Service Manual LOCUST

SERVICE MANUAL
LOCUST
L752, L753, L853, L903, L1203

0. Preface
Table of contents
Preface ................................................................................................................................ 3
1. Hydraulic systems of machines ............................................................................ 4
1.1 Hydraulic circuit of control .................................................................................... 4

1.1.1 Wiring diagrams ....................................................................................................... 5
1.1.2 Other elements of hydraulic circuit of control ............................................................15
1.1.2.1 Electrohydraulic valve ROX ......................................................................................15
1.1.2.2 Remote controller .....................................................................................................16
1.1.2.3 Electrohydraulic valve of shovel levelling..................................................................17
1.1.2.4 Electrohydraulic valve of gearing ..............................................................................19
1.1.2.5 Electrohydraulic valve of AA section.........................................................................20
1.1.2.6 Electrohydraulic control module (L1203) ..................................................................20
1.1.3 Check and measurement of pressure ......................................................................21
1.1.4 Possible malfunctions in hydraulic circuit .................................................................24
1.2 Hydraulic circuit of working equipment ...............................................................25

1.2.1 Wiring diagrams .......................................................................................................25
1.2.1.1 Quick couplers ........................................................................................................34
1.2.2 Other elements of hydraulic circuit of working equipment.........................................35
1.2.2.1 LOCUST 752 ...........................................................................................................35
1.2.2.2 LOCUST 853, 903 ...................................................................................................38
1.2.2.3 LOCUST 1203 .........................................................................................................41
1.2.3 Check and adjustment of working pressure..............................................................44
1.3 Hydraulic circuit of travel ......................................................................................49

1.3.1 Wiring diagrams .......................................................................................................49
1.3.2 Control pump A10VG45 ...........................................................................................52
1.3.3 Hydromotor MCR5 ...................................................................................................54
1.3.4 Check and adjustment of pressure...........................................................................56
1.3.4.1 Directness of travel ..................................................................................................57
2 Electric wiring ........................................................................................................61
2.1 Wiring diagrams.....................................................................................................62
2.2 Shovel levelling (L853, L903) ................................................................................75

2.2.1 Means of sensoring..................................................................................................75
2.2.2 Adjustment of levelling system .................................................................................76
2.3 Electrohydraulic control of section of auxiliary attachment ...............................78

2.3.1 Check of valve operation..........................................................................................78
2.3.2 Distributor SM12, SX12 (load connection)................................................................79
2.3.3 Control unit ..............................................................................................................79
2.3.4 Distributor SX14 (signal connection) ........................................................................80
2.4 Gearing of the 2nd gear .........................................................................................81
2.5 Multifunctional electronic switch..........................................................................82
SERVICE MANUAL 1 LOCUST

0. Preface
2.5.1 Connection of adaptors ............................................................................................84

2.5.2 SB01 Multifunctional electronic substitution .............................................................88
3 Side gears...............................................................................................................89
4 Oil specification .....................................................................................................91
4.1 Engine oils..............................................................................................................91

4.1.1 Viscosity classes ......................................................................................................91
4.1.2 Load classes ............................................................................................................91
4.1.3 Load classes for Diesel engines...............................................................................92
4.2 Gear oils..................................................................................................................93

4.2.1 Viscosity...................................................................................................................93
4.2.2 Load classes ............................................................................................................93
4.3 Hydraulic oils .........................................................................................................93
5. Authorized service .................................................................................................95
6. Conclusion ...........................................................................................................96
Note:
Abbreviation „ELAA“ means electrohydraulic control of auxiliary attachment implemented for

particular machine types as follows:
L 752 from production number 1495/05

L1203 from production number 160/05
Abbreviation „MF“ means built-in multifunctional electronic switch implemented for particular machine
types as follows:

L1203 from production number 188/06
Telspeed from production number 07/06

0. Preface
PREFACE
This manual is intended to fullfil a space between „Operation and maintenance manual“
containing basic information of operation (safety regulations, machine control, maintenance)
and „Workshop manual“ containing dismantling and reassembly procedures and repair
procedures of particular hydraulic elements.
It is following the knowledge that for identification of any malfunction in a system it’s
important to know how the system is connected and how its individual elements work. The
information is complemented by figures with a concise description (diagrams, section views,
graphs) with notice of differences among individual machine types.
The manual is designed as a help for dismantling-free diagnosis of machine malfunctions for
authorized service of the producer. It provides basic information of hydraulic system and
electric wiring where the malfunctions may occur most likely. Also some other malfunctions
that could occur during operation are described. Some information and figures in this manual
are taken from available manuals of Bosch-Reroth, the producer of hydraulic elements.
The „diagnostic service box“ is recommended to use for diagnosis of hydraulic system
malfunctions. It contains all necessary manometers and connections. A standard measuring
unit from retail shops is suitable for diagnosis of electric wiring.

1. Hydraulic systems of machines
Hydraulic systems of machines consist of individual working circuits which take care of their
specific functions.
1.1 Hydraulic circuit of control………………… 2.5 MPa (L752, L1203)

2.8 MPa (L853, L903)
All operations of machines are virtually controlled by hydraulics.

Hydraulic circuit of control cares for transmission of signal (control
pressure) from its source through control units to the desired location
(control pump, distributor).
Gear pump 3 is the source of control pressure. It is located in the front
part 1 of control pump A10VG 45. The safety valve 2 is set to the pressure shown above.
2 3
Fig. 1 Source of control pressure and safety valve
1- Control pump A10VG45, 2- Safety valve of control pressure, 3- Gear pump – the source of control
pressure.
The gear pump 3 – the source of control pressure and safety valve 2 are placed in all stages
of control pump A10VG45. (Valid for all machine types, except L753.)

1.1.1 Wiring diagrams

Wiring of hydraulic circuit of control – block diagram of:
- L 752 to production number 1494/05 (hydraulic control of auxiliary attachment)
- L1203 to production number 159/05
Fig. 2-Wiring of hydraulic circuit of control of L 752, L 1203

1- Front stage of pump A10VG45, 2- Rear stage of pump A10VG45, 3- Electrohydraulic valve,
4- Electrohydraulic valve, 5- Right actuator, 6- Left actuator, 7- Foot pedal actuator, 8- Left
hydromotor, 9- Right hydromotor, 10- Distributor SM 12(L752), SX14 (L1203) 11- Oil tank.


- L 752 from production number 1495/05 (electrohydraulic control of aux. attachment)
Fig. 3- Wiring of hydraulic circuit of control of L752

4- Electrohydraulic valve, 5- Right actuator, 6- Left actuator, 7- Right hydromotor, 8- Left hydromotor,
9- Distributor SM 12(L752), 10- Oil tank.

- L 853 to production number 159/05
- L903 to production number 101/05
Fig. 4- Wiring of hydraulic circuit of control of L853, L903

1-Front stage of pump A10VG45, 2- Rear stage of pump A10VG45, 3- Electrohydraulic valve,
4- Electrohydraulic valve, 5- Right actuator, 6- Left actuator, 7- Foot pedal actuator, 8- Electrohydraulic
valve, 9- Electrohydraulic valve, 10- Logic valve, 11- Logic valve, 12- Right hydromotor MCR5, 13- Left
hydromotor MCR5, 14- Distributor SX12, 15- Oil tank.


7 6
9
8
5 1
2
11
P
1 2
12 3 4
5 6
T 10
Fig. 1-5 Wiring of hydraulic circuit of control L753
1- Filling gear pump for both stages of A20VG45, 2- Gear pum for working equipment, 3- Front stage
of pump A20VG45, 4- Rear stage of pump A20VG45, 5- Electrohydraulic valve DSH 08, 6- Right
actuator, 7- Left actuator, 8- Right hydromotor MCR5, 9- Left hydromotor MCR5, 10- Distributor SM12,
11- Oil filter with vacuum gauge, 12- Oil tank.


- L 853 from production number 160/05 (electrohydraulic control of aux. attachment)
- L903 from production number 102/05
Fig. 5- Wiring of hydraulic circuit of control of L853, L903

1-Front stage of pump A10VG45, 2- Rear stage of pump A10VG45, 3- Electrohydraulic valve,
4- Electrohydraulic valve, 5- Right actuator, 6- Left actuator, 7- Electrohydraulic valve, 8-
Electrohydraulic valve, 9- Logic valve, 10- Logic valve, 11- Right hydromotor MCR5, 12- Left
hydromotor MCR5 , 13- Distributor SX12, 14- Oil tank.


- L1203 from production number 160/05 (electrohydraulic control of aux. attachment)
Fig. 6- Wiring of hydraulic circuit of control

4- Electrohydraulic valve, 5- Right actuator, 6- Left actuator, 8- Left hydromotor, 9- Right hydromotor,
10- Distributor SX14 , 11- Oil tank.

6 5
7
PARK. BRZDA 10
3
4
8 9
2 1
PARK. BRZDA
11
Fig. 7- Wiring diagram of control circuit of L752

1-Control pump A10VG45 of right side drive, 2- Control pump A10VG45 of left side drive,
3- Electrohydraulic valve of hydraulics blocking, 4- Electrohydraulic valve of brake, 5- Right cross
actuator, 6- Left cross actuator, 7- Foot pedal actuator of AA, 8- Left hydromotor, 9- Right
hydromotor, 10- Distributor SM 12, 11- Oil tank with gauge.
PARK. BRZDA
PARK. BRZDA
Fig. 8- Wiring diagram of control circuit of L752 (electrohydraulic control of AA)

1- Control pump A10VG45 of right side drive, 2- Control pump A10VG45 of left side drive,
3- Electrohydraulic valve of hydraulics blocking, 4- Electrohydraulic valve of brake, 5- Right cross
actuator, 6- Left cross actuator, 8- Left hydromotor, 9- Right hydromotor, 10- Distributor SM 12,
11- Oil tank with gauge.

9 8 12
14
13
10
13
14
6
7
5
4 3
2 1
11
Fig. 9- Diagram of hydraulic circuit of control of L853 and L903

1-Control pump A10VG45 of right side drive, 2- Control pump A10VG45 of left side drive, 3- Right
hydromotor, 4- Left hydromotor, 5- Control pump of working equipment, 6- Electrohydraulic valve of
hydraulics blocking, 7-Electrohydraulic valve of brake, 8- Right cross actuator, 9- Left cross actuator,
10- Distributor SX 12, 11- Oil tank, 12- Foot pedal actuator of AA, 13- Electrohydraulic valve of
shovel levelling,14- Logic valve.
9 8 13
12
10
12
13
7 6
5
4 3
2 1
11
Fig. 10- Diagram of hydraulic circuit of control of L853 and L903 (ELAA)
hydraulics blocking, 7-Electrohydraulic valve of brake, 8- Right cross actuator, 9- Left cross actuator,
10- Distributor SX 12, 11- Oil tank, 12- Electrohydraulic valve of shovel levelling, 13- Logic valve.

9 8
10
7 6
5
4 3
2 1
11
Fig. 11- Diagram of hydraulic circuit of control of L1203 (ELAA)

hydraulics blocking, 7- Electrohydraulic valve of brake, 8- Right cross actuator, 9- Left cross actuator,
10- Distributor SX 14, 11- Oil tank with gauge.
Right actuator
Left actuator
Right actuator
10
5
8
4 3 2 1
9
17
11
18
12
Fig. 1-13 Diagram of hydraulic circuit of control of L753 (EL)

1-Filling gear pump for A20VG45, 2- Gear pum of working equipment AZPN-11-028, 3- Front stage of
A20VG45, 4- Rear stage for A20VG45, 5- Electrohydraulic valve DSH 08, 8-Right hydromotor MCR5,
9-Left hydromotor MCR5, 10- Distributor of WE, 11- Oil filter, 12- Oill tank, 17- Oil cooler, 18- Oil
bypass valve of cooler.

4 3
10
6
9
1
8
7 5 12 13 14
11
Fig. 1-13 Diagram of hydraulic circuit of control of L753 (H)

1-Gear feed pump for A20VG45, 2- Distributor SM12, 3- Right joystick, 4- Left joystick, 5- Front stage
of A20VG45, 6- Right hydromotor MCR5, 7- Rear stage for A20VG45, 8- Left hydromotor MCR5, 9-
Electrohydraulic valve DSH 08 (seat), 10- Electrohydraulic valve DSH 08 (brake), 11- Oill tank, 12- Oil
filter, 13- Bypass valve, 14- Oil choler.

