Liebherr TL 445-10 Telescopic Handler Service Repair Manual PDF

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  
Service Manual
Table of contents
0.1.000 Table of contents
Date of
Page No. Title
issue
0.1.000 Table of contents 03.2010
1.0.000 Sub group index "General" 05.2007

1.1.000 Foreword and explanations 10.2007
1.2.000 Safety guidelines 02.2008
1.3.001 Tightening torques 02.2010
1.3.002 Conversion charts 01.2009
1.3.003 Tapping holes 05.2007
1.4.000 Conservation guidelines 02.2010
1.5.000 Material weights 01.2010
2.0.000 Sub group index "Tools and work instructions" 08.2007

2.1.000 Special tools 03.2010
2.2.000 Repair welding 08.2007
2.3.000 Assembly instructions 01.2009
3.0.000 Sub group index "Technical data and Maintenance guidelines" 10.2007
3.1.000 Technical data 01.2010
3.1.001 Technical data 01.2010
3.2.000 Maintenance and inspection schedule 02.2009
3.2.001 Maintenance and inspection schedule 01.2010
3.3.000 Maintenance and inspection guidelines 01.2010
3.4.000 Adjustment check list 01.2010
3.5.000 Inspection and adjustment tasks 01.2010
4.0.000 Sub group index "Engine" 01.2009

4.1.000 Data page 01.2010
4.1.001 Data page 01.2010
4.2.000 Fan and cylinder arrangement 01.2010
4.3.000 Installation kit Liebherr- Diesel particle filter 01.2009
4.4.000 Installation and check list for Diesel particle filter 01.2009
5.0.000 Sub group index "Coupling, splitterbox" 03.2007

5.1.000 Data page 01.2010
5.2.000 Coupling 06.2007
5.3.000 Splitterbox 10.2007
6.0.000 Sub group index "Travel hydraulic" 10.2007

6.1.000 Data page 01.2010
6.2.000 Design 10.2007
6.2.001 Design 02.2010
6.3.000 Function 02.2010
6.3.001 Function 02.2010
6.4.000 Repair work and troubleshooting 10.2007
6.5.000 Component arrangement 08.2007
TL 435-10 F/N xxx-6000 copyright by

TL 445-10 F/N xxx-6000
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TL 442-13 F/N xxx-6000
Service Manual
Table of contents
Date of
Page No. Title
issue
7.0.000 Sub group index "Working hydraulic" 10.2007
7.1.000 Data page 01.2010
7.2.000 Design 10.2007
7.2.001 Design 03.2009
7.3.000 Function 03.2009
7.3.001 Function 03.2009
8.0.000 Sub group index "Steering hydraulic" 10.2007

8.1.000 Data page 01.2010
8.2.000 Design 08.2007
8.3.000 Function 03.2009
8.3.001 Function 03.2009
9.0.000 Sub group index "Brake hydraulic" 10.2007

9.1.000 Data page 01.2010
9.2.000 Design 08.2007
9.2.001 Design 01.2010
9.3.000 Function 03.2009
9.3.001 Function 01.2010
10.0.000 Sub group index "Hydraulic components" 05.2007

10.1.000 Var. displacement pump / Travel pump – Travel hydraulic 03.2007
10.2.000 Var. displacement motor/ Travel motor - Travel hydraulic 03.2007
10.3.000 Regulating pump - Working hydraulic 06.2007
10.3.001 Regulating pump - Working hydraulic 01.2009
10.4.000 Fixed displacement pump 05.2007
10.5.000 Gear motor – fan drive 10.2007
10.6.000 Steering aggregate 05.2007
10.7.000 Proportional control valve block 03.2007
10.8.000 Black / white control valve block 02.2010
10.8.001 Black / white control valve block 02.2010
10.9.000 Brake cylinder 02.2010
10.10.000 Valves 02.2009
10.11.000 Cylinders 02.2009
11.0.000 Sub group index "Electrical system – Diagrams and components" 05.2007
11.1.000 Component description 01.2010
11.1.001 Component description 01.2010
11.2.000 Function list 01.2010
11.2.001 Function list 01.2010
11.3.000 Fuses, notes 01.2009
11.4.000 Circuit diagram 01.2009
11.6.000 Control lever 01.2009
11.7.000 Calibration of the electronic load display 06.2007
11.7.001 Calibration of the electronic load display 10.2007
11.8.000 DMS Sensor installation 10.2007
copyright by TL 435-10 F/N xxx-6000

TL 445-10 F/N xxx-6000
0.1.000 - 2 / 4 Mjfcifss! TL 435-13 F/N xxx-6000
TL 442-13 F/N xxx-6000
Service Manual
Table of contents
Date of
Page No. Title
issue
12.0.000 Sub group index "Electrical system - Descriptions" 01.2009
12.1.000 Evaluation software Travel hydraulic LinDiag 01.2010
12.1.001 Evaluation software Travel hydraulic LinDiag 01.2010
12.2.000 Software Working hydraulic control Bodem 01.2010
12.2.001 Software Working hydraulic control Bodem 02.2010
12.3.000 Service-Code list 02.2010
12.4.000 Software PDL – Diesel particle filter 01.2010
13.0.000 Sub group index "Axles / tires and gear shafts" 10.2007
13.1.000 Data page 01.2010
13.2.000 Design 01.2010
13.3.000 Disk brake 01.2010
13.4.000 Differential 04.2007
13.5.000 Wheel hub and steering axle 02.2009
13.6.000 Gear shafts 06.2007
14.0.000 Sub group index "Main frame installations" 03.2007

14.1.000 Level regulation 03.2009
14.2.130 Stabilizer / side offset 03.2009
14.3.000 Cooler arrangement 05.2007
14.3.001 Cooler arrangement 05.2007
14.4.000 Engine mount 08.2007
14.5.000 Battery installation 03.2007
15.0.000 Sub group index "Tank arrangements" 03.2007

15.1.000 Hydraulic tank 10.2007
15.1.001 Hydraulic tank 03.2009
15.2.000 Fuel tank 08.2007
16.0.000 Sub group index "Operator’s cab, heater, air conditioning system" 03.2007
16.1.000 Operator’s cab 08.2007
16.2.000 Heater and blower 08.2007
16.3.000 Air conditioning system 01.2009
17.0.000 Sub group index "Telescopic boom" 06.2007

17.1.100 Design and function 10.2007
17.2.100 Repair instructions 02.2008
18.0.000 Sub group index "Working attachment" 10.2007

18.1.000 Tool coupler 01.2009
18.2.000 Forklift 08.2007
18.3.000 Bucket 03.2010
18.4.100 Aerial work platform 02.2010

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Service Manual
Table of contents
Date of
Page No. Title
issue
19.0.000 Sub group index "Special equipment" 03.2010
19.1.000 Industrial control 03.2009
19.1.001 Industrial control 03.2009
19.2.000 Rear axle steering 06.2007
19.4.000 Quick coupler 04.2007
19.5.000 Reversible fan 03.2009
19.6.000 Towing hitch device 01.2010
19.7.000 Telescope - Leak oil line 03.2010
20.0.00 Sub group index "Additional documentation" 10.2007

6.3.000 Schematic Travel hydraulic 02.2010
6.3.001 Schematic Travel hydraulic 02.2010
7.3.000 Schematic Working hydraulic 03.2009
7.3.001 Schematic Working hydraulic 03.2009
8.3.000 Schematic Steering hydraulic 03.2009
8.3.001 Schematic Steering hydraulic 03.2009
9.3.000 Schematic Brake hydraulic 03.2009
9.3.001 Schematic Brake hydraulic 01.2010
14.1.000 Schematic Level regulation 03.2009
14.2.130 Schematic Stabilizers and side offset 02.2010
18.4.100 Schematic Aerial work platform 02.2010
19.1.000 Schematic Industrial control 03.2009
19.1.001 Schematic Industrial control 03.2009

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Service Manual General
Sub group index - General
1 General
1.0.000 Sub group index - General
Foreword and explanations .............................................................................. 1.1
Safety guidelines ............................................................................................... 1.2
Charts ................................................................................................................. 1.3

Tightening torques ..........................................................................................................1.3.001
Conversion charts...........................................................................................................1.3.002
Tapping holes .................................................................................................................1.3.003
Conservation guidelines ................................................................................... 1.4
Material weights................................................................................................. 1.5

