Technical documentation

en

Technical documentation

Hydraulic excavator / Material handler

R 924 Compact

from serial number 14749

Document identification
Order number: 10359401
Issue: 09 / 2012
Valid for: R 924 Compact from serial number 14749
Author: LFR - Technical documentation department
LFR / en / Issue: 09 / 2012

Product identification
Manufacturer: Liebherr-France SAS
Type: 198 / 911
Conformity: CE

R 924 Compact
copyright by

MJFCIFSS
 Technical documentation

Address
Liebherr-France SAS
2 avenue Joseph Rey, B.P. 90287
F - 68005 Colmar Cedex

Book data

Book number :
. . . . . . . . . . . . . . . .
Book owner :
. . . . . . . . . . . . . . . .

LFR / en / Issue: 09 / 2012

R 924 Compact
copyright by

MJFCIFSS
Service Manual

1 General information

2 Tools

3 Technical data / Maintenance guidelines

4 Engine

5 Coupling / Splitterbox

6 Hydraulic system

7 Hydraulic components

8 Electrical system

9 Swing gear

10 Swing ring

11 Travel gear

12 Track components

13

14

15

16 Options

17 Cab / Heater / Air conditioning system

18 Central lubrication

copyright by

MJFCIFSS
 Service Manual

copyright by

MJFCIFSS
Service Manual

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

Symbols used in this manual

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

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

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

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

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

Signification of specific punctuation marks in descriptions

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

About the contain of this Service Handbuchs

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

MJFCIFSS
 Service Manual

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

Structuration of our Service Manuals

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

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

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

MJFCIFSS
 Technical documentation

Group 1: General Information

Safety instructions .................................................................................................................1.10

1 Meaning of the symbols in this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10.1
2 Use in accordance with the regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10.2
3 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10.2
4 Servicing the machine safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10.12

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

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

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

1 Application and purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.22.1
2 Requirements / description of procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.22.1
2.1 Tightening with assembly wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.22.2
2.2 Tightening with hydraulic assembly device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.22.4
3 Torque table - Status 13.01.2009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.22.7
3.1 Tightening with assembly wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.22.7
3.2 Tightening with hydraulic assembly device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.22.9

Assembly instruction for piston rod bearings with external threads................................1.24

1 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.24.1
1.1 Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.24.1
2 Tightening torques for factory standard (02.07.2008) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.24.3

Lubricants and operating fluids............................................................................................1.50

R 924 Compact for serial number from 14 749 to 23 158
1 General instructions for the changing of lubricants and other process chemicals. . . . . . . . . . . . . . . . 1.50.1
2 Lubricants table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50.1
3 Fuels, lubricants and process chemicals table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50.2
4 Specifications for fuels, lubricants and process chemicals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50.3
4.1 Lubricating oil for the diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50.3
4.2 Oil change intervals for turbocharged engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50.4
5 Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50.4
5.1 Permitted fuel specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50.4
5.2 Lubricity / Sulphur content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50.4
5.3 Improving Diesel fuel fluidity in cold climates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50.5
LFR / en / Issue: 03 / 2010

6 Hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50.5

6.1 Moneral oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50.5
6.2 Environmentally friendly hydraulic fluids (also called «Bio oils» - bio degradable oils-) . . . . . . 1.50.6
7 Monitoring of hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50.6
7.1 Monitoring of hydraulic oil in normal use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50.6
7.2 Monitoring of hydraulic oil used for dust intensive applications. . . . . . . . . . . . . . . . . . . . . . . . . 1.50.7
7.3 Instructions for the reduction of the contamination of the hydraulic oil in machines . . . . . . . . . 1.50.7
8 Gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50.7
9 Grease and other lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50.8

R 924 Compact 1.00.1

copyright by

MJFCIFSS
 Technical documentation

10 Coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50.8
10.1 Anti-corrosion and antifreeze agents with DCA (ID no. 8503890 - 30 I container) . . . . . . . . . . 1.50.8
10.2 Coolants with DCA 4 (Diesel Coolant Additives) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50.9
10.3 Anti-corrosion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50.9
10.5 New filling of the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50.11
10.6 Change interval of the DCA 4 water-filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50.11
10.7 Fresh water guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50.11

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

R 924 Compact from serial number 23 159
1 General information on changing lubricants and operating fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.51.1
2 Lubricant chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.51.1
3 Fuels, lubricants and process chemicals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.51.2
4 Diesel fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.51.3
4.1 Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.51.3
4.2 Sulphur content of diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.51.3
4.3 Diesel fuels for operation at low temperatures (winter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.51.4
4.4 Diesel fuels with the LIEBHERR Particles filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.51.4
5 Lubricating oil for the diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.51.4
5.1 Viscosity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.51.4
5.2 Lubricating oil change intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.51.5
6 Coolant for the diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.51.6
6.1 General recommandations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.51.6
6.2 Water quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.51.6
6.3 Mixting ratio for coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.51.7
6.4 Permitted corrosion inhibitors / antifreeze agent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.51.7
6.5 Permitted premixed coolants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.51.8
6.6 Permitted corrosion inhibitors without antifreeze agent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.51.8
7 Hydraulic liquids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.51.9
7.1 Hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.51.9
7.2 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.51.10
7.3 Warm-up instruction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.51.11
7.4 Biodegradable hydraulic oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.51.11
7.5 Monitoring, filter change and oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.51.12
7.6 Instructions for the reduction of the contamination of the hydraulic oil in machines . . . . . . . . 1.51.13
8 Lubricating grease and other lubricants. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.51.14

LFR / en / Issue: 03 / 2010

1.00.2 R 924 Compact

copyright by

MJFCIFSS
 Technical documentation Safety instructions
Meaning of the symbols in this manual

Group 1: General Information

1.10: Safety instructions

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

1 Meaning of the symbols in this manual

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

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

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

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

– This symbol identifies a listing.

• This symbol identifies a sub-listing.

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

The machine operator or the maintenance personnel must first fulfil the precondition described,
LFR / en / Issue: 03 / 2010

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

R 924 Compact 1.10.1

copyright by

MJFCIFSS
Safety instructions Technical documentation
Use in accordance with the regulations

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

2 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, while
the transportation of the l oad itself usually takes place without moving the machine. Moving the
machine when it is car rying a load must be carried out wh ile observing the appropriate safety
measures (see section "Notes for safe working").
– Machines used for hoisting are subject to specific conditions and must be fitted with the stipulated
safety devices (see section “Hoisting work”).
– Machines used underground (deep mining and tunnel construction) must be e quipped with ex-
haust gas reducing equipment (e.g. diesel particle filter). Always comply with the statutory regu-
lations applicable at the location of operation.
– Special tasks require special attachments and possibly also special safety dev ices. This equip-
ment may only be attached to the machine and used with the explicit consent of and according to
the instructions of the manufacturer of the basic machine.
– Any other use, in particular transporting persons or working in explosive atmospheres or contam-
inated environments is not deemed to be in accordance with regulations. The manufacturer is not
liable for any 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 deemed
to be appropriate use in accordance with regulations.

3 Safety Instructions

General safety instructions

– Please familiarize yourself with the operating instructions before starting up the machine.
– Ensure that you have obtained, read and understood any additional instructions relating to special
accessories for the machine.
– Only specifically authorized persons may operate, maintain or repair the machine. The legal min-
imum age is to be adhered to.
– Only employ trained or appropriately instructed personnel. Clearly establish which personnel are
responsible for operating, setting up, maintaining and repairing the machine. Give personnel the
power to refuse to carry out unsafe instructions by third parties. This also applies in relation to traf-
fic regulations.
– Only permit apprentices and personnel who are in training or who have only general training to
operate on the machine under the constant supervision of an experienced member of staff.
– As far as possible, monitor personnel to ensure that they are adhering to safe working practices,
are aware of risks and are observing the operating instructions.
LFR / en / Issue: 03 / 2010

– Always wear safe work clothes when you are working on or with the machine. Avoid wearing rings,
wrist watches, ties, scarves, open jackets, baggy clothing etc... There is a risk of injury from, for
example, getting caught up or being drawn in.
– For specific jobs wear individual protective equipment (protective goggles, safety helmets, safety
shoes and gloves, reflective vests and ear protection etc...)..
– Ensure that you obtain information on any special safety regulations for the job site from the site
foreman.
– Always tilt up the safety lever before leaving the operator’s seat.

1.10.2 R 924 Compact

copyright by

MJFCIFSS
 Technical documentation Safety instructions
Safety Instructions

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

Avoidance of crushing and burns

– Do not work beneath the equipment if it is not safely positioned on the ground or supported.
– Do not use any damaged or insufficient load-bearing take-up materials, such as ropes or chains.
– Wear work gloves when working with wire cables.
– When working on the equipment, never use your fingers to locate bores; use the correct punch for
the procedure.
– Ensure that no objects enter the fan when the engine is on. The fan will eject or destroy these
objects and will itself be damaged.
– The engine cooling system is hot and pressurized when near operating temperature. Avoid com-
ing into contact with coolant carrying parts. There is a risk of sustaining burns.
– Only check the coo lant when the sealing cap of the expansion container has cooled to a p oint
where it is possible to touch it. Then turn the cap carefully to let off the overpressure.
LFR / en / Issue: 03 / 2010

– Engine and hydraulic oil, as well the engine exhaust system are hot when near operating temper-
ature. Avoid coming into contact with hot oil or oil-bearing parts and with parts of the exhaust sys-
tem.
– Wear protective goggles and gloves when working on the battery. Avoid sparks and naked flames.
– Never permit the grab to be guided by hand by auxiliary personnel.
– When reaching into the engine compartment, always secure the side doors against unintentional
closing by positioning the supports provided for this purpose.

R 924 Compact 1.10.3

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Safety instructions Technical documentation
Safety Instructions

– Never lay under the machine if it is raised with work equipmen t 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 vici nity of he at 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 mac hine, this will facilitate fighting a
possibly upcoming fire.

Bringing the machine safely into service

– Carry out a careful inspection tour around the machine each time before starting it.
– Ensure that no one, except an authorized person, is in the work and movement area of the ma-
chine.
– 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 lock s 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
LFR / en / Issue: 03 / 2010

– Proceed with the the same precautions to climb up or down onto the machine, as to instal yourself.
– When getting up or down, position the machine on even, 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.

1.10.4 R 924 Compact

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 Technical documentation Safety instructions
Safety Instructions

– Ensure that steps, ladders and hand-rails (grips) are in good condition. In particular, you should
ensure 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 be
dusted with talc or silicon at least every two months or more often if required. The door hinges and
locks should be greased regularly.
– Face the machine when getting in or out and always use three-point support, i.e. two hands and
one foot or two feet and one hand must always be in contact with the access system at the same
time.
– If you are able to reach the door handle with your free hand, open the doors before you climb any
higher. External influences, such a s wind, can make it m ore difficult to open doors. Because of
this, always use your hand for control when opening doors. Ensure that the door is latched open
to prevent it slamming open and shut.
– In case of bad weather conditions, be particulary vigilant to realise the climbing and descent from
the cab with the best safety conditions, and do or give the instuctions to the execution of prior
preparations 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 the
machine.
– If you wish to work with the door open, it is necessary to fasten your safety belt. If unavailable, let
it be instaled before working with the door open.
– For the excavators mounted on a support (pontoon, chariot,...), refer to the operator’s manual of
the complete machine for a safely getting up.

Adjusting the operator’s standing position

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

Protection from vibration - seat adjusting

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

Utilisation in confined spaces

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

Starting the machine safely

– Before starting, check all control lamps and instruments for correct function, place all operator’s
LFR / en / Issue: 03 / 2010

controls in Neutral and tilt the safety lever up.

– Before starting, sound the horn briefly to alert people in the vicinity of the machine.
– Only start the machine from the driver’s seat.
– In the absence of any other instructions, start the engine in accordance with the regulations given
in the operating instructions.
– Tilt the safety lever down and then test all display and checking devices.
– In enclosed spaces, only allow the engine to run when there is adequate ventilation. If necessary,
open doors and windows to ensure sufficient fresh air supplies.

R 924 Compact 1.10.5

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Safety instructions Technical documentation
Safety Instructions

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

Safely getting down

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

Working safely with the machine

– Before you start working, acquaint yourself with the special features of the job site and any special
precautions and warning signals. Examples of particular work environments would be on-site or
traffic obstructions, the load-carrying capacity of the ground and any requirements to make the job
site safe from public use.
– Always maintain a safe distance from overhangs, edges, slopes and unsafe ground.
– Be particularly careful in conditions of reduced visibility and changeable ground conditions.
– Familiarize yourself with the location of power lines on the job site and take particular care when
working near them. If necessary, inform the responsible authorities.
– Maintain a safe distance from electrical aerial lines. Do not allow the equipment to come near ca-
LFR / en / Issue: 03 / 2010

bles when working near electrical aerial lines. Risk of fatality! Inform yourself about required safety
distances.

1.10.6 R 924 Compact

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 Technical documentation Safety instructions
Safety Instructions

– 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 acco rdance with the regulations given in th e
operating instructions.
– Never leave the driver’s seat while the machine is moving.
– Never leave the machine unattended while the engine is running.
– The machine must be positioned, moved and operated in such a way that it is stable and that there
is no danger of overturning. Only known loads may be moved with the equipment; this applies par-
ticularly when using the grab.
– Position the upper structure in the longitudinal direction when moving and hold the load as close
to the ground as possible.
EXCEPTION: “Safe u se when loading and unloading (particularly when loading and unloading
wood)” on page 9.
– Adjust your driving speed to suit local conditions.
– Avoid any working movements which may tip the machine. Should the machine start to tip or slide
sideways, however, turn the upper structure to face downhill and lower the equipment at the same
time.
– As far as possible, work downhill or uphill and not side on to the slope.
– Drive safely on stony, sleepery or inclined ground
– Only drive downhill at the permitted speed or you could lose control of the machine.
– Always shift down to a lower running step before a slope. When doing this, the diesel engine must
run at maximal speed and the speed may only be reduced using the accelerator pedals.
– Load an occupied truck only if all safety requirements are fulfilled, notably in order to protect the
truck operator.
– For demolition work, digging and crane operations etc., always use protective devices specifically
designed for the purpose.
– For terrain which is difficult to gain an overview of and whenever necessary, ask for the assistance
of a spotter. Only permit one person to give you signals.
– Only permit experienced personnel to attach loads and give signals to the machine operator. The
spotter must be positioned within the visual range of the operator or be in voice contact with him.
– Depending on the equipment combination, there is a risk of collision between the work tool and
LFR / en / Issue: 03 / 2010

the cab, the cab protection or the boom cylinders. The greatest degree of care must be taken to
avoid damage when the hoe teeth come within this area.
– Depending on the equi pment combination, there is a ris k of collision between the lift ring of the
attachment and the cab or the cab protection. Before operating, ensure that there is no risk of col-
lision, especially on excavator with cab elevation. If necessary remove the lift ring.

R 924 Compact 1.10.7

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Safety instructions Technical documentation
Safety Instructions

– In case of a thunderstorm :
• lower the attachment to the ground and if possible anchor the digging tool into the soil.
• leave the cab and move away from the machine before the storm breaks out. Otherwise, you
must stop the excavator, turn off the radio and keep inside the closed cab until the end of the
storm.
– Auxiliary control units can have various functions. Always check their functions when starting up
the machine.
– Stop the swinging motion of the uppercarriage when lowering the attachment into a ditch without
striking the attachment on the ditch walls.
– Inspect the machine for damage if the attachment has been swung into a wall or any other obsta-
cles.
– Applications in which the attachme nt is to be used to strike the material being extracted are not
permitted, 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 are
required.
– Do not attach too large bucket or bucket with side cutters or that are during operations with rocky
material. This would prolong the work cycle s and may lead to d amage to the bucket as well a s
further machine components.
– With the 2x45° offset articulation, the offset position may only be employed if the working tool or
the attachment does not touch the material.
– Operation of the offset articulation to drill into the material is not permitted.
– Do not lift th e 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 fo rbidden 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 th e same
place. Change the breaking point. Too long uninterrupted operation of the hydraulic hammer leads
LFR / en / Issue: 03 / 2010

to an unnecessary overheating of the hydraulic oil.

– Do not use the drop force of the hydraulic hammer to break stone or other materials. Do not move
obstacles with the hydraulic hammer. Misuse of this nature would damage both the hammer and
the machine.
– Do not use the hydraulic hammer to lift objects

1.10.8 R 924 Compact

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 Technical documentation Safety instructions
Safety Instructions

Safe use when loading and unloading (particularly when loading and unload-
ing wood)
– According to use, it can be necessary when working with a grab to move with the equipment raised
and the load lifted up; this applies, for example, when loading and unloading wood.
– Here, the centre of gravity of the machine will be displaced upwards in the vertical direction. The
driving characteristics of the mach ine will thus be influenced persistently, e.g. through reduction
of the dynamic stability.
The following instructions are therefore to be observed at all times:
• Adjust ve hicle h andling to suit the alter ed machine ch aracteristics a nd 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 the re is a risk of
objects falling from above.
• Only the maximum permissible load may be taken up using the grab.
– NOTE: The weight of a bsorbent materials, such as logs, is de pendent on length, diameter and
specific weight. The influencing variables present in a natural product, such as moisture, must be
noted.
– Working procedures when using machines with grabs re quire t he m achine operator to r eceive
special instruction and training.
– Use as part of the work process is only permitted when the machine operator has sufficient train-
ing and practical experience.

Safe use of machines with tower elevation

– Due to the tower elevation, the centre of gravity of the machine will be displaced upwards in the
vertical direction. The driving and work characteristics of the machine will thus be influenced per-
sistently, e.g. through reduction of the dynamic stability.
– Due to the heightened centre of gravity, the machine must be aligned horizontally before use. In
horizontal alignment, the centre of gravity of the upper structure is over the centre of the under-
carriage, which reduces the risk of tilting.
– The machine can still sway and tilt despite being aligned!
The following instructions are therefore to be observed at all times:
When moving the machine:
• Rotate the upper structure parallel to the undercarriage undercarriage (transport position).
• Draw the equipment as close as possible to the machine.
• Only at this point may the support feet be retracted and the machine moved.
• Moving with loads is not permitted.
• Check the terrain to be covered to ensure that the ground is solid and even. Potholes and une-
LFR / en / Issue: 03 / 2010

ven surfaces jeopardize the stability of the machine.

• Adjust vehicle handling to suit the altered machine characteristics (high centre of gravity) and
environmental conditions.
• Reduce your speed to prevent the need for sudden braking and steering manoeuvres.
• Avoid sudden speed changes, such as braking, accelerating and changing direction.
• Ascending gradients and obstacles may only be approached in the longitudinal direction in order
to prevent unacceptable banking of the machine.
• Special care should be taken when driving through narrow passages - drive slowly!

R 924 Compact 1.10.9

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MJFCIFSS
Safety instructions Technical documentation
Safety Instructions

When loading and unloading:

• The m achine m ust be sup ported a nd aligned h orizontally b efore m oving (slewing) the up per
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 tec hniques: Speed, steeri ng, brakes, c ontrolling the mac hine’s control elements
when driving and working.
– To a la rge extent, th e ma chine o perator de termines the vibr ational loa ds since he se lects the
speed, gearbox ratio, working method and route himself.
This means that there is a wide range of different vibrational loads for the same machine type.
Whole-body vibrational load for the machine operator can be reduced if the following recommenda-
tions are observed:
– Select suitable machines, equipment parts and auxiliary devices for each part of the job.
– Use a machine that has a suitable seat (i.e. for earth-moving machinery such as hydraulic exca-
vators, this should be a seat which corresponds with EN ISO 7096).
– Keep the seat in good condition and adjust it as follows:
• The seat and its damping action should be adjusted depending on the weight and height of the
operator.
• Check the seat’s damping action and adjustment mechanisms regularly and ensure that these
seat characteristics remain as per the seat manufacturer’s instructions.
– Check the maintenance status of the machine, particularly with respect to: tyre pressure, brakes,
steering, mechanical connections etc.
– Do not steer, brake, accelerate, shift gears, move or load the machine’s equipment jerkily.
– To reduce vibrational load, adjust the machine speed to suit the route as follows:
• Reduce speed when driving on difficult terrain;
• Drive around obstacles and avoid driving on very difficult terrain.
– Keep the terrain on which the machine is working and driving in good condition:
• Remove large stones and obstacles;
• Fill in ruts and holes;
• Have machines ready to prepare and maintain suitable ground conditions and calculate in suf-
ficient time to carry out any work required.
– Drive longer distances (e.g. on public roads) at an appropriate (medium) speed.
– Use special auxiliary systems (if available) which reduce vibration for machines that are driven fre-
quently.
If such auxiliary systems are not available, regulate speed to avoid "oscillating" the machine.
LFR / en / Issue: 03 / 2010

Towing the machine safely

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

1.10.10 R 924 Compact

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 Technical documentation Safety instructions
Safety Instructions

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

Attaching and removing equipment parts safely

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

Removing and installing equipment bolts safely

– If possible, always use a hydraulic bolt press to press out the equipment’s bolts.
– If you have to remove a bolt using a sledge-hammer, a driving punch and a bore hole conductor
held by another person must be used.
– To drive in a bolt, screw the drive screws provided in the toolbox into the bolt's threaded hole and
only hammer these screws.
– When installing bolts locked by means of castle nuts and cotter pins, first drive the bolt to the stop,
LFR / en / Issue: 03 / 2010

then screw the castle nut by hand until contact and then only pull it far enough to push in the cotter
pin.

Transporting the machine safely

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

R 924 Compact 1.10.11

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Safety instructions Technical documentation
Servicing the machine safely

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

4 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 defines
precisely 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,
LFR / en / Issue: 03 / 2010

wrist watches, ties, scarves, open jackets, baggy clothing etc... There is a risk of injury from, for
example, getting caught up or being drawn in.
Protective goggles, safety helmets, safety shoes and gloves, reflective vests and ear protection
etc. 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 injection
pumps (Unit Pumps UP) while the diesel engine is running.
– Do not permit unauthorised persons to approach the machine during maintenance work.

1.10.12 R 924 Compact

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MJFCIFSS
 Technical documentation Safety instructions
Servicing the machine safely

– 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 engine
switched off.
– For some machines, the only one position which enables a secured access to every maintenance
locations on the uppercarriage, is when the uppercarriage is aligned with the undercarriage so that
the sprockets locate at the back-end.
The ladder situated on the undercarriage only corresponds with the uppercarriage’s access when
the 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 the
main 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, fue l 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 first
two 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 following
recommendations :
• the distance between the nozzle and the surface to be cleaned must be no lower than 20 inches
LFR / en / Issue: 03 / 2010

• 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 924 Compact 1.10.13

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MJFCIFSS
Safety instructions Technical documentation
Servicing the machine safely

– After cleaning:
• remove all covers completely.
• check all fue l, engine o il a nd 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.