1.1.2 Other elements of hydraulic circuit of control
1.1.2.1 Electrohydraulic valve DSH 08* (ROX-1)
- Upper electrohydraulic valve (B) connects or disconnects inlet of control pressure to

disc brakes of hydromotors. It is controlled by the left pedal or switch of park brake.
- Lower electrohydraulic valve (A) connects or disconnects inlet of control pressure to

joysticks and distributor of electrohydraulic control of the AA section. It is controlled
by an electric switch in the cabin seat or a pull switch on the left control column.
Fig. 12- Location of electrohydraulic valves

A- Electrohydraulic valve of control blocking, B- Electrohydraulic valve of brake
Actuators
B A
Brakes
Control
Pressure
Oil tank
Fig. 13- Interconnection of electrohydraulic valves DSH 08 (ROX)

A- Valve of hydraulics blocking, B- Valve of brake
*Is mounted from producing number: L752-2023/07, L753-001/06, L853-280/07, L903-397/07, L1203-
235/07

1.1.2.2 Remote controller (joystick) L752, L853, L903, L1203
Purpose of the remote controller is to send signals (electric, hydraulic) to a controlled

element (pump, distributor).
Fig. 14- Remote controller

5- Handle, 6- Slider, 7- Adjustment spring, 8- Return spring, 9- Plunger, 10- Body, 11- Adjustment
opening, 12- Cuff, P- Control pressure - inlet, T- Waste outlet.
Hydraulic part of the controller is connected to the control pressure from electrohydraulic
valve. Proportional valves (fig. 15) act by means of the plunger (9) when the joystick is tilted.
They open inlet of the control poressure to hoses and pipelines leading to a desired element.
Fig. 15- Remote controller – location of proportional valves

Controllers of particular machine types differ from each other in some details (wiring of an
electrical section) therefore they cannot be exchanged. The following table contains ID
numbers shown on body of each controller for an easier reference.
Machine type Left joystick Right joystick
L 752, 753H 08351340 08351339

L853 + L903 08351342 08351341
L 1203 08351340 08351343
L753 (EL) 08351738 SI 08351737 SI
L 853,903 JR* 08351067.1 08351341.1
L453 08351340 SI 08351339 SI
JR* - One hand control
Cleanliness of hydraulic oil is the basic condition for a correct function of the controller.
Detailed information on maintenance and repairs can be found in a manual published by the
producer.
1.1.2.3 Electrohydraulic valve of shovel levelling (L853, L903)
Electrohydraulic valve of shovel levelling used on machines L 853 and L 903 opens or
closes inlet of control pressure to faces of shovel section slider on distributor SX12. Each
valve of a pair servers for levelling during jib movement in one direction – one upwards, the
second one downwards.
Fig. 16- Location of electrohydraulic valves of shovel levelling
Additionally, so called logical valves are connected to this circuit (of shovel). They direct
control poressure coming from two directions (from joystick or electrohydraulic valve) to one
outlet – to the face of shovel section slider. Their interconnection is shown on a diagram (fig.
9, 10, 17).

Control pressure coming from the right joystick (7, fig. 17) at closed valve (1) is directed to
section of the jib (3). After the valve is open, the control pressure is directed through the
logical valve (2) also to the section of shovel (4).
Control pressure coming from the left joystick is directed through the logical valve (2) to
shovel section only.
7 8
5 6
3 4
1
Fig. 17- Diagram of shovel levelling on L 853, L 903
1- Electrohydraulic valve, 2- Logic valve, 3- Jib section, 4- Shovel section, 5- Hydraulic cylinder of the
jib, 6- Hydraulic cylinder of the shovel, 7- Part of the right joystick, 8- Part of the left joystick.
Jib position is controlled by means of sensors (fig. 68, 68a) located on the left column of
the frame. Electric part of the valves (1, fig. 16) is controlled by means of relays located in
a case on the left side plate of the frame (fig. 69).
Detailed information on checking and setting can be found in chapter 2 (page 62) of this
manual.

1.1.2.4 Electrohydraulic valve of the 2nd gear (for Speed + machines)
Purpose of this valve is to open inlet of control pressure to a control section of hydromotor.
The control pressure works on a hydraulic slider that changes direction of working pressure
flow to a rotating section of hydromotor.
The valve is located under the front cross beam of the frame at the right side (fig. 18).
Fig. 18- Location of valve of the 2nd gear on L903
4 3
5
2 1
Fig. 19- Wiring diagram of valve of gearing

1- Control pump A10VG – front stage, 2- Control pump A10VG – rear stage, 3- Right hydromotor,
4- Left hydromotor, 5- Axial pump of AA, 6- Valve of gearing, 7- Oil tank

1.1.2.5 Electrohydraulic valve of auxiliary attachment section (L752, L753, L853, L903)
(Distributors SM 12, SX12)
The control pressure is lead by means of this valve to a face of AA section slider that opens
flow of working pressure to hydromotor in one direction.
Fig. 20- Electrohydraulic valve of AA control

(L752, L753, L853, L903)
1- Slider, 2- Coil, 3- Spring, 4- Sieve, 5- Packing ring.
A- Outlet of control pressure, P- Inlet of control pressure,
T - Waste - to a tank.
Fig. 21- Electrohydraulic valve

of AA control
1.1.2.6 Electrohydraulic control module of auxiliary attachment section (L1203)

(Distributor SX14)
Fig. 22- Control module of AA section

1- Electronics, 2- Changer, 3- Proportional electrohydraulic valve, 4- Mechanic binding of changer,
5-Analog electronic card, 6- Control piston, 7- Converter, 8- Inner pressure chamber, 9-Guide ring,
10- Connecting screw, 11- Input channel of control pressure, 12- Waste channel, 13- Return spring.

1.1.3 Check and measurement of pressure
Check and measurement of pressure is usually needed when a malfunction on a machine

occurs that could be caused by insufficient (low) control pressure or by cutoff of its flow to
a desired location.
Control (filling) pressure rises in the circuit after the engine is started. In case the machine
is not moving, the pressure is always in both branches of control pumps (travel forward and
backward) so it can be measured on all four connectors (A, B, C, D) of working pressure of
travel of right and left sides. Besides that it can be anytime measured on connector (E) of
tandem front stage outlet.
The following rules apply for it:
- Control pressure is of one source, therefore it effects all controlled functions.

- If one function is not working only and others work normally, then the problem is
not in control pressure.
- If no function works at all, then first check value of control pressure by connecting
manometer to connector E (fig. 21). The correct value at 2500 rpm is 2.5 MPa (L752,
L753, L1203), 2.8 MPa (L853, L903).
- If low value is measured, then unscrew and check or clean the safety valve (fig. 1, 24)
or do a quick test by exchanging valves of front and rear stages of pump A10VG45.
- If the problem was not solved after the valve was checked (cleaned or exchanged),
then the filling gear pump 3 (fig. 1) is likely a cause of it.
C A
B
D E
Fig. 23- Connectors for pressure measurement (L752, L853, L903, L1203)
A, B – Connectors for measurement of working (2.5 - 35.0 MPa) and control pressure, C, D-
Connectors for measurement of working (2.5 - 35.0 MPa ) and filling pressure of rear stage of the
pump, E- Connector for measurement of control pressure.
Note:
Measurement of control pressure is recommended to be performed on connector E.
WARNING
Do not touch joysticks inside of cabin when measuring control pressure on
connectors A, B, C, D.

In most cases impurity of safety valve (fig. 25) is the cause of control pressure malfunction.
The pressure value can be changed (increased) by inserting of washer 7 (fig. 25) under the
spring of the valve.
Fig. 24- Position of safety valve of control pressure

„G“- Control pressure, outlet and measuring point directly on the pump
Fig. 25- Safety valve of control pressure

1- Valve body, 2- Slider, 3- Spring cup, 4- Spring, 5- Packing ring 22 x 24 x 1.5, 6- O-ring 23.47 x 2.62,
7- Washer*, (* thicknesses 0.3 mm, 0.5 mm, 1 mm)
Front and rear stages of control pump A10VG45 of travel are equivalent therefore the safety
valve of control pressure is set to the same value.
Summary:
Control pressure taken from the front stage of control pump A10VG45 serves for:
- automatic braking / unbraking of the machine after the engine is stopped / started,
- switching on of emergency and park brake by means of left foot pedal and a switch
on the control panel,
- control of control pumps of travel and distributor of working equipment,
- switching of change of travel gear in hydromotor.

The source of the filling pressure for both stages of A20VG45 and at the same time control
pressure on L753 is the front gear pump.
Fig. 1-28 Gear feed pump L753
The relief valve of the control pressure is common for both stages of A20VG45 pumps and
is situated on the entry block of safety valves (fig.1-29)
Fig. 1-29 Relief valve of control pressure L753
Fig. 1-30 Measuring point of contol pressure L753

1.1.4 Possible malfunctions in hydraulic circuit
Symptom: Machine doesn’t perform work commands by running engine.
Options and procedure
Control pressure Electric wiring

check malfunction (closed
electrohydraulic valve
ROX)
Pressure OK (yes)
(no)
Low (no) pressure
Valve OK (no)
(yes)
Safety valve check

(yes) Clean, set
(replace)
Control pressure
pump malfunction

1.2 Hydraulic circuit of working equipment …....… 0 - 16.5 MPa (L752, L753)
2.0 - 16.5 MPa (L1203)
2.0 - 18.5 MPa (L853, 903)
This hydraulic circuit controls auxiliary attachment, working equip-

ment (shovel) and the jib. Pumps AZPN-11-28 (L752, L753) or
A10VO45 (L853, L903, L1203) located on front stage of tandem
pump A10VG45 are source of oil pressure.
Oil distribution to individual hydromotors is done by distributors SM 12 (L752, L753), SX 12
(L853, L903) and SX 14 (L1203), that are located on the right side of the frame behind the
accumulator. All hydraulic circuits of working equipment are open.
Interconnection of these circuits on individual machines is similar but some differencies in
make are possible.
1.2.1 Wiring diagrams
3 3
6 6
1
2
P T
B
G
A
X1 X2
B
G
A
X1 X2
5
4 5 4
9
Fig. 26- Block wiring diagram of working equipment L 752
1- Gear pump AZPN-11-28 (L752), 2- Distributor SM12, 3- Hydraulic cylinder of shovel,4- Hydraulic
cylinder of jib, 5- Valve of lifting (throttle), 6- Quick-coupler, 7- Valve of emergency jib lowering, 8-
Suction filter, 9- Oil tank,

15 15
4
16 16
9 8
5 1
2
11 13
3
4
14 14
12 P
1 2 2
3 4
5 6
T
10
Obr. 1-32 Block wiring diagram of working equipment L 753 (EL)
1- Filling gear pump for both stages of A20VG45, 2- Gear pump of WE, 3- Front stage of A20VG45, 4-
Rear stage of A20VG45, 5- Electrohydraulic valve DSH08, 8- Right hydromotor MCR5, 9- Left
hydromotor MCR5, 10- Distributor SM12, 11- Oil filter with vacuum gauge, 12- Oil tank, 13- Valve of
shovel leveling, 14- Hydraulic cylinder of jib lifting, 15- Hyraulic cylinder of speed clamp, 16- Quick
coupler.

3 3
6 6
B
G
A
2
X1 X2
P T
B
G
A
X1 X2
4 4
5 5
9
Fig. 26- Block wiring diagram of working equipment L853, L903
1-Axial pump A10VO45, 2- Distributor SX12, 3- Hydraulic cylinder of shovel, 4- Hydraulic cylinder of
jib, 5- Valve of lifting (throttle), 6- Quick-coupler, 7- Valve of emergency jib lowering, 8- Suction filter,
9- Oil tank.

3 3
6 6
1
10
B
G
A
X1 X2
P T
B
G
A
X1 X2
2
4 5 4
5
7
8
9
Fig. 27- Block wiring diagram of working equipment L1203
1- Axial pump A10VO45, 2- Distributor SX14, 3- Hydraulic cylinder of shovel, 4- Hydraulic cylinder of
jib, 5- Valve of lifting (throttle), 6- Quick-coupler, 7- Valve of emergency jib lowering, 8- Suction filter, 9-
Oil tank,10- Valve of EATON shovel levelling.

3 3
6 6
1
10
B
G
A
5 5
X1 X2 P T
B
G
A
X1 X2
4 11 4
11
7
8
9
Fig. 27a- Block wiring diagram of working equipment Telspeed
1- Axial pump A10VO45, 2- Distributor SX14, 3- Hydraulic cylinder of shovel, 4- Hydraulic cylinder of
jib, 5- Hydraulic cylinder of telescope, 6- Quick-coupler, 7- Valve of emergency jib lowering, 8- Suction
filter, 9- Oil tank,10- Levelling valve EATON, 11- Valve of lifting (throttle).