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TL 442-13 F/N xxx-6000
Foreword and explanations
1.1.000 Foreword and explanations

1 For information
This manual contains technical data, design and functional descriptions, work and adjustment
instructions as well as numerous drawings, functional views and illustrations for the
LIEBHERR – Telescopic loader.
This manual should simplify competent customer service of our products. However, it does not
replace expert and qualified user training and attendance of our factory training classes.
Generally valid basic information is not listed. Refer to separate documentation for operational
and spare parts information.
The manual will be updated and expanded as necessary when changes occur in series.
Note!
This symbol is used in the manual for very important notes.
For all tasks on the machine, accident prevention guidelines and safety guidelines must be
strictly observed.
Note!
This manual is solely for the own use of the registered owner and may not be duplicated or
copied, complete or in part, nor passed on to a third person and remains the 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 illustrations in this manual.
Written and published by
LIEBHERR-Werk Telfs GmbH., Technical Documentation Dept.
2 Explanation of layout
To make it easier to find certain information and to simplify filing of updates, the following
structure was developed:
Main group Sub group Type group Page No.
6.3.130 - 1/2
Components (item) Structure of main group Structure based on Continuous running

groups acc. to index according to sub group telescopic boom type (13) number and complete
index and updates (0) pages within the model
group

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General Service Manual
Foreword and explanations
For the 3-digit type group number, the last number provides information regarding updates,
whereby the two other numbers provide information about the type of machine,
for example 000 and no additional machine serial number limitation means that the document is
valid for all TL machine.
for example 100/130 and no additional machine serial number limitation means that this
document is valid for a TL 10 meter boom / TL 13 meter boom.
for example 001/101/131 is a supplement which is valid from a certain machine serial number.
Changes are issued with the same number, but with a later date. Updates have new numbers.
If a page is valid only for a certain machine group, then this is noted in the header.
3 Itemization variations
This symbol denotes a standard listing.
This symbol means:“ The prerequisite must be met“.
The maintenance personnel must first fulfill the described prerequisites, for example, to bring
the machine in working position, to be able to carry out the steps described thereafter.
This symbol denotes an activity step.
The maintenance personnel is to become active on this point and carry out the described
activity.
This symbol denotes a result.
The maintenance personal is alerted that there is a result after an activity step, for example
after pressing the test button, the LED lights up.
4 General
This note shows that a detail view of an illustration is shown rotated by a given angle, as
compared to the actual installation position (in this case 180°).
We hope that with the enclosed information we have taken yet another step to improve the
service on the LIEBHERR telescopic handlers, crawler dozers, crawler loaders and pipe layers.
LIEBHERR-Werk Telfs GmbH.

Technical Documentation

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Safety guidelines
1.2.000 Safety guidelines

1 Introduction
Prior to and during the performance of tests, inspections and repairs, the following
safety guidelines must be observed:
Any type of work may only be carried out by qualified expert personnel or under their guidance
and supervision.
Qualified expert personnel are persons, who, based on their specialized training and experience,
have sufficient knowledge in the area of telescopic handlers and the specific technology of our
machines in particular and who are familiar with all applicable laws and general work protection
regulations, accident prevention guidelines, regulations, guidelines and generally approved rules
concerning technology so that they are able to evaluate if the earthmoving equipment is safe to
operate and if the necessary work can be performed without endangering themselves or third
persons.
Always adhere to the adjustment values noted in the LIEBHERR documentation when
performing adjustment work.
At the delivery of a machine, the operating personnel must be trained using the current operating
instructions. The safety guidelines noted in the instructions must be particularly observed.
These safety guidelines must also be observed during inspection, adjustment or repair work.
However, there are special repair and / or inspection work which require qualified personnel to
follow another procedure than that noted in the safety guidelines. In such cases, qualified
personnel or individuals performing the work under the supervision of such personnel should
assure that additional safety precautions necessary to insure the safety of those involved in the
repair and/ or third persons are taken. Such items of repair and/ or inspection work include, but
are not limited to the following:
- Opening the engine compartment doors while the engine running to carry out tests and / or
adjustments.
In these cases, it should be ensured that the cab door is properly secured during the entire
duration of the work to prevent it from closing unexpectedly and / or inadvertently. Care
should be exercised to assure that there will be no inadvertent or unintended contact of
any part of the body with any moving and / or heated components. Wear only tightly fitted
clothing (no scarves, no tie, no wide sleeves, etc.).

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Safety guidelines
Danger notes in this manual

In the description of work, which can cause dangers for man or machine, the required safety
measures are described in this manual.
They are denoted with the following notes:
Danger!
Warns that certain working procedures without appropriate precautionary measures can result
in fatal injuries.
Warning!
in severe bodily injuries.
Caution!
in bodily injuries or damage to the machine.
Following these notes does not relieve you from observation of additional regulations
and guidelines!
The following must also be observed:
- the safety regulations valid for the jobsite.
- those issued by the legislature "Traffic regulations“.
- the guidelines issued by trade associations.

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Safety guidelines
Safety guidelines in these Operating instructions

The detailed descriptions of the following safety guidelines are in the Operating instructions of
the machine and must be strictly observed.
1 Introduction
2 Destined use
3 Signs on the machine
4 Safety guidelines
4.1 General safety guidelines
4.2 Crushing and burn prevention
4.3 Fire and explosion prevention
4.4 Machine start up safety
4.5 Engine start up safety
4.6 Machine operating safety
4.7 Machine parking safety
4.8 Machine transporting safety
4.9 Machine towing safety
4.10 Machine maintenance safety
4.11 Safety guidelines for welding work on the machine
4.12 Safety guidelines for working on the attachment
4.13 Safety guidelines when loading the machine with a crane
4.14 Safe maintenance of hydraulic hoses and hose lines
4.15 Safety guidelines for maintenance work on machines with hydro accumulators
4.16 Roll over protection (ROPS) and falling object protection (FOPS)
4.17 Attachment and components
4.18 Safe operation for material handling
4.19 Protection from vibration
4.20 Safety guidelines for operation with quick coupler adapter (optional)

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Tightening torques
1.3.001 Tightening torques

The preload values and tightening torques noted in the chart have been taken from the VDI
guidelines 2230 of July 1986.
Installation preload values FM and tightening torques MA for shoulder studs with standard
metric or fine thread per DIN ISO 262 and DIN ISO 965 T2 (replacement for DIN 13 part 13) and
wrench sizes for 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 screws with black or phosphated, zinc plated and
DACROMET 500. Screws and nuts with black, phosphated or zinc plated, lightly
lubricated. Medium friction value G = 0,12.
Note!
Any tightening torque values and/ or tightening procedures noted in drawings / parts lists,
instructions or component descriptions must be adhered to and given preference over factory
standards.
Beginning with grade 10.9, the use of lock washers does no longer provide any safety action.
Always use correctly sized torque wrenches the torque value according to the chart should be
within the upper third of the existing range.
When using impact wrenches, care must be taken so that the torque values are not exceeded.
Check before and intermediately with a torque wrench.

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Tightening torques
1 Preload values and tightening torques with standard metric

thread according to factory standard WN 4037 I
Wrench size,
Metric Preload values FM based Tightening torques MA (x) = according to DIN931, for
standard on grades in N based on grades in Nm Socket head
thread Hex head screw screw
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 x2 55 000 80 000 94 000 125 185 215 (22) 21 (7/8) -- 12 --
M 16 x2 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 x3 175 000 249 000 290 000 670 960 1120 36 1-7/16 19 3/4
M 27 x3 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 x4 410 000 580 000 680 000 2350 3300 3900 55 2-3/16 27 1-1/16
M 39 x4 490 000 700 000 820 000 3000 4300 5100 60 2-3/8 27 1-1/16

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Tightening torques
2 Preload values and tightening torques with fine metric thread

according to factory standard WN 4037 I
Wrench size,
Preload values FM based on Tightening torques MA (x) = according to DIN931, for
Metric fine grades in N based on grades in Nm Socket head
thread
Hex head screw screw
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 x1 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 x2 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 x2 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 x2 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 x2 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 x2 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 x3 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 x3 530 000 750 000 880 000 3200 4600 5300 60 2-3/8 27 1-1/16

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Tightening torques
3 Tightening torque for screws to mount SAE flange