Sight field
– Mirrors, which were possibly removed for the transport, must be inevitably reinstalled and correct-
ly adjusted before the initial set-up of the machine.
– Regularly check that the interior and exterior mirrors are correctly adjusted.
– Control the surroundings, and particularly the nearness area of the machine, during operation or
when travelling.
– Mirrors are installed on the machine :
• on the left on the cab to check the left side of the machine.
• on the front left on the cab to check the front side of the machine.
• on the right on the uppercarriage to check the right side of the machine.
• above the counterweight to check the rear side of the machine; on some machines, this mirror
is replaced or completed with a camera.
– At ea ch ex tension, co nstruction or change on th e m achine, th e sig ht con dtions m ust b e m ain-
tained. These conditions must otherwise be checked according to ISO 5006.
– Mirrors must be cleaned at least at daily intervals.
– Damaged mirrors must be immediately replaced.
– The site has to be organised so that the dangers due to a restricted sight field are minimized, par-
ticularly for machines with an operating weight which is superior to 40 tons.

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 be
checked regularly for cracks, loose connections or other visible damage to maintain operational
safety.
– In order to be able to check for cracks, it is essential that the machine is kept clean and cleaned
regularly.
– 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 equipment
in longitudinal and cross direction for variable loads. Current accident prevention regulations must
be adhered to.
– Special care must be taken when testing load-bearing components, particularly:
• the st eel ch assis m embers an d axle a nd tr ansmission m ountings, th e su pport, the lo wer r im
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.
LFR / en / Issue: 03 / 2010

• 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 pe netration test
should be carried out as a crack test on areas which do not have good v isibility, such as the rim
bearing support, in order to increase testing safety.

1.10.14 R 924 Compact

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MJFCIFSS
 Technical documentation Safety instructions
Servicing the machine safely

– Any da mage fo und mu st be rectified imm ediately. Weld ing wor k on lo ad-bearing pa rts of th e
earth-moving machinery, loading devices and transport devices may only be carried out by trained
specialist personnel and only in accordance with the accepted rules of welding engineering. In
case 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 is
voided.
– 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 negative
terminal first and reconnect it last.
– Nevertheless if welding repair should be done on components which may co ntain inflammable
gases (welded counterweight, hydraulic tank, fuel tank, …), these components must be previously
and 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 welding
current will not run through the swing ring, joints, gears, bushings, rubber parts and seals

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 secure
them on lifting devices them so that they do not present a risk. On ly use suitable and correctly
functioning 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 lo ads and give signals to the crane operator. The
spotter 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.
LFR / en / Issue: 03 / 2010

– Pneumatic cylinders do not have to be used as handles. Open doors and covers carefully, so that
pneumatic 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). Prevent
metal touching metal when doing this.
– For safety r easons, n ever op en an d r emove a track ch ain un less having pr eviously totally re-
leased the pretension of the chain tensioning unit.
– Never lay under the machine if it is ra ised with work equipment and has not been securely sup-
ported with wooden beams.

R 924 Compact 1.10.15

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MJFCIFSS
Safety instructions Technical documentation
Servicing the machine safely

– 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 specialist
personnel.
– 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 start
key in contact position and with the safety lever down into its lowest position, you must operate all
pilot control devices (joystick and pedals) in all directions in order to reduce the actuating and dy-
namic pr essures in th e work circ uits. Yo u m ust th en re duce th e int ernal ta nk pressure a s 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 cables
rectified by personnel.
– Only use original fuses with approved current strength.
– 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 personnel
or 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 white
safety 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 disconnect
them briefly. Insulate adjacent live parts.
– Disconnect the battery before working on the electrical system or car rying out any electric arc
welding on the machine.
First disconnect the negative, then the positive pole. When reconnecting, proceed in the reverse
order.

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.
LFR / en / Issue: 03 / 2010

– 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 by
mechanical working. RISK OF EXPLOSION!
– Only charge the hydraulic accumulator with nitrogen. There is a RISK OF EXPLOSION if oxygen
or 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.

1.10.16 R 924 Compact

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MJFCIFSS
 Technical documentation Safety instructions
Servicing the machine safely

– 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).
– 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 hose
ends and should only be tightened afterwards.
• When tightening the flange on high-pressure hoses and sheathed cables with bent fittings, the
side with the bent fitting must always be tightened first and then the side with the straight fitting
tightened 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),
LFR / en / Issue: 03 / 2010

check before initial start-up that there are no chafing areas in the entire area of movement.

R 924 Compact 1.10.17

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MJFCIFSS
Safety instructions Technical documentation
Servicing the machine safely

LFR / en / Issue: 03 / 2010

1.10.18 R 924 Compact

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

1.20: Tightening torques

1 Tightening torques for screws with metric coarse and fine thread
(Liebherr Standard WN 4037)
The assembly preloads FM given in the table, show a 90% utilisation of the screw extension limit
  0 2  . The tightening torques MA are calculated from FM.
Involved screws are those with the following surface finish:
– black-chrome finished or phosphatised
– galvanized
– DAKROMET 500
– Screws an d nu t withou t r ework or sur face trea tment a nd u ngreased, fo r me an fr iction fa ctor
µ=0,12.

Metric coarse thread Metric fine thread

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

8.8 4050 2,8

M4 10.9 6000 4,1
12.9 7000 4,8
8.8 6600 5,5
M5 10.9 9700 8,1
12.9 11400 9,5
8.8 9400 9,5
M6 10.9 13700 14,0
12.9 16100 16,5
8.8 13700 15,5
M7 10.9 20100 23,0
12.9 23500 27,0
8.8 17200 23,0 8.8 18800 24,5
M8 10.9 25000 34,0 M8×1 10.9 27500 36
12.9 29500 40,0 12.9 32500 43
8.8 24800 36
M9×1 10.9 36500 53
12.9 42500 62
8.8 27500 46,0 8.8 31500 52
M10 10.9 40000 68,0 M10×1 10.9 46500 76
12.9 47000 79,0 12.9 54000 89
8.8 29500 49
M10×1,25 10.9 43000 72
12.9 51000 84
LFR / en / Issue: 03 / 2010

8.8 40000 79,0 8.8 45000 87

M12 10.9 59000 117,0 M12×1,25 10.9 66000 125
12.9 69000 135,0 12.9 73000 150
8.8 42500 83
M12×1,5 10.9 62000 122
12.9 73000 145
8.8 55000 125,0 8.8 61000 135
M14 10.9 80000 185,0 M14×1,5 10.9 89000 200
12.9 94000 215,0 12.9 104000 235

R 924 Compact 1.20.1

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

Metric coarse thread Metric fine thread

8.8 75000 195,0 8.8 82000 205
M16 10.9 111000 280,0 M16×1,5 10.9 121000 300
12.9 130000 330,0 12.9 141000 360
M18 8,8 94000 280 M18×1,5 8,8 110000 310
10,9 135000 390 10,9 157000 440
12,9 157000 460 12,9 184000 520
M18×2 8,8 102000 290
10,9 146000 420
12,9 170000 490
M20 8,8 121000 390 M20×1,5 8,8 139000 430
10,9 173000 560 10,9 199000 620
12,9 202000 650 12,9 232000 720
M22 8,8 152000 530 M22×1,5 8,8 171000 580
10,9 216000 750 10,9 245000 820
12,9 250000 880 12,9 285000 960
M24 8,8 175000 670 M24×1,5 8,8 207000 760
10,9 249000 960 10,9 295000 1090
12,9 290000 1120 12,9 346000 1270
M24×2 8,8 196000 730
10,9 280000 1040
12,9 325000 1220
M27 8,8 230000 1000 M27×1,5 8,8 267000 1110
10,9 330000 1400 10,9 381000 1580
12,9 385000 1650 12,9 445000 1850
M27×2 8,8 255000 1070
10,9 365000 1500
12,9 425000 1800
M30 8,8 280000 1350 M30×1,5 8,8 335000 1540
10,9 400000 1900 10,9 477000 2190
12,9 465000 2250 12,9 558000 2560
M30×2 8,8 321000 1490
10,9 457000 2120
12,9 534000 2480
M33 8,8 350000 1850 M33×1,5 8,8 410000 2050
10,9 495000 2600 10,9 584000 2920
12,9 580000 3000 12,9 683000 3420
M33×2 8,8 395000 2000
10,9 560000 2800
12,9 660000 3300
M36 8,8 410000 2350 M36×1,5 8,8 492000 2680
10,9 580000 3300 10,9 701000 3820
12,9 680000 3900 12,9 820000 4470
LFR / en / Issue: 03 / 2010

M36×3 8,8 440000 2500

10,9 630000 3500
12,9 740000 4100
M39 8,8 490000 3000 M39×1,5 8,8 582000 3430
10,9 700000 4300 10,9 830000 4890
12,9 820000 5100 12,9 971000 5720
M39×3 8,8 530000 3200
10,9 750000 4600
12,9 880000 5300

1.20.2 R 924 Compact

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

2 Tightening torques of screw-in studs (Ermeto)

Mating material: steel (grease well before inserting!)

Type with sealing edge Type with EOLASTIC seal

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

Light-duty series L
GE 06 LM A 3 C M 10×1 18 GE 06 LM ED A 3 C M 10×1 18
GE 06 LR A 3 C G 1/8 A 18 GE 06 LR ED A 3 C G 1/8 A 18
GE 08 LM A 3 C M 12×1,5 30 GE 08 LM ED A 3 C M 12×1,5 25
GE 08 LR A 3 C G 1/4 A 35 GE 08 LR ED A 3 C G 1/4 A 35
GE 10 LM A 3 C M 14×1,5 45 GE 10 LM ED A 3 C M 14×1,5 45
GE 10 LR A 3 C G 1/4 A 35 GE 10 LR ED A 3 C G 1/4 A 35
GE 12 LM A 3 C M 16×1,5 65 GE 12 LM ED A 3 C M 16×1,5 55
GE 12 LR A 3 C G 3/8 A 70 GE 12 LR ED A 3 C G 3/8 A 70
GE 15 LM A 3 C M 18×1,5 80 GE 15 LM ED A 3 C M 18×1,5 70
GE 15 LR A 3 C G 1/2 A 140 GE 15 LR ED A 3 C G 1/2 A 90
GE 18 LM A 3 C M 22×1,5 140 GE 18 LM ED A 3 C M 22×1,5 125
GE 18 LM A 3 C M 22×1,5 140 GE 18 LM ED A 3 C M 22×1,5 125
GE 18 LR A 3 C G 1/2 A 100 GE 18 LR ED A 3 C G 1/2 A 90
GE 22 LM A 3 C M 22×1,5 140 GE 22 LM ED A 3 C M 26×1,5 180
GE 22 LR A 3 C G 3/4 A 180 GE 22 LR ED A 3 C G 3/4 A 180
GE 28 LM A 3 C M 33×2,0 340 GE 28 LM ED A 3 C M 33 x 2,0 310
GE 28 LR A 3 C G1A 330 GE 28 LR ED A 3 C G1A 310
GE 35 LM A 3 C M 42×2,0 500 GE 35 LM ED A 3 C M 42×2,0 450
GE 35 LR A 3 C G 1 1/4 A 540 GE 35 LR ED A 3 C G 1 1/4 A 450
GE 42 LM A 3 C M 48×2,0 630 GE 42 LM ED A 3 C M 48×2,0 540
GE 42 LR A 3 C G 1 1/2 A 630 GE 42 LR ED A 3 C G 1 1/2 A 540
Heavy-duty series S
GE 06 SM A 3 C M 12×1,5 35 GE 06 SM ED A 3 C M 12×1,5 35
GE 06 SR A 3 C G 1/4 A 55 GE 06 SR ED A 3 C G 1/4 A 55
GE 08 SM A 3 C M 14×1,5 55 GE 08 SM ED A 3 C M 14×1,5 55
GE 08 SR A 3 C G 1/4 A 55 GE 08 SR ED A 3 C G 1/4 A 55
GE 10 SM A 3 C M 16×1,5 70 GE 10 SM ED A 3 C M 16×1,5 70
GE 10 SR A 3 C G 3/8 A 90 GE 10 SR ED A 3 C G 3/8 A 80
GE 12 SM A 3 C M 18×1,5 110 GE 12 SM ED A 3 C M 18×1,5 90
GE 12 SR A 3 C G 3/8 A 90 GE 12 SR ED A 3 C G 3/8 A 80
LFR / en / Issue: 03 / 2010

GE 14 SM A 3 C M 20×1,5 150 GE 14 SM ED A 3 C M 20×1,5 125

GE 14 SR A 3 C G 1/2 A 150 GE 14 SR ED A 3 C G 1/2 A 115
GE 16 SM A 3 C M 22×1,5 170 GE 16 SM ED A 3 C M 22×1,5 135
GE 16 SR A 3 C G 1/2 A 130 GE 16 SR ED A 3 C G 1/2 A 115
GE 20 SM A 3 C M 27×2,0 270 GE 20 SM ED A 3 C M 27×2,0 180
GE 20 SR A 3 C G 3/4 A 270 GE 20 SR ED A 3 C G 3/4 A 180
GE 25 SM A 3 C M 33×2,0 410 GE 25 SM ED A 3 C M 33×2,0 310
GE 25 SR A 3 C G1A 340 GE 25 SR ED A 3 C G1A 310

R 924 Compact 1.20.3

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

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

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

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

3 Tightening torques of swivelling connections (Ermeto)

Mating material : steel (grease well before inserting!)

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

Light-duty series L
WH / TH06 LR KDS A G 1/8 A 18 WH / TH 06 LM KDS M 10×1 18
3C A3C
WH / TH08 LR KDS A G 1/4 A 45 WH / TH 08 LM KDS M 12×1,5 45
3C A3C
WH / TH10 LR KDS A G 3/8 A 45 WH / TH 10 LM KDS M 14×1,5 55
3C A3C
WH / TH12 LR KDS A G1/2 A 70 WH / TH 12 LM KDS M 16×1,5 80
3C A3C
WH / TH15 LR KDS A G3/4 A 120 WH / TH 15 LM KDS M 18×1,5 100
3C A3C
WH / TH18 LR KDS A G1 A 120 WH / TH 18 LM KDS M 22×1,5 140
3C A3C
WH / TH22 LR KDS A G 1 1/4 A 230 WH / TH 22 LM KDS M 27×2,0 320
3C A3C
WH / TH28 LR KDS A G 1 1/4 A 320 WH / TH 28 LM KDS M 33 x 2,0 360
3C A3C
WH / TH35 LR KDS A G 1 1/4 A 540 WH / TH 35 LM KDS M 42×2,0 540
3C A3C
WH / TH42 LR KDS A R 1 1/2 A 700 WH / TH 42 LM KDS M 48×2,0 700
3C A3C
Heavy-duty series S
WH / TH 06 SR KDS G 1/4 A 45 WH / TH 06 SM KDS M 12×1,5 45
A3C A3C
WH / TH 08 SR KDS G 1/4 A 45 WH / TH 08 SM KDS M 14×1,5 55
A3C A3C
WH / TH 10 SR KDS G 3/8 A 70 WH / TH 10 SM KDS M 16×1,5 80
A3C A3C
WH / TH 12 SR KDS G 3/8 A 70 WH / TH 12 SM KDS M 18×1,5 100
LFR / en / Issue: 03 / 2010

A3C A3C
WH / TH 16 SR KDS G 1/2 A 120 WH / TH 14 SM KDS M 20×1,5 125
A3C A3C
WH / TH 20 SR KDS G 3/4 A 230 WH / TH 16 SM KDS M 22×1,5 135
A3C A3C
WH / TH 25 SR KDS G1A 320 WH / TH 20 SM KDS M 27×2,0 320
A3C A3C
WH / TH 30 SR KDS G 1 1/4 A 540 WH / TH 25 SM KDS M 33×2,0 360
A3C A3C

1.20.4 R 924 Compact

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

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

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

4 Tightening torques of screw-in studs (Ermeto)

Mating material : steel (grease well before inserting!)

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

VSTI = Hexagon socket plug

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

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

1.22: Installations for pistons and piston nuts by

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

1 Application and purpose

This Liebherr standard applies only to hydraulic cylinders, and in particular to the mounting of pistons
and piston nuts on piston rods from a thread diameter of M42 and greater.
This standard describes the tightening procedure with turning distance and angle.
For threads with dia meters sm aller than M 42, the ap plicable tightening torque is ind icated in the
drawings. The values in the drawings are always binding.

2 Requirements / description of procedure

For the valid torque value number, refer to the drawing. The standard may not be adopted or trans-
ferred to apparently similar geometries.
Use this number to find the applicable turning distance and angle in the torque table (siehe Kap. 3,
”Torque table - Status 13.01.2009” auf Seite 7).
The torque values have been determined empirically and are subject to changes. This standard dif-
ferentiates between two tightening procedures, which are identified with 3-digit and 4-digit numbers
respectively (see chapters 2.1 and 2.2).
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Installations for pistons and piston nuts by hydraulic Technical documentation
Requirements / description of procedure

2.1 Tightening with assembly wrench

This tightening procedure applies to 3-digit tightening numbers.

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

2.1.2 Definitions

Pretightening torque (Mv)

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

Turning distance (4)

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

Turning angle (5)

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

Fig. 1 Torque wrench

A Piston C Assembly wrench

B Torque w rench

When applying the pretightening torque (Mv), the torque wrench (B) must point in the same direc-
tion as the assembly wrench (C). Proceed in the same way to tighten the piston nut, using a suitable
assembly wrench.
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 Technical documentation Installations for pistons and piston nuts by hydraulic
Requirements / description of procedure

Fig. 2 Markings, turning distance, turning angle

1 Markings on the piston and the piston rod thread after application of the
pretightening torque
2 Markings on the piston rod thread
3 Markings on the piston after tightening
4 Turning distance
5 Turning angle
6 Markings on the piston nut and the piston rod thread after application of the
pretightening torque
7 Markings on the piston nut after tightening
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Installations for pistons and piston nuts by hydraulic Technical documentation
Requirements / description of procedure

2.2 Tightening with hydraulic assembly device

This tightening procedure applies to 4-digit tightening numbers.

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

2.2.2 Definitions

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

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

Fig. 3 Torque wrench

A Torque w rench
B Hexagon head
C Torque converter

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

2.2.3 Operation of the assembly device

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

Fig. 4 Operation of the assembly device

A Piston rod
B Piston
C Adapter for piston
D Adapter for piston rod
E Piston nut
F Adapter for piston nut
G Torque converter
H Assembly device
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Installations for pistons and piston nuts by hydraulic Technical documentation
Requirements / description of procedure

Fig. 5 Angle scale

A Dial
B Adjusting screw
C Angle scale

Before tightening, set the dial (A) with the adjusting screw (B) to position 0° on the angle scale (C).
The angle scale indicates the turning angle.
If the opening angle of the assembly device is not sufficient to achieve the prescribed turning angle,
mount the device again for a second tightening process. Note the previously completed angle.
Before continuing the tightening process, set the dial to the last achieved angle value.
Repeat this process as often as necessary to achieve the prescribed turning angle.
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 Technical documentation Installations for pistons and piston nuts by hydraulic
Torque table - Status 13.01.2009

3 Torque table - Status 13.01.2009

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

Piston Piston nut

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

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Installations for pistons and piston nuts by hydraulic Technical documentation
Torque table - Status 13.01.2009

Piston Piston nut

Pretightening Thread M
WN 4121 No Turning Turning
torque [N.m] Turning angle Turning angle [mm]
distance distance
~ [°] ~ [°]
[mm] [mm]
183 200 - - 40 +2 67 68x2
201 200 17 +2 26 16 +1 24 76x2
202 200 26 +2 39 16 +1 24 76x2
203 200 27 +2 41 16 +1 24 76x2
204 200 27 +2 41 16 +1 24 76x2
205 200 13 +2 20 - - 76x2
206 200 25 +2 38 25 +1 38 76x2
207 200 23 +2 35 - - 76x2
208 200 15 +2 22 - - 76x2
209 200 30 +2 45 - - 76x2
231 200 8 +2 11 16 +1 22 85x3
232 200 17 +2 23 16 +1 22 85x3
234 200 22 +2 30 - - 85x3
236 200 15 +2 20 - - 85x3
237 200 19 +2 26 - - 85x3
261 250 20 +2 25 10 +1 12 95x3
265 250 24 +2 29 10 +1 12 95x3
267 250 24 +2 29 - - 95x3
281 250 20 +2 23 13 +1 15 100x3
282 250 25 +2 29 - - 100x3
283 250 25 +2 29 21 +1 24 100x3
284 250 9 +1 10 - - 100x3
301 300 21 +3 22 20 +2 21 110x3
302 300 18 +3 19 20 +2 21 110x3
303 300 20 +3 21 20 +2 21 110x3
304 300 23 +3 24 20 +2 21 110x3
305 300 9 +3 9 - - 110x3
306 300 24 +3 25 - - 110x3
307 300 27 +3 28 - - 110x3
331 400 23 +3 22 20 +2 19 120x3
332 400 11 +3 11 - - 120x3
333 400 27 +3 26 - - 120x3
334 400 20 +3 19 20 +2 19 120x3
335 400 30 +3 29 - - 120x3
336 400 29 +3 28 - - 120x3
LFR / en / Issue: 03 / 2010

501 200 21 +2 30 - - 80x2

531 500 34 +3 28 - - 140x3

1.22.8 R 924 Compact

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 Technical documentation Installations for pistons and piston nuts by hydraulic
Torque table - Status 13.01.2009

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

Piston Piston nut

Pretightening
Thread M
WN 4121 No torque Mv
Turning angle Turning angle [mm]
[N.m]
~ [°] ~ [°]
1000 300 27+1 8+1 240x4
1001 300 18+1 8+1 200x4
1002 300 18+1 8+1 150x4
1003 300 23+1 8+1 170x4
1004 300 21+1 8+1 140x4
1005 300 18+1 8+1 180x4
1006 300 39+1 8+1 150x3
1007
1008
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Installations for pistons and piston nuts by hydraulic Technical documentation
Torque table - Status 13.01.2009

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

1.24: Assembly instruction for piston rod bearings with

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

Scope of application
This factory standard applies exclusively to the assembly of hydraulic cylinders.
For the valid factory standard number, refer to the drawing. The standard may no t be adopted or
transferred to apparently similar geometries.
The torques have been determined empirically and are subject to changes. THe revision and release
dates indicate the latest version of the factory standard.

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

1.1 Definitions

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

Fig. 1 Torque wrench

A Piston C Assembly wrench

B Torque wrench

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

Turning distance:
LFR / en / Issue: 03 / 2010

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.

