liebherr r904c litronic crawler excavator service repair manual sn:23072

Technical documentation

R 900 C-Li - R 904 C-Li

MJFCIFSS

copyright by

Document identificationOrder number: 10069965

Issue: 01 / 2008

Valid for: R 900 C-Li from serial number 13860

R 904 C-Li from serial number 23072

Author: LFR - Technical documentation department

Product identificationManufacturer: LIEBHERR France S.A.S.

Type: 971 / 981 / 982 for R 900 C-Li

983 / 984 / 985 / 993 / 1017 / 1018 for R 904 C-Li

Conformity: CE

en


Hydraulic excavator

R 900 C-Li - R 904 C-Li

Service Manual

copyright by

MJFCIFSS

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

Service Manual

copyright by

MJFCIFSS

Service Manual

MJFCIFSS

IntroductionThis manual contains technical data, design and functional descriptions, as well as service and setup instructions. The documents include numbers of drawings, functional diagrams, as well as detailedviews of units and assemblies of LIEBHERR hydraulic excavators.

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

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

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

Symbols used in this manualIn this manual the description of tasks and procedures that are associated with specific dangers areaccompanied by safety instructions mentioning the danger related to described work. The safetyinstructions 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 :

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

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 procedurebelow.

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 HandbuchsThis manual may not be replicated or made available to third parties without the explicit writtenconsent of LIEBHERR, who retains all rights in this documents.

All rights reserved - Printed in France.

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

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

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

Service Manual

MJFCIFSS

This manual shall be amended without prior notice to reflect new technical developments andmachine series. LIEBHERR reserves the right to make minor technical amendments to the machinesthat 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 ofLIEBHERR-FRANCE SAS 68005 Colmar cedex.

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

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

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. Thissubgroup index also includes the indication of machines modells, types and serial number to whichthe subgroup is relevant.

Example

Main Group 7. = Main Group «Hydraulic com-

ponents»

Sub Group 12. = Sub Group «Variable Flow

Hydraulic Pump - Type LPVD»

Number of the Page in Sub Group 14. = Page «Adjustment for Varia-

ble Flow Hydraulic Pump LPVD»

7. 12. 14


R 900 C-Li - R 904 C-Li 1.00.1copyright by

MJFCIFSS

Group 1: General Information

Safety instructions .................................................................................................................1.101 Use in accordance with the regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10.12 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10.13 Servicing the machine safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10.11

Tightening torques.................................................................................................................1.201 Tightening torques for screws with metric coarse and fine thread (Liebherr Standard WN 4037) . . . 1.20.12 Tightening torques of screw-in studs (Ermeto) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.20.33 Tightening torques of swivelling connections (Ermeto) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.20.44 Tightening torques of screw-in studs (Ermeto) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.20.5

Assembly instruction for pistons and piston nuts (hydraulic cylinders) .........................1.221 Scope of application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.22.12 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.22.1

2.1 Definitions : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.22.13 Tightening torques for factory standard (04.08.2004) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.22.2

Assembly instruction for piston rod bearings with external threads (hydraulic cylinders) ..1.24

1 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.24.11.1 Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.24.1

2 Tightening torques for factory standard (02.07.2008) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.24.3

Tightening torques of screws with LH-washer 340HV........................................................1.251 Identification of the tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.25.1

Preloads and tightening torques (Din 13) ............................................................................1.261 Preloads and tightening torques table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.26.12 Angle tightening process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.26.3

2.1 Retightening angle depending on the clamping lenght - Preloads 50 Nm. . . . . . . . . . . . . . . . . 1.26.42.2 Retightening angle depending on the clamping lenght - Preloads - 100 Nm . . . . . . . . . . . . . . 1.26.52.3 Retightening angle depending on the clamping lenght - Preloads 400 Nm. . . . . . . . . . . . . . . . 1.26.6

Fuel and Lubricants ...............................................................................................................1.501 General specifications for the replacement of fuels and lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50.12 Lubricant Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50.13 Fuel and Lubricants Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50.24 Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50.45 Hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50.56 Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50.8


1.00.2 R 900 C-Li - R 904 C-Licopyright by

MJFCIFSS


R 900 C-Li - R 904 C-Li

Use in accordance with the regulations

1.10.1

Safety instructions

copyright by

MJFCIFSS

Group 1: General Information

1.10: Safety instructions

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, youcan 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 wellas 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 theowner.

1 Use in accordance with the regulations� The hydraulic excavator is a machine with work equipment (eg. hoe type bucket, grab, bucket at-

tachment) designed to detach, lift, transport and shake off earth, stones and other materials, whilethe transportation of the load itself usually takes place without moving the machine. Moving themachine when it is carrying a load must be carried out while observing the appropriate safetymeasures (see section "Notes for safe working").

� Machines used for hoisting are subject to specific conditions and must be fitted with the stipulatedsafety devices (see section �Hoisting work�).

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

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

� Observing the operating instructions and the inspection / maintenance instructions is also deemedto be appropriate use in accordance with regulations.

2 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 thepower 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 tooperate 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.

Safety instructions Technical documentationSafety Instructions


MJFCIFSS

� 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, forexample, getting caught up or being drawn in.

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

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

� 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 sametime.

� 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 securitylever lowered, in order to reduce the actuating and dynamic pressures in the work circuits. Youmust 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 ofsafety 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 excavatorwithout 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.


R 900 C-Li - R 904 C-Li

Safety Instructions

1.10.3

Safety instructions

copyright by

MJFCIFSS

� 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. � 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 apossibly upcoming fire.

Bringing the machine safely into service� Carry out a careful inspection tour around the machine each time before starting it. � Check the machine for loose bolts, cracks, wear, leakage and damage. � Never attempt to operate a damaged machine. � Ensure that any damage is immediately rectified. � Ensure that all hoods and covers are closed, but that locks are unlocked, to facilitate the fight

against fire in case of.� Ensure that all warning signs are present. � Keep windows and interior and exterior mirrors clean. Secure doors and windows against unin-

tended movement. � Ensure that no one is working on or under the machine and warn personnel in the vicinity of the

machine that it is about to start by sounding the horn.

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



MJFCIFSS

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

� Ensure that steps, ladders and hand-rails (grips) are in good condition. In particular, you shouldensure that they are free of dirt, oil, ice and snow. NOTE: To ensure that the doors open properly in all weather conditions, the door seals must bedusted with talc or silicon at least every two months or more often if required. The door hinges andlocks should be greased regularly.

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

� If you are able to reach the door handle with your free hand, open the doors before you climb anyhigher. External influences, such as wind, can make it more difficult to open doors. Because ofthis, always use your hand for control when opening doors. Ensure that the door is latched opento prevent it slamming open and shut.

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

� Be particulary vigilant with those prerequisites conditions.� Now continue to climb up, still using the three-point support and sit down in the operator�s seat as

soon as you enter the cab.� Close the doors and fasten the safety belt (if available), unlock the door, using the planned lever,

and close it immediately using the door handle, befor tilting down the safety lever, and start themachine.

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

Adjusting the operator�s standing position� Before starting the machine, adjust the seat, mirrors, armrests and operator�s controls in such a

way that you are able to work comfortably and safely. � Acoustic insulation devices on the machine must be set to the insulation position throughout 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 theoperator.

� Check the seat�s damping action and adjustment mechanisms regularly and ensure that theseseat 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.


R 900 C-Li - R 904 C-Li

Safety Instructions

1.10.5

Safety instructions

copyright by

MJFCIFSS

� 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. � 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 asecured 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 accesssystem at the same time. Climb down until you can close the doors safely. Always use your handfor 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 ortraffic obstructions, the load-carrying capacity of the ground and any requirements to make the jobsite 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 safetydistances.



MJFCIFSS

� The following actions must be carried out in the event of any transfer of electricity: � do not move the machine or its equipment, � do not leave the driver�s cab, � warn any personnel in the vicinity not to come close to the excavator and not to touch it, � instruct or initiate that someone turns off the voltage.� move the machine, if possible, from the danger zone to a sufficient distance,� Do not leave the machine until you are absolutely sure that voltage in the line, which had been

touched or damaged, has been turned off !� Before moving the machine, always ensure that any attachments are safely secured. � When driving onto public roads, paths and squares, observe current traffic regulations and if 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 closeto the ground as possible. EXCEPTION: �Safe use when loading and unloading (particularly when loading and unloadingwood)� 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 sametime.

� 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 toavoid 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 theattachment 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.


R 900 C-Li - R 904 C-Li

Safety Instructions

1.10.7

Safety instructions

copyright by

MJFCIFSS

� 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 thestorm.

� Auxiliary control units can have various functions. Always check their functions when starting upthe machine.

� Stop the swinging motion of the uppercarriage when lowering the attachment into a ditch withoutstriking 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 notpermitted, even when working in a longitudinal direction.

� 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 arerequired.

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

� With the 2x45° offset articulation, the offset position may only be employed if the working tool orthe 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 leadsto 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 moveobstacles with the hydraulic hammer. Misuse of this nature would damage both the hammer andthe machine.

� Do not use the hydraulic hammer to lift objects



MJFCIFSS

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 raisedand the load lifted up; this applies, for example, when loading and unloading wood.

� Here, the centre of gravity of the machine will be displaced upwards in the vertical direction. Thedriving characteristics of the machine will thus be influenced persistently, e.g. through reductionof 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 andspecific weight. The influencing variables present in a natural product, such as moisture, must benoted.

