, sound the horn briefly to alert people in the vicinity of the machine.
– Only start the machine from the driver’s seat.
– In the absence of any other instructions, start the engine in accordance with the regulations given
in the operating instructions.
– Tilt the safety lever down and then test all display and checking devices.
– In enclosed spaces, only allow the engine to run when there is adequate ventilation. If necessary,
open doors and windows to ensure sufficient fresh air supplies.
– Bring the engine and hydraulic oil to operating temperature. Low oil temperatures make the con-
trol unit react sluggishly.
– Check that the equipment is operating correctly.

R 924 Compact Tier III 1.10.5


copyright by

MJFCIFSS
Safety instructions, Signs on the machine Technical documentation
Safety Instructions

– Move the machine carefully to an open area and then check the function of the running and slew-
ing gear brakes, the steering and the signaling and lighting devices.

Stopping the machine safely


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

Safely getting down


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

Working safely with the machine


– Before you start working, acquaint yourself with the special features of the job site and any special
precautions and warning signals. Examples of particular work environments would be on-site or
traffic obstructions, the load-carrying capacity of the ground and any requirements to make the job
site safe from public use.
– Always maintain a safe distance from overhangs, edges, slopes and unsafe ground.
– Be particularly careful in conditions of reduced visibility and changeable ground conditions.
– Familiarize yourself with the location of power lines on the job site and take particular care when
working near them. If necessary, inform the responsible authorities.
– Maintain a safe distance from electrical aerial lines. Do not allow the equipment to come near ca-
bles when working near electrical aerial lines. Risk of fatality! Inform yourself about required safety
distances.
– The following actions must be carried out in the event of any transfer of electricity:
• do not move the machine or its equipment,
• do not leave the driver’s cab,
• warn any personnel in the vicinity not to come close to the excavator and not to touch it,
• instruct or initiate that someone turns off the voltage.
• move the machine, if possible, from the danger zone to a sufficient distance,
• Do not leave the machine until you are absolutely sure that voltage in the line, which had been
touched or damaged, has been turned off !
– Before moving the machine, always ensure that any attachments are safely secured.

1.10.6 R 924 Compact Tier III


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MJFCIFSS
Technical documentation Safety instructions, Signs on the machine
Safety Instructions

– When driving onto public roads, paths and squares, observe current traffic regulations and if nec-
essary, ensure that the machine has been made safe as per regulations beforehand.
– Always turn on the lights in conditions of poor visibility or darkness.
– Do not permit any passengers in the machine.
– Only work when seated properly and with the safety belt securely fastened (if available).
– Report all function faults and ensure that all necessary repairs are carried out immediately.
– Assure yourself that no one is endangered when you start the machine moving.
– Before you start working, test the brake system in accordance with the regulations given in the
operating instructions.
– Never leave the driver’s seat while the machine is moving.
– Never leave the machine unattended while the engine is running.
– The machine must be positioned, moved and operated in such a way that it is stable and that there
is no danger of overturning. Only known loads may be moved with the equipment; this applies par-
ticularly when using the grab.
– Position the upper structure in the longitudinal direction when moving and hold the load as close
to the ground as possible.
EXCEPTION: “Safe use when loading and unloading (particularly when loading and unloading
wood)” on page 8.
– Adjust your driving speed to suit local conditions.
– Avoid any working movements which may tip the machine. Should the machine start to tip or slide
sideways, however, turn the upper structure to face downhill and lower the equipment at the same
time.
– As far as possible, work downhill or uphill and not side on to the slope.
– Drive safely on stony, sleepery or inclined ground
– Only drive downhill at the permitted speed or you could lose control of the machine.
– Always shift down to a lower running step before a slope. When doing this, the diesel engine must
run at maximal speed and the speed may only be reduced using the accelerator pedals.
– Load an occupied truck only if all safety requirements are fulfilled, notably in order to protect the
truck operator.
– For demolition work, digging and crane operations etc., always use protective devices specifically
designed for the purpose.
– For terrain which is difficult to gain an overview of and whenever necessary, ask for the assistance
of a spotter. Only permit one person to give you signals.
– Only permit experienced personnel to attach loads and give signals to the machine operator. The
spotter must be positioned within the visual range of the operator or be in voice contact with him.
– Depending on the equipment combination, there is a risk of collision between the work tool and
the cab, the cab protection or the boom cylinders. The greatest degree of care must be taken to
avoid damage when the hoe teeth come within this area.
– Depending on the equipment combination, there is a risk of collision between the lift ring of the
attachment and the cab or the cab protection. Before operating, ensure that there is no risk of col-
lision, especially on excavator with cab elevation. If necessary remove the lift ring.
– In case of a thunderstorm :
• lower the attachment to the ground and if possible anchor the digging tool into the soil.
• leave the cab and move away from the machine before the storm breaks out. Otherwise, you
must stop the excavator, turn off the radio and keep inside the closed cab until the end of the
storm.
– Auxiliary control units can have various functions. Always check their functions when starting up
the machine.
– Stop the swinging motion of the uppercarriage when lowering the attachment into a ditch without
striking the attachment on the ditch walls.
– Inspect the machine for damage if the attachment has been swung into a wall or any other obsta-
cles.
– Applications in which the attachment is to be used to strike the material being extracted are not
permitted, even when working in a longitudinal direction.

R 924 Compact Tier III 1.10.7


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MJFCIFSS
Safety instructions, Signs on the machine Technical documentation
Safety Instructions

– Repeated strikes against an object leads to damage to the steel structures and machine compo-
nents.
– Please refer to your LIEBHERR dealer if special teeth for heavy-duty or special applications are
required.
– Do not attach too large bucket or bucket with side cutters or that are during operations with rocky
material. This would prolong the work cycles and may lead to damage to the bucket as well as
further machine components.
– With the 2x45° offset articulation, the offset position may only be employed if the working tool or
the attachment does not touch the material.
– Operation of the offset articulation to drill into the material is not permitted.
– Do not lift the machine during operation. Should this happen, lower the machine slowly back to
the ground.
– Do not let the machine fall heavily on the ground and do not hold it back with the hydraulics. This
would damage the machine.
– During operation with the attachment it is forbidden to raise the machine with the dozing blade
(e.g. carving at the ceiling when tunnelling).

Safe use with a hydraulic hammer


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

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

1.10.8 R 924 Compact Tier III


copyright by

MJFCIFSS
Technical documentation Safety instructions, Signs on the machine
Safety Instructions

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

Safe use of machines with tower elevation


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

R 924 Compact Tier III 1.10.9


copyright by

MJFCIFSS
Safety instructions, Signs on the machine Technical documentation
Safety Instructions

When loading and unloading:


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

Protection from vibration


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

Towing the machine safely


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

1.10.10 R 924 Compact Tier III


copyright by

MJFCIFSS
Technical documentation Safety instructions, Signs on the machine
Safety Instructions

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

Attaching and removing equipment parts safely


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

Removing and installing equipment bolts safely


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

Transporting the machine safely


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

R 924 Compact Tier III 1.10.11


copyright by

MJFCIFSS
Safety instructions, Signs on the machine Technical documentation
Sichere Wartung der Maschine

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

4 Sichere Wartung der Maschine

Allgemeine Sicherheitshinweise - Wartung


– Wartungs- und Reparaturarbeiten dürfen nur durch ausgebildetes Fachpersonal durchgeführt
werden.
– Halten Sie vorgeschriebene oder in der Betriebsanleitung angegebene Fristen für wiederke-
hrende Prüfungen / Inspektionen ein. Zur Durchführung von Instandhaltungsmaßnahmen ist eine
der Arbeit angemessene Werkstattausrüstung unbedingt notwendig.
– Anhand des Inspektions- und Wartungsplanes am Ende dieser Betriebsanleitung ist genau defin-
iert, wer welche Arbeiten durchführen muss bzw. darf.
Nach einer Einweisung dürfen die unter täglich / wöchentlich aufgelisteten Arbeiten vom
Maschinenfahrer oder Wartungspersonal durchgeführt werden.
Die restlichen Arbeiten dürfen nur durch Fachpersonal mit entsprechender Ausbildung ausgeführt
werden.
– Ersatzteile müssen den vom Hersteller festgelegten technischen Anforderungen entsprechen.
Dies ist bei Originalersatzteilen immer gewährleistet.
– Tragen Sie bei der Wartung eine sichere Arbeitskleidung. Vermeiden Sie das Tragen von Ringen,
Armbanduhren, Krawatten, Schals, offenen Jacken, nicht anliegenden Kleidern usw.. Es besteht
Verletzungsgefahr z.B. durch Hängenbleiben oder Einziehen.
Für bestimmte Arbeiten sind Schutzbrillen, Schutzhelm, Sicherheitsschuhe, Schutzhandschuhe,
reflektierende Weste, Gehörschutz usw. notwendig.

1.10.12 R 924 Compact Tier III


copyright by

MJFCIFSS
Technical documentation Safety instructions, Signs on the machine
Sichere Wartung der Maschine

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


Menschen mit Herzschrittmacher dürfen sich nicht näher als 20 cm dem laufenden Dieselmotor
nähern.
Spannungsführende Teile am elektrischen Anschluss der magnetventilgesteuerten Einzeleinsp-
ritzpumpen (Unit Pumps UP) bei laufendem Dieselmotor nicht berühren.
– Halten Sie während der Wartung unbefugte Personen von der Maschine fern.
– Sichern Sie den Instandhaltungsbereich, soweit erforderlich, weiträumig ab.
– Informieren Sie das Bedienungspersonal vor Beginn der Durchführung von Sonder- und Instand-
haltungsarbeiten. Benennen Sie die Aufsichtsführenden.
– Führen Sie, wenn in der Betriebsanleitung nicht anders angegeben, alle Wartungsarbeiten an der
Maschine auf ebenem, festem Grund mit abgelegter Arbeitsausrüstung und abgestelltem Motor
durch.
– Bei bestimmten Geräten ist ein sicherer Zugang zu den Wartungsstellen des Oberwagens (Mo-
torraum, Tanks, ...) gewährleistet nur wenn der Oberwagen in Längsrichtung des Unterwagens
und mit den Antriebsrädern nach hinten zeigend steht.
Nur in dieser Stellung stimmt die Lage der Aufstiegsleitern an der Unterwagenstruktur mit den
Zutrittstellen am Oberwagen überein.
– Ziehen Sie den Zündschlüssel ab und schließen Sie den Batteriehauptschalter.
– Ziehen Sie bei Wartungs- und Instandsetzungsarbeiten gelöste Schraubenverbindungen stets
fest.
– Die Halteschrauben der Haupteile, der Schlaüche und des Gegengewichts müssen nach jeder
Demontage ersetzt werden.
– Ist die Demontage von Sicherheitseinrichtungen beim Rüsten, Warten und Reparieren erforder-
lich, müssen unmittelbar nach Abschluss der Arbeiten die Sicherheitseinrichtungen wieder ange-
baut und überprüft werden.
– Hängen Sie bei Wartungsarbeiten, besonders bei Arbeit unter der Maschine, ein Warnschild
“Nicht einschalten” gut sichtbar an das Startschloss. Ziehen Sie den Startschlüssel ab und
schließen Sie den Batteriehauptschalter.
– Betreiben Sie Verbrennungsmotoren und kraftstoffbetriebene Heizungen nur in ausreichend
belüfteten Räumen. Achten Sie vor dem Starten in geschlossenem Raum auf ausreichende Belüf-
tung.
– Befolgen Sie die für den jeweiligen Einsatzort geltenden Vorschriften.

Reinigung
– Reinigen Sie die Maschine zu Beginn einer Wartung oder Reparatur, und hier insbesondere An-
schlüsse und Verschraubungen, von Öl, Kraftstoff oder Pflegemitteln.
Verwenden Sie keine aggressiven Reinigungsmittel und benutzen Sie faserfreie Putztücher.
– Verwenden Sie zum Reinigen der Maschine keine aggressiven Reinigungsmittel oder Dampfst-
rahlgeräte in den ersten zwei Monaten nach Inbetriebnahme (oder nach Neulackierung).
– Verwenden Sie zum Reinigen der Maschine keine brennbaren Flüssigkeiten.
– Vor dem Reinigen der Maschine mit Wasser oder Dampfstrahl (Hochdruckreiniger) oder anderen
Reinigungsmitteln,
• schmieren Sie alle Lagerstellen, Bolzenverbindungen und den Drehkranz, um das Eindringen
von Wasser und Wasserdampf in die Lagerstellen zu vermeiden.
• decken Sie alle Öffnungen ab bzw. kleben Sie diese zu, in die aus Sicherheits- und / oder Funk-
tionsgründen kein Wasser, Dampf oder Reinigungsmittel eindringen darf.
Besonders gefährdet sind Elektromotoren, Elektrobauteile, Schaltschränke, Steckverbindun-
gen und Luftfilter.
– Achten Sie darauf, dass bei Reinigungsarbeiten des Motorraums Temperaturfühler der Feuer-
warn- und Löschanlagen nicht mit heißem Reinigungsmittel in Berührung kommen.
Die Löschanlage könnte ansprechen.

R 924 Compact Tier III 1.10.13


copyright by

MJFCIFSS
Safety instructions, Signs on the machine Technical documentation
Sichere Wartung der Maschine

– Wenn Sie zum Reinigen der Maschine ein Dampf- und Heißwasserstrahlgerät verwenden, so sind
folgende Vorschriften einzuhalten:
• Der Lanzenabstand zur zu reinigenden Fläche muss mindestens 50 cm betragen.
• Die Wassertemperatur darf 60°C nicht überschreiten.
• Der Wasserdruck darf maximal 80 bar sein.
• Verwenden Sie als Waschmittel handelsübliche Auto-Shampoos (Neutral- Reiniger), 2 bis 3 %
ig zudosiert.
– Nach dem Reingen,
• entfernen Sie die Abdeckungen vollständig.
• untersuchen Sie alle Kraftstoff-, Motoröl- und Hydraulikleitungen auf Undichtigkeiten, gelockerte
Verbindungen, Scheuerstellen und Beschädigungen.
• beheben Sie festgestellte Mängel sofort.
• schmieren Sie alle Lagerstellen, Bolzenverbindungen und den Drehkranz, um evtl. eingedrun-
genes Wasser bzw. Reinigungsmittel zu verdrängen.

