Subgroup - Index: Section Group Type

Service Manual
SUBGROUP - INDEX
Section Group Type
Safety warnings 010.020.1 R 956 - R 960

R 966 - R 980
Tightening torques for pressure relief valves 010.028.1 R 956 - R 960

R 966 - R 980
Tightening torques for screws

(factory standard 4037 K) 010.030.1 R 956 - R 960
R 966 - R 980
Tightening torques for fittings 010.032.1 R 956 - R 960

R 966 - R 980
Assembly instructions for hydraulic cylinders

(factory standard 4121) 010.040.1 R 956 - R 960
R 966 - R 980
Tightening torques for piston rod bearing screws 010.041.1 R 956 - R 960
R 966 - R 980
Special tools for maintenance and repair 010.050.1 R 956 - R 960

R 966 - R 980
Special tools for the hydraulic system 010.051.1 R 956 - R 960

R 966 - R 980
Special tools for electrical connectors 010.052.1 R 956 - R 960

R 966 - R 980
Special tools for Diesel engines 010.053.1 R 956 - R 980
Conservation guidelines 010.060.1 R 956 - R 960

R 966 - R 980
Repair welding 010.070.1 R 956 - R 960

LFR/en/Edition: 07/2015
R 966 - R 980
Material weights 010.080.1 R 956 - R 960

R 966 - R 980
010.000.1
MJFCIFSS
Service Manual
010.000.2
MJFCIFSS
010.020.1
Service
010.020.2
Service l S
010.020.3
Service
10.020.4
Service l S
010.020.5
Service
010.020.6
Service l S
010.020.7
Service
010.020.8
Service l S
010.020.9
Service
010.020.10
Service l S
010.020.11
Service
010.020.12
Service l S
010.020.13
Service
010.020.14
Service l S
010.020.15
Service
010.020.16
Service l S
010.020.17
Service
Service Manual Tightening torques for pressure relief valves
Tightening torques for pressure relief valves

Mating material: steel and cast iron
Tightening torques
Type Complete
Lock nut (2) Lock nut (3)
valve (1)
DBVS 22 75 Nm 28 Nm
DBVZ 22 Px EXTERN 75 Nm 28 Nm
DBVZ 22 Px INTERN 75 Nm 45 Nm 28 Nm
DBV 15 40 Nm 35 Nm 40 Nm
DBE 10 75 Nm 40 Nm
R 956 - R 960 010.028.1

R 966 - R 980 copyright by
MJFCIFSS
Tightening torques for pressure relief valves Service Manual
Tightening torques
Type Complete
Lock nut (2) Lock nut (3)
valve (1)
DBV 22/V 75 Nm 28 Nm
MHDBV 40 300 Nm 28 Nm
MHDBN 561 6231 120 Nm 28 Nm 15 Nm

570 0221
1013 7837 100 Nm
1014 0388
1014 5975 90 Nm
1014 8810 120 Nm
1046 9909 100 Nm
1046 9910 90 Nm
Direct acting pressure relief valve PLC 80 Nm
Tab. 1 Tightening torques for pressure relief valves

010.028.2 R 956 - R 960

copyright by R 966 - R 980
MJFCIFSS
10409969
Standard 004
PRELOADS AND TIGHTENING TORQUES FOR SCREWS WITH METRIC

STANDARD AND FINE THREADS ACCORDING TO DIN ISO 261
010.030.1
10409969
Standard 004
010.030.2
10409969
Standard 004
010.030.3
10409969
Standard 004


010.030.4
Service Manual Tightening torques for fittings
Screw-in studs (Ermeto)
Tightening torques for fittings
1 Screw-in studs (Ermeto)
Mating material: steel (Grease well before inserting!)
Type with sealing edge Type with EOLASTIC seal
Tightening Tightening
Thread Thread
Type torques Type torques
M or G M or G
in Nm in Nm
Light-duty series L Light-duty series L
GE 06 LM A 3 C M 10x1 18 GE 06 LM ED A 3 C M 10x1 18
GE 06 LR A 3 C G 1/8 A 18 GE 06 LR ED A 3 C G 1/8 A 18
GE 08 LM A 3 C M 12x1.5 30 GE 08 LM ED A 3 C M 12x1.5 25
GE 22 Lm A 3 C M 22x1.5 140 GE 22 Lm Ed A 3 C M 26x1.5 180
GE 22 Lr A 3 C G 3/4 180 GE 22 Lr Ed A 3 C G 3/4 A 180
GE 28 Lr A 3 C G1A 330 GE 28 Lr Ed A 3 C G1A 310
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 Lr A 3 C G 1 1/2 A 630 GE 42 Lr Ed A 3 C G 1 1/2 A 540
Heavy-duty series S Heavy-duty series S
GE 06 SM A 3 C M 12x1.5 35 GE 06 SM ED A 3 C M 12x1.5 35
GE 06 SR A 3 C G 1/4 A 55 GE 06 SR ED A 3 C G 1/4 A 55
R 956 - R 960 010.032.1

MJFCIFSS
Tightening torques for fittings Service Manual
Swivelling connections (Ermeto)
Type with sealing edge Type with EOLASTIC seal
Thread Thread
Type torques Type torques
M or G M or G
in Nm in Nm
GE 25 SR A 3 C G1A 340 GE 25 SR ED A 3 C G1A 310
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 SR A 3 C G 1 1/2 A 700 GE 28 SR ED A 3 C M 1 1/2 A 540
Tab. 1 Tightening torques of screw-in studs
GE = Straight screw-in connection (with metric thread M or pipe thread G)
2 Swivelling connections (Ermeto)
Tightening torques Tightening torques

