Service Manual Sections for Hydraulic Excavator

Service Manual
Hydraulic Excavator
A 309 - R 317 Litronic
en

General 1
Tools 2
Technical data / maintenance instructions 3
Drive motor 4
Coupling / pump distribution gear 5
Hydraulic system 6
Hydraulic components 7
Electrical system 8
Slewing gear mechanism 9
Slewing ring 10
Transmission 11
Axles 12
Steering 13
Oscillating axle support 14
Brake system 15
Special equipment / accessory kits 16
Operator's cab / heating and air-conditioning 17
Undercarriage / uppercarriage / attachments 18
Tank arrangement 19

Service Manual
1.1
MJFCIFSS
SUBGROUP - INDEX
Section Group Type
Modification of series 1.02.1 A 309 LI - R 317 LI
Safety instructions 1.10.1 A 309 LI - R 317 LI
Tightening torques WN 4037 1.20.1 A 309 LI - R 317 LI
Tightening torques for screw connections 1.21.1 A 309 LI - R 317 LI
Assembly instruction for cylinder (WN 4121B) 1.22.1 A 309 LI - R 317 LI
Assembly instruction for cylinder (WN 4122B) 1.24.1 A 309 LI - R 317 LI
Fuels, lubricants and other consumables 1.50.1 A 309 LI -R 317 LI
Lubricant list TE-ML 05 1.55.1 A 309 LI -R 317 LI
Lubricant list TE-ML 07 1.56.1 A 309 LI -R 317 LI

Service Manual
1.02.1
Modification of series
MJFCIFSS
Modification of series
Item Type of modification Affected models
(a) Modified actuation of the pressure-relief
valves for slewing gear
Joint control line Xab replaced by separate
control lines Xa / Xb for each valve
Additional orifice 126 in connection P of valve
125
Modified measuring connections
Measuring connections 137 / 138 are moved
from the side to the top
A 314 Li: 11147
A 316 Li: 11152
A 316 Li industrial: 11178
(b) Modified spool
Spool for slewing gear
(change in design from restricted to blocked
outlet)
Spool for chassis
(change in design from restricted to open
outlet)
A 314 Li: 11820
A 316 Li: 11822
(c) Modified pressure balance 244 for stick
cylinder
Change from pressure balance without shock
absorption to pressure balance with 0.4mm
shock absorption
Additional control line from control valve block
connection MLS to pressure balance 244 at
spring side connection LSE
Modified shuttle valves 227
(a3 /b3) for boom cylinder spool
Change from Ø 0.8 mm to Ø 0.6 mm
A 314 Li: 12814
A 316 Li: 12741
(d) Modified fan cycle
Installation of coarse filter 15 in the pressure
line
to oil motor / radiator fan
A 312 Li: 13289
A 314 Li: 13104
A 316 Li: 13105
(e) Various modifications to control valve
block
Tuning improved. Pressure balance 224 pilot-
controlled. Shuttle valve 107 integrated into
control block. Central nozzle 109 screwed in.
New slewing gear module (check valve 123
before spool 120).
Modified TC valve 125
Integrated restrictor 126 and bypass line with
restrictor 129
A 312 Li: 16275
A 314 Li: 16215
A 316 Li: 16141

Modification of series Service Manual
MJFCIFSS
1.02.2
1.02A 309 LI 20221-A 311 LI 20222-A 312 LI 12363-A 314 LI 2001-A 316 LI 2001-A 316 LI-IND 2001-R 317 LI 18161-
(f) Pressure-relief valve in the gear pump /
steering
Gear pump of steering system with integrated
pressure control
A 312 - A 316 Li: 20241
(g) Modified electrical system
Modifications:
K392 (industrial shut-off) omitted,
S5 with 3 push buttons, S382 modified,
S263 modified, S422 added
A 312 Li: 20330
A 314 Li: 20334
A 316 Li: 20340
A 316 Li in.: 20340
(h) New pilot control unit for travel working
movement:
The two individual pilot control units 2x are
replaced by one pilot control unit 4x
R 317 Li: 21205
(i) Optimised control of control valve block
Regulating cylinder spool modified; control of
spool of combined boom / slewing gear with
shuttle valves
Restrictor check valve 171 for stick cylinder is
omitted
A 309 Li: 23503
A 311 Li: 23504
(k) Optimisation of fine control
Spool of the boom and regulating cylinder and
the summary pistons modified. Installation of
priority circuit "Total of boom before total of
stick" with decoupling.
Actuation of boom and stick spools with
additional shuttle valves.
See also service information 07-11-37/2005
A 309 Li: 27110
A 311 Li: 27112
(l) Speed reduction when working at 1950
rpm
Omission of solenoid valve Y330 for zero
boom switching from P2 during travel
The solenoid valve Y330 at the control oil unit
is omitted.
See service information 07-11-37/2005
A 309 Li: 27110
A 311 Li: 27112
(m) Hydraulic slewing ring locking mechanism
A hydraulically operated cylinder (via pilot
control system) with a locking bolt is installed
in the uppercarriage. It is used for the locking
of the uppercarriage during parking and
transport of the machine.
A 309 Li: 26392
A 311 Li: 26396
A 312 Li: 29898
A 316 Li: 28061
A 316 Li ind.: 28061
(n) Changeover to travel operation
By changing over to the 2 HL 270/290
transmission, the travel motor has also been
upgraded to a DMVA 165 motor.
A 316 Li: 28061
A 316 Li ind.: 28061
Item Type of modification Affected models

Service Manual
Proper use
1.10.1
Safety instructions
copyright by
MJFCIFSS
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 observe the safety information, you can
guard against dangers and accidents. This applies especially to persons, who are working on the ma-
chine only occasionally, such as for maintenance work. The following information comprises safety
regulations which, if followed conscientiously, will guarantee your safety and that of other persons,
as well as avoid damage to the machine.
Following these regulations does not release you from the responsibility to follow all safety regula-
tions and guidelines valid for the jobsite, as required by law or issued by trade associations.
For EU countries, guideline 89/655/EEC contains the minimum safety information applicable to the
operator.
1 Proper use
– The hydraulic excavator is a machine with attachments (such as backhoe, grapple, bucket ) de-
signed to loosen, take on, transport and dump soil, rocks and other materials, where the load is
predominantly transported without moving the machine. Moving the machine when it is carrying a
load must be carried out by observing the appropriate safety measures (see section "Notes for
machine operating safety").
– Machines used for load-lifting work are subject to specific conditions and must be equipped with
the stipulated safety devices (see section “Load-lifting work”).
– Other or additional usage, such as for demolition or material handling work, requires special
equipment and may also require special safety devices. These attachments (e.g. log grapple,
demolition hammer, concrete cutter etc.) may only be attached and used with approval and in ac-
cordance with the basic machine manufacturer.
– Transporting persons is not deemed to be intended use. The manufacturer is not liable for damage
resulting from this action. The risk must be assumed solely by the user.
– Observing the operating instructions and the inspection / maintenance instructions is also deemed
to be appropriate and destined use in accordance with regulations.
2 General Safety instructions
– Please familiarize yourself with the operating instructions before starting the machine.
– Please verify that you have supplemental instructions and have read and understood these (this
may concern special options for the machine).
– Only explicitly authorized personnel may operate, maintain or repair the machine. The legal min-
imum age must be observed.
– Use only trained or instructed personnel. Clearly define who is responsible for the operation or
set up, maintenance and repair. Allow personnel to refuse unsafe instructions given by a third per-
son. This also applies to traffic regulations. Reject unsafe instructions by third parties and/or allow
your personnel to reject these. This also applies in regards to traffic regulations.
– Any person still in training should only operate or work on the machine under the constant super-
vision and guidance of an experienced person.
– Check and observe any person working or operating the machine at least periodically if they ob-
serve safety instructions and guidelines given in the Operating manual.
– Wear proper work clothing when operating or working on the machine. Avoid wearing rings,
watches, ties, scarves, open jackets or loose clothing. There is a danger of injury, as these items
could get caught or be pulled in.The following are mandatory for certain tasks: Safety glasses,
safety shoes, safety helmet, work gloves, reflecting vest, hearing protection, ...

Safety instructions Service Manual
Crushing and burn prevention
1.10.2
copyright by
MJFCIFSS
– For certain tasks, safety glasses, hard hats, safety boots, work gloves, reflective vests, ear pro-
tection etc. are required.
– Consult the supervisor at the job site for special safety instructions and regulations.
– Always raise the safety lever before leaving the operator’s seat.
– When entering or leaving the cab, do not use the steering column, the control panel or the joy-
sticks as handholds. Inadvertent movements, which could cause accidents, should be touched off.
– Never jump off the machine, always use the steps, ladders, rails and handles provided to climb
off or on the machine.
– Use both hands to hold on, facing the machine.
– Familiarize yourself with the emergency exit through the front window.
– Proceed as described in the operating instructions, if no other instructions are available for main-
tenance and repairs:
• Place the machine on a solid and level ground and lower the work equipment to the ground.
• Depressurize the hydraulic system.
• Move all control levers to the neutral position.
• Move the safety levers up prior to leaving the machine.
• Remove the ignition key.
– You must also reduce the pressure in the hydraulic system and the interior pressure of the tank
prior to any operation on the hydraulic system as described in these operating instructions.
– Secure all loose parts on the machine.
– Never start a machine before completing a thorough inspection and check, if safety tags are miss-
ing or are illegible.
– Do not complete any modifications, attachments or retrofits on the machine, which could inhibit
safety, without the prior consent of the manufacturer. This also applies to the installation and ad-
justment of safety devices and safety valves as well as to any welding on load carrying parts.
3 Crushing and burn prevention
– Never work underneath the attachment as long as it is not safely resting on the ground or properly
supported.
– Do not use any damaged or insufficiently supporting load carrying devices, such as ropes or
chains.
– Always wear work gloves when handling wire ropes.
– When working on the attachment, never align bores with your fingers, always use a suitable align-
ment tool.
– Please verify that no objects enter the fan while the Diesel engine is running. Rotating fans will
swirl and throw out objects, which can damage the fan.
– At or near operating temperature, the engine cooling system is hot and under pressure. Avoid con-
tact with any components containing coolant. Danger of severe burns.
– Check the coolant level only after the radiator cap on the expansion tank is cool enough to touch.
Turn the cap carefully to relieve the pressure.
– At or near operating temperature, the engine and the hydraulic oil are hot. Do not allow your skin
to come into contact with hot oil or components containing hot oil.
– Always wear safety glasses and protective gloves when handling batteries. Avoid sparks and
open flames.
– Never permit anyone to guide the grapple by hand.
– When working on the engine area, make sure that the side doors are properly secured with the
appropriate supports to prevent them from closing inadvertently.
– Never work underneath the machine if it is raised with the attachment, without being properly sup-
ported from below with hardwood beams.