4
17
7
3
Fig. 28- Hydraulic circuit diagram of working equipment L752 (ELAA)

1- Gear pump AZPN-11-28, 2- Distributor SM 12, 3- Hydraulic cylinders of shovel, 4- Hydraulic
cylinders of jib, 5- Valves of lifting (throttles), 6- Quick-couplers of AA, 7- Valve of emergency jib
lowering, 8- Sieve filter of oil (in tank), 9- Oil tank.

2
3
5
17
10 7
8 11
6 1
9
14 15
13
12 16
Fig. 29a Hydraulic circuit diagram of travel and working equipment L753 (EL)
1- Gear pump AZPN-11-028, 2- Distributor SM12, 3- Shovel levelling valve, 4- Hydraulic cylinders of
the jib, 5- Hydraulic cylinders of the shovel, 6- Pump A20VG45, 7- Right hydromotor MCR5, 8- Pump
A20VG45, 9- Left hydromotor, 10- Electrohydraulical valve DSH 08, 11- Gear feed pump, 12- Oil tank,
13- Oil filter, 14- Oill filter with vacuummeter, 15- Oil cooler, 16- Bypass valve of cooler, 17- Valve of
emergency lowering jib.
4
2
3
18
5
11
7
10
1 12
9
8 6 15 16 17
14
13
Fig. 29b Hydraulic circuit diagram of travel and working equipment L753 (H)
1- Gear pump AZPN-11-028, 2- Distributor SM12, 3- Shovel levelling valve, 4- Hydraulic cylinders of
the jib, 5- Hydraulic cylinders of the shovel, 6- Pump A20VG45, 7- Right hydromotor MCR5, 8- Pump
A20VG45, 9- Left hydromotor, 10- Electrohydraulic valve DSH 08 (seat), 11- Electrohydraulic valve
DSH 08 (brake)12- Gear feed pump, 13- Oil tank, 14- Oil filter, 15- Oill filter with vacuummeter, 16-
Bypass valve of cooler, 17- Oil cooler, 18- Valve of emergency lowering jib.

2 18 MPa
7 4
19 MPa
1
3
8
9
Fig. 29c Hydraulic circuit diagram of working equipment L853, 903 (ELAA)
1- Axial pump A10VO45, 2- Distributor SX 12, 3- Hydraulic cylinders of shovel, 4- Hydraulic cylinders
of jib, 5- Valves of lifting (throttles), 6- Quick-couplers of AA, 7- Valve of emergency jib lowering,
8- Sieve filter of oil (in tank), 9- Oil tank.

6 10
16
MPa
2 17 MPa
4
7
1 3
8
9
Fig. 30- Hydraulic circuit diagram of working equipment L1203

1- Control pump A10VO45, 2- Distributor SX 14, 3- Hydraulic cylinders of quick clamp (shovel),
4- Hydraulic cylinders of jib, 5- Throttling valves of jib, 6- Quick-couplers of AA, 7- Ball valve of
emergency jib lowering, 8- Sieve filter of oil (in tank), 9- Oil tank with gauge, 10- Levelling valve
EATON.

8 9
16
MPa
5
2 17 Mpa
4
7
3
1
11
10
Fig. 30a- Hydraulic circuit diagram of working equipment L1203 Telspeed

1- Control pump A10VO45, 2- Distributor SX 14, 3- Hydraulic cylinders of quick clamp (shovel),
4- Hydraulic cylinders of jib, 5- Hydraulic cylinders of telescope, 6- Throttling valves of jib, 7- Ball valve
of emergency jib lowering, 8- Quick-couplers of AA, 9- Levelling valve EATON, 10- Oil tank with
gauge, 11- Sieve filter of oil (in tank),
1.2.1.1. Quick couplers
L 752, L853, L903 : NV34 GAS F,M – 2FFN34 GAS F,M *

Drainage couplers: NV14 GAS F,M – 2FFI14 GAS F,M *
L 1203: NV1 GAS F,M – 2FFN34-1 GAS F,M *

Drainage couplers: NV14 GAS F,M – 2FFI14 GAS F,M *
Change from 15.03.2007

1.2.2 Other elements of hydraulic circuit of working equipment
1.2.2.1 LOCUST 752
The L752 circuit consists of: Suction filter built in the tank (fig. 31), gear pump AZPN-11-28
(fig. 32), 3-section distributor SM12 with open center (fig. 33, 35), hydraulic cylinders (linear
hydromotors), valves, hoses, pipelines.
Levelling of shovel to jib: Mechanical, both-sided
Fig. 31- Suction filter Fig. 32- Gear pump AZPN-11-28 (L752)
AZPN-11-28 is a standard constant gear pump driven from the front stage of the tandem.
Together with distributor SM12 and hydraulic cylinders it works in an open hydraulic circuit.
Hydraulic distributor SM12 with electrohydraulic control differs from the original one by
modified section of auxiliary attachment with intake of control pressure from the ROX valve.
Primary safety valve on the input is set to pressure of 16.5 ± 0.5 MPa. A secondary safety
valve set to pressure of 18.5 MPa is connected into a section circuit of hydraulic cylinders of
quick clamp (shovel). Another (anticavity) valve is connected in the opposite side.
2 3
A B
4
Fig. 33- Distributor SM 12 with electrohydraulic control of AA section
1- Primary safety valve, 2- Secondary safety valve, 3- Purge (anticavity) valve
4- Return (one-way), A, B- Electrohydraulic valves of AA control

Safety valves 1 and 2 (fig. 33) are identical and mutually exchangeable (valid for distributor
SM12 only). Take care of pressure value, the secondary valve is always set to a higher value
than the primary one.
Fig. 34- Valves

S- Secondary safety valve, A- Purge valve, d- O-ring 21.95 x 1.78, e- Supporting ring,
f- O-ring 14 x 1.78,
WARNING
Never exchange positions of the secondary and purge valves when dismantling
them off the distributor.
Inner relationships in the working section of the distributor with open center are shown in fig.
35.
S S
Fig. 35- Distributor SM 12 with mechanical slider control

1- Section body, 3- Return spring, 7- Return valve, 8- Slider, , A- Outlet to hydromotor (cylinder),
B- Outlet to hydromotor (cylinder), P- Pressure channel, S- Secondary safety valve / purge valve,
T- Waste channel.

Hydraulic cylinders (linear hydromotors), connected in pairs, perform actual movement of
working equipment by extending and contracting their pistons. Structure and dimensions of a
hydraulic cylinder (taken from spare parts catalogue of L752):
5 4
2 9
15
6
10
6
16
17
11
12
13 12
12
1
14 18
Fig. 36- Hydraulic cylinder - details

1- Bearing, 2- Bolt, 3- O-ring 55X3, 4- O-ring 25X2, 5- Sealing ring, 6- Wire, 7-Hydraulic cylinder,
8- Cylinder with cover, 9- Piston, 10- Nut, 11- Cuff, 12- Guiding ring 36X39X5.6, 13 – Front cover,
14- Piston rod with bearing, 15- Cuff L43, 16- Nut of cover, 17- Sealing ring, 18- Piston rod with
bearing.
In case of inner leakage of one valve of a pair controlling the jib of shovel, an unwanted
behaviour occurs – falling of lifted jib or opening of shovel even if engine is stopped. There is
no outer leakage of oil, therefore it’s not easy to find out which valve of the pair is faulty.
A knowledge that temperature of faulty valve is significantly higher can help when doing
a dismantlingless diagnostics.
Machine Quick clamp (shovel) Jib
LOCUST 752 HV 63-36-500 HV 63-36-630

1.2.2.2 LOCUST 853, 903
Circuit of L853, L903 consists of: Suction filter (fig. 31) built in the tank – axial pump
A10VO45 – three section distributor SX12 with LS signal – hydraulic cylinders, valves,
hoses, pipelines.
Levelling of shovel to jib: Hydraulic, both-sided, electronically controlled.
Fig. 37- Axial pump A10VO45 (L853, L903, L1203)

1- Location of max. oil supply regulation
A10VO45 is an axial piston control pump driven from the front stage of the tandem.
Two valves are located on the body of the pump: one for flow rate control, another one for
pressure control and mechanical stop of swinging plate inclination of pump volume setting.
Fig. 38- Axial pump A10VO and valves

1- Flow rate regulator (2.0 MPa), 2- Pressure regulator (19 MPa)

Flow rate regulator is connected by means of a hose to the distributor and it reacts on a
pressure rate on outlet of working section to hydraulic cylinders. Inclination of control plate is
changed accordingly what changes oil amount to distributor.
Pressure regulator acts as a safety valve. If a preset value of pressure (19 MPa) is
exceeded then the regulator opens and returns the control plate of the pump to the zero
position.
Axial pump A10V045 has no own filling pump. Oil is led from a tank through a suction filter
located in its lower part into an inlet section of distributor SX12 (L853, L903) or SX14
(L1203).
Fig. 39- Location of pump A10VO45 on L853, L903, L1203
Hydraulic distributor SX12 with electrohydraulic control of AA section is connected into an

open hydraulic circuit.
Fig. 40- Distributor SX12 (L853, L903)

1- Primary safety valve, 2- Secondary safety valve, 3- Purge (anticavity) valve, 4- Valve of LS
signal with filter (diaphragm, sieve), A, B – Electrohydraulic valves of AA control.

Inner relationships in working section of distributor SX12 with LS signal are shown in fig. 41.
1 5 4
3
6
LS
T
P
Fig. 41- Distributor SX12 with mechanical slider control (L853, L903)
1- Body, 2- Slider, 3- Secondary safety valve, 4- Purge (return) valve, 5- Pressure compensator,
6- Plug, LS- Feedback, P-Pressure channel, T- Waste channel.
Brief description of feedback and impact of LS signal:

When the engine is running, pump A10VO45 produces pressure controlled by valve 1 (fig.
38) to value 2.0 MPa. This pressure inputs channel „P“ and at the same time it’s led to
servocylinder controlling the swinging plate of the pump. If slider 2 (fig. 41) is in neutral
position then swinging plate of the pump returns to position of minimal oil supply. After slider
2 (fig. 41) is set to another position than neutral then pressure from channel „P“ arrives
through compensator 5 (fig. 41) to channel „LS“ and to valve 1 (fig. 38) from the opposite
side. Counterpressure empties the servocylinder and swinging plate of the pump sets to
working position.
Purpose of the LS signal valve with sieve 4 (fig. 40) is to release pressure in the LS branch
after the slider of working section is returned to its neutral position.
If no part of working equipment works and primary safety valve on the distributor is working,
check (clean) valve 2, fig. 38.
If all functions work slowly, check (clean) valve 1, fig. 38.
Hydraulic cylinders of the same construction as those in fig. 28 have the following
parameters:
Machine Quick clamper (shovel) Jib
LOCUST 853 HV 70-40-550 HV 63-36-800

LOCUST 903 HV 70-40-550 HV 63-36-800

1.2.2.3 LOCUST 1203
Circuit of L1203 consists of: Suction filter (fig. 31) built in the tank – axial pump A10VO45
(fig. 37, 38) – three section distributor SX14 with LS signal (fig. 42, 43) – hydraulic cylinders,
valves, hoses, pipelines.
Levelling of shovel to jib: Hydraulic, both-sided.
In difference to L853, L903, levelling of shovel to jib is done by means of double self-
balancing valve EATON.
Fig. 42- Distributor SX14 (L1203)

1- Primary safety valve, 2- Secondary safety valve, 3- Secondary safety valve,
4- Control module, 5- Valve of LS signal with filter (diaphragm, sieve), 6- Connector
Distributor SX14 is connected into an open hydraulic circuit. It is controlled hydraulically

by means of control pressure from controllers. Section of auxiliary attachment is controlled
electrohydraulically.
Fig. 43- Distributor SX14 (L1203)

1- Secondary safety valve, 2- Secondary safety valve, 3- Slider, 4- Pressure compensator,
5- Control module, 6- Return spring,

Hydraulic cylinders, as for other types, are connected in pairs. Throttling valves are
connected to the outlet of oil under cylinder pistons of jib lifting to slow down its lowering.
Machine Quick clamper (shovel) Jib Telescope

LOCUST 1203 HV 80-45-500 HV 80-45-800 -
L 1203 Telspeed HV 80-45-500 HV 80-45-800 PH 40-25-1000
Valve of emergency jib lowering
The valve (fig. 44) is reachable after opening of the rear cover. It enables lowering of a lifted
jib to its basic position in case of hydraulics or engine failure.
Fig. 44- Valve of emergency jib lowering (L1203)
If a failure occurs when only the jib lifting doesn’t work, it’s important to check if this valve is
not opened.
Levelling valve EATON
It is a double self-levelling valve that serves for levelling of shovel position in regard to the jib
in both directions and in the whole working range.
Fig. 44- Location of valve EATON on a machine

Levelling valve „Eaton“ is used on machine L1203 only.
Jib cylinder
Distributor
Shovel cylinder
Fig. 45- Levelling valve EATON – connection (L1203)
Brief description of the valve operation:
If the slider of the working section of shovel is in neutral position and slider of the jib section
is in position for lifting, then oil from distributor inputs channel „B“ of the „Eaton“ valve and
outputs through channel „A“ under the piston of lifting cylinder. Oil from the opposite side of
the lifting cylinder is directed to channel „C“ of the „Eaton“ valve where it is divided by
a throttling diaphragm. Flow division ratio is given by size of the throttling diaphragm. Part of
oil is led through channel „E“ under the pistons of shovel cylinders, rest of oil returns through
channel „D“ back to distributor. Shovel cylinder piston extends when pressure in channel
„E“ opens a relieving slider so that a flow from channel „F“ to channel „D“ and back to
distributor is possible.

