A309 r317

en
Service Manual
Hydraulic excavator
A 309 - R 317 Litronic TCD
1 Document identification
Order number: 10449595

Edition: 09 / 2007
Last update: 07 / 2008
Author: LHB - Technical Documentation Department
2 Product identification
Manufacturer: LIEBHERR Hydraulikbagger GmbH
Document is registered under: 1030314 - 29.01.2009

Model: A 309 - R 317 Litronic TCD
Conformity: CE
3 Address of copyright owner
Liebherr Hydraulikbagger GmbH

Liebherr-Strasse 12
D - 88457 Kirchdorf / Iller Germany
LHB/en/Edition: 07/2008
Manual no. ..............................

User: .........................................
09334011127
09333011127
General Information 1
Tools 2
Technical Data / Maintenance Guidelines 3
Engine 4
Coupling / Splitterbox 5
Hydraulic System 6
Hydraulic Components 7
Electrical System 8
Swing Gear 9
Swing Ring 10
Two Speed Gear Box / Travel Gear 11
Axles / Track Components 12

Steering 13
Oscillating Axle Stabilizer 14
Brake system 15
Special Attachments / Accessory Kits 16
Cab / Heater / Air Conditioning System 17
Undercarriage / Uppercarriage / Attachments 18
Arrangement of Tanks 19
Service Manual
SUBGROUP - INDEX
Section Group Type
Safety instructions 1.10.1 A 312 LI-TCD 36220-

A 314 LI-TCD 30694-
A 316 LI-IND-TCD 29503-
A 316 LI-TCD 29120-
R 313 LI-TCD 39171-
R 317 LI-TCD 30019-
Tightening torques (WN 4037 K) 1.20.1 A 312 LI-TCD 36220-

A 314 LI-TCD 30694-
A 316 LI-IND-TCD 29503-
A 316 LI-TCD 29120-
R 313 LI-TCD 39171-
R 317 LI-TCD 30019-
Tightening torques 1.21.1 A 312 LI-TCD 36220-

A 314 LI-TCD 30694-
A 316 LI-IND-TCD 29503-
A 316 LI-TCD 29120-
R 313 LI-TCD 39171-
R 317 LI-TCD 30019-
Assembly instruction for hydraulilc cylinder 1.22.1 A 312 LI-TCD 36220-

(WN 4121C) A 314 LI-TCD 30694-

A 316 LI-IND-TCD 29503-
A 316 LI-TCD 29120-
R 313 LI-TCD 39171-
R 317 LI-TCD 30019-
Assembly instruction for hydraulic cylinder 1.24.1 A 312 LI-TCD 36220-

(WN 4122B) A 314 LI-TCD 30694-
A 316 LI-IND-TCD 29503-
A 316 LI-TCD 29120-
R 313 LI-TCD 39171-
R 317 LI-TCD 30019-
Lubricants and operating fluids 1.50.1 A 314 LI-TCD 30694-

A 316 LI-IND-TCD 29503-
A 316 LI-TCD 29120-
R 313 LI-TCD 39171-
R 317 LI-TCD 30019-
1.1
MJFCIFSS
Service Manual
TE_ML05 lubricant list 1.55.1 A 312 LI-TCD 36220-

A 314 LI-TCD 30694-
A 316 LI-IND-TCD 29503-
A 316 LI-TCD 29120-
R 313 LI-TCD 39171-
R 317 LI-TCD 30019-
TE_ML07 lubricant list 1.56.1 A 312 LI-TCD 36220-

A 314 LI-TCD 30694-
A 316 LI-IND-TCD 29503-
A 316 LI-TCD 29120-
R 313 LI-TCD 39171-
R 317 LI-TCD 30019-
1.2
MJFCIFSS
Service Manual Safety instructions
Proper use
Safety instructions
Working with the machine holds dangers to which you as the owner, machine operator or mainte-
nance expert could be exposed. If you regularly read and observe the safety information, you can
guard against dangers and accidents. This applies especially to persons, who are working on the ma-
chine only occasionally, such as for maintenance work. The following information comprises safety
regulations which, if followed conscientiously, will guarantee your safety and that of other persons,
as well as avoid damage to the machine.
Following these regulations does not release you from the responsibility to follow all safety regula-
tions and guidelines valid for the jobsite, as required by law or issued by trade associations.
For EU countries, guideline 89/655/EEC contains the minimum safety information applicable to the
operator.
1 Proper use
– The hydraulic excavator is a machine with attachments (such as backhoe, grapple, bucket ) de-
signed to loosen, take on, transport and dump soil, rocks and other materials, where the load is
predominantly transported without moving the machine. Moving the machine when it is carrying a
load must be carried out by observing the appropriate safety measures (see section "Notes for
machine operating safety").
– Machines used for load-lifting work are subject to specific conditions and must be equipped with
the stipulated safety devices (see section “Load-lifting work”).
– Other or additional usage, such as for demolition or material handling work, requires special
equipment and may also require special safety devices. These attachments (e.g. log grapple,
demolition hammer, concrete cutter etc.) may only be attached and used with approval and in ac-
cordance with the basic machine manufacturer.
– Transporting persons is not deemed to be intended use. The manufacturer is not liable for damage
resulting from this action. The risk must be assumed solely by the user.
– Observing the operating instructions and the inspection / maintenance instructions is also deemed
to be appropriate and destined use in accordance with regulations.

2 General Safety instructions
– Please familiarize yourself with the operating instructions before starting the machine.
– Please verify that you have supplemental instructions and have read and understood these (this
may concern special options for the machine).
– Only explicitly authorized personnel may operate, maintain or repair the machine. The legal min-
imum age must be observed.
– Use only trained or instructed personnel. Clearly define who is responsible for the operation or
set up, maintenance and repair. Allow personnel to refuse unsafe instructions given by a third per-
son. This also applies to traffic regulations. Reject unsafe instructions by third parties and/or allow
your personnel to reject these. This also applies in regards to traffic regulations.
– Any person still in training should only operate or work on the machine under the constant super-
vision and guidance of an experienced person.
– Check and observe any person working or operating the machine at least periodically if they ob-
serve safety instructions and guidelines given in the Operating manual.
– Wear proper work clothing when operating or working on the machine. Avoid wearing rings,
watches, ties, scarves, open jackets or loose clothing. There is a danger of injury, as these items
could get caught or be pulled in.The following are mandatory for certain tasks: Safety glasses,
safety shoes, safety helmet, work gloves, reflecting vest, hearing protection, ...
1.10.1
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Safety instructions Service Manual
Crushing and burn prevention
– For certain tasks, safety glasses, hard hats, safety boots, work gloves, reflective vests, ear pro-
tection etc. are required.
– Consult the supervisor at the job site for special safety instructions and regulations.
– Always raise the safety lever before leaving the operator’s seat.
– When entering or leaving the cab, do not use the steering column, the control panel or the joy-
sticks as handholds. Inadvertent movements, which could cause accidents, should be touched off.
– Never jump off the machine, always use the steps, ladders, rails and handles provided to climb
off or on the machine.
– Use both hands to hold on, facing the machine.
– Familiarize yourself with the emergency exit through the front window.
– Proceed as described in the operating instructions, if no other instructions are available for main-
tenance and repairs:
• Place the machine on a solid and level ground and lower the work equipment to the ground.
• Depressurize the hydraulic system.
• Move all control levers to the neutral position.
• Move the safety levers up prior to leaving the machine.
• Remove the ignition key.
– You must also reduce the pressure in the hydraulic system and the interior pressure of the tank
prior to any operation on the hydraulic system as described in these operating instructions.
– Secure all loose parts on the machine.
– Never start a machine before completing a thorough inspection and check, if safety tags are miss-
ing or are illegible.
– Do not complete any modifications, attachments or retrofits on the machine, which could inhibit
safety, without the prior consent of the manufacturer. This also applies to the installation and ad-
justment of safety devices and safety valves as well as to any welding on load carrying parts.
3 Crushing and burn prevention
– Never work underneath the attachment as long as it is not safely resting on the ground or properly
supported.
– Do not use any damaged or insufficiently supporting load carrying devices, such as ropes or
chains.
– Always wear work gloves when handling wire ropes.

– When working on the attachment, never align bores with your fingers, always use a suitable align-
ment tool.
– Please verify that no objects enter the fan while the Diesel engine is running. Rotating fans will
swirl and throw out objects, which can damage the fan.
– At or near operating temperature, the engine cooling system is hot and under pressure. Avoid con-
tact with any components containing coolant. Danger of severe burns.
– Check the coolant level only after the radiator cap on the expansion tank is cool enough to touch.
Turn the cap carefully to relieve the pressure.
– At or near operating temperature, the engine and the hydraulic oil are hot. Do not allow your skin
to come into contact with hot oil or components containing hot oil.
– Always wear safety glasses and protective gloves when handling batteries. Avoid sparks and
open flames.
– Never permit anyone to guide the grapple by hand.
– When working on the engine area, make sure that the side doors are properly secured with the
appropriate supports to prevent them from closing inadvertently.
– Never work underneath the machine if it is raised with the attachment, without being properly sup-
ported from below with hardwood beams.
1.10.2
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Fire and explosion prevention
4 Fire and explosion prevention
– Switch off the Diesel engine prior to filling the tank.

– Routinely check the electrical system.
– Have skilled personnel immediately repair all defects, such as loose connections, blown fuses and
burned out light bulbs, burned or frayed cables.
– Do not smoke and avoid open flames when filling the tank or loading the batteries.
– Always start the Diesel engine according to the regulations in the operating instructions.
– Never store flammable fluids on the machine except in appropriate storage tanks.
– Regularly inspect all lines, hoses and fittings for leaks and damage.
– Repair any leaks immediately and replace damaged components.
– Any oil escaping from leaks can easily cause a fire.
– Be certain that all clamps, guards and heat shields are properly installed to prevent vibration, rub-
bing and heat build up.
– Do not use cold start aids (ether) near heat sources or open flames or in insufficiently ventilated
areas.
– Do not use ether containing starting aids to start Diesel engines with preheat system or flame glow
systems. DANGER OF EXPLOSION!
– Familiarize yourself with the location and use of fire extinguishers on the machine as well as the
local fire reporting procedures and fire fighting possibilities.
5 Transporting the machine safely
– Due to the space restrictions during transport, use only suitable transporting and lifting devices
with sufficient capacity
– Park the machine on a level surface and chock the chains and/or wheels.
– If necessary, remove parts of the attachment during transport.
– The ramp to drive onto the transporting vehicle should not exceed an inclination of 30° and be pro-
vided with a wood covering to prevent sliding.
– Clean the undercarriage. The undercarriage must be swept clean, meaning, the chains / wheels

must be free of snow, ice and sludge prior to driving onto the ramp.
– Align the machine precisely with the loading ramp.
– Attach the manual lever for sensitive driving (crawler excavator) to the driving pedals.
– Note that a guide gives the necessary signals to the machine driver.
– Drop the equipment in and drive it onto the loading ramp. Keep the equipment tight over the load-
ing surface and drive it carefully onto the ramp and further into the transporting vehicle.
– The superstructure must be secured with the undercarriage by using locking bolts (only for A-
equipment), after loading the machine onto the low loader.
– Secure the machine and the remaining equipment parts with chains and chocks against shifting
according to national regulations for loading and transporting.
– Release all pressure lines (as described in these operating instructions), pull the ignition key and
pull the safety lever up prior to leaving the machine.

– Close all cab and panel doors.
– Verify that no one is located on the machine during the transport.
– Investigate the travel route, specifically in reference to limits for width, height and weight prior to
the transport.
– Pay special attention when driving under electrical lines and bridges and when passing through
tunnels.
– Use the same care for unloading as for loading.
1.10.3
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Bringing the machine safely into service
6 Bringing the machine safely into service
– Before starting the machine, perform a thorough walk around inspection.

– Visually check the machine for loose bolts, cracks, wear, leaks and damage.
– Never start or operate a damaged machine.
– Make sure to correct any problems immediately.
– Verify that all hoods, covers and doors are closed, however, the locks should remain unlocked.
– Verify that all safety tags are available.
– Make sure that all windows, as well as the inside and outside mirrors are clean. Secure all doors
and windows to prevent unintentional movement.
– Be certain that no one works on or under the machine and warn any personnel in the surrounding
area with the horn before starting the machine.
– Before operating the machine, adjust the operator’s seat, the mirror, the arm rests and the other
items to ensure comfortable and safe working conditions.
– The noise protection devices on the machine must be in functional protective position during op-
eration.
– Follow the regulations effective for the relevant site.
– Never start the machine without the driver’s cab.
7 Starting the machine safely
– Before start up, check all indicator lights and instruments for proper function, bring all controls into
neutral position and raise the safety lever.
– Honk the horn briefly prior to starting the Diesel engine, in order to warn persons located near the
machine.
– Only start the machine from the driver’s seat.
– Start the Diesel engine according to the regulations in the operating instructions, if you have not
received any other instructions.
– Lower the safety lever and check all indicators, gauges, warning devices and controls for their
proper indication.
– Only operate the Diesel engine in a well ventilated area, if the area is enclosed. Open doors and
windows to ensure sufficient fresh air supply, if necessary.
– Bring the engine and hydraulic oil to operating temperature. Low oil temperatures cause a slow
reaction of the controls.
– Check that all attachment functions are operating properly.
– Carefully take the machine to an open area and check all safety-related functions.
8 Shutting down the machine safely
– Only place the machine on a level and solid ground. The machine must be secured with chocks,
wenn setting it on a slope, to secrure it against rolling away.
– Lower the working equipment and anchor it lightly into the ground.
– Move all control elements into the neutral position. Set the parking and slewing gear brake.
– Switch off the Diesel engine according to the operating instructions and move the safety lever up,
prior to leaving the driver’s seat.
– Lock the machine, as well as all hoods, covers and doors; pull out all keys and secure the machine
against any unauthorized use.
1.10.4
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Towing the machine safely
9 Towing the machine safely
– Always observe the correct procedure: See chapter “Towing the machine” in this operating man-
ual.
– The machine may only be towed in exceptional circumstances, e.g. in order to move the machine
away from a dangerous place.
– Before pulling or towing the machine, check all cables, hooks and couplers for safety and stability.
– Towing equipment must have sufficient tensile strength and must be attached to the undercarriage
at the provided stops.
Be aware that any damage or accidents caused by towing the machine are never covered by the
manufacturer's warranty.
– Never allow anyone to remain in the area of the towing devices.
– During the towing procedure, keep within the required transport position, the permissible speed
and distance.
– After the towing procedure is completed, return the machine to its previous state.
– Proceed as outlined in the operation manual when putting the machine back into service.
10 Working with the machine safely
– Before starting to work, familiarize yourself with the peculiarities of the job site, the special regu-
lations and warning signals. Part of the surrounding area includes, for example, the obstacles in
the working or movement area, the load carrying capacity of the ground and required safeguards
for the job site to shield it from public highway traffic.
– Always keep an adequate safety distance to overhangs, edges, embankments and an unsecured
substrate.
– Be particularly cautious in conditions of reduced visibility and changing ground conditions.
– Familiarize yourself with the location of power lines on the job site and work particularly careful in
their vicinity. If necessary, inform the responsible authorities.
– Maintain a safe distance from electrical overhead lines. Do not approach the line with the
equipment when working near electrical overhead lines. Danger of fatal injury! Inform yourself
about required safety distances.

– In case of a flashover, proceed as follows:
• do not move the machine or its attachment,
• do not leave the operator’s platform,
• warn people in the vicinity not to approach or touch the machine,
• have the power turned off.
– Before moving the machine, always ensure that the attachments are safely secured.
– When travelling on public roads, paths or squares, observe the valid traffic regulations and, if nec-
essary, first bring the machine into proper condition to meet federal and local highway standards.
– Always turn on the lights in conditions of poor visibility or darkness.
– Do not permit any passengers on the machine (except on two way excavators).
– Operate the machine only when seated and with the seat belt fastened.
– Report any problems or needed repairs and make sure that all required repairs are carried out
immediately.
– Personally make sure that no one is endangered by moving the machine.
– Before starting to work, always check the brake system as outlined in the operating manual.
– Never leave the operator’s seat as long as the machine is still moving.
– Never leave the machine unattended while the Diesel engine is running.
1.10.5
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Working with the machine safely
– The machine must be utilized, driven and operated in such way that the stability is ensured and
that there is no danger of tipping over. Only known loads may be moved with the attachments,
especially in grapple operation.
– The maximum approved passable incline / traverse slope of the machine depends on the attached
equipment as well as the substrate.
– For travel, move the uppercarriage in lengthwise direction and hold the load as close as possible
to the ground.
EXCEPTION: see WHEN LOADING AND UNLOADING
– Adjust the travel speed to suit local conditions.
– Avoid working movements which could cause the machine to tip over.
– If possible, always work downhill or uphill, never sideways on a slope.
– Only travel downhill at the permitted speed or you could loose control over the machine.
– Only drive downhill at a low driving speed, since you may otherwise loose control of the machine.
The Diesel engine must run in the upper revolution range and be reduced by selecting the low
driving speed range / the lowest gear.
– Before travelling downhill, always shift to a lower gear. When doing this, the Diesel engine must
run at maximum RPM and the speed may only be reduced using the accelerator pedals.
– When loading a truck, make sure that the truck driver leaves the cab, even if a rock protection is
present.
– Always use the safety devices intended for their specific use for demolition work, clearings, hoist-
ing operations, etc.
– For terrain which is difficult to gain an overview of and whenever necessary, ask for assistance of
a guide. Have only one person signal you.
– Only permit experienced personnel to secure loads and signal the machine operator. The guide
must position himself within view of the operator or be in voice contact with him.
– Depending on the attachment combination, there can be a danger of collision between the work-
ing tool and the operator’s cab, the cab protection or the boom cylinders. To avoid damage, utmost
attention is required when the bucket teeth enter this range.
10.1 Safe application in material handling operation (especially when handling tim-
ber)
– Particularly when working with a grapple it can be necessary to move the machine with a raised
attachment and picked up load, for example when handling wood or timber.
– This will shift the center of gravity of the machine upward in vertical direction. The travel behaviour
of the machine will be strongly influenced, for example reduction of dynamic stability.
For that reason, the following rules must be strictly observed:
• Match your travel behaviour to the changed machine characteristics and surrounding condi-
tions.
• Reduce the travel speed to avoid sudden braking or steering manoeuvres.
• Avoid sudden speed changes, such as braking, acceleration, changes in travel direction.
• Turn the uppercarriage only if the undercarriage is stationary.
• Turn the uppercarriage only after taking on the load.
• Move the machine only after you have taken on the load, lifted it and turned the uppercarriage
in travel position.
• If the attachment is raised, there is a danger due to possible oscillating movements and falling
of the picked up load.
• A protective screen (FOPS) according to ISO 10262 must be attached on the front on the cab.
• The protective screen (FOPS) according to ISO 10262 must be installed if there is a danger of
falling objects from overhead.
• Only the maximum permissible load may be picked up with the grapple.
1.10.6
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– NOTE: The weight of absorbent material, such as wooden logs, depends on the length, the diam-
eter and the specific weight. The existing influencing factors for a natural product, such as mois-
ture, must be considered.
– The working sequences when working with machines with grapples require special instruction and
training of the machine operator.
– The work application is only permitted after the machine operator has received sufficient training
and practical experience.
10.2 Safe application of machines with tower elevation

– Due to the tower elevation, the center of gravity of the machine will shift upward in vertical direc-
tion. The travel and work behaviour of the machine will thereby be strongly influenced, for example
reduction of dynamic stability.
– Due to the elevated center of gravity, the machine must be aligned in horizontal direction before
starting to work. In horizontal direction, the center of gravity of the uppercarriage is above the cent-
er of the undercarriage, which reduces the danger of tipping over.
– The machine can rock despite leveling and tip over!
For that reason, the following rules must be strictly observed:
When driving the machine:
• Swing the uppercarriage parallel to the undercarriage (transport position).
• Pull the attachment as close as possible to the machine.
• Only then may the outriggers be retracted and the machine be driven.
• Driving with loads is not permitted.
• Check the roadway to ensure the ground is solid and even! Pot holes and uneven road surfaces
endanger the stability of the machine.
• Match your travel behaviour to the changed machine characteristics (higher center of gravity)
and surrounding conditions.
• Reduce the travel speed to avoid sudden braking or steering manoeuvres.
• Avoid sudden speed changes, such as braking, acceleration, changes in travel direction.
• Drive uphill and over obstacles only in lengthwise direction, to avoid impermissible transverse
slopes of the machine.
• Special care must be taken when driving through narrow passages – drive slowly!
In material handling operation:

• Before moving (turning) the uppercarriage from transport position, the machine must be sup-
ported and horizontally aligned.
• Make sure to check the placement surface of the outriggers (load carrying capacity of ground).
Sinking of an outrigger below ground level would result in devastating consequences!
• Carry out all movements with increased caution.
• To turn a load, move the attachment as close as possible to the machine (Caution! Oscillating
grapple), while holding the load as close as possible to the undercarriage and above the
ground.
• Avoid abrupt slow down or acceleration of the attachment or uppercarriage.
• Never lift a heavier load than stated in the load chart.
10.3 Additional notes for machines with fixed operator’s cab elevation
– To enter and exit the machine, park the machine on ground, which is level in lengthwise and hor-
izontal direction. Position the uppercarriage to the undercarriage in such a way that the steps and
ladders are aligned.
– Keep steps, ladders and handholds (handles) in proper condition. Make especially sure that they
are free of dirt, oil, ice and snow.
NOTE: To ensure that the doors open in all weather conditions, lubricate the weather strips at
least every two month, or more often, if necessary, with talcum powder or silicon. Lubricate the
door hinges and locks regularly.
1.10.7
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– When entering or leaving the machine, always face the machine and use the three point support,
i.e. always have two hands and one foot or two feet and one hand in contact with the entry system.
– When you can reach the door handle with the free hand, open the door first before climbing higher.
External influences, such as wind, can make it more difficult to open the door. For that reason,
always guide the door by hand when opening the door. Make sure that the door is engaged when
it is open, to prevent it from banging open or closed.
– Continue to climb up and immediately sit on the operator’s seat in the cab. Then close the door
and fasten the safety belt.
– Proceed with the same care when exiting and climbing down as when entering and climbing up
the machine.
– Park the machine only on firm and level ground. Position the uppercarriage to the undercarriage
in such a way that the steps and ladders are aligned.
– Release the safety belt. When exiting, face the machine and use the three point support. Climb
down until you can close the door safely. Always guide the door by hand when closing the door.
– Finally climb down to the ground.
10.4 Protection from vibrations

– The vibration impact on mobile construction machinery is usually the result of the manner of utili-
zation. Especially the following parameters have a significant influence:
• Terrain conditions: Unevenness and potholes;
• Operating techniques: Speed, steering, braking, control of operating elements of the machine
during travel as well as working.
– The machine operator determines the vibration impact to a great part, since he himself selects the
speed, the gear ratio, the working manner and the travel route.
This results in a wide range of various vibration impacts for the same machine type.
The full body vibration impact for the machine operator can be reduced if the following recommenda-
tions are observed:
– Select the appropriate machine, equipment parts and auxiliary devices for the corresponding
tasks.
– Use a machine equipped with the appropriate seat (i.e. for earth moving machines, for example
hydraulic excavators, a seat which meets EN ISO 7096).
– Keep the seat in good order and adjust it as follows:

• The seat adjustment and the suspension should be made according to the weight and the size
of the operator.
• Check the suspension and the adjustment mechanism regularly and make sure that the char-
acteristics of the seat remain as specified by the seat manufacturer.
– Check the maintenance condition of the machine, especially regarding: Tire pressure, brakes,
steering, mechanical connections, etc.
– Do not steer, brake, accelerate and shift or move and load the attachment of the machine in a jerky
manner.
– Match the machine speed to the travel route to avoid vibration impacts.
• Decrease the speed when driving on pathless terrain;
• Drive around obstacles and avoid very impassable terrain.
– Keep the quality of the terrain where the machine is working and travelling in good order:
• Remove large rocks and obstacles;
• Fill furrows and holes;
• To establish and retain suitable terrain conditions, keep machines available and allow for suffi-
cient time.
– Travel longer distances (i.e. on public roads) with suitable (medium) speed.
– For machines, which are frequently used for travel, utilize special auxiliary systems for travel (if
installed), which reduce the vibration for this application.
If such auxiliary systems are not available, regulate the speed to keep the machine from "rocking".
1.10.8
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Safe installation and removal of attachment parts
11 Safe installation and removal of attachment parts
– Equipment and attachment parts made by other manufacturers or those which do not have LIEB-
HERR’s general approval for installation may not be installed on the machine without prior written
approval by LIEBHERR.
LIEBHERR must be provided with the required technical documentation necessary for this pur-
pose.
– When installing attachment parts, which are supplied via the machine's hydraulics system, such
as an attachment with cylinder movement, it must be ensured that different types of oil are not
mixed together.
Mixing environmentally friendly hydraulic oils made by different manufacturers as well as mixing
them with mineral oils must be avoided.
– Set the machine on a level and stable ground prior to any attachment and removal of equipment
parts.
– Lock the uppercarriage with the locking pin to the undercarriage.
– Do not work under the equipment as long as it does not contact the ground or prior to being sup-
ported.
– Never lie under the machine, if it is lifted by the work equipment without properly propping the ma-
chine.
– Before releasing a line or bolt, you must reduce the pressure in the hydraulic system as described
in these operating instructions.
– Do not attempt to lift heavy parts. Use suitable lifting devices with sufficient load carrying capacity.
– Do not use damaged or insufficiently sized ropes or cables. Always wear work gloves when han-
dling wire cables.
– When working on the equipment: Switch off the Diesel engine and turn the safety lever upward.
Never align the holes with your fingers; use a suitable mandrel.
– During repairs: Make sure that the hydraulic lines are properly attached and that all fittings and
connections are properly tightened.
– As soon as an attachment part is removed and supported, close off the openings in the hydraulic
circuit to prevent dirt infiltration. Permit only authorized persons near the machine or the lifting de-
vice.

11.1 Safe removal and installation of attachment pins
– If possible, always use a hydraulic pin pulling device to push out the pins on the attachment.
– If pins must be removed with a sledge hammer, use a punch and a guide tube held by another
person.
– To drive out a pin, install the impact screw from the tool box in the threaded bore of the pin and
hit the screw only.
– For the installation of a pin retained with castle nut and cotter pin, drive the pin in first to the stop,
then install the castle nut by hand until contact and tighten it only to the point where the cotter pin
can be installed.
1.10.9
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Safe maintenance of the machine
12 Safe maintenance of the machine
12.1 General safety instructions

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

• Seal all openings where penetrating water, steam or detergent might cause damage or lead to
malfunctions.
Especially at risk are electric motors, electronic components, switch cabinets, plug connections
and air filters.
– When cleaning the engine compartment, ensure that the temperature sensor of the fire alarm and
extinguishing systems are not accidentally brought into contact with the hot cleaning solution, as
this could trigger an alarm and activate the extinguishing system.
– After completion of the cleaning work:
1.10.10
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MJFCIFSS
• Remove all temporary covers.

• Check all fuel, engine oil and hydraulic lines for leakage, loose connections, chaffing and
damage.
• Repair all detected defects.
• Lubricate slewing ring as well as all bearings and pin connections to eliminate water or detergent
that might have penetrated these assemblies.
12.3 Crack detection

– The machines are subject to various loads and stresses, depending on the actual application,
location of operation, operating hours and the ambient conditions. The various load scenarios
result in service lives of the machine components that might differ from each other. This might lead
to cracks or loose connections, especially on load-bearing parts. This applies in particular to
machines used for loading or industrial purposes, or to machines equipped with optional
equipment, such as demolition excavators. To maintain the operational safety of the machine, it
must be regularly inspected for cracks, loose connections and other visible damage.
– To be able to inspect the machine for cracks, it must be kept clean.
– The inspections must be carried out as described in the inspection and maintenance schedule:
• every 250 operating hours, by the maintenance personnel of the machine operator
• every 500 operating hours by authorised specialist technicians.
– We strongly recommend to carry out these inspections after the machine has been placed on a
firm and level surface, and by applying various different loads in longitudinal and transverse
direction by moving the attachment. Always comply with the applicable workplace safety and
accident prevention regulations.
– Particular care is required for the inspection of load-bearing components, in particular:
• The steel structure of the undercarriage with axle and gearbox bearings, the support system,
the lower slewing ring support, the tower and the slewing ring.
• The steel structure of the uppercarriage with bearing block for booms and boom cylinders, the
upper slewing ring support, the cab bearing, and the securing devices of the slewing gear and
ballasts.
• The steel components of the attachments, e.g. booms, members, quick change adapters,
digging buckets and grapples.
• Hydraulic cylinders, axles, steering components, bolts and pin connections, ladders, steps and
securing devices.

– The crack inspection is a visual inspection. To improve the reliability of the inspection, check areas
where you suspect cracks or areas that are not easily accessible (e.g. at the slewing ring support)
with a dye penetration test.
– Immediately eliminate any detected damage. Welding work on load-bearing parts of earth moving
machines, handling and transport equipment must be carried out by specialist welding technicians
and according to best welding practice. If in doubt, contact the LIEBHERR customer service
department to discuss the envisaged measures.
12.4 Welding work

– Welding, torch-cutting and grinding work on the machine is only permitted with the explicit consent
of the manufacturer. Before carrying out such work, clean the machine and remove any dust and
flammable material around the equipment.
Ensure that the working areas is properly ventilated. Risk of fire and/or explosion!
– Before carrying out arc welding work, or work on the electric components of the machine,
disconnect the battery.
First disconnect the negative pole, then disconnect the positive pole. To reconnect the battery,
first connect the positive pole, then the negative pole.
– For arc welding work, position the earth contact point at the machine as close as possible to the
welding area.
1.10.11
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MJFCIFSS
12.5 Fuels and lubricants

– When handling oil, grease or other chemical products, always comply with the respective safety
instructions provided by the supplier.
– All fuels, lubricants and replaced parts must be disposed of in a safe and environmentally friendly
manner.
– Handle hot fuels and lubricants with particular care to prevent
injury.
12.6 Repairs
– Do not attempt to lift heavy parts by hand but use suitable lifting gear with appropriate load-bearing
capacity. To replace component parts and assemblies, attach and secure them carefully to
suitable lifting tackle and ensure that they cannot cause damage or injury while being transported.
Use only lifting tackle that is in proper working order and has the necessary load-bearing capacity.
Do not stand under suspended loads.
– Never use chaffed or damaged lifting tackle or gear that does not have the necessary load-bearing
capacity.
When working with wire cables, always wear protective gloves.
– Only experienced personnel may attach loads and guide crane operators. The signaller must be
positioned within the sight of the machine operator. Alternatively, the signaller and the operator
might be in contact through walkie-talkies or similar devices.
– When working above head height, use safe ladders and platforms.
Never use machine parts as climbing aids, unless they are designed for this purpose.
When working at great height, wear suitable safety gear.
Keep all handles, steps, railings, platforms and ladders free of dirt, snow and ice.
– When working at the attachment (e.g. replacement of teeth), ensure that it is properly supported.
Avoid metal supports (metal-to-metal contact).
– Never stand below a machine propped up by means of the attachment, unless the machine has
been properly secured with supports.
– Jack up the machine in such a way that shifting weights cannot impair its stability. Avoid metal-to-
metal contact.
– All work on the chassis, brake and steering systems must be carried out by suitably trained
specialists technicians.
– If the machine is to be repaired while standing on a slope, the chains must be secured with sprags
and the uppercarriage must be locked onto the undercarriage with the locking bolt.
– All work on the hydraulic equipment must be carried out by specialist technicians who are trained
and experienced in the field of hydraulics.
– When searching for leaks, always wear protective gloves, as high-pressure liquid might penetrate
the skin and cause damage.
– Before loosening or disconnecting any lines of screwed connections, lower the attachment to the
ground, shut down the diesel engine and release the pressure from the hydraulic system. After
the diesel engine has been shut down, insert the ignition key and turn it to its ON position, then
move all control devices (joystick and pedals) of the pilot control units in all directions in order to
release the control pressure and backpressures in the circuits. Continue with releasing the tank
pressure as described in this manual.
12.7 Electrical system

– Regularly inspect the electrical system.
Ensure that any detected faults such as loose connections, blown fuses and light bulbs, scorched
or chafed cables are eliminated without delay by specialist technicians.
– Use only original fuses of the prescribed amperage.
1.10.12
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MJFCIFSS
– For machines equipped with electrical medium-voltage and high-voltage lines:

• In the event of a disruption in the power supply, immediately shut down the machine.
– All work on the electrical equipment of the machine must be carried out by a trained electrician or
specialist technician under the supervision of an electrician and in accordance with the relevant
electro-technical regulations and guidelines.
– When working on powered parts, always employ a second person with access to the emergency-
stop or main switch to shut down the system in the event of an emergency. Cordon off the work
area, using red and white chain and a suitable warning sign. Always use insulated tools.
– When working on medium-voltage and high-voltage assemblies, first disconnect them from the
power supply, and then short-circuit the supply line and the assemblies (e.g. condensers) using
an earthing rod.
– Check all parts for voltage, then earth them and short-circuit them. Insulate adjacent parts that
remain powered.
– Before carrying out arc welding work, or work on the electric components of the machine,
disconnect the battery.
First disconnect the negative pole, then disconnect the positive pole. To reconnect the battery,
first connect the positive pole, then the negative pole.
12.8 Hydraulic accumulators

– All work on hydraulic accumulators must be carried out by specialist technicians.
– Improper installation and handling of hydraulic accumulators can lead to serious injury.
– Never use hydraulic accumulators that are damaged.
– Before carrying out any work on a hydraulic accumulator, release the pressure from the hydraulic
system as described in this operating manual.
– Do not carry out any welding or soldering work on the hydraulic accumulator and protect it from
mechanical impact.
The hydraulic accumulator might become damaged or ruptured if exposed to heat arising from
mechanical impact. RISK OF EXPLOSION!
– Fill the hydraulic accumulator only with nitrogen. Do not use oxygen or air! RISK OF EXPLOSION!
– During operation, the storage body might become hot, so that there is a risk of injury.
– New hydraulic accumulators must be pressurised to the level required for the actual purpose

before they are commissioned.
– The operating data (minimum and maximum pressure) are permanently attached to the hydraulic
accumulators. Ensure that this identification is legible at all times.
12.9 Hydraulic and other hoses

– The repair of hydraulic and other hoses is prohibited!
– All hoses and fittings must be inspected every 2 weeks for damage. If any damage is suspected,
immediately check the respective line for leakage and visible damage!
Always replace damaged parts without delay! Escaping oil can lead to serious injury or fire!
– Even if stored and used properly, hoses tend to age, so that their service life is limited.
• Improper storage, mechanical damage and inadmissible loads are however the most common
causes of failure.
• As regards the permissible period of use, observe the applicable standards, regulations and
rules for hoses and hose lines.
• Use of the hose with near limit loads and stresses (e.g. at high temperature, frequent movement,
extremely high pulse frequencies, multiple shift operation) may shorten its service life.
– Replace hoses, if the inspection reveals any of the following:
• Damage at the outer jacket exposing the ply (e.g. caused by chafing, wear, cuts or cracks)
• Embrittlement of the outer jacket (formation of cracks in the hose material)
1.10.13
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MJFCIFSS
• Deformation of the hose when pressurised, depressurised, or at bends, resulting in separation

of the layers, bubbles, etc.
• Leakage
• Non-compliance with installation requirements
• Damage or deformation of the hose fittings, which might impair the fitting strength of the
connection between fitting and hose
• Disconnection of the hose from the fittings
• Corrosion at the fittings, impairing its function and strength
– Always replace hoses and hose connections with original spare parts.
– Ensure that all hoses and lines are installed and connected properly. Do not confuse connections.
– When replacing hoses and hose lines:
• Ensure that the hoses are installed without torsion. For high-pressure hoses first insert the
screws at the pipe clips or full flanges at both ends, and then tighten them.
• For high-pressure hoses and lines with angled fittings, first tighten the flange at the angled fitting
and then the one at the straight fitting.
• Pipe clamps at other point of the hose may not be attached and tightened, when the hose ends
are properly secured.
• Daily inspect all hose clips, covers and protective devices to ensure that they are properly
secured and tightened. Avoid vibration and damage during operation.
• To prevent chafing, install hoses and lines in such a way that they are not in contact with other
hoses, lines or machine parts.
• We recommend keeping a minimum distance of 1/2 the outer hose diameter between the hose
and any other parts. The distance should in any case not be less than 10 to 15 mm.
• When replacing hoses and hose lines connected to moving parts (e.g. from the boom to the
stick), first check that they are not rubbing on any other parts when the machine is operated.
12.10 Cab protection (FOPS)

For certain machine applications LIEBHERR offers optional cab protection systems of various
designs. These systems consist of a full length FOPS (falling objects protective structure) or a top
guard and front guard to protect the operator's cab and windscreen area from falling objects (for
example rocks or debris).
The full length FOPS wraps around the operator's cab, is mounted to the uppercarriage and is a
stand-alone system.
The top and front guards are either bolted individually or in combination to the cab structure. In that
case the operator's cab is also part of the cab protection system and is subject to the following
instructions.
– Never operate a machine if one of these protections is damaged in any way.
– Damages may occur due to:
• structural modifications or repairs (for example welding, cutting or drilling)
• deformation after an accident
• falling objects
– Structural modifications or repairs of any kind are prohibited without the expressed, written
approval of LIEBHERR.
1.10.14
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MJFCIFSS
Product code 10409969
Standard Version 001
WN 4037 K
PRELOADS AND TIGHTENING TORQUES FOR SCREWS WITH METRIC

COARSE AND FINE THREADS ACCORDING TO DIN ISO 261
The preloads and torques included in the table are based on the VDI regulations 2230 of July 1986.
(The values of the edition from February 2003 have not been included in the table, as this would not be justified
according to our experience.)
Assembly preloads FM and tightening torques MA at v = 0.9 for headless screws with metric coarse or fine threads
according to DIN ISO 262 (and DIN ISO 965-2);
Head dimensions of hex head screws according to DIN EN ISO 4014 to 4018, screws with hexalobular external
driving heads according to DIN 34800 or Allen head screws according to DIN EN ISO 4762 and "centre" bores
according to DIN EN 20273
Metric coarse thread Metric fine thread
Surface finish: Surface finish:
- black-chrome finish or phosphatised - black-chrome finish or phosphatised
- electro-galvanised oiled - electro-galvanised oiled
- flZn = zinc flake coating - flZn = zinc flake coating
(LH standard 10021432, DAC) (LH standard 10021432, DAC)
Assembly Tightening Assembly Tightening
Thread Class preloads torques Thread Class preloads torques
FM in N MA in Nm FM in N MA in Nm
for mean friction factor µG= 0.12 for mean friction factor µG= 0.12
8.8 4 050 2,8
M4 10.9 6 000 4,1
12.9 7 000 4,8
8.8 6 600 5,5
M5 10.9 9 700 8,1
12.9 11 400 9,5
8.8 9 400 9,5
M6 10.9 13 700 14,0
12.9 16 100 16,5
8.8 13 700 15,5
M7 10.9 20 100 23,0
12.9 23 500 27
8.8 17 200 23 8.8 18 800 24,5

M8 10.9 25 000 34 M8x1 10.9 27 500 36
12.9 29 500 40 12.9 32 500 43
8.8 24 800 36
M9x1 10.9 36 500 53
12.9 42 500 62
8.8 27 500 46 8.8 31 500 52
M10 10.9 40 000 68 M10x1 10.9 46 500 76
12.9 47 000 79 12.9 54 000 89
8.8 29 500 49
M10x1,25 10.9 43 000 72
12.9 51 000 84
8.8 40 000 79 8.8 45 000 87
M12 10.9 59 000 117 M12x1,25 10.9 66 000 125
12.9 69 000 135 12.9 77 000 150
8.8 42 500 83
M12x1,5 10.9 62 000 122
12.9 73 000 145
8.8 55 000 125 8.8 61 000 135
M14 10.9 80 000 185 M14x1,5 10.9 89 000 200
12.9 94 000 215 12.9 104 000 235
8.8 75 000 195 8.8 82 000 205
M16 10.9 111 000 280 M16x1,5 10.9 121 000 300
12.9 130 000 330 12.9 141 000 360
.04.08 LHB Wimbauer Alois owatzky Dirk

Date Plant Created Examined Released
This document may not be copied or otherwise reproduced without the prior consent of LIEBHERR.
This document has been created by electronic means and is valid without signature. 1.20.1
Metric coarse thread Metric fine thread
Surface finish: Surface finish:
- black-chrome finish or phosphatised - black-chrome finish or phosphatised
- electro-galvanised oiled - electro-galvanised oiled
- flZn = zinc flake coating - flZn = zinc flake coating
(LH standard 10021432, DAC) (LH standard 10021432, DAC)
Assembly Tightening Assembly Tightening
Thread Class preloads torques Thread Class preloads torques
FM in N MA in Nm FM in N MA in Nm
for mean friction factor µG= 0.12 for mean friction factor µG= 0.12
8.8 94 000 280 8.8 110 000 310
M18 10.9 135 000 390 M18x1,5 10.9 157 000 440
12.9 157 000 460 12.9 184 000 520
8.8 102 000 290
M18x2 10.9 146 000 420
12.9 170 000 490
8.8 121 000 390 8.8 139 000 430
M20 10.9 173 000 560 M20x1,5 10.9 199 000 620
12.9 202 000 650 12.9 232 000 720
8.8 152 000 530 8.8 171 000 580
M22 10.9 216 000 750 M22x1,5 10.9 245 000 820
12.9 250 000 880 12.9 285 000 960
8.8 175 000 670 8.8 207 000 760
M24 10.9 249 000 960 M24x1,5 10.9 295 000 1090
12.9 290 000 1120 12.9 346 000 1270
8.8 196 000 730
M24x2 10.9 280 000 1040
12.9 325 000 1220
8.8 230 000 1000 8.8 267 000 1110
M27 10.9 330 000 1400 M27x1,5 10.9 381 000 1580
12.9 385 000 1650 12.9 445 000 1850
8.8 255 000 1070
M27x2 10.9 365 000 1500
12.9 425 000 1800
8.8 280 000 1350 8.8 335 000 1540
M30 10.9 400 000 1900 M30x1,5 10.9 477 000 2190
12.9 465 000 2250 12.9 558 000 2560
8.8 321 000 1490
M30x2 10.9 457 000 2120
12.9 534 000 2480

8.8 350 000 1850 8.8 410 000 2050
M33 10.9 495 000 2600 M33x1,5 10.9 584 000 2920
12.9 580 000 3000 12.9 683 000 3420
8.8 395 000 2000
M33x2 10.9 560 000 2800
12.9 660 000 3300
8.8 410 000 2350 8.8 492 000 2680
M36 10.9 580 000 3300 M36x1,5 10.9 701 000 3820
12.9 680 000 3900 12.9 820 000 4470
8.8 440 000 2500
M36x3 10.9 630 000 3500
12.9 740 000 4100
8.8 490 000 3000 8.8 582 000 3430
M39 10.9 700 000 4300 M39x1,5 10.9 830 000 4890
12.9 820 000 5100 12.9 971 000 5720
8.8 530 000 3200
M39x3 10.9 750 000 4600
12.9 880 000 5300
Notes:
− Torques indicated in drawings have precedence over those specified in the factory standards and must
at all times be adhered to.
− For important screw connections, we recommend using a torque angle gauge. For such connections, the
required tightening torques (assembly torque, angle of rotation) must be determined individually by the
technical department.
. 1.20.2
− When tightening in aluminum, with or without Helicoil-Inserts, the values for category 8.8 must be used.
However, tightening torques indicated on drawings are binding, to be treated with priority and must be
adhered to.
. 1.20.3
Service Manual Tightening torques
of screw-in studs (Ermeto)
Tightening torques
1 of screw-in studs (Ermeto)
1.1 mating material: steel (Grease well before inserting!)
Type with sealing edge Type with EOLASTIC seal
Tightening Tightening
Thread Thread
Type torques Type torques
M or G M or G
in Nm in Nm
Light-duty series L Light-duty series L
GE 06 LM A 3 C M 10x1 18 GE 06 LM ED A 3 C M 10x1 18
GE 06 LR A 3 C G 1/8 A 18 GE 06 LR ED A 3 C G 1/8 A 18
GE 08 LM A 3 C M 12x1.5 30 GE 08 LM ED A 3 C M 12x1.5 25
GE 22 Lm A 3 C M 22x1.5 140 GE 22 Lm Ed A 3 C M 26x1.5 180
GE 22 Lr A 3 C G 3/4 180 GE 22 Lr Ed A 3 C G 3/4 A 180

GE 28 Lr A 3 C G1A 330 GE 28 Lr Ed A 3 C G1A 310
GE 35 Lr A 3 C G 1 1/4 A 540 GE 35 Lr Ed A 3 C G 1 1/4 A 450
GE 42 Lr A 3 C G 1 1/2 A 630 GE 42 Lr Ed A 3 C G 1 1/2 A 540
Heavy-duty series S Heavy-duty series S
GE 06 SM A 3 C M 12x1.5 35 GE 06 SM ED A 3 C M 12x1.5 35
GE 06 SR A 3 C G 1/4 A 55 GE 06 SR ED A 3 C G 1/4 A 55
1.21.1
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MJFCIFSS
Tightening torques Service Manual
of swivelling connections (Ermeto)
Type with sealing edge Type with EOLASTIC seal
Thread Thread
Type torques Type torques
M or G M or G
in Nm in Nm
GE 25 SR A 3 C G1A 340 GE 25 SR ED A 3 C G1A 310
GE 30 SR A 3 C G 1 1/4 A 540 GE 30 SR ED A 3 C G 1 1/4 A 450
GE 38 SR A 3 C G 1 1/2 A 700 GE 28 SR ED A 3 C M 1 1/2 A 540
Tab. 1 Tightening torques of screw-in studs
GE = Straight screw-in connection (with metric thread M or pipe thread G)
2 of swivelling connections (Ermeto)
Tightening torques Tightening torques

Type Type
Thread Nm Thread Nm
Light-duty series Light-duty series
WH / TH 06 LR KDS A 3 C G 1/8 A 18 WH / TH 06 LM KDS A 3 C M 10 X 1 18
WH / TH 08 LR KDS A 3 C G 1/4 A 45 WH / TH 08 LM KDS A 3 C M 12 X 1.5 45

WH / TH 18 LR KDS A 3 C G1A 120 WH / TH 18 LM KDS A 3 C M 22 X 1.5 140
WH / TH 22 LR KDS A 3 C G 1 1/4 A 230 WH / TH 22 LM KDS A 3 C M 27 X 2.0 320
Heavy-duty series Heavy-duty series
WH / TH 06 SR KDS A 3 C G 1/4 A 45 WH / TH 06 SM KDS A 3 C M 12 X 1.5 45

WH / TH 25 SR KDS A 3 C G1A 320 WH / TH 20 SM KDS A 3 C M 27 X 2.0 320
1.21.2
copyright by
MJFCIFSS
Service Manual Tightening torques
Tightening torques Tightening torques

Type Type
Thread Nm Thread Nm
WH / TH 30 SR KDS A 3 C G 1 1/4 A 540 WH / TH 25 SM KDS A 3 C M 33 X 2.0 360
WH / TH 38 SM KDS A 3 C M 48 X 2.0 700
Tab. 2 Tightening torques of swivelling connections
3 of screw-in studs (Ermeto)
Screw-in Screw-in
Type VSTI torques Type VSTI torques
thread M thread G
Nm Nm
VSTI 10X1 ED A3C M 10 X 1 12 VSTI 1/8 ED A3C G 1/8 A 13
VSTI 12X1.5 ED A3C M 12 X 1.5 25 VSTI 1/4 ED A3C G 1/4 A 30
VSTI 20X1.5 ED A3C M 20 X 1.5 80 VSTI 1 ED A3C G1A 200
VSTI 22X1.5 ED A3C M 22 X 1.5 90 VSTI 1 1/4 ED A3C G 1 1/4 A 450
VSTI 26X1.5 ED A3C M 26 X 1.5 120 VSTI 1 1/2 ED A3C G 1 1/2 A 450
VSTI 27X2 ED A3C M 27 X 2.0 135
VSTI 33X2 ED A3C M 33 X 2.0 225
VSTI 42X2 ED A3C M 42 X 2.0 360
VSTI 48X2 ED A3C M 48 X 2.0 360

Tab. 3 Tightening torques of screw-in studs
VSTI = Hexagon socket plug

1.21.3
copyright by
MJFCIFSS
Tightening torques Service Manual
1.21.4
copyright by
MJFCIFSS
WN 4121 C
Installations for pistons and piston nuts
by hydraulic cylinders
1. Application and purpose

This Liebherr standard applies only to hydraulic cylinders, and in particular to the
mounting of pistons and piston nuts on piston rods from a thread diameter of M42
and greater.
This standard describes the tightening procedure with turning distance and angle.
For threads with diameters smaller than M42, the applicable tightening torque is
indicated in the drawings. The values in the drawings are always binding.
2. Requirements / description of procedure

For the valid torque value number, refer to the drawing. The standard may not be
adopted or transferred to apparently similar geometries.
Use this number to find the applicable turning distance and angle in the torque table
(see item 4).
The torque values have been determined empirically and are subject to changes.
This standard differentiates between two tightening procedures, which are identified
with 3-digit and 4-digit numbers respectively (see chapters 2.1 and 2.2).
1.22.1
1/7
2.1. Tightening with assembly wrench
This tightening procedure applies to 3-digit tightening numbers.
Preparation:
Clean the contact surfaces (threads contact faces between piston rod, piston and
piston nut) and apply a thin layer of Gleitmo high-performance lubricating grease
(ID no. 8300 004, 40 g tube) to both sides.
Definitions:
Pretightening torque (Mv):

The piston (A) is secured with a torque wrench (B) applied to the square/hexagon
head of the assembly wrench (C). The position of the torque wrench must be
carefully noted (see figure 1).
Turning distance (4):

Radian measure [mm] travelled as a result of the tightening of the piston, or piston
nut along the outer thread diameter, after application of the pretightening torque
(see figure 2).
Turning angle (5):

Angle [°] travelled by the piston or piston nut respectively, after application of the
pretightening torque (see figure 2).
A
Mv B
Figure 1
When applying the pretightening torque (Mv), the torque wrench (B) must point in
the same direction as the assembly wrench (C). Proceed in the same way to
tighten the piston nut, using a suitable assembly wrench.
. 1.22.2
5
4
1 2
5
4
6 2

Figure 2
1: Markings on the piston and the piston rod thread after application of the
pretightening torque
2: Markings on the piston rod thread
3: Markings on the piston after tightening
4: Turning distance
5: Turning angle
6: Markings on the piston nut and the piston rod thread after application of the
pretightening torque
7: Markings on the piston nut after tightening
. 1.22.3
2.2. Tightening with hydraulic assembly device

This tightening procedure applies to 4-digit tightening numbers.
Preparation:
Clean the contact surfaces (threads contact faces between piston rod, piston and
piston nut) and apply a thin layer of Gleitmo high-performance lubricating grease
(ID no. 8300 004, 40 g tube) to both sides.
Definitions:
Pretightening torque:
Torque applied on the piston or piston nut with the torque wrench (A) via the
hexagon head (B) of the torque converter (C) (see figure 1).
Turning angle:
Angle [°] travelled by the piston or piston nut respectively, after application of the
pretightening torque (see figure 3).
C
Figure 1
A: Torque wrench
B: Hexagon head
C : Torque converter
. 1.22.4
Operation of the assembly device:

See separate operating manual of the assembly device (H).
For suitable adapters for the piston rod, piston and piston nut, refer to the piston
parts list (see figure 2).
H
B
C
E
Figure 2
A: Piston rod
B: Piston
C : Adapter for piston
D: Adapter for piston rod
E: Piston nut
F: Adapter for piston nut
G: Torque converter
H: Assembly device
. 1.22.5
B
Figure 3
A: Dial
B: Adjusting screw
C : Angle scale
Before tightening, set the dial (A) with the adjusting screw (B) to position 0° on the
angle scale (C).
The angle scale indicates the turning angle.
If the opening angle of the assembly device is not sufficient to achieve the
prescribed turning angle, mount the device again for a second tightening process.
Note the previously completed angle. Before continuing the tightening process, set
the dial to the last achieved angle value. Repeat this process as often as necessary
to achieve the prescribed turning angle.
. 1.22.6
3. Modifications
4. Other applicable documents

Torque table
Drawing with reference to this Liebherr Standard and the torque number.
. 1.22.7
MJFCIFSS 4. Torque table Status: 16.06.2008
for LH standard 10334184
(Installation instructions for pistons and piston nuts) Page 1 of 2
The date indicates the latest status of the table.

This document is not subject to revision!
Tightening with assembly wrench (see 2.1)
No. Pretightening Piston Piston nut Thread

10334184 torque Turning distance Turning angle Turning distance Turning angle M
- ... [Nm] [mm] ~ [°] [mm] ~ [°] [mm]
071 100 11 +1 30° 21 +1 57° 42x1.5
072 100 21 +1 57° 21 +1 57° 42x1.5
073 100 18 +1 49° 19 +1 52° 42x1.5
075 100 19 +1 52° 21 +1 57° 42x1.5
078 100 20 +1 55° 14 +1 38° 42x1.5
079 100 11 +1 30° 21 +1 57° 42x1.5
080 100 18 +1 49° - - 42x1.5
091 100 13 +1 30° 19 +1 44° 50x2
092 100 25 +1 57° 19 +1 44° 50x2
093 100 24 +1 55° 19 +1 44° 50x2
095 100 13 +1 30° 19 +1 44° 50x2
096 100 10 +1 23° 9 +1 21° 50x2/WS65
097 100 17 +1 39° 19 +1 44° 50x2
098 100 17 +1 39° - - 50x2
099 100 24 +1 55° 19 +1 44° 50x2
111 100 16 +1 33° 18 +1 37° 56x2
112 100 17 +1 35° 18 +1 37° 56x2
113 100 17 +1 35° 19 +1 39° 56x2
114 100 19 +1 39° - - 56x2
115 100 18 +1 37° - - 56x2
116 100 19 +1 39° - - 56x2
121 150 15 +1 29° 19 +1 36° 60x2
123 150 17 +1 32° 19 +1 36° 60x2
126 150 14 +1 27° - - 60x2
127 150 22 +1 42° - - 60x2
151 150 15 +1 27° 19 +1 34° 65x2
152 150 20 +1 35° 19 +1 34° 65x2

153 150 20 +1 35° - - 65x2
171 150 12 +2 20° 18 +1 30° 68x2
173 150 19 +2 32° 18 +1 30° 68x2
174 150 25 +2 42° 18 +1 30° 68x2
175 150 25 +2 42° 18 +1 30° 68x2
176 150 19 +2 32° 18 +1 30° 68x2
177 150 19 +2 32° 18 +1 30° 68x2
179 150 11 +2 19° 18 +1 30° 68x2
180 150 20 +2 34° 18 +1 30° 68x2
181 150 20 +2 34° - - 68x2
183 200 - - 40 +2 67° 68x2
201 200 17 +2 26° 16 +1 24° 76x2
202 200 26 +2 39° 16 +1 24° 76x2
203 200 27 +2 41° 16 +1 24° 76x2
204 200 27 +2 41° 16 +1 24° 76x2
205 200 13 +2 20° - - 76x2
206 200 25 +2 38° 25 +1 38° 76x2
207 200 23 +2 35° - - 76x2
208 200 15 +2 22° - - 76x2
209 200 30 +2 45° - - 76x2
231 200 8 +2 11° 16 +1 22° 85x3
232 200 17 +2 23° 16 +1 22° 85x3
234 200 22 +2 30° - - 85x3
236 200 15 +2 20° - - 85x3
237 200 19 +2 26° - - 85x3
1.22.8
MJFCIFSS 4. Torque table Status: 16.06.2008
for LH standard 10334184
(Installation instructions for pistons and piston nuts) Page 2 of 2

10334184 torque Turning distance Turning angle Turning distance Turning angle M
- ... [Nm] [mm] ~ [°] [mm] ~ [°] [mm]
261 250 20 +2 25° 10 +1 12° 95x3
265 250 24 +2 29° 10 +1 12° 95x3
267 250 24 +2 29° - - 95x3
281 250 20 +2 23° 13 +1 15° 100x3
282 250 25 +2 29° - - 100x3
283 250 25 +2 29° 21 +1 24° 100x3
301 300 21 +3 22° 20 +2 21° 110x3
302 300 18 +3 19° 20 +2 21° 110x3
303 300 20 +3 21° 20 +2 21° 110x3
304 300 23 +3 24° 20 +2 21° 110x3
305 300 9 +3 9° - - 110x3
306 300 24 +3 25° - - 110x3
307 300 27 +3 28° - - 110x3
331 400 23 +3 22° 20 +2 19° 120x3
332 400 11 +3 11° - - 120x3
333 400 27 +3 26° - - 120x3
334 400 20 +3 19° 20 +2 19° 120x3
335 400 30 +3 29° - - 120x3
336 400 29 +3 28° - - 120x3
501 200 21 +2 30° - - 80x2
531 500 34 +3 28° - - 140x3
Tightening with hydraulic assembly device (see 2.2)

10334184 torque Turning angle Turning angle M
- ... Mv [Nm] [°] [°] [mm]
1000 300 27° +1° 8° +1° 240x4
1001 300 18° +1° 8° +1° 200x4

1002 300 18° +1° 8° +1° 150x4
1003 300 23° +1° 8° +1° 170x4
1004 300 21° +1° 8° +1° 140x4
1005 300 18° +1° 8° +1° 180x4
1006 300 39° +1° 8° +1° 150x3
1007
1008
1.22.9
Bezeichnung
Description / Dénomination
Blatt/Page/Feuille: 1
bestehend aus 4 Blatt
Mjfcifss! Assembly instruction
consisting of Pages
composé Feuille
for piston rod bearings with external threads
(hydraulic cylinders) WN 4122 B
Contents
1. Scope of application
2. Description
3. Referenced documents (torque table)
1. Scope of application
This factory standard applies exclusively to the assembly of hydraulic cylinders. For the
valid factory standard number, refer to the drawing. The standard may not be adopted or
transferred to apparently similar geometries.
The torques have been determined empirically and are subject to changes. The revision
and release dates indicate the latest version of the factory standard.
1.24.1
2. Description
Preparation:
Clean the threads and apply a thin layer of Gleitmo high-performance lubricating grease
(ID no. 8300 004, 40 g tube) on both sides.
Definitions:
Pretightening torque:
The piston rod bearing is secured with a torque wrench applied to the square of the
assembly wrench. The position of the torque wrench must be carefully noted (see figure 1).
Figure 1
A Bearing head
B Assembly wrench
C Torque wrench
When applying the pretightening torque, the torque wrench must point in the same
direction as the assembly wrench.
1.24.2
Turning distance:
Radian measure [mm] between the bearing head outer diameter and the cylinder tube,
travelled after application of the pretightening torque (see figure 2).
Turning angle:
Angle [°] travelled by the bearing head after application of the pretightening torque (see
figure 2).
Figure 2 Document is registered under: 1030314 - 29.01.2009

A Marks on the cylinder tube and the auter diameter of the bearing head after application
of the pretightening torque
B Mark on the cylinder tube
C Turning angle
D Turning distance
E Mark on the bearing head after tightening
F Cylinder Tube
G Bearing head
After the bearing head and the cylinder tube have been tightened, apply a notch mark at the
rod side oil connection level, using a flat chisel.
1.24.3
3. List of tightening torques for factory standard 4122
(Assembly instructions for piston and piston nut)
The date indicates the latest version of this table. Edition: 14.09.2007
This document is not covered by the revision service.
NU Preload Piston rod bearing

4122- Torque Turning distance Turning angle
... Mv [Nm] [mm] ~ [°]
001
011 50 7 +1 10
016 100 10 +1 12
017 100 10 +1 12
026 100 9 +1 10
027 100 10 +1 11
031 100 8 +1 8
036 100 8 +1 9
037 100 10 +1 9
039
041 150 9 +1 7
046 200 12 +1 10
047
051
052
053 200 25 +1 18
061 200 10 +1 7
151 400 14 +1 6
1.24.4
Service Manual Lubricants and operating fluids
General information to change lubricants and operating fluids
Lubricants and operating fluids
1 General information to change lubricants and operating fluids
Note!
The quantities given in the lubrication and operating fluid chart as well as on the lubrication chart in
the cab are only guide values.
X Check the level in the corresponding component after each oil change or refill.
Note!
Adhering to regulations for lubrication, level checks and changing of operating fluids guarantees a
high degree of reliability and a long service life for the machine.
It is particularly important to adhere to the oil change intervals and use the specified type of lubri-
cant.
X Observe the following when using and checking lubricants and operating fluids:
– see "Lubricants and operating fluids"
– see "Inspection and maintenance schedule"
Note!
Cleanliness is of the utmost importance when changing oil.
X Clean all filler plugs, filler covers and drain plugs and their surroundings before opening.
X If possible, drain the oil when it is at operating temperature.
X Ensure that old oils are collected and disposed of in an environmentally acceptable manner, in-
cluding removable oil filter cartridges.
Danger!

When checking and changing lubricants and operating fluids, ensure that the following precautions are adhered to:
X Unless otherwise indicated, carry out all work on the machine on level, solid ground and with the
engine shut down.
X Whenever you access the engine compartment, always secure the cover and side doors to pre-
vent them from accidentally falling back or closing.
X Only refuel the machine when the engine is shut down, do not smoke and avoid open flames.
X Turn the battery master switch to position 0 (off) and remove the ignition key.
1.50.1
copyright by
MJFCIFSS
Lubricants and operating fluids Service Manual
Lubricant table
2 Lubricant table
Designation Medium Symbol Classification Name Viscosity
Diesel engine Engine oil Refer to the instructions of the engine manufacturer (see Deutz ma-
nual)
Hydraulic system Hydraulic oil Liebherr Hydraulic Basic 68 ISO VG 68

(System capacity / tank capacity) Liebherr Hydraulic Basic 100 ISO VG 100
Liebherr Hydraulic HVI ISO VG 46 (32-68)
Liebherr Hydraulic Plus ISO VG 46 (32-68)
Liebherr Hydraulic Plus Arctic VG 15-46
Engine oil API - CD / ACEA - E1 SAE 10W

(MB 226.0 and 227.0) SAE 10W-30
SAE 10W-40
API - CD, CE, CF / ACEA - E2, E3, SAE 15W-40
E4 SAE 20W-20
(MB 227.5, 228.1, 228.3 and 228.5) SAE 30W
Slewing gear mechanism Gear oil API-GL-5 SAE 80W-90

(as stop brake) MIL-L 2105 B, C or D - alternatively -
SAE 90 LS
Slewing gear mechanism Gear oil API-GL-5 SAE 90 LS

(as positioning slewing brake) MIL-L 2105 B
Transmission Engine oil ZF TE-ML 07 SAE 10W-30

SAE 10W-20
SAE 10W-40
Travel gear Gear oil ZF TE-ML 07 SAE 80W-90

SAE 90
Rigid axle Gear oil API-GL-5 SAE 90 LS

MIL-L 2105 B
ZF TE-ML 05
Wheel hubs of the rigid axle Gear oil API-GL-5 SAE 90 LS

MIL-L 2105 B
ZF TE-ML 05
Steering axle Gear oil API-GL-5 SAE 90 LS

MIL-L 2105 B
ZF TE-ML 05
Wheel hubs of the steering axle Gear oil API-GL-5 SAE 90 LS

MIL-L 2105 B
ZF TE-ML 05
Tracks and gearing of the slewing Grease Liebherr universal grease 9900 KP2k Consistency 2
ring, bearing of the equipment NLGI grade
Hinges, joints, locks Engine oil - - -
Sealing rubber on doors and co- Silicone spray - - -

vering sections or talcum pow-
der
Tab. 1 Lubricant table
1.50.2
copyright by
MJFCIFSS
Fuels, lubricants and process chemicals
3 Fuels, lubricants and process chemicals
Designation Medium Symbol
Fuel tank Conventional diesel fuel with <= 0.5 % sulphur content
Coolant Corrosion inhibitor and antifreeze agent
Windscreen washer system Conventional windscreen cleaning agent or denatured alcohol -
Coolant of air-conditioning system R 134 a -
Refrigeration oil in a/c compressor PAG ZXL 100 PG -
Tab. 2 Fuels, lubricants and process chemicals
4 Fuels and lubricant for the diesel engine
For details and specifications regarding the diesel fuel, lubricant and coolant for the diesel engine,
see Deutz manual.
5 Hydraulic oil
Hydraulic oils must meet the requirements outlined below.

Non-compliance with these requirements shall void all warranty and liability by LIEBHERR.
Maximum water content of hydraulic oil: < 0.1 %
5.1 Hydraulic oil

LIEBHERR recommends using the following hydraulic oils in its machines (depending on tempera-
ture range):
Tab. 3 Hydraulic oil for use as hydraulic oil (ISO classes)*
1.50.3
copyright by
MJFCIFSS
Hydraulic oil
A Ambient temperature
B Cold-start range with warm-up instruction
C Operating range
* temperature-based selection of the ISO class

Liebherr Hydraulic Plus and Liebherr Hydraulic Plus Arctic are suitable for both biological as well as
prolonged operation.
Use only LIEBHERR hydraulic oils. The use of other oils is not permitted. If LIEBHERR oils are not
available locally, use one of the motor oils listed in the following chapter see 5.2 (before choosing an
oil, contact our customer service department).
5.2 Engine oil

If you wish to use other products, it is your responsibility to obtain a warranty declaration from the oil
supplier.
Engine oils that are to be used as hydraulic oils must conform to the following specifications:
Single grade oils (1): API - CD / ACEA - E1

(MB 226.0 and 227.0)
Multigrade oils (2): API - CD, CE, CF / ACEA - E2, E3, E4
(MB 227.5, 228.1, 228.3 and 228.5)
Tab. 4 Engine oils for use as hydraulic oil

Tab. 5 Engine oil for use as hydraulic oil (SAE classes)*
A Ambient temperature 1 Single grade engine oil

B Cold-start range with warm-up instruction 2 Multigrade oils
C Operating range
* temperature-based selection of the SAE class

** for deviating viscosity grade: consult the LIEBHERR customer service department
1.50.4
copyright by
MJFCIFSS
Biodegradable hydraulic oils
5.3 Warm-up instruction

The black bar B indicates that the ambient temperatures are maximum 20 °C below the operating
range C.
In the event of a cold start at an ambient temperature below range B, the following warm-up instruc-
tion applies to the hydraulic oil:
X 1. Start the diesel engine and run it at approx. 1 / 2 rated speed. Carefully activate the working
hydraulics. Operate the hydraulic cylinder and move them to the stop. After approx. 5 minutes,
start the travel hydraulics. Warm-up time: approx. 10 minutes
After a cold start at even lower ambient temperatures, the following warm-up instruction applies:
X 2. Before starting the engine, warm up the hydraulic oil tank. Then proceed according to the warm-
up instructions in 1.
6 Biodegradable hydraulic oils
Caution!
Risk of damage to the hydraulic unit!
When mixing ester-based biodegradable hydraulic oils with mineral oils, there is a risk of aggressive
chemical reactions, which can damage the hydraulic equipment.
X Do not mix biodegradable hydraulic oils from different suppliers, and never mix with mineral oils.
The use of bypass filters is mandatory.

Depending on the temperature range, LIEBHERR recommends its poly-alpha olefin (PAO, HEPR)
oils that are biodegradable according to CEC-L-33-A-93:
Liebherr Hydraulic Plus or Liebherr Hydraulic Plus Arctic
If these oils are not available locally, use one of the following oils (before choosing an oil, contact our
customer service department).
Fully saturated synthetic ester-based oils, HEES
Before using biodegradable hydraulic oils, you must consult LIEBHERR.

Do not use vegetable oils, as they do not possess the necessary thermal stability.
If you wish to use other products, it is your responsibility to obtain a warranty declaration from the oil
supplier.
6.1 Monitoring, filter change and oil change
Note!
Biodegradable hydraulic oils must be checked regularly by means of an oil analysis.
– Normal operation after change of oil* an then at least every 500 operating hours
– Dust intensive application: after change of oil* an then at least every 250 operating hours
For mineral oils, an oil analysis is only required if the oil change interval is to be extended.
– Normal operation first time after 1500 operating hours, then every 500 operating hours
– Dust intensive application: at least every 250 operating hours
LIEBHERR recommends contracting WEAR-CHECK** with these analyses, and to change the oil
when indicated by the test results in the lab report (see also customer service and product informa-
tion).
1.50.5
copyright by
MJFCIFSS
Biodegradable hydraulic oils
* Change of oil = change from mineral oil to biodegradable hydraulic oil

** Yellow kit for machines with biodegradable oil filling (HEPR and HEES)
Green kit for machines with mineral oil filling
Symbol Description
Filter change for hydraulic oil
Oil sampling
Tab. 6 Key to figures
Hydraulic oil in normal use:
Tab. 7 Oil sampling and filter change in normal use
h Operating hours 1 First oil sample

a Mineral oil 2 Second oil sample
b Biodegradable hydraulic oil 3 Subsequent oil samples: every 500 operat-
ing hours
Oil change after 2000 operating hours, or when indicated by the lab report of the analysis
Intervals for the change of the hydraulic oil return filter (20 / 5 µm): first change after 500 and
1000 operating hours, then every 1000 operating hours and after each hydraulic oil change.
Hydraulic oil used in dust intensive applications:

Tab. 8 Oil sampling and filter change in machines used for dust-intensive applications
h Operating hours 1 First oil sample

a Mineral oil 2 Second oil sample
b Biodegradable hydraulic oil 3 Subsequent oil samples: every 250 operat-
ing hours
1.50.6
copyright by
MJFCIFSS
Grease and other process chemicals
Oil change after 500 operating hours, or when indicated by the lab report of the analysis
Interval for the change of the hydraulic oil return filter (10 µm): first change after 500 operating hours,
then every 500 operating hours and after each hydraulic oil change.
6.2 Instructions for the reduction of the contamination of the hydraulic oil in ma-
chines used for dust intensive applications
If the machine is normally operated with a hydraulic hammer or under similar conditions (considerable
dust generation), the hydraulic oil might become more contaminated than under normal working con-
ditions.
In order to prevent premature wear of the hydraulic components, shorten the intervals between the
oil changes (or oil samples respectively) and observe the following instructions:
– The filter cartridge(s) in the return filter must be replaced every 500 operating hours and after eve-
ry hydraulic oil change.
– Use 10-µm filter cartridges instead of the standard 20 / 5-µm cartridges.
– The 2-µm breather filter must be replaced every 500 operating hours and after every hydraulic oil
change.
Note!
Machines delivered with hydraulic hammer attachment and retrofitted hydraulic hammer kits are al-
ready fitted with 10-µm filter cartridges in the return filter.
7 Grease and other process chemicals
Medium Description / manufacturer

Grease for central lubrication sys- Liebherr recommends using the following products for the lu-
tem, general lube points brication of the machine, and in particular of the slewing ring
roller bearings, bolts, crown gears, axles and screws:
- Liebherr Universalfett 9900

- Liebherr Universalfett Arctic (for low-temperature operation)
The grease must conform to specification KP2k, consistency

grade 2, NLGI grade according to DIN 51818 and DIN 51825
or EP 2 according to NF-T-60 132.
The grease must consist of a lithium complex with a VKA val-
ue of minimum 2300 N according to DIN 51350 or ASTM D
2596 respectively.
Contact spray for slip rings Cramolin
Lubricant for pistons, piston nuts, Gleitmo 800
also used for the mounting of piston
rod bearings at hydraulic cylinders
Special corrosion inhibitor for mount- Castrol-Tarp
ing recesses for sealing elements at
hydraulic cylinders
Tab. 9 Grease and other process chemicals
1.50.7
copyright by
MJFCIFSS
Grease and other process chemicals
1.50.8
copyright by
MJFCIFSS

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2
1.55.4

01 1

4 + " $ (<)'" *
**#**-
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2
1.55.5

01 1

4 + " $ (<)'" *
**#**-
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2
! 1.55.6

01 1

4 + " $ (<)'" *
**#**-
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,, ,I3 3
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764 I35564,)
,, ,I3 3
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>>76 (75 73&734576) 53>) 53565I, ,,7 I653( .0F/
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/1
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Service Manual
SUBGROUP - INDEX
Section Group Type
Special tools - General information 2.01.1 A 312 LI-TCD 36220-

A 314 LI-TCD 30694-
A 316 LI-IND-TCD 29503-
A 316 LI-TCD 29120-
R 313 LI-TCD 39171-
R 317 LI-TCD 30019-
Special tools for diesel engines 2.03.1 A 314 LI-TCD 30694-

A 316 LI-IND-TCD 29503-
A 316 LI-TCD 29120-
R 317 LI-TCD 30019-
Special tools for hydraulic unit 2.05.1 A 312 LI-TCD 36220-

A 314 LI-TCD 30694-
A 316 LI-IND-TCD 29503-
A 316 LI-TCD 29120-
R 313 LI-TCD 39171-
R 317 LI-TCD 30019-
Special tools for electric systems 2.06.1 A 312 LI-TCD 36220-

A 314 LI-TCD 30694-
A 316 LI-IND-TCD 29503-
A 316 LI-TCD 29120-

R 313 LI-TCD 39171-
R 317 LI-TCD 30019-
Special tools for gears 2.07.1 A 312 LI-TCD 36220-

A 314 LI-TCD 30694-
A 316 LI-IND-TCD 29503-
A 316 LI-TCD 29120-
R 313 LI-TCD 39171-
R 317 LI-TCD 30019-
Special tools for axles 2.08.1 A 314 LI-TCD 30694-

A 316 LI-IND-TCD 29503-
A 316 LI-TCD 29120-
Assembly tools for hydraulic cylinders 2.12.1 A 312 LI-TCD 36220-

A 314 LI-TCD 30694-
A 316 LI-IND-TCD 29503-
A 316 LI-TCD 29120-
R 313 LI-TCD 39171-
2.1
MJFCIFSS
Service Manual
R 317 LI-TCD 30019-
Mounting device for piston rod bearings 2.13.1 A 312 LI-TCD 36220-
A 314 LI-TCD 30694-
A 316 LI-IND-TCD 29503-
A 316 LI-TCD 29120-
R 313 LI-TCD 39171-
R 317 LI-TCD 30019-
Slotted nut wrench for slewing gear 2.14.1 A 312 LI-TCD 36220-
A 314 LI-TCD 30694-
A 316 LI-IND-TCD 29503-
A 316 LI-TCD 29120-
R 313 LI-TCD 39171-
R 317 LI-TCD 30019-
Mounting device for slewing gear 2.15.1 A 312 LI-TCD 36220-

A 314 LI-TCD 30694-
A 316 LI-IND-TCD 29503-
A 316 LI-TCD 29120-
R 313 LI-TCD 39171-
R 317 LI-TCD 30019-
Mounting device for travel gear 2.16.1 R 313 LI-TCD 39171-

R 317 LI-TCD 30019-
2.2
MJFCIFSS
Service Manual Special tools - General information
Special tools - General information
for maintenance and repair

Machi
Picture no. Designation Application
Size ID no. ne
1 Measuring neck NW 10 7002404 all

2 NW 12 7008688 types
4 Pressure gauge con- R 1/2" 7002436 all

nection types
5 Pressure gauge direct R 1/2" 7002435 all

connection types

7 High-pressure hose 1,000 7002437 all Connection of the pressu-
length mm types re gauges to all measu-
7002475 ring points (measuring
8 1,500 neck no. 1/2 and screw
mm couplings 10-14)
10 Screw coupling as- M10X1 5005180 all

11 sembly, complete M12X1.5 7402580 types

12 M14X1.5 5004002
13 M16X1.5 7361345
14 R 1/4" 7362579
2.01.1
copyright by
MJFCIFSS
Special tools - General information Service Manual
Machi
Size ID no. ne
15 Pressure gauge 0-1.6 bar 8042577 all Measuring of operating

types pressures of one or more
16 0-1.6 bar 8042578 hydraulic circuits.
*
17 0-10 bar 5002865 * glycerine dampened
*
18 0-40 bar 7361288
*
19 0-60 bar 5002867
*
20 0-250 7361285
bar *
21 0-400 7500002
bar *
22 0-600 5002866
bar *
30 Differential pressure 10288229 all Measuring of difference
measuring kit, consis- types Up between the pump
ting of: and the LS pressure.
30.1 10288155
1 manual measuring
device 3010
30.2 10288152
1 data cable
30.3 10288154
2 measuring cables
30.4 0-600 10288153
2 pressure sensors bar
30.5 10288151
1 power adapter
30.6 7025273
Vehicle connecting ca-
ble see sensors on

30.7 not included in delive- 6140626 01 Page 6
30.8 ry! 6140647 01
pressure sensors
pressure sensors
33 Fitting 4901372 all Pressure compensation
types in connection with tool no.
34 Measuring neck with 7002404 30
metal cap
35 Union nut 4774002
36 Cutting ring 4774001

2.01.2
copyright by
MJFCIFSS
Machi
Size ID no. ne
44 Measuring adapter 8504231 all Measuring of current at

types pump regulation
45 Adapter 9956422 all Measuring of the inducti-

types ve pickup B12 from 3-pin
(LH) to 2-pin (Deutz), in
conjunction with tool no.
44
46 measuring cables 9956436 all Measuring and testing of

types solenoid valves
60 Piezzo speed A 2106 10286429 all Measuring of engine

counter types speed via pulse frequen-
cy of injection line
62 Ornel speed meter HT 460 7006974 all Measuring of speed with Document is registered under: 1030314 - 29.01.2009
types reflective strips
63 Shimpo speed meter DT 205 7364284
Strips
64 614063201 with no. 63
2.01.3
copyright by
MJFCIFSS
Machi
Size ID no. ne
65 Multimeter with digital Chauvin 10018500 all Measuring of voltage,

display Arnoux types current and resistance in
electric components and
valves
70 Thermometer 10024185 all Monitoring of temperatu-

non-contact types re of a medium / outside
(infrared) temperature of a unit
GTH
72 Thermometer with pro- 1150 7020372
be and sensor (mag-
netic)
80 Hand pump 8145666 all Sampling of oil for analy-

types sis
82 Sampling valve for oil 7019068

samples, alternative to
hand pump 80
84 Mineral oil analysis kit * no. 1 8145660 all 1 oil sample

types
85 10029626 4 oil samples
*Analyses carried out by WAER

CHECK Germany, lab report in
German
88 Bio oil analysis kit * no. 3 7026817 all 1 oil sample
types

*Analyses carried out by WAER

CHECK Germany, lab report in
German
2.01.4
copyright by
MJFCIFSS
Machi
Size ID no. ne
90 REFCO vacuum pump RD-4 7027552 all Maintenance and repair

types of a/c system
91 ITE filling hose, blue 1,500 7027553 all See item 90

mm types
92 ITE filling hose, yellow 1,500 7027554

mm
93 ITE filling hose, red 1,500 7027555

mm
94 ITE HGV coupling 253a 7027556 all See item 90

types
95 ITE HGV coupling 254 a 7027557
96 4-valve test fittings M4WS5 7027558 all Maintenance and repair

C types of a/c system

100 Dismantling tool M37X1 9583459 all Dismantling of grapple
101 M42X1.5 9583521 types bolts
102 M48X1.5 9583522
2.01.5
copyright by
MJFCIFSS
Machi
Size ID no. ne
105 Universal Passfix pul- M42X1.5 9584738 all Removal of Passfix bolts
ler M48X1.5 types
M58X1.5
120 Diagnostic instrument 5010474 all Diagnostics of D5 WS au-

types xiliary heating
121 Adapter cable 9614382 Connection to cable har-

ness in right bracket
122 Adapter cable 10025620 Direct plugging to the he-

ating device
130 Testing tool for cooling 7029179 all Pressurisation of engine
system types cooling system (leakage
test)
140 Torque wrench 4-20 Nm 10045464 all Tightening the hose

types clamps
150 B20 pressure switch 9645488 all Testing of switching pres-

conversion kit types sure (dropping) of B20
consisting of: pressure switch
151 Screw-in stud 7617216
152 T-connection fitting 7405617
153 Measuring piece 7409919
154 Screw nozzle 7368150
160 Hand pump with pres- 10454803 all Leakage test of back-
sure gauge types pressure line at particle

filter installation
2.01.6
copyright by
MJFCIFSS
Scope of delivery of the Litronic measuring system

Depending on the requirements, there might be a need for various additional adapters and cables,
which must be ordered separately.
Item Sensors ID no.

2 OEM pressure sensor, measuring range 0 - 1000 bar, output 0 - 20 mA 1001 8329
3 OEM pressure sensor, measuring range 0 - 600 bar, output 0 - 20 mA 6* 6140 624 01
4 OEM pressure sensor, measuring range 0 - 60 bar, output 0 - 20 mA 3* 6140 625 01
5 OEM pressure sensor, measuring range 0 - 10 bar, output 0 - 20 mA 1002 7591
6 OEM pressure sensor, measuring range -1 to +6 bar, output 4 - 20 mA (LWE) 5718 886 08
7 MINIMESS direct connection pressure sensor, 1620 screws 6* 6140 626 01
8 MINIMESS direct connection pressure sensor, 1620 screws, angled by 90° 3* 6140 647 01
9 Pt 100 temperature sensor, measuring range -50 °C to +200 °C 1* 6140 627 01
10 MINIMESS p / t coupling, screw series 1620, G 1/4" 1* 6140 628 01
11 MINIMESS P / T coupling, screw coupling 1620, M10 x 1.5 1* 1004 1274
12 RE 4 - 10 measuring turbine, measuring range 1 to 10 l/min 1* 5010 031
13 RE 3 - 75 measuring turbine, measuring range 7.5 to 75 l/min 1* 6410 629 01
14 RE 3 - 300 measuring turbine, measuring range 15 to 300 l/min 0* 6140 630 01
15 RE 3 - 600 measuring turbine, measuring range 25 to 600 l/min 2* 5009 492
16 DS 03 speed sensor, measuring range 1 to 9999 rpm 1* 6140 631 01
17 Spare reflector foil kit 1* 6140 632 01
18 Magnet holder, for DS 03 speed sensor 1* 6140 633 01
19 Inductive sensor for speed measurement 1* 6140 634 01
Item Accessory ID no.

20 Transport case for RE 3 measuring turbine 1* 6140 635 01
21 MK 12 measuring cable for the connection of the sensors, length 12 m 12* 6140 636 01

24 Power supply cable for connection to the on-board power system, length 6 m 1* 6140 639 01
25 Power supply cable for connection to the on-board power system, length 12 m 0* 6140 640 01
26 DPU 411 thermal printer with power adapter 0* 6140 641 01
27 Thermal paper rolls for DPU 411 0* 6140 642 01
28 Centronics data cable, length 2 m (for DPU 411) 0* 6140 643 01
29 RS 232 data cable, length 2 m (for connection to PC) 1* 9684 327
30 AK 12 adapter cable (for speed measurement with GLR testing instrument) 1* 6140 648 01
31 Litronic Service Program, German version (for DOS operating system) 0* 6140 646 01
32 Evaluation software (d / e / f) on CD-ROM (for Windows, 16 bit) 1* 6004 401

33 Evaluation software (d / e / f) on CD-ROM (for Windows, 32 bit)
34 Measuring adapter for current measurement A 309 - R 317 Litronic 1* 8504 231
36 Y-adapter for current measuring Junior Timer plug 1* 9956 436
37 3-to-2 pin plug adapter 1* 9956 422
* number of units for recommended basic equipment
2.01.7
copyright by
MJFCIFSS
2.01.8
copyright by
MJFCIFSS
Service Manual Special tools for diesel engines
Special tools for diesel engines
for the maintenance and adjustment of DEUTZ diesel engines

Machi
Picture No. Designation Size ID no. Application
ne
1a Compression pressure 8008782 all Measurement of compres-
tester types sion pressure
1b Diagram sheets for 100 10012817

item 1a units
2 Connecting piece for 10455340 all Insert at the position of the

compression pressure types injection valve
tester
10 V-belt measuring in- Krikit 7019872 all Measurement of V-belt ten-

strument types sion

14 Torx too kit 7014716 all
types
22 Torx insert key kits for E 14 7019851 all

(long design) types
24 E 20 7019852
2.03.1
copyright by
MJFCIFSS
Special tools for diesel engines Service Manual
Machi
ne
26 Socket spanner insert 10455333 A 314 - In conjunction with item no.
for valve play adjust- R 317 42
ment
28 Socket spanner insert WS 15 10455345 A 314 -

for valve sensors R 317
30 Socket spanner insert WS 22 10455344 A 314 -

for main bearing R 317
32 Slotted nut wrench 10455339 A 314 -

for cable plug R 317
36 Torque wrench 7019854 all

types
38 Socket open spanner 10455351 A 314 -

for lock nut at valve R 317
play adjusting screw
WS 13
2.03.2
copyright by
MJFCIFSS
Machi
ne
40 Open box end spanner 10455352 A 314 - In conjunction with item no.
R 317 42
42 Rotary angle plate 10413142 A 314 -

R 317
44 Washer 10455341 A 314 - In conjunction with item no.

R 317 46
46 Assembly lever for cy- 10455337 A 314 -

linder bearing sleeve R 317
installation

48 Assembly lever for val- 10455342 A 314 -
ve installation R 317
50 Assembly lever for val- 10455334 A 314 -

ve installation R 317
2.03.3
copyright by
MJFCIFSS
Machi
ne
52 Assembly tool for pen- 10455336 A 314 -
cil-type glow plugs R 317
54 Mounting tool for crank 7021676 A 314 -

shaft seals, front (side R 317
opposite to flywheel)
56 Mounting tool for crank 10455335 A 314 -

shaft seal, rear (fly- R 317
wheel side)
60 Valve seal clamp 10294730 all

types
64 Wheelspin device 10294732 A 314 /

R 317
2.03.4
copyright by
MJFCIFSS
Machi
ne
66 Wheelspin device 10294733 A 314 /
R 317
70 Piston ring mounting 7009319 all

pliers types
72 Pulling tool for injector 10455338 A 314 /

seal ring removal R 317
74 Lever tool for injector 10455353 A 314 /

dismantling R 317

76 Special spanner for 10294736 A 314 /
high-pressure line R 317
2.03.5
copyright by
MJFCIFSS
Machi
ne
78 Slide hammer 8008803 all
types
2.03.6
copyright by
MJFCIFSS
Service Manual Special tools for hydraulic unit
Special tools for hydraulic unit
for the maintenance, repair and adjustment of the hydraulic unit

Machi
Picture no. Designation Size ID no. Application
ne
10 Special spanner for WS 17 9359414 all Adjustment of the primary
pressure-relief valves types and secondary valves in the
control valve block
11 WS 19 9210371
20 Safety cap WS 10 7009315 all Securing the adjusting

types screws
at the hydraulic units
21 short WS 13 7023492
22 long WS 13 l 7615515
23 WS 17 7380629
24 short WS 19 7009316
25 long WS 19 l 7009317
30 Mounting sleeve see group 2.12 all Mounting of O-rings and

types Stepseal rings onto pistons
of hydraulic cylinders and
control pistons of variable-
displacement pumps and re-
gulating motors

40 Expanding sleeve see group 2.12 all See tool no. 40
types
50 Piston wrench see group 2.12 all

types
Diagram of manufacture,
see sheet 2.12-01
A 312 LI-TCD - R 317 LI-TCD 2.05.1

copyright by
MJFCIFSS
Special tools for hydraulic unit Service Manual
Machi
ne
60 Piston wrench see group 2.12 all Loosening and tightening of
types piston nut
61
62
63
64
70 Socket wrench for WS 41 9245656 all Dismantling and mounting of

threaded bushing types damping plugs for two-side
end-of-travel cushioning of
hydraulic cylinders
80 Removal tool for piston M16 9951120 all Removal of piston rod bea-
rod bearing types rings at hydraulic cylinders
M20 9959261
M24 9959262
90 Filling device, complete W 24x 8145359 all Checking and filling of gas
with adapter and hose 1-1/4" types accumulator as well as pis-
3.0m ton and membrane accumu-
lator
W 32x
1-1/4“
3.0m
110 Removal rod M6 9288234 A 312 - Dismantling and mounting of

R 317 the pressure balance piston
in the LSC control block
120 Pin wrench 9922975 A 312 - Dismantling and mounting of

R 317 the check valves in connec-

tion K (with radiator bypass
valve).
2.05.2 A 312 LI-TCD - R 317 LI-TCD

copyright by
MJFCIFSS
Service Manual Special tools for hydraulic unit
Machi
ne
135 Screw-out direction Ø 10 10114826 A 312 - Dismantling of the check val-
mm R 317 ve 123 in the LUDV system
140 Clamping device for Ø 20 10017281 all Clamping of spools during

spool mm types dismantling and mounting of
piston elements
Ø 25 10017282
mm
Ø 32 10017283
mm
160 Mounting sleeve Ø 25 9951457 all Mounting of Turcon-Glyd

mm types rings and scraper rings on
161 Ø 22 9951508 the plunger piston of LIKU-
mm FIX couplings
162 Ø 45 9966421
mm
163 Ø 25 9951458
mm
180 Vacuum pump, comple- 00A7. 7405073 all Retaining of hydraulic tank
te 300 types content
consisting of:

Pump no. 180, vacuum
control valve no. 181
with sealing, hose with
filter no. 187.
181 10097130
Vacuum control valve,
complete
184 Connecting piece to 7002240

185 tank, consisting of: 7407155
Screw-in stud
186 Cone RED connection 7024875
16/8S
Straight nipple
A 312 LI-TCD - R 317 LI-TCD 2.05.3

copyright by
MJFCIFSS
Special tools for hydraulic unit Service Manual
Machi
ne
200 Mounting sleeve see group 2.12 all Calibration of the seal rings
types during the installation of the
piston in the cylinder
(tool no. 950 in the Lidos)
210 Mounting sleeve see group 2.12 all Installation of the piston rod
types bearing on specially shaped
piston rods
(tool no. 960 in the Lidos)
220 Intermediate flange/ 1/2“ 9916093 all Measuring of load pressure

intermediate block with types and leak oil volumes in line
con- to consumer
nection
R1/4“
221 3/4“ 9765104
222 1“ 9759353
223 11/4“ 9309326
225 Sealing plate 1/2“ Installati- all Sealing of hoses and SAE
- on, types connections
1 1/2“ see Tab. 1
Sealing plates for the sealing of hose connections and SAE flanges
Plate without Plate without puncture, with

Size Plate with puncture O-ring Kantsil ring
puncture thread
1/2“ 9107878
3/4“ 9194264
1“ 9174163 9170178 7264508 7367611
1 1/4“ 9413318 9420882 7264687 7367612
1 1/2“ 9465987 7360048 7367613
1/2“ 9327330
3/4“ 9327331
1“ 9327332
1 1/4“ 9327333
1 1/2“ 9327334
Tab. 1 Overview of sealing plates
2.05.4 A 312 LI-TCD - R 317 LI-TCD

copyright by
MJFCIFSS
Service Manual Special tools for electric systems
Special tools for electric systems
for the maintenance and repair of electrical plug-type connectors
Fig. 1 Mate-N-LOK and DT plugs
Fig. 2 Juniortimer and JPC plugs

2.06.1
copyright by
MJFCIFSS
Special tools for electric systems Service Manual
Picture No. Desciption Size Order no. Model Application

10 To crimp contacts for MATE-N- 7367025 all ty-
LOK 1.5mm2 leads pes
12 To crimp contacts for MATE-N- 7366314 all ty-

LOK 2.5mm2 connectors pes
15 Extraction tool to remove crimped 7366655 all ty-

contacts from MATE-N-LOK con- pes
nectors
20 Socket contact for 1.5 mm2 wires 6202619 all ty-

for MATE-N-LOCK connectors pes
21 Pin contact for 1.5 mm2 wires for 6202620

MATE-N-LOCK connectors
22 Socket contact for 2.5 mm2 wires 6202591 all ty-

for MATE-N-LOCK connectors pes
23 Pin contact for 2.5 mm2 wires fo 6202592

MATE-N-LOCK connectors
28 Hand-held tool to crimp contacts 7367086 all ty-

(according to MIL-C5015, pes
VG952234, VG 955342)
29 Crimp turret to crimp contacts 7409779

DEUTSCH-type connectors with
special tool no. 28
30 Tool to crimp contacts of 8503647 all ty-

DEUTSCH - type connectors pes
2.06.2
copyright by
MJFCIFSS
Service Manual Special tools for electric systems

32 Extraction tool to re- Size 4 8503633 all ty-
move crimped con- pes
tacts from DEUTSCH-
type connectors
33 Size 8 8503632
34 Size 12 8145674
35 Size 16 8145673
36 Size 20 8503630
37 Pin contact for wires of Ø 0,8- 7368251 all ty-
DT connectors 1,0 pes
Ø 1,0- 7368406
2,0
Ø 2,0- 6905271
3,0
38 Socket contact for wi- Ø 0,8- 7368252

res of DT connectors 1,0
Ø 1,0- 7368405
2,0
Ø 2,0- 6905272
3,0
39 Stopfen / Plug / Bou- 7368253

chon
55 Extraction tool for 777-310 7022773 all ty-
WAGO connectors pes

60 IC extraction tool 8042630 all ty-
pes
61 IC mounting tool 8042629
70 Ergocrimp pliers 6004391 all ty- To crimp contacts for wires

pes of JPT (Tyco) connectors
2.06.3
copyright by
MJFCIFSS
Special tools for electric systems Service Manual

Ergocrimp matrix all ty- To crimp contacts for leads
pes
72 0.5-2.5 10016253 Junior Power Timer Nr./no.
mm2 927777-3 / 927779-3 /
927846-2
73 0.5-2.5 10016255 Junior power Timer/EDS

mm2 Nr./no. 929938-3 double
spring contact no.
929940-3
74 0.5-2.5 10016256
mm2 flat adapter no. 963745-1 /
963746-1
80 Extraction tool 7415334 all ty- To remove crimped con-
pes tacts from JPT (Tyco) con-
nectors
90 Crimp plier 10016251 all ty- To crimp littlefuse contacts

pes for leads of JPT (Tyco)
connectors, see also no.
92.
92 Ergocrimp matrix 0.5 mm2 10016252 all ty- In connection with no. 90
-3.32 pes and used to crimp contacts
mm2 for leads
receptacle no. 913053/

913065 / 913066 / 913067
/ 913069 / 913079
Double spring contact no.
913071 / 913072
2.06.4
copyright by
MJFCIFSS
Service Manual Special tools for gears
Special tools for gears
for the maintenance and repair of gear systems

Equip
Picture No. Description Size ID no. Application
ment
10 Slotted nut wrench for SAT 9202820 all Releasing and tightening of
slewing gear mecha- 225 types slotted nuts in drive/slew-
nism ing gear mechanisms (SAT
drawing, see page 2.14-
01)
20 Mounting device SAT 9202825 A 309 - Dismantling and assembly

225 R 317 of brake housing/multi-disc
brake for SAT slewing gear
mechanisms (SAT drawing,
see page 2.15-01)
30 Mounting device FAT 9981445 R- Tool used to dismantle and

350/022 machi- mount the multi-disc brake
FAT nes of the FAT slewing gear
350/032 mechanism (drawing, see
FAT page 2.16-01)
350/062

35 Mounting device for FAT 8503594 R- For the mounting of slip
slide ring seals 350/022 machi- ring seals in FAT travel
FAT nes gear systems
350/032
FAT
350/062
2.07.1
copyright by
MJFCIFSS
2.07.2
Special tools for gears
copyright by
MJFCIFSS
Service Manual
Service Manual Special tools for axles
Special tools for axles
for the maintenance and repair of axles

Picture no. Designation Size ID no. Machine Application
70 Magnetic stand MS-E 10454855 A 314/ Use to measure brake pad
3050/ 316 wear, in conjunction with
3060/ dial gauge and extension
3070
MT-E
3050/
3060/
3070
71 Dial gauge 10454856
72 Extension 10454857
80 Slotted nut wrench for MS-E 10346444 A 314/ Used to loosen and tighten
axles 3050/ 316 the slotted nuts in the pla-
3060 netary housing / hub carrier
MT-E
3050/
3060
84 Gripping piece MS-E 10450014 A 314 Used to remove the inner

3050 bearing race from the joint
housing.
In conjunction with tool no.
85 MS-E 10354109 A 316 78
3060

88 Removal insert MS-E 7011520 A 314/
3050/ 316
3060
90 Removing tool MS-E 7026311 A 314/ Used to remove the outer

3050/ 316 bearing race from the joint
3060 housing.
In conjunction with tool no.
90
2.08.1
copyright by
MJFCIFSS
Special tools for axles Service Manual
Picture no. Designation Size ID no. Machine Application

94 Removing tool MS-E 10450013 A 314 Used to pull the shaft seal
3050 ring and the bushing from
the axle housing and the
95 Removing tool MS-E 10353377 A 316 joint housing.
3060 In conjunction with tool no.
90
100 Counter piece MS-E 7026310 A 314/

3050/ 316
3060
104 Mounting tool MS-E 10450012 A 314 Used to insert the outer be-
3050 aring race in the joint hou-
sing.
105 Mounting tool MS-E 7011527 A 316

3060
110 Mounting tool MS-E 10450074 A 314 Used to insert shaft seal
3050 rings / bushings in the axle
housing and the joint hou-
sing.
111 Mounting tool MS-E 10353378 A 316 In conjunction with tool no.
3060 103
113 Handle MS-E 7011518 A 314/

3050/ 316
3060
2.08.2
copyright by
MJFCIFSS
Service Manual Assembly tools for hydraulic cylinders
Assembly wrenches for pistons of hydraulic cylinders WN 4121
Assembly tools for hydraulic cylinders
1 Assembly wrenches for pistons of hydraulic cylinders WN 4121
Fig. 1 Assembly tool (bore for mounting bolt a)
ID no. a b c d e f g h i Square
9131359 52 38 75 200 10 8 8 15 60 1/2“
9131362 60 44 85 200 14 10 10 15 65 1/2“
9231993 68 52 100 220 14 10 10 15 70 1/2“
8007364* 75 54 110 220 14 12 10 20 84 3/4“
8007364* 80 54 110 220 14 12 10 20 84 3/4“
8007365 88 63 120 250 14 12 10 20 90 3/4“
8007366 100 78 135 260 14 14 10 20 95 3/4“
9919856 115 88 150 300 14 14 10 20 105 3/4“
9196978# 125 97 170 320 14 14 10 25 110 3/4“

9196978# 130 97 170 320 14 18 15 25 110 3/4“
8007367 145 113 185 380 14 18 15 25 120 3/4“
9925117 160 125 200 420 14 18 15 25 130 3/4“
9131373 175 135 215 450 14 20 19 25 135 3/4“
9131376 220 156 280 500 14 30 28 40 158 3/4“
0541380 85 72 110 210 11 8 8 15 210 1/2“
0542336 120 100 140 240 12 8 9 152 240 1/2“
0540947 124 100 150 240 12 8 9 15 240 1/2“
0541379 145 125 170 280 11 8 9 15 280 3/4“
0540966 160 135 185 280 12 10 9 20 280 3/4“
LHB/de/Ausgabe: 05/2008
0529897 165 140 190 280 12 10 9 20 280 3/4“
Tab. 1 List of assembly wrenches (all dimensions in mm)
Note!
The dimensions of the pistons and assembly wrenches and the ID numbers can be looked up in
Lidos (* and # correspond to one wrench each)!
2.12.1
copyright by
MJFCIFSS
Assembly tools for hydraulic cylinders Service Manual
Assembly wrenches for piston nuts
2 Assembly wrenches for piston nuts
Fig. 2 Assembly wrenches for piston nuts
Size of piston nut WS Slotted nut

*WS hex. Square ID no.
ID no. paral. Ø
M30X1.5 - 7006469 44 **
M32X1.5 - 7010262 50 **
M33 X1.5 - 9226916 41 1/2“ 9921132
M36X1.5 - 9875702 50 1/2“ 9211967
M42X1.5 - 7010163 62 **
M42X1.5 - 9970088 60 1/2“ 9211967
M42X1.5 - 9113734 55 1/2“ 9921132
M50X2 - 4129202 70 1/2“ 9921123
M50X2 - 9166795 65 1/2“ 9921123

M56X2 - 9921260 80 1/2“ 9921124
M60X2 - 4129203 80 1/2“ 9921124
M65X2 - 9247441 85 1/2“ 9921133
M68X2 - 9129554 90 1/2“ 9921124
M76X2 - 9970448 100 3/4“ 9921125
M85X3 - 9142472 110 3/4“ 9921125
M95X3 - 9101411 120 3/4“ 9921126
M100X3 - 9950036 130 3/4“ 9951123
M110X3 - 9129653 / 9112934 149 3/4“ 9921127

M120X3 - 9143685 165 3/4“ 9921128
M130X3 - 9125066 180 3/4“ 9921129
M150X3 - 9144654 210 3/4“ 9921131
M170X3 - 5008571 230 3/4“ 9921134
Tab. 2 List of piston nuts
* width over flats / ** conventional grooved socket spanner
2.12.2
copyright by
MJFCIFSS
Assembly wrenches for WN 4122 piston rod bearings
3 Assembly wrenches for WN 4122 piston rod bearings
Fig. 3 Assembly wrenches for piston rod bearings
0541665 76 62 95 210 9 6 7 15 70 1/2“
0541666 87,5 72 110 210 10 8 8 15 70 1/2“
0541063 92 75 115 210 12 8 8 15 75 1/2“
0541064 100 80 120 210 12 10 10 15 80 1/2“
0529893 110 90 130 240 12 10 10 15 90 1/2“
0542005 115 95 135 240 12 8 10 15 95 1/2“
0541667 125 98 150 240 12 10 9 15 98 1/2“
0529894 135 110 160 260 12 8 8 15 105 1/2“
0540948 140 120 160 260 12 8 8 15 110 1/2“
0541661 145 120 170 280 12 10 9 15 110 1/2“

0529895 145 120 170 280 12 12 13 15 120 1/2“
0540949 150 130 170 280 12 12 12 20 110 3/4“
0529896 170 140 200 300 12 14 13 20 110 3/4“
0541378 180 160 200 300 12 10 9 20 120 3/4“
Tab. 3 List of assembly wrenches

2.12.3
copyright by
MJFCIFSS
Assembly wrenches for version 5100 pistons
4 Assembly wrenches for version 5100 pistons
Fig. 4 Assembly wrenches for version 5100 pistons
Øa WS
Size of piston nut *WS hex. ID no.
for mounting bolts square
M120X3 175 220 3/4“ 9584641
M140X3 190 240 3/4“ 9581705
* width over flats
4.1 Assembly wrenches for pistons

Fig. 5 Assembly wrenches for pistons
9249886 250 204 310 600 14 30 28 30 175 3/4“
9249741 260 176 330 600 19 36 35 40 180 3/4“
9243215 280 206 354 650 19 36 35 40 190 3/4“
2.12.4
copyright by
MJFCIFSS
Mounting and expanding sleeves
4.2 Assembly wrenches with hex nut for pistons
Fig. 6 Assembly wrenches with hex nut for pistons
mm mm mm mm mm mm mm mm
Piston Piston
ID no.
smallest largest
*SW 6-KT 4-KT l Ø Ø a b c
9600751 80 3/4“ 170 Ø110 Ø140 Ø160 525 15
9602239 85 3/4“ 170 Ø115 Ø140 Ø160 525 15
9600418 90 3/4“ 170 Ø120 Ø150 Ø160 525 15
9597668 100 3/4“ 170 Ø130 Ø160 Ø180 525 15
9600928 110 3/4“ 170 Ø160 Ø190 Ø200 525 15
9600769 120 3/4“ 174 Ø170 Ø200 Ø200 525 15
* width over flats

5 Mounting and expanding sleeves
990 mounting sleeve 991 expanding sleeve

Piston Ø
ID no. ID no.
32 9136418 9136416
32 9113100 9113099
38 9143279 9143280
40 9196902 9136417
40 9580414 9580413
45 9136419 9136417
50 9288953 9288954
63 9170510 9170512
65 9177541 9177540
70 9110556 9110402
80 9227165 9227166
2.12.5
copyright by
MJFCIFSS
990 mounting sleeve 991 expanding sleeve

Piston Ø
ID no. ID no.
85 9998618 9110404
85 9115710 9115708
90 9227161 9227162
98 9289130 9289131
100 9998626 9110405
105 9951984 9951983
106 9583670 9583671
110 9170509 9170511
110 9960483 9960502
115 9998625 9110406
120 9998778 9110407
125 9227163 9227164
125 9960484 9960503
130 9998624 9110408
135 9285578 9285579
140 9998623 9110409
150 9998622 9110410
160 9998621 9110411
170 9107931 9110412
180 9998619 9110413
180 9107932 9110413
190 9907684 9907701
190 9280862 9280863
200 9107933 9110414
Tab. 7 List of mounting and expanding sleeves
2.12.6
copyright by
MJFCIFSS
Mounting sleeves used to insert pistons into cylinders

950 mounting sleeve
Piston Ø
ID no.
65 9177543
80 9231749
90 9248893
90 9248894
100 9248895
110 9248897
120 9248898
130 9248899
140 9177541
140 9952180
160 9248909
190 9281241
210 9281240
250 9951147
260 9284918
Tab. 8 950 mounting sleeves
Note!
The mounting sleeve 950 is required to restore the shape of the expanded sealing elements to suit
the inside diameter of the cylinder (calibration).
Mounting sleeves used to mount the piston rod bearings on the piston rods
960 mounting sleeve

Piston rod Ø

ID no.
90 9282761
105 9287177
140 9926806
Tab. 9 960 mounting sleeves
Note!
The 960 mounting sleeve is required in order to prevent damage to sealing and guide elements.
2.12.7
copyright by
MJFCIFSS
2.12.8
copyright by
MJFCIFSS
Service Manual Mounting device for piston rod bearings
Tool used to dismantle piston rod bearings in hydraulic cylinders
Mounting device for piston rod bearings
1 Tool used to dismantle piston rod bearings in hydraulic cylinders
Fig. 1 Mounting device
Thread in Thread of Length of

Thread in
bearing head mounting driver mounting driver ID -no.
flange ring
M1 M2 L
M12 M16 M10 250 9951120
M16 M20 M12 270 9959261
M20 M24X2 M16 290 9959262
Tab. 1 Mounting devices sizes for various flange ring threads

2.13.1
copyright by
MJFCIFSS
Mounting device for piston rod bearings Service Manual
Tool used to dismantle piston rod bearings in hydraulic cylinders
2.13.2
copyright by
MJFCIFSS
Service Manual Slotted nut wrench for slewing gear
Tool used to remove the slotted nut in the slewing gear mechanism
Slotted nut wrench for slewing gear
1 Tool used to remove the slotted nut in the slewing gear mechanism
Fig. 1 Slotted nut wrench for Sat 225
Slewing gear type ID number

SAT 225 9202820
Tab. 1 ID numbers of slottet nut wrenches

2.14.1
copyright by
MJFCIFSS
Slotted nut wrench for slewing gear Service Manual
Tool used to remove the slotted nut in the slewing gear mechanism
Fig. 2 Technical drawing of slotted nut wrench
SAT A B C D E F G H J K L M N O P
225 90 40 30 55 71.5+0.2 77 100 95 3.8 80 35 30 40 56 7.8
Tab. 2 Dimensions
Material: 42 CrMo 4 hardened to 800 - 950 N/mm2

2.14.2
copyright by
MJFCIFSS
Service Manual Mounting device for slewing gear
Mounting device for slewing gear
Tool used to dismantle and mount the multi-disc brake of the slewing gear mecha-
nism SAT 225
Fig. 1 Mounting device of slewing gear mechanisms

Size SAT 225
A 268
B 40
C 12
D 10
E 10
F 16
G 100
H 117
ID no. 9202825
Tab. 1 List of mounting device sizes
2.15.1
copyright by
MJFCIFSS
2.15.2
Mounting device for slewing gear
copyright by
MJFCIFSS
Service Manual
Service Manual Mounting device for travel gear
Mounting device for travel gear
Tool used to dismantle and mount the multi-disc brake of the FAT 350 travel gear me-
chanism

Fig. 1 Technical drawing of mounting device
FAT 350
Size
022 / 032
A 238
B 205
C 100
D 108
E 40
F 18
G Ø16
H 15
ID no. 9981445
Tab. 1 Dimensions of mounting device (in mm)
2.16.1
copyright by
MJFCIFSS
2.16.2
Mounting device for travel gear
copyright by
MJFCIFSS
Service Manual
Service Manual
SUBGROUP - INDEX
Section Group Type
Technical data 3.09.1 A 309 LI-TCD 40998-
Technical data 3.13.1 R 313 LI-TCD 39171-
Technical data 3.16.1 A 316 LI-IND-TCD 29503-

A 316 LI-TCD 29120-
Technical data 3.17.1 R 317 LI-TCD 30019-
Maintenance- and inspection chart 3.23.1 A 312 LI-TCD 36220-

A 314 LI-TCD 30694-
A 316 LI-IND-TCD 29503-
A 316 LI-TCD 29120-
Maintenance- and inspection chart 3.26.1 R 313 LI-TCD 39171-

R 317 LI-TCD 30019-

Adjustment protocol for A 309 3.43.1 A 309 LI-TCD 40998-
Adjustment protocol for A 316 3.55.1 A 316 LI-IND-TCD 29503-

A 316 LI-TCD 29120-
Adjustment protocol R 313 3.58.1 R 313 LI-TCD 39171-

Adjustment protocol R 317 3.61.1 R 317 LI-TCD 30019-
Adjustment protocol (optional installation) 3.75.1 A 314 LI-TCD 30694-

A 316 LI-IND-TCD 29503-
A 316 LI-TCD 29120-
3.1
MJFCIFSS
Service Manual
Checking and adjusting tasks 3.84.1 A 309 LI-TCD 40998-

A 311 LI-TCD 41128-
A 312 LI-TCD 36220-
A 314 LI-TCD 30694-
A 316 LI-IND-TCD 29503-
A 316 LI-TCD 29120-
Checking and adjusting tasks 3.87.1 R 313 LI-TCD 39171-

R 317 LI-TCD 30019-
3.2
MJFCIFSS
Service Manual Technical data
A 309 Litronic
Technical data
1 A 309 Litronic
Type 1035
Valid from serial number 40998

General 1035
Weight of undercarriage with 2-point support t 3.06
Weight of basic machine with 2-point support t 8.34
Weight of backhoe bucket attachment (blade support) t 11.4
Overall length of undercarriage (with blade support) mm 4295
Overall length (including blade support) mm 8300
Overall width mm 2525
Overall height without attachment mm 3110
Rear reach from centre/slewing radius mm 1600 / 1600
Ground clearance mm 320
Break-out force at tooth kN 44.8 / 68.5
Max. drawing pull (in off-road gear and max. operating pressure) kN 78
Drive motor 1035

Type TCD 2012 L04 2V
Electronic engine control Type EMR 2
Power at rated speed according to DIN ISO 9249 kW 65 (88 PS)
Rated speed rpm 1800
Max. torque Nm 360 ± 10

at 1600 rpm
Oil volume in engine (filling quantity at oil change with filter) l 11.5
Oil quality/oil viscosity and oil change intervals see groups 1.50 and 3.23
Fuel tank capacity l 210
Additional information see group 4.06
8
Hydraulic system 1035

Hydraulic pump Type DPVO 108
Design Axial piston swash plate
pump
Max. flow l/min 194

Hydraulic oil volume (oil change with filter) l approx. 130
Hydraulic oil and filter change intervals see groups 1.50 and 3.23
Control valve block Type M7/NG 20
Rotary connection 7x Type DDF 720
Rotary connection 6x Type 815.006
3.09.1
copyright by
MJFCIFSS
Technical data Service Manual
A 309 Litronic

Boom cylinder (adjustable and gooseneck equipment) Ø piston / rod mm 115 / 70
Stick cylinder with adjustable attachment Ø piston / rod mm 90 / 60
Bucket cylinder Ø piston / rod mm 80 / 50
Swivel cylinder Ø piston / rod mm 90 / 50
Regulating cylinder with boom attachment Ø piston / rod mm 125 / 70
Support cylinder with blade support Ø piston / rod mm 110 / 50
Additional cylinders see group 7.33
Hydraulic pump / pilot control Type Gear pump
Max. flow / pilot control l/min 43
Hydraulic pump / fan drive (cooling) Type Gear pump
Max. flow / fan drive (cooling) l/min 45
Pilot control unit / working attachment / slewing gear Type VG - 7 - 4
Pilot control unit / support Type VG - 7 - 2
Pilot control unit / auxiliary equipment Type VG - 7 - 2
Additional information see group 6 / 7
Electrical system 1035

Operating voltage V 24
Battery capacity Ah 2 x 92 (in series)
Alternator voltage / current V/A 28 / 50
Starter V / kW 24 / 4.8
Slewing gear mechanism 1035

Gearbox Type SAT 225 / 240
Oil motor Type FMF 45
Max. slewing speed rpm 9.0

Oil volume in gearbox l 4.4
Slewing gear brake Type Wet multi-disc brake (ne-
gative)
Transmission 1035
Gearbox Type 2 HL 270
Oil motor Type DMVA 108
Travel speed in creeper / off-road / on-road gear km/h 1.5 / 5.0 / 20.0
Parking brake Type Wet multi-disc brake (ne-
gative)
3.09.2
copyright by
MJFCIFSS
A 309 Litronic
Axles 1035
Steering axle Type 212 / 785
Rigid axle Type 112 / 320
Oil volume in steering axle shaft l 7.1
Oil volume in steering axle wheel hub l 2 x 0.8
Oil volume in rigid axle shaft / wheel hub l 8.0 / 2 x 0.8
Total oil volume in rigid axle l 9.6
Steering axle working brake Type multi-disc brake
Rigid axle working brake Type multi-disc brake
Brake type (positive)
Additional information see groups
12.08 / 12.10 / 12.12
Tyres inch 9.00 - 20
600 / 40 - 22.5
500 / 45 - 20
Steering 1035
Hydraulic pump Type Gear pump
Flow rate l/min 29
Steering valve Type LAGS
Brake system 1035

Flow rate l/min 3.7

3.09.3
copyright by
MJFCIFSS
3.09.4
A 309 Litronic
Technical data
copyright by
MJFCIFSS
Service Manual
A 311 Litronic
Technical data
1 A 311 Litronic
Type 1036

General 1036
Weight of backhoe bucket attachment (blade support) t 12.3
Overall length (including blade support) mm 8650
Drive motor 1036

Type TCD 2012 L04 2V
Power at rated speed according to DIN ISO 9249 kW 68 (92PS)

at 1600 rpm
8

pump
Max. flow l/min 194

3.11.1
copyright by
MJFCIFSS
A 311 Litronic

Swivel cylinder Ø piston / rod mm 90 / 50



gative)
Transmission 1036
gative)
3.11.2
copyright by
MJFCIFSS
A 311 Litronic
Axles 1036
Steering axle Type 262 / 66
Rigid axle Type 162 / 62
Oil volume in steering axle shaft l 7.3 l
Oil volume in rigid axle shaft / wheel hub l 8.2 / 2 x 2.0
Total oil volume in rigid axle l 12.2
12.14 / 12.16 / 12.18
600 / 40 - 22.5
500 / 45 - 20
Steering 1036
Flow rate l/min 29
Brake system 1036

Flow rate l/min 3.7

3.11.3
copyright by
MJFCIFSS
3.11.4
A 311 Litronic
Technical data
copyright by
MJFCIFSS
Service Manual
A 312 Litronic
Technical data
1 A 312 Litronic
Type 1037

General 1037
Weight of backhoe bucket attachment (2-point support) t 13.55
Overall length (including adjusting attachment) mm 8050-8250
Drive motor 1037

Type TDC 2012 LOV4 2V
at 1600 rpm

8

pump
Max. flow l/min 230

3.12.1
copyright by
MJFCIFSS
A 312 Litronic

Support cylinder with outrigger - blade support Ø piston / rod mm 120 / 70 - 110 / 60
Additional information see groups 6. / 7.


gative)
Transmission 1037
Oil volume in gearbox l 3,0
gative)
Axles 1037
Steering axle Type 262/53
3.12.2
copyright by
MJFCIFSS
A 312 Litronic
Axles 1037
Rigid axle Type 162/55
Oil volume in steering axle housing l 8.2 l
Oil volume in rigid axle shaft / wheel hub l 10.5 l
12.20 / 12.22 / 12.24
18.00 - 19.5
315 / 80 - 22.5
600 / 40 - 22.5
Steering 1037
Flow rate l/min 34
Brake system 1037

Flow rate l/min 2

3.12.3
copyright by
MJFCIFSS
3.12.4
A 312 Litronic
Technical data
copyright by
MJFCIFSS
Service Manual
R 313 Litronic
Technical data
1 R 313 Litronic
Type 1038

General 1038
Weight of undercarriage with 600 mm base plates (standard) t 7.14
Weight of basic machine with 600 mm base plates t 11.4
Total weight with backhoe bucket attachment (600 mm base plates) t 18.1
Length of undercarriage mm 3975
Overall length (including gooseneck / adjusting attachment) mm 8650 / 8700
Drive motor 1038

Type TDC 2012 LO4 2V

at 1600 rpm
8

pump
Max. flow l/min 297

3.13.1
copyright by
MJFCIFSS
R 313 Litronic

Bucket cylinder Ø piston / rod mm 90 /60
Pilot control unit / travel drive Type 5 TH 6 NR


gative)
Travel gear 1038

Gearbox Type Gear pump
Oil motor Type A6 VE 55
Travel speed in standard / fast travel mode km/h 2.4 / 5.0
Travel brake Type multi-disc brake
Additional information see groups 11.60 or 11.65
respectively
3.13.2
copyright by
MJFCIFSS
R 313 Litronic
Brake system 1038

Drive Type D4 L / B 60 L
Running rollers Type/ D 4 L / B 60 L
num- 2x7
ber of
rollers
Support rollers Type/ D 4 L / B 60 L
num- 2x2
ber of
rollers
Number of base plates / chains (standard) Units 44 / 46
Base plate width mm 500/ 600/ 700
Specific pressure on ground (max) N/cm2 3.8/ 2.4/ 2.2

3.13.3
copyright by
MJFCIFSS
3.13.4
R 313 Litronic
Technical data
copyright by
MJFCIFSS
Service Manual
A 314 Litronic
Technical data
1 A 314 Litronic
Type 1039
valid from serial no. 30694

General 1039
Weight of the undercarriage with 2-point outrigger t 5,28
Weight of the basic machine with 2-point outrigger t 11,4
Weight with backhoe attachment (2-point outrigger) t 15,35
Total length of undercarriage (with dozer blade) mm 4660
Total length (with gooseneck- / adjustable- boom) mm 7850-8400 / 8200-8800
Total width mm 2550
Total heigth without attachment mm 3120
Tail clearance fom center / swing radius mm 2065 / 2065
Ripping force / break-out force on tooth KN 66,0 / 79,1
Drawbar pull max. (in off-road gear and max. system pressure) KN 83
Engine 1039
Type TDC 2013 LOV4
Performance at rated rpm according to DIN ISO 9249 KW 90 (122 PS)
Rated rpm rpm 1800
max. torque Nm 525 ± 10
at 1600 rpm

Oil quantity in engine (total quantity for oil change with filter) l 15,0
Oil quality / -viscosity and oil change interval refer to group 1.50
and 3.23
further details refer to group 4.10
8

Hydraulic pump Typ DPVO 165
pump
max. flow l/min 297

Hydraulic oil quantity (oil change with filter) l appr.210
Hydraulic oil- and filter change interval refer to group 1.50 and
3.23
7-way rotary connection Type DDF 720
6-way rotary connection Type 815.006
3.14.1
copyright by
MJFCIFSS
A 314 Litronic

Boom cylinde (Adjustable- and gooseneck boom attachment) Ø piston / mm 110 / 70
rod
Stick cylinder on adjustable boom attachment Ø piston / rod mm 115 / 75
Support cylinder for outrigger - dozer blade Ø piston / rod mm 120 / 70 - 110 / 60
Adjusting cylinder for adjustable boom Ø piston / rod mm 140 / 80
further cylinders refer to group 7.36
Hydraulic pump / servo control Type Gear pump
max.flow / servo control l/min 36
Hydraulic pump / fan drive (cooling) Typ Gear pump
max. flow / fan drive (cooling) l/min 45
Pilot control valve / attachment / swing Type VG - 7 - 4
Pilot control valve / outrigger Type VG - 7 - 2
Pilot control valve / additional control Type VG - 7 - 2
further details refer to group 6. / 7.