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

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

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

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

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

2 Tightening torques for factory standard (02.07.2008)

Piston

WN 4122 No. Preload (N.m) Turning

Turning angle
distance
(< °)
(mm)
001
011 50 7 +1 10
016 100 10 +1 12
017 100 10 +1 12
026 100 9 +1 10
027 100 10 +1 11
031 100 8 +1 8
036 100 11 +1 10
037 100 10 +1 9
039
041 150 9 +1 7
046 200 12 +1 10
047
051
052
053 200 25 +1 18
061 200 10 +1 7
091 300 10 +1 5,5
111 300 12 +1 6
151 400 14 +1 6
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Assembly instruction for piston rod bearings with ex- Technical documentation
Tightening torques for factory standard (02.07.2008)

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 Technical documentation Lubricants and operating fluids
General instructions for the changing of lubricants and other process chemicals

1.50: Lubricants and operating fluids

R 924 Compact for serial number from 14 749 to 23 158

1 General instructions for the changing of lubricants and other proc-

ess chemicals

Note!
The filling volumes indicated in the lubricant and process chemical table and in the lubrication sche-
dule in the driver’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 theservice life of the machine. It is veryimportant 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.
 Clean all fill screws, lids and drain plugs and the areas around the 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 ap-
plies 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 es shut down.
 When working inside de engine compartment, always secure the cover and doors against inad-
vertent closing.
 Before refuelling the machine, switch off the engine. Do not smoke or use naked flames.

2 Lubricants table

Description Medium Symbol Classification Viscosity BI *

Diesel engine Engine oil API-CG-4, CF- SAE 5W40 EO 0540

4, SAE 10W30 EO 1030
LFR / en / Issue: 03 / 2010

ACEA E2-96, SAE 10W40 EO 1040

E3-96, E4-98, SAE 15W30 EO 1540
SAE 15W40
CCMC D4, D5

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

Description Medium Symbol Classification Viscosity BI *

Hydraulic tank Engine oil API-CD, CD + SAE 10W EO 10

SF SAE 10W-30 EO 1030
ACEA E1, E3 SAE 10W-40 EO 1040
CCMC D4, D5 SAE 15W-40 EO 1540
Mercedes SAE 20W-20 EO 20
Benz SAE 30W EO 30
226 und 227
227.5, 228.1
und 228.3

Slewing gear me- Engine oil See hydraulic See hydraulic See hy-
chanism (as stop control system control system draulic
brake and as posi- control
tioning slewing bra- system
ke)

Travel gear gear oil API-GL-5 SAE 90 GO 90

MIL-L 2105 B,
C oder D

Pump distribution Gear oil API-GL-5 SAE 90 GO 90

gear MIL-L 2105 C

Track and gearing Grease High pressure Consistency 2 MPG-A

of the slewing gear, grease NLGI class
bearing of the atta- KP2k or EP2
chment

Hinges, joints, locks Engine mo- - - - -

tor

Sealing rubber on Silicone - - - -

doors and paneling spray or tal-
sections cum
powder

Tab. 1 Lubricants table

*BI = Regulation lubricant for construction machines and vehicles according to the German Federation of cons-
truction Industry (see the brochures available at Bauverlag GmbH - Wiesbaden und Berlin, Hinweise
zur Schmier-und Betriebsstofftabelle).

3 Fuels, lubricants and process chemicals table

LFR / en / Issue: 03 / 2010

Description Medium Symbol

Fuel tank Conventional diesel fuel with <= 0,5 % sulphur content

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 Technical documentation Lubricants and operating fluids
Specifications for fuels, lubricants and process chemicals

Description Medium Symbol

Coolant Anti-corrosion and antifreese agent

Filling with DCA 4
BI = SP-C

Windscreen washer Conventional windscreen cleaning agent or denatured al- -

system cohol

Coolant of air-condition- R 134 a -

ning system

Refrigeration oil in a/c PLANETELF PAG SP 10 -

SD 7 H15 compressor ID no. 10017679 (0,25 litre)

Tab. 2 Fuels, lubricants and process chemicals

4 Specifications for fuels, lubricants and process chemicals

4.1 Lubricating oil for the diesel engine

The instructions regarding the lubricating oil for the diesel engine are based on the following classifi-
cation systems:

Classification Specification

API-classification (American Petrol Insti- CG-4, CF-4, CH-4, CI-4 respect the chan-
tute) ge interval of special oil

ACEA (CCMC) - classification (Associa- E2-96 (D4), E3-96 (D5), E4-98

tion des Constructeurs Européens de
l´Automobile)

Tab. 3 Lubricating oil for the diesel engine

Select the oil for the diesel engine according to the following diagram.
LFR / en / Issue: 03 / 2010

Fig. 1 Engine oil for use as a lubricating oil for the diesel engine

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Lubricants and operating fluids Technical documentation
Fuel

4.2 Oil change intervals for turbocharged engines

Operating conditions Sulphur content Oil change interval

of fuel depending on oil quality

CF-4 E3
CG-4 E4
CH-4
CI-4
Temperature normally not max 0.5 % 250 h 500 h
dropping below -10 °C higher than 0.5 % 125 h 250 h
below -10 °C max 0,5 % 125 h 250 h
higher than 0,5 % - 125 h

Tab. 4 Oil change intervals

The oil change intervales of the diesel engine are based on the following criteria:
– First oil and filter change afetr 500 operating hours, if the oil of the first filling was oil of E4
quality
– Subsequent filter changes after 500 operating hours
– Subsequent oil changes depending on the climat, sulphur content of the fuel and oil grade
– If the above number of operating hours is n ot reached within 12 months, change the engine oil
and the oil filter at least once every year.

5 Fuel

5.1 Permitted fuel specifications

The diesel fuels must conform with the minimal requirements regarding to the following fuels specifi-
cations:
DIN EN 590
ASTM D 975 - 89a 1 D und 2 D
Other fuel specifications can be used only after consultation with LIEBHERR diesel engine develop-
ment.

5.2 Lubricity / Sulphur content

In DIN EN 590 is max. 350 mg/kg = max. 0,035 mass% sulphur content.
Fuels with «poor sulphur content», with a sulphur content smaller than 0.05% are not suitable, except
with additives addition. The lubricity of the fuel must be < 460µm in a HFFR test (60°).

Caution!
Fuels with more than 0,5 mass% sulphur, require to halve the oil change interval. Fuels with more
than 1 mass% sulphur are prohibited.
LFR / en / Issue: 03 / 2010

Note!
The ASTM D 975 fuel standard does not specufy that the fuels must undergo a fuel lubricity test. A
written confirmation of compliance must be requested from the fuel supplier. The additives should
be added by teh supplier, who is responsible for the fuel quality. We advise machine operators not
to add any secondary lubricity additives to the fuel.
ASTM D 975 fuels must have a cetane number of minimum 15. A cetane number of more than 50
is preferable, especially at temperatures below 0°C (32°F).

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 Technical documentation Lubricants and operating fluids
Hydraulic oil

5.3 Improving Diesel fuel fluidity in cold climates

As soon as the ouside temperature lowers, diesel fuels form paraffin crystals which amplify the flow
resistance in the fuel filter. This leads to insufficient fuel supply.
In temperate climates, the fluidity at low temperature is guaranteed by the DIN EN 590 until:
0°C / 32°F from 15.04. to 30.09.
-10°C / 14°F from 01.10. to 15.11. and from 1.3. to 14.04.
-20°C / -4°F from 16.11. to 29.02.
When the weather is cold or when the ouside temperatures are lower than -20°C / -4°F, if the fuel is
not fluid enough, we recommand the use of a fuel filter heating.
Other approved fuels :
fuels in conformity with the DIN EN 590 norme until 5% vol. FAME.

Caution!
Supplementation of petrol of gaz is forbidden because of security reasons and also technical
reasons.
Such supplementation is neither compatible with the high pressure nor with the injection system of
your diesel engine. It would lead to engine degradation because of lubrication shortage.

6 Hydraulic oil

6.1 Moneral oil

Use oils meeting one of the below listed recommandations:

Single grade oils: API - CD / CCMC - D4 / ACEA - E1

Mercedes-Benz-recommendations, Page No. 226.0 and
227.0

Multi grade oils: API - CD + SF / CCMC - D5 / ACEA - E3

Mercedes-Benz-recommendations, Page No. 227.5,
228.1 and 228.3

Tab. 5 Recommended oils for hydraulic oil applications

You can choose your engine oil used for hydraulic oil applications according to the following graph:
LFR / en / Issue: 03 / 2010

Fig. 2 Engine oil for hydraulic oil applications

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Lubricants and operating fluids Technical documentation
Monitoring of hydraulic oil

6.1.1 Instruction to heat the engine up

For the temperatures up to 10°C under the given threshold (black bar), follow these instructions:
 After the start up, leave the engine run at about 1 / 2 of its nominal speed.
 Activate the hydraulic cylinders and the hydraulic motors without bringing the cylinders to stop.
Warmup duration: about 10 minutes.
With even colder temperatures: preheat the oil tank before starting up the engine.

6.2 Environmentally friendly hydraulic fluids (also called «Bio oils» - bio degrada-
ble oils-)

Note!
It is absolutely necessary never to mix different brands of environmentally friendly hydraulic fluids
or to mix fluids with mineral oils (see service department information) !

The «environmentally friendly hydraulic fluids» recommanded by LIEBHERR are limited to synthetci
ester based hydraulic fluids with a viscosity according to ISO VG 46.
The first filling is factory-made according to a release list. The use of any other environmentally frien-
dly hydraulic fluids must first be approved by LIEBHERR.
Vegetable based oils may not be used due to unfavorable temperature fluctuations.
The use of derivation filter is required.

7 Monitoring of hydraulic oil

Note!
Environmentally friendly hydraulic oils must be regularly tested by means of an oil analysis. For mi-
neral oils, we recommend carrying out oil analysis at regular intervals. LIEBHERR recommends
contracting WEAR-CHECK top carry out 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

7.1 Monitoring of hydraulic oil in normal use

Fig. 3 Oil sampling from machines in normal use

LFR / en / Issue: 03 / 2010

--- Oil sampling 1 First oil sample

- filter replacement 2 Second oil sample
h Operating hours 3 Subsequent oil samples: every 500 opera-
ting hours

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.

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 Technical documentation Lubricants and operating fluids
Gear oil

7.2 Monitoring of hydraulic oil used for dust intensive applications

Fig. 4 Oil sampling from machines used for dust intensive applications

--- Oil sampling 1 First oil sample

- filter replacement 2 Second oil sample
h Operating hours 3 Subsequent oil samples: every 250 opera-
ting hours

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.

7.3 Instructions for the reduction of the contamination of the hydraulic oil in ma-
chines used in dust-intensive application
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 con-
ditions.
In order to prevent premature wear of the hydraulic components, shorten the intervels between the
oil changes (or oil samplings respectively) and observe the following instructions :
– Every 500 operating hours, replace the filter cartridge(s) in the return filter.
– Use 10-µm filter cartriges instead of the standard 20 / 5 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).

Note!
The machines factory-delivered with a hydraulic hammer are equiped with 10 µm filter cartridges
and 2 µm breather filters.

8 Gear oil
Gear oils must conform to the following specifications:
– API-GL-5 and MIL-L-2105 B, C or D for viscosity grades SAE 90
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Lubricants and operating fluids Technical documentation
Grease and other lubricants

For viscosity grades SAE 80 and SAE 90 according to MIL-L-2105 D, it is possible to use oil belon-
ging to SAE 80W90 viscosity grade.

9 Grease and other lubricants

Lubricants Description / Manufacturer

Grease for the swing ring / general The grease must conform to specification KP2k, consistency
lube points 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 va-

lue 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 Gleitmo 800

used for the mounting of piston rod ID no. 8300004 (40g tube)
bearing and cushioning sleeves to hy- Gleitmo 900
draulic cylinders ID no. 8610227 (400 ml spray can)

Special anti-corrosion for mounting re- Castrol-Tarp

cesses for sealing elements at hydrau- ID no. 8300005 (40g tube)
lic cylinders

Other grease: Liebherr-Special grease CTK

Lubricant used for the mounting of ID no. 861331301 (400g cartridge)
pumps to prevent fretting corrosion on
spline meshes

Coolant for air-conditioning system R 134 A

Drain and fill the system according to the instructions in this
manual (air-conditioning assembly).

Tab. 6 Grease and other lubricants

10 Coolant

10.1 Anti-corrosion and antifreeze agents with DCA (ID no. 8503890 - 30 I container)
In order to improve the quality of the cooling water, LIEBHERR diesel engines are equiped with water
filter installations.
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.
LFR / en / Issue: 03 / 2010

A chemical substance (DCA 4) added to the filter protects all parts of the cooling system that are in
direct contact with the coolant, such as the pump, the cylinder bearing sleeves, etc. against cavita-
tion, corrosion, deposits and foam.
As the various engines and models require different cooling water volumes and filter systems, LIEB-
HERR has introduced four different water filter installations.

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10.2 Coolants with DCA 4 (Diesel Coolant Additives)

Outdoor temperature up to Water proportion in % Anti-corrosion / antifreeze

proportion in %
-37 °C / -34 °F 50 50
-50 °C / -58 °F 40 60

Tab. 7 Water / anti-corrosion / antifreeze proportions

The coo lant mu st contain at least 50 volu me % o f a nti-corrosion an d an tifreeze age nt dur ing all
seasons. This protects the coolant against freezing to a temperature of -37°C and ensures adequate
protection against corrosion.
In the event of less of coolant and subsequent refilling, ensure that the additive concentration does
not drop below 50 volume %.

Note!
Do not exceed a anti-corrosion and antifreeze agent concentration of 60%! Higher concentration
tends to result in poor cooling and antifreeze protection.

As part of the regular maintenance, check the mixing ratio and the DCA 4 concentration.

Note!
– Change the coolant every 2 years
– The DCA 4 concentration must be between 0.3 and 0.8 units per litre.
– To measure this, we recommend using a CC 2602 M test kit from Fleetguard.

10.3 Anti-corrosion
In exceptional cases and where the ambient temperature is alwa ys above the freezing point,
e.g. in tropical zones, and where none of the approved anti-corrosion and antifreeze agents are
available, operators may use a coolant consisting of a mixture of water and DCA 4.

Note!
Completely drain the cooling system when replacing the anti-corrosion / antifreeze with anti-corro-
sion and vice versa.

Use of DCA 4 without anti-corrosion or antifreeze agent

In order to pr otect the cooling system against corrosion, mix app roximately double the amount of
DCA 4 with water see Tab. 7.

Note!
– Change the coolant every year.
– The DCA 4 concentration must be between 0.6 and 1.6 units per litre.
LFR / en / Issue: 03 / 2010

– To test this, we recommend using a CC 2602 M test kit from Fleetguard.

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Use of other water-based anti-corrosion

Note!
– Change the coolant every year.
– The mixture proportion must consist of 7.5% of anti-corrosion and 92.5% of water.
– To test this, use the refractometre 2710 from Gefo.

Use of the refractometre in order to test the mixture proportion

Fig. 10-4 Refractometre Gefo no. 2710

Refractometre adjustment:
 Adjust the 0-line with the adjusting screw (water-line)
 Visual acuity is adjusted by rotating the eyepiece
Mesure :
 Clean meticulously the cover and the prism
 Put 1-2 drops of the sample on the prism
 Close the cover
 the liquide spreads all over the prism
 Observe through the eyepiece by orienting the object in front of a light source. Set the scale ac-
curately
 Read the value on the blue stripline
 Estimate the concentration using the following graph:
Value read on the refractometre in 0-10% Brix

LFR / en / Issue: 03 / 2010

Concentration (vol%)

Fig. 5 Conversion table - refractometre Gefo no. 2710

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Coolant

Permitted hydrosoluble anti-corrosions

Product designation Manufacturer

DCA 4 Diesel Coolant Additives Fleetguard
Caltex CL Corrosion Inhibitor Concentrate Caltex
Chevron Texaco Heavy Duty Extended Life Corrosion Inhibitor Nitrite Free Chevron Texaco
Havoline Extended Life Corrosion Inhibitor (XLI) Arteco
Total WT Supra Total

Tab. 8 Permitted hydrosoluble anti-corrosions

10.5 New filling of the cooling system

 Before filling with new coolant, check the cooling system cleannliness and rinse if necessary.
 By first filling or by new filling after reparations, liquid DCA 4 must be added to the coolant in ad-
dition to the DCA 4 concentration contained in water filters.

Cooling system
Quantity of DCA 4 liquid DCA 4 Water filter
capacity

5,5 liter cans Ident-

Liter or Liter Designation
Ident-Nr. 7363898 No.
24 - 39 3 or 1,4 WF 2071 7367045
40 - 59 4 or 1,9 WF 2072 7381493
60 - 79 5 or 2,4 WF 2073 7367052
80 - 115 8 or 3,8 WF 2073 7367052

Tab. 9 Filling DCA 4 volumes

10.6 Change interval of the DCA 4 water-filter

The DCA 4 water-filter must be replaced every 500 operating hours.
Provided there is no coolant loss from the cooling system, it is sufficient to change the coolant every
500 operating hours in order to have enough DCA 4 concentration in the system.

10.7 Fresh water guidelines

To mix the coolant, only clean, preferably soft water should be used. Often, but not always, regular
drinking water can be used.
Sea water, brackish waters, sole water or industrial waste water may not be used.

Fresh water quality with the use of anti-corrosion / antifreeze agent

Substance of content Quantity

LFR / en / Issue: 03 / 2010

Sum of alkalies (water hardness) 0.6 to 3.6 mmol / l (3 to 20 °dGH)

1° dGH = 1.2° (english hardness)
= 17.9 ppm (US hardness)
ph-value at 20 °C (68°F) 6.5 to 8.5
Chloride - ion content max. 80 mg / l
Sum of Chloride + Sulfate max. 100 mg / l

Tab. 10 Water quality with the use of anti-corrosion / antifreeze agent

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Fresh water quality with the use of DCA 4 coolant

Substance of content Quantity

Sum of alkalies (water hardness) 0.6 to 2.7 mmol / l (3 bis 15 °dGH)
1° dGH = 1.2° (english hardness)
= 17.9 ppm (US hardness)
ph-value at 20 °C (68°F) 6.5 to 8.0
Chloride - ion content max. 80 mg / l
Sum of Chloride + Sulfate max. 80 mg / l

Tab. 11 Water quality with the use of DCA 4 coolant

10.7.1 Permitted anti-corrosion and antifreeze fluids

Concentrated, undiluted

Brand Manufacturer Country

Agip Antifreeze Plus Agip Petrol S.p.A., Rom 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, München 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 / Chevron Texaco, San Ramon, CA USA
Coolant

DEUTZ Kühlschutzmittel 0101 1490 Deutz Service International GmbH, Köln 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
LFR / en / Issue: 03 / 2010

Glacelf Auto Supra Total Nederland N.V., Den Haag NL

Glycoshell AF 405 Shell Deutschland GmbH, Hamburg D
Glycoshell N Shell Deutschland GmbH, Hamburg D
Glysantin (G48-00) BASF AG, Ludwigshafen D

Havoline XLC Arteco, Gent B

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Brand Manufacturer Country

Havoline DEX-Cool Extended Life Anti-Freeze / Chevron Texaco, San Ramon, CA USA
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

Veedol Anti-Freeze O Deutsche Veedol GmbH, Düsseldorf D

Wintershall Kühlerschutz Wintershall Mineralöl GmbH, Düsseldorf D

Tab. 12 Permitted anti-corrosion / antifreeze fluids

50:50 Premix (Water: anti-corrosion / antifreeze)

Brand Manufacturer Country

Liebherr Anti-Freeze APN Mix Ident-Nr. 8611045 Liebherr D
Caltex Extended Life Coolant Pre-Mixed 50/50 Caltex UK Ltd, London GB
(ready-to-use-version)
Chevron DEX-Cool Extended Life Prediluted Chevron Texaco, San Ramon, CA USA
50/50 Anti-Freeze / Coolant
Havoline XLC, 50/50 Arteco, Gent B
Havoline DEX-Cool Extended Life Prediluted Chevron Texaco, San Ramon, CA USA
50/50 Anti-Freeze / Coolant
Organicool 50/50 Total Deutschland GmbH, Düsseldorf D

Tab. 13 Permitted anti-corrosion / antifreeze / 50:50 Premix

LFR / en / Issue: 03 / 2010

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General information on changing lubricants and operating fluids

1.51: Lubricants and operating fluids

R 924 Compact from serial number 23 159

1 General information on changing lubricants and operating fluids

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

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

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

Danger!
When checking and changing lubrication and operating materials, ensure that the following
precautions are adhered to:
 Unless otherwise indicated, carry out all work on the machine on level, solid ground and with the
engine switched off.
 Whenever you reach into the engine compartment, always secure the cover and side doors
against accidentally falling back or closing.
 Only refuel the machine when the engine is switched off, do not smoke and avoid naked flame.
 Turn the main battery switch to position 0 (off) and remove the ignition key.
LFR / en / Issue: 03 / 2010

2 Lubricant chart

Designation Medium Symbol Classification Viscosity

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

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

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Designation Medium Symbol Classification Viscosity

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

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

Hydraulic oil DIN 51524 T2/T3 ISO VG 32

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

LAV < 10 min (air separation charcteristics at

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

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

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

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

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

Travel gear Transmission oil API-GL-5 SAE 90

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

Splitterbox Transmission oil API-GL-5 SAE 90

MIL-L 2105 B, C or D

Tracks and Lubricating High pressure grease Consistency 2

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

Hinges, joints, locks Engine oil - -

Rubber seal on Silicon spray or - -

doors and trim talc
panels

3 Fuels, lubricants and process chemicals

LFR / en / Issue: 03 / 2010

Designation Medium Symbol

Fuel tank Commercially available diesel fuel with sulphur content

between 0,05 % and 0.5 %

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Designation Medium Symbol

Coolant Corrosion inhibitor and antifreeze agent

Windscreen washing Conventional windscreen cleaning agent or denatured

system alcohol

Air conditioning system R 134 a

refrigerant

Refrigerant oil in A/C PLANETELF PAG SP 20

compressor

Tab. 1 * = Guide values

4 Diesel fuels

4.1 Specification

The diesel fuels must meet the minimum requirements of the fuel specifications outlined below.
Approved fuel specifications:
– DIN N
E 90
5
– ASTM D 975 (89a) 1D and 2D
The use of fuels with other specifications is only permitted with the explicit consent of the
LIEBHERR.