(not part of factory standard WN 4037 I)
Listing according to LFR Quality service 2QA 6 051 00 as of Oct. 2001
3.1 Flanges and half flanges for high pressure (Norm 62)
Tightening torques in Nm for screw grade 10.9

Flange nominal
Screw size Flat flange without Flange with
size Half flange
reinforcement rim reinforcement rim
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
3.2 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
3.3 Tightening torque for oil drain plugs on travel gear (40 km/h)
(not part of the factory standard WN 4037 I)
Plug Tightening torques

Thread size in Nm
M 26x1,5 40+10

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Conversion charts
1.3.002 Conversion charts

To obtain -
Unit of measure Multiply by by To obtain
Multiply
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 0,8361 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

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Tapping holes
1.3.003 Tapping holes

1 Tapping holes for metric ISO standard threads
Thread size Ø
Thread
Diameter 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

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Tapping holes
2 Tapping holes for metric ISO fine threads

Hole Ø Diameter Hole Ø 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 24 x 2 22,210 21,835 22
M 1,1 x 0,2 0,921 0,833 0,9 M 25 x 1 24,153 23,917 24
M 1,2 x 0,2 1,021 0,983 1 M 25 x 1,5 23,676 23,376 23,5
M 1,4 x 0,2 1,221 1,183 1,2 M 25 x 2 23,210 22,835 23
M 1,4 x 0,25 1,185 1,129 1,15 M 26 x 1,5 24,676 24,376 24,5
M 1,6 x 0,2 1,421 1,383 1,4 M 27 x 1 26,153 25,917 26
M 1,8 x 0,2 1,621 1,583 1,6 M 27 x 1,5 25,676 25,376 25,5
M 2 x 0,25 1,785 1,729 1,75 M 27 x 2 25,210 24,835 25
M 2,2 x 0,25 1,985 1,929 1,95 M 28 x 1 27,153 26,917 27
M 2,5 x 0,35 2,201 1,121 2,15 M 28 x 1,5 26,676 26,376 26,5
M 3 x 0,35 2,721 2,621 2,65 M 28 x 2 26,210 25,835 26
M 3,5 x 0,35 3,221 3,121 3,15 M 30 x 1 29,153 28,917 29
M 4 x 0,5 3,599 3,459 3,5 M 30 x 1,5 28,676 28,376 28,5
M 4,5 x 0,5 4,099 3,959 4 M 30 x 2 28,210 27,835 28
M 5 x 0,5 4,599 4,459 4,5 M 30 x 3 27,252 26,752 27
M 5,5 x 0,5 5,099 4,959 5 M 32 x 1,5 30,676 30,376 30,5
M 6 x 0,75 5,378 5,188 5,2 M 32 x 2 30,210 29,835 30
M 7 x 0,75 6,378 6,188 6,2 M 33 x 1,5 31,676 31,376 31,5
M 8 x 0,75 7,378 7,188 7,2 M 33 x 2 31,210 30,835 31
M8x1 7,153 6,917 7 M 33 x 3 30,252 29,752 30
M 9 x 0,75 8,378 8,188 8,2 M 35 x 1,5 33,676 33,376 33,5
M9x1 8,153 7,917 8 M 36 x 1,5 34,676 34,376 34,5
M 10 x 0,75 9,378 9,188 9,2 M 36 x 2 34,210 33,835 34
M 10 x 1 9,153 8,917 9 M 36 x 3 33,252 32,752 33
M 10 x 1,25 8,912 8,647 8,8 M 38 x 1,5 36,676 36,376 36,5
M 11 x 0,75 10,378 10,188 10,2 M 39 x 1,5 37,676 37,376 37,5
M 11 x 1 10,153 9,917 10 M 39 x 2 37,210 36,835 37
M 12 x 1 11,153 10,917 11,1 M 39 x 3 36,252 35,752 36
M 12 x 1,25 10,912 10,647 10,8 M 40 x 1,5 38,676 38,376 38,5
M 12 x 1,5 10,676 10,376 10,5 M 40 x 2 38,210 37,835 38
M 14 x 1 13,153 12,917 13 M 40 x 3 37,252 36,752 37
M 14 x 1,25 12,912 112,647 12,8 M 42 x 1,5 40,676 40,376 40,5
M 14 x 1,5 12,676 12,376 12,5 M 42 x 2 40,210 39,835 40
M 15 x 1 14,153 13,917 14 M 42 x 3 39,252 38,752 39
M 15 x 1,5 13,676 13,376 13,5 M 42 x 4 38,270 37,670 38
M 16 x 1 15,153 14,917 15 M 45 x 1,5 43,676 43,376 43,5
M 16 x 1,5 14,676 14,376 14,5 M 43 x 2 43,210 42,835 43
M 17 x 1 16,153 15,917 16 M 45 x 3 42,252 41,752 42
M 17 x 1,5 15,676 15,376 15,5 M 45 x 4 41,270 40,670 41
M 18 x 1 17,153 16,917 17 M 48 x 1,5 46,676 46,376 46,5
M 18 x 1,5 16,676 16,376 16,5 M 48 x 2 46,210 45,835 46
M 18 x 2 16,210 15,835 16 M 48 x 3 45,252 44,752 45
M 20 x 1 19,153 18,917 19 M 48 x 4 44,270 43,670 44
M 20 x 1,5 18,676 18,376 18,5 M 50 x 1,5 48,676 48,376 48,5
M 20 x 2 18,210 17,835 18 M 50 x 2 48,210 47,835 48
M 22 x 1 21,153 20,917 21 M 50 x 3 47,252 46,752 47
M 22 x 1,5 20,676 20,376 20,5 M 52 x 1,5 50,676 50,376 50,5
M 22 x 2 20,210 19,835 20 M 52 x 2 50,210 49,835 50
M 24 x 1 23,153 22,917 23 M 52 x 3 49,252 48,752 49
M 24 x 1,5 22,676 22,376 22,5 M 52 x 4 48,270 47,670 48

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Conservation guidelines
1.4.000 Conservation guidelines

1 General
All parts of a construction machine are exposed to corrosion, especially when the machine is
taken out of service. Corrosion can be compared to wear. However, the effects of corrosion can
greatly exceed that of mechanical wear and shorten the service life of the affected parts
significantly. For that reason, for longer shut down, the machines and its components must be
preserved according to certain guidelines.
In general, these guidelines are tiered according to the following times:
Taking the machine out of service – for an unknown duration
Shut down of the machine
Shut down for up to 2 months
Shut down for up to 12 months
Shut down for longer than 12 months
Return to operation
The required measures are graduated depending on the different time frames. The
conservation measures cannot be strictly standardized and they must be shorted or lengthened
depending on the assessment of necessity (such as environmental influences).
Such influences are, for example:
Placement location of machine (for example in unprotected surrounding, in
closed areas, protected by a roof, temperate surrounding)
Type of climate (for example extreme temperatures, location in water / near the
coast, etc.)
Note!
For conservation for sea transport, special guidelines must be observed, which are not
included in these instructions. Refer to the special operating instructions.
2 Taking the machine out of service – for an unknown duration

If a machine is taken out of service for a longer period of time without conservation, then it must
be operated in intervals not to exceed 14 days, to prevent abnormal corrosion and its effects.
Before putting the machine back into service, check all oil levels and correct them, if
necessary.
Always carry out the specified daily maintenance work before putting the machine back into
service. In addition, carry out the time limited maintenance work according to the inspection
schedule and additional Diesel engine Operating instructions no later than the specified
intervals.
Put the machine into operation according to the Operating instructions and operate it until the
Diesel engine and the hydraulic system has reached the specified operating temperature in
the hydraulic tank and in the coolant circuit.
Actuate all functions of the travel, working hydraulic as well as functions of additionally
installed hydraulic components and alternately operate them over a period of approx. 20
minutes. The hydraulic cylinders must be extended and retracted over their full stroke length.
When turning the machine off, retract all hydraulic cylinders fully, if possible, and fill the fuel
tank. If the machine is parked on soft ground, park the machine on wooden planks or similar
and secure it to prevent it from rolling off.
Check the batteries and remove them and recharge them, if necessary. Check the electrical
contact points and grease them, if necessary.