Battery capacity Ah 2 x 92 (connected in se-
ries)
Alternator Voltage / Current V/A 28 / 55
Starter motor V / KW 24 / 4,8
Swing gear 1039

Oil motor Typ FMF 45
Swing speed max. rpm 9,0

Oil quantity in gearbox l 4,4
Oil quality / -viscosity and oil change interval refer to group 1.50 and
3.23
Swing brake Type wet disc brake (negative
acting)
Transmission 1039
Oil Motor Type DMVA 108

Travel speed in creeper-/ off-road-/ on-road gear km/h 1,5 / 5,0 / 20,0
Oil quantity in gearbox l 3,0
Oil quality / -viscosity and oil change interval refer to group 1.50 u. 3.23
Parking brake Typ wet disc brake (negative
acting)
3.14.2
copyright by
MJFCIFSS
A 314 Litronic
Axles 1039
Steering axles Type MS - E 3050
Rigid axle Type MS - E 3050
Oil quantity in axle housing steering axle l 9,0 l
Oil quantity in wheel hub steering axle l 2 x 2,4
Oil quantity in axle housing rigid axle l 10,0 l
Oil quantity in wheel hub rigid axle l 2 x 2,4 l
Oil quantity / -viscosity and oil change interval refer to group 1.50 and
3.23
Operating brake steering axle Type disc brake
Operating brake rigid axle Type disc brake
Brake type (positive acting)
further details refer to group
12.30 / 12.32 / 12.34
Tires Inch 10.00 - 20
18.00 - 19,5
600 / 40 - 22,5
Steering 1039
Flow l/min 34
Brake system 1039

Hydraulikpumpe Type Gear pump

Flow l/min 2,0
3.14.3
copyright by
MJFCIFSS
3.14.4
A 314 Litronic
Technical data
copyright by
MJFCIFSS
Service Manual
Service Handbuch Technical data
A 316 Litronic
Technical data
1 A 316 Litronic
Typ 1040 / 1041
Type 1040 1041

Valid from serial number 29120 29503
General 1040 1041

Weight of the undercarriage with 2-point outrigger t 4,94 / 6,26
Weight of the basic machine with 2-point outrigger t 13,0 / 16,8
Weight with backhoe attachment (2-point outrigger) t 16,5 / 21,55
Total length of undercarriage (with dozer blade) mm 4660 =
Total length (with gooseneck- / adjustable- boom) mm 8400-8900 / / 8360
8450-8950
Total width mm 2550 =
Total heigth without attachment mm 3130 =
Tail clearance fom center / swing radius mm 2260 / 2260 =
Ground clearance mm 360 =
Ripping force / break-out force on tooth KN 66,8 / 98,3 -/-
Drawbar pull max. (in off-road gear and max. system pressu- KN 110 =
re)
Engine 1040 1041

Type TCD 2013 LOV4 =
Performance at rated rpm according to DIN ISO 9249 KW 94 (128 PS) =

Rated rpm rpm 1800 =
max. torque Nm 550 ± 10 =
at 1600 min-1
Oil quantity in engine (total quantity for oil change with filter) l 15,0 =
Oil quality / -viscosity and oil change interval efer to group 1.50 =
and 3.23
Fuel tank capacity l 290 =
further details refer to group 4.10 =
8
Hydraulic system 1040 1041

Hydraulic pump Typ DPVO 165 =
Design Axial piston swash =
plate pump
max. flow l/min 297 =
Hydraulic oil quantity (oil change with filter) l appr. 210 =
Hydraulic oil- and filter change interval efer to group 1.50 =
and 3.23
3.16.1
copyright by
MJFCIFSS
Technical data Service Handbuch
A 316 Litronic
Hydraulic system 1040 1041

Control valve block Type M7/NG 20 =
7-way rotary connection Type DDF 720 =
6-way rotary connection Type 815.006 =
Boom cylinde (Adjustable- and gooseneck boom attach- mm 120 / 70 =
ment) Ø piston / rod
Stick cylinder on adjustable boom attachment Ø piston / rod mm 120 / 80 110 / 70
Bucket cylinder Ø piston / rod mm 100 / 70 -
Support cylinder for outrigger - dozer blade Ø piston / rod mm 120 / 70 - 110 / 60 =
Adjusting cylinder for adjustable boom Ø piston / rod mm 140 / 80 -
further cylinders refer to group 7.37 =
Hydraulic pump / servo control Type Gear pump =
max.flow / servo control l/min 36 =
Hydraulic pump / fan drive (cooling) Typ Gear pump =
max. flow / fan drive (cooling) l/min 45 =
Pilot control valve / attachment / swing Type VG - 7 - 4 =
Pilot control valve / outrigger Type VG - 7 - 2 =
Pilot control valve / additional control Type VG - 7 - 2 =
further details refer to group 6. / 7. =
Electrical system 1040 1041

Operating voltage V 24 =
Battery capacity Ah 2 x 92 (connected in =
series)
Alternator Voltage / Current V/A 28 / 55 =
Starter motor V / KW 24 / 4,8 =
Swing gear 1040 1041

Gearbox Type SAT 225 / 218 =
Oil motor Typ FMF 45 =
Swing speed max. rpm 9,0 =
Oil quantity in gearbox l 4,4 =
Oil quality / -viscosity and oil change interval refer to group 1.50 =
and 3.23
Swing brake Type wet disc brake (ne- =
gative acting)
Gearbox Type refer to group 9.10 =
Transmission 1040 1041

Gearbox Type 2 HL 290 =
Oil Motor Type DMVA 165 =
Travel speed in creeper-/ off-road-/ on-road gear km/h 1,5 / 5,0 / 20,0 =
Oil quantity in gearbox l 3,0 =
3.16.2
copyright by
MJFCIFSS
Service Handbuch Technical data
A 316 Litronic
Transmission 1040 1041

Oil quality / -viscosity and oil change interval refer to group 1.50 =
u. 3.23
Parking brake Typ wet disc brake (ne- =
gative acting)
Axles 1040 1041

Steering axles Type MS-E 3060 =
Rigid axle Type MT-E 3060 =
Oil quantity in axle housing steering axle l 9,5 l =
Oil quantity in wheel hub steering axle l 2 x 2,5 l =
Oil quantity in axle housing rigid axle l 12,5 l =
Oil quantity in wheel hub rigid axle l 2 x 2,5 l =
Oil quantity / -viscosity and oil change interval refer to group 1.50 =
and 3.23
Operating brake steering axle Type disc brake =
Operating brake rigid axle Type disc brake =
Brake type (positive acting) =
further details siehe Gruppen =
12.30 / 12.32 / 12.34
Tires Inch 10.00 - 20 =
18.00 - 19,5
600 / 40 - 22,5
Steering 1040 1041

Hydraulic pump Type Gear pump =
Flow l/min 47 =
Steering valve Type LAGS =
Brake system 1040 1041

Hydraulikpumpe Type Gear pump =
Flow l/min 2,0 =
3.16.3
copyright by
MJFCIFSS
3.16.4
A 316 Litronic
Technical data
copyright by
MJFCIFSS
Service Handbuch
R 317 Litronic
Technical data
1 R 317 Litronic
Type 1042

General 1042
Weight of undercarriage with 600 mm base plates (STD/LS/LC) t 7.14 / 7.58 / 8.25
Weight of basic machine with 600 mm base plates t 11.4
Total weight with backhoe bucket attachment (600 mm base plates) t 18.1
Length of undercarriage STD/SL/LC mm 3975 / 5000 / 4555
Overall length (including gooseneck / adjusting attachment) mm 8650 / 8700
Overall width STD/LS/LC mm 2600 / 2850
Drive motor 1042

Type TDC 2013 LOV4
Power at rated speed according to DIN ISO 9249 kW 90 (122 HP)
at 1600 rpm

8

pump
Max. flow l/min 297

Rotary connection 7 x Type DDF 520
Rotary connection 6 x Type 815.001
3.17.1
copyright by
MJFCIFSS
R 317 Litronic

Pilot control unit / travel drive Type 5 TH 6 NR



gative)
Travel gear 1042

Gearbox Type Gear pump
Oil motor Type A6 VE 55
Travel speed in standard / fast travel mode km/h 2.4 / 5.0
Travel brake Type Multi-disc brake

Additional information see groups 11.60 or 11.65
respectively
Brake system 1042

Drive Type B60 L
3.17.2
copyright by
MJFCIFSS
R 317 Litronic
Brake system 1042

Running rollers Type/ B 60 L / 2 X 7
num-
ber of
rollers
Support rollers Type/ B 60 L / 2 X 2
num-
ber of
rollers
Number of base plates / chain (STD/LC/SL) Units 44 / 50 / 55
Base plate width mm 500/ 600/ 750/ 900/1000
2
Specific pressure on ground (max) N/cm 5.5/ 4.6/ 3.8/ 2.4/ 2.2

3.17.3
copyright by
MJFCIFSS
3.17.4
R 317 Litronic
Technical data
copyright by
MJFCIFSS
Service Manual
Service Manual Maintenance- and inspection chart
A 312 Litronic - A 316 Litronic
Maintenance- and inspection chart
1 A 312 Litronic - A 316 Litronic
A 312: type 1037, starting with serial no. 36220

A 314: type 1039, starting with serial no. 30694
A 316: type 1040 / 1041, starting with serial no. 29120
Cust.: ................................ Serial no. ................................ Date: .............................
Machine type: ................................ Operating hours: ................................
Note!
Careful maintenance is only possible, if the machine is clean. Especially visual inspections, e.g. for
cracks can only be carried out properly on a clean machine.
Therefore clean the machine thoroughly before starting any maintenance work (see also chapter
"Safe maintenance of machine", subchapters "Cleaning" and "Crack inspection").
Note!
The daily maintenance tasks of the machine operator include a functional test of the brakes (slewing
gear brake, working brake, parking brake), steering, electrical and hydraulic system.
Also to be carried out are a daily visual inspection of the motor, hydraulic system, gearbox and axles
for leakage.
Maintenance/inspection at WORK TO BE CARRIED OUT

operating hours
by maintenance personnel together with authorised specialist

upon acceptance
(machine operator) technicians

(every ...) / notes
Special interval
Initial and single interval

every 8 - 10
every 1000
every 2000
z Repeat interval Initial and single interval

every 500
every 50
7 Annually, at the start of the cold season Repeat interval

When required
DIESEL ENGINE
z z Check the oil level

z z Visual inspection (leakage, dirt, damage)

1) Change diesel engine oil
Change oil filter insert (at least once a year)
Belt drive: Check the belt for wear or damage; check the belt tension and adjust
it, if necessary (change belt every two years)
Check / adjust valve play, replace valve lid seal
3.23.1
copyright by
MJFCIFSS
Maintenance- and inspection chart Service Manual

operating hours

upon acceptance
(every ...) / notes

Special interval Initial and single interval
every 8 - 10
every 1000
every 2000

every 500
every 50

When required
Check intake and exhaust systems for general condition, fixture and leakage
Check oil pan, engine bearings, engine brackets and clamps for proper fixture
3000 Check vibration dampers for deformation
DIESEL ENGINE COOLING SYSTEM
z z Check coolant level

Check cooling and heating systems for general condition and leakage
7 Check corrosion inhibitor and antifreeze agent concentration in coolant
3000 Change coolant (at least every 2 years)
DIESEL ENGINE FUEL SYSTEM
z z Check water separator at the fuel pre-filter and drain off water, if necessary
z Drain water and deposit from fuel tank
4) Check fuel system for leakage and general state
4) Change fuel pre-filter (also in the event of a drop in performance)
Change fuel fine filter
Bleed fuel system
DIESEL ENGINE - AIR FILTER
z z Check underpressure indicator of the air filter

z Clean dust removal valve of the air filter
Change main element of the dry air filter (according to counterpressure indication
/ annually)
Change safety element of the dry air filter (at every third main element change /
annually) - do not clean or reuse!
Check clean air line (during maintenance of filters)
ELECTRICAL SYSTEM OF THE DIESEL ENGINE
Check control device bearing for general condition

Check sensor devices and cable connections
3.23.2
copyright by
MJFCIFSS

operating hours

upon acceptance
(every ...) / notes

Special interval
every 8 - 10
every 1000
every 2000
every 500
every 50

When required
DIESEL ENGINE - PARTICLE FILTER SYSTEM (optional equipment)
z Drain off condensate at the condensate trap

Condensate trap: check and clean sintered metal filter, check connecting clamps
for proper seat
Condensate trap: replace sintered metal filter
Clean particle filter and pre-filter; if required, clean before prescribed interval has
lapsed
HYDRAULIC SYSTEM
z z Check oil level in hydraulic tank

z Check degree of contamination of the bypass oil filter (special equipment); if re-
quired, change filter element
z Clean magnetic rod in return filter (daily during first 300 operating hours)
2) Replace filter insert in return filter
Replace filter cartridge in control oil unit
Check components for proper mounting

Check the hydraulic oil cooler for dirt; clean it, if necessary
Drain water from hydraulic tank
(max. permissible water content for environmentally friendly fluids: 0.1 %; insert
bypass filter, take oil sample)
Check hydraulic system for leakage; complete functional test
Check / readjust servo, primary and secondary pressures
2), 3) Change hydraulic oil in tank (optimise interval by carrying out oil analyses)
2) Change breather filter on hydraulic tank
ELECTRICAL SYSTEM
z z Check indicator lights and indicating devices upon start-up
Check lighting
Check acid density and level, wire terminals and terminal ports of the batteries,
and all the plug connections
Spray slip rings of the slewing gear connection with Cramolin contact spray
3.23.3
copyright by
MJFCIFSS

operating hours

upon acceptance
(every ...) / notes

every 8 - 10
every 1000
every 2000

every 500
every 50

When required
Carry out functional tests of entire unit and all components
SLEWING GEAR MECHANISM
Check oil level; check system for leakage

Carry out functional test of slewing gear brake
Check gearbox and oil motor for proper mounting
Change gear oil
SLEWING RING
Check mounting bolts for press fit; slewing gear pining meshing
TRANSMISSION
Carry out functional test of power shift mechanism and parking brake
Check gearbox, oil motor and joint shafts for proper mounting
Change gear oil
AXLES
z Lubricate steering knuckle bearing and oscillating bolts (weekly or monthly, de-
pending on use)
Check wheel lugs for proper fit

(In new machines: first time after 50, 100 and then 250 operating hours, and after
each wheel change or loosening of the wheel lugs)
Check fixture of the axles and oscillating axle bearing

Lubricate steering knuckle bearing and oscillating bolts (weekly or monthly, de-
pending on use)
Change oil in the axle housing and the planetary drive (front and rear)
If travel accounts for more than 30 % of the total operating hours:

Change oil in the axle housing (front and rear)
Change oil in planetary drive (front and rear)
Check the multi-disc brake for wear (once a year; shorten interval, if necessary)
3.23.4
copyright by
MJFCIFSS

operating hours

upon acceptance
(every ...) / notes

Special interval
every 8 - 10
every 1000
every 2000
every 500
every 50

When required
STEERING
Check system for leakage; complete functional test

Check components and steering system parts for proper mounting
OSCILLATING AXLE SUPPORT
Check system for leakage; complete functional test

Check cylinders for proper mounting
BRAKE SYSTEM
Check system for leakage; check accumulator and brake pressure as well as
check switch
Carry out functional test
OPERATOR'S CAB + HEATING
z Check / add detergent solution in windscreen washer tank
7 Check function of heating

Check heating system for leakage
Check door and window hinges as well as locks
Check water inlet valve for contamination, and clean, if necessary; carry out func-
tional test of valve
AIR-CONDITIONING SYSTEM
z Regularly switch on air-conditioning system (at least 1x every 14 days)

Check condenser for contamination; blow clean, if necessary
Clean re-circulated air / fresh air filter; replace, if necessary; shorten interval if the-
re is excessive generation of dust
Check compressor mounting bolts and drive belts
Check dryer-collector unit (humidity, fill level); replace, if necessary
Check evaporator unit; clean, if necessary
Check electrical lines for chafe marks; check plug connections
3.23.5
copyright by
MJFCIFSS

operating hours

upon acceptance
(every ...) / notes

every 8 - 10
every 1000
every 2000

every 500
every 50

When required
Complete functional test of excess pressure switch

Check cooling performance
Replace dryer-collector unit every 12 months; also check cooling circuit for leaka-
ge and change coolant and refrigeration oil
Every 12 months, employ a refrigeration technician to carry out a functional test of

the air flaps and the defrost thermostat
UNDERCARRIAGE + UPPERCARRIAGE + WORKING ATTACHMENTS
z z Lubricate bearing points, using the semi-automatic central lubrication system; ex-
ception: not required in units with fully automatic central lubrication system (opti-
onal equipment)
z Lubricate bearing positions (undercarriage and working attachments)
Lubricate daily when required due to type of use and/or shift operation
z Inspect teeth for wear
250 Check parts for cracks
250 Check counter weight and tank for proper mounting
Check lines and screwed connections for proper fit
Check panelling hinges, quick fasteners and gas pressure springs of the caps
Instruct operators in the proper use of the equipment
Instruct the operator on how the machine must be lubricated according to the lu-
bricating chart and make him aware of potential operator errors
HYDRAULIC QUICK CHANGE ADAPTER
z z Carry out a functional test of the visual and acoustic warning systems
z z Carry out a visual inspection of the extended locking bolts
z z Check hydraulic hoses and wire harness
z Lubricate locking bolts

Clean mesh filter
MECHANICAL QUICK CHANGE ADAPTER
z z Carry out a visual inspection of the extended locking bolts

z Lubricate locking bolts
3.23.6
copyright by
MJFCIFSS
Note:
1 Replace motor oil more often, if temperatures and the quality of fuels and oils make this seem advisable.
2 In the case of applications with excessive dust generation, observe shortened maintenance intervals; see group 1.50.
3 For environmentally friendly hydraulic fluids, adjust the maintenance interval on the basis of regular analyses. See
group 1.50.
4 The maintenance intervals might have to be shortened, depending on the operating conditions (e.g. generation of
dust, barrel fuelling).
Comments / defects
Date: ......................................... Mecha- ......................................... Cust.: .........................................

nic:

3.23.7
copyright by
MJFCIFSS
3.23.8
copyright by
MJFCIFSS
R 313 - R 317 Litronic
Maintenance- and inspection chart
1 R 313 - R 317 Litronic
R 313:Type 1038 starting with serial no. 39171

R 317:Type 1042 starting with serial no. 30019
Customer: ................................ Serial no.: ................................ Date: .............................
Machine type: ................................ Operating hours: ................................
Notice!
A thorough maintenance can only be carried out if the machine in question is clean. Especially visual
checks for example for cracks can only be carried out on cleaned machines.
Clean the machine prior to starting the maintenance work (also refer to chapter „safe mainte-
nance of the machine“, sub-chapter „cleaning“ and „check for cracks“).
Notice!
The daily maintenance work done by the operator includes a functional test of the brakes (swing-,
operating- and parking brake), steering, electrical and hydraulic system.
Furthermore, a daily visual check must be carried out in regard to leakages on engine, hydraulic
system, gearboxes and axles.
Wartung / Inspektion bei Work to be performed

Betriebsstunden

by maintenance personel by authorized and trained personel
(every...) / Remarks
(excavator operator) first and only interval

Special interval
first and only interval repeated interval

every 8 - 10
every 1000
every 2000
at delivery
z repeated interval
every 500
every 50
7 yearly, before onset of cold season

upon demand
DIESEL ENGINE
z z Check oil level

z z Visual check (for leaks, contamination, damages)
1) Replace engine oil

Replace oil filter cartridge (min. once a year)
Belt drive: check condition and tension, adjust if necessary (replace every 2 years)
Check / adjust valve play, replace valve cover gasket
Check intake and exhaust system for condition, mounting and leaks
3.26.1
copyright by
MJFCIFSS

Betriebsstunden
Special interval first and only interval repeated interval
every 8 - 10
every 1000
every 2000
at delivery
z repeated interval
every 500
every 50

upon demand
Check oil pan, engine suspension, engine brackets and clamps for proper moun-
ting
3000 Check virbration absorber for deformation
COOLING SYSTEM
z z Check coolant level

Check cooling and heating system for condition and leaks
7 Check corrosion- and antifreeze concentration of the coolant
3000 Replace coolant (at least every 2 years)
FUEL SYSTEM
z z Check water separator on fuel prefilter and drain if necessary

z Drain water and residue from the fuel tank
4) Check fuel system for condition and leaks
4) Replace fuel prefilter (or in case of performance loss)
Replace fuel fine filter
Bleed fuel system
AIR FILTER
z z Check vacuum indicator of the air filter

z Clean dust discharge valve of the air filter
Replace dry air primary filter element (according to maintenance indication / once
a year)
Replace dry air safety filter element (every third change of the primary filter ele-
ment / once a year) - never clean!
Check clean air line (during filter maintenance)
DIESEL ENGINE - ELECTRICAL SYSTEM
Check control unit suspension for condition

Check sensors and wiring for condition
3.26.2
copyright by
MJFCIFSS

Betriebsstunden
Special interval
every 8 - 10
every 1000
every 2000
at delivery
z repeated interval
every 500
every 50

upon demand
HYDRAULIC SYSTEM
z z Check oil level in hydraulic tank

z Check contamination of bypass oil filter (optional installation), replace filter ele-
ment if necessary
z Clean magnetic rod in return filter (during the first 300 hours daily)
2) Replace return filter element
Replace filter element on control oil unit
Check components for proper mounting
Check hydraulic oil cooler for contamination, clean if necessary
Drain water from hydraulic tank
(max. 0.1% share of water is permitted when using environmentally friendly fluids,
use bypass filters and take oil samples)
Check hydraulic system for leaks and function
Check / adjust servo-, primary- and secondary pressures
2), 3) Replace oil in the hydraulic tank (or optimise oil change interval by using oil ana-
lysis)

2) Replace breather valve on hydraulic tank
ELECTRICAL SYSTEM
z z Check indicators and display devices when turning on ignition
Check lighting
Check acid density and level, cable clamps and battery terminals as well as all
connectors
Treat the slip rings of the rotary connection (if installed) with Cramolin contact
spray
Check function of the entire system and components
SWING GEAR
Check oil level and for leaks

Check function and effect of swing brake
Check gear and motor for proper mounting
3.26.3
copyright by
MJFCIFSS

Betriebsstunden
every 8 - 10
every 1000
every 2000
at delivery
z repeated interval
every 500
every 50

upon demand
Replace gear oil
SWING RING
Check mounting screws for proper seating and engagement of the swing gear out-
put shaft
FINAL DRIVE
Check oil level and for leaks
Check funtion and effevtiveness of travel drive brake

Check mounting of final drive and oil motor
Replace gear oil
TRACK COMPONENTS
z z z Visually check chain tension, tighten if necessary

z z z z z Clean chain (after end of work)
z Check mounting of track pads and sprocket wheels
Clean gliding surfaces of the tensioning unit, lubricate

Check idler wheel, carrier- and track rollers for leaks
CAB + HEATER
z Check / refill washer fluid in container for windshield washer system

7 Treat rubber seals of the operator’s cab with silicone or talc
7 Treat rubber seals of the access doors on the uppercarriage with silicone or talc
7 Check function of the heater

Check heating system for leaks

Check door and window hinges as well as locks
Check coolant inlet valve for function and contamination, clean if necessary
AIR CONDITION
z Turn on air conditioner regularely (minimum once every 2 weeks)
3.26.4
copyright by
MJFCIFSS

Betriebsstunden
Special interval
every 8 - 10
every 1000
every 2000
at delivery
z repeated interval
every 500
every 50

upon demand
Check condenser for contamination, blow out if necessary

Clean recirculated- and fresh-air filter, replace if necessary, shorten interval in
case of extremely dusty conditions
Check mounting screws and drive belt of the compressor
Check collector-dryer unit (humidity, level and condition), change if necessary
Check evaporator, clean if necessary
Check electrical lines for chafing and connectors for proper mounting
Check high pressure switch for function
Check cooling performance
Replace collector-dryer unit yearly, check cooling circuit for leaks and replace re-
frigerant and oil
Check function of air flaps and thawing thermostat yearly by an A/C technician
UNDER- + UPPERCARRIAGE + WORKING ATTACHMENT
z z Lubricate all bearing points using central lubricating system. Exception: fully auto-
matic lubricating system (optional installation) works fully independant.
z Check grease container of the central lubricating system, refill if necessary

z Lubrication of the bearing points (undercarriage and attachment)
(depending upon application and in multiple shifts daily)
z Visually check wear condition of teeth
250 Check parts for cracks
250 Check counter weight and tank for proper mounting
Check hoses and lines for proper mounting
Check cover hinges, quick fasteners and gas springs of the covers
Inform about appropriate use of the attachment

Have the operator lubricate the machine according to the lubricating chart and
point out potential operating errors
HYDRAULIC QUICK CHANGE ADAPER
z z Check function of the optical and accustic warning device
3.26.5
copyright by
MJFCIFSS

Betriebsstunden
every 8 - 10
every 1000
every 2000
at delivery
z repeated interval
every 500
every 50

upon demand
z z Visually check the extended position of the locking pins

z z Check condition of the hydraulic hoses and wire harness
z Lubricate locking pins
Clean mesh filter
MECHANICAL SQUICK CHANGE ADAPTER
z z Visually check the extended position of the locking pins

z Lubricate locking pins
GENERAL
Check entire machine for correct maintenance and orderly condition
Explain machine literature (especially operator’s manual, safety remarks) to the

operator
Remarks:
1 Depending upon temperature, quality of fuel and oil the engine oil change intervals may have to be reduced.
2 Observe reduced maintenance intervals in dust intensive applications, refer to group 1.50.
3 When using environmentally friendly hydraulic fluids the maintenance interval must be determined by regular oil ana-
lysis, refer to group 1.50.
4 Depending upon the application conditions (f.e. dustintensive application, refueling from barrel) the maintenance in-
tervals may need to be reduced.
Remarks / Fault
Date: ......................................... Mechanic: ......................................... Customer: .........................................
3.26.6
copyright by
MJFCIFSS
Service Manual Adjustment protocol for A 309
A 309 Litronic TCD from 40998
Adjustment protocol for A 309
1 A 309 Litronic TCD from 40998
Type: 1035 (basic machine)
1.1 Excavator control UEC - from software version 1.12

Date: Mechanic: Cust.:
Type: Serial number: Operating hours:
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Machine-specific data
(at display)

Operating hours:
Start menu:
29 h: total operating hours

0 h: daily operating hours
E1033: error code
Software versions: Info software:

Info software menu
M: master (excavator control)

S: slave (auxiliary control)
D: Display
?Read machine type in: 1 (1035) ....... 1

menu Info I/O var-master va-
lues-master item 1
3.43.1
copyright by
MJFCIFSS
Adjustment protocol for A 309 Service Manual
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Diesel engine
Regulated speed / limit load cont-

rol rpm 1800 ....... ....... 1
(in speed step PP) indicated in:
lues-master item 27
?Read speeds in:

lues-master item 3
Low idle rpm rpm 850 +100 ....... ....... 1
High idle rpm rpm 1890 +30 ....... ....... 1
Number of teeth 48
Operating conditions
Warming up machine.
?Read hydraulic oil temperature C° > 50 +10 ....... ....... 1

in:
lues-master item 12
Pilot pressure
Speed step PP.
Set at valve 51. bar 32 ±1 ....... ....... 51 49
3.43.2
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Limit load control
Check Y50
Speed step PP.
Current from Y50 indicated in:

lues-master item 7
Current mA 600 +30 ....... ....... 1
Control pressure bar 8.0 ±1 ....... ....... 59
Check of regulating pressure du-

ring
Emergency operation
Remove the plug from Y50. bar 3.5 ±0.5 ....... ....... 8 59
Set the valve to emergency position
(remove cotter pin and actuate lever).
If required, adjust the pressure with

the adjusting screw 8.
After testing, return the valve to its

neutral position.

3.43.3
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Hydraulic begin of regulation of variable-displacement pump
Basic setting
Speed step 1
Y50 disconnected
Check LR pressure. bar Tank ....... ....... 59

pressure
Lower the pressure value at the se- bar 50 ±2 ....... ....... 88 41/
condary pressure-relief valve 262 42
(extend bucket cylinder)
below the begin of regulation value;
turn in the valve until the actuating
pressure at 44 begins to drop relative
to 41.
Re-connect the plug to Y50.

Adjusting the differential pressure ( -p)
Speed step PP
Super finish (SF) not activated.
Extend bucket cylinder with the func- bar 19 +1 ....... ....... 52 41/
tion. 45
Set the valve 262 to 100-120 bar (at
the measuring point 41).

Note the pressure difference bet-
ween 41 (MP) and 45 (LS).
adjustment bar 20 +1 ....... ....... 52 41/

up to 500 operating hours 45
3.43.4
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Check of output power of the diesel engine (power test)
Note:
Carry out this test when you suspect
problems (e.g. reduced output of die-
sel engine).
Insert the service plug.

Speed step PP.
Lower the pressure value of the se-
condary pressure-relief valves 242
(extending stick cylinder) and 262
(extending bucket cylinder) to a value
below the test pressure.
Power test function at the display

Enter menu Service rs-functions
function item 16 or activate it
with the laptop.
(the fan is automatically set to nemer-
gency).
Slowly increase the pressure value of bar 125 ....... ....... 242/ 41
the secondary pressure-relief valve 262
242 or 262 until the pressure value is
reached.
At the test pressure, the speed of the rpm 1800 +40 ....... .......

diesel engine may not drop below the
rated speed
(read speed at the speedometer at
the engine or at the laptop).
Difference between the measuring bar < 10 ....... ....... 41/

points 41 - 44 44
After the test is completed, switch off
the ignition.
3.43.5
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Pump safety valve
Speed step PP. 104

Turn in the pressure cut-off valve
104 (to block -90°).
Extend the bucket cylinder and incre- bar 400 +20 ....... ....... 105 41
ase the pressure value of the se-
condary pressure-relief valve 262
until the pressure value at the pressu-
re gauge ceases to increase or the
value of 440 bar is reached
(response pressure 105).
3.43.6
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Secondary pressure of the working and travel functions
Speed step PP.

Adjusting screw of the pressure cut-
off valve 104 is turned in 104
(to block - 90°).
-Retract boom cylinder bar 380 +20 ....... ....... 222 45
- Extending boom cylinder bar 380 +20 ....... ....... 221 45
- Retract stick cylinder bar 380 +20 ....... ....... 241 45

+20
-Extend stick cylinder bar 380 ....... ....... 242 45
-Retract bucket cylinder bar 380 +20 ....... ....... 261 45
- Extend bucket cylinder bar 380 +20 ....... ....... 262 45
- Extending regulating cylinder bar 380 +20 ....... ....... 501 45
- Retracting regulating cylinder bar 380 +20 ....... ....... 502 45
- Retracting swivel cylinder bar 250 +20 ....... ....... 581 45

- Extending swivel cylinder bar 250 +20 ....... ....... 582 45
- Reverse travel bar 380 +20 ....... ....... 176 45

+20
- Forward travel bar 380 ....... ....... 177 45
3.43.7
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Accessory kit AS 1 (standard)
Working pressure
Pressurise secondary pressure-relief

valve.
Connection A03 bar 110 +20 ....... ....... 541 45
Connection B03 bar 110 +20 ....... ....... 542 45
Rotating speed
(flow rate)
Checking measurement Y
Connection A02 mm 15.6 ....... ....... 1 1
Connection B02 mm 15.6 ....... ....... 2 2
Operating pressure (pressure cut-off)
Speed step PP
With bucket cylinder movement bar 350 +10 ....... ....... 104 41
3.43.8
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Slewing gear function
Primary pressure
Speed step 2
Torque settings
In menu torque slew
100 % mA 600 +50 ....... .......
Turning left / right bar 230 +10 ....... ....... 11 137

138
The parameters are pre-set by the

UEC.
At display 1
?Read current values in:
lues-master item 74


3.43.9
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Secondary pressure
Speed step 2

For high-pressure adjustment
In menu Service torque slew
Test set the value to 1 (Y451 is po-
wered with max. current).
Swivelling back
Turning right bar 250 +10 ....... ....... 134.2 137

+10
Turning left bar 250 ....... ....... 135.2 138
After testing, set the test value to 0.
Slowing down
Before making the low-pressure set-

tings, remove the pilot control hoses
at the motor.
Turning right bar 90 ± 5 ....... ....... 134.4 137

±5
Turning left bar 90 ....... ....... 135.4 138
3.43.10
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Turning speed
Adjustment of the slewing gear cont-

rol axle 120.
Turning right rpm 9.5 - 10 ....... ....... 120.

1.1
Turning left rpm 9.5 - 10 ....... .......

120.
2.1
Travel functions
Checking of the travel motor 170
Begin of regulation bar 240 ....... ....... 64 45 /

M
End of regulation bar 320 ....... ....... 64 45 /

M
3.43.11
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Output speed
(speed)
Speed of universal joint shaft

Measured at the universal joint shaft
in on-road gear forward / reverse
Standard machine
Forward rpm 1850 ±25 ....... ....... 160.1

.1
Reverse rpm 1850 ±25 ....... ....... 160.2

.1
Speeder machine
Forward rpm 2750 ±25 ....... ....... 160.1

.1
Reverse rpm 2750 ±25 ....... ....... 160.2

.1
Check measurement Y (standard)
on both sides mm 12 ....... ....... 160.

1
160.
2
on both sides mm 14 ....... ....... 160.

1
160.
2
Check measurement X
at travel motor
Stop screw (Qmin)
Standard machine mm 23.8 ....... ....... 35 35
Speeder machine mm 23.8 ....... ....... 35 35
3.43.12
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Hydraulic fan drive
Checking the fan speed
Insert dongle
Speed step PP
(at display)
with the laptop.
n test rpm 1650 +50 12
Read the current value I test at Y352,

using:
lues-master item 9
I test mA 100 ±20 ....... ....... 1

the ignition.
Steering function
Speed step 1

Primary pressure bar 180 +10 ....... ....... 83
Turn the vehicle wheels to the outer
steering stop, and then continue tur-
ning the steering wheel.
Note:
The primary pressure-relief valve 5 in
the steering valve 84 cannot be ad-
justed.
In the event of a fault, replace the en-
tire steering valve 84.
3.43.13
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Braking function
Brake system
Accumulator charge pressure
Switch-on pressure bar 125 ± 5 ....... ....... 74 27
Shut-down pressure bar 150 ± 5 ....... ....... 74 27
Switching pressure B20
dropping bar 100 ± 5 ....... ....... 76 153
increasing bar 125 ± 5 ....... ....... 76 27
Working brake
Front brake circuit bar 50 + 5 102 25

+5
Rear brake circuit bar 50 102 26
Switching pressure B60 bar 5 77 25/

26
3.43.14
copyright by
MJFCIFSS

after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
(at display)

Operating hours:
Start menu:

E1033: error code

Info software menu

D: Display

lues-master item 1
3.46.1
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Diesel engine

rol rpm 1800 ....... ....... 1
lues-master item 27
?Read speeds in:

lues-master item 3
Low idle rpm rpm 850 +100 ....... ....... 1
High idle rpm rpm 1890 +30 ....... ....... 1
Number of teeth 48
Warming up machine.

in:
lues-master item 12
Pilot pressure
Speed step PP.
Set at valve 51. bar 32 ±1 ....... ....... 51 49

3.46.2
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Limit load control
Check Y50
Speed step PP.

lues-master item 7
Current mA 600 +30 ....... ....... 1

ring
Emergency operation


neutral position.

3.46.3
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Basic setting
Speed step 1
Y50 disconnected

pressure
to 41.

Speed step PP
tion. 45

Adjustment bar 20 +1 ....... ....... 52 41/

3.46.4
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Note:
sel engine).

Speed step PP.

with the laptop.
gency).
reached.

rated speed

points 41 - 44 44
the ignition.
3.46.5
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Pump safety valve
Speed step PP. 104

104 (to block -90°).
3.46.6
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Speed step PP.

(to block - 90°).

+20
- Extending regulating cylinder bar 380 +20 ....... ....... 501 45
- Retracting regulating cylinder bar 380 +20 ....... ....... 502 45
- Retracting swivel cylinder bar 250 +20 ....... ....... 581 45

- Extending swivel cylinder bar 250 +20 ....... ....... 582 45

+20
- Forward travel bar 380 ....... ....... 177 45
3.46.7
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Working pressure

valve.
Connection A03 bar 110 +20 ....... ....... 541 45
Connection B03 bar 110 +20 ....... ....... 542 45
Rotating speed
(flow rate)
Connection A02 mm 15.6 ....... ....... 1 1
Connection B02 mm 15.6 ....... ....... 2 2
Speed step PP
3.46.8
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Primary pressure
Speed step 2
Torque settings
In menu torque slew
100 % mA 600 +50 ....... .......

138

UEC.
At display 1
lues-master item 74


3.46.9
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Secondary pressure
Speed step 2

Swivelling back
Turning right bar 250 +10 ....... ....... 134.2 137

+10
Turning left bar 250 ....... ....... 135.2 138
Slowing down

at the motor.
Turning right bar 90 ± 5 ....... ....... 134.4 137

±5
Turning left bar 90 ....... ....... 135.4 138
3.46.10
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Turning speed

rol axle 120.
Turning right rpm 9.5 - 10 ....... ....... 120.

1.1
Turning left rpm 9.5 - 10 ....... .......

120.
2.1
Travel functions

M

M
3.46.11
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Output speed
(speed)

Measured at the universal joint shaft
Standard machine
Forward rpm 1850 ±25 ....... ....... 160.1

.1
Reverse rpm 1850 ±25 ....... ....... 160.2

.1
Speeder machine
Forward rpm 2750 ±25 ....... ....... 160.1

.1
Reverse rpm 2750 ±25 ....... ....... 160.2

.1
on both sides mm 12 ....... ....... 160.

1
160.
2
on both sides mm 14 ....... ....... 160.

1
160.
2
Check measurement X
at travel motor
Stop screw (Qmin)

3.46.12
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Hydraulic fan drive
Insert dongle
Speed step PP
(at display)
with the laptop.
n test rpm 1650 +50 12

using:
lues-master item 9
I test mA 100 ±20 ....... ....... 1

the ignition.
Steering function
Speed step 1

Note:
justed.
3.46.13
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Braking function
Brake system
Switching pressure B20
dropping bar 100 ± 5 ....... ....... 76 153
increasing bar 125 ± 5 ....... ....... 76 27
Working brake

+5
Switching pressure B60 bar 5 77 25/

26
3.46.14
copyright by
MJFCIFSS

after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
(at display)

Operating hours:
Start menu:

E1033: error code

Info software menu

D: Display
Read machine type in: 3 (1037) ....... 1

lues-master item 1
3.49.1
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Diesel engine

rol rpm 1800 ....... ....... 1
lues-master item 27
?Read speeds in:

lues-master item 3
Low idle rpm rpm 850 +100 ....... ....... 1
High idle rpm rpm 1890 +30 ....... ....... 1
Number of teeth 48
Warming up machine.

in:
lues-master item 12
Pilot pressure
Speed step PP.
Set at valve 51. bar 32 ±1 ....... ....... 51 49

3.49.2
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Limit load control
Check Y50
Speed step PP.

lues-master item 7
Current mA 600 +30 ....... ....... 1

ring
Emergency operation


neutral position.

3.49.3
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Basic setting
Speed step 1
Y50 disconnected

pressure
to 41.

Speed step PP
tion. 45

adjustment bar 20 +1 ....... ....... 52 41/

3.49.4
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Note:
sel engine).

Speed step PP.

with the laptop.
gency).
reached.

rated speed

points 41 - 44 44
the ignition.
3.49.5
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Pump safety valve
Speed step PP. 104

104 (to block -90°).
3.49.6
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Speed step PP.

(to block - 90°).

+20

- Forward travel bar 380 +20 ....... ....... 177 45

3.49.7
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Working pressure

valve.
Connection A02 bar 110 +20 ....... ...... 541 45
Connection B02 bar 110 +20 ....... ....... 542 45
Rotating speed
(flow rate)
Connection A02 mm 15.6 ....... ....... 1 1
Connection B02 mm 15.6 ....... ....... 2 2
Speed step PP
3.49.8
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Primary pressure
Speed step 2
Torque settings
In menu torque slew
100 % mA 600 +50 ....... .......

138

UEC.
At display 1
lues-master item 74


3.49.9
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Secondary pressure
Speed step 2

Swivelling back
Turning right bar 250 +10 ....... ....... 134. 137

2
Turning left bar 250 +10 ....... ....... 135. 138

2
Slowing down

at the motor.
Turning right bar 90 ± 5 ....... ....... 134. 137

4
90 ± 5
Turning left bar ....... ....... 135. 138

4
3.49.10
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Turning speed

rol axle 120.
Turning right rpm 9.0 - 9.5 ....... ....... 120.

1.1
Turning left rpm 9.0 - 9.5 ....... .......

120.
2.1
Travel functions

M

M
3.49.11
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Output speed
(speed)

Measures at the universal joint shaft
Standard machine
Forward rpm 1800 +50 ....... ....... 160.1

.1
Reverse rpm 1800 +50 ....... ....... 160.2

.1
Speeder machine
Forward rpm 2700 +50 ....... ....... 160.1

.1
Reverse rpm 2700 +50 ....... ....... 160.2

.1
on both sides mm 12 ....... ....... 160.

1
160.
2
on both sides mm 14 ....... ....... 160.

1
160.
2
Check measurement X
at travel motor
Stop screw (Qmin)
3.49.12
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Hydraulic fan drive
Insert dongle
Speed step PP
(at display)
with the laptop.
n test rpm 1600 +50 12

using:
lues-master item 9
I test mA 100 ±20 ....... ....... 1

the ignition.
Steering function
Speed step 1

Note:
justed.
3.49.13
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Braking function
Brake system
Switching pressure (B20)
dropping bar 100 ± 5 ....... ....... 76 153
increasing bar 125 ± 5 ....... ....... 76 27
Working brake

+5
Switching pressure (B60) bar 5 77 25/

26
3.49.14
copyright by
MJFCIFSS

after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
(at display)

Operating hours:
Start menu:

E1033: error code

Info software menu

D: Display

lues-master item 1
3.52.1
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Diesel engine

rol rpm 1800 ....... ....... 1
lues-master item 27
?Read speeds in:

lues-master item 3
Low idle rpm rpm 850 +100 ....... ....... 1
High idle rpm rpm 1890 +30 ....... ....... 1
Number of teeth 48
Warming up machine.

in:
lues-master item 12
Pilot pressure
Speed step PP.
Set at valve 51. bar 32 ±1 ....... ....... 51 49

3.52.2
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Limit load control
Check Y50
Speed step PP.

lues-master item 7
Current mA 600 +30 ....... ....... 1

ring
Emergency operation


neutral position.

3.52.3
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Basic setting
Speed step 1
Y50 disconnected

pressure
to 41.

Speed step PP
tion. 45

adjustment bar 20 +1 ....... ....... 52 41/

3.52.4
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Note:
sel engine).

Speed step PP.

with the laptop.
(*) display from V 1.10
gency).
reached.

rated speed

points 41 - 44 44
the ignition.
3.52.5
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Pump safety valve
Speed step PP. 104

104 (to block -90°).
Extend the bucket cylinder and incre- bar 400 +20 ................... 105 41
3.52.6
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Speed step PP.

(to block - 90°).
- Retract boom cylinder bar 380 +20 ....... ....... 222 45

+20
- Extend stick cylinder bar 380 ....... ....... 242 45
- Retract bucket cylinder bar 380 +20 ....... ....... 261 45


3.52.7
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Working pressure

valve.
Connection A02 bar 110 +20 ....... ....... 541 45
Connection B02 bar 110 +20 ....... ....... 542 45
Rotating speed
(flow rate)
Connection A02 mm 15.6 ....... ....... 1 1
Connection B02 mm 15.6 ....... ....... 2 2
Speed step PP
3.52.8
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Primary pressure
Speed step 2
Torque settings
In menu torque slew
100 % mA 600 +50 ....... .......

138

UEC.
At display 1
lues-master item 74


3.52.9
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Secondary pressure
Speed step 2

Swivelling back

2
Turning left bar 250 +10 ....... ....... 135. 138

2
Slowing down

at the motor.

4
90 ± 5
Turning left bar ....... ....... 135. 138

4
3.52.10
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Turning speed

rol axle 120.

1.1
Turning left rpm 9.0 - 9.5 ....... .......

120.
2.1
Travel functions

M

M
3.52.11
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Output speed
(speed)

Standard machine
Forward rpm 1920 +50 ....... ....... 160.1

.1
Reverse rpm 1920 +50 ....... ....... 160.2

.1
Speeder machine
Forward rpm 2870 +50 ....... ....... 160.1

.1
Reverse rpm 2870 +50 ....... ....... 160.2

.1
on both sides mm 11.5 ....... ....... 160.

1
160.
2
on both sides mm 14 ....... ....... 160.

1
160.
2
Check measurement X
at travel motor
Stop screw (Qmin)
3.52.12
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Hydraulic fan drive
Insert dongle
Speed step PP
(at display)
with the laptop.
n test rpm 1650 +50 12

using:
lues-master item 9
I test mA 160 - 100 ....... ....... 1

the ignition.
Steering function
Speed step 1

Note:
justed.
3.52.13
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Braking function
Brake system
Switch-on pressure bar 150 ±5 ....... ....... 74 27
Shut-down pressure bar 185 ±5 ....... ....... 74 27
dropping bar 100 ±5 ....... ....... 76 153
increasing bar 125 ±5 ....... ....... 76 27
Working brake
Front brake circuit bar 75 +10 102 25

+10

26
3.52.14
copyright by
MJFCIFSS
A 316 Litronic TCD from 29120 (type 1040) and from 29503 (type 1041)
1 A 316 Litronic TCD from 29120 (type 1040) and from 29503 (type 1041)
Type: 1040 (basic machine) and 1041 (basic machine)

after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
(at display)

Operating hours:
Start menu:

E1033: error code

Info software menu

D: Display

menu Info I/O var-master va- 7 (1041)
lues-master item 1
3.55.1
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Diesel engine

rol rpm 1800 ....... ....... 1
lues-master item 27
?Read speeds in:

lues-master item 3
Low idle rpm rpm 850 +100 ....... ....... 1
High idle rpm min 1890 +30 ....... ....... 1
Number of teeth 48
Warming up machine.

in:
lues-master item 12
Pilot pressure
Speed step PP.
Set at valve 51. bar 32 ±1 ....... ....... 51 49

3.55.2
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Limit load control
Check Y50
Speed step PP.

lues-master item 7
Current mA 600 +30 ....... ....... 1

ring
Emergency operation


neutral position.

3.55.3
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Basic setting
Speed step 1
Y50 disconnected

pressure
to 41.

Speed step PP
tion. 45

adjustment bar 20 +1 ....... ....... 52 41/

3.55.4
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Note:
sel engine).

Speed step PP.

with the laptop.
gency).
reached.

rated speed

points 41 - 44 44
the ignition.
3.55.5
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Pump safety valve
Speed step PP. 104

104 (to block -90°).
3.55.6
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Speed step PP.

(to block - 90°).

+20


3.55.7
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Working pressure

valve.
Connection A02 bar 110 +20 ....... ....... 541 45
Connection B02 bar 110 +20 ....... ....... 542 45
Rotating speed
(flow rate)
Connection A02 mm 15.6 ....... ....... 1 1
Connection B02 mm 15.6 ....... ....... 2 2
Speed step PP
3.55.8
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Primary pressure
Speed step 2
Torque settings
In menu torque slew
100 % mA 600 +50 ....... .......

138

UEC.
At display 1
lues-master item 74


3.55.9
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Secondary pressure
Speed step 2

Swivelling back

2
Turning left bar 250 +10 ....... ....... 135. 138

2
Slowing down

at the motor.

4
90 ± 5
Turning left bar ....... ....... 135. 138

4
3.55.10
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Turning speed

rol axle 120.

1.1
Turning left rpm 9.0 - 9.5 ....... .......

120.
2.1
Travel functions

M

M
3.55.11
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Output speed
(speed)

Standard machine
Forward rpm 1680 +50 ....... ....... 160.1

.1
Reverse rpm 1680 +50 ....... ....... 160.2

.1
Speeder machine
Forward rpm 2520 +50 ....... ....... 160.1

.1
Reverse rpm 2520 +50 ....... ....... 160.2

.1
on both sides mm 11,5 ....... ....... 160.

1
160.
2
on both sides mm 14 ....... ....... 160.

1
160.
2
Check measurement X
at travel motor
Stop screw (Qmin)
Speeder machine mm 25,0 ....... ....... 35 35
3.55.12
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Hydraulic fan drive
Insert dongle
Speed step PP
(at display)
with the laptop.
n test rpm 1600 +50 12

using:
lues-master item 9
I test mA 160 - 100 ....... ....... 1

the ignition.
Steering function
Speed step 1

Note:
justed.
3.55.13
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Braking function
Brake system
Switch-on pressure bar 150 ±5 ....... ....... 74 27
Shut-down pressure bar 185 ±5 ....... ....... 74 27
dropping bar 100 ±5 ....... ....... 76 153
increasing bar 125 ±5 ....... ....... 76 27
Working brake
Front brake circuit bar 75 +10 102 25

+10

26
3.55.14
copyright by
MJFCIFSS
Service Manual Adjustment protocol R 313
R 313 Litronic TCD from 39171
Adjustment protocol R 313
1 R 313 Litronic TCD from 39171

after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
(at display)

Operating hours:
Start menu:

E1033: error code

Info software menu

D: Display
Read machine type in: 4 (1038) ....... 1

lues-master item 1
3.58.1
copyright by
MJFCIFSS
Adjustment protocol R 313 Service Manual
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Diesel engine
Regulated speed / limit load control rpm 1800 ....... ....... 1

lues-master item 27
?Read speeds in:

lues-master item 3
Low idle rpm rpm 850 +100 ....... ....... 1
High idle rpm rpm 1890 +30 ....... ....... 1
Number of teeth 48
Warming up machine.
?Read hydraulic oil temperature C° > 50 +10 1

in:
lues-master item 12
Pilot pressure
Speed step PP.
Set at valve 51. bar 32 ±1 ....... ....... 51 49

3.58.2
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Limit load control
Check Y50
Speed step PP.

lues-master item 7
Current mA 600 +30 ....... ....... 1

ring
Emergency operation


neutral position.

3.58.3
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Basic setting
Speed step 1
Y50 disconnected

pressure
to 41.

Speed step PP
tion. 45
adjustment bar 20 +1 ....... ....... 52 41/

3.58.4
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Note:
sel engine).

Speed step PP.

with the laptop.
gency).
reached.

rated speed

points 41 - 44 44
the ignition.
Pump safety valve
Speed step PP. 104

104 (to block -90°).
3.58.5
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Speed step PP. 104

off valve 104 is turned in
(to block - 90°).
-Retract boom cylinder bar 380 +20 ....... ....... 222
- Extending boom cylinder bar 380 +20 ....... ....... 221
- Retract stick cylinder bar 380 +20 ....... ....... 241
-Extend stick cylinder bar 380 +20 ....... ....... 242
-Retract bucket cylinder bar 380 +20 ....... ....... 261
- Extend bucket cylinder bar 380 +20 ....... ....... 262
Disconnect line 219 from the travel

motor.
Forward travel, left bar 380 +20 ....... ....... 211 45

Reverse travel, left bar 380 +20 ....... ....... 212 45
Forward travel, right bar 380 +20 ....... ....... 213 45
Reverse travel, right bar 380 +20 ....... ....... 214 45

3.58.6
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Working pressure
Pressurise secondary pressure-relief bar 110 +20 ....... ....... 541 45

valve.
Connection A02
Connection B02 bar 110 +20 ....... ....... 542 45
Rotating speed
(flow rate)
Connection A02 mm 15.6 ....... ....... 1 1
Connection B02 mm 15.6 ....... ....... 2 2
Speed step PP

3.58.7
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Primary pressure
Speed step 2
Torque settings
In menu torque slew
100 % mA 600 +50 ....... .......

138

UEC.
At display 1
lues-master item 74

3.58.8
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Secondary pressure
Speed step 2

Swivelling back

2
Turning left bar 250 +10 ....... ....... 135. 138

2
Slowing down

at the motor.

4
Turning left bar 90 ± 5 ....... ....... 135. 138

4
3.58.9
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Turning speed

rol axle 120.

1.1
Turning left rpm 9.0 - 9.5 ....... .......

120.
2.1
3.58.10
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Travel functions
Regulation of regulating travel mo-

tor 200 / 201

motor.
Begin of regulation bar 150 ....... ....... 210 45/

M1
End of regulation bar 150 ....... ....... 210 45/

M1

3.58.11
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Adjustment of the regulating tra-

vel motor 200 , 201
Measure the output speed (speed)

at the tumbler wheel (output speed -
travel gear system).
Normal travel / chassis right rpm 15 ±1 ....... ....... 160.1 14

160.2
.3
Normal travel / chassis left rpm 15 ±1 ....... ....... 180.1 14

180.2
.3
Stroke limitation of spool mm 15.0 ....... ....... 160.1

160.2
Checking measurement Y 180.1
180.2
Actuate the switch S21 (hare sym-

bol).
Fast travel / chassis right rpm 45 ±1 ....... ....... Vmin 14

Fast travel / chassis left rpm 45 ±1 ....... ....... Vmin 14
Straight-ahead travel with same 45 ....... ....... Vmin 14

speed at both sides.
3.58.12
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Hydraulic fan drive
Insert dongle
Speed step PP
(at display)
with the laptop.
n test rpm 1600 +50 12

using:
lues-master item 9
I test mA 100 ....... ....... 1

the ignition.

3.58.13
copyright by
MJFCIFSS
3.58.14
copyright by
MJFCIFSS
Adjustment protocol R 317
1 R 317 Litronic TCD from 30019

after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
(at display)

Operating hours:
Start menu:

E1033: error code

Info software menu

D: Display

lues-master item 1
3.61.1
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Diesel engine
Regulated speed / limit load control rpm 1800 ....... ....... 1

lues-master item 27
?Read speeds in:

lues-master item 3
Low idle rpm rpm 850 +100 ....... ....... 1
High idle rpm rpm 1890 +30 ....... ....... 1
Number of teeth 48
Warming up machine.
?Read hydraulic oil temperature C° > 50 +10 1

in:
lues-master item 12
Pilot pressure
Speed step PP.
Set at valve 51. bar 32 ±1 ....... ....... 51 49

3.61.2
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Limit load control
Check Y50
Speed step PP.

lues-master item 7
Current mA 600 +30 ....... ....... 1

ring
Emergency operation


neutral position.

3.61.3
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Basic setting
Speed step 1
Y50 disconnected

pressure
to 41.

Speed step PP
tion. 45
adjustment bar 20 +1 ....... ....... 52 41/

3.61.4
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Note:
sel engine).

Speed step PP.

with the laptop.
gency).
reached.

rated speed

points 41 - 44 44
the ignition.
Pump safety valve
Speed step PP. 104

104 (to block -90°).
3.61.5
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Speed step PP. 104

off valve 104 is turned in
(to block - 90°).
-Retract boom cylinder bar 380 +20 ....... ....... 222
- Extending boom cylinder bar 380 +20 ....... ....... 221
- Retract stick cylinder bar 380 +20 ....... ....... 241
-Extend stick cylinder bar 380 +20 ....... ....... 242
-Retract bucket cylinder bar 380 +20 ....... ....... 261
- Extend bucket cylinder bar 380 +20 ....... ....... 262

motor.
Forward travel, left bar 380 +20 ....... ....... 211 45

Reverse travel, left bar 380 +20 ....... ....... 212 45
Forward travel, right bar 380 +20 ....... ....... 213 45
Reverse travel, right bar 380 +20 ....... ....... 214 45

3.61.6
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Working pressure

valve.
Connection A02 bar 110 +20 ...... ....... 541 45
Connection B02 bar 110 +20 ....... ....... 542 45
Rotating speed
(flow rate)
Connection A02 mm 15.6 ....... ....... 1 1
Connection B02 mm 15.6 ....... ....... 2 2
Speed step PP

3.61.7
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Primary pressure
Speed step 2
Torque settings
In menu torque slew
100 % mA 600 +50 ....... .......

138

UEC.
At display 1
lues-master item 74

3.61.8
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Secondary pressure
Speed step 2

Swivelling back

2
Turning left bar 250 +10 ....... ....... 135. 138

2
Slowing down

at the motor.

4
Turning left bar 90 ± 5 ....... ....... 135. 138

4
3.61.9
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Turning speed

rol axle 120.

1.1
Turning left rpm 9.0 - 9.5 ....... .......

120.
2.1
3.61.10
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Travel functions
Adjustment of the regulating tra-

vel motor 200 , 201
Measure the output speed (speed)

at the tumbler wheel (output speed -
travel gear system).
Normal travel / chassis right rpm 15 ±1 ....... ....... 160.1 14

160.2
.3
Normal travel / chassis left rpm 15 ±1 ....... ....... 180.1 14

180.2
.3
Stroke limitation of spool mm 15.0 ....... ....... 160.1

160.2
Checking measurement Y 180.1
180.2
Actuate the switch S21 (hare sym-

bol).

Fast travel / chassis right rpm 45 ±1 ....... ....... Vmin 14
Fast travel / chassis left rpm 45 ±1 ....... ....... Vmin 14
Straight-ahead travel with same 45 ....... ....... Vmin 14

speed at both sides.
3.61.11
copyright by
MJFCIFSS
after adjustment
Measuring point
Value measured
Value measured
Location of
adjustment
during test
Setting
Unit
Check / adjustment
Hydraulic fan drive
Insert dongle
Speed step PP
(at display)
with the laptop.
n test rpm 1600 +50 12

using:
lues-master item 9
I test mA 100 - 160 ....... ....... 1

the ignition.
3.61.12
copyright by
MJFCIFSS
Service Handbuch Adjustment protocol (optional installation)
A 309 - 316 Litronic TCD
Adjustment protocol (optional installation)
1 A 309 - 316 Litronic TCD
Type: 1035 / 1036 / 1037 / 1039 / 1040 / 1041 (with optional installation)
1.1 Excavator control system UEC - Software-Version V 1.05

Date: ................................... Mechanic: ......................................... Customer: .........................................
Type: ................................... Serial number: ......................................... Operating hours: .........................................
Measuring value during test
Value after adjustment
Adjustment location
Adjustment value
Test point
Unit
Check / Adjustment
Optional installation AHS 1
Secondary pressure
Rpm step PP
Pressure cut-off 104 turned in
(bottom out and turn back 90°)
45
-extend adjustable boom cylinder 380 +20 501

-retract adjustable boom cylinder 380 +20 502
Adjust pressure cut-off 104 to speci-

fied value after the check, refer to ad-
justment protocol of basic machine
:
3.75.1
copyright by
MJFCIFSS
Adjustment protocol (optional installation) Service Handbuch
Adjustment location
Adjustment value
Test point
Unit
Check / Adjustment
Basic setting secondary valves
Use service plug

Rpm step PP
Warm up machine
Actuate switch S241
Pressure cut-off 104 turned in

(bottom out and turn back 90°)
Low pressure
via display Menue opt1 P1 set va- 1
lue to 0% (Y414 without current)
45
Function A6 bar 100+20 ....... ....... 511
Function B6 bar 100+20 ....... ....... 512
High pressure
via display menue opt1 P1 set va- 1
lue to 100% (Y414 applied with max.
current)
45
380+20
Function A6 bar ....... ....... Y414

20
Function B6 bar 380+20 ....... ....... Y414
20
3.75.2
copyright by
MJFCIFSS
Service Handbuch Adjustment protocol (optional installation)
Adjustment location
Adjustment value
Test point
Unit
Check / Adjustment
Hubbegrenzung Steuerkolben
Spool 513
Check of measurement Y mm 14,7 ....... ....... 513.1 513.1
1.1
513.2 513.2
mm 14,7 ....... .......
(12,0)* 1.1
*for machine with offset main boom
adjustment
Refer to AHS 1 and AHS 11

3.75.3
copyright by
MJFCIFSS
Adjustment protocol (optional installation) Service Handbuch
3.75.4
copyright by
MJFCIFSS
Service Manual Checking and adjusting tasks
General
Checking and adjusting tasks
1 General
1.1 Instructions for adjustment / pre-conditions

– During the warranty period, all adjustment work on the machine must be carried out by authorised
specialist technicians.
– The operating temperature of the hydraulic unit must be minimum 50° C (indicated on display, see
2.3.3).
– The pressure gauges must be glycerine-damped with an indication accuracy of less than 1%.
– The pressure gauges must have an indication accuracy of ±0.3 bar.
– To secure the adjusting screws of the valves against unauthorised interference, they must be
equipped with protective caps (see special tools in group 2.05 ).
1.2 Safety precautions for checking and adjusting work

When carrying out checking and adjusting work, observe the general accident prevention regulations!
For details, see safety instruction in main group 1.
Ensure that the machine operator in the operator's cab and the maintenance workers can at all times
see each other.
1.3 Measuring instruments / adjusting tools / safety of adjusting screws
1.3.1 Measuring instruments

The following measuring instruments of group 2.01 are required for the testing and adjustment of the
hydraulic system:
– High-pressure measuring lines

• Tools no. 7 or 8
– For pilot pressure measurement:
• Pressure gauge 0 - 60 bar, tool no. 19
– For high pressure measurement:
– For actuating pressure measurement:
– For differential pressure Δp measurement:
• Differential pressure gauge no. 30
– For speed measurement:
• Tools no. 60/62-64
– For current measurement:
• Tool no. 65
– For temperature measurement:
• Tools no. 70/72
3.84.1
copyright by
MJFCIFSS
Checking and adjusting tasks Service Manual
General
Alternatively use the following measuring instruments:

– Hand-held measuring device MH 3010 (tool no. 30.1)
• Pressure sensor 0 - 60 bar
– plus measuring cables and accessories for the measuring of speed and temperature
1.3.2 Adjusting tools:

All adjustments to the valves / units can be made with conventional ring spanners, open-end wren-
ches and Allen keys.
3.84.2
copyright by
MJFCIFSS
General
1.4 Location of the measuring points and interface for access authorisation

Fig. 1 Measuring points on the components and interface / dongle
20 Variable-displacement pump 50 Control oil unit

25 Measuring point / front brake circuit 59 Measuring point / LR pressure
at the control oil unit 50 (MLR connec-
tion)
26 Measuring point / rear brake circuit 83 Measuring point / steering system

at steering pump
27 Measuring point/ brake system 100 Compact control block
at brake pump
41 Measuring point for high pressure 130 Slewing gear motor
at the control block 100 (MP connec-
tion)
3.84.3
copyright by
MJFCIFSS
Basic settings
44 Measuring point / actuating pressure 137 Measuring point for slewing gear wor-
at pump 20 (MA connection) king pressure
at slewing gear motor 130
(MA connection / pivot right)
45 Measuring point / LS pressure 138 Measuring point for slewing gear wor-
at pump 20 (X2 connection) king pressure
(MB connection / pivot left)
49 Measuring point / pilot pressure X1167 Interface for dongle
(connection M1) in right control desk
2 Basic settings
2.1 Info hours

Press the button 28 to move the cursor from the start screen to Info-hours.
Press the button 26.
ª The hours (operating hours counter) screen is displayed.
It shows the total operating hours of the machine, e.g. 1.
Repeatedly press the button 28 to call up
• the daily operating hours counter (hours-day)
• the operating hours at the various engine speeds = low for speeds 1 - 5, mid for speeds 6 - 8
and high for speed 9 - 10 (hours-rpm)
• the operating hours with sensor control (hours-sensor)
• the operating hours in travel mode (hours-drive)
Fig. 2 Calling up operating hours counters of machine
25 Display 28 DOWN button

26 ENTER button (confirmation) 29 UP button

27 Push button / cursor to right A Start screen
2.2 Info-Software screen

Press the button 28 to move the cursor from the start screen to Info-Software.
3.84.4
copyright by
MJFCIFSS
Basic settings

ª The screen M: S: D:
The screen shows the software version of the excavator control, the auxiliary control and the machine
display:
Fig. 3 Calling up the software version information
25 Display A Start screen

26 ENTER button (confirmation) D Display
27 Push button / cursor to right M Master (excavation control)
28 DOWN button S Slave (auxiliary control)
29 UP button
2.3 Info I/O (inputs / outputs)
Location of Measuring
Check / adjustment Unit Setting
adjustment point

Machine model A 309 1 - Display
A 311 2 - Display
A 312 3 - Display
A 314 5 - Display
A 316 6 (1040) / 7 (1041) - Display
Regulated speed rpm 1800 - Display
Low idle rpm +100
rpm 850 - Display
High idle rpm +30
rpm 1890 - Display
Hydraulic oil temperature °C > 50 +10 - Display
Tab. 1 Parameters
Press the button 28 to move the cursor from the start screen to Info-I/O, see Fig. 4.
ª The subordinate menu is displayed.
Press the button 28 to move the cursor to var-master.
ª The menu values-master is displayed.
Press the button 28/29 to call up various values/information, e.g.
3.84.5
copyright by
MJFCIFSS
Basic settings
• 1 Excavator type
• 3 Rotational speed / diesel engine
• 7 Current at solenoid valve Y50
• 11 Cooling water temperature
• 12 Hydraulic oil temperature
• 13 Engine oil pressure
• 27 Regulated speed / limit load control
• etc.
Fig. 4 Calling up details and values regarding the machine displayed in the values-master menu

2.3.1 Calling up machine type details

Access menu Info I/O var-master values-master number 1: read the Code no. indicating
the machine type:
examples: code 6 for A 316 TCD type 1040 or code 7 for A 316 Ind. TCD type 1041.
2.3.2 Calling up diesel engine speed

Run engine at speed step PP. Access menu Info I/O var-master values-master number
27: read the regulated speed for limit load control:

Run engine at speed step PP and speed step 1. Access menu Info I/O var-master values-mas-
ter number 3: read the upper and lower idle rpm:
2.3.3 Calling up hydraulic oil temperature

Warm up machine. Access menu Info I/O var-master values-master number 12: read the
actual hydraulic oil temperature:
3.84.6
copyright by
MJFCIFSS
Checking and adjusting the pilot pressure
3 Checking and adjusting the pilot pressure
adjustment point
Pilot pressure bar 32 ±1 51 49
Tab. 2 Settings
Fig. 5 Control oil unit with adjusting screw / pilot control pressure
49 Measuring point / pilot pressure 50 Control oil unit

51 Adjusting screw / pilot control pressure
Connect the pressure sensor or gauge (60 bar) to the measuring point 49.
Start machine and preselect the speed step PP.
Compare the pressure at the pressure sensor with the prescribed pressure, see Tab. 2.

If necessary, adjust the setting of pressure-relief valve 51.
To do this, remove the protective cap and loosen the lock nut (WS 13).
Increasing pressure
Turn the adjusting screw 51 clockwise, using an Allen key (WS 4).
ª The pressure is increased.
Reducing pressure
Turn the adjusting screw 51 anticlockwise, using an Allen key (WS 4).
ª The pressure is reduced.
After the pressure settings have been adjusted, lock the adjusting screw 51.
Replace the protective cap.

Remove the pressure gauge and seal the measuring point.
3.84.7
copyright by
MJFCIFSS
Checking and adjusting the limit load control system
4 Checking and adjusting the limit load control system
adjustment point
Checking of Y50 mA 600 +30 -
bar 8 ±1 - 59
Tab. 3 Settings
Fig. 6 Control oil unit with proportional solenoid valve in normal/emergency position and measu-
ring points
50 Control oil unit Y50 Proportional solenoid valve / power con-

trol
59 Measuring point LR
Connect the pressure sensor/gauge to the measuring point 59, see Fig. 6.
Start the machine.
On the display, change to menu values master , see 2.3 and Fig. 4.
Press the buttons 28 / 29 to call up the current value at Y50 (number 7) and compare it with the
nominal value, see Tab. 6.
Select engine speed step PP.
Compare the actual control pressure at the measuring point 59 with the nominal value, see Tab. 3.
Regulating diagram, see also group 7.42
– Current OK Pressure OK => OK

– Current OK Pressure not => Replace proportional solenoid valve.

OK
– Current not Pressure not => Search for fault in the electrical system and the limit
OK OK load control
3.84.8
copyright by
MJFCIFSS
Note!
The characteristic of the solenoid valve Y50 cannot be adjusted.
4.1 Checking and adjusting the control pressure in emergency mode

Switch off the machine.
Remove the plug from the proportional solenoid valve Y50.
Remove the cotter pin and tilt the lever.
Compare the pressure values with those in Tab. 3 and adjust them, if necessary.
To do this, loosen the lock nut and turn the insert.
ª Turn clockwise (cw) = increase pressure
ª Turn counter-clockwise (ccw) = reduce pressure
Tilt lever back to its original position and insert cotter pin.
Reconnect the plug to the proportional solenoid valve Y 50.
Remove the pressure sensor/gauge and seal the measuring point 59.

3.84.9
copyright by
MJFCIFSS
Checking and adjusting the working pump (basic setting)
5 Checking and adjusting the working pump

(basic setting)
5.1 Checking and adjustment of the hydraulic begin of regulation of pump 20
adjustment point
Pressure at performance regulator bar Tank pressure - 59
Begin of pump regulation bar 50 ±2
88 41
44
Tab. 4 Settings
Fig. 7 Adjustment of begin of regulation of the pump 20
20 Variable-displacement pump 59 Measuring point LR

41 Measuring point MP 88 Adjusting screw / begin of regulation
44 Measuring point / actuating pressure 100 Compact control block
45 Measuring point LS 262 Secondary pressure-relief valve
50 Control oil unit Y50 Solenoid valve
The settings of the hydraulic begin of regulation must be adjusted at minimum pump rate. Before ad-
justing the settings, the pressure must be adjusted, so that the performance regulator = tank pressu-
re.
Disconnect the plug at the proportional solenoid valve LR (Y50 at the control oil unit 50), see Fig.
6.
Connect the pressure sensor or gauge (0 - 60 bar) to the measuring point 59 (control valve block
50), see Fig. 7.
3.84.10
copyright by
MJFCIFSS
100), see Fig. 7.
Connect the pressure sensor or gauge (0 - 600 bar) to the measuring point 44 (pump 20), see Fig.
7.
Start the machine and preselect the speed step 1.
Compare the pressure measured at the measuring point 59 and compare it with Tab. 4.
Extend bucket cylinder.

Set the secondary pressure-relief valve 262 to a value below the begin of regulation (pressure at
measuring point 44 = pressure at measuring point 41)
Slowly turn in the adjusting screw of the secondary pressure-relief valve 262 while monitoring the
pump pressure at the measuring point 41 and the control chamber pressure at the measuring
point 44.
ª At the prescribed begin of regulation (see table), the actuating pressure at the measuring
point 44 must begin to drop relative to the pump pressure at measuring point 41.
If necessary, adjust the control valve settings.

Loosen the lock nut (WS 13) of the adjusting screw 88.
Adjusting the begin of regulation to a later point

Turn the adjusting screw 88 (WS 6) clockwise.
ª Pressure is increased = later begin of regulation
Adjusting the begin of regulation to an earlier point

Turn the adjusting screw 88 (WS 6) counter-clockwise.
ª Pressure is reduced = earlier begin of regulation
Note!
If the begin of regulation is adjusted correctly for minimum output, the pump's begin of regulation is
correct across the entire performance regulating pressure range (GLR).
After completion of the adjustment, lock and secure the adjusting screw 88.

After checking or adjusting the regulating valves, adjust the secondary pressure-relief valve 262
to the prescribed value, see 8.2.
Reconnect the plug connection at the solenoid valve Y50.
3.84.11
copyright by
MJFCIFSS
Checking and adjusting the differential pressure between the pump pressure and the LS pressure
6 Checking and adjusting the differential pressure between the

pump pressure and the LS pressure
adjustment point
Pressure differential between the bar 20 +1 52 41
pump pressure and the LS pressure 45
up to 500 operating hours
from 500 operating hours
Tab. 5 Settings
Fig. 8 Adjustment of the flow regulator
20 Variable-displacement pump 52 Adjusting screw / flow regulator

41 Measuring point 100 Compact control block

45 Measuring point 262 Secondary pressure-relief valve / exten-
ding bucket cylinder
Before adjusting the differential pressure -p, check the begin of regulation and the limit load con-
trol Y50.
Note!
As the tolerance for the differential pressure -p is very small (+1 bar), use measuring instruments
with appropriate accuracy.
100), see Fig. 8.
Adjust the adjusting screw of the secondary pressure-relief valve 262 (set pressure to approx.
100 - 120 bar so that oil can flow through the valve 262 ).
Extend the bucket cylinder to the stop.
Connect the pressure gauge / sensor at connection LS to the measuring point 45 and measure
3.84.12
copyright by
MJFCIFSS
Checking the output power of the diesel engine (power test)
the differential pressure Δp between the measuring points 41 and 45, and compare them with the
prescribed value, see Tab. 5.
If necessary, adjust the differential pressure settingΔp at flow regulator of the variable-displace-
ment pump:
Loosen the lock nut (WS 13) of the adjusting screw 52 Fig. 8.
Increasing the differential pressure

Reducing the differential pressure

Readjust the secondary pressure-relief valve 262, see 8.2.
Note!
To check the dynamic behaviour of the settings, the differential pressure Δp can be checked again
while the extended attachment is slowly lifted. The pressure measured in this process may not differ
significantly from the pressure of the static measurement (difference maximum ±1.0 bar).
7 Checking the output power of the diesel engine (power test)
Principle:
The power of the diesel engine can be assessed by measuring the consumed power of the hydraulic
pump.
The power input of the pump can be calculated with the following formula:

If the pump is maintained at maximum pivot angle, the power input of the powertrain is determined
solely by the pressure and speed. This pressure value has been measured individually for each mo-
del and size of attachment, whereby secondary consumers have also been taken into consideration.
The A149 (UEC) control system ensures that the pump is kept at its maximum pivot angle (max. cur-
rent to Y50) and the fan is set to maximum speed (min. current to Y352). This function can be acti-
vated through the display or a laptop with appropriate program and accessories. The working
pressure is slowly increased to the prescribed value (see adjustment protocol). The engine speed
should not drop below the nominal speed.
adjustment point
Test pressure A 309 bar 125 242 / 262 41
A 311 bar 130 242 / 262 41

A 312 bar 125 242 / 262 41
A 314 bar 115 242 / 262 41
A 316 bar 125 242 / 262 41
Rated speed rpm 1800 - -
Difference between pump pressure bar < 10 - 41/ 44
and adjusting pressure
Tab. 6 Settings
3.84.13
copyright by
MJFCIFSS
Fig. 9 Operator's platform, pump and control block
12 Indicator light / SF function ON/OFF 242 Secondary pressure-relief valve

20 Variable-displacement pump 41 measu- 262 Secondary pressure-relief valve
ring point MP
44 Measuring point / pump actuating pres- S382 Switch / fine regulation SF (only if Tool
sure Control plus is active)

100 Compact control block
7.1 Procedure
Switch off ignition.
Plug the dongle to the interface X1167, see Fig. 1.
Connect the pressure gauge/ sensor gauge (0 - 600 bar) to the measuring point 41, see see Fig.
9.
Connect the pressure gauge/sensor or gauge (0 - 600 bar) to the measuring point 44 at the
pump 20, Fig. 9.

Start the machine.
Press the button 28 to move the cursor from the start screen to Service, see Fig. 10.
Press the button 28 to change to rs-functions.
3.84.14
copyright by
MJFCIFSS

ª The menu function is displayed.
ª The field function is highlighted.
Press the button 27 to change to the value line.
Press the button 29 to increase the figure (currently set to 0) to 16.
Caution!
Before confirming the value 16 with the button 26, ensure that the value 16 is shown on the display.
The input of a different value might cause problems with the A149 (UEC) control system, including
malfunction.
Ensure that the value 16 is entered.

ª The power test for the diesel engine is now activated.
ª The display indicates that the power test is on.

3.84.15
copyright by
MJFCIFSS
Fig. 10 Using Powertest function

* new screen from software version 1.10
Run the engine at speed step PP.

Lower the adjusting pressure at the secondary pressure-relief valve 242 and 262 (axle/stick and
bucket cylinder) to approx. 100 bar.
Disable the fine regulation with the switch S382 on the joystick , seeFig. 9 (only in AHS11/AHS12
with Tool Control plus active).
Extend the stick and bucket cylinder.#'.
Note!
During the build-up of the high pressure, closely monitor the control chamber pressure at the
measuring point 44 of the pump. Ensure that there is no significant pressure difference (≤ 10 bar)
to the measuring point 41 (no regulation of the pumps).
3.84.16
copyright by
MJFCIFSS
Turn in the adjusting screw of the secondary pressure control valve 242 or 262 until the prescribed
value is reached (see adjustment protocol), while checking the speed.
ª The power settings of the diesel engine are correct, when the diesel engine is pushed to ma-
ximum the prescribed value, see Tab. 6.
After checking the engine power, set the diesel engine to speed step 1 and run it at lower idle
speed for approx. 1 minute.
Switch off the engine (ignition off).
ª The Powertest function is deactivated.
Adjust the secondary pressure-relief valves 242 and 262 to the prescribed value, see 8.2.
# It is necessary to complete both movements and turn both secondary pressure-relief valves, in order to ensure that
the entire pump flow volume is fed through the system.

3.84.17
copyright by
MJFCIFSS
Adjusting pressure-relief and cut-off valves
8 Adjusting pressure-relief and cut-off valves
8.1 Checking/adjusting the pump safety valve 105
adjustment point
Pump safety valve bar 400 +20 105 41
Tab. 7 Settings
Fig. 11 Measuring points and valves at the pump, control block and travel motor
41 Measuring point MP 105 Pump safety valve

100 Compact control block 262 Secondary pressure-relief valve
104 Pressure cut-off valve
Connect the pressure sensor/gauge to the measuring point 41 (control block 100).
Increase the pressure cut-off 104 - by turning in the adjusting screw on the block and by turning
it back by a 1/4 rotation (90°).
Start the machine and preselect speed step PP (fine regulation SF disabled, see Fig. 9 optional).
Extend the bucket/grapple cylinder to the stop and fully actuate the right pilot control unit.
Increase the adjusting pressure at the secondary pressure-relief valve 262 (turning in adjusting
screw ) until the pump safety valve 105 responds.
This occurs when a further turning in of the adjusting screw of the secondary pressure-relief valve
262 does not result in a pressure increase at the measuring point 41.
Caution!
For reasons of safety, the pressure peaks above the permissible value may not put a strain onto the
unit.
To ensure this, adjust the pump safety valve 105 to a value of maximum 440 bar (measuring
point 41).
Compare the pressure value with the prescribed pressure of the pump safety valve 105, see Tab.
7 and adjust, if necessary.
3.84.18
copyright by
MJFCIFSS
Loosen the lock nut (WS 17).
Increasing pressure
Turn the adjusting screw clockwise, using an Allen key (WS 5).
Reducing pressure
Turn the adjusting screw counter-clockwise, using an Allen key (WS 5).
After completion of the adjustment, secure the adjusting screw with a lock nut.
8.2 Checking/adjusting the secondary pressure-relief valves 176 / 177, 221 - 262
adjustment point
Secondary pressure for extending boom bar 380 +20 221 45
cylinder bar 380 +20 222 45
Secondary pressure for retracting boom cy-
linder
Secondary pressure for retracting stick cy- bar 380 +20 241 45
linder bar 380 +20 242 45
Secondary pressure for extending stick cy-
linder
Secondary pressure for retracting bucket bar 380 +20 261 45
Secondary pressure for extending bucket
cylinder
Secondary pressure for extending control bar 380 +20 501 45
Secondary pressure for retracting control
cylinder

Secondary pressure for extending swivel bar 250 +20 581 45
cylinder* bar 250 +20 582 45
Secondary pressure for retracting swivel
cylinder*
Secondary pressure for reverse travel bar 380 +20 176 45
Secondary pressure for forward travel bar 380 +20 177 45
Tab. 8 Settings
* only in A 309 / A 311, see Fig. 13

3.84.19
copyright by
MJFCIFSS
Fig. 12 Measuring point and valves at pump, control block and travel motor in A 309 / A 311
Fig. 13 Measuring point and valves at pump, control block and travel motor in A 312 - A 316
20 Variable-displacement pump 241 Secondary pressure-relief valve


170 Travel motor 262 Secondary pressure-relief valve
176 Secondary pressure-relief valve 501 Secondary pressure-relief valve
221 Secondary pressure-relief valve 581* Secondary pressure-relief valve
222 Secondary pressure-relief valve 582* Secondary pressure-relief valve
3.84.20
copyright by
MJFCIFSS
* only in A 309 / A 311, see Fig. 13
Connect the pressure sensor/gauge to the measuring point 45 (variable-displacement pump).

Check the secondary pressure-relief valves 176, 177 221, 222, 241, 242 and 261 by moving the
respective devices to the stop. Adjust the settings, if required, see Tab. 8 (measuring point 45).
Increasing pressure
Reducing pressure
8.3 Checking/adjusting secondary pressure-relief valve for attachment kit AS1
adjustment point
Secondary pressure for turning grapple to bar 110 +20 541 45
the left bar 110 +20 542 45
Secondary pressure for turning grapple to
the right
Turning speed for turning grapple to the bar 15,6 1 1
left bar 15,6 2 2
Turning speed for turning grapple to the
right

Tab. 9 Settings
Fig. 14 Measuring point for LS pressure, control block and additional control axle with secondary
3.84.21
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pressure-relief valves
20 Variable-displacement pump 540 Additional control valve / AS1

45 Measuring point LS 541 Pressure-relief valve
100 Control valve block 542 Pressure-relief valve
Remove the protective cap at the measuring point 45.

Connect a measuring sensor / gauge (600 bar).
Close the stop cocks or disconnect the pressure connections (seal).
Pressurise the accessory kit, using the keys S5L / S5R located at the left pilot control unit.
Compare the pressure indicated at the pressure sensor with the prescribed pressure, see Tab. 9.
If necessary, re-adjust the pressure by means of the adjusting screw at the corresponding pres-
sure-relief valve 541 / 542.
Proceed as follows: Loosen the lock nut. Use a WS 6 Allen key to turn the adjusting screw.
Turn screw in
ª Increasing pressure
Turn screw out
ª Reduce pressure
Remove the pressure sensor and seal the measuring point 45.
Open the stop cocks or pressure connections.
8.4 Adjusting the operating pressure (pressure cut-off valve 104)
adjustment point
Operating pressure bar 350 +10 104 41
Tab. 10 Settings
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Checking the slewing gear
41 Measuring point MP 104 Pressure cut-off valve

Set the operating pressure at the cut-off valve 104 to the prescribed value, see Tab. 10 (measu-
ring point 41).
Increasing pressure
Reducing pressure
9 Checking the slewing gear
adjustment point
Current at Y451 at 100% mA 600 +50
Primary pressure at 100% bar 230 +10 11 137 / 138
Tab. 11 Settings

Fig. 16 Proportional solenoid valve settings
11 Adjusting screw Y451 Proportional solenoid valve

12 Lock nut
Connect the pressure sensor to the measuring points 137 / 138, see Fig. 20.
Block the uppercarriage by applying the slewing gear brake (maximum pressure cannot be rea-
3.84.23
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ched if the uppercarriage is rotating).
In the menu, select torque slew (see Fig. 4).

ª The slewing gear settings must be at 100(%).
If required, adjust the value as described in Fig. 17 to 100.
Press the pilot control unit for "turning left/right" to the stop.
Compare the maximum pressure with the value in Tab. 11 (measuring points 137 / 138).
If required, loosen the lock nut 12 of the proportional solenoid valve Y451 and adjust the maximum
pressure with the adjusting screw 11, see Fig. 16.
After the correct settings are made, secure the adjusting screw with the lock nut 12. Torque set-
tings of slewing gear
The operating behaviour of the slewing gear can be adjusted in the "torque slew" menu to suit the
actual excavation work.
In the menu, select torque slew, see Fig. 17.
Change the value 100 to the desired value, using the buttons 28 / 29.
Change in direction < 100% (e.g. 55) = the slewing gear responds with slight delay (soft movement).
ª The value is saved.
Fig. 17 Torque slew menu start screen with adjustment of torque slew 100(%) to torque slew
55(%) (to software version V1.09)
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70(%) (from software version V1.10)
Note!
By adjusting the torque slew value between 100 and 0%, the primary pressure value is automatically
adjusted, see Tab. 11.
From software version V1.10, the desired pressure value is entered by adjusting the bar rather than
entering the respective figures.
In this case:
Use the buttons 28 / 29 to enter the desired value and confirm with button 26.
9.1 Checking of current to proportional solenoid valve Y451

Note!
The parameters of the torque control characteristic are preset by the UEC excavator control system.
Access menu Info - IO to view the current to the proportional solenoid valve Y451. By adjusting the
torque slew value between 100 and 0%, the current is automatically adjusted, see Tab. 11.

Press the button 28/29 to call up number 74 (current to solenoid valve Y451) and check the actual
current value.
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Fig. 19 Diagram of the slewing gear adjustment by means of proportional solenoid valve Y451
9.2 Checking and adjusting the secondary pressure for the slewing gear
adjustment point
Start-up
Secondary pressure / turning right bar 250 +10 134.2 137
Secondary pressure / turning left bar 250 +10 134.2 138
Slowing down
Secondary pressure / turning right bar 90 ±5 134.4 137
Secondary pressure / turning left bar 90 ±5 134.4 138
Tab. 12 Parameters
3.84.26
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9.2.1 Adjustment of start-up pressure (high pressure settings)

Fig. 20 Slewing gear motor with pressure-relief valves, with sample diagram
I Relationship between the secondary protection and the control pressure for
swivelling
5 Secondary setting, minimum value (braking)
6 Secondary setting, maximum value (starting)
1 Lock nut 130 Slewing gear motor

2 Adjusting screw / high pressure 134 Secondary pressure-relief valve
3 Lock nut 135 Secondary pressure-relief valve
4 Adjusting screw / low pressure 137 Measuring point

138 Measuring point
3.84.27
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Danger!
To check and adjust the slewing gear drive, the system must be pressurised to maximum pressure.
This can lead to inadvertent rotation of the uppercarriage and thus poses a great risk of injury to
mechanics. Objects located within the swivel range of the machine could be damaged. To prevent
this, complete the following steps:
Apply the slewing gear brake.
Anchor the equipment to the ground.

Plug the dongle to the interface X1167,see Fig. 1 and start ignition.
Press the button 28 to preselect submenu torque slew.
Press the button 28 to preselect submenu test.
ª The valve Y451 is powered with maximum current and high pressure can thus be reached, see
Fig. 20.
Note:
In order to ensure accurate pressure limitation/pressure settings of the slewing gear function, the
secondary pressure at the secondary pressure-relief valves 134 / 135 must be at least 10 bar above
the measured maximum primary pressure.
Block the uppercarriage (maximum pressure cannot be reached if the uppercarriage is rotating).

Press the pilot control unit for "turning left" to the stop.
Compare the pressure with that in the adjustment protocol (measuring point 138).
If necessary, remove the lock nut 1 and adjust the settings of the pressure-relief valve 135 with
the adjusting screw 2, see Fig. 20.
Press the pilot control unit for "turning right" to the stop.
After checking the test value, press the button 28 to reset it to 0. Confirm the settings by pressing
the button 26 and then select ⇒back and press the button 27 to return to the menu or switch off
the ignition.
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Fig. 21 Menu for slewing gear settings
25 Display 26 ENTER button (confirmation)

27 Push button / cursor to right 28 DOWN button
29 UP button M Start menu at service level
9.2.2 Adjustment of brake pressure (low pressure settings), Fig. 20

Disconnect and seal the two hose connections to X and Y.
ª If necessary, loosen the lock nut 3 and adjust the settings of the pressure-relief valve 135 with

Re-connect the hose connections at X and Y.
9.3 Adjustment of the maximum turning speed, Fig. 22
Location of Measurin
Machine Check / adjustment Unit Setting
adjustment g point
A 309 - Turning speed / turning right rpm 9, 5 - 10,0 120.1.1 -
A 312 Turning speed / turning left rpm 9, 5 - 10,0 120.2.1 -
A 314 - Turning speed / turning right rpm 9, 0 - 9,5 120.1.1 -
A 316 Turning speed / turning left rpm 9, 0 - 9,5 120.2.1 -
Tab. 13 Settings
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Fig. 22 Slewing gear control axle with stroke limitation
.1 Adjusting screw 120 Slewing gear control axle

.2 Lock nut 120.1 Control piston stroke limitation for turning left
100 Compact control block 120.2 Control piston stroke limitation for turning right
The maximum turning speed of the uppercarriage is determined by the stroke limitation settings of
the spool / slewing gear.
Danger!
To determine the maximum turning speed of the uppercarriage, the uppercarriage must be moved
at full speed for minimum 1 minute. Risk of injury or even death! Ensure that no persons are stan-
ding within the range of operation of the uppercarriage when this measurement is carried out!
All persons must leave the danger area of the machine.
Secure the undercarriage. If necessary, use supports.
Move the pilot control unit for turning slewing gear to the right / left to the stop.
When the maximum turning speed is reached, start the time period for the uppercarriage speed
measurement.
Measure the number of revolutions per minute and compare it with the prescribed values, see
Tab. 13.
ª If necessary, remove the cap nut, loosen the lock nut 2 and turn the stop screw 1 of the stroke
limitation 120.1 / 120.2.
To increase speed:
Turn the adjusting screw 1 out.
ª The speed is increased.
To reduce speed:
Turn the adjusting screw 1 in.

ª The speed is reduced.
Repeat the adjustment on the other side of the spool 120 (left and right rotation).
After the adjustment is completed, secure the adjusting screw with the lock nuts 2 and then re-
place the cap nuts.
3.84.30
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Checking the travel motor 170
10 Checking the travel motor 170
Danger!
For inspection and adjustment work, it is necessary to access the undercarriage.
This can be dangerous for technicians. There is a risk of serious injury or even death from rotating
wheels and shafts, or if the machine begins to move.
Extend the supports.
Place the attachment onto the ground and lift the undercarriage from the ground, if necessary.
Establish visual or acoustic contact with the operating personnel.
10.1 Adjustment of the begin of regulation / end of regulation
adjustment point
Begin of regulation bar 240+10 64 45 / M
End of regulation bar 320 64 45 / M
Tab. 14 Settings

Fig. 23 Checking travel motor
20 Variable-displacement pump 64 Begin of regulation / adjusting screw

35 Threaded stud Qmin stop 170 Travel motor
45 Measuring point M Connection for measuring point
3.84.31
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Note!
The difference between the begin of regulation and the end of regulation of the oil motor is preset
and cannot be adjusted. This means that a change to the end of regulation value automatically re-
sults in a change to the begin of regulation value.
Condition: The outputs of the diesel engine and the hydraulic pump must correspond to the
prescribed values (see adjusting protocols and hydraulic pump settings in group 7.10).
Connect the pressure sensor/gauge to the measuring point 45 (pump 20), see Fig. 22.
Remove the screw plug from the measuring connection M, see Fig. 23.
Screw in the screw coupling assembly M10x1 / M4x1.5 (tool no. 10 / 12 in group 2.01, with ex-
tension, if required) and connect a pressure gauge / sensor.
Jack up the machine and run the travel motor in on-road gear at full speed (operate pilot control
unit). Take all necessary safety precautions.
Operate the brake pedal to slowly apply the working brake (4-wheel brake). High pressure builds
up at the measuring point 45.
ª Below the begin of regulation for the motor (see values in Tab. 14), there should be no pressure
build-up at the measuring connection M, i.e. the oil motor is at minimum pivot angle.
Continue to accelerate the motor to max. value. Pay close attention to the two pressure gauges
(at measuring points 45 and M).
ª From the moment of begin of regulation, the pressure at the measuring connection M must
continue to rise (to about 1/2 high pressure value). The oil motor is adjusted towards the max.
pivot angle.
ª As soon as the high pressure (at measuring point 45) reaches the value of the end of regula-
tion (see Tab. 14), the value measured at the measuring point M increases to the high pressure
value, i.e. the pressures at measuring points 45 and M are identical.
If the pressure value for the end of regulation does not correspond to the prescribed value, it can be
adjusted by means of the adjusting screw 64, see Fig. 23.
Release the adjusting screw 64.
Increasing the end of regulation

ª The end of regulation is increased.
Reducing the end of regulation

Turn adjusting screw 64 out.
ª The end of regulation is reduced.
Remove the two pressure gauges/sensors, remove the screw coupling at M and seal both measu-
ring points.
10.2 Adjustment of the minimum pivot angle
adjustment point
Check dimension X in A 309 - A 312
Standard machine mm 23.8 35 35
Speeder machine mm 23.8 35 35
3.84.32
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Check dimension X in A 314

Check dimension X in A 316
Tab. 15 Settings
Fig. 24 Stop screw (threaded stud) of the swivel yoke for minimum pivot angle
The minimum pivot angle is set by the threaded stud 35, see Fig. 23. The angle is factory-set by the
manufacturer and may not be changed.
The correct position of the threaded stud 35 can be used as a reference value after measuring of the
dimensions X, see Fig. 24 and Tab. 15 and comparison with the adjustment protocol.
10.3 Adjustment of the maximum output speed/maximum travel speed
adjustment point
Universal joint shaft speed in A 309 /
A 311
Standard machineForward travel rpm 1850 ±25 160.1.1 -
Reverse travel rpm 1850 ±25 160.2.1 -

Speeder machine Forward travel rpm 2750 ±25 160.1.1 -
mm 12
Standard machine - 160.1
mm
Speeder machine 14 - 160.2
Universal joint shaft speed in A 312
Speeder machine Forward travel rpm 2700 ±25 160.1.1 -

Standard machine mm 12 - 160.1

mm
3.84.33
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Speeder machineForward travel rpm 2870 ±25 160.1.1 -

mm
Standard machine 11.5 - 160.1
mm
Speeder machineForward travel rpm 2520 ±25 160.1.1 -

mm
Standard machine 11.5 - 160.1
mm
Tab. 16 Settings
Fig. 25 Checking travel motor
3.84.34
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100 Compact control block 160.1.2 Lock nut of the stroke limitation .1
160 Spool / travel drive 160.2 Stroke limitation .2 / forward travel
160.1 Stroke limitation .1, reverse travel 160.2.1 Adjusting screw of the stroke limitation
.2
160.1.1 Adjusting screw of the stroke limitation 160.2.2 Lock nut of the stroke limitation .2
.1
The maximum output speed of the oil motor is determined by the minimum flow consumption of the
oil motor (Qmin) and the maximum flow rate of the spool/chassis 160.
Note!
The max. flow rate is factory-set by the manufacturer by means of the stroke limitation of spool 160
(dimension Y, see above) and may only be adjusted in exceptional circumstances.
If there is a problem with the max. travel speed of the machine, the setting can be modified, if the
max. speed measured at the universal joint shaft (connection between gearbox and axles) is not in
line with the value stated in the adjustment protocol, see Tab. 16.
Adjustment of the maximum output speed:

Jack up the vehicle and run it in on-road gear (travel pedal pressed down to stop).
Measure the maximum speed of one joint shaft, using the HT 460 speed meter (for tool, see
page 2.01.07) and compare with the prescribed speed (see table).
If the measured speed does not correspond to the prescribed speed, proceed as follows:
At the fully actuated pilot control unit, remove the cap nut of the chassis control axle 160 of the
control valve block 100.
Loosen the lock nut .2 of the stroke limitation 160.1/160.2.
Reducing the speed:

Turn the adjusting screw .1 in.

Increasing the speed:

Turn adjusting screw .1 out.
Repeat the adjustment on the other side of the spool 160 (forward and reverse travel).
After adjustment of the speed, secure the adjusting screws 160.1/160.2 and replace the cap nuts.
After completion of the adjustment, retract the support.
11 Checking the fan speed

Locatio
n of Measuring
adjustm point
ent
A 309 - A 311 rpm 2050 +50 - 12
Fan speed during emergency operation
(nnot)
3.84.35
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A 312 rpm 2000 +50 - 12

(nnot)
A 314 - A 316 rpm 1750 +50 - 12
(nnot)
Current at Y352 during emergency operation mA 160 - 1
(nnot)
Current at Y352 during emergency operation mA 100* - 1
(nnot)
Tab. 17 Settings
* from software version 1.10
Fig. 26 Fan motor with proportional solenoid valve
13 Fan motor Y352 Proportional solenoid valve
Danger!
Moving fan blades might cause serious injury to fingers and hands.
Shut down the engine.
Do not reach into the fan operating range until the fan blades have come to a standstill.
The fan speed to be measured depends on the current temperature of the coolant and the hydraulic
oil.
The fan speed and thus the hydraulic circuit (pump / oil motor) can be checked by presetting the mi-
nimum current for the proportional solenoid valve Y352 in the UEC excavator control system (fan
speed for emergency operation).
To activate the check mode through the display, proceed as follows:
Note!
Alternatively, the check mode can be activated through a laptop with the required program and ac-
cessories.
To check the fan speed with the speed counter (tool no. 62 / 63), apply a reflective strip to the fan
blade.
3.84.36
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To check the fan speed, ensure that the temperature of the hydraulic oil is > 50 °C.
Measure the hydraulic oil temperature, see 2.3.
ª If the temperature of the hydraulic oil is too low, heat it up.
Start the machine.
Press the button 28 to preselect submenu rs-functions.
ª The menu functionsee Fig. 27is displayed.
Caution!
malfunction.

ª The fan is now in emergency mode.
Measure the emergency fan speed.
ª Compare the measured fan speed with the prescribed value nnot, see Tab. 17.