4.2 Sulphur content of diesel fuel

Fuel that meets the DIN EN 590 standard may contain maximum 50 mg/kg (maximum 0,005 weight
percent) of sulphur.
The reduction of sulphur content has raised the problem of diesel fuel lubrication characteristics. It
has been shown that diesel fuels containing the maximum permitted European sulphur limit of
0.05 weight per cent can cause the fuel injection system to wear (particularly applicable to distributor-
type injection pumps).
"Low-sulphur" diesel fuels with a sulphur content of less than 0,05% are only suitable after addition
of a lubrication additive. According to HFRR (60) test, the lubricity of the diesel fuel may not exceed
460 µm (lubricity-corrected wear scar diameter [1.4] at 60 °C).
When using diesel fuels with a sulphur content of more than 0,5 weight percent, the oil change inter-
vals must be halved.
Do not use fuels with a sulphur content of more than 1 %.
LFR / en / Issue: 03 / 2010

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

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

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4.3 Diesel fuels for operation at low temperatures (winter)

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

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

4.4 Diesel fuels with the LIEBHERR Particles filter

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

5 Lubricating oil for the diesel engine

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

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

Tab. 2 Lubricating oil for the diesel engine - specifications

Caution !
Particle filter only permitted with oil E6.

5.1 Viscosity
LFR / en / Issue: 03 / 2010

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

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Fig. 1 Temperature-based selection of the SAE class

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

5.2 Lubricating oil change intervals

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

Operating conditions Oil change interval

dependent on oil
quality:
CH-4, CI-4 E4,
E6, E7
LFR / en / Issue: 03 / 2010

Operating conditions Sulphur content of fuel Interval

Climate normal to -10 °C up to 0.5 % 250 h 500 h
above 0.5 % 125 h 250 h
below -10 °C up to 0.5 % 125 h 250 h
above 0.5 % not 125 h
permissible

Tab. 3 Oil change intervals for the diesel engine

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h = operating hours

6 Coolant for the diesel engine

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

6.1 General recommandations

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

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

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

6.2 Water quality

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

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

Tab. 4 Fresh water quality

Fresh water quality when using coolant with DCA 4

Contents Quantity
LFR / en / Issue: 03 / 2010

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

Tab. 5 Fresh water quality with use of DCA 4

Water analysis results are available from the local authorities.

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6.3 Mixting ratio for coolant

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

Outside temperature up to Mixing ratio

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

Tab. 6 Mixture ratio (for all seasons)

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

6.4 Permitted corrosion inhibitors / antifreeze agent

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

Product description Manufacturer Country

Liebherr Antifreeze Concentrate Liebherr D

Addinol Antifreeze Super Addinol Lube Oil GmbH, Leuna D

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

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

LFR / en / Issue: 03 / 2010

Caltex Extended Life Coolant Chevron Texaco *

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

DEUTZ Kühlerschutzmittel 0101 1490 Deutz Service International GmbH, D

Cologne

ESA Frostschutz G48 ESA Burgdorf CH

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Product description Manufacturer Country

Fuchs Fircofin Kühlerfrostschutz Fuchs Petrolub AG, Mannheim D

Glacelf Auto Supra (antifreeze) Total, Paris F

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

Havoline Extend Life Antifreeze / réfrigérent Chevron Texaco *

Havoline XLC Arteco B

Motorex Antifreeze Protect G48 Bucher AG, Langenthal CH

Motul Inugel Optimal Ultra Motul SA, Aubervilliers Cedex F

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

Vienna

* = global / worldwide

6.5 Permitted premixed coolants

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

Product description Manufacturer Country

Liebherr Antifreeze Mix Liebherr D

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

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

Havoline XLC, 50/50 Arteco B

Havoline DEX-COOL Extended Life Prediluted Chevron Texaco *
50/50 Anti-Freeze/Coolant
LFR / en / Issue: 03 / 2010

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

6.6 Permitted corrosion inhibitors without antifreeze agent

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

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Caltex / Chevron / Havoline / Total

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

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

Product description Manufacturer Country

DCA 4 Diesel Coolant Additives Fleetguard / Cummins *
Filtration

Caltex CL Corrosion Inhibitor Concentrate Chevron Texaco *

Chevron Texaco Heavy Duty Extended Life Chevron Texaco *

Corrosion Inhibitor Nitrite Free

Havoline Extended Life Corrosion Inhibitor Chevron Texaco *

(XLI)

Total WT Supra Total, Paris F

* = global

7 Hydraulic liquids

Hydraulic oils must meet the requirement outlined below.

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

7.1 Hydraulic oil

LIEBHERR recommands using the following hydraulic oils in its excavators (depending on
temperature range):
LFR / en / Issue: 03 / 2010

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

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

* Temperature-based selection of the ISO class

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

7.2 Engine oil

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

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

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

Tab. 7 Engine oils for use as hydraulic oil

LFR / en / Issue: 03 / 2010

1.51.10 R 924 Compact

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MJFCIFSS
 Technical documentation Lubricants and operating fluids
Hydraulic liquids

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

A Ambient temperature 1 Single grade engine oil

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

*temperature-based selection of the SAE class

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

7.3 Warm-up instruction

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

7.4 Biodegradable hydraulic oils

Note!
Risk of damage to the hydraulic unit!
When mixing ester-based biodegradable hydraulic oils with mineral oils, there is a risk of aggressive
chemical reactions, which can damage the hydraulic equipment.
LFR / en / Issue: 03 / 2010

 Do not mix biodegradable hydraulic oils from different suppliers, and never mix with mineral oils.

The use of a partial flow filters is mandatory.

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

R 924 Compact 1.51.11

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MJFCIFSS
Lubricants and operating fluids Technical documentation
Hydraulic liquids

Fully saturated synthetic ester-based oils, HEES

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

7.5 Monitoring, filter change and oil change

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

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

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

Symbol Signification
Filter change for hydraulic oil

Oil sampling

Tab. 8 Key to figures

Hydraulic oil in normal use

LFR / en / Issue: 03 / 2010

Fig. 5 Oil sampling and filters change in normal use

h Operating hours 1 First oil sample

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

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

1.51.12 R 924 Compact

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MJFCIFSS
 Technical documentation Lubricants and operating fluids
Hydraulic liquids

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

Hydraulic oil used in dust intensive applications

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

h Operating hours 1 First oil sample

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

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

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

Note!
Machines delivered with hydraulic hammer attachment and retrofitted hydraulic hammer kits are
already fitted with 10-µm filter cartridges in the return filter.
LFR / en / Issue: 03 / 2010

R 924 Compact 1.51.13

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Lubricants and operating fluids Technical documentation
Lubricating grease and other lubricants

8 Lubricating grease and other lubricants

Lubricant Description / manufacturer

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

Contact spray for slip rings Cramolin

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

Tab. 9 Grease and other process chemicals

LFR / en / Issue: 03 / 2010

1.51.14 R 924 Compact

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 Technical documentation

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 ................................................................................2.12

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

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

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

Compression device for brake piston of gear FAT - construction line A .........................2.16

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

Special tool for lifting the counterweight.............................................................................2.28

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

LFR / en / Issue: 09 / 2012

R 924 Compact 2.00.1

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 Technical documentation

LFR / en / Issue: 09 / 2012

2.00.2 R 924 Compact

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MJFCIFSS
 Technical documentation Special tools for maintenance and repair

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

Darstellung Nr. Benennung Größe Ident. Nr. Gerät Anwendung

Representation No. Desciption Size Order no Model Application
Dessin N° Dénomination Grand. N°code Type Application
1 Messstutzen NW 10 7002404 alle
Pipe adaptator Typen
Embout

2 NW 12 7008688

13 Messstutzen M22x1,5 5607671 914 Form K

14 Pipe adaptator M14x1,5 5607616 alle K Form
15 Embout M16x1,5 5607605 alle Forme K
16 M18x1,5 5607617 914/924 Nach / From / Selon –
17 M20x1,5 7409922 914/924 LH673-02
18 M24x1,5 7409923 914/924

25 Manometeran- R 1/2 “ 7002436 alle

schluss Typen
BSP coupling
Raccord

30 Manometer Direktan- R 1/2 “ 7002435 alle

schluss Typen
Direct gauge cou-
pling
LFR / en / Issue: 09 / 2012

Raccord (brancht.
direct du manométre)

R 924 Compact 2.01.1

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Special tools for maintenance and repair Technical documentation

Darstellung Nr. Benennung Größe Ident. Nr. Gerät Anwendung

Representation No. Desciption Size Order no Model Application
Dessin N° Dénomination Grand. N°code Type Application
35 Hochdruckschlauch 1000 mm 7002437 alle Zum Anschließen von
Länge Typen Manometern an allen
High pressure hose 1500 mm 7002475 Messstellen (Messs-
36 Length tutzen Nr. 1/2 und
Flexible haute pres. 5000 mm 7363732 Schraubkupplungen 10-
Long 14)
37
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 Schraubkupplung M10X1 5005180 alle
kpl. Typen
Gauge coupling
Raccord complet

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

45 Manometer 0-1,6 bar 8042577 alle Zur Überprüfung der Be-

Hydraulic pressure Typen triebsdrücke eines bzw.
gauge mehrerer Hydraulikkre-
Mano. à bain de gly- ise.
46 cérine 0-1,6 bar * 8042578
47 0-2,5 bar * 7361292 Used to check system
48 0-6 bar * 7361291 pressure in one or more
49 0-10 bar * 5002865 hydraulik systems.
50 0-25 bar * 7361289
51 0-40 bar * 7361288 Pour le contrôle des pres-
52 0-60 bar * 5002867 sions d’un ou de plusieurs
53 0-160 bar * 7361286 cicuits hydraulique
54 0-250 bar * 7361285
55 0-400 bar * 7500002 * glyceringedämpft
56 0-600 bar * 7361294 * dampened with glycerin
* à bain de glycérine
LFR / en / Issue: 09 / 2012

2.01.2 R 924 Compact

copyright by

MJFCIFSS
 Technical documentation Special tools for maintenance and repair

Darstellung Nr. Benennung Größe Ident. Nr. Gerät Anwendung

Representation No. Desciption Size Order no Model Application
Dessin N° Dénomination Grand. N°code Type Application
75 Differenzdruck- 10288229 alle Zum Messen des Differ-
Mess-Set bestehend Typen enzdruckes p zwischen
aus: Pumpen- und LS Druck.
Measuring device for
differential pres- To measure the differen-
sures contents: tial pressure p between
Instrument de pump- and LS pressure.
mesure pour pres-
sions différentielles, Pour mesurer la diffé-
comprenant: rence de pression p en-
tre pression de pompe et
76 -Messgerät Multi- 10288155 pression LS.
Handy 3010
-Measuring device
M-H 3010
-Instrument de
mesure M-H 3010

77 1 Stk. Datenkabel 10288152

1 wire data transfert
1 jeu de câble pour
transfert de données

78 2 Stk. Messkabel 10288154

2 measuring wire
2 jeux de câble de
mesure

79 -Steckernetzgerät 7025279
230 V
-Power supply unit
230 V
-Unité d’alimentation
230 V

80 -KFZ Anschlusskabel 7025273

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

81 -Transportkoffer 614063501
-Tavel box
Coffret der transport

82 -Adapterkabel / 7025275
Daten-übertrag.
-Adapter wire - data
transfert
LFR / en / Issue: 09 / 2012

-Càble pour transfert

de données

83 -Wechselakku für Nr. 7026910

76
-Replacement Bat-
tery for No. 76
-Aecu de rechange
de No. 76

R 924 Compact 2.01.3

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MJFCIFSS
Special tools for maintenance and repair Technical documentation

Darstellung Nr. Benennung Größe Ident. Nr. Gerät Anwendung

Representation No. Desciption Size Order no Model Application
Dessin N° Dénomination Grand. N°code Type Application
84 -Druckaufnehmer 0-600 bar 614062401 alle
-Pressure sensor Typen
-Capteur de pression
Hydrotechnik

85 -Direktanschluss für 614062601

Druckaufnehmer 614064701
-Connecting wire for
pressure sensor
-Raccord pour cap-
teur de pression

86 -Messkabel MK 12 12 m 614063701
-Measuring wire MK
12
-Càble de mesure
MK 12
100 Stutzen 4901372 alle Zum Druckabgleich in
Pipe adaptator Typen Verbindung mit
Embout de prise de Werkzeug Nr. 75 / 85
pression
For pressure equilibration
101 Messstutzen mit Met- 7002404 in connection with tool no
allkappe 75 / 85
Pipe adaptator with
metalic cap Pour l’équilibrage en
Prise de pression + pression en utilisant l’outil
embout métall n° 75 / 85

102 Überwurfmutter 4774002

Cap nut
Ecrou de raccord

103 Schneidring 4774001

Cutting ring
Bague de sertissage
109 Service Stecker 9684328 Für Kommunikation mit
(grün) und Parametrieren des
Service plug (green) elektronischen Steuer-
Connecteur de ser- kreis über Baggerdisplay
vice (vert) For communicating with
and adjusting the elec-
tronic control circuit via
the display of the excava-
tor
Pour communication
avec et paramétrage du
circuit électronique de
LFR / en / Issue: 09 / 2012

commande, via le display

de la pelle

Gültig für / Valid for / Val-

able pour :
- Litronic 2

2.01.4 R 924 Compact

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MJFCIFSS
 Technical documentation Special tools for maintenance and repair

Darstellung Nr. Benennung Größe Ident. Nr. Gerät Anwendung

Representation No. Desciption Size Order no Model Application
Dessin N° Dénomination Grand. N°code Type Application
110 LMS-Litronic- 614062001 alle Zum Messen und Abspei-
Messsystem kpl. Typen chern aller Drücke, För-
bestehend aus: dermengen, Drehzahlen,
Messgerät, Trans- elektr. Ströme und Span-
portkoffer u. nungen
Trageriemen
Used to measure and
LMS -Litronic-Meas- store hydr. pressures,
uring kpl. containing: pump flow, electrical cur-
measuring tool, car- rent and voltage
rying case and straps
Pour la mesure et la mé-
Systéme de mesure morisation de toutes les
Litronic-LMS com- pressions, débits, ré-
prenant: instruments gimes, tensions et cou-
de mesure, coffret de rants électriques
transport et courroie
d’ épaule
In Verbindung mit
Sensoren und Zube- Werkzeug Nr. 110
111 hör (see “Lieferumfang Li- On connexion with tool
Sensors and Extras tronic Messsystem” on no. 110
Capteurs et Acces- page 10) En liaison avec l’outil n°
soires 110
115 Messadapter 8504231 alle Für Strommessung an
Measuring adapter Typen der Pumpenregelung
Boîtier de mesure
To check current on
pump regulation

Mesure des courants de

régulation sur les pompes

120 Messkabel 9956436 alle Für Messung des Induk-

Measuring wire Typen tivgebers B 12 von 3-polig
Càble de mesure (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 Strommessung
LFR / en / Issue: 09 / 2012

To check current
Mesure des courants

R 924 Compact 2.01.5

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MJFCIFSS
Special tools for maintenance and repair Technical documentation

Darstellung Nr. Benennung Größe Ident. Nr. Gerät Anwendung

Representation No. Desciption Size Order no Model Application
Dessin N° Dénomination Grand. N°code Type Application
125 Drehzahlmesser A 2106 10286429 alle Zum Messen der Mo-
Piezzo 450 Typen tordrehzahl über Impuls-
frequenz der
Revolution - Indicator Einspritzleitung

Compte-tours Piezzo 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 Drehzahlmesser Or- HT 460 7006974 alle Zum Messen der
nel Typen Drehzahl über Reflex-
Revolution - Indicator ions-Streifen
Compte-tours Ornel
To check the RPM via re-
flexions stripe
Drehzahlmesser
131 Shimpo DT 205 7364284 Mesure de régime par
Revolution - Indicator l’intermédiaire d’ une pa-
Compte-tours Shim- tille réflectrice
132 po 614063201
mit / with / avec / n° 130
Streifen / Stripes /
Pastilles
145 Vielfachmessgerät Chauvin 10018500 alle Für Spannungs-, Strom-
mit Digitalanzeige Arnoux Typen und Widerstans-messun-
MAX 3000 gen von Elektroanlagen
Multimeter with digi- und Elektro - Ventilen
tal display
For voltage, current and
Contrôleur universel resistance measure-
à affichage digital ments of electrical sys-
tems and electrical valves

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

146 Zusatz - Mess- 5616316 In Verbindung mit /

werkzeuge To be used with tool /
Measuring tools kit A usiter avec l’ outillage /
Outillages option- n° 145
nels de mesures

147 Meßkabelsatz 886125008 In Verbindung mit /

LFR / en / Issue: 09 / 2012

Measuring cable set To be used with tool /

Lot de câbles de A usiter avec l’ outillage /
mesure n° 145
6001128
148 Bereitschaftstasche In Verbindung mit /
Carrying case To be used with tool /
Pochette de protec- A usiter avec l’ outillage /
tion n° 145

2.01.6 R 924 Compact

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 Technical documentation Special tools for maintenance and repair

Darstellung Nr. Benennung Größe Ident. Nr. Gerät Anwendung

Representation No. Desciption Size Order no Model Application
Dessin N° Dénomination Grand. N°code Type Application
160 Thermometer GMTL 7020372 alle Zum Überwachen der
berührungslos 1826 Typen Temperatur eines Medi-
(Infrarot) ums bzw. der Außen-
Temperatur eines Aggre-
Thermometer gates
Infrared Temperature
sensor Used to monitor the tem-
peratur of any liquid resp.
Thermométre sans the housing temp. of any
contact component

Pour mesurer la temp.

162 Thermometer mit GTH 1150 10024185 d’un liquide ou la temp.
Sonde und Fühler extérieure d’un com-
(magnetisch.) posant
Thermometer with
probe and sensor
(magnetic.)
Thermométre avec
sonde et capteur
(magnetic.)
170 Handpumpe 8145666 alle Zur Entnahme einer Öl-
Sampling pump Typen probe für die Ölanalyse
Pompe manuelle
Used to taking samples
172 Entnahmeventil für 7019068 for oil analysis
Ölproben alternativ
zur Handpumpe Pour prélevement
Sampling valve for oil d’échantillon pour ana-
samples alternative lyse d’huile
to the sampling pump
no.

Vanne de soutirage
d’échantillons d’huile
utilisable au lieu de la
pompe manuelle
175 Öl Analysenset * Nr. 1 7018368 alle 6 Stck. Ölproben
Oil Analysis set * Typen 6 samples
6 pièces
180 Öl Analysenset * 8145660
Oil Analysis set * 1 Stck. Ölprobe
1 sample
*Analysen bei WAER CHECK 1 jeu
Deutschachland Laborbericht in
deutscher Sprache
*Analysis at WAER CHECK Ger-
many
LFR / en / Issue: 09 / 2012

Analysis report in German lan-

guage

Nécessaire pour anallyses d’huiles

* Analyses par Sté WAER CHECK
Belgique Rapport d’analyses en
Francais

R 924 Compact 2.01.7

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Special tools for maintenance and repair Technical documentation

Darstellung Nr. Benennung Größe Ident. Nr. Gerät Anwendung

Representation No. Desciption Size Order no Model Application
Dessin N° Dénomination Grand. N°code Type Application
190 Vakuumpumpe REF- RD-4 7027552 alle Zur Wartung und Repara-
CO Typen tur der Klimaanlage Kon-
Evacuation pump vekta
REFCO
Pompe à vide REF- For sevicing and repair-
CO ing the air conditioning
equipement Konvekta

Pour l’entretien et la répa-

ration du elimatiseur Kon-
vekta
195 Füllschlauch ITE 1500 mm 7027553 alle Siehe Pos. / See Pos. /
blau Typen Voir Pos. / 190
Filling hose ITE blue

Flexible de remplis-
sage ITE bleu

196 Füllschlauch ITE 1500 mm 7027554

gelb
Filling hose ITE yel-
low

Flexible de remplis-
sage ITE jaune

197 Füllschlauch ITE rot 1500 mm 7027555

Filling hose ITE red
Flexible de remplis-
sage ITE rouge
205 KFZ - Kupplung ITE 253a 7027556 alle Siehe Pos. / See Pos. /
Quick coupling ITE Typen Voir Pos. / 190
Attache rapide ITE

210 KFZ - Kupplung ITE 254 a 7027557

Quick coupling ITE
Attache rapide ITE

215 4-Ventil - Prüfarma- M4WS5C 7027558 alle Zur Wartung und Repara-
tur Typen tur der Klimaanlage Kon-
vekta
Test equipement with
4 valves For servicing and repair-
ing the air conditioning
Unité d’essai à 4 cla- equipment Konvekta
LFR / en / Issue: 09 / 2012

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

2.01.8 R 924 Compact

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 Technical documentation Special tools for maintenance and repair

Darstellung Nr. Benennung Größe Ident. Nr. Gerät Anwendung

Representation No. Desciption Size Order no Model Application
Dessin N° Dénomination Grand. N°code Type Application
220 Demon- UTV-M20 7023304 alle Zur Demontage der Greif-
221 tagewerkzeug UTV-M24 7023305 Typen erbolzen
222 UTV-M30 7023306
223 Disassembly tool UTV-M36 7023307 To dis assemble the pins
224 UTV-M42 7023308 of the grabble
Outillage de démon-
tage Pour le démontage des
pivots du grappin

230 Demontagescheibe M14 7023309 alle Zur Demontage der

231 Disassembly tool M20 7023310 Typen Passfix - Bolzen
232 Rondelle d'appui de M24 7023311
233 démontage M30 7023312 For disassembly of pass-
234 M36 7023313 fix bolts
235 M42 7023314
Pour le démontage des
axes à bague de serrage
passfixe

240 Diagnosegerät 5010474 alle Zur Fehlerdiagnose der

Diagnostic tool Typen Zusatz-Heizung D5 WS.
Appareil diagnos-
tique For diagnostic purposes
on the additional cab
heater.

Pour diagnostiser des

anomalies au chauffage
supplémontaire
241 Adapterkabel 9960799
Adapter harness Zum Anschluß im Kabel-
Câble d’adaption baum linke Konsole

To connect to the wire

harness in left control
panel.

Pour brancher au fais-

ceau dans le pupitre
gauche
245 Diagnose - Kit 10008427 alle Kommunikation- und Di-
(CD mit Software Typen agnostesoftware für
und Verbindungska- BEKA-MAX Zentrals-
bel) chmierung

Diagnostic software Communication and diag-

LFR / en / Issue: 09 / 2012

(software on CD and nostic software for BEKA-

connecting cable) MAX central lubrication

Ensemble de diag- Logiciel de communica-

nostic tion et de diagnostic pour
(logiciel sur CD et système de graissage
cäble de raccorde- centralisé BEKA-MAX.
ment)

R 924 Compact 2.01.9

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Special tools for maintenance and repair Technical documentation

Darstellung Nr. Benennung Größe Ident. Nr. Gerät Anwendung

Representation No. Desciption Size Order no Model Application
Dessin N° Dénomination Grand. N°code Type Application
250 Drehmomenschlüs- 4-20 Nm 10045464 alle Zum Anziehen der
sel Typen Schlauchschellen

255 Handpumpe mit ma- 10454803 alle Zur Dichtheitsprüfung der

nometer Typen Gegendruckleitung bei
Partikelfilter Einbau

Lieferumfang Litronic Messsystem

Pos. Bezeichnung Designation / Désignation Ident-Nr.