1.2.3 Check and adjustment of working pressure
Oil pressure produced by a pump of a working equipment is an energy form that is

transformed into a mechanical work – linear movement of a piston inside of
hydraulic cylinders. Should the pressure be insufficient for any reason then the
machine performance decreases or there’s no work at all.
In such a case outer symptoms of a failure are important, e. g. no part of AA is working, only
a jib doesn’t work, a shovel doesn’t work in ine direction only etc. According to these
symptoms a suitable diagnosis and repair sequence can be figured out. If your diagnosis
steps led up to check of the control pressure, then proceed as follows:
● Tilt the cabin and lock it opened while the engine is stopped.
● Unscrew the connection plug of the inflow pipeline before the distributor (fig. 46 – L752,
fig. 47 – L1203), or on the distributor (fig. 48 – L853, L903) and connect there a hose
together with necks and a manometer (0 - 25 MPa).
● Start the engine and perform any working function to its end (limit) position (jib, shovel,
AA). Keep the joystick in the end position and read the pressure value on the manometer.
(The correct value is 16 ± 0.5 MPa for L752, L1203 and 18 ± 0.5 MPa for L853, L903).
● If the pressure is not correct, adjust it using the control screw after the safety nut is loosen.
A B
Fig. 46- Distributor SM12 ( L752)

A- Location of manometer connection, B- Primary safety valve.
Pollution or other problem (broken sealing ring) of a safety valve are the most frequent
causes of a failure (pressure loss) in the working equipment circuit. If a failure is related to
the primary safety valve then all functions are affected in the same way.
WARNING
If the safety valve is working and the pressure still cannot be adjusted (pressure is low
and manometer doesn’t respond to the control screw tigheting) then the pump is the most
likely source of a problem.

For machines with LS signal (L853, 903, 1203), a pressure (1,9 MPa) rises in the branch
between the pump and distributor after the engine is started. It can be read on a connection
adapter for measurement of working pressure (fig. 46).
Fig. 46- Measure point of working Fig. 46a- Measure point of working pressure
pressure of AA for L853, of AA for L 903
(Distributor SM12 Type) (Distributor SX12 Type)
Measure point of working pressure of AA serves also for check of secondary valves. When
doing it, keep in mind that the secondary valves are connected after the primary valve of the
distributor, therefore it’s necessary to change pressure of the primary valve to a higher value
than pressure of the secondary valve is.
Fig. 47- Measure point of working pressure of AA for L1203

Secondary safety valve:

● Leave a manometer connected in the same location when checking adjustment of the
secondary safety valve.
● Increase pressure on the primary valve to 18 MPa – L752, L1203

or 20 MPa – L853, L903.
● Tilt quick clamper to its end position, keep it there and read pressure value on the
manometer. (Correct value is 17 MPa – L752, L1203 and 19 MPa – L853,L903).
● Return pressure on the primary valve to the normal value after check or adjustment
(16 ± 0.5 MPa for L 752, L1203 and 18 ± 0.5 MPa for L853, L903).
● Secure control screws with safety nuts and replace all broken seals.
● If you don’t want to break seal of the primary valve, unscrew both valves (primary and
secondary one) and exchange them one for the other. Then proceed as for
measurement of the primary valve pressure but without tilting of the quick clamper.
(Valid for distributors SM12 – L752, 753, 853 only.)

1.2.4 Possible malfunctions in hydraulic circuit:
A/ Symptom: No function works or working equipment performance

is insufficient when the engine is running
Performance loss No work at all
Check of working
Valve OK
pressure and valve Check of control
pressure and valve
(no) Pressure OK
(yes) (yes)
(no)
Clean, adjust pressure

(replace valve)
No change after Failure of pump

adjustment (replacement) of working equipment
Change after adjustment Failure

(replacement) of safety valve

B/ Symptom: Excavator doesn’t work when connected

to machine and hydraulics
No work at all Slow work
Is pull switch Other functions slow

Is right AA pedal yes pulled out in the as well?
pressed and locked?
left column?
yes
no
no no
Press & Pull out

lock Check valve of LS
signal on the pump
Is electric switch under Is lock button Check AA section slider on

the pedal working? pressed on the right the distributor
controller?
yes
yes
no
no
Press
Are other functions
working?
Repair, replace
yes
Check safety valve on

the excavator distributor

1.3 Hydraulic circuits of travel:……………….…………….2.5 (2.8) - 35 MPa

Two independent hydraulic circuits serve for travel of each machine,
that means each side is driven and controlled independently from
the other one. One section of tandem pump A10VG45 is source of
pressure energy of oil for each circuit. The front section (in travel
direction) serves for driving of the right side, the rear section for
driving of the left side.
Working pressure of the travel for each travel direction is set on safety valves (pos. 1, fig.
52) of the control pump and it can be measured in pos. P1, P2 (fig. 57).
1.3.1 Wiring diagrams:
Fig. 48- Block diagram of travel connection for L752, L853, L903, L1203
1- Front stage of pump A10VG45, 2- Rear stage of pump A10VG45, 3- Electrohydraulic valve ROX
(seat), 4- Electrohydraulic valve ROX (left pedal, switch „P“), 5- Right hydromotor, 6- Left hydromotor,
7- Oil filter, 8- Oil cooler, 9- Bypass valve, 10- Oil tank.

Connection of travel for machines Speed+ differs in valve 11 (fig. 49) that shifts slider in
hydromotor by means of control pressure. In such a case less pistons work and rotor moves
faster for the same amount of oil. However the torque is decreased in about a half.
Fig. 49- Block diagram of travel connection for L853 Speed+, L903 Speed+, L1203 Speed+,
L1203 Telspeed
1- Front stage of pump A10VG45, 2- Rear stage of pump A10VG45, 3- Electrohydraulic valve ROX
(seat), 4- Electrohydraulic valve ROX (left pedal, switch „P“) 5- Right hydromotor, 6- Left hydromotor,
7- Oil filter, 8- Oil cooler, 9- Bypass valve, 10- Oil tank, 11- Electrohydraulic valve (2nd gear)

Hydraulic circuits of travel are closed. Used aggregates (axial control pumps A10VG45 and
radial hydromotors MCR5) by Bosch-Rexroth are used on all types of machines.
8
8
Fig. 50- Hydraulic circuit of travel (L853, L903, L1203)

1- Front stage of control pump A10VG45 of right side drive, 2- Rear stage of control pump A10VG45
of left side drive, 3- Right hydromotor MCR 5 with disc brake, 4- Left hydromotor MCR 5,
5, 6- Electrohydraulic valve, 7- Oil cooler, 8- Oil filter with vacuum manometer, 9- Oil tank with gauge,
10- Bypass valve of hydraulics cooler.
Gearing of the 2nd gear is done electrohydraulically by means of control pressure and valve
11 (fig. 51).
Fig. 51- Hydraulic circuit of travel with 2nd gear possibility (Speed+)
1- Front stage of control pump A10VG45 of right side drive, 2- Rear stage of control pump A10VG45
of left side drive, 3- Right 2-speed hydromotor MCR 5 with disc brake, 4- Left 2-speed hydromotor
MCR 5, 5, 6- Electrohydraulic valve, 7- Oil cooler, 8- Oil filter with vacuum manometer, 9- Oil tank with
gauge, 10- Bypass valve of hydraulics cooler, 11- Electrohydraulic valve of gearing.

1.3.2 Control pump A10VG45
Maximum cleanliness of hydraulic oil for the whole machine lifetime is the basic condition for
failure-free operation of control pumps and the whole hydraulic system.
Even small impurities can cause severe damage to control pumps taking their construction
into account.
1
9 6 7 5 4
Fig. 52- Control pump A10VG45 (L752, L853, L903, L1203)

1- Safety valve 35 MPa (1st direction travel), 2- Safety valve 35 MPa (2nd direction travel),
3- Short circuit valve, 4- Filling gear pump, 5- Valve block, 6- Tilting plate, 7- Rotary group, 8- Shaft
sealing, 9- Servo-cylinder piston,
Tilting plate 6 (fig. 52) is mechanically connected to the piston of servo-cylinder 9, that tilts it
from its neutral position. Direction of plate tilting corresponds to direction of oil flow and
thus the hydromotor rotation direction as well. Size of tilting angle of the plate corresponds
to oil amount from the pump and thus the hydromotor rotation speed as well. The servo-
cylinder is controlled by direct inflow of control pressure from a controller (for the LOCUST
machines) to one or the other side of its piston.
So called short circuit valve 3 (if connected) reads current working pressure in the circuit and
if its preset value is exceeded then it connects the active space of the servo-cylinder to the
tank what returns the tilting plate to its neutral position.

The working pressure for each side and travel direction is set on an individual valve 1 (fig.
52) whose construction enables its use for two work modes (fig. 53):
- Return valve mode, meaning filling of low pressure branch of the control pump. Valve cup
2 (together with pos. 3, 4, 5, 7) moves against the spring 6 when filling.
- Safety valve mode, when the working pressure impacts the valve cone 3 against the
spring 5.
Fig. 53- Safety valve of working pressure of travel / Return valve
1- Valve body, 2- Valve cup, 3- Valve shaft with cone, 4- Control screw, 5- Press spring, 6- Return
valve spring, 7- Safety piece, 9- O-ring 23.47 X 2.62-S-NBR90,
10- Oporný krúžok 20,1X25 X1,4
Pressure control is done by change of spring 5 tension by means of control screw 4, after the
safety piece 7 is loosen.
Check condition of sealing ring 9 during each dismantling of the safety valve. Replace
a broken ring with a new one.
Valve body 1 should be tightened to torque of 160 Nm.
All four safety valves on each machine are the same and mutually interchangeable.

1.3.3 Hydromotor MCR5

A one-speed or two-speed hydromotor can be used according to the machine type.
Fig. 54- Section view of two-speed hydromotor

1- Valve block, 2- Cylinder, 3- Piston, 4- Crank, 5- Rear box, 6- Spring, 7- Seepage channel, 8- Pin,
9- Cover, 10- Brake shaft, 11- Ring 213x2.51 , 12- Safety ring 50, 13- Piston ring Ø 107.125, 14- Nut
M8x40, 15- Piston ring Ø98.725, 16- Cover, 17- Piston ring Ø 97.725, 18- Piston ring Ø 96.725,
19- Piston ring Ø 87.25, 20- Stop, 21- Cover, A, B- Input-output at 1st speed,C, D- Input-output at 2nd
speed.
Hydromotor MCR (hydro base is the basic part of a hydromotor without an output shaft)
works by means of piston movement on a crank. Oil (pressure) is led through channel „A“ to
underneath of piston 3 in the moment when it locates right after the crank peak. Oil pressure
causes the piston to move to the lowest point of the crank where channel „A“ is closing for
the active piston and channel „B“ is opening for draining. Contact of piston with the crank is
by means of cylinder 2. There are 8 pistons placed in the rotor.