Sichtfeld
– Spiegel die für den Transport eventuell abgebaut wurden, müssen unvermeidbar vor Geräte-In-
betriebnahme wieder angebaut und richtig eingestellt werden.
– Überprüfen Sie regelmässig die richtige Einstellung der Innen- und Aussenspiegel.
– Überwachen Sie die Umgebung, und besonders den Nahbereich rund um die Maschine, während
dem Betrieb oder Fahren.
– Aussenspiegel sind an der Maschine angebracht:
• Links an der Kabine zur Überwachung der linken Maschinenseite.
• Vorne-links an der Kabine zur Überwachung der Vorderseite der Grundmaschine.
• Rechts am Oberwagen zur Überwachung der rechten Maschinenseite.
• Über dem Ballastgewicht zur Überwachung der hinteren Maschinenseite; dieser Spiegel ist auf
einigen Geräten durch eine Kamera ersetzt bzw. ergänzt.
– Bei jedem An-, Auf- bzw. Umbau an der Maschine muss gewährleistet bleiben, dass die Sichtver-
hältnisse beibehalten werden. Wird dies nicht gewährleistet, so müssen die Sichtverhältnisse
gemäss ISO 5006 überprüft werden.
– Reinigen Sie mindestens täglich alle Spiegel.
– Beschädigte Spiegel sind umgehend zu erneuern.
– Die Baustelle ist so zu organisieren, dass die Gefährdungen durch eingeschränkte Sichtverhält-
nisse minimiert werden. Dies gilt besonders für Geräte mit einem Dienstgewicht von über 40 Ton-
nen.

Rissprüfung
– Auch bei sorgsamem Umgang mit der Maschine sind in Einzelfällen Überbelastungen nicht aus-
zuschließen, die zu Rissen oder losen Verbindungen führen können. Zur Erhaltung der Betrieb-
ssicherheit ist die Maschine daher regelmäßig auf Risse, lose Verbindungen oder andere
sichtbare Schäden zu prüfen.
– Zur Prüfung auf Risse ist es zwingend erforderlich, dass die Maschine sauber gehalten und
regelmäßig gereinigt wird.
– Die Prüfungen sind gemäß Kontroll- und Wartungsplan durchzuführen,
• vom Wartungspersonal des Maschinenbetreibers alle 250 Betriebsstunden.
• vom autorisierten Fachpersonal alle 500 Betriebsstunden.
– Es ist zweckmäßig, solche Prüfungen abgestützt, auf festem und waagerechtem Untergrund, bei
wechselnder Belastung mittels Ausrüstung in Längs- und Querrichtung durchzuführen. Die jew-
eils gültigen Unfallverhütungsvorschriften müssen eingehalten werden.

1.10.14 R 924 Compact Tier III


copyright by

MJFCIFSS
Technical documentation Safety instructions, Signs on the machine
Sichere Wartung der Maschine

– Besondere Sorgfalt muss hierbei für die Prüfung der tragenden Bauteile gelten, insbesondere:
• Stahlbau Unterwagen mit Achs- und Getriebelagerung, Abstützung, untere Drehkranzauflage
mit Turm und Kugeldrehkranz.
• Stahlbau Oberwagen mit Lagerbock für Ausleger und Hubzylinder, obere Drehkranzauflage,
Kabinenlagerung, Befestigung von Drehwerksgetriebe und Ballastgewicht.
• Stahlbauteile der Arbeitsausrüstungen, z. B. Ausleger, Stiel, Schnellwechseladapter, Grabge-
fäße und Greifer.
• Hydraulikzylinder, Achsen, Lenkung, Bolzen und Bolzenverbindungen, Aufstiege, Leitern und
Befestigungselemente.
– Die Rissprüfung ist optisch durchzuführen. Um die Prüfsicherheit zu erhöhen, ist bei Rissverdacht
oder an schlecht einsehbaren Stellen wie beispielsweise der Drehkranzauflage als Rissprüfung
das Farbeindringverfahren anzuwenden.
– Festgestellte Schäden sind umgehend zu beseitigen. Schweißarbeiten an tragenden Teilen von
Erdbaumaschinen, Umschlaggeräten und Transportgeräten sind nur durch ausgebildetes Fach-
personal und nur nach den anerkannten Regeln der Schweißtechnik durchzuführen. Im Zweifels-
fall sollte Rücksprache mit dem LIEBHERR-Kundendienst gehalten werden, um geeignete
Maßnahmen abzusprechen.

Schweißungen, Bohr-, Brenn- und Schleifarbeiten


– An allen der Kräfteübertragung dienenden Hauptbauteilen (wie Unterwagenrahmen, Drehbühne,
Ausrüstungsteile, ...) darf nur vom Hersteller, oder von einer autorisierten Vertragswerkstatt ge-
schweißt, gebohrt, gebrennt oder geschleift werden. Bei Nichtachtung dieser Vorschrift entfällt die
Garantie
– Führen Sie Schweiß-, Bohr-, Brenn- und Schleifarbeiten an der Maschine nur durch, wenn dies
ausdrücklich genehmigt ist und reinigen Sie vor dem Schweißen, Bohren, Brennen und Schleifen
die Maschine und deren Umgebung von Staub und brennbaren Stoffen.
Sorgen Sie für ausreichende Belüftung. Es besteht Brand- und / oder Explosionsgefahr.
– Vor jeder Lichtbogenschweißung am Gerät muss die Batterie abgeklemmt werden. Den Minuspol
immer zuerst abklemmen und zuletzt wieder anschließen.
– Bei der Durchführung von Schweissarbeiten an Komponenten die entzündbare Gase enthalten
können (Ballastgewicht in geschweisster Konstruktion, Kraftstofftank, Hydrauliktank,...), müssen
diese vorher ausreichend mit Druckluft belüftet werden um jede Brenn- oder Explosionsgefahr
auszuschliessen.
– Das Massekabel des Schweißgerätes ist so nahe wie möglich an der Schweißstelle anzubringen,
damit der Schweißstrom nicht über Teile wie Drehkranz, Gelenke, Lager, Büchsen, Gummiele-
mente oder Dichtungen fließen kann

Betriebs- und Hilfsstoffe


– Beachten Sie beim Umgang mit Ölen, Fetten und anderen chemischen Substanzen die für das
jeweilige Produkt geltenden Sicherheitsvorschriften.
– Sorgen Sie für sichere und umweltschonende Entsorgung von Betriebs- und Hilfsstoffen sowie
Austauschteilen.
– Gehen Sie mit heißen Betriebs- und Hilfsstoffen vorsichtig um
(Verbrennungs- und Verbrühungsgefahr).

Reparatur
– Versuchen Sie nicht, schwere Teile anzuheben. Verwenden Sie dafür geeignete Hilfsmittel mit
ausreichender Tragkraft. Befestigen und sichern Sie Einzelteile und größere Baugruppen beim
Austausch sorgfältig an Hebezeugen, so dass von ihnen keine Gefahr ausgehen kann. Ver-
wenden Sie nur geeignete und technisch einwandfreie Hebezeuge sowie Lastaufnahmemittel mit
ausreichender Tragkraft.
Halten Sie sich nicht unter schwebenden Lasten auf bzw. arbeiten Sie nicht darunter.
– Verwenden Sie keine beschädigten oder in der Tragfähigkeit nicht ausreichende Hebezeuge.
Tragen Sie Schutzhandschuhe beim Umgang mit Drahtseilen.

R 924 Compact Tier III 1.10.15


copyright by

MJFCIFSS
Safety instructions, Signs on the machine Technical documentation
Sichere Wartung der Maschine

– Beauftragen Sie nur erfahrene Personen mit dem Anschlagen von Lasten und Einweisen von
Kranführern. Der Einweiser muss sich in Sichtweite des Bedieners aufhalten oder mit ihm in
Sprechkontakt stehen.
– Verwenden Sie bei Arbeiten über Körperhöhe dafür vorgesehene, sicherheitsgerechte Aufstieg-
shilfen und Arbeitsbühnen.
Maschinenteile nicht als Aufstiegshilfen benutzen, wenn diese nicht dafür vorgesehen sind.
Tragen Sie Absturzsicherungen bei Arbeiten in großer Höhe.
Halten Sie alle Griffe, Tritte, Geländer, Podeste, Bühnen und Leitern frei von Verschmutzung,
Schnee und Eis.
– Gasfedern dürfen nicht als Haltegriffe verwendet werden. Achten Sie darauf dass beim öffnen der
Türen und Hauben die Gasfedern nicht auf Anschlag stossen, dadurch können mechanische Be-
schädigungen der Gasfedern entstehen
– Achten Sie auf eine sichere Abstützung bevor Sie an der Ausrüstung Arbeiten (z. B. Auswechseln
von Zähnen). Vermeiden Sie dabei Metall auf Metall.
– Öffnen und montieren Sie aus Sicherheitsgründen niemals eine Kette ab, ohne vorher die Feder
der Spanneinheit entspannt zu haben.
– Legen Sie sich niemals unter die Maschine, wenn diese mit Hilfe der Arbeitsausrüstung ange-
hoben ist, ohne dass der Unterwagen mit Holzbalken oder anderen geeigneten Auflagen stand-
sicher unterbaut ist.
– Bocken Sie die Maschine immer so auf, dass eventuelle Gewichtsverlagerungen die Standsicher-
heit nicht gefährden und vermeiden Sie dabei den Kontakt von Metall auf Metall.
– Arbeiten an Fahrwerken, Brems- und Lenkanlagen dürfen nur von hierfür ausgebildetem Fach-
personal durchgeführt werden.
– Muss die Maschine am Hang repariert werden, sind die Ketten mit Hemmklötzen zu sichern, der
Oberwagen richtung Bergab zu drehen, und das Arbeitswerkzeug auf dem Boden zu legen. Der
Oberwagen ist mittels Arretierbolzen mit dem Unterwagen zu verbinden, wenn vorhanden.
– An hydraulischen Einrichtungen darf nur Personal mit speziellen Kenntnissen und Erfahrungen
arbeiten.
– Tragen Sie Schutzhandschuhe bei der Suche nach Leckagen. Ein feiner Flüssigkeitsstrahl unter
Druck kann die Haut durchdringen.
– Lösen Sie keine Leitung oder Verschraubung, bevor sie die Ausrüstung abgelegt, den Motor ab-
gestellt und das Hydrauliksystem entlastet haben. Nach dem Abstellen des Motors müssen Sie,
mit dem Zündschlüssel in Kontaktstellung und nach unten geklapptem Sicherheitshebel, alle
Vorsteuergeräte (Kreuzschalthebel und Pedale) in allen Richtungen bewegen, um den Steuer-
druck und die Staudrücke in den Arbeitskreisen abzubauen. Anschließend müssen Sie den
Tankinnendruck, wie in dieser Betriebsanleitung beschrieben, abbauen.

Elektroanlage
– Prüfen Sie regelmäßig die elektrische Anlage.
Lassen Sie sofort alle Fehler, wie lose Verbindungen, durchgebrannte Sicherungen und Glühlam-
pen, angeschmorte oder durchgescheuerte Kabel, von Fachpersonal beheben.
– Verwenden Sie nur Original-Sicherungen mit vorgeschriebener Stromstärke.
– Bei Maschinen mit elektrischen Mittel- und Hochspannungsleitungen:
• bei Störungen in der elektrischen Energieversorgung schalten Sie die Maschine sofort ab.
– Arbeiten an elektrischen Ausrüstungen der Maschine dürfen nur von einer Elektrofachkraft oder
von unterwiesenen Personen unter Leitung und Aufsicht einer Elektrofachkraft gemäß den ele-
ktrotechnischen Vorschriften vorgenommen werden.
– Ziehen Sie bei Arbeiten an spannungsführenden Teilen eine zweite Person hinzu, die im Notfall
den Not-Aus bzw. den Hauptschalter mit Spannungsauslösung betätigt. Sperren Sie den Arbeits-
bereich mit einer rotweißen Sicherungskette und einem Warnschild ab. Benutzen Sie nur span-
nungsisoliertes Werkzeug.
– Bei Arbeiten an Mittel- und Hochspannungsbaugruppen, nach dem Freischalten der Spannung,
schließen Sie das Versorgungskabel an Masse und die Bauteile, z. B. Kondensatoren, mit einem
Erdungsstab kurz.

1.10.16 R 924 Compact Tier III


copyright by

MJFCIFSS
Technical documentation Safety instructions, Signs on the machine
Sichere Wartung der Maschine

– Prüfen Sie die freigeschalteten Teile zuerst auf Spannungsfreiheit, erden und schließen Sie diese
dann kurz. Isolieren Sie benachbarte, unter Spannung stehende Teile.
– Klemmen Sie die Batterie ab, bevor Sie an der Elektroanlage arbeiten oder Lichtbogensch-
weißungen an der Maschine vornehmen.
Lösen Sie zuerst den Minuspol, dann den Pluspol. Verfahren Sie beim Anklemmen in umgekehrt-
er Reihenfolge.

Hydrospeicher
– Alle Arbeiten an den Hydrospeichern dürfen nur von dafür ausgebildetem Fachpersonal ausge-
führt werden.
– Unsachgemäßes Montieren und Handhaben von Hydrospeichern kann schwere Unfälle verur-
sachen.
– Nehmen Sie keine beschädigten Hydrospeicher in Betrieb.
– Vor Arbeiten an einem Hydrospeicher müssen Sie den Druck im Hydrauliksystem (Hydraulikan-
lage einschließlich Hydrauliktank) wie in dieser Betriebsanleitung beschrieben abbauen.
– Schweißen oder löten Sie nicht am Hydrospeicher und führen Sie daran keine mechanischen Ar-
beiten durch.
Der Hydrospeicher kann durch Hitzeeinwirkung beschädigt sowie durch mechanische Bearbei-
tung zum Bersten gebracht werden. ES BESTEHT EXPLOSIONSGEFAHR!
– Befüllen Sie Hydrospeicher nur mit Stickstoff. Bei Verwendung von Sauerstoff oder Luft besteht
EXPLOSIONSGEFAHR!
– Der Speicherkörper kann im Betrieb heiß werden, es besteht Verbrennungsgefahr.
– Neue Hydrospeicher müssen vor Inbetriebnahme mit dem für den Einsatzzweck notwendigen
Druck gefüllt sein.
– Die Betriebsdaten (minimaler und maximaler Druck) sind auf Hydrospeichern dauerhaft geken-
nzeichnet. Sorgen Sie dafür, dass die Kennzeichnung sichtbar erhalten bleibt.

Hydraulikschläuche und Schlauchleitungen


– Reparaturen an Hydraulikschläuchen und Schlauchleitungen sind verboten!
– Alle Schläuche, Schlauchleitungen und Verschraubungen sind regelmäßig alle 2 Wochen, bei
mutmaßlichen Beschädigungen sofort auf Undichtigkeiten und äußerlich erkennbare Beschädi-
gungen zu überprüfen!
Suchen Sie eventuelle Leckstellen nicht mit nackten Händen, verwenden Sie dazu ein Blatt
Papier oder ähnliches Material.
Beseitigen Sie umgehend beschädigte Teile! Herausspritzendes Öl kann zu Verletzungen und
Bränden führen.
– Auch bei sachgemäßer Lagerung und zulässiger Beanspruchung unterliegen Schläuche und
Schlauchleitungen einer natürlichen Alterung. Dadurch ist ihre Verwendungsdauer begrenzt.
• Unsachgemäße Lagerung, mechanische Beschädigungen und unzulässige Beanspruchung
sind die häufigsten Ausfallursachen.
• Im Bezug auf die Verwendungsdauer sind die am Einsatzort gültigen Normen, Regeln und Rich-
tlinien über Schläuche und Schlauchleitungen zu beachten.
• Der Einsatz im Grenzbereich der zulässigen Beanspruchung kann die Verwendungsdauer
verkürzen (z. B. hohe Temperaturen, häufige Bewegungsspiele, extrem hohe Impulsfrequen-
zen, Mehrschichtbetrieb).