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3 Shut down of the machine
Preparations for shut down

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

Optical charge See section To check the battery
tester 2.1 condition and the
antifreeze in the
coolant
WAXOYL 120-4 8504472 Spray can 500ml

Anti corrosion wax Long term protection
for up to 2 years
Ballistol Spray 10025514 Application area:
Corrosion protection Door locks
Dehumidification 10013313 Prevents infiltration
capsule of moisture over an
extended period of
time
Check the entire machine for damage and remedy, if necessary.

Check the machine for paint damage and remedy, if necessary.
Take care of any maintenance work which would fall within the timeframe of the planned shut
down.
Due to the UV exposure of the components, synthetic materials, such as plastic parts, hoses,
rubber etc. must be covered with suitable aids.
Electrical components, contact points and plug connections which are not sealed must be
sealed with conservation wax „Waxoyl 120-4“.

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Apply a thick layer of conservation wax „Waxoyl 120-4“ to cover ball joints, hinges, blank
parts and exposed piston rods. (Do not protect ball bearings with Waxoyl!)
Place a dehumidification capsule into the central electric box.
Protect all door and container locks with „Ballistol Spray“.
Set the battery master switch (if present) to position „0“ and then remove the batteries.
Check the battery acid level and add distilled water, if necessary. Always store the batteries
in a cool and dry area. Check the load current regularly every 6 weeks and recharge, if
necessary.
Close the exhaust outlet with an air and watertight cover.
Pay attention to any additional guidelines for special components or special local conditions.
3.2 Shut down for up to 12 months

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

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3.3 Shut down for longer than 12 months

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

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

Carry out the items according to paragraph 4.1.
Take an oil sample of the hydraulic oil and send it in for analysis.
Carry out the scheduled maintenance and inspection work on the machine before putting it
back into service.
On the Diesel engine, mechanically actuate the AGR flap (exhaust return) and the engine
brake flap and check for easy movement.
Grease the V-belts!
Use a high pressure cleaner with steam (at least 120°C) as well as 5% additive of solvent
(such as petroleum) to clean the anti corrosion wax from the machine and aggregates.
(Caution when walking on surfaces, there is a danger of slipping due to the wax residue.)
Check the V-belt of the Diesel engine and replace it if necessary.
Carry out a Diesel engine test run: Increase the Diesel engine rpm only slowly to ¾ of the
high idle rpm until the operating temperature is reached.
Check the oil pressure display immediately after starting the Diesel engine.
Check the vacuum display of the air filter.
Adjust the chain tension to suit the application (see Operating instructions).

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4.3 After shut down of longer than 12 months

Complete all items outlined in paragraph 4.2 and 4.1.
Note!
After a scheduled shut down of longer than 12 months contact the Service Dept. of the Diesel
engine manufacturer.
Remove all covers and closures, which were installed for conservation measures.
Turn the Diesel engine manually a few turns (use the turning device - flywheel – see Special
tools).
Start the machine and bring it to operating temperature.
After the machine was brought to operating temperature, change all lube and service fluids
as well as filters according to the Operating instructions
Check the entire machine for function and for leaks.
If necessary, carry out any time limited maintenance work at this time.

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Material weights
1.5.000 Material weights

spec. weight1) Loosening Loosening spec. weight
Material
kg/m3 fest in % factor kg/m3 loose
Anthracite coal - raw 1600 35 0,74 1190
- washed - 35 0,74 1100
Ash bituminous coal 590 - 890 8 0,93 550 - 830
Basalt 2970 52 0,66 1960
Bauxite, Kaolin 1900 33 0,75 1420
Bituminous coal - raw 1280 35 0,74 950
- washed - 35 0,74 830
Carnotite, Uranium ore 2200 35 0,74 1630
Soil - dry hardened 1900 26 0,79 1510
- wet loosened 2020 26 0,79 1600
- clay 1540 23 0,81 1250
Gypsum - broken 3170 75 0,57 1810
- ground 2790 75 0,57 1660
Granite - broken 2730 64 0,61 1660
Hematite, iron ore 2130 - 2900 18 0,85 1810 - 2450
Limestone - broken 2610 69 0,59 1540
- ground - - - 1540
Gravel - damp 2170 12 0,89 1930
- dry 1690 12 0,89 1510
- dry 6-50mm 1900 12 0,89 1690
- wet 6-50mm 2260 12 0,89 2020
Coke 860 54 0,65 1560
Loam, clay - seasoned 2020 22 0,82 1660
- dry 1840 24 0,80 1480
- wet 2080 24 0,80 1660
Clay with gravel - dry 1660 17 0,86 1420
- wet 1840 19 0,84 2540
Magnetite, iron ore 3260 17 0,86 2790
Topsoil 1370 44 0,69 950
Natural stone - ground 2670 67 0,60 1600
Pyrite, iron ore 3030 18 0,85 2580
Sand - dry, lose 1600 12 0,89 1420
- damp 1900 12 0,89 1690
- wet 2080 13 0,88 1840
Sand with clay - lose 2020 26 0,79 1600
- compressed - - - 2400
Sand with gravel - dry 1930 12 0,89 1720
- wet 2230 10 0,91 2020
Sandstone 2520 67 0,60 1510
Slate 1660 33 0,75 1250
Slag - broken 2940 68 0,59 1750
Snow - dry - - - 130
Sand with clay - lose - - - 520
Trapp rock - broken 2610 49 0,67 1750
Weathered rock
2790 42 0,70 1960
75% rock, 25% soil
Weathered rock
2280 33 0,75 1720
50% rock, 50% Soil
Weathered rock
1960 24 0,80 1570
25% rock, 75% Soil
1) The actual values depend on the moisture content, the grain size and the compression.
Testing is required to determine more exact values.

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Service Manual Tools and work instructions
Sub group index – Tools and work instructions
2 Tools and work instructions

2.0.000 Sub group index – Tools and work instructions
Special tools .................................................................................................. 2.1
Repair welding ............................................................................................... 2.2
Assembly instructions .................................................................................. 2.3

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Special tools
2.1.000 Special tools

General
The following section is divided into three sections:
1 Special tools - Maintenance
2 Special tools - Repairs
3 Special tools for in-house manufacture
Special tools for maintenance are a must-have to carry out the maintenance and inspection
schedule. In addition, some tools are necessary aids for troubleshooting.
Special tools for repairs are only required in case of a repair of the affected components.
Special tools for in-house manufacture can be made in-house as necessary. The drawings to
make them are made available by the manufacturer.
1 Special tools Maintenance
1.1 Diesel engine
Description Id. No. Remarks Illustration
Turning device for 7090362 To adjust the valve

flywheel JDE83 clearance, install on the
flywheel housing
Adjustment pin 7090360 Is required together with JDE

JDG1571 83 to adjust the valve
clearance.
To hold the flywheel TDC to

adjust the injection pump.
Digital rpm gauge 7364 284 To measure the rpm with

„Shimpo“ reflective tape
Test range:
Reflective tape 6140 632 01 6-8300 rpm
Accuracy:
1 rpm
Use with Shimpo rpm

gauge
Optical charge tester 7408922 To check the battery charge
condition and the antifreeze
in the coolant
V-belt test unit „Krikit2“ 8042829 To check the V-belt tension

TL 445-10 F/N xxx-6000
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Tools and work instructions Service Manual
Special tools
1.2 Hydraulic system

Vacuum pump 12V cpl. 10355585 For faster bleeding of
with accessories hydraulic system, by
Consisting of: enclosing the PVC hose, a
slight excess pressure can
Vacuum pump with be produced.
electrical cable,
PVC hose inside diameter
5mm,
Fitting
Temperature gauge 10024185 Accuracy: 2%/2°
Test range: -18°C - +260°C
Difference pressure test 7025 376 To measure pressure,

set 230V pressure peaks and pressure
Consisting of: difference and suitable for
data transfer to PC
Test unit Multi-Handy
2045
2 pressure sensors 0-600
bar
2 Mini test connections
2 test cables 12m long
KFZ connector cable
Data cable
Power unit
Scale pressure gauge Accuracy:

1% of the scale end value
0-10 5002 865
0-25 7361 289 All pressure gauges are
0-40 7361 288 glycerin filled
0-60 5002 867
0-100 5602 903
0-160 7361 286
0-250 7361 285
0-400 7500 002
0-600 7361 294
0-1000 4601 115