Position of rotor and crank:
Fig. 55- Rotor of hydromotor MCR5 with pistons

1- Shaft, 2- Piston, 3- Cylinder, 4- Crank,
Disc brake of hydromotor is controlled by inflow of control pressure „G“ from the fronst stage
of pump A10VG45 through electrohydraulic valve ROX.
Fig. 56- Section view of disc brake of one-speed hydromotor

1- Ring 107.67x1.68, 2-Piston sealing, 3- Flat spring, 4 – Plug M24, 5- Outer lamella, 6- Inner lamella /
Screw, 7- Piston sealing, 8- Piston, 9- Nut M6x16, G- Control pressure,
Construction of one-speed hydromotor brake enables its mechanical unbraking by

unscrewing of plug 4. Nut M12x1.5 can be screwed into the threaded piston opening with use
of a suitable washer what fastens piston against the spring, pos. 3, to the rear cover and
lamellas can be freed. Other hydromotors that are not equipped with this opening can be
unbraked by loosening of nuts pos. 9 (12 pcs.) on the rear cover circumference.

1.3.4 Check and adjustment of pressure
♦ Lift the jib, support and secure it with a safety bracket.

♦ Stop the engine.
♦ Unlock the cabin, tilt it forwards and lock it in this position.
♦ Mount a hose with necks and manometer (0 – 40 MPa) in place of plug P1
of the front stage of control pump.
♦ Start the engine. (Pull the pull rod of hydraulics blocking in the left control column to
enable engine start when the cabin is tilted.) Set engine revolutions acccording to a load
you‘re about to reach.
♦ Switch on the park brake switch on the control panel.
♦ Move the right joystick of travel control forwards and read the pressure value on the
manometer. The pressure increases up to 35 MPa when hydromotors are braked.
Check the safety valve (fig. 53) if the pressure doesn’t reach specified value and adjust it if
necessary. Safety valves are mutually exchangeable on both stages what can help to identify
a malfunction quickly.
The same procedure can be used to measure or adjust working pressure in hydraulic circuits
of travels of all machine types for each side and travel direction individually.
The following applies (fig. 57):
Front stage: P1 = pressure of right side travel forwards,

P2 = pressure of right side travel backwards.
Rear stage: P1 = pressure of left side travel forwards,
P2 = pressure of left side travel backwards.
Detailed information on control pumps can be found in the „Rexroth“ manual.
Fig. 57- Measurement points of working pressure of travel

A- Safety valve of working pressure of travel (detail on fig. 53)

1.3.4.1 Directness of travel
Should the machine visibly direct to the left or right when both joysticks are equally tilted (to
the maximum), check pressure in tyres first. If the pressure is equal and according to
specifications, then check working pressure of relevant valves for the problematic travel
direction (on front and rear stages of control pump A10VG45). If this pressure is equal as
well, then correct mechanical stops of servo cylinders.
Fig. 58- Regulation point of servo cylinder stops for machine turning
1- Hex key 4, 2- Box end wrench 13.
The servo cylinder body of control pump is marked with marks X1 and X2 for each side
(travel direction) on its top part. Maximum tilt of regulating plate for travel forwards and
backwards can be set with mechanical stops. (Screwing in of the stop decreases tilting range
of the plate, screwing out increases it.)
Access to stop bolts is protected with leaden seals that cannot by removed without damaging
them. After loosening of safety nut do as follows: (basic pattern for L752)
Travel forwards, yaws to the right:

● rear stage of pump (in forward travel direction) – screw-in stop on side X1
Travel forwards, yaws to the left:
● front stage of pump – screw-in stop on side X2
Travel backwards, yaws to the right:
● rear stage of pump – screw-in stop on side X2
Travel backwards, yaws to the left:
● front stage of pump – screw-in stop on side X1
This is only valid if pumps and hydromotors are correctly interconnected. That means that
top output of pump leads to top input of hydromotor and bottom output of pump leads to
bottom input of hydromotor.

Then also:
X1 on servo cylinder = output from pump B (top)

X2 on servo cylinder = output from pump A (bottom)
Location of individual outputs is shown on fig. 59.
X2
X1
R
Fig. 59- Marking of pump outputs
R- Regulation point protected with leaden seal
Lock the position of stop bolt by tightening of safety nut after it was adjusted.
Always use new leaden seals after the travel directness was adjusted.
Spare leaden seals, distinguishable by color from the original ones, can be ordered from the
machine producer.

1.3.5 Possible malfunctions in hydraulic circuit
A/ Symptom: A function of travel doesn’t work correctly (one side)
Doesn’t work at all Insufficient output in Doesn’t work in one direction

one direction
Control pressure check

Check of safety valve of
working pressure
Pressure OK (yes)
Mutual exchange Failure of safety valve of

of valves working pressure
(no)
Change
Check of safety valve (yes)
of intake pump
No change
Valve OK
Hydromotor failure Controller failure
(no)
(yes) Intake pump

Clean, adjust (replace) failure

B/ Symptom: A function of travel doesn’t work correctly (both sides)
Machine yaws to one side Insufficient travel output
Tyre pressure check Underpressure check

on vacuum meter
Pressure OK (no) One side is underpressured High underpressure
(yes) Underpressure OK
Adjust servo cylinder stops Replace filter element

(fig. 12)
See chap. 1.1.3 Check and adjustment

of control pressure
Hydraulic circuits of travel (right and left sides) are identical so connection and possible
malfunctions are the same.
Control pressure output from the front stage is the only difference.
WARNING!
Measurement and adjustment of pressure on safety valves during the warranty period can
only be done by service attendants or personnel trained by the producer.

2. Electric wiring
2. Electric wiring
Electric and electronic systems, whether we like it or not, interfere with our lives more and
more and the Locust loaders are no exception to it.
Building machines usually use electromagnetic coils together with hydraulic sliders, so called
“electrohydraulic valves”. Therefore it’s necessary to identify reasons of malfunction of any
system function separately for its electric and hydraulic parts.
A lead accumulator 12 V / 50 Ah is the primary source of electric energy of the machine.
The energy from the accumulator is actually used for combustion engine starting only. So the
secondary source of electric energy - alternator - is activated.
The negative (-) terminal is grounded by means of the main switch located close to the
accumulator (on the right side) on all machines.
Distribution to individual appliances is provided by distinctive conductors or cable bundle.
Individual electric circuits are protected from overload by fuses located in a fuse box of the
control panel. In case of failure of any function it’s recommended to first check a fuse of the
relevant circuit and eventually replace it.
Arrangement of control units (switches, relays, electromagnetic valves, appliances) and their
interconnection is shown on diagrams that are part of „Operator’s manual“ of each machine
type.
Location of the fuse box is the same for all machine types.
Fig. 59-Location of fuse box on control panel
Purpose of individual fuses (fig. 59):
1- (15A) Disconnector of direction lights, cabin ceiling light, service lamp plug
2- (15A) Warning lamps of fuel level, engine lubrication, accumulator charging, beacon, EH
counter, fuel gauge, thermometer (engine cooling liquid, hydraulic oil)
3- (15A) Switch of seat, inlet to all relays
4- (15A) Sprayer engine, horn
5- (15A) Park brake switch, engine of heating
6- (25A) Front lights, rear lights

2. Electric wiring
2.1 Wiring diagrams

Connection of frame and cabin is shown separately for each machine.
Fig. 60a- Wiring diagram of frame of L752 (ELAA)
M1 – starter, S1 – accumulator disconnector, S2 – engine lubrication warning lamp switch, B2 – float

device of fuel warning lamp, B3 – hydraulic oil temperature sensor, B4 – cooling liquid temperature
sensor, E1 - ESD 1 electronics, Re – relay of engine heating, X1 – outer outlet plug, X3-4 – cabin
disconnection plugs, X5 – disconnection plug for relay of heating, X6 – fuel pump disconnection plug,
X10-11 – mudguard disconnection plug, X12 – fuel gauge disconnection plug, H11 – horn, G1 –
accumulator, G2 – alternator, L3 – working light, L4 – left front group light, L5 – right front group light,
L6 – rear group light, K7 – electrohydraulic valve of brake, K8 – electrohydraulic valve of hydr.
blocking, K9 – engine stop coil, K10 – fuel pump, K12 – left valve of AA, K13 – right valve of AA, Y1 –
engine heating.

2. Electric wiring
Fig. 60b- Wiring diagram of frame of L752 (ELAA-MF)
M1 – starter, S1 - accumulator disconnector, S2 - engine lubrication warning lamp switch, B2 - float

device of fuel warning lamp, B3 - hydraulic oil temperature sensor, B4 - cooling liquid temperature
sensor, E1 - ESD 1 electronics, Re - relay of engine heating, X1 - outer outlet plug, X3-4 - cabin
disconnection plugs, X6 - fuel pump disconnection plug, X10-11 - mudguard disconnection plugs, X12
- fuel gauge disconnection plug, H11 – horn, G1 – accumulator, G2 – alternator, L3 - working light, L4
- left front group ligh, L5 - right front group light, L6 - rear group light, K7 - electrohydraulic valve of
brake, K8 - electrohydraulic valve of hydr. blocking, K9 - engine stop coil, K10 - fuel pump, K12 - left
valve of AA, K13 - right valve of AA, Y1 - engine heating.

2. Electric wiring
Fig. 61a- Wiring diagram of cabin of L752 (ELAA)
H1 – charging indicator, H2 – engine lubrication warning lamp, H3 – direction indicator lights indicator,
H4 – parking brake indicator, H5 – front lights indicator, H6 – rear working light indicator, H7 – beacon
indicator, H8 – engine heating indicator, H9 – fuel margin warning lamp, H10 – warning lights
indicator, H11 – horn, H16 – hydraulics blocking warning lamp, H17 – AA locking warning lamp, K1 –
hydraulics blocking relay, K2 – engine (seat) start blocking relay, K3 – engine (heating) start blocking
relay, K4 – stop coil blocking relay, K5 – stop coil engagement relay, K6 – direction lights
disconnector, K8, 9 – AA locking relay, L1 – right front light, L2 – left front light, L9 – cabin ceiling
light, L10 – instruments illumination, P – proportional AA controller, P1 – engine hours counter, P2 –
cooling liquid thermometer, P3 – hydraulic oil thermometer, P4 – fuel gauge, S3- switch box, S4 –
windscreen wiper switch, S5 – beacon switch, S6 – heating switch, S7 – sidelights and front lights
switch, S8 – rear working light switch, S9 – warning lights switch, S12 – parking brake switch, S13 –
left direction indicator lights switch, S14 – sprayer button, S15 – horn button, S16 – auxiliary
attachment switch, S17 – seat switch, S18 – parking brake switch, S20 – AA locking switch, S21 –
right direction indicator lights switch, E1 – electronic switch of locking, F1-6 – fuse box, X1 –
inspection lamp plug, X2 – magnetic beacon plug, X3-4 – cabin disconnection plugs, X7-8 –
controllers disconnection plugs, X9 – seat disconnection plug, X11 - E1 locking disconnection plug, D1
- diode, D2 - diode, M2 – engine of heating, M3 – engine of sprayer, M4 – engine of wiper.

2. Electric wiring
25 A
15 A
15 A
15 A
15 A
15 A
Fig. 61b- Wiring diagram of cabin of L752 (ELAA-MF)
H1 - charging indicator, H2 - engine lubrication warning lamp, H3 - direction indicator lights indicator,
H4 - parking brake indicator, H5 - front lights indicator, H6 - rear working light indicator, H7 - beacon
indicator, H8 - engine heating indicator, H9 - fuel margin warning lamp, H10 - warning lights indicator,
H11 - horn, H16 - hydraulics blocking warning lamp, H17 - AA locking warning lamp, K1 - hydraulics
blocking relay, K2 - engine (seat) start blocking relay, K4 - stop coil blocking relay, K5 - stop coil
engagement relay, K6 - direction lights disconnector, K9 - AA locking relay, L1 - right front light, L2 -
left front light, L9 - cabin ceiling light, L10 - instruments illumination, P - proportional AA controller, P1 -
engine hours counter, P2 - cooling liquid thermometer, P3 - hydraulic oil thermometer, P4 - fuel gauge,
S3- switch box, S4 - windscreen wiper switch, S5 - beacon switch, S6 - heating switch, S7 - sidelights
and front lights switch, S8 - rear working light switch, S9 - warning lights switch, S12 - parking brake
switch, S13 - left direction indicator lights switch, S14 – sprayer button, S15 – horn button, S16 -
auxiliary attachment switch, S17 - seat switch, S18 - parking brake switch, S20 - AA locking switch,
S21 - right direction indicator lights switch, MF – multipurpose electronic switch, F1-6 - fuse box, X1 -
inspection lamp plug, X2 - magnetic beacon plug, X3-4 - cabin disconnection plugs, X7-8 - controllers
disconnection plugs, X9 - seat disconnection plug, X11 – MF disconnection plug, D1 - diode, D2 -
diode, M2 - engine of heating, M3 - engine of sprayer, M4 - engine of wiper.