Service Manual
Fire and explosion prevention
1.10.3
Safety instructions
copyright by
MJFCIFSS
4 Fire and explosion prevention
– Switch off the Diesel engine prior to filling the tank.
– Routinely check the electrical system.
– Have skilled personnel immediately repair all defects, such as loose connections, blown fuses and
burned out light bulbs, burned or frayed cables.
– Do not smoke and avoid open flames when filling the tank or loading the batteries.
– Always start the Diesel engine according to the regulations in the operating instructions.
– Never store flammable fluids on the machine except in appropriate storage tanks.
– Regularly inspect all lines, hoses and fittings for leaks and damage.
– Repair any leaks immediately and replace damaged components.
– Any oil escaping from leaks can easily cause a fire.
– Be certain that all clamps, guards and heat shields are properly installed to prevent vibration, rub-
bing and heat build up.
– Do not use cold start aids (ether) near heat sources or open flames or in insufficiently ventilated
areas.
– Do not use ether containing starting aids to start Diesel engines with preheat system or flame glow
systems. DANGER OF EXPLOSION!
– Familiarize yourself with the location and use of fire extinguishers on the machine as well as the
local fire reporting procedures and fire fighting possibilities.
5 Transporting the machine safely
– Due to the space restrictions during transport, use only suitable transporting and lifting devices
with sufficient capacity
– Park the machine on a level surface and chock the chains and/or wheels.
– If necessary, remove parts of the attachment during transport.
– The ramp to drive onto the transporting vehicle should not exceed an inclination of 30° and be pro-
vided with a wood covering to prevent sliding.
– Clean the undercarriage. The undercarriage must be swept clean, meaning, the chains / wheels
must be free of snow, ice and sludge prior to driving onto the ramp.
– Align the machine precisely with the loading ramp.
– Attach the manual lever for sensitive driving (crawler excavator) to the driving pedals.
– Note that a guide gives the necessary signals to the machine driver.
– Drop the equipment in and drive it onto the loading ramp. Keep the equipment tight over the load-
ing surface and drive it carefully onto the ramp and further into the transporting vehicle.
– The superstructure must be secured with the undercarriage by using locking bolts (only for A-
equipment), after loading the machine onto the low loader.
– Secure the machine and the remaining equipment parts with chains and chocks against shifting
according to national regulations for loading and transporting.
– Release all pressure lines (as described in these operating instructions), pull the ignition key and
pull the safety lever up prior to leaving the machine.
– Close all cab and panel doors.
– Verify that no one is located on the machine during the transport.
– Investigate the travel route, specifically in reference to limits for width, height and weight prior to
the transport.
– Pay special attention when driving under electrical lines and bridges and when passing through
tunnels.
– Use the same care for unloading as for loading.

Bringing the machine safely into service
1.10.4
copyright by
MJFCIFSS
6 Bringing the machine safely into service
– Before starting the machine, perform a thorough walk around inspection.
– Visually check the machine for loose bolts, cracks, wear, leaks and damage.
– Never start or operate a damaged machine.
– Make sure to correct any problems immediately.
– Verify that all hoods, covers and doors are closed, however, the locks should remain unlocked.
– Verify that all safety tags are available.
– Make sure that all windows, as well as the inside and outside mirrors are clean. Secure all doors
and windows to prevent unintentional movement.
– Be certain that no one works on or under the machine and warn any personnel in the surrounding
area with the horn before starting the machine.
– Before operating the machine, adjust the operator’s seat, the mirror, the arm rests and the other
items to ensure comfortable and safe working conditions.
– The noise protection devices on the machine must be in functional protective position during op-
eration.
– Follow the regulations effective for the relevant site.
– Never start the machine without the driver’s cab.
7 Starting the machine safely
– Before start up, check all indicator lights and instruments for proper function, bring all controls into
neutral position and raise the safety lever.
– Honk the horn briefly prior to starting the Diesel engine, in order to warn persons located near the
machine.
– Only start the machine from the driver’s seat.
– Start the Diesel engine according to the regulations in the operating instructions, if you have not
received any other instructions.
– Lower the safety lever and check all indicators, gauges, warning devices and controls for their
proper indication.
– Only operate the Diesel engine in a well ventilated area, if the area is enclosed. Open doors and
windows to ensure sufficient fresh air supply, if necessary.
– Bring the engine and hydraulic oil to operating temperature. Low oil temperatures cause a slow
reaction of the controls.
– Check that all attachment functions are operating properly.
– Carefully take the machine to an open area and check all safety-related functions.
8 Shutting down the machine safely
– Only place the machine on a level and solid ground. The machine must be secured with chocks,
wenn setting it on a slope, to secrure it against rolling away.
– Lower the working equipment and anchor it lightly into the ground.
– Move all control elements into the neutral position. Set the parking and slewing gear brake.
– Switch off the Diesel engine according to the operating instructions and move the safety lever up,
prior to leaving the driver’s seat.
– Lock the machine, as well as all hoods, covers and doors; pull out all keys and secure the machine
against any unauthorized use.

Service Manual
Towing the machine safely
1.10.5
Safety instructions
copyright by
MJFCIFSS
9 Towing the machine safely
– Always observe the correct procedure: See chapter “Towing the machine” in this operating man-
ual.
– The machine may only be towed in exceptional circumstances, e.g. in order to move the machine
away from a dangerous place.
– Before pulling or towing the machine, check all cables, hooks and couplers for safety and stability.
– Towing equipment must have sufficient tensile strength and must be attached to the undercarriage
at the provided stops.
Be aware that any damage or accidents caused by towing the machine are never covered by the
manufacturer's warranty.
– Never allow anyone to remain in the area of the towing devices.
– During the towing procedure, keep within the required transport position, the permissible speed
and distance.
– After the towing procedure is completed, return the machine to its previous state.
– Proceed as outlined in the operation manual when putting the machine back into service.
10 Working with the machine safely
– Before starting to work, familiarize yourself with the peculiarities of the job site, the special regu-
lations and warning signals. Part of the surrounding area includes, for example, the obstacles in
the working or movement area, the load carrying capacity of the ground and required safeguards
for the job site to shield it from public highway traffic.
– Always keep an adequate safety distance to overhangs, edges, embankments and an unsecured
substrate.
– Be particularly cautious in conditions of reduced visibility and changing ground conditions.
– Familiarize yourself with the location of power lines on the job site and work particularly careful in
their vicinity. If necessary, inform the responsible authorities.
– Maintain a safe distance from electrical overhead lines. Do not approach the line with the
equipment when working near electrical overhead lines. Danger of fatal injury! Inform yourself
about required safety distances.
– In case of a flashover, proceed as follows:
• do not move the machine or its attachment,
• do not leave the operator’s platform,
• warn people in the vicinity not to approach or touch the machine,
• have the power turned off.
– Before moving the machine, always ensure that the attachments are safely secured.
– When travelling on public roads, paths or squares, observe the valid traffic regulations and, if nec-
essary, first bring the machine into proper condition to meet federal and local highway standards.
– Always turn on the lights in conditions of poor visibility or darkness.
– Do not permit any passengers on the machine (except on two way excavators).
– Operate the machine only when seated and with the seat belt fastened.
– Report any problems or needed repairs and make sure that all required repairs are carried out
immediately.
– Personally make sure that no one is endangered by moving the machine.
– Before starting to work, always check the brake system as outlined in the operating manual.
– Never leave the operator’s seat as long as the machine is still moving.
– Never leave the machine unattended while the Diesel engine is running.

Working with the machine safely
1.10.6
copyright by
MJFCIFSS
– The machine must be utilized, driven and operated in such way that the stability is ensured and
that there is no danger of tipping over. Only known loads may be moved with the attachments,
especially in grapple operation.
– The maximum approved passable incline / traverse slope of the machine depends on the attached
equipment as well as the substrate.
– For travel, move the uppercarriage in lengthwise direction and hold the load as close as possible
to the ground.
EXCEPTION: see WHEN LOADING AND UNLOADING
– Adjust the travel speed to suit local conditions.
– Avoid working movements which could cause the machine to tip over.
– If possible, always work downhill or uphill, never sideways on a slope.
– Only travel downhill at the permitted speed or you could loose control over the machine.
– Only drive downhill at a low driving speed, since you may otherwise loose control of the machine.
The Diesel engine must run in the upper revolution range and be reduced by selecting the low
driving speed range / the lowest gear.
– Before travelling downhill, always shift to a lower gear. When doing this, the Diesel engine must
run at maximum RPM and the speed may only be reduced using the accelerator pedals.
– When loading a truck, make sure that the truck driver leaves the cab, even if a rock protection is
present.
– Always use the safety devices intended for their specific use for demolition work, clearings, hoist-
ing operations, etc.
– For terrain which is difficult to gain an overview of and whenever necessary, ask for assistance of
a guide. Have only one person signal you.
– Only permit experienced personnel to secure loads and signal the machine operator. The guide
must position himself within view of the operator or be in voice contact with him.
– Depending on the attachment combination, there can be a danger of collision between the work-
ing tool and the operator’s cab, the cab protection or the boom cylinders. To avoid damage, utmost
attention is required when the bucket teeth enter this range.
10.1 Safe application in material handling operation (especially when handling tim-
ber)
– Particularly when working with a grapple it can be necessary to move the machine with a raised
attachment and picked up load, for example when handling wood or timber.
– This will shift the center of gravity of the machine upward in vertical direction. The travel behaviour
of the machine will be strongly influenced, for example reduction of dynamic stability.
For that reason, the following rules must be strictly observed:
• Match your travel behaviour to the changed machine characteristics and surrounding condi-
tions.
• Reduce the travel speed to avoid sudden braking or steering manoeuvres.
• Avoid sudden speed changes, such as braking, acceleration, changes in travel direction.
• Turn the uppercarriage only if the undercarriage is stationary.
• Turn the uppercarriage only after taking on the load.
• Move the machine only after you have taken on the load, lifted it and turned the uppercarriage
in travel position.
• If the attachment is raised, there is a danger due to possible oscillating movements and falling
of the picked up load.
• A protective screen (FOPS) according to ISO 10262 must be attached on the front on the cab.
• The protective screen (FOPS) according to ISO 10262 must be installed if there is a danger of
falling objects from overhead.
• Only the maximum permissible load may be picked up with the grapple.