Type Type
Thread Nm Thread Nm
Light-duty series Light-duty series
WH / TH 06 LR KDS A 3 C G 1/8 A 18 WH / TH 06 LM KDS A 3 C M 10 X 1 18
WH / TH 08 LR KDS A 3 C G 1/4 A 45 WH / TH 08 LM KDS A 3 C M 12 X 1,5 45
WH / TH 28 LR KDS A 3 C G1A 320 WH / TH 28 LM KDS A 3 C M 33 X 2,0 360
WH / TH 35 LR KDS A 3 C G 1 1/4 A 540 WH / TH 35 LM KDS A 3 C M 42 X 2,0 540
WH / TH 42 LR KDS A 3 C G 1 1/2 A 700 WH / TH 42 LM KDS A 3 C M 48 X 2,0 700
Heavy-duty series Heavy-duty series
WH / TH 06 SR KDS A 3 C G 1/4 A 45 WH / TH 06 SM KDS A 3 C M 12 X 1.5 45

WH / TH 25 SR KDS A 3 C G1A 320 WH / TH 20 SM KDS A 3 C M 27 X 2.0 320
WH / TH 30 SR KDS A 3 C G 1 1/4 A 540 WH / TH 25 SM KDS A 3 C M 33 X 2.0 360
010.032.2 R 956 - R 960

MJFCIFSS
Service Manual Tightening torques for fittings
Tightening torques Tightening torques

Type Type
Thread Nm Thread Nm
WH / TH 38 SM KDS A 3 C M 48 X 2.0 700
Tab. 2 Tightening torques of swivelling connections
3 Screw-in studs (Ermeto)
Screw-in Screw-in
Type VSTI torques Type VSTI torques
thread M thread G
Nm Nm
VSTI 10X1 ED A3C M 10 X 1 12 VSTI 1/8 ED A3C G 1/8 A 13
VSTI 12X1.5 ED A3C M 12 X 1.5 25 VSTI 1/4 ED A3C G 1/4 A 30
VSTI 20X1.5 ED A3C M 20 X 1.5 80 VSTI 1 ED A3C G1A 200
VSTI 22X1.5 ED A3C M 22 X 1.5 90 VSTI 1 1/4 ED A3C G 1 1/4 A 450
VSTI 26X1.5 ED A3C M 26 X 1.5 120 VSTI 1 1/2 ED A3C G 1 1/2 A 450
VSTI 27X2 ED A3C M 27 X 2.0 135
VSTI 33X2 ED A3C M 33 X 2.0 225
VSTI 42X2 ED A3C M 42 X 2.0 360
VSTI 48X2 ED A3C M 48 X 2.0 360
Tab. 3 Tightening torques of screw-in studs
VSTI = Hexagon socket plug

R 956 - R 960 010.032.3

MJFCIFSS
Tightening torques for fittings Service Manual
010.032.4 R 956 - R 960

MJFCIFSS
10334184
Standard 002
WN 4121
Installation instruction for pistons and piston nuts in hydraulic
cylinders
1. Scope and purpose
2. Requirements / description of procedure

not
10334184
Standard 002
2.1. Tightening with assembly wrench
3-digit
Preparation:
thin layer
on both sides
Definitions:
 
after
 after
Mv B
Figure 1:
must point in
the same direction
10334184
Standard 002
5
4
1 2
5
4
6 2
Figure 2
after
after
after
after
2.2. Tightening with hydraulic assembly device

10334184
Standard 002
4-digit
Preparation:
thin layer
on both sides
Definitions:
 after
10334184
Standard 002
Operation of the assembly device:
D
F
H
B
C
E
Figure 1:
10334184
Standard 002
Caution!
maximum permissible operating pressure
If the maximum permissible operating pressure is exceeded, there is a risk of

damage to the adapter and/or assembly device!
Figure 2:
10334184
Standard 002
Figure 3:
10334184
Standard 002
3. Revision log
4. Other applicable documents

MJFCIFSS
Tightening with assembly wrench (see 2.1)
No. Pretightening Piston Piston nut Thread

torque
MJFCIFSS

torque
MJFCIFSS

torque
MJFCIFSS
Tightening with hydraulic assembly device (see 2.2)
Preload
No. Piston Piston nut Assembly device Thread
pressure
MJFCIFSS
Max. permissible operating pressures for the adapters for re-embossing in the field
Adapter ID no.
Fig. 1: Max. permissible operating pressure

indicated on adapter


  

   



 



 

 

 

 
 




 
 
 
 

     

 


  

  
  

 

 













    

     
   
      

   
   
      

   
   
      

   
   
      

   
   
      

   
   
      

   
   
      

   
   
      

   

 


  

  
  


   
      

   
   
      

   
   
      

   
   
      

   
   
      

   
   
      

   
   
      

   


 


  

  
  


 










  


   
 
    

 
 
    

 
 
    

 
 
    

 
 
    

 
 
    

 
 
    

 
 
    

 
 
    

 
 


  

  
  
 
    

 
 
    

 
 
    

 
 
    

 
 


 


