LIEBHERR PR752 SERIES 2 LITRONIC CRAWLER DOZER Service Repair Manual PDF

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Sub Group Index
Foreword and explanation 1.1
Safety guidelines 1.2.01

Hand signals 1.2.02
Service items 1.3.01
Table - charts 1.4

Conversion table 1.4.01
Tightening torques standard screws 1.4.02
Tightening torques SAE screws 1.4.03
Hole diameter before tapping 1.4.04
Couplings 1.4.05
ISO - tolerances 1.4.06
Code letters + terminal designations electric 1.5
Benennung Description Dénomination Typ/ab Type/from Type/ a partir de
Mjfcifss! PR Litronic
LR Litronic
Datum Edition Date RL Litronic
01 01 General information Blatt

Page
Feuille 1.0.00.01
For your information
This manual contains technical data, descriptions of design and function, repair and adjustment guidelines as well
as numerous drawings, functional views and illustrations
LIEBHERR - crawler dozers (PR), crawler loaders (LR) or pipelayers (RL).
This manual should simplify competent customer service of our products, does however, not replace expert and
qualified training and an attendance of our factory schools.
Information which is in trade considered basic knowledge is not included. Operation and spare parts information can
be found in separate manuals.
The manual will be updated as necessary when changes occur in series.
This symbol is used in the manual for very important notes.
During the activities on the machine, accident prevention regulations and safety guidelines must be strictly
observed.
This manual is intended for the exclusive use of the registered owner and may not be reproduced complete or in
part or passed on a third person without written permission.
This manual is still on property of LIEBHERR-Werk Telfs GmbH.
All rights reserved - Printed in Austria.
We reserve the right to make changes of technical details on the machine in comparison to the information and
drawings in this manual.
Printed and published by

LIEBHERR-Werk Telfs GmbH., Service -Training Department.
Explanation of structure (page numbers)

In order to find specific information and add supplements more easily, the following numbering system is being
used:
main group sub group model group page No.
6. 3. 10 01
main group according sub group of main group division based on continuous running
to manual index according to sub group information content or number within the model
index machine model group group, illustrations or
parts list with .00 may be
added at the beginning or
end of each group.
Updated pages retain the same page number, but receive a more recent date when mailed. Supplements have a
new number. If the page is only valid for a certain machine model group, it will so be indicated on the page.
We hope that with the enclosed information we have taken yet another step to improve the service on the
LIEBHERR - crawler dozers, crawler loaders and pipelayers.
LIEBHERR-Werk Telfs GmbH.

Service-Training Dept.
Foreword and explanation LR Litronic
Datum Edition Date
RL Litronic
01 03 General Information Blatt

Page
Feuille 1.1.00.01
Service Items
Notes for the disposition of service fluids and filter:
- Service fluids may not be discharged into the ground, drainage system or waterways.
- Different service fluids and filters should be collected and disposed of in separate containers.
- Do not use containers, which previously held food items or drinks - to prevent danger of mix-ups.
- Dispose of these items in an environmentally friendly manner according to applicable guidelines and
regulations. Observe all state, local and national regulations.
- Do not use old or incorrectly stored service fluids and filters, dispose of them properly.
1. Service fluids for Diesel engines with turbo chargers
1.1. Engine lube oil

Engine lube oils must meet a certain quality and a certain viscosity, depending on their use and ambient
temperatures. Problem-free operation can only be ensured only if the requirements for both areas are met.
1.1.1 Oil quality

To meet the technical demands, only highly alloyed lube oils are used in modern Diesel engines. They
consists of high-quality base oils, mixed with additives. These additives provide the required properties for
these oils.
For LIEBHERR Diesel engines with turbo chargers, oils of the following specifications are approved, the higher
quality oils are preferred:
API - classification : CF-4, CG-4, CH-4, CI-4,
(American Petroleum Institute)
ACEA (CCMC) - classification : E2 (D4), E3 (D5), E4, E5

(Association des Constructeurs Européens de l´Automobile)
Note: For older machines / Diesel engines, if still in use, engine oils according to the lower specification as
noted in the original operation manuals may be used. However, we recommend the use of these new
oils, since the service life of the engine can be extended significantly by using these higher quality
oils. The originally noted oil and filter change intervals may be extended.
1.1.2 Oil viscosity

Z In addition to the quality, the oil must also provide a certain viscosity the selection is made according to the
SAE - classification (Society of Automotive Engineers).
The determining factor for the correct selection of the SAE classification is the ambient temperature. In most
regions, SAE 10W-40 is recommended (see chart below).
If the viscosity is too high, starting problems can occur, if it is too low, the lubrication efficiency can be
endangered, both factors can lead to increased engine wear.
The temperature ranges shown in the following chart are guidelines and may be exceeded or fallen below for a
short time.
For the operation in extreme climate zones, such as in arctic regions, special guidelines apply and are
available from the manufacturer.
LR Litronic
Datum Edition Date
RL Litronic
01 04 Service Items Blatt

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Feuille 01.3.01.01
1.1.3 Oil change intervals
The oil change intervals noted in the Maintenance and Inspection schedules always apply to "normal operating
conditions". They apply for normal, central European temperatures, annual operation of approx. 1000
operating hours, use of oils of the required minimum quality and fuels with a sulfur content of less than 0.5%.
When using higher quality oils, the operating hours per interval may be doubled - see the following chart.
However, the 500 hour interval may not be exceeded.
Engine oil and filters must be changed at least once a year, even if the given change interval has not yet been
reached.
In difficult circumstances, such as repeated cold start, higher sulfur content (above 05.%) in the fuel, more
severe climatic conditions (for example continuous temperatures below -10°C) etc., the intervals must be cut in
half. This means, for each difficulty, the permitted operating hours per interval must be multiplied by a factor of
0.5.
Permissible oil change intervals in operating hours:
Oil quality:
Oil quality:
Applications
CF-4, CG-4, CH-4,
E3 (D5), E4, E5,
CI-4, E2 (D4))
Ambient Sulfur content
Change interval Change interval
temperature in fuel
above -10°C to 0,5% 250 hrs. 500 hrs.

(Normal
temperature) above 0,5% 125 hrs. 250 hrs.
below -10°C to 0,5% 125 hrs. 250 hrs.

Continuous
temperature above 0,5% 60 hrs. 125 hrs.
1.2. Diesel fuels

Diesel fuels must meet the minimum requirements of the following specifications.
The sulfur content may not exceed 0.5%. A higher sulfur content has negative effects on oil change intervals
and engine service life. A higher sulfur content above 1% is not permitted.
Fuels with low sulfur content (for example, according to European regulations <0.05 %) must contain additives
to retain the lubrication efficiency according to HFRR(60°)-Test <400µm - . Insufficient lubrication causes
premature wear of the injection system components, especially distributor injection pumps. The additives should
be added by the fuel supplier, as he is responsible for the quality of the fuel. We do not recommend addition of
secondary lubrication additives by the user.
Approved fuel specifications:

DIN EN 590 + HFRR(60°)-Test <400µm
ASTM D 975 - 89a 1D and 2D + HFRR(60°)-Test <400µm + cetane rating >45 (recommendation: >50)
Diesel fuels in very low temperatures
At ambient temperatures below freezing (0 C), the flow properties of warm temperature Diesel fuel can become
insufficient due to paraffin excretion. The same applies to cold temperature Diesel fuels in temperatures below.
-15 C.
In order to prevent operating problems in even lower temperatures, Diesel fuel with an additive is sometimes
available, for use in temperatures to -20 C.
In order to prevent operating problems in even lower temperatures, mix Diesel fuel with normal gasoline or
petroleum. Addition of normal gasoline is a makeshift measure and may not exceed 30% per volume. Do not
use Super gasoline for mixing.
Mixing fuel can diminish engine performance, for that reason, keep the added fuel as low as possible,
depending on the ambient temperatures.
For safety reasons, mix fuel only in the fuel tank. When refueling, add the lighter additive before the Diesel fuel.
Then let the engine run for a short time until the mixture has been distributed throughout the fuel system.
Diesel fuels - Mixing ratio ( Vol.-%)
Ambient Winter Diesel fuel Winter Diesel fuel
Summer Diesel fuel
temperature to -15°C to -20°C
°C % Fuel % Additive % Fuel % Additive % Fuel % Additive
0 to -10 70 30 100 -- 100 --
-10 to -15 50 50* 100 -- 100 --
-15 to -20 -- -- 70 30 100 --
-20 to -25 -- -- 50 50* 70 30
* = If an addition of more than 50% is required, use only petroleum (no regular gasoline). The Diesel fuel part
may never be more than 50% .
Additives to Diesel fuel (flow improvers)

Commercially available flow improvers can also improve Diesel fuel properties in cold temperatures. Always
read and observe the manufacturers user guidelines and quantities.
1.3. Coolant
Coolants, containing unsuitable anti corrosion / antifreeze fluids or wrong mixed coolants could damage the
engine or its parts, caused by cavitation or corrosion. Additionally heat isolating deposits could be created on
heat transferring parts, which overheat and lead to the damage of the engine.
For a long term, fault free operation, the coolant must be filled year round with a mixture of at least 50%
anticorrosion/antifreeze fluid. This concentration protects the system to approx. -37°C / -34°F.
Antifreeze protection chart
Protection to
Percentage of antifreeze (%)
Note: Do not use more than 60% anti-corrosion / antifreeze fluids, a higher percentage would actually
reduce the cooling and antifreeze protection and causes gel formation in the coolant fluid. Danger of
engine damage!
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Datum Edition Date
RL Litronic

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Feuille 01.3.01.02
Coolant filters are used on some engine series, which filter the coolant in the auxiliary flow and in addition, a
chemical additive in the filter (DCA 4) reinforces the protection against cavitation, corrosion, scale deposits and
foam formation. The DCA4 concentration must be between 0.3 and 0.8 units per liter of coolant. See the
following chapter Coolant with DCA4. This results in a mixing ration of approx. 48.5 % water, 48.5 % anti
corrosion /antifreeze fluid and 3 % DCA4.
Check the mixing ratio regularly during maintenance work. See instructions in section 3.4.
If coolant must be replaced, make sure that the given mixing ratios are retained. Do not fall below this ratios nor
exceed it.
Due to the natural aging process of the coolant, it must be replaced at least once every 2 years. Use only
suitable coolant, free of contaminants. Clean contaminated cooling systems. Note the following regulations.
To replace or add coolant in larger quantities, mix the given parts outside the cooling circuit in a suitable, clean
container first.
Fresh water guidelines:

To mix coolant fluid, use clean, clear water, which is not too hard. Often, but not always, regular tap water may
be used.
Seawater, brine, brackish water, or industrial waste water is not suitable.
Approved fresh water quality (as of 2001) for use with anti corrosion / antifreeze fluid -
- without DCA4 - with DCA4
Sum of alkaline earths (water hardness): : 0,6 to 3,6 mmol/l 0,6 to 2,7 mmol/l
(3 to 20°d) (3 to 15°d)
Ph - value at 20° C : 6,5 to 8,5 6,5 to 8,0
Chloride / ion content : max. 80 mg/l max. 80 mg/l
Sulfate / ion content : max. 100 mg/l max. 80 mg/l
Presently approved anti corrosion / antifreeze fluids (as of December 2003):

Brand name Manufacturer
Agip Antifreeze Plus Agip Petroli S.p.A, Rom / Italien
Agip Langzeit-Frostschutz Autol-Werke GmbH., Würzburg / BRD
Antigel DB 486 Sotragal SA, St. Priest / Frankreich
Aral Kühler-Frostschutz A Aral AG, Bochum / BRD
AVIA Frostschutz APN (G48-00) Deutsche AVIA-Mineralöl GmbH, München / BRD
BP Antifrost X 2270 A Deutsche BP AG, Hamburg / BRD

BP Napgel C 2270/1 BP Chemicals Ltd., London / England
Caltex Engine Coolant DB Caltex (UK) ltd., London / England

Caltex Extended Life Coolant Caltex
Castrol Anti-Freeze O Deutsche Castrol Vertriebs-GmbH, Hamburg /BRD
Century F.L. Antifreeze Century Oils, Hanley, Stoke-on-Trent / England
Chevron DEX-COOL Extended Life Anti-Freeze/Coolant Chevron Texaco
Deutz Kühlschutzmittel 0101 1490 DEUTZ Service International GmbH, Köln / BRD
Esso Kühlerfrostschutz Esso AG, Hamburg / BRD
Fricofin Fuchs Mineraloelwerke GmbH, Mannheim / BRD

Frostschutz Motorex (G48-00) Bucher+Cie, Langenthal / Schweiz
Frostschutz 500 Mobil Oil AG, Hamburg / BRD
Glacelf Auto Supra Total

Glycoshell AF 405 Shell
Glycoshell N Shell
Glysantin (G 48-00) BASF AG, Ludwigshafen / BRD
Havoline XLC ARTECO

Havoline DEX-COOL Extended Life Anti-Freece/Coolant Chevron Texaco
Igol Antigel Type DB Igol France, Paris / Frankreich
Labo FP 100 Labo Industrie, Nanterre / Frankreich
Motul Anti-freeze Motul SA, Aubervilliers Cedex / Frankreich
OMV-Kühlerfrostschutzmittel OMV AG, Schwechat / Österreich

Organifreeze Total
OZO Frostschutz S Total Deutschland GmbH, Düsseldorf / BRD
Total Antigel S-MB 486 Total Deutschland GmbH, Düsseldorf / BRD