Note!
The fan speed cannot be adjusted. The pressure is factory-set by the manufacturer and may not be
changed. The above measurement serves only to establish proper functioning. If the measurement
indicates that there is a substantial difference between the actual and the specified value, check the
hydraulic circuit for faults.
After checking the fan speed, set the diesel engine to speed step 1 and run it at lower idle speed
for approx. 1 minute.
ª The emergency mode function for the fan speed is deactivated.
Remove the dongle.
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Fig. 27 Service function program for emergency operation

3.84.38
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Checking the steering system
12 Checking the steering system
12.1 Checking the pressure-relief valve in the steering valve 84
adjustment point
Primary pressure bar 180 +8 - 83
Tab. 18 Settings
Fig. 28 Measuring point for steering and steering valve with primary and secondary valves
5 Primary pressure-relief valve 83 Measuring point for steering pressure

6 Shock valve 84 Steering valve

Remove the cover cap at the measuring point 83 and connect the pressure sensor or pressure
gauge (600 bar).
Heat the hydraulic system to operating temperature.
Start and run the diesel engine at its lower idle speed (level 1).
Move the vehicle wheels to the outer steering positions (right and left).
Slowly turn the steering wheel against the resistance.
Compare the pressure indicated at the pressure gauge/sensor with the prescribed pressure, see
Tab. 18.
ª If the pressure is not reached at only one of the steering positions (left/right), it is likely that the
shock valve 6 is faulty.
ª If the pressure is not reached in both steering positions, it is likely that the primary pressure-
relief valve 5 is faulty.
3.84.39
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Checking the brake system
Caution!
Faults in the steering valves can cause problems with the steering function or failure of the servo
system. The manufacturer therefore explicitly prohibits repairs / replacements of the safety valves
in the steering valve 84.
If measurements reveal that the necessary steering pressure is not reached, it is likely that the pri-
mary pressure-relief valve / shock valve 5/6 is defective. In this case, the complete steering valve
84 must be replaced.
The installation and dismantling of the steering valve 84 is described in group 13.20 / 13.25.
After the installation of the new steering valve 84, check the steering system again for proper func-
tioning and adjust the pressure settings, if necessary.
Remove the pressure sensor or gauge 83 and mount the cover cap.
13 Checking the brake system
adjustment point
Accumulator charge pressure A 309 -
A 312 bar 125 ±5 74 27
Switch-on bar 150 ±5
pressure
Shut-down
pressure
Accumulator charge pressure A 314 /
A 316 bar 150 ±5 74 27
Switch-on bar 185 ±5
pressure
Shut-down
pressure
Brake pressure A 309
front bar 50 +5 102 25
rear bar 50 +5 102 26

Brake pressure A 311
front bar 55 +5 102 25
rear bar 55 +5 102 26
Brake pressure A 312 - A 316
front bar 75 +10 102 25
rear bar 75 +10 102 26
dropping bar 100 ±5 76 153
increasing bar 125 ±5 76 27
bar 5 77 25/26
Tab. 19 Settings
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Fig. 29 Compact brake block below operator's platform
4 Compact brake block 77 Adjusting screw / pressure switch B60

25 Brake accumulator / front brake circuit 102 Threaded rod / brake valve operation
26 Brake accumulator / rear brake circuit 153 Measuring point / pressure switch B20
27 Measuring point / accumulator charge B20 Pressure switch / accumulator pressure
pressure

74 Adjusting screw / accumulator charge B60 Pressure switch / brake light
pressure
76 Adjusting screw / pressure switch B20
13.1 Checking of the accumulator charge pressure

Connect the 0-600 bar pressure gauge/sensor to measuring point 27 and check the following va-
lues:
13.1.1 Switch-on and shut-off pressure of the charging valve 5

Start the diesel engine and recharge the unit.

ª The pressure at the measuring point 27 rises until the prescribed shut-off pressure is reached
(see table).
ª The accumulator valve 5 is now switched, so that the system is depressurised, and the pres-
sure at the measuring point 27 drops to zero.
Repeatedly actuate the brake pedal 11 until the pressure in the accumulators drops to the switch-
on pressure level.
ª The pressure at measuring point 27 rises again to the level of the shut-off pressure.
3.84.41
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To check the switch-on pressure, remove the pressure switch B20, mount a M10 X 1 screw coupling
assembly and connect a 0-600 bar pressure sensor (if required, use a pressure switch B20 conver-
sion kit, see 13.1.3).
If required, loosen the lock nut 75 and adjust the switch-on and switch-off pressures to the prescri-
bed value by turning the adjusting screw 74 (see table).
Turn in = Increasing pressure
Turn out = Reduce pressure
Protect the adjusting screw with a protective cap.
Fig. 30 Compact brake block with accumulator and brake pedal

11 Brake pedal 27 Measuring point / accumulator charge

pressure
12 Locking lever 74 Adjusting screw / accumulator charge
pressure
14 Brake accumulator / front brake circuit B20 Pressure switch / accumulator pressure
15 Brake accumulator / rear brake circuit B60 Pressure switch / brake light
13.1.2 Switching pressure of pressure switch B20 (increasing)

If there is a fault indicating that the pressure switch is faulty, the switching pressure of the pressure
switch B20 can be checked through the existing measuring point 27 within the increasing range:
Connect a pressure sensor (0-600 bar) to the measuring point 27, see Fig. 31.
Start the diesel engine and monitor the pressure sensor and the indicator LED 24: when the
prescribed switching pressure is reached (see Tab. 19), the indicator LED 24 must be off.
The switching pressure of the pressure switch B20 should only be adjusted after the dropping
switching pressure has been checked, see 13.1.3.
3.84.42
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Fig. 31 Measuring point for accumulator pressure and indicator LED in indicating and control unit
24 Indicator LED for accumulator pressure A150 Indicating and control unit
27 Measuring point / accumulator pressure
13.1.3 Switching pressure of pressure switch B20 (dropping)

TUEV requires that the switching pressure of the pressure switch B20 is checked in the dropping ran-
ge.
Note!
The switching pressure of the pressure switch B20 in the dropping range can only be checked by
installing an additional measuring point 153 between the connection DS2 and the pressure switch
B20, see Fig. 32.
Switch off the engine. Release the pressure from the system.
Disconnect the pressure switch B20 from the connection DS2 and screw in the "pressure switch

B20 conversion kit"; for details, see tool list 2.01 and Fig. 32.
Screw the pressure switch B20 into the screw piece of the "pressure switch B20 conversion kit".
Start the diesel engine and charge the brake accumulator to the maximum level.
Shut down the diesel engine, leave the ignition on and reduce the brake pressure by repeatedly
operating the foot pedal.
ª As soon as the switching pressure (dropping) is reached, the indicator LED 24 at the control
desk is on.
Read the pressure at the additional measuring point 153 at the moment the indicator LED24 is lit,
and compare it with the prescribed pressure value, see Tab. 19.
If the pressure switch B20 does not switch at the prescribed value, adjust it with a screwdriver:
Increase switching pressure

Turn the adjusting screw 76 clockwise.
Reduce switching pressure

Turn the adjusting screw 76 counter-clockwise.
3.84.43
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MJFCIFSS
Caution!
For safety reasons, the pressure switch conversion kit must be removed after the check has been
completed.
To do this, follow the instructions below and then mount the pressure switch B20 in its original
position (connection DS2).
Switch off the engine. Release the pressure from the system.
Screw out the pressure switch B20
Remove the "pressure switch B20 conversion kit".
Screw in the pressure switch B20 to the connection DS2.
Establish the electrical connections and test them.
Fig. 32 Measuring point for accumulator pressure and compact brake block with pressure swit-
4 Compact brake block 152 T-connection fitting
27 Measuring point / accumulator pressure 153 Measuring piece
74 Adjusting screw / accumulator charge 154 Screw piece
pressure
76 Adjusting screw / response pressure B20 Pressure switch / accumulator pressure
B20
77 Adjusting screw / response pressure B60 Pressure switch / brake light
B60
151 Screw-in stud
ches and conversion kit
13.1.4 Switching pressure of pressure switch B60

Connect a pressure sensor (0-600 bar) to the measuring point 25, see Fig. 29.
Start the diesel engine and recharge the brake accumulator.
3.84.44
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Carefully press down the brake pedal 11, see Fig. 33.
ª The brake lights E19 / E20 must be on when the pedal 11 is pressed down only a little.
Read the pressure at the measuring point at the moment the brake lights are lit, and compare it
with the prescribed pressure value, see Tab. 19.
If the pressure switch B60 does not switch at the prescribed value, adjust it with a screwdriver:
Increase switching pressure

Reduce switching pressure

Install additional measuring point.
13.2 Checking of the brake pressure of the working brake

Fig. 33 Brake pedal and operating linkage of the brake valve at the compact brake block
11 Brake pedal 17 Lock nut

12 Locking lever 18 Pin
13 Stop screw / front 29 Stop screw / rear
16 Fork head 102 Threaded bolt
Connect a pressure sensor (0-600 bar) to the measuring points 25 and 26, see Fig. 29.
Start the diesel engine. Press down the foot brake pedal 11 and lock it.
ª The actual brake pressure, as shown at the pressure sensor, must correspond to the respec-
tive value, see Tab. 19.
To adjust the brake pressure, modify the linkage length as follows:
Press the pedal 11 down to the stop and check whether the pedal 11 engages in the locking lever
12.
Adjust stop screw 13 so that there is only minimum play between the locked pedal and the upper
3.84.45
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MJFCIFSS
edge of the screw.

While the pedal 11 is engaged, loosen the lock nut 17 and turn the threaded rod 102 so that the
pressure measured at the measuring points 25 and 26 (Fig. 29) corresponds to the prescribed
pressure.
Re-tighten the lock nut 17 .
Release the pedal 11.
Unlock and drive out the pin 18 (Ø 10 mm) inserted between the fork head 16 and the pedal lever,
and insert a Ø 9 mm pin (drill bore, if necessary).
Loosen and adjust the stop screw 29 until there is no play between the fork head 16 and the in-
serted pin.
Secure the stop screw 29 with a lock nut.
Remove the Ø 9 mm adjusting pin and re-insert and lock the original Ø 10 mm pin 18.
ª The threaded rod is now correctly pre-stressed (1 mm).
After the adjustment is completed, check whether the measuring points 25 and 26 remain without
pressure when the pedal 11 is not pressed.
If required, readjust the position of stop screw 29.
13.2.1 Checking of the brake accumulators 14 and 15

Connect a pressure sensor (0-600 bar) to the measuring point 27, (see Fig. 32 on page44).
Connect a pressure sensor (0-600 bar) to the measuring points 25 and 26, (see Fig. 29 on
page41).
Start the diesel engine. Charge the system all the way up to shut-off pressure.
Shut down the diesel engine and slowly press down foot brake pedal 11, Fig. 29 - at least ten ti-
mes, with short intervals.
ª Having done that 10 x, the brake pressure at measuring points 25 and 26 Fig. 29 should not
drop below 50 bar filling pressure.
ª If the pressure has dropped below the prescribed value, there is most probably a problem with
accumulators 14 / 15. Release the pressure from the system and install new accumulators.
Remove the pressure sensor and seal the measuring points 25, 26 and 27.
3.84.46
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MJFCIFSS
General
Checking and adjusting tasks
1 General
1.1 Instructions for adjustment / pre-conditions

– During the warranty period, all adjustment work on the machine must be carried out by authorised
specialist technicians.
– The operating temperature of the hydraulic unit must be minimum 50° C (indicated on display, see
2.3.3).
– The pressure gauges must be glycerine-damped with an indication accuracy of less than 1%.
– The pressure gauges must have an indication accuracy of ±0.3 bar.
– To secure the adjusting screws of the valves against unauthorised interference, they must be
equipped with protective caps (see special tools in group 2.05 ).
1.2 Safety precautions for checking and adjusting work

When carrying out checking and adjusting work, observe the general accident prevention regulations!
For details, see safety instruction in main group 1.
Ensure that the machine operator in the operator's cab and the maintenance workers can at all times
see each other.
1.3 Measuring instruments / adjusting tools / safety of adjusting screws
1.3.1 Measuring instruments

The following measuring instruments of group 2.01 are required for the testing and adjustment of the
hydraulic system:
– High-pressure measuring lines

• Tools no. 7 or 8
– For differential pressure Δp measurement:
• Differential pressure gauge no. 30
– For speed measurement:
• Tools no. 60/62-64
– For current measurement:
• Tool no. 65
– For temperature measurement:
• Tools no. 70/72
3.87.1
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MJFCIFSS
General
Alternatively use the following measuring instruments:

– Hand-held measuring device MH 3010 (tool no. 30.1)
– plus measuring cables and accessories for the measuring of speed and temperature
1.3.2 Adjusting tools:

All adjustments to the valves / units can be made with conventional ring spanners, open-end wren-
ches and Allen keys.
3.87.2
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MJFCIFSS
General
1.4 Location of the measuring points and interface for access authorisation

Fig. 1 Measuring points on the components and interface / dongle
20 Variable-displacement pump 59 Measuring point / LR pressure

at the control oil unit 50 (MLR connec-
tion)
41 Measuring point for high pressure 100 Compact control block
at the control block 100 (MP connec-
tion)
44 Measuring point / actuating pressure 130 Slewing gear motor
at pump 20 (MA connection)
45 Measuring point / LS pressure 137 Measuring point for slewing gear wor-
at pump 20 (X2 connection) king pressure

(MA connection / pivot right)
49 Measuring point / pilot pressure 138 Measuring point for slewing gear wor-
(connection M1) king pressure
(MB connection / pivot left)
50 Control oil unit X1167 Interface for dongle
in right control desk
3.87.3
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MJFCIFSS
Basic settings
2 Basic settings
2.1 Info hours

Press the button 28 to move the cursor from the start screen to Info-hours.
ª The hours (operating hours counter) screen is displayed.
It shows the total operating hours of the machine, e.g. 1.
Repeatedly press the button 28 to call up
• the daily operating hours counter (hours-day)
• the operating hours at the various engine speeds = low for speeds 1 - 5, mid for speeds 6 - 8
and high for speed 9 - 10 (hours-rpm)
• the operating hours with sensor control (hours-sensor)
• the operating hours in travel mode (hours-drive)
Fig. 2 Calling up operating hours counters of machine

2.2 Info-Software screen

Press the button 28 to move the cursor from the start screen to Info-Software.
ª The screen M: S: D:
The screen shows the software version of the excavator control, the auxiliary control and the machine
display:
3.87.4
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MJFCIFSS
Basic settings
Fig. 3 Calling up the software version information
25 Display A Start screen

26 ENTER button (confirmation) D Display
27 Push button / cursor to right M Master (excavation control)
28 DOWN button S Slave (auxiliary control)
29 UP button
2.3 Info I/O (inputs / outputs)
adjustment point
Machine type R 313 4 - Display
R 317 8 - Display
Regulated speed rpm 1800 - Display

+100
Low idle rpm rpm 850 - Display
High idle rpm +30
rpm 1890 - Display
+10
Hydraulic oil temperature °C > 50 - Display
Tab. 1 Settings

Press the button 28/29 to call up various values/information, e.g.
• 1 Excavator type
• 3 Rotational speed / diesel engine
• 11 Cooling water temperature
• 12 Hydraulic oil temperature
3.87.5
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MJFCIFSS
Basic settings
• 13 Engine oil pressure

• 27 Regulated speed / limit load control
• etc.
Fig. 4 Calling up details and values regarding the machine displayed in the values-master menu

2.3.1 Calling up machine type details

Access menu Info I/O var-master values-master number 1: read the Code no. indicating
the machine type:
e.g. code 4 for R 313 TCD type 1038, code 8 for R 316 TCD type 1042
2.3.2 Calling up diesel engine speed

Run engine at speed step PP. Access menu Info I/O var-master values-master number
27: read the regulated speed for limit load control:
Run engine at speed step PP and speed step 1. Access menu Info I/O var-master values-mas-
ter number 3: read the upper and lower idle rpm:
2.3.3 Calling up hydraulic oil temperature

Warm up machine. Access menu Info I/O var-master values-master number 12: read the
actual hydraulic oil temperature:
3.87.6
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MJFCIFSS
Checking and adjusting the pilot pressure
3 Checking and adjusting the pilot pressure
adjustment point
Pilot pressure bar 32 ±1 51 49
Tab. 2 Settings
Fig. 5 Control oil unit with adjusting screw / pilot control pressure
49 Measuring point / pilot pressure 50 Control oil unit

51 Adjusting screw / pilot control pressure
Connect the pressure sensor or gauge (60 bar) to the measuring point 49.
Compare the pressure at the pressure sensor with the prescribed pressure, see Tab. 2.

If necessary, adjust the setting of pressure-relief valve 51.
To do this, remove the protective cap and loosen the lock nut (WS 13).
Increasing pressure
Turn the adjusting screw 51 clockwise, using an Allen key (WS 4).
Reducing pressure
Turn the adjusting screw 51 anticlockwise, using an Allen key (WS 4).
Replace the protective cap.

Remove the pressure gauge and seal the measuring point.
3.87.7
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MJFCIFSS
4 Checking and adjusting the limit load control system
adjustment point
Checking of Y50 mA 600 +30 -
bar 8 ±1 - 59
Tab. 3 Settings
Fig. 6 Control oil unit with proportional solenoid valve in normal/emergency position and measu-
ring points
50 Control oil unit Y50 Proportional solenoid valve / power con-

trol
59 Measuring point LR
Connect the pressure sensor/gauge to the measuring point 59, see Fig. 6.
Start the machine.
On the display, change to menu values master , see 2.3 and Fig. 4.
Press the buttons 28 / 29 to call up the current value at Y50 (number 7) and compare it with the
nominal value, see Tab. 6.
Select engine speed step PP.
Compare the actual control pressure at the measuring point 59 with the nominal value, see Tab. 3.
Regulating diagram, see also group 7.42
– Current OK Pressure OK => OK

– Current OK Pressure not => Replace proportional solenoid valve.
OK
– Current not Pressure not => Search for fault in the electrical system and the limit
OK OK load control
3.87.8
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MJFCIFSS
Note!
The characteristic of the solenoid valve Y50 cannot be adjusted.
4.1 Checking and adjusting the control pressure in emergency mode

Switch off the machine.
Remove the plug from the proportional solenoid valve Y50.
Remove the cotter pin and tilt the lever.
Compare the pressure values with those in Tab. 3 and adjust them, if necessary.
To do this, loosen the lock nut and turn the insert.
ª Turn clockwise (cw) = increase pressure
ª Turn counter-clockwise (ccw) = reduce pressure
Tilt lever back to its original position and insert cotter pin.
Reconnect the plug to the proportional solenoid valve Y 50.
Remove the pressure sensor/gauge and seal the measuring point 59.

3.87.9
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MJFCIFSS
5 Checking and adjusting the working pump

(basic setting)
5.1 Checking and adjustment of the hydraulic begin of regulation of pump 20
adjustment point
Pressure at performance regulator bar Tank pressure - 59
Begin of pump regulation bar 50 ±2
88 41
44
Tab. 4 Settings
Fig. 7 Adjustment of begin of regulation of the pump 20
20 Variable-displacement pump 59 Measuring point LR

41 Measuring point MP 88 Adjusting screw / begin of regulation
44 Measuring point / actuating pressure 100 Compact control block

50 Control oil unit Y50 Solenoid valve
The settings of the hydraulic begin of regulation must be adjusted at minimum pump rate. Before ad-
justing the settings, the pressure must be adjusted, so that the performance regulator = tank pressu-
re.
3.87.10
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MJFCIFSS
Disconnect the plug at the proportional solenoid valve LR (Y50 at the control oil unit 50), see Fig.
6.
50), see Fig. 7.
100), see Fig. 7.
Connect the pressure sensor or gauge (0 - 600 bar) to the measuring point 44 (pump 20), see Fig.
7.
Compare the pressure measured at the measuring point 59 and compare it with Tab. 4.
Extend bucket cylinder.

Set the secondary pressure-relief valve 262 to a value below the begin of regulation (pressure at
measuring point 44 = pressure at measuring point 41)
Slowly turn in the adjusting screw of the secondary pressure-relief valve 262 while monitoring the
pump pressure at the measuring point 41 and the control chamber pressure at the measuring
point 44.
ª At the prescribed begin of regulation (see table), the actuating pressure at the measuring
point 44 must begin to drop relative to the pump pressure at measuring point 41.
If necessary, adjust the control valve settings.

Loosen the lock nut (WS 13) of the adjusting screw 88.
Adjusting the begin of regulation to a later point

ª Pressure is increased = later begin of regulation
Adjusting the begin of regulation to an earlier point

ª Pressure is reduced = earlier begin of regulation

Note!
If the begin of regulation is adjusted correctly for minimum output, the pump's begin of regulation is
correct across the entire performance regulating pressure range (GLR).
After checking or adjusting the regulating valves, adjust the secondary pressure-relief valve 262
to the prescribed value, see 8.2.
Reconnect the plug connection at the solenoid valve Y50.
6 Checking and adjusting the differential pressure between the

pump pressure and the LS pressure
adjustment point
up to 500 operating hours
3.87.11
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MJFCIFSS

from 500 operating hours
Tab. 5 Settings
Fig. 8 Adjustment of the flow regulator
20 Variable-displacement pump 52 Adjusting screw / flow regulator

41 Measuring point 100 Compact control block
45 Measuring point 262 Secondary pressure-relief valve / exten-

ding bucket cylinder
Before adjusting the differential pressure -p, check the begin of regulation and the limit load con-
trol Y50.
Note!
As the tolerance for the differential pressure -p is very small (+1 bar), use measuring instruments
with appropriate accuracy.
100), see Fig. 8.

Adjust the adjusting screw of the secondary pressure-relief valve 262 (set pressure to approx.
100 - 120 bar so that oil can flow through the valve 262 ).
Extend the bucket cylinder to the stop.
Connect the pressure gauge / sensor at connection LS to the measuring point 45 and measure
the differential pressure Δp between the measuring points 41 and 45, and compare them with the
prescribed value, see Tab. 5.
3.87.12
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MJFCIFSS
If necessary, adjust the differential pressure settingΔp at flow regulator of the variable-displace-
ment pump:
Loosen the lock nut (WS 13) of the adjusting screw 52Fig. 8.
Increasing the differential pressure

Reducing the differential pressure

Readjust the secondary pressure-relief valve 262, see 8.2.
Note!
To check the dynamic behaviour of the settings, the differential pressure Δp can be checked again
while the extended attachment is slowly lifted. The pressure measured in this process may not differ
significantly from the pressure of the static measurement (difference maximum ±1.0 bar).
7 Checking the output power of the diesel engine (power test)
Principle
The power of the diesel engine can be assessed by measuring the consumed power of the hydraulic
pump.
The power input of the pump can be calculated with the following formula:
If the pump is maintained at maximum pivot angle, the power input of the powertrain is determined
solely by the pressure and speed. This pressure value has been measured individually for each mo-
del and size of attachment, whereby secondary consumers have also been taken into consideration.

The pump is held at its maximum pivot angle by means of the control system A149 (UEC) (max. cur-
rent to Y50) and the fan is set to maximum speed (min. current to Y352). This function can be acti-
vated with a program and accessories on the display or by means of a laptop. The working pressure
is slowly increased to the prescribed value (see adjustment protocol). The engine speed should not
drop below the nominal speed.
adjustment point
Test pressure R 313 bar 115 242 / 262 41
R 317 bar 115 242 / 262 41
Rated speed rpm 1800 - -
Difference between pump pressure bar < 10 - 41/ 44

and adjusting pressure
Tab. 6 Settings
3.87.13
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MJFCIFSS
Fig. 9 Operator's platform, pump and control block
12 Indicator light / SF function ON/OFF 100 Compact control block

20 Variable-displacement pump 41 measu- 242 Secondary pressure-relief valve
ring point MP
41 Measuring point LR 262 Secondary pressure-relief valve
44 Measuring point / pump actuating pres- S382 Switch / fine regulation SF (only if Tool
sure Control plus is active)
7.1 Procedure
Plug the dongle to the interface X1167, see Fig. 1.
Connect the pressure gauge/ sensor gauge (0 - 600 bar) to the measuring point 41, see see Fig.
9.
Connect the pressure gauge/sensor or gauge (0 - 600 bar) to the measuring point 44 at the
3.87.14
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MJFCIFSS
pump 20, Fig. 9.

Start the machine.
Press the button 28 to change to rs-functions.
ª The menu function is displayed.
Caution!
malfunction.

ª The power test for the diesel engine is now activated.
ª The display indicates that the power test is on.

3.87.15
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MJFCIFSS
Fig. 10 Using Powertest function

* screen display from version V1.10

Lower the adjusting pressure at the secondary pressure-relief valve 242 and 262 (axle/stick and
bucket cylinder) to approx. 100 bar.
Disable the fine regulation with the switch S382 on the joystick , seeFig. 9 (only in AHS11/AHS12
with Tool Control plus active).
Extend the stick and bucket cylinder*.
Note!
During the build-up of the high pressure, closely monitor the control chamber pressure at the
measuring point 44 of the pump. Ensure that there is no significant pressure difference (≤ 10 bar)
to the measuring point 41 (no regulation of the pumps).
3.87.16
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MJFCIFSS
Turn in the adjusting screw of the secondary pressure control valve 242 or 262 until the prescribed
value is reached (see adjustment protocol), while checking the speed.
ª The power settings of the diesel engine are correct, when the diesel engine is pushed to ma-
ximum the prescribed value, see Tab. 6.
After checking the engine power, set the diesel engine to speed step 1 and run it at lower idle
speed for approx. 1 minute.
ª The Powertest function is deactivated.
Adjust the secondary pressure-relief valves 242 and 262 to the prescribed value, see 8.2.
* It is necessary to complete both movements and turn both secondary pressure-relief valves, in order to ensure that
the entire pump flow volume is fed through the system.
8 Adjusting pressure-relief and cut-off valves
8.1 Checking/adjusting the pump safety valve 105
adjustment point
Pump safety valve 105 bar 400 +20 105 41
Tab. 7 Settings
41 Measuring point MP 105 Pump safety valve


Connect the pressure sensor/gauge to the measuring point 41 (control block 100).
Increase the pressure cut-off 104 - by turning in the adjusting screw on the block and by turning
3.87.17
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MJFCIFSS
Start the machine and preselect speed step PP (fine regulation SF disabled, see Fig. 9 optional).
Increase the adjusting pressure at the secondary pressure-relief valve 262 (turning in adjusting
screw ) until the pump safety valve 105 responds.
Caution!
unit.
To ensure this, adjust the pump safety valve 105 to a value of maximum 440 bar (measuring
point 41).
Compare the pressure value with the prescribed pressure of the pump safety valve 105, see Tab.
7 and adjust, if necessary.
Increasing pressure
Reducing pressure
8.2 Checking/adjusting the secondary pressure-relief valves 211 - 262
adjustment point
Secondary pressure for extending boom bar 380 +20 221 45

Secondary pressure for retracting boom cy-
linder
Secondary pressure for retracting stick cy- bar 380 +20 241 45
linder bar 380 +20 242 45
Secondary pressure for extending stick cy-
linder
Secondary pressure for retracting bucket bar 380 +20 261 45
Secondary pressure for extending bucket
cylinder
Secondary pressure for forward travel / left bar 380 +20 211 45
Secondary pressure for reverse travel / left bar 380 +20 212 45
Secondary pressure for forward travel /right bar 380 +20 213 45
Secondary pressure for reverse travel / bar 380 +20 214 45
right
Tab. 8 Settings
3.87.18
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MJFCIFSS
Fig. 12 Pump, control block and travel motor
20 Variable-displacement pump 214 Secondary pressure-relief valve

45 Measuring point LS 219 Brake release line
200 Travel motor, left 222 Secondary pressure-relief valve
201 Travel motor, right 241 Secondary pressure-relief valve

Connect the pressure sensor/gauge to the measuring point 45 (variable-displacement pump).

To check the secondary pressure-relief valves 211, 212, 213, 214 remove the two covers / travel
drives at the longitudinal member and disconnect the line 219 from the brake release connection
Bre from the regulating motors 200 / 201, see Fig. 12 and seal them.
Check the secondary pressure-relief valves 211, 212 213 , 214, 221, 222, 241, 242 and 261 by
moving the respective devices to the stop. Adjust the settings, if required, see Tab. 8, (measuring
point 45).
Increasing pressure
3.87.19
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MJFCIFSS
Reducing pressure
8.3 Checking/adjusting secondary pressure-relief valve for attachment kit AS1
adjustment point
Secondary pressure for turning grapple to bar 110 +20 541 45
the left bar 110 +20 542 45
Secondary pressure for turning grapple to
the right
Turning speed for turning grapple to the bar 15.6 1 1
left bar 15.6 2 2
Turning speed for turning grapple to the
right
Tab. 9 Settings
Fig. 13 Measuring point for LS pressure and additional control axle with secondary pressure-re-
lief valves
20 Variable-displacement pump 540 Additional control valve / AS1

45 Measuring point LS 541 Pressure-relief valve
100 Control valve block 542 Pressure-relief valve
Remove the protective cap at the measuring point 45.

Connect a measuring sensor / gauge (600 bar).
3.87.20
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MJFCIFSS
Close the stop cocks and disconnect the pressure connections (seal).
Pressurise the accessory kit, using the keys S5L / S5R located at the left pilot control unit.
Compare the pressure indicated at the pressure sensor with the prescribed pressure, see Tab. 9.
If necessary, re-adjust the pressure by means of the adjusting screw at the corresponding pres-
sure-relief valve 541 / 542.
Proceed as follows: Loosen the lock nut. Use a WS 6 Allen key to turn the adjusting screw.
Turn screw in
ª Increasing pressure
Turn screw out
ª Reduce pressure
Remove the pressure sensor and seal the measuring point 45.
Open the stop cocks or pressure connections.
8.4 Adjusting the operating pressure (pressure cut-off valve 104)
adjustment point
Operating pressure bar 350 +10 104 41
Tab. 10 Settings

41 Measuring point MP 104 Pressure cut-off valve

Set the operating pressure at the cut-off valve 104 to the prescribed value, see Tab. 10 (measu-
3.87.21
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MJFCIFSS
ring point 41).
Increasing pressure
Reducing pressure
9 Checking the slewing gear
adjustment point
Current at Y451 at 100% mA 600 +50
Primary pressure at 100% bar 230 +10 11 137 / 138
Tab. 11 Settings
Fig. 15 Proportional solenoid valve settings
11 Adjusting screw Y451 Proportional solenoid valve

12 Lock nut
Block the uppercarriage by applying the slewing gear brake (maximum pressure cannot be rea-
ched if the uppercarriage is rotating).
In the menu, select torque slew (see Fig. 4).

ª The slewing gear settings must be at 100(%).
If required, adjust the value as described in Fig. 16 to 100.
Press the pilot control unit for "turning left/right" to the stop.
Compare the maximum pressure with the value in Tab. 11 (measuring points 137 / 138).
3.87.22
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MJFCIFSS
If required, loosen the lock nut 12 of the proportional solenoid valve Y451 and adjust the maximum
pressure with the adjusting screw 11, see Fig. 15.
After the correct settings are made, secure the adjusting screw with the lock nut 12. Torque set-
tings of slewing gear
The operating behaviour of the slewing gear can be adjusted in the "torque slew" menu to suit the
actual excavation work.
Change the value 100 to the desired value, using the buttons 28 / 29.
Change in direction < 100% (e.g. 55) = the slewing gear responds with slight delay (soft movement).
ª The value is saved.

55(%) (to software version V1.09)
3.87.23
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MJFCIFSS
70(%) (from software version V1.10).
Note!
By adjusting the torque slew value between 100 and 0%, the primary pressure value is automatically
adjusted, see Tab. 11.
From software version V1.10, the desired pressure value is entered by adjusting the bar rather than
entering the respective figures.
In this case:
Use the buttons 28 / 29 to enter the desired value and confirm with button 26.
9.1 Checking of current to proportional solenoid valve Y451
Note!
The parameters of the torque control characteristic are preset by the UEC excavator control system.
Access menu Info - IO to view the current to the proportional solenoid valve Y451. By adjusting the
torque slew value between 100 and 0%, the current is automatically adjusted, see Tab. 11.
Press the button 28/29 to call up number 74 (current to solenoid valve Y451) and check the actual
current value.
3.87.24
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MJFCIFSS
Fig. 18 Diagram of the slewing gear adjustment by means of proportional solenoid valve Y451

9.2 Checking and adjusting the secondary pressure for the slewing gear
adjustment point
Start-up
Secondary pressure / turning right bar 250 +10 134.2 137
Secondary pressure / turning left bar 250 +10 134.2 138
Slowing down
Secondary pressure / turning right bar 90 ±5 134.4 137
Secondary pressure / turning left bar 90 ±5 134.4 138
Tab. 12 Parameters
3.87.25
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MJFCIFSS
9.2.1 Adjustment of start-up pressure (high pressure settings)

Fig. 19 Slewing gear motor with pressure-relief valves, with sample diagram
I Relationship between the secondary protection and the control pressure for
swivelling
5 Secondary setting, minimum value (braking)
6 Secondary setting, maximum value (starting)
1 Lock nut 130 Slewing gear motor

2 Adjusting screw / high pressure 134 Secondary pressure-relief valve
3 Lock nut 135 Secondary pressure-relief valve
4 Adjusting screw / low pressure 137 Measuring point

138 Measuring point
3.87.26
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MJFCIFSS
Danger!
To check and adjust the slewing gear drive, the system must be pressurised to maximum pressure.
This can lead to inadvertent rotation of the uppercarriage and thus poses a great risk of injury to
mechanics. Objects located within the swivel range of the machine could be damaged. To prevent
this, complete the following steps:
Apply the slewing gear brake.
Anchor the equipment to the ground.

Press the button 28 to preselect submenu torque slew.
Press the button 28 to preselect submenu test.
Press the button29 to increase the figure (currently set to 0) to 1.
ª The valve Y451 is powered with maximum current and high pressure can thus be reached, see
Fig. 19.
Note:
In order to ensure accurate pressure limitation/pressure settings of the slewing gear function, the
secondary pressure at the secondary pressure-relief valves 134 / 135 must be at least 10 bar above
the measured maximum primary pressure.

Block the uppercarriage (maximum pressure cannot be reached if the uppercarriage is rotating).

After checking the test value, press the button 28 to reset it to 0. Confirm the settings by pressing
the button 26 and then select ⇒back and press the button 27 to return to the menu or switch off
the ignition.
3.87.27
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MJFCIFSS
Fig. 20 Menu for slewing gear settings
25 Display 26 ENTER button (confirmation)

27 Push button / cursor to right 28 DOWN button
29 UP button M Start menu at service level
9.2.2 Adjustment of brake pressure (low pressure settings), Fig. 19

Disconnect and seal the two hose connections to X and Y.
Re-connect the hose connections at X and Y.
9.3 Adjustment of the maximum turning speed, Fig. 21
adjustment point
Turning speed / turning right rpm 9.0 - 9.5 120.1.1 -
Turning speed / turning left rpm 9. 0 - 9.5 120.2.1 -
Tab. 13 Settings
3.87.28
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MJFCIFSS
Fig. 21 Slewing gear control axle with stroke limitation
.1 Adjusting screw 120 Slewing gear control axle

.2 Lock nut 120.1 Control piston stroke limitation for turning left
100 Compact control block 120.2 Control piston stroke limitation for turning right
The maximum turning speed of the uppercarriage is determined by the stroke limitation settings of
the spool / slewing gear.
Danger!
To determine the maximum turning speed of the uppercarriage, the uppercarriage must be moved
at full speed for minimum 1 minute. Risk of injury or even death! Ensure that no persons are stan-
ding within the range of operation of the uppercarriage when this measurement is carried out!
Place the undercarriage on firm level ground.
All persons must leave the danger area of the machine.

Move the pilot control unit for turning slewing gear to the right / left to the stop.
When the maximum turning speed is reached, start the time period for the uppercarriage speed
measurement.
Measure the number of revolutions per minute and compare it with the prescribed values, see
Tab. 13.
ª If necessary, remove the cap nut, loosen the lock nut 2 and turn the stop screw 1 of the stroke
limitation 120.1 / 120.2.
To increase speed:
Turn the adjusting screw 1 out.
To reduce speed:
Repeat the adjustment on the other side of the spool 120 (left and right rotation).
After the adjustment is completed, secure the adjusting screw with the lock nuts 2 and then re-
place the cap nuts.
3.87.29
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MJFCIFSS
Checking of regulating motor 200 / 201
10 Checking of regulating motor 200 / 201
Danger!
For inspection and adjustment work, it is necessary to access the undercarriage.
This can be dangerous for technicians. There is a risk of serious injury or even death from rotating
chains, or if the machine begins to move.
Ensure that no persons are standing inside or can access the danger zone.
Establish visual or acoustic contact with the operating personnel.
10.1 Checking and adjustment of the begin and end of regulation (only in R 313)
adjustment point
Begin of regulation
Travel right bar 150 ±3 210 45/M1

bar 210
Travel left 150 ±3 45/M1
End of regulation
Travel right 160 ±3 210 45/M1
bar
Travel left 160 ±3 210 45/M1

bar
Fig. 22 Measuring point for high pressure and actuating pressure with adjusting screw / begin of
regulation
20 Variable-displacement pump 208 Brake release valve

45 Measuring point LS 210 Adjusting screw / begin of regulation
200 Travel motor, left 219 Brake release line
201 Travel motor, right M1 Measuring point / begin of regulation
3.87.30
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MJFCIFSS
Note!
Varying begins of regulation between the regulating motors result in poor tracking. If this occurs,
check that the begins of regulation of the two regulating motors are identical and adjust them, if ne-
cessary.
Release pressure from the hydraulic system.
Connect the pressure sensor/gauge to the measuring point 45 (pump 20), see Fig. 22.
Remove the two covers / travel drives at longitudinal member.
Disconnect the line 219 from the brake release connection Bre of the regulating motors 200 / 201
and seal them.
Remove the screw plug from the measuring connection M1, see Fig. 22.
Screw in the screw coupling assembly M10x1 (tool no. 10 in group 2.01, with extension, if re-
quired) and connect a pressure gauge / sensor.
Lift one drive side with the attachment and carefully pressurise the regulating motor of the lifted
side in fast travel gear with the pilot control unit (block status).
High pressure builds up at the measuring point 45.
ª Below the begin of regulation of the motorsee Tab. 1,, there may be no pressure build-up at
measuring connection M1. That means that the oil motor is at minimum pivot angle.
Continue to accelerate the motor to the begin of regulation. Pay close attention to the two pressure
gauges (at measuring points 45 and M1).
ª From the moment of begin of regulation, the pressure at the measuring connection M1 must
continue to rise (to about 1/2 high pressure value). The oil motor is adjusted towards the ma-
ximum pivot angle.
ª As soon as the high pressure (at measuring point 45) reaches the value of the end of regula-
tion (see Tab. 1), the value measured at the measuring point M1 increases suddenly to the
high pressure value, i.e. the pressures at measuring points 45 and M1 are identical.

Note!
and cannot be adjusted. This means that a change to the begin of regulation value automatically
results in a change to the end of regulation value.
If the pressure value for the begin of regulation does not correspond to the prescribed value, it can
be adjusted by means of the adjusting screw 210, see Fig. 22.
Caution!
The adjusting screw 210 for the begin of regulation is located opposite the pressure connections
Bre and X.
In some regulating motors, the adjusting screw for the brake release valve 208 is located near the
pressure connections Bre and X, see Fig. 22|. This screw is however intended exclusively for fac-
tory adjustment.
Therefore do not interfere with the brake release valve 208 as this could result in malfunctions
during travel operation.
Release the adjusting screw 210 and loosen the lock nut.
3.87.31
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MJFCIFSS

ª The begin of regulation is lowered (earlier begin)

ª The begin of regulation is increased (later begin)
10.2 Adjustment of the maximum output speed/maximum travel speed
adjustment point
Output speed of tumbler wheel
160.1.3 14
Normal travel Travel right rpm 15 ±1 160.2.3 14
Travel left rpm 15 ±1 180.1.3 14

180.2.3 14
Fast travel Travel right 45 ±1 Vmin -

rpm
Travel left rpm 45 ±1 Vmin -
Checking measurement Y mm 15 - 160.1

160.2
180.1
180.2
Tab. 14 Settings
3.87.32
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MJFCIFSS
Fig. 23 Checking travel motors
14 Tumbler wheel 180 Spool / chassis left
100 Compact control block 180.1 Stroke limitation .1, reverse travel, left
160 Spool / chassis right 180.1.3 Adjusting screw of stroke limitation .1
160.1 Stroke limitation .1, reverse travel, right 180.1.4 Lock nut of stroke limitation .1
160.1.3 Adjusting screw of stroke limitation .1 180.2 Stroke limitation .2, reverse travel, left

160.1.4 Lock nut of stroke limitation .1 180.2.3 Adjusting screw of stroke limitation .2
160.2 Stroke limitation .2, forward travel, right 180.2.4 Lock nut of stroke limitation .2
160.2.3 Adjusting screw of stroke limitation .2 200 Travel motor, left
160.2.4 Lock nut of stroke limitation .2 201 Travel motor, right
The maximum output speed of the oil motor is determined by the minimum flow consumption of the
oil motor (Qmin) and the maximum flow rate of the spool/chassis 160 / 180.
Note!
The max. flow rate is factory-set by the manufacturer by means of the stroke limitation of spools 160
/ 180 (dimension Y, see above) and may only be adjusted in exceptional circumstances.
If there is a problem with the maximum travel speed of the machine, the setting can be modified, pro-
vided that the maximum speed measured at the tumbler wheel does not correspond to the value in
the adjustment protocol, see Tab. 14.
3.87.33
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MJFCIFSS
10.3 Adjustment of output speed for normal travel:

Run the diesel motor at maximum speed.
Lift one side of the chassis with the attachment.
Operate the corresponding travel drive at normal speed (switch S21 not actuated).
Press the travel pedal to the stop.
Measure the maximum speed of the tumbler wheel and compare with the prescribed value in Tab.
14.
At the fully actuated pilot control unit, remove the cap nut of the chassis control axle 160 / 180 of
the control valve block 100.
Loosen the lock nut .2 of the stroke limitation 160.1/160.2 / 180 .1 / 180.2.
Reducing the speed:

Turn the adjusting screw .1 in.

Turn adjusting screw .1 out.
Repeat the adjustment on the other side of the spools 160 / 180 (forward and reverse travel).
After adjustment of the speed, secure the adjusting screws 160.1/160.2 / 180.1/180.2 and replace
the cap nuts.
After completion of the adjustment, retract the support.
10.4 Adjustment of maximum speed for fast travel:
10.4.1 Adjustment of Qmin stop, see Fig. 23

The maximum output speed of the oil motor at fast travel speed is determined by the minimum flow
consumption of the oil motors (Qmin).
Run the diesel motor at maximum speed.
Lift one side of the chassis with the attachment.
Operate the corresponding travel drive at fast speed (switch S21 actuated).
Press the travel pedal to the stop.
Measure the maximum speed of the tumbler wheel and compare with the prescribed value in Tab.
14,
Remove the cover of the longitudinal member.

Release the Q-min stop screw of the regulating motor 200 / 201.
Loosen the lock nut of the stop screw Vmin.
Reducing the speed:

Turn the adjusting screw Vmin in.
3.87.34
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MJFCIFSS
Checking the fan control system

Turn the adjusting screw Vmin out.
10.4.2 Checking tracking of travel drive

When adjusting the maximum speed of the travel gear system, also check the synchronisation of the
two travel drives (tracking).
The regulating motor rotating faster must be adjusted to the speed of the slower regulating motor
200 / 201.
Turn in the stop screw Vmin of the faster regulating motor 200 / 201.
After adjustment of the synchronised run of the motors, lock and secure the stop screw Vmin.
Mount the cover onto the longitudinal member.
11 Checking the fan control system
11.1 Checking the fan speed
adjustment point
Fan speed
during emergency operation (nnot)
R 313 rpm 2000 +50 - 12
R 317 rpm 1750 +50 - 12
Current to Y352
during emergency operation (nnot)
R 313 mA 100 - 12

R 317 mA 160 - 12
Tab. 15 Settings
Fig. 24 Fan motor with proportional solenoid valve
13 Fan motor Y352 Proportional solenoid valve
3.87.35
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MJFCIFSS
Danger!
Moving fan blades might cause serious injury to fingers and hands.
Shut down the engine.
Do not reach into the fan operating range until the fan blades have come to a standstill.
The fan speed to be measured depends on the current temperature of the coolant and the hydraulic
oil.
The fan speed and thus the hydraulic circuit (pump / oil motor) can be checked by presetting the mi-
nimum current for the proportional solenoid valve Y352 in the UEC excavator control system (fan
speed for emergency operation).
To activate the check mode through the display, proceed as follows:
Note!
Alternatively, the check mode can be activated through a laptop with the required program and ac-
cessories.
To check the fan speed with the speed counter (tool no. 62 / 63), apply a reflective strip to the fan
blade.
To check the fan speed, ensure that the temperature of the hydraulic oil is > 50 °C.
Measure the hydraulic oil temperature, see 2.3.
ª If the temperature of the hydraulic oil is too low, heat it up.
Start the machine.
Press the button 28 to preselect submenu rs-functions.

ª The menu function see Fig. 25 is displayed.
Press the button29 to increase the figure (currently set to 0) to 13.
Caution!
Before confirming the value 13 with the button26, ensure that the value 13 is shown on the display.
malfunction.

ª The fan is now in emergency mode.
Measure the emergency fan speed.
ª Compare the measured fan speed with the prescribed value nnot, see Tab. 15.
3.87.36
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MJFCIFSS
Note!
The fan speed cannot be adjusted. The pressure is factory-set by the manufacturer and may not be
changed. The above measurement serves only to establish proper functioning. If the measurement
indicates that there is a substantial difference between the actual and the specified value, check the
hydraulic circuit for faults.
After checking the fan speed, set the diesel engine to speed step 1 and run it at lower idle speed
for approx. 1 minute.
ª The emergency mode function for the fan speed is deactivated.
Remove the dongle.
Fig. 25 Service function program for emergency operation

3.87.37
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MJFCIFSS
3.87.38
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MJFCIFSS
Service Manual
SUBGROUP - INDEX
Section Group Type
Technical data of diesel engines 4.04.1 A 309 LI-TCD 40998-

A 311 LI-TCD 41128-
Technical data of diesel engines 4.06.1 A 312 LI-TCD 36220-

R 313 LI-TCD 39171-
Technical data of diesel engines 4.10.1 A 314 LI-TCD

A 316 LI-IND-TCD
A 316 LI-TCD
R 317 LI-TCD
Installation and check list 4.25.1 A 309 LI-TCD 40998-

A 311 LI-TCD 41128-
A 312 LI-TCD 36220-
A 314 LI-TCD 30694-
A 316 LI-IND-TCD 29503-
A 316 LI-TCD 29120-
R 313 LI-TCD 39171-
R 317 LI-TCD 30019-
Liebherr diesel particle filter accessory kit 4.30.1 A 309 LI-TCD 40998-
A 311 LI-TCD 41128-
A 312 LI-TCD 36220-

A 314 LI-TCD 30694-
A 316 LI-IND-TCD 29503-
A 316 LI-TCD 29120-
R 313 LI-TCD 39171-
R 317 LI-TCD 30019-
4.1
MJFCIFSS
4.2
MJFCIFSS
Service Manual
Service Manual Technical data of diesel engines
Engine type: TCD 2012 L04 2V
Technical data of diesel engines
1 Engine type: TCD 2012 L04 2V
Installation in machine / type A 309-Li / 1035 A 311 Li / 1036

from serial number: 40998 41128
Power according to DIN / ISO 9249 kW 65 68
PS 88 92
Speed at max. (engine speed) Nm 360 (1500 rpm) 380 (1500 rpm)
Operating data A 309-Li / 40998 A 311 Li / 41128

Design 4-cylinder turbo, intercooled
Type 4-stroke
emission-optimised
Combustion type Direct injection
Bore mm 101
Boom mm 126
3
Displacement cm 4040
Firing sequence 1-3-4-2
Compression ratio 19 : 1
Injection system Pump - line - nozzle
Combustion pressure at starting speed bar 30 - 38
Firing interval °kW 180
Ignition pressure bar 160
Weight (dry) kg 410 (according to DIN 70020 - A)
Direction of rotation (seen from flywheel) Left

Flywheel housing SAE 4
Cooling system liquid-cooled
Lubrication Pressure recirculation lubrication
Speed range A 309-Li / 40998 A 311 Li / 41128

High idle rpm rpm 1890 +30
Low idle rpm rpm 850 +100
Lowest operating speed rpm 1000
Speed at max. torque rpm 1600
Settings A 309-Li / 40998 A 311 Li / 41128

Inlet valve play (cold) mm 75°
Outlet valve play (cold) mm 120°
4.04.1
copyright by
MJFCIFSS
Technical data of diesel engines Service Manual
Settings A 309-Li / 40998 A 311 Li / 41128

Begin of delivery °CA be- 1.3 ± 0.5
fore
TDC
Filling volumes (approx. values) A 309-Li / 40998 A 311 Li / 41128

Lubricating oil in standard oil pan l 10
Filling volumes (for oil change with filter replacement) l approx. 11.5
Cooling liquid including coolant l approx. 22 (5.6 l in engine + 16.4 l in radiator
and lines)
Operating data A 309-Li / 40998 A 311 Li / 41128

Max. lubricating oil temperature °C 125 (in oil pan)
Min. lubricating oil pressure bar 0.8 (at oil temperature of 120° C)
Max. constant cooling fluid temperature °C 110°
Safety valve of lubricating oil pump bar 5.25 - 6.75
Max. engine inclination towards right or left 30°
Max. engine inclination towards fan / flywheel 30 °
Engine wear parts, V-belts and safety devices A 309-Li / 40998 A 311 Li / 41128
preliminary fuel filter 1
Fuel filter 2
Oil filter 1
Air filter 1 Main element
1 Safety element
V-belt 1 11 x 975
1 13x1000
Safety device: oil pressure sensor 1 B16

Coolant temperature sensor 1 B2
Coolant level sensor 1 B3
For order numbers, see respective spare parts list and service packs LHB/en/Edition: 06/2008
4.04.2
copyright by
MJFCIFSS
Tightening torques / oversize levels
2 Tightening torques / oversize levels
A 309-Li / 40998
Installation in models / serial no.:
A 311 Li / 41128
Screw tightening torque:

Tightening instructions General notes
screwed connections
Cylinder head 1. 30 Nm Apply a little oil to the screw
speed thread and head surface
2. 80 Nm
speed
Retigh- 90 degrees According to tightening se-
ten quence
Screw for V-belt pulley / torsional vibra- Pre-tighten with 40 Nm Apply a little oil to the screw
tion damper thread and head surface
1. retightening angle 60 degrees
Flywheel Pre-tighten with Apply a little oil to the screw

with screw length 45 mm 30 Nm thread and head surface
1. 60 degrees
speed
2. 60 degrees
speed

Oversize levels / limit values Tightening instructions General notes
Cylinder
Normal bore mm 101 + 0.013 - 0.005
Wear limit of bore mm 101.1
Piston
Normal diameter mm 100.790 ± 0.009
Axial play of piston ring

Play limit of 1st ring 1. - (double-tapered groove) Measure with tapered groo-
speed ve wear gauge

Play limit of 2nd ring mm 0.065 - 0.11
Play limit of 3rd ring mm 0.04 - 0.08
Piston ring gap

Limit value of 1st ring mm 0.25 - 0.4
Limit value of 2nd ring mm 1.5 - 2.0
4.04.3
copyright by
MJFCIFSS

Limit value of 3rd ring mm 0.03 - 0.55
4.04.4
copyright by
MJFCIFSS
Installation in machine / type A 312-Li / 1037 R 313 Li / 1038

from serial number: 36220 39171
PS 110 103
Speed at max. (engine speed) Nm 472 (1500 rpm) 449 (1500 rpm)
Operating data A 312-Li / 36220 R 313 Li / 39171

Type 4-cycle Common Rail
emission-optimised
Combustion type Direct injection
Bore mm 101
Boom mm 126
3
Injection system DCR (Deutz Common Rail)
Direction of rotation (seen from flywheel) Left

Speed range A 312-Li / 36220 R 313 Li / 39171

Settings A 312-Li / 36220 R 313 Li / 39171

4.06.1
copyright by
MJFCIFSS
Settings A 312-Li / 36220 R 313 Li / 39171

Begin of delivery °CA be- DCR
fore
TDC
Filling volumes (approx. values) A 312-Li / 36220 R 313 Li / 39171

and lines)
Operating data A 312-Li / 36220 R 313 Li / 39171

Rail pressure
New bar 30 - 1600
Engine wear parts, V-belts and safety devices A 312-Li / 36220 R 313 Li / 39171
preliminary fuel filter 1
Fuel filter 2
Oil filter 1
1 Safety element
V-belt 1 11 x 975
1 13x1000
Safety device: oil pressure sensor 1 EMR
Coolant temperature sensor 1 EMR
For order numbers, see respective spare parts list and service packs
4.06.2
copyright by
MJFCIFSS
A 312-Li / 39220
Installation in models / serial no.:
R 313 Li / 39171

screwed connections
Cylinder head 1. 30 Nm Apply a little oil to the screw
2. 80 Nm
speed
Retigh- 90 degrees According to tightening se-
ten quence
Screw for V-belt pulley / torsional vibra- Pre-tighten with 40 Nm Apply a little oil to the screw
tion damper thread and head surface
Flywheel Pre-tighten with Apply a little oil to the screw

with screw length 45 mm 30 Nm thread and head surface
1. 60 degrees
speed
2. 60 degrees
speed

Cylinder
Normal bore mm 101 + 0.013 - 0.005
Piston

Play limit of 1st ring 1. - (double-tapered groove) Measure with tapered groo-
speed ve wear gauge

Play limit of 2nd ring mm 0.065 - 0.11
Play limit of 3rd ring mm 0.04 - 0.08
Piston ring gap

Limit value of 1st ring mm 0.25 - 0.4
Limit value of 2nd ring mm 1.5 - 2.0
4.06.3
copyright by
MJFCIFSS

Limit value of 3rd ring mm 0.03 - 0,55
4.06.4
copyright by
MJFCIFSS
A 314-Li / 30694 A 316-Li / 29120

Installation in machines / from serial no.:
R 317 Li / 30019 A 316-Li Ind./ 29503
PS 123 130
Max. torque (max. engine speed) Nm 525 550
A 314-Li / 30694 A 316-Li / 29120

Operating data
R 317 Li / 30019 A 316-Li Ind./ 29503
Type 4-cycle Common Rail
emission-optimised
Bore mm 108
Boom mm 130
3
Injection system DCR
(Deutz Common Rail)

Direction of rotation (seen from flywheel) left
A 314-Li / 30694 A 316-Li / 29120

Speed range
R 317 Li / 30019 A 316-Li Ind./ 29503

A 314-Li / 30694 A 316-Li / 29120

Settings
R 317 Li / 30019 A 316-Li Ind./ 29503
4.10.1
copyright by
MJFCIFSS
A 314-Li / 30694 A 316-Li / 29120

Settings
R 317 Li / 30019 A 316-Li Ind./ 29503
Begin of delivery °CA be- DCR
fore
TDC
A 314-Li / 30694 A 316-Li / 29120

Filling volumes (approx. values)
R 317 Li / 30019 A 316-Li Ind./ 29503
and lines)
A 314-Li / 30694 A 316-Li / 29120

Operating data
R 317 Li / 30019 A 316-Li Ind./ 29503
Rail pressure
New bar 30 - 1600
A 314-Li / 30694 A 316-Li / 29120

Engine wear parts, V-belts and safety devices
R 317 Li / 30019 A 316-Li Ind./ 29503
Preliminary fuel filter 1
Fuel filter 2
Oil filter 1
1 Safety element
V-belt 1 10 x 975
1 13x1050
Safety device: oil pressure sensor 1 EMR
Coolant temperature sensor 1 EMR
For order numbers, see respective spare parts list and service packs
4.10.2
copyright by
MJFCIFSS
A 314-Li / 30694
Installation in models / serial no.: A 316-Li / 29120 _ A 316-Li Ind./ 29503
R 317 Li / 30019

screwed connections
Cylinder head 1st Pre-tighten with 50 Nm Apply a little oil to the screw
2nd 130 Nm
speed
3rd 90 degrees According to tightening se-
speed quence
Screw for V-belt pulley Pre-tighten with 30-40 Nm Apply a little oil to the screw
thread and head surface
1st retightening angle 60 degrees
2nd retightening angle 60 degrees
Flywheel Pre-tighten with 30 Nm Apply a little oil to the screw

thread and head surface
1st 60 degrees
speed
2nd 60 degrees
speed

Cylinder
Normal bore mm 108 + 0,02
Piston
Piston ring groove

Annular groove Double-tapered groove
Height of 1st ring groove mm 2.0 + 0.1

+ 0.08
Height of oil ring groove mm 3.5 + 0.04
+ 0.02
4.10.3
copyright by
MJFCIFSS

1st limit of play of compression ring 1st - (double-tapered groove) Measure with tapered groo-
speed ve wear gauge
Limit of play of compression ring mm 0.09 - 0.13
Limit of play of grooved piston ring mm 0.03 - 0.075
Piston ring gap

Limit value of 1st compression ring mm 0.3 - 0.55
Limit value of 2nd compression ring mm 1.5 - 2.0
Limit value of grooved piston ring mm 0.3 - 0.6
4.10.4
copyright by
MJFCIFSS
Service Manual Installation and check list
Installation and check list
for the installation of the particle filter
A 314 - R 317 Litronic TCD

Note!
The manufacturer will only confirm the warranty terms, if the completed and signed installation and
check list is returned.
In addition, the prescribed maintenance intervals of the assembly / particle filter must be adhered
to. Always refer to the maintenance instructions in group 4.30 in the service manual.
Installation certificate
Vehicle / diesel engine
Machine:
(type)
Vehicle identification number:
PIN e.g. WLHZ 10400 ZK 325051 (17 digits)
Diesel engine model:
(MODEL, see below)
Serial no. of diesel engine:
(SER NO, see below)
Diesel engine operating hours:
(at display)
Particle filter
ID no. Serial no.
Kit no. ________________

Input element
Centre element / filter
Data logger
Diesel engine Input element 10 Centre element / filter 30

4.25.1
copyright by
MJFCIFSS
Installation and check list Service Manual
Checks
Actual
Measuring point View
Checks value
Specified value Comment
1. Checking of engine yes / no

(prior to filter installation)
1.1 Air filter clean

...............
1.2 Exhaust gas turbocharger tight

...............
1.3 Oil feed line to the diesel engine Liebherr Motoroil

10 W 40 low ash ...............
1.4 Diesel engine injection

no blue fumes ...............
and combustion OK
4.25.2
copyright by
MJFCIFSS
Actual
Checks value
2. Operating conditions
Warm up machine.
2.1 Oil temperature min. 50 +10°C ...............
2.2 Speed step PP
without load 1900 +30rpm ...............
with load 1800 ± 10 rpm ...............

4.25.3
copyright by
MJFCIFSS
Installation and check list Service Manual
Actual
Checks value
3. Tightness of the backpressure Check LED A Check the line between the input
line, with simultaneous Display D module and the data logger for lea-
testing of the warning system. kage, using a hand pump (tool list
Disconnect the backpressure line group 2).
at point T of the input element,
Separating point T for the testing
close the swivel elbow W.
of the backpressure line
Install adapter for a hand pump to
the connection L and produce
test pressure with the hand
pump.
The test pressure must remain
constant (max. 0.5 bar) for mini-
mum 1 minute.
3.1 Lead pressure

Red LED is on A Backpressure
at A175 (Druck/pressure) > 140 mbar Indicating and control unit A175
...............
3.2 Main pressure / limit load
Red LED on A at A175 and buz- Backpressure
zer signal > 160 mbar
3.3 Testing of temperature sen- ...............

sors
3 minutes after the start, the sen- Minimum tempe-
sor in front of the filter must show rature
a higher value than that behind > 80 °C
the filter (at display: temperature
1 > temperature 2). ...............
3.4 Testing of speed indicator

Indicating and control unit A150
The speed value indicated on the (to the right in the control conso-
display of A175 must correspond Tolerance limit le)
with that shown on the display on < ± 100 rpm
A150.
...............
3.5 Testing of the recording func-
tion
After the engine is started, the
display of A175 must switch from
the "Ready for operation" menu
to the "Measurement (pressure,

speed or temperature)" menu.
4.25.4
copyright by
MJFCIFSS
Actual
Checks value
4. Normal backpressure value Read the value from the data log-
(apply load on the diesel engine ger through the indicating and con-
by fully pressurising the hydraulic trol unit A175 and enter the value
<120 mbar ...............
system) at full-load speed here.
1800 rpm
5. Tightness of the exhaust gas Visual inspection yes / no If there are clear signs of leakage,
system check the system for loose connec-
Soot in the exhaust gas system tions.
...............
with connections and soot in the Suspected filter break
end pipe ............... Replace filter.
Danger!
There is a risk of injury from burns when working on the hot and/or running engine.
X When checking the engine, wear protective gloves and suitable protective clothing.
X Inform operating personnel of the potential risks and the danger area associated with the inspec-
tion work.
X Take precautions to ensure that the engine cannot be inadvertently started.
Type: ......................................... Serial no.: ......................................... Operating .........................................

hours:
Date: ......................................... Mechanic: ......................................... Cust.: .........................................

Date: ......................................... Checked for completeness by the Service Center: .........................................
4.25.5
copyright by
MJFCIFSS
4.25.6
Installation and check list
copyright by
MJFCIFSS
Service Manual
Service Manual Liebherr diesel particle filter accessory kit
Function
Liebherr diesel particle filter accessory kit
1 Function
The diesel particle filter can be installed in Liebherr hydraulic excavators as an exhaust gas cleaning
system for the diesel engine.
The particle filter accessory kit consists of the following main components:
– Particle filter 10
– Condensate trap with sintered metal filter 100
– Data logger A133
– Indicating and control unit A175

Fig. 1 Main components of the particle filter accessory kit
10 Particle filter A133 Data logger

100 Condensate trap/filter A175 Indicating / control unit
4.30.1
copyright by
MJFCIFSS
Liebherr diesel particle filter accessory kit Service Manual
Design of the accessory kit
2 Design of the accessory kit
2.1 Particle filter

The particle filter is installed between the exhaust pipes of the diesel engine at the location of the si-
lencer.
The particle filter is made in stainless steel and is fully insulated and noise optimised. It consists of
the following main components:
– Input module 15 adjusted to suit the model, with radial / axial* input.
– Output module 20 adjusted to suit the model, with radial / axial* output.
– Filter module 30 with integrated particle filter
– Centring rings 50 / 60 with seal rings 65
– Connecting clamps 70
Fig. 2 Design of the particle filter
15 Input module 50 Centring ring, output

20 Output module 60 Centring ring, input
30 Filter module 65 Seal rings
31 Silencer / muffler 70 Connecting clamp
* depending on model
4.30.2
copyright by
MJFCIFSS
Design of the accessory kit
2.2 Backpressure monitoring system

The backpressure monitoring system includes a backpressure line from the particle filter to the data
logger. As this line is exposed to great temperature differences during operation (especially during
the cold season), condensate that might contain soot particles collects in the line.
These particles are held back by the filter 100 and must be removed at prescribed intervals.
Regularly drain off condensate, (see “Maintenance of filter (condensate trap) 100” on page 9).
Fig. 3 Condensate trap for exhaust backpressure to the monitoring element
100 Filter, complete 201 Tank with seal ring

103 Sintered metal filter with holder

2.3 Monitoring elements, see Fig. 4
All control and monitoring signals from the particle filter are recorded and stored by the data logger A133.
The particle filter is monitored and controlled by means of the indicating and control unit A175 in the ope-
rator's cab.
Depending on the state and operating hours of the engine, the particle filter might be contaminated
with particles formed in the channels and burnt-off particles from the oil ash.
To check the contamination of the particle filter, the system measures the backpressure in front of
the filter. The greater the contamination, the higher the backpressure. From a certain limit value (de-
termined by machine model), the red warning LED A ( Druck/pressure) at the indicating and control
unit A175 is on. It indicates to the machine operator that the filter's absorption capacity has been re-
ached.
The particle filter is regenerated by increasing the exhaust gas temperature. This can be done by the
machine operator. At a temperature of 250°C or higher in the filter, the collected soot particles are
incinerated. Subsequently, the machine can be operated in normal mode until the red warning LED
is on again. Regeneration, see 2.4.
If the above incineration process does not result in a reduced exhaust backpressure, check the sys-
tem and clean the filter module 30, if required, see 5.1.4.
When the red warning LED A is on and the buzzer sounds (indicating a system error or a limit load
4.30.3
copyright by
MJFCIFSS
Function of diesel particle filter
of the filter 10), check the system and clean the filter module, if required, (see “Maintenance” on
page 8).
Fig. 4 Monitoring elements
A133 Data logger A175 Indicating and control unit
2.4 Filter regeneration

In order to reach the required temperature of minimum 250 °C, operate the diesel engine at full load.
For this purpose actuate the switch of the built-in "full load simulation for particle filter" accessory kit,
which ensures that the hydraulic unit of the machine is operated at full load. This allows you to reach
the necessary high exhaust gas temperature. For instructions regarding the regeneration process,
(see 4.3 on page7).
3 Function of diesel particle filter

3.1 Particle filtering

The exhaust gas cleaning system reduces the diesel particle load (PM) and the concentration of ga-
seous pollutants (CO and HC). The particles are held back in the monolith where they accumulate.
The particles are removed from the exhaust gas when it is fed through the porous channel walls of
the monolith. The inlet channels are sealed at the other end. This means that the exhaust gas must
escape through the coated channel walls. The large number of channels results in an extremely large
filter surface and thus a high retention capacity for soot particles.
4.30.4
copyright by
MJFCIFSS
Monitoring and operation
Fig. 5 Principle of the particle filter
1 Raw gas in front of the filter 3 Channel seal

2 Channel wall 4 Cleaned exhaust gas behind the filter
4 Monitoring and operation
Fig. 6 Indicating and control unit
A175 Indicating / control unit

A Warning LED (Druck/pressure) E Confirmation key

B Error ED (System error) F Menu key
C Operating mode LED (Power) G no function assigned
D Display
4.30.5
copyright by
MJFCIFSS
4.1 Automatic indication at the display and indicator lights
Display/indicator message LED Cause Remedy
Thermocouple 1 (or 2) defective yellow (B) Temperature sensor defective or Press key E: deactivation of warning buzzer
This signal is accompanied by a war- malfunctioning sound.
ning buzzer sound. Check temperature sensor, reconnect or re-
place.
ERROR idle run / temp. yellow (B) Device operated for too long at low Press key E: deactivation of warning buzzer
This signal is accompanied by a war- exhaust gas temperature (low engine sound.
ning buzzer sound. load) Increase machine / motor load (full-load operation)
Idle operation period too long. Operate machine at a higher speed.
Defect at terminal W - Interruption of speed monitoring Press key E: deactivation of warning buzzer
This signal is accompanied by a war- sound.
ning buzzer sound. Check line of the speed meter and replace, if
necessary.
Lead pressure reached. Red LED (A) High load of particle filter from soot Operate the machine at full load until the
on and ash particles back pressure drops.
If the back pressure does not drop: Clean the
filter (call LIEBHERR service department)
Main load pressure reached. Red LED (A) Excessive load of particle filter by Press key E: deactivation of warning buzzer
This signal is accompanied by a war- flashes soot and ash particles sound.
ning buzzer sound. Clean the filter.
Filter defective of pressure line all LEDs Particle filter (or bypass) defective, or Press key E: deactivation of warning buzzer
blocked. flash pressure line blocked, or sound.
This signal is accompanied by an in- leakage in pressure line Check particle filter and pressure line.
terrupted warning buzzer sound. Replace the filter module, remove the blockage
in the pressure line or fix the leakage.
Call LIEBHERR service depart- - Preset operating time to next service/ Press key E:
ment. filter module cleaning task has Complete service/clean filter according to the
lapsed. instructions.
After service, reset the device (reset opera-
ting hour counter):
press and hold keys G and F for minimum 5
seconds.
4.2 Query and operation with key F

After the ignition is switched on, the message "data logger ready" is displayed. After the diesel engine
has been started, the display shows the last used menu.
To navigate through the display menu, press the F key.
X To change display, press and hold the F key for two seconds.
The following information can be called up:
– Temperature 1 (°C) / temperature 2 (°C)
Indicates the two exhaust gas temperatures in front of the filter (engine side) and behind the filter
(exhaust pipe side)
– Pressure (mbar) – displayed after engine start

Indicates the exhaust air back pressure
– Temperature 1 (°C) / pressure (mbar)
Indicates the pressure as well as the exhaust air temperature in front of the filter (engine side).
– Temperature 2 (°C) / pressure (mbar)
Indicates the pressure as well as the exhaust air temperature behind the filter (exhaust pipe side).
– Speed (rpm) / pressure (mbar)
Indicates the exhaust air pressure and diesel engine speed.
4.30.6
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MJFCIFSS
4.3 Regeneration of the built-in particle filter

The particle filter works best if the exhaust gas temperature is above 250 °C for at least 50 % of the
operating time. Under these conditions, it regenerates itself.
If the minimum exhaust gas temperature cannot be reached during the machine operating time, the
permissible exhaust gas backpressure / lead pressure will be reached at some point (warning LED A
at the control unit A175 is on). If this is the case, the filter 30 must be regenerated. During the rege-
neration process, the deposits in the particle filter are pyro-cleaned at a high exhaust gas tempera-
ture. To achieve this, the engine must be operated with full load simulation.
X Actuate the switch S480 of the full load simulation.
ª The indicator light in the switch is on.
ª On the display of the indicating and control unit, the message "particle filter regenerate" is shown.
ª The full load simulation is activated. The hydraulic unit of the machine is now operated so that
the diesel engine is run at full load.
Note!
During full load simulation, the display texts cannot be altered.
X Fully pressurise the bucket cylinder circuit by actuating the right pilot control unit 81.
ª The diesel engine is operated at full load.
X Increase the pressure in the bucket cylinder circuit (max. 10 minutes) until the exhaust gas back-
pressure drops below the permissible value.
X Move the right pilot control unit 81 to its neutral position.
X Press the switch S480 again.
ª The indicator light in the switch is off.
ª The full load simulation function is off.
If the exhaust gas backpressure fails to drop, switch off the diesel engine, wait for approx. 30 minutes
and repeat the above regeneration procedure. If this does not lead to the desired result, dismantle the
filter 30 and return it for cleaning to an authorised workshop (customer service / supplier), see 5.1.4

Fig. 7 Full load simulation switch and indicator
81 Right pilot control unit for boom and bucket A150 Indicating and control unit
S480 Full load simulation switch
4.30.7
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Maintenance
5 Maintenance
Note!
The particle filter may only be used in conjunction with diesel engines filled with Liebherr Motoroil
10 W 40 low ash engine oil.
If other oil products are used, the particle filter might quickly become clogged up with oil ash (making
shorter cleaning intervals / every 1000 operating hours necessary).
5.1 Maintenance of the particle filter

As a rule, the filter element 30 must be cleaned at least every 2000 operating hours. In this case,
the preliminary filter in the input module 15 must also be cleaned.
Caution!
Do not touch the particle filter when it is hot, as this can cause serious injury from burns.
Do not inhale the ash residue in the filter as it can cause damage to the respiratory system.
Fine particles can cause damage to eyes.
X Let the filter cool off.
X Always wear protective gloves.
X When cleaning the filter, wear face mask and protective goggle.
5.1.1 Checking of connecting clamps

The connecting clamps 70 hold together the 3 main elements of the particle filter. If the clamps 70
are released, the exhaust gas system is not air-tight anymore, so that the filter cannot work properly
and the indicated values and statuses are inaccurate.
To ensure tightness, the screws of the clamps 70 must be retightened every 500 operating hours.
with the correct tightening torque (12 Nm).
5.1.2 Dismantling of filter and input module for cleaning

X After the filter 10 has cooled down, release the clamps 70.
X Slide the clamps 70 onto the filter module 30.
X Lift the filter module 30 with the clamps 70 from the machine.
X Remove the centring rings 50 and 60 from the filter module 30.
X Release the clamp (exhaust gas hose) and disconnect the line.
X Disconnect the backpressure line at the input module 15.
X Release the fastening clamp 19.
X Lift the input module 15 from the uppercarriage.
X Clean the filter module, see 5.1.3 and
5.1.3 Cleaning of the preliminary filter after the maintenance interval has lapsed
When the prescribed maintenance interval (2000 operating hours) is reached, the preliminary filter at
the input module 15 must be cleaned as follows:
X Position the input module in front of a funnel with adjusted diameter and a vacuum cleaner hose
or similar piece of equipment.
X Switch on the vacuum cleaner and blow out the preliminary filter with oil-free compressed air.
4.30.8
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MJFCIFSS
Maintenance
X Turn the filter in axial direction and blow it out from the other side.
X After proper cleaning, re-insert the input module 15, see 5.1.5.
5.1.4 Cleaning of the particle filter after the maintenance interval has lapsed or in
the event of a malfunction
Caution!
When the prescribed maintenance interval (2000 operating hours) or the limit load is reached (war-
ning LED A on the control unit A175 is on and the buzzer sounds), clean the filter 30.
If the machine is operated when the particle filter load limit is reached, the engine could be damaged
and the guarantee of the manufacturer is voided.
X Immediately ship the filter to an authorised workshop (customer service / dealer). At the work-
shop, the filter module 30 is autoclaved for 6 hours at approx. 600°C.
X For the handling of replacement modules for the change/cleaning of the filter module 30, observe
the local conditions and the applicable instructions, e.g. VERT specifications for particle filter sys-
tems in BAFU / SUVA filter list.
X When using a replacement module 30.1, secure it with the centring rings 50 / 60, seal rings and
the clamps 70 to the input and output module 15/20, (see “Installation of the input module and the
filter module after cleaning” on page 9)
5.1.5 Installation of the input module and the filter module after cleaning
X Place the input module 15 in the uppercarriage.
X Secure the input module 15 with the fastening clamp 19 after having aligned it in its position.
X Connect the backpressure line to the input module 15.
X Connect the exhaust gas hose to the input module 15 and tighten the clamp.
Note!
The different lengths of the centring rings 50 / 60 in the input and output modules 15 / 20 ensure
that the filter 30 / replacement module 30.1 is installed correctly (in the correct flow direction).

For air-tight installation, mount new sealing rings 65 to the centring rings 50 / 60.
X Remove the old sealing rings 65 from the centring rings 50 / 60 and clean the centring rings 50 /
60 to remove all sealant and adhesive residue.
X Attach new seal rings 65 with sealant-compatible adhesive on both sides of the centring rings 50 / 60.
X Insert the centring rings 50 / 60 at the correct side of the filter module 30 / replacement module 30.1.
X Insert the filter module 30 or the replacement module 30.1 with the clamps 70 and the inserted
centring rings 50 / 60 between the input and the output module 15 / 20 and align in axial and radial
direction.
X Slide the clamps 70 over the gap between the input / filter / output modules.
X Tighten the clamps 70 with a torque of 12 Nm.
5.2 Maintenance of filter (condensate trap) 100
Draining condensate:
The condensate must be regularly drained into a container 201.
X Turn the drain screw 203 by 90° counter-clockwise (direction A), Fig. 8 to drain off the condensate
4.30.9
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MJFCIFSS
Maintenance
into a suitable container.
Caution!
The backpressure monitoring system works only correctly, if the system is completely tight and the
filter 100 is sealed.
The drain valve must therefore be closed properly.
X To close the drain valve, turn the drain screw 203 by 90° clockwise (direction Z), Fig. 8.
Checking / replacing filter 100:

The sintered metal filter 103 must be checked every 500 operating hours and cleaned, if necessa-
ry.
Replace the sintered metal filter 103 every 1000 operating hours.
X Turn the drain screw 203 by 90° counter-clockwise (direction A) to drain off the condensate into
a suitable container.
X Remove the container 201.
X Remove the cap nut 105.
X Pull off the filter parts 104 - 101 and clean or replace the sintered metal filter cartridge 103.
X Reassemble the filter parts 101 - 104 in the correct sequence, see Fig. 8, and position and tighten
the cap nut 105.
X Mount the container 201 with the seal ring 202
X To close the drain valve, turn the drain screw 203 by 90° clockwise (direction Z),.
Fig. 8 Design of the condensate trap
100 Filter, complete 201 Container

101 Centrifuge 202 Seal ring

102 Shield 203 Drain valve
103 Sintered metal filter element
104 Shielding plate A Drain valve open
105 Cap nut Z Drain valve closed
4.30.10
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MJFCIFSS
Retrofitting of particle filter accessory kit
6 Retrofitting of particle filter accessory kit
6.1 Important instructions
Note!
Please note that all work on the exhaust gas system must be carried out by technicians authorised
by LIEBHERR.
6.2 Preconditions
The diesel engine must be filled with Liebherr Motoroil 10 W 40 low ash engine oil.
6.3 Design of the particle filter, see Fig. 1 and Fig. 10
Note!
The particle filter replaces the standard silencer and is installed in its place.
The backpressure monitoring system can only work properly, if the backpressure line from the par-
ticle filter 10 and the filter 100 to the data logger A133 is completely air-tight.
After the filter has been installed, the system must be tested for leakage.
X Check the system for leakage by applying a test pressure.
X Remove the installed silencer.

X Install the particle filter 10 with the provided fastening elements in the uppercarriage. For detailed
instructions, see enclosed installation drawing and assembly parts list.
X Secure the exhaust gas lines and the end pipe at the input / output module.
X Mount the data logger A133 in the proper location.

X Mount the indicating and control unit A175 in the proper location.
X Install the condensate trap 100 in the proper location.
X Mount the backpressure line from the particle filter 10 and the filter 100 to the data logger A133,
maintaining an angle of inclination of 2° (rising).
X Test the backpressure line with a suitable tool (hand pump with pressure indicator, see tool no.
2.01) for tightness, see 6.4.
X Install all electrical connections according to the supplied installation drawings.
X Start the diesel engine and slowly increase the load (allow the engine to warm up).
X Check the values at the control unit A175.
ª With the new filter module, the backpressure in front of the filter (pressure 1) must be max.
120 mbar.
X All values/responses are listed in the enclosed installation and test list. Complete the list and re-
turn it to Liebherr Hydraulikbagger GmbH, Service Center, Liebherrstr. D - 88457 Kirchdorf / Iller,
Germany.
4.30.11
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MJFCIFSS
6.4 Leakage testing of the backpressure line between the filter and the data logger
Caution!
Excessive test pressure might cause damage to the filter and monitoring system.
Never pressurise the exhaust gas system with a compressed air gun or a similar device.
X Apply only pressures of max. 0.5 bar generated with a hand pump.
X Disconnect the backpressure line L at the point T on the input element 15.
X Connect the hand pump adapter (see tool list 2.01) to the backpressure line L. Ensure that the
connection is air-tight.
X Seal the swivel elbow W with a plug.
X Pressurise the exhaust gas system with the hand pump (max. 0.5 bar) and check the pressure
loss.
There may be no pressure loss within a period of 1 minute.
X If a pressure loss is detected, check the connection of the backpressure line L to the data logger.
X If the system is properly sealed, remove the plug and connect the backpressure line L to the input
element 15, ensuring an air-tight connection.
Fig. 9 Separating point for tightness test
15 Input element L Backpressure line

100 Filter, complete T Separating point
A133 to data logger W swivel elbow
4.30.12
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MJFCIFSS
6.5 Layout of the components according to spare parts catalogue
Fig. 10 Particle filter with holder and backpressure line with filter
10 Particle filter 150 Precondition:

engine filled with Liebherr Motoroil 10W40

low ash engine oil
(available in different lot sizes)
100 Condensate trap/filter A133 Data logger
4.30.13
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MJFCIFSS
Fig. 11 Electrical system, part 1
A133 Data logger X1313 Interface to Data logger

A175 Indicating / control unit X1315 Plug connection, 5-pin
X1316 Plug connection, 5-pin
4.30.14
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MJFCIFSS
Fig. 12 Electrical system, part 2, for various machine models

A127 Printed circuit board / power F351 Fuse
E50 Electric box K288 Relay terminal 15
F340 Fuse X1312 Plug connection / CS revolving deck
data logger, 1-pin
Electric diagram, see group 8.102

4.30.15
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MJFCIFSS
Full load simulation (optional accessory for particle filter)
7 Full load simulation (optional accessory for particle filter)
7.1 Design
The full load simulation unit switches the hydraulic unit of the machine to full load operation. This is
done to reach the necessary high exhaust gas temperature.
The pressure value of the valve 105 is normally above the maximum working pressure of the machine
(primary pressure/pressure cut-off). When actuating the full load simulation, the pressure value is re-
duced by the solenoid valve Y445 actuated with the switch S480. As a result, the primary pressure-
relief valve 105 is opened before the pressure cut-off is triggered. The oil from the working pump thus
flows through the valve 105, generating a high power input of the hydraulic system and thus a high
load on the engine.
Fig. 13 Design of the full load simulation system

1 Hydraulic tank Y62/63 Solenoid valve / travel forward

30 Additional pressure stage Y268 Solenoid valve / changeover (optional)
50 Control oil unit Y414 Solenoid valve pressure reduction (optio-
nal)
105 Primary pressure-relief valve Y445 Solenoid valve full load simulation
A150 Indicating and control unit Y414 Solenoid valve flow rate (optional)
S480 Full load simulation switch
4.30.16
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MJFCIFSS
Full load simulation (optional accessory for particle filter)
7.2 Function
The additional pressure stage 30 at the pressure-relief valve 105 is set to the required high pressure
level during normal excavator operation (normal pressure = maximum pressure).
By activating the full load simulation, the solenoid valve Y445 blocks the additional pressure (pilot
control pressure) to the additional pressure stage 30. The pressure-relief valve 105 is thus switched
to a reduced pressure.
Fig. 14 Hydraulic diagram of full load simulation system Document is registered under: 1030314 - 29.01.2009
1 Hydraulic tank 105 Primary pressure-relief valve

20 from working pump A150 Indicating and control unit / display
30 Additional pressure stage S480 Full load simulation switch
50 Control oil unit Y445 Solenoid valve full load simulation

4.30.17
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MJFCIFSS
Electrical system
8 Electrical system
Fig. 15 Electrical system of the full load simulation system

A150 Indicating and control unit X960 Plug connection

S480 Switch for filter regeneration X1196 Plug connection
X2 Plug connection X1197 Plug connection
X29 Plug connection Y445 Solenoid valve / full load simulation
Electric diagram, see group 8.102

4.30.18
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MJFCIFSS
Pressure-relief valve 105 with additional pressure stage (2-stage at full load simulation)
9 Pressure-relief valve 105 with additional pressure stage (2-stage at

full load simulation)
see Fig. 13
The pilot-controlled primary pressure-relief valve 105 with additional pressure stage acts as a safety
valve and protects the system against overpressure.
9.1 Pressure control

The pressure P built up in the consumer circuit acts on the front face of the main cone 5 and, through
the bore D1, also on the rear surface of the main cone 5. At the same time, the pressure acts also on
the pilot control cone 15.
The springs 7 and 18 push the main cone 5 and the pilot control cone 15 into their closing positions
(static status).
As soon as the pressure in the consumer circuit attains a value exceeding the set value of pressure
and adjusting spring 18, pilot control cone 15 is lifted from its seat, and some oil can penetrate into
the return channel. Due to the different cross-sections of the bores D1 in the bushing 6 and the ring
face D2 in the valve insert 2, a pressure difference is built up between the front and rear sides of the
main cone 5.
As a result of this pressure difference, the main cone 5 is shifted against the pressure springs 7, and
a substantial amount of oil flows off to the non-pressurised return side T.
The spring force of the pressure spring 18 determines the pressure value (blow-off pressure / begin
of opening) of the pressure-relief valve. The spring force is determined by the force applied by the
shifting piston 9 onto the piston 8. The pressure value can be preset by changing the pressure applied
to the shifting piston 9 through the connection X. This is done in two stages, see 9.2.
9.2 Additional pressure stage

Stage 1 The connection X is linked to the tank and the preload of the pressure spring 18 is smal-

ler, so that a lower blow-off pressure is reached (simulation of full load).
Stage 2 Pilot-control pressure is applied to connection X. As a result, a greater preload is applied

onto the pressure spring 18 through the shifting piston 9 and the piston 8. As a result, a
higher blow-off pressure is reached (high pressure protecting the system).
4.30.19
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MJFCIFSS
Fig. 16 Primary pressure-relief valve with additional pressure stage

Fig. 17 Sectional drawing of primary pressure-relief valve with additional pressure stage (2-step)
4.30.20
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MJFCIFSS
1 Housing 28 O-ring
2 Valve insert 30 Backing ring
3 Adjusting screw 31 Piston seal
4 Screw 32 O-ring
5 Main cone 33 O-ring
6 Bushing 34 Backing ring
7 Pressure spring 35 O-ring
8 Piston 37 O-ring
9 Shifting piston 105 Pressure-relief valve, 2-step, complete
10 Lock nut
11 Lock nut D1 Bore
15 Pilot control cone D2 Ring face
18 Pressure spring P Pressure from pump
21 Shim T Return channel
27 O-ring X Connection for control pressure
9.3 Checking and adjustment of the primary pressure-relief valve 105

X Connect the pressure sensor/gauge to the measuring point 41 (control block 100).
X Disconnect the control line from the additional pressure stage of the pressure-relief valve 105.
X Seal the control hose but keep the pressure-relief valve connection open (risk of pressure build-
up from leak oil at the control pressure connection X -).
X Increase the pressure cut-off 104 - by turning in the adjusting screw on the block and by turning

Fig. 18 Control block with pressure-relief valve, pressure cut-off and measuring point
41 Measuring point for pump pressure 105 Primary pressure relief valve, 2-step
4.30.21
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MJFCIFSS
9.3.1 Adjustment of pressure stage 2 (higher pressure stage)

X Start machine and preselect the speed step PP.
X Loosen the lock nut 11 and block the shifting piston 9 by screwing in the adjusting screw 4.
X Extend the bucket/grapple cylinder to the stop and fully actuate the right pilot control unit.
X Increase the adjusting pressure at the secondary pressure-relief valve 262 (turning in adjusting
screw ) until the safety valve 105 responds.
Caution!
unit.
X To ensure this, adjust the safety valve 105 to a value of maximum 440 bar (measuring point 41).
X Compare the pressure value with the prescribed pressure of the primary pressure-relief valve 105
and adjust, if necessary:
X Loosen the lock nut 14 and turn the adjusting screw 10 at the pressure-relief valve 105 until the
pressure sensor indicates the nominal pressure for stage 2 (400+20 bar), see adjustment protocol.
X Re-tighten the lock nut 10.
9.3.2 Adjustment of pressure stage 1 (lower pressure level)

X Fully pressurise the bucket cylinder with the right pilot control unit.
X Turn the adjusting screw 4 at the pressure-relief valve 105 until the pressure sensor/gauge
(measuring point 41) indicates the prescribed pressure.
X Re-tighten the lock nut 11.
X Reconnect the control line to the connection X.
Reset the secondary pressure-relief valve 262 and the pressure cut-off 104 to the prescribed values
(see adjustment protocol).
Fig. 19 Adjusting screws and lock nuts of the additional pressure stage
1 Housing 9 Shifting piston

2 Valve insert 10 Lock nut
3 Adjusting screw 11 Lock nut
4 Screw 105 Pressure-relief valve, 2-step, complete
8 Piston X Connection for control pressure
4.30.22
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MJFCIFSS
Service Manual
SUBGROUP - INDEX
Section Group Type
Coupling 5.10.1 A 309 LI-TCD 40998-

A 311 LI-TCD 41128-
A 312 LI-TCD 36220-
A 314 LI-TCD 30694-
A 316 LI-IND-TCD 29503-
A 316 LI-TCD 29120-
R 313 LI-TCD 39171-
R 317 LI-TCD 30019-

5.1
MJFCIFSS
5.2
MJFCIFSS
Service Manual
Service Manual Coupling
Design and function of coupling
Coupling
1 Design and function of coupling
see Fig. 1 and Fig. 2

The flexible coupling (torsion dampers) 5 is mounted between the diesel engine and the variable-dis-
placement pump. It dampens impacts caused by torque and load changes.
It is a permanent coupling and thus transmits the motor torque directly and continuously to the pump.
Decoupling is not possible.
Disk 5.1 is connected with bolts to the flywheel C of the diesel engine. The hub 5.2 is guided axially
by circular disks 5.3 that are riveted onto hub 5.2.
The hub 5.2 can be moved radially on disk 5.1. Eight pressure springs 5.4 mounted on the reference
circle provide a non-positive flexible connection between the disks 5.3 and the hub 5.2.
The drive shaft 10.10 of the variable-displacement pump 10 is connected by means a spline mesh to
the hub 5.2 of the torsion damper 5 (positive connection).
The transmission of power from the diesel engine to the pump 10 consists of the flywheel C, the
mounting bolts 7, the disk 5.1, the pressure springs 5.4, the hub 5.2 with the disks 5.3 and the drive
shaft 10.10 of the pump 10.
Torque impacts upon start-up of the diesel engine and load fluctuations are thus compensated, as
the pressure springs 5.4 are compressed at the moment of impact and subsequently released.
The rotational vibration from the engine is also significantly dampened so that the pump 10 is only
marginally affected.

Fig. 1 Installation of the coupling
5.10.1
copyright by
MJFCIFSS
Coupling Service Manual
Installation and dismantling of the coupling
5 Coupling (torsion damper) 80 Holder

7 Allen head screw 81 Allen head screw
10 Variable-displacement pump C Flywheel
11 Allen head screw D Intermediate housing / engine
12 Retaining washer
2 Installation and dismantling of the coupling
(see Fig. 2 on page3)
2.1 Dismantling
X Secure the variable-displacement pump 10 using a rope.
X Remove the screws 11 and 81.
X Remove the hex retaining washers 12.
X Disconnect the flange connection between the variable-displacement pump 10 and the interme-
diate housing B of the diesel engine, and pull the pump from the coupling 5.
X Note and mark the installation position of the coupling 5.
X Remove the mounting bolts 7.
X Remove the coupling 5 from the flywheel C of the diesel engine.
2.2 Installation
Note!
Note!
Incorrect installation might destroy the coupling 5 due to insufficient engagement of the spline mesh
of the hub 5.2 and the drive shaft 10.10 of the pump.
X Check position A of the installed coupling (see sectional drawing, see Fig. 2).
X Mount the coupling 5 in its correct installation position, see Fig. 2, on the flywheel C.
Screws that are tightened with less than the prescribed torque might become loose and can serious-
ly damage the coupling.
X Tighten all screws with the prescribed torque, using a torque spanner!
X Tighten Allen screws 7 (tightening torque 46 Nm).

X Check the hub 5.2 for concentricity at outer edge (tolerance = 0.1 mm).
X Check the surface of the coupling 5 for side-to-side wobble (tolerance = 0.05 mm).
X Apply a little Liebherr CTK special paste onto the spline mesh of the pump drive shaft and the hub
5.2, see group 1.50.
X Slide the drive shaft 10.10 of the pump into the hub 5.2 and mount the pump 10 on the intermedi-
ate housing D.
X Screw in the Allen head screws 11 / 81 with the retaining washer 12 and the Allen head screws
81 with the retaining washer 12 and the holder 80, see Fig. 2, (tightening torque 46 Nm).
5.10.2
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MJFCIFSS
Service Manual Coupling
Fig. 2 Sectional drawing showing position and alignment of the coupling
5 Coupling (torsion damper) 11 Allen head screw

5.1 Washer 12 Retaining washer

5.2 Hub 81 Allen head screw
5.3 Washers
5.4 Pressure spring A Correct position and alignment of the
coupling
7 Allen head screw B Incorrect position and alignment of the
coupling
5.10.3
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MJFCIFSS
Coupling Service Manual
10 Variable-displacement pump C Flywheel / engine

10.10 Pump drive shaft D Intermediate housing / engine
5.10.4
copyright by
MJFCIFSS
Service Manual
SUBGROUP - INDEX
Section Group Type
LSC system 6.10.1 A 309 LI-TCD 40998-

A 311 LI-TCD 41128-
A 314 LI-TCD 30194-
A 316 LI-IND-TCD 29503-
A 316 LI-TCD 29120-
R 313 LI-TCD 39171-
R 317 LI-TCD 30019-
Design of hydraulic system 6.20.1 A 309 LI-TCD 40998-

A 311 LI-TCD 41128-
Layout of hydraulic system 6.25.1 A 314 LI-TCD 30694-

A 316 LI-IND-TCD 29503-
A 316 LI-TCD 29120-
Hydraulic system 6.40.1 A 309 LI-TCD 40998-

A 311 LI-TCD 41128-
Hydraulic system 6.52.1 R 313 LI-TCD 39171-
Hydraulic unit with dozer blade 6.54.1 R 313 LI-TCD 39171-
Hydraulic system 6.60.1 A 314 LI-TCD 30694-

A 316 LI-TCD 29120-
Hydraulic system 6.62.1 A 316 LI-IND-TCD 29503-

6.1
MJFCIFSS
6.2
MJFCIFSS
Service Manual
Service Manual LSC system
Basic principle - general description of functions
LSC system
1 Basic principle - general description of functions
1.1 General
The LIEBHERR hydraulic excavator generation of the A 309 - R 317 Litronic TCD series is equipped
with the LSC -hydraulic control system (Liebherr synchronous control).
It allows operators to work much faster and much more precisely, thanks to easier and simpler overall
handling of the machine.
The biggest advantage of the LSC system is, however, that handling and operation can be adapted
much better to prevailing working conditions.
The speed of the working movement is determined by the displacement of the control lever / pilot con-
trol valve, not by the load pressure.
Other advantages of the LSC system:
– Several consumers can be handled simultaneously, without any problems, independently of load
pressure and even with saturation deficits.
– The LSC system will adapt flow rates to the requirements of the various consumers.
– Pressures are adapted to the consumer with the highest load.
– Economic operation matched to actual application of the machine
1.2 Design of LSC system

Control elements:
– Load-sensing control
– LUDV system

– Central electronics
– Horsepower and on-demand flow control
Note!
For detailed information on the design of components mentioned above, please refer to the respec-
tive subgroups in the service manual.
1.3 Functional description of LSC system

LSC is a servo pilot-controlled, load-sensing hydraulic system with power control and integrated
LUDV system. The on-board electronics allow, in addition, to adapt pump flow rates to working and/
or consumer conditions, and to increase power control all the way up to load limit.
Load-sensing control (speed control independent of load pressure)

The amount of oil supplied by the pump is adjusted by means of the flow regulator. A gauge orifice
(opening at the spool) generates a pressure difference which corresponds to the spring force (Up)
set at the regulator.
Flow cross-section
The cross-section of the flow supplied by the pump and fed through the spool to the consumers can
6.10.1
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MJFCIFSS
LSC system Service Manual
LUDV system
be controlled by actuating the pilot-control lever. It determines the control pressure, which is propor-
tional to the travel of the lever.
In other words:
– Short travel of lever / pedal at the pilot control valve = low control pressure at the spool = small
flow cross-section = low speed of consumer.
– Long travel of lever / pedal at the pilot control valve = high control pressure at the spool = large
flow cross-section = high speed of consumer.
Flow rate
The applicable law of hydrodynamics tells us that there is a relation between the volumes flowing th-
rough the spool, the aperture of the orifice and the corresponding difference in pressure:
– HighUp value = high flow rate

– LowUp value = low flow rate
Values for Up are pre-set at the pump, i.e. the volume depends on the cross-section.
The on-board electronics make it possible to use a proportional solenoid valve (Y51) to lower Up
continuously and to adapt the speed of working movements to prevailing work conditions and consu-
mer requirements.
2 LUDV system
As part of the load-sensing system, the LUDV system is connected to a spool (gauge orifice) of the
respective consumer, and a subsequent pressure balance. The load pressure of each consumer (LS
signal) is measured at the pressure channel leading to the consumer. The highest measured load
pressure is signalled by the pressure balance of the working pump.
The Up value generated by the pressure spring of the LS regulator (located near the working pump)
is used as a reference Up value for the system.

p1‘ = p2´ corresponds to Up1 = Up2; the flow Qv1 is proportional to cross-section A1, and Qv2 is
proportional to cross-section A2.
The flow generated by the pump at the gauge orifice cross-sections A1 and A2 is proportional to the-
se cross-sections. The Up values at the gauge orifices (Up1 and Up2) are equal, due to the applied
pressure, see Fig. 1.
If several consumers are in use and the flow from the pump Q is not sufficient to saturate the gauge
orifice cross-sections, Up1 and Up2 are reduced. Due to the status signal p2 indicating the highest
load pressure and acting on all pressure balances, the flow distribution remains unaffected by the
load pressure and is determined by the operation of the controls.
6.10.2
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MJFCIFSS
LUDV system

Fig. 1 Principle of LUDV system
A1 Gauge orifice (spool 1) p1’ Pressure in front of pressure balance 1

A2 Gauge orifice (spool 2) p2’ Pressure in front of pressure balance 2
Dw 1 Pressure balance of spool 1) Pp Pump pressure
Dw 2 Pressure balance of spool 2) Up1 Pressure difference between Pp and p1’
F1 External force applied to consumer 1 Up2 Pressure difference between Pp and p2’
F2 External force applied to consumer 2 Up3 Pressure difference between p1 and p1’
FR Flow regulator PQ Pump flow volume
p1 Load pressure at consumer 1 Qv1 Flow rate at consumer 1
p2 Load pressure at consumer 2 Qv2 Flow rate at consumer 2
6.10.3
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MJFCIFSS
Horsepower control by means of proportional solenoid valve Y50
2.1 Proportional split of flow volumes

Example: if a consumer 1 is operated with the required flow rate Q1 = 50 l/min, the oil volume is con-
trolled on the basis of the requirements and made available by the variable capacity pump. If a se-
cond consumer 2 with a required flow rate Q2 = 100 l/min is added, the maximum pump flow rate
Qmax = 200 l /min is split at a ratio of 200 : 250 = 0,8 among both consumers. This means that con-
sumer 1 receives only Q1 = 120 l/min, while consumer 2 receives only Q2 = 80 l/min.
2.2 Performance split

Performance split means the ratio between pump capacity, on the one hand, and useful and lost per-
formance on the other.
The performance of the pump is equal to the flow rate Q of the pump multiplied by the highest consu-
mer pressure (load pressure + Up).
Loss in performance might be caused by volumes required by other consumers, multiplied by the cor-
responding differential pressure (Up at the highest load pressure).
A higher loss of performance arises when a consumer is operated with a pressure cut-off valve.
2.3 Central electronics

Purpose of electronics
– Switching functions
– Displaying and managing important operational data
– Monitoring units and safety devices
– Displaying error and operational status messages
– Controlling functions and processes
– Regulation and control according to current operation
– Proportional solenoid valve Y50
3 Horsepower control by means of proportional solenoid valve Y50

3.1 Regulation of hydraulic performance steps

Horsepower control is effected by means of the spring characteristics on the performance regulator
of the pump and the current at the valve Y50.
3.2 Speed preselection with buttons 3 / 5 of the indicating and control unit:
Press the buttons 3 / 5 (indicating and control unit A150) to preselect one of the 10 speed steps of
the diesel engine:
– Levels 1- 8 = speed levels for various applications in the most ecologically efficient range
– Level 9 - 10 = Max. engine speed
6.10.4
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MJFCIFSS
On-demand flow control
Fig. 2 Horsepower control in LSC system
3 Push button / reduce engine speed A149 UEC central control system
5 Push button / increase engine speed A 150 Indicating and control unit
21 Powertrain (variable-displacement pump) A151 EMR engine control unit
25 Performance regulator R75 Potentiometer for speed adjustment
220 Spool / boom U16 Excavator control (BST)
235 Boom cylinder Y50 Proportional valve (LR)

If the current is smaller than 220 mA = pLR 0 bar (tank pressure), the begin of regulation is equal to
the begin of basic regulation, and the performance drop of the pump is minimal.
If the current increases to a value above 300 mA, the control pressure increases and the begin of
regulation is after the begin of basic regulation, and the performance drop of the pump is also incre-
ased.
4 On-demand flow control
Machines with a load-sensing hydraulic circuit are equipped with on-demand flow control to control
pump flows. As a result, the powertrain of the working pump supplies only the amount of oil needed
by the consumers. This prevents any unnecessary circulation and throttle losses.
4.1 Functional description of the on-demand flow control

If all the spools (160 - 280) are in neutral position (no control oil to spools 160 - 280), the pump sup-
6.10.5
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MJFCIFSS
On-demand flow control
plies only the oil required for stand-by operation. The flow regulator pivots the pump back to the stop
Q min. (stand-by operation = QRest at circulation pressure).
Actuation of a spool (gauge orifice opens) reduces the normal differential pressure (Up) between the
pump and the consumer. As a result of this pressure drop, the flow regulator 26 is shifted by the pre-
set pressure spring (pump pressure is smaller than spring pressure).
The flow via the bores in the spool 220 (160/260/280) is comparable to the flow through a gauge ori-
fice. With increasing flow rates to the consumer, the pressure difference at the gauge orifice also in-
creases.
The balance is established when the pressure difference in the spool reaches the value Up pre-set
at the LS regulator (pump pressure - consumer pressure in LS line).
The flow cross-section of each spool is dimensioned in such a way that the pressure drop is equal to
the value Up(LS) pre-set at the regulator when the desired nominal flow rate has been reached while
the spool is fully open.
If the spool 220 (160/260/280) is shifted back to an interim position, the aperture of the gauge orifice
is reduced, and the pressure difference Up(LS) is reached with a smaller amount of oil. The pump
has a tendency to maintain a constant pressure difference at all times and therefore pivots back to
its initial position.
If several consumers are actuated at the same time, the amount of oil required exceeds the max. ca-
pacity of the pump. The value Up(LS) drops, but remains the same for all consumers, so that all flow
rates are reduced by the same factor.
1 Hydraulic tank 170 to oil motor / travel drive

21 Powertrain 220 Spool / boom cylinder
22 Adjusting device 224 Pressure balance, pilot-controlled
25 LS regulator 235 to boom cylinder
100 Control valve block 260 Spool / bucket cylinder
102 Pressure balance / minimum flow 264 Pressure balance, pilot-controlled
103 Pressure balance / remaining flow 275 to consumer (bucket cylinder)
104 Pressure cut-off valve 280 Spool / support
105 Primary pressure-relief valve 284 Pressure balance, directly controlled

160 Spool / travel drive 295 to the support cylinders
164 Pressure balance, pilot-controlled
6.10.6
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MJFCIFSS
Hydraulic diagram
5 Hydraulic diagram

Fig. 3 Hydraulic schematic: a = pump pivots out, b = pump pivots back
6.10.7
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MJFCIFSS
6.10.8
LSC system
Hydraulic diagram
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MJFCIFSS
Service Manual
Service Manual Design of hydraulic system
Hydraulic tank
Design of hydraulic system
1 Hydraulic tank
Located at the rear of the uppercarriage to the left.
Fig. 1 Hydraulic tank

1 Hydraulic tank 5 Safety check valve
2 Breather filter C Drainage and oil discharge valves
3 Stop valve K Oil level sight glass
4 Return filter
1.1 Purpose
– Takes up all hydraulic oils from the entire equipment
– Separates inlet and return sections. Baffle oil with baffle plates on the inside.
– Supplies purified and cooled oil to the hydraulic pumps.
– Provides reservoir for return oil, with return filters.
– Preloads oil to prevent cavitation.
6.20.1
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MJFCIFSS
Design of hydraulic system Service Manual
Hydraulic tank
1.2 Design
Fig. 2 Section drawing of hydraulic tank
1 Hydraulic tank A Return side

2 Breather filter B Suction side
3 Stop valve D Maintenance access opening
4 Return filter K Oil level sight glass
5 Bypass valve
1.2.1 Classification
– Return side A with return filter 4

– Suction side C with suction pipe, stop cock 3
1.2.2 Filter units

– Return filter 4 with 2-stage fibre glass -filter element -and safety check valve- 5
– Breather filter
1.2.3 Filter size

For various applications, different types of filter inserts for the return filter 4 are required:
– For standard application, 2-stage 20 μ/5 μ,
– Initial equipment (factory equipment) for use in dusty environments 10 μ
– As cleaning element 5 μ
The breather filter 2 is equipped with a mesh size of 2 μ.
1.3 Maintenance
– Check of oil level through the oil level sighting glass K
– Replacement of filter elements in return and breather filter 4.
6.20.2
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MJFCIFSS
Hydraulic pumps
– Removing water from tank through the drain valves
see inspection and maintenance schedule in group 3.
For a detailed description of the hydraulic tank, see group 19.
2 Hydraulic pumps
2.1 Variable-displacement pump 20

Located at the output side of the diesel engine
Fig. 3 Variable-displacement pump 20

20 Variable-displacement pump 31 Gear pump for fan drive
30 Gear pump for pilot control system
2.1.1 Purpose
Supply of all consumers with high pressure oil.
2.1.2 Input
Through the diesel engine via torsion dampers (flexible coupling).
2.1.3 Design
– Axial piston powertrain
– Adjustable unit with swash plate

– Regulating unit with performance regulator (GLR) and flow regulator (LS regulator)
Technical data and description of functions:
– see variable-displacement pump in group 7.10
6.20.3
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MJFCIFSS
Hydraulic pumps
2.2 Gear pumps

Located near the diesel engine and the variable-displacement pump.
Fig. 4 Variable-displacement and gear pumps
20 Variable-displacement pump (main hydrau- 32 Pump for steering

lics)
30 Pump for pilot control 33 Pump for brake system
31 Pump for fan drive/radiator fan
2.2.1 Task / drive system / technical data:

Pump 30 for pilot control:
– Supply of control oil unit, see group 7.42.
– Driven by variable-displacement pump 20
– For flow rate, see "Technical data" in group 3

Pump 31 for fan drive/radiator fan
– Supply of oil motor/fan drive, (see 4 on page6).
– For flow rate see technical data in group 3
Pump 32 for steering:
– Supply of steering system, see group 13.10
– Powered by diesel engine (flange-mounted)
Pump 33 for brake system:
– Supply of braking system, see group 15.10

– Powered by the diesel engine via the gear pump 32 (flange-connected)
6.20.4
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MJFCIFSS
Compact control block
Located at the centre of the uppercarriage in front of the diesel engine.
Fig. 5 Compact control block 100
3.1 Purpose
Distribution of the requested pump flow volumes to the consumers
3.2 Design of compact control block 100

– Integrated LUDV control
– Input section
– 5 spools with one pressure balance each for LUDV control
– Additional control axle for slewing gear, grapple rotator (AS1), swivel bearing and hydraulic boom

adjustment with one pressure balance each
– Flange-mounting option for additional sections, e.g. auxiliary way valve for accessory kits
– Pressure control by means of screwed-in- pressure-relief valves (primary and secondary valves
with suction function) for attachment
– Suction valves for chassis
– Stroke limitation of the spool
– For a description of the functions, see group 7.52
6.20.5
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MJFCIFSS
Hydraulic oil cooler
4 Hydraulic oil cooler
4.1 Purpose
Cooling of return oil by motor-driven fan.
Fig. 6 3-piece combined cooler

13
6 Hydraulic oil cooler FS Finger guard

13 Blower motor H Air scoop
14 Pressure-relief valve LLK Intercooling air cooler
Y352 Proportional solenoid valve MWK Engine water cooler
RL Annular fan
4.2 Design and function

Combined cooler located at the rear of uppercarriage to the right side.
– 3-piece combined cooler consisting of the oil cooler 6 for the hydraulic oil cooler (right), the motor
water cooler MWK (left) and the intercooling air cooler LLK for the diesel engine (top).
– Temperature-controlled cooling by means of annual fans.
The fans are driven by a blower motor 13 with the pressure-relief valve 14 and the proportional
valve Y352.
For a detailed description of the cooling unit, see group 7.20.
6.20.6
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MJFCIFSS
Oil rotary connection
5 Oil rotary connection
5.1 Purpose
Transfer of hydraulic oil from the uppercarriage to the undercarriage and vice versa.
5.2.1 Rotary connection 320 for high pressure

Oil supply to the travel drive, outrigger/blade support, steering cylinder and oil return from these con-
sumers.
For a detailed description, see group 7.76.
5.2.2 Rotary connection 322 for low pressure

Oil supply and return to/from brake system, gear switching system, creeper gear and oscillating axle
support.

Fig. 7 Oil rotary connections
320 Rotary connection for high pressure 322 Rotary connection for low pressure
6.20.7
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MJFCIFSS
Consumers / working attachments
6 Consumers / working attachments

Fig. 8 Consumers and attachments
130 Slewing gear motor 275 Bucket cylinder

170 Travel motor 295 Support cylinder
235 Boom cylinder 515 Regulating cylinder
255 Stick cylinder 595 Swivel cylinder
6.1 Function and classification

– Conversion of hydraulic energy into mechanical energy
– Hydraulic device for the transmission of pushing and/or pulling forces in linear motion with limited
stroke, see 6.2.

– Hydraulic device for the transmission of torque in a rotary motion, see 6.3.
6.20.8
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MJFCIFSS
6.2 Cylinder
6.2.1 Design
– Differential cylinder
• without end-of-travel cushioning
• with single-side or double-side end-of-travel cushioning
For a description of the functions, see group 7.30
– Boom cylinder 235 moving the basic boom, with single-side end-of-travel cushioning
– Stick cylinder 255 moving the bucket stick, with cushioning at both ends
– Bucket cylinder 275 moving the bucket, with single-side end-of-travel cushioning
– Support cylinder 295 moving the outrigger and/or blade support, no end-of-travel cushioning
– Regulating cylinder 515 moving the adjusting boom, with single-side end-of-travel cushioning
– Swivel cylinder 595 moving the swivel bearing, no end-of-travel cushioning
6.3 Oil motor
6.3.1 Design
– Axial piston swash plate
• constant (with constant oil flow consumption)
• regulated (with variable oil flow consumption)
For a description of the functions, see group 7.24, 7.26
– Slewing gear motor 130 with integrated control to drive the uppercarriage by means of the slewing
gear mechanism – constant flow consumption
– Travel motor 170 to drive the vehicle wheels through the transmission – regulated by the travel
brake valve 190

6.20.9
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MJFCIFSS
Pilot control
7 Pilot control
7.1 Purpose
Hydraulic control of all working and travel motions of the machine by means of hand and/or foot-ope-
rated controls (pilot control units, / actuators, etc.)
Fig. 9 Control oil unit and pilot control units on the operator's platform
50 Control oil unit 85 Pilot control unit for support

80 Pilot control unit for stick and rotary move- 86 Pilot control unit for boom adjustment and
ment accessory kits
81 Pilot control unit for boom and bucket/ 87 Pedal for positioning brake
swivel bearing movement
– Pressure generated by separate gear pump , see 2.2

– Control oil unit 50 regulates, monitors, filters, stores and distributes control oil at the required pilot
pressure.
– Proportional solenoid valve Y50 for the control of the variable-displacement pump.
– Proportional solenoid valve Y353 for the control of the travel drive.
– Solenoid valves Y3 / Y24 / Y371
• for the shutting down of the pilot control pressure and the uppercarriage locking mechanism
• for the control of the creeper gear and oscillating axle support
• for the provision of the pilot control pressure for additional excavator functions (e.g. gear shif-
ting).
– Pilot control units 80 - 86 with regulating characteristic for easy excavator operation
• Pilot control units 80 and 81 with joystick used to operate the swivel bearing, the slewing gear
and the attachments, see group 7.45
• Pilot control unit 85 with lever, used to control the support, see group 7.48
• Pilot control unit 86 with pedal, used to control the boom adjustment and the accessory kit, see
group 7.47
6.20.10
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MJFCIFSS
Hydraulic control
– Pedal for positioning brake 87

– Control lines leading from the pilot control units to the control caps of the respective spools
7.3 Maintenance
– Replacement of the filter element (control oil filter in control oil unit 50); for instructions, see in-
spection and maintenance schedule in group 3
8 Hydraulic control
The LIEBHERR hydraulic excavator generation of the A 309 - A 311 Litronic series is equipped with
the LSC hydraulic control system (Liebherr synchronous control).
– Pressures are adapted to the consumer with the highest load.
– Economic operation matched to actual application of the machine
For a detailed description of the principle, design and function, see group 6.10.