� Working procedures when using machines with grabs require the machine operator to receivespecial 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. Inhorizontal 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 900 C-Li - R 904 C-Li

Safety Instructions

1.10.9

Safety instructions

copyright by

MJFCIFSS

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 theoperator.

� Check the seat�s damping action and adjustment mechanisms regularly and ensure that theseseat 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.



MJFCIFSS

� Towing devices such as bars, cables or ropes must have adequate tensile strength and should besecured 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, firmground.

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

� Before loosening lines or unscrewing bolts, you must store the equipment, switch off the engineand press the start key to the contact position and both joysticks and the pushbuttons to �Turngrab� 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 havesufficient load carrying capacity.

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

� When working on the equipment: switch off the engine and keep the safety lever tilted up. Neveruse 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 circuitto 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 cotterpin.

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 900 C-Li - R 904 C-Li

Servicing the machine safely

1.10.11

Safety instructions

copyright by

MJFCIFSS

� The ramp used to drive the machine up onto the flatbed trailer should not exceed an inclination of30° 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 anysnow, 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 duringtransport 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 theundercarriage using the stop bolts (only A devices).

� Secure the undercarriage and the remaining individual parts using chains and blocks to preventslipping.

� Before you leave the machine, reduce pressure on all pressure lines, remove the ignition key andtilt 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 carefullyoff 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.

3 Servicing the machine safely

General safety instructions� Maintenance and repair work may only be carried out by specially trained personnel. � Observe statutory timetables or intervals given in the operating instructions for repeat tests / ins-

pections. It is imperative that a suitably equipped workshop is available in order to carry out main-tenance work.

� The inspection and maintenance schedule given at the end of these operating instructions definesprecisely who is required / permitted to carry out what work.Jobs listed as daily / weekly work may be carried out by the machine's driver or maintenance per-sonnel when they have received appropriate instruction.The remaining work may only be carried out by specialist personnel with appropriate training.

� Replacement parts must correspond to the technical requirements determined by the manufactu-rer. Original replacement parts are always guaranteed to meet these criteria.

� Always wear safe work clothes when carrying out maintenance work. Avoid the wearing of rings,wrist watches, ties, scarves, open jackets, baggy clothing etc... There is a risk of injury from, forexample, getting caught up or being drawn in.Protective goggles, safety helmets, safety shoes and gloves, reflective vests and ear protectionetc. are required for specific jobs.

� Do not remain in direct proximity of the diesel engine while the diesel engine is running.Persons with pacemakers should not approach within 20 cm of the running diesel engine.Do not touch voltage-carrying parts on the electrical connection of the individual solenoid injectionpumps (Unit Pumps UP) while the diesel engine is running.

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

Safety instructions Technical documentationServicing the machine safely


MJFCIFSS

� Cordon off a wide maintenance area if required. � Inform operational personnel before starting to carry out any special work and repair work. Desi-

gnate persons in charge of supervision. � In the absence of any other information in the operating instructions, carry out all maintenance

work on the machine on level, firm ground with the working equipment set aside and the engineswitched off.

� For some machines, the only one position which enables a secured access to every maintenancelocations on the uppercarriage, is when the uppercarriage is aligned with the undercarriage so thatthe sprockets locate at the back-end.The ladder situated on the undercarriage only corresponds with the uppercarriage�s access whenthe excavator is in this configuration.

� Pull out the ignition key and shut off the main battery switch. � Always tighten any loose screw connections during maintenance and repair work.� The mounting bolts of the main components, of the hydraulic hoses and of the counterweight must

be replaced after every removal.� If safety devices have to be dismantled during set-up, maintenance and repair work, they must be

immediately reinstalled and checked at the end of the work. � When carrying out repair work, particularly when working under the machine, hang a �Do not start�

warning sign in a clearly visible position on the starting lock. Pull out the start key and shut off themain battery switch.

� Operate combustion motors and fuel operated heaters only in well ventilated areas. Before ope-rating these units, check ventilation.

� In addition, always follow applicable local regulations.

Cleaning� Clean oil, fuel or care products off the machine before starting maintenance or repair work and

pay particular attention to connections and screw fittings. Do not use aggressive cleaning products and use lint-free cleaning cloths.

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

� Do not use combustible liquids to clean the machine. � Before cleaning the machine with water or steam jets (high pressure cleaner) or other cleaning

materials: � lubricate all bearing points, bolt connections and the rim bearing to prevent water or steam en-

tering the bearing points. � cover or glue shut all openings into which for safety or functional reasons water or steam may

not be permitted to enter. Electric motors, electrical components, control boxes, plug connections and air filters are partic-ularly at risk.

� Ensure that the fire warning systems and fire extinguishers of the engine compartment�s temper-ature sensor do not come into contact with hot cleaning products during cleaning work. The fire extinguisher could start.

� If you use a high pressure cleaner with steam or hot water to clean the machine, observe followingrecommendations :� the distance between the nozzle and the surface to be cleaned must be no lower than 20 inches� the water temperature should not exceed 60°c (140°F)� limit the water pressure to 80 bar maximum (11500 PSI)� if you employ cleaning fluid, only use neutral cleaning agents such as customary car shampoos

diluted to 2 or 3 percent maximum


R 900 C-Li - R 904 C-Li


1.10.13

Safety instructions

copyright by

MJFCIFSS

� After cleaning: � remove all covers completely.� check all fuel, engine oil and hydraulic lines for leakage, loosened connections, chafing and

damage. � rectify any defects found immediately. � lubricate all bearing points, bolt connections and the rim bearing to displace any water or clean-

ing products that may have entered.

Crack testing� Even when the machine is operated carefully, there is a possibility of individual cases of overload-

ing occurring, which could lead to cracks or loose connections. The machine should therefore bechecked regularly for cracks, loose connections or other visible damage to maintain operationalsafety.

� In order to be able to check for cracks, it is essential that the machine is kept clean and cleanedregularly.

� The tests should be carried out in accordance with the monitoring and maintenance plan: � every 250 operating hours by the machine owner�s maintenance personnel. � every 500 operating hours by authorised specialist personnel.

� It is advisable to carry out these tests: supported, on firm, horizontal substrate, with the equipmentin longitudinal and cross direction for variable loads. Current accident prevention regulations mustbe adhered to.

� Special care must be taken when testing load-bearing components, particularly: � the steel chassis members and axle and transmission mountings, the support, the lower rim

bearing support and tower and ball rim bearing. � the steel upper structure members and bearing block for boom and boom cylinder, the upper rim

bearing support, the cab mount and the mount for swing gear and ballast.� the steel components of the working equipment, e. g. the boom, stay, quick change adaptor, and

bucket. � hydraulic cylinders, axles, steering, bolts and bolt connections, steps, ladders and mounting el-

ements. � The crack test should be carried out visually. If a crack is suspected, the dye penetration test

should be carried out as a crack test on areas which do not have good visibility, such as the rimbearing support, in order to increase testing safety.

� Any damage found must be rectified immediately. Welding work on load-bearing parts of theearth-moving machinery, loading devices and transport devices may only be carried out by trainedspecialist personnel and only in accordance with the accepted rules of welding engineering. Incase of doubt, contact the LIEBHERR customer support service to discuss suitable remedies.

Welding, drilling, firing and grinding work� Any welding on structural parts (as undercarriage, uppercarriage, equipment parts,�) may only

be done the manufacturer, or authorized official dealer. If this rule is neglected, the warranty isvoided.

� Only carry out welding, drilling, firing and grinding work on the machine with express authorization.Clean dust and combustible materials off the machine and its surrounding areas before welding,drilling, firing or grinding. Ensure adequate ventilation. Risk of fire or explosion.

� Before welding repairs on other parts, always disconnect the battery. Always remove the negativeterminal first and reconnect it last.

� Nevertheless if welding repair should be done on components which may contain inflammablegases (welded counterweight, hydraulic tank, fuel tank, �), these components must be previouslyand sufficiently ventilated with pressurized air to avoid all fire or explosion hazard

� Before welding, connect the ground cable as close as possible to the welding point, so the weldingcurrent will not run through the swing ring, joints, gears, bushings, rubber parts and seals



MJFCIFSS

Process materials � When working with oils, greases and other chemical substances, observe the appropriate current

safety regulations for the product. � Ensure that process materials and replacement parts are disposed of in a safe and environmen-

tally acceptable manner. � Take care when handling hot process materials

(Risk of burning and scalding).

Repair work� Do not attempt to lift heavy parts. Use devices which are suitable for this purpose and which have

sufficient load capacity. When replacing single parts and larger subassemblies, carefully securethem on lifting devices them so that they do not present a risk. Only use suitable and correctlyfunctioning lifting devices and load take-up devices with adequate load capacity. Do not stand or work under swinging loads.

� Do not use lifting devices which are damaged or do not have sufficient load carrying capacity. Wear work gloves when working with wire cables.

� Only permit experienced personnel to attach loads and give signals to the crane operator. Thespotter must be positioned within the visual range of the operator or be in voice contact with him.

� When working above body height, use safe climbing devices and working platforms which are ap-propriate for the job. Do not use machine parts as climbing devices if they are not designed for this purpose. When working at height, wear a harness to prevent falling. Ensure that all grips, steps, rails, platforms and ladders are free of dirt, snow and ice.

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

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

� For safety reasons, never open and remove a track chain unless having previously totally re-leased the pretension of the chain tensioning unit.

� Never lay under the machine if it is raised with work equipment and has not been securely sup-ported with wooden beams.