R 924 Compact Tier III 1.10.17


copyright by

MJFCIFSS
Safety instructions, Signs on the machine Technical documentation
Sichere Wartung der Maschine

– Schläuche und Schlauchleitungen sind zu ersetzen, wenn bei der Inspektion folgende Zustände
festgestellt werden:
• Beschädigungen an der Außenschicht bis zur Einlage (z. B. Scheuerstellen, Schnitte und
Risse);
• Versprödung der Außenschicht (Rissbildung des Schlauchmaterials);
• Verformungen, die der natürlichen Form des Schlauches oder der Schlauchleitung nicht
entsprechen, sowohl im drucklosen wie auch im druckbeaufschlagten Zustand oder bei Biegun-
gen, z. B. Schichtentrennung, Blasenbildung, Knick- oder Quetschstellen;
• Undichte Stellen;
• Nichtbeachtung der Anforderungen an den Einbau;
• Beschädigungen oder Deformationen der Schlaucharmatur, welche die Festigkeit der Armatur
oder der Verbindung Schlauch / Armatur mindern;
• Herauswandern des Schlauches aus der Armatur;
• Korrosion der Armatur, welche die Funktion und Festigkeit mindern;
– Verwenden Sie beim Austausch von Schläuchen und Schlauchleitungen nur Original-Ersatzteile.
– Verlegen und montieren Sie Schläuche und Schlauchleitungen fachgerecht. Verwechseln Sie An-
schlüsse nicht.
– Beim Austausch von Schläuchen und Schlauchleitungen ist zu beachten:
• Achten Sie immer auf eine torsionsfreie Verlegung der Schläuche und Schlauchleitungen. Bei
Hochdruckschläuchen sind immer die Schrauben der Halbschellen bzw. Vollflansche an beiden
Schlauchenden anzubringen und erst danach anzuziehen.
• Bei Hochdruckschläuche und Schlauchleitungen mit gebogener Armatur muss beim Anziehen
der Flansche immer zuerst die Seite mit der gebogenen Armatur und erst danach die Seite mit
der geraden Armatur angezogen werden.
• Eventuell vorhandene Befestigungsschellen in der Schlauchmitte dürfen erst anschließend an-
gebracht und angezogen werden.
• Prüfen Sie täglich, dass alle Schellen, Abdeckungen und Schutzeinrichtungen richtig befestigt
sind. Dadurch werden während des Betriebs Vibrationen und Beschädigungen vermieden.
• Verlegen Sie die Schläuche und Schlauchleitungen so, dass ein Scheuern mit anderen
Schläuchen und Schlauchleitungen oder sonstigen Teilen ausgeschlossen ist.
• Ein Mindestabstand zu den restlichen Teilen von ca. 1/2 des Außendurchmessers des
Schlauches wird empfohlen. Der Abstand sollte jedoch 10 bis 15 mm nicht unterschreiten.
• Prüfen Sie beim Austausch von Schläuchen und Schlauchleitungen an beweglichen Teilen (z.
B. vom Ausleger zum Stiel) vor der Erstinbetriebnahme, dass über den gesamten Bewegungs-
bereich keine Scheuerstellen vorhanden sind.

1.10.18 R 924 Compact Tier III


copyright by

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

1.20: Tightening torques

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

Involved screws are those with the following surface finish:


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

Metric coarse thread Metric fine thread


Assembly Tightening Assembly Tightening
Thread Class preloads FM torques MA Thread Class preloads FM torques MA
in N in Nm in N in Nm

8.8 4050 2,8


M4 10.9 6000 4,1
12.9 7000 4,8
8.8 6600 5,5
M5 10.9 9700 8,1
12.9 11400 9,5
8.8 9400 9,5
M6 10.9 13700 14,0
12.9 16100 16,5
8.8 13700 15,5
M7 10.9 20100 23,0
12.9 23500 27,0
8.8 17200 23,0 8.8 18800 24,5
M8 10.9 25000 34,0 M8×1 10.9 27500 36
12.9 29500 40,0 12.9 32500 43
8.8 24800 36
M9×1 10.9 36500 53
12.9 42500 62
8.8 27500 46,0 8.8 31500 52
M10 10.9 40000 68,0 M10×1 10.9 46500 76
12.9 47000 79,0 12.9 54000 89
8.8 29500 49
M10×1,25 10.9 43000 72
12.9 51000 84
8.8 40000 79,0 8.8 45000 87
M12 10.9 59000 117,0 M12×1,25 10.9 66000 125
12.9 69000 135,0 12.9 73000 150
8.8 42500 83
M12×1,5 10.9 62000 122
12.9 73000 145
8.8 55000 125,0 8.8 61000 135
M14 10.9 80000 185,0 M14×1,5 10.9 89000 200
12.9 94000 215,0 12.9 104000 235

R 924 Compact Tier III 1.20.1


copyright by

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

Metric coarse thread Metric fine thread


8.8 75000 195,0 8.8 82000 205
M16 10.9 111000 280,0 M16×1,5 10.9 121000 300
12.9 130000 330,0 12.9 141000 360
M18 8,8 94000 280 M18×1,5 8,8 110000 310
10,9 135000 390 10,9 157000 440
12,9 157000 460 12,9 184000 520
M18×2 8,8 102000 290
10,9 146000 420
12,9 170000 490
M20 8,8 121000 390 M20×1,5 8,8 139000 430
10,9 173000 560 10,9 199000 620
12,9 202000 650 12,9 232000 720
M22 8,8 152000 530 M22×1,5 8,8 171000 580
10,9 216000 750 10,9 245000 820
12,9 250000 880 12,9 285000 960
M24 8,8 175000 670 M24×1,5 8,8 207000 760
10,9 249000 960 10,9 295000 1090
12,9 290000 1120 12,9 346000 1270
M24×2 8,8 196000 730
10,9 280000 1040
12,9 325000 1220
M27 8,8 230000 1000 M27×1,5 8,8 267000 1110
10,9 330000 1400 10,9 381000 1580
12,9 385000 1650 12,9 445000 1850
M27×2 8,8 255000 1070
10,9 365000 1500
12,9 425000 1800
M30 8,8 280000 1350 M30×1,5 8,8 335000 1540
10,9 400000 1900 10,9 477000 2190
12,9 465000 2250 12,9 558000 2560
M30×2 8,8 321000 1490
10,9 457000 2120
12,9 534000 2480
M33 8,8 350000 1850 M33×1,5 8,8 410000 2050
10,9 495000 2600 10,9 584000 2920
12,9 580000 3000 12,9 683000 3420
M33×2 8,8 395000 2000
10,9 560000 2800
12,9 660000 3300
M36 8,8 410000 2350 M36×1,5 8,8 492000 2680
10,9 580000 3300 10,9 701000 3820
12,9 680000 3900 12,9 820000 4470
M36×3 8,8 440000 2500
10,9 630000 3500
12,9 740000 4100
M39 8,8 490000 3000 M39×1,5 8,8 582000 3430
10,9 700000 4300 10,9 830000 4890
12,9 820000 5100 12,9 971000 5720
M39×3 8,8 530000 3200
10,9 750000 4600
12,9 880000 5300

1.20.2 R 924 Compact Tier III


copyright by

MJFCIFSS
Technical documentation Tightening torques
Tightening torques of screw-in studs (Ermeto)

2 Tightening torques of screw-in studs (Ermeto)


Mating material: steel (grease well before inserting!)

Type with sealing edge Type with EOLASTIC seal


Tightening Tightening
Thread M or Thread M or
Type torques Type torques
G G
(Nm) (Nm)

Light-duty series L
GE 06 LM A 3 C M 10×1 18 GE 06 LM ED A 3 C M 10×1 18
GE 06 LR A 3 C G 1/8 A 18 GE 06 LR ED A 3 C G 1/8 A 18
GE 08 LM A 3 C M 12×1,5 30 GE 08 LM ED A 3 C M 12×1,5 25
GE 08 LR A 3 C G 1/4 A 35 GE 08 LR ED A 3 C G 1/4 A 35
GE 10 LM A 3 C M 14×1,5 45 GE 10 LM ED A 3 C M 14×1,5 45
GE 10 LR A 3 C G 1/4 A 35 GE 10 LR ED A 3 C G 1/4 A 35
GE 12 LM A 3 C M 16×1,5 65 GE 12 LM ED A 3 C M 16×1,5 55
GE 12 LR A 3 C G 3/8 A 70 GE 12 LR ED A 3 C G 3/8 A 70
GE 15 LM A 3 C M 18×1,5 80 GE 15 LM ED A 3 C M 18×1,5 70
GE 15 LR A 3 C G 1/2 A 140 GE 15 LR ED A 3 C G 1/2 A 90
GE 18 LM A 3 C M 22×1,5 140 GE 18 LM ED A 3 C M 22×1,5 125
GE 18 LM A 3 C M 22×1,5 140 GE 18 LM ED A 3 C M 22×1,5 125
GE 18 LR A 3 C G 1/2 A 100 GE 18 LR ED A 3 C G 1/2 A 90
GE 22 LM A 3 C M 22×1,5 140 GE 22 LM ED A 3 C M 26×1,5 180
GE 22 LR A 3 C G 3/4 A 180 GE 22 LR ED A 3 C G 3/4 A 180
GE 28 LM A 3 C M 33×2,0 340 GE 28 LM ED A 3 C M 33 x 2,0 310
GE 28 LR A 3 C G1A 330 GE 28 LR ED A 3 C G1A 310
GE 35 LM A 3 C M 42×2,0 500 GE 35 LM ED A 3 C M 42×2,0 450
GE 35 LR A 3 C G 1 1/4 A 540 GE 35 LR ED A 3 C G 1 1/4 A 450
GE 42 LM A 3 C M 48×2,0 630 GE 42 LM ED A 3 C M 48×2,0 540
GE 42 LR A 3 C G 1 1/2 A 630 GE 42 LR ED A 3 C G 1 1/2 A 540
Heavy-duty series S
GE 06 SM A 3 C M 12×1,5 35 GE 06 SM ED A 3 C M 12×1,5 35
GE 06 SR A 3 C G 1/4 A 55 GE 06 SR ED A 3 C G 1/4 A 55
GE 08 SM A 3 C M 14×1,5 55 GE 08 SM ED A 3 C M 14×1,5 55
GE 08 SR A 3 C G 1/4 A 55 GE 08 SR ED A 3 C G 1/4 A 55
GE 10 SM A 3 C M 16×1,5 70 GE 10 SM ED A 3 C M 16×1,5 70
GE 10 SR A 3 C G 3/8 A 90 GE 10 SR ED A 3 C G 3/8 A 80
GE 12 SM A 3 C M 18×1,5 110 GE 12 SM ED A 3 C M 18×1,5 90
GE 12 SR A 3 C G 3/8 A 90 GE 12 SR ED A 3 C G 3/8 A 80
GE 14 SM A 3 C M 20×1,5 150 GE 14 SM ED A 3 C M 20×1,5 125
GE 14 SR A 3 C G 1/2 A 150 GE 14 SR ED A 3 C G 1/2 A 115
GE 16 SM A 3 C M 22×1,5 170 GE 16 SM ED A 3 C M 22×1,5 135
GE 16 SR A 3 C G 1/2 A 130 GE 16 SR ED A 3 C G 1/2 A 115
GE 20 SM A 3 C M 27×2,0 270 GE 20 SM ED A 3 C M 27×2,0 180
GE 20 SR A 3 C G 3/4 A 270 GE 20 SR ED A 3 C G 3/4 A 180
GE 25 SM A 3 C M 33×2,0 410 GE 25 SM ED A 3 C M 33×2,0 310
GE 25 SR A 3 C G1A 340 GE 25 SR ED A 3 C G1A 310

R 924 Compact Tier III 1.20.3


copyright by

MJFCIFSS
Tightening torques Technical documentation
Tightening torques of swivelling connections (Ermeto)

GE 30 SM A 3 C M 42×2,0 540 GE 30 SM ED A 3 C M 42×2,0 450


GE 30 SR A 3 C G 1 1/4 A 540 GE 30 SR ED A 3 C G 1 1/4 A 450
GE 38 SM A 3 C M 48×2,0 700 GE 38 SM ED A 3 C M 48×2,0 540
GE 38 SR A 3 C G 1 1/2 A 700 GE 38 SR ED A 3 C G 1 1/2 A 540

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

3 Tightening torques of swivelling connections (Ermeto)


Mating material : steel (grease well before inserting!)

Tightening Tightening
Type Thread torque Type Thread torque
(Nm) (Nm)

Light-duty series L
WH / TH 06 LR KDS A G 1/8 A 18 WH / TH 06 LM KDS M 10×1 18
3C A3C
WH / TH 08 LR KDS A G 1/4 A 45 WH / TH 08 LM KDS M 12×1,5 45
3C A3C
WH / TH 10 LR KDS A G 3/8 A 45 WH / TH 10 LM KDS M 14×1,5 55
3C A3C
WH / TH 12 LR KDS A G1/2 A 70 WH / TH 12 LM KDS M 16×1,5 80
3C A3C
WH / TH 15 LR KDS A G3/4 A 120 WH / TH 15 LM KDS M 18×1,5 100
3C A3C
WH / TH 18 LR KDS A G1 A 120 WH / TH 18 LM KDS M 22×1,5 140
3C A3C
WH / TH 22 LR KDS A G 1 1/4 A 230 WH / TH 22 LM KDS M 27×2,0 320
3C A3C
WH / TH 28 LR KDS A G 1 1/4 A 320 WH / TH 28 LM KDS M 33 x 2,0 360
3C A3C
WH / TH 35 LR KDS A G 1 1/4 A 540 WH / TH 35 LM KDS M 42×2,0 540
3C A3C
WH / TH 42 LR KDS A R 1 1/2 A 700 WH / TH 42 LM KDS M 48×2,0 700
3C A3C
Heavy-duty series S
WH / TH 06 SR KDS G 1/4 A 45 WH / TH 06 SM KDS M 12×1,5 45
A3C A3C
WH / TH 08 SR KDS G 1/4 A 45 WH / TH 08 SM KDS M 14×1,5 55
A3C A3C
WH / TH 10 SR KDS G 3/8 A 70 WH / TH 10 SM KDS M 16×1,5 80
A3C A3C
WH / TH 12 SR KDS G 3/8 A 70 WH / TH 12 SM KDS M 18×1,5 100
A3C A3C
WH / TH 16 SR KDS G 1/2 A 120 WH / TH 14 SM KDS M 20×1,5 125
A3C A3C
WH / TH 20 SR KDS G 3/4 A 230 WH / TH 16 SM KDS M 22×1,5 135
A3C A3C
WH / TH 25 SR KDS G1A 320 WH / TH 20 SM KDS M 27×2,0 320
A3C A3C
WH / TH 30 SR KDS G 1 1/4 A 540 WH / TH 25 SM KDS M 33×2,0 360
A3C A3C

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

WH / TH 38SR KDS A G 1/4 A 700 WH / TH 30 SM KDS M 42×2,0 540


3C A3C
WH / TH 38 SM KDS M 48×2,0 700
A3C

4 Tightening torques of screw-in studs (Ermeto)


Mating material : steel (grease well before inserting!)