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Special tools

Pressure gauge 7002 436 To seal at pressure tests, a
connection square seal ring,
R½ Id.No. 7409 794 must be
used.
Test fitting, cpl. Union nut and compression

ring are affixed on the test
R6L 7409 916 fitting.
R 10 L 7406 864
R 12 L 7409 918
Screw coupling To connect to additional test

points in the machines
M 8x1 7615 321
M 10x1 5608 462
M 12x1.5 7407 071
M 14x1.5 7406 865
R¼ 7409 720
Screw coupling To connect shorter test lines

or for connection between
M 16x2 7407 070 test connection and pressure
sensor
Test hose NW 2 To keep loss of pressure

during tests to a minimum,
1000 mm 7002437 shorter test hoses are
1500 mm 7002475 preferable
4000 mm 7009134
5000 mm 7363732
Hook wrench To loosen / counter when

adjusting the pump
45 50 mm 7403366 regulating range
58 62 mm 7900282
Use with socket wrench HPV

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Special tools

Socket wrench for 9792711 To loosen / counter when
grooved nut HPV adjusting the pump end stop
Use with hook wrench
Groove ø 45.5 +0.5mm
Socket wrench for 0- 9749025 To loosen / counter when

position grooved nut adjusting the hydraulic zero
HPV position
Groove ø 32 +0.5 mm
Angle screwdriver Size 8000989 For cap hydraulic tank

22
Test plates To close off high pressure

connections
For SAE flange 1/2 10355369
A 90mm Material:
B 32mm Ground spring steel
C, r 5mm
For SAE flange 3/4 7370092 Round off end of the plate
A 90mm (simplifies installation, avoids
B 40mm damage to the seal ring)
C,r 5mm
For SAE flange 1 7370093
A 90mm
B 44mm
C,r 5mm
Or to be made
in-house

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Special tools
1.3 Electrical system

LinDiag Diagnostics To adjust the travel hydraulic,
read out the Service Codes
Consisting of: and for troubleshooting on
machines in exhaust stage
Data carrier with latest 10467309 Tier2 and Tier3
software version
Dongle for LinDiag 10297212
7 9124.01.750
Adapter cable for 10035410
LH-ECU-UP/CR
USB - Adapter 693190714 Intermediate adapter from

serial to USB
Is only required for
notebooks without serial
connection
Bodem Software with 10285174 To adjust the working

copy protection plug for hydraulic, read out the
USB connection Service Codes and for
troubleshooting on machines
Bodem Data cable 6905910 To adjust the working

hydraulic
Flash tool Working 10412388 To transfer updates to the

hydraulic controller (is not working hydraulic control
required for adjustments
Digital multi meter 10018500 for

cpl. with cable and bag Voltage (V)-
Amperage (A)-
Resistance ( )-
and
Frequency (Hz)-
tests

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Special tools

Optical charge tester see Pt. 1.1 To check the battery
Diesel engine condition and the antifreeze
in the coolant
LMB Magnet 10354217 For calibration mode of
electronic load display
Already included on tool box.
1.4 Mechanical component groups

Feeler gauge 8145535 To measure the wear on the
brake disks (service brake))
2 Special tools - Repair
2.1 Diesel engine

Note!
The special tools for Diesel engine repair are listed in the Diesel engine workshop manual.

TL 445-10 F/N xxx-6000
TL 442-13 F/N xxx-6000
Special tools
2.2 Hydraulic system

Socket wrench 10430260 For repair of variable motor
Valve sleeve HMV
To remove and install the

valve sleeve of the
directional valve
See section 10.2

Position 73
Mandrel thrust ring For repair of var. pump HPV

or var. motor HMV
HPV 75 10472251
For the installation of the hot
HMV 210 10472261 thrust ring on the drive shaft.
See chapter 10.1 or 8.2.

Position 11
Mandrel [1] and For repair of var. pump HPV

protective sleeve [2] for or var. motor HMV
shaft seal ring
For pressing in the radial
HPV 75 1 10472271 shaft seal ring to push over
the drive shaft (in connection
HPV 75 2 10472273 with the corresponding
protective sleeve)
See section 10.1 or 10.2

HMV 210 1 10472317 Position 12
HMV 210 2 10410295

TL 445-10 F/N xxx-6000
TL 442-13 F/N xxx-6000
Special tools

Installation aid for seal For repair of var. pump HPV
ring on oil guide pipes or var. motor HMV
Pos.1 10472322 The tool is used to install the

HMV 210 O-rings on the oil guide pipes
Pos.2 10472321 See

HPV 75 Section 10.1 Position 46 or
section 10.2. Position 45
Spindle device for swash 10324938 For repair of var. pump HPV
plate mount or var. motor HMV
With this device, the swash

plate mount can be lowered
targeted onto the pump
housing at installation.
Centering pins for swash For repair of var. pump HPV

plate mount or var. motor HMV
M12 HPV 75 10324939 The guide pins are used to

guide the swash plate mount
M14 HMV 210 10472320 at assembly with the pump
housing.
minimum 2 each
maximum 4 each required

TL 445-10 F/N xxx-6000
TL 442-13 F/N xxx-6000
Special tools

Centering device for 10324937 For repair of var. pump HPV
swash plate mount or var. motor HMV
Device to affix the oil guide

pipes at installation of swash
plate mount
2 each required
Note!
The special tools for cylinder repair are listed in the spare parts list.

Crimper To make proper crimp
for connection on MATE-N-LOK
MATE-N-LOK Crimp plug connections
contacts
For 1,5 mm² 7367025

For 2,5 mm² 7366314
Removal tool AMP 7366655 To remove crimp contacts
for from plug connector
MATE-N-LOK Crimp
contacts
Spare insert 7015180
Installation tool AMP 8145432 To insert the pin and bushing

for contacts in MATE-N-LOK
MATE-N-LOK Crimp plug connectors
contacts
Hand Crimper 8503647 To make proper crimp

for „Deutsch“ plug connections
connector

TL 445-10 F/N xxx-6000
TL 442-13 F/N xxx-6000
Special tools

Removal tool Cannon To remove pin and bushing
for „Deutsch“ contacts in „Deutsch“ plug
crimp contacts connectors
AWG 4 8503633
AWG 8 8503632
AWG 12 10114733
AWG 16 885563714
AWG 20 10114732
Removal tool Cannon To remove pin and bushing

for Deutsch crimp contacts in „Deutsch“ plug
contacts connectors (alternate)
(alternate)
AWG 12 8145674
AWG 16 8145673
AWG 20 8503630
Crimper AMP 7415333 To crimp the „JUNIOR

AMP Certi-Lock POWER TIMER“ contacts
Removal tool AMP To remove contacts from the

„JUNIOR POWER TIMER“
AMP 726 503-1 7026266 housing
Crimper To crimp insulated 0.5 -6.0

mm² cable shoes, for
ESA 0760 7409781 example cable connectors
CRB 0560 7409782 CRB 0560 also windshield
wiper motor
Insulating pliers, cpl. 7409777 To insulate the 0.75 mm²

Type 5011-26 electric cable
Spare cutter:
1.5-6.00 qmm 7409788

0.15-2.5 qmm 7409789

TL 445-10 F/N xxx-6000
TL 442-13 F/N xxx-6000
Special tools

Removal tool To remove connector clamps
METRI-PACK on central plug of engine
electronic ECU
wide 7091022
narrow 7091023
2.4 Mechanical component group

Eyebolt 4000785 To install and remove the
operators cab to gain access
to the hydraulic tank
Screw swirl 10490498 To install and remove the

1350kg ballast weight.
2 each required
See section 2.3 Installation

instructions.
Installation aid Ballast see Pt. 3 Tools To remove and install the
weight for in-house 625kg ballast weight to
manufacture equalize the center of gravity
2 each required
See section 2.3 Installation

instructions.
This tool can also be used as
an alternate for the screw
swirl 10490498.