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

� Work on the suspension, brake and steering systems may only be carried out by trained specialistpersonnel.

� If the machine has to be repaired on a slope, secure the crawler with chocks and connect the up-per structure to the chassis using stop bolts.

� Only personnel with special training and experience may work on hydraulic equipment. � When searching for leakage, wear protective gloves. A fine jet of liquid under pressure can pen-

etrate the skin. � Do not unscrew any lines or connections before you have set aside the equipment, switched off

the engine and depressurized the hydraulic system. After switching off the engine, with the startkey in contact position and with the safety lever down into its lowest position, you must operate allpilot control devices (joystick and pedals) in all directions in order to reduce the actuating and dy-namic pressures in the work circuits. You must then reduce the internal tank pressure as de-scribed in these operating instructions.

Electrical system� Check the electrical system regularly.

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

� Only use original fuses with approved current strength.


R 900 C-Li - R 904 C-Li


1.10.15

Safety instructions

copyright by

MJFCIFSS

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

� Work on the machine�s electrical equipment may only be carried out by skilled electrical personnelor by trained personnel under the supervision of an electrician in accordance with electrical regu-lations.

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

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

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

� Disconnect the battery before working on the electrical system or carrying out any electric arcwelding on the machine. First disconnect the negative, then the positive pole. When reconnecting, proceed in the reverseorder.

Hydraulic accumulator� All work on the hydraulic accumulators must be carried out by trained specialist personnel. � Inexpert assembly and handling of hydraulic accumulators can cause serious accidents. � Do not operate damaged hydraulic accumulators. � Before working on a hydraulic accumulator, you must reduce the pressure in the hydraulic system

(hydraulic system including hydraulic tank), as described in these operating instructions.� Do not carry out welding or soldering or do any mechanical work on the hydraulic accumulator.

The hydraulic accumulator can be damaged by heat penetration and can be made to rupture bymechanical working. RISK OF EXPLOSION!

� Only charge the hydraulic accumulator with nitrogen. There is a RISK OF EXPLOSION if oxygenor air is used.

� The accumulator body can become hot during operation; there is a risk of burning. � New hydraulic accumulators must be charged with the pressure required for the purpose of use

before installation. � The operating data (minimum and maximum pressure) are marked permanently on hydraulic ac-

cumulators. Ensure that this marking remains visible.

Hydraulic hoses and sheathed cables. � It is forbidden to carry out repair work on hydraulic hoses and sheathed cables! � All hoses, sheathed cables and bolt connections must be checked regularly every 2 weeks for

externally visible damage and any possible damage must be immediately checked for leakage.� Never check for leaks with your bare hands, use a sheet of paper or something else.� Any damaged parts must be removed immediately! Spurting oil can lead to injury and burns. � Even with correct storage and permitted load, hoses and sheathed cables are subject to the nat-

ural aging process. This restricts their duration of use. � Incorrect storage, mechanical damage and unauthorized load are the most common causes of

failure. � In relation to duration of use, current norms, regulations and guidelines pertaining to hoses and

sheathed cables at place of use must be adhered to. � Use at the limit range of permissible load can shorten duration of use (e.g. high temperatures,

frequent movement cycles, extremely high pulse frequencies, multiple shift usage).



MJFCIFSS

� Hoses and sheathed cables should be replaced if the following are found during inspection: � Damage to the outer sheath as far as the liner (e.g. chafing, cuts and cracks); � Brittleness of the outer sheath (fracture formation in hose material); � Deformations which do not correspond to the natural form of the hose or sheathed cable, wheth-

er in a unpressurized or pressurized state or on bends e.g. sheath separation, blistering; � Unsealed areas;� Non-adherence to requirements during installation; � Damage or deformations to the hose fittings which reduce the tightness of the fittings or the hose

/ fitting connection; � Hoses working themselves out of the fittings; � Corrosion of the fittings which reduces function and tightness;

� When replacing hoses and sheathed cables, use only original replacement parts. � Install and mount hoses and sheathed cables correctly. Do not mix up the connections. � The following is to be noted when replacing hoses and sheathed cables:

� Always ensure that the hoses and sheathed cables are installed free of torsion. For high-pres-sure hoses, the screws from the half-clamps or full flange must always be attached to both hoseends and should only be tightened afterwards.

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

� Any mounting clamps which are located in the centre of the hose may only be attached and tight-ened subsequently.

� Check daily to ensure that all clamps, covers and protective devices are properly fastened. Do-ing this will prevent vibration and damage during operation.

� Install the hoses and sheathed cables in such a way that they cannot chafe on other hoses,sheathed cables or parts.

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

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


R 900 C-Li - R 904 C-Li

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

1.20.1

Tightening torques

copyright by

MJFCIFSS

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

. 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.

0 2

Metric coarse thread Metric fine thread

Thread ClassAssembly

preloads FM in N

Tightening torques MA

in NmThread Class

Assembly preloads FM

in N

Tightening torques MA

in Nm

M48.810.912.9

405060007000

2,84,14,8

M58.810.912.9

6600970011400

5,58,19,5

M68.810.912.9

94001370016100

9,514,016,5

M78.810.912.9

137002010023500

15,523,027,0

M88.810.912.9

172002500029500

23,034,040,0

M8×18.810.912.9

188002750032500

24,53643

M9×18.810.912.9

248003650042500

365362

M108.810.912.9

275004000047000

46,068,079,0

M10×18.810.912.9

315004650054000

527689

M10×1,258.810.912.9

295004300051000

497284

M128.810.912.9

400005900069000

79,0117,0135,0

M12×1,258.810.912.9

450006600073000

87125150

M12×1,58.810.912.9

425006200073000

83122145

M148.810.912.9

550008000094000

125,0185,0215,0

M14×1,58.810.912.9

6100089000104000

135200235

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


MJFCIFSS

M168.810.912.9

75000111000130000

195,0280,0330,0

M16×1,58.810.912.9

82000121000141000

205300360

M18 8,810,912,9

94000135000157000

280390460

M18×1,5 8,810,912,9

110000157000184000

310440520

M18×2 8,810,912,9

102000146000170000

290420490

M20 8,810,912,9

121000173000202000

390560650

M20×1,5 8,810,912,9

139000199000232000

430620720

M22 8,810,912,9

152000216000250000

530750880

M22×1,5 8,810,912,9

171000245000285000

580820960

M24 8,810,912,9

175000249000290000

6709601120

M24×1,5 8,810,912,9

207000295000346000

76010901270

M24×2 8,810,912,9

196000280000325000

73010401220

M27 8,810,912,9

230000330000385000

100014001650

M27×1,5 8,810,912,9

267000381000445000

111015801850

M27×2 8,810,912,9

255000365000425000

107015001800

M30 8,810,912,9

280000400000465000

135019002250

M30×1,5 8,810,912,9

335000477000558000

154021902560

M30×2 8,810,912,9

321000457000534000

149021202480

M33 8,810,912,9

350000495000580000

185026003000

M33×1,5 8,810,912,9

410000584000683000

205029203420

M33×2 8,810,912,9

395000560000660000

200028003300

M36 8,810,912,9

410000580000680000

235033003900

M36×1,5 8,810,912,9

492000701000820000

268038204470

M36×3 8,810,912,9

440000630000740000

250035004100

M39 8,810,912,9

490000700000820000

300043005100

M39×1,5 8,810,912,9

582000830000971000

343048905720

M39×3 8,810,912,9

530000750000880000

320046005300



R 900 C-Li - R 904 C-Li

Tightening torques of screw-in studs (Ermeto)

1.20.3

Tightening torques

copyright by

MJFCIFSS

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

Type with sealing edge Type with EOLASTIC seal

Type Thread M or G

Tightening torques

(Nm)Type Thread M or

G

Tightening torques

(Nm)

Light-duty series L

GE 06 LM A 3 C M 10×1 18 GE 06 LM ED A 3 C M 10×1 18

GE 06 LR A 3 C G 1/8 A 18 GE 06 LR ED A 3 C G 1/8 A 18

GE 08 LM A 3 C M 12×1,5 30 GE 08 LM ED A 3 C M 12×1,5 25













GE 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 G 1 A 330 GE 28 LR ED A 3 C G 1 A 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

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 25 SR A 3 C G 1 A 340 GE 25 SR ED A 3 C G 1 A 310

Tightening torques Technical documentationTightening torques of swivelling connections (Ermeto)


MJFCIFSS

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!)