  
Service Manual Special tools for maintenance and repair
Special tools for tightening torques
Special tools for maintenance and repair
1 Special tools for tightening torques
Size /
Representation No. Designation Ident. No. Application
Quantity
1-12
5 8503599
60-300
10 8503048
Torque wrench 140-760 To tighten the bolt to the
15 7362441
Size in Nm 750-2000 prescribed torque
20 8503600
1500-
22 8503601
3000
25 3 - XLT 7373023
30 Hydraulic wrench 5 - XLT 8502890 To tighten the bolt to the
35 Hytorc 10 - XLT 8503882 prescribed torque
40 30 - XLTC 8503881
45 30 mm 8589150
46 32 mm 8565020
47 36 mm 8589770
48 41 mm 8502436
49 46 mm 8502461
Socket Hytorc
50 50 mm 8502975
51 55 mm 8589940
52 65 mm 7362130
53 75 mm 8503884
54 85 mm 7373022
2 SCULI-software
Size /
Quantity
For the diagnosis of:
Sculi software LIDOS the Diesel engine
the machine
R 956 - R 960 010.050.1

MJFCIFSS
Special tools for maintenance and repair Service Manual
Special tools for temperature measures
Size /
Quantity
Sculi - engine diagnosis
Marx Dongle with a sculi licence -
115 10450053 For the diagnosis of the
engine diagnosis «light»
Diesel engine
116 10450054
engine diagnosis «service»
Sculi - Machine diagnosis service
Master4 diagnosis «service»
120 10333608 For the diagnosis of:
including sculi-engine diagnosis
«light» the Diesel engine
Marx Dongle with a sculi licence - the machine
Master4 diagnosis «service»
121 10489591
including sculi-engine diagnosis
«service»
Upgrade (with a Marx Dongle in possession)
Sculi licence - Diagnosis Master4
125 0010301
«service»
Sculi licence - Engine diagnosis
126 0010300
«service»
3 Special tools for temperature measures
Size /
Quantity
Used to monitor the

Thermometer with
GMTL temperature of a liquid
160 probe and sensor 7020372
1826 or the external tempera-
(magnetic)
ture of a component
Infrared thermome- GTH

162 10024185
ter 1150
010.050.2 R 956 - R 960

MJFCIFSS
Special tools for rotating speed measures
4 Special tools for rotating speed measures
Size /
Quantity
Revolution indicator
131 DT 205 7364284
Shimpo
To check the RPM via

reflexions stripe
132 Stripes 614063201
5 Special tools for the compensation of regulation solenoid valves
Size /
Quantity
250 Cable 10857149
Compensation of regu-
lation solenoid valves
255 Pressure transmitter 4-20mA 10280388
260 Adapter measuring point 1/4" N 614064701

R 956 - R 960 010.050.3

MJFCIFSS
Special tools for the air-conditioning
6 Special tools for the air-conditioning
Size /
Quantity
For servicing and

Evacuation pump
190 RD-4 7027552 repairing the air condi-
REFCO
tioning equipment
195 Filling hose ITE blue 1500 mm 7027553 With tool no. 190
Filling hose ITE yel-
196 1500 mm 7027554
low
197 Filling hose ITE red 1500 mm 7027555
205 Quick coupling ITE 253a 7027556 With tool no. 190
210 Quick coupling ITE 254 a 7027557
For servicing and

Test equipment with
215 M4WS5C 7027558 repairing the air condi-
4 valves
tioning equipment
010.050.4 R 956 - R 960

MJFCIFSS
Special tools for oil analysis
7 Special tools for oil analysis
Size /
Quantity
170 Hand pump 8145666
Used to take samples

Sampling valve for oil samples for oil analysis
172 7019068
alternative to the hand pump
175 Oil analysis set No. 1 7018368 6 samples

180 Oil analysis set 8145660 1 sample
Complete set for oil analysis
181 Analysis by WAER CHECK com- 8503561 For 6 samples

pany
Analysis report in German
188 Bio oil analysis set No. 1 7026817 1 sample

189 Bio Oil analysis set 7026088 6 samples
Complete set for oil analysis
Analysis by WAER CHECK com-

pany
Analysis report in German
8 Other tools
Size /
Quantity
220 UTV-M20 7023304
221 UTV-M24 7023305
To disassemble the pins
222 Disassembly tool UTV-M30 7023306
of the grabble
223 UTV-M36 7023307
224 UTV-M42 7023308
230 M14 7023309

231 M20 7023310
232 M24 7023311
Disassembly To disassemble passfix
233 M30 7023312
washer bolts
234 M36 7023313
235 M42 7023314
R 956 - R 960 010.050.5

MJFCIFSS
Other tools
Size /
Quantity
Removal tool for CMVE 108 To remove the travel

240 10385026
motor motor alone
M12 4026006
M30 4000656 For the lifting of different
Lifting eye M42 4001313 components of the
M48 4900835 excavator
M56 4901609
Filling device com- W24x To check and refill dia-

90 plete with adapter 1-1/4 8145359 phragm and piston type
and filling hose 3,0m accumulations
95 Ø 25 9951457
96 Ø 22 9951508
97 Ø 45 9966421 For assembly of the
Glyd-ring and scraper -
Mounting sleeve ring on plunger piston of
hydraulic coupling
98 Ø 25 9951458 LIKUFIX.
To stop the pressure

Hexagon socket set
106 M6 4901114 which releases the
screw
travel brakes.
010.050.6 R 956 - R 960

MJFCIFSS
Other tools
Size /
Quantity
Vacuum pump,
complete consisting
of: pump no. 180,
TF63/2- Retension of hydraulic
180 vacuum control 7405073
24V tank content
valve no. 181 with
sealing and hose
with filter no. 187.
181 Vacuum control valve, complete 10097130
182 Vacuum control valve 5006213
183 T coupling 7015042
Connecting piece to tank, con-
sisting of:
184 - screw-in stud 7002240
185 - Cone RED connection 16/8S 7407155
186 - straight nipple 7024875