TL 445-10 F/N xxx-6000
TL 442-13 F/N xxx-6000
Special tools
2.5 Telescopic boom

Spacer for the telescopic 9410926 Device to keep two cylinders
cylinder (13m) of the 13m telescope apart
for repair
Eyebolt 9417658 To install and remove tilt

cylinder
Open ended box wrench 8122204 The wrench is ground at the

opening to be able to install
hoses on the solenoid valves
Pin puller 10306272 To pull the two pins from the

cylinder bearing telescopic
cylinder 1 of 13 m telescope
Or to be made
in-house
External bleeding of
telescopic cylinder
Hydraulic hose 9412239 (TL 4xx-13 F/N xxx-

6000 9500)
Flange half 10286359 2 each required
SAE 3/4
Hex head screw 4001246 4 each required
M10x35 10.9
Hose fitting 10815208 (TL 4xx-13 F/N xxx-9501 )
can also be carried out with
the aid of the already
installed hose by using the
fitting
Pulling device 10306606 To replace the hose on the

13m telescopes
from TL 4xx-13 F/N xxx-

9501

TL 445-10 F/N xxx-6000
TL 442-13 F/N xxx-6000
Special tools
3 Special tools for in-house manufacture

Note!
The following dimensions are given in millimeters [mm].
3.1 Pin puller

To pull the two pins from the cylinder bearing telescopic cylinder 1 of the 13 m telescope. See
also section 17.2 Repair
instructions.
Fig. 1 Pin puller

1 Guide rod 5 Hex nut M20
2 Hex fitting 6 Washer ISO 8738 20
3 Impact sleeve 7 2x Washer DIN 433 8,4
4 Allen screw
M8x30 8.8
Note!
Affix the hex nut Pos.5 with three weld points.

TL 445-10 F/N xxx-6000
TL 442-13 F/N xxx-6000
Special tools
3.2 Installation aid for ballast weight

To remove and install the 625kg ballast weight. Is used to equalize the center of gravity, since it
is not located in the center. The angle equalized the distance, so that the ballast weight can be
installed / remove without jamming.
Fig. 2 Installation aid for ballast weight

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TL 442-13 F/N xxx-6000
Repair welding
2.2.000 Repair welding

Caution!
In principle, prior to beginning any welding work on the telescopic handler, disconnect the
electronic boxes and various electronic components (see Operating instructions). In addition,
the ground terminal of the welding unit must be connected directly to the blank work piece,
which is to be welded.
1 Preparation of cracked part

Clean the cracked area to remove paint, grease and any dirt.
To prevent the crack from extending during the preparation and welding process, the end of the
cracks should be drilled out with a drill (at least 8 mm Ø).
Then the crack should be ground, chiseled, or arched out to an angle of approx. 60° .
Be certain that the edges are clean and extend through the full cross section of the material,
without exceeding the space of 1 mm in the lower part. On larger grooves, a welding safety
should be installed.
Fig. 1-1 Ground out / drilled out crack

Certain materials must be preheated to approx. 150°C
Special preparations are necessary when preparing a crack in manganese steel. This material
cannot be prepared with a chisel or planing machine, due to its hardness and peen hardening.
We suggest that the crack is prepared with a slow running and water-cooled grinding wheel to
prevent overheating.
Note!
Another possibility to prepare cracks and remove high alloy welding seams is the use of
cutting electrodes of the type UTP 82 AS.
2 Preparation of a weld
The area to be welded must be fee of grease, paint, oil, moisture and dirt. During rain, the area
to be welded must be covered sufficiently.
Materials with a thickness above 15 mm and high carbon steel (carbon content more than 0.22
%) and difficult to weld steel, the material must be preheated to approx. 80°- 200°C.
Preheating is also necessary when the component temperature at the start of the welding work
is below +5°C and when the construction of the repair part prevents the welding stress to be
released.

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Repair welding
3 Treatment of electrodes
Use only dry electrodes for welding. Electrodes with damaged coating and rusted electrodes
may not be used any longer.
Electrodes must be stored in a dry room with a minimum temperature of 15°C. Open electrode
packages must be carefully closed and stored after the welding work is complete.
4 Welding technique
The welding of material with the required electrodes (see chart under paragraph 7) is carried out
according to DIN 1912.
The adjustment of the welding current dictated by the different thicknesses of the electrodes
can be taken from the chart of the electrode package.
Beginning with material thickness of 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 meld 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 be taken that
they are properly filled in.
If the crack extends towards the outer edge of the material, slap may be trapped or burn holes
may be created. To prevent this, the following aid may be used: tack apiece 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 welding seam must be cooled off slowly and should therefore be protected from rain and
wind.
Fig. 4-1 Crack running to the outer edge of the material / Prepared crack

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Repair welding
5 Reinforcement of welding seam

If the crack of the material is due to on 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 that reason, only general recommendations can be made as to the size and shape of the
reinforcement plates.
5.1 Shape of plate

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 part is avoided. Plates with sharp corners
(such as a rectangular plate) may not be used.
Fig. 5-1 Reinforcement plate against clean pulling / bending and alternating loads
5.2 Plate thickness

The thickness of the reinforcement plate should be up to 2/3 of the thickness of the material to
be reinforced.
5.3 Material quality of the plate

The material properties (yield and tensile strength, etc.) of the reinforcement plate should be
equal to the material to be reinforced.
5.4 Installation of the reinforcement plate

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 20 mm. The correct position and fit of the reinforcement plate
is achieved by clamping and spot welding.
5.5 Welding the reinforcement plate

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.

TL 445-10 F/N xxx-6600
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Repair welding
Welding direction
Fig. 5-2 Welding directions

The size of the welding run "a" is figured out in reference to the thickness "k" of the repair plate.
Use formula: a=0.5 k
Up to a welding run "a" of approx. 3 mm, a single run can be made, however, as a general rule,
a double run should be preferred.
Above a welding run "a" = 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.
Fig. 5-3 3- or 1- layer welding seam

After the welding is completed, clean the welding seam as necessary and grind out the run
between the reinforcement plate and the basic material.
6 Selection of correct welding 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
ruse should be observed.
Note!
To reach the theoretical welding quality, the work must not only be performed in a professional
manner, the electrode manufacturers guidelines must be strictly observed as well.
Caution!
Welding of vertical-down welds is not permitted for steel components!

TL 445-10 F/N xxx-6600
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Repair welding
6.1 Steel chart
Item Description Analysis

HARDOX 400 Weldable, low alloy special steel with high C 0,27% Si 0,7%
wear resistance, a tensile strength of 1250 Mn 1,6% Cr 1,4%
N/mm² and a yield strength limit of 1000 Mo 0,6%
N/mm²
Q St E 380 N Fine grain structural steel poured at special C 0,18%

low turbulence with a guaranteed minimum Si 0,5%
tensile strength of 500 - 640 N/mm² and Mn 1,6%
minimum yield strength limit of 380 N/mm²
Special steel Highly abrasion resistant steel with a tensile C = 0,3% Mn = 0,7%
strength of 1720 N/mm²² 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 Tempered fine grade structural steel with a C 0,18% Si 0,50%
tensile strength 770 - 940 N/mm² and a Mn 1,5% Mo 0,5 %
yield strength limit of 690 N/mm² Ni 1,5 %
Lightly alloyed with V, AI and Cu
6.2 Welding chart for arc welding
Item Description Analysis values in % / Application

per EN 499: E = Arc welding 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 notch impact strength For connection and applied welds,
For example: Böhler B = basic shielded especially for steels with low purity
FOX EV 50 4 = Value for run out and type of and higher carbon content.
current Weldable with DC current, Electrode
2 = Value for welding positions on Plus terminal (+).
H5 = maximum hydrogen content No vertical seams.
per EN 757: E = Arc welding C = 0,05, Si = 0,4, Mn = 1,5,
E 69 6 Mn2NiCrMo B 69 = 760-960 N/mm² tensile strength Cr = 0,4, Ni = 2,0, Mo = 0,5
4 2 H5 6 = Value for notch impact strength
Mn2NiCrMo = Chemical composition For welds, which require high
for example: Böhler B = basic shielded tenacity and crack resistance, use for
FOX EV 85 4 = Value for run out and type of highly alloyed fine grain steel.
current Very low hydrogen content in welding
2 = Value for welding positions material.
H5 = maximum hydrogen content Weldable with DC current, Electrode
on Plus terminal (+).
No vertical seams.
per EN 1600: E = Arc welding 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
8 = Value for notch impact strength
For example: Böhler Mn = Chemical composition For connections between different
FOX A 7 B = basic shielded alloyed and difficult to weld steel
2 = Value for run out and type of Weldable with DC current, Electrode
current on Plus terminal (+).
2 = Value for welding positions No vertical seams