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 38 SR ED A 3 C G 1 1/2 A 540

Type ThreadTightening

torque (Nm)

Type ThreadTightening

torque (Nm)

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

G 1/8 A 18 WH / TH 06 LM KDS A 3 C

M 10×1 18

WH / TH 08 LR KDS A 3 C

G 1/4 A 45 WH / TH 08 LM KDS A 3 C

M 12×1,5 45


G 3/8 A 45 WH / TH 10 LM KDS A 3 C

M 14×1,5 55


G1/2 A 70 WH / TH 12 LM KDS A 3 C

M 16×1,5 80


G3/4 A 120 WH / TH 15 LM KDS A 3 C

M 18×1,5 100


G1 A 120 WH / TH 18 LM KDS A 3 C

M 22×1,5 140


G 1 1/4 A 230 WH / TH 22 LM KDS A 3 C

M 27×2,0 320


G 1 1/4 A 320 WH / TH 28 LM KDS A 3 C

M 33 x 2,0 360


G 1 1/4 A 540 WH / TH 35 LM KDS A 3 C

M 42×2,0 540


R 1 1/2 A 700 WH / TH 42 LM KDS A 3 C

M 48×2,0 700

Heavy-duty series SWH / TH 06 SR KDS A 3 C

G 1/4 A 45 WH / TH 06 SM KDS A 3 C

M 12×1,5 45

WH / TH 08 SR KDS A 3 C

G 1/4 A 45 WH / TH 08 SM KDS A 3 C

M 14×1,5 55


G 3/8 A 70 WH / TH 10 SM KDS A 3 C

M 16×1,5 80


G 3/8 A 70 WH / TH 12 SM KDS A 3 C

M 18×1,5 100


G 1/2 A 120 WH / TH 14 SM KDS A 3 C

M 20×1,5 125


G 3/4 A 230 WH / TH 16 SM KDS A 3 C

M 22×1,5 135


G 1 A 320 WH / TH 20 SM KDS A 3 C

M 27×2,0 320


G 1 1/4 A 540 WH / TH 25 SM KDS A 3 C

M 33×2,0 360


R 900 C-Li - R 904 C-Li

Tightening torques of screw-in studs (Ermeto)

1.20.5

Tightening torques

copyright by

MJFCIFSS

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

VSTI = Hexagon socket plug

WH / TH 38SR KDS A 3 C

G 1/4 A 700 WH / TH 30 SM KDS A 3 C

M 42×2,0 540

WH / TH 38 SM KDS A 3 C

M 48×2,0 700

Type GewindeAnziehdrehmomente

(Nm)Type Gewinde

Anziehdrehmomente

(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 20×1,5 ED A3C M 20×1,5 80 VSTI 1 ED A3C G 1 A 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

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


MJFCIFSS


R 900 C-Li - R 904 C-Li

Scope of application

1.22.1

Assembly instruction for pistons and piston nuts (hy-

copyright by

MJFCIFSS

1.22: Assembly instruction for pistons and piston nuts (hydraulic cylinders)

According to standard WN 4121 B (04/2005)

1 Scope of applicationThis factory standard applies exclusively to the assembly of hydraulic cylinders with a thread diame-ter of M42 and greater. For the valid factory standard number, refer to the drawing. The standard maynot 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.

For threads with diameters smaller than M42, the applicable tightening torques are indicated in the drawings.

The values in the drawings are always binding.

2 Description

Preparation :

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

2.1 Definitions :

Pretightening torque :

The piston is secured with a torque wrench applied to the square / hexagon head of the assembly wrench. The position of the torque wrench must be carefully noted.

Fig. 1 Torque wrench

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

Proceed in the same w<ay to tighten the piston nut, using a suitable assembly wrench.

A Piston C Assembly wrenchB Torque wrench

Assembly instruction for pistons and piston nuts (hy- Technical documentationTightening torques for factory standard (04.08.2004)


MJFCIFSS

Turning distance:

Radian measure [mm] travelled as a result of the tightning of the piston, or piston nut along the outerthread diameter, after application of the pretightening torque.

Turning angle :

Angle [°] travelled by the piston or piston nut respectively, after application of the pretightening torque.

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

Fig. 3 Marks, turning distance and turning angle on the piston nut

3 Tightening torques for factory standard (04.08.2004)

c Marks on the piston and piston rod thread after application of the pretightening torque

d Marks on the piston rod threade Mark on the piston after tightening

Turning angleTurning distance

WN 4121 No. Preload (N.m)

Piston Piston nutThread M (mm)Turning

distance (mm)

Turning angle (< °)

Turning distance (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


R 900 C-Li - R 904 C-Li

Tightening torques for factory standard (04.08.2004)

1.22.3

Assembly instruction for pistons and piston nuts (hy-

copyright by

MJFCIFSS

075 100 19 +1 52 21 +1 57 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

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

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

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

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

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



distance (mm)




Assembly instruction for pistons and piston nuts (hy- Technical documentationTightening torques for factory standard (04.08.2004)


MJFCIFSS

231 200 8 +2 11 16 +1 22 85x3

232 200 17 +2 23 16 +1 22 85x3

234 200 22 +2 30 - - 85x3

261 250 20 +2 25 10 +1 12 95x3

281 250 20 +2 23 13 +1 15 100x3

282 250 25 +2 29 - - 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

501 200 21 +2 30 - - 80x2

531 500 34 +3 28 - - 140x3



distance (mm)





R 900 C-Li - R 904 C-Li

Description

1.24.1

Assembly instruction for piston rod bearings with ex-

copyright by

MJFCIFSS

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 ortransferred 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

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.

A Piston C Assembly wrenchB Torque wrench

Assembly instruction for piston rod bearings with ex- Technical documentationDescription


MJFCIFSS

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

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.

c Marks on piston and piston rod thread after application of the pretightening tor-que

d Mark on the cylinder tubee Mark on the bearing head after tightningg Cylinder tubeh Bearing head

Turning angleTurning distance


R 900 C-Li - R 904 C-Li

Tightening torques for factory standard (02.07.2008)

1.24.3

Assembly instruction for piston rod bearings with ex-

copyright by

MJFCIFSS

2 Tightening torques for factory standard (02.07.2008)


Piston



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

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


MJFCIFSS


R 900 C-Li - R 904 C-Li

Identification of the tightening torques

1.25.1

Tightening torques of screws with LH-washer 340HV

copyright by

MJFCIFSS

1.25: Tightening torques of screws with LH-washer 340HV

According to LIEBHERR standard KR 0015A

1 Identification of the tightening torques

Mounting screws of piston rod bearing according to ISO 4014, ISO 4017 and ISO 4762.� black-chrome finished or phosphatised� LH washer 340 HV - A3C� DACROMET

Friction values:� in the thread µG = 0,14� under the head µK = 0,11 (Values out of the RIBE - Blauheft)

* rounded value out of the RIBE - Blauheft

Filetage Class MG (Nm)

Mk (Nm) MA (Nm)

MA for A3C screws with total friction = 0,10 (Nm) *

Ident. No. D x h

M10 10.9 38 + 31 = 70 60 9918225 18 x 3,0

SW16 12.9 44 + 36 = 80 70 9918225 18 x 3,0

M12 10.9 65 + 52 = 120 105 9918226 21 x 3,5

SW18 12.9 76 + 61 = 140 125 9918226 21 x 3,5

M16 10.9 161 + 127 = 290 9918228 28 x 4,0

SW24 12.9 189 + 148 = 340 9918228 28 x 4,0

M20 10.9 315 + 250 = 565 9918229 34 x 5,0

SW30 12.9 369 + 292 = 660 9918229 34 x 5,0

M24 10.9 544 + 427 = 970 9918230 40 x 5,0

SW36 12.9 637 + 500 = 1130 9918230 40 x 5,0

M27 10.9 794 + 642 = 1440 9586495 45 x 6,0

SW41 12.9 9586495 45 x 6,0

M30 10.9 1080 + 870 = 1950 9918231 52 x 6,0

SW45 12.9 1260 + 1020 = 2250 9918231 52 x 6,0

M36 10.9 1880 + 1500 = 3400 9918232 60 x 7,0

SW55 12.9 2200 + 1760 = 3900 9918232 60 x 7,0

Tightening torques of screws with LH-washer 340HV Technical documentationIdentification of the tightening torques


MJFCIFSS


R 900 C-Li - R 904 C-Li

Preloads and tightening torques table

1.26.1

Preloads and tightening torques (Din 13)

copyright by

MJFCIFSS

1.26: Preloads and tightening torques (Din 13)

for screws with metric coarse and fine threads according to DIN 13, page 12

According to Standard WN 4037 I

1 Preloads and tightening torques tableThe preloads and torques included in the table are based on the VDI regulations 2230 of july 1986.

Assembly preloads FM and tightening torques MA for headless screws with metric coarse or fine threads according to DIN ISO 262 and DIN ISO 965 T2 (DIN 13 part 13 replacement);

Head dimensions of hex head srews according to DIN EN 24014 (DIN 931 part 1 replacement) or Allen head screws according to DIN EN ISO 4762 (DIN 912 replacement)


Surface finish :- black-chrome finish or phosphatised oiled- electro-galvanised oiled- flZn = zinc flakecoating oiled (LH Standard 10021432, DAC)


Thread ClassAssembly preloads FM in N

Tightening torques MA in N Thread Class

Assembly preloads FM in N

Tightening torques MA in N

for mean friction factor µg = 0.12 for mean friction factor µg = 0,12

M48.810.912.9

405060007000

2.84.14.8

M58.810.912.9

6600970011400

5.58.19.5

M68.810.912.9

94001370016100

9.514.016.5

M78.810.912.9

137002010023500

15.523.027

M88.810.912.9

172002500029500

233440

M8x18.810.912.9

188002750032500

24,53643

M9x18.810.912.9

248003650042500

365362

M108.810.912.9

275004000047000

466879

M10x18.810.912.9

315004650054000

527689

M10x1,258.810.912.9

295004300051000

497284

M128.810.912.9

400005900069000

79117135

M12x1,258.810.912.9

450006600077000

87125150

Preloads and tightening torques (Din 13) Technical documentationPreloads and tightening torques table


MJFCIFSS

M12x1,58.810.912.9

425006200073000

83122145

M148.810.912.9

550008000094000

125185215

M14x1,58.810.912.9

6100089000104000

135200235

M168.810.912.9

75000111000130000

195280330

M16x1,58.810.912.9

82000121000141000

205300360

M188.810.912.9

94000135000157000

280390460

M18x1,58.810.912.9

110000157000184000

310440520

M18x28.810.912.9

102000146000170000

290420490

M208.810.912.9

121000173000202000

390560650

M20x1,58.810.912.9

139000199000232000

430620720

M228.810.912.9

152000216000250000

530750880

M22x1,58.810.912.9

171000245000285000

580820960

M248.810.912.9

175000249000290000

6709601120

M24x1,58.810.912.9

207000295000346000

76010901270

M24x28.810.912.9

196000280000325000

73010401220

M278.810.912.9

230000330000385000

100014001650

M27x1,58.810.912.9

267000381000445000

111015801850

M27x28.810.912.9

255000365000425000

107015001800

M308.810.912.9

280000400000465000

135019002250

M30x1,58.810.912.9

335000477000558000

154021902560

M30x28.810.912.9

321000457000534000

149021202480

M338.810.912.9

350000495000580000

185026003000

M33x1,58.810.912.9

410000584000683000

205029203420

M33x28.810.912.9

395000560000660000

200028003300










R 900 C-Li - R 904 C-Li

Angle tightening process

1.26.3


copyright by

MJFCIFSS

2 Angle tightening processThe angle tightening process constists in rotating the screw from a defined angle in order to enable the screw elastic lenghtening and the plates tightening. A tightening torque predetermined according to the screw size, will bring this screw on block against the parts to tighten, in order to determine the beginning of the tightening angle mesure.