6.20.11
copyright by
MJFCIFSS
Hydraulic control
6.20.12
copyright by
MJFCIFSS
Service Manual Layout of hydraulic system
Hydraulic tank
Layout of hydraulic system
1 Hydraulic tank
Located at the centre of the uppercarriage to the left.
Fig. 1 Hydraulic tank
1 Hydraulic tank 5 Safety check valve

2 Breather filter C Oil drain valve (collection area)
3 Stop cock D Oil drain valve (suction side)
4 Return filter K Oil level sight glass

1.1 Purpose
– Takes up all hydraulic oils from the entire equipment.
– Separates inlet and return sections. Baffle oil with baffle plates on the inside.
– Supplies purified and cooled oil to the hydraulic pumps.
– Provides reservoir for return oil, with return filters.
– Preloads oil to prevent cavitation.
6.25.1
copyright by
MJFCIFSS
Layout of hydraulic system Service Manual
Hydraulic tank
1.2 Design
Fig. 2 Section drawing of hydraulic tank
1 Hydraulic tank A Return side

2 Breather filter B Suction side
3 Stop cock C Drain valve (collection area)
4 Return filter D Drain valve (suction side)
5 Safety check valve K Oil level sight glass
– Return side A with return filter 4
– Suction side C with suction pipe, stop cock 3
1.2.2 Filter units

– Return filter 4 with 2-stage fibre glass -filter element -and safety check valve- 5
– Breather filter
1.2.3 Filter size

For various applications, different types of filter inserts for the return filter 4 are required:
– for intake (initial equipment) 10 μ
– for normal use 2-stage 20 μ/5 μ, for use in dusty environments 10 μ
The breather filter 2 is equipped with a mesh size of 2 μ.
1.3 Maintenance
– Check of oil level through the oil level sighting glass K

– Replacement of filter elements in return and breather filter 4
– Drainage of the tank through the drain valves C and D
– For a detailed description, see inspection and maintenance schedule in group 3
For a detailed description of the hydraulic tank, see group 19.
6.25.2
copyright by
MJFCIFSS
Hydraulic pumps
2 Hydraulic pumps
2.1 Variable-displacement pump 20

Located at the output side of the diesel engine
Fig. 3 Variable-displacement pump 20
20 Variable-displacement pump 31 Gear pump for fan drive

30 Gear pump for pilot control system
2.1.1 Purpose
Supply of all consumers with high pressure oil.

2.1.2 Input
Through the diesel engine via torsion dampers (flexible coupling).
2.1.3 Design
– Axial piston powertrain
– Adjustable unit with swash plate
– Regulating unit with performance regulator (GLR) and flow regulator (LS regulator)
Technical data and description of functions:
– see variable-displacement pump in group 7.10
6.25.3
copyright by
MJFCIFSS
Hydraulic pumps
2.2 Gear pumps

Located near the diesel engine and the variable-displacement pump.
Fig. 4 Variable-displacement and gear pumps
20 Variable-displacement pump 32 Pump for steering

30 Pump for pilot control 33 Pump for brake system
31 Pump for fan drive/radiator fan
2.2.1 Task / drive system / technical data:

Pump 30 for pilot control:
– Supply of control oil unit, see group 7.42
Pump 31 for fan drive/radiator fan

– Supply of oil motor/fan drive, see section 4
– For flow rate see technical data in group 3
Pump 32 for steering:
– Supply of steering system, see group 13.10
Pump 33 for brake system:
– Supply of braking system, see group 15.10
– Powered by the diesel engine via the gear pump 32 (flange-connected)
6.25.4
copyright by
MJFCIFSS
Located at the centre of the uppercarriage in front of the diesel engine.
Fig. 5 Compact control block 100
3.1 Purpose
Distribution of the requested pump flow volumes to the consumers.
3.2 Design of compact control block 100

– Integrated LUDV control
– Input section
– 5 spools with one pressure balance each for LUDV-control
– Flange-mounting option for additional sections, e.g. auxiliary way valve for accessory kits

– Pressure control by means of screwed-in- pressure-relief valves (primary and secondary valves
with suction function) for attachment
– Suction valves for chassis
– Stroke limitation of the spool
– For a description of the functions, see group 7.56
6.25.5
copyright by
MJFCIFSS
Hydraulic oil cooler
4 Hydraulic oil cooler
4.1 Purpose
Cooling of return oil by motor-driven fan.
Fig. 6 3-piece combined cooler

13

13 Blower motor H Air scoop
14 Pressure-relief valve LLK Intercooling air cooler
Y352 Proportional solenoid valve MWK Engine water cooler
RL Annular fan

Combined cooler located at the rear of uppercarriage to the right side.
– 3-piece combined cooler consisting of the oil cooler 6 for the hydraulic oil cooler (right), the motor
water cooler MWK (left) and the intercooling air cooler LLK for the diesel engine (top).
– Temperature-controlled cooling by means of annual fans.
The fans are driven by a blower motor 13 with the pressure-relief valve 14 and the proportional
valve Y352.
For a detailed description of the cooling unit, see group 7.20.
6.25.6
copyright by
MJFCIFSS
Oil rotary connection
5 Oil rotary connection
5.1 Purpose
Transfer of hydraulic oil from the uppercarriage to the undercarriage and vice versa.
5.2.1 Rotary connection 320 for high pressure

Oil supply to the travel drive, outrigger/blade support, steering cylinder and oil return from these con-
sumers.
5.2.2 Rotary connection 322 for low pressure

Oil supply and return to/from brake system, gear switching system, creeper gear and oscillating axle
support.

Fig. 7 Oil rotary connections
320 Rotary connection for high pressure 322 Rotary connection for low pressure
6.25.7
copyright by
MJFCIFSS
6 Consumers / working attachments

Fig. 8 Consumers and attachments
130 Slewing gear motor 255 Stick cylinder

170 Travel motor 275 Bucket cylinder
235 Boom cylinder 295 Support cylinder
6.1 Function and classification

– Conversion of hydraulic energy into mechanical energy
– Hydraulic device for the transmission of pushing and/or pulling forces in linear motion with limited
stroke, see 6.2
– Hydraulic device for the transmission of torque in a rotary motion, see 6.3
6.2 Cylinder
6.2.1 Design
– Differential cylinder
• without end-of-travel cushioning
6.25.8
copyright by
MJFCIFSS
• with single-side or double-side end-of-travel cushioning

For a description of the functions, see group 7.30
– Boom cylinder 235 moving the basic boom, with single-side end-of-travel cushioning.
– Stick cylinder 255 moving the bucket stick, with cushioning at both ends.
– Bucket cylinder 275 moving the bucket, with single-side end-of-travel cushioning.
– Support cylinder 295 moving the outrigger and/or blade support, no end-of-travel cushioning
6.3 Oil motor
6.3.1 Design
– Axial piston swash plate
• constant (with constant oil flow consumption)
• regulated (with variable oil flow consumption)
For a description of the functions, see group 7.24, 7.26
– Slewing gear motor 130 with integrated control to drive the uppercarriage by means of the slewing
gear mechanism – constant flow consumption
– Travel motor 170 to drive the vehicle wheels through the transmission – regulated by the travel
brake valve 190

6.25.9
copyright by
MJFCIFSS
Pilot control
7 Pilot control
7.1 Purpose
Hydraulic control of all working and travel motions of the machine by means of hand and/or foot-ope-
rated controls (pilot control units, / actuators, etc.)
Fig. 9 Control oil unit and pilot control units on the operator's platform
50 Control oil unit 85 Pilot control unit for support

80 Pilot control unit for stick and rotary move- 86 Pilot control unit for accessory kit
ment
81 Pilot control unit for boom and bucket move- 87 Pedal for positioning brake
ment
– Pressure generated by separate gear pump, see 2.2.

– Control oil unit 50 regulates, monitors, filters, stores and distributes control oil at the required pilot
pressure.
– Proportional solenoid valve Y50 for the control of the variable-displacement pump.
– Proportional solenoid valve Y353 for the control of the travel drive.
– Solenoid valves Y3 / Y24 / Y371
• for the shutting down of the pilot control pressure and the uppercarriage locking mechanism
• for the control of the creeper gear and oscillating axle support
• for the provision of the pilot control pressure for additional excavator functions (e.g. gear shif-
ting)
– Pilot control units 80 - 86 with regulating characteristic for easy excavator operation
• Pilot control units 80 and 81 with joystick used to operate the slewing gear and the attach-
ments, see group 7.45
• Pilot control unit 85 with lever, used to control the support, see group 7.48
• Pilot control unit 86 with pedal, used to control the accessory kits, see group 7.47
– Pedal for positioning brake 87
6.25.10
copyright by
MJFCIFSS
Hydraulic control
– Control lines leading from the pilot control units to the control caps of the respective spools
7.3 Maintenance
– Replacement of the filter element (control oil filter in control oil unit 50); for instructions, see in-
spection and maintenance schedule in group 3
8 Hydraulic control
The LIEBHERR hydraulic excavator generation of the A 314 - R 317 Litronic series is equipped with
the LSC hydraulic control system (Liebherr synchronous control).
– Pressures are adapted to the consumer with the highest load..
– Economic operation matched to actual application of the machine.
For a detailed description of the principle, design and function, see group 6.20.

6.25.11
copyright by
MJFCIFSS
Hydraulic control
6.25.12
copyright by
MJFCIFSS
Service Manual Hydraulic system
Hydraulic system
Note!
For a detailed description of the design and construction of the hydraulic system and the various
main components, see group 6.20.
Key to circuit diagram I

Items see Items see
group group
1 to hydraulic tank 225 Restrictor Ø 0.8 mm
6 to oil cooler 227 Restrictor check valve (Ø 0.8 mm)
7 Check valve 3.5 bar 7.56 235 Boom cylinder 7.30
8 Preload valve 7.0 bar 7.56 238 Pipe-fracture safety 16.04
20 from the variable-displacement 7.10 240 Spool / stick cylinder 7.52
pump
26 to flow regulator 241 Secondary pressure-relief valve /
retracting
41 Measuring point MP 242 Secondary pressure-relief valve /
extending
50 from control oil unit 7.42 244 Pressure balance, pilot-controlled
80 from pilot control unit 4x / left 7.45 245 Restrictor Ø 0.8 mm
81 from pilot control unit 4x / right 7.45 247 Restrictor check valve (Ø 0.8 mm)
85 from pilot control valve / support 7.48 255 Stick cylinder 7.30
86 from adjusting boom pilot control 7.47 260 Spool / bucket cylinder 7.52
unit
87 from valve / positioning brake 261 Secondary pressure-relief valve /
retracting
100 Compact control block 5x 7.52 262 Secondary pressure-relief valve /

extending
102 Pressure balance / minimum flow 264 Pressure balance, pilot-controlled
103 Pressure balance / remaining flow 275 Bucket cylinder 7.30
104 Pressure cut-off valve 277 Shut-off device for grapple operation
105 Pump safety valve 278 Lines leading to grapple
107 Shuttle valve Ø 0.6 mm / 1.2 mm 279 Restrictor check valve (only with
quick-change adapter)
108 LS central nozzle Ø 1.2 mm 280 Spool / support cylinder 7.52
120 Slewing gear control axle 281 Plug / dummy cartridge
122 Input pressure balance 284 Pressure balance, directly controlled
123 Spool / slewing gear 295 Support cylinder 7.30

125 Restrictor Ø 1.8 mm 297 Support valve / double-load holding 7.82
valve
126 Shuttle valve Ø 0.8 mm / 0.8 mm 320 Rotary connection 7x 7.78
127 Restrictor check valve (Ø 0.8 mm) 322 Rotary connection 6x 7.76
128 Restrictor check valve (Ø 1.2 mm) 500 Spool / regulating cylinder 7.52
A 309 LI-TCD 40998- 6.40.1

A 311 LI-TCD 41128- copyright by
MJFCIFSS
Hydraulic system Service Manual
Items see Items see

group group
130 Slewing gear motor, complete 7.24 501 Secondary pressure-relief valve /
extending
132 Powertrain 502 Secondary pressure-relief valve /
retracting
133 Suction valve 503 Spool / regulating cylinder 7.52
134 Pressure-relief valve with additio- 504 Pressure balance, direct-controlled
nal pressure stage
135 Pressure-relief valve with additio- 507 Restrictor check valve (Ø 1.0 mm)
nal pressure stage
137 Measuring point / turning right 515 Regulating cylinder 7.30
138 Measuring point / turning left 517 Double-load back-pressure valve 7.86
155 Slewing gear brake 9.20 540 Additional control valve / AS1 7.52
grapple rotator
156 Slewing gear mechanism 9.10 541 Secondary pressure-relief valve /
grapple turning right
160 Spool / chassis 7.52 542 Secondary pressure-relief valve /
grapple turning left
161 Suction valve / reverse travel 543 Spool / AS1
162 Suction valve / forward travel 544 Pressure balance, directly controlled
164 Pressure balance, pilot-controlled 550 Oil motor / grapple rotator
165 Restrictor 2 x Ø 0.8 mm 551 Secondary pressure-relief valve /
167 Restrictor check valve (Ø 0.8 mm) 552 Secondary pressure-relief valve /
170 Travel motor 7.26 580 Spool / swivel cylinder 7.52
retracting
173 Control cylinder / regulating unit 582 Secondary pressure-relief valve /

extending
174 Spool / regulating unit 584 Pressure balance, pilot-controlled
175 Check valves 595 Swivel cylinder 7.30
176 Secondary relief valve / forward 597 Double-load back-pressure valve 7.80
177 Secondary relief valve / reverse A149 from UEC central control system 8.10/8.40
185 Transmission 11.20 S5L Push button / grapple rotator, left 8.10/8.40
190 Travel brake valve, complete 7.26 S5R Push button / grapple rotator, right 8.10/8.40
192 Brake piston S19 Switch / grapple rotator 8.10/8.40
193 Restrictor check valve Y22 Solenoid valve / grapple rotation left 8.10/8.40
194 Check valve Y23 Solenoid valve / grapple rotation 8.10/8.40

right
195 Shuttle valve Y24 from solenoid valve / creeper gear 8.10/8.40
196 Check valves Y62 from solenoid valve / forward travel 8.10/8.40
220 Spool / boom cylinder 7.52 Y63 from solenoid valve / reverse travel 8.10/8.40
221 Secondary pressure-relief valve / Y262 from solenoid valve / changeover 8.10/8.40
extending
6.40.2 A 309 LI-TCD 40998-

copyright by A 311 LI-TCD 41128-
MJFCIFSS
Items see Items see

group group
222 Secondary pressure-relief valve / Y451 Proportional solenoid valve / slewing 8.10/8.40
retracting gear control
Index to wiring diagram II

Items see Items see
group group
1 Hydraulic tank 19.10 85 Pilot control unit 2x / support 7.48
2 Breather filter 86 Adjusting boom pilot control valve 2x 7.47
3 Stop valve 87 Valve / positioning brake
4 Return filter 88P Manifold pressure
5 Bypass valve / return filter 88T Collecting pipe return line
6 Oil cooler 89 Collecting pipe return line
13 Oil motor radiator fan 100 from / to control valve block 7.52
14 pressure-relief valve / fan motor 120 to slewing gear axle 7.52
15 Coarse filter 155 to slewing gear brake 9.20
170 Travel motor
20 Variable-displacement pump 7.10 322 to rotary connection 6x 7.76
21 Powertrain 400 to brake system 15.10
22 Control piston 401 to steering system 13.10
23 Measuring cylinder 402 to oscillating axle support 14.10
24 Angular lever 403 to gear shifting 11.32
25 Performance regulator 540 from additional axle AS1 7.52

26 Flow regulator 597 to double load-holding valve / swivel 7.80
bearing
27 Shuttle valve A149 from UEC central control system 8.10/8.40
28 Check valve B335 Pressure switch pst slewing gear 8.10/8.40
29 Restrictor S7 Safety switch 8.10/8.40
30 Gear pump / pilot control S21 Switch / creeper gear 8.10/8.40
31 Gear pump / fan drive S35 Switch / pilot control 8.10/8.40
32 Gear pump / steering S63 Solenoid valve / switchover bucket 8.10/8.40
swivel bearing
33 Brake gear pump S75 Switch / oscillating axle automatic 8.10/8.40
44 Measuring point actuating pressure S263 Switch / travel direction 8.10/8.40
45 Measuring point / LS pressure Y3 Solenoid valve servo release 8.10/8.40

49 Measuring point / pilot pressure M1 Y22 Solenoid valve / grapple rotator 8.10/8.40
50 Control oil unit 7.42 Y23 Solenoid valve / grapple rotator 8.10/8.40
51 Pressure-relief valve Y24 Solenoid valve / creeper gear 8.10/8.40
52 Pressure filter Y50 Proportional solenoid valve / LS 8.10/8.40
control
53 Check valve Y62 Solenoid valve / forward travel 8.10/8.40
A 309 LI-TCD 40998- 6.40.3

MJFCIFSS
Items see Items see

group group
54 Accumulator Y63 Solenoid valve / reverse travel 8.10/8.40
57 Measuring point servo pressure Y262 Solenoid valve / switchover bucket 8.10/8.40
(MLD) swivel bearing
travelling
59 Measuring point servo pressure Y352 Proportional solenoid valve / fan 8.10/8.40
(MLR) control
Power control
64 Cylinder / uppercarriage locking Y352 Proportional solenoid valve / travel 8.10/8.40
mechanism drive
80 Pilot control unit 4x / left 7.45 Y371 Solenoid valve / oscillating axle sup- 8.10/8.40
port
81 Pilot control unit 4x / right 7.45
6.40.4 A 309 LI-TCD 40998-

MJFCIFSS
A 309 LI-TCD 40998- 6.40.5
A 311 LI-TCD 41128- LHB/en/Edition: 06/2008
MJFCIFSS
Fig. 1 Hydraulic system I type 1035 / 1036
A 309 LI-TCD 40998- 6.40.6

MJFCIFSS
Fig. 2 Hydraulic system II type 1035 / 1036
A 309 LI-TCD 40998- 6.40.7

MJFCIFSS
A 309 LI-TCD 40998- 6.40.8

MJFCIFSS
Hydraulic system
Note!
For a detailed description of the hydraulic system and its various components see group
6.30 .
Items see Items see

group group
1 to hydraulic tank 195 Rotary connection 5x 7.77
6 to oil cooler 196 Rotary connection 1x 7.75
7 Check valve 3.5 bar 7.58 200 Travel motor, left 7.29
8 Preload valve 7.0 bar 7.58 201 Travel motor, right 7.29
20 from the variable-displacement 7.10 202 Control piston / powertrain adjust- 7.29
pump ment
26 to regulating valve 203 Shifting piston/ powertrain adjust- 7.29
ment
41 Measuring point MP 204 Powertrain 7.29
50 from control oil unit 7.42 205 Brake valve 7.29
80 from pilot control unit 4x / left 7.45 206 Shuttle valve 7.29
81 from pilot control unit 4x / right 7.45 207 2-way valve / brake control pres- 7.29
sure
82 Pilot control unit 4x / travel 7.46 208 Pressure reduction valve / brake 7.29
pressure
100 Compact control block 5x 7.58 211 Secondary pressure-relief valve 7.29
chassis, reverse left
102 Pressure balance / minimum flow 212 Secondary pressure-relief valve 7.29

chassis, forward left
103 Pressure balance / remaining flow 213 Secondary pressure-relief valve 7.29
chassis, reverse right
104 Pressure cut-off valve 214 Secondary pressure-relief valve 7.29
chassis, forward right
105 Pump safety valve 215 Travel brake 11.65
107 Shuttle valve 216 Travel gear 11.60
108 LS main orifice 220 Spool / boom cylinder 7.58
120 Control axle / slewing gear 221 Secondary pressure-relief valve /
extending
122 Input pressure balance 222 Secondary pressure-relief valve /
retracting
123 Spool / slewing gear 224 Pressure balance, pilot-controlled
125 Nozzle Ø 1.8 mm 227 Restrictor check valve
126 Shuttle valve Ø 0.8 mm / 0.8 mm 233 Distribution block
127 Restrictor check valve 235 Boom cylinder 7.30
128 Restrictor check valve (Ø 1.2 mm) 238 Pipe-fracture safety system (kit)
130 Slewing gear motor, complete 7.24 240 Spool / stick cylinder 7.58
R 313 LI-TCD 39171- 6.52.1

copyright by
MJFCIFSS
Items see Items see

group group
retracting
133 Suction valve 242 Secondary pressure-relief valve /
extending
134 Pressure-relief valve with additio- 244 Pressure balance, pilot-controlled
nal pressure stage
135 Pressure-relief valve with additio- 245 Restrictor 1 x Ø 0.8 mm
nal pressure stage
137 Measuring point / turning right 247 Restrictor check valve
138 Measuring point / turning left 255 Stick cylinder 7.30
155 Slewing gear brake 257 Restrictor check valve
156 Slewing gear mechanism 260 Spool / bucket cylinder 7.58
160 Spool / chassis right 261 Secondary pressure-relief valve /
retracting
161 Suction valve / forward travel 262 Secondary pressure-relief valve /
extending
162 Suction valve / reverse travel 264 Pressure balance, pilot-controlled
164 Pressure balance, directly control- 275 Bucket cylinder 7.30
led
167 Restrictor check valve 277 Distribution block
180 Spool / chassis left 278 Lines leading to grapple
181 Suction valve / forward travel 279 Restrictor check valve
182 Suction valve / reverse travel A149 from UEC central control system 8.30/8.56
184 Pressure balance, directly control- Y451 Proportional solenoid valve / sle- 8.30/8.56
led wing gear fine control
187 Restrictor check valve
6.52.2 R 313 LI-TCD 39171-

copyright by
MJFCIFSS
Items see Items see

group group
1 Hydraulic tank 19.10 52 Pressure filter
2 Breather filter 53 Check valve
3 Stop valve 54 Accumulator
4 Return filter 59 Measuring point servo pressure
(MLR)
Power control
5 Bypass valve / return filter (pres- 80 Pilot control unit 4x / left 7.45
sure)
6 Oil cooler 81 Pilot control unit 4x / right 7.45
13 Oil motor radiator fan 82 Pilot control unit 4x / travel 7.46
14 Pressure relief valve / fan motor 88P Manifold pressure
15 Coarse filter 88T Collecting pipe return line
20 Variable-displacement pump 7.10 100 from / to control valve block 7.58
21 Powertrain 120 Slewing gear control axle 7.58
22 Control piston 195 from rotary connection 5x 7.77
23 Measuring cylinder 200 to travel motor, left 7.29
24 Angular lever 201 to travel motor, right 7.29
25 Performance regulator 402 to slewing gear brake 9.24
26 Flow regulator
27 Shuttle valve A149 UEC central control system 8.30/8.56
30 Gear pump / pilot control S17 Switch / slewing gear brake 8.30/8.56
31 Gear pump / fan drive S21 Switch / fast travel 8.30/8.56

44 Measuring point actuating pressure Y3 Solenoid valve servo release 8.30/8.56
45 Measuring point / LS pressure Y7 Solenoid valve slewing gear brake 8.30/8.56
49 Measuring point / pilot pressure Y24 Solenoid valve / fast travel 8.30/8.56
50 Control oil unit 7.42 Y50 Proportional solenoid valve / LS 8.30/8.56
control
51 Pressure-relief valve Y352 Proportional solenoid valve / fan 8.30/8.56
control
R 313 LI-TCD 39171- 6.52.3

copyright by
MJFCIFSS
6.52.4 R 313 LI-TCD 39171-

copyright by
MJFCIFSS
R 313 LI-TCD 39171- 6.52.5
MJFCIFSS
Fig. 1 Hydraulic system I type 1038
R 313 LI-TCD 39171- 6.52.6

MJFCIFSS
Fig. 2 Hydraulic system II type 1038
R 313 LI-TCD 39171- 6.52.7

MJFCIFSS
R 313 LI-TCD 39171- 6.52.8

MJFCIFSS
Service Manual Hydraulic unit with dozer blade
Hydraulic unit with dozer blade

Note!
For a detailed description of the hydraulic system and its various components see group
6.30 .

Items see Items see
group group
1 to hydraulic tank 201 Travel motor, right 7.29
6 to oil cooler 202 Control piston / powertrain adjust- 7.29
ment
7 Check valve 3.5 bar 7.58 203 Shifting piston/ powertrain adjust- 7.29
ment
8 Preload valve 7.0 bar 7.58 204 Powertrain 7.29
20 from the variable-displacement 7.10 205 Brake valve 7.29
pump
26 to regulating valve 206 Shuttle valve 7.29
41 Measuring point MP 207 2-way valve / brake control pres- 7.29
sure
50 from control oil unit 7.42 208 Pressure reduction valve / brake 7.29
pressure
80 from pilot control unit 4x / left 7.45 211 Secondary pressure-relief valve 7.29
chassis, reverse left
81 from pilot control unit 4x / right 7.45 212 Secondary pressure-relief valve 7.29
chassis, forward left
82 Pilot control unit 4x / travel 7.46 213 Secondary pressure-relief valve 7.29
chassis, reverse right
85 from pilot control unit / 2x support 7.48 214 Secondary pressure-relief valve 7.29

chassis, forward right
100 Compact control block 5x 7.58 215 Travel brake 11.65
102 Pressure balance / minimum flow 216 Travel gear 11.60
103 Pressure balance / remaining flow 220 Spool / boom cylinder 7.58
104 Pressure cut-off valve 221 Secondary pressure-relief valve /
extending
105 Pump safety valve 222 Secondary pressure-relief valve /
retracting
107 Shuttle valve 224 Pressure balance, pilot-controlled
108 LS main orifice 227 Restrictor check valve
120 Control axle / slewing gear 233 Distribution block

122 Input pressure balance 235 Boom cylinder 7.30
123 Spool / slewing gear 238 Pipe-fracture safety system (kit)
125 Nozzle Ø 1.8 mm 240 Spool / stick cylinder 7.58
126 Shuttle valve Ø 0.8 mm / 0.8 mm 241 Secondary pressure-relief valve /
retracting
R 313 LI-TCD 39171- 6.54.1

copyright by
MJFCIFSS
Hydraulic unit with dozer blade Service Manual
Items see Items see

group group
127 Restrictor check valve 242 Secondary pressure-relief valve /
extending
128 Restrictor check valve (Ø 1.2 mm) 244 Pressure balance, pilot-controlled
130 Slewing gear motor, complete 7.24 245 Restrictor 1 x Ø 0.8 mm
132 Powertrain 247 Restrictor check valve
133 Suction valve 255 Stick cylinder 7.30
134 Pressure-relief valve with additio- 257 Restrictor check valve
nal pressure stage
135 Pressure-relief valve with additio- 260 Spool / bucket cylinder 7.58
nal pressure stage
137 Measuring point / turning right 261 Secondary pressure-relief valve /
retracting
138 Measuring point / turning left 262 Secondary pressure-relief valve /
extending
155 Slewing gear brake 264 Pressure balance, pilot-controlled
156 Slewing gear mechanism 275 Bucket cylinder 7.30
160 Spool / chassis right 277 Distribution block
161 Suction valve / forward travel 278 Lines leading to grapple
162 Suction valve / reverse travel 279 Restrictor check valve
164 Pressure balance, directly control- 560 Additional control axle / dozer blade 7.58
led
extending
180 Spool / chassis left 562 Secondary pressure-relief valve /
retracting
181 Suction valve / forward travel 563 Spool / dozer blade
182 Suction valve / reverse travel 564 Pressure balance, directly controlled
184 Pressure balance, directly control- 567 Restrictor check valve

led
195 Rotary connection 7x 7.78 A149 from UEC central control system 8.30/8.56
196 Rotary connection 1x 7.75 Y451 Proportional solenoid valve / sle- 8.30/8.56
wing gear fine control
200 Travel motor, left 7.29
6.54.2 R 313 LI-TCD 39171-

copyright by
MJFCIFSS
Service Manual Hydraulic unit with dozer blade

Items see Items see
group group
1 Hydraulic tank 19.10 53 Check valve
2 Breather filter 54 Accumulator
3 Stop valve 59 Measuring point servo pressure
(MLR)
Power control
4 Return filter 80 Pilot control unit 4x / left 7.45
5 Bypass valve / return filter (pres- 81 Pilot control unit 4x / right 7.45
sure)
6 Oil cooler 82 Pilot control unit 4x / travel 7.46
13 Oil motor radiator fan 85 Pilot control unit / 2x dozer blade 7.48
14 Pressure relief valve / fan motor 88P Manifold pressure
15 Coarse filter 88T Collecting pipe return line
20 Variable-displacement pump 7.10 100 from / to control valve block 7.58
21 Powertrain 120 Slewing gear control axle 7.58
22 Control piston 195 from rotary connection 5x 7.77
23 Measuring cylinder 200 to travel motor, left 7.29
24 Angular lever 201 to travel motor, right 7.29
25 Performance regulator 402 to slewing gear brake 9.24
26 Flow regulator
27 Shuttle valve A149 UEC central control system 8.30/8.56
30 Gear pump / pilot control S17 Switch / slewing gear brake 8.30/8.56
31 Gear pump / fan drive S21 Switch / fast travel 8.30/8.56

44 Measuring point actuating pressure Y3 Solenoid valve servo release 8.30/8.56
45 Measuring point / LS pressure Y7 Solenoid valve slewing gear brake 8.30/8.56
49 Measuring point / pilot pressure Y24 Solenoid valve / fast travel 8.30/8.56
50 Control oil unit 7.42 Y50 Proportional solenoid valve / LS 8.30/8.56
control
51 Pressure-relief valve Y352 Proportional solenoid valve / fan 8.30/8.56
control
52 Pressure filter
R 313 LI-TCD 39171- 6.54.3

copyright by
MJFCIFSS
Hydraulic unit with dozer blade Service Manual
6.54.4 R 313 LI-TCD 39171-

copyright by
MJFCIFSS
R 313 LI-TCD 39171- 6.54.5
MJFCIFSS
R 313 LI-TCD 39171- 6.54.6

MJFCIFSS
R 313 LI-TCD 39171- 6.54.7

MJFCIFSS
R 313 LI-TCD 39171- 6.54.8

MJFCIFSS
Hydraulic system
Note!

Items see Items see
group group
1 to hydraulic tank 192 Brake piston
6 to oil cooler 193 Restrictor check valve
7 Check valve 3.5 bar 7.56 194 Check valve
8 Preload valve 7.0 bar 7.56 195 Shuttle valve
20 from the variable-displacement 7.10 196 Check valves
pump
23 to regulating valve 220 Spool / boom cylinder 7.56
extending
80 from pilot control unit 4x / left 7.45 222 Secondary pressure-relief valve /
retracting
81 from pilot control unit 4x / right 7.45 224 Pressure balance, pilot-controlled
85 from pilot control valve / support 7.48 227 Restrictor check valve
87 from valve / positioning brake 233 Distribution block
88P from manifold P 235 Boom cylinder 7.30
88T to collecting pipe T 238 Pipe-fracture safety system (kit)
100 Compact control block 5x 7.56 240 Spool / stick cylinder 7.56
102 Pressure balance / minimum flow 241 Secondary pressure-relief valve /
extending

103 Pressure balance / remaining flow 242 Secondary pressure-relief valve /
retracting
104 Pressure cut-off valve 244 Pressure balance, pilot-controlled
105 Pump safety valve 247 Restrictor check valve
107 Shuttle valve 255 Stick cylinder 7.30
109 LS central nozzle 260 Spool / bucket cylinder 7.56
120 Slewing gear control axle 261 Secondary pressure-relief valve /
retracting
extending

125 Restrictor Ø 1.8 mm 278 Lines leading to grapple
126 Shuttle valve Ø 0.8 mm / 0.8 mm / 279 Restrictor check valve (only SW)
0.8 mm
127 Restrictor check valve 280 Spool / support cylinder 7.56
Ø 0.8 mm
128 Restrictor check valve 281 Plug / dummy cartridge
Ø 1.2 mm
A 314 LI-TCD 30694- 6.60.1

MJFCIFSS
Items see Items see

group group
130 Slewing gear motor, complete 7.24 284 Pressure balance, directly controlled
132 Powertrain 295 Support cylinder 7.30
133 Suction valve 297 Double-load back-pressure valve
134 Pressure-relief valve with additio- 320 Rotary connection 7x 7.78
nal pressure stage
nal pressure stage
137 Measuring point / turning right 540 Additional control valve / AS1 16.42
grapple rotator
138 Measuring point / turning left 541 Secondary pressure-relief valve /
155 Slewing gear brake 9.20 542 Secondary pressure-relief valve /
156 Slewing gear mechanism 9.10 543 Spool / AS1
160 Spool / chassis 7.56 544 Pressure balance, directly controlled
161 Suction valve / reverse travel 550 Oil motor / grapple rotator
162 Suction valve / forward travel 551 Secondary pressure-relief valve /
164 Pressure balance, pilot-controlled 552 Secondary pressure-relief valve /
167 Restrictor check valve A149 from UEC central control system 8.20/8.50
170 Travel motor 7.26 S5L Push button / grapple rotator, left 8.20/8.50
172 Powertrain S5R Push button / grapple rotator, right 8.20/8.50
173 Control cylinder / regulating unit S19 Button / grapple rotator 8.20/8.50
174 Spool / regulating unit Y22 Solenoid valve / grapple rotation left 8.20/8.50
175 Check valves Y23 Solenoid valve / grapple rotation right 8.20/8.50
176 Secondary relief valve / forward Y24 from solenoid valve / creeper gear 8.20/8.50
177 Secondary relief valve / reverse Y62 from solenoid valve / forward travel 8.20/8.50
185 Transmission 11.20 Y63 from solenoid valve / reverse travel 8.20/8.50
190 Travel brake valve, complete 7.26 Y451 Proportional solenoid valve / slewing 8.20/8.50
gear control
6.60.2 A 314 LI-TCD 30694-

MJFCIFSS

Items see Items see
group group
1 Hydraulic tank 19.10 59 Measuring point servo pressure
(MLR)
Power control
2 Breather filter 64 Cylinder / uppercarriage locking
mechanism
3 Stop valve 80 Pilot control unit 4x / left 7.45
4 Return filter 81 Pilot control unit 4x / right 7.45
5 Bypass valve / return filter 85 Pilot control unit 2x / support 7.48
6 Oil cooler 87 Valve / positioning brake
13 Oil motor radiator fan 88P Manifold pressure
14 Pressure-relief valve / fan motor 88T Collecting pipe return line
15 Coarse filter 100 from / to control valve block 7.56
20 Variable-displacement pump 7.10 155 to slewing gear brake 9.20
21 Powertrain 170 Travel motor
22 Control piston 322 to rotary connection 6x 7.76
23 Measuring cylinder 400 to brake system 15.10
24 Angular lever 401 to steering system 13.10
25 Performance regulator 402 to oscillating axle support 14.10
26 Flow regulator 403 to gear shifting 11.32

32 Gear pump / steering S75 Switch / oscillating axle automatic 8.20/8.50
33 Brake gear pump S263 Switch / travel direction 8.20/8.50
44 Measuring point actuating pres- Y3 Solenoid valve servo release 8.20/8.50
sure
45 Measuring point / LS pressure Y24 Solenoid valve / creeper gear 8.20/8.50
49 Measuring point / pilot pressure Y50 Proportional solenoid valve / LS con- 8.20/8.50
M1 trol
50 Control oil unit 7.42 Y62 Solenoid valve / forward travel 8.20/8.50
51 Pressure-relief valve Y63 Solenoid valve / reverse travel 8.20/8.50

52 Pressure filter Y352 Proportional solenoid valve / fan con- 8.20/8.50
trol
53 Check valve Y352 Proportional solenoid valve / travel 8.20/8.50
drive
54 Accumulator Y371 Solenoid valve / oscillating axle sup- 8.20/8.50
port
A 314 LI-TCD 30694- 6.60.3

MJFCIFSS
Items see Items see

group group
57 Measuring point servo pressure
(MLD)
travelling
6.60.4 A 314 LI-TCD 30694-

MJFCIFSS
A 314 LI-TCD 30694- 6.60.5
MJFCIFSS
Fig. 1 Hydraulic system I type 1039 / 1040
A 314 LI-TCD 30694- 6.60.6

MJFCIFSS
Fig. 2 Hydraulic system II type 1039 / 1040
A 314 LI-TCD 30694- 6.60.7

MJFCIFSS
A 314 LI-TCD 30694- 6.60.8

MJFCIFSS
Hydraulic system
Note!

Items see Items see
group group
1 to hydraulic tank 193 Restrictor check valve
6 to oil cooler 194 Check valve
7 Check valve 3.5 bar 7.56 195 Shuttle valve
8 Preload valve 7.0 bar 7.56 196 Check valves
20 from the variable-displacement 7.10 220 Spool / boom cylinder 7.56
pump
23 to regulating valve 221 Secondary pressure-relief valve /
extending
retracting
80 from pilot control unit 4x / left 7.45 224 Pressure balance, pilot-controlled
81 from pilot control unit 4x / right 7.45 227 Restrictor check valve
85 from pilot control valve / support 7.48 233 Distribution block
87 from valve / positioning brake 235 Boom cylinder 7.30
88P from manifold P 238 Pipe-fracture safety system (kit)
88T to collecting pipe T 240 Spool / stick cylinder 7.56
100 Compact control block 5x 7.56 241 Secondary pressure-relief valve /
extending
102 Pressure balance / minimum flow 242 Secondary pressure-relief valve /

retracting
103 Pressure balance / remaining flow 244 Pressure balance, pilot-controlled
104 Pressure cut-off valve 247 Restrictor check valve
105 Pump safety valve 253 Distribution block
107 Shuttle valve 255 Stick cylinder 7.30
109 LS central nozzle 260 Spool / bucket cylinder 7.56
120 Slewing gear control axle 261 Secondary pressure-relief valve /
retracting
extending

125 Restrictor Ø 1.8 mm 278 Grapple cylinder 7.30
126 Shuttle valve Ø 0.8 mm / 0.8 mm / 278 Grapple cylinder (industrial equip- 7.30
0.8 mm ment)
127 Restrictor check valve (Ø 0.8 279 Restrictor check valve (only SW)
mm)
128 Restrictor check valve (Ø 1.2 280 Spool / support cylinder 7.56
mm)
A 316 LI-IND-TCD 29503- 6.62.1

copyright by
MJFCIFSS
Items see Items see

group group
130 Slewing gear motor, complete 7.24 281 Plug / dummy cartridge
132 Powertrain 284 Pressure balance, directly controlled
133 Suction valve 295 Support cylinder 7.30
134 Pressure-relief valve with additio- 297 Double-load back-pressure valve
nal pressure stage
nal pressure stage
137 Measuring point / turning right 322 Rotary connection 6x 7.76
138 Measuring point / turning left 540 Additional control valve / AS1 16.42
grapple rotator
155 Slewing gear brake 9.20 541 Secondary pressure-relief valve /
156 Slewing gear mechanism 9.10 542 Secondary pressure-relief valve /
160 Spool / chassis 7.56 543 Spool / AS1
161 Suction valve / reverse travel 544 Pressure balance, directly controlled
162 Suction valve / forward travel 550 Oil motor / grapple rotator
164 Pressure balance, pilot-controlled 551 Secondary pressure-relief valve /
170 Travel motor 7.26 A149 from UEC central control system 8.20/8.50
172 Powertrain S5L Push button / grapple rotator, left 8.20/8.50
173 Control cylinder / regulating unit S5R Push button / grapple rotator, right 8.20/8.50
174 Spool / regulating unit S19 Button / grapple rotator 8.20/8.50
175 Check valves Y22 Solenoid valve / grapple rotation left 8.20/8.50
176 Secondary relief valve / forward Y23 Solenoid valve / grapple rotation right 8.20/8.50
177 Secondary relief valve / reverse Y24 from solenoid valve / creeper gear 8.20/8.50
185 Transmission 11.20 Y62 from solenoid valve / forward travel 8.20/8.50
190 Travel brake valve, complete 7.26 Y63 from solenoid valve / reverse travel 8.20/8.50
192 Brake piston Y451 Proportional solenoid valve / slewing 8.20/8.50
gear control
6.62.2 A 316 LI-IND-TCD 29503-

copyright by
MJFCIFSS

Items see Items see
group group
1 Hydraulic tank 19.10 59 Measuring point servo pressure
(MLR)
Power control
2 Breather filter 64 Cylinder / uppercarriage locking
mechanism
3 Stop valve 80 Pilot control unit 4x / left 7.45
4 Return filter 81 Pilot control unit 4x / right 7.45
5 Bypass valve / return filter 85 Pilot control unit 2x / support 7.48
6 Oil cooler 87 Valve / positioning brake
13 Oil motor radiator fan 88P Manifold pressure
14 Pressure-relief valve / fan motor 88T Collecting pipe return line
15 Coarse filter 100 from / to control valve block 7.56
20 Variable-displacement pump 7.10 155 to slewing gear brake 9.20
21 Powertrain 170 Travel motor
22 Control piston 322 to rotary connection 6x 7.76
23 Measuring cylinder 400 to brake system 15.10
24 Angular lever 401 to steering system 13.10
25 Performance regulator 402 to oscillating axle support 14.10
26 Flow regulator 403 to gear shifting 11.32

32 Gear pump / steering S75 Switch / oscillating axle automatic 8.20/8.50
33 Brake gear pump S263 Switch / travel direction 8.20/8.50
44 Measuring point actuating pres- Y3 Solenoid valve servo release 8.20/8.50
sure
45 Measuring point / LS pressure Y24 Solenoid valve / creeper gear 8.20/8.50
49 Measuring point / pilot pressure Y50 Proportional solenoid valve / LS con- 8.20/8.50
M1 trol
50 Control oil unit 7.42 Y62 Solenoid valve / forward travel 8.20/8.50
51 Pressure-relief valve Y63 Solenoid valve / reverse travel 8.20/8.50
52 Pressure filter Y352 Proportional solenoid valve / fan con- 8.20/8.50
trol
53 Check valve Y352 Proportional solenoid valve / travel 8.20/8.50

drive
54 Accumulator Y371 Solenoid valve / oscillating axle sup- 8.20/8.50
port
57 Measuring point servo pressure
(MLD)
travelling
A 316 LI-IND-TCD 29503- 6.62.3

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MJFCIFSS
6.62.4 A 316 LI-IND-TCD 29503-

copyright by
MJFCIFSS
A 316 LI-IND-TCD 29503- 6.62.5
MJFCIFSS
A 316 LI-IND-TCD 29503- 6.62.6

MJFCIFSS
A 316 LI-IND-TCD 29503- 6.62.7

MJFCIFSS
A 316 LI-IND-TCD 29503- 6.62.8

MJFCIFSS
Service Handbuch Hydraulic system
Hydraulic system
Notice!
The design of the hydraulic system and the individual main components is described in group 6.30.
Legend to schematic I
Items refer to group

1 to hydraulic tank
6 to oil cooler
7 Check valve 3.5 bar 7.60
8 Pretension valve 7.0 bar 7.60
20 from variable displacement pump 7.10
26 to regulating valve
41 Test point MP
50 from Control oil unit
80 from 4-way pilot valve left 7.45
81 from 4-way pilot valve right 7.45
82 from 4-way pilot valve travel 7.46
100 5-way compact control valve block 7.60
102 Pressure balance minimum flow
103 Pressure balance remaining flow
104 Pressure cut-off
105 Pump safety valve
106 Shift valve Qmax. variable displacement motor
107 Shuttle-valve

108 LS-main orifice
109 LS - central orifice
120 Control axle / swing
122 Input flow regulator
123 Spool / swing
125 Shuttle-valve Ø 0.8 mm, Ø 0.8 mm, Ø 0.8 mm
126 Check valve
127 Restrictor check valve Ø 1.2
130 Swing motor assembly 7.24
132 Rotary group

133 Suction valve
134 Pressure relief valve with pressure increase
135 Pressure relief valve with pressure increase
137 Test point swing right
138 Test point swing left
155 Swing brake 9.20
R 317 LI-TCD 30019- 6.70.1

copyright by
MJFCIFSS
Hydraulic system Service Handbuch

156 Swing gear 9.10
160 Spool travel right 7.60
161 Suction valve travel reverse
162 Suction valve travel foreward
164 Pressure balance directly operated
180 Spool travel left 7.60
181 Suction valve travel reverse
182 Suction valve travel foreward
184 Pressure balance directly operated
195 5-way rotary connection 7.77
196 1-way rotary connection 7.75
200 Travel motor left 7.28
201 Travel motor right 7.28
202 Control piston 7.28
203 Shift valve - control rotary group 7.28
204 Rotary group 7.28
205 Brake valve 7.28
206 Shuttle valve 7.28
207 2- way shift valve brake pressure 7.28
208 Pressure reducing valve brake pressure 7.28
211 Secondary relief valve travel left foreward 7.28
212 Secondary relief valve travel left reverse 7.28
213 Secondary relief valve travel right foreward 7.28
214 Secondary relief valve travel right reverse 7.28

215 Travel brake 11.65
216 Travel gear 11.60
220 Spool / boom cylinder 7.60
221 Secondary relief valve extend
222 Secondary relief valve retract
224 Pressure balance pilot operated
225 Restrictor 2x Ø 0,8 mm
233 Distributor block
235 Boom cylinders 7.30

238 Pipe fracture safety valve (option)
240 Spool / stick cylinder 7.60
244 Pressure balance, pilot operated
245 Restrictor 2x Ø 0,8 mm
6.70.2 R 317 LI-TCD 30019-

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MJFCIFSS
Service Handbuch Hydraulic system

255 Stick cylinder 7.30
260 Spool / bucket cylinder 7.60
264 Pressure balance pilot operated
275 Bucket cylinder 7.30
277 Shut-off device for grapple operation
278 Lines to the grapple
278 Grapple cylinders (on industrial machines) 7.30
279 Restrictor check valve (only in connection with quick change adap-
ter)
A149 from central control unit UEC 8.30/8.60
Y451 Proportional solenoid valve swing control 8.30/8.60

R 317 LI-TCD 30019- 6.70.3

copyright by
MJFCIFSS
Hydraulic system Service Handbuch
Legend to schematic II
Items refer to Items refer to

group group
1 Hydraulic tank 19.10 52 Pressure filter
2 Breather filter 53 Check valve
3 Shut-off valve 54 Pressure accumulator
4 Return filter 59 Test point Servo pressure (MLR)
performance regulation
5 Bypass valve / return filter (pres- 80 4-way pilot control valve left 7.45
sure)
6 Oil cooler 81 4-way pilot control valve right 7.45
13 Oil motor cooling fan 82 4-way pilot control valve travel 7.46
14 Pressure relief valve fan motor 88P Distributor pressure
15 Strainer 88T Collector return oil
20 Variable displacement pump 7.10 100 from / to control valve block 7.60
21 Rotary group 120 to spool for swing circuit 7.60
22 Adjusting piston 130 to swing motor
23 Measuring piston 155 to swing brake 9.20
24 Angle lever 195 to 5-way rotary connection 7.77
25 Performance regulator
26 Flow regulator A149 Central control unit UEC 8.30/8.60
27 Shuttle valve B335 Pressure switch servo pressure- 8.30/8.60
swing
28 Check valve S7 safety switch 8.30/8.60
29 Orifice S17 Switch swing brake 8.30/8.60
30 Gear pump / servo control S21 Switch / speeder gear 8.30/8.60
31 Gear pump / fan drive Y3 Solenoid valve servo release 8.30/8.60
44 Test point control pressure Y7 Solenoid valve swing brake 8.30/8.60

45 Test point / LS-pressure Y24 Solenoid valve / speeder gear 8.30/8.60
49 Test point control pressure M1 Y50 Prop.-solenoid valve LR-regulation 8.30/8.60
50 Control oil unit 7.42 Y352 Prop.-solenoid valve fan control 8.30/8.60
51 Pressure relief valve
6.70.4 R 317 LI-TCD 30019-

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MJFCIFSS
R 317 LI-TCD 30019- 6.70.5
MJFCIFSS
Fig. 1 Hydraulic system I Type 1042
R 317 LI-TCD 30019- 6.70.6

MJFCIFSS
Fig. 2 Hydraulic system // Type 1042
R 317 LI-TCD 30019- 6.70.7

MJFCIFSS
R 317 LI-TCD 30019- 6.70.8

MJFCIFSS
Hydraulic system
Note!
For a detailed description of the hydraulic system and its various components see group 6.30.
Index to wiring diagram I
Items see
group
1 to hydraulic tank
6 to oil cooler
7 Check valve 3.5 bar 7.60
8 Preload valve 7.0 bar 7.60
20 from the variable-displacement pump 7.10
26 to regulating valve
41 Measuring point MP
50 from control oil unit 7.42
80 from pilot control unit 4x / left 7.45
81 from pilot control unit 4x / right 7.45
82 Pilot control unit 4x / travel 7.46
85 from pilot control unit 2x / left 7.47
100 Compact control block 5x 7.60
102 Pressure balance / minimum flow
103 Pressure balance / remaining flow
105 Pump safety valve

106 Shift valve / Qmax Regulating motor
107 Shuttle valve
108 LS main orifice
109 LS central nozzle
120 Control axle / slewing gear
122 Input pressure balance
123 Spool / slewing gear
125 Shuttle valve Ø 0.8 mm, Ø 0.8 mm, Ø 0.8 mm
126 Check valve
127 Restrictor check valve (Ø 1.2 mm)
130 Slewing gear motor, complete 7.24

132 Powertrain
133 Suction valve
134 Pressure-relief valve with additional pressure stage
135 Pressure-relief valve with additional pressure stage
137 Measuring point / turn right
138 Measuring point / turn left
R 317 LI-TCD 30019- 6.72.1

copyright by
MJFCIFSS
Items see
group
155 Slewing gear brake 9.24
156 Slewing gear mechanism 9.10
160 Spool / chassis right 7.60
161 Suction valve / reverse travel
162 Suction valve / forward travel
164 Pressure balance, directly controlled
180 Spool / chassis left 7.60
181 Suction valve / reverse travel
182 Suction valve / forward travel
195 Rotary connection 7x 7.78
196 Rotary connection 1x 7.75
200 Travel motor, left 7.28
201 Travel motor, right 7.28
202 Adjusting device 7.28
203 Shifting piston/ powertrain adjustment 7.28
204 Powertrain 7.28
205 Brake valve 7.28
206 Shuttle valve 7.28
207 2-way valve / brake control pressure 7.28
208 Pressure reduction valve / brake pressure 7.28
211 Secondary pressure-relief valve chassis, forward left 7.28
212 Secondary pressure-relief valve chassis, reverse left 7.28
213 Secondary pressure-relief valve chassis, forward right 7.28

214 Secondary pressure-relief valve chassis, reverse right 7.28
215 Travel brake 11.65
216 Travel gear 11.60
220 Spool / boom cylinder 7.60
221 Secondary pressure-relief valve / extending
222 Secondary pressure-relief valve / retracting
225 Restrictor 2 x Ø 0.8 mm
233 Distribution block

235 Boom cylinder 7.30
238 Pipe-fracture safety system (kit)
240 Spool / stick cylinder 7.60
6.72.2 R 317 LI-TCD 30019-

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MJFCIFSS
Items see
group
245 Restrictor 2x Ø 0.8 mm
255 Stick cylinder 7.30
260 Spool / bucket cylinder 7.60
275 Bucket cylinder 7.30
277 Shut-off device for grapple operation
278 Lines leading to grapple
278 Grapple cylinder (industrial equipment) 7.30
560 Additional control axle / dozer blade 7.60
563 Spool / dozer blade
575 Dozer blade cylinder 7.30
577 Double lowering brake valve 7.85
A149 from UEC central control system 8.30/8.60
Y451 Proportional solenoid valve / slewing gear fine control 8.30/8.60

R 317 LI-TCD 30019- 6.72.3

copyright by
MJFCIFSS

Items see Items see
group group
1 Hydraulic tank 19.10 51 Pressure-relief valve
2 Breather filter 52 Pressure filter
3 Stop cock 53 Check valve
4 Return filter 54 Accumulator
5 Bypass valve / return filter (pres- 59 Measuring point servo pressure
sure) (MLR)
Power control
6 Oil cooler 80 Pilot control unit 4x / left 7.45
13 Oil motor radiator fan 81 Pilot control unit 4x / right 7.45
14 Pressure relief valve / fan motor 82 Pilot control unit 4x / travel 7.46
15 Coarse filter 85 Pilot control unit 4x / dozer blade 7.48
20 Variable-displacement pump 7.10 88P Manifold pressure
21 Powertrain 88T Collecting pipe return line
22 Control piston 100 from / to control valve block 7.60
23 Measuring cylinder 120 Slewing gear control axle 7.60
24 Angular lever 195 from rotary connection 5x 7.77
25 Performance regulator
26 Flow regulator A149 UEC central control system 8.30/8.60
27 Shuttle valve B335 Pressure switch pst slewing gear 8.30/8.60
28 Check valve S7 Safety switch 8.30/8.60
29 Restrictor S17 Switch / slewing gear brake 8.30/8.60
30 Gear pump / pilot control S21 Switch / fast travel 8.30/8.60
31 Gear pump / fan drive Y3 Solenoid valve servo release 8.30/8.60
44 Measuring point actuating pressure Y7 Solenoid valve slewing gear brake 8.30/8.60
45 Measuring point / LS pressure Y24 Solenoid valve / fast travel 8.30/8.60

49 Measuring point / pilot pressure M1 Y50 Proportional solenoid valve / LS 8.30/8.60
control
50 Control oil unit 7.42 Y352 Proportional solenoid valve / fan 8.30/8.60
control
6.72.4 R 317 LI-TCD 30019-

copyright by
MJFCIFSS
R 317 LI-TCD 30019- 6.72.5
MJFCIFSS
R 317 LI-TCD 30019- 6.72.6

MJFCIFSS
R 317 LI-TCD 30019- 6.72.7

MJFCIFSS
R 317 LI-TCD 30019- 6.72.8

MJFCIFSS
Service Manual
SUBGROUP - INDEX
Section Group Type
Variable displacement pump DPVO 7.10.1 A 309 LI-TCD 40998-

A 311 LI-TCD 41128-
A 314 LI-TCD 30694-
A 316 LI-IND-TCD 29503-
A 316 LI-TCD 29120-
R 313 LI-TCD 39171-
R 317 LI-TCD 30019-
Cooling unit 7.20.1 A 309 LI-TCD 40998-

A 311 LI-TCD 41128-
A 314 LI-TCD 30694-
A 316 LI-IND-TCD 29503-
A 316 LI-TCD 29120-
R 313 LI-TCD 39171-
R 317 LI-TCD 30019-
FMF hydraulic fixed displacement motor 7.24.1 A 309 LI-TCD 40998-

A 311 LI-TCD 41128-
A 314 LI-TCD 30694-
A 316 LI-IND-TCD 29503-
A 316 LI-TCD 29120-
R 313 LI-TCD 39171-
R 317 LI-TCD 30019-

DMVA regulating motor 7.26.1 A 309 LI-TCD 40998-
A 311 LI-TCD 41128-
A 314 LI-TCD 30694-
A 316 LI-IND-TCD 29503-
A 316 LI-TCD 29120-
Regulating motor A6VE 7.28.1 R 317 LI-TCD 30019-
Regulating motor A6VE 7.29.1 R 313 LI-TCD 39171-
Hydraulic cylinder 7.30.1 A 309 LI-TCD 40998-

A 311 LI-TCD 41128-

A 314 LI-TCD 30694-
A 316 LI-IND-TCD 29503-
A 316 LI-TCD 29120-
R 313 LI-TCD 39171-
R 317 LI-TCD 30019-
7.1
MJFCIFSS
Service Manual
Hydraulic double plunger cylinder 7.32.1 A 309 LI-TCD 40998-

A 311 LI-TCD 41128-
A 314 LI-TCD 30694-
A 316 LI-IND-TCD 29503-
A 316 LI-TCD 29120-
R 313 LI-TCD 39171-
R 317 LI-TCD 30019-
Control oil unit 7.42.1 A 309 LI-TCD 40998-

A 311 LI-TCD 41128-
A 314 LI-TCD 30694-
A 316 LI-IND-TCD 29503-
A 316 LI-TCD 29120-
R 313 LI-TCD 39171-
R 317 LI-TCD 30019-
Pilot control unit 4 x 7.45.1 A 309 LI-TCD 40998-

A 311 LI-TCD 41128-
A 314 LI-TCD 30694-
A 316 LI-IND-TCD 29503-
A 316 LI-TCD 29120-
R 313 LI-TCD 39171-
R 317 LI-TCD 30019-
4x pilot control unit for travel drive 7.46.1 R 313 LI-TCD 39171-
R 317 LI-TCD 30019-
Pilot control unit 2x 7.47.1 A 309 LI-TCD 40998-

A 311 LI-TCD 41128-
A 314 LI-TCD 30694-
A 316 LI-IND-TCD 29503-
A 316 LI-TCD 29120-

R 313 LI-TCD 39171-
R 317 LI-TCD 30019-
Pilot control valve 2 x 7.48.1 A 309 LI-TCD 40998-

A 311 LI-TCD 41128-
A 314 LI-TCD 30694-
A 316 LI-IND-TCD 29503-
A 316 LI-TCD 29120-
R 313 LI-TCD 39171-
R 317 LI-TCD 30019-
LSC control valve block 7.56.1 A 309 LI-TCD 40998-

A 311 LI-TCD 41128-
A 314 LI-TCD 30694-
A 316 LI-IND-TCD 29503-
A 316 LI-TCD 29120-
LSC control valve block 7.60.1 R 317 LI-TCD 30019-
7.2
MJFCIFSS
Service Manual
SUBGROUP - INDEX
Section Group Type
Rotary connection 1x 7.75.1 R 313 LI-TCD 39171-

R 317 LI-TCD 30019-
Rotary connection 6x 7.76.1 A 309 LI-TCD 40998-

A 311 LI-TCD 41128-
A 314 LI-TCD 30694-
A 316 LI-IND-TCD 29503-
A 316 LI-TCD 29120-
Rotary connection 5x 7.77.1 R 313 LI-TCD 39171-

R 317 LI-TCD 30019-
Rotary connection 7x 7.78.1 A 309 LI-TCD 40998-

A 311 LI-TCD 41128-
A 314 LI-TCD 30694-
A 316 LI-IND-TCD 29503-
A 316 LI-TCD 29120-
Double load-holding valve / 7.82.1 A 314 LI-TCD 30694-

double lowering brake valve A 316 LI-IND-TCD 29503-
R 313 LI-TCD 39171-
R 317 LI-TCD 30019-
Double load-holding valve for 7.86.1 A 309 LI-TCD 40998-

regulating cylinder A 311 LI-TCD 41128-

7.3
MJFCIFSS
7.4
MJFCIFSS
Service Manual
Service Manual Variable displacement pump DPVO
System description
Variable displacement pump DPVO
1 System description
The variable displacement pump DPVO is an axial piston swash plate pump. Powertrain of the rotary
group, integrated pilot-control gear pump and the attached gear pump for fan control is given through
a flexible coupling (torsion damper) by the diesel engine.
The variable displacement pump regulates its flow depending upon demand (load sensing principle)
and supplies the various users (boom/bucket/stick/travel/outrigger/swing circuit and grapple rotator)
with the necessary oil quantity.
The variable displacement pump consists of several main components:
– Rotary group 21
– Pump housing 40
– Connecting plate 46
– Connecting flange 47
– Regulator housing 49
The variable displacement pump DPVO is connected to the diesel engine over connecting flange 47.
The rotary group is made up out of drive shaft, cylinder and pistons and is variable over the swivel
joke.
The regulator housing 49 is mounted onto the pump housing 40. The performance regulator 25 for
regulation and adjustment of the pump performance is screwed into the regulator housing 49 and re-
ceives feedback about the current swivel angle over a pin.
The flow regulator 26 for regulation of the flow rate and adjustment of the differential pressure Up is
also screwed into the regulator housing 49.
The gear pump 30 (pilot control) is integrated into the connecting plate 46 and the gear pump 31 (fan
control) is flanged onto the connecting plate 46. Both pumps are also driven over the driveshaft.

7.10.1
copyright by
MJFCIFSS
Variable displacement pump DPVO Service Manual
System description
Fig. 1 Components of the DPVO
25 Performance regulator (LR) 48 Qmin-stop screw

26 Flow regulator (LS) 49 Regulator housing
27 Change over valve
28 Check valve A1 Pressure connection
29 Restrictor AX Pressure port, closed
30 Gear pump / pilot control FE Pressure connection of the control oil

pump
31 Gear pump / fan control S Suction connection
40 Pump housing T Leak oil connection
44 Test point pSK (control pressure) X2 Connection LS-pressure
46 Connecting plate X3 Connection to control oil unit LR
47 Connecting flange X4 Connection U-p -reduction
7.10.2
copyright by
MJFCIFSS
Technical data
2 Technical data
A 309 Li TCD
Machine 40998 A 312 Li TCD R 313 Li TCD
starting serial number A 311 Li TCD 36220 39171
41128
Pump-type DPVO 108 DPVO 165 DPVO 165
-1 -1
Input speed 1800 min 1800 min 1800 min-1
Power input of the diesel engine 65 KW 81 KW 76 KW
(rated performance) = Pmax 68 KW
Flow quantity
max. 194 l/min 297 l/min 297 l/min
min. 40 l/min 40 l/min 40 l/min
Hydraulic performance (basic performance) 29 KW 29 KW 29 KW
Begin of regulation (at basic performance) 50 ± 2 bar 50 ± 2 bar 50 ± 2 bar

Control oil pump / pilot control 43 l/min 36 l/min 36 l/min
Control oil pump / fan control 45 l/min 45 l/min 45 l/min
Check measurement X (Q min. stop) 15,6 mm 15,6 mm 15,6 mm
Adjustment- and comparative values:

Current on so- Current on so- Current on so-
lenoid Y50 lenoid Y50 lenoid Y50
P min. 180 +10 mA 180 +10 mA 180 +10 mA
P max. 600 +30 mA 600 +30 mA 600 +30 mA

Control pres- Control pres- Control pressu-

sure of sole- sure of sole- re of solenoid
noid valve Y50 noid valve Y50 valve Y50
P min. 1,5 +1 bar 1,5 +1 bar 1,5 +1 bar
P max. 8 ±1 bar 8 ±1 bar 8 ±1 bar
Tab. 1 Technical data

Machine A 314 Li TCD A 316 Li TCD R 317 Li TCD

starting serial number 30694 29120 30019
Pump-type DPVO 165 DPVO 165 DPVO 165
7.10.3
copyright by
MJFCIFSS
Technical data
Machine A 314 Li TCD A 316 Li TCD R 317 Li TCD

starting serial number 30694 29120 30019
Input speed 1800 min-1 1800 min-1 1800 min-1
Power input of the diesel engine 90 KW 94 KW 90 KW
(rated performance) = Pmax
Flow quantity
max. 297 l/min 297 l/min 297 l/min
min. 40 l/min 40 l/min 40 l/min
Hydraulic performance (basic performance) 29 KW 29 KW 29 KW
Begin of regulation (at basic performance) 50 ± 2 bar 50 ± 2 bar 50 ± 2 bar

Control oil pump / pilot control 36 l/min 36 l/min 36 l/min
Control oil pump / fan control 45 l/min 45 l/min 45 l/min
Check measurement X (Q min. stop) 15,6 mm 15,6 mm 15,6 mm

Current on so- Current on so- Current on so-
lenoid Y50 lenoid Y50 lenoid Y50
P min. 180 +10 mA 180 +10 mA 180 +10 mA
P max. 600 +30 mA 600 +30 mA 600 +30 mA

Control pres- Control pres- Control pressu-
sure of sole- sure of sole- re of solenoid
noid valve Y50 noid valve Y50 valve Y50
P min. 1,5 +1 bar 1,5 +1 bar 1,5 +1 bar
P max. 8 ±1 bar 8 ±1 bar 8 ±1 bar

7.10.4
copyright by
MJFCIFSS
Technical data
Fig. 2 Hydraulic schematic DPVO
1 to hydraulic tank 25 Performance regulator

3 from stopcock / tank 26 Flow regulator
4 Pressue spring / Up 27 Changeover valve

10 Pressure spring/begin of regulation 28 Check valve
13 to oil motor fan drive 29 Restictor
15 Connecting pin (swivel yoke) 30 Gear pump / pilot control
16 Return piston 31 Gear pump / fan control
20 Pump unit DPVO 44 Test point / control pressure
21 Rotary group 45 Test point / LS-pressure
22 Regulating piston 50 from/to control oil unit
23 Measuring piston 100 to control valve block
24 Lever (rocker)
7.10.5
copyright by
MJFCIFSS
Functional description variabel displacement pump
3 Functional description variabel displacement pump
3.1 Rotary group 21, see Fig. 10

Via cylindrical roller bearing 8 and sliding bearing 10 drive shaft 5 is mounted in connecting plate 46
and connecting flange 47. The shaft drives cylinder 16 and the nine pistons with slipper 19 via the
gearing. With the toothed hub on the drive shaft the flanged on gear pump 30 / 31 is also driven.
Pistons 19 with slippers are held on the swivel yoke 7 and gliding plate 31 with retaining plate 34 and
retaining ball 33.
Through bores in pistons 19 hydrostatic bearing reduces high surface pressure between the rotating
slippers and the gliding plate 31.
In a pressureless condition cylinder 16 and retaining ball 33 are pressed against the control plate 17
by pressure springs 35 / 36. With increasing pressure hydraulic forces support the spring tension,
maintaining sufficient oil film for lubrication and keeping leak oil low.
The leak oil will grease all the moving parts of the powertrain, and is then lead to the tank externally.
With every rotation of cylinder 16 each piston 19 carries out a double stroke (piston stroke). The stro-
ke length is determined by the angle of the swivel yoke 7. The swivel yoke is mounted with roller be-
arings 14 and therefor tiltable. The rotation movement of swivel yoke 7 is done via the connection of
the regulating piston 22 with connecting link 37 with every movement of the regulating piston.
The flow rate per pump and time unit is determined by the stroke volume (piston diameter x stroke)
and the speed of drive shaft 5.
Seperation of suction and pressure side of the rotary group is done with control plate 17. Pilot plate
17 has a kidney-shaped opening on the suction side, and three smaller kidney-shaped openings on
the pressure side.
Fig. 3 Section of rotary group
16 Cylinder 33 Retaining ball

17 Control plate 34 Retaining plate
7.10.6
copyright by
MJFCIFSS
Functional description variabel displacement pump
18 Pin 35 Pressure spring

19 Piston 36 Pressure spring
3.1.1 Adjusting the pivot angle on the pump, see Fig. 10

Connecting link 37 provides a mechanical connection between swivel yoke 7 and control piston 22.
The connecting link engages into the opening on control piston 22 and is secured by means of pin 12
and roll pin 11. The axial motion of control piston 22 and thus the rotary motion (the change of the
angle of swivel yoke 7) is determined over the performance regulator and/or flow regulator.
The LS signal generated by the user moves the flow regulator into the actuating position so that pump
pressure can reach the control chamber, the pump pivots. The pump will pivot back as soon as the
control chamber is connected to the tank by the flow regulator (no LS signal) or by the performance
regulator (output too high).
If the pump is in standby-operation, f.e when all joydticks are in neutral position, it delivers minimum
flow (refer to Tab.1 on page 3)
3.1.2 Maximum and minimum swivel angle of the pump

The max. pivot angle of the powertrain of the pump is determined by the dead stop (collar 39) of con-
trol piston 22 in the control cylinder. The stop cannot be adjusted.
The minimum pivot angle of the rotary goup is determined by stop screw 48 (with locknut 38). It is
pre-set by the factory. It is not permitted to tamper with minimum swivel angle under normal circum-
stances.
Fig. 4 Swivel angle adjustment

7 Swivel yoke 37 Connecting link

11 Roll pin 38 Lock nut
12 Pin 39 Sleeve
22 Regulating piston 48 Q-min angle stop screw
7.10.7
copyright by
MJFCIFSS
Pump regulation
4 Pump regulation
4.1 Performance regulator 25 (LR) hyperbolic regulator

The purpose of the performance regulator is to adapt the flow rate of the pump in relationship to the
pump pressure (performance) to the performance curve of the diesel engine. Therefor pump perfor-
mance is regulated according to a hyperbolic curve. The pump delivers larger volumes at low pres-
sure and smaller volumes at high pressures. The basic setting of regulating spring 90 / 91
corresponds to the mechanical begin of basic regulation. It can be switched up to horsepower cont-
rolled regulation via control pressure pMLR on connection X3.
Pressure springs 90 / 91 press control piston 97 to the right against lever 24. This will open control
edge S1, and the control chamber (SK) of regulating piston 22 will receive pump pressure pP. The
pump will pivot to Qmax. The return piston 16 has a mechanical connection with the swivel yoke over
connecting pin 15.
4.1.1 Begin of pump regulation

As soon as operating pressure pP in the system rises to the value of begin of regulation, the force
exercised on measuring piston 23 to lever 24 goes up as well. Control piston 97 is moved against
pressure spring 90 and opens the connection between control chamber (SK) and tank (T) with the
help of control edge S2. The pump pivots back. The pump pivoting back effects an axial movement
of return piston 96 against pressure spring 83 over connecting pin 95 in the swivel yoke bearing pin,
moving the line of force of measuring piston 98 onto lever 99 towards the center of rotation. The force
of lever 94 onto control piston 97 will become smaller, allowing pressure spring 90 to move control
piston 97 back into neutral position. The connection control chamber (SK) to tank (T) will be interrup-
ted. The pump will remain at a constant flow corresponding to the existing pressure pP which equals
a constant performance.
4.1.2 Deflection of the pump (at pressure below begin of regulation)

If the working pressure pP drops within the system, the force on piston 98 onto lever 99 will be redu-
ced. The spring 90 moves control piston 97 against lever 99. The connection from pump pressure (P)
to the control chamber (SK) will be opened via control edge S1. The pump will deflect toward greater
swivel angle. Due to this deflection the return piston 96 is moved toward screw plug 81. Measuring
piston 23 is moved away fom the center of rotation of lever 99. The resulting force of lever 99 onto
psiton 97 increases, which means a balance is produced and the control piston 97 will move into a
closing position (S1 and S2 closed).
Fig. 5 Control edges S1 and S2
90 Pressure spring pP Pump pressure

91 Pressure spring SK Control chamber pressure
97 Control piston T Tank pressure
7.10.8
copyright by
MJFCIFSS
Pump regulation
Fig. 6 Cutaway drawing performance regulator 25
26 Flow regulator assembly 91 Pressure spring

49 Regulator housing 92 Bushing
81 Screw plug 93 Spring plate
82 Threaded pin 94 Ball
83 Pressure spring 95 Connecting pin (swivel yoke)
84 O-ring 96 Return piston
85 O-ring 97 Control piston
86 Regulator housing 98 Piston with slipper (measuring piston)
87 Seal nut 99 Lever
88 Adjusting screw pP Working pressure
89 Screw plug SK Control chamber pressure

90 Pressure sping (begin of regulation) T Tank pressure
Notice!
Tightening torques: screw plugs 81 / 89 = 35 Nm; seal nut 87 = 18 Nm.
7.10.9
copyright by
MJFCIFSS
Pump regulation
4.2 Flow regulator 26 (LS-regulator)

The purpose of the flow regulator 26 is to adapt the flow rate of the pump to the demand of the users.
The flow regulator 26 is screwed into the regulator housing 49. The flow regulator is made up out of
the following main parts: 3-piece piston 63/64/65 and pressure spring 59 with adjustment screw 52.
Control piston 62 is held in regulating position by the balance of the applied pressure (pP, pLS) and
the spring force of pressure spring 59. Due to a change in the pressure forces the control chamber
is connected with tank or the pump pressure is connected with the regulating piston. The spring force
of pressure spring 59 and therefor the adjustment of Up can be changed/adjusted over adjustment
screw 52.
Fig. 7 Flow regulator mounted in the regulator housing

26 Flow regulator assembly 62 Control piston

49 Regulator housing 63 Piston
51 Screw plug 64 Control sleeve
52 Adjustment screw 65 Piston
56 Seal nut 73 O-ring with support ring
58 Lock nut pP Pump pressure
59 Pressure spring (Adjustment Up) pLS LS-pressure
60 Pressure spring T Return
61 Seal X2 Connection control valve block-LS
X4 Connection T to tank
Notice!
SS
Screw flow regulator 26 all the way in and tighten with max. 5 Nm .
Seal nut 56 = 8 Nm; nut 58 = 120 Nm.
7.10.10
copyright by
MJFCIFSS
Pump regulation
4.3 Regelation of the pressure difference Up LS
4.3.1 Stand-by
If all users are closed, the flow rate of the pump produces a back pressure in the channel pP. This
back pressure is reported back to piston 63. If the pressure force exceeds the forces of pressure
springs 59/60, control edge S2 opens and a connection from SK to T is opened. The rotary group will
deflect back until the spring forces and the pressure forces on control piston 62 are balanced or the
rotary group is sitting at Qmin.
4.3.2 Deflection towards maximum

Control piston 62 is moved to the right via pressure springs 59. The control edge S1 opens, and pump
pressure pP reaches the channel SK to the control chamber of the pump. The pump deflects towards
greater swivel angle and the flow rate increases.
Due to the pressure increase on connection pLS (via actuation of the users) the total force on the
spring side of control piston 62 increases; the control piston 62 shifts to the right. Control edge S1
opens:
– Pump pressure pP reaches the control chamber/regulating piston via channel SK.
– the pump deflects toward greater swivel angle
– pump flow rate increases.
The back pressure of pP caused by the increasing pump flow rate now applies to piston 63. If it rea-
ches the adjusted value of the pressure spring 59, control piston 62 will be moved back toward the
left, until control edge S1 closes. The control chamber of the regulating piston is no longer supplied
with pump pressure pP, but is not yet connected to the T channel due to the still closed control edge
S2, which means the rotary group is fixed and the pump flow rate is held at a constant value.
4.3.3 Deflection towards minimum

If pump pressure pP exceeds the total value in pLS (user pressure via X2) over control piston 62 and
the spring force of pressure spring 60
– the control piston 62 is moved to the left,
– control edge S1 closed,
– control edge S2 opens and

– the regulating piston is discharged to tank via SK
– the pump deflects towards minimum
Fig. 8 Control edges S1 and S2 on flow regulator
51 Screw plug 68 Support ring

52 Adjusting screw 72 Support ring
56 Seal nut 73 O-ring
58 Nut
7.10.11
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Adjustment of the variable displacement pump DPVO
59 Pressure spring (adjustment Up) pP Working pressure

60 Pressure spring pLS LS-pressure
62 Control piston S1 Control edge pump pressure
63 Piston S2 Control edge tank pressure
64 Bushing SK Control chamber pressure
65 Piston T Tank pressure
66 Bushing X2 Connection on regulator housing
67 O-ring X4 Connection on regulator housing
5 Adjustment of the variable displacement pump DPVO
5.1 Adjustment of the differential pressure Up LS and hydraulic begin of regulati-

on
Notice!
The procedure for adjusting differential pressure and begin of regulation on the pump is outlined in
group 6 „adjustment protocol“ and „adjustment procedure“.
4 Cover ring 22 Regulating piston

5 Driveshaft 30 Gear pump
6 Regulator housing 31 Thrust washer

7 Swivel yoke 32 Set of discs
8 Cylindrical roller bearing 33 Retaining ball
9 O-ring 34 Retaining plate
10 Gliding bearing 35 Pressure spring
11 Roll pin 36 Pressure spring
12 Pin 37 Connecting link
13 O-ring 38 Hex head nut
14 Cylindrical roller bearing 39 Stop sleeve
15 Pin 40 Pump housing
16 Cylinder with bushing 46 Connecting plate
17 Control plate 47 Connecting flange

18 Pin (antirotation device) 48 Stop screw
19 Piston with slipper 100 Flange with O-ring
7.10.12
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MJFCIFSS
Adjustment of the variable displacement pump DPVO

Fig. 9 Cutaway drawing DPVO
7.10.13
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MJFCIFSS
Regulating characteristic
6 Regulating characteristic
Fig. 10 Performance curve DPVO 165

7.10.14
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MJFCIFSS
Service Manual Cooling unit
Function and design
Cooling unit
1 Function and design
Cooling of the hydraulic oil, the coolant and the intercooling air of the diesel engine.
The speed of the hydrostatically driven annular fan RL is controlled according to the cooling require-
ments (i.e. based on the coolant, intercooling air and hydraulic oil temperature).
The flow rate of the hydraulic oil and the intercooling air is not controlled. The flow rate of the engine
coolant is however thermostat-controlled.
Fig. 1 Cooling unit, e.g. in three parts

7 Water cooler (coolant) / engine H Air scoop
8 Intercooling air cooler / engine RL Annular fan / blower rotor
13 Blower motor Y352 Proportional solenoid valve
14 Pressure-relief valve
1.1 Cooling elements

The cooling unit consists of 3 cooling elements (heat exchangers):
– Oil cooler 6 for the hydraulic oil

– Cooler 7 for the engine coolant
– Cooler 8 for the intercooling air
– They are installed in a shared frame with air ducting plates.
The annular fan required to produce the air flow (equipped with 8 fan blades as standard) is positio-
ned in the opening of the air duct frame.
The annular fan is driven by the gear oil motor 13. The oil motor speed required to produce the ne-
cessary air flow is automatically controlled by the central control unit A149 (UEC) through the propor-
7.20.1
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MJFCIFSS
Cooling unit Service Manual
Function and design
tional solenoid valve Y352 at the fan motor and the necessary signals from the temperature sensors
at the diesel engine and the hydraulic tank.
The blower motor 13 is protected with the pressure-relief valve 14 that is integrated into the radiator
fan circuit. The pressure-relief valve 14 is factory-set.
1.2 Fan control

The hydrostatic fan drive is controlled by the hydraulic oil temperature B285, the coolant temperature
B2 and the intercooling air temperature B48. The fan speed is controlled electronically, relative to the
temperature, through the proportional solenoid valve Y352.
Between the above minimum and maximum values, the current of the control unit A149 to the sole-
noid valve Y352 is nearly linear, i.e. each temperature between these two limit points corresponds to
a specific current and pressure between min. and max., resulting in a specific fan speed.
Note!
If Y352 is disconnected, the fan switches to emergency speed nnot
Diagrams of the hydraulic fan control, see 2.2.
1.2.1 For software versions from 1.10
Current from Valve position

Temperature Fan speed
BST Y352
≤ 60 °C oil temperature and Imax Largest opening nmin
≤ 88 °C coolant temperature
≤ 45 °C intercooling air temperature
60 - 80 °C oil temperature and Imax - Imin Medium opening nmin - nmax
88- 100 °C coolant temperature and
45 - 65 °C intercooling air temperature
≥ 80 °C oil temperature and Imin Smallest opening nmax
≥ 100 °C coolant temperature and
≥ 65 °C intercooling air temperature
1.2.2 For software versions from 1.14
Current from Valve position

Temperature Fan speed
BST Y352
≤ 60 °C oil temperature and Imax Largest opening nmin
≤ 88 °C coolant temperature
≤ 40 °C intercooling air temperature
60 - 80 °C oil temperature and Imax - Imin Medium opening nmin - nmax
88- 100 °C coolant temperature and
40 - 60 °C intercooling air temperature
≥ 80 °C oil temperature and Imin Smallest opening nmax

≥ 100 °C coolant temperature and
≥ 60 °C intercooling air temperature
7.20.2
copyright by
MJFCIFSS
Function of the fan control
Fig. 2 Components of the fan control system
1 Hydraulic tank 31 Gear pump / fan drive

13 Oil motor / fan drive B2 Temperature transducer / coolant

14 Proportional pressure-relief valve B48 Temperature transducer / intercooling air
15 Coarse filter fan motor B285 Temperature transducer / hydraulic oil
20 Variable-displacement pump / double Y352 Proportional solenoid valve / fan control
variable-displacement pump
2 Function of the fan control
The speed of the blower motor is controlled with the proportional solenoid valve Y352. Depending on
the oil and coolant temperature, the UEC (A149) adjusts the current to the proportional solenoid
valve Y352 thus opening / closing it . The more the proportional solenoid valve Y352 is opened, the
less hydraulic oil flows to the blower motor 13 and the lower the fan speed.
If the temperature of the hydraulic oil in the tank and/or the coolant in the engine and/or the intercoo-
ling air in the turbocharger reaches the lower limit valueTÂ285 (min.), TÂ2 (min.), or TÂ48 (min.) re-
spectively, the output current to the proportional solenoid valve Y352 of the UEC (A149) corresponds
to I Y352 (max.).
In this case, the pressure at the proportional solenoid valve Y352 is reduced to a low value. This has
the effect that the speed of the fan is reduced to the minimum working speed n fan (min.). Surplus oil
7.20.3
copyright by
MJFCIFSS
from pump 31 is returned back to tank through the pressure relief valve 14.
If the temperatures increase from the minimum value to the maximum value TÂ285 (max.), TÂ2 (max.)
or TÂ48 (max.) respectively, the current to the proportional solenoid valve Y352 is gradually reduced.
The pressure in the fan drive system corresponds now to the upper nominal value. Nearly all oil from
the pump 31 flows to the fan motor 13. The speed of the fan reaches its upper nominal value nfan
(max.).
Between the above minimum and maximum values, the current of the UEC (A149) to the solenoid
valve Y352 is nearly linear, i.e. each temperature between these two limit points corresponds to a
specific current I and pressure p between min. and max., resulting in a specific fan speed, (see Tab.
4 on page 5).
In emergency mode, i.e. in the event of a failure of the control system (I = 0 mA), the oil pressure in
the hydraulic fan drive reaches the emergency value p(not) set for the pressure-relief valve 14, and
the fan is operated at emergency speed n fan (not).
Fig. 3 Cooling unit and fan circuit
1 Hydraulic tank 100 from control block connection K

6 Cooler for hydraulic oil A149 UEC excavator control system
7 Cooler for engine coolant B2 Temperature transducer / coolant

8 Cooler for the intercooling air B48 Temperature transducer / intercooling air
9 Fan rotor / annular fan B285 Temperature transducer / hydraulic oil
13 Oil motor / fan drive LL Intercooling air
14 Proportional pressure-relief valve MK Engine coolant
15 Coarse filter Y352 Proportional solenoid valve / fan control
31 Gear pump / fan drive
7.20.4
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MJFCIFSS
2.1 Maintenance
Maintenance is limited to inspection and cleaning of the cooling unit fins.
After a repair on the hydraulic components (defective pump, etc.), the coarse filter 15 in the fan circuit
must be inspected for contamination and replaced, if necessary.
2.2 Fan control diagrams
Fig. 4 Temperature – current and current – speed and pressure

B2 Temperature / engine coolant sensor Y352 Proportional solenoid valve

B48 Temperature / intercooling air sensor I Current to proportional solenoid valve
B285 Temperature / hydraulic oil sensor n Speed of annular fan / blower rotor
V1.10- from software version 01.10 p Pressure in cooling circuit
V1.14- from software version 01.14 T Temperature of medium (hydraulic oil,
engine coolant or intercooling air)
7.20.5
copyright by
MJFCIFSS
Note!
Speed during emergency operation (failure of Y352):
Inot = 0 mA = nmax
pnot a the pressure-relief valve 14 = pmax
7.20.6
copyright by
MJFCIFSS
Service Manual FMF hydraulic fixed displacement motor
Function
FMF hydraulic fixed displacement motor
1 Function
The FMF hydraulic fixed displacement motor is of the built-in type. Its purpose is to drive the slewing
gear mechanism of the machine.
The axial piston motor is of the swash plate design and sits on the slewing gear mechanism of the
machine.

Fig. 1 FMF hydraulic fixed displacement motor
7.24.1
copyright by
MJFCIFSS
FMF hydraulic fixed displacement motor Service Manual
General information and tightening torques
2 General information and tightening torques
A 309 Litronic TCD 40998 -

Machines from serial number
A 316 Li Ind. TCD 29503 -
R 313 Litronic TCD 39171 -
R 317 Litronic TCD 30019 -
Type of oil motor FMF 45
Oil flow consumption 45 cm3/rev
Max. leak oil at max. working pressure 6 l/min
Allen head screws 14 118 Nm

Screw plug / leak-oil connection S 68 Nm
Pressure relief valve 134 / 135 100-120 Nm
Screw plug / suction valve 133.1 250 Nm
Measuring connection 137 / 138 27 Nm
Note!
For the adjustment of the valves 134 / 135: see adjustment protocol and checking and adjusting
tasks in group 3.
7.24.2
copyright by
MJFCIFSS
Design
3 Design
Axial-piston oil motors are energy converters characterised by the axial alignment of the pistons in
the cylinder.
The oil motor 130 consists of two main components:
– Motor housing 12 with powertrain 132
– Mounting plate 13 with suction valves 133 and pressure relief valves 134 / 135
Furthermore, there are the measuring connections 137 / 138 at the top of the mounting plate 13.
The powertrain pistons 132 with slippers rotate on the swash plate. The inclined arrangement of the
slide faces is responsible for the stroke of the pistons in the cylinder and, thus, the constant oil flow
consumption of the oil motor.
The force resulting from hydraulic pressure and piston areas generates the required torque on the
output shaft.
Fig. 2 FMF fixed displacement motor
12 Housing 134 Pressure-relief valve with additional pres-

sure stage
13 Mounting plate 135 Pressure-relief valve with additional pres-
sure stage
130 Oil motor, complete 137 Measuring connection MA
132 Powertrain, complete 138 Measuring connection MB

133 Suction valve
7.24.3
copyright by
MJFCIFSS
Functional description
4 Functional description
4.1 Functioning of the oil motor, see Fig. 3 and see Fig. 4
The housing 12contains 9 pistons 5 that are arranged in a circle, parallel to output shaft 3. They run
in cylinder 4, which is geared with output shaft 3.
The piston ends are designed as ball joints and sit in the slippers 5.1. They are held by the return ball
8 and the return plate 7 on the fixed inclined eccentric disc 6.
The hydrostatic bearing arrangement of the slippers 5.1 on thrust washer 6 (by means of bores in
piston 5 and slippers 5.1) reduces the otherwise high friction between the slippers and the eccentric
disc to a minimum.
When there is no pressure, the pressure springs 8.1 built into the return ball8 press the cylinder
4against the disc cam 9. When the pressure increases, the cylinder 4 and the pilot plate 9 are balan-
ced by hydraulic forces in such a way that the oil film at the control surface is maintained at all times,
even under high loads, and the amount of leak oil is reduced to a minimum. Some of the leak oil is
used to lubricate the moving parts of the powertrain and guided externally back to the tank.
If pressure oil is supplied to the operating connections A or B, the respective four pistons 5 are pres-
surised through the kidney-shaped slots in the pilot plate 9. Another group of four pistons 5 displaces
the unpressurised oil through the kidney-shaped slots in the pilot plate 9 and connection B or A to
the tank. A ninth piston is situated in the area of the dead centre, i.e. at the point of return of motion.
The oil acting on the four pistons on the pressure side generates a certain force determined by the
pressure and the piston area. This force acts through the piston 5 and the slipper5.1 on the eccentric
disc 6.
The radial component of the above force (together with the limb of the cylinder acting as a lever arm)
generates a torque, which is transmitted onto the cylinder 4 and the output shaft 3.
The torque can be influenced only by the applied oil pressure, i.e. high pressure = high torque. The
two-way pressurisation of the oil motor (connection A or B) results in a change of direction of the
torque at drive shaft 3 (left or right-hand rotation).
With every rotary motion of cylinder 4, the pistons 5 complete a double stroke. The stroke of the pis-
tons corresponds to the inclination of the eccentric disc 6 and determines the volume of oil consumed.
As the oil flow consumption remains constant at all times, it is the travel / output speed of the oil motor
that is changed accordingly via the spool when the oil supply changes.
7.24.4
copyright by
MJFCIFSS
Fig. 3 Sectional drawing of fixed displacement motor
2 Roller bearing 15 Locking ring

3 Output shaft 16 Radial shaft seal ring
4 Cylinder 17 O-ring

5 Piston 18 O-ring
5.1 Slipper 19 O-ring
6 Eccentric disc 22 Snap ring
7 Return plate 23 Snap ring
8 Return ball 26 Needle bearing
8.1 Pressure spring 27 Shim
9 Pilot plate 28 Shim
10 Locking pin 29 Shim
12 Housing 30 Shim (supplied only with repair set /
locking ring
13 Mounting plate 134 Pressure relief valve B with additional
pressure stage
13.21 Screw plug 135 Pressure relief valve B with additional
pressure stage
14 Allen head screw 137 Measuring point MA / pivot right
138 Measuring point MA / turn left
7.24.5
copyright by
MJFCIFSS
4.2 Functioning of valves on the mounting plate, see Fig. 4
4.2.1 Suction valves 133

The suction valves (acting as check valves) ensure that the oil motor is always properly filled (no ca-
vitation e.g. when relief valves blow off or in the event of leaks). If a vacuum occurs at the connection
A or Bthe cone 133.10 is pushed against the force of the spring 133.14 from its seat, and oil can flow
from the connection S to the suction side A or B. This prevents cavitation in the oil motor.
4.2.2 Pressure relief valves with additional pressure level 134 and 135
These valves limit the high pressure that may arise at main connections A and B with respect to the
control pressure at connections XA / XB.
Pressure control
If the pressure increases in the slewing gear circuit in undesirable ways, damage would occur at the
weakest point, e.g. screwed connections or hydraulic hoses.
In order to prevent this, the system is equipped with a pre-determined breaking point. The increasing
working pressure in the slewing gear circuit acts on a pressure relief valve. It limits the maximum
pressure in the slewing gear circuit and its connection to a pre-set value.
As high flows result in pressure on the pressure-relief valves, the machine is equipped with indirectly
acting (pilot-controlled) pressure-relief valves. In these valves, a pressure-relief valve is installed as
a pilot control valve to actuate a second, larger valve.
The applied pressure (in A or B respectively) acts on the front face of the piston (main cone).19 and
through a small bore also on the reverse side of the piston .19, closing it. Simultaneously, the pilot
control cone .20 is pressurised. The pressure spring .23 pushes the pilot control cone .20 into its clo-
sing position (static status). The pressure springs .24 and .31 serve as return devices.
and adjusting spring .23, pilot control cone .20 is lifted from its seat, and some oil can penetrate into
the return channel.
As the diameter of the boreholes in the bushing.19 differs from that of the valve insert.18, a differential
pressure is built up between the front side and the rear side of the piston.19. As a result of this pres-
sure difference, the piston .19 is shifted against the pressure spring .23, and a substantial amount of
oil flows off to the non-pressurised return side 5 or the opposite side.
Additional pressure level

If the pilot control valve for the actuation of the slewing gear is not actuated, the connection XA / XB
is relieved.
Level 1 (low pressure = braking pressure - see adjustment protocol of hydraulic system)
Connection XA and/or XB is connected to the tank. Pressure spring .23 has a lower pre-loading force.
The pressure limitation of the relief valve 134 / 135 is set to the low value (level 1).
When the pilot control unit for the slewing gear actuation is activated, the pilot control pressure is ap-
plied the piston .12 through the connection XA or XB respectively, the internal boreholes in the moun-
ting plate 13 and the boreholes and the annular gap in the valve 134 / 135.
Level 2 (higher pressure = pivoting pressure - see adjustment protocol of hydraulic system)
Pressure spring .23 is pre-loaded a bit more by shifting piston .12, ball .21 and spring plate .11, so
that there is a higher blow-off pressure.
The pressure limitation of the relief valve 134 / 135 is set to the high value (level 2).
Adjustment of the relief valves 134 / 135 with additional pressure level: see adjustment protocol and
checking and adjusting tasks in group 3.
7.24.6
copyright by
MJFCIFSS
Fig. 4 Sectional drawing of mounting plate
13 Mounting plate 134.19 Piston

14 Allen head screw 134.20 Cone
133 Check valve / suction valve 134.21 Ball
133.10 Cone 134.22 O-ring

133.11 Screw plug 134.23 Pressure spring
133.14 Pressure spring 134.24 Pressure spring
133.17 O-ring 134.25 O-ring
134 Pressure relief valve / turn right A with 134.26 Backing ring
additional
pressure stage
134.10 Adjusting screw 134.27 O-ring
134.11 Spring plate 134.28 O-ring
134.12 Piston 134.29 O-ring
134.13 Nut 134.30 O-ring
134.14 Bushing* 134.31 Pressure spring
134.15 Bushing 134.98 Seal kit

134.16 Nut 135 Pressure relief valve / turn left B with
additional
pressure stage, items .10 - 98, see 134
134.17 Bushing* 137 Measuring point MA / turn right
134.18 Valve seat 138 Measuring point MB / turn left
* one piece (roller bearing)
7.24.7
copyright by
MJFCIFSS
Maintenance and repairs
5 Maintenance and repairs
Note!
Liebherr oil motors do not require any maintenance whatsoever. For sealing and repair jobs, please
refer to separate repair instructions "Liebherr FMF fixed displacement oil motors".
5.1 Sealing jobs on valves on mounting valve
Replacement of O-ring 133.17 or spring 133.14 on the suction valves 133:

Remove the screw plug 133.11 complete with the measuring connection 137 / 138. Remove the cone
133.10, the spring 133.14 and the O-ring 133.17.
Check the cones 133.10 for free movement. Place the new spring or O-ring in the valve, and reas-
semble it.
When installing the valve, tighten the screw plug 133.11 with the measuring connection 137 / 138
(tightening torque: 250 Nm).
Sealing jobs on the pressure relief valves 134 and 135

To seal the valves, use the seal kit .93.
For this purpose, remove and/or dismantle the valve 134 / 135 completely, as needed.
Check whether the parts are in proper working order and can be reused.
Note!
After having replaced the defective sealing element, reassemble it and insert it (tightening torque
between 100 and 120 Nm).
After the replacement of the O-rings .22, .27, .29, the response pressures of the valve must be re-
adjusted. See checking and adjusting tasks and protocol in group 3.
7.24.8
copyright by
MJFCIFSS
Service Manual DMVA regulating motor
Design of hydraulic travel motor
DMVA regulating motor
1 Design of hydraulic travel motor
The axial-piston oil motor is of the swash-plate type. It is flanged to the transmission of the machine.
It consists of a motor housing with built-in powertrain, swivel yoke and a mounting plate with regula-
ting and adjusting unit.
The mounting plate features a brake valve working in both directions of travel. The mounting plate is
also equipped with the secondary pressure-relief valves and the suction valves.
The flow volume of the variable-displacement pump is fed through connections A or B to the travel
motor and acts on the piston of the powertrain. The pistons (moving in the axial direction inside the
cylinder of the powertrain) act on the cylinder and drive shaft and generate a certain torque.
The regulating and adjusting unit built into the mounting plate adjusts the pivot angle to the flow con-
sumption of the oil motor (= flow consumption of the travel motor).
The variable flow consumption of the travel motor determines the torque and speed of the drive shaft.
Both values are in inverse ratio, i.e.:
High flow consumption Qmax = high torque = low speed of travel motor
Low flow consumption Qmax = low torque = high speed of travel motor
The brake valve integrated into the mounting plate restricts the return flow to the control valve block
or the tank respectively, thus slowing down the drive. This approach prevents overspeeding of the
travel motor when travelling down a slope and consequent cavitation.

Fig. 1 DMVA travel motor
7.26.1
copyright by
MJFCIFSS
DMVA regulating motor Service Manual
Technical data
2 Technical data
Machine A 309 Litronic A 312 Litronic

Type 1035 1037
from serial number 40998 36220
Machine A 311 Litronic
Type 1036
from serial number 41128
Oil motor DMVA 108 DMVA 108
3
Max. oil flow consumption 108 cm /rev 108 cm3/rev
Oil flow consumption min. standard 52.3 cm3/rev 52.3 cm3/rev
Speeder 52.3 cm3/rev 52.3 cm3/rev
Begin of regulation (high pressure) 240 +10 bar 240 +10 bar
End of regulation (high pressure) 320 bar 320 bar
Max. permissible leak oil volume 7 l/min 7 l/min
at 350 bar and an oil temperature of 50° C
Adjustable settings of oil motor
A Begin of regulation of the oil motor 240 bar 240 bar
at the adjusting screw 64
B Min. pivot angle
Dimension X of the stop screw 35 (guide value)
Standard machine 23.8 mm 23.8 mm
Speeder 23.8 mm 23.8 mm
C Drive shaft speed

Standard machine 1850 ±25 min-1 1800 ±25 min-1
Speeder 2750 ±25 rpm 2700 ±25 rpm
Adjusting screw 160.1 / 160.2 for stroke limitation

of the control axle 160 (dimension Y)
Standard 12 mm 12 mm
Speeder 14 mm 14 mm
High pressure 125 bar 125 bar

D Secondary pressure-relief valves 380+20 bar 380+20 bar

7.26.2
copyright by
MJFCIFSS
Technical data
Machine A 314 Litronic A 316 Litronic

Type 1039 1040
from serial number 30694 29120
Machine A 316 Li IND
Type 1041
Oil motor DMVA 108 DMVA 165
Max. oil flow consumption 108 cm3/rev 165 cm3/rev
Oil flow consumption min. standard 52.3 cm3/rev 94.6 cm3/rev
Speeder 49.5 cm3/rev 75.2 cm3/rev
Begin of regulation (high pressure) 240 +10 bar 240 +10 bar
End of regulation (high pressure) 320 bar 320 bar
Max. permissible leak oil volume 7 l/min 7 l/min
at 350 bar and an oil temperature of 50° C
A Begin of regulation of the oil motor 240 bar 240 bar
at the adjusting screw 64
B Min. pivot angle
Dimension X of the stop screw 35 (guide value)
Standard machine 23.8 mm 21.0 mm
Speeder 24.6 mm 25.0 mm
C Drive shaft speed

Standard machine 1920 ±25 min-1 1680 ±25 min-1
Speeder 2870 ±25 rpm 2520 ±25 rpm
Adjusting screw 160.1 / 160.2 for stroke limitation

of the control axle 160 (dimension Y)
Standard 11.5 mm 11.5 mm
Speeder 14 mm 14 mm

High pressure 125 bar 125 bar
+20
D Secondary pressure-relief valves 380 bar 380 +20 bar

7.26.3
copyright by
MJFCIFSS
Design
3 Design
The travel motor consists of the following main components:

– Powertrain 172
– Mounting plate 30
– Regulator 60
The housing 80 encloses the entire powertrain 172 with swivel yoke, piston, pilot plate and sliding
disc.
The housing 80 is screwed to the mounting plate 30. The mounting plate contains the secondary
pressure-relief valves 176/177, the control and regulating unit and the brake valve acting in both di-
rections of travel.
Fig. 2 Design of the travel motor
30 Mounting plate 172 Complete powertrain

60 Regulator, complete 176 Secondary pressure-relief valve
80 Housing 177 Secondary pressure-relief valve
7.26.4
copyright by
MJFCIFSS
Functional description of the travel motor
4 Functional description of the travel motor
4.1 Function of powertrain

The housing 80 encloses the powertrain 172 with the drive shaft 4, cylinder 3, piston 2 with slipper,
etc. Parallel to the drive shaft 4, there are nine pistons 2 arranged in a circle. They run in axial arran-
gement in the cylinder 3, which is in gear with drive shaft 4. The bottom ends of the pistons are desi-
gned as ball joints and sit in slippers. They are held on the swivel yoke 9 by the return ball 6 and the
return plate 7 (swash plate).
The hydrostatic bearing of the slipper on the sliding disc 8 of the swivel yoke 9 (through bores in the
piston 2 and the slippers) reduces the high friction to a minimum, despite the high surface pressure
between the slipper and the swivel yoke 9.
When there is no pressure, the cylinder 3 is pressed by the pressure springs 13 in the return ball 6
against the pilot plate 5. When the pressure increases, the cylinder 3 and the pilot plate 5 are balan-
ced by hydraulic forces in such a way that the oil film at the control surface is maintained at all times,
even under high loads, and the amount of leak oil is reduced to a minimum. Some of the leak oil is
used to lubricate the moving parts of the powertrain and guided externally back to the tank.
If pressure oil is supplied to the operating connections A or B, the respective four pistons are pres-
surised through the kidney-shaped slots in the pilot plate 5. Another four pistons press the non-ener-
gised oil through the kidney-shaped openings in the piston plate 5 through the connection A or B to
the tank. A ninth piston is situated in the area of the dead centre, i.e. at the point of return from the
pressure to the suction phase.
The oil acting on the four pistons on the pressure side generates a certain force determined by the
pressure and the piston area. This force acts via the pistons 2 with slippers onto the swivel yoke 9.
The radial component of the above force (together with the section of the cylinder acting as a lever
arm) generates a torque which is transmitted onto the cylinder 3 and the drive shaft 4. Changing the
side of the travel motor (connection A or B) results in a change of direction of the torque at the drive
shaft 4 (clockwise or anticlockwise rotation respectively).
For every rotary motion of the cylinder 3, the pistons execute a double stroke. That stroke corres-
ponds to the inclination of swivel yoke 9 and determines the amount of oil consumed.
4.2 Function of the regulating unit Document is registered under: 1030314 - 29.01.2009
The sectional drawing shows the following regulating positions of the travel motor:
The powertrain 172 (swivel yoke 9) is already set to a maximum swivel angle. The working pressure
acts on the piston face of the control piston 173 (minimum pressure valve at the end of regulation),
see Tab. 1 and Tab. 2.
The regulating piston 174 is in regulating position, i.e. the flow from the high pressure side through
the check valve 175 to the large piston surface of the spool 173 and the flow from the large piston
surface of the spool 173 to the tank side are blocked. The maximum swivel angle is determined by
the stop of the spool 173 at the guide bushing 33. The motor remains in this position, until the high
pressure drops below the pressure value at the end of regulation.

Within the regulated range, the travel motor can reach any position that corresponds to a working
pressure of between Qmax and Qmin. If the working pressure drops below the value at the begin of
regulation, the spool 173 touches the stop screw 35, i.e. the travel motor's flow consumption capacity
is lowest at high drive shaft speed, high speed and low drawing pull.
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Fig. 3 Sectional drawing at the begin of regulation (spool)
32 Mounting plate 38 Lock nut

33 Guide bushing 42 Pin
34 Connecting link 50 Measuring connection of the actuating pres-
sure M
35 Stop screw
4.3 Function prior to the begin of regulation

The pressure oil from the respective high pressure side A or B respectively, acts on the piston ring
surface of the spool 173 through the check valves 175 and the internal bores in the mounting plate
32. The swivel yoke 9 is kept at a small swivel angle by the connecting link 34. The minimum swivel
angle is limited by the stop screw 35.
The working pressure acts on the spool 174 through the check valves 175. The spool 174 is held by
the preloaded adjusting spring 68 in its basic position so that the flow from the high pressure side
through the check valve 175 to the large piston surface of the spool 173 is blocked. The flow from the
large piston surface of the spool 173 to the tank side is opened. The travel motor remains in this po-
sition, until the working pressure exceeds the pressure value of the begin of regulation, (see “Tech-
nical data” on page 2) or (see Tab. 2 on page3).
4.4 Function from begin of regulation

The spool 174 is held in the regulating position by the adjusting spring 68 and the return spring 69 (+
the working pressure acting on the shuttle check valve 195). Regulating position of the spool 174
spring force of the return spring 69 + force resulting from the working pressure on the surface diffe-
rence = spring force of the adjusting spring 68.
If the existing working pressure rises above the value at the begin of regulation, it acts on the surface
difference Ø D - Ø d, (see Fig. 5 on page7) of the spool 174, pushing it against the adjusting spring
68. The control edge of the spool 174 opens the oil flow to the large piston surface of the spool 173.
The surface difference of the spool 173 generates the necessary actuating force to swivel the po-
wertrain in direction Qmax. As a result, the powertrain is swivelled to a large swivel angle. The push
rod 67 acts as a sensing device and relieves the return spring 69, so that the force ratio between the
adjusting spring 68 + return spring 69 differs from the working pressure. As a result, the spool 174
returns to its regulating position (= closed position) and the actuating procedure is completed.
At the respective working pressure (end of regulation) the powertrain is set again to the maximum
7.26.6
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swivel angle.
Fig. 4 Sectional drawing of the regulator
61 Bushing 69 Pressure spring (regulating spring)

62 Bushing 72 Ball
63 Spring plate 77 Lead seal
64 Adjusting screw 174 Spool
65 Spring plate A High pressure through valve 52
66 Spring plate SK Pressure to control piston 173
67 Pressure rod C High pressure through valve 195
68 Compression spring (adjusting spring) T to tank
Fig. 5 Magnified view of the surface difference (detail Z)

7.26.7
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4.5 Fuse
The two pilot-controlled pressure-relief valves 176 / 177 protect the travel motor against overpressure
(secondary protection).
The suction valves (check valves) 196 prevent cavitation when the secondary pressure-relief valves
176 / 177 respond.
Fig. 6 Arrangement of the valves for pressure protection
173 Control piston 194 Check valve

176/177 Secondary pressure-relief valves 196 Check valve
4.6 Creeper gear mode

The travel motor is kept at a maximum swivel angle (creeper gear mode) when the switch S21 (stan-
dard equipment) is actuated on the control console and the solenoid valve Y24 located on the control
oil unit is powered as a result.
When the switch S21 is actuated, the pilot control pressure from the solenoid valve Y24 acts through
the control connection "X" onto the spool 174, which is then pushed against the pressure spring 68.
As a result, the high pressure immediately acts on the large surface of the control piston 173 (inde-
pendent of regulation settings) so that the travel motor is switched to a maximum pivot angle. The
machine is thus easier to steer, while the drawing pull is not increased.
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4.7 Functioning of brake valve

When a travel motion of the machine is initiated, the working pressure that is being built up acts th-
rough the restrictor bolt 193 (restrictor check valve) onto the brake piston 192 and pushes it against
the pressure spring 48. As a result, the flow is opened on the return side A or B so that the oil is dis-
placed to the tank.
If the pressure in the feed line A or B drops, be it as a result of a steering movement or a change in
load, for example during travel down a slope, the pressure in the spring chamber is reduced through
the restrictor bolt 193. The brake piston 192 is put into braking position by the pressure spring 48,
whereby the equilibrium of forces between the pilot control pressure at the brake piston 192 and the
pressure spring 48 determines the automatic brake function. The brake effect results from the rest-
riction of the oil from the motor. Irregular braking of the travel motor is prevented by the check valves
196 with bypass bores, see Fig. 6.