Anziehdreh Anziehdreh
Type Gewinde momente Type Gewinde momente
(Nm) (Nm)
VSTI 10×1 ED A3C M 10×1 12 VSTI 1/8 ED A3C G 1/8 A 13
VSTI 12×1,5 ED A3C M 12×1,5 25 VSTI 1/4 ED A3C G 1/4 A 30
VSTI 14×1,5 ED A3C M 14×1,5 35 VSTI 3/8 ED A3C G 3/8 A 60
VSTI 16×1,5 ED A3C M 16×1,5 55 VSTI 1/2 ED A3C G 1/2 A 80
VSTI 18×1,5 ED A3C M 18×1,5 65 VSTI 3/4 ED A3C G 3/4 A 140
VSTI 20×1,5 ED A3C M 20×1,5 80 VSTI 1 ED A3C G1A 200
VSTI 22×1,5 ED A3C M 22×1,5 90 VSTI 1 1/4 ED A3C G 1 1/4 A 450
VSTI 26×1,5 ED A3C M 26×1,5 120 VSTI 1 1/2 ED A3C G 1 1/2 A 450
VSTI 27×2 ED A3C M 27×2,0 135
VSTI 33×2 ED A3C M 33×2,0 225
VSTI 42×2 ED A3C M 42×2,0 360
VSTI 48×2 ED A3C M 48×2,0 380

VSTI = Hexagon socket plug

R 924 Compact Tier III 1.20.5


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

1.20.6 R 924 Compact Tier III


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Technical documentation Installations for pistons and piston nuts by hydraulic
Application and purpose

1.22: Installations for pistons and piston nuts by


hydraulic cylinders
According to standard 4121 C (06/2008)

1 Application and purpose


This Liebherr standard applies only to hydraulic cylinders, and in particular to the mounting of pistons
and piston nuts on piston rods from a thread diameter of M42 and greater.
This standard describes the tightening procedure with turning distance and angle.
For threads with diameters smaller than M42, the applicable tightening torque is indicated in the
drawings. The values in the drawings are always binding.

2 Requirements / description of procedure


For the valid torque value number, refer to the drawing. The standard may not be adopted or trans-
ferred to apparently similar geometries.
Use this number to find the applicable turning distance and angle in the torque table (siehe Kap. 3,
”Torque table - Status 02.06.2010” auf Seite 7).
The torque values have been determined empirically and are subject to changes. This standard dif-
ferentiates between two tightening procedures, which are identified with 3-digit and 4-digit numbers
respectively (see chapters 2.1 and 2.2).

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

2.1 Tightening with assembly wrench


This tightening procedure applies to 3-digit tightening numbers.

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

2.1.2 Definitions

Pretightening torque (Mv)


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

Turning distance (4)


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

Turning angle (5)


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

Fig. 1 Torque wrench

A Piston C Assembly wrench


B Torque wrench

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

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

Fig. 2 Markings, turning distance, turning angle

1 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

R 924 Compact Tier III 1.22.3


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

2.2 Tightening with hydraulic assembly device


This tightening procedure applies to 4-digit tightening numbers.

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

2.2.2 Definitions

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

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

Fig. 3 Torque wrench

A Torque wrench
B Hexagon head
C Torque converter

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

2.2.3 Operation of the assembly device


See separate operating manual of the assembly device (H).
For suitable adapters for the piston rod, piston and piston nut, refer to the piston parts list (see Fig. 4
on page5).

Fig. 4 Operation of the assembly device

A Piston rod
B Piston
C Adapter for piston
D Adapter for piston rod
E Piston nut
F Adapter for piston nut
G Torque converter
H Assembly device

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

Fig. 5 Angle scale

A Dial
B Adjusting screw
C Angle scale

Before tightening, set the dial (A) with the adjusting screw (B) to position 0° on the angle scale (C).
The angle scale indicates the turning angle.
If the opening angle of the assembly device is not sufficient to achieve the prescribed turning angle,
mount the device again for a second tightening process. Note the previously completed angle.
Before continuing the tightening process, set the dial to the last achieved angle value.
Repeat this process as often as necessary to achieve the prescribed turning angle.

1.22.6 R 924 Compact Tier III


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

3 Torque table - Status 02.06.2010

3.1 Tightening with assembly wrench (siehe Kap. 2.1, ”Tightening with assembly
wrench” auf Seite 2)

Piston Piston nut


Pretightening Thread M
WN 4121 No Turning Turning
torque [N.m] Turning angle Turning angle [mm]
distance distance
~ [°] ~ [°]
[mm] [mm]
071 100 11 +1 30 21 +1 57 42x1,5
072 100 21 +1 57 21 +1 57 42x1,5
073 100 18 +1 49 19 +1 52 42x1,5
074 100 16 +1 44 - - 42x1,5
075 100 19 +1 52 21 +1 57 42x1,5
078 100 20 +1 55 14 +1 38 42x1,5
079 100 11 +1 30 21 +1 57 42x1,5
080 100 18 +1 49 - - 42x1,5
091 100 13 +1 30 19 +1 44 50x2
092 100 25 +1 57 19 +1 44 50x2
093 100 24 +1 55 19 +1 44 50x2
095 100 13 +1 30 19 +1 44 50x2
096 100 10 +1 23 9 +1 21 50x2/SW65
097 100 17 +1 39 19 +1 44 50x2
098 100 17 +1 39 - - 50x2
099 100 24 +1 55 19 +1 44 50x2
103 100 9 +1 21 - - 50x2
111 100 16 +1 33 18 +1 37 56x2
112 100 17 +1 35 18 +1 37 56x2
113 100 18 +1 37 18 +1 37 56x2
114 100 19 +1 39 - - 56x2
115 100 18 +1 37 - - 56x2
116 100 19 +1 39 - - 56x2
121 150 15 +1 29 19 +1 36 60x2
123 150 17 +1 32 19 +1 36 60x2
126 150 14 +1 27 - - 60x2
127 150 22 +1 42 - - 60x2
129 150 7 +1 13 8 +1 15 60x2
151 150 15 +1 27 19 +1 34 65x2
152 150 20 +1 35 19 +1 34 65x2
153 150 20 +1 35 - - 65x2
171 150 12 +2 20 18 +1 30 68x2
172 150 21 +2 35 18 +1 30 68x2
173 150 19 +2 32 18 +1 30 68x2
174 150 25 +2 42 18 +1 30 68x2
175 150 25 +2 42 18 +1 30 68x2
176 150 19 +2 32 18 +1 30 68x2
177 150 19 +2 32 18 +1 30 68x2

R 924 Compact Tier III 1.22.7


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

Piston Piston nut


Pretightening Thread M
WN 4121 No Turning Turning
torque [N.m] Turning angle Turning angle [mm]
distance distance
~ [°] ~ [°]
[mm] [mm]
179 150 11 +2 19 18 +1 30 68x2
180 150 20 +2 34 18 +1 30 68x2
181 150 20 +2 34 - - 68x2
183 200 - - 40 +2 67 68x2
201 200 17 +2 26 16 +1 24 76x2
202 200 26 +2 39 16 +1 24 76x2
203 200 27 +2 41 16 +1 24 76x2
204 200 27 +2 41 16 +1 24 76x2
205 200 13 +2 20 - - 76x2
206 200 25 +2 38 25 +1 38 76x2
207 200 23 +2 35 - - 76x2
208 200 15 +2 22 - - 76x2
209 200 30 +2 45 - - 76x2
231 200 8 +2 11 16 +1 22 85x3
232 200 17 +2 23 16 +1 22 85x3
234 200 22 +2 30 - - 85x3
236 200 15 +2 20 - - 85x3
237 200 19 +2 26 - - 85x3
261 250 20 +2 25 10 +1 12 95x3
265 250 24 +2 29 10 +1 12 95x3
267 250 24 +2 29 - - 95x3
281 250 20 +2 23 13 +1 15 100x3
282 250 25 +2 29 - - 100x3
283 250 25 +2 29 21 +1 24 100x3
284 250 9 +1 10 - - 100x3
285 250 18 +1 20 - - 100x3
301 300 21 +3 22 20 +2 21 110x3
302 300 18 +3 19 20 +2 21 110x3
303 300 20 +3 21 20 +2 21 110x3
304 300 23 +3 24 20 +2 21 110x3
305 300 9 +3 9 - - 110x3
306 300 24 +3 25 - - 110x3
307 300 27 +3 28 - - 110x3
331 400 23 +3 22 20 +2 19 120x3
332 400 11 +3 11 - - 120x3
333 400 27 +3 26 - - 120x3
334 400 20 +3 19 20 +2 19 120x3
335 400 30 +3 29 - - 120x3
336 400 29 +3 28 - - 120x3
501 200 21 +2 30 - - 80x2
531 500 34 +3 28 - - 140x3
561 100 10 +1 25 - - 45x1,5

1.22.8 R 924 Compact Tier III


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

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

Piston Piston nut


Pretightening
Thread M
WN 4121 No torque Mv Turning angle Turning angle [mm]
[N.m] ~ [°] ~ [°]
1000 300 27+1 8+1 240x4
1001 300 18+1 8+1 200x4
1002 300 18+1 8+1 150x4
1003 300 23+1 8+1 170x4
1004 300 21+1 8+1 140x4
1005 300 18+1 8+1 180x4
1006 300 39+1 8+1 150x3
1007 300 27+1 3+1 160x4
1008 300 31+1 5+1 180x4
1009 300 20 +1 - 200x4
1010 300 27 +1 5 +1 180x4
1011 300 18 +1 - 260x4
1012 300 33 +1 - 200x4

R 924 Compact Tier III 1.22.9


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

1.22.10 R 924 Compact Tier III


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Technical documentation Assembly instruction for piston rod bearings with ex-
Description

1.24: Assembly instruction for piston rod bearings with


external threads (hydraulic cylinders)
According to standard 4122 B (01/2005)

Scope of application
This factory standard applies exclusively to the assembly of hydraulic cylinders.
For the valid factory standard number, refer to the drawing. The standard may not be adopted or
transferred to apparently similar geometries.
The torques have been determined empirically and are subject to changes. THe revision and release
dates indicate the latest version of the factory standard.

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

1.1 Definitions

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

Fig. 1 Torque wrench

A Piston C Assembly wrench


B Torque wrench

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

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

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

R 924 Compact Tier III 1.24.1


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Assembly instruction for piston rod bearings with ex- Technical documentation
Description

Fig. 2 Marks, turning angle and distance on the piston rod bearing

c Marks on piston and piston rod thread after application of the pretightening tor-
que
d Mark on the cylinder tube
e Mark on the bearing head after tightning
g Cylinder tube
h Bearing head
Turning angle
Turning distance

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

1.24.2 R 924 Compact Tier III


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Technical documentation Assembly instruction for piston rod bearings with ex-
Tightening torques for factory standard (02.07.2008)

2 Tightening torques for factory standard (02.07.2008)

Piston

WN 4122 No. Preload (N.m) Turning


Turning angle
distance
(< °)
(mm)
001
011 50 7 +1 10
016 100 10 +1 12
017 100 10 +1 12
026 100 9 +1 10
027 100 10 +1 11
031 100 8 +1 8
036 100 11 +1 10
037 100 10 +1 9
039
041 150 9 +1 7
046 200 12 +1 10
047
051
052
053 200 25 +1 18
061 200 10 +1 7
091 300 10 +1 5,5
111 300 12 +1 6
151 400 14 +1 6

R 924 Compact Tier III 1.24.3


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Assembly instruction for piston rod bearings with ex- Technical documentation
Tightening torques for factory standard (02.07.2008)

1.24.4 R 924 Compact Tier III


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

1.51: Lubricants and operating fluids

1 General information on changing lubricants and operating fluids

Note
The quantities given in the lubrication and operating material chart and on the lubrication chart in
the cab are only guide values.
After each oil change or refill, check the level in the relevant unit.

Note!
Adhering to regulations for lubrication, level checks and operating material changes guarantees a
high degree of reliability and a long service life for the machine.
It is particularly important to adhere to the oil change intervals and use the specified type of
lubricant.
Observe the following when using and checking lubricants and operating fluids:
– see "Lubricants and operating fluids"
– see "Inspection and maintenance schedule"

Note!
Cleanliness is of the utmost importance when changing oil.
Clean all filler plugs, filler covers and drain plugs and their surroundings before opening.
For preference, drain off oil when it is at operating temperature.
Ensure that old oils are collected and disposed of in an environmentally acceptable manner
using the removable oil filter cartridges.

Danger!
When checking and changing lubrication and operating materials, ensure that the following
precautions are adhered to:
Unless otherwise indicated, carry out all work on the machine on level, solid ground and with the
engine switched off.
Whenever you reach into the engine compartment, always secure the cover and side doors
against accidentally falling back or closing.
Only refuel the machine when the engine is switched off, do not smoke and avoid naked flame.
Turn the main battery switch to position 0 (off) and remove the ignition key.