From this value 0=0, the preload force is set up regardless of the thread friction coefficient or of the bearing surface, simply by rotating the screw by retightening angle .

Example 1 :

Screw M14 - 10.9, clamping lenght Lk = 80mm;

According to the table, for the 10.9 class:

Preloads MA = 50Nm; Retightening angle ~ 45°

Example 2 :

Screw M24 - 12.9, clamping lenght Lk = 100mm;

According to the table, for the 12.9 class:

Preloads MA = 160Nm; Retightening angle ~ 57°

M368.810.912.9

410000580000680000

235033003900

M36x1,58.810.912.9

492000701000820000

268038204470

M36x38.810.912.9

440000630000740000

250035004100

M398.810.912.9

490000700000820000

300043005100

M39x1,58.810.912.9

582000830000971000

343048905720

M39x38.810.912.9

530000750000880000

320046005300









Preloads and tightening torques (Din 13) Technical documentationAngle tightening process


MJFCIFSS

2.1 Retightening angle depending on the clamping lenght - Preloads 50 Nm


R 900 C-Li - R 904 C-Li

Angle tightening process

1.26.5


copyright by

MJFCIFSS

2.2 Retightening angle depending on the clamping lenght - Preloads - 100 Nm

Preloads and tightening torques (Din 13) Technical documentationAngle tightening process


MJFCIFSS

2.3 Retightening angle depending on the clamping lenght - Preloads 400 Nm


R 900 C-Li - R 904 C-Li

General specifications for the replacement of fuels and lubricants

1.50.1

Fuel and Lubricants

copyright by

MJFCIFSS

1.50: Fuel and Lubricants

1 General specifications for the replacement of fuels and lubricants

2 Lubricant Chart

Note!The filling amounts specified in the fuel and lubricants chart, as well as in the lubrication chart, are reference values only.

After performing an oil-change or top-up, always check the level in the respective aggregate.

Note!Conscientious adherence of the guidelines for lubrication, checking levels and replacing fuels will guarantee increased reliability and life-expectancy of the machine. Particular attention must be paid to the intervals for oil-changes and it is imperative that the stipulated lubricant qualities are adhered to.

Note!Cleanliness is extremely important when carrying out oil-changes.

Clean all filling screws, filler caps and drain plugs, including their immediate surroundings before opening them.

Always ensure that the oil is at operating temperature before draining.

Ensure that used oils are collected and disposed of in an environmentally-friendly manner along with the removed oil filter cartridges.

Danger!It is imperative that the following guidelines are observed when inspecting or changing fuels and lubricants:

Unless otherwise specified, carry out the respective work on the machine on firm, level ground with the engine switched off.

Always secure the cover against falling or closing before leaning into the engine room.

Refuelling may only be carried out with the engine switched off, never smoke and avoid naked flames.

Description Medium Symbol Classification Viscosity BI *

Diesel engine Engine oil API-CG-4, CF-4 or CH-4,ACEA-E2-96, E3-96 or E4-98

SAE 5W40SAE 10W30SAE 10W40SAE 15W30SAE 15W40

EO 0540EO 1030EO 1040EO 1540

Hydraulic oil tank Engine oil API-CD, API-CD+SF,ACEA-E4,

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

EO 10EO 1030EO 1040EO 1540EO 20EO 30

Fuel and Lubricants Technical documentationFuel and Lubricants Chart


MJFCIFSS

Tab. 1 Lubricant Chart

3 Fuel and Lubricants Chart

Tab. 2 Fuel and Lubricants Chart

Swing gear(as holding brake)

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

SAE 80W90orSAE 90

GO 90

Swing gear(as positioning swing brake)

Gear oil API-GL-5MIL-L 2105 B

SAE 90 LS GO 90 LS

Travel gear Gear oil API-GL-5MIL-L 2105 B, C or D

SAE 80W90SAE 90

GO 90

Raceways and toothing of swing ring, bearing of at-tachment

Lubricating grease

High-pressure greaseKP2k or EP2

Consistency 2NLGI class with lithium com-plex Tab. 6

MPG-A

Hinges, articula-tions, locks

Engine oil - - - -

Rubber seals on doors and panelling

Silicon spray or tal-cum

- - - -

*BI = Standardised lubricants for construction machinery and vehicles of the Federation of the GermanConstruction Industry (see brochure from Bauverlag GmbH - Wiesbaden and Berlin, information regard-ing the fuels and lubricants chart).

Description Medium Symbol Classification Viscosity BI *

Description Medium Symbol

Fuel tank Commercially-approved diesel fuel with a sulphur content of <= 0.5 %

Coolant Anticorrosive and antifreezeFilling with DCA 4BI = SP-C

Windshield washing system

Commercially-approved windshield washing agent or de-natured alcohol

-

Refrigerant for air-condi-tioning system

R 134 a -

Refrigerating oil in the air-conditioning com-pressor SD 7 H15

PLANETELF PAG SP 10ID no. 10017679 (0.25 litres)

-


R 900 C-Li - R 904 C-Li

Fuel and Lubricants Chart

1.50.3

Fuel and Lubricants

copyright by

MJFCIFSS

3.0.1 Fuel and lubricant specifications

Lube oil for the diesel engine

The lube oil guideline for diesel engines is based on the following classifications:

Tab. 3 Lube oil for the diesel engine

The engine oil for the diesel engine can be selected in accordance with the following chart.

Fig. 1 Engine oil for utilisation as lube oil for the diesel engine

Oil-change intervals for the turbo engine

Tab. 4 Oil-change intervals

The oil-change intervals for the diesel engine are arranged in accordance with the following criteria:� First oil and filter change at 500 operating hours when using initial fill oil of quality E3-96� Subsequent filter change every 500 operating hours� Subsequent oil-change depending on climate zone, sulphur content in fuel and oil quality E3-96

(D5), E4-98 (see Tab. 4).� Wherever the stipulated number of operating hours has not been reached in any given year, the

engine oil and the oil filter must be changed at least once a year

Classification Specification

API-classification (American Petrol Insti-tute)

CG-4, CF-4, CH-4

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

E2-96 (D4), E3-96 (D5), E4-98

Conditions of use Sulphur content in the fuel

Oil-change intervaldependent on oil quality:

CH-4CG-4CF-4E2-96 (D4)

E3-96 (D5)E4-98

Climate normal to -10 °C up to 0.5 %more than 0.5 %

250 h125 h

500 h250 h

below -10 °C up to 0.5 %more than 0.5 %

125 h-

250 h125 h

Fuel and Lubricants Technical documentationFuel


MJFCIFSS

4 FuelDiesel fuels should comply with the minimum requirements of the permissible fuel specifications stip-ulated below.

4.0.1 Lubricity / sulphur contentIn DIN EN 590 a max. 350 mg/kg = max. 0.035 wt% sulphur content permissible.

�Low-sulphur� diesel fuels with a sulphur content below / less than 0.05% are only permissible if alubricity can be guaranteed with the addition of additives. The diesel fuel lubricity must be 460 µm inaccordance with HFRR (60) Testmax. [lubricity amended �wear scar diameter� (1.4) at 60 °C].

For diesel fuels with a sulphur content above / more than 0.5 wt%, the oil-change intervals areto be halved.Diesel fuels with a sulphur content above / more than 1% are not permissible.

4.0.2 Permissible fuel specificationsDIN EN 590

ASTM D 975 - 89a 1 D and 2 D

Further fuel specifications can be obtained upon consultation with LIEBHERR's diesel engine devel-opment department.

4.0.3 Diesel fuel at low temperatures (winter operation)Paraffin crystals become separated in the diesel fuel as ambient temperatures fall. This causes asubsequent flow resistance in the fuel filter and a sufficient supply of fuel to the diesel engine can nolonger be guaranteed. In moderate climates, optimum flow flexibility can be guaranteed up to:

0 °C from 15.04. to 30.09.

-10 °C from 01.10. to 15.11. and from 1.3. to 14.04.

-20 °C from 16.11. to 29.02.

in accordance with DIN EN 590. We recommend using a fuel filter heater wherever flow flexibility ofthe diesel fuel proves inadequate, or when working in ambient temperatures below -20 °C. Other ap-proved diesel fuels:

Diesel fuel in compliance with DIN EN 590 with up to 5% Vol. FAME.