Fig. 7 Arrangement of the valves for the brake function
45 Valve seat 192 Piston

46 Spring plate 193 Restrictor bolt
47 Lid 194 Check valve
48 Pressure spring
7.26.9
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Maintenance and repairs
5 Maintenance and repairs
Note!
Liebherr oil motors do not require any maintenance whatsoever.
This travel motor has been pre-set by the manufacturer and its settings should not be changed.
For sealing and repair work, please refer to the separate
repair instructions for DMVA regulating motors.
6 Checking and adjusting the travel motor
Danger!
For inspection, adjustment and repair work, it is necessary to access the undercarriage.
This can be dangerous for technicians. There is a risk of serious injury or event death, if the machine
begins to move.
X Extend the supports.
X Place attachments on the ground. Lift the undercarriage from the ground, if required.
X Apply the parking brake.
X Establish visual or acoustic contact with the operating personnel.
6.1 Checking and adjusting the begin of regulation of the travel motor
The checking and adjustment of the begin of regulation of the travel motor is described in detail in
group 3 "Adjustment protocol" and "Testing and adjusting tasks".
6.2 Checking and adjusting of the maximum output speed / maximum travel speed
(setting C)
Note!
The maximum output speed of the travel motor is determined by the minimum flow consumption of
the oil motor and the maximum flow volume of the spool for travelling (stroke limitation 160.1/160.2).
The maximum speed is factory-set by the manufacturer and may not be changed.
The minimum flow consumption of the oil motor is limited by the Qmin stop screw 35.
If the maximum travel speed of the vehicle is unsatisfactory, the setting can be adjusted. To determi-
ne the actual value, check the dimension Y of the stroke limitation adjusting screw 160.1 / 160.2.
To determine the maximum travel speed accurately, measure the speed of the universal joint shaft
(connection of transmission and axle) using a HT 460 speed meter (for tools, see group 2.01). For
settings see Tab. 1 and Tab. 2.
7.26.10
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Checking and adjusting the travel motor
Fig. 8 Control axle / travel at control block
100 Compact control block 160.1 Stroke limitation, reverse travel

160 Control axle / travel 160.2 Stroke limitation / forward travel
6.3 Checking and adjusting the minimum pivot angle (setting B)

The minimum pivot angle, i.e. the minimum flow consumption is determined by the stop screw 35.
The angle is factory-set by the manufacturer and may not be changed.
To check the position of the stop screw 35 in the mounting plate 32, use dimension X (between the
stop screw 35 and the lock nut 38) as a guide value, see Tab. 1 and Tab. 2.
Fig. 9 Setting value of Qmin stop screw
32 Mounting plate 38 Lock nut

35 Stop screw 51 Protective cover
Note!
The location of installation of the oil motor depends on the machine model.
7.26.11
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Hydraulic diagram of the travel motor
6.4 Checking travel motor for leakage

Oil temperature in machine: 50°C
X Disconnect the leak oil hose to connection T1 and seal the hose.
X Screw a matching hose section to connection T1 on the travel motor and place the other end of
the hose in a suitable oil collection container.
X 2. Put the machine in gear, press the brake pedal to the stop and apply the maximum pressure to
the travel motor (maximum high pressure).
X Measure the volume of leaked oil and compare it with the permissible volume, see Tab. 1 and Tab.
2.
If there is excessive leakage, replace the oil motor.
X Remove the hose section and reconnect the leak oil hose to connection T1.
Fig. 10 Connection T1 for the leakage check of the travel motor
7 Hydraulic diagram of the travel motor
34 Connecting link 190 Travel brake valve, complete

35 Stop screw 192 Brake piston
67 Pressure rod 193 Restrictor bolt

68 Compression spring (adjusting spring) 194 Check valve
69 Pressure spring (regulating spring) 195 Shuttle valve
170 Travel motor, complete 196 Check valve
172 Complete powertrain
173 Control piston X Connection for control pressure from sole-
noid valve Y24
174 Spool T1 Leak oil connection
175 Check valve R Pressure/return line connection, reverse
176 Secondary pressure-relief valve V Pressure/return line connection, forward
forward
177 Secondary pressure-relief valve M Measuring connection / control chamber

reverse pressure
7.26.12
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Fig. 11 Hydraulic diagram of the travel motor
7.26.13
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Items Items
2 Piston with slipper 34 Connecting link
3 Cylinder with bushing 35 Stop screw
4 Drive shaft 36 Backing ring
5 Pilot plate 37 O-ring
6 Return ball 38 Lock nut
7 Return plate 39 Allen head screw
8 Sliding disc 41 Jacket ring
9 Swivel yoke 42 Pin
10 Locking ring 43 Roll pin
11 Pin 45 Valve seat
12 Pin 46 Spring plate
13 Pressure spring 47 Lid
14 Cylindrical roller bearing 48 Pressure spring
15 Cylindrical roller bearing 50 Screw cap (measuring point M)
16 Cylindrical roller bearing 51 Protective cap
17 Radial shaft seal ring 80 Housing
18 O-ring 82 O-ring
19 Snap ring 83 Cylinder pin
20 Snap ring 172 Complete powertrain
21 Allen head screw 173 Control piston
22 Roll pin 192 Piston
31 Screw plug 193 Restrictor bolt
32 Mounting plate 194 Check valve
33 Guide bushing
Note!
Observe set value B, see Tab. 1 and Tab. 2.
7.26.14
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Sectional drawings
8 Sectional drawings

Fig. 12 Sectional drawing of transmission and brake valve
7.26.15
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Sectional drawings
Items Items
9 Swivel yoke 71 Circlip
30 Connecting plate, complete 72 Ball
31 Screw plug 73 O-ring
32 Mounting plate 74 O-ring
40 Allen head screw 76 Protective cover
44 Pin 77 Lead seal
45 Valve seat 78 Washer
48 Pressure spring 79 Allen head screw
49 O-ring 80 Housing
60 Regulator, complete 81 Cylinder pin
61 Bushing 173 Control piston
62 Bushing 174 Spool
63 Spring plate 175 Check valve
64 Adjusting screw 176 Secondary pressure-relief valve
65 Spring plate 177 Secondary pressure-relief valve
66 Spring plate 192 Piston
67 Pressure rod 193 Restrictor bolt
68 Compression spring (adjusting spring) 194 Check valve
69 Pressure spring (regulating spring) 195 Shuttle valve
70 Lock nut
Note!
Observe set values A and D, see Tab. 1 and Tab. 2.
7.26.16
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Sectional drawings

Fig. 13 Sectional drawing of pilot plate and brake valve
7.26.17
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Sectional drawings
7.26.18
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Service Manual Regulating motor A6VE
Purpose
Regulating motor A6VE
1 Purpose
The axial piston oil motor of the inclined axle type is inserted into the travel gear of the crawler exca-
vator (plug-in motor).
The travel motor propels the travel gear and, through the tumbler wheel, the chain.
The flow from the variable-displacement pump is fed through brake valve "Connection A or B" to the
oil motor and acts on the pistons of the powertrain. The pistons (moving in axial direction inside the
cylinder of the powertrain) act on the cylinder and drive shaft and generate an input torque.
The regulating and adjusting unit adjusts the pivot angle to the flow consumption of the oil motor (de-
pending on the operating pressure).
The variable flow consumption of the oil motor determines the torque and speed of the drive shaft.
Large flow consumption = large torque, low rpm, low speed

Small flow consumption = small torque, high rpm, high speed
The travel motor can be adjusted by the operator to its minimum pivot angle (electro-hydraulic adjus-
tment) (fast travel).
.

Fig. 1 Regulating motor A6VE
7.28.1
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MJFCIFSS
7.28.2
Purpose
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MJFCIFSS
Service Manual
Purpose
1.1 Technical data
Machine R 317-LI TCD

Unit
Regulating motor Type A6VE 55 HZ
Max. oil flow consumption cm3 54,8
Max. torque Nm 349
Operating pressure bar 350
Max. leak oil l/min 8

Check measurement X.
Qmin Stop 8 mm approx. 15.5
Qmax Stop 11 mm approx. 15.5
Brake release pressure bar approx. 21
Secondary pressure-relief valves 211-214 bar 380 +20
Tab. 1 Technical data and settings

7.28.3
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Regulating motor A6VE Service Manual
Design
2 Design
The regulating motor 200/201 consists of two main components:

– Motor housing 2
– End plate 20
The regulating motor consists of the motor housing 2 with integrated powertrain 1. To the left and
right on the travel motor housing 2, you find the stop screws for Qmin 8 and Qmax. 11.
The motor housing 2 is equipped with a flange-mounted end plate 20. The end plate 20 includes the
powertrain adjusting device 202.
The brake valve 205, double stop valve 209 and the secondary pressure-relief valves 211-214 are
screwed into the end plate 20.
Fig. 2 Design of regulating motor
2 Motor housing 209 Double stop valve

8 Stop screw (Qmin) 211 Secondary pressure-relief valve, chassis ,
forward left
11 Stop screw (Qmax) 212 Secondary pressure-relief valve, chassis,
reverse left
20 End plate 213 Secondary pressure-relief valve, power-
train, forward right
200 Travel motor, left 214 Secondary pressure-relief valve, chassis,

reverse right
201 Travel motor, right A Pressure/return line connection
202 Control piston / adjustment B Pressure/return line connection
205 Brake valve T1 Leak oil connection
7.28.4
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Design
Fig. 3 Hydraulic diagram of regulating motors
50 from control oil unit 208 Pressure reduction valve / brake pressure
100 Compact control valve block 209 Double stop valve
106 Shift valve / Qmax Regulating motors 211 Secondary pressure-relief valve, chassis,
forward left
195 Rotary connection 5x 212 Secondary pressure-relief valve, chassis,

reverse left
forward right
reverse right
201 Travel motor, right 215 Travel brake
7.28.5
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Design
202 Control piston / powertrain adjustment 216 Travel gear

203 Spool S21 Switch (fast travel)
205 Brake valve Y24 Solenoid valve (fast travel)
206 Shuttle valve
7.28.6
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see Fig. 4 and see Fig. 5
3.1 powertrain
The pressure oil from the hydraulic pump is fed through the pressure connection A or B respectively
and through a kidney-shaped orifice in the control lens 13 to the cylinder 12.
Three bores of the cylinder 12 are connected to the pressure side of the control lens 13, and three
bores are connected with the return side. One bore is located at the dead centre, i.e. between the
pressure and suction phase.
The conical pistons 15 moving in axial direction inside the cylinder 12 are sealed by means of two
piston rings each. By applying oil under pressure onto the three piston surfaces, a radial force is cre-
ated at the conical pistons 15, in turn generating a output torque at the perimeter of the powertrain
drive shaft 1.
In idle mode, and during start-up, the cylinder 12 is pressed by the pressure spring 17 mounted on
the centre peg 14 against the control lens 13. When the pressure increases, the cylinder 12 is balan-
ced in such a way that the oil film at the control surface of the cylinder 12 and the control lens 13 is
maintained at all times, even under high loads, and the amount of leak oil is reduced to a minimum.
The leakage oil lubricates the centre peg 14, the conical piston 15 and the tapered roller bearings 39
of the drive shaft.
3.2 Adjustment
The oil motor can only be operated in two powertrain positions (on-off control).
3.2.1 Operation
Switch S21 for fast travel is not actuated.
The operating pressure of the respective high pressure side A or B respectively acts through internal
boreholes and the shuttle valve 206 in the end plate 20, the spool 203 and the restriction pin 30 to

the surface Fg of the control piston 202. The powertrain is set by the control piston 202 and the con-
trol neck 22 to a large pivot angle (Qmax) = large oil volume consumption = high tractive power.
3.2.2 Fast travel gear

The switch S21 for fast travel is actuated.
The solenoid valve Y24 connected to the switch S21 is powered. As a result, the control oil of the
control oil unit flows through Y24, the shift valve 106 (in the control valve block), the rotary connection
196, (see Fig. 3 on page5) and connection X of the end plate 20 and acts on the spool 203.
The spool 203 is moved against the pressure spring 25. As a result, the control edge of the spool 203
is opened and the working pressure acts through the control bushing 23 on the piston surface Fk of
the control piston 202. Simultaneously, the surface Fg is released to the tank by the spool 203.
The control piston 202, through the control neck 22, moves the cylinder 12 to a small pivot angle po-
sition = small oil volume consumption = high speed = low tractive power.
The maximum and minimum pivot angles are set by means of the stop screws 11 and 8 respectively.
7.28.7
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Sectional drawings of the regulating motor
4 Sectional drawings of the regulating motor

Fig. 4 Sectional drawing of the regulating motor
1 Powertrain with drive shaft 12 Cylinder

2 Motor housing 13 Control lens
3 Snap ring 14 Centre peg
4 Radial shaft seal ring 15 Conical piston
5 Back-up washer 16 Tuning disc (S = 3.50 – 4.00 mm)

6 O-ring 17 Pressure spring
7 O-ring 18 Return plate
8 Stop screw (Qmin) 19 Oval head screw
9 Seal-lock collar nut 20 End plate
10 O-ring 39 Tapered roller bearing
11 Stop screw (Qmax)
7.28.8
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20 End plate 37 Double pull-off plug

22 Control neck 202 Control piston / adjustment
23 Control bushing 203 Control piston
25 Pressure spring 205 Brake valve
26 Screw plug 206 Shuttle valve
27 Restriction screw 208 Pressure reduction valve
28 Restriction screw 209 Double stop valve
30 Restriction pin 211 Secondary pressure-relief valve, chassis,
forward left
32 Screw plug 212 Secondary pressure-relief valve,chassis,
reverse left
34 Cylinder pin 213 Secondary pressure-relief valve, chassis,
forward right
35 Double pull-off plug 214 Secondary pressure-relief valve, chassis,
reverse right
36 Screw plug

7.28.9
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Fig. 5 Sectional drawing of adjusting device
7.28.10
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Function of other integrated components
5 Function of other integrated components
5.1 Double stop valve 209
Fig. 6 Double stop valve 209

20 Housing / end plate 97 O-ring
91 Valve cone 209 Double stop valve, complete
92 Pressure spring
93 Valve seat A Pressure/return line connection
94 Valve cone B Pressure/return line connection
95 Pressure spring R Return line from brake valve
96 Screw plug U from/to powertrain and pressure control
5.1.1 Blocking functions, see Fig. 4 and see Fig. 5

As soon as pressure is applied to the operating connection A or B, the valve cone 91 closes the con-
nection to the respective other operating connection B or A respectively. The oil returning from the
brake valve 205 opens the valve cone 91, i.e. the oil can flow through the respective connection A or
B to the control valve block. The valve thus prevents a short circuit.
As soon as pressure is applied to the operating connection A or B, the valve cone 94 opens the con-
nection to the powertrain. The oil returning from the powertrain closes the valve cone 94, and thus
the direct connection to A or B respectively. The oil is thus fed through the brake valve 205 and is
restricted (slowed down).
7.28.11
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5.2 Brake valve 205
Fig. 7 Sectional drawing of brake valve 205
51 Brake piston 56 Restriction screw

52 Screw plug 57 Restriction pin
54 Washer 205 Brake valve, complete
5.2.1 Opening the brake piston (travel), see Fig. 3 and Fig. 7
The pressure oil from the pressurised side A or B flows via the double stop valve 209 to the control
lens of the travel motor and also acts on the brake valve 205. At the same time, the pressure at the
control is built up progressively at the control surface of the brake piston 51 through the control edge
S1 or S2 and the restriction screw 55/56. The brake piston 51 is pressed against the pressure spring
53, opening a connection between A or B and S.
The oil can now drain off through the respective return line (tank). The brake valve is now in normal
travel operation position.
5.2.2 Closing the brake piston (hydraulic braking)

If the pressure at connection A or B drops (e.g. when travelling downhill), the spring 3 presses the
brake piston 51 towards its brake position. The oil flow between A or B and S is gradually restricted,
preventing cavitation or overspeeding of the travel motor. When the travel movement is halted, the
pressure spring 53 pushes the brake piston 51 into its neutral position, thus immediately closing the
connection from A or B to S.
7.28.12
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5.3 Brake release valve 208
Fig. 8 Sectional drawing of brake release valve 208
82 Screw plug 85 Pressure spring

83 Control bushing 86 O-ring
84 Spool 87 Washer
85 Pressure spring
5.3.1 Releasing of multi-disc brake, see Fig. 3 and Fig. 8

If the travel motor is pressurised through connection A or B, a high pressure P is built up through the
shuttle valve 206 at the pressure reduction valve 208. The piston 84 is moved by oil flowing through
internal channels, so that the high pressure is fed via the control edge S3 (limited by pressure spring
15) to connection Bre and the hose, releasing the multi-disc clutch, (see “Technical data and settings”
on page 3).
If the high pressure P is increased (travel operation) at the connection A or B, the control bushing 83
is shifted against the pressure spring 85. The control bushing 83 seals the connection T to the tank.
The brake pressure (Bre) in the spring chamber of the pressure spring 85 further increases the spring

force of the pressure spring 85. The high pressure P, together with the surface ratio of the control
bushing 83 and the interaction between the spring force and the brake pressure keep the control
edge S3 constant while the brake is released.
If there is no pressure at connection A or B, the spring 85 presses the piston 84 and the control bu-
shing 83 into their normal position. The release pressure at the connection Bre is thus released di-
rectly via connection T and the internal restrictor to the tank.
The release pressure is created by the pressure reduction valve 208. This prevents inadvertent re-
lease of the multi-disc brake when the machine is standing still or is travelling.
5.4 Pressure-relief valve with suction function 211 - 214

5.4.1 Function and design

The secondary pressure-relief valves 211 - 214 are of the cartridge type and screwed directly into the
mounting plate of the regulating motor. They put a limit on the pressure between the oil motor and
the control valve block when the spools are closed (secondary function).
In the event of an undesirable pressure rise in the circuit of an attachment, it is the weakest point of
the circuit that would normally break, e.g. screwed connections or hydraulic hoses. In order to prevent
this, machines are equipped with a pre-determined breaking point. The pressure increase in the hy-
7.28.13
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MJFCIFSS
draulic system acts on a built-in pressure-relief valve. It limits the maximum pressure in the consumer
and its connection to the pre-set value. As the pressure valves in the hydraulic system must be able
to cater for large flows of oil, our machines are equipped with indirect (pilot-controlled) pressure-relief
valves for reasons of manufacture and better functioning. In these valves, a pressure-relief valve is
installed that works directly as a pilot control valve to actuate a second, larger valve.
5.4.2 Functional description

The pressure (P) built up in the consumer circuit acts on the front face of the main piston 221 and,
through the bore a on the rear surface of the main piston 221. At the same time, the pressure acts
also on the pilot control cone 222.
The pressure springs 229 and 223 push the main piston 221 and the pilot control cone 222 into their
closing positions (static status).
As soon as the pressure in the oil motor reaches a value above the adjusting value for the pressure
and adjusting spring 223 (due to external forces acting on the powertrain), the pilot control cone 222
is lifted from its seat and a little oil is released into the return channel (T1).
Due to the different cross-sections of the bores a in the main piston 221 and b in the rear section of
the housing 224 respectively, there is a pressure difference between the front and the rear side of the
main piston 221. As a result of this pressure difference, the main piston 221 is shifted against the
pressure springs 229, and a substantial amount of oil flows off to the non-pressurised return side (T2).
The pressure in the system drops, and the main piston 221 is again pushed against the sealing edge
at the front part of the housing 228. Furthermore, the adjusting spring 223 pushes the pilot control
cone 222 against the rear section of the housing 224, i.e. the connection between the pressurised
side and the return side (T1/T2) is closed.
5.4.3 Suction
If there is a vacuum in the high pressure connection A or B, the higher pressure of the low pressure
circuit acts on the ring face of the main piston 221. As a result of the pressure difference across the
effective surface of the main piston 221, it is pressed against the force of the pressure springs 229
so that the required amount of oil can flow through the bore A or B to the respective side of the con-
sumer.
7.28.14
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Fig. 9 Sectional drawing of the pressure-relief valve 211 - 214 Document is registered under: 1030314 - 29.01.2009
221 Main piston 228 Housing (front section)

222 Pilot control cone 229 Pressure spring
224 Housing (rear section) 231 O-ring
225 Protective cover 232 O-ring
226 Adjusting screw 233 O-ring
227 Lock nut
7.28.15
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Inspection, maintenance and adjustment
6 Inspection, maintenance and adjustment
6.1 Maintenance and repair works on oil motor
Note!
Hydraulic regulating motors are maintenance-free!
This hydraulic regulating motor has been pre-set by the manufacturer and must not be changed.
If you detect disturbances in connection with the motor, inspect the secondary protection system.
Proceed according to the adjustment protocol and general checking and adjustment instructions,
see group 3.
repair instructions "A6VE regulating motor".
Danger!
Danger areas: undercarriage - crushing hazard for mechanics, if machine unintentionally starts rol-
ling or if the chassis is moved.
X Park the machine on a level surface.
X If parked on a slope or off the road, secure the machine.
X Block the chassis by applying the parking brake.
X Place attachments on the ground.
X Contact operating personnel.
6.2 Checking oil motor for leakage

X Disconnect hose L leading from the connection T1 of the oil motor to the rotary connection at the
T-piece. Remove the hose and seal the open connection at the T-piece.
X Disconnect and seal the line 219 to the brake.
X Pressurise the regulating motor with maximum high pressure.

X Collect leak oil from the oil motor, using the hose L and a suitable and sufficiently large container.
X Determine how much leak oil you actually collected and compare to the max. admissible value.
(see “Technical data and settings” on page 3)
Oil motors producing too much leak oil should be replaced.
X After completed measurement, reconnect the hoses L and 219.
7.28.16
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Fig. 10 Leak oil check at the regulating motor
219 Brake hose from the oil motor to the multi- L Leak oil line
disc brake
T1 Leak oil connection at oil motor

7.28.17
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7.28.18
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Purpose
1 Purpose
The axial piston oil motor of the inclined axle type is inserted into the travel gear of the crawler exca-
vator (plug-in motor).
The travel motor propels the travel gear and, through the tumbler wheel, the chain.
The flow from the variable-displacement pump is fed through brake valve "Connection A or B" to the
oil motor and acts on the pistons of the powertrain. The pistons (moving in axial direction inside the
cylinder of the powertrain) act on the cylinder and drive shaft and generate an input torque.
The regulating and adjusting unit adjusts the pivot angle to the flow consumption of the oil motor (de-
pending on the operating pressure).
The variable flow consumption of the oil motor determines the torque and speed of the drive shaft.
Large flow consumption = large torque, low rpm, low speed

Small flow consumption = small torque, high rpm, high speed
The travel motor can be held by the machine operator at the maximum pivot angle position by means
of an electro-hydraulic mechanism (creeper gear).
.

Fig. 1 Regulating motor A6VE
7.29.1
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MJFCIFSS
7.29.2
Purpose
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MJFCIFSS
Service Manual
Purpose
1.1 Technical data
Machine R 313-LI TCD

Unit
Regulating motor Type A6VE 55 HA
Max. oil flow consumption cm3/rev 55
Max. torque Nm 349
Operating pressure bar 350
Max. leak oil l/min 8

Check measurement X.
Qmin Stop 8 mm approx. 15.5
Qmax Stop 11 mm approx. 15.5
Begin of regulation bar 150
End of regulation bar 160
Adjustment of brake release valve 208 bar 21+4
Begin of opening bar approx. 10
Secondary pressure-relief valves 211-214 bar 380 +20
Tab. 1 Technical data and settings

7.29.3
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Design
2 Design
The regulating motor 200/201 consists of two main components:

– Motor housing 2
– End plate 20
The regulating motor consists of the motor housing 2 with integrated powertrain 1. To the left and
right on the travel motor housing 2, you find the stop screws for Qmin 8 and Qmax. 11.
The motor housing 2 is equipped with a flange-mounted end plate 20. The end plate 20 includes the
powertrain adjusting device 202.
The brake valve 205, double stop valve 209 and the secondary pressure-relief valves 211-214 are
screwed into the end plate 20.
Fig. 2 Design of regulating motor
2 Motor housing 210 Begin of regulation / adjusting screw

8 Stop screw (Qmin) 211 Secondary pressure-relief valve, chas-

sis, forward left
11 Stop screw (Qmax) 212 Secondary pressure-relief valve, chas-
sis,reverse left
20 End plate 213 Secondary pressure-relief valve, chas-
sis, forward right
200 Travel motor, left 214 Secondary pressure-relief valve, chas-
sis, reverse right
201 Travel motor, right A Pressure/return line connection
202 Control piston / adjustment B Pressure/return line connection
205 Brake valve Bre Brake release connection
208 Brake release valve T1 Leak oil connection

209 Double stop valve X Control pressure connection / off-road
gear
7.29.4
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MJFCIFSS
Design
Fig. 3 Hydraulic diagram of regulating motors
50 from control oil unit 209 Double stop valve

195 Rotary connection 5x 210 Adjusting screw / begin of regulation
forward left
reverse left
201 Travel motor, right 213 Secondary pressure-relief valve, chassis,
forward right
202 Control piston / powertrain adjustment 214 Secondary pressure-relief valve, chassis,
reverse right
203 Spool 215 Travel brake
7.29.5
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Design
205 Brake valve 216 Travel gear

206 Shuttle valve S21 Switch (fast travel)
208 Brake release valve Y24 Solenoid valve (fast travel)
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see Fig. 4 and see Fig. 5
3.1 Powertrain
The pressure oil from the hydraulic pump is fed through the pressure connection A or B respectively
and through a kidney-shaped orifice in the control lens 13 to the cylinder 12.
Three bores of the cylinder 12 are connected to the pressure side of the control lens 13, and three
bores are connected with the return side. One bore is located at the dead centre, i.e. between the
pressure and suction phase.
The conical pistons 15 moving in axial direction inside the cylinder 12 are sealed by means of two
piston rings each. By applying oil under pressure onto the three piston surfaces, a radial force is cre-
ated at the conical pistons 15, in turn generating a output torque at the perimeter of the drive shaft 1.
In idle mode, and during start-up, the cylinder 12 is pressed by the pressure spring 17 mounted on
the centre peg 14 against the control lens 13. When the pressure increases, the cylinder 12 is balan-
ced in such a way that the oil film at the control surface of the cylinder 12 and the control lens 13 is
maintained at all times, even under high loads, and the amount of leak oil is reduced to a minimum.
The leakage oil lubricates the centre peg 14, the conical piston 15 and the tapered roller bearings 39
of the drive shaft.
3.2 Regulation / adjustment

The regulating motor is controlled depending on the preselected powertrain gear position.
– Off-road / working gear
The regulating motor is permanently operated at maximum flow consumption.
– Fast travel gear
The oil motor is automatically switched from min. flow consumption to max. flow consumption or
from max. flow consumption to min. flow consumption, depending on the high pressure level. If
the resistance of the travel gear drive is low, it might reach fast travel (max.) speed.

3.2.1 Off-road / working gear
The switch S21 for fast travel is not actuated.
The indicator lamp in the switch S21 is off.
The spool 203 is pressurised with control pressure through the solenoid valve Y24, the rotary con-
nection 196 and the connection X, so that it is held in controlling position. As a result, the spool 203
cannot be switched, even if the high pressure drops to a level below the begin of regulation, (see Tab.
1 on page3).
As a result, the operating pressure of the respective high pressure side A or B respectively acts th-
rough internal boreholes and the shuttle valve 206 in the end plate 20, the spool 203 and the restric-
tion pin 51 to the surface Fg of the control piston 202. The powertrain is permanently held by the
control piston 202 and the control neck 23 at its large pivot angle (Qmax) = large flow consumption
= high tractive power. This ensures smooth off-road travel of the vehicle.
3.2.2 Fast travel

The switch S21 for fast travel is actuated.
The indicator lamp in the switch S21 is on.
The solenoid valve Y24 connected to the switch S21 is powered, and the connection X of the end
plate 20 is bled through the rotary connection 196 and the solenoid valve Y24 of the control oil unit
7.29.7
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MJFCIFSS
to the tank.
The adjusting spring / begin of regulation 46 holds the spool 203 in position a, so that the travel pres-
sure acts on the surface Fk of the control piston 202. The powertrain is thus set to a small pivot angle
= low flow consumption = high speed = low traction. Simultaneously, the piston surface Fg of the con-
trol piston 202 is released through the spool 203 to the tank side.
If the travel pressure is increased to a value above the set begin of regulation pressure, see Tab. 1,
the spool is moved 203 against the pressure spring 46 in position b. As a result, the control edge of
the spool 203 is opened and the working pressure acts through the control bushing 44 on the piston
surface Fg of the control piston 21.
The control piston 202, through the control neck 23, moves the cylinder 12 to a large pivot angle po-
sition = high flow consumption = low speed = high tractive power.
The preload of the begin of regulation spring is adjustable with the adjusting screw 210 and must be
set according to the manufacturer instructions. The maximum and minimum pivot angles are set by
means of the adjusting screws 11 and 8 respectively.
4 Sectional drawings of the regulating motor

Fig. 4 Sectional drawing of the regulating motor
1 Powertrain with drive shaft 12 Cylinder

2 Motor housing 13 Control lens
3 Snap ring 14 Centre peg
4 Radial shaft seal ring 15 Piston
5 Back-up washer 16 Tuning disc (S = 3.50 – 4.00 mm)
6 O-ring 17 Pressure spring

7 O-ring 18 Return plate
8 Stop screw (Qmin) 19 Oval head screw
9 Seal-lock collar nut 20 End plate
10 O-ring 39 Tapered roller bearing
11 Stop screw (Qmax)
7.29.8
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Key to sectional drawing of adjusting device

20 End plate 67 O-ring
23 Control neck 70 Screw plug
43 Restriction pin 71 Double pull-off plug
44 Control bushing 74 Seal-lock collar nut
46 Pressure spring 202 Control piston / powertrain adjustment
47 Screw plug 203 Spool
48 Restriction screw 205 Brake valve, see Fig. 7
49 Restriction screw 206 Shuttle valve
53 Screw plug 208 Brake release valve
56 O-ring 209 Double stop valve, see Fig. 6
60 Allen head screw 210 Adjusting screw / begin of regulation
61 Allen head screw 211 Secondary pressure-relief valve chassis,
forward left
62 Allen head screw 212 Secondary pressure-relief valve chassis,
reverse left
63 Cylinder pin 213 Secondary pressure-relief valve chassis,
forward right
64 Screw plug 214 Secondary pressure-relief valve chassis,
reverse right
65 Screw plug 999 Seal kit
66 O-ring

7.29.9
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MJFCIFSS
Fig. 5 Sectional drawing of adjusting device
7.29.10
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MJFCIFSS
5 Function of other integrated components
5.1 Double stop valve 209
Fig. 6 Double stop valve 209

9
20 Housing / end plate 97 O-ring

91 Valve cone 209 Double stop valve, complete
92 Pressure spring
93 Valve seat A Pressure/return line connection
94 Valve cone B Pressure/return line connection
95 Pressure spring R Return line from brake valve
96 Screw plug U from/to powertrain and pressure control
5.1.1 Blocking functions, see Fig. 4 and see Fig. 5

As soon as pressure is applied to the operating connection A or B, the valve cone 91 closes the con-
nection to the respective other operating connection B or A respectively. The oil returning from the
brake valve 205 opens the valve cone 91, i.e. the oil can flow through the respective connection A or
B to the control valve block. The valve thus prevents a short circuit.
As soon as pressure is applied to the operating connection A or B, the valve cone 94 opens the con-
nection to the powertrain. The oil returning from the powertrain closes the valve cone 94, and thus
the direct connection to A or B respectively. The oil is thus fed through the brake valve 205 and is
restricted (slowed down).
7.29.11
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5.2 Brake valve 205
Fig. 7 Sectional drawing of brake valve 205
51 Brake piston 56 Restriction screw

52 Screw plug 57 Restriction pin
54 Washer 205 Brake valve, complete
5.2.1 Opening the brake piston (travel), see Fig. 3

The pressure oil from the pressurised side A or B flows via the double stop valve 209 to the control
lens of the travel motor and also acts on the brake valve 205. At the same time, the pressure at the
control is built up progressively at the control surface of the brake piston 51 through the control edge
S1 or S2 and the restriction screw 55/56. The brake piston 51 is pressed against the pressure spring
53, opening a connection between A or B and S.
The oil can now drain off through the respective return line (tank). The brake valve is now in normal
travel operation position.
5.2.2 Closing the brake piston (hydraulic braking)

If the pressure at connection A or B drops (e.g. when travelling downhill), the spring 3 presses the
brake piston 51 towards its brake position. The oil flow between A or B and S is gradually restricted,
preventing cavitation or overspeeding of the travel motor. When the travel movement is halted, the
pressure spring 53 pushes the brake piston 51 into its neutral position, thus immediately closing the
connection from A or B to S.
7.29.12
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5.3 Brake release valve 208
Fig. 8 Sectional drawing of brake release valve 208
A Version from start of series B Layout from change in series

81 Pin 85 Pressure spring
83 Control bushing 87 Washer
84 Spool 88 Threaded stud
85 Pressure spring 89 Collar nut

5.3.1 Releasing of multi-disc brake, see Fig. 3 and Fig. 8
If the travel motor is pressurised through connection A or B, a high pressure P is built up through the
shuttle valve 206 at the pressure reduction valve 208. The piston 84 is moved, so that the high pres-
sure is fed via the control edge S3 (limited by pressure spring 15) to connection Bre and the hose,
releasing the multi-disc clutch, (see “Technical data and settings” on page 3).
If the high pressure P is increased (travel operation) at the connection A or B, the control bushing 83
is pressed against the pressure spring 85. The control bushing 83 seals the connection T to the tank.
The brake pressure (Bre) in the spring chamber of the pressure spring 85 further increases the spring
force of the pressure spring 85. The high pressure P, together with the surface ratio of the control
bushing 83 and the interaction between the spring force and the brake pressure keep the control
edge S3 constant while the brake is released.
If there is no pressure at connection A or B, the spring 85 presses the piston 84 and the control bu-
shing 83 into their normal position. The release pressure at the connection Bre is thus released di-
rectly via connection T and the internal restrictor to the tank.
The release pressure is created by the pressure reduction valve 208. This prevents inadvertent re-
lease of the multi-disc brake when the machine is standing still or is travelling.
7.29.13
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5.4 Pressure-relief valve with suction function 211 - 214
5.4.1 Function and design

The secondary pressure-relief valves 211 - 214 are of the cartridge type and screwed directly into the
mounting plate of the regulating motor. They put a limit on the pressure between the oil motor and
the control valve block when the spools are closed (secondary function).
In the event of an undesirable pressure rise in the circuit of an attachment, it is the weakest point of
the circuit that would normally break, e.g. screwed connections or hydraulic hoses. In order to prevent
this, machines are equipped with a pre-determined breaking point. The pressure increase in the hy-
draulic system acts on a built-in pressure-relief valve. It limits the maximum pressure in the consumer
and its connection to the pre-set value. As the pressure valves in the hydraulic system must be able
to cater for large flows of oil, our machines are equipped with indirect (pilot-controlled) pressure-relief
valves for reasons of manufacture and better functioning. In these valves, a pressure-relief valve is
installed that works directly as a pilot control valve to actuate a second, larger valve.
5.4.2 Functional description

The pressure (P) built up in the consumer circuit acts on the front face of the main piston 221 and,
through the bore a on the rear surface of the main piston 221. At the same time, the pressure acts
also on the pilot control cone 222.
The pressure springs 229 and 223 push the main piston 221 and the pilot control cone 222 into their
closing positions (static status).
As soon as the pressure in the oil motor reaches a value above the adjusting value for the pressure
and adjusting spring 223 (due to external forces acting on the powertrain), the pilot control cone 222
is lifted from its seat and a little oil is released into the return channel (T1).
Due to the different cross-sections of the bores a in the main piston 221 and b in the rear section of
the housing 224 respectively, there is a pressure difference between the front and the rear side of the
main piston 221. As a result of this pressure difference, the main piston 221 is shifted against the
pressure springs 229, and a substantial amount of oil flows off to the non-pressurised return side (T2).
The pressure in the system drops, and the main piston 221 is again pushed against the sealing edge
at the front part of the housing 228. Furthermore, the adjusting spring 223 pushes the pilot control
cone 222 against the rear section of the housing 224, i.e. the connection between the pressurised
side and the return side (T1/T2) is closed.
5.4.3 Suction:
If there is a vacuum in the high pressure connection A or B, the higher pressure of the low pressure
circuit acts on the ring face of the main piston 221. As a result of the pressure difference across the
effective surface of the main piston 221, it is pressed against the force of the pressure springs 229
so that the required amount of oil can flow through the bore A or B to the respective side of the con-
sumer.
7.29.14
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Fig. 9 Sectional drawing of the pressure-relief valve 211 - 214 Document is registered under: 1030314 - 29.01.2009
221 Main piston 228 Housing (front section)

222 Pilot control cone 229 Pressure spring
224 Housing (rear section) 231 O-ring
225 Protective cover 232 O-ring
227 Lock nut
7.29.15
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Maintenance and repair
6 Maintenance and repair
Danger!
To carry out the maintenance and repair work, the worker must access the undercarriage. This can
be dangerous for mechanics.
X If parked on a slope or off the road, secure the machine.
X Block the chassis by applying the parking brake.
X Place attachments on the ground.
X Contact operating personnel.
6.1 Maintenance and repair works on oil motor
Note!
This hydraulic regulating motor has been pre-set by the manufacturer and must not be changed.
During all maintenance and repair work and if there are any malfunctions, the hydraulic regulating
motors must be checked for correct secondary protection settings. Always follow the instructions for
checking and adjusting work and the adjustment protocol, see group 3.
6.2 Repair of oil motor

repair instructions "A6VE regulating motor".
7 Inspection and adjustment

7.1 Checking and adjusting of begin and end of regulation
Note!
Varying begins of regulation between the regulating motors result in poor tracking. If this occurs,
check that the begins of regulation of the two regulating motors are identical and adjust them, if ne-
cessary.
X Release pressure from the hydraulic system.

X Connect the pressure sensor/gauge to the measuring point 45 (pump 20), see Fig. 10.
X Remove the two covers / travel drives at longitudinal member.
X Disconnect the line 219 from the brake release connection Bre of the regulating motors 200 / 201
and seal them.
X Remove the screw plug from the measuring connection M1, see Fig. 10.
X Screw in the screw coupling assembly M10x1 (tool no. 10 in group 2.01, with extension, if re-
7.29.16
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Inspection and adjustment
quired) and connect a pressure gauge / sensor.

X Start machine and preselect the speed step PP.
X Lift one drive side with the attachment and carefully pressurise the regulating motor of the lifted
side in fast travel gear with the pilot control unit (block status).
X High pressure builds up at the measuring point 45.
Below the begin of regulation of the motor,see Tab. 1, there may be no pressure build-up at
measuring connection M1. That means that the oil motor is at minimum pivot angle.
X Continue to accelerate the motor to the begin of regulation. Keep your eyes on the two pressure
gauges (at measuring points 45 and M1).
From the moment of begin of regulation, the pressure at the measuring connection M1 must
continue to rise (to about 1/2 high pressure value). The oil motor is adjusted towards the ma-
ximum pivot angle.
As soon as the high pressure (at measuring point 45) reaches the value of the end of regula-
tion (see Tab. 1), the value measured at the measuring point M1 increases suddenly to the
high pressure value, i.e. the pressures at measuring points 45 and M1 are identical.
Note!
and cannot be adjusted. This means that a change to the begin of regulation value automatically
results in a change to the end of regulation value.
If the pressure value for the begin of regulation does not correspond to the prescribed value, it can
be adjusted by means of the adjusting screw 210, see Fig. 10.
Caution!
The adjusting screw 210 for the begin of regulation is located opposite the pressure connections
Bre and X.
In some regulating motors, the adjusting screw for the brake release valve 208 is located near the
pressure connections Bre and X., see Fig. 2|. This screw is however intended exclusively for factory
adjustment.
X Therefore do not interfere with the brake release valve 208 as this could result in malfunctions
during travel operation.

X Release the adjusting screw 210 and loosen the lock nut.

X Turn the adjusting screw 210 in.
The begin of regulation is lowered (earlier begin)

X Turn adjusting screw 210 out.
The begin of regulation is increased (later begin)
X After completion of the adjustment, lock and secure the adjusting screw 210.
7.29.17
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Fig. 10 Measuring point for high pressure and actuating pressure with adjusting screw / begin of
regulation
20 Variable-displacement pump 210 Adjusting screw / begin of regulation

45 Measuring point LS 219 Brake release line
200 Travel motor, left M1 Measuring point / begin of regulation
201 Travel motor, right
7.2 Checking and adjusting the secondary pressure-release valves

X Connect the pressure sensor/gauge to the measuring point 45 (variable displacement pump).
X To check the secondary pressure-relief valves 211, 212, 213, 214 remove the two covers / travel
drives at the longitudinal member and disconnect the line 219 from the brake release connection
Bre from the regulating motors 200 / 201, see Fig. 11 and seal them.
X Check the secondary pressure-relief valves 211, 212, 213, 214 by actuating them to the max. stop
of the respective travel movement with the prescribed value, see Tab. 1, and adjust them, if ne-
cessary (measuring point 45).
X Loosen the lock nut (WS 17).
Increasing pressure
X Turn the adjusting screw clockwise, using an Allen key (WS 5).
The pressure is increased.
Reducing pressure
X Turn the adjusting screw counter-clockwise, using an Allen key (WS 5).
The pressure is reduced.
X After completion of the adjustment, secure the adjusting screw with a lock nut.
7.3 Checking oil motor for leakage

X Disconnect hose L leading from the connection T1 of the oil motor to the rotary connection at the
T-piece. Remove the hose and seal the open connection at the T-piece.
X Disconnect and seal the line 219 to the brake.
7.29.18
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X Pressurise the regulating motor with maximum high pressure.

X Collect leak oil from the oil motor, using the hose L and a suitable and sufficiently large container.
X Determine how much leak oil you actually collected and compare to the max. admissible value.
(see “Technical data and settings” on page 3)
Oil motors producing too much leak oil should be replaced.
X After completed measurement, reconnect the hoses L and 219.
Fig. 11 Leak oil check at the regulating motor
219 Brake hose from the oil motor to the multi- L Leak oil line
disc brake
Bre Brake release connection T1 Leak oil connection at oil motor

7.29.19
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MJFCIFSS
7.29.20
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MJFCIFSS
Service Manual Hydraulic cylinder
Function
Hydraulic cylinder
1 Function
The LIEBHERR hydraulic cylinders are primarily used as working cylinders for the movement of at-
tachments. Due to their design, they are classified as differential cylinders.
When hydraulic oil is fed to the piston side, the cylinder is extended; when oil is fed to the piston rod
side, the cylinder retracts.
The maximum forces of the cylinder depend on the size and shape of the effective surfaces
Extending Piston surface

Retracting Piston ring surface
and the max. admissible operating pressure, which is greater during extending than retracting. The
speed of the cylinder extending or retracting depends on the amount of oil fed per interval of time,
and on the surface. It is reciprocally proportional to the force, so that it is higher at retracting than at
extending.
LIEBHERR offers hydraulic cylinders for various fields of application that differ in stroke (length of ex-
tension), diameter (power) and cushioning system (end-of-travel cushioning).
Our machines are equipped with hydraulic cylinders with and without end-of-travel cushioning.
Note!
As the machines feature a great range of seals, guides, pistons and cushioning equipment, it was
not possible to cover all components in detail in the service manual. For details, please refer to the
ET spare parts catalogue and the delivery documents.

Fig. 1 Hydraulic cylinder
7.30.1
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MJFCIFSS
Hydraulic cylinder Service Manual
Description
2 Description
Hydraulic cylinders consist basically of a cylinder tube 10 with welded cylinder base and bearing bore,
a screwed-in piston rod bearing 13 (acting as cylinder head) and a piston rod 8 with bearing bore and
screwed-in piston 12.
To seal off the pressure chambers to the inside and outside, the cylinder is equipped with O-rings and
backing rings, as well as Glyd-Rimseal rings and Stepseal seal rings in the piston 12 and the piston
rod bearing 13. The scraper ring in the piston rod bearing 13 protects the piston rod 8 against dirt.
The guide rings on the piston 12 and in the piston rod bearing 13 guide the piston rod.
For a detailed description of the sealing elements of the piston 12 and the piston rod bearing 13, see
Fig. 3.
For further details concerning the piston see Fig. 16, the end-of-travel cushioning see Fig. 17 and the
stroke reductionsee Fig. 18.
Fig. 2 Exploded view of a hydraulic cylinder with various piston, cushioning and stroke shorte-
ning options.
1 Bushing 20 Hex head screw

2 Sleeve (stroke reduction as optional 25 Circlip
extra)
3 Piston (stroke reduction as optional extra) 31 Screw

4 Piston nut 32 Cushioning sleeve
8 Piston rod 33 Disc
9 Cushioning sleeve 34 Cushioning pin
10 Cylinder 35 Threaded bushing
12 Piston 60 Retaining washer
13 Piston rod bearing 65 Allen head screw
7.30.2
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MJFCIFSS
Description
15 Radial seal ring
Fig. 3 Sealing elements at the piston 12 and the piston rod bearing 13
9 Cushioning sleeve 125 Backing ring

12 Piston 126 Piston guide ring
13 Piston rod bearing 131 Guide ring
25 Ring 132 Backing ring
91 O-ring 133 O-ring
92 Seal ring 134 Scraper ring
121 Piston guide ring 135 O-ring
122 Turcon-Glyd ring 136 Rimseal ring (secondary protection)
123 O-ring 137 O-ring
124 O-ring 138 Turcon Stepseal (primary protection)
2.1 Cylinder variants, see Fig. 17 / Fig. 18

The uncushioned hydraulic cylinder (type I) is used mainly with supports and with certain (less fre-
quently used) cylinders for working attachments such as grapple and regulating cylinders, etc. and
for on-road travel.
Cushioned hydraulic cylinders can be equipped with one-side and two-side end-of-travel cushioning.
See type II (one-side) and/or type III and type IV (two-side).
Depending on the application, cylinders might be used in conjunction with stroke reduction. The stro-
7.30.3
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MJFCIFSS
ke can be reduced either by inserting a sleeve 2 (type G) on the piston side, or by inserting a piston
3 on the piston rod side (type H). Both methods result in the desired shortening of the piston stroke.
3.1 One-side end-of-travel cushioning
3.1.1 Extending piston rod 8

The hydraulic oil coming from the control valve block flows through the piston-side connection of the
cylinder 10 and acts on the piston 12. The piston rod is driven out and displaces the oil on the rod
side back through the control valve block to the tank.
Shortly before the end of the stroke is reached, the cushioning sleeve 9 is inserted into the cushioning
bore of the piston rod bearing 13.
When the cushioning sleeve 9 is introduced into the bore, the flow cross-section of the displaced oil
is reduced. The oil is fed from the hydraulic cylinder back to the control valve block. This happens
with the help of three splines sitting around the circumference of the sleeve 9.
The extending motion of the piston rod is slowed down, i.e. cushioned, thanks to the strong restriction
of the return oil flow.
3.1.2 Retracting piston rod 8

The hydraulic oil coming from the control valve block flows through the connection into piston rod be-
aring 13 and pushes against the front face of the cushioning sleeve 9 through the ring gap between
the cushioning sleeve 9 and the piston rod 8 and/or the piston rod bearing 13. Through the radial bo-
res and the splines in the cushioning sleeve 9, the oil acts on the piston 12.
The piston rod retracts and displaces the oil on the piston side through the connection bore and the
control valve block back to the tank.
Fig. 4 Sectional drawing of the hydraulic cylinder
7.30.4
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3.2 Two-side end-of-travel cushioning, see Fig. 5
3.2.1 Extending piston rod 8

The hydraulic oil coming from the control valve block flows through the connection into the piston side
of the cylinder and acts on the cushioning pin 31 and the piston 12 via the longitudinal slots.
The piston rod 8 is extended (see 3.1, page 4).
3.2.2 Retracting piston rod 8

The hydraulic oil coming from the control valve block flows through the connection into the piston rod
bearing 13 and acts on the front face of the cushioning sleeve 9 through the ring gap between the
cushioning sleeve 9 and the piston rod 8. The oil acts on the piston 12 through the radial bores and
splines in the cushioning sleeve 9.
The piston rod retracts and displaces the oil on the piston side back to the tank. Shortly before the
end of the stroke, the cushioning pin 31 is inserted into the base of the cylinder 10. When the cushio-
ning sleeve 32 enters the cushioning bore, the flow cross-section of the displaced oil is reduced. The
oil flows through two longitudinal slots arranged along the circumference of the sleeve 32 and/or the
pin 34 from the hydraulic cylinder back to the control block.
The retracting motion of the piston rod is slowed down i.e. cushioned, thanks to the strong restriction
of the return oil flow.
Fig. 5 Partial section of end-of-travel cushioning device Document is registered under: 1030314 - 29.01.2009
7.30.5
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MJFCIFSS
Removal and installation of hydraulic cylinders
4 Removal and installation of hydraulic cylinders
Caution!
The dismantling and installation of a cylinder requires lifting gear such as a crane and additional per-
sonnel.
When the cylinder is placed in its bearings, there is a risk of serious injury to hands and other limbs
that might become caught and crushed between the cylinder and other equipment parts. To prevent
accidents, the following precautionary measures must be taken:
X Drive the vehicle onto level and firm ground. Place the attachments and the support on the
ground. Ensure that the cylinder is stopped in a suitable position for removal and installation.
X Switch off the diesel engine. Relieve the hydraulic pressure from pressure lines. To do this,
switch on the ignition and the pilot control system and actuate the pilot control units several times
to the stop.
X Relieve the preload of hydraulic tank by loosening the breather filter at the tank.
X Secure the hydraulic cylinder by attaching it to lifting tackle. Secure other loose equipment, if ne-
cessary.
4.1 Dismantling
X Disconnect the flange connections of the hydraulic hoses. Collect the escaping oil in a suitable
container.
X If necessary, unscrew and remove the connection block with the pressure line from the piston rod
bearing and the cylinder base.
X Seal the lines and hoses with cover plates, screw caps, plugs etc.
Sealing work on the machine

X Release and drive out the bearing pin connecting the piston rod eye to the equipment. Pull out
stuck bolts using a special removal tool.
Complete dismantling
X Release and drive out both bearing pins from the piston rod and the cylinder tube. Pull out stuck
bolts using a special removal tool.
4.2 Installation
X Using lifting tackle, place the hydraulic cylinder into the bearing block so that the bearing bores in
the cylinder base and in the attachment component are aligned to each other.
X Slightly grease the bearing pin and drive/pull it in.
X Secure both bearing pins.
X Bleed hydraulic cylinder, see 4.3.

X Move the attachments / support to check their functions and tightness of the cylinder and the hy-
draulic connections.
7.30.6
copyright by
MJFCIFSS
Removal and installation of hydraulic cylinders
4.3 Bleeding cylinder after repair
4.3.1 Bleeding cylinder without bleeder bores
Caution!
After a repair of the cylinder, there is air trapped in the closed chamber. In connection with oil and
high pressure, this could result in explosive ignition ("diesel effect").
This poses a serious risk to persons and property. Therefore complete the following steps:
X When bleeding the cylinder, never extend/retract it to the stop (to prevent maximum pressure
build-up).
X When connecting the pressure lines and tightening the screw connections, ensure that they are
air-tight.
X To accomplish this, connect the hose on the piston side. Completely extend cylinder slowly and
carefully, at low idle rpm, so that the air on the rod side can escape completely from the cylinder.
Collect escaping oil in a suitable container.
X When the cylinder is fully retracted, connect the line to the piston rod.
X Extend and retract the cylinder several times slowly and carefully, at low idle rpm, so that the re-
maining air in the cylinder can escape towards the tank.
X Re-tighten all the lines. Check the screw connections of the flanges for correct torque.
4.3.2 Bleeding of cylinders with integrated bleeder plug, see Fig. 6
Caution!
The cylinder is under pressure.
When you loosen and unscrew the plug 11, it is possible that residual pressure in the line pushes
out the plug with great force, which can result in serious injury.
X Therefore carefully loosen the plug and release the oil pressure (collect oil in suitable container).
X Unscrew the plug 11. (New versions of this design have separate bleeder valves to which an oil

discharge hose can be connected.)
X Insert a mini measuring connection with an oil discharge hose into the bleeder bore and keep a
suitable collecting container ready.
X Completely extend the cylinder slowly and carefully at low idle rpm.
A mixture of air and oil escapes through the hose into the container.
X Remove the mini measuring connection.
X Be sure to properly replace plug after bleeding (torque: 40 Nm).
Fig. 6 Bleeder screw at the hydraulic cylinder
7.30.7
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MJFCIFSS
Replacing seals
5 Replacing seals
Fig. 7 Partial section of the hydraulic cylinder
4 Piston nut 33 Disc

8 Piston rod 121 Piston guide ring
9 Cushioning sleeve 122 Turcon-Glyd ring
12 Piston 123 O-ring
13 Piston rod bearing 124 O-ring
20 Hex head screw 125 Backing ring
25 Snap ring 126 Piston guide ring
5.1 Dismantling
Note!
To disassemble and assemble the piston nut 4 and the piston 12, you need great force. Inadvertent
rotation of the piston rod 8 can lead to damage to the chromium surface finish. To prevent this, com-
plete the following steps:
X Lock the piston rod 8 using a suitable clamping or anti-torsion device.

X Avoid damaging the surface of the piston rod.
X Unscrew the hex head screw 20 with washer 33. Pull the piston rod bearing 13 together with the
piston rod 8 and the piston 12 from the cylinder.
X Place the piston rod on a suitable and clean surface to prevent damage.
X Remove the piston guide rings 121.
X Remove the snap ring 25. Unscrew the piston nut 4 (if any).
X Attach a piston spanner and other special tools (see group 2.05) to the piston 12 . Remove the
piston from the piston rod 8.
X Hydraulic cylinders with end-of-travel cushioning: Remove the cushioning sleeve 9.
X Remove the piston rod bearing 13 from the piston rod 8.

X Remove all sealing elements from the piston, the piston rod bearing and the cushioning system.
7.30.8
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MJFCIFSS
Replacing seals
5.2 Assembly of sealing and guide elements on the piston
5.2.1 Installation in piston rod bearing

X Carefully remove all dirt, dust, chips and other foreign matter from the parts.
X Check all parts for suitability for reuse.
X Parts that show damage to the piston rod such as dents and grooves must be replaced.
X Treat the seal housings with Castrol-Tarp corrosion inhibitor (40g tube - ID no. 830005).
X Apply a little oil to the O-ring 135 / 137 and insert it in the piston rod bearing 13. Apply a little oil
to the seal rings 136 and 138 and insert them into the piston rod bearing 13, see Fig. 10 and Fig.
11.
.
Note!
Ensure that the seal rings 136 and 138 are installed in the correct position and direction (see flow
direction of pressurised oil). Pay attention to the different features of the various seals:
• Turcon - Rimseal 136 (dark grey or turquoise) secondary- flexible - like rubber
• Turcon - Stepseal 138 (light grey) primary, see Fig. 10
Fig. 8 Pressing seal and scraper ring into kidney shape ring for assembly
13 Piston rod bearing 137 O-ring

135 O-ring 138 Turcon Stepseal (primary protection)
136 Rimseal Ring (secondary protection)
X Press Stepseal / Rimseal into kidney shape, avoiding kinking.

X Place the pressed Stepseal / Rimseal over the O-ring 135 / 137 and press it into the groove, in the
direction of the arrow, see Fig. 10.
X Compress and place the scraper ring 134 in the same fashion and insert it in its correct position,
see Fig. 10.
5.2.2 Installing the piston rod bearing

Caution!
For certain piston guide designs, (see Fig. 9, page 10) use a mounting sleeve c (in the ET catalogue,
included with no. 960) for the installation of the piston guide bearing 13.
If this installation aid is not used, the sealing elements in the piston rod bearing 13 get damaged.
X Screw the mounting sleeve c to the piston rod 8.
X Slide the piston rod bearing 13 over the mounting sleeve c onto the piston rod 8.
X Remove the mounting sleeve c.
7.30.9
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MJFCIFSS
Replacing seals
Fig. 9 Mount the piston rod bearing using the mounting sleeve for special piston rod shapes
c Mounting sleeve, see tools in group 2.01 / 8 Piston rod

2.12
13 Piston rod bearing
X Slide the cushioning sleeve 9 (not required for hydraulic cylinders without end-of-travel cushio-
ning) onto the piston rod 8.
7.30.10
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MJFCIFSS
Replacing seals
Note!
)
Distinguishing features of the seal rings 136 / 138. The various shapes of the Rimseal 136 are
shown here in comparison to the Stepseal 138 ring (see Fig. 10).
Fig. 10 Distinguishing features of seal rings
136 Rimseal ring s Flange - inclined

138 Stepseal ring g Flange - straight
• Colour Rimseal 136 => dark grey - polished or turquoise (new)

Stepseal 138 => light grey - matt
• Elasticity Rimseal 136 => flexible

Stepseal 138 => rigid
• Shape Rimseal 136 => flange inclined
Stepseal 138 => flange straight
5.2.3 Mounting to piston
Note!
The Turcon-Glyd ring 122 must be expanded before mounting and then returned to its normal sha-
pe, as it can otherwise not be slid over the outer edge and into the groove.
X To facilitate installation, we recommend to heat the Turcon-Glyd ring 122 in a water or oil bath
(approx. 60°C).
X Apply a little oil to the O-ring 125 and the Turcon-Glyd ring 122 and place them onto the piston 12,
using the mounting sleeve b and the expanding sleeve b (for special tools, see group 2.05).
X After installation, return the Turcon-Glyd ring 122 to its original shape, using the piston tightening
strap.
X Insert the first backing ring 125, the O-ring 124 and the second backing ring into the piston 12.
X Apply Castrol Tarp to the internal piston chamber.
7.30.11
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MJFCIFSS
Mounting of the cylinder after replacement of the seals
Fig. 11 Mounting of sealing and guide elements to the piston, using the mounting sleeve a and
expanding sleeve b
a Mounting sleeve 121 Piston guide ring

b Expanding sleeve 122 Turcon-Glyd ring
9 Cushioning sleeve 123 O-ring
12 Piston 124 O-ring
13 Piston rod bearing 125 Backing ring
6 Mounting of the cylinder after replacement of the seals

6.1 Mounting of the piston and the piston nut onto the piston rod
X Carefully clean all contact and thread faces between the piston rod, the piston and the piston nut.
Apply a thin layer of Gleitmo 800 lubricant (ID no. 8300004) to both sides (see fuels and lubricants
group 1.50).
Note!
If components are mounted without having been treated with lubricant, the turning distance prescri-
bed according to factory standard 4121 cannot be achieved.
As the parts tend to become jammed (seizing), it is also not possible to remove the component at a
later stage.
X Apply Gleitmo 800 lubricant (ID no. 8300004) to all components.
X Screw the piston 12 onto the piston rod 8.

X Attach a piston wrench or special tool (see group 2.05) to the piston 12.
7.30.12
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MJFCIFSS
Note!
Mount the piston and the piston nut following the instruction in the factory standard 4121 B in group
1.22.
The drawing number and the date of assembly are engraved on the cylinder. The factory standard
4121-095 is specified in the hydraulic cylinder list, see group 7.31 – 7.37. This information is engra-
ved on all newly manufactured pistons.
X Tighten the piston 12 to the piston rod 8 according to the installation instructions, see group 1.22.
X Remove the piston wrench.

X Screw the piston nut 4 onto the piston rod 8.
X Tighten the piston nut 4 to the piston rod, using a suitable piston nut wrench and following the in-
stallation instructions, see group 1.22.
X Remove the piston nut wrench.
X Secure the piston nut 4 with a snap ring 25 (drill new hole, if necessary).
6.2 Mounting the cushioning sleeve 32
Cylinder with two-side end-of-travel cushioning, see Fig. 12

X Clean the thread of the screw 31 (remove all grease).
X Apply Loctite no. 270 to the thread of the screw 31. Apply Gleitmo 800 to the shank.
X Secure the sleeve 32 with the screw 31 to the piston rod 8 (torque: 130 Nm).
Fig. 12 Mounting the piston-side cushioning sleeve
8 Piston rod 121 Piston guide ring

31 Screw 126 Piston guide ring
32 Cushioning sleeve
7.30.13
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MJFCIFSS
6.3 Mounting the piston rod in the cylinder tube

X Place the inside piston guide straps 121 (hard) and the outside straps 126 (soft) on the piston 12.
Note:
For perfect piston assembly, we offer special calibrating sleeves (mounting sleeves, see group
2.05, 2.12 for a number of piston sizes.
X Place the piston tightening strap and/or the mounting sleeve on the piston 12. Gently tighten the
guide rings 121 and 126 to the piston.
X Push the piston rod 8 (complete with piston 12) carefully into the cylinder 10.
X Remove the piston tightening strap and/or mounting sleeve.
6.4 Mounting the piston rod bearing 8 (plug-in type)
Fig. 13 Installation of piston rod bearing
10 Cylinder tube 33 Disc

13 Piston rod bearing 132 Backing ring
20 Screw 133 O-ring
Mount the slightly oiled O-ring 133 and the backing ring 132. Observe the installation position of the
backing 132 and the O-ring 133 (concave).
X Push the piston rod bearing 13 into the cylinder 10. Observe the positions of the hydraulic con-
nections.
X Screw in the hex head screw or socket screw 20 (with washer 33, if any).
6.5 Mounting the piston rod bearing 8 (screw-in type)

X Attach the assembly wrench (special tool group 2.12) to the piston rod bearing 13.
Note!
Mount the piston and the piston nut following the instruction in the factory standard 4122 B in group
1.22.
The factory standard 4122-017 is specified in the hydraulic cylinder list, see group 7.34 – 7.36. This
information is engraved on all newly manufactured pistons.
X Tighten the piston rod bearing13 in the cylinder tube 10, following the instructions, see group
1.24.
7.30.14
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MJFCIFSS
Piston rod bearing types
Fig. 14 Assembly wrenches for screw-type piston rod bearings
8 Piston rod 13 Piston rod bearing

10 Cylinder tube
7 Piston rod bearing types
Fig. 15 Piston rod bearing types

D Piston rod bearing 13, plug-in type

E Piston rod bearing 13, screw-in type
7.30.15
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MJFCIFSS
Piston types on hydraulic cylinders
8 Piston types on hydraulic cylinders
Fig. 16 Piston types 12
A Piston 12 secured with piston nut

B Piston 12 with integrated piston nut
7.30.16
copyright by
MJFCIFSS
End-of-travel cushioning
9 End-of-travel cushioning
Fig. 17 Options for end-of-travel cushioning and stroke reduction
Option I without end-of-travel cushioning

Option II one-side end-of-travel cushioning

Option III two-side end-of-travel cushioning
(old)
Option IV two-side end-of-travel cushioning
(new)
9 Cushioning sleeve 34 Cushioning pin

31 Screw 35 Threaded bushing
7.30.17
copyright by
MJFCIFSS
Stroke reduction
32 Cushioning sleeve
10 Stroke reduction
Fig. 18 Cylinder with stroke reduction
Option G Stroke reduction with sleeve 2

Option H Stroke reduction with piston 3
7.30.18
copyright by
MJFCIFSS
Service Manual Hydraulic double plunger cylinder
Design
Hydraulic double plunger cylinder
1 Design
The LIEBHERR double plunger cylinder is used as a working cylinder to move the ditch cleaning /
swivel bucket.
The hydraulic cylinder consists of the following main components:
– The cylinder 20 inserted in the ditch cleaning / swivel bucket 10.
– The piston rod 8 connected through the swivel bearing 70 to the bearing block 60.
Fig. 1 Hydraulic double plunger cylinder in a ditch cleaning bucket
8 Piston rod 70 Swivel bearing

10 Ditch cleaning / swivel bucket 72 Double check valve
20 Cylinder 74 Hydr. connections from AS1 control block
60 Bearing block 76 Hydr. connections to bearing block
The pressure chambers are sealed with Zurcon seal rings in the cylinders 20. The scraper ring in the
cylinder 20 protects the piston rod 8 against dirt. The guide rings 50 guide the piston rod 8 during
movement. For more details regarding the sealing elements, see Fig. 3.
Hydraulic oil if fed to the right side of the piston rod 8, pushing the cylinder to the right and swivelling
the bucket to the right. Hydraulic oil if fed to the left side of the piston rod 8, pushing the cylinder to
the left and swivelling the bucket to the left.
The velocity and the force of the extending cylinder (at constant oil flow and pressure) are the same
7.32.1
copyright by
MJFCIFSS
Hydraulic double plunger cylinder Service Manual
for both movements.

To ensure that there is no leak oil escaping from the extended cylinder, the return oil is fed through
the hydraulically operated double check valve 72. The oil fed through the bearing block 60 opens the
double check valve 72, so that the return oil from the cylinder 20 can flow back to the control block.
The pressure-relief valves in the double check valve 72 act as secondary safety devices.
When the button S5L or S5R for swivelling the bucket is actuated, the oil flows from the additional
control block AS1 connection A02 / B02 through lines to the bucket (see also group 16.42).
The oil in the hydraulic circuit AS1 pressurises the double check valve 62 connection V1-C1 or V2-
C2, through the boreholes in the screw-mounted bearing block 60 and the boreholes in the piston rod
of the cylinder 20.
The pressure in the cylinder 20 pushes the bucket connected to the cylinder 20 outwards and swivels
the bucket around its fulcrum.
The return oil from the other cylinder side (retracting cylinder) is fed through the bearing block 60, the
open double check valve 72 and the lines to the additional control block AS1.
7.32.2
copyright by
MJFCIFSS
Exploded view of hydraulic double plunger cylinder
3 Exploded view of hydraulic double plunger cylinder

Fig. 2 Exploded view of double plunger cylinder
1 Hydraulic cylinder, complete 60 Bearing block

8 Piston rod 70 Swivel bearing
20 Cylinder 72 Double check valve
30 Scraper ring 801 Corrosion inhibitor
40 Zurcon-L ring 999 Seal kit
50 Guide ring
7.32.3
copyright by
MJFCIFSS
Sectional drawing of hydraulic double plunger cylinder
4 Sectional drawing of hydraulic double plunger cylinder
8 Piston rod A1 Oil supply to cylinder / right

10 Bearing pipe / bucket A2 Oil supply to cylinder / left
20 Cylinder C Section through oil supply line
30 Scraper ring D Section through oil supply line
40 Zurcon-L ring E Section through bearing block fixture
50 Guide ring F Section through bearing block fixture
60 Bearing block V1 Retracted cylinder
V2 Extended cylinder
7.32.4
copyright by
MJFCIFSS
Sectional drawing of hydraulic double plunger cylinder

Fig. 3 Sectional drawing of hydraulic double plunger cylinder
7.32.5
copyright by
MJFCIFSS
Removing / installing double plunger cylinder
5 Removing / installing double plunger cylinder
Caution!
When the cylinder is removed from or installed in its bearings, there is a risk of serious injury to
hands and other limbs that might become caught and crushed between the cylinder and other
equipment parts. To prevent accidents, the following precautionary measures must be taken:
X Drive the vehicle onto level and firm ground. Place the bucket on the ground. Ensure that the
cylinder is stopped in a suitable position for removal and installation.
X Switch off the diesel engine. Release the hydraulic pressure from the pressure lines. To do this,
switch on the ignition and the pilot control system and actuate the pilot control units several times
to the stop.
X Release the preload pressure of the hydraulic tank by loosening the breather filter at the tank.
X Secure the swivel bearing by attaching it to lifting tackle. If necessary, secure the bucket.
5.1 Dismantling, see Fig. 4

X Remove the hydraulic hoses from the double check valve 62 and collect the escaping oil in a sui-
table container with the necessary capacity (as piston rod 8 will be moved).
X Move the piston rod 8 to the stop.
X Remove the snap rings 93 and the shims 92.
X Remove the plug 67 of the inlet bore 10a at the bearing pipe / bucket.
X By moving the swivel bearing 70 , move the bearing block 60 with the piston rod 8 in the cylinders
20 in axial direction until the 1st Allen head screw 62 is aligned with the access bore 10a.
X 1. Remove the Allen head screw 62, and move the piston rod 8 further in axial direction to the next
Allen head screw 62 to be removed, etc.
X Pull out the pin 90 between the two tabs 90 and the bearing block 60. If necessary, use a special
removal tool to pull out the pin 90.
X Remove the flanges with hoses from the bearing block 60.
X Remove the bearing block 60 and the seal 66 (roll pins 61 remain in the piston rod 8).
Note!
The locking mechanism of the cylinders 20 in the bearing pipe / bucket comes in two versions:
– With small buckets, one cylinder 20 is locked with a spacer 110 at the pipe end, and the other
cylinder 20 is locked with a locking bolt 82.
– With large (wide) buckets, the two cylinders 20 are locked with a locking bolt 82.
X Release the locking bolt 82 and remove it from the bearing pipe/bucket.
X Remove the seal cover 80.
X Through the access borehole 10b on the bearing pipe /bucket, push the following parts from the
bearing pipe / bucket: cylinder 20, piston rod 8, cylinder 20 and spacer 110 (if installed).
X Carefully place the piston rod 8 on a clean surface and reseal the cylinder 20, if necessary, see 6.
7.32.6
copyright by
MJFCIFSS
5.2 Installation, see Fig. 4

X Clean the inside of the bearing pipe / bucket.
X Insert the spacer 110 (for small buckets) or a bearing bolt 82 (for wide buckets) in the bearing pipe
/ bucket.
X Mount the complete hydraulic cylinder and push it into the bearing pipe / bucket to the stop at the
spacer of bolt.
X Place the seal kit 66 on the bearing pipe / bucket.
X Insert the seal rings 64 in the piston rod 8.
X Ensure that the roll pins 67 are correctly inserted in the baring block 60.
X Place the bearing block 60 in the correct position on the piston rod 8 (observe correct position of
the seal rings 64).
X Move the piston rod in axial and radial direction until the 1st through-hole for the Allen head screws
62 is in line with the access borehole 10a.
X 1. Insert and tighten the 1st Allen head screw 62, and move the piston rod 8 further in axial direc-
tion to the next Allen head screw 62 to be tightened, etc.
Tighten all screws according to the factory standard, see group 1.20.
X Seal the access borehole 10a with the plug 65.
X When the piston rod 8 is in one of its maximum positions, apply a little grease to the pin 91 and
drive it in between the two tabs 90 and the bearing block 60.
X Insert the shims 91 and the snap rings 93.
X Reconnect the flanges with hoses to the bearing block 60.
X Connect the hydraulic hoses from the double check valve 72 to the bearing block 60 according to
the relevant instructions, see 5.3.
X Bleed the hydraulic cylinders, see 5.3.
X Apply maximum pressure to both cylinders 20 (max. working pressure) to test them for leakage.
X Preload the seal 66 with the pressure spring 67:
If the spring preload settings are adjusted correctly with the clamping bolt 68 , the seal is pu-

shed in all positions against the bearing pipe / bucket.
Note!
When working in water or mud, there is a risk that dirt collects in the bearing pipe / bucket, even if
the seal 66 is in its correct position. During the winter time, the sliding face between the seal and
the bearing pipe might freeze tight.
X If this occurs, clean / flush the bearing pipe ,see 5.4.
X To prevent seizing, apply Gleitmo 900 to the sliding face of the seal and the bearing pipe, see
group 1.50.
7.32.7
copyright by
MJFCIFSS
1 Hydraulic cylinder, complete 67 Plug

10 Ditch cleaning bucket 70 Swivel bearing
10a Access borehole / screws 72 Double check valve
10b Access borehole / spacer / cylinder 80 Lid
60 Bearing block 82 Locking bolt
61 Roll pin 90 Tabs
62 Allen head screw 91 Pin
63 Seal ring 92 Shim
64 Pressure spring 93 Snap ring
65 Clamping screw 110 Spacer
66 Seal
7.32.8
copyright by
MJFCIFSS
Fig. 4 Assembly and dismantling of the double plunger cylinder
5.3 Bleeding cylinder after repair

Caution!
After a repair of the cylinder, there is air trapped in the closed chamber. In connection with oil and
high pressure, this could result in explosive ignition ("diesel effect").
This poses a serious risk to persons and property. To prevent this, complete the following steps:
X When bleeding the cylinder, never extend/retract it to the stop (to prevent maximum pressure
build-up).
X When connecting the pressure lines and tightening the screw connections, ensure that they are
7.32.9
copyright by
MJFCIFSS
air-tight.
X Connect the hose and completely extend one cylinder slowly and carefully, at low idle rpm, so that
the air at the other cylinder can escape completely. Collect escaping oil in a suitable container.
X When the cylinder is fully extended, connect the other line.
X Extend and retract the cylinder several times slowly and carefully, at low idle rpm, so that the re-
maining air in the cylinder can escape towards the tank.
X Re-tighten all the lines. Check the screw connections of the flanges for correct torque.
X Now fully pressurise the two cylinder (maximum pressure).
5.4 Maintenance
The bucket maintenance is limited to regular lubrication of the bearing of the bucket and the swivel
bucket. The cylinder does not require any maintenance.
In connection with certain applications, dirt might enter the bearing pipe / bucket near the cylinder,
despite proper preloading and position of the seal 66. In this case, we recommend flushing / cleaning
the system as follows:
X Remove the plug 67.
X Screw off the plug 68 (G1/2“) from the seal 68 and connect the adapter for the water hose and
then connect the water hose.
X Flush the inside of the pipe with water.
X Swivel the bucket several times to remove the dirt from the inside of the pipe.
X After cleaning is completed, disconnect the water line and replace the plug 67 / 68.
Fig. 5 Sealing of bearing pipe
66 Seal 68 Plug
67 Plug
7.32.10
copyright by
MJFCIFSS
Replacing seals
6 Replacing seals
Note!
When dismantling and installing the piston rod 8 , handle the part with great care as the chromium
surface could easily be damaged. Such damage could lead to leakage.
X Avoid damaging the surface of the piston rod.
6.1 Dismantling
X Remove the cylinder 20 with the piston rod 8 from the swivel bucket, see 5.
X Pull the cylinders 20 on both sides from the piston rod 8.
X Remove the scraper ring 30 from the cylinder 20.
Caution!
As it is somewhat difficult to remove the Zurcon seal ring 40 , there is a risk of damage to the groove
faces in the cylinder, which in turn can lead to leakage after installation of the new seal ring 60.
X Do not attempt to remove the seal ring 60 from the groove with a sharp-edged tool.
X Carefully insert a pin-type tool (e.g. tack) into the seal ring 60 and lift it from the cylinder 20.
X If necessary, remove the guide rings 50 from the cylinder 20.
6.2 Assembly
X Carefully remove all dirt, dust, chips and other foreign matter from the parts.
X Check all parts for suitability for reuse.
X Parts that show damage to the piston rod such as dents and grooves near the seal must be re-
placed.
X Treat the seal housings with LIEBHERR corrosion inhibitor (Tarp 40g tube - ID no. 830005).

X Apply a little grease to the guide rings 50 and insert them into the cylinder 20.
Note!
Incorrectly installed seal rings can cause leakage at the cylinder seal.
X Observe correct position for installation (direction of pressure!) of the seal ring 40!
X Apply a little oil to the seal ring 40 and squeeze it together, see Fig. 7, avoiding kinking.
X Insert the seal ring 40 into the cylinder 20.
X Squeeze and place the scraper ring 30 in the same fashion, see Fig. 7, and insert it in its correct
position, see Fig. 6.
7.32.11
copyright by
MJFCIFSS
Replacing seals
Fig. 6 Detailed drawing
8 Piston rod 40 Zurcon-L ring

10 Bearing pipe / ditch cleaning bucket 50 Guide ring
20 Cylinder A1 Oil supply to cylinder / right

30 Scraper ring A2 Oil supply to cylinder / left
.
Fig. 7 Installation of sealing rings
20 Cylinder 40 Zurcon Z ring (secondary protection)

30 Scraper ring
7.32.12
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MJFCIFSS
Replacing seals

7.32.13
copyright by
MJFCIFSS
Replacing seals
7.32.14
copyright by
MJFCIFSS
Service Manual Control oil unit
Design
Control oil unit
1 Design
The control oil unit 50 generates the control pressure for the pilot control system as well as the regu-
lating pressures for the working pump and for the travel drive. It also generates the control pressures
for the actuation of the oscillating axle support, the creeper gear, the multi-disc brake of the slewing
gear and the fast travel gear, see 2.2.
The control oil unit 50 consists of a housing block with integrated oil channels and screwed-in valves.
The pressure-relief valve 51 is inserted at the front of the unit.
At the top of the unit, the solenoid valves Y3, Y24 and Y7 / Y371 are integrated into the block. The
measuring points 49, 57 and 59 and the accumulator 54 are secured with screw connections to the
top of the unit.
The pressure filter 52 is screwed into the base of the unit beside the proportional solenoid valves Y50
and Y353. The control oil block also features an integrated check valve 53.
Fig. 1 Control oil unit and diagram
49 Measuring point / control pres- 57 Measuring point travel servo pressure

sure
50 Control oil unit 59 Measuring point (power control)
51 Pressure-relief valve Y3 Solenoid valve / servo release
52 Pressure filter Y7 Solenoid valve / slewing gear brake (track machi-
nes only)
53 Check valve Y24 Solenoid valve / creeper gear clutch (wheel machi-
nes only)
Solenoid valve / fast travel clutch (track machines only)
7.42.1
copyright by
MJFCIFSS
Control oil unit Service Manual
Design
54 Accumulator Y50 Proportional solenoid valve / power control

55 Dummy plate Y353 Proportional solenoid valve / travel (wheel machi-
nes only)
56 Dummy plate Y371 Solenoid valve / oscillating axle support (wheel
machines only)
1.1 Arrangement of measuring points

Stationary measuring points 49, 57 and 59 are provided for the measurement of the pressures in the
control oil unit.
Measuring point 49
At this point, the current pilot pressure of the entire pilot control system is measured. For instructions
on how to check pressures see main group 3.
Measuring point 57
At this point, the control pressure for automotive travel produced by the solenoid valve Y353 is
measured. For details, see group 8.80.
(Measuring point 57 is omitted in machine R 313 / R317).
Measuring point 59
At this point, the control pressure for the power regulation generated by the solenoid valve Y50 is
measured, see also the basic values and power adjustments in the groups "Adjusting protocols" 3.
and "Pump description" 7.10.
7.42.2
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MJFCIFSS
2.1 Generation of servo pressure

The control oil unit is supplied with oil via the connection P from the gear pump / pilot control system.
The unit contains a pressure relief valve 51 of the cartridge type that is screwed into the unit. It limits
the control pressure to a certain value (see adjustment protocols, group 6).
The oil flows through the filter 52 and the check valve 53 to the accumulator 54.
The accumulator 54 allows for a small number of control operations - after the diesel engine has been
switched off or when the gear pump fails.
2.2 Function of the solenoid valves

Through internal pressure channels in the control oil unit, the pressure oil acts also on the solenoid
valves Y3, Y7 / Y371 and Y24.
The solenoid valves are actuated by the operator with the respective switches; for details, see elec-
trical system.
When switched, the solenoid valves Y3, Y24 and Y7/Y371 provide control pressure to the outlets A1,
A2 and A3. In neutral position, the outlets are connected to the tank.
The solenoid valve Y3 isolates the servo control or releases the control pressure for the pilot control
units through the connection A1.
Through the connection A2, the solenoid valve Y24 controls the transmission for the creeper gear of
the regulating travel control (wheel models) or the switching valve integrated into the control valve
block (track models).
In track models, the solenoid valve Y7 pressurises the multi-disc brake in the slewing gear through
the connection A3. In wheel models, the solenoid valve Y371 controls the oscillating axle support th-
rough the connection A3.
2.3 Function of the proportional solenoid valves Y50 / Y353 Document is registered under: 1030314 - 29.01.2009
The proportional solenoid valves Y50 and Y353 are pressurised through internal pressure channels
in the control oil unit.
The proportional solenoid valves Y50 for the performance control of the working pumps and Y353 for
the automatic travel drive produce a pressure that their outlets that is controlled by the actual electri-
cal current through the coils.
The outlet "LR" of the solenoid valve Y50 is connected to the connection "GLR", which is the pres-
sure connection for the performance control of the working pumps.
The proportional solenoid valve Y353 regulates the control pressure p(LD), which determines the tra-
vel speed. This pressure is applied to the connection P of the solenoid valve Y62 / 63 (forward / re-
verse travel) and thus pressurises the travel spool in the control block, irrespective of the current to
the proportional solenoid valve Y353; see also travel control in group 8.80.
(Proportional solenoid valve Y353 is omitted in machine model R 313 / R 317).
7.42.3
copyright by
MJFCIFSS
Characteristic of the proportional solenoid valve Y50
3 Characteristic of the proportional solenoid valve Y50
Fig. 2 Regulation diagram
The regulation characteristic illustrates the interrelation between the input current (I) of the regulating
solenoids and the regulating pressure (p) at outlet LR.
The effect of the pressures p at the outlet LR) on the performance regulation of the respective wor-
king pump is shown in group 7.
The regulation characteristic of the proportional solenoid valve can be checked by measuring the
pressure at the outlet LR relative to the solenoid currently LR at Y50.
7.42.4
copyright by
MJFCIFSS
Emergency position of the proportional solenoid valve Y50
4 Emergency position of the proportional solenoid valve Y50
By removing the cotter pin 2 and tilting the lever 3 into a horizontal position, the solenoid valve Y50
can be brought into a pre-defined emergency position.
In order to prevent that the control current affects the system when operated in emergency position,
X disconnect the plug 1 to the proportional solenoid valve Y50.
4.1 Adjustment of the emergency position

Set the regulating pressure to the desired fixed value by proceeding as follows:
X Connect pressure sensor to the measuring point 59.
X While the engine is running and the lever 3 is in a horizontal position, remove the lock nut 5 and
turn the adjusting screw 4 until the desired pressure is obtained.
X Re-tighten the locknut 5, holding the adjusting screw 4 in its position and re-check the pressure
settings.
Fig. 3 Emergency position of the regulating solenoid valve Y50

1 Plug 57 Measuring point (travel speed)

2 Cotter pin 59 Measuring point (power control)
3 Lever
4 Adjusting nut Y50 Proportional solenoid valve / power control
5 Lock nut Y353 Proportional solenoid valve / travel speed
7.42.5
copyright by
MJFCIFSS
Emergency position of the proportional solenoid valve Y50
7.42.6
copyright by
MJFCIFSS
Service Manual Pilot control unit 4 x
Design
Pilot control unit 4 x
1 Design
The two pilot control valves with the joystick, (to the left and right of the operator's seat) control the
working functions of lifting, stick movements, bucket cylinder movements and turning of the upper-
carriage.
There are four regulating pistons 19 (pressure control valves) inserted in an axial position in the hou-
sing 10, complete with pressure, return and control connections. The regulating piston 19 is operated
by means of the handle 154/155 (joystick) with universal joint 16 and the switching disc 18.
The handle 154/155 can be moved freely in any direction. With each movement, it presses against
one or several spring-loaded pushrods, which then switch the disc 18 attached to the handle. The
regulating piston 19 located under the disc is operated by means of the regulating spring (see Fig. 4)
and the reset spring (see Fig. 4), so that a connection is established from the pressure channel P to
the outlet 1 / 2 / 3 / 4.
The bellows 150 protects universal joint, pushrods, guide bushing etc. against dirt.
Fig. 1 Diagram of the pilot control unit with joystick and other components
10 Housing / pilot control unit 19 Regulating piston

16 Universal joint 150 Bellows
18 Switch disc 154 / 155 Handle
7.45.1
copyright by
MJFCIFSS
Pilot control unit 4 x Service Manual
see Fig. 4
The pilot control valve is of the pressure regulating type. That means, regulating piston 19 of the pilot
control valve builds up pressure on the discharge side, between pilot control valve and control valve
block, and is, thus, shifted, against the pressure from pressure spring 26.
When the handle 154/155 is moved, the switching disc 18 pushes the pushrod 1 down, and the re-
gulating spring 26 shifts the regulating piston 19. The control oil flows through the radial and axial
boreholes in the regulating piston 19 from the pressure channel P (through connection 1 or 2 , 3 or
4) from the control line to one of the control connections at the control valve block.
As the spools in the control valve block are pressurised, a set pressure that is proportional to the pre-
defined lever travel (see Fig. 2) is built up. The pressure acts on the face of the regulating piston 19
and shifts it against the regulating spring 26 until the connection with the channel P is blocked.
Depending on the position of the handle 154/155 and the stroke travel of the pushrod 1, a preset pilot
pressure is established, which shifts the spool 19 proportionally to the pressure increase. At a set
pressure (corresponding to the end of the fine-control phase of the spool), the pushrod 1 moves the
regulating piston 19 downwards. At this point, maximum control pressure is applied to the spool.
3 Repairs, see Fig. 4 and Fig. 5 / 6
3.1 Dismantling
3.1.1 Dismantling the pilot control unit

X Pull up the bellows150.
X Loosen the locknut 105. Remove the sleeve 100 with the handle 154 / 155.
X Remove the nut 17 and the switch disc 18. Remove the universal joint 16 from the housing 10.
X Remove the protective covers 35 and the lid 32. Pull the pushrod 1 complete with the bushing 2
from the housing 10.
X Press the pushrod 1 out of the bushing 2.

X Remove the O-ring 47 and the PDF seal 46 from the bushing 2.
X Press the regulating piston 19 with the pressure springs 26 and 28 as well as the spring plate 15
from the plate 10, pushing it upwards.
X Pull out the regulating piston 19. Remove the pressure spring 26 with the washers 49 / 50.
3.1.2 Dismantling the handle

X Loosen the hex head screw 163 and remove the cap 162.
X Loosen the screws 158 and remove the handle sections 154 / 155 from the sleeve 100.
X If necessary, disconnect the push button S5/S6 and remove it from the cable harness 85/86.
3.2 Assembly
3.2.1 Assembly of the handle

X Mount the push button S5/S6 to the cable harness 85/86 and insert it in the handle sections 154
/ 155.
7.45.2
copyright by
MJFCIFSS
Repairs, see Fig. 4 and Fig. 5 / 6
X Secure the handle sections 154 / 155 with the screws 158.
X Place the cap 162 over the push button S5 / S6 and tighten the screw 163.
3.2.2 Mounting of the pilot control unit

X Prior to assembling the unit, clean all parts and check whether they are fit for re-use.
X Place the discs 49 / 50, the pressure spring 26 and the spring plate 15 on the regulating piston 19.
X Insert the spring plate 15 with the preassembled regulating piston 19 and the pressure spring 26
into the housing 10 and the bushing 13.
X Insert a new O-ring 47 and PDF seal 46 in the bushing 2.
X Insert the pushrod 1 and install the bushing 2 with the pushrod 1 in the housing 10.
X Replace the lid 32 and the protective cover 35. Screw in the universal joint 16 (torque: 20 Nm).
X Screw in the switch disc 18 complete with the nut 17. Adjust pilot control unit to zero position.
X Screw the sleeve 100 with the handle sections 154/155 into the nut 17 and then tighten the nut
105, ensuring that the handle is in the correct position.
3.3 Pilot control valve adjustment in zero position, see Fig. 4

The switch disc 18 and the pushrod 1 must be set and installed in such a way that there is no play
between them when the pilot control valve is not actuated.
X To adjust: loosen the nut 17. Turn the switch disc 18 until all four pushrods are in zero position,
and there is no more play between switch disc 18 and the four pushrods 1.
X When finished, re-tighten the nut 17.
X Pull the bellows150 down over the disc 140.

Fig. 2 Diagram: c = lever travel in degrees
Built into the machine Point a Point b

A 309 - R 317 6 -0.5 bar 28 +1.5 bar
7.45.3
copyright by
MJFCIFSS
Exploded view
4 Exploded view
Fig. 3 Exploded view of the pilot control unit
1 Pushrod 50 Back-up washer

2 Bushing 55* Ball (shuttle valve)
10 Housing 80 Wire grommet
13 Bushing (pressed in) 81 Wire grommet

15 Spring plate 85 Wire harness
16 Universal joint 86 Wire harness
17 Hex nut 98 Repair kit
18 Switch disc 100 Sleeve
19 Regulating piston 105 Nut
21* Valve seat (shuttle valve) 140 Plate
26 Pressure spring (regulating spring) 150 Bellows
28 Pressure spring (return spring) 154 Handle section
32 Lid 155 Handle section
35 Protective cover
45* Seal plug B19L/R Sensor surface / sensor control

46 PDF seal S5L/R/M Button / grapple rotator
47 O-ring S5L/R/M Button / option
48* Seal plug S263 Switch / travel direction
49 Washer S382 Fine control switch
* only installed in the left pilot control unit
7.45.4
copyright by
MJFCIFSS
Sectional drawing
5 Sectional drawing

Fig. 4 Sectional drawing of the pilot control unit
7.45.5
copyright by
MJFCIFSS
Sectional drawing
85 Wire harness 163 Screw

86 Wire harness 200 Right pilot control unit
100 Sleeve 210 Left pilot control unit
105 Nut B19R Sensor transducer / right
138 Right control desk B19L Sensor transducer / left
139 Left control desk B335 Pressure switch / slewing gear control
140 Plate S5 Left push button
142 Retaining washer S5R Push button (turn grapple right)
144 Spacer sleeve S5L Push button (turn grapple left)
146 Allen head screw S5M Button (reserve)
150 Bellows S6 Right push button
154 Handle section S6R Push button (option)
155 Handle section S6L Push button (option)
158 Allen head screw S6M Push button (horn)
160 Screw S263 Switch / travel direction
162 Cap S382 Fine control switch
7.45.6
copyright by
MJFCIFSS
Sectional drawing
Fig. 5 Pilot control valve, right, with electrical components

Fig. 6 Pilot control valve, left, with electrical components
7.45.7
copyright by
MJFCIFSS
Sectional drawing
7.45.8
copyright by
MJFCIFSS
Service Manual 4x pilot control unit for travel drive
Design
4x pilot control unit for travel drive
1 Design

The travel gear operation is controlled by means of the pilot control unit with two pedals located in
front of the operator seat and integrated into the pedal plate/base of the operator's cab.
There are two regulating pistons 16 (pressure control valves) inserted in an axial position in the hou-
sing 3, complete with pressure, return and control connections. The regulating pistons 16 are opera-
ted by means of two pedals 20 / 25.
The two pedals 20 / 25 can be moved forward and backward, thus pushing the spring-loaded pushrod
8 with the switch disc 6 and the threaded stud 18. As a result, the regulating piston 16 is actuated by
the regulation spring 11.1 and the return spring 11.2 , so that it is in open position (connection P -
control connection 19Fig. 5).
The pushrod, guide bushing, etc. are protected against dirt with a bellows 5.

Fig. 1 Pilot control unit 4x 82 for travel left/right with functional diagram
7.46.1
copyright by
MJFCIFSS
4x pilot control unit for travel drive Service Manual
see Fig. 4 / Fig. 5

The pilot control unit is of the pressure regulating type. That means, regulating piston 16 of the pilot
control unit builds up pressure on the discharge side, between pilot control unit and control valve
block, and is, thus, shifted, against the pressure from pressure springs 11.
When the pedal 20/25 is pressed down, a threaded stud 18 pushes the pushrod 8 down, and the re-
gulating spring 25 shifts the regulating piston 16. The control oil flows through the radial and axial
boreholes in the regulating piston 16 from the pressure channel P through connection 1, 2, 3 or 4,
see Fig. 5 and the control line to one of the control connections at the control valve block.
As the spools in the control valve block are pressurised, a set pressure that is proportional to the pre-
defined lever travel (see Fig. 2) is built up. The pressure acts on the face of the regulating piston 16
and shifts it against the regulating spring 11.1 until the connection with channel P is blocked.
Depending on the position of the switch disc 5 and the stroke travel of the pushrod 8, a preset pilot
pressure is established, which shifts the spool 16 proportionally to the pressure increase. At a set
pressure (corresponding to the end of the fine-control phase of the spool), the pushrod 8 moves the
spool downwards. At this point, maximum control pressure is applied to the spool 12.
With each actuation of the pedal 20/25, the threaded stud 18 pushes the pushrod 12 down. Simulta-
neously, the control oil below the pushrod 12 (fed through the check valve 14) is pressurised and
flows through the nozzle 15 to the parallel-mounted pushrod 12. The restriction ensures that the con-
trol flow flowing off dampens the pedal movement.
The housing 3 of the pilot control units is equipped with the shuttle valves 17 mounted between the
control connections. If the pilot control unit is operated in such a way that control pressure is fed th-
rough a pressure connection the control valve block, the control oil system pressurises the shuttle
valves 17. The ball 45 in the valve 17 closes the connection to the other control line, so that the ap-
plied pressure is available at connection 7 for other control functions (connection 7 is temporarily
closed).
3 Repairs
3.1 Dismantling of the regulating unit

X Remove the screws 26 and fold the pedals 20 / 25 up.
X Remove the screws 41 and remove the base 27 / 28 with the pedal 20 / 25.
X Remove the bellows 5.
Note!
The regulating unit 10 and the pushrod 12 are preloaded by the spring.
X When dismantling and mount the devices, work at a clean workplace and proceed with the ne-
cessary caution.
The regulating unit can only be ordered as a complete item.
X Remove the threaded studs 7.4 and pull out the pins 7.2, using the M4 screw.
X Loosen the screws 7.3 and remove the plate 7.
X Pull the hollow rod 9 with the pushrod 8 from the housing 3.
X Pull/push the regulating unit 10 with the spring set 11 from the housing 3.
7.46.2
copyright by
MJFCIFSS
Repairs
3.2 Installation of regulating unit

Prior to assembling the unit, clean all parts and check whether they are fit for re-use.
X Push the regulating unit 10 with the spring set 11 into the housing 3.
X Push the hollow rod 9 with the pushrod 8 into the housing 3.
X Position the plate 7 and secure it with the screws 7.3.
X Check the pushrod for free movement.
X Insert the switch disc 6 into the bearing of the plate 7 and push in the pins 7.2.
X Secure the pins 7.2 with the threaded studs 7.4.
X Adjustment of pilot control unit, see 3.3
X Place the base 27 / 28 together with the pedal 20 / 25 onto the switch disc 6 and secure it with the
screws 41 (with retaining washers 42).
X Fold the pedal 20 / 25 down and screw in the screws 26, holding the pedal 20 / 25 in the desired
position.
3.3 Adjustment of pilot control unit to zero position
X Turn in the threaded stud 18 (for pushrod 8) so that the pushrod 8 of the threaded stud 18 is ope-
rated only by the threaded stud 18, irrespective of the actual position of the switch disc 6.
X Turn in the threaded stud 18 (for pushrod 8) so that the pushrod 8 of the threaded stud 18 is ope-
rated only by the threaded stud 18, irrespective of the actual position of the switch disc 6.
X Install a measuring point to measure the control pressure between the connection 1 / 2 and the
connection at the respective spool / control valve block.
3.4 Check of shuttle valves 20

X The valve insert 20 is secured with Loctite. Heat it and remove it from the housing, using an Allen
key. Be careful not to loose the ball 45.

X Check valve for dirt and damage.
X Install the ball 45. Insert the seal ring 40 and the valve insert 20. Apply Loctite 572 to the valve
insert and screw it in completely (torque: 10 Nm).
.
Fig. 2 Diagram: Control pressure relative to pedal travel
7.46.3
copyright by
MJFCIFSS
Exploded view and sectional drawing
4 Exploded view and sectional drawing
Fig. 3 Exploded view of pilot control unit operation
2 Pilot control unit, complete 30 Pin

20 Left pedal 31 Washer
25 Right pedal 32 Cotter pin

27 Base 42 Retaining washer
28 Base
7.46.4
copyright by
MJFCIFSS

Fig. 4 Exploded view of pilot control unit
2 Pilot control unit, complete 10 Regulating unit

5 Bellows 11 Spring set
6 Switch disc 12 Pushrod
7 Plate, complete 13 Return spring
7.1 Bearing block 14 Check valve
7.2 Allen head screw 15 Nozzle set
7.3 Pin 16 Regulating piston
7.4 Threaded stud 17 Shuttle valve
8 Pushrod 18 Threaded stud

9 Hollow rod
7.46.5
copyright by
MJFCIFSS
6 Switch disc 11.1 Regulation spring

7 Plate, complete 11.2 Return spring
7.1 Bearing block 12 Pushrod
7.2 Allen head screw 13 Return spring

7.3 Pin 15 Nozzle set
7.4 Threaded stud 16 Regulating piston
8 Pushrod 17 Shuttle valve
9 Hollow rod 18 Threaded stud
10 Regulating unit 19 Control connection
11 Spring set
7.46.6
copyright by
MJFCIFSS
Service Manual Pilot control unit 2x
Design
Pilot control unit 2x
1 Design
The operator controls the operations of the attachment by means of a foot pedal, to the left, in front
of his seat, in the running plate of the base of the operator's platform. It actuates the pilot control val-
ve.
There are two regulating pistons 12 (pressure control valves) inserted in an axial position in the hou-
sing 1, complete with pressure, return and control connections. The regulating pistons 12 are opera-
ted by means of two pedals 2 and 3.
The two pedals 2 / 3 can be pressed down and thus actuate a spring-loaded pushrod via a threaded
stud. This actuates the regulating piston 12 (with regulation spring and return spring) located below
the above assembly, which is now opened towards the pressure channel P, outlet 1/2.
The unit is equipped with a cover protecting the pushrod, guide bushing etc. against dirt.
Fig. 1 Pilot control unit, 2x with components (diagram)

7.47.1
copyright by
MJFCIFSS
Pilot control unit 2x Service Manual
see Fig. 3 / Fig. 4

When the pedal 2 and / or 3 is pressed down, a threaded stud 47 pushes the pushrod 98.1 down,
and the regulating spring 25 shifts the regulating piston 12. The control oil flows through the radial
and axial boreholes of in the regulating piston 12 from the pressure channel P through connection 1
or 2 (see Fig. 4) and the control line to one of the control connections at the auxiliary axle of the control
valve block.
As the spools in the additional control axle are pressurised, a set pressure that is proportional to the
pre-defined lever travel (see Fig. 2) is built up. The pressure acts on the face of the regulating piston
12 and the regulating piston 12 is shifted against the regulating spring 25 until the connection with
channel P is blocked.
Depending on the position of the pedal 2/3, and the stroke travel of the pushrod 98.1, a preset pilot
pressure is established, which , which shifts the spool proportionally to the pressure increase. At a
set pressure (corresponding to the end of the fine-control phase of the spool) in the compact control
block, the pushrod 98.1 moves the regulating piston 12 downwards. At this point, maximum control
pressure is applied to the spool.
There is a valve insert 20 (shuttle valve) in the housing 1 between the control connections. If the pilot
control unit is operated in such a way that control pressure is fed through a pressure connection the
control valve block, the control oil system pressurises the shuttle valve 20. The ball 45 in the valve
20 closes the connection to the other control line, so that the applied pressure is available at connec-
tion 7 for other control functions (connection 7 is temporarily closed).
3 Repairs
3.1 Dismantling of the regulating unit

X Lift the pedal 2 / 3.

X Remove the protective covers 98.5. Remove the screws 46. Remove the bearing block 10 with
the pedals 2 / 3.
X Pull the pushrod 98.1 with the bushing 98.2 from the housing 198.1.
X Press the pushrod 98.1 out of the bushing 98.2.
X Remove the O-ring 98.4 and the PDF seal 98.3 from the bushing 98.2.
X Press the regulating piston 12 with the pressure springs 25 and 26 as well as the spring plate 15
with disc 23 from the plate 1, pushing it upwards.
X Remove the disc 23 from the spring plate 15 .
X Pull the regulating piston 12 from the unit.
X Remove the pressure spring 25 with the washers 49 / 50.
3.2 Installation of regulating unit

X Prior to assembling the unit, clean all parts and check whether they are fit for re-use.
7.47.2
copyright by
MJFCIFSS
Repairs
X Place the washers 49 / 50, the pressure spring 25 and the spring plate 15 on the regulating piston
12. Mount the disc 23.
X Insert the spring plate 15 with the preassembled regulating piston 12 and the pressure spring 25
/ 26 into the housing 1 and the bushing 16.
X Insert a new O-ring 98.4 and PDF seal 98.3 in the bushing 98.2.
X Insert the pushrod 98.1 and install the bushing 98.2 with pushrod 98.1 in the housing 1.
X Place the bearing block 10 with the pedals 2 / 3 onto the unit and secure it with the screws 46.
X Mount the protective covers 98.5 .
X Adjustment of pilot control unit,
3.3 Adjustment of pilot control unit to zero position

The pilot control valve should be adjusted in such a way that the max. control pressure can be rea-
ched in the extreme position (stop), and pedals 2 / 3 can be operated in a comfortable and ergonomic
position.
To adjust the pilot control unit in zero position, loosen the locknut 48 and turn the stud 47 (see Fig.
1) until the pedals reach their new neutral / limit positions and fulfil the above requirements.
Install a measuring point to measure the control pressure between the connection 1 / 2 and the con-
nection at the respective spool / control valve block.
3.4 Check of shuttle valves 20

X The valve insert 20 is secured with Loctite. Heat it and remove it from the housing, using an Allen
key. Be careful not to loose the ball 45.
X Check valve for dirt and damage.
X Install the ball 45. Insert the seal ring 40 and the valve insert 20. Apply Loctite 572 to the valve
insert and screw it in completely (torque: 10 Nm).
.

Fig. 2 Diagram: c = control pressure in bar, d = pusrod 98.1 travel in mm
Built into the machine Point a Point b

A 309 - R 317 Litronic and A 309 - R 317 Litronic TCD 5.8 -0.3 bar 24.3 bar
7.47.3
copyright by
MJFCIFSS
Exploded view
4 Exploded view
Fig. 3 Exploded view of pilot control unit
1 Housing 36 Plug
2 Left pedal 40 Seal ring
2.1 Bushing 41 Washer
3 Right pedal 42 Washer
3.1 Bushing 45 Ball
10 Bearing block 46 Hex head screw

11 Pin 47 Threaded stud
12 Regulating piston 48 Hex nut
13 Bushing (pressed in) 50 Screw plug
15 Spring plate 51 Seal ring
16 Bushing 52 Snap ring
20 Valve insert 98 Repair kit
23 Washer 98.1 Pushrod
25 Pressure spring (regulating spring) 98.2 Bushing
26 Pressure spring (return spring) 98.3 PDF seal
33 Screw plug 98.4 O-ring
35 Plug 98.5 Protective cover
7.47.4
copyright by
MJFCIFSS
Sectional drawing
5 Sectional drawing

7.47.5
copyright by
MJFCIFSS
Sectional drawing
7.47.6
copyright by
MJFCIFSS
Service Manual Pilot control valve 2 x
Description
Pilot control valve 2 x
1 Description
The operator controls outrigger and/or blade support operations by means of the pilot control valve
and lever (on the control console, to the right).
There are two regulating pistons 12 (pressure control valves), sitting in an axial position in housing
70, complete with pressure, return and control connections. There is a sort of tipping switch on top,
(with lever 64) to actuate regulating piston 12.
The tipping switch 3, which can move to and fro, presses with each movement against a screwed-in
threaded thud which, again, presses against a spring-loaded pushrod. This actuates regulating
piston 12 underneath (with regulating spring and return spring) and, thus, opens it towards pressure
channel P, outlet 1 / 2.
There is a cover to protect pushrod, guide bushing etc. against dirt.
Fig. 1 Pilot control valve 2 x with hydraulic diagram

7.48.1
copyright by
MJFCIFSS
Pilot control valve 2 x Service Manual
Upon actuation, lever 64 and tipping switch 3 act on threaded stud 18, which presses pushrod 98.1
down and, at the same time, shifts regulating 12 via regulating spring 25. The radial and axial bore in
regulating piston 12 lets control oil flow from pressure channel P via connection 1 or 2 and the control
line to one of the control connections of the control valve block.
Pressurising the spools in the control block will build up a certain pressure which is proportional to
the pre-defined displacement of the lever (see Fig. 2). The pressure acts on the face of regulating
piston 12 and shifts it against regulating spring 25 until the connection with channel P is interrupted.
3 Repair
3.1 Dismantling the regulating unit

X Loosen hex nut 68. Unscrew lever 64 complete from tipping switch 3.
X Remove bellows 66. Remove screws from connecting link 90. Remove connection link.
X Remove threaded stud or Allen head screw 20.
This will release axle 24.
X Press out axle 24. Lift and take out complete tipping switch 3.
X Remove protective covers 98.5.
X Remove Allen head screw 21.
X Lift and take out cover plate 29.
X Pull pushrod 98.1 with bushing 98.2 from housing 70.
X Press pushrod 98.1 out of bushing 98.2.
X Remove O-ring 98.4 and PDF seal 98.3 from bushing 98.2.
X Press complete regulating piston 12 out of the housing (from below), complete with pressure
springs 25 and 28 and spring plate 15 with disc 23.
X Remove split disc 23 from spring plate 15 .
X Pull out regulating piston 12. Remove pressure spring 25 with washers 49 / 50.
3.2 Installing the regulating unit

Before installation, be sure to clean all parts and check whether they are fit for re-use.
X Place washers 49 / 50, pressure spring 25 and spring plate 15 on regulating piston 12. Place split
disc 23.
X Push spring plate 15 into housing 70 (bushing), complete with pre-installed regulating piston 12
and pressure spring 25 and pressure spring 28.
X Install new O-ring 98.4 and PDF seal 98.3 in bushing 98.2.
X Insert pushrod 98.1. Install bushing 98.2 complete with pushrod 98.1 in housing 70.
X Place plate 29. Screw in screws 21.
X Place protective covers 98.5.
7.48.2
copyright by
MJFCIFSS
Repair
X Place tipping switch 3. Press in axle 24.

X Re-tighten threaded stud / Allen head screw 20.
X Screw lever 64 complete. to tipping switch 3. Re-tighten hex nut 68.
X Adjusting pilot control valve
3.3 Pilot control valve adjustment in zero position

Stud 18 and pushrod 98.1 must be set and installed in such a way that there is no play between them
when the pilot control valve is not actuated.
Loosen lock nut 17. Turn stud 18 until both pushrods 98.1 are in zero position and there is no more
play between screw 18 and pushrod 98.1.
.
Fig. 2 Diagram: c = control pressure in bar, d = lever displacement in angular degree
Contained in equipment starting with serial number Point a Point b

A 309 - A 316 Litronic und A 309 - R 317* Litronic TCD 5.8 -0.3 bar 24.3 bar
* on R 313 and R 317 with dozer blade

7.48.3
copyright by
MJFCIFSS
Exploded view
4 Exploded view
Fig. 3 Exploded drawing: pilot control valve
3 Tipping switch 52 Shim

12 Regulating piston 54 Shim
15 Spring plate 64 Lever
17 Hex nut 65 Handle
18 Threaded stud 66 Bellows

20 Allen head screw 68 Hex nut
21 Allen head screw 70 Housing
23 Split disc 71 Bushing (pressed in)
24 Axle 90 Connecting link
25 Pressure spring (regulating spring) 98 Repair kit
28 Pressure spring (return spring) 98.1 Pushrod
29 Cover plate 98.2 Bushing
49 Washer 98.3 PDF seal
50 Washer 98.4 O-ring
51* Shim 98.5 Protective cover

* Omitted in A 309 - 312 machines from
start of series
in A 314 - 316 machines from serial no.
11500
and A 309 - R 317 Litronic TCD machi-
nes from start of series
7.48.4
copyright by
MJFCIFSS
Sectional drawing
5 Sectional drawing
Fig. 4 Sectional drawing: pilot control valve

7.48.5
copyright by
MJFCIFSS
Sectional drawing
7.48.6
copyright by
MJFCIFSS
Service Manual LSC control valve block
Design, see Fig. 1
LSC control valve block
1 Design, see Fig. 1
The machine is equipped with a LSC control system.