Total Frostfrei Total Deutschland GmbH, Düsseldorf / BRD
Veedol Antifreeze O Deutsche Veedol GmbH, Hamburg / BRD
Wintershall Kühlerschutz Wintershall Mineralöl GmbH, Düsseldorf / BRD
Presently approved anti corrosion / antifreeze fluids / 50:50 Premix (as of December 2003):
(50 % water : 50 % corrosion/antifreeze fluids)

Liebherr Anti-Freeze APN mix Id.Nr. 8611 045 - 20 l bundle LIEBHERR
Caltex Extended Life Coolant Pre-Mixed 50/50 (ready-to-use-version) Caltex
Chevron DEX-COOL Extended Life Prediluted 50/50 Antifreeze coolant Chevron Texaco
Havoline XLC, 50/50 ARTECO
Havoline DEX-COOL Extended Prediluted 50/50 Antifreece coolant Chevron Texaco
Organicool 50/50 Total
Presently approved anti corrosion / antifreeze fluids with DCA4 - ready to use (as of December 2003):
Liebherr Anti-Freeze "pret a l'emploi" Id.Nr. 10 005 347 - 20 l bundle LIEBHERR
The given anti corrosion / antifreeze fluids are approved for all Liebherr Diesel engines (with and without coolant
filter / DCA4).
1.3.1 Coolant with DCA4 (DCA = Diesel Coolant Additive)

The additive DCA4 is "used up" during use. The DCA4 concentration in the filter compensates for this loss
accordingly, if there is no loss of coolant and the correct filter is used at the given change interval.
The DCA4 concentration must be between 0.3 and 0.8 units per liter of coolant. To check, refer to the
"Maintenance and inspection guidelines", section 3.4.
For change intervals for filter and coolant, see Maintenance and inspection schedule , section 3.2.
If the cooling system is filled initially or refilled after repairs, then DCA 4 in liquid form must be added to the
50% anticorrosion / antifreeze and 50% water mixture. The mixture should be mixed outside the cooling
system. Note the safety guidelines issued by the additive manufacturer.
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Datum Edition Date
RL Litronic

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Feuille 01.3.01.03
This results in a coolant mixture ration of approx. 48.5 % water, 48.5 % anticorrosion / antifreeze fluid and 3%
DCA4.
In addition, use a new coolant filter, according to the filling quantity. The correct Id. No. of the filter can be
found in the Parts Manual or the Operation and Maintenance manual of the machine.
Overview chart DCA4 and filter requirements (as of 2001)
Coolant system contents Required quantity of liquid DCA 4 DCA 4 - water filter
Liter Container approx.0.5 liter appr. liter Id. No.
24-39 3 oder 1,5 7367 045
40-59 4 oder 2,0 7381 493
60-79 5 oder 2,5 7367 052
80-115 8 oder 4 7367 052
Container liquid DCA4 at approx. 0.5 l -Id. No. 7363 898
Liebherr coolant (ready to use, 20 liter, above mixing ratio) - Id. No. 10 005 347
1.3.2 Coolant - special filling - with anti corrosion fluids, without antifreeze fluids
In exceptional cases and if ambient temperatures are constantly above the freezing point, for example in
tropical regional, where no anticorrosion / antifreeze fluids is proofed available, fresh water and water-soluble
anticorrosion fluids (Inhibitors) may be used as coolant.
Do not use coolant refiners (anticorrosion oils) with emulsifying capacity. If necessary, flush the cooling system
before refilling.
The fresh water quality must meet use with DCA4 - see chart Approved fresh water quality.
The coolant must be changed once a year.
Use of DCA4
To provide sufficient protection against corrosion, approximately twice the amount of DCA4 must be used as
compared to the above mixing ration, when using anticorrosion / antifreeze fluids and DCA4 - see above
"overview chart and filter requirements".
The DCA4 concentration must be between 0.6 and 1.06 units. It must be checked during maintenance work or
when the coolant filter is changed, and corrected, as necessary.
This results in a mixing ratio of
max. 94 % fresh water and
min. 6 % DCA4 additive
Use of products from Caltex / Chevron Texaco / Havoline / Total

To provide sufficient protection against corrosion with these products, a mixture of 92,5 vol.% coolant and 7,5
vol.% anti corrosion fluid must be kept.
The mixture ratio must be checked during maintenance work and corrected, as necessary. The concentration
of the anti corrosion fluid must not fall below 5 vol.% nor exceed 10 vol.%.
Presently approved anti corrosion fluids (as of December 2003):

DCA4 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
2. Oil for hydraulic system
In the hydraulic system, use only Diesel engine lube oils or special approved oils.
2.1. Oil quality
2.1.1 Approved engine oil classifications

API - classification : CF-4, CG-4, CH-4, CI-4,
(American Petroleum Institute)
ACEA (CCMC) - classification : E2 (D4), E3 (D5), E4, E5,
(Association des Constructeurs Européens de l´Automobile)
Note: The API classifications CC, CD, CE and CF are now obsolete, however, in quality, they had been
approved for use in the hydraulic system.
2.1.2 Special oils

Approval is given for each machine type separately. Special guidelines are issued with the release.
The following product presently considered to be an environmentally friendly hydraulic fluid:
Panolin - HLP Synth - VG 46
2.2. Oil viscosity

In addition to the quality, the oil must also provide a certain viscosity, the selection is made according to the
SAE classification (Society of Automotive Engineers).
The determining factor for the correct selection of SAE classification is the ambient temperature, single grade
oils are preferred.
If the viscosity is too high, it can cause cavitations, if it is too low, the lubrication efficiency may be endangered.
Both can cause failure of hydraulic components.
The temperature ranges shown in the following chart are guidelines. When operating the machine within the
black temperature range, the following warm up procedure should be carried out.
Single grade oils
Multi grade oils
Viscosity for environmentally friendly hydraulic fluids according to ISO: VG 46

(covers SAE 10W and SAE 20W-20 or SAE 10W-30)
For operation in extreme climate zones, such as arctic regions, special guidelines are available from the
manufacturer.
Warm up procedure:
a) In temperatures up to 10° C below the given limit (black range)
After starting, run the Diesel engine at medium speed. Warm up the hydraulic system by carefully actuating
the hydraulic cylinders. Extend and retract the hydraulic cylinders fully for short periods. After 5 minutes,
carefully engage the travel hydraulic as well. Total warm up period is approximately 10 minutes.
b) At even lower temperatures:
Before starting the Diesel engine, preheat the oil in the hydraulic tank, then proceed as described in paragraph
a).
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Datum Edition Date
RL Litronic

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Feuille 01.3.01.04
3. Gear oil
The lube oil specification for gears is based on API and SAE classification. The oil chamber in travel gears for
double lifetime seal is filled with oil from the hydraulic system - see section 2.
3.1. Oil quality
As a general rule, only oils meeting API - classification GL-5 may be used.
3.2. Oil viscosity
The following oils must be used in travel gears, and are highly recommended for use in splitter boxes:
Viscosity classification SAE 85 W - 140 EP
For splitter boxes, oils of Viscosity classification SAE 90 EP or SAE 80 W - 90 EP may also be used.
For the operation in extreme climatic conditions, such as in arctic regions or in extreme temperatures ranges, such
as in slag applications, special oils may be approved if the prevailing ambient temperatures are known operations.
3.3. Lube oil for final drive - sealing chamber

For oil quality and viscosity see section 2, Oil for hydraulic system, but do not use special oils.
4. Lube oil for support shaft bearing

For oil quality and viscosity see section 2, Oil for hydraulic system, but do not use special oils.
5. Hoist gear oil - pipe layers

As a general rule, the guidelines noted in the Operation and Maintenance manual and the winch manufacturer
should be observed.
For lubrication technical reasons, we recommend the use of Diesel lube oil, which meets at least one of the
following quality and viscosity classifications.
5.1. Oil quality
according to API - classification : CF, CF-4, CG-4, CH-4, CI-4,
ACEA (CCMC) - classification : E2 (D4), E3 (D5), E4, E5,
5.2. Oil viscosity
according to SAE - classification : 10W
ISO - classification : VG 32
6. Grease
6.1. General lubrication points and track tensioner

The grease must meet specification KP 2 k - consistency 2 according to NL GI - class and DIN 51818 and DIN
51825 or EP 2 according to NF-T-60 132 .
The grease must also be lithium based, with a VKA value of at least 2300 N according to DIN 51350 or ASTM D
2596.
6.2. Long term grease / grease to protect against corrosion
For the lifetime lubrication of bearing points of lift cylinder suspensions and to protect against corrosion at the
initial installation of dry bearing points, to protect exposed piston rods, to prevent rust formation, etc., a special
calcic, acid free grease should be used.
We recommend LIEBHERR's special paste CTK - Id. No. 8613 313 01
For general conservation - see section 19, Conservation guidelines - other acid free anticorrosion grease may
be used.
7. Miscellaneous
Always observe all guidelines issued in the Operation and Maintenance manuals, repair manuals and on
drawings.
7.1. Rubber seals on doors and covers

Use silicon spray or Talcum powder.
7.2. Hydraulic cylinder installation

Lubricant for threads of pistons, piston nuts and piston rod bearings -
Liebherr High performance lubricant Id. No. 8300 004
Special protection against corrosion for installation of sealing elements -
Liebherr Special anticorrosion grease Id. No. 8300 005
To obtain To
Unit of Measure Multiply by by
Multiply obtain
Length mm 0,039 inch 25,4 mm
m 3,281 feet 0,305 m
m 1,093 yard 0,914 m
km 0,621 mile 1,609 km
Area cm² 0,155 sq. inch 6,452 cm²

m² 10,764 sq. feet 0,093 m²
m² 1,196 sq. yard 0,0863 m²
km² 0,386 sq. mile 2,59 km²
Volume cm³ 0,061 cu. inch 16,387 cm³

m³ 35,314 cu. feet 0,028 m³
m³ 1,308 cu. yard 0,764 m³
l 61,025 cu. inch 0,016 l
l 0,035 cu. feet 28,316 l
l 0,264 gallon 3,785 l
l 1,057 quart 0,946 l
Weight g 0,035 oz. 28,349 g

kg 2,204 lbs. 0,453 kg
t 1,102 short t 0,907 t
Force N 0,225 lbs. 4,449 N

kN 224,732 lbs. 0,0044 kN
Torque Nm 0,737 ft. lbs. 1,356 Nm

Power kW 1,342 HP 0,745 kW
PS 0,736 kW 1,358 PS
PS 0,986 HP 1,014 PS
Pressure bar 14,5 PSI 0,069 bar

(hydraulic) kpa 0,145 PSI 6,896 kpa
Ground pressure kg/cm² 14,223 lbs. sq. inch 0,0703 kg/cm²

kg/m² 0,205 lbs. sq. ft. 4,878 kg/m²
Compression g/cm³ 0,036 lbs. cu. inch 27,78 g/cm³

kg/m³ 0,062 lbs. cu. ft. 16,13 kg/m³
Speed km/h 0,621 mph 1,609 km/h

m/min 3,281 ft. / min 0,305 m/min
Temperature °C (°Cx1,8) + 32 °F (°F-32)/1,8 °C

°C °C+273 °K °K-273 °C
LR Litronic
Datum Edition Date
RL Litronic
01 01 Conversion table Blatt

Page
Feuille 1.4.01.01
The preload and tightening torques listed in the chart are from VDI guidelines 2230 of July 1986.
Installation preload FM and tightening torques MA for shaft screws with metric standard or fine thread per DIN ISO
262 and DIN ISO 965 T2 (replacement for DIN 13 part 13) and screw head dimension of hex head screws with shaft
DIN EN 24014 (replacement for DIN 931 part 1) or socket head screws DIN EN ISO 4762 (replacement for DIN
912).
The chart values are valid for lubricated screws, surface black treated, phosphated or galvanic zinc plated and for
dry screws, surface according to flZn - LH-Norm 10021432 (replaces DACROMET 500)
Medium friction µG = 0,12.