Service Manual
1.10.7
Safety instructions
copyright by
MJFCIFSS
– NOTE: The weight of absorbent material, such as wooden logs, depends on the length, the diam-
eter and the specific weight. The existing influencing factors for a natural product, such as mois-
ture, must be considered.
– The working sequences when working with machines with grapples require special instruction and
training of the machine operator.
– The work application is only permitted after the machine operator has received sufficient training
and practical experience.
10.2 Safe application of machines with tower elevation
– Due to the tower elevation, the center of gravity of the machine will shift upward in vertical direc-
tion. The travel and work behaviour of the machine will thereby be strongly influenced, for example
reduction of dynamic stability.
– Due to the elevated center of gravity, the machine must be aligned in horizontal direction before
starting to work. In horizontal direction, the center of gravity of the uppercarriage is above the cent-
er of the undercarriage, which reduces the danger of tipping over.
– The machine can rock despite leveling and tip over!
For that reason, the following rules must be strictly observed:
When driving the machine:
• Swing the uppercarriage parallel to the undercarriage (transport position).
• Pull the attachment as close as possible to the machine.
• Only then may the outriggers be retracted and the machine be driven.
• Driving with loads is not permitted.
• Check the roadway to ensure the ground is solid and even! Pot holes and uneven road surfaces
endanger the stability of the machine.
• Match your travel behaviour to the changed machine characteristics (higher center of gravity)
and surrounding conditions.
• Reduce the travel speed to avoid sudden braking or steering manoeuvres.
• Avoid sudden speed changes, such as braking, acceleration, changes in travel direction.
• Drive uphill and over obstacles only in lengthwise direction, to avoid impermissible transverse
slopes of the machine.
• Special care must be taken when driving through narrow passages – drive slowly!
In material handling operation:
• Before moving (turning) the uppercarriage from transport position, the machine must be sup-
ported and horizontally aligned.
• Make sure to check the placement surface of the outriggers (load carrying capacity of ground).
Sinking of an outrigger below ground level would result in devastating consequences!
• Carry out all movements with increased caution.
• To turn a load, move the attachment as close as possible to the machine (Caution! Oscillating
grapple), while holding the load as close as possible to the undercarriage and above the
ground.
• Avoid abrupt slow down or acceleration of the attachment or uppercarriage.
• Never lift a heavier load than stated in the load chart.
10.3 Additional notes for machines with fixed operator’s cab elevation
– To enter and exit the machine, park the machine on ground, which is level in lengthwise and hor-
izontal direction. Position the uppercarriage to the undercarriage in such a way that the steps and
ladders are aligned.
– Keep steps, ladders and handholds (handles) in proper condition. Make especially sure that they
are free of dirt, oil, ice and snow.
NOTE: To ensure that the doors open in all weather conditions, lubricate the weather strips at
least every two month, or more often, if necessary, with talcum powder or silicon. Lubricate the
door hinges and locks regularly.

1.10.8
copyright by
MJFCIFSS
– When entering or leaving the machine, always face the machine and use the three point support,
i.e. always have two hands and one foot or two feet and one hand in contact with the entry system.
– When you can reach the door handle with the free hand, open the door first before climbing higher.
External influences, such as wind, can make it more difficult to open the door. For that reason,
always guide the door by hand when opening the door. Make sure that the door is engaged when
it is open, to prevent it from banging open or closed.
– Continue to climb up and immediately sit on the operator’s seat in the cab. Then close the door
and fasten the safety belt.
– Proceed with the same care when exiting and climbing down as when entering and climbing up
the machine.
– Park the machine only on firm and level ground. Position the uppercarriage to the undercarriage
in such a way that the steps and ladders are aligned.
– Release the safety belt. When exiting, face the machine and use the three point support. Climb
down until you can close the door safely. Always guide the door by hand when closing the door.
– Finally climb down to the ground.
10.4 Protection from vibrations
– The vibration impact on mobile construction machinery is usually the result of the manner of utili-
zation. Especially the following parameters have a significant influence:
• Terrain conditions: Unevenness and potholes;
• Operating techniques: Speed, steering, braking, control of operating elements of the machine
during travel as well as working.
– The machine operator determines the vibration impact to a great part, since he himself selects the
speed, the gear ratio, the working manner and the travel route.
This results in a wide range of various vibration impacts for the same machine type.
The full body vibration impact for the machine operator can be reduced if the following recommenda-
tions are observed:
– Select the appropriate machine, equipment parts and auxiliary devices for the corresponding
tasks.
– Use a machine equipped with the appropriate seat (i.e. for earth moving machines, for example
hydraulic excavators, a seat which meets EN ISO 7096).
– Keep the seat in good order and adjust it as follows:
• The seat adjustment and the suspension should be made according to the weight and the size
of the operator.
• Check the suspension and the adjustment mechanism regularly and make sure that the char-
acteristics of the seat remain as specified by the seat manufacturer.
– Check the maintenance condition of the machine, especially regarding: Tire pressure, brakes,
steering, mechanical connections, etc.
– Do not steer, brake, accelerate and shift or move and load the attachment of the machine in a jerky
manner.
– Match the machine speed to the travel route to avoid vibration impacts.
• Decrease the speed when driving on pathless terrain;
• Drive around obstacles and avoid very impassable terrain.
– Keep the quality of the terrain where the machine is working and travelling in good order:
• Remove large rocks and obstacles;
• Fill furrows and holes;
• To establish and retain suitable terrain conditions, keep machines available and allow for suffi-
cient time.
– Travel longer distances (i.e. on public roads) with suitable (medium) speed.
– For machines, which are frequently used for travel, utilize special auxiliary systems for travel (if
installed), which reduce the vibration for this application.
If such auxiliary systems are not available, regulate the speed to keep the machine from "rocking".

Service Manual
Safe installation and removal of attachment parts
1.10.9
Safety instructions
copyright by
MJFCIFSS
11 Safe installation and removal of attachment parts
– Equipment and attachment parts made by other manufacturers or those which do not have LIEB-
HERR’s general approval for installation may not be installed on the machine without prior written
approval by LIEBHERR.
LIEBHERR must be provided with the required technical documentation necessary for this pur-
pose.
– When installing attachment parts, which are supplied via the machine's hydraulics system, such
as an attachment with cylinder movement, it must be ensured that different types of oil are not
mixed together.
Mixing environmentally friendly hydraulic oils made by different manufacturers as well as mixing
them with mineral oils must be avoided.
– Set the machine on a level and stable ground prior to any attachment and removal of equipment
parts.
– Lock the uppercarriage with the locking pin to the undercarriage.
– Do not work under the equipment as long as it does not contact the ground or prior to being sup-
ported.
– Never lie under the machine, if it is lifted by the work equipment without properly propping the ma-
chine.
– Before releasing a line or bolt, you must reduce the pressure in the hydraulic system as described
in these operating instructions.
– Do not attempt to lift heavy parts. Use suitable lifting devices with sufficient load carrying capacity.
– Do not use damaged or insufficiently sized ropes or cables. Always wear work gloves when han-
dling wire cables.
– When working on the equipment: Switch off the Diesel engine and turn the safety lever upward.
Never align the holes with your fingers; use a suitable mandrel.
– During repairs: Make sure that the hydraulic lines are properly attached and that all fittings and
connections are properly tightened.
– As soon as an attachment part is removed and supported, close off the openings in the hydraulic
circuit to prevent dirt infiltration. Permit only authorized persons near the machine or the lifting de-
vice.
11.1 Safe removal and installation of attachment pins
– If possible, always use a hydraulic pin pulling device to push out the pins on the attachment.
– If pins must be removed with a sledge hammer, use a punch and a guide tube held by another
person.
– To drive out a pin, install the impact screw from the tool box in the threaded bore of the pin and
hit the screw only.
– For the installation of a pin retained with castle nut and cotter pin, drive the pin in first to the stop,
then install the castle nut by hand until contact and tighten it only to the point where the cotter pin
can be installed.

Safe maintenance of the machine
1.10.10
copyright by
MJFCIFSS
12 Safe maintenance of the machine
12.1 General safety instructions
– All maintenance and repair work must be carried out by suitably trained specialist technicians.
– Always adhere to the prescribed testing and inspection schedule and the relevant intervals laid
down in the operating manual. To properly maintain the machine, the operator must have access
to a suitably equipped workshop.
– The inspection and maintenance schedule clearly defines the tasks and who is authorised to carry
them out.
Certain work may be carried out by the machine operator (or staff of the company who owns the
machine), while other tasks must be completed by specialist technicians who have been
specifically trained for this type of work.
– All spare parts must conform to the technical specifications laid down by the manufacturer.
Original spare parts always meet these requirements.
– When carrying out maintenance work, wear suitable protective clothing. Always wear suitable
personal protective equipment. For certain work, you must also wear a hard hat, safety footwear,
goggles and protective gloves.
– During maintenance work, keep unauthorised personnel away from the machine.
– If necessary, cordon off the work area.
– Before starting any maintenance work or other special work on the machine, inform the operating
personnel. Appoint a supervisor.
– Unless stated otherwise in the operating manual, all maintenance work must be carried out after
the attachment is lowered, the diesel engine is shut down while the machine is parked on level
and firm ground.
– While carrying out maintenance work, and especially when working under the machine, attach a
warning sign "Do not start" to the ignition. Remove the ignition key and set the battery main switch
to position "0".
– Always retighten all screwed connections that have been loosened for maintenance and repair
purposes.
– If safety devices must be removed, these devices must be mounted and tested immediately after
the work is completed.
12.2 Cleaning
– Prior to any maintenance and repair work, clean the machine and especially all connections and
screws that might be contaminated with oil, fuel or other cleaning products.
Use only mild detergents and lint-free cloths.
– During the first two months after commissioning (or repainting), do not clean the machine with
aggressive detergents or a steam cleaner.
– Do not clean the machine with flammable liquids.
– Before cleaning the machine with water, steam (pressure cleaner) or other detergents:
• Lubricate the slewing ring as well as all bearings and pin connections to prevent water or steam
from penetrating the bearing positions.
• Seal all openings where penetrating water, steam or detergent might cause damage or lead to
malfunctions.
Especially at risk are electric motors, electronic components, switch cabinets, plug connections
and air filters.
– When cleaning the engine compartment, ensure that the temperature sensor of the fire alarm and
extinguishing systems are not accidentally brought into contact with the hot cleaning solution, as
this could trigger an alarm and activate the extinguishing system.
– After completion of the cleaning work:

Service Manual
1.10.11
Safety instructions
copyright by
MJFCIFSS
• Remove all temporary covers.
• Check all fuel, engine oil and hydraulic lines for leakage, loose connections, chaffing and
damage.
• Repair all detected defects.
• Lubricate slewing ring as well as all bearings and pin connections to eliminate water or detergent
that might have penetrated these assemblies.
12.3 Crack detection
– The machines are subject to various loads and stresses, depending on the actual application,
location of operation, operating hours and the ambient conditions. The various load scenarios
result in service lives of the machine components that might differ from each other. This might lead
to cracks or loose connections, especially on load-bearing parts. This applies in particular to
machines used for loading or industrial purposes, or to machines equipped with optional
equipment, such as demolition excavators. To maintain the operational safety of the machine, it
must be regularly inspected for cracks, loose connections and other visible damage.
– To be able to inspect the machine for cracks, it must be kept clean.
– The inspections must be carried out as described in the inspection and maintenance schedule:
• every 250 operating hours, by the maintenance personnel of the machine operator
• every 500 operating hours by authorised specialist technicians.
– We strongly recommend to carry out these inspections after the machine has been placed on a
firm and level surface, and by applying various different loads in longitudinal and transverse
direction by moving the attachment. Always comply with the applicable workplace safety and
accident prevention regulations.
– Particular care is required for the inspection of load-bearing components, in particular:
• The steel structure of the undercarriage with axle and gearbox bearings, the support system,
the lower slewing ring support, the tower and the slewing ring.
• The steel structure of the uppercarriage with bearing block for booms and boom cylinders, the
upper slewing ring support, the cab bearing, and the securing devices of the slewing gear and
ballasts.
• The steel components of the attachments, e.g. booms, members, quick change adapters,
digging buckets and grapples.
• Hydraulic cylinders, axles, steering components, bolts and pin connections, ladders, steps and
securing devices.
– The crack inspection is a visual inspection. To improve the reliability of the inspection, check areas
where you suspect cracks or areas that are not easily accessible (e.g. at the slewing ring support)
with a dye penetration test.
– Immediately eliminate any detected damage. Welding work on load-bearing parts of earth moving
machines, handling and transport equipment must be carried out by specialist welding technicians
and according to best welding practice. If in doubt, contact the LIEBHERR customer service
department to discuss the envisaged measures.
12.4 Welding work
– Welding, torch-cutting and grinding work on the machine is only permitted with the explicit consent
of the manufacturer. Before carrying out such work, clean the machine and remove any dust and
flammable material around the equipment.
Ensure that the working areas is properly ventilated. Risk of fire and/or explosion!
– Before carrying out arc welding work, or work on the electric components of the machine,
disconnect the battery.
First disconnect the negative pole, then disconnect the positive pole. To reconnect the battery,
first connect the positive pole, then the negative pole.
– For arc welding work, position the earth contact point at the machine as close as possible to the
welding area.