The control unit consists of a compact control valve block with LUDV system. The control block con-
tains five spools (working and travel functions) with the corresponding valves.
There is a separate single additional control axle for the slewing gear drive.
For additional functions, several single additional control axles can be flange-mounted to the compact
control block.
The compact control block consists of two distinct sections.
Input section
with the following valves:
– Check valve 7 (3.5 bar) in block for return backpressure
– Preload valve 8 (7 bar) in block for return as radiator bypass valve
– Minimum-flow pressure balance 102 (flow controller) for the stabilisation of the load pressure and
relief of the LS line
– Pressure balance / remaining flow 103 (unloading valve) for a fast and direct response in the sys-
tem
– Pressure cut-off valve 104 as a limiting valve for the working pressure
– Primary pressure relief valve 105 to protect the system
– Shuttle valve 107 for the load signal line to the pump flow regulator
Control and distribution area
with the following components:
– Spool 160 / 220 / 240 / 260 and 280 for the working movements of travel drive, boom, stick, bucket
and support devices.
– The control caps of the various axles with stroke limitation of spools 160 / 220 / 240 / 260 and 280;

control pressure connections a1 - a5 and b1 - b5, and regulating and return spring.
– Secondary pressure-relief valve 221 / 222 / 241 / 242 and 261 / 262 to protect the consumer circuit
in closed condition.
– Suction valves 161 and 162 to prevent cavitation in the travel drive system
– Pressure balance 164 / 224 / 244 / 264 and 284 for LS signal message re. compensation of the
various axles
– Restrictor check valves 127 / 167 / 227 and 247 for the fine control of the spools 160 / 220 and 240.
7.56.1
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MJFCIFSS
LSC control valve block Service Manual
Design, see Fig. 1
1.1 Control block with component
7 Check valve (3.5 bar) 167 Restrictor check valve

8 Preload valve (7.0 bar) 220 Spool / boom cylinder
100 Compact control block 5 x 221 Secondary pressure-relief valve A3
102 Pressure balance: minimum flow 222 Secondary pressure-relief valve B3
103 Pressure balance remaining flow 224 Pressure balance, pilot-controlled
105 Primary pressure-relief valve 240 Spool / stick cylinder
107 Shuttle valve 241 Secondary pressure-relief valve A5
109 Restrictor (LS central nozzle) 242 Secondary pressure-relief valve B5
110 End plate 244 Pressure balance, pilot-controlled
111 Allen head screw 247 Restrictor check valve
120 Slewing gear control axle, see 13 260 Spool / bucket cylinder
134 Control lid 261 Secondary pressure-relief valve A4
135 Allen head screw 262 Secondary pressure-relief valve B4
140 Screw plug 264 Pressure balance, pilot-controlled
160 Spool / travel drive 280 Spool / support
161 Suction valve 281 Screw plug / dummy cartridge
162 Suction valve 284 Pressure balance
Connection:
a1 - a5 Control oil to spool bottom MLS for external load signal
b1 - b5 Control oil to spool top P flow from oil pump
A1 - A5 Supply and return to/from consumer P1“ Load pressure of support
B1 - B5 Supply and return to/from consumer P3“ Load pressure of boom
K Return to hydraulic oil cooler P5" Load pressure of stick
LS Load pressure signal line to pump flow con- S Suction line to slewing gear motor
troller
LS2 for external load signal T Return oil to hydraulic tank
MP Pump pressure
7.56.2
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MJFCIFSS
Design, see Fig. 1

Fig. 1 Control valve block - front and rear view
7.56.3
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MJFCIFSS
Design, see Fig. 1
7.56.4
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MJFCIFSS
Technical data of control valve block A 314 - A 316
2 Technical data of control valve block A 314 - A 316
Contained in: A 314 Litronic TCD A 316 Litronic TCD

Machine 1039 1040 / 1041
Construction from serial no. 30694 M7- from serial no. 29120 M7-
+ 1727-30 1340-31
speeder from serial no. 33466 M7-
1626-30
Industry from serial no. 29503 M7-

1726-30
Spool Unit 220 240 260 160 280 120

Boom Stick Bucket Travel Support Slew-
cylinder cylinder cylinder motor cylinder ing gear
Ex- Re- Ex- Re- Ex- Re- Ex- Re-
tend tract tend tract tend tract tend tract
Nominal width: mm 20 20 20 20 20 20
block
Consumer connec- (“) 3/4“ 3/4“ 3/4“ 3/4“ 3/4“ 1/2“
tion A/B
Ø piston rod mm 25 25 25 25 25 25
Piston stroke mm 9.0 9.0 9.0 9.0 9.0 9.0 9.0 9.0 9.0 9.0
Setting value Y*
A 312 - A 316 mm 14.0 13.6 14.5 14.3 13.2 13.0 12.9 13.0 13.0 12.3
p1bar ± 0.5 mm** bar 7.0 7.0 7.0 7.0 7.0 7.0 7.0 7.0 7.0 7.0
p2bar ± 0.5 mm*** bar 20.6 20.6 20.6 20.6 20.6 20.6 20.6 20.6 20.6 20.6

Qn (A)/Qn(B)°
A 314 l/min 195 85 250 150 210 90 120 75 65 140
A 316 l/min 220 90 250 190 210 90 120 75 65 135
A 316 Industry l/min 220 95 150 250 210 90 120 75 65 135
Restrictor check Ø
valve mm
at connection a / b 0.8 0.8 0.8 0.8 - - 0.8 - - 0.8
Leak oil max. cm3/min 60 60 60 60 60 60
at load pressure bar 150 150 150 150 150 150
at oil temperature °C 50 50 50 50 50 50

* The setting value Y serves as reference

value
** p1 = control pressure at begin of regula-
tion
*** p2 = control pressure in final position
7.56.5
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MJFCIFSS
° Qn A/ Qn B = nominal flow rate at outlet

A / B at U p = nominal value
Components of hydraulic diagram, see Fig. 2
7 Check valve (3.5 bar) 221 Secondary pressure-relief valve A3

8 Preload valve (7.0 bar) 222 Secondary pressure-relief valve B3
41 Measuring point / pump pressure 224 Pressure balance, pilot-controlled
100 Compact control block 5 x 227 Restrictor check valve
102 Pressure balance: minimum flow 240 Spool / stick cylinder
103 Pressure balance remaining flow 241 Secondary pressure-relief valve A5
104 Pressure cut-off valve 242 Secondary pressure-relief valve B5
105 Primary pressure-relief valve 244 Pressure balance, pilot-controlled
107 Shuttle valve 247 Restrictor check valve
109 Restrictor (LS central nozzle) 260 Spool / bucket cylinder
120 Slewing gear control axle 261 Secondary pressure-relief valve A4
160 Spool / travel drive 262 Secondary pressure-relief valve B4
161 Suction valve A2 264 Pressure balance, pilot-controlled
162 Suction valve B2 280 Spool / support
164 Pressure balance, pilot-controlled 281 Screw plug / dummy cartridge
167 Restrictor check valve 284 Pressure balance
220 Spool / boom cylinder 540 Additional control valve AS1
Connection:
a1 - a5 Control oil to spool bottom LS2 for external load signal
b1 - b5 Control oil to spool top MP Pump pressure

A1 - A5 Supply and return to/from consumer MLS External load signal
B1 - B5 Supply and return to/from consumer P flow from oil pump
K Return to hydraulic oil cooler S Suction line to slewing gear motor
LS Load pressure signal line to pump flow con- T Return oil to hydraulic tank
troller
7.56.6
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MJFCIFSS

Fig. 2 Hydraulic diagram of LSC control valve block
7.56.7
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MJFCIFSS
Fig. 3 Exploded view of control block for A 314 - 316

100 Compact control valve block 171 Pressure spring / load-holding valve
105 Primary pressure-relief valve 172 Screw plug
110 End plate 220 Spool / boom
111 Allen head screw 221 Secondary pressure-relief valve*
120 Control axle / slewing gear 222 Secondary pressure-relief valve top
7.56.8
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MJFCIFSS
Functional description (condensed)
130 O-ring 224 Piston / pressure balance (pilot-con-

trolled)
131 Spring plate 227 Restrictor check valve
132 Regulation spring 240 Spool / stick
134 Control lid 241 Secondary pressure-relief valve*
135 Allen head screw 242 Secondary pressure-relief valve
140 Screw plug 244 Piston / pressure balance (pilot-con-
trolled)
160 Spool / travel drive 247 Restrictor check valve
161 Suction valve bottom* 260 Spool / bucket
162 Suction valve top 261 Secondary pressure-relief valve*
164 Piston / pressure balance (pilot-controlled) 262 Secondary pressure-relief valve
165 Spring / pressure balance 264 Piston / pressure balance (pilot-con-
trolled)
167 Restrictor check valve 280 Spool / support
168 Screw plug with O ring 281 Top and bottom screw plug
169 Screw plug with O ring 284 Piston / pressure balance, directly
controlled
170 Cone / load-holding valve
* Valve is identical with top valve (not shown

here).
3 Functional description (condensed)

3.1 Neutral position
All spools 160 / 180 / 220 / 240 / 260 and 280 are maintained in a neutral position by means of regu-
lating and return springs 132. The connection between the pump and consumer is closed. The con-
nection between consumer and tank is closed.
The pressure balances 164 / 224 / 244 / 264 and 284 are in a neutral position (connections are
closed).
The pressure balance / residual flow 103 is open. The pre-set flushing volume is pumped from the
variable displacement pump through 103 to the tank.
3.2 Working position, (see Fig. 12 on page22)

3.2.1 Working position of a spool

Connection between sections P andP’ opens, oil flows.
The respective pressure balance 164/224/244/264/284 is pressurised and opened, while all other ba-
lances remain closed.
When the spool is in its working position, oil flows via the pressure balances on to the flow regulator.
The pressure in the pump is increased and exceeds the load-holding function. The consumer recei-
ves oil.
7.56.9
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MJFCIFSS
The pressure balance 103, see Fig. 9, closes. The entire flow from the pump is now available to the
consumer.
3.2.2 Several spools in working position, see figure 4

The connection between sections P andP’ opens, oil flows.
The respective pressure balances 164 to 284 are pressurised and shifted in the direction of the spring
side (in proportion to the LS pressure), i.e. the consumer with the highest load pressure determines
the LS pressure. The pressure balances 164 to 284 of each spool always switch to the same pressure
difference (U-p), even at different load pressures.
Pivoting of the pump is effected according to the oil requirements of the various consumers.
The oil is fed via the control edge of the respective pressure balance and load-holding valves 170-
172 to section PA or PB, to the consumer connection A1 - A5 or B1 - B5 and to the consumer.
The residual flow pressure balance 103, see Fig. 9, closes. The flow from the pump is now available
to the consumer.
The decisive advantage of the LSC control:
– The pump delivers only the oil required for the individual consumers
– The speeds of the consumers are determined only by the pre-selected pilot pressure on the spool.
It remains constant, irrespective of the load pressure of the consumer in question.
7.56.10
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MJFCIFSS
Fig. 4 View of compact control block from the left with sectional drawing of the a control axle Document is registered under: 1030314 - 29.01.2009
100 Compact control block 240 Spool / stick

104 Pressure cut-off valve 241 Secondary pressure-relief valve
105 Primary pressure-relief valve 242 Pressure relief valve / stick
160 Spool / chassis right / travel drive 244 Pressure balance, pilot-controlled
161 Suction valve 260 Spool / bucket
162 Suction valve 261 Secondary pressure-relief valve
164 Pressure balance, pilot-controlled 262 Pressure relief valve / bucket
220 Spool / boom 264 Pressure balance, pilot-controlled

221 Secondary pressure-relief valve 280 Spool / support
222 Secondary pressure-relief valve / boom 284 Pressure balance, directly controlled
7.56.11
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MJFCIFSS
Input section / input element
4 Input section / input element
Design
The input element contains the central system functions such as the check valve 7 (cooler valve),
check valve 8 (tank valve), primary pressure control (valve 105), LS pressure relief (cut-off valve
104), residual flow pressure balance 103, minimum-flow pressure balance 102 and LS central nozzle
109.
Fig. 5 Exploded drawing of the input element
1 Cone 104 Pressure cut-off valve

2 Pressure spring 105 Primary pressure relief valve
3 O-ring 107 Shuttle valve
4 Screw plug 109 LS central nozzle Ø 1.2 mm
5 Shim 210 Valve seat
6 Pressure spring 211 Restrictor bolt
7 Check valve, complete (radiator) 219 Valve seat
8 Check valve, complete (tank) 275 Screw plug
100 Compact block 321 Spring plate

102 Pressure balance / minimum flow (flow control- 322 Pressure spring
ler)
103 Residual flow pressure balance (unloading
valve)
7.56.12
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MJFCIFSS
Fig. 6 Hydraulic diagram of input section - control valve block
6 to oil cooler 102 Pressure balance / minimum flow (flow

controller)
7 Check valve (3.5 bar) 103 Residual flow pressure balance (unloa-
ding valve)
8 Check valve (7 bar) 104 Pressure cut-off valve
20 from the variable-displacement pump 105 Primary pressure-relief valve
41 Measuring point MP 107 Shuttle valve
100 Compact block 109 LS central nozzle Ø 1.2 mm
4.1 Cooler and tank preload valves 7 / 8, (see Fig. 7 on page14)

The compact control block has central radiator and tank connections. The return lines are preloaded
with the pressure springs 2 / 6 of the check valves 7/8. The resulting back pressure at the outlet gu-
arantees a sufficient inflow in the event of negative loads on the outside (boom down, uphill travel
etc.) and, thus, prevents cavitation.
The amounts required for backfeeding are usually available in the volumes displaced by the consu-
mer.

The priority that returning the oil has over the radiator is implemented by means of differing preloads
for the different valves, thanks to different pressure springs 2 (3.5 bar for tank preload) and 6 (7 bar
for radiator protection). With increasing volumetric flow, the resistance in the cooler line increases,
and the additional volume of oil is fed directly to the tank after valve 8 has opened.
The valves do not require maintenance. In the event of a malfunction, the valve can be removed with the
screw plug, the pressure springs 2 / 6 and the cone 1 from the housing 100 for inspection (contamination,
defect), testing and replacement. If there is leakage at the outside, mount a new O-ring 3.
Note!
When installing/removing the valves 7 and 8, ensure that the correct pressure springs 2 / 6 and
shims 5 are mounted.
7.56.13
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MJFCIFSS
Fig. 7 Sectional drawing of inlet elements in the oil return section
1 Cone 8 Preload valve, complete (7.0 bar)

2 Pressure spring 25 Screw coupling / measuring point MP
3 O-ring 100 Compact block

4 Screw plug 105 Pressure-relief valve
5 Shim K Connection to oil cooler
6 Pressure spring P Connection / pump pressure
7 Check valve, complete (3.5 bar) MP Measuring connection / pump pressure
T Tank channel
7.56.14
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MJFCIFSS
4.2 Minimum flow pressure balance / input pressure balance 102, see Fig. 8 and
Fig. 9
The valve 102 (which is screwed into the block 100 from the bottom) allows a small amount of oil (ap-
prox. 0.7 l/min.) to flow continuously from the LS line to the tank. This allows to eliminate pressure
increases in the LS line due to impacts. The valve 102 also ensure that the LS line is relieved to the
tank if the consumers are not actuated (neutral position of spools).
The 2-way flow limitation valve consists of an orifice and a pressure balance with regulating piston.
The pressure balance keeps pressure decrease Up constant - and, thus, the amount of outflowing
oil independent of the LS pressure. The value Up is derived from the selected cross-section of the
orifice (spool).
The valve cannot be adjusted and needs no maintenance. In the event of disturbances, it is possible
to check the valve for dirt and/or a broken spring: remove and dismantle; if necessary, replace com-
pletely. In the event external leakage, mount a new seal kit.
4.3 Remaining flow pressure balance 103, see Fig. 8 and Fig. 9
During standby operation, there is a continuous flow volume Qmin amounting to about 30 l/min. When
consumers are not in operation, the Up ration of the valve and the additional tank preload generate
a standby pressure at the pump connection MP. Therefore, the system pressure levels out at about
35 bar in this operating condition.
The standby pressure pushes the piston 103 through the integrated channels against the spring 322.
Simultaneously, the LS channel is relieved through the valve 102 to the tank. Thus is established a
connection between pressure side P and tank side T, and the pre-set quantity of oil flows off. The
valve ensures that, in the event of idle run, there is still a minimum volume flow of Qmin at standby
pressure to the tank. There is thus a certain loss of power in this mode, in line with the volume flow.
As soon as a consumer is actuated, the load pressure of the consumer gets to spool 103. Pressure
and spring force push piston 103 in a proportional ratio to the amount required and decrease the out-
let cross-section of the orifice in the direction of the tank.
If the total amount of the consumer volumes is smaller than Qmin, the volume allotted through the
gauge orifice is fed to the consumers first, due to the lower Up ration of the spool. The remaining

differential quantity (Qmin - total of consumer volume) continues to flow via the adjusted control edge
to tank.
As soon as the requested volumes exceed Qmin at one or more spool(s) (i.e. total of consumer volu-
mes greater than Qmin), the valve 103 is closed completely, shutting off the connection to the tank
side.
Above this volume, the system works with the variable displacement pump according to the "closed
centre" and adjust the requested volumes by means of the LS regulator. As long as the performance
requested by the diameter of the gauge-orifice (at the spool) and the highest load pressure is below
the pre-set power curve, the LS regulator maintains the set Up ratio at a constant level.
As soon as the system falls below this point, a saturation deficit occurs. The LS regulator of the pump
is unable to maintain the set Up ratio via the gauge orifices. The pump cannot build up the required
pressure because it has already reached its max. pivot angle. The LS regulator is disabled, and the
pump delivers the highest obtainable volume given the prevailing load pressure.
The valve cannot be adjusted and needs no maintenance. In the event of a malfunction, the valve
103 can be checked for contamination or defects and replaced, if necessary, by unscrewing the
screw plug 275 and removing the parts 321 and 322 from the housing.
7.56.15
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MJFCIFSS
Fig. 8 Sectional drawing of the inlet element "residual pressure balance and pressure cut-off"
100 Compact block 219 Valve seat

102 Pressure balance / minimum flow (flow 275 Screw plug
controller) For details, see Fig. 9
103 Piston/pressure balance (unloading valve) 321 Spring plate
104 Pressure cut-off valve 322 Pressure spring

105 Primary pressure-relief valve LS LS signal from the consumer with the
highest load
107 Shuttle valve LS2 Connection for external load signal
109 LS central nozzle Ø 1.2 mm MLS Connection for external load signal
210 Valve seat P Pump pressure
211 Restrictor bolt T Tank channel
7.56.16
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MJFCIFSS
Fig. 9 Sectional drawing of the inlet element "residual pressure balance and external shuttle val-
ve"
100 Compact block 16 Backing ring/pressure balance

102 Minimum flow pressure balance, com- 103 Residual flow pressure balance (unloading
plete valve)
1 Valve insert/pressure balance 104 Pressure cut-off valve

2 Piston / pressure balance 109 LS central nozzle
3 Pressure spring / pressure balance 275 Screw plug
4 Screw plug/pressure balance 321 Spring plate
14 O-ring/pressure balance 322 Pressure spring
15 O-ring/pressure balance
7.56.17
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MJFCIFSS
4.4 Primary pressure-relief valve 105 (pump safety valve), see Fig. 8
The primary pressure-relief valve protects the pump against excessive pressure in the event of failure
of the secondary pressure-relief valve and cut-off valve. It is supposed to react only in emergencies.
Therefore, its pressure setting is significantly higher than that of the cut-off valve and system pressu-
re.
This valve is identical as regards function and design with the secondary pressure-relief valves of the
control axles for boom, stick and bucket, see Fig. 23.
4.5 LS shuttle valve 107, see Fig. 8

The orifices of LS shuttle 107 limit the volumetric flow to the LS regulator of the pump. The propaga-
tion of abrupt pressure peaks to the regulator and resulting power peaks of the pump are prevented
in the LS line, thanks to the interrelation between the various orifices and capacities. Peaks are com-
pensated thanks to the pulsating of the hose and/or the compressibility of the oil volume. This pre-
vents aggressive or unwanted responses of the pump to sudden peaks, ensuring stable operating
behaviour.
In the event of malfunction, the valve 107 can be removed by screwing off the valve seal 210/219 and
pulling out the double-sided cone 211 so that the valve can be inspected for damage or contamination
and replaced, if necessary (observe correct installation position of double-sided cone).
4.6 LS central nozzle 109, see Fig. 8

The LS central nozzle acts as restrictor and dampener at the LS oil inlet in the input element. When
the pressure cut-off valve 104 is actuated, the restrictor lowers the Up ratio, and the cut-off valve can
be used to reduce the pump volume through the pump flow regulator.
The central nozzle 109 restricts the volume flowing off through the pressure cut-off line. This is par-
ticularly important where several consumers are run to their limit and the fully opened pressure ba-
lances feed oil into the LS line.
7.56.18
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MJFCIFSS
4.7 Pressure cut-off valve 104

LS-pressure cut-off valve 104 works as a pressure controller. As soon as the pre-set pressure value
is reached, it decreases the volumetric delivery of the pump to Qmin. This function has priority over
the pump's power and flow regulation systems. That means, as soon as the pressure cut-off has been
actuated, load-sensing and/or power regulation are no longer possible.
Once a consumer reaches its max. permissible operating pressure, the cut-off valve is actuated, re-
lieving the LS signal behind the LS main nozzle in the control valve block to the tank. The LS signal
to the pump cannot increase any further, and the pump regulates the flow in such a way that a maxi-
mum pump pressure of LS + is built up in the pump channel.
Thanks to the pressure cut-off valve, there is still a certain amount of pump flow within the power con-
trol.
The valve 104 thus prevents that consumers connected in parallel are stopped as soon as one or
more are run at their maximum limit.
The valve must be regularly inspected and readjusted, if necessary (see maintenance schedule).
Fig. 10 Pressure cut-off valve 104


4 Adjusting screw 12 Backing ring
5 Spring plate 13 Backing ring
7 Washer 15 O-ring
8 Lock nut 16 O-ring
10 Circlip 104 Pressure cut-off valve
7.56.19
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MJFCIFSS
5 Control and distribution area
5.1 Control axles, see Fig. 11 and Fig. 12

Each control axle is equipped with the necessary spool and actuation devices (control lid, regulating
springs), a pressure balance and the respective control and high-pressure connections with seconda-
ry protection.
5.2 Spools 160, 220, 240, 260 and 280

The geometry of the spools and their orifices have been designed and adapted specially to match the
characteristics of the individual consumer. The control of the consumer in the LUDV system is inde-
pendent of the load pressure. At a constant Up, the volumetric flow rate is generated by modifying
the cross-section of the gauge orifice and via the stroke of the spool. With that in mind, the max. vo-
lumetric flow rate to the consumer can be derived from the max. cross-section available.
In the event of malfunction, check the spools 160 to 280. To do this, remove the upper control lid 134,
pull out the spool and check it for damage, contamination, etc. If necessary replace it.
5.3 Removal of spools 160 to 280
Caution!
Before dismantling control lines: relieve pressure from hydraulic circuit.
Lid 134 is spring-loaded.
Risk of injury
X Dismantle control line in question.

X Remove the screws 135.
X Remove the lid 134 with O-ring 130.
X Pull the spools 160 to 280 from the control valve block 100.
X Remove the pressure spring 132 and the spring plate 131.
5.4 Installation of spools

Important information for installation / replacement of pistons:
– The individual spools are matched to the specific requirements of their operational functions
(boom, stick, etc.) and are not interchangeable.
– If you wish to remove more than one spool at a time, make sure they are re-installed in their ori-
ginal bores.
– Usually, the bores in the control valve blocks are made for perfect fit. If this applies to all the bores
in the block, the type plate of the block contains the end number "000". 'Perfect fit' and the zeroes
are meant to indicate that the bores have ± 0 µm tolerance. This means that the spools supplied
for replacement usually have a tolerance range of 8-10 µm, and that the amount of leak oil is within
the standard tolerance range.
– Zero-tolerance bores are marked with steel stamping numeral 0. Replacement with spools as spe-
cified in the ET spare parts catalogue is possible.
– If one or several bores of the control block do not fall within zero tolerance standards, this is indi-
cated on the type plate. To find out the bores to which this applied, remove the top lid 134 of the
spool in question.
7.56.20
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MJFCIFSS
– The tolerance is indicated on the front face /control lid of the control block (e.g. 10 = 10 µm). In
this case, it is not possible to replace the spool with a part from the spare parts catalogue, and the
spool must be specially made to fit the tolerance.
– When ordering spare spools, please be sure to give all indications from the type plate. See also
service information no. 1-14-52 / 2000.
Be sure to install spool in the correct position.
X Apply a little oil to the fitting spool and carefully insert it into the control valve block 100.
X Place the spring plate 131 and the pressure spring 132 onto the spool.
X Insert the O-ring 130 and place the lid 134 on the control valve block 100 and secure them with
the screws 135.
Fig. 11 Control axles with regulating springs and control lid at the control valve block
Key, see Fig. 12

7.56.21
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MJFCIFSS
Fig. 12 Control axles for attachment, chassis and support
100 Compact control valve block 227 Restrictor check valve

134 Control lid 240 Spool / stick
160 Spool / travel drive 241/242 Secondary pressure-relief valves
161/162 Suction valves 244 Pressure balance, pilot-controlled
164 Pressure balance, pilot-controlled 247 Restrictor check valve
167 Restrictor check valve 260 Spool / bucket
170 Cone / load-holding valve 261/262 Secondary pressure-relief valves

171 Pressure spring
172 Pressure spring / load-holding valve 264 Pressure balance, pilot-controlled
220 Spool / boom 280 Spool / support
221/222 Secondary pressure-relief valves 281 Screw plug
224 Pressure balance, pilot-controlled 284** Pressure balance, directly controlled
** Sectional drawing, (see Fig. 15 on page25)
7.56.22
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MJFCIFSS
Control lid 134
6 Control lid 134
Fig. 13 Control lid 134
1 Cap nut 140 Screw plug

2 O-ring 167 Restrictor check valve / travel drive
3 Lock nut 227 Restrictor check valve / boom
4 Adjusting screw / stroke limitation 247 Restrictor check valve / stick
130 O-ring
134 Control lid Y Setting value of stroke limitation
The control lid 134 is located on both sides of the spools 120 to 280 and is fixed to the compact block
100. The control oil required for the actuation of the spool is fed through the control connection a / b
of the control lid 134.
Some of the control axles have a shuttle dampening function (restrictor check valve 167 / 227 / 247)
in the inlet area of the control connection. This effects a certain degree of throttling of the oil displaced

by the spool in the opposite control lid and, thus, a reduction of the shifting speed of the spool. This
effects a smooth start of the motion of the consumer and, thus, a good handling and fine-control.
The consumer movement is damped by the restrictor check valve 167 / 227 / 247 in the opposite con-
trol lid. Oil enters into the control lid (e.g. at connection a) through the valve seat, which is opening.
The oil displaced by the spool (e.g. via connection b) closes the valve seat so that the control oil dis-
placed must go through the orifice of the valve. The cross section of the orifice (and thus the shifting
speed) has been matched to the characteristics of each individual consumer. Thanks to the throttling
in the outlet towards T, the dampening effect works with abrupt actuation as well as for abrupt relief.
In addition, the control lid is equipped with a stroke limitation 4 for the spool. Like that, the max. speed
of the consumer can be limited.
The setting has been pre-set by the supplier / manufacturer. Do not tamper. The adjusting screws 4
are secured with the lock nuts 3 and protected against damage by the cap nut 1.
Checking setting value Y works for rough adjustment only. A precise setting of absolute max. quan-
tities going to consumers is possible only using a flow meter on the outlet of the control block.
The flushing grooves a of the spools 160 to 280 form a connection between the tank and control lid
134. Together with the tank preload of the control valve block, this means a continuous flow of oil as
long as the pilot control valve is not actuated. That means that the flushing volume is available for
preheating the control oil circuit.
7.56.23
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MJFCIFSS
Control lid 134
Fig. 14 Sectional drawing: control lid 134
1 Cap nut 167 Restrictor check valve

2 O-ring 220 Spool / boom
3 Lock nut 227 Restrictor check valve
4 Adjusting screw / stroke limitation 240 Spool / stick
5 Shuttle 247 Restrictor check valve
6 Orifice 260 Spool / bucket
100 Control valve block 280 Spool / support

130 O-ring
131 Spring plate a Flushing groove
132 Regulation spring a1-a5 Control pressure connection, bottom
134 Control lid b1-b5 Control pressure connections, top
160 Spool / travel drive
7.56.24
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MJFCIFSS
Directly controlled pressure balance 284
7 Directly controlled pressure balance 284
On-demand flows are controlled by means of the cross-section of the opening of the respective spool
shaft and the LS pressure at the pump regulator.
The effect of differing load pressures in the consumers is compensated by the pressure balances
connected to each spool axle and used in each control valve block.
The LUDV pressure balance 284 with the pressure spring 165 of each section is situated downstream
of the gauge orifice of the spool.
This pressure balance reports to the pump regulator the pressure of the consumer with the highest
load. The pressure balance then compensates the pressure difference between load pressure and
pump pressure in all consumers with a lower load.
When in neutral position, the spool blocks the connection between the pump and the channel p’ (see
Fig. 18). In this position, the pressure in the channel p and behind the load-holding valves is relieved
through the piston play to nearly tank level. The consumer connections are blocked by the spool in
the housing. The consumer is thus located between two oil columns.
Fig. 15 Exploded view and sectional drawing of directly controlled pressure balance
Shown here: pressure balance 284

166 Pressure spring 284 Piston / pressure balance
169 Screw plug with O ring
7.1 High pressure section

As soon as the spool is shifted, the supply orifice of the spool opens the connection between pump
connection p and the channel p’. The resulting pressure in this space shifts the pressure balance.
Via the internal channels in the pressure balance, it also acts on the back side of the load-holding
valves.
Consumer pressure pc of connection A acts via the channels in the spool and is available at the front
side of the left-hand load-holding valve. With pump pressure p’ rising above consumer pressure pc,
the load-holding valve will open. The connection between pump and consumer has been established,
now, and initiates the movement. The displaced oil will flow back to the tank via the outlet orifice. The
secondary pressure relief valves remain closed as long as the pressure in the consumer connection
remains below the pre-set pressure value.
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Fig. 16 Pressure balance in high-pressure position
pc high = LS signal to pump regulator
7.1.1 Consumer with highest load is actuated

In the event of individual movements, or if the load pressure of the consumers pc is the highest within
the system, the pressure balance is fully opened. Channel p’ is connected to consumer connection
pc, without pressure drop.
The consumer pressure is transferred through the pressure balance bores to the spring chamber of
the pressure balance and subsequently to the LS line. The LS signal is transmitted to the flow regu-
lator (LS regulator) of the variable displacement pump, and also to the spring chambers of the other
LUDV pressure balances, which then block the load pressures of the other consumers against the
LS line.
As the LS signal is constantly regenerated by the load-holding valves, the consumer connections re-
main closed until the required working pressure is reached. This prevents sudden pressure drops in
the event of negative (i.e. pulling) loads.
7.2 Low pressure section

7.2.1 Load-sensing function

In the saturated area, the LUDV system operates as a pure load-sensing regulation system. The
speed of the consumer is controlled independently of the load pressure, by means of the opening
cross-section of the gauge orifice (spool).
When several movements overlap, the load pressure of the consumer with the highest pressure is
applied through the central LS line to the spring chambers of the other LUDV pressure balances. The
resulting pressure in channel p’ of this section is derived from the highest reported LS pressure (p’ =
LS + spring force). The LUDV pressure balances automatically regulate pressure p’ of the various
shafts by limiting the flow cross-section to the consumer channel to the same value. As pressure Up
in the P channel of the block is the same everywhere, Up is the same at all gauge orifices. As a con-
sequence, the consumer speed is independent of the difference between the load pressures. As the
pressure balance is under the influence of the load signal with the highest load on the spring side, it
cannot open completely. By mediation of the pressure balance, which is only partly open at this time,
there will be yet another pressure difference which depends on the individual load.
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Fig. 17 Pressure balance in low-pressure position
d = LS = pc high
e = pc low
p’ = LS pressure (approx.)
F = spring chamber
R = regulating orifice
7.2.2 LUDV function

The LUDV system works even in case of a saturation deficit. In such a case, the oil volume called up
via the sum of the open gauge-orifice cross-sections at the existing Up will exceed the max. flow rate
of the pump within the boundaries of the power control. The LS regulator of the pump is no longer in
a position to build up the set Up by means of pivoting the variable displacement pump even further
+. The Up set at the regulator will collapse.
In this condition, the LUDV system will maintain the Up at the same level across all the open gauge
orifices. That means, the consumer(s) with the highest pressure will not just shut down in the event
of a saturation deficit. Instead, the speeds of all the consumers actuated will go down in a proportional
relation to the open cross-sections.

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When all the pressure balances are in balance:

– the LS system pressure in all the spring chambers of the pressure balances will be the same
– the pressure p’ in front of the gauge orifices or the pressure balances of the section with the lower
load corresponds to the LS pressure of the consumer with the highest load
Up inlet orifice = ppump - p’
The Upat the inlet orifices of all consumers is always equal. In the event of a saturation deficit, the
Up will go down, but, again, all consumers to the same degree.
The pressure differences Up inlet orifices between p’ and each individual consumer pressure pc will
be regulated and levelled automatically by adapting the opening cross-section, so that the volumetric
flows are split proportionally.
7.2.3 Negative load

Speed control of the consumers via the aperture of the inlet orifice is not possible with negative (pul-
ling) loads. In such a case, the consumer is controlled in relation to the actual load, via the outlet ori-
fices.
Fig. 18 Pressure balance in position "spool closed"
a no LS signal 280 Spool / travel

b LS signal 284 Piston / pressure balance

100 Control valve block
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Pilot-controlled pressure balance 164 / 224 / 244 / 264
8 Pilot-controlled pressure balance 164 / 224 / 244 / 264
The pilot-controlled pressure balances 164 - 264 fulfil the same purposes as the directly controlled
pressure balance in the LUDV system. Its function therefore corresponds to the basic functions of the
directly controlled pressure balance, (see 7 on page25).
8.1 Additional properties of the pressure balances:

Finer and more precise regulation behaviour thanks to the pilot control pistons 1 with pressure spring
2 in the pressure balance.
Those pilot control pistons with their very fast reaction times take over the blocking and opening func-
tions with respect to the pressure signal between the consumers with the highest and the lower pres-
sures.
Fig. 19 Exploded view and sectional drawing of pilot-controlled pressure balance (here: item 224)
1 Pilot control piston 165 Pressure spring

2 Pressure spring 168 Screw plug with O ring
3 Spring plate 224 Pressure balance, pilot-controlled
4 Spring plate
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8.2 Control positions
8.2.1 Low pressure section:

Pilot control piston 1 is in its starting position, i.e. it connects the current LS pressure of the consumer
with the highest pressure to the spring side of the pressure balance. Like that, the pressure balance
regulates the pump pressure of the consumers with the lower pressure and brings them to the LS
pressure of the consumer.
Fig. 20 Pressure balance low-pressure position (LS signal from consumer with highest pressure)
1 Pilot control piston F Spring chamber

2 Pressure spring P Pump pressure channel
100 Control valve block R Regulating orifice
220 Spool pch High pressure (LS)
224 Pressure balance pcl Low pressure
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8.2.2 High pressure section:

The pilot control piston 1 is shifted against pressure spring 2, thus relieving the spring side of the pres-
sure balance main piston. At the same time, the consumer with the highest load is connected to the
LS pressure. This, again, acts on the LS regulator of the working pump.
Fig. 21 Pressure balance in high-pressure position (pc = LS signal to pump regulator)

1 Pilot control piston P Pump pressure channel

2 Pressure spring pch High pressure (LS)
100 Control valve block pcl Low pressure
220 Spool
224 Pressure balance
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Pressure-relief and feeder valves 105 / 221 - 262
9 Pressure-relief and feeder valves 105 / 221 - 262
see Fig. 23
The pilot-controlled pressure-relief valves 105 / 221 - 262 of the various consumer connections are
all of the cartridge type and screwed directly into the control valve block 100. They limit the pressure
between pump, control block and working attachments and/or between working attachments and
control block when the spools are closed (secondary function).
If the pressure in the working attachment circuit exceeds the maximum permissible limit, it activates
the built-in pressure-relief valve. It limits the maximum pressure in the consumer and its connection
to the pre-set value.
As high flows result in pressure on the pressure valves of the hydraulic unit, the machine is equipped
with pilot-controlled pressure-relief valves. In these valves, a pressure relief valve is installed that
works directly as a pilot control valve to actuate a second, larger valve.
At the same time, the pressure relief valves act as feeder valves. Different flow rates of oil coming in
and going out of the operating cylinders will lead to a vacuum. This happens, for instance, when you
deal with pulling loads on the outside, e.g. 'extend stick cylinder' with particularly long sticks. In such
a case, the speed of the consumer will not be controlled by means of quantities determined by the
gauge orifice, but (independently of loads) via the outlet edge of the spool.
In order to prevent that, the valves connect the return side with the corresponding low-pressure side
so that additional oil can be sucked in.
9.1 Description of functions
9.1.1 Pressure control

The pressure (P) built up in the consumer circuit acts on the front face of the main cone 3 and, through
the bore D1, also on the rear surface of the main cone 3. At the same time, the pressure acts also on
the pilot control cone 4. The springs 8 / 9 and 5 push the main cone 3 and the pilot control cone 4 into
their closing positions (static status).
As soon as the pressure in the consumer circuit reaches a value that is above the set value of pres-
sure and adjusting spring 5, the pilot control cone 4 is lifted from its seat and some oil enters the return
channel T through the ring gap between the housing and the main cone 3.
Due to the different cross-sections of the bores D1 in the main cone 3 and D2 in the valve insert 2,
there is a pressure difference between the front and the spring side of the main cone 3.
As a result of this pressure difference, the main cone 3 is shifted against the pressure springs 8 / 9,
and a substantial amount of oil flows off to the non-pressurised return side T.
9.1.2 Feed
If there is a vacuum in a working circuit, the higher pressure in the hydraulic tank is applied through
the bore T of the housing 1 onto the ring face of the main cone 3. As a result of the pressure difference
across the effective surface of the main cone 3, the main cone is pressed against the force of the
pressure springs 8 / 9 so that the required amount of oil can flow through the bore T and the connec-
tion P to the respective side of the consumer.
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Pressure-relief and feeder valves 105 / 221 - 262
Fig. 23 Pressure and feeder valves 105 / 221 - 262
1 Housing 9 Pressure spring

2 Valve insert 10 Protective cap

3 Main cone 11 Piston seal
4 Pilot control cone 12 O-ring
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Feeder valves 161 / 162
10 Feeder valves 161 / 162
see Fig. 24
Feeder valves (i.e. suction valves / check valves) are mainly used in conjunction with rotating consu-
mers.
The danger of insufficient filling, i.e. cavitation in oil motors is greatest when there are delays in the
operation of the machine (downhill travel). When decelerating, the oil motor of the chassis runs idle.
that means, the pressure peaks due to the high moment of inertia during downhill travel make the
brake valves react while the spools are blocked.
What is more, at a certain inclination, the speed of the motor (and, thus, the oil volume to be fed) is
no longer determined by the aperture of the inlet orifice of the spool, but depends on the load and the
downhill force.
The feeder valve makes the required amount of oil available to the operating connection to avoid ca-
vitation.
10.1 Functional description
10.1.1 Closing position:

The high pressure in channel A/B is applied through the bore D to the spring side of the main cone
3, pressing the cone against the sealing edge of the valve insert 1, so that the valve 161 / 162 / 181
/ 182 is closed towards the consumer side.
10.1.2 Suction:
If there is a vacuum in this working circuit, the higher pressure in the hydraulic tank will act via bore
T of valve insert 1 on the ring face of main cone 3.
As a result of the pressure difference across the effective surface of the main cone 3, the main cone
is pressed against the force of the pressure spring 8 so that the required amount of oil can flow th-
rough the bore T to the respective side of the consumer A / B.
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Feeder valves 161 / 162
Fig. 24 Feeder valves 161 / 162

1 Valve insert 33 O-ring

3 Main cone 34 Backing ring
6 Screw 35 O-ring
31 Piston seal
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Maintenance
11 Maintenance
Periodically check control valve block for leaks. The pressure cut-off valve 104 and the secondary
pressure-relief valves 221 - 262 must be regularly check for correct settings according to the inspec-
tion and maintenance schedule, see adjustment protocol and instructions for inspection and setting
tasks in group 3
12 Repair works on control valve block
Caution!
Before you begin any repair works on the control valve block, be sure to relieve tank and servo pre-
loads.
X Switch off the diesel engine.
X Proceed as follows: Unscrew breather filter on hydraulic tank about 1 turn (slow de-pressurisa-
tion).
Releasing backpressures
X Turn ignition key on position.
X Actuate all pilot control valves in all possible directions.
12.1 Leaks on the outside

Leaks on control valve block: Replace seals on screwed connections, SAE flanges, caps and valves.
12.2 Spool
X Remove the control line (collect escaping oil).
X Remove Allen head screws 135. Remove control lid 134.
X Remove pressure spring 132 with spring plate 131. Pull spool in question out of housing.
Note!
If you want to remove several spools at a time, be sure you put them back into the correct bores
afterwards (markings, etc.).
Spare spools have the spool's axis marking A1 - A5 engraved on the front side opposite the spring
and on the shaft of the spring plate package. Note (see 5.4 on page20)
X Before you install the spool: check for good condition of the housing O-rings (control lid seals).
Check the spool for damage (scores on surface).
X Install in reverse sequence. Insert the spools precisely and with care. Avoid jamming. Do not use
force.
12.3 Pressure balances and valves

X Before repairing the pressure balances 164 - 284 and valves 161 - 262, remove them fully from
the housing.
X Screw out the suction valves 161 / 162 and the secondary pressure-relief valves 221 - 262.
Then screw the respective load-holding valve 170 - 172 from the housing.
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Repair works on control valve block
Caution!
Damaged seals and loose screw connections and valves can lead to leaks in the control block.
Incorrectly mounted valves and screw connections can cause damage to the unit.
X Always ensure that the outer seal ring is undamaged.
X Tighten the valves and screw connections with the prescribed torque.
12.4 Tightening torques for the valves and screws

Screw plug 4 140 Nm Valve seat 210/219 15 Nm
Pressure balance 102 25 Nm Pressure-relief valves 221 - 100 Nm
262
Pressure cut-off valve 104 25 Nm Screw plug 275 30 Nm
Pressure relief valve 105 120 Nm Allen head screw 320 70 Nm
LS central nozzle 109 8 Nm Allen head screw 335 10.4 Nm
Allen head screw 111 70 Nm Valve 341 20 Nm
Restrictor check valve 128 30 Nm Screw plug 369 90 Nm
Allen head screw 135 10.4 Nm Screw plug 373 120 Nm
Screw plug 140 20 Nm Valve seat 466/468 15 Nm
Restrictor check valve 127/167/227/247 20 Nm Screw plug 475 30 Nm
Screw plug 168/169 160 Nm Screw plug 476 60 Nm
Load-holding valve 172 100 Nm Allen head screw 620 55 Nm
Suction valves 161/162 100 Nm
12.5 Installation instructions

– The contact surface must be absolutely even.
– Mounting bolts must be tightened evenly, in a cross-wise pattern.

– Contact faces of SAE connections must be clean.
– Pipes and hose lines must be properly laid, without any twists, warps, tensions etc.
– Observe the prescribed tightening torques for mounting bolts, screwed connections etc. (See also
group 1.20 torques of screws, bolts, screw-in studs)
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Spool / slewing gear
13 Spool / slewing gear
13.1 Design, see Fig. 25

Classification of the element 120:
– Spool 123 for working movements of uppercarriage, turn left and right
– Input pressure balance 122 for priority shifting
– Control lid 334 of the axle with stroke limitation of the spool 123, and regulating and return spring
332
– Shuttle valve 126 affecting the input pressure balance 122
– Restrictor check valves 127 for fine-control of spool 123
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Fig. 25 Slewing gear segment

100 Compact control block 365 Pressure spring

120 Slewing gear segment 369 Screw plug
122 Inlet / supply pressure balance 370 Cone
123 Spool / slewing gear 371 Pressure spring
125 Restrictor Ø 1.8 mm 372 O-ring
126 Shuttle valve 3 x Ø 0.8 mm 373 Screw plug
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127 Restrictor check valve (Ø 0.8 mm) 466 Valve seat

128 Restrictor check valve (Ø 1.2 mm) 468 Valve seat
320 Allen head screw 475 Screw plug
330 O-ring 491 Screw plug
331 Spring plate 610 End plate
332 Regulation spring 620 Allen head screw
334 Control lid Y451 Proportional solenoid valve / slewing
gear
335 Allen head screw
Connection:
a01/b01 Control pressure LSDR Load signal line to the other control
block side
A01/B01 Feed and return line to slewing gear DRDA Pressure line to solenoid valve Y451
motor
Y for external load signal
Fig. 26 Hydraulic diagram of the control axle of the slewing gear 120 with the proportional sole-
noid valve Y451
13.2 Functional description of the slewing gear control axle
13.2.1 Priority of slewing gear

In the one-circuit LUDV system, all consumers are arranged in parallel and supplied by one and the
same working pump. In the LUDV system, it is the slewing gear that has always priority. It can be
controlled independently of all the other consumers.
The question of priorities arises whenever the system must work with a deficit in saturation and the
LUDV system automatically influences the speed of movements with respect to the degree of the ac-
tual saturation deficit.
Putting a priority on the slewing gear turned out to be necessary because most operators do not like
the speed being automatically influenced by other movements. What is more, any automatic accele-
ration due to the LUDV principle is considered as unacceptable.
With those requirements in mind, we put the priority on the slewing gear whenever several move-
ments must be carried out simultaneously. It works like this:
The module is the only consumer in the system that works with a 2-way pressure balance in the sup-
ply flow leading to the gauge orifice. The pressure balance for the section, in front of the gauge orifice,
compares load pressure LS slewing gear and the setting o the spring of the pressure balance to pres-
sure p that it obtains from the gauge orifice. The Up gauge orifice is maintained at a constant level
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(corresponding to the applied spring force), allowing for speed control that is independent of the load
pressure. The only way to modify quantity or speed is a change at the gauge orifice.
13.2.2 Attachment section is consumer with highest load pressure

Thanks to the check valve in the LS line between module and system, it is not possible that the control
of the slewing gear is influenced by consumers with higher loads that happen to run at the same time.
The difference between pump pressure psystem and operating pressure p of the slewing gear ele-
ment is always controlled and regulated by the preceding pressure balance, even when consumer
pressures fluctuate significantly. The regulating cross-section of the pressure balance has been cho-
sen to allow for quick responses in cases of great differences between psystem and p slewing gear and
is increased/opened with decreasing pressure differences.
The volumes supplied by the pump and not taken up by the slewing gear are distributed proportionally
to the other active consumers according to the LUDV principle.
13.2.3 Slewing gear section is consumer with highest load

The LSslewing gear is reported to the LS line of the compact control block (via the check valve) to have
the highest pressure in the system. It acts on the back side of the LUDV pressure balances and the
Up regulator of the variable displacement pump. The volumes supplied by the pump and not taken
up by the slewing gear are distributed proportionally to the other active consumers according to the
LUDV principle.
13.2.4 Slewing gear torque control

For a sensitive acceleration of the slewing gear, we need a torque control (pressure control) in order
to influence the value of the acceleration.
During acceleration from standstill, the slewing gear requires only a small amount of oil. Neverthe-
less, in a pure LS control, it will generate the max. load pressure in the slewing gear and, thus, the
max. rotary acceleration. Any precise speed that is independent of the load pressure (via 2-way sup-
ply pressure balance 122) is thereby overridden by a torque control.
The control pressure chosen by the operator is converted by the pressure sensor B335 (see hydraulic
unit) into a signal that is then sent to the UEC control unit. The UEC control sends a current that cor-
responds to the chosen control pressure to the proportional solenoid valve Y451. Depending on the
current, proportional solenoid valve Y451 closes or opens the primary pressure connection in the sle-

wing gear circuit to the tank. This results in the control of the available torque. The corresponding
operating pressure is generated proportionally to the control pressure, i.e. the angle of the pilot con-
trol valve. By changing the current parameters in %, the operator can adjust the rotational speed to
achieve a more sensitive rotary movement.
13.2.5 Loss-free acceleration

The proportional solenoid valve Y451 is located near the control block in the LS line of the module of
the pressure balance. This design ensures that the slewing gear is supplied only with the quantity of
oil required to build up the necessary working pressure. As soon as the pre-set pslewing gear is rea-
ched, the preceding pressure balance reduces the flow, and only supplies the amount necessary to
maintain the pressure. Thanks to this combination, the acceleration of the slewing gear works without
any losses.
The maximum permissible acceleration pressure is at approx. 10 - 20 bar below the topmost setting
of the 2-step slewing gear valves in the oil motor. That means that the secondary valves will not re-
spond, and the corresponding losses will be avoided. Thanks to the torque control, the quantities sup-
plied to the slewing gear motor will go up when pslewing gear drops until the required pressure
according to the pre-set Up pressure spring has been attained via the gauge orifice.
13.2.6 Deceleration of the slewing gear

Deceleration of the slewing gear is effected via the outlet orifices of the spool leading to the tank, and
the pressure relief valves leading to the motor. Min. deceleration is derived from the lower pressure
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setting of the 2-step slewing gear pressure valves. They have been tuned to a lower level in order to
provide for a smooth deceleration. Again, the rule applies: More pcontrol pressure increases the addi-
tional pressure level of the secondary cartridge continuously all the way up to the max. admissible
value.
Both values can be adjusted independently by controlling the admissible acceleration pressure with
the proportional solenoid valve Y451 and the deceleration via the brake valves on the motor.
In the neutral position of the spool, the slewing gear is hydraulically fixed by means of the locked con-
sumer connections A and B.
Should adjustments become necessary, proceed according to the adjustment protocol and the in-
spection and adjustment instructions; see group 3.
In the event of disturbances, it is possible to check the valve for dirt and/or a broken spring: remove
and dismantle; if necessary, replace completely.
Fig. 27 Sectional drawing of slewing gear element
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120 Spool / slewing gear segment 372 O-ring

122 Inlet/supply pressure balance 373 Screw plug
123 Spool / slewing gear 475 Screw plug
125 Restrictor Ø 1.8 mm D1 Supply gauge orifice p-A01 and/or p-
B01
126 Shuttle valve 3 x Ø 0.8 mm D2 Outlet orifice A01 - T and/or B01 - T
127 Restrictor check valve (Ø 0.8 mm) pV Consumer pressure
334 Control lid pM Pressure in front of gauge orifice
365 Pressure spring a01/b0 Control oil connection
369 Screw plug A01 Consumer connection
370 Cone (load-holding function) B01 Consumer connection
371 Pressure spring
13.3 Repair works on control valve block

Always observe the safety notes, (see 11 on page36).
Leaks on the outside

Replace seal rings of flanges, lids and valves. Replace screw plugs, when no longer tight.
Spool
X Unscrew control line in question.
X Remove the Allen head screws 335.
X Remove control lid 334. (Careful: lid 334 is spring-loaded.)

X Remove pressure spring 332. Pull spool 120 from the housing.
X Install in reverse sequence.
Valves
To repair valves: Take out of housing completely. If necessary, exchange against spares as listed in
ET spare parts catalogue.
13.4 Tightening torques for the valves and screws

(see “Tightening torques for the valves and screws” on page 37)
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Additional control axles
14 Additional control axles
For additional functions, it is possible to flange-mount single auxiliary axles to the compact control
block. The devices for the additional working movements are supplied with oil by the working pump.
Each control axle (additional control block) has the necessary spool complete with actuation (control
lid, regulating springs), required for its respective function, a pressure balance and the corresponding
connections with secondary protection. It has an hydraulic connection to series block 100 via the
pressure, return and LS channels. O-rings seal off the flange faces of the channels.
To retrofit one or more auxiliary axles, remove the end plate 110 or 610 and mount the new axle bet-
ween the block 100 and the plate 110 / 610.
14.1 Additional control axle 540 for accessory kit AS 1

The auxiliary axle 540 consists of the accessory kit AS1 for working movements by the grapple rota-
tor, swivelling ditch cleaning bucket, quick change adapter or Likufix system and is flange-mounted
to the control valve block on the right-hand side adjacent to the slewing gear element.
Models A 314 and A 316 are equipped as standard with the additional control axle 540.
14.2 additional control axles 500 / 510 for accessory kits AHS 1, AHS 11 and AHS 12
For additional function such as hydraulic boom adjustment, hydraulic hammer, etc., the machine can
be equipped with additional single auxiliary axles that are flange-mounted on the left-hand side to the
compact control block.
100 Compact control block 540 Auxiliary axle AS1 / grapple rotator
500 Auxiliary axle AHS1 / regulating cylinder T additional control block for accessory kit
AHS11 with Tool Control
510 Auxiliary axle AHS11 / hydraulic hammer, TP additional control block for accessory kit
etc. AHS11 with Tool Control plus
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Fig. 28 Additional control axles AS1, AHS 1, AHS 11 and AHS 12
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Technical data of additional control axles
15 Technical data of additional control axles
M7 - 20 S3 M7 - 20 S3
M7 - 20 S3
Secondary valve Secondary valve
Product SX/14-1X 2 axles
without pressure with pressure
Unit (AHS 1 + AHS 11)
reduction reduction
Contained in: AS1 AHS 1 AHS11 AHS 12

Spool 540 500 510 500 and 510
for grapple rotator Boom Hydraulic ham- All auxiliary at-
adjusting device mer tachments
left right Exten- Retrac- Connec- Connec-
ding ting tion A6 / tion B6 /
A7 B7
Nominal width of (“) 14 20 20 see AHS 1 / AHS
block (G3/4“) (SAE §/4“) (SAE 3/4“) 11
Consumer connec-
tion
Ø spool 503 / 513 mm 18 25 25 see AHS 1 / AHS
11
Piston stroke mm 8 8 11 11 11 11
Setting value Y see AHS 1 / AHS
A 314 - 316 mm 15.6° 15.6° 14.7 14.7 14.7 14.7 11
p1 ± 0.5 * bar 2.0 2.0 7.0 7.0 7.0 7.0
± 0.5
p2 ** bar 23.4 23.4 20.6 20.6 20.6 20.6
Qn (A)/Qn (B)***
l/min 30- 30- 200 100 200 200
100° 100°
Restrictor check
valves mm - 1.0 1.0#
At connection a mm - 1.0 1.0#
At connection b
Max. leak oil cm3/min 60 60 see AHS 1 / AHS

at load pressure bar 150 150 11
at oil temperature °C 50 50
Tab. 2 List: LSC additional control axles
Magnet Y22 / Y23 / Y417 12 Nm Screw plug 172 100 Nm

Allen head screw 20 / 135 10 Nm Screw plug 275 30 Nm
Hex head screw 25 70 Nm Pressure-relief valve 501 / 502 120 Nm
Hexagon nut 26 70 Nm Pressure-relief valve 511 / 512 100 Nm
Seal-lock collar nut 31 38 Nm Restrictor check valve 507/ 20 Nm
517
Screw plug 71/167 160 Nm Pressure-relief valve 541 / 542 90 Nm
Allen head screws 111 70 Nm Allen head screws 620 55 Nm
*p1 = control pressure at begin of regulation

**p2 = control pressure in final position
***Qn (A) / Qn (B) = nominal flow rate at outlet A / Bat Up = nominal value
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° depending on attachment
# = not required with additional control axle AHS11 with Tool Control plus
15.1 Additional control axle 540 for accessory kit AS 1

The individual segment is equipped with an electromagnetic-hydraulic control of the spool. The pro-
portional control of the spool is designed as an ON-OFF switching system.
The control pressure at the connection a / b is only fed to the spring chamber of the spool 543 after the
solenoids Y22 / Y23 have been switched. The spool is then fully switched over. The pressure balance
544 fulfils the same purpose as the other pressure balances in the compact control block 100.
Adjust the stroke limitation of the spool according to the instructions in group 16.42.
The design and settings of the secondary protection correspond to group 16.42.
Fig. 29 Auxiliary axle at AS1
100 Compact control block 544 Pressure balance

120 Slewing gear axle 610 End plate
540 Spool / additional control block AS1 620 Allen head screw
541 Secondary pressure-relief valve Y22 Solenoid valve / grapple rotation left
542 Secondary pressure-relief valve Y23 Solenoid valve / grapple rotation right
7.56.47
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MJFCIFSS
Fig. 30 Hydraulic diagram of additional control axle AS1
120 Slewing gear control axle 544 Pressure balance

540 Additional axle AS 1 610 End plate
541 Secondary relief valve / turn left Y22 Solenoid valve / grapple rotation left
542 Secondary relief valve / turn right Y23 Solenoid valve / grapple rotation right
543 Spool
7.56.48
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MJFCIFSS
Fig. 31 Sectional drawing of auxiliary control axle AS1
27 Cone / load-holding valve 540 Additional control axle AS1

28 Pressure spring / load-holding valve 541 Secondary pressure-relief valve

29 Screw plug 542 Secondary pressure-relief valve
30 O-ring 543 Spool
31 Seal-lock collar nut 544 Pressure balance
32 Adjusting screw / stroke limitation Y22 Solenoid valve / grapple rotation left
33 Pressure spring Y23 Solenoid valve / grapple rotation right
7.56.49
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MJFCIFSS
15.2 Additional control block 500 for accessory kit AHS 1

The additional axle for the working movement 'hydraulic adjustment of boom' etc. corresponds to the
design and construction of the boom, stick and bucket axles of the compact block.
Description of functioning and adjustment: see group 16.456.
15.3 Additional control block 510 for accessory kit AHS 11

The individual segment for the working movement 'hydraulic hammer' corresponds to the design and
construction of the boom, stick and bucket axles of the compact block.
Instead of the pilot-controlled pressure-relief and suction valves, the additional axle is equipped with
process pressure-controlled secondary pressure-relief valves that reduce the pressure.
With the Tool Control plus function, the volume is further reduced through the flange-mounted pro-
portional solenoid valves Y417-1 / 417-2 on both sides.
For a description of the functions and settings, see groups 16.52, 16.54.
15.4 Additional control valve block for accessory kit AHS 12

The accessory kit requires a combination of the additional control blocks 500 and 510 with variable
flange attachment, see Fig. 32 and Fig. 33.
For a description of the functions and settings, see groups 16.60, 16.62.
Key to figures 32 and 33
15 Control lid 164 Pressure spring

20 Allen head screw 167 Screw plug
25 Stud 170 Cone
26 Hex nut 171 Pressure spring
27 Cone 172 Screw plug

28 Pressure spring 275 Screw plug
29 Screw plug 500 Additional control axle AHS 1
34 O-ring 501 Pressure and feeder valve, factory-set
70 O-ring 502 Pressure and feeder valve, factory-set
71 Screw plug 503 Spool / AHS 1
72 Pressure spring 504 Pressure balance
90 Spring plate 507 Restrictor check valve
91 Pressure spring 510 Additional control axle AHS 11
100 Compact control block 511 Pressure relief valve, process pressure-
controlled
131 Spring plate 512 Pressure relief valve, process pressure-

controlled
132 Pressure spring 513 Spool / AHS 11
134 Control lid 514 Pressure balance
152 Magnet
7.56.50
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MJFCIFSS

Fig. 32 Additional axles AHS 1, AHS 11 and AHS 12 with Tool Control
7.56.51
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MJFCIFSS
Fig. 33 Additional axles AHS 1, AHS 11 and AHS 12 with Tool Control plus
7.56.52
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MJFCIFSS
15.5 Hydraulic unit of accessory kits AHS 1, AHS 11 and AHS 12
100 Compact control block 511 Secondary pressure-relief valve for

pressure reduction
500 Spool / regulating cylinder 512 Secondary pressure-relief valve for
pressure reduction
501 Secondary pressure-relief valve, fac- 513 Spool
tory-set
502 Secondary pressure-relief valve, fac- 514 Pressure balance
tory-set
503 Spool 517 Restrictor check valve
507 Restrictor check valve Y417-1 Proportional solenoid valve
510 Spool / hydraulic hammer etc. Y417-2 Proportional solenoid valve

7.56.53
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MJFCIFSS
Fig. 34 Hydraulic diagrams for model A 314
7.56.54
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MJFCIFSS

Fig. 35 Hydraulic diagrams for model A 316
7.56.55
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MJFCIFSS
Key of sectional drawing, see Fig. 36

15 Control lid 503 Spool / AHS 1
27 Cone 504 Pressure balance
28 Pressure spring 507 Restrictor check valve
29 Screw plug 510 Additional control axle AHS 11
34 O-ring 511 Pressure relief valve, process pressure-
controlled
90 Spring plate 512 Pressure-relief valve, process pressure-
controlled
91 Pressure spring 513 Spool / AHS 11
500 Additional control axle AHS 1 514 Pressure balance
501 Pressure and feeder valve, factory-set 517 Restrictor check valve
502 Pressure and feeder valve, factory-set
7.56.56
copyright by
MJFCIFSS

Fig. 36 Auxiliary control axles, left = AHS 1, right = AHS 11
* various lengths (depend on the number of additional elements)

7.56.57
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MJFCIFSS
Pressure-relief valves 511 / 512
16 Pressure-relief valves 511 / 512
If the pressure in the circuit of a working attachment rises, it begins to act on the built-in hydraulic
device. We call this a pressure-relief valve. It limits the max. pressure in the consumer and its con-
nections with the pre-set value.
As high flows result in pressure on the pressure valves of the hydraulic unit, the machine is equipped
with indirectly responding (pilot-controlled) pressure-relief valves. In these valves, a pressure relief
valve is installed that works directly as a pilot control valve to actuate a second, larger valve.
The pressure-relief valves 511 / 512 are process pressure-controlled. The oil flowing to the tank when
the valve is opened is fed externally via the proportional solenoid valve Y414 that is opened or closed.
The current to the proportional solenoid valve Y414 thus determines the settings of the secondary
protection: Minimum current = low pressure and maximum current = high pressure.
16.1 Functional description of secondary pressure relief valve 511 / 512, see Fig. 39
The pressure P built up in the consumer circuit acts on the front face of the main cone 5 and, through
the bore B1, also on the rear surface of the main cone 5.
The main cone 5 is kept in its closed position as the area B3 is greater than the area B4 exposed to
the same pressure P.
The pressure spring 3 pushes the pilot control cone 4 into its closed position.
As soon as the pressure in the consumer circuit reaches a value exceeding the set value of the pres-
sure and adjusting spring 3, the pilot control cone 4 is lifted from its seat, and some oil can penetrate
through the valve Y414 via connection (T) to the tank, see 16.1.1.
Due to the different cross-sections of the bore B1 in the bushing 12 and the ring face B2 in the screw
plug 6, a pressure difference is built up between the front and rear sides of the main cone 5. The main
cone 5 is lifted and the connection T to the tank is opened. Any excess pressure is thus released to
the tank (secondary relief).
16.1.1 Proportional pressure control / begin of opening of valve 511/512, see Fig. 37
and Fig. 39
In order to achieve proportional pressure control, the pressure (P) in the consumer circuit is controlled
by valve Y414 via the connection Y in the pressure-relief valve 511 / 512.
The pressure settings of pmin. to pmax (depending on menu preselection) is controlled relative to the
current by the central control unit A149 UEC 1 / UEC 2 (auxiliary control with Tool Control Plus).
When the valve Y414 opens the connection to T, a pressure reduction that is proportional to the cur-
rent occurs in the oil column between 511Y / 512Y and Y414. After the valve Y414 has been opened,
the pilot control cone 4 and subsequently the main cone 5 of the connection P - T are opened. The
pressure set in the menu is established. The later the valve Y414 is opened via T1, the higher the
secondary pressure.
For a functional description of Y414, see groups 16.52, 16.54, 16.60 and 16.62.
7.56.58
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MJFCIFSS
Fig. 37 Secondary pressure-relief valve 511 / 512

Fig. 38 Exploded view of pressure-relief valve 511 / 512 (process pressure-controlled)
1 Adjusting screw 510 Additional control axle AHS 11

2 Lock nut 511 Secondary pressure-relief valve for pres-
sure reduction
6 Screw plug 512 Secondary pressure-relief valve for pres-
sure reduction
7 Housing Y414 Proportional solenoid valve
7.56.59
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MJFCIFSS
Fig. 39 Sectional drawing of pressure-relief valve 511 / 512 (process pressure-controlled)
1 Adjusting screw 511 Secondary pressure-relief valve for pres-

sure reduction
2 Lock nut 512 Secondary pressure-relief valve for pres-
sure reduction
3 Pressure and adjusting spring
4 Pilot control cone B1 Bore for pressure behind cone 5
5 Main cone B2 Ring face between screw plug 6 and cone
4
6 Screw plug B3 Effective surface behind cone 5
7 Housing B4 Effective surface in front of cone 5
11 Pressure spring P Pressure connection
12 Bushing T Tank connection
14 Magnetic coil Y Process pressure connection
15 Valve seat
7.56.60
copyright by
MJFCIFSS
General
LSC control valve block
1 General
All machines of the Litronic TDC series are equipped with the LSC control system.
The control unit of the hydraulic LSC control was designed as a compact control block with LUDV
system. The control block contains five spools (working and travel functions) with the corresponding
valves.
There is a separate control block segment for the slewing gear drive.

Fig. 1 LSC compact control block
7.60.1
copyright by
MJFCIFSS
General

8 Preload valve (7.0 bar) 180 Spool / chassis left
100 Compact control block 5 x 181 Suction valve left - forward
102 Pressure balance / minimum flow 182 Suction valve left - reverse
103 Pressure balance / remaining flow 184 Pressure balance
105 Primary pressure-relief valve 220 Spool / boom cylinder
106 Shift valve / fast travel chassis 221 Secondary pressure-relief valve / exten-
ding
107 Shuttle valve 222 Secondary pressure-relief valve / retrac-
ting
108 Restrictor (LS central nozzle) 224 Pressure balance (pilot-controlled)
110 End plate 227 Restrictor check valve
111 Allen head screw 240 Spool / stick cylinder
120 Control axle / slewing gear 241 Secondary pressure-relief valve / retrac-
ting
122 Input pressure balance 242 Secondary pressure-relief valve / exten-
ding
123 Spool 244 Pressure balance (pilot-controlled)
127 Restrictor check valve 247 Restrictor check valve
128 Restrictor check valve 260 Spool / bucket cylinder
134 Control lid 261 Secondary pressure-relief valve / retrac-
ting
135 Allen head screw 262 Secondary pressure-relief valve / exten-
ding
136 Control lid with short screw (only at axle 3, 264 Pressure balance (pilot-controlled)
bottom)
140 Screw plug 334 Control lid
160 Spool / chassis right 540 Additional control valve AS1
161 Suction valve, right, forward 810 End plate

162 Suction valve - right, reverse 811 Allen head screw
7.60.2
copyright by
MJFCIFSS
General

Fig. 2 Design of compact control block
7.60.3
copyright by
MJFCIFSS
General
Fig. 3 Hydraulic schematic: LSC control valve block
7.60.4
copyright by
MJFCIFSS
General

8 Preload valve (7.0 bar) 180 Spool / chassis left
41 Measuring point MP 181 Suction valve left - forward
100 Compact control block 5 x 182 Suction valve left - reverse
102 Pressure balance / minimum flow 184 Pressure balance (directly controlled)*
103 Pressure balance / remaining flow 187 Restrictor check valve
104 Pressure cut-off valve 220 Spool / boom cylinder
105 Primary pressure-relief valve 221 Secondary pressure-relief valve / exten-
ding
106 Shift valve / fast travel chassis 222 Secondary pressure-relief valve / retrac-
ting
107 Shuttle valve Ø 0.6 mm / 1.2 mm 224 Pressure balance (pilot-controlled)
108 LS main orifice Ø 1.2 mm 225 Restrictor 2 x Ø 0.8 mm
109 Restrictor Ø 0.6 mm / Ø 1.2 mm 227 Restrictor check valve
120 Control axle / slewing gear 240 Spool / stick cylinder
122 Input pressure balance 241 Secondary pressure-relief valve / retrac-
ting
123 Spool / slewing gear 242 Secondary pressure-relief valve / exten-
ding
125 Restrictor Ø 1.8 mm 244 Pressure balance (pilot-controlled)
126 Shuttle valve 3 x Ø 0.8 mm 245 Restrictor 2 x Ø 0.8 mm
127 Restrictor check valve Ø 0.8 mm 247 Restrictor check valve
128 Restrictor check valve Ø 1.2 mm 260 Spool / bucket cylinder
160 Spool / chassis right 261 Secondary pressure-relief valve / retrac-
ting
161 Suction valve right - forward 262 Secondary pressure-relief valve / exten-
ding
162 Suction valve, right - reverse 264 Pressure balance (pilot-controlled)
164 Pressure balance (directly controlled)*
* pilot-controlled in undercarriage with

blade support
7.60.5
copyright by
MJFCIFSS
Technical data
2 Technical data
Contained in: R 317 Litronic TCD

Type 1042
Standard model M7-1755 - 30 / 6 M7-22
Industry -
Spool Unit 220 240 260 160 180 120

Boom Stick Bucket Drive Drive Slewing
cylinder cylinder cylinder motor, motor, left gear
right
Ex- Re- Ex- Re- Ex- Re- For- Re- For- Re- Left right
tend tract tend tract tend tract ward ver- ward ver-
se se
Nominal width of mm 22 22 22 22 22 20
block
Consumer connec- (“) 3/4 3/4 3/4 3/4 3/4 3/4
tion
Ø piston rod mm 25 25 25 25 25 25
Piston stroke mm 11.0 11.0 11.0 11.0 11.0 11.0 11.0 11.0 11.0 11.0 9.0 9.0
Setting value Y mm
R 317 17.0 15.5 15.8 15.8 16.0 15.7 16.0 16.0 15.5 15.5 16.0 16.0
p1bar ± 0.5 mm bar 7.0 7.0 7.0 7.0 7.0 7.0 7.0 7.0 7.0 7.0 7.0 7.0
p2bar ± 0.5 mm bar 20.6 20.6 20.6 20.6 20.6 20.6 20.6 20.6 20.6 20.6 20.6 20.6
Qn (A)/Qn(B) l/
R 317 min 270 120 260 210 250 150 125 125 125 125 135 135
Restrictor check mm
valve
at connection a (mm) 0.8 0.8 - 0.8 0.8 0.8

at connection b (mm) 0.8 0.8 - 0.8 0.8 0.8
Leak oil max cm3/min 60 60 60 60 60 60
at load pressure bar 150 150 150 150 150 150
at oil temperature °C 50 50 50 50 50 50

7.60.6
copyright by
MJFCIFSS
3.1 Connections and components of the control block, see Fig. 3

– Connection P for oil pump flow
– Connection K for return flow to hydraulic cooler
– Connection MP for pump pressure
– Connections MLS and LS1 for extreme load signal from 'travel direction right', control-block side
– Connection LS with shuttle 107 for load signal line to pump's flow regulator
– Connection H for pilot control oil of control oil unit 50
– Connections P’3 / P’5 for grapple switching of the bucket cylinder axle with boom and stick func-
tion
– Connection S for direct suction of slewing gear motor 130
– Connection T for return oil to hydraulic tank 1
– Control pressure connections a1 - a5 and b1 - b5
– Operating connections A1 - A5 and B1 - B5 for supply and return flows of consumers
– Check valve 7 (3.5 bar) in block for return backpressure
– Preload valve 8 (7 bar) in block for return as radiator bypass valve
– Minimum-flow pressure balance 102 to stabilise load pressure
– Pressure balance / remaining flow 103 for a fast and direct response in the system
– Pressure cut-off valve 104 as a limiting valve for the working pressure
– Primary pressure-relief valve 105 to protect the system
– Spools 163 / 183 / 223 / 243 and 263 for the working movements of travel drive, boom, stick and
bucket
– Control lids of the individual axles with the regulation and return spring 132 and stoke limitation of
the spools 160 / 180 / 220 / 240 and 260
– Suction valves 161, 162, 181 and 182 to prevent cavitation in the travel drive system
– Pressure balances 164 / 184 / 224 / 244 and 264 for LS signal message re. compensation of the
individual axles
– Secondary pressure-relief valves 221 / 222 / 241 / 242 / 261 and 262 to protect the consumer cir-
cuit in closed condition.

– Restrictor check valves 167 / 187 / 227 and 247 for the fine control of the spools 160 / 180 / 220
and 240
– Flange-mounted additional control axle for slewing gear as standard
Note!
Additional elements with spools serving as auxiliary equipment can be flange-mounted to the com-
pact block, (see “Additional control axles” on page 37).
7.60.7
copyright by
MJFCIFSS
Fig. 4 Components of the control block 100
100 Compact control valve block 170 Cone / load-holding valve

102 Pressure balance / minimum flow 171 Pressure spring / load-holding valve
103 Remaining-flow pressure balance 172 Screw plug
110 End plate 180 Spool / chassis left
111 Allen head screw 182 Suction valve
120 Control axle / slewing gear 184 Piston / pressure balance, directly controlled*
130 O-ring 187 Restrictor check valve
131 Spring plate 220 Spool / boom
132 Regulation spring 222 Secondary pressure-relief valve
134 Control lid 223 Pressure spring
135 Allen head screw 224 Pressure balance, pilot-controlled
140 Screw plug 227 Restrictor check valve
160 Spool / chassis right 228 Spring plate
162 Suction valve 229 Screw plug
163 Screw plug 240 Spool / stick
164 Piston / pressure balance, directly controlled* 242 Secondary pressure-relief valve
165 Spring / pressure balance 244 Pressure balance, pilot-controlled
168 Screw plug 262 Secondary pressure-relief valve
169 Screw plug 264 Pressure balance, pilot-controlled
* pilot-control in undercarriage with blade
support
7.60.8
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MJFCIFSS
4 Functional description (condensed)
4.1 Neutral position

All spools 160 / 180 / 220 / 240 /and 260 are maintained in a neutral position by means of regulating
and return springs 132. The connection between the pump and the consumer and the connection
from the consumer to the tank are closed.
The pressure balances 164 / 184 / 224 / 244 and 264 are in a neutral position (connections are
closed).
Pressure balance / remaining flow 103 is open, i.e. the pre-set flushing volume is pumped from the
variable-displacement pump through 103 to the tank.
4.2 Working position
4.2.1 Working position of a spool

The connection between sections P and P’ opens, oil flows.
The respective pressure balance 164 to 264 is pressurised by the controlled function and fully ope-
ned.
When the spool is in its working position, oil flows via the pressure balances on to the flow regulator.
The pressure in the pump is increased and exceeds the load-holding function. The consumer recei-
ves oil.
Pressure balance 103 closes. That means, the flow from the pump is now available to the consumer.
4.2.2 Working positions of several spools, see Fig. 5

The connection between sections P and P’ opens, oil flows.
The respective pressure balances 164 to 264 are pressurised and shifted in the direction of the spring
side (in proportion to the LS pressure), i.e. the consumer with the highest load pressure determines
the LS pressure. The pressure balances 164 to 264 of each spool always switch to the same pressure

difference (U-p), even at different load pressures.
Pivoting of the pump is effected according to the oil requirements of the various consumers.
The oil is fed via the control edge of the respective pressure balance and load-holding valves 170172
to section PA or PB, to the consumer connection A1 - A5 or B1 - B5 and to the consumer.
Remaining flow pressure balance 103 closes. The flow from the pump is now available to the consu-
mer.
The decisive advantage of the LSC control:
– The pump delivers only the oil required for the individual consumers.
– The speeds of the consumers are determined only by the pre-selected pilot pressure on the spool.
It remains constant, irrespective of the load pressure of the consumer in question.
7.60.9
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MJFCIFSS
Fig. 5 Sectional drawing: control axles

100 Compact control block 222 Secondary pressure-relief valve /

boom
134 Control lid 224 Pressure balance, pilot-controlled
136 Control lid (only at stick axle, bottom, see 227 Restrictor check valve
Fig. 12 )
140 Screw plug (only bucket shaft) 240 Spool / stick
160 Spool / travel right 241 Secondary pressure-relief valve
161 Suction valve, forward 242 Pressure-relief valve / stick
162 Suction valve - reverse 244 Pressure balance, pilot-controlled
164 Pressure balance, directly controlled 247 Restrictor check valve

170 Cone 261 Secondary pressure-relief valve
171 Pressure spring 262 Pressure-relief valve / bucket
172 Cone 264 Pressure balance, pilot-controlled
180 Spool / travel left a1-a5 Control pressure connection, bottom
181 Suction valve, forward b1-b5 Control pressure connections, top
182 Suction valve - reverse A1-A5 Control pressure connection, bottom
7.60.10
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MJFCIFSS
Input section
184 Pressure balance, directly controlled B1-B5 Control pressure connections, top
187 Restrictor check valve X Control axles for chassis right/left
220 Spool / boom X Control axles for boom, stick and buk-
ket
221 Secondary pressure-relief valve
5 Input section
5.1 Design
The input section contains the central system functions such as the primary pressure control (valve
105), LS pressure-relief (cut-off valve 104), residual flow pressure balance 103, minimum-flow pres-
sure balance 102 and LS central nozzle 108, as well as check valve 7 (cooler valve) and check valve
8 (tank valve).
Fig. 6 Exploded drawing: input element
1 Cone 109 Restrictor check valve (nozzles Ø 0.6 mm

/ Ø 1.2 mm) + check valve (RV)
2 Pressure spring 110 End plate

3 Shim 111 Allen head screw
4 O-ring 120 Slewing gear control axle
5 Cone 210 Valve seat
6 Pressure spring 211 Restrictor bolt
7 Check valve (radiator) 219 Valve seat
8 Check valve (tank) 223 Pressure spring
7.60.11
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MJFCIFSS
Input section
9 Pushrod 228 Spring plate

41 Screw coupling, measuring point MP 275 Screw plug
100 Compact block 276 Screw plug
102 Pressure balance / minimum flow 277 Screw plug
103 Pressure balance / remaining flow 278 Screw plug
104 Pressure cut-off valve 320 Allen head screw
105 Primary pressure-relief valve 810 End plate
106 Shift valve / fast travel chassis 811 Allen head screw
107 Shuttle valve 999 Seal kit
108 LS main orifice Ø 1.6 mm
Fig. 7 Hydraulic diagram of input section - control valve block
6 to oil cooler 103 Pressure balance: remaining flow

7 Check valve (3.5 bar) 104 Pressure cut-off valve
20 from the variable-displacement pump 105 Primary pressure-relief valve
26 to LS regulator 107 Shuttle valve Ø 0.6 mm / 1.2 mm
41 Measuring point MP 108 LS central nozzle Ø 1.2 mm
100 Compact block 110 End plate
102 Pressure balance / minimum flow
5.2 Minimum flow pressure balance / input pressure balance 102, Fig. 8
The valve 102 (which is screwed into the block 100 from the top) allows a small amount of oil (approx.
0.7 l/min.) to flow continuously from the LS line to the tank. This eliminates pressure peaks in the LS
line due to impacts. The valve 102 also ensure that the LS line is relieved to the tank if the consumers
are not actuated (neutral position of spools).
7.60.12
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MJFCIFSS
Input section
The 2-way flow limitation valve consists of an orifice and pressure balance with regulating piston 11.
The pressure balance keeps pressure decrease Up constant - and, thus, the amount of outflowing
oil independent of the LS pressure. The value Up is derived from the selected cross-section of the
orifice (spool).
to check the valve for dirt and/or a broken spring: remove and dismantle; if necessary, replace com-
pletely. In the event of leaks on the outside, use new set of seals (items 15 - 18).
Fig. 8 Sectional drawing of chassis control axle
1 Cone 17 Backing ring

2 Pressure spring (7.0 bar) 18 Backing ring

3 Shim 100 Compact control block
4 O-ring 102 Pressure balance / minimum flow
8 Check valve 109 Restrictor check valve Ø 0.6, 1.2 mm
10 Valve insert 160 Spool / travel right
11 Piston 164 Pressure balance
12 Bushing (pressed in) 169 Screw plug
7.60.13
copyright by
MJFCIFSS
Input section
13 Stop sleeve 180 Spool / travel left

14 Pressure spring 184 Pressure balance
16 O-ring
5.3 Remaining flow pressure balance 103, see Fig. 6 and Fig. 10
During standby operation , there is a continuous flow volume Qmin amounting to about 40 l/min.
When consumers are not in operation, the Up ratio of the valve and the additional tank preload ge-
nerate a standby pressure at the pump connection MP. Therefore, the system pressure levels out at
about 35 bar in this operating condition.
The standby pressure pushes the piston 103 through the integrated channels against the spring 223.
Simultaneously, the LS channel is relieved through the valve 102 to the tank. Thus is established a
connection between pressure side P and tank side T, and the pre-set quantity of oil flows off. The
valve (in connection with the LS pump regulator) make sure there is a volumetric flow rate of Qmin at
standby pressure in idle mode. That means, the resulting loss of power in this mode is rather low.
As soon as a consumer is actuated, the load pressure of the consumer acts on the spool. The pres-
sure and the spring act on the push piston 103 in a proportional ratio to the amount required and de-
crease the outlet cross-section of the orifice in the direction of the tank.
If the min. amount of the consumer is smaller, the quantity allotted via the gauge orifice of the spool
is fed with priority to the consumer, due to the lower Up spool. The remaining differential quantity
continues to flow to the tank side via the controlled control edge.
As soon as the amounts called up by one or more spool(s) exceed Qmin, the valve 103 closes com-
pletely and shuts off the connection with the tank side.
to check the valve for dirt and/or damage. Unscrew the screw plug 229. Take the components 223
and 228 out of housing. Check for re-usability and good function. Replace, if necessary.
7.60.14
copyright by
MJFCIFSS
Input section
5.4 Pressure cut-off valve 104

LS-pressure cut-off valve 104 works as a pressure controller. As soon as the pre-set pressure value
is reached, it decreases the volumetric delivery of the pump to Qmin. This function has priority over
the pump's power and flow regulation systems. That means, as soon as the pressure cut-off has been
actuated, load-sensing and/or power regulation are no longer possible.
Once a consumer reaches its max. admissible operating pressure, the cut-off valve 104 is actuated
to relieves the LS signal towards the LS main nozzle in the control valve block to the tank. The LS
signal, which is reported to the pump, cannot increase any further, and the pump regulates the flow
in such a way that a max. pump pressure of LS + Up is built up in the pump channel.
The pressure cut-off valve 104 is a pressure-relief valve of the LS line.
Make sure the pressure-relief valve is periodically checked and adjusted. Use a maintenance sche-
dule.
Fig. 9 Pressure cut-off valve 104

5 Spring plate 14 O-ring

7 Washer 16 O-ring
8 Lock nut 100 Compact control block
10 Circlip 104 Pressure cut-off valve, complete
11 Backing ring
7.60.15
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MJFCIFSS
Input section
5.5 LS shuttle valve 107

The orifices of LS shuttle 107 limit the volumetric flow to the LS regulator of the pump. The propaga-
tion of abrupt pressure peaks to the regulator and, thus, power peaks of the pump are prevented in
the LS line, thanks to the interrelations of the various orifices and capacities (capacities of various
cross-sections). Pressure peaks are compensated thanks to the pulsating of the hose and/or the
compressibility of the oil volume. This prevents aggressive or unwanted responses of the pump to
sudden peaks, ensuring stable operating behaviour.
In the event of disturbances, the valve 107 can be checked for dirt by unscrewing the valve seat 210.
To check the system for damage and correct functioning, pull out the restrictor bolt 211 to inspect it
and replace it, if necessary. When reinstalling the restrictor bolt 211 ensure that it is in the correct
position (observe restrictor grooves, see Fig. 10).
5.6 Primary pressure-relief valve 105 (pump safety valve)

The purpose of the primary pressure-relief valve is to protect the pump against excessive pressure
in case of failure of the secondary pressure-relief valve and cut-off valve. It is supposed to react only
in emergencies. Therefore, its pressure setting is significantly higher than that of the cut-off valve 104
and system pressure.
Functioning and design of this valve are identical with the secondary pressure-relief valves of the con-
trol axles for lifting, stick and bucket.
5.7 Radiator and tank preload valves 7 / 8

The compact control block has central radiator and tank connections. The return lines are preloaded,
thanks to the pressure springs 2 / 6 of the check valves. The resulting back pressure at the outlet
guarantees a sufficient inflow in the event of negative loads on the outside (boom down, uphill travel
etc.) and, thus, prevents cavitation.
The amounts required for backfeeding are usually available in the volumes displaced by the consu-
mer.
The priority of the return flow of the oil through the cooler is implemented by means of different pre-
loads of the valves with the different pressure springs 2 (3.5 bar for tank preload) and 6 (7 bar for
cooler protection). With increasing volumetric flow, the resistance in the radiator line increases too,
and the additional volume is fed directly to the tank.
The valves do not require maintenance. In the event of a malfunction, the valve can be removed with
the screw plug, the pressure springs 2 / 6 and the cone 1 / 5 from the housing 100 for inspection (con-
tamination, defect), testing and replacement. If there are leaks on the outside, replace the O-ring 4 /
10.
5.8 LS central nozzle 108

The LS central nozzle is meant to be a restrictor and dampener at the LS oil inlet at the input element.
When the pressure cut-off valve is actuated, this restrictor reduces Up, and the cut-off valve can lo-
wer the pump volume thanks to the regulator for the remaining flow.
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Input section

Fig. 10 Sectional drawing: input element
1 Cone 211 Restrictor bolt

2 Pressure spring 219 Valve seat
3 Shim 223 Pressure spring
4 O-ring 228 Spring plate
7 Check valve 229 Screw plug
100 Compact block 275 Screw plug

103 Piston / pressure balance K Connection to oil cooler
104 Pressure cut-off valve LS LS signal from the consumer with the
highest load
107 Shuttle valve, complete P Pump pressure
108 LS central nozzle T Tank channel
210 Valve seat
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6 Control and distribution area
6.1 Control axles, see Fig. 11

Each control axle has the necessary spool complete with actuation (control lid, regulating springs),
required for its respective function, a pressure balance and the corresponding connections with se-
condary protection.
6.2 Spools 160, 180, 220, 240 and 260

In the event of malfunction, check the spools 160 to 260. To do this, remove the upper control lid 134,
pull out the spool and check it for damage, contamination, etc. If necessary replace it.
6.3 Removal of spools 160 to 260
Caution!
The control pressure generates a high force on the screw connection at the control lid 134. The
spring preload of the pressure spring 132 acts on the control lid 134.
There is a risk of injury to the mechanic, as the control lid 134 might be propelled from its seat when
it is loosened. In this case, oil might flow across the components of the excavator and contaminate
the ground.
X Before dismantling the control lines, relieve pressure from hydraulic circuit.
X Release the pressure from the respective control pressure line and collect the oil in a suitable
container.
X Carefully remove the screws 135.
X Remove the lid 134 with the O-ring 130.

X Pull the spool 160 to 260 from the control valve block 100.
X Remove the pressure spring 132 and the spring plate 131.
6.4 Installation of spools

Important information for installation / replacement of pistons:
– The various spools installed are matched to the specific requirements of their respective operati-
onal functions (lifting, stick etc.) and cannot be exchanged among each other for that reason.
– If you want to remove several spools at a time, make sure they are re-installed in their original
bores.
– Usually, the bores in the control valve blocks are made for perfect fit. If this applies to all the bores
in the block, the type plate of the block contains the end number "000". 'Perfect fit' and the zeroes
are meant to indicate that the bores have ± 0 µm tolerance. That means, spools supplied for re-
placement usually have a tolerance range of 8-10 µm, and the amount of leak oil is within the nor-
mal range.
– Zero-tolerance bores are marked with steel stamping numeral 0. Replacement with spools accor-
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ding to the spare parts catalogue is possible.

– If one or several bores of the control block do not fall within zero tolerance standards, this is indi-
cated on the type plate. To find out which bore is meant, remove the top lid of the spool in question.
– Find the tolerance of the bore on the front face of the control block, e.g. 10 = 10. That means, re-
placement of the spool according to the spare parts catalgue is not possible. A special spool for
that particular tolerance must be made.
– When ordering spare spools, please be sure to give all indications from the type plate. See also
service information no. 1-14-52 / 2000.
Be sure to install spool in the correct position.
X Choose a matching spool and grease lightly.
X Insert into the control valve block 100 with great care.
X Place the spring plate 131 and the pressure spring 132 on the spool.
X Place the lid 134 together with the O-ring 130 onto the control block 100 and secure it with the
screws 135.
Fig. 11 Control axles in control valve block 100
100 Compact control valve block 180 Spool / chassis left

131 Spring plate 220 Spool / boom
132 Regulation spring 227 Restrictor check valve

134 Control lid 240 Spool / stick
140 Screw plug 260 Spool / bucket
160 Spool / chassis right 999 O-ring
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Control lid 134 / 136
7 Control lid 134 / 136
Fig. 12 Control lid 134
1 Cap nut 140 Screw plug

2 O-ring 167 Restrictor check valve (travel right)
3 Lock nut 187 Restrictor check valve (travel left)
4 Adjusting screw / stroke limitation 227 Restrictor check valve (lifting)
134 Control lid 247 Restrictor check valve (stick)
136 Control lid with short screw 4 (only at Y Setting value of stroke limitation
spool / bottom stock)
The control lid 134 is located on both sides of the spools 160 to 260 and is fixed to the compact block
100. The control oil required for the actuation of the spool is fed through the control connection a / b
of the control lid 134.

Some of the control axles have a shuttle dampening function (restrictor check valve 167 / 187 / 227
/ 247) in the inlet area of the control connection. This effects a certain degree of throttling of the oil
displaced by the spool in the opposite control lid and, thus, a reduction of the shifting speed of the
spool. This results in a smooth start of the motion of the consumer and good handling and fine-con-
trol.
The dampening of the respective consumer movement (A) is effected by means of the restrictor
check valve 167 / 187 / 227 / 247 in the opposite control lid (B). Oil enters the control lid (e.g. at con-
nection a) through the valve seat, which is opening. The oil displaced by the spool (e.g. via connection
b) closes the valve seat so that the control oil displaced must go through the orifice of the valve. The
cross section of the orifice (and thus the shifting speed) has been matched to the characteristics of
each individual consumer. Thanks to the throttling in the outlet towards T, the dampening effect works
with abrupt actuation as well as for immediate relief.
In addition, the control lid is equipped with a stroke limitation 4 for the spool. Like that, the max. speed
of the consumer can be limited.
The setting has been pre-set by the supplier / manufacturer. Do not tamper. The adjusting screws 4
are secured with the lock nuts 3 and protected against damage by the cap nut 1.
Checking the setting value Y serves for rough adjustment only, see Tab. 1. Precise setting of absolute
max. quantities going to consumers is possible only using a flow meter on the outlet of the control
block.
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Control lid 134 / 136
The flushing grooves a of the spools 160 to 260 form a connection between the tank and control lid
134. Together with the tank preload of the control valve block, this means a continuous flow of oil as
long as the pilot control valve is not actuated. That means that the flushing volume is available for
preheating the control oil circuit.

Fig. 13 Sectional drawing of control lid 134
1 Cap nut 167 Restrictor check valve

2 O-ring 180 Spool / chassis left
3 Lock nut 187 Restrictor check valve
4 Adjusting screw / stroke limitation 220 Spool / boom
5 Shuttle 227 Restrictor check valve
6 Orifice 240 Spool / stick
100 Control valve block 247 Restrictor check valve

131 Spring plate 260 Spool / bucket
132 Regulation spring
134 Control lid a Flushing grooves
140 Screw plug a1-a5 Control pressure connection, bottom
160 Spool / chassis right b1-b5 Control pressure connections, top
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Directly controlled pressure balance 164 / 184
8 Directly controlled pressure balance 164 / 184
On-demand flows are controlled by means of the cross-section of the opening of the respective spool
shaft and the LS pressure at the pump regulator.
Responsible for that are the pressure balances connected to each spool shaft and sitting in the con-
trol block.
The LUDV pressure balance 164 / 284 with the pressure spring 165 of each section is situated
downstream of the gauge orifice of the spool.
This pressure balance reports to the pump regulator the pressure of the consumer with the highest
load. For all consumers with lower loads, the pressure balance compensates for the LS pressure with
the prevailing load pressure of the consumer in question.
In the neutral position of the spool, the connection between pump and channel p’ is blocked by the
spool (see Fig. 15). In this position, the pressure in channel p and behind the load-holding valves is
dissipated nearly to tank level, thanks to the movement of the piston. The consumer connections are
blocked by the spool in the housing. That means, the consumer sits between two oil columns and is
fixed.
Fig. 14 Pressure balances 164 / 284

164 Pressure balance / chassis right 184 Pressure balance / chassis left
165 Pressure spring
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8.1 High pressure

As soon as the spool is shifted, the supply orifice of the spool opens the connection between pump
connection p and the channel p’. The resulting pressure in this space shifts the pressure balance.
Via the internal channels in the pressure balance, it also acts on the rear side of the load-holding val-
ves.
Consumer pressure pc of connection A acts via the channels in the spool and is available at the front
side of the left-hand load-holding valve. With pump pressure p’ rising above consumer pressure pc,
the load-holding valve opens. The connection between pump and consumer has been established,
now, and initiates the movement. The displaced oil flows back to the tank via the outlet orifice. The
secondary pressure-relief valves remain closed as long as the pressure in the consumer connection
remains below the pre-set pressure value.
Fig. 15 Pressure balance in high-pressure position
pc high = LS signal to pump regulator
8.2 Consumer with highest load is actuated

For individual movements, or when the load pressure of the consumer pc is the highest in the system,
the LS pressure is generated by the spring space of the corresponding pressure balance. Tapping
pressure at this point guarantees that only the highest load pressure is signalled. The pressure ba-
lances of the other sections block off effects generated by other consumers.
This LS signal is sent to the flow regulator (LS regulator) of the variable-displacement pump, and also
to the spring chambers of the other LUDV pressure balances. The pressure balance is fully open.
Channel p’ is connected to consumer connection pc, without pressure drop.
Feeding the LS signal of the load-holding valves guarantees that the consumer connection is blocked
until the necessary operating pressure is reached, and prevents sudden drops in the event of nega-
tive (pulling) loads.
8.3 Low pressure
8.3.1 Load-sensing function

In the saturated area, the LUDV system operates as a load-sensing regulation system only. The
speed of the consumer is controlled independently of the load pressure, by means of the opening
cross-section of the gauge orifice (spool).
When several movements overlap, the load pressure of the consumer with the highest pressure acts
7.60.23
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via the central LS line in the spring chambers of the other LUDV pressure balances. The resulting
pressure in channel p’ of this section is derived from the highest reported LS pressure (p’ = LS +
spring force). The LUDV pressure balances automatically regulate pressure p’ of the various shafts
by limiting the flow cross-section to the consumer channel to the same value. Up at the gauge orifice
is identical. That means, the speed of the consumer is independent of the difference of the load pres-
sures. As the pressure balance is under the influence of the load signal with the highest load on the
spring side, it cannot open completely. By mediation of the pressure balance, which is only partly
open, generates another pressure difference which depends on the individual load.
Fig. 16 Pressure balance in low-pressure position
d = LS = pc high
e = pc low
F = spring chamber
R = regulating orifice
8.3.2 LUDV function

The LUDV system works even in case of a saturation deficit. In such a case, the oil volume the oil
volume requested on the basis of the sum of the open gauge-orifice cross-sections at the existing Up
exceeds the max. flow rate of the pump within the limits of the power control. The LS regulator of the
pump is no longer in a position to build up the set Up by means of pivoting the variable-displacement
pump even further +. Up set at the regulator collapses.
Under this condition, the LUDV system maintains Up at the same level across all open gauge orifi-
ces. This means that, in the event of a saturation deficit, the system does not simply shut off the con-
sumer(s) with the highest pressure. Instead, the speeds of all the actuated consumers is reduced
proportionally to the open cross-sections.
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When all the pressure balances are in balance:

– the LS system pressure in all the spring chambers of the pressure balances is the same
– the p’ in front of the gauge orifices of the section with the lower load corresponds to the LS pres-
sure of the consumer with the highest load
Up inlet orifice = ppump - p’
Up at the inlet orifices of all consumers is always equal. In the event of a saturation deficit, Up drops,
again, at all consumers to the same degree.
The pressure differences Up inlet orifices between p’ and each individual consumer pressure pc is re-
gulated and balanced automatically by adapting the opening cross-section, so that the volumetric
flows are split proportionally.
8.3.3 Negative load

Speed control of the consumers via the aperture of the inlet orifice is not possible with negative (pul-
ling) loads. In such a case, the consumer is controlled in relation to the actual load, via the outlet ori-
fices.
a No LS signal 164 Piston / pressure balance

b LS signal 180 Spool / travel left

100 Control valve block 184 Piston / pressure balance
160 Spool / travel right
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Pilot-controlled pressure balances 164* / 184* / 224 / 244 and 264
9 Pilot-controlled pressure balances 164* / 184* / 224 / 244 and 264
Pilot-controlled pressure balances 164* / 184* / 224 / 244 and 264 take over the same tasks in the
LUDV system as directly controlled pressure balances 164 and 184. For that reason, the function of
this pilot-controlled pressure balance corresponds to the basic function of the directly controlled pres-
sure balances.
Additional features of pressure balances 164* / 184*/ 224 / 244 and 264:
Finer and more precise regulation behaviour thanks to the pilot control pistons 1 with the pressure
spring 2 in the pressure balance.
These pilot control pistons with their very fast reaction times take over the blocking and opening func-
tions with respect to the pressure signal between the consumers with the highest and the lower pres-
sures.
Fig. 18 Pressure balances, pilot-controlled

164* Pressure balance (pilot-controlled) 193 Spring plate
165 Pressure spring 194 Spring plate
166 O-ring 224 Pressure balance (pilot-controlled)
168 Screw plug 225 Restrictor 2x Ø 0.8 mm

169 Screw plug 244 Pressure balance (pilot-controlled)
184* Pressure balance (pilot-controlled) 245 Restrictor 2x Ø 0.8 mm
191 Pilot control piston 264 Pressure balance (pilot-controlled)
* in undercarriage with dozer blade
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9.0.1 Low pressure section:

The pilot control piston 1 is in its starting position, i.e. it connects the current LS pressure of the con-
sumer with the highest pressure to the spring side of the pressure balance. Like that, the pressure
balance regulates the pump pressure of the consumers with the lower pressure and brings them to
the LS pressure of the consumer.
Fig. 19 Pressure balance low-pressure position (LS signal from consumer with highest pressure)

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9.0.2 High pressure section:

The pilot control piston 1 is shifted against the pressure spring 2. That means, the spring side of the
main piston is relieved. At the same time, the consumer with the highest load is connected to the LS
pressure. This, again, acts on the LS regulator of the working pump.
Fig. 20 Pressure balance in high-pressure position (pc high = LS signal to pump regulator)
1 Pilot control piston 264 Pressure balance

2 Pressure spring F Spring chamber
100 Control valve block R Regulating orifice
224 Pressure balance pch High pressure (LS)
240 Spool pcl Low pressure
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Pressure and feeder valves
10 Pressure and feeder valves
The pilot-controlled pressure-relief valves 105 / 221 - 262 of the various consumer connections are
all of the cartridge type and screwed directly into the control valve block 100. They limit the pressure
between pump, control block and working attachments and/or between working attachments and
control block when the spools are closed (secondary function).
If the pressure increases in the circuit of an attachment in undesirable ways, destruction would hit the
weakest point, e.g. screwed connections or hydraulic hoses. In order to prevent that, we provide a
sort of pre-determined breaking point. In our scenario, the pressure rising in the hydraulic system acts
on a certain type of integrated hydraulic device. We call this a pressure-relief valve. It limits the ma-
ximum pressure in the consumer and its connection to the pre-set value.
As the pressure valves in the hydraulic system must be able to cater for large flows of oil, our machi-
nes are equipped with indirect (pilot-controlled) pressure-relief valves for reasons of manufacture and
better functioning. In these valves, a pressure-relief valve is installed that works directly as a pilot con-
trol valve to actuate a second, larger valve.
At the same time, the pressure-relief valves act as feeder valves. Different flow rates of oil coming in
and going out of the operating cylinders lead to a vacuum. This happens, for instance, when you deal
with pulling loads on the outside, e.g. 'extend stick cylinder' with particularly long sticks. In such a ca-
se, the speed of the consumer is not controlled by means of quantities determined by the gauge ori-
fice, but (independently of loads) via the outlet edge of the spool.
In order to prevent that, the valves connect the return side with the corresponding low-pressure side
so that additional oil can be sucked in.
10.1.1 Pressure control

The pressure (P) built up in the consumer circuit acts on the front face of the main cone 3 and, through
the bore D1, also on the rear surface of the main cone 3. At the same time, the pressure also acts on
the pilot control cone 4. The springs 8 / 9 and 5 push the main cone 3 and the pilot control cone 4 into
their closing positions (static status).

and adjusting spring 5, pilot control cone 4 is lifted from its seat, and some oil can penetrate into the
return channel.
Due to the different cross-sections of the bores D1 in the main cone 3 and D2 in the valve insert 2,
there is a pressure difference between the front and the spring side of the main cone 3.
As a result of this pressure difference, the main cone 3 is shifted against the pressure springs 8 / 9,
and a substantial amount of oil flows to the non-pressurised return side T.
10.1.2 Feed
If there is a vacuum in a working circuit, the higher pressure in the hydraulic tank is applied through
the bore T of the housing 1 onto the ring face of the main cone 3. As a result of the pressure difference
across the effective surface of the main cone 3, the main cone is pressed against the force of the
pressure springs 8 / 9 so that the required amount of oil can flow through the bore T to the respective
side of the consumer.
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Pressure and feeder valves
Fig. 22 Pressure and feeder valves 105 / 221 - 262
1 Housing 10 Protective cover

2 Valve insert 11 Piston seal
3 Main cone 12 O-ring
4 Pilot control cone 13 O-ring
5 Pressure spring 14 Backing ring
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Feeder valves 161 / 162 / 181 / 182

8 Pressure spring 105 Primary pressure-relief valve
9 Pressure spring 221-262Secondary pressure-relief valve
11 Feeder valves 161 / 162 / 181 / 182
see Fig. 23
Feeder valves (i.e. suction valves / check valves) are used with rotating consumers.
The danger of insufficient filling, i.e. cavitation in oil motors is greatest when there are delays in the
operation of the machine (downhill travel). When decelerating, the oil motor of the chassis runs idle.
The pressure peaks due to the high moment of inertia during downhill travel make the brake valves
react while the spools are blocked.
What is more, at a certain inclination, the speed of the motor (and, thus, the oil volume to be fed) is
no longer determined by the aperture of the inlet orifice of the spool, but depends on the load and the
downhill force.
The feeder valve makes the required amount of oil available to the operating connection to avoid ca-
vitation.
11.1.1 Closing position:

The high pressure in channel P is applied through the bore D to the spring side of the main cone 3,
pressing the cone against the sealing edge of the valve insert 1, so that the valve 161 / 162 / 181 /
182 is closed towards the consumer side.
11.1.2 Suction:
If there is a vacuum in this working circuit, the higher pressure in the hydraulic tank acts via bore T
of the valve insert 1 on the ring face of the main cone 3.

As a result of the pressure difference across the effective surface of the main cone 3, the main cone
is pressed against the force of the pressure spring 8 so that the required amount of oil can flow th-
rough the bore T to the respective side of the consumer A2 / B2.
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Feeder valves 161 / 162 / 181 / 182
Fig. 23 Feeder valve 161 / 162 / 181 / 182
1 Valve insert 33 O-ring

3 Main cone 34 Backing ring
6 Screw 35 O-ring
31 Piston seal
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Shift valve for Qmin shifting (fast run) of the regulating motor 106
12 Shift valve for Qmin shifting (fast run) of the regulating motor 106
12.1 see Fig. 24

The 3/2-way shift valve 106 integrated into the control valve block controls the working pressure of
the travel motor and thus the Qmin / Qmax shifting of the regulating travel motors 200/201.
If fast travel of the excavator is pre-selected with the switch S21 (on the right control console, see
electric equipment) (regulating motor to Qmin), the switching from Qmax to Qmin and vice versa is
determined by the working pressure in the travel gear circuit (travel pressure).
Travel pressure 0 bar - 300 bar = regulating motor can be run at normal and fast speed (Qmax./
Qmin.).
Travel pressure > 310 bar = regulating motor is automatically set to Qmax (low speed).
Travel pressure <130 bar = Resetting pressure from Qmax. (low speed = normal travel) to Qmin.
(high speed = fast travel).
12.2 Function
The valve 106 in neutral position feeds the control oil from the control oil unit 50 connection A2 (so-
lenoid valve Y24) through connection c to connection d and a line to connection X of the regulating
motors 200/201.
The maximum control pressure acts on the travel motors and pushes the powertrain to the minimum
pivot angle (Qmin.= fast speed), see also functional description in group 7.28).
If the travel pressure is increased (>310 bar), the shifting piston 6 is pressed against the pressure
spring 4 and the connection between c - d is blocked, while the pressure at the connection X of the
regulating motors 200/201 is released through connection d -L to the tank. As a consequence, the oil
motor switches to Qmax = low speed, despite the pre-set fast speed. $.
If the travel pressure drops to the level or the switching point (<130 bar) of the valve or below, the
pressure spring 4 pushes the shifting piston 6 to its neutral position (connecting lines c - d) and the
regulating motors are switched again to Qmin (fast travel).

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Shift valve for Qmin shifting (fast run) of the regulating motor 106
Fig. 24 Sectional drawing of shifting valve (Qmin shifting)
1 Connecting piece 11 O-ring

2 Bushing 17 Backing ring
3 Piston guide 18 O-ring
4 Pressure spring 50 from control oil unit
5 Spring plate 100 Compact control block
6 Shifting piston 106 Shift valve, complete
7 Piston 200 from/to travel motor left
8 Threaded stud 201 from/to travel motor right
12.3 Repairs
In the event of malfunction, the valve 106 can be screwed out and inspected for damage and dirt.
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Repair works on control valve block
13 Repair works on control valve block
Caution!
Before you begin any repair works on the control valve block, be sure to relieve tank and servo pre-
loads.
X Switch off the diesel engine.
X Proceed as follows: Unscrew breather filter on hydraulic tank about 1 turn (slow de-pressurisa-
tion).
Releasing backpressures
X Turn ignition key to ignition position.
X Actuate all pilot control valves in all possible directions.
13.1 Leaks on the outside

Leaks on control valve block: Replace seals on screwed connections, SAE flanges, caps and valves.
13.1.1 Spool
Description for the installation and removal of the spool, see 6.3
Note!
If you want to remove several spools at a time, be sure you put them back into the correct bores
afterwards (markings, etc.).
Spare spools have the spool's axis marking A1 - A5 engraved on the front side opposite the spring
and on the shaft of the spring plate package.
X Before you install the spool: check for good condition of housing O-rings (spool lid seals). Check
for correct condition of spools (no scores on surface).
X Install in reverse sequence. Insert spools precisely and with care. Avoid jamming. Do not use
force.

13.1.2 Pressure balances and valves
To repair pressure balances and valves, take out of housing completely.
To access the suction valves 161 / 162 / 181 / 182 and the secondary pressure-relief valves 221 -
262, screw the respective load-holding valve 170 - 172 from the housing.
When installing valves: check outside seal rings for good condition.
X Avoid damage, twisting and warping. Fit seals tightly.
Use correct torques for tightening additional shafts, valves and screwed connections.
7.60.35
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Maintenance
13.1.3 Torque values for control valve block 100

check valve 7/8 10 Nm Valve seat 210/219 15 Nm
Pressure balance 102 25 Nm Pressure-relief valves 221 - 262 120 Nm
Pressure cut-off valve 104 25 Nm Screw plug 229 60 Nm
Pressure-relief valve 105 120 Nm Screw plug 275 10 Nm
shift valve 106 80 Nm Screw plug 277 10 Nm
Nozzle 108 6,5 Nm Screw plug 278 10 Nm
Nozzle 109 8 Nm Allen head screw 320 70 Nm
Allen head screw 111 110 Nm Allen head screw 335 10,5 Nm
Allen head screw 135 10,4 Nm Screw plug 369 90 Nm
Plug 140 20 Nm Screw plug 373 120 Nm
Restrictor check valve 127/167/187/227/247 20 Nm Screw plug 475 30 Nm
Plug 163/168/169 300 Nm Screw plug 491 3,5 Nm
Load-holding valve 172 150 Nm Allen head screw 811 55 Nm
Suction valves 161/162/181/182 120 Nm
Information for installation:

– The contact surface must be absolutely even.
– Mounting bolts must be tightened evenly, in a cross-wise pattern.
– Contact faces of SAE connections must be clean.
– Pipes and hose lines must be properly laid, without any twists, warps, tensions etc.
– Be sure to respect correct torques with screws and bolts, screwed connections etc. (See group
1.20 torques of screws, bolts, screw-in studs.)
14 Maintenance
Periodically check control valve block for leaks. Regularly check the pressure cut-off valve 104 and
the secondary pressure-relief valves 221 - 262 for correct settings (see maintenance instructions).
To check the secondary pressure-relief valves 182, increase the set value of the pressure cut-off val-
ve 104 above the expected peak value (see adjustment protocol and guideline for hydraulic system,
group 6).
7.60.36
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15 Additional control axles
15.1 Slewing gear element 120, Fig. 26

Classification of the element:
– Control pressure connections a01 and b01
– Connections A01 and B01 for slewing-gear supply and return flows
– Connection LSDR to DRDA
– Connection DRDA for pressure line to proportional solenoid valve Y451
– Input pressure balance 122 for priority circuit
– Shuttle valve 126 to control the input pressure balance 122
– Spool 123 for the working movement of turning right/left of the uppercarriage with the regulating
and return spring 335.
– Control lid 334 of the axle with stroke limitation of the spool 123 and restrictor check valves 127
for the fine control of the spool 123
15.2 Repair works on control valve block
Leaks on the outside

Replace seal rings of flanges, lids and valves. Replace screw plugs, when no longer tight.
Spool
X Unscrew control line in question.
X Remove the Allen head screws 335.
X Remove the control lid 334. (Careful: lid 334 is spring-loaded.)
X Remove the pressure spring 332. Pull the spool 123 from the housing.
X Install in reverse sequence.