Always observe the tightening torques and/ or procedures listed in drawings / parts lists, instructions of
component descriptions, if noted, they override the factory standards listed in the torque charts.
Never use a standard lock washer with 10.9 or 12.9 screws. If a washer is necessary, use only "heavy duty"
washers, made from hardened material.
Always use torque wrenches with the correct range - the upper third of the range should include the listed torque
value according to the chart.
When using impact screws, make sure that the given tightening torque is observed - should be checked before and
during the tightening procedure with torque wrench (Nm x 0,7375 = ft.lbs.)!
Preload forces and tightening torques for screws with standard metric thread according
to factory standard WN 4037 I
Wrench size
Preload values FM based on Tightening torques MA are (x) = per DIN931, for
screw grades and are given based on screw grades and
Standard Hex head
in N are given in Nm Socket head
metric thread
screws screws
8.8 10.9 12.9 8.8 10.9 12.9 mm Inch mm Inch

M 4 x 0,7 4 050 6 000 7 000 2,8 4,1 4,8 7 9/32 3 --
M 5 x 0,8 6 600 9 700 11 400 5,5 8,1 9,5 8 5/16 4 5/32
M 6 x1 9 400 13 700 16 100 9,5 14,0 16,5 10 -- 5 --
M 7 x1 13 700 20 100 23 500 15,5 23,0 27,0 11 -- -- --
M 8 x 1,25 17 200 25 000 29 500 23 34 40 13 1/2 6 --
M 10 x 1,5 27 500 40 000 47 000 46 68 79 (17) 16 (11/16) -- 8 5/16
M 12 x 1,75 40 000 59 000 69 000 79 117 135 (19) 18 (3/4) -- 10 --
M 14 x 2 55 000 80 000 94 000 125 185 215 (22) 21 (7/8) -- 12 --
M 16 x 2 75 000 111 000 130 000 195 280 330 24 -- 14 9/16
M 18 x 2,5 94 000 135 000 157 000 280 390 460 27 1-1/16 14 9/16
M 20 x 2,5 121 000 173 000 202 000 390 560 650 30 1-3/16 17 --
M 22 x 2,5 152 000 216 000 250 000 530 750 880 (32) 34 -- 17 --
M 24 x 3 175 000 249 000 290 000 670 960 1120 36 1-7/16 19 3/4
M 27 x 3 230 000 330 000 385 000 1000 1400 1650 41 1-5/8 19 3/4
M 30 x 3,5 280 000 400 000 465 000 1350 1900 2250 46 1-13/16 22 7/8
M 33 x 3,5 350 000 495 000 580 000 1850 2600 3000 50 2 24 --
M 36 x 4 410 000 580 000 680 000 2350 3300 3900 55 2-3/16 27 1-1/16
M 39 x 4 490 000 700 000 820 000 3000 4300 5100 60 2-3/8 27 1-1/16
Standard screws LR Litronic
Datum Edition Date
RL Litronic
Tightening Torques Blatt
01 04 Factory standard WN 4037 I Page
Feuille 1.4.02.01
Preload forces and tightening torques for screws with fine metric thread according to
factory standard WN 4037 I
Wrench size
Preload values FM based on Tightening torques MA are (x) = per DIN931, for
screw grades and are given based on screw grades and
Fine metric
in N are given in Nm Socket head
thread
Hex head screws screws
8.8 10.9 12.9 8.8 10.9 12.9 mm Inch mm Inch

M 8 x1 18 800 27 500 32 500 24,5 36 43 13 1/2 6 --
M 9 x1 24 800 36 500 42 500 36 53 62 -- -- -- --
M 10 x 1 31 500 46 500 54 000 52 76 89 17 11/16 8 5/16
M 10 x 1,25 29 500 43 000 51 000 49 72 84 17 11/16 8 5/16
M 12 x 1,25 45 000 66 000 77 000 87 125 150 19 3/4 10 --
M 12 x 1,5 42 500 62 000 73 000 83 122 145 19 3/4 10 --
M 14 x 1,5 61 000 89 000 104 000 135 200 235 22 7/8 12 --
M 16 x 1,5 82 000 121 000 141 000 205 300 360 24 -- 14 9/16
M 18 x 1,5 110 000 157 000 184 000 310 440 520 27 1-1/16 14 9/16
M 18 x 2 102 000 146 000 170 000 290 420 490 27 1-1/16 14 9/16
M 20 x 1,5 139 000 199 000 232 000 430 620 720 30 1-3/16 17 --
M 22 x 1,5 171 000 245 000 285 000 580 820 960 32 -- 17 --
M 24 x 1,5 207 000 295 000 346 000 760 1090 1270 36 1-7/16 19 3/4
M 24 x 2 196 000 280 000 325 000 730 1040 1220 36 1-7/16 19 3/4
M 27 x 1,5 267 000 381 000 445 000 1110 1580 1850 41 1-5/8 19 3/4
M 27 x 2 255 000 365 000 425 000 1070 1500 1800 41 1-5/8 19 3/4
M 30 x 1,5 335 000 477 000 558 000 1540 2190 2560 46 1-13/16 22 7/8
M 30 x 2 321 000 457 000 534 000 1490 2120 2480 46 1-13/16 22 7/8
M 33 x 1,5 410 000 584 000 683 000 2050 2920 3420 50 2 24 --
M 33 x 2 395 000 560 000 660 000 2000 2800 3300 50 2 24 --
M 36 x 1,5 492 000 701 000 820 000 2680 3820 4470 55 2-3/16 27 1-1/16
M 36 x 3 440 000 630 000 740 000 2500 3500 4100 55 2-3/16 27 1-1/16
M 39 x 1,5 582 000 830 000 971 000 3430 4890 5720 60 2-3/8 27 1-1/16
M 39 x 3 530 000 750 000 880 000 3200 4600 5300 60 2-3/8 27 1-1/16
Note: Observe notes on front page!

Tightening torques for screws for SAE split flange installation
Not part of factory standard WN 4037 I

Listing per LFR - Quality service 2QA 6 051 00 as of Oct. 2001
1. Flange and half flange for high pressure (Norm 62)
Tightening torques in Nm for screw grade 10.9

Flange nominal size Screw size flat flange without Flange with
Half flange
reinforcement reinforcement
½" M8 31 -- --
¾" M 10 62 45 65
1" M 12 108 70 110
1 ¼" M 14 172 120 180
1 ½" M 16 264 170 250
2" M 20 350 250 450
2. Half flange for low pressure (Norm 61)
Tightening torques in Nm for

Flange nominal size Screw size
Screw grade 8.8 Screw grade 10.9
½" M8 22 31
¾" M 10 44 62
1" M 10 44 62
1 ¼" M 10 44 62
1 ½" M 12 76 108
2" M 12 76 108
2 ½" M 12 76 108
3" M 14 122 172
3 ½" M 16 187 264
4" M 16 187 264
5" M 16 187 264
Tightening torques for oil drain plugs at travel gears
Not part of factory standard WN 4037 I

Listing per LBC - Quality service as of Oct. 2003
Oil drain plug Tightening torque

thread size in Nm
M 14x1,5 40
M 16x1,5 40
M 18x1,5 40
M 22x1,5 80
M 33x1,5 160
Standard screws LR Litronic
Datum Edition Date
RL Litronic
Tightening Torques Blatt
01 04 Factory standard WN 4037 I Page
Feuille 1.4.02.02
1. Hole diameter for tapping ISO standard Metric (internal) thread
Hole diameter
Thread
limits Drill bit Ø
size
max. min.
M1 0,785 0,729 0,75
M 1,1 0,885 0,829 0,85
M 1,2 0,985 0,929 0,95
M 1,4 1,160 1,075 1,1
M 1,6 1,321 1,221 1,25
M 1,7 1,346 1,258 1,30
M 1,8 1,521 1,421 1,45
M2 1,679 1,567 1,6
M 2,2 1,838 1,713 1,75
M 2,3 1,920 1,795 1,9
M 2,5 2,138 2,013 2,05
M 2,6 2,176 2,036 2,10
M3 2,599 2,459 2,5
M 3,5 3,010 2,850 2,9
M4 3,422 3,242 3,3
M 4,5 3,878 3,688 3,7
M5 4,334 4,134 4,2
M6 5,153 4,917 5
M7 6,153 5,917 6
M8 6,912 6,647 6,8
M9 7,912 7,647 7,8
M 10 8,676 8,376 8,5
M 11 9,676 9,376 9,6
M 12 10,441 10,106 10,2
M 14 12,210 11,835 12
M 16 14,210 13,835 14
M 18 15,744 15,294 15,5
M 20 17,744 17,294 17,5
M 22 19,744 19,294 19,5
M 24 21,252 20,752 21
M 27 24,252 23,752 24
M 30 26,771 26,211 26,5
M 33 29,771 29,211 29,5
M 36 32,270 31,650 32
M 39 35,270 34,670 35
M 42 37,799 39,129 37,5
M 45 40,799 40,129 40,5
M 48 43,297 42,587 43,0
M 52 47,297 46,587 47,0
M 56 50,796 50,046 50,5
M 60 54,796 54,046 54,1
M 64 58,305 57,505 57,6
M 68 62,305 61,505 61,6
Dimensions are in mm
mm x 0,03937 = inches
LR Litronic
Datum Edition Date
RL Litronic
01 04 Hole diameter before tapping Blatt

Page
Feuille 01.4.04.01
2. Hole diameter for tapping ISO fine Metric (internal) thread
Hole diameter Hole diameter

Thread size limits Drill bit Ø Thread size limits Drill bit Ø
max. min. max. min.
M 1 x 0,2 0,821 0,783 0,8 M 25 x 1 24,153 23,917 24
M 1,1 x 0,2 0,921 0,833 0,9 M 25 x 1,5 23,676 23,376 23,5
M 1,2 x 0,2 1,021 0,983 1 M 25 x 2 23,210 22,835 23
M 1,4 x 0,2 1,221 1,183 1,2 M 26 x 1,5 24,676 24,376 24,5
M 1,4 x 0,25 1,185 1,129 1,15 M 27 x 1 26,153 25,917 26
M 1,6 x 0,2 1,421 1,383 1,4 M 27 x 1,5 25,676 25,376 25,5
M 1,8 x 0,2 1,621 1,583 1,6 M 27 x 2 25,210 24,835 25
M 2 x 0,25 1,785 1,729 1,75 M 28 x 1 27,153 26,917 27
M 2,2 x 0,25 1,985 1,929 1,95 M 28 x 1,5 26,676 26,376 26,5
M 2,5 x 0,35 2,201 1,121 2,15 M 28 x 2 26,210 25,835 26
M 3 x 0,35 2,721 2,621 2,65 M 30 x 1 29,153 28,917 29
M 3,5 x 0,35 3,221 3,121 3,15 M 30 x 1,5 28,676 28,376 28,5
M 4 x 0,5 3,599 3,459 3,5 M 30 x 2 28,210 27,835 28
M 4,5 x 0,5 4,099 3,959 4 M 30 x 3 27,252 26,752 27
M 5 x 0,5 4,599 4,459 4,5 M 32 x 1,5 30,676 30,376 30,5
M 5,5 x 0,5 5,099 4,959 5 M 32 x 2 30,210 29,835 30
M 6 x 0,75 5,378 5,188 5,2 M 33 x 1,5 31,676 31,376 31,5
M 7 x 0,75 6,378 6,188 6,2 M 33 x 2 31,210 30,835 31
M 8 x 0,75 7,378 7,188 7,2 M 33 x 3 30,252 29,752 30
M8x1 7,153 6,917 7 M 35 x 1,5 33,676 33,376 33,5
M 9 x 0,75 8,378 8,188 8,2 M 36 x 1,5 34,676 34,376 34,5
M9x1 8,153 7,917 8 M 36 x 2 34,210 33,835 34
M 10 x 0,75 9,378 9,188 9,2 M 36 x 3 33,252 32,752 33
M 10 x 1 9,153 8,917 9 M 38 x 1,5 36,676 36,376 36,5
M 10 x 1,25 8,912 8,647 8,8 M 39 x 1,5 37,676 37,376 37,5
M 11 x 0,75 10,378 10,188 10,2 M 39 x 2 37,210 36,835 37
M 11 x 1 10,153 9,917 10 M 39 x 3 36,252 35,752 36
M 12 x 1 11,153 10,917 11,1 M 40 x 1,5 38,676 38,376 38,5
M 12 x 1,25 10,912 10,647 10,8 M 40 x 2 38,210 37,835 38
M 12 x 1,5 10,676 10,376 10,5 M 40 x 3 37,252 36,752 37
M 14 x 1 13,153 12,917 13 M 42 x 1,5 40,676 40,376 40,5
M 14 x 1,25 12,912 112,647 12,8 M 42 x 2 40,210 39,835 40
M 14 x 1,5 12,676 12,376 12,5 M 42 x 3 39,252 38,752 39
M 15 x 1 14,153 13,917 14 M 42 x 4 38,270 37,670 38
M 15 x 1,5 13,676 13,376 13,5 M 45 x 1,5 43,676 43,376 43,5
M 16 x 1 15,153 14,917 15 M 43 x 2 43,210 42,835 43
M 16 x 1,5 14,676 14,376 14,5 M 45 x 3 42,252 41,752 42
M 17 x 1 16,153 15,917 16 M 45 x 4 41,270 40,670 41
M 17 x 1,5 15,676 15,376 15,5 M 48 x 1,5 46,676 46,376 46,5
M 18 x 1 17,153 16,917 17 M 48 x 2 46,210 45,835 46
M 18 x 1,5 16,676 16,376 16,5 M 48 x 3 45,252 44,752 45
M 18 x 2 16,210 15,835 16 M 48 x 4 44,270 43,670 44
M 20 x 1 19,153 18,917 19 M 50 x 1,5 48,676 48,376 48,5
M 20 x 1,5 18,676 18,376 18,5 M 50 x 2 48,210 47,835 48
M 20 x 2 18,210 17,835 18 M 50 x 3 47,252 46,752 47
M 22 x 1 21,153 20,917 21 M 52 x 1,5 50,676 50,376 50,5
M 22 x 1,5 20,676 20,376 20,5 M 52 x 2 50,210 49,835 50
M 22 x 2 20,210 19,835 20 M 52 x 3 49,252 48,752 49
M 24 x 1 23,153 22,917 23 M 52 x 4 48,270 47,670 48
M 24 x 1,5 22,676 22,376 22,5
M 24 x 2 22,210 21,835 22
Sub Group Index
Special tools 2.1
Special tools Liebherr Diesel engine 2.1.10
Special tools general hydraulic repair 2.1.20
Special tools hydraulic pressure testing 2.1.21
Special tools hydraulic cylinder 2.1.22
Special tools general - electric repair 2.1.30
Special tools wiring harness 2.1.31
Special tools mech. components 2.1.40
Repair welding 2.2.00
Installation guidelines 2.3.01

Installation guidelines Duo-Cone-Seals 2.3.01
Wiring installation guidelines ITT-Cannon plug 2.3.02
Wiring installation guidelines Harting plug 2.3.03
Wiring installation guidelines AMP plug 2.3.04
Special tools LR Litronic
Datum Edition Date
RL Litronic
01 01 Application guidelines Blatt

Page
Feuille 2.0.00.01
Description Id.No. Remarks Illustration
Digital Electronic Impulse 7009 538 test range:

Tachometer 400-6000 RPM
accuracy
all engines 1 RPM
Tachometer - mechanical 5003 069 test range:

100-3000 RPM
accuracy:
1 RPM
Tachometer cable 5003 070 to be used with

Id.No. 5003 069
D904 TB / 904 T
Tachometer cable extension 8122 902 to be used with

Id.No. 5003 070
D904 TB / 904 T
Battery charge / coolant 7408 922 to test the condition of

condition tester the battery charge and
the percentage of
antifreeze in the engine
coolant.
Description Description Dénomination Typ/ab Type/from Type/ a partir de
Diesel engine LR Litronic
Datum Edition Date
RL Litronic
01 04 Special tools Blatt

Page
Feuille 2.1.10.01
Illustration Description Id.No. Remarks
DCA4 Test kit 5608 459 to test the DCA4

„CC2602M“ concentration in
coolant.
includes:
test strip container all engines
50 test strips
plastic container
eye dropper
Compression tester 8008 782 to check the engines

compression pressure.
all engines
Test adapter for 0524 044 to be used in place of

compression tester injector when checking
compression
all engines
Injector tester 7361 236 to check injector

opening pressure
all engines
High pressure hand pump 7009 318 to check the injection

with accessories, complete pump timing.
all engines
Slide hammer 0524 072 to remove injectors
all engines
Adapter 0524 029 to be used with

Id.No. 0524 072
all engines
Angle method torque fixture 0524 062 to torque screws

- cylinder head
- main bearings
- rod bearings
all engines
Engine turning fixture 0524 045 mounted on the flywheel

housing
all engines
(not useable at
D 9406 TI - PR 752,
RL 52, use
Id.No. 9183 785)
Dial gauge to control the delivery

Pos.1 7022 418 begin
from the distribution
Dial fixture Pos.2 7022 420 injection pump
all engines with

distribution injection
pump
Diesel engine LR Litronic
Datum Edition Date
RL Litronic

Page
Feuille 2.1.10.02
V - Belt Measuring Tool 8042 829 to measure V - Belt

„Krikit2“ tension
All engines
Holding fixture 0527 462 to eliminate starting fuel

quantity when adjusting
the delivery begin
motors with MW

injection pumps
D914/916
D924/926
D9306/9308
D9406/9408
Sampling pump pos. 1 8145 666 used for taking oil

samples for the oil
1 Sampling valve for oil analysis.
samples pos. 2 7019 068
Oil analysis set German analysis at WEAR

6 samples 7018 368 CHECK Germany,
12 samples 7018 369 analysis report in
German language.
Oil analysis set French Analysis at WEAR

6 samples 8503 561 CHECK Belgium,
analysis report in
French language
Engine turning fixture 9183 785 to turn the Diesel engine

with ¾" square head drive D 9406 TI - PR 752,
RL 52, for adjustments
fits on the fan side end

of crankshaft
Description Id. No. Remarks Illustration
Vacuum pump, complete 7408 148 for faster bleeding of

with the following accessories: the hydraulic system
the vacuum pump can
Vacuum pump with electr. produce low pressure
cord 7407 987 (appr. 0.4 bar) by
Hose assembly 7407 985 reversing the PVC
Hose assembly 7407 986 hose. The connecting
Fitting S8M 7404 619 point for the machine is
Fitting L6R 4901 110 the bleeder screw on
PVC hose 7360 127 the hydraulic tank.
Terminal clamp - pos. 7408 149
Terminal clamp - neg. 7408 150
Plug - 2 connectors 7408 151
Temperature gauge 7020372 accuracy:
2%/2°
test range:
-18°C - +260°C
Adjustment tool commercially to adjust pump end

for BPV 50, 70, 100 available position via eccentric
screw
Tool to loosen / counter
Note: The 12 point
Item.1 socket ½“ stub should
12 point socket ½“ SW 13 x 85 have an outer diameter
of 18 mm over a length
Adjustment tool of approx. 35 mm
Item.2
Hex head screw handle SW 4 x 200
Item.3 socket wrench SW13 x 120

Hook wrench 7900 282 to loosen / tighten when
58 - 62 mm adjusting the regulating
range of BPV pumps
Adjustment tool for slotted 9792 711 to loosen / tighten lock

nut at HPV 130 nut when adjusting
pump end stop - Qmax
(also usable when
adjusting regulating
range at BPV)
use together with hook
wrench
Id. No. 7900 282
General hydraulic repair LR Litronic
Datum Edition Date
RL Litronic

Page
Feuille 2.1.20.01
Illustration Description Id. No. Remarks
Adjustment tool for 9749 025 to loosen / tighten lock

mechanical neutral position nut when adjusting
slotted nut mechanical neutral
HPV 135-02 position.
Clamping tool for clamping 6427 521 to tighten the spring and
spring at BPV remove ball socket
BPV 35 - 200 trumpet tube when
changing swash plate
bearing
Pin puller 6427 516 used to remove the pin

for pump BPV 35 - 100 for the swash plate
bearing cage retainer
clip
Punch to punch the studs -

for stud BPV 70 - 100 change of needle
bearing segment
Swash plate 7413 894
Housing 4713 895
Installation sleeve for radial for correct mounting the

shaft seal radial shaft seal on the
pump drive shaft
BPV 35 – 70 7404 289
Note:
BPV 100 7404 298 install seal rings with
Loctite 270
BPV 200 7404 567
Measuring device for to measure pressure,

differential pressure 7025 376 differential pressure
contents - 230V and used for Data
230V transfers to the PC
contents of:
measuring device M - H 2045
2 pressure sensors 0-600 bar
2 test fittings
2 test hoses MK 12m
Measuring device for 7025 755 connecting wire - board circuit
differential pressure adapter wire - data transfer
power supply unit
contents 120V
Pressure gauge accuracy:

0-10 5002 865 1% of end value
0-25 7361 289
0-40 7361 288 all pressure gauges are
0-60 5002 867 glycerin filled
0-100 5602 903
0-160 7361 286
0-250 7361 285
0-400 7500 002
0-600 7361 294
0-1000 4601 115
Digital pressure gauge resolution
0,1% of end value
0 - 100 7412 643
accuracy:
0 - 500 7412 644 0,2% of end value
Lithium battery for digital 6002 780 gauge range - static:

pressure gauge up to max. 50 % above
the listed end value
Gauge - coupling to seal the coupling

during pressure tests, a
R½ 7002 436 seal ring,
Id. No. 7409 794, must
be installed.
Test hose NW 2 to avoid loss of

pressure during tests,
1000 mm 7002 437 use the shortest
1500 mm 7002 475 possible test hose
4000 mm 7009 134
5000 mm 7363 732
Test fitting , complete union nut and ferrule

mounted on test fitting.
R6L 7409 916
R 10 L 7406 864
R 12 L 7409 918
Hydraulic pressure testing LR Litronic
Datum Edition Date
RL Litronic

Page
Feuille 2.1.21.01
Screw coupling to connect to additional

machine measuring
M 8x1 7615 321 points
M 10x1 5608 462
M 12x1,5 7409 783
M 14x1,5 7406 865
R¼ 7409 720
Schott screw coupling to connect shorter test
lines or connection
M 16x2 7407 070 between test connection
and pressure sensor
Test plate A to close high pressure

for SAE-flange ¾ 7370 092 ports when checking
Size (in mm) system pressures
A 90
B 40
C,r 5 material:
Test plate B ground resilient steel
for SAE - flange 1 7370 093
Size (in mm)
A 90 taper rounded plate
B 44 ends, round off edges
C,r 5
(simplifies installation,
Test plate C
7370 094 prevents damage to O -
for SAE flange 1¼
Size (in mm)
ring)
A 90
B 52 or to be made in
C,r 5 house
Flange, complete ( 2 each to close high pressure
with O - rings and screws) ports when checking
for support shaft system pressures and
when shaft flange is
PR712/722 9787 796 removed
LR622
RL(4)22 also to protect front
surface when removing
PR732/742 9787 798 support shaft bearings.
LR632
RL(4)42
Fitting to close off control lines
for adjustment of hydr.
pos.1 stopper 2 x 4900 038 motors on the
pos.2 union nut 2 x 4774 001 PR 752
pos 3 elbow fitting 2 x 7403 569
pos 4 reducer fitting 2 x 7404 259
pos 5 fitting 2 x 7410 458
Diagnostics unit CET 08/05 10305903 Required to check /

With adapter cable adjust the travel drive
(consists of the following parts marked - for all machine models
with *) with electronic control / E-
Box Version CEP
* Diagnostics unit 10470376 For application of

diagnostics unit, see
section 10.4.
* Adapter cable 55-pin 9814970
Adapter CET-14/05 for old 7413 106 Adapts the diagnostics unit
Diagnostics unit 08/03 (box) for all machine models
with E-Box Version CEP
Adapter cable 9814 970 Necessary for all tests
55-pin Use for diagnostics units

CET 08/03 and
CET 08/05.
Adapter cable - Y for old 9747 733 Auxiliary cable for special
diagnostics unit 08/03 (Box) tests in travel drive
Accessories 6002 655

Protective cap for plug 6002 654 Use for diagnostics unit
Protective cap for socket CET 08/03
Power supply cable 6002 697 Power supply cable:
cpl. for old diagnostics unit
Plug 3-pin
08/03 (Box)
A: +
consists of:
B: -
Panel plug 7409 682
C: free
Plug 3-pin 7409 676
Shrink tubing for panel plug 7409 681
Shrink tubing for plug 3-pin 7409 679

Panel plug
Cable
Center contact: +
6000 738
Side contact: -
Accessories
Protective cap for plug 3-pin
Use for diagnostics unit
7409 677
CET 08/03
Electric - General LR Litronic
Datum Edition Date
RL Litronic

Page
Feuille 2.1.30.01
E-Box Evaluation kit 9812 435 To read out error stack - E-

Consists of Box
CEP 12/08C, CEP 12/20
Pos.1 Disk with and CEP 1/22
Software CEP 12 7415 329
Pos. 2 Adapter cable 9812 434
Pedal test unit 7414 235 Required for
PR-2-Litronic: Check /
adjustment of inching /
brake pedal
LR-2 Litronic: Check /

adjustment of steering and
brake pedals
LIKOM - Service Set 9793 970 Required to check /

Consists of: adjust the travel drive
LIKOM Software Pos. 1 9758 760 01 - for all machine models
Interface cable Pos. 2 9794 550 with electronic control / E-
Application description not Box Version RST
shown
For application of
diagnostics unit, see
section 10.5.
Application accessories:
6140 645 01
Note Book
6004 217
Transformer 24/230 V
Digital multi meter 6001 231 for
cpl. with cable and bag Voltage (V)-
Amperage (A)-
Resistance ( )-
and
Frequency (Hz)-
tests
Optical charge tester 7408 922 To check the battery

charge condition and the
antifreeze protection in the
coolant
Socket wrench 9797 973

for sensor control motor /
gear or
12 pt. Socket Rework according to
wrench drawing:
SW 27 re- Notched surfaces must be
worked ground out.
Hand crimp tool - Cannon 7367 086 to produce flawless

crimp connections.
M 22 5 20/1-01
application, see group
02.3.02.
Crimp insert - Cannon used with hand crimp

tool
CT 120090-20 7409 779 Id.No. 7367 086
TH 452 7367 084 application, see group

02.3.02.
Reference gauge to check the hand

crimp tool
M 22 5 20/3-1 7409 718 Id.No. 7367 086
application, see group

02.3.02.
Insertion tool for CA - B to insert wired crimp

Crimp contacts contacts into the plug
connectors.
CIT-F80-KIT complete 7409 721
consisting of:
1 Handle 7409 693
1 Insert CIT 20 7409 694 application, see group
1 Insert CIT 16 7409 695 02.3.02.
1 Insert CIT 12 7409 696
1 Insert CIT 8 7409 697
1 Insert CIT 4 7409 698
1 Insert CIT 0 7409 699
Extraction tools for CA - B to remove wired crimp

crimp contacts contacts from the plug
connectors.
CET-F80-KIT complete 7409 700 depending if socket or
consisting of: pin contacts are
1 Handle 7409 701 removed, the
1 Insert CET 20 7409 702 corresponding side of
1 Insert CET 16 7409 703 the tool insert should be
1 Insert CET 12 7409 704 used.
1 Insert CET 8 7409 705 application, see group
1 Insert CET 4 7409 706 02.3.02.
1 Insert CET 0 7409 707
Insertion tool for KPSE application, see group

crimp contacts 02.3.02.
MS 24256 A16 7409 708
MS 24256 A20 7409 709
Electric system - wiring harness LR Litronic
Datum Edition Date
RL Litronic

Page
Feuille 2.1.31.01
Extraction tool for KPSE application, see group

crimp contacts 02.3.02.
MS 24256 R16 7409 710
MS 24256 R20 7409 711
Insertion tool for SURE application, see group

SEAL crimp contacts, 02.3.02.
complete
CITG-SS-1 7367 023
Insertion tip
CIT-SS-1-TIP 7409 712
Contact holder
CT 317-8666-005 7409 713
Extraction tools for SURE P - valid for extraction
SEAL crimp contacts, of socket contacts.
complete S - valid for extraction
CET-SS-P 7367 020
CET-SS-S 7367 022 application, see group
02.3.02.
Extraction tips
CET-SS-P-TIP 7409 714
CET-SS-S-TIP 7409 715
Guiding pin - Cannon for: when installing socket
CA-B Crimp contacts contacts, guiding pins
Size 15S, 16S, 15, 16: must be used.
226-1017-000 7409 716
Size 25, 12 protection against
226-1018-000 7409 717 damage.
SURE SEAL crimp contacts
CT 317-8588-000 7409 745 application, see group
02.3.02.
Auxiliary tool - Cannon for device for holding
SURE SEAL connectors during
insertion and extraction
CIEF-SS-5-6-7 7367 085 of crimped contacts.
4 notch hand crimp tool for creating perfect