R 956 - R 960 010.050.7

MJFCIFSS
Other tools
010.050.8 R 956 - R 960

MJFCIFSS
Service Manual Special tools for the hydraulic system
Special tools for the hydraulic measures
Special tools for the hydraulic system
1 Special tools for the hydraulic measures
Size /
Quantity
1 Pipe Adapter NW 10 7002404
2 NW 12 7008688
13 M22x1,5 5607671
14 M14x1,5 5607616
15 M16x1,5 5607605 K form
Pipe Adapter
16 M18x1,5 5607617 From LH673-02
17 M20x1,5 7409922
18 M24x1,5 7409923
25 BSP coupling R 1/2 7002436
Direct gauge cou-

30 R 1/2 7002435
pling
35 1000 mm 7002437
36 1500 mm 7002475
To connect pressure
gauge on all test points
High pressure hose
(pipe adaptor no 1/2
(Lenght)
37 5000 mm 7363732 and gauge coupling 10-
14)
R 956 - R 960 010.051.1

MJFCIFSS
Special tools for the hydraulic system Service Manual
Size /
Quantity
40 M10X1 5005180
41 M12X1,5 7402580
42 M14X1,5 5004002
43 M16X1,5 7361345
Gauge coupling
44 R 1/4 7362579
45 0-1,6 bar 8042577

46 0-1,6 bar* 8042578
47 0-2,5 bar* 7361292
48 0-6 bar* 7361291 Used to check system
49 0-10 bar* 5002865 pressure in one or more
50 Hydraulic pressure 0-25 bar* 7361289 hydraulic system
51 gauge 0-40 bar* 7361288
52 0-60 bar* 5002867 * dampened with glyc-
53 0-160bar* 7361286 erin
54 0-250bar* 7361285
55 0-400bar* 7500002
56 0-600bar* 7361294
Measuring set LMMS 2010 : 11210083
Multihandy LMMS 2010 11088320
Pressure sensor 0-60 bar 11210093
HySense PR100 0-600 bar 10288153
Cable High End 6m 11210096
12 m 11210097
Measuring set complete, in carry-

11000678
ing case, containing:
Measuring device MH 3020 10814168
Pressure sensor (2 units) 0 -
10288153
600 bar, 0 - 20 mA
Measuring wire, 12 meters (2 To perform adjustment
75 10288154
units) checks
Power supply unit 110 / 220 V 7025279
Data transfer cable 10814169
Connector 1620 614062601
Carrying case 10664392

16 - 600
Turbine RE 4 10024672
l/min
Turbine with throttle
-- To perform adjustment
76 HySense QL 200
checks
0 - 600
Pressure sensor 10288153
bar
Connector 614062601
010.051.2 R 956 - R 960

MJFCIFSS
Size /
Quantity
With tool no. 75 and
78 Power supply cable / cigar lighter 7025273 with Multihandy LMMS
2010
82 Pressure sensor 0-600 bar 7025751
83 Adapter for pressure sensor 7025752
90 Adapter for test point 4901372

91 Test point with metallic cap 7002404
92 Cap nut 4774002
For pressure balancing.
With tool no. 75
93 Cutting ring 4774001
12 Measuring turbine RE 4 - 10 5010 031

1 - 10 l/
min
13 Measuring turbine RE 4 - 75 6140
2 - 75 l/ 62901
min
300 01
9 - 300 l/
min
600
16 - 600 l/
min
600
25 - 600 l/
min
16 Tachometer DS 03 6140 631
1 - 9999 01
U/min
17 Set of spare reflective foils 6140 632

01
18 Magnetic holder for tachometer 6140 633
DS 03 01
19 Inductive sensor for tachometer 6140 634
01
R 956 - R 960 010.051.3

MJFCIFSS
Mounting wrench for hydraulic cylinders
Size /
Quantity
20 Carrying case to 6140 635
carry the measuring 01
turbine RE 3
33 Exploitation transfer CD-rom 10287659
Windows
32 bit
(d / e / f)
10 SW 17 9359414
To adjust primary and

Special wrench for
secondary relief valves
11 relief valves SW 19 9210371 on control valves
2 Mounting wrench for hydraulic cylinders
2.1 Wrench with bores «A» for retaining bolts (N° 400)
Ident. No. 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"
8007364 # 75 54 110 220 14 12 10 20 84 3/4"
80 54 110 220 14 12 10 20 84 3/4"
8007365 88 63 120 250 14 12 10 20 90 3/4"

8007366 100 78 135 260 14 14 10 20 95 3/4"
9919856 115 88 150 300 14 14 10 20 105 3/4"
9196978 # 125 97 170 320 14 14 10 25 110 3/4"
130 97 170 320 14 18 15 25 110 3/4"
8007367 145 113 185 380 14 18 15 25 120 3/4"
010.051.4 R 956 - R 960

MJFCIFSS
Mounting wrench for hydraulic cylinders

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.
2.2 Forked type piston wrench

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)
R 956 - R 960 010.051.5

MJFCIFSS
Piston nut wrench (N° 415)
3 Piston nut wrench (N° 415)
Piston nut Slotted Wrench

SW 6-KT SW 2-FL 4-KT
Size - Ident. No. round nut Ø Ident. No.
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
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
010.051.6 R 956 - R 960

MJFCIFSS
Mounting and spreader sleeve
4 Mounting and spreader sleeve
Mounting sleeve 990 Spreader sleeve 991

Piston Ø
Ident. No. Ident. No.
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
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
R 956 - R 960 010.051.7