Valves
To repair valves, remove the valve from the housing. If necessary, exchange against spares as listed
in the spare parts catalogue.
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Fig. 25 Hydraulic diagram of slewing gear element 120

Fig. 26 Slewing gear segment
7.60.38
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100 Compact control block 365 Pressure spring / input measure balance
120 Spool / slewing gear segment 369 Screw plug / input measure balance
122 Piston / input measure balance 370 Cone / load-holding valve
123 Spool 371 Pressure spring / load-holding valve
125 Restrictor Ø 1.8 mm 372 O-ring / load holding valve
126 Shuttle valve 3 x Ø 0.8 mm 373 Screw plug / load holding valve
127 Restrictor check valve (Ø 0.8 mm) 475 Screw plug
128 Restrictor check valve (Ø 1.2 mm) 491 Screw plug
330 O-ring 810 End plate
331 Spring plate 811 Allen head screw
332 Pressure spring 999 Seal kit
334 Control lid Y451 Proportional solenoid valve
335 Allen head screw
15.3 Functional description of slewing gear spool
15.3.1 Priority of slewing gear

In the one-circuit LUDV system, all consumers are arranged in parallel and supplied by one and the
same working pump. In the LUDV system, it is the slewing gear that has always priority. It can be
controlled independently of all the other consumers.
The question of priorities arises whenever the system must work with a deficit in saturation and the
LUDV system automatically influences the speed of movements with respect to the degree of the ac-
tual saturation deficit.
Putting a priority on the slewing gear turned out to be necessary because most operators do not like
the speed being automatically influenced by other movements. What is more, any automatic accele-
ration due to the LUDV principle is considered as unacceptable.
With those requirements in mind, we put the priority on the slewing gear whenever several move-

ments must be carried out simultaneously. It works like this:
The module is the only consumer in the system that works with a 2-way pressure balance in the sup-
ply flow leading to the gauge orifice. The pressure balance for the section, in front of the gauge orifice,
compares load pressure LS slewing gear and the setting of the spring of the pressure balance to pres-
sure p that it obtains from the gauge orifice. The Up gauge orifice is maintained at a constant level
(corresponding to the type of spring used) and, thus, allows for speed control that is independent of
the load pressure. The only way to modify quantity or speed is a change at the gauge orifice.
15.3.2 Attachment section is consumer with highest load pressure

Thanks to the check valve in the LS line between module and system, it is not possible that the control
of the slewing gear is influenced by consumers with higher loads that happen to run at the same time.
The difference between pump pressure psystem and operating pressure p of the slewing gear ele-
ment is always controlled and regulated by the preceding pressure balance, even when consumer
pressures fluctuate significantly. The regulating cross-section of the pressure balance has been cho-
sen to allow for quick responses in case of great differences between psystem and p and increases /
pens with decreasing pressure differences.
The quantities supplied by the pump and not requested by the slewing gear within the performance
regulation is distributed proportionally to the other active consumers according to the LUDV principle.
7.60.39
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MJFCIFSS
15.3.3 Slewing gear section is consumer with highest load

LSslewing gear is reported to the LS line of the compact control block (via the check valve) to have the
highest pressure in the system. It acts on the rear side of the LUDV pressure balances and Up re-
gulator of the variable-displacement pump. The quantities supplied by the pump and not requested
by the slewing gear within the performance regulation is distributed to the other active consumers ac-
cording to the LUDV principle.
15.3.4 Slewing gear torque control

For a sensitive acceleration of the slewing gear, we need a torque control (pressure control) in order
to influence the value of the acceleration.
During acceleration from standstill, the slewing gear requires only a small amount of oil. With LS con-
trol only, it generates the max. load pressure in the slewing gear and, thus, the max. rotary accelera-
tion. For that reason, the one speed that is independent of the load pressure (via the 2-way supply
pressure balance 122) is overridden by a torque control.
This allows for stepless control via the right pilot control unit, the pressure switch B335, the central
control A149 and the proportional solenoid valve Y451. The torque available at any time is adjusted
depending on the control pressure. That way, the operator can control the rotary acceleration via the
angle of the pilot control valve and, thus, benefit from very sensitive acceleration of the rotary motion.
15.3.5 Loss-free acceleration

The proportional solenoid valve Y451 located at the hose clamp bar is integrated into the LS line of
the pressure balance module. The slewing gear is thus pressurised with control pressure required for
the build-up of the required working pressure. This has the advantage that the upstream pressure
balance is controlled as soon as the preset pslewing gear and only the volume required to maintain the
pressure at the current level. Thanks to this combination, the acceleration of the slewing gear works
without any losses. Furthermore, the max. admissible acceleration pressure at the proportional sole-
noid valve Y451 is approx. 20 bar below the topmost setting of the 2-step slewing-gear valves in the
oil motor. This means that the secondary valves does not respond, and the corresponding losses are
avoided. Thanks to the torque control, the quantities supplied to the slewing gear motor goes up when
pslewing gear drops until the required pressure according to the pre-set Up pressure spring has been
attained via the gauge orifice.
15.3.6 Deceleration of the slewing gear

Deceleration of the slewing gear is effected via the outlet orifices of the spool leading to the tank, and
the pressure-relief valves leading to the motor. Min. deceleration is derived from the lower pressure
setting of the 2-step slewing gear pressure valves. They have been tuned to a lower level in order to
provide for a smooth deceleration. Again, the rule applies that again that a rise in pcontrol pressure
increases the additional pressure level of the secondary cartridge continuously all the way up to the
max. admissible value.
In the neutral position of the spool, the slewing gear is hydraulically fixed by means of the locked con-
sumer connections A and B.
Should adjustments become necessary, proceed according to the adjustment protocol and the in-
spection and adjustment instructions; see group 3.
In the event of disturbances, it is possible to check the valve for dirt and/or a broken spring: remove
and dismantle; if necessary, replace completely.
7.60.40
copyright by
MJFCIFSS
Fig. 27 Sectional drawing of slewing gear segment
122 Input pressure balance 372 O-ring

123 Spool / slewing-gear segment 373 Screw plug
125 Restrictor Ø 1.8 mm 475 Screw plug
126 Shuttle valve 3 x Ø 0.8 mm D1 Supply gauge orifice p-A01 and/or p-
B01
127 Restrictor check valve (Ø 0.8 mm) D2 Outlet orifice A01 - T or B01 - T
334 Control lid pV Consumer pressure
365 Pressure spring pM Pressure in front of gauge orifice
369 Screw plug a01/b01Control oil connection
370 Cone (load-holding function) A01 Consumer connection
371 Pressure spring B01 Consumer connection
7.60.41
copyright by
MJFCIFSS
LSC additional control axles (kit elements)
16 LSC additional control axles (kit elements)

Fig. 28 Additional control axles AS1, AS1+P, AHS 1, AHS 11 and AHS 12
7.60.42
copyright by
MJFCIFSS
P* dozer blade
>with Tool Control
# with Tool Control plus
M7 - 20S M7 - 20S (>)

SX/14-1X SX/14-2X Secondary valve
Secondary valve
with pressure reduc-
without pressure
reduction tion
M7 - 4546 (#)
Product Secondary valve
Unit with pressure
reduction and
control axle with
flow reduction
Contained in: AS1 Dozer blade AHS 1 AHS11

Control axle 540 560 500 510
for grapple rota- Dozer blade Kit AHS 1 Kit AHS 11
tor
left right down up Exten- Retrac- Exten- Retrac-
ding ting ding ting
Nominal width of (“) 14 14 20 20
block (G3/4“) (G3/4“) (SAE §/4“) (SAE 3/4“)
Consumer con-
nection
Ø piston rod mm 18 18 25 25
Piston stroke mm 8 8 8 8 11 11 11 11
Setting value Y
R 317 mm 15.6 15.6 15.6 15.6 14.2 14.2 14.2 14.2
± 0.5
p1 bar 2.0 2.0 2.0 2.0 7.0 7.0 7.0 7.0
± 0.5
p2 bar 234 23.4 23.4 23.4 20.6 20.6 20.6 20.6
Qn (A)/Qn (B)
R 317 l/min 30 30 100 100 200 200 § 200 200*
Restrictor check
valves mm - - 1.0 1.0

At connection a mm - - 1.0 1.0
At connection b
Max. leak oil cm3/min 60 60
at load pressure bar 150 150
at oil temperature °C 50 50
Tab. 2 List: LSC additional control axles
* = when connected to lateral boom adjustment, be sure to reduce flow on both sides. Proceed as follows: To adjust, turn
the stop screw to Y = 15mm (top) and Y = 12 mm (bottom).
§ = when connecting to the regulating cylinder / hydraulic boom adjustment, reduce the flow to the piston rod side to 140
l/min. Proceed as follows: Turn stop screw 270 degrees = 0.7 mm. Measure Y is reduced to 13.5 mm.
(>) with Tool Control ( #) with Tool Control plus
Screw plug 18/29 30 Nm Restrictor check valve 507/517 20 Nm

Allen head screw 111 70 Nm Pressure-relief valves 541 - 562 70 Nm
Hex nut 112 70 Nm Screw plug 567 30 Nm
Allen head screw 135 10.4 Nm Screw plug pressure 544 / 564 60 Nm
balance
Screw plug 167 160 Nm Allen head screws 811-813 55 Nm
Screw plug 172 100 Nm Magnet Y22 / Y23 12 Nm
Pressure-relief valves 501 - 512 100 Nm Magnet Y417-1 /-2 12 Nm
7.60.43
copyright by
MJFCIFSS
– Qn (A) / Qn (B) = nominal flow rate at outlet A / Bat Ur = nominal value

– p1 = control pressure at begin of regulation
– p2 = control pressure in final position
Fig. 29 Additional control axle AS1

Fig. 30 Additional control axle for dozer blade
41 Measuring point MP 540 Additional control axle AS 1

104 Pressure cut-off valve 542 Secondary pressure-relief valve
500 Spool / regulating cylinder 543 Spool
501 Secondary pressure-relief valve 544 Pressure balance
502 Secondary pressure-relief valve - extend 560 Spool / dozer blade
cylinder
504 Pressure balance 561 Secondary pressure-relief valve
507 Restrictor check valve 562 Secondary pressure-relief valve
510 Spool / hydraulic hammer etc. 563 Spool

511 Secondary pressure-relief valve - extend 564 Pressure balance
cylinder, 2-step
512 Secondary pressure-relief valve - retract Y22 Solenoid valve / grapple rotation left
cylinder
514 Pressure balance Y23 Solenoid valve / grapple rotation right
7.60.44
copyright by
MJFCIFSS

Fig. 31 Additional control axles for AHS 1 and AHS 11 / AHS 12 with Tool Control
7.60.45
copyright by
MJFCIFSS
Description of additional control axles
Fig. 32 Additional control axles for AHS 11 and AHS 12 with Tool Control plus
17 Description of additional control axles

17.1 Additional control axle for accessory kit AS 1

The additional element 540 (AS1) is flange-mounted to the control valve block next to the slewing
gear element. That way, the working movements 'turn grapple' and 'tilt bucket' receive oil from the
main working pump, too.
The individual segment for the working movement 'grapple rotator' is equipped with a magnetic-hy-
draulic actuation of the spool 543. The proportional actuation of the piston has been designed as an
on-off control and not in the same way as on the other two additional axles.
The control pressure at connection a / b is led to the spring chamber of the spool 543 only after ac-
tuation of the respective solenoid Y22 / Y23. That way, the spool 543 is fully actuated. The pressure
balance 544 fulfils the same purpose as the other pressure balances in the compact block 100.
The design and settings of the secondary protection correspond to group 16.42.
7.60.46
copyright by
MJFCIFSS
Fig. 33 Additional axle at AS1
27 Cone / load-holding valve 541 Secondary pressure-relief valve

28 Pressure spring / load-holding valve 542 Secondary pressure-relief valve
29 Screw plug / load-holding valve 543 Spool
30 O-ring / load holding valve 544 Pressure balance
31 Seal-Lock collar nut 810 Mounting plate
32 Adjusting screw / stroke limitation 811 Allen head screw
33 Pressure spring Y22 Solenoid valve / grapple rotation left

540 Additional control axle AS1 Y23 Solenoid valve / grapple rotation right
7.60.47
copyright by
MJFCIFSS
17.1.1 Sectional drawing

Fig. 34 Additional control axle AS1
Key, see Fig. 33

17.2 Additional control block for dozer blade attachment

The additional element 560 (dozer blade) is flange-mounted to the control block near the slewing
gear element. In units with built-in attachment kit AS1, it is located beside the additional element AS1.
As a result, the working movements 'lower dower blade' and 'lift dozer blade' receive oil from the main
working pump, too.
7.60.48
copyright by
MJFCIFSS
The individual segment for the dozer blade working movement is equipped with a magnetic-hydraulic
actuation of the spool 563. The device is actuated proportionally by means of the pilot control unit
installed in the right control console. The functions of the pressure balance 564 correspond to those
of the directly controlled pressure balances in the compact block 100.
The design and settings of the secondary protection correspond to those of group 16.68.
Note!
For the fine control of the travel movements during dozing work, the pilot-controlled pressure balan-
ces 164/ 184 must be installed in the chassis axles of the compact control block 100 (see also spare
parts catalogue).

Fig. 35 Additional axle with dozer blade
7.60.49
copyright by
MJFCIFSS
18 Load holding valve 560 Additional control axle / dozer blade

85 Adjusting device 561 Secondary pressure-relief valve
124 Cap 563 Spool / dozer blade
129 Seal 564 Pressure balance
130 Seal kit 567 Restrictor check valve
140 Seal kit 810 End plate
164 Pressure balance / travel right (pilot-con- 812 Allen head screw
trolled)
184 Pressure balance / travel left (pilot-con- 813 Allen head screw
trolled)
Fig. 36 Additional control axle dozer blade

560 Additional control axle / dozer blade 562 Pressure-relief valve / dozer blade up
560.1 Lock nut (WS 22) 563 Spool
560.2 Adjusting screw (size 6 Allen key) 564 Pressure balance
561 Pressure-relief valve / dozer blade
down
17.3 Kit elements (kits AHS 1, AHS 11 and AHS 12)

For additional functions, e.g. accessory kits AHS1, AHS11 and AHS12 (AHS1 + AHS11 more addi-
tional axles can be flange-mounted to the left-hand side of the compact control block.
To control yet another working movement, you can mount an additional 1 x additional element to the
compact block 100.
Each control axle (additional control block) has the necessary spool complete with actuation (control
lid, regulating springs), required for its respective function, a pressure balance and the corresponding
connections with secondary protection. It has an hydraulic connection to the series block 100 via the
pressure, return and LS channels. O-rings seal off the flange faces of the channels.
7.60.50
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MJFCIFSS
To retrofit one or several additional axles, proceed as follows: Remove the end plate 110. Mount the
new axle between the block 100 and the plate 110.
17.3.1 Additional control valve block for accessory kit AHS 1

The individual segment for the working movement 'hydraulic boom adjustment', etc. corresponds to
the design and construction of the lifting, stick and bucket axles of the compact block.
For a description of the functions and settings, see group 16.46.

The individual segment for the working movement 'hydraulic hammer' corresponds to the design and
construction of the lifting, stick and bucket axles of the compact block. The control axle is equipped
with two secondary-relief valves that are controlled by means of a proportional solenoid valve based
on the process pressure.
For a description of the functions and settings, see groups 16.53 / 16.55.

The individual segment for the working movement 'hydraulic adjustment of boom hydraulic hammer
/ hydraulic adjustment of boom telescopic demolition stick / scrap shear / concrete crusher / sorting
grapple' etc. corresponds to the design and construction of the lifting, stick and bucket axles of the
compact block.
Additional control valve block for accessory kit AHS 12, see Fig. 37 and Fig. 41.
The control axle AHS 1 is equipped with two secondary pressure-relief valves that correspond in de-
sign and function to the general secondary pressure-relief valves of the compact control block. The
control axle AHS 11 is equipped with two secondary-relief valves that are controlled by means of a
proportional solenoid valve based on the process pressure.
For a description of the functions and settings, see groups 16.61 / 16.63.
100 Compact block 500 Spool / segment AS 1

110 End plate 501 Pressure and feeder valve, 1-step
111 Allen head screw 502 Pressure and feeder valve, 1-step
134 Control lid 504 Pressure balance
164 Pressure spring 510 Spool / segment AHS 11
166 O-ring 511 Pressure and feeder valve, 2-step
167 Screw plug 512 Pressure and feeder valve, 1-step
170 Cone 514 Pressure balance
171 Pressure spring 517 Restrictor check valve
172 Screw plug 999 Seal kit
* various lengths (depending on the number of additional elements)
7.60.51
copyright by
MJFCIFSS
Fig. 37 Additional axles AHS 1 and AHS 11 with Tool Control / Tool Control plus
7.60.52
copyright by
MJFCIFSS

Fig. 38 Additional axles AHS 12 with Tool Control / Tool Control plus
7.60.53
copyright by
MJFCIFSS
Fig. 39 Exploded view of additional axles AHS 1 and additional axles AHS 11 with Tool Control
7.60.54
copyright by
MJFCIFSS
Fig. 40 Exploded view of additional axles AHS 11 with Tool Control plus

7.60.55
copyright by
MJFCIFSS
Fig. 41 Sectional drawing of additional control axles, left = AHS 1, right = AHS 11 with Tool Con-
trol
7.60.56
copyright by
MJFCIFSS

Fig. 42 Sectional drawing of additional control axle AHS 11 with Tool Control plus
7.60.57
copyright by
MJFCIFSS
Description of the components of the additional axles
18 Description of the components of the additional axles
18.1 Pressure and feeder valves 501 / 502

(see “Pressure and feeder valves” on page 29)
18.2 Pressure and feeder valves 511 / 512

The functions of the pilot-controlled pressure-relief valve 511 / 512 (pressure-relief and feeder valve)
correspond to those of the pressure and feeder valves 501 / 502. For details, see (see “Pressure and
feeder valves” on page 29).
The pressure-relief valves 511 / 512 are also process pressure-controlled. As a result, the begin of
opening can be controlled by the pressure by limiting the ejection oil after opening of the pilot control
stage of the pressure-relief valves 511 / 512.
The function of the proportional pressure regulation by means of the pressure-relief valves 511 / 512
are described below.
18.2.1 Proportional pressure control / begin of opening of pressure-relief valve 511/512

In order to achieve proportional pressure control, the pressure (P) in the consumer circuit is controlled
by the proportional valve Y414 via the connection Y (pilot control stage progress) in the pressure-
relief valve 511 / 512.
The pressure adjustment of pmin. to pmax (depending on the menu settings made at the display) is
regulated by power supply through the central control unit A149 (UEC 01).
When the valve Y414 opens the connection to T, a pressure reduction that is proportional to the cur-
rent occurs in the oil column between 511Y / 512Y and Y414. After the valve Y414 has been opened,
the pilot control cone 4 and subsequently the main cone 5 of the connection P - T are opened. The
pressure set in the menu is now established. The later the valve Y414 is opened via T, the higher the
operating pressure.
Fig. 43 Pressure and feeder valves 511 / 512
7.60.58
copyright by
MJFCIFSS
AHS11* for attachment with Tool Control AHS11** for attachment with Tool Control plus
Fig. 44 Function of pressure control of pressure-relief valve 511 / 512
1 Adjusting screw 15 Valve seat

2 Lock nut 16 Valve cone
3 Pressure and adjusting spring 20 Adjusting screw / max. value
4 Pilot control cone 511 Secondary pressure-relief valve for pres-

sure reduction
5 Main cone 512 Secondary pressure-relief valve for pres-
sure reduction
6 Screw plug Y414 Prop. solenoid valve
7 Housing B1 Bore for pressure behind cone 5
11 Pressure spring B2 Ring face between screw plug 6 and cone 4
12 Bushing B3 Effective surface behind cone 5
7.60.59
copyright by
MJFCIFSS
14 Magnetic coil B4 Effective surface in front of cone 5
18.3 Pressure reduction valves Y417-1 / Y417-1

This pressure reduction valve can be used to adjust the control pressure to the additional spool 513
steplessly depending on the electrical current. As a result, the desired pilot pressure of the accessory
pilot control unit (with pedals) is reduced via the proportional solenoid valve Y417-1/ Y417-2 to the
additional spool 513.
The central control unit UEC 02 (A149 / A155) powers the solenoid 14 according to the set % rate
(desired volumetric oil flow) to reduce the control pressure from connection a6/b6 to A.
The proportional solenoid 14 converts the current into a mechanical force, moving the armature bar
and with it the valve plunger 16. The valve plunger 16 closes the connection between the connection
a6/b6 and A. If the hydraulic force acting on the valve plunger 16 is greater than the magnet force,
the piston is shifted towards the valve seat 15 inwards and opens the connection A - L, thus restricting
the current control pressure.
If the solenoid coil 14 is not powered, the connection a6/b6 is closed and the connection A is linked
with the tank connection L.
Fig. 45 Pressure reduction valve with proportional solenoid Y417-1 / Y417-2

7.60.60
copyright by
MJFCIFSS
Fig. 46 Sectional drawing of proportional pressure reduction valve Y417-1 / Y417-2
14 Magnetic coil 16 Valve plunger

15 Valve seat
Y417-1 Pressure reduction valve for flow reduc- Y417-2 Pressure reduction valve for flow reduc-
tion at connection A6 tion at connection B6

7.60.61
copyright by
MJFCIFSS
7.60.62
copyright by
MJFCIFSS
Service Manual Rotary connection 1x
Design
Rotary connection 1x
1 Design
The rotary connection is situated at the fulcrum between uppercarriage and undercarriage. It con-
nects the hydraulic system of the uppercarriage with the units situated on the undercarriage.
The stator 2 is mounted above the stator of the 5x rotary connection (high pressure) to the undercar-
riage.
The rotor 1 is mounted above the rotor of the 5x rotary connection (high pressure) to the uppercarri-
age.
The connection at the top is connected through the radial and axial bore in the stator 2 and the lines
leading downwards.
The two V seals 21 seal the rotary connection to the outside.
Fig. 1 Rotary connection

7.75.1
copyright by
MJFCIFSS
Rotary connection 1x Service Manual
Connection and hydraulic link
2 Connection and hydraulic link
Connection A Regulating travel motors

Supply from the solenoid valve Y24 to the regulating motor connection X
3 Sealing of the 1x rotary connection, see Fig. 3 and Fig. 4
To carry out sealing work, the rotary connection 30 can remain mounted in the rotary connection 20.
X Disconnect the hydraulic line from the top of the screw fitting 40.
X If necessary, remove the hex head screw 26 and remove the driver 25.
X Remove the nut 4 (secured with Loctite).
X Remove the rotor 1 from the stator 2.
X Remove the V-seals 12 from the nut 4 and the stator 2.
X Remove the thrust washers 3 and the Quad rings 11 from the rotor 1.
X Mount new Quad rings 11 and thrust washers 3 in the rotor 1.
X Remount the V-seals 12 onto the stator 2 and the nut 4.
X Secure the driver 25 using the hex head screw 26 and the retaining washer 27 to the rotary con-
nection 20.
X Place the rotor 1 from the stator 2.
X Carefully remove all oil and grease from the thread of the stator 2 and the nut 4.
X Apply Loctite 270 to both parts.
X Mount the nut 4 and tighten it (tightening torque 30Nm).
X Connect the hydraulic line at the screw fitting 40 of the rotary connection 30.
7.75.2
copyright by
MJFCIFSS
Sealing of the 1x rotary connection, see Fig. 3 and Fig. 4
Fig. 2 Installation and dismantling of the rotary connection
1 Rotor 20 Rotary connection 5x, complete

2 Stator 25 Driver
3 Thrust washer 26 Allen head screw
4 Nut 27 Retaining washer
11 Quad ring 30 Rotary connection 1x, complete
12 V seal 40 Screw connection with screw fitting
7.75.3
copyright by
MJFCIFSS
Exploded view
4 Exploded view
Fig. 3 Exploded view of the rotary connection

1 Rotor 11 Quad ring

2 Stator 12 V seal
3 Thrust washer 999 Seal kit
4 Nut
7.75.4
copyright by
MJFCIFSS
Sectional drawing
5 Sectional drawing
Fig. 4 Sectional drawing of the rotary connection

7.75.5
copyright by
MJFCIFSS
Sectional drawing
7.75.6
copyright by
MJFCIFSS
Design
1 Design
The stator 2, the pipe coupling 4 and the flange 5 with the connections 1-6 are connected to the un-
dercarriage via the stator of the 7 x rotary connection (high pressure). The rotor 1 with the connec-
tions 1-6 is fixed to the uppercarriage through the rotor of the 7 x rotary connection (high pressure).
There are bores leading from line connections 1-6 of the uppercarriage to the annular chambers.
They are sealed by the rotor seal 22 in the rotor 1.
Every annular chamber is connected through a radial and axial bore in the stator 2 to the pipe coup-
ling 4 and the connections of the flange 5.
The two V-seals 21 prevent dirt penetrating the assembly.
The lid 3 secures the rotor 1 in axial direction and also serves as an additional protection against dirt.

7.76.1
copyright by
MJFCIFSS
Connections and hydraulic connections
2 Connections and hydraulic connections
Connection 1 Brake system / working brake

Supply from the foot brake valve (compact brake block), connection B1, to the
multi-disk brakes of the front axle
Connection 2 Transmission
Supply from brake and HBGV switch block (connection A) to shift lock / gearbox
connection P1 (travel in 2nd gear)
Connection 3 Transmission
Supply from brake and HBGV switch block (connection B) to shift lock / gearbox
connection P2 (travel in 1st gear)
Connection 4 oscillating axle support
Supply from solenoid valve Y66 to the support cylinders, connection St
Connection 5 Brake system / working brake
Supply from the foot brake valve (compact brake block), connection B2, to the
multi-disc brakes and/or drum brakes of the rear axle
Connection 6 Regulating travel motor / creeper gear mode
Supply from solenoid valve Y24 to regulator / regulating motor connection X
3 Removal and installation
3.1 Dismantling of 6 x rotary connection for sealing work, see Fig. 2

X Mark the bottom of the hydraulic lines leading to the rotary connection and disconnect them.
X Remove the hollow screw 6 and pull off the flange 5. Be careful with the seal washer 7 and the
cylinder pins 14.
X Mark the top of the hydraulic lines leading to the rotary connection and disconnect them.
X Remove the Allen head screws 32 with the retaining washer 33 and remove the driver 30.
X Remove the nut 29 and the retaining washers 28. Pull the rotary connection 25 from the rotary
connection 40.
3.2 Installation of the 6 x rotary connection after sealing work, see Fig. 2
X Insert the complete rotary connection 25 into the rotary connection 40 and replace the cover 44.
Secure the nuts 29 complete with the washers 28 to the screws 27.
X Place the driver 30 on the rotary connection 40 and secure it with the Allen head screws 32 and
washer 33.
X Place the seal washer 7 in the flange 5. Put the flange 5 on the pipe coupling 4 of the rotary con-
nection. Pay attention to the cylinder pins 14 in the coupling 4, and the bore in the seal washer 7
and the flange 5.
X Insert and tighten the hollow screw 6 with the tooth lock washer 9 (torque: 50 Nm).
X Connect all the hydraulic lines to the completed rotary connection. Pay attention to markings you
made before.
7.76.2
copyright by
MJFCIFSS
Removal and installation
Fig. 2 Installation and dismantling of the rotary connection
4 Pipe coupling 28 Retaining washer

5 Flange 29 Hex nut

6 Hollow screw 30 Driver
7 Seal washer 32 Allen head screw
9 Tooth lock washer 33 Retaining washer
14 Cylinder pin 40 Rotary connection 7x, complete
25 Rotary connection 6x, complete 44 Lid
27 Allen head screw
7.76.3
copyright by
MJFCIFSS
Exploded view
4 Exploded view
Fig. 3 Exploded view of rotary connection
1 Rotor 11 Allen head screw

2 Stator 12 Allen head screw
3 Lid 13 Lock washer
4 Pipe coupling 14 Cylinder pin
5 Flange 21 V seal
6 Hollow screw 22 Rotor seal
7 Seal washer 25 Rotary connection
8 Thrust washer 999 Seal kit
9 Tooth lock washer
7.76.4
copyright by
MJFCIFSS
Sectional drawing
5 Sectional drawing

7.76.5
copyright by
MJFCIFSS
Sectional drawing
7.76.6
copyright by
MJFCIFSS
Design
1 Design
The stator is on the undercarriage. The rotor is held in the axial direction by the lid, which, at the same
time, provides additional protection against dirt. The driving pin locks the rotor with the uppercarriage.
There are cast channels leading from line connections 0 - 4 in the rotor to the annular chambers. Spe-
cial seal rings (seal kit) seal them off against each other. Every annular chamber is connected to its
individual connection 0 - 4 in the stator via a radial and axial bore.
The two outer seal rings (seal kit) seal off the rotor to the outside.
The rotary connection does not need any maintenance.

7.77.1
copyright by
MJFCIFSS
Connections and hydraulic connections
Connection 0 Leak oil

Return line for the leak oil from the travel motors to the tank
Connection 1 Travel motor, right
Supply from the control block connection B1 to the travel motor (right, reverse
motion)
Connection 2 Travel motor, left
Supply from the control block connection B2 to the travel motor (left, reverse
motion)
Connection 3 Travel motor, left
Supply from the control block connection A2 to the travel motor (left, forward
motion)
Connection 4 Travel motor, right
Supply from the control block connection A1 to the travel motor (right, forward
motion)

X Remove all lines and parts that might obstruct the disassembly.
X Mark the hydraulic lines leading to bottom of the rotary connections 1 and 20 and disconnect them
(collect escaping oil in a suitable container).
X Remove the L-piece 25 from the pressure line 24.
X Mark the hydraulic lines leading to the top of the rotary connections 1 and 20 and remove them.
X Remove the hex head screws 42 with the retaining washers 43.
X Carefully pull the rotary connection 20 from the rotary connection 1.
X Remove the hex head screws 17 (if necessary, heat them up, as the hex head screws are glued
in with Omnifit 100) and the retaining washer 18 and remove the driver 19.
X Remove the nuts 34 from the hex head screws 32 and lift off the washer 33.
X Pull the rotary connection 1 from the undercarriage 50.
3.2 Installation of the 5x rotary connection after sealing work, see Fig. 2
X Insert the rotary connection 1 into the undercarriage.
X Screw the nuts 34 with the retaining washers 33 onto the hex head screws 32 and tighten them.
X Slide the rotary connection 20 into the rotary connection 1.

X Screw the hex head screws 42 with the retaining washers 43 into the cover 3 and the rotary con-
nection 20.
X Apply Omnifit 100 to the hex head screws 17 and secure the driver 19 with the hex head screws
17 with the washers 18 to the uppercarriage.
X Re-connect the hydraulic lines to the rotary connections 1 and 20 (top and bottom). Pay attention
to marks you made earlier.
7.77.2
copyright by
MJFCIFSS
X Re-install all other lines and parts you may have removed before.
Fig. 2 Installation position of rotary connection
1 Rotary connection 5x, complete 32 Hex head screw

17 Hex head screw 33 Retaining washer

18 Washer 34 Hex nut
19 Driver 41 Allen head screw
20 Rotary connection 1x, complete 42 Hex head screw
22 Screwed connection 43 Retaining washer
23 Screwed connection 44 Retaining washer
24 Pressure line 50 Undercarriage
7.77.3
copyright by
MJFCIFSS
Exploded view
25 Fitting
4 Exploded view
3 Lid 11 Rotor
4 Screw plug 15 Felt washer
5 Retaining washer 16* Plug
6 Hex head screw 98 Seal kit - consists of 8 seals:
1 felt washer, 2 outer seals top / bottom, 5
inside seals
10 Stator
7.77.4
copyright by
MJFCIFSS
Sectional drawing
5 Sectional drawing

7.77.5
copyright by
MJFCIFSS
Sectional drawing
7.77.6
copyright by
MJFCIFSS
Design
1 Design
The stator is on the undercarriage. The rotor is held in the axial direction by the lid, which, at the same
time, provides additional protection against dirt. The driving pin locks the rotor with the uppercarriage.
There are cast channels leading from line connections 0 - 6 in the rotor to the annular chambers. Spe-
cial seal rings (seal kit) seal them off against each other. Every annular chamber is connected to its
individual connection 0 - 6 in the stator via a radial and axial bore.
The two outer seal rings (seal kit) seal off the rotor to the outside.
The rotary connection does not need any maintenance.

2.1 Model A 309 - A 316 Litronic

Connection 0 Leak oil
Recycling of leak oil from travel motor and auxiliary gearbox
7.78.1
copyright by
MJFCIFSS
Connection 1 Travel motor

Supply from control block connection A2 to travel motor (reverse)
Connection 2 Support cylinders
Supply from control block connection B1 to support cylinders
Connection 3 Travel motor
Supply from control block connection B2 to travel motor (forward)
Connection 4 Support cylinders
Supply from control block connection A1 to support cylinders
Connection 5 Steering
Supply from Servostat to steering cylinder (travel, right)
Connection 6 Steering
Supply from Servostat to steering cylinder (travel, left)

X Remove all lines and parts that might obstruct the disassembly.
X Mark the hydraulic lines leading to rotary connections 10 and 115 and disconnect them.
X Remove the hollow screw 117 and the tooth lock washer 118.
X Remove the flange 116 with the seal 117.
X Remove the nuts 122 and the washer 121.
X Pull the rotary connection 115 from the rotary connection 10.
X Remove the hex head screws 17 (if necessary, heat them up, as the hex head screws are glued
in with Omnifit 100) and the retaining washer 18 and remove the driver 19*.
X Unscrew the hex head screw 12. Lift the rotary connection 10 from the undercarriage 125.
3.2 Installation of the 7x rotary connection after sealing work, see Fig. 2
X Place the rotary connection 10 in the undercarriage, engage the driving pin in the driver 19* and
tighten the screws 12. In models A 309 / A 311, the driving pin is locked with two welded blocks
to the uppercarriage.
X Secure the driver 25 using the hex head screws 27 and the retaining washers 26 to the rotary con-
nection 10.
X Insert the complete rotary connection 115 into the rotary connection 10 and replace the lid 3.
X Secure the nuts 122 complete with the washers 1 21 to the screws 120.
X Apply Omnifit 100 to the hex head screws 17 and secure the driver 19 with the hex head screws
17 with the washers 18 to the uppercarriage*.

X Secure the flange 116 and the seal 117 with the hollow screw 119 (with tooth lock washer 118)
on the rotary connection 115. Observe correct position.
X Re-connect the hydraulic lines to the rotary connections 10 and 115 (top and bottom). Pay atten-
tion to marks you made earlier.
X Re-install all other lines and parts you may have removed before.
7.78.2
copyright by
MJFCIFSS
* in models A 309 / A 311, the driver 19 is omitted

Fig. 2 Installation position of rotary connection
3 Lid 115 Rotary connection 6x, complete

10 Rotary connection 7x, complete 116 Flange
12 Hex head screw 117 Seal
17 Hex head screw 118 Tooth lock washer
18 Retaining washer 119 Hollow screw
19 Driver 120 Allen head screw
26 Retaining washer 121 Retaining washer
27 Allen head screw 122 Hex nut

125 Undercarriage
7.78.3
copyright by
MJFCIFSS
Exploded view
4 Exploded view

3 Lid 11 Rotor
4 Screw plug 12 Hex head screw
5 Screw plug 13 Stator
6 Retaining washer 15 Felt washer
7 Hex head screw 16 Screw plug
10 Rotary connection 98 Seal kit - consists of 9 seals:
1 felt washer, 2 outer seal top /
bottom, 7 inner seals
7.78.4
copyright by
MJFCIFSS
Sectional drawing
5 Sectional drawing

7.78.5
copyright by
MJFCIFSS
Sectional drawing
7.78.6
copyright by
MJFCIFSS
Service Manual Double load-holding valve / double lowering brake val-
Design
Double load-holding valve / double lowering brake

valve
for outrigger and blade support
1 Design
The double load-holding valve is mounted on the piston side connection of the support cylinder. It is
connected by hydraulic lines to the rod side connection of the support cylinder.
It seals the support cylinder 295 when not in operation so that no oil can leak out and the cylinder is
not inadvertently extended or retracted while in support mode.
To open the respective side of the double load-holding valve, the other side is pressurised. The valve
also protects the cylinder against pressure peaks.
The valve consists of the following main components:
– Piston / brake and pressure-relief valves 14a/b with pressure spring and
– valve seat (bypass) check valves 17 a/b with pressure spring
Fig. 1 Double lowering brake valve on cylinder

1 Valve housing, complete 17b Valve seat / check valve, rod side
8 Pressure spring 18 Pressure spring
14a Piston side 295 Support cylinder
14b Piston rod side A1 Connection at control valve block
17a Valve cone / check valve, piston side B1 Connection at control valve block
7.82.1
copyright by
MJFCIFSS
Double load-holding valve / double lowering brake val- Service Manual
Function
2 Function
2.1 Supply to cylinder at piston end

The hydraulic oil flows from the pump and the control valve block through the connection V2 to the
valve. The valve seat 17 (check valve) is shifted against the pressure spring 18 so that oil can flow
from the connection C2 to the piston side of the support cylinder 295. As the rod side of the cylinder
295 (connection C1-V1) is sealed by the piston 14, pressure builds up at the connection V2 acting on
the rod side of the piston 14. The piston is pushed against the pressure spring 8 / 9. The sealing edge
between the piston 14 and the valve seat 17 is opened when the stop of the valve seat 17 at the spring
housing 4 is reached, i.e. when the circuit of the return oil through the connection C1 and V1 to the
control valve block connection B1 (B4) is opened. The cylinder is now extended.
2.2 Locking cylinder

If the hydraulic lines to the support cylinder are not pressurised, the load pressure in the piston cham-
ber pushes the valve seat 17 against the piston 14, thus sealing the connection C2-V2 with the
sealing edge between the valve seat 17 and the piston 14. The piston 14 is supported through the
spring plate 10 by the pressure spring 8 or 9. The return line of the oil to the tank is thus completely
locked off.
All moving parts are sealed with O-rings, Glyd rings or Teflon backing rings.
The function of the piston rod side of the support cylinder 295 operates similarly to that described in
the sections 1 and 2; only the connection codes must be changed accordingly.
Designed specifically for vertical installation on the blade support cylinders, the lowering brake valve
with bleeding function through the perforated spring plate 12 prevents air from accumulating in the
spring chamber on the piston side (pressure spring 9), thus ensuring smooth piston and cylinder mo-
vement.
7.82.2
copyright by
MJFCIFSS
Function
Fig. 2 Double lowering brake valve in various designs

1 Valve housing, complete 12 Spring plate

2 O-ring* 13 O-ring*
3 O-ring* 14 Piston
4 Spring housing 15 Spring bolt
5 Slide ring* 17 Valve seat
7 Slide ring* 18 Pressure spring
8 Pressure spring 19 Washer
7.82.3
copyright by
MJFCIFSS
Inspection and repair
9 Pressure spring 20 Bolt/shuttle check valve

10 Spring plate 22 Washer
11 O-ring*
s2
3 Inspection and repair
Caution!
For safety reasons it is forbidden to carry out any repair work on the lowering brake valves.
In the event of malfunction or a defect, the complete valves must be replaced with new valves preset
by the manufacturer.
Sealing work (at external leaks) on valves is only permitted, if it does not require any dismantling or
disassembly of parts.
3.1 Removing and installing complete valve

Before opening the lines or screw connections, secure the hydraulic cylinder (place support feet or
support blade without load onto the ground) and release all pressure from the valve by repeatedly
operating the pilot control unit for the lifting / lowering of the support while the diesel engine is off (ig-
nition and pilot control system on).
Then carefully release the tank lead pressure by releasing the bleeder filter on the hydraulic tank.
When disconnecting pipelines/hoses or valves, collect escaping oil in a suitable container.
When installing the new valve, ensure that all threads and faces of the valve and cylinder are clean.
Always use new sealing elements for the sealing faces between the components.
7.82.4
copyright by
MJFCIFSS

7.82.5
copyright by
MJFCIFSS
7.82.6
copyright by
MJFCIFSS
Service Manual Double load-holding valve for regulating cylinder
Design
Double load-holding valve for regulating cylinder
1 Design
The double load-holding valve 517 is installed directly at the piston side pressure connection of the
regulating cylinder 515.
The double load-holding valve 517 seals the cylinder connection at the piston and rod sides, preven-
ting the attachment from dropping in the event of a pipe fracture.
To open the sealing piston, it is pressurised at the other side. The valve also protects the regulating
cylinder 515 against pressure peaks.
The double load-holding valve 517 consists of the housing, the two sealing pistons and the check val-
ves (bypassing of stop valve).
Fig. 1 Regulating cylinder with double load-holding valve bolted to attachment

7.86.1
copyright by
MJFCIFSS
Double load-holding valve for regulating cylinder Service Manual
see sectional drawing on page 3 and hydraulic diagram on page 4.
2.1 Extending cylinder 515

The hydraulic oil now flows from the auxiliary control block 500 connection A6 to the valve 517 con-
nection V2. The sleeve 26 is shifted, and pressure oil pressurises the piston side of the cylinder th-
rough connection C2.
As the rod side of the sealing piston 22 is sealed off, pressure builds up in the rod side cylinder cham-
ber, pressurising the connection C1. As a result, the sealing piston 22 is shifted against the pressure
spring 23 and the connection C1- V1 to the return side (spool - hydraulic tank) is opened. The cylinder
515 is extended.
After completion of the working movement, the sealing piston 22 returns to its sealing position. The
return line is blocked, i.e. the load is held without any leak oil.
2.2 Retracting cylinder 515

The hydraulic oil now flows from the auxiliary control block 500 connection B6 to the valve 517 con-
nection V1. The sleeve 26 is shifted, and pressure oil pressurises the rod side of the cylinder through
the connection C1 and the pressure line.
As the piston side of the sealing piston 22 is sealed off, pressure builds up in the piston side cylinder
chamber, pressurising the connection C2. As a result, the sealing piston 22 is shifted against the
pressure spring 23 and the connection C2- V2 to the return side (spool - hydraulic tank) is opened.
The cylinder 515 is retracted.
After completion of the working movement, the sealing piston 22 returns to its sealing position. The
return line is blocked, i.e. the load is held without any leak oil.
2.3 Pressure control

The pressure build-up in the cylinder chambers caused by external forces and while the spool is
closed requires a secondary pressure-relief facility. This is provided by the two sealing pistons 12. If
the secondary pressure in the respective cylinder chamber of the regulating cylinder 515 reaches a
value that is above the preset pressure value of the preloaded pressure spring 13, the sealing piston
12 is shifted and pressure oil from the respective cylinder side flows to the tank side.
1 Housing 21 Valve body

3 Screw plug 22 Sealing piston
4 Shuttle valve 23 Pressure spring
5 Orifice Ø 0.8 mm 24 Spring plate
6 Spacer bolt 25 Adjusting screw
8 Nozzle Ø 0.8 mm 26 Sleeve

10 O-ring 28 Spring plate
11 Ring 29 Cap nut
20 Stop valve, complete 30 Seal ring
7.86.2
copyright by
MJFCIFSS
Sectional drawing
3 Sectional drawing
Fig. 2 Sectional drawing of double load-holding valve

7.86.3
copyright by
MJFCIFSS
Hydraulic diagram
4 Hydraulic diagram
Fig. 3 Diagram of double load-holding valve
4 Shuttle valve 501 Secondary pressure-relief valve / exten-

ding regulating cylinder

5 Orifice Ø 0.8 mm 502 Secondary pressure-relief valve / retrac-
ting regulating cylinder
8 Nozzle Ø 0.8 mm 503 Spool / regulating cylinder
22 Sealing piston 504 Pressure balance, directly controlled
23 Pressure spring 515 Regulating cylinder
7.86.4
copyright by
MJFCIFSS
Hydraulic diagram
86 from auxiliary pilot control unit 517 Double-load back-pressure valve

500 Additional control axle AHS 1

7.86.5
copyright by
MJFCIFSS
Repair and sealing of valve 517
5 Repair and sealing of valve 517

.
Danger!
Defective valves pose a serious risk to persons in the danger area and to the equipment.
For safety reasons, it is forbidden to repair load-holding valves.
X Always replace load-holding valves with all associated parts, and install only new valves sup-
plied and preset by the manufacturer.
X Return defective valves to the manufacturer, indicating the problem or damage you have obser-
ved.
5.1 Sealing work

In the event of external leakage on the double load-holding valve, the valve may only be resealed, if
this work does not require dismantling the valve.
To reseal the valve, use only the seal kit provided by the manufacturer.
5.2 Assembly and dismantling of the double load-holding valve
Danger!
The dismantling, installation or sealing of the valve requires workers to access the danger area of
the machine. This carries risks for the mechanic, as equipment might move uncontrolled when a
valve/hydraulic circuit is opened.
Never open the hydraulic circuit to the load-holding valve while the circuit is pressurised.
X Place the unloaded attachment on the ground (piston side of the cylinder must be fully depres-
surised)
X Release the tank pressure.

X Depressurise the load-holding valve by actuating the pilot control device for lifting and lowering to
the stop and holding it in this position while the diesel engine is off (ignition and pilot control system
on).
After the hydraulic circuit of the double load-holding valve 517 is opened, certain problems might oc-
cur caused by air in the control circuit. The circuit must therefore be bled (collect escaping oil), see
5.3.
5.3 Bleeding of double load-holding valve 517, see Fig. 4

X Remove the protective cap from the measuring neck 48 at the connections T.
X Remove the screw plug from the connection T.
X Screw the G1/4" screw coupling (tool from group 2.01) into the bores.
X Connect the Minimess high pressure hose between the connections T.

X Actuate the boom cylinder to retract it (keep pilot control unit pushed forward).
The control circuit is bled.
X Lower the unloaded attachment onto flat and firm ground.
X Release the tank pressure and the load-holding valve(s) by actuating the pilot control device for
lifting and lowering to the stop and holding it in this position while the diesel engine is off (ignition
and pilot control system on).
7.86.6
copyright by
MJFCIFSS
Repair and sealing of valve 517
X Remove the measuring hose and screw coupling.

X Screw in the screw plug at the connections Pil and T.
Fig. 4 Screw coupling for the bleeding of the hydraulic circuit and the load-holding valve
48 Screw coupling 516 Load-holding valve

515 Regulating cylinder 517 Load-holding valve

7.86.7
copyright by
MJFCIFSS
Checking of double load-holding valve
6 Checking of double load-holding valve
Danger!
The inspection and testing of the load-holding valves require access to the danger area of the ma-
chine. There is a risk to life and limb for mechanics from uncontrolled machine movements.
X Secure it against uncontrolled movement.
X Only carry out inspections, if the machine is fully shut down and properly secured.
X Before opening the hydraulic circuit release all pressure from the hydraulic system.
X Adhere to the accident prevention regulations issued by the German Ground Construction Trade
Association (Tiefbau-Berufsgenossenschaft) for powertrains and earth-moving equipment.
The valves 517 are factory-set by the manufacturer. The readjustment of the double load-holding
valve settings is not permitted for safety reasons.
X Should a subsequent inspection reveal that the settings are incorrect, remove the defective val-
ves and replace them with new valves preset by the manufacturer.
X Return defective valves to the manufacturer, indicating the problem or damage you have obser-
ved.
6.1 Pressure check

Due to the high adjustment pressure, it is not possible to check the pressure on the machine.
7.86.8
copyright by
MJFCIFSS
Hydraulic connections and links
7 Hydraulic connections and links

Fig. 5 Exploded view, spare parts list
100 Compact control block 515 Regulating cylinder

500 AHS1 additional control block 517 Load-holding valve
7.86.9
copyright by
MJFCIFSS
Hydraulic connections and links
7.86.10
copyright by
MJFCIFSS
Service Manual
SUBGROUP - INDEX
Section Group Type
Component arrangement 8.10.1 A 309 LI-TCD 40998-

A 311 LI-TCD 41128-
Component arrangement 8.20.1 A 312 LI-TCD 36220-

A 314 LI-TCD 30694-
A 316 LI-IND-TCD 29503-
A 316 LI-TCD 29120-
Component arrangement 8.30.1 R 313 LI-TCD 39171-

R 317 LI-TCD 30019-
Electrical system / basic machine 8.40.1 A 309 LI-TCD 40998-

A 311 LI-TCD 41128-
Electrical system (basic machine) 8.50.1 A 312 LI-TCD 36220-

A 314 LI-TCD 30694-
A 316 LI-TCD 29120-
Electrical system / basic machine 8.56.1 A 316 LI-IND-TCD 29503-
Electrical system (basic machine) 8.60.1 R 313 LI-TCD 39171-

R 317 LI-TCD 30019-

UEC central control system 8.70.1 A 309 LI-TCD 40998-
A 311 LI-TCD 41128-
A 312 LI-TCD 36220-
A 314 LI-TCD 30694-
A 316 LI-IND-TCD 29503-
A 316 LI-TCD 29120-
Electronic travel drive control 8.76.1 A 309 LI-TCD 40998-

A 311 LI-TCD 41128-
A 312 LI-TCD 36220-
A 314 LI-TCD 30694-
A 316 LI-IND-TCD 29503-
A 316 LI-TCD 29120-
Menu control 8.80.1 A 314 LI-TCD 30694-

A 316 LI-IND-TCD 29503-
A 316 LI-TCD 29120-
R 317 LI-TCD 30019-
8.1
MJFCIFSS
8.2
MJFCIFSS
Service Manual
Service Manual Component arrangement
Control elements
Component arrangement
1 Control elements
1.1 Operator's platform
Fig. 1 Operator's platform seen from the operator

A145 Control / left joystick S5R Push button / turn grapple right
A146 Control / right joystick S6L Push button / auxiliary activation
A149 UEC central control system S6M Switch / switchover bucket swivel
bearing
A150 Indicating and control unit, see Fig. 2 S6R Push button / auxiliary activation
B19L Sensor transducer / left pilot control unit S1-S398 Switches, see Fig. 4
B19R Sensor transducer / right pilot control S18-S422 Switches, see Fig. 3
unit
E8 Cigarette lighter S8-S218 Switches, see Fig. 5
H9 Horn S32 Indicator switch, horn
P5 Operating hour counter, see Fig. 26 S44 Hazard light switch

P6 Engine cooling water temperature indi- S46 Magnet system switch*
cator
P7 Fuel level indicator (tank) S75 Switch / oscillating axle locking
device
P50 Clock S263V Switch / travel direction forward
S4 Horn button S263R Switch / travel direction reverse
S5L Push button / turn grapple left S382 SF switch (with Tool control plus)*
8.10.1
copyright by
MJFCIFSS
Component arrangement Service Manual
Control consoles
S5M Reserve button
* kit
2 Control consoles
2.1 Front right control console (top)
Fig. 2 Indicating and control unit A150
1 Display 16 Indicator light / oscillating axle locking

system
2 Speed indicator 17 Indicator light / air filter contamination
3 Push button / reduce speed (-) 18 Indicator light of parking brake
4 Push button / idle automatic 19 Indicator light / coolant level

5 Push button / increase speed (+) 20 Indicator light / hydraulic oil temperature
6 Indicator light / indicator 21 Indicator light / water in fuel filter
7 Indicator light / forward travel 22 Indicator light / overload warning system
8 Indicator light / reverse travel 23 Indicator light / quick-change adapter
9 Indicator light / engine malfunction 24 Indicator light / accumulator charging
pressure
10 Indicator light / swivel bearing active 25 Indicator light / battery charge
11 Indicator light / sorting grapple 26 Push button / input, confirmation
12 Indicator light / Super Finish (SF) 27 Push button / cursor to right
13 Indicator light / pre-heating 28 Push button / cursor button down
14 Indicator light / oscillating axle support 27 Push button / cursor up

15 Indicator light / engine oil pressure
8.10.2
copyright by
MJFCIFSS
Control consoles
2.2 Front right control console (bottom)
Fig. 3 Switch layout
Switches:
S18 Overload warning system* S241 Additional user (e.g. hydraulic hammer)*
S19 Grapple rotator S335 Blade support / dozer blade*
S21 Creeper gear travel S360 Acknowledgement of quick change adapter
buzzer*

S42 1st gear switching S363 Tempomat / automatic travel (saving nominal
value)
S47 Quick change adapter* S422 Radio mute mode
* kit
8.10.3
copyright by
MJFCIFSS
Control consoles
2.3 Right centre control console
Fig. 4 Ignition switch and switch layout
S1 Ignition lock / ignition / engine start S93 Rotary potentiometer for heating-a/c
system
S16 Parking brake S284 Heating-a/c system blower (4 speeds)
S35 Switch / servo control S318 A/c system*
S92 Rotary potentiometer / air distribution S398 Reversing switch
* kit
2.4 Right control console

Fig. 5 Cigarette lighter, fuses, relays and switches
E8 Cigarette lighter S14 Windscreen wiper

F307-F343Fuses, see Fig. 9 S22* Work headlights, front, front
roof light
8.10.4
copyright by
MJFCIFSS
Control consoles
K414 Relay / windscreen wiper interval S22-1 Rear roof light

S8* Beacon S61 Travel light
S11 Windscreen washer system S218* Roof window wiper
* kit
2.5 Right control console, rear
Fig. 6 Right control desk
A148 Fuse board,see Fig. 11 X29 Opening for plug connection

A149 UEC 1 central control system X204 Opening for plug connection
A155 UEC 2 central control system / X230 Opening for plug connection
slave (only in AHS with Tool Con-

trol plus)
A160 Master Can-Cockpit X952 Opening for plug connection
H342 Buzzer X953 Opening for plug connection
K315 Relay / brake light X954 Opening for plug connection
K391 Relay / horn X955 Opening for plug connection
K481 Relay / power supply X956 Opening for plug connection
K* Relay for kits X960 Opening for plug connection
8.10.5
copyright by
MJFCIFSS
Fuses
X10 Opening for plug connection X980 Opening for plug connection
X11 Opening for plug connection X1167 Dongle interface
X27 Opening for plug connection
3 Fuses
3.1 E50 safety and power switch cabinet
Fig. 7 Layout of fuse box and solenoid valves in the valve console
A127 Printed circuit board / power, see Fig. 8 Y353 Proportional solenoid valve / travel (°)
E50 Fuse and power switch cabinet Y371 Solenoid valve / oscillating axle (°)
Y50 Proportional solenoid valve / perfor-
mance control (°)
(°) (see Fig. 29 on page17)
8.10.6
copyright by
MJFCIFSS
Fuses
Fig. 8 A127 printed circuit board / power
BTKP Refuelling pump (kit) K_F Relay terminal 50

F19/F301 Fuse terminal 19, R60 (50 A) KL15 Plus after ignition
F20/F300 Fuse terminal 15, terminal 30 (50 A) KL1 Pre-heating

F22/F302 Fuses terminal 30, B3, S44 (7.5 A) KL30E Permanent plus (input)
F303 Optional fuse (7.5 A) KL30A Permanent plus (output)
F332 Fuse terminal 50, M1 (25 A) KL31 Ground
F370 Engine control unit fuse (25 A) KLOptional Spacer bolt for kits
F-A to F-H Fuse / optional S1 Test switch fuse
K288 Relay / terminal 15 X_A to X_E Plug connection / optional
K302 Pre-heating relay X13 Screw terminal / power supply of
engine control unit
K476 Relay / engine control unit X43 Screw terminal / KL50 starter
K_A - K_E Base for relay
8.10.7
copyright by
MJFCIFSS
Fuses
3.2 Fuses, right
Fig. 9 Fuses and relays, control console, rear right
F307 7.5A Parking light / tail light

F308 7.5A Right parking light / tail light
F309 7.5A Travel light, left
F310 7.5A Travel light, right
F311 15 A Windscreen wiper / washing system
F317* 7.5A Beacon
F323* 15 A Working light / attachment
F324* 15 A Work headlight, roof
F343* 7.5A Roof window wiper
K414 Relay of interval control device
* kit
3.3 A148 fuse board

Fig. 10 left and right control desk with components
A148 Fuse board,see Fig. 11 T5 Voltage converter, indicating devices

M65-M73 Servo motors of heating / a/c system, X973 Power socket 12 V
see group 17.
S7 Switch, safety lever
8.10.8
copyright by
MJFCIFSS
Fuses
3.4 Fuses, rear right (A148 fuse board)
Fig. 11 Fuse board A148 from top
F304 15 A UEC, control unit, ignition

F305 15 A Internal light, cigarette lighter
F306 15 A Terminal 30 (X10)
F312 7.5 A hazard light
F313 5A Brake light

F314 7.5 A Safety lever, engine control unit
F315 15 A Control unit
F316 7.5 A Control console
F318 20 A Heating / air-conditioning system (kit - terminal 30)
F320 15 A Terminal 15
F321 15 A Terminal 15 (X11), central lubrication system
F322 15 A Voltage transformer
F325 15 A Parking brake, direction of travel
F326 15 A Creeper speed, quick-change adapter, oscillating axle
F327 15 A UEC UB2 (X27)
F328 15 A UEC UB3, quick-change adapter

F329 15 A Servo control
F330 15 A Super Finish, turning grapple
F331 15 A UEC, UB4 (X29)
F336 20 A Illumination
F337 15 A Machine support
F338 15 A Horn, seat heating
8.10.9
copyright by
MJFCIFSS
Fuses
F339 20 A Air-conditioning system

F363 15 A UEC, UB0/1
F372 7.5 A Coolant temperature / fuel level indicator
K63 Hazard light relay
K370 Relay servo
K386 Relay of safety lever
S467 Fuse test switch
X1166 RS232 plug connection
X1167 CAN1 plug connection (interface for dongle)
Fig. 12 Fuse board A148 from bottom
KL15 Potential pin terminal 15

X1160 Plug connection / central electrics, 15-pin

8.10.10
copyright by
MJFCIFSS
Various components
3.5 Fuse in battery box
Fig. 13 Batteries, fuses and battery main switch
F359 7.5A Clock P50

F375 15A Auxiliary heater*
G2 Batteries
S9 Battery main switch
* kit
4 Various components
Fig. 14 Engine control unit and temperature sensor on hydraulic tank
A151 EMR2 engine control unit

B285 Hydraulic oil temperature sensor
8.10.11
copyright by
MJFCIFSS
Various components
Fig. 15 Fuel level sensor B1 (mounted on the fuel tank)
Fig. 16 Temperature transducer / engine coolant B2 (diesel engine output side)
B2 Temperature sensor / engine coolant B48 Transducer / intercooing air tempera-

ture/pressure
B7 Vacuum switch / air filter X17 Diesel engine control central plug
Fig. 17 Coolant level sensor B3 (mounted on coolant / expansion tank)

8.10.12
copyright by
MJFCIFSS
Various components
Fig. 18 Engine, seen from rear
B16 Transducer / motor oil pressure Y20 Magnetic coupling / a/c compressor*
* kit
Fig. 19 Engine output side

B37 Temperature transducer / fuel M69 Servo motor speed regulation
B292 Transducer / cam shaft speed
Fig. 20 Compact brake block located under the operator's cab
B20 Pressure switch / accumulator pres- B266 Proximity switch / oscillating axle automatic
sure
B60 Pressure switch / brake light
8.10.13
copyright by
MJFCIFSS
Various components
Fig. 21 Valve console right
B21 Push button / overload warning system* Y60 Solenoid valve / 2nd gear
Y55 Solenoid valve / 1st gear
* kit
Fig. 22 Diesel filter water sensor B289 (located at fuel prefilter)

Fig. 23 Diesel engine seen from the front
G1 Alternator M1 Starter
8.10.14
copyright by
MJFCIFSS
Various components
Fig. 24 Operator's platform front right
B326 Travel pedal transducer S4 Horn foot switch
Fig. 25 Slewing gear pressure sensor B335 mounted on left pilot control unit Document is registered under: 1030314 - 29.01.2009
Fig. 26 Component arrangement on control console, front right
8.10.15
copyright by
MJFCIFSS
Various components
P5 Operating hour meter X1167 Service interface

X22 Engine data interface
Fig. 27 Switch for release of the windscreen wiper S283 (located in the front right position on the
operator's cab frame)
Fig. 28 Switch of air cushioning and seat heating at the front of the operator seat
S388 Switch air cushioning S389 Switch / seat heating

8.10.16
copyright by
MJFCIFSS
Various components
Fig. 29 Control oil unit with solenoid valves (located at the centre of the valve console)
Y3 Solenoid valve / pilot control pressure Y353 Proportional solenoid valve / travel
speed
Y24 Solenoid valve / creeper gear Y371 Solenoid valve / oscillating axle support
Y50 Proportional solenoid valve / power con-
trol
Fig. 30 Compact control block with control axle AS1 and proportional valve / slewing gear
Y22 Solenoid valve / grapple rotator left Y451 Proportional solenoid valve / slewing gear
Y23 Solenoid valve / grapple rotator right
8.10.17
copyright by
MJFCIFSS
Various components
Fig. 31 Solenoid valves in the left section of the valve console
Y62 Solenoid valve / forward travel Y268 Solenoid valve / changeover regulating
cylinder - hydraulic hammer*
Y63 Solenoid valve / reverse travel Y414 Proportional solenoid valve / pressure
reduction*
Y262 Solenoid valve / switchover bucket Y447 Proportional solenoid valve / flow reduc-
swivel bearing tion*
* kit
Fig. 32 Junction box and solenoid valve in undercarriage (seen from the bottom)
X272 Terminal box / undercarriage Y56 Solenoid valve / blade support*
* kit
8.10.18
copyright by
MJFCIFSS
Various components
Fig. 33 Proportional solenoid valve / fan control Y352 (located on the oil motor / fan)

8.10.19
copyright by
MJFCIFSS
Various components
8.10.20
copyright by
MJFCIFSS
Control elements
1 Control elements

A149 UEC central control system S6L Push button / auxiliary activation
A150 Indicating and control unit, see Fig. 2 S6M Push button / horn
B19L Sensor transducer / left pilot control unit S6R Push button / auxiliary activation
B19R Sensor transducer / right pilot control S1-S398 Switches, see Fig. 4
unit
E8 Cigarette lighter S18-S422 Switches, see Fig. 3
H9 Horn S8-S218 Switches, see Fig. 5
P5 Operating hour counter, see Fig. 28 S32 Indicator switch, horn
P6 Engine cooling water temperature indi- S44 Hazard light switch
cator
P7 Fuel level indicator (tank) S46 Magnet system switch*
P50 Clock S75 Switch / oscillating axle locking
device
S4 Horn button S263V Switch / travel direction forward
S5L Push button / turn grapple left S263R Switch / travel direction reverse
8.20.1
copyright by
MJFCIFSS
Control consoles
S5M Reserve button S382 Switch fine adjustment ON / OFF

(only in AHS with Tool Control
plus)
S5R Push button / turn grapple right
* kit
2 Control consoles
1 Display 16 Indicator light / automatic oscillating axle lok-

king mechanism
2 Speed indicator 17 Indicator light / air filter contamination

3 Push button / reduce speed (-) 18 Indicator light of parking brake
4 Push button / idle automatic 19 Indicator light / coolant level
5 Push button / increase speed (+) 20 Indicator light / hydraulic oil temperature
6 Indicator light / indicator 21 Indicator light / water in fuel filter
7 Indicator light / forward travel 22 Indicator light / overload warning system
8 Indicator light / reverse travel 23 Indicator light / quick-change adapter
9 Indicator light / engine malfunction 24 Indicator light / accumulator charging pres-
sure
10 Indicator light / swivel bearing (A 309/A 311) 25 Indicator light / battery charge
11 Indicator light / sorting grapple 26 Push button / input, confirmation

12 Indicator light / Super Finish (SF) 27 Push button / cursor to right
13 Indicator light / pre-heating 28 Push button / cursor button down
14 Indicator light / oscillating axle locking 27 Push button / cursor up
system
15 Indicator light / engine oil pressure
8.20.2
copyright by
MJFCIFSS
Control consoles
Switches:
S18 Overload warning system* S206 Rear left outrigger*

S19 Grapple rotator S207 Rear right outrigger*
S21 Creeper gear travel S241 Additional user (e.g. hydraulic hammer)*
S42 1st gear switching S335 Blade support / dozer blade*

S47 Quick change adapter* S360 Acknowledgement of quick change adapter
buzzer*
S84 Central lubrication system S363 Tempomat / automatic travel (saving nominal
value)
S204 Front left outrigger* S422 Radio mute mode
S205 Front right outrigger*
* kit
8.20.3
copyright by
MJFCIFSS
Control consoles
S1 Ignition lock / ignition / engine start S93 Rotary potentiometer for heating-a/c
system
S16 Parking brake S284 Heating-a/c system blower (4 speeds)
S35 Switch / servo control S318 A/c system*
S92 Rotary potentiometer / air distribution S398 Reversing switch
* kit

8.20.4
copyright by
MJFCIFSS
Control consoles
F307-F343Fuses, see Fig. 10 S22* Work headlights, front, front

roof light
K414-K449Relay / windscreen wiper interval S22-1 Rear roof light
* kit

A148 Fuse board,see Fig. 12 X29 Opening for plug connection

A149 UEC 1 central control system X204 Opening for plug connection
A155 UEC 2 central control system / X230 Opening for plug connection
slave
(only in AHS with Tool Control plus)
A160 Master Can-Cockpit X952 Opening for plug connection
H342 Buzzer X953 Opening for plug connection
K315 Relay / brake light # X954 Opening for plug connection
8.20.5
copyright by
MJFCIFSS
Fuses
K391 Relay / horn X955 Opening for plug connection

K* Relay for kits X956 Opening for plug connection
X27 Opening for plug connection X1167 Plug connection / dongle interface
*kit # in A 312 from 41856, A 314 from 41863, A 316 from 41869, see also service information 08-10-13/08
3 Fuses
Fig. 7 Installation of the fuse box and solenoid valves at the hydraulic tank
A127 Printed circuit board / power, see Fig. Y268 Solenoid valve / AHS1 - AHS11 control
9 changeover*
E50 Fuse and power switch cabinet Y414 Prop. solenoid valve / pressure reduc-
tion*
Y62 Solenoid valve / forward travel Y447 Proportional solenoid valve / flow reduc-
tion*
Y63 Solenoid valve / reverse travel
* kit
8.20.6
copyright by
MJFCIFSS
Fuses
Fig. 8
BTKP Refuelling pump (kit) K_F Relay terminal 50

F19/F301 Fuse terminal 19, R60 (50 A) KL15 Plus after ignition

F20/F300 Fuse terminal 15, terminal 30 (50 A) KL19 Pre-heating
F22/F302 Fuses terminal 30, B3, S44 (7.5 A) KL30E Permanent plus (input)
F303 Optional fuse (7.5 A) KL30A Permanent plus (output)
F332 Fuse terminal 50, M1 (25 A) KL31 Ground
F370 Engine control unit fuse (25 A) KLOptional Spacer bolt for kits
F-A to F-HFuse / option S1 Test switch fuse
K288 Relay / terminal 15 X_A to X_E Plug connection / optional
K302 Pre-heating relay X13 Screw terminal / power supply of
engine control unit
K476 Relay / engine control unit X43 Screw terminal / KL50 starter
K_A - K_E Base for relay
8.20.7
copyright by
MJFCIFSS
Fuses
3.2 Fuses, right
F307 7.5A Parking light / tail light

F308 7.5A Right parking light / tail light
F311 7.5 A Windscreen wiper / washing system
F317* 7.5A Beacon
F323* 15 A Working light / attachment
F324* 15 A Roof working light / rear
F358* 7.5A Roof working light / front
K414 Relay of interval control device
K447 # Relay of roof working light, front
K448 # Relay of roof working light, rear
K449 # Relay of work headlight, attachment
*kit # omitted in A 312 and A 314

3.3 A148 fuse board

8.20.8
copyright by
MJFCIFSS
Fuses

see group 17.
S7 Switch safety lever
Fig. 12 Fuse board A148 from top

F305 15 A Internal light, cigarette lighter
F306 15 A Terminal 30 (X10)
F312 7.5 A hazard light
F313 5A Brake light
F314 7.5 A Safety lever, engine control unit
F315 15 A Control unit
F321 15 A Terminal 15 (X11), central lubrication system

F322 15 A Voltage transformer
F325 15 A Parking brake, direction of travel
F326 15 A Creeper speed, quick-change adapter, oscillating axle
F327 15 A UEC UB2 (X27)
F328 15 A UEC UB3, quick-change adapter
8.20.9
copyright by
MJFCIFSS
Fuses
F330 15 A Super Finish, turning grapple

F331 15 A UEC, UB4 (X29)
F338 15 A Horn, seat heating
F363 15 A UEC, UB0/1
F372 7.5 A Coolant temperature / fuel level indicator
K63 Hazard light relay
K370 Relay servo
X1166 RS232 plug connection
X1167 CAN1 plug connection (interface for dongle)
Fig. 13 Fuse board A148 from bottom


8.20.10
copyright by
MJFCIFSS
Various components
3.5 Fuse in battery box
F359 7.5A Clock P50

G2 Batteries
* kit

Fig. 15 Engine control unit A151 in uppercarriage, left
8.20.11
copyright by
MJFCIFSS
Various components


8.20.12
copyright by
MJFCIFSS
Various components
Fig. 19 Vacuum switch / air filter B7 (air suction hose of diesel engine)

B16 Transducer / motor oil pressure Y15.2 Solenoid valve, injection cylinder 2
B40.2 Transducer / cam shaft speed Y15.3 Solenoid valve, injection cylinder 3
B49 Transducer / rail pressure Y15.4 Solenoid valve, injection cylinder 4
B51 Transducer / fuel low pressure X17 Diesel engine central plug
Y15.1 Solenoid valve, injection cylinder 1 Y19 Solenoid valve M-prop
8.20.13
copyright by
MJFCIFSS
Various components
Fig. 21 Transducer / crank shaft speed B40.1 (engine radiator side)
Fig. 22 Compact brake block located under the operator's cab
B20 Pressure switch / accumulator pres- B266 Proximity switch / oscillating axle automatic
sure
B60 Pressure switch / brake light
Fig. 23 Boom cylinder with pressure switch, overload warning system B21 (kit)
8.20.14
copyright by
MJFCIFSS
Various components
B48 Intercooling air pressure and tem- M1 Starter

perature sensor
G1 Alternator

Fig. 26 Operator's platform front right
8.20.15
copyright by
MJFCIFSS
Various components
B326 Travel pedal transducer S4 Horn foot switch
Fig. 27 Slewing gear pressure sensor B335 mounted on left pilot control unit

8.20.16
copyright by
MJFCIFSS
Various components

Fig. 31 Lubricating pump of central lubrication system U4
8.20.17
copyright by
MJFCIFSS
Various components
Fig. 32 Control oil unit with solenoid valves (located on the engine side of the hydraulic tank)
B285 Transducer / hydraulic oil temperature Y50 Proportional solenoid valve / power con-
(fan control) trol
Y3 Solenoid valve / pilot control pressure Y353 Proportional solenoid valve / travel
speed
Y24 Solenoid valve / creeper gear Y371 Solenoid valve / oscillating axle support
Fig. 33 Magnetic clutch Y20 at the a/c compressor

8.20.18
copyright by
MJFCIFSS
Various components
Fig. 34 Compact control block with additional control axle for AS1 kit

Fig. 35 HBGV block for transmission on basic boom bearing block
Y55 Solenoid valve / 1st gear Y60 Solenoid valve / 2nd gear
Fig. 36 Junction box and solenoid valve in undercarriage (seen from the bottom)
8.20.19
copyright by
MJFCIFSS
Various components
X272 Terminal box / undercarriage Y217 Solenoid valve / left outrigger

Y218 Solenoid valve / right outrigger
8.20.20
copyright by
MJFCIFSS
Control elements
1 Control elements

A149 UEC central control system S5M Reserve button
A150 Indicating and control unit, 12 S5R Push button / turn grapple right
B19L Sensor transducer / left pilot control unit S6L Push button / turn grapple
B19R Sensor transducer / right pilot control unit S6M Push button / horn
E8 Cigarette lighter S6R Push button / auxiliary activation
H9 Horn S1-S398 Switches, see Fig. 4
P5 Operating hour counter, see Fig. 24 S18-S422 Switches, see Fig. 3
P6 Engine cooling water temperature indicator S8-S218 Switches, see Fig. 5
P7 Fuel level indicator (tank) S46 Magnet system switch*
P50 Clock S382 Switch fine adjustment ON / OFF
(only in AHS with Toolcontrol plus)

S5L Push button / turn grapple left
* kit
8.30.1
copyright by
MJFCIFSS
Control consoles
2 Control consoles
1 Display 19 Indicator light / coolant level

2 Speed indicator 20 Indicator light / hydraulic oil temperature
3 Push button / reduce speed (-) 21 Indicator light / water in fuel filter
4 Push button / idle automatic 22 Indicator light / overload warning*
5 Push button / increase speed (+) 23 Indicator light / quick-change adapter
9 Indicator light / engine malfunction 25 Indicator light / battery charge
12 Indicator light / Super Finish (SF) 26 Push button / input, confirmation
13 Indicator light / pre-heating 27 Push button / cursor to right
15 Indicator light / engine oil pressure 28 Push button / cursor button down
17 Indicator light / air filter contamination 29 Push button / cursor up
* kit
8.30.2
copyright by
MJFCIFSS
Control consoles
Switches:
S17 Slewing gear brake S84 Central lubrication system*

S18 Overload warning system* S241 Additional user (e.g. hydraulic hammer)*
S19 Grapple rotator* S360 Acknowledgement of quick change adapter
buzzer*

S21 Fast travel S422 Radio mute mode
S47 Quick change adapter*
* kit
8.30.3
copyright by
MJFCIFSS
Control consoles
S1 Ignition switch / ignition / engine pre-hea- S284 Heating-a/c system blower (4 speeds)
ting and start
S92 Rotary potentiometer / air distribution S318 A/c system*
S93 Rotary potentiometer for heating-a/c system S398 Reversing switch
* kit


F307-F343Fuses, see Fig. 9 S22* Work headlights, front, front roof light
K414 Relay / windscreen wiper interval S22-1 Rear roof light
8.30.4
copyright by
MJFCIFSS
Control consoles
* kit

A148 Fuse board,see Fig. 11 X204 Plug connection

A149 UEC 1 central control system X230 Plug connection
A155 UEC 2 central control system / X952 Plug connection
slave
(only in AHS with Toolcontrol plus)
A160 Master Can-Cockpit X953 Plug connection
H342 Buzzer X954 Plug connection

K391 Relay / horn X955 Plug connection
K* Relay for kits X956 Plug connection
X27 Plug connection X1167 Plug connection service plug interface
X29 Plug connection
8.30.5
copyright by
MJFCIFSS
Fuses
3 Fuses
Fig. 7 Installation of the fuse box and solenoid valves at the hydraulic tank
A127 Printed circuit board / power, see Fig. 8 E50 Safety and power switch cabinet
8.30.6
copyright by
MJFCIFSS
Fuses
BTKZ Refuelling pump (kit) K302 Relay / pre-heating 15

F-A to F-H Fuse / option K476 Relay / engine control unit
F-L Fuse / optional KL15 Plus after ignition

F19/F301 Fuse terminal 19, R60 (70 A) KL19 Pre-heating
F20/F300 Fuses terminal 15, terminal 30 (50 A) KL30E Permanent plus (input)
F22/F302 Fuses terminal 30, B3, S44 (7.5 A) KL30A Permanent plus (output)
F303 Fuse Y29 (7.5 A) KL31 Ground
F332 Fuse M1, Y12 (25 A) KLoptional Ground for kits
F370 Fuse terminal 50 (25 A) S1 Test switch fuse
K_A - K_ERelay terminal 50 X_A to X_E Plug connection / optional
K_F Relay for kit X13 Plug connection / optional
K288 Relay / terminal 15 X43 Plug connection / optional
8.30.7
copyright by
MJFCIFSS
Fuses
3.2 Fuses, right
F307 7.5A Parking light, left

F308 7.5A Parking light, right
F311 15 A Windscreen wiper / washing system
F317* 7.5A Beacon
F323* 15 A Work light / attachment
F324* 15 A Work headlight, roof
K414 Relay interval control device*
* kit
3.3 A148 fuse board


see group 17.
S7 Switch, safety lever
8.30.8
copyright by
MJFCIFSS
Fuses
Fig. 11 Fuse board A148 (from above)

F305 15 A Interior lights / cigarette lighter / clock
F312 7.5 A not assigned
F313 5A not assigned
F314 3A Safety lever
F315 15 A Control unit, engine control

F322 7.5 A Voltage transformer
F325 7.5 A not assigned
F326 15 A Fast travel / quick-change adapter
F327 15 A UEC UB2
F328 15 A UEC UB3
F329 5A Servo control
F330 7.5 A Super Finish

F338 15 A Horn
F363 15 A UEC UB0/1
8.30.9
copyright by
MJFCIFSS
Fuses
K370 Relay servo

X1166 Plug connection RS232
X1167 Plug connection CAN1 (Interface for service plug)
Fig. 12 Fuse board A148 (from downside)

F
A148 KL15 Potential terminal post15

A148 KL30 Potential terminal post 30
X1160 Plug connection central electric 15 polig

F359 7.5A Indicating instrument P50
8.30.10
copyright by
MJFCIFSS
Various components

G2 Batteries
*Kit
Fig. 14 Engine control unit A151 in uppercarriage, left

8.30.11
copyright by
MJFCIFSS
Various components

Fig. 18 Vacuum switch / air filter B7 (air suction hose of diesel engine)
8.30.12
copyright by
MJFCIFSS
Various components
B16 Switch / engine oil pressure Y15.2 Solenoid valve, injection cylinder 2
B40.2 Transducer / cam shaft speed Y15.3 Solenoid valve, injection cylinder 3
B49 Transducer / rail pressure Y15.4 Solenoid valve, injection cylinder 4
B51 Transducer / fuel low pressure X17 Diesel engine central plug
Y15.1 Solenoid valve, injection cylinder 1 Y19 Solenoid valve M-prop
Fig. 20 Transducer / crank shaft speed B40.1 (engine radiator side)

Fig. 21 Boom cylinder with pressure switch, overload warning system B21 (kit)
8.30.13
copyright by
MJFCIFSS
Various components

B48 Transducer, load pressure and M1 Starter

temperature
G1 Alternator
8.30.14
copyright by
MJFCIFSS
Various components



8.30.15
copyright by
MJFCIFSS
Various components
Fig. 27 Lubricating pump of central lubrication system U4

Fig. 28 Control oil unit with solenoid valves (located on the engine side of the hydraulic tank)
B285 Transducer / hydraulic oil temperature Y50 Proportional solenoid valve / power con-
(fan control) trol
Y3 Solenoid valve / pilot control pressure Y24 Solenoid valve / fast travel
Y7 Solenoid valve / slewing gear brake
8.30.16
copyright by
MJFCIFSS
Various components
Fig. 29 Magnetic clutch Y20 at the a/c compressor

Fig. 30 Compact control block with auxiliary control axle for AS1 kit
8.30.17
copyright by
MJFCIFSS
Various components
8.30.18
copyright by
MJFCIFSS
1 2 3 4 5 6 7 8
register of sheets sheet register of sheets sheet

overview CAN bus 3 display functions 27
A A
overview UEC 1 4 speed control by steering valve 28
overview UEC 2 (option, optional) 5 heating 29
overview display 6 Air conditioning system 30
overview EMR2 7 operator's seatadjustment, setting 30
overview E50 8 seat heating 30
9625938_103285847_4_en
overview fuse board 9 (warning) beacon 30
B battery 10 radio 31 B
main switch 10 loudspeaker 31
starter 10 cigarette lighter 31
PROJEKT:
generator 10 voltage transformer 31
operating hour meter / counter 10 servo 32
ignition switch 11 oscillating axle 32
fuses E50 12 working brake 32
We reserve all rights in this document and in the informa
tion contained therein. Reproduction, use or disclosure
C
fuses printed circuit board 13 travel direction preselection 33 C
to third parties without express authority is strictly
fuses printed circuit board 14 parking brake 33
© LIEBHERR HYDRAULIKBAGGER GMBH
fuses cab 15 creeper gear 33
power supply kit 16 1. speed, gear 33
mass distribution 17 4wheel steering 34
mass distribution 18 sensors 35
power supply UEC 19 pedal 35
EMR 19 fancontrol system / unit, control, controller 35
forbidden.
D D

display 19 fine adjustment slewing gear 35
CAN1 20 accumulator pressure 36
RS232 20 hydraulic oilsensor 36
Für dieses Dokument und den darin dargestellten Gegen
stand behalten wir uns alle Rechte vor. Vervielfältigung,
Bekanntgabe an Dritte oder Verwertung seines Inhaltes
sind ohne unsere ausdrückliche Zustimmung verboten.
diagnosis 20 SF function 36
CAN2 UEC 21 performance regulator 36
diagnosis EMR2 21 pilot pressure reduction 36
EMR2 22 gripper swing 37
E E
preheat 23 &#6552; 37
buzzer 23 pressure reduction 37
safety circuit / lever 23 changeover AHS 37
motor control diesel engine EMR2 24 &#6554; blade 38
motor control diesel engine EMR2 25 slipring contact 38
water sensor fuel filter 26 overload warning (system) 39
F
pressure switch air filter 26 Quick change adapter 40 F
Anlage
A 309 Litronic TCD ab 40998 Seite: 8.40 1 / 65
LIEBHERR register of sheets Ort +CNT
A 311 Litronic TCD ab 41128
Hydraulikbagger gmbh Ausgabe: 07 / 2008
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
register of sheets sheet register of sheets sheet

buzzer mute 40 BMKdirectory 64
A A
windscreen wiper 41 BMKdirectory 65
windscreen washer 41
windscreen wiperroof 41
work (head)light equipment 42
work (head)light roof 42
9625938_103285847_4_en
headlight 43
B rear light 43 B
brake light 43
horn, hooter 44
PROJEKT:
indicator unit 44
steering column switch 44
hazard light 44
refuelling pump 45
C
Travel alarm 46 C
backup alarm 46
reserve transducer handle 46
Auxiliary heating 47
fuel preheating 48
Fan drive Reversible 48
central lubrication (system) 49
changeover control system / unit, control, controller 49
forbidden.
D D
plug grouping 50
plug grouping 51
key of symbols DINStandards 52
BMKdirectory 53
BMKdirectory 54
BMKdirectory 55
BMKdirectory 56
E E
BMKdirectory 57
BMKdirectory 58
BMKdirectory 59
BMKdirectory 60
BMKdirectory 61
BMKdirectory 62
F
BMKdirectory 63 F
Anlage
A 309 Litronic TCD ab 40998 Seite: 8.40 2 / 65
LIEBHERR register of sheets Ort +CNT
1 2 3 4 5 6 7 8
F
C
E
B
D
A
Für dieses Dokument und den darin dargestellten Gegen We reserve all rights in this document and in the informa
stand behalten wir uns alle Rechte vor. Vervielfältigung, tion contained therein. Reproduction, use or disclosure PROJEKT:
Bekanntgabe an Dritte oder Verwertung seines Inhaltes to third parties without express authority is strictly
sind ohne unsere ausdrückliche Zustimmung verboten. forbidden. 9625938_103285847_4_en
© LIEBHERR HYDRAULIKBAGGER GMBH © LIEBHERR HYDRAULIKBAGGER GMBH
1
1
/6.B3
A150
A148
/9.A1
A148
2
2
5
9
CAN 1
X1167
6 CAN 1
1
display
(diagnosis)
diagnosis CAN
/9.A4
CAN1 /20.A7
3
3
CAN 1
Hydraulikbagger
LIEBHERR
A148
fuse board
gmbh
RS232 /9.B4
/4.A7
A149
/20.A3
4
4
(Master)
5
9
UEC1 central control
X1166
1 RS232
diagnosis RS232
CAN 1
5
5
/5.A7
A155
/27.D6
P6
A160
/27.D3
overview CAN bus
display
CAN 2
(Slave)
(VDOSlave)
SATBUS
/27
P7
6
6
coolant temperature
VDOMaster
CAN 2
(VDOSlave)
fuel indicator
Seite:
console, right
7
7
CAN2
(EMRdiagnosis)
/7.B7
A151
+D
8.40 3
Ausgabe: 07 / 2008
/ 65
revolving deck
X22
diagnosis socket EMR
/21.A4
EMR
8
8
Ort
motor control
Anlage
+F
=O

F
C
E
B
D
A
1 2 3 4 5 6 7 8
A A
/3.D4
A149 module NR.: 1
moduledesignation: UEC 1 (Master) A_UEC_MODUL_1
9625938_103285847_4_en
Phys. Adr. sheet EA Description plug PIN Phys. Adr. UB sheet EA Description plug PIN
B B
KL30 /19.F1 100 UB KL30 X1 1 DIN.3 /33.F8 110 feedback, acknowledgement, check back signal parking brake X2 1
UB.0 /19.F3 101 UB0 KL15 X1 2 DIN.4 /23.F5 111 safety lever X2 2
GND.0 /19.F2 GND X1 3 DIN.5 /32.F1 112 servo ON X2 3
PROJEKT:
GND.1 /20.C2 RS232 GND X1 4 DIN.6 /20.F8 113 service plug X2 4

OUT+5V +5V power supply X1 5 DIN.7 /33.F7 114 feedback, acknowledgement, check back signal 1. speed, gear X2 5
AGND.1 /35.F2 AGND control device / unit, controller L X1 6 DIN.8 /32.F7 115 working brake X2 6
AGND.2 X1 7 DIN.9 /37.F2 36 gripper swing L X2 7
AGND.3 /28.F1 AGND pedal X1 8 DIN.10 /37.F2 37 gripper swing R X2 8
AGND.4 /36.F4 AGND hydraulic oil sensor X1 9 DIN.11 /40.F8 38 bolt, pin, stud Quick change adapter extended X2 9

AGND.5 /35.F4 AGND control device / unit, controller R X1 10 DIN.12 /33.F3 39 forwards X2 10
C
OUT+28 /32.A6 107 +28V power supply X1 11 DIN.13 /33.F3 40 backwards, reverse X2 11 C
BOOT /20.C3 BOOTSTRAP X1 12 DIN.14 /40.F2 41 feedback, acknowledgement, check back signal Quick change adapter &#6549;
X2 12
TxD /20 RS232 TxD X1 13 DIN.15 /43.F8 42 pressure switch brake light X2 13

RxD /20.C1 RS232 RxD X1 14 DIN.16 /46.F2 43 acknowledgement Travel alarm X2 14
CAN1.H /20.F6 CAN1.H X1 15 DIN.17 /36.F5 44 SF ON / OFF X2 15

RMes.1 92 X1 16 IOUT.1 165 X2 16
RMes.2 /36.F3 93 hydraulic oil sensor X1 17 BRÜ+/ UB0 /43.A7 154 brake light X2 17

RMes.3 94 X1 18 BRÜ 157 X2 18
RMes.4 95 X1 19 BRÜ+ UB0 156 X2 19
RMes.5 96 X1 20 DO.17 UB0 /40.A6 164 indicator light mute switch for buzzer X2 20
CAN1.GND /20.F8 CAN1.GND X1 21 DO.16 UB0 /23.A5 163 buzzer X2 21
CAN2.H /21.F3 CAN2.H X1 22 DO.15 UB4 /37.A7 162 changeover &#6502; AHS X2 22
forbidden.
D CAN2.L /21.F4 CAN2.L X1 23 DO.14 UB4 /37.A4 161 gripper swing R X2 23 D

CAN1.L /20.F7 CAN1.L X1 24 DO.13 UB4 /37.A3 160 gripper swing L X2 24
AIN.5 130 X1 25 DO.12 UB3 /32.A3 159 servo ON / OFF X2 25

AIN.6 /27.F1 131 level tank sensor X1 26 DO.11 UB3 /40.A1 158 SWA X2 26
AIN.7 /28.F3 132 travelling pedal sensor nominal value, specified value, reference value 2
X1 27 DO.10 UB3 /33.A2 151 backwards, reverse X2 27
AIN.8 /35.F3 133 control device / unit, controller R X1 28 DO.9 UB2 /33.A1 150 forwards X2 28

AIN.9 /35.F1 134 control device / unit, controller L X1 29 DO.8 UB2 /28.A4 149 travel speed X2 29

AIN.10 /35.F6 135 PST slewing gear X1 30 DO.7 UB2 /46.A3 148 Travel alarm X2 30
AIN.1 /32.F5 126 oscillating axle automatic X1 31 DO.6 UB2 /36.A7 147 performance regulator X2 31
AIN.2 /32.F5 127 oscillating axle uppercarriage X1 32 DO.5 UB3 /32.A8 146 oscillating axle uppercarriage X2 32
E
AIN.3 128 pressure switch air filter X1 33 DO.4 UB1 /36.A8 145 pilot pressure reduction X2 33 E
AIN.4 /28.F2 129 travelling pedal sensor nominal value, specified value, reference value 1
X1 34 DO.3 UB1 /35.A8 144 fancontrol system / unit, control, controller X2 34
FRQ.1 /40.F5 170 Quick change adapter activate, actuate, power, start X1 35 DO.2 UB1 /37.A8 143 pressure reduction AHS X2 35
FRQ.2 /40.F6 171 buzzer mute X1 36 DO.1 UB1 /35.A7 142 fine adjustment slewing gear X2 36
FRQ.3 /46.F6 172 switch slipring contact X1 37 UB.1 /19.F3 102 UB1 Kl15 X2 37
FRQ.4 173 X1 38 UB.2 /14.F3 103 UB2 S7 / Kl15 X2 38
DIN.1 /37.F6 108 attachment activate, actuate, power, start X1 39 UB.3 /14.F4 104 UB3 S7 / Kl15 X2 39
DIN.2 109 magnet system X1 40 UB.4 /14.F7 105 UB4 Servo/Kl15 X2 40
F F
A 309 Litronic TCD ab 40998 Anlage =O
overview UEC 1 Seite: 8.40 4 / 65
A 311 Litronic TCD ab 41128 LIEBHERR Ort +F

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
/3.B5
A155 module NR.: 5
9625938_103285847_4_en
moduledesignation: UEC 2
B Phys. Adr. sheet EA Description plug PIN Phys. Adr. UB sheet EA Description plug PIN B
KL30 100 UB KL30 X1 1 DIN.3 110 changeover cylinder external X2 1

UB.0 101 UB0 KL15 X1 2 DIN.4 111 X2 2
PROJEKT:
GND.0 GND X1 3 DIN.5 112 X2 3

GND.1 X1 4 DIN.6 113 X2 4
OUT+5V power supply +5V X1 5 DIN.7 114 X2 5
AGND.1 earth angle sensors X1 6 DIN.8 115 X2 6
AGND.2 /34.A6 earth sensors undercarriage X1 7 DIN.9 /34.F1 36 selector (switch) 4wheel steering X2 7
AGND.3 X1 8 DIN.10 /34.F2 37 selector (switch) dog walk X2 8
AGND.4 X1 9 DIN.11 /34.A6 38 sensor front axle &#6550; X2 9

C
AGND.5 X1 10 DIN.12 /34.A7 39 sensor rear axle &#6550; X2 10 C
OUT+28 /34.A5 107 +28V supply sensors X1 11 DIN.13 40 Stroke limitation OFF X2 11
BOOT X1 12 DIN.14 41 bypass Stroke limitation X2 12

TxD X1 13 DIN.15 42 X2 13
RxD X1 14 DIN.16 43 X2 14
CAN1.H CAN1.H X1 15 DIN.17 44 X2 15
RMes.1 92 X1 16 IOUT.1 165 X2 16
RMes.2 93 X1 17 BRÜ+/ UB0 154 X2 17

RMes.3 94 X1 18 BRÜ 157 X2 18
RMes.4 95 X1 19 BRÜ+ UB0 156 X2 19
RMes.5 96 X1 20 DO.17 UB0 /34.A4 164 changeover valve 4wheel steering X2 20
CAN1.GND CAN1.GND X1 21 DO.16 UB0 /34.A4 163 changeover valve dog walk X2 21
forbidden.
D CAN2.H CAN2.H X1 22 DO.15 UB4 162 continuous operation Mower rake X2 22 D

CAN2.L CAN2.L X1 23 DO.14 UB4 /34.A8 161 &#6505; steering direction left X2 23
CAN1.L CAN1.L X1 24 DO.13 UB4 /34.A7 160 &#6505; steering direction right X2 24
AIN.5 130 B315, angle sensor, angle transmitter boom cylinder X1 25 DO.12 UB3 159 HBG cutoff ON X2 25

AIN.6 131 B316, angle sensor, angle transmitter road adjustment, road settingX1 26 DO.11 UB3 158 regulating cylinder lifting X2 26
AIN.7 132 X1 27 DO.10 UB3 151 Bagger: boom; Kran: jib lifting X2 27

AIN.8 133 X1 28 DO.9 UB2 150 UMSCHALTUNG VORSTEUERUNG X2 28

AIN.9 134 X1 29 DO.8 UB2 149 interlocking steering changeover X2 29
AIN.10 135 X1 30 DO.7 UB2 148 MENGENEINSTELLUNG AHSSEGMENT ASEITE X2 30
AIN.1 126 X1 31 DO.6 UB2 147 MENGENEINSTELLUNG AHSSEGMENT BSEITE X2 31

AIN.2 127 X1 32 DO.5 UB3 146 Bagger: boom; Kran: jib lifting preliminary shutdown X2 32
E E
AIN.3 128 X1 33 DO.4 UB1 145 changeover cylinder external X2 33
AIN.4 129 X1 34 DO.3 UB1 /34.A2 144 indicator light 4wheel steering X2 34
FRQ.1 170 X1 35 DO.2 UB1 /34.A3 143 indicator light dog walk X2 35
FRQ.2 171 X1 36 DO.1 UB1 142 stick shutdown extends X2 36
FRQ.3 172 X1 37 UB.1 102 UB1 Kl15 X2 37
FRQ.4 173 X1 38 UB.2 103 UB2 S7 / Kl15 X2 38
DIN.1 108 SF function external X1 39 UB.3 104 UB3 S7 / Kl15 X2 39
DIN.2 109 Mower rake activate, actuate, power, start X1 40 UB.4 105 UB4 Servo/Kl15 X2 40
F F
overview UEC 2 (option, optional) Seite: 8.40 5 / 65

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
/3.B2
9625938_103285847_4_en
B A150 module NR.: B
moduledesignation: Display
PROJEKT:
Phys. Adr. sheet EA Description plug PIN
Kl.15 /19.F4 KL15 X1 1

Kl.30 /19.F5 KL30 X1 2
GND /19.F6 GND X1 3
GND X1 4
n.c. X1 5
D SUMMER X1 6
C
OUT SUMMER X1 7 C
n.c. X1 8
CAN H /20.F3 CAN.H X1 9

CAN L /20.F4 CAN.L X1 10

GND /20.F5 GND X1 11
n.c. X1 12
n.c. X1 13
n.c. X1 14
n.c. X1 15
DIGIN0 /36.F1 preparation Particle filter X2 1

forbidden.
D DIGIN1 /26.F2 water sensor fuel filter X2 2 D

DIGIN2 /49.F6 changeover control system / unit, control, controller

X2 3
DIGIN3 reserved X2 4
DIGIN4 /21.F1 diagnosis motor control X2 5
DIGIN5 /44.F7 (direction) indicator, flasher, turn signal X2 6
DIGIN6 /27.F2 tank sensor switching point X2 7
DIGIN7 /26.F3 pressure switch air filter X2 8

DIGIN8 /37.F5 &#6552; &#6549; X2 9

DIGIN9 X2 10
DIGIN10 X2 11
DIGIN11 /10.F7 battery indicator light X2 12
E
DIGIN12 X2 13 E
DIGIN13 /28.F5 Vnominal value, specified value, reference value store (in memory)
X2 14
DIGIN14 /28.F6 Vnominal value, specified value, reference value store (in memory) &#6549;
X2 15
DIGIN15 X2 16
DIGIN16 /36.F3 accumulator pressure X2 17

DIGIN17 /39.F2 overload warning (system) X2 18
DIGIN18 /39.F1 pressure switch UL X2 19
DIGIN19 X2 20
n.c. X2 21
F F
overview display Seite: 8.40 6 / 65

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
/3.D7
9625938_103285847_4_en
B B
A151 module Nr.:
module: EMR2 A_EMR_2_MODUL_1
PROJEKT:
plug plug
motor(M) vehicle (F)
Phys. Adr. sheet E/A Description plug &#6563; Phys. Adr. sheet E/A Description plug &#6563;
GND /25.F7 D5.1 1 U Batt /19.F7 KL31 D5.2 1
OUT: Digital 3 /25.A7 D5.1 2 GND (Masse) /21.F7 diagnosis earth D5.2 2
OUT: Digital 4 /23.E2 preheat D5.1 3 OUT: Digital 2 D5.2 3
IN: Temperatur 1 /24.F3 charge (cooling) temperature D5.1 4 OUT: DIG OUT/IN /22.A2 failure (indicator) lamp D5.2 4

C IN: Temperatur 2 /24.F4 Fuel temperature D5.1 5 OUT: Digital 1 D5.2 5 C

IN: Digital 5 /24.F6 cooling water level Signal D5.1 6 IN: Digital 3 D5.2 6

OUT: Digital 7 /25.A8 D5.1 7 IN: Dig. (Geschw. 1) D5.2 7
GND /24.F4 temperature GND; D5.1 8 NC /21.F8 reserve D5.2 8

IN: Analog 3 /24.F5 cooling water temperature D5.1 9 NC /21.F8 reserve D5.2 9
GND /25.F2 speed, rpm SAE, GND D5.1 10 LLeitung /21.F6 diagnosis LLINE D5.2 10
IN: Drehzahl 2 /25.F3 speed, rpm SAE, SIG D5.1 11 KLeitung /21.F6 diagnosis KLINE D5.2 11
GND /25.F1 speed, rpm NW, GND D5.1 12 CANhigh /21.F4 CAN1.H D5.2 12
IN: Drehzahl 1 /25.F2 speed, rpm NW, SIG D5.1 13 CANlow /21.F5 CAN1.L D5.2 13
STG /25.A4 actuator, servo component() EMR D5.1 14 U Batt+ /19.F7 KL15 D5.2 14
STG+ /25.A4 actuator, servo component(+) EMR D5.1 15 OUT: Digital 5 /22.A1 D5.2 15
Schirm /25.A7 actuator, servo component screen D5.1 16 OUT: Digital 7 D5.2 16
forbidden.
D
RF /25.A5 actuator, servo component RF D5.1 17 GND (Masse) D5.2 17 D

RF REF /25.A6 actuator, servo component RF REF D5.1 18 IN: Digital 1 D5.2 18
RF MESS /25.A5 actuator, servo component RF MESS D5.1 19 IN: Digital 4 D5.2 19
GND /24.F7 oil pressure cooling water level GND D5.1 20 IN: Analog 3 D5.2 20
IN: Analog 4 /24.F8 oil pressure motor SIG D5.1 21 IN: Digital 2 D5.2 21
+5V REF /24.F8 oil pressure motor +5VREF D5.1 22 Schirm (PWG) D5.2 22
GND /24.F1 pressure charge (cooling) GND D5.1 23 GND für PWG D5.2 23

IN: Analog 2 /24.F2 pressure charge (cooling) SIG D5.1 24 IN: Analog 1 D5.2 24

+5V LDA /24.F2 pressure charge (cooling) +5V D5.1 25 +5V REF D5.2 25
E E
F F
overview EMR2 Seite: 8.40 7 / 65
A 311 Litronic TCD ab 41128 LIEBHERR Ort +D

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A127 A
F_B F_A F22/F302 F303 F_H F_G F_F F_E F_D F_C F_I F_K F_L F_M
?A ?A 7,5A 7,5A 15A ?A ?A ?A ?A 15A ?A ?A 20A ?A
/12.A4 /12.A4 /12.A3 /12.A5 /12.A8 /12.A8 /12.A7 /12.A7 /12.A6 /12.A6 /12.C2 /12.C2 /12.C3 /12.C3
V43 V45 V1 V23 V26 V29 V31 V34 V35 V40 V3 V4 V5 V6

9625938_103285847_4_en
gn gn gn gn gn gn gn gn gn gn gn gn gn gn
RN3.9 R8 RN1.5 RN3.5 RN3.3 RN3.4 RN3.2 RN3.6 RN3.7 RN3.8 RN1.4 RN1.6 RN1.8 RN1.9
Option2 X36 X39 X40 X41 X2 X1 X15 X18 X20 X22 X24 X25 X26 X27 X28 X29 X32 X33 X34 X35 X3 X4 X5 X6 X7 X8 X9 X10
M5
B B
/12.B5
PROJEKT:
F332 25A F370 25A

/12.C4 /12.C4
F19/F301 50A F20/F300 50A
/12.A2 /12.A1
86 30+ 86 30+ 86 30+ 86 30+
S1.2
V11 K302 V10 K288 V20 K_F V9 K476
/23.C1 /11.E1 /11.E2 /11.B5
S1 F_N ?A
/12.C6 S1.1 /12.A3 85 87 85 87 85 87 85 87

C C
V7 V19 V12 V8 V21 V16 V51 BYV 28150 V2 V24 V17 V22

gn
gn gn gn gn gn gn gn gn gn
R1 RN2.2 R5 V15 RN2.4 R4 R9 RN2.7 R2.6 V13 R2.8 V18
220
K_F:86_1
K_F:86_2
K302:86
K302:85
K288:86
R2 R3
KL31:X2
KL31:X3
KL31:X4
KL31:X5
KL31:X1
V14
M5 KL19 M6 BTKP M6 KL15 M6 KL30/A M6 S1.2 X43 M5 X17 X13 X16
X42
KL30/E Option1 /12.B2 /12.D1
KL31
MP90 M8 M6
/12.A1 /12.B3
RA 86 30+ RB 86 30+ RC 86 30+ RD 86 30+ RE 86 30+
KA KB KC KD KE
forbidden.
V30 V8 V49 V42 V50

D V_A /48.D1 V_B V_C /47.E5 V_D /47.E7 V_E /47.E6 D
gn gn gn gn gn
85 87A 87 85 87A 87 85 87A 87 85 87A 87 85 87A 87
V25 V28 V32 V38 V44 V48 V33 V39

XA5 XA6 XA7 XA8 XA9 XA10 XA3 XA4 XA1 XA2 XB5 XB6 XB7 XB8 XB9 XB10 XB3 XB4 XB1 XB2 XC5 XC6 XC7 XC8 XC9 XC10 XC3 XC4 XC1 XC2 XD5 XD6 XD7 XD8 XD9 XD10 XD3 XD4 XD1 XD2 XE5 XE6 XE7 XE8 XE9 XE10 XE3 XE4 XE1 XE2
RN1 RN2 RN3
E E
1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9
S1.2 S1.2
F F
overview E50 Seite: 8.40 8 / 65

1 2 3 4 5 6 7 8
F
C
E
B
D
A
1
1
A148
/44.D8
/23.D8
/32.C3
K63
A148 /3.E2
K386
K370
/16
F312 F313 F314 F315 F316 F319 F320 F321 F338 F363 F325 F326 F327 F328 F329 F330 F331 F337
2
2
/14
/14
/13.A2
/13.A2
/13.A3
/13.A4
/13.A4
/13.A5
/13.A6
/13.A6
/13.A7
/13.A7
/14.C3
/14.C4
/14.C5
/14.C6
/14.C7
/14.C8
7,5A 5A 7,5A 15A 7,5A 15A 15A 15A 15A 15A 7,5A 15A 15A 15A 15A 15A 15A 15A
3
3
front view
Hydraulikbagger
LIEBHERR
/3.E4
/3.E3
gmbh
F304 F305 F306 F318 F336 F339 F322 F372
4
4
/13.D2
/13.D2
/13.D3
/13.D4
/13.D4
/13.D5
/13.D6
/13.D7
CAN1
RS232
15A 15A 15A 20A 20A 20A 15A 7,5A
5
5
A148.KL15 1
/11.D7
M8
overview fuse board
6
6
rear view
X1162.B X1165.B X1164.B X1161.B X1160.B

/50.B4 /50.B7 /50.B6 /50.B3 /50.B1
Seite:
7
7
8.40 9
Ausgabe: 07 / 2008
X1163.B
/50.B5
/ 65
8
8
Ort
1
/12.E1
A148.KL30
M6
Anlage
+F
=O

F
C
E
B
D
A
F
C
E
B
D
A
1
1
S9
0
12V
G2
S9.X3/1
S9.X4/1
G2.X2
G2.X1
MP88.X1 BK 70.00 mm² BK 70.00 mm²

/18.B3
3
4
+
MP88.X1 S9.X4/2 +FX952.B:16 Ubat +

/27.E8
S9.X4/3 BK Ubat
main switch
/47.F3
BK,BK,BK 1.50 mm²,1.00 mm²,1.00 mm²
mass distribution
12V
G2.1
BK 70.00 mm²
G2.1.X2
G2.1.X1
S9.X2/1 S9.X1/1 RD
1

2
+
5000 70.00 mm² +
S9.X1/2
2
2
RD
5000 6.00 mm²
XF359
F359.XA.1
F359.X1.1
F359.A1 +FX952.B:17
/27.A8
F359
7,5A
5000 6.00 mm²
RD 5006 A 1
1
A
1
F359.A2 A127.XC2 F359.XA.2

/47.A7
RD 3041 A
F110.B1 X101:1 F375.XB.1
15A
/47.E3
F375
RD 3040 B
B
2
3
3
battery box
RD 70.00 mm²
3
Hydraulikbagger
LIEBHERR
4
gmbh
E
5
4
4
F
6
M1KL30.X2
+M
30
M1
M1KL30.X1 RD 5015 10.00 mm²
30
M 30
+M
M8
starter
5
5
31
50
M1KL50.X
2
/18.E1
50
MP50
A127
E50
/8.A1
K_F
5005 2.50 mm²
/11.F3
V13
A127.X/X43
:F332.X2
/12.D4
87
30
F332.A
gn
V17
KL50 M5
operating hour meter / counter
R2.6
battery, main switch, starter, generator,
6
6
+F
P5.X2
+F
+F
+F
+F
P5.X1
X8421.B
MP60.X2
X8421.S
BK 5016 5016,5016 +FX859.B:11 D+

P5 h

/17.B5 /30.D4
5015
+ 3 3
+FMP60.X2
Seite:
MNr.
5016
7
7
+F
A150.X2
5016
+F ADR DIGIN11
/6.E2
MName: Display
X2 12
12
A150
EA
RD 10.00 mm²
+F
4
X954.S
battery indicator light
4
X954.B
Ausgabe: 07 / 2008
+F
8.40 10 / 65
5016
+M
G1
+M
D
M8
G1D+.X1
5016 A127.X/X42 G1/D+

/11.D8
D
1
D+
/18.E1
1
MP50
8
8
3~
Ort
G
Anlage
G1B+.X1
X954.B
+F
G1W.X
generator
W
5902 RD 5015 10.00 mm²

B+
5 1 B+
+D
=O
5902 G1B+.X2 RD 5004 10.00 mm² A127.X/KL30E KL30/E

A127.X/G1:W /12.A1
B+
F
C
E
B
D
A
F
C
E
B
D
A
+F
S1
1
1
0
F322.A
/13.C7
+FX1163.B:1
A127
E50
P0 12
/8.C5
K288
S1.X2
+F
+F
S1.X1
RD +FX1161.B:2
/13.E2
58
30
V10
6119 1.50 mm² 10 1 6122 1.50 mm² F304.A
.B7
.F2
87
X954.B
A127.X/K288:86
+F
+F
+F
X954.S
1013 1013 30/1
.E2
85
K288
K288:86 2 2 5
86+
30
15 54
relay Kl 15
+F
1010
gn
2
2
V21
RN2.4
8
50a 50a
/8.C7
K_F
A127.X/K_F:86
V20
X980.B
+F
+F
X980.S
1010
/10.C5
.F3
K_F:86_1 1 1
87
.E3
K_F
85
K_F:86_2
86+
30
relay Kl 50
3
3
Hydraulikbagger
LIEBHERR
gmbh
4
4
A127
E50
K476
/8.C8
V9
85
5
5
X17
86+
gn
V24
RN2.7
ignition switch
K476
/8.A1
V18
F370.A
6
6
/12.D4
X13
30
87
:F370.X2
gn
V22
X16
R2.8
cab
+F
/9.C5
A148
fuse board
K288
/8.A1
Seite:
A148.KL15
M8
+F
X9671.B
A148.KL15.X2
+K
X9671.S
.F2
KL15/ZS +KKL15/KA.X1
2
/15.A4 1005 1005

V14
A127.X/KL15A
+F
+F
X1169.B
X1169.S
1813 6.00 mm² 1 1 1813 6.00 mm² 2

A148.KL15.X1
F300.A
3
/13.A2 /12.D5
1
87
30
7
7
1 1 1 :F370.X1
gn
V16
6.00 mm² 6.00 mm²
KL15 M6
/14.A2
X30+
5
R4
X42
A127.X/X42
R9
220
V51
BYV 28150
Ausgabe: 07 / 2008
8.40 11 / 65
KL15.A
:F303.X1
8
8
Ort
G1/D+ 5016
/10.B8
Anlage
+MG1D+.X1
/12.A5
+D
=O

F
C
E
B
D
A
F
C
E
B
D
A
+F
/10.B8
E50
/9.D8
A148
1
1
A127
KL30/E
A148.KL30
M6
2
/13.C2
F20/F300
/8.D2
KL30/A
/8.C6
A127.X/KL30A
+F
+F
X1168.B
A127.X/KL30E
X1168.S
1003
A148.KL30.X1
1003 RD RD
3
1
1 6.00 mm² 1 1 6.00 mm²
M6
M8
gn
4
V2
50A
clamp 30
/8.C5
+MG1B+.X2
5
R3
S1.2
fuse board
F301.A :X30+
/23.B3
F_I
X3
?A
/8.B6
X4
F_I_.X1
2
2
gn
V3
F19/F301
/8.C4
BTKP M6
gn
V8
50A
RN1.4
/8.C3
F_K
X5
R2
S1.2
?A
/8.B6
X6
gn
V4
F_K_.X1
F22/F302
X2
RN1.6
A127.X/X7
A127.X/X1
F216.A X1138.B:1 RD 1.50 mm² F302.X1 6993

/45.A1 /44.A8
F216
7,5A
/8.B2
X1
X7
+FX954.B:3
gn
V1
20A
/8.B7
X8
gn
V5
F_L_.X1
RN1.5
3
3
F_N
/8.D2
RN1.8
Option1
F_M
fuses option, optional
X9
M6
?A
gn
V7
/8.C2
?A
F_N_.X1
/8.B7
R1
Hydraulikbagger
X10
LIEBHERR
gn
V6
S1.2
F_M_.X1
F_A
RN1.9
X40
F332
F332.A
?A
/10.C6
gmbh
/8.B2
:K16_1..X30+
X41
gn
V45
25A
F_A_.X1
/8.B7
R8
4
4
F_B
X36
?A
F370
/8.B1
F370.A
X39
gn
V43
/11.A6
F_B_.X1
:K16_2..X30+
25A
/8.B8
RN3.9
Option2
/8.B1
F300.A :X30+
M5
/11.A7
/11.B8
5
5
KL31:X5
F303
KL15.A
X15
A127.X/X18
KL31:X4
F303.A
:2
/23.A2
7,5A
/8.B3
A127.X/K302:86 1
X18
gn
V23
KL31:X3
fuses E50
RN3.5
X738.B:2 BK A127.KL31X2 KL31:X2 F382.A

/48.E3 /19.D7
F382
A127.KL31X2 A151.D5.2:14 1
A127.XA7 BK A127.KL31X1 KL31:X1
15A
/48.E2
S1
/8.B5
/8.C1
A127.KL31X1
X34 X35
gn
V40
F_C_.X1
MP87.X2 BK 2.50 mm² A127.X/KL31

2
/18.B6
A127.X/X34
A127.X3/KL31
6
6
+FMP87.X2
1
RN3.8
3
KL31 M5
S1.1
S1.2
4
F_D
X32
5
MP90
MP/DB2.X1X689.S:6 BK
?A
/47.F8
M5
/8.B5
X33
gn
V35
F_D_.X1
fuses E50
test switch
A127.KL31
RN3.7
F_E
X28
?A
/8.B4
Seite:
X29
gn
V34
F_E_.X1
fuses (KL15)
RN3.6
7
7
F_F
X26
?A
/8.B4
X27
gn
V31
F_F_.X1
Ausgabe: 07 / 2008
RN3.2
F_G
X24
A127.X/RES:A1 RES_A
?A
8.40 12 / 65
A127.X/RES:A
/8.B4
A127.X/RES:B1 RES_B
X25
gn
A127.X/RES:B
V29
F_G_.X1
A127.X/RES:C1 RES_C
A127.X/RES:C
A127.X/RES:D1 RES_D
A127.X/RES:D
RN3.4
A127.X/RES:E1 RES_E
A127.X/RES:E
F340
+F +F +F +F +F +F
8
8
A127.X/RES:F1 RES_F
X20
Ort
A127.X/RES:F
F340.X22 1992 A127.X/X22
Anlage
15A
/48.A3
/8.B3
A127.XA1 X22
X22
gn
V26
F_H_.X1
+D
=O
RN3.3
F
C
E
B
D
A
F
C
E
B
D
A
1
1
A148
A148
fuse board
fuse board
.B8
F_LED
/9.E4
15A
F304
F312
/9.F2
7,5A
A148.KL15
X1161.B
X1160.B
X1161.S
X1160.S
F304.A A149.X1:1 RD F312.A S44.X:15
/19.D1 /44.A7
A148.KL30 2
3
/12.E1
/11.D7
F304.A S1.X1:1 RD 1 1 1 1
M6
M8
/11.A1
F304.A A150.X1:2 RD 2 2
/19.D5
F304.A K481.X:30 3 3
/27.A3
RD 4
2
2
/9.E4
15A
5A
/9.E2
F305
F313
X1161.B
X1160.B
X1161.S
X1160.S
F305.A X967.B:2 RD F313.A X960.S:3