„Buchanan“ crimp connections on
Harting plug
pos1 - Crimp pliers 8123 551 connectors
pos2 - Positioning sleeve 8123 552
Test gauge for inspecting crimp

depth in Harting"
0,5-1 und 2,5 mm 8123 553 connector
1,5 mm 8123 554
Extraction tool for Harting 8123 556 for extraction of crimp

crimp contacts contacts from the
Harting - connector
Insertion tool for “Harting” 8123 555 for insertion of

crimp contacts connected crimp
contacts into the
Harting connector
Crimp tool to crimp contacts of

for MATE - N - LOK
MATE-N-LOK crimp contacts connectors
for 1,5 mm² 7367 025

for 2,5 mm² 7366 314
Extraction tool AMP extraction tool to push a

for crimped contact of the
MATE-N-LOK crimp contacts 7366 655 MATE - N - LOK
connectors
substitute insert 7015 180
Insertion tool AMP 8145 432 to insert pin and socket

for contacts in connectors
MATE-N-LOK Crimp type MATE - N - LOCK
contacts
Hand crimp tool - Cannon 8503 647 to crimp correct

for „DEUTSCH“ Connectors contacts of connectors
type DEUTSCH
crimp turret 7409 779
Extraction tool Cannon extraction tool to push

for crimp contacts pin contacts and socket
DEUTSCH contacts of
AWG 4 8503 633 theDEUTSCH
AWG 8 8503 632 connectors
AWG 12 10 114 733
AWG 16 885 563 714
AWG 20 10 114 732
Crimp tool AMP 7415 333 to crimp the JUNIOR
AMP Certi-Lock POWER TIMER
contacts
Electric system - wiring harness LR Litronic
Datum Edition Date
RL Litronic

Page
Feuille 2.1.31.02
Extraction tool AMP 7370 373 extraction tool to

remove contact of the
JUNIOR POWER
TIMER housing
Crimp tool 7409 781 to crimp insulated wire

CSA 0760 contacts 0,75 - 6,0 mm²
Example: isolated
connectors
Crimp tool 7409 782 to crimp non insulated

CRB 0560 wire contacts
0,5 - 6,0 mm²
Example: connection to
wiper motor
see picture group 9
Wire stripper complete to remove the insulation

on individual wires on
Type 5011-26 7409 777 the electronic wire
harness.
Spare blades 7409 778 0,75 mm²
Blade inserts to strip metric to be installed in wire

wires with the following wire stripper
diameters Id.No. 7409 777
1,5 - 6,0 mm² 7409 788
0,15 - 2,5 mm² 7409 789

track component 7402 603 application, see

measuring tool group 12.2.
R = ring wrench and to adjust bearing play of

E = adjustment template cross roller bearings
for
PR 712 (B) FAT 400/523 R/E 9054 282* *= with new adjustment R =
template bearings
400C563 R 9790 992
E 8123 439
**= with new adjustment
400P553 R 9790 992 template and new
E 8123 438 pin, can also be
used for newer gear
PR 722 (B) FAT 450/514 R/E 9054 281* types see Service
information
450C564 R 9790 996 11-3-5/94 Litronic)
E 8123 440 E=
PR +LR 622 450P554 R 9790 996

+RL (4)22 E 8123 440
1)
PR 732 (B) FAT 500/525 R/E 9054 280** = 8123 445
500C565 R 9790 999 substitution - carrier / bolt

1)
E 8123 442 = 8123 445
for wrench IdNr. 9790 992 and
PR +LR 632 500P555 R 9790 999 IdNr. 9790 996
E 8123 441 bolt IdNr. 9790 995
1)
PR 742 (B) FAT 550/516 R/E 9054 279** = 8123 446 for wrench IdNr. 9790 999
bolt IdNr. 8123 445
550C566 R 9791 003
1)
E 8123 444 = 8123 446 for wrench IdNr. 9791 003
bolt IdNr. 8123 446
PR +RL 42 550P556 R 9791 003
E 8123 443
special wrench - support to loosen and tighten
shaft the ring nut on the
support shaft
9054 840
PR 712/722
LR 622
RL(4)22
9785 922
PR732/742
LR 632
RL 42
Mech. components LR Litronic
Datum Edition Date
RL Litronic

Page
Feuille 2.1.40.01
Illustration Description Id.No Remarks
socket wrench - size 22 mm 9745 376 to release / tighten the

for cable fittings on axle flange cable fittings on the
support axle
PR 732 / LR 632
PR 742
RL 42
clamping tool for parking 9814 884 to dissemble and

brakes assemble of the parking
FAT - Type P/D brake at FAT type - P/D
all types measurements for

except PR 752 / RL 52 manufacturing the
clamping tool see page
2.1.40.02
press - in punch for installation of radial

shaft seal in hoist
Pos.1 installation flange cylinder support.
see chapter 15.2.
PR712/722 A 9786 683 A = für Pos.12
B 9786 684 B = für Pos.11
PR732 A 9786 685 for dimensions to

B 9786 687 manufacture the punch
see page 2.1.40.02
PR742/752 A 9786 686
B 9786 687
Pos.2 screw in handle for all
installation flanges 9786 688
puller commercially to pull out bushings
Pos.1 with counter support available toll Pos.3 ad Pos.4 from
Pos.2 for the following hoist cylinder bearing
dimensions (in mm) cut open support
bushings, pos. 3
from Ø 120mm
PR712 PR732 PR742 PR752
PR722
A 90 110 120 120
B 70 90 90 90
C 247,5 273 273 280
D 90 96 94 120
tension tool track adjuster to install and remove

unit the spring in the track
roller frame on the PR
Pos. 1 - installation flange 9798 353 752. absolutely requires
Pos. 2 - bar 9798 352
Pos. 3 - hex head screw (6 4601 217 application, see

pieces.) „group 12.5.50“
M16x310mm - 10.9
Installation wrench 9416915 Special hook wrench to

Tension unit loosen and attach the
ring nut
Installation tool 9416922 Sleeve to push on the

Tension unit ring nut – prevents
twisting of the ring nut
Mounting sleeve 9817 062 for installation of

outside bearings at the
equalizer bar PR 752
Dimensions to self - manufacture from special tools

1. For disassembly and assembly of the brake housing travel gear FAT - type A / C (without Id. No.)
PR 712 PR 722 PR 732 PR 742

Dim FAT 400/523 FAT 450/514 FAT 500/525 FAT 550/516
(mm) FAT 400 C 563 FAT 450 C 564 FAT 500 C 565 FAT 550 C 566
A 315 340 360 395
B 380 400 420 460
ØC 22 22 22 26
D M20 x 2,5 M20 x 2,5 M20 x 2,5 M24 x 3
E 130 150 170 190
F 30 30 30 36
G 16 16 16 18
ØH 21 21 21 25
ØI 36 36 36 44
Dimensions on drawing are valid for all travel gears FAT 400 to
550.
Mech. components LR Litronic
Datum Edition Date
RL Litronic

Page
Feuille 2.1.40.02
2. For disassembly and assembly of the brake housing travel gear FAT - type P / D (Id. No. see page 2.1.40.01)
Pos. Description Ø Id.No.
1 washer with nut M20 (welded on) 160 mm 9814 883

2 washer for machine size X32, X42 160 mm 9814 881
3 washer for machine size X12, X22 130 mm 9814 882
4 screw M20 x 110 10.9 A3C 4600 161
5 washer A3C 4600 222
3. Mandrel for radial seal ring in lift cylinder bearing

see crawler dozers service manual, chapter 15.2.(Id. No. see page 2.1.40.01)
3.1. Screw type handle

page 2.1.40.01 - item 2, fits for following installation flanges
all dimensions in mm
3.2. Installation flange

page 2.1.40.01 - item 1
A for Pos.12, B for Pos.11 from group 15.2.
Id.No. Maß A Maß B Maß C DIM D
PR 712 / 722 A 9786 683 Ø119-0,3 Ø89±0,1 12 23

-0,3 ±0,1
B 9786 684 Ø71 Ø57 8 18
PR 732 A 9786 685 Ø139-0,3 Ø109±0,1 14 23
B 9786 687 Ø89-0,3 Ø69±0,1 10 18 *edges rounded
PR 742/752 A 9786 686 Ø149-0,3 Ø119±0,1 14 23

-0,3
B 9786 687 Ø89 Ø69±0,1 10 18
4. Intermediate flange travel pump to regulating pump, see 8.1.01.02

PR712(B) - PR732(B), LR622/LR632, RL(4)22 B
With pulling device, IdNo.0524 072 - section 02.1.10.02.,
or with screw M10x100
all dimensions in mm
Prior to beginning any welding on earthmoving equipment, the battery cables and the wires on connection B+ and
D- on the alternator must be disconnected and the electronic control box must be removed. In addition, the ground
cable of the welding unit must be connected directly to the bare metal of the part to be welded.
1. Preparation of a crack
The crack must be free of paint, grease and dirt.
To prevent the crack from extending during the preparation or the welding process, the end of the cracks should
be drilled with a hole of at least 0.32" (8mm) in diameter.
The crack should now be ground, chiseled, torch cut or arced out at a 60° angle. Be certain the edges are clean
and extend through the full cross section of the material, without exceeding the 0.04" (1 mm) space in the lower
part. On larger grooves, a welding safety should be installed.
Certain materials must be preheated to 300°F (150°C) prior to welding.

Special preparations are necessary when preparing a crack in manganese steel. Due to its hardness,
mechanical preparation, such as a chisel or hobbing machine is not possible. We suggest that the crack is
prepared with a slow running and water cooled grinding wheel to prevent overheating.
Other possibilities for preparing cracks or removing high alloy welding seams are the use of cutting electrodes of
the type UTP 82 AS.
2. Preparation of a weld
The area to be welded must be free of paint, grease, oil, moisture and dirt. During rain, the area to be welded
must be covered. Materials with a thickness above 0.60" (15 mm), high carbon steel or steel which is difficult to
weld, the material must be preheated to approximately 176°- 392°F (80°- 200°C).
Pre-heating is also necessary when the ambient or component temperature is below 40°F (5°C) or when the
construction of the component prevent the welding stress to be released.
3. Storing Electrodes
Use only dry and undamaged electrodes. Electrodes which are rusty or damaged should not be used. Electrodes
should be stored in a dry room with a minimum temperature of 59°F (15°C). Open packages should be carefully
closed and stored after the welding work is completed.
LR Litronic
Datum Edition Date
RL Litronic
01 04 Repar Welding Blatt

Page
Feuille 2.2.00.01
4. Welding Technique
The welding of material with the necessary electrodes (see table under paragraph 7) is in accordance with DIN
1912.
The adjustment of the welding machine - dictated by the different thicknesses of the electrodes - can be taken
from the table of the electrode package.
Beginning with a material thickness of 1/4" (8 mm), butt welds must be made in several layers. The weld is
applied in several beads. Wide butt welds are filled with several side by side beads, with the last layer covering
the center. The electrode should melt evenly without creating burrs and peaks. The valley or crater, which is
created when changing electrodes must be filled in and overlapped with the next electrode. To prevent cracks in
those craters, care must betaken that they are properly filled.
If the crack extends towards the outer edge of the material, slag may be trapped or burn holes may be created.
To prevent this, the following aid may be used: Tack a piece of sheet metal to the outer edge of the material. The
welding seam begins now at the sheet metal in the direction of the arrow. After the welding is completed, the
sheet metal is removed and the edge of the material is ground smooth.
The weld must cool off slowly and should therefore be protected from rain and wind.
5. Reinforcement of the welding seam

If the crack of the material is due to an overload or abuse, a reinforcement plate should be welded over the
crack. The selection of the correct reinforcement plate is based on the construction and load factors of the
component to be repaired.
For this reason, only general recommendations can be made as to the size and shape of the reinforcement
plates.
6. General application of reinforcement plates
6.1. Shape of reinforcement plates

The crossover or connection between the reinforced and not reinforced part should be as gradual as possible.
This means that the size of the plate should be selected in such a way that new or unacceptable high stress in
the repaired parts are avoided. Plates with sharp corners (such as a rectangular plate) should not be used.
Suitable reinforcement plate with Suitable reinforcement plate against

high tensile strength. bending and alternating loads.
6.2. Plate Thickness
The thickness of the reinforcement plate should be up to 2/3 (66%) of the thickness of the material to be
reinforced.
6.3. Plate Quality

The yield and tensile strength of the reinforcement plate should be equal to the material to be reinforced.
6.4. Plate Installation

The welded area of the crack should be ground so it is smooth and level.
The size of the plate must be selected in such a way that the longer sides of the plate extend into the
connecting construction of the material to be reinforced. The plate should also overlap the crack on each side
by at least 1" (20 mm). The correct position and fit of the reinforcement plate is achieved through clamping and
spot welding.
6.5. Plate Welding

The reinforcement plate should be welded on by running a welding bead alternately on both sides. The welding
should always start in the middle of the plate and run towards the outside. Be certain to observe that each
welding seam has proper run out.
Direction of weld Direction of weld

The size of the welding run "a" is figured out in reference to the thickness "k" of the reinforcement plate.
Use formula: a=0,5 k
Up to a welding run "a" of approx. 1/8" (3 mm) a single run can be made, however, as a general rule, a double
run should be preferred.
Above a welding run "a" of 1/8"(3 mm), the first run provides excellent penetration between the reinforcement
plate and the basic material. Subsequent runs are added on top of the first run.
After the welding is completed, clean the welding seam as necessary. Grind the run out between reinforcement
plate and basic material.
LR Litronic
Datum Edition Date
RL Litronic