MJFCIFSS
Mounting and spreader sleeve
Mounting sleeve 950

Piston Ø
Ident. No.
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
Tab. 5 Piston mounting sleeves
Notice!
The mounting sleeve 950 are employed to narrow the sealing rings that have been stretched during
installation back to the cylinder diameter.
Mounting sleeve to insert the piston rod bearing on the piston rod
Mounting sleeve 950
Piston Ø
Ident. No.
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.
010.051.8 R 956 - R 960

MJFCIFSS
Service Manual Special tools for electrical connectors
Special tool for electrical measures
Special tools for electrical connectors
1 Special tool for electrical measures
Size /
Quantity
Can be used as an
extension with the other
102 RS232 normal cable 10029996 cables.
With tool no. 103
103 Adapter 10029999
104 USB to RS232 converter 693190714
3m 10513200 Link the PC and the

109 Ethernet cable
1,5 m 10225579 master
Link:
the PC and the
110 Serial cable 10035410 engine
the PC and the
master
To read the contents of

113 Compact flash card reader 11000491
the compact flash card
R 956 - R 960 010.052.1

MJFCIFSS
Special tools for electrical connectors Service Manual
Size /
Quantity
To check regulation cur-

140 Measuring adapter 8504231
rent on the pumps
Chauvin For voltage, current and

resistance measure-
Multimeter with digi- Arnoux
145 10018500 ments of electrical sys-
tal display MAX tems and of solenoid
3000 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
2 Special tools for electrical connectors
Fig. 1 Deutsch connectors Fig. 3 Lugs
010.052.2 R 956 - R 960

MJFCIFSS
Fig. 2 Mate-N-Lock connectors Fig. 4 AMP connectors
Size /
Quantity
8 Transformet set 24 / 230 V 11006157
Repearing kit for connector tech-

nology, including four carrying Contains all the connec-
10 cases with connector technology 10359794 tors and the associated
and one carrying case with spe- tools
ficic tools:
1 - Deutsch connector technology 10359757
- Mate-N-Lock connector tech-
2 10359758
nology
3 - Lugs and fuses 10359759
- Deutsch and AMP connector
4 10360599
technology
5 - Carrying case with tooling 10360630
Tool to crimp contacts of connec-

tors type Deutsch
15 8503647
Included in the carrying case 5
(10360630)
Tool to crimp contacts (from MIL-

28 7367086
C5015, VG 95234, 955342)
Crimp turret to crimp contact of

connectors type Deutsch (KPS -
29 7409779
KPT - PT) sizes with special tool
no. 28
Crimp turret to crimp contact of
connectors type Deutsch (15S/
30 7367084
16S - 15/16 - 25/12) sizes with
special tool no. 28
R 956 - R 960 010.052.3

MJFCIFSS
Size /
Quantity
Pneumatic power
crimp equipment to
35 HDP 400 8504158
crimp inserts for
connectors Deutsch
Tools (sockets and
36 Taille 4 8504159
pins)
Tools (sockets and
37 Taille 8 8504160
pins)
Tools (sockets and
38 Taille 12 8504161
pins)
Tools (sockets and
39 Taille 16 8504162
pins)
45 Extraction tool to Taille 4 8503633
46 push a crimped con- Taille 8 8503632
47 tact of the connec- Taille 12 8145674
tors Deutsch
48 Taille 16 8145673
Included in the car-
49 rying case 1 Taille 20 8503630
(10359757)
Deutsch cable extractor
55 Included in the carrying case 5 7026267
(10360630)
Dynamometric screwdriver -
3 Nm
60 10800772
(10360630)
Hexagonal drive socket for span-
ner (4 mm)
61 10801159
(10360630)
Insertion tool for CA-COM con-

65 7367017
tact (15S - 16S)
Test tip - red

(10359757)
Test tip - black

(10359757)
010.052.4 R 956 - R 960

MJFCIFSS
Size /
Quantity
To crimp contacts for leads of
MATE-N-LOK 1,5mm2
SURE-SEAL
90 FASTON 0,5 - 2,1 mm² 7367025
Junior Power Timer
Mini timer
(10360630)
Extraction tool to push a crimped
contact out of to the MATE-N-
100 LOK connectors 7366655
(10359758)
105 Mini-timer extractor 7027340
Mini-timer extractor
(10360599)
Tool to crimp lugs

(10360630)
Tool to crimp bushes

(10360630)
130 Solenoid tester 6204661

R 956 - R 960 010.052.5

MJFCIFSS
010.052.6 R 956 - R 960

MJFCIFSS
Service Manual Special tools for Diesel engines
Special tools for Diesel engines

See the repair instructions of the Diesel engine.
R 956 - R 980 010.053.1

copyright by
MJFCIFSS
Special tools for Diesel engines Service Manual
010.053.2 R 956 - R 980