/31.A7 /43.A8
6118 1.50 mm² 5 5 F313.A K315.X:3 2 2
/43.A6
6
7
F314.A X980.S:3
/9.E4
15A
/26.A3
/9.E2
F306
F314
7,5A
X1160.B
X1160.S
F314.A S7.X1
/23.A5
3
3
F314.A X22:A 3 3
/21.E6
F306.A
4 4
/16.A2
Hydraulikbagger
LIEBHERR
/9.E4
15A
/9.E2
F318
F315
20A
X1161.B
X1161.S
X1160.S
F318.A X8421.B:1 RD F315.A R91:2

/29.C1 /22.E2
6773 1.50 mm² 8 8 F315.A R90:2 5
/22.E1
9 F315.A A150.X1:1 6 6
/19.D4
gmbh
F315.A X1048.B:12 7 7
/46.A2
8 8
4
4
F316.A X1117.B:1
/9.E4
/34.A1
/9.E2
F336
F316
20A
7,5A
X1161.B
X1160.B
X1161.S
X1160.S
F336.A X967.B:1 RD F316.A S18.X1:5

/43.A1 /39.A2
1809 2.50 mm² 10 10 F316.A K481.X:15 9 9
/27.A3
11 10 10
fuses (KL30)
fuses (KL15)
15A
/9.E2
F339
F319
20A
/9.D4
X1161.B
X1160.B
X1161.S
X1160.S
F339.A X8421.B:6 RD F319.A X8421.B:2

/30.D3 /29.A1
5
5
1814 2.50 mm² 12 12 11 11
13 12
Fres_2
/9.D2
15A
F320
X1161.S
14
fuses printed circuit board
max. 20A
F320.A
15
/16.A2
6
6
/9.D2
15A
F321
F321.A
15A
voltage transformer
F322
/9.D4
X1163.B
X1163.B
X1163.S
X1163.S
F322.A X967.B:3 S1.X2:10 F322.A

/31.A1 /11.D1
6119 2 2 1 1 6119 1.50 mm²
/16.A2
F322.A S422.X2:2
/31.A5
6119
Seite:
/9.D2
15A
F338
X1160.B
X1160.S
F338.A K391.X:3
/44.A1
F338.A X971.S:1 13 13
/30.A5
7
7
14 14
F372
7,5A
X1163.S
X1163.S
/9.C4 2
4 3
/9.D2
15A
F363
X1160.B
X1160.S
F363.A A149.X2:37
max. 20A
/19.D3
Ausgabe: 07 / 2008
F363.A A149.X1:2 15 15
/19.D3
Fres_4
X1163.S
X1163.S
8.40 13 / 65
6 5
max. 20A
F_LED
F_LED
8
8
.E1
Ort
/14.C1
Anlage
+F
=O

F
C
E
B
D
A
F
C
E
B
D
A
1
1
A148
fuse board
/13.E8
F_LED
/9
F325
7,5A
X1162.B
X1162.S
F325.A S16.X1:5 6984
/33.A6
F325.A X1048.B:1 6984 4 4
/33.A3
5 5
2
2
K386
/23.F7
15A
/9
F326
X1162.B
X1162.S
F326.A S21.X1:5 6715
/33.A5
A148.KL15 4
87
30
/11.D7
F326.A XS5:1 6715 6 6

M8
/32.A5
F326.A S47.X1:5 3030 7 7
/40.A5
F326.A X954.S:13 3028 8 8
/40.E7
S7
MNr. 1
ADR UB.2
/9.C2
15A
F327
X1162.B
A149.X2
X1162.S
6029
/4.E5
X2 38
3
3
38 9 9
A149
fuses (safety circuit)
UB2 S7 / Kl15
MName: UEC 1 (Master)
EA 103
F327.A
Hydraulikbagger
LIEBHERR
/16.A4
gmbh
4
4
MNr. 1
ADR UB.3
15A
/9.B2
F328
X1162.B
A149.X2
X1162.S
6030
/4.E5
X2 39
39 10 10
A149
UB3 S7 / Kl15
EA 104
F328.A
/16.A4
5
5
15A
/9.B2
F329
X1162.B
X1162.S
F329.A S35.X1:5 6766

/32.A1
11 11
fuses printed circuit board
K370
F330.A X10461.B:8 6742

/32.F3
15A
/46.A7
/9.B2
F330
X1162.B
X1162.S
F330.A X10461.B:1 6742
6
6
/36.A6
87
30
F330.A S19.X1:5 6739 14 14

/37.A1
F330.A X1048.B:8 6739 15 15
/37.B5
16
MNr. 1
ADR UB.4
15A
/9.B2
F331
X1162.B
A149.X2
X1162.S
6028
/4.F5
fuses (servo)
X2 40
40 17 17
Seite:
A149
UB4 Servo/Kl15
EA 105
F331.A
7
7
/16.A5
Ausgabe: 07 / 2008
8.40 14 / 65
S467:13
15A
/9.B2
F337
X1162.B
18
8
8
F337.A X304.B:1 2000

Ort
/38.A3
F_LED
19 19
Anlage
20
+F
=O
/23.D7
F
C
E
B
D
A
F
C
E
B
D
A
1
1
XF307
F307
7,5A
X967.B
+F
F307.A
X967.S
F307.E
F307.A +FX960.S:13 6964 6964 S61.X1:6 F307.E
/43.A3 /43.E1
A
1
F307.A +FX952.S:20 6964 6 6 1 1 6721 1.50 mm²
/43.A5
F308
7,5A
+F
F308.A
F308.E
F308.A +FX952.S:19 6963 6963
/43.A4
B
2
7 7 1 1
6721 1.50 mm²
F309
7,5A
+F
F309.A
F309.E
F309.A +FX960.S:14 6971 1.50 mm² 6971 1.50 mm² S61.X1:3 F309.E
/43.A3 /43.E1
C
3
8 8 1 1 6722 2.50 mm²
2
2
F310
7,5A
+F
F310.A
F310.E
F310.A +FX952.S:18 6962 1.50 mm² 6962 1.50 mm²
/43.A4
D
4
9 9 1 1
6722 2.50 mm²
E
5
F
6
operator's platform
G
7
3
3
XF311
Hydraulikbagger
LIEBHERR
F311
7,5A
F311.A
F311.E
F311.A S11.X:3, S283:4 6074,6074

/41.A2
A
1
1 1
F317
7,5A
F317.A
F317.E
F317.A +FS8.X1:5 1811

/30.A7
B
gmbh
2
1 1
KL15/KA
1813 2.50 mm²
KL15/KA.X2
1813 2.50 mm²
2
15A
F323
F323.A
2
F323.E
F323.A S22.X1:2, S221.X1:2 1813 2.50 mm²
4
4
/42.A2
C
3
KL15/KA.X1
1808,1808 2.50 mm²,2.50 mm² 1 1 1813 2.50 mm² 3 X9671.S KL15/ZS

4
/11.F7
1
4 1 1813 6.00 mm²
5
15A
F324
F324.A
F324.E
F324.A S22.X1:3, S221.X1:3
M6
/42.A2
D
4
1810,1810 2.50 mm²,2.50 mm² 1 1
1813 2.50 mm²
F343
7,5A
F343.A
F343.E
F343.A S218.X1:2 6886

/41.A7
E
5
1 1
F
6
G
7
5
5
fuses cab
6
6
Seite:
7
7
Ausgabe: 07 / 2008
8.40 15 / 65
8
8
Ort
Anlage
+K
=O

F
C
E
B
D
A
F
C
E
B
D
A
1
1
/46.E3
A148
/9
A148
fuse board
X10.S
MP60.X1 X204.S:2
X1164.B
X1164.S
RD 1800 1.50 mm²
/13.D3
1 1 1 F306.A
Kl30
2 2
3
4
2
2
/13.B6
5 F320.A
Kl15
BK 1.50 mm²
7
X11.S
8
/48.A1 1801 1.50 mm²
X11 /13.B6
/48.A4 1 9 9 F321.A
Kl15
/49.A5 2 10
11
12
13
Kl31
3
3
MP60.X1 BK 1.50 mm² 14
/17.A5
15 15
MP60.X1
pro Pin
max. 15A
Hydraulikbagger
power supply kit
LIEBHERR
BK 1.50 mm²
gmbh
X27.S
X1165.B
X1165.S
1802 1.50 mm² F327.X:2
4
4
/14.C3
1 1 1 F327.A
2 2
3
S7 / Kl15
4
F328.A V175.X:2 6030 1.50 mm² F328.X:2
/40.A2 /14.C4
5 5 F328.A
BK 1.50 mm²
6
7
S7 / Kl15
X29.S
8
X29 1803 1.50 mm² F331.X:2
/49.A6 /14.C7
1 9 9 F331.A
2 10
5
5
11
Servo / Kl15
MP60.X1 BK 1.50 mm² 12
/17.A5
A148:KL31 V175.X:6 BK 13
/40.E2
Kl31
MP60.X1 BK 1.50 mm² 14 14
/17.A5
15 15
MP60.X1 MP60.X1
power supply kit
pro Pin
max. 15A
6
6
Seite:
7
7
Ausgabe: 07 / 2008
8.40 16 / 65
8
8
Ort
Anlage
+F
=O
F
C
E
B
D
A
1 2 3 4 5 6 7 8
/30.E7
/16.E3
/31.E8
/16.E5 /32.E7
/41.E5
/16.E5 /36.E8
MP/KA_O.X1 /41.E8 MP60.X1 MP61.X1
/19.E2 /43.E3
/42.F2 KS UF
/23.E5 /44.E1
A /42.F3 A
/23.E7 /44.E4
/42.E6
/44.E3
/42.E7
/31.E1
MP/KA_U.X1
/41.E2
/41.E7
9625938_103285847_4_en
1.00 mm²,1.50 mm²,1.50 mm²,1.50 mm²,1.50 mm²,1.00 mm²,1.50 mm²
B /30.E8
/10.E6 B
/19.E6
/31.E8
/29.D7
/41.E4
MP/KA_P.X2 MP60.X2 /30.E2 MP88.X3
/41.E7 /18.D4
/33.B7 KS DB
PROJEKT:
/42
alle 1.00qmm
/38.B3
/42.B7
/39.E3
/43.E2
/44.E8
1.00 mm²,1.00 mm²,1.00 mm²,1.50 mm²,1.00 mm²
+DX993.B:2 MP61.X4
/30.E8
C C
BK 10.00 mm²
/27.C2
/27.B3
BK,BK,BK,BK,BK,BK,BK,BK
/27.D7
MP60.X3
BK,BK,BK,BK,BK,BK,BK
BK,BK,BK,BK,BK,BK,BK
/30.E5
/31.E3
BK,BK,BK,BK,BK
/34.E2
/43.F7
BK
forbidden.
D D

X9672.S
1
1
X9672.B
+K
BK 6.00 mm²
BK 6.00 mm²
MP/KA_O.X1
MP/KA_P.X2
MP/KA_U.X1
MP/KA_U.X2
MP/KA_P.X3
MP/KA_P.X1
MP60.X2
MP60.X3
MP60.X1
E E
MP61.X1
MP61.X2
MP61.X4
+K +K +K +K +K +K
1
1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
M8 M8 M8 M8 M8 M8
MP/KA_O MP/KA_U MP/KA_P MP60 MP61 MP62
ground supporting point cab top ground supporting point cab console ground supporting point control console, right internal ground supporting point control console, right external ground supporting point control console, right reserve
ground supporting point cab bottom
+K
control console, right
F cab F
mass distribution Seite: 8.40 17 / 65

1 2 3 4 5 6 7 8
F
C
E
B
D
A
1
1
+M 1
/10.E8
2
/10.F5
3
/23.F3
MP50
M8
5 6
7
+M
MP50.X8 BK 70.00 mm²
ground supporting point motor
2
2
MP52.X1
+F 1
2
M8
MP52
3 4
MP motor/bearingrevolving deck
3
3
MP88.X1 BK 70.00 mm² MP88.X1
1
/10.E1
MP88.X2 BK,BK,BK 1.00 mm²,1.50 mm²,2.50 mm²
2
MP88.X3 BK 10.00 mm²
Hydraulikbagger
LIEBHERR
M8
MP88
3 4
MP revolving deckbattery box
gmbh
MP88.X2
+FMP61.X2 MP88.X3
4
4
/17.B7
/44.E5
/43.E4
/19.E8
MP87.X1 BK,BK,BK,BK,BK,BK,BK,BK,BK,BK,BK,BK,BK 1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²,1.50 mm²,1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²
5
5
MP87.X2 BK,BK,BK,BK,BK,BK,BK,BK,BK,BK,BK,BK 1.50 mm²,1.50 mm²,1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²,2.50 mm²
2
MP87.X3 BK 1.00 mm²
3
4
MP87
M8
5 6
7
mass distribution
8
MP revolving deckfuel tank
MP87.X1
MP87.X2
+FX143.B:2 MP87.X3
/42.F1
/42.F2
/33.E1
/45.E1
/40.E8
/40.B4
/40.B3
/37.E7
/33.E5
/33.E2
/32.E8
/32.E4
/12.E6
/39.E2
/37.E8
/37.E5
/37.E4
/37.E3
/36.E8
/36.E7
/35.E7
/33.E6
/33.E6
/28.E4
6
6
/24.D6
/49.E5
MP86.X1 BK,BK,BK,BK,BK,BK 1.00 mm²,1.50 mm²,1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²

1
MP86.X2 BK,BK,BK,BK,BK,BK,BK,BK,BK 1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²,1.00 mm²

2
3
4
Seite:
MP86
M8
5 6
7
7
7
MP revolving deck hydraulic oil tank
MP86.X1
MP86.X2
/26.C1
/43.E7
/43.E6
/43.E6
/43.E5
/43.E5
/43.E5
/35.E8
/34.E8
/34.E7
/30.E3
/38.C7
Ausgabe: 07 / 2008
8.40 18 / 65
8
8
Ort
Anlage
+D
=O
F
C
E
B
D
A
1 2 3 4 5 6 7 8
A A
9625938_103285847_4_en
B B
PROJEKT:
C C
/13.C7
/13.C7
/13.C4
/13.E2
/13.E2
/12.B6
forbidden.
D D

F304.A
F363.A
F363.A
F315.A
F304.A
F382.A
X1161.B:1
X1160.B:7
X1161.B:3
+DA127.X/X34
X1160.B:15
X1160.B:15
7521 2.50 mm²
BK 2.50 mm²
BK 1.50 mm²
MP60.X2
MP88.X2
MP60.X1
1900
1901
BK
6026
6031
6025 RD
MP60.X1 MP60.X2 +DMP88.X2
/18.D4
/17.A5
/17.B5
E +D +D E
37
14
A149.X1 A149.X1 A149.X1 A149.X2 A150.X1 A150.X1 A150.X1 A151.D5.2 A151.D5.2
3
3
1
1
X1 1 X1 3 X1 2 X2 37 X1 1 X1 2 X1 3 D5.2 14 D5.2 1
ADR KL30 ADR GND.0 ADR UB.0 ADR UB.1 ADR Kl.15 ADR Kl.30 ADR GND +D ADR U Batt+ +D ADR U Batt
MNr. 1 EA 100 MNr. 1 EA MNr. 1 EA 101 MNr. 1 EA 102 MNr. EA MNr. EA MNr. EA MNr. EA MNr. EA
MName: UEC 1 (Master) MName: UEC 1 (Master) MName: UEC 1 (Master) MName: UEC 1 (Master) MName: Display MName: Display MName: Display MName: EMR2 MName: EMR2
A149 A149 A149 A149 A150 A150 A150 A151 A151
/4.B2 /4.B2 /4.B2 /4.E5 /6.C2 /6.C2 /6.C2 /7.D5 /7.C5
UB KL30 GND UB0 KL15 UB1 Kl15 KL15 KL30 GND KL15 KL31
power supply UEC power supply display power supply motor control

F F
power supply UEC, EMR, display Seite: 8.40 19 / 65

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
5 1
9 6
9 6 /3.E4 /3.E3
RS232 CAN1 5 1
A A
RS 232
CAN 1
2
3
4
X1166 X1167 R81
R83
GND 120 Ohm
/23.E7
120 Ohm
9625938_103285847_4_en
16
13
14
10
12
15
11
X1163.S X1163.S X1163.S X1163.S X1163.S X1163.S
9
A148 X1163.B X1163.B X1163.B X1163.B X1163.B
12
7
16
11
10
15
fuse board
B 6732 B
6733
6737
6735
PROJEKT:
14
13
12
A149.X1 A149.X1 A149.X1 A149.X1
4
X1 14 X1 13 X1 4 X1 12
C ADR RxD ADR TxD ADR GND.1 ADR BOOT C

MNr. 1 MNr. 1 MNr. 1 MNr. 1
EA EA EA EA
MName: UEC 1 (Master) MName: UEC 1 (Master) MName: UEC 1 (Master) MName: UEC 1 (Master)
6736,6736
6731,6731 RD,RD
6730,6730 BU,BU
A149 A149 A149 A149
/4.C2 /4 /4.B2 /4.C2
RS232 RxD RS232 TxD RS232 GND BOOTSTRAP
UEC RS232 interface
6731 RD
6730 BU
forbidden.
6736 WH
D D
RD
BU
6730
6736
6731
X1301.B X1301.B X1301.B
3
1
1
X1301.S X1301.S X1301.S
3
6736
6734
6731 RD
6730 BU
R89
120 Ohm
E E
10
15
24
11
21
A150.X1 A150.X1 A150.X1 A149.X1 A149.X1 A149.X1 A149.X2
9
4
X1 9 X1 10 X1 11 X1 15 X1 24 X1 21 X2 4
ADR CAN H ADR CAN L ADR GND ADR CAN1.H ADR CAN1.L ADR CAN1.GND ADR DIN.6
MNr. EA MNr. EA MNr. EA MNr. 1 EA MNr. 1 EA MNr. 1 EA MNr. 1 EA 113
MName: Display MName: Display MName: Display MName: UEC 1 (Master) MName: UEC 1 (Master) MName: UEC 1 (Master) MName: UEC 1 (Master)
A150 A150 A150 A149 A149 A149 A149
/6.C2 /6.C2 /6.C2 /4.C2 /4.D2 /4.D2 /4.B5
CAN.H CAN.L GND CAN1.H CAN1.L CAN1.GND service plug
display CAN bus interface UEC 1 CAN bus interface
F F
CAN1, RS232, diagnosis Seite: 8.40 20 / 65

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
X22
/3.F8
diagnosis EMR
D
H
E
B
A A
X22
7505 0.75 mm²
7506 0.75 mm²
RD
BU
9625938_103285847_4_en
7504 0.75 mm²
7507 0.75 mm²
BK 0.75 mm²
7508
7509
B XS6:1 XS7:1 B
XS6:2 XS7:2
PROJEKT:
12 0.75 mm²
0.75 mm²
7505
7506
13
17
19
16
14
15
X980.S X980.S X980.S X980.S X980.S X980.S X980.S
X980.B X980.B X980.B X980.B X980.B X980.B X980.B
12
13
17
19
16
14
15
C C
BK 1.00 mm²
7505 0.50 mm²
7506 0.50 mm²
7505 0.75 mm²
7506 0.75 mm²
7505 0.50 mm²
7506 0.50 mm²
7504 1.00 mm²
6068 0.75 mm²
7507 1.00 mm²
7508
7509
forbidden.
D D

RD
RD
RD
BU
BU
BU
X1160.B:4
F314.A
+D
/13.C3
R84
120 Ohm 120 Ohm
E +D +D +D +D +D +D +D E
22
23
12
13
10
11
A160.X1 A160.X1 A149.X1 A149.X1 A151.D5.2 A151.D5.2 A151.D5.2 A151.D5.2 A151.D5.2 A151.D5.2 A151.D5.2
3
9
X2 5 X1 3 X1 4 X1 22 X1 23 D5.2 12 D5.2 13 D5.2 11 D5.2 10 D5.2 2 D5.2 8 D5.2 9
ADR DIGIN4 ADR CAN1_HIGH ADR CAN1_LOW ADR CAN2.H ADR CAN2.L +D ADR CANhigh +D ADR CANlow +D ADR KLeitung +D ADR LLeitung +D ADR GND (Masse) +D ADR NC +D ADR NC
MNr. EA MNr. EA MNr. EA MNr. 1 EA MNr. 1 EA MNr. EA MNr. EA MNr. EA MNr. EA MNr. EA MNr. EA MNr. EA
MName: Display MName: MName: MName: UEC 1 (Master) MName: UEC 1 (Master) MName: EMR2 MName: EMR2 MName: EMR2 MName: EMR2 MName: EMR2 MName: EMR2 MName: EMR2
A150 A160 A160 A149 A149 A151 A151 A151 A151 A151 A151 A151
/6.D2 /27.C3 /27.C3 /4.D2 /4.D2 /7.D5 /7.D5 /7.D5 /7.C5 /7.C5 /7.C5 /7.C5
diagnosis motor control CAN2.H CAN2.L CAN1.H CAN1.L diagnosis KLINE diagnosis LLINE diagnosis earth reserve reserve
UEC CAN bus 2 interface
F CANCOCKPIT CAN bus interface EMR2 CAN bus interface F
CAN2 UEC, diagnosis EMR2 Seite: 8.40 21 / 65

1 2 3 4 5 6 7 8
F
C
E
B
D
A
1
1
MNr.
MNr.
+F
R90
A151.D5.2
X980.B
+F
+F
X980.S
F315.A +FX1160.B:6 1900 2 1 7503 7503
/13.C4
MName: EMR2
/7.D5
D5.2 15
5 5 15
A151
EA
EA
ADR OUT: Digital 5
100k
2
2
MNr.
MNr.
+F
R91
A151.D5.2
X980.B
+F
+F
X980.S
F315.A +FX1160.B:6 1900 2 1 7530 7530
/13.C4
D5.2 4
MName: EMR2
/7.C5
18 18 4
A151
4k7
EA
EA
ADR OUT: DIG OUT/IN
failure (indicator) lamp
3
3
Hydraulikbagger
LIEBHERR
gmbh
4
4
5
5
EMR2
6
6
Seite:
7
7
Ausgabe: 07 / 2008
8.40 22 / 65
8
8
Ort
Anlage
+D
=O
F
C
E
B
D
A
1 2 3 4 5 6 7 8
/13.C3
/12.B5
F303.A
F314.A
X1160.B:3
+DA127.X/X18
A A
6068
buzzer
/4.D5
ADR DO.16
6200
MNr. 1 EA 163
MNr. 1 EA
9625938_103285847_4_en
/12.B2
A149 S7.X1
1
X2 21 3 1
B B
A149.X2
21
S7 S7
F301.A
4 2
K302:86
1
S7.X2
PROJEKT:
A127.X/K302:86
30
6704,6704
86+
K302 K302 .F2
V11 V19 87
/8.C3 gn /8.A1
.F2
85 V12
RN2.2
gn
V15 R5
C C
6704
6704
KL19 M6
K302:85
A127.X/K302:85 A127.X/KL19A
6761
+D X1162.B
1
A127
1
X1162.S
/14.C8
E50
/9.D1
6201
6.00 mm²
F_LED
5028
86+
K386
forbidden.
D D

+D +M
X23.S R60.X1 S467 K386 D2
8
M5 test switch fuses .F7
X23.B 1 85
8
R60
H342.X3
+D 2 3 4 5
+M
2
3
4
5
+M +M +M +M
3
2 H342 GND X1167:9 GND

/20.B6 /44.D7
1
H342.X2
+D
A151.D5.1
3
X1 X1 X1 X1 max. 5A
D5.1 3 +M +M +M +M
R60.1 R60.2 R60.3 R60.4
BK
A151 X1162.S
3
E MName: EMR2 A148 E
X1162.B
3
A149.X2 SICHERUNGS
2
MNr. EA
PLATINE
BK
MNr. EA X2 2
ADR OUT: Digital 4 ADR DIN.4
MP60.X1
+D
/7.C2 MNr. 1 EA 111
MP60.X1
preheat +M
M8 3 A149 MP60.X1
/17.A5
K302 /18.E1 MP60.X1 /4.B5
/17.A5
.C1 MP50 safety lever

87 30 +D
.B3
K386
preheat glow plug buzzer safety circuitlever .D7
F relay Kl 19 87 30 F
/14.B2
preheat, buzzer, safety circuit / lever Seite: 8.40 23 / 65

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
&#6558;
cooling water level oil pressure sensor motor
charge pressure +M 0 10 bar
B3 B16 p
p B37.X B2.X
2
9625938_103285847_4_en
U 1 1 U
0 5 V
Sig. 5V B37 B2 0 5 V
+ GND +5V Sig. GND
B GND Sig. 5V Sig.
2 2 1 2 1 2 3 B
+M pressure Ref temperature
1
ws
B37.X B2.X B31.X B3.X B16.X
3
br
gn
B48 +M +M +M
temperature +pressure
1
B48.X
2
4
3
PROJEKT:
charge (cooling) +M +M +M +M
5900
BK
23
24
25
16
20
22
21
X17.S X17.S X17.S X17.S X23.S X17.S X17.S
4
6
X17.B X17.B X17.B X17.B X23.B X17.B X17.B

4
6
16
22
23
24
25
20
21
C C
X17 X17
X23.B
4
X23.S
4
MP87.X1
6100
MP87.X1
/18.A6
+F
X980.B
6
forbidden.
X980.S
6
D +F D
6100
+FXS4:1
+28V
/32
E E
23
24
25
20
22
21
A151.D5.1 A151.D5.1 A151.D5.1 A151.D5.1 A151.D5.1 A151.D5.1 A151.D5.1 A151.D5.1 A151.D5.1 A151.D5.1 A151.D5.1
4
6
D5.1 23 D5.1 24 D5.1 25 D5.1 4 D5.1 8 D5.1 5 D5.1 9 D5.1 6 D5.1 20 D5.1 22 D5.1 21
ADR GND ADR IN: Analog 2 ADR +5V LDA ADR IN: Temperatur 1 ADR GND ADR IN: Temperatur 2 ADR IN: Analog 3 ADR IN: Digital 5 ADR GND ADR +5V REF ADR IN: Analog 4
MNr. EA MNr. EA MNr. EA MNr. EA MNr. EA MNr. EA MNr. EA MNr. EA MNr. EA MNr. EA MNr. EA
MName: EMR2 MName: EMR2 MName: EMR2 MName: EMR2 MName: EMR2 MName: EMR2 MName: EMR2 MName: EMR2 MName: EMR2 MName: EMR2 MName: EMR2
A151 A151 A151 A151 A151 A151 A151 A151 A151 A151 A151
/7.D2 /7.E2 /7.E2 /7.C2 /7.C2 /7.C2 /7.C2 /7.C2 /7.D2 /7.D2 /7.D2
pressure charge (cooling) GND pressure charge (cooling) +5V temperature GND; cooling water temperature cooling water level Signal oil pressure motor +5VREF
pressure charge (cooling) SIG charge (cooling) temperature Fuel temperature oil pressure cooling water level GND oil pressure motor SIG
pressure charge (cooling) EMR2 temperaturesensors EMR2 cooling water level EMR2 oil pressure motor EMR2

F F
motor control diesel engine EMR2 Seite: 8.40 24 / 65

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
actuator, servo component() EMR
actuator, servo component(+) EMR
actuator, servo component RF
actuator, servo component RF MESS
actuator, servo component RF REF
actuator, servo component screen /7.C2 /7.C2
speed, rpm NW speed, rpm SAE /7.D2 /7.D2 /7.D2 /7.D2 /7.D2 /7.D2 ADR OUT: Digital 3 ADR OUT: Digital 7
+M +M
ADR STG ADR STG+ A151 A151 A151 A151 MNr. EA MNr. EA
n n MNr. EA MNr. EA MName: EMR2 MName: EMR2 MName: EMR2 MName: EMR2 MNr. EA MNr. EA
B292 B293
MNr. EA MNr. EA MNr. EA MNr. EA MNr. EA MNr. EA MName: EMR2 MName: EMR2
L L
9625938_103285847_4_en
SAEGehäuse
MName: EMR2 MName: EMR2 ADR RF ADR RF MESS ADR RF REF ADR Schirm A151 A151
A151 A151 D5.1 17 D5.1 19 D5.1 18 D5.1 16 D5.1 2 D5.1 7
GND + GND + D5.1 14 D5.1 15 A151.D5.1 A151.D5.1 A151.D5.1 A151.D5.1 A151.D5.1 A151.D5.1
7
17
19
18
16
B 1 2 1 2 B
A151.D5.1 A151.D5.1
14
15
1
1
B292.X B293.X
2
2
+M +M +M +M
PROJEKT:
Schirm
C C
12
13
10
14
15
17
19
18
11
X17.S X17.S X17.B
1
X17.B X17.B X17.S X17.B
2
12
3
7
13
10
11
14
15
17
19
18
X17
11
10
1
9
7
forbidden.
D D

3
2
12
5
X23.B
+M
M69.X
2
3
4
5
1
1 2 3 4 5
E E
12
13
10
11
A151.D5.1 A151.D5.1 A151.D5.1 A151.D5.1 A151.D5.1
RF REF
RF
RF MESS
STG
STG+
1
+M
D5.1 12 D5.1 13 D5.1 10 D5.1 11 D5.1 1
ADR GND ADR IN: Drehzahl 1 ADR GND ADR IN: Drehzahl 2 ADR GND
MNr. EA MNr. EA MNr. EA MNr. EA MNr. EA
MName: EMR2 MName: EMR2 MName: EMR2 MName: EMR2 MName: EMR2
A151 A151 A151 A151 M A151
/7.D2 /7.D2 /7.C2 /7.D2 /7.C2
speed, rpm NW, GND speed, rpm NW, SIG speed, rpm SAE, GND speed, rpm SAE, SIG M69
speed control
actuator, servo component
speed, rpm NW, EMR2 speed, rpm SAE, EMR2 (KHD Y3)
F actuator, servo component EMR2 F
motor control diesel engine EMR2 Seite: 8.40 25 / 65

1 2 3 4 5 6 7 8
F
C
E
B
D
A
1
1
B289
BK
1
B289.X
MP86.X1 BK
M
Q
/18.A7
1
+DMP86.X1
RD
MNr.
water sensor fuel filter
X953.B
+F
+F
X953.S
+28V +FXS4:1 5907 +
/32.D5
19 19 2 YE
3
+F
+F
+F
A150.X2
+F ADR DIGIN1
5906 5906
Sig
X2 2
/6.D2
MName: Display
2 20 20 3
A150
EA
water sensor fuel filter
2
2
B7
MNr.
P
X980.B
X980.B
+F
+F
+F
+F
+F
X980.S
X980.S
B7.X
B7.X
A150.X2
F314.A
+F ADR DIGIN7
5905 5905 6068 6068
1
/13.C3
X2 8
2
/6.E2
MName: Display
8 2 2 2 1 3 3 +FX1160.B:3
A150
EA
pressure switch air filter
3
3
Hydraulikbagger
LIEBHERR
gmbh
4
4
5
5
water sensor fuel filter,
pressure switch air filter
6
6
Seite:
7
7
Ausgabe: 07 / 2008
8.40 26 / 65
8
8
Ort
Anlage
+M
=O
F
C
E
B
D
A
F
C
E
B
D
A
1
1
X953.B
X953.S
+28V XS4:1 6100
/32.D6
B1
+D
16 16
1
B1.X
+D
6100 GN
+
C
2
AGND.4 7800 1 BK
MNr. 1
/36.C5
2
X953.B:8
ADR AIN.6
3
X952.B
X952.S
A149.X1
7022 7022 VT
100%=1V
0%=4V
/4.D2
U
X1 26
26 15 15 6109 3 YE
A149
S1 S2
tank sensor
level tank sensor
EA 131
MNr.
2
2
X952.B
X952.S
A150.X2
ADR DIGIN6
6109
X2 7
/6.D2
MName: Display
7 14 14
A150
EA
tank sensor switching point
MP60.X3 BK
/17.D5
MP60.X3
A160
/3.D5
K481
A160
K481.X
31
K481.X
31 1981 F304.A
/13.E2
30
3
3
30 X1161.B:3
A160.X1
6388 0.50 mm²
&#6548;
SWITCH OUT 1 KL.30
X1 1
87
1 87 F316.A
ta
BK 0.50 mm² 6068
SWITCH OUT 2 KL.31 /13.C4
2
20 21
15
2 15 X1160.B:10
relay power supply
MP60.X3
87a
/17.D5
ta=
MP60.X3
15s
Hydraulikbagger
LIEBHERR
CAN1_HIGH
3
/21.F2
N.C. CAN1_LOW
4
/21.F2
22
CAN2_HIGH
5
N.C. CAN2_LOW
6
23
gmbh
N.C. N.C.
7
24
KLINIE
8
4
4
ANALOG GND AINPUT 1
9
25
AINPUT 2
AINPUT 3
10 11
420mA INPUT
CAN Master
420mA GND
12 13
8V DC EXT PULLUP
05V DC INPUT
A160.X1
6964 0.50 mm² X960.S:13 F307.A

KL. 58d /43.A3
16 6108 0.50 mm² S363.X1:2 F316.A
KL.15 /28.B7
14 15 16 17
17
5
5
FREQUENCY GND FREQUENCY IN 2
26
FREQUENCY IN 1
18 19
X2 1 2 3 4
display functions
2
3
4
A160.X21
BK
RDBK
X7
X6
6
6
T5
14V/2A
fuel indicator
X3
X2
/3.E5
/3
P7
P6
P7.X1
P6.X1
P6.X1
YE YE
1
1
4
4
1 BK 4 1 BK
Q
C
5
2
5
2
2 RDBK 5 2 RDBK
6
3
6
3
3 6 3
Seite:
2
3
4
A160.X2
P7.X
P6.X
P6.X
7833 0.75 mm² 7830 0.75 mm²

7
7
1 7834 0.75 mm² 4 1 7831 0.75 mm²

display temperature cooling water
2 7835 0.75 mm² 5 2 7832 0.75 mm²

3 6 3
clock, timer
P50
Ausgabe: 07 / 2008
P50.X2
P50.X1
MP60.X3 BK 6964 X952.S:20 F307.A

/17.D5 /43.A5
B
B+
B B+
MP60.X3
8.40 27 / 65
X952.B
X952.B
X952.S
X952.S
Ubat +DS9.X4/2 BK BK 2 1 5006 RD +DF359.XA.1

/10.B1 /10.C3
+
16 16 17 17 5006 RD F359.A1
clock, timer
6964
P50.X3
P50.X3
8
8
Ort
Anlage
S44.X:58
F307.A
+F
=O
/44.C8

F
C
E
B
D
A
1 2 3 4 5 6 7 8
/39.A3
/32.D7
F316.A
S18.X1:5
A A
+28V
travel speed
/4.E5
ADR DO.8
X960.S:1
MNr. 1 EA 149
MNr. 1 EA 139
6108
6100
A149
9625938_103285847_4_en
X2 29
X960.S
6
A149.X2
29
X960.B
6
6100 0.75 mm²
B B
6106
6108 A160.X1:17 F316.A
/27.A5
PROJEKT:
B326.X
3
BK S19.X2:1 MP60.X2
3 S363.X1 S363.X2 /37.B2
1
OG 2 10
BK
+24V
GY BU RD
012
8 6 2
MP60.X2
S363
0,1
B326
RELEASE
4 5 7 9 S21.X2:1
OUT 2
OUT 1
GND
/33.A5
C S363.X1 S363.X2 C
2
4
5
YE BN GN VT
4 1 5 7 6110
B326.X
4
18
X953.S
X953.B
18
6105 0.75 mm²
6103 0.75 mm²
6104 0.75 mm²
6106
6110
6111
forbidden.
D D
+D
Y353.X
1
1
+D
X960.B X960.B X960.B
Y353
X960.S X960.S X960.S

8
2
Y353.X
2
+D
6105
6103
6104
BK
E E
34
27
14
15
A149.X1 A149.X1 A149.X1 A150.X2 A150.X2
8
X1 8 X1 34 X1 27 X2 14 X2 15
ADR AGND.3 ADR AIN.4 ADR AIN.7 ADR DIGIN13 ADR DIGIN14
MNr. 1 EA MNr. 1 EA 129 MNr. 1 EA 132 MNr. EA MNr. EA
MP87.X1
MName: UEC 1 (Master) MName: UEC 1 (Master) MName: UEC 1 (Master) MName: Display MName: Display
A149 A149 A149 A150 A150
/4.C2 /4.E2 /4.D2 +DMP87.X1 /6.E2 /6.E2
/18.A6
AGND pedal travelling pedal sensor nominal value, specified value, reference value 2 Vnominal value, specified value, reference value store (in memory)

travelling pedal sensor nominal value, specified value, reference value 1 Vnominal value, specified value, reference value store (in memory) &#6549;
speed control by steering valve
F F
speed control by steering valve Seite: 8.40 28 / 65

1 2 3 4 5 6 7 8
F
C
E
B
D
A
1
1
/13.E4
/13.C5
M65
F318.A
F319.A
X1161.B:8
X1160.B:11
+3
+2
6773 1.50 mm²
6774 1.50 mm²
Motor
Min +1
X90
Max +4
RD
blower
+
1
2
2
1
2 X8421.B X8421.B
M
3
1
2
3 X8421.S X8421.S
2
2

4
4
5
5
10
X859.B
10
X859.S
K403
K405
.F8
.F8
X859.B
X859.S
87
30
30
87
87 30 30 87 9 9
M71
M
S284
blower
K402.X:30 X859:10
3
3
0 1 2 3 4
S284.X
X860
/30.C1
6 1
+Ub
S284.X
X859.B
X859.S
1 L
2
B
Masse 2 2 2 M1 B
actuator water circulation
Hydraulikbagger
LIEBHERR
3
+Ub 3 3 3 M2
M1 M2 H
4
Ventil auf 4 4 4 H
5
0 6,9V 5
gmbh
4
4
M72
M
E25
X859.B
X859.S
X863
13
16 16 13
S93
X861
X863
Wasserventil
6 1
9
+Ub
actuator air flap
1 9
2
Masse 2
3
+Ub
5
5
3
4
Klappe auf 4
X863
0 6,9V
10
5 12 12 10
S92
S398
Luftverteilung
heating
01
X863
4
15 15 4
X863
S398.X1
S398.X1
2
6
5
13 13 2 6 1 5
M73
2 1
9
12
10
12
M
8
14 14 8
S398.X2
S398.X2
6
6
X863
1
7
1 7
X862
6
5
3
li Ende 6 5 3
1
15
4
5
+Ub 1 X8421.S
2
11
Masse
4
5
2 11
15
X8421.B
3
actuator blower turn, pivot, swing
4
Umsch. li / re 4
5
4933
4934
sw80
analog MP60.X2
/17.B5
Seite:
MP60.X2
2
1
X8422.B
1
2
X8422.S
7
7
+DX987.B:2 4933
/47.D8 Wasserkreislauf/Luftklappe
+DX987.B:1 4934
/47.D8 Gebläse
Ausgabe: 07 / 2008
X863:3
.C2
.F8
K403
8.40 29 / 65
87
X859.B
X859.S
.D8
85
K403
85 86+ 1 1
86+
/30.A1
30
8
8
Ort
.B2
.F8
K405
Anlage
87
X859.B
X859.S
.D8
85
K405
85 86+ 21 21
86+
30
+F
=O

F
C
E
B
D
A
1 2 3 4 5 6 7 8
/13.C7
/15.E4
X863:3 X863:3
/29.B7
S318.X1 S318.X2
5
1
A 5 9 A
F338.A
F317.A
+KF317.A
X1160.B:14
01
S318
6985
1811
1 10
1
S318.X1 S318.X2
2
X971.S S8.X1 S8.X2
5
1
1
5 9
1
X971.B
9625938_103285847_4_en
X859.B X859.B
6
X859.S X859.S S8 01
6
B 1a B
87
01 1 10
87
S389
1
S8.X1
2
S8.X2
K402
PROJEKT:
.F4 S388
30
1b 1
30 6079
6079
6079
X859:10
/29.C3
+K
10
X967.S
X967.B
10
R781
6079
C B294 P B295 C
15
X954.S
X864.S
X864.B
X8421.S
X8421.B
5 BAR
X859.S
X859.B X954.B
15
1 1
6079
2 2 7 7 12 12 1
5034 1.50 mm²
3 3 +D
4 4
M70 M R782 X993.B
1
87
1
2 X993.S
/13.E5
/10.B6
87 +D
X953.S
6
6079
K404
forbidden.
.F5 X953.B +D
6
D D
D+
E9.X1 E91.X1
30
1
F339.A
X1161.B:12
5034
1 1
X8421.S:3
30
+K
70W 70W
M741 +M +D
Y20.X X971.B
2
1
E9 E91
+K
+K
1 X971.S
2
M
17
18
X859.S X859.S +M X859.B 11

M M
RD 2.50 mm²
Y20
X859.B X859.B X859.S

17
18
11
+K
M742 2 2 2
1
Y20.X E9.X2 E91.X2
2
2
14
X8421.S X8421.S +M +D
86+
86+
+K
+K
BK
M
BK 1.50 mm²
X8421.B X8421.B
6
14
86+ 86+
+K +D
BK
BK
K402 K404 X993.S
2
E M743 E
MP86.X1 BK 1.50 mm²
.F4 .F5 X993.B
2
85 85
BK
+D
+K
+K
M
BK
85
85
MP/KA_O.X1
MP/KA_P.X2
MP60.X2
MP60.X3
MP61.X4
MP60.X2 +DMP86.X1 MP60.X3 +KMP/KA_O.X1 MP61.X4 +KMP/KA_P.X2
/17.D5
/17.C7
/17.A2
/17.B5
/18.A7
/17.B3
K402 K404
blower .E4 .E5
air condition operator's seat adjustment, setting seat heating (warning) beacon
F condenser 87 30 87 30 F
coupling compress. .B2 .D3
Air conditioning system, operator's seatadjustment, setting, seat heating, Seite: 8.40 30 / 65
Hydraulikbagger gmbh
(warning) beacon Ausgabe: 07 / 2008
1 2 3 4 5 6 7 8
F
C
E
B
D
A
/13.F7
1
1
cab
F322.A
+FX1163.B:2
1.50 mm²
X65.B
X65.B
X967.B
X65.S
X65.S
+F
X967.S
MP/KA_U.X1 BK 1.50 mm² BK 1.50 mm² RD 6119 1.00 mm²

/17.B2
1 1 RD 6119 2 2 6119 1.50 mm² 3 3
MP/KA_U.X1
cab
bracket, left
console, right
0V
24V
2
2
X973
X967.B
+F
+F
X967.S
X973.X1
6130 T1
1
10A
1 12 12
X973.X2
12V
+F
0V
12V
2
2
MP60.X3
/17.D5
BK 2.50 mm²
+FMP60.X3
BK
6130
6130
A3
nc
A 1
3
3
A3.XA
/39.E3
nc
A3.XB
B50R 2
nc
3
X66.B
X66.S
RR RF
6133 3 6130
+12V perm
4
6134 4 4 1 1
aut. antenn.
5
5 MP60.X2
LF
MP60.X2
Illumination /40.D7
Speaker out
6
6
+FS18.X2:1
6130
Hydraulikbagger
LIEBHERR
+12V/Kl.15
7
+FS360.X2:2
X66.B
X66.S
+ + + +

BK
LR
B50L GND
B 1 2 3 4 5 6 7 8
8
radio, loudspeaker
6132 8 2 2
6131
radio
gmbh
BK
BK
LR
C1 1
+F
S422
cab
RR
2
4996
4996
01
4
4
CDCIN GND
3
Line out
CDCOUT
4
LF
+12V perm.
5
7
RF
+F
S422.X1
2
1
2
2
1
1
+12V +12V Amp
3
6
5
5
4
6
X967.B
+F
+F
X967.S
5
S422.X1
4996
4
3
4
3
GND
1
plug grouping
8
7
13 13 1
6
5
6
5
10
11
9 12
GND
BK
8
7
8
7
Line InL nc
C2 7
8
15 18
+F
14 17 20
13 16 19
S422.X1
mute mode
Line InR nc
8
6
10
C3 13 14 15 16 17 18 19 20
X967.B
+F
+F
X967.S
6
S422.X1
6841
nc
2
B
C
A
14 14 2
RC+12V
F322.A
4997
1 2 6119
/13.F7
9
Remote control
+F
+F
10
+FX1163.B:2
reserve
RCGND
9 10 11 12
5
5
A3.X2
VT Telephone Mute
W1
S422.X2
S422.X2
1 1
E
voltage transformer
radio, loudspeaker, cigarette lighter,
6
6
Seite:
E8
X967.B
+F
X967.S
E8.X
6118 1.50 mm² RD RD F305.A

/13.E2
1
7
7
1 2 2 6118 1.50 mm² +FX1161.B:5

2
2
6090
cab
cigarette lighter
Ausgabe: 07 / 2008
BK 1.50 mm²
MP/KA_P.X2
/17.B3
8.40 31 / 65
MP/KA_P.X2
E7 01
E7.X2
E7.X1
MP/KA_O.X1
8
8
BK
Ort
1
/17.A2
2
cab
2 1
Anlage
MP/KA_O.X1
+K
=O
dashboard illumination

F
C
E
B
D
A
1 2 3 4 5 6 7 8
/14.E5
/14.E2
F329.A
F326.A
X1162.B:7
X1162.B:11
A A
6715
servo ON / OFF +28V power supply oscillating axle uppercarriage
6766
/4.D5 XS5:1 /4.C2 /4.E5
ADR DO.12 XS5:2 ADR OUT+28 ADR DO.5
MNr. 1 EA 159 MNr. 1 EA 107 Fe MNr. 1 EA 146
B266
BK MNr. 1 EA 118 MNr. 1 EA MNr. 1 EA 125
9625938_103285847_4_en
MName: UEC 1 (Master) MName: UEC 1 (Master) MName: UEC 1 (Master)
6715
6715
6715
S35.X1 S35.X2 A149 A149 A149
5
5 9 X2 25 X1 11 + S(+) X2 32
B B
13
21
31
S75.X (BN) (BU) (BK)
A149.X2 A149.X1 A149.X2
11
32
25
01 0 I II 13 21 32 A B C
S35 MP60.X2
S75 B266.X
C
A
B
uppercarriagelocked, interlockedautomatic open close auto 14 22 44
PROJEKT:
7 1 10 S16.X2:1 S75.X
14
22
/33.B8
1
S35.X1 S35.X2
2
6100
6100
6102
6966
7001
BK
7000
7001
15
X1162.B X952.S XS4:2 X960.B
1
C C
1
X1162.S X952.B XS4:1 X960.S
15
6100
/9.C1
6100
6100
6100
6100
6100
6100
6100
6102
11
86+ X952.S
K370
X952.B
11
K370 D1
.F3
7000
6950
6769
6966
7001
85
X953.S:19
X953.S:16
X1047.B:1
X1049.B:1
X980.S:6
X960.S:6
B335.X:1
forbidden.
GND
D /44.D8 D
+28V
+28V
+28V
+28V
+28V
+28V
+28V
A148 +D +D
Y3.X Y371.X
1
1
fuse board
/35.D6
/35.D3
/24
/28.A2
/26.D1
/35.D1
/27.D1
1 1
+D +D
Y3 Y371
2 2
Y3.X Y371.X
2
2
+D +D
BK
BK
BK
E E
32
31
A149.X2 A149.X1 A149.X1 A149.X2

3
6
X2 3 X1 31 X1 32 X2 6
ADR DIN.5 ADR AIN.1 ADR AIN.2 ADR DIN.8
MNr. 1 EA 112 MNr. 1 EA 126 MNr. 1 EA 127 MNr. 1 EA 115
MP87.X2
MP87.X2
MP61.X1
MName: UEC 1 (Master) MName: UEC 1 (Master) MName: UEC 1 (Master) MName: UEC 1 (Master)
A149 A149 A149 A149
/4.B5 MP87.X2 /4.E2 /4.E2 /4.C5 MP87.X2
MP61.X1
/18.B6
/18.B6
servo ON oscillating axle automatic oscillating axle uppercarriage working brake
/17.A7
K370
.D3
servo ON / OFF /14.B6
87 30 oscillating axle uppercarriagelocked, interlockedautomatic oscillating axle uppercarriage
F F
servo, oscillating axle, Seite: 8.40 32 / 65
working brake Ausgabe: 07 / 2008
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
/14.E2
/14.E2
/14.E2
A A
F325.A
F326.A
F325.A
X1162.B:5
X1162.B:6
X1162.B:4
BK MP60.X2
/28.C6
6984
6715
6984
forwards backwards, reverse
/4.E5 /4.D5 MP60.X2
/32.B2
ADR DO.9 ADR DO.10 BK S35.X2:1
MNr. 1 EA 150 MNr. 1 EA 151 S21.X1 S21.X2 S16.X1 S16.X2
5
1
BK
MNr. 1 EA 140 MNr. 1 EA 141 5 9 5 9
9625938_103285847_4_en
MName: UEC 1 (Master) MName: UEC 1 (Master)

A149 A149 01 01
MP60.X2
X2 28 X2 27 X1048.B S21 S16
1
B 1
B
A149.X2 A149.X2
28
27
P
1 10 7 1 10 MP60.X2
J1 1
/17.B5
1
1
S21.X1 S21.X2 S16.X1 S16.X2
2
7
A146 1CO 1CO
PROJEKT:
01 01
S263/V S263/R 7998
7997
2NC 4NO 2NC 4NO
BK
J1 5 3 J1 2 4
5 3 2 4 S42.X1 S42.X2
1
X1048.B X1048.B 5 9
4
01
S42
C C
7 1 10
1
S42.X1 S42.X2
S42.X1
2
7
6967
6979
6982
6980
7012
6981
7997
7999
6967
X952.S X952.S X230.S X230.S X952.S X952.S X952.S
7
6
1
1
X952.B X952.B X230.B X230.B X952.B X952.B X952.B

2
2
7
6
forbidden.
6979
6982
6982
6980
6980
7012
7999
6967
6967
D D
6981

+D +D +D +D +D
X1180.B:4
X1180.B:1
Y62.X Y63.X Y24.X Y60.X Y55.X

1
1
Fahren rückwärts
Fahren vorwärts
1 1 1 1 1
+D +D +D +D +D
Y62 Y63 Y24 Y60 Y55

2 2 2 2 2
Y62.X Y63.X Y24.X Y60.X Y55.X
2
2
/46.D4
/46.D5
+D +D +D +D +D
BK
BK
BK
BK
BK
E E
10
11
A149.X2 A149.X2
A149.X2 A149.X2
1
X2 10 X2 11
X2 5 X2 1
ADR DIN.12 ADR DIN.13
ADR DIN.7 ADR DIN.3
MNr. 1 EA 39 MNr. 1 EA 40
MNr. 1 EA 114 MNr. 1 EA 110
MP87.X2
MP87.X2
MP87.X2
MP87.X1
MP87.X1
A149 A149
A149 A149
/4.C5 /4.C5
MP87.X2 MP87.X2 MP87.X2 +DMP87.X1 +DMP87.X1 /4.B5 /4.B5
forwards backwards, reverse
/18.B6
/18.B6
/18.B6
/18.A6
/18.A6
feedback, acknowledgement, check back signal 1. speed, gear
feedback, acknowledgement, check back signal parking brake
travel forwards / backwards, reverse travel direction preselection creeper gear 2. speed, gear 1. speed, gear

F F
travel direction preselection, parking brake, Seite: 8.40 33 / 65
creeper gear, 1. speed, gear Ausgabe: 07 / 2008
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
/13.C4
&#6505; steering direction left
indicator light dog walk changeover valve 4wheel steering earth sensors undercarriage sensor rear axle &#6550;
indicator light 4wheel steering changeover valve dog walk +28V supply sensors &#6505; steering direction right
1 =O+FX1160.B:9
A sensor front axle &#6550; A
F316.A
=O /5.E5 =O /5.E5 =O /5.D5 =O /5.D5 =O /5.C2 /5.C2 /5.C5 /5.C5 =O /5.D5 =O /5.D5
+F ADR DO.3 +F ADR DO.2 +F ADR DO.16 +F ADR DO.17 +F ADR OUT+28 +F ADR DO.13 +F ADR DO.14
A155 A155 A155
=O
+F MNr. 5 EA 144 MNr. 5 EA 143 MNr. 5 EA 163 MNr. 5 EA 164 MNr. 5 EA 107 MName: UEC 2 MName: UEC 2 MName: UEC 2 MNr. 5 EA 160 MNr. 5 EA 161
X1117.B MNr. 5 EA 123 MNr. 5 EA 122 MNr. 5 EA MNr. 5 EA MNr. 5 EA MNr. 5 EA MNr. 5 EA 38 MNr. 5 EA 39 MNr. 5 EA 119 MNr. 5 EA 120
MName: UEC 2 MName: UEC 2 MName: UEC 2 MName: UEC 2 MName: UEC 2 ADR AGND.2 ADR DIN.11 ADR DIN.12 MName: UEC 2 MName: UEC 2
1
X1117.S +F +F +F
+F A155 A155 A155 A155 A155 =O X1 7 =O X2 9 =O X2 10 A155 A155
=O
X2 34 X2 35 X2 21 X2 20 X1 11 A155.X1 A155.X2 A155.X2 X2 24 X2 23
10
6068
6068 +F +F +F
A155.X2 A155.X2 A155.X2 A155.X2 A155.X1 A155.X2 A155.X2
11
34
35
21
20
24
23
9625938_103285847_4_en
=O =O =O
+F +F +F +F +F +F +F
=O =O =O =O =O =O =O
S309.X
3
1
=O
6844
6845
2007
2008
6397
2012
7980
7979
2011
BK
+F 0 I II 13 21 32
B S309 B
=O
HUND 2RAD 4RAD 14 22 44 +F +F +F
X956.S X956.S X956.S X956.S X956.S X956.S X956.S X956.S
8
1
S309.X
2
1
X956.B X956.B X956.B X956.B X956.B X956.B X956.B X956.B
8
PROJEKT:
6048
6847
+F +F +F
=O
=O =O =O =O
+F +F +F +F
2007
2008
6397
2012
7980
7979
2011
BK
X1117.S X11172.B X11172.B
5
4
X1117.B X11172.S X11172.S
5
4
+F +F +F +F =O
=O =O =O =O +D
X1090.S X1090.S X1090.S X1090.S X1090.S X1090.S
5
1
6848
6849
1
X1090.B X1090.B X1090.B X1090.B X1090.B X1090.B
5
6844
6845
C +D C
=O =O =O =O
+F +F +F +F
X11172.S X1117.B X1117.B

2
3
1
7 8 12 9 10 11
1
X11172.B X1117.S X1117.S

2
+F +F +F +F
=O =O =O =O
7 8 12 9 10 11
6848
6849
6844
6845
N1
slipring contact
=O =O 7 8 12 9 10 11
forbidden.
+F +F
D H191.X H192.X D
2 2
X272
terminal box
H191 H192 undercarriage
2007
2008
+F +F
=O 1 =O 1
=O =O
H191.X H192.X +F +F
+F +F Y2291.X Y2292.X Y2941.X Y2942.X

1
1
=O =O
1 1 1 1
BK
BK
=O Y2291 Y2292 Y2941 Y2942
+F
X1117.S 2 2 2 2
6
=O =O B248V.X B248H.X
4
1
1
+F +F X1117.B Y2291.X Y2292.X Y2941.X Y2942.X
2
2
6
A155.X2 A155.X2 +F +F +F
7
E 1 3 4 1 3 4 E
=O =O =O
=O X2 7 =O X2 8 (BN) (BU) (BK) (BN) (BU) (BK)
+F ADR DIN.9 +F ADR DIN.10
BK
BK
BK
BK
BK
+ S + S
MNr. 5 EA 36 MNr. 5 EA 37
MP60.X3
MP86.X1
MP86.X1
MName: UEC 2 MName: UEC 2
A155 A155 16 16
/5.C5 /5.C5 =O+FMP60.X3
B248V B B248H B =O+DMP86.X1 =O+DMP86.X1
/17.D5
/18.A7
/18.A7
selector (switch) dog walk
X272
selector (switch) 4wheel steering terminal box
undercarriage
dog walk 4wheel steering &#6550; &#6550; steering direction steering direction
front axle rear axle right left
F F
A 309 Litronic TCD ab 40998 Anlage =U
4wheel steering Seite: 8.40 34 / 65
A 311 Litronic TCD ab 41128 LIEBHERR Ort +U

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
PST slewing gear fine adjustment slewing gear fancontrol system / unit, control, controller

/4.E5 /4.E5
A145 A146 0 40 bar ADR DO.1 ADR DO.3
B19/L B19/R MNr. 1 EA 142 MNr. 1 EA 144
B335 p MNr. 1 EA 121 MNr. 1 EA 123
9625938_103285847_4_en
24mA 24mA A MName: UEC 1 (Master) MName: UEC 1 (Master)

+ S + S 420mA A149 A149
+ Sig. X2 36 X2 34
B J4 1 2 3 J4 1 2 3 B
1 2 A149.X2 A149.X2
36
34
1 2 3 1 2 3
1
B335.X
2
1
1
X1047.B X1049.B
2
2
3
3
PROJEKT:
C C
6100
6710
6100
6702
6100
2922
7802
6701
6711
2921
XS4:1
XS4:1
XS4:1
+28V
+28V
+28V
15
X953.S X953.S
5
/32.D6
/32.D6
/32.D5
forbidden.
X953.B X953.B
5
15
D D

7802
2922
+D +D
Y451.X Y352.X
1
1 1
+D +D
Y451 Y352
2 2
Y451.X Y352.X
2
+D +D
BK
BK
E E
29
28
10
30
A149.X1 A149.X1 A149.X1 A149.X1 A149.X1
6
X1 29 X1 6 X1 28 X1 10 X1 30
ADR AIN.9 ADR AGND.1 ADR AIN.8 ADR AGND.5 ADR AIN.10
MNr. 1 EA 134 MNr. 1 EA MNr. 1 EA 133 MNr. 1 EA MNr. 1 EA 135
MP86.X2
MP87.X1
MName: UEC 1 (Master) MName: UEC 1 (Master) MName: UEC 1 (Master) MName: UEC 1 (Master) MName: UEC 1 (Master)
A149 A149 A149 A149 A149
/4.E2 /4.C2 /4.E2 /4.C2 /4.E2 +DMP87.X1 +DMP86.X2
/18.A6
/18.B7
control device / unit, controller L
AGND control device / unit, controller Lcontrol device / unit, controller R
AGND control device / unit, controller R PST slewing gear
sensortransducer control device / unit, controller fancontrol system / unit, control, controlle
F F
sensors, pedal, fancontrol system / unit, control, controller, Seite: 8.40 35 / 65
fine adjustment slewing gear Ausgabe: 07 / 2008
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
/14.E6
/43.C8
F330.A
A A
F313.A
X960.B:3
X1162.B:14
flow reduction
6742
performance regulator pilot pressure reduction
/4.E5 /4.E5
6974
ADR DO.6 ADR DO.4
X10461.B MNr. 1 EA 147 MNr. 1 EA 145
1
MNr. 1 EA 137 MNr. 1 EA 124
1
X10461.S
9625938_103285847_4_en

A149 A149
X2 31 X2 33
1
B B
+D A149.X2 A149.X2
31
33
B20.X1 B285.X
1
1 1
+D
X1046.B
1
B285
PROJEKT:
B20 P
1
100 BAR 2 4 2 J1 1
1
B20.X4 B285.X
2
+D A145 1CO 1CO
01 01
S382
2NC 4NO 2NC 4NO
SF J1 5 3 J1 2 4
6973
7800
7801
C 5 3 2 4 C
X1046.B X1046.B
4
7007
7009
7800 AGND.4 7009
/27.C1
+DB1.X:2
16
X960.B X953.B X953.B X953.S X960.S X953.S
2
4
X960.S X960.S X953.S X953.S X953.B X960.B X953.B
2
4
17
16
7007
7009
7009
4745
6973
7800
7801
X10461.S X10461.S
4
forbidden.
+D +D
D Y50.X Y447.X Y4471.X D
1
X10461.B
3
1 1 1
+D +D
Y50 Y447 Y4471
2 2 2
Y50.X Y447.X Y4471.X
2
6740
+D +D
BK
BK
BK
E E
17
17
15
A150.X2 A150.X2 A149.X1 A149.X1 A149.X2
9
1
X2 1 X2 17 X1 17 X1 9 X2 15
ADR DIGIN0 ADR DIGIN16 ADR RMes.2 ADR AGND.4 ADR DIN.17
MNr. EA MNr. EA MNr. 1 EA 93 MNr. 1 EA MNr. 1 EA 44
MP87.X1
MP61.X1
MP87.X1
MName: Display MName: Display MName: UEC 1 (Master) MName: UEC 1 (Master) MName: UEC 1 (Master)
A150 A150 A149 A149 A149
/6.D2 /6.E2 /4.D2 /4.C2 /4.C5 +DMP87.X1 MP61.X1 +DMP87.X1
/18.A6
/17.A7
/18.A6
preparation Particle filter accumulator pressure hydraulic oil sensor SF ON / OFF
AGND hydraulic oil sensor
hydraulic oil temperature performance regulator flow reduction

F pilot pressure reduction F
accumulator pressure, hydraulic oilsensor, Seite: 8.40 36 / 65
SF function, performance regulator, pilot pressure reduction Ausgabe: 07 / 2008
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
F330.A 6739 6739

/14.E6
A X1162.B:15 BK BK S47.X2:1 MP60.X2 A
/40.D6
S19.X2
pressure reduction AHS
/14.E6
gripper swing L gripper swing R changeover &#6502; AHS
BK
S19.X1 S241.X1 S241.X2
5
1
1
5 9 /4.D5 /4.D5 5 9 /4.D5 /4.E5
ADR DO.13 ADR DO.14 ADR DO.15 ADR DO.2
MP60.X2
MNr. 1 EA 160 MNr. 1 EA 161 MNr. 1 EA 162 MNr. 1 EA 143
F330.A
S19 01 01
X1162.B:15
MNr. 1 EA 119 MNr. 1 EA 120
S241 MNr. 1 EA MNr. 1 EA 122
9625938_103285847_4_en
S363.X2:1 MName: UEC 1 (Master) MName: UEC 1 (Master) MName: UEC 1 (Master) MName: UEC 1 (Master)
/28.B7
1 10 A149 A149 1 10 A149 A149
X2 24 X2 23 X2 22 X2 35
1
1
S19.X1 S241.X1 S241.X2
2
2
S19.X2
6739
B B
A149.X2 A149.X2 A149.X2 A149.X2
22
24
23
35
7048
6703
6703
6703 X1048.B
8
PROJEKT:
12
X10461.B X10461.B
9
8
X10461.S X10461.S
12
9
J2 2
A146 1CO
01
S6M
12
2NC 4NO
9
J2 1
7004
7006
7048
6955
7049
C 7 C
X1048.B
7
12
X1046.B X1046.B
9
9 12
J3 1 J3 4
7510
A145 1CO 1CO
01 01
S5L S5R
2NC 4NO 2NC 4NO
10
J3 2 J3 3 X952.S X952.S
9
13
X952.S X952.S X952.S
3
4
X952.B X952.B
10
10 11
forbidden.
X952.B X952.B X952.B

3
13
6955
7049
D X1046.B X1046.B D
10
11

7004
7006
7510
+D +D +D +D
Y22.X Y23.X Y262.X Y268.X Y414.X
1
1
7510
1 1 1 1 1
10
11
+D +D +D +D
Y22 Y23 Y262 Y268 Y414

2 2 2 2 2
10
11
X10461.S X10461.S
Y22.X Y23.X Y262.X Y268.X Y414.X
2
2
+D +D +D +D
X10461.B X10461.B
10
11
7003
7005
BK
BK
BK
BK
BK
E E
39
A149.X2 A149.X2 A150.X2 A149.X1
7
9
X2 7 X2 8 X2 9 X1 39
ADR DIN.9 ADR DIN.10 ADR DIGIN8 ADR DIN.1
MNr. 1 EA 36 MNr. 1 EA 37 MNr. EA MNr. 1 EA 108
MP87.X2
MP87.X1
MP87.X1
MP87.X1
MP87.X1
MName: UEC 1 (Master) MName: UEC 1 (Master) MName: Display MName: UEC 1 (Master)
A149 A149 A150 A149
/4.C5 /4.C5 +DMP87.X1 +DMP87.X1 +DMP87.X1 /6.E2 /4.E2 MP87.X2 +DMP87.X1
/18.A6
/18.A6
/18.A6
/18.B6
/18.A6
gripper swing L gripper swing R &#6552; &#6549; attachment activate, actuate, power, start
gripper swing changeover bucket/&#6552;
F F
gripper swing, &#6552;, Seite: 8.40 37 / 65
pressure reduction, changeover AHS Ausgabe: 07 / 2008
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
/14.E8
10
12
11
2
9
1
6839 =U
+U
F337.A
X1162.B:19
1 2 3 4 5 6 7 8 9 10 11 12
A N1 A
.D2
.D5
.D6
.D3
.D4
.D7
X1104.B
2
X1104.S
2
X304.B X304.B
3
1
10
12
11
2
9
1
1
1
X304.S X304.S X304.S X304.S
3
BK
2000
BK
2000 br br
S335.X1 S335.X2
1
S439R S439L
5 9
9625938_103285847_4_en
sw ws
01
MP60.X2
S335
6839
B B
2006 7 1 10 MP60.X2
X1104.S X1104.S
/17.B5
3
1
1
S335.X1 S335.X2
2
7
X304.S
2
1
X1104.B X1104.B
3
PROJEKT:
X304.B 2006
2
2004
2005
BK
BK
2006
12
13
X953.S X953.S
X953.S
9
X953.B X953.B X953.B X953.B
12
10
11
13
X953.B
9
MP86.X1
2006
2002
2003
2004
2005
C +D +D +D +D +D +D +DMP86.X1 C
12
X301.B X301.B X301.B X301.B X301.B X301.B
/18.A7
3
9
1
1
X301.S X301.S X301.S X301.S X301.S X301.S
12
3
9
+D +D +D +D +D +D
3 4 5 1 2 6
=U
+U .A7 3 .A7 4 .A7 5 .A7 1 .A7 2 .A7 6
N1
slipring contact
2
5
1
3 4 5 1 2
forbidden.
=U
D +U D
X272
2006
2004
2005
=U =U =U
+U +U +U
Y56.X Y217.X Y218.X

1
GN/YE
=U 1 =U 1 =U 1
6
+U +U +U
Y56 Y217 Y218
2 2 2
Y56.X Y217.X Y218.X
2
2
E +U +U +U E
=U =U =U
HL HR
BK
BK
BK
16 14 15 14 15 14 18 17
=U
+U
X272
terminal box
undercarriage Outrigger/&#6553; rear left
blade front Outrigger/&#6553; rear right
F F
&#6554; blade, Seite: 8.40 38 / 65
slipring contact Ausgabe: 07 / 2008
1 2 3 4 5 6 7 8
F
C
E
B
D
A
1
1
MNr.
B21
+D
P
X953.B
X953.S
A150.X2
B21.X
6958 6958
ADR DIGIN18
4
/6.F2
MName: Display
X2 19
19 14 14 1
B21.X
A150
1
EA
2
pressure switch UL
MP87.X1 BK
/18.A6
+DMP87.X1
2
2
S18
01
MNr.
7
S18.X1
6108 F316.A
/13.C4
5
S18.X1
A150.X2
6763 5 X1160.B:9
ADR DIGIN17
1
/6.E2
MName: Display
X2 18
18 1
A150
EA
2 1
6108
10
6763
9
overload warning (system)
S18.X2
S18.X2
3
3
S363.X1:2
MP60.X2 BK
/17.B5
MP60.X2
F316.A
Hydraulikbagger
LIEBHERR
MP60.X2 BK
/28.A5
/31.B3
S422.X1:6
gmbh
4
4
5
5
6
6
Seite:
7
7
Ausgabe: 07 / 2008
8.40 39 / 65
8
8
Ort
Anlage
+F
=O

F
C
E
B
D
A
1 2 3 4 5 6 7 8
/16.C4
/14.E2
F328.A
F326.A
X1165.B:5
X1162.B:8
A A
SWA indicator light mute switch for buzzer
+A
/4.D5 /4.D5 Fe
B26
ADR DO.11 3033 3033 3033 ADR DO.17
MNr. 1 EA 158 MNr. 1 EA 164
12
MNr. 1 EA 117 X954.S X954.S MNr. 1
9
EA
MName: UEC 1 (Master) MName: UEC 1 (Master) + S(+)
X954.B X954.B
12
9
A149 A149 (BN) (BU) (BK)
MP87.X2
MP87.X2
9625938_103285847_4_en
X2 26 X2 20 1 3 2
1
A149.X2 A149.X2 B26.X
2
3
26
20
MP87.X2 MP87.X2 +A +A +A
3028
3035
B B
BK
BK
BK
/18.B6
/18.B6
3033
3033
3030
4929
+A +A +A
X2626.S
C
B
PROJEKT:
+D +D +D +D X2626.B
C
A
B
X2621.B X2621.B +A +A +A
4
1
X2626
1
X2621.S X2621.S
sw44
3032
3033
3028
3035
+D +D +D +D
X2621 3030
3033
3033
+A +A +A
BK
BK
X2623.S
7
+A X2623.B
7
X2622.B X2622.B S47.X1 S47.X2 S360.X1 S360.X2 +A +A +A
5
1
1
C C
5 9 5 9 X2623
1
X2622.S X2622.S
4
+A
3028
3035
BK
X2622
S47 01 S360 01
3033
3033
3033
+A +A +A
BK
BK
X2622.S
7
6030
+A +A +A +A 1 10 1 10 X2622.B
7
X2623.B X2623.B +A +A +A
2
4
1
1
S47.X1 S47.X2 S360.X1 S360.X2
2
X2622
1
X2623.S X2623.S
2
4
+A +A +A +A BK S422.X1:5 MP60.X2
3028
3035
BK
X2623 /31.B3
3033
3031
BK
3033
3033
BK
BK
+D +D +D
BK
X2621.S
7
forbidden.
D V175.X D
+A +A +A +A X2621.B
7
2 X2624.B X2625.B +D +D +D
2
2
1
MP60.X2
V175 LINE+
X2621
1
X2624.S X2625.S
2
3028
3035
BK
4 IN+ LOAD
8 +A +A +A +A
4 8 S241.X2:1
7,5A
3033
3033
13
14
BK
BK
V175.X V175.X X954.B
/37.A7
GND
3033
X954.S
13
14
6
V175.X
6
4928
3028
3035
3031
BK
BK
+A +A
Y281.X Y282.X
1
E E
12
35
36
A149.X2 1 1 A149.X1 A149.X1 A149.X2
A148:KL31
9
MP87.X2
X2 12 +A +A X1 35 X1 36 X2 9
ADR DIN.14
Y281 Y282 ADR FRQ.1 ADR FRQ.2 ADR DIN.11
X1162.B:8
MNr. 1 EA 41 2 2 MNr. 1 EA 170 MNr. 1 EA 171 MNr. 1 EA 38
F326.A
X1165.B:14 MP87.X2
/16.C5
/18.B6
MName: UEC 1 (Master) Y281.X Y282.X MName: UEC 1 (Master) MName: UEC 1 (Master) MName: UEC 1 (Master)
2
A149 +A +A A149 A149 A149
/14.E2
/4.C5 /4.E2 /4.E2 /4.C5
feedback, acknowledgement, check back signal Quick change adapter &#6549; Quick change adapter activate, actuate, power, start buzzer mute bolt, pin, stud Quick change adapter extended
Quick change adapter bolt, pin, stud extends / RETRACTED Quick change adapter
F mute switch for buzzer F
Quick change adapter, buzzer mute Seite: 8.40 40 / 65

1 2 3 4 5 6 7 8
F
C
E
B
D
A
1
1
S11
01
M3
7
S11.X
F311.A F311.A
/15.E3
M3.XS
M3.XS
M3.X
M3.X
3
S11.X
M31.X
M31.X
MP/KA_U.X1 BK BK 6081 6081 6074
M
1
/17.B2
2 2 2 1 1 1 1
X1
X2
MP/KA_U.X1
8
2
2
windscreen washer
2
S14
6081
012
6
8
3
3
S14.X1
4
S14.X1
4
6076
2
2
6075
6076
S283
5
7
7 6074
Hydraulikbagger
LIEBHERR
1
3
4
3 6074
1
K414
9
10
K414.X
gmbh
K414.X
53c
53c
31b 6074
31b
15
15
4
4
K414.X
MP/KA_P.X2 BK 53e 53e
/17.B3
31
31 6859
I
MP/KA_P.X2
I
interval relay windscreen wiper
6076
5
5
M4
M4.X
M4.X
MP/KA_O.X1
M
/17.A2
31
53
BK
YE
BK 1.50 mm² 31 53
MP/KA_O.X1 6075
31b
WH
31b
windscreen wiper
6074
RD
53a
53a
windscreen wiperroof
windscreen wiper, windscreen washer,
6
6
S218
012
M68
M681.X
M681.X
M68.XS
M68.XS
M68.X
M68.X
S218.X1
S218.X1
MP/KA_U.X1 BK sw16 6882 6882 6886 F343.A F343.A

M
/17.B2 /15.E4
3
2
X2 2 2 1 1 X1 3 2
X1
X2
Seite:
MP/KA_U.X1
6885
6
6
7
7
6884
5
MP/KA_P.X2 BK
/17.B3
7
7
MP/KA_P.X2
Ausgabe: 07 / 2008
9
10
roof windscreen wiper
M60
8.40 41 / 65
M60.X
M60.X
MP/KA_O.X1 BK BK BU YE
M
/17.A2
31
53
BK 1.50 mm² 31 53
MP/KA_O.X1
8
8
BK/BU RD 6886
Ort
53a
53a
Anlage
WH/BU WH
31b
31b
+K
=O

F
C
E
B
D
A
F
C
E
B
D
A
1
1
cab
E1
+A
W38 W3 W38
BK1 0001
X404.B
X404.B
X954.B
X967.B
+F
+F
+F
X404.S
X404.S
X954.S
X967.S
X4041.B
E1.X
E1.X
X4041.B
MP87.X2 BK 0001
+D
+A
+A
+A
+A
+D
+D
+D
X4041.S
X4041.S
/18.B6
31
56
BK 1.50 mm² 3 3 10 3 3 3 31 56 1 1 1 8 1 1 0001 10 10 0001 4 4
70W
+FMP87.X2
1.50 mm² 1.50 mm² 1.50 mm² 1.50 mm² 1.50 mm² 1.50 mm²
0001 1.50 mm²
equipment
E1.1
+A
work (head)light
W38 W3 W3 W38
S22
BK2 0002
E1.1.X
E1.1.X
X404.B
X404.B
X954.B
X967.B
+F
+F
+F
X404.S
X404.S
X954.S
X967.S
X4041.B
X4041.B
MP87.X2 BK 0002 0002
+D
+A
+A
+A
+A
+D
X4041.S
X4041.S
2
2
/18.B6
31
56
BK 1.50 mm² 4 4 4 4 31 56 2 2 2 5
012
11 4 2 9 2 0002 11 11 0002 5
70W
+FMP87.X2
1.50 mm² 1.50 mm² 1.50 mm² 1.50 mm² 1.50 mm² 1.50 mm²
1.50 mm²
1808
S22.X1
S22.X1
F323.A
/15.E4
6
2
6 2 F323.A
E2
8
8
0001
1810
2.50 mm² 2.50 mm²
X1171.B
X1170.B
E2.X
E2.X
X1171.S
X1170.S
MP/KA_O.X1 BK 6123 6123 2.50 mm² F324.A
1
/17.A2 /15.E4
3
31
56
BK 2.50 mm² 1 1 31 56 1 1 1 3 F324.A
70W
MP/KA_O.X1
S22.X2 S22.X2
9
10
1 2
roof front
MP/KA_P.X2 BK
E2.1
/17
3
3
work (head)light
MP/KA_P.X2
E2.1.X
E2.1.X
X1173.B
X1172.B
X1173.S
X1172.S
MP/KA_O.X1 BK 6123 6123 2.50 mm²
/17.A2
31
56
BK 2.50 mm² 1 1 31 56 1 1
70W
MP/KA_O.X1
1808 2.50 mm²
Hydraulikbagger
LIEBHERR
gmbh
4
4
1810 2.50 mm²
5
5
cab
S221
work (head)light roof
012
work (head)light equipment,
S221.X1
S221.X1
X967.B
+F
X967.S
6890
6
2
11 11 6 2
E150
8
6
6
E150.X
E150.X
X1175.B
X1174.B
X1175.S
X1174.S
MP/KA_O.X1 BK 6888 6888 2.50 mm²

1
/17.A2
3
31
56
BK 2.50 mm² 1 1 31 56 1 1 1 3
70W
MP/KA_O.X1
S221.X2 S221.X2
9
6890
10
1 2
MP/KA_P.X2 BK
work (head)light
E150.1
/17.B3
MP/KA_P.X2
X1177.B
X1176.B
E150.1.X
E150.1.X
X1177.S
X1176.S
MP/KA_O.X1 BK 6888 6888 2.50 mm²

roof rear, back, tail, behind
/17.A2
31
56
BK 2.50 mm² 1 1 31 56 1 1
Seite:
70W
MP/KA_O.X1
7
7
Ausgabe: 07 / 2008
8.40 42 / 65
8
8
Ort
Anlage
+K
=O
F
C
E
B
D
A
F
C
E
B
D
A
cab
1
1
+K
S61
012
X967.B
+F
X967.S
S61.X1
S61.X1
+K
+K
+K
F307.E +KF307.E 6721 1.50 mm² 1809 2.50 mm² RD 1809 RD F336.A
/15.B1 /13.E4
6
2
6 2 1 1 2.50 mm² +FX1161.B:10
+K
F309.E +KF309.E 6722 2.50 mm²
/15.B2
3
3
S61.X2
+K
+K
6721
9
10
S61.X2 1 2
MP/KA_P.X2 BK
/17.B3
2
2
+KMP/KA_P.X2
E3
X960.B
E3.X2
+F
+F
+F
+F
E3.X1
X960.S
6971 1.50 mm² 6971 1.50 mm² +FX967.B:8 F309.A
BK
/15.F2
31
56
1.50 mm²
31 56 14 14
70W
+F
+F
MP61.X1 BK 1.50 mm²
/17.A7
31
57
57L
4W
E16.X2 31
+FMP61.X1
headlight left side
X960.B
+F
+F
X960.S
6964 6964 +FX967.B:6 F307.A

/15.F1
3
3
13 13
E16.X1
E16
parking light, left
6964 +FA160.X1:16 F307.A
/27.A5
Hydraulikbagger
LIEBHERR
X952.B
+F
+F
X952.S
6962 1.50 mm² 6962 1.50 mm² +FX967.B:9 F310.A

/15.F2
E4
18 18
E4.X2
E4.X1
BK
gmbh
31
56
31 56
1.50 mm²
70W
X952.B
+F
+F
X952.S
MP88.X2 BK 1.50 mm² 6963 6963 +FX967.B:7 F308.A

/18.D4 /15.F2
31
57
31 57R 19 19
4W
E15.X2
MP88.X2
E15.X1
4
4
headlight right side
E15
parking light right
E22
E22.X2
E22.X1
MP86.X2 BK +FX953.B:1 6970 L

/18.B7 /44.D5
L
31
31 L
MP86.X2
21W
6970
BK 4 2
MP86.X2 BK 3 1
/18.B7
5
5
MP86.X2
6964
E18
X1186
X1186
X952.B
+F
+F
X952.S
E18.X1
6964 6964 +FX967.B:6 F307.A

/15.F1
1 20 20
58L
rear light left side
5W
E18/E20.X2
MP86.X2 BK 6964 +FP50.X1 F307.A

/18.B7 /27.A7
31
31
E20
MP86.X2
E20.X1
6957
1
54
21W
headlight, rear light, brake light
E24
6
6
E24.X2
E24.X1
MP86.X2 BK +FX953.B:2 6968 R

/18.B7 /44.D6
31
R
5
K315.X
X952.B
+F
+F
+F
X952.S
31 R 6957
MP86.X2
3
21W
K315.X
+F
21 21 5 +FX1160.B:2 F313.A
/13.C2
3 6974
6968
BK 4 2
4
MP86.X2 BK 3 1
+F
/18.B7
MP86.X2
K315
6963
E17
X1198
X1198
E17.X1
6963
1
58R
5W
E17/E19.X2
MP86.X2 BK
Seite:
/18.B7
rear light right side
31
31
E19
MP86.X2
E19.X1
6957
7
7
1
54
21W
MNr. 1
MNr. 1
+F
K315
K315.X
K315.X
+F
+F
+F
A149.X2
MP60.X3
+F ADR BRÜ+/
BK 6956
1
/17.D5
Ausgabe: 07 / 2008
2
/4.D5
X2 17
2 1 17
A149
brake light
+FMP60.X3
EA 155
EA 154
8.40 43 / 65
B60
P
MNr. 1
> 5 BAR
8
8
Ort
X960.B
X960.B
+F
+F
+F
+F
+F
+F
+F
X960.S
B60.X2
X960.S
B60.X1
A149.X2
+F ADR DIN.15
6975 6975 6974 6974 +FX1160.B:2 F313.A

Anlage
1
/13.C2
2
/4.C5
X2 13
13 5 5 1 1 3 3
A149
EA 42
+D
=O
pressure switch brake light
F313.A +FB20.X1
/36.A2
6974
F
C
E
B
D
A
1 2 3 4 5 6 7 8
/13.C7
/13.C2
/12.B3
F338.A
F312.A
+DA127.X/X1
F302.X1
X1160.B:1
X1160.B:13
A A
6994
6993
X960.S
X960.B
6985
X954.B
3
6985 6985 6985 6992 X954.S
3
4 4
6993
9625938_103285847_4_en
S32.X S32.X
15
30
30 49a S44.X
swwsgn
rt
15 30
B B
13
S4.X1
13 L 0 R 01
01 S44
S4 S32
PROJEKT:
14 49 49a L R 58 31
swws
swgn
ws
L
R
S4.X2 S44.X
49a
14
49
58
31
K391.X 56a L R
3
10
horn, hooter 3 X960.B
1
S32.X S32.X
5
6987
6995
6992
6970
6968
6964
.F2 6987 X960.S
10
K391
X960.B
X960.S
6968
6992,6992
P50.X1
4 5
K391.X 6968
5
C 12 12 C
F307.A
6970 11 11 6970 6970

6986
X960.S
X960.B
6968
6995
6992
20
21
X960.S X960.B X953.S X953.S
/27.B8
2
1
1
X960.B X960.S X953.B X953.B
2
21
20
12
13
6968 X1162.B
X1162.S
12
13
6986
6987
6970
6970
6968
/9.B1
49 49a
+D
H9.X1 K391.X E21.X1 E23.X1
R
L
forbidden.
D 1 D3 K63 D
X1 L R
K63
+D +D C 31
K391
+DE22.X1
+DE24.X1
H9 E21 E23
.F3
2 21W 21W GND GND
/23.E8 /32.D3
X2 K391.X 31 31
2
21
X1162.S
H9.X2 E21.X2 E23.X2

31
31
A148
+D
R
X1162.B
21
fuse board
/43.C5
/43.C6
6708
BK
BK
BK
BK
BK
A150.X2
6
E E
X2 6
ADR DIGIN5
MNr. EA
MP88.X2
MP60.X2
MP61.X1
MP60.X1
MP61.X1
MName: Display
A150
MP61.X1 MP60.X1 MP61.X1 +DMP88.X2
/18.D4 /6.D2 MP60.X2
/17.A7
/17.A5
/17.A7
/17.B5
(direction) indicator, flasher, turn signal
(direction) indicator, flasher, turn signal rear right
K391 (direction) indicator, flasher, turn signal rear left
horn, hooter .D3
5(direction) indicator, flasher, turn signal front left (direction) indicator, flasher, turn signal front right indicator relay hazard light
F .C1 3 F
4
horn, hooter, indicator unit, steering column switch, Seite: 8.40 44 / 65
hazard light Ausgabe: 07 / 2008
1 2 3 4 5 6 7 8
2
F
C
E
B
D
A
3
1
1
87a
.F2
K30
M6
K30.X3
X1138.B
X1138.S
3006,3006 RD 1.50 mm² RD 1.50 mm² F216.A
/12.E3
30
M6.X2
K30.X4
M6.X1
X1138.B
X1138.S
MP87.X1 BK 1.50 mm² BK 1.50 mm² 3009 1.50 mm² 30 1 1 3006 A127.X/X7
M
/18.A6
87
()
2 2 () (+) 87
(+)
MP87.X1
3006
(GN)
S25
.C1
.F2
K30
87
87a
RD
K30.X2
S25.X2
K30.X1
S25.X1
BK 3008
2
2
.C2
K30
85
85 86+ 4 3
86+
30
kit refuelling pump
3009
3008
S341
V173
(RD)
S59
X1190.B
X1190.S
rt1
1 1
3008
S59.X2
S59.X1
rt2 3005
2 2 2 1
3
3
Hydraulikbagger
LIEBHERR
gmbh
4
4
5
5
refuelling pump
6
6
Seite:
7
7
Ausgabe: 07 / 2008
8.40 45 / 65
8
8
Ort
Anlage
+D
=O

F
C
E
B
D
A
1 2 3 4 5 6 7 8
/14.E6
/13.C4
X10461.S
2
5
6
A A
F330.A
X1162.B:14
F315.A
X1160.B:8
slipring contact mit 2 switch
6742
Travel alarm
/4.E5
2
5
6
1900
ADR DO.7
=U =U
MNr. 1 EA 148 COM COM X10461.B
8
+U +U
MNr. 1 EA 138 S269 S270 X10461.S
8
9625938_103285847_4_en
MName: UEC 1 (Master) NC NO NC NO
12
X1048.B A149
8
9 12 X2 30 X1046.B
2
5
6
B B
A149.X2
30
J3 1 J3 4
X1046.B
8
A146 1CO 1CO 8
+D
01 01
10
12
11
S6R S6L X312.B
2
3
4
9
1
PROJEKT:
J2 2
A145
1
X312.S
12
3
4
9
10
11
2NC 4NO 2NC 4NO
+D 1CO
J3 2 J3 3 01
S5M
4789
10 11
6982
2015
2016
6980
2018
2019
2NC 4NO
X1048.B
11
J2 1
6
1
7
X1046.B
7
C C
X1180.S
6
1
1
X1180.B
7
X204.S
2
1
6982
2016
6980
2019
1
X204.B
2
X10461.S
7
6823
BK
1
X230.B
3
forbidden.
4789
4790
X230.S
3
D D
X230.B:2
X230.B:1
Fahren rückwärts
Fahren vorwärts
X3142.B
2
1
1
X3142.S
2
2020
/33.E3
/33.E4
BK
BK
1
4789
4790
E E
14
37
A149.X2 X3141.B A149.X1
2
1
1
X2 14 X1 37
2
ADR DIN.16 ADR FRQ.3

RD
BK
MNr. 1 EA 43 MNr. 1 EA 172

MP60.X1

A149 A149
/4.C5 acoustic warning X10.S:2 /4.E2
/16.D1
acknowledgement Travel alarm switch slipring contact
H33
F F
Travel alarm, backup alarm, Seite: 8.40 46 / 65
reserve transducer handle Ausgabe: 07 / 2008
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
/10.C3
+
3049
M M52 weekly timer 3041
RD F359.A2
3041 F359.XA.2
+F
S232
11
A S232.X A
8
water pump S232
1 3 5 6 7 8 9 10 11
Diag
SW
SW+
KL58
KL15
KL30
Ext.
2
1
R
R
BK O
1
M52.X
2
4781 3044 K
A127.XC2
Ausg.+
0.75 mm²
3041 RD
WH 0.75 mm²
KL30
GND
XS1.1
Diag
P
BU/WH
BN/WH
GY/BK
XC1
XD1
A127.XC1 A127.XD1
TRS
KL31
RD
YE
BN
BU
+F +F +F +F XC2 XD2
GY
S+
S232.XS
2
3
5
1
2 4 12 1 2 3 4 5 6 7 8 9
9625938_103285847_4_en
1 XS1.2
2 4781
1
S232.X S232.X
2
12
4
5
+F 3 3
sw
3044
3049
3041
BK
X99.S .F5 .F7
KC KD
B K360 K359 B
B2 A B S2 /8.A1 /8.A1
X987.B
3
4
8
5
A B 4 5 4 5
B2 V44 V48 V33 V39
X987.S
3
4
8
5
PROJEKT:
1 3 5 7 9 11 13
XC9
XC3
XC4
XD9
XD3
XD4
XC10
XD10
A127.XC3
A127.XD3
B7 A127
3041
BN / 0.75Q
VT / 0.75Q

2 4 6 8 10 12 14 E50
2 4 6 8 3044
M BK
3049
+ S1
BN / 0.75Q
10 11 12 13 14
4934
4933
burner motor BK / 0.75Q 4781

1 3 5 7 X987.S
2
1
C BN / 1.5Q C
VT / 0.5Q BK/WH / 0.5Q 8
4934 1
X987.B
4933 2
7 X689.S
1
BN / 0.5Q YE / 0.5Q 7 3045
WH / 1.5Q BU / 0.5Q 6 1
Steuergerät
9
Wasserkreislauf/Luftklappe
BU/WH / 0.5Q 5 X689
8
+FX8422.S:2
+FX8422.S:1
V1
glow plug GN / 0.5Q 4 4
A127.XE3
7
.E1 4
RD / 0.5Q BK/RD / 0.5Q 3 3 3042
6
XE10
2
XE9
XE3
XE4
RD / 0.5Q BN / 1.5Q 2 BK X689.S
4
5
BU / 0.5Q RT / 1.5Q 1 1 1.50 mm²

4
Gebläse
&#6555; BU / 0.5Q S1 X101
3
BN / 0.5Q
2
BU / 0.5Q
KE
heating
1
/29.D7
/29.D7
4 5
forbidden.
D B7 D
/8.A1

K358
BK,BK 1.50 mm²,1.00 mm²
temperature sensor .F6
3
water circulation
3046
blower
air flap
XE1
XE2
3040
3048
E30 A127.XE1
flame monitor Auxiliary heating 3044
A127.XC5 A127.XE5 A127.XE6 A127.XD5

X689.S
XC5 XC6 XE5 XE6 XD5 XD6
M53.X KC KE KD
3
1
1 /8.D5 1 RC /8.D8 1 RE /8.D6 1 RD

E 3 E
1 2 3 V49 V50 V42 X689
X689 M53 K360 K358 K359 V3
V1 V2 V3 .F5 V_C gn V_E gn .F7 V_D gn .E2
2 2 .F6 2 2 6
4 5 6 F375.XB.1 M53.X
2
MP/DB2.X1X689.S
6
/10.C3
.C7 .E8 F110.B1
BK
BK
/10.B1 XC7 XC8 XE7 XE8 XD7 XD8
overview diode module Ubat S9.X4/3 A127.XC7 A127.XD7
A127.XE7
4780 4780 4780
fuel metering pump
K360 K358 K359
A127 .E5 .E6 .E7 A127.X3/KL31
5 5 5
/12.E6
E50 .B7 3 .D6 3 .B8 3
4 4 4
F F
Auxiliary heating Seite: 8.40 47 / 65

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
/16.E2
/16.E2
/12.C8
A +F +F A
X11
X11
1
1
2
2
X11.B X11.B BK
A127.X/X22
F340.X22
1801
1801
BK
1801
BK
1992
1801
BK
+F
X11.S
2
1
1801
BK
+F +F +F
9625938_103285847_4_en
X982.B X11.S X1234.B X1234.B
6
1
1
1 A127.XA1
1
X982.S X1234.S X1234.S
6
XA1 XA2
+F +F +F
B B
1801
1801
1801
BK
BK
3
.F1
+F +F +F
K33
13
43
S160.X S160.X H90.X
2
+F +F /8.A1
PROJEKT:
13
X1
S213.X 13 21 31 43
4 5 2
13 21 X1 +F 0,1
V25 V28 01
+F S160 H90
01 1801
S213 +F
14 22 32 44 +F +F 1
XA9
XA3
XA4
XA10
30
30
A127.XA3
KT20.X KT21.X
1
14 22 X2 S160.X S160.X H90.X
14
44
+F +F 30 30 +F
S213.X
14
X2
+F +F .F5 .F5
KT20 KT21
3998
4782
4782
C
A127 C
87a 87 87a 87
E50 X1234.S
4
+F KT20.X +F KT21.X
4783
+F
87
87
X982.S +F +F
3
X1234.B
4
1
4000
3999
3998
4001
X982.B
3
+F 3998
W27 W27
2
1
4782
+F +F
X979.B X738.B X1234.S X1234.S X1235.B X1235.B
2
2
1
1
1
1
X979.S X738.S X1234.B X1234.B X1235.S X1235.S
2
2
3
+F +F
4782
4000
4001
W28 W28
2
1
1
3999
3998
+M
+F +F
86
15
15
A127.XA5 R8 KT21.X KT20.X Y356.X Y357.X
forbidden.
1
D XA5 XA6 D
15 15
1 1
+F +F
1 RA KT21 KT20 Y356 Y357

.F5 .F5
K33 V30 V_A 15s 31 15s 31 2 2
X738.S
2
/8.D2 KT21.X KT20.X Y356.X Y357.X
2
31
31
.F2 gn +F +F
2 X738.B
2
W28 W28
4
BK
BK
BK
+F +F
X1235.S X1235.S
4
XA7 XA8
A127.XA7 X1235.B X1235.B
4
85
+F +F
BK
W27
A127
A127.KL31X1 BK
E BK 3 E
E50
A127.KL31X2
BK 4
A127.KL31X1 A127.KL31X2
/12.E6
/12.E6
Fan outlet fan Slewing direction reversion
Slewing direction reversion fan stop indicator light Slewing direction reversion
fuel preheating +F +F
KT21 KT20
K33 .D5 .D5
.D2 87 87
5 .C7 30 .C6 30
F .B3 3 87a 87a F
4
fuel preheating, Seite: 8.40 48 / 65
Fan drive Reversible Ausgabe: 07 / 2008
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
/16.E2
/16.E5
A A
X11
X29
1
1
X29.B
2
X11.B
1807
1801
1801
BK
BK
BK
1807
BK
X29.S
X1251.B X11.S X1028.B
4
1
1
1
1
X1251.S X1028.S
4
9625938_103285847_4_en
BK
1807
1801
BK
43 1807
B B
13
S84.X1 S84.X2 S405.X S405.X H322.X
2
1
1
1 9 13 21 31 43
2
0,1
01
S405
PROJEKT:
H322
S84 01
1
1801
14 22 32 44
1
S405.X S405.X H322.X
14
44
5 10
4944
4945
4945
S84.X1 S84.X2
2
5
2
3
3082
3083
X1251.S X1251.S X1028.S X1028.S
2
3
3
C C
X1251.B X1251.B X1028.B X1028.B
2
3082 3
3
3083
4944
4945
4945
X998.B X998.B
A
B
X998.S X998.S
A
B
X1030.S X1029.B X1029.B
2
sw
1
2
1
3082
3083
1801
1
X1030.B X1029.S X1029.S
2
forbidden.
4944
4945
4945
D D

X143.B X143.B
1
1
X143.S X143.S
3
Y3851.X Y3852.X
1
1 1
+D
U4 Y3851 Y3852
option, optional
2 2
central lubrication (system)
Y3851.X Y3852.X
2
&#6500;
X143.S 2
E X143.B E
2
A150.X2
3
X2 3
BK
ADR DIGIN2
MNr. EA
MP87.X3
MP86.X3
MP86.X3
standard device, basic machine MName: Display
A150
+DMP87.X3 /6.D2
/18.D6
.E8
.E7
central lubrication (system) &#6500; changeover control system / unit, control, controller
F F
LIEBHERR central lubrication (system), changeover control system / unit, control, controller Seite: 8.40 49 / 65 Ort +F

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
plug grouping fuse board
A A
X1160.S X1161.S X1162.S X1163.S X1164.S X1165.S
/13.B2 /13.E2 /23.D7 /13.C7 /16.B2 /16.B4
/13.B2 /13.B3 /13.E2 /13.E2 /23.E7 /13.C7 /16.B2 /16.B2 /16.B4 /16.B4
3
1 1
1
/32.C3 3 /13.E7 3
/13.B3 /13.B4 /13.E2 /13.E2 /14.C2 4 6 /14.C2 /13.E7 4 6 /13.E8 /16.B2 /16.B2 /16.B4 /16.B4
4
6
/13.B4 /13.E2 /14.C2 /13.C8 /16.B2 /16.B4
/13.B4 /13.B4 /13.E2 /13.E4 /14.C2 7 9 /14.C3 /20.B2 7 9 /20.B2 /16.B2 /16.B2 /16.B5 /16.B5
7
9
/13.B4 /13.E4 /14.C2 /20.B2 /16.B2 /16.B5
/13.B5 /13.E5 /14.C4 10 12 /44.D7 /20.B7 10 12 /20.B8 /16.B3 /16.B5
/13.B4 /13.E4 /16.B3 /16.B5
10
10
10
10
12
12
12
12
/14.C5 /20.B6
/13.B5 /13.E4 /44.D7 13 15 /14.C6 /20.B4 13 15 /20.B8 /16.B3 /16.B5
/13.B7 /13.E6 /16.B3 /16.B5
13
15
13
15
13
15
13
15
/13.B7 /13.E5 /14.C6 /20.B4 /16.B3 /16.B5
/20.B2 18
/13.B7 /13.E6 /14.C6 16 18 /14.C8 16 /16.B3 /16.B5
9625938_103285847_4_en
/14.C7
21 /44.D7
/14.C8 19
/14.C8
B B
PROJEKT:
X1160.B X1161.B X1162.B X1163.B X1164.B X1165.B

/9.B7 /9.C7 /9.E7 /9.D8 /9.C7 /9.D7
X1160.B X1161.B X1162.B X1163.B X1164.B X1165.B

/13.B7 /44.E7 /16.B5
20
19
21
/13.B7 /16.B3 /16.B5
16
17
18
13
14
15
13
14
15
13
14
15
13
14
15
/13.B7 /14.C8 /20.B2
/13.B5 /14.C7
16
17
18
/13.E5
13
14
15
/20.B8
10
12
10
12
10
12
10
12
/13.B4 /13.E4
11
11
11
11
/13.B4 /13.E4 /14.C6 /14.C6 /20.B6
/13.B4 /16.B2 /16.B5
10 13
14
12 15
/20.B8
10
12
7
9
/44.C7
11
/13.B4 /20.B7
/13.E2 /14.C5 /44.C7 /20.B2 /16.B4

/20.B2
11
/13.B4
9
4
6
C /13.B3 /14.C4 /20.B2 C
/14.C2
/14.C3
7
8
9
/13.B2 /13.B3 /13.E2 /13.E2
6
2
3
/14.C2
1
1
/13.B2 /13.E2 /16.B2 /16.B4
/14.C2 /14.C2 /13.E7
4
5
6
/14.C2
3
1
/13.C7
/32 /23.E7
2
3
1
/23.C7
plug grouping display
forbidden.
D D
A150.X1 A150.X2
20
19
21
13
14
15
/39.E1
/20.E5 /36.E3 /39.E2
16
17
18
10
12
/20.E4
11
/28.E5 /28.E6
/20.E3
10 13
14
12 15
7
9
/10.E7
11
4
/26.E3 /37.E5
7
8
9
/19.E5 /19.E6
2
/27
1
/19.E4
/44.E7
4
5
6
/26 /49.E6
2
3
1
/36.E1
E E
F F
plug grouping Seite: 8.40 50 / 65

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
plug grouping UEC 1 plug grouping UEC 2
A A149.X1 A149.X2 A155.X1 A155.X2 A
/40.B6 /14.E7 /34.B4

/35.E4 /35.E6 /33.E3 /46.B3 /34.B7
10 20 30 40 10 20 30 40 10 20 30 40 10 20 30 40
/37.E6 /14.E4
/36.E4 /35.E1 /40.E8 /28 /34.B6
9 19 29 39 9 19 29 39 9 19 29 39 9 19 29 39
/14.E3
/28.E1 /35.E3 /37.E2 /33.B1
8 18 28 38 8 18 28 38 8 18 28 38 8 18 28 38
9625938_103285847_4_en
/36.E3 /46.E6 /43.B7 /19.E3

/28.E3 /37.E2 /33.B2 /34.B6 /34.E1
7 17 27 37 7 17 27 37 7 17 27 37 7 17 27 37
/40.E6 /35.B7
/35.E2 /27.E1 /32.E7 /40.B1
B 6 16 26 36 6 16 26 36 6 16 26 36 6 16 26 36 B
PROJEKT:
/20.E6 /40.E5 /36.E5 /37.B8 /34.B3

/33.E7 /32.B3
5 15 25 35 5 15 25 35 5 15 25 35 5 15 25 35
/20 /28.E2 /46.E2 /35.B8 /34.B2
/20.C2 /20.E7 /20.E8 /37.B3 /34.B7
4 14 24 34 4 14 24 34 4 14 24 34 4 14 24 34
/20.C2 /43.E8 /36.B8
/19.E2 /21.E4 /32.E1 /37.B4 /34.B8
3 13 23 33 3 13 23 33 3 13 23 33 3 13 23 33
/20.C3 /32.E5 /40.E2 /32.B8
/19.E3 /21.E3 /23.E5 /37.B7
2 12 22 32 2 12 22 32 2 12 22 32 2 12 22 32
/32.B6 /32.E5 /33.E3 /36.B7 /34.B5

C /19.E1 /20.E8 /33.E8 /23.B5 /34.B4 C
1 11 21 31 1 11 21 31 1 11 21 31 1 11 21 31
plug grouping plugin board central electrics
+K
X952.S X953.S X954.S X956.S X960.S X967.S X980.S
/32.C4 1 /37.D3 /44.C5 1 /36.D7 1 /44.B8 /34.B4 1 /34.B6 /32.C7 1 /43.B8 /43.B1 1 /31.B1 /11.C2 1 /26.B3
/33.D6 3 /44.C6 3 /11.C2 3 /34.B4 3 /36.D3 3 /31.B7 3 /26.D3 3
forbidden.
D /37.D4 4 6 /33.D6 /36.D8 4 6 /30 /10.D7 4 6 /34.B6 4 6 /34.B5 /44.B2 4 6 /28.B2 /42.B1 4 6 /15.D1 4 6 /24.D6 D

/33.D5 /35.D8 /34.B7 /43.D8 /42.B2 /22.C1
/33 7 9 /37.D7 /36.D3 7 9 /38.C2 7 9 /40.B3 /34.B7 7 9 /28.E2 7 9 /28.E3 /15.D2 7 9 /15.D2 7 9
/33.D2 /36.D4 /34.B8 /28.E1 /15.D2
/37.D8 10 12 10 12 /38.C5 /42.C1 10 12 /40.B4 10 12 /44.C5 10 12 /44.C4 /30.C8 10 12 /31.D2 10 12 /21.C4
/32.C8 /42.C2 /44.C4 /42.C6
/37.D5 13 15 /27.E1 /38.C6 13 15 /35.D7 /40.E7 13 15 /30.C8 13 15 /43.B3 13 15 /32.C7 /31.C4 13 15 /21.C5 13 15 /21.C8
/27.E2 /39.D1 /40.E8 /43.B3 /31.C5 /21.C8
/27.D8 16 18 /43.B4 16 18 /28.D4 16 18 16 18 /36.D8 16 18 16 18 /21.C7 16 18 /22.C2
/27.B8 /36.D1 /21.C6

21 /43.B6 21 21 21 21 /44.C1 21 21
/43.B4 19 /26.D1 19 19 19 19 19 /21.C6 19

/43.B5 /26.D2 /44.C3
X952.B X953.B X954.B X956.B X960.B X967.B X980.B

E /43.B5 /26.C2 /44.C3
E
/43.C6 /44.C1
20
20
20
20
20
20
20
19
19
19
19
19
19
19
21
21
21
21
21
21
21
/43.B4 /26.C1 /21.C6
/27.B8 /43.B4 /28.D4 /21.C6 /22.C2
16
17
18
16
17
18
16
17
18
16
17
18
16
17
18
16
17
18
16
17
18
/27.D8 /27.C1 /36.D8 /21.C7
/27.D2 /27.D1 /39.D1 /35.D7 /40.D8 /30.C8 /43.B3 /32.C7 /31.C5 /21.C8 /21.C8
10 13
14
12 15
10 13
14
12 15
10 13
14
12 15
10 13
14
12 15
10 13
14
12 15
10 13
14
12 15
10 13
14
12 15
/37.D5 /38.C6 /40.D7 /43.B3 /31.C4 /21.C5
/32.D8 /38.C4 /38.C5 /42.C2 /40.B4 /44.C4 /44.C4 /42.C6 /31.D2 /21.C4
11
11
11
11
11
11
11
/37.D8 /38.C3 /42.C1 /44.C5 /30.C8
/33.D2 /37.D7 /36.D4 /38.C2 /40.B3 /34.B8 /28.D1 /28.D3 /15.D2 /15.D2
7
8
9
7
8
9
7
8
9
7
8
9
7
8
9
7
8
9
7
8
9
/33.D1 /36.D3 /34.B7 /28.D2 /15.D2
/33.D5 /33.D6 /35.D8 /30.D3 /10.E8 /34.B7 /34.B5 /43.D8 /28.B2 /42.C2 /15.D1 /22.C1 /24.D6
4
5
6
4
5
6
4
5
6
4
5
6
4
5
6
4
5
6
4
5
6
/37.D4 /36.D8 /10.D7 /34.B6 /44.B2 /42.C1
/33.D6 /37.D3 /44.C6 /36.D7 /11.D2 /44.A8 /34.B4 /34.B6 /36.D3 /43.B8 /31.B7 /31.A1 /26.D3 /26.B3
2
3
2
3
2
3
2
3
2
3
2
3
2
3
1
1
/32.C4 /44.C5 /34.B4 /32.C7 /43.B1 /11.D2
F F
plug grouping Seite: 8.40 51 / 65

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
= plant Fuel and lubricant type clamp Significance fuses

mark mark DIN 407192 Signal Excerpt, extension OFF DIN 72552
A

A309 r317

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en

Order number: 10449595

Author: LHB - Technical Documentation Department

Manufacturer: LIEBHERR Hydraulikbagger GmbH

Document is registered under: 1030314 - 29.01.2009

3 Address of copyright owner

Liebherr Hydraulikbagger GmbH

Manual no. ..............................

Technical Data / Maintenance Guidelines 3

Two Speed Gear Box / Travel Gear 11

Axles / Track Components 12

Document is registered under: 1030314 - 29.01.2009

Oscillating Axle Stabilizer 14

Special Attachments / Accessory Kits 16

Cab / Heater / Air Conditioning System 17

Undercarriage / Uppercarriage / Attachments 18

Section Group Type

Safety instructions 1.10.1 A 312 LI-TCD 36220-

Tightening torques (WN 4037 K) 1.20.1 A 312 LI-TCD 36220-

Tightening torques 1.21.1 A 312 LI-TCD 36220-

Assembly instruction for hydraulilc cylinder 1.22.1 A 312 LI-TCD 36220-

Document is registered under: 1030314 - 29.01.2009

Assembly instruction for hydraulic cylinder 1.24.1 A 312 LI-TCD 36220-

Lubricants and operating fluids 1.50.1 A 314 LI-TCD 30694-

TE_ML05 lubricant list 1.55.1 A 312 LI-TCD 36220-

TE_ML07 lubricant list 1.56.1 A 312 LI-TCD 36220-

Document is registered under: 1030314 - 29.01.2009

3 Crushing and burn prevention

– Always wear work gloves when handling wire ropes.

4 Fire and explosion prevention

– Switch off the Diesel engine prior to filling the tank.

5 Transporting the machine safely

Document is registered under: 1030314 - 29.01.2009

pull the safety lever up prior to leaving the machine.

6 Bringing the machine safely into service

– Before starting the machine, perform a thorough walk around inspection.

7 Starting the machine safely

8 Shutting down the machine safely

9 Towing the machine safely

10 Working with the machine safely

Document is registered under: 1030314 - 29.01.2009

10.2 Safe application of machines with tower elevation

Document is registered under: 1030314 - 29.01.2009

10.4 Protection from vibrations

– Keep the seat in good order and adjust it as follows:

11 Safe installation and removal of attachment parts

Document is registered under: 1030314 - 29.01.2009

12 Safe maintenance of the machine

12.1 General safety instructions

from penetrating the bearing positions.

• Remove all temporary covers.

12.3 Crack detection

Document is registered under: 1030314 - 29.01.2009

12.4 Welding work

12.5 Fuels and lubricants

pressure as described in this manual.

12.7 Electrical system

– For machines equipped with electrical medium-voltage and high-voltage lines:

12.8 Hydraulic accumulators

Document is registered under: 1030314 - 29.01.2009

12.9 Hydraulic and other hoses

• Deformation of the hose when pressurised, depressurised, or at bends, resulting in separation

12.10 Cab protection (FOPS)