1 LMS - Litronic 1* 6140 620 01
Messsystem, bestehend aus:
Measuring kpl. containing :
Système de mesure comprenant :
1.1 Messgerät / Measuring tool / instrument de mesure 6140 621 01
1.2 Transportkoffer / carrying case / coffret de transport 6140 622 01
1.3 Trageriemen / straps / courroie d’épaule 6140 623 01

Zusätzlich werden, je nach Anforderung, verschiedene Aufnehmer und Kabel benötigt, welche ge-
sondert bestellt werden müssen.
Besides, on request, several sensors and wires can be needed, wich have to be ordered in addition.
En outre, selon votre demande, divers capteurs et câbles sont nécessaires, devant être commandé
en sus.

Grösse / Size /
Pos. Sensoren / Sensors / Capteurs Ident-Nr.
Dimensions
2 OEM - Drucksensor, Messbereich 0 - 1000 bar 1001 8329
OEM - Pressure sensor 0 - 20 mA
OEM - Capteur de pression
3 OEM - Drucksensor, Messbereich 0 - 600 bar 6* 6140 624 01
OEM - Pressure sensor 0 - 20 mA
OEM - Capteur de pression
LFR / en / Issue: 09 / 2012

4 OEM - Drucksensor, Messbereich 0 - 60 bar 3* 6140 625 01

OEM - Pressure sensor 0 - 20 mA
OEM - Capteur de pression
5 OEM - Drucksensor, Messbereich 0 - 10 bar 1002 7591
OEM - Pressure sensor 0 - 20 mA
OEM - Capteur de pression

2.01.10 R 924 Compact

copyright by

MJFCIFSS
 Technical documentation Special tools for maintenance and repair

Grösse / Size /
Pos. Sensoren / Sensors / Capteurs Ident-Nr.
Dimensions
6 OEM - Drucksensor, Messbereich -1 / +6 bar 5718 886 08
OEM - Pressure sensor 4 - 20 mA
OEM - Capteur de pression (LWE)
7 Druckaufnehmer Direktanschluss nach MINIMESS Serie 1620 - 0° 6* 6140 626 01
Connection for pressure sensor to MINIMESS
Adaptateur pour pressostat vers MINIMESS
8 Druckaufnehmer Direktanschluss nach MINIMESS Serie 1620 - 90° 3* 6140 647 01
Connection for pressure sensor to MINIMESS
Adaptateur pour pressostat vers MINIMESS
9 Temperaturaufnehmer Pt 100 -50 °C / +200 °C 1* 6140 627 01
Temperature sensor Pt 100
Capteur de température Pt 100
10 P / T - Messkupplung, MINIMESS Serie 1620 1* 6140 628 01
P / T - Measuring coupling, MINIMESS G 1/4“
P / T - Adaptateur prise de mesure, MINIMESS
11 P / T - Messkupplung, MINIMESS Serie 1620 1* 1004 1274
P / T - Measuring coupling, MINIMESS M10 x 1,5
P / T - Adaptateur prise de mesure, MINIMESS
12 Messturbine RE 4 - 10 1* 5010 031
Measuring turbineTurbine de mesure 1 - 10 l/min
13 Messturbine RE 3 - 75 1* 6140 629 01
Measuring turbine 7,5 - 75 l/min
Turbine de mesure
14 Messturbine RE 3 - 300 0* 6140 630 01
Measuring turbine 15 - 300 l/min
Turbine de mesure
15 Messturbine RE 3 - 600 2* 5009 492
Measuring turbine 25 - 600 l/min
Turbine de mesure
16 Drehzahlsensor DS 03 1* 6140 631 01
Tachometer 1 - 9999 U/min
Tachymètre
17 Ersatzreflektionsfolien - Set 1* 6140 632 01
Set of spare reflective foils
Jeu de pastilles réflectives
18 Magnethalter, passend für Drehzahlsensor DS 03 1* 6140 633 01
Magnetic holder for tachometer DS 03
Support magnétique pour tachymètre DS 03
19 Induktivaufnehmer zur Drehzahlmessung 1* 6140 634 01
Inductive sensor for tachometer
Capteur inductif pour tachymètre
LFR / en / Issue: 09 / 2012

Grösse / Size /
Pos. Zubehör / Options / Options Ident-Nr.
Dimensions
20 Transportkoffer zur Aufbewahrung der Messturbinen RE 3 1* 6140 635 01
Carrying case to carry the measuring turbine RE 3
Coffret de transport pour préserver la turbine de mesure RE 3

R 924 Compact 2.01.11

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MJFCIFSS
Special tools for maintenance and repair Technical documentation

Grösse / Size /
Pos. Zubehör / Options / Options Ident-Nr.
Dimensions
21 Messkabel zum Anschluss der Sensoren, länge : MK 12 - 6 m. 12* 6140 636 01
Measuring cable to connect the sensors, length :
Câble de mesure pour connecter les câbles. long. :
22 MK 12 - 12 m. 4* 6140 637 01
23 MK 12 - 18 m. 1* 6140 638 01
24 Stromversorgungskabel zum Bordnetz Anschluss, länge : 6 m. 1* 6140 639 01
Power supply cable to connect to the system, length :
Câble d’alimentation a connecter au réseau , longueur :
25 12 m. 0* 6140 640 01
26 Thermodrucker mit Netzgerät DPU 411 0* 6140 641 01
Network printer
Imprimante réseau
27 Ersatz-Thermopapierrollen für / for / pour 0* 6140 642 01
Exchange thermopaper roll DPU 411
Rouleau de papier thermique de rechange
28 Datenübertragungskabel Centronics, länge : 2m. 0* 6140 643 01
Centronics data transfer cabel, length : für / for / pour
Câble de transfert de données Centronics, longueur : DPU 411
29 Datenübertragungskabel, (Anschluss an PC) RS 232 - 2 m. 1* 9684 327
Data transfer cabel, (to connect to PC)
Câble de transfert de données (à connecter au PC)
30 Adapterkabel (für Drehzahlmessung über Prüfgerät GLR) AK 12 1* 6140 648 01
Adapter cabel (for tachometrical measuring using control ap-
parel GLR)
Câble adaptateur (pour mesure tachymétrique via appareil
GLR)
31 Litronic Service Programm (DOS Betriebssystem) Deutsch 0* 6140 646 01
Litronic Service Program (DOS system) German
Programme d’entretien Litronic (système d’exploitation DOS) Allemand
32 Auswerte-Software CD-rom 1* 6004 401
Evaluation software Windows 16 bit
Programme d’évaluation (d / e / f)
33 Auswerte-Software CD-rom
Evaluation software Windows 32 bit
Programme d’évaluation (d / e / f)
34 Messadapter für Strommessung für / for / pour : 1* 8504 231
Measuring adapter - Litronic 2
Boîtier de mesure
36 Y-Adapter für Strommessung Junior Timer Stecker 1* 9956 436
Y adapter to check current measuring Junior Timer plug
Adaptateur en Y pour mesurer le courant clé Junior Timer
LFR / en / Issue: 09 / 2012

37 Adapter 3- auf 2-polig Stecker 1* 9956 422

Adapter 3- on 2-pole
Adapteur 3- sur 2-bornes

* Stückzahl für empfohlene Grundausstattung / Number of pieces for recommended basic equipment / Nombre de pièces
pour l’équipement de base recommandé.

2.01.12 R 924 Compact

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MJFCIFSS
 Technical documentation Special tools for Liebherr Diesel engines

2.02: Special tools for Liebherr Diesel engines

Spezialwerkzeuge für Liebherr Dieselmotoren

Outillage spécial pour les moteurs Diesel Liebherr

Darstellung Nr. Benennung Größe Ident. Nr. Gerät Anwendung

Representation No. Desciption Size Order no Model Application
Dessin N° Dénomination Grand. N°code Type Application
5 Kompressions-Druck- 8008782 alle Zum Prüfen des Kompres-
prüfer Typen sionsdruckes
Compressiometer-
Compressiométre To check compression

6 Diagrammblätter für 100 Pour le contrôle de la pres-

Pos. 5 Stück 10012817 sion d’injection
Diagramms for item 5
100
pieces
Diagramme pour
pos.5 100
pièces
10 Anschlussstück für 0524044 all Typ An Stelle des Einspritzven-
Kompressions-Druck- except tils einzusetzen
prüfer D 934
D 936 Replaces injection valve
Fitting of the recorder
of compression pres- A monter à la place de l’in-
11 sure 10297211 D 934 jecteur
D 936
Piéce de raccorde-
ment pour compressi-
ométre

12 Pratze 10117612 D 934 Zum Befestigung des An-

D 936 schlussstücks 11.
Claw
To fasten the fitting 11.
Griffe
Pour fixer la pièce 11.

15 Düsenprüfgerät 7361236 alle Zum Prüfen der Einspritz-

Nozzle testing device Typen ventile
LFR / en / Issue: 09 / 2012

Appareil de contrôle
des injecteurs To check injection valve

Pour le contrôle des inject-

eurs

R 924 Compact 2.02.1

copyright by

MJFCIFSS
Special tools for Liebherr Diesel engines Technical documentation

Darstellung Nr. Benennung Größe Ident. Nr. Gerät Anwendung

Representation No. Desciption Size Order no Model Application
Dessin N° Dénomination Grand. N°code Type Application
20 Hochdruck - Handför- 7009318 alle Zum Prüfen und Einstellen
derpumpe mit Zubehör Typen des Förderbeginns der Ein-
spritzpumpe
High-pressure hand
feed pump with acces- Used to check delivery be-
sory gin of the injection pump

Pompe manuelle Pour le contrôle et le ré-

haute pression avec glage de la pression d’in-
accessoires jection de la pompe à
injection
25 Messvorrichtung 7022420 alle Zum Prüfen und Einstellen
Measuring device Typen des Förderbeginns der Ein-
Gabarit de mesure spritzpumpe

Used to check delivery be-

gin of the injection pump

Pour le contrôle et le ré-

glage de la pression d’in-
jection de la pompe à
injection
30 Messuhr 7022418 alle Zum Prüfen und Einstellen
Dial gauge Typen des Förderbeginns in
Comparateur Verbindung mit Nr. 10
To Check delivery begin to
be used with no. 10
Pour le contrôle et le ré-
glage de la pression d’in-
jection à employer avec
l´outillage n° 10
31 Zwischenstück 7022419 In Verbindung mit Nr. 10
Intermediate piece To be used with no. 10
Entretoise A employer avec l´outillage
n° 10
35 Ausziehvorrichtung für 0524072 alle Zum Ausbau der Eispritz-
Einspritzventile Typen ventile
Extracting device for Used to remove injection
injection valve valves
Extracteur à chocs Pour le démontage des in-
pour injecteurs jecteurs

36 Adapter für Auszieh- 0524029 Gemeinsam mit der

vorrichtung Ausziehvorrichtung zu ver-
Adapter for extracting wenden
device Used in connection with
Extracteur pour sup- extracting device
port d’injecteurs A utiliser avec l’extracteur
LFR / en / Issue: 09 / 2012

2.02.2 R 924 Compact

copyright by

MJFCIFSS
 Technical documentation Special tools for Liebherr Diesel engines

Darstellung Nr. Benennung Größe Ident. Nr. Gerät Anwendung

Representation No. Desciption Size Order no Model Application
Dessin N° Dénomination Grand. N°code Type Application
40 Drehvorrichtung/An- 0524045 alle Zum Drehen des
bau am Schwun- Typen Dieselmotors über das
gradgehäuse Schwungrad

Turning-device/attach- Used to turn engine over

ment on flywheel case the flywheel

Vireur (monté sur le Pour virer le moteur ther-

carter du volant mo- mique par dessus le volant
teur) moteur

45 Keilriemen - Mess- Krikit 8042829 alle Zur Messung der Keilrie-

gerät Typen menspannung
Measuring tool To measure of V-belt ten-
Outillage de mesure sion
pour courroies Pour mesurer la tension
des courroies
46 7019872 alle
Typen

50 Kommunikation Soft- 10035429 Für Diagnose und Kommu-

ware UP / CR / DC4 / nikation mit den elektronis-
DC5 chen Steuereinheiten der
Mit Dokumentation LIEBHERR Dieselmotoren
dreisprachig
For diagnosis and commu-
Communication soft- nication with the electronic
ware UP / CR / DC4 / control unit of the LIEB-
DC5 HERR Diesel engines
With documentation
german / englisch / Pour diagnostic et commu-
french nication avec le module
électroniique de com-
Logiciel de communi- mande des moteurs Diesel
cation UP / CR / DC4 / LIEBHERR
DC5
Avec documentation
trilingue
LFR / en / Issue: 09 / 2012

R 924 Compact 2.02.3

copyright by

MJFCIFSS
Special tools for Liebherr Diesel engines Technical documentation

Darstellung Nr. Benennung Größe Ident. Nr. Gerät Anwendung

Representation No. Desciption Size Order no Model Application
Dessin N° Dénomination Grand. N°code Type Application
55 Dongle für PC mit USB 10035431 Für Verwendung der Soft-
Verbindung ware Nr 50
Dongle for PC mit USB For use of software nb 50
port Pour utilisation avec le
Dongle pour PC avec logiciel n° 50
port USB

56 Dongle für PC mit Par- 10035430

allel - Verbindung
Dongle for PC mit par-
allel port
Dongle pour PC avec
port parallèle

57 Dongle für PC mit 10035432

Verbindung PCMIA
Dongle for PC mit port
PCMIA
Dongle pour PC avec
port PCMIA
60 Verbindungskabel (nur Krikit 10035411 Für Verbindung der Motor-
für DC4 / DC5) steuereinheit mit dem PC
Connecting cable (to For connecting the elec-
use only with DC4 / tronic engine control unit to
DC5) PC
Câble de raccorde- Pour raccordement du
ment (seult pour DC4 / module de commande du
DC5) moteur sur PC
61 Verbindungskabel (nur 10035410
für UP / CR)
Connecting cable (to
use only with UP / CR)
Câble de raccorde-
ment (seult pour UP /
CR)

LFR / en / Issue: 09 / 2012

2.02.4 R 924 Compact

copyright by

MJFCIFSS
 Technical documentation Special tools for the hydraulic system

2.03: Special tools for the hydraulic system

Spezialwerkzeuge für die Hydraulikanlage

Outillage spécial pour le circuit hydraulique

Darstellung Nr. Benennung Größe Ident. Nr. Gerät Anwendung

Representation No. Desciption Size Order no Model Application
Dessin N° Dénomination Grand. N°code Type Application
10 Spezialschlüssel für SW 17 9359414 alle Zum Einstellen der Primär-
Druckbegrenzungs- Typen und Sekundär- Ventile im
ventile Steuerblock
Special wrench for re-
lief valves To ajust primary and sec-
Clé spéciale pour cla- ondary relief valves on
pets de limitation de control valves
pression
Pour le réglage des C.L.P.
11 SW 19 9210371 primaires et secondaires
sur le distributeur
15 Spezialschlüssel für 8042837 R 914B Zum Einstellen der 2-
Druckbegrenzungs- R 924B Stufen -Ventile im Zusatz-
ventile Wegeventil (Linde)
Special wrench for re- To ajust of 2-stepvalves on
lief valves control valves (Linde)
Clé spéciale pour cla-
pets de limitation de Pour le réglage des C.L.P.
pression sur le distributeur Linde

18 Spezialschlüssel für 9211987 R 914B Zum Einstellen der Hoch-

Druckbegrenzungs- R 924B druck-Begrenzungsventile
ventile am Drehwerks-Ölmotor
Special wrench for re- (Linde)
lief valves To ajust of high pressure
Clé spéciale pour cla- relief valve on swing motor
pets de limitation de (Linde)
pression Pour le réglage des C.L.P.
haute pression sur le mo-
teur d´ orientation (Linde)

20 Sicherungskappe SW 10 7009315 alle Zum Sichern der Einstells-

Safety - cap Typen chrauben an Hydraulikag-
Capuchon de sécurité gregaten
21 Kurze / short / court SW 13 7018734 To secure the adjusting
22 Lange / long SW 13 l 7615515 screws on the hydraulik ag-
23 SW 17 7380629 gregates
24 Kurze / short / court SW 19 7009316 Pour assurer les vis de ré-
25 Lange / long SW 19 l 7009317 glage sur aggregates hy-
26 M6 7023491 draulique
LFR / en / Issue: 09 / 2012

27 M8 7023492
28 M10 7023493
29 M12 7023494

R 924 Compact 2.03.1

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MJFCIFSS
Special tools for the hydraulic system Technical documentation

Darstellung Nr. Benennung Größe Ident. Nr. Gerät Anwendung

Representation No. Desciption Size Order no Model Application
Dessin N° Dénomination Grand. N°code Type Application
30 Montagehülse Siehe Gruppe 2.12 alle Zur Montage von O-Ring
Mounting sleeve See chapter 2.12 Typen und Stepseal-Ring auf Kol-
Bague de montage dans le groupe 2.12 ben von Hydraulikzyl. und
Stellkolben von Verstell-
pumpe und Verstellmotor.

For assembly of the 0-ring

and stepseal-ring on hy-
draulic zylinderpiston and
variable displacement
pump-regulation piston
and variable dispacement
motor regulating piston.

Pour le montage des joints

toriques et stepseal sur les
pistons des vérins hydr. et
les pistons de posi-
tionnemnet de la pompe et
du moteur hydr. à débit
variable
40 Spreizhülse Siehe Gruppe 2.12 alle Anwendung, siehe
Spreader sleeve See chapter 2.12 Typen Werkzeug Nr. 40
Baque d’écartement dans le groupe 2.12 Application, see also tool
no. 40
Application, voir outillages
n° 40

50 Kolbenschlüssel Siehe Gruppe 2.12 alle

Piston wrench See chapter 2.12 Typen
Clé pour piston de vé- dans le groupe 2.12
rin

Skizze zur Herstellung,

Blatt 2.12
Details to manufact. page
2.12
Voir dessin de fabric.,
feuille 2.12
60 Kolbenschlüssel SW 0541333 alle Zum Lösen und Anziehen
LFR / en / Issue: 09 / 2012

Piston wrench Typen der Kolbenmutter

61 Clé pour piston de vé- To remove and tighten of
rin Siehe Gruppe 2.12 piston nuts
62 See chapter 2.12 Pour le déblocage et le ser-
dans le groupe 2.12 rage de ecrou de piston
63

64

2.03.2 R 924 Compact

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MJFCIFSS
 Technical documentation Special tools for the hydraulic system

Darstellung Nr. Benennung Größe Ident. Nr. Gerät Anwendung

Representation No. Desciption Size Order no Model Application
Dessin N° Dénomination Grand. N°code Type Application
70 Steckschlüssel für SW 41 9245656 alle Zur Demontage und Mon-
Gewindebuchse SW 46 9247110 Typen tage des Dämpfungszap-
Socket wrench for SW 50 9244173 fens bei doppelseitiger
threaded bushing Endlagendämpfung am
Clé pour douille filetée Hydraulikzylinder.
Used to remove and install
damper pin on hydraulic
cylinders with damper on
piston / piston rod side.
Utilisé pour le démontage
et le montage de la douille
d’amortissement sur les
vérins équipés d’un amor-
tisseur de fin de course bi-
latéral
80 Abdrückwerkzeug für M16 9951120 alle Zum Abdrücken von Kol-
Kolbenstangenlager Typen benstangenlager an Hy-
Puller for piston rod draulikzylinder
bearing M20 9959261 To remove the piston rod
Arrache de palier de bearing
vérin M24 9959262 Pour retiver la culasse du
vérin
90 Füllvorrichtung kpl. mit W24,3 8145359 alle Zum Überprüfen und
Adapter und Fülls- 2x1/14“ Typen Nachfüllen von Blasens-
chlauch 3,0m peicher sowie Kolben- und
Filling device epl. with Membranspeicher
adupter and filling To check and refill dia-
hose phragm and piston type ac-
Dispositif de rempllis- cumulations
sage kpl. avec adap- Pour la vérifieation et rem-
teur et flexible de remp plissage des accumula-
lissage teurs à piston et
àmembrane
95 Montagehülse Ø 25 9951457 alle Zur Montage von Glyd-
96 Ø 22 9951508 Typen Ring und Abstreifring auf
97 Ø 45 9966421 den Plungerkolben von
98 Ø 25 9951458 LIKUFIX-Kupplungen.
For assembly of the Glyd-
ring and scraper - ring on
plunger piston of hydraulic
coupling LIKUFIX.
Pour le montage des ba-
gues Glyd et racleur sur les
pistons des accouple-
ments rapide du LIKUFIX.
105 Montagehülse 9280580 R 914 Zum Montieren und De-
Assambly Jacket R 924 montieren des Dichtrings
LFR / en / Issue: 09 / 2012

Douille de Montage im Pumpensicherheitsven-

til (Linde Steuerblock)
To disassemble and reas-
semble the pump release
valve (Control value Linde)
Pour l’assemblage et de-
sassemblage du clapet de
sécurité de la pompe (Dis-
tributéur Linde)

R 924 Compact 2.03.3

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MJFCIFSS
Special tools for the hydraulic system Technical documentation

Darstellung Nr. Benennung Größe Ident. Nr. Gerät Anwendung

Representation No. Desciption Size Order no Model Application
Dessin N° Dénomination Grand. N°code Type Application
106 Gewindestift mit Inn- M6 4901114 R 906 Zum Anhalten des
ensechskant R 916 Freigebedrucks der Fahr-
Hexagon socket set R 926 bremsen.
screw Classic To stop the pressure which
Vis sans tête à six releases the travel-brakes.
pans creux Pour stopper la pression
de déblocage des freins de
translation.

110 Abziehstange M6 9288234 R 900C Zur Demontage und Mon-

Rod R 904 tage des Kolbens der
Barre Druckwaage im LSC-Steu-
erblock
Used to remove and install
piston of pressure balance
on LSC - control valve
block
Utilisé pour le démontage
et le montage de piston /
compensateur de la LSC -
distributeur
115 Vakuumpumpe mit TF63/ 7405073 alle Zum Filtern des geschloss-
Unterdruck- DB-Ventil 2-24V Typen enen Drehwerkskreises
nach Reparatur oder bei
Vacuum pump with Pumpen- bzw. Ölmo-
vacuum valve torschäden.