2. Electric wiring
Fig. 62a- Wiring diagram of frame of L853, L903 Speed+ (ELAA)
M1 – starter, S1 - accumulator disconnector, S2 - engine lubrication warning lamp switch, S3 – cooler

switch, S4- backward travel alarm switch, S5- backward travel alarm switch, B1 - float device of
hydraulic oil warning lamp, B2 - float device of fuel warning lamp, B3 - hydraulic oil temperature
sensor, B4 - cooling liquid temperature sensor, E1 - ESD 1 electronics, X1 - outer outlet plug,
X2- ½ speed electronics disconnection plug, X3-4 - cabin disconnection plugs, X5- disconnection plug
for relay of heating, X10-11 - mudguard disconnection plugs, X12 - fuel gauge disconnection plug,
IS1 – control of levelling 1, I1 – inductive sensor of upward levelling, I2 – inductive sensor of
downward levelling, H21 – backward travel horn, H11 – horn, G1 – accumulator, G2 – alternator,
L3 - working light, L4 - left front group light, L5 - right front group light, L6 - rear group light,
K7 - electrohydraulic valve of brake, K8 - electrohydraulic valve of hydraulics blocking, K9 - engine
stop coil, K10- electrohydraulic valve of ½ speed, K11 - fuel pump, K15 – electrohydraulic valve of
upward shovel levelling, K16 – electrohydraulic valve of downward shovel levelling, Y1 – engine
heating, E2 - ½ speed electronics.

2. Electric wiring
Fig. 62b- Wiring diagram of frame of L853, L903 Speed+ (ELAA-MF)
M1 - starter, S1 - accumulator disconnector, S2 - engine lubrication warning lamp switch, , S3 - cooler

switch, S4 - backward travel alarm switch, S5 - backward travel alarm switch, B1 - float device of
hydraulic oil warning lamp, B2 - float device of fuel warning lamp, B3 - hydraulic oil temperature
sensor, B4 - cooling liquid temperature sensor, E1 - ESD 1 electronics, X1 - outer outlet plug,
X3-4 - cabin disconnection plugs, X6 – fuel pump disconnection plug, X10-11 - mudguard disconnection
plugs, X12 - fuel gauge disconnection plug, X13 – levelling disconnection plug, IS1 - control of
levelling 1, I1 - inductive sensor of upward levelling, I2 - inductive sensor of downward levelling,
H21 - backward travel horn, H11 - horn, G1 - accumulator, G2 - alternator, L3 - working light, L4 - left
front group light, L5 - right front group light, L6 - rear group light, L8 – auxiliary working light,
K7 - electrohydraulic valve of brake, K8 - electrohydraulic valve of hydraulics blocking, K9 - engine
stop coil, K10 - fuel pump, K11 - electrohydraulic valve of ½ speed, K12 – left AA valve, K13 – right AA
valve, K15 - electrohydraulic valve of upward shovel levelling, K16 - electrohydraulic valve of
downward shovel levelling, Y1 - engine heating, Re - engine heating relay.

2. Electric wiring
Fig. 63a- Wiring diagram of cabin of L853, L903 Speed+ (ELAA)

H11 - horn, H12 – 1st speed indicator, H13 – 2nd speed indicator, H15 – oil margin warning lamp,
H16 - hydraulics blocking warning lamp, H17 - AA locking warning lamp, H18 – levelling warning lamp,
K1 - hydraulics blocking relay, K2 - engine (seat) start blocking relay, K3 - engine (heating) start
blocking relay, K4 - stop coil blocking relay, K5 - stop coil engagement relay, K6 - direction lights
disconnector, K7 - ½ speed switching relay, K 8 – shovel levelling relay, K 9,10 - AA locking relay,
L1 - right front light, L2 - left front light, L9 - cabin ceiling light, L10 – instruments illumination,
P - proportional AA controller, P1 - engine hours counter, P2 - cooling liquid thermometer, P3 -
hydraulic oil thermometer, P4 - fuel gauge, S3 - switch box, S4 - windscreen wiper switch, S5 - beacon
switch, S6 - heating switch, S7 - sidelights and front lights switch, S8 - rear working light switch,
S9 - warning lights switch, S12 - parking brake switch, S13 - direction indicator lights switch,
S14 - sprayer button, S15 - horn button, S16 - auxiliary attachment switch, S17 - seat switch, S18 -
parking brake switch, S19- ½ speed switching switch, S20- shovel levelling switch, F1-6 - fuse box,
X1 - inspection lamp plug, X2 - magnetic beacon plug, X3-4 - cabin disconnection plugs,
X7-8 - controllers disconnection plugs, X9 - seat disconnection plug, X10 - E2 ½ speed disconnection
plug, X11 – levelling disconnection plug, D1 - diode, D2 - diode, M2 - engine of heating, M3 - engine
of sprayer, E2- electronic switch of speed ½, M4 - engine of wiper

2. Electric wiring
Fig. 63b- Wiring diagram of cabin of L853, L903 Speed+ (ELAA-MF)
H11 - horn, H13 – 2nd speed indicator, H15 - oil margin warning lamp (optional), H16 - hydraulics
blocking warning lamp, H17 - AA locking warning lamp, K1 - hydraulics blocking relay, K2 - engine
(seat) start blocking relay, K4 - stop coil blocking relay, K5 - stop coil engagement relay, K6 - direction
lights disconnector, K9 - AA locking relay, L1 - right front light, L2 - left front light, L9 - cabin ceiling
light, L10 - instruments illumination, P1 - engine hours counter, P2 - cooling liquid thermometer,
P3 - hydraulic oil thermometer, P4 - fuel gauge, S3 - switch box, S4 - windscreen wiper switch,
S5 - beacon switch, S6 - heating switch, S7 - sidelights and front lights switch, S8 - rear working light
switch, S9 - warning lights switch, S13 – left direction indicator lights switch, S14 - sprayer button,
S15 - horn button, S16 - auxiliary attachment switch, S17 - seat switch, S18 - parking brake switch,
S19 - ½ speed switching switch, S20 - shovel levelling switch, S21 – right direction indicator lights
switch, S22 – AA locking switch, F1-6 - fuse box, X1 - inspection lamp plug, X2 - magnetic beacon
plug, X3-4 cabin disconnection plugs, X7-8 - controllers disconnection plugs, X9 - seat disconnection
plug, X10 – MF disconnection plug, D1 - diode, D2 - diode, M2 - engine of heating, M3 - engine of
sprayer, M4 - engine of wiper.

2. Electric wiring
Fig. 64a- Wiring diagram of frame of L1203 Speed+ (ELAA)

device of hydraulic oil warning lamp, B2 - float device of fuel warning lamp, B3 - hydraulic oil
temperature sensor, B4 - cooling liquid temperature sensor, E1 - ESD 1 electronics, E2 - ½ speed
electronics, Re – engine heating relay, X1 - outer outlet plug, X2 - ½ speed electronics disconnection
plug, X3-4 - cabin disconnection plugs, X5 – engine heating relay disconnection plug, X6 - fuel pump
disconnection plug, X10-11 - mudguard disconnection plugs, X12 - fuel gauge disconnection plug, X21
- AA control electrohydraulic valve disconnection plug, H11 – horn, G1 – accumulator, G2 – alternator,
L3 - working light, L4 - left front group light, L5 - right front group light, L6 - rear group light, K7 -
electrohydraulic valve of brake, K8 - electrohydraulic valve of hydraulics blocking, K9 - engine stop
coil, K10 - fuel pump, K11 - electrohydraulic valve of 1/2 speed, K12 – AA electrohydraulic valve, Y1 -
engine heating.

2. Electric wiring
Fig. 64b- Wiring diagram of frame of L1203 Speed+ (ELAA-MF)

device of fuel warning lamp, B3 - hydraulic oil temperature sensor, B4 - cooling liquid temperature
sensor, E1 - ESD 1 electronics, Re – engine heating relay, X1 - outer outlet plug, X3-4 - cabin
disconnection plugs, X6 - fuel pump disconnection plug, X10-11 - mudguard disconnection plugs, X12
- fuel gauge disconnection plug, X21 – AA control electrohydraulic valve disconnection plug, H11 –
horn, G1 – accumulator, G2 – alternator, L3 - working light, L4 - left front group light, L5 - right front
group light, L6 - rear group light, K7 - electrohydraulic valve of brake, K8 - electrohydraulic valve of
hydraulics blocking, K9 - engine stop coil, K10 - fuel pump, K11 - electrohydraulic valve of 1/2speed,
K12 – AA electrohydraulic valve, Y1 – engine heating

2. Electric wiring
25 A
15 A
15 A
15 A
15 A
15 A
Fig. 65b- Wiring diagram of cabin of L1203 Speed+ (ELAA-MF)
H11 - horn, H13 – 2nd speed indicator, H15 – hydraulic oil margin warning lamp, H16 - hydraulics
blocking warning lamp, H17 - AA locking warning lamp, K1 - hydraulics blocking relay, K2 - engine
(seat) start blocking relay, K4 - stop coil blocking relay, K5 - stop coil engagement relay,
K6 - direction lights disconnector, L1 - right front light, L2 - left front light, L9 - cabin ceiling light,
L10 - instruments illumination, M2 - engine of heating, M3 - engine of sprayer, M4 - engine of wiper,
P1 - engine hours counter, P2 - cooling liquid thermometer, P3 - hydraulic oil thermometer, P4 - fuel
gauge, P - proportional AA controller, S3 - switch box, S4 - windscreen wiper switch, S5 - beacon
switch, S6 - heating switch, S7 - sidelights and front lights switch, S8 - rear working light switch,
S9 - warning lights switch, S12 - parking brake switch, S13 – left direction indicator lights switch,
S14 - sprayer button, S15 - horn button, S16 - auxiliary attachment switch, S17 - seat switch,
S18 - parking brake switch, S19 – 1/2 speed switching switch, S20 – AA locking switch, S21 – right
direction indicator lights switch, F1-6 - fuse box, X1 - inspection lamp plug, X2 - magnetic beacon plug,
X3-4 - cabin disconnection plugs, X7-8b - controllers disconnection plugs, X9 - seat disconnection
plug, X10 – 1/2 speed disconnection plug, X11 – AA locking disconnection plug, D1 - diode,
D2 - diode, MF – multifunctional electronic switch.

2. Electric wiring
25 A
15 A
15 A
15 A
15 A
15 A
Fig. 65c- Wiring diagram of cabin of L1203 Telspeed

H11 – horn, H13 - 2nd speed indicator, H15 - hydraulic oil margin warning lamp, H16 - hydraulics
blocking warning lamp, H17- AA locking warning lamp, K1 - hydraulics blocking relay, K2 - engine
(seat) start blocking relay, K4 - stop coil blocking relay, K5 - stop coil engagement relay, K6 - direction
lights disconnector, L1 - right front light, L2 - left front light, L9 - cabin ceiling light, L10 - instruments
illumination, P1 - engine hours counter, P2 - cooling liquid thermometer, P3 - hydraulic oil
thermometer, P4 – fuel gauge, P5 - proportional telescope controller, P6 - proportional AA controller,
S3 - switch box, S4 - windscreen wiper switch, S5 - beacon switch, S6 - heating switch, S7 - sidelights
and front lights switch, S8 - rear working light switch, S9 - warning lights switch, S12 - parking brake
switch, S13 - left direction indicator lights switch, S14 - sprayer switch, S15 - horn switch,
S16 - auxiliary attachment switch, S20- AA locking switch, S21- right direction indicator lights switch,
F1-6 - fuse box, X1 - inspection lamp plug, X2 - magnetic beacon plug, X3-4 - cabin disconnection
plugs, X7-8b - controllers disconnection plugs, X9 - seat disconnection plug, X11- MF disconnection
plug, D1, D2- diode, M2 - engine of heating, M3 - engine of sprayer, M4 - engine of wiper,
MF - multifunctional electronic switch, S17 - seat switch, S18 - parking brake switch, S19- ½ speed
switching switch.