2 Lubricant chart

Designation Medium Symbol Classification Viscosity

Diesel engine Engine oil API-CI-4, CH-4, SAE 5W40


ACEA E4, E6, E7 SAE 10W30
SAE 10W40
SAE 15W30
SAE 15W40

R 924 Compact Tier III 1.51.1


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Lubricants and operating fluids Technical documentation
Fuels, lubricants and process chemicals

Designation Medium Symbol Classification Viscosity

Hydraulic tank Engine oil API-CD / ACEA E1 SAE 10W


(MB 226.0 and 227.0) SAE 10W-30
SAE 10W-40
API-CD, CE, CF SAE 15W-40
ACEA - E2, E3, E4 SAE 20W-20
(MB 227.5, 228.1, 228.3 SAE 30W
and 228.5)

Hydraulic oil DIN 51524 T2/T3 ISO VG 32


ISO11158 HM/HV ISO VG 46
ASTM D6158 HM/HV ISO VG 68
ISO VG 100

LAV < 10 min (air separation charcteristics at


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

Swing gear Transmission oil API-GL-5 SAE 80W-90


(as parking brake) MIL-L 2105 B, C or D or
SAE 90 LS

Swing gear Transmission oil API-GL-5 SAE 90 LS


(as positioning MIL-L 2105 B, C or D
swing brake)

Travel gear Transmission oil API-GL-5 SAE 90


MIL-L 2105 B, C or D SAE 80W-90

Splitterbox Transmission oil API-GL-5 SAE 90


MIL-L 2105 B, C or D

Tracks and Lubricating High pressure grease Consistency 2


corresponding grease KP2k or EP2 NLGI Class
gearing of swing
ring, equipment
mounting

Hinges, joints, locks Engine oil - -

Rubber seal on Silicon spray or - -


doors and trim talc
panels

3 Fuels, lubricants and process chemicals

Designation Medium Symbol

Fuel tank Commercially available diesel fuel with sulphur content


between 0,05 % and 0.5 %

1.51.2 R 924 Compact Tier III


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Technical documentation Lubricants and operating fluids
Diesel fuels

Designation Medium Symbol

Coolant Corrosion inhibitor and antifreeze agent

Windscreen washing Conventional windscreen cleaning agent or denatured


system alcohol

Air conditioning system R 134 a


refrigerant
Refrigerant oil in A/C PLANETELF PAG SP 20
compressor

Tab. 1 * = Guide values

4 Diesel fuels

4.1 Specification

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

4.2 Sulphur content of diesel fuel


Fuel that meets the DIN EN 590 standard may contain maximum 50 mg/kg (maximum 0,005 weight
percent) of sulphur.
The reduction of sulphur content has raised the problem of diesel fuel lubrication characteristics. It
has been shown that diesel fuels containing the maximum permitted European sulphur limit of
0.05 weight per cent can cause the fuel injection system to wear (particularly applicable to distributor-
type injection pumps).
"Low-sulphur" diesel fuels with a sulphur content of less than 0,05% are only suitable after addition
of a lubrication additive. According to HFRR (60) test, the lubricity of the diesel fuel may not exceed
460 µm (lubricity-corrected wear scar diameter [1.4] at 60 °C).
When using diesel fuels with a sulphur content of more than 0,5 weight percent, the oil change inter-
vals must be halved.
Do not use fuels with a sulphur content of more than 1 %.

Note!
The ASTM D 975 fuel standard does not specify that the fuels must undergo a fuel lubricity test.
A written confirmation of compliance from fuel supplier must be submitted. The additives should be
added by the supplier, who is responsible for the quality of the fuel. We advise machine operators
not to add any secondary lubricity additives to the fuel

ASTM D 975 fuels must have a cetane number of minimum 45. A cetane number of more than 50
is preferable, especially at temperatures below 0 °C (32 °F).

R 924 Compact Tier III 1.51.3


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Lubricants and operating fluids Technical documentation
Lubricating oil for the diesel engine

4.3 Diesel fuels for operation at low temperatures (winter)


At low temperatures, paraffin crystals are formed in the diesel fuel. They increase the flow reduction
in the fuel filter, so that the diesel engine might not be supplied with sufficient fuel.

Caution!
For technical and reasons, it is forbidden to add petroleum fuel to the diesel.
For arctic climates, use special diesel fuels developed for such extreme conditions.
In the case of insufficient fluidity of th diesel fuel or températures below -20 °C: use a start-up
aid, such as a fuel filter heater.

4.4 Diesel fuels with the LIEBHERR Particles filter

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

5 Lubricating oil for the diesel engine

Modern diesel engines must be lubricated with high-performance oils. They consist of a basic oil
with special additives.
The lubricating oil requirements for LIEBHERR diesel engines are based on the following standards
and regulations:

Classification Specification
API classification (American Petrol CI-4, CH-4
Institute) Caution: observe shorter oil change
intervals
ACEA (CCMC) - classification E4, E6, E7
(Association des Constructeurs
Européens de l´Automobile)

Tab. 2 Lubricating oil for the diesel engine - specifications

Caution !
Particle filter only permitted with oil E6.

5.1 Viscosity
The choice of the lubricating oil viscosity is done according to the SAE classification (Society of
Automotive Engineers).
The relevant factor for the right choice of the SAE class is the ambient temperature.
The SAE classification does not provide any indication as regards the quality of a lubricating oil.
Excessively high viscosity might lead to start-up problems. If the viscosity is too low, the oil's
lubrication might not be sufficiently efficient.
The temperature ranges shown in the diagram are approximate ranges that might temporarily be
exceeded.

1.51.4 R 924 Compact Tier III


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Technical documentation Lubricants and operating fluids
Lubricating oil for the diesel engine

Fig. 1 Temperature-based selection of the SAE class


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

5.2 Lubricating oil change intervals


Change intervals: see chapter "Maintenance and inspection schedule".
Subsequent oil changes depend on the climate, sulphur content of the fuel and oil grade. For details,
see the table below.
If the specified operating hours (h) per year are not reached, the diesel engine oil and filter must be
changed at least once every year.
A number of adverse factors (unfavorable operating conditions) affect the length of the change
interval.
Such adverse factors include:
– Frequent cold starts
– Sulphur content in fuel greter than 0,5 %
– Ambiant temperature below -10° C
If such a factory apply, the oil and filter must be changed according to th table below:

Operating conditions Oil change interval


dependent on oil
quality:
CH-4, CI-4 E4, E6, E7
Operating conditions Sulphur content of fuel Interval
Climate normal to -10 °C up to 0.5 % 250 h 500 h
above 0.5 % 125 h 250 h
below -10 °C up to 0.5 % 125 h 250 h
above 0.5 % not 125 h
permissible

Tab. 3 Oil change intervals for the diesel engine

h = operating hours

R 924 Compact Tier III 1.51.5


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Lubricants and operating fluids Technical documentation
Coolant for the diesel engine

6 Coolant for the diesel engine


The coolant consists of an aqueous solution containing a corrosion inhibitor and an antifreeze agent.
It can be mixed by the operator using the products named below. Alternatively, it can be purchased
as a premixed solution.

6.1 General recommandations

The radiator works only properly when pressurised. It is therefore imperative that it is kept clean and
sealed at all times, that the radiator plug and working valves work properly and that the required
coolant level is maintained.
Corrosion inhibitors/antifreeze agents approved by LIEBHERR ensure proper protection against
frost, corrosion and cavitation without causing damage to seals and hoses and without foaming.

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

Note!
The use of emulsifiable corrosion inhibitor oils is not permitted.

6.2 Water quality


Clear and clean water free of particles that meets the following chemical requirements is suitable as
coolant.
Do not use sea water, brackish water, brine or industrial wastewater.

Contents Quantity
Total earth alkaline content (water 0.6 to 3.6 mmol / l (3 to 20 °d)
hardness)
pH value at 20 °C 6.5 to 8.5
Chloride ion content max. 80 mg / l
Sulphate ion content max. 100 mg / l

Tab. 4 Fresh water quality

Fresh water quality when using coolant with DCA 4

Contents Quantity
Total earth alkaline content (water 0.6 bis 2.7 mmol/l (3 to 15 °d)
hardness)
ph value at 20 °C 6.5 to 8.0
Chloride-ion content max. 80 mg / l
Sulphate ion content max. 80 mg / l

Tab. 5 Fresh water quality with use of DCA 4

Water analysis results are available from the local authorities.

1.51.6 R 924 Compact Tier III


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Technical documentation Lubricants and operating fluids
Coolant for the diesel engine

6.3 Mixting ratio for coolant


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

Outside temperature up to Mixing ratio

°C °F Water % A%
-37 -34 50 50
-50 -58 40 60

Tab. 6 Mixture ratio (for all seasons)

Fig. 2 Temperature-based mixing ratio of water + corrosion inhibitor and anti-freeze agent
A Corrosion inhibitor/antifreeze agent content in coolant

6.4 Permitted corrosion inhibitors / antifreeze agent

Note!
The mixture of certain corrosion inhibitors and antifreeze agents might negatively affect the
properties of the coolant.
Do not mix different products.

Product description Manufacturer Country


Liebherr Antifreeze Concentrate Liebherr D

Addinol Antifreeze Super Addinol Lube Oil GmbH, Leuna D


Agip Antifreeze Plus Aral AG, BochumEni S.p.A., Rome I
Agip Langzeit-Frostschutz Eni S.p.A., Würzburg D
Antigel DB 486 Sotragal S.A., St. Priest F
Aral Antifreeze Extra Aral AG, Hambourg D
Avia Antifreeze APN G48 Avia Mineralöl AG, Hambourg D

BP Isocool BP p.l.c., Londres GB

Caltex Extended Life Coolant Chevron Texaco *


Castrol Antifreeze NF Castrol, London GB
Chevron Extended Life Coolant Chevron Texaco *

DEUTZ Kühlerschutzmittel 0101 1490 Deutz Service International GmbH, D


Cologne

ESA Frostschutz G48 ESA Burgdorf CH

R 924 Compact Tier III 1.51.7


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MJFCIFSS
Lubricants and operating fluids Technical documentation
Coolant for the diesel engine

Product description Manufacturer Country

Fuchs Fircofin Kühlerfrostschutz Fuchs Petrolub AG, Mannheim D

Glacelf Auto Supra (antifreeze) Total, Paris F


GlycoShell Longlife Shell International Petroleum GB
Company, London
Glycoshell N Shell International Petroleum GB
Company, London
Glysantin G 48 BASF AG, Ludwigshafen D

Havoline Extend Life Antifreeze / réfrigérent Chevron Texaco *


Havoline XLC Arteco B

Motorex Antifreeze Protect G48 Bucher AG, Langenthal CH


Motul Inugel Optimal Ultra Motul SA, Aubervilliers Cedex F

OMV Kühlerfrostschutz / Coolant Plus OMV Refining & Marketing GmbH, A


Vienna

* = global / worldwide

6.5 Permitted premixed coolants

Note!
The combination of different coolants might impair their properties.
Do not mix different products.

Product description Manufacturer Country


Liebherr Antifreeze Mix Liebherr D

Caltex Extended Life Coolant Pre-Mixed 50/50 Chevron Texaco *


(ready-to-use-version)
Chevron DEX-COOL Extended Life Prediluted Chevron Texaco *
50/50 Anti-Freeze/Coolant
Coolelf Auto Supra -37 °C Total, Paris F

Havoline XLC, 50/50 Arteco B


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

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

6.6 Permitted corrosion inhibitors without antifreeze agent


In exceptional circumstances and at ambient temperatures that are always above freezing
points, e.g. during use in tropical areas where there are no corrosion inhibitors/antifreeze agents
available, the following inhibitors must be added to the coolant:
DCA 4 (Diesel Coolant Additives 4)

1.51.8 R 924 Compact Tier III


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MJFCIFSS
Technical documentation Lubricants and operating fluids
Hydraulic liquids

Caltex / Chevron / Havoline / Total


In this case, the coolant must be changed annually.
As part of regular maintenance work, check the concentration and correct it, if necessary.

Note!
The admixture of certain corrosion inhibitors might negatively affect the properties of the coolant.
Do not mix different products.
Drain off a coolant before changing from a corrosion inhibitor with antifreeze agent to a standard
corrosion inhibitor and vice versa.

Product description Manufacturer Country


DCA 4 Diesel Coolant Additives Fleetguard / Cummins *
Filtration

Caltex CL Corrosion Inhibitor Concentrate Chevron Texaco *

Chevron Texaco Heavy Duty Extended Life Chevron Texaco *


Corrosion Inhibitor Nitrite Free

Havoline Extended Life Corrosion Inhibitor Chevron Texaco *


(XLI)

Total WT Supra Total, Paris F


* = global

7 Hydraulic liquids

Hydraulic oils must meet the requirement outlined below.


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

7.1 Hydraulic oil


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

R 924 Compact Tier III 1.51.9


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Lubricants and operating fluids Technical documentation
Hydraulic liquids

Fig. 3 Hydraulic oil for use as hydraulic oil (ISO classes)*.

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

* Temperature-based selection of the ISO class


Liebherr Hydraulic Plus and Liebherr Hydraulic Plus Arctic are suitable for both biological as well as
prolonged operation.
Use only LIEBHERR hydraulic oils. The use of other oils is not permitted.If LIEBHERR oils are not
available locally, use one of the motor oils listed in the following chapter see 7.2(before choosing an
oil, contact our customer service department).

7.2 Engine oil


If you wish to use other products, it is your responsibility to obtain a warranty declaration from the oil
supplier.
Engine oils that are to be used as hydraulic oils must conform to the following specifications:

Single-grade oils (1): API - CD / ACEA - E1


Mercedes-Benz regulations, sheet no. 226.0 and 227.0
Multigrade oils (2): API - CD, CE, CF / ACEA - E2, E3, E4
Mercedes-Benz regulations, sheet no. 227.5, 228.1,
228.3 et 228.5

Tab. 7 Engine oils for use as hydraulic oil

1.51.10 R 924 Compact Tier III


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Technical documentation Lubricants and operating fluids
Hydraulic liquids

Fig. 4 Engine oils for use as hydraulic oil (SAE classes)*

A Ambient temperature 1 Single grade engine oil


B Cold-start range with warm-up instruction 2 Multigrade oils
C Operating range

*temperature-based selection of the SAE class


** for deviating viscosity grade: consult the LIEBHERR customer service department

7.3 Warm-up instruction


The black bar B indicates that the ambient temperatures are maximum 20 °C below the operating
range C.
In the event of a cold start at an ambient temperature included in range B, the following warm-up
instruction applies to the hydraulic oil:
1. Start the diesel engine and run it at approx. 1/2 rated speed. Carefully activate the working
hydraulic circuits. Operate a hydraulic cylinder (Stick- for example) and move them to the stop
quickly and many times. After approx. 5 minutes, start the travel hydraulic circuits.
Warm-up duration: approx 10 minutes
At even lower temperature:
2. Before starting the engine, warm up the hydraulic oil tank. Then proceed according to the warm-
up instructions in 1.

7.4 Biodegradable hydraulic oils

Note!
Risk of damage to the hydraulic unit!
When mixing ester-based biodegradable hydraulic oils with mineral oils, there is a risk of aggressive
chemical reactions, which can damage the hydraulic equipment.
Do not mix biodegradable hydraulic oils from different suppliers, and never mix with mineral oils.

The use of a partial flow filters is mandatory.


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

R 924 Compact Tier III 1.51.11


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Lubricants and operating fluids Technical documentation
Hydraulic liquids

Fully saturated synthetic ester-based oils, HEES


Before using biodegradable hydraulic oil, you must consult LIEBHERR.
Do not use vegetable oils, as they do not possess the necessary thermal stability.
If you wish to use other products, it is your responsibility to obtain a warranty declaration from the oil
supplier.

7.5 Monitoring, filter change and oil change

Note!
Biodegradable hydraulic oils must be checked regularly by means of an oil analysis.
– Normal operation after change of oil* an then at least every 500 operating hours
– Dust intensive application: after change of oil* an then at least every 250 operating hours
For mineral oils, an oil analysis is only required if the oil change interval is to be extended.
– Normal operation first time after 1500 operating hours, then every 500 operating hours
– Dust intensive application: at least every 250 operating hours
LIEBHERR recommends contacting WEAR-CHECK** with these analysis,and to change the oil
when indicated by the test results in the lab report (see also customer service and product
information).