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Repair welding
6.3 Welding chart for metal inert gas weld with solid wire electrodes
Item Description Analysis values in % / Application

per EN 440: G = G = Metal inert gas weld with solid C = 0,1, Si = 1,0, Mn = 1,7
G4Si1 wire electrodes
4 = 500-640 N/mm² tensile strength For connection and applied welds,
For example: Böhler Si = Chemical properties especially for steels with low purity
EMK 8 1 = Value for run out and type of and higher carbon content.
current Weldable with DC current, Electrode
Shielding gas: Argon + 15-20% CO2
or 100% CO2
No vertical seams
Per EN 12534: G = Metal inert gas weld with solid wire C = 0,1, Si = 0,6, Mn = 1,6, Cr =
G3CrNi1Mo electrodes 0,25,
3 = 900 N/mm² tensile strength Ni = 1,3, Mo = 0,25, V = 0,1
For example: Böhler CrNi1Mo = Chemical composition
X 70 - IG For welds, which require high
tenacity and crack resistance, use for
highly alloyed fine grain steel.
Weldable with DC current, Electrode
Shielding gas: Argon + 15-20% CO2
or 100% CO2
No vertical seams
per EN 12072: G = Metal inert gas weld with solid wire C = 0,08, Si = 0,9, Mn = 7,0,
G 18 8 Mn electrodes Cr = 19,2, Ni = 9,0
18 = 580-730 N/mm² tensile strength
For example: Böhler 8 = Value for notch impact strength For connections between different
A7 IG Mn = Chemical composition alloyed and difficult to weld steel
Weldable with DC current, Electrode
Shielding gas: Argon + max. 2,5%
CO2

TL 445-10 F/N xxx-6600
TL 442-13 F/N xxx-6600
Installation guidelines
2.3.000 Installation guidelines

1 General
Described in this section are installation notes for various components, which must be observed
at reinstallation in case of a repair.
2 Installation notes
2.1 Equipment
The threaded bores required to take on the 625 kg ballast weight are located outside the
center of gravity of the weight. For that reason, the weight can get stuck at removal. To avoid
this, the installation aids X (see section 2.1 Special tools) must be used.
Because there is a risk of damage to the machine, the chains must be spread with the
assistance of a suitable aid.
Fig. 2-1 Removal – Ballast weight 625kg

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TL 442-13 F/N xxx-6600
2.2 Travel hydraulic
1.1.1 Variable displacement pump

Since the installation notes refer to the positions in the sectional drawing, they are described in
section 10.1 „Variable displacement pump – Travel hydraulic“.
1.1.2 Variable displacement motor

section 10.2 „Variable displacement motor – Travel hydraulic“.
1.1.3 Gear pump

The double gear pump is accessible via the cover on the inside of the main frame.
Raise the telescope and secure it with the aid of the hoist support.
Remove the cover plate
At installation of the fixed displacement pump – double gear pump, the following must be
observed:
Clean and grease the sealing surfaces on motor and pump.
Seal the sealing surfaces with liquid seal.
Fig. 2-2 Double gear pump

In addition, it must be observed that the distance between flange and gear is at least 0.5 mm.
2.2.1 Collector block

When removing or replacing the pressure filter, pay attention to the flow direction (marked on
the filters) at installation.
When removing or replacing the check valve (cold start valve) 57, pay attention to the opening
direction at installation. The correct flow direction is marked on the valve.

TL 445-10 F/N xxx-6600
TL 442-13 F/N xxx-6600
Fig. 2-3 Installation of the pressure filter on the collector block
2.3 Working hydraulic
2.3.1 Telescope
section 17.1 „Design and function“ or 17.2 „Repair instructions“.
2.3.2 Industrial control - Boom suspension

Warning!
Before starting any maintenance and repair work on the stabilizing module of the emergency
down screw 252 (covered by a plug) back it out by 2-3 turns to relieve the pretension of the
pressure accumulator 256 to the tank (connection T).
Before putting it back into service, adhere the screw with Loctite.
Fig. 2-4 Pressure accumulator

The pretension of the pressure accumulator is reestablished when the telescope is raised.
2.4.1 DMS Sensor – rear axle

See section 11.8 „DMS Sensor installation“.

TL 445-10 F/N xxx-6600
TL 442-13 F/N xxx-6600
2.5 Main frame
2.5.1 Variable motor mount

Observe the correct arrangement of the components at installation.
Tighten the hex head screws 5 with a tightening torque of 350 Nm.
Fig. 2-5 Variable motor mount and installation of RPM sensor B2
Installation of RPM sensor

Tighten the impulse sensor with 30Nm.
Secure the sensor with Loctite to prevent it from twisting.
With the aid of shims, adjust the distance between the RPM sensor B2 and the perforated
plate 10.
2.5.2 Cab mount

See section 16.1 „Operator’s cab“.
2.5.3 Stabilizers
Secure the screws 24 at installation with Loctite.
Fig 2-6 Installation of stabilizers for 13m telescopic loader

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TL 442-13 F/N xxx-6600
Service Manual Technical data and Maintenance guidelines
Sub group index – Technical data and Maintenance guidelines
3 Technical data and Maintenance

guidelines
3.0.000 Sub group index – Technical data and
Maintenance guidelines
Technical data................................................................................................ 3.1
Maintenance and inspection schedule ........................................................ 3.2
Maintenance and inspection guidelines...................................................... 3.3
Adjustment check list ................................................................................... 3.4
Inspection and adjustment tasks ................................................................. 3.5

TL 445-10 F/N xxx-6000
TL 442-13 F/N xxx-6000
Service Manual Technical data and maintenance guidelines
Technical data
3.1.000 Technical data
TL435- TL445- TL435- TL442-

10 10 13 13
Diesel engine
Type D504 T
4 cyl. In-line, water cooled,
Version
turbocharged
Rating according to ISO 9249 kW 80 (109 PS)
Nominal RPM RPM 2400
Low idle RPM RPM 1050 (with working hydraulic on)
850 (with working hydraulic off)
High idle RPM RPM 2450
Displacement l 4.5
Oil quantity incl. filter l 12
Oil quality / viscosity See operating instructions
Max. permissible machine incline all directions 30°
Firing order 1342
Coolant / DCA 80 L See operating instructions
Fuel tank capacity l 125
Fuel usage approx. l/h 5 - 15
Splitterbox
Type 4519.02
Version Spur gear 1-stage
Ratio i 0,8974
Oil quantity l 1,7
Hydraulic system
Variable pumps Travel hydraulic Type HPV75 - 02
Max. flow - Qmax l/min 203
Operating pressure (M1 / M2) pmax bar 420
Tandem gear pumps replenishing -
Cooling circuit / fan drive Size 28/ 11
Max. flow replenishing - Qmax l/min 65
Operating pressure (SP) pmax bar 20
Max. flow - fan drive - Qmax l/min 26
Operating pressure (electronically regulated) - pmax bar 180
Gear motor fan drive Size 8
Operating RPM RPM presently 2000 / 2600
Variable motor Travel hydraulic Type HMV 210 (25 km/h)
Regulating pump Working hydraulic Type A10V 045

Stand-by pressure (HD) bar 35
Operating pressure (HD) pmax bar 300
Hydraulic tank capacity l 95

Circuit, additionally l 95
TL 435-10 F/N xxx-6000 9500 copyright by

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TL 442-13 F/N xxx-6000 9500
Technical data and maintenance guidelines Service Manual
Technical data
TL435- TL445- TL435- TL442-

10 10 13 13
Electrical system
Operating voltage V 12
Batteries Ah 170
Alternator 12 V,65 A
Starter kW 4,2
Central fuse A 125
Individual fuses See operating instructions
Front axle
(45% Self locking differential)
Front axle Type 212 / 415 / 709
Planetary gear (axles) i 1:6
Axle ratio, total 1:26.25
Oil quantity in axle casing - front axle See Operating instructions
Oil quantity in wheel head front axle See Operating instructions
Oil quality / viscosity and oil change intervals See Operating instructions
Service brake / parking brake front axle Type Disk brake
Tires See section 3.4
Rear axle
Rear axle Type 212 / 416 / 710
Planetary gear (axles) i 1:6
Axle ratio, total 1:26.25
Oil quantity in axle casing rear axle See Operating instructions
Oil quantity in wheel head rear axle See Operating instructions
Rear axle No brake
Steering
Regulating pump Type A10V 045
Max. flow l/min 120
Steering / Servostat Type LAGU 250/ 125
Steering cylinder Type Synchronous cylinder
Priority valve LPS 160
Brake system
Supply via regulating pump
working pump
copyright by TL 435-10 F/N xxx-6000 9500