Pompe à vide avec For filtration of the closed

clapet de limitation de swing loop after repairs or
pression négative. remplacement of defective
pump.
120 Unterdruck-DB-Ventil 5006213
Vacuum valve Pour filtrer le circuit fermé
Clapet de limitation de d'orientation après répara-
pression négative tion ou échange d'une
pompe ou d'un moteur dé-
125 T-Stück / Coupling / 7015042 fectueux
Raccord LFR / en / Issue: 09 / 2012

2.03.4 R 924 Compact

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 Technical documentation Special tools for the hydraulic system

Darstellung Nr. Benennung Größe Ident. Nr. Gerät Anwendung

Representation No. Desciption Size Order no Model Application
Dessin N° Dénomination Grand. N°code Type Application
130 Prüfkit zur Ver- 9565384 Zum Beurteilen des Ver-
schleißmessungen der schleißzustandes der
BPV Pumpen Drehwerkspumpe BPV
Test kit for wear of oder des Drehwerksmo-
BPV pumps tors. Skizze zur Herstel-
Nécessaire de con- lung, siehe Blatt Nr. 2.12
trôle d'usure des
pompes BPV To check wear of swing
besteht aus / consists / pump BPV or swing motor.
comprenant For details to manufacture,
A Stellschraube 9569343 see page no. 2.12
Adjustment screw
Vis de réglage Pour définir l'état d'usure
de la pompe d'orientation
B Gewindehülse 9569342 BPV ou du moteur d'orien-
Threaded fitting tation. Voir dessin de fabri-
Douille filetée cation, feuille n° 2.12

C Blindplatte 9170178
End plate
Plaque d'obturation

D Zylinderschraube 4000613
Allen head screw
Vis cylindrique
LFR / en / Issue: 09 / 2012

R 924 Compact 2.03.5

copyright by

MJFCIFSS
Special tools for the hydraulic system Technical documentation

LFR / en / Issue: 09 / 2012

2.03.6 R 924 Compact

copyright by

MJFCIFSS
 Technical documentation Special tools for electrical connectors

2.06: Special tools for electrical connectors

Spezialwerkzeuge für elektrische Steckverbindungen

Outillage spécial pour les connecteurs électriques

Fig. 1 Mate-N-LOK-Stecker und DT-Stecker

Fig. 2 Juniortimer Stecker und JPC-Stecker

Darstellung Nr. Benennung Größe Ident. Nr. Gerät Anwendung

Representation No. Desciption Size Order no Model Application
Dessin N° Dénomination Grand. N°code Type Application
10 Zum Crimpen der Kontakte für Ad- 7367025 alle
ern für Steckverbinder Typen
MATE-N-LOK 1,5 mm2
SURE-SEAL
FASTON 0,5 - 2,1 mm²

To crimp contacts for leads of

MATE-N-LOK 1,5mm2
SURE-SEAL
FASTON 0,5 - 2,1 mm²

Pour sertir les contacts pour con-

ducteurs sur connecteurs
MATE-N-LOK 1,5mm2
SURE-SEAL
LFR / en / Issue: 09 / 2012

FASTON 0,5 - 2,1 mm²

R 924 Compact 2.06.1

copyright by

MJFCIFSS
Special tools for electrical connectors Technical documentation

Darstellung Nr. Benennung Größe Ident. Nr. Gerät Anwendung

Representation No. Desciption Size Order no Model Application
Dessin N° Dénomination Grand. N°code Type Application
12 Zum Crimpen der Kontakte für Ad- 7366314 alle
ern 2,5 mm2 für Steckverbinder Typen
MATE-N-LOK

To crimp contacts for leads

2,5mm2 of MATE-N-LOK connec-
tors

Pour sertir les contacts pour con-

ducteurs 2,5mm2 sur connect-
eurs MATE-N-LOK

15 Werkzeug zum Ausbauen der 7366655 alle

verkabelten Crimpkontakte aus Typen
den Steckverbindern MATE-N-
LOK

Extraction tool to push a crimped

contact of to the MATE-N-LOK
connectors.

Outil pour extraire les contacts

sertis des connecteurs MATE-N-
LOK

LFR / en / Issue: 09 / 2012

2.06.2 R 924 Compact

copyright by

MJFCIFSS
 Technical documentation Special tools for electrical connectors

Darstellung Nr. Benennung Größe Ident. Nr. Gerät Anwendung

Representation No. Desciption Size Order no Model Application
Dessin N° Dénomination Grand. N°code Type Application
28 Handcrimpzange (nach MIL- 7367086 alle
C5015, VG 95234, VG 955342) Typen

Tool to crimp contacts (after MIL-

C5015, VG952234, VG 955342

Pince pour sertissage des con-

tacts (d’aprés MIL-C5015, VG
95234, 955342)

29 Crimpeinsatz zum Crimpen für 7409779

DEUTSCH (KPS - KPT - PT)
Steckverbinder mit Zange NR. 28

Crimp turret to crimpcontact of

connectors type DEUTSCH (KPS
- KPT - PT) sizes with special tool
no. 28

Tête de sertissage à utiliser pour

connecteurs DEUTSCH (KPS -
KPT - PT) avec la pince à sertir n°
28

30 Crimpeinsatz zum Crimpen für 7367084

DEUTSCH (15S/16S - 15/16 - 25/
12) Steckverbinder mit Zange NR.
28

Crimp turret to crimpcontact of

connectors type DEUTSCH (15S/
16S - 15/16 - 25/12) sizes with
special tool no. 28

Tête de sertissage à utiliser pour

connecteurs DEUTSCH (15S/16S
- 15/16 - 25/12) avec la pince à
sertir n° 28
35 Einsteckwerkzeug für CA-COM 7367017 alle-
kontakte (15S - 16S) Typen
Insertion tool for CA-COM contact
(15S - 16S)
Outil pour insérer les contacts CA-
COM (15S - 16S)

40 Handcrimpzange zum Crimpen 8503647 alle-

der Kontakte der Steckverbinder Typen
DEUTSCH
LFR / en / Issue: 09 / 2012

Tool to crimp contacts of connec-

tors type DEUTSCH

Pince pour sertissage des con-

tacts des connecteurs DEUTSCH

R 924 Compact 2.06.3

copyright by

MJFCIFSS
Special tools for electrical connectors Technical documentation

Darstellung Nr. Benennung Größe Ident. Nr. Gerät Anwendung

Representation No. Desciption Size Order no Model Application
Dessin N° Dénomination Grand. N°code Type Application
45 Werkzeug zum Aus- Größe 4 8503633 alle
bauen der verkabelten Typen
Crimpkontakte an
Steckverbindungen
DEUTSCH
Extraction tool to push Size 4
a crimped contact of
the connectors
DEUTSCH
Outil pour extraire les Grand.
contacts sertis des 4
connecteurs
DEUTSCH

33 Size 8 8503632
34 Size 12 8145674
35 Size 16 8145673
36 Size 20 8503630
37 Stiftkontakt für Adern alle
der Steckverbinder DT Ø 0,8- 7368251 Typen
Pin contact for cable 1,0
for connector DT 7368406
Broches pour conduc- Ø 1,0-
teurs pour connect- 2,0 6905271
eurs DT
Ø 2,0-
38 Buchsenkontakt für 3,0
Adern der Steck- 7368252
verbinder DT
Socket contact for ca- 7368405
ble for connector DT Ø 0,8-
Douilles pour conduc- 1,0 6905272
teurs pour connect-
eurs DT Ø 1,0-
2,0

39 Stopfen / Plug / Bou- Ø 2,0-

chon 3,0 7368253
AMP / MATE-N-LOK alle
40 Buchsenkontakte / 1,5 mm² 6202619 Typen
41 Socket contact / 2,5 mm² 6202591
Douille
42 1,5 mm² 6202620
43 Stiftkontakt / Pin con- 2,5 mm² 6202592
tact / Broche
LFR / en / Issue: 09 / 2012

2.06.4 R 924 Compact

copyright by

MJFCIFSS
 Technical documentation Special tools for electrical connectors

Darstellung Nr. Benennung Größe Ident. Nr. Gerät Anwendung

Representation No. Desciption Size Order no Model Application
Dessin N° Dénomination Grand. N°code Type Application
Buchsenkontakt / mm² alle
Socket contact / Typen
45 Douille 0,8 - 1,3 6003031
DEUTSCH / DT; HD;
DRC (size 20) AWG
46 16-18 1,31 - 7368405
DEUTSCH / DT; HD; 2,08
DRC (size 16) AWG
47 14-16 1,95 - 6905272
DEUTSCH / DT; HD; 3,31
DRC (size 12) AWG
48 12-14 5,26 - 7369773
DEUTSCH / DT; HD; 8,4
DRC (size 8) AWG 8-
49 10 7369772
DEUTSCH / DT; HD;
DRC (size 4) AWG 6

Stiftkontakt / Pin con-

50 tact / Broche 0,8 - 1,3 7368251
DEUTSCH / DT; HD;
DRC (size 20) AWG
51 16-18 1,31 - 7368406
DEUTSCH / DT; HD; 2,08
DRC (size 16) AWG
52 14-16 1,95 - 6905271
DEUTSCH / DT; HD; 3,31
DRC (size 12) AWG
53 12-14 5,26 - 7369775
DEUTSCH / DT; HD; 8,4
DRC (size 8) AWG 8-
54 10 7369774
DEUTSCH / DT; HD;
DRC (size 4) AWG 6

CANNON / CA-COM mm² alle

55 Buchsenkontakt / 1,5 6202638 Typen
Socket contact /
Douille
CANNON / SURE
56 SEAL 1,5 6202434
Buchsenkontakt /
57 Socket contact / 1,5 6202444
Douille
Stiftkontakt / Pin con-
tact / Broche
58 AMP; BOSCH / MI- 1,5 6202010
CROTIMER
LFR / en / Issue: 09 / 2012

Buchsenkontakt /
Socket contact /
Douille

R 924 Compact 2.06.5

copyright by

MJFCIFSS
Special tools for electrical connectors Technical documentation

Darstellung Nr. Benennung Größe Ident. Nr. Gerät Anwendung

Representation No. Desciption Size Order no Model Application
Dessin N° Dénomination Grand. N°code Type Application
60 Pneumatic power HDP 8504158 alle
crimp equipment to 400 Typen
crimp inserts for con-
nectors DEUTSCH
Pneumatische Börde-
lanlage zum
quetschen der
Deutsch Kontakte
Sertiseuse pneuma-
tique pour contacteur
61 Deutsch 4 8504159
62 Werkzeug (Buchsen 8 8504160
63 und Stifte) 12 8504161
64 Tools (sockets and 16 8504162
pins)
Outillage (douilles et
broches)
70 Einbauwerkzeug zum Einführen 7367023 alle
der verkabelten Crimpkontakte in Typen
die Steckverbinder SURE-SEAL
CT 31

Insertion tool to insert crimped

contact into the connectors SURE-
SEAL CT 31

Outil d’insertion des contacts ser-

tis dans les connecteurs SURE-
SEAL CT 31
75 A:Ausbauwerkzeug Stiftkontakte 7567020 alle
aus Steckverbinder SURE SEAL Typen

Extraction tool for pin contacts of

connectors SURE SEAL

Outil d’extraction pour broches

des connecteurs SURE-SEAL
80 B: Ausbauwerkzeug Buchesen- 7567022 alle
kontakte Typen

Extraction tool for socket contacts

Outil d’extraction pour douilles

C: Ausbauwerkzeug für Kontakte 7370373

der Steckverbinder MICROTIMER

Extraction tool for contacts of con-

LFR / en / Issue: 09 / 2012

nectors MICROTIMER

Outil d’extraction pour contacts

des connecteurs MICROTIMER
85 Einbauröhrchen für CT 31 7022464 alle
Werkzeug Nr. 42 Typen

Pipe for tool no. 42

Tube pour outil n° 42

2.06.6 R 924 Compact

copyright by

MJFCIFSS
 Technical documentation Special tools for electrical connectors

Darstellung Nr. Benennung Größe Ident. Nr. Gerät Anwendung

Representation No. Desciption Size Order no Model Application
Dessin N° Dénomination Grand. N°code Type Application
90 Hilfswerkzeug zum halten des 7367021 alle
SURE-SEAL Steckverbinder 2, 3, Typen
und 4 polig beim Ein und Ausbau
der angecrimten Kontakte

Auxilitary tool for holding SURE-

Seal connectors with 2, 3 and 4
contacts during insertion and ex-
traction of crimped contacts

Outil de maintien des connecteurs

SURE-SEAL 2, 3 et 4 pôles pen-
dant l’insertion et l’extraction des
contacts sertis

95 Gleich wie Werkzeug 324 für 5, 6 7367085

und 7 polig

The same as tool 342, for connec-

tions with 5, 6 and 7 contacts

Idem 342, pour connecteurs 5,6 et

7 pôles
100 Reparatur - Set 7015073 alle
beinhaltet Sonderwerkzeuge 40 Typen
,41, 42, 45 und 46, sowie Bedie-
nungsanleitung und Gleitmittel

Kit for fielt repair

contents special tools 40, 41, 42
45 and 46, operating instruction
and lucatingfluid

Nécessaire de réparation contient

les outillages spéciaux 40, 41, 42,
45 et 46, une notice d’utilisation et
le lubrifant pour les contacts
105 Ausbauwerkzeug CA- 15S 7367019 alle
COM Kontakte 16S Typen
Extraction tool CA-
COM contact
Outil d'extraction de
contacts CA-COM

110 Zylinderspule Auswährter 6204661 alle

Solenoid tester Typen
Testeur solénoïde
LFR / en / Issue: 09 / 2012

R 924 Compact 2.06.7

copyright by

MJFCIFSS
Special tools for electrical connectors Technical documentation

Darstellung Nr. Benennung Größe Ident. Nr. Gerät Anwendung

Representation No. Desciption Size Order no Model Application
Dessin N° Dénomination Grand. N°code Type Application
115 Thermometerpistole 10024185 alle
Heat gun Typen
Pistolet thermometre

120 Entriegelung- 777-310 7022773 alle

swerkzeug für WAGO Typen
- Steckelemente

Extraction tool for

WAGO - connectors

Outil d’extraction pour

connecteurs WAGO

125 IC-Ausziehwerkzeug 8042630 alle

A IC-Extraction tool Typen
Outil d’extraction de Circuits In-
tégrés

125 IC-Einsetzwerkzeug 8042629

B IC-Mouting tool
Outil de sertissage de Circuits In-
tégrés

130 Ergocrimp - Handzange 6004391 alle Zum Crimpen der Kontakte

Ergocrimp - plier Typen für Steckverbinder JPT
Ergocrimp - pince (Tyco)

To crimp contacts for leads

of JPT (Tyco) connectors

Pour sertis les contacts

pour connecteurs JPT
(Tyco)
Ergocrimp - Matrize alle Zum Crimpen der Kontakte
Ergocrimp - matrix Typen To crimp contacts for leads
Ergocrimp - matrice Pour sertir les contacts
mm2 pour conducteurs
132 0,5-2,5 10016253 Junior Power Timer Nr.
927777-3 / Nr. 927779-3 /
133 0,5-2,5 10016255 927846-2
Junior power Timer/EDS
LFR / en / Issue: 09 / 2012

134 0,5-2,5 10016256 Nr. 929938-3/Dop-

pelfederkontakt Nr.
929940-3
Flachstecker Nr. 963745-1
/ Nr. 963746-1

2.06.8 R 924 Compact

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MJFCIFSS
 Technical documentation Special tools for electrical connectors

Darstellung Nr. Benennung Größe Ident. Nr. Gerät Anwendung

Representation No. Desciption Size Order no Model Application
Dessin N° Dénomination Grand. N°code Type Application
140 Ausdrückwerkzeug 7415334 alle zum Ausbauen der verka-
Extraction tool Typen belten Crimpkontakte aus
Outil den Steckverbindern JPT
(Tyco)
To push a crimped contact
of to the JPT (Tyco) con-
nectors
Pour extraire les contacts
sertis des connecteurs JPT
(Tyco)
145 Crimpzange 10016251 alle Zum Crimpen der Little-
Crimp - plier Typen fuse-Kontakte für Steck-
Crimp - pince verbinder JPT (Tyco),
siehe auch NR. 92.

To crimp littlefuse-contacts
for leads of JPT (Tyco)
connectors, see also No.
92.

Pour sertir les littlefuse-

contacts pour connecteurs
JPT (Tyco), voir N°.92.
147 Ergocrimp - Matrize mm2 10016252 alle Zum Crimpen der Kontakte
Ergocrimp - matrix 0,5 Typen in Verbindung mit Nr. 90
Ergocrimp - matrice -3,32
In connection with No°. 90
and used to crimp contacts
for leads.

Pour sertir les contacts

pour conducteurs, avec
crimp-pince N°.90.

Steckhülse Nr. 913053/Nr.

913065 / Nr. 913066 / Nr.
913067 / Nr. 913069 / Nr.
913079
Doppelfeder kontakt Nr.
913071 / Nr. 913072
150 Handschuhe size B 8503765 alle tested at 10000 V.
Gloves size C 8503764 Typen tested at 10000 V.
Gants size B 8503762 tested at 20000 V.
size C 8503763 tested at 20000 V.
LFR / en / Issue: 09 / 2012

155 Spannungsanzeiger 8503757 alle

Voltage detector Typen
Tensiometre

R 924 Compact 2.06.9

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MJFCIFSS
Special tools for electrical connectors Technical documentation

Darstellung Nr. Benennung Größe Ident. Nr. Gerät Anwendung

Representation No. Desciption Size Order no Model Application
Dessin N° Dénomination Grand. N°code Type Application
160 Isolierteppich alle
Insulating carpet Typen
Tapis isolant

165 Multifunktion Zange 8503758 alle

Multi-function tool Typen
Pince multi fonctions
170 Multi Spannung MJ10 8503759 alle
Werkzeug BM12 Typen
Multi-voltage tool
Outillage multi-voltage
175 Widerstand und Erde Einrichtung 8503760 alle
Earthing tool Typen
Caténaire résistance et terre

180 Teleskopischer Isolierter Stock 8503761 alle

Insulated telescopic rod Typen
Canne téléscopique isolée

LFR / en / Issue: 09 / 2012

2.06.10 R 924 Compact

copyright by

MJFCIFSS
 Technical documentation Special tools for gears

2.07: Special tools for gears

Model Application
Designation Nb Designation Size Order no

Socket for wrench for- SAT To loosen and tighten the

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

Compression device FAT For disassembly and as-

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

Compression device FAT For disassembly and as-

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

Installation tool for FAT To install the slipring seals

slipring seals 350/022 8503594 into the travel gears FAT.
350/032 See details in subgroup
400/063 8503179 2.19.
LFR / en / Issue: 09 / 2012

400/073
450/044 8503181
450/064 8503181
500/035 10027892
550P046 10027891
600P067 10027894

R 924 Compact 2.07.1

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MJFCIFSS
Special tools for gears Technical documentation

LFR / en / Issue: 09 / 2012

2.07.2 R 924 Compact

copyright by

MJFCIFSS
 Technical documentation Common tools

2.08: Common tools

Werkzeuge allgemein

Outillage général

Ident.
Darstellung Nr. Benennung Größe Nr. Gerät Anwendung
Representation No. Desciption Size Order Model Application
Dessin N° Dénomination Grand. no Type Application
N°code
5 Drehmomentschlüs- 1-12 8503599 alle Zum anziehen der Bolzen
10 sel - größe in Nm 60-300 8503048 Typen am vorgeschriebenen
15 Torque wrench - size 140-760 7362441 Drehmoment Wert.
20 in Nm 750-2000 8503600 To tighten the bolt to the
Clé dynamométrique - 1500-3000 8503601 prescribed torque.
Grandeur en Nm Pour serrer les boulons
au couple prescrit.

25 Hydraulischer Schlüs- 3 - XLT 7373023 alle Zum anziehen der große

30 sel Hytorc 5 - XLT 8502890 Typen Bolzen am vorgeschrie-
35 Hydraulic wrench Hy- 10 - XLT 8503882 benen Drehmoment Wert.
40 torc 30 - XLTC 8503881 To tighten the big bolt to
Clé hydraulique Hytorc the prescribed torque.
Pour serrer les gros bou-
lons au couple prescrit.