1.10.12
copyright by
MJFCIFSS
12.5 Fuels and lubricants
– When handling oil, grease or other chemical products, always comply with the respective safety
instructions provided by the supplier.
– All fuels, lubricants and replaced parts must be disposed of in a safe and environmentally friendly
manner.
– Handle hot fuels and lubricants with particular care to prevent
injury.
12.6 Repairs
– Do not attempt to lift heavy parts by hand but use suitable lifting gear with appropriate load-bearing
capacity. To replace component parts and assemblies, attach and secure them carefully to
suitable lifting tackle and ensure that they cannot cause damage or injury while being transported.
Use only lifting tackle that is in proper working order and has the necessary load-bearing capacity.
Do not stand under suspended loads.
– Never use chaffed or damaged lifting tackle or gear that does not have the necessary load-bearing
capacity.
When working with wire cables, always wear protective gloves.
– Only experienced personnel may attach loads and guide crane operators. The signaller must be
positioned within the sight of the machine operator. Alternatively, the signaller and the operator
might be in contact through walkie-talkies or similar devices.
– When working above head height, use safe ladders and platforms.
Never use machine parts as climbing aids, unless they are designed for this purpose.
When working at great height, wear suitable safety gear.
Keep all handles, steps, railings, platforms and ladders free of dirt, snow and ice.
– When working at the attachment (e.g. replacement of teeth), ensure that it is properly supported.
Avoid metal supports (metal-to-metal contact).
– Never stand below a machine propped up by means of the attachment, unless the machine has
been properly secured with supports.
– Jack up the machine in such a way that shifting weights cannot impair its stability. Avoid metal-to-
metal contact.
– All work on the chassis, brake and steering systems must be carried out by suitably trained
specialists technicians.
– If the machine is to be repaired while standing on a slope, the chains must be secured with sprags
and the uppercarriage must be locked onto the undercarriage with the locking bolt.
– All work on the hydraulic equipment must be carried out by specialist technicians who are trained
and experienced in the field of hydraulics.
– When searching for leaks, always wear protective gloves, as high-pressure liquid might penetrate
the skin and cause damage.
– Before loosening or disconnecting any lines of screwed connections, lower the attachment to the
ground, shut down the diesel engine and release the pressure from the hydraulic system. After
the diesel engine has been shut down, insert the ignition key and turn it to its ON position, then
move all control devices (joystick and pedals) of the pilot control units in all directions in order to
release the control pressure and backpressures in the circuits. Continue with releasing the tank
pressure as described in this manual.
12.7 Electrical system
– Regularly inspect the electrical system.
Ensure that any detected faults such as loose connections, blown fuses and light bulbs, scorched
or chafed cables are eliminated without delay by specialist technicians.
– Use only original fuses of the prescribed amperage.

Service Manual
1.10.13
Safety instructions
copyright by
MJFCIFSS
– For machines equipped with electrical medium-voltage and high-voltage lines:
• In the event of a disruption in the power supply, immediately shut down the machine.
– All work on the electrical equipment of the machine must be carried out by a trained electrician or
specialist technician under the supervision of an electrician and in accordance with the relevant
electro-technical regulations and guidelines.
– When working on powered parts, always employ a second person with access to the emergency-
stop or main switch to shut down the system in the event of an emergency. Cordon off the work
area, using red and white chain and a suitable warning sign. Always use insulated tools.
– When working on medium-voltage and high-voltage assemblies, first disconnect them from the
power supply, and then short-circuit the supply line and the assemblies (e.g. condensers) using
an earthing rod.
– Check all parts for voltage, then earth them and short-circuit them. Insulate adjacent parts that
remain powered.
– Before carrying out arc welding work, or work on the electric components of the machine,
disconnect the battery.
First disconnect the negative pole, then disconnect the positive pole. To reconnect the battery,
first connect the positive pole, then the negative pole.
12.8 Hydraulic accumulators
– All work on hydraulic accumulators must be carried out by specialist technicians.
– Improper installation and handling of hydraulic accumulators can lead to serious injury.
– Never use hydraulic accumulators that are damaged.
– Before carrying out any work on a hydraulic accumulator, release the pressure from the hydraulic
system as described in this operating manual.
– Do not carry out any welding or soldering work on the hydraulic accumulator and protect it from
mechanical impact.
The hydraulic accumulator might become damaged or ruptured if exposed to heat arising from
mechanical impact. RISK OF EXPLOSION!
– Fill the hydraulic accumulator only with nitrogen. Do not use oxygen or air! RISK OF EXPLOSION!
– During operation, the storage body might become hot, so that there is a risk of injury.
– New hydraulic accumulators must be pressurised to the level required for the actual purpose
before they are commissioned.
– The operating data (minimum and maximum pressure) are permanently attached to the hydraulic
accumulators. Ensure that this identification is legible at all times.
12.9 Hydraulic and other hoses
– The repair of hydraulic and other hoses is prohibited!
– All hoses and fittings must be inspected every 2 weeks for damage. If any damage is suspected,
immediately check the respective line for leakage and visible damage!
Always replace damaged parts without delay! Escaping oil can lead to serious injury or fire!
– Even if stored and used properly, hoses tend to age, so that their service life is limited.
• Improper storage, mechanical damage and inadmissible loads are however the most common
causes of failure.
• As regards the permissible period of use, observe the applicable standards, regulations and
rules for hoses and hose lines.
• Use of the hose with near limit loads and stresses (e.g. at high temperature, frequent movement,
extremely high pulse frequencies, multiple shift operation) may shorten its service life.
– Replace hoses, if the inspection reveals any of the following:
• Damage at the outer jacket exposing the ply (e.g. caused by chafing, wear, cuts or cracks)
• Embrittlement of the outer jacket (formation of cracks in the hose material)

1.10.14
copyright by
MJFCIFSS
• Deformation of the hose when pressurised, depressurised, or at bends, resulting in separation
of the layers, bubbles, etc.
• Leakage
• Non-compliance with installation requirements
• Damage or deformation of the hose fittings, which might impair the fitting strength of the
connection between fitting and hose
• Disconnection of the hose from the fittings
• Corrosion at the fittings, impairing its function and strength
– Always replace hoses and hose connections with original spare parts.
– Ensure that all hoses and lines are installed and connected properly. Do not confuse connections.
– When replacing hoses and hose lines:
• Ensure that the hoses are installed without torsion. For high-pressure hoses first insert the
screws at the pipe clips or full flanges at both ends, and then tighten them.
• For high-pressure hoses and lines with angled fittings, first tighten the flange at the angled fitting
and then the one at the straight fitting.
• Pipe clamps at other point of the hose may not be attached and tightened, when the hose ends
are properly secured.
• Daily inspect all hose clips, covers and protective devices to ensure that they are properly
secured and tightened. Avoid vibration and damage during operation.
• To prevent chafing, install hoses and lines in such a way that they are not in contact with other
hoses, lines or machine parts.
• We recommend keeping a minimum distance of 1/2 the outer hose diameter between the hose
and any other parts. The distance should in any case not be less than 10 to 15 mm.
• When replacing hoses and hose lines connected to moving parts (e.g. from the boom to the
stick), first check that they are not rubbing on any other parts when the machine is operated.
12.10 Cab protection (FOPS)
For certain machine applications LIEBHERR offers optional cab protection systems of various
designs. These systems consist of a full length FOPS (falling objects protective structure) or a top
guard and front guard to protect the operator's cab and windscreen area from falling objects (for
example rocks or debris).
The full length FOPS wraps around the operator's cab, is mounted to the uppercarriage and is a
stand-alone system.
The top and front guards are either bolted individually or in combination to the cab structure. In that
case the operator's cab is also part of the cab protection system and is subject to the following
instructions.
– Never operate a machine if one of these protections is damaged in any way.
– Damages may occur due to:
• structural modifications or repairs (for example welding, cutting or drilling)
• deformation after an accident
• falling objects
– Structural modifications or repairs of any kind are prohibited without the expressed, written
approval of LIEBHERR.

01/2005 1.20.1
Bezeichnung
Description / Dénomination
Blatt/Page/Feuille: 1
bestehend aus 6 Blatt
Mjfcifss! Preloads and tightening torques consisting of
composé
Pages
Feuille
for screws with metric coarse and fine
threads
according to DIN 13, sheet 12 WN 4037 I
The preload forces and tightening torques compiled in the table
are based on the VDI 2230, 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 (replaces DIN 13, part 13)
and head dimensions of hexagon head bolts according to DIN EN 24014 (replaces DIN 931, part 1)
or hexagon socket head cap screws according to DIN EN ISO 4762 (replaces DIN 912)
Metric coarse thread Metric fine thread
Surface finish:
- black-chrome finished or phosphatised oiled
- electro-galvanized
- flZn according to LH standard 10021432 dry
Surface finish:
Thread Class Assembly preload
FM in N
Tightening
torque
MA in Nm
FM in N
Tightening
torque
MA in Nm
for mean friction factor µG= 0.12 for mean friction factor µG= 0.12
8.8 4 050 2.8
M4 10.9 6 000 4.1
12.9 7 000 4.8
8.8 6 600 5.5
M5 10.9 9 700 8.1
12.9 11 400 9.5
8.8 9 400 9.5
M6 10.9 13 700 14.0
12.9 16 100 16.5
8.8 13 700 15.5
M7 10.9 20 100 23.0
12.9 23 500 27
8.8 17 200 23 8.8 18 800 24.5
M8 10.9 25 000 34 M8x1 10.9 27 500 36
12.9 29 500 40 12.9 32 500 43
8.8 24 800 36
M9x1 10.9 36 500 53
12.9 42 500 62
8.8 27 500 46 8.8 31 500 52
M10 10.9 40 000 68 M10x1 10.9 46 500 76
12.9 47 000 79 12.9 54 000 89
8.8 29 500 49
M10x1.25 10.9 43 000 72
12.9 51 000 84
8.8 40 000 79 8.8 45 000 87
M12 10.9 59 000 117 M12x1.25 10.9 66 000 125
12.9 69 000 135 12.9 77 000 150
8.8 42 500 83
M12x1.5 10.9 62 000 122
12.9 73 000 145
8.8 55 000 125 8.8 61 000 135
M14 10.9 80 000 185 M14x1.5 10.9 89 000 200
12.9 94 000 215 12.9 104 000 235
8.8 75 000 195 8.8 82 000 205
M16 10.9 111 000 280 M16x1.5 10.9 121 000 300
12.9 130 000 330 12.9 141 000 360