Note!An approval can be granted in correspondence with the quality of the diesel engine lube oil! Fuel standard ASTM D 975 does not stipulate that the fuels must pass a fuel lubricity test. A written con-firmation from the fuel suppliers must be acquired. The additives must be added by the supplier in his capacity as sole responsible agent for quality of the fuel. The addition of secondary lubricity ad-ditives by the customer is not recommended.� A cetane number of at least 45 is required for fuels in accordance with ASTM D 975. A cetane

number above 50 is recommended, particularly when working in temperatures below 0 °C or32 °F.

Caution!Improving flow of the diesel fuel by adding petroleum or regular benzine, or flow improvers from al-ternate manufacturers which can be readily purchased in stores, even in insignificant quantities, is absolutely prohibited. Such an addition is not compatible with the high-pressure injection system of your diesel engine and would lead to ruination of the diesel engine as a direct result of inadequate lubrication.


R 900 C-Li - R 904 C-Li

Hydraulic oil

1.50.5

Fuel and Lubricants

copyright by

MJFCIFSS

5 Hydraulic oil

5.0.1 Mineral oilEngine oils are stipulated in accordance with the following specifications and guidelines:

Tab. 5 Prescribed engine oils for utilisation as hydraulic oil

Engine oil for utilisation as hydraulic oil can be selected in accordance with the following chart.

Fig. 2 Engine oil for utilisation as hydraulic oil

Warm-up directive

The following warm-up directive applies for temperatures up to 10 °C below the stipulated limit (blackbar):

Following start-up, regulate the diesel engine to approx. 1 / 2 the nominal speed. Actuate hydrauliccylinders and hydraulic motors, do not allow the cylinders to run at full load. Warm-up periodapprox. 10 minutes.

In even lower temperatures: Preheat the oil reservoir before starting up the engine.

5.0.2 Environmentally-friendly hydraulic fluids

All environmentally-friendly hydraulic oils recommended by LIEBHERR are restricted to oils featuringsynthetic ester base and a viscosity in compliance with ISO VG 46.

Initial filling is carried out at the factory in accordance with a list of approved suppliers. It is essentialthat the utilisation of environmentally-friendly hydraulic oils is first agreed with the LIEBHERR com-pany.

Plant-based oils are not to be used due to their poor temperature resistance.

The utilisation of partial flow filters is absolutely essential.

Single-grade oils: API - CD / CCMC - D4 / ACEA - E1Mercedes-Benz Guidelines, page no. 226.0 and 227.0

Multi-grade oils: API - CD + SF / CCMC - D5 / ACEA - E3Mercedes-Benz Guidelines, page no. 227.5, 228.1 and 228.3

Note!Mixing environmentally-friendly hydraulic oils from different manufacturers, as well as mixing with mineral oils is strictly forbidden (see also information from after-sales services)!

Fuel and Lubricants Technical documentationHydraulic oil


MJFCIFSS

5.0.3 Hydraulic oil monitoring

5.0.4 Hydraulic oil monitoring in normal conditions

Fig. 3 Taking oil samples in normal conditions

Oil-change in accordance with analysis and laboratory report.

Change intervals for the hydraulic oil return-flow filters (20/5 µm): first after 500 operating hours withsubsequent changes every 1000 operating hours.

5.0.5 Hydraulic oil monitoring in extremely dusty conditions

Fig. 4 Taking an oil sample in extremely dusty conditions

Oil-change in accordance with analysis and laboratory report.

Change intervals for the hydraulic oil return-flow filters (10 µm): first after 500 operating hours withsubsequent changes every 500 operating hours.

5.0.6 Tips for reducing contamination of the hydraulic oil in extremely dusty conditionsIf the machine is being operated predominantly with hydraulic hammer or comparable applications(extremely dusty conditions), it is likely that the hydraulic oil will become more contaminated than usu-al.

Note!Environmentally-friendly hydraulic fluids are to undergo regular inspections via oil analysis .Oil analysis is recommended for mineral oils.

Machines working in normal conditions: at least every 500 operating hours

Machines working in extremely dusty conditions: at least every 250 operating hoursLIEBHERR recommends that the oil analyses be undertaken by the WEAR-CHECK company, and that the oil-change is performed in accordance with the respective laboratory report (see also after-sales service information and product information).

--- Taking an oil sample 1 First oil sample- Filter change 2 Second oil sampleh Operating hours 3 Additional oil samples every 500 operating

hours

--- Taking an oil sample 1 First oil sample- Filter change 2 Second oil sampleh Operating hours 3 Additional oil samples every 250 operating

hours


R 900 C-Li - R 904 C-Li

Hydraulic oil

1.50.7

Fuel and Lubricants

copyright by

MJFCIFSS

To avoid premature wear of the hydraulic components, the oil-change intervals (or the intervals sep-arating the taking of oil samples) are to be reduced and the following guidelines are to be observed:

� The filter cartridge(s) in the return-flow filter must be replaced every 500 operating hours� For the return-flow filter, 10-µm filter cartridges must be used instead of the regular 20 / 5-µm filter

cartridges� The ventilation filter on the hydraulic oil tank is to be replaced with a 2 µm fine filter (refinement of

the standard filter is 7 µm)� The 2-µm ventilation filter is to be replaced each time a hydraulic oil-change is performed (every

500 operating hours)

5.0.7 Gear oilGear oils must comply with the specifications� API-GL-5 and MIL-L-2105 B or C or D for viscosity class SAE 90

For viscosity classes SAE 80 and SAE 90 in accordance with MIL-L-2105 D, oils of viscosity classSAE 80W90 may also be used.

Lubricating grease and other lubricants

Note!Machines which have been equipped with a hydraulic installation kit in the factory, as well as ma-chines featuring a retrofitted kit for the hydraulic hammer, are already equipped with these 10-µm filter cartridges and 2-µm ventilation filter.

Lubricants Description / manufacturer

Lubricating grease for the swing ring / general lubrication points

The grease must comply with specification KP2k, consistency 2 or NLGI class in accordance with DIN 51818 and DIN 51825 or EP 2 in accordance with NF-T-60 132.The grease must comprise a lithium complex and must indicate a VKA-value of at least 2300 N in ac-cordance with DIN 51350 or ASTM D 2596.

Contact spray for sliprings CramolinID no. 7024145

Lubricant for pistons, piston nuts and the mounting of piston rod bearings and damping sleeves on hydraulic cyl-inders

Gleitmo 800ID no. 8300004 (40g tube)Gleitmo 900ID no. 8610227 (400 ml spray can)

Special anticorrosive for installation points on the hydraulic cylinders for sealing elements

Castrol-TarpID no. 8300005 (40g tube)

Other greases:Lubricant for the assembly of pumps to prevent fretting corrosion on the splined shaft toothing

Liebherr special paste CTKID no. 861331301 (400g cartridge)

Refrigerant for the air-conditioning system

R 134 aDraining and filling of the system must be per-formed in accordance with the guidelines (see air-conditioning system componentry).

Fuel and Lubricants Technical documentationCoolant


MJFCIFSS

Tab. 6 Lubricating grease and other lubricants

6 Coolant

6.0.1 Anticorrosive and antifreeze with DCA (ID no. 8503890 - 30 l drum)Water filter accessories are introduced to LIEBHERR diesel engines to improve quality of the coolingwater.

This allows a supplementary filtering of the coolant in the bypass flow where it is purified of dirt or rustparticles which could cause leakages in the cooling pumps.

Additionally, a chemical admixture in the filter (DCA 4) protects the cooling system, or parts whichcome into contact with the coolant such as coolant pumps, cylinder liners etc. against cavitation, cor-rosion, limescale and the build-up of foam.

Four different water filter accessories have been implemented due to the diverse volumes of coolingwater or diverse water accessories on engines or equipment.

6.0.2 Coolant with DCA 4 (DIESEL COOLANT ADDITIVES)

Tab. 7 Mix ratio of water / anticorrosive / antifreeze

The coolant must comprise at least 50 vol-% of anticorrosive and antifreeze all year round. This cor-responds with a freeze protection down to -37 °C and guarantees ample protection against corrosion.

In the event that coolant is disappearing at an unusual rate, ensure that the minimum 50 vol-% is be-ing adhered to when refilling.

The mix ratio and the DCA 4 concentration must be checked when carrying out the maintenancetasks.

6.0.3 AnticorrosiveIn exceptional cases and if ambient temperatures are continuously above freezing point, e.g.in tropical regions, in which no approved anticorrosive /antifreeze is readily available, a mixtureof water and water-based anticorrosive may be used as coolant.

Utilisation of DCA 4 without anticorrosive / antifreeze

To protect the cooling system from corrosion, approximately double the amount of DCA 4 must beadded to achieve the same mix ratio of water and DCA 4 (see Tab. 7).

Ambient temperatures up to Percentage (%) of water Percentage (%) of anticorrosive / antifreeze

-37 °C / -34 °F 50 50-50 °C / -58 °F 40 60

Note!Do not use more than 60 % anticorrosive and antifreeze! Cooling effect and freeze protection will be minimised if higher percentages are added.

Note!� The coolant is to be changed every 2 years.� The DCA 4 concentration must total between 0.3 and 0.8 units per litre.� Test kit CC 2602 M from Fleetguard is recommended for checking.