* Change of oil = change from mineral oil to environmentally-friendly hydraulic oil


** Yellow kit for machines with environmentally-friendly oil filling (HEPR and HEES)
Green kit for machines with mineral oil filling

Symbol Signification
Filter change for hydraulic oil

Oil sampling

Tab. 8 Key to figures

Hydraulic oil in normal use

Fig. 5 Oil sampling and filters change in normal use

h Operating hours 1 First oil sample


a Mineral oil 2 Second oil sample
h Biodegradable hydraulic 3 Subsequent oil samples every 500 operating
oil hours

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

1.51.12 R 924 Compact Tier III


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MJFCIFSS
Technical documentation Lubricants and operating fluids
Hydraulic liquids

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

Hydraulic oil used in dust intensive applications

Fig. 6 Taking oil samples and changing return filters in heavy dust environments

h Operating hours 1 First oil sample


a Mineral oil 2 Second oil sample
h Biodegradable hydraulic 3 Subsequent oil samples: every 250 operating
oil hours

Oil change after 500 operating hours, or when indicated by the lab report of the analysis.
Interval for the change of the hydraulic oil return filter (10 µm): first change after 500 operating hours,
then every 500 operating hours and after each hydraulic oil change.

7.6 Instructions for the reduction of the contamination of the hydraulic oil in ma-
chines used for dust intensive applications
If the machine is normally operated with a hydraulic hammer or under similar conditions (considerable
dust generation), the hydraulic oil might become more contaminated than under normal working
conditions.
In order to prevent premature wear of the hydraulic components, shorten the intervals between the
oil changes (or oil samples respectively) and observe the following instructions:
– The filter cartridge(s) in the return filter must be replaced every 500 operating hours and after
every hydraulic oil change.
– Use 10-µm filter cartridges instead of the standard 20 / 5-µm cartridges.
– The 2-µm breather filter must be replaced every 500 operating hours and after every hydraulic oil
change.

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

R 924 Compact Tier III 1.51.13


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Lubricants and operating fluids Technical documentation
Lubricating grease and other lubricants

8 Lubricating grease and other lubricants

Lubricant Description / manufacturer


Grease for swing ring and general The grease must correspond with the specification
lubrication points KP2k, consistency 2 or NLGI grade in accordance with
DIN 51818 and DIN 51825 or EP 2 in accordance with
NF-T-60 132.
The grease must consist of a lithium complex and have
a four ball tester value of at least 2300 N in accordance
with DIN 51350 and ASTM D 2596.
For use in central lubrication systems
• for the temperature range +60° C to -10° C
( 140° F to -50° F) LIEBHERR recommends:
Multi service grease RPL
LIEBHERR order nb: 8501565 (1 pack with 5
cartridges of 400 grams).
• if ambient temperatures are expected to
remain under -10° C, it is recommended to
make an early change of the grease type to a
specific "LOW TEMPERATURE" grade
This grease must have the necessary
pumpability and "WORKED PENETRATION"
consistency between 265 - 295 at -10° C
temperature.

Contact spray for slip rings Cramolin


Lubricant for pistons, piston nuts and Gleitmo 800
piston bearing installations on the
hydraulic cylinders
Special anti-corrosive material for Castrol-Tarp
installation areas of sealingelements
on hydraulic cylinders
Anti-corrosion grease for open piston Liebherr special grease CTK
rods (cylinders that do not move
often or transportation)

Tab. 9 Grease and other process chemicals

1.51.14 R 924 Compact Tier III


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Technical documentation

Group 2: Tools

Special tools for maintenance and repair ............................................................................2.01

Special tools for Liebherr Diesel engines D 934 / D 936.....................................................2.02

Special tool for the hydraulik system...................................................................................2.03

Special tools for electrical connectors.................................................................................2.06

Special tools for gears ...........................................................................................................2.07

Common tools ........................................................................................................................2.08

Measuring tool for spool travel .............................................................................................2.10

Mounting tools for hydraulic cylinders ................................................................................2.12


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

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

Compression device for brake piston of gear SAT .............................................................2.15

Compression device for brake piston of gear FAT .............................................................2.16

Tools for installing the slipring seals ...................................................................................2.19

Special tools for the lifting of the uppercarriage.................................................................2.30

R 924 Compact Tier III 2.00.1


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Technical documentation Special tools for maintenance and repair

Group 2: Tools

2.01: Special tools for maintenance and repair

Size /
Representation No. Designation Ident. No. MachineApplication
Quantity
1 Pipe Adapter NW 10 7002404 all types
2 NW 12 7008688

13 Pipe Adapter M22x1,5 5607671 all types K Forme


14 M14x1,5 5607616 From – LH673-02

15 M16x1,5 5607605
16 M18x1,5 5607617
17 M20x1,5 7409922
18 M24x1,5 7409923

25 BSP coupling R 1/2 “ 7002436 all types

30 Direct gauge coupling R 1/2 “ 7002435 all types

R 924 Compact Tier III 2.01.1


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MJFCIFSS
Special tools for maintenance and repair Technical documentation

Size /
Representation No. Designation Ident. No. MachineApplication
Quantity
35 High pressure hose 1000 mm 7002437 all types To connect pressure gauge
36 (Lenght) 1500 mm 7002475 on all test points (pipe adaptor
no 1/2 and gauge
37 5000 mm 7363732 coupling 10-14)

40 Gauge coupling M10X1 5005180 all types


41 M12X1,5 7402580
42 M14X1,5 5004002
43 M16X1,5 7361345
44 R 1/4’’ 7362579

45 Hydraulic pressure gauge 0-1,6 bar 8042577 Used to check system pres-
46 0-1,6 bar * 8042578 sure in one or more hydraulik
47 0-2,5 bar * 7361292 system
48 0-6 bar * 7361291
49 0-10 bar * 5002865 * dampened with glycerin
50 0-25 bar * 7361289
51 0-40 bar * 7361288
52 0-60 bar * 5002867
53 0-160 bar * 7361286
54 0-250 bar * 7361285
55 0-400 bar * 7500002
56 0-600 bar * 7361294
75 Measuring set complete, in carrying 11000678 all types To perform adjustment checks
case, containing:
- Measuring device MH 3020 10814168
- Pressure sensor (2 units) 0 - 600 bar, 10288153
0 - 20 mA
- Measuring wire, 12 meters (2 units) 10288154
- Power supply unit 110 / 220 V 7025279
- Data transfer cable 10814169
- Connector 1620 614062601
- Carrying case 10664392
78 Power supply cable / cigar lighter 7025273 With tool no. 75
82 Pressure sensor 0-600 bar 7025751 all types
83 Adapter for pressure sensor 7025752
84 Measuring cable MK12 12 m 7025753

2.01.2 R 924 Compact Tier III


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MJFCIFSS
Technical documentation Special tools for maintenance and repair

Size /
Representation No. Designation Ident. No. MachineApplication
Quantity
90 Adapter for test point 4901372 all types For pressure balancing.
91 Test point with metalic cap 7002404 With tool no. 75

92 Cap nut 4774002


93 Cutting ring 4774001

100 Service plug (green) 9684328 all types To adjust the electronic con-
except trol circuit via the display of
Ad- the excavator.
vanced

101 RS232 crossover cable 9684327 all types To save the error codes con-
except tained in the BBT.
Ad-
vanced

102 RS232 normal cable 10029996 all types Can be used as an extension
with the other cables.
With tool no. 103

103 Adapter 10029999 all types

104 USB to RS232 converter 693190714 all types

110 PME cable 10035410 all types To establish the link between:
- PC and engine
- PC and machine (advanced)

R 924 Compact Tier III 2.01.3


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Special tools for maintenance and repair Technical documentation

Size /
Representation No. Designation Ident. No. MachineApplication
Quantity
113 Compact flash card reader 10223095 Ad- To read the contents of the
vanced compact flash card (see 2.04,
advanced)

Sculi software LIDOS all types For the diagnosis of:


- the Diesel engine
- the machine (advanced)
Sculi - Engine diagnosis all types For the diagnosis of the Diesel
engine
115 - Marx Dongle with a sculi licence - en- 10450053
gine diagnosis «light»
116 - Marx Dongle with a sculi licence - en- 10450054
gine diagnosis «service»
Sculi - Master 4 diagnosis Advan- For the diagnosis of:
120 - Marx Dongle with a sculi licence - Mas-10333608 ced - the Diesel engine
ter 4 diagnosis «service» including sculi- - the machine (advanced)
engine diagnosis «light»
121 - Marx Dongle with a sculi licence - Mas-10489591
ter 4 diagnosis «service» including sculi-
engine diagnosis «service»
Upgrade (already beeing in possessi-
on with a Marx Dongle)
125 - Sculi licence - Diagnosis Master4 «ser-0010301 Advan-
vice» ced
126 - Sculi licence - Engine diagnosis «ser- 0010300 all types
vice»
131 Revolution indicator DT 205 7364284 all types To check the RPM via reflex-
Shimpo ions stripe
132 Stripes 614063201

140 Measuring adapter 8504231 all types To check regulation current on


the pumps

2.01.4 R 924 Compact Tier III


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MJFCIFSS
Technical documentation Special tools for maintenance and repair

Size /
Representation No. Designation Ident. No. MachineApplication
Quantity
145 Multimeter with digital dis- Chauvin 10018500 all types For voltage, current and re-
play Arnoux sistance measurements of
MAX 3000 electrical systems and of sole-
noid valves
146 Measuring tool kits 5616316 With tool no. 145
147 Measuring cable set 886125008 With tool no. 145
149 Measuring cable set 6204166 With tool no. 145

160 Infrared thermometer GMTL 1826 7020372 all types Used to monitor the temper-
atur of a liquid or the external
temperature of a component

162 Thermometer with probe GTH 1150 10024185 all types


and sensor (magnetic)

170 Hand pump 8145666 all types Used to take samples for oil
172 Sampling valve for oil samples alterna- 7019068 analysis
tive to the hand pump

175 Oil analysis set No. 1 7018368 all types 6 samples


180 Oil analisys set 8145660 1 sample
181 Complete set for oil analysis ** 8503561 For 6 samples
** Analysis by WAER CHECK society
Analysis report in German

188 Bio oil analysis set No. 1 7026817 all types 1 sample
189 Bio Oil analisys set 7026088 6 samples
Complete set for oil analysis **
** Analysis by WAER CHECK society
Analysis report in German

R 924 Compact Tier III 2.01.5


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MJFCIFSS
Special tools for maintenance and repair Technical documentation

Size /
Representation No. Designation Ident. No. MachineApplication
Quantity
190 Evacuation pump REF- RD-4 7027552 all types For servicing and repairing the
CO air conditioning equipment

195 Filling hose ITE blue 1500 mm 7027553 all types With tool no. 190
196 Filling hose ITE yellow 1500 mm 7027554
197 Filling hose ITE red 1500 mm 7027555

205 Quick coupling ITE 253a 7027556 all types With tool no. 190
210 Quick coupling ITE 254 a 7027557

215 Test equipment with 4 M4WS5C 7027558 all types For servicing and repairing the
valves air conditioning equipment

220 Disassembly tool UTV-M20 7023304 all types To disassemble the pins of the
221 UTV-M24 7023305 grabble

222 UTV-M30 7023306


223 UTV-M36 7023307
224 UTV-M42 7023308

2.01.6 R 924 Compact Tier III


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MJFCIFSS
Technical documentation Special tools for maintenance and repair

Size /
Representation No. Designation Ident. No. MachineApplication
Quantity
230 Disassembly washer M14 7023309 all types To disassemble passfix bolts
231 M20 7023310
232 M24 7023311
233 M30 7023312
234 M36 7023313
235 M42 7023314

240 Removal tool for CMVE 108 motor 10385026 all types To remove the travel motor
alone

245 Diagnostic set 10008427 all types Communication and diagnos-


(software on CD and connecting cable) tic software for BEKA-MAX
central lubrication

Associated products :

Pos. Sensors Ident. no.


2 OEM - Pressure sensor 0 - 1000 bar 1001 8329
0 - 20 mA
3 OEM - Pressure sensor 0 - 60 bar 6140 625 01
0 - 20 mA
4 OEM - Pressure sensor 0 - 10 bar 1002 7591
0 - 20 mA
5 OEM - Pressure sensor -1 / +6 bar 5718 886 08
4 - 20 mA
(LWE)
6 OEM - Pressure sensor -1 / +6 bar 1028 5368
0 - 20 mA
(LWE)
7 Adapter for pressure sensor to MINIMESS Serie 1620 - 0° 6140 626 01
8 Adapter for pressure sensor to MINIMESS Serie 1620 - 90° 6140 647 01
9 Temperature sensor Pt 100 -50 °C / +200 °C 6140 627 01
10 P / T - Measuring coupling, MINIMESS Serie 1620 6140 628 01
G 1/4“
11 P / T - Measuring coupling, MINIMESS Serie 1620 1004 1274
M10 x 1,5
12 Measuring turbine RE 4 - 10 5010 031
1 - 10 l/min

R 924 Compact Tier III 2.01.7


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Special tools for maintenance and repair Technical documentation

Pos. Sensors Ident. no.


13 Measuring turbine RE 4 - 75 6140 62901
2 - 75 l/min
14 Measuring turbine RE 4 - 300 6140 630 01
9 - 300 l/min
15 Measuring turbine RE 4 - 600 5009 492
16 - 600 l/min
15 Measuring turbine RE 7 - 600 1100 2327
25 - 600 l/min
16 Tachometer DS 03 6140 631 01
1 - 9999 U/min
17 Set of spare reflective foils 6140 632 01
18 Magnetic holder for tachometer DS 03 6140 633 01
19 Inductive sensor for tachometer 6140 634 01

Pos. Options Size Ident. no.