1.20.2 01/2005
Metric coarse thread Metric fine thread
Surface finish:
Surface finish:
FM in N
Tightening
torque
MA in Nm
FM in N
Tightening
torque
MA in Nm
for mean friction factor µG= 0.12 for mean friction factor µG= 0.12
8.8 94 000 280 8.8 110 000 310
M18 10.9 135 000 390 M18x1.5 10.9 157 000 440
12.9 157 000 460 12.9 184 000 520
8.8 102 000 290
M18x2 10.9 146 000 420
12.9 170 000 490
8.8 121 000 390 8.8 139 000 430
M20 10.9 173 000 560 M20x1.5 10.9 199 000 620
12.9 202 000 650 12.9 232 000 720
8.8 152 000 530 8.8 171 000 580
M22 10.9 216 000 750 M22x1.5 10.9 245 000 820
12.9 250 000 880 12.9 285 000 960
8.8 175 000 670 8.8 207 000 760
M24 10.9 249 000 960 M24x1.5 10.9 295 000 1090
12.9 290 000 1120 12.9 346 000 1270
8.8 196 000 730
M24x2 10.9 280 000 1040
12.9 325 000 1220
8.8 230 000 1000 8.8 267 000 1110
M27 10.9 330 000 1400 M27x1.5 10.9 381 000 1580
12.9 385 000 1650 12.9 445 000 1850
8.8 255 000 1070
M27x2 10.9 365 000 1500
12.9 425 000 1800
8.8 280 000 1350 8.8 335 000 1540
M30 10.9 400 000 1900 M30x1.5 10.9 477 000 2190
12.9 465 000 2250 12.9 558 000 2560
8.8 321 000 1490
M30x2 10.9 457 000 2120
12.9 534 000 2480
8.8 350 000 1850 8.8 410 000 2050
M33 10.9 495 000 2600 M33x1.5 10.9 584 000 2920
12.9 580 000 3000 12.9 683 000 3420
8.8 395 000 2000
M33x2 10.9 560 000 2800
12.9 660 000 3300
8.8 410 000 2350 8.8 492 000 2680
M36 10.9 580 000 3300 M36x1.5 10.9 701 000 3820
12.9 680 000 3900 12.9 820 000 4470
8.8 440 000 2500
M36x3 10.9 630 000 3500
12.9 740 000 4100
8.8 490 000 3000 8.8 582 000 3430
M39 10.9 700 000 4300 M39x1.5 10.9 830 000 4890
12.9 820 000 5100 12.9 971 000 5720
8.8 530 000 3200
M39x3 10.9 750 000 4600
12.9 880 000 5300
Notes:
Torques indicated in drawings have precedence over those specified in the factory standards
and must at all times be adhered to.
For very important screw connections, we recommend applying the angle tightening method.
Alternatively determine the total friction factor by carrying out a series of tests and refer to VDI
2230 or consult the technical department for the relevant tightening torques.

01/2005 1.20.3
Appendix:
Angle tightening method
With the angle tightening method, the bolt is turned by a defined angle , which is based on the
flexible elongation of the bolt and compression of the screwed plates. Depending on the bolt
size, it is preloaded by a given torque before it is inserted into the parts to be secured, so that
the zero point of the angle measurement can be determined. From this zero angle o = 0, the
bolt can be preloaded - irrespective of the friction factor of the thread and the contact surface -
by turning it by the retightening angle .
Example 1:
Bolt: M14 – 10.9, grip length Lk=80mm;
According to table (strength class 10.9):
Pretightening torque MA = 50Nm; retightening angle 45°
Example 2:
Bolt: M24 – 12.9, grip length Lk=100mm;
According to table (strength class 12.9):
Pretightening torque MA = 160Nm; retightening angle 57°

Service Manual
of screw-in studs (Ermeto)
1.21. 1
Tightening torques
MJFCIFSS
Tightening torques
1 of screw-in studs (Ermeto)
1.1 mating material: steel (Grease well before inserting!)
Type with sealing edge Type with EOLASTIC seal
Type
Thread
M or G
Tightening
torques
in Nm
Type
Thread
M or G
Tightening
torques
in Nm
Light-duty series L Light-duty series L
GE 06 LM A 3 C M 10x1 18 GE 06 LM ED A 3 C M 10x1 18
GE 06 LR A 3 C G 1/8 A 18 GE 06 LR ED A 3 C G 1/8 A 18
GE 08 LM A 3 C M 12x1.5 30 GE 08 LM ED A 3 C M 12x1.5 25
GE 22 Lm A 3 C M 22x1.5 140 GE 22 Lm Ed A 3 C M 26x1.5 180
GE 22 Lr A 3 C G 3/4 180 GE 22 Lr Ed A 3 C G 3/4 A 180
GE 28 Lr A 3 C 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 Heavy-duty series S
GE 06 SM A 3 C M 12x1.5 35 GE 06 SM ED A 3 C M 12x1.5 35
GE 06 SR A 3 C G 1/4 A 55 GE 06 SR ED A 3 C G 1/4 A 55

Tightening torques
1.21. 2
Service Manual
of swivelling connections (Ermeto)
MJFCIFSS
Tab. 2 Tightening torques of screw-in studs
GE = Straight screw-in connection (with metric thread M or pipe thread G)
2 of swivelling connections (Ermeto)
GE 25 SR A 3 C G 1 A 340 GE 25 SR ED A 3 C G 1 A 310
GE 30 SR A 3 C G 1 1/4 A 540 GE 30 SR ED A 3 C G 1 1/4 A 450
GE 38 SR A 3 C G 1 1/2 A 700 GE 28 SR ED A 3 C M 1 1/2 A 540
Type with sealing edge Type with EOLASTIC seal
Type
Thread
M or G
Tightening
torques
in Nm
Type
Thread
M or G
Tightening
torques
in Nm
Type
Tightening torques
Type
Tightening torques
Thread Nm Thread Nm
Light-duty series Light-duty series
WH / TH 06 LR KDS A 3 C G 1/8 A 18 WH / TH 06 LM KDS A 3 C M 10 X 1 18
WH / TH 08 LR KDS A 3 C G 1/4 A 45 WH / TH 08 LM KDS A 3 C M 12 X 1.5 45
WH / TH 18 LR KDS A 3 C G 1 A 120 WH / TH 18 LM KDS A 3 C M 22 X 1.5 140
WH / TH 22 LR KDS A 3 C G 1 1/4 A 230 WH / TH 22 LM KDS A 3 C M 27 X 2.0 320
Heavy-duty series Heavy-duty series
WH / TH 06 SR KDS A 3 C G 1/4 A 45 WH / TH 06 SM KDS A 3 C M 12 X 1.5 45

Service Manual
1.21. 3
Tightening torques
MJFCIFSS
Tab. 2 Tightening torques of swivelling connections
3 of screw-in studs (Ermeto)
Tab. 2 Tightening torques of screw-in studs
VSTI = Hexagon socket plug
WH / TH 25 SR KDS A 3 C G 1 A 320 WH / TH 20 SM KDS A 3 C M 27 X 2.0 320
WH / TH 30 SR KDS A 3 C G 1 1/4 A 540 WH / TH 25 SM KDS A 3 C M 33 X 2.0 360
WH / TH 38 SM KDS A 3 C M 48 X 2.0 700
Type
Tightening torques
Type
Tightening torques
Thread Nm Thread Nm
Type VSTI
Screw-in
thread M
Tightening
torques
Nm
Type VSTI
Screw-in
thread G
Tightening
torques
Nm
VSTI 10X1 ED A3C M 10 X 1 12 VSTI 1/8 ED A3C G 1/8 A 13
VSTI 12X1.5 ED A3C M 12 X 1.5 25 VSTI 1/4 ED A3C G 1/4 A 30
VSTI 20X1.5 ED A3C M 20 X 1.5 80 VSTI 1 ED A3C G 1 A 200
VSTI 22X1.5 ED A3C M 22 X 1.5 90 VSTI 1 1/4 ED A3C G 1 1/4 A 450
VSTI 26X1.5 ED A3C M 26 X 1.5 120 VSTI 1 1/2 ED A3C G 1 1/2 A 450
VSTI 27X2 ED A3C M 27 X 2.0 135
VSTI 33X2 ED A3C M 33 X 2.0 225
VSTI 42X2 ED A3C M 42 X 2.0 360
VSTI 48X2 ED A3C M 48 X 2.0 360

Tightening torques
1.21. 4
Service Manual
MJFCIFSS

09 / 2005 1.22.1
Bezeichnung
Mjfcifss! Assembly instruction
consisting of
composé
Pages
Feuille
for pistons and piston nuts
(hydraulic cylinders) WN 4121 B
Contents
1. Scope of application
2. Description
3. Referenced documents (torque table)
This factory standard applies exclusively to the assembly of hydraulic cylinders with a
thread diameter of M42 and greater. For the valid factory standard number, refer to the
drawing. The standard may not be adopted or transferred to apparently similar
geometries.
The torques have been determined empirically and are subject to changes. The revision
and release dates indicate the latest version of the factory standard.
For threads with diameters smaller than M42, the applicable tightening torques are
indicated in the drawings.
The values in the drawings are always binding.

1.22.2 09 / 2005
2. Description
Preparation:
Clean the contact surfaces (threads contact faces between piston rod, piston and piston
nut) and apply a thin layer of Gleitmo high-performance lubricating grease (ID no. 8300
004, 40 g tube) on both sides.
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 (see figure
1).
Figure 1
A Piston
B Assembly wrench
C Torque wrench
When applying the pretightening torque, the torque wrench must point in the same
direction as the assembly wrench.
Proceed in the same way to tighten the piston nut, using a suitable assembly wrench.