R 900 C-Li - R 904 C-Li

Coolant

1.50.9

Fuel and Lubricants

copyright by

MJFCIFSS

Utilisation of other water-based anticorrosives

Checking using a refractometer

Fig. 6-1 Gefo refractometer no. 2710.

Setting the refractometer:

Adjusting screw for adjusting the 0�line (water line)

Visual acuity is adjusted by turning the eyepiece.

Measuring procedure:

Clean cover and prism thoroughly

Apply 1�2 drops of test fluid onto the prism.

The fluid is distributed by closing the flap.

Look at a bright background through the eyepiece and adjust so that the scale can be seen clearly.

Read off the values on the blue dividing line.

Determine the concentration using the conversion table.

Note!� The coolant is to be changed once a year.� The DCA 4 concentration must total between 0.6 and 1.6 units per litre.� Test kit CC 2602 M from Fleetguard is recommended for checking.

Note!� The coolant is to be changed once a year.� The mix ratio must comprise 7.5 % anticorrosive and 92.5 % water.� Refractometer 2710 from the Gefo company is recommended for checking.



MJFCIFSS

Fig. 5 Gefo refractometer no. 2710 - conversion table.

Summary of approved water-based anticorrosives

Tab. 8 Water-based anticorrosive

6.1.4 Refilling the cooling systemBefore filling new coolant into the cooling system, ensure that it is clean and rinse as necessary

When filling or refilling the cooling system following the carrying out of repair work, liquid DCA 4 must be added to the coolant to supplement the DCA 4 concentration in the water filters

Tab. 9 Filling amounts of coolant with DCA 4

6.1.5 Change intervals for the DCA 4 water filterThe DCA 4 water filter must be replaced every 500 operating hours.

If no loss of coolant has been determined in the cooling system, a sufficient DCA 4 concentration inthe cooling system is assured for change intervals of 500 operating hours.

Concentration (vol%)

Product description Manufacturer

DCA 4 Diesel Coolant Additives FleetguardCaltex CL Corrosion Inhibitor Concentrate CaltexChevron Texaco Heavy Duty Extended Life Corrosion Inhibitor Nitrite Free Chevron TexacoHavoline Extended Life Corrosion Inhibitor (XLI) ArtecoTotal WT Supra Total

Cooling system content Required amount of liquid DCA 4 DCA 4 water filter

Litre 0.5 litre drumID no. 7363898 or Litre Designation ID no.

24 - 39 3 or 1,4 WF 2071 736704540 - 59 4 or 1,9 WF 2072 738149360 - 79 5 or 2,4 WF 2073 7367052

80 - 115 8 or 3,8 WF 2073 7367052


R 900 C-Li - R 904 C-Li

Coolant

1.50.11

Fuel and Lubricants

copyright by

MJFCIFSS

6.1.6 Guideline for quality of fresh waterClean water which is not too hard should be used for the preparation of the coolant. Tap water usu-ally, however, not always, fulfils this requirement.

Sea water, brackish water, salt water and industrial waste water are not suitable.

Fresh water quality when using anticorrosive and antifreeze

Tab. 10 Water substance content with anticorrosive and antifreeze

Fresh water content when using coolant with DCA 4

Tab. 11 Water substance content for coolant with DCA 4

6.1.7 Approved anticorrosive and antifreeze

Undiluted concentrate

Substance of content Quantity

Total alkaline earths (water hardness) 0.6 to 3.6 mmol / l (3 to 20 °d)pH-value at 20 °C 6.5 to 8.5Chloride-Ion content max. 80 mg / lTotal Chloride + Sulphate max. 100 mg / l

Substance of content Quantity

Total alkaline earths (water hardness) 0.6 to 2.7 mmol / l (3 to 15 °d)pH-value at 20 °C 6.5 to 8.0Chloride-Ion content max. 80 mg / lTotal Chloride + Sulphate max. 80 mg / l

Brand Manufacturer Country

Agip Antifreeze Plus Agip Petrol S.p.A., Rome IAgip Langzeit-Frostschutz Autol-Werke GmbH, Würzburg DAntigel DB 486 Sotragal SA, St. Priest FAral Kühlerfrostschutz A Aral AG, Bochum DAvia Frostschutz APN (G48-00) Deutsche Avia-Mineralöl GmbH, Munich D

BP Antifrost X 2270 A Deutsche BP AG, Hamburg DBP Napgel C 2270 / 1 BP Chemicals LTD., London GB

Caltex Engine Coolant DB Caltex UK Ltd, London GBCaltex Extended Life Coolant Caltex UK Ltd, London GBCastrol Anti-Freeze O Deutsche Castrol Vertriebs GmbH, Hamburg DCentury F.L. Anti-Freeze Century Oils, Hanley, Stoke-on-Tent GBChevron DEX-Cool Extended Life Anti-Freeze / Coolant

Chevron Texaco, San Ramon, CA USA

DEUTZ Kühlschutzmittel 0101 1490 Deutz Service International GmbH, Cologne D



MJFCIFSS

Tab. 12 Approved anticorrosive and antifreeze

50:50 Premix (water: anticorrosive / antifreeze)

Esso Kühlerfrostschutz Esso AG, Hamburg D

Fircofin Fuchs Mineralölwerke GmbH, Mannheim DFrostschutz Motorex (G48-00) Bucher & Cie, Langenthal CHFrostschutz 500 Mobil Oil AG, Hamburg D

Glacelf Auto Supra Total Nederland N.V., Den Haag NLGlycoshell AF 405 Shell Deutschland GmbH, Hamburg DGlycoshell N Shell Deutschland GmbH, Hamburg DGlysantin (G48-00) BASF AG, Ludwigshafen D

Havoline XLC Arteco, Gent BHavoline DEX-Cool Extended Life Anti-Freeze / Coolant


Igol Antigel Type DB Igol France, Paris F

Labo FP 100 Labo Industrie, Nanteree F

Motul Anti-Freeze Motul SA, Aubervilles F

OMV Kühlerfrostschutzmittel OMV AG, Schwechat AOrganifreeze Total Deutschland GmbH, Düsseldorf DOZO Frostschutz S Total Deutschland GmbH, Düsseldorf D

Total Antigel S-MB 486 Total Deutschland GmbH, Düsseldorf DTotal Frostfrei Total Deutschland GmbH, Düsseldorf D

Veedol Anti-Freeze O Deutsche Veedol GmbH, Düsseldorf D

Wintershall Kühlerschutz Wintershall Mineralöl GmbH, Düsseldorf D

Brand Manufacturer Country

Product description Manufacturer Country

Liebherr Anti-Freeze APN Mix ID no. 8611045 LIEBHERR DCaltex Extended Life Coolant Pre-Mixed 50/50 (ready-to-use-version)

Caltex UK Ltd, London GB

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


Havoline XLC, 50/50 Arteco, Gent BHavoline DEX-Cool Extended Life Prediluted 50/50 Anti-Freeze / Coolant



R 900 C-Li - R 904 C-Li

Coolant

1.50.13

Fuel and Lubricants

copyright by

MJFCIFSS

Tab. 13 Approved anticorrosive / antifreeze / 50:50 Premix

Organicool 50/50 Total Deutschland GmbH, Düsseldorf D

Product description Manufacturer Country



MJFCIFSS


R 900 C-Li - R 904 C-Li 2.00.1copyright by

MJFCIFSS

Group 2: Tools

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

Special tools for Liebherr Diesel engines............................................................................2.02

Special tools for the hydraulic system.................................................................................2.03

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

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

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

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

Mounting tools for hydraulic cylinders ................................................................................2.121 Mounting wrench for hydraulic cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12.12 Piston nut wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12.23 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

Mounting device for disk brake on travel gear ....................................................................2.17

Eichwerten LMS System / Valeurs de calibrage.................................................................2.19

Pump test kit ...........................................................................................................................2.21

Tools for installing the slipring seals...................................................................................2.22



MJFCIFSS


R 900 C-Li - R 904 C-Li 2.01.1

Special tools for maintenance and repair

copyright by

MJFCIFSS

Group 2: Tools

2.01: Special tools for maintenance and repair

Spezialwerkzeuge zur Wartung und Reparatur

Outillage spécial utilisé pour l�entretien et les réparations

DarstellungRepresentationDessin

Nr.No.N°

BenennungDesciptionDénomination

Größe SizeGrand.

Ident. Nr.Order noN°code

GerätModelType

AnwendungApplicationApplication

1

2

MessstutzenPipe adaptatorEmbout

NW 10

NW 12

7002404

7008688

alle Typen

131415161718

MessstutzenPipe adaptatorEmbout

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

560767156076165607605560761774099227409923

914allealle914/924914/924914/924

Form KK FormForme KNach / From / Selon � LH673-02

25 Manometeran-schlussBSP couplingRaccord

R 1/2 � 7002436 alle Typen

30 Manometer Direktan-schlussDirect gauge cou-plingRaccord (brancht. direct du manométre)

R 1/2 � 7002435 alle Typen

Special tools for maintenance and repair Technical documentation


MJFCIFSS

35

36

37

HochdruckschlauchLängeHigh pressure hoseLengthFlexible haute pres.Long

1000 mm

1500 mm

5000 mm

7002437

7002475

7363732

alle Typen

Zum Anschließen von Manometern an allen Messstellen (Messstut-zen Nr. 1/2 und Schraub-kupplungen 10-14)

To connect pressure gauges on all check points (pipe adapter no 1/2 and gauge coupling 10 -14)

Pour le branchement des manométres sur tous les embouts 1/2 es raccords complets 10-14.