copyright by
MJFCIFSS
Service Manual Conservation guidelines
General
Conservation guidelines
1 General
All parts of a construction machine are exposed to corrosion, especially when the machine is taken
out of service. Corrosion can be compared to wear. However, the effects of corrosion can greatly
exceed that of mechanical wear and shorten the service life of the affected parts significantly. For
that reason, for longer shut down, the machines and its components must be preserved according to
certain guidelines.
In general, these guidelines are tiered according to the following times:
Taking the machine out of service for an unknown duration
Shut down of the machine
Shut down for up to 2 months
Shut down for up to 12 months
Shut down for longer than 12 months
Return to operation
The required measures are graduated depending on the different time frames. The conservation
measures cannot be strictly standardized and they must be shorted or lengthened depending on the
assessment of necessity (such as environmental influences).
Such influences are, for example:
Placement location of machine (for example in unprotected surrounding, in closed areas,
protected by a roof, temperate surrounding)
Type of climate (for example extreme temperatures, location in water / near the coast, etc.)
Note!
For conservation for sea transport, special guidelines must be observed, which are not included in
these instructions. Refer to the special operating instructions.
2 Taking the machine out of service for an unknown duration
If a machine is taken out of service for a longer period of time without conservation, then it must be
operated in intervals not to exceed 14 days, to prevent abnormal corrosion and its effects.
Before putting the machine back into service, check all oil levels and correct them, if necessary.
Always carry out the specified daily maintenance work before putting the machine back into
service. In addition, carry out the time limited maintenance work according to the inspection
schedule and additional Diesel engine Operating instructions no later than the specified intervals.
Put the machine into operation according to the Operating instructions and operate it until the
Diesel engine and the hydraulic system has reached the specified operating temperature in the
hydraulic tank and in the coolant circuit.
Actuate all functions of the travel, working hydraulic as well as functions of additionally installed
LHB/en/Edition: 11/2013
hydraulic components and alternately operate them over a period of approx. 20 minutes. The
hydraulic cylinders must be extended and retracted over their full stroke length.
When turning the machine off, retract all hydraulic cylinders fully, if possible, and fill the fuel tank.
If the machine is parked on soft ground, park the machine on wooden planks or similar and secure
it to prevent it from rolling off.
Check the batteries and remove them and recharge them, if necessary. Check the electrical
contact points and grease them, if necessary.
R 956 - R 960 010.060.1

MJFCIFSS
Conservation guidelines Service Manual
3 Shut down of the machine
3.1 Preparations for shut down

Park the machine on horizontal, dry and solid ground and secure it to prevent it from rolling off.
Lower the working attachment to the ground level so that there is no longer any residual pressure
of the hydraulic.
Clean the machine diligently according to the procedure outlined in the Operating instructions.
The machine must be completely dry before starting the conservation measures. Dry electronic
components and damp areas on the machine with pressurized air.
If freezing temperatures are expected for the intended duration of shut down, then the fuel tank
must be filled with winter fuel. Then start the Diesel engine and let it run for some time to bring the
winter fuel into the fuel circuit. Then add enough fuel to the fuel tank until it is full.
Note!
When a conserved machine is moved for loading or transport, then the conservation protection on
the piston rods of the cylinders will most often be removed by the scraper ring. For that reason, if
the machine is transported, the conservation of the piston rods must be rechecked after loading
and carried out again, if necessary.
Note!
Despite completed conservations measures, the machine must still be inspected in certain
intervals and touched up, if necessary. This is within left to the discretion of the operator, but these
inspections should be carried out regularly (monthly), especially in aggravated conditions (cold,
heat, near the coast, etc.).
3.2 Shut down for up to 2 months
3.2.1 Required tools / Service items
Description Id. No. Description Display

Optical charge 7408922 To check the battery
tester condition and the
antifreeze in the
coolant
WAXOYL 120-4 Anti 8504472 Spray can 500ml

corrosion wax Long term protection
for up to 2 years
Ballistol Spray 10025514 Application area:
Corrosion protection Door locks
Dehumidification 10013313 Prevents infiltration

capsule of moisture over an
extended period of
time
Check the entire machine for damage and remedy, if necessary.

Check the machine for paint damage and remedy, if necessary.
Take care of any maintenance work which would fall within the timeframe of the planned shut
010.060.2 R 956 - R 960

MJFCIFSS
down.
Due to the UV exposure of the components, synthetic materials, such as plastic parts, hoses,
rubber etc. must be covered with suitable aids.
Electrical components, contact points and plug connections which are not sealed must be sealed
with conservation wax Waxoyl 120-4.
Apply a thick layer of conservation wax Waxoyl 120-4 to cover ball joints, hinges, blank parts and
exposed piston rods. (Do not protect ball bearings with Waxoyl!)
Place a dehumidification capsule into the central electric box.
Protect all door and container locks with Ballistol Spray.
Set the battery master switch (if present) to position 0 and then remove the batteries. Check the
battery acid level and add distilled water, if necessary. Always store the batteries in a cool and
dry area. Check the load current regularly every 6 weeks and recharge, if necessary.
Close the exhaust outlet with an air and watertight cover.
Pay attention to any additional guidelines for special components or special local conditions.
3.3 Shut down for up to 12 months

Carry out all measures according to paragraph 3.1. In addition, the following is required:
Clean the Diesel engine externally.
Drain water from the fuel tank or condensation of the Diesel engine prefilter (see Operating
instructions).
Add commercially available Diesel fuel to the fuel tank until it is completely full. If the shut down
is during the cold time of the year, fill the fuel dank with winter Diesel fuel (Winter Diesel fuel is
suitable up to a temperature of -22°C / -7.6°F). Then start the Diesel engine and let it run for some
time to bring the winter fuel into the fuel circuit. Then add enough fuel to the fuel tank until it is full.
Check the coolant to ensure it has sufficient corrosion and antifreeze protection - at least 50%
corrosion inhibitor antifreeze fluid (for guidelines refer to the Operating instructions).
Seal the entire machine (Diesel engine, hydraulic aggregates, main frame, tank, track / axles,
equalizer bar, working attachments, etc.) with preservation wax Waxoyl 120-4. (Amount of
preservative agent: An area of approx. 5m² can be treated with one liter Waxoyl)
Note!
The following points must be observed when applying the corrosion inhibitor wax:
Observe a drying time of 3 hours.
Ambient temperature at least +15°C / 59°F.
Use protective equipment (breathing protection, safety glasses, respirator, etc.).
The solvents of the anti corrosion wax are flammable! (Do not smoke and avoid open flames!)
Cold resistant to a temperature of -40°C / -40°F.
Release the chain tension by relieving the tension cylinder (see Operating instructions).
Check the machine monthly and reapply conservation protective measures if necessary.
R 956 - R 960 010.060.3