09 / 2005 1.22.3
Turning distance:
Radian measure [mm] travelled as a result of the tightening of the piston, or piston nut
along the outer thread diameter, after application of the pretightening torque (see figures
2 and 3).
Turning angle:
Angle ° travelled by the piston or piston nut respectively, after application of the
pretightening torque (see figures 2 and 3).
Figure 2
A Marks on the piston and piston rod thread after application of the
pretightening torque
B Mark on the piston rod thread
C Turning angle
D Turning distance
E Mark on the piston after tightening
Figure 3
A Marks on the piston nut and piston rod thread after application of the
pretightening torque
B Mark on the piston rod thread
C Turning angle
D Turning distance
E Mark on the piston nut after tightening

09 / 2005 1.22.5
3. List of tightening torques for factory standard 4121
(Assembly instructions for piston and piston nur)
The date indicates the latest version of this table. Edition: 11.04.2005
This document is not covered by the revision service.
FS Preload Piston Piston nut Thread
4121- Torque Turn.distance Turning angle Turns distance Turning angle M
... Mv [Nm] [mm] ~ [°] [mm] ~ [°] [mm]
071 100 11 +1 30 21 +1 57 42x1,5
072 100 21 +1 57 21 +1 57 42x1,5
073 100 18 +1 49 19 +1 52 42x1,5
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
231 200 8 +2 11 16 +1 22 85x3
232 200 17 +2 23 16 +1 22 85x3

1.22.6 09 / 2005
FS Preload Piston Piston nut Thread
4121- Torque Turn.distance Turning angle Turns distance Turning angle M
... Mv [Nm] [mm] ~ [°] [mm] ~ [°] [mm]
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

09 / 2005 1.24.1
Bezeichnung
Mjfcifss! Assembly instruction
consisting of
composé
Pages
Feuille
for piston rod bearings with external threads
(hydraulic cylinders) WN 4122 B
Contents
2. Description
3. Referenced documents (torque table)
This factory standard applies exclusively to the assembly of hydraulic cylinders. For the
valid factory standard number, refer to the drawing. The standard may not be adopted or
transferred to apparently similar geometries.
The torques have been determined empirically and are subject to changes. The revision
and release dates indicate the latest version of the factory standard.

1.24.2 09 / 2005
2. Description
Preparation:
Clean the threads and apply a thin layer of Gleitmo high-performance lubricating grease
(ID no. 8300 004, 40 g tube) on both sides.
Definitions:
Pretightening torque:
The piston rod bearing is secured with a torque wrench applied to the square of the
assembly wrench. The position of the torque wrench must be carefully noted (see figure 1).
Figure 1
A Bearing head
B Assembly wrench
C Torque wrench
When applying the pretightening torque, the torque wrench must point in the same
direction as the assembly wrench.

09 / 2005 1.24.3
Turning distance:
Radian measure [mm] between the bearing head outer diameter and the cylinder tube,
travelled after application of the pretightening torque (see figure 2).
Turning angle:
Angle ° travelled by the bearing head after application of the pretightening torque (see
figure 2).
Figure 2
A Marks on the cylinder tube and the auter diameter of the bearing head after application
of the pretightening torque
B Mark on the cylinder tube
C Turning angle
D Turning distance
E Mark on the bearing head after tightening
F Cylinder Tube
G Bearing head
After the bearing head and the cylinder tube have been tightened, apply a notch mark at the
rod side oil connection level, using a flat chisel.

1.24.4 09 / 2005
3. List of tightening torques for factory standard 4122
(Assembly instructions for piston and piston nur)
The date indicates the latest version of this table. Edition: 24.01.2005
This document is not covered by the revision service.
.
NU Preload Piston rod bearing
4122- Torque
Turning
distance Turning angle
... Mv [Nm] [mm] ~ [°]
001
011 50 7 +1 10
016 100 10 +1 12
017 100 10 +1 12
026 100 9 +1 10
027 100 10 +1 11
031 100 8 +1 8
036 100 8 +1 9
039
041
046
047
051
052
151 400 14 +1 6

Service Manual
General instructions regarding the change of fuel, hydraulic oils, lubricants, etc.
1.50. 1
Fuels, lubricants and other consumables
MJFCIFSS
1 General instructions regarding the change of fuel, hydraulic oils,
lubricants, etc.
Note!
The fill volumes specified in the fuel and lubricant table in the operator manual, and in the
documentation of the assemblies, as well as in the lubrication schedule in the operator's cab are
only approximate values.
After each oil change or refilling, check the fill level in the respective tank or unit.
Note!
Compliance with the instructions regarding lubrication, fill level checks and oil changes improve the
reliability and prolong the service life of the machine. It is very important that the prescribed intervals
for oil change are adhered to and that only products of the prescribed quality and grade are used.
Note!
Cleanliness during the oil change is of crucial importance.
Always clean all fill screws, lids and drain plugs and the area around fill openings.
When draining oil, ensure that the oil is at operating temperature.
Carefully collect the old oil and dispose of it in an environmentally friendly manner. This also
applies to the oil filter cartridges.
Danger!
When checking and/or changing lubricants and fuels:
If not instructed otherwise, ensure that the machine is standing on level and firm ground and that
the engine is shut down.
When working inside the engine compartment, always secure the cover and doors against
inadvertent closing.
Before refuelling the machine, switch off the engine. Do not smoke or use naked flames.

1.50. 2
Service Manual
MJFCIFSS
1.1 Lubricant table
Description Medium Symbol Classification Viscosity
Diesel engine Engine oil Refer to the instructions of the engine
manufacturer
(see Deutz manual)
Hydraulic tank Engine oil API-CD, API-
CD+SF,
CCMC-D4,
CCMC-D5,
ACEA-E1,
ACEA-E3
SAE 10W
SAE 10W-30
SAE 10W-40
SAE 15W-40
SAE 20W-20
SAE 30W
Slewing gear mechanism
(as stop brake)
Gear oil API - GL -5
MIL-L 2105 B,
C or D
SAE 80W90
or
SAE 90
Slewing gear mechanism
(as positioning slewing
brake)
MIL-L 2105 B
SAE 90 LS
Steering axle Gear oil API - GL -5
MIL-L 2105 B
ZF TE-ML 05
SAE 90 LS
Rigid axle
with multi-disc brake
MIL-L 2105 B
ZF TE-ML 05
SAE 90 LS
Rigid axle
with drum brake
MIL-L 2105 B
ZF TE-ML 05
SAE 90 LS
Wheel hubs in steering and
rigid axles with multi-disc
and drum brakes
MIL-L 2105 B
ZF TE-ML 05
SAE 90 LS
Transmission Gear oil ZF TE-ML 07 SAE 10 W 30
SAE 10 W 20
Travel gear Gear oil API - GL -5
MIL-L 2105 B
ZF TE-ML 05
SAE 80W90
or
SAE 90

Service Manual
1.50. 3
MJFCIFSS
Tab. 1 Lubricant table
1.1.1 Fuel and consumables
Tab. 2 Fuel and consumables
Tracks and gearing of the
slewing ring, bearing of the
equipment
Grease High-pressure
grease
KP2k or EP2
Consiste
ncy 2
NLGI
grade
with
lithium
complex
Tab. 8
MPG-A
Hinges, joints, locks Engine oil - - - -
Sealing rubber on doors
and covering sections
Silicone
spray or
talcum
powder
- - - -
*BI = Lubricant for building machinery and vehicles recommended by the Federation of the German
Construction Industry (Hauptverband der Deutschen Bauindustrie e. V.), see brochure published by
Bauverlag GmbH, Wiesbaden and Berlin regarding the use of lubricant and fuel tables.
Description Medium Symbol Classification Viscosity
Description Medium Symbol
Fuel tank Conventional diesel fuel with <= 0.5 % sulphur content
Coolant Anticorrosion and antifreeze agent
Windscreen washer
system
Conventional windscreen cleaning agent or denatured
alcohol
-
Coolant of air-
conditioning system
R 134 a -
Refrigeration oil in SD
7H15 a/c compressor
PLANETELF PAG SP 20
ID no. 8504414 (0.25 litre) or. 7620633 (1.0 litre)
-

1.50. 4
Service Manual
Specifications for fuels, lubricants and consumables
MJFCIFSS
2 Specifications for fuels, lubricants and consumables
2.1 Lubricating oil for the diesel engine
Refer to the instructions of the engine manufacturer (see Deutz manual):
Tab. 3 Lubricating oil for the diesel engine
2.1.1 Oil change intervals for turbocharged engines
Tab. 4 Oil change intervals
The oil change intervals of the diesel engine are based on the following criteria:
– First oil and filter change after 500 operating hours, if the oil of the first filling was an oil of E3-96
grade
– Subsequent filter changes after 500 operating hours
– Subsequent oil changes depending on the climate, sulphur content of the fuel and oil grade, Tab.
4.
– If the above number of operating hours is not reached within 12 months, change the engine oil
and the oil filter at least once every year.
2.2 Fuel
Diesel fuels should meet the minimum requirements of the fuel specifications named below.
The sulphur content should not exceed 0.5 mass %. A higher sulphur content affects the oil change
intervals and the service life of the engine.
2.2.1 Lubricity
By reducing the sulphur content in diesel, the issue of lubricity has come to the fore. It has been
shown that diesel fuels with the sulphur levels of maximum 0.05 %, which corresponds to the limit in
the European Union, can lead to wear in the injection system (especially in distributor fuel injection
pumps).
Classification Specification
API classification (American Petrol
Institute)
CG-4, CF-4, CH-4
ACEA (CCMC) classification
(Association des Constructeurs
Européens de l´Automobile)
E2-96 (D4), E3-96 (D5), E4-98
Operating conditions
Sulphur content
of fuel
Oil change interval
depending on oil quality:
CH-4
CG-4
CF-4
E2-96 (D4)
E3-96 (D5)
E4-98
E5-99
Temperature normally not
dropping below -10°C
max. 0.5 %
higher than 0.5 %
250 h
125 h
500 h
250 h
below -10 °C max. 0.5 %
higher than 0.5 %
125 h
-
250 h
125 h

Service Manual
1.50. 5
MJFCIFSS
Branded fuels in Germany and elsewhere therefore contain lubricating additives. The lubricity of the
fuel must be < 400 µm in a HFFR test (60°).
The additives should be added by the supplier, who is responsible for the quality of the fuel. We
advise machine operators not to add any secondary lubricity additives to the fuel.
2.2.2 Improvement of fluidity by adding petrol
At outdoor temperatures below approx. 0 °C, the fluidity of summer diesel might not be sufficient, due
to the separation of paraffin.
This also applies to winter diesel at temperatures below approx. -15 °C. There is however diesel fuel
on the market, containing additives that make it suitable for use at temperatures to -20 °C.
In order to avoid malfunction at low temperatures, diesel must be mixed with normal petrol or
petroleum.
This approach must be considered an emergency measure and the petrol content may never exceed
30 % (volume).
Do not use premium petrol for this mixture. Please note that the engine output might be reduced due
to the addition of petrol. The addition of petrol should therefore be based on the actual outdoor
temperature and kept as low as possible.
Approved fuel specifications
DIN EN 590
ASTM D 975 (89 a) 1D and 2D
DIN EN 590 with max. 5 volume % FAME* according to draft standard prEN 14214 (formerly: DIN
51606)
Danger!
For safety reasons, the diesel-petrol mix must be produced in the fuel tank.
Note!
When filling tank, first fill in the lighter additional fuel (petrol) and than add the diesel. Run the motor
until the entire fuel system is filled with the fuel mix (see Tab. 6, page 6).