40

41424344

Schraubkupplung kpl.Gauge couplingRaccord complet

M10X1

M12X1,5M14X1,5M16X1,5R 1/4�

5005180

7402580500400273613457362579

alle Typen

45

4647484950515253545556

ManometerHydraulic pressure gaugeMano. à bain de gly-cérine

0-1,6 bar

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

8042577

80425787361292736129150028657361289736128850028677361286736128575000027361294

alle Typen

Zur Überprüfung der Be-triebsdrücke eines bzw. mehrerer Hydraulikkre-ise.

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

Pour le contrôle des pres-sions d�un ou de plusieurs cicuits hydraulique

* glyceringedämpft* dampened with glycerin* à bain de glycérine


Nr.No.N°


Größe SizeGrand.


GerätModelType



R 900 C-Li - R 904 C-Li 2.01.3


copyright by

MJFCIFSS

75

76

77

78

79

80

81

82

83

Differenzdruck-Mess-Set bestehend aus:Measuring device for differential pres-sures contents:Instrument de mesure pour pres-sions différentielles, comprenant:

-Messgerät Multi- Handy 3010-Measuring device M-H 3010-Instrument de mesure M-H 3010

1 Stk. Datenkabel1 wire data transfert1 jeu de câble pour transfert de données

2 Stk. Messkabel2 measuring wire2 jeux de câble de mesure

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

-KFZ Anschlusskabel-Connecting wire-bord circuit- Câble de brancht. au tableau

-Transportkoffer-Tavel boxCoffret der transport

-Adapterkabel / Dat-en-übertrag.-Adapter wire - data transfert-Càble pour transfert de données

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

10288229

10288155

10288152

10288154

7025279

7025273

614063501

7025275

7026910

alle Typen

Zum Messen des Dif-ferenzdruckes p zwischen Pumpen- und LS Druck.

To measure the differen-tial pressure p between pump- and LS pressure.

Pour mesurer la dif-férence de pression p entre pression de pompe et pression LS.


Nr.No.N°


Größe SizeGrand.


GerätModelType




MJFCIFSS

84

85

86

-Druckaufnehmer-Pressure sensor-Capteur de pression Hydrotechnik

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

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

0-600 bar

12 m

614062401

614062601614064701

614063701

alle Typen

100

101

102

103

StutzenPipe adaptatorEmbout de prise de pression

Messstutzen mit Met-allkappePipe adaptator with metalic capPrise de pression + embout métall

ÜberwurfmutterCap nutEcrou de raccord

SchneidringCutting ringBague de sertissage

4901372

7002404

4774002

4774001

alle Typen

Zum Druckabgleich in Verbindung mit Werkzeug Nr. 75 / 85

For pressure equilibration in connection with tool no 75 / 85

Pour l�équilibrage en pression en utilisant l�outil n° 75 / 85

109 Service Stecker (grün)Service plug (green)Connecteur de serv-ice (vert)

9684328 Für Kommunikation mit und Parametrieren des elektronischen Steuer-kreis über BaggerdisplayFor communicating with and adjusting the elec-tronic control circuit via the display of the excava-torPour communication avec et paramétrage du circuit électronique de commande, via le display de la pelle

Gültig für / Valid for / Val-able pour :- Litronic 2


Nr.No.N°


Größe SizeGrand.


GerätModelType



R 900 C-Li - R 904 C-Li 2.01.5


copyright by

MJFCIFSS

110

111

LMS-Litronic-Messsystem kpl. be-stehend aus: Messgerät, Trans-portkoffer u. Trageriemen

LMS -Litronic-Meas-uring kpl. containing: measuring tool, car-rying case and straps

Systéme de mesure Litronic-LMS com-prenant: instruments de mesure, coffret de transport et courroie d� épaule

Sensoren und Zube-hörSensors and ExtrasCapteurs et Acces-soires

614062001

(see �Lieferumfang Li-tronic Messsystem� on page 11)

alle Typen

Zum Messen und Abs-peichern aller Drücke, Fördermengen, Dreh-zahlen, elektr. Ströme und Spannungen

Used to measure and store hydr. pressures, pump flow, electrical cur-rent and voltage

Pour la mesure et la mé-morisation de toutes les pressions, débits, ré-gimes, tensions et cour-ants électriques

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

115 MessadapterMeasuring adapterBoîtier de mesure

8504231 alle Typen

Für Strommessung an der Pumpenregelung

To check current on pump regulation

Mesure des courants de régulation sur les pompes

120 MesskabelMeasuring wireCàble de mesure

9956436 alle Typen

Für Messung des Induk-tivgebers B 12 von 3-polig (LH) in Verbindung mit Werkzeug Nr. 115

To check of the RPM-Sensor B 12 from 3-pole (LH) in connection with tool no. 115

Mesure des capteur in-ductif B 12 3-bornes (LH) en utilisant l� outil n° 115

Für StrommessungTo check currentMesure des courants


Nr.No.N°


Größe SizeGrand.


GerätModelType




MJFCIFSS

125 Drehzahlmesser Piezzo

Revolution - Indicator

Compte-tours Piezzo

A 2106 450

10286429 alle Typen

Zum Messen der Motor-drehzahl über Impulsfre-quenz der Einspritzleitung

To check the engine RPM via impulse frequency of the injection line

Mesure de régime du mo-teur thermique par rap-port aux impulsions de la pompe à injection

130

131

132

Drehzahlmesser Or-nelRevolution - IndicatorCompte-tours Ornel

Drehzahlmesser ShimpoRevolution - IndicatorCompte-tours Shim-po

Streifen / Stripes / Pastilles

HT 460

DT 205

7006974

7364284

614063201

alle Typen

Zum Messen der Dreh-zahl über Reflexions-Streifen

To check the RPM via re-flexions stripe

Mesure de régime par l�intermédiaire d� une pa-tille réflectrice

mit / with / avec / n° 130

145

146

147

148

Vielfachmessgerät mit Digitalanzeige

Multimeter with digit-al display

Contrôleur universel à affichage digital

Zusatz - Mess-werkzeugeMeasuring tools kitOutillages option-nels de mesures

MeßkabelsatzMeasuring cable setLot de câbles de mesure

BereitschaftstascheCarrying casePochette de protec-tion

ChauvinArnouxMAX 3000

10018500

5616316

886125008

6001128

alle Typen

Für Spannungs-, Strom- und Widerstans-messun-gen von Elektroanlagen und Elektro - Ventilen

For voltage, current and resistance measure-ments of electrical sys-tems and electrical valves

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

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




Nr.No.N°


Größe SizeGrand.


GerätModelType



R 900 C-Li - R 904 C-Li 2.01.7


copyright by

MJFCIFSS

160

162

Thermometerberührungslos (Infrarot)

ThermometerInfrared Temperature sensor

Thermométre sans contact

Thermometer mit Sonde und Fühler (magnetisch.)Thermometer with probe and sensor (magnetic.)Thermométre avec sonde et capteur (magnetic.)

GMTL 1826

GTH 1150

7020372

10024185

alle Typen

Zum Überwachen der Temperatur eines Medi-ums bzw. der Außen-Temperatur eines Aggre-gates

Used to monitor the tem-peratur of any liquid resp. the housing temp. of any component

Pour mesurer la temp. d�un liquide ou la temp. extérieure d�un com-posant

170

172

HandpumpeSampling pumpPompe manuelle

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

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

8145666

7019068

alle Typen

Zur Entnahme einer Öl-probe für die Ölanalyse

Used to taking samples for oil analysis

Pour prélevement d�échantillon pour ana-lyse d�huile

175

180

Öl Analysenset * Nr. 1Oil Analysis set *

Öl Analysenset *Oil Analysis set *

*Analysen bei WAER CHECK Deutschachland Laborbericht in deutscher Sprache*Analysis at WAER CHECK Ger-many Analysis report in German lan-guage

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

7018368

8145660

alle Typen

6 Stck. Ölproben6 samples6 pièces

1 Stck. Ölprobe1 sample1 jeu


Nr.No.N°


Größe SizeGrand.


GerätModelType




MJFCIFSS

190 Vakuumpumpe REF-COEvacuation pump REFCOPompe à vide REF-CO

RD-4 7027552 alle Typen

Zur Wartung und Reparatur der Klimaan-lage Konvekta

For sevicing and repair-ing the air conditioning equipement Konvekta

Pour l�entretien et la répa-ration du elimatiseur Kon-vekta

195

196

197

Füllschlauch ITE blauFilling hose ITE blue

Flexible de remplis-sage ITE bleu

Füllschlauch ITE gelbFilling hose ITE yel-low

Flexible de remplis-sage ITE jaune

Füllschlauch ITE rotFilling hose ITE redFlexible de remplis-sage ITE rouge

1500 mm

1500 mm

1500 mm

7027553

7027554

7027555

alle Typen

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

205

210

KFZ - Kupplung ITEQuick coupling ITEAttache rapide ITE

KFZ - Kupplung ITEQuick coupling ITEAttache rapide ITE

253a

254 a

7027556

7027557

alle Typen

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

215 4-Ventil - Prüfarma-tur

Test equipement with 4 valves

Unité d�essai à 4 cla-pets

M4WS5C 7027558 alle Typen

Zur Wartung und Reparatur der Klimaan-lage Konvekta

For servicing and repair-ing the air conditioning equipment Konvekta

Pour l�entretien et la répa-ration du elimatiseur Kon-vekta


Nr.No.N°


Größe SizeGrand.


GerätModelType


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