Page
Feuille 2.2.00.02
7. Selecting the correct electrodes
For repair welding, only lime based {Kb} electrodes should be used, and as a rule, the electrodes {additional
material} should be "softer" than the basic material. Exceptions to this rule should be observed.
Important: To reach the theoretical welding quality, the work must not only be performed in a
professional manner, the electrode manufacturer's guidelines must absolutely be observed as
well.
Welding of vertical-down welds on steel components is not permissible!
7.1. Electrode Selection

Electrode - Protective gas welding wire
Welding area Material
norm description norm description
BASIC MACHINE
Roller frame - Main St 52 - 3 according to EN 499: according to EN 440:
frame QStE 380 N E42 5 B 4 2 H5 G4Si1
according to AWS A5.1-91: according to AWS A5.18-93:
E7018-1 H4 R ER 70 S-6
LH 690 according to EN 757: according to EN 12534:
preheat to app. E 69 6 Mn2NiCrMo B 4 2 H5 G3CrNi1Mo
100-150°C according to AWS A5.5-96: according to AWS A5.28-96:
(210-300°F) E 11018-G ER110S-G
ATTACHMENT
Blade Q St E 380 N according to EN 499: according to EN 440:
Bucket HARDOX 400 E42 5 B 4 2 H5 G4Si1
E7018-1 H4 R ER 70 S-6
Push frame St 52 - 3 according to EN 499: according to EN 440:
Bucket arm E42 5 B 4 2 H5 G4Si1
RL-Boom according to AWS A5.1-91: according to AWS A5.18-93:
E7018-1 H4 R ER 70 S-6
LH 690 according to EN 757: according to EN 12534:
preheat to app. E 69 6 Mn2NiCrMo B 4 2 H5 G3CrNi1Mo
100-150°C according to AWS A5.5-96: according to AWS A5.28-96:
(210-300°F) E 11018-G ER110S-G
Ripper St 52 - 3 according to EN 499: according to EN 440:
Q St E 380 N E42 5 B 4 2 H5 G4Si1
HARDOX 400 according to AWS A5.1-91: according to AWS A5.18-93:
E7018-1 H4 R ER 70 S-6
WEAR ITEMS
Adapter, Tooth adapter Special steel Root runs Root runs
Ripper according to EN 499: according to EN 440:
E42 5 B 4 2 H5 G4Si1
E7018-1 H4 R ER 70 S-6
Cover layers with Cover layers with
high-strength electrode high-strength electrode
according to EN 1600: according to EN 12072:
E 18 8 Mn B 2 2 G 18 8 Mn
E 307-15 ER307
7.2. Steel Table
Description Explanation Analysis

HARDOX 400 Weldable, low alloy special steel highly C 0,27% Si 0,7%
wear resistant, tensile strength 1250 N/mm² Mn 1,6% Cr 1,4%
yield strength 1000 N/mm² Mo 0,6%
Q St E 380 N Structural steel poured at low turbulence C 0,18%

with a guaranteed minimum tensile strength Si 0,5%
of 500 - 640 N/mm² and minimum yield Mn 1,6%
strength of 380 N/mm²
Special steel Highly abrasion resistant steel with a tensile C = 0,3% Mn = 0,7%
strength of 1720 N/mm² Si = 0,5% Cu = 0,65%
Mo = 0,3% V = 0,05%
St 52 - 3 Structural steel poured at low turbulence C 0,22%
S355J2G3 with a guaranteed minimum tensile strength
of 510 N/mm²
LH 690 Heat treated fine grain structural steel with C 0,18% Si 0,50%
a tensile strength of 770 - 940 N/mm² and Mn 1,5% Mo 0,5 %
yield strength of 690 N/mm² Ni 1,5 %
lightly alloyed with V, AI and Cu
7.3. Welding addition chart
7.3.1 For arc welding
Description Explanation Analysis - Value in % / Use

according to EN 499: E = Arc welding, Rod electrode C = 0,07, Si = 0,5, Mn = 1,1
E42 5 B 4 2 H5 42 = 500-640 N/mm² Tensile strength
5 = Value for resistance to impact For connection and application
e.g. Böhler B = Shielded metal arc welding, especially for steel with low
FOX EV 50 4 = Reference number for run out and purity and higher carbon content.
type of flow Weldable with direct current, electrode
2 = Reference number for welding connected to plus terminal (+).
positions No vertical seams
H5 = maximum hydrogen content
according to EN 757: E = Arc welding, Rod electrode C = 0,05, Si = 0,4, Mn = 1,5,
E 69 6 Mn2NiCrMo B 4 2 H5 69 = 760-960 N/mm² Tensile strength Cr = 0,4, Ni = 2,0, Mo = 0,5
6 = Value for resistance to impact
e.g. Böhler Mn2NiCrMo = Chemical composition For welding, which require high
FOX EV 85 B = Shielded metal arc viscosity and crack resistance. Use for
4 = Reference number for run out and high tensile refined fine-grained steel.
type of flow Very low hydrogen content in weld
2 = Reference number for welding metal.
positions Weldable with direct current, electrode
H5 = maximum hydrogen content connected to plus terminal (+).
No vertical seams
according to EN 1600: E = Arc welding, Rod electrode C = 0,1, Si = 0,7, Mn = 6,5,
E 18 8 Mn B 2 2 18 = 620-770 N/mm² Tensile strength Cr = 18,8, Ni = 8,8
e.g. Böhler Mn = Chemical composition For connections between various
FOX A 7 B = Shielded metal arc alloyed and steel which is difficult to
2 = Reference number for run out and weld.
type of flow Weldable with direct current, electrode
2 = Reference number for welding connected to plus terminal (+).
positions No vertical seams
LR Litronic
Datum Edition Date
RL Litronic

Page
Feuille 2.2.00.03
7.3.2 For MIG welding with solid electrodes:
Description Explanation Analysis - Value in % / Use

according to EN 440: G = MIG welding with solid electrodes C = 0,1, Si = 1,0, Mn = 1,7
G4Si1 4 = 500-640 N/mm² Tensile strength
Si = Chemical composition For connection and application welding,
e.g. Böhler 1 = Reference number for run out and especially for steel with low purity and
EMK 8 type of flow higher carbon content.
Weldable with direct current, electrode
connected to plus terminal (+).
Protective gases: Argon + 15-20% CO2
or 100% CO2
No vertical seams
according to EN 12534: G = MIG welding with solid electrodes C = 0,1, Si = 0,6, Mn = 1,6, Cr = 0,25,
G3CrNi1Mo 3 = 900 N/mm² Tensile strength Ni = 1,3, Mo = 0,25, V = 0,1
CrNi1Mo = Chemical composition
e.g. Böhler For welding, which require high viscosity
X 70 - IG and crack resistance. Use for high
tensile refined fine-grained steel.
Protective gases: Argon + 15-20% CO2
or 100% CO2
No vertical seams
according to EN 12072: G = MIG welding with solid electrodes C = 0,08, Si = 0,9, Mn = 7,0,
G 18 8 Mn 18 = 580-730 N/mm² Tensile strength Cr = 19,2, Ni = 9,0
e.g. Böhler Mn = Chemical composition For connections between various
A7 IG alloyed and steel which is difficult to
weld.
Protective gases: Argon+max. 2,5% CO2
No vertical seams
Duo-cone seal design for: sealing against outside, sealing against inside
1 Retainer
2 O-ring
3 Metal ring
4 Sealing surface
Note: At the present time, for design reasons, we

only use seals protecting against the outside.
Duo-cone seals are precision components made out of chilled cast iron. They are manufactured in pairs and should
never be mixed whether they are new or used.
Avoid shocks and beats as the sealing surfaces of the metal seal rings can get damaged.
Eliminate sharp edges on the seal-retainers.
Before installation the Duo-Cone-Seals and the retainers must be clean and free of grease. The toric or O-rings may
not be oiled.
Installation: Push the seal rings (with toric ring) with an installation tool into the seal seat. Even pressure must be
exerted on the toric ring around the complete circumference to push the toric ring past the seal
retaining lip.
A standard installation tool, as shown on the reverse side, is folded over the seal ring and transfers
even pressure directly onto the toric ring.
If no suitable installation aid is available, place a round rubber cord or coil spring (as shown below) to
provide a distance between the seal ring and the O-ring and hold it so that the O-ring cannot roll up on
the conical seal ring surface when each half of the seal ring is pressed in.
1 Retainer
2 O-ring
3 Metal ring
5 Installation tool
6 Installation aid, such as coil
spring, rubber cord or rope,
etc.
If no installation tool is used, the toric O-ring can roll up on the conical seal seat surface. If pressure is exerted only
on one side, the seal may not be positioned vertically and / or the O-ring can be distorted. These installation
problems can cause leaks as well as damage to the sealing surfaces.
Installation position: incorrect - incorrect -
correct O-ring Seal

distorted is not vertical
Before the components are assembled, check if the seal rings protrude evenly. Measure the distance from the seal
seat to the seal rings on at least 3 locations, 120° apart.
Check the sealing surfaces again to ensure they are clean and lightly lubricated.
Installation guidelines LR Litronic
Datum Edition Date
RL Litronic
01 02 Duo-Cone-Seals Blatt
Page
Feuille 2.3.01.01
Listing of available installation tools for travel gear - Duo-Cone seals:
The tools may be ordered by the spare parts dept. from Liebherr Werk Telfs
GmbH. - under the description of "Duo-Cone-Seal installation tool" and the
corresponding Id. No.
Gear - Gear - Machine - Duo cone seal - Installation tool -

Type Ident-No. Type PR/LR/RL Ident-No. tool number Ident-No.
FAT 400 / 523 9443 850 712 7610 242 07590 39022 1001 7428
FAT 450 / 514 9443 090 722 7610 243 07590 38886 1001 7430
FAT 500 / 525 9443 100 732 7610 244 07590 38891 1001 7436
FAT 550 / 516 9443 105 742 7610 245 07590 39023 1001 7433
FAT 400 C 563 9443 410 712 7610 544 07590 39022 1001 7428
FAT 450 C 564 9443 430 722 7610 545 07590 38886 1001 7430
FAT 500 C 565 9443 450 732 7610 543 07590 38891 1001 7436
FAT 550 C 566 9443 470 742 7610 546 07590 39023 1001 7433
FAT 500 P 595 D 9444 380 x32 7610 244 07590 38891 1001 7436
7610 249 00100 07500 1001 8934
FAT 550 P 596 D 9444 390 x42 7610 245 07590 39023 1001 7433
7610 548 07590 41339 1001 7456
FAT 400 P 553 9443 340 x12 7610 242 07590 39022 1001 7428
FAT 450 P 554 9443 270 x22 7610 243 07590 38886 1001 7430
FAT 500 P 555 9443 310 x32 7610 244 07590 38891 1001 7436
FAT 550 P 556 9443 390 x42 7610 245 07590 39023 1001 7433
FAT 400 D 583 9444 305 x12 7610 244 07590 38891 1001 7436
7610 242 07590 39022 1001 7428
FAT 450 D 584 9444 315 x22 7610 245 07590 39023 1001 7433
7610 243 07590 38886 1001 7430
FAT 500 D 585 9444 260 x32 7610 237 07590 41338 1001 7468
7610 244 07590 38891 1001 7436
FAT 550 D 586 9444 325 x42 7610 548 07590 41339 1001 7456
7610 245 07590 39023 1001 7433
FAT 650 / 508 9443 830 x52 7610 241 00100 01300 1001 7472
7610 245 07590 39023 1001 7433
1 General repair guidelines
2 Crimp tool and use
3 Installation guidelines - CA - B / CA - COM - B cable connector
4 Installation guidelines - KPSE cable connector
5 Installation guidelines - SURE SEAL cable connector
6 Installation guidelines - DEUTSCH cable connector
1. General Repair Guidelines

When working with cable connectors, the following must be observed:
Keep hands, work place and connectors clean, dry and free of grease.
Always use the special installation tool - see paragraph 3.1.31 - for installation. For CA - COM - B connectors
use the same special tool as for CA - B connectors. Check tools for wear before use - a wrong or defective
tool as well as improper handling can damage the cable connector components.
When cutting cables to proper length, make sure they are the same length and the cutting edge is straight.
Do not compress or squeeze the cable.
For 90 ° cable routing, cut the cable to proper length when in angled position.
The cable covering must reach under the crimp joint.
Check installation guidelines for correct length to be stripped. When stripping the cable, make sure that the
individual wires are not damaged, kinked, bent or soiled.
Before installation, check crimp connections of all contacts:
- Individual wires must be visible in the inspection hole of the

contact.
- All wires must be tightly caught in the crimp connection.
- The wire insulation must reach the contact.
When removing and reinstalling contacts, make sure to check the

flow direction and use isopropyl alcohol (rubbing alcohol) as a lubricant, do not twist contacts and tool.
Do not reuse damaged parts. Contacts in size 60/100, 160 and 500 can only be crimped hydraulically. If
these contacts are damaged, the complete wire must be replaced.
Make sure all parts are positioned correctly, check charts!.
On straight cable feeds, insert the contacts from the center to the outside. On 90° cable feeds, insert them in
a row from the bottom to the top.
Even contacts, which are not wired, need to be installed. Close off any empty chambers with a plug.
Visually check if all mating ends of the contacts are at the same level.
Route the wires free of tension and fasten them.
Wiring installation guidelines LR Litronic
Datum Edition Date
RL Litronic
01 04 ITT-Cannon plug Blatt

Page
Feuille 2.3.02.01
2. Use of crimp tool
2.1. Adjust the manual crimp tool - M 22 520 / 01 - 01
Set the selector dial on the handle to the appropriate diameter, see installation
guidelines on wiring chart.
2.2. To adjust turret head TH 452 and CT 1200 90 - 20

Install the proper turret head with a 9/64 Allen wrench.
Push switch 1.
Adjust color coded crimp position on knob 2 according to the wiring chart.
Push knob 2 in to the stop and push the tool once more.
2.3. Use
Before crimping, strip the wire endings to the length noted in the
installation guidelines, using the appropriate tool - see paragraph
2.1.31.
Insert the stripped wires into the contact crimp sleeve as far as possible
until they are visible in the inspection port
Insert contact and wire into the preset crimp tool.
Push the tool handles together all the way.
Note:
The locking mechanism will not allow you to open the tool until the crimping operation has been completed.
Pull the crimped contact with wire from tool. Check the crimp, see paragraph 1.
2.4. Check crimp tool wear.