MJFCIFSS
Return to operation
3.4 Shut down for longer than 12 months
Note!
If a shut down for longer than 12 months is scheduled, then contact the Service Dept. of the Diesel
engine manufacturer.
Carry out all measures according to paragraph 3.1 and 3.2. In addition, the following is required:
Close off all openings, such as air filter, exhaust pipe, vent openings on components, etc. airtight.
The vent for the fuel tank (if present) must remain open for safety reasons!
Rub the rubber seal of the cab and containers with talcum powder, close the doors. If the cab is
not installed, cover the operators platform properly. If necessary, remove the operators seat.
Cover the instrument panel and protect it.
4 Return to operation
4.1 After a shut down of 2 months

Remove the dehumidification capsule from the electronic box.
Check the fill levels and lubricate the machine according to the Operating instructions.
Install the batteries and clean / grease the battery terminals.
Open the exhaust outlet.
Drain water from the fuel tank or drain any condensation of the Diesel engine prefilter (see
Operating instructions).
Clean anti corrosion wax from ball joints, hinges, blank parts and exposed piston rods.
Put the machine back into service as outlined in the Operating instructions.
Before working with the machine, check all functions of the machine and remedy and defects
immediately. Carry out a thorough visual inspection on the machine.
Actuate all functions of the travel, working hydraulic as well as functions of additionally installed
hydraulic components and alternately operate them over a period of approx. 20 minutes. The
hydraulic cylinders must be extended and retracted over their full stroke length.
Observe any additional guidelines for special components or special local conditions.
4.2 After a shut down of 12 months

Carry out the items according to paragraph 4.1.
Take an oil sample of the hydraulic oil and send it in for analysis.
Carry out the scheduled maintenance and inspection work on the machine before putting it back
into service.
On the Diesel engine, mechanically actuate the AGR flap (exhaust return) and the engine brake
flap and check for easy movement.
Grease the V-belts!
Use a high pressure cleaner with steam (at least 120°C) as well as 5% additive of solvent (such
as petroleum) to clean the anti corrosion wax from the machine and aggregates. (Caution when
walking on surfaces, there is a danger of slipping due to the wax residue.)
Check the V-belt of the Diesel engine and replace it if necessary.
010.060.4 R 956 - R 960

MJFCIFSS
Return to operation
Carry out a Diesel engine test run: Increase the Diesel engine rpm only slowly to ¾ of the high idle
rpm until the operating temperature is reached.
Check the oil pressure display immediately after starting the Diesel engine.
Check the vacuum display of the air filter.
Adjust the chain tension to suit the application (see Operating instructions).
4.3 After shut down of longer than 12 months
Note!
After a scheduled shut down of longer than 12 months contact the Service Dept. of the Diesel
engine manufacturer.
Complete all items outlined in paragraph 4.2 and 4.1.

Remove all covers and closures, which were installed for conservation measures.
Turn the Diesel engine manually a few turns (use the turning device - flywheel see Special tools).
Start the machine and bring it to operating temperature.
After the machine was brought to operating temperature, change all lube and service fluids as well
as filters according to the Operating instructions
Check the entire machine for function and for leaks.
If necessary, carry out any time limited maintenance work at this time.
R 956 - R 960 010.060.5

MJFCIFSS
Return to operation
010.060.6 R 956 - R 960

MJFCIFSS
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  
  
  
  
  
  
   

 
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

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
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  
 
       
     
     
      
      
      
     
    
    
   

 
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

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
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  
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  
           
       
 
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  
 
 
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  
  
     

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     
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  
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   

 
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

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
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  
       
        
      

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 
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 
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  
          
          
         
 
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     
   

 
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

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
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  
 
 
       
     
       
              
 
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 
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  
       
             
         
         
            
       
 
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
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  
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
  
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   

 
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

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
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      
     
  
     

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 
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         
    
      
 
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 
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   

 
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

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
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      
      
       
       
      
       
      
 
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     
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  
            
     
    
 
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 
      
      
 
      
 
   
       
 
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   

 
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

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
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 
  
           
       
 
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 
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  
          
         
      
 
     
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   

 
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

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
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     
     
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   
   
   
  
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      
      
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   
 
 
  
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   

 
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

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
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      
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  
  
  
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
 
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   
   
   
   

 
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

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
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   
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   
  
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      
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  
  
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 
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   

 
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

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
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  
  
      
 
        
           
 
         
 
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
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  
       
 
       
 
     
 
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
   

 
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

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
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  
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  
 
 
 
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
 
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            
             
    
 
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      
      
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   

 
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

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
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  
          
            
            
 
       
 
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  
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
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  
            
 
       
           
 
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   

 
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

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
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 
  
             
            
           
 
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    
      
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 
 
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 
 
 
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      
     
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   

 
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

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
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 
      

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 
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 
 
      

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
     
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   

 
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

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
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 
      
            
     
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 
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  
            
 
      
   
       
    
         
 
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   

 
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

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
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 
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     
     
     
 
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         
 
       
     