2. Electric wiring
Fig. 65d- Wiring diagram of frame of Telspeed
M1 – starter, S1 - accumulator disconnector, S2 - engine lubrication warning lamp switch, S3 - cooler

switch, B1 - float device (hydraulic oil), B2 - float device of fuel warning lamp, B3 - hydraulic oil
temperature sensor, B4 - cooling liquid temperature sensor, E1 - ESD 1 electronics, X1 - outer outlet
plug, X3-4 - cabin disconnection plugs, X6 - fuel pump disconnection plug, X10-11 - mudguard
disconnection plugs, X12 - fuel gauge disconnection plug, X21- AA electrohydraulic valve
disconnection plug, X22- telescope electrohydraulic valve disconnection plug, H11 – horn,
G1 – accumulator, G2 – alternator, L3 - working light, L4 - left front group light, L5 - right front group
light, L6 - rear group light, K7 - electrohydraulic valve of brake, K8 - electrohydraulic valve of
hydraulics blocking, K9 - engine stop coil, K10- fuel pump, K11- ½ speed switching electric valve,
K12- AA electrohydraulic valve, K13- telescope electrohydraulic valve, Y1 – engine heating,
Re - engine heating relay.

2. Electric wiring
2.2 Shovel levelling (L853, L903)

Shovel levelling system is based on position sensoring of A, B, C plates that are screwed on
a segment attached to the inner side of the left jib arm.
2.2.1 Means of sensoring

When a plate disrupts electromagnetic field from a sensor by its raised part the sensor sends
signal with voltage of 12 V to a control coil of a relay. The relay disengages resulting in a
power outage to the electrohydraulic valve of levelling.
Plate A
Plate B
Segment
Sensor 1
Plate C
Sensor 2
Fig. 66- Positions of sensors 1, 2 and plates A, B, C by lifted jib
When the jib moves upwards, sensor 1 reads raised part of plate B (marked by hatching).
The shovel levelling is disengaged in this time. When the piston of the jib cylinder extends to
approx. 130 mm the B plate gets to the position that is unreadable by sensor 1 and
additional movement of the jib upwards engages the shovel levelling. If sensor 1 begins to
read the raised part of plate C, hapenning about 2 mm before the full extension of the jib
cylinder, the shovel is levelled no more.
When the jib moves downwards, the shovel levelling works from its top position until sensor 2
begins to read the raised part of plate A, happening about 30 mm before facing surface of
the jib sits on the front cross beam of the machine frame. The shovel levelling works no more
for additional jib movement downwards.

2. Electric wiring
2.2.2 Adjustment of shovel levelling system for L853 and L903
• First, a correct distance of sensors 1 and 2 to plates A, B, C is needed to be set. The

distance of sensors to raised parts of the plates should be in range of 3(+20%) mm.
Should low production accuracy disallow to keep equal distances of plates B and C to
sensor 1, then it’s necessary to use a suitable washer for the more distant plate.
• The initial position of the shovel levelling for upward jib movement is to be set as
follows: Lift the jib so the piston of the lifting cylinder is extended to 130 mm. Set
plate B in this position so that sensor 1 disengages the relay (relay disengagement is
possible to be checked by hearing as evident click) and consequently engages valve
of shovel levelling upwards. Fasten tightening screws of the plate after it’s set
correctly.
• The shovel levelling disengagement in the upper jib position is to be set as follows:
Lift the jib so the piston of the lifting cylinder is extended to 798 mm (2 mm to full
piston extension). Set plate C in this position so that sensor 1 engages the relay
resulting in disengagement of the levelling valve for upward jib movement. Fasten
tightening screws of the plate after it’s set correctly.
• Now, levelling for downward jib movement can be set: Lower the jib into a position in
which the distance of the jib stops and the front cross beam of the frame is approx. 30
mm. Sensor 2 should begin to read the raised part of plate A in this position resulting
in engagement of the relay and disengagement of the levelling valve for downward jib
movement. Fasten tightening screws of the plate after it’s set correctly.
• The shovel levelling system must be checked after all three plates are set. Should
a problem occur, then remove it as described above. Tightening screws of the plates
must be then secured from loosening by a suitable screw securer (e. g. Loctite 243).
Fig. 67- Positions of sensors 1, 2 and plates A, B, C by lifted jib

1- Plate A, 2- Plate B, 3- Segment, 4- Sensor 1, 5- Plate C, 6- Sensor 2.

2. Electric wiring
Location of the relay
Fig. 68- Shovel levelling relay
Check connection markings in case of problems with the levelling system (defective relay
replacement) for their correct reconnection. Purpose of the (general) relay is shown on fig.
69, 70.
Elecntical appliance
Switch (+) Earth (-)

off
Supply constant +
Fig. 69- Disengaged relay
Elecntical appliance
Switch (+) Earth (-)

on
Supply constant +
Fig. 70- Engaged relay

2. Electric wiring
2.3 Electrohydraulic control of section of auxiliary attachment

Electrohydraulic control of the AA function increases comfort of operation and
simplifies construction of the control system on all machine types. Electrohydraulic
valves are located directly in the auxiliary attachment section of the distributor where
the control pressure from the ROX valve is led through one hose.
Fig. 71- Distributor SX 12 (L853, L903) with electrohydraulic valves
2.3.1 Check of electrical operation of valve (fig. 72)

Necessary tools - Gauge (3)
- Connector (2)
Procedure:
- Connect connector 1 to the working section of the distributor.
- Parallelly connect connector 2 and connect with inlput from joystick.
- Start up the AA function and check amperage on the gauge.
- Power consumption should be 1.7 A in the limit position of the joystick.
Fig. 72- Gauge connection

1- Connector, 2- Parallel connector, 3- Gauge

2. Electric wiring
2.3.2 Distributor SM12, SX12 (load connection of controller)

Used on L 752, L 853, L 903.
Principle: The current and voltage flow from the controller directly to individual valves for this
type of connection.
Measurement: Use ampere-meter serially connected to the valve to measure the valve
current. If the joystick is tilted to one of its limit positions, then the valve current is 1.7 to 1.9
A. The same is valid for its opposite position.
The voltage / current inlet from the controller can be checked in this way.
If a gauge is not available then the function of the valve itself can be checked also by
disconnecting of the connector on the valve a connecting there 12 V from the accumulator.
The slider inside the valve must move.
If it doesn’t move, consider the valve to be defective and replace it.
2.3.3 Controller
If blue wires are not marked (little color partex), they can be identified by measurement. Find
wires from switches using a multimeter (Ω) and put them aside. Three wires are left. Measure
them using a multimeter on a crossing of diodes (mV). Voltage between blue and blue-yellow
wires must be 190 to 250 mV. Voltage between blue and blue-green wires must also be 190
to 250 mV. There is no voltage between blue-yellow and blue-green wires. This
measurement shows which wire is blue, blue-yellow and blue-green. Two wires are two-
colored (one for L and another one for P valve). The pure blue wire is common for both
valves.
Circuit blue-green
Red
Black
Circuit blue-yellow
Blue
Fig. 73- Symbol controller

2. Electric wiring
Fig. 74- Right joystick with electric controller of AA

1- Electric controller of AA
2.3.4 Distributor SX 14 (signal connection of controller)

Used on L 1203.
The distributor is connected to the electric part of the controller with a 4-pin connector.
- pin 1: 12 V,
- pin 2: ground,
- pin 3: signal from the controller (0.7 V – 4.3 V),
- pin 4: 5 V output for controller powering.
Fig. 75- Distributor SX14

1- 4-pin connector

2. Electric wiring
Measurement: Voltage on the controller is measured when the connector is connectred to

the distributor.
Black wire to red wire must be 5 V.
Black to white wire:
Controller in neutral: 2.5 V
Controller in the left (max.): 0.7 V
Controller in the right (max.): 4.3 V
Red (+ 5V)
White
Black
Fig. 76- Symbol controller
The voltages must be in range of min. 0.7 V to max. 4.3 V. If this is not valid then the AA
section will not work. These voltages can be measured on connector pins 3 and 2 of the
distributor as well. If all the measured voltages are in the range then the failure of AA
control is not in wiring.
2.4 The 2nd speed gearing (Speed+)

An electronic block (fig. 77), located in the control panel, and electric shock absorber, located
in the front of the frame, are connected in the electric circuit of the 2nd speed gearing.
Fig. 77- Electronic block

1- Connector, 2- Electronics

2. Electric wiring
The same electronic block is also connected in circuits of:

- locking of a started AA
- shovel levelling switch-off (L903)
If problems of control occur in any of these functions, the three blocks can be mutually
exchanged for a quick diagnostics. Their characteristics and connectors are identical. All
three blocks are located in the control panel of the machine.
Electric shock absorber, located on the frame beside the electrohydraulic valve of the 2nd
speed gearing, serves for softening (slowing down) of process of switching on (and off) of the
selected speed and thus elimination of machine tugging.
2.5 Multifunctional electronic switch
This switch was built into all machine types. Its purpose is to control the process of switching
on and off of some functions (AA locking, speed changing, shovel levelling switch-off). It
substitutes function of electronic blocks (fig. 77) that were located in the control panel.
Fig. 78 Multifunctional electronic switch
Some components can be put out of work and electronic blocks replaced with multifunctional
switch in case of repeating problems with control of functions described above (shock
absorber). In such a case it’s necessary to use an adapter (fig. 78a) for connection of the
switch. It’s delivering together with the switch.
Fig. 78a Connection adapter

2. Electric wiring
Connection of terminal „CANNON 25 pin“ for multifunctional switch (MF)
1,14 GND - (-) ground

2 +5V Outlet for handle L 1203, Telspeed
3 Inlet 1 Reserve (change of pre-heating time)
4 Button „ 37, 42, 43“ Inlet button „speed“
5 Inlet- charging indicator lamp 19A
6 Signal lamp of outlet 4 Detent of AA (1203, Telspeed) (switched
on = 12V)
7 Oultet 4 Detent of AA to valve (L1203, Telspeed)
(s_on.=4,25V/s_of.=0,7-4,3V from joystick
8,20 Outlet 3-proportional PWM (Speed)
9,21 Outlet 2 Switch off Bucket levelling L903
(zap.=12V)
10,22 Outlet 1 Reserve (pre-heating)
11,23 Outlet 0 Outlet of detent AA to valve
(L752, 853,903) (s_on=12V)
12,13 + pole-power supply + 12V
24,25 + pole-power supply + 12V
16 Button „10“ Inlet of detent AA to valve
(L752,853,903)
17 Button „43“ Inlet s_off Bucket levelling L 903
18 Button „10“ Inlet of detent AA to valve
(L1203, Telspeed)
19 Inlet of proportional value from the L1203, Telspeed
joystick
Notes:
1. There are the twin pins on the 0,1,2,3 outlets besause of load carrying capacity The
indicator lam is connected to valve parallel.
2. GND has twin pin.
3. + pole power supply feed by 4 pins.
4. Outlet 3 is proportional.
5. Signal „proportional value from the joystick“ is connected to outlet 4. In active
position of joystick + 4,25V
6. Indicator lamp of outlet 4 – in active position connected +12V for 2W lamp.
7. Indicator lamps and valves are common point GND, that is outlet connect + pole to
load.