Check the crimping die for wear with a M 22 520 / 3 - 1 gauge (see paragraph
2.1.31.02), without the crimping head in place.
Set the dial on the handles of the crimp tool to No. 4.
Turret both sides of the gauge into the crimp opening of the tool.
The GREEN - side (good) must fit easily between the crimp dies, or the
adjustment of the tool and the crimp die must be checked.
The RED - side (oversize) may not fit, or the tool are not closed all the way
or the crimp dies are worn and must be replaced.
Caution: Do not operate the crimp tool when the gauge is inserted!
3. Installation Guidelines for CA - B / CA - COM - B Cable Connectors
3.1. Description
A = Plug B = Socket
Components
1 Grommet
2 Insulator
3 Cylinder barrel
3.1 Seal ring
4 End bell with nut
5 Bayonet coupling nut
5.1 Spring washer
(on CA-COM-B)
6 Socket contacts
7 Pin contacts
Tightening torque for end bell: CA 3106 E 32- 8SB – 03

Size: CA 06COM E 32- 8SB – 03 – LH
10 SL max. 3 Nm Other specifications
14S/14 max. 5 Nm Size
20 max. 9 Nm Classification
32 max. 15 Nm Type of housing
Model
3.2. Overview table

Number / Type of
Plug Description Contact - Size Insertion Tool Crimp Tool Notes
S=Socket, P=Pins
Removal: CET-F80-16 Tool: M 22520/1-01 Contact size 15
CA 3106 E 32-8SB-03 24 / S - 15
CA 06 COM-E 32-8SB- Installation: CIT-F80-16 Turret: TH 452 metric
03-LH
Socket (30 pole) on main Removal: CET-F80-12 Tool: M 22520/1-01 Contact size 25
wiring harness - large 6 / S - 25
Installation: CIT-F80-12 Turret: TH 452 metric
24 / P - 15
CA 3106 E 32-8SB-04 Installation: CIT-F80-16 Turret: TH 452 metric
Plug (30 pole) in
instrument panel for main Removal: CET-F80-12 Tool: M 22520/1-01 Contact size 25
wiring harness large 6 / P - 25
16 / S - 15
CA 3106 E 32-6SB-03 2 / S - 25
CA 06 COM-E 32-6SB- Installation: CIT-F80-12 Turret: TH 452 metric
03-LH
Socket (23 pole) on main Removal: CET-F80-8
wiring harness small 3 / S - 60
Installation: CIT-F80-8 If these crimp contacts
Hydraulic crimp tool and
are damaged, replace
hand pump
Removal: CET-F80-4 small instrument cable kit
2 / S - 160
Installation: CIT-F80-4
Datum Edition Date
RL Litronic

Page
Feuille 2.3.02.02
Number / Type of
Plug Description Contact - Size Insertion Tool Crimp Tool Notes
S=Socket, P=Pins
16 / P - 15
2 / P - 25
CA 3106 E 32-6PB-04 Installation: CIT-F80-12 Turret: TH 452 metric
Plug (23 pole) in
instrument panel for main Removal: CET-F80-8
wiring harness small 3 / P - 60
Installation: CIT-F80-8 If these crimp contacts
Hydraulic crimp tool and
are damaged, replace
hand pump
Removal: CET-F80-4 small instrument cable kit
2 / P - 160
Installation: CIT-F80-4
CA 3102 E 20-27 SB-03-

A176 Removal: CET-F80-16 Tool: M 22520/1-01
CA 06 COM-E 20-27 SB- Contact size 15
14 / S - 15
03-LH Socket (14 pole) Installation: CIT-F80-16 Turret: TH 452 metric
on electronic wiring
harness for joystick
CA 3106 E 14S-6 SB-03-

A176
CA 06 COM-E 14S-6 SB-
03-LH Socket (6 pole) on Removal: CET-F80-16 Tool: M 22520/1-01 Contact size 15S
electronic wiring harness 6 / S - 15 S
for engine speed sensing
potentiometer and
outrigger wiring harness -
right / left
CA 3106 E 10SL-3SB-03
CA 06 COM-E 10 SL- Removal: CET-F80-16 Tool: M 22520/1-01
3SB-03-LH Plug (6 pole) Contact size 15S
6 / P - 15 S
on outrigger wiring Installation: CIT-F80-16 Turret: TH 452 metric
harness right / left for
electronic wiring harness
CA 3106 E 10SL-3SB-03
CA 06 COM-E 10 SL- Removal: CET-F80-16
3SB-03-LH Socket Tool: M 22520/1-01 Contact size 15S
(3pole) on electronic and 3 / S - 15 S Installation: CIT-
Turret: TH 452 metric
variable motor wiring F80-16
harness - left / right for
solenoid valves
For guide pins and various additional tools , see paragraph 2.1.31
3.3. Removal of Contacts

Note general guidelines in paragraph 1.
Carefully lift the plastic insulation (see manufacturer s guidelines), slit it

carefully and remove.
Caution: Do not damage the insulation and wires inside the
cover insulation!
Unscrew the housing from the cylinder and push the seal over the wires.
Push out the contacts with appropriate tool out of the insulator - see paragraph 3.2 by applying even and
continuous pressure towards the connector, keep the tool parallel to the axis of the plug connector. Stop when
the shoulder of the tool touches the front of the insulator. Carefully pull
the tool from the insulator.
Remove all contacts in the same way, make sure to note different
versions / tools.
Important: The tool must fit properly into or over the contacts.
The housing and seal normally stay on the wiring. If necessary, pull the
wires and contacts carefully from the seal, remove the housing from
the wires.
3.4. To wire the Contacts

Contact size Contact Wire diameter Adjustment - Crimp tool
Stripping
type Color
length
Metric AWG S=Socket mm² AWG Dial No. Crimping
(mm)
P=Pin insert
P +0,5 5 blue
1,0 18 6,0
S 5 green
15S 16S
P 6 blue
1,5 16 6,0+0,5
S 6 green
P 5 green
1,0 18 6,0+0,5
S 5 red
15 16
P +0,5 6 green
1,5 16 6,0
S 6 red
P +0,5 8 red
25 12 2,5 12 6,0
S 8 red
Strip the wire as noted on chart and crimp - see paragraph 2.1 to 2.3
3.5. Insertion of Contacts

Push the plastic insulation over the housing onto the wires.
If housing and sealer were removed, push on housing, dip seal into isopropyl alcohol and guide contact with
cable from the side marked with letter. Use the appropriate insertion tool.
Important: The seal housing must align with the insulator housing!
Note the installation position of the wire as noted on number coding plan.
Insert contacts into the guide tool, push the insertion tool to the top of the
connector tip.
On socket type contacts, insert guide pin. Dip in isopropyl alcohol and insert
straight into insulator until it snaps into position.
Important: Make sure to check number coding chart.
Remove guide pin and insertion tool. Slightly pull the wire to check proper
seating of the contact, plug chambers with empty contacts.
Datum Edition Date
RL Litronic

Page
Feuille 2.3.02.03
Push sealer and housing into cylinder housing, carefully tighten nut. If necessary, use the counter part of the
connector as a retainer.
To retain all parts, loosen nut by 1/4 turn and retighten properly, secure with adhesive.
On electronic wiring harness, insert heat seal (Ray-blocker) on end of insulation and adhere during the following
shrinking procedure.
Pull shrink fit sleeve over housing and evenly heat with hot air blower
until all parts are tightly covered.
Caution: Do not pull the wires during the shrink fit procedure. Do
not apply heat above 125° C (257° F).
4. Installation Guidelines KPSE plug Connector
4.1. Design
A = Socket B = plug
Item listing
1 Insulator
1.1 Contact retainer
(integrated in insulator)
2 Barrel
2.1 Seal ring
3 Cone ring
4 Housing
5 Bayonet coupling nut
6 Socket type contact with crimped
wire
7 Pin type contact with crimped wire
Tightening torque for end bell:

Size:
8, 10 max. 4 Nm
12,14,16 max. 6 Nm
18, 20, 22, 24 max. 10 Nm
KPSE 06 E 22- 21PB – DN
Other specifications
Size
Classification
Type of housing
Model
4.2. Chart
Number / Type of
contact size Insertion tool Crimp tool Notes
Plug description
S=Socket, P=Pins
Removal: MS24256 R16
KPSE 06E22-21PB-DN Tool: M 22520/1-01 Contact size 16 per
Plug (21 pole) on wiring 21 / P - 16 Installation: MS24256
Insert: CT120090-20 AWG
harness - Cab A16
KPSE 07E22-21SB Removal: MS24256 R16

Tool: M 22520/1-01 Contact size 16 per
Socket (21 pole) in 21 / S - 16
instrument panel for Installation: MS24256 AWG
Insert: CT120090-20
Wiring harness - Cab A16
KPSE 06E22-55SB-DN Removal: MS24256 R20

Socket (55 pole) on 55 / S - 20
electronic wiring harness Installation: MS24256 AWG
Insert: CT120090-20
for electronic box A20
KPSE 06E8-3A SB-DN Removal: MS24256 R20

Plug (3 pole) on var. 3 / S - 20
motor wiring harness left / Installation: MS24256 AWG
Insert: CT120090-20
right for RPM sensor A20
4.3. Removal of contacts

Note general guidelines in paragraph 1 .
Carefully cut and remove shrink fit sleeve per manufacturers guidelines.
Important: Do not damage insulator and inside wires.
Remove housing, loosen cone ring, housing cone and push nut over the wires.
Select proper removal tool for contact size per paragraph 4.2.
Check and apply tool first while empty, check the ejector point and hollow needle for damage. Improper or
damaged tools can damage plug parts.
On pin contacts set tool above the pin until mark 1 straight on the
insulator. On jack contacts, insert tool over socket until mark 2 into
the insulator.
Applying even pressure to tool, move ejector with thumb and

forefinger forward and push contact from retainer clip.
Carefully remove tool from insulator and pull contact by the wire from
the socket.
Remove all contacts the same way. Remove all connector

components from wire harness.
Datum Edition Date
RL Litronic

Page
Feuille 2.3.02.04
4.4. Wiring of contacts
Contact size Contact Wire diameter Adjustment - Crimp Tool
Insulator
type Color
Length
AWG S=Jack mm² AWG Dial No. Crimping
(mm)
P=Pins Insert
P
20 0,96 18 5,0 5 red
S
P
16 1,5 16 6,5 6 blue
S
Insulate wire as noted on chart and crimp - see paragraph 2.1 to 2.3
4.5. Installation of Contacts

Note general guidelines in paragraph 1..
Push the shrink fit sleeve and nut in proper sequence over the wires.
Insert contact (see chart) by hand into reverse side of plug, until the top of the
contact is no more than 3 mm from the insulator.
Push appropriate guide tool over the contact connector and hold it vertical to
the front the insulator. Contact size 16 and 12 are inside the tool, the tool
pushed against the top of the contact. On contacts, size 20, the side pushes
against the end of the contact, therefore the contact is farther outside the tool.
Dip all parts in isopropyl alcohol and push evenly into insulator until you hear
the contact click in.
Remove the tool and check if the contact is seated properly by a slight pull on the wires. Close off empty
chambers with plug.
Push cone ring as far as possible over the insulator. Apply isopropyl alcohol to lubricate contact surfaces. Push
housing, on sockets also nut, onto cylinder housing and tighten carefully. If necessary, use plug connector part
as holder. To set the parts, loosen the housing by 1/4 turn, retighten and secure with adhesive.
Pull shrink fit sleeve over housing and evenly heat with heater fan until
all parts are tightly covered.
Caution: Do not pull the wires during the shrink fit procedure.
Do no apply heat above 125° C (257° F).
5. Installation Guidelines SURE SEAL Plug Connector
5.1. Design
A = Plug B= Socket
1 Housing
2 Pin type contact
3 Socket type contact
4 Seal
5.2. Chart
Number / Type of
contact Insertion Tool Crimp Tool Notes
Plug description
S=Jack, P=Pin
SURE SEAL SS 5 P plug
2-P Removal: CET-SS-P/S Tool: M 22520/1-01
P valid only for
(5 pole) on electronic - removal of socket
3-S Installation: CITG-SS-1 Insert: CT120090-20
wiring harness
SURE SEAL SS 5 R plug S valid only for
(5 pole) on var. motor 3-P Removal: CET-SS-P/S Tool: M 22520/1-01 removal of pin type
wiring harness - left/ right 2-S Installation: CITG-SS-1 Insert: CT120090-20 contacts

Remove the plug, loosen connection. Remove shrink fit sleeve as described by manufacturer, or carefully slit
open and remove.
Caution: Do not damage the insulation or wires inside the cable!
Use proper extraction tool - see paragraph 5.2 - insert from contact side parallel to the plug axis into the socket
or over the pin contact. Apply even pressure and push contacts out in direction of the cable.
Carefully pull extraction tool from plug, clean wire.
5.4. To wire contacts