 
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
    
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   

 
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

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
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  
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    
 
 
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   
 
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  
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   
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   
    
   
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        
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   
            
        
 
        
 
   
            
     
     
 
 
   

 
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

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
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  
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  
  
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      
       
       
         
 
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 
      
     
     
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     
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   

 
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

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
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 
 
  
   
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     
     
  
      
          
 
 
 
 
       
 
   
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      
      
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   

 
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

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
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  
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  
             
     
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     
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  
 
 
      
     
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   
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     
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   

 
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

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
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  
   
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       
      
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   
   
 
 
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      
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   

 
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

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
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  
       
      
          
            
 
  
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        
 
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  
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   
        
            
            
          

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      
   

 
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

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
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   
       
     
     

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      
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   
         
       
 
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  
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      
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 
 
   

 
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

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
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  
      
 
 
   
 
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    
    
      
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  
         
          
 
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   

 
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

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
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   
  
       
 
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   
  



 
    
 


  

  
 
    
 


  
 
  


   

   

 
   
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  

    
 
  
 


  

  
 
    
 


  
 
  

   

 



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



   

   



       
          
 
       
          


 




 
 
            
 
 
  
          
 
 


   

    


   


  

   

 







  
 



 




  

   
   
   

  

 


    















   

 






  
 
   


   
  
  
     

    
     
 
 
 
 
      
    

 
 
      
 
 
     
 
 
   

 






     
     
 
 
 
     

 
      
 
 
 
     
       

 
   

 






     
   
 
 
     
 
 
      
    
 
 
 
    

 
   

 






     
     
 
 
     
 

 
  






 
    
 
 
 


 
     
    
 
  
 
     
 

 
 
 
 
   

 






  


   
  
  
     

           
 
 
 


 
 
 
 
        
 
 
 
   

 






 
 
 



 
 
  

   
  
  
  
    
 
 
     



 
 
 
   
   
 
  

 
   

 






       
    
 
      
     
         
 
 

     
  

     


 
   
 
  
 
 


 
   
 
 
 
 

 
   

 






    
 
 



   

 
   
 
 


 
   
 
 


 
   

 






   
 
 

   

 
    






 
 






 
 





 
   

 






 
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
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

 
 
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
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

 
 


 
  





 
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
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

 
   

 
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



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 
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



 
 





 

   

 

Material weights
Spec.
Spec. weight1)
Material Loosening in % Loosening factor weight kg/m3
kg/m3 solid
loose
1
Spec.
Spec. weight1)
Material Loosening in % Loosening factor weight kg/m3
kg/m3 solid
loose

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Service Manual

Section Group Type

Safety warnings 010.020.1 R 956 - R 960

Tightening torques for pressure relief valves 010.028.1 R 956 - R 960

Tightening torques for screws

Tightening torques for fittings 010.032.1 R 956 - R 960

Assembly instructions for hydraulic cylinders

Special tools for maintenance and repair 010.050.1 R 956 - R 960

Special tools for the hydraulic system 010.051.1 R 956 - R 960

Special tools for electrical connectors 010.052.1 R 956 - R 960

Special tools for Diesel engines 010.053.1 R 956 - R 980

Conservation guidelines 010.060.1 R 956 - R 960

Repair welding 010.070.1 R 956 - R 960

Material weights 010.080.1 R 956 - R 960

Tightening torques for pressure relief valves

R 956 - R 960 010.028.1

MHDBN 561 6231 120 Nm 28 Nm 15 Nm

Direct acting pressure relief valve PLC 80 Nm

Tab. 1 Tightening torques for pressure relief valves

010.028.2 R 956 - R 960

PRELOADS AND TIGHTENING TORQUES FOR SCREWS WITH METRIC

Tightening torques for fittings

1 Screw-in studs (Ermeto)

Mating material: steel (Grease well before inserting!)

Type with sealing edge Type with EOLASTIC seal

R 956 - R 960 010.032.1

Type with sealing edge Type with EOLASTIC seal

Tab. 1 Tightening torques of screw-in studs

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

2 Swivelling connections (Ermeto)

Mating material: steel (Grease well before inserting!)

Tightening torques Tightening torques

WH / TH 10 SR KDS A 3 C G 3/8 A 70 WH / TH 10 SM KDS A 3 C M 16 X 1.5 80

010.032.2 R 956 - R 960

Tightening torques Tightening torques

Tab. 2 Tightening torques of swivelling connections

3 Screw-in studs (Ermeto)

Mating material: steel (Grease well before inserting!)

Tab. 3 Tightening torques of screw-in studs

VSTI = Hexagon socket plug

R 956 - R 960 010.032.3

010.032.4 R 956 - R 960

1. Scope and purpose

2. Requirements / description of procedure

2.2. Tightening with hydraulic assembly device

maximum permissible operating pressure

If the maximum permissible operating pressure is exceeded, there is a risk of

4. Other applicable documents

Tightening with assembly wrench (see 2.1)

No. Pretightening Piston Piston nut Thread

No. Pretightening Piston Piston nut Thread

No. Pretightening Piston Piston nut Thread

Tightening with hydraulic assembly device (see 2.2)

Fig. 1: Max. permissible operating pressure

  

Special tools for maintenance and repair

1 Special tools for tightening torques

R 956 - R 960 010.050.1

3 Special tools for temperature measures

Used to monitor the

Infrared thermome- GTH

010.050.2 R 956 - R 960

4 Special tools for rotating speed measures

25 BSP coupling R 1/2 7002436

Carrying case 10664392

M150X3 - 9144654 210 3/4 9921131