2. Electric wiring
2.5.1 Connection of adaptors
connect to ind. Lamp of charging H1
Fig. 79- Connecton of adaptor L752, L853
DISCONNECTION
OF SHOVEL
LEVELLING
AA
Fig. 79a- Connecton of adaptor L903

2. Electric wiring
AA
Connect to ind. Lamp of charging H1
Fig. 79b- Connecton of adaptor L853 Speed+
AA
Connect to relay K9
Fig. 79c- Connecton of adaptor 1203

2. Electric wiring
DISCONNECTION
OF SHOVEL
LEVELLING
Connect to ind. Lamp of II. Speed H13
AA
Fig. 79d- Connecton of adaptor L903 Speed+

2. Electric wiring
Connect to ind. Lamp of II. Speed H13
AA
Connect to relay K9
Fig. 79e- Connecton of adaptor L1203 Speed+, Telspeed

2. Electric wiring
2.5.2 SB01 Multifunctional electronic substitution for 1/2 electronic switches for
L1853 Speed, L903 Speed.
Instruction for modification:

It is necessary to disconnect the No. 106 and 107 wires from the K7 relay and from the H12, H13 tell-tale
lamps. Disconnect the No. 103 wire from the K7 relay and connect it to the H13 tell-tale lamp where also
the No. 103 wire from the SB01 connector will be connected.
Connect the No. 19A wire from the SB01 to the H1 tell-tale lamp of charging.
For the “SPEED” version: It is necessary to disconnect the E2 electric shock absorber and connect
the K11 valve following the picture.
MODIFICATION IN THE ELECTRIC WIRING OF FRAME
New connection with SB01
Previous connection
connect this wire to the H1 tell-tale lamp

of charging
Fig. 80a Adjustment of electrical installation L853 Speed and L903 Speed
BLUE BLUE RED BLACK WHITE
Instruction for modification:

It is necessary to disconnect the No. 106 and 107 wires from the K7 relay and from the H12, H13 tell-tale
lamps. Disconnect the No. 103 wire from the K7 relay and connect it to the H13 tell-tale lamp where also
the No. 103wire from SB01 connector will be connected. The No. 202 wire with 15K resistance
connected to the K9 relay is necessary to disconnect and connect the No. 202 from the SB01 to its place.
Next, it is necessary to interrupt the connection between the No. 202 and 210 wires at the X8 connector
of the right control lever. Connect the No. 19A wire from the SB01 to the H1 tell-tale lamp of charging.
For the “SPEED” version: It is necessary to disconnect the E2 electric shock absorber and connect
the K11 valve following the picture.
MODIFICATION IN THE ELECTRIC WIRING OF FRAME
New connection with SB01
connect this wire to the H1 tell-tale lamp

of charging
Previous connection
Fig. 80b Adjustment of electrical installation L1203, L1203 Speed+, Telspeed

3. Side gears
3. Side gears
Side gears serve for transmission of torque from hydromotor to machine wheels. Working
principle is the same for all machine types, construction differs in gearing ratios and
dimensions.
Every gear box is equipped with a pinion (4) for input of the torque from the hydromotor and
with two output shafts for traction of the wheels. The torque is transmitted by four inserted
gear wheels placed on sliding bearings. The box is filled with gear oil. Oil level is determined
by position of a check hole on the inner side of the gear box.
Fig. 81- Position of pinion and box sealing

1- O-ring 214x2.62, 2- Nut M6x12, 3- Cover, 4- Pinion, 5- Safety ring 50, 6- Gufero 60x75x8,
7- Bearing 31310, 8- Bearing 6209, 9- Draining plug M16x1,5,
In case of hydraulic oil level decrease, when the leak is not visible from outside, check the oil
level in both side gears. If (gear, mixed with hydraulic) oil flows out when the check plug (on
the inner side of the gear box) is open, the problem is in untightness of the gufero (6)
between the cover (3) and the pinion (4). Broken gufero must be replaced with a new one.
Procedure:
• dismantle the hydrobasis,
• remove safety ring 5
• unscrew nuts 2 (6 pcs.)
• screw three nuts M8x1.5 into displacing holes and press out cover 3 with bearing 7
and gufero 6,
• pull off the bearing and replace the gufero,
• mount the cover and hydrobasis back on the gear box in a reverse order.

3. Side gears
Drain all the oil from the side gear and fill it with a new gear oil.
This construction solution is identical for all types of side gears. Differences of individual
types are shown in table of selected parameters.
WHEELBASE
Fig. 82- Side gear Locust

1- Filling plug M16x1.5
There are two drain plugs located in the end (lowered) part of the gear box.
Table of selected parameters:

Machine Gearing ratio Wheelbase Oil filling Weight
(mm) (l) (kg)
L 752 2.33 1020 17 184
L 853, L903 2.33 1150 19 193
L 1203 3.19 1100 21 198
Telspeed 3.19 1260 23 216

4. Oil specification
4. Oil specifications
Viscosity is a variable quantity depending on temperature.

The goal is to vary the viscosity by temperature as little as possible.
4.1 Engine oils:

4.1.1 Viscosity classes:
Specific SAE (Society of Automotive Engineers):
There are 6 winter classes used that are marked by a number and letter „W“ and 5 summer
classes marked by a number.
Winter classes: 0W (-35), 5W (-30), 10W (-25), 15W (-20), 20W (-15), 25W (-5)
Summer classes: 20, 30, 40, 50, 60
The winter marking defines usage by low temperatures (e. g. oil SAE 15W has a pumping
limit at -25 °C).
If only one class is used for marking, it means the oil is monograde (winter or summer).
If a combination of summer and winter classes is used (e. g. 5W-40), it means the oil is
multigrade or all-year. Nowadays almost all used oils are multigrade. The most common
class for our climate region is SAE 15W-40.
4.1.2 Load categories:

Load specification defines current or long-term properties of engine oil for different styles of
working load. Diverse properties are evaluated, e. g. oxidation stability, evaporation,
protection of wearing, sedimentation, corrosion etc.
The following norms are used:
- API classification (American Petroleum Institute, USA)
- ACEA classification (Assciation des Constructeurs Eurpéens d´ Automobile, EU)
- CCMC classification (Cmité des Constructeurs d´ Autombile du Marché Commun, EU)
- internal norms of engine and vehicle producers (VW, MB, MAN, VOLVO, LIAZ, TATRA)
- MIL-L classification (U. S. Military norms)
- other classifications (e. g. ILSAC)

4.1.3 Load classes for Diesel engines:

CA- Oils for no-turbo, low load Diesel engines (produced 1940 - 1960)
CB- Oils for no-turbo, mid load Diesel engines (1940 - 1963)
CC- Oils for turbo engines, mid loaded (1964 - 1970)
CD- Oils for turbo engines, high loaded. They contain additives for prevention of high
temperature sediments and bearing corrosion.
CE- Oils for high performance, high load, high speed turbo engines (after 1983)
CF- Replacement for CD oils for engines with indirect injection with improved properties.
CF-2- Oils for two stroke engines.
CF-4- Oils for the most loaded engines of trucks working in the toughest conditions.
CG-4- Oils for the most loaded high speed engines working in the toughest conditions.
Temperature exterior
Fig. 83- Grafical representation of engine oil viscosity

4.2 Gear oils

4.2.1 Viscosity:
There are used 3 winter and 3 summer classes:
Winter classes: 75W (-40), 80W (-26), 85W (-12)
Summer classes: 90, 140, 250
Similarly to engine oils, gear oils are monograde or multigrade (all-year: 80W-90).
4.2.2 Load categories:

According to API, markings consist of letters „GL“ (Gear Lubricant) and a number indicating
a load level. There are 6 levels but only 3 are used in the present:
GL-4- Oils with high additives designed mostly for manual gear boxes and low loaded hypoid
gearing
GL-5- Oils designed for high loaded hypoid gearing working in the toughest conditions.
GL-6- Oils for hypoid gearing working in extreme conditions. They are rarely used.
Producers of gear boxes recommend oils according to load specification, e. g. API GL-4, API
GL-5 and viscosity specification of SAE, e. g. 75W, 80W-90.
4.3 Hydraulic oils:

Hydraulic oil is considered to be one of construction components with the following main
functions:
- Transmission of pressure energy

- Transmission of signals by pressure waves
- Lubrication of inner moving parts
- Heat release
- Drainage of impurities
Viscosity is the most important property of hydraulic oils. It should vary by
temperature as little as possible.
Operating viscosity ensures the full functionality at 100 % load.
V operating = 12 – 60 mm2/s-1
It is recommended to select operating viscosity of an optimal range according to expected
efficiency and lifetime.
Optimal operating viscosity = 25 - 36 mm2/s-1

Viscosity index is a numerical indication of oil sensitivity to temperature change. The higher
viscosity index indicates a more flat viscosity curve, meaning lower viscosity variation by
temperature.
Viscosity index of oils Paramol HM 32, 46, 68 etc. is 110, solidification point is -40, -34, -30.
Viscosity classes of oils are marked by letters „VG“ and a number 32, 46, 68…
Hydraulic oils PARAMOL „HM“

They are highly refined petroleum oils containing additives increasing oxidation stability, anti-
corrosion, wearing and anti-foam properties.
Hydraulic oils PARAMOL „HV“

They are highly refined petroleum oils containing all the HM additives plus pattern invariable
viscosity modificator that improves their properties at high and low temperatures.
Viscosity index of oils Paramol HV 32, 46, 68 etc. is 170, 165, 160, solidification point is -40,
-38, -38.

5. Authorized service
5. Authorized service
5.1 Slovak Republic

No. Firm name and Address Phone Fax/e-mail
residence
1. WAY INDUSTRY a. s. Priemyselná 937/4 00421/ 045 / 5501 226 00421/ 045 / 5501 232
KRUPINA 963 01 Krupina
jdemian@way-industry.sk
molah@way-industry.sk
2. HYDREX, spol s r.o. Partizánska 1877 045 / 5497 025 045 / 5497 675
HRIŇOVÁ 962 05 HRIŇOVÁ 026
hydrex@hydrex.sk
029
3. HYDREX, spol s r.o. Bajkalská 2 051 / 7762 933 051 / 7762 933
PREŠOV 080 10 PREŠOV
4. HYDREX, spol s r.o. Mlynské Nivy 70 02 / 5363 3077 02 / 5363 3077
Bratislava (Areál Doprastavu)
821 05 Bratislava

6. Conclusion
6. Conclusion
This manual doesn’t contain detailed information on dismantling and mounting of individual
aggregates that are part of service manuals of a particular node producer. The manual was
made keeping in mind that it will be used by personnel with a complete training at producer‘s
and a basic knowledge of the machine construction and its individual system functions.

Service Manual LOCUST

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SERVICE MANUAL

L752, L753, L853, L903, L1203

1.1 Hydraulic circuit of control .................................................................................... 4

1.2 Hydraulic circuit of working equipment ...............................................................25

1.3 Hydraulic circuit of travel ......................................................................................49

2 Electric wiring ........................................................................................................61

2.1 Wiring diagrams.....................................................................................................62

2.2 Shovel levelling (L853, L903) ................................................................................75

2.3 Electrohydraulic control of section of auxiliary attachment ...............................78

2.4 Gearing of the 2nd gear .........................................................................................81

2.5 Multifunctional electronic switch..........................................................................82

SERVICE MANUAL 1 LOCUST

2.5.1 Connection of adaptors ............................................................................................84

4 Oil specification .....................................................................................................91

4.1 Engine oils..............................................................................................................91

4.2 Gear oils..................................................................................................................93

4.3 Hydraulic oils .........................................................................................................93

5. Authorized service .................................................................................................95

Abbreviation „ELAA“ means electrohydraulic control of auxiliary attachment implemented for

L 752 from production number 1495/05

L 752 from production number 1732/06

SERVICE MANUAL 2 LOCUST

SERVICE MANUAL 3 LOCUST

1. Hydraulic systems of machines

1.1 Hydraulic circuit of control………………… 2.5 MPa (L752, L1203)

All operations of machines are virtually controlled by hydraulics.

SERVICE MANUAL 4 LOCUST

1.1.1 Wiring diagrams

Fig. 2-Wiring of hydraulic circuit of control of L 752, L 1203

SERVICE MANUAL 5 LOCUST

Wiring of hydraulic circuit of control – block diagram of:

Fig. 3- Wiring of hydraulic circuit of control of L752

SERVICE MANUAL 6 LOCUST

Fig. 4- Wiring of hydraulic circuit of control of L853, L903

SERVICE MANUAL 7 LOCUST

Wiring of hydraulic circuit of control – block diagram of:

Fig. 1-5 Wiring of hydraulic circuit of control L753

SERVICE MANUAL 8 LOCUST

Wiring of hydraulic circuit of control – block diagram of:

Fig. 5- Wiring of hydraulic circuit of control of L853, L903

SERVICE MANUAL 9 LOCUST

Wiring of hydraulic circuit of control – block diagram of:

Fig. 6- Wiring of hydraulic circuit of control

SERVICE MANUAL 10 LOCUST

Fig. 7- Wiring diagram of control circuit of L752

Fig. 8- Wiring diagram of control circuit of L752 (electrohydraulic control of AA)

SERVICE MANUAL 11 LOCUST

Fig. 9- Diagram of hydraulic circuit of control of L853 and L903

SERVICE MANUAL 12 LOCUST

Fig. 11- Diagram of hydraulic circuit of control of L1203 (ELAA)

Fig. 1-13 Diagram of hydraulic circuit of control of L753 (EL)

SERVICE MANUAL 13 LOCUST

Fig. 1-13 Diagram of hydraulic circuit of control of L753 (H)

SERVICE MANUAL 14 LOCUST

1.1.2 Other elements of hydraulic circuit of control

1.1.2.1 Electrohydraulic valve DSH 08* (ROX-1)

- Upper electrohydraulic valve (B) connects or disconnects inlet of control pressure to

- Lower electrohydraulic valve (A) connects or disconnects inlet of control pressure to

Fig. 12- Location of electrohydraulic valves

Fig. 13- Interconnection of electrohydraulic valves DSH 08 (ROX)

SERVICE MANUAL 15 LOCUST

1.1.2.2 Remote controller (joystick) L752, L853, L903, L1203

Purpose of the remote controller is to send signals (electric, hydraulic) to a controlled

Fig. 14- Remote controller