45 Steckschlüssel 30 mm 8589150 alle

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

Ringschraube M12 4026006 R914 Zum heben von ver-

Lifting eye M30 400656 R924 schiedenen Bagger Ge-
Vis à anneau M42 4001313 genstände.
M48 4900835 For the lifting of different
M56 4901609 components of the exca-
vator.
Pour soulever divers com-
posant de la pelle.
LFR / en / Issue: 09 / 2012

R 924 Compact 2.08.1

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MJFCIFSS
Common tools Technical documentation

LFR / en / Issue: 09 / 2012

2.08.2 R 924 Compact

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MJFCIFSS
 Technical documentation Measuring tool for spool travel

2.10: Measuring tool for spool travel

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

Fig. 1 Messvorrichtung / Measuring tool / Appareil de mesure

1 Hubmessvorrichtung / Measuring tool / Appareil de mesure

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

Hub bei grösse / Stroke for size /

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

Tab. 1 Hub bei grösse / Stroke for size / Course pour la taille
LFR / en / Issue: 09 / 2012

R 924 Compact 2.10.1

copyright by

MJFCIFSS
Measuring tool for spool travel Technical documentation

Fig. 2 Technische Zeichnung / Technical drawing / dessin technique

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

(mm x 0.03937 = inches)
LFR / en / Issue: 09 / 2012

2.10.2 R 924 Compact

copyright by

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

2.12: Mounting tools for hydraulic cylinders

1 Mounting wrench for hydraulic cylinders

Wrench with bores «A» for retaining bolts

Id.-Nr. a b c d e f g h i 4-KT
9131359 52 38 75 200 10 8 8 15 60 1/2"
9131362 60 44 85 200 14 10 10 15 65 1/2"
9231993 68 52 100 220 14 10 10 15 70 1/2"
8007364 # 75 54 110 220 14 12 10 20 84 3/4"
80 54 110 220 14 12 10 20 84 3/4"
8007365 88 63 120 250 14 12 10 20 90 3/4"
8007366 100 78 135 260 14 14 10 20 95 3/4"
9919856 115 88 150 300 14 14 10 20 105 3/4"
9196978 # 125 97 170 320 14 14 10 25 110 3/4"
130 97 170 320 14 18 15 25 110 3/4"
8007367 145 113 185 380 14 18 15 25 120 3/4"
9925117 160 125 200 420 14 18 15 25 130 3/4"
9131373 175 135 215 450 14 20 19 25 135 3/4"
9131376 220 156 280 500 14 30 28 40 158 3/4"
0541380 85 72 110 210 11 8 8 15 210 1/2"
0542336 120 100 140 240 12 8 9 152 240 1/2"
0540947 124 100 150 240 12 8 9 15 240 1/2"
0541379 145 125 170 280 11 8 9 15 280 3/4"
0540966 160 135 185 280 12 10 9 20 280 3/4"
LFR / en / Issue: 09 / 2012

0529897 165 140 190 280 12 10 9 20 280 3/4"

Tab. 1 Chart for mounting wrenches (with bores)

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

R 924 Compact 2.12.1

copyright by

MJFCIFSS
Mounting tools for hydraulic cylinders Technical documentation
Piston nut wrench

Forked type piston wrench

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

Tab. 2 Chart for mounting wrenches (forked type)

2 Piston nut wrench

Piston nut wrench

Slotted
Bauform SW 6-KT SW 2-FL 4-KT Id.-Nr.
round nut Ø
Size - Identific. number.
LFR / en / Issue: 09 / 2012

M30X1,5 - 7006469 44 *
M32X1,5 - 7010262 50 *
M33 X1,5 - 9226916 41 1/2“ 9921132
M36X1,5 - 9875702 50 1/2“ 9211967
M42X1,5 - 7010163 62 *
M42X1,5 - 9970088 60 1/2“ 9211967
M42X1,5 - 9113734 55 1/2“ 9921132

2.12.2 R 924 Compact

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

Piston nut wrench

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

Tab. 3 Chart for piston nut mounting wrenches

* commercially available slotted nut wrench

3 Mounting and spreader sleeve

Kolben Ø Mounting sleeve 990 Spreader sleeve 991

Piston Ø Identification number Identification number
32 9136418 9136416
32 9113100 9113099
38 9143279 9143280
40 9196902 9136417
45 9136419 9136417
50 9288953 9288954
63 9170510 9170512
65 9177541 9177540
70 9110556 9110402
80 9227165 9227166
LFR / en / Issue: 09 / 2012

85 9998618 9110404
85 9115710 9115708
90 9227161 9227162
100 9998626 9110405
105 9951984 9951983
110 9170509 9170511
110 9960483 9960502

R 924 Compact 2.12.3

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

Kolben Ø Mounting sleeve 990 Spreader sleeve 991

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

Tab. 4 Mounting and spreader sleeve chart

Mounting sleeve to insert the piston into the jack

Piston Ø Mounting sleeve 950

Identification number
65 9177543
80 9231749
90 9248893
90 9248894
100 9248895
110 9248897
120 9248898
130 92487899
LFR / en / Issue: 09 / 2012

140 9177541
140 9952180
160 9248909
190 9281241
210 9281240
250 9951147
260 9284918

2.12.4 R 924 Compact

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

Tab. 5 Piston mounting sleeves

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

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

Piston Ø Mounting sleeve 950

Identification number
90 9282761
105 9287177
140 9926806

Tab. 6 Piston rod mounting sleeves

Notice !
The mounting sleeve 960 are destined to preserve the sealing and guiding elements from damage
during the piston rod bearing installation.
LFR / en / Issue: 09 / 2012

R 924 Compact 2.12.5

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

LFR / en / Issue: 09 / 2012

2.12.6 R 924 Compact

copyright by

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

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

Fig. 1 Wrench socket for slotted nut

Swing gear SAT

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

Tab. 1 Identification numbers of the wrench sockets

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

LFR / en / Issue: 09 / 2012

R 924 Compact 2.14.1

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

Fig. 2 Definition of dimensions of the sockets

SAT A B C D E F G H J K L M N O
225 90 40 30 55 71,5+0,2 77 100 95 3,8 80 35 30 40 7,8
250 100 55 46 60 81,5+0,2 86 110 105 3,8 90 35 30 50 7,8
275 110 55 46 70 92,2+0,2 95 120 105 3,8 90 35 30 50 7,8
300 125 55 46 80 106,5+0,2 110 140 120 3,8 105 35 30 50 7,8
325 126,5 55,5 46 50 115 115,5 150 115,5 3,8 94 35 30 55 7,8
LFR / en / Issue: 09 / 2012

350 137,5 55,5 46 50 125 126,2 160 113,5 3,8 92 35 30 55 7,8

400 173,5 60 46 60 144,3 146 189,5 145 6,7 117 35 30 85 19,7
450 179 50 30 0 164 166 198 127 6,5 107 35,47 33 76 20

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

2.14.2 R 924 Compact

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 Technical documentation Compression device for brake piston of gear SAT

2.15: Compression device for brake piston of gear SAT

Fig. 1 Dimensions of the compression devices

Swing Gear Identificat.

A B C D E F G H
SAT / Type number
SAT 200 9206110 252 40 12 10 10 14 90 110
SAT 225 9202825 268 40 12 10 10 16 100 117
SAT 250 9199319 300 40 12 10 10 18 110 131
SAT 275 9202826 326 40 12 10 10 18 120 143
SAT 300 9202827 364 50 20 15 15 22 130 157
SAT 325 / 204 9202828 390 50 20 15 15 22 142 170
SAT 350 / 205 9202829 410 50 20 15 15 22 154 180
SAT 375 / 253 10849325 430 50 20 15 15 14 162 191
SAT 400 / 206 9393900 440 50 20 15 15 18 175 202.
SAT 400 / 256 5
SAT 450 / 207

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

LFR / en / Issue: 09 / 2012

R 924 Compact 2.15.1

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MJFCIFSS
Compression device for brake piston of gear SAT Technical documentation

LFR / en / Issue: 09 / 2012

2.15.2 R 924 Compact

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MJFCIFSS
 Technical documentation Compression device for brake piston of gear FAT -

2.16: Compression device for brake piston of gear FAT -

construction line A
For travel gears FAT corresponding to construction line A
FAT 350/..., 400/..., 450/... & 500/...

Travel gears Identificat.

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

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

To convert dimensions in inches

(mm x 0.03937 = inches)
LFR / en / Issue: 09 / 2012

R 924 Compact 2.16.1

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MJFCIFSS
Compression device for brake piston of gear FAT - Technical documentation

LFR / en / Issue: 09 / 2012

2.16.2 R 924 Compact

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 Technical documentation Tools for installing the slipring seals

2.19: Tools for installing the slipring seals

Fig. 1 Definition of the dimensions of the mounting tool

Travel gear Ordering Slipring seal

Ø1 Ø2 Ø3 Ø4 Ø5
FAT number Type Ø6
350 P 012 8503594 76.90 H - 28 341 350 340 310 334 343
350 P 022
350 / 012 8503178 76.90 H - 30 A1 375 384,1 372 325 369 377,5
355 P 076 76.90 H - 30
355 P 077
LFR / en / Issue: 09 / 2012

400 / 023 8503179 76.90 H - 60 394 402 392 365 384 395
400 / 043
400 / 063
400 / 073
400 / 013 8503180 76.90 H - 70 415 424 414 390 405 417
450 / 064 8503181 76.90 H - 61 457 465 455 415 446 458
450 / 044
500 / 035 10027892 76.90 H - 65 A2 495 504 494 430 485 497

R 924 Compact 2.19.1

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Tools for installing the slipring seals Technical documentation

Travel gear Ordering Slipring seal

Ø1 Ø2 Ø3 Ø4 Ø5
FAT number Type Ø6

550 / 026 10027891 76.90 H - 74

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

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

LFR / en / Issue: 09 / 2012

2.19.2 R 924 Compact

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MJFCIFSS
 Technical documentation Special tool for lifting the counterweight

2.28: Special tool for lifting the counterweight

There is no special tool necessary for lifting the counterweight, see sub-group 6.75.
LFR / en / Issue: 09 / 2012

R 924 Compact 2.28.1

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MJFCIFSS
Special tool for lifting the counterweight Technical documentation

LFR / en / Issue: 09 / 2012

2.28.2 R 924 Compact

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 Technical documentation Special tools for lifting the uppercarriage

2.30: Special tools for lifting the uppercarriage

For R 924 Compact types 911 / 198

Fig. 1 Definition of the dimensions of the standoff

LFR / en / Issue: 09 / 2012

R 924 Compact 2.30.1

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MJFCIFSS
Special tools for lifting the uppercarriage Technical documentation

For R 924 Compact Tier III types 1055 / 1056

Fig. 2 Definition of the dimensions of the standoff

LFR / en / Issue: 09 / 2012

2.30.2 R 924 Compact

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MJFCIFSS
 Technical documentation

Group 3: Technical Data /

Maintenance guidelines

Technical data.........................................................................................................................3.10
R 924 Compact Tier III Type 1055 from serial number 20472
R 924 Compact Tier III Type 1056 from serial number 23772
R 924 Compact Tier III Type 1083 from serial number 21909

Control and maintenance chart.............................................................................................3.60

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

Control and maintenance chart.............................................................................................3.70

R 924 Compact Tier III Type 1083 from serial number 21909
LFR / en / Issue: 03 / 2010

R 924 Compact 3.00.1

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MJFCIFSS
 Technical documentation

LFR / en / Issue: 03 / 2010

3.00.2 R 924 Compact

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MJFCIFSS
 Technical documentation Technical data

Group 3: Technical Data /

Maintenance guidelines

3.10: Technical data

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

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

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

1083
LFR / en / Issue: 03 / 2010

Hydraulic system 1055 1056

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

R 924 Compact 3.10.1

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MJFCIFSS
Technical data Technical documentation

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

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

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

1083
Swing gear 1055 1056
LFR / en / Issue: 03 / 2010

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

3.10.2 R 924 Compact

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MJFCIFSS
 Technical documentation Technical data

1083
Swing gear 1055 1056
Tunnel
Swing brake Type disc brake (negativ)
Further informations see group 9

1083
Travel gear 1055 1056
Tunnel
Travel gear Type FAT 350 P 022
normal speed / high speed km / h 3,2 / 5,3
Travel motor Type FMV
Gear oil quantity l 2x3
Oil quality / -viscosity and oil change intervals see sub-group 1.50, 1.51 and 3.60
Travel brake Type disc brake (negativ)
Further informations see group 11

1083
Track 1055 1056
Tunnel
Track Type B60 D6C
Track roller Type D6
Qutity 8
Carrier roller Type B60
Qutity 2
Track pad width mm 500 - 600 - 500 - 600 600
750
Spec. ground pressure (by weight on first page) N /cm2 0,43 - 0,62 0,46 - 0,67 0,45
Further informations see group 12

1083
Centralized lubrication 1055 1056
Tunnel
Grease quantity per working hour cm3 18
Grease quantity in the container kg 4 2,5
Further informations see group 18
LFR / en / Issue: 03 / 2010

R 924 Compact 3.10.3

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MJFCIFSS
Technical data Technical documentation

LFR / en / Issue: 03 / 2010

3.10.4 R 924 Compact

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 Technical documentation Control and maintenance chart

3.60: Control and maintenance chart

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

Maintenance /
WORK TO BE CARRIED OUT
inspection at
R 924 Compact
operating hours

By maintenance personnel By authorized specialist personnel Note

At 1000, 3000

At 2000, 4000

(machine owner)
Every 10 -50

At 500, 1500
Every 8 - 10
On delivery

 First and only interval

 Repeat interval  First and only interval
 Special interval every 250 hours  Repeat interval

DIESEL ENGINE AND SPLITTERBOX

      Check oil level in engine

      Check oil pressure and coolant temperature during operation

      Check air filter on maintenance display

     Check and drain water separator on fuel filter (or when the corresponding sym-
bol appears on the display)
     If mounted, drain regularly the water in the water separator of the particles filter
system
    Check coolant level

    Drain off water and sediment at fuel tank

    Empty dust discharge valve on air filter (shorten or extend interval as required)

    Check oil level in splitterbox

   Check and clean cooler and ventilator

   Check condition of belt for A/C compressor and alternator installation

   Replace lubricating oil filter cartridge (at least 1 x yearly)

   Replace engine oil (at least 1 x yearly) 1)

   Replace splitterbox oil

   Check oil, cooling and fuel system for leaks and condition

   Check anti-corrosion fluid / antifreeze in coolant, if necessary rectify the mixtu-

LFR / en / Issue: 03 / 2010

re concentration
   Check electronic control unit mounting

   Check sensor and cable connections for sound condition

   If mounted, carry out the maintenance of the diesel particulate filter LIEBHERR

   If mounted, carry out the maintenance of the diesel particulate filter Engelhard

R 924 Compact 3.60.1

copyright by

MJFCIFSS
Control and maintenance chart Technical documentation

Maintenance /
WORK TO BE CARRIED OUT
inspection at
R 924 Compact
operating hours

By maintenance personnel By authorized specialist personnel Note

At 1000, 3000

At 2000, 4000

(machine owner)
Every 10 -50

At 500, 1500
Every 8 - 10
On delivery

 First and only interval

 Repeat interval  First and only interval
 Special interval every 250 hours  Repeat interval

   Check intake and emission system for leaks and condition (first time at 500 op.
hours)
   Check the exhaust return shut-off flap

   If mounted, replace bypass oil filter element (first 500 hours, and at least every
6 months)
  Check / adjust valve clearance

  Check engine console, oil sump and splitterbox mounts

  Grease flywheel tooth

  Replace fuel fine filter cartridge (or if powerloss) 4)

  Replace fuel preliminary filter cartridge (or if powerloss) 4)
   Replace oil separator fliter

Check heat flange (before start of winter)

Replace air filter main element (according to maintenance display / at least an-
nually)

Replace air filter safety element (every third change of main element / at least Never
annually) clean!

Check air hoses between air filter and engine (at filter maintenance)

Replace antifreeze and anticorrosive coolant mixture (every 2 years or every

3000 hours) (only for authorized specialist personnel)

Check vibration damper for distortion (every 3000 op. hours)

HYDRAULIC SYSTEM

      Check oil level in hydraulic tank

      Clean magnetic bar in return-line filter (daily during first 300 op. hours)

   Replace filter unit on control oil unit

LFR / en / Issue: 03 / 2010

   Check unit mounts

   Check and clean hydraulic oil cooler and ventilator 4)

   Drain off water in hydraulic tank
(when using environmentally acceptable fluids, max. 0.1 % water proportion
permissible, insert partial flow filter, take oil sample)
   If mounted check return filter for hydraulic hammer for cleanliness, replace ele-
ment if necessary

3.60.2 R 924 Compact

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MJFCIFSS
 Technical documentation Control and maintenance chart

Maintenance /
WORK TO BE CARRIED OUT
inspection at
R 924 Compact
operating hours

At 1000, 3000 By maintenance personnel By authorized specialist personnel Note

At 2000, 4000
(machine owner)
Every 10 -50

At 500, 1500
Every 8 - 10
On delivery

 First and only interval

 Repeat interval  First and only interval
 Special interval every 250 hours  Repeat interval

   Replace filter unit in return-line filter (first time at 500 op. hours) 2)
   Clean or replace filter unit of leak oil filter (first time at 500 op. hours) 2)
Replacement necessary after max. 3 cleanings
   If mounted, replace bypass oil filter element (first time at 500 op. hours) 2)
  Check hydraulic system for leaks and function

  Check / adjust servo, primary and secondary pressures

 Replace hydraulic oil in tank (or optimise interval with oil analyses) 2), 3)
 Bleed hydraulic pumps (when replacing oil)

 Replace ventilation and vent filters on hydraulic tank 2)

ELECTRICAL SYSTEM

      Check indicator lights and display devices

   Check lighting

   Check acid concentration and level on batteries

   Check cable terminals and pole ends on batteries

   Spray slip rings on swing connection (if present) with Cramolin contact spray

   Check function of entire system and units

SWING GEAR TRANSMISSION

    Check oil level and look for leaks

   Replace transmission oil (first time at 500 op. hours).

  Check function and operation of slewing gear brake

  Check transmission and oil motor mounts

LFR / en / Issue: 03 / 2010

BALL SWING RING

  Check mounting screws for correct positioning

  Check pinion gear mesh

TRAVEL GEAR

    Check for leaks

R 924 Compact 3.60.3

copyright by

MJFCIFSS
Control and maintenance chart Technical documentation

Maintenance /
WORK TO BE CARRIED OUT
inspection at
R 924 Compact
operating hours

By maintenance personnel By authorized specialist personnel Note

At 1000, 3000

At 2000, 4000

(machine owner)
Every 10 -50

At 500, 1500
Every 8 - 10
On delivery

 First and only interval

 Repeat interval  First and only interval
 Special interval every 250 hours  Repeat interval

  Check transmission and oil motor mounts

  Replace transmission oil (first time at 500 op. hours)

TRACKS

      Visual check on track tension, retension if necessary

  Clean track (when work is finished)

    Check mounts on track pads and sprockets

   Clean and grease sliding surfaces of tensioning device

   Check for leaks on idlers, carrier rollers and track rollers

CAB + HEATING

    Check / refill washing fluid in windscreen washer system container

   Check heating function (before start of winter)

  Check heating system for leaks

  Check door and window hinges and locks

 Check water inlet valve for function and dirt, clean if necessary

AIR-CONDITIONING SYSTEM

    Switch on air-conditioning system regularly (at least 1 x every 14 days)

   Check capacitor for contamination, blow out if required

   Clean recirculated / fresh air filter, replace if required, shorten maintenance in-
terval for heavy dust use
   Check mounting screws and compressor drive belt

   Check dryer-collector unit (moisture, fill and condition), replace if required

LFR / en / Issue: 03 / 2010

 Check evaporator unit, clean if required

 Check electrical lines for abrasions and plug connections for correct positio-
ning
 Check overpressure switch for function

 Check refrigerating capacity after opening or repair, or as required

3.60.4 R 924 Compact

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MJFCIFSS
 Technical documentation Control and maintenance chart

Maintenance /
WORK TO BE CARRIED OUT
inspection at
R 924 Compact
operating hours

At 1000, 3000 By maintenance personnel By authorized specialist personnel Note

At 2000, 4000
(machine owner)
Every 10 -50

At 500, 1500
Every 8 - 10
On delivery

 First and only interval

 Repeat interval  First and only interval
 Special interval every 250 hours  Repeat interval

Replace dryer-collector unit annually, check coolant circuit for leaks and re-
place refrigerant and refrigerant oil

Have function of ventilation flaps and defrost thermostat checked annually by

a refrigeration engineer

UNDERCARRIAGE + UPPERCARRIAGE + ATTACHMENT

    Grease bearing points via centralised lubrication system (using button into the
cab for semi automatic systems or no handling for fully automatic systems).
    Grease bearing points by hand if they are not connected to the centralised lu-
brication system (if required on bucket, specials undercarriages and attach-
ments).
    Visually check wear condition of teeth

    Check parts for cracks

    Check ballast weight and tanks mounts

   Check line and screw connections for correct positioning

  Check trim panel hinges, quick-release fasteners and gas pressure springs of
hatches. Lubricate or change the components if necessary.
   Check the lowering speed of the attachment ~4 sec.
 Indicate appropriate use of attachment
 Have device lubricated according to lubrication chart by device operator and
indicate any operating errors.

HYDRAULIC QUICK-CHANGE ADAPTER

      Check function of visual and acoustic warning devices

     Visually check drawn out position of locking pins

     Check condition of hydraulic hoses and of cable kit

LFR / en / Issue: 03 / 2010

    Lubricate locking pins

 Clean sieve filter in bolt connections of hydraulic hoses

MECHANICAL QUICK-CHANGE ADAPTER

     Visually check drawn out position of locking pins

    Lubricate locking pins

R 924 Compact 3.60.5

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MJFCIFSS
Control and maintenance chart Technical documentation

Tab. 1 Control and maintenance chart

1 Engine oil change intervals can be shortened dependent on temperature, fuel and oil quality.
2 Note shortened maintenance intervals for heavy dust use.
3 When using environmentally acceptable hydraulic fluids, the maintenance interval is to be determined by regular
analyses.
4 Shorten the maintenance interval dependent on conditions of use (eg. heavy dust use, barrel refuelling).

LFR / en / Issue: 03 / 2010

3.60.6 R 924 Compact

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MJFCIFSS
 Technical documentation Control and maintenance chart

3.70: Control and maintenance chart

R 924 Compact Tier III Type 1083 from serial number 21909

Maintenance /
WORK TO BE CARRIED OUT
inspection at
R 924 Compact
operating hours

By maintenance personnel By authorized specialist personnel Note

At 1000, 3000

At 2000, 4000

(machine owner)
Every 10 -50

At 500, 1500
Every 8 - 10
On delivery

 First and only interval

 Repeat interval  First and only interval
 Special interval every 250 hours  Repeat interval

DIESEL ENGINE AND SPLITTERBOX

      Check oil level in engine

      Check oil pressure and coolant temperature during operation

      Check air filter on maintenance display

     Check and drain water separator on fuel filter (or when the corresponding sym-
bol appears on the display)
     If mounted, drain regularly the water in the water separator of the particles filter
system
    Check coolant level

    Drain off water and sediment at fuel tank

    Empty dust discharge valve on air filter (shorten or extend interval as required)

    Check oil level in splitterbox

   Check and clean cooler and ventilator

   Check condition of belt for A/C compressor and alternator installation

   Replace lubricating oil filter cartridge (at least 1 x yearly)

   Replace engine oil (at least 1 x yearly) 1)

   Replace splitterbox oil

   Check oil, cooling and fuel system for leaks and condition

   Check anti-corrosion fluid / antifreeze in coolant, if necessary rectify the mixtu-

LFR / en / Issue: 03 / 2010

re concentration
   Check electronic control unit mounting

   Check sensor and cable connections for sound condition

   If mounted, carry out the maintenance of the diesel particulate filter LIEBHERR

   If mounted, carry out the maintenance of the diesel particulate filter Engelhard

R 924 Compact 3.70.1

copyright by

MJFCIFSS
Control and maintenance chart Technical documentation

Maintenance /
WORK TO BE CARRIED OUT
inspection at
R 924 Compact
operating hours

By maintenance personnel By authorized specialist personnel Note

At 1000, 3000

At 2000, 4000

(machine owner)
Every 10 -50

At 500, 1500
Every 8 - 10
On delivery

 First and only interval

 Repeat interval  First and only interval
 Special interval every 250 hours  Repeat interval

   Check intake and emission system for leaks and condition (first time at 500 op.
hours)
   Check the exhaust return shut-off flap

   If mounted, replace bypass oil filter element (first 500 hours, and at least every
6 months)
  Check / adjust valve clearance

  Check engine console, oil sump and splitterbox mounts

  Grease flywheel tooth

  Replace fuel fine filter cartridge (or if powerloss) 4)

  Replace fuel preliminary filter cartridge (or if powerloss) 4)
  Replace oil separator fliter

Check heat flange (before start of winter)

Replace air filter main element (according to maintenance display / at least an-
nually)

Replace air filter safety element (every third change of main element / at least Never
annually) clean!