1.50. 6
Service Manual
MJFCIFSS
Diesel fuel – petrol mixing ratio
Tab. 5 Summer diesel fuel – petrol mixing ratio
Tab. 6 Winter diesel fuel – petrol mixing ratio
* If an additive content of 50 % is required, use only petroleum (not standard petrol).
2.2.3 Diesel fuel additives (fluidity improvers)
Fluidity improvers are widely available and help improve the fluidity of diesel at low temperatures.
When using such additives, always adhere to the dosing and handling instructions of the
manufacturers.
2.3 Hydraulic oil
2.3.1 Mineral oil
Use only motor oils that conform to the specifications and requirements below:
Tab. 7 Engine oils to be used as hydraulic oils
Select the engine oil for use as hydraulic oil according to the following diagram.
Outdoor temperature
°C
Summer diesel fuel %
Addition of
petrol %
0 to -10 70 30
-10 to -15 50 50*
-15 to -20 - -
-20 to -25 - -
Outdoor
temperature °C
Winter diesel fuel % Addition of petrol %
Grade -15
°C
Grade -20
°C
Grade -15
°C
Grade -20
°C
0 to -10 100 100 - -
-10 to -15 100 100 - -
-15 to -20 70 100 30 -
-20 to -25 50 70 50* 30
Single grade engine
oils:
API - CD / CCMC - D4 / ACEA - E1
Mercedes-Benz specifications, sheet no. 226.0 and
227.0
Multigrade engine
oil:
API - CD + SF / CCMC - D5 / ACEA - E3
Mercedes-Benz specifications, sheet no. 227.5 and
228.3

Service Manual
1.50. 7
MJFCIFSS
Fig. 1 Engine oil for use as hydraulic oil
Warm-up instruction
At temperatures to 10 °C below the indicted limit (black bar), the oil must be warmed up as follows:
Start diesel engine and run it at approx. 1 / 2 the rated speed. Operate the hydraulic cylinders and
motors, but do not move the cylinders to their stops. Warm-up time: approx. 10 minutes
At lower temperatures: Before starting the engine, warm up the oil tank.
2.3.2 Environmentally friendly hydraulic oils
LIEBHERR will fill the system before delivery, based on a list of approved oils. Before using
environmentally friendly oils, you must consult LIEBHERR.
The list of products recommended by LIEBHERR contains only ester-based synthetic oils with a
viscosity according to ISO VG 46.
Do not use vegetable oils, as they do not possess the necessary thermal stability.
2.3.3 Monitoring of hydraulic oil
2.3.4 Monitoring of hydraulic oil in normal use
Fig. 2 Oil sampling from machines in normal use
Note!
Do not mix different brands of environmentally friendly hydraulic oils or such oils with mineral oils
(see customer service information)!
Note!
Environmentally friendly hydraulic oils must be regularly tested by means of an oil analysis. For
mineral oils, we recommend carrying out oil analyses at regular intervals. LIEBHERR
recommends contracting WEAR-CHECK with these analyses, and to change the oil when indicated
by the test results (see also customer service and product information).
Machines in normal use: at least every 500 operating hours
Machines used for dust intensive applications: at least every 250 operating hours

1.50. 8
Service Manual
MJFCIFSS
Oil change based on analysis and lab report.
Interval for the change of the hydraulic oil return filter (20/5 µm): first change after 500 operating
hours, then every 1000 operating hours.
2.3.5 Oil sampling from machines used for dust intensive applications:
Fig. 3 Oil sampling from machines used for dust intensive applications
Oil change based on analysis and lab report.
Interval for the change of the hydraulic oil return filter (10 µm): first change after 500 operating hours,
then every 500 operating hours.
2.3.6 Instructions for the reduction of the contamination of the hydraulic oil in
machine used for dust intensive applications
If the machine is normally operated with a hydraulic hammer or under similar conditions (considerable
dust generation), the hydraulic oil might become more contaminated than under normal working
conditions.
In order to prevent premature wear of the hydraulic components, shorten the intervals between the
oil changes (or oil samples respectively) and observe the following instructions:
– Every 500 operating hours, replace the filter cartridge(s) in the return filter.
– Use 10-µm filter cartridges instead of the standard 20 / 5-µm cartridges.
– Replace the breather filter on the hydraulic tank with a 2-µm fine filter (mesh size of series filters:
7 µm).
– Replace the 2-µm breather at each change of the hydraulic oil (i.e. every 500 operating hours).
2.4 Gear oil
Gear oils must conform to the following specifications:
– API-GL-5 and MIL-L-2105 B, C or D respectively for viscosity grade SAE 90
Engine oils used in gearboxes must conform to the following specifications:
– API-CG-4, CF-4, CF for viscosity grade SAE 20
h Operating hours 2 Second oil sample
1 First oil sample 3 Subsequent oil samples: every 500
operating hours
h Operating hours 2 Second oil sample
1 First oil sample 3 Subsequent oil samples: every
250 operating hours
Note!
– Machines that are delivered with a fully installed AHS 11 or AHS12 accessory kit, and machines
with retrofitted kits are already equipped with 10-µm filter cartridges 2-µm breather filters.
– All machines produced after approx. September 2005 have been equipped with 2-µm breather
filters.

Service Manual
1.50. 9
MJFCIFSS
For viscosity grades SAE 80 and SAE 90 according to MIL-L-2105 D, you may use an oil of viscosity
grade SAE 80W90.
2.4.1 Grease and other process chemicals
Tab. 8 Grease and other process chemicals
2.5 Coolant
In order to improve the quality of the cooling water, LIEBHERR diesel engines are equipped with
water filter installations for Deutz engines.
This ensures that the coolant is also filtered in the bypass flow where dirt and rust particles that might
lead to leakage in the cooling pump are removed.
Process chemicals Description / manufacturer
Grease for slewing ring / general
lube points
The grease must conform to specification KP2k,
consistency grade 2, NLGI grade according to
DIN 51818 and DIN 51825 or EP 2 according to
NF-T-60 132.
The grease must consist of a lithium complex
with a VKA value of minimum 2300 N according
to DIN 51350 or ASTM D 2596 respectively.
Contact spray for slip rings Cramolin
ID no. 7024145
Lubricant for pistons, piston nuts,
also used for the mounting of piston
rod bearings and cushioning
sleeves to hydraulic cylinders
Gleitmo 800
ID no. 8300004 (40g tube)
Anti-friction varnish and lubricant for
LIKUFIX coupling system
Gleitmo 900
ID no. 8610227 (400 ml spray can)
Special corrosion inhibitor for
mounting recesses for sealing
elements at hydraulic cylinders
Castrol-Tarp
ID no. 8300005 (40g tube)
Other grease:
Lubricant used for the mounting of
pumps to prevent fretting corrosion
on spline meshes
LIEBHERR CTK special lubricant
ID no. 861331301 (400g cartridge)
Coolant for air-conditioning system R 134 A
Drain and fill the system according to the
instructions in this manual (air-conditioning
assembly).
Refrigeration oil for a/c compressor The SD5H14 / SD7H15 a/c compressors are
factory-filled with Planetelf PAG SP 20.
ID no. 8504414 (0.25 litre can)
ID no. 7620633 (1.0 litre can)
The compressor supplier does not permit the use
of any other refrigeration oil.

1.50. 10
Service Manual
MJFCIFSS
Tab. 9 Mixing ratio water : corrosion inhibitor / antifreeze agent
The coolant must contain at least 50 volume % of corrosion inhibitor and antifreeze agent during all
seasons. This protected the coolant against freezing to a temperature of -37 °C and ensures
adequate protection against corrosion. In the event of loss of coolant, ensure that the additive
concentration does not drop below 50 volume %.
As part of the regular maintenance, check the mixing ratio.
Before refilling the cooling system with new coolant, ensure that it is clean and rinse it, if required.
2.5.1 Requirements regarding the fresh water quality
To prepare the coolant, use clean water with as little limestone content as possible. In most cases,
the local drinking water meets these requirements. Do not use sea water, brackish water, brine or
industrial wastewater.
Requirements regarding the fresh water quality for coolants with corrosion inhibitors
and antifreeze agents
Tab. 10 Max. concentration of water contaminations for use with corrosion inhibitors and
antifreeze agents
Outdoor temperature to Water content in %
Content of corrosion
inhibitors/antifreeze
agents in %
-37 °C / -34 °F 50 50
-50 °C / -58 °F 40 60
Note!
Do not exceed a corrosion inhibitor and antifreeze agent concentration of 60 %! Higher
concentrations tend to result in poor cooling and antifreeze protection.
Note!
– Change the coolant every 2 years.
Substance Volume
Total of alkaline earths (water
hardness)
0.6 to 3.6 mmol / l (3 to 20 °d)
pH at 20 °C 6.5 to 8.5
Chloride ion content max. 80 mg / l
Total chloride and sulphate max. 100 mg / l

Service Manual
1.50. 11
MJFCIFSS
F
Fig. 4 Mixing ratio water : corrosion inhibitor / antifreeze agent
2.5.2 Approved corrosion inhibitors and antifreeze agents
Concentrates
A % of corrosion inhibitor and antifreeze agent
B Antifreeze agent to indicated temperature, according to value A
Brand Producer Country
Agip Antifreeze Plus Agip Petrol S.p.A., Rome I
Agip Langzeit-Frostschutz Autol-Werke GmbH, Würzburg D
Antigel DB 486 Sotragal SA, St. Priest F
Aral Kühlerfrostschutz A Aral AG, Bochum D
Avia Frostschutz APN (G48-00) Deutsche Avia-Mineralöl GmbH, Munich D
BP Antifrost X 2270 A Deutsche BP AG, Hamburg D
BP Napgel C 2270 / 1 BP Chemicals LTD., London GB
Caltex Engine Coolant DB Caltex UK Ltd, London GB
Caltex Extended Life Coolant Caltex UK Ltd, London GB
Castrol Anti-Freeze O Deutsche Castrol Vertriebs GmbH, Hamburg D
Century F.L. Anti-Freeze Century Oils, Hanley, Stoke-on-Tent GB
Chevron DEX-Cool Extended Life Anti-Freeze /
Coolant
Chevron Texaco, San Ramon, CA USA
DEUTZ Kühlschutzmittel 0101 1490 Deutz Service International GmbH, Cologne D
Esso Kühlerfrostschutz Esso AG, Hamburg D
Fircofin Fuchs Mineralölwerke GmbH, Mannheim D
Frostschutz Motorex (G48-00) Bucher & Cie, Langenthal CH
Frostschutz 500 Mobil Oil AG, Hamburg D
Glacelf Auto Supra Total Nederland N.V., The Hague NL
Glycoshell AF 405 Shell Deutschland GmbH, Hamburg D
Glycoshell N Shell Deutschland GmbH, Hamburg D