20 Carrying case to carry the measuring turbine RE 3 6140 635 01
21.1 Measuring cable to connect the sensors (7 on 6 poles) MK12 6 meters 1029 5330
21 Measuring cable to connect the sensors MK12 6 meters 6140 636 01
22 Measuring cable to connect the sensors MK12 12 meters 6140 637 01
23 Measuring cable to connect the sensors MK12 18 meters 6140 638 01
24 Power supply cable 6 meters 6140 639 01
25 Power supply cable 12 meters 6140 640 01
26 Network printer DPU 411 6140 641 01
27 Exchange thermopaper roll for DPU 411 6140 642 01
28 Centronics date transfer cable 2 meters 6140 643 01
for DPU 411
29 Data transfer cable (to connect to PC) RS 232 - 2 m. 9684 327
33 Exploitation transfer CD-rom 10287659
Windows 32 bit
(d / e / f)

2.01.8 R 924 Compact Tier III


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Technical documentation Special tools for Liebherr Diesel engines D 934 /

2.02: Special tools for Liebherr Diesel engines D 934 /


D 936

Size /
Representation No. Designation Ident. No. Machine Application
Quantity
Sculi special tools see 2.01 all types For the diagnosis of the Die-
sel engine and of the machine
20 Compressiometer 8008782 all types To check the compression
pressure
21 Diagramms 100 10012817
pieces

25 Connecting piece for the compressi- 10297211 all types To insert instead of the injec-
ometer tion valve

26 Claw 10117612 all types To fasten the piece 25.

35 Extracting device for injection valve 0524072 all types To remove injection valves

36 Adapter for extracting device 0524029 Has to be used with the ex-
tracting device

37 Adapter 10220689 all types To remove injection valves


Has to be used with the ex-
tracting device

R 924 Compact Tier III 2.02.1


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MJFCIFSS
Special tools for Liebherr Diesel engines D 934 / Technical documentation

Size /
Representation No. Designation Ident. No. Machine Application
Quantity
40 Turning gear on the flywheel hous- 0524045 all types To turn the Diesel engine over
ing the flywheel

41 Turning gear 10116805 all types To turn the Diesel engine

42 Turning gear on the air compressor 10117936 all types To turn the Diesel engine

43 Turning gear for vibration damper 10118801 all types To turn the Diesel engine

44 Rotation device 1/2’’ - An- 0524062 all types To drive the turning gear
gle

45 Rotation device 3/4’’ - An- 10023839 all types To drive the turning gear
gle

50 Pin 9078119 all types To install and to dismantle the


crankshaft

51 Mounting bolt 0528470 all types To install and to dismantle the


flywheel

52 Mounting bolt 0528472 all types To install and to dismantle the


aggregate carrier

2.02.2 R 924 Compact Tier III


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MJFCIFSS
Technical documentation Special tools for Liebherr Diesel engines D 934 /

Size /
Representation No. Designation Ident. No. Machine Application
Quantity
53 Mounting bolt 0524059 all types To install and to dismantle the
oil cooler housing with oil
cooler

54 Stamp 0523639 all types To install and to dismantle the


regulating valve

60 Extractor 0526855 all types To install and to dismantle the


cylinder liner

61 Extractor 0528462 all types To install and to dismantle the


cylinder liner

62 Holding fixture 0528464 all types To hold the cylinder liner in its
position
Zylinderlaufbuchsen in ihrer
Lage halten

63 Dial gauge holder 10023885 all types To hold the dial gauge

70 Hook 7019858 all types Dismantling the crankshaft


seal

71 Press-in device 10116249 all types Installing the crankshaft seal

72 Press-in device 10116250 all types Installing the crankshaft seal

75 Special spanner 10020852 all types Installing and dismantling the


injection lines

R 924 Compact Tier III 2.02.3


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MJFCIFSS
Special tools for Liebherr Diesel engines D 934 / Technical documentation

Size /
Representation No. Designation Ident. No. Machine Application
Quantity
76 Nozzle tester 10340104 all types To test the nozzle

77 Suction device 10337931 all types To test the nozzle

78 Adapter 10340119 all types To test the nozzle

79 Nozzle cleaning tool 10340120 all types To clean the nozzle

85 Testing device 10340121 all types Concentric running test and


wobble measurement

86 Dial gauge 8004064 all types For wobble measurement

87 Dynamometer 10340124 all types Dismantling and reassem-


bling the injection nozzle

88 Force sensor 10340125 all types Reassembling the injection


nozzle

2.02.4 R 924 Compact Tier III


copyright by

MJFCIFSS
Technical documentation Special tools for Liebherr Diesel engines D 934 /

Size /
Representation No. Designation Ident. No. Machine Application
Quantity
89 Press-in device 10340126 all types Reassembling the injection
nozzle

90 Mounting collar 10289319 all types Reassembling the injection


nozzle

91 Mounting collar 10289320 all types Reassembling the injection


nozzle

R 924 Compact Tier III 2.02.5


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MJFCIFSS
Technical documentation Special tool for the hydraulik system

2.03: Special tool for the hydraulik system

Size /
Representation No. Designation Ident. No. Machine Application
Quantity
10 Special wrench for relief SW 17 9359414 all types To adjust primary and sec-
11 valves SW 19 9210371 ondary relief valves on control
valves

20 Safety cap SW 10 7009315 all types To secure the adjusting


21 short SW 13 7018734 screws on the hydraulic com-
ponents
22 long SW 13l 7615515
23 SW 17 7380629
24 short SW 19 7009316
25 long SW 19l 7009317
26 M6 7023491
27 M8 7023492
28 M10 7023493
29 M12 7023494
30 Mounting sleeve see sub-group 2.12 all types For assembly of the o-ring
and stepseal-ring on the pis-
tons of the hydraulic cylinders
and on the positioning piston
of the pump and of the varia-
ble displacement motor

40 Spreader sleeve see sub-group 2.12 all types

50 Piston wrench see sub-group 2.12 all types

Voir sous-groupe 2.12

R 924 Compact Tier III 2.03.1


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MJFCIFSS
Special tool for the hydraulik system Technical documentation

Size /
Representation No. Designation Ident. No. Machine Application
Quantity
60 Piston wrench SW 0541333 all types To remove and to tighten the
61 see sub-group 2.12 piston nuts

62
63
64

70 Socket wrench for thread- SW 41 9245656 all types Used to remove and install
ed bushing SW 46 9247110 damper pin on hydraulic cylin-
ders with damper on piston /
SW 50 9244173 piston rod side.

80 Puller for piston rod bear- M16 9951120 all types To remove the piston rod
ing M20 9959261 bearing

M24 9959262

90 Filling device complete W24x 8145359 all types To check and refill diaphragm
with adapter and filling 1-1/4“ and piston type accumula-
hose 3,0m tions

95 Mounting sleeve Ø 25 9951457 all types For assembly of the Glyd-ring


96 Ø 22 9951508 and scraper - ring on plunger
piston of hydraulic coupling
97 Ø 45 9966421 LIKUFIX.
98 Ø 25 9951458

106 Hexagon socket set M6 4901114 R 906 To stop the pressure which
screw R 916 releases the travel brakes.
R 926
Classic
Advanced

2.03.2 R 924 Compact Tier III


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MJFCIFSS
Technical documentation Special tool for the hydraulik system

Size /
Representation No. Designation Ident. No. Machine Application
Quantity
180 Vacuum pump, complete TF63/2- 7405073 all types Retension of hydraulic tank
consisting of: Pump no. 24V content
180, vaccum control
valve no. 181 with seal-
ing, hose with filter no.
187.
181 Vacuum control valve, complete 10097130
182 Vacuum control valve 5006213
183 T coupling 7015042
Connecting piece to tank, consisting
of:
184 - screw-in stud 7002240
185 - Cone RED connection 16/8S 7407155
186 - straight nipple 7024875

R 924 Compact Tier III 2.03.3


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Technical documentation Special tools for electrical connectors

2.06: Special tools for electrical connectors

Fig. 1 Deutsch connectors Fig. 3 Lugs

Fig. 2 Mate-N-Lock connectors Fig. 4 AMP connectors

R 924 Compact Tier III 2.06.1


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MJFCIFSS
Special tools for electrical connectors Technical documentation

Size /
Representation No. Designation Ident. No. Machine Application
Quantity
8 Transformet set 24 / 230 V 11006157 all types

10 Repearing kit for connector technol- 10359794 all types Contains all the connectors
ogy, including four carrying cases and the associated tools
with connector technology and one
carrying case with speficic tools:
1 - Deutsch connector technology 10359757
2 - Mate-N-Lock connector technolo- 10359758
gy
3 - Lugs and fuses 10359759
4 - Deutsch and AMP connector tech- 10360599
nology
5 - Carrying case with tooling 10360630
15 Tool to crimp contacts of connectors 8503647 all types
type Deutsch
Included in the carrying case 5
(10360630)

28 Tool to crimp contacts (from MIL- 7367086 all types


C5015, VG 95234, 955342)
29 Crimp turret to crimp contact of con- 7409779
nectors type Deutsch (KPS - KPT -
PT) sizes with special tool no. 28
30 Crimp turret to crimp contact of con- 7367084
nectors type Deutsch (15S/16S -
15/16 - 25/12) sizes with special tool
no. 28

35 Pneumatic power crimp HDP 400 8504158 all types


equipment to crimp in-
serts for connectors
Deutsch
36 Tools (sockets and pins) Taille 4 8504159
37 Tools (sockets and pins) Taille 8 8504160
38 Tools (sockets and pins) Taille 12 8504161
39 Tools (sockets and pins) Taille 16 8504162
45 Extraction tool to push a Taille 4 8503633 all types
46 crimped contact of the Taille 8 8503632
connectors Deutsch
47 Included in the carrying Taille 12 8145674
48 case 1 (10359757) Taille 16 8145673
49 Taille 20 8503630

2.06.2 R 924 Compact Tier III


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MJFCIFSS
Technical documentation Special tools for electrical connectors

Size /
Representation No. Designation Ident. No. Machine Application
Quantity
55 Deutsch cable extractor 7026267 all types
Included in the carrying case 5
(10360630)
60 Dynamometric screwdriver - 3 Nm 10800772 all types
Included in the carrying case 5
(10360630)
61 Hexagonal drive socket for spanner 10801159
(4 mm)
Included in the carrying case 5
(10360630)
65 Insertion tool for CA-COM contact 7367017 all types
(15S - 16S)

80 Test tip - red 884191214 all types


Included in the carrying case 1
(10359757)
81 Test tip - black 884191114 all types
Included in the carrying case 1
(10359757)

90 To crimp contacts for leads of 7367025 all types


MATE-N-LOK 1,5mm2
SURE-SEAL
FASTON 0,5 - 2,1 mm²
Junior Power Timer
Mini timer
Included in the carrying case 5
(10360630)
100 Extraction tool to push a crimped 7366655 all types
contact out of to the MATE-N-LOK
connectors
Included in the carrying case 2
(10359758)
105 Mini-timer extrator 7027340 all types

110 Mini-timer extrator 7026266 all types


Included in the carrying case 4
(10360599)

120 Tool to crimp lugs 8502520 all types


Included in the carrying case 5
(10360630)

121 Tool to crimp bushes 7367665 all types


Included in the carrying case 5
(10360630)

R 924 Compact Tier III 2.06.3


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MJFCIFSS
Special tools for electrical connectors Technical documentation

Size /
Representation No. Designation Ident. No. Machine Application
Quantity
125A IC-Extraction tool 8042630 all types

125B IC-Mouting tool 8042629

130 Solenoid tester 6204661 all types

2.06.4 R 924 Compact Tier III


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MJFCIFSS
Technical documentation Special tools for gears

2.07: Special tools for gears

Model Application
Designation Nb Designation Size Order no

Socket for wrench for- SAT To loosen and tighten the


5 slotted nut in swing 225 9202820 slotted nut at the roller
10 gear SAT 250 9199665 bearing of the output shaft
15 275 9202821 in the swing ring SAT. See
20 300 9202822 details in subgroup 2.14.
25 325 9202823
30 350 9202824
35 400 9960374
40 450 9960410
Compression device SAT For disassembly and as-
50 225 9202825 sembly of the piston of the
52 250 9199319 multidiscs brake in the
54 275 9202826 swing gear SAT. See de-
56 300 9202827 tails in subgroup 2.15.
58 325 9202828
60 350 9202829
62 400 9393900
450 9393900

Compression device FAT For disassembly and as-


80 350 / 400 9196958 sembly of the piston of the
multidiscs brake in the
82 450 / 500 9199294 travel gear FAT. See de-
tails in subgroup 2.16.

Compression device FAT For disassembly and as-


90 350/022 9981445 sembly of the piston of the
350/032 multidiscs brake in the
92 400/063 9392820 travel gear FAT. See de-
400/073 tails in subgroup 2.16.

Installation tool for FAT To install the slipring seals


slipring seals 350/022 8503594 into the travel gears FAT.
350/032 See details in subgroup
400/063 8503179 2.19.
400/073
450/044 8503181
450/064 8503181
500/035 10027892
550P046 10027891
600P067 10027894

R 924 Compact Tier III 2.07.1


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MJFCIFSS
Technical documentation Common tools

2.08: Common tools

Size /
Representation No. Designation Ident. No. Machine Application
Quantity
5 Torque wrench 1-12 8503599 all types To tighten the bolt to the
10 Size in Nm 60-300 8503048 prescribed torque
15 140-760 7362441
20 750-2000 8503600
22 1500-3000 8503601

25 Hydraulic wrench Hytorc 3 - XLT 7373023 all types To tighten the bolt to the
30 5 - XLT 8502890 prescribed torque
35 10 - XLT 8503882
40 30 - XLTC 8503881

45 Socket Hytorc 30 mm 8589150 all types


46 32 mm 8565020
47 36 mm 8589770
48 41 mm 8502436
49 46 mm 8502461
50 50 mm 8502975
51 55 mm 8589940
52 65 mm 7362130
53 75 mm 8503884
54 85 mm 7373022

Lifting eye M12 4026006 all types For the lifting of different
M30 400656 components of the excavator
M42 4001313
M48 4900835
M56 4901609

R 924 Compact Tier III 2.08.1


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MJFCIFSS
Technical documentation Measuring tool for spool travel

2.10: Measuring tool for spool travel


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

Fig. 1 Messvorrichtung / Measuring tool / Appareil de mesure

1 Hubmessvorrichtung / Measuring tool / Appareil de mesure


2 Dichtung / Seal / Joint
3 Deckel des Steuerschiebers / Spool cover / Couvercle du tiroir
4 Schieberstange / Spool / Tiroir

Hub bei grösse / Stroke for size /


Course pour la taille
NG 16 9 mm
NG 22 12 mm
NG 25 14 mm
NG 32 15 mm
NG 40 20 mm

Tab. 1 Hub bei grösse / Stroke for size / Course pour la taille

R 924 Compact Tier III 2.10.1


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MJFCIFSS
Measuring tool for spool travel Technical documentation

Fig. 2 Technische Zeichnung / Technical drawing / dessin technique

Dimensionen sind in mm / Dimensions are in mm / Les dimensions sont en mm


(mm x 0.03937 = inches)

2.10.2 R 924 Compact Tier III


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MJFCIFSS
Technical documentation Mounting tools for hydraulic cylinders
Mounting wrench for hydraulic cylinders

2.12: Mounting tools for hydraulic cylinders

1 Mounting wrench for hydraulic cylinders


Wrench with bores «A» for retaining bolts

Id.-Nr. a b c d e f g h i 4-KT
9131359 52 38 75 200 10 8 8 15 60 1/2"
9131362 60 44 85 200 14 10 10 15 65 1/2"
9231993 68 52 100 220 14 10 10 15 70 1/2"
75 54 110 220 14 12 10 20 84 3/4"
8007364 #
80 54 110 220 14 12 10 20 84 3/4"
8007365 88 63 120 250 14 12 10 20 90 3/4"
8007366 100 78 135 260 14 14 10 20 95 3/4"
9919856 115 88 150 300 14 14 10 20 105 3/4"
125 97 170 320 14 14 10 25 110 3/4"
9196978 #
130 97 170 320 14 18 15 25 110 3/4"
8007367 145 113 185 380 14 18 15 25 120 3/4"
9925117 160 125 200 420 14 18 15 25 130 3/4"
9131373 175 135 215 450 14 20 19 25 135 3/4"
9131376 220 156 280 500 14 30 28 40 158 3/4"
0541380 85 72 110 210 11 8 8 15 210 1/2"
0542336 120 100 140 240 12 8 9 152 240 1/2"
0540947 124 100 150 240 12 8 9 15 240 1/2"
0541379 145 125 170 280 11 8 9 15 280 3/4"
0540966 160 135 185 280 12 10 9 20 280 3/4"
0529897 165 140 190 280 12 10 9 20 280 3/4"

Tab. 1 Chart for mounting wrenches (with bores)

Notes!
• In this chart all size indications are in mm.
• The size for pistons and mounting wrenches and their respective identification numbers are to
be found in the Lidos.
• # These wrenches can be used with two different pin distances, resp. pin sizes.