Check air hoses between air filter and engine (at filter maintenance)

Replace antifreeze and anticorrosive coolant mixture (every 2 years or every

3000 hours) (only for authorized specialist personnel)

Check vibration damper for distortion (every 3000 op. hours)

HYDRAULIC SYSTEM

      Check oil level in hydraulic tank

      Clean magnetic bar in return-line filter (daily during first 300 op. hours)

   Replace filter unit on control oil unit

LFR / en / Issue: 03 / 2010

   Check unit mounts

   Check and clean hydraulic oil cooler and ventilator 4)

   Drain off water in hydraulic tank
(when using environmentally acceptable fluids, max. 0.1 % water proportion
permissible, insert partial flow filter, take oil sample)
   If mounted check return filter for hydraulic hammer for cleanliness, replace ele-
ment if necessary

3.70.2 R 924 Compact

copyright by

MJFCIFSS
 Technical documentation Control and maintenance chart

Maintenance /
WORK TO BE CARRIED OUT
inspection at
R 924 Compact
operating hours

At 1000, 3000 By maintenance personnel By authorized specialist personnel Note

At 2000, 4000
(machine owner)
Every 10 -50

At 500, 1500
Every 8 - 10
On delivery

 First and only interval

 Repeat interval  First and only interval
 Special interval every 250 hours  Repeat interval

   Replace filter unit in return-line filter (first time at 500 op. hours) 2)
   Clean or replace filter unit of leak oil filter (first time at 500 op. hours) 2)
Replacement necessary after max. 3 cleanings
   If mounted, replace bypass oil filter element (first time at 500 op. hours) 2)
  Check hydraulic system for leaks and function

  Check / adjust servo, primary and secondary pressures

 Replace hydraulic oil in tank (or optimise interval with oil analyses) 2), 3)
 Bleed hydraulic pumps (when replacing oil)

 Replace ventilation and vent filters on hydraulic tank 2)

ELECTRICAL SYSTEM

      Check indicator lights and display devices

   Check lighting

   Check acid concentration and level on batteries

   Check cable terminals and pole ends on batteries

   Spray slip rings on swing connection (if present) with Cramolin contact spray

   Check function of entire system and units

SWING GEAR TRANSMISSION

    Check oil level and look for leaks

   Replace transmission oil (first time at 500 op. hours).

  Check function and operation of slewing gear brake

  Check transmission and oil motor mounts

LFR / en / Issue: 03 / 2010

BALL SWING RING

  Check mounting screws for correct positioning

  Check pinion gear mesh

TRAVEL GEAR

    Check for leaks

R 924 Compact 3.70.3

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Control and maintenance chart Technical documentation

Maintenance /
WORK TO BE CARRIED OUT
inspection at
R 924 Compact
operating hours

By maintenance personnel By authorized specialist personnel Note

At 1000, 3000

At 2000, 4000

(machine owner)
Every 10 -50

At 500, 1500
Every 8 - 10
On delivery

 First and only interval

 Repeat interval  First and only interval
 Special interval every 250 hours  Repeat interval

  Check transmission and oil motor mounts

  Replace transmission oil (first time at 500 op. hours)

TRACKS

      Visual check on track tension, retension if necessary

  Clean track (when work is finished)

    Check mounts on track pads and sprockets

   Clean and grease sliding surfaces of tensioning device

   Check for leaks on idlers, carrier rollers and track rollers

CAB

  Check door and window hinges and locks

UNDERCARRIAGE + UPPERCARRIAGE + ATTACHMENT

    Grease bearing points via centralised lubrication system (using button into the
cab for semi automatic systems or no handling for fully automatic systems).
    Grease bearing points by hand if they are not connected to the centralised lu-
brication system (if required on bucket, specials undercarriages and attach-
ments).
    Visually check wear condition of teeth

    Check parts for cracks

    Check ballast weight and tanks mounts

   Check line and screw connections for correct positioning

  Check trim panel hinges, quick-release fasteners and gas pressure springs of
hatches. Lubricate or change the components if necessary.
LFR / en / Issue: 03 / 2010

   Check the lowering speed of the attachment ~4 sec.

 Indicate appropriate use of attachment
 Have device lubricated according to lubrication chart by device operator and
indicate any operating errors.

HYDRAULIC QUICK-CHANGE ADAPTER

3.70.4 R 924 Compact

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 Technical documentation Control and maintenance chart

Maintenance /
WORK TO BE CARRIED OUT
inspection at
R 924 Compact
operating hours

At 1000, 3000 By maintenance personnel By authorized specialist personnel Note

At 2000, 4000
(machine owner)
Every 10 -50

At 500, 1500
Every 8 - 10
On delivery

 First and only interval

 Repeat interval  First and only interval
 Special interval every 250 hours  Repeat interval

      Check function of visual and acoustic warning devices

     Visually check drawn out position of locking pins

     Check condition of hydraulic hoses and of cable kit

    Lubricate locking pins

 Clean sieve filter in bolt connections of hydraulic hoses

MECHANICAL QUICK-CHANGE ADAPTER

     Visually check drawn out position of locking pins

    Lubricate locking pins

Tab. 1 Control and maintenance chart

1 Engine oil change intervals can be shortened dependent on temperature, fuel and oil quality.
2 Note shortened maintenance intervals for heavy dust use.
3 When using environmentally acceptable hydraulic fluids, the maintenance interval is to be determined by regular
analyses.
4 Shorten the maintenance interval dependent on conditions of use (eg. heavy dust use, barrel refuelling).
LFR / en / Issue: 03 / 2010

R 924 Compact 3.70.5

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Control and maintenance chart Technical documentation

LFR / en / Issue: 03 / 2010

3.70.6 R 924 Compact

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 Technical documentation

Group 4: Diesel Engines

Technical data of diesel engines ..........................................................................................4.10

1 Engine type: D 924 TI - E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10.1
1.1 Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10.3
1.2 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10.3
1.3 Tightening instructions for the flywheel’s housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10.3
1.4 Tightening instructions for the cylinder’s head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10.4
LFR / en / Issue: 03 / 2010

R 924 Compact 4.00.1

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 Technical documentation

LFR / en / Issue: 03 / 2010

4.00.2 R 924 Compact

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 Technical documentation Technical data of diesel engines
Engine type: D 924 TI - E

Group 4: Diesel Engines

4.10: Technical data of diesel engines

1 Engine type: D 924 TI - E

Version: A4

Mounted on machines type / from serial no. R 924 B «Compact» / 14675

Performance per DIN / ISO 9249 KW 121
PS 164
-1
Torque max. with 1530 min engine speed Nm 750

General data R 924 B «Compact» / 14675

Type 4 cylinders - Turbo
Working principle 4 - cycle - direct injection
Bore mm 122
Stroke mm 142
Displacement cm3 6640
Firing order 1-3-4-2
Compression ratio 17,2 : 1
Compression pressure at starting RPM bar 20 - 26
Firing sequence ° crankshaft 180
Weight of engine (dry) kg 710
Rotation direction (when facing flywheel) links
Flywheel housing SAE 1
Cooling system Water circulation

Range of speeds R 924 B «Compact» / 14675

-1
Nominal engine speed min 1800
High idle min-1 1860+20
Low idle min-1 1050±20
Lowest operating RPM min-1 1000
RPM at max. torque min-1 1000
LFR / en / Issue: 03 / 2010

Adjustments R 924 B «Compact» / 14675

Valve clearance-intake-cold mm 0,25
Valve clearance-exhaust-cold mm 0,30
Begin of delivery ° Cranshaft See marker plate
Backlash - oil pump mm 0,15 - 0,25 (engine in montage
position: cylinder head down-
wards)

R 924 Compact 4.10.1

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Technical data of diesel engines Technical documentation
Engine type: D 924 TI - E

Capacities R 924 B «Compact» / 14675

Engine oil - standart oil pan l max. 20,5 / min. 13,5
Lubricating oil system (filter / cooler / l 5
Schmierölsystem (Filter / Kühler / ducts)
Engine oil quantity (with filter change) l 23
Coolant - inclusive radiator l 26,5

Operating values R 924 B «Compact» / 14675

Coolant temperature °C 83 to max. 100
Thermostat setting °C 83
Cooling system pressure bar at least 1,1 at engine operat-
ing temperature (coolant tem-
perature >75°C) measured on
coolant pump outlet (heater
connection) with engine nomi-
nal rotation speed
Lube oil temperature °C max. 115
Min. engine oil pressure bar 1,5 bar at 800 min-1 (oil tem-
perature 100 °C)
2,5 bar at 1400 min-1 (oil tem-
perature 100 °C)
3,5 bar at 1800 min-1 (oil tem-
perature 100 °C)
Injection valves DLLA 142P632
Injection pressure
New bar 225 +8
Worn out bar 217 +8
Max. machine inclination - left / right 45 °
Max. machine inclination - forward / backward 45 °

Wear parts R 924 B «Compact» / 14675

Fuel double filter 1 part Prefilter 50-60X10-6
1 part Fine mesh filter 7X10-6
Oil filter 2 parts
Air filter 1 part Main element
1 part Safety element
V-belts 1 part 8PK 1850 NDIN 7867
Oil pressure sensor 1 part Shifting pressure 0,5 bar
Coolant temperature sensor 1 part Schifting temperature 100
±3
LFR / en / Issue: 03 / 2010

°C
Coolant level sensor 1 part
Catalogue number is given in corresponding spare parts list or service package

Antifreeze ration Antifreeze until Water Antifreeze

-37°C 50% 50%

4.10.2 R 924 Compact

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 Technical documentation Technical data of diesel engines
Engine type: D 924 TI - E

Note!
The percentage of antifreeze should not exceed 60%. A higher percentage would reduce the cool-
ing effect and freeze protection!

1.1 Tightening torques

Tightening
Tightening torques: Retightenin
Preload instruction
Screw connections g
(angle)
Bearing cap (1) 30 Nm
Main bearing cap 1. step 30°
2. step 30°
Main bearing screws 3. step 30°
Total 90°
Connecting rod (1) 30 Nm
1. step 45°
Connecting screws 2. step 30°
3. step 30°
Total 105°
Flywheel housing (1) 30 Nm 30 or 80 Nm see
Fig. 1
Cylinder head with (1) 30Nm see Fig. 2
Metal-elastomer sealing 1. step 90 Nm
2. step 70°
3. step 70°
4. step 70°
5. step 70°
Total 280°
Drive shaft forward crankshaft end (1) 30 Nm
1. step 45° or 100 Nm
2. step 45° or 160 Nm
Total 90° or 160 Nm
Flywheel (1) 30 Nm
1. step 30° or 180 Nm
2. step 35° or 330 Nm
Total 65° or 330 Nm
Intermediate wheel (2) 60 Nm 70° or 280 Nm
Camshaft flywheel (M20x1,5) (2) 130 Nm 145° or 650 Nm

1.2 General notes

 (1) Grease screws’ threads and head holders
 (2) Stick loctite 242 / 243 on screws’ threads
LFR / en / Issue: 03 / 2010

1.3 Tightening instructions for the flywheel’s housing

Caution!
Follow this order: 1 - 2 - 3 - 4 - 5 - 6 - 7 - 8 - 9 - 10 - 11 while tightening!

R 924 Compact 4.10.3

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Technical data of diesel engines Technical documentation
Engine type: D 924 TI - E

Fig. 1 Flywheel housing at diesel engine

1.4 Tightening instructions for the cylinder’s head

Caution!
Follow this order: 1 - 2 - 3 - 4 - 5 - 6 while tightening!

LFR / en / Issue: 03 / 2010

Fig. 2 Cylinder head cover at diesel engine

4.10.4 R 924 Compact

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 Technical documentation

Group 5: Coupling / Splitterbox

Coupling ..................................................................................................................................5.10
1 Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10.1
2 Construction and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10.2
3 Removal and installation of the torsional vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10.3
3.1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10.3
3.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10.3

Splitterbox...............................................................................................................................5.20
1 Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.20.1
2 General data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.20.1
3 General note for removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.20.2
4 Important installation notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.20.2

Remove, disassembly, assembly and installation of splitterbox ......................................5.30

1 To remove gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.30.1
2 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.30.2
3 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.30.2
4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.30.3
LFR / en / Issue: 03 / 2010

R 924 Compact 5.00.1

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 Technical documentation

LFR / en / Issue: 03 / 2010

5.00.2 R 924 Compact

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 Technical documentation Coupling
Use

Group 5: Coupling / Splitterbox

5.10: Coupling

1 Use
The elastic coupling (torsional vibration damper), is installed between the Diesel engine and the split-
terbox for the hydraulic pumps. It compensates for shaft (cranshaft-pump input shaft) misaligne-
ments, which could be caused by manufacturing and dimensional varriations. It absorbs the residual
torsional vibration of the Diesel engine as well the torque jolts caused by load fluctuations.
It transfers engine power to the double pump directly and constantly, which means that it can’t be
disengaged.
LFR / en / Issue: 03 / 2010

Fig. 1 Engine coupling

R 924 Compact 5.10.1

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Coupling Technical documentation
Construction and function

2 Construction and function

A disc 2 is attached to the flywheel 7 of the diesel engine. Hub 4 is guided axially by the circular disc
5, which is attached to the Hub.
Hub 4 is radially movable on disc 2. This elastic connection is made by the eight springs 3 set around
the circular disc 2.
The input shaft of the splitterbox is frictionally connected with the hub of the torsional vibration damp-
er.
Any torsional vibration at diesel engine start up and any load fluctuations are compensed by the
spring 3 compression and relaxation.

Fig. 2 Coupling section view

1 Elastic coupling 5 Disc

2 Disc 6 Mounting screw
3 Springs 7 Flywheel
4 Hub 8 Flywheel housing (SAE)
A Dimension for removal B Mounting face of splitterbox
LFR / en / Issue: 03 / 2010

5.10.2 R 924 Compact

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 Technical documentation Coupling
Removal and installation of the torsional vibration damper

3 Removal and installation of the torsional vibration damper

Fig. 3 Coupling removal and installation

1 Elastic coupling 10 Splitterbox

6 Hexagonal screw 11 Hexagonal screw
7 Flywheel 12 Washer
8 Flywheel housing (SAE)

3.1 Removal
 Attach the splitterbox with a sling.
 Unscrew the screw 11.
 Remove the splitterbox 10 from the flywheel housing 8 on the diesel engine and remove from the
elastic coupling 1.

Caution
Note the installation position of elastic coupling 1.
LFR / en / Issue: 03 / 2010

 Remove mounting screws 6.

 Remove the elastic coupling 1 from the flywheel on the diesel engine.

3.2 Installation
 Set the complete elastic coupling 1 onto the flywheel.

R 924 Compact 5.10.3

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Coupling Technical documentation
Removal and installation of the torsional vibration damper

Note
Use the note made during the removal to position the elastic coupling.

 Remove mounting screws 6*.

 Lightly lubricate the gear on the splitterbox drive shaft and hub (preferably with «Optimol White T»
ident Nr 8500307)
 Push the input shaft of the splitterbox 10 into the hub 4.
 Remove the splitterbox 10 on the flywheel housing 8 with the mounting screws 11*.

LFR / en / Issue: 03 / 2010

5.10.4 R 924 Compact

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 Technical documentation Splitterbox
Use

5.20: Splitterbox

1 Use
The splitterbox is a spur gear, installed between engine and hydraulic pumps.
It is driven directly via the elastic coupling by the flywheel on the diesel engine and transfers engine
output to the hydraulic pumps.
The different ratios between working double pump and swing pump allow for an exact flow for working
and swing movements.

Fig. 1 Splitterbox

2 General data

Types 911 / 198

Excavator R 924 Compact Types 911 / 198
from 14751 until
serial number from 15214
15213
Splitterbox type PVG 352 C 352 PVG 353
Working pumps type DPVP 108
Ratio to working pumps P1 and P2 0,902
Cooler fan pump type Gear pump 25 cm3
Ratio to cooler fan pump 0,732
Oil quantity in gear see group 3
LFR / en / Issue: 03 / 2010

Oil specification see group 3

Oil viscosity see group 3
For nominal speed oil quantities and output power of the different hydraulic pumps, see the subgroup «Tech-
nical data» of the concerned excavator in the group 3.

R 924 Compact 5.20.1

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Splitterbox Technical documentation
General note for removal and installation

3 General note for removal and installation

Recommanded sealing, retaining and lubrication compounds
To degrease screws Activator T
To secure screws Loctite No 577
To install cylinder pins Loctite No 243
To seal housing Loctite No 562, 573
Grease to insert seals Vaseline
To glue in shaft seal 60 Omnivisc 1050
Grease for grooves - shaft seal 60 Barrieta L55

4 Important installation notes

Do not reuse any parts, which have been damaged during removal of a component, such a shaft
seals, packing and O-rings, ball and roller bearing and other seals. Any damage (scratches) to sur-
faces during removal must be removed before installation.
Flush all areas of components, especially corners and angles, until they are clean. If necessary, use
diesel fuel or gasoline. Clean every parts before reinstallation, check every part for wear and damage.
Before installation, coat all surfaces in the gear with a thin layer of oil.
Apply oil to the O-rings or lightly grease them before installation.
When securing cylinder pins in bore holes, apply Loctite to screws threads, cylinder pin and to the
bore hole.
Before pressing in shafts, bearings..., apply oil to both parts.

LFR / en / Issue: 03 / 2010

5.20.2 R 924 Compact

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 Technical documentation Remove, disassembly, assembly and installation of
To remove gear

5.30: Remove, disassembly, assembly and installation of

splitterbox

1 To remove gear
 Close shut off valve on hydraulic tank.
 Disconnect suction, pressure, control and leak oil lines from hydraulic pumps.
 Attach the splitterbox and the pumps with a sling
 Remove cooler fan pump (see sub-group 7.19).
 Drain the gear oil with drain valve 82.
 Remove mounting screws on flywheel housing to remove splitterbox with working pumps.
 Remove screws 41/42.
 Remove splitterbox 6 from pumps housing 7.
 Remove the three o-rings 16 from pumps housing 7.
 Remove seal 45 from splitterbox 6.
LFR / en / Issue: 03 / 2010

R 924 Compact 5.30.1

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Remove, disassembly, assembly and installation of Technical documentation
Disassembly

Remove dipstick 34:

 Unscrew dipstick 34 complete from pump housing 7.

2 Disassembly
Disassembly of spur gear 12:
 Remove spur gear 12 complete with roller bearings 31 and 33 from the splitterbox 6.
 Remove bearings 31 and 33 on both sides from spur gear 12.

Note!
Never invert inner races or outer races of both bearings.

Disassembly of drive shaft 10:

 Take out drive shaft 10 complete with bearings 30 and 31 from the splitterbox 6.
 Remove bearings 30, 31 and shim rings 61 from drive shaft 10.
 Push out carefully shaft seal ring 60 from splitterbox 6.

Note!
If the bearing 30, 31 and / or gears on drive shaft 10 are damaged, replace shaft 10 complete with
bearing 30 and 31.

3 Assembly
Installation of drive shaft 10:

Note!
Always mount one shim ring 61 less than what has been dismantled.
The shaft seal ring thus will be set up more inwards and seals anew on a flat running tread.
If there was no shim ring left while dismantling, a new drive shaft with shim rings 61 must be assem-
bled.

 Push drive shaft 10 complete with roller bearings 30, 31 and shim rings 61 into splitterbox 6.

LFR / en / Issue: 03 / 2010

 Clean installation surface of shaft seal ring 60 in the splitterbox 6 and apply «Omnivisc 1050»
 Fill about 1/4 space between seal rings 60 with Barrieta L55 of grease, and pull shaft seal ring 60
into splitterbox 6.

Installation of spur gear 12:

 Press bearings 31 and 33 on both sides onto gear 12.

5.30.2 R 924 Compact

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 Technical documentation Remove, disassembly, assembly and installation of
Installation

 Push the spur gear 12 complete with bearings 31 and 33 into splitterbox 6.

Note
To push the bearing, use a press or installate a flatplate with two bore holes onto the stud. Tighten
the two nuts evenly. Push an intermediate piece under the flatplate to press the spur gear all the
way in.

4 Installation
Installation of dipstick 34:
 Insert dipstick guide 34 in the pumps housing 7 and screw.

Installation of splitterbox 6:
 Reinstall o-rings 16 in the pumps housing 7.
 Reinstall seal 45 on splitterbox 6 with the help of the stud bolts 40.
 Reinstall splitterbox 6 complete on the pumps housing 7 and fasten both parts together with the
help of the screws 41 and 42 and the washers 43, 44 and 46.
 Lightly lubricate the teeth on the splitterbox drive shaft and on the coupling (preferably with «Op-
timol white T, ident Nr 8500307).
 Install the splitterbox 6 complete to the engine flywheel housing and tighten with cylindrical head
screws.
 Install cooler fan pump (see sub-group 7.19).
 Connect suction, pressure, control and leak oil lines.
 Open shut off valve on hydraulic tank.
 Add gear oil to the mark on the dipstick.
 Bleed hydraulic pumps, see sub-group 7.01.
 Let the engine run a short time.
 Check the oil level.
LFR / en / Issue: 03 / 2010

R 924 Compact 5.30.3

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Remove, disassembly, assembly and installation of Technical documentation
Installation

LFR / en / Issue: 03 / 2010

5.30.4 R 924 Compact

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 Technical documentation Remove, disassembly, assembly and installation of
Installation

6 Splitterbox 41 Hexagonal head screws

7 Pumps housing 42 Hexagonal head screws
10 Drive shaft 43 Lock Washer
12 Spur gear - cooler fan pump 44 Lock Washer
16 O-ring 45 Seal
25 O-ring 46 Lock Washer
30 Roller bearing 60 Lip seal
31 Roller bearing 61 Shim ring
33 Roller bearing 82 Drain valve
34 Dipstick 83 Sealing ring
40 Stud bolt
LFR / en / Issue: 03 / 2010

R 924 Compact 5.30.5

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Remove, disassembly, assembly and installation of Technical documentation
Installation

Fig. 1 Splitterbox backview

LFR / en / Issue: 03 / 2010

5.30.6 R 924 Compact

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 Technical documentation Remove, disassembly, assembly and installation of
Installation

Fig. 2 Section A-A

LFR / en / Issue: 03 / 2010

R 924 Compact 5.30.7

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Remove, disassembly, assembly and installation of Technical documentation
Installation

Fig. 3 Section B-B

LFR / en / Issue: 03 / 2010

5.30.8 R 924 Compact

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 Technical documentation Remove, disassembly, assembly and installation of
Installation

Fig. 4 Section L-L

6 Splitterbox 41 Hexagonal head screw

7 Pumps housing
11 Drive shaft of the working pump
LFR / en / Issue: 03 / 2010

R 924 Compact 5.30.9

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Remove, disassembly, assembly and installation of Technical documentation
Installation

Fig. 5 Schematic drawing of the splitterbox

10 Drive shaft (z=41) 12 Spur gear / cooler fan pump (z=30)

11 Drive shafts of the working pumps (z=37)
LFR / en / Issue: 03 / 2010

5.30.10 R 924 Compact

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