1.50. 12
Service Manual
MJFCIFSS
Tab. 11 Approved corrosion inhibitors and antifreeze agents
50:50 premixed products (water: corrosion inhibitor / antifreeze agent)
Tab. 12 Approved corrosion inhibitors / antifreeze agents / 50:50 premix
Glysantin (G48-00) BASF AG, Ludwigshafen D
Havoline XLC Arteco, Ghent B
Chevron 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 A
Organifreeze Total Deutschland GmbH, Düsseldorf D
OZO Frostschutz S Total Deutschland GmbH, Düsseldorf D
Total Antigel S-MB 486 Total Deutschland GmbH, Düsseldorf D
Total Frostfrei Total Deutschland GmbH, Düsseldorf D
Castrol Anti-Freeze O Total Deutschland GmbH, Düsseldorf D
Wintershall Kühlerschutz Wintershall Mineralöl GmbH, Düsseldorf D
Brand Producer Country
Product Producer Country
Liebherr Anti-Freeze APN Mix ID no. 8611045 Liebherr D
Caltex 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, Ghent B
Chevron DEX-Cool Extended Life Prediluted 50/
50 Anti-Freeze / Coolant
Organicool 50/50 Total Deutschland GmbH, Düsseldorf D

Product groups
Lubricant classes for service fills (1)
without with
wet multi-disc brakes and / or
multi-disk limited-slip differentials
1. Axles (exception see section 2-5)
Differentialsx
Wheel hubsx
Stub shafts
ZF-Powerfluidx
05A / 05B / 05C / 05D /
05E / 05F / 05G
ZF-Powerfluidx
05C / 05D / 05E / 05F / 05G
2. Axles with hypoid drive
(AP 420R; AV230; MT-C 2025; MT-C2035;
MT-C2075)
05A / 05B / 05C / 05D 05C / 05D
3. MT-D 3105 (only oil circuit brake)
MT-L 3000 (with sintered brake linings)
--- ZF-Powerfluid
05E / 05F / 05G
4. MS-T 3025, MS-T 3035, MS-T 3045,
MS-T 3055, MS-T 3060x
MT-T 3025, MT-T 3035, MT-T 3045
MT 2075 (old: AP 2075),
MT 2085 (old: AP 2085)
ZF-Powerfluid
05A / 05B / 05C / 05D
05E / 05F / 05G
ZF-Powerfluid
05E / 05F / 05G
5. ZF-half-shafts (planetary final drives) for
tractor transmissions T-7000
05A / 05B / 05C / 05D ---
(1) Refer to the following pages for approved commercial products.
A lithium saponified multipurpose grease of NLGI class 2 which is mixable with mineral oil is to be used at greasing points
(grease code KP2K-30 in acc. with DIN 51825 or ISO-L-XCCHB2 in accordance with ISO 6743-9).
Additives of any kind added later to the oil change the oil in a manner that is unpredictable, and they are therefore not
permitted. No liability of any kind will be accepted by ZF for any damage resulting from the use of such additives.
Off-Road Driveline Technology
and Axle Systems
Axles for off-road vehicles List of lubricants TE-ML 05
The list of lubricants TE-ML 05, Edition 01.04.2005 replaces all
previous editions. The current list can be requested from any ZF
after-sales service center or accessed on the Internet under
www.zf.com.
ZF Passau GmbH ZF Friedrichshafen AG
D-94030 Passau D-88038 Friedrichshafen
phone: + 49 7541 77 3505
fax: + 49 7541 77 7319
09 / 2005 1.55.1

Oil change intervals
Lubricant class 05A, 05B, 05C, 05D, 05E, 05F ZF Powerfluid
05G
Load class Oil change interval
1 1500 h 2000 h
2 1000 h 1500 h
3 500 h 1000 h
Load classes
Load class Examples of applications
1
- Dumper
- Mobile excavator with low driving-mode share (<25%)x
- Wheel loader with hydrostatic drivex
- Other axles without wet brakes
2
- Mobile excavator with increased driving-mode share (>25%)
- Wheel loader, grader, backhoe, telescopic handlerx
- T 7000 half shafts
3
- Wheel loader operated under extreme braking conditions
- Mobile excavator, material-handling areasx
- At ambient temperatures > 40°C
Continued ZF Friedrichshafen AG / List of lubricants TE-ML 05, edition 01.04.2005
1.55.2 09 / 2005

Lubricant class 05A
Gear oilx
Viscosity grades: SAE 75W-90 / 75W-140 / 80W-90 / 80W-140 / 85W-90 / 85W-140 / 90
Manufacturer (05A) Trade name (05A)
ADDINOL LUBE OIL GMBH, LEUNA/D ADDINOL GETRIEBEÖL GH 80W-90
ADDINOL LUBE OIL GMBH, LEUNA/D ADDINOL GETRIEBEÖL GH 85W-90
ADDINOL LUBE OIL GMBH, LEUNA/D ADDINOL GETRIEBEÖL GX 80 W 90 ML
AGIP SCHMIERTECHNIK GMBH, WÜRZBURG/D AUTOL HYPOID-GETRIEBEÖL SAE 80W-90
ARAL AG, BOCHUM/D ARAL GETRIEBEOL EP PLUS 80W-90
ARAL AG, BOCHUM/D ARAL GETRIEBEOL HYP 85W-90
ARAL AG, BOCHUM/D ARAL GETRIEBEÖL HYP SAE 85W-140
ARMORINE S.A., LANESTER CEDEX/F PM 90
AVIA MINERALÖL-AG, MÜNCHEN/D AVIA HYPOID 90 EP
AVIA MINERALÖL-AG, MÜNCHEN/D AVIA SYNTOGEAR FE 80W-90
BAYWA AG, MÜNCHEN/D BAYWA HYPOID GETRIEBEÖL 85W-90
BAYWA AG, MÜNCHEN/D BAYWA SUPER 8090 MC
BEIJING TONGYI PETROLEUM CH. CO. LTD., BEIJING/CN XIECHENG 85W-90 GEAR OIL
BLASER SWISSLUBE AG, HASLE-RÜEGSAU/CH HYPOID-GETRIEBEÖL 80W90
BLASER SWISSLUBE AG, HASLE-RÜEGSAU/CH HYPOID-GETRIEBEÖL 85W140
BLASER SWISSLUBE AG, HASLE-RÜEGSAU/CH HYPOID-GETRIEBEÖL 90
BP INTERNATIONAL, PANGBOURNE, READING/GB BP ENERGEAR DL 80W-90
BP INTERNATIONAL, PANGBOURNE, READING/GB BP ENERGEAR HT 80W-90
BP INTERNATIONAL, PANGBOURNE, READING/GB BP ENERGEAR HYPO 80W-90
BP INTERNATIONAL, PANGBOURNE, READING/GB BP ENERGEAR HYPO 85W-140
BP INTERNATIONAL, PANGBOURNE, READING/GB BP ENERGEAR HYPO 90
BP INTERNATIONAL, PANGBOURNE, READING/GB ENERGEAR HT 85W140
BP INTERNATIONAL, PANGBOURNE, READING/GB FRONTOL GETRIEBEÖL FE SAE 80W-90
BP INTERNATIONAL, PANGBOURNE, READING/GB FRONTOL HYPOID GETRIEBEÖL B SAE 85W-140
BP INTERNATIONAL, PANGBOURNE, READING/GB FRONTOL HYPOID GETRIEBEÖL B SAE 90
BUCHER AG LANGENTHAL, LANGENTHAL/CH MOTOREX GEAR OIL UNIVERSAL 80W/90
BUCHER AG LANGENTHAL, LANGENTHAL/CH MOTOREX GEAR OIL UNIVERSAL 85W/140
CALPAM MINERALÖL-GMBH, ASCHAFFENBURG/D CALPAM MULTI GEAR OIL FE 80W90
CALPAM MINERALÖL-GMBH, ASCHAFFENBURG/D CALPAM SUPER GEAR OIL 85W90 GL 5
CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL AF-STO 85W140
CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL AGRI GEAR GL5 90
CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL AGRI GEAR ULTRA
CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL DYNADRIVE 80W-90
CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL EPX 85W-140
CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL EPX 90
CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL EPX M 90
CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL MULTIDRIVE 80W90
CEPSA LUBRICANTS S.A., MADRID/E CEPSA TRANSMISIONES EP 90
CEPSA LUBRICANTS S.A., MADRID/E CEPSA TRANSMISIONES EP MULTIG. 85W-140
CEPSA LUBRICANTS S.A., MADRID/E CEPSA TRANSMISIONES EP MULTIGRADO 80W-90
CEPSA LUBRICANTS S.A., MADRID/E ERTOIL EP CAMBIOS Y DIFERENCIALES SAE 90
CEPSA LUBRICANTS S.A., MADRID/E ERTOIL EP MULT. CAMBIOS Y DIFERENCIALES 80W-90
CEPSA LUBRICANTS S.A., MADRID/E ERTOIL EP MULT. CAMBIOS Y DIFERENCIALES 85W-140
CHEVRONTEXACO GLOBAL LUBRICANTS, SAN RAMON/USA CHEVRON RPM UNIVERSAL GEAR LUBRICANT SAE 80W-90
CHEVRONTEXACO GLOBAL LUBRICANTS, SAN RAMON/USA CHEVRON RPM UNIVERSAL GEAR LUBRICANT SAE 85W-140
CHEVRONTEXACO, GHENT/B GEARTEX EP-B 85W-90
CHEVRONTEXACO, GHENT/B GEARTEX EP-C 85W-140
CHEVRONTEXACO, GHENT/B MULTIGEAR 80W-90
CHEVRONTEXACO, SYDNEY/AUS CALTEX HYPOID LD SAE 85W-90
CHEVRONTEXACO, SYDNEY/AUS CALTEX HYPOID LD SAE 90
CONDAT LUBRIFIANTS, CHASSE SUR RHONE/F GEAR S 80W90
CONDAT LUBRIFIANTS, CHASSE SUR RHONE/F GEAR S 85W140
DE OLIEBRON B.V., ZWIJNDRECHT/NL TOR SUPER GEAR OIL 80W90
ENI S.P.A. REFINING & MARKETING DIVISION, ROME/I AGIP ROTRA MP 85W-140
ENI S.P.A. REFINING & MARKETING DIVISION, ROME/I AGIP ROTRA TRUCK GEAR 85W-140
ENI S.P.A. REFINING & MARKETING DIVISION, ROME/I ROTRA MP 80W-90
ENI S.P.A. REFINING & MARKETING DIVISION, ROME/I ROTRA TRUCK GEAR 80W-90
EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA ESSO GEAR OIL GX-D 85W-90
EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA ESSO GEAR OIL TDL 80W-90
EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA MOBILUBE HD-A 85W-90
EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA MOBILUBE S 80W-90
FALCON OIL COMPANY LTD., SHARJAH/UAE FALCON SUPER MP GEAR OIL 85W/140 GL-5
FALCON OIL COMPANY LTD., SHARJAH/UAE FALCON SUPER MP GEAR OIL 80W/90 GL-5
FL SELENIA S.P.A., VILLASTELLONE/I AKCELA GEAR 135H EP (SAE 80W90)
FL SELENIA S.P.A., VILLASTELLONE/I AKCELA GEAR 135H EP (SAE 85W140)
FL SELENIA S.P.A., VILLASTELLONE/I AKROS EP 90 SAE 80W90
Continue ZF Friedrichshafen AG / List of lubricants TE-ML 05, edition 01.04.2005
09 / 2005 1.55.3

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