TL 445-10 F/N xxx-6000 9500
3.1.000 - 2 / 4 Mjfcifss! TL 435-13 F/N xxx-6000 9500
TL 442-13 F/N xxx-6000 9500
Service Manual Technical data and maintenance guidelines
Technical data
TL435- TL445- TL435- TL442-

10 10 13 13
General
Travel speed
Normal range III km/h 0 25
Reduced range II km/h 0 16
Reduced range I km/h 0 8
Max. traction
Depending on ground conditions kN 56
Basic machine
Overall height (without beacon) mm 2500
Overall length to front carrier mm 5810
Overall width via standard tires mm 2364
Height over rear mm 1710
Wheel base mm 2950
Rear overhang mm 1130
Track width mm 1970
Ground clearance (center of vehicle) mm 440
Width over supported stabilizers mm 3150
Turning radius via tips of forklift prongs mm 5150
Turning radius via tires mm 3850
Operating weight
Basic machine kg 8593 9129 9559 10565
Basic machine with standard forklift kg 8857 9424 9839 10866
Basic machine with standard bucket kg 8941 9477 9929 10913
Standard forklift LH (various fork prongs)

100x50 125x50 100x50 100x50
Fork prongs dimensions mm
x1100 x1100 x1100 x1100
Max. prong distance mm 955 955 955 955
Operating weight kg 266 295 266 301
Load carrying capacity (depends on prongs) kg 3500 4500 3500 4200
Standard bucket LH

Bucket width mm 2450 2450 2450 2450
Bucket capacity m³ 1 1 1 1
Operating weight kg 347 347 347 347
Load capacity kg 1800 1800 1800 1800
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TL 442-13 F/N xxx-6000 9500
Service Manual Technical data and Maintenance guidelines
Technical data
3.1.001 Technical data
TL435- TL445- TL435- TL442-

10 10 13 13
Diesel engine
Type
TL 4xx-xx F/N xxx-9501 10999 D 504 TI
TL 4xx-xx F/N xxx-11000 CD 4045 HF 287
4 cyl. In-line, water cooled,
Version
turbocharged
Rating according to ISO 9249 kW 84 (114 PS)
Nominal RPM RPM 2400
Low idle RPM RPM 1050
High idle RPM RPM 2430
Displacement l 4,5
Oil quantity incl. filter See operating instructions
Max. permissible machine incline all directions 30°
Firing order 1342
Coolant / DCA 80 L See operating instructions
Fuel tank capacity l 125
Fuel usage approx. l/h 5 - 15
Splitterbox
Type 4519.02
Version Spur gear 1-stage
Ratio i 0,8974
Oil quantity See operating instructions
Hydraulic system
Variable pumps Travel hydraulic Type HPV75 - 02
Operating pressure (M1 / M2) pmax bar 420
Tandem gear pumps replenishing -
Cooling circuit / fan drive Size 28/ 11
Max. flow replenishing - Qmax l/min 65
Operating pressure (SP) pmax bar 20
Max. flow - fan drive - Qmax l/min 26
Operating pressure (electronically regulated) - pmax bar 180
Gear motor fan drive Size 8
Operating RPM RPM 2000
Variable motor Travel hydraulic
TL 20-25 km/h Type HMV 210
TL 40 km/h Type ICVD GT-S1N-233V-094
Regulating pump Working hydraulic Type A10V 045

Stand-by pressure (HD) bar 35
Operating pressure (HD) pmax bar 300
Hydraulic tank capacity l 95

Circuit, additionally l 95

TL 445-10 F/N xxx-9501
TL 442-13 F/N xxx-9501
Technical data and Maintenance guidelines Service Manual
Technical data
TL435- TL445- TL435- TL442-

10 10 13 13
Electrical system
Operating voltage V 12
Batteries Ah 170
Alternator 12 V,75 A
Starter kW 4,2
Central fuse A 125
Individual fuses A See operating instructions
Front axle
Front axle (20-25 km/h) Type 212 / 415 / 709
Front axle (40 km/h) Type 212 / 797
Planetary gear (axles) i1:6
Axle ratio, total (20-25 km/h) i1:26,25
Axle ratio, total (40 km/h) i1:17,50
Oil quantity in axle casing - front axle See Operating instructions
Oil quantity in wheel head front axle See Operating instructions
Service brake / parking brake front axle Type Disk brake
Rear axle
Rear axle (20-25 km/h) Type 212 / 416 / 710
Rear axle (40 km/h) Type 212 / 798
Planetary gear (axles) i1:6
Axle ratio, total (20-25 km/h) i1:26,25
Axle ratio, total (40 km/h) i1:17,50
Oil quantity in axle casing - rear axle See Operating instructions
Oil quantity in wheel head rear axle See Operating instructions
Service brake rear axle (20-25 km/h) No brake
Service brake rear axle (40 km/h) Type Disk brake
Steering
Regulating pump Type A10V 045
Max. flow l/min 120
Steering / Servostat Type LAGU 250/ 125
Steering cylinder Type Synchronous cylinder
Priority valve LPS 160
Brake system
Supply via regulating pump
working hydraulic

TL 445-10 F/N xxx-9501
TL 442-13 F/N xxx-9501
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Liebherr TL 445-10 Telescopic Handler Service Repair Manual PDF

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Liebherr TL 445-10 Telescopic Handler Service Repair Manual PDF

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0.1.000 Table of contents

1.0.000 Sub group index "General" 05.2007

2.0.000 Sub group index "Tools and work instructions" 08.2007

4.0.000 Sub group index "Engine" 01.2009

5.0.000 Sub group index "Coupling, splitterbox" 03.2007

6.0.000 Sub group index "Travel hydraulic" 10.2007

TL 435-10 F/N xxx-6000 copyright by

8.0.000 Sub group index "Steering hydraulic" 10.2007

9.0.000 Sub group index "Brake hydraulic" 10.2007

10.0.000 Sub group index "Hydraulic components" 05.2007

copyright by TL 435-10 F/N xxx-6000

14.0.000 Sub group index "Main frame installations" 03.2007

15.0.000 Sub group index "Tank arrangements" 03.2007

17.0.000 Sub group index "Telescopic boom" 06.2007

18.0.000 Sub group index "Working attachment" 10.2007

TL 435-10 F/N xxx-6000 copyright by

20.0.00 Sub group index "Additional documentation" 10.2007

copyright by TL 435-10 F/N xxx-6000

Safety guidelines ............................................................................................... 1.2

Charts ................................................................................................................. 1.3

Conservation guidelines ................................................................................... 1.4

Material weights................................................................................................. 1.5

TL 435-10 F/N xxx-6000 copyright by

1.1.000 Foreword and explanations

Main group Sub group Type group Page No.

Components (item) Structure of main group Structure based on Continuous running

TL 435-10 F/N xxx-6000 copyright by

LIEBHERR-Werk Telfs GmbH.

copyright by TL 435-10 F/N xxx-6000

1.2.000 Safety guidelines

TL 435-10 F/N xxx-6000 copyright by

Danger notes in this manual

copyright by TL 435-10 F/N xxx-6000

Safety guidelines in these Operating instructions

TL 435-10 F/N xxx-6000 copyright by

1.3.001 Tightening torques

TL 435-10 F/N xxx-6000 copyright by

1 Preload values and tightening torques with standard metric

copyright by TL 435-10 F/N xxx-6000

2 Preload values and tightening torques with fine metric thread

TL 435-10 F/N xxx-6000 copyright by

3 Tightening torque for screws to mount SAE flange

Tightening torques in Nm for screw grade 10.9

3.2 Half flange for low pressure (Norm 61)

Tightening torques in Nm for

Plug Tightening torques

copyright by TL 435-10 F/N xxx-6000

1.3.002 Conversion charts

TL 435-10 F/N xxx-6000 copyright by

1.3.003 Tapping holes

TL 435-10 F/N xxx-6000 copyright by

2 Tapping holes for metric ISO fine threads

copyright by TL 435-10 F/N xxx-6000

1.4.000 Conservation guidelines

2 Taking the machine out of service – for an unknown duration

Use with Shimpo rpm

Groove ø 45.5 +0.5mm

Angle screwdriver Size 8000989 For cap hydraulic tank