Contact size Contact Wire diameter Adjustment - crimp tool
Stripping
type
length Color Crimp
AWG S=Socket mm² AWG Dial. No
(mm) insert
P=Pin
P 5 gray
SS10 0,96 18 6,0+0,3
S 5 gray
Datum Edition Date
RL Litronic

Page
Feuille 2.3.02.05
Depending on the number of poles, the minimum stripping length must be adhered to on covered cables.
No. of Min. stripping
poles length (mm)
2, 3, 4 40
5, 6, 7 45
8, 9, 10 50
Strip the wire to the length shown on chart and crimp - see paragraph 2.1 to 2.3
5.5. To install contacts

Note general guidelines described in paragraph 1.
Push shrink fit sleeve onto wires. Insert plug into installation tool, see paragraph 2.1.31 to facilitate this process.
Insert wired contact into the insertion tool, see paragraph 5.2,
keeping contact 1, cable 2 and tool 3 in a straight line and push until
tool shoulder touches contact..
On socket type contacts, add guide pin.
Dip parts into isopropyl alcohol and push into plug, see chart,
applying even pressure parallel to the length axis until it snaps in
place. Remove guide pin, pull tool carefully from plug and check if
wire is seated properly, by pulling slightly..
Remove plug from installation tool.
Check seating and position of contacts again. On the end of the cover, insert seal (Ray-Block), and push shrink
fit sleeve over plug. Evenly heat is with hot air fan until the Ray-Block is melted and the components are
covered tightly.
Caution: Do not pull on the wires during the shrink fit procedure. Do not overheat the connector..
6. Installation Guidelines DEUTSCH Plug Connector

General:
In machines, plug connections type Deutsch DT and Deutsch HDP Series are used - see the following overview
chart.
Plug Connector series DT
A = Socket B = Plug
Item listing:
1 Housing
2 Grommet
3 Locking wedge socket
4 Locking wedge plug
5 Seal plug
6 Pin
7 Socket
Plug Connector series HDP
A = Socket B = Plug
Item listing:
1 Socket housing with pin

2 Plug housing with socket
3 Grommet
4 Union nut
6.1. Overview chart

Number / Type of
contact - size Notes
Plug description Plug series Crimp tool for designations
S=Socket, P=Pins see group. 09
Deutsch plug 2-S Tool: M 22520/1-01

(2 pole)
DT
Insert: CT120090-20 Y14
2-P
Deutsch Plug 3-S Tool: M 22520/1-01

(3 pole)
DT
Insert: CT120090-20 B5, B6, X34(S2)
3-P
Deutsch Plug
(4 pole) 4-S Tool: M 22520/1-01 X69, X70, X71, X72,
DT
4-P Insert: CT120090-20 X77
Deutsch Plug
(6 pole) 6-S Tool: M 22520/1-01
DT
Insert: CT120090-20 X6, X7
6-P
Deutsch Plug
(8 pole) 8-S Tool: M 22520/1-01
DT
Turret: CT120090-20 X6, X/
8-P
Deutsch Plug
(12 pole) 12 - S Tool: M 22520/1-01
DT
Insert: CT120090-20 X65, X73
12 - P
Deutsch plug
(18 pole) 18 - S Tool: M 22520/1-01
HDP
Insert: CT120090-20 X64
18 - P
6.2. Wiring of contacts

contact size contact Wire diameter Adjustment - Crimp tool
Insulator
type
Length color crimping
AWG S=Jack mm² AWG Dial No..
(mm) insert
P=pin
P
20 0,75 20 5,0 4 red
S
P
18 1,0 18 5,0 5 red
S
P
16 1,5 16 6,0 6 blue
S
P
12 2,5 12 6,0 8 gray
S
In case of repairs, crimp contacts >2,5 mm² must be soldered on the central cable harness.
Datum Edition Date
RL Litronic

Page
Feuille 2.3.02.06
6.3. Crimping of contacts
See installation instructions, point 1 to 2.4
6.4. Installation of contacts DT Series:

Contacts must engage properly at installation (click). Installation is made without tools.
Inserted Engaged
After positioning the contacts, the locking wedge must be inserted, see illustration DT-Series.
Note: Insert the contacts straight, do not kink. Use Isopropyl alcohol (rubbing alcohol) .
6.5. Removal of contacts DT Series:

Remove the locking wedge and use a small screw driver to loosen the pin or bushing lock and pull the contact
with the cable from the housing .
6.6. Installation of contacts HDP Series:

Installation is made without tools.
Contacts must engage properly (click).
Inserted Engaged
Note: Insert the contacts straight, do not kink. Use Isopropyl alcohol (rubbing alcohol) .
6.7. Removal of contacts HDP Series:

To remove the contacts, use special tool, see section 02.1.31.
Select tool according to cable diameter and push over cable and pin
or bushing contact. Push the lock in to loosen and pull out the cable
together with contact and tool.
Loosen the lock Pull out

Directions for use of Four Notch Hand Crimping Tool
1. General:
Protect the pliers from contamination.
Do not open with force.
When crimping, push the tool together all the way before opening it again.
Use positioning sleeve for „HAN D“ contacts, see section 02.1.31.
2. Four notch hand crimping tool, see section 02.1.31.

Parts list:
1 Pliers
2 Positioning sleeve
3 Locking bar
4 Lock screw
5 Adjustment scale
6 Adjustment screw
2.1. Attach the positioning sleeve

Loosen the lock screw 4 on the locking bar, pull the bar 3 back and insert the sleeve 2,
close the bar and retighten the lock screw 4.
Set the crimping depth.
Determine the diameter of the conductor and select the corresponding pin = crimping
depth.
For pin Id. No., see section 2.1.31.
Conductor ø Pin ø
mm² AWG HAN D
0,50 20 1,55
0,75 18 1,55
1,00 18 1,55
1,38 16 1,60
1,50 16 1,80
2,10 14 1,45
2.50 14 1,55
Open and close the crimping tool several times and then hold in open position.
Turn the adjustment screw, pos.6 until the edge of the indicator bar aligns with the line of the selected pin
diameter.
Close the tool and check the setting with the pin.
If set correctly, the pin * must fit without a clearance into the existing tool opening.
Caution: When the pin is inserted, do not open or close the tool - danger of breaking
correct incorrect
Datum Edition Date
RL Litronic
01 01 Harting plug Blatt

Page 2.3.03.01
Feuille
2.2. Crimping
Before crimping, insulate the ends of the wire with a suitable tool - see section 02.1.31.
8 mm on 0.75 – 1.50 mm contacts
6 mm on 2.50 mm contacts
Note: The cable wires must be visible in the control bore.
All cable wires must be caught in the crimping point.
The insulation must reach the contact.
Insert the cable with the contact into the pre-set tool.
Push the tool together, quickly and all the way.
Pull the cable with the crimped contact from the tool and check the
crimping.
Note: The tool can only be opened when the cable is crimped
completely.
2.3. Installation of pin contacts - plug section on instrument

panel
Set the plug section, pos.1 into the instrument panel.

Set the pin contacts, pos.3 in to the contact base, pos.2. Screw
the base with the plug section, pos.1.
2.4. Installation of bushing contacts / plug section central wiring

harness
Push the shrink fit sleeve or shrink fit part over the cable before
installation of the contact base .
Push the clamping section, pos.5, rubber seal with washers,
pos.4, screw fitting, pos.3 and plug housing, pos.1 over the
cable.
For installation of contacts, use insertion tool, see section
02.1.31.
Insert the bushing contacts into the contact base, pos. 2, screw the base together with the housing, pos. 1.
Caution: The cables can be stuck / damaged when connecting. Screw the screw fitting, pos. 3 into the plug
housing and tighten. Insert the rubber seal with washers and attach wiring harness with clamping section on
the plug housing, pos. 1.
Note: Do not use damaged parts.
Make sure all parts are positioned correctly, check corresponding plug illustrations (see section
9.2).
Visually check the installation position of the contacts, route the cable free of tension.
2.5. Sealing
Push the shrink fit sleeve over the clamping section, pos.5 and push in the screw fitting, pos.3 and use a hot air
blower to heat evenly until the sleeve is shrunk in place.
Note: Do not heat the components of the screw connection above 125°C ( 257°F).
2.6. Removal of pin and bushing contacts

For removal, use removal tool, see section 02.1.31.
Push the removal tool over the pin or bushing and loosen the lock, push the contacts out.
Installation guidelines for MATE-N-LOK and JUNIOR POWER TIMER plug connectors
1. MATE-N-LOK
Design:
Plug with contact pin Socket with contact bushings
1.1. Use of hand crimping tool

Profile 1 Pos.2 Wire diameter 0.5 – 1.3 mm²
Profile 2 Pos.3 Wire diameter 1.3 – 2.1 mm²
Open the pliers, pos.1 all the way to insert the contact, which is to be crimped (note the
correct profile) and slowly push the pliers together until the contact is lightly clamped on
the crimping sleeve.
Insert the wire, which is to be insulated (insulation length 5 mm).
Push the pliers all the way together.
Pull the crimped contact from the pliers and check the crimping.
Contact pin with crimped wire Contact bushing with crimped wire
* = Contact notch
1.2. Installation of contacts

Note: Check contact notches before installation for damage or breaks.
Contacts must audibly click when engaging in the housing.

Use:
Push the tool, pos.2 over the pin or bushing contact and push the
contact notches together, pull the contact on the cable from
housing, pos. 1 .
Datum Edition Date
RL Litronic
01 01 AMP plug Blatt

Page 2.3.04.01
Feuille
2. JUNIOR POWER TIMER
Design:
Plug with contact pins Socket with contact bushings
2.1. Use of hand crimping tool
Mark:
Red for cable diameter 0.25 - 1.60 mm²
Blue for cable diameter 1.00 - 2.60 mm²
Yellow for cable diameter 2.70 - 6.60 mm²
Open the pliers all the way to insert the contact, which is to be crimped with the seal and slowly push the pliers
together until the contact is lightly clamped on the crimping sleeve.
Insert the wire, which is to be insulated (insulation length 5 mm).
Push the pliers all the way together.
Pull the crimped contact 1 from the pliers.

Check the crimping with seal 2.
2.2. Installation of contacts

Note: Check contact notches before installation for damage or breaks.
Contacts must audibly click when engaging in the housing.

Use:
Push the tool, pos.2 over the pin or bushing contact and push the
contact notches together, pull the contact on the cable from housing,
pos. 1.
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LIEBHERR PR752 SERIES 2 LITRONIC CRAWLER DOZER Service Repair Manual PDF

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Safety guidelines 1.2.01

Service items 1.3.01

Table - charts 1.4

Tightening torques standard screws 1.4.02

Tightening torques SAE screws 1.4.03

Hole diameter before tapping 1.4.04

ISO - tolerances 1.4.06

Code letters + terminal designations electric 1.5

Benennung Description Dénomination Typ/ab Type/from Type/ a partir de

01 01 General information Blatt

Printed and published by

Explanation of structure (page numbers)

main group sub group model group page No.

LIEBHERR-Werk Telfs GmbH.

Benennung Description Dénomination Typ/ab Type/from Type/ a partir de

01 03 General Information Blatt

1. Service fluids for Diesel engines with turbo chargers

1.1. Engine lube oil

1.1.1 Oil quality

ACEA (CCMC) - classification : E2 (D4), E3 (D5), E4, E5

1.1.2 Oil viscosity

Benennung Description Dénomination Typ/ab Type/from Type/ a partir de

01 04 Service Items Blatt

above -10°C to 0,5% 250 hrs. 500 hrs.

below -10°C to 0,5% 125 hrs. 250 hrs.

1.2. Diesel fuels

Approved fuel specifications:

Additives to Diesel fuel (flow improvers)

Antifreeze protection chart

Percentage of antifreeze (%)

Benennung Description Dénomination Typ/ab Type/from Type/ a partir de

01 04 Service Items Blatt

Fresh water guidelines:

Presently approved anti corrosion / antifreeze fluids (as of December 2003):

BP Antifrost X 2270 A Deutsche BP AG, Hamburg / BRD

Caltex Engine Coolant DB Caltex (UK) ltd., London / England

Esso Kühlerfrostschutz Esso AG, Hamburg / BRD

Fricofin Fuchs Mineraloelwerke GmbH, Mannheim / BRD

Glacelf Auto Supra Total

Havoline XLC ARTECO

Labo FP 100 Labo Industrie, Nanterre / Frankreich

Motul Anti-freeze Motul SA, Aubervilliers Cedex / Frankreich

OMV-Kühlerfrostschutzmittel OMV AG, Schwechat / Österreich

Total Antigel S-MB 486 Total Deutschland GmbH, Düsseldorf / BRD

Veedol Antifreeze O Deutsche Veedol GmbH, Hamburg / BRD

Wintershall Kühlerschutz Wintershall Mineralöl GmbH, Düsseldorf / BRD

Brand name Manufacturer

1.3.1 Coolant with DCA4 (DCA = Diesel Coolant Additive)

Benennung Description Dénomination Typ/ab Type/from Type/ a partir de

01 04 Service Items Blatt

Use of products from Caltex / Chevron Texaco / Havoline / Total

Presently approved anti corrosion fluids (as of December 2003):

2.1. Oil quality

2.1.1 Approved engine oil classifications

2.1.2 Special oils

2.2. Oil viscosity

Single grade oils

Multi grade oils

Viscosity for environmentally friendly hydraulic fluids according to ISO: VG 46

Benennung Description Dénomination Typ/ab Type/from Type/ a partir de

01 04 Service Items Blatt

3.3. Lube oil for final drive - sealing chamber