R 924 Compact Tier III 2.12.1


copyright by

MJFCIFSS
Mounting tools for hydraulic cylinders Technical documentation
Piston nut wrench

Forked type piston wrench

Ident-Nr. a b c d e f g h i 4-KT
9249886 250 204 310 600 14 30 28 30 175 3/4“
9249741 260 176 330 600 19 36 35 40 180 3/4“
9243215 280 206 354 650 19 36 35 40 190 3/4“

Tab. 2 Chart for mounting wrenches (forked type)

2 Piston nut wrench

Piston nut wrench


Slotted
Bauform SW 6-KT SW 2-FL 4-KT Id.-Nr.
round nut Ø
Size - Identific. number.
M30X1,5 - 7006469 44 *
M32X1,5 - 7010262 50 *
M33 X1,5 - 9226916 41 1/2“ 9921132
M36X1,5 - 9875702 50 1/2“ 9211967
M42X1,5 - 7010163 62 *
M42X1,5 - 9970088 60 1/2“ 9211967
M42X1,5 - 9113734 55 1/2“ 9921132

2.12.2 R 924 Compact Tier III


copyright by

MJFCIFSS
Technical documentation Mounting tools for hydraulic cylinders
Mounting and spreader sleeve

Piston nut wrench


Slotted
Bauform SW 6-KT SW 2-FL 4-KT Id.-Nr.
round nut Ø
Size - Identific. number.
M50X2 - 4129202 70 1/2“ 9921123
M50X2 - 9166795 65 1/2“ 9921123
M56X2 - 9921260 80 1/2“ 9921124
M60X2 - 4129203 80 1/2“ 9921124
M65X2 - 9247441 85 1/2“ 9921133
M68X2 - 9129554 90 1/2“ 9921124
M76X2 - 9970448 100 3/4“ 9921125
M85X3 - 9142472 110 3/4“ 9921125
M95X3 - 9101411 120 3/4“ 9921126
M100X3 - 9950036 130 3/4“ 9951123
M110X3 - 9129653 / 9112934 149 3/4“ 9921127
M120X3 - 9143685 165 3/4“ 9921128
M130X3 - 9125066 180 3/4“ 9921129
M150X3 - 9144654 210 3/4“ 9921131
M170X3 - 5008571 230 3/4“ 9921134
M200X4 - 5008563 260 3/4“ 9921135

Tab. 3 Chart for piston nut mounting wrenches

* commercially available slotted nut wrench

3 Mounting and spreader sleeve

Kolben Ø Mounting sleeve 990 Spreader sleeve 991


Piston Ø Identification number Identification number
32 9136418 9136416
32 9113100 9113099
38 9143279 9143280
40 9196902 9136417
45 9136419 9136417
50 9288953 9288954
63 9170510 9170512
65 9177541 9177540
70 9110556 9110402
80 9227165 9227166
85 9998618 9110404
85 9115710 9115708
90 9227161 9227162
100 9998626 9110405
105 9951984 9951983
110 9170509 9170511
110 9960483 9960502

R 924 Compact Tier III 2.12.3


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MJFCIFSS
Mounting tools for hydraulic cylinders Technical documentation
Mounting and spreader sleeve

Kolben Ø Mounting sleeve 990 Spreader sleeve 991


Piston Ø Identification number Identification number
115 9998625 9110406
120 9998778 9110407
125 9227163 9227164
125 9960484 9960503
130 9998624 9110408
135 9285578 9285579
140 9998623 9110409
150 9998622 9110410
160 9998621 9110411
170 9107931 9110412
180 9998619 9110413
180 9107932 9110413
190 9907684 9907701
190 9280862 9280863
200 9107933 9110414
210 9192854 9192853
220 9113008 9113009
230 9144914 9144912
240 9903977 9903978
300 9135351 9135350

Tab. 4 Mounting and spreader sleeve chart

Mounting sleeve to insert the piston into the jack

Piston Ø Mounting sleeve 950


Identification number
65 9177543
80 9231749
90 9248893
90 9248894
100 9248895
110 9248897
120 9248898
130 92487899
140 9177541
140 9952180
160 9248909
190 9281241
210 9281240
250 9951147
260 9284918

2.12.4 R 924 Compact Tier III


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MJFCIFSS
Technical documentation Mounting tools for hydraulic cylinders
Mounting and spreader sleeve

Tab. 5 Piston mounting sleeves

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

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

Piston Ø Mounting sleeve 950


Identification number
90 9282761
105 9287177
140 9926806

Tab. 6 Piston rod mounting sleeves

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

R 924 Compact Tier III 2.12.5


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MJFCIFSS
Technical documentation Wrench for the slotted nut on the swing gear SAT

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

Fig. 1 Wrench socket for slotted nut

Swing gear SAT


Identification number.
Type
SAT 225 9202820
SAT 250 9199665
SAT 275 9202821
SAT 300 9202822
SAT 325 9202823
SAT 350 9202824
SAT 400 9960374
SAT 450 9960410

Tab. 1 Identification numbers of the wrench sockets

R 924 Compact Tier III 2.14.1


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MJFCIFSS
Wrench for the slotted nut on the swing gear SAT Technical documentation

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

Fig. 2 Definition of dimensions of the sockets

SAT A B C D E F G H J K L M N O
225 90 40 30 55 71,5+0,2 77 100 95 3,8 80 35 30 40 7,8
250 100 55 46 60 81,5+0,2 86 110 105 3,8 90 35 30 50 7,8
275 110 55 46 70 92,2+0,2 95 120 105 3,8 90 35 30 50 7,8
300 125 55 46 80 106,5+0,2 110 140 120 3,8 105 35 30 50 7,8
325 126,5 55,5 46 50 115 115,5 150 115,5 3,8 94 35 30 55 7,8
350 137,5 55,5 46 50 125 126,2 160 113,5 3,8 92 35 30 55 7,8
400 173,5 60 46 60 144,3 146 189,5 145 6,7 117 35 30 85 19,7
450 179 50 30 0 164 166 198 127 6,5 107 35,47 33 76 20

Fig. 3 All the dimensions are indicated in mm (inches = mm x 0.03937).

2.14.2 R 924 Compact Tier III


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Technical documentation Compression device for brake piston of gear SAT

2.15: Compression device for brake piston of gear SAT

Fig. 1 Definition of the dimensions of the compression devices

Swing Gear Identificat.


A B C D E F G H
SAT / Type number
SAT 200 9206110 252 40 12 10 10 14 90 110
SAT 225 9202825 268 40 12 10 10 16 100 117
SAT 250 9199319 300 40 12 10 10 18 110 131
SAT 275 9202826 326 40 12 10 10 18 120 143
SAT 300 9202827 364 50 20 15 15 22 130 157
SAT 325 / 204 9202828 390 50 20 15 15 22 142 170
SAT 350 / 205 9202829 410 50 20 15 15 22 154 180
SAT 400 / 206 9393900 440 50 20 15 15 18 175 202.
SAT 450 / 207 5

Tab. 1 Compression devices / Identification numbers and dimensions in mm

R 924 Compact Tier III 2.15.1


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Technical documentation Compression device for brake piston of gear FAT

2.16: Compression device for brake piston of gear FAT


A) For travel gears FAT 350/..., 400/..., 450/... & 500/...

Fig. 1 Definition of the dimensions of the compression devices

Travel gears Identificat.


A B C D E F G
SAT Type number
FAT 350 / 400 9196958 350 318 284 16 33 50 10
FAT 450 / 500 9199294 400 360 340 20 30 47 20

Tab. 1 Compression devices / Identification numbers and dimensions in mm

R 924 Compact Tier III 2.16.1


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MJFCIFSS
Compression device for brake piston of gear FAT Technical documentation

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

Fig. 2 Definition of the dimensions of the compression devices

Travel gears SAT Identifica


A B C D E F G H
Type t. number
FAT 350 / 022 /032 9981445 238 205 100 108 40 18 Ø 16 15
FAT 400 / 063 / 073 9392820 280 245 123 125 40 Ø 21 Ø 16

Tab. 2 Compression devices / Identification numbers and dimensions in mm

2.16.2 R 924 Compact Tier III


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MJFCIFSS
Technical documentation Tools for installing the slipring seals

2.19: Tools for installing the slipring seals

Fig. 1 Definition of the dimensions of the mounting tool

Travel gear Ordering Slipring seal


Ø1 Ø2 Ø3 Ø4 Ø5
FAT number Type Ø6
350 P 012 8503594 76.90 H - 28 341 350 340 310 334 343
350 P 022
350 / 012 8503178 76.90 H - 30 A1 375 384,1 372 325 369 377,5
355 P 076 76.90 H - 30
355 P 077
400 / 023 8503179 76.90 H - 60 394 402 392 365 384 395
400 / 043
400 / 063
400 / 073
400 / 013 8503180 76.90 H - 70 415 424 414 390 405 417
450 / 064 8503181 76.90 H - 61 457 465 455 415 446 458
450 / 044
500 / 035 10027892 76.90 H - 65 A2 495 504 494 430 485 497

R 924 Compact Tier III 2.19.1


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MJFCIFSS
Tools for installing the slipring seals Technical documentation

Travel gear Ordering Slipring seal


Ø1 Ø2 Ø3 Ø4 Ø5
FAT number Type Ø6

550 / 026 10027891 76.90 H - 74


550 P 046
600 / 047 10027894 76.90 H - 82
600 P 067

Tab. 1 Slipring seals installation tools / Ordering numbers and dimensions in mm

2.19.2 R 924 Compact Tier III


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Technical documentation Special tools for the lifting of the uppercarriage

2.30: Special tools for the lifting of the uppercarriage


For R 924 Compact types 911 / 198

Fig. 1 Definition of the dimensions of the standoff

R 924 Compact Tier III 2.30.1


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MJFCIFSS
Special tools for the lifting of the uppercarriage Technical documentation

For R 924 Compact Tier III types 1055 / 1056

Fig. 2 Definition of the dimensions of the standoff

2.30.2 R 924 Compact Tier III


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MJFCIFSS
Technical documentation

Group 3: Technical Data /


Maintenance guidelines

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

Control and maintenance chart.............................................................................................3.62


R 924 Compact Tier III Type 1055 from serial number 20472
R 924 Compact Tier III Type 1056 from serial number 23772

Control and maintenance chart.............................................................................................3.63


R 924 Compact Tier III Tunnel Type 1083 from serial number 21909

Lubrication chart ....................................................................................................................3.82


R 924 Compact Tier III Type 1055 from serial number 20472
R 924 Compact Tier III Type 1056 from serial number 23772

Lubrication chart ....................................................................................................................3.92


R 924 Compact Tier III Tunnel Type 1083 from serial number 21909

R 924 Compact Tier III 3.00.1


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MJFCIFSS
Technical documentation Technical data

Group 3: Technical Data /


Maintenance guidelines

3.12: Technical data


R 924 Compact Tier III Type 1055 from serial number 20472
R 924 Compact Tier III Type 1056 from serial number 23772
R 924 Compact Tier III Type 1083 from serial number 21909
Types 1055 / 1056 / 1083 Tunnel

1083
General 1055 1056
Tunnel
Operating weight kg 25150 - 29050 32440
Length mm 4555 5040 5070
Width mm 3150 3000
Height of machine without attachment mm 3140 / 3255 3151
Tail swing mm 1690 1695
Ground clearance mm 470 - -
Digging force kN 97 - 111 85
Breakout force kN 117 - 141 135
Total drawbar max. (at compound speed and max. working kN 264 260
pressure)

1083
Engine 1055 1056
Tunnel
Type D 934 S A6
Rating at nominal speed per DIN ISO 9249 KW 120 kW (163 PS)
Nominal speed U / min 1800
Max. torque N.m 760 (at 1500 rpm)
Oil quantity (fulling quantity on oil change with filter) l 29
Oil quality / -viscosity and oil change intervall see sub-group 1.50, 1.51 and 3.60
Fuel tank capacity l 345
Further informations see group 4

1083
Hydraulic system 1055 1056
Tunnel
Hydraulic pump Type DPVP 108
Design Swash plate - axial pump piston
max. power of the working pumps KW 87 87 (96 with
milling cut-
ter)
max. volume cm3 2 x 107,7
max. flow (theoretical) l / min 2 x 215

R 924 Compact Tier III 3.12.1


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MJFCIFSS
Technical data Technical documentation

1083
Hydraulic system 1055 1056
Tunnel
max. flow (Qmax) l / min 416
min. flow (Qmin) l / min 137

Oil quantity (fulling quantity on oil change with filter) l 174 in tank (360 in whole hydraulic circuit)
Oil quality / -viscosity and oil change intervall see sub-group 1.50, 1.51 and 3.60
Control valve block Type M9-1039-00 / 7M9-25 M9-1047-
00 / 9M9-25
1 way rotary connection Type 1-way - -
815.001
5 ways rotary connection Type DDF 525 - 5-ways
815.005
7 ways rotary connection Type - DDF 720 DDF 720
Boom cylinder mm (2x) 130 / 90 (2x) 140 /
Ø piston / rod 85
Stick cylinder mm 140 / 95 160 / 95
Ø piston / rod
Bucket cylinder mm 120 / 80 125 / 80
Ø piston / rod
Swivel bearing cylinder mm - 140 / 80
Ø piston / rod
Offset cylinder mm 160 / 95 -
Ø piston / rod
Hydraulic pump / servo control Type Gear pump
max. flow / servo control l / min 46
Hydraulic pump / fan drive (cooling) Type Gear pump
max. flow / fan drive (cooling) l / min 60
Further informations see group 6
,

1083
Electrical system 1055 1056
Tunnel
Voltage V 24 (2x 12 switched in series)
Battery capacity Ah 135
Alternator voltage / max current V/A 24 / 80 24 / 100
Starter power V / KW 24 / 7,8

1083
Swing gear 1055 1056
Tunnel
Gear Type SAT 275 / 266
Swing gear Type KUD 64 VJ 003-001 KUD 64 VJ
004-000
Motor oil Type FMF 058
Swing speed max. U / min 12
Gear oil quantity l 6
Oil quality / -viscosity and oil change intervals see sub-group 1.50, 1.51 and 3.60

3.12.2 R 924 Compact Tier III


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